Fireye PPC6000 Series User manual

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

2
Other options include, two Variable speed drive (VSD) outputs via daughter board, Oxygen Trim
using Fireye’s proven heated zirconia oxide probe and optional interface, a wide variety of
communications platforms such as Modbus is also available.
An optional internal freely programmable logic section of the PPC6000 means that external
PLC’s and expensive stand-alone sequencing controls may no longer be needed. Easy to
program and protect, this new feature will make the PPC6000 suitable for many unique or
unusual applications. Functions such as lead lag, sequencing, feedwater control and draft
control are just some of the ways this feature can be used.
Optional ComFire software allows the user to view and control all aspects of the burner system,
provides real time trending and logging, upload and download of profiles and options. The user
can build custom screens or import actual photographs of the combustion equipment for
animation.
Summary of PPC6000 Features
State of the art surface mount technology
Smallest footprint available: 7.0” x 4.5” x 2.5”
Capable up to ten servomotors powered from the control
Two PID loops for precise process control
Simple four wire CANbus wiring reduces time and mistakes
Optional VSD card provides two VSD’s and one Analog output
Re-transmittal of most data as 420mA output (requires NXDBVSD
option)
VSD encoder feedback available
Standby lag boiler on water temp.
Built in lead/lag sequencing for up to four boilers
Fully programmable function block programming allows for custom
applications such as draft control or feedwater control
Two levels of displays: 12 Key Keypad with Backup, 10.4” Color
Touchscreen
Unparalleled worldwide support

3
Safety information
WARNING
When this equipment is fitted to an appliance due regard must also be given to the requirements of that
appliance.
Before attempting to install, commission or operate this equipment all relevant sections of this
document must be read and fully understood. If in doubt about any requirements consult Fireye.
Installation, commissioning or adjustment of this product MUST be carried out by suitably trained
engineers or personnel qualified by training and experience.
After installation or modifications to the installation all functions of the equipment MUST be checked
to ensure safe and reliable operation of the control.
The manufacturer of this equipment accepts no liability for any consequences resulting from inappropriate,
negligent or incorrect installation, commissioning or adjustment of operating parameters of the equipment.
Control panels must not be left uncovered while power is on. If it is essential to do so while rectifying faults
only personnel qualified by training and experience should be involved.
The time any covers are off must be kept to a minimum and warning notices must be posted.
Before attempting any work on this equipment or any equipment controlled by or connected to this equipment,
all related electrical supplies must be isolated.
Safety interlocks must not be removed or over-ridden. Any faults once detected must be corrected before
the control is operated.
CAUTION – SOME VERSIONS OF THIS EQUIPMENT CONTAIN
A LITHIUM BATTERY IN THE DISPLAY UNIT
NOTE
The manufacturer of this equipment has a policy of continual product improvement and reserves the right to
change the specification of the equipment and the contents of this manual without notice.
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 herein is
installed, operated and commissioned in compliance with the requirements of all national and local
legislation, which may prevail.

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Table of contents
This manual describes the installation, commissioning, operation and maintenance of the PPC6000 series fuel
air ratio controls. It may be used in conjunction with the following other manuals:
NEX-1502 - ComFire combustion analysis tool user manual
Please read the safety information at the front of this manual before proceeding.
1Technical specification 11
1.1General 11
1.2Servo-motor control – IMPORTANT: See Section 3.2 11
1.3Digital outputs (PPC6000) 12
1.4Alarm output (PPC6000) 12
1.5Digital inputs (PPC6000) 13
1.6Pressure/Temperature Input (PPC6000) 13
1.7Communications interface (PPC6000) 13
1.8Optional Oxygen Probe Interface Unit (NXO2INT) - optional 14
1.9Optional Ambient Air Temperature Unit (NXIATS) - optional 14
1.10Variable Speed Drive (VSD) Daughter Board (NXDBVSD) - optional 14
1.11Fireye NXC04, NXC12, NXC20, NXC20A, NXC40 Servo Motors 15
1.12Fireye NXO2INT Oxygen Probe Interface Unit (optional) 15
1.13Fireye NXIATS Ambient Air Temperature Sensor (optional) 16
1.14Approvals 16
1.15Parts List with Description 16
2Installation 18
2.1Mounting details for the PPC6000 control 19
2.2Mounting details for the display module 20
2.3Mounting details for optional Oxygen Probe Interface unit, NX02INT 21
2.4The oxygen trim option 22
2.4.1Oxygen Probe description 22
2.4.2Installation of oxygen probe 22
2.4.3Mounting the oxygen probe 23
2.4.4Mounting arrangements for Temperature and Steam pressure sensors 24
2.4.5Boiler temperature sensors 24
2.4.6Steam pressure sensors 25
2.5Option link selection (PPC6000) 26
2.5.1General (Access to jumper’s and fuse’s is gained by removing the back cover of the PPC6000)
26
2.5.2Line supply voltage (LK1 - 4) (PPC6000) 26
2.5.3SENS IN and SENS SUPP (boiler temp/pressure sensor) (PPC6000) 27
2.5.4REMOTE SETPOINT (PPC6000) 27
2.5.5RS485 serial communications termination resistor (PPC6000) 27
2.5.6RS485 serial communications termination resistor (daughter board) 27
IN 27
IN 27
IN 27
IN 27
2.6Wiring 29
2.6.1General 29

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2.6.2Grounding cable screens 32
2.6.3GROUND (EARTH) connection 32
2.6.4Ground (earth) Connection (display unit) 33
2.6.5Terminal Designation 33
2.6.6LINE and NEUTRAL supply (PPC6000) PE1 & PE2 35
2.6.7Safety Shutdown output (PPC6000) 36
2.6.8Controlled Shutdown Relay Output (PPC6000) 36
2.6.9Alarm Relay output – RELAY 4 (on the PPC6000) 36
2.6.10Auxiliary Relay Outputs (display) 37
2.6.11Fuel Select /Profile Select Input/Purge and Ignition Prove Outputs (PPC6000) 37
2.6.12Low Voltage Digital Inputs (PPC6000) – relevant Engineer’s Keys EK1-EK4 (Sec. 6.6.2) 38
2.6.13Servo-motor and Display Connection (PPC6000) 38
2.6.14Display Connection with PPC6000 and BurnerLogix YB110 39
2.6.15Oxygen Probe Interface Connection (PPC6000) 40
2.6.16Pressure/temperature sensor input (PPC6000) 40
2.6.17Remote Setpoint (Analog Input 5) (PPC6000) 41
2.6.18RS485 interface (PPC6000) 41
2.6.19Variable Speed Drive Selection: 42
2.6.20PPC6000 Variable Speed Drive Daughter Board P/N NXDBVSD 43
2.6.21LIVE and NEUTRAL supply (optional Oxygen Probe Interface unit) 44
2.6.22Oxygen probe connection (optional Oxygen Probe Interface unit), NX02INT 44
2.6.23Inlet temperature sensor (optional) 46
2.7Final checks 47
3Servo-motor selection and calibration 48
3.1Servo-motor selection 48
3.1.1Motor requirements 48
3.2IMPORTANT: Servo-motor direction warning 49
3.3Locking the servo-motor to the valve shaft 50
3.4Feedback potentiometer 50
3.5Adjusting microswitch positions 51
3.6Servomotor Replacement 52
4Description of operation 53
4.1The Display / Keypad 53
4.2Start-up sequence 54
4.3Non-volatile lockout 59
4.4Modulation 59
4.4.1Normal/Remote mode. 59
4.4.2Local mode. (LOC 1, LOC 2) 59
5Commissioning the control 60
5.1General 60
5.2Commissioning data 61
5.2.1Option parameters 61
5.2.2Setpoints 61
5.3The Commissioning process 61
5.3.1Navigation 61
5.4Description of Touchscreen operation. 63
5.4.1The Touchscreen 63
5.4.2Touchscreen Power on. 63
5.4.3The Operation Mode line and Status messages 63
5.4.4Touchscreen Overview display. 65

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5.4.5Touchscreen Lockout Reset (Alarm Mute) Function. 66
5.4.6Touchscreen LED Indication. 66
5.4.7Touchscreen Fuel/Profile Select. 67
5.4.8Touchscreen ‘Control’ screen. 68
5.4.9Touchscreen ‘Menu’ button. 68
5.4.10Touchscreen ‘Burner Settings’ button. 68
5.4.11Touchscreen ‘Fault/Event Log’ button. 70
5.4.12Touchscreen ‘Screen Configuration’ button. 70
5.4.13Cleaning the Touchscreen 71
5.4.14Touchscreen Commission mode. 72
5.5Using option set mode 74
5.5.1Option parameter list 74
Option 00.1 - Site passcode (0 - 999) DEFAULT VALUE is 154. LV3 74
Option 00.2 - Serial communications control address (0 - 15) LV3 74
Option 00.3 - Reset hours run (0 - 1) LV3 75
Option 00.4 – User program select (0 / 1) LV1 75
Option 00.6 – Reserved 75
Option 00.7 – Modbus device address (1 – 99) LV3 75
Option 00.8 – Modbus communications speed (0 – 3) LV3 76
Option 01.0 – Power Up Option (0 - 30) LV3 76
Option 01.1 – Keyboard Auto/Manual enable (0 - 1) LV3 [Engineer’s Key 33] 76
Option 01.2 – Mute/Reset Input enable (0 - 2) LV3 76
Option 02.x – Drive Name LV3 77
Option 03.x – Drive Serial Number LV3 78
Option 04.x – Drive Usage Information LV3 78
Option 05.x – Drive Options LV3 79
Options 06.1-06.4 – Profile Naming LV3 80
Options 07.x, 08.x– RESERVED 80
Option 09.0 - Inverter control accuracy (0 / 1) LV3 80
Option 09.1 - Inverter error tolerance (0 / 1) LV3 80
Option 09.2 - Inverter closed loop gain (15 – 125%) LV3 81
Option 09.3 - Inverter stop time (0 – 100 seconds) LV3 81
Option 09.4 - Inverter acceleration time (0–100 seconds) (60 seconds max. recommended) LV381
Option 09.6 – VSD2 Speed Encoder Scaler (255 - 999) LV3 82
Option 09.7 – Reserved 82
Option 09.8 – Reserved 82
Option 14.1 – Limit Relay (0 - 8) LV3 83
Option 14.2 – Oxygen and Flue Temperature Limit Relay (0 - 8) LV3 83
Option 15.0 - Modulation sensor input type (0 - 3) LV3 84
Option 15.1 – Modulation input decimal places (0 to 2) 84
Option 15.2 – Modulation input zero value (-999 to +999 / -99.9 to +99.9 / -9.99 to
+9.99) LV3 85
Option 15.3 – Modulation input span value (-999 to +999 / -99.9 to +99.9 / -9.99 to
+9.99) LV3 85
Option 15.4 – Setpoint display units (0 – 3) LV3 85
Option 15.5 - Boiler high safety limit (0 - 999 / 0.0 - 99.9 / 0.00 – 9.99) LV3 85
Option 15.6 – Modulation Time (0 – 120 seconds) LV3 85
Option 15.7 – Bumpless Transfer (0 or 1) LV3 86
Option 15.8 – Low before Off (0 or 1) LV3 86
Option 15.9 - reserved 86
Option 16.2 – Allow profile swap (0 to 16) LV3 87
Option 18.1 to 18.4 – Low Voltage Fail-safe Alarm / Lockout Inputs (0 – 460) LV3 91

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Option 19.1 to 19.4 – Fail-safe Alarm / Lockout Display Messages LV3 93
Option 20.0 – Set-point Select input (0 - 35) LV3 94
Option 20.1 – Boiler Shutdown input (0 - 35). LV3 95
Option 20.2 – Low Fire Hold input (0 - 35). LV3 95
Option 20.3 – Oxygen Trim Disable input (0 - 35). LV3 95
Option 20.4 – Ignition Wait input (0 - 35). LV3 96
Option 20.5 – Purge Hold input (0 - 35). LV3 96
Option 20.6 – Purge Time Start input (0 - 35). LV3 96
Option 20.7 – Analog Input 5 function (0 - 2). LV3 96
Option 20.8 – Digital Input - Lead Boiler Select (0 – 35) LV3 97
Option 21.0 – Set-point 1 enable (0 - 1) LV1 97
Option 21.1 – Set-point 1 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 97
Option 21.2 – Set-point 1 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV197
Option 21.3 – Set-point 1 integral time (0 – 999 seconds) LV1 97
Option 21.4 – Set-point 1 derivative time (0 – 999 seconds) LV1 98
Option 21.5 - Setpoint 1 control limit type (0 - 2) LV3 98
Option 21.6 - Setpoint 1 low limit control value (Cut In) (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 98
Option 21.7 - Setpoint 1 high limit control value (Cut Out) (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV198
Option 21.8 – Remote Setpoint 1 zero (4ma) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 98
Option 21.9 – Remote Setpoint 1 span (20mA) value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 98
Option 22.0 – PID (set-point) 2 enable (0 - 1) LV1 98
Option 22.1 – Set-point 2 control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 99
Option 22.2 – Set-point 2 proportional band (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 99
Option 22.3 – Set-point 2 integral term (0 – 999 seconds) LV1 99
Option 22.4 – Set-point 2 derivative term (0 - 100) LV1 99
Option 22.5 - Setpoint 2 control limit type (0 - 2) LV3 99
Option 22.6 - Setpoint 2 low limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 100
Option 22.7 - Setpoint 2 high limit control value (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 100
Option 22.8 – Maximum modulation rate 100
Option 22.9 – Reserved 100
Option 23.0 – Warming Enable (0 or 1) LV1 100
Option 23.1 – Warming Limit (0 - 999 / 00.0 - 99.9 / 0.00 - 9.99) LV1 100
Option 23.2 – Warming Time (0 to 999 minutes) LV1 100
Options 24.x – Sequencing 101
Option 24.0 Sequence Slaves (number of boilers) (0-3) LV1 102
Option 24.1 -24.3 Priority Number(s) LV1 102
Option 24.4 – Lead OFF Time LV1 103
Option 24.5 – Lead (master) Boiler Select Method LV1 103
Option 24.6 – lag (slave) On Rate (0-100%) LV1 104
Option 24.7 – lag (slave) On Delay (0-999 minutes) LV1 104
Option 24.8 – lag (slave) Off Rate (0-100%) LV3 104
Option 24.9 – lag (slave) Off Delay (0-999 minutes) LV3 104
Option 25.0 – Banking based on temperature / water temperature standby for steam boiler LV3104
Option 25.1 – Water temperature zero value LV3 105
Option 25.2 – Water temperature span value LV3 105
Option 25.3 – Water temperature cut-in LV1 105
Option 25.4 – Water temperature cut-out LV1 105
Option 25.5 – Temperature based warming limit LV1 105
Option 25.6 – Lag wait time LV1 105
Option 28.0 – Analog Input decimals (0-2) LV3 105
Option 28.1 – Analog Input 1 zero (0-999) LV3 105
Option 28.2 – Analog Input 1 span (0-999) LV3 105
Option 28.3 – Analog Input 2 decimals (0-2) LV3 105
Option 28.4 – Analog Input 2 zero (0-999) LV3 105
Option 28.5 – Analog Input 2 span (0-999) LV3 105

8
Option 28.6 – Analog Input 3 decimals (0-2) LV3 105
Option 28.7 – Analog Input 3 zero (0-999) LV3 106
Option 28.8 – Analog Input 3 span (0-999) LV3 106
Option 29.0 – 4-20mA Output 1 function if not VSD LV3 106
Option 29.1 – Output1 zero value (4mA output) LV3 106
Option 29.2 – Output1 span value (20mA output) LV3 106
Option 29.3 – 4-20mA Output 2 function if not VSD LV3 107
Option 29.4 – Output2 zero value (4mA output) LV3 107
Option 29.5 – Output2 span value (20mA output) LV3 107
Option 29.6 – 4-20mA Output 3 function if not VSD LV3 107
Option 29.7 – Output3 zero value (4mA output) LV3 107
Option 29.8 – Output3 span value (20mA output) LV3 107
Option 30.0 – Oxygen probe interface serial number LV3 109
Option 30.1 - Oxygen probe calibration offset value (0 – 999) LV3 109
Option 30.2 - Oxygen probe calibration gain value (0 – 999) LV3 110
Option 30.4 – Flue and inlet sensor temperature units (0 – 1) LV3 110
Option 30.5 - Oxygen input function (0/1) LV3 110
Option 30.6 - Oxygen probe calibrate enable (0 – 2) LV3 110
Option 30.7 - Boiler transport delay (5 – 60 seconds) LV3111
Option 30.8 - Reset oxygen trim profile (0/1) LV3 111
Option 30.9 – Automatic trim commissioning (0 / 1) LV3 111
Options 31.1 to 31.4 - Trim Type for profiles 1 to 4 (0 to 2) LV3 113
Option 32.0 - Trim limit default (0/1) LV3 114
Options 33.1 to 33.4 - Trim integral gain (Default 10%) LV3 114
Option 34.0 - Trim proportional gain (0/1) LV3 115
Options 34.1 to 34.4 - Trim proportional gain (0.0 – 99.9%) LV3 115
Option 34.5 - Calculating and entering the flow values manually LV3 115
Option 35.0 – Inlet temperature sensor serial number LV3 118
Options 35.5 to 35.8-Calorific values of fuels/profiles 1 to 4 respectively (0.0 – 99.9) LV3 118
Option 35.9 - Boiler radiated heat loss (0.0 – 9.9%) LV3 119
Option 36.0 - Flue temperature alarm select (0/1) LV3 119
Options 36.1 to 36.4 - Flue temperature low alarm values (0 – 999) LV3 119
Option 38.0 - Oxygen alarm select (0 – 2) LV3 120
Options 38.1 to 38.4 - Oxygen low alarm values at low fire (0.0 – 99.9%) LV3 120
Options 39.1 to 39.4 - Oxygen low alarm values at high fire (0.0 – 99.9%) LV3 120
Options 40.1 to 40.4 - Oxygen high alarm values at low fire (0.0 – 99.9%) LV3 120
Options 41.1 to 41.4 - Oxygen high alarm values at high fire (0.0 – 99.9%) LV3 120
Option 42.0 – Second Oxygen probe interface serial number LV3 121
Option 42.1 – Second Oxygen probe calibration offset value (0 – 999) LV3 121
Option 42.2 – Second Oxygen probe calibration gain value (0 – 999) LV3 121
Option 42.3 – Second Oxygen probe calibrate enable (0 – 2) LV3 122
Option 42.4 – Max oxygen variation (0 – 9.9 %) LV3 122
Option 42.5 – Max flue temp variation (0 to 999 ºC) LV3 123
Option 42.7 – Air pressure monitoring* – input number LV3 123
Option 42.8 – Air pressure monitoring* – Span LV3 123
Option 42.9 – Air pressure monitoring* – max error LV3 123
Option 43.0 – Water level / expansion unit** LV3 - Reserved 123
Option 43.1 – Water level / expansion unit** LV3 - Reserved 123
Option 44.0 - Set real time clock (0/1) LV1 123
Option 44.1 – Set Year (00 – 99) LV1 123
Option 44.2 – Set Month (1 – 12) LV1 123
Option 44.3 – Set Day of Month (1 – 31) LV1 123
Option 44.4 – Set Day of Week (1 - 7) LV1 124
Option 44.5 – Set Hours (0 - 23) LV1 124
Option 44.6 – Set Minutes (0 - 59) LV1 124
Option 44.7 – Set Seconds (0 - 59) LV1 124

9
Option 44.9 – Reset Fault Log (0 - 1) LV3 124
Option 45.0 - Erase / Restore enable (0 - 1) LV3 124
Option 45.1 - Erase command (0 - 5) LV3 125
Option 45.2 - Restore command (0 - 999) LV3 125
5.6Commission ratio mode 126
5.6.1Description 126
5.6.2Using commission ratio mode 126
5.6.3Leaving commission ratio mode 128
5.7Adjust ratio mode 128
5.7.1Description 128
5.7.2Entering adjust ratio mode 128
5.7.3Using adjust ratio mode 129
5.7.4Leaving adjust ratio mode 130
5.8Interrogating the software issue 130
6Faults and fault finding 131
6.1The fault display 131
6.2What to do when a fault occurs 131
6.3Non-volatile lockout 132
6.4Fault subsets 132
6.5Fault listing 132
6.6The engineer's key 139
6.6.1Fault history 140
6.6.2Engineer’s key parameter list 140
6.7Troubleshooting 150
6.7.1Display / General 150
6.7.2Startup 151
6.7.3Commissioning 151
6.7.4Modulation 152
6.7.5Inverters 153
6.8YB110/TSD104 Fault Messages 155
7Inverter (variable speed) drives 157
7.1System configuration 157
7.2Description of control method 158
7.3Setting up the inverter for use with the PPC6000 series 158
7.4Setting up the PPC6000 series for use with a inverter drive 159
8The oxygen trim option 160
8.1Oxygen Pro probe description 160
8.1.1Installation of oxygen probe 160
8.1.2Mounting the oxygen probe 160
9Appendix 163
9.1Calibrating and servicing the oxygen probe 163
9.1.1Probe calibration 163
9.1.2Oxygen Probe Filter Testing 164
9.1.3Removing the oxygen probe from the flue 164
9.1.4Filter replacement 165
9.1.5Probe mounted flue thermocouple replacement. 165
9.2Troubleshooting inverter problems 167
9.3PID Tutorial 168

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9.4Combustion Profile Setup Guideline 169
9.5Fireye PPC6000 Efficiency Calculations 170
9.6Typical Wiring Diagrams 172
9.7Operator’s Guide 179
9.7.1Introduction 179
9.7.2General 179
9.7.3Password 179
9.7.4Adjusting Cut IN and Cut OUT 180
9.7.5Manual Modulation 181
9.7.6Resetting the Control 181
9.7.7Fault and Fault Finding 182
9.7.8Fault subsets 182
9.7.9Fault listing 183
9.7.10PID Tutorial 183
9.7.11The startup / shutdown stages are as follows: 184
9.7.12Non-volatile lockout 187
9.8Fireye Nexus Combustion Curve 188
10Function Block Programming Details 189
Introduction to Fireye’s Abacus Programming Software 189
1.1.Introduction 189
1.4.The schematic toolbar 193
1.5.Place Function blocks 194
1.6.Moving and editing the link lines 194
11Circuit board connections 196
11.1Inlet Air Temperature Sensor (Optional) 196
11.2PPC6000 Variable Speed Drive Daughter Board P/N NXDBVSD 197
11.3Oxygen probe connection (optional Oxygen Probe Interface unit) 198
11.4PPC6000 199

11
1 Technical specification
1.1 General
Supply voltage
Power consumption
Supply frequency
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 clean 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 176 x 115 x 92mm (6.93 x 4.53 x 3.62 in) deep
Display 132 x132 x 36mm (5.20 x 5.20 x 1.42 in) deep
Control unit 1.55kg (3.42 lbs)
Display 0.90Kg (1.98 lbs)
Type of display 2 lines x 20 characters, vacuum fluorescent display with membrane
keypad.
1.2 Servo-motor control – IMPORTANT: See Section 3.2
Type
Maximum (total) number of servo-motors
Maximum number of fuel profiles
Max. number of setpoints per profile
Positioning accuracy
Response time to positioning error
Number of fuel motors
Number of air (non fuel) motors
CANbus
10 (see section 3 regarding servo-motors)
4
24 including close, purge and ignition
+/-0.1
15s for 1.0, 1s for 5.0
Not Limited by profile (e.g. 2 or 3 fuel motors). All
non-monotonic.
Not Limited by profile (e.g. 2 or 3 fuel motors). All
non-monotonic.
NOTE: Number of servomotors is limited in all
profiles by VA rating. See Section 3.1

12
Interface to PPC6000
Speed
Microswitches
Torque
CANbus
30 seconds for 90 degrees.
Open & close positions
Driving Holding
NXC04 4Nm/ 3 ft/lb 2Nm
NXC12 12Nm/ 9 ft/lb 18Nm
NXC20, NXC20A 20Nm/ 14.7 ft/lb 18Nm
NXC40 40Nm/ 29 ft/lb 20Nm
Voltage:
VA rating / Temperature
Protection Category
Typical accuracy
Accuracy (as specified by EN12067)
24-30Vac supplied from control only
NXC04 – 3VA NXC04 = 0°C – 60°C
NXC12 = 5VA NXC12 = 0°C – 60°C
NXC20 = 10VA NXC20 = 0°C – 60°C
NXC20A = 10VA NXC20A = -20°C – 60°C
NXC40 = 18VA NXC40 = -20°C – 60°C
NXC04 = IP40, NEMA 1
NXC12, NXC20, NXC20A = IP54, NEMA 3S
NXC40 = IP65, NEMA 4
+/-0.1
+/-0.5
1.3 Digital outputs (PPC6000)
Controlled Shutdown, Safety Shutdown
Type
Minimum current
Maximum current (per output)
Maximum voltage
On-off relay, de-energize for off.
200mA rms
8A rms
250Vac rms
1.4 Alarm output (PPC6000)
Alarm
Type
Minimum current
Maximum current (per output)
Maximum voltage
On-off relay, de-energize for off.
200mA rms
4A rms
250Vac rms

13
1.5 Digital inputs (PPC6000)
Low Voltage digital inputs 1 to 4, HIGH
input, AUTO input.
Digital, Switching 0V to 5V pulsed. Feed must be taken from
the correct terminal as indicted in this manual. Inputs 1-4
configurable for 4-20Ma. Via function block programming.
Less than 25mA
10V absolute maximum
Profile Select High voltage inputs Digital, 0V for off, 90-264Vac for on.
1.6 Pressure/Temperature Input (PPC6000)
0-5V
Maximum current
Maximum voltage
Input accuracy (typical)
Input accuracy (as specified 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 specified by EN12067)
2 wire loop or ext. powered
0 to 25mA maximum
220 Ohm nominal
1.0%
1.1%
1.7 Communications interface (PPC6000)
2-wire RS485 plus ground, with termination resistor selected using a link. See Section 2.5.5.
An isolated 2-wire RS485 interface is available as an option. See Section 2.5.6.
See MOD-6101 (FIREYE serial communications protocol manual) for details.

14
1.8 Optional Oxygen Probe Interface Unit (NXO2INT) - optional
Supply voltage
Power consumption
Supply frequency
Ambient temperature range
Protection category
Unit dimensions
Weight
Interface to PPC6000 series.
Interface 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 specific CANbus.
FIREYE specific or 4-20mA
1.9 Optional Ambient Air Temperature Unit (NXIATS) - optional
Type
Ambient temperature range
Protection category
Unit dimensions
Weight
Interface to PPC6000 series.
CANbus
0 to 60C (32 to 140F)
NEMA3 (IP54)
57 x 63 x 35 mm (2.25 x 2.5 x 1.37 inches)
0.15 kg (5.4 oz.)
FIREYE specific CANbus.
1.10 Variable Speed Drive (VSD) Daughter Board (NXDBVSD) - 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 (fits inside PPC6000 unit).
3 max (non-isolated)
120ohms
3 max (isolated)
250 ohms
50v
Modbus RTU

15
1.11 Fireye NXC04, NXC12, NXC20, NXC20A, NXC40 Servo Motors
Interface to PPC6000
Speed
Microswitches
Torque
CANbus
30 seconds for 90 degrees.
Open & close positions
Driving Holding
NXC04 4Nm/ 3 ft/lb 2Nm
NXC12 12Nm/ 9 ft/lb 18Nm
NXC20 20Nm/ 14.7 ft/lb 18Nm
NXC40 40Nm/ 29 ft/lb 20Nm
Voltage:
VA rating
Protection Category
Typical accuracy
Accuracy (as specified by EN12067)
24-30Vac supplied from control only
NXC04 = 3VA
NXC12 = 5VA
NXC20, NXC20A = 10VA
NXC40 = 18VA
NXC04 = IP40, NEMA 1
NXC12, NXC20, NXC20A = IP54, NEMA 3S
NXC40 = IP65, NEMA 4
+/-0.1
+/-0.5
1.12 Fireye NXO2INT Oxygen Probe Interface Unit (optional)
Supply voltage
Power consumption
Supply frequency
Ambient temperature range
Protection category
Unit dimensions
Weight
Interface to PPC6000 / NX6100
Interface 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 specific CANbus.
FIREYE specific or 4-20mA

16
1.13 Fireye NXIATS Ambient Air Temperature Sensor (optional)
Type
Ambient temperature range
Protection category
Unit dimensions
Weight
Interface 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 specific CANbus.
1.14 Approvals
Tested in accordance with the Gas Appliance Directive (GAD 90/396 EEC), encompassing the following
standards:
SIL Level 3 – Kiwa Gastec Report #123836
ANSI/UL 462, Heat Reclaimers for Gas, Oil, or Solid Fuel-Fired Appliances
ANSI/UL 1995, Heating and Cooling Equipment
ANSI/UL 1998, Software in Programmable Components
CAN/CSA-C22.2 No. 236, Heating and Cooling Equipment
FM
ENV1954, Internal and external behavior of safety related electronic parts
EN60730-1, Automatic electrical controls for household and similar use
prEN12067, Gas/air ratio controls for gas burners as gas burning appliances
SIL level 3 per Kiwa report #123836
1.15 Parts List with Description
PART NO* DESCRIPTION
PPC6000 FUEL AIR RATIO CONTROLLER
PPC6000 Stand-alone parallel positioning controller, with up to ten (10) selectable function
CANbus servo-motor outputs. Includes user configurable function blocks for
custom applications. Display ordered separately.
DISPLAY MODULES FOR PPC6000
NX610 CANbus display for PPC6000 with upload/download of PPC6000 data and three
programmable relays
NXTSD104** 10.4” Touchscreen Display with upload/download, full commissioning, data log,
internet connection, four programmable relays, 10 line voltage Digital Inputs.
SERVO-MOTORS FOR PPC6000
NXC04 4 wire CANbus Servo-motor, 3 ft lbs. torque, 4 Nm, 50/60 Hz, 24 VAC.

17
PART NO* DESCRIPTION
NXC12 4 wire CANbus Servo-motor, 9 ft lbs. torque, 12 Nm, 50/60 Hz, 24 VAC.
NXC20, NXC20A 4 wire CANbus Servo-motor, 14.75 ft lbs. torque, 20 Nm, 50/60 Hz, 24 VAC.
NXC40 4 wire CANbus Servo-motor, 29.5 ft lbs. torque, 40 Nm, 50/60 Hz, 24 VAC.
EXPANSION INTERFACE MODULES FOR PPC6000
NXDBMB Modbus RTU communications card
NXDBVSD
VSD interface daughter board with two VSD channels, one analog output, two
counter inputs, two programmable relays, isolated RS485, Modbus RTU
communications
NXO2INT CANbus O2 interface module with Fireye and generic (4-20mA) probe inputs.
O2 PROBES FOR PPC6000
NXO2PK4 O2 probe assembly (for flues 300mm to 1000mm). Includes NXIATS CANbus
ambient temperature sensor, flange kit.
NXO2PK6 O2 probe assembly (for flues 600mm to 2000mm). Includes NXIATS CANbus
ambient temperature sensor, flange kit.
NXO2PK8 O2 probe assembly (for flues 1200mm to 4000mm). Includes NXIATS CANbus
ambient temperature sensor, flange kit.
NXIATS PPC6000 CANbus Inlet (ambient) Air Temperature Sensor Sensor -29C to
60C (-20F to 140F)
SENSORS FOR PPC6000
PXMS-15 Steam Pressure Sensor: 0 - 15 PSI, 0 - 1 bar, 4-20mA output, 1/2" NPT, non
self-check (for use with PPC6000).
PXMS-200 Steam Pressure Sensor: 0 - 200 PSI, 0 - 14 bar, 4-20mA output, 1/2" NPT, non
self-check (for use with PPC6000).
PXMS-300 Steam Pressure Sensor: 0 - 300 PSI, 0 - 21 bar, 4-20mA output, 1/2" NPT, non
self-check (for use with PPC6000).
BLPS-15 Steam Pressure Sensor: 0 - 15 PSI, 0 - 1 bar, 4-20mA output, 1/2" NPT, non
self-check (for 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
self-check (for 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
self-check (for 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
self-check (for use with PPC5000 / PPC6000 / NX3100 / NX4100 / NX6100).
TS350 (-2), (-4), (-8)
Temperature Sensor, Range 32oF-350oF (0-176oC), 4-20mA linear
output, includes 1/2 - 14 NPT well. See bulletin BLZPTS-1 for
complete description.
TS752 (-2), (-4), (-8)
Temperature Sensor, Range 32oF-752oF (0-400oC), 4-20mA linear
output, includes 1/2 - 14 NPT well. See bulletin BLZPTS-1 for
complete description.
SOFTWARE
NXAM ComFire communications software on CD for Nexus and PPC controls.
COMMUNICATION INTERFACE GATEWAY
NXDBVSD
VSD interface daughter board with two VSD channels, one analog output, two
counter inputs, two programmable relays, isolated RS485 – Modbus RTU
communications
NXMBIV2 Modbus RTU Communications daughter board.
* FOR ADDITIONAL PARTS SEE FIREYE PRICE BOOK CG-14
** SOME FEATURES INCLUDED ON NXTSD MANUFACTURED AFTER MAY 2011.

18
2 Installation
This section contains basic installation information concerning choice of control and servomotor environment,
wiring specification and connection details.
WHEN INSTALLING THIS PRODUCT:
Read these instructions carefully and ensure you fully understand the product requirements. Failure to
follow them could damage the product or cause a hazardous condition.
Check the ratings given in these instructions to ensure the product is suitable for your application.
After installation is complete, check the product operation is as described in these instructions
CAUTION
Disconnect the power supply before beginning installation to prevent electrical
shock, equipment and/or control damage. More than one power supply
disconnect may be involved.
Wiring must comply with all applicable codes, ordinances and regulations.
Loads connected to the PPC6000 series must not exceed those listed in the
specifications as given in this manual.
All external components connected to the control must be approved for the
specific purpose for which they are used.
WARNING
EXPLOSION OR FIRE HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY OR DEATH
To prevent possible hazardous burner operation, verification of safety
requirements must be performed each time a control is installed on a burner, or
the installation modified in any way.
This manual may cover more than one model in the PPC6000 controls. Check for
Additional Information at the end of this chapter.
This control must not be directly connected to any part of a Safety Extra Low
Voltage (SELV) circuit.

19
2.1 Mounting details for the PPC6000 control
A Template for mounting is provided at the end of this manual for convenience. See Section 8.
There are two versions of the control, one that is intended to be mounted inside of a burner control cabinet, the
other which has provision for conduit storage of field wiring etc. that can be mounted without the need for a
burner control cabinet. If the version which is designed to be fitted inside of a burner control cabinet is being
used the cabinet should have a minimum protection level of NEMA1 (IP40) for indoor use or NEMA3 (IP54) for
outdoor use.
The control can be mounted in any attitude; clearances of a least 2.36-inch (60mm) should be left around the
unit to allow sufficient space for wiring and to ensure reliable operation.
The ambient operating temperature range of the equipment is 0 to 60°C (32 to 140°F). Refer to section 7 for
more details.
0.75”
(19mm)
3.15”
(80mm)
6.26” (159mm)
6.93” (176mm)
4.65”
(118mm)
Terminal Block PA
Terminal Block PB
Terminal Block PE
Screen
Termination
Clamps

20
2.2 Mounting details for the display module
A Template for mounting is provided at the end of this manual for convenience. See Section 8.
NOTE: The four (4) M4 clearance holes are the mounting holes for the display. After removing the
back cover, carefully remove the four brass hex standoff’s to secure the display to the panel.
The display should be mounted on the front of the burner cabinet, or similar accessible location.
It extends for 31mm (1.22 inches) behind the panel, and 4mm (0.16 inches) in front of the panel.
The maximum allowable panel thickness is 7mm (0.275 inches).
8mm
The display is held in using the four brass standoffs. The panel is cut out inside the four mounting holes only.
Remove the four brass standoffs, insert the screw studs through the mounting holes, then re-install the brass
standoffs. Do not over tighten the standoffs.
A Template for mounting is provided at the end of this manual for convenience. See Section 8.
REMOVE AND REUSE
For Mounting
8mm
8mm