AUTOFLAME Mk8 MM User manual

Mk8 MM
Installation and
Commissioning Guide

Mk8 MM
Installation and Commissioning Guide
Issued by:
AUTOFLAME ENGINEERING LTD
Unit 1-2, Concorde Business Centre
Airport Industrial Estate, Wireless Road
Biggin Hill, Kent TN16 3YN
Tel: [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.autoflame.com/
Registered Holder:
Company:
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. 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 is 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
1DIMENSIONS AND WIRING .................................................................................. 1
1.1 Mk8 MM .................................................................................................................................1
1.1.1 Fixing Holes and Dimensions...........................................................................................2
1.2 Wiring Schematic.....................................................................................................................3
1.2.1 Mk8 MM .........................................................................................................................3
1.2.2 Mk8 Expansion Board.....................................................................................................4
1.2.3 Fuse Ratings.....................................................................................................................5
1.3 Electrical Specifications ...........................................................................................................6
1.3.1 MM Inputs and Outputs...................................................................................................6
1.3.2 Expansion Board Inputs and Outputs ..............................................................................7
1.3.3 Cable Specifications ........................................................................................................8
1.3.4 MM Terminals Description...............................................................................................9
1.3.5 Expansion Board Terminals Description........................................................................ 13
1.4 Connection Between Mk8 MM and Mk8 EGA EVO ............................................................ 16
1.5 Connection Between Mk8 MM and Mk8 DTI....................................................................... 17
1.6 Sequencing Connection Diagram......................................................................................... 18
2OPTIONS AND PARAMETERS ............................................................................... 19
2.1 Options................................................................................................................................. 19
2.2 Parameters............................................................................................................................ 43
2.3 Expansion Options ............................................................................................................... 52
3COMMISSIONING PROCEDURE ........................................................................... 71
3.1 Overview
.............................................................................................................................. 71
3.2 Installation Checks ................................................................................................................ 72
3.2.1 Commissioning Checks.................................................................................................. 72
3.2.2 Operational Checks...................................................................................................... 72
3.2.3 Installation Precautions ................................................................................................. 72
3.2.4 Maintenance and Servicing.......................................................................................... 72
3.3 Servomotors.......................................................................................................................... 73
3.3.1 Adjusting the Servomotor Potentiometer....................................................................... 73
3.3.2 Servomotor Feedback Voltage..................................................................................... 74
3.3.3 Servomotors – Direction Change.................................................................................. 75
3.3.4 Servomotors with Autoflame Valves ............................................................................. 76
3.4 Commissioning Fuel and Air Positions................................................................................... 77
3.4.1 Starting Commissioning ................................................................................................ 78

3.4.2 Enter CLOSED Position ................................................................................................. 79
3.4.3 Enter OPEN Position ..................................................................................................... 80
3.4.4 Set up START Position ................................................................................................... 81
3.4.5 Phase Hold.................................................................................................................... 82
3.4.6 Add Trim Data During Commissioning.......................................................................... 83
3.4.7 Commissioning VSD...................................................................................................... 85
3.4.8 Set GOLDEN START Position........................................................................................ 86
3.4.9 Set FGR Position ........................................................................................................... 88
3.4.10 Set HIGH Position ......................................................................................................... 90
3.4.11 Set INTER Position......................................................................................................... 91
3.4.12 Set INTER or START Position......................................................................................... 92
3.4.13 Save Commission.......................................................................................................... 93
3.5 Fuel Flow Metering............................................................................................................... 94
3.5.1 Commissioning Fuel Flow Through MM........................................................................ 94
3.5.2 Commissioning Fuel Flow Through 4-20mA Feedback ................................................. 96
3.5.3 Calorific Fuel Data........................................................................................................ 97
3.5.4 Conversion Factor for Imperial Gas Flow Meters ......................................................... 98
3.5.5 Correction Factor for Burners Significantly Above Sea Level ....................................... 98
3.5.6 Gas Volume Conversion Factors................................................................................... 99
3.6 Gas/ Air Pressure Commission ........................................................................................... 101
3.7 Single Point Change ........................................................................................................... 102
3.8 Online Changes.................................................................................................................. 107
4FUEL OUTPUT MODES AND CHANGEOVER OPTIONS.......................................... 108
4.1 Overview............................................................................................................................ 108
4.2 Fuel Output Modes on the Mk8 MM.................................................................................. 108
4.3 Single Fuel Output Mode (SFOM)...................................................................................... 110
4.3.1 Fuel Configuration and Wiring in SFOM .................................................................... 110
4.3.2 Pressure Sensors in SFOM.......................................................................................... 110
4.3.3 Commissioning in SFOM............................................................................................. 110
4.3.4 Fuel Changeover Process in SFOM ............................................................................ 110
4.4 Dual Fuel Output Mode (DFOM) ....................................................................................... 111
4.4.1 Fuel Configuration and Wiring in DFOM ................................................................... 111
4.4.2 Pressure Sensors in DFOM ......................................................................................... 111
4.4.3 Commissioning in DFOM ............................................................................................ 112
4.4.4 Fuel Changeover Process in Dual Fuel Output Mode ................................................. 112
4.5 Fuel Change on the Fly (COF)............................................................................................ 114
4.5.1 Overview.................................................................................................................... 114

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
4.6 Gas Pressure Sensors and Valve Proving in DFOM with COF............................................ 120
4.7 Limitations of DFOM and COF ........................................................................................... 121
5M.M. FEATURES................................................................................................. 122
5.1 Calibration of the Actual Value .......................................................................................... 122
5.2 External Modulation........................................................................................................... 123
5.3 External Setpoint ................................................................................................................ 123
5.4 Second Setpoint Select ....................................................................................................... 123
5.5 Start Position Interlock and Purge Position Interlock ........................................................... 124
5.6 Purge Pressure Proving/ Purge Hold .................................................................................. 125
6ERRORS AND LOCKOUTS .................................................................................. 126
6.1 Errors .................................................................................................................................. 126
6.2 Lockouts.............................................................................................................................. 130
6.3 Alarms and Warnings......................................................................................................... 136
6.4 Settings Conflicts................................................................................................................. 145
6.5 Forced Commission Reasons............................................................................................... 151
6.6 Troubleshooting and Further Information ........................................................................... 153
6.6.1 UV Shutter Faults ........................................................................................................ 153
6.6.2 UV Problems ............................................................................................................... 153
6.6.3 Snubbers..................................................................................................................... 153
6.6.4 Channel Positioning Error ........................................................................................... 154
6.6.5 Input Fault................................................................................................................... 154
7STANDARDS ..................................................................................................... 155

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1DIMENSIONS AND WIRING
1.1 Mk8 MM

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1.1.1 Fixing Holes and Dimensions

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1.2 Wiring Schematic
1.2.1 Mk8 MM

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1.2.2 Mk8 Expansion Board

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1.2.3 Fuse Ratings
Fuse
Rating
Spare Part Number
1
6.3A (T)
FU10026
Fuse 1 protects the mains input to the MM, including the mains output terminals 50 – 64.
2
2A (T)
FU10034
•
Fuse 2 protects the power supply (terminal 69) for the servomotors, alarm and 2 port valve. If this
fuse blows, error ‘Triac Power Supply Error (Check F2)’ will occur.
3
500mA
FU10040
•
Fuse 3 protects the 13.5V power supply to the oil pressure sensor and IR scanner on terminal 49. If
this fuse blows, error ‘Fused 13.5V Supply Error (Check F3)’ will occur.
4
500mA
FU10040
•
Fuse 4 protects the 12V power supply to the gas/air pressure sensor and steam pressure detector
on terminals 34 and 39. If this fuse blows, error ‘Fused 12V Supply Error (Check F4)’ will occur.
5
2A (T)
FU10034
•
Fuse 5 protects the power supply (terminal PF) for the expansion servos and alarm outputs. If fuse
5 blows, error ‘Expansion PF Output (Check F5)’ will occur.
6
2A
FU10027
•
Fuse 6 protects the DC circuits. If this fuse blows, the display will be off and both LEDs adjacent to
fuse 7 and 8 will be off.
7
4A
FU10050
•
Fuse 7 protects the internal 5V supply. If this fuse blows the display will be off and the LED
adjacent to the fuse will be off.
8
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.

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1.3 Electrical Specifications
Classification according to BS EN298:2012
Mains
Supply:
Single phase 230V, +10%/-15%}
47-63 Hz, unit max. consumption 140W
Single phase 120V, +10%/-15%}
Climate:
Min. Temperature
0
O
C (32
O
F)
Recommended Temperature
Less than 40
O
C (104
O
F)
Max. Temperature
60
O
C (140
O
F)
Humidity
0 to 90% non-condensing
Storage:
Temperature
-20 to 85
O
C (-4 to 185
O
F)
Protection
Rating:
The unit is designed to be panel mounted in any orientation and the front facia is IP65,
NEMA4. The back of the unit is IP20, NEMA1.
1.3.1 MM Inputs and Outputs
230V Unit:
Outputs
Terminal
57
250mA
Must be connected through contactor
Max Load 6A
58
250mA
Must be connected through contactor
59
1A
0.6 power factor
60
1A
0.6 power factor
61
1A
0.6 power factor
62
1A
0.6 power factor
63
1A
0.6 power factor
78
100mA
To drive relay only – switched neutral
79
100mA
To drive relay/lamp only – switched neutral
120V Unit:
Outputs
Terminal
57
250mA
Must be connected through contactor
Max Load 6A
58
250mA
Must be connected through contactor
59
2A
0.6 power factor
60
2A
0.6 power factor
61
2A
0.6 power factor
62
2A
0.6 power factor
63
2A
0.6 power factor
78
100mA
To drive relay only – switched neutral
79
100mA
To drive relay/lamp only – switched neutral
Note:
1. The high and low voltage connections are not safe to touch. Protection against electric shock is
provided by correct installation. CAUTION – ELECTRIC SHOCK HAZARD.
2. Control voltage cabling should be maximum 10m, screened (if not screened then less than 1m,
however servomotors can be unscreened up to 10m)
3. Any cabling over 10m must have additional surge protection.
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.

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1.3.2 Expansion Board Inputs and Outputs
Outputs:
120/230 V
All outputs with the exception of PF are switched neutrals
BFW
250mA
Must be connected through contactor
BB
250mA
Must be connected through contactor
HWV
100mA
(alarm indicator)
2LA
100mA
(alarm indicator)
2LV
100mA
(alarm indicator)
H1A
100mA
(alarm indicator)
1LV
100mA
(alarm indicator)
79
100mA
(alarm indicator on MM board)
TB
250mA
Solenoid only, must be connected through contactor
PF
Maximum 2A
(load currents for above terminals)
Note:
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.

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1.3.3 Cable Specifications
Low Voltage
The screened cable used for low voltage wiring from the MM to the servomotors, detectors and
variable speed drive must conform to the following specification:
U.V. cable length should not exceed 25m, all other screened cable should not exceed 50m.
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:
1Belden 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.
When using a VSD, please review the manufacturer’s guidelines on installations to prevent EMC
including the recommendations for reactors and filters.

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1.3.4 MM Terminals Description
S
All terminals marked S are internally connected. They are provided for connections
to the various screened cables.
1
Current Input, 0-20mA/ 4-20mA. For channel 5 only. Can be connected to the
current output of a VSD or tachometer system or 4-20mA servomotor feedback
2
Voltage Input, 0-10V. For channel 5 only. Can be connected to the voltage output
of a VSD or tachometer system
3
0V common for Terminals 1 or 2
4
Current Input, 0-20mA/ 4-20mA. For channel 6 only. Can be connected to the
current output of a VSD or tachometer system or 4-20mA servomotor feedback
5
Voltage Input, 0-10V. For channel 6 only. Can be connected to the voltage output
of a VSD or tachometer system
6
0V common for Terminals 4 or 5
7
Current Input, 4-20mA. Used for external modulation or external required setpoint
8
Voltage Input, 2-10V. Used for external modulation or external required setpoint
9
0V common for Terminals 7 or 8
10
Current Output, 0-20mA/ 4-20mA. For channel 5 only. Can be connected to the
current input of a VSD or tachometer system or 4-20mA servomotor feedback
11
Voltage Output, 0-10V. For channel 5 only. Can be connected to the voltage input
of a VSD or tachometer system
12
0V common for Terminals 10 or 11
13
Current Output, 0-20mA/ 4-20mA. For channel 6 only. Can be connected to the
current input of a VSD or tachometer system or 4-20mA servomotor feedback
14
Voltage Output, 0-10V. For channel 6 only. Can be connected to the voltage input
of a VSD or tachometer system
15
0V common for Terminals 13 or 14
16
Current Output, 4-20mA/ 0-20mA. Varies in accordance with firing rate
17
Voltage Output, 0-10V/ 2-10V. Varies in accordance with firing rate
18
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

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25, 26
Communications port connections to an Exhaust Gas Analyser (EGA)
27, 28
Communications port connections for DTI and/or IBS
29, 30
Digital communications connections to an Autoflame IR scanner
31, 32
Digital communications connections to an Autoflame air pressure sensor and/or
Autoflame gas pressure sensor
33
0V supply to an Autoflame air pressure sensor and/or Autoflame gas pressure
sensor
34
+12V supply to an Autoflame air pressure sensor and/or Autoflame gas pressure
sensor
35
Signal inputs from Autoflame oil pressure sensor
48
0V supply to an Autoflame oil pressure sensor and/or Autoflame IR scanner
49
+13.5V supply to an Autoflame oil pressure sensor and/or Autoflame IR scanner
37
0V supply to an Autoflame temperature or pressure detector, 0-10V external load
detector
38
Signal input from an Autoflame temperature or pressure detector, 0-10V external
load detector
39
12V supply to an Autoflame pressure detector
40
0V supply to channel 1 and channel 2 servomotors
41
+12V supply to channel 1 and channel 2 servomotors
42
Signal from channel 1 servomotor, indicating position
43
Signal from channel 2 servomotor, indicating position
44
Signal from channel 3 servomotor, indicating position
45
Signal from channel 4 servomotor, indicating position
46
0V Supply to channel 3 and channel 4 servomotors
47
+12V supply to channel 3 and channel 4 servomotors
50, 51
Connections to an Autoflame UV scanner
52
Mains voltage input – external auxiliary delay to purge/ secondary proving set in
option/parameter 157
53
Mains voltage input – burner on/off signal, running interlock circuit
54
Mains voltage input – air proving switch
55
Mains voltage input - proving circuits, e.g. gas valve proof of closure

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56
Mains voltage input- lockout reset
57
Mains voltage output – call for heat
58
Mains voltage output – burner motor
59
Mains voltage output – start/pilot valve
60
Mains voltage output – main fuel valve 1
61
Mains voltage output – main fuel valve 2
62
Mains voltage output – vent valve
63
Mains voltage output – ignition transformer
64
Fuel 2 Main Valve 1(Dual Fuel Output Mode & Change on the Fly)
66
Mains supply – earth
67
Main supply – neutral
68
Mains supply – live/hot
69
Mains voltage output, power to servomotors and/or servomotor stepdown
transformer
70
Switched neutral – drives channel 1 servomotor clockwise
71
Switched neutral – drives channel 1 servomotor counter clockwise
72
Switched neutral – drives channel 2 servomotor clockwise
73
Switched neutral – drives channel 2 servomotor counter clockwise
74
Switched neutral – drives channel 3 servomotor clockwise
75
Switched neutral – drives channel 3 servomotor counter clockwise
76
Switched neutral – drives channel 4 servomotor clockwise
77
Switched neutral – drives channel 4 servomotor counter clockwise
78
Switched neutral – 2-port valve for IBS operation
79
Switched neutral – alarm output for MM lockout/MM error/EGA error.
80
Start position interlock (selectable via option 154)
81
Purge position interlock/ delay purge time (selectable via option 155)
82
Fuel 2 valves C.P.I/POC (Dual Fuel Output Mode & Change on the Fly)
83
Fuel 2 Main Valve 2 (Dual Fuel Output Mode & Change on the Fly)