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Oxygen probe kit

The oxygen probe kit (series PPC5000) AH221245 consists of:

1 x NX280PK Oxygen probe

1 x Mounting flange kit

1 x Ambient air temperature sensor

1 x Probe heater transformer

Nexus PPC5000 Fuel Air Ratio Control System Commissioning sheet

General and Drive Positions

Site:

Engineer:

Comments

Serial No.

Boiler No;

Fuel:

Date

Profile:

Drive Position (°)

Setpoint

Drive:

Measured Oxy-
gen (%)

Flow
Value (%)

Oxygen
Setpoint (%)

PO (close)

P1 (purge)

P2 (ignition)

P10

P11

P12

P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

Summary of Contents for PPC5000

Page 1: ...ratio of one fuel to the other is maintained correctly A single 4 to 20mA signal varies the mix of the two fuels being fired Oxygen trim is needed for all simultaneous firing applications Fuels or fue...

Page 2: ...ation 20 Safety shutdown burner lockout 20 The display 21 Motor adjustment 24 Feedback potentiometer 24 Control direction 24 Adjusting microswitch positions 24 Locking the servo motor to the valve sha...

Page 3: ...oting inverter problems 50 Option parameters 51 Option parameter selection of profiles and drives 72 Derivation of modulation rate 73 Faults and fault finding 74 Fault listing 75 The engineer s key 79...

Page 4: ...ating parame ters of the equipment This equipment MUST only be mounted on to burners as detailed in the contracted specification The supplier must approve any change in the specification in writing Co...

Page 5: ...ft 61 meters to terminal inputs Operating limits interlocks valves etc b Modbus communications The maximum cable length of wire is 3200 feet 1000 meters for RS 485 FIGURE 1 Mounting the Control Unit...

Page 6: ...m 3 26 32 97mm 4 1 8 105mm 4 27 32 123mm so PANEL FRONT The display should be mounted on the front of the burner cabinet or similar accessible location as close to the con troller as is practical Refe...

Page 7: ...rews and remove the grey plastic lid to expose the connectors 7 Remove all the connectors 8 Undo the four hexagonal pillars and lift away the retainer frame 9 Carefully remove the distribution board 1...

Page 8: ...either supply 5v or 15v DC to the potentiometers If the potentiometer moves over its entire 270 range for 90 of servo motor travel select a 5v supply If the potentiometer is a 340 type but only moves...

Page 9: ...protected with a suitable fuse for the motors being used The fuse must not exceed 3A to ensure that damage to the control unit does not occur The servo motor time for 90 movement must not be less tha...

Page 10: ...000 controller This must be located as close as possible to the unit To comply with EMC requirements wire the control unit using the specified cable sizes and shield connections Clamp all signal cable...

Page 11: ...or interconnection to approved burner controllers should be obtained from the manufacturer Alternatively specific infor mation should be obtained by reference to the sup plier of this equipment These...

Page 12: ...ia its switched inputs so that the internal micro switches prevent the motor being damaged if it is driven to either end of its travel Motor feedback potentiom eter cabling must be overall shielded 3...

Page 13: ...nals externally or inter nally powered the PXMS XXX steam pressure sensor or a three wire resis tance thermometer Refer to the option links section for details on setting the correct voltage and input...

Page 14: ...ected to the COM PC5 terminal when the 5000 is at purge position The IGN PC6 terminal will be connected to the COM PC5 terminal when the 5000 is at the igni tion position See Appendix for details of h...

Page 15: ...checks The unit is set for the correct line supply voltage All other link positions are correct All fuses within the unit are intact and of the correct value All wiring and connections have been made...

Page 16: ...the burner select input PC12 is on for more than 3 seconds the unit will go to status 2 with F56 All drives motors and inverters are driven to their close P0 positions 4 WAIT FOR PURGE The safety shu...

Page 17: ...selected fuel drives are driven to their close P0 positions The unit will proceed to status 8 when all fuel drives have stopped moving The high low initiate input PC11 is ignored If the burner select...

Page 18: ...ured drive positions do not match P2 the unit will change to status 2 with a drive positioning fault 11 MOVING TO THE The safety shutdown output PC1 2 and the controlled LOW FIRE shutdown output PC3 4...

Page 19: ...and 17 and the high low initiate input PC11 are ignored 14 POST PURGE The safety shutdown output PC1 2 and the controlled shutdown output PC3 4 are both closed All selected air and option drives are d...

Page 20: ...ccur under the following conditions In stages 5 6 7 8 10 11 12 or 14 if a drive is not in the correct position During stage 6 a drive speed has been measured to be outside the allowable range During m...

Page 21: ...connected to the system For a motor drive the display may be in OPTION 1 5 terms of angular degrees or percentage opening For an inverter the display is 0 999 When the burner is on only the drives cu...

Page 22: ...f percentage concentration If the wiring or oxygen probe is faulty or if the probe has not reached it s operating temperature yet this display will show This display parameter may not be available dep...

Page 23: ...entage flow deviation from 25 to 25 If trim is selected but not currently available e g the burner is running through the start up sequence or oxygen probe not up to temperature the display will show...

Page 24: ...correct check that the correct potentiometer supply voltage has been selected Adjusting Microswitch Positions Each time a burner start up sequence is initiated the unit will move the fuel and air damp...

Page 25: ...otors are correct each motor must be locked to its valve shaft In order to prevent the joint between motor and shaft moving it is recommended that the device used to link the two items is pinned toget...

Page 26: ...to enter a commission mode Three pass codes are available for this purpose Supplier passcode allows entry to all commissioning modes Adjust ratio passcode allows adjustment of some option parameters a...

Page 27: ...t the option value then use the UP DOWN keys to change the value of the option parameter If the value has been changed the value will flash Press the key labeled COM ENTER to store the new value It wi...

Page 28: ...is essential that the combustion is verified at each firing position to ensure a hazardous condition cannot occur and for the data to be stored in the controller To adjust the position of a servomoto...

Page 29: ...e cur rent commissioning session are not lost and the AUTO MAN NEXT key may be used to step through the start up sequence and fire the burner 11 If a safety shutdown occurs the set points are kept in...

Page 30: ...oint number An and use the UP DOWN keys to adjust the value Each setpoint in the profile is referred to with a letter and number No Name Comments A0 Close The close setpoint cannot be altered in adjus...

Page 31: ...Wait for the motors to stop moving Leaving Adjust Ratio Mode To leave adjust ratio mode and return to run mode press the key labeled COM ENTER for 3 sec onds then press the same key again to return t...

Page 32: ...95 11 6 486 19 13 873 32 95 D 470 18 5 659 25 95 1013 39 88 Dimension 02 02 PROBE T C PROBE T C FLUE T C FLUE T C HEATER HEATER CUSTOMER CONNECTIONS INCH EQUIVALENTS ARE IN ALL DIMENSIONS IN MILLIMETR...

Page 33: ...ved to mount the probe Sulfate condensation will occur if the flue wall of an oil fired boiler falls below approximately 130 C The sulfate problem does not occur in gas fired installations but vapor m...

Page 34: ...ormance PART A PART B FLUE WALL MOUNTING PLATE BE220069 FLUE APERTURE COVER BE220059 GASKET BE220060 IN 2 POS NS PROBE MOUNT SYSTEM FLAT WALL FLUE PROBE MOUNT SYSTEM CYLINDRICAL VIEW OF MOUNTING PLATE...

Page 35: ...s Probe Cell Signal Cable Max voltage in use 15V dc Overall braid shielded 2 conductor PVC insulated 24AWG 7 32AWG 300V 80 C Max cable length 20 meters between units Heater and Flue Max voltage in use...

Page 36: ...ctor 22AWG 7 30 300V 80 C 7 0 2mm PVC insulated cable Wiring must com ply with all applicable codes ordinances and regulations and where required must comply with NEC Class 1 Line Voltage wiring 10 9...

Page 37: ...he unit only using the cable clamp provided If this cable is run in conduit with other cables its specification may need to be increased to ensure its voltage rating exceeds the maximum voltage carrie...

Page 38: ...hen enter The oxygen trim function will remain disabled and the system will be in calibrate refer ence gas mode 7 Apply the calibration gas to the oxygen probe calibration port ensuring that its value...

Page 39: ...probe body complete with the plug Since the body of the probe will be hot it will be necessary to use heat resistant gloves to hold the probe Remove the six retaining screws The probe can be extracte...

Page 40: ...l oxygen setpoint for the current point in the firing range Using air or fuel flow information entered into the unit at commission time the trim drive motor will be moved by an amount which will give...

Page 41: ...just ratio mode 2 Ensure oxygen trim or monitoring is selected by option parameter 30 0 1 or 2 3 Use the scroll keys to select the desired setpoint and move up and or down A4 for example The system wi...

Page 42: ...e oxygen reading has stabilized then record the excess air value at location b1 in the table relating to the current profile position 8 Repeat the above for all other profile positions including low f...

Page 43: ...c8 9 A a9 b9 c9 d9 e9 c9 d9 f9 e9 f8 g9 f9 y c9 10 A a10 b10 c10 d10 e10 c10 d10 f10 e10 f9 g10 f10 y c10 11 A a11 b11 c11 d11 e11 c11 d11 f11 e11 f10 g11 f11 y c11 12 A a12 b12 c12 d12 e12 c12 d12 f1...

Page 44: ...he new oxygen setpoint 3 The unit moves the air drives up to the point above the current setpoint leaving the fuel drive in the same position The display will show Flow calc An 1 When the new oxygen r...

Page 45: ...rature display Efficiency cannot be calculated for mul tiple fuel combinations Enter the value for the fuel in use Enter the flow values Oxygen display shows Burner off Transport delay not expired Pro...

Page 46: ...Oxygen Dry Oxygen Wet Notes 1 ETCsystemsdisplay Oxygen Wet Carbon dioxide Dry 2 North seagasR 0 32 Relationship between flue gases Heavy Fuel Oil Excess Air 0 00 2 00 4 00 6 00 8 00 10 00 12 00 14 00...

Page 47: ...nverter representing the speed of the motor In addition to the 4 20mA signals the inverter also requires a motor start signal that must be taken from the burner controller The motor start signal must...

Page 48: ...ystem will work with most inverters which meet the fol lowing criteria 4 20mA speed reference input 4 20mA speed feedback output Remote run stop command Fault relay for internal inverter and external...

Page 49: ...nter commission mode Look at the display for the drive mapped to the inverter output e g air damper 2 The display should show 0 for a feedback signal of 4mA and 999 for a feedback signal of 20mA If th...

Page 50: ...at the same time as the Nexus PPC 5000 fuel air ratio control system Check that the inverters output is selected to be linear and that the inverters own PID loop is disabled Current limit reached Noi...

Page 51: ...Motor supply voltage 0 1 The basic drive board AH221243 and isolated drive board AH221244 are supplied in two differ ent type variants The first variant is suitable for low voltage up to 50Vac high cu...

Page 52: ...nits or 1 for F units Note Changing option 03 1 will only change the temperature units for the RTD input the inlet tem perature display and the flue temperature display All other temperature related p...

Page 53: ...n parameter to 1 and leave setup mode The HOURS RUN display will reset and this option parameter will automatically be set back to 0 Options 04 1 to 06 5 Drive output mapping 0 12 Each drive shown on...

Page 54: ...ch all other drive positions are referenced when the burner is modulating The position of the lead drive must always increase consistently as the other drives move up the fir ing range If a drive does...

Page 55: ...their closed positions after the burner has turned off and there is no post purge If a post purge is desired this option may be set between 1 and 999 seconds inclusive Note This optional software cont...

Page 56: ...asured value input display range up to 9 99 with PID control Option 11 1 Setpoint 1 zero value 0 999 00 0 99 9 0 00 9 99 Option 13 1 Setpoint 2 zero value 0 999 00 0 99 9 0 00 9 99 When the appropriat...

Page 57: ...ed Option 11 7 Setpoint 1 remote zero value 0 999 When setpoint 1 is selected and the remote setpoint function is enabled see option parameter 03 3 this is the PID control value displayed when a 4mA s...

Page 58: ...t The parameter may be adjusted if the following conditions exist The unit is in set up or commission mode Option 12 0 14 0 is not set to zero The appropriate setpoint is selected Option 12 4 Setpoint...

Page 59: ...2 and parameter 16 3 determines the function of output 3 The digital output functions are detailed below 0 No function The output will always be off 1 Manual selected from keyboard The output will be...

Page 60: ...on 21 0 1 0 All air drives will be used except air dampers 2 3 and 4 1 All air drives will be used except air dampers 3 and 4 2 All air drives will be used except air dampers 2 and 4 3 All air drives...

Page 61: ...a stand alone mode 1 Sequence control enabled The unit will modulate and sequence its boiler according to instructions received from the lead boiler If communication with the lead boiler is lost the...

Page 62: ...gain value 0 999 This option parameter is only available if option 30 0 is set to 1 and an FMI board is installed in option slot 2 This option parameter must be set to the calibration gain value which...

Page 63: ...e fuel air ratio and start a timer As soon as the measured oxygen read ing begins to change stop the timer Set the option parameter to the recorded timer value in sec onds Automatic trim commissioning...

Page 64: ...ination to any value between 0 0 and 99 9 As a general recommendation the integral gain should be initially set to 15 0 If the burner is firing it is only possible to make an adjustment to the option...

Page 65: ...s 0 0 to 9 9 Option 37 0 Flue temperature alarm select 0 1 Option parameter 37 0 is only available with a flue monitor interface FMI board installed in option slot 2 If option 37 0 is set to 0 the flu...

Page 66: ...is interpolated between the two points For example if the oxygen limit has been entered as 5 of setpoint at low fire and 10 of setpoint at high fire the limit at mid fire will be 7 5 The alarm limits...

Page 67: ...p p m and therefore an entered value of 999 means 9990 p p m Option 46 0 CO level high alarm select 0 1 Options 46 1 to 46 7 CO level high alarm values 0 999 Option parameter 46 0 is only available if...

Page 68: ...displayed when 4mA and 20mA appear at the 4 20mA NOx input PM15 16 on the FMI board Note The values entered for these option parameters are in units of x10 p p m and therefore an entered value of 999...

Page 69: ...the high alarm value for any profile combination may be adjusted When the SOx level rises above the high alarm value for the selected profile combination a fault number will appear See section xxx fo...

Page 70: ...03 3 When output functions 2 to 12 are used the output zero and span values must be entered The option parameters determining zero and span values are detailed below Option parameter Zero Span 58 0 58...

Page 71: ...the unit has left set up mode this parameter will automatically be reset to 0 If this option parameter is set to 2 see warning above Option 70 1 Erase command 0 8 When erase enable option 70 0 is set...

Page 72: ...Profile 2 PC14 Profile 3 PC17 Input selection of profile Option params 20 X Option params 21 X FUEL 1 AIR 1 OPT 1 FUEL 2 FUEL 3 AIR 2 AIR 3 AIR 4 OPT 2 OPT 3 OPT 4 OPT 5 04 1 05 1 06 1 04 2 04 3 05 2...

Page 73: ...SWITCH by 13 0 13 0 0 13 0 1 13 0 2 3 4 5 ZERO SPAN 13 1 13 2 13 4 13 5 13 6 14 X PID LIMITS Modulation Measured value 13 3 Serial comms LOWEST PRIORITY HIGHEST PRIORITY Selection of Setpoint 2 Setpo...

Page 74: ...ccur but has now cleared For example F60 Means fault 60 has occurred and still exists L75 Means alarm limit 75 has been exceeded and is still being exceeded C73 Means fault or alarm limit 73 has occur...

Page 75: ...urred for one of the following reasons A potentiometric feedback signal from a servomotor is outside the range of 0 5v A 4 20mA feedback signal from a inverter drive is below 3 5mA above 21 0mA or has...

Page 76: ...option board installed correctly F46 Option slot 2 board not recognized The option board installed in option slot 2 is not recognized by the unit Is the option board installed correctly F47 Option slo...

Page 77: ...ot exist Are the lead drive option parameters set correctly Are the correct boards installed Subset lead drive F64 Drive not mapped A fuel air ratio has been selected which has one or more un mapped d...

Page 78: ...xceeded The measured SOx level has exceeded the high alarm value for the current profile or the SOx feedback signal is outside 4 20mA F91 Option board 1 calibration fault The calibration data on the b...

Page 79: ...it is not possible to change any parameters Therefore it is not possi ble to affect the operation of the burner Viewing engineer s key parameters After pressing the engineer s key The display will sh...

Page 80: ...stopped moving EK18 Fault alarm 0 Fault alarm off 1 Fault alarm on EK19 Setpoint low alarm 0 Setpoint low alarm off 1 Setpoint low alarm on The temperature pressure measured value has fallen below th...

Page 81: ...and ignition 4 Close purge ignition and 1 profile point 5 As 4 with 2 profile points 6 24 Continued as above EK41 Commission status Determines the current commissioning mode where 0 Run mode 1 Adjust...

Page 82: ...t setpoint Represents which drives are currently at their set points where 0 All drives are at their set points and are not moving NON ZERO One or more drives are not at or are unable to get to their...

Page 83: ...5 to 25 EK88 Excess air Excess combustion air at the current firing position EK89 Oxygen setpoint Current oxygen setpoint This is only available if trim is enabled and working EK90 101 Fuel 1 Option 5...

Page 84: ...rofile selected Hours run 999 hours Select oil or gas profile 1st digits show thousands 2nd show units Modulation rate is 0 Burner not modulating Wait for burner to finish startup sequence Burner stat...

Page 85: ...Set option parameter usually XX 0 to a non zero value to enable other params in group Option parameter not adjustable Wrong passcode entered or burner fir ing Enter the supplier passcode and or turn...

Page 86: ...ss RUN then ENTER to enter run mode Drives are stuck in purge position when burner is turned off Has post purge been selected Check option parameter 9 1 Post purge does not occur Has post purge been s...

Page 87: ...ioning accuracy 0 1 Possible option configurations1 1 x IDB 1 x FMI or 2 x IDB Basic motor drive board standard Maximum number of servo motors 4 Maximum motor current 150mA RMS high voltage pcb Maximu...

Page 88: ...ltage 5V D C for pot with full range travel 15V D C for 340 pot with 90 travel Potentiometer resistance2 set by jumper on PCB 1 to 5K ohms 5V 3 to 15K ohms 15V Number of isolated 4 20mA current output...

Page 89: ...transformer Nexus PPC5000 Fuel Air Ratio Control System Commissioning sheet General and Drive Positions Site Engineer Comments Serial No Boiler No Fuel Date Profile Drive Position Setpoint Drive Driv...

Page 90: ...X 2 XX 3 XX 4 XX 5 XX 6 XX 7 XX 8 XX 9 00 X 01 X 02 X 03 X 04 X 05 X 06 X 07 X 08 X 09 X 10 X 11 X 12 X 13 X 14 X 15 X 16 X 20 X 21 X 22 X 25 X 30 X 32 X 33 X 34 X 35 X 36 X 37 X 38 X 39 X 40 X 41 X 4...

Page 91: ...91 Distribution Board Connections AH221250 For use with 2 x IDB...

Page 92: ...92 AH221312 FOR USE WITH 1 X IDB 1 X FMI...

Page 93: ...S 232 only one ground IC485 12 vdc P S Belden 9939 E350 2 E350 2 PPC 5000 ED610 ED610 E110 EP160 E110 EP160 E300 E300 1 3 2 4 6 TXA RXA TXB RXB A B 1 3 2 4 6 7 8 MODBUS I F Ground PS 7 to 35 VDC NXMBI...

Page 94: ...is found defective in material or workmanship or which otherwise fails to conform to the description of the product on the face of its sales order THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES AND...

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