AUTOFLAME MK8 EGA EVO User manual

Combustion Management Systems
MK8 EGA EVO
MM82004/E
Setup Guide
Technical Manual
04.12.2019

AUTOFLAME ENGINEERING LTD
Unit 1-2, Concorde Business Centre
Airport Industrial Estate
Wireless Road, Biggin Hill
Kent TN16 3YN
United Kingdom
Combustion Management Systems
[phone]
Tel:
[e-mail]
Email:
www.autoflame.com
Website:
Technical Manual
Mk8 EGA EVO Setup Guide
Part No. MM82004/E
4 December 2019
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. We
therefore reserve the right to amend specifications and/or data without prior notice. All details contained in
this manual are correct at the time of going to print.

Important Notes
A knowledge of combustion related procedures and commissioning is essential before embarking work on
any of the M.M./E.G.A. systems. This is for safety reasons and effective use of the M.M./ E.G.A. system.
Hands on training is required. For details on schedules and fees relating to group training courses and
individual instruction, please contact the Autoflame Engineering Ltd. offices at the address listed on the front.
Short Form - General Terms and Conditions
A full statement of our business terms and conditions are printed on the reverse of all invoices. A copy of
these can be issued upon application, if requested in writing.
The System equipment and control concepts referred to in this Manual MUST be installed, commissioned
and applied by personnel skilled in the various technical disciplines that are inherent to the Autoflame
product range, i.e. combustion, electrical and control.
The sale of Autoflame’s systems and equipment referred to in this Manual assume that the dealer, purchaser
and installer has the necessary skills at his disposal. i.e. A high degree of combustion engineering
experience, and a thorough understanding of the local electrical codes of practice concerning boilers,
burners and their ancillary systems and equipment.
Autoflame’s warranty from point of sale
•Two years on all electronic systems and components.
•One year on all mechanical systems, components and sensors.
The warranty assumes that all equipment supplied will be used for the purpose that it was intended and in
strict compliance with our technical recommendations.
Autoflame’s warranty and guarantee is limited strictly to product build quality, and design. Excluded
absolutely are any claims arising from misapplication, incorrect installation and/or incorrect commissioning.

CONTENTS
1INSTALLATION AND WIRING ..................................................................................................................1
1.1 Mk8 EGA.............................................................................................................................................1
1.1.1 Inside View..................................................................................................................................2
1.2 Fixing Holes and Dimensions .............................................................................................................3
1.3 Technical Specifications .....................................................................................................................4
1.4 Standards............................................................................................................................................4
1.5 Flying Lead Wiring ..............................................................................................................................5
1.5.1 EGA Connections .......................................................................................................................5
1.5.2 Flying Leads................................................................................................................................6
1.6 Installing Sampling Probe and EGA ...................................................................................................7
1.6.1 Sampling Probe Dimensions ......................................................................................................7
1.6.2 Sampling Probe – Internal Layout ..............................................................................................9
1.6.3 Assembly of Dry Filter...............................................................................................................10
1.6.4 Sampling Probe Installation ......................................................................................................11
1.6.5 EGA Installation ........................................................................................................................13
1.6.6 Cable Specification ...................................................................................................................14
1.7 Wiring Schematics ............................................................................................................................15
1.7.1 Connection between EGA and Mk8 MM ..................................................................................15
1.7.2 Connection between EGA, MM and DTI ..................................................................................16
1.7.3 Connection between EGA and DTI...........................................................................................17
1.8 Ancillary Parts ...................................................................................................................................18
1.8.1 Air Inlet Filter.............................................................................................................................18
1.8.2 External Particulate Filter..........................................................................................................19
1.8.3 Chilled Environmental Enclosure..............................................................................................20
1.8.4 Pre-Heated Air Sensor..............................................................................................................22
2COMMISSIONING EGA ...........................................................................................................................23
2.1 Operating Modes ..............................................................................................................................23
2.1.1 EGA through MM ......................................................................................................................23
2.1.2 Standalone EGA .......................................................................................................................25
2.2 EGA Settings ....................................................................................................................................26
2.2.1 Commission Mode Settings ......................................................................................................29
2.2.2 Fuel Setup Settings ..................................................................................................................37
2.2.3 Analogue Setup Settings ..........................................................................................................43
2.3 Commissioning MM with EGA ..........................................................................................................50
2.4 Calibration Schedule.........................................................................................................................51
2.5 Resetting Data ..................................................................................................................................53
2.5.1 Reset Cells to Factory Calibration ............................................................................................53
2.5.2 Reset Run Times ......................................................................................................................53
2.5.3 Reset Other Data ......................................................................................................................53
3SYSTEM CONFIGURATION....................................................................................................................54
3.1 Language ..........................................................................................................................................54

3.2 Set Clock...........................................................................................................................................55
3.3 Online Changes ................................................................................................................................56
3.3.1 Settings .....................................................................................................................................56
3.3.2 Fuel Setup.................................................................................................................................56
3.3.3 Calibration Schedule.................................................................................................................56
3.4 Run Times.........................................................................................................................................57
3.5 Diagnostics .......................................................................................................................................58
3.6 System Log .......................................................................................................................................59
3.7 Manual ..............................................................................................................................................60
3.8 Cell Information.................................................................................................................................61
3.8.1 O2Cell Characteristics..............................................................................................................62
3.8.2 CO, NO, NO2and SO2Cell Characteristics..............................................................................63
3.8.3 CO2 Sensor ..............................................................................................................................64
3.9 Calibrate Now ...................................................................................................................................64
4EGA OPERATION....................................................................................................................................65
4.1 Sampling Screen Icons.....................................................................................................................65
4.1.1 Temperature .............................................................................................................................66
4.1.2 Emissions..................................................................................................................................67
4.1.3 Pressure....................................................................................................................................68
4.1.4 Fuel Flow ..................................................................................................................................69
4.1.5 Faults ........................................................................................................................................70
4.2 EGA Overview ..................................................................................................................................71
4.2.1 Features and Benefits...............................................................................................................71
4.2.2 System Operation .....................................................................................................................71
4.2.3 Overview of 3-Parameter Trim..................................................................................................72
4.3 EGA Trim Function ...........................................................................................................................73
4.3.1 Trim Operation ..........................................................................................................................73
4.3.2 Importance of Measuring 3-Parameters ...................................................................................74
4.3.3 Trim Correction Calculation ......................................................................................................75
4.3.4 Trim Timing Operation ..............................................................................................................77
4.3.5 Channel 5 Trim (Mk8 MM Only)................................................................................................78
4.3.6 Trim Delay.................................................................................................................................78
4.4 Combustion Efficiency Calculations .................................................................................................79
4.5 Combustion Limits ............................................................................................................................80
4.5.1 O2Combustion Limits ...............................................................................................................81
4.5.2 NO Combustion Limits..............................................................................................................82
4.5.3 CO Combustion Limits..............................................................................................................83
4.5.4 Temperature Limits ...................................................................................................................84
4.6 Emission Gases Data Logging Units ................................................................................................85
4.7 Downloading EGA Long Term Logs .................................................................................................85
5REMOTE MONITORING ..........................................................................................................................87
5.1 Overview.................................................................................................................................................87
5.2 Wiring................................................................................................................................................87

5.3 Direct Modbus Settings.....................................................................................................................88
5.4 Modbus Addresses ...........................................................................................................................88
6SERVICING AND TROUBLESHOOTING ...............................................................................................90
6.1 Servicing ...........................................................................................................................................90
6.1.1 Sampling Probe Maintenance...................................................................................................90
6.1.2 Servicing EGA Sampling Probe................................................................................................91
6.2 Shipping ............................................................................................................................................92
6.3 Fault Codes.......................................................................................................................................93
6.3.1 General Troubleshooting ..........................................................................................................95
6.3.2 Faults on MM ............................................................................................................................95

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Mk8 EGA EVO Setup Guide Page | 1
1 INSTALLATION AND WIRING
1.1 Mk8 EGA

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1.1.1 Inside View
Figure 1.1.1.i Inside view of the EGA
1. Dry filter
2. Chiller block
3. Pinch valve
4. Drain solenoid
5. NO2cell (optional)
6. SO2 cell (optional)
7. NO cell
8. O2cell
9. CO cell
10. CO2cell
11. Battery
12. Pump
13. Fan
1
4
2
3
9
5
6
7
8
10
11
12
13

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1.2 Fixing Holes and Dimensions
Drawing No. 7976

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1.3 Technical Specifications
Electrical Supply
230/110V (minimum 100V, maximum 240V)
50/60 Hz
Power Rating
160W
Max Power Consumption
225W
Fuse Rating
4A
Environmental Rating
IP20, NEMA 1
Internal Temperature
5 – 40°C (40 – 104°F)
K Type Thermocouple
0 – 400°C (32 – 752°F)
Sampling Tubing Environment
Temperature
Maximum 60°C (140°F)
Pump Flow
600ml/min
Heating Sampling Line
Requires separate power supply.
Power consumption will depend on application and length.
Fuse rating on EGA for HSL is 20A.
1.4 Standards
The Mk8 EGA EVO conforms to the following legislations, standards and technical specifications:
•Low Voltage Directive: 2014/35/EU
•EMC Directive: 2014/30/EU
•Safety requirements for electrical equipment for measurement standard: BS EN 61010-1:2010
•Industrial, scientific and medical equipment standard: BS EN 55011:2016+A1:2017
•Electromagnetic compatibility (EMC) standards: BS EN 61000-4-2:2009, BS EN 61000-4-3:2006
+A1:2008 +A2:2010, BS EN 61000-4-4:2012, BS EN 61000-4-5:2014, BS EN 61000-4-6:2014, BS
EN 61000-4-8:2010, BS EN 61000-3-2:2014, BS EN 61000-3-3:2013
•Canadian Standard for Temperature-Indicating and –Regulating Equipment: CSA C22.2
•US Standard for Limit Controls: UL 353
•US Combustion Safeguards and Flame Sensing Systems: FM 7610 1997
•US Low Water Level Limit Controls for Boilers: FM 7710 2003
The Mk8 EGA EVO is Manufactured and calibrated in compliance with the requirements of ISO 9001:2015
Quality Management System.

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1.5 Flying Lead Wiring
1.5.1 EGA Connections
1. Pre-heated air sensor connection
2. Exhaust temperature thermocouple connection
3. Sampling line connection
4. Mains flying leading connection
5. Data flying leading connection
6. Auxiliary flying lead connection
1
2
3
6
5
4

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1.5.2 Flying Leads
Mains Flying Lead
Pin
Description
1
Live
2
Live for HSL*
3
Earth for HSL
4
Neutral for HSL
5
Neutral
6
Earth
*Note: If a Heated Sample Line (HSL) is fitted, then a
separate power supply is required.
Figure 1.5.2.i Mains
(Insert Pin Mating View)
Data Flying Lead
Pin
Description
Figure 1.5.2.ii Data
(Insert Pin Mating View)
1
Channel 1 4-20mA Output (+)
2
Channel 2 4-20mA Output (+)
3
Channel 3 4-20mA Output (+)
4
Channel 4 4-20mA Output (+)
5
Channel 5 4-20mA Output (+)
6
Channel 6 4-20mA Output (+)
7
Common for 4-20mA Outputs (-)
8
Fuel 1 Select Input
9
Fuel 2 Select Input
10
Fuel 3 Select Input
11
Fuel 4 Select Input
12
Common for Fuel Select Input
13
MM Comms (-)
14
MM Comms (+)
15
DTI Comms (-)
16
DTI Comms (+)
17
Common for Fuel Flow 4-20mA Input (-)
18
Fuel Flow 4-20mA Input (+)
19
Unused
*Note: For standalone mode, a fuel select must be
connected to pin 12 Common for Fuel Select Input.
Auxiliary Flying Lead
Pin
Description
1
External Drain (0V)*
2
Unused
3
Unused
4
Unused
5
External Drain (24V)
6
Unused
*Note: If an external particulate filter is fitted, then the
24V DC power supply required for the external drain,
comes from the EGA.
Figure 1.5.2.iii Auxiliary
(Insert Pin Mating View)

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1.6 Installing Sampling Probe and EGA
The sampling probe must be purchased separately to the EGA and is supplied with the sampling tube for the
exhaust gases and the thermocouple. The sampling tube and thermocouple is available in the below
standard lengths, however if a different length is required, please contact Autoflame.
Sampling Probe
Sampling Tube and Thermocouple Length
MM10033
3m (10ft)
MM10033/5
5m (16ft)
MM10033/10
10m (33ft)
The EGA should be checked before installing it on site. It is advisory that EGA remains upright during any
tests and checks. Thereafter the E.G.A should be turned off for a period (couple of hours), and turned back
on again to drain out any excess moisture remaining in the EGA.
1.6.1 Sampling Probe Dimensions
1. Internal filter
2. Set screw 2mm (5/64”)
3. Threaded probe socket 1.5” BSP/ NPT
4. Exhaust temperature thermocouple slot
5. Set screw 2mm (5/64”)
6. Sampling line hole
Figure 1.6.1.i Sampling Probe Assembly
1
4
5
6
2
3
Drawing No. 9058

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Figure 1.6.1.ii Sampling Probe Dimensions
Drawing No. 7978

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1.6.2 Sampling Probe – Internal Layout
Figure 1.6.2.i Sampling Probe Internal Layout

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1.6.3 Assembly of Dry Filter
If pump faults are occurring on the EGA it is advised to check the dry filter in the EGA and check for any
blockages and make sure that the filter material has not become saturated.
This filter is specifically used as a dry filter to remove and dust particulate before the dry gas passed into the
cells. The filter is carefully packed as a complete replacement part and should be repacked or the filter
material changed in the field, as the filter is critically calibrated for a specific pressure drop. 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.

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1.6.4 Sampling Probe Installation
The sampling probe must be installed as per the below guide to prevent any blockages in the line and
incorrect operation.
1. Install a 1.5” BSP socket on the flue where the sampling probe is to be positioned.
a. If using the Autoflame draft control system, the sampling probe should be positioned after
the stack damper and air pressure sensor.
b. If using a single EGA on a twin furnace, the sampling probe should be positioned after the
individual flues are combined into one stack.
c. If an economiser is fitted to the flue, the sampling probe should be positioned before the
economiser.
2. Mount the sampling probe at an angle of approximately 45Ointo the stack. This will allow any
condensate in the sample to flow down to the EGA rather causing blockages in the sampling line. A
build-up of condensation in the EGA could result in a pump failure.
3. Mount the main body of the sampling probe as far in as possible; adjustment is made by loosening
the grub screws in the flats of the 1.5” BSP bush supplied on the probe.
Notes
•Keep the thermocouple and blue sampling tube away from hot surfaces.
•The thermocouple should be positioned away from high voltage cabling.
•Ensure that the thermocouple and sampling tube run from the sampling probe to the EGA with no
coils or loops.
•The sampling probe must be positioned without air leaks as this will result in incorrect readings on all
cells.
•If the thermocouple is run in conduit from the sampling probe to the EGA, this must be earthed.
Figure 1.6.4.i EGA Probe 45OIn Flue
Drawing No. 7978

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Figure 1.6.4.ii Incorrect installation of
the sampling probe: a gully is formed in
the sampling line will cause blockage
Figure 1.6.4.iii Correct installation of the
sampling probe: the sample can flow
down the sampling line with no
restriction.

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1.6.5 EGA Installation
Once the sampling probe has been positioned and installed into the stack as per the guidelines in section
1.6.4, it can be connected to the EGA following the guidelines below.
1. Push the sampling line into the inlet tube.
2. Plug the thermocouple connector into the socket and tighten the screw.
Notes
•If the unit is started up for the first time, it may take some time for the chiller to cool down.
•To obtain optimum performance and reliability do not mount the unit in ambient temperatures above
40°C (104°F) or areas of direct heat radiation. If the ambient temperature is greater than 40°C
(104°F), a chilled environmental enclosure is required, see section 1.8.3.
•For environments with high humidity, a chilled environmental enclosure is recommended to avoid
corrosion on the electronics board, see section 1.8.3.
•If the EGA is placed in an enclosure or cabinet, to avoid the EGA being recalibrated on contaminated
gases, ensure that the drain solenoid is taking in fresh air during calibration.
•Ensure that the air flow to the intake in the bottom of the EGA unit is not impeded and the air
temperature is less than 40°C (104°F). If the burner air temperature is greater than 40°C (104°F),
then a pre-heated air sensor is required, see section 1.8.4.
•Position the sample tube so that the sample slopes down to the EGA unit at all times. The EGA unit
must always be mounted lower than the EGA probe. This helps drain excessive condensate from the
flue gases, which may cause blockages in the sample tube.
•If extension tubing is attached to the drain solenoid, check that the end of the tubing is clear of any
obstructions or contaminants. When the EGA performs an air calibration, the air is sucked into the
EGA through the solenoid.
•Condensate in the EGA could also occur from the load demand not being so high at certain times,
resulting in the back end temperature of the boiler being low and not warm enough to evaporate the
condensation quick enough. This will cause a large build-up of moisture in the EGA, and so the time
period between drains may need to be shorted in Commission Mode settings 43 and 44.
•Do not mount the units where excessive vibration occurs.
•The EGA should be positioned away from high voltage cabling.
•The EGA O2, CO, NO, SO2and NO2cells have a 6 month shelf-life. If ordering an EGA for project
that will be installed later we would advise to purchase an EGA without these cells, and then
purchase the cells when they are due to be installed. This EGA will come with the CO2cell 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.

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1.6.6 Cable Specification
Low Voltage
The screened cable used for low voltage wiring from the EGA for the fuel flow 4-20mA input, and channels 1
to 6 4-20mA outputs must conform to the following specification:
16/0.2mm PVC insulated overall braid, screened, PVC sheathed.
Sixteen wires per core
Diameter of wires in each core 0.2mm
Rated at 440V AC rms at 1600Hz
DEF 61-12 current rating per core 2.5A
Maximum operating temperature 70oC (158oF)
Nominal conductor area 0.5sq mm per core
Nominal insulation radial thickness on core 0.45mm
Nominal conductor diameter per core 0.93mm
Nominal core resistance at 20oC. 40.1Ω/1000m
Nominal overall diameter per core 1.83mm
Fill factor of braid screen 0.7
Equivalent imperial conductor sizes 14/0.0076
Use the number of cores suitable for the application. A universal part numbering system appears to have
been adopted for this type of cable as follows:
16-2-2C 2 Core
16-2-3C 3 Core
16-2-4C 4 Core
16-2-6C 6 Core
16-2-8C 8 Core
(5 Core not readily available)
Note: If using 4 Core cable and interference is detected, use 2 sets of 2 Core.
Data Cable
Data cable must be used for communication connections between MMs for sequencing applications as well
as between MMs to EGAs, MMs to a DTI and DTI to BMS systems.
Communication cable should not exceed 1km.
Types of data cable that can be used:
1 Belden 9501 for 2-core shielded cable (1 twisted pair)
2 Belden 9502 for 4-core shielded cable (2 twisted pairs)
3 STC OS1P24
Samples are available upon request. Low voltage and data cable can be ordered directly from Autoflame
Engineering, please contact Autoflame Sales.