Nexus PPC5000 User manual

PPC5000 Fuel / Air Ratio Controller
Safety information
The equipment described in this bulletin contains hazardous voltages capable of inflicting
severe or lethal electric shock. 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 local Health & Safety and applicable legislation, regulations and Codes of
Practice.
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 the
supplier.
Installation, commissioning or adjustment of this product MUST be carried out by suitably trained
engineers or personnel qualified by training and experience.
In all cases it is the responsibility of the owner or user of this equipment to ensure that it is
installed, operated and commissioned in accordance with the applicable legislation for the country
in which it is being operated.
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.
This equipment must only be fitted to burners as detailed in the contract specification. The supplier must
approve any change in the specification in writing.
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, the electrical supplies must be isolated.
Safety interlocks must not be removed or over-ridden. Any faults once detected must be corrected before
the unit is operated.
CAUTION – THIS EQUIPMENT MAY CONTAIN A LITHIUM BATTERY
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 bulletin without notice.

Table of contents
This bulletin (PPC-5001) describes the installation and commissioning of the PPC5000 fuel / air ratio
controller. It may be used in conjunction with the following bulletins :
•Nexus NEX-1001 bulletin
•Nexus PPC5000 NEX – 1501 ComFire combustion analysis tool user bulletin
•Nexus PPC5000 NEX-SO boiler sequencing bulletin
Please read the safety information at the front of this bulletin before proceeding.
1. Installation 5
1.1 Mounting the control unit 5
1.2 Mounting the display 6
1.3 Circuit board removal 7
1.4 Changing the software EPROM and inserting communications feature IC 7
1.5 Control unit exploded view 7
1.6 Option link selection 8
1.7 Servo-motor Selection 9
1.8 Wiring 10
1.9 Final checks 15
2. Operation in run mode 17
2.1 Start-up Sequence 17
2.2 Modulation 21
2.3 Safety shutdown (burner lockout) 21
3. The display 23
3.1 Control unit display 23
3.2 Display parameters 24
4. Motor adjustment 26
4.1 Feedback potentiometer 26
4.2 Control direction 26
4.3 Adjusting microswitch positions 26
4.4 Locking the servo-motor to the valve shaft 27
5. Operation in commissioning mode 29
5.1 General 29
5.2 Commissioning data 30
5.3 Option set mode 30
5.4 Commission ratio mode 31
5.5 Adjust ratio mode 34
5.6 Finding the software issue & unit configuration 35
6. The oxygen trim option 37
6.1 Oxygen probe description 37
6.2 Installation of oxygen probe 38

6.4 Calibrating and servicing the oxygen probe 43
6.5 SOx, NOx, smoke, CO, AUX1, AUX2, O/P1, O/P2 46
6.6 Oxygen trim operation 46
6.7 Commissioning Oxygen trim 47
6.8 Troubleshooting 52
7. Inverter (variable speed) drives 55
7.1 System configuration 55
7.2 Description of control method 56
7.3 Setting up the inverter for use with the 5000 56
7.4 Setting up the 5000 for use with a inverter drive 58
7.5 Troubleshooting inverter problems 59
8. Option parameters 61
8.1 Option parameter list 61
8.2 Option parameter selection of profiles and drives 86
8.3 Derivation of modulation rate 87
9. Faults and fault finding 89
9.1 The fault display 89
9.2 Fault description 89
9.3 What to do if a fault occurs 90
9.4 Fault subsets 90
9.5 Fault Listing 91
9.6 The engineer's key 99
9.7 Troubleshooting 106
10. Technical specification 111
10.1 General 111
10.2 Basic motor drive board (standard) 111
10.3 Burner interface board (standard) 111
10.4 Power supply and boiler I/O board (standard) 112
10.5 Isolated drive board (optional) 112
10.6 Flue monitor interface board (optional) 112
10.7 Oxygen probe kit 112
11. 5000 Commissioning sheet 115
11.1 General & drive positions 116
11.2 Option parameters 117
12. Distribution board connections 119
12.1 AH221250 (for use with 2 x IDB) 119
12.2 AH221312 (for use with 1 x IDB & 1 x FMI) 120

1. Installation
Installation
This section contains basic installation information concerning the PPC5000 system (controller and panel-
mounted display), the servo-motors and the wiring.
Mounting the control unit
The control unit is designed to be fitted inside the
burner control cabinet. The cabinet should have a
minimum protection level of NEMA 12 (IP40) for indoor
use, or NEMA 4 (IP54) for outdoor use.
The control unit should be mounted so that the circuit
boards within it are vertical, to maximise cooling
efficiency.
A clearance is required of a least 3.2” (80mm) above
and 1” (25mm) below and at the sides of the controller
enclosure.
The operating temperature range of the equipment is
32 to 140F (0 to 60°C).
Mounting the display and display connections –
Wiring connections are:-
DISPLAY CONTROLLER PPC5000
1=5v PA8
2=key return PA9
3=data PA10
4=clock PA11
5=strobe PB3
6=ground PA15
5.7” (144mm)
2.7” (70mm)
8.1”
(205
mm)
8.7”
(220
mm)
7.6”
(192
mm)
1/8” (M4) CLEAR
ALL DIMENSIONS IN INCHES (MILLIMETERS)
FRONT VIEW
UP

Mounting the display
The display should be mounted on the front of the
burner cabinet, or similar accessible location.
It extends for [40mm]/[1.6in] behind the panel, and
[4mm]/0.2in] in front of the panel.
The maximum allowable panel thickness is
[7mm]/[0.3in].

Circuit board removal
Please refer to the exploded unit drawing over the page.
1. Disconnect the unit’s power supply.
2. Undo the four screws and remove the grey plastic lid to expose the connectors.
3. Remove all the connectors.
4. Undo the four hexagonal pillars, and lift away the retainer frame. Carefully remove the distribution
board.
5. Each of the daughter boards can now be removed as required by pulling on the edge of the PCB ( do
not pull the connector strips ).
Changing the software EPROM and inserting communications feature IC
To change the software EPROM, and add the communications features IC, it is necessary to follow the
steps detailed below :

1. Remove all of the daughter boards as described in the preceding
section.
2. The software EPROM is the device mounted in the socket immediately
adjacent to the CPU (see diagram). To remove it, gently lever each end
alternately until the device comes free. Avoid touching the pins and
place the device on a flat, conductive surface.
3. Before inserting the new software EPROM, it may be necessary to bend
the leads inwards slightly by pressing the device against a flat conductive
surface. Ensure that the device is inserted the correct way round by
ensuring that the notch on the device lines up with the notch in the socket.
Avoid touching the pins of the device.
4. The communications feature IC is inserted into the socket as on the
above diagram. Ensure that this device is inserted the correct way round.
Avoid touching the pins of the device.
5. Re-assemble the control unit.
Option link selection
General
The unit has a number of option selection links, located on various boards. The function and settings are
marked along side each link. These links must be set to the correct position before power is applied.
Power supply voltage
The 5000 control system must be set for the correct supply voltage.
The supply voltage is selected via a link arrangement on the power supply board. The possible supply
voltages are tabulated below, together with the necessary fuse rating.
Supply voltage(V) Links required Fuse rating (mA)
110 LK1 and LK3 315 anti-surge
120 LK4 and LK6 315 anti-surge
220 LK2 and PARK 160 anti-surge
240 LK5 and PARK 160 anti-surge
In order to set these links and fit the correct supply fuse, the power supply board must be removed (See
section 1 section 0-Circuit board removal on page 7).
Boiler pressure & temperature sensor type and supply
If a boiler pressure/temperature sensor or modulation potentiometer is used, the links LK9 and LK10 on the
power supply board must be set to suit the type of sensor. For example :
For a 4-20mA loop-power sensor, choose a +20V supply with current (I) input.
For a 0-5V modulation potentiometer, choose a +5V supply with voltage (V) input
Ensure that option parameter 3.2 is set to match this jumper position.
Potentiometer supply voltage
The 5000 can either supply +5v or +15v DC to the potentiometers.
IC14
IC17
IC15
COMMS IC
SOFTWARE
EPROM
C
P
U

If the potentiometer moves over its entire 270º range for 90º of servo-motor travel, select a +5v supply.
If the potentiometer is a 340º type but only moves over 90º of its range for 90º of servo-motor travel, select
a +15v supply.
For the basic drive board, a single jumper link (LK1) is fitted which determines the supply voltage for all
four feedback potentiometers connected to the board. The position for each supply voltage is printed on
the circuit board adjacent to the jumper.
For the isolated drive board, two jumper links are fitted which determine the supply to each of the two
feedback potentiometers connected to the board. The positions for each supply voltage are printed on the
board next to the link. LK1 selects the supply voltage for feedback potentiometer 1.
In order to set the feedback potentiometer supply jumpers, the boards must be removed from the
enclosure. For details of how to do this, See section 1 Circuit board removal
Potentiometer
type Supply voltage Minimum potentiometer
value(Ohms)
Maximum
potentiometer
value(Ohms)
270° with full travel 5V 1K 5K
340° with 90° travel 15V 3K 15K
RS485 TERM (RS485 serial communications termination resistor)
The position of this link is important only if the RS485 serial
communications are to be used. The two units at the end of the
communications bus should have this link set to the IN position.
All other units should have the link set to the OUT position. If
only two units are on the communications bus, set the links on
both units to the IN position.
This link is LK1 on the burner interface board.
Servo-motor Selection
Motor requirements
Since the servo-motors are not always supplied as part of the 5000 system, a few guidelines are useful
when selecting suitable motors other than those supplied by Fireye.
•All servo-motors must be of the same operating voltage, not exceeding 250V rms / 50V rms depending
on board type.
•All motors must be AC
•The servo-motor current must not exceed 150mA rms / 750mA rms depending on board type.
•If the motor voltage is lower than the mains supply voltage then a suitable power supply (such as a
transformer) must be provided
•The motor supply to the 5000 must be protected with a suitable fuse for the motors being used. The
fuse must not exceed 3A to ensure that damage to the control unit does not occur
•The servo-motor time for 90° movement must not be less than 10 seconds or more than 60 seconds
•All servo-motors must have internal limit switches fitted which are adjusted to prevent excessive
rotation
IN
OUT
RS485
TERM
IN
OUT
RS485
TERM
IN
OUT
RS485
TERM

•All servo-motors must have suitable protection for the burner environment (for example, IP65 for
applications exposed to the weather).
If in any doubt about a particular servo-motor’s suitability, seek confirmation from your equipment
supplier, who have a list of suitable motors.
Potentiometer requirements
All servo-motor potentiometers should be good quality plastic film types, with high resolution.
Depending on the supply voltage, a minimum resistance is allowed for the feedback potentiometers to
prevent excessive current consumption. See section 1 - Potentiometer supply voltage on page 8 for
details.
The potentiometer must be securely fixed to the output shaft of the gearbox in such a way as to give
accurate indication of the shaft position under all conditions and at all times.
Wiring
General
WIRING INSTALLATION MUST BE CARRIED OUT BY A COMPETENT ELECTRICIAN AND IS
SUBJECT TO ALL LOCAL WIRING REGULATIONS AND/OR LOCAL STANDARDS WHICH MAY
PREVAIL.
HAZARDOUS VOLTAGES MUST BE ISOLATED BEFORE SERVICE WORK IS CARRIED OUT.
The clamping bar on the control unit performs only an ground function and does not provide strain relief.
Secure all cables carried in conduit at both ends using a suitable anchorage method in the cabinet.
If the mains power is known to be noisy or suffer
from occasional brown-outs or black-outs then a
correctly rated (20w) UPS power supply should be
used to ensure a clean continuous mains power
supply to the 5000 controller. This must be
located as close as possible to the unit.
To comply with EMC requirements, wire the control unit using the specified cable sizes and shield
connections. Clamp all signal cable shields to ground using the clamping bar provided on the control unit.
Connect all cable shields to ground at the control unit end only, with the exception of the cables that
connect the display and pressure sensors.
The unit case and PA6 must be connected to Ground.
Using the cable clamp
A clamping bar is provided on the control unit for termination of cable shields where necessary.
The cable should be prepared by cutting around the outer sleeve, taking care not to damage the shield (1).
!
8mm
(1)
(2)
(3)