Fireye PPC6000 Series Operator's Manual
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Fireye PPC6000 Series Operator's Manual

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DESCRIPTION:
This document supplies the owner/operator with sufficient information to make
appropriate changes to operating parameters associated with normal boiler plant
needs. Items such as system setpoint adjustments e.g. temperature, pressure, PID
adjustments and alarm corrective action and adjustments.
The following items are covered in this manual:
1
2
3
4
5
6
7
8
9
10
11
Introduction _____________________________________________________2
General _________________________________________________________2
Password _______________________________________________________2
Adjusting Cut IN and Cut OUT_____________________________________3
Manual Modulation ______________________________________________4
Resetting the Control _____________________________________________4
Fault and Fault Finding __________________________________________11
Fault subsets ___________________________________________________11
Fault listing ____________________________________________________12
PID Tutorial____________________________________________________18
The Startup / Shutdown Stages ____________________________________19
NXOG-6001
MARCH 9, 2007
OPERATOR'S
GUIDE
PPC6000
SERIES
FOR

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  • Page 1: Table Of Contents

    NXOG-6001 MARCH 9, 2007 OPERATOR’S GUIDE PPC6000 SERIES DESCRIPTION: This document supplies the owner/operator with sufficient information to make appropriate changes to operating parameters associated with normal boiler plant needs. Items such as system setpoint adjustments e.g. temperature, pressure, PID adjustments and alarm corrective action and adjustments.

  • Page 2: Introduction

    Introduction As an operator there are generally only a few items of interest as far as operating the Nexus PPC6000. They are: Setting the system’s operating pressure or temperature. Adjusting the cut in or cut out value. Manually modulating the boiler. Resetting the control after a safety shut down.

  • Page 3: Adjusting Cut In And Cut Out

    Note: The next time you enter the site password you will return to the last option selected. Adjusting Cut IN and Cut OUT Follow steps 1 through 3 above. 4. If the display shows the angular positions of the servomotors, press the MODE key to change to option parameters.

  • Page 4: Manual Modulation

    If for some reason the Nexus detects a fault, the cause of the fault will be displayed if still present. If not displayed, pressing the ENGINEERS key once will reveal the fault, a second press will reveal the fault and subset in the upper right hand corner. The ENGINEERS key is hidden behind the Fireye logo on the display.
  • Page 5 Engineer’s key parameter list Name Description Shows the state of each input. Low Voltage Digital Input 1 (PA5–PA11) Where : Low Voltage Digital Input 2 (PA6–PA11) 0 = OFF (Open circuit) Low Voltage Digital Input 3 (PA7–PA11) 1 = ON Low Voltage Digital Input 4 (PA8–PA11) Low Voltage ‘HIGH’...
  • Page 6 Modulation rate (%) The current modulation rate of the burner. 0 = Low Fire 100 = High fire Status of the start-up sequence. See section 4.2 EK30 Burner Status of Fireye Bulletin PPC-6001 The currently selected fuel profile. EK31 Fuel Profile Selected...
  • Page 7 The number of times adjust ratio mode has been EK42 Adjust ratio counter used. EK43 Commission ratio counter The number of times commission ratio mode has been used. EK44 Oxygen measured value The current flue oxygen value as measured by the FIREYE probe (if fitted).
  • Page 8 Name Description EK45 Oxygen probe status +1 - Internal fault. +2 - Internal fault. +4 - Heater fault. Causes F50. +8 - Cell temperature out of range. +16 - Cell millivolts out of range. +32 - CANbus error. +64 - Probe calibrating in reference gas. See option parameter 30.6.
  • Page 9 Name Description EK59 Digital (relay) outputs on. Represents which drives are currently at their setpoints, where: 0 – All drives are at their setpoints and are not moving. Non- zero – One or more drives are not at their setpoint. EK60 Spare The combination of digital outputs currently...
  • Page 10 0 for OFF (open circuit) and 1 for ON. EK72 Oxygen probe cell temperature. The temperature of the zirconia cell inside the FIREYE oxygen probe, if fitted. This value should be very close to 650ºC for accurate operation. EK73 Ambient temperature.

  • Page 11: Fault And Fault Finding

    Where applicable, the subsets are given in the fault listing in section 6 - Faults and Fault Finding, of Fireye Bulletin PPC6001. For details of how to view a subset,...

  • Page 12: Fault Listing

    Fault listing Fault Cause Description Number External Alarm Fault 1 See Option parameters 19.1 to 19.4. External Alarm Subset : burner status. Fault 2 External Alarm Fault 3 External Alarm Fault 4 Not enough A fuel/air ratio profile has been selected which does not have at setpoints entered least four setpoints commissioned.
  • Page 13 Fault Cause Description Number Drive 0 position A drive-positioning fault has occurred, which will cause a non- fault volatile lockout of the burner. This fault has occurred for one of the following reasons: Drive 1 position fault 1. During close position prove, when a drive stops at a position that is outside the close set position by more than five Drive 2 position degrees.
  • Page 14 Fault Cause Description Number ADC fault One of the internal checks on the analog to digital converter has failed. Subset : Failure mode. RAM test fault The main memory in the control has malfunctioned. Interrupt power to the control. This could be due to high levels of electrical interference getting into the product.
  • Page 15 Fault Cause Description Number Boiler safety limit The boiler’s measured value has exceeded the exceeded pressure/temperature safety limit. Subset : 4 - safety limit exceeded Burner not OFF. This fault will lock the burner out if the AUTO input (PA10 – PA11) is made when the control thinks the burner should not be firing.
  • Page 16 Fault Cause Description Number The oxygen level measured value has exceeded the oxygen Oxygen high limit setpoint high alarm value for the current profile. alarm Subset: 0 = Limit violation, 1 = Probe Failed. The trim drive has reached the allowed maximum deviation limit. Trim limit alarm Change trim limit.
  • Page 17 Fault Cause Description Number Profile Invalid This fault means that the control can’t fire the currently selected profile because it isn’t sure it still matches the burner / site configuration. It could lead to a hazardous situation. There are three possible causes to this fault : 1 –...

  • Page 18: Pid Tutorial

    Fault Cause Description Number Secondary program A fault has occurred with the program memory in the control. If memory checksum the fault persists for 11 consecutive tests then the burner will fault shutdown. Contact supplier Subset : Not applicable. Secondary A fault has occurred with the CPU watchdog.

  • Page 19: The Startup / Shutdown Stages

    Derivative Enabling the derivative has the effect of sensing the rate of change in the process variable (pressure or temperature) and increasing or holding up the firing rate output despite the integral term. This in effect amplifies the output to anticipate the effect of a sudden change in load demand. Derivative acts inversely when the set point is exceeded.
  • Page 20 Stage Stage name Description Wait for purge The ‘controlled shutdown’ output on PE3 will be switched on, to tell the burner controller there is a call for heat. This control waits for a fuel/profile select signal on one of the (line (EK5) voltage) terminals PE9, PE10, PE11 or PE12 and a purge request (EK11-14)
  • Page 21 Stage Stage name Description Pre-purge The controller confirms all required drives are at their purge positions, and gives a ‘purge proved’ signal by providing (line voltage) to terminal PE8 (high-fire-switch). The control will remain in this status until the burner controller signals the end of pre-purge by breaking PA11 –...
  • Page 22 Stage Stage name Description Moving to low fire Once the AUTO signal is received the fuel and air motors are moved from their ignition positions to their low fire positions. These positions may or may not be the same as the ignition positions. The ‘ignition prove’...
  • Page 24 Fireye shall be limited exclusively to the right to replacement or repair as above provided. In no event shall Fireye be liable for consequential or special damages of any nature that may arise in connection with such product or part.

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