PPC-4001 OCTOBER 20, 2011 PPC4000 SERIES FUEL AIR RATIO CONTROLLER DESCRIPTION Fireye PPC4000, the newest member of the Nexus family, is a state of the art parallel positioning system for all types of liquid or gaseous fuel fired combustion systems. When combined with a Fireye flame safeguard system such as the Fireye BurnerLogix control, the PPC4000 offers the most compact and advanced parallel positioning system available.
When required, the operating system of the PPC4000 and NXD410 will automatically direct the user to the passcode setup screen and when entered correctly will take the user directly to the parameter requested, making the entire system user-friendly.
Warning: Electro-mechanical high steam pressure or high water temperature limits must remain in the running interlock circuit of the flame safeguard control. This manual describes the installation, commissioning, operation and maintenance of the PPC4000 series fuel air ratio controls.
TABLE OF CONTENTS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Oxygen Probe Setup . . . . . . . . . . . . . . . . . . . . . 41 Key Features of the PPC4000 System . . . . . . . . 2 Setting Trim Limits. . . . . . . . . . . . . . . . . . . . . . . 43 PPC4000 System Specifications . . . . . . . . . . . . . 5 Commissioning Procedure . . . . . . . . . . . . . . . . 48 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Commissioning Rules . . . . . . .
PPC4000 SYSTEM SPECIFICATIONS PPC4000 Control: Supply Voltage: PPC4000 120 VAC (+10%, -15%) 50/60 Hz Power Consumption: 25 VA Temperature Rating: 32°F to 140°F (0°C to +60°C) Protection Category: NEMA 1 (IP01) Unit Dimensions: 5.0" (127 mm) W x 8.0" (203.2mm) H x 4.0” (101.6mm) D Shipping Weight: PPC4000: Approx. 3.2 lbs. (1.
FX20: 20 Nm, 15 ft./lb. FX50: 50 Nm, 37 ft./lb. Rotational Span: 1 degree to 99.9 degrees Actuating time of 90 degree rotation: 30 seconds Accuracy: 0.1 degree Shipping Weight: FX04: Approx. 2.27 lbs (1.1 kg) FX20: Approx. 5.43 lbs (2.5 kg) FX50: Approx. 6.10 lbs (2.77 kg) Temperature Sensors: Temperature Measurement Range: TS350-X: 32°F to 350°F (0°C to 176°C) TS752-X: 32°F to 752°F (0°C to 400°C) RTD Type: Platinum, 100 ohms ± 0.1% @32°F (0°C) Temperature Coefficient:.
APPROVALS Underwriter’s Laboratories Inc.: File MJAT.MH10808, UL353 • LISTED SECTION OF A FUEL AIR RATIO SYSTEM File MJAT2.MH10808, UL353 - COMPONENT File MJAT7.MH10808, CSA-C22.2 No 24 • LISTED SECTION OF A FUEL AIR RATIO SYSTEM File MJAT8.MH10808, CSA-C22.
PART NUMBERS AND APPROVALS Table 1: Agency Approvals Fireye Part Number Control PPC4000 X X X User Interface NXD410 X Servos FX04, FX04-1 X X X FX20, 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 Flame Safeguard YB110UV X X X X X X YB110UVSC X X X X X X YB110IR X X X X X X YB110FR X X X X X X
ORDERING INFORMATION Control PPC4000 Parallel positioning system, 120 VAC input. Used with flame safeguard control NXCESVFD Plug-in assembly provides variable frequency (VFD/VSD) capability 60-2926 Enclosure, 12.5” x 10.5” x 6.5”, UL listed, fitted for PPC4000 129-190 Kit, fan replacement NXD410 User Interface with keypad, 24 VDC operation, 4 line back lit LCD display, panel mount only, includes mounting brackets.
INSTALLATION PROCEDURE 1) A UL listed fuel/air ratio system is comprised of the following items. a.) PPC4000, fuel/air ratio controller b.) 60-2926, enclosure c.) NXD410, user interface d.) FX series servos 2) Wiring must comply with all applicable codes, ordinances and regulations. 3) Wiring must comply with NEC Class 1 (Line Voltage) wiring. 4) To minimize interference from radio frequency energy generated by the PPC4000 control, it is necessary that all control wiring be placed in conduit.
FIGURE 1. Mounting Kit Completed Assembly Gasket Fastening Screw Bracket Fastening Nut Bracket mounting locations (4 places) Peel paper from gasket surface The bracket assembly mounts from the rear of the display with the fastening nut against the backside of the panel. Use the following dimensions for the panel cutout. FIGURE 2. Panel Cutout 3.78” (96mm) PLC Port 5.35” (136mm) Use Fireye cable, part number 59-562-2 to connect from the NXD410 to the PPC4000 control.
P15 1. TBD 2. HIGH 3. LOW 4. AUTO 5. P4 6. P3 7. P2 8. P1 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. SD Activity P1 3 Pin 1 Pin 1 P1 5 Pin 1 P3 P5 Pin 1 P4 P3 L1 - LINE IN L2 - NEUTRAL EARTH P4 1. ALARM IN 2. ALARM OUT 3. OCRC IN 4. OCRC OUT 12 STATUS/ALARM Pin 1 P5 10. KS In 9. P 8. TBD 7. TBD 6. TBD 5. TBD 4. TBD 3. AUX 2. 8 1.
P12 1. mbus A 2. mbus B 3. seq A 4. seq B 5. servo A 6. servo B 7. dis TX,ye 8. dis TY,bl 9. dis Rb,br 10. dis Ra,or 11. O2 A 12. O2 B 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. n P12 Pin Pin 1 Pi n 1 Pi P14 P11 Pin P2 P15 1 P13 1 Pi n 1. encoder (2) 2. encoder (1) 3. 4-20 in (2) 4. 4-20 in (1) 5. 4-20 out (2) 6. 4-20 out (1) 1 P14 1 Pin P2 1. 24 vdc 2. 24 vdc Servos 3. 24 vdc Servos 4. 0 v 5. 0 v 6. 0 v P15 1. TBD 2. HIGH 3. LOW 4.
PPC4000 INSTALLATION Install the PPC4000 control where the relative humidity never reaches the saturation point. The Nexus PPC4000 system is designed to operate in a maximum 90% relative humidity continuous, non-condensing environment. Do not install the PPC4000 system where it can be subjected to vibration in excess of 0.5G continuous maximum vibration. The PPC4000 system is not a weather tight enclosure. The standard vertical position is recommended.
The PPC4000 is mounted to the cabinet back plate using 4 X #8-32 screws. Following the mounting dimensions shown in Figure 4, drill and tap 4 mounting holes. Firmly screw the control to the cabinet back plate. WIRING CONNECTIONS Terminal Type P3.1 L1 Line Voltage Supply P3.2 L2/N Line Voltage Common EARTH 120 VAC (+10%, -15%) 50/60 Hz Chassis ground connection P4.1 Input Alarm Relay Input Voltage free contacts P4.2 Output Alarm Relay Output Voltage free contacts, 3A 250VAC P4.
Terminal Type P13.1 D1 10 Digital Input #10 120 VAC @ 1mA P13.2 D1 9 Digital Input #9 120 VAC @ 1mA P13.3 D1 8 Digital Input #8 120 VAC @ 1mA P13.4 D1 7 Digital Input #7 120 VAC @ 1mA P13.5 D1 6 Digital Input #6 120 VAC @ 1mA P13.6 D1 5 Digital Input #5 120 VAC @ 1mA P13.7 D1 4 Digital Input #4 120 VAC @ 1mA P13.8 D1 3 Digital Input #3 120 VAC @ 1mA P13.9 D1 2 Digital Input #2 120 VAC @ 1mA P13.10 D1 1 Digital Input #1 120 VAC @ 1mA P13.
PPC4000 MOUNTING AND WIRING As a convenience, the PPC4000 is equipped with de-pluggable type terminal blocks. It is recommended the PPC4000 be wired with the terminal blocks inserted into the control as shipped. Following the wiring connections table above, make all electrical connections in accordance with the application requirements. The suggested order of wiring is as follows: 1. Power inputs, L1, L2, Earth (AWG 18, 300 vac) P3.1, P3.2 2. NXD410 user interface using Fireye cable 59-562-2 P12.7-P12.
Table 2: SENSOR RANGE and SETTINGS Part Number Sensor Type Set Point Range 1.0 - 14.0p 70m - 950m Mod Range Increment Decrement Cut In Cut Out 0 - 6.0p 0 - 410m 0.3 - 6.0p 20m - 410m 0.3 - 6.0p 20m - 410m 0.1p 10m BLPS-15 0 - 15 psi 0 - 1030m BLPS-25 -14.7 - 25 psi 1.0 - 14.0p -1013 - 1720m 70m - 1500m 0 - 6.0p 0 - 410m 0.3 - 6.0p 20m - 410m 0.3 - 6.0p 20m - 410m 0.1p 10m BLPS-30 0 - 30 psi 0 - 2070m 1.0 - 28.0p 70m - 1950m 0 - 6.0p 0 - 410m 0.3 - 6.0p 20m - 410m 0.3 - 6.
MOUNTING TEMPERATURE SENSORS The immersion style temperature sensors have a ½” NPT mounting for the 2", 4", and 8" thermowell probes, and a ½” conduit fitting for electrical connections. WARNING: Location of the temperature sensor to monitor boiler water temperature of a steam boiler is critical. The sensor should be mounted where it is always exposed to the circulation of the boiler water, not too close to a hot or cold inlet or steam coil.
SERVO MOTOR SETUP AND WIRING The PPC4000 requires at least one servo in each profile to be named as AIR. AIR is always the primary servo. The modulation rate, low fire to high fire, and therefore the air and fuel servo positions are derived from the AIR servo commissioning values. Each servo is equipped with an internal rotary switch that is used to select its communication address. The address range is 1 to 10.
Cables and Connectors Cord sets having female connectors on both ends are available in 6 and 40 foot lengths. Field wireable 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 each wire strip length is 7 mm (0.275 in). To use cable 59-565, strip one end as specified. Strip each wire and wire to connector as shown.
NXCES02 OXYGEN PROBE The NXCESO2 oxygen sensing probe is designed to operate with the PPC4000 and provides trimming of the air or fuel servos to maintain predefined O2 target levels resulting in optimum combustion. Refer to Commissioning and Adjust Ratio procedures. The NCESO2 also provides the stack temperature measurement. The user has the option to activate both O2 level and flue temperature level alarms and the alarms can be selected to be warning or lockout.
NXCESO2 Dimensional Information FIGURE 5. CLEARANCE REQUIRED TO REMOVE AND INSTALL FROM FLUE . SEE DIM "C" SEE DIM "B" FROM FACE OF MOUNTING FLANGE 119.4 4.70 OVERALL VERTICAL DIM SEE DIM "Y" 1/2 NPT CONDUIT ENTRY SEE DIM "A" CLEARANCE REQUIRED TO REMOVE AND INSTALL. FROM FLUE. SEE DIM "D" FLUE GAS OVERALL HORIZONTAL DIM SEE DIM "X" 38.10 1.50 MODEL NUMBER DIM "A" DIM "B" DIM "C" DIM "D" DIM "X" DIM "Y" NXCES02-8 ( 44) 1.69 (216) 8.50 (426) 16.75 (324) 12.75 (445)17.50 (121) 4.
NXD410 User Interface The NXD410 User Interface provides the means to setup, monitor and display all information from the PPC4000 Control and connected accessories. The NXD410 provides a four line backlit LCD display screen and a multi-function tactile feel keypad. The NXD410 is panel mounted and connects directly to the PPC4000 using Fireye cable 59-562-2. Explanation of NXD410 keypad The > and < characters act as alignment indicators.
The NXD410 and PPC4000 Control contain a number of Quick Keys that allow the user to access that function directly. For these Quick Keys to operate the installer or operator must first access the KEYPAD SETUP menu where the user defines if a Quick Key is used or unused. Quick Keys are also non-volatile meaning the state of the switch function is retained in memory should a power recycle occur. No LED Key Name Description 1 BURNER ON/OFF KEYPAD SETUP required. Used to turn the burner ON or OFF.
The HOME key is used to bring the user directly back to the top layer menu and display the default items. Any item in the top layer menu that contains a > character indicates there is a sub menu below it. The NEXT key is used to move to the next sub menu showing parameters for that item. The BACK key is used to revert from the sub menu back to the previous level menu. Various menu items may have several sub menus.
The UP and DOWN keys are used to scroll forward and backward through the top layer menu. The menu is continuous in both directions. That is, when you reach the bottom and continue with the DOWN key, for example, the very top of the menu will be displayed on the next line. As stated earlier, hitting the HOME key from anywhere will bring you back to the HOME screen. The shaded area shown in the Top Layer Menu section on page 25 is the HOME screen.
On first application of power, with conditions as stated above, the display will indicate: > S S M M T E E O A T A D N P S U D O U L B I R A Y N E T T D I O V N A L R A T U U E N N U U s S S 0 E E 0 1 D D % < The Operating control relay (OCRC) will remain open and the servos will remain at their respective installed positions. For PASSCODE protected parameters, if the passcode is not enabled, the user will be automatically directed to the PASSCODE setup screen.
SERVO SETUP From the HOME screen the user scrolls to SERVO SETUP and presses NEXT to enter the sub menu. The following is displayed: > < D S S S I E E E S R R R P V V V L O O O A S Y S S P I E F E N T O E S U R D T P M A T A L L D 3 E D E 0 0 G S > < The user can select between degrees and percent full scale and the speed of the servos with the range of 30s, 60s, 90s or 120s. This is the speed of the servos from 0 degrees to 90 degrees.
The first parameter that must be set is to name the servo. Each servo must be named and at least one servo of each profile must be named AIR. The table below lists the options for naming the servo and also to what profiles the servo is tagged.
position to 10.0 degrees. Press SAVE and the display will indicate the original position and change as the servo is moving toward its target position. The final display for servo 1 should look like the following: > < S A D S S E S I E E R S R R R V I E V V O G C O O N T N M I P 1 A E O O M N N S E T I T I O N 1 0 A I . C 0 R 1 W < ° Press the BACK key to return to the SERVO SETUP sub menu. Select SERVO 2 using the NEXT key to move the SERVO 2 sub menu.
For this application, at SENSOR TYPE press MDFY. Use the UP or DOWN keys to select STEAM and press SAVE. At SENSOR RANGE, press MDFY and use the UP or DOWN keys to select 15psi and press SAVE. The display will be as follows: > < S S S E E E N N N S S S O O O R R R T R 1 Y A P N E G S 1 E T 5 E p A s M i < Press the BACK key twice to get back to the top layer at the point where we left it or press HOME to go directly back to the HOME screen.
Definitions: LIMIT TYPE DEV - Values that deviated from setpoint. The advantage is these values will float with the setpoint. SETPOINT - The target pressure or target temperature the control will maintain. CUT IN (Cut In Value) - Determines the point in which the steam pressure (or water temperature) must reach to start a burner cycle. In DEV option, this a differential value that is subtracted from the steam pressure or water temperature setpoint.
PROFILE SETUP In the top layer scroll to PROFILE SETUP and press NEXT to enter this sub menu. This menu provides the means to name the profile, set the maximum modulation rate for this profile and when necessary erase the profile setpoints. > < P P P P E P R R R R R R O O O O A O F F F F S F I I I I E I L L L L L E E E E A E L S 1 2 3 4 L E T U P N N N N D A T A E T U P O O O O N N N N E E E E N > > > > O < N 1 O 0 N 0 N E % O < Using the NEXT key, select PROFILE 1.
The list of general purpose functions for all digital inputs is as follows: > M B S U E L R T O A N U O N P W A A S T 2 E O L L F T R R I F A R B I N I R M C C M C T R M O D K U O 2 E D E N N R U S O N U T S H E L T V A S R L O S A B R B E O C L E T C D L D L T D T E K E E < If DIGITAL INPUT 1 (DI1) is to be set as BURNER CONTROL, at DI1 press the NEXT key to display the following: > < U A D S C I E T 1 S E T U P U I O N U N S A E N D D < AND / OR FUNCTION For fun
VARIABLE FREQUENCY DRIVE In addition to using a precision servo motor to control the air flow into a combustion chamber, the PPC4000 can control one or two variable frequency drives (VFD/VSD) with the result being better control over air flow and improvements in combustion. Electrical energy savings and additional gains in efficiency are quickly realized when controlling P14 pin 1 the combustion blower motor with a VFD.
Each VFD channel has its own separate and independent sub menu. The following assumes that VFD2 is moved between the two tick marks and the NEXT key is pressed to display the following configuration menu. < V A D E R G I T A S V V F S I N U A N O C T F F D S S C N I T L C O D D I P O N E E E P N G L D M 2 A N A E O M M Y R D E E A N D I P L C E M O N F C T O O R U M N A T 4 T S U , N 3 E 2 G R L 2 R A / T E C E S E L I T I O U , C 1 A 0 S 2 N 0 U .
a.Gain is the amplification of the error signal. This error signal is the deviation between feedback and control. A high gain can result in unstable operation and cause overshoot. The range is 1.0% to 100% with an increment of 0.1% and a default of 20.0%. b.Integral is the time between error corrections or updates to the VFD. A high rate of updates (short integral time) to the VFD can result in unstable operation.
6. Removal of a VFD from the commissioning table (set ASSIGNMENT to 0), will require a re-commissioning without the VFD. That is, lockout will occur if the profile (with the missing VFD) is used during the next burner cycle. 7. VFD's normally require motor start signals. This is usually derived from a relay energized by terminal M (combustion blower output) of the flame safeguard. The normally open contacts are connected to the start input terminals located the VFD. 8.
ANALOG OUT SETUP This menu is found in the top layer and is used to map various signal values to 1 of 3 available 4-20 mA outputs: ANA 0 OUT Output P11.5 Return P11.4 VFD 1 OUT VFD 2 OUT P14.6 P14.4 P14.12 P14.
OXYGEN PROBE SETUP The NXCESO2 oxygen probe provides continuous oxygen (O2) content and stack temperature readings from the stack and when properly connected and configured to the PPC4000 allows the PPC4000 to trim the air or fuel servo to achieve optimum combustion. Refer to earlier sections of this bulletin for information regarding installation and wiring of the NXCESO2.
Menu item HEAT LOSS TURNDOWN RATIO CALIBRATE ENABLE TRANSPORT DELAY TRIM TYPE TRIM LIMIT RATIO TRIM LIMIT TRIM LIMIT (X) TRIM P-GAIN (X) TRIM I-GAIN (X) Value 0.0% 3 NO YES 0s AIR FUEL 3 DEFAULT MANUAL 2 6% 95 WARNING LOCKOUT O2 FAULT ALM O2 LEVEL ALM 42 UNUSED WARNING LOCKOUT Description Used to calculate boiler efficiency. Percentage of boiler output lost through the shell of the boiler at high fire. The default is 0% and ranges to 9.9% in 0.1% increment.
Menu item O2 LO ALM@LO (X) O2 LO ALM@HI (X) O2 HI ALM@LO (X) O2 HI ALM@HI (X) Value 0.5% UNUSED WARNING LOCKOUT FLUE TEMP ALM FLUE TEMP LO (X) FLUE TEMP HI (X) 40F 40F Description LO refers to O2 level alarm limits below the O2 curve. HI refers to O2 level alarm limits above the O2 curve The values entered are the deviation from the current target value. The default value is 0.5% O2 deviation and the range of values is 0.1% to 5.0% in 0.1% increment.
At lower firing rates, a small movement of the servo is required to cause a significant change in the air/fuel ratio as compared to high fire. It is the responsibility of the installing and operating personnel to ensure the trim limits selected do not allow a hazardous combustion condition to occur. In the event of an O2 probe failure the untrimmed commissioned servo setpoints will be used. Trim limit ratio = 3 Trim Limit = 2 degrees Firing Trim limit rate% Degrees 0 2.0 10 2.4 20 2.8 30 3.2 40 3.
FIGURE 7. O2 Level Alarm Limits 10 O x y g e n L e v e l Hi ALM @ LO 9 O2 ALM@Hi 8 O2 Level 7 O2 ALM@Lo 6 Lo ALM @ LO 5 Hi ALM @ HI 4 3 2 0 10 20 30 40 50 60 70 80 90 100 Lo ALM @ HI Firing Rate Each profile will have its own set of alarm level values. The alarm value for each succeeding profile setpoint is interpolated from these inputs. Rules for alarm notification: a. The O2 level drops below the absolute value of 0.5% O2 for 30 seconds. b.
FIGURE 8. Flue Temperature Limits 700 Degrees 600 Acceptance 500 Zone 400 Flue Temp Flue Temp Lo Flue Temp Hi 300 200 0 10 20 30 40 50 60 70 80 90 100 Firing Rate Note: The PPC4000 requires the flue temperature to be above the high limit or below the low limit for 30 seconds before action takes place. GAIN TERMS O2 trim is performed using the current O2 level, the current saved target value and the boiler transport delay.
The message O2 FAULT eXX contains the error message causing the lockout or warning event.
COMMISSIONING PROCEDURE: WARNING It is the purpose of this bulletin to explain the operation of the PPC4000 control and the NXD410 User Interface along with required FX servo motors and pressure/temperature transducers. The servo motors control the air and fuel on the burner independently in accordance with the commissioned information.
COMMISSIONING RULES 1. Commissioning mode is used for entering new setpoints in a profile. 2. Existing setpoints can be modified in commission mode or adjust ratio mode. 3. Only commissioning mode can be used to modify setpoints P00, P01 and P02. 4. Setpoints P03 and higher will not be affected when C-MODE is exited at P02 or lower. 5. There are 24 possible positional setpoints per profile, number P00 to P23. P00, P01 and P02 are reserved for closed (standby), purge and ignition.
For illustrative purposes the shaded line represents the > < characters on the keypad and the AIR servo shown below is selected for modifications. > < A G O C I A I O R S L M ( ( ( M 1 3 2 I ) ) ) S I O N I N G 3 1 2 p . . . 0 1 9 6 0 ° ° ° < To move a servo press the MDFY key and use the UP and DOWN keys to select the target position. > < A G O C I A I O R S L M ( ( ( M 1 3 2 I ) ) ) S I O N I N G 8 1 2 p . . .
also enter the purge position and output to the PPC4000 the high fire command. The high fire command output from YB terminal X is connected to a designated digital input, HIGH, on the PPC4000 controller. If a profile is selected but terminal X, P15.
Note: Since it is easily assumed the first 'guess' at the ignition positions will not provide a satisfactory light-off, it would be suggested to place the YB110 in the CHECK position during PTFI and MTFI to allow adjustment of the above servo positions to get the optimum light-off firing condition. To adjust the servos, the aforementioned procedure is used. The SAVE key retains the data. After reaching the AUTO stage, the YB110 outputs this state on its terminal 11.
The above graph is an example of a commissioned burner. It is by no means representative of any particular burner. It is shown for illustrative purposes only. The intent of the graph is to show the AIR and GAS servo positions in degrees after commissioning profile setpoints P00 through P11 and to show the calculated modulation firing rate curve. Position P03 is 0% and position P11 is 100%. The last setpoint entered is considered the high fire or 100% modulation point.
For AUTO modulation: A M A G > U O I A T D R S O U ( ( L 1 3 A ) ) T I O N R A T 6 3 1 9 8 s 0 . . 1 0 5 0 6 % ° ° 6 3 1 9 8 s 0 . . 1 0 5 0 6 % ° ° E < For MANUAL modulation: A M A G > U A I A T N R S O U ( ( A 1 3 L ) ) M O D R A T E < To adjust the modulation rate, the user will press MDFY and use the UP and DOWN keys to position the servos. The modulation will change with the UP and DOWN arrows.
At each profile setpoint the target value is saved to interim memory by first using the MDFY key to position the air or fuel servo to their appropriate positions and pressing the SAVE key. After a sufficient wait time to achieve a reliable O2 reading the NEXT key is pressed to save the target value to the setpoint table and move forward to the succeeding profile setpoint. During commissioning and adjust ratio, O2 trim is not enabled.
ADJUST RATIO PROCEDURE Adjust ratio is used after the profile has been commissioned and all setpoints have been entered. Adjust ratio mode is used only for modifying an existing profile from low fire (P03 through P23) through high fire. No new setpoints can be entered with adjust ratio. It is not possible to modify the close (P00), purge (P01) or ignition (P02) positions using adjust ratio mode. All other commissioned setpoints can be modified in any order.
While in adjust ratio mode and in STANDBY, s01, the burner can be made to turn on and will cycle through its normal sequence. 1. During the purge and ignition sequence the user will be able to view all programmed setpoints for that profile. No change to any setpoint can be made when below p03. 2. Upon reaching the AUTO state, s16, the modulation rate or servo positions will move to the point corresponding with the displayed adjust ratio setpoint. 3.
4. Flue temperature is required to calculate efficiency. 5. Efficiency will be shown in AUTO only. 6. Items relating to efficiency are not shown if O2 OPERATION is DISABLED. Sensor 4 and 5 Sensors 4 and 5 are provided to connect an inlet air temperature to be used for the boiler efficiency calculation. Fireye provides 3 ranges of inlet air temperature: -50°F to 300°F (-45°C to 149°C), -40°F to +140°F (-40°C to 60°C), 32°F to 350°F (0°C to 176°C). The following table applies to both sensor 4 and 5.
perature) is reached, the firing rate motor is positioned according to the modulating control algorithm. The units and range displayed are determined by the sensor type selected. • MIN. LOW FIRE (Low fire minimum): Use this selection to set the servo positions are the calculated firing rate position during the low fire method operation. The range is 0 to 100% and the increments are 1%. . SEGMENT METHOD: This method of cold start thermal shock protection is generally used with Fire Tube Boilers.
NOTE: 1. If the sensor being used for thermal shock is the same type as the PCV sensor (steam or water) the Thermal Shock Exit value cannot be greater than the PCV setpoint. THERMAL OVERRIDE: The Timed Override Per Segment Setpoint (THERMAL OVERRIDE) allows the user to program a maximum time period, 0 to 60 minutes, in which the control will wait before forcing an in increase in firing rate to the next segment position.
SETBACK OPERATION With the real time clock in the PPC4000, scheduled setback operation can be implemented to allow the system to operate to an alternate steam pressure or water temperature during off peak times. The scheduled setback time applies to every day of the week. That is, there are not individual setback times for each day of the week.
Assured Low Fire Cutoff If the modulation rate is greater than 25% at the Begin Setback period (BEGIN STBCK) when the PPC4000 is scheduled to operate according to the reduced setback setpoints, the PPC4000 will delay opening the operating control output until the servo motors reach the low fire position, P03.
TRACK MODULATION Track modulation is the application of a 4-20 mA signal to the sensor 1 input and having the modulation rate move the servos associated with the current profile to the corresponding firing rate position. The 4-20 mA input signal corresponds to 0% to 100% firing rate with 4 mA being 0% firing rate and 20 mA being 100% firing rate. To use TRACK MODULATION, SENSOR 1 usage must be set to TRACK.
The current burner stage is usually shown on the NXD410 User Interface placed after the current burner status. The following describes each possible stage. LOGIC STATE MESSAGE s01 STANDBY s01 s02 WAIT FOR PURGE s02 s03 s04 s05 s06 N/A Burner is in off condition. Burner control switch is open. Keypad Burner ON/OFF commanding burner off. Servos are in P00 position. Command given to turn burner on.
AUTO, move to modulation Fuel Valve YB110-7 YB110-11 Pilot Valve PTFI MTFI P03 to P23 YB110 low fire start time expired P02, move servos to ignition position servos exit open damper position servos at ignition position begin low fire start End of purge Purge time begins YB110-6 servos at damper open position Servos move to P01 move to damper open position wait for purge selects profile wait for profile select Ignitor Xfrmr P0 Assumptions: PCV below cut-in PPC4000 control commissioned A
Unit powered, setup and commissioned PPC4000 Sequence of Operation Revision 1.4 State 01 Servos in closed position, P00, operating control relay open, safety relay can be closed, low fire output on STANDBY NO burner switch closed? YES After State 01 and throughout the cycle – If Burner Switch Off or Profile input lost or PCV above cutout, go to State 17 and shutdown.
From page 1 When low fire purge is completed by flame safeguard, PTFI begins IGNITION State 11 – State 14 reserved for future – ignition and main light off sequence (PTFI, PILOT, MTFI, MFEP) NO Wait for AUTO signal from flame safeguard State 15 Move to LOW FIRE position State 16 AUTO MODULATION Digital Input or Keypad Low Fire has priority if AUTO signal on NO During modulation (AUTO or MANUAL), if at low fire output low fire signal (D). If at high fire output high fire signal (8).
FIGURE 9.
TDBTDB+ Drain 24 Vdc Return (Black) 24 Vdc (Red) 1 NXCESO2 P5 Non-Recycling Running Interlocks 10 9 KS P 8 7 6 5 4 3 2 1 8 Disconnect Means and Overload Protection Required. A Good Earth Ground is Essential.
FIGURE 10.
TDBTDB+ Drain 24 Vdc Return (Black) 24 Vdc (Red) 1 NXCESO2 P5 Non-Recycling Running Interlocks 10 9 KS P 8 7 Fuel Valve End Switch 6 5 4 3 2 1 8 D Disconnect Means and Overload Protection Required. A Good Earth Ground is Essential.
BOILER SEQUENCING Sequencing is used in a multiple boiler (2-4) environment where a master boiler, during normal operation, is established to control the remaining slave boilers in order to achieve the desired setpoint as set in the master boiler. Any boiler can be a master, and in a sequencing operation, only one boiler can be the master at a time.
MASTER SELECT METHOD This parameter provides for the selection of the master boiler via the keypad, digital input or communications. The available selections are: UNUSED: No SEQUENCING selected, operates on own PID. KEYPAD: Master selection via the Keypad - the LEAD/LAG button is used to select the master. INPUT: Master via digital input. (Refer to DIGITAL INPUT select) COMMS: Master selection via modbus communications. Note: modbus communications will be available when this note is no longer shown.
In sequencing, SETPOINT 2 is used as the STANDBY WATER setpoint. Although commanded to remain off by the master, each slave is to maintain the STANDBY WATER setpoint which is typically the 'warm' state. When commanded to be on by the master boiler, the slave's SETPOINT 2 setpoint values are ignored because its operation and firing rate is controlled by the master boiler. While in STANBY WATER, the slave will modulate according to its own PID.
OPERATION NOTES: If the master boiler is turned off, fails to come on within 30 seconds, or goes to lockout while operating as the master, it will stop communicating and sequencing will be disabled. All slave boilers will revert to their own PID settings. Should a slave boiler fail to come on within 3 minutes, due to a burner limit being off, lockout or associated lockout in the flame safeguard, the master will call for the next slave in the priority list.
SD CARD OPERATION The PPC4000 provides the means to backup and restore settings and profile data using a secure digital (SD) memory card. The front of the PPC4000 contains a slot where the SD card is inserted and removed. An LED is included that illuminates when SD operations are being processed. An SD card should never be inserted or removed while the LED is lit. Figure 11 SD Activity LED Indicator Insert SD Card Label Side Down SD cards are available in various types and capacities.
tify the file type. To insure accuracy and consistency it is extremely useful to assure the real time clock of the PPC4000 is correctly set prior to any BACKUP operation. Backup Option All profiles with setup data All profiles only Individual profiles Profile 1 Profile 2 Profile 3 Profile 4 Setup data only Format PFLWddmmyyhhmm.ext PFLOddmmyyhhmm.ext Example PFLW2206110847.PFW PFLO2206110849.PFO PFL1ddmmyyhhmm.ext PFL2ddmmyyhhmm.ext PFL3ddmmyyhhmm.ext PFL4ddmmyyhhmm.ext SETPddmmyyhhmm.
The PPC4000 performs a read back of the file written to the SD card and if found to be incorrect the display will indicate the failure: > < I V W N S A N E R O D L V R I L A I T S O L F E D P P I Y E R D P C R O F R A A F F A O R T I O I T D I L R L E O E M E C I N S A D T N & D A T A T S A < O T B N A O L R L T E E D D Note: only the single reason for failure is indicated. The SD card can be removed by pressing lightly on the SD card and then releasing.
As a convenience, only file names with the extension pertaining to the function selected will appear. The UP and DOWN keys are used to scroll downward and upward through the list of files. Files that have been renamed by the user will also appear as long as the extension and file name length are correct. The user selects the file to be restored and presses NEXT to begin the RESTORE operation.
At this time the user can press the BACK key to remain in the BACKUP selection sub menu or press the HOME key to exit SD operations. FORMAT OPERATION The PPC4000 can be used to format the SD card. The formatting method will only be FAT32. At the FORMAT on the SD OPS SETUP sub menu press NEXT to display the following: > < D F A O T R A M A T W I L L B E L O S T > < Execution of each of the FORMAT command will be activated by pressing the NEXT key.
Profile Setup Work Sheet Commissioning Date ______________________ Location ___________________ Profile# ______________________ Profile Setpoint Drive # Name CW CCW VFD# ❒ ❒ (°) ❒ ❒ (°) ❒ ❒ (°) ❒ ❒ (°) %FS CNTS ENCODE OXYGEN LEVEL Wet STACK TEMP CO Net Eff Dry °F / °C PPM p00 p01 p02 p03 p04 p05 p06 p07 p08 p09 p10 p11 p12 p13 p14 p15 p16 p17 p18 p19 p20 p21 p22 p23 Notes: Setpoint Cut-in Cut-out P-Band Integral Derivative Boiler Manuf.
Profile Setup Work Sheet Commissioning Date ______________________ Location ___________________ Profile# ______________________ Profile Setpoint Drive # Name CW CCW VFD# ❒ ❒ (°) ❒ ❒ (°) ❒ ❒ (°) ❒ ❒ (°) %FS CNTS ENCODE OXYGEN LEVEL Wet Notes: 82 CO Dry p00 p01 p02 p03 p04 p05 p06 p07 p08 p09 p10 p11 p12 p13 p14 p15 p16 p17 p18 p19 p20 p21 p22 p23 Setpoint Cut-in Cut-out P-Band Integral Derivative STACK TEMP Boiler Manuf. Boiler Type Boiler Size Burner Type Burner Size Ambient Temp.
LOCKOUTS: When a safety shutdown occurs, the control will indicate the reason for the lockout through the Alarm/Status LED and also describe the lockout on the User Interface. The alarm relay located on terminals P4.1 to P4.2 will be energized. The non-volatile memory will remember the status (Run or Lockout) of the control even if a power failure occurs.
MARGINAL ALARMS The user has the option to program in marginal high limits for each of the analog transducers, including the O2 probe. A marginal condition is expected to occur before a non-volatile lockout state, giving the operator sufficient time to resolve the condition and avoid a nuisance shutdown.
