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This manual describes the installation, commissioning, operation and maintenance of the PPC4000
series fuel air ratio controls. It may be used in conjunction with the following other manuals:

•

BL-1001 – BurnerLogix Flame Safeguard Bulletin

•

YZEM-3001 – YZ300 Interlock Annunciator for use with BurnerLogix

•

E-1101 – Flame-Monitor Flame Safeguard Bulletin

•

E-3001 – E300 Expansion Module for use with Flame-Monitor

•

NEXBK-1000 - Nexus bracket and coupling accessories

•

NEX-3004 - Nexus FX04 series 4Nm servo motor

•

NEX-3020 - Nexus FX20 series 20Nm servo motor

•

NEX-3050 - Nexus FX50 series 50Nm servo motor

•

NXCESO2-1001 - OXYGEN PROBE

•

133-750 - O2 mounting flange installation instructions

•

NXD-4101 - NXD410 User Interface

•

NXCESVFD - VFD plug-in board installation

•

NXTSD-4001 - Touchscreen user’s guide

•

FXIATS-1 - Ambient air temperature transmitter

The equipment described in this manual is capable of causing property damage, severe
injury, or death. It is the responsibility of the owner or user to ensure that the equipment
described is installed, operated and commissioned in compliance with the requirements of
all national and local codes.

Warning: Electro-mechanical high steam pressure or high water temperature limits
must remain in the running interlock circuit of the flame safeguard control.

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Содержание PPC4000 SERIES

Страница 1: ...ependent PID control loops for temperature or pressure control provide precise accurate control of firing rate for unmatched response to load changes Ten safety rated user definable line voltage input...

Страница 2: ...ction limits mechanical stress Assured low fire cutoff Sequencing for up to 6 boilers SD Secure Digital interface for backup and restore Modbus RTU communications via RS485 with read write capability...

Страница 3: ...motor NEX 3050 Nexus FX50 series 50Nm servo motor NXCESO2 1001 OXYGEN PROBE 133 750 O2 mounting flange installation instructions NXD 4101 NXD410 User Interface NXCESVFD VFD plug in board installation...

Страница 4: ...ency Drive 37 Commissioning with VFD 41 Oxygen Probe Setup 42 Setting Trim Limits 44 General Rules for O2 Alarm Notification 45 Flue Temperature Alarm Limits 46 Gain Terms 47 Understanding O2 Error Co...

Страница 5: ...age 4 F to 158 F 20 C to 70 C Humidity Rating 85 RH non condensing Protection Category NEMA 4X indoors only IP65 Unit Dimensions Panel Cutout 5 35 136mm W x 3 78 96mm H Shipping Weight NXD410 Approx 1...

Страница 6: ...16 9 2 lbs 4 17kg NXCES02 30 11 4 lbs 5 17kg Servos Supply Voltage FX04 24 VDC 10 FX20 24 VDC 10 FX50 24 VDC 10 Power Consumption Peak FX04 5 VA Nominal 7 5 VA peak FX20 15 VA nominal 35 VA peak FX50...

Страница 7: ...o 85 C Fitting 1 4 NPT Male Electrical 1 2 Conduit and Terminal Strip APPROVALS Underwriter s Laboratories Inc File MJAT MH10808 UL353 LISTED SECTION OF A FUEL AIR RATIO SYSTEM File MJAT2 MH10808 UL35...

Страница 8: ...FX20 1 X X X FX50 FX50 1 X X X Oxygen Probe NXCESO2 8 NXCESO2 16 NXCESO2 30 Transducers BLPS 15 X X BLPS 25 X X BLPS 30 X X BLPS 200 X X BLPS 300 X X TS350 2 4 8 X X TS 752 2 4 8 X X FXIATS 140 X Fla...

Страница 9: ...onnectors on both ends PVC jacket temperature rating 40 C to 105 C meets NEMA 1 3 4 6P and IEC67 59 565 40 Cordset 40 feet 1 2 NPT connectors on both ends PVC jacket temperature rating 40 C to 105 C m...

Страница 10: ...nduit with line voltage circuits Use separate conduit where necessary 7 Maximum wire lengths a Terminal inputs Operating limits interlocks valves etc 200 feet 61 meters b Line voltage inputs 500 feet...

Страница 11: ...ugs into the PLC port located on the backside of the NXD410 The cable dis tance from the PPC4000 to the NXD410 is limited to 10 feet 3 meters wire run FIGURE 3 NXD410 Rear View The bottom edge of the...

Страница 12: ...IGH 3 LOW 4 AUTO 5 P4 6 P3 7 P2 8 P1 P4 1 ALARM IN 2 ALARM OUT 3 OCRC IN 4 OCRC OUT EARTH P3 L1 LINE IN L2 NEUTRAL 10 KS In 9 P 8 TBD 7 TBD 6 TBD 5 TBD 4 TBD 3 AUX 2 8 1 D P13 1 DI 10 2 DI 9 3 DI 8 4...

Страница 13: ...PCV 11 0 P3 L1 LINE IN L2 NEUTRAL EARTH P13 1 DI 10 2 DI 9 3 DI 8 4 DI 7 5 DI 6 6 DI 5 7 DI 4 8 DI 3 9 DI 2 10 DI 1 11 12 1 2 3 4 6 5 7 8 9 10 11 12 P14 top P14 bottom P14 1 encoder 2 2 encoder 1 3 4...

Страница 14: ...em where it can be subjected to vibra tion in excess of 0 5G continuous maximum vibration The PPC4000 system is not a weather tight enclosure The standard vertical position is recommended Allow at lea...

Страница 15: ...terface Servo VDC Return 0 VDC 59 562 BLACK P2 5 Common O2 User Interface Servo VDC Return 0 VDC 59 565 BLACK P2 6 Common O2 User Interface Servo VDC Return 0 VDC 59 565 BLACK P11 1 Common 0 VDC VDC R...

Страница 16: ...1mA P15 4 Input AUTO FSG Modulation Mode 120 230 VAC 1mA P15 5 Input P4 Profile 4 Select 120 230 VAC 1mA P15 6 Input P3 Profile 3 Select 120 230 VAC 1mA P15 7 Input P2 Profile 2 Select 120 230 VAC 1mA...

Страница 17: ...Table 2 Note A general rule to follow when selecting the sensor range is that the expected value of the monitored pressure or sensor should fall between 35 75 of the upper range of the sensor For exam...

Страница 18: ...9 Make all pipe connections in accordance with approved standards 10 When tightening the sensor apply a wrench to the hex flats located just above the pressure fitting DO NOT tighten by using a pipe...

Страница 19: ...rate conduit DO NOT install sensor wiring in any conduit or junction boxes with high voltage wiring 5 Maximum wiring distance for sensor wiring is 100 feet WARNING Location of the temperature sensor t...

Страница 20: ...aving female connectors on both ends are available in 6 and 40 foot lengths Field wire able connectors and cable are also available See ORDERING INFORMATION for part numbers Servo types FX04 FX20 and...

Страница 21: ...ld wire able connectors are available in kit form 129 192 Fireye recommends cable part number 59 565 to be used for servo wiring As shown above the cable strip length is specified at 30 mm 1 2 in and...

Страница 22: ...The fan will turn on when the internal temperature exceeds 70 C 158 F and turn off when the temperature drops below 45 C 113 F The O2 probe mounts in the stack using Fireye mounting flange kit 35 381...

Страница 23: ...12 11 4 N C 3 EARTH DRAIN EARTH 2 DGND RETURN BLACK P2 5 1 24V POWER RED P2 1 Remove power when servicing SW1 Provides fault reset and forced calibration JP1 Baud rate selector In is 57600 PPC4000 Out...

Страница 24: ...of NXD410 keypad The and characters act as alignment indicators To move to a sub menu or modify a parameter the user places the menu line or parameter between these two characters Several functions o...

Страница 25: ...trol to be MASTER or SLAVE The LED illu minated indicates the unit is a MASTER If the SEQUENCING does not provide for keypad selection then this key has no function 4 AUTO MAN Switch to automatic cont...

Страница 26: ...L T H I S T O R Y P A S S C O D E S E T U P O I L T E M P 3 1 4 7 F S T A C K T E M P 4 3 2 5 F G A S P R E S 5 X X X i n w c 1 1 3 6 A M 1 7 A U G 1 0 W A I T F O R P U R G E s 0 6 HOME S E T P O I...

Страница 27: ...shown above with DISPLAY FORMAT lying between the characters pressing the MDFY SAVE key will allow you to scroll through options to select the desired value Pressing the MDFY SAVE key will save the se...

Страница 28: ...scode 2 Go back to the PASSCODE menu now change the SITE CODE Level 1 passcode as desired REAL TIME CLOCK The PPC4000 contains a real time clock that is used to record fault history and implement the...

Страница 29: ...used to direct the control to scan the servo communication port and return the number of servos found This is done by hitting the NEXT key only For this example after doing this the display should be...

Страница 30: ...checking the movement of the servo and driven member Take care not to overdrive the servo such that the driven member is attempting to move beyond its mechanical end stop The servo can be left in any...

Страница 31: ...ensor and range of sensor From the top layer menu move SENSOR SETUP to between the characters and press NEXT to enter the SENSOR SETUP sub menu The parameter UNITS is to select units of measurement fo...

Страница 32: ...etpoint and set the values for that setpoint based on the sensor selected The SETPOINT SETUP menu is as follows Select SETPOINT 1 and press the NEXT key to enter the sub menu The values shown are the...

Страница 33: ...ure or water temperature will increase the control output signal causing the valves and dampers to move toward their respec tive high fire positions The value of the P BAND determines how the PPC4000...

Страница 34: ...sum of SETPOINT plus CUT OUT Alarm points for stack monitoring can be set anywhere within the sensor range Both INTEGRAL and DERIVATIVE terms are used to eliminate steady state error and reduce over s...

Страница 35: ...l inputs The digital inputs are located on terminal block P13 10 DI1 through P13 1 DI10 All digital inputs are user defined from a list of functions The same function can be tagged to multiple digital...

Страница 36: ...ED and only the digital inputs can be used to realize the function If only one digital input is used and is set to AND then this alone being active will realize the function KEYPAD SETUP Several hot k...

Страница 37: ...the O2 probe The intent is to provide this output to a chart recorder or some other display device of the user s choice See ANALOG OUT SETUP submenu Each VFD channel if selected to be used as a VFD is...

Страница 38: ...endent on the encoder used a Total encoder count is determined by the encoder s counts per revolution specification and motor s maximum revolutions per minute RPM The allowable range is 300 to 5000 wi...

Страница 39: ...ring the accel decel period the VFD is allowed to move to its next posi tion and not be checked for errors until the time has expired 9 When using flame safeguard controls that require the air flow sw...

Страница 40: ...complete commissioning or adjust ratio procedure is executed immediately after the change and for all profiles using the VFD Performance notes 1 When controlling a VFD setting GAIN and INTEGRAL to in...

Страница 41: ...arious signal values to 1 of 3 available 4 20 mA outputs The ANALOG OUTPUT SETUP menus is displayed as follows Pressing MDFY SAVE at the prompt will open the selection menu for items than can be mappe...

Страница 42: ...the means to enter all O2 parameters relating to trim If not enabled when pressing the MDFY key the user will be diverted to the passcode screen where at least the Adjust ratio code must be entered M...

Страница 43: ...es to degrees of trim at low fire Selecting DEFAULT will implement a trim limit of 0 1 degrees at low fire MANUAL allows users to enter trim limit at low fire for each profile assigned See section tit...

Страница 44: ...atio between air and fuel in any combustion system and therefore if select ing fuel as the trimming servo trim limits should be selected so as to allow only sufficient movement to achieve the desired...

Страница 45: ...lustrates the HI and LO settings for above and below the O2 curve It is the responsibility of the installing and operating personnel to ensure the trim limits selected do not allow a hazardous combust...

Страница 46: ...l alarm timer is reset to 0 when the actual O2 level returns to within the accept able zone FLUE TEMPERATURE ALARM LIMITS The PPC4000 provides flue temperature limits for each profile Available is the...

Страница 47: ...econd A value of 0 is a special case and disables the integrator A lower value of integration will slow down calculations and add time to reach the target value 3 BOILER TRANSPORT DELAY can be defined...

Страница 48: ...UNDER LIMIT Temperature in probe is lower than 13F 25C 60 CPU CRC ERROR Hardware fault in probe 61 CPU RAM ERROR 62 CPU SELF TEST 63 24 VOLT LOW FAULT Voltage in probe not within 18 30 vdc limits 64...

Страница 49: ...on commissioning or adjustment of operating parameters of the equipment A profile is a set of points defining the servo motor positions along the burner s operating curve The operating curve begins at...

Страница 50: ...rule applies to commis sioning points greater than P03 low fire A violation of this rule will prevent the user from moving to the next commissioning point or exiting commissioning 12 If a user is modi...

Страница 51: ...ssed the value on the line showing the servo being modified will change back to the current position This value will be changing as the servo moves to the new target position Repeat as necessary for t...

Страница 52: ...the UP and DOWN keys the user moves the servo to be posi tioned into the shaded area and presses the MDFY key The UP and DOWN keys are then used to select the new target position The displayed value r...

Страница 53: ...sioned unit hitting the NEXT key at P03 moves the display to indicate P04 but with the same servo positions as P03 At each subsequent setpoint position the user will most likely increase each servo po...

Страница 54: ...ng Points The firing rate curve a k a modulation rate is automatically established by the installer during the commissioning process of the burner Setpoint p03 is the first position in AUTO and corres...

Страница 55: ...e the AIR servo is close to 35 degrees Graph 2 VFD used The reason for the difference between the two example curves is due to the AIR servo s upward curv ing slope but the FUEL servo s slope is strai...

Страница 56: ...be used to start and adjusted accord ingly during system check out During commissioning with oxygen and with the O2 OPERATION set to CONTROL the O2 level and flue temperature currently being measured...

Страница 57: ...hin dead band about target 5 O2 level stable stable being steady reading plus minus 0 2 6 Servos stop moving for 20 seconds regardless the O2 level The trim servo will never move the maximum range of...

Страница 58: ...d If not currently enabled the system directs the user to the passcode setup screen where the user must enter the necessary adjust ratio passcode level 2 If the user enters the commissioning passcode...

Страница 59: ...no non linear setpoints entered This means that no setpoint will be allowed that would make the servo movement change direction as the setpoint number is increased from a03 to the maximum setpoint ent...

Страница 60: ...one under SENSOR SETUP in the top layer menu The values shown represent the maximum value of the sensor range COLD START THERMAL SHOCK PROTECTION Cold Start Thermal Shock Protection is a method to slo...

Страница 61: ...il the thermal shock start point is achieved The units and range displayed are determined by the sensor type selected THERMAL EXIT Thermal Shock Exit Point Sets the steam pressure or water tempera tur...

Страница 62: ...PPC4000 will automatically advance the firing rate position to the next segment position COMMUNICATIONS SETUP The communications setup is needed to configure the PPC4000 to effectively perform Modbus...

Страница 63: ...setback setup information is cancelled or erased END STBCK End Setback Period This setpoint determines at what time the PPC4000 changes over from the setback setpoint to the normal setpoint SETPOINT 1...

Страница 64: ...according to its setback setpoints for as long as this contact is closed regardless of the pro grammed setback schedule FORCED SETBACK has highest priority STANDBY WATER Only Sensor 2 can be used to m...

Страница 65: ...l is displayed as a 0 to 100 level cor responding to the level of the signal being applied The modulation rate will be identical to this value and the servos will be moved to their respective position...

Страница 66: ...PPC4000 Safety relay contacts to be placed in 3 P circuit of YB110 LOGIC STATE MESSAGE DESCRIPTION s01 STANDBY s01 Burner is in off condition Burner control switch is open Keypad Burner ON OFF comman...

Страница 67: ...o damper open position Servos move to P01 PPC4000 8 servos at damper open position Purge time begins servos exit open damper position End of purge YB110 12 begin low fire start P02 move servos to igni...

Страница 68: ...rd is used for profile select Wait for LOW fire start request from flame safeguard Turn off high fire switch output 8 Send low fire start signal D to flame safeguard HIGH and AUTO are OFF To page 2 St...

Страница 69: ...Burner switch closed PCV below cut out AUTO signal from flame safeguard on Go to low fire position Output low fire signal D Drive servos to low fire position Go To STATE 01 after NO profile select NO...

Страница 70: ...5 6 7 8 9 10 11 1 1 1 12 10 12 11 2 3 8 9 7 6 5 4 1 1 2 1 1 4 3 2 1 1 1 6 5 4 3 1 2 TDB TDB 59 562 2 Burner Switch and other Recycling Running Interlocks FX20 1 ORG BRW All drain wires to be attached...

Страница 71: ...H FIRE LOW FIRE AUTO P15 P4 P5 1 24 Vdc Red 4 Vdc Return Black 2 8 7 6 5 4 3 2 1 1 3 4 1 1 8 D P KS 1 2 3 5 6 7 8 10 9 1 4 TDB TDB 13 3 P S1 S2 L1 L2 N E BURNERLOGIX SYSTEM CONFIGURATION YB110 YP1XX S...

Страница 72: ...8 9 10 11 1 1 1 12 10 12 11 2 3 8 9 7 6 5 4 1 1 2 1 1 3 2 1 1 1 6 5 4 3 1 2 TDB TDB 59 562 2 Burner Switch and other Recycling Running Interlocks FX20 1 ORG BRW All drain wires to be attached to grou...

Страница 73: ...L HIGH FIRE LOW FIRE AUTO P15 P4 P5 1 24 Vdc Red 4 Vdc Return Black 2 8 7 6 5 4 3 2 1 1 3 4 1 1 8 D P KS 1 2 3 5 6 7 8 10 9 1 4 TDB TDB 13 3 P S1 S2 L1 L2 N E FLAME MONITOR SYSTEM CONFIGURATION E110 E...

Страница 74: ...ded pair is recommended such as Belden and each unit is daisy chained to the next unit That is a cable is routed from the first unit to the second unit A connected to A B connected to B from the secon...

Страница 75: ...n and off Below is a table showing parameters programmed into each master The value in the last column of the 1st 2nd and 3rd Slave On values are the communication addresses previously mentioned that...

Страница 76: ...ns when the modulation rate exceeds the SLAVE ON RATE While the time set above is expiring and the boiler load falls below the slave ON RATE the com mand to begin to bring on the slave will be cancell...

Страница 77: ...mer master will await commands from the new master If the master boiler is switched to manual modulation it will remain as master bringing on slave boil ers as required This will allow the master boil...

Страница 78: ...n order to enter any of the sub menus listed above an SD card must be installed BACKUP OPERATION The BACKUP function provides options that backup all profiles and setup data collectively all pro files...

Страница 79: ...peration by moving the selection between the two tick marks on the display Use the UP and DOWN keys as necessary Press the NEXT key to begin the BACKUP operation If the pass code is not enabled the us...

Страница 80: ...our profiles in the PPC4000 will be overwritten and replaced from a file extension PFO 3 TO PROFILE X restores profile data only to a specific PPC4000 profile X can be 1 2 3 or 4 from a file with exte...

Страница 81: ...ze properly DELETE OPERATION The purpose of DELETE is to allow the user to remove files from the SD card The files to be removed are files located on the SD card in the FIREYE folder pertaining to the...

Страница 82: ...le may not agree with the number of servos connected to the PPC4000 Also the addresses and assign ment designations in the servo setup may not agree with the data in the profile Likewise when paramete...

Страница 83: ...file Setpoint Drive VFD OXYGEN STACK CO Net Eff Name LEVEL TEMP CW r r r r FS CCW r r r r CNTS Wet Dry ENCODE F C PPM p00 p01 p02 p03 p04 p05 p06 p07 p08 p09 p10 p11 p12 p13 p14 p15 p16 p17 p18 p19 p2...

Страница 84: ...file Setpoint Drive VFD OXYGEN STACK CO Net Eff Name LEVEL TEMP CW r r r r FS CCW r r r r CNTS Wet Dry ENCODE F C PPM p00 p01 p02 p03 p04 p05 p06 p07 p08 p09 p10 p11 p12 p13 p14 p15 p16 p17 p18 p19 p2...

Страница 85: ...lay contacts are welded Check wiring to specific terminal e5 SAFETY RELAY OFF This means that the system is not sensing a live inter lock voltage on its safety relay input This could be as a result of...

Страница 86: ...2 has reached user defined limit setting This could be normal operation e31 SENSOR2 HIGH LIMIT SENSOR 2 has reached user defined limit setting This could be normal operation e32 SENSOR3 HIGH LIMIT SEN...

Страница 87: ...supply voltage at the probe e65 O2 FAULT O2 Probe 12V supply open Replace O2 Probe e66 O2 FAULT O2 Probe 12V supply low Replace O2 Probe e67 O2 FAULT O2 Probe 12V supply high Replace O2 Probe e68 O2 F...

Страница 88: ...ss selection check wiring add 200 resistor e124 SERVO 3 LOST Communications to the servo has stopped Check servo address selection check wiring replace servo e125 SERVO 4 LOST Communications to the se...

Страница 89: ...LT Replace servo e166 SERVO 5 ERROR Servo has detected an Internal FAULT Replace servo e167 SERVO 6 ERROR Servo has detected an Internal FAULT Replace servo e168 SERVO 7 ERROR Servo has detected an In...

Страница 90: ...OFF RATIO Servo may have exceeded its torque capacity In this order Excessive torque position hitting hard stop defective servo e225 SERVO 4 OFF RATIO Servo may have exceeded its torque capacity In t...

Страница 91: ...D BOARD FAULT VFD Board CPU error Replace VFD Board e269 VFD BOARD FAULT VFD Board CPU error Replace VFD Board e270 VFD BOARD FAULT VFD Board CPU error Replace VFD Board e271 VFD BOARD FAULT VFD Board...

Страница 92: ...ng RESET will restore factory default values e332 NO FAULT HISTRY DATA Stored fault history data is corrupted Pressing RESET will restore factory default values e333 NO SETBACK DATA Stored setback dat...

Страница 93: ...cing data is corrupted Pressing RESET will restore values from stored memory e386 PPC4000 FAULT o2 setup data is corrupted Pressing RESET will restore values from stored memory e387 PPC4000 FAULT adju...

Страница 94: ...on pressed on servo 4 Inspect Servo for button obstruction wires touching e424 SERVO FAULT Manual move button pressed on servo 5 Inspect Servo for button obstruction wires touching e425 SERVO FAULT Ma...

Страница 95: ...s purge time is needed to create the free air 20 95 oxygen concentration condition that is expected in order for the probe to calibrate properly Extended purge time may be required for larger systems...

Страница 96: ...r to the combined system or its overall performance WARRANTIES FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture of its products to replace or at its o...

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