Fireye PPC4000 SERIES User manual

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DESCRIPTION
Fireye PPC4000, the newest member of the Nexus family, is a state of the art parallel positioning
system for all types of liquid or gaseous fuel fired combustion systems. When combined with a Fir-
eye flame safeguard system such as the Fireye BurnerLogix control, the PPC4000 offers the most
compact and advanced parallel positioning system available. Four fuel profiles allow the PPC4000
to accommodate a variety of applications such as two fuels, with and without, the optional variable
frequency/speed drive (VFD/VSD). With each profile having up to 24 points entered to assure a
smooth “curve”, the microprocessors within the PPC4000 interpolate points between entered values
and precisely position fuel and air servos to within ± 0.1 degree, and the VFD to within 0.1% of its
full scale range. The result is improved efficiency by eliminating hysteresis typically found in slide
wire or single point positioning systems. Additional gains in burner efficiency can be realized by
adding the optional (VFD/VSD) drive board and Fireye O2 probe. The PPC4000 is capable of con-
trolling a total of ten servo motors, four servos per profile. All servo motors and displays operate on
a secure communications protocol and can be “daisy chained”/ multi-dropped together for simplified
wiring. Available servos from Fireye have torque ranges of 4 Nm (3 ft./lb.), 20 Nm (15 ft./lb.), and
50 Nm (37 ft./lb.). Two independent PID control loops for temperature or pressure control provide
precise, accurate control of firing rate for unmatched response to load changes. Ten safety rated user
definable line voltage inputs are standard and can be configured for functions such as burner on, set-
point select, lead lag, setback, etc. The PPC4000 also contains programmable relays that can be used
for various functions throughout the burner sequence. Built in lead lag sequencing for up to four
boilers is included in every PPC4000. The PPC4000 contains an SD (Secure Digital) card interface
that provides data logging of a burner’s operation at user defined intervals as well as upload/down-
load capability.
The User Interface, NXD410, contains a tactile feel keypad and a four line backlit LCD screen. The
NXD410 offers dedicated keys that facilitate various every day tasks done by the boiler operator.
Among these are C-MODE, BURNER ON/OFF, ADJUST SETPOINT, LOW FIRE, AUTO/MAN
(modulation) and LEAD LAG (sequencing). This eliminates the tedious task of entering various
modes and passcodes to search for the desired parameter. The NXD410 has a HOME screen that
shows four lines of instant and pertinent information about the current state of the burner. A HOME
key on the keypad will direct the user to this screen from anywhere within the menu system. An intu-
itive menu system and easy to use navigation keys optimally placed on the keypad provide an easy
flow to all parameters in the system. An INFO key is available that allows the installer/operator to
PPC-4001
JUNE 20, 2016
PPC4000
SERIES
FUEL AIR
RATIO
CONTROLLER

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quickly check key system values while in commissioning mode. The NXD410 is panel mount only
and is rated for NEMA 4X indoor environments.
When required, the operating system of the PPC4000 and NXD410 will automatically direct the user
to the passcode setup screen and when entered correctly will take the user directly to the parameter
requested, making the entire system user-friendly.
Key features of the PPC4000 system
• Four line user interface with direct key functions
• 7” and 13” Touchscreen support
• Capable of controlling up to 10 servos when application driven
• Non-monotonic servo operation
• Two independent VFD control channels
• Ten line voltage user-defined digital inputs
• Voltage free alarm relay contacts (normally open in non-lockout state)
• Four user selected line voltage burner profiles
• Five 4-20 mA analog transducer inputs
• Cold start thermal shock protection limits mechanical stress
• Assured low fire cutoff
• Sequencing for up to 6 boilers
• SD (Secure Digital) interface for backup and restore
• Modbus-RTU communications via RS485 with read/write capability
• PID operation for precise process control
• Intuitive menu driven design
• User defined 4-20 mA outputs
• Minimal wiring to flame safeguard
• Optional O2 trim
• Track Modulation
• Boiler efficiency calculation
• Compatible with BurnerLogix
• Compatible with Flame-Monitor
• Engineered and manufactured to ACE standards for product excellence
• Small footprint: 5.0”(127mm) W x 8.0”(203.2mm) H x 4.0”(101.6mm) D
• No wiring base necessary
• Expert support from the Fireye team
A minimal Nexus system includes the PPC4000 parallel positioning controller, NXD410 User Inter-
face, 59-562-2 UI interface cable, appropriate Fireye pressure and/or temperature transducers, and a
minimum of two servos for a single fuel application. Optionally an O2 probe and (VFD/VSD) card
can be added. Although a BurnerLogix flame safeguard is recommended, the Flame-Monitor pro-
vides direct compatibility to the PPC4000.

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This manual describes the installation, commissioning, operation and maintenance of the PPC4000
series fuel air ratio controls. It may be used in conjunction with the following other manuals:
• BL-1001 – BurnerLogix Flame Safeguard Bulletin
• YZEM-3001 – YZ300 Interlock Annunciator for use with BurnerLogix
• E-1101 – Flame-Monitor Flame Safeguard Bulletin
• E-3001 – E300 Expansion Module for use with Flame-Monitor
• NEXBK-1000 - Nexus bracket and coupling accessories
• NEX-3004 - Nexus FX04 series 4Nm servo motor
• NEX-3020 - Nexus FX20 series 20Nm servo motor
• NEX-3050 - Nexus FX50 series 50Nm servo motor
• NXCESO2-1001 - OXYGEN PROBE
• 133-750 - O2 mounting flange installation instructions
• NXD-4101 - NXD410 User Interface
• NXCESVFD - VFD plug-in board installation
• NXTSD-4001 - Touchscreen user’s guide
• FXIATS-1 - Ambient air temperature transmitter
The equipment described in this manual is capable of causing property damage, severe
injury, or death. It is the responsibility of the owner or user to ensure that the equipment
described is installed, operated and commissioned in compliance with the requirements of
all national and local codes.
Warning: Electro-mechanical high steam pressure or high water temperature limits
must remain in the running interlock circuit of the flame safeguard control.

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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Key Features of the PPC4000 System. . . . . . . . . . . . . 2
PPC4000 System Specifications . . . . . . . . . . . . . . . . . .5
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Part Numbers and Approvals. . . . . . . . . . . . . . . . . . . . 8
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . 10
NXD410 User Interface . . . . . . . . . . . . . . . . . . . . . . 10
PPC4000 Installation. . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . 15
PPC4000 Mounting and Wiring . . . . . . . . . . . . . . . . 17
Pressure and Temperature Sensors . . . . . . . . . . . . . . 17
Wiring Pressure and Temperature Sensors . . . . . . . . 19
Servo Motor Setup and Wiring . . . . . . . . . . . . . . . . . 20
NXCESO2 Oxygen Probe. . . . . . . . . . . . . . . . . . . . . 22
NXD410 User Interface . . . . . . . . . . . . . . . . . . . . . . 24
Navigating Through Display Menus. . . . . . . . . . . . . 25
PPC4000 Control Operation . . . . . . . . . . . . . . . . . . . 27
Passcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Servo Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sensor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Sensor Setpoint Setup . . . . . . . . . . . . . . . . . . . . . . . . 32
Profile Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Keypad Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . . 37
Commissioning with VFD. . . . . . . . . . . . . . . . . . . . . 41
Oxygen Probe Setup . . . . . . . . . . . . . . . . . . . . . . . . . 42
Setting Trim Limits . . . . . . . . . . . . . . . . . . . . . . . . . . 44
General Rules for O2 Alarm Notification . . . . . . . . . 45
Flue Temperature Alarm Limits . . . . . . . . . . . . . . . . .46
Gain Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Understanding O2 Error Codes . . . . . . . . . . . . . . . . .47
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . .49
Profile Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Commissioning Rules. . . . . . . . . . . . . . . . . . . . . . . . .50
Commissioning O2 Trim with the O2 Probe . . . . . . .56
Operation with O2 Trim. . . . . . . . . . . . . . . . . . . . . . .57
Adjust Ratio Procedure . . . . . . . . . . . . . . . . . . . . . . .58
Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Cold Start Thermal Shock Protection. . . . . . . . . . . . .60
Communications Setup. . . . . . . . . . . . . . . . . . . . . . . .62
Setback Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Standby Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Track Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . .65
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . .68
PPC4000 System Wiring Diagram. . . . . . . . . . . . . . 70
Boiler Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SD Card Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .78
Backup Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Restore Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Delete Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Format Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Profile Setup Work Sheet . . . . . . . . . . . . . . . . . . . . . .83
Lockouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
MarginalAlarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fault History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Warranties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
TABLE OF CONTENTS

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PPC4000 SYSTEM SPECIFICATIONS
PPC4000 Control:
Supply Voltage:
PPC4000 120 VAC (+10%, -15%) 50/60 Hz
PPC4000-230V 230 VAC (+10%, -15%) 50/60 Hz
Power Consumption: 15 VA
Temperature Rating:
Operating: 32°F to 140°F (0°C to 60°C)
Storage: -4°F to 158°F (-20°C to 70°C)
Humidity Rating: 85% RH, non-condensing
Protection Category: NEMA 1 (IP01)
Unit Dimensions: 5.0" (127 mm) W x 8.0" (203.2mm) H x 4.0” (101.6mm) D
Shipping Weight: PPC4000: Approx. 3.2 lbs. (1.45 kg)
NXD410 User Interface:
Supply Voltage: NXD410 24 VDC @ 250 mA (supplied by PPC4000)
Power Consumption: 6 VA
Temperature Rating:
Operating: 32°F to 140°F (0°C to 60°C)
Storage: -4°F to 158°F (-20°C to 70°C)
Humidity Rating: 85% RH, non-condensing
Protection Category: NEMA 4X indoors only, IP65
Unit Dimensions: Panel Cutout: 5.35 (136mm)W x 3.78 (96mm)H
Shipping Weight: NXD410: Approx. 1.0 lbs. (.45 kg)
NXTSD407 Touchscreen Interface:
Supply Voltage: 24 VDC @ 0.65A
Power Consumption: 15.6 VA
Temperature Rating:
Operating: 32°F to 122°F (0°C to 50°C)
Storage: -4°F to 158°F (-20°C to 70°C)
Humidity Rating: 85% RH, non-condensing
Protection Category: NEMA 4X indoors only, IP66 (front)
Unit Dimensions: Panel Cutout: 7.36 (187mm)L x 5.79 (147mm)H
Shipping Weight: Approx. 2.2 lbs. (1 kg)
NXTSD413 Touchscreen Interface:
Supply Voltage: 24 VDC @ 1.15A
Power Consumption: 27.6 VA
Temperature Rating:
Operating: 32°F to 122°F (0°C to 50°C)
Storage: -4°F to 158°F (-20°C to 70°C)
Humidity Rating: 85% RH, non-condensing

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Protection Category: NEMA4X indoors only, IP66 (front)
Unit Dimensions: Panel Cutout: 13.22 (336mm)L x 10.51 (267mm)H
Shipping Weight: Approx. 6.2 lbs. (2.8 kg)
NXCESO2 Oxygen Probe:
Supply Voltage: 24 VDC ± 10%
Power Consumption: 27 VA, 13 VA (steady state)
Temperature Rating:
Operating: 32°F to 140°F (0°C to 60°C)
Storage: -4°F to 158°F (-20°C to 70°C)
Humidity Rating: 85% RH, non-condensing
Protection Category: NEMA 1 (IP01)
Unit Dimension: see Figure 6 on page 23
Shipping Weight:
NXCES02-8: 8.1 lbs (3.67 kg)
NXCES02-16: 9.2 lbs (4.17kg)
NXCES02-30: 11.4 lbs (5.17kg)
Servos:
Supply Voltage:
FX04: 24 VDC ±10%
FX20: 24 VDC ±10%
FX50: 24 VDC ±10%
Power Consumption (Peak):
FX04: 5 VA Nominal, 7.5 VA peak
FX20: 15 VA nominal, 35 VA peak
FX50: 20 VA nominal, 38 VA peak
Temperature Rating:
Operating: -4°F to 140°F (-20°C to 60°C)
Storage: -4°F to 158°F (-20°C to 70°C)
Humidity Rating: 85% RH, non-condensing
Protection Rating: NEMA 4, IP65
Torque Rating:
FX04: 4 Nm, 3.0 ft./lb.
FX20: 20 Nm, 15 ft./lb.
FX50: 50 Nm, 37 ft./lb.
Rotational Span: 1 degree to 99.9 degrees
Actuating time of 90 degree rotation: min = 30 seconds, max = 120 seconds
Accuracy: 0.1 degree
Shipping Weight:
FX04: Approx. 2.27 lbs (1.1 kg)
FX20: Approx. 5.43 lbs (2.5 kg)
FX50:Approx. 6.10 lbs (2.77 kg)

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Temperature Sensors:
Temperature Measurement Range:
FXIATS-140: -40°F to 140°F (-40°C to 60°C) - see FXIATS-1 bulletin for technical info
TS350-X: 32°F to 350°F (0°C to 176°C)
TS752-X: 32°F to 752°F (0°C to 400°C)
RTD Type: Platinum, 100 ohms ± 0.1% @32°F (0°C)
Temperature Coefficient:.00385 ohms/°C
Output: 4-20 mA, linear with temperature
Operating Temperature Range: -13°F to 185°F (-25°C to 85°C)
Accuracy: ± 0.75% of span
Thermowell Case: 300 Series stainless steel
Mechanical Fittings: 1/2”-14 NPT
Pressure Sensors:
Pressure Measurement Range: 0 to 15, -14.7 to 25, 0 to 30, 0 to 200, 0 to 300 PSI
Excitation Voltage: 9-30Vdc (supplied by PPC4000 control)
Accuracy: ± 0.25% Full Scale (at 25°C)
Output: 4-20 mA, linear with pressure
Maximum Over Pressure: 200% of full scale
Maximum Burst Pressure: 800% of full scale
Operating Temperature Range: -40°F to 185°F (-40°C to 85°C)
Fitting: 1/4”NPT Male
Electrical: 1/2”Conduit and Terminal Strip
APPROVALS
Underwriter’s Laboratories Inc.:
File MJAT.MH10808, UL353
• LISTED SECTION OF A FUELAIR RATIO SYSTEM
File MJAT2.MH10808, UL353 - COMPONENT
File MJAT7.MH10808, CSA-C22.2 No 24
• LISTED SECTION OF A FUELAIR RATIO SYSTEM
File MJAT8.MH10808, CSA-C22.2 No 24
Factory Mutual:
FM Class 7610
WARNING: This equipment generates and can radiate radio frequency energy, and if
not installed and used in accordance with the instruction manual may cause interfer-
ence to radio communications. It has been tested and found to comply with the limits for
a Class A computing device pursuant to Subpart J of part 15 of FCC Rules, which are
designed to provide reasonable protection against such interference when operated in a
commercial environment. Operation of this equipment in a residential area is likely to
cause interference in which case the user, at his own expense, will be required to take
whatever measures which may be required to correct the interference.

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PART NUMBERS AND APPROVALS
Table 1: Agency Approvals
X = CERTIFICATION IN HAND
Fireye Part Number
Control
PPC4000 XXX
PPC4000-230V
User Interface
NXD410 X
NXTSD407 X
NXTSD413 X
Servos
FX04, FX04-1 XXX
FX20, FX20-1 XXX
FX50, FX50-1 XXX
Oxygen Probe
NXCESO2-8
NXCESO2-16
NXCESO2-30
Transducers
BLPS-15 XX
BLPS-25 XX
BLPS-30 XX
BLPS-200 XX
BLPS-300 XX
TS350-2, -4, -8 XX
TS-752-2, -4, -8 XX
FXIATS-140 X
Flame Safeguard
YB110UV XXXXXX
YB110UVSC XXXXXX
YB110IR XXXXXX
YB110FR XXXXXX
YB110DC XXXXXX

NOTE: The PPC4000 is compatible and agency approved with existing E110 Flame Monitor systems

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ORDERING INFORMATION
Control
PPC4000 Parallel positioning system, 120 VAC input. Used with flame safeguard control.
PPC4000-230V Parallel positioning system, 230 VAC input. Used with flame safeguard control.
NXCESVFD Plug-in assembly provides variable frequency (VFD/VSD) capability
60-2926 Enclosure, 12.5” x 10.5” x 6.5”, UL listed, fitted for PPC4000
129-190 Kit, fan replacement
Display
NXD410 User Interface with keypad, 24 VDC operation, 4 line back lit LCD display, panel mount only, includes mounting brack-
ets.
59-562-2 Cable assembly, 10 feet length, for interfacing NXD410 to PPC4000
NXTSD407/NXTSD413 7” TFT or 13.3” wide color Touchscreen display, 800x480 or 1280x800 pixel (WVGA) resolution, LED backlight, 24VDC,
includes mounting brackets
129-196-2 Replacement cable kit. Contains one 12’ communications, one 12’ power cable, and DB9 connector plug.
Servos
FX04 Servo motor, 24 VDC operation, 4Nm, 3 lb.-ft. torque, without connectors, accepts 1/2 inch NPT fitting, minimum travel
time of 30 seconds for 90°
FX04-1 Servo motor, 24 VDC operation, 4Nm, 3 lb.-ft. torque, with connectors, minimum travel time of 30 seconds for 90°
FX20 Servo motor, 24 VDC operation, 20Nm, 15 lb.-ft. torque, without connectors, accepts
1/2 inch NPT fitting, minimum travel time of 30 seconds for 90°
FX20-1 Servo motor, 24 VDC operation, 20Nm, 15 lb.-ft. torque, with connectors, minimum travel time of 30 seconds for 90°
FX50 Servo motor, 24 VDC operation, 50Nm, 37 lb.-ft. torque, without connectors, accepts
1/2 inch NPT fitting, minimum travel time of 30 seconds for 90°
FX50-1 Servo motor, 24 VDC operation, 50Nm, 37 lb.-ft. torque, with connectors, minimum travel time of 30 seconds for 90°
Servo Cables
59-565-6 Cordset, 6 feet, 1/2” NPT connectors on both ends, PVC jacket, temperature rating -40°C to 105°C, meets NEMA
1,3,4,6P and IEC67
59-565-40 Cordset, 40 feet, 1/2” NPT connectors on both ends, PVC jacket, temperature rating -40°C to 105°C, meets NEMA
1,3,4,6P and IEC67
Connector Kit
129-192 Connector, field wireable. Used for FX04-1, FX20-1, FX50-1 servos with connectors. Use cable 59-565
129-194 Male quick disconnect to convert non connector type FX series servos.
59-565 Cable, 1 twisted pair, 2 power wires, suitable for servo and Oxygen probe hookup.
O2 Probe
NXCESO2-8, -16, -30 O2 probe assembly, insertion length is 8, 16, 30 inches
NXCESO2-8,-16,- 30-KIT O2 probe assembly kit includes NXCESO2 probe, 35-381-2 flange and FXIATS-140 sensor
NXCES02P42, -1 Cartridge, probe replacement (model -1 for engineering code 00 only)
35-381-2 Flange, O2 probe mounting
129-189 Cover, mounting flange
Pressure Transducers
BLPS-15, -25, -30 Pressure transducer, 0 to15 PSI (0 to 1030 mb), -14.7 to 25 PSI (-1013 to 1720 mb), 0 to 30 PSI (0 to 2070 mb), 4-20
mA output linear with pressure. ¼” NPTF mounting. Screw terminal connections and conduit adapter cover.
BLPS-200 Pressure transducer, 0 to 200PSI (0 to 13.8 Bar), 4-20 mA output linear with pressure. ¼” NPTF mounting. Screw
terminal connections and conduit adapter cover.
BLPS-300 Pressure transducer, 0 to 300 PSI (0 to 20.7 Bar), 4-20 mA output linear with pressure. ¼” NPTF mounting. Screw
terminal connections and conduit adapter cover.
Temperature Transducers
TS350-2, -4, -8 Temperature sensor, Range 32°F to 350°F (0°C to 176°C), 4-20 mA output, linear with temperature. Insertion length is
2, 4, 8 inches. Stainless steel thermowell included.
TS-752-2, -4, -8 Temperature sensor, Range 32°F to 752°F (0°C to 400°C), 4-20 mA output, linear with temperature. Insertion length is
2, 4, 8 inches. Stainless steel thermowell included.
FXIATS-140 Ambient air temperature transmitter, -40°F to 140°F, 4-20mA output, 7 to 40VDC, NEMA enclosure

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INSTALLATION PROCEDURE
1) A UL listed fuel/air ratio system is comprised of the following items.
a.) PPC4000, fuel/air ratio controller
b.) 60-2926, enclosure
c.) NXD410, user interface
d.) FX series servos
2) Wiring must comply with all applicable codes, ordinances and regulations.
3) Wiring must comply with NEC Class 1 (Line Voltage) wiring.
4) To minimize interference from radio frequency energy generated by the PPC4000 control, it is
necessary that all control wiring be placed in conduit. It is recommended that all low voltage sig-
nal wiring, i.e. servos, O2 probe, pressure/temperature transducer be placed in a separate conduit
from line voltage wiring, i.e. relay outputs, line voltage digital inputs, profile select, flame safe-
guard interface signals.
5) Limit switches, interlocks and relay outputs must be rated to simultaneously carry and break
current to the ignition transformer, pilot valve(s) and main fuel valve(s) of the flame safeguard
control.
6) Recommended wire routing of lead wires:
a) Do not run high voltage ignition transformer wires in the same conduit with any other wires.
b) Do not route analog transducer cables, display communication cables, modbus cables or servo
motor cable in conduit with line voltage circuits. Use separate conduit where necessary.
7) Maximum wire lengths:
a) Terminal inputs (Operating limits, interlocks, valves, etc.): 200 feet. (61 meters).
b) Line voltage inputs: 500 feet (152 meters) to a normally open remote reset push-button, but
should remain within sight and sound of the burner.
c) Modbus communications RS-485: 1000 ft (305 meters) for baud rates of 19.2kbps & below.
d) Servo & O2 probe: 200 feet (61 meters)
e) Sensors: 100 feet (30 meters)
A good ground system should be provided to minimize the effects of AC quality problems. A prop-
erly designed ground system meeting all the safety requirements will ensure that any AC voltage
quality problems, such as spikes, surges and impulses have a low impedance path to ground. A low
impedance path to ground is required to ensure that large currents involved with any surge voltages
will follow the desired path in preferences to alternative paths where extensive damage to equipment
may occur.
NXD410 User Interface
The NXD410 is a panel mounted device. The device includes a gasket that must be properly seated
to assure NEMA 4X (IP65) rating. Packed with every NXD410 device is a gasket and remote mount-
ing bracket kit (not sold separately) containing four bracket assemblies as shown.
Replacement Fuses
23-227, F1 Main input protection
fuse, 5A, 250VAC, radial can
23-197, F3 Safety relay protection
fuse, 10A, 250VAC, radial can

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FIGURE 1. Mounting Kit
The bracket assembly mounts from the rear of the display with the fastening nut against the backside
of the panel. Use the following dimensions for the panel cutout.
FIGURE 2. Panel Cutout
Use Fireye cable, part number 59-562-2 to connect from the NXD410 to the PPC4000 control. The
DA15-FM connector plugs into the PLC port located on the backside of the NXD410. The cable dis-
tance from the PPC4000 to the NXD410 is limited to 10 feet (3 meters) wire run.
FIGURE 3. NXD410 Rear View
The bottom edge of the display must be mounted at least two inches from any cabinet door edge to
allow sufficient clearance for the 59-562-2 cable.
Gasket
Assembly
Completed
Bracket
Fastening
Nut
Fastening
Screw
Peel paper from
gasket surface
Bracket mounting
locations (4 places)
PLC Port
3.78”
(96mm)
5.35”
(136mm)
59-562-2
Insert
Here
Observe
Polarity

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P15
P13
P5
P4
P3
P5
STATUS/ALARM
SD ACTIVITY
P15
1. TBD
2. HIGH
3. LOW
4. AUTO
5. P4
6. P3
7. P2
8. P1
P4
1. ALARM IN
2. ALARM OUT
3. OCRC IN
4. OCRC OUT
EARTH
P3
L1 - LINE IN
L2 - NEUTRAL
10. KS In
9. P
8. TBD
7. TBD
6. TBD
5. TBD
4. TBD
3. AUX
2. 8
1. D
P13
1. DI 10
2. DI 9
3. DI 8
4. DI 7
5. DI 6
6. DI 5
7. DI 4
8. DI 3
9. DI 2
10. DI 1
11. TBD
12. TBD

13

P13
P15
P4
P3
P11
P14
P2
P11
P12
P12
1. mbus A
2. mbus B
3. seq A
4. seq B
5. servo A
6. servo B
7. dis TX,ye
8. dis TY,bl
9. dis Rb,br
10. dis Ra,or
11. O2 A
12. O2 B
1. 0
2. 24 vdc
3. 24 vdc
4. 0
5. ANA0
6. SENS 5
7. SENS 4
8. SENS 3 (AUX 2)
9. SENS 2 (AUX 1)
10.SENS 1 (PCV)
11. 0
P3
L1 - LINE IN
L2 - NEUTRAL
EARTH
P13
1. DI 10
2. DI 9
3. DI 8
4. DI 7
5. DI 6
6. DI 5
7. DI 4
8. DI 3
9. DI 2
10. DI 1
11.
12.
123465
789101112
P14 top
P14 bottom
P14
1. encoder (2)
2. encoder (1)
3. 4-20 in (2)
4. 4-20 in (1)
5. 4-20 out (2)
6. 4-20 out (1)
P15
1. TBD
2. HIGH
3. LOW
4. AUTO
5. P4
6. P3
7. P2
8. P1
P4
1. ALARM IN
2. ALARM OUT
3. OCRC IN
4. OCRC OUT
Connect all Drain wires here
P2
1. 24 vdc
2. 24 vdc Servos
3. 24 vdc Servos
4. 0 v
5. 0 v
6. 0 v
7-12 common
pin

14

PPC4000 INSTALLATION
Install the PPC4000 control where the relative humidity never reaches the saturation point. The
Nexus PPC4000 system is designed to operate in a maximum 85% relative humidity continuous,
non-condensing environment. Do not install the PPC4000 system where it can be subjected to vibra-
tion in excess of 0.5G continuous maximum vibration. The PPC4000 system is not a weather tight
enclosure. The standard vertical position is recommended. Allow at least one inch clearance around
the control for service and installation.
Refer to Figure 4 for mounting dimensions.
FIGURE 4. Mounting Dimensions
7.56”
192mm
4.31”
109.5mm
.38”
9.5mm
5.06”
128.5mm
.38”
9.5mm
.25”
6.4mm
8.06”
204.7mm
.25”
6.4mm
TAP FOR 8-32 SCREW
BASE PLATE OUT LINE

15

The PPC4000 is mounted to the cabinet back plate using 4 X #8-32 screws. Following the mounting
dimensions shown in Figure 4, drill and tap 4 mounting holes. Firmly screw the control to the cabinet
back plate.
WIRING CONNECTIONS
Terminal Type Description Rating/wiring
P3.1 L1 Line Voltage Supply 120/230 VAC (+10%, -15%) 50/60 Hz
P3.2 L2/N Line Voltage Common
EARTH (stud) Protective Earth Chassis ground connection
P4.1 Input Alarm Relay Input Voltage free contacts
P4.2 Output Alarm Relay Output Voltage free contacts, 3A 250VAC
P4.3 Input Operating Control Input Connect to recycle limits In
P4.4 Output Operating Control Output Connect to recycle limits Out, 16A
250VAC
P2.1 Power O2 Probe & User Interface Power 24 VDC, 59-562 - RED
P2.2 Power Servo Power, uC controlled 24 VDC, 59-565 - RED
P2.3 Power Servo Power, uC controlled 24 VDC, 59-565 - RED
P2.4 Common O2, User Interface, Servo VDC Return 0 VDC, 59-562 - BLACK
P2.5 Common O2, User Interface, Servo VDC Return 0 VDC, 59-565 - BLACK
P2.6 Common O2, User Interface, Servo VDC Return 0 VDC, 59-565 - BLACK
P11.1 Common 0 VDC VDC Return
P11.2 Power Temp/Pressure Source Voltage 24 VDC Nominal (class 2)
P11.3 Power Temp/Pressure Source Voltage 24 VDC Nominal (class 2)
P11.4 Common 0 VDC VDC Return
P11.5 Output Analog Output 4-20mA output
P11.6 Input SENS 5 Sensor Analog Input
See Table 2 for sensor type, range
and settings
P11.7 Input SENS 4 Sensor Analog Input
P11.8 Input SENS 3 (AUX2) Sensor Analog Input
P11.9 Input SENS 2 (AUX1) Sensor Analog Input
P11.10 Input SENS 1 (PCV) Sensor Analog Input
P11.11 Common 0 VDC VDC Return
P12.1 Modbus-RTU A
P12.2 Modbus-RTU B
P12.3 SEQUENCING A
P12.4 SEQUENCING B
P12.5 Servo Comms A1 59-565, ORANGE
P12.6 Servo Comms B1 59-565, BROWN
P12.7 User Interface, Tx 59-562, YELLOW
P12.8 User Interface, Ty 59-562,BLUE
P12.9 User Interface, Rb 59-562, BROWN
P12.10 User Interface, Ra 59-562, ORANGE
P12.11 O2Comms A1 59-565, ORANGE
P12.12 O2Comms B1 59-565, BROWN

16

Terminal Type Description Rating/wiring
P13.1 D1 10 Digital Input #10 120/230 VAC @ 1mA
P13.2 D1 9 Digital Input #9 120/230 VAC @ 1mA
P13.3 D1 8 Digital Input #8 120/230 VAC @ 1mA
P13.4 D1 7 Digital Input #7 120/230 VAC @ 1mA
P13.5 D1 6 Digital Input #6 120/230 VAC @ 1mA
P13.6 D1 5 Digital Input #5 120/230 VAC @ 1mA
P13.7 D1 4 Digital Input #4 120/230 VAC @ 1mA
P13.8 D1 3 Digital Input #3 120/230 VAC @ 1mA
P13.9 D1 2 Digital Input #2 120/230 VAC @ 1mA
P13.10 D1 1 Digital Input #1 120/230 VAC @ 1mA
P13.11 TBD Reserve 120/230 VAC @ 1mA
P13.12 TBD Reserve 120/230 VAC @ 1mA
P15.1 TBD 120/230 VAC @ 1mA
P15.2 Input HIGH, FSG High Purge Output 120/230 VAC @ 1mA
P15.3 Input LOW, FSG Low Fire Start 120/230 VAC @ 1mA
P15.4 Input AUTO, FSG Modulation Mode 120/230 VAC @ 1mA
P15.5 Input P4, Profile 4 Select 120/230 VAC @ 1mA
P15.6 Input P3, Profile 3 Select 120/230 VAC @ 1mA
P15.7 Input P2, Profile 2 Select 120/230 VAC @ 1mA
P15.8 Input P1, Profile 1 Select 120/230 VAC @ 1mA
P5.1 Output To FSG Low Fire Input (D) 120/230 VAC, 8A 250VAC
P5.2 Output To FSG Open Damper Input (8) 120/230 VAC, 8A 250VAC
P5.3 Output Aux Relay 1 120/230 VAC, 8A 250VAC
P5.4 Output Reserve
P5.5 Output Reserve
P5.6 Output Reserve
P5.7 Output Reserve
P5.8 Output Reserve
P5.9 Output Safety Relay Output (P) 120/230 VAC, connect to non-recycle
limits
P5.10 Output Safety Relay Input 120/230 VAC, connect to non-recycle
limits
P14.1 Encoder Input (2)
P14.2 Encoder Input (1)
P14.3 4-20 mA IN (2) VFD (2) feedback
P14.4 4-20 mA IN (1) VFD (1) feedback
P14.5 4-20 mA OUT (2) VFD (2) drive
P14.6 4-20 mA OUT (1) VFD (1) drive
P14.7 - P14.12 Common Signal return

17

PPC4000 MOUNTING AND WIRING
As a convenience, the PPC4000 is equipped with de-pluggable type terminal blocks. It is recom-
mended the PPC4000 be wired with the terminal blocks inserted into the control as shipped.
Following the wiring connections table above, make all electrical connections in accordance with the
application requirements. The suggested order of wiring is as follows:
1. Power inputs, L1, L2, Earth (AWG 18, 300 vac) P3.1, P3.2
2. NXD410 user interface using Fireye cable 59-562-2 P12.7-P12.10; P2.1, P2.4
3. Servo motors P2.2, P2.3, P2.5, P2.6, P12.5, P12.6, P12.11, P12.12
4. Alarm relay contacts if required (AWG 16-18, 300 vac)
5. Digital inputs (AWG 14-16, 300 vac) P13.1 - P13.10
6. Operating control to limit switches and flame safeguard P4.3, P4.4
7. Flame safeguard inputs to PPC4000 (AWG 18, 300 vac) P15.2, P15.3, P15.4
8. Relay outputs to flame safeguard (AWG 14-16, 300 vac) P5.1, P5.2, P5.9, P5.10
9. Profile select inputs (AWG 18, 300 vac) P15.5-P15.8
10.Pressure / Temperature sensors (shielded cable, Belden 9318)
PRESSURE AND TEMPERATURE SENSORS
1. Insure that the range of the selected pressure or temperature sensor is appropriate for the applica-
tion. See Table 2.
Note: A general rule to follow when selecting the sensor range is that the expected value of the
monitored pressure or sensor should fall between 35-75% of the upper range of the sensor. For
example, a steam boiler maintains 15 lbs. pressure, select the BLPS-30 Pressure Sensor, with a 0-
30 PSI range
2. The sensors must be located where the ambient temperature will not exceed the maximum ambi-
ent operating temperature specified for the sensor. Insure that the pressure range programmed on
the PPC4000 Control matches the installed pressure sensor.
3. Vacuum return systems will occassionally pull a positive pressure sensor into a vacuum condition
which will cause a “sensor out of range” fault, requiring a manual reset. The BLPS-25’s range is -
14.7 to 25 PSI and will operate normally should the system go to vacuum. Please note however,
the available set point range is 1.0 PSI to 23.0 PSI in 0.1 PSI increments.
4. Do not mount any of the sensors where they could be used as a footstep.
Installation must be performed by a trained, experienced flame safeguard technician.
CAUTION: Ensure that electric power is turned off. Refer to SN-100 for
recommended grounding techniques.
Be aware that power to some interlocks (operating controls, air flow
switches, modulating circuits, etc.) may be derived from sources other
than what is controlling the PPC4000.

18

Table 2: SENSOR RANGE and SETTINGS
MOUNTING PRESSURE SENSORS
1) The steam pressure sensors (BLPS-15, -25, -30, -200, -300) provide a 1/4” NPT female fitting for
connection to the steam header.
2) Make sure the boiler is shut down and zero steam pressure exists in the boiler vessel.
3) Disconnect power to the boiler controller so the boiler cannot sequence during installation of the
steam pressure sensor.
4) Always mount the steam pressure sensor above the water line of the boiler.
5) Locate the pressure sensors where the ambient temperature will not exceed 185F.
6) Use only a small amount of pipe compound to seal the connection joints. Excess pipe compound
may clog the fitting and prevent proper operation of the sensor.
7) Although the unit can withstand substantial vibration without damage or significant output
effects, it is good practice to mount the pressure sensor where there is minimum vibration.
8) A steam trap (siphon loop) must be connected between the boiler and the pressure sensor to pre-
vent boiler scale and corrosive vapors from affecting the pressure sensor element.
9) Make all pipe connections in accordance with approved standards.
10)When tightening the sensor, apply a wrench to the hex flats located just above the pressure fitting.
DO NOT tighten by using a pipe wrench on the housing. Do not tighten the pressure sensor by
hand.
WARNING: The electro-mechanical high steam limit and/or high hot water
temperature limit MUST REMAIN in the 3-P running interlock circuit.
Part
Number SensorType Set Point Range Cut In Cut Out Mod Range Increment Decrement
0 - 15 PSI 1.0 - 14.0p 0 - 6.0p 0.3 - 6.0p 0.3 - 6.0p 0.1p
0 - 1030m 70m - 950m 0 - 410m 20m - 410m 20m - 410m 10m
-14.7 - 25 PSI 1.0 - 23.0p 0 - 6.0p 0.3 - 6.0p 0.3 - 6.0p 0.1p
-1013 - 1720m 70m - 1500m 0 - 410m 20m - 410m 20m - 410m 10m
0 - 30 PSI 1.0 - 28.0p 0 - 6.0p 0.3 - 6.0p 0.3 - 6.0p 0.1p
0 - 2070m 70m - 1950m 0 - 410m 20m - 410m 20m - 410m 10m
0 - 200 PSI 10 - 190p 0 - 60p 3 - 60p 3 - 60p 1.0p
0 - 13.8B 0.70 - 13.0B 0.0 - 4.1B 0.2 - 4.10B 0.20 - 4.10B .05B
0 - 300 PSI 10 - 280p 0 - 60p 3 - 60p 3 - 60p 1.0p
0 - 20.7B 0.70 - 19.3B 0.0 - 4.1B 0.2B - 4.10B 0.2B - 4.10B .05B
32º - 350ºF 35º - 338ºF 0º - 60ºF 3º - 60ºF 3º - 60ºF 1ºF
0º - 176ºC 4º - 170ºC 0º - 60ºC 3º - 60ºC 3º - 60ºC 1ºC
32º - 752ºF 35º - 725ºF 0º - 60ºF 3º - 60ºF 3º - 60ºF 1ºF
0º - 400ºC 4º - 385ºC 0º - 60ºC 3º - 60ºC 3º - 60ºC 1ºC
BLPS-15
BLPS-30
BLPS-200
BLPS-300
m = millibar, p = psi, B= BAR
Note: 1 PSI = 68.94757 mbar
TS350-X*
TS752-X*
BLPS-25
*Select Length X = -2”, -4” or -8”

19

MOUNTING TEMPERATURE SENSORS
The immersion style temperature sensors have a ½” NPT mounting for the 2", 4", and 8" thermowell
probes, and a ½” conduit fitting for electrical connections.
WIRING PRESSURE AND TEMPERATURE SENSORS
1. All wiring must be in accordance with National Electrical Code and local codes, ordinances, and
regulations.
2. Sensor housing provides connection for 1/2” conduit.
3. The pressure and temperature sensors require 2 conductor, 18 gauge, shielded cable. Power lim-
ited, rated for 300V @105C. Use Belden 9318 or equivalent. The shield should be connected to
the earth ground terminal on the base of the PPC4000 Control. The shield should be taped at the
sensor to avoid unintended contact with the sensor housing.
4. All sensor wiring should be in a separate conduit. DO NOT install sensor wiring in any conduit or
junction boxes with high voltage wiring.
5. Maximum wiring distance for sensor wiring is 100 feet.
WARNING: Location of the temperature sensor to monitor boiler water
temperature of a steam boiler is critical. The sensor should be mounted
where it is always exposed to the circulation of the boiler water, not too
close to a hot or cold inlet or steam coil. Consult the boilermanufacturer
for guidance for its location or refer to Bulletin BLZPTS-1 for proper
location and wiring of this temperature sensor.
CAUTION: Disconnect power supply from the PPC4000 Control before con-
necting wires to prevent electrical shock and equipment damage.
TS350/TS752 BLPS SENS1 SENS2 SENS3 SENS4 SENS5
1+ +EXC P11.2 P11.2 P11.3 - -
2- -COM P11.10 P11.9 P11.8 - -
FXIATS-140
1+ - - - P11.3 P11.3 P11.3
2- - - - P11.8 P11.7 P11.6
BLPS
For 4-20 mA output, use + EXC
and - COM terminals
TS350 / TS752
For 4-20 mA output, use terminals
1 (+) and 2 (-)
FXIATS-140

20

SERVO MOTOR SETUPAND WIRING
The PPC4000 must have a “master servo” in order to generate a valid modulation curve. In a typical
setup, without VFD, the AIR servo is selected as the master servo; if a VFD is used, the first fuel
servo is then selected as the master servo. The modulation rate, low fire to high fire, and therefore the
servo(s) positions are derived from the master servo commissioning values. Each servo is equipped
with an internal rotary switch that is used to select its communication address. The address range is 1
to 10. It does not matter what each servo address is but it is required that each servo have its own
unique address.
The servo addresses are learned during power on.
It is recommended that servos be wired to the PPC4000 in a multi-drop configuration. That is,
cabling traverses from the control to the first servo, to the second servo, to the third servo, etc. Servo
types FX04-1, FX20-1 and FX50-1 are pre-wired to connectors located on the body of the servo.
Cordsets having female connectors on both ends are available in 6 and 40 foot lengths. Field wire-
able connectors and cable are also available. See ORDERING INFORMATION for part numbers.
Servo types FX04, FX20 and FX50 allow the installation of conduit fittings and the user to wire
directly to the servos using the terminal strips located inside the servo. Always connect the ground
first to eliminate any ESD (electro-static discharge) potential.
.
Servo Wiring Diagram, internal
Refer to bulletins NEX-3004, NEX-3020 and NEX-3050 for operational details, setting the
addresses and servo movement.
FX04-1
UNIT ADDRESS MANUAL MOVEMENT
FX20-1
UNIT
ADDRESS
MANUAL
MOVEMENT
CCW
CCW
CW CW
11 44 2255
WARNING-DONOTUSETHEMANUALMOVEMENTSWITCHESONTHESERVOMOTORSDURING
AUTOMATICOPERATIONORTHEFIRINGCYCLEOFTHEBURNER. USEOFTHEMANUALMOVEMENT
SWITCHESOPERATESTHESERVOMOTORSINDEPENDENTOFTHEPPC4000CONTROLANDCOULDRESULT
INANOFF-RATIOCONDITIONIFOPERATEDDURINGAUTOMATICOPERATIONORTHEFIRINGCYCLE
PIN 1 BLACK
RS-485 B(-)
PIN 2 BLUE
24 VDC RETURN
PIN 3 GREEN/YELLOW
EARTH GROUND
PIN 4 BROWN
RS-485 A(+)
PIN 5 WHITE
24 VDC SUPPLY
To P12.5
To P2.4, P2.5 or P2.6
To P12.6
To P2.2 or P2.3