fireye NXTSD104 10.4 Inch Touch Screen User Manual
- June 9, 2024
- fireye
Table of Contents
NXTSD104 10.4 Inch Touch Screen
NXOGTSD-6101 APRIL 8, 2013
OPERATOR’S GUIDE FOR
NX6100 WITH 10.4″ COLOR TOUCHSCREEN
DESCRIPTION: This document supplies the owner/operator with sufficient
information to make appropriate changes to operating parameters associated
with normal boiler plant needs. Items such as system setpoint adjustments e.g.
temperature, pressure, PID adjustments and alarm corrective action and
adjustments.
CONTENTS:
The following items are covered in this manual:
1 INTRODUCTION ……………………………………………………………………………………………………………………………………. 4 1.1
GENERAL ……………………………………………………………………………………………………………………………………………. 4 1.2
PASSWORD………………………………………………………………………………………………………………………………………….. 4
2 DESCRIPTION OF TOUCHSCREEN OPERATION. ………………………………………………………………………………. 5 2.1
THE TOUCHSCREEN ……………………………………………………………………………………………………………………………… 5 2.2
TOUCHSCREEN POWER ON. ……………………………………………………………………………………………………………………. 5 2.3 THE
OPERATION MODE LINE AND STATUS MESSAGES ……………………………………………………………………………….. 6 2.4
TOUCHSCREEN OVERVIEW DISPLAY. ………………………………………………………………………………………………………. 8 2.5
TOUCHSCREEN LOCKOUT RESET (ALARM MUTE) FUNCTION. ……………………………………………………………………..
8 2.6 TOUCHSCREEN LED INDICATION. ………………………………………………………………………………………………………….. 9
2.7 TOUCHSCREEN FUEL/PROFILE SELECT. …………………………………………………………………………………………………… 9
2.8 TOUCHSCREEN CONTROL’ SCREEN. ……………………………………………………………………………………………………… 10 2.9 TOUCHSCREENMENU’ BUTTON…………………………………………………………………………………………………………… 11 2.10
TOUCHSCREEN BURNER SETTINGS’ BUTTON. ………………………………………………………………………………………… 11 2.11 TOUCHSCREENFAULT/EVENT LOG’ BUTTON. ………………………………………………………………………………………..
12
2.12 TOUCHSCREEN `SCREEN CONFIGURATION’ BUTTON.
………………………………………………………………………………..13 2.13 CLEANING THE
TOUCHSCREEN………………………………………………………………………………………………………………13 2.14 TOUCHSCREEN
COMMISSION MODE………………………………………………………………………………………………………..15
3 SETPOINT, CUT IN/CUT OUT AND MODULATION OPTION PARAMETERS ……………………………………16
3.1
OPTION 21.0 SET-POINT 1 ENABLE (0 – 1) LV1 ……………………………………………………………..17
3.2
OPTION 21.1 SET-POINT 1 CONTROL VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1……………17
3.3
OPTION 21.2 SET-POINT 1 PROPORTIONAL BAND (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 …….17
3.4 OPTION 21.3 SET-POINT 1 INTEGRAL TIME (0 999 SECONDS) LV1………………………………………………………….17
3.5 OPTION 21.4 SET-POINT 1 DERIVATIVE TIME (0 999 SECONDS) LV1 ……………………………………………………….18
3.6
OPTION 21.5 – SETPOINT 1 CONTROL LIMIT TYPE (0 – 2) LV3……………………………………………..18
3.7 OPTION 21.6 – SETPOINT 1 LOW LIMIT CONTROL VALUE (CUT IN) (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1…………19
3.8 OPTION 21.7 – SETPOINT 1 HIGH LIMIT CONTROL VALUE (CUT OUT) (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 …….19
3.9 OPTION 21.8 REMOTE SETPOINT 1 ZERO (4MA) VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 …………………….20
3.10 OPTION 21.9 REMOTE SETPOINT 1 SPAN (20MA) VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1…………………..20
3.11 OPTION 22.0 PID (SET-POINT) 2 ENABLE (0 – 1) LV1………………………………………………………………………………20
3.12 OPTION 22.1 SET-POINT 2 CONTROL VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 ……………………………………20
3.13 OPTION 22.2 SET-POINT 2 PROPORTIONAL BAND (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 …………………………….20
3.14 OPTION 22.3 SET-POINT 2 INTEGRAL TERM (0 999 SECONDS) LV1 …………………………………………………………20
3.15 OPTION 22.4 SET-POINT 2 DERIVATIVE TERM (0 – 100) LV1…………………………………………………………………….21
3.16 OPTION 22.5 – SETPOINT 2 CONTROL LIMIT TYPE (0 – 2) LV3 ……………………………………………………………………..21
3.17 OPTION 22.6 – SETPOINT 2 LOW LIMIT CONTROL VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 ……………………..21
3.18 OPTION 22.7 – SETPOINT 2 HIGH LIMIT CONTROL VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1……………………..21
3.19 OPTION 22.8 REMOTE SETPOINT 2 ZERO (4MA) VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 ……………………21
3.20 OPTION 22.9 REMOTE SETPOINT 2 SPAN (20MA) VALUE (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1…………………..22
3.21 OPTION 23.0 WARMING ENABLE (0 OR 1) LV1 ……………………………………………………………………………………..22
3.22 OPTION 23.1 WARMING LIMIT (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 ……………………………………………………..22
3.23 OPTION 23.2 WARMING TIME (0 TO 999 MINUTES) LV1 …………………………………………………………………………22
4 MANUAL MODULATION AND LOW FIRE HOLD ……………………………………………………………………………….22
4.1 AUTO/MAN KEY LV1 ………………………………………………………………………………………………………………………..22 4.2 LOW FIRE HOLD LV1…………………………………………………………………………………………………………………………..23
5 OPTIONS 24.X SEQUENCING …………………………………………………………………………………………………………….23
5.1 OPTION 24.0 SEQUENCE SLAVES (NUMBER OF BOILERS) (0-3) LV1 …………………………………………………………….24 5.2 OPTION 24.1 -24.3 PRIORITY NUMBER(S) LV1 ………………………………………………………………………………………..25 5.3 OPTION 24.4 – RESERVED ………………………………………………………………………………………………………………………25 5.4 OPTION 24.5 LEAD (MASTER) BOILER SELECT METHOD LV1 ………………………………………………………………….25 5.5 OPTION 24.6 LAG (SLAVE) ON RATE (0-100%) LV1 ………………………………………………………………………………26 5.6 OPTION 24.7 LAG (SLAVE) ON DELAY (0-999 MINUTES) LV1 ………………………………………………………………….26 5.7 OPTION 24.8 LAG (SLAVE) OFF RATE (0-100%) LV3 ……………………………………………………………………………..26 5.8 OPTION 24.9 LAG (SLAVE) OFF DELAY (0-999 MINUTES) LV3 …………………………………………………………………26 5.9 OPTION 25.0 BANKING BASED ON TEMPERATURE LV3……………………………………………………………………………26 5.10 OPTION 25.1 WATER TEMPERATURE ZERO VALUE LV3…………………………………………………………………………..27 5.11 OPTION 25.2 WATER TEMPERATURE SPAN VALUE LV3 …………………………………………………………………………..27 5.12 OPTION 25.3 WATER TEMPERATURE CUT-IN LV1 ………………………………………………………………………………….27 5.13 OPTION 25.4 WATER TEMPERATURE CUT-OUT LV1 ……………………………………………………………………………….27
6 RESETTING THE CONTROL ………………………………………………………………………………………………………………..27
7 START-UP SEQUENCE ………………………………………………………………………………………………………………………….28
2
8 FAULTS AND FAULT FINDING …………………………………………………………………………………………………………… 30 8.1
THE FAULT DISPLAY …………………………………………………………………………………………………………………………… 30 8.2 WHAT
TO DO WHEN A FAULT OCCURS……………………………………………………………………………………………………. 30 8.3 NON-
VOLATILE LOCKOUT ……………………………………………………………………………………………………………………. 31 8.4 FAULT
SUBSETS …………………………………………………………………………………………………………………………………. 31 8.5 FAULT
LISTING ………………………………………………………………………………………………………………………………….. 31 8.6 THE
ENGINEER’S TAB ………………………………………………………………………………………………………………………….. 41 8.7 SYSTEM
EVENT/FAULT HISTORY. …………………………………………………………………………………………………………. 41 8.8
ENGINEER’S KEY PARAMETER LIST ……………………………………………………………………………………………………….. 41
9 TROUBLESHOOTING ………………………………………………………………………………………………………………………….. 52 9.1
DISPLAY / GENERAL …………………………………………………………………………………………………………………………… 52 9.2
STARTUP…………………………………………………………………………………………………………………………………………… 53 9.3
COMMISSIONING ………………………………………………………………………………………………………………………………… 53 9.4 GAS
VALVE PROVING ………………………………………………………………………………………………………………………….. 54 9.5
MODULATION ……………………………………………………………………………………………………………………………………. 54 9.6
INVERTERS………………………………………………………………………………………………………………………………………… 55 9.7 OXYGEN
MEASUREMENT AND TRIM ………………………………………………………………………………………………………. 56
10 PID TUTORIAL …………………………………………………………………………………………………………………………………. 57 11
COMBUSTION PROFILE SETUP GUIDELINE ………………………………………………………………………………… 58 12
FIREYE NX6100 EFFICIENCY CALCULATIONS…………………………………………………………………………….. 59 13
TYPICAL WIRING DIAGRAMS ……………………………………………………………………………………………………….. 61
3
1 Introduction
This guide can be downloaded from the Fireye web site at www.Fireye.com.
Search bulletins for NXOGTSD6101 under the Nexus products family.
As an operator there are generally only a few items of interest as far as
operating the Nexus NX6100. They are:
Setting the system’s operating pressure or temperature. (Section 3.6)
Adjusting the cut in or cut out value. (Section 3.6) Manually modulating the
boiler. (Section 4.1) Resetting the control after a safety shut down. (Section
2.5) Finding the Fault that caused the shut down. (Section 2.11) Changing
Fuel/Profiles. (Section 2.7)
All of the other options and adjustments should be done by the combustion
technician, as changes to certain parameters could result in an unsafe
operating mode.
1.1 General
The Nexus touchscreen display allows the operator (or combustion technician)
access to all setpoints and option parameters for commissioning and operating
the Nexus NX6100.
1.2 Password
Several levels of passwords protect the integrity of the control. The only
password an operator should require is the “site Passcode.” This can be set as
a number from 0-999. The factory default number is 154. The site Passcode can
be changed if desired, however, this requires the use of a higher-level
Passcode.
Warning: Should the Password be changed and forgotten, the NX6100 will have to
be reprogrammed by using the higher-level Password. Until then, no adjustments
are possible. Using the site Password, all options can be reviewed, but only a
limited number can be changed
Password entry Method one:
From the Touchscreen, press the Control button. This brings up the process
control (see Section 2.8) where normal operating setpoints are adjusted. Press
the desired value to change, such as the SP (setpoint) or CO (Cut Out), which
will bring up the numeric keypad. Enter the site password (default is 154) and
press OK. The numeric keypad will disappear and an open lock will appear on
the top line of the display. Again press the Control button, press the desired
value to change and use the up/down arrow keys to set the new value. The value
is stored when you press the Set key. The Control will lock out requiring
reentry of the password five minutes after the last keystroke.
Password entry Method two:
From the Touchscreen, press the Menu button followed by the Burner Settings
button. The Com key will appear in the bottom right of the Burner Settings
screen. Press the Com key and enter the site password (default 154) on the
numeric keypad. Press OK. Now, depending upon what parameter you want to
change, you can press the Control key or press the Options tab on the Burner
Settings screen.
4
To use the Options tab, you must scroll to the desired option, press the
current value followed by the Set key. This will bring up the numeric keypad
where you will enter the new value. Pressing OK will save the value. Note, the
original value turns blue when you first press it, yellow to indicate a new
value has been saved. WARNING: If the default site password (154) has been
change (using the full commissioning password) and forgotten, no values can be
changed without the full password.
2 Description of Touchscreen operation.
2.1 The Touchscreen
The touchscreen provides all of the functions required to control and monitor
the burner, it is also used to commission the control. Once commissioning mode
is selected the display background changes to red to alert the user that the
control is in commissioning mode and therefore unable to monitor certain
safety functions such as fuel air ratio positions. 2.2 Touchscreen Power on.
Initialization of the control and display will take approximately 16 seconds,
during this initialization period the status LED will remain red. The display
backlight will come on and the relays will be held in their no alarm state to
avoid the possibility of nuisance alarms, which may otherwise occur.
Five (5) seconds after power is applied the Fireye splash screen (shown below)
will be displayed for 6 seconds, after which a period of 5 seconds of a blank
white screen will show.
Once the initialization is complete the touchscreen will show the overview
screen (shown in section 2.3) and the control will operate normally, changing
the LED to green and relays to operate in line with the control status.
5
2.3 The Operation Mode line and Status messages The line at the top of the
screen displays the current burner: operating mode, profile, modulation mode
and unit address. Burner status, and fault information, if applicable, is
displayed in the bottom right corner of the display. Dependent on the actual
fault the audible alarm may be active and the control may move to safety
shutdown.
Dedicated buttons’ at the lower edge of the screen perform the following functions: Mute / Reset used to reset a burner lockout, mute alarms or to test audible alarms. If an alarm is present the button is yellow and the text on thebutton’ changes to Alarm Mute. Burner Start/Stop starts the burner,
grayed out if the burner is already operating. Fuel allows selection of
which fuel/profile is to be used, from a list of fuels/profiles available.
Control used to enable selection of modulation mode, setpoint used, low fire
hold, and make adjustments to normal operating parameters. Menu used to
access configuration, adjustment modes. Overview returns screen to burner
overview mode. The following table shows the Icons that are displayed on the
touchscreen above the information panels and their details.
6
Icon
Description
Details
State of CANbus connection
Displays when CANbus communication is faulty
State of Oxygen Interface Displays when Oxygen Interface related fault is present.
COM
Indicates commissioning mode
Displays when the control is operating in commissioning mode.
MAN
Indicates HAND modulation mode.
Displays when the control is operating in HAND modulation mode.
AUTO
Indicates AUTO modulation mode.
Displays when the control is operating in AUTO modulation mode.
R /
Indicates Boiler Setpoint
L(1) / L(2) mode
Displays Boiler setpoint selected, remote, local setpoint 1 or local setpoint 2.
1 / 2 / 3 / 4 Indicates profile selected Displays the profile number for the selected profile.
13:07:16 Indicates Time and Date
2008-05-20
Displays Actual Time and Date, used for fault history and event logging. Date format is yyyy-mm-dd
7
2.4 Touchscreen Overview display.
While the burner is changing status’ the bottom-right one sixth of the display is used to provide a graphical indication of changing status. The sequences displayed in this manner include, burner start-up, burner shutdown and fuel changeover. In each case there is alamp’ for each stage, providing a ripple through lamp
system to clearly indicate the progress of the change in burner `status’.
The example shown in the picture is for the burner start-up sequence display.
Once the sequence is complete then the display will return, after a short
delay, to the overview screen.
2.5 Touchscreen Lockout Reset (Alarm Mute) Function.
The Reset (Alarm Mute) `button’ on the touchscreen is multi-functional. In
normal operation it may be used to test the alarms, this is achieved by
holding the button for in excess of 10 seconds after which the alarm relays
will activate.
The Reset (Alarm Mute) button is also used to mute alarms and reset the
control following a safety shutdown. If the alarm is sounding, the button will
show the text Mute, pressing the button will mute (silence) the alarm, and
then the text in the button will change to Reset, holding the button for
greater than 3 seconds will allow the burner to restart if the faults have
cleared. Further details of the functionality of this button are defined
below.
There are three types of fault (alarm):
Alarm Only This will allow the burner to continue to operate, while the alarm
is sounding.
If the Reset (Alarm Mute) button is pressed while the control is in this mode
and the alarm is sounding the alarm will be muted and the burner will continue
to operate.
Controlled Shutdown This will cause the burner to perform a controlled
shutdown, and the alarm will sound, once the fault clears the burner will
restart without the requirement for manual intervention.
If the Mute/ Reset button is pressed while the control is in this mode the
alarm will be muted and the burner will remain in controlled shutdown. If the
Mute/Reset button is pressed after the control has restarted following a
controlled shutdown the alarm will be muted and the burner will continue to
operate.
8
Safety Shutdown This will cause the burner to perform a safety shutdown, and
the alarm will sound, once the fault has cleared the burner will remain in
safety shutdown until a Mute/ Reset is performed. If the Mute/ Reset button is
pressed while the control is in safety shutdown and the fault is still present
the alarm will be muted and the burner will remain in safety shutdown. When
the fault clears the alarm will sound once more. If the Mute/ Reset button is
pressed while the control is in safety shutdown and the fault has cleared the
alarm will be muted and if the button is held for in excess of 3 seconds the
burner will re-start. 2.6 Touchscreen LED Indication. The Touchscreen also
houses a multi-functional LED for indication of current status. The LED will
be green, permanently on, if no faults or limits are present. The LED will be
red, flashing, if there is a limit or an alarm condition present, which does
not cause a lockout. The LED will be red, permanently on, if there is a fault
present, even if the fault has been muted, which causes a lockout. 2.7
Touchscreen Fuel/Profile Select. Once the Fuel soft-button is pressed, a pop-
up window appears on the right giving the user a choice of available
fuels/profiles. The NX6100 allows for a maximum of four profiles. Any
profiles, which are not programmed and therefore not available, will be
`grayed-out’.
9
The Name’ for each available profile will be either the default as set by the relevant option parameter or that entered via the Configuration Screen. If the profile change is made while the burner is firing, there are two possibilities dependent on the options set in the control. If the unit does not have the option to perform an online changeover enabled (switch profile without the burner going off) the burner will go through a controlled shutdown on the original profile and then restart on the new profile. The online changeover allows a digital input to be configured to allow a profile swap without turning the burner off. If this input is ON and a fuel profile selection change is made, the control will go to low fire then back to pilot ignition (P2) on the original profile. It will then drop the main fuel valves and run with just the pilot on (and the ignition transformer if option parameter 14.6 is not set to 1). It will then move all drives to the P2 position of the new profile and open the appropriate main fuel valves. To exit this operation window and return to the overview screen press the Overview button. 2.8 TouchscreenControl’ screen. Once the Control button is pressed, a window
appears giving the user a choice of options. If an option is unavailable it
will be `grayed out’, for example Manual Modulation may be disabled during
commissioning.
If the burner is firing, then the modulation percentage will be displayed ion
the vertical bar graph (0-100%), as well as numerically inside the box..
Using the buttons available from this window will change the way the burner is
operating.
To exit this control mode window and return to the overview screen use the
Overview button.
10
2.9 Touchscreen Menu’ button. Once the Menu button is pressed, a pop-up window appears on the right giving the user a choice of options. If an option is unavailable it will begrayed
out’.
Using the buttons available after pressing the Menu button will generate a new pop-up window in the left hand area of the screen.
To exit this operation window and return to the overview screen press the Overview button.
Settings’ button.
2.10 Touchscreen `Burner
Once the Burner Settings button is pressed, a window appears giving the user a choice of data types by Tab. Selecting, by touching a tab, it as possible to view a variety of data, in the example here the Option Parameters are available.
11
In the following example the Engineers Key values are displayed. The scroll
bar at the side of the data tab allows the user to move up and down the table.
2.11 Touchscreen `Fault/Event Log’ button. Once the Fault/Event Log button is
pressed, a window appears showing the Fault/Event history. Users may select to
see Fault data only, Events data only or a combined history as shown in this
example. For more information on fault codes and fault finding refer to the
Fault Finding section of the NX6100 manual Fireye bulletin NEX-6101.
12
2.12 Touchscreen Screen Configuration’ button. Once the Screen Configuration button is pressed, a window appears giving the user a choice of options. From the General Tab a name may be entered for each profile in use. Highlight the profile for which a name is to be entered or modified and press the Modify button. This will cause a window to appear allowing the required name to be entered using the button pad. Once the name is displayed against the required profile the mode can be exited by pressing theX’ in the top
right corner of the Touchscreen Configuration window. To exit this
configuration window and return to the overview screen press the Overview
button. 2.13 Cleaning the Touchscreen
WARNING
To prevent possible damage to the touchscreen, ensure the correct fluid’ is used when cleaning the screen. Before attempting to clean the screen ensure the clean screen function is enabled to ensure operation of the burner is not affected Once theClean Screen’ function is selected the display keys will be
unavailable for 20 seconds
13
Before attempting to clean the screen it is essential to select the Clean
Screen function to prevent any pressure applied to clean the touchscreen being
seen’ as abutton press’. The function can be accessed by selecting the Menu
button at the base of the touchscreen and then, selecting Clean Screen from
the list of functions available.
When cleaning the touchscreen ensure the correct LCD screen cleaner is used.
Use of any other cleaning fluid or water may damage the screen. There are
designated commercial cleaning solutions on the market for touchscreens only.
Also, these products are recommended to be used only with a very soft cloth.
Please note the directions and the warnings on the product.
CAUTION
Do NOT use any ammonia-based window cleaner. These chemical cleaners can ruin
the touchscreen surface.
Do NOT use any abrasive rags, towels or paper towels. An abrasive towel can
scratch the touchscreen.
14
2.14 Touchscreen Commission mode.
To allow Option Parameters or Drives to be adjusted it is necessary to enter
the relevant access passcode. To enter the passcode press the COM button. This
will prompt the keypad pane to appear, allowing the relevant passcode to be
entered using the soft keypad and confirmed by pressing the OK button.
CAUTION
Use extreme care while commissioning the system. While operating in
commissioning mode the safety of the system is the sole responsibility of the
commissioning engineer.
Ensure a pre-purge position is entered for the relevant drives. Incorrect
positioning of either fuel or air could cause a hazardous situation to
occur. If the servo-motor positions have been up-loaded it 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 control. It is recommended
that the close position for each servo motor is re-entered as part of the
burner service regime, to compensate for wear in the servo-motor micro-switch
during operation. Once all profile positions have been adjusted/entered it is
essential that all profile points are checked to verify that the fuel air
ration is acceptable for the appliance being controlled.
15
Once the correct passcode is entered the unit will enter commissioning mode
and allow the option parameters and profile points to be adjusted, the text on
the COM button will change to RUN. To warn the `user’ that the unit is in
commissioning mode the overall display background changes to red and COM is
displayed top-center on the screen
3 Setpoint, Cut In/Cut Out and Modulation Option Parameters
NOTE: For the following Options 21.x and 22.x, see Section 10 for PID
Tutorial.
Setpoint/Modulation entry Method one: From the Touchscreen, press the
Control button. This brings up the process control where normal operating
setpoints are adjusted (See Touchscreen section 2.8). Press the desired value
to change, such as the SP (setpoint) which will bring up the numeric keypad.
Enter the site password (default is 154) and press OK. The numeric keypad will
disappear and an open lock will appear on the top line of the display. Again
press the Control button, press the desired value to change and use the
up/down arrow keys to set the new value. The value is stored when you press
the Set key. The Control will lock out requiring reentry of the password five
minutes after the last keystroke. Setpoint/Modulation entry Method two:
16
From the Touchscreen, press the Menu button followed by the Burner Settings
button (See Touchscreen Section 2.10). The Com key will appear in the bottom
left of the Burner Settings screen. Press the Com key and enter the site
password (default 154) on the numeric keypad. Press OK. Now, depending upon
what parameter you want to change, you can press the Control key or press the
Options tab on the Burner Settings screen.
To use the Options tab, you must scroll to the desired option, press the
current value followed by the Set key. This will bring up the numeric keypad
where you will enter the new value. Pressing OK will save the value. Note, the
original value turns blue when you first press it, yellow to indicate a new
value has been saved.
NOTE: If the default site password (154) has been change (using the full
commissioning password) and forgotten, no values can be changed without the
full password.
3.1
Option 21.0 Set-point 1 enable (0 – 1) LV1
This option parameter is used to enable setpoint 1. (Option 22.0 for setpoint 2)
3.2
Option 21.1 Set-point 1 control value (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1
This is the desired pressure or temperature control value used in the PID control loop for setpoint 1. When the control is in auto mode, the PID control loop will modulate the boiler to maintain the measured value at the same level as set by this parameter.
3.3
Option 21.2 Set-point 1 proportional band (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1
This is the width of the proportional (modulation) band that is used by the
PID control loop for setpoint 1. For example, if the setpoint was 100 psi, and
this term was set to 10 psi, then the proportional band would be from 90 psi
to 100 psi. A measured value of 90 psi would give high fire, and 100 psi would
give low fire, assuming no integral or derivative terms were entered.
A value of 0 means no proportional band the burner would stay at low fire
until the high limit (Cut Out) is reached, then turn off. Proportional control
is therefore needed to allow the burner to modulate.
3.4 Option 21.3 Set-point 1 integral time (0 999 seconds) LV1
This is the integral time used in the PID control loop for setpoint 1. It may
be set to any value from 0 to 999, seconds. If a value of 0 is entered the
integral function is disabled, otherwise the time entered is the number of
seconds the control will take to give an additional modulation change equal to
that currently given by the proportional term. The lower the number (apart
from zero), the more affect the integral function has. A large number will
cause the integral term to act very slowly.
17
Integral control is required for the burner to accurately reach its setpoint.
3.5 Option 21.4 Set-point 1 derivative time (0 999 seconds) LV1
This is the derivative time used in the PID control loop for setpoint 1. It
may be set to any value from 0 to 999. A value of zero will disable the
derivative function. A non-zero value will have the effect of `advancing’ the
modulation rate change caused by a constantly changing measured value by the
number of seconds given. A low value will have little effect; a large value
will cause a large effect.
Derivative control is seldom needed for boilers, but can improve the response
of the modulation system to sudden load changes. Too much can cause control
instability.
3.6
Option 21.5 – Setpoint 1 control limit type (0 – 2) LV3
This option parameter defines the control limit type for setpoint 1. The control limits are used to automatically turn the burner off when it is not needed, and bring it back on when it is needed.
Option parameter 21.5 value 0
1
2
Meaning
No limits. The burner will run until another method is used to switch it off.
Absolute limit. The values entered in option parameters 21.6 and 21.7 are the
actual limit values. Deviation limit. The values entered in option parameters
21.6 and 21.7 represent a deviation (i.e. offset) from the setpoint 1 control
value. This means that if the setpoint control value is changed, the limits
are automatically changed correspondingly.
The following are examples of Deviation and Absolute limit. These examples
assume the user is using Method Two approach (from Password entry in section
1.2). Alternately, method one can also be used.
Deviation Example setting Opt 21.5 to 2 To maintain 100 psi on the boiler,
cut out at 115 psi, cut in at 95 psi.
NOTE: Opt 15.5 Boiler High Safety Limit If this option is set to a
nonzero, exceeding this value causes a non-volatile lockout.
Opt 21.1 Setpoint (22.1) …………. set to ………… 100 psi Opt 21.5 Control
Type……………… set to ……………. 2 Opt 21.6 Cut In (22.6)…………….. set to ……………. 5 Opt
21.7 Cut Out (22.7)* ………….. set to ………….. 15
RESULTS: Boiler OFF (Cut Out) at…. …………………… 115 psi
18
Boiler ON (Cut In) at ……………………………. 95 psi Boiler maintains (Setpoint)
………………….. 100 psi via PID Changing ONLY the Setpoint Opt 21.1 (22.2)
…………….change to………. 60 psi NEW RESULTS from Setpoint Change: Boiler OFF (Cut
Out) at ………………………… 75 psi Boiler ON (Cut In) at ……………………………. 55 psi Boiler
maintains (Setpoint) ……………………. 60 psi via PID
NOTE: NEW I (integral time) and D (derivative time) values – Option Parameters
21.3(22.3) and 21.4(22.4), may be required to achieve desired results.
Absolute Example setting Opt 21.5 to 1: Opt 21.1 Setpoint (22.1)………… set to
…………100 psi Opt 21.5 Control Type ……………. set to …………….1 Opt 21.6 Cut In
(22.6) …………… set to …………..95 Opt 21.7 Cut Out (22.7)…………. set to …………115
RESULTS: Boiler OFF (Cut Out) at ………………………. 115 psi Boiler ON (Cut In) at
……………………………. 95 psi Boiler maintains (Setpoint) ………………….. 100 psi via PID
Changing ONLY the Setpoint Opt 21.1 (22.2) …………….change to………. 60 psi NEW
RESULTS from Setpoint Change: Boiler OFF (Cut Out) at ………………………. 115 psi
Boiler ON (Cut In) at ……………………………. 95 psi Boiler maintains (Setpoint)
……………………….. 60 psi via PID
NOTE: NEW Cut In and Cut Out values as well as new I (integral time) and D
(derivative time) values – Option Parameters 21.3(22.3) and 21.4(22.4), may be
required to achieve desired results.
In BOTH examples ( ) represents PID2
3.7 Option 21.6 – Setpoint 1 low limit control value (Cut In) (0 – 999 / 00.0
– 99.9 / 0.00 – 9.99) LV1
If the boiler is off due to a controlled shutdown, this parameter defines the
measured value at which the boiler will be turned on again.
3.8 Option 21.7 – Setpoint 1 high limit control value (Cut Out) (0 – 999 /
00.0 – 99.9 / 0.00 – 9.99) LV1
19
If the boiler is on and firing, this parameter defines the measured value at
which the boiler will be turned off via a controlled shutdown.
3.9 Option 21.8 Remote Setpoint 1 zero (4ma) value (0 – 999 / 00.0 – 99.9 /
0.00 – 9.99) LV1
This is the zero value for the remote setpoint function specified by option
parameter 20.7.
3.10 Option 21.9 Remote Setpoint 1 span (20mA) value (0 – 999 / 00.0 – 99.9
/ 0.00 – 9.99) LV1
This is the span value for the remote setpoint function specified by option
parameter 20.7.
3.11 Option 22.0 PID (set-point) 2 enable (0 – 1) LV1
This option parameter is used to select setpoint 2.
3.12 Option 22.1 Set-point 2 control value (0 – 999 / 00.0 – 99.9 / 0.00 –
9.99) LV1
This is the control value used in the PID control loop for setpoint 2. When
the control is in auto mode, the PID control loop will modulate the boiler to
maintain the measured value at the same level as set by this parameter.
3.13 Option 22.2 Set-point 2 proportional band (0 – 999 / 00.0 – 99.9 / 0.00
– 9.99) LV1
This is the width of the proportional (modulation) band that is used by the
PID control loop for setpoint 2. For example, if the setpoint was 100 psi, and
this term was set to 10 psi, then the proportional band would be from 90 to
100 psi. A measured value of 90 psi would give high fire, and 100 psi would
give low fire, assuming no integral or derivative terms were entered. A value
of 0 means no proportional band the burner would stay at low fire until the
high limit (Cut Out) is reached, then turn off. Proportional control is
therefore needed to allow the burner to modulate.
3.14 Option 22.3 Set-point 2 integral term (0 999 seconds) LV1
This is the integral time used in the PID control loop for setpoint 2. It may
be set to any value from 0 to 999, seconds. If a value of 0 is entered the
integral function is disabled, otherwise the time entered is the number of
seconds the control will take to give an additional modulation change equal to
that currently given by the proportional term. The lower the number (apart
from zero), the more affect the integral function has. A large number will
cause the integral term to act very slowly. Integral control is required for
the burner to accurately reach its setpoint.
20
3.15 Option 22.4 Set-point 2 derivative term (0 – 100) LV1
This is the derivative time used in the PID control loop for setpoint 2. It
may be set to any value from 0 to 999. A value of zero will disable the
derivative function. A non-zero value will have the effect of `advancing’ the
modulation rate change caused by a constantly changing measured value by the
number of seconds given. A low value will have little effect; a large value
will cause a large effect.
Derivative control is seldom needed for boilers, but can improve the response
of the modulation system to sudden load changes. Too much can cause control
instability.
3.16 Option 22.5 – Setpoint 2 control limit type (0 – 2) LV3
This option parameter defines the control limit type for setpoint 2. The control limits are used to automatically turn the burner off when it is not needed, and bring it back on when it is needed.
Option parameter 22.5 value 0
1
2
Meaning
No limits. The burner will run until another method is used to switch it off.
Absolute limit. The values entered in option parameters 22.6 and 22.7 are the
actual limit values. Deviation limit. The values entered in option parameters
22.6 and 22.7 represent a deviation (i.e. offset) from the setpoint 1 control
value. This means that if the setpoint control value is changed, the limits
are automatically changed correspondingly.
3.17 Option 22.6 – Setpoint 2 low limit control value (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1
If the boiler is off due to a controlled shutdown, this parameter defines the
measured value at which the boiler will be turned on again.
3.18 Option 22.7 – Setpoint 2 high limit control value (0 – 999 / 00.0 – 99.9
/ 0.00 – 9.99) LV1
If the boiler is on and firing, this parameter defines the measured value at which the boiler will be turned off via a controlled shutdown.
3.19 Option 22.8 Remote Setpoint 2 zero (4mA) value (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1 This is the zero value for the remote setpoint function specified by option parameter 20.7.
21
3.20 Option 22.9 Remote Setpoint 2 span (20mA) value (0 – 999 / 00.0 – 99.9
/ 0.00 – 9.99) LV1
This is the span value for the remote setpoint function specified by option
parameter 20.7.
3.21 Option 23.0 Warming Enable (0 or 1) LV1
This parameter allows a warming function to be applied to the boiler, and
makes option parameters 23.1 and 23.2 available. If zero is entered, no
warming limit is applied.
3.22 Option 23.1 Warming Limit (0 – 999 / 00.0 – 99.9 / 0.00 – 9.99) LV1
If, when the burner starts up and reaches modulation, the measured pressure /
temperature value is lower than that specified here, the control will hold the
boiler at low fire until the value specified is reached. The control will hold
the boiler at low fire (in status 15) indefinitely unless a non-zero time has
been entered in option parameter 23.2. Note: If during normal modulation, the
measured value falls below this limit having once been above it, the warming
function will not be re-applied. The warming function is only applied on a
burner start-up.
3.23 Option 23.2 Warming Time (0 to 999 minutes) LV1
This parameter specifies a maximum time to hold the burner at low fire for,
before ignoring the warming limit and allowing normal modulation.
Additionally, when the burner goes off (for any reason other than power
interruption), and the measured value falls below the warming limit, the
warming function will not be activated again until this time has passed. NOTE:
Further parameters (up to 29.9) may be available here if they are part of a
users program or non-standard manufacturers program.
4 Manual Modulation and Low Fire Hold
4.1 AUTO/MAN key LV1 Pressing AUTO/MAN key toggles the burner in and out of
manual or automatic modulation. To place the boiler in manual from automatic
no password is required.
1. Press the AUTO/MAN key 2. Use the up/down arrow keys to set the firing
rate. 3. Press the AUTO key to place in automatic
22
Note: The firing rate will be shown on the display. This function can be
disabled via option parameter 1.1. To do so requires the suppliers (highest)
passcode.
4.2 Low Fire Hold LV1
Pressing the Low Fire Hold button will return burner to low fire and remain
there.. To exit press the AUTO button.
5 Options 24.x Sequencing
Sequencing (lead/lag) is managed by using the “setpoint select” function
internally to choose between Setpoint 1 and Setpoint 2 via the communications
bus between NX6100’s. The “lead” or “master” boiler controls the “lag” or
“slave” boiler(s) by switching them from setpoint 2 (“lag stand by” or
“banking”) to the setpoint 1 values, and turns on based on Option 24.6 (lag
(slave) On Rate) value. The lead boiler will override the modulation rate of
the last lag boiler to come on and cause it to modulate in unison with the
lead (master) boiler. If both the lead (master) boiler and last lag (slave)
boiler remain above the Option 24.6 value another lag (slave) boiler will be
started after Option 24.7 (lag (slave) on delay) value has expired. Other lags
(slaves) that are on will remain at high fire until the last lag is turned
off. At this point, the next lag boiler will begin to modulate with the lead
(master) and so on until the lead (master) is carrying the load. The sequence
in which boilers are turned on is set in Option 24.1-24.3 via communications
addresses of each NX6100. When a lead (master) boiler is deselected as lead
(master) and Option 24.0 has not been changed to 0, the boiler remains as lead
(master) until a new lead (master) takes control. Once the new lead (master)
takes control, the previous lead (master) may be turned off based on the
demand and Option 24.1-24.3 settings.
If the lead (master) boiler is turned off, or fails to come on within three
minutes, while operating as the lead, sequencing will be disabled and all lag
(slave) boilers will revert to their own PID settings. Should a lag boiler
fail to come on within three minutes, or the NX6100 is faulted, sequencing
will immediately call for the next lag in the priority list.
If the lead (master) boiler is switched to manual modulation it will remain as
lead bringing on lag (slave) boilers as required. This will allow the operator
to “base load” a lead boiler if required.
The NX6100 can be the “master” (lead) boiler in a system that has PPC5000 or
NX3100/4100 series as the communications message are the same. The NX6100
cannot be controlled by the PPC5000 or NX3100/4100 series controls as a
boiler.
Stand by or Banking values
The “lag stand by” or “banking” temperature or pressure is entered as PID 2 or
Setpoint 2 values however, options 22.2, 22.3, 22.4 (the P, I and D) values
are unnecessary as the burner will start and remain at low fire until the “lag
stand by” or “banking” cut out is reached. These values will be entered by;
1. Setting option parameter 22.0 to 1 (Enable Setpoint 2) 2. Setting option
parameter 22.1 to the desired setpoint value when in stand by. 3. Setting
option parameter 22.5 to 1 (Absolute Value) 4. Setting option parameter 22.6
to the desired cut in value when in stand by. 5. Setting option parameter 22.7
to the desired cut out value when in stand by.
23
For example: If the normal operating setpoint is 100 PSI, and the desired stand by pressure is 75 PSI. The setup would be:
Option Parameter 22.0 22.1 22.5 22.6 22.7
Setting 1 75 1 75 (cut in or minimum pressure) 80 (cut out or maximum pressure)
STANDBY WATER TEMPERATURE FOR STEAM BOILER
If a steam boiler is being banked based on boiler temperature, a temperature sensor must be fitted into the boiler water jacket. The temperature sensor must be a 4-20mA device. If this device is to be loop-powered by the NX6100, it should be connected to the 30V output, “sensor supply” on PA16 and PA15. See option 25.0 25.4.
Example:
Fireye Temp. Sensor TS350 Sensor Terminal (1) 4-20mA Sensor Terminal (2)
Current
The language program needs to be 15 or higher. EK200 shows the current version
NX6100 NX6100 Terminal NX6100 Terminal
PA16 PA15
Option/Parameters
20.7 = 0 Using AUX. input 5 25.0 = 5, AUX 5 input 25.1 = 32, Zero value of temp. sensor 25.2 = 350, Span value of temp. sensor 25.3 = Cut-in temp. 25.4 = Cut-out temp.
No PID involved, lag boiler will turn on and off on low fire.
Relevant Engineers Keys:
EK136, 0 = inactive. Only active when held off by the lead boiler. EK159,
Actual water temp.
NOTE: When using sequencing, setpoint 2 is unavailable for use with any
digital input unless the boiler is removed from sequencing completely.
5.1 Option 24.0 Sequence Slaves (number of boilers) (0-3) LV1
This option is set to 1, 2 or 3 in each NX6100 to equal the number of lag “slave” boilers in the system. Once set, option parameters 24.1, 24.2, and 24.3 will become available. If the value is set to 0 the boiler will be taken out of sequencing and operate on its own PID. OPTION PARAMETER 00.6 MUST BE SET TO 0 FOR SEQUENCING TO OPERATE
24
5.2 Option 24.1 -24.3 Priority Number(s) LV1
The order in which boilers sequence on is entered as the communication
address(s) of the boilers in Options 24.1, 24.2 and 24.3. The first to be
turned on will have a priority number one above that of the lead boiler.
For example: If the communications address of the four boilers were 1, 2, 3, and 4 (set in Option 0.2), boiler 1 master (lead), with the following entered in Options 24.1-24.3
Option parameter 24.x value 24.1 24.2 24.3
Comms. Address
2 3 4
Boiler
2 3 4
The sequencing order would be boiler 2, 3 and 4. If boiler 2 were set to lead via Option 24.5, the order would be boiler 3, 4 and 1. Setting boiler 3 to master (lead), the order would be boiler 4, 1 and 2. Other sequencing orders can be achieved by changing the communications address entered in Options 24.1-24.3.
Note: Communications addresses should be changed while the boilers are not in sequencing (more than one boiler on) so as not to disrupt operation.
5.3 Option 24.4 – Reserved
5.4 Option 24.5 Lead (master) Boiler Select Method LV1
This option parameter selects the lead (master) boiler via the keypad, digital
input or communications (Comfire 2). The values are:
0 = Not lead, operates on own PID or as commanded by master (lead) 1 = lead
(master) via Keypad 2 = lead (master) via digital input. (Digital Input
Selected via Option 20.8) 3 = lead (master) via communications such as Comfire
2.
Note: When a lead (master) boiler is deselected as lead (master) and Option
24.0 has not been changed to 0, the boiler remains as lead (master) until a
new lead (master) takes control. Once the new lead (master) takes control, the
previous lead (master) may be turned off based on the demand and Option
24.1-24.3 settings.
25
5.5 Option 24.6 lag (slave) On Rate (0-100%) LV1
This value determines the firing rate of the lead (master) boiler at which the
first and all subsequent slave(s) (lag) boilers come on. The slave(s) (lag)
boiler(s) will be delayed in coming on by the time set in Option parameter
24.7. At this point, the lead (master) and the will begin to modulate in
unison. If the lead (master) and modulate above this point, the next as
determined by priority number (Option 24.1, 24.2, 24.3) will be turned on.
When more than one boiler is on, the master and last slave will modulate in
unison while the other slaves are held at high fire.
5.6 Option 24.7 lag (slave) On Delay (0-999 minutes) LV1
This option sets the time delay between the modulation rate of the lead
(master) boiler (and last boiler on if any) exceeding the value set in Option
24.6 and the next being turned on.
5.7 Option 24.8 lag (slave) Off Rate (0-100%) LV3
When the lead (master) boiler and last boiler modulate below this modulation
rate and exceed the value set in Option 24.9, the last turned on will be
turned off. At this point, the lead (master) and the previous (if any) turned
on will begin to modulate in unison until they together are below this
setting. This will continue until only the lead (master) boiler remains on.
5.8 Option 24.9 lag (slave) Off Delay (0-999 minutes) LV3
This option sets the time delay between the modulation rate is at or below the
value set in Option 24.8 and the last turned on being turned off. This also
sets the time delay between successive slaves (lag) being turned off should
the modulation rate stay below the setting in Option 24.8.
5.9 Option 25.0 Banking based on temperature LV3
This option sets which input will be used and the 4-20mA current input from
the temperature sensor must be connected into one of the 5 possible current
inputs:
0 = lag banking on temperature is not enabled. NOTE: Inputs 1 through 4 and
remote tracking are externally powered. See NOTE below for use with loop-
powered sensor.
1 = uses analog input 1. PA7(+) PA11(-). 2 = uses analog input 2. PA8(+)
PA11(-). 3 = uses analog input 3. PA9(+) PA11(-).
26
4 = uses analog input 4. PA12(+) PA11(-). This input circuit needs an external
220-Ohm burden resistor.
5 = uses the remote tracking input as a 4-20mA input. PA15(+), PA14(-) and
option 20.7 must be set to 0 and jumper JP2 must be set to the “IN” position
(which sets the auxiliary input to be 4-20mA).
NOTE – If a loop-powered sensor is used, the “+” to the sensor is taken from
PA16 for all inputs, and the “-” from
the sensor to PA7, PA8, PA9, PA12 or PA15 depending on which input number is
to be used. If the temperature sensor gives a current feedback that is out of
range, i.e. Less than 3.5mA or greater than 21mA, lag banking on temperature
will be cancelled and the sequence lag boiler will bank based on steam
pressure.
The following option parameters are only visible if option 25.0 is non-zero:
5.10 Option 25.1 Water temperature zero value LV3
Sets the zero value for the 4-20mA input (usually 0 for a 0-xxx degree
temperature sensor).
5.11 Option 25.2 Water temperature span value LV3
Sets the span value for the 4-20mA input (i.e. the sensor range xxx).
5.12 Option 25.3 Water temperature cut-in LV1
Sets the low banking cut-in temperature.
5.13 Option 25.4 Water temperature cut-out LV1
Sets the high banking cut-out temperature.
6 Resetting the Control
To reset the Nexus, the MUTE/RESET key will have to be pressed and held for
one second to first silence (mute) the alarm and then a second press for three
seconds to clear the fault. A prolonged key press will do both. (See
Touchscreen Section 2.5) NOTE: The key changes from MUTE to RESET if an alarm
has been silenced. If for some reason the Nexus detects a fault, the cause of
the fault will be displayed if still present. If not displayed, using the
ENGINEERS tab will reveal the fault (see section 8.6).
27
7 Start-up sequence
When a fuel selection is made and the `burner select’ (PE6) signal is given to
start up the burner, the control runs through the sequence described below. If
a gas profile is selected, the control also performs safety valve pressure
proving in parallel with the start-up sequence (see section 4.3 in Fireye
Bulletin NEX-6101).
Stage no. 0. 1.
2.
3. 4. 5. 6.
7.
8. 9.
Stage name
Description
Non-volatile lockout Burner off
Wait for purge
Open fuel valve
Hold fuel valve Prove closed positions Prove air pressure
Prove purge positions
Pre-purge Move to ignition positions
The burner is held in this state until all faults are removed.
The burner is checked to make sure that it has switched off completely. This
includes main fuel safety valves closed, no flame signal and a no air pressure’ signal. The control will remain in this state until there is a call for heat. The control waits for both a burner select and a fuel/air profile to be selected. Progression to stage 3 or 5 maybe held off by external influences, e.g. Communications control or digital input controlled by an external relay. E.g. building automation system If gas and valve proving are selected, the gas motor is moved up for five seconds to allow any gas in the test section to be vented easily during the proving sequence. The fuel motor is held in position until step 1 of the safety valve proving sequence (open main valve 2, or vent valve) is completed. If gas is selected, the gas valve proving sequence begins. The fuel and air motors are moved down until they stop. The final positions are compared with the closed positions stored in memory. The burner motor is started and air pressure prove time t1 is initiated. The selected motors are moved up towards the purge position, unless thefan start
early’ option parameter has been set in which case the motors will not move
until that time has expired. See Option Parameter 7.0.
When the air pressure prove time t1 has elapsed, the air pressure switch must
give a pressure’ signal or the control will lockout the burner. If primary air is selected both primary and secondary air signals must change from ‘no pressure’ topressure’ status. The selected motors are moved up until they
stop.
Once the servo-motors are at their purge positions the timed prepurge t2 is
initiated.
When t2 has elapsed, the fuel and the air motors are moved to the ignition
position for the selected profile. The control will wait for the gas valve
proving sequence to finish if it is still in progress.
28
Stage no. 10. 11.
12. 13.
14. 15. 16. 17.
18.
Stage name Pre-ignition Pilot ignition
Pilot ignition interval Main ignition
Wait for flame established Moving to low fire Modulation Move to postpurge
Post-purge
Description
Once the fuel and air motors are at their ignition positions, the ignition
transformer output is energized and pre-ignition time t3 is initiated. The
Ignition transformer only is on at this stage.
Once t3 has elapsed then: When firing on Gas, the pilot valve is energized and
safety time t4 is initiated. Main Gas Valve 1 may also be energized if
required and selected for pilot. When firing on Oil, the pilot valve is
energized and safety time t4 is initiated. Main Oil valves may also be
energized if Direct Ignition with Oil is selected. The ignition output may
terminate at the end of t4 if Early Spark Termination is set by option 14.6.
See Gas/Oil Start-up Timing Charts (following this table).
When the first safety time t4 has expired, a flame must be detected or the
control will proceed to safety shutdown and lockout the burner.
The ignition transformer may be ON or OFF as set by option 14.6.
Once the pilot interval time t5 has elapsed, the ignition transformer is
turned off, the second (and first if not already open) main valve output(s)
for gas or main oil valve output for oil is energized and the second safety
time t6 is initiated. If firing on oil and ignition with main valve was
selected the main oil valve will have already opened for pilot ignition.
The ignition transformer may be ON or OFF as set by option 14.6.
When the second safety time t6 has expired, the pilot valve output is turned
off. If permanent pilot is selected and the burner is firing on gas the pilot
will remain open with the main valves. Main interval time t7 is initiated.
This allows the main flame to stabilize before modulating.
When interval time t7 has elapsed, the flame is considered established and the
fuel and air motors are moved from their ignition positions to their low fire
positions.
Once the fuel and air motors reach their low fire positions, they are
modulated according to the demand placed on the burner.
If the fuel selection is changed or the `burner on’ signal is removed, the
main valve output(s) are turned off. The fuel motor is moved to its closed
position, and the selected motor(s) are moved to their purge position(s), if a
post purge is selected and the post purge time is initiated.
When the post purge time has elapsed, the burner motor is turned off and the
control returns to state 1 to wait for another startup.
29
Faults and fault finding
8.1 The fault display
The NX6100 carries out a number of internal and external checks during operation. If a fault is found, a fault number (displayed with a text description) is used to identify the type of problem. A list of fault numbers may be found later in this chapter.
To view or review faults, use the MENU button, the FAULT/EVENT LOG button. (See Sections 2.9 and 2.11)
Many of the faults detected and displayed by the controller will cause a non- volatile lockout of the burner, that is to say that removing the power to the controller will not cancel a fault. Some other fault or limit messages will be displayed as a warning but operation of the burner will not be affected.
Each fault number is prefixed on the display by a letter as follows:
F
This means that a fault has occurred and is still present.
The fault may be internal or external to the controller.
C
This means that a fault did occur but has now cleared.
L
This means a programmed limit has been exceeded.
For example :
217PSI Actual AUTO F10:Flame Failure
Many of the faults detected and displayed by the controller will cause a non-
volatile lockout of the burner. Other faults will be displayed as a warning
but operation of the burner will not be affected. A complete list of faults
may be found later in this chapter.
Some fault information may be lost from the display if power is interrupted.
However, the fault history in the display is retained by battery back up.
8.2 What to do when a fault occurs
If faults or limits are present and either the alarm or limit alarm/relay is
on,(closed), then press the MUTE RESET key to mute the alarm (open the relay
contacts). (See Touchscreen Section 2.9)
Take note of the fault message and use the Fault Listing to identify why the
fault occurred.
If the faults, which cause a non-volatile lockout, are still present when the
alarm is muted, then the alarm will operate again when the alarm clears, to
indicate to the operator that the control burner may be restarted.
Once all faults have been diagnosed, rectified and cleared, press the MUTE
RESET key for approximately three seconds to remove the fault messages and re-
start the burner.
The function of the MUTE RESET key may also be achieved via Comview or by
using the FAULT MUTE input. See option parameter 1.2 in Fireye Bulletin
NEX-6101.
30
8.3 Non-volatile lockout
If power is removed from the controller while a fault is still present, the
fault will be stored in non-volatile memory. When power is restored to the
controller, the fault number will still be present and it will be necessary to
remove the fault before restarting the burner.
8.4 Fault subsets
As an aid to fault finding, most faults also have a fault subset that gives additional information about the type of fault or what the burner was doing when the fault occurred. Where applicable, the subsets are given in the fault listing in section 8.5. The fault subsets can be viewed using the engineer’s key (see section 8.6).
8.5 Fault listing
No
Cause
F01
External Alarm
Fault 1
F02
External Alarm
Fault 2
F03
External Alarm
Fault 3
F04
External Alarm
Fault 4
F05
External Alarm
Fault 5
F06
External Alarm
Fault 6
F07
External Alarm
Fault 7
F08
External Alarm
Fault 8
F09
External Alarm
Fault 9
Description
One of the low voltage alarm / lockout inputs is causing an alarm. The fault
may be prefixed by either an L’ or anF’ and may or may not shutdown /
lockout the burner.
See Option parameters 1918.1 to 1918.9. Subset : burner status.
31
No
Cause
Description
F10
Flame Failure
The flame detector did not register the presence of a flame
when it should be present.
Subset : burner status
F11
False Flame
The flame detector registered the presence of a flame when
it should not be present or when the shutter (if selected) was
closed.
Subset : burner status
F12
External Alarm
The high voltage alarm / lockout input number 12 is causing
Fault from Input 12 an alarm.
The alarm number fault is may be prefixed by either an L’ or anF’ and may
or may not shutdown / lockout the burner.
See Option parameter 16.3.
Subset : burner status.
F13
External Alarm
The high voltage alarm / lockout input number 13 is causing
Fault from Input 13 an alarm.
The fault may be alarm number is prefixed by either an L’ or anF’ and may
or may not shutdown / lockout the burner.
See Option parameter 16.4.
Subset : burner status.
F14
Main (secondary) The main (secondary) combustion air pressure switch failed
combustion air
to register air pressure when it should be present.
pressure not
detected
Subset : burner status
F15
Main (secondary) The main (secondary)combustion air pressure switch
combustion air
registered air pressure when it should not be present (subset
pressure detected : 1), or the air pressure switch registered air pressure for
| when it should not more than 3 minutes after the burner was turned off (subset |
|---|
be.
2).
Secondary air
pressure. detected
F16
Optional second
The primary air pressure switch failed to register air pressure
P(primary) air
when it should be present.
pressure not
detected
Subset : burner status
32
No
Cause
Description
F17
Optional second
The primary air pressure switch registered air pressure when
(primary) air
it should not be present (subset : 1), or the air pressure
pressure detected switch registered air pressure for more than 3 minutes after
when it should not the burner was turned off (subset : 2).
be.
Primary air
pressure detected
F18
Not enough
A fuel/air ratio profile has been selected which does not have
setpoints entered at least four setpoints commissioned. Use commission ratio
mode to enter more setpoints.
Subset : fuel code
F19
Circuit board
The circuit board has an incorrect on-board reference level.
voltage reference
fault
Ensure ALL analog inputs (4-20mA, 0 5Vv) are in
the range 0 to 5Vdc. It is critical to the controller
operation that none of the inputs are higher than
5V.0 volts.
If the problem persists even when all analog inputs
are disconnected, check EK37 and contact supplier.
Subset : +1 out of range, +2 zero check failed, +4 span check failed.
33
No
Cause
Description
F20
Drive 0 position
A drive-positioning fault has occurred, which will cause a
fault
non-volatile lockout of the burner. This fault has occurred for
one of the following reasons:
F21
Drive 1 position
1. During `Close’ position prove, the measured position
fault
when a drive stops at a position that is outside the
commissioned `Close’ set position, by more than five
degrees.
F22
Drive 2 position fault
2. During Purge position prove, the measured position is in error, to the commissioned `Purge’ position, by more than
five degrees.
F23
Drive 3 position
3. when a drive stops at a position that is outside the purge
fault
set position by more than five degrees.
4. During pre-purge, ignition or post-purge, when a drive
F24
Drive 4 position
moves from its setpoint.
fault
5. During modulation, when a drive is not at its correct
setpoint as defined by the commissioned fuel/air ratio for
the selected profile.
F25
Drive 5 position fault
A servo drive is defined as having moved from its setpoint if its positional error is more than 1° for 15s, or more than 5°
for 1s. For positional errors between 1° and 5°, the detection
F26
Drive 6 position
time is variable between 15s and 1s.
fault
Inverter (VSD) drive error bands variable and set in option
parameter 09.1.
F27
Drive 7 position
fault
Note : Only the selected drives (i.e. used on the current fuel/
air profile) drives are checked. The other drives are ignored.
F28
Drive 8 position fault
Subset : burner status. 000 016 = Burner Status
032 048 = CAN communications error. Display shows
F29
Drive 9 position fault
064
ERR1 under drive name = Internal servo fault. Display shows ERR2
ERR7 under drive name
F30
Gas Proof of
The gas (main 2) valve proof of closure signal is not
Closure fault
responding correctly. The fuel valve “proof of closure” switch
must change state (e.g. open or close) within 7 seconds of
the valve being energized or de energized.
Subset : burner status.
34
No
Cause
Description
F31
Oil Proof of
The oil valve proof of closure signal is not responding
Closure fault
correctly. The fuel valve “proof of closure” switch must
change state (e.g. open or close) within 7 seconds of the
valve being energized or de energized.
Subset : burner status.
F32
Safety input fault
One or more of the fail-safe low voltage inputs is registering
a fault. Check digital inputs 1 to 8 are wired to the correct
commons.
Subset : Combination of failed inputs, (binary coded).
F33
Burner input fault One or more of the fail-safe high voltage inputs is registering
a fault.
Subset : Failure modeI input number.
F34
Primary relay fault One or more of the internal relays is not responding
correctly.
Subset : Failed Relay.
F35
ADC fault
One of the internal checks on the analog to digital converter has failed.
Subset : Failure mode.
F37
RAM test fault
The main memory in the controller has malfunctioned.
Interrupt power to the controller. This could be due to high levels of
electrical interference
getting into the product. Check all cables are correctly screened, and screens
are terminated correctly. Ensure the mains supply is not excessively noisy. If
this fault persists, the controller must be returned to the supplier.
Subset : Failed Page.
35
No
Cause
Description
F38
Program memory The program memory in the controller has been corrupted.
CRC fault
Interrupt power to the controller
This could be due to high levels of electrical interference
getting into the product. Check all cables are correctly
screened, and screens are terminated correctly. Ensure
the mains supply is not excessively noisy.
If this fault persists, the controller must be returned to the
supplier.
Subset : Failed Page.
F39
Profile table CRC The profile table memory in the controller has been
fault
corrupted.
Interrupt power to the controller. Erase the system using option parameter
45.1 = 5 and re
commission (or restore with option parameter 45.2). This could be due to high
levels of electrical interference
getting into the product. Check all cables are correctly screened, and screens
are terminated correctly. Ensure the mains supply is not excessively noisy. If
this fault persists, the controller must be returned to the supplier.
Subset : Failed Page.
F40
Single fuel only
This fault will appear if a an attempt is made to commission
fault
an oil profile on a gas only unit, or a gas profile on an oil only
unit. Check option parameters 6.1 to 6.4
F41
Boiler safety limit
The boiler’s measured value has exceeded the
exceeded
pressure/temperature safety limit, or the Fireye
pressure/temperature sensor is not responding correctly.
Subset : 1 = – sensor feedback < 1V, 2 =- sensor feedback > 5V, 3 =- sensor failed during test, 4 =- safety limit exceeded
F42
Valve proving fault The measured gas pressure was not correct during the gas
valve proving test.
Subset: Valve prove status.
36
No
Cause
Description
F43
Gas pressure limit The measured gas pressure is outside the operating limits
S(subset : valve prove status) , or 10 = the gas pressure
sensor is not responding correctly (subset : 10).
F46
EEPROM memory The EEPROM memory in the controller has been corrupted.
CRC fault
This memory is used to store the option parameters,
Interrupt power to the controller Erase the system using option parameter 45.1
= 5 and re
commission (or restore with option parameter 45.2). This could be due to high
levels of electrical interference
getting into the product. Check all cables are correctly screened, and screens
are terminated correctly. Ensure the mains supply is not excessively noisy. If
this fault persists, the controller must be returned to the supplier.
Subset : Failed Page.
F50
Oxygen probe
The probe heater has failed to heat to the correct
heater fault
temperature after 30 minutes of system power up.
Is the probe heater wiring correct? Is the probe cell thermocouple wiring correct?
Once the fault is rectified, it will be necessary to interrupt the power to the oxygen probe interface to make it attempt to heat the probe once more.
Subset: O2 probe status.
L52
Oxygen low limit alarm
The oxygen level measured value is below the oxygen setpoint low alarm value for the current profile.
Subset: 0 = Limit violation, 1 = Probe Failed.
L53
Oxygen high limit alarm
The oxygen level measured value has exceeded the oxygen setpoint high alarm value for the current profile.
Subset: 0 = Limit violation, 1 = Probe Failed.
37
No
Cause
Description
F54
Oxygen probes
This fault occurs when two oxygen probes are used to give
mismatch fault
fail-safe oxygen monitoring. If this fault occurs, check and
calibrate both oxygen probes. It may be necessary to
increase option parameter 42.4 or 42.5 (within safe limits) if
the oxygen probes are in different parts of the flue.
Subset :
1 = Oxygen values do not match,
2 = Flue temperatures do not match
3 = Neither the flue temperature and/or oxygen levels do not
match
4 = Second oxygen probe is faulty/not ready. See EK 76.
The trim drive has reached the allowed maximum deviation
L55
Trim limit alarm
limit.
Change trim limit. Re-commission fuel / air ratio.
Subset : Not applicable.
F57
Auto trim commissioning
The measured oxygen level exceeded 15.0% during auto trim commissioning. The burner is shutdown.
fault
Subset : Last auto trim commission setpoint (+32 if adding
air).
L58
Flue temperature low alarm value
The measured flue temperature is below the low alarm value for the current profile, or the flue thermocouple is faulty.
exceeded
Subset : Not applicable.
L59
Flue temperature high alarm value
The measured flue temperature has exceeded the high alarm value for the current profile.
exceeded
Subset : Not applicable.
F63
Option parameters The option parameters have been uploaded via serial
uploaded
communications. Check all values are correct and match the
application, then set option parameter 45.0 to 0.
38
No
Cause
Description
F64
Profile Invalid
This fault means that the controller can’t fire the currently selected profile because it isn’t sure it still matches the
burner / site configuration. It could lead to a hazardous
situation.
There are three possible causes to this fault :
1 A drive has been commissioned in this profile but has now been deselected. E.g. – If a profile is commissioned with two air dampers but then the second air damper is deselected with option parameter 4.0 to 4.9, then obviously the profile is no longer valid.
Subset : Drive number (0 to 9)
2 Servo / Drive changed. If the system is commissioned then later one of the servos is changed for a new one (i.e. different serial number), any profiles that use the original at servo are now considered invalid. (This is to ensure that the maintenance engineer checks that the new servo is mechanically fixed the same way as the original one.)
Subset : Invalid profile + 100 (101 to 104).
3 The selected profile has been uploaded from a PC, but has not been verified on this burner.
Subset : Invalid profile + 100 (101 to 104).
In all cases the F64 can be cleared by switching to another (valid/good)
profile, or by re-commissioning the profile in commission ratio’ mode, making sure all points up to and including high fire are acknowledged using the NEXT’ key (or `ENTER’ if the points are adjusted).
F65
Power-up Lockout The controller has locked out on power-up. This will normally
be because option parameter 1.0 is set to 1.
Subset : 0 See option parameter 1.0. 254 Serial EEPROM write failure. 255 NV Lockout verification failed.
F66
Flame Test
The flame test (dark test) has failed. This could be a problem
with the flame input circuitry, or a shutter problem / failed UV
tube if a shuttered UV is used.
Subset : burner status.
39
No
Cause
Description
F67
Secondary relay
A secondary fault has occurred with the main 1, main 2, pilot,
fault
vent or non-volatile lockout relays. Tests are performed
once an hour. If two consecutive tests fail then the controller
will Lockout and display the fault number.
Contact supplier
Subset : Failed relay number.
F68
Secondary
A fault has occurred with the program memory in the
program memory controller. Tests are performed once an hour. If two
checksum fault
consecutive tests fail then the controller will Lockout and
display the fault number.
Contact supplier
Subset : Not applicable.
F69
Secondary
watchdog fault
F70 F79 User Faults
A fault has occurred with the CPU watchdog. Tests are performed once an hour.
If two consecutive tests fail then the controller will Lockout and display the
fault number.
Contact supplier
Subset : 1 = Late test failed. 2 = Early test failed.
These fault numbers are generated by the user programmable section of the
controller and will vary with the application.
40
8.6 The engineer’s tab
By selecting the engineer’s tab it is possible to read the values of internal
system variables and external input and output states. It is also possible to
see the values of fault subsets, in order to obtain more detailed information
about a fault that has occurred. When using the engineer’s tab it is not
possible to change any parameters. Therefore, it is not possible to affect the
operation of the burner. After pressing the MENU button, press BURNER SETTING
button, then the Engineers Values tab. (See Touchscreen Section 2.9)
8.7 System Event/Fault history.
The NX6100 stores information on events and faults. The memory in the unit
will store the last 128 events/faults, and associated status data and, as an
option, a date and time stamp. The 100 most recent events/faults are available
via the display unit and all 128 are available though Comfire 2.
8.8 Engineer’s key parameter list
No.
EK1 EK2 EK3 EK4 EK5 EK6 EK7 EK8 EK9
Name
Low Voltage Digital Input 1 PB9 PB10
Low Voltage Digital Input 2 PB9 PB11
Low Voltage Digital Input 3 PB9 PB12
Low Voltage Digital Input 4 PB9 PB13
Low Voltage Digital Input 5 PB14 PB15
Low Voltage Digital Input 6 PB14 PB16
Low Voltage Digital Input 7 PB14 PB17
Digital Input 8 / Profile 1
Digital Input 9 / Profile 3
Description
Shows the state of each input. Where :
0 = OFF 1 = ON
41
No.
EK10 EK11 EK12 EK13 EK14 EK15 EK16
EK17
EK18
EK19
Name
Profile 2 (PB8 PB6) Profile 4 (PB8 PB7) Profile 3 Select (Low Voltage)
High voltage digital input 12. PE4 High voltage digital input 13. PE5 Burner
Select Input (High Voltage) PE6 Airflow Input (Low Voltage) PB18 PB19 Warming
limit
Flame Detected
Boiler status
Confirm to adjust
Description
0 – Measured value above warming limit, burner free to modulate. 1 – Measured
value below warming limit, burner held at low fire if the controller is in
auto or sequencing mode. 0 No flame detected. 1 Flame detected. When both
flame inputs are used together, this value will only show `1′ when both inputs
are above their flame threshold. 0 – Burner will not fire because the
temperature / pressure measured value has exceeded the high controller value.
1 – Burner will fire because the temperature / pressure measured value has
fallen below the low controller value. 0 – Controller not in commission mode
or control is in commission mode and drives moving to setpoints. 1 –
Controller in commission mode and drives may be adjusted using the UP/DOWN
keys.
42
No.
EK20
EK21 EK22 EK23 EK24 EK25 EK26 EK27
EK28
Name
Drive moved
Positions proved Fault alarm Oxygen Trim Enable Oil warming Active CAN_TX
Failures Commission status Commission setpoint
Commission Setpoints entered
Description
0 – Controller not in commission mode or control is in commission mode and
drives have not been moved using the UP/DOWN keys.
1 – Controller in commission mode and drives have been moved using the UP/DOWN
keys.
0 – Drives have stopped moving, ready for position prove test.
1 – Ready for position prove test but drives still moving.
0 No un-muted alarms (faults) present. +1 – Un-muted fault alarm present
(prefix : F) +2 – Un-muted limit alarm present (prefix : L) +4 Un-muted
flue-monitoring alarm present (faults 50 to 59).
0 Oxygen trim off or not working. 1 Oxygen trim on and working.
The burner will not fire because the oil is not up to temperature and the oil
warming function is active.
A count of the number of times the can bus controller has failed to send a
message since power-up. This should be zero unless there has been a problem.
Current commissioning mode, where :
0 – Normal run mode. 1 – Adjust ratio mode. 2 – Commission ratio mode.
The current setpoint being commissioned.
0 – Closed setpoint. 1 – Purge setpoint. 2 – Ignition setpoint. 3 – Low fire
setpoint. 4 – 24 – profile setpoints
The number of setpoints that have been successfully entered during this
commission ratio session.
43
No.
EK29 EK30 EK31 EK32
EK33
EK34
EK35
EK36 EK37 EK38 EK39
Name
Modulation rate (%) Burner Status Fuel Profile Selected Number of commission
setpoints
Modulation mode
Photocell / IR sensor signal value
UV sensor signal value
Nearest setpoint Voltage reference error (V) Boiler Sequencing Status Fuel
Swap Status
Description
The current modulation rate of the burner. 0 = Low Fire 100 = High fire
Status of the start-up sequence. See section 7.
The currently selected fuel profile.
The number of setpoints entered in the current commission ratio session :
0 – No setpoints entered. 1 – Close setpoint only. 2 – Close and purge
setpoints. 3 – Close, purge and ignition. 4 – 24 – profile setpoints.
The current modulation mode :
0 – Auto mode. 1 – Manual from external input. 2 – Manual from keyboard. 3 –
Boiler sequencing controller. 4 – Low fire hold.
Signal value received from the flame sensor input. For the photocell / IR
input : 0 – Fully dark. 999 – Fully light.
Signal value received from the flame sensor input.
0 – No flame detected. 999 – Flame detected.
The number of the profile setpoint which setpoint that is nearest to the
current modulation position.
The error between the measured voltage reference and the calibrated value.
Currently unused.
Currently unused.If non zero, the controller is in the process of performing a
fuel profile swap (without turning the burner off).
44
No.
EK40 EK42 EK43 EK44 EK45
EK46
Name
Shutdown setpoint
Adjust ratio counter
Commission ratio counter
Oxygen measured value
Oxygen probe status
Oxygen trim status
Note: The values to the right are binary.
If the value of EK46 is not specifically listed to the right: first, subtract
the highest value you can, and then from the remainder, subtract the next
highest value you can, and so on.
Each value is a potential reason why the trim is not working. See example
below.
Description
The nearest setpoint (EK36) when the burner last locked out.
The number of times adjust ratio mode has been used.
The number of times commission ratio mode has been used.
The current flue oxygen value as measured by the Fireye probe (if fitted).
+1 – Internal fault. +2 – Internal fault. +4 – Heater fault. Causes F50. +8 –
Cell temperature out of range. +16 – Cell millivolts out of range. +32 – Can
bus error. +64 – Probe calibrating in reference gas. See option parameter
30.6. +128 – Probe calibrating in air. See option parameter 30.6.
0 – O trim working, or 2
+1 no oxygen interface connected. +2 no oxygen probe serial number
entered,
or, option 30.5 not 1, or, option 30.8 not 0 or, no trim type selected by
option 31.x,
trim not selected via aux input or, trim not selected via dig i/p, serial
comms +4 O2 setpoints or flow values incorrect +8 – Option 20.6 not 0 +16-
Not modulating +32- In commission mode +64- Probe faulty (see EK45)
45
No.
EK47 EK48 EK49 EK50 EK51 EK52 EK53 EK54 EK55 EK56 EK57
Name
Description
Example: If EK46 = 70, for possible reasons why the trim is not working:
The highest description number that can be subtracted from 70 is 64, so the
first possible reason is +64 – “Probe faulty” (noted above)
Since 70-64=6 there could be an additional reason. Since the highest
description number that can be subtracted from 6 is 4, the second possible
reason is +4 “O2 setpoints or flow values incorrect” (noted above)
Since 70-64-6=2 there could still be an additional reason. The highest
description number that can now be subtracted from 2 is 2, so the third
possible reason is +2 “(entire +2 description noted above)”
Oxygen setpoint (%) Excess air (%) Oxygen error (%) Trim deviation (% flow)
Gas pressure (mBar display units)
VPS Valve close time ttest (s)
Gas pressure change (Ptest display units) Valve prove status Main PCB issue
Software issue. Spare
Current oxygen setpoint. This is only available if trim is enabled and working.
Excess combustion air at the current firing position.
Error between O measured value and O
2
2
setpoint.
Deviation in air flow/airflow imposed by trim (25 to +25%)
Measured gas pressure from the gas pressure sensor (sensor must be enabled and gas must be selected).
Time for which each half of the valve prove test will be conducted, This time counts down to zero during stages 2 and 4 of the valve prove test.
Maximum Pressure drop/rise limit allowed during the valve prove test.
Status of valve proving sequence.
The issue number of the main circuit board that the firmware is expecting. This may be different to the actual PCB issue if they are compatible.
The current revision of the main product firmware.
N/A
46
No.
EK57EK 58
EK59
Name
CPU serial number (low 4 digits)CPU serial number (high 3 digits)
Drives at setpoint
EK60
Digital (relay) outputs on.
EK61
Analog Input 1. Main Unit Terminal PA7.
Description
The 6 digit CPU board serial number. The serial number is displayed in 2
blocks of 3 digits.
Represents which drives are currently at their setpoints, where:
0 All drives are at their setpoints and are not moving.
Non- zero One or more drives are not at their setpoint.
The combination of digital outputs currently switched on.
+1 : Digital Output 1 ON. Display, PR3(COM), PR1(NO), PR2(NC). Low voltage or
line voltage.
+2 : Digital Output 2 ON. Display, PR3(COM), PR5(NO), PR4(NC). Low voltage or
line voltage.
+4 : Digital Output 3 ON. Display, PR7(COM), PR9(NO), PR8(NC). Low voltage or
line voltage.
+8 : Digital Output 4 ON. Main Unit, PD6(COM), PD7(NO), PD8(NC). Low voltage
or line voltage.
+16 : Digital Output 5 ON. Main Unit, PD6(COM), PD4(NO), PD5(NC). Low voltage
or line voltage.
+32 : Digital Output 6 ON. Main Unit, PD1(COM), PD2(NO), PD3(NC). Low voltage
or line voltage.
+64 : Digital Output 7 ON. Daughterboard, PZ15 PZ16. LOW VOLTAGE AND CURRENT
ONLY.
+128 : Digital Output 8 ON. Daughterboard, PZ17 PZ17. LOW VOLTAGE AND
CURRENT ONLY.
The raw ADC counts from analog input 1.
0 to 1023 for 0 to 5.00 volts.
4mA = 180 counts
20mA = 900 counts
47
No.
EK62
EK63
EK64
EK65
EK66
EK67 EK68 EK69 EK70 EK71
Name
Analog Input 2. Main Unit Terminal PA8.
Analog Input 3. Main Unit Terminal PA9.
Analog Input 4. Main Unit Terminal PA12 (also gas pressure).
Analog Input 5. Main Unit Terminal PA15 (also remote setpoint).
Analog Input 6. Main Unit Terminal PA19 (also boiler measured value).
Analog input 7. Daughterboard terminal PZ12(-) PZ13(+). Also VSD1. Analog
input 8. Daughterboard terminal PZ13(-) PZ14(+). Also VSD2. Daughter board
Frequency input 1 (PZ7). 0 to 12 volts.
Daughter board Frequency input 2 (PZ9). 0 to 12 volts.
Daughter board Frequency input 3 (PZ11). 0 to 12 volts.
Description
The raw ADC counts from analog input 2. 0 to 1023 for 0 to 5.00 volts. 4mA =
180 counts 20mA = 900 counts
The raw ADC counts from analog input 3. 0 to 1023 for 0 to 5.00 volts. 4mA =
180 counts 20mA = 900 counts
The raw ADC counts from analog input 4. 0 to 1023 for 0 to 5.00 volts. 4mA =
180 counts 20mA = 900 counts
The raw ADC counts from analog input 5. 0 to 1023 for 0 to 5.00 volts. 4mA =
180 counts 20mA = 900 counts
The raw ADC counts from analog input 6. 0 to 1023 for 0 to 5.00 volts. 4mA =
180 counts 20mA = 900 counts
The ADC counts from analog input 7. 0 to 999 for 4 to 20mA.
The ADC counts from analog input 8. 0 to 999 for 4 to 20mA.
Gives the measured frequency in Hz on this input. If the input is not
changing, this value will be 0 for OFF (open circuit) and 1 for ON.
Gives the measured frequency in Hz on this input. If the input is not
changing, this value will be 0 for OFF (open circuit) and 1 for ON.
Gives the measured frequency in Hz on this input. If the input is not
changing, this value will be 0 for OFF (open circuit) and 1 for ON.
48
No.
EK72
EK73 EK74 EK75
EK76
EK77
EK78 EK79 EK80 89
EK90 EK91 EK92Ek99
Name
Oxygen probe cell temperature.
Ambient air temperature. CPU utilization (%). Second O2 level (%) Longest task
time.
Second probe status Longest task number.
Last program byte address Program size.
Second cell temp (ºC) Second flue temp (ºC) Drive Error values for drives 0 to
9.
Burner cycles Burner Lockouts Spare
Description
The temperature of the zirconia cell inside the Fireye oxygen probe, if
fitted. This value should be very close to 650ºC for accurate operation.
The temperature measured by the inlet temperature sensor, if fitted. Units are
ºC.
The percentage utilization of the CPU. Should be less than 95% at all times.
The measured flue oxygen level as measured by the second oxygen probe
interface.(%)The current longest internal software task time. This is provided
for manufacturers diagnostics only and may be removed in future versions.
The same as EK45, but for the second oxygen probe. The current longest
internal software task number. This is provided for manufacturers diagnostics
only and may be removed in future versions.
This is the length of the currently running user / manufacturers program. If a
user program is selected, this should match the program length given by the
`abacus’ software.
The internal zirconia cell temperature of the second oxygen probe, if fitted.
The flue temperature, as measured by the second oxygen probe, if fitted.
The current error value for drives 0 to 9. These values will freeze when the
controller performs a safety shutdown, so it may be possible to look at these
values after a lockout to help determine the cause.
The number of times the burner has attempted to start.
The number of times the burner has locked out.
N/A
49
No.
EK100
Name
Firmware type PT22xxxx…
Description
This shows the last four digits of the firmware part number for the NX6100
firmware. It is used for product variant identification.
The product allows for customization of various non-safety critical functions including the modulation control. The engineers’ keys shown below relate to the default modulation control function programmed in the control at the factory. To verify this has not been replaced by an application specific function check with the equipment supplier and / or check option parameter 00.4, if available.
No.
EK101 EK102 EK103
Name
PID1 Active PID2 Active Control Limits Active
EK104
User modulation mode
EK105
PID not required
EK106 EK107
Burner Firing Warming Limit Active
EK108
Remote Tracking Active
Description
If the value is 1, Setpoint / PID set 1 is active.
If the value is 1, Setpoint / PID set 2 is active.
If the value is 1, the control limits are active and will turn the burner on
and off as the load dictates. The low and high limits are shown on EK153 and
154. If the control limits are holding the burner off, EK18 will be zero.
This will normally be zero. A custom modulation program may change this value
if it is modifying the modulation rate.
If this value is 1, the internal modulation PID is not running. This may be
because the burner is off, in commission / manual mode or for another reason.
If this value is 1, the burner is firing (fuel valves open), or it is in post-
purge.
If this value is 1, the warming limit function (see option parameter 23.0) is
holding the burner at low fire (status 15).
If this value is 1, the remote tracking function is active. See option
parameter 20.7. The AUTO modulation rate will come from analog input 5.
50
No.
EK109
Name
Remote Setpoint 1 Active
EK110 to EK119
EK120 EK121 EK122 EK123 EK124 EK125 EK126
Not used by the standard manufacturers program. May be used by a custom
program.
Lead selected
Running as lead
Ist Slave ON 2nd Slave ON 3rd Slave ON
New Lead asserted
Lead in Prop band
EK127 EK128 EK129 EK130 EK131 EK132 EK133 to EK150.
EK151 EK152 EK153
Burner available 2 Slaves 3 Slaves Don’t control SL1 Don’t control SL2 Don’t control SL3 Not used by the standard manufacturers program. May be used by a custom program. Setpoint 1 control value Setpoint 2 control value Low control limit
EK154
High control limit
EK155 EK156
Spare Measured Value
Description
If this value is 1, the remote setpoint 1 function is active. See option
parameter 20.7. The value of Setpoint 1 will come from analog input 5. N/A
Controller has a command to be Lead Controller has control of the sequence
system Ist Slave is required ON 2nd Slave is required ON 3rd Slave is required
ON A new lead has been selected Lead is modulating to the load in the
proportional band 1 = Burner available for sequencing 1 = 2 slaves available 1
= 3 slaves available 1 = Slave 1 will not be used 1 = Slave 2 will not be used
1 = Slave 3 will not be used N/A
The actual value of setpoint 1 being applied. The actual value of setpoint 2
being applied. The actual value of the low control limit (cut-in point) being
applied. The actual value of the High control limit (cutout point) being
applied. N/A The current boiler measured value (actual value) shown with
increased precision.
51
No.
EK157
Name
AUTO modulation rate
EK158
Sequence status
EK159 to EK199.
EK200
Not used by the standard manufacturers program. May be used by a custom
program.
Prog:
Description
The modulation rate that the boiler will fire to if in AUTO mode (providing
option parameter 15.0 is not zero or 1).
0= Not available for sequence +1= Available for sequencing +2= New Lead
selected +4= Running as Lead +8= Firing from setpoint 1 +16= Burner status < 8
N/A
Currently running manufacturers / custom (user) modulation program name and
revision number (if applicable).
9 Troubleshooting
9.1 Display / General
Problem
Display shows it’s serial number but not data from controller unit
Possible cause
Display CAN bus wired incorrectly. Main controller not running.
Display updates slowly or seems to freeze when scrolling a parameter number.
Display will not light at all.
One of the CAN devices has the two CAN wires crossed over.
24VAC supply to display missing. Main controller not running.
Measured value incorrect.
Wrong sensor voltage. Wrong sensor input type. Incorrect sensor wiring. Wrong zero or span.
Hours run shows ‘—‘. Modulation rate is 0.
No profile selected. Burner not modulating.
Suggested action
Check wiring of CAN bus (PT3 and PT4).
Check main controller low voltage electronics fuse FS2. If blown, investigate
all low voltage external wiring and replace fuse, if necessary, with a new one
of the correct type and rating. Check wiring of the can cable.
Check for 24VAC on PT1 and PT2. Check fuse FS1. If blown, investigate all high
and low voltage external wiring and replace fuse, if necessary, with a new one
of the correct type and rating. Check SENS SUPP link (see Error! Reference
source not found.) Check SENS IN link (see Error! Reference source not
found.). Check wiring to terminals PA18 to PA20.. Check option parameters
15.0, 15.1, 15.2. Select oil or gas profile. Wait for burner to finish start-
up sequence.
52
Problem
Burner status is flashing.
Gas pressure not shown. Gas pressure incorrect.
Possible cause
Controller in non-volatile lockout mode. Gas sensor not selected.
Incorrect span value.
Suggested action
Burner status before shutdown displayed.
Select sensor using option parameter 10.0
Check option parameter 10.1
9.2 Startup
Problem
Burner will not start.
Possible cause
Controller in non-volatile lockout. High control limit exceeded. Control in
commission ratio mode. Burner off via serial comms.
Drive positioning fault occurs before drives move to purge.
Air pressure switch still made. No fuel selected. Burner not selected. .
Stored close positions do not match actual close positions.
Drive positioning fault
Stored purge positions cannot
occurs when drives reach be reached.
purge.
Drives stuck at ignition and burner has not fired.
Pilot, main 1 and main 2 valves will not open.
Drives stuck at ignition and burner has fired.
Drives cannot reach ignition position. No feed on BURNER SEL.
Ignition time has not elapsed.
9.3 Commissioning
Suggested action
Hold FAULT MUTE key when faults clear.
Check EK18 and wait for press/temp to drop. Press NEXT to advance to next
setpoint.
Turn the burner ON using Comview software (if fitted), or Profibus / Modbus
interface. Use section 7 and burner status (EK30) to define what the
controller is waiting for. Also check EK310, EK10=1, EK15=0.
Check feedback potentiometers and motor micro-switches. Reset close positions
using commission ratio mode. Check feedback potentiometers and motor micro-
switches. Reset purge positions using commission ratio mode. Check motor
micro-switches and linkages.
Check terminal PE6.
Wait for ignition time to elapse. Reduce ignition time (option parameter
04.1).
Problem
Cannot get past P0. ‘Px’ or ‘Ax’ display flashes constantly and motor
positions cannot be altered.
Option parameter not
Possible cause
See `burner will not start’ above. Drives are moving to position. Burner off
in adjust ratio mode. A0, A1, A2 displayed. Valve proving test in progress.
Another option parameter must
Suggested action
See `burner will not start’ above. Wait for drives to position. Turn burner on
if you need to adjust points Aa3 onwards. Wait for valve proving test to
finish.
Set option parameter (usually XX.0) to a
53
Problem
available.
Option parameter not adjustable. Not possible to enter commission ratio mode.
Not possible to enter adjust ratio mode.
Possible cause
be set first.
Wrong passcode entered or burner firing. Supplier passcode incorrect. Burner
firing (goes into adjust ratio mode). Supplier passcode incorrect.
Suggested action
non-zero value to enable other param’s in group. Enter the supplier passcode
and/or turn the burner off before changing the value. Enter correct passcode.
Turn burner off and try again.
Enter supplier passcode with the burner on.
9.4 Gas valve proving
Problem
Proving sequence takes a long time. Main valve 2 does not open. Vent valve
does not open. Main valve 1 and/or main valve 2 do not open.
Possible cause
Nominal gas pressure, test volume or leakage rate wrong. Vent valve has been
selected.
Vent valve not selected. Valve proving not selected. No feed on BURNER SEL.
9.5 Modulation
Suggested action
Check option parameters 10.1 to 10.7. Expected time shown on EK52. Check
option parameter 10.7.
Check option parameter 10.7. Check option parameter 10.0. Check for feed on
terminal PE6.
Problem
Sensor or modulation rate inaccurate. Intermittent positioning faults.
Possible cause
V/I input setting incorrect. 5/30V supply setting incorrect. Profile setpoint
is too close to the P0 micro-switch position.
Suggested action
Check option parameter. Check SENSOR IN and SUPPLY links. Move the increase
the setpoint end points further away from the P0 position high/low.
Controller stuck at low fire.
Poor Earth or screening. Feedback potentiometer faulty.
Communication to servo motor(s). Meas. value exceeds setpoint. Warming limit
active Controller in MANUAL mode. External low fire hold, or missing AUTO
input from burner controller.
Check wiring. Move motor across range and check the feedback in commission
ratio mode with the burner off. Check wiring.
No fault. Wait for boiler to warm up. Check EK16. Press the AUTO key to change
to auto mode Remove feed from Aux inputs (if selected). Check EK 6.
In manual mode.
Controller stuck at a
Serial communications.
Increase the mod. rate using `UP’ key.
Check PID, proportional band must be greater than zero to modulate Disable or
change modulation slider in
54
SPEED
SPEED
SPEED
SPEED
SPEED
SPEED
modulation rate. 9.6 Inverters
Problem
TIME TIME TIME TIME
TIME TIME
Computer software. Controller in commission mode. Press RUN then ENTER to enter run mode.
Possible Cause
Inverter does not start because it does not receive a RUN signal.
Solution
Ensure that the inverter receives a RUN signal from the burner fan motor
output daughter board fitted on the NX6100 control.
Inverter has a slow start.
Non-linear output from inverter or inverter’s PID is enabled
Current limit reached
Noise
Ensure that the inverter’s slow start feature is disabled.
Check that the inverter’s output is selected to be linear, and that the
inverter’s own PID loop is disabled.
Slow down the inverter by increasing its acceleration / deceleration time
settings.
Check cable screens.
Current limit reached.
Non-linear output from inverter or inverter’s PID is enabled.
Fan failed to stop before restart.
Slow down the inverter by increasing its acceleration / deceleration time
settings.
Check that the inverter’s output is selected to be linear, and that the
inverters own PID loop is disabled.
Increase the inverter stop time by increasing option parameter 09.3 on the
NX6100 series control3.
Control is unstable
Adjust option parameters 9.0 and 9.2 on the NX6100 control to reduce accuracy
& slow down control response.
Check Option parameter 9.4 matches the acceleration / deceleration time
programmed into the VSD.
VSD is current limiting. Increase acceleration / deceleration time in
55
VSD and option parameter 9.4.
In extreme cases, it may be necessary to increase the inverter error tolerance
to prevent non-volatile lockouts caused by positioning faults (set option 9.1
= 1). This must only be changed if an inverter error of 55 will not cause
unsafe combustion
9.7 Oxygen measurement and trim
Problem
Oxygen display not available.
Possible cause
No oxygen probe interface unit serial number entered.
Suggested action
Enter serial number into option parameter 30.0
No inlet temperature display Inlet or flue temperature display flashes ‘Hi’
No efficiency display or efficiency incorrect.
Oxygen display shows –
No inlet temperature unit serial number entered.
Inlet air temperature sensor / O2 probe not installed and wired correctly.
No oxygen display. No inlet temperature display. No calorific value for the
current fuel been entered into 35.X? Probe not heated up yet, or other probe
fault.
Enter serial number into option parameter 35.0 Check wiring.
See No oxygen display’ SeeNo inlet temperature display’
Enter the value for the fuel in use. Check EK45. Check EK72 must be above
600ºC to work.
Oxygen trim will not work Trim is not operative.
Boiler just fired up.
Probe calibration values not entered correctly. Probe not heated up yet. Probe
installed incorrectly. Set to monitor only. Probe in calibration. Trim being
reset.
Trim limits set to 0.0% of flow. Trim integral gain set to zero. Commissioning
data missing.
Use EK45 and 46 to decide if trim is operative. Check that option 30.5 =1.
Check option parameter 31.1 to 31.4. Wait for the boiler transport time (after
ignition). Wait for modulation.
Re enter values (options 320.1, 320.2) Check EK75 must be above 600ºC to
work. Check wiring.
Check option parameter 30.5 set to 1. Check option parameter 30.6 set to 0.
Check option parameter 30.8 set to 0.
Check option parameters 32.X. Check option parameters 33.X are non zero. Check
oxygen and flow values been entered for all profile points in the firing
range.
56
PID Tutorial
PID Adjustment
The NX6100 utilizes and advanced algorithm in order to maintain setpoint over
a variety of load conditions. This three term PID can be infinitely adjusted
to suit almost any application. The operator should have a basic understanding
of the relationship between the three terms – proportional, integral and
derivative.
Proportional
Typical older modulating systems employ only proportional control. This would
be similar to the slide wire type found on most steam boilers. When using only
a proportional control the system rarely achieves setpoint as the burner
firing rate is lowered as the pressure comes up. At some point the input meets
the actual demand and the pressure no longer raises or lowers, thus an offset
between desired setpoint and actual operating pressure occurs. The only time
the pressure and setpoint are the same is if the actual load equals the lowest
firing rate of the burner, this is rare. An example of proportional only set
up might be; Setpoint is 100 PSI, proportional range is 10 PSI. That is low
fire is at 100 PSI, high fire is at 90 PSI with a 1:1 relationship in between,
e.g.: 95PSI equals 50% rate.
Integral
If the integral term is turned on, the control compares the actual pressure
against setpoint at an adjustable interval. If there is an offset, the firing
rate is increased by a small percentage until the next interval. This will
continue until the pressure equals the setpoint. The same routine occurs as
the pressure rises above the setpoint. Too much or too little integral will
cause over and undershoot of the setpoint. Integral is set in seconds per
repeat in the NX6100.
For example, if the P were set at 10 psi with a boiler set point of 100 psi,
the burner would first remain at high fire until the pressure reached 90 psi,
and then start to modulate down. If the load was equal to 50% firing rate, the
pressure would stall at 95 psi. Adding and “I” value of 10 would ramp the
output up to 100% (high fire) in 10 seconds, assuming no change in the boiler
pressure. Setting and “I” value of 300 increases the output up to 100% (high
fire) in 5 minute (300 seconds). As the boiler reaches setpoint, the same
timing effect occurs above setpoint. Therefore, too much “I” can cause
over/under shoot as loads change. Too little “I” may cause rapid hunting.
Derivative
Enabling the derivative has the effect of sensing the rate of change in the
process variable (pressure or temperature) and increasing or holding up the
firing rate output despite the integral term. This in effect amplifies the
output to anticipate the effect of a sudden change in load demand. Derivative
acts inversely when the setpoint is exceeded. Derivative is set in seconds on
the NX6100.
Start with a P value of about 10% of setpoint, and an I value of 20 seconds
with a D value of 5 seconds. After observing the operation through normal load
swings, adjust each value, usually one at a time, and observe the results.
When making a change it is recommended the value be doubled or halved to
determine which direction you need to go. Bear in mind, the burner should not
continuously hunt or swing to maintain the desired setpoint. It is normal for
a slight over and undershoots of setpoint during serious load changes. The
values for the PID’s are found at option parameters 21.2, 21.3 and 21.4 for
setpoint 1 (PID1), and 22.2, 22.3 and 22.4 for setpoint 2 (PID2). These values
are adjustable using the Site Passcode 154.
57
11 Combustion Profile Setup Guideline
It is safe to say that most burners do not have fuel and air control devices
that have linear flow characteristics. When commissioning the Fireye Nexus/PPC
parallel positioning system, the following procedure will help assure the
maximum benefit will be realized. Before starting the installation, the
commissioning engineer should try to verify the maximum combustion air damper
(flow) position so as to know the “target” high fire position. This can be
done by rotating the original jack shaft before it is removed and measuring
the air damper opening. If possible, it should be marked for reference.
There are 24 points available for creating a profile, P0 (closed/off) to P23
(high fire). The first three positions, P0, P1&P2 are required to reach
ignition which may or may not be the same as low fire (P3). After establishing
a good low fire and entering the values at P3, the display will now indicate
P4 with the drives at the P3 position. At this time the main air drive or
drives should be increased a minimum of one degree or until the observed
oxygen level increases approximately 1.0 to 2%, do not press enter at this
time. At this point the fuel drive should be increased slowly to bring the
oxygen level back down to the desired level and entered at this time.
Following this procedure from low to high fire will yield a relatively linear
profile. That is to say, each position will increase the fuel and air flows by
nearly equal amounts from low to high fire, thus making the profile somewhat
linear. This will aid in setting up O2 trim.
The NX6100’s Engineers Key 44 (see section 8.8) displays the actual O2 value
of the Fireye oxygen probe when fitted. It should be noted that the reading of
the Fireye probe will be between 1 and 1.5% lower than most portable
combustion analyzers. This is normal and due to the difference between wet and
dry samples. Bear in mind the NX6100 will trim to the value of the Fireye
probe, not to the value of a portable analyzer.
For example:
Position P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13
Air Drive 5.0 7.5 12.0 17.0 24.0 29.0 35.0 43.0 53.0 66.0 80.0
Fuel Drive 15.0 18.0 22.0 28.0 33.0 38.0 45.0 55.0 67.0 79.0 88.0
Observed O2% 7.0 7.0 6.0 5.0 4.0 4.0 4.0 3.5 3.5 3.5 3.5
Increased O2% 8.5 8.5 7.5 6.5 5.5 5.5 5.5 5.0 5.0 5.0
High Fire
NOTE: The angular change in the air drive position required to achieve the 1.0 to 2.0% increase in observed oxygen level may increase as the burner fires at higher rates. This is normal as the air “damper” will not likely be linear. When approaching high fire large increases in the air drive servomotor travel may be required to increase the oxygen reading by 1.0 to 2.0%. As a rule, this should be avoided as the burner is potentially “out
58
of air” and in so doing, the effective input to the boiler will be negligible.
This would also affect the operation of oxygen trim should this option be
used.
12 Fireye NX6100 Efficiency Calculations
Fireye NX6100 controls can display calculated combustion efficiency.
For the displayed efficiency to be meaningful the correct values for Calorific
Value and Hydro-Carbon Ratio for the fuel in use must be entered in the
related Fireye NX6100 option parameters.
Efficiency may be displayed as Net or Gross.
The calorific value of a fuel is the heat given out when unit quantity of the
fuel is completely burnt, any fuel containing hydrogen has two calorific
values, these being the gross or higher calorific value and the net or lower
calorific value.
The gross calorific value is the heat given out when unit quantity of fuel at
15.6 oC (60 oF) is completely burnt and the products of combustion are cooled
to 15.6 oC (60 oF), as such any steam present in the products of combustion
due to the burning of the hydrogen will be condensed to water, giving up its
latent heat of vaporization and some of its sensible heat loss. This heat
recovery is not possible under practical conditions and the net value is
approximately the gross value less this quantity of heat which is usually
taken at 2.45 MJ/Kg of steam formed.
Therefore if gross efficiency is required, gross calorific value is used and
the latent heat of vaporization due to any steam present in the products of
combustion is taken as a loss in the efficiency calculation.
However, if net efficiency is required, net calorific value is used and
therefore the latent heat of vaporization due to any steam present in the
products of combustion is already taken into account, so the latent heat loss
in the efficiency equation is set to zero.
In addition when considering gross efficiency it is normal to also take
account to the boiler radiated heat loss. This will be a fixed heat loss from
the boiler shell in the order of 1% to 3% of the boiler high fire output,
which if the burner is operating with say a 6 to 1 turn down would equate to a
6% to 18% loss at low fire.
Comparison of Fireye NX6100 with Hand Held Equipment
When comparing the efficiency as displayed by the NX6100 control and other
equipment it is important to ensure the same parameters are being used by both
units.
-
Ensure the efficiency is selected to be either net or gross in both units, hand held equipment usually uses net since it is rare for hand held equipment to have knowledge of the boiler firing rate to include the radiated heat loss.
-
Ensure the same calorific value is being used by both units. 3) Ensure the same value for hydro-carbon ratio is being used by both units. 4) Ensure the ambient (inlet) temperature being measured by the hand held is physically at the air intake
to the burner, as it should be for the NX6100. If the hand held equipment does not measure the inlet temperature, ensure the value it is using for ambient air temperature is representative of the application. 5) Ensure the flue temperature and oxygen value are being measured at the same location in the flue to reduce the possibility of errors being introduced due to stratification of the flue gas.
59 -
Fireye O2 probes measure oxygen in the flue without extracting and drying flue gases. If attempting to compare the oxygen values being measured by the NX6100 and a hand held equipment ensure the value being given by the hand held is corrected from a dry to a
wet’ value, as it will almost certainly be measured as adry’ value. The water being removed to prevent damage to the sensor cells in the hand held equipment.
When comparing the values of efficiency displayed by the NX6100 equipment and hand held equipment, first check that the following values are the same or very close: -
Inlet temperature. 2) Flue gas temperature. 3) Calorific value 4) Hydro- carbon ratio. 5) Oxygen value (after making correction for dry to wet on the hand held). 6) Selection of net or gross. 7) If a radiated heat loss value is being included ensure the hand held equipment has corrected the value
for the current firing rate of the burner.
Other points to remember: In a typical package boiler radiation losses are usually in the order of 3%, blow down losses typically 2% and flue gas losses 15% to 20%. Giving a typical overall efficiency of 100 – 3 – 2 – 20 = 75%. The major area for attention to improve boiler efficiency is the flue gas losses, with the object of minimizing excess air, within the bounds of safe and reliable boiler operation. O2 Trim is the best tool for ensuring consistent optimum combustion and minimization of excess air.
The NX6100 ensures consistent fuel: air ratios. The Fireye O2 Trim option continuously compensates for changes that affect efficient combustion due to such variables as: viscosity of liquid fuels, density of gaseous fuels, changes in temperature of fuels, changes in gas and oil pressures, worn and damaged burners, dirty burners, scaling if boiler tubes, ambient temperature, barometric pressure and tramp air.
60
13 Typical Wiring Diagrams
System connection drawing
L1 – 115/230Vac
N
PE1 PE2
Ignition Tx Dig Input 12 Dig Input 13 Burner Select Input
PE3 PE4 PE5 PE6
Supply
PD1
PD2 Combustion Air Fan
PD3 Aux / Oil Pump
M
PD4 Gas Block Vent Valve
PD5
Lockout alarm
Line Voltage Terminals
Line Voltage Terminals
CANBus to servos, display module and O2 Probe controller
Main Gas1 Main Gas2 Pilot valve
Main Oil1
PE7 PE8 PE9 PE10
24Vac 24Vac CAN + CAN –
PA1 / PB1 PA2 / PB2 PA3 / PB3 PA4 / PB4
PF1 PF2
UV flame scanner
PC1 PC2 PC3 PC4 PC5 PC6
RS485 Isol. (MODBUS) 0v RS485 Isol. (MODBUS) B(-) RS485 Isol. (MODBUS) A(+) RS485 (COMFIRE) 0v RS485 (COMFIRE) B(-) RS485 (COMFIRE) A(+)
3 L1-L3
Infra-red flame
scanner
Supply (5Vdc) Input
Analogue I/P 1+ Analogue I/P 2+ Analogue I/P 3+
Sensor Test Sensor 0V / Ai1/2/3 COMMON
Sensor i/p Sensor supply
5/30Vdc
Aux Mod. 0V Aux Mod. i/p
Aux Mod. Supply 30Vdc
PA5 PA6
PA7 PA8 PA9
PA10 PA11 PA12 PA13
PA14 PA15 PA16
Sensor Test Sensor 0V Sensor i/p
Sensor supply 5/30Vdc
PA17 PA18 PA19 PA20
Boiler sensor terminals
Aux Mod. i/p Terminals
Gas Pressure / VPS sensor terminals
NX6100 Controller
PB5 PB6 PB7 PB8
Dig. Low test2 Dig. i/p 8 (P1/P2 SEL) Dig. i/p 9 (P3/P4 SEL) Dig. High test
PB9 PB10 PB11 PB12 PB13
Dig. Low test 1 Dig. i/p 1 Dig. i/p 2 Dig. i/p 3 Dig. i/p 4
PB14 PB15 PB16 PB17
Dig. Low test 2 Dig. i/p 5 Dig. i/p 6 Dig. i/p 7
PB18 PB19
Combustion Air Pressure circuit
4-20mA o/p1 4-20mA o/p1 +
4-20mA o/p 2 4-20mA o/p 2 +
PZ1 PZ2
PZ3 PZ4
Daughter board option
PZ18 PZ17
PZ16 PZ15
Relay7 N/O Relay7 Common
Relay8 N/O Relay8 Common
PZ12 PZ13 PZ14
PZ7 PZ8 PZ9 PZ10 PZ11
PZ5 PZ6
= Screen terminated at the controller.
4-20mA i/p1 4-20ma i/p1+ & i/p2-
4-20mA i/p2 +
Counter i/p1 +12Vdc
Counter i/p2 +12Vdc
Counter i/p3
4-20mA o/p3 4-20mA o/p3 +
VSD feedback options
61
NOTICE
When Fireye products are combined with equipment manufactured by other and/or
integrated into systems designed or manufactured by others, the Fireye
warranty, as stated in its General Terms and Conditions of Sale, pertains only
to the Fireye products and not to any other equipment or 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 option, to repair
any product or part thereof (except lamps and photocells) 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 WARRANTIES AND FIREYE MAKES NO WARRANTY OF
MERCHANTABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Except as
specifically stated in these general terms and conditions of sale, remedies
with respect to any product or part number manufactured or sold by Fireye
shall be limited exclusively to the right to replacement or repair as above
provided. In no event shall Fireye be liable for consequential or special
damages of any nature that may arise in connection with such product or part.
FIREYE 3 Manchester Road Derry, New Hampshire 03038 USA www.fireye.com
NXOGTSD-6101 April 8 2013
Supersedes DECEMBER 18, 2008
62