Combustion Management Systems

AUTOFLAME
SENSORS GUIDE

04.08.2020
 Autoflame Engineering Ltd.
Unit 1-2 Concorde Business Centre
Airport Industrial Estate
Combustion Management Systems Wireless Road, Biggin Hill
Kent TN16 3YN
United Kingdom
Tel: +44 (0)1959 578 820
Email: [email protected]
Web: www.autoflame.com

AUTOFLAME
SENSORS GUIDE

04.08.2020

This manual and all the information contained herein is copyright of Autoflame Engineering Ltd. It may not be
copied in the whole or part without the consent of the Managing Director.

Autoflame Engineering Ltd’s policy is one of continuous improvement in both design and manufacture. We
therefore reserve the right to amend specifications and/or data without prior notice. All details contained in this
manual are correct at the time of going to print.
Important Notes

A knowledge of combustion related procedures and commissioning is essential before embarking work on any
of the MM/EGA systems. This is for safety reasons and effective use of the MM/EGA system. Hands on training
is required. For details on schedules and fees relating to group training courses and individual instruction,
please contact the Autoflame Engineering Ltd. offices at the address listed on the front.

Short Form - General Terms and Conditions

A full statement of our business terms and conditions are printed on the reverse of all invoices. A copy of these
can be issued upon application, if requested in writing.

The System equipment and control concepts referred to in this Manual MUST be installed, commissioned and
applied by personnel skilled in the various technical disciplines that are inherent to the Autoflame product
range, i.e. combustion, electrical and control.

The sale of Autoflame’s systems and equipment referred to in this Manual assume that the dealer, purchaser
and installer have the necessary skills at their disposal. i.e. A high degree of combustion engineering
experience, and a thorough understanding of the local electrical codes of practice concerning boilers, burners
and their ancillary systems and equipment.

Autoflame’s warranty from point of sale

• Two years on all electronic and electro-mechanical equipment, assemblies and components.
• One year on all EGA systems and UV & IR scanners, including parts, components, cells 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.
IMPORTANT SAFETY NOTES
Autoflame sensors must only be installed, wired, commissioned or
adjusted by an Autoflame trained and certified technician. !
Any person installing, wiring, commissioning or adjusting the sensors
without undergoing proper Autoflame training and without full understanding of the Micro
Modulation (MM) system may put themselves and others in a seriously dangerous
situation that can result in serious injury or even death, and may cause permanent
equipment failure and substantial property damage.

Some of the wiring connections are live, make sure to totally and safely isolate the mains
power before undergoing any work related to the sensors. Failure to do so can result in
fatal injury.

It is the responsibility of the commissioning technician to ensure that all relevant Valve
Proving System (VPS) and air pressure proving standards are adhered to.

This guide must be read in conjunction with the relevant MM system manual.
Contents

1. AUTOFLAME SENSORS............................................................................................................... 6
2. GAS & AIR PRESSURE SENSORS (MK8 SERIES) .................................................................... 7
2.1. Installation ........................................................................................................................................ 10
2.2. Mk8 MM Gas Pressure Sensor Applications ................................................................................... 13
2.2.1. VPS / Pressure Limits with Vent Valve ............................................................................. 13
2.2.2. VPS / Pressure Limits, No Vent Valve.............................................................................. 14
2.2.3. VPS / Pressure Limits with Vent Valve, Single Valve Pilot............................................... 14
2.2.4. VPS / Pressure Limits, No Vent Valve, Single Valve Pilot ............................................... 15
2.2.5. External VPS .................................................................................................................... 15
2.3. Mini Mk8 MM Gas Pressure Sensor Applications ........................................................................... 16
2.3.1. VPS / Pressure Limits with Vent Valve ............................................................................. 16
2.3.2. VPS/ Pressure Limits, No Vent Valve............................................................................... 17
2.3.3. VPS / Pressure Limits with Vent Valve, Single Valve Pilot............................................... 17
2.3.4. VPS / Pressure Limits, No Vent Valve, Single Valve Pilot ............................................... 18
2.3.5. VPS Using Low Pressure Switch ...................................................................................... 18
2.3.6. External VPS .................................................................................................................... 19
2.4. Valve Proving Time and Pressure Change ..................................................................................... 20
2.5. Combustion Air Pressure Proving ................................................................................................... 22
2.6. Draft Pressure Control – Mk8 MM ................................................................................................... 23
2.7. Gas / Air Pressure Monitoring with Mk8 DTI ................................................................................... 24
3. OIL PRESSURE SENSOR ........................................................................................................... 25
3.1. Dimensions ...................................................................................................................................... 26
5.2. Installation ........................................................................................................................................ 26
4. STEAM PRESSURE SENSOR .................................................................................................... 27
4.1. Dimensions ...................................................................................................................................... 28
4.2. Installation ........................................................................................................................................ 29
5. TEMPERATURE SENSOR .......................................................................................................... 30
5.1. Dimensions ...................................................................................................................................... 32
5.2. Temperature Sensor’s Applications ................................................................................................. 33
6. OUTSIDE TEMERATE COMPENSATION .................................................................................. 35
6.1. Outside Temperature Sensor .......................................................................................................... 37
6.2. Outside Temperature Compensation Module.................................................................................. 38
Annex: IP Ratings ............................................................................................................................... 40
1 Autoflame Sensors

1. AUTOFLAME SENSORS

Autoflame offers the following range of sensors for use with the Mk8 and Mini Mk8 MM systems:

• Air pressure sensors.

• Gas pressure sensors.
• Oil pressure sensors.
• Temperature sensors.
• Steam pressure (load) sensors.
• Outside temperature sensors.

The picture below illustrates some of the applications of these sensors on a steam boiler.

Steam Pressure
Air Pressure Sensor (Load) Sensor
for Draft Control

Combustion Air
Pressure Sensor

Gas Pressure Sensor

(VPS / Gas Pressure Limits)

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2 Gas & Air Pressure Sensors (Mk8 Series)

2. GAS & AIR PRESSURE SENSORS (MK8 SERIES)

Gas pressure sensors can be used for the following purposes:

• Gas Valves Proving System (VPS) and/or gas pressure limits when used with an MM system.
• Gas pressure limits only when used with an MM system.

Air pressure sensors can be used for the following purposes:

• Combustion air pressure proving when used with an MM system.

• Draft pressure control when used with the Mk8 MM.

The gas and air pressure sensors can also be used for gas / air pressure monitoring application when used
with the Mk8 DTI.

Specifications
IP Rating 65
NEMA Rating 4
Check type Self-check
Channels Dual channel
Communication Digital (RS485) and analogue
Max. Operating Temperature 85°C (185°F)
Min. Operating Temperature -25°C (-13°F)
Housing Aluminium
Wiring connection 2m (6.5ft) flying lead, pre-wired, screened
Installation 90° vertical (+/-10°)
Pressure measuring port ¼” parallel NPT / BSP female
Differential pressure port 1/8” parallel NPT / BSP female
Supplied with ¼” tapered NPT / BSP male nipple
Flying lead connector torque 1 to 3Nm max. tighten by hand only, do not over-tighten
Warranty 2 years limited warranty

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2 Gas & Air Pressure Sensors (Mk8 Series)

Gas and Air Pressure Sensors Range

Gas Pressure Sensors Range

Pressure Range Zero Range

Part #
mbar “wg PSI mbar “wg PSI
MM80006 ±68 ±27 ±1 ±1.36 ±0.54 ±0.02
MM80008 ±344 ±138 ±5 ±6.88 ±2.76 ±0.1
MM80011 ±1034 ±415 ±15 ±20.68 ±8.3 ±0.3
MM80012 ±2068 ±831 ±30 ±41.36 ±16.62 ±0.6
MM80014 ±6894 ±2770 ±100 ±137.88 ±55.4 ±2

Air Pressure Sensors Range

Pressure Range Zero Range

Part #
mbar “wg PSI mbar “wg PSI
MM80005 ±68 ±27 ±1 ±1.36 ±0.54 ±0.02
MM80013 ±137 ±55 ±2 ±2.74 ±1.1 ±0.04

ATEX Certified Gas and Air Pressure Sensors

An ATEX approved range of the gas and air pressure sensors is also available for use in
Hazardous Environments application where Explosion Proof equipment is required.

Classification: Ex Na IIC Gc

ATEX Certified Gas Pressure Sensors Range

Pressure Range Zero Range

Part #
mbar “wg PSI mbar “wg PSI
MM80006/EXP ±68 ±27 ±1 ±1.36 ±0.54 ±0.02
MM80008/EXP ±344 ±138 ±5 ±6.88 ±2.76 ±0.1
MM80011/EXP ±1034 ±415 ±15 ±20.68 ±8.3 ±0.3
MM80012/EXP ±2068 ±831 ±30 ±41.36 ±16.62 ±0.6
MM80014/EXP ±6894 ±2770 ±100 ±137.88 ±55.4 ±2

ATEX Certified Air Pressure Sensors Range

Pressure Range Zero Range

Part #
mbar “wg PSI mbar “wg PSI
MM80005/EXP ±68 ±27 ±1 ±1.36 ±0.54 ±0.02
MM80013/EXP ±137 ±55 ±2 ±2.74 ±1.1 ±0.04

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2 Gas & Air Pressure Sensors (Mk8 Series)

Gas / Air Pressure Sensor’s Ports

The sensor has 2 pressure ports:

• Gas/ air pressure measuring port: used to measure the gas / air pressure.
• Differential pressure port: used as a reference to measure the atmospheric pressure, therefore it
should always be exposed to atmospheric pressure.

Gas / Air Pressure Sensor’s Selection

When selecting a gas pressure sensor for a specific application, it is necessary that the sensor’s measuring
range should be the closest to the gas pressure range of the application.

For example; a gas pressure sensor is required for the purpose of valve proving and gas pressure limits for a
boiler with maximum gas pressure supply of 170mbar, therefore MM80008 should be selected. MM80011,
MM80012, MM80014 or MM80006 should not be used.

Wiring Gas / Air Pressure Sensor to an MM

For the purpose of VPS, gas pressure limits and air pressure proving, the sensors can be wired as follows:

Wire Colour Mk8 MM Terminal Mini Mk8 MM Terminal

Brown RS485 - 31 29
Purple RS485 + 32 30
Blue 0V DC 33 48
Red 15V DC 34 49
Screen Do not connect at MM side

The screen wire on the flying lead is only used when connecting the sensor’s lead to the MM / DTI through a
terminal block, it must not be connected on the MM / DTI side.

Drawing and Dimensions

All dimensions in mm, 1 inch = 25.4mm.

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.1. Installation

The pressure sensor must be installed at a vertical angle, perpendicular to the gas/air flow direction.

When the gas pressure sensor is used for gas pressure limits or valve proving, the sensor should measure
regulated gas pressure, therefore it should be installed after the gas pressure regulator (governor).

It is recommended to connect the differential pressure port to atmospheric pressure outside the boiler house,
as the pressure inside the boiler house could differ from atmospheric pressure. this can be done by piping the
port to a vent inside the boiler house that is exposed to atmospheric pressure or using a pipe to connect the
port to the atmosphere outside the boiler house.

It is recommended to connect the gas sensor using a pigtail pipe to prevent moisture traveling to the sensor.

IP Rating of the Gas & Air Pressure Sensors

The gas / air pressure sensor is rated IP65 / NEMA 4, and can be safe for external use providing that the
following conditions are met;

• The flying lead is tightened according to specifications, over tightening the flying lead connector can
cause damage to the seal and therefore the IP65 rating will not apply.
• The sensor’s pressure measuring port should be connected to the gas pipe/air duct using tapered
thread NPT connector, PTFE tape should be used to seal the thread connection and the connection
must be tightened according to the specifications.
• The sensor’s differential pressure port should be piped using tapered thread NPT connector, PTFE
tape should be used to seal the thread and the connection must be tightened according to the
specifications, make sure this pipe is always dry / free from water, moisture and dust.

The gas pressure sensor is rated IP52 / NEMA 3 if the atmospheric pressure port is not piped, the supplied
plastic plug must be secured in place. Please check the Annex at the end of this manual for the explanation of
different IP ratings.

Figure 1.1. Correct Installation of the Gas Sensor

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2 Gas & Air Pressure Sensors (Mk8 Series)

Figure 1.2. Correct Installation of the Gas Pressure Sensor for IP65 / NEMA4 rating

IP52 installation – Differential Pressure port is not IP65 installation – Differential pressure port is piped
piped (plastic cap must be placed)

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2 Gas & Air Pressure Sensors (Mk8 Series)

Air Pressure Sensor Differential Pressure

The Autoflame Air Pressure Sensor has a differential pressure port, this can be installed as shown below to
measure a differential pressure. This is necessary where the air pressure at low fire is below 1 mbar (0.4 "wg)
or when it is a local code requirement. It is also necessary if IP65 protection rating for the sensor is required
when using the sensor for outdoor applications for example.

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.2. Mk8 MM Gas Pressure Sensor Applications

Autoflame Gas Pressure Senor can be used with the Mk8 MM for the purpose of Valve Proving System (VPS)
or Gas Pressure Limits or both at the same time.

The following options/parameters are related to the operation of the gas pressure sensor:

Option / Parameter Mk8 MM

125 Fuel pressure sensor mode – fuel 1
126 Fuel pressure sensor mode – fuel 2
127 Fuel pressure sensor mode – fuel 3
128 Fuel pressure sensor mode – fuel 4
129 VPS operation
130 Gas valve configuration
132 Gas valve proving time
133 Maximum pressure change allowed during VPS
134 VPS valve opening time
136 Gas pressure switch – offset lower limit
137 Gas pressure switch – offset upper limit
Parameter 41 Gas pressure units

2.2.1. VPS / Pressure Limits with Vent Valve

Setting for
Option /Parameter Option #
VPS / Pressure Limits Gas Pressure Limits
125 (Fuel 1)
126 (Fuel 2) 1 - pressure Limits, Valve
Fuel Pressure Sensor Mode 2 - Pressure Limits
127 (Fuel 3) Proving
128 (Fuel 4)
1 - Vent Normally Closed
Gas Valve Configuration 130
2 - Vent Normally Open

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.2.2. VPS / Pressure Limits, No Vent Valve

Setting for
Option /Parameter Option #
VPS / Gas Pressure Limits Gas Pressure Limits
125 (Fuel 1)
126 (Fuel 2) 1 - pressure Limits, Valve
Fuel Pressure Sensor Mode 2 - Pressure Limits
127 (Fuel 3) Proving
128 (Fuel 4)
Gas Valve Configuration 130 0 – No vent valve

2.2.3. VPS / Pressure Limits with Vent Valve, Single Valve Pilot

Setting for
Option / Parameter Option #
VPS / Gas Pressure Limits Gas Pressure Limits
125 (Fuel 1)
126 (Fuel 2) 1. pressure Limits, Valve
Fuel Pressure Sensor Mode 2. Pressure Limits
127 (Fuel 3) Proving
128 (Fuel 4)
4. Vent Normally Closed, Single Valve Pilot.
Gas Valve Configuration 130
5. Vent Normally Open, Single Valve Pilot .

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.2.4. VPS / Pressure Limits, No Vent Valve, Single Valve Pilot

Setting for
Option / Parameter Option #
VPS / Gas Pressure Limits Gas Pressure Limits
125 (Fuel 1)
126 (Fuel 2) 1. pressure Limits, Valve
Fuel Pressure Sensor Mode 2. Pressure Limits
127 (Fuel 3) Proving
128 (Fuel 4)
Gas Valve Configuration 130 3. No Vent Valve, Single Valve Pilot.

2.2.5. External VPS

Autoflame gas pressure sensor is not used.

Option / Parameter Option # Setting for VPS

125 (Fuel 1)
126 (Fuel 2)
Fuel Pressure Sensor Mode 3. External VPS
127 (Fuel 3)
128 (Fuel 4)

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.3. Mini Mk8 MM Gas Pressure Sensor Applications

If the Valve Proving System (VPS) facility is to be used then specific options/parameters must be set.

Option / Parameter Mini Mk8 MM

125 Fuel pressure sensor mode – fuel 1
126 Fuel pressure sensor mode – fuel 2
128 VPS sensor type
129 VPS operation
130 Gas valve configuration
131 Gas pressure units
132 Gas valve proving time
133 Maximum change allowed during proving time
134 VPS valve opening time
136 Gas pressure switch – offset lower limit
137 Gas pressure switch – offset upper limit
138 Gas static line pressure lower limit offset
156 Terminal T82 function

2.3.1. VPS / Pressure Limits with Vent Valve

Setting for
Option /Parameter Option #
VPS / Pressure Limits Gas Pressure Limits
125 (Fuel 1) 1. pressure Limits, Valve
Fuel Pressure Sensor Mode 2. Pressure Limits
126 (Fuel 2) Proving
VPS Sensor Type 128 1. Pressure Sensor
1. Vent Normally Closed
Gas Valve Configuration 130
2. Vent Normally Open

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.3.2. VPS/ Pressure Limits, No Vent Valve

Setting for
Option /Parameter Option #
VPS / Gas Pressure Limits Gas Pressure Limits
125 (Fuel 1) 1 - pressure Limits, Valve
Fuel Pressure Sensor Mode 2 - Pressure Limits
126 (Fuel 2) Proving
VPS Sensor Type 128 1. Pressure Sensor
Gas Valve Configuration 130 0. No vent valve

2.3.3. VPS / Pressure Limits with Vent Valve, Single Valve Pilot

Setting for
Option / Parameter Option #
VPS / Gas Pressure Limits Gas Pressure Limits
125 (Fuel 1) 1. pressure Limits, Valve
Fuel Pressure Sensor Mode 2. Pressure Limits
126 (Fuel 2) Proving
VPS Sensor Type 128 1. Pressure Sensor
4. Vent Normally Closed, Single Valve Pilot.
Gas Valve Configuration 130
5. Vent Normally Open, Single Valve Pilot .

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.3.4. VPS / Pressure Limits, No Vent Valve, Single Valve Pilot

Setting for
Option / Parameter Option #
VPS / Gas Pressure Limits Gas Pressure Limits
125 (Fuel 1) 1. pressure Limits, Valve
Fuel Pressure Sensor Mode 2. Pressure Limits
126 (Fuel 2) Proving
VPS Sensor Type 128 1. Pressure Sensor
Gas Valve Configuration 130 3. No Vent Valve, Single Valve Pilot.

Note: Void to boiler phase is done via

the pilot valve.

2.3.5. VPS Using Low Pressure Switch

Option / Parameter Option # Setting for VPS

125 (Fuel 1)
Fuel Pressure Sensor Mode 1. Valve Proving, Pressure Limits
126 (Fuel 2)
VPS Sensor Type 128 0. Mains Input
Terminal 82 Function 156 1. Valve Proving Mains Input

Note: During VPS, the input on terminal 82

should be on during the VPS air proving and
gas proving phases, and at all other VPS
phases, the input to terminal 82 should be
off. The pressure detected is the static line
pressure, so the pressure switch should be
set at a value just below this line pressure.
When the burner is firing, terminal 82 is not
checked.

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.3.6. External VPS

Option / Parameter Option # Setting for VPS

125 (Fuel 1)
Fuel Pressure Sensor Mode 1. Valve Proving, Pressure Limits
126 (Fuel 2)
VPS Sensor Type 128 0. Mains Input

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.4. Valve Proving Time and Pressure Change

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.

Valve Proving Time:

𝑙𝑙𝑙𝑙 × 𝑃𝑃𝑃𝑃
𝑉𝑉𝑉𝑉𝑉𝑉 = 4 × �� � + 1�
𝑀𝑀𝑀𝑀𝑀𝑀 ÷ 1000

Vpt Valve proving time in seconds.

Ip Inlet pressure in millibars.
Pv Pipe volume in litres (volume = πr2 x length, total volume of any interconnecting pipe
between valve seals)
Mtp Maximum gas throughput in litres per hour.

Pressure change:

𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑐𝑐ℎ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 0.25 × 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚)

Example

Valve proving time:

Inlet pressure = 50 mbar

Pipe volume = 5 litres
Max gas flow = 100,000 litres per hour

50 × 5
𝑉𝑉𝑉𝑉𝑉𝑉 = 4 × �� � + 1�
100,000 ÷ 1000

𝑉𝑉𝑉𝑉𝑉𝑉 = 14𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠

Set option and parameter 132 = 15 seconds

Note: option 132 is set in increments of 5 seconds, values must be rounded up.

Pressure change:

Inlet pressure = 50 mbar

𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑐𝑐ℎ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 0.25 × 50 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚

Set option and parameter 133 = 12.5 mbar

Note: This is a metric formula, therefore imperial units must be converted before applying this calculation.

Conversion PSI to mbar Ft3 to Litres Ft3/hr to Litres

Multiplier 68.94. 28.31 28.31

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2 Gas & Air Pressure Sensors (Mk8 Series)

Mk8 MM Gas Valve Proving / Oil High-Low Pressure Limits Diagram

The figure above shows the sequence for the Mk8 MM gas valve proving and high/low pressure limits using
an Autoflame gas sensor.

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.5. Combustion Air Pressure Proving

For the purpose of air pressure proving, the air pressure sensor can be wired as follows:

Wire Colour Mk8 MM Terminal Mini Mk8 MM Terminal

Brown RS485 - 31 29
Purple RS485 + 32 30
Blue 0V DC 33 48
Red 15V DC 34 49
Screen Do not connect at MM side

The screen wire on the flying lead is only used when connecting the sensor’s lead to the MM / DTI through
terminal block, it must not be connected on the MM / DTI side.

To use the air pressure sensor for combustion air pressure proving on an MM system, the following options /
parameters must be set:

Mk8 MM Mini Mk8 MM

Air proving pressure threshold for purge 141 141
Air pressure error window 147 147
Air pressure sensor type 148 148
Air proving pressure threshold 149 149
Air pressure sensor units Parameter 43 146

Note:
1. Position 2 must be 0.25”wg (0.62 mbar) higher than position 1.
2. Minimum pressure in normal run mode must be higher than position 2.
3. Position 8 must be set equal to position 2 or higher.
4. Default settings for minimum and maximum is 15% above and below entered value.

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.6. Draft Pressure Control – Mk8 MM

The air pressure sensor can be used with the Mk8 MM for the purpose of controlling the boiler’s draft pressure.
Please see the Mk8 MM manual for full details.

Draft Control is used to manage the excess draft from stacks, so heat transfer from the hot gases to the boiler
tubes can be optimised. The MM draft control stores the pressure conditions at the commissioning stage and
modulates with the firing curve to maintain this, irrespective of changing firing rate and stack conditions.

Wiring

Wire Colour Mk8 MM Terminal

Brown RS485 - DT-
Purple RS485 + DT+
Blue 0V DC DP-
Red 15V DC DP+
Screen Do not connect at MM side

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2 Gas & Air Pressure Sensors (Mk8 Series)

2.7. Gas / Air Pressure Monitoring with Mk8 DTI

The Mk8 DTI allows monitoring gas and air pressure throughout the boiler house. Up to ten Mk8 gas pressure
sensors, Mk8 air pressure sensors or any combination of both can be connected to the DTI. The DTI stores 3
years of pressure readings data. Live readings can be seen via the DTI’s display as well as the logged history
data.

Please see the Mk8 DTI manual for further information.

Wiring

Wire Colour Mk8 DTI Terminal

Brown RS485 -
Purple RS485 +
Blue 15V DC +
Red 15V DC -
Black S

The Pressure Sensor screen on the DTI displays the status of all the sensors connected directly to the DTI.
This screen also provides history graphs for the logged data.

Pressure Sensor Screen on the DTI

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3 Oil Pressure Sensor

3. OIL PRESSURE SENSOR

Autoflame oil pressure sensor can be used with the Mk8 MM for the purpose of checking the running oil
pressure and setting up pressure limits when firing on liquid fuels.

Specifications
Part # MM60009
Compatibility Mk8 MM only
Output Signal 1-6V
IP rating 65
NEMA rating 4X
Valve material Stainless Steel
O-Ring material Viton
Operating Temperature -25 to 85 °C (-13 to 185 °F)
Media Temperature -25 to 125 °C (-13 to 257 °F)
Operating Range 0 to 40 Bar (0 to 600 PSI)
Over Pressure Rating 80 Bar (1160 PSI)
Burst Pressure Rating 290 Bar (4350 PSI)
Connection ¼” NPT Parallel female
Fitting Size M19
Fitting torque 25Nm
Lead 1.5m (5ft) prewired with waterproof protective conduit
Warranty 2 year limited warranty

Wiring

Wire Colour Mk8 MM Terminal

White 2 35
Blue 3 48
Brown 1 49
Screen Do not connect on the MM side

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3 Oil Pressure Sensor

3.1. Dimensions

5.2. Installation

To use the oil pressure sensor with a Mk8 MM, the following options/parameters must be set:

Option/Parameter Mk8 MM
125 Fuel pressure sensor mode – fuel 1
126 Fuel pressure sensor mode – fuel 2
127 Fuel pressure sensor mode – fuel 3
128 Fuel pressure sensor mode – fuel 4
139 Oil pressure switch – offset lower limit
140 Oil pressure switch – offset upper limit
Parameter 42 Oil pressure units

• Plug fits correctly in one position only, do not force.

• Do not use case to tighten pressure connection.

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4 Steam Pressure Sensor

4. STEAM PRESSURE SENSOR

Autoflame Steam Pressure Sensor can be used with the MM system for the purpose of measuring the steam
(load) pressure.

Specifications
Output Signal 1-6V
IP rating 65
NEMA rating 4
Torque setting Max 25Nm
Valve material Stainless Steel
O-Ring material Viton
Operating Outside Temperature -25 to 85 °C (-13 to 185 °F)
Media Temperature -25 to 125 °C (-13 to 257 °F)
Operating Range 0 to 40 Bar (0 to 600 PSI)
Over Pressure Rating 80 Bar (1160 PSI)
Burst Pressure Rating 290 Bar (4350 PSI)
Fitting Size M27
Fitting torque 15 to 20Nm (11 to 14.8 ft lb)
Lead 1.5m (5ft) prewired with inside waterproof protective conduit
Warranty 2 year limited warranty

Wiring

Wire Colour MM Terminal

White (2) 38
Blue (3) 37
Brown (1) 39
Screen Do not connect on MM side

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4 Steam Pressure Sensor

4.1. Dimensions

Part # Connection Sensor’s Range Over Pressure Burst Pressure

MM10010 ¼” BSP tapered
0 – 3.4 bar (0 – 50 PSI) 8 bar (116 PSI) 12 bar (174 PSI)
MM10010/U ¼” NPT tapered
MM10008 ¼” BSP tapered
0 – 20 bar (0 – 300 PSI) 50 bar (725 PSI) 75 bar (1087 PSI)
MM10008/U ¼” NPT tapered
MM10009 ¼” BSP tapered
0 – 34 bar (0 – 500 PSI) 80 bar (1160 PSI) 100 bar (1450 PSI)
MM10009/U ¼” NPT tapered
MM10017 ¼” BSP tapered
0 – 100 bar (0 – 1450 PSI) 200 bar (2900 PSI) 300 bar (4351 PSI)
MM10017/U ¼” NPT tapered

Autoflame Sensors Guide Page | 28

4 Steam Pressure Sensor

4.2. Installation

• For correct operation, the detector must be installed with a pressure siphon loop.
• Plug fits correctly in one position only, do not force.
• Do not use case to tighten connection.
• An isolation vale can be installed between the sensor and the pressure vessel.

To calibrate the actual value, parameter 29 can be used to adjust the pressure sensor reading between a
range of 80.0% and 120.0%.

The load sensor can be calibrated via Commissioning Mode or through Online Changes.

The percentage change may not be linear to the current temperature, i.e. 80% of 10 bar may not translate to
8 bar.

Autoflame Sensors Guide Page | 29

5 Temperature Sensor

5. TEMPERATURE SENSOR

Autoflame Temperature Sensor is a resistance type temperature detector for use with the MM system for the
purpose of:

• Measuring load temperature.

• Monitoring the exhaust temperature or the
coil/tube temperature of the boiler on the Mk8
MM.
• Heat Flow metering applications on the Mk8
MM.
• Fully Metered Combustion applications on the
Mk8 MM.
• Exhaust Temperature Shutdown Threshold on
the Mk8 MM.

Autoflame temperature detector is available with

various probe lengths ranging from 100mm to 400mm,
other lengths are available upon request, please
contact Autoflame with your requirements.

Specifications
Range 0 to 400°C (0 to 752°F)
Sensor Type RTD PT1000, 2 wire.
IP Rating 65
NEMA Rating 4
Max. Operating Temperature 85°C (185°F)
Min. Operating Temperature -25°C (-13°F)
Max. Pressure Rating 40 bar (580 PSI)
Housing Stainless Steel
Probe Stainless Steel
Cable Gland PG11
Wiring connection Not included, 2 core screened cable (16-2-2C 2 Core) recommended
Installation Any orientation, probe must be in in full contact with the medium being
measured
Installation torque 25Nm (18ft lb)
Thermal Response 0.1s
Stability +/- 0.05%
Warranty 2 years limited warranty

Autoflame Sensors Guide Page | 30

5 Temperature Sensor

The table below provides the temperature vs. resistance data for the Autoflame temperature sensor:

Temp. °C Temp. °F ꭥ ꭥ/°C ꭥ/°F

0 32 1000.0 3.90 2.17
10 50 1039.0 3.89 2.16
20 68 1077.9 3.88 2.16
30 86 1116.7 3.87 2.15
40 104 1155.4 3.86 2.14
50 122 1194.0 3.84 2.13
60 140 1232.4 3.83 2.13
70 158 1270.7 3.82 2.12
80 176 1308.9 3.81 2.12
90 194 1347.0 3.80 2.11
100 212 1385.0 3.79 2.11
110 230 1422.9 3.77 2.09
120 248 1460.6 3.77 2.09
130 266 1498.3 3.75 2.08
140 284 1535.8 3.73 2.07
150 302 1573.1 3.73 2.07
160 320 1610.4 3.72 2.07
170 338 1647.6 3.70 2.06
180 356 1684.6 3.70 2.06
190 374 1721.6 3.68 2.04
200 392 1758.4 3.67 2.04
210 410 1795.1 3.66 2.03
220 428 1831.7 3.15 1.75
230 446 1863.2 4.13 2.29
240 464 1904.5 3.62 2.01
250 482 1940.7 3.62 2.01
260 500 1976.9 3.60 2.00
270 518 2012.9 3.59 1.99
280 536 2048.8 3.57 1.98
290 554 2084.5 3.57 1.98
300 572 2120.2 3.55 1.97
310 590 2155.7 3.55 1.97
320 608 2191.2 3.53 1.96
330 626 2226.5 3.52 1.96
340 644 2261.7 3.50 1.94
350 662 2296.7 3.50 1.94
360 680 2331.7 3.48 1.93
370 698 2366.5 3.48 1.93
380 716 2401.3 3.46 1.92
390 734 2435.9 3.45 1.92
400 752 2470.4 3.44 1.91

Autoflame Sensors Guide Page | 31

5 Temperature Sensor

Wiring

Mk8 MM / Mini Mk8 MM Mk8 MM

Wire Colour
As load sensor Heat Flow / Fully Metered / Spare Temp. Sensor
Blue 37 -
Red 38 T1, T2, T3
Screen S S

5.1. Dimensions

mm (inch)
Part # Connection Gland
A B C D
MM10006/100 PG11 211.42 185.75 120 100
MM10006/100U ½” NPSM (8.32) (7.31) (4.72) (4)
MM10006/150 PG11 261.42 235.75 170 150
MM10006/150U ½” NPSM (10.29) (9.28 (6.69) (6)
MM10006/200 PG11 311.42 285.75 220 200
½” BSP / NPT
MM10006/200U ½” NPSM (12.26) (11.25) (8.86) (8)
MM10006/250 PG11 361.42 335.75 270 250
MM10006/250U ½” NPSM (14.23) (13.22) (10.63) (10)
MM10006/400 PG11 511.42 485.75 420 400
MM10006/400U ½” NPSM (20.13) (19.12) (16.54) (12)

Autoflame Sensors Guide Page | 32

5 Temperature Sensor

5.2. Temperature Sensor’s Applications

Th temperature sensor can be used for several applications with the MM systems, please see the relevant MM
manual for full details.

Load Sensor

Autoflame temperature sensor can be used as a load sensor with the Mk8 MM or Mini Mk8 MM, for this the
following options must be set:

# Description Setting
Option 1 Boiler temperature / pressure sensor 0. temperature (MM10006, 0 – 400°C /
type 752°F)
Parameter 29 Load sensor adjustment As required – the temperature reading can
be adjusted to calibrate the actual value
Parameter 30 Load sensor filter time (the time it takes As required, 10 sec. default
to update the sensor reading on the MM)

To calibrate the actual load value, parameter 29 can be used to adjust the temperature sensor reading between
a range of 80.0% and 120.0%.

The load sensor can be calibrated via Commissioning Mode or through Online Changes on the MM.

The percentage change may not be linear to the current temperature, i.e. 80% of 100°C may not show 80°C.

For example, if the actual temperature was showing as 91°C on the MM, but the true temperature was 79°C,
change the value in parameter 29 until the correct temperature adjustment has been made. Figure 3.9.1.i
shows the load sensor adjusted by 96.0% to display 79°C.

Heat Flow Applications

To use the temperature sensor for Heat Flow applications on the Mk8 MM, the following expansion options
must be set:

# Description Temperature Sensor Used

120 2 Steam Flow T1 input temp.
3 Steam Flow with Economiser T1 Input temp, T2 Feedwater temp.
4 Steam Flow with Deaerator T1 Makeup temp, T3 condensate temp.
6 Steam Flow with Deaerator and Feed T1 makeup temp, T2 feedwater temp, T3
Sensor condensate temp.
7 Hot Water Flow T1 input temp.
9 Hot Water flow with Economiser T1 input temp, T2 feedwater temp.
11 Steam Flow from Feed Water Meter T1 input temp.
and Feed Sensor

Please see the Mk8 MM manual for full details about heat flow.

Autoflame Sensors Guide Page | 33

5 Temperature Sensor

Spare Temperature Sensor

The Spare Temperature Sensor feature on the Mk8 MM allows an addition temperature sensor to be used for
monitoring either the exhaust temperature or the coil / tubes temperature on a boiler. This also allows the
configuration of a temperature shutdown threshold.

# Default Range Description

130 0 Temp: Spare Temperature Sensor Function
0 Disabled
1 Coil Temperature
2 Exhaust Gas Temperature
131 0 Temp: Spare Temperature Shutdown Threshold
0 Disabled
1 – 2000 Degree °C

This feature is available with the Heat Flow function, the sensor used for this depends on the setting for the
Heat Flow function, the table below explains the sensor used for each setting.

# Setting Spare Temperature Sensor Used

1 Steam Flow with default values T3
2 Steam Flow T3
3 Steam Flow with Economiser T3
4 Steam flow with Deaerator T2
10 Steam Flow from Feed Water Meter T3
11 Steam Flow from Feed Water Meter and Feed Sensor T3
12 Spare Temperature Sensor Only T3

Exhaust Temperature Shutdown Threshold

Expansion option 131 allows a spare temperature shutdown threshold to be set. The burner will shutdown and
an alarm will be triggered when this threshold temperature is reached. This alarm can only be reset when the
spare temperature sensor reading drops below this threshold.

The Exhaust Temperature Threshold is not an ultimate safety feature and it does not replace the need for
high limit stat.

Autoflame Sensors Guide Page | 34

6 Outside Temperature Compensation

6. OUTSIDE TEMERATE COMPENSATION

Outside Temperature Compensation (OTC) is a function which allows the boiler’s required setpoint to be
automatically adjusted according to the outside air temperature. As the ambient air temperature increases the
required setpoint will be decreased, and vice versa.

The way OTC is configured depends on whether the MM is operating as stand-alone or in a sequencing loop,
the table below describes different possible setups:

Mk8 MM (not in Outside Temperature Sensor is required (part # MM60007), and can be wired
sequencing or DTI loop) directly to the Mk8 MM.

Mini Mk8 MM (not in OTC Module (part # MM70015) and OTC Temperature Sensors (part #
sequencing or DTI loop) MM60007) are required, the OTC module is wired to the Mini Mk8 MM and the
sensor is connected to the OTC module.

MMs in a sequencing OTC hardware is wired for the lead boiler only and the lag MMs take their
loop (no DTI) with fixed OTC temperature reading from the lead MM.
ID lead boiler

MMs in a sequencing An OTC module and sensor is connected to the sequencing loop, and all the
loop (no DTI) with MMs in the sequencing loop can take their OTC temperature reading from the
rotating lead boiler same OTC module.

MMs in a sequencing Mk8 DTI can act as an OTC unit if it is connected to the internet and
loop with Mk8 DTI configured to get local weather data online. No need for an OTC module or
temperature sensor hardware. All the MMs in the DTI loop will get their OTC
temperature readings from that DTI

The following options and parameters are related to Outside Temperature Compensation:

Option Mk8 MM and Mini Mk8 MM

80 Outside temperature compensation
81 Setpoint at minimum outside temperature
82 Minimum outside temperature
83 Setpoint at maximum outside temperature
84 Maximum outside temperature
Parameter 88 Outside temperature sensor adjustment

If the actual outside temperature exceeds the boundaries set in options 82 and 84, the boiler setpoint will
remain at the maximum or minimum setpoints specified by options 81 and 83.

Please check the Mk8 MM and Mini Mk8 MM manuals for further details on Outside Temperature
Compensation function.

Autoflame Sensors Guide Page | 35

6 Outside Temperature Compensation

Outside Temperature Compensation Screen – Mk8 MM

Outside Temperature Compensation Screen – Mini Mk8 MM

Autoflame Sensors Guide Page | 36

6 Outside Temperature Compensation

6.1. Outside Temperature Sensor

Autoflame Outside Temperature Sensor can be

wired directly to the Mk8 MM or connected to the
Outside Temperature Compensation Module for
use with the Mini Mk8 MM. The sensor’s body is
made from aluminium and has 2 fixing holes to
mount the sensor to a surface. The sensor comes
with 2 metre screened cable, pre-wired to the
sensor and shielded with protective, waterproof
conduit.

Specifications
Sensor Type RTD PT1000, 2-wire
IP Rating 65
NEMA Rating 4
Max. Operating Temperature 85°C (185°F)
Min. Operating Temperature -25°C (-13°F)
Housing Aluminium
Cable Gland Conduit gland
Wiring lead 2m (6.5ft) prewired inside a plastic conduit
Installation Any direction
Mounting 2x M4 Screws
Thermal Response 0.1s
Stability +/- 0.05%
Warranty 2 years limited warranty

Wiring
Wire Colour Mk8 MM Terminal OTC Module Terminal
Blue 19 -
Red 20 +
Screen S S

Drawing

Autoflame Sensors Guide Page | 37

6 Outside Temperature Compensation

6.2. Outside Temperature Compensation Module

The outside temperature module can be used to:

• Interface an OTC temperature sensor to a

Mini Mk8 MM
• Connect a temperature sensor to MMs in a
squencing loop so that all MMs in the loop
can get their OTC temperature readings
from that sensor.

Specifications
Supply voltage 110V or 230V AC – switch must be set before use
Communication RS485
IP Rating IP20
NEMA Rating 1
Max. Operating Temperature 60°C (140°F)
Min. Operating Temperature 0°C (23°F)
Warranty 2 years limited warranty

Drawing

Autoflame Sensors Guide Page | 38

6 Outside Temperature Compensation

Wiring

Wire Colour Mini Mk8 MM Terminal

Black RS485 - 27
Red RS485 + 28
Screen S

Autoflame Sensors Guide Page | 39

Annex: IP Ratings

The IP (International Protection) rating given to a piece of electrical apparatus is a two digit code indicating the
degree of protection its enclosure affords it. The first digit represents protection against penetration by solid
objects accessing hazardous parts, the second describing the enclosures, protection against the ingress of
water. An X in place of either digit means that either the enclosure has not been tested or that the test is not
applicable.

First Mechanical protection Second Water ingress protection

digit digit
0 No protection 0 No protection

1 Protected against 1 Protected against vertically

solid objects over falling drops of water e.g.
50mm, e.g. condensation
accidental touch by
hands
2 Protected against 2 Protected against direct
solid objects over sprays of water up to 15 °
12mm, e.g. fingers from the vertical

3 Protected against 3 Protected against direct

solid objects over sprays of water up to 60 °
2.5mm, e.g. tools & from the vertical
wires
4 Protected against 4 Protected against water
solid objects over splashed from all directions,
1mm, e.g. wires, limited ingress permitted
nails etc.

5 Protected against 5 Protected against low

dust limited ingress, pressure jets of water from all
not harmful deposits directions, limited ingress
permitted

6 Totally protected 6 Protected against strong jets

against dust of water e.g. on ships deck,
limited ingress permitted

n/a n/a n/a 7 Protected against the effects

of temporary immersion
between 15cm and 1m.
Duration of test 30 minutes
n/a n/a n/a 8 Protected against long
periods of immersion under
pressure

Note: In the event of additional holes being drilled, pierced or knockouts removed, suitable measures should
be taken to restore the product to its original rating IEC 529, BS EN 60529 does not apply to protection against
the risk of explosion or conditions such as humidity, corrosive gases, fungi or vermin. In certain cases
equipment designed to be mounted in an enclosure will contribute towards the stated IP rating, (e.g.
pushbuttons mounted in an enclosure). Different parts of enclosures can have different degrees of protection
and still conform to the standard.

Autoflame Sensors Guide Page | 40

AUTOFLAME
SENSORS GUIDE
04.08.2020

Autoflame Engineering Ltd.

Unit 1-2, Concorde Business Centre
Airport Industrial Estate, Wireless Road
Biggin Hill, Kent TN16 3YN
United Kingdom

Tel: +44 (0)1959 578 820

Email: [email protected]
Website: www.autoflame.com

Combustion Management Systems