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Fireye NX6100 Operator's Manual

10.4” color touchscreen
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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.
CONTENTS:
The following items are covered in this manual:
1
INTRODUCTION ....................................................................................................................................................... 4
1.1
................................................................................................................................................................ 4
1.2
.............................................................................................................................................................. 4
2
DESCRIPTION OF TOUCHSCREEN OPERATION. ........................................................................................... 5
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
................................................................................................................................................ 5
. ..................................................................................................................................... 5
. ...................................................................................................................... 8
. .......................................................................................................................... 9
. .................................................................................................................. 9
'
. ..................................................................................................................... 10
'
. .......................................................................................................................... 11
'
'
TOUCHSCREEN
............................................................................................ 6
. ................................................................................ 8
. ...................................................................................................... 11
. ..................................................................................................... 12
NXOGTSD-6101
APRIL 8, 2013
OPERATOR'S
GUIDE FOR
NX6100 WITH
10.4" COLOR

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Summary of Contents for Fireye NX6100

  • Page 1: Table Of Contents

    NXOGTSD-6101 APRIL 8, 2013 OPERATOR’S GUIDE FOR NX6100 WITH 10.4” COLOR TOUCHSCREEN 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 2.12 ‘S ’ ..................... 13 OUCHSCREEN CREEN ONFIGURATION BUTTON 2.13 ..........................13 LEANING THE OUCHSCREEN 2.14 ........................15 OUCHSCREEN OMMISSION MODE SETPOINT, CUT IN/CUT OUT AND MODULATION OPTION PARAMETERS .......... 16 21.0 – S (0 - 1) LV1 ............... 17 PTION POINT ENABLE...
  • Page 3 ..............................53 OMMISSIONING ............................54 AS VALVE PROVING ............................... 54 ODULATION ................................55 NVERTERS ........................56 XYGEN MEASUREMENT AND TRIM PID TUTORIAL ..............................57 COMBUSTION PROFILE SETUP GUIDELINE ..................... 58 FIREYE NX6100 EFFICIENCY CALCULATIONS..................59 TYPICAL WIRING DIAGRAMS ........................61...

  • Page 4: Introduction

    This guide can be downloaded from the Fireye web site at www.Fireye.com. Search bulletins for NXOGTSD- 6101 under the Nexus products family. As an operator there are generally only a few items of interest as far as operating the Nexus NX6100. They are: ...

  • Page 5: Description Of Touchscreen Operation

    Five (5) seconds after power is applied the Fireye splash screen (shown below) will be displayed for 6 seconds, after which a period of 5 seconds of a blank white screen will show.

  • Page 6: The Operation Mode Line And Status Messages

    The Operation Mode line and Status messages The line at the top of the screen displays the current burner: operating mode, profile, modulation mode and unit address. Burner status, and fault information, if applicable, is displayed in the bottom right corner of the display.
  • Page 7 Icon Description Details State of CANbus Displays when CANbus communication is faulty connection State of Oxygen Interface Displays when Oxygen Interface related fault is present. Indicates commissioning Displays when the control is operating in mode commissioning mode. Indicates HAND Displays when the control is operating in HAND modulation mode.

  • Page 8: Touchscreen Overview Display

    Touchscreen Overview display. While the burner is changing ‘status’ the bottom-right one sixth of the display is used to provide a graphical indication of changing status. The sequences displayed in this manner include, burner start-up, burner shutdown and fuel changeover. In each case there is a ‘lamp’...

  • Page 9: Touchscreen Led Indication

    Once the Fuel soft-button is pressed, a pop-up window appears on the right giving the user a choice of available fuels/profiles. The NX6100 allows for a maximum of four profiles. Any profiles, which are not programmed and therefore not available, will be ‘grayed-out’.

  • Page 10: Touchscreen 'Control' Screen

    The ‘Name’ for each available profile will be either the default as set by the relevant option parameter or that entered via the Configuration Screen. If the profile change is made while the burner is firing, there are two possibilities dependent on the options set in the control.

  • Page 11: Touchscreen 'Menu' Button

    Touchscreen ‘Menu’ button. Once the Menu button is pressed, a pop-up window appears on the right giving the user a choice of options. If an option is unavailable it will be ‘grayed out’. Using the buttons available after pressing the Menu button will generate a new pop-up window in the left hand area of the screen.

  • Page 12: Touchscreen 'Fault/Event Log' Button

    Fault data only, Events data only or a combined history as shown in this example. For more information on fault codes and fault finding refer to the Fault Finding section of the NX6100 manual – Fireye bulletin NEX-6101.

  • Page 13: Touchscreen 'Screen Configuration' Button

    2.12 Touchscreen ‘Screen Configuration’ button. Once the Screen Configuration button is pressed, a window appears giving the user a choice of options. From the General Tab a name may be entered for each profile in use. Highlight the profile for which a name is to be entered or modified and press the Modify button. This will cause a window to appear allowing the required name to be entered using the button pad.
  • Page 14 Before attempting to clean the screen it is essential to select the Clean Screen function to prevent any pressure applied to clean the touchscreen being ‘seen’ as a ‘button press’. The function can be accessed by selecting the Menu button at the base of the touchscreen and then, selecting Clean Screen from the list of functions available.

  • Page 15: Touchscreen Commission Mode

    2.14 Touchscreen Commission mode. To allow Option Parameters or Drives to be adjusted it is necessary to enter the relevant access passcode. To enter the passcode press the COM button. This will prompt the keypad pane to appear, allowing the relevant passcode to be entered using the soft keypad and confirmed by pressing the OK button.

  • Page 16: Setpoint, Cut In/Cut Out And Modulation Option Parameters

    Once the correct passcode is entered the unit will enter commissioning mode and allow the option parameters and profile points to be adjusted, the text on the COM button will change to RUN. To warn the ‘user’ that the unit is in commissioning mode the overall display background changes to red and COM is displayed top-center on the screen Setpoint, Cut In/Cut Out and Modulation Option Parameters NOTE:...

  • Page 17: Option 21.0 - Set-Point 1 Enable (0 - 1) Lv1

    From the Touchscreen, press the Menu button followed by the Burner Settings button (See Touchscreen Section 2.10). The Com key will appear in the bottom left of the Burner Settings screen. Press the Com key and enter the site password (default 154) on the numeric keypad. Press OK. Now, depending upon what parameter you want to change, you can press the Control key or press the Options tab on the Burner Settings screen.

  • Page 18: Option 21.4 - Set-Point 1 Derivative Time (0 - 999 Seconds) Lv1

    Integral control is required for the burner to accurately reach its setpoint. Option 21.4 – Set-point 1 derivative time (0 – 999 seconds) LV1 This is the derivative time used in the PID control loop for setpoint 1. It may be set to any value from 0 to 999. A value of zero will disable the derivative function.

  • Page 19: Option 21.6 - Setpoint 1 Low Limit Control Value (Cut In) (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) Lv1

    Boiler ON (Cut In) at ........95 psi Boiler maintains (Setpoint) ....... 100 psi via PID Changing ONLY the Setpoint – Opt 21.1 (22.2) ....change to ..60 psi NEW RESULTS from Setpoint Change: Boiler OFF (Cut Out) at ......75 psi Boiler ON (Cut In) at ........

  • Page 20: Option 21.8 - Remote Setpoint 1 Zero (4Ma) Value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) Lv1

    If the boiler is on and firing, this parameter defines the measured value at which the boiler will be turned off via a controlled shutdown. Option 21.8 – Remote Setpoint 1 zero (4ma) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 This is the zero value for the remote setpoint function specified by option parameter 20.7.

  • Page 21: Option 22.4 - Set-Point 2 Derivative Term (0 - 100) Lv1

    3.15 Option 22.4 – Set-point 2 derivative term (0 - 100) LV1 This is the derivative time used in the PID control loop for setpoint 2. It may be set to any value from 0 to 999. A value of zero will disable the derivative function. A non-zero value will have the effect of ‘advancing’ the modulation rate change caused by a constantly changing measured value by the number of seconds given.

  • Page 22: Option 22.9 - Remote Setpoint 2 Span (20Ma) Value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) Lv1

    3.20 Option 22.9 – Remote Setpoint 2 span (20mA) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 This is the span value for the remote setpoint function specified by option parameter 20.7. 3.21 Option 23.0 – Warming Enable (0 or 1) LV1 This parameter allows a warming function to be applied to the boiler, and makes option parameters 23.1 and 23.2 available.

  • Page 23: Low Fire Hold Lv1

    (slave) boilers will revert to their own PID settings. Should a lag boiler fail to come on within three minutes, or the NX6100 is faulted, sequencing will immediately call for the next lag in the priority list.

  • Page 24: Option 24.0 Sequence Slaves (Number Of Boilers) (0-3) Lv1

    Option 24.0 Sequence Slaves (number of boilers) (0-3) LV1 This option is set to 1, 2 or 3 in each NX6100 to equal the number of lag “slave” boilers in the system. Once set, option parameters 24.1, 24.2, and 24.3 will become available. If the value is set to 0 the boiler will be taken out of sequencing and operate on its own PID.

  • Page 25: Option 24.1 -24.3 Priority Number(S) Lv1

    Option 24.1 -24.3 Priority Number(s) LV1 The order in which boilers sequence on is entered as the communication address(s) of the boilers in Options 24.1, 24.2 and 24.3. The first to be turned on will have a priority number one above that of the lead boiler. For example: If the communications address of the four boilers were 1, 2, 3, and 4 (set in Option 0.2), boiler 1 master (lead), with the following entered in Options 24.1-24.3 Option parameter...

  • Page 26: Option 24.6 - Lag (Slave) On Rate (0-100%) Lv1

    Option 24.6 – lag (slave) On Rate (0-100%) LV1 This value determines the firing rate of the lead (master) boiler at which the first and all subsequent slave(s) (lag) boilers come on. The slave(s) (lag) boiler(s) will be delayed in coming on by the time set in Option parameter 24.7.

  • Page 27: Option 25.1 - Water Temperature Zero Value Lv3

    4 = uses analog input 4. PA12(+) PA11(-). This input circuit needs an external 220-Ohm burden resistor. 5 = uses the remote tracking input as a 4-20mA input. PA15(+), PA14(-) and option 20.7 must be set to 0 and jumper JP2 must be set to the "IN" position (which sets the auxiliary input to be 4-20mA). NOTE - If a loop-powered sensor is used, the "+"...

  • Page 28: Start-Up Sequence

    When a fuel selection is made and the ‘burner select’ (PE6) signal is given to start up the burner, the control runs through the sequence described below. If a gas profile is selected, the control also performs safety valve pressure proving in parallel with the start-up sequence (see section 4.3 in Fireye Bulletin NEX-6101). Stage...
  • Page 29 Stage Stage name Description Pre-ignition Once the fuel and air motors are at their ignition positions, the ignition transformer output is energized and pre-ignition time t3 is initiated. The Ignition transformer only is on at this stage. Pilot ignition Once t3 has elapsed then: When firing on Gas, the pilot valve is energized and safety time t4 is initiated.

  • Page 30: Faults And Fault Finding

    The fault display The NX6100 carries out a number of internal and external checks during operation. If a fault is found, a fault number (displayed with a text description) is used to identify the type of problem. A list of fault numbers may be found later in this chapter.

  • Page 31: Non-Volatile Lockout

    Non-volatile lockout If power is removed from the controller while a fault is still present, the fault will be stored in non-volatile memory. When power is restored to the controller, the fault number will still be present and it will be necessary to remove the fault before restarting the burner.
  • Page 32 Cause Description Flame Failure The flame detector did not register the presence of a flame when it should be present. Subset : burner status False Flame The flame detector registered the presence of a flame when it should not be present or when the shutter (if selected) was closed.
  • Page 33 Cause Description Optional second The primary air pressure switch registered air pressure when (primary) air it should not be present (subset : 1), or the air pressure pressure detected switch registered air pressure for more than 3 minutes after when it should not the burner was turned off (subset : 2).
  • Page 34 Cause Description Drive 0 position A drive-positioning fault has occurred, which will cause a fault non-volatile lockout of the burner. This fault has occurred for one of the following reasons: Drive 1 position 1. During ‘Close’ position prove, the measured position fault when a drive stops at a position that is outside the commissioned ‘Close’...
  • Page 35 Cause Description Oil Proof of The oil valve proof of closure signal is not responding Closure fault correctly. The fuel valve “proof of closure” switch must change state (e.g. open or close) within 7 seconds of the valve being energized or de energized. Subset : burner status.
  • Page 36 Check option parameters 6.1 to 6.4 Boiler safety limit The boiler’s measured value has exceeded the exceeded pressure/temperature safety limit, or the Fireye pressure/temperature sensor is not responding correctly. Subset : 1 = - sensor feedback < 1V, 2 =- sensor feedback > 5V,...
  • Page 37 Cause Description Gas pressure limit The measured gas pressure is outside the operating limits S(subset : valve prove status) , or 10 = the gas pressure sensor is not responding correctly (subset : 10). EEPROM memory The EEPROM memory in the controller has been corrupted. CRC fault This memory is used to store the option parameters, ...
  • Page 38 Cause Description Oxygen probes This fault occurs when two oxygen probes are used to give mismatch fault fail-safe oxygen monitoring. If this fault occurs, check and calibrate both oxygen probes. It may be necessary to increase option parameter 42.4 or 42.5 (within safe limits) if the oxygen probes are in different parts of the flue.
  • Page 39 Cause Description Profile Invalid This fault means that the controller 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 40 Cause Description Secondary relay A secondary fault has occurred with the main 1, main 2, pilot, fault vent or non-volatile lockout relays. Tests are performed once an hour. If two consecutive tests fail then the controller will Lockout and display the fault number. ...

  • Page 41: The Engineer's Tab

    Touchscreen Section 2.9) System Event/Fault history. The NX6100 stores information on events and faults. The memory in the unit will store the last 128 events/faults, and associated status data and, as an option, a date and time stamp. The 100 most recent events/faults are available via the display unit and all 128 are available though Comfire 2.
  • Page 42 Name Description EK10 Profile 2 (PB8 – PB6) EK11 Profile 4 (PB8 – PB7) EK12 Profile 3 Select (Low Voltage) High voltage digital input 12. EK13 High voltage digital input 13. EK14 Burner Select Input (High Voltage) EK15 Airflow Input (Low Voltage) PB18–...
  • Page 43 Name Description EK20 Drive moved 0 - Controller not in commission mode or control is in commission mode and drives have not been moved using the UP/DOWN keys. 1 - Controller in commission mode and drives have been moved using the UP/DOWN keys. EK21 Positions proved 0 - Drives have stopped moving, ready for...
  • Page 44 Name Description EK29 Modulation rate (%) The current modulation rate of the burner. 0 = Low Fire 100 = High fire Status of the start-up sequence. See section EK30 Burner Status The currently selected fuel profile. EK31 Fuel Profile Selected EK32 Number of commission setpoints The number of setpoints entered in the...
  • Page 45 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). EK45 Oxygen probe status +1 - Internal fault. +2 - Internal fault. +4 - Heater fault. Causes F50.
  • Page 46 Name Description Example: If EK46 = 70, for possible reasons why the trim is not working: The highest description number that can be subtracted from 70 is 64, so the first possible reason is +64 - “Probe faulty” (noted above) Since 70-64=6 there could be an additional reason.
  • Page 47 Name Description EK57EK CPU serial number (low 4 The 6 digit CPU board serial number. The digits)CPU serial number (high 3 serial number is displayed in 2 blocks of 3 digits) digits. EK59 Drives at setpoint Represents which drives are currently at their setpoints, where: 0 –...
  • Page 48 Name Description EK62 Analog Input 2. The raw ADC counts from analog input 2. Main Unit Terminal PA8. 0 to 1023 for 0 to 5.00 volts. 4mA = 180 counts 20mA = 900 counts EK63 Analog Input 3. The raw ADC counts from analog input 3. Main Unit Terminal PA9.
  • Page 49 Name Description 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 air temperature. The temperature measured by the inlet temperature sensor, if fitted.
  • Page 50 Description EK100 Firmware type PT22xxxx… This shows the last four digits of the firmware part number for the NX6100 firmware. It is used for product variant identification.  The product allows for customization of various non-safety critical functions including the modulation control. The engineers’ keys shown below relate to the default modulation control function programmed in the control at the factory.
  • Page 51 Name Description If this value is 1, the remote setpoint 1 EK109 Remote Setpoint 1 Active function is active. See option parameter 20.7. The value of Setpoint 1 will come from analog input 5. EK110 to Not used by the standard manufacturers program.

  • Page 52: Troubleshooting

    Name Description The modulation rate that the boiler will fire to if EK157 AUTO modulation rate in AUTO mode (providing option parameter 15.0 is not zero or 1). 0= Not available for sequence EK158 Sequence status +1= Available for sequencing +2= New Lead selected +4= Running as Lead +8= Firing from setpoint 1...

  • Page 53: Startup

    Problem Possible cause Suggested action Burner status is flashing. Controller in non-volatile Burner status before shutdown displayed. lockout mode. Gas pressure not Gas sensor not selected. Select sensor using option parameter 10.0 shown. Gas pressure incorrect. Incorrect span value. Check option parameter 10.1 Startup Problem Possible cause...

  • Page 54: As Valve Proving

    Problem Possible cause Suggested action available. be set first. non-zero value to enable other param’s in group. Option parameter not Wrong passcode entered or Enter the supplier passcode and/or turn the adjustable. burner firing. burner off before changing the value. Not possible to enter Supplier passcode incorrect.

  • Page 55: Inverters

    09.3 on the NX6100 series control3. TIME   Control is unstable Adjust option parameters 9.0 and 9.2 on the NX6100 control to reduce accuracy & slow down control response.  Check Option parameter 9.4 matches the acceleration / TIME deceleration time programmed into the VSD.

  • Page 56: Oxygen Measurement And Trim

    VSD and option parameter 9.4. In extreme cases, it may be necessary to increase the inverter error tolerance to prevent non-volatile lockouts caused by positioning faults (set option 9.1 = 1). This must only be changed if an inverter error of 55 will not cause unsafe combustion Oxygen measurement and trim Problem...

  • Page 57: Pid Tutorial

    PID Tutorial PID Adjustment The NX6100 utilizes and advanced algorithm in order to maintain setpoint over a variety of load conditions. This three term PID can be infinitely adjusted to suit almost any application. The operator should have a basic understanding of the relationship between the three terms - proportional, integral and derivative.

  • Page 58: Combustion Profile Setup Guideline

    This is normal and due to the difference between wet and dry samples. Bear in mind the NX6100 will trim to the value of the Fireye probe, not to the value of a portable analyzer. For example:...

  • Page 59: Fireye Nx6100 Efficiency Calculations

    4) Ensure the ambient (inlet) temperature being measured by the hand held is physically at the air intake to the burner, as it should be for the NX6100. If the hand held equipment does not measure the inlet temperature, ensure the value it is using for ambient air temperature is representative of the application.
  • Page 60 6) Fireye O2 probes measure oxygen in the flue without extracting and drying flue gases. If attempting to compare the oxygen values being measured by the NX6100 and a hand held equipment ensure the value being given by the hand held is corrected from a dry to a ‘wet’ value, as it will almost certainly be measured as a ‘dry’...

  • Page 61: Typical Wiring Diagrams

    Supply (5Vdc) Infra-red flame Input Dig. i/p 8 (P1/P2 SEL) scanner Dig. i/p 9 (P3/P4 SEL) Dig. High test Analogue I/P 1+ NX6100 Analogue I/P 2+ Controller Analogue I/P 3+ Dig. Low test 1 Dig. i/p 1 Sensor Test PA10 PB10 Dig.
  • Page 62 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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