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 ........................................
.12 2.13 2.14 3 4 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 3.4 3.5 OPTION 21.2 – SET-POINT 1 PROPORTIONAL BAND (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ....... 17 OPTION 21.
8 FAULTS AND FAULT FINDING ........................................................................................................................... 30 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9 THE FAULT DISPLAY ............................................................................................................................................. 30 WHAT TO DO WHEN A FAULT OCCURS ...................................................................................................................
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.
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 2.
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.
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.
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 a ‘lamp’ 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.
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.
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.
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 be ‘grayed 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. 2.10 Touchscreen ‘Burner Settings’ button.
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.
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.
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 a ‘button 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.
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.
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.
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.
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.
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) .........................
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.
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.
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.
Note: 4.2 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. 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.
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.
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.
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.
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.
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. Stage name Description 0. Non-volatile lockout The burner is held in this state until all faults are removed. 1.
Stage no. 10. Stage name Description Pre-ignition 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. 11. Pilot ignition 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.
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.
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.
No Cause F10 Flame Failure Description 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 Fault from Input 12 The high voltage alarm / lockout input number 12 is causing an alarm.
No Cause F17 Optional second (primary) air pressure detected when it should not be. Primary air pressure detected The primary air pressure switch registered air pressure when it should not be present (subset : 1), or the air pressure switch registered air pressure for more than 3 minutes after the burner was turned off (subset : 2). F18 Not enough setpoints entered A fuel/air ratio profile has been selected which does not have at least four setpoints commissioned.
No Cause F20 Drive 0 position fault A drive-positioning fault has occurred, which will cause a non-volatile lockout of the burner. This fault has occurred for one of the following reasons: F21 Drive 1 position fault 1. During ‘Close’ position prove, the measured position when a drive stops at a position that is outside the commissioned ‘Close’ set position, by more than five degrees.
No Cause F31 Oil Proof of Closure fault Description The oil valve proof of closure signal is not 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. 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).
No Cause F38 Program memory CRC fault Description The program memory in the controller has been corrupted. 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.
No Cause 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 CRC fault The EEPROM memory in the controller has been corrupted. This memory is used to store the option parameters, Description Interrupt power to the controller Erase the system using option parameter 45.1 = 5 and re commission (or restore with option parameter 45.2).
No Cause F54 Oxygen probes mismatch fault L55 Trim limit alarm Description This fault occurs when two oxygen probes are used to give 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.
No F64 Cause Profile Invalid Description 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.
No Cause F67 Secondary relay fault Description A secondary fault has occurred with the main 1, main 2, pilot, 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 program memory checksum fault A fault has occurred with the program memory in the controller. Tests are performed once an hour.
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.
No. Name EK10 Profile 2 (PB8 – PB6) EK11 Profile 4 (PB8 – PB7) EK12 Profile 3 Select (Low Voltage) High voltage digital input 12. Description PE4 EK13 High voltage digital input 13. PE5 EK14 Burner Select Input (High Voltage) PE6 EK15 Airflow Input (Low Voltage) PB18– PB19 EK16 Warming limit 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.
No. Name Description EK20 Drive moved 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. EK21 Positions proved 0 - Drives have stopped moving, ready for position prove test. 1 - Ready for position prove test but drives still moving. EK22 Fault alarm 0 – No un-muted alarms (faults) present.
No. Name Description EK29 Modulation rate (%) The current modulation rate of the burner. 0 = Low Fire 100 = High fire EK30 Burner Status Status of the start-up sequence. See section 7. EK31 Fuel Profile Selected The currently selected fuel profile. EK32 Number of commission setpoints 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.
No. Name Description EK40 Shutdown setpoint The nearest setpoint (EK36) when the burner last locked out. EK42 Adjust ratio counter The number of times adjust ratio mode has been used. EK43 Commission ratio counter The number of times commission ratio mode has been used. EK44 Oxygen measured value The current flue oxygen value as measured by the Fireye probe (if fitted). EK45 Oxygen probe status +1 - Internal fault. +2 - Internal fault. +4 - Heater fault. Causes F50.
No. 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.
No. Name Description EK57EK 58 CPU serial number (low 4 digits)CPU serial number (high 3 digits) The 6 digit CPU board serial number. The serial number is displayed in 2 blocks of 3 digits. EK59 Drives at setpoint 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. EK60 Digital (relay) outputs on. The combination of digital outputs currently switched on.
No. Name Description EK62 Analog Input 2. The raw ADC counts from analog input 2. Main Unit Terminal PA8. 0 to 1023 for 0 to 5.00 volts. 4mA = 180 counts 20mA = 900 counts EK63 Analog Input 3. The raw ADC counts from analog input 3. Main Unit Terminal PA9. 0 to 1023 for 0 to 5.00 volts. 4mA = 180 counts 20mA = 900 counts EK64 Analog Input 4. The raw ADC counts from analog input 4. Main Unit Terminal PA12 (also gas pressure). 0 to 1023 for 0 to 5.00 volts.
No. Name Description EK72 Oxygen probe cell temperature. The temperature of the zirconia cell inside the Fireye oxygen probe, if fitted. This value should be very close to 650ºC for accurate operation. EK73 Ambient air temperature. The temperature measured by the inlet temperature sensor, if fitted. Units are ºC. EK74 CPU utilization (%). The percentage utilization of the CPU. Should be less than 95% at all times. EK75 Second O2 level (%) Longest task time.
No. Name Description EK100 Firmware type PT22xxxx… 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.
No. Name Description EK109 Remote Setpoint 1 Active 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. EK110 to N/A EK119 Not used by the standard manufacturers program. May be used by a custom program.
No. Name Description EK157 AUTO modulation rate The modulation rate that the boiler will fire to if in AUTO mode (providing option parameter 15.0 is not zero or 1). EK158 Sequence status 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 EK159 to EK199. Not used by the standard manufacturers program. May be used by a custom program.
Problem Possible cause Suggested action Burner status is flashing. Controller in non-volatile lockout mode. Gas sensor not selected. Burner status before shutdown displayed. Select sensor using option parameter 10.0 Incorrect span value. Check option parameter 10.1 Problem Possible cause Suggested action Burner will not start. Controller in non-volatile lockout. High control limit exceeded. Control in commission ratio mode. Burner off via serial comms. Hold FAULT MUTE key when faults clear.
Problem Possible cause Suggested action available. be set first. Option parameter not adjustable. Not possible to enter commission ratio mode. Wrong passcode entered or burner firing. Supplier passcode incorrect. Burner firing (goes into adjust ratio mode). Supplier passcode incorrect. 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.
modulation rate. Computer software. Controller in commission mode. 9.6 Press RUN then ENTER to enter run mode. Inverters Possible Cause Solution Inverter does not start because it does not receive a RUN signal. 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 Ensure that the inverter’s slow start feature is disabled.
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 Possible cause Suggested action Oxygen display not available. No oxygen probe interface unit serial number entered. Enter serial number into option parameter 30.
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.
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.
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.
6) 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 a ‘dry’ value. The water being removed to prevent damage to the sensor cells in the hand held equipment.
Typical Wiring Diagrams System connection drawing L1 - 115/230Vac N 3 Infra-red flame scanner Supply (5Vdc) Input Analogue I/P 1+ Analogue I/P 2+ Analogue I/P 3+ Sensor i/p Sensor supply 5/30Vdc Aux Mod. 0V Aux Mod. i/p Aux Mod. Supply 30Vdc Sensor Test Sensor i/p Sensor supply 5/30Vdc 4-20mA o/p1 4-20mA o/p1 + 4-20mA o/p 2 - PA17 PA18 PA19 PA20 PB18 PB19 PZ18 PZ17 PZ3 PZ4 4-20mA o/p3 - = Screen terminated at the controller.
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.
