Fireye PPC6000 Series Operating instructions

P P C
PROGRAMMING
GUIDE
FOR
PPC6000
SERIES
DESCRIPTION:
This document supplies the commissioning engineer with sufficient information to make
appropriate setup and changes to the commissioning of the PPC6000.
NOTE: For additional information on Installation and Wiring information, please
refer to the complete installation manual - Fireye bulletin PPC-6001
For ease of navigation (see section 1.3.1), the symbols below will be used throughout
the Commissioning Process in this manual to indicate the correct application for each
commissioning OPTION, for use by the Commissioning Personnel.
A convenient check box has been added to the beginning of the symbols so that the
Commissioning Personnel can mark each appropriate option as it is completed.
SYMBOL MEANS:
Commissioning Personnel MUST execute this option
For Customers with O2 TRIM option, Commissioning
Personnel MUST ALSO execute this option
For Customers with VFD options, Commissioning Personnel
MUST ALSO execute this option
NXPG-6001
APRIL 8, 2013
PPC
O 2
V F D
After each appropriate option parameter is
complete, CHECK THE BOX!

2
The following items are covered in this manual:
1 COMMISSIONING THE CONTROL........................................................................................................ 5
1.1 General .....................................................................................................................................................5
1.2 Commissioning data ................................................................................................................................6
1.2.1 Option parameters.........................................................................................................................6
1.2.2 Setpoints........................................................................................................................................6
1.3 The Commissioning process....................................................................................................................6
1.3.1 Navigation.....................................................................................................................................6
1.4 Using option set mode..............................................................................................................................7
1.4.1 Option parameter list.....................................................................................................................8
Option 00.1 - Site passcode (0 - 999) LV3................................................................................................8
Option 00.2 - Serial communications control address (0 - 15) LV3..........................................................8
Option 00.3 - Reset hours run (0 - 1) LV3 ................................................................................................8
Option 00.4 – User program select (0 / 1) LV1.........................................................................................8
Option 00.5 – Language select (0 / 1) LV1 ...............................................................................................9
Option 00.6 – Remote / Local Control (0 - 2) LV3 ...................................................................................9
Option 01.0 – Power Up Option (0 - 30) LV3...........................................................................................9
Option 01.1 – Keyboard Auto/Manual enable (0 - 1) LV3 [Engineer’s Key 33].....................................9
Option 01.2 – Fault Mute Input enable (0 - 2) LV3 ................................................................................10
Option 02.x – Drive Name LV3 ..............................................................................................................11
Option 03.x – Drive Serial Number LV3 ................................................................................................12
Option 04.x – Drive Usage Information LV3..........................................................................................13
Option 05.x – Drive Options LV3 ...........................................................................................................13
Options 06.1-06.4 – Profile Naming LV3 ...............................................................................................14
Options 07.x, 08.x– RESERVED .............................................................................................................14
Option 09.0 - Inverter control accuracy (0 / 1) LV3................................................................................14
Option 09.1 - Inverter error tolerance (0 / 1) LV3...................................................................................14
Option 09.2 - Inverter closed loop gain (15 – 125%) LV3......................................................................15
Option 09.3 - Inverter stop time (0 – 100 seconds) LV3.........................................................................15
Option 09.4 - Inverter acceleration time (0 –60 seconds recommended) LV3........................................15
Option 09.5 – VFD1 Speed Encoder Scaler (255 - 999) LV3.................................................................15
Option 09.6 – VFD2 Speed Encoder Scaler (255 - 999) LV3.................................................................16
Option 09.7- RESERVED ........................................................................................................................16
Option 09.8- RESERVED ........................................................................................................................16
Option 09.9- RESERVED ........................................................................................................................16
Option 14.0 – Primary Fault Relay (0-8) LV3.........................................................................................16
Option 14.1 – Limit Relay (0-8) LV3......................................................................................................17
Option 14.2 – Oxygen and Flue Temperature Limit Relay (0-8) LV3....................................................17
Option 15.0 - Modulation sensor input type (0 - 1) LV3.........................................................................18
Option 15.1 – Modulation input decimal places (0 to 2) LV2.................................................................19
Option 15.2 – Modulation input zero value (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3..............................19
Option 15.3 – Modulation input span value (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3 .............................19
Option 15.4 – Setpoint control units (0 – 3) LV3....................................................................................20
Option 15.5 - Boiler high safety limit (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3.......................................20
Option 15.6 – Modulation Time (0 – 120 seconds)*...............................................................................20
Option 15.7 – Bumpless Transfer (0 or 1)* LV3.....................................................................................20
Option 15.8 – Low before Off (0 or 1)* LV3..........................................................................................21
Option 16.1 – Go back to pilot (0-15) LV3.............................................................................................21
Option 16.2 – Allow profile swap (0-16) LV3........................................................................................22

3
Option 18.1 to 18.4 – Low Voltage Fail-safe Alarm / Lockout Inputs (0 – 360) LV3. .......................... 23
Option 19.1 to 19.4 – Fail-safe Alarm / Lockout Display Messages LV3.............................................. 24
Option 20.0 – Set-point Select input (0 - 16) LV3.................................................................................. 25
Option 20.1 – Boiler Shutdown input (0 - 16). LV3............................................................................... 25
Option 20.2 – Low Fire Hold input (0 - 16). LV3 .................................................................................. 25
Option 20.3 – Oxygen Trim Disable input (0 - 16). LV3 ....................................................................... 25
Option 20.4 – Ignition Wait input (0 - 16).............................................................................................. 26
Option 20.5 – Purge Hold input (0 - 16). LV3........................................................................................ 26
Option 20.6 – Purge Time Start input (0 - 16). LV3............................................................................... 26
Option 20.7 – Analog Input 5 function (0 - 2). LV3............................................................................... 26
Option 21.0 – PID (setpoint) 1 enable (0 - 1) LV1 ................................................................................. 26
Option 21.1 – Set-point 1 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1.................................. 26
Option 21.2 –Set-point 1 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ........................... 27
Option 21.3 – Set-point 1 integral time (0 – 99.9 minutes) LV1 ........................................................... 27
Option 21.4 – Set-point 1 derivative time (0 – 999 seconds) LV1 ......................................................... 27
Option 21.5 - Setpoint 1 control limit type (0 - 2) LV3.......................................................................... 27
Option 21.6 - Setpoint 1 low limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 .................... 28
Option 21.7 - Setpoint 1 high limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ................... 28
Option 21.8 – Remote Setpoint 1 zero (4ma) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1................ 28
Option 21.9 – Remote Setpoint 1 span (20mA) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ............ 28
Option 22.0 – PID (set-point) 2 enable (0 - 1) LV1................................................................................ 28
Option 22.1 – Set-point 2 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1.................................. 28
Option 22.2 – Set-point 2 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 .......................... 28
Option 22.3 – Set-point 2 integral term (0 – 999 seconds) LV1............................................................ 28
Option 22.4 – Set-point 2 derivative term (0 - 100) LV1 ....................................................................... 28
Option 22.5 - Setpoint 2 control limit type (0 - 2) LV3.......................................................................... 29
Option 22.6 - Setpoint 2 low limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 .................... 29
Option 22.7 - Setpoint 2 high limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ................... 29
Option 22.8 – Remote Setpoint 2 zero (4mA) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1............... 29
Option 22.9 – Remote Setpoint 2 span (20mA) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ............ 29
Option 23.0 – Warming Enable (0 or 1) LV1 ......................................................................................... 29
Option 23.1 – Warming Limit (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 ................................................ 29
Option 23.2 – Warming Time (0 to 999 minutes) LV1 .......................................................................... 30
Options 24.x - Sequencing: ................................................................................................................................. 30
Option 24.0 Sequence Slaves (number of boilers) (0-3) LV3................................................................. 31
Option 24.1 -24.3 Priority Number(s) LV3 ............................................................................................ 31
Option 24.4 - Reserved............................................................................................................................ 31
Option 24.5 – Lead (master) Boiler Select Method LV3....................................................................... 32
Option 24.6 - Lag (slave) On Rate (0-100%) LV3 ................................................................................. 32
Option 24.7 - Lag (slave) On Delay (0-999 minutes) LV3..................................................................... 32
Option 24.8 - Lag (slave) Off Rate (0-100%) LV3................................................................................. 32
Option 24.9 - Lag (slave) Off Delay (0-999 minutes) LV3 .................................................................... 32
Option 30.0 – Oxygen probe interface serial number LV3..................................................................... 33
Option 30.4 – Flue and inlet sensor temperature units (0 – 1) LV3 ........................................................ 33
Option 30.5 - Oxygen input function (0/1) LV3...................................................................................... 34
Option 30.6 - Oxygen probe calibrate enable (0 – 2) LV3 ...................................................................... 34
Option 30.7 - Boiler transport delay (5 – 60 seconds) LV3 .................................................................... 34
Option 30.8 - Reset oxygen trim profile (0/1) LV3. ................................................................................ 35
Option 30.9 – Automatic trim commissioning (0 / 1) LV3..................................................................... 35
Option 31.0 - Limit Modulation Range (0 to 2) LV3 .............................................................................. 35
Options 31.1 to 31.4 - Trim Type for profiles 1 to 4 (0 to 2) LV3 .......................................................... 36
Option 32.0 - Trim limit default (0/1) LV3 ............................................................................................. 36

4
Options 32.1 to 32.4 - Trim limits (0.0 – 25.0) LV3................................................................................36
Options 33.1 to 33.4 - Trim integral gain (0.0 – 99.9%) LV3..................................................................37
Option 34.0 - Trim proportional gain default (0/1) LV3..........................................................................37
Options 34.1 to 34.4 - Trim proportional gain (0.0 – 99.9%) LV3..........................................................37
Option 34.5 - Calculating and entering the flow values manually – optional LV3.................................37
Option 35.0 – Inlet temperature sensor serial number LV3.....................................................................41
Options 35.1 to 35.4-Hydrocarbon ratios of each fuel respectively (0.00 – 9.99) LV3 ..........................41
Options 35.5 to 35.8-Calorific values of fuels/profiles 1 to 4 respectively (0.0 – 99.9) LV3 .................41
Option 35.9 - Boiler radiated heat loss (0.0 – 9.9%) LV3.......................................................................42
Option 36.0 - Flue temperature alarm select (0/1) LV3 ...........................................................................42
Options 36.1 to 36.4 - Flue temperature low alarm values (0 – 999) LV3...............................................42
Options 37.1 to 37.4 - Flue temperature high alarm values (0 – 999) LV3 .............................................42
Option 38.0 - Oxygen alarm select (0 – 2) LV3.......................................................................................43
Options 38.1 to 38.4 - Oxygen low alarm values at low fire (0.0 – 99.9%) LV3....................................43
Options 39.1 to 39.4 - Oxygen low alarm values at high fire (0.0 – 99.9%) LV3...................................43
Options 40.1 to 40.4 - Oxygen high alarm values at low fire (0.0 – 99.9%) LV3...................................43
Options 41.1 to 41.4 - Oxygen high alarm values at high fire (0.0 – 99.9%) LV3 ..................................43
Option 42.0 – Second Oxygen probe interface serial number LV3.........................................................44
Option 42.1 – Second Oxygen probe calibration offset value (0 – 999) LV3..........................................44
Option 42.2 – Second Oxygen probe calibration gain value (0 – 999) LV3............................................44
Option 42.3 – Second Oxygen probe calibrate enable (0 – 2) LV3 .........................................................45
Option 42.4 –Oxygen variation probe 1 to probe 2 LV3 .........................................................................45
Option 44.0 - Set real time clock (0/1) LV1............................................................................................45
Option 44.1 – Set Year (00 – 99) LV1 ....................................................................................................45
Option 44.2 – Set Month (1 – 12) LV1 ...................................................................................................45
Option 44.3 – Set Day (1 – 31) LV1 .......................................................................................................45
Option 44.4 – Set Hours (0 - 23) LV1.....................................................................................................45
Option 44.5 – Set Minutes (0 - 59) LV1..................................................................................................45
Option 44.9 – Reset Fault Log (0 - 1) LV3 .............................................................................................45
Option 45.0 - Erase / Restore enable (0 - 1) LV3....................................................................................46
Option 45.1 - Erase command (0 - 5) LV3..............................................................................................46
Option 45.2 - Restore command (0 - 999) LV3.......................................................................................46
1.5 Commission ratio mode.........................................................................................................................47
1.5.1 Description..................................................................................................................................47
1.5.2 Using commission ratio mode.....................................................................................................47
1.5.3 Leaving commission ratio mode .................................................................................................48
1.6 Adjust ratio mode ..................................................................................................................................49
1.6.1 Description..................................................................................................................................49
1.6.2 Entering adjust ratio mode..........................................................................................................49
1.6.3 Using adjust ratio mode ..............................................................................................................50
1.6.4 Leaving adjust ratio mode...........................................................................................................51
1.7 Interrogating the software issue ...........................................................................................................51
2 APPENDIX............................................................................................................................................. 52
2.1 Terminal Designation ............................................................................................................................52
2.2 Typical Wiring Diagram / BurnerLogix..............................................................................................53
2.3 Combustion Profile Setup Guideline....................................................................................................55

5
1 Commissioning the control.
WARNING
1.1 General
If any settings in the control are to be changed, it is necessary to enter a commission mode. Three passcodes
are available for this purpose, shown as LV1 (Level 1), LV2 (Level 2), and LV3 (Level 3) in this manual
Supplier passcode – LV3 – allows entry to all commissioning modes.
Adjust ratio passcode – LV2 -- allows adjustment of some option parameters and entry to adjust ratio
mode.
Site passcode – LV1 -- allows adjustment of some option parameters.
This manual may cover more than one model from the PPC6000 series.
Check for additional information at the end of this chapter.
While the control is operating in commissioning mode or adjust ratio mode
certain safety checks cannot be performed by the control and therefore the
safety of the system operation is the sole responsibility of the
commissioning engineer.
Do not allow fuel to accumulate in the combustion chamber. If fuel is
allowed to enter the chamber for longer than a few seconds without
igniting, an explosive mixture could result.
If a flame failure occurs at any point the control will not attempt a re-start
until the fault is cleared. Before moving to the ignition position to attempt a
re-start the system will perform any selected pre-purge.
3
1
RUN
MODE
SUPPLIER
PASSCODE
LV3
SITE
PASSCODE
LV1
ADJUST
RATIO MODE
LV2
COMMISSION
RATIO MODE
BURNER ON
BURNER OFF
<COM>
OPTION SET
MODE
<MODE>
<COM> <COM>
2

6
PPC
1.2 Commissioning data
1.2.1 Option parameters
The PPC6000 series is configured by programming Option Parameters (memory registers), which describe the
configuration of the burner and the boiler. Option parameters are set and adjusted in Option Set mode, but it
may not be possible to adjust all of them if the burner is on.
1.2.2 Setpoints
Setpoints contain information about required motor positions. There are four profiles (or tables) of setpoints. A
minimum of four positions (P0, P1, P2, and P3) MUST be entered for the PPC6000 to run in automatic.
Profile 1 (Gas)
position ( )
Air position
( )
Profile 2 (Oil)
position( )
Air position( )
2.1 1.9
CLOSE(P0) 1.7 1.9
2.1 88.9
PURGE(P1) 1.7 88.9
24.6 30.6
IGNITION(P2) 10.6 28.7
21.3 25.8
LOW FIRE(P3) 10.6 28.7
76.8 85.6
HIGH FIRE(Px) 50.2 83.5
Up to 24 setpoints may be entered for each profile, including close, purge, and ignition.
New setpoints must be entered in commission ratio mode.
Existing setpoints may be modified in adjust ratio mode or commission ratio mode.
1.3 The Commissioning process.
1.3.1 Navigation.
The symbols below will be used throughout the Commissioning Process in this manual to indicate the correct
application for each commissioning OPTION, for use by the Commissioning Personnel.
A convenient check box has been added to the beginning of the symbols so that the Commissioning
Personnel can mark each appropriate option as it is completed.
SYMBOL MEANS:
Commissioning Personnel MUST execute this option
For Customers with O2 TRIM option, Commissioning Personnel
MUST ALSO execute this option
For Customers with VFD options, Commissioning Personnel MUST
ALSO execute this option
PPC
O 2
V F D
After each appropriate option parameter is complete,
CHECK THE BOX!

7
1.3.1.1 Entering commission ratio mode
To enter commission ratio mode, turn the burner off. Once the burner has completely shut down, press the
key labeled COM and select the supplier passcode value using the UP/DOWN keys. The supplier passcode is
normally 2 sets of three numbers and is entered as shown below.
If the entered passcode is correct, ‘P 0’ will be seen on the display. This represents the closed position
setpoint.
1.3.1.2 Changing from Commission / Adjust Ratio mode to Option Set mode
To enter option set mode, enter commission ratio mode or adjust ratio mode (see sections 1.3.1 or 1.6.2
respectively) and press the key labeled MODE.
1.3.1.3 Changing from option set to Commission / Adjust ratio modes
1.3.1.4 Exiting from commission mode
To exit from any commission mode to run condition, press the key labeled RUN and then ENTER.
e.g.
NOTE: Exiting from “full commissioning” mode at P3 or higher will erase any point above the displayed Px. If
this is undesirable,exit “full commissioning” mode at HIGH FIRE.
1.4 Using option set mode
Use the UP/DOWN keys to select the Option parameter to be adjusted.
Use the Scroll keys to navigate between Option numbers and the Option values.
Use the UP/DOWN keys to change the value of the option parameter. When the correct value is selected
then press the ENTER key to store the new value.
Set or adjust all of the parameters as required by moving between the parameters and adjusting as
detailed above.
COM ENTER
Supplier passcode 1st
set of numbers
Run mode, burner of
f
Run mode
Option set mode
MODE
Commission / Adjust ratio mode Option set mode
MODE Commission ratio / Adjust ratio mode
Option set mode
ENTERRUN
ENTER
Supplier passcode 2nd
set of numbers

8
1.4.1 Option parameter list
CAUTION
Note: Option parameters are marked with LV1, LV2, and LV3, which indicate what level passcode is
required. If, when using the supplier passcode (LV3), it is not possible to adjust the value of an option
parameter, then the burner must be turned off to make the adjustment.
Option 00.1 - Site passcode (0 - 999) LV3
This is a three digit passcode that will allow the site engineer or end-user to enter option set mode and adjust
a limited range of option parameters (those not marked with ‘LV2’ or ' LV3' in this section). This passcode can
be zero, in which case the user only needs to press the COM / ENTER key twice to enter option set mode with
limited access.
Option 00.2 - Serial communications control address (0 - 15) LV3
If the control is to be connected to other equipment via the serial communications interface, it must be given a
unique address using this option parameter. Additionally if more than one control unit is connected on the
CAN bus (for example to share a display), the units must all have unique addresses BEFORE THEY ARE
CONNECTED TO THE SAME CANbus.
Option 00.3 - Reset hours run (0 - 1) LV3
This option parameter allows the HOURS RUN display for all fuels to be reset to zero. To perform a reset, set
this option parameter to 1and leave option set mode. When the burner begins to modulate, the HOURS RUN
display will be reset and the option parameter automatically returns back to 0.
Option 00.4 – User program select (0 / 1) LV1
This parameter may not be available. Where it is available, it allows the user to de-select the Fireye’s standard
modulation program, and select a user program. The user program may be modified using PC software to
change the controls behavior for non-standard applications.
The programmable system only allows access to non-safety related functions such as modulation, enabling /
disabling burner start-up and other similar functions. Only the user program can be modified, and Fireye’s
program can be re-selected at any time by changing this parameter back to zero.
Option 00.4
value
Meaning
0 Run standard manufacturer modulation program. Controls PID, control limits, and
Use extreme care when entering option parameters. Incorrect data entry could
cause a hazardous situation to occur.
It is possible that additional parameters may be present in the unit depending on
the application and/or supplier.

9
some Input / Output settings (see option parameters 20.0 to 29.9)
1 Run user program, if available.
Option 00.5 – Language select (0 / 1) LV1
DEFAULT: 0
This parameter may not be available. Where it is available, it allows the user to change the language used for
the display. Depending on spare memory and customer requirements, this option may only change the text
displayed to users in RUN mode, and not in COMMISSION mode – or all text can be changed to a second
language.
Option 00.5
value
Meaning
0 Operate with standard language (usually ENGLISH).
1 Operate with alternate language, at least in RUN mode – but possibly in other modes
depending on specification of the control.
Option 00.6 – Remote / Local Control (0 - 2) LV3
This parameter can be used to force the control to operate the boiler using setpoint 1 or 2, ignoring all remote
influences.
Option 00.5
value
Meaning
0 Normal (remote) operation. The boiler will be controlled to setpoint 1 or 2 depending
on options 20.0, 20.7 to 22.X. The setpoint and control limits can be overridden by
external influences such as analog / digital inputs and serial communications.
1 The boiler will be controlled to setpoint 1 as set in option parameter 21.X. Inputs that
would affect this such as the remote setpoint function on option parameter 20.7 and all
serial communications inputs are disabled.
2 The boiler will be controlled to setpoint 2 as set in option parameter 21.X. Inputs that
would affect this such as the remote setpoint function on option parameter 20.7 and all
serial communications inputs are disabled.
Option 01.0 – Power Up Option (0 - 30) LV3
This option can be used to modify the behavior of the control at power-up.
Option 01.0
value
Meaning
0 Normal power-up. If no faults and fuel / burner selected, the burner will start.
1 Lockout. The burner will always lockout after a power-up. An F75 will be generated
which will require manual intervention to clear.
2 – 30 The control will power-up as normal, but wait for 2 to 30 seconds before checking the
digital inputs for fault conditions. This may be useful to prevent nuisance lockouts at
power-up due to water levels and plant interlocks. The control will remain in safety
shutdown (but not locked out) for this time.
Option 01.1 – Keyboard Auto/Manual enable (0 - 1) LV3 [Engineer’s Key 33]
DEFAULT: 1

10
It is possible to enable/disable the auto/man facility from the keyboard. Selecting a 0 will disable the operation
of the ‘auto/man’ function from the keyboard. Selecting a 1 will enable the operation of the ‘auto/man’ function
from the keyboard.
Option 01.2 – Fault Mute Input enable (0 - 2) LV3
The Fault Mute function is available via Comfire 2, on the keyboard and can also be selected to be from a
digital input. Selecting a non-zero value will enable the operation of the ‘Fault Mute’ function from the
corresponding digital input. It should be ensured that the digital input selected is not used for any other
function (option parameters 1.x, 16.x and 18.x, 20.x). MUST be connected as shown in section 3.6.11.
Please note any key/button providing a fault mute function must be mounted local to the burner.
Number entered in
parameter 01.2
Fault Mute Function Digital inputs used
0 Comview & Keyboard only NONE
1 Input 1 Input 1, PA5 to PA11 Low Voltage
2 Input 2 Input 2, PA6 to PA11 Low Voltage
3 Input 3 Input 3, PA7 to PA11 Low Voltage
4 Input 4 Input 4, PA8 to PA11 Low Voltage
Servomotor Shaft Position Warning
It is not possible to reposition the shaft of the servomotor other than to the factory settings of either
clockwise or counter clockwise. That is, the shaft flat (as viewed from the shaft end) will either be in the
9-12 o’clock or 6-9 o’clock position at PO (burner off). Using the “out of the box” settings will make
future replacement of servomotors easier.
Some motors have a clutch release to allow for the driven device to be rotated for inspection after
commissioning. It must be noted that releasing the clutch while the motor is powered will cause the
servomotor to drive back to the commissioned P0 position. Power should be removed if the clutch is
used for this purpose.

11
Option 02.x – Drive Name LV3
CAUTION
Each Drive connected to the system can be given a name which will than be shown on the text display, The
are a maximum of 10 drives (0 – 9), which can be connected, the names are set by option parameter 02.0 to
02.9.
The drives are displayed with the drive number first, then a three character label, such as ‘1GAS’, ‘2AIR’,
‘3AIR’ etc.
The permitted drive names are:
Number
entered in
parameter
02.X
Drive
Name
Considered
as :
Trim if
selected :
Meaning
0 N/A Not used N/A This drive will not be used.
1 FUE Fuel drive YES Generic fuel drive
2 GAS Fuel drive YES A gas drive
3 OIL Fuel drive YES An oil drive
4 CUP Fuel drive YES Cup speed for rotary cup burners
5 FGR Fuel drive NO Flue Gas Recirculation damper
6 PUM Fuel drive YES VFD controlled oil pump. Can be used for
oil warming – see option parameter 9.0
7 WAS Fuel drive YES Waste fuel (combined fuel firing)
8 PRI Fuel drive YES Primary (flame shaping) air
9 FUE Fuel drive NO Generic fuel, but not trimmed.
10 AIR Air drive YES Main combustion air damper
11 FAN Air drive YES Main combustion air fan
12 SEC Air drive YES Secondary air (same as 10 apart from
name)
13 AIR Air drive NO Generic Air, but not trimmed.
14 SLE Air drive YES Burner Sleeve
Two (or more) drives can be allocated the same name.
The number entered also tells the control information about the drive. If the number entered here is less than
10, the drive is considered a fuel. If the number is greater than or equal to 10, it is considered an air drive. This
only makes a difference when oxygen trim is enabled for a particular drive, since it determines the trim
direction. Selection of fuel trim or air trim is made with option parameters 31.1 to 31.4.
Primary air is considered a fuel drive since it is used for flame shaping and should normally track the fuel
valve.
The total electrical load for all connected servo motors must not exceed 40VA.
P P C

12
Option 03.x – Drive Serial Number LV3
CAUTION
Each Drive
connected to the system has a unique serial number allocated to it during production testing. This number
cannot be changed and is used to uniquely identify each drive.
When the system is in commissioning mode the serial number of all the connected drives is read by the main
unit and displayed as a ‘list’ to allow the selection of the relevant serial number unit for each drive (0 – 9) to be
made.
Scrolling the list in an upward direction will scroll through all drive options available until ‘0, No Drive’ is
displayed. Enter this value to disconnect the specified drive from any hardware.
Scrolling the list in a downward direction will stop when the currently selected item is displayed, and the value
will stop flashing.
The display will show type information for each drive present (such as the torque rating of a servo), but the
commissioning engineer should be aware of which serial number servo is connected to which item on the
burner.
If the optional VFD daughterboard is fitted, four additional options are present:
Displayed Option Meaning
-a,VFD1:mA VFD channel 1 is used with a 4-20mA feedback
-b,VFD1:Hz VFD channel 1 is used with an encoder pulse (frequency) feedback
-c,VFD2:mA VFD channel 2 is used with a 4-20mA feedback.
-d,VFD2:Hz. VFD channel 2 is used with an encoder pulse (frequency) feedback.
Variable Speed Drive Selection:
Important Note: When selecting a VSD or variable frequency drive (VFD) consideration must be given to the
size and weight of the blower wheel. While a “fan” application is by nature a variable torque load, the inertia
(weight) of the blower wheel must be considered. Typical HVAC type drives do not speed up or slow down
large blower wheels with enough control to operate within the tolerance of the PPC or NX series control.
Therefore, a VSD (VFD) with some built in breaking capability, such as a constant torque drive, should be
used. At a minimum, if the drive has a constant torque setting, it must be enabled to minimize faults due to
drive hunting.
If a drive serial number is changed, any profiles using that drive will require re-commissioning. A ‘profile
invalid’ fault (see FAULT 64) will lock the burner out on an attempt to fire a profile which has had a previously
commissioned drive removed. The profile can be re-commissioned by using the NEXT / ENTER keys in
commission ratio mode to verify all points on the combustion curve.
The total electrical load for all connected servo motors must not exceed 40VA.
PPC

13
Option 04.x – Drive Usage Information LV3
The system will allow a maximum of four fuel / air profiles to be entered. Each drive (servo or VFD) can be
selected to operate for any, all or none of these profiles. This way the system can be programmed to use the
‘gas’ servo (for example) on a gas profile – but not an oil profile.
When the control is firing a profile that doesn’t use a specific drive, that drive can be disconnected or faulty
and the control will carry on working. So if the gas servo is broken, the burner can be run on oil, for example.
The number to be entered is a binary code:
+1 if the drive is used for profile 1,
+2 if the drive is used for profile 2,
+4 if the drive is used for profile 3,
+8 if the drive is used for profile 4.
This means that the number entered is from 0 to 15:
Number entered in parameter 4.X Drive X used for
profile(s)
0 NONE
1 1
2 2
3 1,2
4 3
5 1,3
6 2,3
7 1,2,3
8 4
9 1,4
10 2,4
11 1,2,4
12 3,4
13 1,3,4
14 2,3,4
15 1,2,3,4 (ALL)
If these parameters are changed after the burner has been commissioned, any profiles affected will need to be
re-commissioned. A drive selection fault will lock the burner out on an attempt to fire a profile which has had a
previously commissioned drive removed.
Example of use:
Option parameter 4.0 = 4 drive 0 used for profile 3 only.
Option parameter 4.2 = 1 drive 2 used for profile 1 only.
Option parameter 4.0 = 15 drive 0 used for all profiles.
Option parameter 4.4 = 5 drive 4 used for profile 3 and profile 1 only.
Option 05.x – Drive Options LV3
PPC
P P C

14
This parameter is used to specify direction for each servo drive. This parameter has no effect for variable
speed drives (VFD). If this parameter is changed, affected profiles must be re-commissioned by a qualified
engineer.
Number entered in parameter 5.X Drive Options
0 Drive moves counter-clockwise (looking at output shaft).
1 Drive moves clockwise (looking at output shaft).
Options 06.1-06.4 – Profile Naming LV3
This selects the fuel associated with each profile (1 thru 4) to be displayed after the burner-on hours, e.g. 861
hours Profile 1 Gas, visible on the main display during operation.
Options 07.x, 08.x– RESERVED
Option 09.0 - Inverter control accuracy (0 / 1) LV3
Variable Speed Drive Selection:
Important Note: When selecting a VSD or variable frequency drive (VFD) consideration must be given to the
size and weight of the blower wheel. While a “fan” application is by nature a variable torque load, the inertia
(weight) of the blower wheel must be considered. Typical HVAC type drives do not speed up or slow down
large blower wheels with enough control to operate within the tolerance of the PPC or NX series control.
Therefore, a VSD (VFD) with some built in breaking capability, such as a constant torque drive, should be
used. At a minimum, if the drive has a constant torque setting, it must be enabled to minimize faults due to
drive hunting.
This parameter affects all inverters connected to the unit.
Option
parameter 09.0
value
Meaning
0 Low accuracy (normal setting). Control will be performed to within approximately
0.45Hz for a 0-50Hz system.
1High accuracy. Control will be performed to within approximately 0.15Hz for a 0-
50Hz system.
Note: When using the high accuracy setting, the control may have difficulty with controlling the speed of the
inverter. If this occurs, use the low accuracy setting for reliable operation.
Option 09.1 - Inverter error tolerance (0 / 1) LV3
This option parameter affects all inverters connected to the unit.
V F D
V F D

15
Option parameter 09.1
value
Meaning
0 Small tolerance (normal setting). The control will perform a non-volatile
lockout if the inverter positioning error exceeds 30 for 15 seconds or 55 for
3 second (units conform to those seen on the display).
1 Large tolerance. The control will perform a non-volatile lockout if the inverter
positioning error exceeds 55 for 3 seconds (units conform to those seen on
the display).
Note: Only use the large tolerance setting if an inverter error of up to 55 will not cause an unsafe combustion
condition to occur at any firing position.
Option 09.2 -Inverter closed loop gain (15 – 125%) LV3
DEFAULT: 100
This option parameter affects all inverters connected to the control.
For normal operation, use 100%. If the inverter control is unstable, reducing this value has the effect of
damping the inverter’s response as its speed approaches its setpoint.
Option 09.3 - Inverter stop time (0 – 100 seconds) LV3
Determines the minimum time between a burner shutdown and subsequent startup. Set this parameter to give
the inverter(s) sufficient time to stop before the burner restarts. This parameter will increase the time the
burner is held in status 5.
Option 09.4 - Inverter acceleration time (0 –60 seconds recommended) LV3
DEFAULT 30
The value entered for this parameter should be the time in seconds for the inverter(s) to move from minimum
to maximum speed.
The inverter(s) should also be able to move from maximum to minimum speed in the same time, if this is not
the case adjust the time in the inverter(s) to ensure the time to accelerate and de-accelerate are the same.
If this option parameter does not match the true VSD acceleration / deceleration times, drive positioning will be
compromised and position faults will be likely.
Note: This parameter can be set to values between 60 and 100, but this should only be used as a last resort if
required, and is not recommended. If a very slow inverter is used, care must be taken during commissioning
that UP / DOWN keys are not held for more than a few seconds. It is possible that the control could get out of
step with the inverter and cause a position fault during the commission process. This control is not designed to
work with inverters that take more than 60 seconds to drive from zero to maximum speed.
Option 09.5 –VFD1 Speed Encoder Scaler (255 - 999) LV3
When using encoder feedback for VFD1, this option should be programmed to ensure that the feedback signal
gives between 950 and 995 when the motor is at maximum speed (drive signal at 20mA). The value for the
parameter may be calculated using the following formula:
(Motor Max RPM x No of teeth on encoder) = Scaler
V F D
V F D
V F D
V F D

16
60
The value may need adjustment once the unit has been tested. Specifically, it must be ensured that the
feedback received never exceeds this value. In practice this may mean adding 2% to 5% to this value.
Option 09.6 – VFD2 Speed Encoder Scaler (255 - 999) LV3
When using encoder feedback for VFD2, this option should be programmed to ensure that the feedback signal
gives between 950 and 995 when the motor is at maximum speed (drive signal at 20mA). The value for the
parameter may be calculated using the following formula:
(Motor Max RPM x No of teeth on encoder) = Scaler
60
The value may need adjustment once the unit has been tested. Specifically, it must be ensured that the
feedback received never exceeds this value. In practice this may mean adding 2% to 5% to this value.
Option 09.7- RESERVED
Option 09.8- RESERVED
Option 09.9- RESERVED
Option 14.0 – Primary Fault Relay (0-8) LV3
This option parameter assigns the primary faults to a specific relay. Relays 1 & 2 share a common connection.
Option parameter 14.0
value
Meaning Connection Details
0 Primary faults not assigned to any relay. N/A
1 Primary faults assigned to relay 1 Display, PR3(COM), PR1(NO),
PR2(NC). Low voltage or line
voltage.
2 Primary faults assigned to relay 2 Display, PR7(COM), PR5(NO),
PR6(NC). Low voltage or line
voltage.
3 Primary faults assigned to relay 3 Display, PR7(COM), PR9(NO),
PR8(NC). Low voltage or line
voltage.
4 Primary faults assigned to relay 4 Main Unit, PE4 (line voltage out).
5 No function. N/A
6 No function. N/A
7 Primary faults assigned to relay 7 Daughterboard, PZ15 – PZ16. LOW
VOLTAGE AND CURRENT ONLY.
8 Primary faults assigned to relay 8 Daughterboard, PZ18 – PZ17. LOW
VOLTAGE AND CURRENT ONLY.
V F D

17
These relays MUST NOT be used to provide a safety function.
A relay can be used to indicate any combination of fault conditions from 14.0, 14.1 and 14.2 – this means that
one relay could be used for all faults. When used for an alarm function, the relay will de-energize when in the
fault condition, so an alarm bell would be wired in series with the normally closed contacts.
Option 14.1 – Limit Relay (0-8) LV3
This option parameter assigns the limits to a specific relay. Relays 1 & 2 share a common connection.
Option parameter 14.1
value
Meaning Connection Details
0 Limits not assigned to any relay. N/A
1 Limits assigned to relay 1 Display, PR3(COM), PR1(NO),
PR2(NC). Low voltage or line
voltage.
2 Limits assigned to relay 2 Display, PR7(COM), PR5(NO),
PR6(NC). Low voltage or line
voltage.
3 Limits assigned to relay 3 Display, PR7(COM), PR9(NO),
PR8(NC). Low voltage or line
voltage.
4 Limits assigned to relay 4 Main Unit, PE4 (line voltage out).
5 No function. N/A
6 No function. N/A
7 Limits assigned to relay 7 Daughterboard, PZ15 – PZ16. LOW
VOLTAGE AND CURRENT ONLY.
8 Limits assigned to relay 8 Daughterboard, PZ18 – PZ17. LOW
VOLTAGE AND CURRENT ONLY.
These relays MUST NOT be used to provide a safety function.
A relay can be used to indicate any combination of fault conditions from 14.0, 14.1 and 14.2 – this means that
one relay could be used for all faults. When used for an alarm function, the relay will de-energize when in the
fault condition, so an alarm bell would be wired in series with the normally closed contacts.
Option 14.2 – Oxygen and Flue Temperature Limit Relay (0-8) LV3
This option parameter assigns the limits to a specific relay. Relays 1 & 2 share a common connection.

18
Option parameter 14.2
value
Meaning Connection Details
0 Flue Limits not assigned to any relay. N/A
1 Flue Limits assigned to relay 1 Display, PR3(COM), PR1(NO),
PR2(NC). Low voltage or line
voltage.
2 Flue Limits assigned to relay 2 Display, PR7(COM), PR5(NO),
PR6(NC). Low voltage or line
voltage.
3 Flue Limits assigned to relay 3 Display, PR7(COM), PR9(NO),
PR8(NC). Low voltage or line
voltage.
4 Flue Limits assigned to relay 4 Main Unit, PE4 (line voltage out).
5 No function. N/A
6 No function. N/A
7 Flue Limits assigned to relay 7 Daughterboard, PZ15 – PZ16. LOW
VOLTAGE AND CURRENT ONLY.
7 Flue Limits assigned to relay 8 Daughterboard, PZ18 – PZ17. LOW
VOLTAGE AND CURRENT ONLY.
These relays MUST NOT be used to provide a safety function. (See below)
A relay can be used to indicate any combination of fault conditions from 14.0, 14.1 and 14.2 – this means that
one relay could be used for all faults. When used for an alarm function, the relay will de-energize when in the
fault condition, so an alarm bell would be wired in series with the normally closed contacts.
Option 15.0 - Modulation sensor input type (0 - 1) LV3
The modulation sensor input caters for connection to a standard 0-5V or 4-20mA signal. When using a 4-
20mA sensor, the control may be used to monitor the boiler high safety limit and perform a non-volatile lockout
if it is exceeded, additional external limits must still be in place to protect the boiler in case of a sensor failure.
Ensure that the links on the circuit board are set to correspond with the requirements of the sensor/signal
being used. Incorrect link setting may damage or destroy the units being connected.
PPC

19
Option parameter
15.0 value
Meaning
0 0 - 5V operation. Set the JP1 link to ‘OUT’. Set the JP3 link as
required. This option is used to provide a 0 to 5 volt tracking input only.
The burner modulation will track the voltage applied, going to high fire
for 5 volts. There is no ‘measured value’, just a tracking setpoint.
Option parameters 15.0 to 15.5 are unavailable.
1 4 - 20mA operation. Set the JP1 link to ‘IN’. Set the JP3 link to’30V’.
This option allows for connection to a 4 to 20mA pressure or
temperature sensor. The burner modulation will track the current
applied, going to high fire for 20mA and low fire for 4mA. If the current
goes outside the range, the burner will go to low fire. There is no
‘measured value’, just a tracking setpoint. Option parameters 15.0 to
15.5 are unavailable.
2 4 - 20mA operation. Set the JP1 link to ‘IN’. Set the JP3 link to’30V’.
This option allows for connection to a 4-20mA measured value input
device such as a pressure or temperature sensor. The internal PID will
be used, if selected.
Option 15.1 –Modulation input decimal places (0 to 2) LV2
This parameter specified the number of decimal places to which the measured value and setpoint are
displayed. It also affects the scaling of the zero, span and safety limit – it is vital that this parameter is set
before parameters 15.2, 15,3 and 15.5
Option parameter
15.1 value
Meaning
0 Measure value and setpoint displayed with no decimal places. Range
of values is from 000 to 999.
1 Measure value and setpoint displayed with one decimal place. Range
of values is from 00.0 to 99.9.
2 Measure value and setpoint displayed with two decimal places. Range
of values is from 0.00 to 9.99.
Option 15.2 –Modulation input zero value (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3
This value will normally be left at zero. It is the measured value to be displayed when the sensor connected is
at its minimum value.
If a 4-20mA sensor is used, this parameter should be set to the 4mA value (usually zero).
Option 15.3 – Modulation input span value (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3
This value is the measured value to be displayed when the sensor connected is at its maximum value.
If a 4-20mA sensor is used, this parameter should be set to the 20mA value.
P P C
P P C
PPC

20
Option 15.4 – Setpoint control units (0 – 3) LV3
This option selects the displayed units for setpoint and measured value.
Option parameter
15.4 value
Meaning
0 Show measured value as ‘PSI’.
1 Show measured value as ‘bar’.
2 Show measured value as ‘°F’
3 Show measured value as ‘°C’
Option 15.5 - Boiler high safety limit (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3
If a 4-20mA sensor is used, this parameter may still be configured to give a lockout when a high limit is
reached. In this case, a value other than zero must be entered. Note: When a 4-20mA sensor is used,
external limits must be in place to protect the boiler in case of sensor failure.
Option 15.6 – Modulation Time (0 – 120 seconds)*
This option parameter sets the minimum time the burner will take to modulate from low to high fire or vice
versa. Note - only the modulation speed in AUTO mode is affected. The burner may modulate slower than this
setting if the drive speeds dictate this at any point in the range.
Option 15.7 – Bumpless Transfer (0 or 1)* LV3
This parameter affects the burner operation whilst in MANUAL mode only.
Option parameter
15.7 value
Meaning
0 When the burner comes back on after going off, it will remain at low
fire.
1 When the burner comes back on after going off, it will go to the last
modulation rate that it was set to in manual mode and stay there.
PPC
PPC