COMBUSTION MANAGEMENT SYSTEM

OPTIMISING CB
COMPLETE, PRECISE CONTROL FOR CLEAVER BROOKS BOILERS
Autoflame Engineering offers complete retrofit solution for Cleaver Brooks boilers to
replace the existing linkage system with direct servo drive and micro modulation control.
• Complete kit featuring precision gear drive made from high strength stainless steel and
mounting bracket to enable direct servo drive for the air damper with up to 0.1°
accuracy.
• Able to reduce fuel consumption by 10-35%.
• Drastically reduce CO2, CO, SO2 and NOX emissions.
• Increase boiler efficiency and reliability.
• Reduce operation and maintenance cost.
• Suitable for all types, models and sizes of Cleaver Brooks boilers.
• Suitable for any gas, oil or dual fuel with option for fuel change on the fly without
shutting down the boiler.
• Connection to BMS via Modbus and remote control options.
• Complete prewired panel available with built in latest micro modulation controller.
• Exhaust Gas Analyser option for emissions monitoring and combustion trim.

COMBUSTION MANAGEMENT SYSTEM

AIR DAMPER RETROFIT KIT FOR
CLEAVER BROOKS BOILERS

Autoflame Engineering designed a complete kit that fits directly to the air damper arm without
the need for any welding; just simple mechanical work, eliminating the need for inaccurate
mechanical linkage which is prone to hysteresis and providing direct servo drive for the air
damper, the gears are made from stainless steel using CNC precision cut technology.

This kit comes in different sizes to suit any size and model of Cleaver Brooks boilers, The table
below shows the specific gears required for each boiler size (gear 1 is the drive gear and gears
2, 3, 4 & 5 are the spur gears). The drive gear is the same size for all boiler sizes, the spur gear
size varies depending on the boiler size and damper shaft diameter.

Please contact us and we are happy to recommend the ideal solution for your application.

COMBUSTION MANAGEMENT SYSTEM

 AIR DAMPER KIT

MOUNTING BRACKET DRIVE GEAR SPUR GEAR

Part Number Boiler Size Shaft Diameter Gears Needed

MMGR001 96” 400-800hp 3.2300” 1&2
MMGR002 96” 400-800hp 2.9880” 1&3
MMGR003 78” 250-350hp 2.4750” 1&4
MMGR004 60” 50-200hp 2.3745” 1&5

COMBUSTION MANAGEMENT SYSTEM

INSTALLATION
• The old inaccurate linkage system can be
completely removed and replaced by direct
servo drive.
• The mounting bracket is screwed to the burner
plate, an Autoflame Large Servo Motor is
installed directly into the mounting plate and
the drive gear is connected directly to the
servo’s drive shaft.
• The spur gear is fixed to the air damper rotating
arm, the spur gear to the drive gear ratio is 2:1
which allows for 90° movement on the servo
motor for 45° movement of the air damper.
• The servo motor provides up to 25Nm of torque
with 0.1°accuracy, available in metal or
polycarbonate housing. ATEX approved version
is also available for hazardous environments.

COMBUSTION MANAGEMENT SYSTEM

 FUEL / AIR RATIO CONTROL
Gas Valves (flanged or threaded) CNC machined from Aluminum or Stainless steel
and oil valves (spillback or metering) are available with direct servo drive, this
enables the fuel to be controlled to 0.1° providing infinite level of fuel/air ratio
control.
In case of dual fuel applications, it is possible to control both fuels using the same
servo, also possible to have fuel change on the fly.

FLAME SAFEGUARD
Wide range of UV and IR Scanners available, including self
checked to allow for unmanned boiler house conditions, ATEX
approved scanners also available.

COMBUSTION MANAGEMENT SYSTEM

 Although it is possible to utilise the existing control panel, a complete UL
CB CONTROL PANEL approved control panel can be supplied so as to reduce the down time
and any labour time/costs required on site. The Autoflame control panel
directly replaces the existing panel and is installed in the same location.
All wiring diagrams including the external panel layout, internal panel
layout and wiring schematic will be supplied for approval. Any additional
items can be installed. All schematics are then supplied with the control
panel for installation on site.
As standard the control panel is supplied with the following items:
• Autoflame Mk8 or Mini Mk8 MM Controller
• Flame failure lamp
• Load demand lamp
• Burner on/off selector switch
• Fuel selector switch (single/dual fuel)
• Hand/Auto/Low flame hold selector switch
• Fuel valve open lamp
• Low water lamp
COMBUSTION MANAGEMENT SYSTEM
EXHAUST GAS ANALYSER (EGA)
Autoflame Exhaust Gas Analyser can be used with Cleaver Brooks
boilers for the purpose of emission monitoring and combustion trim,
when optimized for trim, it can achieve further energy savings in the
region of 1-3% by ensuring the commissioned combustion values are
always maintained.
• Autoflame EGA enables 3 parameter trim on Mk8 MM
Controller for improved burning efficiency.
• Continuous Emissions Monitoring System (CEMS) for O2, CO2,
CO, NO, NO2, SO2
• Record and download emission data for up to 3 years
• MM Controller or Standalone Operation modes
• Six 4-20mA analogue outputs of all combustion data for
remote logging, printing or chart recording
• Direct Modbus Connectivity

COMBUSTION MANAGEMENT SYSTEM

DATA TRANSFER INTERFACE (DTI)
The Mk8 DTI (Data Transfer Interface) lets users know in real
time how the boilers are performing, either on-site through its
built-in touch screen, via a local PC, or remotely via a BMS
system. It stores MM and EGA system data for a rolling 2 year
period.
The DTI is a gateway for communicating with the Autoflame
MM Controller and/or EGA range of products. The DTI collects
and stores information from a maximum of 10 Autoflame
Systems in one location. The information gathered is instantly
available for transmission to an external source such as a BMS
via RS422 or Ethernet link. The Mk8 DTI also includes
Autoflame DTI Manager software as standard, allowing data
collection over a local network or over the internet. The Mk8
DTI also supports the Modbus protocol over Ethernet and
RS422 as standard.

COMBUSTION MANAGEMENT SYSTEM

 Autoflame Engineering Ltd.
Unit 1 & 2 Concorde Business Centre, Wireless Road, Biggin Hill, Kent, TN16 3YN, United Kingdom
+44 (0) 845 872 2000
enquiries@autoflame.com

COMBUSTION MANAGEMENT SYSTEM