AUTOFLAME Mk8 MM Installation And Commissioning Manual
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AUTOFLAME Mk8 MM Installation And Commissioning Manual

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  • Page 1 Mk8 MM Installation and Commissioning 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 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 6: Table Of Contents

    MM Terminals Description ....................9 1.3.5 Expansion Board Terminals Description................ 13 Connection Between Mk8 MM and Mk8 EGA EVO ............16 Connection Between Mk8 MM and Mk8 DTI ............... 17 Sequencing Connection Diagram ..................18 OPTIONS AND PARAMETERS ................19 Options ..........................
  • Page 7 Online Changes ........................107 FUEL OUTPUT MODES AND CHANGEOVER OPTIONS .......... 108 Overview ..........................108 Fuel Output Modes on the Mk8 MM .................. 108 Single Fuel Output Mode (SFOM) ..................110 4.3.1 Fuel Configuration and Wiring in SFOM ..............110 4.3.2...
  • Page 8 4.5.2 Checks before COF can take place ................115 4.5.3 COF Changeover Position ..................115 4.5.4 COF Fuel Changeover ....................116 4.5.5 Checks after COF Fuel Changeover ................117 4.5.6 Continuous Pilot with COF ..................118 Gas Pressure Sensors and Valve Proving in DFOM with COF ..........120 Limitations of DFOM and COF ...................

  • Page 10: Dimensions And Wiring

    1 DIMENSIONS AND WIRING 1 DIMENSIONS AND WIRING 1.1 Mk8 MM 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 1...

  • Page 11: Fixing Holes And Dimensions

    1 DIMENSIONS AND WIRING 1.1.1 Fixing Holes and Dimensions Page 2 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 12: Wiring Schematic

    1 DIMENSIONS AND WIRING 1.2 Wiring Schematic 1.2.1 Mk8 MM 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 3...

  • Page 13: Mk8 Expansion Board

    1 DIMENSIONS AND WIRING 1.2.2 Mk8 Expansion Board Page 4 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 14: Fuse Ratings

    2.5A FU10042 • Fuse 8 protects the internal 12V supply. If this fuse blows the display will be off and the LED adjacent to the fuse will be off. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 5...

  • Page 15: Electrical Specifications

    4. Low voltage cables should be screened cable as specified in section 1.3.3. 5. The burner ‘High Limit Stat’ must be a manual reset type. Note: There is a lid (back plate) fitted onto the back of the Mk8 MM with a Warning label to prevent any unauthorised fuse replacements.

  • Page 16: Expansion Board Inputs And Outputs

    Max number of alarm indicators on at any time is 3 (1LV, 2LA, 2LV) Main Voltage Signal Inputs: At 120V current loading is approximately maximum 0.7mA per input. At 230V current loading is approximately maximum 1.5mA per input. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 7...

  • Page 17: Cable Specifications

    Samples are available upon request. Low voltage and data cable can be ordered directly from Autoflame Engineering, please contact Autoflame Sales. When using a VSD, please review the manufacturer’s guidelines on installations to prevent EMC including the recommendations for reactors and filters. Page 8 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 18: Mm Terminals Description

    Current Output, 4-20mA/ 0-20mA. Varies in accordance with firing rate Voltage Output, 0-10V/ 2-10V. Varies in accordance with firing rate 0V common for Terminals 16 or 17 19, 20 Connections to an Autoflame outside temperature sensor 21, 22 Connections to an Autoflame self-check UV sensor 23, 24 Communications port connections for multi-burner operation 09.05.2019...
  • Page 19 31, 32 Digital communications connections to an Autoflame air pressure sensor and/or Autoflame gas pressure sensor 0V supply to an Autoflame air pressure sensor and/or Autoflame gas pressure sensor +12V supply to an Autoflame air pressure sensor and/or Autoflame gas pressure...
  • Page 20 Purge position interlock/ delay purge time (selectable via option 155) Fuel 2 valves C.P.I/POC (Dual Fuel Output Mode & Change on the Fly) Fuel 2 Main Valve 2 (Dual Fuel Output Mode & Change on the Fly) 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 11...
  • Page 21 Mains voltage input – warming start or night setback input (selectable via option Mains voltage input – selects hand operation (overrides mode set on MM screen) Mains voltage input – selects low flame hold operation (overrides mode set on MM screen) Page 12 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 22: Expansion Board Terminals Description

    Signal from draught control servomotor, indicating position 5T+, 5T- Digital communications from bottom blowdown module and 2 low probe 0V supply to 2 low resistance probe +12V supply to 2 low resistance probe 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 13...
  • Page 23 First Out annunciation line voltage input 14 FO15 First Out annunciation line voltage input 15 External high water auxiliary input External 1 low water auxiliary input External 2 low water auxiliary input Page 14 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 24 Switched neutral – drives feed water servomotor counter clockwise Switched neutral – drives top blowdown servomotor counter clockwise Switched neutral – drives draught control servomotor clockwise Switched neutral – drives draught control servomotor counter clockwise 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 15...

  • Page 25: Connection Between Mk8 Mm And Mk8 Ega Evo

    1 DIMENSIONS AND WIRING 1.4 Connection Between Mk8 MM and Mk8 EGA EVO Page 16 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 26: Connection Between Mk8 Mm And Mk8 Dti

    1 DIMENSIONS AND WIRING 1.5 Connection Between Mk8 MM and Mk8 DTI 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 17...

  • Page 27: Sequencing Connection Diagram

    1 DIMENSIONS AND WIRING 1.6 Sequencing Connection Diagram Page 18 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 28: Options And Parameters

    2.1 Options The Options, Parameters and Expansion Options must only be changed by factory trained and certified technicians who have a thorough appreciation of the Autoflame combustion systems and the combustion process in general. Any person changing these settings without the correct factory training and understanding of the boiler plant may place themselves and others in a potentially dangerous situation.
  • Page 29 . Press on to change the value of an incorrect entry. Note: The commissioning password should not be distributed to anyone who is not a factory trained and a certified engineer. Page 20 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 30 • Set the time and date • Upload/download commissioning data • Unlock expansion features • Set the language • View fault logs, system log and diagnostics • View fuel commission data 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 21...
  • Page 31 To set all the options, parameters and expansion options to the default values and erase the commissioning data, set option/ parameter 160 to 5. The MM will then automatically restart and go into Commission mode. Page 22 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 32 The value of ‘n’ is the number of seconds set in this option; if set to 0, there will be no integral control. Disabled 1 – 250 Seconds 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 23...
  • Page 33 2 or 3 in online changes, going through single point change, and added trim data for each fuel-air position. Not optioned Monitoring only Applies trim Applies trim, combustion limits tested Page 24 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 34 If the current CO value is above this offset limit from the commissioned value, an alarm/ warning (see option 13) will occur, for option 12 set to 3. Disabled 1 – 200 1 – 200 ppm CO 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 25...
  • Page 35 MM. The MM will continue to fire to meet the previous required setpoint. 5 – 9990 F, PSI or 0.1 bar or 0.01 bar for low pressure sensor (depends on load detector set in option 1 and metric/imperial units set in parameter 40) Page 26 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 36 1 - 15 F, PSI or 0.1 bar or 0.01 bar for low pressure sensor (depends on load detector set in option 1 and metric/imperial units set in parameter 40) Unused 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 27...
  • Page 37 When using the multi-burner function, the multi-burner IDs must be set on the MMs This option should be set to 1 for the master, and 2 onwards for the slave MMs. 1 – 10 Multi-burner Id Page 28 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 38 120 C (248 F). This option can only be used if an EGA is optioned and operational. FGR temperature threshold disabled FGR temperature threshold enabled 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 29...
  • Page 39 4). For metric units, fuel flow is commissioned in MW for metric units and MMBTU/hr for imperial units. Disabled Enabled Enabled with 4-20mA feedback Unused Page 30 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 40 Channel 1 Purge Position Channel 1 to purge position Channel 1 to remain closed for purge Channel 2 Purge Position Channel 2 to purge position Channel 2 to remain closed for purge 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 31...
  • Page 41 F, PSI or 0.1 bar or 0.01 bar for low pressure sensor (depends on load detector set in option 1 and metric/imperial units set in parameter 40) Minimum Outside Temperature 0 – 145 Value 30 = -10 C or -10 F (see parameter 40) Page 32 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 42 IO Unit 4-20mA servomotor, 1.0 degree control VSD Operation Channel 5 Disabled Enabled Output from MM to VSD Channel 5 Output range 4 to 20mA Output range 0 to 20mA Output range 0 to 10V 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 33...
  • Page 43 Output Units Displayed, VSD Channel 6 Selected output signal Hertz Output Low Speed from MM to VSD Channel 6 1 – 200 Hertz Output High Speed from MM to VSD Channel 6 1 – 200 Hertz Page 34 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 44 8% of the whole VSD range. 5 – 40 0.5% – 4.0% 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 35...
  • Page 45 See option/ parameters 150 – 153. This does not apply for intermittent pilot, see option/ parameter 111. For firing on oil, see option/ parameter 123. 3 – 10 Seconds Page 36 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 46 This does not apply to any requirements on purge timing such as any additional proving inputs. Disabled 1 – 3600 Seconds 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 37...
  • Page 47 Fuel Pressure Sensor Mode – Fuel 1 Gas: For setting 1, valve proving and pressure limits are checked by an Autoflame gas sensor. For setting 2, low pressure limit can be checked by external pressure switch. For setting 3, the system will wait for a mains voltage input on terminal 55 to confirm that the VPS test is completed.
  • Page 48 The NFPA post-purge will occur under any normal shutdown or lockout at any point in firing. Purge time in seconds Purge time in minutes NFPA post-purge in seconds NFPA post-purge in minutes 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 39...
  • Page 49 This is the minimum air pressure that must be detected by the MM during purge, when using an Autoflame air pressure sensor. If this is set to 0, then MM will look for the minimum air pressure set in option/ parameter 149.
  • Page 50 This is the minimum air pressure that must be detected by the MM during normal firing and during purge when option/ parameter 141 is set to 0, when using an Autoflame air pressure sensor. See parameter 43 for air pressure display units.
  • Page 51 Clear all commissioning data, options and parameters Reset all options to default values Reset all parameters to default values Reset all safety options and parameters to default values Reset all expansion options to default values Page 42 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 52: Parameters

    To set all the options, parameters and expansion options to the default values and erase the commissioning data, set option/ parameter 160 to 5. The MM will then automatically restart and go into Commission mode. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 43...
  • Page 53 CO to calculate the required trim correction. Disabled Enabled Commission Fuel-Rich Trim The % of air damper movement when commissioning fuel-rich trim. 20 – 75 2.0% - 7.5% Page 44 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 54 A cycle is the period between when does the EGA carries out a drain to get rid of excess moisture in the exhaust gas sample. This parameter sets the number of trim corrections in between drains. 1 – 50 Unused Unused 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 45...
  • Page 55 Code 2 Display Units Metric units Imperial units Gas Pressure Units This will set the units displayed for the Autoflame gas pressure sensor optioned. Note, PSI units are not available for sensor MM80006. mbar “WG Oil Pressure Units This will set the units displayed for the Autoflame oil pressure sensor optioned.
  • Page 56 This sets the highest MM ID number for that sequence or DTI loop. 1 –10 Sequence ID (Mk7 EGA only) – Air Calibration on Start-up For the Mk8 EGA, the air calibration schedule is set on the EGA itself. Disabled Enabled Unused 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 47...
  • Page 57 If enabled, terminals 7, 8, and 9 are used for external required setpoint. The range and filtering of the input is set in parameters 69 and 70. The required setpoint range is set in options 30 and 31. Disabled Enabled Page 48 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 58 If the stat exerciser period is enabled, then T53 will be turned off for this timer set, and then turned off for this timer set, repeatedly. This should be used in test/inspection conditions. Disabled 1 – 3600 Seconds 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 49...
  • Page 59 99. Disabled Enabled Shuffle Sequencing This allows the sequence order to be changed remotely through the DTI or Modbus. See option 16 and expansion option 100. Disabled Enabled Unused Unused Page 50 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 60 If options 110 – 160 are not identical with the parameters 110 – 160, then the MM will go straight to Commissioning Mode and an option/ parameter conflict message will appear. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 51...

  • Page 61: Expansion Options

    Flow at the bottom of the screen, the expansion options can be grouped together by feature. To change the expansion options, the relevant expansion feature must be unlocked. See Mk8 MM Expansion Features Installation and Commissioning Guide for more information.
  • Page 62 For the possible water level sensing device combinations, please see section 3.3. Auxiliary alarm inputs disabled Auxiliary alarm inputs enabled 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 53...
  • Page 63 For setting 0, it is recommended that an auxiliary second low mains input is wired to terminals 2AI. For setting 1, the Autoflame conductive second low probe is wired to terminals 4P-, 4P+, 6T- and 6T-. Please see local codes/ regulations for second low probe and auxiliary second low alarm setup.
  • Page 64 As default the servomotor is set as fully open, however this setting can be decreased to shorten the operational movement range of the servomotor. 100 – 900 10.0 – 90.0 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 55...
  • Page 65 If water does not drop to the first low level in this time period, then MM will revert back to normal run mode and cancel the shunt switch test. 30 – 600 Seconds Page 56 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 66 The filter time is the rolling time period over which the capacitance probes take the water level reading. When a moving water level is detected this time period reduces in proportion linearly to the movement. 1 – 30 Seconds 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 57...
  • Page 67 Top blowdown using solenoid Top blowdown using servo (2-state) Top blowdown using servo (continuous) TDS Units The TDS units can be displayed in ppm or µS/cm. Concentration in ppm Conductivity in µS/cm Page 58 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 68 48, the solenoid valve or top blowdown servomotor goes fully closed to allow the sample to stabilise for this settle time. 2 – 60 Seconds 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 59...
  • Page 69 As default the servomotor is set as fully open, however this setting can be decreased to shorten the operational movement range of the servomotor. 100 – 900 10.0 – 90.0 Unused Unused Unused Unused Page 60 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 70 0 – 5000 0 – 500000 kg/hour or 0 – 1102310l lb/hr (see parameter 40) Unused Unused Unused Unused Unused Unused Unused 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 61...
  • Page 71 82, at all other times other than the closed position. During commissioning, the servomotor position cannot be set low than this minimum angle value, except for the closed position. 0 – 90 – 90 Page 62 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 72 2.00 – 100.00 mbar or 2.00 – 100.00 ”WG (see parameter 43) Integral Time For a slower response to the changes in draught air pressure, increase the integral time. For a quicker response, decrease the integral time. 1 – 1000 Seconds Unused 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 63...
  • Page 73 If direct Modbus is enabled, then option 16 must be set to 0, as Intelligent Boiler Sequencing cannot be used with direct Modbus. Please see section 7.3 in the ‘Mk8 MM Expansion Features Installations and Set-up Guide’ for the available Modbus addresses.
  • Page 74 0 – 200 0.00 – 2.00% Blow Down Losses This is the typical losses resulting from top blowdown and bottom blowdown. 0 – 100 0.00 – 10.0% 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 65...
  • Page 75 IO module connected to the DTI. The ID number of the IO module must be set in expansion option 129. Sensors connected to MM 1 – 10 Sensors connected to IO Unit 1 – 10 Unused Unused Unused Unused Unused Unused Page 66 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 76 Air Flow Meter Scaling The air flow meter is scaled by setting the flow rate at 20mA feedback from the flow meter. 0 – 65535 0 – 65535 m /hr (0ft /hr) £ 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 67...
  • Page 77 For setting 2, the MM generates a warning and disables the air adjustment and the air servomotor returns to the original commissioned curve. Generate alarm Generate warning Generate warning, disable air adjustment Page 68 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 78 For setting 1, the MM generates a warning. For setting 2, the MM generates a warning and disables the fuel adjustment and the fuel servomotor returns to the original commissioned curve. Generate Alarm Generate Warning Generate Warning, Disable Fuel Adjustment 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 69...
  • Page 79 If there is excess fluctuation in the flow readings, increase the filter time. To improve the system’s response to changes in flow, decrease the filter time. 1 – 60 1s to 60s Unused Page 70 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 80: Commissioning Procedure

    The commissioning procedure as described must be strictly adhered to. Anybody commissioning an MM must be trained in operating combustion equipment safely. The Autoflame products must only be installed, set up, commissioned and adjusted by an Autoflame certified technical engineer.

  • Page 81: Installation Checks

    The reliability of the equipment may be impaired if used in environments where strong electromagnetic fields exist e.g. if the equipment is installed in a boiler house where radio systems exist then additional EMC (Electro Magnetic Compatibility) measures may have to be considered. Please contact Autoflame for more information.

  • Page 82: Servomotors

    3 COMMISSIONING PROCEDURE 3.3 Servomotors Autoflame supply three standard sizes of servomotors – small, large and industrial, which can be used for all channels. Autoflame fuel valves require small or large servomotors only. Both small and large servomotors can be configured to drive clockwise or counter clockwise to open a valve or damper.

  • Page 83: Servomotor Feedback Voltage

    For fuel servomotors carry out the following procedure: On Autoflame gas, oil and gas/oil piggy-back valves it is necessary to remove the servomotor. Manually position the oil/gas valve slot to its closed position. Observe the position of the drive pin on the servomotor.

  • Page 84: Servomotors - Direction Change

    3 COMMISSIONING PROCEDURE 3.3.3 Servomotors – Direction Change 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 75...

  • Page 85: Servomotors With Autoflame Valves

    The same servomotor will be correct for both types of valve, as the servomotor for the threaded valve is mounted at 90 degrees different from the flanged valve. Figure 3.3.4.i Valve Pin Positions Page 76 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 86: Commissioning Fuel And Air Positions

    Note: If a fault occurs, the boiler goes above the high limit stat or power is lost to the MM during commissioning, no data is stored. The points entered are only stored within the MM once the commission has been completed. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 77...

  • Page 87: Starting Commissioning

    Figure 3.4.1.i shows the Commissioning screen. In the Commissioning screen, the 7 channel positions will be shown, with the unused channels greyed out. Once the MM goes through its internal relay checks and VPS (if optioned), the message ‘Select Commissioning’ will display. Page 78 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 88: Enter Closed Position

    Incorrect calibration can cause serious injury or death. Press to store the CLOSED position. The burner motor output T58 will energise at this point. A message will then be displayed ‘Enter OPEN Position.’ 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 79...

  • Page 89: Enter Open Position

    OPEN position simultaneously. This is normally 90.0 for Autoflame gas butterfly valves and burner air dampers, but may be set to less than 90.0 if there are mechanical stops/limits on third party valves. Channels 5 and 6 cannot be adjusted at this stage, its calibration is dictated by the drive set-up and relevant options.

  • Page 90: Set Up Start Position

    START position, where a light off can take place. These fuel and air positions are not stored permanently as it is just a light-off position to put a flame in the boiler and begin the commissioning process. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 81...

  • Page 91: Phase Hold

    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 SERIOUS EQUIPMENT DAMAGE, CRITICAL INJURY OR DEATH. Page 82 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 92: Add Trim Data During Commissioning

    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 readings’ will display. Figure 3.4.6.i Sampling Press on the EGA tab to display the EGA readings. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 83...
  • Page 93 Note: If the MM has not been enabled for trim during commissioning, this can be added later by setting option12 for trim, and going into Single Point Change to add trim to each point, see section 3.7. Page 84 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 94: Commissioning Vsd

    The minimum feedback variation applies to both the upper and lower limits so the total commission must allow for the two combined. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 85...

  • Page 95: Set Golden Start Position

    GOLDEN START position and continue with the full commissioning procedure. in section 3.4.9 if FGR START has been enabled, or 3.4.10 if no FGR START is enabled. Page 86 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 96 Golden Start can be set in Option 29 to start from first ignition instead of after the main flame stabilisation phase has passed, this is particularly useful for briefly providing additional fuel when starting an oil flame with direct spark (no pilot mode – see option 111) 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 87...

  • Page 97: Set Fgr Position

    START and GOLDEN START (if enabled) positions. After the entering the light-off START or GOLDEN START (if enabled) position, the message ‘Set FGR Position’ will appear; press to enter the stored FGR START position and continue with the full commissioning procedure in section 3.4.10. Page 88 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 98 FGR can be set as a Timer, Offset or Temperature Threshold (see options 48, 49 and 50). Note: Golden start takes priority over FGR. Once the golden start timer has finished, the servomotors will go straight to the FGR start position. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 89...

  • Page 99: Set High Position

    It is not possible to enter the HIGH position higher than the OPEN position. The servomotors must be driven 0.5 up/down from the previous point initially, before entering the next point, the fuel. Press to store this HIGH position. Page 90 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 100: Set Inter Position

    There must be a minimum of 3 INTER points entered on the fuel-air curve, and a maximum of 18. Points can be added/removed in Single Point Change mode (see section 3.6). Continue this process until all the required INTER points have been entered. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 91...

  • Page 101: Set Inter Or Start Position

    (and VSD) to the START/ LOW FIRE position, and then press to store this. Note: If Golden Start or FGR Start are in use, the Start position is only used for Low Fire. Page 92 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 102: Save Commission

    Note: If commissioning a fuel for the first time the default required setpoint will be 2.0bar/20PSI/20 C/20 F. The burner will shut down at commission completion due to the low default required setpoint. Go to the Status screen to change the required setpoint. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 93...

  • Page 103: Fuel Flow Metering

    MW if metric of MMBTu/hr if imperial. On the Mk8 MM, fuel flow metering can be taken as the values entered in the fuel flow commissioning screen from the fuel flow meter or through a 4-20mA signal on terminals EX- and EX+.
  • Page 104 3 COMMISSIONING PROCEDURE Figure 3.5.1.i System Configuration Screen On the System Configuration screen press . You will be prompted to enter the Online Change password. Press to access the Online Changes screen. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 95...

  • Page 105: Commissioning Fuel Flow Through 4-20Ma Feedback

    After each heat value is displayed, press enter to go to the next fuel flow point. Page 96 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 106: Calorific Fuel Data

    0.00039 0.00039 0.00038 1°F Btu/U.S. gallon (US standard) 140,000 150,000 160,000 Lb/U.S. gallon (US standard) 7.01 7.01 % lighter than water 1 u.s. Gallon of oil / ft of air 1402 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 97...

  • Page 107: Conversion Factor For Imperial Gas Flow Meters

    (Pressure of gas at meter x 0.00228) + (0.948 – (height above sea level x 0.0001075)) Example: As above but 250 m above sea level: Correction factor = (58x0.00228) + (0.948 – (250 x 0.0001075)) = 1.05 Page 98 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 108: Gas Volume Conversion Factors

    1.3951 5.777 4064 298.73 39.851 398.416 1.4201 6.138 4318 317.4 42.341 423.317 1.4452 6.499 4572 336.071 44.832 448.218 1.4703 6.86 4826 354.741 47.323 473.119 1.4953 7.221 5080 373.412 49.813 498.02 1.5204 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 99...
  • Page 109 1000. Represented as an equation:- Firing rate = (Measured Volumetric flow per minute x 60 x Conversion factor x 1000) Btu/hr Page 100 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 110: Gas/ Air Pressure Commission

    0 when doing the first gas sensor commission on the system to store the valve proving gas pressure. During normal running, option/parameter 129 can be set to 1. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 101...

  • Page 111: Single Point Change

    Select the point to be edited or added trim to by pressing to go up and down the fuel curve, then press The Status screen will display the message ‘Select change to make.’ Page 102 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 112 To add trim data to a point press , see section 3.4.6 and Figure 3.7.iv. Note: It is not possible to delete LOW or HIGH FIRE positions or have less than 3 INTER points. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 103...
  • Page 113 If a point is overwritten, the trim data is cleared and the trim data will need to be added. Press to remove the point; there must be a minimum of 3 INTER points. Page 104 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 114 3 COMMISSIONING PROCEDURE Figure 3.7.iv Single Point Change – Trim The MM will store the trim values for this position. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 105...
  • Page 115 The fuel flow commissioning must be entered (again) if the following changes are made in single point change • HIGH or START position is changed. • EGA trim data has been added. • Points have been added. Please go to section 3.5 Fuel Flow Commissioning. Page 106 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 116: Online Changes

    • Reset system log • Reset bottom blowdown log • Reset boiler configuration • Reset run times • Reset steam flow metering • Restart MM if the burner is in standby 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 107...

  • Page 117: Fuel Output Modes And Changeover Options

    MM via IR Lead using Autoflame Download Manager software (version 8.13 and above). COF is available only on Revision 4 of the Mk8 MM, for more information please contact Autoflame.
  • Page 118 The fuel curves must be commissioned according to the optioned fuel output mode, so if Single Fuel Output Mode is optioned the fuels has to be commissioned in Single Fuel Output Mode, changing the fuel valve output mode requires recommissioning of any fuel used in that mode. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 109...

  • Page 119: Single Fuel Output Mode (Sfom)

    4.3 Single Fuel Output Mode (SFOM) Single Fuel Output Mode (SFOM) is the standard (default) mode of operation for the Mk8 MM, it can be selected by setting Option/ Parameter 131 to 0. On this mode it is possible to configure and commission 4 fuels utilising the main set of fuel outputs on the MM using changeover relays.

  • Page 120: Dual Fuel Output Mode (Dfom)

    Valve proving may be used with or without a vent valve (Option 130 setting 2 or 3). If 2 liquid fuels are configured in DFOM, it is not possible to use pressure sensors for both fuels at the same time. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 111...

  • Page 121: Commissioning In Dfom

    Once the MM reaches the Recycle/Standby state, the fuel changeover takes place and the burner will restart on the newly selected fuel. Page 112 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 122 4 FUEL OUTPUT MODES AND CHANGEOVER OPTIONS Figure 4.4: Fuel Changeover Process in Dual Fuel Output Mode 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 113...

  • Page 123: Fuel Change On The Fly (Cof)

    If COF is not enabled, the MM will change fuel in the same way as in Dual Fuel Output Mode, shutting down the burner and restarting on the newly selected fuel. Page 114 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 124: Checks Before Cof Can Take Place

    VSD signal output on both fuels when commissioning the fuels in Dual Fuel Output Mode, this is to ensure that sufficient amount of air is present for both fuels to fire at the COF Changeover Position. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 115...

  • Page 125: Cof Fuel Changeover

    MM Phase: Fuel Changeover – COF 1 Safety The new fuel main valves are opened starting its main flame. The two fuels fire together for the main flame proving time (Option 117). Page 116 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 126: Checks After Cof Fuel Changeover

    This verifies that no leaks are present on the non-running fuel valves. Failure of valve proving will cause a lockout that stops the burner. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 117...

  • Page 127: Continuous Pilot With Cof

    When fuel selection is changed, the MM moves to the restart position of the selected fuel, inhibiting the burner from starting until the new position is reached. Please refer to the Autoflame MM Application Possibilities guide for full details about Continuous Pilot. Page 118 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 128 4 FUEL OUTPUT MODES AND CHANGEOVER OPTIONS Figure 4.5: Fuel Changeover on the Fly Process 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 119...

  • Page 129: Gas Pressure Sensors And Valve Proving In Dfom With Cof

    (Option 13 setting 0 or 3). Fuel pressure limits continue to be tested for the currently firing fuel as normal, including when other operations such as valve proving are taking place on the other fuel. Page 120 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 130: Limitations Of Dfom And Cof

    Dual Fuel Output Mode and COF features will not be displayed on the Mk7 DTI, only Mk8 DTI is able to display these features. WARNING: COMMISSIONING OR BURNER START-UP MUST ONLY BE CARRIED OUT BY A FACTORY TRAINED TECHNICIAN. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 121...

  • Page 131: M. Features

    79degC, change the value in parameter 29 until the correct temperature adjustment has been made. Figure 3.9.1.i shows the load sensor adjusted by 96.0% to display 79degC. Figure 4.1.i Load Sensor Adjusted Page 122 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 132: External Modulation

    0V the MM uses the internal ‘Required’ setpoint value. When a line voltage input is provided on terminal 87, the MM uses the internal ‘Reduced’ setpoint value. A second setpoint input (T87) may be used to select the reduced setpoint. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 123...

  • Page 133: Start Position Interlock And Purge Position Interlock

    UL, FM or CE. Figure 4.5.i End Switch Wiring Schematic End Limit Switches are mounted on the end of bespoke valves (please contact Autoflame regarding bespoke valve manufacture) which are attached to the air and fuel valve and commissioned depending on the use of the End Limit Switches.

  • Page 134: Purge Pressure Proving/ Purge Hold

    Caution: When it is desired to end the continuous purge, it is necessary to disable the burner prior to turning the manual switch back to the normal position. Otherwise the burner will start up. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 125...

  • Page 135: Errors And Lockouts

    Channel 1 Movement Error Servomotor moves when not expected and vice versa • Check wiring and voltages on terminals 70 & 71 • Check servomotors drive in correct direction and valve is not stuck Page 126 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 136 Check VSD feedback against commissioned VSD and ensure the feedback is stable Channel 6 VSD Error Feedback incorrect • Check VSD feedback against commissioned VSD and ensure the feedback is stable 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 127...
  • Page 137 Check wiring on terminal PF • Check fuse 5 (2A) on expansion board WL Alarm Output Internal Fault Internal fault • Check expansion option 5 • Check wiring and voltages on terminals HAI, 1AI, 2AI Page 128 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 138 Internal fault • Contact Autoflame approved local Tech Centre Software error Internal fault • Contact Autoflame approved local Tech Centre Software error Internal fault • Contact Autoflame approved local Tech Centre 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 129...

  • Page 139: Lockouts

    Shutter Fault UV signal detected during shutter operation on self-check • Check wiring on terminals 21 and 22 • Check UV scanner type and check option/ parameter 110 is set accordingly Page 130 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 140 Oil pressure below offset lower limit during running • Check option/parameter 139 • Check oil pressure sensor Oil Pressure Too High Oil pressure above offset upper limit during running • Check option/parameter 140 • Check oil pressure sensor 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 131...
  • Page 141 Terminal 85/86 Fault Hardware fault on terminals 85/86 • Check wiring and voltages on terminals 85, 86 and contact Autoflame Proving Circuit Fail T52 Loss of input on terminal 52; MM must see input at all times from position to purge to post-purge •...
  • Page 142 Time set in option/parameter 124 has elapsed • Check option/parameter 124 Oil Pressure Sensor Fault No comms received from oil pressure sensor • Check wiring and screen on terminals 48, 49 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 133...
  • Page 143 Proof of closure switch not made after valves closed • Check wiring on terminal 55 and check proof of closure switches Lockout 199 Internal fault • Contact Autoflame approved local tech centre Page 134 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 144 MM status after lockout has been reset (Modbus) Power up CPU Test Fail Internal check failed • Contact Autoflame approved local tech centre Power up EEPROM Test Fail Internal check failed • Contact Autoflame approved local tech centre 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 135...

  • Page 145: Alarms And Warnings

    Check exhaust gas readings and option 27 NO Upper Limit NO value is above upper limit offset of commissioned value* • Alarm or warning depending on option 13 • Check exhaust gas readings and parameter 94 Page 136 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 146 Check wiring on terminals 1P+, 1P-, 1T+ and 1T- Cap Probe 2 Short Circuit Hz reading is below 10kHz • Alarm • Check water level Hz reading • Check wiring on terminals 2P+, 2P-, 2T+ and 2T- 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 137...
  • Page 147 Reading of one of the probes/sensor is less than or equal to its end-of-probe value or the difference between probes/sensor readings is greater than the mismatch threshold • Alarm • Check expansion option 27 • Check capacitance probes and sensor readings Page 138 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 148 Check wiring on terminals P-, FW and P+ • Check signal cable form the MM to the servomotor is screened at one end • Check that the servomotor is zeroed correctly 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 139...
  • Page 149 Check servomotor drives in correct direction • Check top blowdown valve is not stuck Top Blowdown Reading High TDS value detected too high • Warning • Check expansion option 46 and TDS value Page 140 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 150 Check wiring on terminals EX- and EX+ Fuel flow Feedback Below Fuel flow signal below fuel flow feedback fault tolerance Tolerance • Warning • Check feedback from external fuel flow input • Check option 60 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 141...
  • Page 151 Check wiring on terminals 89, 90, 91 and 92 Multi-Burner Config (Fuel Fuel type is not the same for all MMs in multi-burner loop Type) • Alarm • Check option/parameters 150 – 153 on all MMs in multi-burner loop Page 142 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 152 Check for wiring on terminals 6T+ and 6T- Servo Control I/O Unit 4-20mA output detects open circuit Channel 1 Output Fault • Alarm • Check wiring on output 1 on I/O module 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 143...
  • Page 153 A combustion limit error will occur if the current exhaust value has crossed the combustion limit for the number of trim cycles set in parameter 17 (the default value is 3 cycles). Page 144 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 154: Settings Conflicts

    Check options 43, 44 and 47 (43) (52) Differential Firing Rate Limit requires Fully-Linked Multi-Burner • Differential Firing Rate Limit requires Fully- Linked Multi-Burner operation • Check options 43 and 52 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 145...
  • Page 155 Check option/parameters 118 and 135 (125) (150) Valve proving cannot be optioned when fuel type is oil (fuel 1) • Valve proving can only be used for gas • Check option/parameters 125 and 150 Page 146 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 156 (E17) (E40) Bypass valve cannot be optioned with solenoid top blowdown. • Bypass and solenoid top blowdown cannot be used together, as they use same terminals. • Check expansion options 17 and 40. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 147...
  • Page 157 (E140) (E141, E143) Fuel temperature cannot be optioned with mass flow meter. • Fuel temperature sensor cannot be used with a fuel mass flow meter in fully metered control. • Check expansion options 140, 141 and 143. Page 148 Mk8 MM Installation and Commissioning Guide 09.05.2019...
  • Page 158 (88) (E129) Servo channel 3 via I/O unit cannot be optioned with heatflow sensors via I/O unit. • Heat flow sensors from the I/O unit cannot be optioned with servo channel via I/O unit. • Check option 88 and expansion 129. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 149...
  • Page 159 (E81) (E129) Servo channel 7 via I/O unit cannot be optioned with heatflow sensors via I/O unit. • Heat flow sensors from the I/O unit cannot be optioned with servo channel via I/O unit. • Check expansion options 81 and 129. Page 150 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 160: Forced Commission Reasons

    Air pressure at one or more commissioned points is less than option/parameters 147 and/or 149. IR Upload was completed successfully, check configuration then restart. • Check data has uploaded successfully before restarting in run mode. 09.05.2019 Mk8 MM Installation and Commissioning Guide Page 151...
  • Page 161 Fully metered control has been enabled but not commissioned. Fully metered configuration does not match commissioning. • One or more sensors used for fully metered control that were not present during commissioning are now enabled. Page 152 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 162: Troubleshooting And Further Information

    This can cause internal damage to the MM Snubbers can be used on these old gas valves to protect the MM from these spikes; they should be fitted across the power terminals of the gas valves. Please contact Autoflame Sales for more information.

  • Page 163: Channel Positioning Error

    This will cause an Input Fault lockout to occur. If this lockout persists, the mains input should be checked. To troubleshoot this issue, please check for any DC voltage in the mains voltage and contact your local power supplier. Page 154 Mk8 MM Installation and Commissioning Guide 09.05.2019...

  • Page 164: Standards

    7 STANDARDS 7 STANDARDS The Mk8 MM has been tested and approved to the following standards: UL 372, 5 Edition C22.2 No. 199 – M89 BS EN 298:2012 BS EN 12067-2:2004 BS EN 1643:2014 BS EN 1854 ISO 23552-1:2007 AS 4625 – 2008 AS 4630 –...
  • Page 165 Notes...
  • Page 169 Autoflame Engineering Ltd Unit 1-2, Concorde Business Centre Airport Industrial Estate, Wireless Road Biggin Hill, Kent TN16 3YN United Kingdom Tel: +44 (0)845 872 2000 www.autoflame.com...

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