Fireye NEXUS NX6100 series User manual

NX6100
SERIES
INTEGRATED
BURNER
CONTROLLER
DESCRIPTION
The Fireye NEXUS NX6100 Integrated Controller is a microprocessor based, Flame Sa eguard and
Parallel Positioning Combustion Controller built into one compact, user con igurable package. The system
consists o the Controller, Display, Temperature / Pressure Sensors, Servo-Motors and optional Com ire
So tware.
The Flame Sa eguard portion o the control package provides burner sequencing including sa e start
check, proo o main valve closure, selectable main gas sa ety proving sequence, supervised pre-purge,
low ire starting position, pilot and main trials or ignition, main lame supervision, and post purge. Sa ety
event timings are provided to meet North American and CE Standards. Time proven Fireye Flame
Scanners and ampli ication circuits using UV, UV-Sel Check and In rared sensors, provide ast reliable
scanning o most commonly burned uels. For exotic uels and applications, the NX6100 is also
compatible with Fireye Phoenix and Insight Integrated Flame Scanners. Seven low voltage and two line
voltage user de ined auxiliary inputs provide supervision o sa ety critical and non-sa ety critical inputs. A
large menu o alarm messages provides enhanced diagnostics.
Control o up to our pro iles using an independent Servo-Motor or each controlled element allows precise
positioning, accurate to 0.1
o
, o the uel and air metering devices over the burner’s iring range. Each
pro ile can be de ined to include up to 10 servomotors. Pro iles can be con igured to share common uel
servomotors or as independent (one pro ile per uel) and are not limited by uel. Up to 24 positions per
pro ile including: Closed, Purge, Ignition (Pre erred Start), Low Fire and an additional 20 intermediate
points rom low to high ire. Each individual servomotor’s position and speed are veri ied and lockout will
occur should either o these parameters be exceeded. All servomotors are controlled via secure CANbus
communications link.
Modulation control is provided via the pressure/temperature sensor’s input. The Fireye NX1025, NX1030
or NX1040 sensors provide checking circuits or ail sa e operation. Two PID setpoints are available or
the chosen modulation input, selectable up to two decimal points. Track modulation is available or those
applications requiring less precise control.
The NX6220 and NX6330 Twelve-Key Display allows commissioning and current status o the system
through the use o its tactile membrane keypad. Multi- unction keys allow the commissioning engineer the
ability to access the various Ratio Modes and Option Select menus. The our-line OLED Display clearly
illuminates the Control Variable, Firing Mode, Fuel Selected and Hours Run. It urther allows the Boiler
Operator access to the Auto/Manual selector, Motor Data (servo positions) and other operational
parameters such as System Sequence Position, Valve Proving Sequence Status, Gas Pressure, Flame
Signal, Modulation Rate and Setpoint, as necessary.
Multiple Boiler Sequencing is accomplished through an RS485 Communications bus using Com ire
so tware. Lead/Lag and Standby set points or up to our (4) boilers can be con igured.
NEX-6101
December 12, 2018

2
Safety information
WARNING
When this equipment is itted to an appliance due regard must also be given to the requirements o that
appliance.
Before attempting to in tall, commi ion or operate thi equipment all relevant ection of thi
document mu t be read and fully under tood. If in doubt about any requirement con ult Fireye.
In tallation, commi ioning or adju tment of thi product MUST be carried out by uitably trained
engineer or per onnel qualified by training and experience.
After in tallation or modification to the in tallation all function of the equipment MUST be checked to
en ure afe and reliable operation of the control.
The manu acturer o this equipment accepts no liability or any consequences resulting rom inappropriate,
negligent or incorrect installation, commissioning or adjustment o operating parameters o the equipment.
Control panels mu t not be le t uncovered while power is on. I it is essential to do so while recti ying aults
only personnel quali ied by training and experience should be involved.
The time any covers are o must be kept to a minimum and warning notices mu t be posted.
Be ore attempting any work on this equipment or any equipment controlled by or connected to this equipment,
all related electrical supplies mu t be isolated.
Sa ety interlocks mu t not be removed or over-ridden. Any aults once detected mu t be corrected be ore the
control is operated.
CAUTION – SOME VERSIONS OF THIS EQUIPMENT CONTAIN A LITHIUM BATTERY
IN THE DISPLAY UNIT
NOTE
The manu acturer o this equipment has a policy o continual product improvement and reserves the right to
change the speci ication o the equipment and the contents o this manual without notice.
The equipment described in this manual is capable o causing property damage, severe injury, or
death. It is the responsibility o the owner or user to ensure that the equipment described herein is
installed, operated and commissioned in compliance with the requirements o all national and local
legislation, which may prevail.

3
Table of content
This manual - NX6101, describes the installation, commissioning, operation and maintenance o the NX6100
integrated burner controls.
Plea e read the afety information at the front of thi manual before proceeding.
Note: The ymbol in Section 5.5.1 highlight the minimum Option Parameter required
to et up the NX6100
1. Technical pecification 11
1.1 General 11
1.2 Servo motor control – IMPORTANT: See Section 3.2 11
1.3 Digital output (NX6100 and optional daughter board – P/N - NXDBVSD) 12
1.4 Alarm output (NX6100) 13
1.5 Digital input 13
1.6 Pre ure/temperature input 14
1.7 Auxiliary Analog Input 14
1.8 Ga pre ure input 14
1.9 Flame en ing device 15
1.10 Communication interface 15
1.11 Fireye NX1020-1,-2 ga pre ure en or 15
1.12 Fireye NX1030-1,-2 and NX1034-1,-2 team pre ure en or 16
1.13 Fireye NX1040-1 and NX1044-1 boiler temperature en or 16
1.14 Fireye NXC04, NXC12, NXC20, NXC40 Servo Motor 17
1.15 Fireye NXO2INT Oxygen Probe Interface Unit (optional) 17
1.16 Fireye NXIATS Ambient Air Temperature Sen or (optional) 18
1.17 Fireye NXDBVSD Variable Speed Drive (VSD) Daughter Board (optional) 18
1.18 Approval 18
1.19 Part Li t with De cription 19
2. In tallation 21
2.1 Mechanical mounting detail for the NX6100 22
2.2 Mechanical mounting detail for the di play module. 22
2.3 Mounting detail for optional Oxygen Probe Interface unit 23
2.4 Mounting arrangement for Temperature, Ga pre ure and Steam pre ure en or 24
2.4.1 Boiler temperature sensors 24
2.4.2 Gas pressure sensors 24
2.4.3 Steam pressure sensors 25
2.4.4 Oxygen probe description 26
2.5 In tallation of oxygen probe 27
2.5.1 Mounting the oxygen probe 27
2.6 Option link election (NX6100) 28
2.6.1 General 28
2.6.2 Line supply voltage (LK1 - 4) (NX6100) 30
2.6.3 SENS IN and SENS SUPP (boiler temp/pressure sensor) (NX6100) 30
2.6.4 REMOTE SETPOINT (NX6100) 31

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2.6.5 RS485 serial communications termination resistor (NX6100) 31
2.6.6 Isolated (MODbus) RS485 serial communications termination resistor (daughter
board) 31
2.7 Wiring 31
2.7.1 General 31
2.7.2 Grounding cable screens. 35
2.7.3 GROUND (EARTH) connection 36
2.7.4 Ground (earth) Connection (display unit) 36
2.7.5 Ground (earth) Connection (oxygen probe interface) 36
2.7.6 Ground (earth) Connection (servo motors and sensors) 36
2.7.7 Terminal Designation 37
2.7.8 LIVE and NEUTRAL supply (NX6100) 42
2.7.9 Burner an output (NX6100) 42
2.7.10 Ignition, main valves, pilot valve, vent and pump (NX6100) 42
2.7.11 Auxiliary Relay Outputs (display) 43
2.7.12 Burner select input (NX6100) 43
2.7.13 Fuel and Pro ile Select inputs (optional) (NX6100) 44
2.7.14 Low Voltage Digital Inputs 1 to 7 (NX6100) 45
2.7.15 Low Voltage Air Flow Input (NX6100) 45
2.7.16 Servo motor and Display Connection (NX6100) 45
2.7.17 Pressure sensor screen termination 47
2.7.18 Pressure/temperature sensor input (NX6100) 47
2.7.19 Gas pressure sensor input (NX6100) 48
2.7.20 UV lame scanner 48
2.7.21 Photocell/ I.R. lame scanner 48
2.7.22 Remote Setpoint (Analog Input 5) (NX6100) 49
2.7.23 Analog Input 1 to 3 (NX6100) 49
2.7.24 RS485 inter ace (NX6100) 50
2.7.25 Variable Speed Drive Selection: 51
2.7.26 Variable Speed Drive Daughter Board P/N NXDBVSD. 52
2.7.27 LIVE and NEUTRAL supply external inter ace – P/N NXO2INT 53
2.7.28 Oxygen probe connection (optional Oxygen Probe nterface unit) 53
2.7.29 Inlet temperature sensor (optional) 55
2.8 Final check 56
3. Servo-motor election and calibration 57
3.1 Servo-motor election 57
3.1.1 Motor requirements 57
3.2 IMPORTANT: Servo-motor direction warning 58
3.3 Locking the ervo-motor to the valve haft 59
3.4 Feedback potentiometer 59
3.5 Adju ting micro witch po ition 60
3.6 Servomotor Replacement 61
4. De cription of operation 62
4.1 OLED (Organic LED) Di play & Keypad option 62
4.2 Start-up equence 63
4.3 Ga afety valve proving equence (VPS) 68
CLOSEDD 69
4.4 Modulation 69
4.4.1 Normal/Remote mode. 69
4.4.2 Local mode. (LOC 1, LOC 2) 69

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5. Commi ioning the control 70
5.1 General 70
5.2 Commi ioning data 71
5.2.1 Option parameters 71
5.2.2 Setpoints 71
5.3 The Commi ioning proce 71
5.3.1 Navigation 71
5.4 De cription of Touch creen operation. 73
5.4.1 The Touchscreen 73
5.4.2 Touchscreen Power on. 73
5.4.3 The Operation Mode line and Status messages 73
5.4.4 Touchscreen Overview display. 75
5.4.5 Touchscreen Lockout Reset (Alarm Mute) Function. 76
5.4.6 Touchscreen LED Indication. 76
5.4.7 Touchscreen Fuel/Pro ile Select. 77
5.4.8 Touchscreen ‘Control’ screen. 78
5.4.9 Touchscreen ‘Menu’ button. 78
5.4.10 Touchscreen ‘Burner Settings’ button. 79
5.4.11 Touchscreen ‘Fault/Event Log’ button. 80
5.4.12 Touchscreen ‘Screen Con iguration’ button. 80
5.4.13 Cleaning the Touchscreen 81
5.4.14 Touchscreen Commission mode. 82
5.5 U ing option et mode 84
5.5.1 Option parameter list 84
Option 00.1 - Site passcode (0 - 999) DEFAULT VALUE is 154. LV3 84
Option 00.2 - Serial communications control address (0 - 15) LV3 84
Option 00.3 - Reset hours run (0 - 1) LV3 85
Option 00.4 – User program select (0 / 1) LV1 85
Option 00.6 – Reserved 85
Option 00.7 – MODBUS device address (1 – 99) LV3 85
Option 00.8 – MODBUS communications speed (0 – 3) LV3 86
Option 01.0 – Power Up Option (0 - 30) LV3 86
Option 01.1 – Keyboard Auto/Manual enable (0 - 1) LV3 [Engineer’s Key 33] 86
Option 01.2 – Mute/Reset Input enable (0 - 2) LV3 86
Option 01.3 – External pro ile select enable (0 - 2) LV3 87
Option 01.4 – Gas Valve Proo o Closure select (1 - 13) LV3 87
Option 01.5 – Oil Valve Proo o Closure select (0 - 13) LV3 88
Option 01.6 – Second Air low switch enable (0 - 3) LV3 88
Option 01.7 – Sa ety time con iguration set (0 - 1) 89
Option 01.8 – Reserved 89
Option 02.x – Drive Name LV3 90
Option 03.x – Drive Serial Number LV3 91
Option 04.x – Drive Usage In ormation LV3 91
Option 05.x – Drive Options LV3 92
Options 06.1-06.4 – Pro ile Naming LV3 92
Option 07.0 – Fan On Early Time (0 to 120 seconds) LV3 93
Option 07.1 – Air Proving Time (t1) (5 to 120 seconds) LV3 93
Option 07.2 – Pre-Purge Time (t2) (5 to 300 seconds) LV3 93
Option 07.3 – Pre-Ignition Time (t3) (0 to 10 seconds) LV3 93
Option 07.4 – Pilot Ignition Time (t4) (1 to 10 seconds) LV3 94
Option 07.5 – Pilot Hold Time (t5) (1 to 30 seconds) LV3 94

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Option 07.6 – Main Ignition Time (t6) (1 to 10 seconds) LV3 94
Option 07.7 – Ignition Hold Time (t7) (1 to 30 seconds) LV3 95
Option 07.8 – Low Fire Hold Time (t8) (0 to 999 seconds) LV3 95
Option 07.9 – Post Purge Time (t9) (0 to 999 seconds) LV3 95
Option 08.0 – Ignition Spark Output Check (0 - 1) LV3 96
Option 08.1 – Flame Failure Response Time (t9) (0-3 seconds) LV3 96
Option 08.2 – Extend False Flame Response Time (t9) LV3 96
Option 09.0 - Inverter control accuracy (0 / 1) LV3 97
Option 09.1 - Inverter error tolerance (0 / 1) LV3 97
Option 09.2 - Inverter closed loop gain (15 – 125%) LV3 97
Option 09.3 - Inverter stop time (0 – 100 seconds) LV3 98
Option 09.4 - Inverter acceleration time (0–100 seconds) (60 seconds max.
recommended) LV3 98
Option 09.6 – VSD2 Speed Encoder Scaler (255 - 999) LV3 98
Option 09.7 – Reserved 99
Option 09.8 – Reserved 99
Option 10.0 - Gas pressure select (0 - 4) LV3 99
Option 10.1 - Gas pressure sensor span (mbar, bar, inches o water, PSI) LV3 100
Option 10.2 - Gas pressure nominal (mbar, bar, inches o water, PSI) LV3 100
Option 10.3 - Gas pressure low limit (mbar, bar, inches o water, PSI) LV3 100
Option 10.4 - Gas pressure high limit (mbar, bar, inches o water, PSI) LV3 100
Option 10.5 - Test volume (0.0 - 99.9 liters or 0 to 999 cubic inches) LV3 100
Option 10.6 - Maximum permissible leakage rate (0 - 99.9 liters per hour or 0 to 999 cubic
inches per hour) LV3 100
Option 10.7 - Vent valve select (0 - 2) LV3 100
Option 10.8 – Valve proving selection (0 - 360) LV3 100
Option 12.0 - Flame detection device I.R. or Direct coupled (0 – 2) LV3 101
Option 12.1 – Pilot Flame Threshold Photocell or I.R. (1 -100) LV3 102
Option 12.2 – Main Flame Threshold Photocell or I.R. (0 – 100) LV3 102
Option 13.0 - Flame detection device U.V. or Sel -Check (shuttered) U.V.
(0 – 2) LV3 102
Option 13.1 – Pilot Flame Threshold U.V. or Shuttered U.V. (0 – 100) LV3 103
Option 13.2 – Main Flame Threshold U.V. or Shuttered U.V. (0 – 100) LV3 103
Option 14.0 – Primary Fault Relay (0 - 8) LV3 103
Option 14.1 – Limit Relay (0 - 8) LV3 103
Option 14.2 – Oxygen and Flue Temperature Limit Relay (0 - 8) LV3 104
Option 14.3 – Permanent gas pilot select (0 - 1) LV3 105
Option 14.4 – Pilot with/without main valve select (0 – 1) LV3 105
Option 14.5 – Direct Ignition on Oil (0 - 1) LV3 105
Option 14.6 – Spark Termination (0-3) LV3 105
Option 14.7 – Aux / Oil Pump Relay Function. (0 - 6) LV3 106
Option 14.8 – Extended Oil Pilot (0-15 seconds) LV3 106
Option 15.0 - Modulation sensor input type (0 - 3) LV3 106
Option 15.1 – Modulation input decimal places (0 to 2) 107
Option 15.2 – Modulation input zero value (-999 to +999 / -99.9 to +99.9 / -
9.99 to +9.99) LV3 107
Option 15.3 – Modulation input span value (-999 to +999 / -99.9 to +99.9 /
-9.99 to +9.99) LV3 108
Option 15.4 – Setpoint display units (0 – 3) LV3 108
Option 15.5 - Boiler high sa ety limit (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3 108
Option 15.6 – Modulation Time (0 – 120 seconds) LV3 108

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Option 15.7 – Bumpless Trans er (0 or 1) LV3 108
Option 15.8 – Low be ore O (0 or 1) LV3 109
Option 15.9 - reserved 109
Option 16.2 – Allow pro ile swap (0 to 16) LV3 110
Option 16.3 – High voltage Input 12 Alarm / Lockout Function (0 - 360) LV3 110
Option 16.4 – High voltage Input 13 Alarm / Lockout Function (0 - 360) LV3 110
Option 16.5 – High voltage Input 12 Fail-sa e Alarm / Lockout Display Messages (0 - 999)
LV3 110
Option 16.6 – High voltage Input 13 Fail-sa e Alarm / Lockout Display Messages (0 - 999)
LV3 110
Option 17.0 – Relay output unction LV3 111
Option 18.1 to 18.9 – Low Voltage Fail-sa e Alarm / Lockout Inputs (0 – 360) and option
parameters 16.3 & 16.4. LV3 115
Option 19.1 to 19.9 – Fail-sa e Alarm / Lockout Display Messages and option parameters
16.5 & 16.6. LV3 116
Option 20.0 – Set-point Select input (0 - 35) LV3 117
Option 20.1 – Boiler Shutdown input (0 - 35). LV3 119
Option 20.2 – Low Fire Hold input (0 - 35). LV3 119
Option 20.3 – Oxygen Trim Disable input (0 - 35). LV3 119
Option 20.4 – Ignition Wait input (0 - 35). LV3 119
Option 20.5 – Purge Hold input (0 - 35). LV3 119
Option 20.6 – Purge Time Start input (0 - 35). LV3 120
Option 20.7 – Analog Input 5 unction (0 - 2). LV3 120
Option 20.8 – Digital Input - Lead Boiler Select (0 – 35) LV3 120
Option 21.0 – Set-point 1 enable (0 - 1) LV1 121
Option 21.1 – Set-point 1 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99)
LV1 121
Option 21.2 – Set-point 1 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 -
9.99) LV1 121
Option 21.3 – Set-point 1 integral time (0 – 999 seconds) LV1 121
Option 21.4 – Set-point 1 derivative time (0 – 999 seconds) LV1 121
Option 21.5 - Setpoint 1 control limit type (0 - 2) LV3 121
Option 21.6 - Setpoint 1 low limit control value (Cut In) (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99)
LV1 122
Option 21.7 - Setpoint 1 high limit control value (Cut Out) (0 - 999 / 00.0 - 99.9 / 0.00 -
9.99) LV1 122
Option 21.8 – Remote Setpoint 1 zero (4ma) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 122
Option 21.9 – Remote Setpoint 1 span (20mA) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99)
LV1 122
Option 22.0 – PID (set-point) 2 enable (0 - 1) LV1 122
Option 22.1 – Set-point 2 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 122
Option 22.2 – Set-point 2 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 122
Option 22.3 – Set-point 2 integral term (0 – 999 seconds) LV1 122
Option 22.4 – Set-point 2 derivative term (0 - 100) LV1 123
Option 22.5 - Setpoint 2 control limit type (0 - 2) LV3 123
Option 22.6 - Setpoint 2 low limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 123
Option 22.7 - Setpoint 2 high limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 123
Option 22.8 – Maximum modulation rate 123
Option 22.9 – Reserved 123
Option 23.0 – Warming Enable (0 or 1) LV1 124
Option 23.1 – Warming Limit (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 124
Option 23.2 – Warming Time (0 to 999 minutes) LV1 124
Options 24.x – Sequencing 124
Option 24.0 Sequence Slaves (number o boilers) (0-3) LV1 126

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Option 24.1 -24.3 Priority Number(s) LV1 126
Option 24.4 – Lead OFF Time LV1 126
Option 24.5 – Lead (master) Boiler Select Method LV1 126
Option 24.6 – lag (slave) On Rate (0-100%) LV1 127
Option 24.7 – lag (slave) On Delay (0-999 minutes) LV1 127
Option 24.8 – lag (slave) O Rate (0-100%) LV3 127
Option 24.9 – lag (slave) O Delay (0-999 minutes) LV3 127
Option 25.0 – Banking based on temperature / water temperature standby or steam boiler
LV3 127
Option 25.1 – Water temperature zero value LV3 128
Option 25.2 – Water temperature span value LV3 128
Option 25.3 – Water temperature cut-in LV1 128
Option 25.4 – Water temperature cut-out LV1 128
Option 25.5 – Temperature based warming limit LV1 128
Option 25.6 – Lag wait time LV1 128
Option 28.0 – Analog Input 1 decimals (0-2) LV3 128
Option 28.1 – Analog Input 1 zero (0-999) LV3 128
Option 28.2 – Analog Input 1 span (0-999) LV3 128
Option 28.3 – Analog Input 2 decimals (0-2) LV3 129
Option 28.4 – Analog Input 2 zero (0-999) LV3 129
Option 28.5 – Analog Input 2 span (0-999) LV3 129
Option 28.6 – Analog Input 3 decimals (0-2) LV3 129
Option 28.7 – Analog Input 3 zero (0-999) LV3 129
Option 28.8 – Analog Input 3 span (0-999) LV3 129
Option 29.0 – 4-20mA Output 1 unction i not VSD LV3 129
Option 29.1 – Output1 zero value (4mA output) LV3 130
Option 29.2 – Output1 span value (20mA output) LV3 130
Option 29.3 – 4-20mA Output 2 unction i not VSD LV3 130
Option 29.4 – Output2 zero value (4mA output) LV3 130
Option 29.5 – Output2 span value (20mA output) LV3 130
Option 29.6 – 4-20mA Output 3 unction i not VSD LV3 130
Option 29.7 – Output3 zero value (4mA output) LV3 130
Option 29.8 – Output3 span value (20mA output) LV3 131
Option 30.0 – Oxygen probe inter ace serial number LV3 133
Option 30.1 - Oxygen probe calibration o set value (0 – 999) LV3 133
Option 30.2 - Oxygen probe calibration gain value (0 – 999) LV3 133
Option 30.4 – Flue and inlet sensor temperature units (0 – 1) LV3 134
Option 30.5 - Oxygen input unction (0/1) LV3 134
Option 30.6 - Oxygen probe calibrate enable (0 – 2) LV3 134
Option 30.7 - Boiler transport delay (5 – 60 seconds) LV3 135
Option 30.8 - Reset oxygen trim pro ile (0/1) LV3 135
Option 30.9 – Automatic trim commissioning (0 / 1) LV3 135
Options 31.1 to 31.4 - Trim Type or pro iles 1 to 4 (0 to 2) LV3 137
Option 32.0 - Trim limit de ault (0/1) LV3 138
Options 33.1 to 33.4 - Trim integral gain (De ault 10%) LV3 138
Option 34.0 - Trim proportional gain (0/1) LV3 139
Options 34.1 to 34.4 - Trim proportional gain (0.0 – 99.9%) LV3 139
Option 34.5 - Calculating and entering the low values manually LV3 139
Option 35.0 – Inlet temperature sensor serial number LV3 142
Options 35.5 to 35.8-Calori ic values o uels/pro iles 1 to 4 respectively (0.0 – 99.9) LV3 142
Option 35.9 - Boiler radiated heat loss (0.0 – 9.9%) LV3 143
Option 36.0 - Flue temperature alarm select (0/1) LV3 143
Options 36.1 to 36.4 - Flue temperature low alarm values (0 – 999) LV3 143
Option 38.0 - Oxygen alarm select (0 – 2) LV3 144
Options 38.1 to 38.4 - Oxygen low alarm values at low ire (0.0 – 99.9%) LV3 144
Options 39.1 to 39.4 - Oxygen low alarm values at high ire (0.0 – 99.9%) LV3 144

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Options 40.1 to 40.4 - Oxygen high alarm values at low ire (0.0 – 99.9%) LV3 144
Options 41.1 to 41.4 - Oxygen high alarm values at high ire (0.0 – 99.9%) LV3 144
Option 42.0 – Second Oxygen probe inter ace serial number LV3 145
Option 42.1 – Second Oxygen probe calibration o set value (0 – 999) LV3 145
Option 42.2 – Second Oxygen probe calibration gain value (0 – 999) LV3 145
Option 42.3 – Second Oxygen probe calibrate enable (0 – 2) LV3 146
Option 42.4 – Max oxygen variation (0 – 9.9 %) LV3 146
Option 42.5 – Max lue temp variation (0 to 999 ºC) LV3 146
Option 42.7 – Air Pressure Input (0-3) LV3 * 147
Option 42.8 – Air Pressure Span (0-99.9) LV3 * 147
Option 42.9 – Air Pressure Error (0-25%) LV3 * 147
Option 43.0 – Enable Water level / expansion unit – Set to 3 or 4 ONLY! LV3 ** 147
Option 43.1 – Unit Address o Water level / expansion unit - Set to 10. LV3 ** 147
Option 44.0 - Set real time clock (0/1) LV1 147
Option 44.1 – Set Year (00 – 99) LV1 148
Option 44.2 – Set Month (1 – 12) LV1 148
Option 44.3 – Set Day o Month (1 – 31) LV1 148
Option 44.4 – Set Day o Week (1 - 7) LV1 148
Option 44.5 – Set Hours (0 - 23) LV1 148
Option 44.6 – Set Minutes (0 - 59) LV1 148
Option 44.7 – Set Seconds (0 - 59) LV1 148
Option 44.9 – Reset Fault Log (0 - 1) LV3 148
Option 45.0 - Erase / Restore enable (0 - 1) LV3 149
Option 45.1 - Erase command (0 - 5) LV3 149
Option 45.2 - Restore command (0 - 999) LV3 150
5.6 Commi ion ratio mode 151
5.6.1 Description 151
5.6.2 Using commission ratio mode 152
5.6.3 Leaving commission ratio mode 153
5.7 Adju t ratio mode 153
5.7.1 Description 153
5.7.2 Entering adjust ratio mode 154
5.7.3 Using adjust ratio mode 154
5.7.4 Leaving adjust ratio mode 155
5.8 Interrogating the oftware i ue 155
6. Fault and fault finding 156
6.1 The fault di play 156
6.2 What to do when a fault occur 156
6.3 Non-volatile lockout 157
6.4 Fault ub et 157
6.5 Fault li ting 157
6.6 The engineer' key 168
6.6.1 System Event/Fault history. 168
6.6.2 Engineer’s key parameter list 169
6.7 Trouble hooting 181
6.7.1 Display / General 181
6.7.2 Startup 183
6.7.3 Commissioning 183
6.7.4 Gas valve proving 184
6.7.5 Modulation 184
6.7.6 Inverters 185
6.7.7 Oxygen measurement and trim 186

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7. Inverter (variable peed) drive 187
7.1 Sy tem configuration 187
7.2 De cription of control method 188
7.3 Setting up the inverter for u e with the NX6100 erie 188
7.4 Setting up the NX6100 erie for u e with a inverter drive 189
8. The oxygen trim option 190
8.1 Oxygen Pro probe de cription 190
8.1.1 Installation o oxygen probe 190
8.1.2 Mounting the oxygen probe 191
9. Appendix 193
9.1 Calibrating and ervicing the oxygen probe 193
9.1.1 Probe calibration 193
9.1.2 Oxygen Probe Filter Testing 194
9.1.3 Removing the oxygen probe rom the lue 194
9.1.4 Filter replacement 195
9.1.5 Probe mounted lue thermocouple replacement. 195
9.2 Trouble hooting inverter problem 197
9.3 PID Tutorial 198
9.4 Combu tion Profile Setup Guideline 199
9.5 Fireye NX6100 Efficiency Calculation 200
9.6 Typical Wiring Diagram 202
9.7 Fireye EP and YP Serie Programmer Equivalent 203
10. Function Block Programming Detail 204
Introduction to Fireye’ Abacu Programming Software 204
1.1. Introduction 204
1.4. The chematic toolbar 208
1.5. Place Function block 209
1.6. Moving and editing the link line 209
11. CANbu Servomotor - Drawing & Template 211
11.1 NXC04 4Nm (3 ft/lb) Servo 211
11.2 NXC12 10Nm (9 ft/lb) Servo 211
11.3 NXC20 20Nm (15 ft/lb) Servo 212
11.4 NXC40 40Nm (30 ft/lb) Servo 213
11.5 NX6110 12 Key Di play 214
11.6 NXTSD104 10.4” Touch creen Di play 215
11.7 NXO2INT Oxygen Interface 216
12. Circuit board connection 217
12.1 Variable Speed Drive (VSD) Daughter Board P/N NXDBVSD 217
12.2 Oxygen probe connection (optional xygen Probe Interface unit) 218
12.3 Inlet Air Temperature Sen or 219
12.4 NX6100 Terminal Detail 221

11
1. Technical pecification
1.1 General
Supply voltage
Power consumption
Supply requency
Ambient temperature range
Control unit protection category
Unit dimensions
Weight
120/230Vac +10% - 15%
Approx. 60VA
50/60 Hz ±5%
0 to 60°C (32 to 140°F)
IP20. The control must be situated in a P1 or P2 environment
according to EN6730-1.
Indoor: Control must be mounted in an NEMA1 (IP40) enclosure
Outdoor: Control must be mounted in an NEMA3 (IP54) enclosure
Control unit 210 x 125 x 80mm (8.27 x 4.92 x 3.15 in) deep
Display 158 x145 x 44mm (6.22 x 5.71 x 1.73 in) deep
Control unit 2.13kg (4.70 lbs)
Display 0.90Kg (1.98 lbs)
Type o display 2 lines x 20 characters, vacuum luorescent display with membrane
keypad.
1.2 Servo motor control – IMPORTANT: See Section 3.2
Type
Maximum (total) number o servo motors
Maximum number o uel pro iles
Max. number o setpoints per pro ile
Positioning accuracy
Response time to positioning error
Number o uel motors
Number o air (non uel) motors
CANbus
10 (see section 3 regarding servo motors)
4
24 including close, purge and ignition
+/-0.1°
15s or ±1.0°, 1s or ±5.0°
Not Limited. All non-monotonic
Not Limited. All non-monotonic
NOTE: Number of ervomotor i limited in all
profile by VA rating. See Section 3.1.1.

12
1.3 Digital output (NX6100 and optional daughter board – P/N - NXDBVSD)
Alarm, ignition, Limit alarm & Fault mute retransmission.
Type
Minimum current
Maximum current (per output)
Fuse requirement
Maximum voltage
On-o relay, de-energies or o .
200mA rms
4A rms (power actor > 0.6)
4A maximum
250Vac rms
Burner motor, vent, main and pilot valve outputs
Type
Minimum current
Maximum current (per output)
Fuse requirement
Maximum voltage
On-o relay, de-energies or o .
200mA rms
2A rms (pilot duty)
4A rms (power actor > 0.6)
4A maximum
250Vac rms
Ignition output
Type
Minimum current
Maximum current
Fuse requirement
Maximum voltage
On-o relay, de-energies or o
200mA rms
2A rms (ignition load)
4A rms (power actor > 0.6)
4A maximum
250Vac rms
* Max total simultaneous current (Main 1 + 2 + Pilot + Oil) Outputs 8A rms

13
1.4 Alarm output (NX6100)
Alarm
Type
Minimum current
Maximum current (per output)
Maximum voltage
On-o relay, de-energize or o .
200mA rms
4A rms
250Vac rms
1.5 Digital input
Low Voltage digital inputs 1 to 7. Digital, Switching 0V to 5V pulsed. Feed must
be taken rom the correct terminal as indicated
in this manual.
Less than 25mA
±10V absolute maximum
Low Voltage Fuel / pro ile select inputs (x2).
Digital Inputs 8 & 9
Maximum current
Maximum voltage
2.5v OFF. Switching to 5V or 0v depending on
switch direction. Four combinations in total.
May also be used as Digital inputs (2).
See Section 2.7.13
Less than 25mA
±10V absolute maximum
Burner select
Maximum current
Digital, 0V or o , 90-264Vac or on, also
provides eed or pilot valve, oil valve, main
valve 1 and main valve 2.
Supplying circuit must be able to carry
su icient current or all valves connected to the
relay outputs and be used at a maximum o
4A, unless each output is used at 4A in which
case the input use may be 8A.
High voltage digital inputs 12 & 13
Maximum current
Digital, 0V or o , 90-264Vac or on.
3mA

14
1.6 Pre ure/temperature input
0-5V
Maximum current
Maximum voltage
Input accuracy (typical)
Input accuracy (as speci ied by EN12067)
Less than 2mA
0 to 5.0 volts maximum.
±0.1%
±0.3%
4-20mA
Maximum current
Burden (load) resistor
Input accuracy (typical)
Input accuracy (as speci ied by EN12067)
2 wire loop or ext. powered
0 to 25mA maximum
220 Ohm nominal
±1.0%
±1.1%
Fireye NX103x boiler pressure sensor
Fireye NX104x boiler temperature sensor
See sensor speci ications. See Sections
1.11 and 1.12.
1.7 Auxiliary Analog Input
0-5V
4-20 mA - externally powered –
See Section 2.7.23
Maximum current
Maximum voltage
Input accuracy (typical)
Input accuracy (as speci ied by EN12067)
Less than 2mA
±50V absolute maximum
±0.1%
±0.3%
1.8 Ga pre ure input
Fireye NX102x gas pressure sensor See sensor speci ications

15
1.9 Flame en ing device
UV scanner: Fireye Type: UV1A, UV2,
UV8A, UV90, 45UV3, 45UV5-1007,
45UV5-1009
First sa ety time
Response time to lame ailure
Continuous operation
The scanner and its installation should meet
the requirements o UL, cUL, FM and EN298
clause 7.4.2 and EN230 clause 5.2.2.
Selectable
1 - 3 seconds, selectable
UV when used with a sel -check (shuttered)
scanner.
Photocell or I.R. Fireye Type: 48PT2,
95DSS2WR, 85UVF3WR, 85UVF1WR,
85IRF1WR. 85IRF3WR
Minimum light resistance
First sa ety time
Response time to lame ailure
Continuous operation
The sensor and its installation should meet
the requirements o UL, cUL, FM and EN230
clause 5.2.1.
11KΩ
Selectable
1 - 3 seconds selectable
Only i set or a.c. response.
1.10 Communication interface
2-wire RS485 plus ground, with termination resistor selected using a link. See Section 2.6.5
An isolated 2-wire RS485 inter ace is available as an option. See Section 2.6.6
See MOD-6101 (FIREYE serial communications protocol manual) or details.
1.11 Fireye NX1020-1,-2 ga pre ure en or
Supply voltage
Supply current
Working range (zero – span)
Ambient temperature range
Protection category
Dimensions
Pipe thread mounting details
Conduit thread details
Weight
Maximum working pressure
Burst pressure
Typical Accuracy
Accuracy (as speci ied by EN12067)
30Vdc ±10%
Approximately 10mA
0 – 600mBar (0-8.702psi)
0 to 70°C (32 to 158°F)
IP44
44mm dia. x 85mm long (excluding connector)
G 1/4"
PG7
600g
600mbar or all applications
1bar
±0.1% o span
±0.3% o span
±0.9% o value

16
1.12 Fireye NX1030-1,-2 and NX1034-1,-2 team pre ure en or
Supply voltage
Supply current
Working range (zero – span)
Ambient temperature range
Protection category
Dimensions
Pipe thread mounting details
Conduit thread details
Weight
Maximum working pressure
Burst pressure
Typical Accuracy
Accuracy (as speci ied by EN12067)
30Vdc ±10%
Approximately 10mA
0 – 25 bar
0 to 70°C (32 to 158°F)
IP44
44mm dia. x 85mm long (excluding connector)
G ¼"
PG7
450g
25bar (20 bar S class)
80bar
±0.1% o span
±0.3% o span
±0.9% o value
1.13 Fireye NX1040-1 and NX1044-1 boiler temperature en or
Supply voltage
Supply current
Working range (zero – span)
Ambient temperature range
Protection category
Probe dimensions
Body dimensions
Conduit thread details
Weight
Maximum temperature
Sensor Element Accuracy
Typical Accuracy
Accuracy (as speci ied by EN12067)
30Vdc ±10%
Approximately 10mA
0 to 150°C (32 to 302°F) & 0 to 400°C (32 to 752°F)
0 to 60°C (32 to 140°F)
IP44
6mm dia. x 200mm long (excl. body)
65mm dia. x 75mm long
M16
200g
450°C (842°F)
±0.5% o span
±0.1% o span
±0.1% o span
±0.6% o value
Temperature sensor must be mounted in a ‘well’ (pocket) to enable replacement without draining
boiler.

17
1.14 Fireye NXC04, NXC12, NXC20, NXC40 Servo Motor
Inter ace to NX6100
Speed
Microswitches
Torque
CANbus
30 seconds or 90 degrees.
Open & close positions
Driving Holding
NXC04 4Nm/ 3 t/lb 2Nm
NXC12 12Nm/ 9 t/lb 18Nm
NXC20 20Nm/ 14.7 t/lb 18Nm
NXC40 40Nm/ 29 t/lb 20Nm
Voltage:
VA rating
Protection Category
Typical accuracy
Accuracy (as speci ied by EN12067)
24-30Vac supplied rom control only
NXC04 = 3VA
NXC12 = 5VA
NXC20 = 10VA
NXC40 = 18VA
NXC04 = IP54
NXC12, NXC20 & NXC40 = IP65
+/-0.1°
+/-0.5°
1.15 Fireye NXO2INT Oxygen Probe Interface Unit (optional)
Supply voltage
Power consumption
Supply requency
Ambient temperature range
Protection category
Unit dimensions
Weight
Inter ace to PPC6000 / NX6100
Inter ace to oxygen probe.
115/230Vac ± 15%
Approximately 60VA
50/60Hz ± 5%
0 to 60°C (32 to 140°F)
NEMA4 (IP65).
160 x 98 x 63mm (6.30 x 3.86 x 2.48“) deep
1.34Kg (2.95 lbs)
FIREYE speci ic CANbus.
FIREYE speci ic or 4-20mA

18
1.16 Fireye NXIATS Ambient Air Temperature Sen or (optional)
Type
Ambient temperature range
Protection category
Unit dimensions
Weight
Inter ace to PPC6000 / NX6100
CANbus
-29°C to 60°C (-20°F to 140°F)
NOTE: Accuracy below 0°C (32°F) may
vary slightly. Agency testing conducted to
0°
°°
°C only.
NEMA3 (IP54)
FIREYE speci ic CANbus.
1.17 Fireye NXDBVSD Variable Speed Drive (VSD) Daughter Board (optional )
Ambient temperature range
Protection category
Analog inputs (4 – 20mA)
Input impedance
Analog outputs (4 – 20mA)
Maximum loop resistance
Isolation voltage
RS485 communications.
0 to 60°C (32 to 140°F)
Not applicable ( its inside NX6100 unit).
3 max (non-isolated)
120ohms
3 max (isolated)
250ohms
50v
FIREYE Protocol / Modbus RTU
1.18 Approval
Tested in accordance with the Gas Appliance Directive (GAD 90/396 EEC), encompassing the ollowing
standards:
• SIL Level 3 – Kiwa Gastec Report #123836
• ANSI/UL 462, Heat Reclaimers or Gas, Oil, or Solid Fuel-Fired Appliances
• ANSI/UL 1995, Heating and Cooling Equipment
• ANSI/UL 1998, So tware in Programmable Components
• CAN/CSA-C22.2 No. 236, Heating and Cooling Equipment
• FM
• ENV1954, Internal and external behavior o sa ety related electronic parts
• EN60730-1, Automatic electrical controls or household and similar use
• prEN12067, Gas/air ratio controls or gas burners as gas burning appliances

19
1.19 Part Li t with De cription
PART NO*
DESCRIPTION
NX6100 FUEL AIR RATIO CONTROLLER
NX6100
Stand-alone parallel positioning controller, with up to ten (10) selectable
unction CANbus servo-motor outputs. Includes user con igurable unction
blocks or custom applications. Display ordered separately.
DISPLAY MODULES FOR NX6100
NX6110
12 key CANbus display or NX6100 with upload/download o NX6100 data and
three programmable relays.
NX6220
12 key Canbus Organic LED (OLED) display or NX6100 with upload/download
o NX6100 data and three programmable relays. USB port or updates and
uture unctions TBD.
NX6330
12 key Canbus Organic LED (OLED) display or NX6100 with upload/download
o NX6100 data and three programmable relays. USB port or updates and
uture unctions TBD. Also itted with RJ45 Ethernet port or BAS integration.
Onboard Modbus TC/PIP and BACnet protocals.
NXTSD104**
10.4” Touchscreen Display with upload/download, ull commissioning, data log,
internet connection, our programmable relays, 10 line voltage Digital Inputs.
SERVO-MOTORS FOR NX6100
NXC04
4 wire CANbus Servo-motor, 3 t lbs. torque, 4 Nm, 50/60 Hz, 24 VAC.
NXC12
4 wire CANbus Servo-motor, 9 t lbs. torque, 12 Nm, 50/60 Hz, 24 VAC.
NXC20
4 wire CANbus Servo-motor, 14.75 t lbs. torque, 20 Nm, 50/60 Hz, 24 VAC.
NXC40
4 wire CANbus Servo-motor, 29.5 t lbs. torque, 40 Nm, 50/60 Hz, 24 VAC.
EXPANSION INTERFACE MODULES FOR NX6100
NXDBMB
Modbus communications card
NXDBVSD
VSD inter ace daughter board with two VSD channels, one analog output, two
counter inputs, two programmable relays, isolated RS485 – Modbus RTU
NXO2INT
CANbus O2 inter ace module with Fireye and generic (4-20mA) probe inputs.
O2 PROBES FOR NX6100 ONLY
NXO2PK4
O2 probe assembly ( or lues 300mm to 1000mm). Includes NXIATS CANbus
ambient temperature sensor, lange kit.
NXO2PK6
O2 probe assembly ( or lues 600mm to 2000mm). Includes NXIATS CANbus
ambient temperature sensor, lange kit.
NXO2PK8
O2 probe assembly ( or lues 1200mm to 4000mm). Includes NXIATS CANbus
ambient temperature sensor, lange kit.
NXIATS
NX6100 CANbus Inlet (ambient) Air Temperature Sensor -29°C to 60°C (-
20°F to 140°F)
SENSORS FOR PPC6000 / NX3100 / NX4100 / NX6100
NX1034-1
Steam Pressure Sensor: 0-58 PSI, 0-4 bar, 1/4” BSP.
Includes 1/4" emale BSP to 1/2” NPT male adaptor.
For use with NX3100 / NX4100 / NX6100
NX1034-2
Steam Pressure Sensor: 0-58 PSI, 0-4 bar, 1/4” BSP.
For use with NX3100 / NX4100 / NX6100
NX1030-1
Steam Pressure Sensor: 0-362.5 PSI, 0-25 bars, 1/2” NPT.
For use with NX3100 / NX4100 / NX6100

20
PART NO*
DESCRIPTION
NX1030-2
Steam Pressure Sensor: 0-362.5 PSI, 0-25 bars, 1/4” BSP.
For use with NX3100 / NX4100 / NX6100
NX1040-1
Boiler Temperature Sensor: 32-302
o
F, 0-150
o
C, 6” length, 1/4" dia.,
thermowell required, not provided.
For use with NX3100 / NX4100 / NX6100
NX1044-1
Boiler Temperature Sensor: 32-752
o
F, 0-400
o
C, 6” length, 1/4" dia.,
thermowell required, not provided.
For use with NX3100 / NX4100 / NX6100
PXMS-15
Steam Pressure Sensor: 0 - 15 PSI, 0 - 1 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
PXMS-200
Steam Pressure Sensor: 0 - 200 PSI, 0 - 14 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
PXMS-300
Steam Pressure Sensor: 0 - 300 PSI, 0 - 21 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
BLPS-15
Steam Pressure Sensor: 0 - 15 PSI, 0 - 1 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
BLPS-30
Steam Pressure Sensor: 0 - 30 PSI, 0 - 1 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
BLPS-200
Steam Pressure Sensor: 0 - 200 PSI, 0 - 14 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
BLPS-300
Steam Pressure Sensor: 0 - 300 PSI, 0 - 21 bar, 4-20mA output, 1/2" NPT, non
sel -check ( or use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
TS350 (-2), (-4), (-8)
Temperature Sensor, Range 32
o
F-350
o
F (0-176
o
C), 4-20mA linear
output, includes 1/2 - 14 NPT well. See bulletin BLZPTS-1 or complete
description.
TS752 (-2), (-4), (-8)
Temperature Sensor, Range 32
o
F-752
o
F (0-400
o
C), 4-20mA linear
output, includes 1/2 - 14 NPT well. See bulletin BLZPTS-1 or complete
description.
SOFTWARE
NXAM Com ire communications so tware on CD or Nexus and PPC controls.
COMMUNICATION INTERFACE GATEWAY
NXDBMB
"Modbus RTU" inter ace card or PPC6000 / NX6100. Networks up to
15 Fireye Nexus Systems – one card per control...
NXDBVSD
VSD inter ace daughter board with two VSD channels, one analog output, two
counter inputs, two programmable relays, isolated RS485 – Modbus RTU
* FO R A DD I T I ON A L P A R T S SE E F I R EY E P RI C E BO O K CG -1 4
** S OM E F E A T UR E S IN C L UD E D O N N XT S D M AN U FA C TU R E D AF T ER MA Y 2 01 1.