NX6100 SERIES INTEGRATED BURNER CONTROLLER - …

1 1 NEX-6101 January 27, 2020 NX6100 SERIES INTEGRATED BURNER CONTROLLER DESCRIPTION The Fireye NEXUS NX6100 INTEGRATED CONTROLLER is a microprocessor based, Flame Safeguard and Parallel Positioning Combustion CONTROLLER built into one compact, user configurable package. The system consists of the CONTROLLER , Display, Temperature / Pressure Sensors, Servo-Motors and optional Comfire Software. The Flame Safeguard portion of the control package provides BURNER sequencing including safe start check, proof of main valve closure, selectable main gas safety proving sequence, supervised pre-purge, low fire starting position, pilot and main trials for ignition, main flame supervision, and post purge. Safety event timings are provided to meet North American and CE Standards. Time proven Fireye Flame Scanners and amplification circuits using UV, UV-Self Check and Infrared sensors, provide fast reliable scanning of most commonly burned fuels. For exotic fuels and applications, the NX6100 is also compatible with Fireye Phoenix and Insight INTEGRATED Flame Scanners.

2 Seven low voltage and two line voltage user defined auxiliary inputs provide supervision of safety critical and non-safety critical inputs. A large menu of alarm messages provides enhanced diagnostics. Control of up to four profiles using an independent Servo-Motor for each controlled element allows precise positioning, accurate to , of the fuel and air metering devices over the BURNER s firing range. Each profile can be defined to include up to 10 servomotors. Profiles can be configured to share common fuel servomotors or as independent (one profile per fuel) and are not limited by fuel. Up to 24 positions per profile including: Closed, Purge, Ignition (Preferred Start), Low Fire and an additional 20 intermediate points from low to high fire. Each individual servomotor s position and speed are verified and lockout will occur should either of these parameters be exceeded. All servomotors are controlled via secure CANbus communications link. Modulation control is provided via the pressure/temperature sensor s input.

3 The Fireye NX1025, NX1030 or NX1040 sensors provide checking circuits for fail safe operation. Two PID setpoints are available for the chosen modulation input, selectable up to two decimal points. Track modulation is available for those applications requiring less precise control. The NX6220 and NX6330 Twelve-Key Display allows commissioning and current status of the system through the use of its tactile membrane keypad. Multi-function keys allow the commissioning engineer the ability to access the various Ratio Modes and Option Select menus. The four-line OLED Display clearly illuminates the Control Variable, Firing Mode, Fuel Selected and Hours Run. It further allows the Boiler Operator access to the Auto/Manual selector, Motor Data (servo positions) and other operational parameters such as System Sequence Position, Valve Proving Sequence Status, Gas Pressure, Flame Signal, Modulation Rate and Setpoint, as necessary. Multiple Boiler Sequencing is accomplished through an RS485 Communications bus using Comfire software.

4 Lead/Lag and Standby set points for up to four (4) boilers can be configured. 2 Safety information WARNING 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. 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.

5 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.

6 3 Table of contents This manual - NX6101, describes the installation, commissioning, operation and maintenance of the NX6100 INTEGRATED BURNER controls. Please read the safety information at the front of this manual before proceeding. Note: The symbol in Section highlights the minimum Option Parameters required to set up the NX6100 1. Technical specification 11 General 11 Servo motor control IMPORTANT: See Section 11 Digital outputs ( NX6100 and optional daughter board P/N - NXDBVSD) 12 Alarm output ( NX6100 ) 13 Digital inputs 13 Pressure/temperature input 14 Auxiliary Analog Inputs 14 Gas pressure input 14 Flame sensing devices 15 Communications interface 15 Fireye NX1020-1,-2 gas pressure sensor 15 Fireye NX1030-1,-2 and NX1034-1,-2 steam pressure sensors 16 Fireye NX1040-1 and NX1044-1 boiler temperature sensors 16 Fireye NXC04, NXC12, NXC20, NXC40 Servo Motors 17 Fireye NXO2 INT Oxygen Probe Interface Unit (optional) 17 Fireye NXIATS Ambient Air Temperature Sensor (optional) 18 Fireye NXDBVSD Variable Speed Drive (VSD) Daughter Board (optional)

7 18 Approvals 18 Parts List with Description 19 2. Installation 22 Mechanical mounting details for the NX6100 23 Mechanical mounting details for the display module. 23 FIREYE NX6220, NX6330 MOUNTING DETAILS 24 Mounting details for optional Oxygen Probe Interface unit 25 Mounting arrangements for Temperature, Gas pressure and Steam pressure sensors 26 Boiler temperature sensors 26 Gas pressure sensors 26 Steam pressure sensors 27 Oxygen probe description 28 Installation of oxygen probe 29 Mounting the oxygen probe 29 Option link selection ( NX6100 ) 30 General 30 Line supply voltage (LK1 - 4) ( NX6100 ) 32 SENS IN and SENS SUPP (boiler temp/pressure sensor) ( NX6100 ) 32 REMOTE SETPOINT ( NX6100 ) 33 4 RS485 serial communications termination resistor ( NX6100 ) Isolated (MODbus) RS485 serial communications termination resistor (daughter board)

8 Wiring 33 33 33 General 33 Grounding cable screens. 35 GROUND (EARTH) connection 36 Ground (earth) Connection (display unit)36 Ground (earth) Connection (oxygen probe interface) 36 Ground (earth) Connection (servo motors and sensors) 36 Terminal Designation 37 LIVE and NEUTRAL supply ( NX6100 ) 42 BURNER fan output ( NX6100 ) 42 Ignition, main valves, pilot valve, vent and pump ( NX6100 ) 42 Auxiliary Relay Outputs (display) 43 BURNER select input ( NX6100 ) 43 Fuel and Profile Select inputs (optional) ( NX6100 ) 44 Low Voltage Digital Inputs 1 to 7 ( NX6100 ) 45 Low Voltage Air Flow Input ( NX6100 ) 45 Servo motor and Display Connection ( NX6100 ) 45 Pressure sensor screen termination 47 Pressure/temperature sensor input ( NX6100 ) 47 Gas pressure sensor input ( NX6100 ) 48 UV flame scanner 48 Photocell/ flame scanner 48 Remote Setpoint (Analog Input 5) ( NX6100 ) 49 Analog Input 1 to 3 ( NX6100 ) 49 RS485 interface ( NX6100 )

9 50 Variable Speed Drive Selection: 51 Variable Speed Drive Daughter Board P/N LIVE and NEUTRAL supply external interface P/N NXO2 INT 53 Oxygen probe connection (optional Oxygen Probe Interface unit) 53 Inlet temperature sensor (optional) 55 Final checks 56 3. Servo-motor selection and calibration57 Servo-motor selection 57 Motor requirements 57 IMPORTANT: Servo-motor direction warning 58 Locking the servo-motor to the valve shaft 59 Feedback potentiometer 59 Adjusting microswitch positions 60 Servomotor Replacement 61 4. Description of operation 62 OLED (Organic LED) Display & Keypad option 62 Start-up sequence 63 Gas safety valve proving sequence (VPS) 68 CLOSED 69 Modulation 69 Normal/Remote mode. 69 Local mode. (LOC 1, LOC 2) 69 5 5. Commissioning the control 70 General 70 Commissioning data 71 Option parameters 71 Setpoints 71 The Commissioning process 71 Navigation 71 Description of Touchscreen operation.

10 73 The Touchscreen 73 Touchscreen Power on. 73 The Operation Mode line and Status messages 73 Touchscreen Overview display. 75 Touchscreen Lockout Reset (Alarm Mute) Function. 76 Touchscreen LED Indication. 76 Touchscreen Fuel/Profile Select. 77 Touchscreen Control screen. 78 Touchscreen Menu button. 78 Touchscreen BURNER Settings button. 79 Touchscreen Fault/Event Log button. 80 Touchscreen Screen Configuration button. 80 Cleaning the Touchscreen 81 Touchscreen Commission mode. 82 Using option set mode 84 Option parameter list 84 Option - Site passcode (0 - 999) DEFAULT VALUE is 154. LV3 84 Option - Serial communications control address (0 - 15) LV3 84 Option - Reset hours run (0 - 1) LV3 85 Option User program select (0 / 1) LV1 85 Option Reserved 85 Option MODBUS device address (1 99) LV3 85 Option MODBUS communications speed (0 3) LV3 86 Option Power Up Option (0 - 30) LV3 86 Option Keyboard Auto/Manual enable (0 - 1) LV3 [Engineer s Key 33] 86 Option Mute/Reset Input enable (0 - 2) LV3 86 Option External profile select enable (0 - 2) LV3 87 Option Gas Valve Proof of Closure select (1 - 13) LV3 87 Option Oil Valve Proof of Closure select (0 - 13) LV3 88 Option Second Airflow switch enable (0 - 3) LV3 88 Option Safety time configuration set (0 - 1)