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Mk8 EGA 

Set-Up and Trim Guide

Содержание MK8 EGA EVO

Страница 1: ...Mk8 EGA Set Up and Trim Guide...

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Страница 3: ...red Holder Company Department This manual and all the information contained herein is copyright of Autoflame Engineering Ltd It may not be copied in the whole or part without the consent of the Managi...

Страница 4: ......

Страница 5: ...cal disciplines that are inherent to the Autoflame product range i e combustion electrical and control The sale of Autoflame s systems and equipment referred to in this Manual assume that the dealer p...

Страница 6: ......

Страница 7: ...one Mk8 EGA and Mk7 DTI 8 2 2 4 Interconnection between Mk8 MM Mk8 EGA and Mk7 DTI 9 2 3 Components 10 2 3 1 Inside View 10 2 3 2 EGA Connections 11 2 4 Cell Characteristics 12 2 4 1 O2 Cell 12 2 4 2...

Страница 8: ...Functions 44 3 7 5 O2 Limits Example 45 3 7 6 NO Limits Example 46 3 7 7 CO Limit Example 47 3 7 8 Temperature Limits Example 48 4 DIMENSIONS AND EQUIPMENT 49 4 1 Mk8 EGA Dimensions 49 4 2 Technical S...

Страница 9: ...1 Ambient Conditions 60 5 2 2 Fuses 60 5 2 3 O2 Reading 60 5 3 Mk8 EGA Faults 61 5 3 1 Trim Delay 63 5 3 2 Assembly of Dry Filter 63 5 4 EGA Best Practice 64 5 4 1 Servicing the EGA 65 5 4 2 Shipping...

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Страница 11: ...nted internally within the analyser Only the supplied sample tubing should be used between the sampling probe and analyser The internal diameter of the sampling tube is 3mm if a large diameter tubing...

Страница 12: ...art to trim back on the air by closing the air damper In reality this trim process is not trimming the combustion gases at this point but is in fact trimming the exhaust gases with the excess O2 This...

Страница 13: ...ata on the Mk7 DTI The DTI will need to be set up as EGA direct through the Edit Boiler screen and the EGA setup for standalone operation EGA selects fuel Using the EGA in conjunction with the MM modu...

Страница 14: ...ut 9 Fuel 2 Select Input 10 Fuel 3 Select Input 11 Fuel 4 Select Input 12 Fuel Select Input common 13 MM Comms 14 MM Comms 15 DTI Comms 16 DTI Comms 17 4 20mA Input 18 4 20mA Input 19 Not Connected No...

Страница 15: ...i Mains Connector Insert Pin Mating View Pin Number Assigned function 1 Live 2 Live for HSL 3 Earth for HSL 4 Neutral for HSL 5 Neutral 6 Earth Auxiliary Connector Figure 2 1 iii Auxiliary Connector I...

Страница 16: ...2 Wiring and Components Page 6 Mk8 EGA Set Up and Trim Guide 12 04 2016 2 2 Electrical Schematics 2 2 1 Interconnection between EGA and Mk8 MM...

Страница 17: ...2 Wiring and Components 12 04 2016 Mk8 EGA Set Up and Trim Guide Page 7 2 2 2 Interconnection between EGA and Mini Mk8 MM Module...

Страница 18: ...2 Wiring and Components Page 8 Mk8 EGA Set Up and Trim Guide 12 04 2016 2 2 3 Interconnection between Stand Alone Mk8 EGA and Mk7 DTI...

Страница 19: ...2 Wiring and Components 12 04 2016 Mk8 EGA Set Up and Trim Guide Page 9 2 2 4 Interconnection between Mk8 MM Mk8 EGA and Mk7 DTI...

Страница 20: ...im Guide 12 04 2016 2 3 Components 2 3 1 Inside View Figure 2 3 1 i Inside View 1 Particulate Filter 2 Chiller Block 3 Pinch Valve 4 Drain Solenoid 5 NO Cell 6 CO Cell 7 O2 Cell 8 CO2 Cell 9 CR Batter...

Страница 21: ...ons 1 Heated Sample Line HSL Power Connection EPA only 2 Heated Sample Line Fuse EPA only 3 Pre Heated Air Thermocouple Connection 4 Exhaust Temperature Thermocouple 5 Sample Line connection Power and...

Страница 22: ...rent flow between the electrodes is proportional to the oxygen concentration in the flue gases measured The O2 readings are not influenced from CO H2 S NOXand SOX so there is no cross sensitivity Figu...

Страница 23: ...2 readings are restored to a level within the pre programmed limits Figure 2 4 2 i NO and CO Cells Gas range Fuel Oil range Resoltuion at 20 C Repeatability Shelf Life CO 0 1000ppm Optional 1ppm 1 of...

Страница 24: ...s the user with detailed information about the current operation of the EGA components shown on this screen Fuel being fired and current EGA status Air calibration run etc Exhaust gas temperature Ambi...

Страница 25: ...ogen Dioxide Oxygen Sulphur Dioxide System Components Piping no flow Piping gas flowing Piping water condensate draining or air sample flowing Pump Pinch Valve Open Pinch Valve Closed Temperature Sens...

Страница 26: ...e unit 4 System language 5 Units being used Imperial Metric Note Buttons with the symbol are password protected or Press either of these buttons to toggle the units used by the system The text display...

Страница 27: ...s This information is arranged as follows 1 Image of the cell currently selected 2 Detailed information on the cell currently selected The status icons are OK Indicates the cell is healthy Not Fitted...

Страница 28: ...on the error This error is then logged onto the Error Log and can be accessed at any time by pressing the button on the sampling screen The last 10 errors are logged on this record and can be download...

Страница 29: ...r inaccurate combustion readings Errors are more serious damaging faults than warnings and would require immediate rectification Any warnings that occur are less damaging than errors however they shou...

Страница 30: ...from Figure 3 2 2 i and enter the password on the keypad displayed Upon entering the factory settings screen an overview of the EGA is displayed 1 The EGA ID current operating mode EGA status and cel...

Страница 31: ...that can be outputted 2 Select the desired data to be outputted by pressing on the appropriate button from the menu 3 A number pad will now appear allowing the minimum value of the data selected to be...

Страница 32: ...ing an EGA in standalone mode with a DTI it is necessary to give each EGA a different ID number 2 Mode of operation EGA with MM EGA selects fuel 3 Efficiency calculation European English 4 Presence of...

Страница 33: ...he currently set time 2 The currently set date 3 The new time and date to be set 4 Buttons to set a new date 5 Buttons to set a new time To change the time or date press the relevant button to what yo...

Страница 34: ...ton at any time To proceed with changing the password 1 Enter the new desired password using the keyboard Note this password down for future reference 2 Press 3 A prompt stating Retype New Password wi...

Страница 35: ...fuel setup screens press the Setup button at the top left of the EGA screen go to the Factory Settings you will be required to enter the password Press on the button in the bottom left corner of the s...

Страница 36: ...that can be used for each The calorific values for each are not configurable If a fuel cannot be found that has similar properties to what is required for accurate CEMS data analysis please contact A...

Страница 37: ...the fuel consumption can be determined based on the MM fuel flow metering which is entered through option 57 on the MM For the MM fuel flow metering based audits press the Fuel Flow Source button and...

Страница 38: ...uel cost and currency Once a fuel has been set accurate CEMS data can be obtained by entering an accurate cost per unit of fuel fired This is done using the Cost per Unit Currency and Costing Units bu...

Страница 39: ...Data Screens Figure 3 3 i Gas History Press the button to view the emissions data logging for up to 2 years Press to view the gas history The graph can be zoomed in by pressing 2 points on the axis T...

Страница 40: ...Page 30 Mk8 EGA Set Up and Trim Guide 12 04 2016 Figure 3 3 ii Pressure History Press to view the atmospheric ambient pressure history for up to 2 years The graph can be zoomed by pressing 2 points on...

Страница 41: ...e temperature history for up to 2 years for the ambient temperature exhaust temperature delta temperature relative humidity percentage and efficiency percentage The graph can be zoomed in by pressing...

Страница 42: ...time deselect the other fuels above the graph The left and right arrows are used to change the data range hours days months to the next available one The zoom out button is used to go back to the nex...

Страница 43: ...ption audits Select a time period using the arrow section on the CEMS data for which the fuel consumption will be calculated for Figure 3 4 i Product Totals Press to view the product and fuel totals T...

Страница 44: ...o view information on the fuel weights volumes and total costs as well as the total calorific value heat input total useful heat into the system and the average combustion efficiency As detailed in th...

Страница 45: ...CO2 upper limit offset 21 CO upper limit offset 22 O2 lower limit offset 23 CO2 lower limit offset 25 O2 absolute limit 26 CO2 absolute limit 27 CO absolute limit 28 Trim threshold 32 Trim delay 76 M...

Страница 46: ...ng procedure can be interrupted due to excess temperature or pressure causing the burner to turn off In these instances the commissioning data accumulated so far is not lost When the burner is called...

Страница 47: ...3 individually sampled parameters O2 CO CO2 in order to verify the combustion performance either side of the commissioned value The software within the MM unit will inflict minute corrections to the c...

Страница 48: ...tion 6 3 1000 5 5 10 5 50 Trim Values in red are ones that are not viewable using an O2 trim system State 1 The burner is operating under normal conditions State 2 Over a period of time boilers are su...

Страница 49: ...stion map button on the M M home screen The combustion map clearly shows the commissioned EGA values for O2 CO2 and CO The graph on the left of the screen shows the amount of trim being added by the M...

Страница 50: ...ING RATE RESIDENCE TIME AT CURRENT FIRING RATE RESIDENCE TIME AT CURRENT FIRING RATE RESIDENCE TIME AT CURRENT FIRING RATE RESIDENCE TIME AT CURRENT FIRING RATE RESIDENCE TIME AT CURRENT FIRING RATE R...

Страница 51: ...r fuel rich side of the commissioned value 3 The adjustment which would give rise to the current reading is calculated by linear interpolation of the commissioned values 4 Negate this adjustment to pr...

Страница 52: ...rection Weighting Weighted Correction O2 6 3 1 5 9 4 CO2 3 3 1 0 3 3 CO 3 0 1 0 3 0 Total 3 5 15 7 Average 4 5 Giving an additional trim of 4 5 which is then added to any existing trim if for example...

Страница 53: ...anges or input output min max Hertz are altered then re commissioning will be necessary as the stored feedback values for each MM entered point will now be incorrect These stored feedback values are u...

Страница 54: ...the commissioning of the EGA system has been completed throughout the firing range of the burner according to health and safety requirements or environmental regulations 3 7 3 Absolute Limits Absolut...

Страница 55: ...If the offset limit was set to 2 than the burner would alarm depending on the terminal 79 operation when the actual O2 value dropped below 2 offset from the commissioned value If the absolute lower l...

Страница 56: ...et limit was set to 20ppm than the burner would alarm depending on the terminal 79 operation when the actual NO value rose above 20ppm offset from the commissioned value If the absolute higher limit w...

Страница 57: ...mit was set to 20ppm than the burner would alarm depending on the terminal 79 operation when the actual CO value rose above 20ppm offset from the commissioned value If the absolute higher limit was se...

Страница 58: ...100deg F than the burner would alarm depending on the terminal 79 operation when the actual exhaust temperature value rose above 100deg F offset from the commissioned value If the absolute higher lim...

Страница 59: ...4 Dimensions and Equipment 12 04 2016 Mk8 EGA Set Up and Trim Guide Page 49 4 DIMENSIONS AND EQUIPMENT 4 1 Mk8 EGA Dimensions Figure 4 1 i Mk8 EGA Dimensions...

Страница 60: ...ations Electrical Electrical Supply Power 230 110V 50 60 Hz 160W Max Power Consumption Fuse Rating 225W 4A Pump Flow 110 120 mBar 600ml min Environmental Rating IP20 NEMA 1 Temperature Range E G A Min...

Страница 61: ...this will give incorrect readings on all sensors EGA Sampling System Unit Installation 1 Push the sample tube onto the inlet tube Plug the thermocouple connector into the socket and tighten the screw...

Страница 62: ...4 Dimensions and Equipment Page 52 Mk8 EGA Set Up and Trim Guide 12 04 2016 4 3 2 Sampling Probe Assembly Figure 4 3 2 i Sampling Probe Assembly Figure 4 3 2 ii Sampling Probe Dimensions...

Страница 63: ...4 Dimensions and Equipment 12 04 2016 Mk8 EGA Set Up and Trim Guide Page 53 4 3 3 Sampling Probe Internal Filter Figure 4 3 3 i Sampling Probe Internal Filter...

Страница 64: ...EGA to sample If the pump pressure or flow rate drops below 110mBar or 550 ml min respectively then the filtering material should be replaced To disassemble the probe unscrew the casing from the base...

Страница 65: ...office Figure 4 4 1 i External Particulate Filter Note For applications firing on heavy or dirty oil an external particulate filter is highly recommended to be fitted with the Mk8 EGA The external par...

Страница 66: ...can successfully be used to measure combustion exhaust gases when burning HFO it is very important that the fuel is carefully maintained at a constant and known composition The fuel temperature and p...

Страница 67: ...ssary to use an environmental enclosure with the EGA module This protects the EGA from dust and ensures that the EGA is well protected Using the enclosures allows the EGA to operate under optimal oper...

Страница 68: ...A Set Up and Trim Guide 12 04 2016 4 4 4 Pre Heat Air Sensor A Pre Heat Air Sensor has been incorporated into the Mk8 EGA to ensure an accurate efficiency calculation when using pre heated air This Pr...

Страница 69: ...supplied and marked Fragile Scientific Instruments and Do Not Drop It is possible to remove and re install the EGA at a later date without the burner needing to be re commissioning if using the trim f...

Страница 70: ...decreasing its temperature then check the operation of the fan If the ambient air in the boiler house is high it may be necessary to draw cooler air into the EGA In warm environments an air condition...

Страница 71: ...rozen Error Auto Clear Chiller Temperature has gone below zero 9 Chiller Temperature High Warning Auto Clear Chiller cannot maintain required temperature 10 Chiller Output Error Auto Clear Chiller cur...

Страница 72: ...Error Warning User Clear Thermocouple sensor in exhaust probe has a fault 1 Temperature HSL Error Warning User Clear Thermocouple sensor in HSL jacket has a fault 2 Temperature Chiller In Not Used Th...

Страница 73: ...mum of 40 seconds should be added Parameter 24 is set as default to 120 seconds so option 32 should be set to a minimum time of 160 seconds The total time before trim is applied is 200 seconds option...

Страница 74: ...his must read below 12 C 55 F before the E G A is ready to sample o If the unit is started up for the first time this could take a while for the unit to cool down o If the fan is not working this coul...

Страница 75: ...ility of the EGA Further issues such as pump problems chiller faults and inaccurate trim operation will occur 5 4 2 Shipping the EGA The EGA is a scientific instrument with delicate components Wheneve...

Страница 76: ...6 Standards Page 66 Mk8 EGA Set Up and Trim Guide 12 04 2016 6 STANDARDS UL 353 CSA C22 2 No 24...

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Страница 79: ...Notes...

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Страница 82: ...Autoflame Engineering Ltd 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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