AUTOFLAME Mini Mk8 M.M. Installation And Commissioning Manual Download Page 1

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Summary of Contents for Mini Mk8 M.M.

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Page 2: ..._____________________________________ Department _________________________________________________ This manual and all the information contained herein is copyright of Autoflame Engineering Ltd It may...

Page 3: ...iplines that are inherent to the Autoflame product range i e combustion electrical and control Autoflame The sale of Autoflame s systems and equipment referred to in this Manual assume that the dealer...

Page 4: ...3 1 1 Commissioning Procedure 49 3 2 Installation Checks 49 3 2 1 Commissioning Checks 49 3 2 2 Operational Checks 49 3 2 3 Installation Precautions 50 3 2 4 Maintenance and Servicing 50 3 3 Servomoto...

Page 5: ...line Changes 87 3 9 General Operation 89 3 9 1 Calibrating the Actual Value 89 3 9 2 External Modulation 90 3 9 3 Additional Functions 90 4 REMOTE CONTROL 92 4 1 Modbus Settings Modbus 92 4 2 Modbus A...

Page 6: ...6 1 1 Mini Mk8 M M MK8 1 1 1 Fixing Holes and Dimensions...

Page 7: ...7 1 2 Wiring Schematic...

Page 8: ...8...

Page 9: ...tection Rating The unit is designed to be panel mounted in any orientation and the front facia is IP65 NEMA4 The back of the unit is IP20 NEMA1 IP65 NEMA4 IP20 NEMA1 1 3 2 Inputs and Outputs Inputs an...

Page 10: ...The high and low voltage connections are not safe to touch Protection against electric shock is provided by correct installation CAUTION ELECTRIC SHOCK HAZARD 2 Control voltage cabling should be maxim...

Page 11: ...ollowing The screened cable used for low voltage wiring from the M M to the servomotors detectors and variable speed drive must conform to the following specification 16 0 2mm PVC insulated overall br...

Page 12: ...d cable 2 twisted pairs Beldon 9502 4 3 STC OS1P24 STC OS1P24 Samples are available upon request Low voltage and data cable can be ordered directly from Autoflame Engineering please contact Autoflame...

Page 13: ...flame Autoflame 37 38 39 Connections to an Autoflame boiler temperature detector pressure Autoflame 40 0V supply to channel 1 and channel 2 servomotors 1 2 0v 41 12V supply to channel 1 and channel 2...

Page 14: ...71 Switched neutral drives channel 1 servomotor counter clockwise 1 72 Switched neutral drives channel 2 servomotor clockwise 2 73 Switched neutral drives channel 2 servomotor counter clockwise 2 74...

Page 15: ...15 1 4 Connection Between Mini Mk8 M M and Mk8 E G A Mk8 Mk8 E G A...

Page 16: ...16 1 5 Connection Between Mini Mk8 M M and Mk7 D T I Mk8 Mk7 D T I...

Page 17: ...17 1 6 Sequencing Connection Diagram Mk8...

Page 18: ...1 CH2 CH3 and CH4 refer to the rows of buttons respectively starting with CH1 at the top CH1 CH2 CH3 CH4 CH1 The options and parameters are all viewable while the M M is in run mode and the burner is...

Page 19: ...ng Password is displayed Use the keypad to enter the password then press Press on or to change the value of an incorrect entry Note The commissioning password should not be distributed to anyone who i...

Page 20: ...der and BC MM and Display software In the Commission Mode screen all the options parameters can be adjusted the gas pressure sensor can be commissioned the commissioned IR data can be uploaded and the...

Page 21: ...to the Commission Mode screen A full list of options are detailed on the next pages Options parameters 110 160 are the burner control settings and are safety critical these must be entered the same fo...

Page 22: ...alue and vice versa At times other than modulation the motors move at full speed or at the value set in option 75 Movement is limited by the slowest channel i e the slowest moving motor 75 6 100 3 0 U...

Page 23: ...Channels 1 2 3 1 2 3 Note If Option 8 is changed after commissioning then the M M will need to be re commissioned unless this option is returned to its previous value 8 8 9 1 Internal Stat Operation...

Page 24: ...be generated regardless of option 13 13 E G A 2 Applies trim 3 Applies trim combustion limits tested Note If option12 is set to 0 or 1 then the M M is commissioned without trim however trim can be ad...

Page 25: ...18 1 Carry Forward of Trim When the system modulates the correction that may already exist on the air damper position can be carried forward This option is only relevant if an E G A is operational on...

Page 26: ...ed from the required setpoint If the actual value is below this offset then the E G A will not trim If the trim is to be effective at all times then set this value to zero This Option must also be set...

Page 27: ...M will demand lag burners to be brought online or offline depending on load requirements See Parameters 86 and 87 for change down and up thresholds 86 87 1 100 Sequence scan time minutes Note Accurat...

Page 28: ...es a standby setpoint to keep the boiler in a standby condition This value is an absolute value set in this option When the standby setpoint is in effect the burner is held at low flame hold 43 0 Unus...

Page 29: ...50 If Centigrade Fahrenheit or PSI units effective 0 1 5 0 If Bar units effective 50 0 Flue Gas Recirculation Temperature Threshold The M M channels servomotors variable speed drive are held at the FG...

Page 30: ...ion 65 to either Metric or Imperial units 1 65 100 65000 100 1 00 MJ m3 or 100 Btu ft3 Note If switching from metric to imperial the value will need to be changed accordingly 62 2068 Fuel 2 Calorific...

Page 31: ...78 0 Unused 79 0 Unused 80 0 Outside Temperature Compensation 0 Disabled 1 Enabled 81 90 Setpoint at Minimum Outside Temperature 50 999 If Centigrade Fahrenheit or PSI units effective 5 0 99 9 If Bar...

Page 32: ...rvomotor Control Method 2 0 Autoflame servomotor 0 1 degree control Autoflame 0 1 1 Autoflame servomotor 0 5 degree control Autoflame 0 5 2 Industrial servomotor 0 1 degree control 0 1 3 Industrial se...

Page 33: ...o M M from VSD channel 4 4 0 200 Hertz 98 0 Input high speed to M M from VSD channel 4 4 0 200 Hertz 99 0 Unused 100 0 Sequencing D T I or Modbus operation D T I Modbus 0 M M D T I Sequencing D T I 1...

Page 34: ...r type 1 Standard scanner 2 Self check scanner 111 0 Interrupted Pilot 0 Interrupted pilot 1 Intermittent pilot 2 No pilot Note No pilot cannot be used with single valve pilot option 133 or switchover...

Page 35: ...nds 122 0 Flame sensor operation 0 UV 2 Ionisation 4 IR 5 IR and UV 6 IR and Ionisation 7 Ionisation to UV Switchover Note Ionisation to UVSwitchover is intended for Interrupted Pilot it cannot be use...

Page 36: ...s input 1 Pressure sensor 129 0 VPS Operation VPS 0 VPS operates before burner start up VPS 1 VPS operates after burner shutdown VPS 2 VPS operates before burner startupo and after burner shutdown VPS...

Page 37: ...pressure switch offset lower limit This Option has two functions 1 Static inlet pressure check lower limit This is checked prior to burner firing 2 Run pressure check lower limit This is an offset fro...

Page 38: ...0 wg 1 mbar 147 0 Air Pressure Error Only active during modulation The burner will shut down if outside this window 0 300 0 wg 0mbar 12 040 wg 30 0mbar 148 0 Air Pressure Sensor Type 0 Air switch on T...

Page 39: ...Input 156 0 Terminal T82 Function T82 0 Warming Stat 1 Valve Proving Mains Input 157 0 Unused 158 0 Unused 159 0 Unused 160 0 Clear ALL commissioning data 5 Clear ALL commissioning data and restore o...

Page 40: ...meters screen Like with the Options the Parameters can be easily viewed by feature by pressing the tabs MM PID EGA DTI and BC Figure 2 2 i MM PID EGA DTI BC A full list of parameters are detailed on t...

Page 41: ...ues are stored This allows some time for the E G A values to stabilise E G A E G A E G A 10 120 Seconds 5 10 Modulation Timeout If the boiler is not modulating after being asked to contribute to the l...

Page 42: ...time between calibrations if burner does not go of Mk 7 E G A 1 50 Value 12 6 0 hours 12 6 0 17 3 Number of Trims Before Limits Error Generated Number of trims before an E G A error is flagged when th...

Page 43: ...Efficiency Calculation Method Mk7 E G A only Mk7 E G A 0 English USA Canada incorporates hydrogen moisture loss 1 European 32 0 Unused 33 0 Unused 34 0 Unused 35 0 Unused 36 0 Unused 37 0 Unused 38 C...

Page 44: ...0 20 Bar PSI or 20 deg C deg F 20 20 Bar PSI 20 deg C deg F 56 0 External Load Detector Minimum Voltage 0 100 Value 100 10 0V 100 10 0V 57 10 Sequencing Highest M M ID This sets the number of M M s in...

Page 45: ...n Control Range The range is set for either low fire to high fire or zero to high fire 69 0 External Modulation Input Range 0 0 10V 0 20mA 1 2 10V 4 20mA Note A 500ohm resistor needs to be placed acro...

Page 46: ...actual reading is too high set a negative value to adjust if the reading is too low set a positive value 500 2000 Value 1000 100 0 1000 100 0 89 0 Stat Exerciser Period 0 3600 Seconds 90 0 Unused 91...

Page 47: ...or Modbus D T I Modbus 0 Disabled 1 Enabled 102 0 Unused 103 0 Unused 104 0 Unused 105 0 Unused 106 0 Unused 107 Online Changes Password Code 1 1 0 255 Code 1 1 108 Online Changes Password Code 2 2 0...

Page 48: ...fuel valve to the open position without increasing the air damper position Improper use may result in property damage serious physical injury or death If the M M is commissioned without an E G A then...

Page 49: ...ect operation of 1 Each operating control temperature pressure etc 2 Each limit switch temperature pressure low water cut off etc 3 Each interlock switch airflow switch high and low fuel pressure or t...

Page 50: ...these parts is usually diagnosed by the M M Contact Autoflame for preventative maintenance procedures please refer to the Valves and Servomotors manual for general checks Autoflame 3 3 Servomotors Au...

Page 51: ...ut the M M will only display from 6 to 96 degrees 90 360 6 96 All Channel 1 to 3 readings displayed on the M M are in angular degrees It is necessary to adjust the potentiometer in the servomotor asse...

Page 52: ...in on the servomotor Use the relevant channel up down buttons to position the pin so that when the servomotor is reassembled to the valve it is in line with the slot Reassemble the servomotor to the v...

Page 53: ...53 3 3 3 Servomotors Direction Change...

Page 54: ...butterfly valve 0 For both valves the external visual position indicator is in line with the position of the butterfly valve Regardless of the type of valve being used the servomotor is dispatched fro...

Page 55: ...um of 3 INTER points entered on the fuel air curve and a maximum of 18 Points can be added in Single Point Change mode see section 3 7 3 18 3 7 During commissioning the required setpoint is not active...

Page 56: ...ssioning Figure 3 4 1 i Starting Commissioning Once the options and parameters have been set press on the Commission Mode screen in Figure 2 1 ii If the M M has already been commissioned then press on...

Page 57: ...limitations that may be present on the damper valve This may cause damage to the servomotor and or the damper valve Use the buttons to set the positions to 0 0O 0 0 Note Double check the damper valve...

Page 58: ...3 i Enter OPEN Position Press and then drive the fuel and air servomotors to their OPEN position The button hold facility allows multiple channels to be driven up or down at the same time Press on th...

Page 59: ...nnot be adjusted at this stage its calibration is dictated by the drive set up and relevant options 90 90 4 4 Press to save the OPEN positions Pressing on the Fuel Air tab at any time will give you a...

Page 60: ...the burner to make adjustments to the start gas flame if needed If the flame goes out during this time a lockout is set after 20 seconds If the flame is present and the phase hold condition is left i...

Page 61: ...ssioning process WARNING IT IS THE RESPONSIBILITY OF THE FACTORY TRAINED TECHNICIAN TO ENSURE THAT USE OF THE PHASE HOLD FACILITY DOES NOT LEAD TO A HAZADOUS SITUATION FAILURE TO DO SO WILL RESULT IN...

Page 62: ...ing the servomotors for the HIGH INTER GOLDEN START FGR START and START positions the trim data will also need to be saved for the fuel rich and air rich trim conditions The message Waiting for EGA re...

Page 63: ...6 ii After you press to save those servomotor positions the E G A will carry out its fuel rich and air rich trim E G A Once these trim values have been saved the system will continue with the commissi...

Page 64: ...64 3 4 7 Commissioning VSD Figure 3 4 7 i Commissioning VSD Press on the VSD tab to view the VSD output and input signal during commissioning...

Page 65: ...just add the GOLDEN START position or go through the entire commissioning process again 29 1 To re commission the M M proceed as described in sections 3 4 2 and 3 4 3 After entering the START positio...

Page 66: ...mbustion curve If the Golden Start fuel position is outside of the main curve then both the air damper and fuel will go to the Low Fire position Once on the commission curve the M M will modulate as p...

Page 67: ...y a quantity approximately 15 of the boiler flue gases are fed back to the burner and mixed with the combustion air The virtue of FGR is the reduction of NOx gases With the FGR facility servomotor cha...

Page 68: ...r and fuel valve some degrees alternatively so that more fuel is added gradually WARNING IT IS THE RESPONSIBILITY OF THE COMMISSIONING ENGINEER TO ENSURE THAT THE FLAME IS SAFE AND THERE IS A GOOD COM...

Page 69: ...he first INTER position There must be a minimum of 0 5O gap between the positions entered on the fuel channel Press to store this INTER position 0 5O There must be a minimum of 3 INTER points entered...

Page 70: ...ER points have been added you will be prompted to either enter another INTER point or the START LOW FIRE position 3 Press to drive the servomotors and VSD to the START LOW FIRE position and then press...

Page 71: ...power loss to the unit will result in a loss of data for the fuel selected If during commissioning the burner turns off due to the running interlock opening or a lockout it is possible to carry on co...

Page 72: ...If there is E G A trim data to be added then continue to section 3 7 Single Point Change before section 3 5 Fuel Flow Commissioning 3 5 E G A 3 5 3 7 Note If commissioning a fuel for the first time th...

Page 73: ...will assume a default burner rating which is based on the fractional fuel valve angle The fuel flow is commissioned from the high fire point down to low fire If a fuel flow meter is not being used and...

Page 74: ...1 56 1 08 Fuel flow metering serves to totalise the amount of fuel being used at each position If any changes are made to the curve through Single Point Change then fuel flow will need to be re commi...

Page 75: ...75 Figure 3 5 ii System Configuration Screen On the System Configuration screen press You will be prompted to enter the Online Change passwords Press and to access the Online Changes screen Press...

Page 76: ...rn key to save that point Note The servomotors will drive up to the high fire position and then drive down as the fuel flow commissioning points are entered Precautions must be taken to ensure that th...

Page 77: ...nt Redwood No 1 Redwood Viscosity at 37 8 C 100 F 37 8 C 100 F 33 approx 250 max 1000 max 3500 max Freezing point C F Below 40 Below 40 Below 40 Below 40 Below 40 Cloud point C max 2 2 Gross calorific...

Page 78: ...ulations Correction factor pressure of gas at meter x 0 00228 0 948 x 0 00228 0 948 Reading on gas meter required gas flow correction factor Example Pressure of gas at meter 58 wg 58 wg Required gas f...

Page 79: ...71 2 491 24 901 1 0443 15 0 542 381 28 006 3 736 37 352 1 0569 20 0 722 508 37 341 4 981 49 802 1 0694 25 0 903 635 46 677 6 227 62 253 1 0819 30 1 083 762 56 012 7 472 74 703 1 0944 35 1 264 889 65 3...

Page 80: ...his volume flow by 60 to give volumetric flow per hour i e ft3 hr 1 60 1 3 Measure the pressure of the gas supply 4 Use the table above to obtain a conversion factor 5 Multiply the volume flow per hou...

Page 81: ...essure values along the curve Once these values are stored the upper and lower offset limits will be adjusted to the new commissioned gas pressure values VPS If the burner turns off during the gas air...

Page 82: ...3 7 i Single Point Change Press in the system configuration screen and enter the password to access Single Point Change mode Select the point to be edited or added trim to by pressing or to go up and...

Page 83: ...djustments to the positions as needed see Figure 3 7 iiii 3 7 iiii To enter a new point press To add trim data to a point press see section 3 4 6 and Figure 3 7 iv EGA 3 4 6 3 7 iv Note It is not poss...

Page 84: ...the fuel air and or VSD commissioned value of that point Once the changes have been made press to save this position If a point is overwritten the trim data is cleared EGA Press to remove the point t...

Page 85: ...85 Figure 3 7 iv Single Point Change Trim EGA The M M will store the trim values for this position EGA...

Page 86: ...Figure 3 7 i and press 3 7 i Press to leave Single Point Change mode The fuel flow commissioning must be entered again if the following changes are made in single point change HIGH or START position...

Page 87: ...em configuration screen and then entering the password The Online Changes feature allows the following Fuel flow commissioning section 3 5 3 5 Change non safety critical options and parameters Reset b...

Page 88: ...start M M if the burner is in standby Press on or to change the settings For the Reset function press the data to be reset e g and then press on Press on while the burner is in standby to restart the...

Page 89: ...rated via Commissioning Mode or through Online Changes Note The percentage change may not be linear to the current temperature pressure i e 80 of 100 C may not show 80 C 100 80 80 For example if the a...

Page 90: ...hold input Terminal 82 is used for warming stat and valve proving mains input Proving valves end switch provide a secondary confirmation that a valve has reached a predefined position 154 155 156 80 8...

Page 91: ...k Autoflame 3 9 3 i 6 S1 S2 S1 S2 80 81 If option parameter 154 is set to 1 then the M M waits at RUN TO IGNITION until this interlock is made on terminal 80 If option parameter 155 is set to 1 then M...

Page 92: ...ce ID by setting option 104 10 Mk8 27 28 104 Mk8 Modbus The maximum block of addresses the Mini Mk8 M M can read and write to is 127 as per Modbus having a built in limit of 255 byte packets Mk8 127 M...

Page 93: ...ent to 90 0O 0 65534 1 Modbus 900 90 0O 4x Read Write analogue outputs variable adjustments 4x 0x 00001 Enable Disable M M 0 Burner is enabled 0 1 Burner is disabled 1 This changes the state of the en...

Page 94: ...urner not disabled 0 1 Burner is disabled 1 This shows the state of the enable disable button on the home screen Returns same value as address 00001 00001 3x 30101 Firing Rate 30102 Firing Status 0 No...

Page 95: ...0 457 value would be 45 7O 457 45 7O 30110 Channel 2 Position 2 Degrees x 10 x 10 30111 Channel 3 Position 3 Degrees x 10 x 10 30113 M M Error Number Error code See section 6 1 6 1 30115 E G A Run O2...

Page 96: ...E G A Commission NO Value E G A NO ppm x 10 30128 E G A Commission SO2 Value E G A SO2 ppm x 10 3x 30129 E G A Error Code E G A Error code See Mk8 E G A Set Up and Trim Guide manual Mk8 E G A 30130 M...

Page 97: ...MBTU hr MMBTU hr Remainder after whole number of MW hr or MMBTU x 1000 taken away x 1000 E g 1 5MW hr gives 500 value and 15 1MMBTU gives 100 value MW hr MMBTU x 1000 1 5MW hr 500 15 1MMBTU 100 30135...

Page 98: ...elta Metric O C x 10 O C x 10 Imperial O F x 10 O F x 10 30804 Channel 4 VSD Output 4 mA x 10 V x 10 55 value is 5 5mA or 5 5V 55 5 5mA 5 5V 30805 Channel 4 VSD Input 4 mA x 10 V x 10 This input reads...

Page 99: ...rial Temperature O F Pressure PSI Low Pressure PSI x 10 O C Bar x 10 Bar x 100 O F PSI PSI x 10 After 1 minute of no Modbus communications to the unit the M M will ignore this required value and use t...

Page 100: ...47 40 47 Check signal cable from the M M to the servomotor is screened at one end Check potentiometer is zeroed correctly Go into Commissioning mode check the servomotor position and ensure that close...

Page 101: ...ect direction Check valve is not stuck 10 Channel 2 Movement Error 2 No movement detected when servomotor requested to move Check wiring and voltages on terminals 40 47 and 70 75 40 47 70 75 Check act...

Page 102: ...act Autoflame Autoflame 17 Watchdog Timeout Internal fault Check wiring and voltages on all terminals and if no fault found contact Autoflame Autoflame 18 Processor Clock Error Internal fault Check wi...

Page 103: ...7 Load Sensor Error Load sensor is out of range Check load sensor wiring and ensure that the return voltage resistance is less than 1V 1k 1V 1k 28 VSD Error Feedback incorrect Check VSD feedback again...

Page 104: ...6 VSD Sampling Error VSD feedback current voltage too high Check wiring on terminals 1 3 and 10 12 1 3 10 12 37 VSD Feedback Too Low VSD feedback value is too low during commissioning Check wiring on...

Page 105: ...er 136 136 Re commission gas pressure sensor 41 Air Pressure Commission Fault Air pressure commissioned value too low for main curve golden start Check option parameters 147 and 149 147 149 Re commiss...

Page 106: ...running 3 Ignition Output Fault Voltage detected when output is off and vice versa Check wiring and voltage on terminal 63 63 4 Motor Output Fault Voltage detected when output is off and vice versa C...

Page 107: ...ately Call a certified Commissioning Engineer to investigate If during shutdown a post purge maybe required for after burn 11 VPS Air Proving Fail VPS Leak detected during air proving part of VPS VPS...

Page 108: ...tion 17 Gas Pressure Low Gas pressure low limit exceeded gas sensor Check gas pressure Check option parameter 136 136 18 Gas Pressure High Gas pressure high limit exceeded gas sensor Check gas pressur...

Page 109: ...toflame Autoflame 28 Watchdog Fail 2D 2D Internal check failed Check wiring and voltages on all terminals and if no fault found contact Autoflame Autoflame 29 Input Fault Power supply fault Check main...

Page 110: ...ed when there should be Check wiring on terminal 64 64 Visually check flame Check IR scanner Call a certified Commissioning Engineer to investigate Lockout Message Description 52 High IR Ambient Flame...

Page 111: ...es on terminals and if no fault found contact Autoflame Autoflame 67 Gas Pressure Sensor Timeout Signal lost from gas pressure sensor Check gas pressure sensor wiring on terminals 29 30 48 and 49 29 3...

Page 112: ...ed Value Wrong Incorrect air pressure value Check air pressure sensor value during VPS VPS Check wiring on terminals 29 30 48 and 49 29 30 48 49 76 Air Pressure Out of Window Incorrect air pressure va...

Page 113: ...5 3 Troubleshooting and Further Information 5 3 1 UV Shutter Faults UV shutter fault there are two LED s on the back of the self check UV The red LED indicates the presence of a flame the yellow LED...

Page 114: ...ed to use a swivel mount assembly UVM60003 UVM60004 in order to obtain maximum pick up This will allow the commissioning engineer to reliably sight the UV for optimum performance and trouble free oper...

Page 115: ...ng M M Error is caused by incorrect wiring and incorrect servomotor position In addition to checking the wiring and zeroing the potentiometer please also check that the correct voltage is supplied to...

Page 116: ...sample period then it will get stuck in an unsafe state This will cause an Input Fault lockout to occur 50 75 If this lockout persists the mains input should be checked To troubleshoot this issue plea...

Page 117: ...maximum allowed Second Safety Time Option 123 is 10 seconds 2 151 123 10 128 156 128 156 T82 is not set as VPS input 128 156 T82 VPS If Gas Pressure Limits Valve Proving is Optioned and Configured as...

Page 118: ...erciser should not be optioned if sequencing is enabled 16 45 45 16 External Modulation cannot be used with sequencing 45 16 45 16 External Modulation cannot be used with sequencing 45 16 81 82 83 84...

Page 119: ...vos is different than that stored in the commission data VSD configuration does not match commissioning Option 90 Option 91 Option 95 90 91 95 VSD configuration has changed since commissioning May be...

Page 120: ...et to default values Parameters have been reset Parameters could not be loaded from non volatile storage and were reset to default values VPS sensor not commissioned VPS Gas pressure sensor has been o...

Page 121: ...old in Option 147 or Option 149 147 149 IR Upload was completed successfully check configuration then restart This message appears once after every successful upload Options and or Parameters reset to...

Page 122: ...122 Notes...

Page 123: ...123...

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Page 125: ...125 Autoflame Engineering Ltd Autoflame Unit1 2 Concorde Business Centre Airport Industrial Estate Wireless Road Biggin Hill Kent TN16 3YN United Kingdom 44 0 845 872 2000 www autoflame com...

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AUTOFLAME Mini Mk8 M.M., Installation And Commissioning Manual

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