AUTOFLAME Mk8 EGA Set-Up And Trim Manual
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AUTOFLAME Mk8 EGA Set-Up And Trim Manual

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Mk8 EGA
Set-Up and Trim Guide

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  • Page 1                                                                     Mk8 EGA 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 EGA and Mini Mk8 MM Module ..........7 2.2.3 Interconnection between Stand-Alone Mk8 EGA and Mk7 DTI ........8 2.2.4 Interconnection between Mk8 MM, Mk8 EGA and Mk7 DTI .......... 9 Components .......................... 10 2.3.1 Inside View ........................10 2.3.2...
  • Page 8 CEMS Data Screens ......................29 CEMS Energy Audits ......................33 Trim Settings .......................... 35 3.5.1 Commissioning Procedure..................... 36 Mk8 EGA Trim ........................37 3.6.1 Trim Operation ......................37 3.6.2 Trim Timing Operation ....................40 3.6.3 Trim Correction Calculation ..................41 Example ............................
  • Page 9 Troubleshooting ........................60 5.2.1 Ambient Conditions ...................... 60 5.2.2 Fuses ..........................60 5.2.3 Reading ........................60 Mk8 EGA Faults ........................61 5.3.1 Trim Delay ........................63 5.3.2 Assembly of Dry Filter ....................63 EGA Best Practice ......................... 64 5.4.1 Servicing the EGA ......................65 5.4.2...

  • Page 11: Introduction

    1.1.2 System Operation The Mk8 EGA samples the combustion gases via the stack mounted sampling probe (purchased separately from the analyser). The exhaust gases are drawn from the stack by a pump mounted internally within the analyser.

  • Page 12: 3-Parameter Trim

    1 Introduction 3-Parameter Trim The 3-parameter trim function can be enabled when the Mk8 EGA is used in conjunction with an MM module to manage the combustion. When the EGA 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: Continuous Emissions Monitoring System

    1 Introduction Continuous Emissions Monitoring System The Mk8 EGA now has the CEMS function included as standard, logging the exhaust gas and fuel data for up to 2 years. This data includes the gas readings, flue temperature, calculated efficiency and fuel consumption.

  • Page 14: Wiring And Components

    Note: Fuel Select Inputs in standalone mode are low voltage. To select a fuel, put a link on the ‘Fuel X Select Input’ to the Fuel Select Input Common e.g. to select fuel 1, link pin 8 to pin 12 to select fuel 1 in standalone mode. Page 4 Mk8 EGA Set-Up and Trim Guide 12.04.2016...
  • Page 15 Live for HSL Earth for HSL Neutral for HSL Neutral Earth Auxiliary Connector Figure 2.1.iii Auxiliary Connector – Insert Pin Mating View Pin Number Assigned function External Drain (0V) External Drain (+24V) 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 5...

  • Page 16: Electrical Schematics

    2 Wiring and Components Electrical Schematics 2.2.1 Interconnection between EGA and Mk8 MM Page 6 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 17: Interconnection Between Ega And Mini Mk8 Mm Module

    2 Wiring and Components 2.2.2 Interconnection between EGA and Mini Mk8 MM Module 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 7...

  • Page 18: Interconnection Between Stand-Alone Mk8 Ega And Mk7 Dti

    2 Wiring and Components 2.2.3 Interconnection between Stand-Alone Mk8 EGA and Mk7 DTI Page 8 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 19: Interconnection Between Mk8 Mm, Mk8 Ega And Mk7 Dti

    2 Wiring and Components 2.2.4 Interconnection between Mk8 MM, Mk8 EGA and Mk7 DTI 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 9...

  • Page 20: Components

    3. Pinch Valve 4. Drain Solenoid 5. NO Cell 6. CO Cell 7. O Cell 8. CO Cell 9. CR Battery 10. Software Update Jumpers 11. Cell Pump 12. EGA Fan Page 10 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 21: Ega Connections

    2. Heated Sample Line Fuse (EPA only) 3. Pre-Heated Air Thermocouple Connection 4. Exhaust Temperature Thermocouple 5. Sample Line connection Power and Data Connections 1. Power Connector 2. Data Connector 3. External Particulate Filter/ External Drain Connector 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 11...

  • Page 22: Cell Characteristics

    EGA 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. Page 12 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 23: Co, No, No Cells

    Mk8 EGA 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 EGA The life of the cells depends on the concentration of the gases measured over time.

  • Page 24: Set-Up

    Fuel being fired and current EGA status (Air calibration, run etc.)  Exhaust gas temperature  Ambient air temperature surrounding EGA  Delta temperature (difference between the exhaust gas and ambient temperatures)  Current combustion efficiency (see section 3.6.7.) Page 14 Mk8 EGA Set-Up and Trim Guide 12.04.2016...
  • Page 25 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 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 15...

  • Page 26: Mk8 Ega Settings

    Press this button to clean the touch screen. Pressing this button will lock the screen for 30 seconds to allow the screen to be cleaned. Page 16 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 27: 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. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 17...

  • Page 28: Fault History

    The last 10 errors are logged on this record and can be downloaded through an MM (if used). Each error contains the following information: 1. Fault number (in reverse chronological order). 2. Type of fault. 3. Date and time at which the fault occurred. Page 18 Mk8 EGA Set-Up and Trim Guide 12.04.2016...
  • Page 29 Figure 3.1.4.ii Warning Log Screen With the Mk8 EGA there are now 2 types of faults, errors and warnings. Any error that occurs will cause the EGA to stop sampling to avoid damage to the unit or inaccurate combustion readings. Errors are more serious/damaging faults than warnings, and would require immediate rectification.

  • Page 30: Factory Settings Screen

    1. The EGA ID, current operating mode, EGA status and cells selected. 2. The run times for each fuel and totalised run time. 3. Each cells run time. 4. Navigational Keys. Use the navigational keys to select the following screens. Page 20 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 31: 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 with immediate effect. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 21...

  • Page 32: Operating Mode Set-Up

    To change any of the settings above, press the corresponding button and select from the available options. If setting the EGA for standalone operation, the operation mode should be selected as ‘EGA selects fuel.’ Please see section 2.1 for information on standalone fuel selection. Page 22 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 33: Time And Date

    Range: 1 – 31 Choose from the available options. Range: 0 – 99 (20## is automatically appended upon entering the value). Range: 0 – 24. Range: 0 – 59. Range: 0 - 59. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 23...

  • Page 34: 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 24 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 35: Cems Set-Up

    ‘Factory Settings’; you will be required to enter the password. Press on the button in the bottom left corner of the screen. Figure 3.2.1.i EGA Settings – CEMS EGA Note: Fuel setup is required for CEMS recording on the EGA and DTI. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 25...
  • Page 36 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 37: Fuel Flow Source

    MM or a fuel flow meter. If the Mk8 EGA is being used in conjunction with an MM, then the fuel consumption can be determined based on the MM fuel flow metering which is entered through option 57 on the MM. For the MM fuel flow metering based audits, press the ‘Fuel Flow Source’...

  • Page 38: 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 28 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 39: 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. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 29...
  • Page 40 3 Set-Up Figure 3.3.ii Pressure History Press to view the atmospheric (ambient) pressure history for up to 2 years. The graph can be zoomed by pressing 2 points on the axis. Page 30 Mk8 EGA Set-Up and Trim Guide 12.04.2016...
  • Page 41 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. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 31...
  • Page 42 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 32 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 43: Cems Energy Audits

    3 Set-Up CEMS Energy Audits Once the fuel set-ups have been entered, it is possible on the Mk8 EGA 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 44 As detailed in this section 3.3 the totalised values can be viewed for a particular time period if required. Page 34 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 45: Trim Settings

    Number of trims before limits error generated Maximum trim during run Commission air-rich trim Add air when CO present Trim samples per cycle NO upper limit offset Exhaust temperature upper limit offset Exhaust temperature absolute limit 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 35...

  • Page 46: Commissioning Procedure

    Single Point Change. Ensure that option 12 is now set to trim. Once in single point change you will then be able to activate the trim by pressing the ‘trim’ button when on a particular point. Page 36 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 47: Mk8 Ega Trim

    This residence time is displayed in the combustion map screen. The residence time is typically longer at low fire that at high fire due to the volume of the gases passing through the boiler. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 37...
  • Page 48 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 49 The red circle indicates the current position of the trim being applied and the current combustion values are displayed at this point as well. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 39...

  • Page 50: Trim Timing Operation

    TRIM AND CHECK COMBUSTION LIMITS (IF REQUIRED) Figure 3.6.2.i Trim Timing Operation If a calibration is due during the trim cycle, the MM will delay the calibration until the cycle has completed. Page 40 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 51: Trim Correction Calculation

    The following shows an example calculation. At the current firing rate the interpolated commissioned values are: Fuel Rich (A-) Commissioned Value (CV) Air Rich (A+) 2.8% 3.0% 3.4% 10.2% 10.0% 9.7% 8ppm 5ppm 0ppm The current measured values are: Measured 3.5% 9.7% 2ppm 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 41...
  • Page 52 This trim fraction is then applied to the air channel, so if for example the air servo was at 52.0° a correction of -2.1° would be applied resulting in an air servo angle of 49.9°. Page 42 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 53: Channel 5 Trim

    Ambient Air Temperature in Boiler House Note: To use these equations temperatures must be converted to °C. European Calculation: 20.9% 0.66 Natural Gas (F1/4) 0.68 Fuel Oil (F2/F3) 0.009 Natural Gas (F1/F4) 0.007 Fuel Oil (F2/F3) 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 43...

  • Page 54: Combustion Limits

    MM module, the system will remain in a lockout condition. The following figures give a graphical presentation of how the standard limits of combustion works. Page 44 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 55: Limits Example

    (depending on the terminal 79 operation) when the actual O value dropped below 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%. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 45...

  • Page 56: 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. Page 46 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 57: 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. 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 47...

  • Page 58: 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. Page 48 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 59: Dimensions And Equipment

    4 Dimensions and Equipment DIMENSIONS AND EQUIPMENT Mk8 EGA Dimensions Figure 4.1.i Mk8 EGA Dimensions 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 49...

  • Page 60: Technical Specifications

    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) K Type Thermocouple 0 - 400°C (32 - 752°F) Sampling probe tubing Max: 60°C (140°F) Page 50 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 61: Sampling Probe

    EGA 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 EGA Unit 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 51...

  • Page 62: 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 Page 52 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 63: Sampling Probe Internal Filter

    4 Dimensions and Equipment 4.3.3 Sampling Probe Internal Filter Figure 4.3.3.i Sampling Probe Internal Filter 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 53...

  • Page 64: 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 EGA and check the pump pressure and flow. Page 54 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 65: 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 EGA or retrofitted onto an existing E.G.A at our Autoflame London office.

  • Page 66: Air Inlet Filter

    4.4.2 Air Inlet Filter The Mk8 EGA air inlet filter (part no. EGA80106) is designed to protect the EGA from dust and other particles that may cause damage or reduce the performance of the EGA over time. The air inlet filter will fit over the fan that cools the EGA and stop dust and particles from getting inside the EGA.

  • Page 67: 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 EGA Autoflame also manufacture a heated enclosure for low temperature and for anti-condensing sites.

  • Page 68: Pre-Heat Air Sensor

    4 Dimensions and Equipment 4.4.4 Pre-Heat Air Sensor A Pre-Heat Air Sensor has been incorporated into the Mk8 EGA to ensure an accurate efficiency calculation when using pre-heated air. This Pre-Heat sensor uses a K-Type Thermocouple. Page 58 Mk8 EGA Set-Up and Trim Guide...

  • Page 69: Error Checking And Self-Diagnostics

    EGA error is reset and becomes fully operational once again. Should the fault require the EGA to be returned to Autoflame ensure the EGA sampling system should be carefully packed into the carton in which it was supplied and marked “Fragile – Scientific Instruments”...

  • Page 70: 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 Mk8 EGA is sampling fresh air. To troubleshoot this:  Check all piping is airtight ...

  • Page 71: Mk8 Ega Faults

    EGAs Fault Temperature Error – User Temperature sensor is faulty – see temperature Sensor Clear sensor faults below Pressure Sensor Error – User Pressure sensor is faulty Clear 12.04.2016 Mk8 EGA Set-Up and Trim Guide Page 61...
  • Page 72 On-board ambient air temperature sensor has a Ambient fault Temperature Error – User Clear Thermistor sensor in chiller block has a fault Chiller Temperature CO Error – User Clear Thermistor sensor in CO block has a fault Page 62 Mk8 EGA Set-Up and Trim Guide 12.04.2016...

  • Page 73: Trim Delay

    The filter should always be dry, if any carryover of liquid or moisture is sent in the filter, please isolate the EGA and contact Autoflame Technical Support. 12.04.2016...

  • Page 74: Ega Best Practice

    This EGA 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 75: Servicing The Ega

    To avoid any potential damage to the EGA during transit and to stop the PCBs from flexing there are pads between the two PCBs of the Mk8 EGA, and the casing of the EGA 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 76: Standards

    6 Standards STANDARDS UL 353 CSA C22.2 No. 24 Page 66 Mk8 EGA Set-Up and Trim Guide 12.04.2016...
  • Page 79 Notes...
  • Page 82 Autoflame Engineering Ltd Unit1-2 Concorde Business Centre Airport Industrial Estate, Wireless Road Biggin Hill, Kent TN16 3YN United Kingdom +44 (0) 845 872 2000 www.autoflame.com...

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