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AUTOFLAME Mk7 Manual

Exhaust gas analyser, e.g.a. set-up and trim guide
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Mk7 Manual:
E.G.A. Set-Up and Trim
Guide

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  • Page 1                                                                   Mk7 Manual: E.G.A. Set-Up and Trim 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 7: Table Of Contents

    Interconnection between E.G.A. and M.M. Module ............3 2.1.2 CEMS E.G.A. with D.T.I....................4 2.1.2.1 Wiring .......................... 5 2.1.3 Interconnection between Stand-Alone Mk7 E.G.A. and Mk7 D.T.I ......... 6 Components ..........................7 2.2.1 Inside View ........................7 2.2.2 Inside View Schematic ..................... 8 Cell Characteristics ........................
  • Page 8 Mk7 E.G.A. Trim ........................32 3.3.1 Trim Operation ......................32 3.3.2 Quick Commission ......................34 3.3.3 Trim Timing Operation ....................36 3.3.4 Graphical Trim Operation .................... 37 3.3.5 Channel 5 Trim ......................38 3.3.5 Combustion Efficiency Calculations ................38 Combustion Limits ......................... 39 3.4.1...
  • Page 9 E.G.A. Best Practice ......................58 5.3.1 Servicing the E.G.A....................... 59 5.3.2 Shipping the E.G.A....................... 59 MK7 CEMS E.G.A..................60 Overview of the Mk7 CEMS E.G.A..................60 6.1.1 C.E.M.S. Upgrade ......................60 CEMS Set-Up ........................61 6.2.1 Fuel Selection ........................ 61 6.2.2...

  • Page 11: Introduction

    Overview and Benefits 1.1.1 Features and Benefits The Mk7 Exhaust Gas Analyser (E.G.A.) monitors the emissions in the flue produced from the burner/boiler system. The E.G.A. can improve combustion, increase efficiency, reduce fuel consumption and improve safety through its 3 parameter trim function and combustion safety limits.

  • Page 12: 3-Parameter Trim

    1 Introduction 3-Parameter Trim The 3-parameter trim function can be enabled when the Mk7 E.G.A. is used in conjunction with an M.M. module to manage the combustion. When the E.G.A. detects any differences in the online exhaust gas readings to the original commissioned values, the trim function will make small corrections to the air damper (and channel 5 if optioned for trim), to bring those online values back to the commissioned readings.

  • Page 13: Wiring And Components

    CH. 6 + to DTI CH. 5 + CH. 4 + CH.1- CH.6 CH. 3 + Analogue LIVE CH. 2 + Output CH. 1 + SCREEN BLACK DATA CABLE CONTROL FUSE September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 3...

  • Page 14: Cems E.g.a. With D.t.i

    ‘Edit Boiler’ screen and the E.G.A. setup for standalone operation (E.G.A. selects fuel). Using the CEMS E.G.A. in conjunction with the Mk7 M.M. module and D.T.I, a data link will be required between the M.M. and E.G.A. and from the E.G.A. to the D.T.I. (see section 2.1.2.1). The D.T.I.

  • Page 15: Wiring

    CH. 4 I + CH.1- CH.6 CH. 3 I + Analogue LIVE CH. 2 I + Output I - CH. 1 I + DATA CABLE 3-WAY PLUG POWER 3-WAY PLUG September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 5...

  • Page 16: Interconnection Between Stand-Alone Mk7 E.g.a. And Mk7 D.t.i

    2 Wiring and Components 2.1.3 Interconnection between Stand-Alone Mk7 E.G.A. and Mk7 D.T.I Page 6 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 17: Components

    2.2.1 Inside View Sample in from E.G.A. Probe NO Cell Filter Chiller Cell Cell Pinch Valve Cell CO Cell Data Port & Mains Input 4-20mA Outputs Pump Sensor Drain Solenoid September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 7...

  • Page 18: Inside View Schematic

    2 Wiring and Components 2.2.2 Inside View Schematic 4  Figure 2.2.2.i E.G.A. Inside View Schematic Page 8 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 19: Cell Characteristics

    E.G.A. flags this up on the screen. Cells will need to be changed every 9 to 12 months firing on gas, and 6 to 9 months firing on oil. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 9...

  • Page 20: Co, No, No

    Mk7 E.G.A. unit. The accuracy of these cells is within limits of ± 5% at 100ppm. From experience we would expect to see a drift of ± 10ppm per annum without calibration. In our view, this drift would not be detrimental to the operation or application of the E.G.A.

  • Page 21: Set-Up

    Fuel being fired and current E.G.A. status (Air calibration, run etc.)  Exhaust gas temperature  Ambient air temperature surrounding E.G.A.  Delta temperature (difference between the exhaust gas and ambient temperatures)  Current combustion efficiency (see section 3.3.6) September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 11...
  • Page 22 Piping (water/condensate draining or air sample flowing) Pump Pinch Valve Open Pinch Valve Closed Temperature Sensor Pressure Sensor Chiller Status Restrictor Note: Components that are not ready/malfunctioning are denoted by a Page 12 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 23: Mk7 E.g.a. Settings

    Press this button to toggle the units used by the system. The text displayed indicates the unit currently selected. This will take you to the Fault History where up to 10 faults are recorded, see section 3.2.4. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 13...

  • Page 24: Cell Status Screen

    Not Fitted – Indicates the cell is not fitted. Refer to Section 3.1.7 on how to enable cells if they are present. Error – Indicates there is an error with the cell. Press to get further information. Page 14 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 25: Fault History

     Fault number (in reverse chronological order).  Type of fault.  Date and time at which the fault occurred. See Section 5 for possible faults and solutions. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 15...

  • Page 26: Factory Settings Screen

    The factory settings screen displays the following information:  The E.G.A. ID, current operating mode, E.G.A. status and cells selected.  The run times for each fuel and totalised run time.  Each cells run time. Page 16 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 27: 4-20Ma Set-Up

    This is the same procedure as entering the minimum value. 5. Repeat steps 1 to 4 for each output as desired. Note: All changes will be stored for immediate effect. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 17...

  • Page 28: Operating Mode Set-Up

    To change any of the settings above, press the corresponding button and select from the available options. If setting the E.G.A. for standalone operation, the operation mode should be selected as ‘E.G.A. selects fuel.’ Page 18 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 29: Cell Calibration

    1. Select the cell to be calibrated by pressing on the cell symbol. 2. Verify the correct cell has been selected. Press the button to begin entering the calibration code. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 19...
  • Page 30 5. A text block will now appear to confirm if the code has been accepted or was incorrect. Press button to return to the factory settings screen. Page 20 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 31: Time And Date

    Each button has the following ranges: Range: 1 – 31 Choose from the available options. Range: 0 – 99 Range: 0 – 24. Range: 0 – 59. Range: 0 - 59. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 21...

  • Page 32: Change Password

    If the passwords entered in steps 1 and 3 are identical a box will appear stating “Password Changed”. Should the passwords not match or if the button is pressed a box will appear stating “Password Not Changed”. Page 22 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 33: Emissions History Screens

    It is possible to select/deselect which gas concentrations are shown on the graph by pressing which gas you wish to select/deselect at the top of the graph. The Mk7 CEMS E.G.A. displays the exhaust gas data, temperature and combustion efficiency for up to 2 years.
  • Page 34 T and efficiency from the past 24 hours. As with the gas history graph the graph can be manipulated and it is also possible to select/deselect what data is shown on the graph. Page 24 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 35: Trim Settings

    3.2.1 Relevant M.M. Options The following table gives all the options in the Mk7 M.M. which are relevant to the E.G.A. settings. When changing the options for the E.G.A. such as the alarm operation, trim threshold and trim delay, it is good practice to adjust one and check the effects on the trim operation before adjusting another.
  • Page 36 0 - 200 % CO Absolute Value ppm CO: System checks for CO readings higher than value specified in this option regardless of the commissioned values. 0 - 200 ppm CO Page 26 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...
  • Page 37 Trim channel: If an E.G.A. is optioned, the trim can be applied to either Channel 2 (servomotor) or channel 5 (VSD). If trim on channel 5 is used, Options 91 to 97 must be entered correctly. Trim on channel 2. Trim on channel 5. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 27...

  • Page 38: Relevant M.m. Parameters

    3 Set-Up 3.2.2 Relevant M.M. Parameters The following table shows the relevant parameters for the Mk7 E.G.A. operation on the Mk7 M.M. It is important to remember that changing these parameters will dramatically change the trim operation. The majority of these parameters can be left with the default settings in most applications; any adjustments to these parameters should be made one at a time.
  • Page 39 20 - 360 Seconds. E.G.A. - Time between each sample (trim). 5 - 100 Seconds. E.G.A. - Number of samples (trims) between each trim cycle. 1 - 50 Number of trims. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 29...
  • Page 40 Upper offset limit exhaust temperature: This is an offset limit from the commissioned values. 0 - 999 deg C/ deg F Absolute limit exhaust temperature: System checks for exhaust temperature readings higher than this value 0 - 999 deg C/ deg F Page 30 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 41: Commissioning Procedure

    The factory trained technician must be completely familiar with the commissioning of the M.M. unit before commissioning with the E.G.A. The Mk7 M.M. commissioning procedure is shown in Mk7 Manual: M.M. Installation and Commissioning Guide.

  • Page 42: Mk7 E.g.a. Trim

    , and CO at the commissioned value. Deviations from these ideal values are held and accessible via the Combustion Map button the Mk7 M.M. This data shows the commissioned values of the emissions, the current values of the emissions and the amount of trim that is being used.
  • Page 43 CO is produced. The Autoflame analyser has seen this ambiguous case and returns the air damper back to the commissioned value in order to ensure that the O...

  • Page 44: Quick Commission

    Single point change can be accessed at a later time at load to add the trim curve. (See Mk7 Manual: M.M. Installation and Commissioning Guide). The amount of trim is proportional to the area that the damper is open. During normal commissioning with E.G.A., the air damper is opened and closed (during air rich and fuel rich) based on 5% of the...
  • Page 45 3 Set-Up Figure 3.3.2.i Combustion Map Screen The combustion map screen is enabled by setting Parameter 74 to 1 prior to commissioning the Mk7 M.M. and also requires an E.G.A. to be optioned. The combustion map (see Figure 3.3.2.i) shows how the trim function works on the system. The combustion map screen can be accessed by pressing the ‘combustion map’...

  • Page 46: Trim Timing Operation

    3.3.3 Trim Timing Operation Figure 3.3.3.i Trim Timing Operation If an air calibration is due during the trim cycle, the M.M. will delay the calibration until the cycle has completed. Page 36 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 47: Graphical Trim Operation

    3 Set-Up 3.3.4 Graphical Trim Operation Figure 3.3.4.i Graphical Trim Operation September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 37...

  • Page 48: Channel 5 Trim

    When trim is set on channel 5, changing the M.M. options will make a difference between errors occurring or not. For the purposes of trim, the Mk7 M.M. needs to know how the VSD will behave, in terms of a change in the VSD input and its effect on the feedback (output) signal, which is why the VSD Options (90 –...

  • Page 49: Combustion Limits

    M.M. module, the system will remain in a lockout condition. The following figures give a graphical presentation of how the standard limits of combustion works. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 39...

  • Page 50: Limits Example

    2% offset from the commissioned value. If the absolute lower limit was set to 3%, the burner would alarm when the actual O value dropped below 3%. Page 40 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 51: Limits Example

    (depending on the terminal 79 operation) when the actual NO value rose above 20ppm offset from the commissioned value. If the absolute higher limit was set to 40ppm, the burner would alarm when the actual NO value rose above 40ppm. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 41...

  • Page 52: Co Limit Example

    (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 set to 20ppm, the burner would alarm when the actual CO value rose above 20ppm. Page 42 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 53: Temperature Limits Example

    100deg.F offset from the commissioned value. If the absolute higher limit was set to 500deg.F, the burner would alarm when the actual exhaust temperature value rose above 500deg.F. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 43...

  • Page 54: Dimensions And Equipment

    4 Dimensions and Equipment DIMENSIONS AND EQUIPMENT Mk7 E.G.A. Dimensions Figure 4.1.i Mk7 E.G.A. Dimensions Page 44 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 55: Technical Specifications

    230/110V 50/60 Hz Power 160W Max Power Consumption 225W Pump Flow 110 – 120 mBar 600ml/min Environmental Rating IP20 NEMA 1 Temperature Range E.G.A Min : 5°C (40°F) Max: 40°C (104°F) September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 45...

  • Page 56: Sampling Probe

    E.G.A. unit must always be mounted lower than the E.G.A. probe. This helps drain excessive condensate from the flue gases, which may cause blockages in the sample tube. Figure 4.3.1.i Incorrect and Correct Installation of an E.G.A. Unit. Page 46 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 57: Sampling Probe Assembly

    4 Dimensions and Equipment 4.3.2 Sampling Probe Assembly Figure 4.3.2.i Sampling Probe Assembly Figure 4.3.2.ii Sampling Probe Dimensions September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 47...

  • Page 58: Sampling Probe Internal Filter

    4 Dimensions and Equipment 4.3.3 Sampling Probe Internal Filter Figure 4.3.3.i Sampling Probe Internal Filter Page 48 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 59: Sampling Probe Maintenance

    11. Use a small rod to pack the material down a little at a time. 12. Reassemble by sliding the assembly into the casing and screw together. 13. After reassembly connect the probe to the E.G.A. and check the pump pressure and flow. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 49...

  • Page 60: Ancillary Equipment

    Due to the nature of this product it can only be installed by Autoflame and cannot be fitted on site. The external particulate filter can be ordered with a new E.G.A. or retrofitted onto an existing E.G.A at our Autoflame London office.
  • Page 61 E.G.A. The external particulate filter drain will operate in the same manner and at the same time as the E.G.A. drain solenoid. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 51...

  • Page 62: Air Inlet Filter

    4.4.2 Air Inlet Filter The Mk7 E.G.A. air inlet filter (part no. EGA70106) is designed to protect the E.G.A. from dust and other particles that may cause damage or reduce the performance of the E.G.A. over time. The air inlet filter will fit over the fan that cools the E.G.A.

  • Page 63: Chilled Environmental Enclosure

    The temperature is user adjustable by means of a thermostat counted on the unit but is nominally set for 35°C (95°F), which ensures ideal operating conditions for the E.G.A. Autoflame also manufacture a heated enclosure for low temperature and for anti-condensing sites.

  • Page 64: Error Checking And Self-Diagnostics

    (lower pipe connection). If the error is resolved then check the filter (Section 5.2.4) and sampling line with the E.G.A. If error persists replace the pump. Page 54 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...
  • Page 65 Exhaust Temperature Absolute Limit Exceeded Check Parameter 97 and Section 3.4 Should the fault require the E.G.A. to be returned to Autoflame ensure the E.G.A. sampling system should be carefully packed into the carton in which it was supplied and marked “Fragile – Scientific Instruments”...

  • Page 66: Troubleshooting

    Any sign of this activity and the unit should be returned to the supplier. 5.2.3 O Reading If you get a continuous O reading of 20%, this tells you that the Mk7 E.G.A. is sampling fresh air. To troubleshoot this:  Check all piping is airtight ...

  • Page 67: Trim Delay

    The filter should always be dry, if any carryover of liquid or moisture is sent in the filter, please isolate the E.G.A. and contact Autoflame Technical Support. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 57...

  • Page 68: Best Practice

    This E.G.A. will come with the CO cell only (patent no: MM72004/NC) as this can only be fitted at Autoflame office. We recommend that the cells are replaced 12-18months for gas firing from manufacturing date and 6-12 months for heavy oil firing applications.

  • Page 69: Servicing The E.g.a

    To avoid any potential damage to the E.G.A. during transit and to stop the PCBs from flexing there are pads between the two PCBs of the Mk7 E.G.A., and the casing of the E.G.A. and the PCBs. This extra support stops flexing of the PCBs during transit. The top of the cells will be covered in bubble wrap to protect them from damage during transit.

  • Page 70: Mk7 Cems E.g.a

    It is possible to upgrade an existing standard Mk7 E.G.A. that has already been purchased. The E.G.A is required to be returned to the Autoflame UK Office, so that it can re-configured for the CEMS E.G.A. features. Please note that this process will include the service and re-calibration of the E.G.A. incurring additional costs.

  • Page 71: Cems Set-Up

    ‘Factory Settings’; you will be required to enter the password. Press on the ‘Fuel Set-Up’ button in the bottom left corner of the screen. Figure 6.2.1.i EGA Settings – CEMS E.G.A. Note: Fuel setup is required for CEMS recording on the EGA and DTI. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 61...
  • Page 72 CEMS fuel data can be entered for up to 4 fuels. There are several pre-set fuels 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 Autoflame Technical Support.

  • Page 73: Fuel Flow Source

    M.M. or a fuel flow meter. If the Mk7 CEMS E.G.A. is being used in conjunction with an M.M., then the fuel consumption can be determined based on the M.M. fuel flow metering which is entered through option 57 on the M.M.

  • Page 74: Unit Measurement

    This is done using the ‘Cost per Unit’, ‘Currency’ and ‘Costing Units’ buttons on the right hand side of the Fuel Set-up screen. If further currencies or unit measurements are required, please contact Autoflame Technical Support. Page 64 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 75: Cems Data Screens

    The graph can be zoomed in by pressing 2 points on the axis. To view one gas at a time, deselect the other gases above the graph. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 65...
  • Page 76 Figure 6.3.ii Pressure History Press to view the atmospheric (ambient) pressure history for up to 2 years. The graph can be zommed by pressing 2 points on the axis. Page 66 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...
  • Page 77 The graph can be zoomed in by pressing 2 points on the axis. To view one temperature graph at a time, deselect the other temperatures above the graph. September 2014 Mk7 Manual: E.G.A. Set-Up and Trim Guide Page 67...
  • Page 78 To view overnight data, a two day view is required (e.g. From 20:00 on day 1 to 08:00 on day 2). The hourly data for each day is displayed from 00:00 to 24:00. Page 68 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...

  • Page 79: Cems Energy Audits

    6 Mk7 CEMS E.G.A. CEMS Energy Audits Once the fuel set-ups have been entered, it is possible on the Mk7 CEMS E.G.A. to take fuel consumption audits. Select a time period using the arrow section on the CEMS data for which the fuel consumption will be calculated for.
  • Page 80 As detailed in this section (6.4) the totalised values can be viewed for a particular time period if required. Page 70 Mk7 Manual: E.G.A. Set-Up and Trim Guide September 2014...
  • Page 82 Notes...
  • Page 85 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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