Combustion Management Control System

AutoflameMK7 Combustion Controller and Function IntroductionShao

MM micro adjustment/flame protection

• Fuel/air ratio control

• Control up to 4 positioning motors and 2 variable speed drives (VSD/VFD)

• 4 independent fuel programs

• Fully adjustable PID load control for temperature and pressure

• External voltage/current load control and set point adjustment

• Various boiler load detectors

• Dual burner function

• Compatible with control frequency driver *

• Fuel flow meter function

• Internal flame protection - flame monitoring with ultraviolet and infrared self checking

• Gas valve groupLeakage supervision and gas pressure monitoring

• Air pressure calibration and monitoring

EGA exhaust gas analysis(Option)

• Balance adjustment of 3 parameters: O2, CO2, and CO

• Analysis of O2, CO2, CO, NO, exhaust gas temperature, efficiency, andΔT

• Optional analysis of NO2 and SO2

• Perform recalibration, replace battery, user settings, and display local data for independent operation

• Upper/lower limits of O2, CO2, CO, NO, and exhaust temperature/limit

• Six 4-20mA output signals for data exchange with other control/chart recorders

IBS intelligent sorting boiler (priority/lag control)

• The system will sort hot water boilers and steam boilers by prioritizing/lagging load allocation

• Fully adjust control based on actual usage through user options in the system

• System control for isolating valves or pumps

• Set fictional set values and perform standby heating for lagging boilers through timing and pressure compensation or automatic water temperature regulators.

DTI Data Transmission Interface(Option)

• The system will collect operational data from up to 10 micro adjustment modules, 10 EGA modules, 10 analog I/O modules, and 10 digital I/O modules on site. Data transmission via RS232/485linkTransfer to a local computer running WinPC DTI or Building Management System (BMS).

• The modem compatible software can remotely provide information and control the operation of the boiler room.

• Compatible with MODBUS and Johnson's Metasys

WL water level control

• Fully regulated water level control, including all safety settings, second low water level, first low water level, first low water level pre alarm, high water level pre alarm, and high water level.

• 15 First Out Annunciation inputs

• Automatic bottom discharge

• Surface Discharge Management (TDS - Total Dissolved Solids)

• Steam flowmeter

IIF O2 interface module

• Face to face connection with existing online O2 analyzers via 4-20mA

PCC PC compatibility

• Download all debugging data from the micro adjustment module

• Upload debugging data to the micro adjustment module

I/O digital&analog input/output module

• These modules can be configured to input and output data for the DTI system

• The simulation module has 6 4-20mA inputs and outputs

• It can mark all inputs/outputs for specific use, and arrange alarm status or only monitor status.

1.1.3 Comparison of Micro Adjustment Systems

1.2 Micro adjustment (MM)

To achieve the maximum efficiency of any boiler operation, two requirements are extremely important. *The requirement is to keep the air to fuel ratio as low as possible to ensure sufficient combustion within the limits of the combustion head design, and once these settings are achieved, they should be able to repeat infinitely and maintain an accuracy of *. The second requirement is that the target temperature and pressure of the boiler are monitored by the combustion system, and precise amounts of fuel and air must be burned at all times to achieve the target values. Under no circumstances should these target values be exceeded or not reached, regardless of changes in load.

The self lag phenomenon of all mechanical systems that traditionally use cam and connecting rod to establish fuel air ratio makes it impossible to achieve the above accuracy. The reaction accuracy of fuel addition corresponding to the monitored boiler temperature/pressure values means that the target values set by the operator are often exceeded or not reached.

The micro adjustment system provides a simple programming and flexible way to optimize combustion quality throughout the entire required load range of the boiler/burner. At the same time, ensure that the accuracy of the temperature is within 1 degree Celsius (2 degrees Fahrenheit); The pressure accuracy is within 1.5 psi (0.1 bar). The maximum rotation angle error between two servo motors at any position within the load range is 0.1 degrees.

The core of a micro adjustment system is a control module that includes a microprocessor and a power supply. The display interface of MK7 MM is a 10.4”The touch screen can display the operating position, combustion speed, and actual situation/And the required temperature and pressure values, if equipped with EGA equipment, can also display smoke information. The Mini MK7 is equipped with an LCD display and a responsive keyboard and status indicator. All necessary information such as combustion speed, servo motor position, required temperature/pressure values, and actual temperature/pressure values are displayed on the LCD screen.

A servo motor with up to 4 double-layer copper coils wound around it is connected to the control module through a high-speed solid-state switch. One motor is responsible for positioning the air damper, the other is responsible for the fuel valve, and the remaining two will be used as needed, such as the flue gas recirculation valve.

This new burner control system achieves automatic locking of the air fuel mixture ratio within the fuel input range of the boiler, while maintaining precise temperature and pressure target values. The load control incorporates user variable PID control. The PID controller can be infinitely adjusted to meet any boiler room requirements.

The MM module is the fundamental component of the Autoflame system. The complete system based on Mk7 MM integrates all of the following control devices and features:

• 6 communication channels: 4 positioning motors and 2 variable speed drive interfaces

• 4 independent fuel configurations

• Flame monitoring with ultraviolet and infrared self checking monitoring equipment

• The first 16 boiler lock history, including date and time

• Single point change function

• IBS steam sorting, with priority/lag and standby heating

• IBS hot water heating boiler sorting, with priority/lag and circuit two-way valve control

• Gas Valve Gas Device Leakage Inspection System

• Gas pressure monitoring and display

• High and low gas pressure monitoring

• Fuel pressure high/low limit monitoring

• User defined * ignition position selection–Golden Start

• User defined ignition position selection for flue gas recirculation

• Variable servo motor rotation speed

• Adjustable gas air mixture ratio adjustment communication channel

• Burner control optional operation - * times/second safety check

• Air pressure calibration–Display and monitoring

• Internal PID 3-degree load control

• External temperature compensation for boiler selection point

• Fuel flow measurement–Instant and Total Value

• Exhaust gas temperature reading value

• Three parameter gas mixture ratio adjustment–O2, CO2, CO

• Combustion efficiency calculation

• NO, NO2, Monitoring and display of SO2

• User defined combustion limit

• Second set point–User selectable

• Manual/low flame holding equipment

• Password protection for all security related options and parameters

• Infrared serial port for uploading and downloading debugging data

• Dual burner control capability

• External adjustable 4-20mA/0-10V input

• 4-20mA/0-10V output to confirm combustion speed

• Fuel conversion can be performed without shutting down (special software)

• 10.4”touch screen

• 110 or 230V standard operation

• Install the panel control surface facing outward.

1. Exhaust Gas Analysis (EGA) 3 Parameter Gas Mixing Control System (Option)

The use of EGA regulation system can expand the system function of micro regulation (MM) to measure and display O2, CO2, CO, NO, NO2, SO2, exhaust gas temperature and boiler efficiency. At the same time, minor corrections are made to the position of the air damper to ensure that the original input debugging data is maintained, regardless of changes in chimney pressure or air pressure conditions. Due to its standard 4-20mA output, the system can be connected to an energy management system through an appropriate interface to track and record information generated by EGA. The control form of MM/EGA is PID forward transmission and intervention of all input data. MM/EGA also comes with system component self identification or data error handling inspection and self diagnosis software.

On the basis of maintaining O2, CO2, and CO at the values set during the debugging phase, the three parameter adjustment function is achieved through each pair of air/fuel ratios. For moderate deviations from these ideal values, the deviation data can be integrated and represented as angle values, so that the system can be returned to its debugging values at any time and under various load conditions by performing precise air door adjustments, without affecting the safety of the system.

All EGA data can be obtained through one or all of the following methods:

1. On the touchscreen display of EGA

2. On MM's display screen

3. 6 x 4-20mA output devices

Perform EGA settings and calibration based on the display on the touch screen.

1. Intelligent Boiler Sorting (IBS)

The intelligent boiler sorting function on each micro adjustment module further extends the potential use of this system. The purpose of this control form is to ensure that only a minimal amount of boiler equipment is in operation at any time to meet the required heat generation of the boiler equipment.

Users can choose between two types of intelligent boiler sorting through the option program. One sorting is about hot water heating boilers, and the other sorting is about steam boilers.

1. Hot water heating boiler IBS

Up to 10 micro adjustment modules can be interconnected through a two wire shielded data cable. Any series of interconnected modules can identify one of them as the leading boiler or boiler 1. The confirmation of the "leading" boiler can be achieved through one of the following two methods:

1. Connect the power supply voltage to terminal 88

2. Appointed through DTI remote monitoring.

Once the leading boiler is selected, the system will operate in the following way:

After completing the user set scanning time, the leading boiler establishes its own combustion speed by querying the fuel valve position in the load index and its maximum heating capacity. The input of this information is usually done when the boiler/burner equipment is debugged. After establishing the percentage of combustion rate and maximum heating capacity, IBS will calculate the heat contribution of this boiler to the system. Then the IBS in the leading micro adjustment module is sequentially connected to each micro adjustment module in the sorting circuit, and information is collected from all micro adjustment modules. The leading micro adjustment module then calculates whether to restart another burner to meet the load requirements or to shut down a burner due to a decrease in load requirements.

There is a terminal connection on the fine-tuning section that can control a two-way valve. Usually, this two-way valve is installed on the common return manifold in the boiler return pipeline. This device ensures that the offline boiler does not supply reflux temperature water to the flow manifold, thereby affecting and reducing the flow temperature to the building.

example:

For example, four boilers are connected to each other in the above way, with a heating capacity of 586kw (2MBtu) per boiler. If each boiler burns 410kw (1.4MBtu) (70% of its maximum output), the leading boiler will guide boiler 4 to shut down, and then boilers 1, 2, and 3 can adjust their combustion speed to compensate for the heat that boiler 4 should have produced.

In the above two operating schemes, all four boiler units provide a total of 1640kW (5.6MBtu) of energy to the system. However, after IBS intervention, only three boilers were able to operate under load, which is a more fuel-efficient operating mode. If the building load continues to decrease, IBS will continue to shut down more boilers in the boiler group, as long as the remaining operating boilers in the system can meet the load requirements at that time.

When the system load increases, the opposite process can be used. For example, when two boilers are running at near load combustion, IBS will turn on the third boiler in the boiler arrangement to help produce the required heat.

1. Steam boiler sorting control

When IBS is used in steam boilers, the IBS operation in this situation is similar to the IBS operation of hot water boilers mentioned above, but there are also some additional features and functions, which are introduced as follows.

When heating a hot water boiler, there are only two control modes: on or off. When using IBS on steam boilers, there are three operating states that are controlled in sequence.

*The state is "online", at which point the boiler * operates under the control of the internal PID load controller of the micro adjustment module.

The second state is "standby", in which the boiler is operating at a lower set point. For example, if the set point of the online boiler is 7 Bar (100 PSI), the standby boiler control is at the set point of 5 Bar (72 PSI). This way, once the load increases, the standby boiler can quickly start providing steam. The lower set point is a user adjustable option. Its adjustment method is the same as adjusting the normal control pressure set point.

The third state is' offline '. At this point, the boiler is turned off and in a cold state. If the load on the boiler room increases, the boiler state will shift to standby condition.

In addition to the differences mentioned above, the ranking of steam boilers and hot water boilers is * *. IBS ensures that a minimal number of boilers should be in operation at any given time to meet the load requirements for the boiler room.

1. Remote Monitoring (DTI) (option)

Overview of the operation of the data transmission interface

Through our Data Transfer Interface (DTI), users can collect operational data from up to 10 micro adjustment modules and then transmit it to a local PC or Building Management System (BMS) via RS232. This device can also be operated remotely. This cost efficient system can greatly meet the requirements of today's EMS and BMS systems in providing all necessary boiler operation data and alarm status, thereby achieving energy-saving operation.

Up to 10 micro adjustment modules are connected to a DTI device in a circular connection. The information collected by DTI from each MM device can then be transmitted to EMS or BMS.

Through DTI, remote control of burner on/off, adjustment of temperature/pressure set points, and selection of IBS boilers can be achieved. In order to accommodate and collect status information of other equipment related to the boiler, DTI can process up to 160 direct power voltage inputs, 80 no voltage outputs, 60 4-20mA inputs, and 60 4-20mA outputs.

Possible input/output values

Data available from various micro adjustment modules:

• Required boiler temperature or pressure

• Actual boiler temperature or pressure

• Burner on/off

• The burner has the highest combustion speed

• MM ID Number

• Selected fuel

• error state

• Automatic/Manual/Low Flame Keep Running

• All fine-tuning signal channels

• Operating hours and start-up for various fuels

• Real time and total values of fuel flow measurement

• Locked/Error Status

• Online combustion air pressure

• Online fuel pressure

• data recording–Online status, actual values, and combustion speed

• Lead boiler status

• Combustion status of burner

• Choose to execute intelligent boiler sorting

• Status of intelligent boiler sorting

• Activated/Closed Status

Available EGA data

• Choose to execute EGA

• Current values of O2, CO2, CO, NO, SO2, and NO2

• Exhaust gas temperature

• ΔTnumerical value

• Combustion efficiency value

• O2, CO2, CO, NO, SO2, Debugging values with NO2

• ΔTDebugging values

• Combustion efficiency debugging values

• EGA status

DTI control input value

• Change the required set points–Global or individual changes

• Select the leading boiler

• Change the order of sorting–Change sorting order

• Boiler on/off

• Change load index/combustion rate

Water level data

• Water level status

• Steam temperature, inlet water temperature, pump status, and valve position

• Instant and total values of steam flow measurement

• Water level alarm status

• 15 First Outannunciationstatus