Autoflame Engineering

banner2-720x380AutoflameAutoflame is a world leader in boiler/burner management systems for both commercial and industrial applications. We are passionate about boiler plants and our every effort is centred on heightening its efficiency and reliability for our clients.

Autoflame systems focus on reducing oil and natural gas consumption, boiler house emissions, and labour costs. Systems feature touchscreen interfaces and rugged steel construction. Autoflame engineered solutions are proven and trusted for some of the most demanding and critical boiler applications.

Our sophisticated burner management systems, the result of many years of practical experience, maximise the efficiency of the boiler plant, dramatically reducing fuel consumption, costs and harmful emissions. Autoflame currently has more than 10,000 systems in operation globally, and is now specified as standard equipment in some of the world’s most prestigious organisations.

Autoflame has partnerships with more than 90 technology centres worldwide, providing local engineering, installation and support for Autoflame systems. These centres have been thoroughly vetted for quality and reliability, and they receive regular training to ensure they are up to date with the latest innovations.

Whether developing advanced burner control systems, providing service and commissioning support, or upgrading existing plant with retrofit packages, we are committed to delivering high quality, innovative and effective solutions for our clients virtually anywhere in the world.

Based near London, England, we ensure industry-leading quality control and innovation by performing inhouse R&D, engineering, software development, manufacturing production, and technical support.

FeatureMini Mk8 MM
Controller
Mk7 MM
Controller
Mk8 MM
Controller
Mini Mk8 MM ControllerMk7 MM ControllerMk8 MM Controller
3 parameter (O2, CO2, CO) trimRequires EGARequires EGARequires EGA
Air pressure monitoring & proving

✔

✔

✔

Air/fuel ratio control

✔

✔

✔

Analogue water level monitoring–-–-Unlock with software
access code. Also requires Autoflame water level monitoring access code.
Autoflame water level monitoring–-Requires Expansion BoardUnlock with software
access code.
Back up commissioning data via IR port

✔

✔

✔

Boiler log entries1000161000
Bottom blowdown–-Requires Expansion BoardUnlock with software
access code
Channels3 servos/1 VSD4 servos/2 VSD4 servos/2 VSD
(5th servo via software access code)
Commissioning

✔

✔

✔

Commissioning points (not including Open, Closed, FGR & Golden Start)201720
Customisable graphics

✔

–-

✔

Deaerator Control–-–-

✔

Download Manager for viewing & troubleshooting MM configuration & performance through a PCAdvanced graphing & table interfaceLimited tabular
interface
Advanced graphing &
table interface
Draft control–-Requires Expansion BoardUnlock with software
access code
Dual fuel support

✔

✔

✔

Emissions monitoring & reportingRequires EGARequires EGARequires EGA
Error loggingMost recent
64 errors
Most recent
16 errors
Most recent
128 errors
Feedwater management–-Requires Expansion BoardUnlock with software
access code
FGR (Flue Gas Recirculation)

✔

✔

✔

First out annunciation–-Requires Expansion BoardUnlock with software
access code
Flame rod/UV change over option

✔

–-Dual IR and/or UV
Flame safeguard

✔

✔

✔

Fuel flow metering

✔

✔

✔

Fully metered, cross-limited combustion control–-–-Unlock with software
access code
IBS/lead-lag sequencing

✔

✔

✔

Lockout loggingMost recent
64 lockouts
Most recent
16 lockouts
Most recent
128 lockouts
Login security

✔

✔

✔

Modbus connectivity

✔

Requires DTIUnlock with software
access code or use DTI
Multi language displayEnglish (UK)
English (US)
Chinese
German
Spanish
Polish
Turkish
(More coming)
English (UK)
English (US)
Chinese
German
Spanish
Danish
Polish
French
Hungarian
Czech
English (UK)
English (US)
Chinese
German
Spanish
Turkish
Polish
(More coming)
Multi-burner synchronisation on a single boiler–-Twin burners
1 master, 1 slave
Up to ten burners
1 master, 9 slaves
Conditional fault response
Number of fuel curves244
O2 trimRequires O2 ModuleRequires O2 ModuleRequires O2 Module
Oil pressure monitoring & proving–-

✔

✔

On-board technical manual

✔

✔

✔

Outside temperature

✔

✔

✔

OverviewIdeal for budget applications.
Focused mainly on burner control.
Superseded in 2016 by Mk8 MMOffers even greater expandability.
Focused on complete boiler control.
Reporting/graphing

✔

✔

✔

Scheduling

✔

✔

✔

Screen size7″” (14×10.7cm)10.4″” (21x16cm)12.1″ (24.5×18.5cm)
Self-diagnostics for identifying electrical and temperature changes to the MM

✔

–-

✔

Steam/heat flow metering–-Requires Expansion BoardUnlock with software
access code
Top blowdown/TDS–-Requires Expansion BoardUnlock with software
access code
TouchscreenSingle-touch
resistive
Single-touch
resistive
Multi-touch
capacitive
UL/CE/AGA approvals

✔

✔

✔

VPS (Gas Valve Proving)

✔

✔

✔

VSD management

✔

✔

✔

download-brochure

Maximum efficiency and reduced emissions through improved control

Autoflame burner controls enable users to achieve significant fuel and emission savings over conventional systems. Typically fuel savings of 8-12% are seen where replacing linkage control systems, with some users reporting even greater savings.

Precise control of air and fuel

Using high precision directly coupled servomotors, the Autoflame MM system enables the position of fuel valves and air dampers to be precisely controlled to 0.1o accuracy, ensuring combustion efficiency is optimized at all firing rates. Reduced electrical consumption and further improvements in combustion control can be achieved through the use of variable frequency drives controlled through dedicated channels within the MM controller.

Reliably satisfying plant demand

Employing a sophisticated PID philosophy, the burners firing rate is modulated to satisfy plant demand. Regardless of your load requirements the system can be set up to respond quickly and effectively.

Optimal combustion performance maintained through three parameter trim

Where coupled with an Exhaust gas analyzer, all Autoflame burner controls will carry out three parameter combustion air trim. The system will make minor adjustments to the combustion air damper or variable speed drive controlling a forced draft fan to counteract the reductions in efficiency caused by variations in barometric conditions, stack pressure etc.

Simple and intuitive user interface

Built with end users in mind, Autoflame controls are simple and straightforward to use. All MM controls employ a simple intuitive user interface with clear backlit LCD displays and can easily be monitored and controlled through building management systems.

Setting the benchmark for safe and reliable operation

Incorporating a host of innovative and rigorous safety features, Autoflame MM systems can be depended upon to ensure the safe and reliable operation of your boiler plant. We work closely with the relevant bodies to ensure that our controls not only comply with, but exceed the requirements of the relevant industry approvals.

Free combustion efficiency audit

To obtain a free forecast of the savings that can be achieved through upgrading to Autoflame controls, and discuss your application in further detail, please contact a member of Autoflame’s technical sales team.

Complete Boiler/Burner Control: Mini Mk8 Controller

Perfect for industrial and commercial steam and hot water boiler applications, the Autoflame Mini Mk8 Controller offers cutting edge technology that can significantly reduce emissions and fuel costs.

Complete Burner Management in a Compact, Affordable System

  • Able to reduce fuel consumption by 5-7% over traditional linkage systems
  • Capable of reducing CO2 emissions by 10%
  • Repeatable, accurate positioning system reduces maintenance costs
  • Controls fuel, VSD, scheduling, sequencing and other automatic settings
  • Robust steel construction
  • Available in a control panel package

The Mini MK8 is a cutting-edge Micro-Modulating system that provides an easily programmable and flexible me

 

ans of optimising combustion throughout the load requirement range of the boiler/burner.

This control module encompasses all the functions required for reliable burner management. Built into this system is a fully automated flam

 

e safeguard and valve proving system, MODBUS connectivity, and a new touchscreen interface.
This system ensures the burner temperature is accurate to within 1° and pressure to within 1 psi. The positioning accuracy of the direct drive

motors controlling the air damper and fuel valve is 0.1 angular degrees throughout the load range. This accuracy ensures repeatable fuel-to-air ratio that leads to improved fuel economy and reduced carbon footprint.

Main Features

  • Direct replacement for Mini MK7
  • Micro Modulation of fuel/air ratio control
  • 2 fuel curve capability
  • 3 servomotor channel control
  • 1 VSD channel control
  • Internal flame safeguard control
  • Full flame supervision with self-check UV, IR or ionisation flame detection
  • Self-check UV detection (optional)
  • Lead lag/IBS (Intelligent Boiler Sequencing)
  • Precise target setpoint control (PID)
  • 3 parameter trim, O2, CO2, & CO (requires EGA option)
  • NFPA compliant
  • Outdoor Temperature Compensation (requires OTC module)
  • Time clock feature

Improvements over Mini MK7 Controller

  • Touchscreen interface on High Definition XVGA 1024X768 screen
  • Software update through Micro SD card
  • Dual-core safety processor. Both processors run the same code in parallel, and if there are discrepancies the system fails safe
  • Direct power to the IR scanner removes need for external power supply
  • Logging of 64 most recent lockouts and 64 most recent errors
  • Add additional “inter” points during single point change
  • Scheduling enables up to 5 different states per day (Reduced/Off/On)
  • Grouping of options/parameters in relation to function
  • Gas pressure sensor monitoring
  • Gas valve proving system
  • Air pressure sensor proving system
  • Low Flame Hold integrated into interface, removing need for panel switch operation

Modification to Mini Mk8 Controller

In mid-2016, Autoflame modified the cosmetics of the Mini Mk8 from a light blue fascia to the current black fascia. This was to maintain consistency with the new black Mk8 MM Controller.

Micro Modulation Fuel/Air Ratio Control

  • Independently controlled fuel and air positioning motors with an accuracy of 0.1 of an angular degree
  • Single point change facility for commissioned fuel/air ratio
  • User-defined optimum ignition position
  • FGR management—delay from startup of FGR until exhaust temperature, boiler setpoint, or time delay achieved

Burner Functions

  • Burner control functions with user configurable timings

User Features

  • Editing of parameters protected by user-configurable password
  • IR COM’s port for upload/download of commissioned data and operating history
  • Boiler screen configuration
  • Data exportable via Modbus
  • Internal calendar clock display
  • Multiple languages
  • On-screen 24 hour data logging
  • Setpoint Control Features
  • Internal 3 term PID control to maintain required setpoint for both pressure and temperature
  • Software-adjustable thermostat/pressure stat facility (lockable)
  • Lead-lag for both steam and hot water
  • Lead boiler select facility
  • 2 port valve operation for hot water sequencing
  • Fuel flow metering—instantaneous and totalised
  • Software-adjustable Hand/Auto/Low flame hold facility
  • 0-10V input for external modulation
  • Ability to use external temperature or pressure detectors

External Inputs

  • Low/high pressure switches
  • Low/high end switches

Specifications

  • 120/230V, 50/60 Hz switch mode
  • IP65/NEMA 4 enclosure with panel facia mounting (IP65 front facia, IP20 back of unit)
  • Manufactured under BS EN ISO 9001:2000

EGA (optional module)

  • O2, CO2, CO trim, NO, SO2, and NO2 continuous monitoring and display
  • User definable combustion limits on O2, CO2, CO, NO, and exhaust gas temperature
  • Exhaust temperature, ambient temperature and difference in temperature displayed
  • Combustion efficiency calculation – net or gross displayed
  • Patented three parameter  trim

Unlock Your Boiler’s Potential

All of the above features can be enabled without any additional modules or hardware (except for emissions monitoring, which requires EGA).

The Mk8 MM Controller is a Micro-Modulating system that offers comprehensive control over industrial and commercial boiler/burners.

  • Manage virtually all boiler processes from a single 12.1” multi-touch screen interface without any added modules.
  • Ideal for steam and water boilers (watertube or firetube), kilns and steam generators. Designed for oil, natural gas or both fuels.
  • Linkageless servomotor system and automated flame safeguard create conditions for unmanned boilerhouse.
  • Modbus connectivity allows for remote monitoring and management.

Control more with software unlocks

Access codes unlock advanced features without the inconvenience of hardware changes or added modules:
✓ Autoflame water level management
✓ Analogue water level (requires Autoflame water level)
✓ TDS/Top blowdown
✓ Bottom blowdown
✓ Draught control
✓ Direct Modbus connectivity
✓ First out annunciation
✓ Fully metered, cross-limited control
✓ Steam flow & water flow metering

FeatureMk8 MM
Controller
FeatureMk8 MM Controller
Screen size12.1″ (24.5×18.5cm)
TouchscreenMulti-touch capacitive
Flame safeguard

✔

Air/fuel ratio control

✔

IBS/lead-lag sequencing

✔

Scheduling

✔

Commissioning

✔

VSD management

✔

Reporting/graphing

✔

FGR (Flue Gas Recirculation)

✔

Channels4 servos/2 VSD (5th servo via software access code)
Lockout loggingMost recent 128 lockouts
Error loggingMost recent 128 errors
Number of fuel curves4
VPS (Gas Valve Proving)

✔

Outside temperature

✔

Login security

✔

Back up commissioning data via IR port

✔

Boiler log entries1000
Dual fuel support

✔

Air pressure monitoring & proving

✔

Oil pressure monitoring & proving

✔

Fuel flow metering

✔

Commissioning points (not including Open, Closed, FGR & Golden Start)20
Customisable graphics

✔

Flame rod/UV change over optionDual IR and/or UV
Multi language displayEnglish (UK)
English (US)
Chinese
German
Spanish
Turkish
Polish
(More coming)
Deaerator Control

✔

Multi-burner synchronisation on a single boilerUp to ten burners: 1 master, 9 slaves. Conditional fault response. One Mk8 MM Controller is required for each burner.
Download Manager for viewing & troubleshooting MM configuration & performance through a PCAdvanced graphing & table interface
Self-diagnostics for identifying electrical and temperature changes to the MM

✔

UL/CE/AGA approvals

✔

On-board technical manual

✔

Modbus connectivityUnlock with software access code or use DTI
Autoflame water level monitoringUnlock with software access code
Analogue water level monitoringUnlock with software access code. Also requires Autoflame water level monitoring access code.
Feedwater managementUnlock with software access code
Steam/heat flow meteringUnlock with software access code
Top blowdown/TDSUnlock with software access code
Bottom blowdownUnlock with software access code
Draft controlUnlock with software access code
Fully metered, cross-limited combustion controlUnlock with software access code
First out annunciationUnlock with software access code
O2 trimRequires O2 Module
3 parameter (O2, CO2, CO) trimRequires EGA
Emissions monitoring & reportingRequires EGA

Autoflame Mk8 MM Compared to PLC Boiler Control

The Mk8 MM Controller compares extremely favourably across a wide variety of variables to traditional PLC boiler management systems.

Boiler Emissions Monitoring & Trim: Mk8 EGA EVO

Overview

CEMS emissions auditing and trim control

For decades, boilerhouses, manufacturing plants and other industrial environments have used EGA’s to monitor flue emissions to comply with environmental regulations & to reduce fuel usage & emissions. The EGA EVO can operate as a standalone independent continuous monitor,  or it can feed back its readings to an Autoflame MM Boiler Controller, allowing the MM to adjust the fuel/air ratio (trim) of the burner for optimised performance.

  • Simultaneous & continuous sampling of up to 6 exhaust gases (O2, CO2, CO, NO, NO2 & SO2) at a fraction of the price of alternative systems. Use with Autoflame MM Controller or Standalone Mode.
  • Enables 3 parameter trim control in MM Controller for improved fuel efficiency and emission reduction

With built-in CEMS Auditing software, view reports by user-definable time periods (24 hours, 2 weeks, 1 month, 2 years, etc) based on:

  •  Total weight & volumetric emissions
  • Weight/volumetric emissions per exhaust
  • Total cost of fuel

Features

  • Continuous Emissions Monitoring System (CEMS) for display & data trending
  • Specifically designed for current regulations on emissions monitoring
  • Simultaneous & continuous sampling of up to 6 exhaust gases: O2, CO2, CO, NO, NO2, SO2
  • 10.4” Full colour touch screen
  • Stored information is updated every minute
  • Online monitoring of cell status to identify cell replacement requirement
  • MM Controller or Standalone Operation modes
  • Complete diagnostic information
  • Quick & easy installation using plug-in connectors
  • Designed to minimize maintenance
  • Six 4-20mA analogue outputs of all combustion data for remote logging, printing or chart recording
  • Standard alarm conditions for cell failure, probe blockage & analyser failure
  • Via the Autoflame Mk7 Data Transfer Interface (DTI), all CEMS data from EGA EVOcan be communicated & transferred to a Building Management System (BMS) via Ethernet connection/RS422
  • Online manual & user guide
  • Cells contain calibration data and serial number for easy cell replacement
  • Automated cell calibrations on bottled calibration gas (EPA version of EGA EVO)

Maintenance

It is recommended that the EGA EVO is sent back to Autoflame for full service & recalibration every 12-18 months if firing on gas or 9-12 months if firing on oil. System includes reusable packaging to simplify shipping.

Online Data Logging & Historical Trending

  • All of the data that is recorded in the Mk8 EGA EVO can be displayed on the touch screen & through the Mk7 DTI. The resulting data & screens can be outputted for printing/hardcopy records. This data can be exported in real-time for further management, manipulation & adjustment to suit the user’s requirements.
  • Online trending & logging of all combustion parameters, including totalised values
  • Online data is updated every second
  • Historical data is updated every minute & hourly averages are taken
  • User-selectable time function to view historical data, e.g., monthly, weekly, daily, hourly
  • Two years of data stored within the EGA including gases, pressures, atmospheric pressure, temperatures, efficiency, fuel usage

CEMS Auditing

  • Ability to input accurate fuel composition data to improve CEMS analysis
  • 4-20mA input from a fuel flow meter for accurate fuel usage in CEMS calculation
  • View reports by user-definable time periods (6 hours, 8 days, 500 days, etc.) based on:
    • Total weight & volumetric emissions
    • Total cost of fuel (calculated by current cost per tonne of fuel)
    • Weight & volumetric emissions per exhaust gas (O2, CO2, CO, NO, NO2, SO2) & per fuel

Operation with Autoflame MM Controller

  • By connecting the Mk8 EGA EVO to an MM Controller, all of the following functionality is available for improving combustion performance, reducing energy costs & improving safety:
  • The EGA enables Autoflame’s unique 3 parameter trim. The system sends output signals based on three exhaust gases (O2, CO2, & CO) to enable the MM Controller to perform trim. Controller will impose small corrections to the air damper or Variable Speed Drive in order to maintain optimum combustion performance for the system. These minute changes ensure that the original commissioned combustion data is maintained irrespective of changes to stack pressure, barometric pressure & temperature.
  • The MM Controller may be set with upper & lower limits on O2, CO2, CO, NO & exhaust gas temperature. The system can be optioned so that a lockout occurs when limits are exceeded.
  • Additional Components:
    • Includes exhaust gas sampling probe complete with internal filter, thermocouple and sampling tube
    • Optional environmental enclosure available for non-standard conditions, harsh environments
    • Optional external filter available for high condensate fuels or humid environments

Technical Specification

  • Power Supply: 110 – 240V, 50 – 60Hz
  • Ambient Temperature Limits: 5°C(41°F) to 40°C(104°F)
  • Environmental Rating: IP20 NEMA1
  • Gas available: O2, CO2, CO, NO, NO2, SO2

Improvements of Mk8 EGA EVO over Mk8 EGA

  • Moving to same capacitive touch high-resolution screen as the Mk8 MM Control.
  • Full glass front.
  • Clear user interface, similar visually to the Mini and MM Mk8s.
  • Diagnostics screen and system log for fault finding.
  • Graphical calibration schedule.
  • Complete language support.
  • Full download and upload of settings using updated Download Manager.
  • PC download of CEMS data.

Improvements over Mk7 EGA

Key Points

  1. Retains 2 years of exhaust and fuel consumption data.
  2. Plug-and-play cell replacement (no typing in codes).
  3. CEMS data logging and analysis within the EGA is now standard.

Hardware

  1. Design of case has been changed to reduce overall dimensions while maintaining internal space.
  2. External filter has been redesigned to increase filter material area.
  3. Connectors have been replaced with screw type fitting. (flying leads)
  4. Additional External filter power connector has been added.

PCB Assembly

  1. PCB design has been reduced from two boards to a single board.
  2. Main processor has been changed to a dual core processor designed with safety certification.
  3. PROM has been removed; software updates will now be via the display SD card.
  4. New pressure sensor hardware with digital interfaces to reduce noise.
  5. Chiller In/Out/Block and cell temperature sensors have been changed for improved accuracy in the low temperature range.
  6. Fuel select lines are now low voltage rather than mains. This means all connections in the secondary connector are low voltage.
  7. Fan has speed read back so that a blocked fan can be detected.

Software

  1. Cell details have been improved to show cell serial number and cell life %.
  2. Cell calibration history is now accessible from the home screen by clicking the cell images so that the lifetime graph can be viewed on a standard EGA.
  3. Completely new Errors based on the new hardware design. A number of errors have also been reduced to Warnings that allow the unit to continue running.
  4. EGA implements calibration drift storage and error reporting in line with EPA CEMS requirements.
  5. An option for remote inlet air temperature sensing has been added.  When enabled data from the internal ambient air temperature sensor is replaced by readings from the third thermocouple connector.  This is enabled with the option “Enable Pre-heat Sensor”.

More About Autoflame EGA’s

The Autoflame Exhaust Gas Analyser (EGA) has been designed to be a cost effective, low maintenance

analyser specifically for boiler applications. Developed over 20 years, the EGA system measures O2, CO, CO2 and NO as standard with additional upgrades enabling the measurement of SO2 and NO2. Through its innovative user interface the analyser will clearly display its operational status, alarm conditions and when it is scheduled to be serviced.

When combined with an Autoflame burner control, the system can be set up to carry out combustion air trim.

Mk8 EGA EVO with optional vortex compressed air cooler

Mk8 EGA EVO with optional cabinet cooler

Using an innovative three parameter system to monitor O2, CO2 and CO emissions simultaneously, the system will make minor adjustments to the air damper or variable speed drive controlling the delivery of combustion air to maintain the as commissioned optimum performance. Variations in combustion characteristics and the corresponding reduction in combustion efficiency caused by changes in barometric conditions, stack pressure, fuel pressure etc. can be completely counteracted. Fuel savings in the region of 2-4% are typical, with higher savings seen on a number of applications.

The EGA has been used at the heart of a number of innovative emissions monitoring solutions. Systems have been set up to monitor alarm, and in some cases shut down a burner whenever NOx or CO emissions exceed required levels. Where used in conjunction with an Autoflame data transfer interface, users have been able to carry out continuous emissions monitoring, logging historical data to satisfy local statutory requirements. The latest developments of the EGA product line include revisions to include a touchscreen user interface and MCERTS approval.

To learn more about the benefits of installing an Autoflame EGA on your boiler, please contact a member of Autoflame’s technical sales team.

Mk8 EGA EPA Conformance

Conforms to EPA Emissions Guidelines

Meets all requirements set by US Environmental Protection Agency

Includes all the benefits of the Stanard Mk8 EGA (CEMS Software, monitors up to 6 gases, touch screen) plus:

  • Additional back box enabling ability to self-calibrate sensors every 24 hours
  • 4 Connectors added to the bottom of the EGA., so that 4 different span gas bottles can be added for self-calibration purposes
  • Heated Sample Line to maintain Exhaust Gas temperature during sampling
  • Quick connect H.S.L. fitting on the top of the EGA

Overview

The US Environmental Protection Agency have certain requirements for monitoring boiler flue emisssions. The Mk8 EGA EPA Conformance model has been specifically designed to conform to these requirements.

Self Calibration

Enables automated cell calibrations on bottled calibration gas (4 bottles). Self calibration process occurs once every 24 hours. During this process, the cells are each recalibrated using a zero value, and a span value. The following configuration options are available:

  • User-defined span gas configuration
  • Customisable timings for sample and purge of each span gas
  • E.G.A. can perform up to two automated cell calibrations per day. User configurable to sample to certain times of day (eg, 9am & 9pm) or after a prescribed interval of hours.
  • Ranging of 4-20mA signal from fuel flow meter to maximise accuracy

Additionally, the EPA EGA has the following information:

  • Graph indicating remaining life and accuracy of each cell
  • On-screen indication of self-calibration stage and which bottle is used
  • Logging of cell calibration, readings, and drift over time
  • Calibration drift measured over the space of 5 calibrations. If excessive calibration drift is measured, the last valid calibration data is used

Heated Sample Line (HSL)

  • Heated Sample Line ensures sample gas is not diluted by water (condensate). The HSL maintains the exhaust gas temperature until the gases enter the E.G.A.
  • HSL temperature can be controlled to user-defined setting. The temperature is monitored to provide warning when not at the prescribed setting
  • The HSL operates by using a PI loop to maintain the set temperature

Boiler Monitoring: Data Transfer Interface (DTI)

Overview

The DTI (Data Transfer Interface) lets users know in real time how the boilers are performing, either on-site through its built-in touch screen, via a local PC, or via a BMS system. It stores data history of all boilers for 2 years.

The DTI is a gateway for communicating with the Autoflame MM Controller/EGA range of products. The DTI can collect and store information from a maximum of 10 Autoflame Systems in one location. The information gathered is later available for transmission to an external source such as a BMS via RS422 or Ethernet links. The data gathered by the Autoflame DTI can be synchronised and viewed using the included CEMS (Continuous Emissions Monitoring) software, which allows data collection over a local network or over the internet. The Mk7 DTI also supports the Modbus protocol over ethernet and RS422 as standard.

Main Features

The DTI can collect information from up to 10 of each of the following Autoflame products:

  • Mk7 MM Controller, Mini Mk8 MM Controller, Mini Mk7 MM Controller, or any combination to a total of 10 unitsAutoflame Exhaust Gas Analyser, either used in conjunction with an MM Controller for trim, or linked directly to the DTI for monitoring purposes only
  • Autoflame Exhaust Gas Analyser, either used in conjunction with an MM Controller for trim, or linked directly to the DTI for monitoring purposes onlyUp to 10 Input/Output modules with both analogue and digital connections
  • Up to 10 Input/Output modules with both analogue and digital connections

There are up to 150 items of information that are viewable via the DTI from each MM Controller & EGA.

MM Controller Data (Viewable & stored within the DTI for two years):

  • Required and actual boiler temperature or pressure
  • Burner firing rate (%)
  • Fuel selected & flow metering values
  • Auto/Hand/Low flame hold operation
  • Number of control channels optioned showing both actual & commissioned positions
  • Maximum/minimum set point accepted from DTI
  • Sequence status (on, stand-by, warm, off) & lead boiler status
  • Enable/disabled status & error conditions
  • Alarm status
  • First out annunciation*
  • Draft control*

Flame Safeguard Functions

  • Burner firing status (off, firing, purge, ignition, off line)
  • Hours run & number of start-ups
  • Lockout status
  • Gas pressure (online & commissioned)
  • Oil pressure (online & commissioned)
  • Air pressure (online & commissioned)

Water Level Control Functions

  • Operational information: steam and feedwater*
  • Temperature, pump status and valve position*
  • Probe information: temperature, signal value*
  • Steam flow metering data*

*Requires Mk8 MM or Mk7 MM Controller with Expansion Board

EGA Information (Viewable & stored within the DTI for 2 years)

  • O2 , CO2 , CO, NO, SO2 & NO2 percentile & ppm values
  • Exhaust temperature, combustion efficiency, fuel consumption & emissions auditing data
  • EGA error conditions
  • Flow-metering & on-line Exhaust Gas Analysis data, both instantaneous & totalised for: O2, CO2, H2O, NO, CO, SO2, N2, total emissions as a weight, & corresponding volume at exhaust exit temperature & pressure
  • Heat input, heat loss & net useful heat
  • Net efficiency, gross efficiency & temperature change
  • Fuel flow per hour & fuel flow totalised
  • Calculated cost of fuel used (cost per tonne)

DTI Input values

The following settings may be modified in individual MM Controllers via the DTI:

  • Alter setpoint (individual & global)
  • Enable/disable burner
  • Re-order boiler sequencing & select lead boiler
  • Input/Output labelling & control
  • Remote load index control

Connectivity

The Autoflame network operates using a two-core screened cable. The DTI assesses each item on the network periodically, storing up-to-date information on the DTI & outputs to defined Modbus addresses. These are then available to third party systems. The DTI features dedicated data ports for RS422 & Ethernet connections. The 10.4” touch-screen displays the operational status of the DTI’s communications, with corresponding error conditions in the event of a communication failure.

  • Autoflame CEMS Audit Software Manager/Supervisor
  • Customizable site layouts, boiler images, site naming, ancillaries, mechanical & electrical drawings
  • Ability to view live streamed data through a Mk8 MM Controller screen & EGA screen
  • Remote or local control
  • Remote connection to DTI over internet or LAN
  • The data is sampled at 1 minute intervals & stored on an SD Card within the Mk7 DTI and within the EGA.

A variety of configurations are available, including the ability to monitor multiple DTI’s from a single PC (requires additional products). Contact Autoflame or your local technology centre for more information.