Commissioning & Operation Maintenance Guide

1 of 761
PRINCESS NOURA BINT ABDULRAHMAN UNIVERSITY FOR WOMEN

Riyadh, Saudi Arabia
Testing-Comissioning & Operation-Maintenance

Manuals
BOILER MANUFACTURER
HURST Boiler & Welding Co., Inc.
Coolidge, GA. USA
www.hurstboiler.com
CONSULTANT
Dar Al-Handasah
www.dargroup.com
MAIN CONTRACTOR
El Seif Engineering & Contracting Co. Ltd.
www.el-seif.com.sa
Prepared By
(MANUFACTURER’S REP)
Asabbagh Est. for Electro Mechanical Works/MOREX Inc.
www.morexinc.com
6/01/2010
Page 1 of 761
2 of 761
TABLE OF CONTENTS
PAGE
NO.
I. TABLE OF CONTENTS 2
II BOILER WIRING DIAGRAM 4
III OPERATION & MAINTENANCE MANUALS
3.1 Hurst Boiler & Welding Co. 5

Boilers
Start-Up, Operation & Maintenance - Gas or Oiled Fired Packaged Boilers 6
Manufacturer's Test Data Report, Form P-2 as per ASME Code Section I 39
3.2 McDonnell & Miller 41

Boiler Controls
Low Water Cut-Off Control Unit w/ Manual Reset (LWCO-1) (McDonnell & Miller Model 750-MT-120) 42
Remote Sensor (McDonnell & Miller Model RS-1-BR-1)
Sensor Probe Rod (McDonnell & Miller Model P-SS) 54
3.3 Kunkle 60
Boiler Safety Valves (Series 927)
Safety Relief Valves (2 nos.) (Kunkle Model 927BJH, 2"x3", Part# 927BJHM06ABE0200) 61
Safety Relief Valve (1 no.) (Kunkle Model 927BHG 1.5"x2.5", Part# 927BHGM06ABE0200)
3.4 ST Johnson 86
Burners, Local Control Panels
Dual Fuel Burner (ST Johnson 30 ppm Low NOx Burner w/ FGR, Forced Draft Type FD68-LN, Burner Size 1000, Model 87
FD68CA1000LM-LN, Catalog# FD68-LN-3 Rev 6/09)
3.5 Tuthill Pump Group 156

Fuel Oil Pumps
Oil Pump (Tuthill Lubrication Type w/ Viton Seal Model 5LE) 157
3.6 Atlas Copco 181

Air Compressors
Air Compressor (Atlas Copco General and Technical Data, integral 7.5 hp motor, 380/3/60, TEFC, Class F Insulation, Design B, DOL 182
Start, Base Version Model LE7)
3.7 Cashco Co. 256

Oil pressure relief valves
Air Pressure Regulator - Option (Cashco Model CA-2, 1/2" NPT, Product Code A2J-3S27-1L) 257
3.8 Maxitrol Co. 273

Gas Pressure Regulators
Pressure Regulator (Maxitrol Gas Pressure Regulator, 3/8" NPT, Model 325-3) 274
3.9 Siemens 280

Actuators
3 of 761
TABLE OF CONTENTS
PAGE
NO.
Blocking Gas Valve Actuator (Siemens Gas Valve Actuator, SPDT, 110-120 VAC, Product# SKP15.011U1) 281
Main Gas Valve Actuator w/ Governor (Siemens Gas Valve Actuator, 110-120 VAC, Product# SKP25.013U1 w/ AGA22) 286
Temperature Control - Modulating (Siemens Model RWF40.000497 or approved equal ) 294
Temperature Sensor c/w Immersion Well (Siemens Immersion Type Sensor Part# QAE20 or approved equal ) 296
3.10 Mercoid 298

Temperature Controls
Operating, High Limit & Low Fire Hold (Mercoid Model DA-7035-153-5N) 299
3.11 Autoflame 303

Combustion Management System
Overview and Introduction to the Features and Benefits of the M.M./E.G.A. System. 304
Micro Modulation Fuel Air Ratio Control, Control Box Functions & P.I.D. Load Controller. 326
Exhaust Gas Analysis Trim System CO2 + CO + O2 + Flue Temp. + Eff. Monitoring NO & SO2. 484
Intelligent Boiler Sequencing, Lead Lag Selection. 544
Data Transfer Interface Remote Control, Monitoring and Data Acquisition from Total System. 556
Application Possibilities for the M.M. E.G.A. System. 664
Ancillary & Peripheral Equipment for the M.M. E.G.A. System, Oil & Gas Valves, Positioning Motors, Load Detectors. 682
Miscellaneous Component Information: Parts List. 724
Appendix: Approvals, Compatibility, Warranty, Terms and Conditions etc. 740
4 of 761
5 of 761
3.1 HURST Boiler & Welding Co.

21971 Highway 319 Coolidge GA 31738 USA
www.hurstboiler.com
6 of 761
Operation & Maintenance Manual

Hurst Boiler & Welding Company, Inc.
Packaged Boilers

P.O. Drawer 530 - Highway 319 North - Coolidge, Georgia 31738
Toll Free: 877-99HURST – Local: 229-346-3545 – Fax: 229-346-3874
www.HurstBoiler.com
7 of 761

P.O. Drawer 530 - Highway 319 North
Coolidge, Georgia 31738
877-99HURST – Toll Free

229-346-3545 – Local
229-346-3874 – Fax
www.hurstboiler.com
START UP, OPERATION & MAINTENANCE

GAS OR OIL FIRED PACKAGED BOILER
This manual contains important information regarding the operation of and the maintenance
required on your HURST boiler. Failure to read and follow the instructions contained herein
can lead to damaged equipment, or injury to those personnel involved with the daily operation.
WARRANTY ISSUES
HURST will gladly assist you in the return of items for warranty consideration. Our policy for
handling such returns is stated below:
The first step for returning items for warranty is to call 229-346-3545 ext. 192 and request a
“Return Goods Authorization” (RGA) number. When making this call, you need to have the
following information available:
u Customer name
u Job location
u Job number
u Date equipment was installed
u Reason for return – specify the problem
u Where to ship replacement
u To whom billing is to be directed
All replacement items are shipped on a Net-10 day schedule. Payment is expected within
this period. Any warranty will be credited upon receipt of credit from the vendor for the
defective part.
All RGA shipments to HURST must have the RGA number on the outside of the shipping
container.
Any item not received at HURST within 21 days of the RGA request, will be deemed “not
returned” and no credit consideration will be made.
Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers
www.hurstboiler.com Page 1 of 31 - Rev 04//07
8 of 761
GENERAL FEATURES OF YOUR HURST BOILER
Your Hurst boiler has been designed, constructed and certified to meet the requirements of the
American Society of Mechanical Engineers (ASME) Code for boilers.
HURST maintains its own quality control personnel with all the necessary equipment and
instrumentation to verify constructions standards equal to or greater than those required by the
ASME.
All units are first inspected by HURST personnel and then by a “third party” inspector who is a
member of the National Board of Boiler and Pressure Vessel Inspectors to verify compliance
with all Code requirements. Then, he witnesses the hydrostatic pressure test performed on the
pressure vessel and authorizes the stamping of the proper ASME symbol on the vessel.
A manufacturer’s Data Report is then completed and the unit is registered with the National
Board. A copy of the Data Report is available from HURST or from the National Board.
After completion of the pressure vessel and the addition of certain other features of the unit, a
burner and associated fuel train are added to the package. The burner may have the UL or
cUL Label, and may have the Factory Mutual (FM), GE Gap (IRI) or other agency
identifications.
Many state and local authorities have laws/codes governing the installation or operation of
boilers and pressure vessels. You should verify with those local authorities regarding
compliance with their requirements.
9 of 761
BOILER IDENTIFICATION
PRESSURE VESSEL:
Each boiler is stamped with a Serial Number and a National Board Number. These numbers
can be found on the identification plate that is attached to the front door of the boiler and they
are stamped on the boiler shell near the front tubesheet on the right hand side of the boiler.
Besides simply identifying this unit, the Serial Number and National Board number identify the
characteristics of this boiler for Maximum Allowable Working Pressure (MAWP) and
temperature, if applicable and the Fireside Heating Surface available.
Both of these numbers are unique to this particular boiler, so when inquiring about your unit
regarding warranty, service or parts, having these numbers available for reference will speed
the service we can provide.
BURNER:
If supplied by HURST, the burner on your unit will also have a recorded Serial Number that is
unique to this unit. Should you need to make an inquiry regarding this burner for service or
parts, it is helpful to HURST for you to provide this serial number. Other burner plate
information will include maximum BTU throughput and the UL registration number for that
burner.
INSTALLATION
The installation of your boiler should have been planned long before you take delivery of the
unit. Drawings and specifications are often prepared by individuals familiar with steam or hot
water systems.
This document assumes that the installation has been planned out and documented. Here, we
only suggest some approaches to issues that might need a little additional detail.
General:
The boiler should be placed on a flat, level concrete slab or on housekeeping pads that run the
full length of the base rails.
If the boiler is not in a building, be sure that all the controls, the control panel and the burner –
at a minimum – are designed for outdoor operation.
If the unit is inside a building, the space allowed on either side, at the front and at the back of
the unit must be adequate to maintain the required maintenance and operation of the boiler.
Minimum dimensions for these clearances are set by UL and perhaps by other local codes. Be
sure to determine whether your unit meets these ordinances before you place the unit. Most
codes require a minimum of 7 feet clear of obstruction above the manway for access on high
pressure boilers and 5 feet clear on low pressure boilers. These obstructions include piping,
catwalks or building structure. Your local codes may be even more conservative.
10 of 761
Building openings:
We suggest one opening large enough for the boiler to pass. Additionally, one man door and
adequate openings for admission of combustion air (see Combustion Air Requirements in this
manual) are absolutely necessary. Other openings may be supplied as the owner sees fit. Be
sure to check with local authorities for building code requirements.
Lighting:
Adequate lighting is a must for proper operation and maintenance. Be sure to include enough
lighting in the boiler room so that the operator can read nameplates and instructions on the
equipment without the use of supplemental lighting.
Power:
The motor(s) and controllers that are part of your boiler system all depend on a constant
supply of electrical power. The interconnection of these devices is accomplished through the
pre-wired electrical control panel that has been furnished with your unit. Normally, the power
supply will only be required to be made to one point on the control panel. That power
requirement is specific to your unit and will be specified by HURST. It is the responsibility of
the customer to supply that power to the panel.
Steam boilers typically have a feedwater system supplied with electric motor driven pumps that
requires a separate power supply to the panel supplied with it.
Piping:
No piping should be at or near the floor level to cause tripping accidents. Floor drains and pipe
trenches are essential for maintaining an orderly, clean facility. Piping may be placed in drains
so you will not need separate trenches. These trenches should drain to a point outside the
boiler room or to a sump to be pumped out as required. All trenches should be covered with
adequate grating or floor plate.
Connections:
There are several connection points on the boiler that must be connected to other systems
within the scope of the installation. Some of these connections are common to both steam and
hot water systems. Others will be designated as “steam” or “hot water”.
1. Safety Valve: The safety valve(s) will be located on the top centerline of the boiler.
The outlet of the safety valve must be piped to a point of safe discharge, and it must
be the size of the valve outlet or larger. NEVER reduce the discharge line size.
2. Vent Stack: This is the large opening at the end of the boiler through which the
gases from the combustion process must be vented to some point outside of the
boiler room. When using factory manufactured stacks, we recommend the use of
stacks rated for pressurized systems. UL Listed double wall stack systems may be a
good choice. It must be gas-tight to eliminate the chances of leakage into the boiler
room. Check with local authorities for any requirement they may have for height
requirements above the roof.
11 of 761
3. Fuel: The fuel connection(s) will be for natural gas, manufactured gas, light oil or
“heavy” oil. The connection points are on the sides of the boiler or near the burner
(for oil). The gas piping must be approved by the local gas company and will be
inspected by their personnel. Oil piping must be appropriate for the application, and
insulated if firing oil that requires heating.
4. Supply: This is generally the largest opening on the boiler, and it will be on the top.
This is the opening through which steam or hot water is allowed to exit the boiler to
enter the external system. This must be piped as required by local jurisdictional
requirements and as good construction requirements demand. In multiple boiler
installations, some of this piping may need to be constructed and stamped according
to the ASME Code.
Connections that are specific to Steam Boilers:
1. Feedwater: This is the opening on the side of the boiler through which water enters
to re-supply water lost through evaporation. This must be connected from the
feedwater supply system. The design requirements for pressure in this line must be
greater than the MAWP of the boiler.
2. Bottom Blowdown: This opening or openings are in the lowest part of the boiler at
the bottom centerline. There will be one or more bottom blowdown openings. See
Blowoff-Blowdown in this manual.
3. Water Column Blowdown: This refers to the piping directly below the water
column/gauge glass. This is the valve through which the unwanted contaminants will
be expelled from the Low Water Cutoff/Pump Control device. See Blowoff-Blowdown
in this manual.
4. Surface Blowoff: This opening is generally on the top centerline of the boiler and is
the opening through which surface contaminants will be expelled. See Blowoff-
Blowdown in this manual.
Connections that are specific to Hot Water Boilers:
1. Return: This opening will be located on the top centerline of the boiler and will
generally be the same size as the Supply Nozzle. Water returns from the system
and re-enters the boiler at this point to be reheated.
2. Drain: The drain connection on a hot water boiler is similar to the bottom blowdown
opening on a steam boiler, and it will be located at the lowest part of the boiler at the
bottom centerline. This discharge should be piped to a point of safe release such as
a blowdown tank or pit.
3. Water column Blowdown: Some hot water boilers may have a blowdown connection
on the water column. This should be piped to a point of safe discharge.
12 of 761
COMBUSTION AIR
The burner on your boiler requires oxygen to support combustion of the fuel. This oxygen
supply comes from the air in the boiler room, so an adequate supply of “combustion air” is
essential for efficient operation of your boiler.
Allow 8 cubic ft per minute (cfm) of air for each rated boiler horsepower up to 1000 ft elevation,
and it is suggested to limit the velocity of the air movement in the boiler room to 250 ft per min
(fpm). Above 1000 ft elevation, add 3% additional volume for each additional 1000 ft.
Two (2) air supply openings should be supplied in the outer walls of the boiler room, preferable
on opposite ends or sides of the boiler. Fans are not required nor recommended, but simple
louvered openings are suggested. These openings may be covered with wire mesh, but the
mesh should have at least ½” openings.
Example:
250HP
Requires 250 x 8 = 2000 cfm
Then 2000 cfm/250fpm = 8 sq ft opening.
So, 2 openings of 4 sq ft each in opposite walls are required.
Even for the smallest boiler, the air supply opening should be at least 1 sq ft.
CLEANING – BOIL OUT
After the installation of your boiler has been completed, and before any operation is begun it is
highly advisable to clean the water side surfaces of the boiler and the piping system to which
the boiler is connected.
The piping system may contain oil, grease, welding slag, thread cuttings and other
contaminates that should not be left in the system piping. If left in the piping, it is only a matter
of time before it will find its way to the boiler. Slag and thread cuttings can block or damage
gaskets, valves and control devices.
A new boiler is likely to have oil, grease, or other protective coatings that were on the metal
parts during the manufacturing process. These contaminants must be removed prior to
beginning operation since any one of them may cause priming, foaming, inefficient heat
transfer or contamination of the process to which the steam is directed.
Most boiler chemical suppliers can supply the chemicals and the expertise to affect an
appropriate method for cleaning your boiler.
However, in the absence of such consultation, suggested procedures are outlined below.
13 of 761
Before beginning any internal cleaning procedure, you must determine the experience level of
anyone who will be assisting in the cleaning procedure and make suitable safety garments
available to each of them. It is preferable that all personnel be familiar with the procedure and
what the results could be if they are not careful with handling the chemicals involved.
As a minimum, the safety equipment should include face mask, goggles, rubber gloves, and
apron. Severe burns can result from improper handling of caustic chemicals.
PROCEDURE: Please read the entire procedure before beginning any part of the procedure.
Steam boilers:
1. Close all external valves, such as feedwater, steam supply, chemical feed, and
blowdown to avoid loss of chemical and to isolate the boiler internal parts.
2. Remove the safety valves.
3. Remove the manway cover, if so supplied and if it is in the uppermost part of the shell.
4. Fill boiler with fresh water to a level 2-3 inches above the top of the top row of tubes.
Just basic tap water is acceptable for this filling.
5. Determine how many gallons of water the boiler will contain when complete ly filled.
6. Mix Tri-sodium phosphate and caustic soda (Sodium Hydroxide) in the amount of one (1)
pound of each for each 100 gallons of water content in the boiler. Add the chemicals
slowly into a bucket or barrel with water as necessary to dissolve them. Stir constantly to
be sure that the chemicals are thoroughly dissolved.
7. Add the dissolved chemicals carefully through the largest opening available in the top of
the boiler.
8. Complete filling of the boiler to the top.
9. Begin firing the boiler at the lowest rate possible and intermittently, as necessary to get
the water temperature just above 200 degrees F. During this early firing, the water
volume will swell and tend to overflow the openings in the top, so operate the bottom
blowdown as necessary to maintain flooded condition in the vessel while minimizing
overflow.
10. Continue this low heat input for a minimum of 4 hours, and shut the burner off.
11. Allow boiler water to cool to a temperature of 120 degrees F or less, and drain to a point
of safe discharge.
12. Remove all handhole plates or other inspection openings and wash the interior
thoroughly with high pressure water. On large boilers, a fire hose is recommended.
13. If interior surfaces are not clean, you may repeat the above procedure.
14. If you determine the water side to be adequately clean, proceed to replace the safety
valves, re-close the handhole and manhole plates with new gaskets, and refill the boiler
with treated water from your feedwater system. (Additional information about treatment
of boiler water is in another section of this manual)
15. When filled to the normal level, the boiler should be checked for leaks and may be fired
normally. Allow the trapped air to escape the boiler during this initial filling.
14 of 761
Hot Water boilers:
1. Close all external valves, such as feedwater, Supply, Return, and drains to avoid loss of
chemicals and to isolate the boiler internal parts.
2. Remove the safety valves
3. Remove the manway cover, if so supplied and if it is in the uppermost part of the shell
4. Fill the boiler with fresh water to a level 2-3 inches above the top of the top row of tubes.
Just basic tap water is acceptable for this filling.
5. Determine how many gallons of water the boiler will contain when completely filled.
6. Mix Tri-sodium phosphate and caustic soda (Sodium Hydroxide) in the amount of one
(1) pound of each for each 100 gallons of water content in the boiler. Add the chemicals
slowly into a bucket or barrel with water as required to dissolve them. Stir constantly to
be sure that the chemicals are thoroughly dissolved.
7. Add the dissolved chemicals carefully through the largest opening available in the top of
the boiler.
8. Complete filling of the boiler to the top.
9. Begin firing the boiler at the lowest rate possible and intermittently, as necessary to get
the water temperature just above 200 degrees F. During this early firing, the water
volume will swell and tend to overflow the openings in the top, so operate the bottom
drain as necessary to maintain flooded condition in the vessel while minimizing
overflow.
10. Continue this low heat input for a minimum of 4 hours, and shut the burner off.
11. Allow boiler water to cool to a temperature of 120 degrees F or less, and drain to a point
of safe discharge.
12. If interior surfaces are not clean, you may repeat the above procedure.
13. If you determine the water side to be adequately clean, proceed to replace the safety
valves, re-close the handhole and manhole plates with new gaskets, and refill the boiler.
(Additional information about treatment of boiler water is in another section of this
manual)
14. When filled to the normal level, the system should be checked for leaks and the boiler
may be fired normally. Allow the trapped air to escape the system during this initial
filling.
15 of 761
PRE START-UP – STEAM

HURST assumes that everyone involved with the start-up or operation of this boiler has some
training or experience with similar equipment. If not, he/she should not be allowed to be
directly involved with the operation or maintenance of the unit. Training is available and should
be pursued.
Satisfactory operation of your boiler system depends on attention to details. The following
steps should be attended to at initial startup and after any period of shutdown.
1. Check the Feedwater tank (deaerator) to verify that water level is correct and that
feed valve that supplies water to the tank is open.
2. Pump suction valves are open
3. Power is available to the pump(s)
4. Main steam supply valve(s) is open
5. Safety valve(s) is correct for this boiler design for pressure and capacity
6. Boiler water is at correct level and Feedwater valve(s) is open
7. Verify low water cutoff operation by opening water column blowdown valve until
alarm sounds and feed pump starts
8. Verify that Auxiliary Low Water Cutoff is operational. (You may close feed valve
and open bottom blowdown for this check. Be sure to re-open feed valve after
you close blowdown valve.) Pump should start and bring water level in the boiler
back to normal operating level
9. Verify water treatment system(s) is operational and valves are open
10. All control cabinets should be clean –inside and out – with completely functional
doors that are closed
11. Equipment guards should be in place
12. Fuel valves should not be open at this time
PRE START-UP – HOT WATER

directly involved with the operation or maintenance of the unit. Training is available and should
be pursued.
Satisfactory operation of yo ur boiler system depends on attention to details. The following

steps should be attended to at initial startup and after any period of shutdown.
1. Check that feed valve that supplies water to the system is open
2. Supply and return valves are open
3. Safety valve (s) is correct for this boiler design for pressure and capacity
4. System water is at correct level
5. Verify low water cutoff operation
6. Verify chemical treatment has been performed and is satisfactory
7. All control cabinets should be clean – inside and out – with completely functional
doors that are closed
8. Equipment guards should be in place
9. Fuel valves should not be open at this time
16 of 761
STARTING FROM COLD
directly involved with the operation or maintenance of this unit. Training is available and should
be pursued.
Be sure to read PRE START-UP in this manual before attempting any start up.
When all points in the PRE START-UP have been completed, you may proceed to start the
unit.
Open the vent on top of the boiler to allow trapped air to escape as pressure is building in the
boiler. This may be accomplished by opening the vent valve – if supplied – or by removing the
plug from the top of the water column balancing line.
See the manufacturer’s manual for the particular burner on your boiler for instructions
regarding initial firing.
Set the firing rate controller to the lowest firing rate possible. This will allow the burner to begin
heating the water at a rate that will minimize stresses to the metal parts. It will also allow the
lower, colder, zones to warm at a rate more consistent with that of the higher, hotter, zones.
The firing rate should not be increased until after steam pressure is evident on the steam
pressure gauge.
Remember, there is some refractory in your boiler that has not been completely cured.
Therefore, the initial firing should be at a very low rate for a minimum of 2-3 hours to
completely drive out any free moisture that remains in the refractory.
When steam is detected at the vent valve, close the air vent.
Maintain this low fire rate as steam pressure begins to build after which the firing rate can be
increased and fuel/air ratios can be adjusted for optimum combustion at various rates per the
manufacturer’s instructions.
Subsequent firing, from cold, may require a cursory re-reading of the manufacturer’s
instructions. Unless changes have been made to linkages, valves, or other components,
further starts, after shutdowns should only require assuring yourself of the points found in PRE
START-UP.
Verifying combustion conditions should be made at time of start up and periodically thereafter
using a combustion gas analyzer. No other special tools are required.
17 of 761
FUEL INPUT
To know the rate of fuel consumption in your boiler is important for maintaining cost records
and to know when you are under firing or over firing your unit.
OIL FIRING:
To determine oil cons umption rate, you need to place an oil meter in your fuel train and simply
record meter readings at specific times. By doing this, you can calculate the oil consumed
within that period of time.
Example: Assume you are firing No. 2 oil (140,000 Btu per gallon)
8:00 AM meter reading = 1020 gallons

9:00 AM meter reading = 1048 gallons
Difference= 28 gallons
Time = 1 hour,
So, 28 gallons in 1 hour = 28 x 140,000 = 3,920,000 Btuh (input)
At 85% efficiency, = 3,920,000 x .85 = 3,332,000 Btuh (output)
1 Boiler HP = 33,475 Btuh (output), So, 3,332,000/33475 = 99.5 HP
If you are firing a 100 HP boiler, your firing rate is almost perfect.
GAS FIRING:
To determine gas consumption you must have access to a gas meter – which your gas
supplier probably has already installed in your gas line.
If the boiler is not the only load on the meter, you may have to further isolate that supply or
stop operating the other equipment while measuring boiler input.
You need to verify the gas pressure and temperature at the meter and determine the inlet gas
pressure and temperature that was used to calibrate the meter. Your gas supplier should be
able to help you with all of this information.
You will need pressure and temperature correction factors as shown on the following chart
bases on the values determined above.
Example:
8:00 AM meter reading = 5000

9:30 AM meter reading = 5040
Difference = 40
Time = 1.5 hour (90 minutes)
18 of 761
Assuming a value of 1000 Btu per cu ft of natural gas (typical). Your gas supplier can be more
specific about your particular gas.
Assuming a pressure correction factor or 1.324,

Assuming a temperature correction factor of 1.020,
Using 3600 as the number of seconds in one hour,
Multiply 40 x 3600 x 1.324 x 1.020 = 194,469

Then divide by 90 = 2160.8 CFH
2160.8 x 1000 = 2,160,800 Btu (input)
At 82% efficiency = 2,160,800 x .82 = 1,771,856 (output)
1 Boiler Horsepower = 33,475 Btuh (output)
So, 1,771,856 / (33475 x 1.5) = 35.3 HP
If you are firing a 35 HP boiler, you are firing it about 1% over rating.
19 of 761
GAS PRESSURE CORRECTION FACTORS
PSIG Meter Base Pressure

at 4 oz. 8 oz. 10 oz. 1 Lb. 2 Lbs.
Meter (7 iwc) (14 iwc) (17.5 iwc) (28.0 iwc) (56.0 iwc)
0 0.983 0.966 0.958 0.935 0.878
1/4 1.000 0.983 0.975 0.951 0.893
1/2 1.017 1.000 0.992 0.968 0.909
5/8 1.026 1.008 1.000 0.976 0.916
1 1.051 1.034 1.025 1.000 0.939
2 1.119 1.101 1.092 1.065 1.000
3 1.188 1.168 1.158 1.130 1.061
4 1.256 1.235 1.225 1.195 1.122
5 1.324 1.302 1.291 1.260 1.183
6 1.392 1.369 1.358 1.325 1.244
7 1.461 1.436 1.424 1.390 1.305
8 1.529 1.503 1.491 1.455 1.366
9 1.597 1.570 1.557 1.520 1.427
10 1.666 1.638 1.624 1.584 1.488
12 1.802 1.772 1.757 1.714 1.610
14 1.939 1.906 1.890 1.844 1.732
16 2.075 2.040 2.023 1.974 1.854
18 2.212 2.174 2.156 2.104 1.976
20 2.348 2.309 2.290 2.234 2.098
22 2.485 2.443 2.423 2.364 2.220
24 2.621 2.577 2.556 2.494 2.341
26 2.758 2.711 2.689 2.623 2.463
28 2.894 2.846 2.822 2.753 2.585
30 3.031 2.980 2.955 2.883 2.707
35 3.372 3.315 3.288 3.208 3.012
40 3.713 3.651 3.621 3.532 3.317
45 4.055 3.987 3.953 3.857 3.622
50 4.396 4.322 4.286 4.182 3.927
60 5.078 4.993 4.952 4.831 4.537
70 5.761 5.664 5.617 5.481 5.146
80 6.444 6.336 6.283 6.130 5.756
90 7.126 7.007 6.948 6.779 6.366
100 7.809 7.678 7.614 7.439 6.976
110 8.491 8.349 8.280 8.078 7.585
120 9.174 9.020 8.945 8.727 8.195
130 9.857 9.691 9.611 9.377 8.805
140 10.540 10.360 10.280 10.030 9.415
150 11.220 11.030 10.940 10.680 10.020
160 11.900 11.70 11.610 11.320 10.630
170 12.590 12.380 12.270 11.970 11.240
180 13.270 13.050 12.940 12.620 11.850
190 13.950 13.720 13.600 13.270 12.460
200 14.630 14.390 14.270 13.920 13.070
20 of 761
GAS TEMPERATURE CORRECTION FACTORS
Gas Meter Calibration Temperature

Temp
°F 60° F 65° F 68° F 70° F 72° F
0 1.130 1.141 1.148 1.152 1.157
5 1.118 1.129 1.135 1.140 1.144
10 1.106 1.117 1.123 1.128 1.132
15 1.095 1.105 1.112 1.116 1.120
20 1.083 1.094 1.100 1.104 1.108
25 1.072 1.082 1.089 1.093 1.097
30 1.061 1.071 1.078 1.082 1.086
35 1.051 1.061 1.067 1.071 1.075
40 1.040 1.050 1.056 1.060 1.064
45 1.030 1.040 1.046 1.050 1.053
50 1.020 1.029 1.035 1.039 1.043
55 1.010 1.019 1.025 1.029 1.033
60 1.000 1.010 1.015 1.019 1.023
65 0.990 1.000 1.006 1.010 1.013
70 0.981 0.991 0.996 1.000 1.004
75 0.972 0.981 0.987 0.991 0.994
80 0.963 0.972 0.978 0.981 0.985
85 0.954 0.963 0.969 0.972 0.976
90 0.945 0.955 0.960 0.964 0.967
95 0.937 0.946 0.951 0.955 0.959
100 0.929 0.938 0.943 0.946 0.950
105 0.920 0.929 0.935 0.938 0.942
110 0.912 0.921 0.926 0.930 0.933
115 0.904 0.913 0.918 0.922 0.925
120 0.897 0.905 0.910 0.914 0.917
ATMOSPHERIC PRESSURE 14.4 PSI

BAROMETER 29.31 INCHES
21 of 761
OPERATION – STEAM (Gas or Oil fired)
The design of your HURST boiler is such that in general operation, the starting, ramping up,
slowing, and stopping is all controlled automatically. (See START UP in this manual).
Some of the devices you may find on your unit are the Burner, Firing Rate Controls, Feedwater
Controls, Low Water Cutoff, A uxiliary Low Water Cutoff, and High Level Alarm.
As with any automatically controlled device, the key to continued successful operation is to
maintain the correct operating characteristics of the devices that are doing the controlling.
LWCO
This is especially true with a float-type low water cutoff (LWCO). This device will protect your
boiler from firing when the water level is too low, but there are several things that can go awry
and cause this device to fail.
The first, is allowing the interconnecting piping from the boiler to the device to become plugged
with sludge. “Sludge” is an all-encompassing term for material that has settled out of the water
and blocked normally open paths where water or steam should pass. This sludge may also
enter the float chamber of the LWCO and block the float from properly responding to changing
water levels in the boiler.
DAILY attention to controlling this sludge buildup by blowing down and physical inspection is a
must.
Modifying the electrical or mechanical characteristics of the LWCO in any way may cause it to
incorrectly sense boiler water level. If there is any question as to the proper operation of the
LWCO, you should shut the boiler down and correct the malfunction.
ALWCO
The Auxiliary Low Water Cutoff (ALWCO), if fitted, is a back-up device in the event of failure of
the LWCO. However, it is never a good idea to simply begin to rely on the ALWCO if you know
something is wrong with the LWCO. A failure of the ALWCO could also occur leaving you with
no safety device to shut the burner off in the event of low water. The ALWCO may be a float-
type device or it may be a probe-type control.
FIRING RATE CONTROLLER:
The unit firing rate is controlled by pressure (temperature) sensitive devices that have limits
within which they cause the burner to respond. The limits of this control must always be within
the range of the safety valve(s) setting.
Example: 150 psi designed boiler, 150 psi safety valve setting, and Operating Control range
not higher than 135 psi (about 90% of safety valve setting with a High Limit control set at 138-
140 psi. The High Limit Control is another backup device that only functions if the Operating
Control fails.
22 of 761
The Operating Control starts and stops the burner in response to pressure in the vessel.
If fitted, the Modulating Control varies the firing rate of the burner within the range of the start-
stop action of the Operating Control. The full modulating range must be lower than the upper
limit of the operating control.
The High Limit Control is a backup to the Operating Control, so that in the event pressure in
the boiler continues to go higher than the Operating Control set point, the High Limit control will
shut down the burner. This control generally requires operator involvement for manual re-set
before the unit will recycle.
BURNER:
The burner on your unit is a “forced draft” design meaning that the combustion air fan provides
oxygen to the combustion process in a pressurized fashion and pushes the products of
combustion through the boiler and out the exhaust stack.
All modern forced draft burners are supplied with an automatic ignition device and a flame
safeguard control. These devices sequence the burning of the fuel in a proper, systematic
fashion. No effort should ever be made to bypass any of these devices.
FEEDWATER CONTROL:
As steam is allowed to escape the boiler, water must be forced into the unit to maintain the
Normal Operating Water Level. This make-up water is normally supplied from a pump that is
dedicated to this one unit.
The starting and stopping of the feedwater pump (on smaller units) is typically controlled by the
same device that acts as the LWCO. When the water level drops to a point just above the
LWCO point, it starts the pump and allows it to run and pump water through the feedwater line
until the upper level limit is satisfied. Then, the pump is allowed to stop until the next cycle is
required.
On larger units, the water is normally fed continuously to the boiler through a Modulating
Feedwater Valve allowing only the amount of water to pass as is necessary to maintain the
Normal Operating Water Level in the boiler. This means that the feedwater pump runs
continuously. The Modulating Feedwater Valve may be pneumatic or electric and it monitors
the water level in the boiler to control the rate of water allowed into the unit.
HIGH WATER ALARM:

On some units there may also be a High Water Level Alarm. Normally, this control does not
shut anything down, but sounds an audible alarm to alert the operator that a higher than
normal water level exists in the boiler. High water level can lead to wet steam and may cause
problems in the system by the introduction of water into the steam lines.
We urge the use of Operational Logs to maintain optimum operational efficiency of your boiler
system. Maintaining regular, systematic recordings of operational data such as steam
pressure, stack temperature, Feedwater temperature, fuel meter readings, boiler water
23 of 761
chemical levels, and any other data – even the outdoor temperature – can be very helpful in
analyzing problems that may arise. Some owners/operators prefer hourly recordings, while
others may feel daily recordings to be appropriate for their operation.
Remember that during periods of cold weather, the piping that supplies fresh water to the
system must be protected from freezing.
24 of 761
OPERATION – HOT WATER (Gas or Oil fired)
The design of your HURST boiler is such that in general operation, the starting, ramping up,
slowing, and stopping is all controlled automatically. (See START UP in this manual).
Some of the devices you may find on your unit are the Burner, Firing Rate Controls, Feedwater
Controls, Low Water Cutoff, and High Temperature Cutoff.
As with any automatically controlled device, the key to continued successful operation is to
maintain the correct operating characteristics of the devices that are doing the controlling.
LWCO
This is especially true with a float-type low water cutoff (LWCO). This device will protect your
boiler from firing when the water level is too low.
DAILY operational check of this device is a must
Modifying the electrical or mechanical characteristics of the LWCO in any way may cause it to
incorrectly sense boiler water level. If there is any question as to the proper operation of the
LWCO, you should shut the boiler down and correct the malfunction.
FIRING RATE CONTROLLER

The unit firing rate is controlled by temperature sensitive devices that have limits within which
they cause the burner to respond.
Example: Operating to maintain 180 degree F bulk water temperature within the boiler.
(Temperature range must not exceed 250 degrees F). Operating control will be set at 180 so
that any time the bulk temperature drops below 180, the burner will fire to bring the
temperature back up to 180 at which time the burner will shut down.
If fitted, the Modulating Control varies the firing rate of the burner within the range of the start-
stop action of the Operating Control. The full modulating range must be lower than the upper
limit of the operating control.
HIGH TEMPERATURE CUTOFF:

The High Temperature Cutoff is a backup to the Operating Control. In the event temperature in
the boiler continues to go to a higher temperature than the Operating Control range, the High
Temperature Cutoff will shut down the burner. This control generally requires operator
involvement for manual re-set before the unit will recycle.
BURNER:
The burner on your unit is a “forced draft” design meaning that the combustion air fan provides
oxygen to the combustion process in a pressurized fashion and pushes the products of
combustion trough the boiler and out the exhaust stack.
25 of 761
All modern forced draft burners are supplied with an automatic ignition device and a flame
safeguard control. These devices sequence the burning of the fuel in a proper, systematic
fashion. No effort should ever be made to bypass any of these devices.
FEEDWATER CONTROL:
As water is allowed to escape the boiler, water must be forced into the unit to maintain the
Normal Operating Water Level. This make-up water may be introduced at the boiler or in an
expansion tank and may be available from a pumping system or other system that delivers at a
pressure adequate to overcome system pressure.
We urge the use of Operational Logs to maintain optimum operational efficiency of your boiler
system. Maintaining regular, systematic recordings of operational data such as supply
temperature, return temperature, stack temperature, fuel meter readings, water makeup meter
readings, chemical additions and any other data – even the outdoor temperature – can be very
helpful in analyzing problems that may arise. Some owners/operators prefer hourly recordings,
while others may feel daily recordings to be appropriate for their operation.
BLOWOFF-BLOWDOWN
Steam:
Part of a water maintenance program will include “blowing off” or “blowing down”.
Because of the nature of introducing hot water under pressure to a point outside the boiler, it is
advisable to utilize a blowdown vessel or pit to minimize the obvious hazards.
Blowoff/Blowdown is required on all steam boilers and will help maintain the quality of boiler
water that is required for proper steam purity, control of dissolved or suspended solids that are
in the boiler water that can lead to encrustation on the heated parts of the boiler. No water
treatment program can completely eliminate all undesirable substances from your boiler water.
The most efficient method for removal of sludge that may accumulate in the bottom of your
boiler along with some dissolved solids suspended in the boiler water is through Bottom
Blowdown.
This is an intermittent, manual opening of the water space to the outside. This exercise will
generally be performed once every 8 hours of operation, but the final schedule should be
determined by your water quality consultant.
Functionally, the typical unit will have one or more “slow-opening” globe valves and one “quick
opening” valve mounted to piping that is connected at one or more points along the belly of the
boiler.
The operation is such that the “quick opening” valve is opened first, followed by opening of the
globe valve(s). As soon as the globe valve is fully open, begin immediately to close it. When it
is closed, close the “quick opening” valve. This process should probably lower the level in the
gage-glass approximately one-half inch.
26 of 761
Surface Blowoff is a common method for removing oil and other impurities that accumulate at
the surface of the water in the boiler.
Functionally, this method utilizes a collection pipe or pipes that are mounted just below the
normal water level in the boiler. This piping culminates just outside the boiler with a control
valve that controls the rate at which water is allowed to flow depending on the analysis of the
collected water. This analysis may be intermittent with manual valve adjustments or it may be
automatic with instrumentation that will adjust the valve accordingly.
The ultimate discharge of this water must also be directed properly to avoid contact with
property or personnel.
Water Column Blowdown is another procedure for controlling or eliminating sediment from
the low water cutoff device and the associated piping. This procedure should be executed at
least one time every 12 hours of operation. The operation of the pump control and the low
water cutoff should be verified each time this blowdown is executed. The importance of this
procedure must never be underestimated and is probably the most important function you can
perform to help eliminate low-water failures in your boiler.
Hot Water:
Normally, no blowdown is required on a water boiler because there is little make-up of water in
a closed system. However, water quality should be checked periodically to determine need for
adjustment to your water quality program.
27 of 761
SHUT DOWN
Steam Boilers:
Short term:
If you intend to shut your boiler down for a period not to exceed 3 days, (72 hours), you may
simply turn off the power, close the valves and leave the water at the normal operating level
without further preparation.
Long term:
If you intend to shut your boiler down for a period exceeding 3 days – up to 14 days, you
should turn off the power, fill the boiler completely with water, close all the valves, and take no
further steps of preparation.
However, in both cases sited above, if there are other boilers connected in the system with this
unit, precautions must be taken to ascertain that no bleed-over is taking place that would
pressurize the idled boiler either through the introduction of feedwater or steam.
Extended period:
For periods of shutdown beyond 14 days, you must consider either a “wet layup” or a “dry
layup”.
Wet layup means to fill the boiler completely with treated water, close all valves on the boiler,
and to carefully monitor the quality of the water at least weekly during the layup period. You
must also verify weekly that leakage or other influences have not lowered the water level in the
boiler. If it is not full, you must add water to maintain a condition of full.
The success of this storage method depends largely upon eliminating any air coming in
contact with any of the water side of the unit while maintaining good boiler-quality water inside.
Dry layup means to drain all the water from the boiler, wash and flush as necessary to
remover all sludge from the water side, and use whatever method is available to
COMPLETELY dry the water side of the unit.
Then, when the unit is completely dry inside, place moisture absorbing material inside on pans,
if possible, and seal the water side as tightly as possible from the outside environment. The
absorbing materials must be checked weekly and replaced when they become damp.
The success of this storage method depends largely upon eliminating any moist air from
coming in contact with any metal surface inside the boiler for the entire period of lay up.
If you are in an area subject to freezing temperatures, be sure to disconnect and drain all
connecting lines.
28 of 761
For this extended period of shutdown, it is recommended that all gas-side surfaces be brushed
to remove all soot or other foreign deposits which could lead to corrosion of the metal parts
during the time of shutdown.
Hot Water Boilers:
Wet and Dry Layup procedures are the same for hot water systems (as steam systems) that
are to shut down for extended periods of time.
Danger of freezing with wet layup is of particular concern in a water system because of the
volume of water involved and the piping system that may extend to no -heated areas of the
facilities.
MAINTENANCE
The importance of maintenance cannot be overemphasized when discussing boiler operations.
The cleanliness of the entire boiler room will impact how long some of the controls will continue
to function and how accurate that functionality will be.
DAILY:
u Sweep or wash down the floor

u Wipe up oil spills
u Clean the dust from top of control panels and other flat surfaces
u Blow down water column every 12 hours to prove functionality (steam)
u Blow down bottom blow ever 8 hours (steam)
u Record stack temperature. This is helpful in determining the need for cleaning the
fireside of the boiler.
u Note feedwater temperature (and tank pressure, if system is pressurized) (steam)
u Note by visual inspection that the water level in the boiler is at the normal operating
level. (steam)
u Note steam (or water) pressure gauge reading
u Perform water quality analysis and record results
u Check for leaks at all piping connections and inspection opening on the boiler. Reduce
boiler pressure to below 15psi before attempting any tightening of handholes,
gage glass fittings or the like. Replace gaskets as soon as practicable.
u Check softener tanks and re-supply, if applicable
u Always be sensitive to tube leaks. Water dripping to the floor at the front or rear of the
boiler especially when the unit is shut down, or when steam vapor in the stack, this
should be investigated immediately. Do not attempt to expand tubes while the boiler
is under pressure.
29 of 761
WEEKLY:
u Verify the operation of the steam pressure controls (steam)

u Perform water quality analysis and adjust surface blowoff rate, if applicable (steam)
u Check softener supplies and re-order as needed
u Check handhole and manway gasket inventory and re-order as needed
u Compare stack temperature reading records and note trend in temperature gradient
(Increasing temperatures may indicate a need for fireside cleaning).
Remember, many motors and other moving components start and stop automatically.
Be sure to disconnect power before servicing to avoid possible injury to yourself or
others.
Steam and hot water can severely injure or kill. Do not attempt adjustments or repairs
while system is “hot” and under pressure.
SEMI ANNUALLY OR ANNUALLY:
u Plan ahead for the periodic insurance company or jurisdictional inspection. Have
manpower and tools available to mi nimize the time required for this important
inspection.
u Be sure to have new gaskets available for all the gasketed openings that must be
disassembled.
All jurisdictions and insurance companies require periodic waterside and fireside
inspections. These vary with the states and companies, so you need to determine their
schedule requirement so you will be prepared. These inspections can usually be carried
out at the same time to minimize down time for your operation.
u Each time the boiler is opened for an internal inspection, use this time to note any
sludge buildup on any surface, especially in the belly of the boiler and wash this out
thoroughly.
u Also, note any suspicious area of pitting or chemical buildup on the tubes or furnace.
Involve your chemical supplier for a possible re-evaluation of your water treatment
program; and after his inspection, thoroughly wash these areas clean.
u Note the condition of the fireside of the boiler. The furnace, tubes, front and rear
smokeboxes and the stack should all be brushed, or vacuumed as necessary to remove
any foreign materials. Note especially any evidence of tube leaks on the front and rear
tube sheets and in the turnaround space, if so fitted. This is the time to contact your
local boiler service company and have those leaking tubes repaired.
30 of 761
When preparing for a waterside inspection, stop all fuel input at least 18 hours prior to
the inspection. Allow the boiler to cool slowly to minimize stresses in the heated parts.
On steam boilers, blow the bottom blowdown frequently during this cool down period to
introduce cooler water and flush out settled sludge.
About 6 hours before the inspection, open front and rear doors. As soon as boiler
pressure has gone to 0 psig, close feedwater valves and remove manway. Open top air
vent. Turn off all power to the boiler.
Open all bottom blowdown (drain) valves to begin draining the boiler. As water is
drained, you may begin washing down as you see fit until internal parts are clean.
WATER QUALITY
The life expectancy of yo ur boiler is greatly impacted by the quality of the water you place into
it. If you take steps to assure the water to be free of contaminants and solids and to have the
correct pH, only periodic waterside inspections are necessary to maintain an efficient, long-life
operation.
STEAM BOILERS:
When the water that you place into your boiler is converted into steam; that steam leaves the
boiler, but the contaminants that were in the water stay in the boiler and have the potential to
form sludge and scale.
Sludge is generally a soft, settleable material that over time will drop to the bottom of the boiler
and may be removed through bottom blowdown. It can impact heat transfer since it will also
build up on furnace the tubes. Left uncontrolled, it can contribute to foaming and priming
thereby compromising steam quality.
Scale however, is that material that will cake on the furnace and tubes in a hard, baked-on
layer that will lead to poor heat transfer and may cause overheating of those surfaces to the
point of rupture. Ultimately, this scale must be removed, so it is better to take steps to eliminate
the very formation of the scale. Removal of scale from the water side of a boiler can be very
labor intensive and costly.
pH is the measure of how acidic the wate r is. If the pH is not properly adjusted, the metal
surfaces can experience conditions that can lead to corrosion, pitting and ultimate failure.
Sludge, scale and pH are all controllable. The condition of the raw boiler water must be
analyzed and corrected before it is introduced into the boiler. Filters, softeners, dealkalizers
and chemical feed systems are some of the pre-treatment methods used to create suitable
boiler water. Additional chemical treatment is sometimes required to be injected internally into
the boiler.
A water quality consultant can make an analysis of your boiler water and make
recommendations for treatment.
31 of 761
Some recommendations for conditions of acceptable boiler water are:
Oxygen <.007 ppm

Total hardness <5 ppm
Total Alkalinity (CACO3) <700 ppm
Total Iron (Fe) <10 ppm
Silica (SI02) <150 ppm
Suspended Solids <300 ppm – (up to 300psi)
<250 ppm – (300 - 450psi)
<150 ppm – (450 - 600psi)
Total Solids <3000 ppm
pH 7.5 – 11
Hot Water Boilers:
At the time of filling the system for the first time, the water quality should be checked and
treated. Chemicals to prevent scale formation, elimination of dissolved gases and control of pH
should be of particular importance.
Although these systems are considered “closed”, there are conditions that can lead to water
losses which must be made up. Leakage through handholes, threaded pipe fitting, pump seals
and a variety of other issues in the system can lead to make-up water being required in the
system water.
A meter on the make-up water line is a good method for determining the amount of water that
has been added to the system over a given period of time. This will alert the operator to verify
system water quality and adjust treatment as necessary.
Shot-type feeders are generally the method used for introducing chemicals into the system.
32 of 761
SATURATED STEAM PROPERTIES
Specific
ABS INTERNAL ENERGY
Temp Volume ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F)
Press. 3 (Btu/lb)
(ft /lb)
E E E
Sat. Sat. Sat. V Sat. Sat. V Sat. Sat. V Sat.
PSIA °F
Liquid Vapor Liquid A Vapor Liquid A Vapor Liquid A Vapor
P P P
h s u
P t vf vg hf fg hg sf fg sg uf fg ug
14.696 212.00 0.01672 26.80 180.07 970.3 1150.4 0.3120 1.4446 1.7566 180.02 897.5 1077.5
15 213.03 0.01672 26.29 181.11 969.7 1150.8 0.3135 1.4415 1.7549 181.06 896.7 1077.8
16 216.32 0.01674 24.75 184.42 967.6 1152.0 0.3184 1.4313 1.7497 184.37 894.3 1078.7
17 219.44 0.01677 23.39 187.56 965.5 1153.1 0.3231 1.4218 1.7449 187.51 892.0 1079.5
18 222.41 0.01679 22.17 190.56 963.6 1154.2 0.3275 1.4128 1.7403 190.50 889.9 1080.4
19 225.24 0.01681 21.08 193.42 961.9 1155.3 0.3317 1.4043 1.7360 193.36 887.8 1081.2
20 227.96 0.01683 20.089 196.16 960.1 1156.3 0.3356 1.3962 1.7319 196.10 885.8 1081.9
21 230.57 0.01685 19.192 198.79 958.4 1157.2 0.3395 1.3885 1.7280 198.73 883.9 1082.6
22 233.07 0.01687 18.375 201.33 956.8 1158.1 0.3431 1.3811 1.7242 201.26 882.0 1083.3
23 235.49 0.01689 17.627 203.78 955.2 1159.0 0.3466 1.3740 1.7206 203.71 880.2 1083.9
24 237.82 0.01691 16.938 206.14 953.7 1159.8 0.3500 1.3672 1.7172 206.07 878.5 1084.6
25 240.07 0.01692 16.303 208.42 952.1 1160.6 0.3533 1.3606 1.7139 208.34 876.8 1085.1
26 242.25 0.01694 15.715 210.62 950.7 1161.3 0.3564 1.3544 1.7108 210.54 875.2 1085.7
27 244.36 0.01696 15.170 212.75 949.3 1162.0 0.3594 1.3484 1.7078 212.67 873.6 1086.3
28 246.41 0.01698 14.663 214.83 947.9 1162.7 0.3623 1.3425 1.7048 214.74 872.1 1086.8
29 248.40 0.01699 14.189 216.86 946.5 1163.4 0.3652 1.3368 1.7020 216.77 870.5 1087.3
30 250.33 0.01701 13.746 218.82 945.3 1164.1 0.3680 1.3313 1.6993 218.73 869.1 1087.8
31 252.22 0.01702 13.33 220.73 944.0 1164.7 0.3707 1.3260 1.6967 220.63 867.7 1088.3
32 254.05 0.01704 12.940 222.59 942.8 1165.4 0.3733 1.3209 1.6941 222.49 866.3 1088.7
33 255.84 0.01705 12.572 224.41 941.6 1166.0 0.3758 1.3159 1.6917 224.31 864.9 1089.2
34 257.58 0.01707 12.226 226.18 940.3 1166.5 0.3783 1.3110 1.6893 226.07 863.5 1089.6
35 259.28 0.01708 11.898 227.91 939.2 1167.1 0.3807 1.3063 1.6870 227.80 862.3 1090.1
36 260.95 0.01709 11.588 229.60 938.0 1167.6 0.3831 1.3017 1.6848 229.49 861.0 1090.5
37 262.57 0.01711 11.294 231.26 936.9 1168.2 0.3854 1.2972 1.6826 231.14 859.8 1090.9
38 264.16 0.01712 11.015 232.89 935.8 1168.7 0.3876 1.2929 1.6805 232.77 858.5 1091.3
39 265.72 0.01714 10.750 234.48 934.7 1169.2 0.3898 1.2886 1.6784 234.36 857.2 1091.6
40 267.25 0.01715 10.498 236.03 933.7 1169.7 0.3919 1.2844 1.6763 235.90 856.1 1092.0
41 268.74 0.01716 10.258 237.55 932.6 1170.2 0.3940 1.2803 1.6743 237.42 855.0 1092.4
42 270.21 0.01717 10.029 239.04 931.6 1170.7 0.3960 1.2764 1.6724 238.91 853.8 1092.7
43 271.64 0.01719 9.810 240.51 930.6 1171.1 0.3980 1.2726 1.6706 240.37 852.7 1093.1
44 273.05 0.01720 9.601 241.95 929.6 1171.6 0.4000 1.2687 1.6687 241.81 851.6 1093.4
45 274.44 0.01721 9.401 243.36 928.6 1172.0 0.4019 1.2650 1.6669 243.22 850.5 1093.7
46 275.80 0.01722 9.209 244.75 927.7 1172.4 0.4038 1.2613 1.6652 244.60 849.5 1094.1
47 277.13 0.01723 9.025 246.12 926.7 1172.9 0.4057 1.2577 1.6634 245.97 848.4 1094.4
48 278.45 0.01725 8.848 247.47 925.8 1173.3 0.4075 1.2542 1.6617 247.32 847.4 1094.7
49 279.74 0.01726 8.678 248.79 924.9 1173.7 0.4093 1.2508 1.6601 248.63 846.4 1095.0
50 281.01 0.01727 8.515 250.09 924.0 1174.1 0.4110 1.2474 1.6585 249.93 845.4 1095.3
51 282.26 0.01728 8.359 251.37 923.0 1174.4 0.4127 1.2442 1.6569 251.21 844.3 1095.5
52 283.49 0.01729 8.208 252.63 922.2 1174.8 0.4144 1.2409 1.6553 252.46 843.3 1095.8
53 284.70 0.01730 8.062 253.87 921.3 1175.2 0.4161 1.2377 1.6538 253.70 842.4 1096.1
54 285.90 0.01731 7.922 255.09 920.5 1175.6 0.4177 1.2346 1.6523 254.92 841.5 1096.4
55 287.07 0.01732 7.787 256.30 919.6 1175.9 0.4193 1.2316 1.6509 256.12 840.6 1096.7
56 288.23 0.01733 7.656 257.50 918.8 1176.3 0.4209 1.2285 1.6494 257.32 839.7 1097.0
57 289.37 0.01734 7.529 258.67 917.9 1176.6 0.4225 1.2255 1.6480 258.49 838.7 1097.2
33 of 761
Specific
ABS INTERNAL ENERGY
Press. 3 (Btu/lb)
(ft /lb)
E E E
PSIA °F
P P P
h s u
58 290.50 0.01736 7.407 259.82 917.1 1176.9 0.4240 1.2226 1.6466 259.63 837.8 1097.4
59 291.61 0.01737 7.289 260.96 916.3 1177.3 0.4255 1.2197 1.6452 260.77 836.9 1097.7
60 292.71 0.01738 7.175 262.09 915.5 1177.6 0.4270 1.2168 1.6438 261.90 836.0 1097.9
61 293.79 0.01739 7.064 263.20 914.7 1177.9 0.4285 1.2140 1.6450 263.00 835.2 1098.2
62 294.85 0.01740 6.957 264.30 913.9 1178.2 0.4300 1.2112 1.6412 264.10 834.3 1098.4
63 295.90 0.01741 6.853 265.38 913.1 1178.5 0.4314 1.2085 1.6399 265.18 833.4 1098.6
64 296.94 0.01742 6.752 266.45 912.3 1178.8 0.4328 1.2059 1.6387 266.24 832.6 1098.8
65 297.97 0.01743 6.655 267.50 911.6 1179.1 0.4342 1.2032 1.6374 267.29 831.8 1099.1
66 298.99 0.01744 6.560 268.55 910.8 1179.4 0.4356 1.2006 1.6362 268.34 831.0 1099.3
67 299.99 0.01745 6.468 269.58 910.1 1179.7 0.4369 1.1981 1.6350 269.36 830.2 1099.5
68 300.98 0.01746 6.378 270.60 909.4 1180.0 0.4383 1.1955 1.6338 270.38 829.4 1099.8
69 301.96 0.01747 6.291 271.61 908.7 1180.3 0.4396 1.1930 1.6326 271.39 828.6 1100.0
70 302.92 0.01748 6.206 272.61 907.9 1180.6 0.4409 1.1906 1.6315 272.38 827.8 1100.2
71 303.88 0.01749 6.124 273.60 907.2 1180.8 0.4422 1.1881 1.6303 273.37 827.0 1100.4
72 304.83 0.01750 6.044 274.57 906.5 1181.1 0.4435 1.1857 1.6292 274.34 826.3 1100.6
73 305.76 0.01751 5.966 275.54 905.8 1181.3 0.4447 1.1834 1.6281 275.30 825.5 1100.8
74 306.68 0.01752 5.890 276.49 905.1 1181.6 0.4460 1.1810 1.6270 276.25 824.7 1101.0
75 307.60 0.01753 5.816 277.43 904.5 1181.9 0.4472 1.1787 1.6259 277.19 824.0 1101.2
76 308.50 0.01754 5.743 278.37 903.7 1182.1 0.4484 1.1764 1.6248 278.12 823.3 1101.4
77 309.40 0.01754 5.673 279.30 903.1 1182.4 0.4496 1.1742 1.6238 279.05 822.5 1101.6
78 310.29 0.01755 5.604 280.21 902.4 1182.6 0.4508 1.1720 1.6228 279.96 821.7 1101.7
79 311.16 0.01756 5.537 281.12 901.7 1182.8 0.4520 1.1698 1.6217 280.86 821.0 1101.9
80 312.03 0.01757 5.472 282.02 901.1 1183.1 0.4531 1.1676 1.6207 281.76 820.3 1102.1
81 312.89 0.01758 5.408 282.91 900.4 1183.3 0.4543 1.1654 1.6197 282.65 819.6 1102.2
82 313.74 0.01759 5.346 283.79 899.7 1183.5 0.4554 1.1633 1.6187 283.52 818.9 1102.4
83 314.59 0.01760 5.285 284.66 899.1 1183.8 0.4565 1.1612 1.6177 284.39 818.2 1102.6
84 315.42 0.01761 5.226 285.53 898.5 1184.0 0.4576 1.1592 1.6168 285.26 817.5 1102.8
85 316.25 0.01761 5.168 286.39 897.8 1184.2 0.4587 1.1571 1.6158 286.11 816.8 1102.9
86 317.07 0.01762 5.111 287.24 897.2 1184.4 0.4598 1.1551 1.6149 286.96 816.1 1103.1
87 317.88 0.01763 5.055 288.08 896.5 1184.6 0.4609 1.1530 1.6139 287.80 815.4 1103.2
88 318.68 0.01764 5.001 288.91 895.9 1184.8 0.4620 1.1510 1.6130 288.63 814.8 1103.4
89 319.48 0.01765 4.948 289.74 895.3 1185.1 0.4630 1.1491 1.6121 289.45 814.1 1103.6
90 320.27 0.01766 4.896 290.56 894.7 1185.3 0.4641 1.1471 1.6112 290.27 813.4 1103.7
91 321.06 0.01767 4.845 291.38 894.1 1185.5 0.4651 1.1452 1.6103 291.08 812.8 1103.9
92 321.83 0.01768 4.796 292.18 893.5 1185.7 0.4661 1.1433 1.6094 291.88 812.2 1104.1
93 322.60 0.01768 4.747 292.98 892.9 1185.9 0.4672 1.1413 1.6085 292.68 811.5 1104.2
94 323.36 0.01769 4.699 293.78 892.3 1186.1 0.4682 1.1394 1.6076 293.47 810.9 1104.4
95 324.12 0.01770 4.652 294.56 891.7 1186.2 0.4692 1.1376 1.6068 294.25 810.2 1104.5
96 324.87 0.01771 4.606 295.34 891.1 1186.4 0.4702 1.1358 1.6060 295.03 809.6 1104.6
97 325.61 0.01772 4.561 296.12 890.5 1186.6 0.4711 1.1340 1.6051 295.80 808.9 1104.7
98 326.35 0.01772 4.517 296.89 889.9 1186.8 0.4721 1.1322 1.6043 296.57 808.3 1104.9
0..473
99 327.08 0.01773 4.474 297.65 889.4 1187.0 1 1.1304 1.6035 297.33 807.7 1105.0
100 327.81 0.01774 4.432 298.40 888.8 1187.2 0.4740 1.1286 1.6026 298.08 807.1 1105.2
101 328.53 0.01775 4.391 299.15 888.2 1187.4 0.4750 1.1268 1.6018 298.82 806.5 1105.3
102 329.25 0.01775 4.350 299.90 887.6 1187.5 0.4759 1.1251 1.6010 299.57 805.9 1105.4
103 329.96 0.01776 4.310 300.64 887.1 1187.7 0.4768 1.1234 1.6002 300.30 805.3 1106.6
104 330.66 0.01777 4.271 301.37 886.5 1187.9 0.4778 1.1216 1.5994 301.03 804.7 1105.7
34 of 761
Specific
ABS INTERNAL ENERGY
Press. 3 (Btu/lb)
(ft /lb)
E E E
PSIA °F
P P P
h s u
105 331.36 0.01778 4.232 302.10 886.0 1188.1 0.4787 1.1199 1.5986 301.75 804.1 1105.9
106 332.05 0.01778 4.194 302.82 885.4 1188.2 0.4796 1.1182 1.5978 302.47 803.5 1106.0
107 332.74 0.01779 4.157 303.54 884.9 1188.4 0.4805 1.1166 1.5971 303.19 802.9 1106.1
108 333.42 0.01780 4.120 304.26 884.3 1188.6 0.4814 1.1149 1.5963 303.90 802.4 1106.3
109 334.10 0.01781 4.084 304.97 883.7 1188.7 0.4823 1.1133 1.5956 304.61 801.8 1106.4
110 334.77 0.01782 4.049 305.66 883.2 1188.9 0.4832 1.1117 1.5948 305.30 801.2 1106.5
111 335.44 0.01782 4.015 306.37 882.6 1189.0 0.4840 1.1101 1.5941 306.00 800.6 1106.6
112 336.11 0.01783 3.981 307.06 882.1 1189.2 0.4849 1.1085 1.5934 306.69 800.0 1106.7
113 336.77 0.01784 3.947 307.75 881.6 1189.4 0.4858 1.1069 1.5927 307.38 799.4 1106.8
114 337.42 0.01784 3.914 308.43 881.1 1189.5 0.4866 1.1053 1.5919 308.05 798.9 1106.9
115 338.07 0.01785 3.882 309.11 880.6 1189.7 0.4875 1.1037 1.5912 308.73 798.4 1107.1
116 338.72 0.01786 3.850 309.79 880.0 1189.8 0.4883 1.1022 1.5905 309.41 797.8 1107.2
117 339.36 0.01787 3.819 310.46 879.5 1190.0 0.4891 1.1007 1.5898 310.07 797.2 1107.3
118 339.99 0.01787 3.788 311.12 879.0 1190.1 0.4900 1.0992 1.5891 310.73 796.7 1107.4
119 340.62 0.01788 3.758 311.78 878.4 1190.2 0.4908 1.0977 1.5885 311.39 796.1 1107.5
120 341.25 0.01789 3.728 312.44 877.9 1190.4 0.4916 1.0962 1.5878 312.05 795.6 1107.6
121 341.88 0.01790 3.699 313.10 877.4 1190.5 0.4924 1.0947 1.5871 312.70 795.0 1107.7
122 342.50 0.01791 3.670 313.75 876.9 1190.7 0.4932 1.0933 1.5865 313.35 794.5 1107.8
123 343.11 0.01791 3.642 314.40 876.4 1190.8 0.4940 1.0918 1.5858 313.99 793.9 1107.9
124 343.72 0.01792 3.614 315.04 875.9 1190.9 0.4948 1.0903 1.5851 314.63 793.4 1108.0
125 344.33 0.01792 3.587 315.68 875.4 1191.1 0.4956 1.0888 1.5844 315.26 792.8 1108.1
126 344.94 0.01793 3.560 316.31 874.9 1191.2 0.4964 1.0874 1.5838 315.89 792.3 1108.2
127 345.54 0.01794 3.533 316.94 874.4 1191.3 0.4972 1.0859 1.5832 316.52 791.8 1108.3
128 346.13 0.01794 3.507 317.57 873.9 1191.5 0.4980 1.0845 1.5825 317.15 791.3 1108.4
129 346.73 0.01795 3.481 318.19 873.4 1191.6 0.4987 1.0832 1.5819 317.77 790.7 1108.5
130 347.32 0.01796 3.455 318.81 872.9 1191.7 0.4995 1.0817 1.5812 318.38 790.2 1108.6
131 347.90 0.01797 3.430 319.43 872.5 1191.9 0.5002 1.0804 1.5806 318.99 789.7 1108.7
132 348.48 0.01797 3.405 320.04 872.0 1192.0 0.5010 1.0790 1.5800 319.60 789.2 1108.8
133 349.06 0.01798 3.381 320.65 871.5 1192.1 0.5018 1.0776 1.5793 320.21 788.7 1108.9
134 349.64 0.01799 3.357 321.25 871.0 1192.2 0.5025 1.0762 1.5787 320.80 788.2 1109.0
135 350.21 0.01800 3.333 321.85 870.6 1192.4 0.5032 1.0749 1.5781 321.40 787.7 1109.1
136 350.78 0.01800 3.310 322.45 870.1 1192.5 0.5040 1.0735 1.5775 322.00 787.2 1109.2
137 351.35 0.01801 3.287 323.05 869.6 1192.6 0.5047 1.0722 1.5769 322.59 786.7 1109.3
138 351.91 0.01801 3.264 323.64 869.1 1192.7 0.5054 1.0709 1.5763 323.18 786.2 1109.4
139 352.47 0.01802 3.242 324.23 868.7 1192.9 0.5061 1.0696 1.5757 323.77 785.7 1109.5
140 353.02 0.01802 3.220 324.82 868.2 1193.0 0.5069 1.0682 1.5751 324.35 785.2 1109.6
141 353.57 0.01803 3.198 325.40 867.7 1193.1 0.5076 1.0669 1.5745 324.93 784.8 1109.7
142 354.12 0.01804 3.177 325.98 867.2 1193.2 0.5083 1.0657 1.5740 325.51 784.3 1109.8
143 354.67 0.01804 3.155 326.56 866.7 1193.3 0.5090 1.0644 1.5734 326.08 783.8 1109.8
144 355.21 0.01805 3.134 327.13 866.3 1193.4 0.5097 1.0631 1.5728 326.65 783.3 1109.9
145 355.76 0.01806 3.114 327.70 865.8 1193.5 0.5104 1.0618 1.5722 327.22 782.8 1110.0
146 356.29 0.01806 3.094 328.27 865.3 1193.6 0.5111 1.0605 1.5716 327.78 782.3 1110.1
147 356.83 0.01807 3.074 328.83 864.9 1193.8 0.5118 1.0592 1.5710 328.34 781.9 1110.2
148 357.36 0.01808 3.054 329.39 864.5 1193.9 0.5124 1.0580 1.5705 328.90 781.4 1110.3
149 357.89 0.01808 3.034 329.95 864.0 1194.0 0.5131 1.0568 1.5699 329.45 780.9 1110.4
150 358.42 0.01809 3.015 330.51 863.6 1194.1 0.5138 1.0556 1.5694 330.01 780.5 1110.5
152 359.46 0.01810 2.977 331.61 862.7 1194.3 0.5151 1.0532 1.5683 331.10 779.5 1110.6
154 360.49 0.01812 2.940 332.70 861.8 1194.5 0.5165 1.0507 1.5672 332.18 778.5 1110.7
35 of 761
Specific
ABS INTERNAL ENERGY
Press. 3 (Btu/lb)
(ft /lb)
E E E
PSIA °F
P P P
h s u
154 360.49 0.01812 2.940 332.70 861.8 1194.5 0.5165 1.0507 1.5672 332.18 778.5 1110.7
156 361.52 0.01813 2.904 333.79 860.9 1194.7 0.5178 1.0483 1.5661 333.26 777.6 1110.9
158 362.53 0.01814 2.869 334.86 860.0 1194.9 0.5191 1.0459 1.5650 334.23 776.8 1111.0
160 363.53 0.01815 2.834 335.93 859.2 1195.1 0.5204 1.0436 1.5640 335.39 775.8 1111.2
162 364.53 0.01817 2.801 336.98 858.3 1195.3 0.5216 1.0414 1.5630 336.44 775.0 1111.4
164 365.51 0.01818 2.768 338.02 857.5 1195.5 0.5229 1.0391 1.5620 337.47 774.1 1111.5
166 366.48 0.01819 2.736 339.05 856.6 1195.7 0.5241 1.0369 1.5610 338.49 773.2 1111.7
168 367.45 0.01820 2.705 340.07 855.7 1195.8 0.5254 1.0346 1.5600 339.51 772.3 1111.8
170 368.41 0.01822 2.675 341.09 854.9 1196.0 0.5266 1.0324 1.5590 340.52 771.4 1111.9
172 369.35 0.01823 2.645 342.10 854.1 1196.2 0.5278 1.0302 1.5580 341.52 770.5 1112.0
174 370.29 0.01824 2.616 343.10 853.3 1196.4 0.5290 1.0280 1.5570 352.51 769.7 1112.2
176 371.22 0.01825 2.587 344.09 852.4 1196.5 0.5302 1.0259 1.5561 343.50 768.8 1112.3
178 372.14 0.01826 2.559 345.06 851.6 1196.7 0.5313 1.0238 1.5551 344.46 767.9 1112.4
180 373.06 0.01827 2.532 346.03 850.8 1196.9 0.5325 1.0217 1.5542 345.42 767.1 1112.5
182 373.96 0.01829 2.505 347.00 850.0 1197.0 0.5336 1.0196 1.5532 346.38 766.2 1112.6
184 374.86 0.01830 2.479 347.96 849.2 1197.2 0.5348 1.0175 1.5523 347.34 765.4 1112.8
186 375.75 0.01831 2.454 348.92 848.4 1197.3 0.5359 1.0155 1.5514 348.29 764.6 1112.9
188 376.64 0.01832 2.429 349.86 847.6 1197.5 0.5370 1.0136 1.5506 349.22 763.8 1113.0
190 377.51 0.01833 2.404 350.79 846.8 1197.6 0.5381 1.0116 1.5497 350.15 763.0 1113.1
192 378.38 0.01834 2.380 351.72 846.1 1197.8 0.5392 1.0096 1.5488 351.07 762.1 1113.2
194 379.24 0.01835 2.356 352.64 845.3 1197.9 0.5403 1.0076 1.5479 351.98 761.3 1113.3
196 380.10 0.01836 2.333 353.55 844.5 1198.1 0.5414 1.0056 1.5470 352.89 760.6 1113.5
198 380.95 0.01838 2.310 354.46 843.7 1198.2 0.5425 1.0037 1.5462 353.79 759.8 1113.6
200 381.79 0.01839 2.288 355.36 843.0 1198.4 0.5435 1.0018 1.5453 354.68 759.0 1113.7
205 383.86 0.01842 2.234 357.58 841.1 1198.7 0.5461 0.9971 1.5432 356.88 757.1 1114.0
210 385.90 0.01844 2.183 359.77 839.2 1199.0 0.5487 0.9925 1.5412 359.05 755.2 1114.2
215 387.89 0.01847 2.134 361.91 837.4 1199.3 0.5512 0.9880 1.5392 361.18 753.2 1114.4
220 389.86 0.01850 2.087 364.02 835.6 1199.6 0.5537 0.9835 1.5372 363.27 751.3 1114.6
225 391.79 0.01852 2.0422 366.09 833.8 1199.9 0.5561 0.9792 1.5353 365.32 749.5 1114.8
230 393.68 0.01854 1.9992 368.13 832.0 1200.1 0.5585 0.9750 1.5334 367.34 747.7 1115.0
235 395.54 0.01857 1.9579 370.14 830.3 1200.4 0.5608 0.9708 1.5316 369.33 745.9 1115.3
240 397.37 0.01860 1.9183 372.12 828.5 1200.6 0.5631 0.9667 1.5298 371.29 744.1 1115.4
245 399.18 0.01863 1.8803 374.08 826.8 1200.9 0.5653 0.9627 1.5280 373.23 742.4 1115.6
250 400.95 0.01865 1.8438 376.00 825.1 1201.1 0.5675 0.9588 1.5263 375.14 740.7 1115.8
255 402.70 0.01868 1.8086 377.89 823.4 1201.3 0.5697 0.9549 1.5246 377.01 739.0 1116.0
260 404.42 0.01870 1.7748 379.76 821.8 1201.5 0.5719 0.9510 1.5229 378.86 737.3 1116.1
265 406.11 0.01873 1.7422 381.60 820.1 1201.7 0.5740 0.9472 1.5212 380.68 735.6 1116.3
270 407.78 0.01875 1.7107 383.42 818.5 1201.9 0.5760 0.9436 1.5196 382.48 733.9 1116.4
275 409.43 0.01878 1.6804 385.21 816.9 1202.1 0.5781 0.9399 1.5180 384.26 732.3 1116.6
280 411.05 0.01880 1.6511 386.98 815.3 1202.3 0.5801 0.9363 1.5164 386.01 730.7 1116.7
285 412.65 0.01883 1.6228 388.73 813.7 1202.4 0.5821 0.9327 1.5149 387.74 729.1 1116.8
290 414.23 0.01885 1.5954 390.46 812.1 1202.6 0.5841 0.9292 1.5133 389.45 727.5 1116.9
295 415.79 0.01887 1.5689 392.16 810.5 1202.7 0.5860 0.9258 1.5118 391.13 725.9 1117.0
300 417.33 0.01890 1.5433 393.84 809.0 1202.8 0.5879 0.9225 1.5104 392.79 724.3 1117.1
310 420.35 0.01894 1.4944 397.15 806.0 1203.1 0.5916 0.9159 1.5075 396.06 721.3 1117.4
320 423.29 0.01899 1.4485 400.39 803.0 1203.4 0.5952 0.9094 1.5046 399.26 718.3 1117.6
330 426.16 0.01904 1.4053 403.56 800.0 1203.6 0.5988 0.9031 1.5019 402.40 715.4 1117.8
340 428.97 0.01908 1.3645 406.66 797.1 1203.7 0.6022 0.8970 1.4992 405.46 712.4 1117.9
36 of 761
Specific
ABS INTERNAL ENERGY
Press. 3 (Btu/lb)
(ft /lb)
E E E
PSIA °F
P P P
h s u
350 431.72 0.01913 1.3260 409.69 794.2 1203.9 0.6056 0.8910 1.4966 408.45 709.6 1118.0
360 434.40 0.01917 1.2895 412.67 791.4 1204.1 0.6090 0.8851 1.4941 411.39 706.8 1118.2
370 437.03 0.01921 1.2550 415.59 788.6 1204.2 0.6122 0.8794 1.4916 414.27 704.0 1118.3
380 439.60 0.01925 1.2222 418.45 785.8 1204.3 0.6153 0.8738 1.4891 417.10 701.3 1118.4
390 442.12 0.01930 1.1910 421.27 783.1 1204.4 0.6184 0.8683 1.4867 419.88 698.6 1118.5
400 444.59 0.0193 1.1613 424.0 780.5 1204.5 0.6214 0.8630 1.4844 422.6 695.9 1118.5
410 447.01 0.0194 1.1330 426.8 777.7 1204.5 0.6243 0.8578 1.4821 425.3 693.3 1118.6
420 449.39 0.0194 1.1061 429.4 775.2 1204.6 0.6272 0.8527 1.4799 427.9 690.8 1118.7
430 451.73 0.0194 1.0803 432.1 772.5 1204.6 0.6301 0.8476 1.4777 430.5 688.2 1118.7
440 454.02 0.0195 1.0556 434.6 770.0 1204.6 0.6329 0.8426 1.4755 433.0 685.7 1118.7
450 456.28 0.0195 1.0320 437.2 767.4 1204.6 0.6356 0.8378 1.4734 435.5 683.2 1118.7
460 458.50 0.0196 1.0094 439.7 764.9 1204.6 0.6383 0.8330 1.4713 438.0 680.7 1118.7
470 460.68 0.0196 0.9878 442.2 762.4 1204.6 0.6410 0.8283 1.4693 440.5 678.2 1118.7
480 462.82 0.0197 0.9670 444.6 759.9 1204.5 0.6436 0.8237 1.4673 442.9 675.7 1118.6
490 464.93 0.0197 0.9470 447.0 757.5 1204.5 0.6462 0.8191 1.4653 445.2 673.4 1118.6
500 467.10 0.0197 0.9283 449.5 755.8 1205.3 0.6487 0.8147 1.4645 449.5 671.7 1118.6
37 of 761
STANDARDS
American Society of Mechanical Engineers (ASME)

345 East 47th Street
New York, NY 10017
212-705-8500
American National Standards Institute (ANSI)

11 West 42nd Street
New York, NY 11036
212-642-4900
Canadian Standards Association (CSA)

178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
416-747-4044
Canadian Gas Association (CGA)

55 Scarsdale Road
Don Mils, Ontario, Canada M3B 2R3
416-447-6465
National Board of Boiler and Pressure Vessel Inspectors (NB)

1055 Crupper Avenue
Columbus, OH 43229
614-888-8320
National Electric Code (NEC)

1 Batterymarch Park
Quincy, MA 02269
Underwriters Laboratories (UL and cUL)

333 Pfingsten Road
Northbrook, IL 60062
Underwriters Laboratories of Canada (ULC)

7 Crouse Road
Scarborough, Ontario, Canada M1R 3A9
38 of 761
Ref. Instruction Manuals
- HURST Boiler Recommended Water Conditions -
General Info
(Note: Consult your Water Treatment contractor/
specialist.)
(Specs Clause 1.3.M)
39 of 761
40 of 761
41 of 761
3.2 Mcdonnell & Miller

8200 N. Austin Ave. Morton Grove, IL 60053 USA
www.mcdonnellmiller.com
42 of 761
McDonnell & Miller

Installation & Maintenance
Instructions
MM-213(F)
750 - MT - 120
U.S. Pat. No. 6,571,625
Series 750 ®
Series 750
Serie
s
Pro 750
Low be Type
Probe Type Wate
Probe Type Low Water Low Water Cu

t-off
r Cut-
off
Cut-Offs with Remote Sensors

Series 750 Series 750P-MT
Control Unit Control Unit
Applications:
– Primary conductance type control for
commercial or industrial hot water boilers
with remote or integral sensing provisions.
– Secondary control for commercial or
Remote Sensor Remote Sensor
industrial steam boilers. Model RS-1-LP Model RS-1-BR-1
! WARNING
CAUT
ION
• Before using product, read and understand instructions.
ING
WARN
• Save these instructions for future reference.

• All work must be performed by qualified personnel trained in the proper application, installation,
and maintenance of plumbing and electrical equipment and/or systems in accordance with all
applicable codes and ordinances.
• Boiler manufacturer schematics should always be followed. In the event that the boiler
manufacturer’s schematic does not exist, or is not available from the boiler manufacturer,
refer to the schematics provided in this document.
• To prevent serious burns, allow the control and surrounding equipment to cool to 80˚F (27˚C)
and allow pressure to release to 0 psi (0 bar) before servicing.
• To prevent an electrical fire or equipment damage, electrical wiring insulation must have a
rating of 167˚F (75˚C) if the liquid's temperature exceeds 180˚F (82˚C).
• This low water cut-off must be installed in series with all other limit and operating controls
installed on the boiler. After installation, check for proper operation of all the limit and
operating controls, before leaving the site.
• We recommend that secondary (redundant) Low Water Cut-Off controls be installed on all
steam boilers with heat input greater than 400,000 BTU/hour or operating above 15 psi of
steam pressure. At least two controls should be connected in series with the burner control
circuit to provide safety redundancy protection should the boiler experience a low water
condition. Moreover, at each annual outage, the low water cut-offs should be dismantled,
inspected, cleaned, and checked for proper calibration and performance.
• When using mixed voltages, do not jumper from terminal 1 to terminal 3.
• To prevent electrocution, when the electrical power is connected to the control, do not touch
the terminals, or electrical wires.
• To prevent electrical shock, turn off the electrical power before making electrical connections.
Failure to follow this warning could cause property damage, personal injury or death.
43 of 761
SPECIFICATIONS Red
The Series 750 controls provide continuous protection against low Amber Low
Test LED Water Reset Button
(if applicable)
water conditions for commercial and industrial applications. Newer
models feature user-friendly diagnostic LEDs and increased
probe sensitivity to prevent nuisance shut-downs.
Control Unit
Series 750
Temperature Ratings: Control
5-1/2"
Unit
Storage: -40˚F to 135˚F (-40˚C to 57˚C)
Ambient: 32˚F to 135˚F (0˚C to 57˚C)
Humidity: 85% (non-condensing)
Previous Models
Electrical Enclosure Rating: NEMA 1 General Purpose
RS-1-BR1 Remote Sensor
Maximum Steam Pressure: 250 psi (17.6 kg/cm2)
Maximum Water Pressure: 250 psi (17.6 kg/cm2)
Green Red
Maximum Water Temperature: 406˚F (208˚C) Power On Low
LED Reset Button
Electrical Enclosure Rating: NEMA 1 General Purpose Test Water
(if applicable)
Connection Size: 1” NPT
RS-1-LP
Maximum Water Pressure: 160 psi (11.2 kg/cm2) Series 750
Control
Maximum Water Temperature: 250˚F (121˚C) 5-1/2"
Unit
Electrical Enclosure Rating: NEMA 1 General Purpose
Connection Size: 3/4” NPT
PA-800 Probe (included with 750P-MT-120) Newer Models
PA-800-U Probe (included with 750P-MT-U-120)
Maximum Water Temperature: 250˚F (121˚C)
Connection Size: 3/4” NPT
Electrical Specifications
Motor Switch Rating (Amperes) Control Voltage: 120 VAC
Model Voltage Full Load Locked Rotor Pilot Duty Hz: 50/60
120 VAC 7.2 43.2 125 VA at Control Power Consumption: 3 VA (max.)
120 VAC 120 or 240 VAC Probe Sensitivity: 20,000 ohm
240 VAC 3.6 21.6 50 or 60 Hz
Automatic Reset Models CSD-1 Code Compliance

Whenever water is below the level of the probe, the On Manual Reset units, if the control is in a low
control will go into a low water condition. When the water condition (water off probe) when there is an
water level has been restored, the control will auto- interruption of power, the control will remain in a low
matically return to a run condition. water condition when power is restored. The reset
button will need to be pressed when the water level
Manual Reset Models is restored to a level above the probe.
If a low water condition occurs (water off probe), the
manual reset button must be pressed once the
water level is restored to a level above the probe.
2
44 of 761
STEP 1 - Where to Install the Remote Sensors
Determine where to install the remote sensor based on the following requirements:
a. The tip of the probe or extension
must be installed above the min- SERIES 750
RS1-BR-1
SENSOR
imum safe water level, as deter- LWCO
RS-1-LP
SERIES 750
LWCO
SENSOR
mined by the boiler manufacturer.
b. Probes must be installed vertically

if they are more than 5" (127mm)
long.
c. There must be a minimum 1/4"
(6.4mm) clearance between the
probe and any grounding surface
inside the boiler.
STEP 2 - Installing the Remote Sensor

For the Model RS-1-BR-1 sensors, only:
a. Cut the probe to desired length. Screw, clockwise,
the threaded stainless steel probe extension (A) B
into the remote sensor (B). Carefully tighten the
locking nut to approximately 1 ft•lb (1.7 N•m). Do
not cut the clear plastic protective tube.
For All Remote Sensors
b. Apply a small amount of pipe dope to the first

threads (L) of the remote sensor.
IMPORTANT: Do not use Teflon® tape or thread

sealant. OR
L
L
3
45 of 761
c. Insert the remote sensor (B) into the boiler tap- B

ping (M) as determined in Step 1.
M
1/4" MIN. (6.4 mm)

1/4" MIN. (6.4 mm)
d. Using a wrench (N), tighten the brass hex

adapter (P) on the remote sensor (B) to
B N
approximately 63 ft•lb (85 N•m). DO NOT
TIGHTEN BY TURNING THE SENSOR
HOUSING. P
STEP 3 - Installing the Control Box

a. Using the flatblade screwdriver or nut driver (C),
loosen the two (2) screws (D) and remove
cover (E).
C
D (x2)
Series 750
Control
Unit
E
IMPORTANT: To protect control from damage

caused by liquid or debris, mount as shown with
buttons on top.
b. Using the four (4) 3/16" (4.8mm) mounting
holes (F), attach the control (G) to the boiler
jacket, entry plate, or other suitable location.
G
NOTE: Mounting hardware is not included.
F
(x4)
4
46 of 761
STEP 4 - Locating and Installing the 750P-MT (Unimount)
a. Based on the following criteria locate a suitable position for the probe (A):
For all Applications:

1. Make sure probe is installed above minimum
1/4"
safe water line as determined by the boiler (6mm)
manufacturer. A
2. Make sure that ends and sides of the probe
are at least 1/4” (6.4mm) from all internal
metal surfaces.
3. Make sure the probe is positioned to shut off Tee Fitting Probe
the boiler before the water level falls below Control
1/4" (6mm)
the lowest visible part of the gauge glass. Riser
Pipe
For Steam Boilers:

1. Refer to boiler manufacturers instructions to
determine suitable tapping for the probe.
For Hot Water Boilers:

1. Refer to boiler manufacturers instructions to
determine suitable tapping for the probe. Hot Water
Boiler
2. Locate probe in supply piping using a tee
fitting.
Probe
Control
Minimum Safe
Water Level
(May vary Steam or
by boiler Hot Water
manufacturer) Boiler
5
47 of 761
b. Apply a small amount of pipe dope to the first

external threads (D) of the probe (A).
A
IMPORTANT: Do not use Teflon® tape or thread
D
sealant.
c. Using a wrench, tighten the probe (A) into the

tapped connection (E) that was determined in
Step 1 of these instructions. Tighten to 47 ft•lb F
(64 N•m). E
NOTE: Be sure to align the probe so that the
mounting screws (F) are in a horizontal position.
d. Using the flatblade screwdriver, loosen

the two (2) screws that secure the
cover (G) to the control about 1-1/2
turns and remove cover.
D (x2)
Series 750
Control
Unit
G
6
48 of 761
Direct Mounting - Unimount Models
a. Push out the probe knockouts and remove

completely from the control housing.
b. Using a flatblade screwdriver, loosen the probe

mounting screws (F) 1/8" (3mm) about 1-1/2 turns
and slip the control housing (G) over these two
screws at a 20˚ angle.
G
F
{
PROBE
KNOCKOUTS
c. Rotate the control housing (G) 20˚ counterclockwise

so that the slots in the control base are firmly under
the screw heads. Tighten the mounting screws (F)
to approximately 2 ft•lb (2.6 N•m).
d. Remove wingnut from probe and position ring

terminal of probe wire on threaded probe rod.
Secure with wingnut. Probe Probe G
Wire Wingnut
F
7
49 of 761
STEP 5 - Electrical Wiring
! IMPORTANT ! WARNING
Boiler manufacturer schematics should always be To prevent an electrical fire or equipment damage,
followed. In the event that the boiler manufacturer’s electrical wiring must have a rating of 167˚F (75˚C) if the
schematic does not exist, or is not available from liquid's temperature exceeds 180˚F (82˚C).
the boiler manufacturer, refer to the schematics Failure to follow this warning could cause property
provided in this document. damage, personal injury or death.
• Mount Control Box in a suitable location near

RS1-BR-1
the boiler’s main electrical panel. SERIES 750 SENSOR
LWCO
NOTE
Boiler sight glass must be visible from location of
Control Box and must be within 25 feet of Control
Body.
a. Remove the sensor housing cover (Q). R

Q
1. For Model RS-1-BR-1, using a flathead B
screwdriver (R), remove the four (4) screws
and separate the housing cover (Q) from the
Q
sensor (B). B OR R
2. For Model RS-1-LP, using a flathead screw-
driver or nut driver (R), loosen the two (2)
screws and separate the housing cover (Q)
from the sensor (B).
Model RS-1-BR-1 Model RS-1-LP
• Install electrical conduit between Probe

Housing and Control Box. RS1-BR-1
SERIES 750 SENSOR
LWCO
NOTE
Wire must be 18 AWG stranded with glass braided
silicone jacket (UL 3071) suitable for high temper-
ature (200˚C) service.
NOTE
Refer to and follow local codes and standards
when selecting conduit and electrical fittings.
Wires from Probe Housing and Control Box must
be in their own conduit. If they are run in conduit
with other wires, there may be interference that
can affect the performance of the control.
8
50 of 761
b. For all wire connections to the terminal block (M).

1. Strip about 1/3" (8.5 mm) of insulation from
the wire.
2. Loosen the terminal screw (N), DO NOT N
REMOVE, and move the wire clamping plate P
(P) back until the plate touches the back side
of the screw head.
M
3. Insert the stripped end of the wire under the
wire clamping plate (P) and securely tighten
the terminal screw (N).
Wiring Diagram Legends

1. Bold lines indicate action to be taken in Step shown.
2. Dotted black lines indicate internal wiring.
Remote Sensor Wiring:

• Connect wire from probe end to Terminal ‘P’
• Connect wire from remote sensor green
ground screw to chassis green ground screw P 1 2 3 4 5
Unimount Sensor Wiring:

• Connect ring terminal of wire to probe end
• Slide female spade connection of wire onto male
spade connection on terminal board WHITE
NEUTRAL
Burner Limit
Control Wiring: ALARM OR
Circuit
HOT
WATER FEEDER
• Connect 120V hot wire to terminal 1
• Connect 120V neutral wire to terminal 2
• Connect jumper wire from Terminal 1 to
Terminal 3
• Connect wire from beginning of Burner circuit
(thermostat, gas valve, limits, etc.) to terminal 5
• Connect wire from end of Burner circuit to terminal 2
c. Secure the sensor housing cover (Q).

R
Q
1. For model RS-1-BR-1, using the flatblade screw- R
driver (R), tighten the four (4) screws into the
housing (Q) to approximately 3 ft•lb (4 N•m). Q
2. For model RS-1-LP, using the flatblade screw-
driver or nut driver (R), tighten the two (2) screws OR
into the housing (Q) to approximately 2 ft•lb (2.6 N•m).
Model RS-1-BR-1 Model RS-1-LP
d. Secure the control housing cover by using the flat-

R
blade screwdriver or nut driver (R) to tighten the two D (x2)
(2) screws (D) to approximately 2 ft•lb (2.6 N•m). Series 750

Control
Unit
9
51 of 761
STEP 6 -Testing and Diagnostic Procedures
Series 750 LWCO with Green Power On LED and Red Low Water LED
Start-Up
a. Before filling the system, turn on the electric power to the boiler. Green Red
Power On Low
1. Upon initial power up, the Green and Red lights will flash simultaneously Reset Button
4 times. Test LED Water
(if applicable)
2. The Green and Red lights will turn "ON".
3. The burner will never turn "ON" during power up, if water is off the
probe.
b. Now fill the boiler with water.
(auto reset units only)
1. When water touches the probe, the Green light will remain "ON". Series 750
2. The Red light will turn "OFF" and the burner will turn “ON” as long Control
5-1/2"
Unit
as there is water on the probe.
(manual reset units only)
(When water returns to the probe, nothing will happen until the manual
reset button is depressed.) Newer Models
1. After depressing manual reset button, the Green and Red lights will
flash simultaneously 4 times.
2. Then the Green light will turn "ON" and the Red light will turn “OFF”.
4. The burner will turn "ON" as long as there is water on the probe.
Manually Testing Control
c. Slowly drain the boiler of water.
(both auto and manual reset units)
1. When water drops off the probe, the Green light will remain "ON".
2. The Red light will turn “ON” and the burner will turn “OFF”, if water is off the probe.
Testing Control Using "Test Button"
d. Depressing test button with "water on probe" (auto reset units only):
(Must depress and hold the test button to activate test cycle.)
1. When test cycle is activated the Red and Green lights will flash simultaneously 3 times.
2. The Red light will turn “ON”.
3. Burner will turn "OFF".
4. The Green light will continue flashing as long as test button is depressed.
(Release test button, if water is still on probe)
5. The Green light will stop flashing and turn "ON".
6. The Red light will turn "OFF".
7. Burner will turn "ON" as long as there is water on the probe.
e. Depressing test button with "water on probe" (manual reset units only):
(Must depress and hold test button to activate test cycle.)
1. When test cycle is activated the Red and Green lights will flash simultaneously 3 times.
2. The Red light will turn "ON".
3. Burner will turn "OFF".
4. The Green light will continue flashing as long as test button is depressed.
(Release test button. You must depress the manual reset button to unlock the low water cut-off.)
5. After depressing manual reset button, the Green and Red lights will flash simultaneously 4 times.
6. Then the Green light will turn "ON" and the Red light will turn "OFF".
7. The burner will turn "ON" as long as there is water on the probe.
f. Depressing test button with "water off probe" (both auto and manual reset units):
Since control is in "low water" the Green light will flash and the Red light will remain “ON”. The burner will remain “OFF”.
CSD-1 Compliance
On Manual Reset units, if the control is in a low water condition (water off probe) when there is an interruption of
power, the control will remain in a low water condition when power is restored. The reset button will need to be
pressed when the water level is restored to a level above the probe.
10
52 of 761
Series 750 LWCO with Amber LED and Red Low Water LED
For Control Unit Models with a Test Switch

Red
a. Hold the test switch down while noting the amber LED on
Amber Low
top of the control housing. Test LED Water Reset Button
(if applicable)
1. If the amber LED glows dimly, the water
level is above the probe.
2. If the amber LED is off, the water level may
be below the probe or the water is too pure and
may require the addition of boiler water treatment.
3. If the amber LED glows brightly, it could Series 750
indicate a grounded (non-operable) probe. If this Control
5-1/2"
Unit
is the case, proceed to "Troubleshooting" on page 12.
b. Test for correct burner circuit wiring.

1. Hold down the test switch while the burner Older Models
is running.
2. If the burner shuts off while the test switch is
depressed, the burner circuit is wired correctly.
3. For automatic reset models - release the test
switch and the burner should resume firing
provided that the boiler water is in contact with
the probes.
4. For manual reset models - the burner will not
return to normal operation until the reset switch
is depressed.
If you believe the probe to be grounded, perform the

following steps for control with test switch.
1. Make sure that the liquid level is below the probe.
2. Depress the test switch. If the amber LED turns
“ON” the probe may indeed be grounded. If so,
check the probe to make sure that it is the proper
length, or replace the grounded probe.
11
53 of 761
Troubleshooting
McDonnell & Miller
If control fails to operate as required, perform the following diagnostic checks:
1. Check to be sure that the water level in the boiler is at or above the level of the probe.
2. Re-check all wiring to ensure proper connections as specified in boiler manufacturer’s wiring diagrams
or these instructions.
3. Check to ensure that Teflon® tape has not been used on the threaded connection of the electrode
to the boiler.
4. Re-check the electrical ground connection for the remote sensor and control unit.
5. Check the quality of the boiler water to ensure adequate conductance.
MAINTENANCE
SCHEDULE:
• Test the low water cut-off annually or more frequently.
• Remove and inspect the self-cleaning probe every 5 years.
! CAUTION
Replace Probe if:
• Teflon® insulator is cracked or worn.
• Probe is loose.
Failure to follow this caution could cause property damage, personal injury or death.
• Replace probe every 10 years.

• Replace the low water cut-off every 15 years.
NOTE
Clean probe by wiping with non-abrasive cloth and rinsing with clean water. DO NOT
use sharp instruments to remove any accumulations of rust or scale.
McDonnell & Miller ©2006 ITT Corporation

8200 N. Austin Ave. Printed in U.S.A. 11-06 210210
Morton Grove, IL 60053
tel: 847-966-3700
fax: 847-966-9052
Installation & Maintenance 54 of 761
Instructions MM-251(A)
Series 750B-C3 Chamber

with 3 Probes
with 4 Probes
Features
• Cast Iron Body
• Sight Glass Tappings
• Gage Cock Tappings
• Stainless Steel Probes
• NEMA 4X Electrical Enclosure
• 250 psi Maximum Working Pressure
Remote Chamber
Designed for use with the Series 750B remote
mount control module to make a complete system
for level control in a boiler or other vessel.
! WARNING
ING
CAUT
ION • Before using this product read and understand instructions.
WARN
• Save these instructions for future reference.
• All work must be performed by qualified personnel trained in the proper application,
installation, and maintenance of plumbing, steam and electrical equipment and/or systems in
accordance with all applicable codes and ordinances.
• To prevent serious burns, the boiler must be cooled to 80˚F (27˚C) and the pressure must
be 0 psi (0 bar) before servicing.
• To prevent electrical shock, turn off the electrical power before making electrical
connections.
• This low water cut-off must be installed in series with all other limit and operating controls
installed on the boiler. After installation, check for proper operation of all the limit and
operating controls, before leaving the site.
• To prevent serious personal injury from steam blow down, connect a drain pipe to the
control opening to avoid exposure to steam discharge.
• To prevent a fire, do not exceed the switch contact rating.
Failure to follow this warning could cause property damage, personal injury or death.
55 of 761
SPECIFICATIONS
Maximum Water Temperature: 406˚F (208˚C)
All probes are cut to 9" length (229mm). Any of these probes can
be used as the low water cut-off level probe. The remaining
probes can be ‘cut to length’ in the field using a metal cutting saw
to achieve desired pump control or additional alarm activation.
C3 C4
No. of 3 4
Probes
A X X
B X X
C X X
D X
ELECTRODE
1/2" NPT A B
CONDUIT
CONNECTION 4-3/8"
1" (111)
1/2" NPT NPT
C D
2-1/2" 4-3/16"
PRE-CUT (63.5)
(106.4)
9" PROBE ROD
CUT AS
3-1/4"
1/2" NPT NEEDED
(82.5)
18-5/8"
(473)
11-1/2"
3-1/4" (292)
(82.5)
1/2" NPT
3-1/8"
1" NPT (79.4)
1" NPT
INSTALLATION –
TOOLS NEEDED:
One (1) pipe wrench, one (1) flathead screwdriver and/or 11/32" nut driver,
one (1) metal-cutting saw, and pipe sealing compound.
2
56 of 761
Chamber
If the control will be the primary low water fuel
cut-off, size the steam (top) and water (bottom)
equalizing pipe lengths so that the cut-off level
mark is 11/2” (38mm) below the boiler’s normal
water level, but not lower than the lowest safe
permissible water level, as determined by the
boiler manufacturer. Pump Off
OR Pump On
If the control will be the secondary low water Burner Off 2-5/16" (6mm)
fuel cut-off, size the steam (top) and water (bottom)
equalizing pipe lengths so that the cut-off level LOWER
EQUALIZING
mark is at or above the lowest safe permissible LINE
water level, as determined by the boiler

manufacturer.
Probes and Electrical Connections

• Each probe is made up of an electrode and a probe rod. Each
probe rod must be cut to an appropriate point of operation.
• A 9" rod will be positioned at the low water cut-off level.
Cut other rods for the pump operating probes to the desired
length.
• After cutting, secure the probe rod to the electrode and lock
the thread using the jamnut in the electrode sleeve. Insert the
probe into the chamber and tighten by hand. Then torque to
22-25 ft/lbs (30-34 N/m).
IMPORTANT: Do not use Teflon® tape or hardening type

thread sealant. Use of pipe dope or hi-temp boiler grease
is recommended.
• Refer to and follow all local codes and standards.

• Secure the electrical enclosure to the chamber with gasket
between. Note that the electrical connection opening can be
orientated in any of 4 positions. Tighten screws to 30 - 35 in/lbs
(3.4-4.0 N/m).
• Probe wire and conduit connections should be made following
accepted electrical practices.
NOTE
Wire must be 18 AWG stranded with glass braided silicone jacket
(UL 3071) suitable for high temperature (200˚C) service.
CUT-OFF
LEVEL
• Install electrical cover enclosure after making all connections
and after control has been tested for proper operation.
Tighten screws to 30 - 35 in/lbs (3.4-4.0 N/m).
3
57 of 761
MAINTENANCE
SCHEDULE:
• Blow down control as follows when boiler is Proper Blow-down Procedure:
in operation. (Using dual valve system)
– Daily if operating pressure is above 15 psi (1 bar) 1. With water in the boiler at its normal level, open
– Weekly if operating pressure is below 15 psi (1 bar) “Positive Shut-off Ball Valve”.
NOTE: More frequent blow-down may be neces- 2. Open “Throttling Gate Valve” slowly until drain
sary due to dirty boiler water and/or local codes. piping heats up and then open fully. Observe that
• Remove and inspect probes annually. Replace the water level starts falling in the gauge glass.
probes if they are worn, corroded or have an 3. Close “Throttling Gate Valve” after verifying that
excessive coating of scale or rust. the pump contacts have closed and the burner
• Inspect the chamber and equalizing piping contacts have opened thus shutting down the boiler.
annually. Remove all sediment and debris. Note: If this does not happen, immediately close
When blowing down a control at pressure, the blow all valves, turn off burner and correct the problem.
down valve should be opened slowly. The piping 4. Close “Positive Shut-off Ball Valve”.
needs to be warmed up and stagnant water in the
5. Observe that the water level returns to its normal
drain piping needs to be pushed out. Suddenly
level before leaving site.
opening a blow down valve causes steam to con-
dense, which creates water hammer. Damage to
components can occur when water hammer occurs
due to improper blow down piping.
For these reasons, McDonnell & Miller recommends
a dual valve blow-down system for each control.
! CAUTION
To prevent serious personal injury from steam
pipe blow down, connect a drain pipe to the
control opening to avoid exposure to steam
discharge.
Failure to follow this caution could cause
personal injury.
BALL VALVE DUAL

VALVES
FOR
BLOW
GATE VALVE DOWN
3500 N. Spaulding Avenue

Chicago, Illinois 60618
tel: 773 267-1600
fax: 773 267-0991
©2002 ITT Industries Inc.

Printed in U.S.A. 8-02 210016
08. Water Feeders 70-76• 3/6/07 1:48 PM Page 72
58 of 761
Liquid Level Controls McDonnell & Miller
Series RS – High Pressure Sensors & Probes

For Conductance Actuated Controls
Series RS Sensors
Series-RS-X-BR-1:
• NEMA 4X Enclosure
• For sophisticated multi-level control in tanks, boilers and
hydronic systems
• Remote sensors, which thread into the top of the boiler
or tank, are available with 1, 2, 3, 4 or 5 probes of
varying lengths that can easily be cut to desired set points High Pressure
Remote Sensor
• Probe lengths 12 - 72" (2.5 - 183cm) in 12" (2.5cm) Model RS-1-BR-1
increments (purchased separately)
• Control, remote sensor and probe(s) must be ordered
separately. Order Spacer S-4 when 2 or more probes
greater than 36" (914mm) will be used
• No blow down required
• Maximum Temperature 406°F (208°C)
• Maximum Pressure 250 psig (17.6 kg/cm) High Pressure
Remote Sensor
Model RS-2-BR-1
High Pressure Remote Sensors and Probes Model RS-3-BR-1
Model Part Weight

Number Number Description lbs. (kg)
RS-1-BR-1 179524 Remote Sensor; 1 level 1.7 (.8)
RS-2-BR-1 179525 Remote Sensor; 2 levels 3.3 (1.5)
RS-3-BR-1 179526 Remote Sensor; 3 levels 3.3 (1.5)
RS-4-BR-1 179527 Remote Sensor; 4 levels 4.0 (1.8) High Pressure
RS-5-BR-1 179528 Remote Sensor; 4 levels 4.3 (1.95) Remote Sensor
for non-metallic tanks Model RS-4-BR-1
Model RS-5-BR-1
See page 73 for probe rods.
Dimensions, in. (mm)

Remote Sensor A B C Remote Sensor D E F
1 Probe 1 NPT 111⁄16 (43) 1
⁄2 NPT 1 Probe 4 9⁄16 (116) 11⁄4 (32) 31⁄4 (83)
2 or 3 Probes 2 NPT 211⁄32 (59.5) 1
⁄2 NPT 2 or 3 Probes 37⁄8 (98) 4 (102) –
4 or 5 Probes 21⁄2 NPT 215⁄32 (63) 1
⁄2 NPT 4 or 5 Probes 4 (102) 4 (102) –
RS-1-HP
Series-RS High Pressure Remote Sensor:
• NEMA 1 Enclosure
• Maximum Temperature 406°F (208°C)
• Maximum Pressure 250 psig (17.6 kg/cm)
• For single sensor applications with high-pressure
Remote Sensor
environments. Requires additional probe rod. See page 73. Model RS-1-HP
Ordering Information Dimensions, in. (mm)

Model Part Weight Model K L M N
Number Number Description lbs. (kg) RS-1-HP 3
⁄8 NPT 7⁄8 (22) 3 (80) 33⁄8 (86)
RS-1-HP 176199 High pressure remote sensor 0.5 (.23) Remote Sensor
72
08. Water Feeders 70-76• 3/6/07 1:48 PM Page 73
59 of 761
Liquid Level Controls McDonnell & Miller
Sensors – High Pressure

with 3 Probes

with 4 Probes
Specifications Chamber
• NEMA 4X chamber enclosure and listed
• Maximum steam pressure 250 psig (17.6 kg/cm2)
• Designed for use with the Series 750B remote mount
control module to make a complete system for level
control in a boiler or other vessel. See page 78.
Ordering Information
Model Part Weight
750B-C3 176316 Cast iron chamber w/3 probes 26 (11.8) Remote Chamber
750B-C4 176317 Cast iron chamber w/4 probes 26 (11.8)
Probe Rods
• Stainless steel - Series 316 material
• Teflon® coated probe ends provide protection from false
signals [available on 24-72" (610 - 1829mm) probes]
• For use with RS sensors
Ordering Information
Model Part Weight
G-2-SS 179156 24" (610mm) Ground Probe 1.0 (.5)
G-5-SS 179159 60" (1524mm) Ground Probe 2.5 (1.1)
G-6-SS 179160 72" (1829mm) Ground Probe 3.0 (1.4)
P - 1⁄3 SS 176208 41⁄2" (114mm) Probe 0.5 (.23)
P-1-SS 179530 12" (305mm) Probe 0.5 (.23)
P-2-SS 179535 24" (610mm) Probe w/Teflon® 1.0 (.5)
P-5-SS 179550 60" (1524mm) Probe w/Teflon® 2.5 (1.1)
P-6-SS 179555 72" (1829mm) Probe w/Teflon® 3.0 (1.4) P-SS Probes G-SS Probes
Selecting control according to anticipated use, the sensor should be selected according to the number of probes required.
The probe rods are ordered separately according to length needed. The control, sensor and each probe rod must be
specified separately, using the appropriate model and part numbers.
73
60 of 761
3.3 Kunkle
953 Old US Hwy 70, Black Mountain, NC 28711 USA
www.kunklevalve.com
Pressure Relief Valves
Installation and Operating Instructions 61 of 761
Pre-Installation Handling
Verification of Model and Service This pressure relief valve is designed to protect equipment from overpressure. The valve should be
Media/Capacity/Temperature/Pressure handled with care, not subjected to heavy shock loads, and protected to prevent contamination
Limits from getting inside. It should be installed correctly per A.S.M.E. Boiler & Pressure Vessel Code
(Reference attached Model requirements, where applicable. Failure to do so could result in property damage or serious injury
Description/Guide.) Verify the Model Number to personnel. When hoisting the valve into position for installation, care should be exercised so
on the tag against the Model Number of the that lifting straps do not contact the valve lift lever.
order. For European service, verify the "CE
Mark" tag is connected to the valve. Verify the Installation
Service Media, Capacity, and Temperature
Always wear proper safety equipment, including safety glasses and ear protection.
and Pressure Limits of the valve against the
1. Mount the valve in a vertical position so that the valve body is self-draining. If a body drain port
application. Please note the marked capacity
is provided, make sure it is open when required by the ASME code. Do not plug any bonnet
is based on Standard Temperature and
vent openings. The inlet piping should be as short as possible, with no elbows, and equal to or
Pressure conditions and is valid only for the
greater than the size of the pressure relief valve inlet connection. This will help to limit the inlet
service media noted on the catalog order
pressure drop to 3% or less when the valve is relieving.
guide. Adjustments to the capacity must be
2. When discharge piping is connected to valve outlet, make sure it is self-draining if a body drain
performed for different temperatures or
port is not used. The valve should not be connected to any discharge pipe that contains
service media, and are the responsibility of
pressure before the valve opens or to any pipe where the pressure build-up is greater than
the end user to determine.
10% of the set pressure when the valve is open and relieving.
Discharge piping, other than a short tailpipe, must be supported. For steam service, a drip pan
elbow or flexible connection between the valve and the pipe should be used to prevent
excessive pipe stress, due to thermal expansion, from being imposed on the valve body.
3. For threaded valves, to prevent sealing compound from entering and damaging the valve,
apply a small amount of pipe thread sealing compound to external threads only. Do not put
any sealing compound on the first thread or on any internal threads. To do so may cause the
sealing compound to enter the valve and cause seat leakage.
Do not use the valve body or bonnet for installing the valve in threaded connections. Use the
wrench flats provided to tighten the valve to the connecting pipe. Torque valve enough to
ensure a pressure-tight seal and do not overtighten. To do so may cause valve leakage.
4. For flanged valves, use new gaskets and tighten the mounting studs evenly.
5. Do not paint, lubricate or allow contaminates to enter or cover the interior or any working parts
of the valve.
6. Remove gag screw (if valve is so equipped) before system start up.
Operation
1. Maintain a system operating pressure at least 5 psig or 10% below the set pressure of the
valve, whichever is greater. Operating too close to the valve set pressure will cause seat
leakage and will shorten the time between valve maintenance.
2. Do not use the safety valve as a control valve to regulate system operating pressure. Excessive
operation will cause the seat to leak and will require more frequent valve maintenance.
3. ASME Section I and VIII valves equipped with lift levers are designed to be operated only when
the system pressure is 75% of set pressure or greater. ASME Section IV valves may be
operated at any set pressure. When hand operating the valve, hold it open long enough to
purge any foreign matter from the seat area. If a cable or wire is attached to the lift lever for
remote actuation, make sure the direction of pull is the same as it would be if the lever were
pulled directly by hand.
Maintenance
Maintenance should be performed on a regular basis. An initial inspection interval of 12 months is
recommended. Depending on the service conditions and the condition of the valve, the
inspection interval may be decreased or increased. Use only Kunkle parts for repair. Depending on
the local jurisdictional requirements where the valve is installed, repairs may have to be made by a
repair facility holding a VR stamp.
Kunkle Valve Division

953 Old US 70, Black Mountain, NC 28711 WARNING!
Removal of the seal wires or any attempt to adjust, repair or modify this product by non-VR
Certified personnel voids the product guarantee and may cause serious damage to equipment,
personal injury, and death. Kunkle Valve is not liable for any damage resulting from misuse or
misapplication of its products.
www.kunklevalve.com We reserve the rights to change the contents without notice KUKMC-6302-EN-0705
Rev E 05/24/2007
Kunkle Safety and Relief Products
Data Supplement
62 of 761
Data Supplement for Safety and Relief Products
Kunkle is either a trademark or registered trademark of Tyco International Services AG or its affiliates in
the United States and/or other countries. All other brand names, product names, or trademarks belong
to their respective holders.
Copyright © 2009 Tyco Flow Control. All rights reserved. KUKMC-0396-US-0906

Data Supplement
63 of 761
Contents
ASME Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Seat Tightness Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valve Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Sizing and Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Kunkle Industries, Inc. Terms and Conditions of Sales . . . . . . . . . . . . . . . . . . . . 13-15
All valve dimensions are for reference only.
ASME Codes
The ASME (American Society of Steam Boilers High Temperature Water to

Mechanical Engineers) boiler and Valve capacity must be selected to Steam Heat Exchanger
pressure vessel code requirements for prevent the boiler pressure from rising Valve must be set at a pressure not
overpressure protection as they relate to more than 5 psig [0.35 barg] above the greater than 15 psig [1.0 barg] and with
Kunkle products are as follows: MAWP. sufficient capacity to prevent the pressure
from rising more than 5 psig [0.35 barg]
ASME Section I Hot Water Boilers above the MAWP.
This code applies to boilers where steam Safety valve must be set to relieve at a
or other vapor is generated at a pressure pressure not greater than the MAWP of ASME Section VIII
greater than 15 psig [1.0 barg] and high the boiler. If more than one safety valve is This code applies to unfired pressure
temperature water boilers intended for used, the secondary valve(s) may be set vessels with an inside diameter larger than
operation at pressures exceeding 160 up to 6 psig [0.41 barg] above the MAWP 6 inches [130 mm] and designed for use
psig [11.03 barg] and/or temperatures for boilers with MAWPs up to and above 15 psig [1.0 barg]. Valve(s) must
exceeding 250°F [121°C]. including 60 psig [4.13 barg], and 5% for prevent the pressure from rising more than
boilers with MAWPs greater than 60 psig 10% or 3 psig [0.21 barg], whichever is
Boiler Pressure Accumulation [4.13 barg]. Capacity must be selected to greater, above the MAWP. For a single
No more than 6% above the highest prevent the pressure from rising more than valve installation, the set pressure may not
pressure at which any valve is set, or no 10% above the MAWP if one valve is used be greater than the MAWP. For multiple
more than 6% above MAWP. or 10% above the set pressure of the valve installations, the first valve cannot be
highest set valve if more than one valve set higher than the MAWP, but the other
Set Pressure is used. valves can be set up to 5% above the
The set pressure of a one-valve installation MAWP. The pressure rise for multiple valve
cannot be higher than the MAWP. The set Tanks/Heat Exchangers High installations can be 16% or 4 psig [0.27
pressure of the second or other valves in Temperature Water-to-Water barg], whichever is greater. When the
a multiple valve installation can be up to Heat Exchangers vessel is exposed to an external heat
3% above the MAWP. The complete Valve(s) must be set at a pressure not source, such as fire, the pressure rise can
range of valve settings for multiple valve greater than the MAWP and with sufficient be 21% above the MAWP.
installations cannot be greater than 10% capacity to prevent the pressure from
of the highest set pressure. For high increasing more than 10% above the
temperature water boilers, this 10% range Note
MAWP.
may be exceeded. Information stated above is based on latest Code
Steam to Hot Water Supply at time of publication.
ASME Section IV Valve must be at least 1" [25 mm]
This code applies to steam boilers diameter with set pressure not greater
operating at pressures not greater than than MAWP of the tank.
15 psig [1.0 barg] and hot water heating
boilers operating at pressures not greater
than 160 psig [11.03 barg] and/or
temperatures not greater than 250°F
[121°C].
Copyright © 2009 Tyco Flow Control. All rights reserved. KUKMC-0396

2
Data Supplement
64 of 761
ASME Code Requirements
National Board Power Boiler - Section I - Code “V”

Kunkle valves are manufactured at
facilities that meet the manufacturing Set Pressure Set Pressure Blowdown Overpressure
requirements of the ASME Sections I, IV, psig [barg] Tolerance
and VIII codes for pressure relief valves.
Valves that have the relief capacity 15 - 66 [1.03 - 4.55] 2 - 4 psig [0.14 - 0.28 barg]
certified by the National Board of Boiler 67 - 100 [4.62 - 6.90] 2 psi [0.14 barg] - 6%
and Pressure Vessel Inspectors bear the 101 - 250 [6.96 - 17.24] 2% - 6% See Note below1
following code symbol stamp on the 251 - 374 [17.31 - 25.79] 2% - 15 psig [1.03 barg]
nameplate and the letters NB. Most 375 - 1000 [25.86 - 68.96] 2% - 4%
Kunkle Valves have NB certified 15 - 69 [1.03 - 4.75] ±2 psig [±0.14 barg]
capacities. 70 - 300 [4.83 - 20.69] ±3 %
301 - 1000 [20.95 - 68.96] ±10 psig [±0.69 barg]
Code Stamps
1001 and up [69.03 and up] ±1%
“V” - applies to all ASME Note

Section I valves
1. Overpressure would be 2 psig [0.14 barg] for pressures between 15 - 70 psig [1.03 - 4.83 barg].
Pressures above 70 psig [4.83 barg] would have an overpressure of 3%.
“HV” - applies to all ASME

Heating Boiler - Section IV - Code “HV”
Section IV valves
Set Pressure Set Pressure Blowdown Overpressure
psig [barg] Tolerance
±2 psig 2 - 4 psig 5 psig
“UV” - applies to all ASME 15 psig Steam 15 [1.0]
[±0.14 barg] [0.14 - 0.28 barg] [0.34 barg]
Section VIII valves
±3 psig
Hot Water 15 - 60 [1.0 - 4.14] N/A 10%
[±0.21 barg]
Hot Water 61 - 160 [4.20 - 11.0] ±5% N/A 10%
Note
Unfired Pressure Vessel - Section VIII - Code “UV”
Information stated above is based on latest Code
at time of publication. Set Pressure Set Pressure Blowdown Overpressure
psig [barg] Tolerance
15 - 30 [1.0 - 2.07 barg] ±2 psig [±0.14 barg] N/A 3 psig [0.21 barg]
31 - 70 [2.14 - 4.83 barg] ±2 psig [±0.14 barg] N/A 10%
71 and up [4.90 barg and up] ±3% N/A 10%
Non-code Set Pressure Tolerance

Set Pressure, psig [barg] Set Pressure Tolerance, psig [barg]
Below 15 psig [1.0 barg] to 10 psig [0.69 barg] +/- 2.0 psig [± 0.14 barg]
Below 10 psig [0.69 barg] to 5.0 psig [0.34 barg] +/- 1.0 psig [± 0.07 barg]
Below 5.0 psig [0.34 barg] +/- 0.5 psig [± 0.03 barg]
Below 0.0" Hg [0.0 mb] to 10" Hg [337 mb] +/- 1.0" Hg [± 33.7 mb]
Below 10" Hg [337 mb] to 20" Hg [674 mb] +/- 2.0" Hg [± 67.4 mb]
Below 20" Hg [674 mb] +/- 4.0" Hg [± 134.8 mb]

3
Data Supplement
65 of 761
Seat Tightness Performance Standards
Kunkle Factory Standard

Code Section Service Performance Standard
No visible leakage for 15 seconds at 20% below nameplate
I and VIII Steam set pressure or at 5 psig [0.35 barg] below nameplate
set pressure, whichever is greater.
No audible leakage for 15 seconds at 20% below nameplate
VIII Air/Gas set pressure or at 5 psig [0.35 barg] below name plate
No visible leakage for 30 seconds at 20% below nameplate
IV and VIII Liquid set pressure or at 5 psig [0.35 barg] below name plate
IV Steam No visible leakage for 30 seconds at 12 psig [0.83 barg].
API-527 Standard
Model Code Service Performance Standard
Section
API 527 - No visible leakage for 1 minute at 10%
300, 600
I and VIII Steam below nameplate set pressure or 5 psig [0.35 barg]
900, 6000
below nameplate set pressure, whichever is greater.
6000 (O-ring seat) API 527 - Bubble tight for 1 minute at 10% below
916/917 (soft seat) VIII Air/Gas1 nameplate set pressure or 5 psig [0.35 barg] below
918/919 (soft seat) nameplate set pressure, whichever is greater.
API 527 - D and E orifice: 40 bubbles/min,
910/912 F through J orifice: 20 bubbles/min at 10% below
VIII Air/Gas1
911/913 nameplate set pressure or 5 psig [0.35 barg] below
nameplate set pressure, whichever is greater.
API 527 - No leakage for 1 minute at 10% below
916/917 (soft seat)
VIII Liquid nameplate set pressure, or 5 psig [0.35 barg] below
918/919 (soft seat)
nameplate set pressure, whichever is greater.
API 527 - 10 cc/h for inlet sizes less than 1" or
10 cc/h/in of inlet valve size for inlet sizes 1" and
910/912
VIII Liquid larger at 10% below nameplate set pressure or
911/913
5 psig [0.35 barg] below nameplate set pressure,
whichever is greater.
Note
1. API 527 is not available on air service for:
• Plain lever “J” orifice
(Model 900 and Model 6000)
• Plain lever (Model 900) above 444 psig
[30.6 barg] set pressure.

4
Data Supplement
66 of 761
Valve Selection Guide

(For specific minimum/maximum temperature/pressure ranges refer to individual product sections.)
Steam (ASME Section I - Power Boilers)

Model(s) Material Connections Inlet Size Range Min/Max1 Press. Min/Max Temp.
Body Trim NPT FLGD in [mm] psig [barg] °F [°C]
300, 600 CS SS X 11/4 - 6" [31.75 - 152.4] 15/1000 [1.0/69] -20/800 [-29/427]
920, 921, 927
CS SS X 1/ 2 - 2" [12.7 - 50.8] 15/1400 [1.0/96.5] -20/800 [-29/427]
(special use – 10% blowdown)
6010, 6021, 6121, 6182 1/2
Bronze Brass X - 21/2" [12.7 - 63.5] 3/250 [0.69/17.2] -60/406 [-51/208]
6186, 6221, 6283
6030, 6130, 6230 Bronze SS X 1/ 2 - 2 1/ 2" [12.7 - 63.5] 3/300 [0.69/20.7] -60/425 [-51/219]
6252 Iron SS X X 11/2 - 6" [38.1 - 152.4] 10/250 [0.69/17.2] -20/406 [-29/208]
Steam (ASME Section VIII - Unfired Steam Equipment)

1 and 2 Bronze Brass X 1/2 - 1" [12.7 - 25.4] 5/250 [0.34/17.2] -60/406 [-51/208]
264, 265 CS SS X 1/ 2 - 1" [12.7 - 25.4] 4/3300 [0.28/227.6] -20/750 [-29/399]
266, 267 SS SS X 1/2 - 1" [12.7 - 25.4] 4/3300 [0.28/227.6] -20/750 [-29/399]
300, 600 CS SS X 11/4 - 6" [31.75 - 152.4] 15/1000 [1.0/69] -20/750 [-29/399]
910 CS SS X O 1/2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -20/800 [-29/427]
911 SS SS X O 1/ 2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/800 [-195/427]
912 Bronze Brass X 1/2 - 2" [12.7 - 50.8] 3/250 [0.21/17.2] -320/406 [-195/208]
913 Bronze SS X 1/ 2 - 2" [12.7 - 50.8] 3/300 [0.21/20.7] -320/425 [-195/219]
6010, 6021, 6121, 6182, 1/2
Bronze Brass X - 21/2" [12.7 - 63.5] 3/250 [0.21/17.2] -60/406 [-51/208]
6186, 6221, 6283
6030, 6130, 6230 Bronze SS X 1/ 2 - 2 1/ 2" [12.7 - 63.5] 3/300 [0.21/20.7] -60/425 [-51/219]
6252 Iron SS X X 1 1/ 2 - 6" [38.1 - 152.4] 10/250 [0.69/17.2] -20/406 [-29/208]
Steam (ASME Section IV - Low Pressure Steam Heating Boilers)

930 Iron Bronze X 2 - 3" [50.8 - 76.2] 15 only [1.0] 250 only [122]
6933, 6934 Bronze Brass X 1/ 2 - 2" [12.7 - 50.8] 15 only [1.0] 250 only [122]
6935 Bronze SS X 1/2 - 2" [12.7 - 50.8] 15 only [1.0] 250 only [122]
6254 Iron SS X X 1 1/ 2 - 6" [38.1 - 152.4] 15 only [1.0] 250 only [122]
Steam (Non-code)2
40R, 40RL SS SS X 1/ 2 - 3/ 4" [12.7 - 19.05] 1/400 [0.07/27.6] -60/850 [-51/454]
X = Standard O = Optional
Notes
1. Set pressures less than 15 psig [1.0 barg] are
non-code only.
2. See also ASME Section VIII steam valves for
non-code steam applications.

5
Data Supplement
67 of 761

Air/Gas (ASME Section VIII)

Model(s) Material Connections Inlet Size Range Min/Max3 Press. Min/Max4 Temp.
1 and 2 Brass Brass X 1/2 - 1" [12.7 - 25.4] 5/250 [0.34/17.2] -60/406 [-51/208]
30 Brass Brass X 1/ 4" [6.35] 60/4000 [4.1/275.8] 20/300 [-6.6/150]
189 Bronze SS X 1/2 - 3/4" [12.7 - 19.05] 1000/2500 [69/344.8] -320/350 [-195/177]
264, 265 CS SS X 1/ 2 - 1" [12.7 - 25.4] 4/3300 [0.28/227.6] -20/750 [-29/399]
266, 267 SS SS X 1/2 - 1" [12.7 - 25.4] 4/3300 [0.28/227.6] -20/750 [-29/399]
300, 600 CS SS X 11/4 - 6" [31.75 - 152.4] 15/1000 [1.0/69] -20/800 [-195/427]
330 (Kynar® seat) Aluminum SS X 1/4" [6.35] 1000/5500 [69/379.3] -20/185 [-29/85]
330S, 333S (Kynar® seat) Aluminum SS 1/ 4" [6.35] 2000/6500 [138/448.3] -20/185 [-29/85]
337 Iron Bronze X 2 - 3" [50.8 - 76.2] 1/60 [0.07/4.14] -20/406 [-29/208]
338 Aluminum Brass X 2" [50.8] 5/30 [0.3/2.07] -30/400 [-34/204]
363 Bronze SS X 1/2 - 3/4" [12.7 - 19.05] 50/1000 [3.4/69] -320/350 [-195/177]
389 SS SS X 1/ 2 - 3/ 4" [12.7 - 19.05] 50/2500 [3.4/172.4] -320/350 [-195/177]
541 (Buna disc), 542 1/4
Brass Brass X - 1/2" [6.35 - 12.7] 3/400 [0.21/27.6] -20/400 [-29/204]
(Viton® disc), 548 (SS disc)
910, 916 (soft seat)4 CS SS X O 1/ 2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -20/800 [-29/427]
911, 917 (soft seat)4 SS SS X O 1/2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/800 [-195/427]
912, 918 (soft seat)4 Bronze Brass X 1/ 2 - 2" [12.7 - 50.8] 3/300 [0.21/20.7] -320/406 [-195/208]
913, 919 (soft seat)4 Bronze SS X 1/2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/425 [-195/219]
6010, 6121, 6182
Bronze Brass X 1/ 2 - 2 1/ 2" [12.7 - 63.5] 3/250 [0.21/17.2] -60/406 [-51/208]
6186, 6221, 62831
6030, 6130, 6320 Bronze SS X 1/2 - 21/2" [12.7 - 63.5] 3/300 [0.21/20.7] -60/425 [-51/219]
6252 Iron SS X X 11/2 - 6" [38.1 - 152.4] 10/250 [0.69/17.2] -20/406 [-29/208]
Air/Gas2 (Non-code)
230 (Kynar® seat) Aluminum SS X 1/4" [6.35] 300/1500 [20.7/103.4] -20/185 [-29/85]
803 (Kynar® seat) Aluminum SS X 1/ 4" [6.35] 1000/6000 [69/413.8] -20/185 [-29/85]
818 (Teflon® seat) CS SS/Brass X 2" [50.8] 120/150 [8.3/10.3] -20/300 [-29/150]
Air/Gas (Vacuum) in Hg [mm Hg]

215V Iron Bronze X 2 - 3" [50.8 - 76.2] 2/29 [50/736] -20/406 [-29/208]
910, 916 (soft seat)4 CS SS X O 1/ 2 - 2" [12.7 - 50.8] 6/29 [152/736] -20/800 [-29/427]
911, 917 (soft seat)4 SS SS X O 1/2 - 2" [12.7 - 50.8] 6/29 [152/736] -320/800 [-195/427]
912, 918 (soft seat)4 Bronze Brass X 1/ 2 - 2" [12.7 - 50.8] 6/29 [152/736] -320/406 [-195/208]
913, 919 (soft seat)4 Bronze SS X 1/ 2 - 2" [12.7 - 50.8] 6/29 [152/736] -320/425 [-195/219]
Notes
1. Soft seat available on some models. 3. Set pressures less than 15 psig [1.0 barg] are
2. See also Section VIII air valves for non-code only.
non-code air/gas applications. 4. Temperature limits of soft seats determine
operating limits of valve.

6
Data Supplement
68 of 761

Liquid (ASME Section IV - Hot Water Boilers)

Model(s) Material Connections Inlet Size Range Min/Max1 Press. Min/Max2 Temp.
537 (soft seat) Iron/Bronze Brass X 3/ 4 - 2" [19.05 - 50.8] 15/160 [1.0/11] -20/250 [-29/121]
Liquid (ASME Section VIII)

910, 916 (soft seat)2 CS SS X O 1/2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -20/800 [-29/427]
911, 917 (soft seat)2 SS SS X O 1/ 2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/800 [-195/427]
912, 918 (soft seat)2 Bronze Brass X 1/2 - 2" [12.7 - 50.8] 3/300 [0.21/20.7] -320/406 [-195/208]
913, 919 (soft seat)2 Bronze SS X 1/ 2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/425 [-195/219]
Liquid (Non-code)
19, 20 Bronze Bronze X O 1/2 - 3" [12.7 - 76.2] 1/300 [0.07/20.7] -60/406 [-51/208]
19M, 20M Bronze SS X O 21/2 - 3" [63.5 - 76.2] 1/500 [0.07/34.5] -60/406 [-51/208]
71S Iron SS X 1/2 - 2" [12.7 - 50.8] 1/250 [0.07/17.2] -20/406 [-29/208]
171, 171P CS SS X 1/ 2 - 2" [12.7 - 50.8] 1/400 [0.07/27.6] -20/550 [-29/288]
171S SS SS X 1/2 - 2" [12.7 - 50.8] 1/400 [0.07/27.6] -20/550 [-29/288]
91 Iron Bronze X X 1 1/ 2 - 6" [38.1 - 152.4] 5/400 [0.34/27.6] -20/406 [-29/208]
218,228 Iron Bronze X 3, 4, and 6" [76.2 - 152.4] 60/200 [4.1/13.8] -20/406 [-29/208]
140 SS SS X 3/ 8 - 1/ 2 " [9.5 - 12.7] 10/300 [0.69/20.7] -60/406 [-51/208]
264, 265 CS SS X 1/2 - 1" [12.7 - 25.4] 4/3300 [0.28/227.6] -20/750 [-29/399]
266, 267 SS SS X 1/ 2 - 1" [12.7 - 25.4] 4/3300 [0.28/227.6] -20/750 [-29/399]
910, 916 (soft seat)2 CS SS X O 1/2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -20/800 [-29/427]
911, 917 (soft seat)2 SS SS X O 1/ 2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/800 [-195/427]
912, 918 (soft seat)2 Bronze Brass X 1/2 - 2" [12.7 - 50.8] 3/300 [0.21/20.7] -320/406 [-195/208]
913, 919 (soft seat)2 Bronze SS X 1/ 2 - 2" [12.7 - 50.8] 3/1400 [0.21/96.5] -320/425 [-195/219]
Liquid - Underwriters Laboratories (UL) For Oil Services

200A Bronze Brass X 3/4 - 11/2" [19.05 - 38.1] 1/200 [0.07/13.8] -60/406 [-51/208]
200H Bronze SS X O 3/ 4 - 2" [19.05 - 50.8] 1/200 [0.07/13.8] -60/406 [-51/208]
Liquid - Underwriters Laboratories (UL) and Factory Mutual Research (FM) For Fire Pump Water Relief
218, 228 Iron Bronze X X 3, 4 and 6" [76.2 - 152.4] 60/200 [4.1/13.8] -20/406 [-29/208]
918 (soft seat)2, 3 Bronze Brass X 3/ 4 - 1" [19.05 - 25.4] 60/250 [4.1/17.2] -20/406 [-29/208]
Other - Drip Pan Elbow

299 Iron N/A X X 2 - 8" [50.80 - 203.2] N/A N/A -20/406 [-29/208]
Notes
1. Set pressures below 15 psig [1.0 barg] are non-code only.
2. Temperature limits of soft seats determine operating limits of valve.
3. FM Approved only.

7
Data Supplement
69 of 761
Sizing and Selection
1. For Steam 3. For Air-Gas

A. To obtain lb/h for sizing, divide BTU A. Valves for cold or cryogenic temperatures
(max. firing rate) by 1000. (below -20°F [-29°C]) must be made from
bronze, brass, or stainless steel to avoid
To obtain kg/h for sizing, divided KW
the brittleness found in other materials at
by 0.6461.
these temperatures. Many valves are
2. For Liquid offered with cryogenic materials as an
option/extra.
A. Liquid valves must be sized closely to
actual flow; oversizing causes “chatter,”
undersizing causes high pressure.
B. Liquid relief valves are normally
capacity rated at 25% overpressure.
Refer to Catalog capacity correction
tables for 10% overpressure. ASME
Section VIII Liquid Valves are rated at
10% overpressure.
Sizing – Gas Flow Conversions
If flow is expressed in actual volume, such as Conversions from one volumetric flow rate to
cfm (cubic feet per minute) or acfm (actual another or to weight flow (and vice versa) may
cfm) as is often done for compressors, where only be done when the volumetric flow is
the flow is described as displacement or expressed in the standard conditions shown
swept volume, the flow may be converted to above. If flows are expressed at temperature
scfm as follows (or from flow expressed in or pressure bases that differ from those listed
m3/h to Nm3/h). above, they must first be converted to the
standard base.
Inch-Pound Units Metric Units
( )cfm 14.7 + p 520 1.013 + p 273

scfm = or x –––––––– x ––––––– Nm3/h = m3/h = x ––––––––– x –––––––
acfm 14.7 460 + t 1.013 273 + t
Where: Where:
p= gauge pressure of gas or vapor in p= gauge pressure of gas or vapor in

psig barg
t = temperature of gas or vapor in °F t = temperature of gas or vapor in °C
Conversion Formulas
Degrees Fahrenheit (°F) Degrees Celsius (°C)
F + 459.67 = R (Rankine) C + 273.15 = K (Kelvin)
(F - 32) x 0.556 = C (Celsius) (C x 1.8) + 32 = F (Fahrenheit)

8
Data Supplement
70 of 761
Sizing
Air and Gas Temperature Correction Factors

Temperature Tc Temperature Tc Temperature Tc
°F [°C] °F [°C] °F [°C]
0 [-18] 1.062 140 [60] .931 380 [193] .787
10 [-12] 1.051 160 [71] .916 400 [204] .778
20 [-7] 1.041 180 [82] .902 420 [216] .769
30 [-1] 1.030 200 [93] .888 440 [227] .760
40 [4] 1.020 220 [104] .874 460 [238] .752
50 [10] 1.009 240 [116] .862 480 [249] .744
60 [16] 1.000 260 [127] .849 500 [260] .737
70 [21] .991 280 [138] .838 550 [288] .718
80 [27] .981 300 [149] .828 600 [316] .701
90 [32] .972 320 [160] .817 650 [343] .685
Note
100 [38] .964 340 [171] .806 700 [371] .669
1. For temperatures other than 60°F [15.6°C] at
valve inlet, multiply SCFM by Tc. 120 [49] .947 360 [182] .796 750 [399] .656
Physical Properties
Gas or Vapor M k C
Molecular Specific Gas Constant
Weight Heat Ratio
Air 28.97 1.40 356
Ammonia, Anhydrous 17.03 1.31 348
Butane-n (Normal Butane) 58.12 1.09 326
Carbon Dioxide 44.01 1.29 346
Carbon Monoxide 28.01 1.40 356
Dowtherm A 165.00 1.05 321
Dowtherm E 147.00 1.00 315
Ethane 30.07 1.19 336
Ethylene (Ethene) 28.05 1.24 341
Helium 4.00 1.67 378
Hydrogen 2.02 1.41 357
Methane 16.04 1.31 348
Natural Gas (specific gravity = 0.60) 17.40 1.27 344
Nitrogen 28.01 1.40 356
Octane 114.23 1.05 321
Oxygen 32.00 1.40 356
Propane 44.10 1.13 330
Steam 18.02 1.31 348

9
Data Supplement
71 of 761
Sizing
Steam Super Heat Correction Factor, Ks (continued on page 11)

For capacities of super heated steam, multiply saturated steam capacity by correction factor below.
Set Saturated Steam Temperature in, °F [°C]

Pressure Steam Temp 340 360 380 400 420 440 460 480 500 520 540
psig [barg] °F [°C] [171] [182] [193] [204] [216] [227] [238] [249] [260] [271] [282]
15 [1.0] 250 [121.1] 0.99 0.99 0.98 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91
20 [1.4] 259 [126.1] 0.99 0.99 0.98 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91
40 [2.8] 287 [141.7] 1.00 0.99 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91
60 [4.1] 308 [153.4] 1.00 0.99 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91
80 [5.5] 324 [162.2] 1.00 1.00 0.99 0.99 0.98 0.97 0.96 0.94 0.93 0.92 0.91
100 [6.9] 338 [170.9] 1.00 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92
120 [8.2] 350 [177.0] 1.00 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92
140 [9.6] 361 [182.6] 1.00 1.00 0.99 0.98 0.96 0.95 0.94 0.93 0.92
160 [11.0] 371 [188.6] 1.00 0.99 0.98 0.97 0.95 0.94 0.93 0.92
180 [12.8] 380 [193.0] 1.00 0.99 0.98 0.97 0.96 0.95 0.93 0.92
200 [13.7] 388 [198.0] 1.00 0.99 0.99 0.97 0.96 0.95 0.93 0.92
220 [15.1] 395 [201.0] 1.00 1.00 0.99 0.98 0.96 0.95 0.94 0.93
240 [16.5] 403 [205.7] 1.00 0.99 0.98 0.97 0.95 0.94 0.93
260 [17.9] 409 [209.4] 1.00 0.99 0.98 0.97 0.96 0.94 0.93
280 [19.2] 416 [213.3] 1.00 1.00 0.99 0.97 0.96 0.95 0.93
300 [20.6] 422 [217.0] 1.00 0.99 0.98 0.96 0.95 0.93
350 [24.1] 436 [224.3] 1.00 1.00 0.99 0.97 0.96 0.94
400 [27.5] 448 [231.0] 1.00 0.99 0.98 0.96 0.95
450 [31.0] 460 [238.0] 1.00 0.99 0.97 0.96
500 [34.4] 470 [243.0] 1.00 0.99 0.98 0.96
550 [37.9] 480 [249.0] 1.00 0.99 0.97
600 [41.3] 489 [253.4] 1.00 0.99 0.98
650 [44.8] 497 [258.0] 1.00 0.99
700 [48.2] 506 [263.3] 1.00 0.99
750 [51.7] 513 [267.7] 1.00 1.00
800 [55.2] 520 [271.3] 1.00
850 [58.6] 527 [275.0] 1.00
900 [62.1] 533 [278.4] 1.00
950 [65.5] 540 [282.2]
1000 [69.0] 546 [285.6]

10
Data Supplement
72 of 761
Sizing
Steam Super Heat Correction Factor, Ks

For capacities of super heated steam, multiply saturated steam capacity by correction factor below.
Set Saturated Steam Temperature in, °F [°C]

Pressure Steam Temp 560 580 600 620 640 660 680 700 720 740 760
psig [barg] °F [°C] [293] [304] [316] [327] [338] [349] [360] [371] [382] [393] [404]
15 [1.0] 250 [121.1] 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84 0.83 0.83 0.82
20 [1.4] 259 [126.1] 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84 0.83 0.83 0.82
40 [2.8] 287 [141.7] 0.90 0.89 0.88 0.87 0.87 0.86 0.85 0.84 0.84 0.83 0.82
60 [4.1] 308 [153.4] 0.90 0.89 0.88 0.87 0.87 0.86 0.85 0.84 0.84 0.83 0.82
80 [5.5] 324 [162.2] 0.90 0.89 0.89 0.88 0.87 0.86 0.85 0.84 0.84 0.83 0.82
100 [6.9] 338 [170.9] 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.85 0.84 0.83 0.82
120 [8.2] 350 [177.0] 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.85 0.84 0.83 0.82
140 [9.6] 361 [182.6] 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.85 0.84 0.83 0.82
160 [11.0] 371 [188.6] 0.91 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84 0.83 0.82
180 [12.8] 380 [193.0] 0.91 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84 0.83 0.82
200 [13.7] 388 [198.0] 0.91 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84 0.83 0.83
220 [15.1] 395 [201.0] 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.84 0.83
240 [16.5] 403 [205.7] 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.84 0.83
260 [17.9] 409 [209.4] 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.85 0.84 0.83
280 [19.2] 416 [213.3] 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.85 0.84 0.83
300 [20.6] 422 [217.0] 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84 0.83
350 [24.1] 436 [224.3] 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83
400 [27.5] 448 [231.0] 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.84
450 [31.0] 460 [238.0] 0.94 0.93 0.92 0.91 0.89 0.88 0.87 0.86 0.86 0.85 0.84
500 [34.4] 470 [243.0] 0.94 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84
550 [37.9] 480 [249.0] 0.95 0.94 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84
600 [41.3] 489 [253.4] 0.96 0.94 0.93 0.92 0.90 0.89 0.88 0.87 0.86 0.85 0.84
650 [44.8] 497 [258.0] 0.97 0.95 0.94 0.92 0.91 0.90 0.89 0.87 0.86 0.86 0.85
700 [48.2] 506 [263.3] 0.97 0.96 0.94 0.93 0.91 0.90 0.89 0.88 0.87 0.86 0.85
750 [51.7] 513 [267.7] 0.98 0.96 0.95 0.93 0.92 0.90 0.89 0.88 0.87 0.86 0.85
800 [55.2] 520 [271.3] 0.99 0.97 0.95 0.94 0.92 0.91 0.90 0.88 0.87 0.86 0.85
850 [58.6] 527 [275.0] 0.99 0.98 0.96 0.94 0.93 0.92 0.90 0.89 0.88 0.87 0.86
900 [62.1] 533 [278.4] 1.00 0.99 0.97 0.95 0.93 0.92 0.90 0.89 0.88 0.87 0.86
950 [65.5] 540 [282.2] 1.00 0.99 0.97 0.95 0.94 0.92 0.91 0.89 0.88 0.87 0.86
1000 [69.0] 546 [285.6] 1.00 0.99 0.98 0.96 0.94 0.93 0.91 0.90 0.89 0.87 0.86

11
Data Supplement
73 of 761
General Information
Definition of Units Operating Pressure Safety Relief Valve Pointers

GPM - Gallons per minute (liquid flow) The gauge pressure at which a pressure vessel 1. ASME Codes require that valves for air,
is maintained in normal operation. steam and water service over 140°F [60°C]
SCFM - Standard cubic feet per minute
have test levers.
(air or gas flow) Overpressure
The permitted increase in pressure developed 2. Steam safety valves may be used for air
#/h - Pounds per hour (steam flow) after the valve has opened. service but not vice versa. Liquid valves
Nm3/h - Normal cubic meter per hour should be used on liquid only.
Pre-open/Warn
BHP - Horsepower (energy) An audible or visual discharge at a pressure 3. Safety relief valves should be installed
slightly lower than the set pressure. Warns the vertically with the drain holes open or piped
Kv - Flow Coefficient operator that the valve is about to cycle. to a convenient location.
F - ° Fahrenheit (temperature) Set Pressure 4. The inlet to and outlet from a safety relief
The gauge pressure at which a safety valve valve must be at least as large as the inlet
C - ° Centigrade (temperature)
visibly and audibly opens or a setting at which a and outlet connections of the pressure relief
Hg - Inches of mercury (pressure) relief valve discharges a 1" long, unbroken valve.
stream of liquid.
psig - Pounds per square inch, gauge Maintenance
(pressure) Safety and Relief Valves 1. Develop a regular program of visual
psia - Pounds per square inch, The terms “safety valve” and “relief valve” are inspection, looking for clogged drains and
absolute (pressure) frequently used interchangeably. This is discharge pipe, dirt build-up in and around
satisfactory to the extent that both safety and the valve seat and broken or missing parts
barg - (pressure) bar, gauge relief valves of the spring-loaded model are or seals.
similar in external appearance and both serve
Definitions and Commonly the broad general purpose of limiting media 2. Test the valve every six to 12 months
Used Terms (liquid and gaseous) pressures by discharging (depending on plant’s age and condition)
some of the pressurized liquid or gas. Some preferably by raising the system pressure to
Blowdown the valve’s set pressure or operating the
authorities restrict “safety valves” to those
The difference in pressure between the opening hand lever. Note: Minimum of 75% of set
installed on boilers, superheaters, and fired
pressure and reclose pressure. May be required before using lever to test.
vessels - all others being classified as relief
expressed in percent of set pressure or “psig.”
valves. We prefer, however, to briefly define 3. Do not paint, oil, or otherwise cover any
Drag them as follows: interior or working parts of any safety valve.
Occurs when a valve does not close completely They do not require any lubrication or
Safety valves are used with gases - which
after popping and remains partly open until the protective coating to work properly.
include air and steam. Their design always
pressure is further reduced.
includes a huddling chamber which utilizes When safety/relief valves require repair, service
Lift the expansion forces of these gases to adjustments, or set pressure changes, work
The distance between the seat and disc effect quick opening (popping) and closing shall be accomplished by the manufacturer, or
seating surfaces when the valve is open. actions. The difference between the opening holders of “VR” stamp.
and closing pressures is termed
MAWP “blowdown,” and for steam safety valves
Maximum allowable working pressure. This blowdown limitations are defined in the
data is found on the pressure vessel nameplate ASME Power Boiler Code.
and is the maximum pressure at which the
lowest set safety valve must be set (stamped). Relief valves are normally used for
liquid service, although safety valves may
also be used. Ordinarily, relief valves do not
have an accentuated huddling chamber or a
regulator ring for varying or adjusting
blowdown. Therefore, they operate with
more of a modulating action as pressure
increases or decreases.

12
Data Supplement
74 of 761
Terms and Conditions of Sales
1. Offer or Acceptance. If this document automatically escalate at the rate of two installation by the first user of such goods or
constitutes an offer to sell by Seller percent [2%] per month for the duration of eighteen (18) months from date of shipment
(sometimes referred to as “Tyco Valves & the delay or in an amount equal to Seller’s from the factory, whichever period shall be
Controls LP, Black Mountain (Kunkle)”), increased cost, whichever is greater. first completed. The warranty hereunder
Seller’s offer is expressly subject to Buyer’s granted does not apply to products or
3. Drawings. If drawings are submitted
acceptance of all the terms and conditions components (such as electric or pneumatic
herewith they are submitted only to show the
contained herein and no other, unless mechanisms) manufactured by other
general style, arrangement and approximate
otherwise mutually agreed to by both Seller companies or to any goods manufactured by
dimensions of the goods offered. No work is
and Buyer in a writing signed by both Tyco Valves & Controls LP, Black Mountain
to be based on drawings unless the
parties, and any response by Buyer which (Kunkle) that have been subjected to misuse,
drawings are certified. Dimensional drawings
constitutes additional or different terms shall improper installation, improper storage or
certified by Seller will be furnished if agreed.
not operate as an acceptance if such protection prior to installation or use,
In no event will manufacturing or proprietary
acceptance would vary, delete or add to the negligence by Buyer or user, accident,
drawings be supplied.
terms and conditions contained herein. If this corrosion, chemical attack or misapplication,
document constitutes an acceptance by 4. Risk of Loss. Buyer bears the risk of loss or that have been modified or repaired by
Seller of Buyer’s offer to buy the goods or for damage to or destruction of the goods unauthorized persons. Tyco Valves &
services specified on the face hereof, such from and after the time same said goods are Controls LP, Black Mountain’s (Kunkle)
acceptance is expressly subject to all the delivered either to the carrier for shipment to obligation and Buyer’s remedy under this
terms and conditions contained herein and Buyer or to the Buyer, whichever occurs first, warranty are limited to: (a) correction, repair,
no others, unless otherwise mutually agreed and regardless of whether or not Buyer may or replacement, at Tyco Valves & Controls LP,
to by both Seller and Buyer in a writing have the right to reject or revoke acceptance Black Mountain’s (Kunkle) option, of any
signed by both parties. Any of Buyer’s of said goods. defective unit of goods or (b) refund to Buyer
proposed terms and conditions which are in of the purchase price allocable to the
addition to or different from those contained 5. Shipment. If delivery specified is F.O.B. defective unit of goods if Tyco Valves &
herein are hereby objected to and shall be of Seller’s plant with freight allowed, Buyer shall Controls LP, Black Mountain (Kunkle) is
no effect. Buyer will in any event be deemed pay to Seller, in addition to the purchase unable to repair, replace or correct such
to have assented to all terms and conditions price, any and all transportation charges defect in a reasonable time. Tyco Valves &
contained herein if any part of the goods sold (including insurance). Controls LP, Black Mountain’s (Kunkle)
hereunder are accepted. 6. Taxes. In addition to any prices specified liability under this warranty is conditioned
herein, Buyer shall pay the gross amount of upon Buyer giving Tyco Valves & Controls LP,
2. Shipping Dates. The shipping dates, if any,
any present or future sales, use, excise, Black Mountain (Kunkle), immediate (but in
set forth herein are approximate and are not
value-added, or other tax (whether federal, any event within five (5) working days) written
guaranteed. Seller shall not be liable for any
state, local or foreign) applicable to the price, notice of any such defect. Any goods
loss or damage for delay, non-delivery or
sale, possession, or delivery of any goods or repaired or replaced of defective goods or
other impairment of performance due to the
services furnished hereunder or to the use parts shall, at Tyco Valves & Controls LP,
actions or inactions of government, military
thereof by Buyer, or Buyer shall furnish Seller Black Mountain’s (Kunkle) option, occur at its
authority, or Buyer, or by any reason of ‘force
with a tax-exemption certificate acceptable to plant in Houston, Texas and Tyco Valves &
major’, which shall be deemed to mean all
the levying taxing authority. Controls LP, Black Mountain (Kunkle) shall
other causes whatsoever not reasonably
reimburse Buyer all reasonable freight costs
within the control of Seller, including, but not 7. Payments. Buyer shall make payment in full incurred in transporting defective goods or
limited to, acts of God, war, riot, sabotage, for all goods ordered hereunder prior to parts to and from Tyco Valves & Controls LP,
fires, floods, strikes, lockouts or other shipment to Buyer, unless Buyer has entered Black Mountain’s (Kunkle) plant in the event
industrial disturbances, delays of carriers, into and agreed to Seller’s Standard Credit of a valid warranty claim. In the event Tyco
and inability to secure materials, fuel labor, Application and Agreement, in which event Valves & Controls LP, Black Mountain
transportation or manufacturing facilities at such Agreement is incorporated herein by (Kunkle) elects to provide replacement good
Seller’s expected prices. Any delay resulting reference and made a part hereof, unless or parts to buyer to repair defective goods,
from any such cause shall extend shipping and until such Agreement is terminated. The Buyer agrees to install said replacement
dates correspondingly. Seller shall in no prices specified are in USA currency. parts or goods at its cost and, further, Tyco
event be liable for any special, incidental or
Valves & Controls LP, Black Mountain
consequential damages arising from delay 8. Warranties; Remedies. Tyco Valves &
(Kunkle), shall in no event be liable for any
irrespective of the reason thereof, and receipt Controls LP, Black Mountain (Kunkle)
labor or material costs of Buyer with respect
by Buyer shall constitute acceptance of warrants only that the goods delivered
to de-installing or repairing defective goods
delivery and waiver of any claims due to hereunder when paid for and properly
or installing replacement parts or goods. Tyco
delay. Should delivery be delayed due to installed, operated, and maintained shall be
Valves & Controls LP, Black Mountain
Buyer’s actions or inactions, or should free from defects in material and workman-
(Kunkle) shall have the option of requiring the
delivery be delayed at the request of Buyer, ship under normal use and service for a
return of the defective goods or parts
the selling price of the goods shall period of twelve (12) months from the date of
thereof, transportation prepaid, to establish

13
Data Supplement
75 of 761

(continued)
the claim. Tyco Valves & Controls LP, Black special, indirect, incidental or consequential the written consent of Seller prior to
Mountain (Kunkle) shall not be held liable for damages whenever occurring including, but shipment and Buyer’s acceptance of
damages caused by delays in repair or not limited to, damages for loss of use of Seller’s cancellation charges which shall
replacement of any defective items. plant or property, damage to or destruction protect Seller against all costs and losses.
Certification by a separate writing as to of equipment, downtime cost, cost of capital, Seller shall have the right to cancel the sale
compliance with specifications, blueprints, economic loss, loss of good will, labor cost, of any or all of the goods sold hereunder,
part numbers, quality test or otherwise will loss of profits or revenues, or claims resulting without liability to Buyer except for the
not create any warranty by or obligation of from contracts between Buyer, its customers refund of monies already paid hereunder,
Tyco Valves & Controls LP, Black Mountain and/or suppliers, regardless of whether any the event manufacture or sale of the goods
(Kunkle). The provisions in Tyco Valves & of the foregoing arises from this document or is or becomes technically or economically
Controls LP, Black Mountain’s (Kunkle) Tyco Valves & Controls LP, Black Mountain impractical.
literature and specifications are descriptive (Kunkle) by any human being for personal
12. Product Modification. Seller reserves the
only unless expressly stated as warranties. injury or wrongful death. Tyco Valves &
right to discontinue the manufacture of, or
EXCEPT FOR THE LIMITED EXPRESS Controls LP, Black Mountain (Kunkle) and
charge or modify the design and/or
WARRANTY SET FORTH IN THIS SECTION, Buyer acknowledge and agree that the
construction of goods sold pursuant to this
KUNKLE EXPRESSLY DISCLAIMS ALL exclusions of remedies and limitations of
document for the purpose of product
WARRANTIES, EXPRESS AND IMPLIED, liability and damages herein reflect a
improvement, without incurring any
ORAL AND WRITTEN, INCLUDING, bargained-for allocation and limitation of risk,
obligation to Buyer with respect thereto.
WITHOUT LIMITATION, AND FITNESS FOR liability and damages. Tyco Valves & Controls
A PARTICULAR PURPOSE, WHETHER LP, Black Mountain (Kunkle) will not defend, 13. Patents. Seller agrees as its option, to
ARISING FROM STATUTE, COMMON LAW, indemnify or hold harmless Buyer or others defend at its safe cost and expense, and to
CIVIL CODE, CUSTOM OR OTHERWISE. for any claim, expense or liability. This pay any damages and cost awarded
KUNKLE’S WARRANTY OBLIGATIONS AND Section shall apply notwithstanding any other against Buyer, from any claim, suit or
BUYER’S REMEDIES FOR BREACH OF provision of this document. proceeding against Buyer to the extent
WARRANTY, EXCEPT AS TO TITLE, ARE such claim, suit or proceeding is based on
10. Limitation of Liability to Third-Party
SOLELY AND EXCLUSIVELY AS STATED IN an allegation that goods manufactured by
Purchases. Prior to Buyer’s transfer or sale
THIS SECTION. No modification or addition Seller and delivered to Buyer hereunder
of any goods sold pursuant hereto, or the
to this document with respect to the infringe any United Sates letter patent,
transfer or sale of any interest in such
foregoing warranty by Tyco Valves & Controls provided: (1) Seller is notified promptly in
goods, Buyer shall notify the Transferee of
LP, Black Mountain (Kunkle) either before or writing by Buyer of any such claim, suit or
the full text of Sections 8 and 9 hereof in
after execution of this document, shall be proceeding; (2) Seller is given information
writing and shall provide Seller with written
made except in writing by the President or a and assistance by Buyer as may be
acknowledgment and acceptance by the
Vice President of Tyco Valves & Controls LP, requested by Seller; and (3) Seller is given
transferee of the terms of Sections 8 and 9
Black Mountain (Kunkle). full authority (including authority to settle) by
hereof. Further, Buyer shall incorporate
Buyer to conduct such defense as Seller
9. Limitation of Liability. In any event, the verbatim Sections 8 and 9 hereof in any
deems appropriate. Seller’s obligation under
total liability of Tyco Valves & Controls LP, contract between Buyer and any Transferee
this Section does not apply to any goods
Black Mountain (Kunkle) arising from any concerning any such transfer or sale. Buyer
the designs, instructions and/or
cause of action or claim whatsoever, whether shall also include a written copy of Section
specifications for which are partially or
(a) in contract, (b) in tort, (including 8 and 9 hereof with any goods covered
completely supplied by Buyer or to any
negligence, whether sole, joint, contributory, hereby that are transferred or sold to a
claim, suit or proceeding in which the
concurrent or antipollution law or regulation), transferee. IF TRANSFER IS MADE
alleged infringement results from alteration
(c) connected with any toxic or hazardous CONTRARY TO THE PROVISIONS OF
of goods; use of goods for purposes other
substance or constituent, (d) arising out of THIS SECTION 10, BUYER SHALL, IN
than those for which the goods were
any representation or instruction, or under ADDITION TO ANY OTHER LEGAL OR
intended, or use of the goods in
any warranty, (e) or otherwise, arising out of, EQUITABLE RIGHTS OF SELLER,
combination with products not
connected with, or resulting from the design, INDEMNIFY SELLER AGAINST ANY
manufactured by Seller. If in any suit
manufacture, sale, resale, delivery, repair, LIABILITIES, CLAIMS, COSTS, DAMAGES
covered by this Section, the use of goods is
replacement or use of any goods or the AND ATTORNEY’S FEES INCURRED BY
enjoined, Seller shall at its option and sole
furnishing of any service shall in no event SELLER IN EXCESS OF THOSE SET
cost and expense either: (a) procure for
exceed the price allocable to and paid to FORTH IN SECTIONS 8 AND 9 HEREOF.
Buyer the right to continue using the goods;
Tyco Valves & Controls LP, Black Mountain This Section 10 shall apply notwithstanding
(b) replace the goods with non-infringing
(Kunkle) for the individual unit of goods or any other provisions of this document.
goods; (c) modify the goods to be non-
services or part thereof which gives rise to
11. Returns; Cancellations. No goods may infringing; or (d) refund to Buyer or (d)
the cause of action or claim. In no event shall
be returned except on prior written approval refund to Buyer the purchase price of the
Tyco Valves & Controls LP, Black Mountain
of Seller. Orders placed with and accepted goods and transportation costs related
(Kunkle) or its affiliates be liable for any
by Seller may not be canceled except with thereto. Seller shall have no liability with

14
Data Supplement
76 of 761

(continued)
respect to patent or trademark rights of 16. Merger. Seller and Buyer agree that there
countries foreign to the USA. The foregoing are no understandings, agreements,
shall be Seller’s sole and entire liability for representations or warranties between or
patent infringement by the goods furnished by either of them, either oral or written,
pursuant hereto. relative to the goods or services sold,
pursuant hereto, including any made in or
14. Data. Buyer agrees that all drawings, prints
implied from past dealings, relative to the
and other technical material (collectively
goods or services sold pursuant hereto,
‘Materials’) which Seller provides to Buyer,
except those that are fully expressed
whether prepared by Seller or by third
herein. The provisions of this document
parties under contract to Seller, contain
supercede and control any previous
data which embody trade secrets and
understanding or agreement between the
confidential know-how of commercial value
parties with respect to the subject matter
to Seller or to third parties under contract
hereof and this document is an expression
to Seller. Buyer agrees that Buyer and its
of the complete and final understanding of
agents and employees; (a) will keep
the parties. Any representation, promise,
confidential all such Materials; (b) will not
course of dealing or trade usage not
disclose such Materials to any other
contained or referenced herein will not be
person, corporate division or entity, except
binding on the parties hereto. Seller’s
to employees of Buyer who need such
branch managers or sales representatives,
Materials in order to perform Buyer’s
distributors, and dealers appointed by
obligations hereunder; (c) will not use such
Seller are not authorized to make
Materials, except in connection with goods
modifications, waivers or changes in or to
supplied hereunder; and (d) will not sell,
these terms and conditions of sale. Buyer
lease, loan or permit any other person,
represents and agrees that it is Buyer’s sole
corporate division or entity to use such
obligation and responsibility to determine
Materials for any purpose, without Seller’s
the suitability of the goods for Buyer’s use
prior written consent. Nothing herein shall
and application and any statements made
restrict use of data or information available
by Seller's salespersons are opinion only
to the general public.
and not representations or warranties of
15. Applicable Law: Section Headlines. Seller and will not be relied on by the Buyer.
This document shall be deemed to
have been executed and entered into
the State of Texas, USA, and this
document, and its formation,
operation and performance, shall be
governed, construed, performed and
enforced in accordance with the
substantive laws of the State of
Texas, USA. The parties hereto agree that
any civil action or lawsuit arising out of this
document or the subject matter hereof shall
be brought and maintained solely in state or
federal courts located in Harris County,
Texas, USA, and Buyer and Seller each
hereby consents and submits to the
personal jurisdiction of said courts. Any
action or claim in any part arising out of or
related to this document or the subject
matter hereof, may be commenced or
brought within one (1) year from the date
the claim or action shall first arise or
accrue, or be barred forever. The Section
headings herein contained are for ease of
reference only and shall not be construed
to be part of this document.

15
Data Supplement 77 of 761
953 Old U.S. Highway 70

Black Mountain, North Carolina 28711-2549
Facility Phone: 1-828-669-3700 www.kunklevalve.com
Tyco Flow Control (TFC) provides the information herein in good faith but makes no representation as to its comprehensiveness or accuracy. This data sheet is intended only as a guide to TFC products and services.
Individuals using this data sheet must exercise their independent judgment in evaluating product selection and determining product appropriateness for their particular purpose and system requirements. TFC
MAKES NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
WITH RESPECT TO THE INFORMATION SET FORTH HEREIN OR THE PRODUCT(S) TO WHICH THE INFORMATION REFERS. ACCORDINGLY, TFC WILL NOT BE RESPONSIBLE FOR DAMAGES (OF ANY KIND OR
NATURE, INCLUDING INCIDENTAL, DIRECT, INDIRECT, OR CONSEQUENTIAL DAMAGES) RESULTING FROM THE USE OF OR RELIANCE UPON THIS INFORMATION. Patents and Patents Pending in the U.S.and
foreign countries. Tyco reserves the right to change product designs and specifications without notice. All registered trademarks are the property of their respective owners. Printed in the USA.
Copyright © 2009 Tyco Flow Control. All rights reserved. KUKMC-0396 www.tycoflowcontrol.com
16
Model 900
78 of 761
Models 910, 911, 916 and 917 – ASME Section VIII,

Air/Gas/Steam/Liquid, “UV” National Board certified.
Models 920, 921 and 927 – ASME Section I Special use or
application, “V” National Board certified. Also available for
vacuum service. PED certified for non-hazardous gas.
Not for use with oxidizing fluids.
Features
• Available with soft seats.
• Threaded cap standard (back
pressure tight). Maximum back
pressure 50 psig [3.4 barg].1
• Hex on valve nozzle provides for easy
installation.
• Warn ring offers easy adjustability.
• Pivoting disc design offers exceptional
seat alignment.
• Guide to nozzle ratio reduces friction.
• Valve bodies are heavy duty casting.
• Full nozzle design for optimum flow
performance.
• Threaded side outlet for piped off
discharge to eliminate fugitive
emissions.
• Each Kunkle valve is tested and
inspected for pressure setting and
leakage.
Model Descriptions
Model 910: Carbon Steel (CS) body and
bonnet with Stainless Steel (SS) trim.
Model 910
Model 911: All SS construction.
Model 916: Same as model 910 resilient
seat/seals. Superior “leak-free”
performance.
Model 917: Same as model 911 except
resilient seat/seals. Superior “leak-free”
performance. Applications • Overpressure relief and protection of
Model 920: Steel body and bonnet with • Air/gas compressors, intercoolers, pumps, tanks, lines and hydraulic
screwed cap and stainless steel spring for aftercoolers. systems.
organic fluid vaporizers (ASME Section I - • Bypass relief or pressure regulation.
• Liquid filled pressure vessels/systems,
“V” Special Use or application).
ASME Section VIII (UV). • All SS Model 911 may be suitable for
Model 921: Steel body and bonnet with sanitary/edible applications.
• Vacuum systems including pumps,
plain lift lever and stainless steel spring for
tanks and equipment. • Process and industrial corrosive
forced flow steam generators (ASME
Section I - “V” Special Use or application). • Pressure vessels - containing gas, air, applications.
liquid or steam, including tanks and Note:
Model 927: Steel body and bonnet with
receivers. 1. Back pressure increases set pressure on a
packed lift lever and SS spring for high
one to one basis, and reduces capacity.
temperature/pressure hot water boilers • Oil/gas separators. Back pressure in excess of 10% of set
(ASME Section I - “V” Special Use or pressure is not recommended.
application).
Kunkle is either a trademark or registered trademark of Tyco International Services AG or its affiliates in
the United States and/or other countries. All other brand names, product names, or trademarks belong
to their respective holders.
Copyright © 2009 Tyco Flow Control. All rights reserved. KUKMC-0392-US-0910

Model 900
79 of 761
Specifications - Models 910, 911, 916, 917, 920, 921 and 927
Options Pressure Limits

• Threaded cap. (variation 01) See Specification Table
• Threaded cap with gag. (variation 02)
Temperature Limits
• Plain lever. (variation 03) Model 910:
-20°/800°F [-28.9°/427°C]
• Plain lever with gag. (variation 04)
• Plain lever with vibration dampener.
Model 911:
-320°/800°F [-195°/427°C]
(variation 05)
• Packed lever. (variation 06)
Models 916 and 917:
Temperatures limited by Elastomer seat
• Packed lever with gag. (variation 07) material.
• Models 910 and 911 available with
150#, 300# and 600# inlet flanges and
150# outlet flange per ANSI B16.5.
Note
• Model 911 available with Tri-Clover
1. ASME standard valves for air, steam and hot
Adapter Inlet. water above 140°F [60°C] must have lift
lever.
Model Inlet Orifice Outlet
911 ZDE 1" D 1"
911 ZEE 1" E 11/4"
911 ZFG 11/2" F 11/2"
911 ZGG 11/2" G 2"
911 ZGH 2" G 2"
911 ZHH 2" H 21/2"
911 ZJJ 21/2" J 3"

2
Model 900
80 of 761
Service Recommendations for Resilient Seat/Seal Materials

Seat/Seal Materials Service Recommendation
Air, Anhydrous Ammonia, Butane, Carbon Dioxide, Diesel Oil, Ethyl Chloride, Ethyl Ether,
BUNA-N (-40° to 275°F) [-40° to 135°C] Freons #11 and 12, Fuel Oil, Gasoline, Helium, Hydrogen Sulphide, Kerosene, Lube Oil,
Natural Gas, Nitrogen, Oxygen (Gas), Propane, Propylene, Sulphur Dioxide, Vinyl Chloride
Acetone, Air, Amyl Alcohol, Aniline, Benzine, Butane, Carbon Disulphide, Carbon Tetrachloride
Dowtherm “A” and “J,” Ethyl Chloride, Ethylene, Ethylene Glycol, Ethyl Alcohol, Gasoline, Hexane,
Viton® A (-10° to 406°F) [-23° to 208°C] Hydrogen Sulphide, Isobutyl Alcohol, JP - 4 Fuel, JP - 5 Fuel, Kerosene, Lube Oil, Natural Gas,
Naphtha, Nitrogen, Propane, Propylene, Propyl Alcohol, Sulphur Dioxide, Toluene,
Trichloroethylene,Turpentine, Water, Xylene
Silicone (-100° to 406°F) [-73° to 208°C] Air, Helium, Nitrogen, Oxygen (Gas)
Ethylene Propylene (-70° to 400°F) [-57° to 205°C] Steam, Hot Water
Air, Anhydrous Ammonia, Butane, Butyl Alcohol, Castor Oil, Denatured Alcohol, Ethanol, Ethyl
Neoprene (-45° to 300°F) [-43° to 149°C] Alcohol, Freons (12, 13, 14 and 22), Glycols, Natural Gas and Silicate Esters
Specifications
Model Orifice Connections Min/Max Min/Max ––––—––––– Dimensions, in [mm] –––––—–––– Approx.
Number1 ANSI Standard Set Pressure7 Temp.2 A B C C C Weight
Inlet Outlet psig [barg] (°F)2 [°C] Threaded Plain Packed lb [kg]
Cap Lever Lever
1/2" 1" 3/14004 -320/800 23/8 15/8 71/4 83/8 9 3
9*BDC# D
[12.7] [25.4] [0.2/96.5] [-195/427] [60.3] [41.3] [184.2] [212.7] [228.6] [1.4]
3/4" 1" 3/14004 -320/800 23/8 15/8 71/4 83/8 9 3
9*BDD# D
[19.0] [25.4] [0.2/96.5] [-195/427] [60.3] [41.3] [184.2] [212.7] [228.6] [1.4]
1" 1" 3/14004 -320/800 25/8 15/8 71/2 85/8 91/8 3
9*BDE# D
[25.4] [25.4] [0.2/96.5] [-195/427] [66.7] [41.3] [191.0] [219.0] [232.0] [1.4]
3/4" 11/4" 3/10005 -320/800 25/8 2 75/8 83/4 93/8 4
9*BED# E
[19.0] [31.8] [0.2/68.9] [-195/427] [66.7] [50.8] [193.7] [222.3] [238.1] [1.8]
1" 11/2" 3/7006 -320/800 27/8 23/8 83/4 97/8 101/2 6
9*BFE# F [25.4] [38.1] [0.2/48.3] [-195/427] [73.0] [60.3] [222.3] [250.8] [266.7] [2.7]
11/4" 2" 3/600 -320/800 31/4 25/8 101/8 111/4 113/4 8
9*BGF# G
[31.8] [50.8] [0.2/41.4] [-195/427] [82.6] [66.7] [257.2] [285.8] [298.5] [3.6]
1 ea.
9*BHG# H 11/2" 21/2" 3/500 -320/800 31/2 23/4 111/8 13 121/2 11
[38.1] [63.5] [0.2/34.5] [-195/427] [88.9] [69.9] [282.6] [330.2] [317.5] [5.0]
2 ea.
2" 3" 3/5008 -320/800 4 31/4 121/2 141/2 151/8 15
9*BJH# J3
[50.8] [76.2] [0.2/34.5] [-195/427] [101.6] [82.6] [317.5] [368.3] [384.2] [6.8]
Dimensions are for reference only.
Notes
1. Replace asterisk with desired Model
Number. Replace # with seat material
designation. Data applicable to all models.
2. Temperature limits for Model 910 = C C C
-20°/800°F [-28.9°/427°C]; for Model 911 =
-320°/800°F [-195°/427°C]. Temperature
limits for elastomer seats per above table.
3. For C dimensions: pressures above 200 psig
[14 barg] add 1.25" [31.8 mm] to the
overall height.
A A
4. 1044 psig [72 barg] for steam service with A
standard stainless steel spring.
5. 900 psig [62 barg] for liquid service, or with B B B
high-temperature alloy steel spring.
6. 600 psig [41.4 barg] for liquid service, or Plain Lever Threaded Cap Packed Lever
with high-temperature alloy steel spring.
7. Subject to pressure and temperature limits of
flanged or tri-clover connections.
8. 367 psig [25.3 barg] for plain lever with gag.
Copyright © 2009
2005 Tyco Flow Control. All rights reserved.
2008 KUKMC-0392
3
Model 900
81 of 761
Parts and Materials - Models 910 and 911 Threaded Cap

No. Part Name 910, 916, 920, 921, 927 911, 917
1 Nozzle SS, SA351-CF8M3 SS, SA351-CF8M3
2 Body O-ring1 Teflon® Teflon® 27
28
3 Body Steel, SA216 Gr. WCB SS, SA351-CF8M 18 29
4 Warn Ring SS, A743-CF8M SS, A743-CF8M 17
5 Disc SS, A479-316 SS, A479-316 19
16
6 Set Screw Nut SS 18-8 SS 18-8 20
15, 26
7 Set Screw SS, Commercial Gr. 18-8 SS, A479-316
14 21
8 Set Screw Seal Teflon® Teflon®
9 Retainer Ring SS, A303-316 SS, A313-316 16 22
10 Disc Holder SS, A351-CF8M SS, A351-CF8M
13
11 Guide SS, A743-CF8M SS, A743-CF8M
12 Screw SS, Commercial Gr. 18-8 SS, Commercial Gr. 18-8 12
25
13 Coiled Spring Pin SS, A313-302 SS, A313-302 11, 24
SS: A313-316 or A313-T631 10
14 Spring 23
Alloy steel: A681-H12 or B637-X750
9
15 Bonnet Steel, A108 Gr. 1117 SS, SA479-316
16 Spring Step SS, A479-316 SS, A479-316 8
17 Stem SS, A479-316 SS, A479-316 7
18 Wire and Seal SS wire and lead seal, Commercial SS wire and lead seal, Commercial
6
19 Cap Steel, A108 Gr. C1018 SS, A479-316
20 Compression
SS, A479-316 SS, A479-316 5
Screw
4
21 Jam Nut SS 18-8 or SS A479-316 SS 18-8 or SS A479-316
3
22 Cap O-ring BUNA-N BUNA-N
2
23 Body Plug Steel, A108 Gr. C1018 SS, Commercial Gr. 18-8
Guide2 SS, A479-316 SS, A479-316 1
24 Guide Locknut2 SS, A479-316 SS, A479-316
Shield2 SS, A167-316 SS, A167-316 Threaded Cap Option
25 Bonnet Gasket1 Teflon® Teflon® (shown with Gag Option)
Bonnet Cap4 Steel, A108 Gr. 1117 SS, A479-316
26 Cap O-ring4 BUNA-N BUNA-N
Bonnet4 Steel, A108-1018 SS, A312-316
275 Gag Screw Steel A108-1018/Zinc Plated
286 Gag Screw Plug SS 18-8
296 Gag Screw Gasket Teflon®
No. Part Name Flanged Option Flanged Option

1 Inlet Flange CS, A105 SS, A182-F316 Outlet
2 Inlet Stub End SS, A479-316 SS, A479-316
3 Outlet Flange CS, A105 SS, A182-F316
4
4 Outlet Stub End SS, A479-316 SS, A479-316
3
2
Notes
1. For threaded cap and packed lever only.
2. 3-piece design for “J” orifice only. 1
Inlet
3. “D” and “E” orifice nozzle material is SS, SA479-316.
4. 3-piece design (not shown) for “H” and “J” orifices only.
Flanged Option
5. Gag screw ships with valve, not installed.
6. For threaded cap and packed lever gag options only.

4
Model 900
82 of 761
Parts and Materials - Tri-Clover Inlet Option

No. Part Name 910, 911, 916, 917, 920, 921 and 927
1 Nozzle SS A479-316
Tri-Clover (Inlet only)
34
Parts and Materials - Models 916 and 917 Soft Seat, D and E Orifice
35
No. Part Name 916 917
36 34 Spindle SS A479-316 SS A479-316
35 Disc Holder SS A479-316 SS A479-316
36 Retainer SS A479-316 SS A479-316
37 37 O-ring Seat1
38 Seat Retainer Screw SS 18-8 SS 18-8
38
Soft Seat D and E Orifice
10
Parts and Materials - Models 916 and 917 Soft Seat, F to J Orifice
8 No. Part Name 916 917
8 Disc SS A479-316 SS A479-316
9
9 Ring, Retainer SS A313-316 SS A313-316
10 Disc Holder SS A351-CF8M SS A351-CF8M
33 Molded Seat1
33
Soft Seat F to J Orifice Note

1. Material Letter Designation
BUNA-N - B
Ethylene Propylene (EPR/EPDM) - E
Neoprene - N
Silicone - S
Viton® - V

5
Model 900
83 of 761
Parts and Materials - Models 910, 911, 916, 917 and 927 Packed Lever
No. Part Name Materials
18 Cap O-ring BUNA-N 70
19 Jam Nut SS, A479-316 32
20 Lift Cam SS, A743-CF8M 25 33
21 Cotter Pin CS, Commercial 24 34
22 Lever Steel, Zinc Plated A108-GR. 1018 26
23 Drive Screw SS, Commercial 23 27
24 Retainer Nut SS, A479-316 22
28
25 Retainer O-ring BUNA-N 21 29
26 Lift Cam O-ring BUNA-N
27 Cap (Model 910) Steel, A216 GR. WCB, (Model 911) SS, A743-CF8M
28 Lift Nut SS, A479-316 20
29 Lift Washer SS, A479-316
19
30 Stem SS, A479-316 30
31 Compression Screw SS, A479-316 18
31
332 Gag Screw Plug SS 18-8
342 Gag Screw Gasket Teflon®
Notes Packed Lever

1. Gag screw ships with valve, not installed.
(shown with Gag Option)
2. For threaded cap and packed lever gag
option only.
Parts and Materials - Models 910, 911, 916, 917 and 921 Plain Lever
No. Part Name Materials
Cadmium plated steel: A231/A231M
11 Spring SS: A313-302
SS: A313-316
22
Alloy steel: A681-H12
12 Bonnet (Model 910) Steel, A108-1117, (Model 911) SS, A479-316
13 Jam Nut SS, A479-316 16
15
14 Compression Screw SS, A479-316 17
15 Lever Steel, A109 Cadmium Plated 18
14
16 Cap Aluminum, Anodized
17 Lift Nut SS, A479-316 13
18 Lift Washer SS, A479-316
19
19 Rivet Steel, Commercial
12
20 Cap Screw SS, Commercial 18-8
21 Spring Step SS, A479-316 11
20
21
Plain Lever
(shown with Gag Option)

6
Model 900
84 of 761
Order Information - Models 910, 911, 916, 917, 920, 921 and 927
NOTES:
For the 2 Kunkle Model 927BJH, 2"x3", Model
Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Part# is: 927BJHM06ABE0200. Position
For the 1 Kunkle Model 927BHG 1.5"x2.5", Example 9 1 0 B J H M 0 1 A K E 0 3 0 0
Part# is: 927BHGM06ABE0200.

Model
910, 911, 916, 917, 920, 921, 927
Connection Model
B- Male x Female NPT M- 300# Flange x 300# Flange
E - 150# Flange x FNPT N- 600# Flange x 150# Flange
G- 300# Flange x FNPT P- 600# Flange x 300# Flange
J - 150# Flange x 150# Flange X- 600# Flange x FNPT
L - 300# Flange x 150# Flange Z- Tri-clover Inlet
Orifice
D, E, F, G, H, J
Inlet Size
C - 1/2" [12.7 mm] F - 11/4" [31.8 mm]
D - 3/4" [19.1 mm] G - 11/2" [38.1 mm]
E - 1" [25.4 mm] H - 2" [50.8 mm]
Seat/Seal Material
M - Metal-to-metal – Models 910, 911, 920, 921, 927
B - BUNA-N – Models 916, 917 only
E - EPR – Models 916, 917 only
S - Silicone – Models 916, 917 only
V - Viton® – Models 916, 917 only
N - Neoprene – Models 916, 917 only
Variation (01 to 99)

Number provided only by Kunkle to cover specific feature or option.
01 - Threaded cap 05 - Plain lever with vibration dampner
02 - Threaded cap with gag 06 - Packed lever
03 - Plain lever 07 - Packed lever with gag
04 - Plain lever with gag 60 - BSP Threads with threaded cap
Design Revision
Orifice Size
Models D E F G H J
910 A A A A A A
911 A A A A A A
916 B B A A A A
917 B B A A A A
920 A A A A A A
921 A A A A A A
927 A A A A A A
Valve Service
B - High-temperature Hot Water ASME Sect. I (Model 927 only) - Packed lever only
C - Organic Fluid ASME Section I (Threaded Cap only) (Model 920 only)
J - Liquid ASME Section VIII (Threaded Cap/Packed Lever only)
K - Air/Gas ASME Section VIII (Plain Lever/Packed Lever required for air)
L - Steam ASME Section VIII (Plain Lever/Packed Lever required)
M - Non-code Liquid (Threaded Cap/Packed Lever only)
N - Non-code Air/Gas
P - Non-code Steam
Q - Vacuum (Threaded Cap/Packed Lever only)
R - Forced Flow Steam ASME Section I (Plain Lever only) (921 only)
Spring Material
E - SS (-60° to 550°F) [-51° to 288°C]
F - High-temperature Alloy Steel (-60° to 800°F) [-51° to 427°C]
200 psig (0200) Set Pressure

3 psig (0003) to 1400 psig (1400) [0.2 barg to 96.5 barg]
Vacuum 6" [200 mbarg] HG (inches of Mercury) (0006) to 29" [1000 mbarg]
HG (0029) Models 910, 911, 920, 921

7
Model 900
85 of 761
Capacities - Models 920, 921, 927
ASME Section I Steam (U.S., lb/h) - Flow Coefficient = 0.8781

Set Pressure ––——––——––———— Orifice Area, in2 ———––––––————––
(psig) D E F G H J
(0.1213) (0.2157) (0.3369) (0.553) (0.864) (1.415)
NOTE #1: 15 174 309 482 792 1237 2026
Per ASME Code Section I, the lb/hr on this 25 228 406 635 1042 1628 2665
35 283 504 787 1292 2018 3305
reference is how safety valves for high 45 338 601 939 1541 2408 3944
temp hot water boilers can also be 55 393 699 1091 1791 2798 4583
65 448 796 1243 2041 3189 5222
specified. This is used as the same relieving
75 504 896 1399 2297 3589 5877
capacity as steam boilers … to make it 85 560 996 1556 2554 3991 6536
simpler. 95 617 1097 1713 2812 4393 7194
100 645 1147 1791 2940 4594 7523
For BTUH relieving capacity of the safety
125 786 1398 2183 3583 5599 9169
valve, multiply the value by 970 (or use 150 927 1649 2575 4227 6604 10815
1000 for safety factor). 175 1068 1900 2967 4870 7609 12461
200 1209 2150 3359 5513 8614 14107
NOTE#2 : 225 1350 2401 3751 6156 9619 15753
For the 2 Kunkle Model 927BJH, 2"x3", 250 1492 2652 4143 6800 10624 17399
275 1633 2903 4534 7443 11629 19045
Part# is: 927BJHM06ABE0200, each with
300 1774 3154 4926 8086 12634 20691
max. relieving capacity 14,107,000 BTUH. 325 1915 3405 5318 8730 13639 22337
For the 1 Kunkle Model 927BHG 1.5"x2.5", 350 2056 3656 5710 9373 14644 23983
375 2197 3907 6102 10016 15649 25629
Part# is: 927BHGM06ABE0200, each with
400 2338 4158 6494 10659 16654 27275
max. relieving capacity 8,614,000 BTUH. 425 2479 4409 6886 11303 17659 28921
450 2620 4660 7278 11946 18664 30567
475 2761 4910 7670 12589 19669 32212
500 2902 5161 8061 13232 20674 33858
525 3044 5412 8453 13876 — —
550 3185 5663 8845 14519 — —
575 3326 5914 9237 15162 — —
600 3467 6165 9629 15805 — —
625 3608 6416 10021 — — —
650 3749 6667 10413 — — —
675 3890 6918 10805 — — —
700 4031 7169 11196 — — —
725 4172 7419 — — — —
750 4313 7670 — — — —
775 4455 7921 — — — —
800 4596 8172 — — — —
850 4878 8674 — — — —
875 5019 8925 — — — —
900 5160 9176 — — — —
925 5301 9427 — — — —
950 5442 9678 — — — —
975 5583 9928 — — — —
1000 5724 10179 — — — —
1050 6007 — — — — —
1100 6289 — — — — —
Note 1200 6853 — — — — —
1300 7418 — — — — —
1. See Specifications Table (page 3) for
Pressure and Temperature Limitations. 1400 7982 — — — — —

13
86 of 761
3.4 ST Johnson
925 Stanford Ave., Oakland CA 94608 USA
www.johnsonburners.com
87 of 761
FD68-LN Low NOx Burner

With Induced FGR
KEY FEATURES:
• Fuel efficient combustion with low NOx

• Energy efficient Axial-flow blower
• Swing-open housing for easy maintenance
• Multi-fuel firing capability
• Lower installation costs
• Proven reliable construction
• Quiet operation – lowest noise levels
• Optional Variable Speed Blower
DESCRIPTION:
The Type FD68-LN burner combines high

performance axial airflow design with low NOx burner
technology to create a very compact, quiet, and
energy efficient unit. Units are available in sizes up to
1000 HP firing natural gas, LP gas and #2 fuel oil.
Other fuel firing capabilities are available.
All systems include an integral axial-flow blower

assembly. Efficient airflow, in conjunction with the
built-in silencing end cover, results in a lower blower
HP requirement, and the lowest noise levels of any
300 HP firetube boiler application
packaged forced-draft system.
The axial-flow design also gives the FD68-LN burner

its sleek, inline appearance, and puts the “P” in
performance with intimate mixing of the fuel, air and
FGR. The innovative design features S.T. Johnson’s
trademark swing-open housing allowing easy access
to the firing head, ignition assembly, blower motor and
flame detector. The pilot, firing head-diffuser
assembly, and oil drawer can be easily removed
individually, or as a complete unit within a few
minutes.
The optional Variable Speed Blower (VSB) package

provides additional energy and operating cost
reductions, and reduces noise even further. With a 20
to 40% electricity cost reduction, the average VSB
package pays for itself within a couple of years
depending on motor size, load demand, and utility
cost. This says nothing of the long-term savings
generated by reduced wear and tear on the fan and
motor.
150 HP natural gas & #2 oil flextube boiler application
The Johnson FD68-LN package provides Low NOx with Lower Costs!
Gas fired systems for 30-ppm NOx emissions.
88 of 761
JOHNSON Type FD68-LN Low NOx Capacities & Specifications
Burner Capacities (1) Pump HP-RPM (2) Air Emissions (3)
Burner MBH GPH Boiler Blower Press. Air Compr. NOx CO
Size Gas #2 Oil HP HP Atom. #2 Atom. # 2 HP (ppmdv) (ppmdv)
125 4,730 34 112 2 3/4-1725 1/3-1725 2 30 100
150 6,330 45 150 2 3/4-1725 1/3-1725 2 30 100
200 8,490 61 202 5 3/4-1725 1/3-1725 2 30 100
250 9,460 68 225 7.5 1-1725 1/3-1725 2 30 100
300 12,670 91 301 7.5 1 1/2-3450 1/2-1725 2 30 100
300SP 14,190 101 337 10 1 1/2-3450 1/2-1725 3 30 100
400 17,100 122 406 15 n/a 3/4-1725 3 30 100
400SP 18,250 130 434 15 n/a 3/4-1725 3 30 100
500 21,290 152 506 20 n/a 3/4-1725 3 30 100
500SP 22,300 159 530 25 n/a 3/4-1725 3 30 100
625 26,600 190 632 25 n/a 3/4-1725 5 30 100
800 28,390 203 675 30 n/a 3/4-1725 5 30 100
1000 35,490 254 844 40 n/a 1-1150 5 30 100
1000SP 39,030 279 928 40 n/a 1-1150 7.5 30 100
1200 42,000 300 1000 60 n/a 1-1150 7.5 30 100
Notes: (1) Gas input based on 1,000 BTU/CF gas & 0.64 specific gravity. Oil input based on No. 2 CSG, 140,000 BTU/Gal. Boiler capacity based on minimum 80%
combustion efficiency. Capacity rated against +0.75" w.c. furnace pressure. 60 cycle current at sea level. (2) Oil burner pumps and atomizing air compressor sets are
remote mounted and direct-driven. (3)Typical emissions corrected to 3% O2. Capacities and specifications shown for 30 ppm NOx. Lower emissions may require a
larger burner size and motor HP requirements. Control system selection, and boiler design and condition greatly affect emissions performance. Always consult with
factory for emissions guarantee.
Dimensions (inches)
Type FD68-LN
H
N
NOTE:
J 30 ppm System Oil Pump

"K" O.D.
FGR INLET Motor upgrade
to 1.5 hp rating
A @ 1725 rpm.
G
D C F B
E
MAIN GAS
CONNECTION
1/4" O.D.
PILOT GAS CONDENSATION
CONNECTION DRAIN CONNECTION
Size A B C D E F G H J K L M N
125-200 41.75 26.5 24 19.25 12.75 19.13 22.63 31.75 35.88 4 10.5 13.5 12.5
300-300SP 49 31.50 29 28.75 12.75 19.13 17.38 39.25 43.63 6 12.5 16.75 15
400-400SP 53.13 31.50 29 28.75 13.5 22 17.38 40.25 43.63 6 12.5 16.75 15
500-500SP 53.88 36.50 34 35 13.50 22.75 20.5 42.69 51 8 14.25 16.75 17.5
625 53.88 36.50 34 35 13.50 23.75 20.5 42.69 51 8 14.25 16.75 17.5
800 80.88 40.50 38 39 13.50 23.75 21.56 55.13 71.63 10 16.25 20.75 19.5
1000 & SP 80.88 40.50 38 39 15 28 21.56 55.13 71.63 10 16.25 20.75 19.5
1200 100 40.50 38 48 16 30.25 26 64.5 93 12 20.25 20.75 21.5
Note: Specifications and dimensions are subject to change without notice. Certain dimensions and specifications may change according to the application and
emission reduction goals. Always consult factory for current information.
S.T. JOHNSON COMPANY PO Box 8627, Oakland, CA 94608 U.S.A.

Tel: (510) 652-6000 – Fax: (510) 652-4302
FD68-LN-3 Rev 6/09 www.JOHNSONBURNERS.com
89 of 761
90 of 761
S.T.JOHNSONCOMPANY 1of3
PARTSLIST:FD68CALMBURNERS
SIZES8001200OPERATINGAT60Hz
ITEM DESCRIPTION SIZE800 SIZE1000 SIZE1000SP SIZE1200 ITEM

1 AIRSILENCERENDCOVER B8658 B8658 B8658 B8658 1
2 SILENCERENDCOVERNUTS(4) 1/4"ACORN 1/4"ACORN 1/4"ACORN 1/4"ACORN 2
3 SILENCERENDCOVERSTANDOFFS(4) A7999 A7999 A7999 A7999 3
4 SILENCERHOUSING C5929 C5929 C5929 C5929 4
5 SILENCERSUPPORTBAND C5928 C5928 C5928 C5928 5
6 AIRSHUTTERASSEMBLY C5926 C5926 C5926 C5926 6
7 AIRSHUTTERLINKAGERING A7997 A7997 A7997 A7997 7
8 AIRSHUTTERLINKAGERINGBEARINGS(8) C59261 C59261 C59261 C59261 8
9 AIRSHUTTERSHAFTBEARING,OUTER(8) C592612 C592612 C592612 C592612 9
10 AIRSHUTTERSHAFTLOCKINGCOLLAR(16) C592610 C592610 C592610 C592610 10
11 AIRSHUTTERSHAFT(8) C592611 C592611 C592611 C592611 11
12 AIRSHUTTERBLADE(8) B8660 B8660 B8660 B8660 12
13 AIRSHUTTERADAPTERFLANGE A7993 A7993 A7993 A7993 13
14 AIRSHUTTERSHAFTBEARING,INNER(8) C59269 C59269 C59269 C59269 14
15 AIRINLETRING A7994 A7994 A7994 A7994 15
16 BLOWERWHEEL C565910 C565913 C565914 16243790% 16
17 BLOWERMOTOR 25HP 40HP 40HP 60HP 17
18 BLOWERHOUSINGASSEMBLY C5924 C5924 C5924 C5924 18
19 WINDBOXASSEMBLY C5927 C5927 C5927 C5927 19
20 REFRACTORYTILE A7313 B8510 B8510 B8510SP 20
21 FIRINGHEADASSEMBLY C5657 D21931 D21931 D21931 21
22 AIRDIFFUSER C4902 D2192 D2192 D2192 22
23 AIRROTATIONBLADES A7245 A7245A A7245A A7245A 23
24 NOZZLEAIRSLEEVE NOTUSED NOTUSED NOTUSED NOTUSED 24
25 AIRDISTRIBUTIONSLEEVE NOTUSED NOTUSED NOTUSED NOTUSED 25
26 SCANNERSWIVELMOUNT 32612A 32612A 32612A 32612A 26
27 SCANNERSIGHTTUBE A72805 A72806 A72806 A72806 27
28 PILOTBODY A7875 A80141 A80141 A80141 28
91 of 761
29 IGNITIONELECTRODE A4447 B80072 B80072 B80072 29
'IndicatesThatThePart#IsIdenticalToTheNumberToTheLeft

30 S.S.PILOTSLEEVE A7311 A80142 A80142 A80142 30
31 OILNOZZLEBODY A70493 A70493 A70493 A70493 31
32 OILNOZZLETIPC169WA 250x70 300x80 300x80 350x80 32
33 JACKSHAFTBRACKET/ELECTRICALBOX D2173 D2173 D2173 D2173 33
34 ELECTRICALJUNCTIONBOXCOVER A8006 A8006 A8006 A8006 34
35 WINDBOXJACKSHAFT A608765 A608765 A608765 A608765 35
36 JACKSHAFTBUSHINGS(2) FF6005 FF6005 FF6005 FF6005 36
37 JACKSHAFTSTOPCOLLARS(2) CS8A CS8A CS8A CS8A 37
38 JACKSHAFTCRANKARMS(4) A7939 A7939 A7939 A7939 38
39 MODULATINGMOTOR M9484F1031 M9484F1031 M9484F1031 M9484F1031 39
40 MODULATINGMOTORTRANSFORMER 192168GA 192168GA 192168GA 192168GA 40
41 ATOMIZINGAIRPRESSURESWITCH L404F1078 L404F1078 L404F1078 L404F1078 41
42 ATOMIZINGAIRPRESSUREGAUGE 0–30PSIG 0–30PSIG 0–30PSIG 0–30PSIG 42
43 NOZZLEOILPRESSUREGAUGE 0–60PSIG 0–60PSIG 0–60PSIG 0–60PSIG 43
44 OILSOLENOIDVALVE 8266D77V 8266D77V 8266D77V 8266D77V 44
45 2ndOILSOLENOIDVALVE 8266D77V 8266D77V 8266D77V 8266D77V 45
46 OILMETERINGVALVE 1/2"O100 1/2"O100 1/2"O100 1/2"O100 46
47 OILSUPPLYBACKPRESSUREREGULATOR CA2 CA2 CA2 CA2 47
48 OILSUPPLYPRESSUREGAUGE 0100PSIG 0100PSIG 0100PSIG 0100PSIG 48
49 IGNITIONTRANSFORMER 1112PF 1112PF 1112PF 1112PF 49
50 PILOTSOLENOIDVALVE 8262G13 8262G13 8262G13 8262G13 50
51 PILOTGASREGULATOR 3/8"3253 3/8"3253 3/8"3253 3/8"3253 51
52 PILOTGASSHUTOFFCOCK 3/8"BALLVALVE 3/8"BALLVALVE 3/8"BALLVALVE 3/8"BALLVALVE 52

53 PILOTGASPRESSUREGAUGE 032"W.C. 032"W.C. 032"W.C. 032"W.C. 53
54 GASCONTROLVALVE 3” 4” 4” 4” 54
55 GASINLETCOUPLING C4676 C4676 C4676 C4676 55
56 GASINLETGASKET A79765 A79765 A79765 A79765 56
57 GASINLETFLANGE C5661 C5661 C5661 C5661 57
58 OUTERGASSPUDS N/A A79463 A79463 A79463 58
59 INTERMEDIATEGASSPUDS N/A A79462 A79462 A79462 59
92 of 761
60 SECONDARYINNERGASSPUDS N/A A7946 A7946 A7946 60

61 PRIMARYGASSPUDS N/A A79461 A79461 A79461 61
93 of 761
Page 85 of 329
94 of 761
95 of 761
S.T. JOHNSON CO.

Type FD68
Gas, Pressure and Air Atomizing Oil Burners

Installation, Operation, and Maintenance
Instruction Manual

NOTICE: This manual is provided to supply general information on the installation, operation and
maintenance of the FD68 burner system. The burner must be installed and operated by trained personnel,
guided by generally accepted industry practice. Do not attempt to operate the burner without familiarizing
yourself with these instructions and the manufacturer’s instructions for all components in the system. Failure
to do so can result in personal injury, loss of life and damage to property.
Specifications and procedures are subject to change without notice. Please consult factory for older unit
specifications, or whenever the equipment supplied does not match descriptions in this manual.
S.T. Johnson Company Tel (510) 652‐6000
925 Stanford Avenue Fax (510) 652‐4302
Oakland, CA 94608 www.johnsonburners.com
96 of 761
Combustion Equipment
& Control Systems S.T. JOHNSON CO.
TABLE OF CONTENTS: PAGE
GENERAL INFORMATION ............................................................................................................... 1
MODEL DESIGNATIONS .......................................................................................................... 1
ORDERING INFORMATION ..................................................................................................... 2
GENERAL MODEL DESCRIPTION .......................................................................................... 3
INSTALLATION INSTRUCTIONS ..................................................................................................... 4
BURNER ASSEMBLY ............................................................................................................... 4
BURNER MOUNTING DIMENSIONS ....................................................................................... 4
Burner Size ................................................................................................................................ 4
REFRACTORY INSTALLATION ............................................................................................... 5
REFRACTORY TILE CURING INSTRUCTIONS ...................................................................... 5
SWING CYLINDER HINGE AND LATCH ADJUSTMENT ........................................................ 5
CONTROL PANEL & SAFETY CONTROLS INSTALLATION .................................................. 6
STANDARD CONTROL PANEL MOUNTING DIMENSIONS ........................................... 6
REQUIRED SAFETY LIMIT CONTROLS FOR ALL MODELS ......................................... 7
GENERAL STARTUP PROCEDURE ............................................................................................... 8
PRE-FIRING CHECKOUT ......................................................................................................... 8
COMBUSTION AIR ADJUSTMENT .......................................................................................... 9
INTEGRAL FAN BURNERS .............................................................................................. 9
REMOTE FAN BURNERS ................................................................................................ 9
IGNITION SYSTEM ADJUSTMENT PROCEDURE................................................................ 10
STANDARD GAS-ELECTRIC PILOT SYSTEMS ........................................................... 10
OPTIONAL DIESEL/ELECTRIC IGNITION SYSTEMS .................................................. 10
FIRING HEAD ADJUSTMENT PROCEDURE ........................................................................ 11
AIR DIFFUSER SPECIFICATIONS ................................................................................ 11
AIR ROTATION BLADE SETTINGS ............................................................................... 12
FAN WHEEL SPECIFICATIONS FOR 60HZ INSTALLATIONS ............................................. 13
FAN WHEEL SPECIFICATIONS FOR 50HZ INSTALLATIONS ............................................. 14
MAINTENANCE RECOMMENDATIONS FOR ALL BURNERS ..................................................... 15
ROUTINE (OPERATIONAL) BURNER CHECKS ................................................................... 15
ROUTINE (OPERATIONAL) SAFETY CONTROL CHECKS.................................................. 15
NON-OPERATIONAL CHECKS .............................................................................................. 15
LUBRICATION ......................................................................................................................... 15
REPLACEMENT PARTS ......................................................................................................... 15
SPECIAL MAINTENANCE RECOMMENDATIONS FOR BELT-DRIVE (50 Hz) BURNERS ......... 16
SPROCKET & BELT ADJUSTMENTS FOR BELT DRIVE MODELS ..................................... 16
FAN SHAFT BEARINGS ......................................................................................................... 16
REPLACEMENT PARTS ......................................................................................................... 16
OPTIONAL AIR FILTER ASSEMBLIES .......................................................................................... 17
MAINTENANCE RECOMMENDATIONS: ............................................................................... 17
REPLACEMENT FILTERS: ..................................................................................................... 17
TROUBLESHOOTING GUIDE ........................................................................................................ 18
GAS SYSTEMS STARTUP ............................................................................................................. 19
GAS TRAIN INSTALLATION ................................................................................................... 19
SELECTION & SIZING .................................................................................................... 19
LOCATION ...................................................................................................................... 19
FIELD PIPING ................................................................................................................. 19
VENT CONNECTIONS ................................................................................................... 19
MAIN GAS ADJUSTMENT ...................................................................................................... 20
GAS PRESSURE SETTINGS: SIZE 50 TO 625 ............................................................. 21
GAS PRESSURE SETTINGS: SIZE 1000 ONLY ........................................................... 22
GAS VALVE LINKAGE ADJUSTMENT................................................................................... 22
Rev 3/09 ii
97 of 761
AIR ROTATION BLADE & AIR BAND SETTINGS .................................................................. 23
SIZE 1000 GAS FIRING HEAD CONFIGURATION ................................................................ 23
AIR ROTATION BLADE SETTINGS ............................................................................... 23
PRIMARY AIR SLEEVE .................................................................................................. 23
AIR DISTRIBUTION SLEEVE ......................................................................................... 24
LE94 FIRING HEAD CONFIGURATION ................................................................................. 24
GAS SPUD ROTATION................................................................................................... 24
PRIMARY/SECONDARY GAS SPUD ORIFICES ........................................................... 24
OIL SYSTEM STARTUP: PRESSURE ATOMIZED MODEL P-LM ................................................ 25
INITIAL MAIN BURNER ADJUSTMENT ................................................................................. 25
METERING VALVE LINKAGE SETTINGS ..................................................................... 26
MODEL P-LM OIL SYSTEM SETTINGS: 60 Hz OPERATION ............................................... 27
OIL PUMP SPECIFICATIONS: 60 Hz OPERATION ....................................................... 27
OIL PIPING SCHEMATIC: 60 HZ OPERATION ............................................................. 27
MODEL P-LM OIL SYSTEM SETTINGS: 50 Hz OPERATION ............................................... 28
OIL PUMP SPECIFICATIONS: 50Hz OPERATION ........................................................ 28
OIL PIPING SCHEMATIC: 50 HZ OPERATION ............................................................. 28
OIL PIPING SCHEMATIC: OPTIONAL DIESEL/ELECTRIC PILOT SCHEMATIC......... 29
REMOTE OIL PUMP INSTALLATION..................................................................................... 30
DIRECT-SPARK IGNITION SYSTEM SETTINGS .................................................................. 31
OIL SYSTEM STARTUP: AIR ATOMIZED OIL SYSTEMS MODELS A-LM, A-MM, A-HM ........... 33
INITIAL MAIN BURNER ADJUSTMENTS ............................................................................... 33
HAUCK FIXED GRADIENT OIL METERING VALVES ................................................... 34
MAXON ADJUSTABLE GRADIENT OIL METERING VALVES...................................... 35
OPTIONAL ELECTRONIC METERING SYSTEM .......................................................... 35
AIR ATOMIZING OIL NOZZLE SPECIFICATIONS ................................................................. 36
NOZZLE POSITIONING .................................................................................................. 36
NOZZLE PIN SETTING ................................................................................................... 36
MODEL A-LM OIL SYSTEM SETTINGS ................................................................................. 37
60 HZ OPERATION ......................................................................................................... 37
50 HZ DIRECT-DRIVE OPERATION (EXPORT) ............................................................ 38
50 HZ BELT-DRIVE OPERATION (EXPORT) ................................................................ 39
OIL PIPING SCHEMATIC: SYSTEMS WITH OIL METERING VALVE .......................... 40
OIL PIPING SCHEMATIC: SYSTEMS WITH CENTRAL OIL SUPPLY SYSTEM .......... 40
MODEL A-MM (#4 OIL) OIL SYSTEM SETTINGS ................................................................. 41
60 HZ OPERATION ......................................................................................................... 41
MODEL A-HM (#6 OIL) SYSTEM SETTINGS ......................................................................... 43
60 Hz OPERATION ......................................................................................................... 43
50 Hz DIRECT-DRIVE OPERATION (EXPORT) ............................................................ 44
50 Hz BELT-DRIVE OPERATION (EXPORT)................................................................. 45
AIR ATOMIZED BURNERS WITH ELECTRONIC OIL METERING SYSTEM (EMS) ............ 47
MODEL A-LM #2 OIL EMS SETTINGS........................................................................... 47
MODEL A-HM #6 OIL EMS SETTINGS .......................................................................... 48
ELECTRONIC OIL METERING SYSTEM PIPING SCHEMATIC ........................................... 49
MODEL A-LM #2 OIL SYSTEMS .................................................................................... 49
MODEL A-HM #6 OIL SYSTEMS .................................................................................... 49
ATOMIZING AIR COMPRESSOR INSTALLATION & ADJUSTMENT PROCEDURE ................... 50
INSTALLATION ....................................................................................................................... 50
DIMENSIONS: ATLAS COPCO MODELS LE2, -3, -5 .................................................... 50
PIPING ..................................................................................................................................... 51
START-UP ............................................................................................................................... 51
ADJUSTMENT ......................................................................................................................... 51
MAINTENANCE ....................................................................................................................... 51
Rev 3/09 iii

98 of 761
OIL PUMP INSTALLATION ............................................................................................................. 52
DIRECT-DRIVE OIL PUMP SET ............................................................................................. 52
60Hz OPERATION .......................................................................................................... 52
50Hz OPERATION .......................................................................................................... 53
BELT-DRIVE HEAVY OIL PUMP INSTALLATION ................................................................. 54
ELECTRONIC OIL METERING PUMP INSTALLATION ........................................................ 55
INDUCED FGR OPTION (LOW NOx OR FUTURE LOW NOx BURNERS ONLY)........................ 56
STACK CONNECTION:........................................................................................................... 56
FGR PIPE SIZING: .................................................................................................................. 56
FGR CONTROL VALVE: ......................................................................................................... 56
LIMITED WARRANTY ..................................................................................................................... 57
Rev 3/09 iv
99 of 761
GENERAL INFORMATION
MODEL DESIGNATIONS : FD68CA1000LM-LN
FD68 C A 150 L M BD
FORCED DRAFT BD-BELT-DRIVEN

MODEL 68 RF-REMOTE FAN
FUEL MODULATING
A-OIL ONLY
G-GAS ONLY TYPE OF OIL
C-GAS/OIL L-LIGHT OIL
M-MEDIUM, BLENDED
TYPE OF ATOMIZING H-HEAVY OIL
P-PRESSURE
A-AIR BURNER SIZE
Model -LM: Designed for use with grade #2 oil or lighter. No provision for pre-heating oil is incorporated on the
burner itself. Standard design includes an oil supply back pressure regulating valve for recirculating oil from the
oil inlet on the burner. Pressure atomization is available up to size 300. Air atomization is available for all sizes.
Model -MM: Designed for use with blended fuel oils up through grade #5. A single oil pre-heater is incorporated
into the burner design to raise the oil to atomizing temperature. Standard design includes an oil supply back
pressure regulating valve for recirculating oil from the discharge of the oil heater. Pre and post firing nozzle
purge system is available as an option.
Model -HM: Designed for use with the heaviest grades of fuel oil. Oil is heated to atomizing temperature with a
single heater on sizes 50 - 125 and dual heaters on sizes 150 - 1000. Standard design includes a triple-pass oil
manifold to continually keep all oil piping hot up to the nozzle, an oil supply back pressure regulating valve for
recirculating the oil from the burner inlet, a relief valve for recirculating oil from the oil heater discharge, and a
pre and post firing nozzle purge system.
Rev 3/09 1
100 of 761
ORDERING INFORMATION
The following information is required to process orders or quotations:
All systems: Burner Model desired (see Page 1000-01).

Burner capacity of boiler HP.
Type of boiler or furnace.

Furnace pressure to be fired against.
Electrical specifications.
Elevation (if greater than 2,000 ft.)
Insurance or local code requirements (if other than U.L.)
Control system programmer desired.
Control options desired.
Gas systems: Type of gas.

Gas supply pressure at burner installation.
Oil systems: Grade of oil to be burned.

If oil supply system is independent, or common with other burners.
If oil transfer pump, or pump and heater set is required.
Rev 3/09 2
101 of 761
GENERAL MODEL DESCRIPTION
A flange mounted windbox assembly, a firing head assembly, a stainless steel encased refractory burner tile, a
gas/electric ignition system, modulating motor with a jackshaft and linkage assembly, a wiring junction box, a
flame scanner, and an observation port.
Size 50 to 1000-SP packaged burners include an integral forced draft, axial-flow, backward-inclined, blower
assembly hinge mounted to the windbox incorporating a triple-disc air shutter assembly with a jackshaft and
linkage connected to the windbox jackshaft with a swivel linkage, an air proving switch, and a latch switch. All
sizes also include a silencer on the blower inlet.
Burner models with a -BD suffix are constructed with an integral FD fan, as described above, but with a belt
drive arrangement. These models are intended for use with 50Hz power sources only. Burner models with an -
RF suffix are for use with a separate FD fan. They are designed for applications involving very high furnace
pressures, 50Hz power sources, and/or high elevations.
A separate NEMA 1 control panel for remote mounting, incorporating a full-modulating flame safeguard
programmer, a motor starter and overload relay for the blower motor, on-off switch, a manual/auto firing rate
selector switch, a manual firing rate limiting potentiometer, and (4) indicating lights for: "POWER ON",
"IGNITION", "FUEL" AND "SAFETY". Numerous other control features are available as options.
GAS FIRED SYSTEMS:
Standard gas train components include a gas butterfly control valve mounted on the burner, automatic gas shut-
off valves, pressure switches, pressure regulators, and manual gas cocks shipped loose. Gas train assemblies
are available to meet any local or national codes required. Optional factory pre-piped gas trains are available as
an option.
Standard systems are designed for use with natural gas and/or propane gas. Applications involving the use of
other fuel gases are reviewed on an individual basis after receiving details regarding the fuel analysis.
PRESSURE ATOMIZED OIL FIRED SYSTEMS:
An oil supply pump on a separate mounting base is provided to supply oil to the burner system at 300 psig. The
burner mounted oil pipe train includes a solenoid shut-off valve, oil supply pressure gauge, return flow oil
nozzle, oil return solenoid valve, oil return pressure gauge, and a return flow metering valve. The control system
also includes an oil pump motor starter & overload relay.
AIR ATOMIZED OIL FIRED SYSTEMS:
Three different models are available for use with #2 oil, blended medium grade oil, and #6 oil. The model
designations for these fuels are -LM, -MM, -HM respectively.
An oil supply pump on a separate mounting base is provided to supply oil to the burner system. The burner
mounted oil pipe train includes a solenoid shut-off valve, oil supply pressure gauge, oil nozzle pressure gauge,
oil metering valve, oil nozzle, and an oil back pressure regulating/relief valve.
A compressor set on a separate mounting base is provided to supply atomizing air to the system. The burner
mounted atomizing air train includes an atomizing air pressure switch and an air pressure gauge.
Systems designed to fire with #4 oil also include one electric oil heater. A post-firing nozzle purge system is
available as an option. Systems designed to fire with #6 oil include either one or two electric oil heaters,
depending on the burner size, a post-firing nozzle purge system, and a oil recirculating system to maintain
heated oil piping up to the oil nozzle at all times.
Rev 3/09 3
102 of 761
INSTALLATION INSTRUCTIONS
BURNER ASSEMBLY
If unsure of component identification refer to the component I.D. drawings included in the installation/operation
manual furnished for each specific job:
The burner system is shipped with the refractory tile separate from the burner assembly to prevent damage in
transit. The refractory tile should be bolted to the windbox mounting flange prior to mounting the assembly to the
furnace mounting plate.
The firing head assembly can be installed inside the windbox after the burner has been mounted on the furnace.
The adjustable firing head mounting brackets have been factory set for proper positioning of the head relative to
the refractory burner throat. Because the refractory throat may not be positioned exactly the same at the
installation as it was in the factory, a slight adjustment to the mounting brackets may be necessary to position
the head concentric with the ID of the throat.
WARNING:
Both the windbox and the swing-away FD fan assembly have provision for installing a lifting lug, however the
entire burner assembly should only be lifted using a lifting lug on the windbox. The weight of the burner should
not be supported by using a lifting lug on the swing-away blower assembly. A lifting lug should only be used on
the blower assembly should it become necessary to remove the blower assembly from the windbox.
BURNER MOUNTING DIMENSIONS

30°
Burner Size X Y Z
50-125 18 21 ¼ 6
150-250 21 25 ¼ 6
300 22 30 ¼ 6 X
400 24 30 ¼ 6
500-625 25 35 ¼ 6 Y
CUT-
OUT
800 25 39 ½ 12
1000 30 39 ½ 12
All dimensions in inches.
(Z) 1/2" MTG STUDS
(SOLID LOCATIONS for SIZE 800 & UP ONLY)
Rev 3/09 4
103 of 761
REFRACTORY INSTALLATION
Plastic refractory must be “rammed" into the area between the O.D. of the burner tile and the I.D. of the furnace.
This refractory must extend a minimum of 2-1/2" beyond the tube sheet of water wall of the boiler. Refractory
which extends beyond the end of the burner tile should be formed from the I.D. of the tile at a minimum angle of
45 degrees.
TUBE
SHEET
2-1/2"
HIGH TEMP MIN
GASKET
MATERIAL
45° MINIMUM
BURNER MTG
FLANGE
BURNER TILE
PLASTIC
REFRACTORY
BOILER FRONT
PLATE
REFRACTORY TILE CURING INSTRUCTIONS
A gradual refractory heat up schedule must be followed to ensure proper curing of the burner tile and any plastic
refractory used during installation. Improperly cured refractory can blister, crack, or explode due to too rapid
heating and excessive vaporization of moisture in the material. Excessive steam issuing from the refractory
indicates that temperature is increasing too rapidly. Hold temperature until steaming subsides.
The following schedule does not supersede the manufacturer’s schedule, but should be viewed as a minimum
requirement. Always follow the plastic refractory manufacturer’s instructions for proper curing and longest
refractory service life.
1. Initially fire the burner at low fire for 30 minutes.
2. Shutdown for 30 minutes.
3. Repeat steps 1 and 2 for 6 to 8 hours. This will incrementally, but gradually raise the refractory to
proper curing temperature. Do not take the firing rate past minimum until the refractory is fully cured.
Fine surface cracks are normal in a properly cured refractory and do not indicate defect or failure. Large
penetrating cracks or missing pieces indicate the refractory was improperly installed or cured too rapidly. All
damaged refractory should be repair or replaced immediately to avoid damage to the burner.
SWING CYLINDER HINGE AND LATCH ADJUSTMENT
Jarring during shipment can cause misalignment of the swing-away blower assembly to the windbox, or of the
latch lug to the latch lock. The blower assembly is aligned to the windbox with adjusting bolts on the hinges; the
weight of the blower assembly must be supported should it become necessary to loosen the fastening bolts for
readjustment.
The latch assembly can be readjusted in both the horizontal and vertical directions after loosening the mounting
screws. The latch lug can also be adjusted to insure tight closure of the blower assembly to the windbox by
loosening the jam nut behind the lug and threading the lug closer to, or farther away from the latch lock.
The position of the latch handle relative to the latch lug can be changed by pulling out on the handle while
pushing in on the end of the latch shaft and rotating the handle to the desired position.
Rev 3/09 5
104 of 761
CONTROL PANEL & SAFETY CONTROLS INSTALLATION
The control panel is furnished as a separate item and should be installed in a location other that immediately
next to, or in line with the burner. It should be mounted on an adjacent wall or the side of the appliance. All
wiring must comply with, and all branch circuits must be protected according to the national electrical code.
Flame detector wiring between the burner and the control panel should be run in separate conduit from high
voltage conductors.
All safety controls indicated on the wiring schematic furnished with the burner must be installed and wired in the
control system as shown. Any discrepancies, or changes, must be approved by the S.T. JOHNSON CO. prior to
initial firing of the burner system.
All signal wiring should be run in separate conduit and shielded according to the wiring schematic supplied with
the equipment.
STANDARD CONTROL PANEL MOUNTING DIMENSIONS
The installation dimensions for standard NEMA 1 control panel enclosures follow. Specifications for other than
NEMA 1 enclosures, and/or the inclusion of optional control equipment, may result in different installation
dimensions. If mounting dimensions are critical, check with the factory for information on specific jobs.
DESIGNATION A B C D E F G H
FD68 STD 21.375 21.375 7.25 19 14.875 .38 1.125 1.875
FD68 LARGE 27.5 21.5 7.25 25 14.75 .38 1.25 3.25
FD68 X-LARGE 27.5 21.5 12 25 14.75 .38 1.25 3.25
All dimensions in inches.
Rev 3/09 6
105 of 761
REQUIRED SAFETY LIMIT CONTROLS FOR ALL MODELS
All burner systems must be installed with a pressure or temperature operating control and high limit control.
These controls must be installed on the appliance in a location where they can accurately sense the pressure of
the vapor, or temperature of the liquid being heated. Contact the appliance manufacturer if unsure of the correct
mounting location. The electrical wiring schematic furnished with the burner indicates where these controls need
to be wired into the control system.
The operating control functions to limit the firing of the burner to those pressures, or temperatures, below the set
point of the control. Its N.C. contacts break upon rise of the pressure, or temperature. Typical operating controls
are:
Honeywell L404A for pressure Honeywell L4006A for temperature
The high limit control functions to shut off the burner system at a pressure, or temperature slightly above the set
point of the operating control. The set point of the high limit control must be less than the maximum pressure, or
temperature, or the appliance the burner is applied to. The N.C. contacts of this control break on a rise in
pressure, or temperature, and must result in manual reset of the control to resume operation of the burner
system. Typical high limit controls are:
Honeywell L404C for pressure Honeywell L6006E for temperature
If safety limit controls were not furnished with the burner system, or with the appliance on
which the burner is being installed, contact S.T. JOHNSON CO. or the appliance manufacturer
to obtain the proper controls for installation prior to initial firing of the system.
DO NOT attempt to fire any appliance, whether boiler or furnace without the necessary safety
limit controls.
Rev 3/09 7
106 of 761
GENERAL STARTUP PROCEDURE
PRE-FIRING CHECKOUT
WARNING!
The initial firing, and/or adjustment of these combustion systems must be performed by authorized and properly
trained personnel. Lack of extensive knowledge of these systems and/or the failure to explicitly follow these
instructions, and the manufacturer’s instructions provided for all components in the system, can result in
personal injury or property damage.
Qualified personnel must follow the instructions before proceeding with the initial firing of this equipment.
Unqualified personnel must not proceed with initial firing; contact S.T. JOHNSON CO for recommendations for
qualified personnel to initially fire the burner system.
This equipment must not be started up, or run at any time, without all guards, cover plates, and enclosures
properly secured in place. Guards and cover plates must only be removed for maintenance and service.
The entire combustion system must be checked prior to attempting the initial operation. These checks must
include, but are not limited to:
1. All piping must be checked against the provided piping drawings to insure proper installation. Tightness of all
fittings should also be checked.
2. All wiring must be checked against the provided wiring drawings to insure completeness and accuracy. Check
for loose connections or short circuits prior to applying power to the system.
3. The electrical power supply must be checked to insure the voltage coincides with the motor and control
voltages listed on the equipment nameplates.
4. Check gas supply pressure to insure it is compatible with the pressure regulators installed on the gas train.
5. Check oil supply to verify the grade of oil corresponds to that specified on the burner nameplate. Also insure
that transfer pumps, if used, do not supply oil to the burner pump at a pressure higher than the manufacturer’s
specification, generally 3 PSIG.
6. Check linkages to all fuel control valves and the air shutter to insure proper operation without binding or
slippage.
7. Insure all pumps have been properly primed with oil and that the compressor, on air atomized systems, has
been filled with the proper grade of compressor oil.
8. Check for proper rotation of all motors by momentarily closing the motor starter contacts.
9. Referring to the manufacturer’s instructions included in the operating manual furnished, check for the proper
setting and operation of all safety related controls; this could include but is not limited to:
• Boiler operating and high pressure limit controls
• Boiler pressure safety relief valves
• Boiler low water cutouts
• Burner gas pressure switches
• Burner blower air pressure switch
• Burner atomizing air pressure switch
• Burner oil pressure switch
• Low & high oil temperature switch (-MM, -HM models)
Rev 3/09 8
107 of 761
COMBUSTION AIR ADJUSTMENT
INTEGRAL FAN BURNERS
Burners with an integral, swing-away, blower assembly should have the air shutter completely closed at low fire
for proper pilot performance and maximum turndown of the main flame. On applications involving a positive
furnace pressure the air shutter should be adjusted for full opening at high fire to obtain the maximum catalog
capacity. On applications involving a negative furnace pressure the opening of the air shutter should be limited
to a point where the fan motor will not draw more current than 115% of the nameplate amperage.
To insure complete closure of the air shutter at low fire the linkage between the main jackshaft and the air
jackshaft should be adjusted to provide a slight amount of over-travel of the linkage into the overtravel or swivel
assembly when the air shutter is closed.
On applications where a very high draft, or a changing draft, such as boiler conversions with high stacks or
where multiple boilers utilize a common stack, serious consideration must be given to control the draft through
the combustion chamber/burner. Uncontrolled draft can cause low efficiency, noisy combustion and instability.
REMOTE FAN BURNERS
Remote fan burners (-RF model designation) can be furnished with a multi-blade air damper on the inlet of the
burner, or with an inlet vortex damper on the remote fan. Remote fans and associated air ducting must be sized
to provide the following differential windbox air pressures (over & above the furnace pressure):
CAPACITY DIFFUSER LOSS DAMPER LOSS TOTAL LOSS

BURNER SIZE
(MBH) (Inches w.c.) (Inches w.c.) (Inches w.c.)
50 2,100 0.6 0.1 0.7
75 3,570 1.5 0.3 1.8
100 4,620 2.5 0.5 3.0
125 5,600 3.6 0.7 4.3
150 7,350 2.5 0.3 2.8
200 10,050 4.7 0.5 5.2
250 11,200 5.8 0.6 6.4
300 14,280 6.1 0.4 6.5
400 20,160 6.2 0.7 6.9
500 24,150 7.3 0.4 7.7
625 31,500 10.0 0.7 10.7
625 33,600 11.7 0.8 12.5
1000 42,000 12.5 0.7 13.2
Rev 3/09 9
108 of 761
IGNITION SYSTEM ADJUSTMENT PROCEDURE
Note: The "TEST/RUN" switch on the flame safeguard programmer may be used to provide additional time for
adjustment; refer to the programmer instructions furnished with the burner.
STANDARD GAS-ELECTRIC PILOT SYSTEMS
Standard piloting arrangements are designed for use with natural gas or propane and include a pilot solenoid
valve, pressure gauge, ball valve, ignition transformer and regulator rated for 10 PSIG max inlet pressure. The
regulator should be adjusted to provide an outlet pressure of 3 to 6" w.c. The internal orifice in the pilot
assembly may be drilled out to 1/8" maximum in applications where a larger pilot flame may be desired.
PI COMPONENT IDENTIFICATION
3/8" NPT CONNECTION FROM 1. 3/8" BALL VALVE

MAIN GAS TRAIN INLET SECTION
2. 3/8" MAXITROL 325-3 REGULATOR
3. 0 - 35"W.C. PRESSURE GAUGE
1 2 3 4 4. 1/4" ASCO 8262G13 SHUTOFF VALVE
OPTIONAL DIESEL/ELECTRIC IGNITION SYSTEMS
Diesel oil pilot systems are designed to operate with 100 to 110 PSIG oil pressure on the pilot nozzle. The exact
piping configuration and adjustment procedure differs according to the burner model. Heavy oil burners include
a separate pilot oil pump and a time delay relay in the control system to interrupt the pilot pump after
establishment of the main flame. Standard arrangements for pressure or air atomized light oil burners utilize the
main oil pump for the pilot, however a separate pilot oil pump can be furnished as an option.
Rev 3/09 10
109 of 761
FIRING HEAD ADJUSTMENT PROCEDURE
AIR DIFFUSER SPECIFICATIONS
The air diffuser is a critical component in the burner design. A damaged or deteriorated air diffuser will adversely
affect combustion performance. The following dimensional information is furnished as a maintenance guide
especially for checking for proper louver openings. Although these dimensions are the factory standard, certain
special applications may have required opening the outside of the diffuser louvers further.
Burner Size A B C D
50, 75, 100 9.69"/246mm 4"/102mm .31"/7.9mm 9.81"/249mm
125 9.69"/246mm 5"/127mm .56"/14.3mm 9.81"/249mm
150, 200 12.63"/321mm 5.63"/143mm .38"/9.5mm 12.75"/324mm
250 12.63"/321mm 6"/152mm .50"/13mm 12.75"/324mm
300 13.63"/346mm 6.25"/159mm .38"/9.5mm 13.75"/349mm
400 15.63"/397mm 6.25"/159mm .50"/13mm 15.75"/400mm
500 16.38"/416mm 7.5"/191mm .50"/13mm 16.50"/419mm
625, 800 17.38"/441mm 7.88"/454mm .50"/13mm 17.50"/445mm
900, 1000 20.31"/517mm 9.25"/235mm .50"/13mm 20.50"/521mm
Rev 3/09 11
110 of 761
AIR ROTATION BLADE SETTINGS
The air rotation blades serve to control the amount of, and swirl of, the combustion air flowing through the center
of the air diffuser. This air has a rotation opposite to that of the air flowing through the outer diffuser louvers. The
rate of fuel/air mixing and flame geometry can also be changed by the rotation blade setting especially when
firing oil. Closing the blades more will result in a higher degree of swirl to the flame carrying the fuel/air mixture
further out toward the furnace walls.
Oil only burners, especially those firing heavy oil, typically should have the rotation blades open further as
indicated by position "B" below. Burners designed to fire on gas, or gas/oil, would typically have the blades set
in the normal position "A". The closed position "C" is almost never recommended
Positioning the blades so the stem is on the outward side will result in lower emissions on those installations
where NOx control is incorporated.
Gas systems designed with gas spuds located behind the air diffuser can incur combustion behind the diffuser
on initial light-off if the blades are open further than position "A" and the system is adjusted for maximum
turndown. This condition should be checked for after initial commissioning and the blades closed further if the
problem exists.
After initial setup the air rotation blades should only need to be checked, or re-set, if and when the air diffuser is
replaced.
Rev 3/09 12
111 of 761
FAN WHEEL SPECIFICATIONS FOR 60HZ INSTALLATIONS
The following fan wheel dimensions are those for burners fabricated for 60Hz installations utilizing standard
ODP motors. Burners built with special motors may have a different hub size.
All dimensions are expressed as (Inches/mm).
Burner Size W OD ID Bore
50 2.06 / 52 8.63 / 219 5.00 / 127 0.63 / 16
75 2.50 / 63 10.50 / 267 6.00 / 152 0.63 / 16
100 2.91 / 74 12.25 / 311 7.00 / 178 0.63 / 16
125-150 4.81 / 122 12.25 / 311 7.19 / 183 0.63 / 16
200 5.53 / 140 14.00 / 356 8.19 / 208 1.13 / 29
250-300 6.22 / 158 15.63 / 397 9.19 / 233 1.13 / 29
400 6.84 / 174 17.38 / 441 10.19 / 259 1.38 / 35
500 7.56 / 192 19.13 / 486 11.19 / 284 1.63 / 41
625 8.28 / 210 20.88 / 530 12.19 / 310 1.63 / 41
800 8.28 / 210 19.13 / 486 13.00 / 330 1.63 / 41
1000 8.28 / 210 20.88 / 530 14.50 / 368 1.63 / 41
1000-SP 7.50 / 190 22.63 / 575 15.5 / 394 1.88 / 48
Rev 3/09 13
112 of 761
FAN WHEEL SPECIFICATIONS FOR 50HZ INSTALLATIONS
The following fan wheel dimensions are those for burners fabricated for 50Hz installations utilizing standard
ODP motors. Burners built with special motors may have a different hub size.
All dimensions are expressed as (Inches/mm).
Burner Size W OD ID Bore
100 2.91 / 74 12.25 / 311 7.00 / 178 0.63 / 16
125-150 4.81 / 122 12.25 / 311 7.19 / 183 0.63 / 16
200 5.53 / 140 14.00 / 356 8.19 / 208 1.13 / 29
250-300 6.22 / 158 15.63 / 397 9.19 / 233 1.13 / 29
300-SP 6.84 / 174 17.38 / 441 10.19 / 259 1.38 / 35
400 6.84 / 174 17.38 / 441 10.19 / 259 1.38 / 35
400-SP 7.56 / 192 19.13 / 486 11.19 / 284 1.38 / 35
500 7.56 / 192 19.13 / 486 11.19 / 284 1.63 / 41
500-SP 8.28 / 210 20.88 / 530 12.19 / 310 1.63 / 41
625 8.28 / 210 20.88 / 530 12.19 / 310 1.63 / 41
800 8.28 / 210 19.13 / 486 13.00 / 330 1.63 / 41
1000 8.28 / 210 20.88 / 530 14.50 / 368 1.63 / 41
1000-SP 7.50 / 190 22.63 / 575 15.5 / 394 1.88 / 48
Rev 3/09 14
113 of 761
MAINTENANCE RECOMMENDATIONS FOR ALL BURNERS
ROUTINE (OPERATIONAL) BURNER CHECKS

1. Check visual appearance of flame (no impingement on furnace, etc)
2. Check for gas or oil leaks in fuel piping system
3. Check for abnormal bearing noise from motors
4. Inspect for loose or bent control linkage
5. Inspect for deteriorating refractory (broken pieces in furnace)
ROUTINE (OPERATIONAL) SAFETY CONTROL CHECKS
Note: The following procedures will result in a burner shut-down for a short period; if the burner does not shut
down during any of the following steps, the control being tested must be replaced before placing the equipment
back into service. Refer to the manufacturer’s literature for check-out instructions for each specific control.
1. Manually shut off the source of fuel; the burner system should shut down within 4 seconds. If not the
flame detector and/or the amplifier portion of the primary safety control must be replaced.
2. Reduce the set point of the operating limit control below the existing pressure, or temperature,
condition. The burner should shut down immediately.
3. Reduce the set point of the high limit control below the existing pressure, or temperature, condition.
The burner should shut down immediately requiring a manual reset to restart.
4. Reduce the set point of the low pressure switch for the fuel being used, either gas or oil, to a point
below the operating pressure. The burner should shut down requiring a manual reset.
NON-OPERATIONAL CHECKS
1. Check for cleanliness of flame scanner lens.
2. Check for deterioration of pilot, ignition electrode & firing head components.
3. Check for dirt build-up on ignition electrode insulator and ignition cable.
4. Check for dirt build-up on fan blades.
5. Check for proper and safe operation of flame safeguard programmer according to the manufacturer’s
instructions provided in the manual furnished with the burner.
6. Leak test all fuel safety shut-off valves according to the manufacturer’s instructions provided in the
operating manual furnished with the burner.
LUBRICATION
Fan motors should be lubricated every 6 months under normal operating conditions, or more often with high
ambient temperatures. For motors up through 10 HP use #2 consistency, lithium based, grease. For 15 HP and
larger motors use #2 consistency, polyurea grease.
REPLACEMENT PARTS
When ordering parts, or requesting information on equipment, always include the nameplate data including shop
order number.
Rev 3/09 15
114 of 761
SPECIAL MAINTENANCE RECOMMENDATIONS FOR BELT-DRIVE (50 Hz) BURNERS
SPROCKET & BELT ADJUSTMENTS FOR BELT DRIVE MODELS
The "HPT" style drives do not require as much belt tension as standard "V-BELT" type drives but sprocket
alignment is very important to insure long belt life. A straight edge should be used to insure correct alignment of
the sprockets.
The motor can be re-positioned on the adjustable motor mounting base to insure correct alignment of the motor
shaft with the fan shaft in the vertical plane. If necessary, loosen the bolts holding the motor to the adjustable
base and position on the motor to obtain proper shaft alignment in the vertical plane.
The motor mounting base can be adjusted to insure that the center line of the motor shaft and the center line of
the fan shaft are parallel. If necessary, loosen the (4) locking bolts on the side of the adjustable base and
change the height of either the front or the back of the mounting plate using the adjusting bolts located on top of
the base.
After properly aligning the shafts, the height adjusting bolts on top of the adjustable base can be used to obtain
the proper tension on the drive belt. When adjusting belt tension all (4) height adjusting bolts should be changed
by the same amount in order to maintain proper shaft alignment. Exact belt tension can be determined by
applying a perpendicular force to the center of the belt width, and the center of the belt span, with a spring
scale. The following belt deflections should occur when a force of 5kg is applied:
BURNER SIZE 50 - 125 150 -250 300 -400 500 - 700 1025 - 1040
Deflection: 5 mm 6 mm 8 mm 10 mm 12mm
Note: Burner size 1040 furnished with a TEFC motor should have a deflection of 12mm when a force of 7.3 kg is
applied.
FAN SHAFT BEARINGS
Fan shaft bearings should be lubricated with the same grease, and at the same interval as recommended for
the fan motor.
The inner race of the fan shaft bearings is locked to the shaft with set screws; tightness of this set screw should
be checked at regular maintenance intervals to insure the bearing race does not rotate on the fan shaft.
REPLACEMENT PARTS
order number.
Rev 3/09 16
115 of 761
OPTIONAL AIR FILTER ASSEMBLIES
FD68 air filter assemblies utilize a reticulated flexible polyester urethane foam filter media which have a three
dimensional structure of skeletal strands to provide exceptional filtering characteristics at very low resistance to
airflow. The media has the following specifications:
TEMPERATURE LIMITATIONS: -40F to 250F (-4C to 120C)
DUST HOLDING CAPACITY: .18lb/ Sq Ft (7.9gm/Sq M)
AIR PRESSURE DROP(CLEAN): 0.1" w.c. (.004 mm Aq)
WARNING:
The air filter media should not be exposed to prolonged periods of direct sunlight, strong acids,
caustics, or chlorine. Exposure to aromatic hydrocarbons will cause swelling of the material, however,
the original dimensions can be restored by removal of the hydrocarbons via cleaning.
MAINTENANCE RECOMMENDATIONS:
Normal cleaning procedures will simply involve vacuuming from the outside of the material or reverse flushing
with water.
Oil and entrapped particulate can be removed by immersing in hot water and detergent.
REPLACEMENT FILTERS:
order number.
Rev 3/09 17
116 of 761
TROUBLESHOOTING GUIDE
SYMPTOM PROBABLE CAUSE

• High limit control "LOCKED OUT".
• Low water cut-out "LOCKED OUT".
• Flame safeguard programmer "LOCKED OUT".
Call for heat but burner will not start.
• Blower motor overload relay tripped.
• Blower motor circuit protection tripped.
• Blower motor defective.
• Blower air pressure switch not making.
• Fuel pressure switch not making.
Burner starts but will not complete
• Aux contact on blower starter is open.
the prepurge cycle.
• Aux contact on pump or compressor starter is open.
• Defective flame safeguard programmer module.
Purge complete but ignition is
• Low fire start switch in mod motor not making.
unsuccessful.
• Pilot gas cock is closed.
• Pilot gas pressure is insufficient.
Ignition is attempted but • Ignition transformer is defective.
unsuccessful. • Pilot solenoid valve is defective.
• Incorrect flame scanner sighting.
• Flame scanner is defective.
• Main fuel valve is closed.
Pilot established but main flame • High fuel pressure switch is tripping when main fuel valve opens.
ignition is unsuccessful. • Main gas control valve completely closed @ low fire.
• Improper fuel-air ratio @ low fire.
• Improper fuel-air ratio @ mid-firing range.
Main flame established but burner
• Insufficient gas pressure from regulator.
shuts down when modulating to high
• Low fuel pressure switch set too high.
fire.
• High limit control set too low or defective.
• Modulating controller set too low or defective.
Burner remains @ low fire with
• Modulating motor is defective.
increasing load demand.
• Control system in "MANUAL, LOW FIRE" mode.
• Oil nozzle needs cleaning.
Lack of flame retention when firing
• Improper atomizing air pressure.
on oil.
• Heavy oil temperature too high.
• Oil nozzle needs cleaning.
Creation of soot in furnace when • Fuel-air ratio is set too fuel rich.
firing on oil. • Atomizing air pressure too low.
• Spray angle of nozzle not correct for furnace.
Oil pressure is uncontrollably high @ • Cold oil is plugging oil nozzle. Check for proper operation of the
light-off nozzle purge solenoid and check valves.
Rev 3/09 18
117 of 761
GAS SYSTEMS STARTUP
GAS TRAIN INSTALLATION
SELECTION & SIZING
Gas trains are selected according to local code & insurance requirements. Components are sized according to
available gas supply pressure, burner capacity, and furnace pressure. As a guide standard sizes are listed in
the catalog bulletin along with the required outlet pressure of the main pressure regulator. Installation manuals
for each job include drawings of the gas train furnished with the burner system.
LOCATION
Gas trains should be located as close to the burner assembly as possible, preferably on the left side of the
burner to facilitate easy connection to the gas control valve. Temperature limitations of all the components
should be taken into account when mounting directly on the heating appliance. (Refer to the specifications and
installation instructions furnished with the operating manual).
FIELD PIPING
The piping should contain as few direction changes as possible between the main pressure regulator and the
burner inlet to minimize the pressure drop. Proper sizing of components often results in a main pressure
regulator with a smaller pipe size than the shut-off valves; this transition in pipe size should be made with a "bell
type" reducer at least 4 pipe diameters downstream of the regulator outlet. Gas shut-off valves and regulators
are all uni-directional and must be installed accordingly. Gas train assembly drawings are provided in the
installation & operating manual with each system.
VENT CONNECTIONS
Gas train assemblies to meet IRI code, and all gas trains for capacities greater than 12500 MBTU/HR, include a
N.O. vent valve for installation between the (2) shut-off valves. This valve should be installed in a horizontal run
of piping with the solenoid coil on the top. The pipe size of the vent line must be no smaller than the valve
furnished with the burner system. Vent connections from all pressure regulators and pressure switches should
also be vented to the outside of the building using 1/4" OD tubing as a minimum and may be manifolded
together but the size of the common vent line must be at least equal in area to the largest vent plus 50% of the
area of the remaining vent lines. The vent line from the N.O. vent valve must be run separately.
WARNING:
All piping and gas train components must be leak tested prior to the initial start up of the burner
system. The manual gas cock installed downstream of the shut-off valves is provided for this testing.
Gas shut-off valves should be leak tested periodically to insure there is no leakage through the valve
seats. It is recommended this leak testing be performed monthly.
Rev 3/09 19
118 of 761
MAIN GAS ADJUSTMENT
WARNING: Before proceeding with the main fuel/air adjustment, all appropriate PREFIRING CHECKOUTS
must be performed. Also insure that all linkages move smoothly without binding and are properly set to provide
for the minimum positions of both the air shutter and fuel valve at low fire. Make sure all connectors are tight.
A pilot turndown test must be performed according to the flame safeguard manufacturer's instructions provided
with this burner system. This test must ensure that the main burner flame can be smoothly ignited with the
smallest flame that can be detected by the flame detector. The orientation of the flame detector can be changed
if necessary by readjusting its swivel mount. A spark pickup test should also be conducted to ensure that UV
radiation from the ignition spark is not being detected whenever a UV flame detector is in use. Please refer the
manufacturer’s instructions.
The use of the "test/run" switch on the flame safeguard programmer, and the manual firing rate potentiometer, is
recommended to facilitate main fuel/air adjustment. Before attempting main fuel/air adjustment insure that the
system is in the low-fire, manual mode.
Flue gas constituents should be analyzed at all firing rates to optimize the levels of O2 & CO2 and insure that
the level of CO is not excessive. The exact percentage of these constituents can vary according to the
application but O2 levels will typically be 6-8% @ low fire and gradually decrease to 3-4% @ high fire. The
required low fire adjustment is often affected by the combustion chamber size, with smaller chambers requiring
more air to achieve proper flame geometry. If precise fuel/air ratios are required, or if acceptable levels are
difficult to achieve due to application variables, a gas control valve with an adjustable characteristic cam must
be considered.
If an adjustable characteristic cam is not used, the fuel/air ratio is determined merely by the low and high fire
setting of the gas butterfly valve and the position of the valve crankarm relative to the position of the jackshaft
crankarm. The effect of changing these relative positions is shown under GAS VALVE LINKAGE
ADJUSTMENT.
Manifold gas pressure should be measured and recorders using a manometer connected to the test port located
between the gas control valve and the burner inlet. The gas pressure at minimum fire will be negligible and
difficult to read; for this reason the fuel/air adjustment is best accomplished by sight and flue product analysis.
High fire manifold pressures to achieve the nominal burner capacity (i.e. 250HP for size 250), and the maximum
cataloged capacities are listed under GAS PRESSURE SETTINGS in the proceeding section.
Burners designed to burn fuel other than natural gas will typically be constructed with different gas jet porting
and will require manifold pressures similar to those previously listed for natural gas. All burners with special
configurations will have the proper high fire manifold pressure stamped on the burner nameplate.
Gas combustion in a confined combustion chamber with a small cross-sectional area can result in combustion
harmonics especially if the length to diameter ratio of the chamber is large. Model FD68 burners are designed to
eliminate this problem for most applications, however if this problem occurs the following corrective steps should
be attempted in the order listed:
1. An adjustable characteristic gas valve cam should be used.
2. The fuel/air ratio must be changed to compensate.
3. The jackshaft and valve crank positions must be changed.
4. The position of the air rotation blades on the firing head must be changed.
5. The position of the air band around the gas jet plenum should be changed.
6. Some of the inner gas jets should be plugged and the manifold pressure increased.
Rev 3/09 20
119 of 761
GAS PRESSURE SETTINGS: SIZE 50 TO 625
The following tables should be used as a guide to setting the high fire gas manifold pressure for sea level
operation. The pressures listed for the nominal burner capacity are those required when firing against the
furnace pressure listed. The maximum capacities & manifold pressures listed are for firing against a balanced
furnace pressure. Manifold pressures for firing into higher furnace pressures can be closely estimated by adding
60 to 65% of the additional furnace pressure to the manifold pressure listed.
Final fuel/air adjustments should be made by flue gas analysis.
NATURAL GAS MANIFOLD PRESSURE:
TABLE A: STANDARD MODELS OPERATING @ 60 HZ
BURNER SIZE 50 75 100 125 150 200 250 300 400 500 625
Nominal MBTU/Hr 2,100 3,150 4,200 5,250 6,300 8,400 10,500 12,600 16,800 21,000 26,250
Manifold Pressure
2.7 4.5 6.8 8.0 7.8 8.5 11.1 7.7 8.7 10.9 12.8
Inches w.c.
Furnace Pressure
.75 .75 1.0 1.0 1.5 2.0 2.0 3.0 4.0 4.0 4.0
Inches w.c.
Maximum MBTU/Hr 2,500 3,750 5,100 5,600 7,500 10,050 11,200 15,000 20,250 25,200 31,500
Manifold Pressure
3.0 5.1 7.5 8.4 9.2 10.4 11.3 7.6 9.0 11.3 15.0
Inches w.c.
TABLE B: STANDARD MODELS OPERATING @ 50 HZ
BURNER SIZE 50 75 100 125 150 200 250 300 400 500 625
Nominal
240 506 730 890 945 1,540 1,835 2,730 3,935 4,640 6,435
kcal/Hr
Manifold Pressure
45 68 107 116 89 130 155 135 170 188 285
mmAq
Furnace Pressure
50 50 50 50 50 50 50 50 50 50 50
mmAq
Maximum
515 650 1,055 1,160 1,555 2,085 2,320 3,110 4,200 5,225 6,535
kcal/Hr
Manifold Pressure
52 63 158 146 160 182 197 133 160 200 262
mmAq
TABLE C: BELT-DRIVE MODELS (-BD) OPERATING @ 50 HZ
BURNER SIZE 100 125 150 200 250 300 350 400 500 600 700
Nominal
1,045 1,230 1,500 2,100 2,700 3,440 4,200 4,870 5,820 7,225 8,000
kcal/Hr
Manifold Pressure
205 215 130 175 310 230 210 260 315 365 440
mmAq
Furnace Pressure
50 50 50 50 50 50 50 50 50 50 50
mmAq
Maximum
1,275 1,400 1,875 2,510 3,050 3,750 4,510 5,150 6,250 7,800 8,450
kcal/Hr
Manifold Pressure
190 213 156 205 350 237 208 257 328 390 455
mmAq
Rev 3/09 21
120 of 761
GAS PRESSURE SETTINGS: SIZE 1000 ONLY
The following tables should be used as a guide to setting the high fire gas manifold pressure for sea level
operation. The manifold pressures and capacities listed are the maximum obtainable for the corresponding
furnace pressure. Manifold pressures for firing into higher furnace pressures can be closely estimated by adding
60-65% of the additional furnace pressure to the manifold pressure listed.
Final fuel/air adjustments should be made by flue gas analysis.
NAT GAS MANIFOLD PRESSURE
TABLE A: STANDARD MODELS OPERATING @ 60 HZ
Furnace Pressure
0.0 1.0 2.0 3.0 4.0 5.0 7.0
Inches w.c.
Max Capacity
42,000 39,350 37,255 35,700 33,900 32,200 29,800
MBTU/Hr
Manifold Pressure
13.0 13.6 14.2 14.9 15.5 16.2 17.4
Inches w.c.
TABLE B: STANDARD MODELS OPERATING @ 50 HZ
Furnace Pressure
0 25 50 75 100 125
mmAq
Max Capacity
8715 7875 7430 6850 6475 6140
x1000 kcal/Hr
Manifold Pressure
13.0 13.6 14.2 14.9 15.5 16.2
mmAq
Burners ordered specifically for firing with a fuel gas other than natural gas can be furnished with special orifices
in the gas spuds which will result in manifold pressures different from those listed above.
GAS VALVE LINKAGE ADJUSTMENT
The following changes can be made to increase or decrease the rate of gas valve travel at low or high fire:
GAS VALVE POSITION CRANKARM

TOWARD THIS POSITION
FOR FASTER RATE OF
INCREASE FROM
LOW FIRE
MAIN JACKSHAFT
TOTAL TRAVEL
LESS
MORE
TOTAL TRAVEL MORE
LESS
SIZE 50 - 250 SHOWN @ LOW FIRE

(JACKSHAFT ON LARGER SIZES
ROTATES IN OPPOSITE DIRECTION)
Rev 3/09 22
121 of 761
AIR ROTATION BLADE & AIR BAND SETTINGS
The air rotation blades may be changed as shown. It must be kept in mind that combination gas/oil burners will
probably require a normal to open setting of these blades for oil firing. The air band (if supplied) may also be
repositioned to change the amount of air introduced to the gas jet plenum.
AIR BAND
(AROUND PERIMETER)
FIRING HEAD
(FRONT VIEW)
OPEN POSITION
CLOSED POSITION
NORMAL POSITION
INNER GAS JETS
SIZE 1000 GAS FIRING HEAD CONFIGURATION
AIR ROTATION BLADE SETTINGS
The air rotation blades are factory set so that a straight edge place on the blades will be tangent with the
primary sleeve on the firing head. Rotating the blades further open will result in more air being delivered into the
center of the flame. Closing the blades will force more air toward the outside of the flame and will result in more
rotation to the flame. Oil fired systems will generally require the blades to be open at least as far as the factory
setting. The shaft of the blades should be facing toward the center of the firing head for lowest emissions.
PRIMARY AIR SLEEVE
The percentage of laminar air flow through the center of the air diffuser can be controlled with the setting of the
primary air sleeve. The primary air opening "E" is factory set at the maximum opening. In general the primary air
opening should be set for its maximum value particularly on oil fired systems.
"E"
"D"
INNER GAS JET
AIR DISTRIBUTION SLEEVE
OUTER GAS JET
PRIMARY AIR SLEEVE
Rev 3/09 23
122 of 761
AIR DISTRIBUTION SLEEVE
The air distribution sleeve is only furnished with gas only, LE-series firing heads. It controls the flow of air
through the center of the diffuser. The dimension "D" is factory set at 5/8" but this dimension can be increased if
lower NOx levels are required. The sleeve will result in a slower mixing flame when firing with oil and can be
removed if a faster mixing oil fire, with more rotation, is required when firing in relatively small combustion
chambers.
LE94 FIRING HEAD CONFIGURATION
The Series LE firing head design incorporates several features which enable field adjustment to change the rate
of fuel/air mixing, flame geometry, and emission levels. Most installations will not require any changes from the
factory settings as described below. In general NOx levels will decrease as more fuel is added to the outside of
the flame. More gas can be directed to the outside of the flame until an unstable non-combustible, mixture is
obtained in the center of the flame. Instability is usually only a limiting factor when firing into small diameter
firetube boilers.
GAS SPUD ROTATION
The flame geometry and emission levels are affected by the direction at which the primary fuel gas is injected
into the combustion air stream. The direction of the gas flow from the primary gas orifices of the outer spuds can
be changed by rotating the spuds. The center orifice is factory set in position "A", directed toward the center of
the firing head. Rotating in the direction of position "B" will result in more fuel being delivered to the outside of
the flame. Rotating toward position "C", against the flow of air through the diffuser louvers, will also result in
faster mixing but generally is not recommended because of the generation of higher levels of CO and NOx.
PRIMARY/SECONDARY GAS SPUD ORIFICES
For natural gas, two of the three primary gas orifices are plugged at the factory. If more fuel is desired in the
center of the flame, one or both of the primary orifice plugs can be removed. The center secondary orifice, on
the face of the spud, may also be plugged resulting in less fuel being delivered to the outside of the flame.
Lower NOx emissions are generally achieved with two of the primary orifices open, and all five of the secondary
orifices open. Orifice configuration will vary for fuels other than natural gas.
Rev 3/09 24
123 of 761
OIL SYSTEM STARTUP: PRESSURE ATOMIZED MODEL P-LM
Refer to general pre-firing checkout of the burner & controls.
Refer to all preceding sections including combustion air and IGNITION SYSTEM adjustments.
Refer to all manufactures’ components instruction manuals.
INITIAL MAIN BURNER ADJUSTMENT
Please refer to each manufacturer’s manual for system components prior to making any adjustments to the
burner.
Prime the suction line to the pump by filling the suction line strainer with oil prior to checking for proper rotation
of the pump. If supply pressure is not developed shortly after starting the pump, check for improper or loose
connections in the suction line, or improper pump rotation. Prolonged operation without a proper prime will
cause damage to the pump.
Modulating pressure atomizing systems utilize a return-flow nozzle with a constant oil supply pressure and a
variable return flow pressure. The return flow pressure is determined by the position of the oil metering valve
located in the oil return line on the left front of the burner. Refer to OIL SYSTEM SETTINGS for nominal supply
and return pressures and valve settings, OIL PIPING SCHEMATIC, and METERING VALVE SETTINGS for
linkage adjustments. The settings listed should be used as a guide for initial firing with final adjustments made
according to the results of a flue gas analysis. Typical O2 readings are 3 - 4 % @ high fire and 6 - 8 % @ low
fire. A smoke reading should also be taken to insure proper adjustment and good atomization or the oil.
The presence of white smoke indicates too little oil which normally can be eliminated by changing the position of
the metering valve to a lower number on the index plate. Black smoke indicates too much oil and the need to
change the metering valve to a higher numbered setting. If either of these conditions exists at one end of the
firing range, but not the other, the rate of travel of the metering valve will have to be changed by changing the
position of the valve crank arm relative to the position of the crank arm on the jackshaft.
Check for a dirty or clogged oil nozzle when experiencing difficulty obtaining proper combustion or
recommended return oil pressures. If proper supply pressure cannot be obtained, check for restrictions in the oil
suction line, especially the oil strainer.
After making final adjustments check tightness of all linkage connections and ensure there is no binding of
linkages during travel between maximum and minimum positions. Record all pressures and valve settings for
future reference.
WARNING: The system must be checked for smooth and reliable ignition of the main flame
after main burner adjustments are made. All safety related controls must also be checked for
proper, and safe operation.
Rev 3/09 25
124 of 761
METERING VALVE LINKAGE SETTINGS
Typical linkage and crankarm arrangements for the oil metering valve are shown below for the different sizes of
pressure atomized oil burners
The alternate positions of the crankarm, and the different locations of the linkage swivels, are shown as an aid
to properly set the rate of fuel increase to match the rate of air increase when the burner modulates between
low & high fire. The alternate positions apply to all burner sizes.
TOWARD HIGH FIRE
MORE
TOTAL TRAVEL
LESS
MORE
TOTAL TRAVEL
SHOWN @ LOW FIRE

LESS
SIZE 50 - 250
POSITION CRANKARM
FOR FASTER RATE OF
INCREASE FROM
HIGH FIRE
SHOWN @ LOW FIRE TOWARD HIGH FIRE
SIZE 300 & UP
Rev 3/09 26
125 of 761
MODEL P-LM OIL SYSTEM SETTINGS: 60 Hz OPERATION
DELAVAN RETURN
METERING VALVE SUPPLY FIRING
BURNER VARIFLO PRESSURE
VALVE POSITION PRESSURE RATE GPH
SIZE NOZZLE PSIG
SIZE PSIG
QTY (4) HIGH LOW HIGH LOW HIGH LOW
50 2.5 x 60 S3-5 0 6 275 130 65 15 8
75 3.5 x 60 S3-5 0 9 260 130 70 23 9
100 4.5 x 60 S3-5 0 7.5 275 138 70 30 10
125 5.5 x 60 S3-7 0 6 275 130 65 38 12
150 7.0 x 80 S3-9 0 8 260 135 65 45 15
200 9.0 x 80 S3-9 0 9 275 118 65 60 20
250 10.0 x 80 S3-11 0 8 300 161 70 75 24
300 12.0 x 80 S3-13 0 8 300 155 90 90 30
Maximum capacity listed is @ sea level firing against furnace pressures no greater than:+0.75"wc for sizes 50 &
75, +1.0"wc for sizes 100 & 125, +1.5"wc for size 150, +2.0 "wc for sizes 200 & 250, +3.0"wc for size 300.
Metering valve settings and return flow pressures are those recommended for initial adjustment. Final settings
are to be made according to operating conditions and flue gas analysis.
OIL PUMP SPECIFICATIONS: 60 Hz OPERATION
BURNER SIZE PUMP SIZE HP RPM GPH
50-150 V024D 3/4 1725 110
200-250 V026D 1 1725 155
300 V024D 1.5 3450 240
OIL PIPING SCHEMATIC: 60 HZ OPERATION
2 1 7 6
COMPONENTS
TO
NOZZLE
5
1&2 SOLENOID VALVE
OIL SUPPLY
FROM
NOZZLE 3 OIL METERING VALVE
4 OIL RETURN PRESSURE GAUGE
4 5 OIL RETURN SOLENOID VALVE
6 OIL SUPPLY PRESSURE GAUGE

OIL RETURN
TO SUPPLY
7 OIL PRESSURE SWITCH (OPTIONAL)
3
FACTORY PIPING
FIELD PIPING
Rev 3/09 27
126 of 761
MODEL P-LM OIL SYSTEM SETTINGS: 50 Hz OPERATION
DELAVAN RETURN
METERING VALVE SUPPLY FIRING
BURNER VARIFLO PRESSURE
VALVE POSITION PRESSURE RATE kg/Hr
SIZE NOZZLE PSIG
SIZE PSIG
QTY (4) HIGH LOW HIGH LOW HIGH LOW
100 3.5 x 60 S3-5 0 9 260(267) 130 70 79 26
125 4.5 x 60 S3-7 0 7 275(292) 138 70 98 32
150 5.5 x 80 S3-7 0 6 275(292) 130 65 124 38
200 7.0 x 80 S3-9 0 8 260(262) 135 65 146 49
250 9.0 x 80 S3-9 0 9 275(278) 118 65 195 64
300 10.0 x 80 S3-11 0 8 295(300) 161 70 244 81
300-SP 12.0 x 80 S3-11 0 8 293(300) 155 90 293 97
Maximum capacity listed is @ sea level firing against furnace pressures no greater than:+20mm Aq for sizes 50
& 75, +25mm Aq for sizes 100 & 125, +38mm Aq for size 150, +50mm Aq for sizes 200 & 250, +75mm Aq for
size 300.
Metering valve settings and return flow pressures are those recommended for initial adjustment. Final settings
are to be made according to operating conditions and flue gas analysis. The oil supply pressure listed in
parenthesis is the pump pressure; the lower pressure is the actual pressure @ the oil nozzles.
OIL PUMP SPECIFICATIONS: 50Hz OPERATION
BURNER SIZE PUMP SIZE HP RPM LPH
100-200 V024D 3/4 1425 360
250-300 V026D 1 1425 470
300-SP V024D 1 2850 725
OIL PIPING SCHEMATIC: 50 HZ OPERATION
2 1 7 6
TO COMPONENTS
NOZZLE
5
OIL SUPPLY 1&2 SOLENOID VALVE
FROM
NOZZLE
3 OIL METERING VALVE
4 OIL RETURN PRESSURE GAUGE

4
5 OIL RETURN SOLENOID VALVE
OIL RETURN
TO SUPPLY
7 OIL PRESSURE SWITCH
(OPTIONAL)
3
FACTORY PIPING
FIELD PIPING
Rev 3/09 28
127 of 761
OIL PIPING SCHEMATIC: OPTIONAL DIESEL/ELECTRIC PILOT SCHEMATIC
COMPONENTS
1. OIL SOLENOID VALVES (2)
2. MAIN OIL SUPPLY PRESSURE GAUGE
3. MAIN OIL RETURN PRESSURE GAUGE
4. PILOT SOLENOID VALVE
5. OIL METERING VALVE
6. PILOT OIL SOLENOID VALVE
7. PILOT OIL PRESSURE GAUGE
8. MAIN OIL BACKPRESSURE REGULATOR
9. PILOT OIL BACKPRESSURE REGULATOR
Rev 3/09 29
128 of 761
REMOTE OIL PUMP INSTALLATION
All FD68 pressure atomizing oil burners are furnished with a separate pump set mounted on a steel base for
remote mounting. The pump requires a two-pipe system. Pump warranty will be voided if a one-pipe system is
utilized.
The following drawing shows the available piping connections on the pump and the table indicates the
recommended suction line sizing for various conditions. Contact the factory for installations involving suction lift
greater than that listed in the table.
GAUGE PORT
1/4" NPT
SUPPLY PORT
TO BURNER PRESSURE
1/4" NPT ADJUSTMENT
PREFFERED INLET
ON PUMP COVER
1/2" NPT
OPTIONAL INLET OPTIONAL INLET

3/8" NPT 3/8" NPT
OIL RETURN PORT

3/8" NPT
ROTATION
(FROM OPPOSITE SHAFT END)
BODY STYLE "D"
Suction Pipe Size

LIFT
Length: 25 ft 50 ft 75 ft 100 ft
5 ft ½” ½” ½” ½”
10 ft ½” ¾” ¾” ¾”
13 ft ¾” ¾” 1” 1”
The burner supply and oil return line sizes can be one pipe size smaller than the suction line size.
All pump installations must utilize a proper oil filter, such as a cartridge type, or 100 mesh basket strainer.
Failure to install a proper suction filter may result in damage to the pump and void the warranty. The oil filter and
suction line must be sized so as not to exceed 10” Hg vacuum (suction) at the oil pump suction port.
A fusible link valve and/or an overhead anti-siphon valve should be used as applicable by local code.
WARNING!
DO NOT use Teflon tape. Use of Teflon tape will void pump warranty.
Rev 3/09 30
129 of 761
DIRECT-SPARK IGNITION SYSTEM SETTINGS
Model FD68 pressure atomized light oil burners arranged for direct-spark ignition of the main flame have a dual-
electrode ignition assembly fastened directly to the nozzle body. The nozzle body, nozzles, & ignition
components can be easily removed from the firing head as one assembly for inspection, electrode setting or
nozzle cleaning/replacement.
If it is necessary to remove the oil nozzles from the body it is recommended to first remove the ignition electrode
assembly from the body to avoid disrupting the electrode setting and then re-fastening the ignition assembly to
the body in the correct position after replacing the nozzles.
The correct electrode settings are as follows:
DIMENSIONS, mm (in)
NOZZLE
BURNER SIZE SPRAY A B C
ANGLE
4.8 - 6.4 7.9 - 9.5 4.0 -4.8
50 - 125 60
(3/16 - 1/4) (5/16 - 3/8) (5/32 - 3/16)
3.2 - 4.8 9.5 - 11.1 4.0 -4.8
150 - 250 80
(1/8 - 3/16) (3/8 - 7/16) (5/32 - 3/16)
3.2 - 4.8 9.5 - 11.1 4.0 -4.8
300 - 300SP 80
(1/8 - 3/16) (3/8 - 7/16) (5/32 - 3/16)
WARNING!
It is imperative to insure that the low fire settings for the metering valve position, supply pressure, and
return pressure shown in OIL SYSTEM SETTINGS are not exceeded for reliable and safe light-off.
Rev 3/09 31
130 of 761
This page intentionally left blank
Rev 3/09 32
131 of 761
OIL SYSTEM STARTUP: AIR ATOMIZED OIL SYSTEMS MODELS A-LM, A-MM, A-HM
Refer to pre-firing check-out.
Refer to air shutter & pilot adjustment.
Refer to all manufactures’ component instruction manuals.
Final air and oil adjustments should be made by analyzing the flue gas. Optimum CO2 readings will vary
according to oil being burned, but O2 readings should be approximately 3-4% @ high fire and 5-7% @ low fire.
These settings generally will result in a turndown ratio of 5:1; a larger turndown can be achieved with higher O2
readings @ low fire.
After adjustments are completed all safety related controls, including the flame safeguard programmer,
temperature or pressure limit controls, and blower air & atomizing air pressure switches must be tested for
proper operation by deliberately simulating component failure and/or changing the setting of the temperature
and pressure limit controls to force safety shut-down of the burner system.
INITIAL MAIN BURNER ADJUSTMENTS
Refer to the PIPING DIAGRAM for -LM, -MM, or -HM burners respectively.
Preliminary settings should include:

Atomizing air pressure setting: 8 - 10 psig (at low fire).
Oil pressure switch setting 10 psig less than oil supply pressure.
Oil backpressure valve (A-HM burners): 10 - 12 psig (at low fire).
Low oil temp. switch (A-MM &-HM burners): 10 degrees less than proper atom. temp.
Oil heater thermostat (A-MM & -HM burners): Set for proper oil atomizing temp.
Optimum atomizing temperature for the oil can very considerably but the following recommendations can be
used as a guide to obtain the required 100 - 150 SSU viscosity at the nozzle:
Oil Atomizing Temperature (Degrees F)
Grade of Oil
Minimum Typical Max
#4 70 F 110 F 135 F
#5 130 F 150 F 175 F
#6 185 F 210 F 240 F
Improper atomization and high smoke readings will result if the oil temperature is too low and unstable,
pulsating combustion will result from too high of an atomizing temperature. Model A-HM burners with (2) oil
heaters should have the thermostats set at slightly different temperatures to avoid having both heaters cycle
simultaneously causing wide swings in temperature.
The oil delivery rate to the burner is determined by the oil metering valve position and the oil supply pressure to
the inlet of the metering valve. Higher numbered positions on the metering valve and/or a higher supply
pressure will result in a greater oil delivery rate.
The oil supply pressure is set by adjusting the backpressure regulating valve, which is located on the left-front of
the burner assembly (right rear on sizes 800 and larger) between the oil supply and oil return connections. The
optimum oil supply pressure setting will depend on the viscosity of oil at the burner inlet and other operating
parameters such as furnace pressure, altitude, and desired firing rates.
Rev 3/09 33
132 of 761
HAUCK FIXED GRADIENT OIL METERING VALVES
Oil metering valves are factory set to travel between the minimum and maximum positions indicated on the OIL
SYSTEMS SETTING page for the respective burner model. The linkage to the metering valve can be adjusted
to change the minimum or maximum firing rate, or to change the rate of increase of the oil flow from minimum to
maximum.
Typical linkage and crank arm arrangements for the oil metering valve are shown below for the different sizes of
air atomized oil burners when the optional adjustable characteristic cam is not used. The alternate positions of
the crank arm, and the different locations of the linkage connectors, are shown as an aid to properly set the rate
of fuel increase to match the rate of air increase when the burner modulates between low & high fire. The
alternate positions apply to all burner sizes.
POSITION CRANKARM
FOR FASTER RATE OF
INCREASE FROM
HIGH FIRE
OIL
RETURN
LESS
TOTAL
TRAVEL
MORE
TOTAL MORE
SUPPLY
OIL
TRAVEL
LESS
SHOWN @ LOW FIRE TOWARD HIGH FIRE
TOWARD HIGH FIRE
OIL
RETURN
SUPPLY
OIL
SHOWN @ LOW FIRE
Rev 3/09 34
133 of 761
MAXON ADJUSTABLE GRADIENT OIL METERING VALVES
The linkage should be set to allow for full travel of the valve quadrant. The cover plate on the quadrant needs to
be removed to allow access to the adjusting screws which are not factory set. Field adjustment of this valve is
required. Turning the adjusting screws in (clockwise) will result in a higher fuel flow at that specific valve
position.
Proper adjustment will result in each screw being slightly further in than the lower numbered screw adjacent to
it. The highest numbered screw should not be in further than the face of the casting. If more fuel flow is needed
with a maximum adjustment of the screw then the oil supply pressure should be increased.
Refer to the manufacturer’s instruction manual for additional operating and maintenance procedures.
OPTIONAL ELECTRONIC METERING SYSTEM
Refer to OIL, AIR AND PUMP ARMATURE VOLTAGE SETTINGS for -LM, -MM, or -HM respectively.
Refer to the OIL PIPING DIAGRAM for -LM, -MM, or -HM with ELECTRONIC OIL METERING SYSTEM
respectively.
The oil return line on the right side of the burner includes a backpressure regulating valve which should initially
be set to provide 10 to 11 psig oil pressure at the nozzle pressure gauge in the low fire position during pre-
purge. After final burner adjustment this pressure should be set to equal the low fire oil pressure.
Initial temperature & pressure switch settings should be made as indicated for the oil metering valve system. All
other adjustments should be made according to the ELECTRONIC OIL METERING SYSTEM INSTRUCTIONS
in the proceeding section.
Rev 3/09 35
134 of 761
AIR ATOMIZING OIL NOZZLE SPECIFICATIONS
Note: The C169WA nozzle supplied with the burner is specially designed for S.T. Johnson Co. Other C169WA
variants can cause smoke, sooting and carbon formation. Replacement nozzles can be purchased from any
S.T. Johnson dealer.
NOZZLE POSITIONING
The position of the oil nozzle relative to the air diffuser is shown below.
Burner Size A
50 - 125 1.125” / 29mm

"A"
150 - 250 1.25” / 32mm
300 - 1000 1.5” / 38mm
NOZZLE PIN SETTING
Proper nozzle pin setting is critical to obtaining proper atomization. Correct settings for each nozzle size are
shown below.
NOZZLE COMPONENTS
1. Body
2. Tip
3. Disc
4. Metering pin
5. Locknut
NOZZLE SIZE PIN SETTING
30, 40 0.030” (0.762 mm)
50, 60, 80 0.040” (1.016 mm)
100 0.050” (1.270 mm)
125, 150, 200, 250 0.062” (1.575 mm)
Rev 3/09 36
135 of 761
MODEL A-LM OIL SYSTEM SETTINGS
60 HZ OPERATION
BURNER SIZE 50 75 100 125 150 200 250 300 350 400 450 500 625
FIRING MAX GPH* 18.2 26.6 36.4 40.0 53.5 72 80 107 119 144 155 180 224
RATE
NOM GPH* 15.0 22.5 30.0 37.5 45.0 60 75 90 105 120 135 150 188
FURN. PRESS. 0.75 0.75 1.0 1.0 1.5 2.0 2.0 3.0 3.0 4.0 4.0 4.0 4.0
"W.C.
MIN GPH 7 7 8 9 9 12 15 18 18 24 24 30 37
NOZZLE SIZE GPH 30 30 40 40 60 60 80 100 125 150 150 200 250

C169WA ANGLE 50 50 50 50 70 70 70 70 70 70 70 70 70
NOZZLE AIR MAX 20 22 21 22 20 23 20 22 17 20 24 21 23

PRESSURE, NOM 17 22 21 22 20 20 20 22 16 19 21 19 21
@ HIGH OIL MAX 22 28 28 32 28 36 30 33 25 31 37 28 29

FIRE NOM 17 26 26 30 26 30 29 30 21 25 28 24 26
CONTROL VALVE S3-5 S3-7 S3-7 S3-7 S3-9 S3-9 S3-11 S3-13 S3-13 S3-16 S3-16 S3-16 S3-16
SIZE
CONTROL MAX 16 10 15 15 15 15 15 15 15 15 15 15 15
VALVE
SETTING MIN 10 4 4.5 4.5 3.5 3 3 3 3 3 3 3 3
OIL SUPPLY
SETTING** MAX 55 50 54 62 60 74 56 59 58 50 58 56 71
PSI NOM 34 42 44 57 41 56 52 49 46 39 44 44 55
OIL PUMP
SIZE 0LE 0LE 0LE 0LE 0LE 0LE 1LE 1LE 1LE 2LE 2LE 2LE 2LE
RATING (GPH) 78 78 78 78 78 78 144 144 144 276 276 276 276
*The max firing rate listed is the maximum recommended with a balanced, or negative, furnace
pressure. The nominal firing rate listed is the maximum recommended when firing against the furnace
pressure listed. Reduced firing rates will result in reduced air and oil supply pressure settings. Rates
based on grade #2 fuel oil @ 140,000 BTU/GAL.
The nozzle pressures listed are those recommended for most applications. The same firing rates can
be obtained by either raising or lowering both the air & oil pressures. The flame geometry will be
affected by the nozzle pressure with slower mixing, wider flames resulting from lower pressures.
**Recommended oil supply pressure settings are typical for the maximum firing with grade #2 fuel oil
@ 40 SSU. Final settings will vary according to the furnace pressure, desired firing rate, and oil
viscosity; The optimum setting is determined by flue gas analysis.
Rev 3/09 37
136 of 761
50 HZ DIRECT-DRIVE OPERATION (EXPORT)
BURNER SIZE 100 125 150 200 250 300 300SP 400 400SP 500 500SP 625 1000
FIRING MAX GPH* 27 32 41 57 64 85 95 115 127 139 168 180 240

RATE KGH* 88 104 134 186 208 277 309 375 414 453 547 586 782
MIN GPH* 8 9 10 11 12 16 18 21 24 26 31 34 42
KGH* 26 29 33 36 39 52 59 68 78 85 100 111 137
NOZZLE SIZE GPH 40 40 40 60 60 100 125 125 150 150 200 250 250
ANGLE 50 50 70 70 70 70 70 70 70 70 70 70 70
NOZZLE AIR PSI 15 20 20 19 21 23 20 17 20 22 20 21 23

PRESSURE Kg/CM2 1.05 1.41 1.41 1.34 1.48 1.62 1.41 1.20 1.41 1.55 1.41 1.48 1.62
@ HIGH
FIRE OIL PSI 23 26 31 28 35 33 29 22 26 29 26 26 29
Kg/CM2 1.62 1.83 2.18 1.97 2.46 2.32 2.04 1.55 1.83 2.04 1.83 1.83 2.04
CONTROL VALVE S3-7 S3-7 S3-9 S3-9 S3-11 S3-13 S3-13 S3-13 S3-16 S3-16 S3-16 S3-16 ½-O
SIZE
CONTROL MAX 15 15 15 15 15 15 15 15 15 15 15 15 15
VALVE
SETTING MIN 4.5 4.5 3.5 3 3 3 3 3 3 3 3 3 3
OIL SUPPLY
SETTING** PSI 36 44 62 52 65 62 50 46 40 45 48 54 68
Kg/CM2 2.53 3.09 4.36 3.66 4.57 4.36 3.52 3.23 2.81 3.16 3.37 3.80 4.78
OIL PUMP
SIZE OLE OLE OLE OLE 1LE 1LE 1LE 2LE 2LE 2LE 2LE 2LE 2LE
RATINGLPH 238 238 238 238 431 431 431 840 840 840 840 840 840
*The high fire rate listed is the maximum recommended with +25 mm Aq furnace pressure. Higher positive furnace pressure
will result in a reduced capacity and reduced air and oil supply pressure setting. Contact the factory for maximum firing rates
firing against higher furnace pressures. Rates based on grade #2 fuel oil @ 10,300 KCAL/KG.
**Recommended oil supply pressure settings are nominal settings for typical grade #2 fuel oil. Final settings will vary
according to the furnace pressure, desired firing rate, and oil viscosity. The optimum setting is determined by flue gas
analysis.
Rev 3/09 38
137 of 761
50 HZ BELT-DRIVE OPERATION (EXPORT)
BURNER SIZE 100 125 150 200 250 300 350 400 500 600 700
FIRING MAX GPH 36 40 54 72 79 107 120 144 180 200 224

RATE * KGH 117 130 176 235 257 349 391 469 586 652 730
NOM GPH 30 37.5 45 60 75 90 105 120 150 180 210

KGH 98 122 147 196 244 293 342 391 489 586 684
FURN PRESS 25 25 37 50 50 75 75 100 100 100 100
MM Aq
MIN GPH 8 9 10 11 13 17 17 22 28 31 34
KGH 26 29 33 36 42 55 55 72 91 101 111
NOZZLE GPH 40 40 60 60 80 100 125 150 200 250 250

SIZE ANGLE 50 50 70 70 70 70 70 70 70 70 70
NOZZLE AIR MAX 1.41 1.41 1.34 1.48 1.55 1.41 1.13 1.41 1.34 1.41 1.48
PRESSURE NOM 1.41 1.41 1.27 1.41 1.62 1.48 1.05 1.27 1.27 1.34 1.41
Kg/CM2
@ HIGH
FIRE * OIL MAX 1.97 2.11 1.90 2.46 2.18 2.18 1.62 1.97 1.90 1.83 1.97
NOM 1.76 1.97 1.69 2.11 2.18 2.04 1.41 1.62 1.69 1.69 1.90
CONTROL VALVE S3-7 S3-7 S3-9 S3-9 S3-11 S3-13 S3-13 S3-16 S3-16 S3-16 S3-16
SIZE
CONTROL MAX 15 15 15 15 15 15 15 15 15 15 15
VALVE
SETTING MIN 4.5 4.5 3.5 3 3 3 3 3 3 3 3
OIL SUPPLY
SETTING** MAX 3.20 4.31 3.48 5.26 3.93 4.06 3.95 3.24 3.88 4.28 5.04
NOM 2.62 3.90 2.78 4.05 3.76 3.37 3.19 2.50 3.07 3.67 4.60
OIL PUMP
SIZE 009 009 009 009 009 009 009 009 009 015 015
RATINGLPH 356 356 356 356 356 681 681 681 681 1135 1135
*The maximum (max) firing rate listed is the maximum recommended with a balanced, or negative furnace pressure. The
nominal (nom) firing rate listed is the maximum recommended when firing against the furnace pressure listed. Higher positive
furnace pressure will result in a reduced capacity and reduced air and oil pressure settings. Maximum firing rates are based
on grade #2 oil @ 10,300 KCAL/KG. Nozzle pressures are based on an oil viscosity = 40 SSU @ the nozzle.
**Recommended oil supply pressure settings are typical settings for grade #2 oil. Final settings will vary according to the
furnace pressure, desired firing rate and oil viscosity; The optimum setting is determined by flue gas analysis.
Rev 3/09 39
138 of 761
OIL PIPING SCHEMATIC: SYSTEMS WITH OIL METERING VALVE
8 9
COMPONENTS
TO ATOMIZING AIR 1 SUPPLY PRESSURE REGULATING VALVE

NOZZLE FROM COMPRESSOR
7 6 5 2 OIL SUPPLY PRESSURE GAUGE
3 5&6 OIL SOLENOID VALVE

2
1 7 OIL NOZZLE PRESSURE GAUGE
OIL RETURN 8 ATOMIZING AIR PRESSURE GAUGE

TO SUPPLY
4 9 ATOMIZING AIR PRESSURE SWITCH

OIL SUPPLY
FROM PUMP
FACTORY PIPING
FIELD PIPING
OIL PIPING SCHEMATIC: SYSTEMS WITH CENTRAL OIL SUPPLY SYSTEM
8 9 10
COMPONENTS
TO ATOMIZING AIR 1 SUPPLY PRESSURE REGULATING VALVE

NOZZLE
7 2 OIL SUPPLY PRESSURE GAUGE

6 5
5&6 OIL SOLENOID VALVE

3
2
7 OIL NOZZLE PRESSURE GAUGE
1
OIL SUPPLY
8 ATOMIZING AIR PRESSURE GAUGE
4 9 ATOMIZING AIR PRESSURE SWITCH

FACTORY PIPING
FIELD PIPING
Rev 3/09 40
139 of 761
MODEL A-MM (#4 OIL) OIL SYSTEM SETTINGS
60 HZ OPERATION
BURNER SIZE 50 75 100 125 150 200 250 300 350 400 450 500 625
FIRING MAX GPH* 17.6 25.7 35.1 38.6 51.6 69 77 103 114 139 149 174 216
RATE NOM GPH* 14.5 21.7 28.9 36.2 43.4 58 72 87 101 116 130 145 182
FURN. PRESS. .75 .75 1.0 1.0 1.5 2.0 2.0 3.0 3.0 4.0 4.0 4.0 4.0
"W.C.
MIN GPH 7 7 8 9 9 12 14 17 17 23 23 29 36
NOZZLE SIZE GPH 30 30 40 40 60 60 80 100 125 150 150 200 250

C169WA ANGLE 50 50 50 50 70 70 70 70 70 70 70 70 70
NOZZLE AIR MAX 20 22 21 22 20 23 20 22 17 20 24 21 23

PRESSURE, NOM 17 22 21 22 20 20 20 22 16 19 21 19 21
@ HIGH OIL MAX 22 28 28 32 28 36 30 33 25 31 37 28 29

FIRE NOM 17 26 26 30 26 30 29 30 21 25 28 24 26
SIZE
CONTROL MAX 16 10 15 15 15 15 15 15 15 15 15 15 15
VALVE
SETTING MIN 10 4 4.5 4.5 3.5 3 3 3 3 3 3 3 3
OIL SUPPLY
SETTING** MAX 48 62 54 62 49 75 55 56 56 46 48 54 72
PSI NOM 33 48 43 56 40 58 52 47 46 36 40 44 58
OIL PUMP
SIZE OLE OLE OLE OLE OLE OLE 1LE 1LE 1LE 2LE 2LE 2LE 2LE
RATING, GPH 78 78 78 78 78 78 144 144 144 276 276 276 276
*The max firing rate listed is the maximum recommended with a balanced, or negative, furnace pressure. The nominal firing
rate listed is the maximum recommended when firing against the furnace pressure listed. Firing against higher furnace
pressures will result in reduced capacity and lower air and oil supply pressure settings. Rates based on grade #4 fuel oil @
145,000 BTU/GAL.
The nozzle pressures listed are based on an oil viscosity = 40 SSU @ the nozzle, and are those recommended for most
applications. The same firing rates can be obtained by either raising or lowering both the air & oil pressures. The flame
geometry will be affected by the nozzle pressure with slower mixing, wider flames resulting from lower pressures.
**Recommended oil supply pressure settings are typical for the maximum firing with grade #4 fuel oil @ 150 SSU pumping
viscosity. Final settings will vary according to the furnace pressure, desired firing rate, and oil viscosity. The optimum setting
is determined by flue gas analysis.
Rev 3/09 41
140 of 761
ATOMIZING AIR
TO FROM COMPRESSOR
NOZZLE
OIL SUPPLY
FROM PUMP
OIL RETURN
TO PUMP
FACTORY PIPING
FIELD PIPING
COMPONENTS:
1 SUPPLY PRESSURE REGULATING VALVE
3 OIL TEMPERATURE GAUGE
4 LOW OIL PRESSURE SWITCH
6 OIL SOLENOID VALVE
7 2ND OIL SOLENOID VALVE
8 NOZZLE OIL PRESSURE GAUGE
9 ELECTRIC OIL HEATER
10 LOW OIL TEMPERATURE SWITCH
12 ATOMIZING AIR PRESSURE SWITCH
Rev 3/09 42
141 of 761
MODEL A-HM (#6 OIL) SYSTEM SETTINGS
60 Hz OPERATION
BURNER SIZE 50 75 100 125 150 200 250 300 350 400 450 500 625
FIRING MAX GPH* 17 25 34 37 50 67 74 100 111 135 144 168 210

RATE
NOM GPH* 14 21 28 35 42 56 70 84 98 112 126 140 175
FURN. PRESS. 0.75 0.75 1.0 1.0 1.5 2.0 2.0 3.0 3.0 4.0 4.0 4.0 4.0
"W.C.
MIN GPH 8 8 9 9 10 11 13 17 17 22 22 28 34
NOZZLE SIZE GPH 30 30 40 40 60 60 80 125 125 150 200 200 250

C169WA ANGLE 50 50 50 50 70 70 70 70 70 70 70 70 70
NOZZLE AIR MAX 22 22 20 21 21 20 22 17 18 21 22 22 26

PRESSURE, NOM 20 22 20 20 21 18 22 15 17 18 18 21 23
PSIG
@ HIGH OIL MAX 28 36 30 33 28 34 33 30 36 40 41 47 59
FIRE NOM 23 30 27 30 25 29 32 24 30 31 33 39 46
SIZE
CONTROL MAX 16 10 15 15 15 15 15 15 15 15 15 15 15
VALVE
SETTING MIN 10 4 4.5 4.5 3.5 3 3 3 3 3 3 3 3
OIL SUPPLY
SETTING** MAX 55 64 57 65 50 75 59 56 68 56 59 72 97
PSI NOM 41 44 45 59 41 57 55 42 55 42 47 56 72
OIL PUMP SIZE 4312 4312 4312 4312 4312 4312 4312 4312 4312 4312 4312 4313 4313
RATING (GPH) 95 95 95 95 95 95 95 180 180 180 180 300 300
rate listed is the maximum recommended when firing against the furnace pressure listed. Reduced firing rates will result in
reduced air and oil supply pressure settings. Rates based on grade #6 fuel oil @ 150,000 BTU/GAL.
The nozzle pressures listed are those recommended for most applications, and are based on an oil viscosity of 150 SSU @
the nozzle. The same firing rates can be obtained by either raising or lowering both the air & oil pressures. The flame
geometry will be affected by the nozzle pressure with slower mixing, wider flames resulting from lower pressures.
**Recommended oil supply pressure settings are typical for firing with a medium grade #6 fuel oil @ 140oF delivery
temperature to the burner. Final settings will vary according to the furnace pressure, desired firing rate, and oil viscosity. The
optimum setting is determined by flue gas analysis.
Rev 3/09 43
142 of 761
50 Hz DIRECT-DRIVE OPERATION (EXPORT)
BURNER SIZE 100 125 150 200 250 300 300SP 400 400SP 500 500SP 625 1000
FIRING MAX GPH 25 30 39 54 60 80 90 108 119 130 157 170 205

RATE * KGH 90 108 140 194 216 288 324 389 428 468 565 612 738
MIN GPH 8 9 10 11 12 16 18 21 24 26 31 34 42
KGH 28 32 36 40 43 58 65 75 86 94 112 122 151
NOZZLE SIZE GPH 40 40 40 60 60 100 125 125 150 150 200 250 250
ANGLE 50 50 70 70 70 70 70 70 70 70 70 70 80
NOZZLE, AIR PSI 15 17 20 16 16 19 17 16 18 16 22 19 25

PRESSURE Kg/cm2 1.05 1.20 1.41 1.13 1.13 1.34 1.20 1.13 1.27 1.13 1.55 1.34 1.76
@ HIGH
FIRE * OIL PSI 20 24 32 24 26 27 25 24 26 24 33 29 38
Kg/cm2 1.41 1.69 2.25 1.69 1.83 1.90 1.76 1.69 1.83 1.69 2.32 2.04 2.67
CONTROL VALVE S3-7 S3-7 S3-9 S3-9 S3-11 S3-13 S3-13 S3-13 S3-16 S3-16 S3-16 S3-16 ½”-O
SIZE
CONTROL MAX 15 15 15 15 15 15 15 15 15 15 15 15 MAX

VALVE
SETTING MIN 4.5 4.5 3.5 3 3 3 3 3 3 3 3 3 MIN
OIL SUPPLY PSI 48 50 50 65 50 50 55 65 45 45 60 65 70
SETTING** Kg/cm2 3.38 3.52 3.52 4.57 3.52 3.52 3.87 4.57 3.16 3.16 4.22 4.57 4.92
OIL PUMPSIZE 4312 4312 4312 4312 4312 4312 4312 4312 4312 4312 4312 4313 4313
RATING LPH 356 356 356 356 356 356 681 681 681 681 681 1135 1135
*The high fire rate listed is the maximum recommended with +25 mm Aq furnace pressure. Higher positive furnace pressure
will result in a reduced capacity and reduced air and oil pressure settings. Maximum firing rates are based on 9,700
KCAL/KG. Nozzle pressures are based on an oil viscosity = 150 SSU @ the nozzle.
**Recommended oil supply pressure settings are nominal settings for medium viscosity #6 oil @ 60 C. pumping temperature.
Final settings will vary according to the furnace pressure, desired firing rate, oil viscosity, and pumping temperature; The
Rev 3/09 44
143 of 761
50 Hz BELT-DRIVE OPERATION (EXPORT)
BURNER SIZE 100 125 150 200 250 300 350 400 500 600 700
FIRING MAX GPH 34 37 50 67 74 100 113 135 168 188 210

RATE * KGH 122 133 180 241 266 360 410 486 604 676 755
NOM GPH 28 35 42 56 70 84 98 112 140 158 175

KGH 108 126 151 201 252 302 389 432 504 568 630
FURN PRESS 25 25 37 50 50 75 75 100 100 100 100
MM Aq
MIN GPH 8 9 10 11 13 17 17 22 28 31 34
KGH 28 32 36 40 47 61 61 79 101 112 122
NOZZLE GPH 40 40 60 60 80 100 125 150 200 250 250

SIZE ANGLE 50 50 70 70 70 70 70 70 70 70 70
NOZZLE AIR MAX 1.41 1.48 1.48 1.41 1.55 1.20 1.27 1.48 1.55 1.48 1.83
PRESSURE NOM 1.41 1.41 1.48 1.27 1.55 1.05 1.13 1.27 1.48 1.34 1.62
Kg/CM2
@ HIGH
FIRE * OIL MAX 2.11 2.32 1.97 2.39 2.32 2.11 2.46 2.81 3.30 3.44 4.15
NOM 1.90 2.11 1.76 2.04 2.25 1.69 1.97 2.18 2.74 2.00 3.23
CONTROL VALVE S3-7 S3-7 S3-9 S3-9 S3-11 S3-13 S3-13 S3-16 S3-16 S3-16 S3-16
SIZE
CONTROL MAX 15 15 15 15 15 15 15 15 15 15 15
VALVE
SETTING MIN 4.5 4.5 3.5 3 3 3 3 3 3 3 3
OIL SUPPLY
SETTING** MAX 4.00 4.57 3.52 5.27 4.15 3.94 4.78 3.94 5.06 5.56 6.82
NOM 3.16 4.15 2.88 4.01 3.87 2.95 3.73 2.95 3.94 3.48 5.06
OIL PUMP
SIZE 4312 4312 4312 4312 4312 4312 4312 4312 4312 4313 4313
RATING LPH 356 356 356 356 356 681 681 681 681 1135 1135
*The maximum (max) firing rate listed is the maximum recommended with a balanced, or negative furnace
pressure. The nominal (nom) firing rate listed is the maximum recommended when firing against the furnace
pressure listed. Higher positive furnace pressure will result in a reduced capacity and reduced air and oil pressure
settings. Maximum firing rates are based on grade #6 oil @ 9,700 KCAL/KG. Nozzle pressures are based on an oil
viscosity = 150 SSU @ the nozzle.
**Recommended oil supply pressure settings are for medium viscosity #6 oil @ 60 C. pumping temperature. Final
settings will vary according to the furnace pressure, desired firing rate, oil viscosity, and pumping temperature; The
Rev 3/09 45
144 of 761
TI PI
PS PI TS
ATOM AIR SUPPLY

S
S S
OIL RETURN
TS
TS
PS PI
OIL RETURN
FACTORY PIPING
FIELD PIPING
OIL SUPPLY FROM PUMP

5000 SSU MAX
COMPONENTS:
1. SUPPLY PRESSURE REGULATING VALVE 12. OIL NOZZLE BODY
2. OIL SUPPLY PRESSURE GAUGE 13. OIL NOZZLE TIP & SPINNER
3. OIL METERING VALVE 14. TRIPLE-PASS OIL MANIFOLD
4. OIL HEATER #1 15. OIL TEMPERATURE GAUGE
5. OIL HEATER THERMOSTAT #1 16. OIL NOZZLE PRESSURE GAUGE
6. OIL HEATER #2 (BURNER SIZE 150-625) 17. LOW OIL TEMPERATURE SWITCH
7. OIL HEATER THERMOSTAT #2 18. ANTI-SURGE VALVE
8. N.O. NOZZLE PURGE SOLENOID VALVE 19. 3-WAY OIL SOLENOID VALVE
9. NOZZLE PURGE CHECK VALVE 20. 2nd OIL VALVE
10. ATOMIZING AIR PRESSURE SWITCH 21. OIL PRESSURE SWITCH
11. ATOMIZING AIR PRESSURE GAUGE
Rev 3/09 46
145 of 761
AIR ATOMIZED BURNERS WITH ELECTRONIC OIL METERING SYSTEM (EMS)
MODEL A-LM #2 OIL EMS SETTINGS

BURNER SIZE 50 75 100 125 150 200 250 300 350 400 450 500 625
FIRING MAX GPH* 18.2 26.6 36.4 40.0 53.5 72 80 107 119 144 155 180 224
RATE
NOM GPH* 15.0 22.5 30.0 37.5 45.0 60 75 90 105 120 135 150 188
FURN. PRESS. .75 .75 1.0 1.0 1.5 2.0 2.0 3.0 3.0 4.0 4.0 4.0 4.0
"W.C.
MIN GPH 7 7 8 9 9 12 15 18 18 24 24 30 37
NOZZLE SIZE GPH 30 30 40 40 60 60 80 100 125 150 150 200 250

C169WA ANGLE 50 50 50 50 70 70 70 70 70 70 70 70 70
NOZZLE AIR MAX 20 22 21 22 20 23 20 22 17 20 24 21 23

PRESSURE, NOM 17 22 21 22 20 20 20 22 16 19 21 19 21
@ HIGH OIL MAX 22 28 28 32 28 36 30 33 25 31 37 28 29

FIRE NOM 17 26 26 30 26 30 29 30 21 25 28 24 26
SIZE 30LE 30LE 00LE 00LE 00LE 00LE 0LE 0LE 1LE 1LE 1LE 1LE 2LE
STD
PUMP Varm@MAX 65 93 73 80 79 ALT 83 ALT 60 73 78 ALT 63
SETTINGS
Varm@NOM 55 80 60 75 67 95 78 84 53 61 70 80 53
SIZE 0LE 1LE 2LE

ALT
PUMP Varm@MAX 68 58 53
SETTINGS
Varm@NOM 55 49 45
The nozzle pressures listed are those recommended for most applications. The same firing rates can be obtained by either
raising or lowering both the air & oil pressures. The flame geometry will be affected by the nozzle pressure with slower mixing,
wider flames resulting from lower pressures.
The alternate pumps may be used on sizes 200, 300 & 500 for obtaining nominal capacity @ the Varm indicated. The
alternate pumps must be used on sizes 300, 300 & 500 to obtain the maximum capacity @ the Varm indicated.
Rev 3/09 47
146 of 761
MODEL A-HM #6 OIL EMS SETTINGS
BURNER SIZE 50 75 100 125 150 200 250 300 400 500 625
FIRING MAX GPH* 17.0 24.8 34.0 37.3 49.9 67.2 74.6 100 135 168 210
RATE
NOM GPH* 14.0 21.0 28.0 35.0 42.0 56.0 70.0 90.0 84.0 140 175
FURN. PRESS. .75 .75 1.0 1.0 1.5 2.0 2.0 3.0 4.0 4.0 4.0
"W.C.
MIN GPH 7 7 7 9 9 11 13 17 22 28 34
NOZZLE SIZE GPH 30 30 40 40 60 60 80 125 150 200 250

C169WA ANGLE 50 50 50 50 70 70 70 70 70 70 70
NOZZLE AIR MAX 22 22 20 21 21 20 22 17 21 22 26

PRESSURE, NOM 20 22 20 20 21 18 22 15 18 21 23
@ HIGH OIL MAX 28 36 30 33 28 34 33 30 40 47 59

FIRE NOM 23 30 27 30 25 29 32 24 31 39 46
SIZE 30LE 30LE 00LE 00LE 00LE 00LE 0LE 0LE 1LE 1LE 2LE
STD
PUMP Varm@MAX 62 90 53 64 81 ALT 72 ALT 73 ALT 63
SETTINGS
Varm@NOM 51 76 43 68 68 95 67 87 61 76 53
SIZE 0LE 1LE 2LE

ALT
PUMP Varm@MAX 65 58 52
SETTINGS
Varm@NOM 54 49 43
The nozzle pressures listed are those recommended for most applications. The same firing rates can be obtained by either
raising or lowering both the air & oil pressures. The flame geometry will be affected by the nozzle pressure with slower mixing,
wider flames resulting from lower pressures.
The alternate pumps may be used on sizes 200, 300 & 500 for obtaining nominal capacity @ the Varm indicated. The
alternate pumps must be used on sizes 300, 300 & 500 to obtain the maximum capacity @ the Varm indicated.
Refer to catalog section 9400 for complete metering pump flow charts including recommended armature voltages for low fire
settings.
Rev 3/09 48
147 of 761
ELECTRONIC OIL METERING SYSTEM PIPING SCHEMATIC
MODEL A-LM #2 OIL SYSTEMS
1 2
COMPONENTS:
ATOMIZING AIR
2 ATOMIZING AIR PRESSURE SWITCH
TO OIL NOZZLE
FROM COMPRESSOR
7
3 3 NOZZLE OIL PRESSURE GAUGE
4 5
4 2-WAY OIL SOLENOID VALVE
5 3-WAY OIL SOLENOID VALVE
OIL SUPPLY FROM 6 ANTI-SURGE VALVE

METERING PUMP
6
7 LOW OIL PRESSURE SWITCH
OIL RETURN TO
PUMP SUCTION
LINE OR TANK
FACTORY PIPING
FIELD PIPING
MODEL A-HM #6 OIL SYSTEMS
12 11 10 18
15 14
9
13
16 17
6 7 8
4 5
1 18
COMPONENTS:
1 OIL HEATER #1 10 OIL NOZZLE PRESSURE GAUGE
2 OIL HEATER THERMOSTAT #1 11 OIL TEMPERATURE GAUGE
3 OIL HEATER THERMOSTAT #2 12 OIL NOZZLE TIP & SPINNER
4 OIL HEATER #2 (BURNER SIZE 150-625) 13 OIL NOZZLE BODY
5 TRIPLE-PASS OIL MANIFOLD 14 ATOMIZING AIR PRESSURE GAUGE
6 2nd OIL VALVE 15 ATOMIZING AIR PRESSURE SWITCH
7 3-WAY OIL SOLENOID VALVE 16 N.O. NOZZLE PURGE SOLENOID VALVE
8 ANTI-SURGE VALVE 17 NOZZLE PURGE CHECK VALVE
9 LOW OIL TEMPERATURE SWITCH 18 LOW OIL PRESSURE SWITCH
Rev 3/09 49
148 of 761
ATOMIZING AIR COMPRESSOR INSTALLATION & ADJUSTMENT PROCEDURE
INSTALLATION
All compressor sets furnished with series FD68 air atomized burners are mounted on steel bases for mounting
separately from the burner. The base must be firmly anchored as close to the burner as possible to avoid
excessive pressure drop in the atomizing air piping. Vibration isolators are not required, but may be used.
If remote mounting is necessary good piping design must be utilized to ensure sufficient atomizing air pressure
at the burner nozzle.
DIMENSIONS: ATLAS COPCO MODELS LE2, -3, -5
Rev 3/09 50
149 of 761
PIPING
Compressors are not furnished with reservoir tanks as the output is closely matched to the air requirement of
the burner. To eliminate the possibility of pressure fluctuations at the burner nozzle it is good practice to install a
short run of oversized piping at the compressor outlet to act as a small accumulator.
START-UP
In general, compressors are shipped without oil in the crankcase. Follow the manufacturer’s instructions for
filling with the proper grade of oil prior to starting. Because most installations involve prolonged periods of
operation it is recommended to use 500 SUS napthenic base compressor oil for lubrication. SAE 30, non-
detergent, automotive grade oil can be substituted but it is not recommended for continuous operation.
ADJUSTMENT
Compressors are furnished with a bypass line and adjusting valve from the discharge to the inlet to enable
adjustment of the air volume delivered to the burner nozzle. If adjustment is required refer to the burner
adjusting instructions for proper setting of the atomizing air pressure.
In general, too little atomizing air pressure will result in poor atomization while too high a pressure can result in a
pulsating flame and even combustion harmonics especially in restricted combustion chambers.
MAINTENANCE
Compressor oil level must be checked at least twice a week during periods of continuous operation.
Compressors installed in areas of high ambient temperatures and/or little ventilation will run hotter and may
consume some oil. Refer to the manufacturer’s manual for complete recommendations.
Rev 3/09 51
150 of 761
OIL PUMP INSTALLATION
DIRECT-DRIVE OIL PUMP SET
60Hz OPERATION
Standard direct-drive burner oil pumps furnished with series FD68 burners should be floor or boiler base
mounted in close vicinity to the burner with no valving installed between the pump set and the burner inlet.
The following chart may be used as a suction line sizing guide considering a suction lift of 10 feet. The return
line from the burner may be one pipe size smaller than the recommended suction line size.
SUCTION LINE LENGTH

BURNER PUMP MOTOR PORT
GPH
SIZE MODEL HP SIZE
25’ 50’ 75’ 100’
50-200 0LE 1/3 ½” 78 ½” ½” ½” ½”
250-300 1LE 1/2 ½” 144 ½” ½” ¾” ¾”
400-800 2LE 3/4 ½” 276 ¾” 1” 1” 1”
1000 5LE 1 1” 360 ¾” 1” 1” 1”
5LE RPM = 1150, ALL OTHERS RPM = 1725
Rev 3/09 52
151 of 761
50Hz OPERATION
Standard direct-drive burner oil pumps furnished with series FD68 burners should be floor or boiler
base mounted in close vicinity to the burner with no valving installed between the pump set and the
burner inlet.
The following chart may be used as a suction line sizing guide considering a suction lift of 10 feet.
The return line from the burner may be one pipe size smaller than the recommended suction line
size.
SUCTION LINE LENGTH

BURNER PUMP MOTOR PORT
LPH
SIZE MODEL HP SIZE
25’ 50’ 75’ 100’
50-200 0LE 1/3 ½” 238 ½” ½” ½” ½”
250-300SP 1LE 1/2 ½” 431 ½” ½” ¾” ¾”
400SP-1000 2LE 3/4 ½” 908 ¾” 1” 1” 1”
PUMP RPM = 1425 FOR ALL SIZES
Rev 3/09 53
152 of 761
BELT-DRIVE HEAVY OIL PUMP INSTALLATION
Standard belt-drive burner oil pumps furnished with series FD68 burners should be floor or boiler
base mounted in close vicinity to the burner with no valving installed between the pump set and the
burner inlet.
The following chart may be used as a suction line sizing guide considering a suction lift of 10 feet & a
viscosity of 2000 SSU. The return line from the burner may be one pipe size smaller than the
recommended suction line size.
SUCTION LINE LENGTH

BURNER PUMP PUMP MOTOR PORT
GPH LPH
SIZE MODEL RPM HP SIZE
25’ 50’ 75’ 100’
50-250 4312 300 3/4 1” 95 360 1 ¼” 1 ¼” 1 ¼” 1 ¼”
300-500 4312 600 3/4 1” 180 681 1 ¼” 1 ¼” 1 ¼” 1 ¼”
625-800 4313 600 1-1/2 1 ¼” 300 1136 1 ¼” 1 ¼” 1 ½” 1 ½”
1000 4313 800 2 1 ¼” 420 1590 1 ½” 1 ½” 2” 2”
MOTOR RPM = 1725 FOR ALL SIZES 60Hz & 1450 FOR ALL 50Hz SYSTEMS
Rev 3/09 54
153 of 761
ELECTRONIC OIL METERING PUMP INSTALLATION
Variable speed oil metering pumps furnished with series FD68 burners should be floor or boiler base mounted in
close vicinity to the burner with no valving installed between the pump set and the burner inlet.
The following chart may be used as a suction line sizing guide considering a suction lift of 10 feet. The return
line from the burner may be one pipe size smaller than the recommended suction line size.
SUCTION LINE LENGTH

BURNER STD PUMP MOTOR MAX
PORT SIZE
SIZE MODEL HP GPH
25’ 50’ 75’ 100’
50-75 30LE 1/3 ½” 28 ½” ½” ½” ½”
100-200 00LE 1/3 ½” 60 ½” ½” ½” ½”
250-300 0LE 1/3 ½” 112 ½” ½” ½” ½”
400-500 1LE 1/3 ½” 180 ½” ½” ¾” ¾”
625-800 2LE 1/2 ½” 300 ¾” 1” 1” 1”
ADD 1-1/4" FOR OPTIONAL DIGITAL

FLOW READOUT
Rev 3/09 55
154 of 761
INDUCED FGR OPTION (LOW NOx OR FUTURE LOW NOx BURNERS ONLY)
WARNING! The induced FGR option should be used for FD68 burners designed for Low NOx
operation. Application to standard models may result in serious damage and injury.
STACK CONNECTION:
The FGR connection to the stack should be in a location which will result in the straightest run of piping to the
burner inlet, connection near the discharge of the stack must be avoided to eliminate the possibility of entraining
air into the system. If a stack damper is used the connection should be between the boiler outlet and the
damper. If an I.D. FAN is used the connection should be on the discharge of the fan.
The FGR piping should protrude into the stack with a beveled inlet to enhance the flow of flue gas into the piping
with a minimum pressure drop.
FGR EXISTING
STACK FGR
NEW FGR FLUE GAS NEW FGR

DUCT DUCT
STACK CONNECTION w/ BEVELED INLET ALTERNATE INLET
FGR PIPE SIZING:
The required FGR pipe size is affected by the burner size, required NOx threshold, length of piping, and the
expected number of direction changes. Recommendations will be made on an individual job basis.
FGR CONTROL VALVE:
An FGR control valve is furnished to shut off the recirculation during purging and ignition cycles and for the
purpose of modulating the amount of recirculation during firing cycles. It can be mounted anywhere in the FGR
piping but mounting close to the burner assembly reduces the length of wiring required from the burner to the
valve actuator.
Systems incorporating a single-point positioning control system incorporate a Q181A aux potentiometer
mounted on the burner modulating motor to control the position of the modulating motor on the FGR control
valve. Systems incorporating a parallel positioning control system include a servomotor mounted on the FGR
valve.
The Q181A aux potentiometer has an adjustable pick-up & span which needs to be adjusted after installation to
provide for proper modulation of the FGR valve.
Rev 3/09 56
155 of 761
LIMITED WARRANTY
Innovative Combustion Technologies, Inc. d.b.a. S.T. Johnson Company, hereinafter called “Seller” of 925
Stanford Avenue, Oakland, CA hereby warrants the goods manufactured by seller to be free from defects in
material and workmanship under normal use and service for 12 months from date of shipment. If within the
warranty period any of the goods fail to conform, or are found to have been defective in material or
workmanship when shipped, and within said period seller receives written notice thereof, such defective goods
shall, at seller's option, either be repaired or replaced by seller, F.O.B. Oakland, California. As a condition to
securing warranty repair or replacement, a Return Goods Authorization shall be obtained, and warranted
equipment shall be returned to seller freight prepaid. If inspection by seller discloses defects not covered by this
warranty, seller shall notify buyer/owner. Said equipment, at owner’s/buyer’s option, may be repaired or
replaced and transported at the expense of owner/buyer.
EXCLUDED FROM THIS WARRANTY ARE DEFECTS IN WARRANTED EQUIPMENT CAUSED BY FREIGHT
DAMAGE, FAULTY INSTALLATION, MISUSE OR NEGLIGENCE. Equipment that is repaired or replaced shall
carry a warranty equal to the unexpired portion of the original warranty period. No credit will be given for returns
except by prior approval of seller at Oakland, California. No special materials or equipment may be returned. No
burner nozzle, burner block, or other parts directly exposed to flame, even for short periods, may be returned
after use.
IN ALL EVENTS, SELLER SHALL NOT BE LIABLE FOR, AND WILL NOT REIMBURSE ANY LABOR,
MATERIAL, OR OTHER REPAIR CHARGES INCURRED BY ANYONE OTHER THAN SELLER ON ANY
WARRANTY EQUIPMENT. SELLER SHALL HAVE NO LIABILITY TO BUYER FOR ANY INDIRECT OR
CONSEQUENTIAL DAMAGES ATTRIBUTABLE TO THE WARRANTED EQUIPMENT. SELLER DISCLAIMS
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR USE BY THE BUYER OR ITS CUSTOMERS.
WARNINGS The improper installation or application of the goods; their use with improper wiring, piping, or
ventilation; improper system design or engineering; inadequate inspection or testing; the lack of regular careful
maintenance of both the goods and any equipment in connection with which the goods are used; the
employment of insufficient or unqualified personnel; the lack of careful supervision, proper warnings, operating
instructions, and safety precautions; the exposure of the goods to excessive heat, moisture, dust, dirt, corrosion,
or any other deleterious condition, each constitutes a hazard which can result in loss of life, serious personal
injury, heavy property or business damage, and buyer /owner agrees with seller to itself take and require others
to take all reasonable measures to avoid each such hazard.
Rev 3/09 57
156 of 761
3.5 Tuthill Pump Group

12500 South Pulaski Rd., Alsip IL 60803 USA
www.tuthill.com
157 of 761
Service Manual #11
Tuthill Pump Group

12500 South Pulaski Road
Alsip, IL 60803
USA
o 708.389.2500
f 708.388.0869
Installation and Service

Instructions
L Series Pumps
V1.1 1 of 12 02/06/2009
158 of 761
Service Manual # 11
General Description
Tuthill’s LA and LE Series are compact, highly efficient, cast iron positive displacement rotary
gear pumps with a mechanical seal. Built in six sizes, they provide nominal capacities from .5 to
14 gallons per minute and pressures up to 500 psi (300 psi in the 5LE). They are self priming
and particularly suited to handle liquids of 35 to 1000 SSU viscosity. Higher viscosities can be
handled at reduced speeds.
The LA Series is supplied with a two bolt flange, the LE Series with a three bolt flange. Optional
mounting feet are available for both Series. An internal relief valve is an option with the LE
Series.
Both Series are bi-rotational (unless outfitted with a relief valve) and designed for direct drive at
standard motor speeds, with modifications available for indirect drive.
The Pumping Principle
Tuthill’s LA and LE Series employ the internal

gear pumping principle. There are only two
moving parts. Pumping action is based on a
rotor, idler gear and crescent-shaped partition
cast integral with the cover.
Power applied to the rotor is transmitted to the

idler gear with which it meshes. The space
between the outside diameter of the idler and
the inside diameter of the rotor is sealed by the
crescent.
As the pump starts, the teeth come out of mesh,

increasing the volume. This creates a partial
vacuum, drawing the liquid into the pump
through the suction port.
The liquid fills the spaces between the teeth of

the idler and the rotor and is carried past the
crescent partition through the pressure side of
the pump.
When the teeth mesh on the pressure side, the

liquid is forced from the spaces and out through
the discharge port.
V1.2 2 of 12 04/01/2009
159 of 761
Service Manual # 11
! WARNING
Failure to follow these instructions could result in serious bodily injury or death.
These pumps should not be used for handling plain water, corrosive or abrasive liquids or liquids
not possessing adequate lubricity.
Do not attempt to work on any Tuthill pump installation before completing the steps below.
Disconnect the drive so that it cannot be started while work is being performed.
Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to
determine its characteristics and the precautions necessary to ensure safe handling.
Vent all pressure within the pump through the suction or discharge lines.
All Tuthill pumps contain residual 200 SSU lube oil from the factory production test. Determine if
this is compatible with the fluid you are pumping. If the fluid is incompatible, consult the factory.
Location
LA and LE Series pumps are designed for working pressures up to 500 psi (300 psi in the 5LE)
and are required to develop 25” mercury vacuum at 0 psi on factory test. While these pumps will
develop as high as 27” of vacuum, it is a sound engineering practice to avoid extreme vacuum
whenever possible. Select a pipe size to reduce line friction loss to a minimum.
The pump should be located as close to the source of supply as conditions permit and if possible,
below the level of the liquid in the reservoir. When necessary to locate the pump in a pit,
provisions should be made to safeguard against flooding. Care must be taken to properly
support the suction and discharge piping so that no strain is put on the pump due to either weight
or expansion. Piping strain can result in misalignment, hot bearings, worn couplings, and
vibration. It is important that the piping used be clean and free of chips or scales.
Proper Installation
Unsatisfactory pump installations are usually characterized by poor suction conditions for the
specific liquid being handled. Suction conditions should be minimized to prevent vaporization of
the liquid. If vacuum conditions force the liquid to vaporize, cavitation will occur, resulting in loss
of capacity, premature wear and noisy operation.
When handling high viscosity liquids, the speed of the pump must be reduced and the size of the
lines increased to prevent cavitation.
Note: Pipe line friction increases at a rapid rate with an increase in viscosity. For a given pump
and motor, larger pipe lines are necessary to maintain the same pump pressure when changing
from a thin fluid to a thick one.
Most Tuthill LA and LE Series pumps are supplied with both ports on the same plane. Pumps
with this type of porting arrangement should always be installed with both ports pointing upward
to
insure proper priming. If it is necessary to install the pump with the ports pointing to either side, it
is recommended that the top port be the suction port. This will prevent gravity induced drainage
V1.2 3 of 12 04/01/2009
160 of 761
Service Manual # 11
of fluid through the suction port. When pipe lines are installed, an inverted “U” bend should be
incorporated into the suction line close to the pump for priming purposes.
The multiple port arrangement in the 5LE offers flexibility but is limited to some common sense
restrictions. There is an inlet and an outlet side to the pump. There must always be at least one
pipe on each side. Units ordered with the side port option (modification S) are shipped with port
plugs in the top ports. To adapt to a 90° porting arrangement, the plugs must be relocated.
Because of its size, the 5LE will not mount onto a NEMA 48 frame motor unless the motor is
shimmed approximately ¼”.
With the ports facing up, and viewing the pump from the shaft end, the inlet port is on the right for
clockwise rotation and on the left for counter-clockwise rotation. Pumps with built in relief valves
are directional. Therefore rotation must be specified at time of order. The adjusting screw of the
internal relief valve must always be located on the suction side of the pump.
Pumps should be filled with oil at installation and should never be allowed to run dry.
Every pump installation should have a good foundation. Its structure should be sufficiently strong
to hold the pump rigid and to absorb any strain or shock that may be encountered. The
installation should be leveled, checked for proper piping alignment, and then fastened securely.
Method of Drive
Direct drive through a traditional flexible coupling is recommended. However, do not expect the
flexible coupling to compensate for misalignment. Contact the coupling manufacturer to
determine the maximum amount of misalignment to which the coupling can be subjected.
LA and LE Series pumps can be driven in either direction of rotation, unless outfitted with an
internal relief valve. The seal chamber communicates with the neutral zone and therefore the
seal is subjected to approximately one half of the discharge pressure.
All pump and motor units must be properly aligned during assembly and periodically checked
since misalignment may occur later due to abuse or other conditions. Pipe strain can force the
pump and motor shafts out of alignment. Therefore, all piping to the pump must be properly
supported. Do not allow the pump to act as a pipe support.
Provide for proper expansion of pipes when handling hot liquids. Allow pump to reach operating
temperature slowly. Rapid temperature change can result in damage to the cast iron
components. Recheck the alignment.
Never align a pump and motor supplied with a pin type coupling without first removing the pins.
Never depend upon sight or feel. Use proper gauges when aligning the pump.
Never operate the pump without all guards in place.
V1.2 4 of 12 04/01/2009
161 of 761
Service Manual # 11
Relief Valve Protection
The LA and LE Series are positive displacement pumps. As the pump rotates, liquid is positively
delivered to the discharge side of the pump. If the discharge line is closed off, pressure will
increase until the drive stalls and/or fails, the pump breaks or ruptures, or the piping bursts. To
prevent this from happening, the use of a pressure relief valve is required. A relief valve that
directs the flow back to the supply tank is recommended.
The internal relief valve available on LE Series pumps is designed for overpressure protection
only. It is not intended as a flow control device or for any similar use. Continuous operation of
the relief valve will result in excessive heat buildup within the pump cavity which could cause
serious internal damage. Make certain the adjusting screw of the relief valve is located on the
suction side of the pump.
Unless otherwise specified at the time of order, all LEV pumps are supplied with the standard
spring, with a range of 55-120 psi (40-70 in the 5LE), set to provide full bypass relief at 55 psi.
To adjust the relief setting within the range of a given spring’s capability:
• Remove the acorn nut. (Not supplied with model 5LEV).

• Insert a screwdriver into the slot of the adjusting screw and hold it steady.
• Loosen the locking nut with a wrench by turning counterclockwise.
• Throttle the outlet line until the differential pressure at the pump port is at the desired level:
• If the pressure fails to reach this level with the throttling valve closed, turn the
adjusting screw inward (clockwise) until the desired pressure is reached. (Adjusting
clockwise raises the pressure setting).
• If the pressure reaches the desired level before the throttling valve is completely
closed, turn the adjusting screw outward (counterclockwise) until the desired
pressure is reached. (Adjusting counterclockwise lowers the pressure setting).
• Retighten the nut to lock the setting in place and replace the acorn nut.
• Recheck the pressure gauge reading.
If an internal relief valve has not been supplied with the pump some other means of protection
must be utilized. These include in-line safety relief valves, pressure shutdown switches or other
similar devices.
Strainer Protection
Strainers are used to remove contaminated particles from the fluid system and extend pump life.
Every pump should be protected from these particles by a strainer in the suction line.
Strainer size and mesh of screen are determined by the rate of flow and viscosity of the fluid.
Consult the strainer manufacturer for recommendations.
Never use a strainer with a built-in automatic by-pass on the suction line set to open under 30”
Hg. vacuum.
Install the strainer according to the designated direction of flow, locating it so that it is accessible
for servicing. Use a duplex type strainer when shutdown during service is not possible.
Provide a vacuum gauge in the suction line for determining when the strainer requires cleaning.
Make certain strainer baskets are properly reinforced so as not to collapse under 30” Hg.
vacuum.
V1.2 5 of 12 04/01/2009
162 of 761
Service Manual # 11
! WARNING
If the pump is to operate at elevated temperatures, it should be brought up to operating

temperature gradually. Rapid or sudden introduction of liquid at an elevated temperature into the
cold liquid chamber of the pump could cause damage to the seal or other internal parts.
Do not run the pump dry. This could cause severe damage to the seal, bushings and/or metal
parts.
Startup
Prior to starting the pump double check the following:
• Pressure and vacuum gauges should be installed as close as possible to the pump.
• Rotate pump shaft to ensure it turns freely without binding.
• Recheck alignment and ensure all guards are in place.
• Make sure piping is independently supported and no strain is being transmitted to the pump.
• Make sure the safety relief valve is installed correctly.
• Check pump rotation.
• Open suction and discharge gate valves.
• Check for any leaks once gate valves are open.
After completing these checks the pump can be started.
! CAUTION
The pump should not be run dry. If after approximately 60 seconds there is no discharge of
liquid, stop the pump and investigate the possible cause. Failure to comply with this could cause
severe damage to internal seals, bushings and/or metal parts.
Pump Performance Data
size capacity (gpm)
30L .3
00L .8
0L 1.6
1L 2.7
2L 4.9 Based on pumping a fluid of 200 SSU
5L 12.9 viscosity at 100 psi and 1750 rpm.
V1.2 6 of 12 04/01/2009
163 of 761
Service Manual # 11
! WARNING
Failure to follow these instructions could result in serious bodily injury or death.
Do not attempt to work on any Tuthill pump installation before completing the steps below.
Disconnect the drive so that it cannot be started while work is being performed.
Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to
determine its characteristics and the precautions necessary to ensure safe handling.
Vent all pressure within the pump through the suction or discharge lines.
Disassembly of Seal
The seal assembly in LA and LE Series pumps can be changed without disassembly of the rest
of the pump.
• Place the pump in a vise with the shaft facing up so that one jaw grips across the two ports.
Do not tighten excessively as the pump housing may be distorted.
• Inspect the shaft at the keyway, flat or tang. Any burrs will interfere with removal of the
housing plug and bearing assembly.
• Remove the housing plug with a face-type spanner wrench, available from Tuthill as part
number 0L 506.
• Remove the seal from the shaft. The rubber boot will be bonded to the shaft, so it is
necessary to push down on the seal to break this bond. Grasp the metal outer shell with any
suitable device and pull the seal assembly upward. Remove the spring and washer.
V1.2 7 of 12 04/01/2009
164 of 761
Service Manual # 11
• Models 30LA through 1LA and models 30LE through 1LE have a snap ring on the shaft to
back up the seal assembly. Do not remove this snap ring unless you are completely
disassembling the pump. Models 2LA, 2LE and 5LE do not have a snap ring. A step on the
shaft is used as the seal backup.
• Remove the stationary seal face from the housing plug by pressing out from the opposite
side.
• If damaged, remove the O ring from the OD of the housing plug.
Disassembly of Pump
The seal assembly must be removed before the pump can be disassembled.
• Remove the snap ring from the shaft on all models except 2LA, 2LE and 5LE.
• Mark the cover and housing of the pump for proper re-assembly.
• Remove cover screws, cover, idler and rotor from the housing.
Inspection
Check the pump housing, rotor, idler gear. idler pin and cover for wear and chipped or broken
teeth.
The housing bore and rotor OD may be checked for wear by positioning the rotor in the housing
and checking for clearance in the bearing. The shaft must turn freely without any detectable side
play. Any side play will require replacement of the housing and/or rotor. If either of these two
parts must be replaced, it is economically advisable to replace the entire pump.
Assembly of Pump
The following must be carefully followed when the pump is re-assembled:
• Clean all parts thoroughly using great care to eliminate all dirt.
• Install the rotor in the pump housing.
• Apply the gasket to the cover. Use a new gasket if the old one is damaged. (Models 30LA,
30LE and 5LE are also supplied with an O ring in the cover. Replace if damaged.)
• Place the idler gear on the pin in the cover assembly.
• Place the cover assembly with gear on the pump, aligning the matching marks for proper
location.
• Install the cover screws. Tighten gradually, alternating from a screw on one side to a screw
on the opposite side.
• Install the snap ring on the shaft (except models 2LA, 2LE and 5LE).
Assembly of Seal
• Clean all parts thoroughly using great care to eliminate all dirt.
• Oil the shaft with a suitable lubricating oil. (If the pump has an EPR seal, apply a silicon
based lubricant instead.)
• Apply the appropriate lubricant to the inside of the new seal assembly.
V1.2 8 of 12 04/01/2009
165 of 761
Service Manual # 11
For standard full length shafts with flat and/or keyway:
• Place seal assembly on the pump shaft.

• Push seal down with your fingers to a position approximately half way down the
shaft.
For modification “A” tang shafts:
• Use tapered plastic sleeve, available from Tuthill as part number 1LPF 531 7010.
• Lubricate the sleeve.
• Place seal assembly on the sleeve. The tapered end of the sleeve fits into the spring
end of the seal assembly.
• Place the slotted end of the sleeve on a bench. Press down on the carbon face of
the seal with your fingers and slide the seal to about the midpoint on the sleeve.
• Place the slotted end of the sleeve over the tang on the pump shaft. Line up the
outside diameters of the sleeve and shaft by eye.
• Push seal down with your fingers so that it passes from the sleeve to a position
approximately halfway down the shaft.
• Press the stationary face into the housing plug. The lapped surface must be up. Protect this
lapped surface by covering it with a piece of paper when pressing down on the face. Use
your fingers for this operation.
• Place a new O ring on the OD of the housing plug, if required, and lubricate.
• Lubricate the carbon face liberally.
• Re-assemble the housing plug into position over the pump shaft. Do not nick the seal face
by hitting the pump shaft. Tighten the housing plug with the spanner wrench. The seal will
automatically be positioned by this operation.
• If the pump is equipped with a ball bearing (modification K), press the bearing onto the shaft.
Press on the bearing inner race with a suitable sleeve. Do not hammer into position or press
on the bearing outer race.
• Check pump for free rotation by turning the shaft with a suitable wench. There will be a
definite resistance to turning because of the seal load. The pump must turn freely without
binding.
Changing Rotation
LA and LE Series pumps are bi-directional and will work equally well in either direction with no
modification. However, if outfitted with an internal relief valve (model LEV), these pumps become
rotational. Rotation cannot be changed in the field unless the housing is replaced.
To change the location of the suction port on a pump outfitted with Tuthill’s unique automatic
reversing feature (models RLA and RLE):
• Remove the cover screws.

• Rotate the cover 180° so that the boss on the cover points to the new suction (inlet) port.
• Align the mounting holes and reinstall the cover screws.
Note: Location of the suction port cannot be changed in the field on RLEV pumps unless the
housing is replaced.
V1.2 9 of 12 04/01/2009
166 of 761
Service Manual # 11
Troubleshooting
No fluid is delivered.
• Power is not on.

• Net positive suction head available (NPSHA) is lower than required for the inlet
conditions and the vapor pressure of the liquid pumped. Calculate NPSHA and
redesign piping if necessary.
• Leaks in suction line or port passages. These can be detected by submerging the
pressure line from the discharge side of the pump into a pail of liquid where the air
will be seen in the form of bubbles.
• Direction of shaft rotation is incorrect.
• Pump shaft is not rotating. The coupling is defective or the tongue and groove are
not engaged.
• The relief valve setting is too low. Liquid is discharging through the by-pass port.
Capacity is too low.
• There are air leaks in the suction line.

• Suction losses are too high. The suction lift is too great or the suction line too small
or too long. This can be detected by installing a vacuum gauge directly at the pump
suction. The maximum vacuum at the pump suction should never exceed 15” of
mercury. Vaporization caused by higher vacuums will generally result in capacity
drop off. Suction conditions must be redesigned.
• Pump speed is too slow.
• The strainer is too small or obstructed.
• The suction port or pipe is not immersed deeply enough in the liquid.
• Piping is improperly installed, permitting an air pocket to form in the pump.
• Increased clearances or wear in the pump will sometimes cause the pump to deliver
an insufficient supply of fluid. This can generally be corrected by reducing the
thickness of the cover gaskets. A folded gasket or a slight amount of dirt can
exaggerate the problem and cause leakage.
Pump works spasmodically.
• Leaky suction line.

• Varying suction conditions.
• Air or vapor in the fluid.
Excessive power draw.
• Pressure too high.

• Liquid is more viscous than originally expected.
• Suction or discharge lines obstructed.
• Insufficient horsepower.
• Drive shaft and pump misaligned.
• Pump binding due to insufficient end clearance.
• Pump shaft is bent.
• Misalignment within the pump due to bad piping or poor installation, causing strain or
distortion.
V1.2 10 of 12 04/01/2009
167 of 761
Service Manual # 11
Pump is noisy.
• Pump is cavitating due to inadequate suction conditions.

• Misalignment of coupling.
• Coupling is set too close to pump.
• Vibration of pump due to worn or bent shaft.
• Air leaks on suction side of pump or air entrainment in the fluid.
Pump leaks.
• Cover bolts need tightening or cover gasket is defective.

• Worn or defective seal.
Material Returns
If it becomes necessary to return a pump to the factory, a Return Goods Authorization (RGA)
must be obtained from either your local Authorized Distributor or our Chicago plant. No RGA can
be issued until a completed Material Safety Data Sheet (MSDS) has been forwarded to our
Chicago plant and return of the pump approved.
• Tuthill pumps are precision built and must be handled with care.
• Pumps must be drained of all fluid and the ports plugged to prevent foreign material
from getting into the pump.
• Pumps must be packaged securely to prevent damage while in transit.
V1.2 11 of 12 04/01/2009
168 of 761
Service Manual # 11
Notes:
Tuthill Pump Group

Alsip, IL 60803
USA
o 708.389.2500
f 708.388.0869
V1.2 12 of 12 04/01/2009
Tuthill Pump Group
Alsip, Illinois 60803
USA 169 of 761
Date: 6/24/2009 Phone: 708-389-2500
Fax: 708-388-0869
pumpxpert@tuthill.com
5LE-7, (Model 5LE) www.tuthillpump.com
Project Description: #2 oil

1.5
100 PSI
1.25
1
Power (BHP)
0.75
0.5
0.25 0 PSI
800 0 PSI
100 PSI
600
Flow (US GPH)
400
200
0
0 250 500 750 1000 1250 1500 1750 2000 2250
Speed (RPM)
L Series internal-gear pump
Material of Construction: Cast Iron
PUMP FEATURES Operating Conditions:
mechanical seal RPM: 1725
viton mech seal Power Requirement: 1.312 BHP
3 bolt flange (LE) Capacity: 628.8 US GPH
no relief valve Suction Pressure: 0 in. Hg vac
bi-rotational (ports change with rotation) Discharge Pressure: 100.0 PSIG
Port Orientation: CW=RHS, CCW=LHS (std) Differential Pressure: 100.0 PSI
Temperature 70.00 Fahrenheit
Mechanical Efficiency: 46.62 %
Volumetric Efficiency: 72.94 %
NPSHr: 10.85 ft. H20 abs
Fluid Data:
Name: Oil-Diesel Fuel (20 30 40 50)
Viscosity: 40.00 SSU
Specific Gravity: 0.9000
Fluid is: flammable
non-toxic
Non Abrasive Clean Liquid
tuthilllpump.com PumpXpert Version 3.1.A.11 (Dec 22 2004)

170 of 761
L SERIES ENGINEERING
DATA PACK
Contents:
Pump Performance Data
Page 2: L/4100 Pump Performance Data (40, 200 & 500 SSU)
Page 3: L/4100 Pump Performance Data (1000 & 5000 SSU)
LE Pumps
Page 4: Pump Mounting Dimensions (30LE with pump options)

Page 5: Pump Mounting Dimensions (00LE, 0LE, 1LE & 2LE with pump options)
Page 6: Pump Mounting Dimensions (5LE with pump options)
Page 7: Pump Mounting Dimensions (LSA pump)
Page 8: LE Pump Model Number System
Page 9: Temperature Limits
Page 10: LE Pump Materials of Construction
Page 11: NPSH Data (L, 4100, and Cartridge Series)
Page 12: Dimensions for 30LE-2LE Close Coupled to a 48 Frame Single Phase Motor
Page 13: Dimensions for 30LE-2LE Close Coupled to a 56 Frame Single Phase Motor
Page 14: Dimensions for 30LE-2LE Close Coupled to a 48 Frame Three Phase Motor
Page 15: Dimensions for 30LE-2LE Close Coupled to a 56 Frame Three Phase Motor
Page 16: Dimensions for 5LE Close Coupled to a 56 Frame Single Phase Motor
Page 17: Dimensions for 5LE Close Coupled to a 56 Frame Three Phase Motor
Page 18: Dimensions for 30LE-2LE Adapter Mounted to a 56 Frame Single & Three Phase Motor
Page 19: Dimensions for 30LE-2LE Adapter Mounted to a 143/145 Frame Single & Three Phase Motor
Page 20: Dimensions for 5LE Adapter Mounted to a 56 Frame Single & Three Phase Motor
Page 21: Dimensions for 5LE Adapter Mounted to a 143/145 Frame Single & Three Phase Motor
Page 22: Dimensions for LE Series Mounting Foot
Cartridge Pumps
Page 23: Pump Mounting Dimensions (00RF, 0RF, 1RF, & 1R1F-A)
Page 24: Pump Mounting Dimensions (00LFD, 0LFD, 1LFD & 2LFD)
Page 25: Pump Mounting Dimensions (00RFD, 0RFD, 1RFD & 2RFD)
Page 26: Cartridge Pump Model Number System
Page 27: Cartridge Pump Materials of Construction
4100 Pumps
Page 28-29: 4100/LE Cross Reference List

Page 30: 4100 Pump Model Number System
Page 31: Temperature Limits
Page 32: 4100 Pump Materials of Construction
1 November, 2004
40 SSU 200 SSU 500 SSU
0 PSI 50 PSI 100 PSI 0 PSI 50 PSI 100 PSI 200 PSI 300 PSI 500 PSI 0 PSI 50 PSI 100 PSI 200 PSI 300 PSI 500 PSI
SIZE RPM GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP
300 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
900 0.2 8 0.1 8 0.1 8 0.1 8 0.1 8 0.1 8 0.1 8 0.1 8 0.1 8 0.2 8 0.2 8 0.1 8 0.1 8 0.1 8 0.1 8
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
30 1200 0.3 8 0.2 8 0.2 8 0.3 8 0.2 8 0.2 8 0.2 8 0.2 8 0.2 4 0.2 8 0.2 8 0.2 8 0.2 8 0.2 8 0.2 4
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1800 0.4 8 0.4 8 0.3 8 0.4 8 0.4 8 0.3 8 0.3 4 0.3 4 0.3 3 0.4 8 0.3 8 0.3 4 0.3 4 0.3 4 0.3 4
1 1 1 1 1 1 1 1 1 1
3600 - - - - - - 0.8 4 0.8 4 0.8 4 0.8 3 0.7 2 - - 0.8 4 0.7 4 0.7 4 0.6 4 0.6 3 - -
1 1
300 .15 8 .10 8 - - - - - - - - - - - - - - - - - - - - - - - - - -
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
900 .45 8 .40 8 .35 8 0.4 8 0.4 8 0.4 8 0.3 8 0.2 4 0.1 4 0.4 8 0.4 8 0.4 8 0.4 8 0.4 8 0.3 4
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
00 1200 .65 8 .55 8 .50 8 0.5 8 0.5 8 0.5 8 0.4 4 0.4 4 0.3 3 0.6 8 0.6 8 0.6 8 0.5 8 0.5 4 0.4 4
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1800 .95 8 .90 8 .85 4 0.9 8 0.9 8 0.8 8 0.7 4 0.7 3 0.5 2 0.9 8 0.9 8 0.8 8 0.8 4 0.8 4 0.7 2
1 1 1 1 3 1 1 1 1 3
3600 - - - - - - 1.8 4 1.7 4 1.7 3 1.6 2 1.5 4 - - 1.7 4 1.7 4 1.6 3 1.5 2 1.5 4 - -
300 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
900 0.8 8 0.7 8 0.6 8 0.8 8 0.8 8 0.8 8 0.7 4 0.5 3 0.3 2 0.7 8 0.7 8 0.7 8 0.6 4 0.6 4 0.5 2
1 1 1 1 1 1 1 1 3 1 1 1 1 1 1
0 1200 1.0 8 0.9 8 0.8 4 1.0 8 1.0 8 1.0 8 0.9 4 0.8 2 0.6 4 1.0 8 1.0 8 1.0 4 0.9 4 0.9 3 0.7 2
2
1 1 1 1 1 1 1 3 1 1 1 1 1 3
1800 1.6 4 1.4 4 1.3 4 1.6 8 1.6 4 1.6 4 1.5 4 1.4 4 1.2 1 1.6 8 1.5 4 1.5 4 1.4 2 1.4 2 1.3 4
1 1 1 1 1 1 1 3 1
3600 - - - - - - 3.2 4 3.1 3 3.1 2 3.1 2 2.9 1 - - 2.9 3 2.8 2 2.8 2 2.8 4 2.8 12 - -
1 1 1 1 1 1 1 1 1 1 1 1
300 0.4 8 0.3 8 - - 0.4 8 0.4 8 0.2 8 0.1 8 - - - - 0.4 8 0.4 8 0.4 8 0.3 8 0.3 4 0.3 4
1 1 1 1 1 1 1 1 3 1 1 1 1 1 3
900 1.4 4 1.1 4 1.1 3 1.4 8 1.4 8 1.2 4 1.0 3 0.8 2 0.4 4 1.3 8 1.3 8 1.3 4 1.1 3 1.1 2 0.9 4
1 1 1 1 1 1 1 1 3 1 1 1 1 1
1 1200 1.9 4 1.7 4 1.5 3 1.9 8 1.9 8 1.7 4 1.5 3 1.4 2 1.2 4 1.8 8 1.8 8 1.7 4 1.6 3 1.4 2 1.1 1
1 1 1 1 1 1 1 3 1 1 1 1 1 1
1800 2.9 4 2.7 2 2.5 2 2.9 8 2.8 4 2.7 3 2.5 2 2.3 4 2.1 1 2 2.7 4 2.7 4 2.6 3 2.5 2 2.4 1 2.2 1 2
1 1 3 1 1 1 3 1
3600 - - - - - - 5.6 3 5.6 2 5.5 4 5.2 1 5.1 1 2 - - 5.3 2 5.2 2 5.2 4 5.0 12 4.9 2 - -
1 1 1 1 1 1 1 1 1 1 1 1 1 1
300 0.9 8 0.7 4 0.5 3 0.9 8 0.8 8 0.8 8 0.7 4 0.6 4 - - 0.9 8 0.9 8 0.8 8 0.7 4 0.7 4 0.5 2
1 1 3 1 1 1 1 3 1 1 1 1 1 1
900 2.8 4 2.5 2 2.2 4 2.8 8 2.7 4 2.7 4 2.6 2 2.4 4 2.2 1 2 2.7 8 2.6 8 2.3 4 2.1 2 2.1 2 1.8 1
L/4100 Pump Performance Data
1 1 3 1 1 1 1 1 1 1 1 1 3 1
2 1200 3.7 3 3.4 2 3.1 4 3.7 8 3.4 4 3.1 4 2.8 2 3.0 1 2.8 1 2 3.6 8 3.5 4 3.3 3 2.8 2 2.7 4 2.0 1 2
1 3 1 1 1 3 1 1 1 1
1800 5.4 2 4.9 4 4.8 1 5.5 4 4.9 3 4.9 2 4.6 4 4.3 1 2 3.8 2 5.3 4 5.2 3 4.9 2 4.4 1 4.0 112 3.0 2
3600 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1 1 1 1 1 1 1 1 1
300 2.0 8 1.4 8 0.8 4 2.2 8 1.7 8 1.4 4 - - - - - - 2.2 8 2.0 8 1.8 4 - - - - - -
1 1 1 1 3 1 1 3
900 6.3 8 5.0 2 3.6 1 6.8 4 6.4 2 6.0 4 5.6 112 4.9 2 - - 6.8 4 6.6 2 6.3 4 6.1 112 5.5 2 - -
1 3 1 1 1 3 1
5 1200 9.0 4 7.6 4 6.0 1 9.0 3 8.6 2 8.2 1 7.7 2 7.1 3 - - 8.7 2 8.6 4 8.5 12 8.2 2 7.8 3 - -
171 of 761
1 1 1 1 1
1800 11.5 3 11.1 1 10.7 1 2 13.7 2 13.3 1 12.9 12 10.9 3 10.2 5 - - 12.9 1 12.8 1 2 12.7 2 12.5 3 12.0 5 - -
November, 2004
3600 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
172 of 761
5LE Pump Mounting Dimensions

(2) 1-11 1 N.P.T. PORTS 69 51
2 16 8
15
17 17 432 37
16 16 32
3 25
8 132
1
14
1
15
32
311
16
LL P UM
HI P
T
TU
CO
Ø0.4361
0.4356
.
2.123
CHICAGO U.S.A. Ø2.121
0.391
0.388 30°
#404 WOODRUFF
33
16 KEYWAY
(3) Ø 9 MOUNTING HOLES

32
Ø2.752 B.C.
2.748
RELIEF VALVE 15
4
32
ROTATION ROTATION 11
16
9
16
Port Types
1"-11 1/2 NPT STD 0.245
0.243
1 3/16”-12 UNC (SAE 14) OPT
1 5/16”-12 UNC (SAE 16) OPT
1”-11 BSPP OPT
V-C V-CC
SHAFT END VIEW MODIFICATION "A"
5LE WITH OPTIONAL SIDE PORTING

1 1
(2) 1-11 2 N.P.T. PORTS 69 5
16 8
7 7 15 (2) 1" PIPE PLUG
1 1 9
432 37
16 16 32
64 3 25
8 132
1
14
1
15
32
311
16
P UM
I LL P
H
T
TU
CO
Ø0.4361
0.4356
.
5
8 2.123
CHICAGO U.S.A. Ø2.121
0.391
0.388 30°
3 #404 WOODRUFF
316
KEYWAY
(3) Ø 9 MOUNTING HOLES

32
Ø2.752 B.C.
2.748
6 November, 2004
173 of 761
L Pump Model Number System
Size Model SAE Port Option*

30 LE SAE8
00 LSA SAE14
0 SAE16
1 *See Pump Mounting
2 Pump Options Modifications Dimensions for port
5 V Valve -A Tang Shaft availability.
H High Pressure -5 Neoprene Seal
K Outboard Ball Bearing -6 Teflon Seal
U Cover Rotated 180° -7 Viton Seal
T Combination of H & K -8 EPR Seal
-N No Flat/Keyway
*Reversing Feature
R in Shaft
*Not Available on 30
& 5 Size Models
Rotation (Valved Models) Carbon Bushing Option
-C Clockwise Rotation -Z
-CC Counterclockwise Rotation
Or
Suction Port Location (On Pumps
With reversing Feature)
-RH Right Hand Suction
-LH Left Hand Suction
1.) PUMP'S MODEL NUMBER IS LOCATED

IN BETWEEN THE PUMP PORTS.
IN IN
2.) ROTATION AND SUCTION (IN) AND
DISCHARGE (OUT) ARE STAMPED
AS WELL.
IN IN
1L
EV
-CC
IN LE LEU LEV -C LEV-CC
BI-DIRECTIONAL BI-DIRECTIONAL DIRECTIONAL DIRECTIONAL
OUT IN IN OUT OUT IN IN OUT
RLA/RLE-RH RLA/RLE-LH RLEV-RH RLEV-LH

RIGHT HAND SUCTION LEFT HAND SUCTION RIGHT HAND SUCTION LEFT HAND SUCTION
8 November, 2004
174 of 761
600 °F
LE Pump Temperature Limits
550 °F
500 °F
450 °F
400 °F
350 °F
300 °F
Teflon
Carbon Bushings
250 °F
Ethylene Propylene (EPR)

Bronze Bushings
200 °F
Viton
150 °F
Neoprene
Buna-N
100 °F
50 °F
0 °F
-50 °F
-100 °F
Notes:
1. A pump’s performance is dependent on more than just the temperature ranges of the component
materials.
9 November, 2004
175 of 761
LE Pump Materials of Construction

Part Name Material Standard Comments Availability
Housing Cast Iron ASTM A48 – 96a Classes 25, 30, 35, or 40 Std.
Steel AISI 12L14 Std.

Housing
Carbon Carbon Graphite Resin Opt.
Bushing
Bronze SAE 660 Available on 2L size only Std.
Cover Cast Iron ASTM A48 – 96a Classes 25, 30, 35, or 40 Std.
Rotor Steel ASTM A311 Stressproof Std.
P/M Steel MPIF-0508-P Std.
Idler Steel C1118 or C1117 Opt.
Plastic PPS Available on 30L size only Std.
Idler Pin Steel C1117 Heat Treated Std.
Idler Bronze SAE 660 Std.*

Bushing
Carbon Carbon Graphite Resin Opt.
Housing DU Bushing is assembled in
Steel AISI 12L14 Std.
Plug housing plug
Standard Oriented Polyester Std.
Gaskets
Standard Buna Coated Aluminum Available on 2L size only Std.
Buna Std.
Viton Opt.
O-Rings Neoprene Opt.
EPR Opt.
Teflon Opt.
* Bronze idler bushing standard on 5LE pumps only.
10 November, 2004
176 of 761
L Series NPSH Data

NPSH Required for Tuthill “L” Series pumps
0-1000 SSU
SPEED RPM
300 600 900 1200 1500 1800
PUMP SERIES
30L FT. 1.0 1.7 1.9 2.1 2.3
00L FT. 1.0 1.7 2.0 2.3 2.6
0L FT. 1.0 1.8 2.2 2.5 2.9
1L FT. 1.1 1.8 2.3 2.9 3.5
2L FT. 1.1 2.3 3.0 3.8 5.8 7.0
5L FT. 1.7 2.8 4.6 6.6 9.2 12.3
Notes:
1. For liquid viscosity up to 1000 SSU.
2. NPSHA (Net Positive Suction Head Available) must be greater than the NPSHR (Net Positive Suction
Head Required) value provided in the table.
3. Values above are for feet of liquid with a Specific Gravity of 1.0
Viscosity Correction Factor
Viscosity (SSU)
2500 5000 10000
Correction Factor 1.3 1.7 2.0
11 November, 2004
1
(2) 1"-112 NPT PORTS
DIM. TO CONDUIT BOX
VARIES DEPENDING 3.21
MOTOR LENGTH VARIES 4.77 ON MFGR.
DEPENDING ON MFGR.
4.44 2.70 1.44 1.44
COVER USED ON
SINGLE PHASE
MOTORS ONLY
3.69
NAMEPLATE
DEPENDING ON MFGR.
20
MOTOR HEIGHT VARIES
3.50
3.00 2.75 ASSEMBLY STYLES
2.44 2.44
Single & Three Phase Motor
A B
Dimensions for 5LE Adapter Mounted to a 56 Frame
C D
177 of 761
November, 2004
178 of 761
WATTSAVER® PREMIUM EFFICIENCY MOTORS
GENERAL PURPOSE
WATTSAVER®
The WATTSAVER® line of premium efficiency have been verified to IEEE 112B test standards
motors is now inverter capable. LEESON’s by LEESON’s NVLAP-Certified lab.
unique IRIS™ voltage-spike-resistant insulation Cast iron 170 series motors can be field modified
system is standard at no extra cost. for forced ventilation service to extend the
WATTSAVER® motors carry a three-year inverter-fed operating range and an encoder
warranty in general purpose and inverter fed package is stocked for closed-loop vector
applications. These motors meet or exceed most inverter systems. These motors can be
utility rebate programs and the EPACT federally converted to IEEE841 compliant using the
mandated efficiency levels. The efficiency ratings Custom PDQ Program. Contact LEESON.
Both 3/4 and full load efficiencies are listed on the

Efficiencies meet or exceed NEMA Premium on stainless steel nameplate for your convenience in
all WATTSAVER® motors except as noted. calculating realistic energy savings. Unique serial
Rugged cast iron construction on number identifies each motor and is stamped clearly
three phase, 3-100 HP models. These on the metal nameplate.
motors share features with normal
efficiency 150 Series motors detailed on
page 14. Add an optional cast iron fan Independently verified efficiencies
guard for severe duty applications. by the Canadian Standards
Association, an internationally
recognized testing laboratory. CSA
Report Number EEV78720-1.
Three phase models suitable

for inverter duty, as well as Premium efficiency motors finished
both 50 Hz and 60 Hz operation. with primer and chemical resistant
green acrylic matte enamel.
Modification to meet IEEE 841

available through Custom PDQ.
Meets or exceeds the 1997 (See page 62.) Includes addition of
mandated efficiency standards watertight Inpro shaft seals, two-part
of the Energy Policy Act of 1992. epoxy finish, and plated hardware.
Also meets or exceeds efficiency
requirements of most electric
utility rebate programs.
Connections include red leads for NC thermostats One-way, corrosion resistant condensate
attached to windings for over-temperature protection. drains. (TEFC models) release condensation
and moisture.
Second-generation, high temperature, spike-resistant

magnet wire for extended motor life. Stator impregnated
with extra-heavy varnish system. 1.15 Service Factor. All
WATTSAVER® motors have Class F insulation with a
Class B rise.
LEESON’s Inverter Rated Insulation System (IRIS™) hygroscopic, high temperature varnish are just a few
provides superior protection against voltage spikes features contributing to extra protection. All this plus
induced by variable frequency drives. This total second generation spike-resistant magnet wire.The
insulation system protects better than spike-resistant IRIS™ total insulation system is standard at no extra
magnet wire alone. Specially formed phase insulation, cost in all LEESON stock NEMA three-phase motors,
cushioned and sleeved connections (from the leads all 1 HP and larger.
the way into the turns), and deep-penetrating, non-
UL and CSA Recognition

CSA certified under report number LR62104
CSA Energy Efficiency Verification report number EEV78720-1
UL recognized insulation system, file number E55555
UL recognized construction, file number E57948
15
179 of 761
C FACE MOTORS • THREE PHASE
WITH BASE • GENERAL PURPOSE
C Face Motors
DRIP PROOF • C FACE WITH BASE • THREE PHASE TEFC • C FACE WITH BASE • THREE PHASE
RPM App. F.L. % “C” App. F.L. % “C”
60 NEMA Catalog List Disc. Wgt. Amps F.L. Dim. NEMA Catalog List Disc. Wgt. Amps F.L. Dim.
HP Hz Frame Number Price Sym. (lbs.) Voltage 230V Eff. (Inches) Frame Number Price Sym. (lbs.) Voltage 230V Eff. (Inches)
1/3 1725 S56C 100599 $311 A 18 208-230/460 1.6 64.3 9.49 S56C 102921● $343 A 18 208-230/460 1.3 77.0 9.56
1725 … … … … … … … … … S56C 102922 342 A 19 208-230/460 1.3 77.0 10.19
1725 S56C 103021 W 361 A 23 208-230/460 1.3 77.0 10.24 S56C 102697 W 439 A 22 208-230/460 1.3 77.0 10.19
1/2 3450 S56C 100600 296 A 17 208-230/460 2.4 69.0 9.31 56C 110182● 340 A 26 208-230/460 1.6 82.5 10.40
3450 … … … … … … … … … 56C 114142 340 A 21 208-230/460 2.6 68.0 10.81
1725 S56C 100601 352 A 20 208-230/460 2.0 68.0 9.99 S56C 102919● 397 A 22 208-230/460 2.0 77.0 10.06
1725 … … … … … … … … … S56C 102917 397 A 19 208-230/460 2.0 73.0 10.19
1725 S56C 103022 W 381 A 26 208-230/460 1.8 77.0 10.74 S56C 102024 W 472 A 23 208-230/460 1.8 77.0 10.69
1140 … … … … … … … … … 56C 110914 533 A 25 208-230/460 2.4 70.0 11.31
3/4 3450 S56C 102971 335 A 21 208-230/460 2.4 79.0 9.85 56C 110915 368 A 23 208-230/460 2.4 75.5 10.81
1725 S56C 100602 391 A 25 208-230/460 2.8 75.0 10.49 56C 110916 427 A 22 208-230/460 2.8 77.0 10.81
1725 56C 116762 W 404 A 30 208-230/460 2.4 81.5 10.86 56C 114624 W 507 A 25 208-230/460 2.7 81.5 11.31
1140 … … … … … … … … … 56C 116340 558 A 29 208-230/460 3.0 75.5 11.81
1140 … … … … … … … … … 143TC 120485 558 B 34 208-230/460 3.0 75.5 13.25
1 3450 56C 116784 384 A 23 208-230/460 3.2 77.0 9.84 56C 110181 435 A 24 208-230/460 3.2 77.0 10.81
1725 56C 110901 458 A 28 208-230/460 4.2 78.5 10.38 56C 110912 455 A 24 208-230/460 3.6 77.0 11.31
1725 56C 116763 W 577 A 33 208-230/460 3.4 85.5 11.68 56C 116745 W 715 A 34 208-230/460 3.4 85.5 12.81
1740 … … … … … … … … … 145TC G121286 501 B 35 208-230/460 3.8 82.5 13.25
1725 143TC G121650 453 B 34 208-230/460 3.1 82.5 11.28 143TC 121179 W 715 B 34 208-230/460 3.4 85.5 13.25
1140 … … … … … … … … … 145TC G120428 608 B 35 208-230/460 3.6 80.0 13.25
11⁄2 3450 56C 116785 455 A 28 208-230/460 4.2 81.5 10.84 56C 110917 488 A 29 208-230/460 4.2 81.5 11.81
3450 … … … … … … … … … 143TC G121290 525 B 27 208-230/460 4.0 82.5 13.25
3450 … … … … … … … … … 143TC 121672 W 645 B 33 208-230/460 3.6 84.0 13.25
1725 56C 110902 482 A 29 208-230/460 5.6 78.5 10.88 56C 110918 480 A 30 208-230/460 5.0 78.5 11.81
1725 56C 116764 W 599 A 37 208-230/460 5.6 86.5 12.68 Oil
56Cpump motor
116746 W selection
741 A 37 208-230/460 5.6 86.5 13.31
1725 143TC 121674 W 577 B 34 208-230/460 3.4 85.5 12.12 … … … … … … … … …
1725 145TC G121651 474 B 32 208-230/460 4.4 84.0 12.12 145TC G121287 500 B 37 4.4 84.0 13.25
1725 145TC 121675 W 599 B 37 208-230/460 5.6 86.5 13.12 121180 W
1125 … … … … … … … … … 56HC 114198 ᔥ 643 A 41 208-230/460 5.7 77.0 13.31

1140 … … … … … … … … … 56HCZ 116592❋ 643 A 44 208-230/460 5.7 77.0 13.75
2 3450 56C 114218 563 A 34 208-230/460 5.6 82.5 11.40 56C 113927 553 A 34 208-230/460 5.6 82.5 12.31
3450 … … … … … … … … … 145TC G121510 577 B 45 208-230/460 5.2 84.0 13.25
3450 … … … … … … … … … 145TC 121673 W 661 B 44 208-230/460 4.8 85.5 13.75
1725 56HC 116630ᔥ 506 A 32 208-230/460 6.2 78.5 11.38 56HC 116106 ᔥ 512 A 36 208-230/460 6.2 81.5 12.81
1725 56HC 116765 W 676 A 42 208-230/460 5.8 86.5 13.18 56HC 116747ᔥ W 775 A 43 208-230/460 5.8 86.5 13.82
1725 145TC G120275 508 B 35 208-230/460 5.6 84.0 12.62 145TC G120276 524 B 45 208-230/460 5.6 84.0 13.75
1725 145TC 121676 W 676 B 42 208-230/460 5.8 86.5 13.62 145TC 121181 W 775 B 43 208-230/460 5.8 86.5 14.26
1140 … … … … … … … … … 184TC G131497 769 B 76 208-230/460 7.2 86.5 15.47
3 3450 … … … … … … … … … 56HC 114615♣ ᔥ 616 A 38 208-230/460 7.6 84.0 12.81
3500 145TC G121072 509 B 35 230/460 7.6 84.0 12.78 145TC G120991 655 B 35 208-230/460 7.4 85.5 13.75
3515 … … … … … … … … … 182TC G131899 725 B 61 208-230/460 7.6 85.5 13.97
3450 … … … … … … … … … 182TC 132079 W 954 B 70 208-230/460 7.6 86.5 13.96
3510 … … … … … … … … … 182TC G151564 772 C 94 208-230/460 8.5 87.5 16.76
1740 … … … … … … … … … 56HC 116107 ᔥ 649 B 45 208-230/460 8.6 82.5 13.81
1740 56HCZ 116631ᔥ 586 A 38 208-230/460 8.6 82.5 13.62 56HCZ 116388❋ 649 A 46 208-230/460 8.6 82.5 14.25
1760 182TC G130325 582 B 58 208-230/460 8.4 86.5 12.69 182TC G130326 650 B 68 208-230/460 8.2 87.5 13.96
1760 182TC 132081 W 732 B 76 208-230/460 7.8 89.5 14.20 182TC 131504 W 836 B 75 208-230/460 7.8 89.5 14.96
1750 … … … … … … … … … 182TC G151565 754 C 94 208-230/460 8.5 87.5 16.14
1140 … … … … … … … … … 215TC G140602 963 B 118 230/460 12.0 87.5 17.71
● These motors are totally enclosed, non-ventilated — Others are fan cooled.
♣ These totally enclosed three phase motors have 1.0 service factors. SHADED FRAME INDICATES CAST IRON CONSTRUCTION
■ Combination 56H base motors have mounting holes for NEMA 56 and NEMA 143-145T and standard
NEMA 56C face and shaft.
❋ 56HCZ motors have mounting holes for NEMA 56 and NEMA 143-5T Catalog numbers in green are EPACT motors.
and a standard NEMA 143-5T shaft.
Premium efficiency WATTSAVER® Motors.
All three phase motors, 1 HP and above, are inverter
All 180 and 210 frame Rolled Steel motors have Class F Insulation.
rated. Refer to page 5 for speed ranges.
26 CONTINUED ON NEXT PAGE
180 of 761
ELECTRIC MOTORS, GEARMOTORS
AND DRIVES

Home News Products Product Quick Search Technical Information Custom Solutions Literature Where to Buy Service & Warranty Contact Us
Product Features
/LVW3ULFH

&DWD R
&DWDORJ1R 0RGHO
3URGXFWW\SH ! 6WRFN "
'HVFULSWLRQ #$&#!&'
Information shown is for current motor's design +,
(QJLQHHULQJ'DWD
Volts Volts Volts =#
F.L. Amps F.L. Amps F.L. Amps #=
S. F Amps S. F Amps S. F Amps #
RPM Hertz <#
HP Duty >?>@ @ TYPE '
KW
Frame Serv. Factor Phase
Max Amb Design J Code
Insul Class F Protection > >' Therm.Prot.
Eff 100% Eff 75% PF <
UL K*QW'' >@W!'X CSA K Bearing OPE <
CC Number CE K Bearing PE <
Load Type Inverter Type Speed Range > >'
Motor Wt. Enclosure ' Lubrication & WK!'Z'
Nameplate == Mounting !?? Rotation !'+
Assembly Shaft Dia. #?> Ext. Diag.
Cust Part No Outline <* Ext. Diag2
Packaging J Outline Dash No Winding <<
Carton Label W&:[\ GROUP:
Iris Paint Test Card
Const Torque Speed

Form Factor RMS Amps
Range
Torque Peak
181 of 761
3.6 Atlas Copco

8516 Tamarron Dr., Charlotte, NC 28227 USA
www.atlascopco.us
Instruction book 182 of 761
Atlas Copco Stationary Air Compressors
LE2, -3, -5, -7, -10, -15, -20

LT2, -3, -5, -7, -10 (50 Hz)
LT15/60, -15-30, -15, -20, -20-30
LF2, -3, -5, -7, -10
Instruction book
Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.
This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.
No. 2920 1585 00
Registration code: APC L / 38 / 985
2004-07
2920 1585 00 -1-

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency
and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and
proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the
machine in good condition.
Keep the book available for the operator and make sure that the machine is operated and that
maintenance is carried out according to the instructions. Record all operating data, maintenance
performed, etc. in an operator's logbook available from Atlas Copco. Follow all relevant safety
precautions, including those mentioned on the cover of this book.
Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further
information.
In all correspondence mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal
data".
The company reserves the right to make changes without prior notice.
2920 1585 00 -2-

1 Leading particulars .................................................................................................................................. 5

1.1 General description.............................................................................................................................. 5
1.1.1 Compressor variants ..................................................................................................................... 8
1.2 Air flow ................................................................................................................................................. 9
1.2.1 LE/LF2 up to -5, LE7 and LE10 50 Hz (Fig. 1.10)......................................................................... 9
1.2.2 LE10 60 Hz, LE15, -20, LF7, -10 and LT (Fig. 1.11).................................................................... 9
1.3 Regulating system ............................................................................................................................. 12
1.3.1 LE/LF/LT2 up to -7 with DOL starter (Fig. 1.10).......................................................................... 12
1.3.2 LE/LT5 up to -20, LF5 up to -10, each with Y/D starter (Fig. 1.11)............................................. 12
1.3.3 LE/LF/LT Trolley (Fig. 1.12) ........................................................................................................ 13
2 Installation and handling ....................................................................................................................... 15
2.1 Dimension drawings........................................................................................................................... 15
2.2 Installation proposals ......................................................................................................................... 36
2.2.1 LE/LF/LT...................................................................................................................................... 38
2.2.2 LE/LF/LT Trolley.......................................................................................................................... 39
2.3 Electrical connections ........................................................................................................................ 39
2.4 Settings of overload relay - fuses - cable size .................................................................................. 43
2.4.1 Settings of overload relay - fuses of compressors with DOL starter........................................... 43
2.4.2 Settings of overload relay - fuses of compressors with Y-D starter ............................................ 44
2.4.3 Cable size.................................................................................................................................... 45
2.5 Pictographs ........................................................................................................................................ 46
3 Operating instructions ........................................................................................................................... 47
3.1 Initial start-up ..................................................................................................................................... 47
3.2 Starting............................................................................................................................................... 47
3.3 Stopping............................................................................................................................................. 48
3.4 Taking out of operation at end of compressor service life ................................................................. 49
4 Maintenance............................................................................................................................................ 50
4.1 Petrol engine maintenance ................................................................................................................ 50
4.2 Preventive maintenance schedule of the compressor 1)................................................................... 50
4.3 Lubrication of LE/LT compressors ..................................................................................................... 51
4.4 Service kits......................................................................................................................................... 51
5 Servicing and adjustment procedures ................................................................................................. 53
5.1 Unloader or check valve .................................................................................................................... 53
5.2 Valves ................................................................................................................................................ 53
5.2.1 Replacement of valve discs (Figs. 5.1 and 5.2) .......................................................................... 55
5.3 Air filter ............................................................................................................................................... 56
5.4 Adjustment of MDR4S pressure switch (Figs. 5.4 up to 5.6)............................................................. 57
5.5 Adjustment of MDR3 pressure switch (Figs. 5.7 and 5.8) ................................................................. 59
5.6 Adjustment of pilot valve on Trolley (Fig. 5.9) ................................................................................... 60
5.7 Safety valve (SV-Figs. 1.4, 1.6 and 1.8) 1)........................................................................................ 61
5.7.1 Testing on LE/LF/LT.................................................................................................................... 61
5.7.2 Testing on LE/LF/LT Trolley........................................................................................................ 61
5.8 Relief valve (8-Fig. 1.1) on LF7, -10, LE10 up to -20 and LT ........................................................... 61
6 Problem solving...................................................................................................................................... 62
7 Principal data .......................................................................................................................................... 64
7.1 Reference conditions ......................................................................................................................... 64
7.2 Limitations.......................................................................................................................................... 64
7.3 Compressor data for LE 10 bar ......................................................................................................... 64
7.3.1 50 Hz ........................................................................................................................................... 64
7.3.2 60 Hz ........................................................................................................................................... 65
7.4 Compressor data for LF 10 bar.......................................................................................................... 66
7.4.1 50 Hz ........................................................................................................................................... 66
7.4.2 60 Hz ........................................................................................................................................... 66
7.5 Compressor data for LT 15 bar.......................................................................................................... 67
7.5.1 50 Hz ........................................................................................................................................... 67
2920 1585 00 -3-

7.5.2 60 Hz ........................................................................................................................................... 67
7.6.1 50 Hz ........................................................................................................................................... 68
7.6.2 60 Hz ........................................................................................................................................... 68
7.7.1 50 Hz ........................................................................................................................................... 69
7.7.2 60 Hz ........................................................................................................................................... 69
8 Conversion list of SI units into US/British units ................................................................................. 70
9 PED (Pressure Equipment Directive) ................................................................................................... 70
9.1 Components subject to 97/23/EC Pressure Equipment Directive ..................................................... 70
9.2 Overall rating...................................................................................................................................... 70
2920 1585 00 -4-

1 Leading particulars
1.1 General description
LE, LF and LT are air-cooled, single-acting piston compressors. LE and LT are lubricated compressors;
LF are oil-less compressors which deliver oil-free air. LF2 up to LF5, LE2 up to LE7 and LE10 50 Hz are
single-stage compressors; LE10 60 Hz, LE15, -20, LF7, -10 and LT are two-stage compressors.
LT and LE/LF2 up to -7 and LE10 50 Hz are two-cylinder compressors, LE10 60 Hz, LF10, LE15, -20 are
three-cylinder compressors.
Note: Take care that three-cylinder compressors rotate in the direction as indicated by the arrow on the
fan housing (counter-clockwise seen from fan cowl side).
LE/LF are built for effective working pressures up to 10 bar. LT are built for effective working pressures up
to 30 bar (LT2 only for 15 and 20 bar).
Fig. 1.1 Compressor Block with unloading valve Fig. 1.2 Power Pack with unloading valve
2920 1585 00 -5-

AF Air filter
DP Oil drain plug
FN Fan
M Motor
SG Oil level sight-glass
1 Cover
2 Intercooler
3 Air inlet silencer
4 Crankcase
5 Cooling pipe
6 Cylinder
7 Unloader
8 Relief valve
9 HP cylinder
10 LP cylinder
Fig. 1.3 Power Pack
Figs. 1.1 up to 1.3 General views, Compressor Block - Power Pack
Fig.1.5 Tank-mounted unit, LE10 60 Hz, LE5-20, LT15,

Fig. 1.4 Tank-mounted unit, LE/LT/LF2, -3,
-20 and LT/LF5-10 (standard receiver is 250 l)
horizontal receiver (standard receiver is
120 l)
2920 1585 00 -6-

AF
1
11
10
FN
7
5
AR
Dm
D0656
Fig. 1.6 Tank-mounted unit, LE/LT/LF2, -3, -5, vertical Fig. 1.7 Tank-mounted unit, three-cylinder
receiver (standard receiver is 250 l)
2920 1585 00 -7-

Fig. 1.8 Base-mounted Fig. 1.9 LE/LF/LT with CD dryer
AC Air cooler 2 Blow-off silencer

AF Air filter 3 Air inlet silencer
AR Air receiver 4 Dewpoint indicator
AV Air outlet valve 5 Cooling pipe
CV Check valve 6 Electric cabinet
Dm Condensate drain valve 7 Unloader
FC Filler cap 8 Relief valve
FN Fan 9 Pictograph, switch off voltage and
Gp Air pressure gauge depressurize before maintenance or repair
M Motor 10 LP cylinder
P1 Hourmeter, running time 11 HP cylinder
SV Safety valve 12 DD filter
Y1 Loading solenoid valve 13 Air pressure switch with on/off switches
1 Cover 14 PD filter
15 CD dryer
Figs. 1.4 up to 1.9 General views
1.1.1 Compressor variants
The Compressor Block (Fig. 1.1) includes:

- Crankcase (4) and cylinders (6)
- Air inlet filter (AF) and inlet silencer (3)
- Fan (FN)
- Air cooler piping (2) and (5)
- Unloader (7, as standard on LE/LF/LT5 up to -10, LE15, -20 and LT15 up to -20)
- Interstage relief valve (8, for LF7, -10, LE10 60 Hz, LE15, -20 and LT)
The Power Pack comprises (Figs. 1.2/1.3):

- For LE/LF/LT2 and -3: the Compressor Block as described above, with flanged-on electric motor (M), check
valve (CV-Fig. 1.4), and on 60 Hz air pressure switch with on/off switches (13-Fig. 1.4).
2920 1585 00 -8-

- For LE/LF/LT5 up to -10, LT15 up to -20: the Compressor Block as described above, with flanged-on
electric motor (M) and solenoid valve (Y1-Fig. 1.5).
The Tank-mounted unit comprises:

- For LE/LF/LT2 and -3: the Power Pack mounted on a horizontal (Fig. 1.4) or vertical (Fig. 1.6) air
receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV), air pressure switch
with on/off switches (13) and condensate drain valve (Dm).
- For LE/LF/LT5 up to -10, LE15, -20 and LT15, -20 (Fig. 1.5/1.7): the Power Pack mounted on an air
receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV) and condensate drain
valve (Dm). An electric cubicle (6) includes the motor starter. A separate air pressure switch (13) is
provided.
A silencing canopy (1-Fig. 1.13) is available as an option. The canopy has a hinged top to allow easy
access for maintenance.
The Base-mounted unit (Fig. 1.8) is a fully operational unit with air pressure switch and on/off switches
mounted on a frame (no air receiver). A silencing hood can be added as an option.
LE, LF and LT Trolley units (Figs. 1.15 and 1.16) are mobile compressors. They are equipped with either
a directly flanged electric motor (LE/LF/LT ETROL - Fig. 1.15) or a petrol engine (LE/LF/LT PETROL - Fig.
1.16). The compressors have two outlet connections:
- a connection for compressed air at working pressure
- a connection for compressed air at reduced pressure via a pressure regulator
The Full-Feature compressor is a Tank-mounted compressor additionally provided with an FX dryer and
DD/PD filters.
1.2 Air flow
1.2.1 LE/LF2 up to -5, LE7 and LE10 50 Hz (Fig. 1.10)
Air drawn through air filter (AF) and inlet silencer (1) into cylinders (3) is compressed, then discharged
through cooler piping (4) and (6) and check valve (CV) into air receiver (AR).
1.2.2 LE10 60 Hz, LE15, -20, LF7, -10 and LT (Fig. 1.11)
Air drawn through air filter (AF) and inlet silencer (1) into LP (low-pressure) cylinder(s) (7) is compressed,
then discharged to HP (high-pressure) cylinder (8) via intercooler (10).
The air is further compressed and discharged through cooler piping (6) and check valve (CV) into air
receiver (AR).
2920 1585 00 -9-

1 AF
FN FC COMPRESSED AIR (1)

3
3
4 M
4
6
SG
Gp SV DP
CV
AR
5
AV 2
Dm MDR
50980D
(1) Compressed air
Fig. 1.10 Air flow of LE and regulating system of LE/LF/LT2 up to -7 with DOL starter and separate
air pressure switch
1 AF
8
FC COMPRESSED AIR (1)
7
10 10 M
FN
6
SG UA
9
Gp SV DP
12 5 11
13 Y1
UV
CV
AV
AR
Dm
MDR
50981D
(1) Compressed air
Fig. 1.11 Air flow of LT and regulating system of LE5 up to -20, LF5 up to -10, LT5 up to -10 and
LT15 up to -20 with Y/D starter and electric cabinet
2920 1585 00 - 10 -
AF
1
COMPRESSED AIR (1)
FN FC
3 3
4 4 M
UA
6
SG 9
12
DP
13 5
11
UV
CV
PD
Dm14 Gp SV
AV1
AV2 RV
PD
D0338_1
Dm
(1) Compressed air
Fig. 1.12 Air flow of LE Trolley and regulating system of LE/LF/LT Trolley
AF Air filter UV Unloading valve

AR Air receiver Y1 Loading solenoid valve
AV Air outlet valve 1 Air inlet silencer
AV1/2 Air outlet valves 2 Pressure release valve
CV Check valve 3 Cylinder
Dm Condensate drain valve 4 Cooler
DP Oil drain plug 5 On/off switch
FC Oil filler cap 6 Cooling pipe
FN Fan 7 LP cylinder
Gp Air pressure gauge 8 HP cylinder
M Motor 9 Blow-off silencer
MDR Air pressure switch 10 Intercooler
PD Pulsation damper 11 Electric cabinet
RV Pilot valve 12 Plunger
SG Oil level sight-glass 13 Spring
SV Safety valve 14 Pressure regulator
UA Unloader
Figs. 1.10 up to 1.12 Air flow and regulating systems
2920 1585 00 - 11 -
1.3 Regulating system

1.3.1 LE/LF/LT2 up to -7 with DOL starter (Fig. 1.10)
The regulating system includes:
- Check valve (CV)
- Air pressure switch (MDR) with pressure release valve (2) and on/off switches (5).
Operation
Air pressure switch (MDR) opens and closes its contacts at pre-set pressures. During loaded operation,
the contacts are closed: the motor is running.
When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts as well as
pressure release valve (2) are opened. The motor stops, the air at the delivery side of the compressor is
vented to atmosphere and check valve (CV) closes to prevent venting of the receiver.
When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the air
pressure switch close and pressure release valve (2) closes. The motor restarts and compressed air is
supplied to the receiver again.
1.3.2 LE/LT5 up to -20, LF5 up to -10, each with Y/D starter (Fig. 1.11)
- Electric cubicle (11)
- Air pressure switch (MDR)
- On/off switch (5)
- Solenoid valve (Y1)
- Unloader (UA) with integrated check valve (CV)
Operation
Air pressure switch (MDR) opens and closes its contacts at pre-set pressures. During loaded operation,
the contacts are closed: the motor is running and solenoid valve (Y1) is energized preventing the
compressed air from flowing to unloader (UA).
When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts of pressure
switch (MDR) open. The motor stops and solenoid valve (Y1) is de-energized. Compressed air from the
receiver will flow via the solenoid valve to plunger (12) which causes unloading valve (UV) to open. The
air at the delivery side of the compressor is blown through silencer (9) to atmosphere and check valve
(CV) closes to prevent venting of the receiver.
When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the
pressure switch close. The motor restarts and, after switching over from star to delta, solenoid valve (Y1)
is energized. Control air from the unloader plunger chamber is vented to atmosphere. Unloading valve
(UV) closes and compressed air is supplied to the receiver again.
2920 1585 00 - 12 -
Fig. 1.13 Optional silencing hood Fig. 1.14 Pack compressor with optional silencing
hood
AV Air outlet valve

Dm Condensate drain valve
1 Silencing hood (standard option)
2 Electric cabinet
3 On/off switch
4 Air pressure switch with on/off switches
Figs. 1.13 and 1.14 Pack - silencing hood
1.3.3 LE/LF/LT Trolley (Fig. 1.12)

- Pilot valve (RV)
- Unloader (UA) with integrated check valve (CV)
- Electric cabinet (11) (only on electric motor driven Trolley compressors)
Operation
Pilot valve (RV) opens and closes at pre-set pressures. During loaded operation, pilot valve (RV) is
closed preventing the compressed air from flowing to unloader (UA).
When the pressure in the pulsation dampers (PD) reaches the pre-set maximum pressure, pilot valve (RV)
will open. Compressed air from the pulsation dampers will flow to plunger (12) which causes unloading
valve (UV) to open. The air at the delivery side of the compressor is blown through silencer (9) to
atmosphere and check valve (CV) closes to prevent venting of the pulsation dampers. The compressor
runs unloaded.
When the pressure in the pulsation dampers decreases to the pre-set minimum pressure, the pilot valve
closes. Control air from the unloader plunger chamber is vented to atmosphere. Unloading valve (UV)
closes and compressed air is supplied to the pulsation dampers again.
2920 1585 00 - 13 -
Fig. 1.15 LE/LF/LT ETROL Fig. 1.16 LE/LF/LT PETROL
AF Air filter UA Unloader

AV1 Air outlet valve 1 Lifting yoke
Dm Condensate drain valve 2 Cylinder
Gp Air pressure gauge 3 Towing handle
Me Electric motor 4 Blow-off silencer
Mp Petrol engine 5 Cover
PD Pulsation damper 6 Air inlet silencer
RV Pilot valve 7 Fuel tank
Figs. 1.15 and 1.16 LE/LF/LT Trolley
2920 1585 00 - 14 -
2 Installation and handling
2.1 Dimension drawings
(1)
(14)
2-5 2-3
(5)
(3)
(4)
2
3
(14) 5
2
3
5
(5) (5)
(3) (3)
9820 2239 01/3

55749D
See page 35 for the text on this figure
Fig. 2.1 Dimension drawing, LE/LT2 up to -5 and LF2, -3 Power Pack
2920 1585 00 - 15 -
7 5-7 10
(1)
(14)
(3)
(5)
(4)
5
7
10
7
7
10
9820 2239 02/3
(3) 55750D
(5)
Fig. 2.2 Dimension drawing, LE/LT7, -10 and LF5, -7 Power Pack
2920 1585 00 - 16 -
10 10 15-20
(1)
(3)
(5)
(1)
(3)
(5)
(4) (4)
10
10 9820 2239 03/2
55751D
15
20
Fig. 2.3 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Power Pack
2920 1585 00 - 17 -
(1)
(14)
(3)
(5)
(4)
15
20
15-30 9821 0468 00/8
55755D
20-30
Fig. 2.4 Dimension drawing, LT15, -20 and LT15-30, LT20-30 Power Pack
2920 1585 00 - 18 -
(1)
(14)
(3)
(15)
(4)
Base-
mounted
2
3
5 9820 2239 42/1
55752D
2
3
5
Fig. 2.5 Dimension drawing, LE/LT2 up to -5 and LF2 Base-mounted
2920 1585 00 - 19 -
(1)
(14)
(3)
(15)
(4) (4)
Base
-mounted
5
7
9820 2239 43/1
10 55753D
7
7
10
Fig. 2.6 Dimension drawing, LE/LT7 up to -10 and LF5, -7 Base-mounted
2920 1585 00 - 20 -
10 10 15 - 20
(1)
(3)
(19)
(4)
9820 2239 44
55754D
Fig. 2.7 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Base-mounted
2920 1585 00 - 21 -
(14)
(1)
(3)
(15)
9820 8011 00/2

15 55756D
20
Fig. 2.8 Dimension drawing, LT15, -20 Base-mounted
2920 1585 00 - 22 -
2-7 2-7 10
(9) (9)
(10)
(13)
(12)
(4)
2
3
5
5
7
10
9820 2239 41/4
55757D
Fig. 2.9 Dimension drawing, LE/LF/LT2 up to -7 and LE/LT10 50 Hz Pack with optional silencing hood
2920 1585 00 - 23 -
10 10 15-20
(9) (9)
(10)
(13)
(12)
(4)
10
15
10
20
9820 2239 40/3
55758D
Fig. 2.10 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Pack with optional silencing hood
2920 1585 00 - 24 -
2-5 2-3
(1)
(14)
(3)
(5)
(2)
(6)
9820 2239 21/3

55759D
(8) (4)
2
3
5
2
3
5
Fig. 2.11 Dimension drawing, Tank-mounted LE/LT2 up to -5 and LF2, -3 (horizontal 120 l receiver)
2920 1585 00 - 25 -
2-5
(14)
(5)
(7)
(6)
(8) (4)
9820 2239 23/2
55760D
2
3
5
2
3
5
Fig. 2.12 Dimension drawing, Tank-mounted LE/LT2 up to -5 (vertical 250 l receiver)
2920 1585 00 - 26 -
(14)
(1) 5
(3)
(5)
(2)
(6)
(8) (4)
9820 2239 22/2
5 55764D
Fig. 2.13 Dimension drawing, Tank-mounted LE/LT5 (horizontal 250/475 l receiver)
2920 1585 00 - 27 -
10 10 15-20
(3)
(5)
(7)
(6)
(8) (4)
10
10
15
9820 2239 27/5

20 55765D
Fig. 2.14 Dimension drawing, Tank-mounted LE10 up to -20 and LF10 (horizontal 250/475 l receiver)
2920 1585 00 - 28 -
(14) (1)
(3)
(16)
(5)
(17)
(6)
(18) (4)
15/60
15
20
(8) (4)
15/60
15
20
9821 1041 00/8

52784D
Fig. 2.15 Dimension drawing, Tank-mounted LT15, -20 (horizontal 250/475 l receiver)
2920 1585 00 - 29 -
2-5 2-3
(9) (9)
(3)
(5)
(2)
(6)
(8) (4)
9820 2239 24/5

55767D
Fig. 2.16 Dimension drawing, LE/LT2 up to -5 and LF2, -3 Tank-mounted with optional silencing hood
2920 1585 00 - 30 -
7 5-7 10
(9) (9)
(3)
(5)
(2)
(6)
(8) (4)
10
10
9820 2239 26/5

55768D
Fig. 2.17 Dimension drawing, LE/LT7, -10 and LF5, -7 Tank-mounted with optional silencing hood
2920 1585 00 - 31 -
5-20
(14)
(3)
(5)
(7)
(6)
2-3
(14)
(3)
(5)
(6)
(4)
2-3
7-10
7-10
15-20
7
10
9820 8006 00/3

55769D
Fig. 2.18 Dimension drawing, LE/LT/LF with CD dryer
2920 1585 00 - 32 -
2-10 2-7
(12)
(11)
(14)
(3)
(8) (4)
5 9820 2239 71/3

55770D
5
7
10
Fig. 2.19 Dimension drawing, LE/LF/LT Trolley with electrical motor
2920 1585 00 - 33 -
(5)
(5)
3-7
(14)
(8) (4)
3
5 9820 2239 91
55771D
5
7
Fig. 2.20 Dimension drawing, LE/LF/LT Trolley with petrol engine
2920 1585 00 - 34 -
Texts on figures 2.1 up to 2.20
(1) Air inlet

(2) Hole, 15 x 25 (4x)
(3) Cooling air inlet
(4) Net mass
(5) Compressed air outlet, G 1/2
(6) Manual condensate drain
(7) Hole, 15 x 25 (3x)
(8) Receiver
(9) Cooling air outlet
(10) Motor cooling air inlet
(11) Compressed air outlet
(12) Hole, 15 x 24 (4 x), can be used for fixing without rubber pads
(13) Compressor cooling air and air inlet
(14) For dismantling air filter
(15) Compressor air outlet with flexible (2 meter)
(16) Electric cable entry (on rear side)
(17) Hole (4x)
(18) EURO receiver
(19) Air outlet
2920 1585 00 - 35 -
2.2 Installation proposals
9820 2332 03
52790D
9820 2332 00
52791D
Fig. 2.21 Installation proposal for Tank-mounted unit Fig. 2.22 Installation proposal for Tank-mounted unit
(120 l receiver) (250/475 l receiver)
2920 1585 00 - 36 -
(1)
(2)
9820 2332 04
52792D
9820 2332 02
52794D
Fig. 2.23 Installation proposal for Tank-mounted Fig. 2.24 Installation proposal for Tank-mounted
unit (vertical 250 l receiver) unit with optional silencing hood

(2) Compressor air and cooling air inlet
2920 1585 00 - 37 -
(1)
(2)
9820 2332 01
52793D

(2) Compressor air and cooling air inlet
Fig. 2.25 Installation proposal for Pack compressors
2.2.1 LE/LF/LT
Install the compressor horizontally, in a cool but frost-free and well-ventilated room. Place the compressor
as level as possible; however, LE/LT can be operated with an angular deviation below 22.5 degrees in any
direction, LF can operate with any angular deviation, in any direction. The air should be clean.
A Pack Unit must be installed away from walls to allow easy maintenance. Keep the ventilation openings
free.
It is recommended to install an automatic condensate drain (available as an option) on the air receiver to
ensure continuous condensate removal.
2920 1585 00 - 38 -
2.2.2 LE/LF/LT Trolley
- The compressors are equipped with a lifting eye or yoke (1-Figs. 1.15 and 1.16).
- When running, the compressor must be installed as level as possible; however, it can be operated
temporarily in an out-of-level position not exceeding 15 degrees. Keep the compressor in a frost-
free and well-ventilated place.
2.3 Electrical connections
The electrical installation must be carried out by an electrician and correspond to the local codes.
The indications on the motor data plate must correspond to the mains supply voltage and frequency. The
installation must include an isolating switch in the power line near to the unit and be protected against
short-circuits by fuses in each phase. See section 2.4.
The mains supply and earthing lines must be of suitable size. See section 2.4.
For DOL starters, connect the power supply cables as shown on Figs. 2.27/2.28. For Y/D starters,
connect the power supply cables to strip (X1-Fig. 2.26) as shown on Figs. 2.29/2.31. Check the setting of
the overload relay. See section 2.4.
F1 Fuse
F4 Overload relay
K1 Line contactor with integrated Y-D timer
K2 Star contactor
K3 Delta contactor
P1 Hourmeter, running hours
X1 Terminal strip
S1 On/off switch
Fig. 2.26 Electric cabinet
2920 1585 00 - 39 -
9820 2220 01 9820 2220 02

50924D 50925D
Fig. 2.27 Electrical diagram of single-phase Fig. 2.28 Electrical diagram of 3-phase LE/LF/LT2
LE/LF/LT with direct-on-line starter up to -7 with direct-on-line starter
9820 8059 00/4

52787D
Fig. 2.29 Electrical diagram of 3-phase LE/LT5 up to -10, LE15, -20, LF5 up to -10 and LT15/60, LT15, -20
with star-delta starter
2920 1585 00 - 40 -
L1
L2
3 Un
L3
(b)
N
(d)
PE
(1)
This connection should be delivered
in cubicle by the supplier
1X1 1X1 1X1 1X1
L1 L2 L3 PE
T1 [c]
1 3
F1 MDR
1 2 13 14 21 22 95 96
S1
F4 1
1 2
5
P
F3
F2
4 2
2
6
1 3 5 1 3 5 1 3 5
K1 K3 K2
2 4 6 2 4 6 2 4 6
53 13 67 55
K2 K1 K1 K1
54 14 68 56
21 21
K2 K3
(f)
1 3 5
22 22
F4
2 4 6 A1 A1 A1 A1
1X1
PE K1 P1 K3 K2
W1 V2 A2 A2 A2 A2
(e)
V1 U2
U1 W2
M1
A1 9820 8067 00/2
Y1 52788D
A2
(1) This connection should be provided in cubicle by supplier
Fig. 2.30 Electrical diagram of 3-phase LE/LT5 up to -10, LE15, -20, LF5 up to -10 and LT15/60, LT15, -20
with transformer and star-delta starter
2920 1585 00 - 41 -
(e)
K3
L1 FOR 230V A (CUBICLE COMPRESSOR)
X1 CONNECT
L2
3 Un N
L3
X1 1 2
(b) L2 F2
N
(d)
PE
F2 TO BE ADDED KDCA1 (2)
95
variant:
1 3 5 A2
1X1 1X1 1X1 1X1 1X1
KDC
L1 L2 L3 N PE 2 4 6 96 KDC
F1 A
13 14 MECHANICAL
1 2 1 3 5 (3)
S1 2 4 6
TIMER
21
P ELECTRONIC
TIMER
MDR
22 (4)
CD 2-3-6
95
F4
96
1 3 5 1 3 5 1 3 5
K1 K3 K2 CD
2 4 6 2 4 6 2 4 6
TD
53 13 67 55
K2 K1 K1 K1
54 14 68 56
CUBICLE COMPRESSOR
21 21
K2 K3 A
(g)
1 3 5
22 22
F4 K3 K3
2 4 6 A1 A1 A1 A1
1X1
PE K1 P1 K3 K2
W1 V2 A2 (f) A2 A2 A2
2A A
V1 U2
U1 W2
M1 (2)
A1
1 3 5 variant:
Y1 KDC
KDC
A2 2 4 6
A1 X
X
X X
X
95 1 3 5
X X
KDC
A2 96 2 4 6
ELECTRONIC
TIMER (4)
CD 7 24
P1 P4
CD ELECTRONIC
52789D TD
TIMER
(2) Variant
(3) Mechanical timer
(4) Electronic timer
Fig. 2.31 Electrical diagram of 3-phase LE/LT5 up to -10, LE15, -20 and LF5 up to -10 with star-delta
starter and CD dryer
F1/3 Fuses
F4 Overload relay
K1 Line contactor
K2 Star contactor
K3 Delta contactor
M Compressor motor
MDR Air pressure switch
P1 Hourmeter, running hours
S1 On/off switch
T1 Transformer
X1 Terminal strip
Y1 Loading solenoid valve
Figs. 2.27 up to 2.31 Electrical diagrams
2920 1585 00 - 42 -
2.4 Settings of overload relay - fuses - cable size
2.4.1 Settings of overload relay - fuses of compressors with DOL starter
50 Hz
Type Voltage Overload relay Fuses

(V) (A) (A)
LE/LF/LT2 230 (1-phase) 9.3 16
LE/LF/LT2 230 6.7 10
LE/LF/LT2 400 4.1 10
LE/LF2 500 3.5 10
LE/LF/LT3 230 (1-phase) 13.7 25

LE/LF/LT3 230 9.3 16
LE/LF/LT3 400 5.6 10
LF/LT5 230 15.7 25

LE/LF/LT5 400 9.3 16
LE/LF/LT7 230 20.3 25

LE/LT7 400 12.4 25
LT10 400 14.7 25
60 Hz

(V) (A) (A)
LE/LF/LT2 230 8.1 10
LE/LF/LT2 440 4.1 10
LE/LF/LT3 440 5.7 10
LE/LT5 380 11.1 25

LE/LT5 440 9.8 16
LE/LT5 460 9.4 16
LE/LT7 230 25.1 40

LE/LF7 440 12.8 25
LE/LT7 575 8.3 10
LE/LT10 230 28.5 40

LE/LT10 460 14.5 25
LE/LT10 575 11.7 25
LE15 230 39.9 63

LE15 460 20.2 40
LE20 575 19.9 40
2920 1585 00 - 43 -
2.4.2 Settings of overload relay - fuses of compressors with Y-D starter
50 Hz

(V) (A) (A)
LE/LT5 230 9.1 25
LE/LT5 400 5.4 16
LE/LT5 500 4.3 16
LE/LF/LT7 230 12.2 25

LE/LF/LT7 500 5.5 16
LE/LF/LT10 230 14.5 40

LE/LF/LT10 400 8.5 25
LF10 500 7.0 25
LE15 230 21.5 63

LE15 400 13.1 40
LE15 500 9.8 25
LE20 230 29.4 63

LE20 400 16.9 40
LE20 500 13.7 40

(V) (A) (A)
LT15-30 230 22.4 40
LT15-30 400 12.9 25
LT15 230 22.4 40

LT15 400 12.9 25
LT20 230 30.8 63

LT20 400 17.9 40
LT20-30 230 30.8 63

LT20-30 400 17.9 40
2920 1585 00 - 44 -
60 Hz

(V) (A) (A)
LE5 230 11.8 25
LE5 380 6.9 25
LE/LT5 440 5.7 16
LE5 460 5.4 16
LE/LT5 575 4.3 16
LE7 230 14.4 40

LE7 380 8.2 25
LF/LT7 460 6.5 16
LE/LT10 380 10.5 25

LE/LF/LT10 440 9.0 25
LE15 230 20.1 40

LE15 460 12.7 40
LE20 230 27.2 63

LE20 380 16.7 40
LE20 440 17.6 40
LE20 460 17.0 40

(V) (A) (A)
LT15-30 230 28 63
LT15-30 380 15.7 40
LT15 230 28 63
LT15 380 15.7 40
LT20 380 18.1 40
LT20-30 380 18.1 40
2.4.3 Cable size
Starter Cable size

mm²
LE/LF/LT2, -3 DOL 2.5
LE/LF/LT5, -7 DOL 4
LT10 DOL 6
LE/LT5 Y/D 2.5
LE/LF/LT7 Y/D 4
LE/LF/LT10 - LT15/60 – LT15-30 Y/D 6
LE15 - LT15 Y/D 6
LE20 – LT20 – LT20-30 Y/D 10
2920 1585 00 - 45 -
2.5 Pictographs
1 Temperature
2 Pressure
3 On
4 Off
5 Warning: voltage
6 Switch off voltage and depressurize before
maintenance or repair
7 Read Instruction book before starting
8 Consult Instruction book for correct direction
of rotation
9 Do not adjust switch if it is depressurized
Fig. 2.32 Pictographs (typical examples)
2920 1585 00 - 46 -
3 Operating instructions
Safety precautions
The operator must apply all relevant safety precautions, including those mentioned in this book.
3.1 Initial start-up
If the compressor has not run for the past 6 months (at initial start-up check the date on the data plate), it
is strongly recommended to improve the lubrication of the compressor element: drain the oil, refill the
compressor with the same oil while turning the crankshaft.
It is strongly recommended to install an interstage drain kit, to remove excess condensate, on LT

compressors with a load factor less than 20% per hour. Consult Atlas Copco.
1. For Tank-mounted units, remove the transport brackets from underneath the compressor.
2. Check the electrical installation, which must be in accordance with the instructions given in section
2.3.
3. LE/LT are filled with PAO (polyalphaolefine) compressor oil. Check that the oil level is still near the
top of the red circle of sight-glass (SG-Fig. 1.3). Top up, if necessary.
4. Switch on the voltage. Start the motor.
5. On three-cylinder compressors, check for correct direction of rotation as indicated by the arrow on the
fan housing. If the rotation direction is wrong, switch off the voltage and reverse two of the input line
connections.
6. Check the operation of the air pressure switch. See section 5.4 or 5.5. Check the operation of pilot
valve (RV) on LE/LF/LT Trolley. See section 5.6.
3.2 Starting
LE/LF/LT
1. On LE/LT, check the oil level, which must be near the top of the red circle of sight-glass (SG-Fig. 1.3).
The minimum level is the lower part of the red circle.
2. Switch on the voltage.
3. Move switch (4-Fig. 5.6) to position I or push switch (S1-Fig. 2.26) to position I.
4. Open the air outlet valve (AV-Figs. 1.4/1.6).
5. Regularly drain condensate (Dm-Figs. 1.4/1.7).
LE/LF/LT Trolley with electrical motor

2. Set pilot valve (RV-Fig. 1.12) in the unload position by turning the red handle 90 degrees (see section
5.6).
3. Attach the air lines to the air outlets.
4. Plug in and switch on the voltage at the main circuit breaker.
Warning
Never move the compressor after plugging in.
5. Move switch (4-Fig. 5.6) to position I or push switch (S1-Fig. 2.26) to position I.
2920 1585 00 - 47 -
6. Open the outlet valves (AV1/2-Figs. 1.12 and 1.16).

7. Set pilot valve (RV-Fig. 1.16) in the load position by turning the red handle 90 degrees (see section
5.6).
8. Turn the regulating knob of the pressure regulator (14-Fig. 1.12) clockwise or anti-clockwise to
increase or decrease the pressure at the outlet of the pressure regulator.
9. Regularly drain condensate (Dm-Fig. 1.15).
LE/LF/LT Trolley with petrol engine

2. Check the engine oil level as follows:
- Remove the oil filler cap and wipe the dipstick clean.
- Insert the dipstick into the filler neck, but do not screw it in.
- The oil level must show between the minimum and maximum marks on the dipstick.
3. Fill the fuel tank with unleaded or low-leaded petrol (gasoline).
4. Start the engine, consult the engine "Owner's manual".
5. Attach the air lines to the air outlets.
6. Open the outlet valves (AV1/2-Figs. 1.12 and 1.16).
7. Set pilot valve (RV-Fig. 1.16) in the load position by turning the red handle 90 degrees (see section
5.6).
8. Turn the regulating knob of the pressure regulator (14-Fig. 1.12) clockwise or anti-clockwise to
increase or decrease the pressure at the outlet of the pressure regulator.
9. Regularly drain condensate (Dm-Fig. 1.16).
3.3 Stopping
LE/LF/LT
1. Move switch (4-Fig. 5.6) to position 0 or push switch (S1-Fig. 2.26) to position 0.
2. Close air outlet valve (AV-Figs. 1.4/1.6).
3. Switch off the voltage.
If a compressor with pressure switch with pressure release valve stops during operation through a power
failure, the pressure from the air receiver must be released by moving the switch on top of the air pressure
switch to 0 to prevent the compressor from restarting against back-pressure when the power becomes live
again.
LE/LF/LT Trolley
1. Set pilot valve (RV-Fig. 1.16) in the unload position by turning the red handle 90 degrees (see section
5.6).
2. On LE/LF/LT Trolley with electrical motor, move switch (4-Fig. 5.6) to position 0 or push switch
(S1-Fig. 2.26) to position 0.
If the compressor is not required for immediate further use, switch off the voltage at the main circuit
breaker and unplug.
3. On LE/LF/LT Trolley with petrol engine:
Stop the engine, consult the engine "Owner's manual".
4. Close the air outlet valves (AV1/2-Fig. 1.12 and 1.16). Depressurize and disconnect the air lines from
the outlet valves.
2920 1585 00 - 48 -
3.4 Taking out of operation at end of compressor service life
At the end of the service life of the compressor, proceed as follows:
1. Stop the compressor and close the air outlet valve(s).

2. Switch off the voltage and disconnect the compressor from the mains.
3. Depressurize the compressor.
4. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the
compressor from the air net.
5. On LE/LT, drain the oil.
2920 1585 00 - 49 -
4 Maintenance
4.1 Petrol engine maintenance

Consult the engine "Owner's manual".
4.2 Preventive maintenance schedule of the compressor 1)

The schedule contains a summary of the maintenance instructions. Read the respective section before
taking maintenance measures.
When servicing, replace all disengaged packings, e.g. gaskets,

O-rings, washers.
The "longer interval" checks must also include the "shorter interval" checks.
Period 2) Running Consult See Preventive Operation

hours 2) section notes maintenance
below kit (Fig. 4.1)
table
Weekly ------ 3.2 1 -- On LE/LT, check oil level
" ------ -- -- -- Drain condensate from air receiver or
pulsation damper
6-monthly ------ 5.7/5.8 2 -- Test safety valve, and if provided also

relief valve
" ------ 4.4/5.3 3/4 2 Inspect air filter
Yearly 500 4.4/5.3 3/4 2 On LF10, LE15, LT15/60 LT15 and

LE/LT20, replace air filter
" 600 4.4/5.3 3/4 2 On LE/LT5, -7, -10 and LF5, -7,
replace air filter
" 800 4.4/5.3 3/4 2 On LE/LF/LT2, -3, replace air filter
" 2000 -- -- 2 Change blow-off silencer, if provided
" 2000 4.3 -- -- On LE/LT, if mineral oil is used, change
oil
2-yearly 3000 4.3 -- 5 On LE/LT, if Atlas Copco PAO oil is

used, change oil
----- 3000 to 4.4/5.1 -- 3/4 Replace check valve or unloader

4000
----- 4000 4.4/5.2 -- 1 On LE/LT2, -3, -5, LT15/60, -15, -20,
replace valve discs
----- 5000 4.4/5.2 -- 1 On LE/LT7, -10, replace
valve discs
----- 7500 4.4/5.2 -- 1 On LF, replace valve discs
Notes
1. Maintain the level in the red circle of the sight-glass.
2. Wear gloves and safety glasses.
3. For normal operation in clean surroundings. More frequently when operating in a dusty environment.
4. In a dusty environment, a heavy-duty filter (available as an option) is essential.
2920 1585 00 - 50 -
4.3 Lubrication of LE/LT compressors

It is strongly recommended to use the Atlas Copco approved PAO (polyalphaolefine) compressor oil to
keep the compressor in excellent operating condition.
Atlas Copco PAO oil can be ordered in following quantities:
PAO oil Ordering number

1-litre can 1503 6142 63
5-litre can 1503 6142 60
1 Valve kit
2 Filter kit
3 Check valve
4 Unloader
5 PAO oil
Fig. 4.1 Preventive maintenance kits (typical examples) 3)
4.4 Service kits

Service kits are available offering the benefits of genuine Atlas Copco parts while keeping the
maintenance budget low. The kits comprise all parts needed for servicing. Consult the Parts list for the
contents of all kits.
Service kit for air filter (AF) Ordering number Ref. on Fig. 4.1
For LE/LF/LT2, -3 1503 6143 60 2
For LE/LF/LT5 up to -7 and LE/LT10 50 Hz 1503 6129 60 2
For LE10-60 Hz, LF10, LE15, LE20, LT15 and 1503 6130 60 2
LT20
Service kit for unloader (UA) Ordering number Ref. on Fig. 4.1
For LE/LF/LT5 up to –10 1503 6176 60 4
Service kit for check valve (CV) Ordering number Ref. on Fig. 4.1
For all LE/LF/LT5 up to -20 1503 6177 60 3
2920 1585 00 - 51 -
Service kit for valve discs Ordering number Ref. on Fig. 4.1
For LE2 up to -5 and LF2, -3 1503 5800 60 1
For LE7, LE10 50 Hz and LF5, LF7 1503 5800 61 1
For LT2 up to -5 1503 5800 62 1
For LT7, LT10 50 Hz 1503 5800 63 1
For LE10 60 Hz, LE15, LE20 and LF10 1503 5800 64 1
For LT15/60 and LT15 1503 6140 60 1
For LT20 1503 6141 60 1
Footnotes chapter 4
1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.
2) Whichever interval comes first. The local Sales Company may overrule the maintenance schedule,
especially the service intervals, depending upon the environmental and working conditions of the
compressor.
3) For the contents of all kits, consult the Parts list.
2920 1585 00 - 52 -
5 Servicing and adjustment procedures
Warning
Release the pressure from the compressor before starting repair or maintenance works. Switch off the
voltage and isolate the compressor from the mains.
5.1 Unloader or check valve

It is recommended to replace the unloader or check valve as indicated in section 4.2.
Dirt, condensate, coke formation and oxidation influence the proper operation of the valve. Depending on
the environmental and working conditions (ambient temperature, working pressure, load cycle, oil type),
the local Sales company may overrule the maintenance schedule (consult Atlas Copco).
5.2 Valves
A faulty valve must be replaced immediately. A faulty valve can be discovered as stated in section 6,
points 1 and 4. Consult Atlas Copco.
It is highly recommended to replace the valve discs, O-rings and gaskets if disassembling the cylinder
heads.
Fig. 5.1 LE2 up to -7, LE10 50 Hz, LF2 up to -5 Fig. 5.2 High-pressure side of LF7, LT15/60, LT15-
Low-pressure side of LE10 60 Hz, LE15, -20, 30, LT15, LT2 up to -10
LF7, -10, LT15/60, LT15-30, LT15, -20, LT20-
30, LT2 up to -10
2920 1585 00 - 53 -
12
16
5
6
7
8
9
14
15
13
3 2
4
52826D 10
Fig. 5.3 High-pressure side of LE10 60 Hz, LE15, -20, LF10, LT20, LT20-30
1 Bolt 9 Guide pin

2 Joint 10 Joint
3 O-ring 11 Cylinder
4 Spring 12 Cylinder cover
5 Outlet valve guard 13 Cylinder head
6 Outlet valve disc 14 Joint
7 Valve seat 15 Outlet cap
8 Inlet valve disc 16 Joint
Figs. 5.1 up to 5.3 Cylinder heads
2920 1585 00 - 54 -
5.2.1 Replacement of valve discs (Figs. 5.1 and 5.2)
LE2, -3, -5, -7 HP cylinder HP cylinder Operation sequence

LE10 50 Hz for for
LF2, -3, -5 LF7 LE10 60 Hz
LT15/60, -15 LE15, -20
LP cylinder for LT15-30 LF10
LE10 60 Hz LT2, -3, -5, -7 LT20
LE15, -20 LT10 LT20-30
LF7, -10
LT15/60, -15, -20
LT15-30, LT20-30
LT2, -3, -5, -7, -10
See Figs. 5.1/5.2 See Figs.5.1/5.2 See Fig. 5.3
X X X Remove the fan guard, unscrew the cap and remove
the cover (1-Fig. 1.1), air filter and cover of the air
inlet silencer.
X Disconnect cylinder head cover (12) from the inlet
and outlet pipe flanges. Remove cover (12).
X X Disconnect head (13) from the inlet and outlet pipe
flanges. Remove cylinder head cover (12). Remove
head (13).
X X X Remove spring (4), outlet valve guard (5) and outlet
valve disc (6).
X X X Lift off valve seat (7) and remove inlet valve disc (8).
Do not remove guide pins (9).
X X X Remove and discard all O-rings/gaskets and joints.
X X X If necessary, remove the carbon deposits from the
inlet valve guard at the cylinder top. Take care that
no dirt drops into the cylinder.
X X X Clean and inspect all parts.
X X X Fit a new joint (10). Do not stretch the cord while
inserting it in its groove; the ends should meet.
X X X Put a new inlet valve disc (8) into place and install
valve seat (7).
X X X Fit a new O-ring (3) and joint (2).
X X X Install a new outlet valve disc (6), guard (5) and
spring (4).
X Install cylinder head cover (12). Fit new O-
rings/gaskets for the pipe flanges. Fit the flange and
cylinder head bolts and tighten them alternately.
X Reinstall head (13). Fit a new joint (14). Install
cylinder head cover (12). Fit new O-rings/gaskets for
the pipe flanges. Fit the flange and cylinder head
bolts and tighten them alternately.
X Fit a new joint (16) and install head (13) and cap (15).
Fit a new joint (14). Install cylinder head cover (12).
Fit new O-rings/gaskets for the pipe flanges. Fit the
flange and cylinder head bolts and tighten them
alternately.
X X X Reinstall the fan guard, cover of the air inlet silencer,
air filter, cover (1-Fig. 1.1) and cap.
2920 1585 00 - 55 -
Torque value Torque value Torque value

M6: 10 Nm +/- 2 M8: 23 Nm +/- 2 M10: 46 Nm +/- 5
5.3 Air filter
1. Stop the compressor.

2. On LE/LF/LT2 up to -7, LE/LT10 50 Hz, LT15, -20 and LT15-30, LT20-30: unscrew the cap on top of
cover (1-Fig. 1.1). Lift off the cover and filter element. Take care that no dirt drops inside the suction
silencer.
On LE10 60 Hz, LF10 and LE15, -20: unscrew cap (1-Fig. 1.7) and take out the air filter. Take care
that no dirt drops inside the suction silencer.
3. Using a damp cloth, clean the filter chamber and cover. Discard damaged elements.
4. Install the new element, cover and cap.
2920 1585 00 - 56 -
5.4 Adjustment of MDR4S pressure switch (Figs. 5.4 up to 5.6)
The adjustment of the maximum or stopping pressure of the compressor is effected by means of the air
pressure switch. The switch also controls the pressure difference between the maximum pressure
(stopping pressure) and that at which compression is resumed (starting pressure).
Caution
- Adjust the air pressure switch while it is pressurized.
- Switch off the voltage before removing the cover of the switch; reinstall it after an adjustment has
been made and before the voltage is switched on again.
Adjustment
The maximum pressure is controlled by adjusting screw (4). Turn the screw clockwise to raise the
maximum or stopping pressure, anti-clockwise to lower it.
The pressure difference is adjusted by means of screw (5). To reduce the difference between the
stopping and starting pressures, i.e. increase the starting pressure, turn the screw anti-clockwise. To
increase the pressure difference, turn the screw clockwise. The adjustment range is shown on the
diagrams (Fig. 5.6).
Fig. 5.4 View of air pressure switch MDR4S Fig. 5.5 Adjusting screws, MDR4
1 Air pressure switch

2 Solenoid valve
3 Pressure release valve
4 Adjusting screw, stopping pressure
5 Adjusting screw, pressure difference
Figs. 5.4 and 5.5 Air pressure switch
2920 1585 00 - 57 -
Example: LE
Stopping pressure: 7 bar(e)
Starting pressure: adjustable between 3 and 5.7 bar(e)
Fig. 5.6 Pressure difference diagrams, MDR4S/11 bar and MDR4S/25 bar
2920 1585 00 - 58 -
5.5 Adjustment of MDR3 pressure switch (Figs. 5.7 and 5.8)
The switch allows the operator to select the stopping pressure and the pressure difference between
stopping and starting pressures. The stopping and starting pressures are the opening and closing
pressures of the switch.
The stopping pressure is controlled by adjusting screw (2). Turn the screw clockwise to raise the stopping
pressure, anti-clockwise to lower it.
The pressure difference between starting and stopping is adjusted by means of adjusting screw (3). The
adjustment range is given in Fig. 5.8. Turn the screw anti-clockwise to reduce the pressure difference,
clockwise to increase it.
1 Dial, overload relay

2 Adjusting screw, stopping pressure
3 Adjusting screw, pressure difference
4 On/off switch
Figs. 5.7 Air pressure switch MDR3 with ON/OFF switch (30 bar units)
52831D
STARTING PRESSURE (1)
30
26
22
18
bar(e)
14
10
6 10 14 18 22 26 30 34
STOPPING PRESSURE (2)
bar(e)
(1) Starting pressure

(2) Stopping pressure
Figs. 5.8 Pressure difference diagram, MDR3 30 bar
2920 1585 00 - 59 -
5.6 Adjustment of pilot valve on Trolley (Fig. 5.9)
The adjustment of the maximum or unloading pressure of the compressor is effected by means of pilot
valve (RV-Fig. 1.16). The valve also controls the difference between the preset maximum pressure and
that at which compression is resumed.
A Control air to unloader

R Vent hole
1 Unloading handle
2 Pressure adjusting screw
3 Nuts
4 Shims
Fig. 5.9 Pilot valve on LE/LT Trolley
Unload mechanism
The pilot valve is equipped with a hand-operated unload mechanism: by turning the red handle (1) 90
degrees, the plunger of the valve will be lifted, releasing the spring force. The air pressure from the
pulsation dampers will force down unloader plunger (12-Fig. 1.12), the compressor will run unloaded. By
turning handle (1) 90 degrees further, the plunger returns to its original position so that the pilot valve will
again unload and load the compressor at the pre-set pressures.
Setting of the pilot valve

The maximum pressure is controlled by adjusting screw (2):
- Loosen handle (1) and the two nuts (3).
- Turn the adjusting screw (2) clockwise to increase the maximum pressure.
- The pressure difference can be increased by removing one or more shims (4).
- Fit the two nuts (3) and handle (1) in their original position.
2920 1585 00 - 60 -
5.7 Safety valve (SV-Figs. 1.4, 1.6 and 1.8) 1)
Replace the valve if it does not open at the correct pressure. No adjustments are allowed.
Testing
Testing as described below shall only be carried out by competent personnel.
5.7.1 Testing on LE/LF/LT

1. Close the air outlet valve, depressurize and disconnect the hose or pipe from the valve.
2. Start the compressor and run it until it stops automatically.
3. Switch off the voltage.
Remove the cover from the air pressure switch and, with the air receiver now under pressure, turn the
adjusting screw one turn clockwise to increase the stopping pressure (see also sections 5.4/5.5).
Reinstall the cover.
4. Switch on the voltage, slightly open the outlet valve and start the compressor.
5. Gradually close the outlet valve while checking the air pressure gauge. If the safety valve has not
opened at the pressure specified in section 7, it must be replaced by a new one. If the compressor
unloads before the specified opening pressure is reached, repeat the procedure as mentioned from
step 3.
6. Readjust the unloading pressure as described in sections 5.4 and 5.5.
7. Reconnect the hose or pipe to the closed air outlet valve.
5.7.2 Testing on LE/LF/LT Trolley

1. Close the air outlet valves, depressurize and disconnect the hoses from the valves.
2. Loosen the red handle of the pilot valve (1-Fig. 5.9) and the two nuts (3).
3. Open outlet valve (AV1-Fig. 1.16) a fraction. Start the compressor.
4. Gradually turn adjusting screw (2-Fig. 5.9) clockwise while checking pressure gauge (Gp-Fig. 1.16).
If the safety valve has not opened at the pressure specified in section 7, it must be replaced by a new
one.
5. Readjust the normal working pressure after testing. Consult section 5.6.
6. Fit nuts (3-Fig. 5.9) and handle (1) in their original positions.
5.8 Relief valve (8-Fig. 1.1) on LF7, -10, LE10 up to -20 and LT
The relief valve protects the LP side of the compressor. No adjustments are allowed.
Testing
Testing as described below shall only be carried out by competent personnel.
Remove the relief valve and fit a 3/8 inch B.S.P. plug instead. Remove the safety valve from the air
receiver and replace it by the relief valve. The latter can then be tested at increasing air receiver pressure
after the compressor has been started with open air outlet valve. If the valve has not opened at the
pressure specified in section 7, it must be replaced by a new one. Reinstall the valves in their respective
places after testing.
Footnote chapter 5
1) Not on Compressor Block/Power Pack
2920 1585 00 - 61 -
6 Problem solving
1 Insufficient air pressure

a Air leak
a Check and correct as necessary
b Air filter choked
b Replace filter
c Air pressure switch incorrectly set
c Adjust switch
d Air consumption exceeds maximum output of compressor
d Check equipment connected
e Damaged valve
e Inspect valves and replace parts where necessary
f Unloader 1) malfunctioning
f Inspect and replace parts where necessary
g Solenoid valve 1) out of order
g Remove and check. Replace if necessary
2 Unit does not speed up

a Voltage drop at motor terminals
a Consult power supplier. Use correct size of cable
b Unloader malfunctioning
b See 1f
c Solenoid valve out of order
c See 1g
d Blow-off silencer 1) choked
d Replace
3 Air receiver pressure rises above maximum and causes safety valve to blow
a Air pressure switch or pilot valve 1) incorrectly set or out of order
a Check. Replace switch or valve, if necessary
b Solenoid valve defective
b See 1g
c Unloader malfunctioning
c See 1f
d Blow-off silencer choked
d See 2d
4 Relief valve blows 1)

a Defective inlet valve in HP cylinder head
a Inspect and replace part(s) as necessary
b Relief valve not airtight
b Replace valve
5 Receiver does not hold pressure

a Check valve leaks
a Check for broken valve and springs
b Air leaks
b Check and correct as necessary
6 Too frequent starting/too short operating periods

a Air pressure switch or pilot valve 1) incorrectly set
2920 1585 00 - 62 -
a Increase pressure difference

b Check valve leaks
b See 5a
7 High oil consumption on LE/LT compressors

a Oil level too high
a Do not overfill crankcase. Keep level in red circle of sight-glass
b Piston ring(s) worn or broken
b Have condition of piston rings checked
8 Unit does not start

a Electrical failure
a Have electrical system checked. Check fuses and line terminals for tightness
b Overload relay cut out
b Reset overload relay. If the relay cuts out again after starting, see point 9
c Air pressure above pre-set starting pressure
c Compressor will start when air pressure is lower than pre-set starting pressure of air pressure
switch
9 Overload relay cuts out

a Overload relay incorrectly set
a Check and adjust. Reset relay
b Solenoid valve out of order
b See 1g
c Unloader plunger jammed
c See 1f
d Blow-off silencer choked
d See 2d
e Ambient temperature too high
e Improve ventilation of room
f Motor stops and starts too frequently
f See 6
g Overcurrent due to motor or compressor failure
g Consult Atlas Copco
Footnote chapter 6
1) If provided.
2920 1585 00 - 63 -
7 Principal data
7.1 Reference conditions
Inlet pressure (absolute) bar 1

Relative air humidity % 0
Air inlet temperature °C 20
Working pressure:
- for LE 10 bar bar(e) 7
- for LF 10 bar bar(e) 7
- for LT 15 bar bar(e) 12
7.2 Limitations
Minimum inlet temperature °C 0

Maximum inlet temperature °C 40
Maximum working pressure bar(e) See below
7.3 Compressor data for LE 10 bar

7.3.1 50 Hz
Compressor type LE2 LE3 LE5 LE7 LE10 LE15 LE20

Maximum working pressure for LE bar(e) 10 10 10 10 10 10 10
Maximum working pressure for LE bar(e) 9.5 9.5 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LE bar 1 1 1 1 1 1 1
Trolley
Temperature at outlet valve,
approx.
- Unsilenced compressor °C 40 44 66 59 80 65 91
- Silenced compressor °C 48 52 74 67 88 73 99
Power input at max. working kW 1.82 2.54 4.57 6.11 8.28 10.69 14.92
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500 1500 1500
Free air delivery 2) l/s 3.4 4.4 8.4 11.7 15.7 18.6 23.9
Oil capacity l 0.8 0.8 0.8 1.4 1.4 1.7 1.7
Opening pressure of safety valve bar(e) 11 11 11 11 11 11 11
(not for Block/Power Pack)
Maximum sound pressure level 1):
-Standard version dB(A) 78 79 79 80 81 84 85
-Silenced Tank-mounted version dB(A) 65 66 66 70 70 73 73
-Base-mounted version dB(A) 63 64 64 68 68 70 70
2920 1585 00 - 64 -
7.3.2 60 Hz
Compressor type LE2 LE3 LE5 LE7 LE10 LE15 LE20

Maximum working pressure for LE bar(e) 10 10 10 10 10 10 10
Maximum working pressure for LE bar(e) 9.5 9.5 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LE bar 1 1 1 1 1 1 1
Trolley
approx.
pressure
Oil capacity l 0.8 0.8 0.8 1.4 1.7 1.7 1.7
Opening pressure of safety valve bar(e) 11 11 11 11 11 11 11
2920 1585 00 - 65 -
7.4 Compressor data for LF 10 bar
7.4.1 50 Hz
Compressor type LF2 LF3 LF5 LF7 LF9

Maximum working pressure for LF bar(e) 10 10 10 10 10
Maximum working pressure for LF bar(e) 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LF bar 1 1 1 1 1
Trolley
approx.
- Unsilenced compressor °C 40 44 45 50 51
- Silenced compressor °C 48 52 53 58 59
Power input at max. working kW 2.05 2.71 5.11 5.89 8.65
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500
Free air delivery 2) l/s 3.1 4.0 7.6 9.2 14.4
Opening pressure of safety valve bar(e) 11 11 11 11 11
-Standard version dB(A) 82 83 83 84 86
-Silenced Tank-mounted version dB(A) 69 70 70 74 77
-Base-mounted version dB(A) 67 68 68 72 74
7.4.2 60 Hz
Compressor type LF2 LF3 LF5 LF7 LF10

Maximum working pressure for LF bar(e) 10 10 10 10 10
Maximum working pressure for LF bar(e) 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LF bar 1 1 1 1 1
Trolley
approx.
pressure
2920 1585 00 - 66 -
7.5 Compressor data for LT 15 bar

7.5.1 50 Hz
Compressor type LT2 LT3 LT5 LT7 LT10

Maximum working pressure for LT bar(e) 15 15 15 15 15
Maximum working pressure for LT bar(e) 13.7 13.7 13.7 13.7 13.7
Trolley
Pre-set pressure difference for LT bar 1 1 1 1 1
Trolley
Temperature at outlet valve, °C
approx.
pressure
Oil capacity l 0.8 0.8 0.8 1.4 1.4
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5
7.5.2 60 Hz
Compressor type LT2 LT3 LT5 LT7

Maximum working pressure for LT bar(e) 15 15 15 15
Maximum working pressure for LT bar(e) 13.7 13.7 13.7 13.7
Trolley
Pre-set pressure difference for LT bar 1 1 1 1
Trolley
Temperature at outlet valve, approx.
- Unsilenced compressor °C 57 66 81 65
- Silenced compressor °C 65 74 89 73
Power input at max. working pressure kW 2.49 3.44 6.16 8.27
Motor shaft speed r/min 1800 1800 1800 1800
Free air delivery 2) l/s 3.6 4.7 7.9 10.9
Oil capacity l 0.8 0.8 0.8 1.4
Opening pressure of safety valve (not bar(e) 16 16 16 16
for Block/Power Pack)
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5
-Standard version dB(A) 80 81 81 82
-Silenced Tank-mounted version dB(A) 67 68 68 72
-Base-mounted version dB(A) 65 66 66 70
2920 1585 00 - 67 -
7.6.1 50 Hz
Compressor type LT2 LT3 LT5 LT7 LT10 LT15/60 LT15 LT20
Maximum working pressure bar(e) 20 20 20 20 20 20 20 20
approx.
- Unsilenced compressor °C 37 49 60 43 56 52 76 90
- Silenced compressor °C 45 57 68 51 64 60 84 96
Power input at max. working kW 2.04 2.56 4.21 5.33 6.97 6.25 9.76 12.2
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500 1500 1500 1500
Free air delivery 2) l/s 2.1 2.9 5.0 6.7 9.1 10.2 15.1 18.0
Oil capacity l 0.8 0.8 0.8 1.4 1.4 5.1 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5
Maximum sound pressure level 1)
-Standard version dB(A) 78 79 79 80 81 85 86.5 86
-Silenced Tank-mounted version dB(A) 65 66 66 70 70 76 77 80
-Base-mounted version dB(A) 63 64 64 68 68 -- 72 75
7.6.2 60 Hz
Compressor type LT2 LT3 LT5 LT7 LT15/60 LT15 LT20

Maximum working pressure bar(e) 20 20 20 20 20 20 20
approx.
pressure
Oil capacity l 0.8 0.8 0.8 1.4 5.1 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5 6.5 6.5
2920 1585 00 - 68 -
7.7.1 50 Hz
Compressor type LT3 LT5 LT7 LT10 LT15-30 LT20-30

Maximum working pressure bar(e) 30 30 30 30 30 30
approx.
- Unsilenced compressor °C 49 60 42 58 52 52
- Silenced compressor °C 57 68 50 66 60 60
Power input at max. working kW 2.83 4.73 6.11 7.89 6.8 13.5
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500 1500
Free air delivery 2) l/s 2.5 4.4 6.4 8.5 9.28 17.0
Oil capacity l 0.8 0.8 1.4 1.4 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5 6.5
-Standard version dB(A) 79 79 80 81 85 86
-Base-mounted version dB(A) 64 64 68 68 76 80
7.7.2 60 Hz
Compressor type LT3 LT5 LT7 LT15-30 LT20-30

Maximum working pressure bar(e) 30 30 30 30 30
Temperature at outlet valve, approx.
Power input at max. working pressure kW 3.44 5.77 7.63 8.42 16.4
Oil capacity l 0.8 0.8 1.4 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5
Footnotes chapter 7
1) According to CAGI PNEUROP PN8NTC2.2.

2) At reference conditions
2920 1585 00 - 69 -
8 Conversion list of SI units into US/British units
1 bar = 14.504 psi

1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 m = 3.281 ft
1 mm = 0.039 in
1 m 3/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x degrees °C = (32 + 1.8 x) °F 1)
Footnote chapter 8
1) A temperature difference of 1 °C = a temperature difference of 1.8 °F.
9 PED (Pressure Equipment Directive)
9.1 Components subject to 97/23/EC Pressure Equipment Directive
Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to Category II
Part number Description PED Class

0830 1007 40 Safety valve IV
9.2 Overall rating
The compressors are conform to PED article 3 paragraph 3 (less than category I)
2920 1585 00 - 70 -
Notes:
2920 1585 00 - 71 -
Notes:
2920 1585 00 - 72 -
254 of 761
O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................
SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:
These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.
2920 1377 03 1/2 (continued on inside of cover)

255 of 761
SAFETY PRECA UTIONS (continued)

14. If the ground is not level or can be subject to variable inclination, 5. Never use flammable solvents or carbon tetrachloride for cleaning
consult Atlas Copco. parts. Take safety precautions against toxic vapours of cleaning
liquids.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses. 6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
Operation clean cloth, paper or tape.
1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
through a hose or air line, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.
2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:
8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.
1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.
2920 1377 03 2/2

256 of 761
3.7 Cashco Co.

607 West 15th St., Ellsworth, KS 67439 USA
www.cashcosolutions.com
257 of 761
MODELS CA-1 & CA-2 CA-TB

02-09
TECHNICAL BULLETIN
MODEL CA-1
BACK PRESSURE / RELIEF REGULATOR
The Model CA-1 is a compact, forged bronze body

back pressure regulator used to control inlet pressure
level between atmospheric and 475 psig (32.8 Barg) by
relieving excess pressure.
FEATURES
Self-Aligning Seat ring floats within mechanically-
Plug/Seat: contained zone.
Tight Shutoff: Lapped seat surfaces allow for leakage

rates to approach levels of composition
seats.
MODEL CA-1
APPLICATIONS
CAUTION
Widely used in liquid recirculation around a pump.
This is not a safety device and must not be substituted Used as a bypass flow regulator in fuel oil systems. For
for a code approved pressure safety relief valve or a general air, oil, water, and gas services. Not recom-
rupture disc. mended for steam service.
STANDARD/GENERAL SPECIFICATIONS
Body Size: 1/8" or 1/4" (DN6 or 8) with NPT fe- Gaskets: PTFE
male pipe threads. Inlet connection
size is equal to outlet connection Temperature SST Diaphragm: -325 to +300°F
size. Range: (-198 to +149°C).
Buna-N Diaphragm: -20 to +200°F
Body Three to choose from: (-29 to +94°C).
Orientation: Globe: Side inlet, side outlet.
Angle: Side inlet, bottom outlet. Maximum Design 475 psig (32.8 Barg).
Flow-Thru: Two side inlets, bottom Pressure:
outlet.
Range Springs: Spring Ranges
Body Material: Forged Bronze - ASTM B283, Alloy psig (Barg)
37700. 2 - 15 (.14 - 1.0)
2 - 30 (.14 - 2.1)
Spring Chamber Bronze. 10 - 50 (.69 - 3.5)
40 - 90 (2.8 - 6.2)
Material:
40-125 (2.8 - 8.6)
100-175 (6.9-12.0)
Diaphragm: Metal – 302 SST. Composition 175-360 (12.0-24.8)
– Buna-N. See Table 2.
Seat: Metal – 303 SST. See Table 2. Cv's / Capacities: Up to 0.46 Cv (0.40 kv) (See Table 4.)
258 of 761
OPTION SPECIFICATIONS
Option-2: HANDWHEEL. Plastic handwheel for fre- ing screw. Cleaned for oxygen service per
quent set point changes. Cashco Spec. #S-1134. Applicable tempera-
ture range -325° to +300°F (-198° to +149°C).
Option-5: CRYOGENIC CONSTRUCTION. Metal Mount in horizontal piping with adjusting
diaphragm with S2 Trim only. SST adust- screw oriented downwards.
TECHNICAL SPECIFICATIONS
TABLE 1 TABLE 2
BODY AND SPRING CHAMBER TRIM MATERIAL COMBINATIONS
MAXIMUM PRESSURE WITH TEMPERATURE RATINGS
Trim Designation
Materials Inlet Pressure * Temperature Part Number
Body/Sp. Ch./TDN psig (Barg) °F (°C) S2 * S2B
475 (32.8) -325 to +100 (-198 to +38) Diaphragm 302 SST Buna-N
390 (26.9) -325 to +150 (-198 to +66) Plug 303 SST 303 SST
BRZ/BRZ/S2 375 (25.8) -325 to +200 (-198 to +93) Seat Ring 303 SST 303 SST
350 (24.1) -325 to +250 (-198 to +121) * For cryogenic applications
325 (22.4) -325 to +300 (-198 to +149)
475 (32.8) -20 to +100 (-29 to +38)
BRZ/BRZ/S2B 390 (26.9) -20 to + 150 (-29 to +66)
375 (25.8) -20 to + 200 (-29 to + 93)
* Inlet and outlet at same Pressure vs. Temperature ratings.
TABLE 4
CAPACITY - Cv (FL = 0.90)
TABLE 3 1/8" or 1/4" (DN6 or DN8) Sizes
MISCELLANEOUS MATERIALS
Setpoint (P1) Metal Diaphragm Composition Diaphragm
Part Material Pressure Wide
% Build % Build
Open
Pressure Plate Nut psig (Barg) 5% 10% 20% 30% 5% 10% 20% 30%
SST
& Lock Washer
10 (.69) .03 .07 .17 .27 .04 .09 .22 .35
Pressure Plate Brass 25 (1.72) .03 .08 .20 .30 .05 .10 .24 .38
Diaphragm Stop Brass 50 (3.44) .08 .19 .25 .36 .11 .24 .32 .46
Spring Button Brass 100 (6.9) .07 .16 .24 .34 .09 .20 .30 .44
0.50
Range Spring SST 150 (10.3) .07 .16 .25 .36 .09 .20 .32 .46
250 (17.2) .08 .18 .22 .30 .08 .20 .24 .34
Adjusting Screw
Std. – Plated CS 300 (20.7) .06 .16 .20 — .07 .18 .22 —
& Lock Nut
345 (23.8) .07 — — — .08 — — —
METRIC CONVERSION FACTOR: Cv / 1.16 = kv
2 CA-TB
259 of 761
TABLE 5 — AIR CAPACITY – SCFH

S.G. = 1.0 T = 60°F FL = 0.90
All Sizes – Composition Diaphragm Only
Outlet Pressure Setpoint Pressure 1/8" (DN6) Body % Build 1/4" (DN8) Body % Build
(psig) (psig) 5% 10% 20% 30% 5% 10% 20% 30%
10 40 80 210 340 40 80 210 340
25 70 150 380 630 70 150 380 630
50 260 590 850 1300 260 590 850 1300
100 380 880 1430 SONIC 380 880 1430 2250
ATM
150 550 1270 SONIC SONIC 550 1270 2210 SONIC
250 790 SONIC SONIC SONIC 790 2050 2680 SONIC
300 820 SONIC SONIC HI BUILD 820 2200 SONIC HI BUILD
345 1070 HI BUILD HI BUILD HI BUILD 1070 HI BUILD HI BUILD HI BUILD
50 250 560 800 1220 250 560 800 1220
100 380 880 1430 2250 380 880 1430 2250
150 550 1270 2210 3420 550 1270 2210 3420
25
250 790 2050 2680 4100 790 2050 2680 4100
300 820 2200 2920 HI BUILD 820 2200 2920 HI BUILD
100 360 830 1350 2120 360 830 1350 2120
150 540 1260 2190 3380 540 1260 2190 3380
50 250 790 2050 2680 4100 790 2050 2680 4100
300 820 2200 2920 HI BUILD 820 2200 2920 HI BUILD
150 460 1070 1850 2860 460 1070 1850 2860
250 770 2010 2610 4000 770 2010 2610 4000
100
300 810 2180 2900 HI BUILD 810 2180 2900 HI BUILD
250 700 1820 2380 3630 700 1820 2380 3630
150 300 770 2070 2750 HI BUILD 770 2070 2750 HI BUILD
NOTE: Where “SONIC” is indicated within the above capacity tables, outlet velocity with Schedule 40 pipe has reached sonic velocity of 1118
fps. Additional flow cannot be obtained, and pipeline velocity is in excess of customary pipe velocity design limits. Max. flow will be
approximatley the last indicated value in the column above “SONIC”.
METRIC CONVERSION FACTORS: psig / 14.5 = Barg; SCFH / 35.31 = Sm3/Hr; SCFH / 37.32 = Nm3/Hr
TABLE 6 — WATER CAPACITY – GPM

S.G. = 1.0 T = 60°F FL = 0.90
Outlet Pressure Setpoint Pressure 1/8" (DN6) Body % Build 1/4" (DN8) Body % Build
(psig) (psig) 5% 10% 20% 30% 5% 10% 20% 30%
10 0.1 0.3 0.8 1.3 0.1 0.3 0.8 1.3
25 0.3 0.5 1.4 1.9 0.3 0.5 1.4 1.9
50 0.7 1.6 2.2 3.3 0.7 1.6 2.2 3.3
100 0.8 1.9 3.2 4.5 0.8 1.9 3.2 4.5
0
150 1.0 2.3 3.9 5.8 1.0 2.3 3.9 5.8
250 1.2 3.0 3.7 5.5 1.2 3.0 3.7 5.5
300 1.1 2.9 3.8 HI BUILD 1.1 2.9 3.8 HI BUILD
345 1.4 HI BUILD HI BUILD HI BUILD 1.4 HI BUILD HI BUILD HI BUILD
10 0.1 0.2 0.6 1.0 0.1 0.2 0.6 1.0
25 0.2 0.5 1.3 2.0 0.2 0.5 1.3 2.0
50 0.8 1.7 2.2 3.3 0.8 1.7 2.2 3.3
100 0.8 1.9 3.2 4.5 0.8 1.9 3.2 4.5
5
150 1.0 2.3 3.9 5.8 1.0 2.3 3.9 5.8
250 1.2 3.0 3.7 5.5 1.2 3.0 3.7 5.5
300 1.1 2.9 3.8 HI BUILD 1.1 2.9 3.8 HI BUILD
25 0.2 0.4 1.1 1.8 0.2 0.4 1.1 1.8
50 0.7 1.6 2.3 3.3 0.7 1.6 2.3 3.3
100 0.8 1.9 3.2 4.5 0.8 1.9 3.2 4.5
10 150 1.0 2.3 3.9 5.8 1.0 2.3 3.9 5.8
250 1.2 3.0 3.7 5.5 1.2 3.0 3.7 5.5
300 1.1 2.9 3.8 HI BUILD 1.1 2.9 3.8 HI BUILD
25 0.2 0.4 1.0 1.6 0.2 0.4 1.0 1.6
50 0.7 1.5 2.1 3.3 0.7 1.5 2.1 3.3
100 0.9 1.9 3.2 4.5 0.9 1.9 3.2 4.5
15 150 1.0 2.3 3.9 5.8 1.0 2.3 3.9 5.8
250 1.2 3.0 3.7 5.5 1.2 3.0 3.7 5.5
300 1.1 2.9 3.8 HI BUILD 1.1 2.9 3.8 HI BUILD
50 0.6 1.3 1.9 2.9 0.6 1.3 1.9 2.9
100 0.8 1.8 3.2 4.5 0.8 1.8 3.2 4.5
150 1.0 2.3 3.9 5.8 1.0 2.3 3.9 5.8
25
250 1.2 3.0 3.7 5.5 1.2 3.0 3.7 5.5
300 1.1 2.9 3.8 HI BUILD 1.1 2.9 3.8 HI BUILD
NOTE: Where is indicated, the flow has reached or exceeded the velocities indicated based on Sch. 40 pipe. Size Max Vel. Exceeds
Where is indicated, the flow is into “full cavitation”.
1/8" 5 fps
METRIC CONVERSION FACTORS: psig / 14.5 = Barg; GPM x 3.785 = LPM
1/4" 8 fps
CA-TB 3
260 of 761
DIMENSIONS & WEIGHT
FLOW-THRU BODY DESIGN GLOBE BODY DESIGN ANGLE BODY DESIGN
ENGLISH UNITS – inches & lbs. METRIC UNITS – mm & kg
Option DIMENSION - Inch Option DIMENSION - mm

Weight - lbs. Weight - kg.
No. A B C No. A B C
Std. 3.38 Std. 89
0.50 2.25 1.1 13 57 0.5
-2 3.69 -2 94
MODEL CA-1 PRODUCT CODE 02/03/09
A1 Table
1 3 Table
2 7 1 Table
3
Table
4
00 0 00B
TABLE 1 - SIZE TABLE 2 - TRIM TABLE 3 - RANGE SPRING
Size Connection DESIGNATION NO.
CODE psig (Barg) CODE
in (DN) Orientation SST Trim
2 - 15 (.14 - 1.0) A
1/8" (6) Globe — side inlet 1
Desig. CODE
1/4" (8) side outlet 2 2 - 30 (.14 - 2.1) B
S2 * S2
1/8" (6) B 10 - 50 (.69 - 3.4) C
Angle — side inlet,
bottom outlet S2B SB
1/4" (8) C 40 - 90 (2.8 - 6.2) D
1/8" (6) F * For Cryogenic Service
Flow-Thru — two side 40 -125 (2.8 - 8.6) E
1/4" (8) inlets, bottom outlet G
100 -175 (6.9-12.1) F
175 -360 (12.1 -24.8) G
TABLE 4 - OPTIONS
Description Option CODE
No Option — 0
Handwheel -2 2
Cryogenic Construction
S2 Trim Only. Includes special -5 5
cleaning suitable for O2 service
1. NUMERIC digits assigned first in “ascending” order.

2. ALPHA designations are assigned second in “alphabetical” order.
3. Left justify.
4. Add “0” to all unused squares.
5. If insufficient quantity of squares, consult factory for proper code.
4 CA-TB
261 of 761
MODEL CA-2
BACK PRESSURE / RELIEF REGULATOR
The Model CA-2 is a compact, forged bronze body

back pressure regulator used to control inlet pressure
level between atmospheric and 600 psig (41.3 Barg) by
relieving excess pressure.
FEATURES
Self-Aligning Seat ring floats within mechanically-

Plug/Seat: contained zone.
Tight Shutoff: Lapped seat surfaces allow for leak-

age rates to approach levels of com-
position seats.
MODEL CA-2
APPLICATIONS
CAUTION Widely used in liquid recirculation around a pump.

Used as a bypass flow regulator in fuel oil systems. For
This is not a safety device and must not be substituted
general air, oil, water, and gas services. Not recom-
for a code approved pressure safety relief valve or a
rupture disc.
mended for steam service.
STANDARD/GENERAL SPECIFICATIONS
Body Size: 3/8" or 1/2" (DN10 or 15) with NPT Temperature SST Diaphragm: -325 to +300°F
female pipe threads. Inlet connection Range: (-198 to +149°C).
size is equal to outlet connection Buna-N Diaphragm: -20 to +200°F
size. (-29 to +94°C).
Opt - UL with SST Diaphragm:
Body Three to choose from: -20 to +125°F (-29 to +52°C).
Orientation: Globe: Side inlet, side outlet.
Angle: Side inlet, bottom outlet. Maximum Design 600 psig (41.3 Barg).
Flow-Thru: Two side inlets, Pressure: Opt - UL: 150 psig (10.3 Barg).
bottom outlet.
Range Springs: Spring Ranges
Body Material: Forged Bronze - ASTM B283, psig (Barg)
Alloy 37700. 3 - 30 (.21- 2.8)
30 - 50 (2.8 - 3.4)
Spring Chamber Bronze. 50 - 80 (3.4 - 5.5)
Material: 80-150 (5.5-10.3)
150-250 *(10.3-17.2)
Diaphragm: Metal – 302 SST. Composition 250-400 *(17.2-27.6)
– Buna-N. See Table 2. * Not for use on UL Model - Code "A3"
Seat: Metal - 303 SST. See Table 2. Cv's / Capacities: Up to 0.97 Cv (0.84 kv) (See Table 4.)
Gaskets: PTFE
CA-TB 5
262 of 761
OPTION SPECIFICATIONS
Option-1: CLOSING CAP. Removeable cap discour- Option-UL: Model - code "A3" UL Listed. Available
ages tampering with range spring setting. in 3/8" and 1/2" (DN10 or 15) sizes. Bronze
body & spring chamber with brass closing
Option-2: HANDWHEEL. Plastic handwheel for fre- cap. SST (S2) trim, for set pressures 3-150
quent set point changes. psig (.21-10.3 Barg). Not recommended in
oil service heavier than No. 6 oil.
Option-5: CRYOGENIC CONSTRUCTION. Metal dia-
phragm S2 Trim only. SST adusting screw. Option-55: SPECIAL CLEANING. BRZ body materials
Cleaned for oxygen service per Cashco Spec. only. Cleaned per Cashco Spec. #S-1134.
#S-1134. Applicable temperature range With properly selected materials, cleanliness
-325° to +300°F (-198° to +149°C). Mount level suitable for oxygen service.NOTE: De-
in horizontal piping with adjusting screw ori- sign Pressure Rating shall not exceed 290
ented downwards. psig (20.0 Barg) when cleaned per Option-
55 for Oxygen Service.
Option-22: PANEL MOUNTING. Includes a locknut and
a handwheel. Option-56: SPECIAL CLEANING. BRZ body materials
only. Cleaned per Cashco Spec. #S-1542.
Not suitable for oxygen service.
TECHNICAL SPECIFICATIONS
TABLE 1
BODY AND SPRING CHAMBER TABLE 2
MAXIMUM PRESSURE WITH TEMPERATURE RATINGS TRIM MATERIAL COMBINATIONS
Materials Inlet Pressure* Temperature Trim Designation Number

Part
Body/Sp. Ch./TDN psig (Barg) °F (°C) S2 * S2B **
600 (41.4) -325 to +100 (-198 to +38) Diaphragm 302 SST Buna-N
490 (33.8) -325 to +150 (-198 to +66) Plug 303 SST 303 SST
BRZ/BRZ/S2 470 (32.4) -325 to +200 (-198 to +93) Seat Ring 303 SST 303 SST
440 (30.3) -325 to +250 (-198 to +121) * For cryogenic applications
410 (28.3) -325 to +300 (-198 to +149) ** Not for use on UL Model - Code "A3"
600 (41.4) -325 to +100 (-198 to +38)

BRZ/BRZ/S2B 490 (33.8) -325 to +150 (-198 to + 66)
470 (32.4) -325 to +200 (-198 to +93)
* Inlet and outlet at same Pressure vs. Temperature ratings.
TABLE 4
TABLE 3 CAPACITY - Cv (FL = 0.90)
MISCELLANEOUS MATERIALS 3/8" or 1/2" (DN10 or DN15) Sizes
Part Material Setpoint (P1) Metal Diaphragm Composition Diaphragm

Wide
Pressure Plate Nut Pressure % Build % Build
SST Open
& Lock Washer psig (Barg) 5% 10% 20% 30% 5% 10% 20% 30%
Pressure Plate Brass 10 (.69) .13 .29 .51 .69 .19 .40 .70 .95
Diaphragm Stop Brass 25 (1.72) .14 .32 .55 .71 .20 .54 .75 .97
Spring Button Brass 50 (3.44) .11 .26 .45 .68 .17 .36 .62 .90
Range Spring SST 100 (6.9) .11 .26 .45 .68 .15 .32 .55 .72
Adjusting Screw 150 (10.3) .12 .27 .45 .65 .16 .35 .58 .78 1.0
Std. – Plated CS
& Lock Nut 250 (17.2) .12 .24 .38 .56 .14 .29 .53 .68
300 (20.7) .14 .29 .46 .67 .17 .35 .64 .82
350 (24.1) .17 .34 .53 .78 .20 .41 .74 .95
400 (27.6) .19 .38 .61 .90 .22 .46 .85 1.00
METRIC CONVERSION FACTOR: Cv / 1.16 = kv
6 CA-TB
263 of 761
TABLE 5 — AIR CAPACITY – SCFH

S.G. = 1.0 T = 60°F FL = 0.90
Outlet Setpoint 3/8" (DN10) Body 1/2" (DN15) Body
Pressure Pressure % Build % Build
(psig) (psig) 5% 10% 20% 30% 5% 10% 20% 30%
10 170 360 660 930 170 360 660 930
25 290 810 1190 1620 290 810 1190 1620
50 400 890 1640 2540 400 890 1640 2540
100 640 1410 2620 3690 640 1410 2620 3690
0 150 980 2230 4000 SONIC 980 2230 4000 5790
250 1380 2980 SONIC SONIC 1380 2980 5920 8190
300 1990 4280 SONIC SONIC 1990 4280 SONIC SONIC
350 2710 SONIC SONIC SONIC 2710 5820 SONIC SONIC
400 3400 SONIC SONIC SONIC 3400 7430 SONIC SONIC
50 380 840 1540 2390 380 840 1540 2390
100 630 1410 2620 3680 630 1410 2620 3680
150 980 2230 4000 5790 980 2230 4000 5790
25 250 1380 2980 5920 8190 1380 2980 5920 8190
300 1990 4280 8510 11770 1990 4280 8510 11770
350 2710 5820 11420 SONIC 2710 5820 11420 15840
400 3400 7430 SONIC SONIC 3400 7430 14930 18990
100 600 1330 2470 3470 600 1330 2470 3470
150 970 2210 3960 5740 970 2210 3960 5740
250 1380 2980 5920 8190 1380 2980 5920 8190
50
300 1990 4280 8510 11770 1990 4280 8510 11770
350 2710 5820 11420 15840 2710 5820 11420 15840
400 3400 7430 14930 18990 3400 7430 14930 18990
150 820 1870 3350 4850 820 1870 3350 4850
250 1340 2910 5770 8000 1340 2910 5770 8000
100 300 1970 4240 8430 11660 1970 4240 8430 11660
350 2700 5800 11380 15780 2700 5800 11380 15780
400 3390 7420 14920 18970 3390 7420 14920 18970
250 1220 2640 5250 7270 1220 2640 5250 7270
300 1870 4030 8010 11090 1870 4030 8010 11090
150
350 2630 5630 11060 15340 2630 5630 11060 15340
400 3340 7300 14670 18660 3340 7300 14670 18660
NOTE: Where “SONIC” is indicated within the above capacity tables, outlet velocity with Schedule 40 pipe has reached sonic velocity of 1118
fps. Additional flow cannot be obtained, and pipeline velocity is in excess of customary pipe velocity design limits. Max. flow will be
approximately the last indicated value in the column above “SONIC”.
METRIC CONVERSION FACTORS: psig / 14.5 = Barg; SCFH / 35.31 = Sm3/Hr; SCFH / 37.32 = Nm3/Hr
TABLE 6 — WATER CAPACITY – GPM

S.G. = 1.0 T = 60°F FL = 0.90
Outlet Setpoint 3/8" (DN10) Body 1/2" (DN15) Body
Pressure Pressure % Build % Build
(psig) (psig) 5% 10% 20% 30% 5% 10% 20% 30%
10 0.6 1.3 2.4 3.4 0.6 1.3 2.4 3.4
25 1.3 2.8 4.1 5.0 1.3 2.8 4.1 5.0
50 1.1 2.4 4.3 6.5 1.1 2.4 4.3 6.5
100 1.4 3.0 5.4 7.4 1.4 3.0 5.4 7.4
0 150 1.8 4.0 7.0 9.8 1.8 4.0 7.0 9.8
250 2.0 4.3 8.3 11.0 2.0 4.3 8.3 11.0
300 2.7 5.7 10.9 14.6 2.7 5.7 10.9 14.6
350 3.4 7.2 13.6 18.2 3.4 7.2 13.6 18.2
400 4.1 8.7 16.8 20.5 4.1 8.7 16.8 20.5
10 0.4 1.0 1.9 2.7 0.4 1.0 1.9 2.7
25 1.2 2.6 3.8 5.1 1.2 2.6 3.8 5.1
50 1.2 2.5 4.3 6.5 1.2 2.5 4.3 6.5
100 1.4 3.0 5.4 7.4 1.4 3.0 5.4 7.4
5 150 1.8 4.0 7.0 9.8 1.8 4.0 7.0 9.8
250 2.0 4.3 8.3 11.0 2.0 4.3 8.3 11.0
300 2.7 5.7 10.9 14.6 2.7 5.7 10.9 14.6
350 3.4 7.2 13.6 18.2 3.4 7.2 13.6 18.2
400 4.1 8.7 16.8 20.5 4.1 8.7 16.8 20.5
25 1.0 2.3 3.4 4.6 1.0 2.3 3.4 4.6
50 1.1 2.4 4.4 6.5 1.1 2.4 4.4 6.5
100 1.4 3.0 5.4 7.4 1.4 3.0 5.4 7.4
150 1.8 4.0 7.0 9.8 1.8 4.0 7.0 9.8
10
250 2.0 4.3 8.3 11.0 2.0 4.3 8.3 11.0
300 2.7 5.7 10.9 14.6 2.7 5.7 10.9 14.6
350 3.4 7.2 13.6 18.2 3.4 7.2 13.6 18.2
400 4.1 8.7 16.8 20.5 4.1 8.7 16.8 20.5
50 0.9 2.0 3.7 5.7 0.9 2.0 3.7 5.7
100 1.3 3.0 5.4 7.4 1.3 3.0 5.4 7.4
150 1.8 4.0 7.0 9.8 1.8 4.0 7.0 9.8
25 250 2.0 4.3 8.3 11.0 2.0 4.3 8.3 11.0
300 2.7 5.7 10.9 14.6 2.7 5.7 10.9 14.6
350 3.4 7.2 13.6 18.2 3.4 7.2 13.6 18.2
400 4.1 8.7 16.8 20.5 4.1 8.7 16.8 20.5
NOTE: Where is indicated, the flow is into “full cavitation”.

METRIC CONVERSION FACTORS: psig / 14.5 = Barg; GPM x 3.785 = LPM
CA-TB 7
264 of 761
FLOW-THRU BODY DESIGN GLOBE BODY DESIGN ANGLE BODY DESIGN
ENGLISH UNITS – inches & lbs. METRIC UNITS – mm & kg
Option DIMENSION - Inch Weight – Option DIMENSION - mm Weight –

No. A B C D lbs No. A B C D kg
Std. 5.38 1.06 3.12 – Std. 137 27 79 –
-1 5.75 1.06 3.12 – -1 146 27 79 –
3.6 1.6
-2 5.69 1.06 3.12 – -2 144 27 79 –
-22 5.69 1.06 3.12 1.88 -22 144 27 79 48
MODEL CA-2 PRODUCT CODE 02-03-09
A Table
1
Table
2
3 Table
3 7 1 Table
4
Table
5
0 0 0 00A
TABLE 1 - VALVE TABLE 2 - SIZE TABLE 3 - TRIM TABLE 4 - RANGE SPRING
DESCRIPTION Size CODE DESIGNATION NO.
Connection Orientation psig (Barg) CODE
Description CODE in (DN) SST Trim
3 - 30 (.21-2.1) K
3/8" (10) 3
Standard Construction 2 Globe — side inlet side outlet Desig. CODE
1/2" (15) 4 30 - 50 (2.1 - 3.4) L
"UL" Listed 3 S2 S2
3/8" (10) D 50 - 80 (3.4 - 5.5) M
Angle — side inlet, bottom outlet
1/2" (15) E S2B * SB
80-150 (5.5 -10.3) N
3/8" (10) Flow-Thru — two side inlets, H * Not for use on UL
bottom outlet Model - Code "A3". 150-250 * (10.3-17.2)* P
1/2" (15) J
250-400 * (17.2-27.6)* S
* Not for use on UL Model

TABLE 5 - OPTIONS Code "A3".
Description Option CODE
No Option — 0
Closing Cap (Included on UL Listed) -1 1
Handwheel (Non-Cryogenic) * -2 2
Cryogenic Construction * Includes

special cleaning suitable for O2 -5 5
service. Must select trim No. S2.
Panel Mounting *
-22 C
Includes Opt.-2 Handwheel.
Special Cleaning: Per Cashco Spec

-55 M
#S-1134.
Special Clean per Cashco Spec.

-56 N
#S-1542.
Cashco, Inc.
P.O. Box 6 * Not for use on UL Model - Code "A3"
Ellsworth, KS 67439-0006
PH (785) 472-4461 1. NUMERIC digits assigned first in “ascending” order.
Fax (785) 472-3539 2. ALPHA designations are assigned second in “alphabetical” order.
www.cashco.com 3. Left justify.
E-mail: sales@cashco.com 4. Add “0” to all unused squares.
exportsales@cashco.com 5. If insufficient quantity of squares, consult factory for proper code.
Printed in U.S.A. Model CA TB
265 of 761
INSTALLATION, OPERATION & MAINTENANCE MANUAL IOM-CA

11-08
MODELS CA-1 AND CA-2

BACK PRESSURE / RELIEF REGULATORS
SECTION I
I. DESCRIPTION AND SCOPE
Models CA-1 and CA-2 are back pressure/relief regulators used to control upstream (inlet or P1) pressure. Sizes for
CA-1 – 1/8" and 1/4" (DN6 and DN8); for CA-2 – 3/8" and 1/2" (DN10 and DN15). Both models are bronze bodied
units. With proper trim utilization, both units are suitable for liquid and gaseous service. Refer to Technical Bulletin
CA-TB for specific design conditions and selection recommendations.
The instructions in this manual will refer to both models, unless otherwise stated.
CAUTION A
This is not a safety device and must not be substituted for a code approved pressure
safety relief valve or rupture disc.
SECTION II
II. INSTALLATION
1. An inlet block valve should always be installed. Supply
@P
1
2. If service application is continuous such that
shutdown is not readily accomplished, it is rec
ommended that an inlet block valve, outlet block PI SRV System
valve, and a manual bypass valve be installed.
3. Pipe unions should be installed to allow removal Models CA-1/CA-2 Bypass

from piping. BP/Relief Regulator
Flow-Thru Design
4. An inlet pressure gauge should be located ap- P

1
proximately ten pipe diameters upstream, and P
2
within sight. An outlet pressure gauge is op-
tional. Discharge
Recommended Piping Schematic For Back Pressure/Relief Station

5. All installations should include an upstream
safety relief device if the inlet pressure could
exceed the pressure rating of any equipment or 6. Clean piping of all foreign material including chips,
the maximum inlet pressure rating of the unit. welding scale, oil, grease and dirt before installing
the regulator. Strainers are recommended.
WARNING 1 7. In placing thread sealant on pipe ends prior to

engagement, ensure that excess material is re-
The maximum inlet pressure is equal to 1.5 times the moved and not allowed to enter regulator upon
larger number of the stated range spring on the nameplate, startup.
and is the recommended "upper operative limit" for the
sensing diaphragm. Higher pressures could damage the
diaphragm. (Field hydrostatic tests frequently destroy 8. Flow Direction: Install so the flow direction
diaphragms. DO NOT HYDROSTATIC TEST THRU AN aligns with the word “IN” stamped on the body.
INSTALLED UNIT; ISOLATE FROM TEST.) Connect the inlet pressure to the body (1) side
266 of 761
connection(s). Fluid will relieve out the bottom downwards. Orient such that the spring chamber
connection for Angle or Flow-Thru design and out (2) vent hole does not collect rainwater.
the other side connection for Globe design (side
inlet-side outlet). 10b. Cryogenic Regulator, Opt-5 – Recommended in-
stallation is in horizontal line with spring chamber
9. Regulator may be installed in a vertical or hori- (2) oriented downwards below the body (1).
zontal pipe.
11. Regulators are not to be direct buried under-
10a. Basic Regulator - (Refer to Figure 1): Regulator ground.
may be rotated around the pipe axis 360°. Recom-
mended position is with spring chamber vertical 12. For insulated piping systems, the recommenda-
tion is to not insulate the regulator.
SECTION III
inlet pressure drops, the range spring (6) pushes
III. PRINCIPLE OF OPERATION the diaphragm (11) down, closing the port; as inlet
pressure increases, the diaphragm (11) pushes
1. Movement occurs as pressure variations register
up and the port opens.
on the diaphragm (11). The registering pressure
is the inlet, P1, or upstream pressure. The range
2. A complete diaphragm (11) failure will cause the
spring (6) opposes diaphragm (11) movement. As
regulator to fail closed.
SECTION IV
IV. START-UP 7. Observing the inlet (upstream) pressure gauge,
simultaneously rotate the adjusting screw (3)
1. Start with the block valves closed. A bypass valve clockwise (CW) slowly and begin to close the
may be used to maintain inlet pressure in the bypass valve, if installed, until the inlet pressure
upstream system without changing the following begins to rise. Rotate adjusting screw (3) CW until
steps. the desired setpoint is reached.
2. Relax the range spring (6) by turning the adjusting 8. Continue to slowly open the inlet (upstream block
screw (3) counter clockwise (CCW) a minimum of valve. If the inlet (upstream) pressure exceeds
three (3) full revolutions. This reduces the inlet the desired setpoint pressure, rotate the adjusting
(upstream) pressure setpoint. screw (3) CCW until the pressure decreases.
3. If it is a “hot” piping system, and equipped with 9. When flow is established steady enough that both
a bypass valve, slowly open the bypass valve the outlet and inlet block valves are fully open, en-
to pre-heat the system piping and to allow slow sure that the bypass valve is closed, if installed.
expansion of the piping. Closely monitor inlet
(upstream) pressure via gauge to assure not 10. Develop system flow to a level near its expected
over-pressurizing. NOTE: If no bypass valve is normal rate, and reset the regulator setpoint by
installed, extra caution should be used in starting turning the adjusting screw (3) CW to increase
up a cold system; i.e. do everything slowly. inlet pressure, or CCW to reduce inlet pressure.
4. Crack open the inlet (upstream) block valve. 11. Reduce system flow to a minimum level and ob-
serve setpoint. Inlet pressure will rise from the
5. Slowly open the outlet (downstream) block valve setpoint of Step 9. (Assure that this rise does not
observing the inlet (upstream) pressure gauge. exceed the stated upper limit of the range spring
Determine if the regulator is flowing. If not, slowly (6) by greater than 50% i.e. 40-90 psig (2.8 - 6.2
rotate the regulator adjusting screw (3) clockwise Barg) range spring (6), at maximum flow the inlet
(CW - viewed from spring chamber (2) top) until pressure should not exceed 1.5 x 90 psig (6.2
flow begins. Barg), or 135 psig (9.3 Barg). If it does, consult
factory).
6. Continue to slowly open the outlet (downstream)
block valve until fully open. 12. Increase flow to maximum level, if possible. Inlet
(upstream or P1) pressure should fall off. Readjust
setpoint as necessary at the normal flow rate.
2 IOM-CA
267 of 761
SECTION V
V. SHUTDOWN
CAUTION B
1. On systems with a bypass valve, and where sys-
tem pressure is to be maintained as the regulator Do not walk away and leave a bypassed regu-
is shut down, slowly open the bypass valve while lator unattended.
closing the inlet (upstream) block valve. Fully
close the inlet (upstream) block valve. (When on 2. If the regulator and system are to both be
bypass, the system pressure must be constantly shut down, slowly close the inlet (upstream)
observed and manually regulated. Close the out- block valve. Close the outlet (downstream)
let (downstream) block valve. valve only if regulator removal is required.
SECTION VI
2. Relax range spring (6) by loosening the
VI. MAINTENANCE locknut (4) and turning adjusting screw (3)
CCW until removed from spring chamber (2).
WARNING 2 NOTE: If the Option -2 handwheel is utilized,
the adjusting screw (3) and lock nut (4) are re
SYSTEM UNDER PRESSURE. Prior to performing placed with a knob (18) and lock nut (4). With
any maintenance, isolate the regulator from the the Option-22 panel mounting w/handwheel,
system and relieve all pressure. Failure to do so the adjusting screw (3) and lock nut (4) are
could result in personal injury. replaced with a knob (18), lock nut (4) and a
panel mounting nut (19).
A. General:
3. Loosen spring chamber (2) by placing wrench
on “flats” and rotating CCW.
1. Maintenance procedures hereinafter are
based upon removal of the regulator unit from 4. Remove spring chamber (2), spring button (5)
the pipeline where installed. range spring (6), and diaphragm stop (9).
2. Owner should refer to owner's procedures for 5. Remove the diaphragm subassembly consist-
removal, handling, cleaning and disposal of ing of the pressure plate nut (7), lock washer
nonreuseable parts, i.e. gaskets, etc. (8), pressure plate (10), diaphragm (11), plug
gasket (13) and plug (14). NOTE: Refer to the
3. Refer to Figure 1, Model CA-1 or CA-2 for quantity of diaphragms (11) incorporated per
the basic regulator. Blow-ups of options are the bill of materials listing. Depending on inlet
included with each drawing. pressure level, multiple metal diaphragms
(11) may be “stacked”.
B. Diaphragm Replacement
8 7
CAUTION C 10
11
To prevent damage to body, use lead jaws when
placing body in a vise. Position so that vise closes
over inlet and outlet of the body.
1. Securely install the body (1) in a vise with the 13 14

spring chamber (2) directed upwards.
Model's CA-1/CA-2 Diaphragm Subassembly
WARNING 3 6. Loosen pressure plate nut (7) and separate

all parts (7, 8, 10, 11, 13 & 14) of the dia-
SPRING UNDER COMPRESSION. Prior to re-
phragm subassembly.
moving spring chamber, relieve spring compres-
sion by backing out the adjusting screw. Failure
7. Inspect pressure plate (10) to ensure no
to do so may result in flying parts that could cause
deformation due to over-pressurization. If
personal injury.
deformed, replace.
IOM-CA 3
268 of 761
8. Remove diaphragm gasket (12) for metal dia- 15. Reinstall adjusting screw (3) with locknut (4)
phragm (11). NOTE: No diaphragm gasket into the spring chamber (2).
(12) for composition diaphragm (11). 16. Pressurize with air and spray liquid leak de-
9. Clean body (1) and diaphragm flange. NOTE: tector to inspect entire body (1) and spring
On regulators originally supplied as “oxygen chamber (2) for leakage. Ensure that an inlet
clean”, Option -5 or Option -55, maintenance pressure is maintained during this leak test
must include a level of cleanliness equal to of at least mid-range spring level; i.e. 40-90
Cashco's cleaning standard #S-1134. Con- psig (2.8-6.2 Barg) range spring, 65 psig (4.5
tact factory for details. Barg) test pressure minimum.
10. Reassemble diaphragm subassembly by C. Trim Replacement

placing plug gasket (13), diaphragm(s) (11),
pressure plate (10) and lock washer (8) over 1. Trim inspection requires the diaphragm
threaded post of plug (14). Ensure the pres- subassembly be removed. Refer to previous
sure plate (10) is placed with curved outer procedure, Section VI.B.
rim down next to the diaphragm (11) surface.
2. Inspect inside surface of seat ring (15) and
seating surface of plug (14). If seating surface
CAUTION D shows signs of erosion/wear, the seat ring
Use only gaskets supplied by Cashco, Inc. (15) and plug (14) should be replaced.
for these products.
3. Clean body (1) cavity. Clean all parts to be
Place a thread sealant compound similar to reused. NOTE: On regulators originally sup-
Loctite #271 on the threads of the plug's (14) plied as “oxygen clean”, Option -5 or Option
post prior to tightening the pressure plate nut -55, maintenance must include a level of
(7) to the following torque values: cleanliness equal to Cashco's cleaning stan-
dard #S-1134. Contact factory for details.
Sizes Diaphragm Torque
Metal 60 In-lbs. 6.8 N-m 4. Inspect the surface in the body (1) cavity
ALL
Composition 15 In-lbs. 1.7 N-m where seat ring (15) rests. If surface area of
11. Place diaphragm gasket (12) on body either mating part shows signs of erosion/
(1), then insert the diaphragm subas- wear, replace with new regulator.
sembly into the body (1).
5. Place seat ring (15) in center of body (1) cav-
12. Place diaphragm stop (9) and range ity. Ensure that the shoulder on outer edge of
spring (6) over the pressure plate nut seat ring (15) faces up towards the diaphragm
(7) of the diaphragm subassembly. (11).
13. Place multi-purpose, high temperature
6. Reinstall diaphragm subassembly per Sec-
grease into depression of spring button
tion VI.B., Diaphragm Replacement.
(5) where adjusting screw (3) bears. Set
spring button (5) onto range spring (6);
7. Bench test unit for suitable operation. NOTE:
ensure spring button (5) is laying flat.
Regulators are not tight shut off devices.
14. Rotate the spring chamber (2) CW by Even if pressure falls below setpoint, a regu-
hand into the threaded portion of the lator may or may not develop bubble tight
body (1) assuring not to cross thread. shut off. In general, tighter shut off can be
Continue hand rotating CW until firmly expected with composition seat.
seated against the diaphragm stop (9).
Wrench tighten securely to the following 8. Pressurize with air and spray liquid leak de-
torque values: tector to inspect entire body (1) and spring
chamber (2) for leakage. Test pressure
Model Torque should be the maximum allowed by the range
spring at the inlet.
CA-1 20-25 Ft-lbs. 27-34 N-m
CA-2 25-30 Ft-lbs. 34-40 N-m
4 IOM-CA
269 of 761
SECTION VII
VII. TROUBLE SHOOTING GUIDE
1. Erratic operation; chattering.

Possible Causes Remedies
A. Oversized regulator. A1. Check actual flow conditions, re-size regulator for minimum
and maximum flow.
A2. Increase flow rate.
A3. Decrease regulator pressure drop; decrease inlet pressure by
placing a throttling orifice in inlet piping union.
A4. Install next step higher range spring. Contact factory.
A5. Before replacing regulator, contact factory.
B. Worn plug. B. Replace regulator.
2. Regulator inlet (upstream) too high:

A. Regulator undersized. A1. Confirm by opening bypass valve together with regulator.
A2. Check actual flow conditions, re-size regulator; if regulator has
inadequate capacity, replace with larger unit.
B. Incorrect range spring (screwing in CW B. Replace range spring with proper lower range. Contact factory
of adjusting screw does not allow
bringing pressure level up to proper
level.
C. Too much rise (build). C1. Review rise (build) expected.
C2. Contact factory.
3. Leakage through the spring chamber vent hole.

A. Normal-life diaphragm failure. A. Replace diaphragm.
B. Abnormal short-life diaphragm failure. B1. Can be caused by excessive chattering. See No. 1. to remedy
chatter.
B2. Can be caused by corrosive action. Consider alternate
diaphragm material.
B3. For composition diaphragms, assure not subjecting to
over-temperature conditions.
B4. Upstream (inlet) pressure build-up occurring that overstresses
diaphragms. Relocate regulator or protect with safety relief
valve.
4. Sluggish operation.

A. Plugged spring chamber vent. A. Clean vent opening.
B. Fluid too viscous. B. Heat fluid. Contact factory.
IOM-CA 5
270 of 761
SECTION VIII
VIII. ORDERING INFORMATION:

NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR
To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped
on the metal name plate and attached to the unit. This information can also be found on the Bill of Material
(parts list) that was provided when unit was originally shipped.) (Serial Number typically 6 digits). Product Code
typical format as follows: (last digit is alpha character that reflects revision level for the product).
– 7–
NEW REPLACEMENT UNIT:
Contact your local Cashco, Inc., Sales Represen-

tative with the Serial Number and Product code.
With this information they can provide a quotation
for a new unit including a complete description,
price and availability.
CAUTION
Do not attempt to alter the original construction of
any unit without assistance and approval from the
factory. All purposed changes will require a new
name plate with appropriate ratings and new prod-
uct code to accomodate the recommended part(s)
changes.
PARTS "KIT" for FIELD REPAIR:
Contact your local Cashco, Inc., Sales Represen-

tative with the Serial Number and Product code.
Identify the parts and the quantity required to repair
the unit from the Bill of Materials sheet that was
provided when unit was originally shipped.
NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” reflect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".
If the "BOM" is not available, refer to the cross-

sectional drawings included in this manual for part
identification and selection.
Local Sales Representative will provide quota-

tion for appropriate Kit Number, Price and Avail-
ability.
6 IOM-CA
271 of 761
MODEL CA-1
4
18
2
5 4
6 2
7
*
8 Option-2 Handwheel
9
10
11 *
12 *
13 *
14 *
*
15
1
Figure 1:
Basic Model CA-1 with Option-5 Cryogenic Construction
3-Connection Flow-Thru Body Installed in horizontal line with spring chamber ori-
ented downwards below the body. Body and spring
chamber Item Numbers are identical to Figure 1.
I Repair Parts
Item No. Description Kit B
1 Body
2 Spring Chamber
3 Adjusting Screw
4 Lock Nut
5 Spring Button
6 Range Spring
7 Pressure Plate Nut *
8 Lock Washer
9 Diaphragm Stop
10 Pressure Plate
11 Diaphragm
12 Diaphragm Gasket *
*
13 Plug Gasket
*
14 Plug *
15 Seat Ring *
17 Nameplate
18 Knob
IOM-CA 7
272 of 761
MODEL CA-2
Option-5 Cryogenic Construction

Installed in horizontal line with spring chamber ori-
3 ented downwards below the body. Body and spring
chamber Item Numbers are identical to Figure 1.
4
2
5
6
7 * 18
8 3
9 * 4
10 19
11 *
2
12 *
13 *
14 * Option-22 Panel Mounting (handwheel portion is same
for Option-2 Handwheel)
15 *
1
Figure 1:
Basic Model CA-2 with
3-Connection Flow-Thru Body
Repair Parts
Item No. Description Kit B
1 Body
2 Spring Chamber
3 Adjusting Screw
4 Lock Nut
5 Spring Button
6 Range Spring
7 Pressure Plate Nut *
8 Lock Washer
9 Diaphragm Stop
10 Pressure Plate
11 Diaphragm *
12 Diaphragm Gasket *
13 Plug Gasket *
ITEMS NOT SHOWN 14 Plug
16 Closing Cap *
15 Seat Ring *
20 Closing Cap Gasket 17 Nameplate
21 Drive Screw 18 Handhweel or Knob
22 UL Label 19 Mounting Nut
Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH (785) 472-4461
FAX (785) 472-3539
www.cashco.com
E-mail: sales@cashco.com
exportsales@cashco.com
Printed in U.S.A. IOM-CA
273 of 761
3.8 Maxitrol Co.

23555 Telegraph Rd., Southfield MI 48033 USA
www.maxitrol.com
274 of 761
LEVER ACTING DESIGN

GAS APPLIANCE PRESSURE REGULATOR
CSA 6.3 and ANSI Z21.18

Design Certified - 325-3, 325-5A
Maximum Inlet Pressure:
ANSI Z21.18 Certified - 325-3, 325-5A .....2psi (140 mbar), 5 psi (345 mbar)
Maxitrol-tested: all models......................10 psi ( 690 mbar)
With 12A09 or 12A39:

Max. inlet pressure (LP)........................2 psi (140 mbar)
Max. inlet pressure (natural)...................5 psi (345 mbar)
Emergency Exposure Limits

All models (inlet side only).......................65 psi (4.5 bar)
Maximum Individual Load

Largest single appliance served by the regulator
325-3......................................................100,000 Btu/hr
325-5A....................................................250,000 Btu/hr
325-7......................................................900,000 Btu/hr
Capacity:
Total load of all appliances combined
325-3 (3/8”, 1/2”)......................................150,000 Btu/hr
325-5A (1/2”, 3/4”, 1”)..................................300,000 Btu/hr
325-7 (1-1/4”, 1-1/2”)..............................1,000,000 Btu/hr
325-3*, 325-5A*, 325-7
Pipe sizes from 3/8” to 1-1/2”
Ambient Temperature Limits * Design Certified - 325-3, 325-5A
All models...............................-40° to 205°F (-40° to 96°C)
DVGW...........................................32° to 140°F (0° to 60°C)
EN................................................5° to 176°F (-15° to 80°C)
When vented to the outdoors
Vent Pipe Connection Size: the 325 Series is suitable for
multi-poise mounting. When
325-3 ..............................................................1/8" NPT
using the vent limiting
325-5A.............................................................3/8" NPT
device, the regulator (325-3,
325-7................................................................1/2" NPT 325-5A) must be mounted in
a horizontal upright position.
Gases: Suitable for application in natural, manufactured, mixed Install the regulator properly
gases, liquefied petroleum gases, and LP gas-air mixture piping Upright with gas flowing as indicated
systems. by the arrow on the casting
(also see the Safety Warning
NOTE: All Maxitrol gas appliance regulators must be installed Instructions bulletin).
and operated in accordance with Maxitrol's 'Safety Warning'
bulletin.
© 2008, Maxitrol Company, All Rights Reserved 1

275 of 761
Lever Acting Design
325 series 325-3*, 325-5A* & 325-7

FEATURES:
• Designed for multi-poise mounting...
• Self-aligning valve with lever action for dead end lockup...
• Durable, corrosion-resistant construction...
• High performance type for pounds to inches reduction...
• Available in six pipe sizes from 3/8" to 1-1/2"...
BENEFITS:
• Ease of installation...
• Longer life, less maintenance...
• May be used for both 2 psi and 5 psi corrugated
stainless steel tubing (CSST) systems.
• Precise regulation from pilot flows to full
regulator capacity...
• Meets many utility specifications.
The 325 Series is a pounds to inches regulator, meeting utility NOTE: Vent limiters are designed for use indoors and in
specifications. The 325 Series regulator is for use on spaces where limiting the amount of gas escapement due to
residential, commercial, and industrial applications where diaphragm failure is critical. Vent limiters are not to be
adequate inlet pressures are available. used outdoors if they are exposed to the environment.
13A15 vent protector is available for outdoor use when vent
They are a high performance type regulator and can be used
protection is required.
as a single stage regulator - reducing pounds pressure to
normal burner pressure. They can also be used as a line The 325 Series regulators are Maxitrol-tested for inlet
regulator on equipment already fitted with an appliance pressures up to 10 psi (CSA certified for 2 psi and 5 psi).
regulator. With the 12A09 or 12A39 installed, maximum inlet pressure
is 2 psi (LP) and 5 psi (natural). Inlet pressures exceeding 2
The 325-3 and 325-5A models are CSA certified and widely
psi (LP), or 5 psi (natural) require a vent line.
accepted with 2 psig and 5 psig house piping systems. In
fact, the entire concept (using semi-rigid copper or flexible The self-aligning valve is made of nitrile rubber. Housings
stainless steel tubing) would not have been possible without are durable aluminum die castings and all internal parts are
the development of the compact 325 series regulators. carefully selected and corrosion resistant. The diaphragms
are of high quality supported synthetic rubber compounds.
The 325-7, designed especially for the growing segment of
electronic ignition equipment, permits the utilization of greater The 325 Series regulators are suitable for multi-poise
capacities without sacrificing performance. All 325 Series mounting. But when using the vent limiting device, the
models are also certified through DVGW to European EN 88. regulator (325-3, 325-5A) must be mounted in a
horizontal upright position. Install the regulator properly
To deliver positive dead-end lock up, the 325 Series feature a
with gas flowing as indicated by the arrow on the casting.
high leverage valve linkage assembly. Lockup pressure can
vary with the speed of the solenoid valve and its location. The These regulators provide no downstream over-pressure
regulators are capable of precise regulating control from full protection in the event of failure. At supply pressures in
flow down to pilot flows. excess of 2 psi they should not be used unless downstream
appliance controls are rated for supply pressure or protected
As an optional accessory, the 325-3 and 325-5A offer
by some other means. Consult Maxitrol Company for
automatic vent limiting devices. The 12A09 and 12A39 vent
additional assistance.
limiters eliminate the need to run vent piping to a safe area -
in the event of a diaphragm rupture, gas escapement is
limited to within the ANSI/CSA standards level.
* CSA design certified

276 of 761
Capacities and Pressure Drop

CAPACITIES - based on 1" w.c. pressure drop, from set point*. 0.64 sp gr gas expressed in CFH (m3/h).
Outlet CSA Operating Inlet Pressure
Model Number Pressure Max. 1/2 psi 3/4 psi 1 psi 2 psi 5 psi 10 psi
Set Point CFH (34 mbar) (52 mbar) (69 mbar) (138 mbar) (345 mbar) (690 mbar)
4.0” w.c. 150 160 (4.5) 190 (5.4) 220 (6.2) 220 (6.2) 300 (8.5) 320 (9.1)
325-3* 7.0” w.c. 150 120 (3.4) 150 (4.2) 180 (5.1) 220 (6.2) 290 (8.2) 320 (9.1)
10.0” w.c. 150 100 (2.8) 120 (3.4) 150 (4.2) 220 (6.2) 280 (7.9) 320 (9.1)
4.0” w.c. 300 300 (8.5) 340 (9.6) 416 (11.8) 500 (14.2) 600 (17.0) 680 (19.3)
325-5A*
7.0” w.c. 300 245 (6.9) 315 (8.9) 340 (9.6) 480 (13.6) 600 (17.0) 680 (19.3)
10.0” w.c. 300 225 (6.4) 270 (7.6) 312 (8.8) 430 (12.2) 560 (15.9) 680 (19.3)
4.0” w.c. - 670 (19.0) 900 (25.5) 1050 (29.7) 1450 (41.1) 1750 (49.6) 2000 (56.6)
325-7 -
7.0” w.c. 590 (16.7) 760 (21.5) 900 (25.5) 1250 (35.4) 1750 (49.6) 2000 (56.6)
10.0” w.c. - 470 (13.3) 650 (18.4) 800 (22.7) 1250 (35.4) 1750 (49.6) 2000 (56.6)
*NOTE: Maximum Individual Load: 325-3 is 100 CFH (2.8 m3/h), 325-5A is 250 CFH (7.0 m3/h), 325-7 is 900 CFH (25.5 m3/h)
Approval based on use as an appliance regulator.
PRESSURE DROP - 0.64 sp gr gas expressed in CFH (m3/h) (for system pressure drop calculations)
Model 7.0” w.c. (17 mbar) 1/2 psi (34 mbar) 3/4 psi (52 mbar) 1 psi (69 mbar) 2 psi (138 mbar)
325-3 145 (4.0) 204 (5.8) 250 (7.0) 289 (8.2) -
325-5A 338 (9.6) 476 (13.5) 583 (16.5) 673 (19.1) -
325-7 690 (19.5) 972 (27.6) 1191 (33.8) 1375 (39.0) 1975 (55.9)
Sizing Instructions Pressure Drop Chart

When 325 Series regulators are used on 2 psig piping systems -
often times the 2 psig residential systems are sized with a 1-1/2
psi pressure drop through the copper or stainless steel tubing.
This means there will be 2 psi at the inlet of the regulator under
no flow conditions, and 1/2 psi at the regulator inlet under
maximum flow conditions.
To select a 325 series appliance regulator of ample flow - one
Pressure Drop ( P)
must know:
1. Available inlet pressure (maximum static/minimum
operating).
2. Desired outlet pressure.
3. Required maximum flow rate.
4. Pipe size.
Example: To select a 325 series regulator of ample capacity to
handle flow. . .
KNOWN:
Desired flow rate 145 CFH; pipe size 1/2"; operating inlet
pressure 2 psi; outlet pressure 7" w.c.; lockup required.
SOLUTION:
Check pressure drop chart above - the 325-3's pressure drop at
a flow rate of 145 CFH is 7" w.c. - well below the available
differential of 1.75 psi. The 325-3 (1/2") used with a 4" to 12"
spring, set at 7", is the correct regulator to use for this application.

277 of 761
Dimensions and Spring Ranges
325-3 325-5A
A
A
C
B
DIMENSIONS - inches (millimeters)

Model Pipe Swing Call-Outs
Number Size* Radius A B C
3/8 x 3/8 3 3-1/2 4-1/4 3-7/8

325-3
1/2 x 1/2 (76) (89) (108) (98)
325-7 A
1/2 x 1/2 4-7/8 5-1/4 5-7/8 5-7/16

325-5A 3/4 x 3/4 (124) (133) (149) (138)
1x1
1-1/4 x 1-1/4 6-1/8 7-1/4 8 7 C
325-7
1-1/2 x 1-1/2 (156) (184) (203) (178)
* standard models NPT, 'M' models available with BSP threads
SPRING SELECTION CHART - inches w.c. (mbar) unless noted
Model CSA Certified Standard

2 psi (138 mbar) 5 psi (345 mbar) Other Springs Available
Number Spring
5-9 7 - 11 6 - 10 7 - 11 4 to 12 2-6 10 - 22 15 - 30 1 - 2 psi
325-3
(12.5 -22.5) (17 - 27) (15 - 25) (17 - 27) (10 to 30) (5 - 15) (25 - 55) (37 - 75) (69 - 139)
5-9 7 - 11 6 - 10 7 - 11 4 to 12 2-6 10 - 22 15 - 30 1 - 2 psi
325-5A
(12.5 - 22.5) (17 - 27) (15 - 25) (17 - 27) (10 to 30) (5 - 15) (25 - 55) (37 - 75) (69 - 139)
4 to 12 2-5 10 - 22 15 - 30 20 - 42
325-7 - - - -
(10 to 30) (5 - 12) (25 - 55) (37 - 75) (50 - 104)
Maxitrol Company www.maxitrol.com

23555 Telegraph Rd., PO Box 2230 © 2008, Maxitrol Company,
4 All Rights Reserved.
Southfield, MI 48037-2230 U.S.A.
325LVR_MS_EN_03.2008
Replaced Bulletin MS2055-03/05
278 of 761
VENTING CODE - NFPA 54/ANSI Z223.1 NATIONAL FUEL GAS CODE

5.8.5 Venting
5.8.5.1 Line Gas Pressure Regulators
Line gas pressure regulators shall comply with the following:
1. An independent vent to the exterior of the building, sized in accordance with the regulator manufacturer's
instructions, shall be provided where the location of the regulator is such that a ruptured diaphragm will cause a
hazard.
A. Where there is more than one regulator at a location, each regulator shall have a separate vent to the
outdoors, or if approved by the authority having jurisdiction, the vent lines shall be permitted to be
manifolded in accordance with accepted engineering practices to minimize back pressure in the event of
diaphragm failure. (See 5.9.7 for information on properly locating the vent.)
B. Materials for vent piping shall be in accordance with section 5.6.
Exception: A regulator and vent limiting means combination listed as complying with ANSI Z21.80 / CSA 6.22,
Line Pressure Regulators, shall be permitted to be used without a vent to the outdoors.
2. The vent shall be designed to prevent the entry of water, insects, or other foreign materials that could cause
blockage.
3. At location where regulators might be submerged during floods, a special antiflood-type breather vent fitting shall
be installed, or the vent line shall be extended above the height of the expected flood waters.
4. A regulator shall not be vented to the appliance flue or exhaust system.
Codes for Vent Limiters

Vent limiters are designed for use indoors and spaces where limiting the amount of gas escapement due to diaphragm
failure is critical. Vent limiters should not be used outdoors if they are exposed to the environment.
Regulators used outdoors must be installed in accordance with one of the following national codes:
A. National Fuel Gas Code; ANSI Z223.1 / NFPA 54 2006 section "9.1.19 Venting of Gas Appliance Pressure
Regulators.
Venting of gas appliance pressure regulators shall comply with the following requirements: (2) Vent limiting means shall
be employed on listed appliance regulators only. (3) In the case of vents leading outdoors, means shall be employed to
prevent water from entering this pipe and also to prevent blockage of vents by insects and foreign matter."
B. International Fuel Code 2003 section "410.3 Venting of Regulators.
Pressure regulators that require a vent shall have an independent vent to the outside of the building. The vent shall be
designed to prevent the entry of water or foreign objects. Exception: A vent to the outside of a building is not required for
regulators equipped with and labeled for utilization with approved vent-limiting devices installed in accordance with the
manufacturer's instructions."
279 of 761
C. Uniform Plumbing Code IAPMO/ANSI UPCI-2003 section "1209.7.5 Venting (A) Line Gas Pressure Regulators.
(1) An independent vent to the outside of the building, sized in accordance with manufacturer's instructions, shall be
provided where the location of a regulator is such that a ruptured diaphragm will cause a hazard. Where there is more
than one regulator at a location, each regulator shall have a separate vent to the outside, or if approved by the Authority
Having Jurisdiction, the vent lines shall be permitted to be manifolded in accordance with accepted engineering practices
to minimize back pressure in the event of diaphragm failure. [See NFPA 54:5.9.7] for information of properly locating the
vent.) Materials for vent pipes shall be in accordance with Section 1209.5.
Exception: A regulator and vent-limiting means combination listed as complying with ANSI Z21.80 / CSA 6.22 Standard
for Line Pressure Regulators shall be permitted to be used without a vent to the outdoors.
(2) The vent shall be designed to prevent the entry of water, insects, or other foreign materials that could cause
blockage."
Vent limiters will not prevent water, insects, or other foreign materials from entering the regulator.
CAN CSA B149.1 Natural Gas & Propane Gas Installation Code Canada
5.2.2 Additional requirements for pressure regulators for propane applications
5.2.2.4. When used on a system operating at 2 psig (14 kPa) or less, a line pressure regulator equipped with a leak
limiting system orificed for 1 ft³/h (0.0283 m³/h) shall be exempt from the requirement of Clause 5.2.1.5(b). A regulator
with vent limiting means shall be installed in a ventilated space only.
5.2.3. Additional requirements for pressure regulators for natural gas applications
5.2.3.1. When used on a system operating at 2 psig (14 kPa) or less, a line pressure regulator equipped with a leak
limiting system orificed for 2.5 ft³/h (0.0706 m³/h) shall be exempt from the requirement of Clause 5.2.1.5(b). A regulator
with vent limiting means shall be installed in a ventilated space only.
5.2.3.2. For systems with inlet pressures above 2 psig (14 kPa) a pressure regulator equipped to limit the escape of gas
from the vent openings, even in the event of a main diaphragm failure, to less than 2.5 ft³/h (0.0706 m³/h), having an
overpressure cut-off (OPCO) device set to a pressure either below 2 psig (14 kPa) or 2 times the delivery pressure on the
system and certified to CSA 6.18, is exempt from compliance with Clause 5.2.1.5(b) of this Code.
280 of 761
3.9 Siemens
1000 Deerfield Parkway, Buffalo Grove IL 60089 USA
www.buildingtechnologies.usa.siemens.com
281 of 761
Technical Instructions
Document No. 155-751
SKP15…U..
July 1, 2005
SKP Series
SKP15…U.. Gas Valve Actuator with
Safety Shutoff Function
Only when assembled to Series VG… Gas valves

Description SKP15… electro-hydraulic actuators are used in combination with VG… series gas
valves to provide safety shut-off control for industrial and commercial burner
applications.
The compact SKP15… actuator opens slowly and closes immediately when power is
interrupted. The modular design allows the SKP15… to be used in combination with all
VG… series gas valves bodies from 1/2-inch to 6 inches in size. The actuator is easily
mounted on the square flange of any VG… valve with four pre-mounted screws. A
visible position indicator on the front of the actuator displays the entire stroke of the
valve. A light indicates when the actuator is powered.
Features • UL listed, FM approved, CSA certified for USA and Canada, IRI approvable, and
ISO 9001 certified. European, Australian and Japanese approved versions
available.
• Proof of Closure with Over Travel (POC) versions are available.
• Optional NEMA 4 protection.
• Visual position indication.
• "Power on" indication light
• Quick connect wiring terminals
• Optional adjustable auxiliary switch available.
• Modular design with 360o actuator rotation for easy field wiring and installation.
• Low, 13.5 VA power consumption.
Application SKP15… series actuators are combined with 1/2-inch to 6-inch VG… series gas valve
bodies. VG… series gas valves must be ordered separately (See VG…U... Technical
Instructions, P/N 155-512P25).
Siemens Building Technologies, Inc.

282 of 761
Technical Instructions SKP15...U Electro-hydraulic Actuators
Document Number 155-751
July 1, 2005
Product Numbers Table 1.
Product Number1 Operating Proof of Closure Auxiliary Type of Switch

Voltage Switch 2 Switch 2*
SKP15.013U1 – – –
SKP15.012U1 110 to 120 Vac X X SPDT SPDT
SKP15.011U1 X – SPDT
SKP15.013U2 – – –
220 to 240 Vac
SKP15.012U2 X X SPDT SPDT
Note:
1. European, CE certified models are available (see …data sheet ….)
2. Proof of closure and auxiliary switches cannot be field installed.
Accessories
AGA66 Sealing gasket to provide NEMA 3, 3R, and 4 protection (for VGG…/VGD…valves)
Specifications As safety shut-off valve UL/429, FM/7400, ANSI Z21.21/CGA6.5 C/I

Agency marks apply only for SKPxx.xxxU actuators
Agency approvals with VGxxx.xxxU series gas valve bodies.
Power supply Operating voltage 110 to 120 Vac + 10% to -15%

220 to 240 Vac + 10% to -15%
Operating frequency 50 to 60 Hz + 6%
Power consumption 13.5 VA
Duty cycle continuous
Operating environment Ambient operating temperature 5°F to 140°F (–15°C to 60°C)
Mounting position Any position except upside down
Physical characteristics Weight 2.4 lb (1.1 kg)
Enclosure NEMA 1, 2, 5, and 12 for indoor use
NEMA 3, 3R, and 4 with optional AGA66 gasket
Dimensions See Figure 3
Specification for valve bodies See gas valve Technical Instructions
P/N 155-512P25
Conduit connection Two 1/2-inch NPSM threaded knock-outs
Electrical connection Spring loaded terminals for 14 AWG wires
Operating characteristics Output force 100 lb (450 N)
Maximum stroke 1 inch (26 mm)
Opening time for maximum stroke Varies with valve size, 14 seconds for max. stroke
Closing time <0.8 seconds
Auxiliary features Proof of closure switch Non-adjustable
Setting range of auxiliary switch 40% to 100% of stroke
Switch rating 6A/250 Vac resistive; 3A/120 Vac pilot duty
Page 2 Siemens Building Technologies, Inc.

283 of 761
SKP15…U Electro-hydraulic Actuators Technical Instructions
July 1, 2005
Operation
Figure 1. SKP15… Operation.

The electro-hydraulic actuator consists of a cylinder filled with oil, a piston containing an
electric oscillating pump, and a relief system. When power is supplied to the actuator, the
relief system closes, and the pump moves oil from the reservoir into the pressure
chamber. This action causes the piston to move downward in the cylinder, opening the
gas valve. When power to the actuator is interrupted, the relief system opens and the gas
valve closes in less than 0.8 seconds.
A position indicator, visible through the transparent portion of the terminal cover, shows
the entire stroke range of the actuator. A light, which is visible through the lower left
transparent portion of the terminal cover, indicates when the actuator receives power. An
optional, non-adjustable SPDT proof of closure over travel switch signals the closed
position after the gas valve has closed. An optional SPDT auxiliary switch is adjustable
between 40% and 100% of the stroke. The adjustment screw and scale are located on
the right side in the terminal box, and are visible through the transparent portion of the
terminal cover.
Installation WARNING:
• Personal injury or loss of life may occur if procedures are not followed
as specified.
• All installations must be performed by qualified personnel only.
• Do not pull the actuator shaft.
• The AGA66 gasket must be installed between the actuator and the
gas valve body to provide NEMA 3, 3R, and 4 protection rating for
VGG… and VGD… valves.
• The SKP15… actuator is directly coupled to the VG… series valve body by four pre-
mounted 4 mm Allen key screws.
• The square mounting flange can be rotated in steps of 90o to provide four different
mounting positions. The SKP15… actuator can be mounted in any position except
upside down.
• The actuator can be mounted or replaced while the valve body is under pressure.
• The SKP15… actuator has two knock-outs for the installation of 1/2”-14 NPSM
conduit connections.
• When conduit routing is connected, flexible conduit must be used.
• Liquid tight conduit must be used in combination with AGA66 to provide NEMA 3, 3R,
and 4 protection.
• The terminal marked GND, located above the wiring terminals, must be connected to
the electrical ground.
Siemens Building Technologies, Inc. Page 3

284 of 761
July 1, 2005
Installation, NOTE: Wiring must meet all relevant electrical codes.

Continued
Wiring and Switch • The actuator is equipped with spring-loaded terminals for 14 AWG wires.
Adjustment • The actuator has two line and two neutral terminals.
(See Terminal • Insert one wire into the opening of the terminal while pressing the lever downward
Designations) with a screwdriver or hard object. Make sure that all strands insert into the opening.
• Adjust the auxiliary switch (if provided) according to the wiring diagram on the label
below the terminals (see figure 2). The adjustment screw and scale are located on
the right side of the terminal box, and are visible through the transparent portion of
the terminal cover.
NOTES: 1. The auxiliary switch is adjustable between 40% and 100% of the stroke. The
factory setting is at 40%.
2. The auxiliary switch must not be used for proof of closure detection or other
safety interlock functions.
3. The Proof of Closure Switch is non-adjustable.
Service There are no serviceable parts on the SKP15… series actuators. If inoperative, replace
the entire actuator. Tag wires before servicing.
Terminal
Designations
GAS0049R1
SKP15.012U… SKP15.011U… SKP15.013U…

Figure 2. Terminal Designations.

285 of 761
July 1, 2005
Dimensions
(Dimensions in
inches;
millimeters in
parentheses)
7.40
(188)
1/2"-14
NPSM
3.15
(80)
3.82
(97)
GAS0051R1
2.16
(55)
3.20 3.39 SQUARE
(81) (86)
Figure 3. SKP15…U.. Dimensions.
Information in this publication is based on current specifications. The company reserves the right to make changes in specifications and models as
design improvements are introduced. Other product or company names mentioned herein may be the trademarks of their respective owners.
© 2005 Siemens Building Technologies, Inc.
Siemens Building Technologies, Inc. Your feedback is important to us. If you have Document No. 155-751
1000 Deerfield Parkway comments about this document, please send Country of Origin: US
Buffalo Grove, IL 60089-4513 them to SBT_technical.editor@siemens.com Page 5
U.S.A.
286 of 761
Technical Instructions
SKP25…U..
November 1, 2007
SKP Series
SKP25…U.. Pressure Regulating Gas
Valve Actuator with Safety Shut-off
Function
Only when assembled to Series VG… Gas valves

Description SKP25… pressure regulating electro-hydraulic actuators are used in combination with
VG… series gas valve bodies to provide safety shut-off and gas pressure regulation for
industrial and commercial burners. The SKP25… can also be applied as a 1:1 air/gas
ratio regulator or zero governor.
Since a single valve performs two or more functions, fewer gas train components and
fittings are required. This significantly reduces both the size and weight of the gas train.
In addition, smaller diameter gas valves can be used.
The compact SKP25… actuator opens slowly and closes immediately when power is
interrupted. The modular design allows the SKP25… to be used in combination with all
VG… series gas valve bodies from 1/2-inch to 6-inch in size. The actuator is easily
mounted on the square flange of any VG… valve with four pre-mounted screws. A
visible position indicator on the front of the actuator displays the entire stroke of the
valve. A light indicates when the actuator is powered.
Features • UL listed, FM approved, CSA certified for USA and Canada, IRI approvable, ISO
9001 certified. European, Australian and Japanese approved versions available.
• Certified as a ventless pressure regulator.
• Safety shut-off function and pressure regulating function in one compact unit.
• Proof of Closure with Over Travel (POC) versions are available.
• Optional NEMA 4 protection.
• Visual position indication.
• "Power on" indication light
• Quick connect wiring terminals
• Optional adjustable auxiliary switch available.
• Applicable as 1:1 air/gas ratio regulator or zero governor.
• Accurate pressure control characteristics, and zero offset (droop).
• Modular design with 360o actuator rotation for easy field wiring and installation.
• Low, 13.5 VA power consumption.
Siemens Building Technologies, Inc.

287 of 761
Technical Instructions SKP25…U.. Pressure Regulating Gas Valve Actuators
November 1, 2007
Application SKP25… series actuators are combined with 1/2-inch to 6-inch VG… series gas valve
bodies. VG… series gas valves must be ordered separately (See VG…U...Technical
Instructions, P/N 155-512P25).
Product Numbers Table 1.
Product Number1 Operating Function Proof of Closure Auxiliary Type of

Voltage Switch 5 Switch 5 Switch
SKP25.011U1 regulator x – SPDT
SKP25.012U1 regulator x x SPDT SPDT
SKP25.013U1 110 to 120 Vac regulator – – –
2 regulator – SPDT
SKP25.411U1 x
3 ratio regulator – SPDT
SKP25.611U1 x
4 ratio regulator _ SPDT
SKP25.011U1P x
SKP25.012U2 regulator x x SPDT SPDT
220 to 240 Vac
SKP25.013U2 regulator – – –
NOTES: 1. European, CE certified models are available (see data sheet 7643)
2. High outlet pressure model for 1.5 to 20 psi outlet pressure regulation
3. High bias air/gas ratio regulator with factory installed spring for 0" to –4" WC bias.
4. Low bias air/gas ratio regulator with factory installed spring for 0" to –0.6" WC bias.
5. Proof of closure and auxiliary switches cannot be field installed.
Accessories Table 2.
Product Number Description
AGA22 Yellow setpoint spring for 6” to 48” WC (1.5 to 10 psi for SKP25.411U1)
AGA23 Red setpoint spring for 40” to 100” WC (8.5 to 20 psi for SKP25.411U1)
AGA25 Damping orifice for mounting into vent connection of SKP25.0…models
AGA28 Black bias spring to install if SKP25.0… is used as air/gas ratio regulator or zero governor
AGA29 Unpainted setpoint spring for 0” to 8.5” WC (included in SKP25.0… as standard)
AGA66 Sealing gasket to provide NEMA 3, 3R, and 4 protection (for VGG…/VGD…valves)
Specifications As a safety shut-off valve UL/429, FM/7400, ANSI Z21.21/CGA 6.5 C/I
Agency marks apply only for SKPxx.xxxU actuators
Agency approvals assembled with VGxxx.xxxU series gas valve bodies.
As a pressure regulator ANSI Z21.18/CGA 6.3
Power supply Operating voltage 110 to 120 Vac + 10% to -15%
220 to 240 Vac + 10% to -15%
Operating frequency 50 to 60 Hz +6%
Power consumption 13.5 VA
Duty cycle continuous
Operating environment Ambient operating temperature 5°F to 140°F (-15°C to 60°C)
Mounting position Any position
Maximum inlet gas pressure Same as VG… series
288 of 761
SKP25…U.. Pressure Regulating Gas Valve Actuators Technical Instructions
November 1, 2007
Specifications, Weight 3.5 lb (1.6 kg)

Continued Enclosure NEMA 1, 2, 5 and 12 for indoor use
NEMA 3, 3R, and 4 with optional AGA66 gasket
Physical characteristics
Dimensions See Figure 4
Specification for valve bodies See gas valve Technical Instructions,
P/N 155-512P25
Connections Conduit connection Two 1/2-inch NPSM threaded knock-outs
Electrical connection Spring loaded terminals for 14 AWG wires
Gas connection 1/4” NPT
Air connection 1/4” NPT
Gas pressure test connection Hose barb with close-off screw
Operating characteristics Output force 100 lb (450 N)
Maximum stroke 1 inch (26 mm)
Opening time for maximum stroke Varies with valve size, 14 seconds for max. stroke
Closing time < 0.8 seconds
Operation/installation Outlet pressure spring range
SKP25.0… 0" to 8.5" WC (factory-installed, unpainted spring,
AGA29)
6" to 48" WC (yellow spring, AGA22)
40" to 100" WC (red spring, AGA23)
SKP25.411U1 1.5 to 10 psi (factory-installed, yellow spring, AGA22)

8.5 to 20 psi (red spring, AGA23)
SKP25.0… ± 0.4" WC bias (replace with black spring AGA28)

(1:1 air/gas ratio regulator or
zero governor)
SKP25.611U1 0" to −4.0" WC bias (factory installed, white spring)

(1:1 air/gas ratio regulator)
SKP25.011U1P 0” to −0.6 “ WC (factory installed, lavender spring)

(1:1 air/gas ratio regulator)
Maximum sensing line pressure 20 psi
Maximum sensing line vacuum 3 psi for SKP25.0… models
Minimum sensing line diameter 1/4" inside diameter
Minimum distance between 5 times the pipe diameter
sensing line and gas valve outlet
Minimum time required for high to low fire 5 seconds
load changes
Auxiliary features Proof of closure switch Non-adjustable
Setting range of auxiliary switch 40% to 100% of stroke
Switch rating 6A/250 Vac resistive; 3A/120 Vac pilot duty

289 of 761
November 1, 2007
Operation The electro-hydraulic actuator consists of a cylinder filled with oil, a piston containing an
electric oscillating pump, and a relief system. When power is supplied to the actuator,
(See Figure 1)
the relief system closes, and the pump moves oil from the reservoir into the pressure
chamber. This action causes the piston to move downward in the cylinder, opening the
Safety Shut-off Function gas valve. When power to the actuator is interrupted, the relief system opens and the
gas valve closes in less than 0.8 seconds.
A position indicator, visible through the transparent portion of the terminal cover, shows
the entire stroke range of the actuator. A light, which is visible through the lower left
transparent portion of the terminal cover, indicates when the actuator receives power.
An optional, non-adjustable SPDT proof of closure over travel switch signals the closed
position after the gas valve has closed. An optional SPDT auxiliary switch is adjustable
between 40% and 100% of the stroke. The adjustment screw and scale are located on
the right side in the terminal box, and are visible through the transparent portion of the
terminal cover.
Gas Sensing Line
-
+
PGas
GAS0062R1
Figure 1. SKP25… Operation.
Constant Pressure The outlet gas pressure sensing line is connected to the 1/4“ NPT port marked GAS on
Regulation Function the back of the pressure regulator housing. The outlet pressure acts on the regulator
diaphragm. The diaphragm is opposed by an adjustable setpoint spring force, which
(See Figure 1)
represents the desired gas pressure value. The movement of the diaphragm modulates
a hydraulic bypass valve connecting the pressure chamber to the hydraulic fluid
reservoir. When the outlet gas pressure is lower than the desired value, the bypass
valve is closed by the movement of the diaphragm, causing the actuator piston to open
the gas valve. The opposite occurs when the outlet gas pressure is higher than the
desired value; the diaphragm moves to open the bypass causing the actuator piston to
close the gas valve. The movement of the actuator piston stops once the outlet gas
pressure is equal to the setpoint. In this position the bypass valve is partially open so
that the oil flow supplied by the pump is identical to the return flow. Unlike the
conventional direct acting regulators, the SKP25… servo operated regulating system
displays virtually zero droop (offset) across the turndown range.

290 of 761
November 1, 2007
Air/Gas Ratio Regulator The SKP25.0… models may be applied as a 1:1 air/gas ratio regulator or as a zero
Function governor. For either application, the standard spring has to be replaced with the black
AGA28 spring, which allows to bias the gas pressure between 0.4" and –0.4" WC.
The low bias model SKP25.011U1P air/gas ratio regulator is designed as 1:1 air/gas
ratio regulator which allows to bias the gas pressure between 0” and −0.6” WC. with the
factory installed lavender spring. The actuator has a built in proof of closure switch.
The high bias model SKP25.611U1 air/gas ratio regulator model is designed as 1:1
air/gas ratio regulator which allows to bias the gas pressure between 0” and –4” WC.
with the factory installed white spring. The actuator has a built in proof of closure switch.
For air/gas ratio regulation, the air pressure sensing line must be connected to the port
marked “AIR".
Air Sensing Line
Gas Sensing Line
PGas bias +
GAS0061R1
Figure 2. SKP25… Operation as 1:1 Air/Gas Ratio Regulator.
NOTES:
1. The gas bias has the greatest effect at low fire.
2. To adjust the gas pressure or bias, remove the brass cap in the center of the
regulator cover.
3. To increase the downstream gas pressure, turn the adjustment screw clockwise.
4. SKP25.4… models must not be used as air/gas ratio regulator.
5. When using the double valve VGD…, mount the SKP2… on the downstream valve.
6. To avoid oscillation, do not oversize the VG… valve body. (See Technical
Instructions, P/N 155-512P25.)

291 of 761
November 1, 2007
Installation WARNING:
• Personal injury or loss of life may occur if procedures are not followed
as specified.
• All installations must be performed by qualified personnel only.
• Do not pull the actuator shaft.
• If minimum gas pressure detection is required, the pressure switch must
be mounted upstream of the regulating gas valve to ensure sufficient
gas pressure before starting the burner. If maximum gas pressure
detection is required the pressure switch must be mounted downstream.
• The AGA66 gasket must be installed between the actuator and the gas
valve body to provide NEMA 3, 3R, and 4 protection rating for VGG…
and VGD… valves.
• The gas pressure sensing line must be at least 1/4-inch inside diameter.
• The gas pressure sensing line connection must be flush with the inner
wall of the gas pipe in order to sense turbulence free pressure. The gas
sensing line connection should be located at least five pipe diameters
downstream of the valve, elbow, coupling, or other flow disturbing fitting.
Do not use the taps on the valve body for the gas sensing line
connection since these locations typically have strong turbulence.
The pressure connection pipe should be as short as possible to allow
the regulator to react to sudden changes.
• The SKP25… actuator is directly coupled to the VG… series valve body by four
pre-mounted 4 mm Allen key screws.
• The square mounting flange can be rotated in steps of 90o to provide four different
mounting positions. The SKP25… actuator can be mounted in any position with the
diaphragm vertical, except upside down.
• The actuator can be mounted or replaced while the valve body is under pressure.
• The SKP25… actuator has two knock-outs for the installation of 1/2”-14 NPSM
conduit connections.
• When conduit routing is connected, flexible conduit must be used.
• Liquid tight conduit must be used in combination with AGA66 to provide NEMA 3,
3R, and 4 protection.
• The terminal marked GND, located above the wiring terminals, must be connected
to the electrical ground.
NOTE: Wiring must meet all relevant electrical codes.

292 of 761
November 1, 2007
Start-up The gas outlet pressure setpoint adjustment screw is located at the center of the
regulator cover. Clockwise rotation of the setpoint adjustment screw increases the outlet
Regulator gas pressure. The hexagonal cap must be tightened after the setpoint screw has been
adjusted and may be sealed from tampering by means of a wire and lead seal. The
outlet gas pressure can be measured at the hose barb at the back of the regulator
housing. Turn the screw 1/2 turn counterclockwise before attaching the hose and tighten
the screw after removing the hose.
The SKP25.0… models are available with three interchangeable setpoint springs for an
adjustable range outlet pressure range of 0” to 100” WC. The factory-installed unpainted
spring ranges from 0” to 8.5” WC. Other springs need to be ordered separately. (See
Table 2.)
The SKP25.411U… models are available with two interchangeable setpoint springs for
an adjustable range of 1.5 to 20 psi. The factory installed yellow spring ranges from 1.5
to 10 psi. The red spring (AGA23) for an adjustable range of 8.5 to 20 psi needs to be
ordered separately.
Air/Gas Ratio For SKP25.0… models used as 1:1 air/gas ratio regulator connect the air sensing line to
Regulators the port marked AIR and replace the factory installed spring with the black spring
(AGA28) which needs to be ordered separately. The gas bias can be adjusted at the
center of the regulator housing. For bias pressure ranges of all 1:1 air/gas ratio
regulators see Operation, Specifications or Tables 1 and 2.
WARNING:
When firing at maximum burner capacity, ensure that the SKP25… /VG… is
not in the fully open position. If this is the case, either the gas valve is sized
too small or the gas supply pressure is too low.
Wiring and Switch • The actuator is equipped with spring-loaded terminals for 14 AWG wires.
Adjustment • The actuator has two line and two neutral terminals.
(See Terminal • Insert one wire into the opening of the terminal while pressing the lever downward
Designations) with a screwdriver or hard object. Make sure that all strands insert into the opening.
• Adjust the auxiliary switch (if provided) according to the wiring diagram on the label
below the terminals (see Figure 3). The adjustment screw and scale are located on
the right side of the terminal box, and are visible through the transparent portion of
the terminal cover.
NOTES:
1. The auxiliary switch is adjustable between 40% and 100% of the stroke. The
factory setting is at 40%.
2. The auxiliary switch must not be used for proof of closure detection or other safety
interlock functions.
3. The Proof of Closure Switch is non-adjustable.

293 of 761
November 1, 2007
Service There are no serviceable parts on the SKP25… series actuators. If inoperative, replace
the actuator. Tag wires before servicing.
Terminal
Designations
GAS0049R1
SKP25.012U.. SKP25.011U.. SKP25.013U..

Figure 3. Terminal Designations.
Dimensions
1/4" 3.78
FEMALE (96) PRESSURE 1/4"-18 NPT
1.30 TEST PORT FEMALE
(33) 0.35" (8.5) O.D.
1.02
(26)
1.41
(36)
8.70
(221)
7.95
(202)
1/2"-14
NPSM 6.61
7.87 (168)
(200) 3.15
(80)
3.82
(97)
GAS0052R1
2.16
(55)
3.39 SQUARE 3.20
(86) (81)
Figure 4. SKP25…U.. Dimensions in Inches, Millimeters in Parentheses.
1000 Deerfield Parkway comments about this document, please send them Country of Origin: US
Buffalo Grove, IL 60089-4513 to SBT_technical.editor.us.sbt@siemens.com Page 8
U.S.A.
294 of 761
Technical Specification Sheet
Ref: Hot Water Boiler Trim January 2, 2008
- Temperature Sensor for the Modulating
Temperature Control RWF40
Immersion Well Temperature Sensors
Description Specifications
The Immersion Well Temperature Sensors monitor Temperature Range Controller dependent
and transmit changes in temperature to the building Output Signals Changing resistance
control system. Specific devices within the range are Sensing Element Type NTC Thermistor, Platinum
compatible with whatever North American RTD, or Nickel RTD
manufactured building automation system you may be Accuracy
installing. They thread into a well in a pipe and sense NTC Thermistors, ±1.0°F (±0.5°C)
the medium temperature in the pipe. All sensors mid-range
incorporate precision temperature sensing elements to Pt RTD and Ni RTD, ±0.75°F (±0.4°C)
accurately and reliably measure temperature. mid-range
Installation
Wiring 2-conductor: 18 to 22 AWG
Features twisted pair (per code
requirements)
• Variety of sensing elements Calibration Adjustments NTC: None required
• Suitable for hot or chilled medium RTD: Adjust for increased
temperature offset (a
• Responsive to temperature change constant) as required,
• Accurate and reliable indication of temperature related to added resistance
of the field wiring
• Familiar installation requires no special tools
External Installation Threads 1/2-inch – 14 NPT
Conduit Connection Threads 1/2-inch – 14 NPSMI
Housing Material Cast zinc
Immersion Well Material 300 Series Stainless Steel
Figure 1. Immersion Well Temperature Sensor.
Siemens Building Technologies, Inc. Page 1 of 2

295 of 761
Accessories Ordering Information Product Ordering Information

Description Part Number UNIVERSAL SENSOR PROGRAM QAE 2 0 x x . x x x
TYPE SENSOR Q
2.5 in. (64 mm) AQE2000.005 MEASURING UNIT TEMPERATURE A
Immer
Wells
-sion
4 in. (100 mm) AQE2000.010 APPLICATION/LOCATION IMMERSION E

SENSOR CATEGORY STANDARD 2
6 in. (153 mm) AQE2000.015 HOUSING TYPE
METAL HOUSING 0
PT 1000 Ohm (385 α) AQE2012 TEMP OUTPUT SIGNAL
Ni 1K Ohm, Siemens AQE2020 PLATINUM 1000 OHM 1
NICKEL 1000 OHM 2
Immersion Well
Ni 1000 Ohm, JCI AQE2021 NEGATIVE TEMP COEFFICIENT (NTC) 3

Repair Kit
TEMP OUTPUT INFORMATION

NTC 10K Ohm Type II AQE2030 FOR PLATINUM: PT 1000 (385 ALPHA) 2
NTC 10K Ohm Type III AQE2032 FOR NICKEL: NI 1000 (Siemens) 0
NI 1000 (JCI) 1
NTC 2.252K Ohm AQE2033
FOR NTC OUTPUT: 10K OHM TYPE II 0
NTC 3K Ohm AQE2034 10K OHM TYPE III 2
2,252 OHM 3
NTC 20K Ohm Type II AQE2036 3K OHM 4
NTC 1.8K Ohm AQE2037 20K OHM 6
1.8K OHM 7
Repair kits have components to fill any of the three SEPARATOR .
LENGTH DESCRIPTION (NOMINAL)
Immersion Wells offered. 2.5 in. (64 mm) 005
4 in. (100 mm) 010
6 in. (153 mm) 015
Immersion Well Temperature Sensor
Product Numbers Part Number Example:
QAE2032.010=Pipe Temperature Sensor,
Product Number Sensing Element Immersion Type, NTC, 10K Type III Sensing Element,
QAE2037.XXX 1.8K Ω NTC
4-inch Probe.
QAE2030.XXX 10K Ω NTC Type II
QAE2032.XXX 10K Ω NTC Type III
QAE2036.XXX 20K Ω NTC Type II
QAE2012.XXX 1K Ω Pt (385α)
QAE2020.XXX 1K Ω Ni Siemens
QAE2021.XXX 1K Ω Ni JCI
XXX Insertion Length in Inches (mm)
.005 2.5 (63.5)
.010 4 (101.6)
.015 6 (152.4)
Information in this document is based on specifications believed correct at the time of publication. The right is reserved to make changes as
design improvements are introduced. Products or company names mentioned herein may be the trademarks of their respective owners.
1000 Deerfield Parkway comments about this document, please send them to Country of Origin: US
Buffalo Grove, IL 60089-4513 SBT_technical.editor.us.sbt@siemens.com Page 2 of 2
296 of 761
Ref: Hot Water Boiler Trim Installation Instructions
- Temperature Sensor
December 12, 2005
(QAE20)
Immersion Well Temperature Sensor
Product Description Prerequisites

• The appropriate field wiring within the maximum
The Immersion Well Temperature Sensor provides a
wiring run length for the individual field panel or
temperature input to a controller. It threads into a coupling
equipment controller must be in place.
on a piping system.
• All wiring must comply with National Electric Code
(NEC) and local regulations.
Contents
• A 1/2-inch (13 mm) NPT mounting coupling must
• Immersion well be installed in the piping system at the sensor
• Sensing element location. Figures 1 and 2 show two types of
installation in a pipe joint.
• Pulling elbow for wiring connections
Product Numbers
Product Number Sensing Element
QAE2030.XXX 10KΩ NTC Type II
QAE2032.XXX 10KΩ NTC Type III
QAE2036.XXX 20KΩ NTC Type II
QAE2012.XXX 1KΩPt (385α)
QAE2020.XXX 1KΩ Ni Siemens
QAE2021.XXX 1KΩ Ni JCI
.XXX U (Insertion Length in Inches [mm])
.005 2.5 (63.5) Figure 1. Pipe Surface Installation.
.010 4 (101.6)
.015 6 (152.4)
Required Tools
• Power screwdriver with 1/4-inch (6 mm) hex
extension or medium flat-blade screwdriver
• 1-1/4 inch (32 mm) open-end wrench or
equivalent adjustable wrench
• Medium crescent wrench
• Pipe sealant
• Wire stripper
Expected Installation Time Figure 2. Pipe Joint Installation.
3 hours
Item Number 129-462, Rev. AA Page 1 of 2

297 of 761
Installation Instructions
December 12, 2005
TERMINATION STRIP
Installation
SENSING
NOTE: It is not recommended or necessary to separate ELEMENT
the well and the pulling elbow to install the sensor AI
1 SENSOR
INPUT
assembly. The pulling elbow should only be
SEN0343R1
SHIELD
removed to replace a damaged or defective FIELD
WIRING
sensing element.
1. Clean any dust away from the coupling for the well. 1. Configure the analog input (AI) point for sensor
input.
2. Apply pipe sealant to the threads of the well and
insert the entire sensor assembly into the coupling. Figure 4. Wiring to a Controller.
3. Hand-tighten the sensor assembly. Finish tightening
the assembly by using a 1-1/4 inch (32 mm) open- NOTE: 1. Some Controllers may require a shield
end wrench. Tighten the assembly until the outlet of termination.
the pulling elbow is aligned with the controller. 2. For individual panel wiring details, see the
appropriate hardware manual.
4. Pull the field wiring to the pulling elbow and connect
the field wiring to the Thermistor. See Figure 3. The installation is now complete.
NOTE: In applications where condensate may
accumulate (chillers, low temperature
sensing, etc.) seal all wire connections
with RTV adhesive (ordered separately,
P/N 535-495).
5. Connect the field wiring at the controller as shown in
Figure 4.
Figure 3. Immersion Sensor Installation.
1000 Deerfield Parkway comments about this document, please send them Country of Origin: US
Buffalo Grove, IL 60089-4513 to SBT_technical.editor@siemens.com Page 2 of 2
U.S.A.
298 of 761
3.10 Mercoid Controls

102 Indiana Highway 212, Michigan City IN 46361 USA
www.mercoid.com
IN-526-N 8/30/05 2:06 PM Page 1
Bulletin IN-526-N
299 of 761
Installation Instructions (Preliminary)

Series D-7000-(N) Remote Bulb Temperature Controls
ENCLOSURES – TYPE NO. PREFIX
GENERAL PURPOSE WEATHER-RESISTANT EXPLOSION PROOF EXPLOSION PROOF

Prefixed by Prefixed by Prefixed by Prefixed by
DA, DL, DR, DS DAW, DLW, DRW, DSW DAH, DLH, DRH, DSH DAE, DLE, DRE, DSE
CONTROL NUMBERS BULB PROTECTION
Part of the control number following Type No. Prefix identifies the style of the There are three ways to protect bulb No. 2:
control case. 1. Before tightening packing gland, pull bulb back into union as far as possi-
The digit 5 of 7035 denotes a plain case with bottom connection. ble (standard No. 2 bulb with 3/4˝ union only). The union is recessed to pro-
The digit 8 of 7038 denotes a flanged case with bottom connection. vide some support.
The digit 9 of 7039 denotes a flanged case with back connection. 2. Where insertion depth is greater than bulb length, use extension sleeve “B”.
See illustration Nos. 8, 9, and 10.
CIRCUITS (SWITCH OPERATION) 3. Separable Wells (see drawing No. 10): wells slow down heat transfer of
Suffix number after control number denotes number of circuits and circuit temperature changes to the bulb and consequently increase response time
operation. of control the union will slide back on capillary allowing complete immersion
Suffix -153 designates SPDT - one circuit closes as other circuit opens. of bulb in any depth of well.
Suffix - 804 designates 2 ea. SPDT switches - two circuits close as two cir-
cuits open. FOR DIMENSIONS OF BULBS, SEE CHART - PAGE 3
Caution: When installing bulbs with union connections, be careful not to twist
LOCATION AND MOUNTING OF CONTROL CASE the flexible tubing. Loosen packing nut or union so that the union can turn
Follow equipment manufacturer’s instructions or proceed as follows: freely around tubing. After union is firmly secured to the pipe or tank, position
Vibration causes erratic operation of any instrument and shortens its life. It is bulb by sliding tubing through union and then tighten the packing gland nut.
important to select a location that is reasonably free of vibration. All controls
must be mounted vertical and level. Delrin bushed movements prolong con- CROSS AMBIENT TEMPERATURE EFFECTS
trol life by alleviating excessive wear of metal surfaces due to vibration and/or There are no cross ambient effects associated with these gas actuated units
pulsation. It is identified by the letter “B” after the suffix number. Example: - which are designed with a range number ending with “n”, i.e. -5N.
2B, -3B, -804B, etc.
WHERE TURBULENT OR FAST
General Purpose Types - DA, DS, DL, DR - These controls without a FLOWING LIQUIDS PREVAIL
flange plate are mounted by means of a bracket supplied with the control. For Bulb supports for bulb No. 2 are used where the bulb is mounted in turbulent
panel mounted use the holes provided on the flanged case. See drawing or fast flowing liquids or where it is desired to insert the remote bulb at some
1000F on page 4. distance within a vessel, pipe, or tank. See “B” in illustration Nos. 8, 9 and 10.
The remote bulb should be positioned so that at least one inch of the bulb is
Weather Resistant Types - DAW, DSW, DRW, DLW - For surface mount- within the extension sleeve “B” (dimension “B”) in order to insure firm support.
ing only. Has flanged case with bottom connection. See drawing 1062 on No. 2 bulb union is threaded to receive extension sleeve “B”. Extension addi-
page 4. tion “A” permits extending the mounting through insulation.
Explosion-Proof Types - DAE, DSE, DLE, DRE, DLH, DAH, DSH, DRH -
Secure with the mounting lugs provided on the housing. See drawings 98D
and 1350 on page 4.
LOCATION OF REMOTE BULB

To Insure Proper Control Operation:
1. The temperature bulb should be completely immersed in the medium being
controlled.
2. BULB MUST BE CORRECTLY LOCATED AND PROPERLY INSTALLED so
that the temperature changes at the bulb reflect actual temperature changes
of the medium being controlled.
3. Be sure the bulb will not be affected by external temperatures.
4. Bulb may be installed vertically or horizontally. The following precautions ILLUSTRATION ILLUSTRATION
should be taken: ILLUSTRATION NO. 5 NO. 6 NO. 7
(a) Do not install bulb in dead end of pipe, tank, etc., where it would not be
subject to free circulation of the medium being controlled. See illustration No. INCORRECT RECOMMENDED
5. INSTALLATION INSTALLATION
(b) If bulb No. 2 is located in a pipe or duct with diameter larger than the bulb Note that a very small These two illustrations indicate the bulb is completely
length, the bulb can be installed perpendicular to the pipe if protected from portion of the bulb is exposed (in direct path) of medium being controlled.
possible damage due to flow velocity. exposed to the direct
(c) If bulb No. 2 is to be inserted into a pipe with a diameter smaller than the path of medium being
bulb length (ex. a 2-7/8˝ long bulb in a 1˝ pipe) the bulb should be located lon- controlled. section
gitudinaly in the pipe so that the entire length is exposed to the flowing medi- containing bulb has
um (ex. replace an elbow in the pipe with a tee and install bulb as shown in no flow so its temper-
illustration No. 6 and 7. If pipe is 1˝ diameter or less, provide an enlarged sec- ature is affected by
tion around the bulb so that it does not restrict flow. radiation to or from
(d) When bulb No. 2 is to be inserted in a rapidly flowing stream of fluid in a the surrounding air.
pipe or duct, make sure that it is mechanicaly protected against the velocity ILLUSTRATION ILLUSTRATION
in order to prevent the bulb from breaking off at the capillary. NO. 8 NO. 9
5. Gas activated bulbs, unlike vapor pressure bulbs, do not have any eleva-
tion effects. Therefore, no compensation is required.
MERCOID DIVISION Phone: 219/879-8000 www.dwyer-inst.com

DWYER INSTRUMENTS, INC. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
P.O. BOX 258 • MICHIGAN CITY, INDIANA 46361, U.S.A.
IN-526-N 8/30/05 2:06 PM Page 2
300 of 761
WELLS
Wells (with dimensions “A” and “C” in illus- TWO-STAGE TEMPERATURE CONTROL
tration 10) are used to protect the remote SERIES D-7435
bulb from physical damage or to permit
removal of the bulb without draining the
system.
The use of a well will increase the time lag
of the control since the temperature
change of the controlled medium must be
transmitted through the wall of the well
and then the bulb. Thus when wells are
used, it is important that the well dimen-
sion “C” be greater than or equal to the
bulb length “B” to insure that all of the
temperature sensistive portion of the bulb
is within the liquid area. ILLUSTRATION
NO. 10
WIRING
Wire in accordance with local electrical codes or follow equipment manu-
facturer’s recommendations. On general purpose controls, do not attach
ridged conduit to case. use a short strip of BX to relieve conduit expansion
and contraction strains.
Where a control is connected directly into the load circuit, it must be con-
nected into the hot side of line.
Do not overload electrically - see nameplate attached to control for electri-
cal rating. TYPES DA-7435, DAW-7438, DAH-7435, DAE-7435 – This series incor-
porates two single pole, double throw snap switches, actuated by the
same Bourdon Tube. The operating point of each switch is adjustable
through an outside knob. The change in temperature which opens and
ADJUSTMENTS closes each switch at its respective setting is the “fixed differential” (sensi-
How to Set Operating Point of Control tivity) of the switch. The temperature represented by the difference
between the two adjustment points is the temperature “spread” between
DA – DOUBLE ADJUSTMENT TYPES – operation of the two switches. Upper pointer indicates the operating point
FULLY AUTOMATIC of the “high” temperature circuit. Lower pointer indicates the operating
Prefixed by DA, DAE, DAH, DAW – point of the “low” temperature circuit.
Provided with double adjustments. Adjust
the upper pointer to set the “high” tem- OPERATING RANGES/SERIES D-7435
perature point for switch operation. Adjust With Snap-Action Contacts
the lower pointer to set the “low” temper- Range Max. Temperature Min. Spread Fixed Deadband
ature operating point. The difference
between the upper and lower pointers is No. Scale Range Not To Exceed Between Switches Each Switch
the operating differential between “on-off” 1N -60 to 30°F (-50 to 0°C) 150°F (65°C) 12°F (7°C) 4°F (2°C)
switch operation. Minimum differential for 3N 0 to 100°F (-18 to 40°C) 240°F (115°C) 13°F (8°C) 4°F (2.5°C)
each range is shown on Page 3. 4N 50 to 150°F (10 to 65°C) 250°F (120°C) 13°F (8°C) 4°F (2.5°C)
5N 100 to 200°F (40 to 95°C) 300°F (150°C) 12°F (7°C) 4°F (2.5°C)
7N 140 to 300°F (60 to 150°C) 500°F (260°C) 18°F (10°C) 6.5°F (4°C)
SINGLE ADJUSTMENT TYPES –
DS – FULLY AUTOMATIC 8N 250 to 415°F (120 to 215°C) 550°F (290°C) 18°F (10°C) 7°F (4°C)
9N 350 to 550°F (175 to 290°C) 600°F (315°C) 22°F (13°C) 8°F (4.5°C)
Prefixed by DS, DSE, DSH, DSW –
Equipped with a single adjustment. The 10N 100 to 300°F (40 to 150°C) 500°F (260°C) 22°F (13°C) 8°F (4.5°C)
single pointer on the scale sets the tem- 11N 100 to 500°F (40 to 260°C) 600°F (315°C) 46°F (26°C) 16°F (9°C)
perature where switch operation occurs.
Differential is fixed (not adjustable). For
fixed differential of each respective range, ELECTRICAL RATING
see Page 3. AC capacities: 5A @ 120 V, 5A @ 240 V. (Not available for 440 V).
DC capacity: 5A, 30 V resistive.
SEMI-AUTOMATIC CONTROL
DR – WITH MANUAL RESET
DR-7035-153U. A single adjustment sets
the operating point for automatic opera-
tion. A push button reset must be operat-
ed manually to restore the circuit to the
original position after automatic operation.
Example – Type DR-7035-153L: circuit will
open automatically on a temperature rise
to the temperature indicated by the pointer
on the scale – no matter how much the temperature drops, the circuit will
not reclose until the reset button is operated.
Suffix -L denotes control will operate automatically on an increase.
Suffix -U denotes control will operate automatically on a decrease.
IN-526-N 8/30/05 2:06 PM Page 3
OPERATING RANGES/SERIES D-7000

With Snap-Action Contacts Types: DA-7035, DA-7235-153 & DA-7235-804 301 of 761
Adjustable Deadband Adjustable Deadband Fixed Deadband Bulb Furnished With 6˝
DS-7235-804 Capillary Unless
DS-7035-153 DS-7235-153 Otherwise Specified (1)
(2) SPDT
Adjustable Max. Process Bulb Min.
Operating Range Temp. Not To Minimum Fixed Fixed Insertion
Range No. Exceed Deadband Deadband Deadband Bulb No./Cap. Mat’l. Depth (2)
-60 to 30°F (-50 to 0°C) 1N 150°F (65°C) 23°F (13°C) 5°F (3°C) 5°F (3°C) No. 2 SS/Copper 2-7/8˝ (73 mm)
0 to 100°F (-18 to 40°C) 3N 240°F (115°C) 25°F (14°C) 5°F (3°C) 5°F (3°C) No. 2 SS/Copper 2-7/8˝ (73 mm)
50 to 150°F (10 to 65°C) 4N 250°F (120°C) 25°F (14°C) 5°F (3°C) 5°F (3°C) No. 2 SS/Copper 2-7/8˝ (73 mm)
140 to 300°F (60 to 150°C) 7N 500°F (260°C) 41°F (23°C) 8°F (4.5°C) 8°F (4.5°C) No. 2 SS/Copper 2-7/8˝ (73 mm)
250 to 415°F (120 to 215°C) 8N 550°F (290°C) 42°F (23°C) 9°F (5°C) 9°F (5°C) No. 2 SS/SS 2-7/8˝ (73 mm)
ELECTRICAL RATINGS See Code D See Code E See Code G
(1) All bulbs, including those with a copper capillary, are made or Type 304 Stainless Steel Repeatability: ±1% of full scale.
(2) Insertion depth may be increased through use of bulb supports or wells.
AC Capacity DC Resistive Horsepower
Circuit Circuit
Suffix No. Switch Action Code Suffix No. 120V 240V 440V 120V 240V AC DC
-153 SPDT one circuit OPENS as other CLOSES D -153 15A 15A 15@480V 1/2A 1/4A 1/8 NA
-804 Two SPDT operate simultaneously in one direction upon increase E -153 15A 15A NA NA
(or decrease when specified) G -804 5A 5A NA NA NA
1/4 HP at 120V AC, 1/2 HP at 240V AC.
DC rated controls (up to 10A), consult factory.
5A, 30V DC resistive.
GENERAL BULB INFORMATION
All bulbs are made of 304 stainless steel; capillary material is either copper or 316 stainless steel, as shown in the range table. The maximum pressure of bulbs
with a process connection is 300 psi. Other bulbs are for non-pressurized (e.g., open tank) use only. Consult the factory for higher pressure applications.
RANGE TABLE – NO. 2 BULB
Standard 11/16˝ Diameter Series D Bulb & 3/4˝ NPT Connection Optional 11/16˝ Bulb & 1/2˝ NPT Connection
Range Numbers Range Numbers
Bulb (1)/
6 ft. Cap. 1N, 3N, 4N, 1N, 3N, 4N,
Tubing 5N, 7N, 10N 8N, 11N 9N 5N, 7N, 10N 8N, 11N 9N
SS Bulb/ E=2-7/8˝ N.A. N.A. E=3-1/2˝ N.A. N.A.
Copper B=2-7/8˝ Optional B=2-7/8˝
Capillary Standard 11/16˝ Bulb
with
SS Bulb/ E=2-7/8˝ E=2-7/8˝ E=4-7/8˝ 1/2˝ NPT E=3-1/2˝ E=3-1/2˝ E=5-1/2˝
SS Cap. B=2-7/8˝ B=2-7/8˝ B=4-7/8˝ Process B=2-7/8˝ B=2-7/8˝ B=4-7/8˝
Option Standard Standard Conn.

Optional 1/2˝ & 3/8˝ Diameter Bulbs with 3/4˝ NPT Connection Optional 1/2˝ Bulb & 3/8˝ Bulbs with 1/2˝ NPT Connection
Bulb (1)/ Range Numbers Range Numbers
6 ft. Cap. 1N, 3N, 4N, 8N, 11N 9N 1N, 3N, 4N, 8N, 11N 9N
Tubing 5N, 7N, 10N 5N, 7N, 10N
SS Bulb/ E=5-3/4˝ N.A. N.A. Optional E=6-3/8˝ N.A. N.A.
Optional 1/2˝ Diameter Bulb Copper B=5-3/4˝ B=5-3/4˝
with 3/4˝ NPT 1/2˝ Bulb
Process Connection SS Bulb/ E=5-3/4˝ E=5-3/4˝ E=10˝ with E=6-3/8˝ E=6-3/8˝ E=10-5/8˝
SS Cap. B=5-3/4˝ B=5-3/4˝ B=10˝ 1/2˝ NPT B=5-3/4˝ B=5-3/4˝ B=10˝
SS Bulb/ E=11-3/8˝ N.A. N.A. Optional E=11-3/8˝ N.A. N.A.
Optional 3/8˝ Diameter Bulb Copper B=11-3/8˝ 3/8˝ Bulb B=11-3/8˝
with 3/4˝ NPT with
Process Connection SS Bulb/ E=11-3/8˝ E=11-3/8˝ E=19-7/8˝ E=11-3/8˝ E=11-3/8˝ E=19-7/8˝
SS Cap. B=11-3/8˝ B=11-3/8˝ B=19-7/8˝ 1/2˝ NPT B=11-3/8˝ B=11-3/8˝ B=19-7/8˝
11/16˝ Diameter Series D Bulb for Open Tank Use
Range Numbers NOTES:
Bulb (1)/
6 ft. Cap. 1N, 3N, 4N, Dim. “E” = MINIMUM INSERTION DEPTH
Tubing 8N, 11N 9N Minimum clearance distance for bulb insertion: measured from the top outside
5N, 7N, 10N surface of female NPT.
SS Bulb/ B=2-7/8˝ N.A. N.A.
Copper Dim. “B” = ACTIVE BULB LENGTH
Standard Length of bulb that responds to temperature change: measured from the free
SS Bulb/ B=2-7/8˝ B=4-7/8˝ end. Process fluid must have good contact with the bulb over this length.
B=2-7/8˝
SS Cap. Option Standard Standard
(1) All bulbs, including those with a copper capillary are made of Type 304 Stainless Steel
Well Pressure Ratings

Temp. Brass SS CAUTIONS
Protective Well Assemblies 70°F 1000 psi 2400 psi Control movement must not be oiled.
For Series D. No. 2 Bulb, (Standard 11/16˝ Diameter) (21°C) 6890 kPa 16500 kPa
Bulb Ass’y Well Dim. Well Ass’y # 200°F 900 psi 2250 psi Do not overload – note electrical rating on nameplate and be sure total current
Range E (Min.) C Brass S.S. (95°C) 6200 kPa 15500 kPa passing through switch is within specified rating.
1N, 3N, 4N, 2-7/8˝ 3-1/4˝ 300°F 500 psi 2150 psi
WARNING: A failure resulting in injury or damage may be caused by over-pres-
5N, 7N, 10N 73 mm 83 mm 49-543 49-251SS-1 (150°C) 3440 kPa 14800 kPa sures, excessive vibration or pressure pulsation, excessive temperature, corro-
2-7/8˝ 3-1/4˝ 400°F 160 psi - sion of pressure containing parts and movement assembly, electrical overload,
8N, 11N 73 mm 83 mm N/A 49-251SS-1 (205°C) 1100 kPa - or other misuse. Do not tamper with switch wires. Position of these wires is
4-7/8˝ 5-1/4˝ 550°F Do Not 2000 psi essential to proper operation. Tampering with these wires will void warranty.
9N 124 mm 134 mm N/A 49-253SS-1 (285°C) Use 13700 kPa
IN-526-N 8/30/05 2:06 PM Page 4
302 of 761
LOCKING DEVICE Explosion-Proof
When the control has been adjusted to desired range, the locking bar may Types DAH, DRH, DSH, DLH
be inserted between the adjustment screws with slot passing over the pro- Drawing No. 1350
jecting lug. By placing a sealing wire between the locking bar and the hole
in the lug protruding from adjustment assembly, adjustments cannot be
tampered with.
For DAH and DSH, sealing wire may pass through locking bar and hole in
hub above adjusting knobs.
DAW, DRW, DSW, adjusting knob cover may be sealed in place with seal-
ing wire through cover bolt hole.
CONTROL DIMENSIONS
Note: Dimensional drawings shown are for general reference only.
Comprehensive drawings are available from factory upon request.
General Purpose
Types DA, DS, DR, DL
Drawing No. 1000B
Explosion-Proof
Types DAE, DRE, DSE, DLE
Drawing No. 98D
Flange for Surface Mounting

Drawing No. 1000F
Weather-Proof
Types DAW, DSW, DRW, DLW
Drawing No. 1062
©Copyright 1997 Dwyer Instruments, Inc. Printed in U.S.A. 2/97 FR# 92-442122-00
MERCOID DIVISION Phone: 219/879-8000 www.dwyer-inst.com

DWYER INSTRUMENTS, INC. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
P.O. BOX 258 • MICHIGAN CITY, INDIANA 46361, U.S.A.
303 of 761
3.11 Autoflame
2121 E. 9th Ave., Winfield KS 67156 USA
www.autoflame.com
304 of 761
M.M./E.G.A. Technical Manual

Mk6 (Mk7) Mini Mk6 Mini Mk5
Evolution Evolution
MM60001/E MMM60016 MMM5002/E
Issued by:
AUTOFLAME ENGINEERING LIMITED
Unit 19, Bellingham Trading Estate
Franthorne Way, Bellingham
London SE6 3BX
Tel. +44 (0)20 8695 2000

Fax. +44 (0)20 8695 2010
Email: sales@autoflame.com
Website: http://www.autoflame.com/
Registered Holder:
Company:
Department:
This manual and all the information contained herein is copyright of Autoflame Engineering Limited.
It may not be copied in the whole or part without the consent of the Managing Director.
Autoflame Engineering'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 press.
Issue: 1.1.2007 Autoflame Technical Manual Section 0

305 of 761
M.M./E.G.A. Technical Manual INDEX
Overview and Introduction to the Features and Benefits of the
M.M./E.G.A. System. 1
M.M. Micro Modulation Fuel Air Ratio Control, Control

Box Functions & P.I.D. Load Controller.
2
E.G.A. Exhaust Gas Analysis Trim System CO2 + CO + O2

+ Flue Temp. + Eff. Monitoring NO & SO2.
2
3
Intelligent Boiler Sequencing

I.B.S. Lead Lag Selection. 4
W.L. Water Level Control, First Out Annunciation,

Bottom Blowdown and TDS Management
5
D.T.I. Data Transfer Interface Remote Control, Monitoring

and Data Acquisition from Total System.
6
Application Possibilities for the M.M. E.G.A. System. 7
Ancillary & Peripheral Equipment for the M.M. E.G.A. System,

8
Oil & Gas Valves, Positioning Motors, Load Detectors.
Miscellaneous Component Information: Parts List. 9
Appendix: Approvals, Compatibility, Warranty, 10

Terms and Conditions etc.

306 of 761
M.M./E.G.A. Technical Manual Introduction
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, commis-
sioned 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.
If in doubt regarding any technical aspect of the system contact your authorised dealer or the Autoflame
Technical Sales Department. Either of the above will be pleased to give advice and Technical
Information.

307 of 761
Section 1: Overview and Introduction of M.M. E.G.A. System
1.1 Schematic of M.M./E.G.A. System Capabilities and Inter-

Relationship of Software Modules
1.2 Schematic Illustrating Burner Combination Possibilities
1.3 Schematic Illustrating Typical System Application
1.4 Burner Management Systems Comparison
1.5 Overview of Micro Modulation System
1.6 Overview of Exhaust Gas Analysis
1.7 Overview of Intelligent Boiler Sequencing
1.8 Overview of the Data Transfer Interface
1.9 Overview of the Additional Modules
1.10 Overview of P.C. Compatibility
1.11 Overview of the Analogue Output Unit
Issue: 1.1.2007 Autoflame Technical Manual Section 1: Index

D.T.I. PC WITH
Analog MONITORING
I.O. SOFTWARE
Digital DATA TRANSFER
MODULE INTERFACE
Input/Output Module I.O.
6 in/6 out x 4-20mA. REMOTE MONITORING & TELECOM
MODULE MODEM
NETWORK
Issue: 1.1.2007
CONTROL VIA D.T.I.
Input/Output Module
ALTER SETPOINTS, TURN
8 x Volt Free Contacts
E.C. BURNERS ON OR OFF.
16 x Line Inputs
VIEW & HARD COPY OF
ERROR CHECKING CLIENT'S
I.B.S. ALL SYSTEM DATA.
DIAGNOSTIC SOFTWARE B.M.S.
INTELLIGENT BOILER TO INTENSIVELY INTERROGATE
SEQUENCING TOTAL SYSTEM.
SHOWS ERROR CODE FOR
Lead/Lag COMPONENT OR DATA
STORAGE FAILURE.
HOT WATER-STEAM TIME/DATE/STATUS.
LEAD/LAG LOAD
DISTRIBUTION
M.M. E.G.A.
Micro Modulation EXHAUST GAS ANALYSER
3 PARAMETER TRIM CO, CO & O
² ²
FUEL AIR RATIO CONTROL EFFICIENCY&EXHAUSTTEMPERATURE
P.I.D. LOAD CONTROL
CONTROLS 3/4 POSITIONING MOTORS OPTION ANALYSIS FOR NO & SO
²
SOFTWARE FOR TEMPERATURE OR PRESSURE
INTERNAL FLAME SAFEGUARD DISPLAYS ALL OF ABOVE
TWIN BURNER CAPABILITY AS STANDARD "COMMISSIONED"&"ON-LINE"VALUES.
VARIOUS LOAD DETECTORS AVAILABLE
DISPLAYS CHANNEL POSITIONS 6 OPTIONAL OUTPUT
REQUIRED SETPOINT & ACTUAL SIGNALS4-20mA.
LIMITS
Autoflame Technical Manual

CO, CO², O²,
NO & EXH TEMP
USER SELECTABLE
UPPER & LOWER LIMITS O2, CO2, CO
ABSOLUTE LIMITS
F.F.M. ALARM ONLY/BURNER SHUTDOWN
I.I.S. W.L.
FUEL FLOW
MEASUREMENT SPLITTER MODULE
WATER LEVEL CONTROL
INSTANTANEOUS & FOR EXISTING O2 TRIM
Section
TOTALIZED VALUES MODULATING FEEDWATER VALVE
P.C.C. PUMP ON/OFF
STEAM FLOW METERING
DOWNLOAD ALL
COMMISSIONING DATA FIRST OUT ANNUNCIATION
FROM M.M. MODULE. SURFACE BLOWDOWN/T.D.S.
308 of 761
SET UP AND CALIBRATE E.G.A. BOTTOM BLOWDOWN
1.1.1
VIA RS232 SERIAL PORT.
INTER RELATIONSHIP OF SOFTWARE MODULES.
SCHEMATIC OF M.M. E.G.A. SYSTEM CAPABILITIES &
LOG RUNNING
309 of 761
Overview - Features and Benefits of the Autoflame Micro

Modulation and Exhaust Gas Analysis Trim Systems
M.M. Micro Modulation/Flame Safeguard

* Fuel/air ratio control
* Control up to 4 positioning motors and 2 variable speed drives (VSD/

VFD)- 6 channels
* 4 independent fuel programs
* Fully adjustable P.I.D. load control for temperature and pressure
* External voltage/current load control and setpoint adjustment
* Various boiler load detectors available
* Twin burner capability
* Fully compatible with control frequency drives
* Fuel flow metering software
* Internal flame safeguard- full flame supervision with UV self check
* Gas valve train leak supervision and gas pressure monitoring
* Air windbox pressure proving and monitoring
E.G.A. Exhaust Gas Analysis

* 3 parameter Trim of O², CO² and CO
* Displays O², CO², CO Efficiency, Delta T and exhaust gas temperature
* NO, SO² (or NO²) monitoring
* Local display for re-calibration, changing cells, user configuration and

stand-alone operation
* Upper/lower/absolute limits for O², CO², CO, NO and exhaust

temperature
* Six 4-20mA output signals to interface with other controls/chart recorders
Issue: 1.1.2007 Autoflame Technical Manual Section 1.1.2

310 of 761
I.B.S. Intelligent Boiler Sequencing (Lead/Lag control)

* System will Sequence hot water boilers and steam boilers via lead/lag
load distribution
* Fully adjustable via user option with the system to enable the control to
be tailored to the application
* System control for isolation of valves or pumps
* Phantom setpoint and standby warming for lag boilers via a timing
sequence and pressure offset or aquastat
D.T.I. Data Transfer Interface
* System will collect operational data for up to 10 M.M. modules on one

site, transmit via RS232 data link to a local PC running winPCDTI or
Building Management System (B.M.S.)
* Modem compatibility software to give information and control of boiler

house operation remotely
* MODBUS and Johnson's Metasys compatible
W.L. Water Level Control
* Fully modulating water level control including all safeties, 2nd low, 1st
low, 1st low pre-alarm, high water pre-alarm, high water
* 15 First Out Annunciation inputs
* Automatic bottom blowdown
* Surface blowdown management (TDS- total dissolved solids)
* Steam flow metering
I.I.F. O² Interface Module, Splitter Module
* Interface with existing on-line O² analysers via 4-20mA
* Split one E.G.A. signal for two M.M.s for use on common or twin furnace
boilers
P.C.C. Personal Computer Compatible
* Down load all commissioning data from M.M. module
* Set up and calibrate E.G.A. via RS232 serial por

311 of 761
I/O Digital & Analogue Input/Output Units
* These units can be configured to give inputs and outputs for the DTI
system
* Analog modules have six 4-20mA inputs and outputs
* Digital modules have 16 line voltage inputs and 8 volt free contacts
* All inputs/outputs can be labelled for the specific application and set
for alarm or monitor only status

312 of 761
winPCDTI
USER INTERFACES
MODBUS/Metasys compatible
Modem
LEAD BOILER
SELECT SWITCH
1 AMP
LIVE SUPPLY
GUN TYPE BURNER
DUAL FUEL
GUN TYPE BURNER

DUAL FUEL
ROTARY INDUSTRIAL
BURNER DUAL FUEL

313 of 761

314 of 761
M.M./E.G.A. Technical Manual Burner Management Systems Comparison
Mk6 Mini Mk6 Mini Mk5 EVO

Micro Modulation Fuel/Air Ratio Control
Servo channels 4 3 or 4 3
VSD channels 2 0 or 1 0
Fuel profiles 4 4 2
Selectable trim channel (Damper or VSD)
Error diagnostics displayed
Single point change
User defined optimum ignition
FGR management
Exhaust Gas Analyser (requires EGA)
CO2, O2, CO trim
CO2, O2, CO, NO, SO2 displayed
Exhaust temperature and combustion efficiency displayed
User definable limits to CO2, O2, CO
Burner Control
User configurable timings
Internal flame safeguard controller for UV
Gas valve proving system -
Air wind-box pressure proving -
Gas pressure supervision -
Air pressure supervision -
Oil pressure supervision -
Lockout history
Setpoint Control
Internal 3 term PID load control to required setpoint
Software adjustable thermostat/pressure-stat
Second setpoint selectable -
Outside temperature compensation - -
Night setback facility - -
Further Features
IBS hot water
IBS steam
IBS low pressure steam -
Fuel flow metering - instantaneous
Fuel flow metering - totalised
Hand/Auto/Low flame hold
Input for external load control 4-20mA/0-10V 4-20mA/0-10V 0-10V
Output of firing rate 4-20mA/0-10V - -
Twin burner capability -
User Features
Password protected configurable options and parameters
Infrared communications port
Systems data export via DTI
Internal calendar clock display and logging
Proximity sensor screen saver - -
LCD Display 1/4 VGA 20x4 line 20x4 line
Mk6 MM Mini Mk6 MM Mini Mk5 EVO MM

315 of 761
M.M./E.G.A. Technical Manual Overview: M.M.
MICRO MODULATION (M M)
Overview of System Operation: Features and Benefits
To ensure maximum efficiency in the operation of any boiler, two requirements are of paramount
importance, the first being that the air to fuel ratio is kept to the minimum to ensure complete
combustion within the limitations of the combustion head design and that these settings once arrived
at are infinately repeatable to an incredibly high degree of accuracy. The second requirement should
be that the target temperature or pressure of the boiler is monitored by the combustion system and
that at all times exactly the right amount of fuel and air is fire to achieve the target value and that
at no time irrespective of load change is this target exceeded or fallen short of.
The inherent hysterisis of all mechanical systems that have traditionally involved cams and linkages
to characterise the fuel air ratio have made this sort of accuracy impossible. The accuracy of response
of fuel input to the monitored target temperature/pressure of the boiler has meant that the target
value set by the operator has at most times been exceeded or fallen short of.
The Micro Modulation system provides an easily programmable and flexible means of optimising
combustion quality throughout the load requirement range of the boiler/burner unit whilst ensuring
the temperature is accurate to within 1 deg C (2 deg. F.) and pressure to within 1.5 p.s.i. The maximum
error in degrees angular rotation between the two servo motors at any position in the load range is 0.1
degrees.
At the heart of the system is the control module which contains the micro computer and power supply.
The display panel features touch sensitive key pad entry data, readouts and status indicators, all
protected beneath a tamper-proof transparent plastic cover. The M.M. system shows angular position
of air damper motor and fuel valve. “Required” and “Actual” temperatures are displayed.
Interfaced with the control module by means of high speed solid state switching are up to three dual
wound servo motors. One motor is responsible for positioning the air damper and the other operates
a fuel valve by which it is possible to meter the input of gas, oil, or dual fuel.
The position of each servo motor is monitored by a voltage dividing system enabling digitalised
position information to be encoded into the control modules memory. The relative positions of the
air and fuel motors are constantly checked by the system at the rate of 50 times per second.
This new system of burner control achieves ‘Locked On’ near stoichiometric air fuel mixing throughout
the fuel input range of the boiler while maintaining exact temperature or pressure target values.
The load control incorporates user variable P.I.D. values.
Operating in conjunction with the above control specification is a full three term infinitely adjustable
P.I.D. load control package. This ensures that the control of set point temperature is accurate to within
1 deg C (2 deg F.) and pressure to within 0.1 bar (1.5 P.S.I.) Software for temperature or pressure is a
user variable option, also various ranges of temperature and pressure are selectable by the user.

316 of 761
M.M./E.G.A. Technical Manual Overview: M.M.
The Micro Modulation (M.M.) module is the basic building block of the M.M./E.G.A. system. A
complete system based on the Mk6 MM incorporates all of the following control facilities and features:
· 6 channel: 4 positioning motors and 2 Variable Speed Drive interfaces.

· 4 separate fuel profiles
· Full flame supervision control with UV self check- system meets self check criteria on all outputs
· A lockout history of the last 16 incidents held in memory. Time, date, function, re-set
· Single point change capability
· IBS steam sequencing with lead/lag
· IBS heating boiler sequencing- lead/lag- control of return line 2 port valve
· Gas valve train leak proving system
· Gas pressure monitoring and display
· High and Low gas pressure supervision
· Oil pressure high/low limits
· Oil pressure monitoring & display
· User definable optimum ignition position selection- golden start
- User definable flue gas recirculation ignition position selection
· Variable modulation speed (motor travel time user variable)
· Selectable trim channel
· Burner control selectable operation- first/second safety times
· Air wind box pressure proving- display & supervision
· Internal PID 3 term load control- temperature & pressure
· Outside temperature compensation of boiler set point, user adjustable with night seback facility
· Fuel flow metering- instantaneous and totalised readings- user defined units of measurement
· Exhaust temperature and ambient temperature net and absolute readings displayed
· 3 parameter trim- CO2, O2 & CO
· Combustion efficiency calculation- net or gross displayed
· NO and SO2 monitoring & display
· User definable combustion limits on all CO2, O2 & CO values
· Second set point user selectable
· Internal calendar clock display and logging functions
· Software adjustable thermostat/pressure stat. facility
· Hand/Auto/Low flame hold facilities
· Password protection of all safety related options and parameters
· Infrared Coms port for upload and download of commissioned data and lockout history
· Twin burner control capability
· 4-20mA/0-10V input for external load control of firing rate
· 4-20mA/0-10V output confirming firing rate position
· Changeover of fuels without shutdown (Special PROM)
· Quarter VGA screen with dynamic display capabilities and IR proximity screen saver
· 110 or 230 volt standard operation
· Panel facing mounting

317 of 761
MK6 EVOLUTION BURNER MANAGEMENT SYSTEM
EXTERNAL VARIABLE
Issue: 1.1.2007
LOAD OR SPEED DRIVE
FLUE
SENSOR
CH.6
GAS
GAS VALVE PROVING SAMPLING
PRESSURE HIGH/LOW GAS CAPACITANCE PROBE
SENSOR PRESSURE PROVING PROBES
STEAM TEMP.
OIL SENSOR SENSOR
PRESSURE
SENSOR
OIL T.D.S.
PROBE
AIR CH.1
PRESSURE FUEL
SENSOR SERVO
FEEDWATER TEMP. SURFACE

SERVO SENSOR BLOWDOWN
U.V
CH.4 CH.2 CH.3
AUX. AIR AUX. FEEDWATER
FORCED BOILER VALVE
SERVO SERVO SERVO
DRAFT

EXTERNAL
OR FLAME BOTTOM
VARIABLE
SWITCH BLOWDOWN
SPEED
CH.5 DRIVE
Section
1.5.3
EXTERNAL MODULATION
OUTSIDE SECOND SETPOINT FACILIT
TEMP. SENSOR
318 of 761
M.M./E.G.A. Technical Manual Overview: E.G.A.
EXHAUST GAS ANALYSIS (E.G.A.) TRIM SYSTEM
Overview of E.G.A. System Operation
With the E.G.A. trim system it is possible to expand the M.M. so that it will measure and display O2, CO2,
CO and exhaust temperature, together with boiler efficiency: At the same time inflicting minute
corrections on the air damper position to ensure that the originally entered commissioning data is
adhered to, irrespective of variations in stack pressure or barometric conditions. As standard, outputs
are available which can be connected with appropriate interfacing to an energy management computer
to track and record the information that is generated by the E.G.A. system. To expand the M.M. system
to the above E.G.A. specification the additional sampling unit and exhaust gas sampling probe must be
purchased. The M.M./E.G.A. control form is P + I + D feed forward, and interpolates between all entered
data, it also carries error checking self diagnostic software for self identification of system component
or data handling failure.
The system trim function is achieved by every paired value for air and fuel having stored values for O2,
CO2 and CO at the commissioned value. Deviations from these ideal values are held, this data is
integrated and expressed as a degree angular value, so that an exact amount of air damper trim may
be inflicted at any time to return the system to it’s commissioned value at any load condition.
The E.G.A. can also be fitted with NO and SO2 sensors for monitoring.
All the information available on the E.G.A. can be accessed by one or all three of the following methods:
1. Displayed on the E.G.A. local display.

2. Displayed on the M.M. facia.
3. 6 channel 4-20mA output facility for the above values.
Options #1 and #3 enable the E.G.A. to be used as a Stand Alone on-line continuous monitoring system.
E.G.A. setup and calibration is carried out via the local display or by a PC using an RS232 serial port.

319 of 761
M.M./E.G.A. Technical Manual Overview: I.B.S.
INTELLIGENT BOILER SEQUENCING (I.B.S)
Overview of I.B.S. System Operation
The Intelligent Boiler Sequencing software, which is included in every M.M./E.G.A. module, further
extends the application possibilities of the system. The objective of this control form is to ensure that
the minimum number of boiler/burner units are in operation at any one time to satisfy the heat
requirement imposed upon the boiler plant, particularly in the case of multi boiler installations.
There are two variations of I.B.S. software that can be selected by the user via the Options procedure.
The first variation relates to heating boilers and the second variation to steam boilers.
Heating Boilers Sequential Control:
A maximum of ten M.M./E.G.A. modules may be interconnected by a two wire screened data cable:
(See interconnection drawing). Any string of modules interconnected as detailed can have one of it’s
number designated No. 1 or lead boiler. This identifying of “lead” boiler is achieved by either of the
following methods:
a) Connecting a mains voltage onto terminal No. 41.

b) Instructing the modules via the D.T.I. module (Data Transfer Interface) by software.
Once a “lead” boiler has been selected the system works in the following way:
Typically every five minutes the sequencing software in the lead boiler identifies it’s own firing rate by
looking at the position of the fuel valve in the load index and also the maximum heating capacity of the
No 1. “lead” boiler. This information would normally be entered when this boiler/burner unit is
commissioned. Having established percentage firing rate, and maximum heating capacity, the I.B.S.
software calculates the amount of heat being contributed to the system by this boiler. The I.B.S. software
in the “lead” M.M./E.G.A. module then contacts in turn each of the modules connected to this loop
and gathers similar information from each. The “lead” module’s I.B.S. software then calculates the
minimum number of boiler/burner units that need to be operational to satisfy the building load, imposed
upon the plant at that time, and switches the remainder off.
There is a terminal connection on the M.M./E.G.A. module for controlling a two port valve that would
normally be installed in the boiler’s return pipe connection to the common return header. This facility
ensures that boilers that are switched “off line” do not contribute return temperature water to the flow
header thereby diluting the flow temperature to the building: (See relevant data sheets and drawings
showing the control sequence detailed above).
Example:
There are four boilers interconnected as above, each with a heating capacity of 586kW(2MBtu.) In the
event of each boiler firing 440 kW (1.5MBtu) (3/4 of it’s maximum rate), the No. 1 lead boiler would
instruct the No. 4 boiler to shut down and boilers No.s 1, 2 and 3 would adjust their firing rate to
maximum.
In both cases the boilers are contributing 1758kW (6MBtu) to the system but, after intervention of the
I.B.S. sequencing software, three boilers only are carrying the load which is a more fuel efficient method
of operation.

320 of 761
M.M./E.G.A. Technical Manual Overview: I.B.S.
If the building load continued to decrease the three boilers would reach a point where they were each
firing 381kW (1.3MBtu) each. At this point the I.B.S. software would switch off the No. 3 boiler as two
boilers would be capable of generating the 1172kW (4MBtu) required. When the load on the system
increases, the reverse procedure applies, i.e. when, for example, two boilers are firing at near 100%
load and the setpoint temperature on either of the modules is not being achieved, the I.B.S. software
would switch on a third boiler to assist with the generation of the heat requirement. Any boiler can be
nominated “lead” boiler by the connection of an input to the appropriate terminal or by a software
instruction via the D.T.I.
Steam Boiler Sequential Control:
When the I.B.S. software control package is applied to steam boilers, it’s operation is exactly the same
as above but with the additional features and enhancements as explained in the following.
In the case of heating boilers only two states in the control form exist, either on or off. When steam boiler
variation of I.B.S. is optioned there are three states which are controlled sequentially. The first is “on-
line”, this is when the boiler is operating purely under the control of the M.M./E.G.A. module's internal
P.I.D. load controller.
The second state is “stand-by”: In this case the boiler is operated at a reduced pressure setpoint, e.g. if
the on-line boiler or boilers are set at a setpoint of 7 bar (100 p.s.i.) the stand-by boiler controls at a
setpoint of 5 bar (72 p.s.i.). In this way if the load increases the stand-by boiler can begin to contribute
steam quickly. The reduced setpoint is a user variable option in the same way as the normal control
pressure setpoint.
The third state is “off-line”, this is with the burner shut down and the boiler is cold. If the load on the boiler
house increases, this boiler would move into a “Stand By” condition.
Apart from the variations detailed above, the steam sequencing works in precisely the same way as the
heating boiler sequencing: The sequencing software package ensures that at all times the minimum
number of boilers are operational to satisfy the load imposed on the boiler house.

321 of 761
M.M./E.G.A. Technical Manual Overview: D.T.I.
REMOTE MONITORING AND CONTROL (D.T.I.)
Overview of Data Transfer Interface Operation
By means of our Data Transfer Interface (D.T.I.) module, all the operational data, stored within each
of up to ten M.M. modules, can be collected by the D.T.I. for transmission by direct RS232 data link
to a local terminal, screen and printer or Building Management System (B.M.S.). This facility can also
be achieved remotely via modem/telecom link up. This cost effective system more than meets the
requirements of today’s E.M.S. and B.M.S. systems in providing all the necessary operational and alarm
status and control of boiler plant to achieve its maximum energy efficient operation.
Up to a maximum of ten M.M. modules (one per burner) can be connected to one D.T.I. module by
means of a series RS485 data link. The information gathered by the D.T.I. from each M.M. module is
then available for transmission to the E.M.S. or B.M.S. via either an RS232 data link or modem/telecom
data link.
Remote on/off control of the burners can also be achieved as well as adjustment of the temperature or
pressure setpoints and selection of sequence lead boiler. To accommodate the status information from
other plant related equipment, the D.T.I. can handle upto 160 direct mains voltage inputs, 80 volt free
outputs, 60 4-20mA inputs and 60 4-20mA outputs. Typical remote E.M.S., B.M.S. information and
operational facilities that can be achieved are as follows, but are subject to the particular site and
management system requirements that are to be accommodated.
The capability exists within the standard D.T.I. software for the end user to label any mains voltage signal
input as an "Alarm" condition. When labelled as an "Alarm" condition the system can 'autodial' out onto
the general telephone network to a word pager and/or a remote office.
Possible Input/Output Values:
Values available from each MM :
Required boiler temperature (deg. C/F) or pressure (Bar/PSI).

Actual boiler temperature (deg. C/F) or pressure (Bar/PSI).
Burner on/off (internal stat on/off status).
Burner maximum firing rate.
Burner firing rate (%).
M.M. identification number.
Fuel selected.
Boiler control detector type (temperature/pressure).
Error conditions.
Auto/Hand/Low flame hold operation.
All MM channels (positioning motors and variable speed drives).
Number of hours run/start-ups for each fuel.
Instantaneous and totalised fuel flow metering.
Lockout/error status.
Online combustion air pressure.
Online fuel sensor pressure.
Data logging- online status, actual value, firing rate- stored in monthly accessible files.

322 of 761
M.M./E.G.A. Technical Manual Overview: D.T.I.
Values available from each MM : cont../...
Maximum set point accepted from DTI.

Minimum set point accepted from DTI.
Lead boiler status.
Burner firing status (off, firing, purge, ignition, pilot proving, main flame proving).
Sequencing optioned.
Sequence status (on, stand-by, warming, off).
Enabled/disabled status.
Additional information available if system has E.G.A.:
E.G.A. operation optioned.

Flue gas oxygen present value.
Flue gas carbon dioxide present value.
Flue gas carbon monoxide (unburnt combustibles) present value.
Flue gas nitrogen oxide present value.
Flue gas sulphur dioxide present value.
Flue gas exhaust temperature present value.
Ambient temperature present value.
Delta T present value (difference between exhaust temperature and ambient temperature).
Combustion efficiency present value.
Flue gas oxygen commission value.
Flue gas carbon dioxide commission value.
Flue gas carbon monoxide (unburnt combustibles) commission value.
Flue gas nitrogen oxide commission value.
Flue gas sulphur dioxide commission value.
Flue gas exhaust temperature commission value.
Ambient temperature commission value.
Delta T commission value (difference between exhaust temperature and ambient temperature).
Combustion efficiency commission value.
E.G.A. error conditions.
DTI control input values:
Change required set point- global and individual.

Select lead boiler.
Shuffle sequencing- change lead/lag order.
Boiler enable/disable.
Change load index/firing rate- global and individual.
Additional information available if system has Water Level controls:
Water level status- control point, high water, 1st low water, 2nd low water, pre-alarms.
Steam temperature, feedwater temperature, pump status and valve position.
Instantaneous and totalised steam flow metering.
Water level alarm status.
15 First Out annunciation input status.
T.D.S. (Total Dissolved Solids) target and measured values- surface blowdown.

323 of 761
M.M./E.G.A. Technical Manual Overview: Additional Modules
ADDITIONAL MODULES
1. O2 Interface.
Where an existing O2 measuring device is fitted the O2 interface module can receive a 4-20mA signal
from the O2 probe and a 0-10V signal from the thermocouple mounted in the stack for use by the M.M.
for one parameter O2 trim. Values for CO2, CO, Exhaust Gas Temperature and Efficiency will be
displayed as 0.
2. EGA Splitter.
On water tube or common furnace boilers it is possible to use one E.G.A. unit to sample the common
flue gases and split the signal for use by two M.M. modules. Trim is inflicted on both burners based on
the common products of combustion and will therefore not optimise the combustion performance of
each burner.

324 of 761
M.M./E.G.A. Technical Manual Overview: P.C.C.
1.10 P.C. COMPATIBILITY
M.M. Infrared Upload/Download
The Mk.6, mini Mk.6 and mini Mk.5 EVO M.M. units each contain an Infra Red Upload/Download
port which enables all the commissioning data from a single unit to be downloaded onto a PC using
Autoflame IR lead and software. Data can be stored on disk. Stored backup data can be uploaded in
to the M.M.
Information includes:
1. Site name, Engineer, Boiler Type, Data, Software revisions, M.M. identification number.
2. All channel positions entered during commissioning for each fuel.
3. E.G.A. values O2%, CO2%, COppm, NOppm, SO2ppm, Ambient Temperature, Exhaust
temperature, Delta T, Efficiency % for commissioned, and also autotrim values of O2,
CO2 and CO at each position.
4. All Option number setting, default- * indicates options changed.
5. All Parameter numbers, setting, default- * indicates Parameters changed.
6. Flow Metering - if entered.
7. Lockout/error history (last 16 events).
8. Water level commissioned data and set-up values.
9. First Out annunciation labels.
10. Bottom blowdown timings and surface blowdown settings.
which can then be used to generate a hard copy Commissioning Report and be stored on disk for
future reference.
E.G.A.
The E.G.A. is fitted with a local display. All set-up, configuration and calibration tasks (calibration
code and test gas calibration) can be carried out with the use of this display and facia buttons. Each
cell is provided with its own unique calibration number which alleviates the need for costly on site
calibration with test gas etc. It is also possible to use the RS232 serial port on the E.G.A. for connection
to a P.C. to carry out the above procedures.

325 of 761
M.M./E.G.A. Technical Manual Overview: A.O.U.
1.11 ANALOGUE INPUT/OUTPUT UNIT
This unit has 6 individually programmable outputs and 6 individually programmable inputs providing
a means of converting items of data within the M.M./E.G.A. system in 4-20mA signals.
The unit can be supplied with outputs readily configured or with the use of the DTI lead and Windows
Terminal mode software the outputs are user configurable.
The following functions are available for output data:-
Firing Rate - Percentage %

Actual - Temperature/Pressure, °C/°F or bar/psi.
Required - Temperature/Pressure, °C/°F or bar/psi.
NO - p.p.m.
CH1 - Angular Degrees of travel.
% O2 Flue - Percentage %
% CO2 Flue - Percentage %
CO Flue - p.p.m.
Exhaust Temp. - Degrees °C
Efficiency - Percentage %
Fuel Flow Rate - Units/Min.
MM Error - 4mA no error, 20mA error.
EGA Error - 4mA no error, 20mA error.
Additionally, the A I/O can be connected directly to a Mini Mk5. In this case, the A I/O uses terminals
48 and 49 of the M.M. therefore neither Sequencing nor the D.T.I. may be used with the A I/O.
Channel 1 input can be used as the Remote setpoint change.

Mk7
326 of 761
Micro Modulation
Section 2.17: Mk7 M.M. Micro Modulation
2.17.1 Mk.7 M.M. Control Unit
2.17.2 Commissioning and Setting Up Procedure

2.17.2.1 Introduction
2.17.2.2 Programming Fuel/Air Positions
2.17.2.3 Setting Positioning Motors
2.17.2.4 Setting Options
2.17.2.5 Setting Parameters
2.17.2.6 Valve Proving
2.17.2.6.1 Explanation
2.17.2.6.2 Gas Pressure Sensor
2.17.2.6.2.1 Oil Pressure Sensor
2.17.2.6.3 Commissioning Valve Proving
2.17.2.7 Air Pressure Proving
2.17.2.7.2 Air Pressure Sensor
2.17.2.7.3 Air Pressure Tapped Fitting
2.17.2.8 Outside Air Temperature Compensation
2.17.2.8.2 Outside Air Sensor
2.17.2.9 Electrical Specifications
2.17.2.9.1 Classifications
2.17.2.9.2 Fuse Ratings
2.17.2.9.3 Terminals Description
2.17.2.9.4 Cables
2.17.2.10 Variable Speed Drives
2.17.2.11 Installation Checks
2.17.3 Control Box Functions

2.17.3.1 Burner Control Sequence Diagrams
2.17.3.2 Self Check UV Scanner
2.17.3.3 Standard European UV Scanner - Side viewing
2.17.3.4 Standard North American UV Scanner - End viewing
2.17.3.5 Selection of UV Scanner Types
2.17.3.6 UV Self Adaptive Pulse Width Modulation
2.17.3.7 Standard IR Scanner
2.17.4 Error Checking, Self Diagnostic Fault Analysis, I.D. Codes

2.17.4.1 Key to Errors
2.17.4.2 Key to Lockouts
2.17.4.3 Troubleshooting
2.17.5 Interacting with the Mk7 Interface
Issue: 08.12.2009 Autoflame Technical Manual Section 2.17: Index

Mk7 Evolution
327 of 761
Micro Modulation
Sec tio n 2.17 : M k7 M .M . Mi cro Mo dula tio n
2.17.6 Electrical Schematics Showing all Terminal Interconnections

2.17.6.1 Mk.7 Connection Diagram
2.17.6.3 Boiler Steam Pressure Detector Connection Diagram
2.17.6.6 E.G.A. Mk.7 Interconnection Diagram
2.17.6.11 O2 Interface Interconnection Diagram
2.17.7 Twin Burner Operation

2.17.7.1 Operations/Guidelines
2.17.7.3 Interconnecting Wiring
2.17.8 Hand/Auto and Low Flame Hold Facilities
2.17.9 Fault Finding
2.17.10 Other Information and Illustrations

2.17.10.1 Mk.7 M.M. Front Facia Details
2.17.10.2 Mk.7 M.M. Enclosure Dimensions
2.17.10.3 IR Download Lead
2.17.10.4 Maintenance and Servicing
2.17.10.5 Installation Precautions
2.17.10.6 External Modulation
2.17.11 Fuel Flow Measurement and Metering operation
2.17.12 Golden Start choke operation
2.17.13 One Point Change Facility
2.17.14 Flue Gas Recirculation
2.17.15 Pause Facility
2.17.16 Time Clock Facility
2.17.18 Automatic Re-commission of air and gas sensors

2.17.18.1 Air sensor re-commission
2.17.18.2 Gas sensor re-commission
2.17.19 Flame Detection Using External Flame Switch
2.17.20 On-line Changes
Ñ
Issue: 08.12.2009 Autoflame Technical Manual Section 2.17: Index
Mk7 Evolution
328 of 761
Micro Modulation Introduction
2. 17.1 MK .7 EVOLUTION M.M. CONTROL UNIT
Issue: 08.12.2009 Autoflame Technical Manual Section 2.17.1.1

Mk7 Evolution
329 of 761
Micro Modulation Commissioning and Setting up Procedure: Introduction
2.17.2 MK.7 COMMISSIONING AND SETTING UP PROCEDURES
2.17.2.1 Introduction
Important Note: Prior to commissioning, the fuel and air servomotors must be calibrated to ensure
that the position of the valves and dampers are corresponding to the potentiometer feed-back signal as
displayed on the Mk7 screen/display, i.e. when the valve is fully closed, the Mk7 displays zero degrees.
The commissioning procedure as described must be strictly adhered to.

Anybody commissioning a Micro Modulation system must have an
adequate understanding of combustion plant. In the wrong hands
The fundamental idea of the system is to set a fuel valve position and then
set a corresponding air damper position. Care must be taken when
adjusting the fuel and air positions so as not to create any unstable or
hazardous combustion conditions, e.g. moving the fuel valve to the open
position without increasing the air damper position. Improper use may
result in property damage, serious physical injury or death.
If the system being commissioned is an M.M., without E.G.A., then a combustion monitor is required to
check the exhaust gases. If the system does have an E.G.A., then a combustion monitor should not be
necessary as the E.G.A. performs all normal exhaust gas measurements. When burning oil a smoke
detection device is necessary to check that the smoke generated is within limits.
Ideally to implement commissioning as quickly as possible arrange for a substantial load on the boiler.
The commissioning procedure can be interrupted due to excess temperature or pressure, causing the
burner is called back on the system starts up automatically and commissioning can proceed from where
and CH2 positions must always be less than the ones previously entered. However with CH3 - CH6 it
is possible to move the position above or below the previously entered point.
COMMISSIONING PROCEDURE (Systems without Exhaust Gas Analyser).
On a newly installed system the following procedures should be carried out as listed.
1. Check all interconnecting wiring between the M.M. and external components is correct.
2. Set options and parameters required (refer to sections 2.17.2.4 and 2.17.2.5).
3. Set up positioning motors.
4. Program fuel/air positions.
On a previously commissioned system, it is possible to omit steps #1, 2 or 3.
Issue: 08.12.2009 Autoflame Technical Manual Section 2.14.2.1.1

Mk7 Evolution
330 of 761
Micro Modulation Commissioning and Setting up Procedure: Introduction
Notes on Programming Fuel Air Positions
If during commissioning the burner turns off, due to the 'running interlock' opening or a lockout, it is
possible to carry on commissioning from the last entered position. This is possible as long as the HIGH
position has been entered, and the fuel selected is not changed. When the 'running interlock' is closed
again, or the lockout is cleared, the system will purge automatically. Commissioning will then be
resumed at Step 7. Automatically the system bypasses the HIGH position entry and resumes the
commissioning procedure from the last entered INTER position . Effectively commissioning can now be
carried on from Step 12.
If continues to flash when pressed, this indicates that the running interlock (terminal #53) is
not made, there is an E.G.A. error or the water level is not commissioned (if using the Autoflame water
level control). Please refer to the fault finding section 2.17.9.
During commissioning press to display the channel 1 to 6 values.
Press to display the fuel selected, actual value and required setpoint. (The required setpoint
will be displayed but cannot be adjusted during commissioning. During commissioning the internal stat
remains made all the time regardless of the actual value). Note: Ensure that the high limit stat is set
correctly and wired into the non-recycling interlock.
The OPEN and CLOSE are now stored during commissioning. This means if a lockout occurs upon the
first burner light off during commissioning there is now no need to re-enter the open and close positions.
The burner will restart once the lockout has been reset and go straight to purge, once purge is complete
you are asked to again set the start position. However, if power is completely removed from the system
then these positions are not retained in the memory and the open and close positions will need to be
reset.

Mk7 Evolution
331 of 761
Micro Modulation Commissioning and Setting up Procedure: Programming Fuel/Air Positions
2.17.2.2 Programming Fuel Air Positions (Systems without E.G.A. )
CH1, CH2 etc refers to the rows of buttons with CH1 at the top.
Note: Throughout the commissioning procedure the COM l.e.d. is illuminated.
1. Ensure 'stat' control circuit is closed (refer to 2.17.6.1), i.e. ensure that there is an input on
terminal #53.
2. Select fuel. CLOSE flashes. 'ENTER PASSWORD' is displayed.
Note : If fuel selected is being re-commissioned, press before COM l.e.d.

stops flashing (five seconds).
3. Enter Access Code. Adjust the numbers using the CH1 and CH2 buttons.
When numbers are set, press (CLOSE l.e.d. steady, ENTER flashes)
4. “SYSTEM ACTIVATE, WATER LEVEL CONFIGURE” is displayed.
On this password screen, it is necessary to set both CH1 and CH3. These are both set to #3 if the
Autoflame water level system is to be active. Alternatively, these are both set to #7 for Mk7 use
without the water level system. It is also necessary to set the CH5 value for First Out Annunciation.
Set this to #0 to disable the First Out Annunciation, #1 to display the First Out Annunciation (but
not to lock out) and to #2 to enable First Out Annunciation, i.e. burner locks out.
Then press .
5. The display indicates angular position of servo motors. After the internal checks are made (CLOSE
flashes). Press to start entering the close position.
Note : No error checking of the servomotors is enabled at this stage. Therefore, be careful
not to drive the servomotors/dampers beyond any mechanical limitations that may be
present on the damper/valve.
6. Use CH1 to CH4 (as optioned) buttons to set positioning motors to 0.0.
Press (OPEN flashes). The servomotor error checking is now enabled.
7. Press (OPEN steady, ENTER MEMORY flashes).
8. Use CH1 to CH4 buttons to set positioning motors to their fully open positions.

Mk7 Evolution
332 of 761
This is nominally 90.0 for gas butterfly valves and burner air dampers, but may be set to less
than 90.0 degrees if there are mechanical stops/limits.
Press (System purges, at end of purge START flashes).
9. Press (START steady, ENTER MEMORY flashes).
**WARNING** Do not enter START position before reducing fuel input. This
could result in a potentially dangerous situation, serious physical damage or
death.
10. Use CH1 to CH6 to set positioning motors to positions where ignition can
take place.
Note: Ensure that the main fuel valve is manually isolated until the pilot flame has been
successfully established. Once this has been successfully established, gradually
introduce the main fuel supply to the burner observing the flame stability.
Continue to introduce fuel until the main fuel valve is fully open providing safe
and stable combustion is maintained. If the combustion is not safe and stable then
adjust the fuel/air ratio accordingly.
11. P r e s s (burner ignites, HIGH flashes).
12. P r e s s (HIGH steady, ENTER MEMORY flashes).
13. Use CH1 to CH6 to set maximum firing input (it is not possible to exceed the OPEN
position values). Always increase the air first followed by the fuel angular positions.
14. P r e s s (INTER, or INTER and START flash).
Note: Only INTER flashes if the number of INTER positions entered so far is less than or equal
to three, thereafter INTER and START flash.
15. P r e s s or (INTER or START steady, ENTER MEMORY flashes).
16. Use CH1 to CH6 (as optioned) to reduce the positions. Always reduce the fuel
first followed by reducing the air angular position.
If present position is an INTER position, go back to 14, otherwise proceed further.

Mk7 Evolution
333 of 761
17. Press . At this point all commissioning data is permanently stored. (After a short
pause RUN flashes).
18. Press to set the system into normal modulating mode and to store the
commissioning program.
Note : If the burner has been previously commissioned then once RUN is pressed then
this will overwrite the previous data for the fuel selected. Failure to hit RUN will
result in the commissioning data not being stored within the unit. If this is done, a
loss of power will result in a loss of data for the fuel selected.

Mk7 Evolution
334 of 761
Micro Modulation Commissioning and Setting up Procedure: Setting Positioning Motors
Setting Positioning Motors
Autoflame supply three standard sizes of positioning motors - small, large and industrial. All can be used
for positioning fuel and air dampers.
Both types can be configured to drive clockwise or counter clockwise to open a valve or damper.
Layout of small positioning motor, refer to Section 2.17.2.3.4

Layout of large positioning motor, refer to Section 2.17.2.3.4
Layout of industrial positioning motor, refer to Section 8.10
Viewing the shaft end-on, from the potentiometer end, all positioning motors drive in a clockwise
direction if power is applied between the LIVE and CW terminals, and counter clockwise if the power
is applied between the LIVE and CCW terminal.
The operation of fuel valves and air dampers is often such that they open in a clockwise direction. If
the operation needs to be reversed, it is necessary to swop various wiring connections between the
M.M. and the positioning motor(s). An example of reversing the operation of a fuel valve is shown in
figure B, section 2.17.2.3.4. Figure A shows the connections for normal operation.
Set Up Procedure
Before a burner is fired it is essential to set up each Micro Modulation positioning motor.
A tamper proof screwdriver is required (these can be ordered from Autoflame).
Usually control valves/air dampers that the positioning motors drive, move through up to 90 degrees
angular. The M.M. system has the ability to drive valves through up to 96 degrees. Please contact
Autoflame technical department for advice on applications for ranges greater than 90 degrees.
All readings displayed on the M.M. are in degrees angular. It is necessary to adjust the potentiometer
in the positioning motor assembly so that the M.M. reads 0.0 when the relevant valve/damper is at its
fully closed position. The technician must physically check the mechanical position of the dampers and
valves. DO NOT ASSUME THEY HAVE BEEN PREVIOUSLY SET CORRECTLY.
To set up a positioning motor, first ensure option 12 is set to 0, (this prevents E.G.A. errors from allowing
continuation). Put the M.M. into the commissioning mode so that the CLOSE l.e.d. is steady and the
ENTER l.e.d. flashes (see section on commissioning). By doing this it is possible to position the valve/
damper mechanically by using the appropriate up and down buttons.
**WARNING** Electrical Connections are live/hot and mis-application may result in

serious physical injury or death.
Remove the positioning motor cover.

Mk7 Evolution
335 of 761
Micro Modulation Commissioning and Setting up Procedure: Setting Positioning Motors
For air positioning motor(s) carry out the following procedure:
Use the up/down buttons for the relevant air damper to position the air damper to its physically closed
position. Loosen the two tamper proof screws just sufficiently to enable the potentiometer to rotate.
Rotate the potentiometer clockwise or counter clockwise until the relevant display window reads 0.0.
Tighten the two tamper proof screws gently until the potentiometer is secure. Do not overtighten the
screws. Check that the display still reads 0.0. If not repeat the adjustment process.
For fuel positioning motor(s) carry out the following procedure:
On Autoflame gas, oil and gas/oil combination valves it is necessary to remove the positioning motor.
Manually position the oil/gas valve slot to its closed position. Observe the position of the drive pin on
the positioning motor. Use the relevant up/down buttons to position the pin so that when the positioning
motor is reassembled to the valve it is in line with the slot. Reassemble the positioning motor to the valve,
loosen the two tamper proof screws and proceed to adjust the potentiometer position until 0.0 is
displayed. Use the external position indicator to ensure the valve is in the fully closed position.
In applications where the servomotor is not positioned close to the display then it is possible to measure
the feedback voltage from the servomotor in order to ensure that 0.0 degrees is displayed. By testing
the DC voltage between the blue and green wires (wiper and 0V) on the servomotor low voltage
terminals this will read 0.21V DC when the reading on the display is 0.0 degrees.

Mk7 Evolution
336 of 761
Micro Modulation
Important Note for Autoflame valves:
On threaded valves, the pin on the top of the valve is 90 degrees opposite from the position of the
butterfly valve.
On flanged valves, the pin on the top of the valve is in line with the position of the butterfly valve.
For both valves the external visual position indicator is in line with the position of the butterfly valve.
Regardless of the type of valve being used, the servomotor is dispatched from the factory with the
potentiometer in the zero position. The same servomotor will be correct for both types of valve, as the
servomotor for the threaded valve is mounted at 90 degrees different from the flanged valve.

Mk7 Evolution
337 of 761
Micro Modulation Commissioning Procedure: Positioning Motors
Small Positioning Motor
POTENTIOMETER
ADJUSTING CLIPS
POSITIONING MOTOR
TAMPER PROOF SCREWS
FIXING HOLES 5mm (7/32") DIA.
P.C.B./2 FIXING POINTS M3
POTENTIOMETER
W
-
L CW CCW
+
CCW CW L + W -
M4 EARTH STUD
Large Positioning Motor

M4 EARTH STUD
- +
W L CW CCW
- +
W L CW CCW
POTENTIOMETER
ADJUSTING CLIPS
POSITIONING MOTOR TAMPER PROOF SCREWS

POTENTIOMETER
The servomotors shown are 230V in which the low voltage cables and mains voltage cables must enter
the servomotor through separate glands. For the 24V servomotors only one gland is required for both
the low voltage cables and mains voltage cables.

Mk7 Evolution
338 of 761
Micro Modulation
Positioning Motors Direction Change

Mk7 Evolution
339 of 761
Micro Modulation
Replacing the servomotor, servicing the servomotor and the importance of using the
servomotors within the specified torque range.
Replacement:
Anytime that a servomotor is changed in the field it is important to verify that the physical position of
the fuel valve, air damper, FGR valve or other damper is correct in accordance with the potentiometer
feed back as displayed on the Autoflame controller. When the valve is completely closed as indicated
on the valve/damper then the potentiometer reads zero angular degrees on the M.M. display. It must
not be assumed that the original commissioning engineer has the servomotor set in the correct position.
N ote: Once the servomotor has been changed it is imperative to check the combustion performance
throughout the firing range in a safe and reliable manner, based on the original data. If the combustion
performance is different then either a re-commission is required or single point change of the fuel/air
ratio.
Servicing:
It is good practice to periodically (minimum once a year) check the equipment and most notably the
following for the servomotors:
1- Overall mechanical soundness, i.e. look for corrosion or mechanical damage.

2- Coupling and associated linkage is tight.
3- Any associated set screws and fixings are secure.
4- Mechanical pins, i.e. roll pins/split pins do not show any signs of corrosion and do not show
indication of fatigue.
5- When the burner is off and the power has been securely isolated, remove the servomotor from the
damper/valve, and ensure that the damper/valve does not require excessive torque to operate. Make
sure that the servomotor is working within its recommended torque rating.
6- Do not stand on the servomotors as this may cause internal damage to the PCB potentiometer leading
to a system failure.
7- Do not remove the PCB inside the servomotor as this will affect the integrity of the repeatability and
void any warranty that may apply.
Servomotor torque ratings:
It is important that the servomotors are not used outside of their specified operating range.
Servomotor Part Number Rating
Small servomotor (MM10005) 0.89 ftlbs (1.2Nm)

Large servomotor (MM10004) 11 ftlbs (15Nm)
Industrial servomotor 5 (MM10070) 37 ftlbs (40Nm)

Mk7 Evolution
340 of 761
Micro Modulation Commissioning and Setting up Procedure: Options
2.17.2.4 Options
Important Note: The options and parameters must only be changed by factory trained
and certified technicians who have a thorough appreciation of the Autame combustion
systems and the combustion process in general. Anyone changing the options and
parameters who does not have the correct factory training and understanding of these
settings/adjustments may place themselves and others in a potentially dangerous
situation.
If in doubt contact Autoflame technical support directly through - sales@autoflame.com
Note: -CH1, CH2, CH3 refer to the rows of buttons respectively

starting with CH1 at the top.
-Options and Online Options are different. The following instructions refer
to Options (accessible only whilst in COM mode).
Option values can be changed by entering the option mode. The password must first be entered.
To enter the password follow the steps listed:
Either deselect and then select fuel or power down and then up.
If system is already commissioned, press when the system starts up.

If system is not already commissioned, commissioning mode will be set automatically.
“ENTER PASSWORD” is displayed.
Use the CH1 and CH2 to set the password codes. Then press to accept.
“SYSTEM ACTIVATE, WATER LEVEL CONFIGURE” is displayed.

On this password screen, it is necessary to set both CH1 and CH3. These are both set to 3 if the
Autoflame water level system is to be active. Alternatively, these are both set to 7 for Mk7 use without
the water level system. It is no longer necessary to set a value for First Out Annunciation.
Now press .
At this point, if a water level board is present press to access the MM commissioning
(thusly allowing for MM options to be accessed).
To enter the ‘SET OPTIONS’ screen, two methods are available:
1. Press (this allows the selection of multiple buttons at once). Now press CH1
buttons followed by button.
2. Alternatively, press the button.
To change the parameter number use the CH2 buttons.

To change the value use the CH3 buttons.
Any number of option values can be changed when in option mode.
When changes have been completed press .
All newly entered option values are now permanently stored.

Mk7 Evolution
341 of 761
ting
o. et lue n
N S Va tio
n ry n i p
t io cto tio scr
p
O Fa O p De
1. 3 Boiler temperature/pressure sensor type:
3 Temperature sensor (MM10006 & 7) 20-390 C (50 - 730 F)

4 Unused
5 Unused
6 Medium pressure sensor (MM10008) 2.0 - 23.0 bar (30 - 330 PSI)
7 High pressure sensor (MM10009) 2.0 - 38.0 bar (30 - 550 PSI)
8 Low pressure sensor (MM10010) 0.2 - 3.80 bar (1.5 - 55 PSI)
9 Unused
10 External temperature sensor (voltage input)- range set by parameters #52-56
11 External pressure sensor (voltage input)- range set by parameters #52-56
2. 60 Motor travel speed during modulation: The value is not specific to a time/
distance ratio. If the speed of the motor is too fast then increase this value. If too
slow, decrease the value. At times other than modulation the motors move at full
speed or at the value set in option #75. Movement is limited by the slowest
channel, i.e. slowest moving motor.
5-240 Adjustment Range 5 = 43 seconds from 00 to 900

60 = 120 seconds from 00 to 900
240 = 390 seconds from 00 to 900
3. 0 Unused :
4. 0 Unused :
5. 1 Purge position : This selects the purge position. (Applicable to channels 1-4
when selected; see options #67-70). VSD channels 5 & 6, if optioned, purge at
open position regardless of this option setting. It also applies to post purge if
option #118 is set to a value greater than 0.
0 Selected channels purge at HIGH position (high fire position)

1 Selected channels purge at OPEN position (full span of servomotor as entered
during commissioning)

Mk7 Evolution
342 of 761
ting
o. et lue n
N S Va tio
n ry n i p
io ct
o io cr
pt pt De
s
O Fa O
6. 10 Proportional control (P) : This option sets the proportional band. This is the
offset point at which the burner will begin to change modulation.
Example of proportional band offset: Required setpoint = 100 C, Proportional

offset = 10 (i.e. option 6 set to value 10).
Proportional Offset
Maximum Flame
Minimum Flame
90 C 100 C
(202 F) (212 F)
Proportional ban d: Value entered- Centigrade, Fahrenheit, Bar or PSI dependent

on the type of control sensor used and display units selected- options #1 and #65.
5-250 If Centigrade, Fahrenheit or PSI units effective.

0.5-25.0 If Bar units effective.
Note : Decreasing this value could lead to overshooting of the required setpoint.
Increasing this value may cause the burner to modulate too early taking a longer
time to reach the required setpoint.
7. 60 Integral control (I) time : Every n seconds 10% of the present offset from
setpoint value is added or subtracted to the present proportional value. The value
of n is the number of seconds set in this option. It is possible to set this option to
'off'. If 'off' is selected there will be no integral control. Parameter #106 enables
a % variation.
OFF-250 Seconds.
Note : Integral is equivalent to 'Reset'.
8. 1 Number of servomotor channels to be enabled : Channel "1" is always

enabled (Fuel Position Motor). Set option #8 to the number of additional
channels required (Minimum of 1).
1 Channels 1 & 2 in use.

2 Channels 1, 2 & 3 in use.
3 Channels 1, 2, 3 & 4 in use.
Note: If option #8 is changed after commissioning then the M.M. unit will need
to be recommissioned unless this option is returned to its previous value.

Mk7 Evolution
343 of 761
. lue n
No Va p tio
n n ri
io tio sc
Opt Op D e
9. 1 Internal stat operation : The 'internal stat' serves the purpose of turning the
burner on and off according to the actual value relative to the required setpoint.
There are three settings for this option. The first keeps the 'internal stat' closed all
the time. In this instance, a 'working stat’ must be fitted to the boiler. The second
setting opens the 'internal stat' at an offset above the required setpoint and closes
it at an offset below the required setpoint. The third setting opens the 'internal stat'
at an offset above the required setpoint and closes it at an offset also above the
required setpoint. The following diagrams illustrate this operation. The offset
values are set in options #10 and #11.
0 Internal stat always closed.

1 Burner starts below required setpoint.
2 Burner starts above required setpoint.
Option #9 = 1, exampleusing 100 C (212 F). Required setpoint.
103 C Burner stops at this point and above

(215 F )
Offset = 3 (value set in option #10)
Required Value 100 C
(212 F )
97 C Burner starts at this point and below
(209 F )
Option #9 = 2, exampleusing 100 C (212 F). Required setpoint.
106 C Burner stops at this point and above

(218 F )
103 C Burner starts at this point and below
(215 F )
Required Value 100 C
(212 F )
10 . 3 Offset above required setpoint at which the burner is stopped:

(Only relevant if option #9 is set to 1 or 2).

11 . 3 Offset below/above required setpoint at which the burner is

start ed:
(Only relevant if option #9 is set to 1 or 2).


Mk7 Evolution
344 of 761
ting
o. et lue n
N S Va tio
n ry n i p
t io cto tio scr
p
O Fa O p De
12 . 0 E.G.A. options: If this option has a setting 1/2/3/4/5/6/8/9 then the E.G.A.
will trim and the burner must be commissioned with the E.G.A. operational. The
trim is applied to channel 2 or 5, dependent on the setting of option #76.
0 E.G.A. not optioned.

1 If an E.G.A. error occurs then the burner will continue to fire. The servomotors will
return to the original commissioned fuel/air ratio and the trim function will not be
operational until the E.G.A. error is reset. No combustion/single point changes
can be made whilst the E.G.A. is in an error condition. Terminal #79 is not
energised in the event of an E.G.A. error.
2 If an E.G.A. error occurs then the burner will stop firing. The burner will not start
until the E.G.A. error has been cleared and the E.G.A. is inside its operating
temperature range. Terminal #79 is not energised in the event of an E.G.A. error.
3 Same as 1, except terminal #79 is energised in the event of an E.G.A. error.
5 Same as 1, plus the combustion limits are also tested (options #19-27).
6 Same as 2, plus the combustion limits are also tested (options #19-27).
7 System commissioned on M.M. only- E.G.A. used only for monitoring and display
purposes.
Note: If the E.G.A. is removed for servicing or this option is set to 0 or

7, then any single point changes made during this time will result in
complete re-commissioning when this option is implemented again.
13 . 0 0-30 Reset options to original factory settings: To reset all of the options back
to their original factory set values, set option #13 to 26 and press enter.
14 . 0 Twin burner application: Twin burner operation enables two burners to run
at the same time and with the same firing rate. The identification numbers must be
set for each M.M. unit, e.g. 1 and 2 (see option #33).
0 Normal single burner operation.

1 Twin burner operation for twin furnace firetube applications- Both burners always
fire simultaneously. If one of the burners develops a fault, then both burners are
shut down. Only one load detector is required and this is connected to the odd
numbered M.M. unit.
2 Twin burner operation for common furnace watertube applications- Both burners
will fire simultaneously or independently. If both burners are firing then they will
synchronise together and fire at the same firing rate. If an error/lockout occurs
on one burner then the other burner will continue to fire independently. Two load
sensors are required (one for each M.M. unit).
Note : If communications are lost then a flashing error 100 will appear when
viewing the M.M. screen if option #14 is set to 1.

Mk7 Evolution
345 of 761
ting
o. et lue n
N S Va tio
n ry p
n ri
p t io cto
p tio esc
O Fa O D
15 . Unused :
16 . 0 Lead/lag (IBS) and D.T.I: A lead boiler can be selected by connecting line
voltage to terminal #88 on the appropriate M.M. Only 1 M.M. may be selected
as lead boiler at a time or the sequencing will not operate. The lead boiler can
be selected via the D.T.I. However, for this to be effective all the M.M. units on
the system must have terminal #88 volt free. Line voltage on terminal #88
overrides the D.T.I. command.
0 No sequencing. M.M. units still communicate and can be seen on the D.T.I.
1 Sequencing enabled- the M.M. unit will respond to sequencing commands.
2 Setpoint & enable/disable commands accepted from D.T.I.
3 Both of 1 & 2.
Note : Accurate fuel flow metering must be entered for sequencing to operate.
A RS485 data cable (BELDON9501) must be connected between each M.M. unit
(see section 6.11.1 for correct connection)
17 . 0 NO & CO displayed when running on oil: If fuels 2 or 3 are selected, then

the displaying of CO & NO can be on or off. This option is only relevant if an
E.G.A. is operational on the system. The pinch valve settings must also be
changed in the E.G.A. in order for CO & NO to be displayed.
0 NO & CO display blanked- not displayed.

1 NO & CO is displayed normally.
18 . 1 Carry forward of trim: When the system modulates, the correction that may
be existing on the air damper position can be carried forward. This option is only
relevant if an E.G.A. is operational on the system.
0 No carry forward of trim.

1 Trim carried forward.
19 . 0 Upper offset limit % O 2 :

E.G.A. limits: Options #19-27 are only relevant if an E.G.A. is operational on
the system. Option #12 must be set to 5/6/8 or 9 if any of the following limit
checks are to be invoked. This is an offset from the commissioned values.
0-10.0 % O2.
20 . 0 Upper offset limit % CO 2 :

0-10.0 % CO2
21 . 0 Upper offset limit ppm CO:

0-200 ppm CO

Mk7 Evolution
346 of 761
ti ng
o. et lue n
N S Va tio
n ry n i p
io ct
o io cr
pt pt De
s
O Fa O
22 . 0 Lower limit % O 2 :
0-10.0 % O2
23 . 0 Lower limit % CO 2 :
0-10.0 % CO2
24 . Unused :
25 . 0 Absolute value % O 2: System checks for O2 values lower than value specified
in this otion regardless of the commissioned values.
0-20.0 % O2
26 . 0 Absolute value % CO 2 : System checks for CO2 values higher than value
specified in this option regardless of the commissioned values.
0-20.0 % CO2
27 . 0 Absolute value ppm CO: System checks for CO readings higher than value
specified in this option regardless of the commissioned values.
0-200 ppm CO
28 . 2 0 Trim threshold: This option is only relevant if an E.G.A. is operational on the

system. The value set in this option is subtracted from the required setpoint. If the
actual value is below the offset then the E.G.A. will not operate. If the trim is to
be effective at all times then set the value to zero. This option must also be set to
zero for the E.G.A. to operate when external modulation is optioned.

0-5.0 If Bar units effective.
Note : No single point changes can be made if the actual value is below the offset
value.
29 . 1 Golden start: See section 2.17.12. Parameter #15- sets the time the golden start
is maintained from the ignition point.
0 Golden Start operates.

1 Golden Start does not operate.
30 . 5 0 D.T.I.- Required setpoint minimum limit: If the system is being used with a
D.T.I. a maximum and minimum limit for the required setpoint must be set. If a value
is received from the D.T.I, that is outside these limits, it will be ignored and the
system uses its previous required setpoint. Practical range is limited to range of
sensor selected.


Mk7 Evolution
347 of 761
ting
. S et e
o a lu io
n
N y V t
n r n ip
t io cto tio scr
a
Op F Op De
31 . 10 0 D.T.I.- Required setpoint maximum limit:

32 . 2 0 Trim delay: After ignition the E.G.A. does not sample for the period of time set
in this option (only relevant if E.G.A. is operational on system). This allows for
the combustion to stabilise before sampling commences. The timing starts at the
ignition point.
0-250 Period (seconds) after ignition no sampling takes place.
33 . 1 M.M. Identification: The identification number must be set on all M.M. units
in the boiler house. If not, then problems will occur with sequencing/twin burner
and with the D.T.I. communications. Each unit must have a different ID number.
1-10 Identification number.
34 . 5 Rating of burner:
1-999 See option #77 for units.
35 . 1 0 Sequence scan time: This is the time period that the M.M. controlling the lead/
lag (sequencing) requests information from the other M.M. units to check whether
load demand is satisfied.
1-100 Sequence Scan time (minutes).
36 . 0 E.G.A. sensor selection: Available when using an E.G.A. system fitted with
NO/SO2 sensors. The following option is for selecting the type of sensors used.
The pinch valve configuration must also be checked in the E.G.A. unit.
SO2 NO
0 Off Off
1 Off On
2 On Off
3 On On
37 . 0 Derivative control (D) time interval: The time interval between the controller
comparing the actual value and the required setpoint value (derivative is equiva-
lent to 'Rate').
0 (0=off)
1-200 Seconds.

Mk7 Evolution
348 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p p
O Fa O De
38. 2 Derivative control (D) deadband: The deadband is the margin above and
below the required setpoint within which no derivative control occurs.

39. 10 Derivative control (D) response sensitivity:
The sensitivity value indicates the amount of percentage firing rate increase or
decrease that is inflicted by the derivative action, e.g. if the chosen value was 10%
then 10% of the maximum firing rate would be added to the existing rate of fire,
i.e. if the burner was firing at 50% load and the derivative action was triggered the
firing rate would increase by 10+50 to 60%.
The following is an example of the above control philosophy in action:
Note: “Time Between Readings” set to 20 seconds.

“Deadband” set to 2°C (2°F.)
"Response Sensitivity” set to 10%.
Setpoint Information:
“Required Setpoint” set to 90°C (190°F.)
“Actual Value” reads 86°C (186°F.)
Firing Rate Information:
Burner firing at 50% of capacity.
In the example situation there has been 4°C (4°F) drop in temperature below the
required setpoint. The deadband is set at 2°C (2°F.), therefore the derivative
action will be triggered as the deviation from the required setpoint is in excess of
2°C (2°F.). In this example 10% will be added to the 50% firing rate resulting
in an increase in firing rate to 60% of capacity.
The “Time Between Readings” is set for 20 seconds and if after this time interval
the actual value is not within the 2°C (2°F) deviation from the required deadband
another 10% would be added to the 60% firing rate which would result in a 70%
firing rate.
By careful selection of “Time Between Readings”, “Deadband” and “Response
Sensitivity” an ideal response to rate of change over time can be configured.
The control philosophy detailed operates inversely if the “Actual” temperature
exceeds the required setpoint and is outside the “Deadband”.
To enable or switch on the Derivative action the “Time Between Readings” must
be set in excess of 10 seconds.
1-100 %

Mk7 Evolution
349 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p p
O Fa O De
40. 0 Warming facility for low pressure steam sequencing: For lead/lag
(sequencing) applications where check (non-return) valves are not installed, it is
not possible to use a phantom setpoint to keep the boilers in a standby warming
condition. Therefore, the facility exists to install a thermostat (aquastat) in the
boiler shell. The thermostat will input 230V/120V on terminal #93 and this
initiates warming (see option #41). The boiler will remain in a warming state
based on the settings for options #53/54.
0 Disabled.
1 Enabled.
41. 0 2/3 state steam sequencing: This option sets 2 states of operation for the lag
boilers. Either one boiler is kept in a standby warming state and the other boilers
are off, or all lag boilers are kept in a standby warming state and there are no off
boilers.
0 3 state steam sequencing- LEAD, STANDBY, OFF, OFF, OFF, OFF...

1 2 state steam sequencing- LEAD, STANDBY, STANDBY, STANDBY...
42. 20 Warming facility for medium/high pressure steam sequencing-

phantom setpoint: For lead/lag (sequencing) applications where check (non-
return) valves are installed, it is possible to use a phantom setpoint to keep the
boilers in a standby warming condition. This value is an offset below the normal
required setpoint. When the phantom setpoint is in effect, the burner is held at a
low flame position.

43. 5 Offset above phantom setpoint when the burner stops:

44. 5 Offset below phantom setpoint when the burner starts up:


Mk7 Evolution
350 of 761
g
tin lue
o. t n
N Se Va tio
n y n ip
t io tor tio scr
p c p
O Fa O De
45. 0 External modulation: When enabled the internal PID control is disabled and
the firing rate is set by an external controller applied to the appropriate input
terminals #7/8/9. This input control signal can be 0-10V, 2-10V, 4-20mA or 0-
20mA representing low to high fire. A high limit stat must be fitted. A working stat
may be required depending on the setting of this option.
0 Disabled.
1 Enabled- no working stat facility (internal stat always closed- option #9), no local
display of pressure/temperature. Required setpoints not displayed. An external
working stat is required.
2 Enabled- no working stat facility (internal stat always closed- option #9), load
sensor used for local display of pressure/temperature. Required setpoints not
displayed. An external working stat is required.
3 Enabled- load sensor used for working stat facility and for local display of
pressure/temperature. Required setpoints displayed. External working stat not
required.
Note: The fuel flow metering must be entered (option #57). If this is not entered
then the M.M. will remain in the low flame hold state. Option #55 must be set to
zero if option #45 is set to 1/2/3.
46. 0 Unused:
47. 0 Cold start routine: On burner start-up, if the actual value is below 30% of the
required setpoint, then the burner will be held at the low flame hold position for
no longer than the number of minutes set in this option. If the boiler is at or below
60% of its required setpoint then the burner firing rate would be held at 50% firing
for no longer than the number of minutes set in this option. When the actual value
exceeds the P band offset on the PID philosophy then the burner reverts to normal
PID control. If the burner turns off then the timer is reset.
0 Off.
1-2000 Number of minutes cold start operates.
Note: The cold start routine cannot be used with external modulation (options
#45/55 are used).
48. 0 Flue gas recirculation- timer: This is the time that the M.M. channels
(positioning motors/variable speed drives) are held at the FGR start positions,
after which modulation then takes place. This timer starts at the end of main
flame proving. Also see parameter #90 regarding the commissioning of the
FGR positions.
0 Disabled.
0-600 Seconds.

Mk7 Evolution
351 of 761
ting e
o. Set a lu n
N y V tio
n r n ip
t io cto t io scr
p p
O Fa O De
49. 0 Flue gas recirculation- offset: This is an offset from the required setpoint.
The M.M. channels (positioning motors/variable speed drives are held at the
FGR start positions until the actual value reaches the offset value below the
required setpoint.

50. 0 Flue gas recirculation- flue gas temperature: The M.M. channels
(positioning motors/variable speed drives) are held at the FGR start positions
until the flue gas temperature has reached 120°C or 248°F. (An E.G.A. must
be present and optioned).
0 Not optioned.
1 Optioned.
51. 0 Unused: Units of Temperature. See option #65.
52. 0 Unused: Units of Pressure. See option #65.
53. 1 Steam boiler sequencing burner ‘off’ time: The steam boiler type
sequencing is enabled by setting option #1 to a respective pressure sensor.
Options #42/43/44 are relevant to the "Standby" boiler operation.
1-200 Burner "Off" time (minutes) during warm up cycle.

Intelligent boiler sequencing- steam boiler applications.
54. 5 Steam boiler sequencing burner 'on' time:
1-30 Burner "On" time (minutes) during warm up cycle.

Intelligent boiler sequencing- steam boiler applications.
55. 0 Internal PID/external modulation selectible using terminal #88:

(Cannot be used with lead lag/intelligent boiler sequencing)
0 Normal operation- internal PID.

1 Terminal 88 = 0 V- internal PID.
Terminal 88 = Line voltage- external modulation. This option also removes the
reduced setpoint from the Mk7 display if it is not a requirement.
Note: Option #45 must be set to zero if option #55 set to 1. Option #9 will
be used as set. If option #9 is set to zero the required setpoint is not displayed.
The fuel flow metering must be entered (option #57). If this is not entered then
the M.M. will remain in the low flame hold state.

Mk7 Evolution
352 of 761
ting e
o. Set a lu n
N y V tio
n r n ip
t io cto t io scr
p p
O Fa O De
56. 1 Operation of alarm output for all system errors/lockouts and
E.G.A. errors on terminal #79:
1 Relay normally off, on when alarm.

2 Relay normally on, off when alarm.
Note: This is a switched neutral and not a voltage output terminal.
57. 0 Fuel flow metering: To set this option and initiate the fuel flow metering
program, the Enter button must be pressed when viewing this option.
0 No flow metering.
1 Flow metering operates and recalibrated.
58. 15 Unused:
59. 0 Unused:
60. 1 Hand/auto bumpless transfer operation:
0 Fuel valve goes directly to last set hand position.

1 Hand position (taken on present fuel valve position when changing from auto to
hand operation).
2 As 0, but hand position is not stored in permanent memory.
61. 1 Flow metering units fuel 1- gaseous:
0 Cubic feet.
1 Cubic meters.
2 DO NOT USE.
3 DO NOT USE.
4 DO NOT USE.
62. 3 Flow metering units fuel 2- liquid:
0 DO NOT USE.
1 Lbs.
2 Kilograms.
3 Litres.
4 US gallons.

Mk7 Evolution
353 of 761
ting e
o. Set a lu n
N y V tio
n r n ip
t io cto t io scr
p p
O Fa O De
63. 3 Flow metering units fuel 3- liquid:
0 DO NOT USE.
1 Lbs.
2 Kilograms.
3 Litres.
4 US gallons.
64. 1 Flow metering units fuel 4- gaseous:
0 Cubic feet.
1 Cubic meters.
2 DO NOT USE.
3 DO NOT USE.
4 DO NOT USE.
65. 0 Type of fuel flow metering:
0 Old fuel flow metering.

1 Imperial fuel flow metering.
2 Metric fuel flow metering.
66. 0 Unused:
67. 1 Channel 1 purge position: The following options tell the M.M. which channels
are to be included in the Purge sequence. See option #5 for purge position.
0 Channel 1 to purge position.

1 Channel 1 to remain closed for purge.
68. 0 Channel 2 purge position:




Mk7 Evolution
354 of 761
g
tt in e
o. Se a lu n
N ry V tio
n n ip
t io cto t io scr
p a p
O F O De
71. 0 Fuel 1- fuel type:
0 Natural gas.
1 DO NOT ADJUST.
2 DO NOT ADJUST.
3 DO NOT ADJUST.
4 DO NOT ADJUST.
5 Fuel 1.
0 DO NOT ADJUST.
1 Light distillate oil.
2 Heavy fuel oil.
3 DO NOT ADJUST.
4/5 Fuel 2.
0 DO NOT ADJUST.
1 Light distillate oil.
2 Heavy fuel oil.
3 DO NOT ADJUST.
4/5 Fuel 3.
0 Natural gas.
1 DO NOT ADJUST.
2 DO NOT ADJUST.
3 DO NOT ADJUST.
4 DO NOT ADJUST.
5 Fuel 4.
75. 0 Purge motor travel speed: During a purge sequence the motor travel speed
can be set independent of option #2. This effects all selected channels.
0 -100 0 = Quickest time.

100 = Slowest time.
76. 0 Trim channel: If an E.G.A. is optioned, the trim can be applied to either Channel
2 (positioning motor) or channel 5 (VSD). If trim on channel 5 is used, options
#91/97 must be entered correctly.
0 Trim on channel 2.
1 Trim on channel 5.

Mk7 Evolution
355 of 761
g
tt in e
o. Se a lu n
N ry V tio
n n ip
t io cto t io scr
p a p
O F O De
77. 0 Burner rating units: Display purposes only for fuel flow metering.
0 KW x 100 /hr 6 Btu x 1000 /hr

1 Kg x 100 /hr 7 Hp x 10 /hr
2 MW /hr 8 lbs x 1000 /hr
3 Btu x 100 /hr 9 Btu x 1000 000 /hr
4 Hp x 100 /hr
5 lbs x 100 /hr
78. 0 Unused:
79. 0 Lowest required setpoint:
0-995 Minimum required setpoint allowed when O.T.C. optioned.

See option #80 and parameter #88. Point A- see diagram in section 2.17.2.8.1.
80. 0 Outside temperature compensation:
0 Disabled.
1 Enabled.
Note: A line voltage on terminal #93 invokes a 'Night Setback' offset value, see
option #85.
81. 140 Maximum boiler required setpoint at minimum outside temperature:

Point B- see diagram in section 2.17.2.8.1.
50-999 Value limited in accordance with sensor selected by option #1.
82. -30 Minimum outside temperature: Point C- see diagram in section 2.17.2.8.1.
-40 +40 For Centigrade.

-40 +105 If Fahrenheit.
83. 65 Minimum boiler required setpoint at maximum outside temperature:
50-999 Value limited in accordance with sensor selected by option #1.
84. 30 Maximum outside temperature: Point D- see diagram in section 2.17.2.8.1.
-20 +40 For Centigrade.

-4 +105 If Fahrenheit.

Mk7 Evolution
356 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p p
O Fa O De
85. 10 Night setback 'depression' offset value: This offset is subtracted from
the normal required setpoint and activated by a line voltage on terminal #93.
0-100 °C/°F/PSI.
86. 0 Channel 1 softened error checking select: Increases positioning error.

fom 0.1° to 0.5° for an industrial servomotor.
0 CH1 normal positioning motor.

1 CH1 industrial positioning motor/softened error checking.
87. 0 Channel 2 softened error checking select:



90. 0 VSD operation channel 5:
0 Not optioned.
1 Optioned.
91. 0 Output from M.M. to VSD:
0 Output units displayed as 4-20 milliamps.

1 Output units displayed as 0-10 volts.
2 Output units displayed as hertz.
92. 25 Output low speed from M.M. to VSD: Same value as set on the VSD.
1-200 Hertz.
93. 50 Output high speed from M.M. to VSD: Same value as set on the VSD.
1-200 Hertz.

Mk7 Evolution
357 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p p
O Fa O De
94. 2 Input signal to M.M. from VSD:
0 4-20 milliamps.
1 0-10 volts.
2 0-20 milliamps.
95. 0 Input units displayed:
0 Selected input signal.

1 Hertz.
96. 0 Input low speed to M.M. from VSD: Same value as set on the VSD.
0-200 Hertz.
97. 50 Input high speed to M.M. from VSD: Same value as set on the VSD.
0-200 Hertz.
98. 0 Unused:
99. 0 Unused:
100. 0 VSD operation channel 6:
0 Not optioned.
1 Optioned.
101. 0 Output from M.M. to VSD:
0 Output units displayed as 4-20 milliamps.

1 Output units displayed as 0-10 volts.
2 Output units displayed as hertz.
102. 25 Output low speed from M.M. to VSD: Same value as set on the VSD.
1-200 Hertz.
103. 50 Output high speed from M.M. to VSD: Same value as set on the VSD.
1-200 Hertz.

Mk7 Evolution
358 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p p
O Fa O De
104. 2 Input signal to M.M. from VSD:
0 4-20 milliamps.
1 0-10 volts.
2 0-20 milliamps.
105. 0 Input units displayed:
0 Selected input signal.

1 Hertz.
106. 0 Input low speed to M.M. from VSD: Same value as set on the VSD.
0-200 Hertz.
107. 50 Input high speed to M.M. from VSD: Same value as set on the VSD.
0-200 Hertz.
108. Unused:
109. Unused:

Mk7 Evolution
359 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p a p
O F O De
For safety reasons, options #110-150 also

have to be entered in as parameters.
It is the responsibility of the commissioning
Engineer to ensure that all settings are set in
accordance with the appropriate standards,
local codes and practices, e.t.c.
If the M.M. system is stuck in the ‘idle’ condition, it is likely

that options #110-150 are not identical to parameters
#110-150. If the commissioning mode is entered, the
relevant options/parameters not set correctly will be
displayed at the bottom of the screen. If more than 1
option/parameter is not set correctly, these will be
displayed in numerical order, i.e. on entering the
commissioning mode again the next sequential option/
parameter not set correctly will be displayed.
110. 1 Burner flame scanner type:
1 Internal non-permanent operation- standard scanner.

2 Internal permanent operation- self-check scanner.
111. 0 Pilot:
0 Interrupted pilot.
1 Intermittant pilot (expanding flame).
112. 40 Pre purge time:
05-300 Seconds/minutes- see option #135.
113. 3 Pre ignition time: Time ignition transformer is on before pilot gas valve opens.
3-5 Seconds.
114. 3 First safety time: Time pilot valve is open before UV is checked.
3-10 Seconds.

Mk7 Evolution
360 of 761
g e
o. ttin lu n
N Se V a tio
n y n ip
t io tor t io scr
p c p
O Fa O De
115. 3 Pilot prove time- pilot trial for ignition PTFI:
3-5 Seconds.
116. 3 Fuel 1 & fuel 4 (gas programs) second safety time- main trial for
ignition MTFI: Pilot/main valve overlap.
(Not Applicable to expanding flame - see option #111).
3-10 Seconds.
117. 5 Main flame prove time: Time period from main valves open to burner
modulating- delay to modulation.
5-20 Seconds.
118. 0 Post purge time :
0-100 Seconds (0- No post purge) U.V. Not checked during post purge. See also
option #135.
119. 10 Control box recycle time: Time delay from burner shut down to startup.
3-120 Seconds.
120. 10 UV threshold:
5-50 Minimum Flame Signal Strength during pilot. (At all other times UV threshold
is fixed at 5).
121. 5 Delay from start of pre purge after which air switch checked:
5-10 Seconds.
122. 0 Flame switch operation: If this option is enabled Terminals 85/86 are
used in conjunction with a flame switch to monitor the presence of a flame.
0 Normal UV scanner operation.

1 Flame switch operation.
2 InfraRed Scanner operation.
123. 3 Fuel 2 & fuel 3 (oil programs) second safety time- main trial for
ignition MTFI: Pilot/main flame overlap.
(Not Applicable to expanding flame - see option #111).
3-15 Seconds.

Mk7 Evolution
361 of 761
g
tt in lue
o. e n
N yS Va tio
n r n ip
t io cto t io scr
p a p
O F O De
124. 1 Gas valve proving pressure sensor type:
0 Nominal range 0–25" w.g./ 0–65 mbar/ 0–1 psi (Sensor MM60006)
Note. PSI display not available with this sensor
1 Nominal range 0–135"w.g./ 0–340 mbar/ 0–5 psi (Sensor MM60008)
4 Nominal Range 0-1650”w.g/0-4125 mbar/0-60psi (Sensor MM60014)
125. 0 Gas valve proving & high-low pressure limit checked- fuel 1:
0 Not checked on fuel 1.

1 Gas valve proving on + high/low pressure limits (see options #136/137).
2 Do not select.
3 Gas high/low pressure Limit. If options #136/137 are set to 0, then the online
values are displayed only.
4 External VPS optioned. It is possible within the unit to use an external VPS
controller for this operation. If this is set then the system will wait for a mains
voltage input on terminal #55 to confirm that the external VPS operation is
completed. The time period for this is 10 minutes before the voltage input must
be seen, otherwise a lockout will occur (contact Autoflame before use).
126. 0 Fuel 2/oil high-low pressure limit checked- fuel 2:

1 Do not select.
2 Oil high/low pressure limit. If options #139/140 are set to 0, then the online
3 Do not select.
4 External VPS. See option #125 for information.
127. 0 Fuel 3/oil high-low pressure limit checked- fuel 3:

1 Do not select.
2 Oil high/low pressure limit. If options #139/140 are set to 0, then the online
3 Do not select.

Mk7 Evolution
362 of 761
g
tin lue
o. e t n
N yS Va tio
n r n ip
t io cto t io scr
p a p
O F O De
128. 0 Gas valve proving & high-low pressure limit checked- fuel 4:

1 Gas valve proving on + high/low pressure limits (see options #136/137).
2 Do not select.
3 Gas high/low pressure limit. If options #139/140 are set to 0, then the online
values displayed only.
129. 0 VPS operation: This option must be set to 0 during commissioning. Once
commissioning is complete it can then be set to 1.
0 VPS operates before burner start up.

1 VPS operates after burner run (low gas not checked before burner starts).
130. 2 Gas valve proving:
0 Two valve gas valve proving.

1 Three valve gas valve proving. Vent valve normally closed.
2 Three valve gas valve proving. Vent valve normally open.
3 Two valve gas valve proving- single valve pilot.
4 Three valve gas valve proving- single valve pilot. Vent valve normally closed.
5 Three valve gas valve proving- single valve pilot. Vent valve normally open.
131. 0 Gas pressure units: PSI not available for MM60006 - see option #124.
0 "wg (inches water gauge).

1 mbar (millibars).
2 psi (pounds per square inch) - units displayed to 2 decimal places.
132. 20 Gas valve proving time:
10-30 Seconds.
133. 5.0 Maximium pressure change allowed during proving time:
0.1-5 "wg/ 0.2-12.4mbar/ psi not available (Sensor MM60006)

0.4-25.2 "wg/ 1.1-63 mbar/ 0.02 - 0.91 psi (Sensor MM60008)
1-56 "wg/ 2.5-140 mbar/ 0.04 - 2.03 psi (Sensor MM60011)
1.9-103 "wg/ 4.6-356 mbar/ 0.07 - 5.16 psi (Sensor MM60012)
Note: Option #124 for pressure sensor range in use, default value will
change accordingly. See Section 2.17.2.6.2.

Mk7 Evolution
363 of 761
ting
e
o. Set a lu io
n
N y V t
n r n ip
t io cto i o scr
p
O Fa pt De
O
134. 3 VPS valve opening time:
3-20 Seconds.
135. 0 Change purge time:
0 Seconds.
1 Minutes.
2 NFPA post purge- post purge time in seconds is set in option #118.
Note: If this option is set to 2 (NFPA post purge) then option #118 must be set
to a value of 15 or greater otherwise a lockout warning message will occur.
During the NFPA post purge the elements will remain at the position that they
were in during normal shutdown or lockout (see also options #67-70). The
NFPA post purge will occur under any normal shutdown or lockout at any point
in the start up/firing sequence
136. 5.0 Gas pressure switch- offset lower limit: This option has two functions:
- Static inlet pressure check- lower limit. This is checked prior to burner firing.
- Run pressure check- lower limit.
This is an offset from the commisioned value. Note options #124/131.
0 Off- lower limit not checked.

0.1-25.2 "wg/ 1.1-63 mbar/ 0.02 - 0.91 psi (Sensor MM60008)
137. 1.0 Gas pressure switch- offset upper limit:

This is an offset from the commisioned value.
Note settings of options #124/131.
0 Off- upper limit not checked.

138. 0 Oil pressure units:
0 Bar.
1 PSI.

Mk7 Evolution
364 of 761
ting
e
o. Set a lu io
n
N y V t
n r n ip
t io cto i o scr
p
O Fa pt De
O
139. 1.0 Lower limit oil pressure switch: Offset from commissioned value.
0 Off- lower limit not checked.

0.8-4 Bar- lower limit from operating pressure.
0-50 PSI- lower limit from operating pressure.
140. 1.0 Upper limit oil pressure switch: Offset from commissioned value.
0 Off- upper limit not checked.

0.8-4 Bar- upper limit from operating pressure.
0-50 PSI- upper limit from operating pressure.
141. 0 Purge air pressure proving: During pre purge this option enables the
air proving pressure to be tested at a value independent of option #149.
Option #148 must be set.
0 Off- no purge air pressure proving.

0-26.9 “wg.
0.1-67 mbar.
Note: If option #141 is set without option #148 a lockout will occur when
the system starts to purge. The lockout message displayed warns that option
#141 is incorrectly set.
142. 0 Unused:
143. 0 Unused:
144. 0 Unused:
145. 0 Autoflame air pressure sensor:
0 Autoflame air pressure sensor not optioned.

1 Autoflame air pressure sensor optioned 0-1 PSI (Sensor MM60005)
2 Autoflame air pressure sensor optioned 0-2 PSI (Sensor MM60013)
146. 0 Air pressure units:
0 "wg.
1 mBar.

Mk7 Evolution
365 of 761
ting
e
o. Set a lu io
n
N y V t
n r n ip
t io cto i o scr
p
O Fa pt De
O
147. 0 Air sensor error checking window: Only active during modulation
(error #82). The burner will shut down if outside the window.
0 No error checking.
0-3 "wg (maximum = +/- 3 "wg).
0 - 7.5 mbar (maximum = +/- 7.5 mbar).
148. 0 Autoflame air proving selected:
0 Not used- requires external air proving switch on terminal #54 (applies to all
4 fuels).
1 Air proving- requires Autoflame air pressure sensor but no input on terminal
#54 (applies to all 4 fuels).
2 Air proving- requires Autofame air pressure sensor and terminal #54 (applies
to all 4 fuels).
149. 0.3 Minimum air pressure proving value: Air pressure switch function.
0.3 - 4.9 " wg.

1 - 12.5 mbar.
150. 0 Clear ALL commissioning data and gas/air sensor re-commission:
0 - 10 Range.
5 Clear commissioning data- restore options/parameters to factory settings.
7 Air sensor automatic recomission (see section 2.17.18.1 in the technical
manual for more information).
8 Gas sensor automatic recommision (see section 2.17.18.2 in the technical
manual for more information).
For safety reasons, options #110 to 150 also

have to be entered in as parameters.
It is the responsibility of the commissioning
Engineer to ensure that all settings are set in
accordance with the appropriate standards,
local codes and practices, e.t.c.

Mk7 Evolution
366 of 761
Micro Modulation Commissioning and Setting up Procedure: Parameters
2.17.2.5 Parameters
To Select Parameter Mode (for parameters while the burner is firing refer to section 2.17.5.4.6):
CH1, CH2, CH3 refer to the rows of buttons respectively starting with CH1 at the top.
Parameter values can be changed by entering the Parameter mode. The password must first be entered.
To enter the password follow the steps listed:
Either deselect and then select fuel or power down and then up.
If system is already commissioned, press at system startup.
If system is not already commissioned, commissioning mode will be set automatically.
“ENTER PASSWORD” is displayed.
Use the CH1 and CH2 to set the Password codes. Then press .
“SYSTEM ACTIVATE, WATER LEVEL CONFIGURE” is displayed.
On this password screen, it is necessary to set both CH1 and CH3. These are both set to 3 if the
Autoflame water level system is to be active. Alternatively, these are both set to 7 for Mk7 use without
the water level system. It is no longer necessary to set a value for First Out Annunciation.
At this point, if a water level board is present press to access the MM commissioning
(thusly allowing for MM options to be accessed).
Then press .
On the following screen “Select to commission combustion fuel air ratio”.
To enter the 'SET PARAMETERS' screen, two methods are available:
1. Press (this allows the selection of multiple buttons at once). Now press and
buttons followed by button.
2. Press the button.
To change the parameter number use the CH2 buttons.

To change the value use the CH3 buttons.
As many Parameters as required can be set/changed when in Parameter mode.
Upon completion of changes, press .
All newly entered option values are now permanently stored.

N.B. The E.G.A. related parameters have the factory default settings from years of
testing on many fuels and applications. It is advised to be cautious when changing these
parameters, and is recommended not to do so.
Mk7 Evolution
367 of 761
o. g ue
N ttin Val
ter Se te r
tion
e e
am ory m crip
r c t ra s
Pa Fa Pa De
1 3 0-20 Sequencing: Offset value when unit goes off line, i.e. if the standby boiler fails
to start the scan time will be decreased by 3 minutes. If the scan time is set to 10
minutes, this would be reduced to a 7 minute scan time.
2 1 1-10 Sequencing: Time between data requests (seconds). Bus driver request
information every second, M.M's transmit every second, D.T.I. only listens to
transmissions.
3 1 1-10 Sequencing: Number of boilers initially set on after powerdown.
4 45 5-100 E.G.A: Number of seconds the ENTER is button disabled after E.G.A. is pressed.
5 4 1-50 Sequencing: Number of minutes, time out value to reach modulation, i.e. If the
boiler is not modulating after being asked to contribute to load, it is kicked out of
sequence loop. After being asked to modulate the burner must start to modulate
in 4 minutes.
6 60 5-100 Unused:
7 16 01-50 Unused:
8 30 5-240 E.G.A: Delay after draining before trim cycle start, i.e. wash out period. When
cells being cleaned with air, this value maintains the last readings until the air
sampled during the drain period has gone.
9 60 5-240 E.G.A: Auto commission time.
10 0 0-1 E.G.A: E.G.A enter version.

0 Mk6 E.G.A Operation.
1 Mk7 E.G.A Operation.
11 25 5-60 E.G.A: Air flush time. This is the flush out period between going fuel rich and air
rich during auto commission (seconds) in order to remove any excess CO
produced.
12 0 0-1 E.G.A: CO included in trim calculation on F2 & F3 (see option #17), i.e. required
when using natural gas on F2 & F3.
0 No.
1 Yes.
13 20 5-30 E.G.A: ÷4 = % of air damper movement. Amount of auto commission trim.
Applies only to air (-) (fuel rich).
14 20 1-200 E.G.A: ÷2 number of degrees the fuel valve moves before negative trim is reset.
15 5 2-100 Golden start timer: Number of seconds that the positioning motors are held at
the "choke" position. Applies to golden start only, see option #29. This time starts
from the ignition point.

Mk7 Evolution
368 of 761
e
o. ing a lu
N tt V
er Se n
t
e ry ter tio
e ip
ram cto ram scr
Pa Fa Pa De
16 12 1-50 E.G.A: Time between calibrations (÷ 2 = Hours). The E.G.A. calibrates every
6 hours if the burner does not turn off.
17 3 0-10 E.G.A: Number of trims before an E.G.A. error is flagged when limits exceeded.
Each Trim = 30 Seconds.
18 20 5-60 E.G.A: Trim amount during run ÷ by 2 = % of trim. This value cannot be set
above 20 (10%) or an ERROR 25 will occur.
19 20 5-30 E.G.A: ÷4 = % of air damper movement. Amount of auto commission trim.

Applies only to air (+) (air rich).
20 0 0-40 Reset parameters to original factory settings: To reset all of the

parameters back to their original factory set values, set option #20 to 26 and
press enter.
21 0 Unused:
22 0 DTI: Do not adjust.

23 0 E.G.A: Trim- add air when CO present. When trim is taking place, if the O2 and
CO2 appear on the air rich side but the CO appears on the fuel rich side then the
air damper will open further to remove the CO.
0 Enabled.
1 Disabled.
24 120 20-240 E.G.A: Calibration time (seconds).
25 30 5-100 E.G.A: Time between samples.
26 8 1-50 E.G.A: Number of samples per trim cycle.
27 25 0-255 E.G.A: Minimum operating temperature (÷ 5=deg C).
28 200 0-255 E.G.A: Maximum operating temperature (÷ 5=deg C).
29 0 0-10 Unused:
30 10 0-40 Filters load sensor readings: Temperature and pressure detectors.
0 No filtering.
20 Maximum filtering.
31 0 0-1 Selects efficiency to be displayed:
0 English (USA/Canada- incorporates Hydrogen & moisture loss).

1 European.
Mk7 Evolution
369 of 761
e
o. ing alu
N tt V
ter Se ter tion
e e
am ory am crip
r ct r s
Pa Fa Pa De
32- Unused:
37
38 254 0-255 M.M. password: Channel 1.
39 1 0-255 M.M. password: Channel 2.
40- Unused:
43
44 0.4 0-40 E.G.A: O2 window inside which no further trim takes place.
45 0.2 0-20 E.G.A: CO2 window inside which no further trim takes place.
46- Unused:
47
48 0.8 0.01- Integral control (I) threshold: This is a percentage below the required
0.99 setpoint to the proportional band offset at which point the integral control takes
effect, i.e. if the required setpoint is 100psi, option #6 = 10psi, parameter #48
= 0.8, the integral control will take effect when the actual value is above 92psi.
49 0 0-1 Required setpoint: Set to 1 if required setpoint not to be stored permanently

in memory. This is important to set if using parameter #72.
50- Unused:
51
52 0 0-2 External load detector: Number of decimal points (please see table below).
53 0 0-9990 External load detector: Maximum value (please see table below).
54 0 0-100 External load detector: Maximum voltage (please see table below).
55 0 0-9990 External load detector: Minimum value (please see table below).
56 0 0-100 External load detector: Minimum voltage (please see table below).
Example 1: Pressure Application Example 2: Temperature Application
Required/Actual Range- 0.0-100.0bar Required/Actual Range- 1000-2000F
Input Signal- 0-10 Volts Input Signal- 1-6 Volts
Option 1- 11 Option 1- 10
Option 65- metric units Option 65- imperial units
Parameter 52- 1 Parameter 52- 0
Parameter 54- 10.0 Parameter 54- 6.0
Parameter 56- 0.0 Parameter 56- 1.0

Mk7 Evolution
370 of 761
e
o. ing alu
N tt V
ter Se ter tion
e e
am ory am crip
r ct r s
Pa Fa Pa De
57 Unused:
58 1 E.G.A. calibration on start up:
1 E.G.A: Calibration on start up.

0 E.G.A: No calibration on start up.
59 Unused:
60 0 E.G.A. or O2 trim interface module:
0 Normal E.G.A. operation.

1 O2 trim interface operation.
61 900 0 - 999 Display backlight on time (seconds): Set to zero for the backlight to remain
on at all times.
62 0 0-1 Hot Water Sequencing: If this parameter is set to a value of 1, then the hot
water sequencing will operate in the same method as the steam sequencing
(contact Autoflame before use).
63 0 0 -1 Reset lockout history: Set to 1 for 2 seconds, then set back to 0 to clear
lockout history.
64 0 0-1 Reset totalised fuel flow metering: Set to 1 for 2 seconds, then set back to
0 to reset totalised fuel metering values for all 4 fuels. To reset the totalised fuel
flow metering for individual fuels see option #57.
65 0 0-1 Reset burner history: Set to 1 for 2 seconds, then set back to 0 to reset
burner history, hours run and number of start ups.
66- Unused:
68
69 0 0-1 External modulation input range:
0 0-20mA, 0-10V.
1 4-20mA, 2-10V.
70 0 0 - 20 Filtering of the analogue input: Terminals #7/8/9. The value set is the
number of readings over which an average is taken. The smaller the setting the
quicker the response time.
0 Default value of 5.
1 Minimum.
20 Maximum.

Mk7 Evolution
371 of 761
e
o. ing alu
N tt V
ter Se ter tion
e e
am ory am c rip
r ct r s
Pa Fa Pa De
71 0 0-20 Resolution of the analogue input: Terminals #7/8/9. The effect of resolution
is to filter the noise on the input which causes hunting as the M.M. responds to
a changing signal.
0 Default value of 5.
1 Minimum.
20 Maximum.
72 0 External required setpoint: If this parameter is enabled, the analogue input

terminals #7/8/9 are used to set the required setpoint. Input signals can be 0-
10/2-10V or 0-20/4-20mA (see parameters #69/70/71). The range of the
required setpoint is set by options #30 & 31. Set parameter #49 to 1. Set
option #16 to 2.
0 Disabled.
1 Enabled.
73- Unused:
78
79 0 EGA splitter for twin burner application: When using a twin burner it is
possible to use the E.G.A. data from the master M.M. module for the slave
M.M. module. This means that only one E.G.A. is required for the 2 M.M. units
in a twin burner application. This only works with option #14 set to 1 (both
burners operate together). Parameter #79 is set to 1 on the slave unit only and
parameter #79 is set to 0 on the master M.M. module.
80 40 1 - 50 Unused: Do not adjust.
81 Do not adjust:
82 Unused:
83 0 Display diagnostic values:
0 Disabled.
1 Enabled.
84 0 Display diagnostic values for lead/lag (intelligent boiler sequencing):
0 Disabled.
1 Enabled.

Mk7 Evolution
372 of 761
e
o. ing a lu
N tt V
ter Se ter tion
e ry e ip
ram cto ram scr
Pa Fa Pa De
85 0 0-250 Modulation exerciser: Repeatedly run between high and low flame. The
higher the value, the longer the high/start position is maintained.
86 0 0 - 99 IBS change down threshold: If left at 0 change down threshold = 85%

firing rate.
87 0 0 - 100 IBS change up threshold: If left at 0 change up threshold = 95% firing rate.
Note: If parameter #86 is set greater than parameter #87 then they will default
to 85% and 95% respectively.
88 0 -50 - +50 Adjust errors in the OTC sensor reading: If actual reading is too high set a
negative value to adjust, if reading is too low set a positive value.
0 No adjustment made.
Each unit 1°F or 0.5°C (see option #65 for units of temperature).
89 0 Unused:
90 0 Flue gas recirculation:
0 Positions entered after commissioning by performing the single-point change

procedure (see section 2.17.13 in the technical manual).
1 Positions entered during commissioning.
91 0 Unused:
92 0 Boiler differential pressure proving:
0 Disabled.
1 Enabled. The system will be held in a purge condition until a proven input from
a differential pressure switch is registered on Terminal #85. Terminal #85 must
be reset before start up can take place. If Terminal #85 resets during purge, the
system returns to the beginning of the start up sequence.
2 Enabled. This is the same as 1 but if terminal #85 resets during purge, then a
lockout will occur.
93 Unused:
94 0 Upper offset limit ppm NO:
0-200 ppm NO.
95 0 Unused:

Mk7 Evolution
373 of 761
o. g ue
N ttin Val
er e n
et ry S ter tio
e
am cto am crip
r r s
Pa Fa Pa De
96 0 Upper offset limit exhaust temperature:
0-999 °C/F.
97 0 Absolute limit value exhaust temperature: System checks for exhaust

temperature readings higher than value specified in this option.
0-999 °C/F.
Note: An E.G.A. must be installed and the exhaust temperature reading correct.
98- 0 Unused:
99
100 0 Assured low fire shut off:
0 Not operational.
1 Burner modulates to low fire before turning off when above the internal stat.
101 0 Shuffle sequencing:
0 Not operational.
1 Boiler sequence order changed from the Win PC DTI software.
102 0 Super “I” control offset: The default value is zero which turns off the “Super
I”. The range can be up to 50°C, 50°F, 50 psi or 5 bar.
0 Not operational.
1 Sets the point at which the “Super I” control algorithm is put into operation.
103 0 Super “I” control speed of integration/time:
0-30 Seconds (1 second increments).
104 0 Super “I” control amount of integration:
0-5 Degrees (0.1 degree increments).
105 0 Super “I” control dead band: The range of 10 would apply to 10°F, 10°C,
10 PSI or 1.0 bar.
0-10 The range is 0-10 and this can be adjusted in increments of 1.0.

Mk7 Evolution
374 of 761
o. g ue
N ttin Val
er e n
et ry S ter tio
e
am cto am crip
r r s
Pa Fa Pa De
106 0 Integral control (I) percent: Percent variation.
1-25 Every “n” seconds (set in option #7) 10% of the present offset from setpoint
value is added or subtracted to the present proportional value. This enables a
% variation.
107 14 0-255 On-line changes password: Channel 1.
108 14 0-255 On-line changes password: Channel 2.
109 0 0-1 Advanced Water Level Adjusters: If set to 1 this will give advanced access
to the water level controls.
NB. Parameters 110 to 150 are a repeat of their

respective options. These values need to be entered
as both an option value and a parameter value for
safety reasons.

Mk7 Evolution
375 of 761
Micro Modulation Commissioning and Setting up Procedure: Valve Proving
2.17.2.6 Gas Valve Proving

Mk7 Evolution
376 of 761
2.17.2.6.2 Gas Pressure Sensors
Part Number: Range

MM60006 12.5-65 mbar / 0.18-1 psi / 5-25 “wg
MM60008 52-340 mbar / 0.75-5 psi / 25-135 “wg
MM60011 115-750 mbar / 1.8-11 psi / 50-300 “wg
MM60012 207-1380 mbar / 3-20 psi / 83-550 “wg
MM60014 0.4-4 bar / 6-60 psi / 162-1620 “wg
Notes
IP 52
NE M A 5
HOU SING & L ID ALLUMINIUM
P OWER CONSU MP T ION 0.1 WATTS
MOU NT ING V ER TICAL AS SHOWN.
BR EATHER HOLES AWAY FR OM ANY WATER SOUR CE.
Actual Operating Range

mb a r " w .g. psi
min. max. † zero range min. max. † zero range min. max. † zero range
MM60006 –2.5 65 1373.8 –2.5 to 1.25 –1 25 554 –1.0 to 0.5 –0.04 1 20 –0.04 to 0.02
MM60008 –12.5 340 1373.8 –12.5 to 6.25 –5 135 554 –5.0 to 2.5 –0.2 5 20 –0.2 to 0.1
MM60011 –30 750 2060.7 –30 to 15 –12 300 831 –12.0 to 6.0 –0.44 11 30 –0.44 to 0.22
MM60012 –55 1380 4121.4 –55 to 27.5 –22 550 1662 –22.0 to 11.0 –0.8 20 60 –0.8 to 0.4
† maximum pressure above which causes permanent sensor failure

Mk7 Evolution
377 of 761
2.17.2.6.2.1 Oil Pressure Sensor
NOTE:
MAXIMUM 2.5mm FLAT BLADE SCREW DRIVER FOR ELECTRICAL CONNECTIONS

I.P. 65
NEMA 4
TORQUE SETTING = MAX. 25Nm
DO NOT USE CASE TO TIGHTEN PRESSURE CONNECTION.
O-RING MATERIAL = VITON
MAX. STORAGE TEMP. -25 TO +85 DEG. C (-13 TO 185 DEG. F)
MAX. OPERATING TEMP. -25 TO +85 DEG. C (-13 TO 185 DEG. F)
MEDIA TEMP -25 TO +125 DEG. C (-13 TO 257 DEG. F)
OPERATING RANGE 0 TO 600 PSI / 0 TO 40 BAR
OVER PRESSURE RATING 1160 PSI / 80 BAR
BURST PRESSURE RATING 4350 PSI / 290 BAR
Issue: 08.12.2009 Autoflame Technical Manual Section 2.17.2.6.2.1

Mk7 Evolution
378 of 761
Micro Modulation
Commissioning and Setting up Procedure: Valve Proving
2.17.2.6.3 Commissioning Valve Proving

If the Valve Proving System (VPS) facility is to be utilised then specific options/parameters must be
set (refer to section 2.17.2.4.1 and 2.17.5.4.6. Only options are detailed below, all respective
parameters must be set to the same value).
Options #125 through #128 set VPS operation depending on the fuel selected, i.e. Fuels 1,2,3,4.
Option #125 - VPS operational on Fuel 1 (set value = 1).

The following options must be set to configure the VPS operation.
Option #124 - Gas pressure range (low/high).

Option #125 - Valve proving arrangement (two/three valves).
Option #131 - Gas pressure units (“wg/mBar).
Option #132 - Valve proving time.
Option #133 - Pressure change allowed during proving time.
IT IS THE RESPONSIBILITY OF THE COMMISSIONING ENGINEERS TO ENSURE THAT

THE RELEVANT VALVE PROVING SYSTEM STANDARDS ARE ADHERED TO.
The following formulae may be used for calculating the proving time and pressure change allowed.
They are based on DVGW requirements of a leakage rate of 0.1% of the maximum volume flow.
Proving time:
Abbreviations:
Vpt - Valve proving time in seconds.
Ip - Inlet pressure in millibars.
Pv - Pipe volume in litres (volume = «r2 x length).
Mtp - Maximum gas throughput in litres per hour.
Formula:
Vpt = 4 x Ip x Pv +1
Mtp/1000
The pipe volume is the total volume of any interconnecting pipe between the valve seals.
Pressure change:
Formula:
0.25 x Nominal inlet pressure (mBar).
Issue: 08.12.2009 Autoflame Technical Manual Section

2.17.2.6.3
Mk7 Evolution
379 of 761
Example:
Proving Time -
Inlet pressure = 50 mBar.

Pipe volume = 5 litres.
Mtp = 100,000 litres per hour.
Vpt =4x 50 x 5 +1
100,000 / 1000
= 14 seconds.
Set option #132 = 15 seconds.

Set parameter #132 = 15 seconds.
Note: option #132 is set in increments of 5 seconds, values must be rounded up.
Pressure change -
Inlet pressure = 100mBar.
0.25 x 100 = 25.0 mBar.
Set option #133 = 25.0 mBar

Set parameter #133 = 25.0 mBar
General Note
This is a metric formulae, therefore imperial units must converted before applying this calculation.

Mk7 Evolution
380 of 761
Micro Modulation Commissioning and Setting up Procedure: Air Pressure Proving
2.17.2.7 Air Pressure Proving

Mk7 Evolution
381 of 761
2.17.2.7.2 Air Pressure Sensor
NOTE:
I.P. RATING 52
NEMA 5
MATERIAL SPECIFICATION- ALUMINIUM
POWER CONSUMPTION- 0.1W
MOUNTING- VERTICAL AS SHOWN
WORKING RANGE- 0.3 TO 25 “ WG / -0.75 TO 65 MBAR (MM60005)
0.6 TO 50 “ WG / -1.5 TO 130 MBAR (MM60013)
ZERO RANGE- -1 TO 0.5 “ WG / -2.5 TO 1.25 MBAR (MM60005)
-2 TO 1” WG / -5 TO O2.5 MBAR (MM60013)

Mk7 Evolution
382 of 761
Air Pressure Tapped Fitting
The Autoflame Mk7 Air Pressure Sensor is supplied with a tapped fitting to be installed as shown
below, to measure a differential pressure. This is only necessary where the air pressure at low fire is
below 0.4" w.g. or 1 mbar or when it is a local code requirement.
Air Pressure
Sensor
ΔP
-P +P
Air Flow
ê FD Fan Boiler
Burner
See options #145 to 149

Mk7 Evolution
383 of 761
Micro Modulation Commissioning and Setting up Procedure: Outside Air Temperature Compensation
2.17.2.8 Outside Temperature Compensation

Outside Temperature Compensation
4 2 5
OTC enables the boiler setpoint to be varied according to the outside air temperature, i.e. as the
air temperature drops the boiler setpoint can be increased accordingly.
On the MK7 Evolution the outside temperature compensation graph is displayed such that the
outside temperature scale is from left to right as the outside temperature increases. The limits of
opeartion of this feature can be set through the Options menu. To enable Outside Temperature
Compensation, set Option 80 to 1.
1. Maximum boiler required setpoint at minimum outside temperature (Option 81).
2. Current outside temperature and calculated actual required setpoint.
3. Minimum boiler required setpoint at maximum outside temperature (Option 83).
4. Minimum outside temperature (Option 82).
5. Maximum outside temperature (Option 84).
Note: If the actual outside temperature exceeds the boudaries set forth by Options 82 and 84, the
boiler setpoint will remain at the maximum or minimum setpoints specified by Options 81 and 83.

Mk7 Evolution
384 of 761
Micro Modulation Commissioning and Setting up Procedure: Outside Air Temperature Compensation
Ouside Temperature Sensor
NOTE:
I.P. RATING 65
NEMA 4
HOUSING- ALUMINIUM
POWER CONSUMPTION- POWERED BY MK7 M.M.
MOUNTING- ANY ORIENTATION

Mk7 Evolution
385 of 761
Micro Modulation Commissioning and Setting up Procedure: Mk.7 Electrical Specification
2.17.2.9 Mk7 Electrical Specifications

2.17.2.9.1 Classifications
Classification According to EN298 - F B L L J B

Mains Supply: 230V, +10%/-15% }
47 - 63 Hz, Unit max. power consumption 62W
120V, +10%/-15% }
Max Leakage: 3.5 mA
Climate: Temperature 0 to +400C (32 to 1040F).
Humidity 0 to 90% non-condensing.
Storage: Temperature -20 - 850C (-4 to 1850F).
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.
Inputs & Outputs:

230V Unit:
Outputs Terminal 57 250 mA Must be connected through contactor
Max. load 6 Amp.

58 250 mA Must be connected through contactor
59 1Amp, 0.6 power factor
78 100mA To drive relay only - switched neutral
79 100mA To drive relay/lamp only - switched neutral
Analogue I/O.s 240 Ω or less.
120V Unit:
Outputs Terminal 57 250 mA Must be connected through contactor

58 250 mA Must be connected through contactor Max. load 6 Amp.
78 100mA To drive relay only - switched neutral
79 100mA To drive relay/lamp only- switched neutral
Analogue I/O.s 240 Ω or less.
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- Cabling should be a maximum 25m.
3- Use screened cable as specified in Section 2.17.2.9.4.
4- The burner 'High Limit Stat' must be of the manual reset type.

Mk7 Evolution
386 of 761
2.17.2.9.2 Fuse Ratings
630mA(T) Time lag 2A(T) Time lag

Part No. FU10028 Part No. FU10027
(Internal Electronic (Short Circuit on 12V)
Fault)
230V/110V Mains Supply 6.3A(T) Time lag 630mA(T) Time lag

230V - 2A(T) Time lag Part No. FU10026 Part No. FU10028
120V - 2A(T) Time lag (Terminals #50 to 64) (UV Shutter Short
Part No. FU10034 Circuit)
(Servo Short Circuit)
Text in brackets indicates possible cause of fuse blowing.
All fuses should be time lag type (T).
If an L.E.D. next to a fuse is extinguished, then this indicates that the fuse is blown.

Mk7 Evolution
387 of 761
2.17.2.9.3 Terminals Description
1 Current Input, 0-20mA. For channel 5 VSD use only. Can be connected to the
current output of a VSD or tachometer system as appropriate.
2 Voltage Input, 0-10V. For channel 5 VSD use only. Can be connected to the
voltage output of a VSD or tachometer system as appropriate.
3 Common for terminals #1 and 2.
4 Current Input, 0-20mA. For channel 6 VSD use only. Can be connected to the
current output of a VSD or tachometer system as appropriate.
5 Voltage Input, 0-10V. For channel 6 VSD use only. Can be connected to the
voltage output of a VSD or tachometer system as appropriate.
7 Current Input, 0-20mA. Used for external modulation or external required sepoint.
8 Voltage Input, 0-10V. Used for external modulation or external required sepoint.
10 Current Output, 4-20mA. For channel 5 VSD use only. Can be connected to the
current input of a VSD.
11 Voltage Output, 0-10V. For channel 5 VSD use only. Can be connected to the
voltage input of a VSD.
13 Current Output, 4-20mA. For channel 6 VSD use only. Can be connected to the
current input of a VSD.
14 Voltage Output, 0-10V. For channel 6 VSD use only. Can be connected to the
voltage input of a VSD.
16 Current Output, 4-20mA. Varies in accordance with firing rate.
17 Voltage Output, 0-10V. Varies in accordance with firing rate.
18 0V common for terminals #16 and 17.
Note that all the common terminals (3, 6, 9, 12, 15, 18) are connected to each other internally. All
of the circuitry, associated with the analogue inputs and outputs detailed above, is isolated from
earth/ground potential, i.e. floating.
Note: It is advised to put a jumper/link between terminals #3 and #S in order to protect against
electrical interference.

Mk7 Evolution
388 of 761
19, 20 Connections to the Autoflame outside temperature sensor.

21, 22 Connections to an Autoflame self check UV sensor.
23, 24 Communications port connections for twin burner operation.
25, 26 Communications port connections to an Exhaust Gas Analyser (E.G.A.).
27, 28 Communications port connections for DTI and/or IBS/lead-lag operation.
29, 30 Communications port (currently unassigned).
31, 32 Signal inputs from Autoflame air pressure sensor.
33 0V supply to Autoflame air/gas/oil pressure sensors.
34 +12V supply to Autoflame air/gas/oil pressure sensors.
35 Signal input from Autoflame oil pressure sensor.
35, 36 Signal inputs from Autoflame gas pressure sensor.
37, 38 Connections to an Autoflame boiler temperature detector.
37, 38, 39 Connections to an Autoflame boiler pressure detector.
40 0V supply to channel 1 and channel 2 positioning motors.
41 +12V supply to channel 1 and channel 2 positioning motors.
42 Signal from channel 1 positioning motor, indicating position.
46 0V Supply to channel 3 and channel 4 positioning motors.
47 +12V Supply to channel 3 and channel 4 positioning motors.
48, 49 No terminals allocated.

Mk7 Evolution
389 of 761
50,51 Connections to an Autoflame UV sensor.

52 Mains voltage input- external auxiliary delay to purge.
53 Mains voltage input- burner on/off signal. Running interlock circuit.
54 Mains voltage input- safety circuits, e.g. air proving.
55 Mains voltage input- proving circuits, e.g. gas valve proof of closure.
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 Unused.
65 No terminal allocated.
66 Mains supply- earth.
67 Main supply- neutral.
68 Mains supply- live/hot.
69 Mains voltage output. Power to positioning motors.
70 Switched neutral- drives channel 1 positioning motor clockwise.
71 Switched neutral- drives channel 1 positioning motor counter clockwise.
78 Switched neutral- to drive 2-port valve for IBS/lead-lag operation.
79 Switched neutral- alarm output for M.M. lockout/M.M. error/E.G.A. error./T.D.S.
limits

Mk7 Evolution
390 of 761
80 Unused- do not connect.

85 Mains voltage input. For use when using an external flame switch- 0V when at no
flame state. Or when using boiler differential proving.
86 Mains voltage input. For use when using an external flame switch- line voltage when
at no flame state.
87 Mains voltage input. Select second required sepoint- second set-point facility.
88 Mains voltage input. Can be used to select this M.M. as lead boiler when IBS/lead-
lag is implemented. If this terminal is used to select the lead boiler, it will take
priority over a lead boiler set via the DTI. Also used as an input to select external
modulation using an external PID loop.
89 Mains voltage input- selects fuel 1 curve.
93 Mains voltage input- if low pressure steam operation is optioned, this input is used to
detect low boiler temperature (by means of an appropriate temperature switch/
aquastat). If outside temperature compensation is optioned, this input is used to
activate the night setback.
94 Mains voltage input- selects hand operation.
95 Mains voltage input- selects low flame hold operation.
S All terminals marked S are internally connected. They are provided for
connections to the various screened cables. Refer to the schematic connection
diagrams, e.g. section 2.17.6.1.

Mk7 Evolution
391 of 761
Micro Modulation
2.17.2.9.4 Cables
Screened Cable
The screened cable used from the M.M. to the servo motors and detectors 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 440 volts a.c. rms at 1600 Hz;
DEF 61-12 current rating per core 2.5 Amps;
Maximum operating temperature 70 degrees C (158 degrees F);
Nominal conductor area 0.5 square mm per core;
Nominal insulation radial thickness on core 0.45mm;
Nominal conductor diameter per core 0.93mm;
Nominal core resistance at 20 degrees C. 40.1 Ohm/1000m.;
Nominal overall diameter per core 1.83 mm;
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 Cores
16-2-3C 3 Cores
16-2-4C 4 Cores
16-2-6C 6 Cores
(5 Cores not readily available).
Data Cable
Data cable must be used for connections between MMs for twin burner/sequencing applications and
between M.M.’s and E.G.A.’s.
Types of data cable that can be used:
1. Beldon 9501 for 2-core shielded cable (1 twisted pair);

2. Beldon 9502 for 4-core shielded cable (2 twisted pairs);
3. STC OS1P24;
Samples are available upon request.

Cable can be ordered directly from Autoflame Engineering.

Mk7 Evolution
392 of 761
Micro Modulation Commissioning and Setting up Procedure: Variable Speed Drives
2.17.2.10 Variable Speed Drives
Installation
The following recommendations are to assist with the installation and fault finding when using variable
speed drives (VFD’s/inverters).
Inverter Selection
Variable speed drive selection is critical to proper operation. Ensure that the correct size inverter has
been selected for the application and is suitable for the motor, and has the necessary input/output
signals as shown in section 2.17.6.1.
Mains Cable Connections
Power connections from the variable speed drive to the motor- it is recommended for mains cabling (3
phase) and fuses, that they are to be dimensioned in accordance with the kW rating required.
Motor Cabling
A four core conductor screened cable is recommended. This is due to the rapid voltage changes
occurring in variable speed drive systems.
To Avoid Disturbances
It is advised that the motor cables should not be installed with other cable routes- avoid long parallel
runs with other cables.
Disturbances caused by radiation from the motor cable can be reduced by installing in-line chokes in
the motor cable. However, these chokes may reduce the motor voltage and the maximum available
torque. If noise problems exist and unstable output signals cannot be contained within the window
and disparity band shown in section 2.17.2.10.3, you should contact the supplier of the variable
speed drive for more detailed information and advice.
Setting the VSD for Operation
Due to the vast range of variable speed drives it is not possible to give settings/parameters for all
types, however some basic rules apply. The minimum and maximum Hz (rpm) should be adjusted
before commissioning the Micro Modulation unit. Also the ramp time should be set for the fastest time
possible, taking into account limitation of the motor and the application.
Normal settings would be, low speed 25Hz and high speed 50/60Hz. It is not recommended to set
low speed lower than 20Hz. This is because the feed back signal tends to be unstable in this range
and over heating of the motor may occur.

Mk7 Evolution
393 of 761
Input and Output Signals in Relationship to Frequency

Mk7 Evolution
394 of 761
Operational Characteristics of Inverter Output/M.M. Module Input in Relationship to Frequency

Mk7 Evolution
395 of 761
Variable Speed Drive Safety Software

In a typical example the motor speed at 50Hz would be 2900rpm and the motor speed at 25Hz would
be 1450rpm. This example is typical as there is a linear relationship between linear speed and cycles
Hertz. The variable speed drive software allows the following amount of error (disparity) between
signal out to the variable speed drive and signal return to the M.M.
Signal V
V
V Disparity = +/- 2Hz
Window = +/- 1Hz
+ Band (15 bits)
Signal Parity
Band (10 bits)
-
V
V
V
1 2 3
Time in Seconds
The “Window” tolerance has been implemented to accommodate small variations between input and
output signal that result from processing through the various A-D and D-A converters involved in the
control loop, also motor “Slip”, acceleration and deceleration times, all of which produce small
variations.
The “Disparity” tolerance which is time limited to a short duration is implemented to deal with the
transient disparity/error between input and output signals that results from the PI control mechanism that
is typical in variable speed drives (motor speed control mechanism) not operating in phase with the PI
(D) control philosophy in the M.M. (Micro Modulation Fuel Air Ratio Controller). This transient
disparity occurs and is always self-correcting within the three second time tolerance nominated in the
Autoflame control philosophy.
1. Notwithstanding the above, to deal with transients of a very small time scale but of an amplitude
greater than the disparity (area Y) as in section 2.17.2.10.3, there is an additional mechanism
in the software that allows transient deviations of any amplitude to be tolerated for a duration
of less than one second. Under these conditions an error will not be flagged.
Note: area Z in section 2.17.2.10.3. Any signal deviation longer than one second in area Z
will activate safety errors. The tolerance safety time is set for 3 seconds.
2. The “Window” tolerance is +/- 5 bits = 1 Hz = 58rpm (on a motor rotating at 2900rpm at
50Hz).
3. The disparity tolerance is +/- 10 bits = 2Hz = 116rpm (on a motor rotating at 2900rpm at
50Hz). Note that disparity band 2Hz is limited to a maximum of 3 seconds.
4. Fan laws state that: a) Speed and volume are a direct linear progression.
b) Speed increase as a percentage affects pressure produced by
the fan as a square root function.
5. The variations in signal allowed in our software would have considerably less effect on the fuel
air ratio supplied to the combustion process than variations in ambient temperature/air density
e.t.c.

Mk7 Evolution
396 of 761
Control Philosophy
When the M.M. is commissioned all the positions for the fuel/air ratio are entered into the memory.
These positions are stored together with a motor speed and air damper position. This allows the M.M.
to measure the slip by measuring output signal to the variable speed drive, return signal from a tacho
and learning the difference for any air position/motor speed setting. This control form gives the
facility for a different combination of air/motor speed settings to be accommodated for varying fuels,
i.e. F1, F2, F3 & F4. This facility accommodates variances for air requirement for different fuels which
is fundamental to the hydrocarbon ratio of the fuel.
Diagram to show Increase in Slip Caused by Damper Sited on Inlet to Combustion Fan
(Caused by pressure/density variations that fan operates in as a function of
its position in load index).
Hz
20 mA
rpm
X ity
par
s
Di
50
3000
w
do
in
W
High
Inter 1
Inter 2
4-20mA output
ity
from M.M. ar
sp
Di
-
-
-
module.
ow
Inter 5 ind
W
Inter 6
Inter 7
START
1000
Y
20
4
4 - 10 V DC
20 - 50 Hz
1000 - 3000 rpm
0-10V feedback signal from tachometer or VFD.
Actual Feed back signal

Expected Feed back signal
During commissioning, each time a position is entered (HIGH/INTER/START) the M.M. also stores the
feedback signal value. When the START (low flame) position is entered these values are stored perma-
nently in the memory. A set of values can be stored for each fuel (max. 4). When the M.M. is in the
RUN mode the set of values stored for the fuel presently selected is used to generate the window and
disparity error checking bands. In commissioning mode error checking is disabled. During run the
error checking is disabled during the start up cycle.

Mk7 Evolution
397 of 761
Micro Modulation Commissioning and Setting up Procedure: Installation Checks
2.17.2.11 Installation Checks
Commissioning Checks
When the installation and all burner adjustments are completed, the entire burner control system
should be tested in accordance with the manufacturer’s instructions. The procedure should verify the
correct operation of:
1. Each operating control (temperature, pressure, e.t.c.).

2. Each limit switch (temperature, pressure, low water cutoff, e.t.c.).
3. Each interlock switch (airflow switch, high & low fuel pressure or temperature switches, purge
and low fire switches, fuel valve proof of closure interlock, e.t.c.).
4. Pilot flame failure response and lockout.
5. Main flame failure response and lockout.
6. Tight shut off of all valves.
Operational Checks
1. Close manual main shut-off valve.

2. Recheck all limit circuit wiring for proper operation and correct connection.
3. Confirm that the automatic main fuel valves are wired correctly.
4. Power the control and electronically check the proper sequence of operation.
5. After assuring yourself that all the interlocks and valves are properly wired and that the sequence
of operation is correct, open the manual main shut-off fuel valve and proceed cautiously through
the boiler light off process. Check all safety interlocks for proper shutdown of the boiler.
Commissioning or start-up must only be carried out by a

factory trained technician.

Mk7 Evolution
398 of 761
Micro Modulation Burner Control Sequence Diagrams
Interrupted Pilot

Mk7 Evolution
399 of 761
Lockout

Mk7 Evolution
400 of 761
Intermittent Pilot

Mk7 Evolution
401 of 761
Post Burner Operation VPS

Mk7 Evolution
402 of 761
Diagram Notes
If VPS is not optioned on the fuel selected, the VPS phases are bypassed.
point idle:
this phase is set at power up when no fuel selected on exit from lockout.
point recycle:
this phase is set on exit from firing and post purge if VPS has not operated after burner run.
point post purge:

this phase is set only if post purge is optioned.
point standby:
this phase is set if VPS has operated after burner run.
Normal lockout is reset when either the mains lockout reset input is set for 2 second or the front facia
lockout reset button is pressed for 2 seconds.
Prolonged lockout reset/special lockout is set if either the mains lockout reset input lockout reset or
front facia lockout reset input is set for 10 or more seconds. Normal lockout is set on exit from
permanent lockout reset/special lockout after 20 seconds and is reset in the normal way.
Bold waveforms indicate required condition. Values above/below waveform are time in seconds that
the state must be continuously incorrect after which a lockout is set. If the waveform is not bold then
the status is not important.

Mk7 Evolution
403 of 761
Micro Modulation Control Box Functions Overview
2.17.3.2 Self Check UV Scanner
Part Numbers: MM60003 Connections

MM60003/HS
Red Terminal #51
Maximum operating temperature- 500C / 1220F Blue Terminal #50
Black Screen
Yellow Terminal #21
Green Terminal #22
NOTE:
I.P. RATING 54
NEMA 5
POWER CONSUMPTION- MAXIMUM 0.5W
HOUSING- ALUMINIUM
MOUNTIN- ANY ORIENTATION

Mk7 Evolution
404 of 761
2.17.3.2 Self Check Side View UV Scanner
Part Numbers: MM60003/HS/SV Connections
Red Terminal #51

Maximum operating temperature- 500C / 1220F Blue Terminal #50
Black Screen
Yellow Terminal #21
Green Terminal #22

Mk7 Evolution
405 of 761
2.17.3.3 Standard European UV Scanner - Side-viewing
Part Numbers: MM60004

MM60004/HS
Maximum operating temperature- 600C / 1400F
View A Î
IP 54
NEMA 5
HOUSING: ALUMINIUM
POWER COMSUMPTION: POWERED BY MK.7 MM
MOUNTING: ANY ORIENTATION AS LONG AS PHOTO TUBE FACES THE FLAME
Connections
Red Terminal 51
Blue Terminal 50
Black Screen
View A
(with cover removed)
50 51
Note: If wired incorrectly a limited U.V. will

be detected but the L.E.D. will not illuminate.
Two red LEDs show UV detection

Mk7 Evolution
406 of 761
2.17.3.4 Standard North American UV Scanner - End viewing
Part Numbers: MM60004/U

MM60004/HSU
Maximum operating temperature- 600C / 1400F
View A Î
IP 54
HOUSING: ALUMINIUM
POWER COMSUMPTION: POWERED BY MK.7 MM
MOUNTING: ANY ORIENTATION AS LONG AS PHOTO TUBE FACES THE FLAME
Connections
Red Terminal #51

Blue Terminal #50
Black Screen
View A
(with cover removed)
50 51
Note: If wired incorrectly a limited U.V. will

be detected but the L.E.D. will not illuminate.
Two red LEDs show UV detection

Mk7 Evolution
407 of 761
2.17.3.4 Standard North American UV Scanner - End Viewing Dimensions
Dimensions

Mk7 Evolution
408 of 761
Micro Modulation
2.17.3.5 Selection of UV Scanner Types
Normal Sensitivity
If the distance from the UV scanner to the flame is up to 20 inches (500mm) the normal sensitivity UV
scanner types may be used.
Normal Sensitivity Scanner Types:
MM60003 Self Check

MM60004 Standard (Side View)
MM60004/U Standard (End View)
Dependant on the application (e.g. flame size/shape/intensity, flame obstruction e.t.c.) where the
signal strength is low, a high sensitivity scanner type may be necessary for distances below 20 inches.
High Sensitivity
If the distance from the UV scanner to the flame exceeds 20 inches (500mm) the high sensitivity UV
scanner types are recommended. The maximum distance from the flame is dependant on the amount
of radiated UV. This will vary between applications but the typical maximum distance is 6ft (1500mm).
High Sensitivity Scanner Types:
MM60003/HS Self Check

MM60004/HS Standard (Side View)
MM60004/HSU Standard (End View)
The information above is based on the results of tests using a simulated pilot flame. The flame was
simulated by means of a bunsen burner flame with a flame size of 100x20mm.

Mk7 Evolution
409 of 761
Micro Modulation
2.17.3.6 UV Self Adaptive Pulse Width Modulation
1 COUNT AS SEEN ON M.M. DISPLAY

PURGE VOLTAGE
IGNITION VOLTAGE
NOTE: 1
380
TYPICAL RESPONSE FROM CELL
330
300
VOLTAGE DC
TIME REDUCTION
0
0
TIME ms
0 1000
10 ms (NOTE 4)
240 ms
500 ms (NOTE 3)
750 ms (NOTE 2) 10 ms
1000 ms
NOTE: 1
AFTER FIRST SAFETY TIME VOLTAGE IS REDUCED BY 5 VOLTS EVERY 500 ms, THIS IS PROVIDING THE FLAME SIGNAL IS ABOVE THE U.V. SETPOINT.
IF BELOW THE U.V. THRESHOLD VOLTAGE WILL REMAIN AT 330 VOLTS. THE VOLTAGE WILL NOT INCREASE DURING MAIN FLAME OPERATION.
NOTE: 2
IF 5 COUNTS OR LESS HAVE BEEN DETECTED OVER ANY 730 ms PERIOD THE SYSTEM WILL INVOKE A LOCKOUT.
A SHORT CIRCUIT BETWEEN THE 2 WIRES CONNECTED TO THE U.V. WOULD PRODUCE 3 COUNTS OR LESS. THIS IS THE REASON FOR
NOMINATING 5 COUNTS AS THE LOCKOUT LEVEL.
NOTE: 3
DURING NORMAL OPERATION 300 VOLTS WOULD BE APPLIED FOR A 240 ms PERIOD AFTER THE SECOND SAFETY TIME. THIS IS PROVIDING
THE U.V. SIGNAL IS ABOVE THE U.V. SETPOINT WHICH IS SET AT 25 COUNTS. THE SETPOINT CAN NOT BE ADJUSTED.
NOTE: 4
WHEN THE SIGNAL IS ABOVE THE U.V. SETPOINT, THE TIME VOLTAGE IS APPLIED TO THE CELL IS REDUCED BY 1 ms EVERY 500 ms.
THE TIME WOULD CONTINUE TO REDUCE UNTIL A MINIMUM OF 10 ms HAS BEEN REACHED.
AT THIS STAGE NO FURTHER TIME IS DEDUCTED FROM THE VOLTAGE APPLIED TO THE CELL.
NOTE: 5
EVERY 500 ms THE RECORDED COUNTS ARE AVERAGED AND DISPLAYED ON THE M.M. SCREEN. 4113/19:04:00/SBK

Mk7 Evolution
410 of 761
Micro Modulation Error Checking, Self Diagnostic Fault Analysis Codes, I.D. Codes
2.17.4 Error Checking, Self Diagnostics Fault Analysis and I.D. Codes
Self Diagnostic Fault Identification Software
The “Error Checking” software, which is included in every M.M. E.G.A. module, continually interrogates
the system for component or data handling failure. This intensive self checking programme is inflicted
on all peripherals such as positioning motors and load detectors as well as the main M.M./E.G.A. system
hardware. The safety related areas, both hardware and software, have been examined and accepted
for CE, UL, FM and TUV.
Any error identified by the system is indicated by “ERROR” being displayed and the relevant error
number. In the case of E.G.A. related faults, “ERROR EGA” is displayed with the corresponding error
identification code.
2.17.4.1 Key to Errors Detected in Mk7 M.M. System
ERROR- confirms that error has been detected in the M.M. System.
Error Fault Type Code No
CH1 Positioning Error 01

CH2 Positioning Error 02 - Check wiring & motor
CH1 Gain Error 41

CH2 Gain Error 42 - Check wiring & potentiometers are
CH3 Gain Error 43 zeroed correctly
CH4 Gain Error 46
CH5 VSD Error 80 - CH5 variable speed drive error

CH6 VSD Error 81 - CH6 variable speed drive error
CH5 VSD Feedback Error 83 - CH5 variable speed drive feedback
signal different to commissioned values
CH6 VSD Feedback Error 84 - CH6 variable speed drive feedback
signal different to commissioned values
See section 2.17
.2.10
Load Detector 03 - Open circuit on temperature sensor
12V/5V Supply Error 44 - Internal 5V/12V supply outside limits.

Check 12V on terminals #40 & 41
Gas Sensor Recommission Error GASRECOMM - Reset option/parameter

#150 back to 0 and reset options/
parameters #136/137 back to original
values

Mk7 Evolution
411 of 761
Error Fault Type Code No
Air Sensor Recommission Error AIR RECOMM - Reset option/parameter

#150 back to 0 and reset option/
parameter #147 back to original value
Watchdog - Error CR2 45 - Unit hardware failure

Option/parameter #110 is set to 0
A/D Converter Error 47 - Check 12V supply on terminals #40, 41
Twin Burner Communications Failed 100 - Flashing error- no communications

between the M.M. units
Air Pressure Outside Limits 82 - During run mode actual air pressure
outside limits, commissioned +/- 0.3 “wg
(see option #147)
Gas Pressure Sensor MM60008 optioned 110 - See options #124 & 133 to 137.
together with psi units PSI display cannot be chosen for this
sensor range
WL probes detected 251 - Water level probes are detected but the
WL not optioned MM is configured for operation without
Check WL configure the water level. Check the second
password screen
2.17.4.2 Mk.7 Burner Control Lockouts
Lockout Message Cause
CPI input wrong state Proof of closure switch opened during ignition sequence
Check terminal #55 and proof of closure switches
(cpi = close position interlock / proof of closure)
No air proving No air pressure during start/firing

Check terminal #54 and air switch
VPS air proving fail Leak detected during ‘air proving’ part of VPS
Check 1st main valve
VPS air zeroing fail When valve C opens, zero value outside limit +0.5 to -1.0” wg
Check vent valve
VPS gas proving fail Leak detected during ‘gas proving’ part of VPS
Check 2nd main valve and vent valve
Check pilot valve if using single pilot operation (option #130)
VPS gas pressure low Gas pressure below minimum application pressure
Check option #133 for minimum allowable pressure
No flame signal No flame signal during ignition/firing

Mk7 Evolution
412 of 761
Lockout Message Cause
Simulated flame The flame is present when it should not be. Call for service
immediately. This is potentially a dangerous condition.
Fail safe relay fault 57

Vent valve output fault 62 These terminals are self checked within
Main gas output 1 fault 61 the Mk7. If a voltage is detected when
Main gas output 2 fault 60 the output is off (and vice versa) a
Start gas output fault 59 lockout occurs.
Motor output fault 58
Ignition output fault 63
Shutter fault UV signal detected during shutter operation on UV self check

Check wiring on terminals #21/22
Prolonged lockout reset Prolonged voltage present on terminal #56/lockout reset

button permanently pressed
No CPI reset Proof of closure switch not made after valves closed after
firing
Check terminal #55 and proof of closure switches
Gas pressure low limit Gas pressure low limit exceeded when using a gas sensor
Check option #136
Gas pressure high limit Gas pressure high limit exceeded when using a gas sensor
Check option #137
Gas pressure low Low gas pressure before start up
UV short circuit Connections to UV tube shorted
Oil pressure low limit Oil pressure low limit exceeded when using an oil sensor
Check option #139
Oil pressure high limit Oil pressure high limit exceeded when using an oil sensor
Check option #140
Purge air pressure low Insufficient air pressure during purge

Check option #141
Option #141 incorrect Option #141 is set without option #148
Freeze timeout Pilot turndown test time exceeded (10 minutes)

See section 2.17.15

Mk7 Evolution
413 of 761
Watchdog fault 1a
Watchdog fault 1b
Watchdog fault 1c Internal fault diagnostics - contact
Watchdog fault 1d Autoflame and report code displayed.
Watchdog fault 2a
Watchdog fault 2b
Watchdog fault 2c
Watchdog fault 2d
Ram test failed

Prom test failed
CPU test failed Internal fault diagnostics - contact
Input fault Autoflame and report code displayed.
BC input short
Lockout 198, 199, 200, 201, 202
Terminal 86 inverse Terminals #85/86 both have an input or teminals #85/86

both do not have an input when using the flame switch or
IR sensor operation- see option #122.
Termminal 85-86 fault Electronics fault on either terminal #85 or #86.
Prove cct fail Loss of input on terminal #52. Terminal #52 must see an
input at all times from the position to purge to the end of the
post purge (cct = closed circuit).
Option 118 incorrect If using the NFPA post purge (option #135 = 2) then option
#118 must have a setting of 15 or above.
Boiler DP proving If using boiler differential proving (parameter #92 = 2), and
the input on terminal #85 is reset then this lockout will occur.
Gas Sensor Related
Sensor supply voltage 12V supply to sensor outside limits (11.75 - 12.25V)
Zero low gas sensor see section 2.17.2.6.2 for zero limits
Zero high gas sensor see section 2.17.2.6.2 for zero limits
Excessive VPS Operations VPS has operated 3 times without burner firing
Signal dev - gas sensor redundant signals from sensor do not match
Counts low - gas sensor sensor fault - stuck on signal value
Counts high - gas sensor sensor fault - stuck on reference value
Signal high - gas sensor gas pressure exceeds maximum range value
Gas sensor (+ number) sensor/Mk7 internal fault - report to Autoflame

Mk7 Evolution
414 of 761
Air Sensor Related
Sensor supply voltage 12V supply to sensor outside limits (11.75 - 12.25V)
Zero low air sensor lower limit is -1.0”w.g.
Zero high air sensor upper limit is +0.5"w.g.
Signal dev - air senso redundant signals from sensor do not match
Counts low - air sensor sensor fault - stuck on signal value
Counts high - air sensor sensor fault - stuck on reference value
Signal high - air sensor air pressure exceeds maximum range value
Air sensor (+ number) sensor/Mk7 internal fault - report to Autoflame
The “Error Checking” software, which is included in every M.M. module, continually interrogates the
system for component or data handling failure. This intensive self checking programme is inflicted on
all peripherals, e.g. positioning motors/load detectors as well as the main M.M. system hardware. The
safety related areas, both hardware and software, have been examined and accepted for CE, UL, FM
and TUV.

Mk7 Evolution
415 of 761
2.17.4.3 Troubleshooting Guide
Gas/air sensor Diagnostic Codes
Shown at the bottom of the display if parameter #83=1.
Example:
Gas 43 1001
42 42 1000
Air 50 969
51 51 970
Explanation:
Average Pressure Reference

Signal Signal Signal
Gas 43 1001 Senso r Channel 1
Gas {
42 42 1000 Senso r Channel 2
Air 50 969 Senso r Channel 1
Air {
51 51 970 Senso r Channel 2
Typical reference signals are 1000±14. If the reference signal values display 0 or are blank then the
sensor is wired incorrectly.
Each sensor has two channels. Each channel gives out two values- a pressure signal and a reference
signal. The values displayed are ‘digitised’ signals (range 0-1023). The two pressure signals should
be the same. The two reference signals should be the same.
If the two pressure signals are different by more than 10 the averaged value will show 01 and not the
average of the two signals.
With no pressure applied to the sensor the pressure signal value should be between 20 to 60 (typically
between 40 to 50). If the reading goes below 5 then an error will occur due to a negative pressure on
the sensor.
Note: These values are only displayed once the burner has been commissioned.

Mk7 Evolution
416 of 761
AC Drive Diagnostic Codes
Shown at bottom right of the display if parameter #83=1.
Example:
0 0 250 253 254
0 0 100 120 121
Explanation:
1 2 3 4 5
CH5 AC Dri ve 0 0 250 253 254
CH6 AC Dri ve 0 0 100 120 121
1 & 2- should normally be 0.
3 to 5- digitised values, 0-255.
3- represents linearly (0-255) 4-20mA/0-10V the analog output from the MK7.
4- represents linearly (0-255) 4-20mA/0-10V the analog commissioned value.
5- represents linearly (0-255) 0-20mA/0-10V the analog input into the MK7.
1- window error count value will increment if the difference between 4 & 5 is greater than 10. An
M.M. error will occur if the count reaches 150. This takes approximately 3 seconds.
2- disparity error count value - will increment up if the difference between 4 & 5 is greater than 15. An
M.M. error will occur if the count reaches 50. This takes approximately 1 second.
Error checking is only carried out when the burner is firing.
The correct feedback signals must be attained for purge & ignition to progress, i.e. 5 must be as 4±15.

Mk7 Evolution
417 of 761
UV Shutter Faults
UV shutter fault– there are two LED’s on the back of the self-check UV. The red LED indicates the presence
of a flame, the yellow LED indicates shutter operation. The red LED will flicker in the presence of UV
light. Every 60 seconds the yellow LED will come on, indicating that the shutter is closing. The red LED
should then extinguish briefly. If this is not happening check the wiring to self check UV sensor:
Green wire = terminal #22

Yellow wire = terminal #21
Blue wire = terminal #50
Red wire = terminal #51
UV Problems
If the red LED’s fail to illuminate but the burner operates, the flame signal will be reduced. It is
likely that the 2 wires are crossed. This must be corrected. Once corrected a full flame signal
strength will be displayed/registered.
The Autoflame UV software utilises early spark termination within the internal flame safeguard
control. Therefore, detection of the ignition spark is allowed. During start-up the ignition is de-
energised and the pilot flame must be proven without the spark before the main fuel valves are open
(safety shut off). Due to the above statement it is not necessary to have a sight tube on the UV for
pick-up. This, in fact, will drastically reduce the flame pick-up.
If insufficient UV is detected, it is advised to use a swivel mount assembly (UVM60003/

UVM60004) in order to obtain maximum pick-up. This will allow the commissioning engineer to
reliably sight the UV for optimum performance and trouble free operation.
Note: Under no cicumstances is a non-Autoflame UV scanner

permitted to be used. This is in breach of all codes and
approvals associated with the Autoflame combustion
management system. This may lead to serious
equipment damage, critical injury or death.
If a non-Autoflame scanner is required then please contact Autoflame directly for technical support.

Mk7 Evolution
418 of 761
Micro Modulation Interacting with the Mk7 Interface
2.17.5 Interacting with the Mk7 Interface

2.17.5.1 Operating Mode - Mk6 Mode
The Mk6 mode emulates the user experience of the Mk6 units (the mode of operation is selectable on the
system configuaration screen and allows seamles transition between Mk6 and Mk7 modes of operation).
Whilst in this mode, all features and screens are the same as those on standard Mk6 units. Due to the
nature of resistive touch-screen technology, two buttons cannot be physically pressed simultaneously
on-screen. This feature is implemented through the use of “Button Hold” facility.
- Button Hold: This button toggles multiple button press on/off.
- Press Buttons: This button is used to press currently selected buttons.
Button hold instructions:

1. Press “Button Hold” button . The on-screen LED ( ) will appear confirming that the
button is active.
2. Select the buttons you wish to press simultaneously. A square box will surround the currently
selected buttons (e.g. )
3. Press the “Press Buttons” button to press the selected buttons simultaneously.
Note: Two additional buttons have been added to the Mk6 screen to facilitate the process of
accessing the options and parameters menu. These buttons are only available when the MM is in
commissioning mode.
Mk7 Evolution
419 of 761
Operating Mode - Mk7 Mode
Selecting Mk7 mode by pressing on the System Configuration screen will show the above
screen. This is screen is termed “Home Screen” and displays the current boiler room setup. It provides
operating information about each component of the boiler in real time. Pressing on a component
(selectable components highlighted above) will display further information about it.
Note: - For flame graphics to appear correctly, fuel flow metering data must exist (refer to 2.17.5.5.7).
- All commissioning procedures are carried out in Mk6 mode. The MM will automatically switch
to this mode when appropriate.

Mk7 Evolution
Micro Modulation
Issue: 08.12.2009
Status
Lockout Record Status
Lockout Record Setpoint History
Water Level Alarms
Servo Position History
Efficincy History
MM Servo Channels VSD Ch5
Gas History EGA
VSD Ch6
Temperature Hisotry
Status
Safeguard IBS
Flame Safeguard Boiler Firing History
First Outs
Online
Mk7 Fuel Flow
Mode Flow Rate History
Mk6
Home Screen
Set Clock Flow
Mk 7 - Screen Map
Clock Steam Flow Metering Steam

Run Times
Screen Calibration Heat
Language Selection Screen System Configuration Fuel
Boiler Configuaration VPS

Boiler Room Configuaration Air
View Options Outside Temperature Compensation
View Options/Parameters
View Parameters
Boiler
Change Options
Online Changes Water Levels Probes
Change Paramters
History
420 of 761
Section 2.17.5.2.2
Interacting with the Mk7 Interface
Mk7 Evolution
421 of 761
Home Screen (Buttons)
The Home Screen comprises of various buttons that can be selected to navigate through the various
screens of the Mk7 unit. The buttons that appear on screen depend on the boiler room configuration.
Button Button Name Notes

Action: This button will open the MM
Servo Channels (section 2.17.5.5.2)
screen.
Servo motor button This button is animated to display real time
information corresponding to the servo
movement. It may appear in several places
on screen.
Action: This button will open the MM Servo
Channels screen (section 2.17.5.5.2).
VSD button
The fan will rotate when the fan motor/VSD
is active.
Action: This button will display the flame safeguard
screen (section 2.17.5.5.3).
Flame safeguard
Button The number of counts will be displayed above this
button if a UV/IR sensor is used. If a flame switch
is used, the current state of the flame (on/off) is
displayed.
Action: This button will display the flame safeguard
Flame safeguard screen (section 2.17.5.5.3).
button
It will animate during the burner’s sequence.
Action: This button will display water level screen
(section 2.17.5.5.9).
The temperature icon will display the current
Water level button water inlet temperature in real time.
(This button will only appear if a water level board

has been connected & configured)
Action: Pressing this button will display the status
screen (section 2.17.5.5.1).
The exact display of this button will vary greatly

to match the current boiler room setup
(eg: existence of feedwater management, current
fuel being used, boiler type, etc).
Boiler status button The flame colour will correspond to the current fuel
being used (blue = F1 & F4 (Gas) or orange = F2
& F3 Oil).
The flame length will correspond to the current

firing rate. Fuel flow metering must be completed
for this function to be accurately displayed.

Mk7 Evolution
422 of 761
Button Button Name Notes

Action: this button will open the EGA screen
(section 2.17.5.5.6).
It will display in real time, the values of O2, CO2,

E.G.A. button CO, exhaust gas temperature and current
combustion efficiency. This button will only appear
if an EGA has been optioned.
Action: This button will open the IBS screen

(section 2.17.5.5.4).
This button will display in real time the ID number

I.B.S. button of the current boiler and the current IBS status.
This button will only appear if IBS is optioned

(option 16).
Action: This button will open the VPS screen

((section 2.17.5.5.8).
Fuel pressure
sensor history This button will animate to show each stage of the
button VPS sequence in real time. This button is available
in 2 and 3-valve configurations (option 130).
Action: This button will open the OTC screen

Outside (section 2.17.5.5.11).
temperature
It will display the current outside temperature.
compensation Note: Not to be confused with water temperature
button sensors (shown in blue on Home Screen).

Mk7 Evolution
423 of 761
Home Screen (Components)
- Servo - Variable Speed Drive
- Gas Pipe (no flow) - Gas Pipe (gas passing)
- Oil Pipe (no flow) - Oil Pipe (oil passing)
- Water Pipe (no flow) - Water Pipe (water passing)
- Feed Water Valve - Flue Gas Recirculation Valve
- Damper - Piping (gas is currently flowing)
- Gas Valve (solenoid closed) - Gas Valve (solenoid open)
- Fuel Valve (closed) - Fuel Valve (open)
- Regulator - Flame Detector
- Temperature Sensor (water) - Temperature Sensor (outside)
- Pressure Sensor (air/steam) - Pressure Sensor (fuel)
- Intelligent Boiler Sequencing

information
- Emissions Gas Analyzer
information
- Fan
- Water Level - Water Level Probes

Mk7 Evolution
424 of 761
- Gas flame
- Oil Flame
- Firetube Boiler
- Watertube Boiler

Mk7 Evolution
425 of 761
2.17.5.4 System Configuration
This is the main configuration screen of the Mk7. The system configuration screen is divided into the
following sections:
1. The serial number of the unit and software versions currently in use (BC, MM and DI).
2. The current date and time.
Boiler configuration – here you can enter the Language Select screen or the Boiler Room
Configuration screen.
Mode – here you can select the current operational mode: Mk7 or Mk6. The current mode selected
is marked by a blue L.E.D ( ).
View Options/Parameters – here you can view all 150 options and parameters as well as the values
for each of them. No password is needed to view this information as their setting cannot be changed
via this screen.
Clock – here you can set the current date and time (Set Clock) and program the Run Times.
On-line Changes - here you can enter Single Point Change and do on-line changes (options and
parameters #1- #109).
Calibrate Screen – this will allow the user to calibrate the screen.

Mk7 Evolution
426 of 761
Language Selection
The language screen allows for selection of on-screen language. This language will be applied
throughout the Mk7 screens.
The Mk7 can accommodate any language. If you are interested in translating the on-screen text to a
language that does not appear on this menu, please contact Autoflame technical support directly on
sales@autoflame.com.

Mk7 Evolution
427 of 761
Boiler Configuration
The boiler room configuration screens allow you to define the exact configuration of your boiler.
The settings optioned on this screen will appear on the Main Screen once they have been entered.
and - Navigational buttons used to moved though the verious screens.
- Currently selected options are denoted by this blue LED.
- When boiler room configuration is complete, navigate to Page 3 and this button
to accept the current configuration.
Note: the buttons on Page 3 are only selectable/applicable when the “Water Level Configuration
Screen” (displayed after entering the password when in commissioning mode) is set to 3 and 3 and
“Steam” boiler is selected on Page 1.
Mk7 Evolution
428 of 761
Viewing Options and Parameters
These screens allow you to view all 150 options and parameters while the burner is firing. The options
cannot be modified from these screens. In order to change options 1 – 109, refer to the online
changes part of this manual (section 2.17.5.4.6). To change options 110 - 150, the unit must be in
commissioning mode.
Whilst viewing, the currently selected value for each option is listed on the right most side of said
option. All options/parameters are selectable and pressing on an option will display further
information.

Mk7 Evolution
429 of 761
Micro Modulation Interacting with the MK7 Interface
Single Point Change
Single point change is only available while the burner is firing. At all other times, the button
is disabled.
Commissioning of the fuel curve (as with all forms of commissioning) is done via Mk6 mode. To this
end, the MM will switch to the MK6 commissioning screen automatically until single point change has
been completed.
In order to successfully carry out single point change, follow these instructions:
1. Press button. The unit will switch to Mk6 mode.
2. You will be presented with a password screen. Enter the main password using
buttons (CH1 & CH2).
3. Press . The button will be disabled.
4. Both RUN and ENTER buttons will begin to flash. If you do not wish to proceed with single
point change, press followed by . To begin single point change, select the inter
point to be changed using CH1 buttons and press to start modifying that point.
Upon pressing enter, the “target” column will appear.

Mk7 Evolution
430 of 761
5. Use CH1 - CH6 buttons to change the “TARGET” value of each servo motor. Upon
release of the servo motor corresponding to that channel will modulate to the target
position. Note: “POSITION” denotes the current position of the servo.
6. Once the curent point has been modified to match requirements, press to store the new
commissioning data. If an E.G.A. is optioned, press and a timer (with the value of
Parameter 4) will appear and begin count down. During this time, the button is
disabled. If the emmissions are satisfactory, press to perform AUTOTRIM (given that
Option 12 is set to 1, 2, 3, 4, 5, 6, 8 or 9). Upon completion of AUTOTRIM, the commissioning
data will be stored.
8. Use to select next point to be changed, followed by to edit that point.
9. Repeat steps 6 to 8 for each commissioned point to be changed.
10. Once satisfied, press followed by to resume normal operation.

Mk7 Evolution
431 of 761
Online Changes
1. Enter the online changes password using buttons followed by .

Note: The main password is used to access this screen. You will notice the button is
disabled. This button will be enabled when a change has been made.
2. Select the option you wish to change by pressing on the text (outlined above). The screen for
the selected option will appear. If the Option/Parameter requires a value within a range, select
this using the buttons. If the Option/Parameter requires a value from a
given set, select this by pressing on the text itself.
4. Navigate through the various screens using the and buttons or press
to return to the main Options/Parameters screen.
5. Once the desired Options/Parameters have been altered, press button to confirm the
changes. If you wish to discard the changes made, press without pressing .

Mk7 Evolution
432 of 761
Setting the time
The Set Clock screen is used to set the time used for all functions within the Mk7. It is particularly
mportant for logging functions such as Lockout and Water Level Alarms.
1. Press the button to access the Set Clock screen (this was formerly known as the Time
Clock screen on the Mk6).
2. Using the buttons, enter the Run Time password (CH1 = 10, CH2 = 10).
and press the button.
3. Using the arrows, you can edit each part of the clock to correspond
with the current date and time.
4. Once complete, press followed by to return to the main configuration menu.

Mk7 Evolution
433 of 761
Setting Running Times
The Run Times screen allows the user to set the times at which the boiler will initiate, be off or on
reduced setpoint. This reduced setopint is set on the status screen(section 2.17.5.5.1) for further
details on this feature).
1. Press the button to access the Run Times screen (this was formerly known as the Time
Clock screen on the Mk6).
2. Using the buttons, enter the Run Time password (CH1 = 11, CH2 = 11)
and press the button.
3. Directly beneath Run Times title, the current boiler status is shown. By default, the Time Clock
facility is disabled. To enable/disable this facility, press on the current status text.
4. If the time clock facility is enabled, editing of the the run times will be enabled. In order to select
the Start Time, Stop Time and Mode of operation for any given day, press on the text for that
day (see above image).
5. Pressing on the desired date will show you a screen similar to that below:

Mk7 Evolution
434 of 761
6. Using the buttons, select the time at which the burner starts (Start:), the time at which the
burner stops (Stop:) and the mode of operation for that day. Once the desired settings for the
current day have been set up, press button to return to the main Run Times screen.
Note: the time range between the start and stop times refers to the ON times. All times outside
of this range will either be off, or in a reduced setpoint. For modes “always off” and “always
on”, the times section is disabled as this is no longer applicable.
7. Repeat steps 5 and 6 until each day has been set up as desired. Once complete, press
to record the changes, followed by to return to the System Configuration screen.
Note: If is pressed without firstly pressing , all changes made will be discarded.

Mk7 Evolution
435 of 761
2.17.5.5 Operating Mode Screens
- Status Screen
3 6 7
2
5
The status screen allows ajustment of the required and reduced setpoints using the arrows.
It also displays the following information:
(1) - The Burner Rating
(2) - The current fuel being fired (highlighted) and the other available fuels
- The number of times each fuel has been started and the total time in hours the burner has run
per given fuel (cumulative)
(3) - The current firing rate
- The current actual temperature/pressure reading within the boiler
- The current required setpoint
- The current run mode (relates to Run Times - section 2.17.5.4.8.1)
(4) - Current T#53 status (call for heat)
- Current date and time
(5) - Burner start (option 11) and stop (option 10) temperature/pressure
(6) - Required setpoint. Note: if the required value has been locked, the arrows shown in the
above image will not appear.
(7) - Reduced setpoint (relates to Run Times - section 2.17.5.4.8.1)
Note: the colour of bars (6) and (7) indicates which is active/inactive. Red = active, Grey = inactive.

Mk7 Evolution
436 of 761
Status Screen
Pressing the button shows the setpoint history graph where values for required setpoint,
actual pressure/temperature and firing rate for the past 24h are displayed. Note: the draggable
buttons cannot be used if is enabled.
Some important information from the previous screen remains:
1. - The Burner Rating
2. - The current fuel being fired (highlighted) and the other available fuels
- The number of times each fuel has been started and the total time in hours the burner has run
per given fuel (cumulative)
3. - The current firing rate
- The current actual temperature/pressure reading within the boiler
- The current required setpoint
- The current run mode (relates to Run Times - section 2.17.5.4.8.1)
4. - Current T#53 status (call for heat)
- Current date and time

Mk7 Evolution
437 of 761
MM Servo Channels
The MM servo channel screen displays current and historical servo positioning information as well as
VSD information.
1. Current servo motor position
2. Current input and output values for the two VSD channels
- Displays VSD Channel 5 History.
- Displays VSD Channel 6 History.

Mk7 Evolution
438 of 761
Flame Safeguard
5
2
6
3 8
The flame safeguard screen displays the current status of the system and associated valves.
1. This shows the current phase of the MM. It will update to display the current checks being
carried out in real time.
2. If a flame scanner (not a switch) is optioned, the current signal strength will be shown here.
This section only appears in the presence of a compatible scanner
3. When VPS is optioned, this section displays the valve arrangement and the current status of
each valve during the proving sequence. If an Autoflame gas sensor is used for the proving,
the current gas concentration will be displayed from startup to shut down.
Safeguard diagram:
Throughout the entire firing sequence, the vertical discontinuous line will move horizontally showing
the currently active components. The inactive components are shown in grey, whilst the active
components are displayed in red.
4. The pre and post purge sequence time
5. Servo motor position
6. Main gas valve
7. Start gas valve
8. (Pre-)Ignition
9. Air motor/VFD

Mk7 Evolution
439 of 761
I.B.S.
2
5
The flame safeguard screen displays the current status of the system and associated valves.
The IBS screen shows the status of all the boilers that are set up for IBS. It displays which boiler is the
lead boiler and the current status of burner.
1. The current MM/Boiler ID (black) and the selected lead boiler (red)
2. IBS information for the current boiler
3. Required setpoint, actual pressure and phantom setpoint information. It also displays the type
of sequencing for the current boiler
4. Boiler number
5. Firing rate for each boiler
6. Current burner status (on/off)
- Pressing this button will display the firing rate for each IBS boiler over the passed 24h
(shown below).

Mk7 Evolution
440 of 761
- Pressing this button will display the Boiler Firing History graph. Firing rate information for
a 24h period will be shown for all boilers in the Lead-Lag loop.

Mk7 Evolution
441 of 761
E.G.A.
2 3
Upon entering the E.G.A. screen, the gas history graph will be displayed.
1. The current E.G.A status is displayed here (eg: calibrating, sampling, etc.)
2. The values at time of commissioning (commissioned values).
3. The instantaneous values for each cell, the current exhaust and ambient temperatures.
- Pressing this button will display the gas history graph. This graph shows the measured
concentrations of each gas over the elapsed time period.
- Pressing this button will display the temperature history screen on this screen, both the
ambient temperature and the temperature of the exhaust gases is displayed over the elapsed
time period.
- Pressing this button will display the efficiency history graph showing the combustion efficiency
over the elapsed time period.

Mk7 Evolution
442 of 761
Fuel Flow (Screen)
3
2
If the fuel flow button on the Home Screen is pressed the above screen will be displayed. This screen
shows the commissioned fuel curve for both fuel and air servo positions. It also displays the current
rate of flow of fuel at the current positions. The information of the Fuel Flow screen (online) shown
above information is distributed as follows:
1. Firing rate, flow rate and totalised consumption of all fuels fired
2. Current position of the fuel and air servos
3. Current flow rate at current servo positions.
Note: - Shown on the above screen are commissioned fuel-air values making up the Fuel Curve.
These points are denoted by .
- Pressing on a point inside the the commissioned line will display the curresponding fuel and
air servo positions.

Mk7 Evolution
443 of 761
– Pressing this button displays the Flow Rate History graph. This graph displays current and
totalized flow rate information.
1. Firing rate, flow rate and totalised consumption of all fuels fired
2. Totalized fuel consumption divided by fuel type.

Mk7 Evolution
444 of 761
Fuel Flow (Commissioning)
Fuel flow metering serves to:

Totalized the amount of fuel used
Calculate firing rate and all functions that utilize firing rate information (e.g. flame
graphics, IBS and steam flow metering).
Note: Fuel flow metering information MUST be set in order to allow data download when using a DTI.
If fuel flow metering is being entered for the first time,

1. Start the unit in commissioning mode and set option 57 to 1.
2. Press to accept the change. The unit will restart automatically after a short period.
3. The unit will carry out the burner initiation procedures. Upon reaching “Modulation”, the fuel
flow metering screen will appear automatically.
4. The Mk6 fuel flow metering screen will be automatically appear (even if the MM has is set to
run in Mk7 mode). The display will show the fuel valve position in angular degrees and the

Mk7 Evolution
445 of 761
flow units which can be adjusted by using the CH1/CH2/CH3/CH4/CH5 buttons as

specified at the bottom of the screen. It will also display the number of the current point being
changed.
Note:
a) The minimum numerical value for fuel flow that can be entered into memory is 0.01.
The maximum numerical value for fuel flow that can be entered into memory is 999.0.
b) The values are entered in descending order, i.e. point #10 is maximum flame and
point #1 is at minimum flame. The 10 sequential points on the load index are all
located automatically by the M.M. All values are in units/minute or units/hour.
5. Press button to store this value into M.M. memory.

6. To enter fuel flow data for the next point, press .
7. Repeat steps 4 to 6 until fuel flow data has been entered for each value.
8. Upon entering the fuel flow data for the last point (point No. 1), has been entered the burner
will continue to fire (check what needs to be entered for the burner to continue to fire).
Note: The unit will display the Home Screen if set to Mk7 mode.
9. To reset all totalised values for each fuel use parameter #64.

Mk7 Evolution
446 of 761
Valve Proving System
1 2
2
1
The VPS screen (show above) delivers the fuel and air pressure readings from burner start-up up to a
maximum of 24h. This information is arranged in the following way:
1. Past and current fuel pressure.

2. Past and current air pressure.
- Pressing this button displays the air pressure

histrory graph (shown left).
2
- Pessing this button will display the fuel pressure
histrory graph.

Mk7 Evolution
447 of 761
Water Levels
10
11
1
9
3
5 6 7
12
If a water level component is pressed on the Home Screen, the above screen will be displayed. All
water level information can be viewed here. The information is separated as below:
1. Steam infomration: current rate of flow of steam, current pressure of steam and temperature
of the steam.
2. Feed water information: temperature of the feed water, current angular degree of the feed
water valve and pump status (on/off).
3. Top blow down information: Interval between samples, target solute concentration and
sampled solute concentration.
4. Bottom blow down information: current status (on/off), duration of each bottom blow down
and number of repeats.
5. Feed water pump.
6. Feet water temperature sensor and currently sampled temperature .
7. Feed water valve and current angular position.
8. Capacitance probes.
9. Current operating point (level of water measured).
10. Current steam pressure.
11. Same as 3. Current status and currently sampled solute density.
12. Bottom blow down valve (on/off).

Mk7 Evolution
448 of 761
2
3
- Pressing this button will display the detailed probe information (seen above). This
information is arranged as follows:
1. Current capacitance values for probe 1 & 2.

2. Average of values read in 1.
3. Commissioned capacitance values for each control point.

Mk7 Evolution
449 of 761
- Pressing this button will display the a history of the capacitance values read over the past
24h (seen above). This information is arranged as follows:
1. Commissioned capacitance values for each control point.

Mk7 Evolution
450 of 761
Steam Flow Metering
The steam flow metering screen displays the flow characteristics of both the feed water entering the
boiler and the steam exiting the boiler.
1. The rate of output of steam, heat input to produce said steam, the pressure of said steam and
the temperature of the steam is shown here. This information is shown in the diagram.
2. The feed water temperature is show in real time here.
3. Current feedwater temperature.
4. Current steam temperature and pressure.
5. Amount of heat inputted to raise 1 lb of water at temperature 3. to steam at temperature
and pressure 4.

Mk7 Evolution
451 of 761
- Pressing this button will show the flow rate

history graph (see below). The graph displays the
current rate of flow of steam out of the boiler and
the totalised flow rate. This totalised flow rate is
cumulative (not time averaged).
- Pressing this button will display the steam

history graph. This graph graph displays the
temperature and pressure of the steam inside the
boiler over the course of 24h.
- Pressing this button will display the

temperature history of both the feed water and
steam. It will also display the current heat input.

Mk7 Evolution
452 of 761
Outside Temperature Compensation
4 2 5
The outside temperature compensation screen shows the current outside temperature and the
current (calculated) boiler setpoint. To enable Outside Temperature Compensation, set Option 80 to 1.
1. Maximum boiler required setpoint at minimum outside temperature (Option 81).
2. Current outside temperature and calculated actual required setpoint.
3. Minimum boiler required setpoint at maximum outside temperature (Option 83).
4. Minimum outside temperature (Option 82).
5. Maximum outside temperature (Option 84).
Note: If the actual outside temperature exceeds the boudaries set forth by Options 82 and 84, the
boiler setpoint will remain at the maximum or minimum setpoints specified by Options 81 and 83.

Mk7 Evolution
453 of 761
2.17.5.6 Lockouts, Alarms & Errors
- Lockout Record
1 2 3
The lockouts screen list the last 16 lockouts to occur in chronological order. The format used to display
this information is:
1. Lockout information
2. Phase of the firing sequence at which the lockout occurred
3. Date and time of the lockout. Note: the time used for logging lockouts is that used in the
global clock (refer to 2.17.5.4.7)
4 Date and time when the lockout was reset
- Pressing this button will display the water level alarm record screen.
- The reset button will be enabled when a lockout occurs (uncleared lockout appears in red
text). When it is pressed for 3 seconds the lockout will be reset and the reset button will be
disabled.

Mk7 Evolution
454 of 761
Water Level Alarm Record
1 2
The water level alarm record screen displays the last 16 water level alarms.
1. The type of water level alarm
2. The date and time at which the alarm occurred
3. Date and time when the lockout was reset
- The reset button will be enabled when a lockout occurs (uncleared lockout appears in red
text). When it is pressed for 3 seconds the lockout will be reset and the reset button will be
disabled.

Mk7 Evolution
455 of 761
First Outs
1 2 3 4
The First Outs screen displays all uploaded First Out data. This data is displayed accros 4 columns:
1. First out label.

2. Past and current air pressure.
3. Action.
4. Current status.
- Press and hold this button for 5 seconds to reset a First Out alarm. It is only available in the
event of an alarm.

Mk7 Evolution
456 of 761
Errors
The MM error screen will appear when an error occurs. Errors are major faults that cause the MM to
cease the functioning of all Autoflame controlled components simultaneously. The MM must be
restarted manually for the error to be reset.
1. Cause of the error (please refer to section 2.17.4.1 for a list of error codes)
After the MM has been restarted, the error screen will reappear until the cause of the error has been
resolved.

50
UV
DETECTOR 51
GREEN
I+
YELLOW
BLUE
CH 5 INPUT
21 50 +V
SELF CHECK FROM VSD
RED I-/OV
1 2 3
22 U.V DETECTOR 51 0-10V/4-20mA
EXTERNAL AUXILIARY
Mk7 Evolution
I+
DELAY TO PURGE CH 6 INPUT
NON-RECYCLING INTERLOCK +V
FROM VSD
LIMIT STAT
Micro Modulation
BURNER ON/OFF I-/OV
S 4 5 6
0-10V/4-20mA
Issue: 08.12.2009
RUNNING INTERLOCK
AIR PROVING SWITCH
SAFETY INTERLOCK CIRCUIT I+
GAS VALVES C.P.I./POC AUX ANALOGUE EXTERNAL
PRE-IGNITION +V
S 7 8
INPUT LOAD/MODULATION
LOCKOUT RESET I-/OV
9
0-10V/0-20mA CONTROLLER
CALL FOR HEAT
I+
CH 5 OUTPUT
N BURNER MOTOR +V
INLET TO VSD
I-/OV
OUTLET PRESS. START/PILOT FUEL VALVE 0-10V/4-20mA
PRESS.
(OPTIONAL) MAIN FUEL VALVE 1 I+
CH 6 OUTPUT
GAS BOOSTER MAIN FUEL VALVE 2 +V
TO VSD
I-/OV 0-10V/4-20mA
VENT VALVE
IGNITION TRANSFORMER I+
AUX ANALOGUE FIRING
+V
50 51 S 52 53 54 55 56 57 58 59 60 61 62 63 64
NOT USED OUTPUT RATE
I-/OV
EARTH 0-10V/4-20mA %
10 11 12 S 13 14 15 S 16 17 18 S
NEUTRAL
BLUE
LIVE/HOT OUTSIDE TEMP.
RED
SENSOR
YELLOW
CW 19 20 S 21 22 GREEN
L CH1
LINES.
*NOTE:
CCW
CW 23
TWIN BURNER
110Vac
L CH2 24
CCW RS485
6A FUSED SUPPLY
CW 23 E.G.A. ANALYSER
L CH3 31 RS485 Mk.7
CCW
LINE VOLTAGE
24Vac
LOW VOLTAGE
27
POSITIONING MOTORS
CW 28
DTI/IBS RS485
L CH4 SERIAL PORT
CCW
L N
I.B.S. 2-PORT VALVE INFRA RED
L N
23 24 S 25 26 27 28 S 29 30
L/O, MM & EGA ALARM OUTPUT SERIAL PORT

(COMMON SYSTEM ALARM)
YELLOW
AIR PRESSURE
GREEN

SENSOR
NOT USED BLUE
RED
A 110-24v TRANSFORMER AS SHOWN IN DOTTED

YELLOW GREEN
HIGH INTERLOCK, DELAY PURGE TIME
35
GAS PRESSURE OIL PRESSURE INFRA RED
66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84
(SEE PARAMETER 92) GREEN
SENSOR SENSOR POWER
S 31 32 33 34 35 36 S
MM70001/E WITH OR WITHOUT WATER LEVEL P.C.B. 120/230Vac
FOR 110v, TERMINAL 69 FEEDS POSITIONING MOTORS VIA

RED BOILER WATER
0V
OR
FLAME SWITCH WHITE TEMP. SENSOR
AT NO FLAME STATE. LINE V BLUE
3 BOILER STEAM CH1 CH2
GREEN
SECOND SET POINT SELECT 2 PRESSURE FUEL AIR
RED
LEAD BOILER SELECT (IBS)/LOCAL-REMOTE PID 1 SENSOR 0V W +V 0V W +V
FUEL 1
FUEL 2
FUEL 3
FUEL 4
NIGHT SET BACK/
STANDBY WARMING
HAND
POTENTIOMETERS
L.F.H.
POSITIONING MOTOR
85 86 87 88 89 90 91 92 93 94 95
457 of 761
S 37 38 39 S 40 41 42 43 44 45 46 47 S
AUTO
0V W +V 0V W +V
CH3 CH4
Section 2.17.6.1
Electrical Schematics
Mk7 Evolution
458 of 761
Micro Modulation Electrical Schematics
Steam Pressure Sensor
Part Numbers- MM10008/9/10/16
NOTES
MAXIMUM 2.5mm FLAT BLADE SCREW DRIVER FOR ELECTRICAL CONNECTIONS

I.P. RATING 65
NEMA 4
TORQUE SETTING- 15-20Nm
DO NOT USE CASE TO TIGHTEN PRESSURE CONNECTION.
O-RING MATERIAL- VITON
MAX. STORAGE TEMP. -25 TO +85 DEG. C
MAX. OPERATING TEMP. -25 TO +85 DEG. C
MEDIA TEMP (STEAM) -25 TO 85 DEG. C
Part no. Actual Range Over Pressure Burst Pressure

MM10010 3.0 - 55.0 psi (0 - 3.80 bar) 145 psi (10 bar) 174 psi (12 bar)
MM10008 30 - 330 psi (0 - 23.0 bar) 870 psi (60 bar) 1087 psi (75 bar)
MM10009 30 - 550 psi (0 - 38.0 bar) 1160 psi (80 bar) 1740 psi (120 bar)

Mk7 Evolution
459 of 761
Interconnection between M.M. Module and E.G.A. Sampling Unit
EGA Unit
Fuse
Holder
Heated Sample
FUEL 1 Line Control
FUEL 2 4-20mA Input
NEUTRAL
N EARTH _ +
4-20mA
CH. 6 I +
to DTI
CH. 5 I +
CH. 4 I +
CH. 3 I + Common
LIVE Analogue
CH. 2 I + Output I -
FUEL 4
CH. 1 I +
FUEL 3
M.M. Module
CONTROL
DATA CABLE
FUSE

Mk7 Evolution
460 of 761
Interconnection between M.M. Module and O2 Interface Module

Mk7 Evolution
461 of 761
O2 Interface Module
The O2 interface module allows the use of an existing O2 sensor and in-situ probe to be used in
conjunction with the M.M. control.
The O2 analyser is only measuring the O2 reading from the sensor and the exhaust gas temperature
via a thermocouple mounted into the stack. It is important to note that the signal from the O2 sensor
must be a 4-20mA and the thermocouple reading must be a 0-10V signal. These signals must be ranged
as below:
O2 reading: 4 - 20mA = 0 - 20.9% O2

Thermocouple reading: 0 - 10V = 50C - 400C (122F - 752F)
Although the analyser is only measuring the O2 reading from the stack it is possible for the O2 interface
module to extrapolate a CO2 value from the O2 sensor reading. These value can then be displayed
on the M.M. facia (via the E.G.A. button) or via the D.T.I. on a PC or BMS interface.
Parameter #60 is used to set the operation of the O2 interface module.
If this is set to a value of 0 then the efficiency will be calculated from the exhaust temperature and CO2
value and this will be displayed on the M.M. facia. The CO reading will always be displayed as a zero
value.
If this is set to a value of 1 then the CO, NO, exhaust temperature and efficiency will remain blank.
If using the O2 interface module it is possible to use the limits for O2 readings and exhaust gas
temperature readings.

Mk7 Evolution
462 of 761
Micro Modulation Twin Burner Operation
2.17.7 Twin Burner Operation
2.17.7.1 Twin Burner Commissioning
Options #14 and #33 have to be set to correctly implement twin burner operation. Refer to the option
section. For commissioning purposes it is easiest to set option #14 on each M.M. to value 0, and
commission each burner individually. It is the commissioning engineer’s responsibility to ensure that
no adverse effects are caused as a result of this, particularly, stress to a boiler not designed to have only
one burner firing. If this is the case then both burners must be commissioned simultaneously.
AFTER COMMISSIONING SET OPTION #14 TO IT'S TWIN BURNER VALUE ON BOTH M.M.s
Before commencing commissioning set the following options (refer to options section for more details):
Option #33:
Set value of left hand burner to its appropriate identification number, e.g. #1. Set the right hand burner
to the Identification of the left hand burner +1, i.e. #2.
Option #33 will have to be interpreted if the boilers are numbered right to left. The details here are for
left to right numbering.
Other options may be set as usual.
Normal Operation
Only the odd numbered M.M. needs an input on terminal #88 to make this boiler lead boiler. If a
connection is made to the even number M.M. it will be ignored. The same applies for the hand/auto/
low flame hold inputs #94/95, i.e. they do not need any connection on the even number M.M. if option
#14 = 1. If option #14 = 2 then terminals #94/95 should be wired as normal for hand operation.
The even number burner always takes its load index from the odd number burner including when in
‘Hand’ mode. If communications between the two burners fail, each M.M. will open its internal stat and
approximately every three seconds the displays on each M.M. show a flashing ERROR 100 to indicate
a communications failure if option #14 = 1. If option #14 = 2 then the 2 M.M.s run stand-alone.
When entering the flow metering for sequencing purposes it is necessary to put both M.M.s into the
“Flow Metering” mode at the same time,
i.e. Start up both burners, wait until both are modulating then press and on one
of the M.M. units.
Within 10 seconds press and on the other M.M.
Keep the firing rate of each burner similar when entering profile, i.e. do ‘point 1’ on each M.M. then
‘point 2’ on each M.M, e.t.c. This is important as the boiler may be susceptible to stress if one tube is
fired at a different rate to the other. The required setpoint and actual value on the even numbered M.M.
will mimic the values on the odd number M.M.

Mk7 Evolution
463 of 761
The internal stat of the even numbered M.M. follows the odd number M.M.
If Option #14 = 1, i.e. both burners fire simultanesouly and together at all times, then the internal stat
of both M.M.s will open if there is a period of more than 10 seconds when one M.M. is modulating
and the other is not. Therefore, both burners will be off. If one burner locks out then the other burner
will shut down immediately.
There are various points that are checked when the system starts up, such as position to purge, purge,
position to start, ignition and modulation. This ensures that both burners are operating together and
simultaneously.
The load detector input in the even numbered M.M. can be left open circuit, it will not be error checked.
If an error condition arises on one or other of the M.M. units and option #14 = 1 then the other unit
will open its internal stat and flash ERROR 100.

Mk7 Evolution
464 of 761
Interconnection between the M.M. Modules for Twin Burner Operation
The same arrangement applies to the Mk7 and Mk6 Evo.

Mk7 Evolution
465 of 761
Micro Modulation Hand/Auto & Low Flame Hold Facilities
2.17.8 Hand/Auto and Low Flame Hold Facilities
Low Flame Hold and Hand Operation
‘Low Flame Hold’ and ‘Hand’ operation are only effective when the burner is firing. They have no effect
when the burner is off or during the burner start up cycle. They are effected by applying a mains voltage
signal to terminal #95 for low flame hold, or terminal #94 for hand operation. When these inputs have
no mains signals applied, the system is in an automatic mode and modulates according to the PID
control.
Low flame hold is brought into operation if terminal #95 has mains voltage applied when the burner is
modulating or firing. The minimum flame position will be maintained from now on, until the input from
terminal #95 is removed. Low flame hold will be established again by applying an input to terminal
#95 again. During low flame hold the PID control is ignored.
‘Hand’ operation enables the fuel valve and air damper (and other channel) positions to be set to a
specific position, in the range of minimum to maximum flame. Once a position has been set it is recorded
in the M.M. units memory. As a default setting (option #60) the next time the system is put into a hand
operation, the system will take on a fuel/air ratio in the commissioning curve similar to the current firing
rate. The M.M. system sets the channel positions to the hand position whenever there is a mains signal
on terminal #94. Once the burner is firing the ‘hand’ position can be adjusted by switching to the M.M.
screen or Display Status screen and using the bottom row of buttons on the Mk7 facia.
See option #60 for details on bumpless transfer.
If hand and low flame hold operations are selected at the same time, via inputs both on terminals
#94 and on #95, then low flame hold takes priority.
Note: Lead/Lag and sequencing will not operate if either

terminal #94 or #95 has mains voltage applied.

Mk7 Evolution
466 of 761
Micro Modulation Other Information and Illustrations
2.17.10 Other Information and Illustrations
2.17.10.1 Mk7 Evolution M.M. Front Facia Details

Mk7 Evolution
467 of 761
2.17.10.2 Mk.7 M.M. Fixing Holes & Dimensional Details
Bottom View shown with lid in position.

Mk7 Evolution
468 of 761
2.17.10.3 Schematic View Of IR Upload Download
Software installation:
Insert CD and follow the installation procedure (setup.exe).
When SETUP has completed, insert the key diskette into drive A: click on start and choose run. Type
A:\INSTALL.bat and press enter.
The software needs to be configured to the serial (COM) port that the IR lead is connected to. This
happens the first time the Mk7 Upload/Download software is run.
WARNING
IT IS THE RESPONSIBILITY OF THE FACTORY TRAINED

TECHNICIAN TO ENSURE THAT AFTER AN UPLOAD ALL THE
OPTIONS, PARAMETERS AND FUEL/AIR RATIO COMMISSION
DATA ARE CHECKED FOR CORRECTNESS. FAILURE TO DO
SO WILL RESULT IN SERIOUS EQUIPMENT DAMAGE, CRITICAL
INJURY OR DEATH.

Mk7 Evolution
469 of 761
2.17.10.4 Maintenance and Servicing
The Micro Modulation unit uses solid state technology. It requires no routine maintenance.
The positioning motors/gas/oil/FGR valves do require routine maintenance. Any fault associated with
these parts is usually diagnosed by the M.M. Contact Autoflame for preventative maintenance
procedures.
2.17.10.5 Installation Precautions
The reliability of the equipment may be impaired if used in environments where strong electromagnetic
fields exist. If for example the equipment is installed in a boiler house where radio systems exist then
additional EMC (Electro Magnetic Compatability) measures may have
to be considered

Mk7 Evolution
470 of 761
2.17.10.4 External Modulation
EXTERNAL
MODULATION
INPUT 0-10V
OR 4-20mA
-I/0V
+V
+I
1
9
2
3
7
8
S
Mk.7 / Mk6 EVO
To use external modulation it is required to use a 0-10V or 4-20mA input on the terminals as
detailed above. See options #45 and #55 for setting external modulation and the two possible
methods for setting this.
Important note:
It is necessary to use a signal isolator to prevent any excessive voltages being applied to these
terminals. The signal isolator used must have the following charcteristics:
Signal isolation voltage- 3.75kV

Creepage- 5mm
Clearance- 4mm
The equipment and cables must be housed in a clean environment- IP55

Mk7 Evolution
471 of 761
Micro Modulation Fuel Flow Measurement & Metering
2.17.11 Fuel Flow Measurement and Metering Operation
1. Go to options, set option #57 to 1 (default 0).
2. When the above is displayed press , this will initiate the flow metering setup mode.
3. Next time the burner starts the M.M. will go into the ten point setup mode for flow metering
automatically.
4. In this mode the display will show the fuel valve position in degrees angular and the flow
units which can be adjusted by using the CH1/CH2/CH3/CH4/CH5 buttons as
shown at the bottom of the screen.
Note:
a) The CH4 window confirms to the commissioning engineer which of the 10 points are
currently being measured.
b) The minimum numerical value for fuel flow that can be entered into memory is 0.01.
The maximum numerical value for fuel flow that can be entered into memory is 999.0
c) The values are entered in descending order, i.e. point #10 is maximum flame and
point #1 is at minimum flame. The 10 sequential point on the load index are all
located automatically by the M.M. All values are in units/minute or units/hour.
5. When fuel flow has been calculated or read off of a commissioning fuel flow meter the value
is entered as detailed in point #4.
The button is then pressed and the value is logged in the M.M. memory.
6. The above detailed data entry routine is repeated until all 10 points have flow values
allocated to them.
7. When the last (10th) point has been entered the burner continues to fire.
8. To display Fuel Flow Metering press button.
9. To reset the totalising value to 0 (zero) for the individual fuel selected set option #57 to 2,
press at that time. To reset all totalised values for each fuel use parameter #64.
Note: Fuel flow metering measurement now automatically starts totalling the amount of fuel used
from the moment the main gas valves are energised. If the fuel flow metering is not entered then the
firing rate display will read 00% and the system will not totalise the fuel input. Also, any control
logic that requires the fuel flow metering, e.g. lead/lag and sequencing and steam flow metering,
will not work correctly.

Mk7 Evolution
472 of 761
Micro Modulation Golden Start
2.17.12 Golden Start
This facility enables an ideal ignition/start position to be set into memory that is not necessarily low
flame or indeed part of the standard modulating load index.
To enable this facility to go to option #29, set to 0 (default value = 1) and press
To disable this facility go to option #29, set to 1 and press
To implement the above the system/burner is commissioned in the normal way, i.e. press
Enter the password, enter the close position, enter the open position, enter the start (light-off)
position (adjust fuel/air positioning motors to give initial arbitrary ignition position). This position is
not memorised. The burner will fire and the start position LED will flash again.
Press , LED will remain stable, adjust the fuel/air positioning motors to give the ideal
ignition/start up position.
Press and proceed with the commissioning routine in the normal way.
Notes:
1. The golden start/ignition position of the fuel and air positioning motors is completely
independent from the modulating load index commissioned value data.
2. The facility is particularly useful on combustion systems with large turndowns and when firing
heavy fuel oil, as it enables the burners to start/ignite at a fuel rich position and then, after a
stable flame is established, to revert to the commissioned values for fuel/air ratio.
3. WARNING- this facility is common to all fuels (F1, F2, F3 & F4). A value must be entered on
each programmed fuel. Note: As of June 2005, the golden start only needs to be entered for
the required fuel.
4. The time that the M.M. holds the golden start position for is adjustable, see parameter #15.
(default value is 5 seconds, range 0-100 seconds). This timer starts from the ignition point. After
this time the air damper will open and the fuel valve will remain at the same position until the
fuel/air ratio is on the original commissioning curve. At this point the M.M. will start to modulate
based upon the load demand and the PID control.
5. If the commissioning engineer wishes to change the golden start position retrospectively this
can be re-entered, without fully recommissioning the burner, in the following manner:
Go into the commission mode, enter the password, enter the close and the open positions and
enter, as previously described, to the point where high flashes then deselect fuel or power down.
In this way the new golden start position is entered.
6. It is important to appreciate that the golden start position is completely independent of the fuel/
air paired values that are entered for the normal modulating load index/range.

Mk7 Evolution
473 of 761
Micro Modulation One Point Change
2.17.13 Single Point Change (One Point Change)
To change a point, two methods are available. The first is described in section 2.17.5.4.5.1. The second
is done using Mk6 mode. The Mk6 method is as follows:
Start up the burner in the normal way.
Once modulating press (This allows the selection of two buttons at once)
Select and then select the button.
The ‘ENTER PASSWORD’ screen should now be displayed.
Set the password and press the same way as if going into normal commissioning, the channel
position values should be displayed. The valves track to the nearest commission point.
(e.g. HIGH/INTER/START).
When all the values have settled at their appropriate positions ENTER flashes. If this point is to be
changed press . If not press the CH1 button to move to the next point up or
the CH1 button to go to the next point down. The M.M. detects which point has been
selected and will steady the appropriate LED on either HIGH, INTER or START as during normal
commissioning. Once the correct point to be changed is displayed press . It should now
be possible to adjust the fuel/air ratio by using the CH1 - CH6 buttons. Adjust the values
as desired and when the correct values are set press . If an E.G.A. is optioned the
button will flash, press to view. If the E.G.A. is optioned for AUTOTRIM then this will be carried out
and E.G.A. values stored.
Once complete the M.M. will revert to just ENTER and RUN flashing. If desired another point can be
selected and changed. Otherwise press and the M.M. reverts to normal modulation.
If the CH1 (fuel) HIGH or START position has been adjusted check the flow metering. It is likely that
the 10 point flow calibration must be carried out again.

Mk7 Evolution
474 of 761
Micro Modulation Flue Gas Recirculation
2.17.14 Flue Gas Recirculation
Flue Gas Recirculation (FGR) is a method whereby a quantity (approximately 15%) of the boiler
flue gases are fed back to the burner and mixed with the combustion air. The virtue of FGR is the
reduction of NOx gases. With the FGR facility, positioning motor channels 3 or 4 can be used to
control the amount of flue gas fed back. It is not good practice to feed back the gases when the flue
gas is cold, so all the elements (i.e. positioning motors and VFD’s) can be set at ‘FGR’ positions
until the gases are hot. During this time the elements (CH3 or CH4) controlling the FGR would
normally be set closed. Once the gases are hot, modulation takes place in the normal way using
the curve entered during commissioning.
To ascertain if the gases are hot a number of options have been added:
Option #48
A time in seconds that the FGR positions are held for. This timer starts from the point of
release to modulation. If a golden start is used in conjunction with the FGR start then the FGR
start timer will begin at the end of the golden start timer.
Option #49
An offset amount (e.g. 20) below the required setpoint (e.g. 100). This gives a threshold
value of 80 (100 – 20). The FGR positions are held until the actual value has attained the
threshold value (80). Once this actual value is reached then normal modulation will occur.
Option #50
This is an enable/disable type option. If enabled an E.G.A. must be present on the system.
The FGR positions are held until the exhaust temperature value from the E.G.A. reaches 248F
(120C). Once the exhaust gases reach this temperature then normal modulation will occur.
It is possible to use all three of the above options in order to keep the FGR start positions. If this
is done then the timer will be held firstly and then the other two options must be satisfied for
release to modulation.
It is important to check the setting of parameter #90, which determines at what time the FGR start
position will be entered.
If the burner has been commissioned and it is necessary to add an FGR start position, set parameter
#90 to 1, and one of the above options to enable FGR start. Then enter the commissioning mode
and after the start position is entered the M.M. will prompt for the FGR start position to be entered.
After this is entered the M.M. can be reset and this FGR start position will be stored in the memory.

Mk7 Evolution
475 of 761
Micro Modulation Pause Facility
2.17.15 Pilot Turndown/Check Switch Facility
When the system is in commissioning mode only, a facility has been provided that enables a
commissioning engineer to pause the ignition sequence of the burner. If the lockout button is pressed
during the first safety time the burner control will ‘pause’ at this position. This enables the commission-
ing engineer to make adjustments to the start gas flame. If the flame goes out during this time a lockout
is set after 15 seconds. If the flame is present and the ‘pause’ condition is left indefinitely a lockout
will be set after 10 minutes. If the lockout button is pressed again the ignition sequence continues.
While paused the lockout LED on the front fascia flashes. The ‘pause’ facility can also be activated
during the pilot prove and main flame prove phases. When the system is in a run mode the facility is
disabled.
WARNING
IT IS THE RESPONSIBILITY OF THE FACTORY TRAINED

TECHNICIAN TO ENSURE THAT USE OF THE PAUSE FACILITY
DOES NOT LEAD TO A HAZADOUS SITUATION. FAILURE TO DO
SO WILL RESULT IN SERIOUS EQUIPMENT DAMAGE, CRITICAL
INJURY OR DEATH.

Mk7 Evolution
476 of 761
Micro Modulation Time Clock Facility
2.17.16 Time Clock Facility
Time Clock Set Up
To adjust the time clock settings refer to section 2.17.5.4.8. Alternatively, enter commissionning mode
and proceed as follows. The 'ENTER PASSWORD' screen should now be displayed. It is also possible
to change the time clock settings online- see section 2.17.20.
Set the password to 11 and press CLOSE.

11
The 'Time Clock' screen will be displayed:
Note: items marked * not displayed during setup
Use the channel 6 up/down buttons to select the day and item to be adjusted. The selected item will
flash.
For start/stop times:

Set the hour by means of the channel 1 up/down buttons.
Set the minute by means of the channel 2 up/down buttons.
For Mode:
Select the desired operation by means of the channel 1 up/down button.
To enable/disable the time clock operation use the channel 5 up/down buttons.
Press ENTER to memorise the time clock configuration. If enabled, the time clock operates from now
on when in run mode. To disable time clock operation, enter the password as described above and set
the time clock to disabled using the channel 5 up/down buttons and press ENTER.
Time Clock Operation
Operation during and outside the start/stop times is according to the mode selected:
ON off The burner runs and modulates according to the normal required setpoint during the
start/stop times. Outside of the start/stop times the burner is held off.
ON rsp The burner runs and modulates according to the normal required setpoint during the
start/stop times. Outside of the start/stop times the burner runs and modulates according to the reduced
setpoint.
The normal setpoint and reduced setpoint are adjustable by means of the channel 3 and channel 4 up/
down buttons respectively when the DISPLAY STATUS screen is selected. In normal run operation the
Time Clock screen is selected on the third press of the display status button.

Mk7 Evolution
477 of 761
Micro Modulation Automatic Commission Of Gas Pressure Values
2.17.18.1 Automatic Commission of Air Pressure Values
A facility has been added to the Mk7 so that the air pressure values for each fuel/air ratio point
entered can be commissioned without having to carry out a full fuel air ratio commission.
To invoke this facility the system must already be commissioned on fuel /air ratio. Option/parameter
#150 must be set to value 7 then the enter button pressed. Option/parameter #147 must be noted and
set to 0- off so that air pressure limit errors do not occur while the system is running.
Start up the system as normal. Once the burner is firing the system attains the high fire positions and
samples and stores the air pressure at that point. The first fuel/air ratio inter positions are then attained
and the air pressure again sampled and stored. This process is repeated until all fuel/air ratio inter and
start positions are complete. The new air pressure values are then permanently stored and thereafter
an MM ERROR is set - AIR RECOMMSSION (this is to bring to the attention of the operator that options/
parameters must be adjusted back to operational settings). The error must be cleared and option/
parameter #150 set back to 0. If not set back to 0 the air values will be commissioned again and the
M.M. ERROR will ensue. Option/parameter #147 must also be adjusted to the appropriate value.
2.17.18.2 Automatic Commission of Gas Pressure Values
A facility has been added to the Mk7 so that the gas pressure values (during VPS and for each
fuel/air ratio point entered) can be commissioned without having to carry out a full fuel air ratio
commission.
To invoke this facility the system must already be commissioned on fuel /air ratio. Option/parameter
#150 must be set to value 8 then the enter button pressed. Options/parameters 136/137 must be noted
and set to 0- off so that gas pressure limit errors do not occur while the system is running.
Start up the system as normal. Once the burner is firing the system attains the high fire positions and
samples and stores the gas pressure at that point. The first fuel/air ratio inter positions are then attained
and the gas pressure again sampled and stored. This process is repeated until all fuel/air ratio inter and
start positions are complete. The new gas pressure values are then permanently stored and thereafter
an MM ERROR is set - GAS RECOMMSSION (this is to bring to the attention of the operator that
options/parameters must be adjusted back to operational settings). The error must be cleared and
option/parameter #150 set back to 0. If not set back to 0 the gas values will be commissioned again
and the MM ERROR will ensue. Options/parameters #136/137 must also be adjusted to their
appropriate values.
THE FACTORY TRAINED TECHNICIAN MUST NOW CHECK

THE SYSTEM FOR CORRECT OPERATION.
Check the gas pressure commission value displayed during VPS operation. Once the burner is firing,
check the gas pressure commission values for each fuel/air ratio point entered - this can be achieved
by means of the hand operation facility.

Mk7 Evolution
478 of 761
Micro Modulation Flame Detection Using External Flame Switch
2.17.19 Flame Detection using an External Flame Switch
To configure operation with a flame switch option/parameter #122 must be set to 1.
The operation of terminals #85 and #86 must be as follows:
When the flame switch is indicating no flame, the voltage on terminal #85 must be 0Vac, and the
voltage on terminal #86 must be mains voltage (110/230Vac).
When the flame switch is indicating the presence of a flame, the voltage on terminal #85 must be
mains voltage (110/230Vac), and the voltage on terminal #85 must be 0Vac.
Terminal #85 is the functional input for detecting the flame.
Terminal #86 is solely for the purpose of checking that terminal #85 is operating correctly.
Terminal #86 must seen to be the inverse of terminal #85, i.e. if terminal #85 is at 0Vac, terminal
#86 must be at mains voltage and if terminal #85 is at mains voltage, terminal #86 must be at 0Vac.
If terminal #86 does not follow the inverse of terminal #85 the following lockout will occur -
terminal #86 inverse.
Flame Switch Configuration
Within the M.M. there is a latency of 250 milliseconds on the monitoring of terminal #85. To
ensure a 1 second overall flame failure response time, it is essential that the response time of the
flame switch is set to no more than 750 milliseconds.
Flame switches often provide a volt free change over contact to indicate the flame status.
Alternatively, they may provide a pair of `inverse’ outputs. If the flame switch only provides a
single output terminal, a relay will have to be installed between the flame switch and the M.M. to
provide a set of volt free changeover contacts.

Mk7 Evolution
479 of 761
Micro Modulation On-line Changes
2.17.20 Online Changes
A facility exist in the Mk7 M.M. Evolution that allows certain changes to be made whilst the burner
is firing- ‘on-line changes’. The various changes that can be made are listed below:
1. Lock the required setpoint and reduced setpoint.

2. Change options.
3. Change parameters.
4. Change the time-clock facility settings.
5. Change the channel labels.
To make on-line changes
1. It is important to firstly be in the screen.
2. Press and hold for 5 seconds. If this button is not held for 5 seconds then step 1
and 2 must be repeated. Once this is entered correctly a screen prompting a password will appear.
3. Use the CH1 and CH2 buttons to enter the password and then press . If
the password is entered incorrectly then the system will not allow the user to proceed.
4. Once the password is entered correctly the ‘SELECT FUNCTION’ screen will appear. Using
the CH1 buttons it is possible to scroll through the various items that can be changed.
When the desired selection is displayed press to select it.
Note: can be pressed at any time in order to return to normal operation.
The current selected function will only be updated if the button is pressed.
Lock-Unlock Required Setpoint and Reduced Setpoint
Is is pressed when ‘LOCK REQUIRED VALUE’ is displayed it is possible to lock or unlock
the required and reduced setpoints. Use the CH1 button to lock the setpoints. Use the CH1
button to unlock the setpoints. Press to permanently save the setting. The ‘SELECT
FUNCTION’ screen will now be displayed again. It is now possible to press to return to
normal operation, or make further changes on-line.

Mk7 Evolution
480 of 761
Options
If is pressed when ‘OPTIONS’ is displayed then the ‘SET OPTIONS’ screen will be
displayed and options are able to be changed on-line (whilst in run-mode, burner on/off). Refer to
section 2.17.2.4 for instructions on changing options. Press to permanently save the
setting. The ‘SELECT FUNCTION’ screen will now be displayed again. It is now possible to
press to return to normal operation, or make further changes on-line.
Note: Certain options will not be available for changing whilst the burner is running. These
include all burner control options (options #110-150), number of servomotors, E.G.A. option #12,
VSD options #90/100.
Parameters
If is pressed when ‘PARAMETERS’ is displayed then the ‘SET PARAMETERS’ screen
will be displayed and parameters are able to be changed on-line (whilst in run-mode, burner on/
off). Refer to section 2.17.2.5 for instructions on changing parameters. Press to
permanently save the setting. The ‘SELECT FUNCTION’ screen will now be displayed again. It is
now possible to press to return to normal operation, or make further changes on-line.
Note: Certain parameters will not be available for changing whilst the burner is running. These
include all burner control parameters (parameters #110-150).
Time Clock Facility
If is pressed when ‘TIME CLOCK’ is displayed then the ‘TIME CLOCK’ screen will be
displayed and it is possible to make changes to the timings for the time clock. Refer to section
2.17.16 for instructions on changing the time clock. Press to permanently save the
setting. The ‘SELECT FUNCTION’ screen will now be displayed again. It is now possible to
press to return to normal operation, or make further changes on-line.

Mk7 Evolution
481 of 761
Changing the Channel Labels
If is pressed when ‘CHANNEL LABELS’ is displayed then the ‘M.M. STATUS’ screen is
displayed but without the numerical values (channel positions).
To change the channel 1 label use the CH1 buttons.
The possible label selections for each channel are:
Blank/CH 1/CH 2/ CH 3/ CH 4/ CH 5/ CH 6/FUEL/GAS/OIL/AIR/FGR/P-AIR/S-AIR/T-AIR/ID

FAN/FD FAN/STEAM/VFD/BLOWER/SLEEVE/HEAD/INLET/OUTLET
Press to permanently save the setting. The ‘SELECT FUNCTION’ screen will now be
displayed again. It is now possible to press to return to normal operation, or make further
changes on-line.

Mk7 Evolution
482 of 761
Micro Modulation

Mk6 Evolution
483 of 761
Water Level Control Introduction
5.5 First Out Annunciation
When the control circuit has a long series chain of various thermostat and switching elements, it is
sometimes difficult to identify which element has opened the control circuit (see schematic detail
under).
The First Out Annunciation can be set in any of the following ways:
Disabled- First Out does not appear on the MM screen (not in use).
Displayed- First Out status is viewed on the MM screen. The burner will continue to operate
if a First Out fails.
Enabled- First Out status is viewed on the MM screen. In the event of a First Out the burner
will shutdown until the error is corrected.
Issue: 08.12.2009 Autoflame Technical Manual Section 5.5

484 of 761
Section 3: E.G.A. Exhaust Gas Analysis
3.1 Introduction
3.1.1 Features and Benefits

3.1.2 Overview of System Operation
3.1.3 An inside view
3.1.3.1 An inside view Schematic
3.2 Sensor Characteristics
3.2.1 O2 Sensor
3.2.2 CO, NO and SO2 Sensors
3.2.3 CO2 Sensor
3.3 Commissioning and Setting up Procedures
3.3.1 Introduction
3.3.2 Programming of Fuel/Air Positions
3.3.3 Combustion Trim Operation- 3 Parameter Trim
3.3.4 Trim Timing Operation
3.3.5 Graphical Trim Operation
3.3.6 Efficiency Calculation
3.4 Error Checking, Self Diagnostics
3.4.1 Keys to Errors Detected

3.4.2 LED Status Indication
3.6 Electrical Schematics Showing all Terminal Interconnections
3.6.1 Interconnections Between M.M and E.G.A.

3.6.2 Interconnections Between E.G.A. and DTI
3.7 Test and Calibration
3.7.1 Approach to Testing & Calibrating on E.G.A.
3.8 E.G.A. Local Display
3.9 E.G.A. Setup Software Introduction
123456789012345678901234
123456789012345678901234

123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
Issue: 1.1.2007 Autoflame Technical Manual 123456789012345678901234
123456789012345678901234
123456789012345678901234
Section 3: Index
123456789012345678901234
123456789012345678901234
485 of 761
Section 3: E.G.A. Exhaust Gas Analysis
3.10 Limits on Five Measured Combustion Parameters:- O2, CO2, CO, NO

and Exhaust Gas Temperature
3.10.1 Overview of System Operation Features & Benefits

3.10.2 Example of Limits for O2
3.10.3 Example of Limits for CO2
3.10.4 Example of Limits for CO
3.11 EGA Dimensions & Fixing Details
3.12 Standard EGA Sampling Probe
3.12.1 Installation and Maintenance

3.12.2 E.G.A. Sampling Probe Assembly
3.12.3 E.G.A. Sampling Probe Assembled
3.12.4 Maintenance of Sampling Probe
3.12.5 Installation Precautions
3.12.6 Servicing the Sampling Probe
3.13 Internal Tubing Diagram
3.15 Other Information and Illustrations
3.15.1 Technical Specifications

3.15.2 General Assembly of the Dry Filter
3.15.3 General Assembly of the External Particulate Filter
3.15.4 High Temperature Probes
3.15.5 'S' Type Thermocouple
3.15.6 Ceramic Sampling Probe Assembly
3.15.7 O2 Interface Module
3.15.8 Chilled Environmental Enclosure
3.16 Shipping the E.G.A.
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
1
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
486 of 761
E.G.A. Exhaust Gas Analysis Introduction
3.1 Introduction
3.1.1 Features and Benefits
The E.G.A. Mk.6 is the accomplishment of twenty years on-going research and development for the exhaust
gas sampling system. The E.G.A. can be used for three separate applications:
Application No.1: E.G.A. stand alone
Stand alone sampling system. The emissions levels can be accessed via:
The local display on the front of the E.G.A. facia (serial numbers 5000+)
The remote display pod, local to the installation (max. distance 15m)- older E.G.A. units
The 6 channel 4-20mA signals, user configurable (max. load 250 Ohms each)
The Data Transfer Interface module (D.T.I.); this enables connection to a PC, BMS, PLC, e.t.c.
Application No.2: E.G.A. combustion trim
Interfaced with the Micro Modulation (M.M.) system enabling combustion trim. The combustion/emissions
levels can be accessed via:
The M.M. unit. This displays both the commissioned values and the actual values
The 6 channel 4-20mA signals, user configurable
From the M.M. unit via the Data Transfer Interface module (D.T.I.); this enable connection to a PC, BMS,
PLC, e.t.c.
Application No.3: EPA compliant C.E.M.S. (Continuous Emission Monitoring

Software)
Ability to monitor the exhaust gases and determine the exact amounts (volumetric and weight) of each of
the exhaust gas parameters. These values are dependent on the fuel input, the calorific value of the fuel and
the exhaust gas values (%, ppm).
Monitoring Capabilities.
O2 Oxygen % by volume
CO Carbon Monoxide ppm
CO2 Carbon Dioxide % by volume
NO Nitrogen Oxide ppm
SO2 Sulphur Dioxide ppm
NO2 Nitrogen Dioxide ppm
Combustion Efficiency % (a calculation of CO2 and delta temperature)
Exhaust gas temperature Degrees Celsius or Fahrenheit
Ambient temperature Degrees Celsius or Fahrenheit
Delta temperature Degrees Celsius or Fahrenheit
NO and SO2 or NO2 are monitored only, not used for combustion trim, although limits can be set for NO.

487 of 761
3.1.2 Overview of system operation
The analyser samples the combustion gas via the stack mounted sampling probe (part #MM10003)
purchased separately from the analyser. The exhaust gas is drawn from the stack by a pump mounted
internally within the analyser. Ensure that the supplied sample tubing is used between the sampling
probe and the analyser. The internal diameter of the sample tubing is 3mm; if a larger diameter tubing
is used the sample gas remains resident in the tubing for a longer period. This will seriously effect the
correct operation of the combustion trim. Contact Autoflame sales team for advice on applications.
Once the exhaust gas has entered the analyser the gas is reduced in temperature by the chiller block.
The chiller block serves two functions; firstly reducing the gas temperature and secondly removing the
condensation from the gas prior to the gas entering the sensors. The condensate accumulated in the
chiller unit is drained every 4 minutes automatically through the drain solenoid.
The exhaust gas is then filtered through the dry filter. This is a fine filter which removes any dust particles
carried over from the cooling process. On leaving the filter the exhaust gas is checked to ensure a
vacuum is maintained prior to entering the pump. On exiting the pump the exhaust gas is again checked
to ensure the pump is producing a pressure. Both pressure switches indicate there operation by the status
indication L.E.D.s. (located next to each pressure switch).
The conditioning process of the exhaust gas is now complete. The gases are now measured by the
sensors. The exhaust gas now exits the sampling system from the clear tubing located at the rear of the
chiller unit.
Important note:
The exhaust gas is vented into the air stream leaving the E.G.A. unit. This is located on the outside of
the E.G.A. enclosure next to the drain solenoid outlet. It is extremely important that the exhaust gas
is vented to atmosphere, i.e. do not install the E.G.A unit within a sealed enclosure. This would cause
the E.G.A. unit to self calibrate on contaminated gas. The E.G.A. unit will self calibrate every 6 hours
or when the burner starts and stops.
If the E.G.A. unit is to be installed in an area of harsh environmental conditions outside those as quoted
for the E.G.A. module then an environmental enclosure is required. Please contact Autoflame sales for
further information on this unit.

488 of 761
3.1.3 E.G.A. Mk.6 an Inside View (cover removed)
Thermocouple I/P
NO Cell SO or NO Cell CO Cell

Sample In From
² ²
E.G.A. Probe
Sample Inlet CO/NO Bypass SO
Pinch Valve Pinch Valve ²
Pinch Valve
Filter
Chiller
Block
O Cell
CO Cell ²
²
Pump
L.E.D.
Bank
(See Note)
SO Pump
²
Green O.K.
Red Fault
PC Output
(Via Lead)
Pt.No. DTI20018)
Vacuum Drain Mains Pressure Fan

Switch Solenoid Input Switch
Data Port
& 4-20mA
Note: Outputs
Green #1 = O.K.
Red #2 = Fault or Service
Yellow #3 to 8 = Service Period Indicators (1 LED extinguishes every 2 Months)
Mains Supply = 230V/110V Standard

489 of 761
3.1.3.1 E.G.A. Mk.6 an Inside View (cover removed)

490 of 761
E.G.A. Exhaust Gas Analysis Sensor Characteristics
3.2 Sensor Characteristics
3.2.1 O2 Sensor
This electrochemical cell is used for the detection of oxygen covering a concentration range of 0 to 100%. Due
to the construction of the sensor they offer a long life and a high resistance when used with high sulphur content
fuels. It is therefore suited to analysis when firing heavy or light fuel oil. The cell employs the principles detailed
below:-
The oxygen sensor incorporates a lead oxygen cell with a lead anode and a gold cathode, using a specific acid
electrolyte. Oxygen molecules which diffuse through a non porous Teflon membrane into the electrochemical
cell are reduced at the gold electrode. The current flow between the electrodes is proportional to the oxygen
concentration in the flue gases measured.
Retaining Band
Features:
Virtually no influence from CO, H2, S, NOx, SOx and H2, i.e. no cross sensitivity.
No warm up time required.
Operation ranges:
Detection range 0-20.9% O2

Accuracy ± 0.3%
Operating temperature 5°C to 40°C (41°F to 104°F)
Shelf life 6 months from date of dispatch
(In normal operation the sensor has a life expectancy of 2 years & is guaranteed for 1 year)
Long Term Output Drift < 1% signal/month typically.
< 10% over operating life.

491 of 761
3.2.2 CO ,NO and SO2 Sensors
These sensors are electrochemical cells which are specifically managed by the calibration philosophy within the
E.G.A. unit. The accuracy of these sensors are within ±5% at 100ppm. From our experience over the last five
years we would expect to see a drift of ± 10ppm per annum without calibration. In our view this drift would
not be detrimental to the operation or application of the E.G.A. The EPA compliant E.G.A. unit ensures that this
problem does not occur by performing an automatic self calibration every 24 hours with known constituents of
test gas. The life of the sensors is a function of the concentration of gases measured over time. In order to optimize
the life of the CO cell, the electronics will detect when the signal level from the cell reaches or exceeds 600ppm
and will isolate the CO & NO cells. The gas flow to these cells is restored once the O2 & CO2 readings are restored
to a level within the pre-programmed limits.
Retaining Screws, Remove when

replacing Sensor
Input Tube
CO Measurement:
On Gas Fuel Measuring Range 0-1000ppm
On Fuel Oil Optional, CO is not normally measured as standard
Resolution at 20 deg C 1ppm
Repeatability 1% of signal
NO Measurement:
On Gas Fuel Measuring Range 0-1000ppm
On Fuel Oil Optional, NO is not normally measured as standard
SO 2 Measurement:
On Gas Fuel Optional, SO2 is not normally measured as standard
On Fuel Oil Measuring Range 0-1000ppm
492 of 761
3.2.3 CO2 Sensor
This is manufactured to an Autoflame specification and the technology employed is thermal conductiv-
ity. This sensor has no moving parts and is not an electrochemical cell. The exact description of how
this works is commercially sensitive. The accuracy is ±0.3% of reading. The cross sensitivity is virtually
zero to other gases due to the method of calibration used within the E.G.A. unit. The lifetime is not less
than two years on gas firing, and on oil firing is dependent on the sulphur content of the fuel.
Retaining Band
Measuring Range 0-20%


493 of 761
E.G.A. Exhaust Gas Analysis Commissioning and Setting Up Procedures
3.3 Commissioning and Setting up Procedures
3.3.1 Introduction
Commissioning with the E.G.A. is an extension to commissioning with the M.M. The factory trained technician
must be completely familiar with the commissioning of the M.M. unit before commissioning with the E.G.A.
module. Section #2 of the Technical manual clearly explains commissioning with the M.M. unit.
The commissioning procedure as described must be strictly adhered to. Anybody commissioning an M.M./
E.G.A. system must have an adequate understanding of combustion plant and be officially certified by Autoflame
Engineering or their registered Distributors. In the wrong hands, hazardous conditions could be made to exist
that could lead to product damage, critical injury or death.
The fundamental idea of the system is to set a fuel valve position and then set a corresponding air valve position.
Care must be taken when adjusting the fuel and air positions so as not to create any unstable combustion
conditions, e.g. moving the fuel valve to the open position without increasing the air valve correspondingly.
If the system being commissioned is an M.M. without an E.G.A. then a combustion monitor is required to check
the exhaust gases. If the system does have an E.G.A. then a combustion monitor should not be necessary as the
E.G.A. performs all normal exhaust gas measurements. When burning oil a smoke detection device is necessary
to check smoke generated is within government guide lines.
Ideally, to implement commissioning as quickly as possible arrange for a substantial load on the boiler. The
commissioning procedure can be interrupted due to excess temperature or pressure, causing the burner to turn
off. In these instances the commissioning data accumulated so far is not lost. When the burner is called back
on, the system starts up automatically and commissioning can proceed from where it left off.
Once the burner has been fired the maximum fuel position is entered first then descending fuel positions are
entered consecutively until finally a minimum fuel position is entered. The CH1 and CH2 positions must always
be less than the ones previously entered. However with CH3 - CH6 it is possible to move the position above or
below the previously entered points. This is important if these channels are used to control FGR (flue gas
recirculation) or atomisation of oil.
On a newly installed system the following procedures should be carried out as listed:
1. Check all interconnecting wiring between the M.M. and external components are correct.
2. Set the options required (refer to option section #2.14.2.4).
3. Set up positioning motors.
4. Programme fuel/air positions.

494 of 761
3.3.2 Programming Fuel Air Positions (Systems with the Exhaust Gas Analyser)
CH1, CH2 etc refers to the rows of buttons with CH1 at the top.
Note: Throughout the commissioning procedure the COM l.e.d. is illuminated.
1. Ensure 'stat' control circuit is closed, i.e. ensure that there is an input on terminal #53.
2. Select fuel. CLOSE flashes. 'ENTER PASSWORD' is displayed.

COM
Note: If fuel selected is being re-commissioned, press before COM l.e.d.
stops flashing (five seconds).
3. Enter Access Code. Adjust the numbers using the CH1 and CH2 buttons.
CLOSE
When numbers are set, press (CLOSE l.e.d. steady, ENTER flashes)
4. “SYSTEM ACTIVATE, WATER LEVEL CONFIGURE” is displayed.
On this password screen, it is necessary to set both CH1 and CH3. These are both set to #3 if the
Autoflame water level system is to be active. Alternatively, these are both set to #7 for Mk6 use
without the water level system. It is also necessary to set the CH5 value for First Out Annunciation.
Set this to #0 to disable the First Out Annunciation, #1 to display the First Out Annunciation (but
not to lock out) and to #2 to enable First Out Annunciation, i.e. burner locks out.
ENTER
Then press
MEMORY
5. The display indicates angular position of servo motors. After the internal checks are made (CLOSE
CLOSE
flashes). Press to start entering the close position.
6. Use CH1 to CH4 (as optioned) buttons to set positioning motors to 0.0.
ENTER
Press MEMORY
(OPEN flashes).
OPEN
7. Press (OPEN steady, ENTER MEMORY flashes).
8. Use CH1 to CH4 buttons to set positioning motors to their fully open positions.
This is nominally 90.0 for gas butterfly valves and burner air dampers, but may be set to less
than 90.0 degrees if there are mechanical stops/limits.
The E.G.A. unit will now carry out a calibration for 2 minutes.
ENTER
Press (System purges, at end of purge START flashes).
MEMORY
9. Press START (START steady, ENTER MEMORY flashes).
**WARNING** Do not enter START position before reducing fuel input. This
could result in a potentially dangerous situation.

495 of 761
10. Use CH1 to CH6 to set positioning motors to positions where ignition can
take place.
ENTER
11. P r e s s MEMORY
(Burner ignites, HIGH flashes).
HIGH
12. P r e s s (HIGH steady, EGA flashes).
13. Use CH1 and CH6 to set maximum firing input (it is not possible to exceed the OPEN
position values). Always increase the air first followed by the fuel angular positions.
12
12
14. P r e s s E.G.A (HIGH steady, EGA steady, ENTER flashes) to view the online combustion
readings. If the readings are satisfactory go to step #16, otherwise go to step #15.
12
12
15. P r e s s M.M. (HIGH steady, EGA flashes).
Make adjustments to fuel and/or air valve positions. Go to step #14.

ENTER
16. P r e s s MEMORY
(Combination of MM, EGA and RUN flashes).
The system will now carry out 'Auto Commission' routines. No operator intervention will be
permitted during this time. This takes approximately two minutes. While the autocommission is
taking place the EGA. and MM. l.e.d.s flash initially (fuel rich autocommission), then RUN and
MM flash (air rich autocommission). When finished INTER flashes or INTER and START flash.
Note: Only INTER flashes if the number of INTER positions entered so far is less than or equal
to three, thereafter INTER and START flash.
INTER START
17. P r e s s or (INTER or START steady, EGA flashes).
18. Use CH1 to CH6 to reduce the Fuel and Air positions. Always reduce the fuel first
followed by the air angular position.

123
123
123
19. P r e s s (START or INTER steady, EGA steady, ENTER flashes).
E.G.A
Observe combustion readings and wait for these values to stabilise. If readings are
satisfactory go to step #22, other wise go to step #20.
123
123
123
20. P r e s s M.M. (START or INTER steady, MM steady, EGA flashes).
21. Use CH1 to CH6 to adjust valve settings. Go to step #19.

ENTER
22. P r e s s (Combination of MM, EGA and RUN flashes).
MEMORY
The system will now carry out 'Auto Commission' routines. No operator intervention will be
permitted during this time. This takes approximately two minutes. While the autocommission is
taking place the EGA. and MM. l.e.d.s flash initially (fuel rich autocommission), then RUN and
MM flash (air rich autocommission). When finished INTER flashes or INTER and START flash.
(If START position has just been entered then RUN flashes).

496 of 761
If the position just entered was the START position, go to step #24, otherwise go to step #23.
INTER START
23. Press or (START or INTER steady, MM steady, EGA flashes).
Go to step #18.
RUN
24. P r e s s to set system into normal modulating mode.
25. If an EGA error occurs in commissioning mode, it cannot be reset using the "press close/open
button". If the fault in the EGA can be cleared the error will reset automatically.

497 of 761
3.3.3 E.G.A. combustion trim operation
With the E.G.A. trim facility it is possible to expand the M.M. so it will measure and display O2, CO,
CO2 and exhaust gas temperature, together with boiler temperature or pressure. It is also possible to
use these values for 3 parameter trim in order to optimise the burner combustion capabilities throughout
the firing range of the burner in a safe manner. This means that the safety is never compromised by
efficiency, but the best burner/boiler efficiency is maintained.
During commissioning, for every paired value of fuel and air, the corresponding values of O2, CO,
CO2 are stored. These values are known as the commissioned values. The system will then automatically
induce an 'autotrim' cycle in which the air damper will close 5% of the entered air damper position
and then hold this position for 60 seconds. This is known as the fuel rich part of the autotrim cycle.
After the 60 seconds the values of O2, CO, CO2 are stored. The 60 seconds allows the combustion
gases to move through the passes (2/3/4) in order to obtain the new combustion values. After these
values have been stored then the E.G.A. will stop sampling from the stack for 25 seconds and sample
from atmosphere (through the solenoid valve) in order to clear any CO residue that may have been
produced during this fuel rich autotrim. During this time the air damper will now 5% of the entered air
damper position and then following the 25 seconds air flush period the air damper position will be
held for 60 seconds. This is known as the air rich part of the autotrim cycle. After the 60 seconds the
values of O2, CO, CO2 are stored. It is now possible to move to the next position in the fuel and air
curve to be entered. Again, this same process will occur and every fuel and air position entered. This
builds up a complete map of the burner's combustion performance (see the graphs on the following
pages).
During the normal run mode, the on-line sample at any position within the burner's firing rate is compared
to the commissioned values. There are 3 individually sampled parameters (O2, CO, CO2) in order to
verify the combustion performance either side of the commissioned value. The software within the
M.M. unit will inflict minute corrections to the channel 2 air damper positions or the channel 5 variable
speed drive in order to maintain the commissioned values. These minute changes ensure that the
originally entered commissioning data is adhered to, irrespective of variations in stack pressure, ambient
temperature (pressure) fluctuations, barometric conditions or fuel pressure changes.
The system trim function is achieved by every paired value for air and fuel having stored values for
O2, CO2 and CO at the commissioned value. Deviations from these ideal values are held and acces-
sible via the "COM" button on the MM facia when in E.G.A mode. This data is integrated and ex-
pressed as a degree angular value; this ensures the exact amount of channel 2 or channel 5 trim may
be inflicted at any time to return the system to it’s commissioned value at any load condition.

498 of 761
The importance of measuring 3 parameters
The E.G.A. is continually measuring the formation of CO. The on-line CO value is compared to the
commissioned value. A higher CO reading can be contributed to both lean and rich combustion. A
lack of air will produce imcomplete combustion and the formation of CO up the stack. Also, excess air
around the flame envelope has the effect of chilling the flame edge causing incomplete combustion
and higher CO levels.
An ingress of tramp air through an ill fitting boiler door or flue section will distort the O2 reading and
show an increase in this value. This is now not measuring the combustion gases but in fact the influence
of the tramp air.
Single parameter O2 trim systems would see both of these conditions as rich (excess air) combustion
and start to trim back the air damper position by closing the air damper. In reality this trim process is
not trimming the combustion gases at this point, but is in fact trimming the exhaust gases which have a
higher influence of O2. This can potentially lead to the formation of excessive amounts of CO but
more importantly this can lead to the formation of dangerous combustion conditions, i.e. incomplete
combustion.
Similiarly single parameter CO2 trim systems would see an ingress of air as lower CO2 levels in the
flue, inflicting similar dangerous conditions in the boiler.
By referencing all 3 parameters against mapped combustion performance the burner can be trimmed
back to the original commissioned values whilst maintaining the highest degree of safety.
An added benefit of mapped combustion is 'feed forward trim'. In a fuel rich situation where air is
being added, as the burner modulates to a new position the deviation in the air damper is added to
each air position and so maintaining optimum combustion during modulation.
As a safety feature during lean (lack of air) combustion, where air is being subtracted, when modulating,
the fuel and air ratio will return back to the commissioned fuel and air mix for every 10 degrees of fuel
valve movement. Once this position is held the system will determine whether closing the air damper
is still required at this new position. This ensures safe combustion at all times and the safety is never
compromised by efficiency.

499 of 761
3.3.4 Trim Timing Operation

500 of 761
3.3.5 Graphical Trim Operation

501 of 761
3.3.6 Combustion Efficiency Calculations
Based on dry gas.
English Calculation:
% Combustion Efficiency = 100 - (sensible heat loss + Hydrogen and moisture loss).
= 100 -
(( K1 (TG-TA) + (K2 (1121.4 + (TG-TA))
%C02 )
K1=0.38 Natural Gas(F1)
K1=0.56 Fuel Oil (F2/F3)
K2=0.0083 Natural Gas (F1)

K2=0.0051 Fuel Oil (F2/F3)
European Calculation:
% Combustion Efficiency = 100 - sensible heat loss
= 100 - ((TG-TA) x ((A/(20.9-02)) + B))
A=0.66 Natural Gas (F1)

A=0.68 Fuel Oil (F2/F3)
B=0.009 Natural Gas (F1)

B=0.007 Fuel Oil (F2/F3)
TG: Flue Gas Temperature

TA: Ambient Air Temperature in Boiler House

502 of 761
E.G.A. Exhaust Gas Analysis Error Checking, Self Diagnostics
3.4 Error Checking, Self Diagnostics
3.4.1 Key To Errors Detected
Errors detected in the E.G.A. part of the system are indicated when COM or E.G.A. display modes are
selected on the M.M. In the event of an E.G.A. failure, the E.G.A. screen on the M.M. will display a
flashing error to enable the operator to identify the issue. This will automatically default to this flashing
display in the event of an E.G.A. error. At this time all other screens will be viewable. The switched
neutral alarm output terminal (#79) can be set to become active or remain inactive in the event of an
E.G.A. error (see option #12 in section 2.14.2.4). Depending on the setting of this option will determine
how the burner will operate, i.e. continue to run based on the original commissioned values (trim and
limits testing disabled) or become disabled until the E.G.A. error is reset and becomes fully operational
once again.
Error Number Fault Description
01 No communications to E.G.A.
Check communications between terminals #23/31 on the E.G.A.
and terminals #25/26 (E+/E-) on the M.M. module.
Ensure that the E.G.A. is earthed (grounded).
08 O2 Upper limit exceeded

Check option #19 and section 3.10
09 CO2 Upper limit exceeded

10 CO Upper limit exceeded

11 O2 Lower limit exceeded

12 CO2 Lower limit exceeded

14 O2 Absolute limit exceeded (O2 less than specified value)

15 CO2 Absolute limit exceeded (CO2 greater than specified value)

16 CO Absolute limit exceeded (CO greater than specified value)

20 Pump fault --- pump failed/sample system blocked

Check that the sampling probe is not blocked (filter in probe)
Remove sample inlet tubing and press open/close on the facia via
the E.G.A. screen in order to force the unit into a re-calibration. If
the error is cleared then the blockage is in the probe/sampling tube.

503 of 761
20 Pump fault --- pump failed/sample system blocked (continued)

If error persists check the flow through the E.G.A. module. Isolate
each section and test the flow (this should be 550-650cc/min)
If error persits then remove the inlet to the pump (lower pipe
connection). If the error is resolved then check the filter and
sampling line within the E.G.A.
If error persists replace the pump.
21 O2 Cell failure
Check terminal connections on the wires from the cell
Check voltage across the O2 cell
22 CO2 Cell failure

Ensure the temperature sensor is plugged in (right side of cell)
23 CO Cell failure
30 NO Upper limit exceeded

Check parameter #94 and section 3.10
33 Exhaust temperature upper limit exceeded

35 Exhaust temperature absolute limit exceeded (exhaust temperature greater

than specified value)
Sampling system should be carefully packed in the carton in which was supplied or similar and marked
"Fragile - Scientific Instruments" and "Do Not Drop".
When plugs are removed to disconnect the sampling system, the M.M./E.G.A. control module will
recognise that the sampling system has been removed and will run on M.M. values only depending on
the setting of option #12. The fault Error Code, displayed on the M.M./E.G.A. module will remain
displayed but only when the control unit is in the E.G.A. or commissioning display modes. When it is
in the M.M. mode, all normal values and functions would be displayed. When the fault has been
rectified on the sampling system and it is returned from your dealer, the E.G.A. sampling system can be
plugged in and the M.M./E.G.A control module can be put into E.G.A. mode.
Note: If the E.G.A. is removed then no single point changes can be made to the commissioning
curve since the E.G.A. data will not be present. If the E.G.A. is optioned out in order to make
any single point changes, then once the E.G.A. is optioned back in (option #12), then the
system will need to be re-commissioned or the old data uploaded into the M.M. module.
The Error Code that is displayed can be cleared by pressing " OPEN" and "CLOSE" simultaneously. The
system will now operate normally in the E.G.A. mode and the displays will return to their normal
function.
When first going into commissioning mode, the MM invokes an EGA calibration. If an error occurs at
this stage it will be necessery to fix the EGA and set commissioning mode again (reselect fuel).

504 of 761
Other Possible Problems
On the M.M. display there are 4 lines of text that may appear when the E.G.A. is awaiting various
parameters to be met.
1- Ambient Temperature- this will read OK, high or low. This must be between 5-40C (40-104F)
or the settings of parameters #27/28. The temperature is measured by a sensor on the
electronics PCB and is cross reference with the sensor on the side of the CO2 cell.
2- E.G.A. Trim Threshold- this will be OK or low and is looking at the setting of option #28. This
value is an offset from setpoint, before which the E.G.A. will not operate. This ensures that the
E.G.A. does not pull in high amounts of condensate.
3- Cooler- this will be Ready or Not Ready. There is a temperature sensor on the chiller unit and
this chiller must get down to a set temperature before the pump will start to draw a sample from
the stack.
Check the operation of the fan. When the E.G.A. is powered the fan is the first
component to start-up and the purpose of this is to cool the chiller unit. Ensure that the
door of the E.G.A. is closed and that the 24V dc is present on the fan. If the ambient air
in the boiler house is high, it may be necessary to draw cooler air into the E.G.A.
Check that the cable to the right of the chiller is connected and all pins follow through.
Check the voltage selector switch is set to the correct voltage, i.e. if set for 230V and
the mains voltage input is 120V, the fan will run slowly and not cool the unit.
4- Comms- this can read OK or Not Ok and this is checking for continuity between the E.G.A. and
M.M. Check the wiring between the M.M. and E.G.A. modules.
Fuse keeps blowing
If the EGA is mounted in an excessively dusty environment a build up of particles on the terminals can
cause arcing. If the particles are corrosive then any attack to the conformal coating on the printed
circuit boards can cause tracks to arc & component failure. Any sign of this activity & the unit should
be returned to the supplier.
Continuous O2 reading at 20.9%
Check all piping is airtight

Check sample tube is not blocked.
Check that there are no leaks on the flue.
Check the CO/NO pinch valve (V1) tubing for leaks.

505 of 761
3.4.2 L.E.D. Status Indication
To assist the end user to determine the basic status and fault diagnosis, the P.C.B. is fitted with status
indication in the form of L.E.D.s. The following indications are available:
Green = O.K. System operates correctly.

Red = Fault.
Yellow = 6 L.E.D.’s each L.E.D. indicates a 2 month operation period.
(1 L.E.D. is extinguished every 2 months- this time is also active during storage).
Red = Pressure switch fail (located: right of drain solenoid).
Green = Pressure switch proved (located: right of drain solenoid).
Red = Vacuum switch fail (located: left of drain solenoid).
Green = Vacuum switch proved (located: left of drain solenoid).
See L.E.D. positions below.
Once all the yellow L.E.D.s have been extinguished the red L.E.D. will be illuminated, this is an indication
that the analyser now requires servicing. The service must be carried out by an Autoflame certified
technician or alternatively returned to our factory in the UK or US. The system will still continue to operate
during this time. When both the green & red LED's are illuminated, this indicates that a service is required,
the unit will continue to operate in this condition.
* important: when shipping the E.G.A. unit back to our factory, the unit must be returned in the original
packaging, therefore avoiding additional charges due to transit damage.

506 of 761
E.G.A. Exhaust Gas Analysis Electrical Schematics
3.6 Electrical Schematics
3.6.1 Interconnection between E.G.A. and M.M. Module
EGA Unit
Fuse
Holder
NEUTRAL EARTH
4-20mA
CH. 6 I +
to DTI
CH. 5 I +
CH. 4 I +
CH. 3 I + Common
LIVE Analogue
CH. 2 I + Output I -
CH. 1 I +
M.M. Module
CONTROL
DATA CABLE
FUSE

507 of 761
E.G.A. Exhaust Gas Analysis Electrical Schematics
3.6.2 Interconnection between stand alone E.G.A. modules and DTI unit
EGA Mk6 EGA Mk6
EGA Mk6
AUTOFLAME
The control phases to each EGA module & DTI unit must be the same.
The ID must be set for all EGAs connected directly to the DTI.

508 of 761
E.G.A. Exhaust Gas Analysis Test and Calibration
3.7 Testing & Calibration
!!! WARNING !!!

As always observe health and safety procedures. An operator working on the E.G.A. must be of
proficient technical standard. Take care when removing the front cover of the analyser. If the Analyser
is powered, the cooling fan will be in operation.
3.7.1 Approach to Testing & Calibrating an E.G.A.
Please see section 3.8 for E.G.A. modules with a serial number greater than 5000 (all calibration, cell
replacement and testing is made through a local display).
Please see section 3.9 for E.G.A. modules with a serial number less than 5000 (all calibration, cell
replacement and testing is made through a PC).
The information contained in this manual provides a comprehensive understanding and operation of
the Exhaust Gas Analyser (E.G.A.) units. If using this manual for the first time please read all of it
thoroughly before working on an E.G.A. unit.
The method test and calibration is based on the E.G.A. being connected to PC running the ‘EGA PC
Calibration Software’. (This is a standard product available from Autoflame pt No. DTI20018, com-
prising software supplied on a diskette and a lead that connects from a PC serial port to the EGA setup
port. The lead is identified by red shrouds at each end).
For brevity, the various screens, information and actions that may be carried out on the PC are not
covered in detail in this manual, only a brief overview is given. Operators can quickly familiarise
themselves by working hands on through the various menus on a real system. Throughout the manual
any examples of text that are displayed on the PC screen are shown in bold.
To install the software on the PC make a subdirectory on the hard drive, using the DOS copy com-
mand, simply copy all files from the diskette to the PC hard drive. To start the program type EGATOPC
<return>. (The program runs in DOS only. A mouse is NOT supported). The first time the software is
run select SYSTEM from the main menu. This is the setup of the PC configuration to work as mono-
chrome/colour screen, printer port.... can be set. Once all items have been worked through the
settings are stored immediately. The next time the program is run these settings will be restored
automatically. If the system settings need modifying subsequently then select the SYSTEM menu and
change the settings as desired.
At all times when the EGA is sampling, during day to day operation or testing, it must be kept upright
otherwise condensate may find its way out of the chiller block, into the filter and beyond.

509 of 761
E.G.A. Exhaust Gas Analysis E.G.A. display features
3.8 EGA local display features and capabilities
The following information is provided in order to enable the Autoflame E.G.A. system to be set-up,
calibrated and serviced by the end-user. With the local display it is possible to perform all the
operations previously accessed through the EGA to PC software.
To ensure that the combustion readings are correct, it is recommended that the E.G.A. should be
either checked or calibrated once a year. Error codes and fault history displayed on the E.G.A.
screen or through the Micro Modulation unit must be observed. The E.G.A. will log up to 10 faults,
with the oldest being discarded after 10 faults, and will record the error type and date and time
when the error occurred.
RUN
At any point during the E.G.A. set-up procedure, press to revert back to the online
RUN
combustion values. If using an SO2 or NO2 sensor it is necessary to press again to view
these online values.
The online display shows:

O2- %
CO2- %
CO- ppm
NO- ppm (if optioned)
Ambient temperature- 0C or 0F
Exhaust gas temperature- 0C or 0F
Delta temperature- 0C or 0F
Combustion efficiency- %
SO2- ppm (if optioned) OR NO2- ppm (if optioned)

510 of 761
E.G.A. Exhaust Gas Analysis E.G.A. display features
3.8.1 Fault history

123
123
123 FAULT
Press HISTORY to view the fault history log. Up to 10 errors are logged in the E.G.A. and each
error is displayed with the date and time when it occurred. To view the previous 10 errors in time
12
12
FAULT
sequential order press HISTORY
to move through each one.
3.8.2 E.G.A. Status

12
12
Press STATUS to view the various E.G.A. status screens.
The first status screen shows:

E.G.A. operating mode- with MM or stand alone
Software version
Fuel selected
Date, month, year and time
123
123
123
Press the STATUS button to move to the next status screen. This shows the number of hours run
in each fuel.
123
123
Press the STATUS button to move to the last of the status screens. This shows when the E.G.A. is
next due for a service. This date will be exactly one year since the unit was sent out, and
corresponds to the 6 amber L.E.D's on the E.G.A. These lights can only be seen when the door is
open (in the bottom left hand corner). One light is extinguished every 2 months, and once these
have all gone out then the E.G.A. is due a service. It is recommended that each E.G.A. is sent back
for an annual service.

511 of 761
E.G.A. Exhaust Gas Analysis E.G.A. display set-up guide
3.8.2 E.G.A. local display set-up guide and calibration options
3.8.2.1 E.G.A. set-up guide

RUN
To enter the set-up mode, firstly press the button to display the online combustion values.
COM
Press to enter the set-up mode. Once this button is pressed the password screen will
activate. Enter the password using the CH1 and CH2 buttons. The CH1
buttons change the units and the CH2 buttons change the tens value.
COM
Once the correct password has been entered, press to enter the "SELECT FUNCTION"
mode.
3.8.2.1 Select Function
The "SELECT FUNCTION" screen is displayed.
Use the CH1 buttons to select the function to be changed. Once the desired function is
ENTER
selected, press to change the settings for that function.
MEMORY
The various settings you can change include:

Setting the date and time
Configuration of the E.G.A.
Configuration of the six 4-20mA outputs
3.8.2.2 Setting the date/time

ENTER
Once "SET DATE/TIME" is displayed press
MEMORY
The CH1 buttons scroll through the various options to change,
i.e. date, month, year, hour and minute.
The CH2 buttons change the actual value for each option.
ENTER
Once the date/time has been set, press to return to the "SELECT FUNCTION" menu.
MEMORY

512 of 761
3.8.2.3 Configuration of the E.G.A.

ENTER
Once "E.G.A. CONFIGURE" is displayed press
MEMORY
The CH1 buttons scroll through the various settings that can be changed. When the
ENTER
desired setting is displayed, press to start making any changes.
MEMORY
The settings that are adjustable through the "E.G.A. CONFIGURE" menu include:
(For each setting the function of CH1 and CH2 buttons are shown)
CH1 CH2
Operating mode with MM or stand alone no function
Temperature unts imperial or metric no function
Efficiency calculation english or european no function
ID number 1-10 no function
NO sensor fitted or not fitted no function
SO2 sensor fitted or not fitted no function
CO/NO pinch valve selects fuel selects open or close
Change the password units tens
ENTER
Once the required changes are made for a particular selection, press to move to the next
MEMORY
ENTER
selection, i.e. after changing the ID number press to move to the NO sensor selection.
MEMORY
Once all required changes have been made, use the CH1 buttons to scroll to the
ENTER
"RETURN TO SELECT FUNCTION" screen and press
MEMORY

513 of 761
3.8.2.4 Configuration of the six 4-20mA outputs

ENTER
Once the "4-20mA OUTPUTS" screen is displayed, press to set the correct outputs and
MEMORY
signal range.
The CH1 selects which output (1-6) is to be changed. When the correct ouput is
ENTER
displayed press to make the changes.
MEMORY
Use the CH1 to select which output signal is required.
The possible output signals are listed below:

O2- %
CO2- %
CO- ppm
NO- ppm
Exhaust temperature- 0C or 0F
Efficiency- %
SO2- ppm
Smoke density
Air temperature- 0C or 0F
Ambient temperature- 0C or 0F
Ready Status
ENTER
Once the desired output signal is selected press . For each output (1-6) and chosen
MEMORY
output signal it is necessary to set a range (4-20mA).
Firslty the lower range is set (4mA). The CH1 changes the units (i.e. 0.1%, 1ppm,e.t.c)
and the CH2 changes the tens (i.e. 1.0%, 10ppm, e.t.c). When the correct lower range
ENTER
is set press .
MEMORY
Next the upper range is set (20mA). The CH1 changes the units (i.e. 0.1%, 1ppm,e.t.c)
and the CH2 changes the tens (i.e. 1.0%, 10ppm, e.t.c). When the correct upper range
ENTER
is set press .
MEMORY
The next 4-20mA signal will now need to be set. Once these are all set (or the desired ouputs are
set), use the CH1 buttons to scroll to the "RETURN TO SELECT FUNCTION" screen and
ENTER RUN
press , or press to return to the online cambustion values.
MEMORY

514 of 761
E.G.A. Exhaust Gas Analysis E.G.A. display calibration method
3.8.3 Changing the cells and test gas calibration
This section describes the procedure for changing out the cells of the E.G.A. in the field and also
applying a test gas to calibrate the cells.
RUN
When in the normal operating mode, i.e. the button is illuminated. Hold down the
123
123
CAL button for 2 seconds in order to enter the calibration menu. Once this is done the
"CALIBRATION METHOD" menu will appear.
Use the CH1 buttons to select which calibration method is to be used. The 2 choices are
"CALIBRATION CODE" and "GAS CALIBRATION". Once the correct screen is displayed press
ENTER
to proceed.
MEMORY
3.8.3.1 Calibration code

ENTER
Once has been pressed "SELECT CELL TYPE" will appear. Use the CH1 to
MEMORY
ENTER
select the cell that is to be replaced and then press
MEMORY
It is now necessary to enter the 15 digit code. This code contains information regarding the
manufacture date and range it was set for.
To do this use the CH1 buttons to move left and right to select the digit to change. Then
use the CH2 buttons to change the value for each digit.
ENTER
Once the correct code has been entered press
MEMORY
ENTER
If the wrong code has been inputted, then "INCORRECT CODE" is displayed. Press to
MEMORY
return to the "SELECT CELL TYPE" screen and start again.

RUN
Press when finished to go back to the online combustion values.

515 of 761
E.G.A. Exhaust Gas Analysis E.G.A. display calibration method
3.8.3.2 Gas calibration

ENTER
Once has been pressed "SELECT CAL GASES" is displayed. Use the CH1 to
MEMORY
select the gas and use CH2 to select "YES/NO" for each gas.
ENTER
Once the correct test gas constituents are selected press to continue.
MEMORY
"SET GAS SPANS" will be displayed. Now it is necessary to set the percentage of each gas is the
test gas.
Use CH1 buttons to select the gas and the CH2 buttons to select the
percentage for each gas.

ENTER
Once this is set press to continue. The E.G.A. will perfrom a zero calibration and then the
MEMORY
"CONNECT CAL GAS" screen will be displayed. Once the test gas is connected, and the flow is set
ENTER
with the flow gauge (550-600cc), press to perfom the test gas calibration.
MEMORY
RUN
Press once this is finished to return to the online combustion values.

516 of 761
E.G.A. Exhaust Gas Analysis EGA Set-up Software Introduction
3.9 EGA Set-up Software Introduction
The following information is provided to enable the Autoflame E.G.A. system to be calibrated and
serviced by a factory trained technician.
The software is operating a context sensitive help system. This means that by pressing the F1 func-
tion key you will get a help message specific to the function selected in the program. If you are
unable to find the HELP you require in the software notes go to the desired function in the program
and press F1.
The E.G.A. calibration software is accessed using an IBM PC or compatible, running MS DOS
together with the software and data cable provided. The PC operates via the RS 232 serial port,
either COM1 or COM2 and the corresponding serial port in the E.G.A. (see diagram 3.1.3) The
serial port in the E.G.A. is a 9 pin ‘D’ type connector on the cell board. The dust cover on the D
connector must be replaced after use.
To ensure the combustion readings are correct the E.G.A. should be either checked or calibrated
once a year. Error codes and information displayed on the local display, the remote display pod
(used for stand alone analysers) or the M.M. unit (used for combustion trim) must be observed.
The E.G.A. will log faults and retain the types of fault stating the date the fault occurred. Up to 10
values will be logged with the oldest fault being discarded. The logged values may be displayed on
the PC.
Once connected it is important to establish communication is correct. This is displayed on the PC

screen, top left, with the message “EGA Communicating OK”.
Should there be a communications problem please check the following points:
1) The data cable that is being used is the correct type as supplied with the software.
2) All interconnections are correct and secure.
3) The E.G.A. is powered and operational.
4) The correct serial port is selected from the software, (COM1 or COM2)
2 Metres
Serial Connection Connection to E.G.A.

to Computer (red) Serial Port (red)
Cable & Disk Part No. DTI20018
3.5" Floppy Disk (EGADISK)

517 of 761
E.G.A. Exhaust Gas Analysis EGA Set-up Software Introduction
3.9.0.1 Software Possiblities
The E.G.A. 6 channel analogue output facility is PC configurable to enable the user to set the range and
items of data required and also user selectable. Via the same software and connection lead (part no.
DTI 20018) the E.G.A. can be configured and operated as required. This can also be used to service,
fault find and calibrate the unit in two ways:-
Replacement sensors are supplied pre-coded which is entered into the EPROM of the unit to
calibrate the cell.
Test gas calibration by placing known concentrations of gas through the E.G.A. module.
Selecting the output signals of the 4-20mA

There are eleven possibilities:-
1. O2 range adjustable
2. CO2 range adjustable
3. CO range adjustable
4. NO range adjustable
5. SO2 range adjustable.
6. Exhaust gas temperature
7. Efficiency/nett/gross
8. Input for ambient air temperature i.e. combustion air inlet on burner
9. Air temperature input 4-20mA
10. E.G.A. unit air temperature ambient
11. Smoke density auxiliary input/output 0-10v from smoke obscuration 4 to 20 mA output.

518 of 761
E.G.A. Exhaust Gas Analysis EGATOPC Software
3.9.1 Using The Software
Calibrate Sensor (Replacing a Sensor)
The use of this facility will enable the user to calibrate the sensors within the E.G.A.. Each sensor is
supplied by Autoflame complete with it’s own unique calibration code number.
step 1. Removing the sensor to be replaced. Power the unit down before removing the sensor.
a) For O2 and CO2 sensors disconnect the corresponding plugs associated with the
sensor and the two plastic tubes, now remove the sensor retaining strap and install the
new sensor following the steps in reverse order.
b) For CO, SO2 and NO sensors, disconnect the corresponding plugs associated with
the sensor, now remove the three screws located on the top of the sensor, only replace
the sensor head. Do not remove the plastic tubing from the sensor housing. When
tightening the new sensor in place ensure a tight fit so that the cell does not leak, but
ensure that the screws are not over-tightened as this can lead to cracks in the cell that
would cause leaks.
step 2. Select Calibrate Sensor from the tool bar displayed at the bottom of the screen page. This
command will allow you to change a sensor without the need for test calibration gas.
step 3. After selection of the desired type of sensor from the menu listing, press the Enter key.
step 4. Type in the calibration code at the prompt and type Enter.
step 5. The E.G.A. communications will update the P.C. with information regarding the types of
sensor fitted, i.e. CO, NO, SO2, CO2 and O2.
step 6. Changing of the sensor is now complete, remove serial connection and replace cover
on the E.G.A. unit. If the cover is left off the E.G.A. the internal components may over
heat due to lack of cooling air from the fan located on the base of the unit. If the internal
temperature is above +40 deg C (104F) or below +5 deg C (40F) the pod or M.M. unit
will display “Ambient Temperature High” or “Ambient Temperature Cool” respectively.
Note: Only sensors purchased as spares have a code number issued.

519 of 761
3.9.2 Status
When the status toolbar option is selected the PC will display all the information from the E.G.A. unit.
The information will only be received provided the E.G.A. is communicating with the PC. Ensure the
E.G.A. is powered.
The Status screen will display the following information typically:
EGA Identification Number: 1

Operating Mode: EGA with MM
Operating Status: Ready for operation
Monitoring: Oxygen O2
Carbon Dioxide CO 2
Carbon Monoxide 1 CO
Nitrous Oxide NO
Sulphur Dioxide SO2
Run Time (Fuel 1) 433 Hours
Note: The above information is an example of Status information available
3.9.3 Faults
The Faults screen page shows the listing of all fault conditions that have occurred on either the M.M.
unit or the Stand alone display Pod. Up to 10 faults can be stored and displayed after this, subsequent
faults will erase the oldest fault listed. The date the error was detected and the Error number will also
be listed.
Example:
1 : 12/09/96 O2 cell failed (21) Error number

2 : 04/10/96 Pump failed (20) Error number

520 of 761
3.9.3 Options
This facility allows the user to select those options for the desired operation of the software. The user
can configure the various options by pressing the Enter key when set to the required menu. Once
Options has been selected the Configuration Menu will be displayed, showing the following menu
options.
3.9.3.1 4 - 20mA Outputs
As standard the E.G.A. unit is supplied with 6 4-20mA output channels. The user can programme the
required output from the function menu and configuring to the desired range. The minimum output is
4mA the maximum output is 20mA, each can be set to the range required.
Standard Factory Setup
CH No. Selection Min Max
CH1 O2 0 20.9
CH2 CO2 0 15
CH3 CO 0 999
CH4 NO 0 999
CH5 Deg C 0 400
CH6 Eff % 0 100
An external PSU is not required for the analogue outputs. The maximum permissable load on each
analogue output is 250Ω. All the negative terminals are common to each other. The analogue outputs
as a whole are isolated.
3.9.3.2 EGA Operating Mode
The E.G.A. Mode Setup allows the user to select the type of sensors and the desired operation on the
analyser. The menus for each option show the selection available at each point. Use the Enter key to
move to the next value, use ‘Y’ to denote selection of the NO and SO2 sensors, or ‘N’ if not in use.
When selections are complete press Enter.
If you select this option but decide not to change any values press the Escape key.
Setup configurations available:
Identification Number
CO Sensor type
Stand Alone or MM operation
Efficiency Calculation
NO2 Sensor fitted
SO Sensor fitted

521 of 761
3.9.3.3 Pinch Valve Control
This facility allows the user to measure CO and NO when operating on F2 or F3 fuel programmes. As
standard, CO and NO will only be measured when operating on fuel programme F1. This F1 pro-
gramme should always be used for the operation of gas firing. This facility may be required if gas is
operating on F2 programme or the user would like to measure CO and NO when burning fuel oil.
V1 = Pinch valve No.1 (brown)- CO/NO pinch valve. This pinch valve is located at the top of the cell
PCB. Second from the left, with a brown top to the valve.
V2 = Pinch valve No.2- SO2 pinch valve.
To check the pinch valves operate correctly:
The Pinch valves are checked in the M.M. Run mode. Select fuel 1 (F1), press E.G.A. to display the
E.G.A. information. Check that pinch valve 1 is open. The black topped pinch valve (V3) should close
when an E.G.A. calibration takes place, at this stage the sample line is closed and the drain solenoid
is opened. At all other times, i.e. when no calibration is taking place the black topped valve should be
open.
Select fuel 2 (F2). Check pinch valve 1 is closed all the time fuel 2 is selected, unless this has been
changed by the user as described earlier in this section.
V3 pinch valve. V1 Pinch valve No.1 V2 Pinch valve No 2.

522 of 761
3.9.3.4 System Configuration.
This function allows the user to select the following:

Language: English, German or French.
Serial Port: 1 or 2
Monitor: Colour: Yes or No
Printer Port: PRN as standard
Baud Rate: 9600 as standard
3.9.3.5 Test and Calibration Menu.
Options available:
a. Enter report details
b. Set time and date
c. Clear fault records
d. Print report
e. Modify Distributor details
f. Load fault record to disk
g. Sensor calibration dates
h. Return to main menu
3.9.3.6 Return to Main Menu (press ESC key)
3.9.3.7 Quit.
This will return the user to the DOS prompt.

523 of 761
E.G.A. Exhaust Gas Analysis Limits on Five Measured Combustion Parameters O2, CO, CO2, NO, exh temp
3.10 Limits on Five Measured Combustion Parameters
3.10.1 Overview of System Operation: Features and Benefits
The limits control software, which is included in every M.M. E.G.A. module, further extends the
application and control possibilities of the system when the E.G.A. sampling system is fitted. The
function of the limits control software enables the end user or commissioning engineer to insert upper,
lower and absolute limits on either or all of the five combustion parameters that the E.G.A. system
measures; O2, CO2, CO, NO and exhaust gas temperature. To invoke this additional control facility,
follow the commissioning data and technical information sheet within this section.
The limits control software is configured in two distinct forms: “Standard” limits or “Absolute” limits.
Either configuration is a user variable selection via the options in section 2.14.2.4
“Standard” Limits:
“Standard” limits are a set percentage volume, ppm or temperature above or below the commissioned
value for O2CO2, NO and exhaust gas temperature. In the case of CO, it is a specific amount of ppm
(parts per million) above the commissioned value. These values are entered when commissioning of
the E.G.A. system has been completed throughout the load index of the burner.
“Absolute” Limits:
“Absolute” limits are a specific percentage volume (numerical value). In this form only an ultimate low
value may be put on O2 in percentage volume and an ultimate high value for CO2 in percentage volume,
ppm or temperature. In the case of CO an ultimate high value in ppm may be entered. In the case of
exhaust gas temperature an ultimate high temperature maybe entered. These values are entered when
commissioning of the E.G.A. system has been completed throughout the load index of the burner.
The values for either “Absolute” or “Standard” limits are implemented via the Micro Modulation
Controller options as in section 2.14.2.4. When an entered limit is exceeded, either in “Absolute” or
“Standard” configuration, the following alternative control functions are available to the user (selected
via options).
Control Function 1.
The trim function is turned off automatically and the system runs on M.M. fuel and air positions only,
i.e. the original commissioning data. Also an error value is displayed (see error listings). The error value
displayed can be cleared and the trim function reinstated by pressing the “Open” and “Close” buttons
simultaneously when viewing the E.G.A. error or data.
Control Function 2.
The combustion system is shut down, i.e. the burner stops running. Also an error value is displayed (see
error listings). The error value displayed can be cleared and the combustion system restarted by pressing
the “Open” and “Close” buttons simultaneously when viewing the E.G.A. error or data.
(See relevant data sheets and drawings showing the control forms and facilities detailed above).

524 of 761
E.G.A. Exhaust Gas Analysis Limits on Three Measured Combustion Parameters O2 ,CO, CO2
3.10.2

525 of 761
3.10.3

526 of 761
3.10.4

527 of 761
E.G.A. Exhaust Gas Analysis EGA Dimensions and Fixing Details
3.11 EGA Dimensions
If EGA is in a hot area, cool air should be directed from a lower level or from outside with a filter.

528 of 761
E.G.A. Exhaust Gas Analysis Standard EGA Sampling Probe
3.12 Standard E.G.A. Sampling Probe
3.12.1 Installation and Maintenance
E.G.A. Sampling Probe Installation.
Mount the sampling probe at an angle of approximately 45 degrees.
Install a 1.5" B.S.P. socket on the flue or other point that the sampling probe is to be positioned.
Mount the main body of the probe as far in as possible; adjustment is made by loosening the grub
screws in the flats of the 1.5" B.S.P. bush supplied on the probe.
Keep the thermocouple cable and sample tube away from hot surfaces.
Note: For correct E.G.A. operation, the probe must be positioned without air leaks as this will give
incorrect readings on all sensors.
E.G.A. Sampling System Unit Installation
Push the sample tube onto the inlet tube. Plug the thermocouple connector into the socket and tighten
the screw.
To obtain optimum performance and reliability do not mount the unit in ambient temperatures above
40 degrees C (104F) or areas of direct heat radiation. Ensure that the air flow to the intake in the
bottom of the E.G.A. unit is not impeded and the air temperature is less than 40 degrees C (104F).
Do not mount the units where excessive vibration occurs (floor standing racks are available from
Autoflame Engineering Ltd).
Position the sample tube so that the sample slopes down to the E.G.A. unit at all times.
The E.G.A. unit must always be mounted lower than the E.G.A. probe.
Diagram to show correct mounting/fixing position.
Probe
Sample Tube
Mk.6 E.G.A. Mk.6 E.G.A.
Unit Unit
Incorrect Correct
Fixing. Fixing.

529 of 761
3.12.2

530 of 761
3.12.3

531 of 761
3.12.4 Maintainance of the Sampling Probe
On gas only applications it is unlikely that there should be continual maintenance required on the stack
mounted probe. It is advised that the probe is checked annualy on gas firing applications in order to
ensure that the probe is free of any blockages. On heavy or solid fuel applications, deposits may build
up in the outlet part of the tube. If the tube blocks a 'pump failure' will be displayed on the M.M. unit
(See Section 3.3.1).
The deposits can be cleared by running a long drill (7mm)(.275") up into the outlet tube by hand. Twist
and withdraw the drill often so as to pull out the deposits, otherwise the deposits will be pushed further
into the probe assembly.
Sectional Diagram to Show Method of Clearing a Blocked Outlet Tube.
Outlet Tube
Drill
Mounting Bush
3.12.6 Servicing E.G.A. Sampling Probe.
If the filter assembly in the E.G.A. sampling probe is blocked then it is necessary to disassemble the probe
and fit a new pre-formed fine filter and coarse filter material. To check if the E.G.A. probe is blocked
connect it to the E.G.A. If the flow drops by more than 100 cc/min then the filtering materials must be
replaced.
To disassemble the probe, remove the two cap headed screws visible on the outside of the assembly (one
each end). The whole of the internal assembly can now be withdrawn from the sample connection end.
Remove all traces of the filtering materials from the stainless steel filter. Check that the ways in the
stainless steel filter are clear and also the inner sample tube. Very carefully (the pre-formed fine filter
is delicate) push the pre-formed filter onto the stainless steel filter.
Slide the inner assembly back into the stainless steel outer casing. Pack the void between the fine filter
and the outer casing with coarse filtering material as shown on the filter assembly diagram. Use a small
rod to pack the material down a little at a time. Reassemble the exhaust gas inlet end plate and the two
screws.
After reassembly connect the probe to the E.G.A. and check that the drop in flow is no more than
50 cc/min.

532 of 761
BACK (N/O)
3.13
SO2 CELL
SO2 ATMOSPHERIC AIR INLET GLASS
RESTRICTOR
Issue: 1.1.2007
(GREEN RING)
SO2 EXHAUST
DOUBLE (YELLOW RING)
PINCH VALVE
(BLACK TOPPED PINCH VALVE)

SINGLE PINCH VALVE (N/0)
FRONT (N/C) EGA 24V PUMP
SAMPLE IN
VACUUM SWITCH
CHILLER BLOCK
PRESSURE SWITCH
DRAIN SOLENOID
DRY FILTER AT THIS POINT
EGA 24V PUMP CHECK FLOW OF PUMP
GLASS DRAIN

RESTRICTOR IS 600-650cc/min
Mk.6 E.G.A. Internal Tubing Pipework
CO CELL
FRONT (N/0) EXHAUST
(RED RING)
GLASS CO CELL NO CELL

RESTRICTOR
3mm PVC TUBE DOUBLE
CO2 CELL O2 CELL
PINCH VALVE No.1
CO/NO BYPASS
(BLUE RING)
Section 3.13
BACK (N/C)
Internal Tubing
533 of 761
E.G.A. Exhaust Gas Analysis Other Information and Illustrations
3.15 Technical Specifications
Electrical Supply: 230V/50Hz or 110V/60Hz (selectable)
Pump Flow: 550-650 cc/min (0.55-0.65 l/min)
Environmental Rating: IP20

NEMA1
Air Conditioned Unit: IP54

NEMA13
Temperature Range:-
E.G.A. Min. +5 deg C (40F)

Max. +40 deg C (104F)
Ceramic sampling Probe 0-1600 deg C (32-2912F)
Type "S" Thermocouple 0-1600 deg C (32-2912F)
Type "K" Thermocouple 0-400 deg C (32-752F)

534 of 761
3.15.2 General Assembly of Dry Filter
SAMPLE OUT
SAMPLE IN
GREEN RED
FILTER MATERIAL IS
PACKED UP TO THE TOP
FILTERING MATERIAL (AS SUPPLIED)
SPACE ALLOWS EVEN

FILTERING OVER TOTAL
SURFACE AREA OF FILTER
N.B. FREE SPACE MUST BE LEFT AT BOTTOM TO STOP ANY PREMATURE BLOCKAGE
THE SAMPLE IN & OUT PIPES MUST BE CONNECTED CORRECTLY OR BLOCKAGE
WILL OCCUR WITHIN A FEW HOURS.

535 of 761
3.15.3 General Assembly & exploded view of the Particulate Filter
INLET TUBE
TOP CAP
SAMPLE IN
PT No.OR70026 "O" RING
GLASS OUTER SLEEVE
FILTER RETAINING CAP
Pt. no. FILTER1002 FILTER
Pt. no. FILTER1001

CARTRIDGE
FILTERS
PT No.OR70026 "O" RING
INTERNAL BODY
SAMPLE OUT
ASSEMBLY SHOWN
FULL SIZE
OUTLET TUBE

536 of 761
3.15.4 High Temperature Probes

537 of 761
"S" TYPE HIGH TEMPERATURE THERMOCOUPLE ASSEMBLY

3.15.5
Issue: 1.1.2007
CODE H20S - ALUMINIUM ALLOY
CONNECTION HEAD
WEATHERPROOF IP68
FINISH: EPOXY PAINTED
3/4" BSP PARALLEL 15mm O/dia X 10mm I/dia TUBE

THREAD & LOCKNUT ONE END CLOSED
CERAMIC CEMENT MATERIAL: CERAMIC AL23
"S" Type Thermocouple
3/4" NB SCH 40 PIPE

MATERIAL:
TYPE "S" SINGLE Pt 10%Rh-Pt
310 STAINLESS STEEL
THERMOCOUPLE
AL23 CERAMIC INSULATOR

CERAMIC TERMINAL 4mm DIA X 0.8mm TWIN BORE
BLOCK
EARTH SCREW
TERMINAL BLOCK
40mm PN16 FLANGE
TO BS 4504
CABLE ENTRY MATERIAL: ASTM A182 F316 ORANGE +ve
M20 X 1.5 THREAD
HOT JUNCTION
Section 3.15.5
WHITE -ve
Other Information and Illustrations
WIRING DIAGRAM
TYPE "S" SINGLE THERMOCOUPLE
538 of 761
3.15.6 Ceramic Sampling Probe Assembly

539 of 761
3.15.7 O2 Interface Module
The O2 interface module allows the use of an existing O2 sensor and in-situ probe to be used in
conjunction with the M.M. control.
The O2 analyser is only measuring the O2 reading from the sensor and the exhaust gas temperature
via a thermocouple mounted into the stack. It is important to note that the signal from the O2 sensor
must be a 4-20mA and the thermocouple reading must be a 0-10V signal. These signals must be ranged
as below:
O2 reading: 4 - 20mA = 0 - 20.9% O2

Thermocouple reading: 0 - 10V = 50C - 400C (122F - 752F)
Although the analyser is only measuring the O2 reading from the stack it is possible for the O2 interface
module to extrapolate a CO2 value from the O2 sensor reading. These value can then be displayed
on the M.M. facia (via the E.G.A. button) or via the D.T.I. on a PC or BMS interface.
Parameter #60 is used to set the operation of the O2 interface module.
If this is set to a value of 0 then the efficiency will be calculated from the exhaust temperature and CO2
value and this will be displayed on the M.M. facia. The CO reading will always be displayed as a zero
value.
If this is set to a value of 1 then the CO, NO, exhaust temperature and efficiency will remain blank.
If using the O2 interface module it is possible to use the limits for O2 readings and exhaust gas
temperature readings.

540 of 761
Interconnection between M.M. Module and O2 Interface Module

541 of 761
3.15.8 Chilled Environmental Enclosure
In areas of harsh ambient conditions, or excessive heat, it is necessary to utilise an environmental

enclosure with the E.G.A. module. This allows protection to the E.G.A. from excessive heat and
dust and ensures that the E.G.A. is well protected. By utilising this enclosure, this allows the E.G.A.
to operate under the correct conditions in order to sample the exhaust gases.
Autoflame manufacture a chilled environmental enclosure that uses a chiller modules and control
panel in order to maintain the E.G.A. that is installed within the enclosure at a set temperature. The
temperature is user-adjustable by means of a thermostat counted on the unit but is nominally set for
35C (95F), which ensures ideal operating conditions for the E.G.A.
Please see the diagram below showing information on the chilled environmental enclosure. Please
contact Autoflame sales for further information.
E MISSION
MONITORING
C ON TINU OUS
E.G.A.
EXHA UST GA S AN ALYSIS SYSTEM
TRIM
SYSTEM
CO2 − O2 − CO − NO − SO2 − T − Eff.

Aut of lame En gin eering L imite d L on do n SE6 3BX Te l: 01 81 − 695 − 2000 F ax: 01 81 − 69 5 − 2010
Th is Equ ipment is prot ected un de rth e Europ ean Pat ent No .001 95886
EMISSION
MON ITORIN G
C ONTINUOUS
E.G.A.
EXHA USTGA S ANALYSIS SYSTEM
TR IM
SYSTEM
CO2 − O2− C O − N O − SO2 − T − Eff.

Aut ofla me Eng in eering Limited Lo nd on SE6 3BX Tel: 018 1 − 69 5 − 2 000 Fa x: 018 1 − 695 − 2010
This Eq uip men t is pro tec ted und er the Eu ro pea n Paten t No 0
. 019 5886

542 of 761
3.16 Shipping the E.G.A.
The EGA is a scientific instrument with delicate components. Whenever the EGA is shipped, it is
essential that the EGA is packed carefully in an Autoflame EGA shipping carton as originally sup-
plied.
Ensure that delivery carriers treat the package appropriately. Label the package as containing
delicate scienctific instrument.
If the EGA is damaged, repair costs will be incurred.
Please contact Autoflame Engineering or your local dealer to obtain a new Autoflame carton.

543 of 761

544 of 761
IBS Intelligent Boiler Sequencing
Section 4: I.B.S. Intelligent Boiler Sequencing
4.1 Overview - Features & Benefits of I.B.S. control
4.2 Commissioning and Setting Up Procedure
4.2.1 Guide to Commissioning Sequencing
4.4 Electrical Schematics Showing all Terminal Interconnections
4.4.1 Sequencing Connection Diagram

4.4.2 DTI/Sequencing Connection Diagram
4.5 Other Information and Illustrations.
4.5.1 Sequencing Operation

4.5.2 Sequencing Combinations
4.5.3 Diagram showing Data Transmission/Reception
4.5.4 Mini Mk5 Sequencing Status Information
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
Section 4: Index
123456789012345678901234
123456789012345678901234
123456789012345678901234
123456789012345678901234
545 of 761
4.1 INTELLIGENT BOILER SEQUENCING (I.B.S.)
Overview of System Operation: Features and Benefits
The Intelligent Boiler Sequencing software, which is included in every M.M. E.G.A. module, further
extends the application possibilities of the system. The objective of this control form is to ensure
that the minimum number of boiler/burner units are in operation at any one time to satisfy the heat
requirement imposed upon the boiler plant, particularly in the case of multi boiler installations.
There are two variations of I.B.S. software that can be selected by the user via the Options procedure.
The first variation relates to heating boilers and the second variation to steam boilers.
Heating Boilers Sequential Control:
A maximum of ten M.M. E.G.A. modules may be interconnected by a two wire screened data cable:
(See interconnection drawing). Any string of modules interconnected as detailed can have one of
it’s number designated No. 1 or lead boiler. This identifying of “lead” boiler is achieved by either of
the following methods:
a) Connecting a mains voltage onto terminal No. 41.

b) Instructing the modules via the D.T.I. module (Data Transfer Interface) by software.
Once a “lead” boiler has been selected the system works in the following way:
Typically every five minutes the sequencing software in the lead boiler identifies it’s own firing rate by
looking at the position of the fuel valve in the load index and also the maximum heating capacity of
the No 1. “lead” boiler. This information would normally be entered when this boiler/burner unit
is commissioned. Having established percentage firing rate, and maximum heating capacity, the I.B.S.
software calculates the amount of heat being contributed to the system by this boiler. The I.B.S.
software in the “lead” M.M. E.G.A. module then contacts in turn each of the modules connected to
this loop and gathers similar information from each. The “lead” module’s I.B.S. software then
calculates the minimum number of boiler/burner units that need to be operational to satisfy the building
load, imposed upon the plant at that time, and switches the remainder off. There is a terminal
connection on the M.M. E.G.A. module for controlling a two port valve that would normally be
installed in the boiler’s return pipe connection to the common return header. This facility ensures that
boilers that are switched “off line” do not contribute return temperature water to the flow header
thereby diluting the flow temperature to the building: (See relevant data sheets and drawings showing
the control sequence detailed above).
Example:
There are four boilers interconnected as above, each with a heating capacity of 586kw (2 Mbtu.)
In the event of each boiler firing 440kW (1.5 Mbtu) (3/4 of it’s maximum rate), the No. 1 lead boiler
would instruct the No. 4 boiler to shut down and boilers No.s 1, 2 and 3 would adjust their firing rate
to maximum. In both cases the boilers are contributing 1758kW (6 Mbtu) to the system but, after
intervention of the I.B.S. sequencing software, three boilers only are carrying the load which is a more
fuel efficient method of operation.
If the building load continued to decrease the three boilers would reach a point where they were each
firing 390kW (1.33 Mbtu) each.

546 of 761
At this point the I.B.S. software would switch off the No. 3 boiler as two boilers would be capable
of generating the 1172kW (4 Mbtu) required. When the load on the system increases, the reverse
procedure applies, i.e. when, for example, two boilers are firing at near 100% load and the setpoint
temperature on either of the modules is not being achieved, the I.B.S. software would switch on a third
boiler to assist with the generation of the heat requirement. Any boiler can be nominated “lead” boiler
by the connection of an input to the appropriate terminal or by a software instruction via the D.T.I.
Steam Boiler Sequential Control:
When the I.B.S. software control package is applied to steam boilers, it’s operation is exactly the same
as above but with the additional features and enhancements as explained in the following.
In the case of heating boilers only two states in the control form exist, either on or off. When steam
boiler variation of I.B.S. is optioned there are three states which are controlled sequentially.
The first is “on-line”, this is when the boiler is operating purely under the control of the M.M. E.G.A.
module's internal P.I.D. load controller.
The second state is “Standby Warming”: In this case the boiler is operated at a reduced pressure
setpoint, and runs for a number of minutes each hour: e.g. if the on-line boiler or boilers are set at a
setpoint of 7 bar (100 p.s.i.) the standby warming boiler controls at a setpoint of 5 bar (72 p.s.i.). In
this way if the load increases the standby warming boiler can begin to contribute steam quickly. The
reduced setpoint is a user variable option in the same way as the normal control pressure setpoint.
The number of minutes run time is also adjustable.
The third state is “off-line”, this is with the burner shut down and the boiler cold. If the load on the boiler
house increases, this boiler would move into a “warming” condition.
Apart from the variations detailed above, the steam sequencing works in precisely the same way as
the heating boiler sequencing: The sequencing software package ensures that at all times the minimum
number of boilers are operational to satisfy the load imposed on the boiler house.
Note:
It should be appreciated that all data and control variables can be shown on a screen via the addition
of the D.T.I. module to the data loop. The screen and keyboard can be sited locally in the boiler house
or the whole system can be addressed remotely via the normal telecommunications network.
In the software in the D.T.I. there is a histogram facility which shows the firing rate and state of each
boiler in the boiler house.

547 of 761
IBS Intelligent Boiler Sequencing Guide to Commissioning Sequencing
4.2.1 GUIDE TO COMMISSIONING SEQUENCING
Before any attempt is made to implement Sequencing operation, it is necessary that the fuel/air positions
and load index are already entered. Refer to Sections 2 or 3 for Commissioning fuel/air positions.
The load index is implemented using the same ten point load index entry method used for the Flow
Metering as detailed in Sections 2 and 3 of the manual. If the Flow Metering has already been optioned
and the ten point load index entered then it is not necessary to enter this again. However if it is not
entered, proceed as detailed below.
1. Set Option 57 to Value 1 (Refer to Section 2.2.4 - Setting Options).
2. Press ENTER whilst 57 and 1 are being displayed in the Air and Required windows
MEMORY respectively.
3. Next time the burner starts the M.M. will automatically go into the ten point load index entry
mode. The firing range is automatically divided into ten equal parts. Each of the ten divisions
from high to low has a fuel flow value in whatever unit of flow measurement the user requires
allocated to it. (All extrapolated fuel flow values between the ten points are calculated from a
“best fit” mathematical formula).
4. In this mode the Fuel

Position
window will show fuel value in degrees angular.
The Air
Position
window will be blank.
The Required window and its associated buttons will be used to enter the
fuel flow in the chosen fuel flow unit per minute value.
Note:
a) The Actual window confirms to the commissioning engineer which of the 10

points are currently being measured.
When the positioning motors are moving from one calibrated point to another the
Actual
display flashes. When it reaches the next point to be calibrated, with a
flow value, the display remains steady.
b) The minimum numerical value for fuel flow that can be entered into memory is 0.01.
The maximum numerical value for fuel flow that can be entered into memory is 999.
c) The values are entered in descending order, i.e. Point No.1 is maximum flame and
Point No.10 is at minimum flame.

548 of 761
IBS Intelligent Boiler Sequencing Guide to Commissioning Sequencing
The 10 sequential points on the load index are allocated automatically by the M.M.
5. When fuel flow has been calculated or read off of a commissioning fuel flow meter the value
is entered as detailed in Point No.4.
The ENTER button is then pressed and the flow value is passed into the M.M. memory.
MEMORY
6. The above detailed data entry routine is repeated until all 10 points have flow values allocated
to them.
7. When the last (10th) point has been entered the M.M. stops the burner and implements the
calculations necessary to enable the Load Index to be actioned. Whilst the calculations are being
carried out a rolling decimal point is displayed.
8. If it is not required to subsequently display the Flow Metering values, set Option 57 back to value
0.
9. If implementing "hot water" Sequencing set Options as follows ON EACH M.M.:
Set Option 16 to Value 1 or 3.

Set Option 33 to identification number accordingly.
Set Option 34 to the rating of burner.
Set Option 35 to time between Sequence scans.
ENSURE OPTION 53 IS SET TO 0.
10. If implementing "steam" Sequencing set Options as follows ON EACH M.M.:
Set Option 16 to Value 1 or 3.

Set Option 33 to identification number accordingly.
Set Option 34 to the rating of burner.
Set Option 35 to time between Sequence scans.
Set Option 53 to the time required for the boiler to be off.
Set Option 54 to the time required for the boiler to be on.
Note: Options 53 and 54 are relevant to the "Stand-by Warming" state.

Option 53 is the indication to this M.M. that the Sequencing being done is either
hot water or steam (i.e. 0 - Hot water, non zero value - Steam).

549 of 761
4.4 ELECTRICAL SCHEMATICS
Sequencing Connection Diagram
MINI Mk.6 M.M./E.G.A. System Pt. No. MMM60016
Combustion Management Systems
ENTER
MEMORY
INTER
HIGH
START FUEL
METERING
OPEN IBS
SEQUENCING
CLOSE FLAME
SCANNER
RESET
LOCKOUT
COM DISPLAY
STATUS
RUN
E.G.A. M.M.
MINI Mk.5 M.M./E.G.A. System Pt. No.MMM50016

550 of 761
DTI/Sequencing Connection Diagram
If a voltage on terminal 88 is used to select lead boiler, it will take priority over a lead boiler set via
the DTI.
MINI Mk.6 M.M./E.G.A. System Pt. No. MMM60016
Combustion Management Systems
ENTER
MEMORY
INTER
HIGH
START FUEL
METERING
OPEN IBS
SEQUENCING
CLOSE FLAME
SCANNER
RESET
LOCKOUT
COM DISPLAY
STATUS
RUN
E.G.A. M.M.
MINI Mk.5 M.M./E.G.A. System Pt. No.MMM50016

551 of 761

552 of 761

Diagram showing Example of Data Communications with Reference to Flickering L.E.D.s
This is the M.M. that is working communications:
Eg.: - M.M. No. 1.
A0 A0 A2 A0 A3 A0 A4 A0
Issue: 1.1.2007
Open >
Close R0 R1 A1 R0 R2 R0 R3 R0 R4 R0
>
Same waveforms
apply to M.M. No.s
This is an M.M. that is not working communications.
5 to 10.
Eg.: M.M. No. 3.
Open R0 A0 R1 A1 R0 A0 R2 A2 R0 A0 R3 R0 A0 R4 A4 R0 A0
>
Close A3
>

R0 - Request to D.T.I. A0 - Answer from D.T.I.
Note:- Only 1 M.M. works R1 - Request to M.M. 1 A1 - Answer from M.M. 1
the communications. R2 - Request to M.M. 2 A2 - Answer from M.M. 2
R3 - Request to M.M. 3 A3 - Answer from M.M. 3
553 of 761
Section 4.5.3
554 of 761
4.5.4 Mini Mk5 Sequencing Status Information
If parameter 32 = 1 then the information below is displayed instead of the Flow Metering Grand
Total. (Totalising still continues to work in the background).
*1 *2
*3 *4
Sequencing Status Information
Sequence Code: Sequence Code:
Steam Hot Water
0 On On
1 Standby/Warming Off *1
2 Off Off
3 Off Off
Receiving CR1 Working

Sequencing Information Relay Status Communications/
Sequencing
*2
0 = No 0 = Off 0 = No
1 = Yes 1 = On 1 = Yes
Status of Input 41 Disabled Status
Unused 0 = 0V AC 0 = Enabled *3
1 = 230V AC 1 = Disabled
(110V AC)
Lead Boiler
0
1 to 10
=
=
No Lead Boiler Selected
Number of Lead Boiler
*4

555 of 761

556 of 761
Section 6: D.T.I. Data Transfer Interface

6.1 DTI Module
6.2 Information Available from the DTI system
6.3 Complete DTI Standard System Application Example
6.4 Multi Kiln DTI Special System Application Example
6.5 Front Facia Layout
6.7 I/O System Capabilities
6.8 Communication Interface schematic system capabilities
6.9 Wiring Connection Terminals Diagram
6.10 DTI Fixing Holes and Dimensional Details
6.11 DTI Interconnections
6.11.1 MM Modules
6.11.2 EGA Modules
6.12 PCB Switch Settings and Link Arrangements
6.12.1 Restore To Factory Settings
6.13 DTI, PC and Modem Interconnections
6.14 Analogue Input/Output Module Index
6.15 Digital Input/Output Module Index
6.17 Modbus Interface Index
6.18 Autoflame WinPCDTI Software
6.19 Johnson Metasys Interface Index
6.20.1 Loop Back Test

6.20.2 Communication Interfaces
Issue: 1.1.2007 Autoflame Technical Manual Section 6 Index

557 of 761
D.T.I. Data Transfer Interface Introduction
6.1 Data Transfer Interface Module

558 of 761
D.T.I. Data Transfer Interface Information
6.1.2 Overview of Data Transfer Interface Operation
By means of the Autoflame Data Transfer Interface (D.T.I.) module, all of the operational data, stored
within each of up to ten M.M. modules, can be collected by the D.T.I. for transmission to a local terminal
(PC), screen and printer, Building Management System (B.M.S.) or PLC. This facility can also be
achieved remotely via modem/telecom link up. This cost effective system more than meets the
requirements of today’s E.M.S. and B.M.S. systems in providing all the necessary operational and alarm
status and control of boiler plant to achieve its maximum energy efficient operation.
Up to a maximum of ten M.M. modules (one per burner) can be connected to one D.T.I. module by means
of a series RS485 data link (daisy chain). The information gathered by the D.T.I. from each M.M. module
is then available for transmission to the E.M.S. or B.M.S. via either an RS232 data link, an RS422 data
link, an RS485 data link or modem/telecom data link. The RS232 and RS422 data links are used to send
the data via the Autoflame software package for PC management or MODBUS communications for a
Building Management System. The RS485 data link is used to send the data via Metasys communications.
Remote on/off control of the burners can also be achieved as well as adjustment of the temperature or
pressure setpoints and selection of sequencing order. To accommodate the status information from
other plant related equipment, the D.T.I. can handle upto 160 direct mains voltage inputs, 80 volt free
outputs, 60 4-20mA inputs and 60 4-20mA outputs. Typical remote E.M.S., B.M.S. information and
operational facilities that can be achieved are as follows, but are subject to the particular site and
management system requirements that are to be accommodated.
The capability exists within the standard D.T.I. software for the end user to label any mains voltage signal
input as an "Alarm" condition. When labelled as an "Alarm" condition the system can 'autodial' out onto
the general telephone network to a remote office. It is also possible via a MODBUS to Ethernet
converter to utilise this feature for data aquisition.

559 of 761
6.2 Information avaiable from the DTI
DTI Information:
MM Information:
Required boiler temperature (deg. C/F) or pressure (Bar/psi).

Actual boiler temperature (deg. C/F) or pressure (Bar/psi).
Burner on/off status.
Burner maximum firing rate.
Burner firing rate (%).
Fuel selected.
Control detector type (temperature/pressure).
Error conditions.
Low flame hold operation.
Hand operation.
Channel 1-Channel 4 positioning motor feedback signal
Channel 5-Channel 6 output and input signals to the VFD (inverter)
Maximum set point accepted from DTI.
Minimum set point accepted from DTI.
Lead boiler status.
Burner firing status (off, firing, purge, ignition).
Sequencing optioned.
Sequence status (on, stand-by, warm, off).
Enabled/disabled status.
Total hours run and number of start-ups per fuel.
Fuel type, instantaneous flow rates and totalised flows per fuel.
Online air and fuel pressure values.
EGA Information:
EGA operation optioned.

Flue gas oxygen present value.
Flue gas carbon dioxide present value.
Flue gas carbon monoxide (unburnt combustibles) present value.
Flue gas nitirc oxide present value.
Flue gas sulphur dioxide present value.
Flue gas exhaust temperature, ambient temperature and delta temperature present value.
Combustion efficiency present value.
Flue gas oxygen commission value.
Flue gas carbon dioxide commission value.
Flue gas carbon monoxide (unburnt combustibles) commission value.
Flue gas nitirc oxide commission value.
Flue gas sulphur dioxide commission value.
Flue gas exhaust temperature, ambient temperature and delta temperature commission value.
Combustion efficiency commission value.
Cooler condition.
Identification number.
Fuel selected.
EGA error conditions.

560 of 761
DTI Information:
DTI Input values:
Boiler enable/disable.
Change required set point.
Select lead boiler.
Shuffle sequencing.
Set Load Index.
Water Level Information:
Actual Water Level

End of probe position
2nd low position
1st low position
1st low pre-alarm position
Control point position or pump on and pump off positions
High water pre-alarm position
High water position
15 First Out Annunciation inputs status
Instantaneous steam flow metering
Totalised steam flow metering
Feed water temperature
Steam temperature
Continuous Emissions Monitoring Software (CEMS):
Current emissions by weight and volume (O2, CO2, CO, NO, SO2, H2O, N2, Total)
Totalised emissions by weight (O2, CO2, CO, NO, SO2, H2O, N2, Total)
Efficiency
Exhaust temperature
Boiler exit velocity
Total heat input into boiler
Net useful heat into boiler
Heat loss to stack
Fuel flow

561 of 761
ANALOGUE DIGITAL ANALOGUE DIGITAL

I/O UNIT I/O UNIT I/O UNIT I/O UNIT
Issue: 1.1.2007
MK.6 E.G.A. MK.6 E.G.A. MK.6 E.G.A. MK.6 E.G.A.
BOILER No.1 BOILER No.2 BOILER No.3 BOILER No.4

Mk.6 M.M. Mk.6 M.M. Mini Mk.6 M.M. Mini Mk.5 M.M.
PC
Section 6.3
D.T.I. UNIT
Complete DTI Standard System Application Example
562 of 761
Mini Mk.5 M.M. Mini Mk.5 M.M. Mini Mk.5 M.M. Mini Mk.5 M.M.
Issue: 1.1.2007
KILN No.1 KILN No.2
4 X THERMOCOUPLES
4 X THERMOCOUPLES
OTHER
CONTROL
X8
Mini Mk.5 M.M. Mini Mk.5 M.M. Mini Mk.5 M.M. Mini Mk.5 M.M.

ANALOGUE ANALOGUE
I/O UNIT I/O UNIT
DIGITAL
I/O UNIT
BURNER RATE SIGNAL BURNER RATE SIGNAL

KILN No.1 KILN No.2
ALARMS
X 16
Section 6.4
Multi Kiln Special System Application Example
PC
DTI UNIT
563 of 761
D.T.I. Data Transfer Interface DTI Front Facia Layout
6.5 Front Facia Layout

564 of 761
D.T.I. Data Transfer Interface Input/Output System Capabilities
6.7 Input/Output System Capabilities

565 of 761
D.T.I. Data Transfer Interface Communication Interface Schematic System Capabilities
6.8 Communication Interface Schematic System Capabilities
The following communications ports are available on the DTI (contact Autoflame sales for other
applications or other required protocols, i.e. BacNet, Ethernet, e.t.c.):
RS232 (serial port)- used for local PC's (less than 10m/40ft) using the Autoflame software or MODBUS
RS422 port- used for remote PC's (up to 1000m/4000ft) using the Autoflame software or MODBUS
RS485 port- used strictly for Metasys communications only
Modem port- used for telephone communications and the Autoflame software

566 of 761
D.T.I. Data Transfer Interface Wiring Connection Terminals Information Diagram
6.9 Wiring Connection Terminals Diagram
MODEM
PC
RS 485 POSITIVE +
RS 485 NEGATIVE -
EARTH RS 485 SCREEN
SUPPLY NEUTRAL
SUPPLY LIVE I/O POSITIVE +
I/O NEGATIVE -
MM SCREEN I/O SCREEN
MM NEGATIVE -
MM POSITIVE + RS 422 TX +
RS 422 TX -
EGA SCREEN RS 422 RX +
EGA NEGATIVE - RS 422 RX -
EGA POSITIVE + RS 422 SCREEN

567 of 761
D.T.I. Data Transfer Interface DTI Fixing Holes and Dimensional Details
6.10 DTI Fixing Holes and Dimensions

568 of 761
D.T.I. Data Transfer Interface DTI Interconnections
6.11 DTI Interconnections
6.11.1 M.M. Modules (M.M./E.G.A.)

569 of 761
D.T.I. Data Transfer Interface MM/EGA and DTI Interconnections
6.11.2 E.G.A. Modules (standalone E.G.A.)
EGA EGA
EGA
AUTOFLAME

570 of 761
D.T.I. Data Transfer Interface PCB Switch Settings
6.12 PCB Switch Settings
Switch Bank 1 Switch Bank 2
100s 10s 1s ON
OFF
1 2 3 4 5 6 7 8
Standard DTI - when used with WinPCDTI Software
Switch Bank 1 - not relevant, set to 001
Switch Bank 2 - ways 1 to 8 all set to off unless using the older Mk5 and mini Mk5 M.M. modules
Way 8 MM Port Baud Rate

off - 9600 (Mk6, Mini Mk6 and Mini Mk5 MMs)
on - 4800 (Older Mk5 and Mini MMs)*
* Technical Memo: Data Communication Compatibility 3/9/1999
Settings for switch banks 1 & 2 may be different if the DTI is used for both WinPCDTI and Modbus/
Metasys operation. See sections 6.17.6.

571 of 761
D.T.I. Data Transfer Interface PCB Switch Settings
6.12.1 To Restore Factory Settings
This procedure clears all congifuration data in the DTI and sets it back to default settings (configuration
data includes, for example, alarm trigger conditions and labels).
Procedure Switch Bank 1
1. Power off the unit.

100s 10s 1s
2. Set Switch Bank 1 address value to 789:

100s = 7
10s = 8
1s = 9
(Switch Bank 2 settings are irrelevant).
3. Power up.
4. Wait until the I/O transmit LED flashes (approx. 25 seconds)
5. Power off.
6. Set switches back to the required operational settings.
7. Power on unit.

572 of 761
D.T.I. Data Transfer Interface DTI, PC and Modem Interconnections
6.13 DTI, PC and Modem Interconnections
Connection between PC and DTI MODEM
Connection between PC and DTI RS-422 port
Example shown using line drive type

GW232F made by Greenwich Instruments
Limited.

573 of 761
D.T.I. Data Transfer Interface DTI, PC and Modem Interconnections
Direct connection between PC and DTI RS-232 PC port
PC-DTI Cable (for older DTI units that do not use a standard PC serial lead)

574 of 761
Section 6.14: Analogue Input/Output Module Index
6.14.1 Introduction, Features & Benefits
6.14.2 Facia Layout and Internal Connections
6.14.3 Setup Configuration for direct connection to M.M. unit
6.14.4 Front Facia Layout with LED description
6.14.5 Fixing Holes & Dimensional Details
6.14.6 Wiring Connection Diagram
6.14.7 M.M. to Analogue Input/Output Unit Connection Diagram
6.14.8 DTI to Analogue Input/Output Unit Connection Diagram
6.14.9 Application Example
Issue: 1.1.2007 Autoflame Technical Manual Section 6.14 Index

575 of 761
D.T.I. Data Transfer Interface Analogue I/O Module
6.14.1 Introduction, Features and Benefits
Each analogue I/O unit has 6 analogue inputs and 6 analogue outputs. Each analogue input can be
individually configured for 0-10 V, 0-20 mA or 4-20 mA, and each analogue output can be individu-
ally configured for 0-10 V or 4-20 mA. The unit is primarily for use with a Data Transfer Interface (DTI)
unit. However, it can also be used in conjunction with most M.M. units to convert M.M. items of data
to analogue outputs. Before operation the unit must be setup for its particular modes of operation by
means of a serial port and a personal computer (emulating a terminal, e.g. windows hyperterminal).
When used with a DTI, up to 10 analogue input/output units can be linked together. These are linked
in series (daisy chain) using an RS485 2-core shielded data cable. As well as the actual analogue
inputs and outputs being configurable, the data range for each input and output can also be individu-
ally set. Text labels can also be assigned to each input and output. The latter items (data range/text
labels) can be of use when the DTI is being used for a building management system or programmable
logic controller type interface. It is also possible to set each of the analogue inputs to simply monitor
the required control signal or this can be set to alarm if the signal exceeds a user-defineable value or
if the signal drops below a user-defineable value. These alarm settings are unique for each input and
also carry a time delay setting until the alarm is actually recorded. This ensures that if the signal is
fluctuating, annoyance alarms are avoided. The analogue inputs can also be set to totalise and so an
instantaneous reading is recorded and displayed, but a totalising value is also stored in the background
and is viewable. However, in the vast majority of cases, these setups can be left as supplied.
Notes:
An external PSU is not required for the analogue outputs.

The maximum permissable load on each analogue output is 250Ω.
All the negative terminals are common to each other.
The analogue outputs as a whole are isolated.
The analogue inputs are not powered internally by the analogue I/O module and so a 24V dc supply
may be required for each input, depending on the controller.

576 of 761
RS485 TO D.T.I.
I/O SCREEN EARTH
I/O NEGATIVE - SUPPLY NEUTRAL
I/O POSITIVE + SUPPLY LIVE
SCREEN POSITIVE +
ANALOGUE ANALOGUE
NEGATIVE - NEGATIVE -
INPUT 1 OUTPUT 6
POSITIVE + SCREEN
SCREEN POSITIVE +
ANALOGUE ANALOGUE
INPUT 2 OUTPUT 5
POSITIVE + SCREEN
SCREEN POSITIVE +
ANALOGUE ANALOGUE
INPUT 3 OUTPUT 4
POSITIVE + SCREEN
SCREEN POSITIVE +
ANALOGUE ANALOGUE
INPUT 4 OUTPUT 3
POSITIVE + SCREEN
SCREEN POSITIVE +
ANALOGUE ANALOGUE
INPUT 5 OUTPUT 2
POSITIVE + SCREEN
SCREEN POSITIVE +
ANALOGUE ANALOGUE
INPUT 6 OUTPUT 1
POSITIVE + SCREEN
N.B. All Negative connections are common to each other.

577 of 761
6.14.3 Setup Configuration for direct connection to M.M. unit
SETUP
To configure the unit connect a pc serial port to the setup port (use the Autoflame I/O setup lead). The
pc must be running a terminal emulation program with the transmit and receive parameters set as
follows:
Baud rate: 4800

Data bits 8
Parity none
Stop bits 1
(Check the COM port is set to the one actually being used).
Pressing the <return> key should bring up the following opening message:
Analog I/O unit setup mode
Pressing the <ESC> key at any time during setup will cause exit from setup. If no keys are pressed for
a period of approximately 5 minutes the unit will automatically exit from setup and revert to normal
operation. During setup the unit will not carry out its normal functions. A test mode can be invoked
during set up so the operation of the inputs and outputs can be checked. Every detail of the setup is
not covered here as it is very repetitive. Experience can be quickly gained by working with an actual
unit in setup mode (note that during normal operation if the PC is connected textual messages are
displayed indicating communication between input/output units and the DTI).
If an existing setting is to be left unchanged then just press the <return> key.
The following shows samples of the various items that can be set. Text that is displayed on the screen
is shown in bold.
Present input range for analog input 1 is A 0-10 volts
Ranges available
0 - 10 volts A
0 - 20 milliamps B
4 - 20 milliamps C
Make new selection or <return>

This can be set for all 6 inputs.
Present mode of operation is with DTI

Press M to set MM mode or <return to proceed>
If DTI mode is selected, by just pressing <return> in this example, the following items are displayed
(if M.M. is selected please see later in this section):

578 of 761
Address is currently set to 1
Press <return> or enter new address(1-10) then <return>:
The address must be set in sequence for each analog I/O unit, e.g. if there are 3 analogue I/O units
on the system the first should be set address 1, the second to address 2 and the third to address 3.
Conflicts will occur if addresses are not set correctly and communications issues will occur.
Input number 1:-

Present label : Analog Input 1
Enter new label : Up to 30 alpha numeric characters can be used for a label
Present low range digital value : 0

Enter new low range value : This is the low data range value, it must be in the range 0-255
Present high range digital value : 255

Enter new high range value : This is the high data range value, it must be in the range 0-255
The label, low range and high range values can be set for all 6 inputs and all 6 outputs. After the
ouput 6 high range value the setup mode is exited and the following appears on the screen:
SETUP TERMINATED !
Operation will revert to normal.
If the MM mode of operation is selected then the following items are displayed
Firing rate A
Required value B
Actual value C
Channel 1 position D
Channel 2 position E
Channel 3 position F
Channel 4 position G
MM error H
EGA error I
O2 value J
CO2 value K
CO value L
NO value M
SO2 value N
Exhaust Temperature O
Efficiency P
Present selection for analogue output 1 is : A - Firing rate

Present low range value : 0
Present high range value : 100

579 of 761
If the <return> key is pressed the screen refreshes with the same display but for analogue output 2. If
a selection is made then a low range value and a high range value are subsequently requested.
The low and high range values are values at which the output ranges itself from zero to span, i.e.
0-10V or 4-20 mA. After all 6 analogue outputs have been covered the setup mode is automatically
exited and the screen displays:
SETUP TERMINATED !
It must be noted that the numeric values for the low and high range do not accept decimal points. If the
value normally has a decimal point then the value should be entered without the decimal point, e.g.
for the channel 2 position, if the output was set to give 0-10 volts over 10.0 to 80.0 degrees then the
low and high range should be entered as 100 and 800 respectively.
Configuration of M.M. when used directly with an analogue I/O unit
If an analogue I/O unit is connected directly to an M.M. to provide analogue outputs, the first analogue
input may be used to set the the required setpoint. Analogue input channels 2 to 6 are of no relevance
when the unit is used with an M.M.
If the required setpoint is to be set by the channel 1 input then the following options/parameters
should be set on the M.M. (see section 2.14.2.4)
Option #16 = 2
Option #30 = lowest required setpoint
Option #31 = highest required setpoint
Option #33 = 1 (identification number)
Parameter #49 = 1
The channel 1 input can be configured for voltage/current as described in the earlier sections of the
setup procedure.
On later versions of the analogue I/O unit software (3.01 onwards) there is an additional set up to set
the type of MM connected.
Example:
RS485 port baud rate is set at 9600 (Mk6, MiniMk6, MiniMk5)

Press 4 to set to 4800 <return> to proceed.
Also on the later versions the following text is displayed when not in set up mode.
MM comms = nnn required value = nnn
M.M. comms increments each time the analogue I/O unit receives data from the M.M. Required
value is the value that has been calculated for transmission back to the M.M.
Note: Sequencing/D.T.I. and analogue I/O unit cannot be used at the same
time if the analogue I/O module is to be used for setpoint changes
on the M.M. If the analogue I/O module is used for monitoring and
standard DTI operation then all of these features are available.

580 of 761
6.14.4 Front Facia Layout with LED Description
6 Channel Output
6 X 4 -20mA - 0 -10V - I/O
Part No. DTI20021
6 Channel Input
Power
O.K.
Rx
Tx

581 of 761
6.14.5 Fixing Holes & Dimensional Details
The depth of the unit is 38mm (1.5").

These units are back plate mounted not mounted on the front.

582 of 761
6.14.6 Wiring Connections Diagram

583 of 761
6.14.7 M.M. to Analogue Input/Output Unit Connection Diagram

584 of 761
6.14.8 DTI to Analogue Input/Output Unit Connection Diagram

585 of 761
AIR DAMPER AIR DAMPER AIR DAMPER AIR DAMPER 6.14.9
Issue: 1.1.2007
MM10072
MM10072
MM10072
MM10072
OV37021 BURNER OV37021 BURNER OV37021 BURNER OV37021 BURNER
OIL
No.1 No.2 No.3 No.4
MM10004
MM10004
MM10004
MM10004
LOCAL LOCAL LOCAL LOCAL

SERVICES SERVICES SERVICES SERVICES
PANEL PANEL PANEL PANEL
M.M. UNIT M.M. UNIT M.M. UNIT M.M. UNIT

MMM50016 MMM50016 MMM50016 MMM50016
4-20 mA i/O 4-20 mA i/O 4-20 mA i/O 4-20 mA i/O

Module Module Module Module
DTI20021 DTI20021 DTI20021 DTI20021
LOAD CONTROL
LOAD CONTROL
LOAD CONTROL
LOAD CONTROL
FUEL POSITION
FIRIING RATE
ERROR / FAULT
FUEL POSITION
FIRIING RATE
ERROR / FAULT
FUEL POSITION
FIRIING RATE
ERROR / FAULT
FUEL POSITION
FIRIING RATE
ERROR / FAULT
SPARE
SPARE
SPARE
SPARE
AIR PISITION
SPARE
AIR PISITION
SPARE
AIR PISITION
SPARE
AIR PISITION
SPARE
Section 6.14.9
Analogue I/O Module
CLLIENT'S CONTROL ROOM X 12

Application Example: M.M. unit to Analogue Input/Output Unit Direct Connection
586 of 761
Section 6.15: Digital Input/Output Module Index
6.15.1 Introduction, Features & Benefits
6.15.3 Setup Configuration for direct connection to DTI unit only
6.15.5 Fixing Holes & dimensional Details
6.15.7 DTI to Digital Input/Output Unit Connection Diagram

587 of 761
D.T.I. Data Transfer Interface Digital I/O Module
6.15.1 Introduction, Features and Benefits
Each digital I/O unit has 16 mains voltage inputs and 8 individual volt free mains voltage switches.
The unit is used in conjunction with a Data Transfer Interface (DTI) unit. The mains voltage inputs can
be used to wire in any alarms from the boiler house. The volt free mains voltage switches can be used
to turn various components on/off. Before operation the unit must be setup for operation by means of
a serial port and a personal computer (emulating a terminal). Up to 10 digital input/output units can
be chained together. Text labels can also be assigned to each input and output. The latter items (data
range / text labels) can be of use when the DTI is being used for a building management system or
programmable logic controller type interface. It is also possible to set each of the digital inputs to
simply monitor the required control signal or this can be set to alarm if the input signal is present ot not
present, i.e. high or low. These alarm settings are unique for each input and also carry a time delay
setting until the alarm is actually recorded. This ensures that if the signal is fluctuating, annoyance
alarms are avoided.
Refer to DTI manual for interconnections between the digital I/O unit & the DTI.

588 of 761
RS485 TO D.T.I.
I/O SCREEN
I/O NEGATIVE -
I/O POSITIVE +
SUPPLY LIVE
SUPPLY NEUTRAL
COMMON EARTH
INPUT 1
OUTPUT 8
INPUT 2
INPUT 3
OUTPUT 7
INPUT 4
INPUT 5
OUTPUT 6
INPUT 6
INPUT 7
OUTPUT 5
INPUT 8
INPUT 9
OUTPUT 4
INPUT 10
INPUT 11
OUTPUT 3
INPUT 12
INPUT 13
OUTPUT 2
INPUT 14
INPUT 15 OUTPUT 1
INPUT 16

589 of 761
6.15.3 Setup configuration for direct connection to D.T.I. unit
To configure the unit connect a pc serial port to the setup port (use the Autoflame I/O setup lead).
The pc must be running a terminal emulation program with the transmit and receive parameters set
as follows:
Baud rate: 4800

Data bits 8
Parity none
Stop bits 1
(Check the COM port is set to the one actually being used).
Pressing the <return> key should bring up the following opening message:
Digital I/O unit setup mode
Pressing the <ESC> key at any time during setup will cause exit from setup. If no keys are pressed
for a period of approximately 5 minutes the unit will automatically exit from setup and revert to
normal operation. During setup the unit will not carry out its normal functions. A test mode can be
invoked during set up so the operation of the inputs and outputs can be checked. Every detail of
the setup is not covered here as it is very repetitive. Experience can be quickly gained by working
with an actual unit in setup mode. Note that during normal operation if the PC is connected textual
messages are displayed indicating communication between input/output units and the DTI.
If an existing setting is to be left unchanged then just press the <return> key.
The following shows samples of the various items that can be set. Text that is displayed on the
screen is shown in bold.
Address is currently set to 1
Press <return> or enter new address(1-10) then <return>:
The address must be set in sequence for each digital I/O unit, e.g. if there are 3 digital I/O units on
the system the first should be set to address 1, the second to address 2 and the third to address 3.
Conflicts will occur if addresses are not set correctly.
Input number 1:-

Present label : Digital Input 1
Enter new label : Up to 30 alpha numeric characters can be used for the label
Present Monitor/Alarm status is : Monitor

Enter M/A or <return to proceed>
Present Active High/Low status is : High

Enter H/L or <return> to proceed
The label, M/A status and H/L status are repeated for all 16 inputs.

590 of 761
Output number 1:-

Present label : Digital Output 1
Enter new label : Up to 30 alpha numeric characters can be used for the label.
The label entry is repeated for all eight outputs. After all 8 digital outputs have been covered the
setup mode is automatically exited and the screen displays
SETUP TERMINATED !

591 of 761
8 X Volt Free Contacts

Outputs
8 X Volt Free Outputs - 16 X Line Inputs
Part No. DTI20020
16 X 230V/110V Inputs
Inputs
Power
O.K.
Rx
Tx

592 of 761
6.15.5 Fixing holes & Dimensional Details
The depth of the unit is 38mm (1.5").

These units are back plate mounted not mounted on the front.

593 of 761

594 of 761
6.15.7 DTI to Digital Input/Output Unit Connection Diagram

595 of 761
Section 6.17: Modbus Interface Index
6.17.1 Overview
6.17.2 OX References - coils
6.17.2.1 Enable/Disable commands for each M.M

6.17.2.2 Digital Input/Output module outputs
6.17.3 1X References - Inputs
6.17.3.1 Digital Input/Output module

6.17.3.2 M.M. System
6.17.3.3 E.G.A. System
6.17.3.4 Online Offline Status
6.17.4 3X References - Input Registers
6.17.4.1 Analogue Input/Output module

6.17.4.3 E.G.A. System
6.17.5 4X References - Holding Registers

6.17.5.2 Analogue Input/Output module outputs
6.17.6 PCB Switch Settings
6.17.7 Other Information
6.17.7.1 Modbus Transmission Serial Port Settings

6.17.7.2 Supported Commands
6.17.7.3 Supported Exception Responses
6.17.7.4 Serial Port Connections
6.17.8 Relevance of MM/EGA Data
6.17.9 Further Information

596 of 761
D.T.I. Data Transfer Interface Modbus
6.17.1 Overview
This manual details information regarding the Data Transfer Interface (DTI) 'Modbus' type interface.
This interface allows the DTI to simultaneously communicate with the standard Autoflame Windows
95 PCDTI System.
Some knowledge of the Micro Modultion system is necessary to appreciate the meaning of the infor-
mation contained within this manual.

597 of 761
6.17.2 0X Reference Addresses - Coils
6.17.2.1 Enable/Disable command for each MM
MM ID number Reference Address

1 00001
2 00002
3 00003
4 00004
5 00005
6 00006
7 00007
8 00008
9 00009
10 00010
6.17.2.2 Digital I/O module output
Digital Output Number

I/O Module Number
1 2 3 4 5 6 7 8
1 00017 00018 00019 00020 00021 00022 00023 00024
2 00025 00026 00027 00028 00029 00030 00031 00032
3 00033 00034 00035 00036 00037 00038 00039 00040
4 00041 00042 00043 00044 00045 00046 00047 00048
5 00049 00050 00051 00052 00053 00054 00055 00056
6 00057 00058 00059 00060 00061 00062 00063 00064
7 00065 00066 00067 00068 00069 00070 00071 00072
8 00073 00074 00075 00076 00077 00078 00079 00080
9 00081 00082 00083 00084 00085 00086 00087 00088
10 00089 00090 00091 00092 00093 00094 00095 00096

598 of 761
6.17.3 1X Reference Addresses - Inputs
6.17.3.1 Digital Input
Digital Input Number

I/O Module Number
1 2 3 4 5 6 7 8
1 10001 10002 10003 10004 10005 10006 10007 10008
2 10017 10018 10019 10020 10021 10022 10023 10024
3 10033 10034 10035 10036 10037 10038 10039 10040
4 10049 10050 10051 10052 10053 10054 10055 10056
5 10065 10066 10067 10068 10069 10070 10071 10072
6 10081 10082 10083 10084 10085 10086 10087 10088
7 10097 10098 10099 10100 10101 10102 10103 10104
8 10113 10114 10115 10116 10117 10118 10119 10120
9 10129 10130 10131 10132 10133 10134 10135 10136
10 10145 10146 10147 10148 10149 10150 10151 10152
Digital Input Number

I/O Module Number
9 10 11 12 13 14 15 16
1 10009 10010 10011 10012 10013 10014 10015 10016
2 10025 10026 10027 10028 10029 10030 10031 10032
3 10041 10042 10043 10044 10045 10046 10047 10048
4 10057 10058 10059 10060 10061 10062 10063 10064
5 10073 10074 10075 10076 10077 10078 10079 10080
6 10089 10090 10091 10092 10093 10094 10095 10096
7 10105 10106 10107 10108 10109 10110 10111 10112
8 10121 10122 10123 10124 10125 10126 10127 10128
9 10137 10138 10139 10140 10141 10142 10143 10144
10 10153 10154 10155 10156 10157 10158 10159 10160

599 of 761
6.17.3.2 1X Reference Addresses - input
MM Number
1 2 3 4 5
CR1 Relay Status 10193 10273 10353 10433 10513
10194 10274 10354 10434 10514
10195 10275 10355 10435 10515
10196 10276 10356 10436 10516
10197 10277 10357 10437 10517
10198 10278 10358 10438 10518
10199 10279 10359 10439 10519
10200 10280 10360 10440 10520
Boiler Temp/Pressure 10201 10281 10361 10441 10521

10202 10282 10362 10442 10522
10203 10283 10363 10443 10523
10204 10284 10364 10444 10524
10205 10285 10365 10445 10525
10206 10286 10366 10446 10526
10207 10287 10367 10447 10527
10208 10288 10368 10448 10528
10209 10289 10369 10449 10529

Flow Metering On 10210 10290 10370 10450 10530
CO displayed on F2/F3 10211 10291 10371 10451 10531
10212 10292 10372 10452 10532
C or F 10213 10293 10373 10453 10533
Bar or PSI 10214 10294 10374 10454 10534
External Voltage 10215 10295 10375 10455 10535
10216 10296 10376 10456 10536
EGA Optioned 10217 10297 10377 10457 10537

Actual up to Trim Threshold 10218 10298 10378 10458 10538
Cooler Ready 10219 10299 10379 10459 10539
Ambient Temp OK 10220 10300 10380 10460 10540
NO optioned 10221 10301 10381 10461 10541
SO2 optioned 10222 10302 10382 10462 10542
Temp HI/LO 10223 10303 10383 10463 10543
OK to sample 10224 10304 10384 10464 10544
Sequencing optioned 10225 10305 10385 10465 10545

Setpoint/Enable Accepted 10226 10306 10386 10466 10546
10227 10307 10387 10467 10547
10228 10308 10388 10468 10548
10229 10309 10389 10469 10549
10230 10310 10390 10470 10550
10231 10311 10391 10471 10551
10232 10312 10392 10472 10552
Addresses with no detailed function are unused.
600 of 761
1X Reference Addressees - inputs
MM Number
1 2 3 4 5
Hand Operation 10233 10313 10393 10473 10553
Low Flame Hold 10234 10314 10394 10474 10554
10235 10315 10395 10475 10555
10236 10316 10396 10476 10556
10237 10317 10397 10477 10557
10238 10318 10398 10478 10558
MM working COMMS 10239 10319 10399 10479 10559
Input 41 status 10240 10320 10400 10480 10560
Lead boiler status 10241 10321 10401 10481 10561

Disabled status 10242 10322 10402 10482 10562
10243 10323 10403 10483 10563
10244 10324 10404 10484 10564
10245 10325 10405 10485 10565
10246 10326 10406 10486 10566
10247 10327 10407 10487 10567
10248 10328 10408 10488 10568
Slave burner left/right 10249 10329 10409 10489 10569

10250 10330 10410 10490 10570
10251 10331 10411 10491 10571
10252 10332 10412 10492 10572
10253 10333 10413 10493 10573
10254 10334 10414 10494 10574
10255 10335 10415 10495 10575
10256 10336 10416 10496 10576
10257 10337 10417 10497 10577

10258 10338 10418 10498 10578
10259 10339 10419 10499 10579
10260 10340 10420 10500 10580
10261 10341 10421 10501 10581
10262 10342 10422 10502 10582
10263 10343 10423 10503 10583
10264 10344 10424 10504 10584
10265 10345 10425 10505 10585

10266 10346 10426 10506 10586
10267 10347 10427 10507 10587
10268 10348 10428 10508 10588
10269 10349 10429 10509 10589
10270 10350 10430 10510 10590
10271 10351 10431 10511 10591
10272 10352 10432 10512 10592
601 of 761
1X Reference Addresses - inputs
MM Number
6 7 8 9 10
CR1 Relay Status 10593 10673 10753 10833 10913
10594 10674 10754 10834 10914
10595 10675 10755 10835 10915
10596 10676 10756 10836 10916
10597 10677 10757 10837 10917
10598 10678 10758 10838 10918
10599 10679 10759 10839 10919
10600 10680 10760 10840 10920
Boiler Temp/Pressure 10601 10681 10761 10841 10921

10602 10682 10762 10842 10922
10603 10683 10763 10843 10923
10604 10684 10764 10844 10924
10605 10685 10765 10845 10925
10606 10686 10766 10846 10926
10607 10687 10767 10847 10927
10608 10688 10768 10848 10928
10609 10689 10769 10849 10929

Flow Metering On 10610 10690 10770 10850 10930
CO displayed on F2/F3 10611 10691 10771 10851 10931
10612 10692 10772 10852 10932
C or F 10613 10693 10773 10853 10933
Bar or PSI 10614 10694 10774 10854 10934
External Voltage 10615 10695 10775 10855 10935
10616 10696 10776 10856 10936
EGA Optioned 10617 10697 10777 10857 10937

Actual up to Trim Threshold 10618 10698 10778 10858 10938
Cooler Ready 10619 10699 10779 10859 10939
Ambient Temp OK 10620 10700 10780 10860 10940
NO optioned 10621 10701 10781 10861 10941
SO2 optioned 10622 10702 10782 10862 10942
Temp HI/LO 10623 10703 10783 10863 10943
OK to sample 10624 10704 10784 10864 10944
Sequencing optioned 10625 10705 10785 10865 10945

Setpoint/Enable Accepted 10626 10706 10786 10866 10946
10627 10707 10787 10867 10947
10628 10708 10788 10868 10948
10629 10709 10789 10869 10949
10630 10710 10790 10870 10950
10631 10711 10791 10871 10951
10632 10712 10792 10872 10952
602 of 761
MM Number
6 7 8 9 10
Hand Operation 10633 10713 10793 10873 10953
Low Flame Hold 10634 10714 10794 10874 10954
10635 10715 10795 10875 10955
10636 10716 10796 10876 10956
10637 10717 10797 10877 10957
10638 10718 10798 10878 10958
MM working COMMS 10639 10719 10799 10879 10959
Input 41 status 10640 10720 10800 10880 10960
Lead boiler status 10641 10721 10801 10881 10961

Disabled status 10642 10722 10802 10882 10962
10643 10723 10803 10883 10963
10644 10724 10804 10884 10964
10645 10725 10805 10885 10965
10646 10726 10806 10886 10966
10647 10727 10807 10887 10967
10648 10728 10808 10888 10968
Slave burner left/right 10649 10729 10809 10889 10969

10650 10730 10810 10890 10970
10651 10731 10811 10891 10971
10652 10732 10812 10892 10972
10653 10733 10813 10893 10973
10654 10734 10814 10894 10974
10655 10735 10815 10895 10975
10656 10736 10816 10896 10976
10657 10737 10817 10897 10977

10658 10738 10818 10898 10978
10659 10739 10819 10899 10979
10660 10740 10820 10900 10980
10661 10741 10821 10901 10981
10662 10742 10822 10902 10982
10663 10743 10823 10903 10983
10664 10744 10824 10904 10984
10665 10745 10825 10905 10985

10666 10746 10826 10906 10986
10667 10747 10827 10907 10987
10668 10748 10828 10908 10988
10669 10749 10829 10909 10989
10670 10750 10830 10910 10990
10671 10751 10831 10911 10991
10672 10752 10832 10912 10992
603 of 761

The information on this page is only relevant to standalone EGAs connected directly to the DTI via the EGA port
EGA Number
1 2 3 4 5
Air Calibration in progress 10993 11009 11025 11041 11057
Gas Calibration in progress 10994 11010 11026 11042 11058
Cooler ready 10995 11011 11027 11043 11059
Ambient temperature OK 10996 11012 11028 11044 11060
Ambient temperature HIGH 10997 11013 11029 11045 11061
Ambient temperature LOW 10998 11014 11030 11046 11062
10999 11015 11031 11047 11063
EGA ready 11000 11016 11032 11048 11064
CO optioned 11001 11017 11033 11049 11065

NO optioned 11002 11018 11034 11050 11066
SO2 optioned 11003 11019 11035 11051 11067
°C(0) or °F(1) optioned 11004 11020 11036 11052 11068
Sampling optioned 11005 11021 11037 11053 11069
2nd thermocouple optioned 11006 11022 11038 11054 11070
Voltage input optioned 11007 11023 11039 11055 11071
11008 11024 11040 11056 11072
EGA Number
6 7 8 9 10
Air Calibration in progress 11073 11089 11105 11121 11137
Gas Calibration in progress 11074 11090 11106 11122 11138
Cooler ready 11075 11091 11107 11123 11139
Ambient temperature OK 11076 11092 11108 11124 11140
Ambient temperature HIGH 11077 11093 11109 11125 11141
Ambient temperature LOW 11078 11094 11110 11126 11142
11079 11095 11111 11127 11143
EGA ready 11080 11096 11112 11128 11144
CO optioned 11081 11097 11113 11129 11145

NO optioned 11082 11098 11114 11130 11146
SO2 optioned 11083 11099 11115 11131 11147
°C(0) or °F(1) optioned 11084 11100 11116 11132 11148
Sampling optioned 11085 11101 11117 11133 11149
2nd thermocouple optioned 11086 11102 11118 11134 11150
Voltage input optioned 11087 11103 11119 11135 11151
11088 11104 11120 11136 11152
20.08.97
604 of 761
1X Reference Addresses - On line/Off line Status
In all cases, off line is indicated by 0, on line by 1.
MM No. Reference Address EGA No. Reference Address

1 11793 1 11809
2 11794 2 11810
3 11795 3 11811
4 11796 4 11812
5 11797 5 11813
6 11798 6 11814
7 11799 7 11815
8 11800 8 11816
9 11801 9 11817
10 11802 10 11818
Digital I/O No. Reference Address Analogue I/O No. Reference Address
1 11825 1 11841
2 11826 2 11842
3 11827 3 11843
4 11828 4 11844
5 11829 5 11845
6 11830 6 11846
7 11831 7 11847
8 11832 8 11848
9 11833 9 11849
10 11834 10 11850

605 of 761
1X Reference Addresses- Water Level

MM Number
1 2 3 4 5
Water level optioned- no(0)/yes(1) 12001 12201 12401 12601 12801
Units- imperial(0)/metric(1) 12002 12202 12402 12602 12802
Feed water pump- off(0)/on(1) 12003 12203 12403 12603 12803
TDS units- ppm(0)/uSiemens(1) 12004 12204 12404 12604 12804
WL ready- no(0)/yes(1) 12005 12205 12405 12605 12805
TDS optioned- no(0)/yes(1) 12006 12206 12406 12606 12806
First out 1- normal(0)/fail(1) 12009 12209 12409 12609 12809
MM Number
6 7 8 9 10
Water level optioned- no(0)/yes(1) 13001 13201 13401 13601 13801
Units- imperial(0)/metric(1) 13002 13202 13402 13602 13802
Feed water pump- off(0)/on(1) 13003 13203 13403 13603 13803
TDS units- ppm(0)/uSiemens(1) 13004 13204 13404 13604 13804
WL ready- no(0)/yes(1) 13005 13205 13405 13605 13805
TDS optioned- no(0)/yes(1) 13006 13206 13406 13606 13806

606 of 761
6.17.4 3X Reference Addresses - Input Registers
Analog Inputs
Analogue Input Number

I/O Module Number
1 2 3 4 5 6
1 30017 30018 30019 30020 30021 30022
2 30025 30026 30027 30028 30029 30030
3 30033 30034 30035 30036 30037 30038
4 30041 30042 30043 30044 30045 30046
5 30049 30050 30051 30052 30053 30054
6 30057 30058 30059 30060 30061 30062
7 30065 30066 30067 30068 30069 30070
8 30073 30074 30075 30076 30077 30078
9 30081 30082 30083 30084 30085 30086
10 30089 30090 30091 30092 30093 30094
Software Version
30097 Software Version Number

30098 Software Issue Number

607 of 761
3X Reference Addresses - Input Registers
MM Number
1 2 3 4 5
Load index 30101 30151 30201 30251 30301
Startup/firing status 30102 30152 30202 30252 30302
Sequence status 30103 30153 30203 30253 30303
Burner rating 30104 30154 30204 30254 30304
Actual value 30105 30155 30205 30255 30305
Required value 30106 30156 30206 30256 30306
Fuel selected 30107 30157 30207 30257 30307
Number of channels 30108 30158 30208 30258 30308
Channel 1 position 30109 30159 30209 30259 30309
MM error number 30113 30163 30213 30263 30313
Single/twin operation 30114 30164 30214 30264 30314
Run O2 30115 30165 30215 30265 30315
Run CO2 30116 30166 30216 30266 30316
Run CO 30117 30167 30217 30267 30317
Run exhaust temperature 30118 30168 30218 30268 30318
Run efficiency 30119 30169 30219 30269 30319
Run NO 30120 30170 30220 30270 30320
Run SO2 30121 30171 30221 30271 30321
Comm. O2 30122 30172 30222 30272 30322
Comm. CO2 30123 30173 30223 30273 30323
Comm. CO 30124 30174 30224 30274 30324
Comm. Exhaust temperature 30125 30175 30225 30275 30325
Comm. Efficiency 30126 30176 30226 30276 30326
Comm. NO 30127 30177 30227 30277 30327
Comm. SO2 30128 30178 30228 30278 30328
EGA error number 30129 30179 30229 30279 30329
Minimum required value 30130 30180 30230 30280 30330
Maximum required value 30131 30181 30231 30281 30331
Present flow units 30132 30182 30232 30282 30332
Present flow thousands 30133 30183 30233 30283 30333
Fuel 1 flow total units 30134 30184 30234 30284 30334
Fuel 1 flow total thousands 30135 30185 30235 30285 30335
Fuel 1 flow total millions 30136 30186 30236 30286 30336
Run ambient 30143 30193 30243 30293 30343
Run delta T 30144 30194 30244 30294 30344
COM ambient 30145 30195 30245 30295 30345
COM delta T 30146 30196 30246 30296 30346
Mk6/Mini6/Mini5 (0,4,5) 30147 30197 30247 30297 30347

608 of 761
MM Number
6 7 8 9 10
Load index 30351 30401 30451 30501 30551
Startup/firing status 30352 30402 30452 30502 30552
Sequence status 30353 30403 30453 30503 30553
Boiler capacity 30354 30404 30454 30504 30554
Actual value 30355 30405 30455 30505 30555
Required value 30356 30406 30456 30506 30556
Fuel selected 30357 30407 30457 30507 30557
Number of channels 30358 30408 30458 30508 30558
MM error number 30363 30413 30463 30513 30563
Single/twin operation 30364 30414 30464 30514 30564
Run O2 30365 30415 30465 30515 30565
Run CO2 30366 30416 30466 30516 30566
Run CO 30367 30417 30467 30517 30567
Run exhaust temperature 30368 30418 30468 30518 30568
Run efficiency 30369 30419 30469 30519 30569
Run NO 30370 30420 30470 30520 30570
Run SO2 30371 30421 30471 30521 30571
Comm. O2 30372 30422 30472 30522 30572
Comm. CO2 30373 30423 30473 30523 30573
Comm. CO 30374 30424 30474 30524 30574
Comm. Exhaust temperature 30375 30425 30475 30525 30575
Comm. Efficiency 30376 30426 30476 30526 30576
Comm. NO 30377 30427 30477 30527 30577
Comm. SO2 30378 30428 30478 30528 30578
EGA error number 30379 30429 30479 30529 30579
Minimum required value 30380 30430 30480 30530 30580
Maximum required value 30381 30431 30481 30531 30581
Present flow units 30382 30432 30482 30532 30582
Present flow thousands 30383 30433 30483 30533 30583
Run ambient 30393 30443 30493 30543 30593
Run delta T 30394 30444 30494 30544 30594
COM ambient 30395 30445 30495 30545 30595
COM delta T 30396 30446 30496 30546 30596
Mk6/Mini6/Mini5 (0,4,5) 30397 30447 30497 30547 30597

609 of 761
MM Number
1 2 3 4 5
Channel 5 output 0-255 30804 30854 30904 30954 31004
Channel 5 input 0-255 30805 30855 30905 30955 31005
Channel 6 output 0-255 30806 30856 30906 30956 31006
Channel 6 input 0-255 30807 30857 30907 30957 31007
Option 1 30808 30858 30908 30958 31008
Option 77 30809 30859 30909 30959 31009
Option 90 30810 30860 30910 30960 31010
Option 91 30811 30861 30911 30961 31011
Option 92 30812 30862 30912 30962 31012
Option 93 30813 30863 30913 30963 31013
Option 94 30814 30864 30914 30964 31014
Option 95 30815 30865 30915 30965 31015
Option 96 30816 30866 30916 30966 31016
Option 97 30817 30867 30917 30967 31017
Option 98 30818 30868 30918 30968 31018
Option 99 30819 30869 30919 30969 31019
Option 100 30820 30870 30920 30970 31020
Option 101 30821 30871 30921 30971 31021
Option 102 30822 30872 30922 30972 31022
Option 103 30823 30873 30923 30973 31023
Option 104 30824 30874 30924 30974 31024
Option 105 30825 30875 30925 30975 31025
Option 106 30826 30876 30926 30976 31026
Option 107 30827 30877 30927 30977 31027
Option 108 30828 30878 30928 30978 31028
Option 109 30829 30879 30929 30979 31029
Lockout code 30830 30880 30930 30980 31030
Option 71 fuel 1 type 30831 30881 30931 30981 31031
Option 72 fuel 2 type 30832 30882 30932 30982 31032
Option 73 fuel 3 type 30833 30883 30933 30983 31033
Option 74 fuel 4 type 30834 30884 30934 30984 31034
Option 61 flow units fuel 1 30835 30885 30935 30985 31035
Fuel 1 hours run 30839 30889 30939 30989 31039
Fuel 2 hours run 30840 30890 30940 30990 31040
Fuel 3 hours run 30841 30891 30941 30991 31041
Fuel 4 hours run 30842 30892 30942 30992 31042
Fuel 1 start ups 30843 30893 30943 30993 31043
Fuel 2 start ups 30844 30894 30944 30994 31044
Fuel 3 start ups 30845 30895 30945 30995 31045
Fuel 4 start ups 30846 30896 30946 30996 31046
Air pressure 30847 30897 30947 30997 31047
Air pressure coding 30848 30898 30948 30998 31048
Gas pressure 30849 30899 30949 30999 31049
Gas pressure coding 30850 30900 30950 31000 31050
610 of 761
MM Number
6 7 8 9 10
Channel 5 output 0-255 31054 31104 31154 31204 31254
Channel 5 input 0-255 31055 31105 31155 31205 31255
Channel 6 output 0-255 31056 31106 31156 31206 31256
Channel 6 input 0-255 31057 31107 31157 31207 31257
Option 1 31058 31108 31158 31208 31258
Option 77 31059 31109 31159 31209 31259
Option 90 31060 31110 31160 31210 31260
Option 91 31061 31111 31161 31211 31261
Option 92 31062 31112 31162 31212 31262
Option 93 31063 31113 31163 31213 31263
Option 94 31064 31114 31164 31214 31264
Option 95 31065 31115 31165 31215 31265
Option 96 31066 31116 31166 31216 31266
Option 97 31067 31117 31167 31217 31267
Option 98 31068 31118 31168 31218 31268
Option 99 31069 31119 31169 31219 31269
Option 100 31070 31120 31170 31220 31270
Option 101 31071 31121 31171 31221 31271
Option 102 31072 31122 31172 31222 31272
Option 103 31073 31123 31173 31223 31273
Option 104 31074 31124 31174 31224 31274
Option 105 31075 31125 31175 31225 31275
Option 106 31076 31126 31176 31226 31276
Option 107 31077 31127 31177 31227 31277
Option 108 31078 31128 31178 31228 31278
Option 109 31079 31129 31179 31229 31279
Lockout code 31080 31130 31180 31230 31280
Option 71 fuel 1 type 31081 31131 31181 31231 31281
Option 72 fuel 2 type 31082 31132 31182 31232 31282
Option 73 fuel 3 type 31083 31133 31183 31233 31283
Option 74 fuel 4 type 31084 31134 31184 31234 31284
Fuel 1 hours run 31089 31139 31189 31239 31289
Fuel 2 hours run 31090 31140 31190 31240 31290
Fuel 3 hours run 31091 31141 31191 31241 31291
Fuel 4 hours run 31092 31142 31192 31242 31292
Fuel 1 start ups 31093 31143 31193 31243 31293
Fuel 2 start ups 31094 31144 31194 31244 31294
Fuel 3 start ups 31095 31145 31195 31245 31295
Fuel 4 start ups 31096 31146 31196 31246 31296
Air pressure 31097 31147 31197 31247 31297
Air pressure coding 31098 31148 31198 31248 31298
Gas pressure 31099 31149 31199 31249 31299
Gas pressure coding 31100 31150 31200 31250 31300
611 of 761
The information on this page is only relevant to standalone EGAs connected directly to the DTI via the EGA port.
EGA Number
1 2 3 4 5
Fuel selected 30601 30621 30641 30661 30681
% O2 30602 30622 30642 30662 30682
% CO2 30603 30623 30643 30663 30683
ppm CO 30604 30624 30644 30664 30684
ppm NO 30605 30625 30645 30665 30685
ppm SO2 30606 30626 30646 30666 30686
Exhaust temperature 30607 30627 30647 30667 30687
Efficiency 30608 30628 30648 30668 30688
Error number 30609 30629 30649 30669 30689
% voltage input 30610 30630 30650 30670 30690
Exhaust ? T 30611 30631 30651 30671 30691
Ambient 30612 30632 30652 30672 30692
Auxiliary temperature 30613 30633 30653 30673 30693
Service L.E.D.'s 30614 30634 30654 30674 30694
EGA Number
6 7 8 9 10
Fuel selected 30701 30721 30741 30761 30781
% O2 30702 30722 30742 30762 30782
% CO2 30703 30723 30743 30763 30783
ppm CO 30704 30724 30744 30764 30784
ppm NO 30705 30725 30745 30765 30785
ppm SO2 30706 30726 30746 30766 30786
Exhaust temperature 30707 30727 30747 30767 30787
Efficiency 30708 30728 30748 30768 30788
Error number 30709 30729 30749 30769 30789
% voltage input 30710 30730 30750 30770 30790
Exhaust ? T 30711 30731 30751 30771 30791
Ambient 30712 30732 30752 30772 30792
Auxiliary temperature 30713 30733 30753 30773 30793
Service L.E.D.'s 30714 30734 30754 30774 30794

612 of 761
MM Number
1 Error 31301
2 Error 31302
3 Error 31303
4 Error 31304
5 Error 31305
6 Error 31306
7 Error 31307
8 Error 31308
9 Error 31309
10 Error 31310
Please see section 6.17.8.4 for a list of the error codes that can be seen for each Modbus
address.
MM Number
1 Lockout 31311
2 Lockout 31312
3 Lockout 31313
4 Lockout 31314
5 Lockout 31315
6 Lockout 31316
7 Lockout 31317
8 Lockout 31318
9 Lockout 31319
10 Lockout 31320
Please see section 6.17.8.5 for a list of the lockout codes that can be seen for each Modbus
address.

613 of 761
3X Reference Addresses - Analogue inputs- totalised values
Analogue Channel Number

I/O Module Number 1 2 3 4 5 6
1 byte 7/6 31324 31328 31332 31336 31340 31344
byte 5/4 31323 31327 31331 31335 31339 31343
byte 3/2 31322 31326 31330 31334 31338 31342
byte 1/0 31321 31325 31329 31333 31337 31341
2 byte 7/6 31348 31352 31356 31360 31364 31368
byte 5/4 31347 31351 31355 31359 31363 31367
byte 3/2 31346 31350 31354 31358 31362 31366
byte 1/0 31345 31349 31353 31357 31361 31365
3 byte 7/6 31372 31376 31380 31384 31388 31392
byte 5/4 31371 31375 31379 31383 31387 31391
byte 3/2 31370 31374 31378 31382 31386 31390
byte 1/0 31369 31373 31377 31381 31385 31389
4 byte 7/6 31396 31400 31404 31408 31412 31416
byte 5/4 31395 31399 31403 31407 31411 31415
byte 3/2 31394 31398 31402 31406 31410 31414
byte 1/0 31393 31397 31401 31405 31409 31413
5 byte 7/6 31420 31424 31428 31432 31436 31440
byte 5/4 31419 31423 31427 31431 31435 31439
byte 3/2 31418 31422 31426 31430 31434 31438
byte 1/0 31417 31421 31425 31429 31433 31437
6 byte 7/6 31444 31448 31452 31456 31460 31464
byte 5/4 31443 31447 31451 31455 31459 31463
byte 3/2 31442 31446 31450 31454 31458 31462
byte 1/0 31441 31445 31449 31453 31457 31461
7 byte 7/6 31468 31472 31476 31480 31484 31488
byte 5/4 31467 31471 31475 31479 31483 31487
byte 3/2 31466 31470 31474 31478 31482 31486
byte 1/0 31465 31469 31473 31477 31481 31485
8 byte 7/6 31492 31496 31500 31504 31508 31512
byte 5/4 31491 31495 31499 31503 31507 31511
byte 3/2 31490 31494 31498 31502 31506 31510
byte 1/0 31489 31493 31497 31501 31505 31509
9 byte 7/6 31516 31520 31524 31528 31532 31536
byte 5/4 31515 31519 31523 31527 31531 31535
byte 3/2 31514 31518 31522 31526 31530 31534
byte 1/0 31513 31517 31521 31525 31529 31533
10 byte 7/6 31540 31544 31548 31552 31556 31560
byte 5/4 31539 31543 31547 31551 31555 31559
byte 3/2 31538 31542 31546 31550 31554 31558
byte 1/0 31537 31541 31545 31549 31553 31557

614 of 761
3X Reference Addresses - Water Level Input Registers
MM Number
1 2 3 4 5
Probe 1 signal 32001 32101 32201 32301 32401
Probe 1 reference 32002 32102 32202 32302 32402
32003 32103 32203 32303 32403
Probe 1 Version/Issue (ms/ls byte) 32004 32104 32204 32304 32404
Probe 2 signal 32005 32105 32205 32305 32405
Probe 2 reference 32006 32106 32206 32306 32406
32007 32107 32207 32307 32407
Alarm status 32009 32109 32209 32309 32409
Level status 32010 32110 32210 32310 32410
WL version/Issue (ms/ls byte) 32011 32111 32211 32311 32411
Alarm code 32012 32112 32212 32312 32412
32013 32113 32213 32313 32413
Steam temperature °C 32014 32114 32214 32314 32414
Feed water temperature °C 32015 32115 32215 32315 32415
Steam rate lb/hr 32016 32116 32216 32316 32416
Heat to steam Btus/lb 32017 32117 32217 32317 32417
Control element % 32018 32118 32218 32318 32418
32019 32119 32219 32319 32419
Control point raised 32020 32120 32220 32320 32420
32021 32121 32221 32321 32421
FO CRC 32022 32122 32222 32322 32422
Totalised steam lbs (ls word) 32023 32123 32223 32323 32423
Totalised steam lbs (ms word) 32024 32124 32224 32324 32424
Steam temperature F 32025 32125 32225 32325 32425
Feed water temperature F 32026 32126 32226 32326 32426
Steam rate Kgs/hr 32027 32127 32227 32327 32427
Heat to steam KJ/Kg 32028 32128 32228 32328 32428
Totalised steam Kgs (ls word) 32029 32129 32229 32329 32429
Totalised Steam Kgs (ms word) 32030 32130 32230 32330 32430
Probe 1 temperature °C 32031 32131 32231 32331 32431
Probe 1 temperature °F 32033 32133 32233 32333 32433
Max load index (%) 32035 32135 32235 32335 32435
Min load index (%) 32036 32136 32236 32336 32436
Cold start status- off(0)/on(1) 32037 32137 32237 32337 32437
Probe 1 corrected working 32038 32138 32238 32338 32438
TDS target 32040 32140 32240 32340 32440
TDS measured 32041 32141 32241 32341 32441
WL commdata CRC 32042 32142 32242 32342 32442
WL control type 32043 32143 32243 32343 32443

615 of 761
3X Reference Addresses - Water Level Input Registers
MM Number
6 7 8 9 10
Probe 1 signal 32501 32601 32701 32801 32901
Probe 1 reference 32502 32602 32702 32802 32902
32503 32603 32703 32803 32903
Probe 2 signal 32505 32605 32705 32805 32905
Probe 2 reference 32506 32606 32706 32806 32906
32507 32607 32707 32807 32907
Alarm status 32509 32609 32709 32809 32909
Level status 32510 32610 32710 32810 32910
WL version/Issue (ms/ls byte) 32511 32611 32711 32811 32911
Alarm code 32512 32612 32712 32812 32912
32513 32613 32713 32813 32913
Steam temperature °C 32514 32614 32714 32814 32914
Feed water temperature °C 32515 32615 32715 32815 32915
Steam rate lb/hr 32516 32616 32716 32816 32916
Heat to steam Btus/lb 32517 32617 32717 32817 32917
Control element % 32518 32618 32718 32818 32918
32519 32619 32719 32819 32919
Control point raised 32520 32620 32720 32820 32920
32521 32621 32721 32821 32921
FO CRC 32522 32622 32722 32822 32922
Totalised steam lbs (ls word) 32523 32623 32723 32823 32923
Totalised steam lbs (ms word) 32524 32624 32724 32824 32924
Steam temperature F 32525 32625 32725 32825 32925
Feed water temperature F 32526 32626 32726 32826 32926
Steam rate Kgs/hr 32527 32627 32727 32827 32927
Heat to steam KJ/Kg 32528 32628 32728 32828 32928
Totalised steam Kgs (ls word) 32529 32629 32729 32829 32929
Totalised Steam Kgs (ms word) 32530 32630 32730 32830 32930
Max load index (%) 32535 32635 32735 32835 32935
Min load index (%) 32536 32636 32736 32836 32936
Cold start status- off(0)/on(1) 32537 32637 32737 32837 32937
TDS target 32540 32640 32740 32840 32940
TDS measured 32541 32641 32741 32841 32941
WL commdata CRC 32542 32642 32742 32842 32942
WL control type 32543 32643 32743 32843 32943

616 of 761
6.17.5 4X Reference Addresses - Holding Registers
Individual Required value for each Micro Modulation unit
MM ID number Reference Address

1 40001
2 40002
3 40003
4 40004
5 40005
6 40006
7 40007
8 40008
9 40009
10 40010
Global Required Value for all MMs

40011
Lead Boiler selection

40012
Reserved - DO NOT USE

40013 - 40016
Load Index commands- ability to change the firing rate remotely
MM Number
1 2 3 4 5
DTI load index value 40121 40122 40123 40124 40125
DTI load index command- off(0)/on(1) 40131 40132 40133 40134 40135
MM Number
6 7 8 9 10
DTI load index value 40126 40127 40128 40129 40130
DTI load index command- off(0)/on(1) 40136 40137 40138 40139 40140

617 of 761
4X Reference Addresses - Holding Registers
Analogue Output Number

I/O Module Number
1 2 3 4 5 6
1 40017 40018 40019 40020 40021 40022
2 40025 40026 40027 40028 40029 40030
3 40033 40034 40035 40036 40037 40038
4 40041 40042 40043 40044 40045 40046
5 40049 40050 40051 40052 40053 40054
6 40057 40058 40059 40060 40061 40062
7 40065 40066 40067 40068 40069 40070
8 40073 40074 40075 40076 40077 40078
9 40081 40082 40083 40084 40085 40086
10 40089 40090 40091 40092 40093 40094

618 of 761
6.17.6 Switch Settings - Modbus Operation
100s 10s 1s ON
OFF
1 2 3 4 5 6 7 8
Set the Modbus address accordingly. 1 off - Modbus 'ASCII' mode

on - Modbus 'RTU' mode
For example, to set address number 123:
2 Transmission settings
100s =1 off - 8 data bits, 1 stop bit, no parity.
10s =2 on - 8 data bits, 1 stop bit, even parity.
1s =3
3-5 no user function, must be set off
6 Windows PCDTI/MODBUS operation

off - 422 port set for Windows PCDTI
on - 422 port set for MODBUS
7 Windows PCDTI/MODBUS operation

off - PC port set for WinPCDTI
on - PC port set for MODBUS
8 MM Port Baud Rate

off - 9600 (Mk6, Mini Mk6 and Mini Mk5 MMs)
on - 4800 (Older Mk5 and Mini MMs)*
* Technical Memo: Data Communication Compatibility 3/9/1999

619 of 761
6.17.7 Other Information
Modbus Transmission Interface
There is no hardware or software flow control on any port.
Baud Rate 9600.
Supported MODBUS Commands
1 Read coil status

2 Read input status
3 Read holding registers
4 Read input registers
5 Force single coil
6 Preset single register
15 Force multiple coils
16 Preset multiple registers
6.17.7.3 Supported Exception Responses
Exception responses are not supported. No response is given to an unrecognised request.
6.17.7.4 Serial Port Connections
RS232 'PC' port - 9 Way Female D connector
PIN Function
2 Data out
3 Data in
5 Signal ground
RS422 port - Screw terminal blocks
Receive and transmit connections are as identified on printed circuit board.

620 of 761
6.17.8 Relevance of MM/EGA data
Each MM/EGA can provide the following information. All values are instantaneous. Each MM/
EGA system updates the DTI approximately once every 20 seconds. Certain values and some
values under certain conditions may require a decimal point. In these cases the user must add the
decimal point accordingly (* only valid if EGA operational on system)
Digital Inputs (1x references)
Command status of M.M. ‘CR Relay’ 0- Off

1- On
Flow detector type 0- Temperature
1- Pressure
Optioned for flow metering 0- No
1- Yes
CO off/on on fuel 2 (fuel 1 CO always on) 0- Off
1- On
Temperature units 0- C
1- F
Pressure units 0- bar
1- psi
Optioned for voltage input modulation 0- No
1- Yes
Optioned for EGA 0- No
1- Yes
Boiler up to ‘trimming’ temperature 0- No
1- Yes
EGA cooler temperature ready 0- No
1- Yes
EGA ambient temperature OK 0- No
1- Yes
Optioned to display NO 0- No
1- Yes
Option to display SO2 0- No
1- Yes
EGA ambient temperature low/high 0- LOW
(relevant if bit 3 (ambient temperature) is 0) 1- HIGH
Optioned for sequencing 0- NO
1- YES
Setpoint/Disable commands accepted 0- NO
1- YES
Hand operation status 0- Modulating
1- Hand Operation
Low flame hold status 0- Modulating
1- Low Flame Hold
This MM controlling DTI bus communication 0- NO
1- YES
Input 88/41 set (lead boiler select) 0- NO
1- YES

621 of 761
Lead boiler status 0- not lead boiler

1- lead boiler
‘Disabled’ status 0- enabled
1- disabled
Slave burner indication status - test bit 0 0- master plus one
1- master minus one
Analogue Inputs (3x references)
0-100 Firing rate/load index - percentage
0-250 Maximum firing rate- value number entered in option #34
0-999 Actual value of boiler flow temperature/pressure- degrees C/F/psi

0.0-99.9 Pressure- bar
0-999 Required setpoint of boiler flow temperature/pressure- degrees C/F/psi

0.0-99.9 Pressure- bar
0-2 Present fuel selected 0- Fuel 1 (usually GAS)

1- Fuel 2 (usually OIL)
2- Fuel 3 (usually OIL)
1-7 Number of channels in operation (add one to this to get total number)
-6.0-96.0 CH1 positioning motor position degrees angular

-6.0-96.0 Ch4 positioning motor position degrees angular
0-N Fatal Error Code 0 - System is OK

1 - N system shut down
Value is as MM ERR display
0-2 Single/twin burner operation

0 - single burner
1 - twin burner (both together only)
2 - twin burner (both together/one or the other)
0-25.5 Present value percentage oxygen in flue gas

0-25.5 Present value percentage carbon dioxide in flue gas
0-999 Present value ppm carbon monoxide in flue gas
0-999 Present value flue gas temperature
0-99.9 Present value percentage combustion efficiency
0-999 Present value NO
0-999 Present value SO2

622 of 761
0-25.5 Commissioned value percentage oxygen in flue gas

0-25.5 Commissioned value percentage carbon dioxide in flue gas
0-999 Commissioned value ppm carbon monoxide in flue gas
0-999 Commissioned value flue gas temperature
0-99.9 Commissioned value percentage combustion efficiency
0-999 Commissioned value NO
0-999 Commissioned value SO2
0-N EGA error code normal- 0. Any other value indicates an error.
0-99.9 Minimum setpoint accepted(0-999, 0-99.9)

0-99.9 Minimum setpoint accepted(0-999, 0-99.9)
0-999 Flow value units

0-999 Flow value thousands
(multiply thousands value by 1000 then add units value then divide by 100 to get
flow value)
0-999 Fuel 1 totalised value units

0-999 Fuel 1 totalised value thousands
0-999 Fuel 1 totalised value millions




623 of 761
The following table lists the startup/firing status codes along with an explanation of what the codes
mean. This is for Modbus addresses:
30102 MM ID #1
30152 MM ID #2
30202 MM ID #3
30252 MM ID #4
30302 MM ID #5
30352 MM ID #6
30402 MM ID #7
30452 MM ID #8
30502 MM ID #9
30552 MM ID #10
Code Explanation
19 Waiting for stat circuit to complete
20 Waiting for command to drive air damper to purge position
21 Driving air damper to purge position
22 Purging: Waiting for command o drive valves to ignition position
23 Driving valves to ignition position
24 Ignition taking place
25 Burner firing and modulating
26 Post purge taking place
If 0, then the indicated transmission is direct from an E.G.A.
The following table lists the sequence status for each M.M. This is for Modbus addresses:
30103 MM ID #1
30153 MM ID #2
30203 MM ID #3
30253 MM ID #4
30303 MM ID #5
30353 MM ID #6
30403 MM ID #7
30453 MM ID #8
30503 MM ID #9
30553 MM ID #10
Code Explanation
0 On
1 Standby
2 Warm
3 Off

624 of 761
The following table lists the error codes along with an explanation of what the codes mean. This is for
Modbus addresses:
31301 MM ID #1
31302 MM ID #2
31303 MM ID #3
31304 MM ID #4
31305 MM ID #5
31306 MM ID #6
31307 MM ID #7
31308 MM ID #8
31309 MM ID #9
31310 MM ID #10
Code Error Message/Explanation

1 CH1 positioning error
3 load detector
4 Software error
5 PROM memory fault
6 Commisssion data fault
7 RAM memory fault
40 CR1 test failure
41 CH1 gain error
42 CH2 gain error
43 CH3 gain error
44 5 volt supply error
45 Watchdog- CR2 safety test failed
46 CH4 gain error
47 A/D converter
80 CH5 error
81 CH6 error
83 CH5 feedback signal error
84 CH6 feedbcak signal error
92 Air pressure outside limits
100 Twin burner communications failed

625 of 761
The following table lists the lockout codes along with an explanation of what the codes mean. This is
for Modbus addresses:
31311 MM ID #1
31312 MM ID #2
31313 MM ID #3
31314 MM ID #4
31315 MM ID #5
31316 MM ID #6
31317 MM ID #7
31318 MM ID #8
31319 MM ID #9
31320 MM ID #10
Code Lockout M essage Code Lockout M essage

1 CPI wrong state 27 Watchdog fail 2c
2 No air proving 28 Watchdog fail 2d
3 Ignition output fault 29 Input faulty
4 M otor output fault 30 Gas sensor error
5 Start gas output fault 31 Air sensor error
6 M ain gas output 1 fault 32 Low gas pressure
7 M ain gas output 2 fault 33 VPS air zeroing fail
8 Vent valve output fault 34 VPS gas pressure low
9 Fail safe relay fault 35 UV short circuit
10 Simulated flame 36 Oil pressure too low
11 VPS air proving fail 37 Oil pressure too high
12 VPS gas proving fail 38 CPU test failed
13 No flame signal 39 Freeze timeout
14 Shutter fault 40 Purge air pressure low
15 No cpi reset 41 Option 141 incorrect
16 Lockout permanently active 42 Terminal 86 inverse
17 Gas pressure too low 43 Terminal 85-86 fault
18 Gas pressure too high 44 Prove cct fail
19 RAM test failed 45 No prove cct set
20 PROM test failed 46 No prove cct reset
21 Watchdog fault 1a 198 BC input short
22 Watchdog fault 1b 199 Lockout 199
23 Watchdog fault 1c 200
24 Watchdog fault 1d 201 Lockout 201
25 Watchdog fail 2a 202 EEPROM faulty
26 Watchdog fail 2b

626 of 761
The following lists show the various codes for the water level Modbus addresses:
WL control type:
0- Modulating standard
1- On/off
2- Modulating high high
3- Modulating pre 1st low/pre high
Level status- the is the current level of the water:

0- Ok
1- High water
2- 1st low
3- 2nd low
4- High high water
5- Pre 1st low
6- Pre high water
Alarm code:
0- Ok
1- 2nd low
2- probe 1 comms
3- Probe 2 comms
4- Probe 1 short
5- Probe 2 short
6- Probe mismatch
7- Probe 1 TC
8- Probe 2 TC
9- Permanent reset
10- Permanent test
11- Keystuck reset
12- PU Eeprom
13- PU bogus EE state
14- Incompatible config
15- Probe 1 bogus comm data
16- Probe 2 bogus comm data
17- Config range check fail
18- 1st low
19- High water
20- Probe 1 still water
21- Probe 2 still water
22- Probes diverse
23- Pre 1st low
24- Pre high water
See section 5 for further explanation of the alarm codes.

627 of 761
6.17.9 Further Information
For more detailed information regarding the Modbus protocol, refer to the following publication:
Modicon Modbus Protocol Reference Guide,

PI-MBUS-300
Also visit the website: www.modicon.com

628 of 761
D.T.I. Data Transfer Interface WinPCDTI Software
6.18 Autoflame winPCDTI Software
The Autoflame WinPCDTI software runs under Windows 95/98/NT4/XP and brings together our current
range of products.
There are two modes of program operation:

Plant Supervisor for local control
Plant Manager for remote monitoring via modem for a number of sites
The software is presented in an intuitive graphical format where pictures and buttons are used to lead
the operator through all the available functions.
Win PC DTI Operation (local PC connected directly)
The procedure detailed below indicates the set-up of the Autoflame winPCDTI software installed on a
local PC connected directly to the DTI via a standard serial lead from the serial port on the back of the
DTI to the serial port on the PC.
Components Checklist
1x DTI*
1x DTI to PC comms lead*
1x DTI System CD-ROM*
1x PC running Windows
* Included in the DTI System Package
Instructions
1. Wire all the MM and EGA modules, EGA units that are being used for standalone analysis
and I/O modules to the DTI as shown in section 6.11.
2. On the back of the DTI, set the switches as shown in section 6.17.6 for winPCDTI operation.
Usually, the rotary switches on switch bank 1 will be set to 001 and ways 1-8 on switch
bank 2 will all be set to off.
3. Connect the DTI to the PC via a serial lead. One end will connect to the DTI’s RS232 PC
Port. The other will connect to the PC’s serial port, usually COM1 or COM2.
4. Power up the DTI and the PC.
5. Insert the DTI system CD-ROM into the PC. Follow the instructions on the CD case to install
the Autoflame winPCDTI software.
6. When the installation is complete, run winPCDTI. As this is the first time that the software
has been run, it will prompt you to select Plant Manager/Plant Supervisor mode. Select
Plant Supervisor.
If the DTI and other MM/EGA system modules are operational, they should appear on-line and be
accessible from the PC.

629 of 761
6.18.1.2 Win PC DTI Operation (remote PC connected via modem)
remote PC connected to the DTI via the modem on the DTI.
1x DTI* (this must be part number DTI60100/MD- DTI with internal modem)
2x Modem and PC serial lead (one installed on the back of the DTI as supplied)
Instructions
3. Connect the modem on the DTI to the telephone socket.
4. Power up the DTI.
5. At the PC, connect the modem to the PC and the modem to the telephone socket.
6. Power up the modem and the PC.
Plant Manager.
9. The site list will be empty to start of with. Click New Site to create a site entry in the data-
base. Enter a name and telephone number for the site and save the changes.
10. Go back to the site list, click on your site and click Connect to dial into the remote DTI. If
the other MM/EGA system modules are operational, they should appear on-line and be

630 of 761
6.18.1.3 Win PC DTI Operation (remote PC connected via a line driver)
remote PC (up to 1km/4000ft) connected to the DTI via the RS422 port on the DTI to a line driver.
1x DTI*
1x Line driver and power supply
1x Standard PC modem lead
Instructions
3. Connect the long distance wiring to the RS422 port of the DTI as shown in section 6.13. At
the PC end, connect the long distance wiring to the line driver. Set the switch on the line
driver to DCE and plug the line driver to the PC using a standard PC Modem lead.
4. Power up the DTI, the PC and then the line driver (using its external power supply).
Plant Supervisor.
If the DTI and other MM/EGA system modules are operational, they should appear on-line and be

631 of 761
Section 6.19: Johnson Metasys Interface Index
6.19.1 Overview
6.19.2 Connecting the DTI to Metasys
6.19.3 Network Point Table
6.19.3.1 First 10 addresses (MM/EGA units)

6.19.3.2 Eleventh address (I/O units)

632 of 761
D.T.I. Data Transfer Interface Metasys
6.19.1 Overview
Autoflame's DTI unit interfaces with the Autoflame MM/EGA system. In doing so it provides a simple
means of gathering information and presenting it to a bus or network. The DTI will interface with up to
ten MM/EGA systems and up to ten analogue and/or digital units. This section details information
regarding the Data Transfer Interface (DTI) 'Metasys' interface.
6.19.1.2 Requirements
Compatible software versions are:
DTI unit (DTI60100) All serial numbers

DTI unit (DTI60100/MD) All serial numbers
Mk6 unit All serial numbers
Mini Mk6 unit All serial numbers
Mini Mk5 evo All serial numbers
Old DTI unit (DTI20010) Serial number 095132 onwards

Old DTI EPROM Metasys v1.02 onwards
MM Mk5 EPROM 300/0/15/4
mini Mk5 EPROM (2channel) 610/1/15/3
mini Mk5 EPROM (3channel) 620/1/15/3

633 of 761
6.19.2 Connecting the DTI to Metasys
The DTI has a port which provides direct access to the Metasys network. Connection is made via a
screw terminal block labelled 'RS485+', 'RS485-' and 'RS485 screen'. Only the DTI address needs to
be set by the installation engineer. The following diagram illustrates the connections required.
100s 10s 1s ON
OFF
1 2 3 4 5 6 7 8
N2 +
Selecting the DTI address N2 -
SCREEN
The DTI N2 address is selected by means of Switch Bank 1. Set the three rotary switches appropriately.
For example, to set address number 123: 100s = 1
10s = 2
1s = 3
The DTI can occupy any address on the Metasys network, however the DTI requires eleven free
consecutive address, starting from and including the address selected using the switches. If the DTI is
given address 30, 30 is selected on SW1. However addresses 31 to 40 must also be free on the network.
If Metasys operation is required alongside Modbus operation, the Metasys address and Modbus
address will have to be the same.
If winPCDTI/Modbus/Metasys combinations are used, the required value and enable/disable com-
mands can be implemented by any of these three means.

634 of 761
6.19.3 Network Point Table
The DTI occupies 11 (eleven) addresses on the network. The first 10 address are used to read data
from the 10 MM/EGA systems and only the MM/EGa systems. The last (eleventh) address is used to
read and write data to the analogue and digital units. This address is also used to read the status of
MM/EGA systems and write values to them. All of the systems addresses implement internal integer
and byte values only. A full network point table follows.
Technical Note
Please be aware that the Change of State feature is not implemented on the DTI/Metasys interface.
Therefore, normal Metasys COS (alarm limits for analogue values and normal condition for binary)
notification will be defeated. If COS notification is required, then it is necessary for the operator to:
- Map the specific object(s) requiring COS to a CS object

- Define a AD or BD object with the CS object of the required COS point
- Assign Alarm Limits to the AD
- The AD or BD point will only be scanned at a minimum of 30 seconds
- The normal state of the BO must be updated (written to) by GPL
Analogue/binary input points that are mapped in directly that do not support COS will never report a
change of state condition. They will report the current value when read but no alarm notification will
occur. A read will only occur if a focus window is open or a feature requires the current value.

635 of 761
Network point table for first 10 (ten) addresses (read values from MM/EGA systems).
NPT NPA UNITS DESCRIPTION RANGE NOTE
AI Not - - - -
used
BI Not - - - -
used
AO Not - - - -
used
BO Not - - - -
used
ADF 01 % Load index 0 to 100.0
ADF 02 Startup/Firing status 19 - 28 19 = Waiting for stat. circuit to
complete.
20 = Waiting for command to drive
air damper to purge position.
21 = Driving air damper to purge
position.
22 = Purging, waiting for command
to drive values to ignition position.
23 = Driving valves to ignition
position.
24 = Ignition taking place.
25 = Burner firing and modulating.
26 = Post purge taking place.
27 = Not used.
28 = Golden start.
ADF 03 Sequence status 1 to 10
ADF 04 Boiler capacity see option 34 on MM
ADF 05 Actual value For units see Options 1, 51, and 52
on associated MM
ADF 06 Required value For units see Options 1, 51, and 52
on associated MM
ADF 07 Fuel selected 0 to 3 0 = Fuel 1 (usually gas)
1 = Fuel 2 (usually oil)
3 = Fuel 4 (Aux.)
ADF 08 Number of channels 0 to 8
ADF 09 Channel 1 position -6.0 to 96.0 Displayed as –6.0 to 96.0
ADF 13 MM error number 00 to 73 see section 2.3.1.2 of manual
ADF 14 Single/Twin operation 0 to 1 0 = single
1 = twin burner
ADF 15 % Run O2 0 to 20.9 Displayed as 0 to 20.9
ADF 16 % Run CO2 0 to 15 Displayed as 0 to 15.0
ADF 17 ppm Run CO 0 to 999.0
ADF 18 Run exhaust temperature 0 to 999.0 for units see option 51 on MM
ADF 19 % Run efficiency 0 to 100.0
ADF 20 ppm Run NO 0 to 999.0
ADF 21 ppm Run SO2 0 to 999.0
ADF 22 % Comm. O2 0 to 20.9 Displayed as 0 to 20.9
ADF 23 % Comm. CO2 0 to 15.0 Displayed as 0 to 15.0
ADF 24 ppm Comm. CO 0 to 999.0
ADF 25 Comm. exhaust temp 0 to 999.0 for units see option 51 on MM
ADF 26 % Comm. efficiency 0 to 100.0

636 of 761

ADF 27 ppm Comm. NO 0 to 999.0
ADF 28 ppm Comm. SO2 0 to 999.0
ADF 29 EGA error number 0 to 25 see section 3.4.1 of manual
ADF 30 Minimum required value For units see Options 1, 51, and 52
on associated MM
ADF 31 Maximum required value For units see Options 1, 51, and 52
on associated MM
ADF 32 Present flow units 0 to 999.0
ADF 33 Present flow thousands 0 to 999.0
ADF 34 Fuel 1 flow total units 0 to 999.0
ADF 36 Fuel 1 flow total thousands 0 to 999.0
ADF 37 Fuel 1 flow total millions 0 to 999.0
ADF 48 Not Used
ADF 49 Not Used
ADF 50 Not Used
ADF 54 Channel 5 output 0 to 255.0
ADF 55 Channel 5 input 0 to 255.0
ADF 56 Channel 6 output 0 to 255.0
ADF 57 Channel 6 input 0 to 255.0
ADF 58 Option 1 3 to 8 See option table in manual
ADF 68 Not Used
ADF 69 Not Used

637 of 761

ADF 78 Not Used
ADF 79 Not Used
ADF 80 Lockout Code 0 to 255 See option table in manual
ADF 81 Option 71 Fuel 1 Type 0 to 3 0 = Fuel 1 (usually gas)
3 = Fuel 4 (Aux.)
3 = Fuel 4 (Aux.)
3 = Fuel 4 (Aux.)
3 = Fuel 4 (Aux.)
ADF 85 Option 61 Flow Units Fuel 1 0 to 4 0 = Cubic Feet
1 = Cubic Meters
2 = Kilograms
3 = Litres
4 = US Gallons
1 = Cubic Meters
2 = Kilograms
3 = Litres
4 = US Gallons
1 = Cubic Meters
2 = Kilograms
3 = Litres
4 = US Gallons
1 = Cubic Meters
2 = Kilograms
3 = Litres
4 = US Gallons
ADF 89 Fuel 1 Hours Run 0 to 9999.0
ADF 93 Fuel 1 Start ups 0 to 999.0
ADF 97 Air Pressure 0 to 999.0 Value is correctly scaled by DTI
dependent on ADI 98

638 of 761

ADF 98 Air Pressure Coding 8 Bit Pattern Bit0 = 0 = off
1 = on
Bit =
1 0 = “WG
1 = mbar
Bit Bit =00 = 0 decimal places
2 + 3
01 = 1 decimal places
Bit =
4 unused
Bit =
5 unused
Bit =
6 unused
Bit =
7 unused
ADF 99 Gas Pressure 0 to 999.0 Value is correctly scaled by DTI
dependent on ADI 100
ADF 100 Gas Pressure Coding 8 Bit Pattern Bit =
0 0 = off
1 = on
Bit Bit =00 = “WG
1+ 4
10 = mbar
01 = BAR
11 = PSI
2 + 3
Bit =
5 unused
Bit =
6 unused
Bit =
7 unused
ADF 101 Fuel Selected 0 to 3 0 = Fuel 1 (usually gas)
3 = Fuel 4 (Aux.)
ADF 102 % E.G.A. O2 0 to 20.9 Displayed as 0 to 209
ADF 103 % E.G.A. CO2 0 to 15.0 Displayed as 0 to 15.0
ADF 104 ppm E.G.A. CO 0 to 999.0
ADF 105 ppm E.G.A. NO 0 to 999.0
ADF 106 ppm E.G.A. SO2 0 to 999.0
ADF 107 E.G.A. Exhaust temp 0 to 999.0
ADF 108 % E.G.A. Efficiency 0 to 100.0
ADF 109 E.G.A. Error Number 0 to 25.0
ADF 110 % E.G.A. Voltage Input 0 to 100.0
ADF 111 E.G.A. Exhaust ∆T 0 to 999.0
ADF 112 E.G.A. Ambient 0 to 50.0
ADF 113 E.G.A. Auxiliary Temp 0 to 999.0
ADF 114 Service LEDS 8 Bit Pattern Bit to Bit =
0 5
000000 = EGA requires servicing

000001 = 2 Months to service
000011 = 4 Months
000111 = 6 Months
001111 = 8 Months
011111 = 10 Months
111111 = 1 Year
Bit = 1 = System Fault
6
Bit = 1 = O.K. – EGA can run

7
ADF 115 Not Used

ADF 116 Not Used
ADF 117 Not Used
ADF 118 Not Used
ADF 119 Not Used

639 of 761

ADF 120 Not Used
ADF 121 Hz Probe 1 Signal Frequency
ADF 122 Hz Probe 1 Reference Frequency
ADF 123 Not Used
ADF 124 Probe 1Version/Issue ms/ls byte
ADF 125 Hz Probe 2 Signal Frequency
ADF 126 Hz Probe 2 Reference Frequency
ADF 127 Not Used
ADF 128 Probe 2 Version/Issue ms/ls byte
ADF 129 Alarm Status 0 – OK
1 – High Water
2 – 1 Low
st
3 – 2 Low
nd
ADF 130 Level Status As Alarm Status just above

ADF 131 WL Version/Issue ms/ls byte
ADF 132 Alarm Code 0-OK
1-2 Low
nd
2-Probe 1 Comms
3-Probe 2 Comms
4-Probe 1 Short
5-Probe 2 Short
6-Probe Mismatch
7-Probe 1 TC
8-Probe 2TC
9-Permanent Reset
10-Permanent Test
11-Keystuck Reset
12-Power Up EEprom
13-Bogus EEprom State
14-Incompatible Config
15-Probe 1 Bogus Comm Data
17-Config Range Check Fail
18-1 Low
st
19-HighWater
20-Probe 1 Still Water
22-Probes Diverse
255-OK/Reset
ADF 133 Not Used
ADF 134 C Steam Temp
ADF 135 C Feed Water Temp
ADF 136 lb/hr Steam Rate
ADF 137 Btus/lb Heat to Steam
ADF 138 % Control Element
ADF 139 Not Used
ADF 140 % Control Point Raised 0-Normal
1 to 99 - % raised between ‘Control
Point’ and ‘High Water’ positions
ADF 141 Not Used
ADF 142 Not Used
ADF 143 lbs Totalised Steam
ADF 144
ADF 145 F Steam Temp
ADF 146 F Feed Water Temp
ADF 147 Kgs/hr Steam Rate

640 of 761

ADF 148 KJ/Kg Heat to Steam
ADF 149 Kgs Totalised Steam
ADF 150 Not Used
ADF 151 C Probe 1 Temperature
ADF 152 C Probe 2 Temperature
ADF 153 F Probe 1 Temperature
ADF 154 F Probe 2 Temperature

641 of 761

ADI 01 % Load index 0 to 100
ADI 02 Startup/Firing status 19 – 28 19 = Waiting for stat. circuit to complete.
20 = Waiting for command to drive air
damper to purge position.
21 = Driving air damper to purge position.
22 = Purging, waiting for command to drive
values to ignition position.
23 = Driving valves to ignition position.
24 = Ignition taking place.
25 = Burner firing and modulating.
26 = Post purge taking place.
27 = Not used.
28 = Golden start.
ADI 03 Sequence status 1 to 10
ADI 04 Boiler capacity see option 34 on MM
ADI 05 Actual value see option 1 on MM
ADI 06 Required value see option 1 on MM
ADI 07 Fuel selected 0 to 3 0 = Fuel 1 (usually gas)
3 = Fuel 4 (Aux.)
ADI 08 Number of channels 0 to 8
ADI 09 Channel 1 position -6.0 to 96.0 Displayed as -60 to 960
ADI 13 MM error number 00 to 73 see section 2.3.1.2 of manual
ADI 14 Single/Twin operation 0 to 1 0 = single
1 = twin burner
ADI 15 % Run O2 0 to 20.9 Displayed as 0 to 209
ADI 16 % Run CO2 0 to 15
ADI 17 ppm Run CO 0 to 999
ADI 18 Run exhaust temperature 0 to 999 for units see option 51 on MM
ADI 19 % Run efficiency 0 to 100
ADI 20 ppm Run NO 0 to 999
ADI 21 ppm Run SO2 0 to 999
ADI 22 % Comm. O2 0 to 20.9 Displayed as 0 to 209
ADI 23 % Comm. CO2 0 to 15
ADI 24 ppm Comm. CO 0 to 999
ADI 25 Comm. exhaust temp 0 to 999 for units see option 51 on MM
ADI 26 % Comm. efficiency 0 to 100
ADI 27 ppm Comm. NO 0 to 999
ADI 28 ppm Comm. SO2 0 to 999
ADI 29 EGA error number 0 to 25 see section 3.4.1 of manual
ADI 30 Minimum required value see option 30 on MM
ADI 31 Maximum required value see option 31 on MM
ADI 32 Present flow units 0 to 999
ADI 33 Present flow thousands 0 to 999
ADI 34 Fuel 1 flow total units 0 to 999
ADI 36 Fuel 1 flow total 0 to 999
thousands
ADI 37 Fuel 1 flow total millions 0 to 999

642 of 761

thousands
thousands
ADI 48 Not Used
ADI 49 Not Used
ADI 50 Not Used
thousands
ADI 54 Channel 5 output 0 to 255
ADI 55 Channel 5 input 0 to 255
ADI 56 Channel 6 output 0 to 255
ADI 57 Channel 6 input 0 to 255
ADI 58 Option 1 3 to 8 See option table in manual
ADI 68 Not Used
ADI 69 Not Used
ADI 78 Not Used
ADI 79 Not Used
ADI 80 Lockout Code 0 to 255 See option table in manual
ADI 81 Option 71 Fuel 1 Type 0 to 3 0 = Fuel 1 (usually gas)
3 = Fuel 4 (Aux.)

643 of 761

3 = Fuel 4 (Aux.)
3 = Fuel 4 (Aux.)
3 = Fuel 4 (Aux.)
ADI 85 Option 61 Flow Units 0 to 4 0 = Cubic Feet
Fuel 1 1 = Cubic Meters
2 = Kilograms
3 = Litres
4 = US Gallons
2 = Kilograms
3 = Litres
4 = US Gallons
2 = Kilograms
3 = Litres
4 = US Gallons
2 = Kilograms
3 = Litres
4 = US Gallons
ADI 89 Fuel 1 Hours Run 0 to 9999
ADI 93 Fuel 1 Start ups 0 to 999
ADI 97 Air Pressure 0 to 999 See point 98 for units
ADI 98 Air Pressure Coding 8 Bit Pattern Bit =
0 0 = off
1 = on
Bit =
1 0 = “WG
1 = mbar
Bit Bit = 00 = 0 decimal places
2 + 3
Bit =unused
4
Bit =unused
5
Bit =unused
6
Bit =unused
7
ADI 99 Gas Pressure 0 to 999 See point 100 for units

644 of 761

ADI 100 Gas Pressure Coding 8 Bit Pattern Bit0 = 0 = off
1 = on
Bit Bit = 00 = “WG
1+ 4
10 = mbar
01 = BAR
11 = PSI
2 + 3
Bit =unused
5
Bit =unused
6
Bit =unused
7
ADI 101 Fuel Selected 0 to 3 0 = Fuel 1 (usually gas)

3 = Fuel 4 (Aux.)
ADI 102 % E.G.A. O2 0 to 20.9 Displayed as 0 to 209
ADI 103 % E.G.A. CO2 0 to 15
ADI 104 ppm E.G.A. CO 0 to 999
ADI 105 ppm E.G.A. NO 0 to 999
ADI 106 ppm E.G.A. SO2 0 to 999
ADI 107 E.G.A. Exhaust temp 0 to 999
ADI 108 % E.G.A. Efficiency 0 to 100
ADI 109 E.G.A. Error Number 0 to 25
ADI 110 % E.G.A. Voltage Input 0 to 100
ADI 111 E.G.A. Exhaust ∆T 0 to 999
ADI 112 E.G.A. Ambient 0 to 50
ADI 113 E.G.A. Auxiliary Temp 0 to 9999
ADI 114 Service LEDS 8 Bit Pattern Bit to Bit =
0 5
000000 = EGA requires servicing

000001 = 2 Months to service
000011 = 4 Months
000111 = 6 Months
001111 = 8 Months
011111 = 10 Months
111111 = 1 Year
Bit = 1 = System Fault
6
Bit = 1 = O.K. – EGA can run

7
ADI 115- Not Used

120
ADI 121 Hz Probe 1 Signal U integer Frequency
ADI 122 Hz Probe 1 Reference U integer Frequency
ADI 123 Not Used
ADI 124 Probe 1Version/Issue U integer ms/ls byte
ADI 125 Hz Probe 2 Signal U integer Frequency
ADI 126 Hz Probe 2 Reference U integer Frequency
ADI 127 Not Used
ADI 128 Probe 2 Version/Issue U integer ms/ls byte
ADI 129 Alarm Status U integer 0 – OK
1 – High Water
2 – 1 Low
st
3 – 2 Low
nd
ADI 130 Level Status U integer As Alarm Status just above

ADI 131 WL Version/Issue U integer ms/ls byte

645 of 761

ADI 132 Alarm Code U integer 0-OK
1-2nd Low
2-Probe 1 Comms
3-Probe 2 Comms
4-Probe 1 Short
5-Probe 2 Short
6-Probe Mismatch
7-Probe 1 TC
8-Probe 2TC
9-Permanent Reset
10-Permanent Test
11-Keystuck Reset
12-Power Up EEprom
13-Bogus Eeprom State
14-Incompatible Config
17-Config Range Check Fail
18-1st Low
19-HighWater
22-Probes Diverse
255-OK/Reset
ADI 133 Not Used
ADI 134 C Steam Temp U integer
ADI 135 C Feed Water Temp U integer
ADI 136 lb/hr Steam Rate USE ADF
ADI 137 Btus/lb Heat to Steam USE ADF
ADI 138 % Control Element U integer Mod Valve close-open as percentage
VSD min/max speed as percentage
ADI 139 Not Used
ADI 140 % Control Point Raised U integer 0-Normal
1 to 99 - % raised between ‘Control Point’ and
‘High Water’ positions
ADI 141 Not Used
ADI 142 Not Used
ADI 143 lbs Totalised Steam USE ADF
ADI 144 Not Used USE ADF
ADI 145 F Steam Temp U integer
ADI 146 F Feed Water Temp U integer
ADI 147 Kgs/hr Steam Rate USE ADF
ADI 148 KJ/Kg Heat to Steam USE ADF
ADI 149 Kgs Totalised Steam USE ADF
ADI 150 Not Used
ADI 151 C Probe 1 Temperature U integer
ADI 152 C Probe 2 Temperature U integer
ADI 153 F Probe 1 Temperature U integer
ADI 154 F Probe 2 Temperature U integer
N.B. In the case of ADI/ADF points 101 through 114, values correspond to an EGA
address not an MM address e.g. address 1 would correspond to E.G.A. #1 etc.

646 of 761

BD 01 CR Relay status 1 = burner run
0 = burner off
BD 02 Not used
BD 03 Not used
BD 04 Not used
BD 05 Not used
BD 06 Not used
BD 07 Not used
BD 08 Not used
BD 09 Temp./Pressure 0 = Temp.
1 = Press.
BD 10 Not used
BD 11 Not used
BD 12 Not used
BD 13 Not used
BD 14 Not used
BD 15 Not used
BD 16 Not used
BD 17 Not used
BD 18 Flowmetering on 1 = yes
0 = no
BD 19 CO displayed on F2/F3 1 = Displayed
0 = not displayed
BD 20 Not used
BD 21 ºC or ºF 1=F
0=C
BD 22 Bar or PSI 1 = PSI
0 = Bar
BD 23 External Voltage 1 = yes
0 = no
BD 24 Not used
BD 25 EGA optioned 1 = yes
0 = no
BD 26 Actual up to trim 1 = yes
threshold 0 = no
BD 27 E.G.A. cooler ready 1 = yes
0 = no
BD 28 E.G.A ambient temp OK 1 = yes
0 = no
BD 29 Optioned to display NO 1 = yes
0 = no
BD 30 Optioned to display SO2 1 = yes
0 = no
BD 31 E.G.A. ambient temp. 1 = Hi
low/high 0 = Lo
BD 32 Not used
BD 33 Sequencing optioned 1 = yes
0 = no
BD 34 Setpoint/Enable 1 = yes
commands accepted 0 = no
BD 35 Not used
BD 36 Not used
BD 37 Not used
BD 38 Not used
BD 39 Not used

647 of 761

BD 40 Not used
BD 41 Hand operation status 1 = Hand operation
0 = Modulating
BD 42 Low flame hold status 1 = Low flame hold
0 = Modulating
BD 43 Not used
BD 44 Not used
BD 45 Not used
BD 46 Not used
BD 47 MM working comms 1 = yes
0 = no
BD 48 Input 41 set (lead boiler 1 = yes
select) 0 = no
BD 49 Lead boiler status 1 = Lead boiler.
0 = Not lead boiler.
BD 50 ‘Disabled’ status 1 = Disabled
0 = Enabled
BD 57 Slave burner left/right 1=
0=
BD 58-80 Not Used
BD 81 Water Level Enabled
BD 82 Units imp(0)metric(1)
BD 83 Feed Water Pump ON/OFF
BD 84-88 Not Used
BD 89 First Out 1
BD 90 First Out 2
BD 91 First Out 3
BD 92 First Out 4
BD 93 First Out 5
BD 94 First Out 6
BD 95 First Out 7
BD 96 First Out 8
BD 97 First Out 9
BD 98 First Out 10
BD 99 First Out 11
BD 100 First Out 12
BD 101 First Out 13
BD 102 First Out 14
BD 103 First Out 15
BD 104- Not Used
112

648 of 761
Network point table for last (eleventh) address (read/write values from/to analog and digital units
also to MM/EGA).
AI Not - - - -
used
BI Not - - - -
used
AO Not - - - -
used
BO Not - - - -
used
ADF 01 MM 1 new required for range see option for units see Options 1, 51, and
value 30 and 31 on MM 52 on associated MM
write only – floating point
representation.
representation.
representation.
ADF 04 MM 4 new required see option 30 and for units see Options 1, 51, and
value 31 on MM 52 on associated MM
representation.

representation.
representation.
representation.
representation.
representation.
representation.
ADF 11 Global required value for units see Options 1, 51, and
52 on MM 1
representation.

649 of 761

ADI 01 MM 1 new required value for range see write only
option 30 and
31 on MM
option 30 and
31 on MM
option 30 and
31 on MM
ADI 04 MM 4 new required value see option 30 write only
and 31 on
MM
option 30 and
31 on MM
option 30 and
31 on MM
option 30 and
31 on MM
option 30 and
31 on MM
option 30 and
31 on MM
option 30 and
31 on MM
ADI 11 Global required value write only
ADI 12 Lead boiler select 1 to 10 write only
ADI 13 Number of MM’s on system 1 to 10 write only
ADI 14 Not used
ADI 15 Not used
ADI 16 Not used
ADI 17 Analog unit 1 output 1 0 to 255 read and write
ADI 23 Not used
ADI 24 Not used
ADI 31 Not used
ADI 32 Not used

650 of 761

ADI 39 Not used
ADI 40 Not used
ADI 47 Not used
ADI 48 Not used
ADI 55 Not used
ADI 56 Not used
ADI 63 Not used
ADI 64 Not used
ADI 71 Not used
ADI 72 Not used
ADI 79 Not used
ADI 80 Not used

651 of 761

ADI 87 Not used
ADI 88 Not used
ADI 95 Not used
ADI 96 Not used
ADI 97 Not used
ADI 98 Not used
ADI 99 Not used
ADI 100 Not used
ADI 101 Not used
ADI 102 Not used
ADI 103 Not used
ADI 104 Not used
ADI 105 Not used
ADI 106 Not used
ADI 107 Not used
ADI 108 Not used
ADI 109 Not used
ADI 110 Not used
ADI 111 Not used
ADI 112 Analog unit 1 input 1 0 to 255 read only
ADI 118 Not used
ADI 119 Not used
ADI 126 Not used
ADI 127 Not used

652 of 761

ADI 134 Not used
ADI 135 Not used
ADI 142 Not used
ADI 143 Not used
ADI 150 Not used
ADI 151 Not used
ADI 158 Not used
ADI 159 Not used
ADI 166 Not used
ADI 167 Not used
ADI 174 Not used
ADI 175 Not used
ADI 182 Not used

653 of 761

ADI 183 Not used

654 of 761

BDREAD 01 Digital unit 1 input 1 0 or 1 see digital unit setup

655 of 761


656 of 761


657 of 761

BDREAD 161 MM 1 on/off line status 0 = off line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
BDREAD 171- Not used
192
BDREAD 193 Digital unit 1 on/off line status 0 = off line read only
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
BDREAD 203 Not used
BDREAD 204 Not used
BDREAD 205 Not used
BDREAD 206 Not used
BDREAD 207 Not used
BDREAD 208 Not used
BDREAD 209 Analog unit 1 on/off line status 0 = off line read only
1 = on line
1 = on line
1 = on line
1 = on line
1 = on line
BDREAD 214 Anal4og unit 6 on/off line status 0 = off line read only
1 = on line

658 of 761

1 = on line
1 = on line
1 = on line
1 = on line

659 of 761
BDWRITE 1 MM 1 Enable/disable 1 = off line write only
0 = on line
0 = on line
0 = on line
0 = on line
0 = on line
0 = on line
BDWRITE 7 MM 7 Enable/disable 1 = off line writ only
0 = on line
0 = on line
0 = on line
0 = on line
BDWRITE 11 Not used
BDWRITE 12 Not used
BDWRITE 13 Not used
BDWRITE 14 Not used
BDWRITE 15 Not used
BDWRITE 16 Not used
BDWRITE 17 Digital unit 1 output 1 0 = off, 1 = on write only

660 of 761


661 of 761
D.T.I. Data Transfer Interface Other Information and Illustrations
6.20.1 Loop Back Test
A facility exists which enables the hardware connection to the RS232 PC port and the RS422 port
to be checked.
On the dual inline switch (switch bank 2) set way 5 on and all other ways off.
Any character on the receive line is then echoed back immediately on the transmit line.
This facility is intended to be used in conjunction with a terminal emulator, such as Hyperterminal
(hypertrm.exe) which is included with Windows.
The communications settings should be as follows:
Bits per second: 9600

Data bits: 8
Parity: none
Stop bits: 1
Flow control: None (i.e. no hardware or software flow control)
Full duplex.
6.20.2 Setting up the Hyperterminal for the DTI echo test
Connect the DTI to the PC via a serial lead.
Click on the Windows start button and choose Run.
Type hypertrm.exe in the Open box and press Enter.
Wait for the Connection Description box to appear.
In the name box type Autoflame DTI Echo Test and click OK.
Under Connect Using choose Direct to COM1.
Use the following Port Settings for COM1 and choose OK:
Bits per second (baud rate): 9600

Data bits: 8
Parity: none
Stop bits: 1
Flow control: None (i.e. no hardware or software flow control)
(Full duplex if necessary)

662 of 761
D.T.I. Data Transfer Interface Other Information and Illustrations
6.20.2 Communication Interfaces
This page is for information only.

RS 232
A B
0 1
TX -8v +8v
RX
0 1
FULL
RX -8v +8v
TX DUPLEX
SG SG
< 10 meters
RS 422
A B
I=1 I=0
TX RX
FULL
DUPLEX
RX TX
1 Km
RS 485
TX RX RX TX
A B
HALF
DUPLEX
TX/RX SWITCH TX/RX SWITCH

Example of a network

663 of 761

664 of 761
Application Possibilities
Section 7: Application Possibilities for M.M./E.G.A.
7.1 Pressure Jet/Gun Type Burners
7.2 Rotary Burners
7.2.1 Diagram showing System with Rotary Burner
7.3 Flue Gas Recirculation Control (NOx).
7.4 Steam Generator Feed Water Control
7.5 Water Injection
7.7 System Configurations
7.7.1 Mk.6 EVO MM/EGA System Schematic

7.7.2 Mini Mk.6 MM/EGA System Schematic
7.7.3 Mini Mk.5 EVO MM/EGA System Schematic
7.8 Changover on the Fly
7.9 No Pre-purge Software
7.10 Hot Standby Software
7.11 Staged Combsution for Oil Firing
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
665 of 761
Application Possibilities Pressure Jet/Gun Type Burners
7.1 Application Possibilities for M.M./E.G.A. System
The M.M. system is basically a fuel/air ratio control designed to improve the energy efficiency and
control of a standard pressure jet or rotary burner. The ability to control up to 6 channels, however,
greatly expands the areas in which it can be used and any application in which it is necessary to
precisely mix fuel and air from up to 6 sources is a possibility.
Pressure Jet/Gun Type Burners
The simplest system requiring only two servo motors for control. The energy saving benefits come from
several sources:
a) Elimination of mechanical hysteresis due to cams and linkages.
b) Precise control of the fuel/air ratio throughout the combustion range without the compromises
which limit a cam.
c) Control of the setpoint to ±1 degree C. (± 2 degrees F.) or ±1.5 psi via the PID controller,
eliminating the wastage or pressure higher than required. This is set internally within the
M.M. controller and is a 4-term PID loop controller.
d) No compromise required when changing between fuels since the air/fuel ratio for each are
completely seperate.
e) The ability to maximise the turndown capability of the burner without compromising the start
position. This is achieved by the ability to use a golden start position.

666 of 761
Application Possibilities Rotary Burners
Rotary Burners
control of a standard pressure jet or rotary burner.
The ability to control up to 6 channels however greatly expands the areas in which it can be used.
Any application in which it is necessary to precisely mix fuel and air from up to 8 sources is a possibility
and one of the possible applications is the use of rotary burners.
The benefits of this system are similar to that of pressure jet/gun burners but by utilising the third
channel , to control the primary air supply, the best possible mixing is achieved. The energy saving
benefits are as follows:
a) Elimination of mechanical hysteresis due to cams and linkages;
b) Precise control of the fuel/air ratio throughout the combustion range without the compromises
which limit a cam.
c) Control of the output to ±1 degree C. (± 2 degrees F.) or ± 1.5 psi via the P.I.D. controller,
eliminating the wastage or pressure higher than required. This is set internally within the
M.M. controller and is a 4-term PID loop controller.
d) No compromise required when changing between fuels since the air/fuel ratio for each are
completely seperate.
e) The ability to maximise the turndown capability of the burner without compromising the start
position. This is achieved by the ability to use a golden start position.

667 of 761

668 of 761
Flue Gas Re-Circulation Control (NOx)
control of a standard pressure jet or rotary burner. The ability to control up to 6 channels, however,
The additional channels can be used to control a recirculation damper which is a common method in
the control of NOX production. As with most forms of NOX control this method reduces the
temperature in the combustion chamber and hence reduces thermal efficiency. Use of the M.M./E.G.A.
will minimise the excess air to the burner which itself reduces NOX and will also affect some of this loss
of efficiency.

669 of 761
Application Possibilities Steam Generator Feed Water Control
Steam Generator Feed Water Control
The M.M. system is basically an air/fuel ratio control designed to improve the energy efficiency and
control of a standard pressure jet or rotary burner. The ability to control up to 6 channels however
The 3rd channel can also be used to control the feed water.

670 of 761
Application Possibilities Water Injection
Water Injection
The M.M. system is basically an air/fuel ratio control designed to improve the energy efficiency and
control of a standard pressure jet or rotary burner. The ability to control up to 6 channels however
The 3rd channel can be used in this instance to control the water injection.

671 of 761
7.7.1
EXTERNAL VARIABLE
LOAD OR SPEED DRIVE
FLUE
SENSOR
Issue: 1.1.2007
CH.6
GAS
PRESSURE HIGH/LOW GAS CAPACITANCE PROBE

SENSOR PRESSURE PROVING PROBES
STEAM TEMP.
OIL SENSOR SENSOR
PRESSURE
SENSOR
OIL T.D.S.
PROBE
AIR CH.1
PRESSURE FUEL
SENSOR SERVO
FEEDWATER TEMP. SURFACE

SERVO SENSOR BLOWDOWN
U.V
CH.4 CH.2 CH.3
Mk6 Evolution M.M./E.G.A. System
AUX. AIR AUX. FEEDWATER

FORCED BOILER VALVE
SERVO SERVO SERVO
DRAFT
EXTERNAL

OR FLAME BOTTOM
VARIABLE
SWITCH BLOWDOWN
SPEED
CH.5 DRIVE
EXTERNAL MODULATION
OUTSIDE SECOND SETPOINT FACILITY
15 X FIRST OUT ANNUNCIATION
Section 7.7.1
TEMP. SENSOR
672 of 761
7.7.2
EXTERNAL
LOAD OR
FLUE
SENSOR
Issue: 1.1.2007
GAS
PRESSURE HIGH/LOW GAS PROBE

SENSOR PRESSURE PROVING
STEAM
OIL SENSOR
PRESSURE
SENSOR
OIL
AIR CH.1
PRESSURE FUEL
SENSOR SERVO
Mini Mk6 M.M./E.G.A. System
U.V
CH.4 CH.2 CH.3
AUX. AIR AUX.
FORCED BOILER
SERVO SERVO SERVO
DRAFT

EXTERNAL
OR FLAME
VARIABLE
SPEED SWITCH
CH.4 DRIVE
OR
EXTERNAL MODULATION
Section 7.7.2
SECOND SETPOINT FACILIT
673 of 761
7.7.3
FLUE
Issue: 1.1.2007
GAS
SAMPLING
PROBE
STEAM
SENSOR
OIL
AIR CH.1
PRESSURE FUEL
SWITCH SERVO
U.V
CH.2 CH.3
AIR AUX. OR FLAME ROD
FORCED BOILER
SERVO SERVO
DRAFT
Mini Mk5 Evolution M.M./E.G.A. System

EXTERNAL MODULATION
SECOND SETPOINT FACILITY
Section 7.7.3
674 of 761
Changeover on the Fly
Changeover on the fly software enables up to two fuels to be accommodated (not four as on the
standard Mk6 product) and if two fuels are commissioned they can run independently or
simultaneously. Changing between the fuels is possible without the need to shutdown the burner.
The system and burner suitability must be considered for each COF application.
Hardware requirements:
• Autoflame manufactured control panel housing the following units:

o Mk6 MM Evolution (software- BC 20.x; MM 20.x; DI 20.x)
o Digital IO unit modified for COF (software- 1.00 modified for COF)
The digital IO must be set with identification #1 (use the PC & IO setup lead and follow the
instructions in section 6 of the technical manual- if any other identification number is set then the
communications to the MM will fail). The MM identification number (option #33) can be set to any
number as usual.
Communications to the digital IO module is via the twin burner terminals #23/24 (so twin burner
operation is not possible).
Operational Components:
Terminal #89 input selects fuel 1

Terminal #90 input selects fuel 2
Terminal #91 input selects simultaneous firing
Terminal #92 input is unused
Three or four servomotors must be used and all servomotors must be connected at all times.
• Channel 1 must be fuel 1, e.g. gas

• Channel 2 must be air
• Channel 3 must be fuel 2, e.g. oil
A VSD can be optioned. If a VSD is optioned then the low flame positions/settings on the drive
must be the same for both fuels. Fuel and air positions may vary.
An EGA (Exhaust Gas Analyser) can be used but trim can only be selected on channel 2 (air
damper) and no trim is available on channel 5 (VSD).
COF will not operate if the target ‘change over’ curve is not commissioned.
The fuel flow metering or 10 point load index entry is referenced to channel 2 (air).
A type 1 c/o (changeover) sequence is where the air opens then the valve opens
A type 2 c/o is where the valve closes then the air closes

675 of 761
Important options/parameters to set:
• Option #111 must be set = 0 (interrupted pilot)

• Option #8 must be set = 2 (i.e. 3 channels)
• Option #69 must be set = 1 (channel 3 at close for purge position)
• Parameter #108 = 0 (pilot off during fuel 2 burn)
• Parameter #108 = 1 (pilot on during fuel 2 burn)
COF Operation:
For a detailed schematic of the COF procedures please see the attached block diagrams. For these
please use the following key:
F1 = Fuel 1 (Propane in this case)

F2 = Fuel 2 (Hydrogen in this case)
CH1 = Channel 1
CH2 = Channel 2
CH3 = Channel 3
C1 = Curve 1 (uses F1 select input terminal #89) = Propane (Channel 1 and 2)

C2 = Curve 2 (uses F2 select input terminal #90) = Hydrogen (Channel 2 and 3)
C3 = Curve 3 (uses F3 select input terminal #91) = Propane + Hydrogen (Channel 1,2,3)
LF = Low flame
Only 1 fuel may be selected during burner start-up. If more than 1 input is selected the MM will
reset.
Once the burner is firing/modulating the appropriate indication output will be set (during
commissioning the indication outputs do not operate). Once an indication output is set, COF may
be carried out.
A ‘non current’ input must be set for 5 seconds for it to be recognised. Once recognised it must not
reset or the MM will reset causing the burner to stop. The ‘current’ input may be deselected any
time from now on. The changeover will take place. Once the burner is modulating on the new fuel
the inputs are looked at again. If two inputs are left permanently set, changeovers will occur
repeatedly.
If a COF is attempted and the target fuel ‘fuel available’ input is reset a COF will not be initiated.
If a fuel is burning and its ‘fuel available’ input becomes reset then a lockout is set.
The fuel available input for the selected fuel must be set at all times this fuel is selected.
The COF input has to be set for the COF operation to take place. When the COF input is set there
is a 5 second filter time on the fuel select inputs to allow the inputs to be switched. When the COF
input is reset, the fuel select inputs respond as a standard Mk6 and stop the burner immediately
when deselected. The burner will restart when a fuel is next selected.
The proof of closure inputs must be set when a valve is closed and reset when open. Both inputs
are monitored regardless of which fuel is selected.

676 of 761
COF lockout messages:
Dio ignition check

- Input 1 of the digital IO (monitoring the ignition relay) is not in the correct state– the
output/relay is apparently on when should be off (or vice versa).
Dio pilot check

- Input 2 of the digital IO (monitoring the pilot relay) is not in the correct state– the output/
relay is apparently on when should be off (or vice versa).
Dio fuel 1 check

- Input 3 of the digital IO (monitoring the fuel 1 relay) is not in the correct state– the output/
Dio fuel 2 check

- Input 4 of the digital IO (monitoring the fuel 2 relay) is not in the correct state– the output/
Dio off line

- There is no communication between the Mk6 control & the digital IO unit.
Fuel 1 loss
- Fuel 1 available (digital IO input #15) is/has become reset when this fuel selected.
Fuel 2 loss
- Fuel 2 available (digital IO input #16) is/has become reset when this fuel selected.
Fuel 1 cpi
- The cpi (poc) input for fuel 1 (digital IO input #5) is not in the correct state.
Fuel 2 cpi
- The cpi (poc) input for fuel 2 (digital IO input #6) is not in the correct state.

677 of 761
No pre-purge
In the Mk6 Evolution unit it is now possible to allow the burner to start-up as quickly as possible
without the need for a pre-purge, i.e. the pre-purge is bypassed. The major advantage of this control
means that the overall boiler efficiency is increased by minimising the heat loss to the stack during a
purge cycle. Also, the burner starts-up quicker so reaching setpoint in a reduced time is achieved.
According to the EN676 European regulation, the burner is allowed to restart without a pre-purge if
the burner has recycled due to operational temperature/pressure or when the burner on-off switch
has been cycled, i.e. loss of input on terminal #53. When the burner is stopped by a lockout then
this procedure is not allowed and the burner will have to start-up in the normal manner with a pre-
purge. In order for no pre-purge to be allowed, there is one thing that needs to take place and that
is that before the start without a pre-purge, valve proving (VPS) must take place and finish
successfully. If this VPS operation is successful and all of the valves are checked then the burner
may start-up without a pre-purge.
This is has been incorporated into the following software revision and is not in the standard Mk6
software control. Please contact Autoflame Engineering Ltd for such applications.
BC 6.26
MM 6.28
DI 6.29
Operation:
In order to initiate the no pre-purge software, option and parameter #143 must be set to a value of
1. During the first start-up the burner will start in the usual manner and a pre-purge will be initiated.
Until the complete commissioning program has been entered and the burner started successfully, the
burner will start-up every time with the VPS operation and a pre-purge.
Once fully commissioned and the burner started successfully then the system will now allow the no
pre-purge software to be initiated. If the burner goes above its setpoint and so turns off in a
controlled manner, or if the input on terminal #53 (burner on/off switch) is lost, then the next time
the burner starts-up, it will go through the VPS operation and then light off without a pre-purge, i.e.
the burner has shutdown in a controlled manner and the gas valves have been checked for integrity.
If a lockout occurs or the burner shuts down in an abrupt manner, i.e. loss of power to the unit, then
the next time the burner starts-up a complete purge will be initiated.
According to the EN 676 regulation, the burner is only allowed to work in this manner if option and
parameter #129 is set to a value of 0, i.e. the VPS must operate before the burner starts–up.
The start sequence without pre-purge is as follows. Firstly the system goes through its internal tests
and relay checks as per the usual start-up sequence. Then the call for heat on terminal #57
activates and the system will go through the VPS operation. If this operation is successful then the
Mk6 will drive the channels to the light off or start position. Once all channels reach the start
position then the burner will light off in the usual manner.
It is important to note that this control logic only conforms with European regulations at present and
does not conform with NFPA and UL.

678 of 761
Hot Standby
In the Mk6 Evolution unit it is now possible to enable hot standby control (continuous pilot) which
means that when the burner goes above its switching point, i.e. off differential, then the burner
continues to fire with only the pilot valves energised.
This is has been incorporated into the following software revision and is not in the standard Mk6
software control. Please contact Autoflame Engineering Ltd for such applications.
BC 6.32
MM 6.32
DI 6.32
Operation:
To set up this facility option #9 must be set to a value of 3 or 4. This means that once the boiler
gets up to temperature (pressure), the burner will not switch off but will in fact switch to pilot firing.
These additional settings work in the same way as settings 1 and 2 but enable this continuous pilot
operation. If option #9 is set to 3 then the burner goes to pilot firing at an offset above setpoint (set
in option #10) and will switch back to main flame a number of degrees below the setpoint as set in
option #11. If option #9 is set to 4 then the burner goes to pilot firing at an offset above setpoint
(option #10) and will switch back to main flame a number of degrees above setpoint as set in
option #11. When you put option #9 to a value of 3 or 4 then an external on/off thermostat or
pressure switch must be installed.
In the situation when the burner switches back to pilot flame then the burner will open the pilot
valves and after the same time as the second safety time (option #116), the burner will close its
main valves. Also during the hot standby position the gas pressure is checked by the gas sensor, so
it is important that the main valves and pilot valves are connected with a small measuring pipeline.
When the burner comes back to the point when it should go back to main flame the main fuel valves
will open and after the second safety time the pilot valves will be closed and the normal operation
will start again.

679 of 761
Staged Combustion for Oil Firing
In the Mk6 Evolution unit it is now possible to use staged combustion when firing on fuel #2 (oil).
This allows full modulating control when firing on fuel #1/3/4 (natural gas) but allows this staged
combustion control, i.e. energising solenoids, on fuel #2. This is has been incorporated into the
following software revision and is not in the standard Mk6 software control. Please contact
Autoflame Engineering Ltd for such applications.
BC 5.03
MM 7.01
DI 7.01
The software works as follows:
When firing on fuels #1/3/4, the standard Mk6 operation is observed for full modulation when
commissioning the fuel and air ratio curve. The standard PID control is used.
When firing on fuel #2, there are 4 outputs that can be implemented in order to allow up to 4
stages for staged combustion. These can be used for bypass solenoids or simply to allow additional
fuel to be inputted. These terminals are:
Terminal #60- mains voltage output for solenoid 1

Terminal #74- switched neutral to relay contact for solenoid 2
The first nozzle comes on with terminal #60 from the burner control main fuel valve output. The
number of nozzles on is set by offsets from the required setpoint. The offsets are adjustable
between 2 to 50. The three offsets are set by:
Parameter #47 = 1st offset default 5

Parameter #48 = 2nd offset default 5
Parameter #107 = 3rd offset default 5
Nozzle 1&2 on when first offset below required. 2 nozzles on

Nozzle 1&2&3 on when first+second offset below required 3 nozzles on
Nozzle 1&2&3&4 on when first+second+third offset below required 4 nozzles on
Parameter #108 (range 1 to 9, default 7) sets a point between each commissioned point where the
nozzle turns on as a compromise for the transient experienced between air rich & air lean.

680 of 761
Staged Combustion for Oil Firing
Commissioning for fuel #2:
Set the close and open positions as standard. Also set the first start position as standard, i.e. nozzle
1 will be energised at this point.
The start button will flash again- press enter. Adjust and set accordingly using the EGA values and
then press enter- this sets the combustion for nozzle 1 which is already on.
The inter button flashes, press inter and adjust the elements to a point where flame should be
maintained ready for nozzle 2 to be set on- press enter- nozzle 2 opens. Adjust and set
accordingly using the EGA values and then press enter- this sets the combustion for nozzle 2.
Inter flashes again- proceed as for nozzle 2- this time for nozzle 3.
High flashes- enter as for previous nozzle- this time for nozzle 4
Enter- RUN flashes- will run to low flame.
Press RUN when low flame attained progresses to modulation.
On fuel #2, all points entered must be ascending including VSD channels
Limitations:
1- Channels #3/4 are switched neutrals and are used for the staged combustion control.
Therefore, these cannot be used as standard for servomotors when firing on fuels #1/3/4,
i.e. FGR will not operate on any fuel (flue gas recirculation).
2- Channels #5/6 can be used on fuel #1, but only channel #5 can be used on fuel #2, i.e.
channel #6 cannot be used on fuel #2.
3- If the burner locks out or restarts during commissioning on fuel #2, then the system will see
this as if the system had been powered down (fuel deselected) and will reset itself.
4- If low flame hold is selected, then the burner runs to low flame- just one nozzle on (terminal
#60 nozzle).
5- If hand is selected, then the burner will go to high fire- all 4 nozzles.
6- Option #147, the air checking window with the air sensor does not check on fuel #2- this is
checked on other fuels.
7- One point change is not possible- the system will reset if attempted.
8- Twin burner cannot be used.
9- There is no EGA trim on fuel #2, only the EGA run screen can be selected. The other fuels
#1/3/4 operate in the normal method.
10- There is no fuel flow metering on fuel #2. The other fuels #1/3/4 operate in the normal
method.
11- The download will not read correctly on fuel #2. The other fuels #1/3/4 operate in the
normal method

681 of 761

682 of 761
M.M./E.G.A. Peripherals
Section 8: Ancillary & Peripheral Equipment.

8.0 Valve Specifications
8.0.1 Oil Valve Selection
8.1 Screwed Gas Valves (small positioning motor)

8.2 Flanged Gas Valves (small positioning motor)
8.3 Flanged Gas Valves (large positioning motor)
8.3.3 Screwed Gas Valve + Oil Valve + Small positioning motor

8.3.4 Flanged Gas Valve + Oil Valve + Small positioning motor
8.3.6 Gas Valve Pressure Drop Graph
8.4 Type 1/2/5/6/8/9 Oil Control Valves
8.5 Type 3/4/7 Oil Control Valves
8.6 Oil Control Valve Flow Characteristics
8.6.1 Type 1 Spillback Graph

8.6.5 Type 3 Metering Graph
8.7 Small Positioning Motor
8.8 Large Positioning Motor
8.9 Temperature Detector
8.10 Industrial Positioning Motor
8.10.0 Overview
8.10.1 External Drawings
8.10.2 Specification
8.10.3 Installation
8.10.4 Manual Operation
8.10.5 Troubleshooting
8.10.6 4-20mA Industrial Positioning Motor
12345678901234567890123
12345678901234567890123
12345678901234567890123
12345678901234567890123
12345678901234567890123
1
12345678901234567890123
12345678901234567890123
12345678901234567890123
12345678901234567890123
Section 8: Index
12345678901234567890123
12345678901234567890123
12345678901234567890123
683 of 761
8.0 VALVE SPECIFICATIONS
When using high viscosity low temperature fuel oils through smaller valves, turbulent flow
characteristics can reduce volume throughput significantly.
All flow pressure graphs published for oil valves are using light distillate oil @ 20°C and a viscosity
of 5 centistokes.
Autoflame will carry out flow characteristic tests on specific valves against customer fuel/viscosity
and temperature specifications. Price on application.
Standard oil valve build execution is stainless steel valve body with stainless steel bobbin. The top
and bottom closing plates are manufactured out of aluminium.
All valves can be supplied in non-standard material at extra cost. Price on application.
The standard execution of the gas valve is an aluminium body with stainless steel metering disk and
stem. The gas valves can also be supplied for corrosive/contaminated fuels in all stainless steel
construction. Price on application.
The standard execution of the FGR valve (flue gas recirculation) is an aluminium body with stainless
steel disk and stem but is dependent upon the application. Two grease nipple points are used for
easy service of the FGR valves.
Maximum pressure is 350 psi (oil valves); 10 psi (GV4 gas valves); 25psi (GVF gas valves).
For further information please contact Autoflame sales.

684 of 761
8.0.1 Oil Valve Selection
8.0.1.1 Spillback/Bypass Application
For assistance, fill in the actual data and return to Autoflame.

685 of 761
8.0.1.2 Metering/Simplex Application
For assistance, fill in the fields below and return to Autoflame:
A: ________
C: ________
D: ________

686 of 761
8.1.1 Gas Valve- threaded (metric)- small positioning motor

687 of 761
8.1.2 Gas Valve- threaded (imperial)- small positioning motor

688 of 761
8.2.1 Gas Valve- flanged (30mm thick metric)- small positioning motor

689 of 761
8.2.2 Gas Valve- flanged (30mm thick imperial)- small positioning motor

690 of 761
8.3.1 Gas Valve- flanged (50mm thick metric)- large positioning motor

691 of 761
8.3.2 Gas Valve- flanged (50mm thick imperial)- large positioning motor

692 of 761
8.3.3 Piggy-back Assembly of gas and oil valve
The example shown below shows the design behind utilising one servomotor for both the gas and
the oil valve. This shows a Type 2 oil valve with a 2" threaded gas valve using only one small
positioning servomotor.

693 of 761
8.3.4 Piggy-back Assembly of gas and oil valve- metric
the oil valve. This shows a Type 2 oil valve with a flanged gas valve using only one small positioning
servomotor.

694 of 761
8.3.5 Piggy-back Assembly of gas and oil valve- imperial
the oil valve. This shows a Type 2 oil valve with a flanged gas valve using only one small positioning
servomotor.

695 of 761
8.3.6 Autoflame Butterfly valve flow data (valve sizing)

696 of 761
8.4 Oil Control Valves
All of the Autoflame oil valves (types 1-9) can be supplied as metering/simplex or spillback/bypass.
There are eighteen different oil valves available, nine metering and nine spillback valves. Each
valve has different flow charcteristics as shown in this section of the manual. It is important to
ensure the correct oil valve selection for the application, otherwise the correct input and turndown
available for the burner will not be met.
When using the oil control valve for a dual fuel application, i.e. gas and oil, and if the valves are to
be piggy-backed, then the bottom aluminium plate of the oil valve must be removed for assembly
with the gas control valve as in section 8.3.3.
8.4.1 Spillback/bypass application

697 of 761
8.4.2 Metering/simplex application
The metering valves are identifiable by the prefix OVM whereas the spillback valves have the
prefix OVS.
For the small oil control valves, types 1/2/5/6/8/9, they have the following dimensions:
Height: 50mm (2") including bottom plate

Width: 30mm (1.125")
Length: 60mm (2.375")
The small oil control valves use a small servomotor for positioning control.

698 of 761
8.5 Large oil valve
For the large oil control valves, types 3/4/7, they have the following dimensions:
Height: 70mm (3") including bottom plate

Width: 50mm (2")
Length: 110mm (4.375")
The large oil control valves use a large servomotor for positioning control.
8.5.1 Spillback/bypass application

699 of 761
8.5.2 Metering/simplex application

700 of 761
8.6 Oil Valve flow characteristics

701 of 761

702 of 761

703 of 761

704 of 761

705 of 761

706 of 761

707 of 761

708 of 761
8.7 Small Positioning Servomotor- part number MM10005

709 of 761
M.M./E.G.A. Peripherals M.M./E.G.A. Small Positioning Motor
Note:
The Autoflame product must only be installed, set-up, commissioned and adjusted by
an Autoflame certified technical engineer.
To adjust the potentiometer loosen the tamper proof screws using a tamper proof screwdriver as
supplied by Autoflame Engineering. After adjustment, ensure tightness but do not overtighten. Use
fingers only to adjust the position of the potentiometer. Do not raise the potentiometer from the
PCB.
POTENTIOMETER
ADJUSTING CLIPS
POSITIONING MOTOR
TAMPER PROOF SCREWS
POTENTIOMETER
G
W1
R
Y
W2
C1
WIRES MUST BE
R1 R2
CONNECTED R3
INDIVIDUALLY
W
+ -
L CW CCW
CCW CW L + W -
240V
M4 EARTH STUD VOLTAGE

LABEL
Specification
Suppl y Vo l tage 24/230V, 50/60Hz
Output Shaft To rque 1.2Nm / 0.89 ft l bs
Operati ng Angl e 0-90°
Operati ng Ti me No mi nal 20 seco nds
Max R ated Po wer 3W
Ambi ent Temperature 0°C to 60°C / 32°F to 140°F
Industri al Pro tecti o n R ati ng IP54 / NEMA 13
Mo unti ng Angl e 360°
P o s i ti o n i n g MM Dri ve
Dri ve Mo to r Synchro no us
Bo dy Materi al Mi l d Steel CR 4
Co ati ng Interpo n 700 Po wder Co at
Wei ght 0.55kg
Di mensi o ns 99x92x64mm
Wi ri ng Co nnecti o n PG11 Gl and

710 of 761
8.8 Large Positioning Servomotor- part number MM10004

711 of 761
M.M./E.G.A. Peripherals M.M./E.G.A. Large Positioning Motor
Note:
fingers only to adjust the position of the potentiometer. Do not raise the potentiometer from the
PCB. M4 EARTH STUD
- +
W L CW CCW
- +
W L CW CCW
POTENTIOMETER
ADJUSTING CLIPS
POSITIONING MOTOR TAMPER PROOF SCREWS

POTENTIOMETER
Specification
Suppl y Vo l tage 24/230V, 50/60Hz
Output Shaft To rque 15Nm / 11 ft l bs
Operati ng Angl e 0-90°
Operati ng Ti me No mi nal 30 seco nds
Max R ated Po wer 9W
Ambi ent Temperature 0°C to 60°C / 32°F to 140°F
Industri al Pro tecti o n R ati ng IP54 / NEMA 13
Mo unti ng Angl e 360°
P o s i ti o n i n g MM Dri ve
Dri ve Mo to r Synchro no us
Bo dy Materi al Mi l d Steel CR 4
Co ati ng Interpo n 700 Po wder Co at
Wei ght 1.85kg
Di mensi o ns 145x112x94
Wi ri ng Co nnecti o n PG11 Gl and

712 of 761
8.9 Boiler Water Temperature Sensor- part number MM10006

713 of 761
8.10 Industrial Servomotor
Overview/Outline
This system is a rotary type electric actuator, suitable for use with the M.M. module.
The body is made with aluminium die-cast, thus it is light, compact, highly efficient and powerful.
Features
Light and compact.
Easy to handle and suitable for use in narrow spaces.
Simple structure design.
Trouble free mounting on air damper, maintenance and testing.
Manual operation function by crank handle supplied with the servomotor.

Manual operation is only possible when the power is disconnected, with the attached manual
crank handle. If manual operation is performed whilst the unit has power this will cause damage.
Protect function.
Thermal protector is built-in to prevent motor burn out by overloading.
Easy for wiring.

Connection is simplified by a terminal block inside.

714 of 761
8.10.1 External Drawings
Appearance and Nomenclature
No Name
1 Body
2 Autoflame feedback potentiometer
3 Drive unit cover
4 Power instruments cover
5 Control unit/terminal strip cover
6 Output shaft
7 Manual handle shaft
8 Cord lock for conduit connection

715 of 761
8.10.1.2 Dimensions
Metric Units:
Part Number Torque Dimensions Shaft Dimensions Mounting Detail Dimensions
Nm W H B L A/F R S T1 T2
MM10070 40 159 111 115 12 12 68 60 M8 M6
MM10072 98 208 137 123 16.5 15 82 70 M8 M6
MM10074 200 257 145 157 26.5 23 118 84 M10 M10
MM10078 400 257 145 157 26.5 23 118 84 M10 M10
Imperial Units:
Part Number Torque Dimensions Shaft Dimensions Mounting Detail Dimensions
ft lbs W H B L A/F R S T1 T2
MM10070 37 6.26 4.37 4.53 0.47 0.47 2.68 2.36 M8 M6
MM10072 72 8.19 5.39 4.84 0.65 0.59 3.23 2.76 M8 M6
MM10074 148 10.12 5.71 6.18 1.04 0.91 4.65 3.31 M10 M10
MM10078 295 10.12 5.71 6.18 1.04 0.91 4.65 3.31 M10 M10

716 of 761
8.10.2 Specification
Item Specification
Power 220/240VAC 50/60Hz

110VAC 60Hz
Output Shaft Torque MM10070- 40Nm (37ft lbs)

MM10072- 98Nm (72 ft lbs)
MM10074- 200Nm (148ft lbs)
MM10078- 400Nm (295ft lbs)
Operating Angle 0-90 degrees

Operating Time 15-30 seconds/50Hz (nominal)
Protect System Thermal protector built in
Ambient Temperature -25C - 55C (-13F - 131F)
Rated Current MM10070- 0.4A/200V (0.75A/100V)

MM10072- 0.3A/200V (0.6A/100V)
MM10074- 0.45A/200V (1A/100V)
MM10078- 0.9A/200V (2A/100V)
Insulation Resistance 100Mohm/500VDC

Withstand Voltage 1500VAC/minute
Manual Operation Crank handle attached
Stopper Mechanical stopper- open/close adjustable
Enclosure IP65/NEMA4
Mounting Angle 360 degrees- all directions
Positioning M.M. drive
Drive Motor MM10070- 8W (E type)

MM10072- 20W (E type)
MM10074- 30W (E type)
MM10078- 90W (E type)
Body Material Die cast aluminium ADC12

Coating Baking varnish
Weight MM10070- 2kg (4.4lbs)

MM10072- 4.5kg (9.9lbs)
MM10074- 9kg (19.8lbs)
MM10078- 9.5kg (20.9lbs)
Wiring Conduit PF1/2 x 1

Resin connector attached

717 of 761
8.10.3 Installation
Positioning
Ambient temperature: Within -25°C to +55°C (--13 F. to +131 F.)
Avoid hazardous ambient conditions.
Depending on the condition of installation, consider to reserve spaces for wiring conduit cover, and
manual maintenance works.
Mounting on Air Damper
Ensure that the industrial servomotor is not powered before making manual operations.
Move the damper by hand and make sure that it is free then set it at totally closed position. Make
sure that the shaft is smooth in motion and there is no decentering/inclination, by turning the manual
handle.
Using the Autoflame supplied industrial servomotor mounting brackets, mount the servomotor to the
bracket and secure. Then mount this assembly to the damper or valve ensuring that the damper or
valve is in the fully closed position and then tighten the bolts and make sure that the assembly is fully
secure.

718 of 761
8.10.3.1 Positioning Motor Connections

719 of 761
8.10.3.3 Positioning Motor
The Autoflame product must only be installed, set-up, commissioned and adjusted by an
Autoflame certified technical engineer.
fingers only to adjust the position of the potentiometer. Do not raise the potentiometer from the PCB.
Potentiometer Tamper Proof Screws
Potentiometer
Adjusting Clips P.C.B./1 Fixing Points
M3

720 of 761
8.10.4 Manual Operation
Before starting manual operation,

check that the power source is
switched off.
Remove rubber cap of the drive
unit, and insert the manual handle
level into the hexagonal hole.
Turn the manual handle clockwise
and the shaft moves in the CLOSE
direction.
Turn the manual handle counter
clockwise and the shaft moves in the
OPEN direction.
Note:
Do not overturn the handle with excessive strength, as otherwise, it may cause problems with the
other parts on the servomotor. Any excessive force may damage the servomotor.
If power is not removed then the servomotor will try to return to the original position during manual
operation. This may damage the servomotor and may cause physical injury.
Dimensions of Manual Handle
Opposite sides of hexagon shaft (mm): MM10070/MM10072 5mm

MM10074/MM10078 6mm
Number of handle turns: 15
Length of handle (mm): MM10070/MM10072 100mm
MM10074/MM10078 120mm
Maintenance
Lubrication: Since the unit is sufficiently lubricated with a long life and pressure proof
di-sulfied molybdenum grease (MOS2), no further lubrication is required.
Periodical Test: In case the motor is very seldomly rotated or after a long period of rest, it is
suggested to have a periodical test and check if there is no irregularity. Remove
power to the servomotor and check manual operation as described above. Check
wiring and visually inspect the integrity of the valve.

721 of 761
8.10.5 Troubleshooting
Trouble Probable Cause Solution
Motor does not start
Power switch is off Switch on
Wire/terminals are broken or Replace the wire or properly connect the

disconnected terminals
Supply voltage is too low/high Check the voltage with a meter

or incorrect
Effect of the thermal protector Lower/raise the ambient temperature or

(due to a high/low ambient manually open/close the damper when power
temperature or blocked damper is removed from the motor

722 of 761
8.10.6 4-20mA Positioning Motor
Within the control of the Mk6 M.M. there are up to six channels of control for the fuel/air ratio.
The fifth and sixth have typically been used for variable speed drive (VFD) control using a 4-20mA
output to the drive and a 4-20mA feedback signal from the drive at each positon from high to low
fire. It is now possible, using a new set of servomotors, to use these two channels for additional
servomotor control. These servomotors use a 4-20mA input signal and send back a feedback signal
to the M.M. control. Therefore, although these servomotors are similar in appearance and rating to
the industrial servomotors, they operate in a different manner.
Please follow section 8.10 for an in depth user guide.
The diagram below shows the wiring between the 4-20mA servomotor and the Mk6 if the
servomotor is used for channel 5. Please use terminals #4/6 and #13/15 for channel 6 use.

723 of 761

724 of 761
Miscellaneous Component Information
Section 9: Miscellaneous Component Information
9.1 Parts List
9.1.1 MM Control Units and UV Flame Scanners

9.1.2 Air/Gas/Oil Pressure Sensors
9.1.3 Boiler Load Detectors
9.1.4 Servo Motors
9.1.5 E.G.A. Components
9.1.6 Inverter, Splitter and Interface Modules
9.1.7 DTI Modules and PC Software and Accessories
9.1.8 Water Level Control Equipment
9.1.9 Oil Control Valves
9.1.10 Gas Control Valves- Screwed
9.1.11 Gas Control Valves- Flanged
9.1.12 Sundries and Spare Parts
9.1.13 MM System Spares and UV Scanner Spares
9.1.14 E.G.A. Spares and Gas/Oil Valve Spares
9.1.15 DTI Spares amd Servomotor Spares
9.1.16 Demo/Test Equipment

725 of 761
Miscellaneous Component Information Parts List
MM Control Units
Description KGs Part No.
Mk6 MM Evolution Module, 230V 3.5 MM60001/E
Mk6 MM Evolution Module, 120V 3.5 MM60001/E/110
Mk6 MM Evolution Module + Expansion PCB, 230V 4.0 MM60001/E/WL
Mk6 MM Evolution Module + Expansion PCB, 120V 4.0 MM60001/E/WL/110
Mini Mk6 MM Module, 230V 3.5 MMM60016
Mini Mk6 MM Module, 120V 3.5 MMM60016/110
Mini Mk5 MM Evolution Module, 230V 2.5 MMM5002/E
Mini Mk5 MM Evolution Module, 120V 2.5 MMM5002/E/110
UV Flame Scanners
Self Check UV Sensor, End View 0.8 MM60003
Self Check UV Sensor, High Sensitivity, End View 0.8 MM60003/HS
Self Check UV Sensor, High Sensitivity, Side View 0.85 MM60003/HS/SV
Standard UV Sensor, Side View 0.2 MM60004
Standard UV Sensor, End View 0.2 MM60004/U
Standard UV Sensor, High Sensitivity, End View 0.2 MM60004/HSU
Swivel Mount Assembly, 1" Connection 1.5 UVM60003
Swivel Mount Assembly, 1/2" Connection 1.5 UVM60004

726 of 761
Air/Gas/Oil Pressure Sensors
Air Pressure Sensor 0.42 MM60005

0 to 65 MBar, 0 to 25"wg, 0 to 1 PSI
Air Pressure Sensor 0.42 MM60013

Gas Pressure Sensor 0.42 MM60006

12.5 to 65 MBar, 5 to 25"wg, 0.18 to 1 PSI

52 to 340 MBar, 25 to 135"wg, 0.75 to 5 PSI

115 to 750 MBar, 50 to 300"wg, 1.8 to 11 PSI


0 to 4 Bar, 162 to 1620"wg, 6 to 60 PSI
Oil Pressure Sensor 0.42 MM60009

0 to 40 Bar, 0 to 600 PSI
Outside Temperature Sensors
Outside Air Temperature Sensor 0.32 MM60007
Outside Air Temperature Module MM60015

727 of 761
Boiler Load Detectors
Temp. Detector, 100mm length 0.45 MM10006/100
Pressure Detector, 2-23 Bar 0.21 MM10008
Pressure Detector, 0.2-3.8Bar 0.21 MM10010
Pressure Detector, 30-267 PSI 0.21 MM10008U
Pressure Detector, 1.5-44.5 PSI 0.21 MM10010U

728 of 761
Servo Motors
Large Servo Motor 15 Nm, 230V 50/60 Hz 1.85 MM10004
Large Servo Motor 15 Nm, 24V 50/60 Hz 1.85 MM10004/D
Small Servo Motor 1.2 Nm, 230V 50Hz 0.55 MM10005
Small Servo Motor 1.2 Nm, 230V 60HZ 0.55 MM10005/B
Small Servo Motor 1.2 Nm, 24V 50Hz 0.55 MM10005/C
Small Servo Motor 1.2 Nm, 24V 60Hz 0.55 MM10005/D
Industrial Servo Motor 05, 230V 4 MM10070
Industrial Servo Motor 05, 120V 4 MM10070/110
Industrial Servo Motor 20, 230V 6 MM10074/B
Industrial Servo Motor 20, 120V 6 MM10074/B/110

729 of 761
EGA Components
E.G.A. Sampling Unit Mk6 with Local Display, 230V 11 MM62004
E.G.A. Sampling Unit Mk6 with Local Display, 110V 11 MM62004/110
E.G.A. Sampling Probe (0-400°C) 1 MM10003
SO2 Sensor + Extra Pump (factory fitted) 0.2 EGA20008
NO Sensor (factory fitted) 0.2 EGA20005
NO2 Sensor (factory fitted) 0.2 EGA20009
EGA Mk6 External Particulate Filter 2 EGA20103
Ceramic Sampling Probe 1 EGA20105
EGA Mk6 High Temp. Thermocouple 4.5 EGA20104
Chilled E.G.A. Enclosure EGAENC
Inverter, Splitter & Interface Modules
O2 Interface Module, 230V 0.65 MM10013
O2 Interface Module, 120V 0.65 MM10013/110

730 of 761
DTI Modules
Data Transfer Interface + Internal Modem, 230V 4.5 DTI60100/MD/230
Data Transfer Interface + Internal Modem, 120V 4.5 DTI60100/MD/110
Data Transfer Interface, 230V 4.5 DTI60100
Data Transfer Interface, 120V 4.5 DTI60100/110
Digital I/O Module, 230V 1 DTI20020
Digital I/O Module, 120V 1 DTI20020/110
Analogue I/O Module, 230V 1 DTI20021
Analogue I/O Module, 120V 1 DTI20021/110
DTI Internal Modem US 0.25 DTI20025
DTI Internal Modem Europe 0.25 DTI20026
PC Software and Accessories
MM Infrared Upload/Download Software and IR Lead 0.13 MM60010
E.G.A. to P.C. Software and Lead 0.5 DTI20018
DTI-PC Communication Lead- Standard Serial Lead 0.25 DTI60022
DTI-PC Communication Line Driver and Lead 0.5 DTI20012

731 of 761
Water Level Control Equipment
Expansion PCB with Extended Housing 0.75 WLCPCBH
Replacement Expansion PCb 0.55 WLCPCB
Capacitance Probe, 20" (500mm) 1.5 WLCP500
Surface Blowdown, TDS Probe and Assemby, 230V 3 TDS60001
Surface Blowdown, TDS Probe and Assembly, 120V 3 TDS60001/110
Flanged Feed Water Valves
Feed Water Valve, PN40, 25mm (1") 7 WLCVO25/FL
Feed Water Valve, PN40, 40mm (1.5") 8 WLCVO40/FL
Feed Water Valve, PN40, 50mm (2") 9 WLCVO50/FL
Feed Water Valve, ANSI 300lb, 1" (25mm) 7 WLCVO25/FLU
Feed Water Valve, ANSI 300lb, 1.5" (40mm) 8 WLCVO40/FLU
Feed Water Valve, ANSI 300lb, 2" (50mm) 9 WLCVO50/FLU
Threaded Feed Water Valves

Feed Water Valve, BSP/NPT Fitting, 0.5" (15mm) 4 WLCVO15
Feed Water Valve, BSP/NPT Fitting, 0.75" (20mm) 5 WLCVO20

732 of 761
Oil Control Valves
Type 1 - Spillback 0.6 OVS31015
Type 1 - Metering 0.6 OVM31015
Type 3 - Spillback 1.8 OVS33L17
Type 3 - Metering 1.8 OVM33L17

733 of 761
Gas Control Valves - Screwed
BSP 25mm (1”) 0.55 GV42521
BSP 40mm (1.5”) 0.7 GV44022
BSP 50mm (2”) 0.74 GV45023
BSP 65mm (2.5”) 0.85 GV46524
BSP 80mm (3”) 0.98 GV48025
NPT 25mm (1”) 0.55 GV42521U
NPT 40mm (1.5”) 0.7 GV44022U
NPT 50mm (2”) 0.74 GV45023U
NPT 65mm (2.5”) 0.85 GV46524U
NPT 80mm (3”) 0.98 GV48025U

734 of 761
Gas Control Valves - 30mm Flanged
PN16 65 mm (2.5”) 5 GVF46526/30
PN16 80 mm (3”) 6 GVF48027/30
PN16 100 mm (4”) 7 GVF410026/30
PN16 125 mm (5”) 8 GVF12527/30
PN16 150 mm (6”) 9 GVF415028/30
ANSI 150lb 65 mm (2.5”) 5 GVF46526/30U
ANSI 150lb 80 mm (3”) 6 GVF48027/30U
ANSI 150lb 100 mm (4”) 7 GVF410026/30U
ANSI 150lb 125 mm (5”) 8 GVF12527/30U
ANSI 150lb 150 mm (6”) 9 GVF415028/30U
Gas Control Valves - 50mm Flanged
PN16 65 mm (2.5”) 9 GVF46526/50
PN16 80 mm (3”) 10 GVF48027/50
PN16 100 mm (4”) 11 GVF410026/50
PN16 125 mm (5”) 12 GVF12527/50
PN16 150 mm (6”) 13 GVF415028/50
ANSI 150lb 65 mm (2.5”) 9 GVF46526/50U
ANSI 150lb 80 mm (3”) 10 GVF48027/50U
ANSI 150lb 100 mm (4”) 11 GVF410026/50U
ANSI 150lb 125 mm (5”) 12 GVF12527/50U
ANSI 150lb 150 mm (6”) 13 GVF415028/50U

735 of 761
Sundires and Spare Parts
M.M./E.G.A. Technical Manual, Hard Copy 1 SP10001
M.M./E.G.A. Technical Manual, CD-ROM 0.1 SP10001/CD
Autoflame Sales Brochure 0.1 SP2000/US
Tamper Proof Screwdriver 0.07 SP10002
Transformer 230V/120V-24V 0.65 SP10003
Ferrite Core Set 0.22 SU10010
Anti Voltage Surge Module 0.15 SU10011
Cables
Screened Cable 1 core 0.05 CAB50001
Sceened Cable 6 core 0.12 CAB50006
Screened Data Cable 1 pair 0.2 CAB50020
Relays
Relay LY2 12V DC 0.04 EC50200
Relay Base 12V 0.05 EC50201
Relay MY 240V AC 0.04 EC50206
Relay Base 240V 0.05 EC50207

736 of 761
MM System Spares
Mk6 EPROMS, Set of 3 0.2 MK6PROMS
Mk6/Mini Mk6 MM Fuse Set, (TE5) 2A (T) 0.1 FU10034
Mk6/Mini Mk6 MM Fuse Set, (TE5) 630mA (T) 0.1 FU10028
Mini Mk5 MM Fuse Set, .315A (T) 0.1 FU10024
Mini Mk5 MM Fuse Set, 630mA (T) 0.1 FU10025
Mk6 MM Connector Plugs 0.5 CON1060
Mk6 Water Level Control Connector Plugs 0.2 CON1065
Mini Mk6 MM Connector Plugs 0.5 CON1064
Mini Mk5 MM Connector Plugs 0.5 CON1063
Mk5 MM Connector Plugs 0.5 CON1050
MM Enclosure Mounting Clamps 0.1 ENC10061
MM Water Level Enclosure and Pillars 0.2 ENC10065
UV Scanner Spares
Replacement Bulb + PCB for MM60003 0.1 SP1036
Replacement Bulb + PCB for MM60003/HS 0.1 SP1036HS
Replacement Bulb + PCB for MM60004/U 0.1 SP1037U
Replacement Bulb + PCB for MM60004/HSU 0.1 SP1037HSU

737 of 761
EGA System Spares
O2 Sensor 0.02 SP10004
CO2 Sensor 0.09 SP10005
NO Sensor 0.04 SP10007
CO Sensor 0.04 SP10008
SO2 Sensor 0.01 SP10013
EGA Pump 230V 0.33 SP10009
EGA Pump 120V 0.33 SP10006
EGA Pump 24V 0.33 SP10010
EGA Replacement Internal Filter 0.06 SP10011
EGA Replacement Sampling Probe Filter 0.15 SP10012
EGA Replacement Particulate Filter 0.06 SP10018
Mk6 EGA Fuse Set 0.1 SP1040
EGA Connector Plugs 0.5 CON1010
EGA Type K Thermocouple only 0.25 SP1044
EGA Type K Thermocouple only 0.25 SP1044/5
EGA Type K Thermocouple only 0.25 SP1044/10
EGA Probe Sample Tube Set 0.01 SP10019
Mk6 EGA Spare Key 0.1 SP1045
Gas/Oil Valve Spares
O-ring Type 1,2,5,6,8,9 Small Oil Valve 0.01 OR70003
O-ring Type 3,4,7 Large Oil Valve 0.01 OR70004

738 of 761
DTI System Spares
Mk6 DTI Fuse Set 0.1 SP1060
Digital I/O Fuse Set 0.1 SP1061
Analogue I/O Fuse Set 0.1 SP1062
Mk6 DTI Connector Plugs 0.5 CON1065
Digital I/O Connector Plugs 0.5 CON1066
Analogue I/O Connector Plugs 0.5 CON1067
Servomotor Spares
Small Servo Fixing Screws 0.01 F5015
Small Servo Mounting Bracket/Coupling 0.5 SP10015
Small Valve to Large Servo Mounting Coupling 0.5 SP10017
Large Servo Fixing Screws 0.01 F6015
Large Servo Mounting Bracket/Coupling 0.5 SP10016
Industrial Servo 05 Mounting Bracket 0.8 SP10028/05

For MM10070
Industrial Servo 10 Mounting Bracket 0.8 SP10028/10

For MM10072
Industrial Servo 20/40 Mounting Bracket 1 SP10028/20

For MM 10074 & MM10078

739 of 761
Demo/Test Equipment
Mk6 MM Water Level Demo Case, 230V 13 MM10022/WL
Mk6 MM Water Level Demos Case, 120V 13 MM10023/WL
Mk6 MM Demo Case, 230V 12 MM10022
Mk6 MM Demo Case, 120V 12 MM10023
Mini Mk6 Demo Case, 230V 12 MM10030
Mini Mk6 Demo Case, 120V 12 MM10030/110
Mini Mk5 Evo Demo Case, 230V 9 MM10032
Mini Mk5 Evo Demo Case, 120V 9 MM10032/110
DTI Demo Case, 230V 12 MM10027
DTI Demo Case, 120V 12 MM10027/110
Mk6 Protection Test Tool 0.5 MM6000TB

740 of 761
Appendix
Section 10: Appendix
10.1 Terms and Conditions
10.3 Patent Number Information Relevant to the System
10.4 International Type Approvals Information
10.5 Conversion Data
10.5.1 Calorific Fuel Data

10.5.2 Gas Volume Conversion Factors
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
Section 10: Index
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
741 of 761
Appendix
10.1 Terms and Conditions
All equipment and services offered and sold by Autoflame Engineering are subject to our published
terms and conditions of business a copy of which is supplied with each consignment of goods and a
copy of which will be supplied seperately on request.
All terms and conditions are subject to English law.

742 of 761
Appendix
10.3 Patent Numbers Relevant to the System
Patent Number: Product: Applicable Country:
US6,024,561 UV Scanner USA
CA2,295,458 UV Scanner Canada (pending)
EP1,022,515 UV Scanner Europe- U.K.

Germany
France
Holland
Italy
02138610 M.M. U.K.

Australia
1317356 M.M. Canada
02169726 E.G.A. U.K.
00195866 E.G.A. Europe- U.K.

Switzerland
Belgium
France
Germany
Holland
Luxembourg
Sweden
GB97 15898.4 Mk6 Worldwide
PCT/GB97/02010 Mk6 Worldwide
GB97 15899.2 Mk6 U.K.
GB97 15900.8 Mk6 U.K.
US6,520,122 Water Level Control USA

Turbulence (pending)
EP1,384,944 Water Level Control Europe- U.K.

Turbulence Germany
France
Holland
Italy

743 of 761
Appendix
10.3 Patent Numbers Relevant to the System
Patent Number: Product: Applicable Country:
EP1,373,796 Steam Flow Metering Europe- U.K.

Germany
France
Holland
Italy
EP1,384,945 Capacitance Probes Europe- U.K.

Germany
France
Holland
Italy
EP1,384,946 Feedwater Flow Europe- U.K.

Germany
France
Holland
Italy
US6,978,741 Total Dissolved Solids (TDS) USA
GB04 15052.0 Total Dissolved Solids (TDS) UK (pending)
EP05 252163.0 Total Dissolved Solids (TDS) Europe (pending)

744 of 761
Appendix

745 of 761
Appendix

746 of 761
Appendix

747 of 761
Appendix

748 of 761
Appendix

749 of 761
Appendix
10.3 Product Approvals to the System
Approval Component
USR/CNR Mk6 or mini Mk6 primary safety control system with No:
MM60003/U, MM60004/U or MM60001 sensor sensor
MM60001/EW combination primary safety control/limit control with No:

MM60001, MM60003/U or MM60004/U flame sensor
Actuator assemblies, parts MM10004 and MM10005
Oil valves and gas valves sections- 10.4.8 and 10.4.9 remain the same
USL/CUL Listed Mk6 Evo/Water Level

Mini Mk5 Evo
Mini Mk5
TDS probe
Control Panels
Actuators
EN298 2003 Mk6 Evo

Mk6
Mini Mk5 Evo
EN230:2004 Mk6 Evo

Mk6
Mini Mk6
FM Mk6 Evo with Water Level control

Mk6
Mini Mk6
PED(97/23/EC) Water Level probes

(Pren12953.9)

750 of 761
Appendix

751 of 761
Appendix

752 of 761
Appendix

753 of 761
Appendix

754 of 761
Appendix

755 of 761
Appendix

756 of 761
Appendix

757 of 761
Appendix

758 of 761
Appendix

759 of 761
Appendix Conversion Data
10.5 CONVERSION DATA
10.5 .1 Calorific Fuel Data
Stats Kerosene Gas Oil Light fuel Oil Medium fuel Heavy Fuel Oil
SG CI/SH SG Oil SG SG
Relative density 0.79 0.835 0.93 0.94 0.96
15.6°C (60°F) approx.
/ = litres x = kg
Flash point (closed) min °C (°F) 37.8 (100) 65.6 (150) 65.6 (150) 65.6 (150) 65.6 (150)
Viscosity kinematic (cSt) at - - - - -
15.6°C (60°F) approx. 2.0 - - - -
37.8°C (100°F) approx. - 3.0 - - -
82.2°C (180°F) approx. - 12.5 30 70
Equivalent Redwood No.1 - 33 approx 250 max 1000 max 3500 max
Viscosity at 37.8°C (100°F)
Freezing point °C / °F Below -40 Below -40 Below -40 Below -40 Below -40
Cloud point °C max - -2.2 - - -
Gross calorific values
KJ/kg approx. 46,520 45,590 43,496 43,030 42,800
Btu/ib approx. 20,000 19,600 18,700 18,500 18,400
KWh/litre approx. 10.18 10.57 11.28 11.22 11.42
Therms/gallon approx. 1.58 1.64 1.75 1.74 1.77
kW/kg - 12.66 12.08 - 11.89
Sulphur content % wt. 0.2 0.6 2.3 2.4 2.5
Water content % vol. Negligible 0.05 0.1 0.20 0.30
Sediment content % wt - Negligible 0.2 0.03 0.04
Ash content % wt - Negligible 0.02 0.03 0.04
Mean specific heat between
0°C - 100°C approx. 0.50 0.49 0.46 0.45 0.45
Volume correction factor per 1°C 0.00083 0.00083 0.00070 0.00070 0.00068
Volume correction factor per 1°F 0.00046 0.00046 0.00039 0.00039 0.00038
Btu/U.S. gallon (US standard) - 140,000 - 150,000 160,000
Lb/U.S. gallon (US standard) - 7.01 - - 7.01
% lighter than water 20% 4%
1 u.s. Gallon of oil / ft of air 1402
Conversion Factor for Imperial Gas Flow Meters
Required Data: Pressure of gas at meter in “wg

Required gas flow in ft³/min
Calculations: Correction factor = (pressure of gas at meter x 0.00228 ) + 0.948

Reading on gas meter = Required gas flow / correction factor
Example: Pressure of gas at meter = 58” wg

Required gas flow = 95 ft³/min
Conversion factor = (58 x 0.00228) + 0.948 = 1.08
Reading on Meter = 95 / 1.08 = 88 ft³/min
Correction Factor for burners significantly above sea level. I.e. >200m (1 ft = 0.3048m)
Height above sea level in meters, Calculation for correction factor: =
(Pressure of gas at meter x 0.00228) + (0.948 – (height above sea level x 0.0001075))
Example: As above but 250 m above sea level:

• Correction factor = (58x0.00228) + (0.948 – (250 x 0.0001075)) = 1.05

760 of 761
Appendix Conversion Data
10.5 .2 Gas Volume Conversion Factors - Measured conditions to standard reference
Assumed gas temperature 10 °C 50 °F

Standard pressure 760 mmHg 101.3612 Kpa
Standard temperature 15.56 °C
Ambient pressure 101.325 Kpa
"Wg PSI mmH2O mmHg Kpa Millibar Conversion factor
1 0.036 25.4 1.867 0.249 2.490 1.0218
2 0.072 50.8 3.734 0.498 4.980 1.0243
3 0.108 76.2 5.601 0.747 7.470 1.0268
4 0.144 101.6 7.468 0.996 9.960 1.0293
5 0.181 127.0 9.335 1.245 12.451 1.0318
6 0.217 152.4 11.202 1.494 14.941 1.0343
7 0.253 177.8 13.069 1.743 17.431 1.0368
8 0.289 203.2 14.936 1.993 19.921 1.0393
9 0.325 228.6 16.804 2.242 22.411 1.0418
10 0.361 254.0 18.671 2.491 24.901 1.0443
15 0.542 381.0 28.006 3.736 37.352 1.0569
20 0.722 508.0 37.341 4.981 49.802 1.0694
25 0.903 635.0 46.677 6.227 62.253 1.0819
30 1.083 762.0 56.012 7.472 74.703 1.0944
35 1.264 889.0 65.347 8.717 87.154 1.1070
40 1.444 1016.0 74.682 9.963 99.604 1.1195
45 1.625 1143.0 84.018 11.208 112.055 1.1320
50 1.805 1270.0 93.353 12.453 124.505 1.1445
55 1.986 1397.0 102.688 13.699 136.956 1.1571
60 2.166 1524.0 112.024 14.944 149.406 1.1696
65 2.347 1651.0 121.359 16.189 161.857 1.1821
70 2.527 1778.0 130.694 17.435 174.307 1.1947
75 2.708 1905.0 140.030 18.680 186.758 1.2072
80 2.889 2032.0 149.365 19.925 199.208 1.2197
85 3.069 2159.0 158.700 21.171 211.659 1.2322
90 3.250 2286.0 168.035 22.416 224.109 1.2448
95 3.430 2413.0 177.371 23.661 236.560 1.2573
100 3.611 2540.0 186.706 24.907 249.010 1.2698
110 3.972 2794.0 205.377 27.397 273.911 1.2949
120 4.333 3048.0 224.047 29.888 298.812 1.3199
130 4.694 3302.0 242.718 32.379 323.713 1.3450
140 5.055 3556.0 261.388 34.869 348.614 1.3700
150 5.416 3810.0 280.059 37.360 373.515 1.3951
160 5.777 4064.0 298.730 39.851 398.416 1.4201
170 6.138 4318.0 317.400 42.341 423.317 1.4452
180 6.499 4572.0 336.071 44.832 448.218 1.4703
190 6.860 4826.0 354.741 47.323 473.119 1.4953
200 7.221 5080.0 373.412 49.813 498.020 1.5204
How to use this information:-

1. Measure Volumetric flow of gas for 1min in ft3 (i.e. ft3/min). Note 1m3 = 35.31ft3
2. Multiply this volume flow by 60 to give volumetric flow per hour (i.e. ft3/hr).
3. Measure the pressure of the gas supply.
4. Use the table above to obtain a conversion factor.
5. Multiply the volume flow per hour by the conversion factor to obtain a volume at reference conditions.
6. For natural gas, the calorific value is typically 1000 Btu/ft3. To obtain the firing rate of the boiler at
standard reference conditions multiply the volume at reference conditions by 1000.
Represented as an equation:-
Firing rate = ( Measured Volumetric flow per minute * 60 * Conversion factor * 1000 ) Btu/hr

761 of 761
Appendix

Commissioning &amp; Operation Maintenance Guide

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Commissioning &amp; Operation Maintenance Guide

Uploaded by

Copyright:

Available Formats

1 of 761

PRINCESS NOURA BINT ABDULRAHMAN UNIVERSITY FOR WOMEN

Testing-Comissioning & Operation-Maintenance

II BOILER WIRING DIAGRAM 4

III OPERATION & MAINTENANCE MANUALS

3.1 Hurst Boiler & Welding Co. 5

3.2 McDonnell & Miller 41

3.5 Tuthill Pump Group 156

3.6 Atlas Copco 181

3.7 Cashco Co. 256

3.8 Maxitrol Co. 273

3.9 Siemens 280

3.10 Mercoid 298

3.11 Autoflame 303

3.1 HURST Boiler & Welding Co.

Operation & Maintenance Manual

Hurst Boiler & Welding Company, Inc.

Hurst Boiler & Welding Company, Inc.

877-99HURST – Toll Free

START UP, OPERATION & MAINTENANCE

GENERAL FEATURES OF YOUR HURST BOILER

Connections that are specific to Steam Boilers:

Connections that are specific to Hot Water Boilers:

CLEANING – BOIL OUT

Hot Water boilers:

PRE START-UP – STEAM

PRE START-UP – HOT WATER

Satisfactory operation of yo ur boiler system depends on attention to details. The following

STARTING FROM COLD

8:00 AM meter reading = 1020 gallons

At 85% efficiency, = 3,920,000 x .85 = 3,332,000 Btuh (output)

1 Boiler HP = 33,475 Btuh (output), So, 3,332,000/33475 = 99.5 HP

8:00 AM meter reading = 5000

Assuming a pressure correction factor or 1.324,

Multiply 40 x 3600 x 1.324 x 1.020 = 194,469

2160.8 x 1000 = 2,160,800 Btu (input)

At 82% efficiency = 2,160,800 x .82 = 1,771,856 (output)

1 Boiler Horsepower = 33,475 Btuh (output)

So, 1,771,856 / (33475 x 1.5) = 35.3 HP

GAS PRESSURE CORRECTION FACTORS

PSIG Meter Base Pressure

GAS TEMPERATURE CORRECTION FACTORS

Gas Meter Calibration Temperature

ATMOSPHERIC PRESSURE 14.4 PSI

OPERATION – STEAM (Gas or Oil fired)

FIRING RATE CONTROLLER:

HIGH WATER ALARM:

OPERATION – HOT WATER (Gas or Oil fired)

DAILY operational check of this device is a must

FIRING RATE CONTROLLER

HIGH TEMPERATURE CUTOFF:

Hot Water Boilers:

The importance of maintenance cannot be overemphasized when discussing boiler operations.

u Sweep or wash down the floor

u Verify the operation of the steam pressure controls (steam)

SEMI ANNUALLY OR ANNUALLY:

Some recommendations for conditions of acceptable boiler water are:

Oxygen <.007 ppm

Hot Water Boilers:

SATURATED STEAM PROPERTIES

American Society of Mechanical Engineers (ASME)

American National Standards Institute (ANSI)

Canadian Standards Association (CSA)

Canadian Gas Association (CGA)

Commissioning & Operation Maintenance Guide

Commissioning & Operation Maintenance Guide