Page 1 Mk7 Manual: Expansion Board Set-Up Guide...
Page 3 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 Managing Director. Autoflame Engineering Ltd’s policy is one of continuous improvement in both design and manufacture.
Page 5: Important Notes
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, purchaser and installer has the necessary skills at his disposal. i.e. A high...
Page 7 Commissioning Procedure..................... 20 2.3.2 Operational Checks ...................... 23 First Outs Set-Up ........................24 Integrating Other Water Level Controls with Autoflame ............26 WATER LEVEL PROBES ................... 27 Breaking Bubbles/Spray ....................... 27 3.1.1 Thermal Currents (heat energy in water) ..............27 3.1.2...
Page 8 Solenoid Valve TDS Blowdown ..................57 4.3.4 Installation of TDS Probe Assembly ................58 TDS Probe and Autoflame Sampling Vessel ................. 59 Top Blowdown Adjusters ...................... 60 Sample Routine ........................62 Relationship between Conductivity, Temp and TDS Values ..........63 BOTTOM BLOWDOWN ..................
Page 9 Heat Flow Metering ....................111 6.2.4 Heat Flow Metering with Economiser ................. 112 DRAFT CONTROL ....................113 Introduction to Draft control ....................113 Autoflame Fully Integrated Draft Control ................113 Set-Up ..........................115 7.3.1 Terminals ........................115 7.3.2 Draft Control Expansion Options ................115 Commissioning with Draft Control ..................
Page 11: Introduction
It follows that the water feed would then turn off or go to a low flow condition. The Autoflame system identifies this ambiguous condition by monitoring the sudden increase in burner firing rate to meet the load demand and increases the “required water level”...
Page 12: Water Level Schematic
1 Introduction 1.1.2 Water Level Schematic Page 2 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 13: Water Level Features
‘control point’ level. The commissioning procedure for water level control, with a Mk7 M.M. unit and Mk7 Expansion Board, is extremely time-efficient and can be performed at operating pressure.
Page 14 The bottom of probe level is used to identify the point below which the probe cannot obtain a valid water level, it has no operational use. Figure 1.2.i Capacitance Probe Page 4 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 15: Set-Up
2 Set-Up SET-UP Expansion Board Wiring and Dimensions 2.1.1 Wiring Diagram October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 5...
Page 16: Dimensions
2 Set-Up 2.1.2 Dimensions Page 6 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 17: Terminals Description
VSD signal input circuitry is earthed, do NOT install a link. ALL TERMINALS MARKED “S” ARE CONNECTED TO MAINS EARTH TERMINAL 66 ON THE MK7 M.M. AND ARE ONLY FOR CONNECTION TO CABLE SCREENS Terminal Block 1 Top Bowdown and Feed water valve position potentiometer...
Page 18 3T+ Connections solely dedicated to the Autoflame T.D.S. probe Connections solely dedicated to the Autoflame T.D.S. probe 1P+ Connections solely dedicated to the Autoflame control probe 1 Connections solely dedicated to the Autoflame control probe 1 1T+ Connections solely dedicated to the Autoflame control probe 1...
Page 19 FO14 First Out annunciation input 14 FO15 First Out annunciation input 15 High water auxiliary input low auxiliary input Only available with Autoflame Water Level Control low auxiliary input System alarm reset/mute System test Motorised draft control damper positioning motor – increase (output switched neutral) Motorised draft control damper positioning motor –...
Page 20: Electrical Specification
Commissioning Guide for other general ratings. The Autoflame water level PCB has one main fuse located next to the PF Terminal. It is a 2A (T) Fuse. When upgrading or replacing an existing older version water level board to the current expansion board, you can use the existing water level software or the latest expansion board software.
Page 21: Options
Expansion Options. These expansion options will need to be configured before commissioning the water level probes. To go into the additional water level set-ups, set M.M. parameter 109 to 1. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 11...
Page 22 Mk6 mode screen. The visual alarm will still be displayed until the fault condition has cleared when the water level reaches the operating level. Disabled This option disables Autoflame water level control. Modulating Feedwater control element: Required for display purposes.
Page 23 RUNS STOPS Boiler Standing Losses: Percentage of boiler Maximum Continuous Rating, for the purpose of 1.00% steam flow metering only. 0 - 2.00 % (Increments of 0.1) October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 13...
Page 24 - see Expansion Board Set-Up Guide. Expansion Option 22.1 must be set to 0, 3 or 4 so the TB output terminal performs the Top Blow Down function, or TB and TB2 perform t TDS Continuous Blowdown. Disabled Enabled Page 14 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 25 Minimum Bottom Blowdown Time 0 - 60 Seconds Boiler Steam Production Rating (units are set through M.M. option 77) 36.4 0 - 1000 37.1 Second Low Probe Enable/Disable Disabled Enabled October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 15...
Page 26 Pressure Tolerance Before Fault: This is the maximum allowable pressure change from commissione draft air pressure values over 2 minutes before an error message is displayed on the screen. 0 - 50 PSI (0.0 - 5.0 Bar) Page 16 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 27 1 - 60 Seconds 42.1 Enable TDS and Feedwater Servo Checks Feedwater and TDS Servo checks do not operate Feedwater and TDS Servo checks operate manually October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 17...
Page 28 Non-movement detection: If the water is still, the frequency will drop below 10Hz and a fault occurs. Detect Turbulence Time: 1 - 100 Seconds Note: If expansion option J.1 is set to 0, then this function is disabled. Page 18 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 29 Steam Flow Stop Pressure Offset: This is an offset below the required pressure. If the pressure drops below 5 units, steam flow metering will stop. 0 - 100 PSI (0.0 - 10.0 Bar) 1000 Maximum Probe Reference Drift: Disabled 1 - 3000 October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 19...
Page 30: Commissioning Water Level
Once the burner is commissioned with the Mk7 M.M., the water level probes will need to be recommissioned once the boiler is up to pressure, and water in the boiler is hot enough. If the water level control is optioned, the M.M. will be in error and cannot be commissioned until the probes have been set-up.
Page 31 Once the expansion setups have been set for the application, press to commission the water level probes. For commissioning the screen will be in Mk6 mode. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 21...
Page 32 CH1 and CH2. Again, after allowing some time for the values to stabilise, press then to save the current water level. Page 22 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 33: Operational Checks
Once the water level control has passed these operational checks, the burner can now be commissioned with a fuel to air curve, after which the probes are re-commissioned at boiler pressure. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 23...
Page 34: First Outs Set-Up
“normal” to “fail” as detailed above. This first out fail status will remain until reset. To set First Outs in a Mk7 M.M. it is required to use the IR Upload/Download software to label the First Outs and specify what action is taken if a First Out fails.
Page 35 When using First Out Annunciation with a Mk7 M.M. it is not always necessary to tie in switches to the burners run circuits as the Mk7 M.M. is fully capable of turning off the burner if the First Out has been set to Recycle or Non-Recycle.
Page 36: Integrating Other Water Level Controls With Autoflame
Integrating Other Water Level Controls with Autoflame It is possible to retain the site’s existing float type level controls. Autoflame have allocated 3 terminals to accommodate “high”, “1st low” and “2nd low”. This is a user selectable facility which can be accessed by the expansion options.
Page 37: Water Level Probes
A second set of turbulence is the wave reflections off the sides of the boiler. The whole of the above is largely attenuated away by mounting the probes externally to the main boiler shell in a separate pot or pots. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 27...
Page 38: Steam Flow Induced Surge
The Autoflame system takes into account all of these variables and uses them to create a control algorithm that produces perfect level control with absolute safety.
Page 39: Schematic Explanation Of The Water Level Probe Operation
3 Water Level Probes Schematic Explanation of the Water Level Probe Operation October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 29...
Page 40: Capacitance Probe
3 Water Level Probes 3.2.1 Capacitance Probe Figure 3.2.1.i Capacitance Probe – External View Figure 3.2.1.ii Capacitance Probe – Internal View Page 30 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 41: Schematic Of The Probe Sampling Software
3 Water Level Probes Schematic of the Probe Sampling Software October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 31...
Page 42: Capacitance Probe – Externally Mounted Pots
CODES MUST BE ADHERED TO IN ALL CASES. IT IS IMPORTANT TO USE ONLY QUALIFIED AND EXPERIENCED INSTALLATION PERSONNEL. AUTOFLAME TECH CENTRES CAN ADVISE. UNDER ALL CODES THAT AUTOFLAME ARE AWAR OF, IT IS NOT PERMITTED TO FIT 2 PROBES IN ON EXTERNAL POT. IF IN DOUBT, PLEASE CONTACT AUTOFLAME.
Page 43 PURPOSES ONLY. LOCAL, NATIONAL AND STATE CODES MUST BE ADHERED TO IN ALL CASES. IT IS IMPORTANT TO USE ONLY QUALIFIED AND EXPERIENCED INSTALLATION PERSONNEL. AUTOFLAME TECH CENTRES CAN ADVISE. UNDER ALL CODES THAT AUTOFLAME ARE AWAR OF, IT IS NOT PERMITTED TO FIT 2 PROBES IN ON EXTERNAL POT. IF IN DOUBT, PLEASE CONTACT AUTOFLAME.
Page 44: Capacitance Probe – Internally Mounted Pots
*IMPORTANT NOTE: THE NOTES AND MECHANICAL EXECUTIONS IMPLICIT IN THESE DRAWINGS ARE FOR GUIDANCE PURPOSES ONLY. LOCAL, NATIONAL AND STATE CODES MUST BE ADHERED TO IN ALL CASES. IT IS IMPORTANT TO USE ONLY QUALIFIED AND EXPERIENCED INSTALLATION PERSONNEL. AUTOFLAME TECH CENTRES CAN ADVISE.
Page 45 *IMPORTANT NOTE: THE NOTES AND MECHANICAL EXECUTIONS IMPLICIT IN THESE DRAWINGS ARE FOR GUIDANCE PURPOSES ONLY. LOCAL, NATIONAL AND STATE CODES MUST BE ADHERED TO IN ALL CASES. IT IS IMPORTANT TO USE ONLY QUALIFIED AND EXPERIENCED INSTALLATION PERSONNEL. AUTOFLAME TECH CENTRES CAN ADVISE. IF IN DOUBT, PLEASE CONTACT AUTOFLAME.
Page 46: Capacitance Probe – Installation For A Water Tube Boiler
3 Water Level Probes Capacitance Probe – Installation for a Water Tube Boiler Page 36 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 47: External Probe Chamber Dimensions
3 Water Level Probes External Probe Chamber Dimensions October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 37...
Page 48: Capacitance Probe Specification
Power Supply - Green Data Transmission + Yellow Data Transmission - Probe No.2 Colour Description Terminal Power Supply + Blue Power Supply - Green Data Transmission + Yellow Data Transmission - Page 38 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 49: Water Level Treatment
Autoflame system. The water level treatment will also affect the long term operational life of the Autoflame capacitance probes. Water treatment companies should be able to assist with the selection and implementation of a suitable water treatment regime.
Page 50: Nd Low Probe
 Certified low water cut off probe  Internal relay self-checking  Can be used with the Autoflame system, or as standalone  Volt free contacts for external safety devices or circuits  Stainless steel and PTFE construction ...
Page 51: Modulating Feed Water Valve
Spare Kit Item Part Number Material Internal bronze liner Bronze liner M4 x 10 Stainless Steel M5 x 70 Stainless Steel Bobbin shaft o-ring seal Aflas Body o-ring seal Aflas October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 41...
Page 52: Feed Water Valve Specification
*Please note that for the US valves with 300lb rated flanges, the maximum allowable pressure is 300 PSI. For other valves, the maximum allowable pressure is 580 PSI (40 bar). Page 42 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 53: Bronze Liner
3 Water Level Probes 3.10.3 Bronze Liner The Autoflame feed water control valves have been modified to include bronze liners. The liners have been incorporated within the design of the valve to assist with applications where the supply feed water is high in particulate, which can lead to premature valve failure. This is particularly applicable where feed water is insufficiently filtered.
Page 54: Feed Water Valve Sizing Calculations
70008 31822 21.28 1.38 8200 136.6 82011 37278 Autoflame Part No. WLCV040 – 1 ½” feed water valve water flow calculations @20°C Water Velocity Pressure Drop Across Valve Water Flow Rate Steam Flow Rate ∆P PSI ∆P Bar Ft/sec M/sec...
Page 55: Flanged Feed Water Valve
3.10.6 Flanged Feed Water Valve Size 1” 244.5mm 9.62” 160.0mm 6.30” 160.0mm 6.30” 123.8mm 4.87” 1 ½” 252.2mm 9.93” 200.0mm 7.87” 160.0mm 6.30” 155.6mm 6.13” 2” 269.9mm 10.62” 230.0mm 9.06” 160.0mm 6.30” 164mm 6.46” October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 45...
Page 56: Threaded Feed Water Valve
3 Water Level Probes 3.10.7 Threaded Feed Water Valve ½” Threaded inches 1.22 3.91 4.81 3.56 7.22 2.56 2.36 1.97 Page 46 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 57 3 Water Level Probes ¾” Threaded Inches 5.59 2.00 6.54 4.37 8.86 3.58 3.54 2.36 October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 47...
Page 58: Replacing The Servomotor For A Feed Water Valve
90 degrees to the feed water valve (flow through the valve). When the servomotor is supplied, it comes in the 0 degree position. Figure 3.10.8.i Feed water Valve and Industrial Servomotor Page 48 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 59 3 Water Level Probes Figure 3.10.8.ii Industrial Servomotor Internal Wiring Figure 3.10.8.iii Industrial Servomotor Potentiometer October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 49...
Page 60: Storage, Operation And Maintenance
3.10.9 Storage, Operation and Maintenance Delivery and Storage All Autoflame feed water valves are shipped in appropriate packing in the fully open position. They should be stored in a weatherproof building, and protected from ambient conditions, salt laden atmosphere and the ingress of foreign matter. If the feed water valves are not required immediately, please make sure they are stored correctly.
Page 61: Total Dissolved Solids Management
– hole size, temperature, pressure, pressure drop across the solenoid and the time that the solenoid is open for. It can be seen from the above that the Autoflame TDS system deals succinctly with three of the main problem areas that are encountered when designing an accurate TDS control solution.
Page 62: Tds Probe Calibration
Once the expansions have been set for the TDS probe, the probe must be calibrated. While the M.M. is in Run mode, press and then press in the System Configuration screen as in Figure 4.2.i. Page 52 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 63 Figure 4.2.ii shows the TDS management screen. Press to calibrate the TDS probe. The TDS probe does not operate when the M.M. is in Make a Change mode or when the burner is not firing. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 53...
Page 64 The sample settlement time is set in the TDS adjusters; once this time has elapsed, the sample measurement is recorded. Page 54 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 65 10% - 990% of the probe reading to avoid incorrect calibration. If there is an air lock, the TDS probe will not be calibrated as the reading will be 0ppm. When the probe calibration is completed, press and exit this screen. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 55...
Page 66: Method Of Tds Control
PI loop BLOWDOWN MEASUREMENT TIME Default: 25 seconds (2 - 10 seconds) Valve remains fully closed whilst TDS sample is taken MEASURED VALUE LESS THAN TARGET VALUE ? Page 56 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 67: Continuous Tds Blowdown
60-300 seconds. This sample time interval is user variable. 6. The duration of the sample time is 3-10 seconds. This is user variable. 7. The system then repeats this cycle. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 57...
Page 68: Installation Of Tds Probe Assembly
4 Total Dissolved Solids Management 4.3.4 Installation of TDS Probe Assembly Illustrated below is the installation method for the T.D.S. probe incorporating Autoflame’s sampling system. (All dotted components are to be supplied by the customer). Note: There must be a minimum of 3ft (0.9m) straight pipe installed from the valve, of the same diameter as the actual valve.
Page 69: Tds Probe And Autoflame Sampling Vessel
4 Total Dissolved Solids Management TDS Probe and Autoflame Sampling Vessel PLUG & SOCKET October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 59...
Page 70: Top Blowdown Adjusters
10. Press RUN to return to normal operation. When the run button is pressed, all Adjuster values are stored in memory. Page 60 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 71 TDS value has fallen below the limit value. Another alarm will not be generated until the measured TDS value has been continuously below the limit value for 10 minutes. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 61...
Page 72: Sample Routine
At the start of each measurement cycle the sample is checked for polarization. This background voltage effect is taken into the conductivity calculations. Temperature and pressure is measured by the Autoflame system and this information is used to continually modify the calculated conductivity/TDS value from its calibrated point. Nominally for every 1 degree C increase or decrease, 2% is added or subtracted from the conductivity value.
Page 73: Relationship Between Conductivity, Temp And Tds Values
5000. If the reading from the probe electronics does not agree with this a correction multiplier or divider is implanted into this specific probes electronic memory. This is its own dedicated CCC value. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 63...
Page 74: Bottom Blowdown
Bottom blowdown is used to remove solids which build up at the bottom of steam boilers. In the Autoflame system, there are options to either manage the blowdowns through automatic timings, or to manually trigger them. The programmable electronic automatic blowdown ensures repeatable blowdown timings, without the need of a compressed air supply.
Page 75: Bottom Blowdown Time Reduction
Calculated Bottom Blowdown Losses With a typical loss in steam generation of 3% from the conventional bottom blowdown management, Autoflame have developed a Bottom Blowdown Time Reduction feature to minimise these losses which occur when keeping the boiler heat transfer surfaces clean.
Page 76 If the adjusted blowdown time is calculated lower than the minimum blowdown time set in expansion option 36.3, and expansion option 36.2 is set for minimum blowdown enforced then: , then Minimum blowdown time is enforced Page 66 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 77 When using the time reduced bottom blowdown in standalone operation, the maximum steam flow rate and the average steam flow rate are taken from the 4-20mA input to the bottom blowdown module. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 67...
Page 78: Bottom Blowdown Valve Drawings
5 Bottom Blowdown 5.1.3 Bottom Blowdown Valve Drawings Page 68 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 79 Forged Socket Head Cap Screw- Metric ANSI B18.3.1M – M4x0.7 x 12 Forged Socket Head Cap Screw- Metric ANSI B18.3.1M – M4x0.7 x 10 Forged Socket Head Cap Screw- Metric Body o-ring seal Aflas October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 69...
Page 80: Front Facia And Dimensions
5 Bottom Blowdown 5.1.4 Front Facia and Dimensions Page 70 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 81: Bottom Blowdown Configuration
24 hours. New Style Autoflame bottom blowdown module, bottom blowdown valve and 24V DC Unic 5 servomotor required for up to 4 timed blowdowns with configurable timings and intervals with no manual trigger needed for blowdown to commence.
Page 82 36.3 may be set to avoid missed blowdowns. Enabled, Minimum Blowdown Not Enforced Bottom blowdown timing is adjusted according to the boiler’s steam production. If there is no steam contribution, no blowdown will take place. Page 72 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 83 5 Bottom Blowdown Figure 5.2.1.iii Expansion Option 36.3 Expansion option 36.3 sets the minimum blowdown time when expansion option 36.2 is set for minimum blowdown enforced. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 73...
Page 84 Expansion option 36.4 allows the user to define the maximum steam production for the boiler so that the M.M. can use this rating to calculate the ratio of time decreases allowed in bottom blowdown time reduction according to the steam production. Page 74 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 85: Commissioning Bottom Blowdown Module With M.m
If changes are required, please refer to section 5.2.2 for how to set-up the bottom blowdown module with the bottom blowdown configurator. There are 4 expansion options to configure the bottom blowdown. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 75...
Page 86 Commission Mode screen shown in Figure 5.2.2.i. Press this button to set the closed and open positions for the bottom blowdown valve as well as to test the battery back-up operation. Page 76 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 87 To clear the fault, press as shown in the bottom blowdown module screen in Figure 5.2.2.ii. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 77...
Page 88 It takes 3 seconds quicker to go from the open position to the parked position, than to go from the open to the closed position. Press to check the positions that have been set. Page 78 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 89: Battery Test
2.3.1. After the M.M. has been commissioned for water level probes and fuel-to-air ratio, the timings and intervals of the bottom blowdown can be set. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 79...
Page 90: Bottom Blowdown Timer Configuration
Figure 5.2.4.i Configure Screen – Run Mode In the Configure screen of Run mode, a button will appear, see Figure 5.2.4.i. Pressing this button will take you to the timings and intervals adjustment screen. Page 80 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 91 Figure 5.2.4.ii shows the Bottom Blowdown Configuration screen, here up to 4 blowdowns can be selected with their corresponding times, durations and repeats. Each blowdown can be a maximum of 60 seconds, with a maximum of 10 repeats. Press and then October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 81...
Page 92 Then press buttons on the duration and repeats to set the total blowdown time required. Once all the required blowdown times have been configured, press before exiting the screen. Page 82 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 93: Commissioning Standalone Bottom Blowdown Module
PC via the USB lead provided. Download the Bottom Blowdown Board Configurator from the USB stick provided, and open the program. Figure 5.3.i Disconnected To begin the configuration press button as displayed in Figure 5.3.i. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 83...
Page 94 (see section 5.2.3. for further information). To check the battery option, drive the valve to the closed position, and then press . The valve will be opened to parked position mains power, and then driven to fully closed on battery power. Page 84 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 95 The maximum duration that can be set is 60 seconds, and the maximum movements that can be set is 10. To set the time use the button, as shown in Figure 5.3.iii. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 85...
Page 96 ‘Input Reading’ provides online information of the steam production. A minimum blowdown time can also be set so that if timed reduced bottom blowdown is set, then the time of the blowdown will never go below this value, see Figure 5.3.iv. Page 86 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 97: Bottom Blowdown Operation
Go into the water level screen on the M.M. to see what stage the bottom blowdown is in. Press the feed water valve in the bottom right corner of the main boiler screen to access the bottom blowdown status information. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 87...
Page 98 5.4.ii, as well as the duration of that next blowdown with its repeats. When it is due, the status will show IMMINENT, and when it begins this will change to IN PROGRESS. Page 88 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 99 5 Bottom Blowdown Figure 5.4.iii Bottom Blowdown Log To go to the bottom blowdown sequence log screen, press , see Figure 5.4.iii. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 89...
Page 100: Further Bottom Blowdown Time Reduction Savings Calculations
M.C.R. over 8 hours would be £61.50 ($93.62). Assuming that £14.96 ($22.80) gives 1,000,000 BTU for firing on no.2 oil, the cost of conventional bottom blowdown management at M.C.R. over 8 hours would be £85.27 ($129.94). Page 90 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 101 From this data, and keeping the same fuel consumption as before, using the reduced time bottom blowdown would give savings: Typical Annual Savings (Gas) £25,373.49 Typical Annual Savings (Oil) £35,101.27 October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 91...
Page 102 Standing Losses Blowdown Losses Net Efficiency 82.91% – 1% 3% Net Efficiency 78.91% Gross Heat Input into Boiler 25,000,000 Net Heat Input into Boiler 25,000,000 78.91% Net Heat Input into Boiler 19,727,500 Gross Input 25,000,000 Gross Input 7,321.87 £0.034 Fuel Cost £248.94/ Energy required to raise 1lb steam from 180 F to 327 F 1040 BTU 18,968.75 / Fuel Cost £13.12/1000 Page 92 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 103 1,000,000 Net Heat Input into Boiler 9,556,250 Gross Input 12,500,000 Gross Input 3660.93 £0.034 Fuel Cost £124.47/ Energy required to raise 1lb steam from 180 F to 327 F 1040 BTU 9188.7 / Fuel Cost £13.55/1000 Fuel Cost £124.47/ Fuel Cost per day 16 hours operation £1991.52 Fuel Cost per year 365 days operation £726,904.80 Total Steam Production 53,662,008 lbs October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 93...
Page 104 12,500,000 79.45% Net Heat Input into Boiler 9,931,250 Gross Input 12,500,000 Gross Input 3660.93 £0.034 Fuel Cost £124.47/ Energy required to raise 1lb steam from 180 F to 327 F 1040 BTU 9549.28 / Fuel Cost £13.03/1000 Fuel Cost £124.47/ Fuel Cost per day 16 hours operation £1991.52 Fuel Cost per year 365 days operation £726,904.80 Total Steam Production 55,767,795 lbs Page 94 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 105 5 Bottom Blowdown Therefore: Per year with an 50% boiler output : Total Steam Production with Standard Blowdown 53,662,008 lbs Total Steam Production with Time Adjusted Blowdown 55,767,795 lbs An additional 2,105,787 lbs of steam produced for the same cost. If producing the same amount of steam the following saving is deduced: £0.01303 x 2,105,787 £27.438.40 savings 3.77% overall savings October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 95...
Page 106: Shunt Switch
The ability to implement a controlled by-pass of the low water cut off’s during a manual water column blowdown, boiler blowdown or evaporation test is available on the Mk7 M.M. with water level control. This is incorporated into the Autoflame controller so as to avoid the requirement for any additional push buttons/key switches on the control panel.
Page 107: Steam And Heat Flow Metering
STEAM AND HEAT FLOW METERING Steam Flow Metering Autoflame steam flow metering is available in the water level control; it has been granted an international patent. By the addition of one temperature detector it is possible to extrapolate steam flow from a boiler both as an instantaneous value and a totalised amount over time. A full steam flow...
Page 108 Instantaneous values are calculated using the above. Totalized values for steam flow use the same mechanism but sample values are taken every 5 seconds and integrated over the run time of the boiler burner system. Page 98 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 109 6 Steam and Heat Flow Metering Figure 6.1.ii Steam Flow Rate History The steam flow rate history screen logs the flow rate and totalised steam production for up to 24 hours. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 99...
Page 110 6 Steam and Heat Flow Metering Figure 6.1.iii Steam Flow Metering Steam History The steam history logs the boiler actual pressure and the calculated temperature from the steam tables. Page 100 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 111 6 Steam and Heat Flow Metering Figure 6.1.iv Steam Flow Metering Heat History The heat history screen logs the input water temperature, steam temperature and the heat value for up to 24 hours. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 101...
Page 112: Steam Flow Metering Incorporating A Deaerator
“weighted average” of the condensate return temperature and makeup water temperature. The outlet steam temperature is measured by a temperature sensor in exactly the same way as in a system without a deaerator. Page 102 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 113: Calculations For Steam Flow Metering With Deaerator
Weighted Average = 176 - = 153.4°F To implement the above control form the following calculations have been imbedded in the revised software to obtain the “Weighted Average Temperature” (T ave). October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 103...
Page 114: Steam Flow Metering Without Deaerator
6 Steam and Heat Flow Metering 6.1.3 Steam Flow Metering without Deaerator Expansion Option 38.1 set to 2. Page 104 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 115: Steam Flow Metering Without Deaerator, With Economiser
6 Steam and Heat Flow Metering 6.1.4 Steam Flow Metering without Deaerator, with Economiser Expansion Option 38.1 set to 3. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 105...
Page 116: Steam Flow Metering With Deaerator
6 Steam and Heat Flow Metering 6.1.5 Steam Flow Metering with Deaerator Expansion Option 38.1 set to 4. Page 106 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 117: Steam Flow Metering With Deaerator And Economiser
6 Steam and Heat Flow Metering 6.1.6 Steam Flow Metering with Deaerator and Economiser Expansion Option 38.1 set to 5. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 107...
Page 118: Steam Flow Metering With Deaerator And Feed Water Sensor
6 Steam and Heat Flow Metering 6.1.7 Steam Flow Metering with Deaerator and Feed water Sensor Expansion Option 38.1 set to 6. Page 108 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 119: Heat Flow Metering
6.2.1 Calculation for Heat Output and Volume Flow Radiation Losses Efficiency % 100% Stack loss Firing Rate Efficiency Useful Heat into Water Total Heat Useful heat MBTU/Hr Volume Flow in lbs/hr SP Ht BTU/lb/°F Flow Temp – Return Temp ⁄ Volume Flow in lbs hr Volume Flow in cu ft Hr Density of Water at Return Temperature Since 1 cu ft Hr 0.124676 US G. P. M. Volume Flow in US G. P. M. Volume Flow in cu ft Hr 0.124676 October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 109...
Page 120: Heat Flow Metering Calculation
1,885.2 US G. P. M. It can be seen from the above that by adding the expansion P.C.B. and a return temperature detector to the Mk7 M.M. system that you get the following additional useful information. “Useful heat into water” (BTU/hr) &...
Page 121: Heat Flow Metering
6 Steam and Heat Flow Metering 6.2.3 Heat Flow Metering Expansion Option 38.1 set to 8. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 111...
Page 122: Heat Flow Metering With Economiser
6 Steam and Heat Flow Metering 6.2.4 Heat Flow Metering with Economiser Expansion Option 38.1 set to 9. Page 112 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 123: Draft Control
Reduce soot accumulation Autoflame Fully Integrated Draft Control The Autoflame draft control stores pressure conditions at the commissioning stage and modulates with the firing curve to maintain this, irrespective of changing firing rate and stack conditions. Normally there is a vertical main stack which has a horizontal cross connection from the boiler flue gas outlet;...
Page 124 Figure 7.2.iii Draft Control Schematic Page 114 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 125: Set-Up
7 Draft Control Set-Up To maintain the stack pressure through the Autoflame draft control system, the following is required:  Mk7 M.M. with Expansion Board  Air Pressure Sensor MM70005 (SN 100 upwards)  Industrial Servomotor Note: A small or large servomotor can be used for smaller applications, however an industrial servomotor is recommended for the appropriate softened error checking for a large damper.
Page 126 Draft Pressure Filter Time: The draft pressure filter time filters the pressure readings over this time set 41.4 this option. Increase this value to remove excessive fluctuation in draft pressure reading. Decrease this value to improve the pressure sensor's responsiveness. 1 - 60 Seconds Page 116 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 127: Commissioning With Draft Control
7 Draft Control Commissioning with Draft Control The Autoflame draft control system is commissioned during the burner commissioning process. As with all M.M. commissioning procedures on burners, safety must be taken in every step. Once the installation and all burner adjustments are completed, the entire burner control system should be tested in accordance with the manufacturer’s instructions.
Page 128 7 Draft Control Figure 7.4.i Commission Mode Screen 1. Power on the unit, and press the commission button. Make sure the expansion board is activated. Page 118 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 129 P and I options are set to default. If changes to either the P or the I are required, it is suggested that small changes are done to each at a time, to avoid less than satisfactory or excessive trim on the stack damper. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 119...
Page 130 40.3). The draft control damper can be increased/ decreased using CH 7 up and down arrows Note: Once a CLOSE position is entered the draft servomotor will drive to the minimum baffle angle limit, expansion option 40.3. Page 120 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 131 5. Enter the OPEN position. A draft pressure is stored at each recorded position during the commissioning process. 6. Enter the STARTt position (this position is not stored within the M.M., but is used as an initial light off position). October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 121...
Page 132 7 Draft Control Figure 7.4.v High Position 7. Drive the servomotors up to HIGH FIRE position and then press Enter. Page 122 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 133 8. Enter up to 15 inter positions to make up the firing curve (minimum 3 inter positions). Note: It is not possible to drive the draft servomotor past the minimum baffle angle limit, expansion option 40.3 October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 123...
Page 134 Page 124 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 135 10. The M.M. will then release to modulation. Draft control information can be viewed on the M.M. screen by pressing on the pressure sensor located on the stack in the boiler home screen. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 125...
Page 136 The draft control pressure curve displays the current draft pressure in comparison to the commissioned value in relation to the current fuel valve position. In addition the pressure trend for the whole firing rate is visible. Page 126 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 137 In addition the commissioned servomotor positions for the whole firing rate are visible. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 127...
Page 138 Figure 7.4.xi Draft Control History Screen 13. The draft control history, displays the draft pressure and servomotor position, running values and respective commissioned values at that stage, over a 96 minute period. Page 128 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 139 2 minutes, than an error message will appear. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 129...
Page 140 15. When the pressure cannot be maintained, the pressure a yellow box will flash as an indication that the air pressure sensor in the stack is reading outside of limits. Page 130 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 141 Any servomotor errors will result in a burner shutdown which will not permit the burner to be restarted until rectified. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 131...
Page 142: Draft Control Operation
For Autoflame draft control, corrections are made to the stack damper to compensate for changes in wind and ambient conditions which cause the stack pressure to differ from the commissioned stack pressure along the fuel curve.
Page 143 7 Draft Control Figure 7.5.1.i Trim Deactivation Window October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 133...
Page 144: Trim Operation
40.6 is the maximum percentage of the commissioned draft servomotor angle to which the stack damper will trim negative or positive. See figure 7.5.2.i for a graphical representation of example trim angles. Figure 7.5.2.i Trim Angle Page 134 Mk7 Manual: Expansion Board Set-Up Guide October 2014...
Page 145: Troubleshooting And Diagnostics
Probe 1 has short circuit failure. This probe’s water level is currently outside of the normal operating limits range. This may be caused by a probe hardware failure. Contact an Autoflame technology centre. Probe 2 has short circuit failure. This probe’s water level is Probe 2 Short currently outside of the normal operating limits range.
Page 146 On power up, the EEprom test has failed; the water level control has not been used before, has a faulty EEprom. If the problem persists after resetting the error, contact Autoflame. Bogus PU State The EEProm is in a bogus state, if the problem persists after resetting the error, contact Autoflame.
Page 147 The draft control pressure tolerance is outside the configured tolerance band for longer than 2 minutes. Tolerance Fail The bottom blowdown operation has not been commissioned. Bottom Commissioned 254 WL Board Reset Please contact Autoflame. October 2014 Mk7 Manual: Expansion Board Set-Up Guide Page 137...
Page 149 Notes...
Page 151 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...

AUTOFLAME Mk7 Setup Manual

Quick Links

Need help?

Questions and answers

Related Manuals for AUTOFLAME Mk7

Summary of Contents for AUTOFLAME Mk7

Table of Contents