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Option 03.6 - Limit Modulation Range (0/1)*

By default, the unit modulates the burner between the set points P3 (low fire) and Px (high fire),
where Px is the last setpoint entered in commission ratio mode. If oxygen trim is fitted, it is not pos-
sible for any drive position to be trimmed lower than point P3 (low fire) or higher than point Px
(high fire).

This option parameter allows the normal modulation range of the burner to be limited so that the
burner may only modulate between points P4 (one setpoint above low fire) and Px-1 (one setpoint
below high fire). Since oxygen trim is not affected by this limitation, each drive may be trimmed
between the points P3 and Px. This means that it is not possible to over-fire or under-fire the burner
but full trim may still be achieved at high and low fire.

0

-

Not limited. Burner modulates from P3 to Px

Oxygen trim works over full range from P3 to Px

1

-

Normal modulation range limited to P4 to Px-1

Oxygen trim works over full range from P3 to Px.

Option 03.8 - Reset hours run (0/1)*

This option parameter allows the HOURS RUN display for all fuels to be reset to zero. To perform a
reset, set this option 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 the display may be mapped to a particular output. See section 8.2 for a dia-
grammatic explanation.

If a drive is not required (such as fuel 2 on a single fuel burner) then its mapping value should be set
to zero. If a drive is required, then its corresponding mapping value should be set to a value between
1 and 12, which then maps that drive to the specified output (see table below).

OUTPUT NO.

OUTPUT

CONNECTOR

0

No drive required

Output

Feedback Input

1

Basic drive board, motor output 1

PE2-PE3

PD16-PD18

2

Basic drive board, motor output 2

PE4-PE5

PD11-PD13

3

Basic drive board, motor output 3

PE7-PE8

PD8-PD10

4

Basic drive board, motor output 4

PE9-PE10

PD2-PD4

5

Isolated drive board 1, motor output 1,

PF7-PF8

PG8-PG10

6

Isolated drive board 1, motor output 2,

PF5-PF6

PG3-PG5

7

Isolated drive board 2, motor output 1

PJ7-PJ8

PK8-PK10

8

Isolated drive board 2, motor output 2

PJ5-PJ6

PK3-PK5

9

Isolated drive board 1, inverter 4-20mA 1

PH4-PH5

PH11-PH12

10

Isolated drive board 1, inverter 4-20mA 2

PH2-PH3

PH9-PH10

11

Isolated drive board 2, inverter 4-20mA 1

PL4-PL5

PL11-PL12

12

Isolated drive board 2, inverter 4-20mA 2

PL2-PL3

PL9-PL10

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Содержание PPC5000

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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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