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Fireye PPC6000 Series - User Manual

Fireye PPC6000 Series
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PPC6000
SERIES
FUEL AIR
RATIO
CONTROLLER
DESCRIPTION
The Fireye PPC6000 is a state of the art stand-alone parallel positioning system for all types of
liquid or gaseous fuel fired combustion systems. When combined with a Fireye flame safeguard
system such as the Fireye BurnerLogix control, the PPC6000 offers the most compact and
advanced parallel positioning system available. Four fuel profiles allow the PPC6000 to
accommodate a variety of applications such as two fuels, with and without, the optional variable
speed drive (VSD). With each profile having up to 24 points entered to assure a smooth “curve”,
the microprocessor interpolates points between entered values and precisely positions fuel and
air to within +- .1 degree. This eliminates hysteresis for improved efficiency. The PPC6000 is
capable of powering up to ten 24volt servomotors supplied from the integral transformer. All
servomotors and displays operate on a secure CANbus communications protocol and can be
“daisy chained” together for simplified wiring. Two independent PID control loops for
temperature or pressure control provide precise, accurate control of firing rate for unmatched
response to load changes. Four safety rated user definable digital inputs are standard and can
be configured for functions such as lead lag, night setback, thermal shock warm up, etc. Digital
inputs can also be configured as analog inputs via the optional programmable function blocks
using Fireye Abacus software. Built in lead lag sequencing for up to four boilers is included in
every PPC6000. More elaborate lead lag schemes may be possible using the programmable
function blocks.
Two variations of multifunction displays are available:
NXTSD104 10.4” Color Touchscreen display with Ethernet, Modbus TCPIP, 4
programmable relays and backup.
NX610 display provides automatic storage of operating parameters and profiles for
upload/download to the PPC6000. In addition, three line voltage fully programmable relays
are mounted inside the display.
PPC-6001
JANUARY 18, 2016

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Summary

Description

Summary of PPC6000 Features

Safety Information

Technical Specification

General Specifications

Provides general specifications like supply voltage, dimensions, and weight.

Servo-motor Control

Details servo-motor control type, quantity, accuracy, and response time.

Digital Outputs

Describes controlled shutdown and safety shutdown output specifications.

Alarm Output

Specifies alarm output type, minimum and maximum current, and voltage.

Digital Inputs

Details low voltage and high voltage digital inputs and their configurations.

Pressure;Temperature Input

Outlines specifications for 0-5V and 4-20mA pressure/temperature inputs.

Communications Interface

Describes the RS485 interface and optional isolated RS485 options.

Optional Oxygen Probe Interface Unit

Lists specifications for the optional oxygen probe interface unit.

Optional Ambient Air Temperature Unit

Details specifications for the optional ambient air temperature unit.

Variable Speed Drive Daughter Board

Provides specifications for the VSD daughter board, including inputs and outputs.

Fireye Servo Motors

Details specifications for various Fireye servo motors, including torque and VA rating.

Fireye Oxygen Probe Interface Unit

Lists specifications for the optional oxygen probe interface unit, including voltage and protection category.

Fireye Ambient Air Temperature Sensor

Provides specifications for the optional ambient air temperature sensor.

Approvals

Lists standards and directives the product has been tested against.

Parts List

Lists part numbers and descriptions for the controller, displays, and servo motors.

Installation

PPC6000 Control Mounting Details

Provides dimensions and mounting clearances for the PPC6000 control unit.

Display Module Mounting Details

Details the panel cut-out and mounting procedure for the display module.

Optional Oxygen Probe Interface Unit Mounting

Specifies mounting requirements and enclosure details for the oxygen probe interface.

Oxygen Trim Option

Covers the oxygen trim function, probe description, and installation guidelines.

Option Link Selection

Explains the function and correct setting of circuit board option links.

Wiring Guidelines

Provides general wiring guidelines, including shielded wire requirements.

Servo-motor Selection and Calibration

Servo-motor Selection

Outlines motor requirements, connection method, and available models.

Servo-motor Direction Warning

Warns about setting servo-motor direction correctly to avoid damage and ensure proper operation.

Locking Servo-motor to Valve Shaft

Emphasizes the importance of securely connecting motors to valve shafts for safe operation.

Feedback Potentiometer

Details securing the feedback potentiometer to prevent disconnection from the motor shaft.

Adjusting Microswitch Positions

Provides a procedure for setting microswitch positions to ensure correct closed and open positions.

Servomotor Replacement

Guides on replacing servomotors, including determining direction and serial numbers.

Description of Operation

Display and Keypad

Describes the 2-line display and membrane keypad functions.

Start-up Sequence

Details the stages of the burner start-up and shut-down sequence.

Non-volatile Lockout

Explains conditions leading to non-volatile lockouts, which are not cleared by power removal.

Modulation

Covers burner modulation modes (Remote, Local) and PID functions.

Commissioning the Control

General Commissioning

Explains the necessity of entering commission mode for changing settings and safety precautions.

Commissioning Data

Covers option parameters and setpoints used for configuring the burner and boiler.

Commissioning Process Navigation

Details navigation within the commissioning process and symbols used.

Touchscreen Operation

Explains the functions and displays of the touchscreen interface.

Faults and Fault Finding

Fault Display Interpretation

Describes how fault numbers are displayed with prefixes indicating status.

Fault Handling Procedure

Provides steps for addressing faults, including muting alarms and clearing faults.

Non-volatile Lockout Explanation

Explains that faults stored in non-volatile memory persist after power loss.

Fault Subsets

Defines fault subsets as additional information about fault type or burner status.

Fault Listing

Lists common faults, their causes, and descriptions.

Engineers Key Usage

Explains how to use the engineer's key to view system variables and fault details.

General Troubleshooting

Offers general troubleshooting guidance for display and general issues.

Startup Troubleshooting

Lists common startup problems and their suggested solutions.

Commissioning Troubleshooting

Addresses common commissioning issues and their resolution steps.

Modulation Troubleshooting

Details troubleshooting steps for modulation-related problems.

Inverter Troubleshooting

Provides solutions for inverter-related issues, including start-up and control problems.

Inverter (Variable Speed) Drives

System Configuration

Describes the system configuration for controlling inverter drives with PPC6000.

Control Method Description

Explains the control method for drives, including start-up and modulation.

Setting Up Inverter for PPC6000

Details the criteria and steps for setting up an inverter for use with the PPC6000.

Setting Up PPC6000 for Inverter Drive

Provides step-by-step instructions for configuring the PPC6000 to work with an inverter drive.

The Oxygen Trim Option

Oxygen Pro Probe Description

Describes the oxygen trim function and the NX2012 oxygen probe.

Oxygen Probe Installation

Covers the installation procedure for the oxygen probe, including mounting guidelines.

Oxygen Probe Mounting

Details specific mounting instructions and considerations for the oxygen probe.

Appendix

Oxygen Probe Calibration and Servicing

Provides a step-by-step guide for calibrating the oxygen probe.

Probe Calibration Procedure

Details the procedure and requirements for calibrating the oxygen probe.

Oxygen Probe Filter Testing

Explains how to test the oxygen probe filter without removing it from the flue.

Removing Oxygen Probe from Flue

Provides safety precautions and steps for removing the oxygen probe from the flue.

Filter Replacement

Guides on replacing the oxygen probe filter assembly.

Probe Mounted Flue Thermocouple Replacement

Details the procedure for replacing the flue thermocouple mounted on the probe.

Troubleshooting Inverter Problems

Lists common inverter problems and their suggested solutions.

PID Tutorial

Explains the PID control concept and how to adjust proportional, integral, and derivative terms.

Combustion Profile Setup Guideline

Provides guidelines for setting up combustion profiles and entering data.

Efficiency Calculations

Explains how efficiency is calculated and the parameters required for accurate results.

Function Block Programming Details

Introduction to Abacus Programming

Introduces Abacus software for programming PPC6000 and NX6100 controls.

Schematic Toolbar

Describes the function block toolbar and its buttons for creating schematics.

Placing Function Blocks

Explains how to place function blocks onto the schematic page.

Moving and Editing Link Lines

Guides on selecting and moving link lines to adjust the schematic appearance.

Circuit Board Connections

Inlet Air Temperature Sensor Connection

Shows the circuit board connections for the optional NXIATS Inlet Air Temperature Sensor.

PPC6000 VSD Daughter Board Connections

Details the circuit board connections for the PPC6000 VSD daughter board.

Oxygen Probe Interface Connection

Illustrates the circuit board connections for the optional NX02INT Oxygen Probe Interface.

PPC6000 Jumper and Fuse Details

Shows the jumper and fuse detail on the PPC6000 unit backplate.

Summary

Description

Summary of PPC6000 Features

Safety Information

Technical Specification

General Specifications

Provides general specifications like supply voltage, dimensions, and weight.

Servo-motor Control

Details servo-motor control type, quantity, accuracy, and response time.

Digital Outputs

Describes controlled shutdown and safety shutdown output specifications.

Alarm Output

Specifies alarm output type, minimum and maximum current, and voltage.

Digital Inputs

Details low voltage and high voltage digital inputs and their configurations.

Pressure;Temperature Input

Outlines specifications for 0-5V and 4-20mA pressure/temperature inputs.

Communications Interface

Describes the RS485 interface and optional isolated RS485 options.

Optional Oxygen Probe Interface Unit

Lists specifications for the optional oxygen probe interface unit.

Optional Ambient Air Temperature Unit

Details specifications for the optional ambient air temperature unit.

Variable Speed Drive Daughter Board

Provides specifications for the VSD daughter board, including inputs and outputs.

Fireye Servo Motors

Details specifications for various Fireye servo motors, including torque and VA rating.

Fireye Oxygen Probe Interface Unit

Lists specifications for the optional oxygen probe interface unit, including voltage and protection category.

Fireye Ambient Air Temperature Sensor

Provides specifications for the optional ambient air temperature sensor.

Approvals

Lists standards and directives the product has been tested against.

Parts List

Lists part numbers and descriptions for the controller, displays, and servo motors.

Installation

PPC6000 Control Mounting Details

Provides dimensions and mounting clearances for the PPC6000 control unit.

Display Module Mounting Details

Details the panel cut-out and mounting procedure for the display module.

Optional Oxygen Probe Interface Unit Mounting

Specifies mounting requirements and enclosure details for the oxygen probe interface.

Oxygen Trim Option

Covers the oxygen trim function, probe description, and installation guidelines.

Option Link Selection

Explains the function and correct setting of circuit board option links.

Wiring Guidelines

Provides general wiring guidelines, including shielded wire requirements.

Servo-motor Selection and Calibration

Servo-motor Selection

Outlines motor requirements, connection method, and available models.

Servo-motor Direction Warning

Warns about setting servo-motor direction correctly to avoid damage and ensure proper operation.

Locking Servo-motor to Valve Shaft

Emphasizes the importance of securely connecting motors to valve shafts for safe operation.

Feedback Potentiometer

Details securing the feedback potentiometer to prevent disconnection from the motor shaft.

Adjusting Microswitch Positions

Provides a procedure for setting microswitch positions to ensure correct closed and open positions.

Servomotor Replacement

Guides on replacing servomotors, including determining direction and serial numbers.

Description of Operation

Display and Keypad

Describes the 2-line display and membrane keypad functions.

Start-up Sequence

Details the stages of the burner start-up and shut-down sequence.

Non-volatile Lockout

Explains conditions leading to non-volatile lockouts, which are not cleared by power removal.

Modulation

Covers burner modulation modes (Remote, Local) and PID functions.

Commissioning the Control

General Commissioning

Explains the necessity of entering commission mode for changing settings and safety precautions.

Commissioning Data

Covers option parameters and setpoints used for configuring the burner and boiler.

Commissioning Process Navigation

Details navigation within the commissioning process and symbols used.

Touchscreen Operation

Explains the functions and displays of the touchscreen interface.

Faults and Fault Finding

Fault Display Interpretation

Describes how fault numbers are displayed with prefixes indicating status.

Fault Handling Procedure

Provides steps for addressing faults, including muting alarms and clearing faults.

Non-volatile Lockout Explanation

Explains that faults stored in non-volatile memory persist after power loss.

Fault Subsets

Defines fault subsets as additional information about fault type or burner status.

Fault Listing

Lists common faults, their causes, and descriptions.

Engineers Key Usage

Explains how to use the engineer's key to view system variables and fault details.

General Troubleshooting

Offers general troubleshooting guidance for display and general issues.

Startup Troubleshooting

Lists common startup problems and their suggested solutions.

Commissioning Troubleshooting

Addresses common commissioning issues and their resolution steps.

Modulation Troubleshooting

Details troubleshooting steps for modulation-related problems.

Inverter Troubleshooting

Provides solutions for inverter-related issues, including start-up and control problems.

Inverter (Variable Speed) Drives

System Configuration

Describes the system configuration for controlling inverter drives with PPC6000.

Control Method Description

Explains the control method for drives, including start-up and modulation.

Setting Up Inverter for PPC6000

Details the criteria and steps for setting up an inverter for use with the PPC6000.

Setting Up PPC6000 for Inverter Drive

Provides step-by-step instructions for configuring the PPC6000 to work with an inverter drive.

The Oxygen Trim Option

Oxygen Pro Probe Description

Describes the oxygen trim function and the NX2012 oxygen probe.

Oxygen Probe Installation

Covers the installation procedure for the oxygen probe, including mounting guidelines.

Oxygen Probe Mounting

Details specific mounting instructions and considerations for the oxygen probe.

Appendix

Oxygen Probe Calibration and Servicing

Provides a step-by-step guide for calibrating the oxygen probe.

Probe Calibration Procedure

Details the procedure and requirements for calibrating the oxygen probe.

Oxygen Probe Filter Testing

Explains how to test the oxygen probe filter without removing it from the flue.

Removing Oxygen Probe from Flue

Provides safety precautions and steps for removing the oxygen probe from the flue.

Filter Replacement

Guides on replacing the oxygen probe filter assembly.

Probe Mounted Flue Thermocouple Replacement

Details the procedure for replacing the flue thermocouple mounted on the probe.

Troubleshooting Inverter Problems

Lists common inverter problems and their suggested solutions.

PID Tutorial

Explains the PID control concept and how to adjust proportional, integral, and derivative terms.

Combustion Profile Setup Guideline

Provides guidelines for setting up combustion profiles and entering data.

Efficiency Calculations

Explains how efficiency is calculated and the parameters required for accurate results.

Function Block Programming Details

Introduction to Abacus Programming

Introduces Abacus software for programming PPC6000 and NX6100 controls.

Schematic Toolbar

Describes the function block toolbar and its buttons for creating schematics.

Placing Function Blocks

Explains how to place function blocks onto the schematic page.

Moving and Editing Link Lines

Guides on selecting and moving link lines to adjust the schematic appearance.

Circuit Board Connections

Inlet Air Temperature Sensor Connection

Shows the circuit board connections for the optional NXIATS Inlet Air Temperature Sensor.

PPC6000 VSD Daughter Board Connections

Details the circuit board connections for the PPC6000 VSD daughter board.

Oxygen Probe Interface Connection

Illustrates the circuit board connections for the optional NX02INT Oxygen Probe Interface.

PPC6000 Jumper and Fuse Details

Shows the jumper and fuse detail on the PPC6000 unit backplate.

Fireye PPC6000 Series Specifications

General IconGeneral
CategoryController
DisplayLCD with backlight
OutputsMultiple configurable outputs
CommunicationModbus RTU
Relay OutputsConfigurable relay outputs
Analog InputsConfigurable analog inputs
Digital InputsConfigurable digital inputs
Enclosure RatingNEMA 4X

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