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Table of Contents

This manual (NEX-1001) describes the installation, commissioning, operation and maintenance of the
NX3000/3100/4000/4100/5100* integrated burner controllers with software revision up to and including Version 3.10.
It may be used in conjuction with the following other manuals:

NEX-1501 - ComFire combustion analysis tool user manual
NEX-SO - Boiler sequencing manual
NEX-1002 NEXUS Expansion Interface and Expanded Burner Control System
NEX-2004 Nexus, NX04-1, -2 Servo-Motor Installation
NEX-2020 Nexus, NX20-1, -2 Servo-Motor Installation
NEX-2050 Nexus, NX50-1, -2 Servo-Motor Installation
NEX-1001/3.1 Supplement - Describes special operation of the NX5100

Description.....................................................................................................................................1

Technical Specifications ............................................................................................................... 4

Approvals...................................................................................................................................... 7

Safety Information ........................................................................................................................ 7

Installation .................................................................................................................................... 8

Wiring ......................................................................................................................................... 13

Option Link Selection................................................................................................................. 21

Flame Scanners........................................................................................................................... 23

Operation in Run Mode .............................................................................................................. 24

Start-Up Sequence ...................................................................................................................... 25

Gas Safety Valve Proving Sequence........................................................................................... 26

The Display................................................................................................................................. 28

Control LED Indicators .............................................................................................................. 29

Servo-Motor Adjustment ............................................................................................................ 30

Operation in Commissioning Mode............................................................................................ 32

Operation in Adjust Ratio Mode................................................................................................. 36

Option Parameters ...................................................................................................................... 38

Faults and Fault Finding ............................................................................................................. 53

Engineer’s Key ........................................................................................................................... 59

Trouble Shooting ........................................................................................................................ 63

Commissioning Sheet ................................................................................................................. 66

Ordering Information.................................................................................................................. 81

Wiring Base Layout .................................................................................................................... 83

*Refer to NEX-1001/3.1 Supplement for NX5100 wiring and operation details.

Содержание NEXUS NX3000

Страница 1: ...g Closed Purge Ignition Preferred Start Low Fire and an additional 20 interme diate points from low to high fire Each individual servo motor s position and speed are verified and lockout will occur sh...

Страница 2: ...protec tion of the commissioned values All Setpoints and Options are password protected through the three levels of protection The various password levels provide Operators with Site protection Owner...

Страница 3: ...Motor Installation NEX 2050 Nexus NX50 1 2 Servo Motor Installation NEX 1001 3 1 Supplement Describes special operation of the NX5100 Description 1 Technical Specifications 4 Approvals 7 Safety Infor...

Страница 4: ...0kg including wiring base Type of Display 2 line 20 character dot matrix vacuum fluorescent Servo Motor Control Type AC up down with feedback potentiometer Maximum Number of Servo Motors 3 Channel 2 F...

Страница 5: ...Maximum Current 250 mA approximately supplied from unit Burner Select Type Digital 0V for off 90 264VAC for on Also provides feed for the pilot main 1 and main 2 Maximum Current Supplying circuit mus...

Страница 6: ...3 IP44 Dimensions 1 3 4 44mm dia x 3 3 8 85mm long incl connector Pipe Thread Mounting Dimensions NPT 1 BSP 2 Weight 1 lb 450g Working Pressure NX1025 0 58psi 0 4 bar NX1030 0 375psi 0 20 bar Burst P...

Страница 7: ...tallation commissioning or adjusting of this product MUST be carried out by suit ably trained engineers or personnel qualified by training and experience The manufacturer of this equipment accepts no...

Страница 8: ...signed to be mounted inside the burner control cabinet The cabinet should have a minimum protection level of NEMA 12 IP52 for indoor use or NEMA 4 IP54 for outdoor use The control unit should be mount...

Страница 9: ...mounted on the front of the burner cabinet or similar accessible location It extends for 1 2 40mm behind the panel and 0 2 3mm in the front of the panel 1 5 8 40mm 4 HOLES M4 CLEAR PANEL CUT OUT 3 7 1...

Страница 10: ...10 FIGURE 3 Control Unit Exploded View listed wiring base CONTROL UNIT ENCLOSURE CPU BOARD BACKPLANE BOARD BASEPLATE COVER BASEPLATE PSU BOARD UL listed base only...

Страница 11: ...mounting of the Motor to the Air Damper or Fuel Valve being controlled The Servo Motor MUST provide permanent connection to the controlled element to provide safe reliable and repeatable operation FIG...

Страница 12: ...servo motors must have internal limit switches fitted which are adjusted to prevent excessive rotation All servo motors must be able to drive the load imposed on them All servo motors must have suitab...

Страница 13: ...or UL approval all single conductor wiring should be TEW AWM or MTW within the cabinet Conductors to be pulled through conduit should be THHN or TFFN The maximum wire size that the wiring base will ac...

Страница 14: ...HOT L1 and NEUTRAL N L2 must be connected using multi strand single conductor PVC insulated 16 18 20 AWG 600V 90 C 16 02mm wire Wiring must comply with all applicable codes ordinances and regulations...

Страница 15: ...f a safety shutdown alarm relay 2 will go OFF connecting alarm 2 COM PC6 to alarm 2 N C PC5 These outputs must be connected using multi strand single conductor PVC insulated 16 18 20AWG 600V 90 C 16 0...

Страница 16: ...een the relevant terminals provided Do not connect these inputs to Line Voltage Flow com output and flow no flow inputs These terminals should be connected to the appropriate terminals on the burner s...

Страница 17: ...re temperature cabling must be overall shielded multi core number of conductors as required by the relevant sensor PVC insu lated 22AWG 7 30 300V 80 C 7 0 2mm wire Wiring must comply with all applicab...

Страница 18: ...ge rating must exceed the maximum voltage carried by any other cable in the same conduit UV Flame Sensor In the case of a non self checking scanner UV1A UV2 UV8A 45UV3 connect the scanner leads to ter...

Страница 19: ...e wiring Since this cable may be run in conduit with other wiring its voltage rating must exceed the maximum voltage carried by any other cable in the same conduit RS485 EXPANSION MODULE SEQUENCING CO...

Страница 20: ...lated cable 4 Fit sleeving to the braid to insulate the earth cable formed by the braid 5 Fit adhesive lined heatsink to cover the folded back screen and hold the earth sleeving 6 Adjust the earth con...

Страница 21: ...or For example POT SUPP potentiometer supply voltage JP1 The Controller can either supply 5V or 15V DC to the potentiometers and is selected with link JP1 If the potentiometer moves over its entire 27...

Страница 22: ...t the end of the communications bus should have this link set to the IN position All other units should have the link set to the OUT position If only two control modules are on the communications bus...

Страница 23: ...nfrared 1 2 90q angle mount 48 1 2m cable UV1A3 UV1A6 UV8A UV2 45UV3 1050 UV90 3 UV90 6 UV90 9 SC 102 UV 1 2 straight 36 0 9m flex conduit UV 1 2 straight 72 flex 1 8m conduit UV 1 2 90q head 72 1 8m...

Страница 24: ...position and the final measured positions are compared with the purge positions stored in memory 8 Pre Purge The timed pre purge t2 is initiated The fuel motor is moved towards the closed position du...

Страница 25: ...n fuel valve 4 Hold fuel valve 5 Prove closed posi tions 6 Prove air pres sure 7 Prove purge posi tions 8 Pre purge 9 Move to igni tion posi tions 10 Pre igni tion 11 Pilot igni tion 12 Pilot igni tio...

Страница 26: ...pressure may not drop by more than Ptest If this occurs the unit will indicate a fault A check is also made to ensure that the test section pressure is between the low gas pressure limit and high pre...

Страница 27: ...yboard up down keys if the NX550 Display is mounted or the external up down signals Safety Shutdown A safety shutdown will occur under the following conditions If any step of the gas proving sequence...

Страница 28: ...e 21 mA the display will flash Hi This display parameter is not available if tracking modulation input is selected SETPOINT Indicates the required pressure or temperature of the boiler according to th...

Страница 29: ...ion of the lead drive where 0 is low fire and 100 is high fire GAS PRESSURE Measured gas pressure in mBar This parameter is only available if the gas pressure sensor input is enabled see section on Op...

Страница 30: ...position decreases as UP is pressed or increases as DOWN is pressed reverse the servo motor output UP DOWN connections Adjusting microswitch positions Each time a burner start up sequence is initiate...

Страница 31: ...correct each servo motor must be locked to its shaft for all dampers and fuel valves In order to prevent the joint between servo motor and shaft moving it is recommended that the device used to link t...

Страница 32: ...al If any settings in the unit are to be changed it is necessary to enter a commission mode Three pass codes are available for this purpose 1 Site passcode allows adjustment of some option parameters...

Страница 33: ...isplay will flash COM Using option set mode Use the LEFT RIGHT scroll keys to point the select arrow at the option number on the top line of the display and use the UP DOWN scroll keys to display the...

Страница 34: ...ode the safety of the system is the sole responsibility of the commissioning engineer Incorrect positioning of either fuel or air could cause a hazardous situation to occur If the servo motor position...

Страница 35: ...red before and no change is required press AUTO MAN NEXT Otherwise move each servo motor to the required low fire position and press COM ENTER P04 next profile setpoint above low fire is displayed 8 R...

Страница 36: ...was correct A n will be seen on the display in addition to the servo motor positions for the servos being used for the selected profile where n is the number of the setpoint cur rently under adjustme...

Страница 37: ...ps 2 5 as required Each time step 5 is completed the new positions will be stored permanently 7 Leave adjust ratio mode If the A n display is flashing it will not be possible to adjust the position of...

Страница 38: ...oth fuels 4 Second damper stays open during purge for both fuel options If a second air damper is selected option 1 3 3 the air servo motor is available for both fuels air switch 2 is not required The...

Страница 39: ...the unit before a gas pressure limit fault is given For safety reasons this value should not be set to more than 200mBar below the nominal gas pressure Option 2 5 Gas pressure high limit 0 999 mBar T...

Страница 40: ...only applicable to the UL only product NX3100 4100 NX3000 4000 is always less than 1 second Option 3 5 Fan establish time 0 120 sec This option delays the opening of the valve and damper servos for th...

Страница 41: ...15 of the start up sequence this is the time at which the drives remain in their low fire positions before modulation Option 4 3 Post purge time 0 999 sec The time at which the drives remain in their...

Страница 42: ...and Px This means that it is not possible to over fire or under fire the burner but full trim may still be achieved and high and low fire Option 4 9 Direct Ignition on Oil 0 1 This Option allows the...

Страница 43: ...fety limit and perform a shutdown if the limit is exceeded see Fault Code Listing F41 for details Option 5 7 System modulation units 0 3 The system modulation units may be selected as shown below 0 If...

Страница 44: ...d this term was set to 1 00 then the proportional band would be from 4 00 to 5 00 bar A value of 0 means no proportional band Option 6 5 Setpoint 1 integral term 0 100 This is the integral term which...

Страница 45: ...ing limit 0 999 00 0 99 9 0 00 9 99 If the boiler s measured value is below the value of this parameter and the unit is in auto or sequenc ing mode the burner will be held at low fire Note the warming...

Страница 46: ...e 0 means no integral term Option 8 6 Setpoint 2 derivative term 0 100 This is the derivative term which is used in the PID control loop for setpoint 2 It may be set to any value from 0 to 100 where 0...

Страница 47: ...tical functions 14 to 20 Refer to Aux A to E inputs in wiring section for terminal designations If more than one input is selected to have the same function the lower number input is used Refer to fol...

Страница 48: ...d prevents the unit from going into a controlled shutdown condition burner off If the high level is removed the display will show LIMIT 42 and the limit relay will operate This is the function require...

Страница 49: ...the flame check is incorrect in either the false flame or flame not detected conditions Fault 9 or 10 6 Valve proving The output will be on if any fault related to the value leakage tests occur Fault...

Страница 50: ...see option parameters 10 1 and 10 2 the unit will assert itself as the lead boiler If two or more units have been set as lead sequencing is disabled Option 12 5 Standby low limit control value 0 999 0...

Страница 51: ...s a 2 the option parameter data has been up loaded into the unit ensure all option parameters are set to match the requirements of the burner it is connected to Failure to do so could cause a hazardou...

Страница 52: ...nt modulation setting Numbers refer to Option Parameters ZERO SPAN PID LIMITS 6 0 0 6 0 1 2 3 SETPOINT SELECT LOWEST PRIORITY ZERO SPAN LOWEST PRIORITY HIGHEST PRIORITY ZERO SPAN If 3 3 1 PE14 is 20mA...

Страница 53: ...550 display Use the Engineer s select key to view the FAULT NUMBER and look up the fault num ber s shown to discover why the fault occurred If all faults which caused a safety shutdown have cleared ho...

Страница 54: ...eed 2 During this time a speed measurement is made for each drive F7 Air damper 1 illegal speed These faults will occur if a drive is outside the allowable speed range of 10s 90 to 60s 90 Is the POT S...

Страница 55: ...this function when the unit is firing on gas F23 Forced lockout oil firing A forced lockout has occurred due to the removal of the high level on auxiliary input configured to provide this function wh...

Страница 56: ...ed The boiler s measured value has exceeded the pressure temperature safety limit or the Fireye pressure temperature sensor is not responding correctly Subset 1 sensor feedback 1V 2 sensor feedback 5V...

Страница 57: ...tpoint as defined by the commissioned fuel air ratio for the selected profile Reference error on expansion unit or communications error L60 between units A drive is defined as having moved from its se...

Страница 58: ...ption parameter Its value is displayed on EK 90 F76 Secondary flame sen sor input fault The flame sensor input is not responding correctly If the fault persists for 23 hours the burner will be shutdow...

Страница 59: ...value above warming limit burner free to modulate 1 Measured value below warming limit burner held at low fire if the unit is in auto or sequencing mode EK17 PID SP Selected 1 2 Indicates which setpoi...

Страница 60: ...ission ratio profile where 1 Gas profile 1 2 Oil profile 1 3 Gas profile 2 4 Oil profile 2 EK31 Commission Setpoint The current commission ratio setpoints 0 Closed setpoint 1 Purge setpoint 2 Ignition...

Страница 61: ...Damper 1 Servo Motor Setpoint EK48 Air Damper 2 Servo Motor Setpoint EK49 Gas Servo Motor Error How far each servo motor is from its setpoint in angular degrees EK50 Oil Servo Motor Error EK51 Air Da...

Страница 62: ...y trim 25 to 25 EK78 Excess Air Excess combustion air at the current firing position EK79 Oxygen Setpoint Current oxygen setpoint This is only available if trim is enabled and work ing EK80 Fuel Flow...

Страница 63: ...before shutdown displayed Gas pressure not shown Gas sensor not selected Select sensor using option parameter 02 0 Gas pressure incorrect Wrong zero or span Check option parameters 2 1 and 2 2 PROBLEM...

Страница 64: ...meter supply incorrectly selected Change the link on the backplane board to select a 5V potentiometer supply Servo motor feedback will only go up to approx 35 5V potentiometer supply incorrectly selec...

Страница 65: ...across range and check f back Modulation rate sticks at a profile setpoint Lead drive position similar or same as adja cent setpoint Enter commission ratio mode and change the lead drive setpoints or...

Страница 66: ...relay output not used 1 Auxiliary relay output used to control the Oil Pump off unless firing on oil and burner status between sequence 10 and 16 Table 1 Start up sequence 2 Auxiliary relay output use...

Страница 67: ...for V P S 2 Type NO valve Output energized to close valve powered at sequence 5 2 9 Fuel Valve Proof of Closure 0 Deselected no proof of closure function selected 1 Gas Valve Main 2 Only checked 2 Oil...

Страница 68: ...mode 5 4 Modulation Speed 25 100 Default 100 5 5 Modulation Sensor Input Type 0 0 5V operation Set the SENSOR IN link to V Set the SENSOR SUPPLY link as required 1 4 20 mA operation Set the SENSOR IN...

Страница 69: ...d 7 2 are the actual limit values 2 Deviation limit The values entered in option parameters 7 1 and 7 2 represent a deviation from the setpoint 1 con trol value This means that if the setpoint control...

Страница 70: ...elease to ignite 6 Release to modulate 7 Lead boiler select 8 Profile select 9 Purge Hold Switch close hold purge 10 Oil valve proof of closure 11 Gas valve proof of closure 12 Trim Enable 10 1 I P A...

Страница 71: ...LLOWABLE VALUES 10 7 I P 3 Function Oil Select 0 Oil Selected 1 Auto Manual selection 2 Manual Up 3 Manual Down 4 Setpoint select 5 Release to ignite 6 Release to modulate 7 Lead boiler select 8 Profi...

Страница 72: ...ating 9 Burner Control Value Exceeded 10 Safety Limit Exceeded 11 Burner at Low Fire Hold 12 Burner in Manual Control 13 Burner in PID or Tracking Modulation Control 14 Fuel 1 Selected 15 Fuel 2 Selec...

Страница 73: ...ter speed control enabled for relevant fuel profile 2 Auxiliary damper control enabled for relevant fuel pro file 3 Inverter and auxiliary damper enabled for relevant fuel profile 14 4 Inverter Auxili...

Страница 74: ...file 3 0 0 99 9 24 4 Trim Integral Gain Profile 4 0 0 99 9 25 0 Trim Proportional Gain default 0 Not selected 1 Selected Proportional Gain available for each profile 25 1 Trim Proportional Gain Profil...

Страница 75: ...O non volatile lockout 2 Alarms Enabled WITH non volatile lockout 29 1 Oxygen Low Alarm values at Low Fire for Profile 1 0 99 9 29 2 Oxygen Low Alarm values at Low Fire for Profile 2 0 99 9 29 3 Oxyge...

Страница 76: ...not modulating 2 Boiler pressure Temperature measured value 3 Boiler pressure Temperature setpoint 4 Calculated efficiency 5 Inlet temperature 6 Flue temperature 7 Oxygen level 8 CO2 level 9 Gas press...

Страница 77: ...nput 0 999 41 2 Span values for AUX 2 input 0 999 41 3 High Limit values for AUX 2 input 0 999 42 0 4 20 mA Input function AUX 3 Same as 40 0 42 1 Zero values for AUX 3 input 0 999 42 2 Span values fo...

Страница 78: ...ith the FGR damper closed is achieved Table 3 SAFETY TIME CONFIGURATION OPTION 4 0 CONFIGURATION PROVE AIR PRESSURE SUPERVISE D PURGE PRE IGNITION PILOT TRIAL FOR IGNITION PILOT IGNITION INTERVAL MAIN...

Страница 79: ...Profile 3 Fuel 1 Air 1 Air 2 Close P0 Close P0 Purge P1 Purge P1 Ignition P2 Ignition P2 Low Fire P3 Low Fire P3 P4 P4 P5 P5 P6 P6 P7 P7 P8 P8 P9 P9 P10 P10 P11 P11 P12 P12 P13 P13 P14 P14 P15 P15 P1...

Страница 80: ...Profile 4 Fuel 2 Air 1 Air 2 Close P0 Close P0 Purge P1 Purge P1 Ignition P2 Ignition P2 Low Fire P3 Low Fire P3 P4 P4 P5 P5 P6 P6 P7 P7 P8 P8 P9 P9 P10 P10 P11 P11 P12 P12 P13 P13 P14 P14 P15 P15 P1...

Страница 81: ...t mounting UL recognized links and fuse set for 230V Display Part Number Description NX550 Panel mount 2 line by 20 character vacuum fluorescent display with eight multi function key pad NX551 Hand he...

Страница 82: ...to be ordered per site NXSO Passcodes to enable ComFire software for Nexus or PPC controllers for boiler lead lag sequenc ing Note Passcodes are based on the serial number of the Nexus or PPC5000 cont...

Страница 83: ...Damper 1 pot ground Ov Damper 2 pot supply Damper 2 feedback in Damper 2 pot ground Ov Aux modulation input supply 24V Aux modulation input in I P Aux modulation input ground Ov Gas pressure sensor su...

Страница 84: ...84...

Страница 85: ...85...

Страница 86: ...ells which 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 WARR...

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