STEAM BOILER OPERATION MANUAL LX-50 LX-100 LX-150 LX-200 LXH-200 LXL-50 LXL-100 LXL-150 LXL-200 INFORMATION IN THIS MANUAL MAY BE CHANGED WITHOUT ANY NOTICE. Please ensure that operation manual is read and observed in full by all persons working with the steam boiler. Please also ensure that it is stored in a location where it may be easily accessed by said persons. Operation Manual Number : T519-998-9000 Date of issue : July 31, 2007 Main Sections 1. INTRODUCTION 4 2. PURPOSE & PRINCIPLE OF OPERATION 14 3. COMPONENT NAMES & FUNCTIONS 17 4. BASIC PRECAUTIONS 22 5. PRE-OPERATION INSPECTION 28 6. USING BOILER CONTROLS 32 7. PREPARING FOR STARTUP 44 8. OPERATING THE STEAM BOILER 48 9. INSPECTION & MAINTENANCE 52 10. BREAKDOWN & COUNTERMEASURES 70 11. SPECIFICATIONS 79 12. APPENDIX 91 1 Table of Contents Main Sections .....................................................................................................................................................1 Table of Contents ................................................................................................................................................2 1 INTRODUCTION.........................................................................................................................................4 1.1 Safety Indicators................................................................................................................................5 1.2 Glossary ............................................................................................................................................6 1.3 Guarantee .........................................................................................................................................7 1.4 Introduction ........................................................................................................................................7 1.5 Features ............................................................................................................................................8 1.6 Description ......................................................................................................................................10 1.7 Acts & Regulations ..........................................................................................................................12 1.8 National Regulatory Organizations .................................................................................................13 2 PURPOSE & PRINCIPLE OF OPERATION .............................................................................................14 2.1 Flow Chart .......................................................................................................................................15 3 COMPONENT NAMES & FUNCTIONS ...................................................................................................17 4 BASIC PRECAUTIONS ............................................................................................................................22 4.1 Items to Check before Use ..............................................................................................................23 4.2 Clothing Requirements for Safe Operation .....................................................................................24 4.3 Warning Labels ...............................................................................................................................24 4.4 Dealing with Abnormal Conditions ..................................................................................................25 4.5 Precautions for Boiler Usage ..........................................................................................................26 4.6 Fire Extinguishers & First Aid Boxes ...............................................................................................26 4.7 Prohibition of Unapproved Modification ..........................................................................................27 4.8 When Reselling or Relocating .........................................................................................................27 5 PRE-OPERATION INSPECTION .............................................................................................................28 6 USING BOILER CONTROLS ...................................................................................................................32 6.1 Names & Functions of Control Panel Items ....................................................................................33 6.2 Working with the Display .................................................................................................................34 6.2.1 Display Content ...........................................................................................................................34 6.2.2 Using the Display (―DATA‖ & ―SELECT‖) ....................................................................................35 6.2.3 Display Content for Heat Management Mode ............................................................................36 6.2.4 Display Content for User Setting Mode ......................................................................................37 6.2.5 Display Content for Fault History Mode ......................................................................................40 6.3 Confirming Gauge Readings ...........................................................................................................41 6.4 Operating the Main Steam Valve .....................................................................................................42 7 PREPARING FOR STARTUP ...................................................................................................................44 8 OPERATING THE STEAM BOILER .........................................................................................................48 8.1 Boiler Startup ...................................................................................................................................49 8.2 Inspection during Operation ............................................................................................................50 8.3 Boiler Shutdown ..............................................................................................................................51 2 9 INSPECTION & MAINTENANCE .............................................................................................................52 9.1 Preparing for Possible Freezing ......................................................................................................53 9.1.1 Bleeding Water to Protect against Freezing ...............................................................................53 9.2 Maintenance during Extended Inactivity .........................................................................................54 9.3 Regular Maintenance Tasks and Timing .........................................................................................55 9.4 Spare Parts ......................................................................................................................................57 9.5 Overview of Inspection ....................................................................................................................58 9.5.1 Checking the Chemical Feeder ..................................................................................................58 9.5.2 Checking the Water Softness .....................................................................................................59 9.5.3 Checking the Gas Pressure ........................................................................................................60 9.5.4 Checking the Steam Pressure ....................................................................................................60 9.5.5 Blowdown & Testing of the Low Water Level Interlock ...............................................................61 9.5.6 Cleaning the Air Filter..................................................................................................................63 9.5.7 Cleaning the Feed-water Strainer ...............................................................................................64 9.5.8 Cleaning the Feed-water Tank ....................................................................................................66 9.5.9 Checking the Water Quality ........................................................................................................68 9.5.10 Inspecting the Safety Valve.........................................................................................................69 9.5.11 Cleaning the UV Sensor’s Protective Glass ...............................................................................69 10 BREAKDOWN & COUNTERMEASURES ..........................................................................................70 10.1 Alarm and Red Status Lamp – Alarm ..............................................................................................71 10.2 Yellow Status Lamp – Caution.........................................................................................................72 10.3 Action to be Taken before Ordering Repairs ...................................................................................73 10.3.1 Bleeding Air from the Feed Water Pump ....................................................................................76 10.3.2 Inspecting Water Level Probes ...................................................................................................77 10.3.3 Resetting the High Pressure Limit Shutoff Switch ......................................................................77 10.3.4 Resetting Blower Overcurrent .....................................................................................................78 11 SPECIFICATIONS ...............................................................................................................................79 12 APPENDIX...........................................................................................................................................91 3 1 INTRODUCTION 4 Safety Indicators The following headings are used within this manual in order to ensure safe and efficient operation of your steam boiler. Please ensure that you fully understand the meaning of each and use the boiler accordingly. WARNING Failure to use the steam boiler correctly could possibly lead to serious injury or death of the user. CAUTION Failure to use the steam boiler correctly could possibly lead to injury of the user or to property damage. NOTE Important information from the point-of-view of preventing boiler malfunction and ensuring efficient operation, or information that will prove useful during operation of the steam boiler. Meaning of safety indicators The number contained within this symbol indicates a relevant page. This symbol is used to indicate forbidden actions. Specific details of these actions will be presented together with the symbol. 5 Glossary Please use the following table to confirm the meanings of special terms used within the operation manual. Term Meaning Low water level The action of preventing ignition when the normal water level has not been interlock achieved. Pre-purge Purging with air from the boiler’s combustion chamber before the start of combustion. Post-purge Purging with air from the boiler’s combustion chamber after the end of combustion. Pilot ignition Ignition of the pilot burner. Pilot only A condition wherein only the pilot burner is lit. Main ignition Ignition of the main burner. Low fire A condition wherein combustion takes place at approximately 35% of maximum combustion performance. (70% for the LX-50) High fire A condition wherein the boiler is operating at maximum combustion performance. Scale The buildup of water impurities such as calcium and magnesium on water tubes. Sludge Impurities that precipitate inside the boiler. Untreated water Water that has not yet been treated. Soft water Water which has had calcium and magnesium removed. Boiler makeup (water) Treated water that is supplied to the boiler, or the act of sending this water. Equivalent evaporation The mass of steam generated in one hour when water at 212F is changed into steam at 212F. Carry over The unwanted discharge of moisture or impurities in the steam. Blowdown The discharge of water contained within the boiler. Water tube A tube making contact with combustion gas on the outside, and through which boiler water flows. Deaerator A device used to heat the boiler makeup water in order to reduce the level of oxygen dissolved in it. Cavitation A situation where air enters a pump and prevents normal operation. 6 Guarantee Refer to your warranty documents for specific details. A six-month labor warranty from boiler startup may be available. Contact local sales and service representatives for details. This labor warranty covers routine inspection and repairs at the installation site. Travel and lodging expenses are not covered, except in the case of local representatives. This product is covered by a one-year standard parts warranty from the boiler commissioning date or for 18 months from the shipping date, whichever occurs first. Express shipping costs for overnight or next-day delivery of parts are not included. Damage to the boiler or any of its component parts after leaving the factory is not covered. Parts replaced under this warranty must be returned to MIURA. If any defective parts are not returned, you will be charged for the corresponding new item. This product’s pressure vessel is covered by a seven-year limited factory warranty against material or workmanship defects. Introduction MIURA Boiler Co., Ltd. began North American activities in 1988, when the manufacturing plant in Brantford, Ontario, was established. Subsequently, our engineering department developed procedures to meet ASME codes and to gain listing approval from UL, CSA. The United States corporate sales office, MIURA Boiler, Inc., was then established and has since developed relationships with national, state and city inspectors and agencies. Our North American network consists of branches in Atlanta, Chicago, Los Angeles, New York, and Ontario. The parent company, MIURA Boiler Ltd. of Japan, is the leading manufacturer of boilers and other thermal equipment in the Pacific Rim region with market share in excess of 55%. Operating factories in five countries, our production volume now exceeds 14,000 units per year. As a result of design necessities in Japan — such as limited space and a total dependence on foreign energy — the MIURA Steam Boiler has been engineered with a highly efficient, vertical water tube, oncethrough, forced-flow design. Featuring a compact unit with low water content, the MIURA Boiler is designed to be run with simple push-button controls and a minimum amount of maintenance. Operation is quiet, radiant heat losses are minimal, and steam quality is second to none. Furthermore, MIURA Boilers are often installed in a multiple boiler network. MIURA Boilers, in combination with the patented MIURA Multiple Installation panel, allow the required horsepower to be brought on and off line quickly in order to meet sophisticated production needs with maximum fuel economy. The MIURA Advantage — proven in the field over forty years of excellent service — is the ability of our boilers to reach full output steam from a cold start in less than five minutes using the least amount of energy and having the lowest environmental impact. In recognition of its compact, safe, and costeffective design, the high-efficiency MIURA Boiler has won numerous awards from engineering societies and gas associations. 7 Features The MIURA Steam Boiler features a once-through, forced flow, low water content, water-tube design, which can achieve full output within five minutes. What’s more, this boiler is designed to be run with simple pushbutton controls and a minimum amount of maintenance. Using the patented MIURA BL11 computer controller, we can monitor precise characteristics of boiler operation from our offices and provide fast, accurate feedback data. Radiant heat losses are minimal and steam quality is second to none. In addition, MIURA Boilers are often installed in a multiple boiler network. MIURA Boilers, in combination with the patented MIURA Multiple Installation panel, allow the required horsepower to be brought on and off line quickly in order to meet sophisticated production needs with maximum fuel economy. The high-efficiency MIURA Boiler has received numerous accolades in Japan, including awards from the Japanese Society of Mechanical Engineers and the Japanese Gas Association. This boiler is characterized by compact, safe, cost-saving performance — an advantage that is underscored by our greater than 55% market share in the Pacific Rim region. MIURA Boiler Co., Ltd. has developed the Low NOx Boiler using state-of-the-art technologies, and both the flat burner and rectangular boiler vessel have been uniquely designed for the LX. NOx (PPM) All NOx Concentrations Converted to 3% Excess Oxygen (measured by authorized laboratories) Rated Load (%) NOX TEST DATA It is generally accepted that the temperature of a combustion flame should be less than 3,272F (1,800C) in order to prevent NOx generation. Nevertheless, combustion flames will generally have some high temperature areas generating this harmful pollutant. Miura engineers determined the temperature distribution in the combustion and heat exchanging areas of our boilers, and through exhaustive theoretical analysis and rigorous testing, optimized the boiler design so as to have a uniform temperature distribution at less than 3,272F (1,800C). Specifically, an ideal combustion process was achieved by making the burner surface as large as possible, and the furnace volume as small as possible. As a result, the LX and LXL boast NOx emission levels of less than 20 PPM at 3% converted O2 (based on natural gas combustion). Thanks to its highly compact design, the LX fits through a standard door opening, thereby eliminating the need to demolish doorways or knock down walls during installation. 8 The completely packaged LX features the following as standard: UL, c-UL approved and labeled boiler design (FM available) HIGH GAS and LOW GAS pressure switches LOW AIR pressure switch Control Steam Pressure transducer with a backup control pressure switch High steam limit pressure switch featuring a manual reset ASME steam safety relief valves for the boiler and an optional economizer Main gas line and pilot line regulators Dual pilot-gas solenoid valves Dual main-gas fluid actuator valves and plugged leak-test port (vent valve also available) Forced-draft blower and motor Completely enclosed, heavy gauge casing ASME stamped pressure vessel with internal inspection ports Two independent low-water fuel cutoffs, one featuring a manual reset Digital steam-pressure display with a backup pressure gauge Thermocouples on water tubing in order to prevent overheating due to low water or scale buildup Water volume control Intermittent Automatic Blowdown system with a strainer and manual shutoff valve External separator Blower-cover dust warning MIURA BL Microprocessor Boiler Control featuring a user-friendly digital display Communication interface functionality Display of hours of operation and logging of the seven most recent faults Support for remote modem-based monitoring of boiler performance and troubleshooting from a MIURA technical center 9 Description The following answers frequently asked questions by providing a general overview of the design and operational characteristics of MIURA Boilers. The MIURA boiler design comprises straight water tubes between upper and lower headers. Both headers are encased in a castable refractory leaving only the tubes exposed to combustion gases. There is very little water and consequently very little energy stored within the steam boiler. Water remains exclusively inside the tubes, with only incidental bubbling in the upper header. Therefore, the design features no natural circulation such as the riser or downcomer effect common to natural circulation boilers. Water is forced into the bottom header and tubes by means of a feed water pump. The water is flashed into steam in the tubes, realizing a dynamic bubbling system that also cools the tubes. This bubbling action may be best described as a ―steam gradient,‖ with more steam at the top of the tubes than at the bottom. Steam is accumulated in the upper header with a final separation in the external separator. Condensate separated in the external separator is fed back into the lower header. As a result of this steam gradient characteristic, there are no strictly defined steam and water levels, and thus, the boiler requires no sight glass. Furthermore, special modifications are incorporated into the boiler construction and safety system in order to accommodate this. First of all, the water control system relies on an electrical conductance system — specifically, when water makes contact with a probe, a circuit is formed. Three such probes control the boiler feed, with a short probe for low-fire, a medium length probe for high-fire, and a long probe for low water cutout. This safety configuration may seem confusing to the inspector who encounters the MIURA Steam Boiler in the field for the first time, particularly because a water column typically suggests a fixed water level. This is not true for our steam boilers, however, because of the low water content and the fierce boiling action of the steam gradient. Control of this dynamic system has been made possible by adding a special modification in the form of the water column in order to create an artificial level. The flanged pipe leading from the boiler body runs through the column, with three holes drilled in the pipe to realize an orifice effect. Nevertheless, even with this orifice effect, the artificial level oscillates — especially with swings in system load. This oscillation is desired and is directly proportional to the volume of water in the boiler tubes. Secondly, the water volume control relies on electrical resistance, and the bubbling action is what cools the tubes. As the volume of water in the steam boiler is consumed, there is less bubbling at the top of the tubes, increasing the amount of electrical resistance. Should the water volume ever become so low as to lose effective contact with the low-water cutout probe, the boiler will shut down. In certain models, an extra probe will activate the feed water pump until the bubbles re-establish effective contact with the probe. Third in the list of safety modifications are thermocouples, attached directly to the tubes. These thermocouples measure the temperature of the tubes and will shut down the boiler if a low water volume condition is detected due to insufficient bubbling, if dry fire occurs, or if scale buildup is detected. Scale formation reduces heat transfer rates and is therefore monitored directly based on any increase in tube surface temperature. This temperature sensing method can detect scale buildup of less than 1/64‖ and will shut down the boiler if necessary. The early detection of scale formation is an important factor in maintaining a high efficiency boiler. According to the US National Bureau of Standards, 1/4‖ of scale buildup on heating units requires up to 55% more energy to attain the same temperature. Other methods of detecting scale, such as a pressure gauge on the discharge of the feed water pump, are much less sensitive. The boiler will not operate should any of these low-water safeties fail. Only through tampering could the boiler operate without these safeties and give rise to a dry fire condition. Even in the unlikely event that such a situation should occur, by the time the tubes superheat to the level required to overcome the steel’s tensile strength, the amount of energy contained in the remaining water would be so small that the possibility of a pressure explosion is negligible. The MIURA Steam Boiler design has been used for more than 40 years, and over 200,000 units are presently in operation worldwide. There is no record of ANY pressure vessel explosion. 10 Steam is produced within five minutes from cold start-up and selected tubes can be visually inspected through two-inch openings located in the top and bottom headers. A full inspection is typically completed within 30 minutes. All MIURA steam boilers are annotated as a forced flow steam generator (with no fixed steam or water level) on the pressure vessel’s P-3 form and registered with the National Board. The complete packaged steam boiler is listed as a standard with UL, the CSA, and the CGA, and it can be tuned to meet FM and/or ASMECSD1 requirements at the customer’s request. Please note that all flanges used on our boilers are class 150# (300# for the LXH) and comply with ASME/ANSI standard B16.5. The 150# stamping refers to a standard classification, and not the Maximum Allowable Working Pressure (MAWP). As specified in Table A-361 of ASME codes, Section I, 2004 edition, the MAWP for 150# flanges is 205 PSIG for saturated steam services and 170 PSIG for boiler-feed and blowdown line services. This specification matches the 170 PSI MAWP rating of the LX boiler. CAUTION All steam systems require continuous, appropriate water treatment. This treatment is mandatory from the time of installation of your MIURA Steam Boiler. Failure to follow the recommended water treatment and maintenance procedures could shorten the service life (and efficiency) of your boiler and could also affect the warranty. 11 Acts & Regulations There are a number of codes, standards, laws and regulations for boilers and related equipment that and should be considered. Regulatory requirements are dictated by a variety of sources and are focused primarily on safety. This equipment shall be installed in accordance with the current regulations, codes, and specifications of the applicable municipal, national, provincial, state, and/or federal agencies. Authorities having jurisdiction should be consulted before the commencement of installation work. For more information on how the various rules affect boiler selection and operation, you may want to contact your local MIURA authorized representative or the engineering firm designing your boiler installation. Here are some essential rules to take into consideration: a. The boiler industry is tightly regulated by the American Society of Mechanical Engineers (ASME) and ASME codes, which control boiler design, inspection, and quality assurance. All boiler pressure vessels — including economizers, deaerators, blowdown tanks, and the like — should have an ASME stamp. b. All pressure vessels should be inspected and registered with the National Board. c. In Canada, the design of all boilers, pressure vessels, fittings, and piping must be registered with your local province as required in CSA B51. d. The insurance company insuring your facility or boiler may dictate additional requirements. Boiler manufacturers can provide special boiler trim according to the requirements of major insurance companies such as IRI and FM. Special boiler trim items usually take the form of added safety controls. Some industries — such as food processing, brewing, or pharmaceuticals — may also have additional regulations that have an impact on the boiler and boiler room. e. CSA/CGA, c-UL, UL approval may be required in order to verify safe boiler performance. f. A full-time boiler operator may be required. Operator requirements depend on the boiler’s size, pressure, heating surface area and volume of water. Boilers can be selected to minimize the boiler operator requirements, either by choosing a boiler that is exempt from certain rules, or by installing special equipment that gives the operator more freedom within the facility. Contact your local boiler inspector for more details. g. Most state, provincial, and local authorities have a permit that must be acquired in order to install and operate a boiler. Additional restrictions may apply in non-attainment areas where air quality does not meet the national ambient air quality standards and where emission regulations are more stringent. Be sure to investigate these requirements before purchasing a boiler. h. Most states or provinces require an annual boiler inspection, and additional requirements may also apply to piping. i. Most regional authorities have established a maximum temperature at which water can be discharged to the sewer system. In such a case, a blowdown separator or blowdown tank will be required. j. U.S. Federal emission standards — including permit and report-related procedures — apply to all new boilers with inputs over 10 million BTU/Hr. k. Boiler ratings are based on operation at sea level. For operation at elevations above 2,000 feet (600 m), ratings must be reduced at a rate of 4% per 1,000 feet (300 m) above sea level. 12 National Regulatory Organizations In order to obtain assistance in the identification of, and compliance with, codes and regulations, we recommend contacting your actual insurance provider as well as the utility companies. A partial list of agencies having jurisdiction over boiler installation and operation is given below. This list is comprehensive, but by no means all-inclusive. UNDERWRITERS LABORATORIES 333 Pfingsten Rd. Northbrook, IL 60062 (847) 272-8800 CSA INTERNATIONAL 178 Rexdale Blvd. Toronto, Ontario M9W 1R3 (416) 747-4000 NATIONAL BOARD 1055 Crupper Ave. Columbus, OH 43229 (614) 888-8320 T.S.S.A. 3300 Bloor St., West 16th Floor, Centre Tower Toronto, Ontario M8X 2X4 (877) 682-8772 A.S.M.E. 345 East 47th St. New York, NY 10017 (212) 705-7800 N.F.P.A. 1 Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9101 (800) 344-3555 AMERICAN GAS ASSOCIATION 1515 Wilson Boulevard Arlington, VA 22209 FACTORY MUTUAL RESEARCH CORPORATION 1151 Boston-Providence Turnpike, Norwood, MA 02062 (617) 762-4300 OCCUPATIONAL SAFETY & HEALTH ADMINISTRATION LOCAL FIRE MARSHAL AMERICAN NATIONAL STANDARD INSTITUTE 11 West 42nd Street, New York, NY 10036 LOCAL BOILER INSPECTORS ENVIRONMENT PROTECTION AGENCY LOCAL BUILDING AND CONSTRUCTION INSPECTORS FOOD & DRUG ADMINISTRATION 13 2 PURPOSE & PRINCIPLE OF OPERATION 2.1 Flow Chart ............................................................................... 15 14 Flow Chart ■ Hard-Leak Alarm (Colormetry) ■ Chemical Feeder Monitors the treated soft water after the water softener. Feeds chemicals into the boiler in order to prevent it from corroding. ■ Water Softener The water supply is usually hard water. The water softer converts this to soft water. NOTE Tap water and well water contain a wide range of dissolved impurities in varying amounts. If this water is used without removing the impurities in advance, buildup of scale, carry-over, corrosion, and other similar factors would have a detrimental effect on the boiler’s efficiency and service life. For this reason, the installation of water treatment equipment and thorough control of water quality are critical. The above flowchart sets forth a standard for water treatment system. 15 ■ Boiler Makeup Tank Main gas valve Main feed water valve Two different varieties of boiler makeup tank are available – namely, the water tank and the deaerator tank. ■ Once-through steam boiler Main power Gas 16 Circuit breaker Water delivered to the inside of the tubes is heated by the combustion of fuel using a burner. As a result of this heating, the boiler water successively evaporates to form steam, which is then supplied to the load application. 3 COMPONENT NAMES & FUNCTIONS 17 LX-200SG Blower Delivers the air required for combustion into the combustion chamber. Pressure gauge Displays the level of steam pressure within the pressure vessel. Control panel Provides switches and display devices required for operating the boiler. Emergency stop button In an emergency, push this button to stop combustion 18 Safety valve Allows pressure to escape from the pressure vessel when it reaches an abnormal level (i.e., exceeding the maximum pressure). Main steam outlet Used to provide steam to the load application. (Control/connection of steam to the load application) Control box Contains electrical parts used to control the boiler. 19 Economizer Collects heat in the exhaust gas and uses it for preheating feed-water. Warning label Presents cautions and warnings that must always be read before using the boiler. For more details, please refer to SECTION 4. BASIC PRECAUTIONS. 20 LX BOILER SECTION VIEW 21 4 BASIC PRECAUTIONS 4.1 Items to Check before Use ...................................................... 23 4.2 Clothing Requirements for Safe Operation ............................. 24 4.3 Warning Labels ........................................................................ 24 4.4 Dealing with Abnormal Conditions .......................................... 25 4.5 Precautions for Boiler Usage ................................................... 26 4.6 Fire Extinguishers & First Aid Boxes ....................................... 26 4.7 Prohibition of Unapproved Modification................................... 27 4.8 When Reselling or Relocating ................................................. 27 22 WARNING The following precautions must all be observed before operating the boiler. Failure to do so may result in injury. Items to Check before Use Check the boiler’s installation condition. Check the boiler’s installation condition. Confirm that it has been installed correctly as set forth in SECTION 5. PREOPERATION INSPECTION. Trial operation must always be performed before actual use. When you have confirmed that the boiler is correctly installed, please arrange for trial operation to be conducted by MIURA maintenance personnel or distributor. Ensure that you use the boiler correctly. Do not attempt to operate or service the steam boiler until you have read and fully understood this operation manual. 23 Clothing Requirements for Safe Operation Be sure to wear suitable clothes for working on the boiler. To operate or service this steam boiler, avoid wearing loose clothes or accessories that could become caught on valves or other mechanical components. In addition, clothing stained with oil or grease poses a fire risk and it should not be worn. Always wear protective clothing. Helmet, safety glasses, safety footwear, and leather gloves must always be worn. Handling of hazardous chemicals may cause injury when contact with eyes or skin. Therefore, it is crucial that safety glasses and rubber gloves should be worn during this dangerous operation. Warning Labels Location of warning labels Warning labels have been applied to indicate locations where hazards exist. For more details regarding these locations, refer to SECTION 3: COMPONENT NAMES & FUNCTIONS. Maintenance of warning labels Any peeling or torn warning labels must be replaced. Please contact a MIURA sales office or your local dealer regarding this and other warning-label inquiries. 24 WARNING The following precautions must all be observed before operating the boiler. Failure to do so may result in injury. Dealing with Abnormal Conditions Immediately push the "EMERGENCY STOP" button to stop combustion and close the main gas valve first, then cut out the main power supply to the boiler whenever you notice abnormal noise, strange smells, black smoke, gas leaks, or any other unusual conditions. Failure to react to this precaution may result in fire or gas explosion. No ignition source near gas leaks When a gas leak is suspected, open windows and doors to ventilate the area. You must not turn fans or other electrical devices on or off without good reason in such situation. Failure to observe this precaution may result in explosion. E S M T E O R P G E N C Y Ventilation Responding to abnormal conditions Always follow the instructions given by MIURA sales offices or local dealers when abnormal conditions arise. In addition, discontinue to use the boiler until the abnormality has been removed. Failure to observe this precaution can result in fire, explosion, and other dangerous situations. 25 Precautions for Boiler Usage Always use the recommended fuel. Usage of any fuels other than those recommended could result in the boiler explosion. No ignition source near boiler fuel or combustible materials. Boiler fuel and highly flammable material can easily be ignited in the presence of a ignition source. No combustible materials should be present within the minimum distance of the boiler required by the local code. Failure to observe this precaution may result in fire. Do not place combustible materials inside the control box. Failure to this precaution may result in fire. Always store flammable materials in a safe location, away from ignition source. Failure to observe this precaution may result in fire. Use ventilation equipment (or air vents) during operation. Fans should be running during operation of the boiler, and ensure ventilation ports are not blocked. Failure to observe this precaution could result in incomplete combustion, which in turn could lead to carbon monoxide gas poisoning or boiler explosion. Do not touch the boiler during operation. With the exception of the control panel, avoid contact with any part of the boiler while it is operating. Failure to follow the precaution can result in electric shock, burns, and other injury. NEVER BURN GARBAGE OR PAPER IN THE UNIT Fire Extinguishers & First Aid Boxes Provide fire extinguishers. In order to be prepared for the outbreak of fire, ensure that fire extinguishing equipment is provided near the boiler, and that its operation is fully understood. Provide a first aid box. Select suitable locations for the first aid boxes, and ensure that they are always there. 26 WARNING All the following precautions must be observed before operating the boiler. Failure to do so may result in injury. Prohibition of Unapproved Modification No customizing or modification Any customizing or modification of the boiler other than that recommended by MIURA (for example, connection to additional equipment and piping work) can have serious consequences in terms of safety. Always confer with MIURA maintenance personnel before carrying out any such modification work. Note that MIURA will not be responsible for the consequences of unapproved modification. When Reselling or Relocating Contact us when intending to move or sell your boiler Whenever the boiler is to be relocated, it is important that the installation work be carried out correctly and the required equipment for moving is available. Always contact a MIURA sales office or your local dealer before moving or reselling the steam boiler. Inappropriate installation work or the connection of unsuitable ancillary equipment can result in injury and must be avoided. Include the operation manual if reselling This operation manual must be read by all who intend to use the boiler. This manual must be given to the new use 27 5 PRE-OPERATION INSPECTION Refer to the “INSTALLATION MANUAL” for more details. 28 WARNING Before operating the boiler, please check each of the installation points below. Do not use the boiler if it has not been correctly installed. Failure to follow this precaution may have serious consequences. Boiler Room Installation of ventilation equipment (or air vents) Confirm the boiler room is installed with ventilation fan or air supply and exhaust vents. Insufficient ventilation can result in incomplete combustion, which in turn can lead to carbon monoxide gas poisoning or boiler explosion. Ventilation fan Air supply and exhaust vent Boiler Installation Installation on a non-flammable floor Confirm that the boiler is installed on a floor that is not made of wood or another flammable material. Installation on a flammable surface can lead to the outbreak of fire and have other undesirable consequences. Combustible materials should distant from the boiler Hazardous materials with flammable nature should not be handled near the boiler, and combustible materials should be located at the minimum distance required by local code. Flammable material Minimum distance required by local code Fuel Piping No fuel leaking from piping Installation of gas leak alarm LPG-fired boilers must be provided with gas-leak alarm equipment. This fuel is heavier than air and builds up close to the ground, where it is not easily noticed. It is crucial that you provide a gas leak alarm in order to prevent explosion. Combustible materials 10 ft. approx Gas leak alarm 29 Electrical Work Failure to observe warnings relating to electrical work can lead to electric shock. Fuse or circuit breaker Dedicated power supply for the boiler Confirm that the boiler has a dedicated supply of main power and a dedicated breaker installed on the power-supply line. Fuse or Circuit breaker capacity Installation of a fuse (or a time-limit type circuit breaker) Confirm a fuse (or a time-limit type circuit breaker) is installed on the main power supply line. The rating of the fuse is on the boiler name plate. Please refer to SECTION 11: SPECIFICATIONS. Power supply lines with the required wire gauge Confirm the wire gauge of the power supply lines is as required. For more details regarding power-supply line gauges, please refer to SECTION 11: SPECIFICATIONS. Ground terminal connected to a grounding wire Confirm that a grounding wire is connected to the ground terminal located inside the boiler’s control box. Wiring Ground Ground terminal Chimney Installation Non-flammable parts in contact with chimney path Confirm that any section of roof or wall which the chimney passes through is made of nonflammable material. Flammable material in the vicinity of the chimney poses fire hazard. 6 inches minimum Screw Seal Area around chimney outlet should be free of combustible material Confirm that no flammable materials are present near the chimney outlet. Any flammable material in that area poses fire hazard. Non-flammable material Properly sealed and secured joints Confirm that joints have been properly sealed and secured in place. If this is not the case, exhaust gas may leak and rise the risk of carbon monoxide poisoning. 2 ft. or more 3 ft. or more 30 WARNING Before operating the boiler, please check each of the installation points. Do not use the boiler if it has not been correctly installed. Failure to follow this precaution may have serious consequences. Safety-Valve Discharge Piping End of discharge piping to be pointing in a safe direction Confirm the end of the safety valve’s discharge piping is pointed in a direction that would not endanger anyone when steam is discharged. If this is not the case, discharged steam could cause burns and other injuries. Safety valve Discharge piping Drain piping No movement of discharge piping during discharge Confirm by hand that the discharge piping is secured in place. If this is not the case, the piping could move in reaction to the discharge of steam, which could then cause burns and other injuries. Thermal insulation Steam Piping Fully insulated steam piping Confirm that any sections of steam piping passing through inflammable walls are fully insulated. Insufficient insulation can result in the outbreak of fire. Wall Blowdown Piping No movement of the piping during blowdown Confirm by hand that the blowdown piping is secured in place. If this is not the case, the piping could move in the reaction of steam discharge, which could then cause burns and other injuries. Blowdown piping Pit 31 6 USING BOILER CONTROLS 6.1 Names & Functions of Control Panel Items ............................ 33 6.2 Working with the Display ......................................................... 34 6.2.1 Display Content ............................................................. 34 6.2.2 Using the Display (―DATA‖ & ―SELECT‖) ...................... 35 6.2.3 Display Content for Heat Management Mode ............... 36 6.2.4 Display Content for User Setting Mode ......................... 37 6.2.5 Display Content for Fault History Mode ........................ 40 6.3 Confirming Gauge Readings ................................................... 41 6.4 Operating the Main Steam Valve ............................................ 42 32 Names & Functions of Control Panel Items Names & Functions of Switches Status lamps Display ―DATA‖ button • To select parameters for individual modes of operation such as Monitoring mode and Heat Management mode. • To turn off audible alarms. • To reset the display after the output of cautions. Emergency Stop button To shutoff main control power and stop the boiler in the case of emergency. (In normal situations, use the ―OPERATION‖ switch to stop the boiler.) 33 ―SELECT‖ switch To switch between parameters for each mode of operation, to modify values, and to select individual characters. ―OPERATION‖ switch • To start water-level control, chemicalcharging control, and combustion within the boiler. • To reset alarms and the display of cautions. Working with the Display 6.2.1 Display Content Operation Status & Parameters (Monitoring mode) Typical display: Upper row of display: Boiler operation mode HIGH FIRE STEAM NOTE If switches are not operated for a period of time, the system will automatically switch over to Monitoring mode and the display will show steam-pressure data. 100PSI Lower row of display: Monitoring data for selected parameter Status presented in upper row of display DISPLAY CONTENT DISABLE STAND-BY FEED WATER PREPURGE IGNITION PILOT MAIN IGNITION LOW FIRE HIGH FIRE POSTPURGE PILOT HOLD LOW FIRE HOLD PREPURGE HOLD BOILER OPERATION MODE Operation stopped Standby Low water level interlock Pre-purge Pilot ignition Pilot only Main ignition Low fire High fire Post-purge Pilot fire hold Low fire hold Pre-purge hold Parameters presented in lower row of display MONITORED TYPICAL OUTPUT PARAMETER Steam Pressure STEAM 999PSI Exhaust Gas Temperature FLUE GAS 999F Feed Water Temperature FEED WATER 999F Scale Monitor Temperature SCALE MNTOR 999F Overheat Thermostat HIGH LIMIT 999F Temperature Flame Current FLAME 99.9μA Remaining Blowdown Time NEXT B/DOWN 999Hr Condensate Blowdown SFCE B/DOWN ON/OFF Valve On / Off Water Conductivity CONDUCT 9990μS Water Level Condition W/LEV L2 LMSD SS Date & Time MM/DD/YY HH:MM 34 Purpose of Each Mode Monitoring Mode In this mode, data required for boiler control such as the steam pressure and exhaust gas temperature is presented. Refer to page 34 for more details regarding the actual display content. In this mode, data required for heat management such as the boiler efficiency and fuel Heat Management Mode consumption is presented. Refer to page 36 for more details regarding the actual display content. User Setting Mode This mode is used to make steam pressure and time settings. Refer to page 37 for a description of how to set the system time (i.e., program-time setting). Fault History Mode Use this mode to view the content of the seven most recent alarms and cautions, together with the corresponding times of occurrence. Refer to page 40 for more details on how to view this content. The four operation modes – Monitoring, Heat Management, User Setting, and Fault History – can be displayed using the ―DATA‖ button. 6.2.2 Using the Display (―DATA‖ & ―SELECT‖) Using the ―DATA‖ Button Press the ―DATA‖ button to scroll through the four operation modes – Monitoring, Heat Management, User Setting, and Fault History. DATA Monitoring Heat Management User Setting Fault History Using the ―SELECT‖ Switch Turn the ―SELECT‖ switch to change the displayed parameter or the corresponding value. SELECT 35 6.2.3 Display Content for Heat Management Mode You can display a total of 11 heat-management parameters in Heat Management mode, with the corresponding values being presented in the lower row. Typical display: Boiler’s current mode of operation HIGH FIRE IGN CYCLE 9999 Heat Management Parameters Parameters displayed for Heat Management mode 1 HEAT MANAGEMENT PARAMETER Ignition Cycles IGN CYCLE 9999 2 Gas-fired Low Fire Duration GAS L HRS 99:99 3 Gas-fired High Fire Duration GAS H HRS 99:99 GAS L TEMP 999F 1F GAS H TEMP 999F 1F FW AVG TEMP 999F 1F № 7 Gas-fired Average ExhaustGas Temperature (low fire) Gas-fired Average ExhaustGas Temperature (high fire) Average Feed Water Temperature Gas-fired Boiler Efficiency 8 4 5 6 DISPLAY OUTPUT RESOLUTION 1 Hours: Minutes Hours: Minutes GAS EFFIC 99.9% 0.1% Gas Consumption GAS U 999999SCF 1 SCF 9 Boiler Makeup Water F WATER 99999GAL 1 Gal 10 Steam Generated STEAM 999999LB 1 Lb. 11 Surface Blowdown Volume B/DOWN 99999GAL 1 Gal For these parameters, the display shows cumulative value from the Segment Start Time of the current day to the current time (or for the Segment Interval). For these parameters, the display shows cumulative value from the Segment Start Time of the current day to the current time (or for the Segment Interval). For these parameters, the display shows cumulative value from the Segment Start Time of the current day to the current time (or for the Segment Interval). (Segment Start Time) The value displayed corresponds to the 24-hour (Segment Start Time) period from the previous Segment Start Time to the current Segment Start Time. The value displayed corresponds to the interval from 00:00 to 01:00. The value displayed corresponds to the interval from 00:00 to 02:00. *: Data is updated every hour. NOTE The Segment Start Time can be set in intervals of one hour. (The default setting is 00:00.) If you need to change this setting, please arrange for MIURA maintenance personnel to do so. 36 6.2.4 Display Content for User Setting Mode In User Setting mode, you can set steam pressure levels and the current time (YY/MM/DD HH:MM). NOTE The current time is used by a range of different processes working with control data, and for this reason, you must set it correctly. Although the time is set before the boiler is shipped from the manufacturing plant, you should check to confirm that it is correct. DATA 1) Press the ―DATA‖ button to select User Setting mode. 2) Press and hold the ―DATA‖ button for two seconds to switch to User Setting mode. Parameters for this mode change as follows in response to pressing of the ―DATA‖ button. INI SET MODE PRESS&HOLD―DATA‖ DATA Steam Pressure (low fire) Differential (low fire) Steam Pressure (high fire) Differential (high fire) Time: Month Time: Day Time: Year Time: Hours Time: Minutes Air Bleed 3) STEAM SET(L) 100PSI STEAM SET(L) 100PSI To exit User Setting mode, again press and hold the ―DATA‖ button for two seconds. 37 DATA Setting Steam Pressures NOTE If no switches are operated for a certain period of time, the system will automatically switch over to Monitoring mode and the display will show steam-pressure data. (This action does not cause any settings to change.) DATA 1) Press the ―DATA‖ button to select User Setting mode. 2) Press the ―DATA‖ button to select the steam pressure setting to be changed. INI SET MODE PRESS&HOLD―DATA‖ DATA PARAMETERS Steam Pressure (low fire) Differential (low fire) Steam Pressure (high fire) Differential (high fire) 3) DETAILS If the pressure of steam inside the pressure vessel reaches or exceeds this setting, the boiler will switch to low-fire operation. Furthermore, the boiler will return to high-fire operation if the pressure of steam inside the pressure vessel drops to (Steam Pressure (low fire) – Differential (low fire)). If the pressure of steam inside the pressure vessel reaches or exceeds this setting, the boiler will switch to stand-by. Furthermore, the boiler will restart combustion if the pressure of steam inside the pressure vessel drops to (Steam Pressure (high fire) – Differential (high fire)). Use the ―SELECT‖ switch to change a pressure setting. SELECT NOTE Do not change either Steam Pressure value (i.e., for high or low fire) to 150 PSI or higher. If you wish to operate the boiler in this elevated range, please consult with a MIURA sales office. STEAM SET(L) 100PSI STEAM SET(L) 100PSI 4) When you have finished changing settings, press and hold the ―DATA‖ button for two seconds to leave User Setting mode. Settings are updated as you leave this mode. Failure to carry out this action will result in the original settings remaining unchanged. 5) Confirm that the pressure settings have been changed as intended. 38 DATA Setting the System Date & Time NOTE If no switches are operated for a certain period of time, the system will automatically switch over to Monitoring mode and the display will show steam-pressure data. (This action does not cause any settings to change.) DATA 1) Press the ―DATA‖ button to select User Setting mode. INI SET MODE PRESS&HOLD―DATA‖ DATA 2) Press the ―DATA‖ button to select the Time Setting screen. The current month will start to flash. When a setting flashes in this way, its value can be changed. TIME SET 07/01/06 08:00 DATA 3) Using the ―DATA‖ button, move to the setting that you want to change. 4) Use the ―SELECT‖ switch to change the setting as required. 5) When you have finished changing the settings, press and hold the ―DATA‖ button for two seconds to leave User Setting mode. Settings are updated as you leave this mode. Failure to carry out this action will result in the original settings remaining unchanged. 6) Confirm that the date and time have been changed as required. 39 TIME SET 07/01/06 08:00 SELECT TIME SET 07/01/06 DATA 13:00 6.2.5 Display Content for Fault History Mode Using Fault History mode, you can review the content of recent alarms and cautions, together with the corresponding times of occurrence. Specifically, you can use the ―DATA‖ button to display the seven most recent alarms and cautions. For more details regarding this mode’s display items, refer to Section 10.3: Action to be Taken before Ordering Repairs. DATA 1) Select Fault History mode using the ―DATA‖ button. 2) Press and hold the ―DATA‖ button for two seconds to switch to Fault History mode. In addition, you can use the ―SETTING‖ switch to display the possible causes of alarms and cautions. FAULT HISTORY PRESS&HOLD―DATA‖ DATA Typical display: Stage triggering alarm or caution Operating mode, date, and time at triggering of alarm or caution Operating mode, date, and time at triggering of warning or system notice HI FIRE 11,08:30 BURNER ALARM 5 Details of alarm or caution Typical display of possible causes: NO FUEL or UV SENSOR ERROR 3) To exit Fault History mode, press and hold the ―DATA‖ button for two seconds. 40 Confirming Gauge Readings Steam Pressure Display The steam pressure gauge measures the pressure of steam inside the boiler. The measured value is presented in both digital and analog format. The analog display is in units of ** PSI. The digital display has a resolution of 1 PSI. <Analog display> NOTE As a result of the different measurement-error characteristics of the analog and digital displays, there may be a slight difference in the pressures indicated by each. HIGH FIRE STEAM Water Level Display The control system provides information regarding the amount of water in the boiler in terms of electrode conditions. The display presents the status of the electrode on which water is detected. 100PSI HIGH FIRE W/LEV L2 LMSD SS Water level: Low High Displayed by default during combustion. 41 Operating the Main Steam Valve WARNING The main steam valve is located high on the boiler with limited space available for footing. It is important to wear suitable protective clothing (i.e., long sleeves and trousers, safety footwear, a helmet, gloves) whenever opening or closing this valve. As the entire boiler will remain at a high temperature for some time after shutdown, avoid to touch any boiler part other than the handle of the main steam valve. Failure to follow this precaution can result in burns and other injuries. NOTE If a steam header has been installed on the piping, ensure that the main steam valve is left open. In this type of setup, the steam header’s valve will act as the main steam valve for the boiler. 1) Setup a ladder. Open 2) 3) Confirm that the position of the valve and the required direction of turning in advance. Close Handle Main steam valve Climb the ladder and open or close the main steam valve as required. WARNING Do not jump on or jump off the ladder. You must keep both hands and one foot, or both feet and one hand in contact with the ladder at all times when ascending or descending. Failure to observe this precaution may result in a fall and the associated injury. 42 43 7 PREPARING FOR STARTUP 44 The following checks must be carried out before starting the boiler. 1) Turn on the breaker for the boiler’s main power. WARNING Do not carry out this procedure with wet hands. Failure to observe this precaution may lead to electric shock and have other undesirable consequences. WARNING All cover plates, enclosures and guards must be in place at all times, except during maintenance and servicing. NOTE Even when the boiler is not in use, the main-power breaker should not be turned off. If the boiler receives no power for an extended period of time, the data stored in its memory will be lost. In addition, communication will not be possible if no power is being supplied. 2) Open Open the pressure vessel’s air bleed valve for approximately five seconds, and then fully close the valve. WARNING Never open the pressure vessel’s air bleed valve when the boiler is pressurized, no matter how small the pressure level. You must always confirm that the steam pressure gauge reads 0 PSI at this time. Opening the valve at any pressure above 0 PSI will result in the discharge of steam, which could cause burns and other injuries. Open 3) After confirming that the feed water tank is at least two-thirds full of water, open the main feed-water valve. 4) Open the main gas valve. As described in Section 9.5.3: Checking the Gas Pressure, confirm that the value indicated by the gas pressure gauge is within the rated range. 45 Open 5) As described in Section 9.5.2: Checking the Water Softness, confirm that the feed water has been correctly softened. 6) Confirm that the main steam valve is closed. If this is not the case, apply the method described in Section 6.4: Operating the Main Steam Valve and close the valve. 46 Close 47 8 OPERATING THE STEAM BOILER 8.1 Boiler Startup ........................................................................... 49 8.2 Inspection during Operation .................................................... 50 8.3 Boiler Shutdown ...................................................................... 51 48 Boiler Startup 1) Perform the checks described in SECTION 7: PREPARING FOR STARTUP. WARNING This is a shop-tested, assembled, and fully-packaged boiler. Each unit and assembly has been carefully adjusted at the factory. It is very important not to make any adjustments without first consulting a MIURA sales office or the local dealer. 2) Turn on the ―OPERATION‖ switch. The Status lamp will light in green, and the system will begin water level control. The Status lamp will light in red at this time if the water level is too low. 3) When the normal water level has been reached, the Status lamp will turn green and pre-purging will begin. Combustion will follow pre-purging. When the pre-purge has been completed, the control system will perform ignition on pilot burner. Following main ignition, the system will perform low fire combustion for approximately 10 seconds, before switching to high fire. WARNING Steam pressure gauge Fans and other ventilation equipment must be turned on at this time. Insufficient ventilation can result in incomplete combustion, which in turn can lead to carbon monoxide gas poisoning or boiler explosion. 4) Stand by until the pressure level indicated by the steam pressure gauge reaches the rated level (i.e., at least 70 PSI). 5) Applying the method described in Section 6.4: Operating the Main Steam Valve, slowly open the main steam valve. The boiler will alternate high-fire combustion and lowfire combustion in order to deliver steam at the rated pressure level. 49 Open Main steam valve Inspection during Operation WARNING At any time, when a gas leak is suspected, immediately turn off the ―OPERATION‖ switch, close the main gas valve and open windows and doors in order to fully ventilate the area around the boiler. You must never turn fans or other electrical device on or off without good reason in such a situation. Failure to observe this precaution may result in explosion. Immediately turn off the ―OPERATION‖ switch and close the main gas valve whenever you notice abnormal noise, strange smells, black smoke, or any other unusual conditions. Failure to observe this precaution may result in fire, gas explosion, and other dangerous situations. Always follow the instructions given by MIURA sales offices or local dealers whenever strange or abnormal conditions arise. In addition, discontinue use of the boiler until the abnormality has been removed. Failure to observe this precaution can result in fire, explosion, and other dangerous situations. Listen to the blower, feed water pump, and other devices and confirm that no abnormal operating noise is being generated. Should be emitting a smooth operating hum sound. Confirm that the readings on the steam pressure gauge and the gas pressure gauge are within the normal ranges, and the gauge pointers are not swinging wildly. Gas Confirm that there is no gas leaking from the piping. Gas 50 Boiler Shutdown 1) Turn off the ―OPERATION‖ switch. Confirm that the Status lamp turns off. 2) Apply the method described in Section 6.4: Operating the Main Steam Valve and close the valve. Close Main steam valve 3) Close the main feed water valve and the main gas valve. Close Main feed water valve NOTE If there is any concern regarding freezing of the boiler, implement the protective measures described in Section 9.1: Preparing for Possible Freezing. Refer to Section 9.2: Maintenance during Extended Inactivity if the boiler will not be used for an extended period of time. 51 Close Main gas valve 9 INSPECTION & MAINTENANCE 9.1 Preparing for Possible Freezing .............................................. 53 9.1.1 Bleeding Water to Protect against Freezing ................. 53 9.2 Maintenance during Extended Inactivity.................................. 54 9.3 Regular Maintenance Tasks and Timing ................................. 55 9.4 Spare Parts .............................................................................. 57 9.5 Overview of Inspection ............................................................ 58 9.5.1 Checking the Chemical Feeder ..................................... 58 9.5.2 Checking the Water Softness........................................ 59 9.5.3 Checking the Gas Pressure .......................................... 60 9.5.4 Checking the Steam Pressure ...................................... 60 9.5.5 Blowdown & Testing of the Low Water Level Interlock ....................................... 61 9.5.6 Cleaning the Air Filter .................................................... 63 9.5.7 Cleaning the Feed-water Strainer ................................. 64 9.5.8 Cleaning the Feed-water Tank ...................................... 66 9.5.9 Checking the Water Quality .......................................... 68 9.5.10 Inspecting the Safety Valve ......................................... 69 9.5.11 Cleaning the UV Sensor’s Protective Glass ................ 69 52 Preparing for Possible Freezing NOTE The following describes one specific set of measures to protect against freezing. Ensure that the measures implement for both boiler and ancillary equipment are suitable for the local region and boiler installation. If you require more information regarding such countermeasures, please do not hesitate to contact MIURA sales office. 9.1.1 Bleeding Water to Protect against Freezing Bleeding Water from the Pressure Vessel 1) Shut down the boiler as described in Section 8.3: Boiler Shutdown. 2) Stand by until the pressure reading on the steam pressure gauge reaches 30 PSI. 3) Slowly open the boiler blowdown valve and carry out boilerwater blowdown. Steam pressure gauge WARNING All parts of the boiler will be extremely hot at this time. Touch only those parts clearly identified in the instructions. Failure to observe this precaution can result in burns and other injuries. Do not open the boiler blowdown valve rapidly. Anything other than slow opening of this valve will result in the violent discharge of steam, which could cause burns and other injuries. 4) Stand by until the pressure reading on the steam pressure gauge reaches 0 PSI. 5) Slowly open the boiler’s air bleed valve. Open slowly Boiler blowdown valve WARNING Steam pressure gauge Steam may be discharged from the boiler’s air bleed valve. For reasons of safety, therefore, ensure that no work is being done in the direction of discharge. Failure to follow this precaution can result in burns and other injuries. 6) Open the water sampling valve and confirm no water is discharged. 7) Close the boiler blowdown valve, the boiler air-bleed valve, and the water sampling valve. Open slowly Boiler air-bleed valve Close Close Boiler blowdown valve 53 Boiler air-bleed valve Bleeding Water from the Feed-Water Pump WARNING Piping near the feed water pump is extremely hot. For this reason, you should wait until it has sufficiently cooled down (at least two hours after boiler shutdown) before performing this work. Failure to observe this precaution can result in burns and other injuries. 1) Close the feed-water stop valve and the main feedwater valve. 2) Open the feed water pump’s water bleed valve and air bleed valve. Discharge water contained in the feed water pump via the water bleed valve. Close Feed-water stop valve Close Main feed water valve NOTE Do not rotate the handle for both the water bleed valve and the air bleed valve for more than one complete turn. Failure to observe this precaution may result in the gushing out of water. 3) Stand by until water is no longer discharged from the water bleed valve. 4) Close the feed water pump’s water bleed valve and air bleed valve. Maintenance during Extended Inactivity NOTE A boiler that is inactive for an extended period of time must be properly maintained. It is often the case that boiler maintenance is neglected once it has become inactive. Failure to maintain suitable storage conditions for the pressure vessel during extended periods of inactivity can result in the start and acceleration of corrosion. In order to avoid this outcome, one of two maintenance methods may be used – namely, wet lay-up (the application of volatile corrosive inhibitors) or dry lay-up. To prevent internal corrosion during periods of extended shutdown (5 to 9 days), deoxidizing agent should be maintained at 150-200 mg/L in the boiler water and the boiler water pH level must be kept between 11-12 to reduce corrosion For shutdown longer than 10 days, the boiler must be filled up with water with higher deoxidizing, to maintain a chemical residual of 200-400 mg/L in the boiler water or drained and treated with inert gas or deoxidizing agent Please contact Miura service office for further details. 54 Since the EX is a small water content boiler, in places where freezing is a problem, caution should be taken when storing with water inside the pressure vessel. Finally, check to make sure all manual valves (water inlet, steam outlet, main & pilot gas,...) are closed tightly and turn off the main power supply to boiler during shutdown. Starting the boiler after a long period of shutdown Drain the water and chemicals in the boiler. Fill up the boiler with feed water, run the boiler until the boiler pressure reaches 30PSIG, and blow off the water too remove chemicals in the boiler. Repeat this process once again. Conduct an internal inspection of the pressure vessel, and clean the water level probes. Install the inspection port plugs and probes and operate the boiler normally. If the boiler is to be inactive for a protracted period of time, please contact a MIURA sales office or your local dealer. Regular Maintenance Tasks and Timing WARNING No work other than that clearly indicated below is to be carried out on the boiler. Failure to observe this precaution may result in injury. The inspection and cleaning tasks listed below must be carried out on a regular basis in order to prevent breakdown and to maintain the high levels of cost effectiveness and safety delivered by your LX steam boiler over a long service life. (Some of the listed items may not apply to your system. If in doubt, please contact MIURA maintenance personnel.) This table presents the standard timing for each inspection and cleaning task, and certain operating conditions (for example, extremely bad water quality) may dictate inspection and cleaning on a more frequent basis. It is important to follow the priority given to instructions by MIURA maintenance personnel regarding the required frequency of maintenance work. TIMING INSPECTION OR CLEANING TASK Daily As shown on display Chemical Feed Check Page 58 Water Softness Check Page 59 Gas Pressure Check Page 60 Steam Pressure Check Page 60 Low Water Level Interlock Test Page 61 Blowdown Page 62 Air Filter Cleaning Page 63 Feed-water Strainer Cleaning Page 64 Once every four months 55 Yearly Feed-water Tank Interior Cleaning Page 66 Water Quality Check Page 68 Safety Valve Inspection Page 69 Electric motors are pre-lubricated at the factory and do not require additional lubrication at startup. Motors with grease fittings should be lubricated using lithium-base grease only and at the frequency given in the table below: TYPE OF SERVICE FREQUENCY OF GREASING Seasonal (i.e., the motor or blower is idle for more than six months) Annually Intermittently (i.e., normal daily operation of the boiler) Semi-annually Continuous Quarterly Do not over-grease the bearings. Over-greasing will cause bearing heat to increase and can result in bearing and motor failure. Always follow the instructions given on the motor nameplate. 56 Spare Parts It is not necessary to order replacement parts from MIURA when the parts warranty has expired. One of our design advantages is the use of non-proprietary parts. The electrical controlled components and assorted valves may be purchased from any industrial parts supplier. The list below is not all-inclusive, but in general, is more than required. For the customer who does not have a standby boiler and far away from a service representative, or desires to maintain a more comprehensive selection of spare parts, contact MIURA for a customized list. The cost of standard ground shipment of a warranty replacement part is paid by MIURA, but for express shipping, the customer will be charged for the extra cost. In addition, the shipment cost for the return of a defective part to MIURA is also paid by the customer. If a warranty-replacement defective part is not returned to MIURA, the customer will be invoiced for the replacement. Furthermore, if the defective part failure is determined to be not a manufacturing defect, the customer will be invoiced by MIURA. PART NAME Damper coupling rubber assembly Relay PART NUMBER Lovejoy 5/8" × 7/16" L070 LY-2, CSA, 120V CA7-85-19-120 CA7-72-11-120 Magnetic contactor CA7-60-11-120 for blower. CA7-43-11-120 Manufactured by Sprecher 1 1 1 1 1 1 1 1 1 1 1 1 1 208 V 230 V 1 208 V 230 V 208V 208 V 230 V 208 V 230 V 208 V 230 V 460 V 575 V 460 V 575 V CA7-37-10-120 CA7-30-10-120 One of each, depending on boiler CA7-16-10-120 model and voltage CA7-12-10-120 CA7-60-10-120 CA7-43-10-120 Magnetic contactor CA7-37-10-120 for water pump CA7-30-10-120 Manufactured by Sprecher CA7-23-10-120 One of each depending on boiler CA7-16-10-120 model and voltage CA7-12-10-120 Spark rod Level sensor * LX-50 LX-100 LX-150 LX-200 LXH-200 LX-300 LXH-300 SR100300 Warrick 3H1C LX-300 985201 LX 985167 (Seal: Feed pump seal 96455086 & gasket: repair kit 96455090) CR2/4/8 (CR1/3/5) LXL 985167 (Seal: 96455086 & gasket: 96455090) Thermocouple Type K ungrounded CF 100000 Compression Fitting (for thermocouple) Burner element FB 100200 (not pre-cut) packing (issue quantity is sq. ft.) 230 V 460 V 575 V 208 V 230 V 460 V 575 V 460 V 575 V 460 V 575 V 460 V 575 V 208 V 230 V 208 V 230 V 208 V 230 V 208 V 230 V 460 V 575 V 1 1 208 V 230 V 208 V 230 V 460 V 575 V 1 1 460 V 575 V 1 1 460 V 575 V 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 57 208 V 230 V 208 V 460 V 575 V 460 V 460 V 575 V 575 V 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 3 3 Overview of Inspection 9.5.1 Checking the Chemical Feeder NOTE A chemical feeder (not included) is a critical component of the overall water management system for a boiler. Be sure to read and understand your chemical feeder’s operation manual thoroughly, and to operate the feeder in a strict accordance with the instructions given. You should also ensure the chemical feeder’s operation manual is stored together with this operation manual in a location that can be readily accessed by persons working on the boiler system. 1) Confirm that the chemical feed is as required. 2) Confirm that sufficient liquid is present to properly dissolve chemicals. 3) Confirm that there is no air in the chemical feed pump or feed line. WARNING Protective glasses and rubber gloves must be worn when adding chemical compounds. These compounds may cause sight loss, burns, and other injuries when they contact with skin or eyes. If boiler chemical comes into direct contact with skin, immediately wash away using cold water. If this chemical enters an eye, immediately wash away with cold water and seek medical attention. NOTE Always follow the instructions of your water treatment personnel in terms of chemical dosage. Insufficient replenishment of chemical compounds can lead to air entering the chemical feed pump and the interruption of supply to the boiler. Accordingly, chemical level checks must be carried out in a proper manner. If the level of chemical in the chemical tank does not reduce at the expected rate, it could indicate that air has become trapped in the pump. In such a case, bleed air from the chemical feed pump. 58 9.5.2 Checking the Water Softness NOTE A water softener (not included) is a critical component of overall water management for a boiler. Be sure to read and understand your water softener’s operation manual thoroughly, and to operate the softener in strict accordance with the instructions given. You should also ensure that the water softener’s operation manual is stored together with this operation manual in a location that can be readily accessed by persons working on the boiler system. 1) To prepare for sampling, rapidly discharge approximately two liters of water from the water sampling port. 2) Thoroughly wash the sampling beaker with the sample water. 3) Add four drops of hardness indicator to the sampling beaker. 4) Add approximately 20 mL of sample water and agitate well to mix. Water sampling port Hardness indicator 5) After agitating, fill the sampling beaker up to the 50-mL level by collecting more sample water. 6) Determine the water hardness based on the color of the solution in the sampling beaker. Light or dark blue : Water is sufficiently soft Purple or red : Water has not been sufficiently softened. CAUTION Do not use a finger to mix the water in the sampling beaker. This type of mixing is not sufficient for hardness measurement. It order to reliably determine the water hardness, it is crucial that only four drops of hardness indicator be added, and 50 mL of sample water. When adding drops of hardness indicator, do it slowly with the bottle held vertically. After agitating well, add more sampled water to increase the overall volume in the sampling beaker to 50 mL, and then immediately check the color of the solution. The color will change after approximately 10 minutes, so any judgment after 10 minutes will be unreliable. 59 9.5.3 Checking the Gas Pressure 1) Open the main gas valve. 2) Using the boiler’s gas pressure gauge, confirm whether the gas is pressurized to the required range (i.e., 3 to 5 PSI). 3) If the reading on the gas pressure gauge is not within the required range, immediately shutdown the boiler as described in Section 8.3: Boiler Shutdown and contact a MIURA sales office or your local dealer for further instruction. Main gas valve Open Gas pressure gauge 9.5.4 1) Checking the Steam Pressure Startup the boiler as described in Section 8.1: Boiler Startup. Steam pressure gauge 2) Confirm that the reading on the steam pressure gauge is in the normal range, and that the gauge pointer is not swinging wildly. WARNING If the steam pressure is not within the normal range, immediately shutdown the boiler and contact a MIURA sales office or your local dealer for further instruction. Continued use of the boiler with abnormal steam pressure levels may result in boiler damage, which in turn could lead to injury. 60 9.5.5 Blowdown & Testing of the Low Water Level Interlock WARNING Do not start blowdown until you have first confirmed that the boiler has been shutdown. Failure to observe this precaution can result in burns and other injuries. (There is no need to carry out blowdown immediately after the display presents a blowdown request during normal boiler operation. It is recommended to wait until the next startup on the following operating day.) NOTE The system will inform you that regular blowdown is required by lighting the Status lamp in yellow and outputting the message ―BOILER CHECK1‖ on the display. (The display’s ―B‖ indicator will also flash at this time.) Although the Status lamp will turn off and the display’s blowdown request will be cleared when the ―DATA‖ button is pressed, the ―B‖ indicator will not. Blowdown must always be carried out in strict accordance with instructions given by MIURA maintenance personnel. Blowdown Procedure 1) Carry out steps 1 to 3 of the boiler startup procedure described in Section 8.1: Boiler Startup. 2) Confirm that the steam pressure gauge is reading 30 PSI. 3) Turn off the ―OPERATION‖ switch. Confirm that the Status lamp turns off. (The main steam valve should also be closed at this time.) Steam pressure gauge WARNING Blowdown must not be carried out if the pressure reading on the steam pressure gauge is above 30 PSI. If this precaution were to be ignored, steam and hot water could be violently discharged from the boiler, which in turn could cause burns and other injuries. (The steam pressure can be lowered by temporarily opening the main steam valve.) 4) Slowly open the boiler’s blowdown valve and carry out boiler-water blowdown. Boiler blowdown valve WARNING All parts of the boiler will be extremely hot at this time. In order to avoid burns and other injuries, avoid touching any part of the boiler other than the blowdown valve. Do not open the boiler blowdown valve rapidly. If the valve is not opened slowly, violent discharge of steam, will cause burns and other injuries. Open slowly 61 WARNING Confirm that the blowdown piping has been firmly secured in place in order to prevent it moving in reaction to the blowdown discharge. Confirm that the outlet of the blowdown piping is fully open and in a safe location, such as inside a pit. 5) Confirm that the display’s ―B‖ indicator turns off. 6) Close the boiler blowdown valve. 7) Turn on the ―OPERATION‖ switch. 8) Confirm that the Status lamp lights in red. If the Status lamp flashes in green at this time, it will indicate that a water level probe error has occurred. In such a case, refer to Section 10.3.2: Inspecting Water Level Probes. DISABLE STEAM 0PSI Boiler blowdown valve Close Once the normal water level has been reached, the Status lamp will switch from red to green, and after a short while, combustion will begin. 9) Normal operation procedures (i.e., from step 3 of the startup sequence detailed in Section 8.1: Boiler Startup) apply from this point onward. Low Water Level Interlock Test If the water volume, for any reason, falls below the pre-determined water volume, combustion will immediately be stopped and if it is not recovered after 15 sec after combustion shutoff, a warning alarm will be activated. The display will read, ―WATER ALARM 1‖. For testing the Low Water Volume Cut-off, open the ball valve at the bottom of the LVC and allow time for the steam pressure to force the water out of the LVC. When the low water cut-off probe loses contact with the water for more than 15 seconds, the boiler will shift to stand-by mode first and shut down 15 seconds, the alarm will sound and the BL11 Microcomputer will display ―WATER ALARM 1‖. 62 9.5.6 Cleaning the Air Filter NOTE If dust or other foreign matter has caused the air filter to become clogged, the control system will inform you by lighting the Status lamp in yellow and presenting the message ―BOILER CHECK3‖ on the display. Incomplete combustion could occur if this situation is not addressed, therefore, it is important that the air filter is cleaned whenever blockage has occurred. We recommend that the filter also be cleaned on a regular basis in order to ensure clean, safe operation of this steam boiler. Extra care must be taken regarding to the cleaning of filters in cement factories, textile plants, and other locations where a large amount of airborne material is present inside the boiler room. WARNING Before attempting to clean the air filter, be sure to always receive instruction from MIURA maintenance personnel and to fully familiarize yourself with the process involved. 1) Turn off the breaker for the boiler’s main power. WARNING Allow sufficient time for the boiler to cool down before performing this task. As all parts of the boiler remain at a high temperature for some time after shutdown, failure to observe this precaution can result in burns and other injuries. The main-power breaker must be turned off in advance of this procedure. If the blower were to operate, injury such as the loss of fingers could easily occur. Never operate the breaker for the boiler’s main power supply with wet hands. Failure to observe this precaution may lead to electric shock and have other undesirable consequences. 2) Main power Setup a ladder and climb onto the top of the boiler. WARNING Do not jump onto or jump off the ladder. You must keep both hands and one foot, or both feet and one hand in contact with the ladder at all times when ascending or descending. Failure to observe this precaution may result in a fall and the associated injury. Use only the indicated footing. Failure to observe this precaution may result in a fall from the boiler or damage to the boiler itself. 3) Clean the filter using a soft brush. 4) If the filter is damaged or extremely dirty, it must be replaced. In such a case, please contact MIURA maintenance personnel. 63 Brush Filter 9.5.7 Cleaning the Feed-water Strainer WARNING Water in the feed-water tank for the boiler connecting to a deaerator or hot water tank is extremely hot. For this reason, you should wait until the boiler’s water supply lines have sufficiently cooled down (at least two hours after boiler shutdown) before performing this work. Failure to observe this precaution can result in burns and other injuries. 1) Turn off the breaker for the boiler’s main power. Confirm that the steam pressure gauge is reading 0 PSI. If this is not the case, stand by until the pressure reading drops to zero. WARNING Main power Never operate the breaker for the boiler’s main power supply with wet hands. Failure to observe this precaution may lead to electric shock and have other undesirable consequences. 2) Confirm that the main feed water valve is closed. 3) Open the boiler blowdown valve and carry out boiler-water blowdown. Steam pressure gauge Close Close Main feed water valve Main feed water valve WARNING Main feed water valve Be sure to always carry out boiler-water blowdown before cleaning the feed water strainer. If reverse flow of boiler water were to occur during this procedure, it could result in burns or other injury. 4) Open When the discharge of boiler water has stopped, close the boiler blowdown valve. 5) Open the feed water pump’s air bleed valve. This action releases pressure from the feed water piping. 6) Using wrenches, open the feed water strainer’s cap. Boiler blowdown valve Main feed water valve Close NOTE Water will discharge from the piping when you open the feed water strainer’s cap. Particularly in cases where the piping is long, a relatively large amount of water may come out, and buckets or containers should be used to prevent spillage. Feed water strainer Wrenches Cap 64 7) Remove the filter and clean it using a brush. If rust cannot easily be removed from gaps or significant deformation has occurred, the filter must be replaced. In such a case, please contact a MIURA sales office or your local dealer. Filter Brush 8) Return the filter to its original position inside the feed water strainer. Cap 9) Wrap PTFE tape around the cap’s contact surface, and then secure the cap tightly using wrenches. NOTE Be sure to wrap the PTFE tape neatly and in the opposite direction to that of cap tightening. Failure to observe this precaution can result in the leakage of water. Cap PTFE tape 10) Close the feed water pump’s air bleed valve. When the feed water strainer has been cleaned, it is important to bleed air from the feed water pump as described in Section 10.3.1: Bleeding Air from the Feed Water Pump before operating the boiler. 65 9.5.8 Cleaning the Feed-water Tank WARNING Water in supply lines for boilers connecting to a deaerator or hot water tank is extremely hot. For this reason, you should wait until the tank water has sufficiently cooled down (at least two hours after boiler shutdown) before performing this work. Failure to observe this precaution can result in burns and other injuries. Main makeup valve Feed water tank Feed water tank’s blowdown valve Cleaning the Feed-water Tank 1) Turn off the breaker for the boiler’s main power. Confirm that the steam pressure gauge is reading 0 PSI. If this is not the case, stand by until the pressure reading drops to zero. Main power WARNING Steam pressure gauge Never operate the breaker for the boiler’s main power supply with wet hands. Failure to observe this precaution may lead to electric shock and have other undesirable consequences. 2) Close the main makeup valve. Main makeup valve Close 3) Open the blowdown valve for the feed water tank. Open Feed water tank’s blowdown valve 66 4) When the discharge of water ends, close the feed water tank’s blowdown valve. 5) Open the main makeup valve. Close Feed water tank’s blowdown valve Main makeup valve Open 67 9.5.9 Checking the Water Quality NOTE You must check the water quality once every four months. The quality of tap water, underground water, industrial supply water, and other sources typically change from season to season. Failure to carry out regular quality checks could lead to drop in boiler efficiency and boiler water tube damages. Please contact a MIURA sales office or your local dealer for assistance regarding water quality checking. ITEM UNITS pH (at 25C) BOILER WATER MAKE UP WATER （FEED WATER） 11.0 - 11.8 7-9 -0.0- -0.0- Hardness mg/L CaCO3 Oxygen PPM O2 P Alkalinity mg/L CaCO3 150 - 600 M Alkalinity mg/L CaCO3 250 - 800 Below 0.5 PPM or above 90C - Sulfites PPM S Conductivity (at 25C) S/cm Detectable Detectable 1,500 - 4,000 - Chloride mg/L Cl Below 400 Below 30 Silica mg/L SiO2 Below 250 Below 30 Iron and Manganese mg/L Fe + Mn Below 1.0 Total below 0.5 NOTE One of the most common causes of boiler damage is scale. Water hardness must be tested daily. The conventional method of testing water hardness is through manual testing. Results can vary due to sample and reagent amounts, personal interpretation, and lack of continuity in monitoring hardness. An optional MIURA Colormetry CMU solves all of these problems by offering an automatic monitoring system for sample water collection, chemical reagent injection, mixing and evaluation. With this option, MIURA boiler will also display the message ―CAUTION – CHECK SOFTENER‖ whenever the MIURA Colormetry CMU detects hardness. 68 9.5.10 Inspecting the Safety Valve WARNING The safety valve must be inspected on a regular basis. Failure to do so can result in valve damage, which in turn can lead to boiler explosion and have other undesirable consequences. NOTE The safety valve’s release pressure has been adjusted to match the indicated value. Despite the fact that a small amount of deviation may occur, you must not tamper with the pressure setting. If you suspect leakage or some other abnormality, please contact a MIURA sales office or your local dealer. Please arrange for MIURA maintenance personnel to carry out safety-valve inspection. 9.5.11 Cleaning the UV Sensor’s Protective Glass WARNING Main power As all parts of the boiler remain at a high temperature for some time after shutdown, you should allow sufficient time for cooling down before performing this work. Failure to observe this precaution can result in burns and other injury. Before attempting to clean the UV sensor’s protective glass, be sure to always receive instruction from MIURA maintenance personnel and to fully familiarize yourself with the process involved. UV sensor 1) Turn off the breaker for the boiler’s main power. WARNING Never operate the breaker for the boiler’s main power supply with wet hands. Failure to observe this precaution may lead to electric shock and have other undesirable consequences. Screws 2) Extract the UV sensor. 3) Remove the mounting screws from the phototube base. 4) Using a soft cloth, wipe all soot from the glass at the bottom of the UV sensor’s base. 5) Reassemble and replace the sensor in its original condition and position. UV sensor base Glass 69 Packing 10 BREAKDOWN & COUNTERMEASURES 10.1 Alarm and Red Status Lamp – Alarm .................................... 71 10.2 Yellow Status Lamp – Caution .............................................. 72 10.3 Action to be Taken before Ordering Repairs ......................... 73 10.3.1 Bleeding Air from the Feed Water Pump .................... 76 10.3.2 Inspecting Water Level Probes ................................... 77 10.3.3 Resetting the High Pressure Limit Shutoff Switch ...... 77 10.3.4 Resetting Blower Overcurrent ..................................... 78 70 10.5 Alarm and Red Status Lamp – Alarm NOTE A ―alarm‖ is activated when the control system determines that dextended operation of the boiler would constitute a safety hazard and potential boiler damage. In such a case, the system stops combustion and provides notification in the form of an audible alarm and display message. Combustion is automatically stopped when an alarm is triggered. At this time, the control system sounds an alarm and lights the Status lamp in red. In addition, details of the alarm are shown on the display. 1) Press the ―DATA‖ button to stop the alarm. NOTE In the case of certain alarms, the display will request action that must be carried out by MIURA maintenance personnel. Refer to Section 10.3: Action to be Taken before Ordering Repairs for details regarding the correct action to be taken in response to an alarm. 2) Take note of the alarm details, and then turn off the ―OPERATION‖ switch. This action will clear the alarm display. NOTE In certain cases, the alarm will not stop in response to steps (1) and (2) above. In such a case, turn off the breaker for the boiler’s main power, and then contact a MIURA sales office for further instruction. 3) Eliminate the cause of the alarm as described in Section 10.3: Action to be Taken before Ordering Repairs. WARNING Procedures aimed at removing the cause of an alarm must be carried out in strict accordance with the given instructions. Failure to do so may have serious consequences. 4) Startup the boiler as described in Section 8.1: Boiler Startup. If the same alarm reoccurs, it may be the result of additional factors. In such a case, contact a MIURA sales office or your local dealer for further instruction. 71 10.6 Yellow Status Lamp – Caution NOTE A ―caution‖ is issued upon the occurrence of a situation that could result in the activation of an alarm if left unaddressed. If the control system identifies a condition that could lead to the activation of an alarm during subsequent operation, combustion is allowed to continue as is, or the control method is changed automatically in order to facilitate ongoing operation. At this time, the system lights the Status lamp in yellow. No alarm is sounded upon the issuance of a caution. Details pertaining to the caution are presented on the display. NOTE In the case of certain caution, the display will request action that must be carried out by MIURA maintenance personnel. Refer to Section 10.3: Action to be Taken before Ordering Repairs for details regarding the correct action to be taken in response to a caution. The display of caution details can be reset by pressing the ―DATA‖ button, even during operation of the boiler. 1) Carry out steps (1) and (2) from Section 10.1: Alarm and Red Status Lamp – Alarm. 2) Eliminate the cause of the alarm as described in Section 10.3: Action to be Taken before Ordering Repairs. WARNING Procedures aimed at removing the cause of an alarm must be carried out in strict accordance with the given instructions. Failure to do so may have serious consequences. 72 10.7 Action to be Taken before Ordering Repairs WARNING Whenever taking action in response to an alarm or a caution, be sure to always turn off the boiler’s ―OPERATION‖ switch, and follow the action in the table below, to carry out the required work in strict accordance with the corresponding instructions. If the cause of the alarm or caution persists, despite repair work having been carried out as instructed, immediately shut down the boiler as described in Section 8.3: Boiler Shutdown and contact a MIURA sales office or your local dealer for further instruction. No work other than that indicated below is to be carried out. Failure to observe this precaution may result in injury. SYMPTOMS OR DISPLAY CONTENT CAUSE No power is being supplied to the boiler. Display does not turn on BURNER ALARM 2 The breaker for the boiler’s main power is turned off. Problem with the volume of air required for combustion. REQUIRED ACTION Confirm whether a power failure has occurred. Turn on the breaker for the boiler’s main power. Inspect the air pressure switch. Turn the ―OPERATION‖ switch off and then back on. (This action will clear the alarm display.) If the same alarm occurs again, immediately shut down the boiler as described in Section 8.3: Boiler Shutdown and contact a MIURA sales office or your local dealer for further instruction. PAGE － － － BURNER ALARM 4 Overcurrent has occurred in the blower. WATER ALARM 2 Overcurrent has occurred in the feed water pump. BURNER ALARM 5 Either the main gas valve is closed or a problem has occurred in the UV sensor. Either the main gas valve is closed or there is a problem with the volume of air required for combustion. Open the main gas valve. － A problem has occurred with the air damper. Inspect the damper. － Open the main feed-water valve. － Close the blowdown valve. － Bleed air from the feed water pump. 76 Clean the feed water strainer. 64 Inspect the water system upstream of the feed water equipment. 66 Inspect the probe. 77 BURNER ALARM 7 78 76 BURNER ALARM 13 Red Status Lamp BURNER ALARM14 WATER ALARM 1 The main feed water valve is closed and no water is being delivered. The blowdown valve is open and water is being discharged from the boiler. Air has become trapped in the feed water pump, preventing it from operating correctly. The feed water strainer is blocked and no water is being delivered. A problem may have occurred upstream of the feed water equipment. WATER ALARM 6 WATER ALARM 8 WATER ALARM 10 WATER ALARM 11 Poor electrical contact with the water level probe. WATER ALARM 12 WATER ALARM 13 WATER ALARM 17 73 SYMPTOMS OR DISPLAY CONTENT CAUSE REQUIRED ACTION PAGE WATER ALARM 3 WATER ALARM 7 WATER ALARM 14 WATER ALARM 15 There is poor continuity in the water level probe. Inspect the probe. 77 WATER ALARM 16 WATER ALARM 18 CONTROL ALARM 1 CONTROL ALARM 2 A problem has occurred with the control system. － CONTROL ALARM 3 SAFETY STOP 1 SAFETY STOP 2 SAFETY STOP 4 SAFETY STOP 5 Red Status Lamp SAFETY STOP 6 SAFETY STOP 7 SAFETY STOP 8 A problem has occurred with the combustion control system. A problem has occurred with the fuel supply equipment. A problem has occurred with the UV sensor. The exhaust-gas temperature is not within the normal range. A safety device was activated. A high steam-pressure cutout was activated. A wire has broken for the overheat thermocouple. Turn the ―OPERATION‖ switch off and then back on. (This action will clear the alarm display.) If the same alarm occurs again, immediately shut down the boiler as described in Section 8.3: Boiler Shutdown and contact a MIURA sales office or your local dealer for further instruction. － － － － － 77 － SAFETY STOP 11 Abnormal combustion is occurring. － SAFETY STOP 44 A wire has broken for the scale monitor. － SAFETY STOP 45 SAFETY STOP 46 SAFETY STOP 47 A problem has occurred with the water softener. The regulator has malfunctioned or a wire has broken for the pressure switch. The chimney damper has malfunctioned. SAFETY STOP 48 The gas valve has malfunctioned. SAFETY STOP 49 The chimney is blocked. SENSOR ALARM 1 A problem has occurred with the air pressure switch. UTILITY ALARM 1 A power failure has occurred. UTILITY ALARM 3 An emergency stop device was activated. UTILITY ALARM 2 UTILITY ALARM 14 Inspect the water softener. 56 － Turn the ―OPERATION‖ switch off and then back on. (This action will clear the alarm display.) If the same alarm occurs again, immediately shut down the boiler as described in Section 8.3: Boiler Shutdown and contact a MIURA sales office or your local dealer for further instruction. An earthquake detector was activated, causing the boiler to shutdown.(not Reset the earthquake detector. supplied) Confirm that sufficient gas Either the main gas valve is closed or remains and/or open the main there is no gas left. gas valve. 74 － － － － － － － － SYMPTOMS OR DISPLAY CONTENT CAUSE WATER CHECK 1 The strainer is blocked or the blowdown valve is open. WATER CHECK 2 The check valve is damaged. WATER CHECK 4 WATER CHECK 5 WATER CHECK 7 WATER CHECK 8 There is poor insulation in the water level probe. There is poor continuity in the water level probe. Either the surface-blowdown strainer has become blocked or the solenoid valve has malfunctioned. A wire has broken in the conductivity sensor. The level of voltage in the backup battery has dropped. A problem has occurred with the feed-water temperature sensor. A problem has occurred with the scale monitor. A problem has occurred with the overheat thermocouple. A problem has occurred with the exhaust-gas temperature sensor. A problem has occurred with the exhaust-gas temperature sensor. A problem has occurred with the steam pressure sensor. A problem has occurred with the UV sensor. SECURITY CHECK 2 SECURITY CHECK 3 SECURITY CHECK 4 SENSOR CHECK 1 SENSOR CHECK 3 SENSOR CHECK 4 Yellow Status Lamp SENSOR CHECK 5 SENSOR CHECK 6 SENSOR CHECK 8 SENSOR CHECK 11 DATA COM CHECK 1 DATA COM CHECK 2 REQUIRED ACTION A communication problem has occurred. Clean the strainer and/or close the blowdown valve. Contact a MIURA sales office or your local dealer for assistance. PAGE 64 － Inspect the probe. 77 Clean the strainer. － Inspect the conductivity sensor. － Replace the battery. － － The boiler’s control system has identified a condition that could lead to the occurrence of an alarm during subsequent operation. Although operation of the boiler may be continued, you should contact a MIURA sales office or your local dealer for assistance. － － － － － 69 Immediately contact a MIURA sales office or your local dealer for assistance. Carry out measures to protect against freezing. Turn on fans and other ventilation equipment. － UTILITY CHECK 1 There is a danger of freezing. UTILITY CHECK 3 Ventilation is not sufficient. BOILER CHECK 1 BOILER CHECK 2 The scheduled time for blowdown has been reached. Perform blowdown. 61 BOILER CHECK 3 The air filter is blocked. Clean the air filter. 63 Inspect the water softener. 59 Add chemical. 58 Immediately contact a MIURA sales office or your local dealer for assistance. － MISC CHECK 1 MISC CHECK 2 DATA COM ERROR1 DATA COM ERROR2 DATA COM ERROR3 DATA COM ERROR4 DATA COM ERROR6 DATA COM ERROR7 DATA COM ERROR8 DATA COM ERROR10 DATA COM ERROR11 A problem has occurred with the water softener. There is insufficient chemical in the system. A communication problem has occurred. 75 53 － 10.3.1 Bleeding Air from the Feed Water Pump WARNING Water in supply lines for boilers connecting to a deaerator or hot water tank is extremely hot. For this reason, you should wait until the boiler’s water supply lines have sufficiently cooled down (at least two hours after boiler shutdown) before performing this work. Failure to observe this precaution can result in burns and other injuries. 1) Carry out steps (1) to (3) from Section 10.1: Alarm and Red Status Lamp – Alarm. 2) Open the main feed-water valve. 3) Open the feed water pump’s air bleed valve. A mixture of air and water will be discharged from the air bleed valve. Air bleeding will be completed when air is no longer contained in the discharged water. Open NOTE Ensure that you rotate the handle for the air bleed valve by no more than one complete turn. Failure to observe this precaution may result in the rushing out of water. 4) Confirm that all air has been bled from the system and that only water is being discharged. 5) Close the feed water pump’s air bleed valve. 76 Main feed water valve Main feed water valve Main feed water valve Main feed water valve 10.3.2 Inspecting Water Level Probes 1) Carry out steps (1) and (2) from Section 10.1: Alarm and Red Status Lamp – Alarm. WARNING Allow sufficient time for the boiler to cool down (at least two hours after boiler shutdown) before performing this task. As all parts of the boiler remain at a high temperature for some time after shutdown, failure to observe this precaution can result in burns and other injuries. Rubber electrode cap Water level probe 2) Remove the rubber electrode cap from the top of the electrode, and reconnect the terminal. Following this, return the rubber electrode cap to its original position. 3) Startup the boiler in accordance with the prescribed manual procedure. If the same alarm reoccurs, immediately shutdown the boiler and contact a MIURA sales office or your local dealer for further instruction. 10.3.3 Resetting the High Pressure Limit Shutoff Switch 1) Carry out steps (1) and (2) from Section 10.1: Alarm and Red Status Lamp – Alarm. 2) If the boiler shuts down due to high pressure, you need to press the reset lever on the pressure switch to restart the boiler. 3) Startup the boiler in accordance with the prescribed manual procedure. If the same alarm reoccurs, immediately shutdown the boiler and contact a MIURA sales office or your local dealer for further instruction. NOTE Please check the pressure transducer and BL11 Microcomputer settings as well as the control pressure switch for any malfunction or incorrect setting. The control pressure switch should have a lower setting than the high pressure limit switch, and the microcomputer should have a lower setting than both steam pressure switches. When testing the high pressure limit switch, set it lower than the BL11 Microcomputer setting so that it will shut down the boiler when the set pressure is reached. After testing, be sure to set it back to the original setting and to reset the high pressure limit switch. 77 Terminal 10.3.4 Resetting Blower Overcurrent 1) Carry out steps (1) and (2) from Section 10.1: Alarm and Red Status Lamp – Alarm. 2) Startup the boiler in accordance with the prescribed manual procedure. If the same alarm reoccurs, immediately shutdown the boiler and contact a MIURA sales office or your local dealer for further instruction. NOTE Short-circuiting or prolonged overloading of the blower motor will result in boiler shutdown. In addition, an alarm will be activated and the display will show ―BURNER ALARM 4‖. Some motors have an internal stator-winding thermal overload feature, in case of tripping because of these internal overload protection, operation will not resume until the blower motor has cooled down. 78 11 SPECIFICATIONS 79 Specifications for LX-50 ITEM UNITS LX-50 G LX-50 SG Boiler Type Multiple water tube, once through, forced flow, steam boiler Boiler Horsepower Rating BHP 50 Maximum Pressure PSIG (Kg/cm²) 170 (11.95) design Equivalent Output Lb/Hr (Kg/Hr) 1,725 (782) Heat Output 1,674,000 (421,800) Btu/Hr (KCal/Hr) Heat Input 2,092,000 (527,200) 1,969,000 (496,200) Efficiency (fuel to steam) % 80 85 Boiler Heating Surface Area Ft² (m²) 192.4 (17.9) Operational Weight Lb (Kg) 3,380 (1,530) 3,710 (1,680) Shipping Weight Lb (Kg) 3,150 (1,430) 3,480 (1,580) Combustion Control 3 position step burner HIGH-LOW-OFF Combustion System Forced draft, pre-mixed burner Ignition System Electric spark ignited interrupted gas pilot Power Supply 575, 460, 230 or 208V 3 phase, 60 Hz Max. Electrical Consumption – KVA 6.5 with or w/o MI Check Valve option Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Main Steam Outlet Safety Valve Outlet Feedwater Inlet Fuel Gas Inlet HP (KW) SCFH (Nm3/Hr) PSIG SCFH (Nm3/Hr) Ft/s (m/s) F (C) Inches Automatic "Surface" Blowdown 3.0 (2.25) 2,090 (56.1) 1,960 (52.5) 3 - 5 (natural gas or propane) 27,500 (750) 26,300 (706) 23,400 (639) 22,400 (600) 17.3 (5.3) 13.1 (4.0) 450 (230) 270 (130) 2" NPT 1¼" NPT 3 /4" NPT 1½" NPT 3 /8" NPT Boiler & LVC Drain 2 x 1" NPT Chimney Diameter 12" ID Flame Detector Ultraviolet flame eye sensor Overheat Protection High tube temperature & Low water cut-off. NOTE: i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. iii. iv. v. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. Thermal efficiencies are based on high heating values of fuels. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Boiler Safety valve Outlet size may increase if set below 170 PSIG. Page 80 Specifications for LXL-50 ITEM Boiler Type Boiler Horsepower Rating UNITS LXL-50 G LXL-50 SG Multiple water tube, once through, forced flow, steam boiler BHP 50 Maximum Pressure PSIG (Kg/cm²) 15 (1.05) design Equivalent Output Lb/Hr (Kg/Hr) 1,725 (782) Btu/Hr (KCal/Hr) 1,674,000 (421,800) 2,092,000 (527,200) 1,969,000 (496,200) % 80 85 Heat Output Heat Input Efficiency (fuel to steam) Boiler Heating Surface Area Ft² (m²) 192.4 (17.9) Operational Weight Lb (Kg) 4,040 (1,830) 4,370 (1,980) Shipping Weight Lb (Kg) 3,690 (1,670) 4,020 (1,820) Combustion Control 3 position step burner HIGH-LOW-OFF Combustion System Forced draft, pre-mixed burner Ignition System Electric spark ignited interrupted gas pilot Power Supply Max. Electrical Consumption Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature 575, 460, 230 or 208V, 3 phase, 60 Hz KVA 5.0 with MI Check Valve option HP (KW) 4.9 without MI Check valve option 3.0 (2.25) SCFH (Nm3/Hr) PSIG 2,090 (56.1) 1,960 (52.5) 3 - 5 (natural gas or propane) 27,500 (750) 26,300 (706) 23,400 (639) 22,400 (600) Ft/s (m/s) 17.3 (5.3) 13.1 (4.0) F (C) 450 (230) 270 (130) SCFH (Nm3/Hr) Main Steam Outlet 4" FLG Safety Valve Outlet 2½" NPT 3 Feedwater Inlet Fuel Gas Inlet /4" NPT Inches 1½" NPT 3 Automatic "Surface" Blowdown /8" NPT Boiler & LVC Drain 2 x 1" NPT Chimney Diameter 12" ID Flame Detector Overheat Protection Ultraviolet flame eye sensor High tube temperature & Low water cut-off. NOTE: i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. iii. Thermal efficiencies are based on high heating values of fuels. iv. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Page 81 Specifications for LX-100 ITEM UNITS LX-100 G LX-100 SG Boiler Type Multiple water tube, once through, forced flow, steam boiler Boiler Horsepower Rating BHP 100 Maximum Pressure PSIG (Kg/cm²) 170 (11.95) design Equivalent Output Lb/Hr (Kg/Hr) 3,450 (1,565) Heat Output 3,348,000 (843,600) Btu/Hr (KCal/Hr) Heat Input 4,184,000 (1,054,000) 3,938,000 (992,400) Efficiency (fuel to steam) % 80 85 Boiler Heating Surface Area Ft² (m²) 269.0 (25.0) Operational Weight Lb (Kg) 5,590 (2,540) 6,070 (2,750) Shipping Weight Lb (Kg) 4,990 (2,260) 5,470 (2,480) Combustion Control 3 position step burner HIGH-LOW-OFF Combustion System Forced draft, pre-mixed burner Ignition System Electric spark ignited interrupted gas pilot Power Supply 575, 460, 230 or 208V, 3 phase, 60 Hz Max. Electrical Consumption – KVA 13.3 with or w/o MI Check Valve option Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Main Steam Outlet Safety Valve Outlet Feedwater Inlet Fuel Gas Inlet Automatic "Surface" Blowdown Boiler & LVC Drain Chimney Diameter Flame Detector Overheat Protection NOTE: HP (KW) SCFH (Nm3/Hr) PSIG 10 (7.5) 4,180 (112.1) 3,920 (105.5) 3 - 5 (natural gas or propane) 55,000 (1,500) 52,500 (1,407) SCFH (Nm3/Hr) 46,800 (1,279) 44,900 (1,203) Ft/s (m/s) 34.7 (10.6) 26.0 (7.9) 450 (230) 270 (130) F (C) 2" NPT 2" NPT 1" NPT 2" NPT Inches 3 /8" NPT 2 x 1" NPT 12" ID Ultraviolet flame eye sensor High tube temperature & Low water cut-off. i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. iii. iv. v. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. Thermal efficiencies are based on high heating values of fuels. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Boiler Safety valve Outlet size may increase if set below 170 PSIG. Page 82 Specifications for LXL-100 ITEM Boiler Type Boiler Horsepower Rating UNITS LXL-100 G LXL-100 SG Multiple water tube, once through, forced flow, steam boiler BHP 100 Maximum Pressure PSIG (Kg/cm²) 15 (1.05) design Equivalent Output Lb/Hr (Kg/Hr) 3,450 (1,565) Btu/Hr (KCal/Hr) 3,348,000 (843,600) 4,184,000 (1,054,000) 3,938,000 (992,400) % 80 85 Heat Output Heat Input Efficiency (fuel to steam) Boiler Heating Surface Area Ft² (m²) 269.0 (25.0) Operational Weight Lb (Kg) 6,950 (3,150) 7,430 (3,370) Shipping Weight Lb (Kg) 6,050 (2,740) 6,530 (2,960) Combustion Control 3 position step burner HIGH-LOW-OFF Combustion System Forced draft, pre-mixed burner Ignition System Electric spark ignited interrupted gas pilot Power Supply Max. Electrical Consumption 575, 460, 230 or 208V, 3 phase, 60 Hz 10.9 with MI Check Valve option KVA 10.6 without MI Check Valve option Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature HP (KW) 3 SCFH (Nm /Hr) PSIG 10 (7.5) 4,180 (112.1) 3,920 (105.5) 3 - 5 (natural gas or propane) 55,000 (1,500) 52,500 (1,407) 46,800 (1,279) 44,900 (1,203) Ft/s (m/s) 34.7 (10.6) 26.0 (7.9) F (C) 450 (230) 270 (130) SCFH (Nm3/Hr) Main Steam Outlet 6" FLG Safety Valve Outlet 2 x 2½" NPT Feedwater Inlet Fuel Gas Inlet 1" NPT Inches 2" NPT 3 Automatic "Surface" Blowdown /8" NPT Boiler & LVC Drain 2 x 1" NPT Chimney Diameter 12" ID Flame Detector Overheat Protection Ultraviolet flame eye sensor High tube temperature & Low water cut-off. NOTE: i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. iii. Thermal efficiencies are based on high heating values of fuels. iv. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Page 83 Specifications for LX-150 ITEM Boiler Type Boiler Horsepower Rating Maximum Pressure Equivalent Output Heat Output Heat Input Efficiency (fuel to steam) Boiler Heating Surface Area Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption – with or w/o MI Check Valve option Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Main Steam Outlet Safety Valve Outlet Feedwater Inlet Fuel Gas Inlet Automatic "Surface" Blowdown Boiler & LVC Drain Chimney Diameter Flame Detector Overheat Protection NOTE: UNITS LX-150 G LX-150 SG Multiple water tube, once through, forced flow, steam boiler BHP 150 PSIG (Kg/cm²) 170 (11.95) design Lb/Hr (Kg/Hr) 5,175 (2,347) 5,022,000 (1,265,000) Btu/Hr (KCal/Hr) 6,277,000 (1,582,000) 5,908,000 (1,489,000) % 80 85 Ft² (m²) 388.2 (36.1) Lb (Kg) 7,650 (3,470) 8,620 (3,910) Lb (Kg) 6,850 (3,110) 7,820 (3,550) 3 position step burner HIGH-LOW-OFF Forced draft, pre-mixed burner Electric spark ignited interrupted gas pilot 575, 460, 230 or 208V, 3 phase, 60 Hz KVA 22.1 HP (KW) SCFH (Nm3/Hr) PSIG 15 (11.2) 6,250 (167.4) 5,880 (158.3) 3 - 5 (natural gas or propane) 83,700 (2,242) 78,800 (2,111) SCFH (Nm3/Hr) 71,500 (1,916) 67,300 (1,803) Ft/s (m/s) 19.1 (5.8) 14.1 (4.3) 470 (240) 270 (130) F (C) 3" FLG 2½" NPT 1" NPT 2" NPT Inches 3 /8" NPT 2 x 1" NPT 20" ID Ultraviolet flame eye sensor High tube temperature & Low water cut-off. i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. iii. iv. v. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. Thermal efficiencies are based on high heating values of fuels. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Boiler Safety valve Outlet size may increase if set below 170 PSIG. Page 84 Specifications for LXL-150 ITEM Boiler Type Boiler Horsepower Rating UNITS LXL-150 G LXL-150 SG Multiple water tube, once through, forced flow, steam boiler BHP 150 Maximum Pressure PSIG (Kg/cm²) 15 (1.05) design Equivalent Output Lb/Hr (Kg/Hr) 5,175 (2,347) Btu/Hr (KCal/Hr) 5,022,000 (1,265,000) Heat Output Heat Input Efficiency (fuel to steam) 6,199,000 (1,562,000) 5,908,000 (1,489,000) % 81 85 Boiler Heating Surface Area Ft² (m²) 496 (46.1) Operational Weight Lb (Kg) 10,700 (4,860) 12,340 (5,600) Shipping Weight Lb (Kg) 9,800 (4,500) 11,500 (5,200) Combustion Control 3 position step burner HIGH-LOW-OFF Combustion System Forced draft, pre-mixed burner Ignition System Electric spark ignited interrupted gas pilot Power Supply Max. Electrical Consumption KVA Blower Motor Output HP Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature 575, 460, 230 or 208V, 3 phase, 60 Hz 18.6 with MI Check Valve option 18.3 without MI Check Valve option 15 SCFH (Nm3/Hr) PSIG 6,250 (167.4) 5,880 (158.3) 3 - 5 (natural gas or propane) 83,700 (2,242) 78,800 (2,111) 71,500 (1,916) 67,300 (1,803) Ft/s (m/s) 38.9 (11.9) 28.7 (8.7) F (C) 470 (240) 270 (130) SCFH (Nm3/Hr) Main Steam Outlet 8" FLG Safety Valve Outlet 2 x 4‖ for boiler and optional 1¼‖ for economizer Feedwater Inlet Fuel Gas Inlet 1" NPT Inches 2" NPT 3 Automatic "Surface" Blowdown Boiler & LVC Drain /8" NPT 2 x 1" NPT Chimney Diameter 20" ID Flame Detector Overheat Protection Ultraviolet flame eye sensor High tube temperature & Low water cut-off. NOTE: i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. iii. Thermal efficiencies are based on high heating values of fuels. iv. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Page 85 Specifications for LX-200 ITEM Boiler Type Boiler Horsepower Rating Maximum Pressure Equivalent Output Heat Output Heat Input Efficiency (fuel to steam) Boiler Heating Surface Area Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption – with UNITS LX-200 G LX-200 SG Multiple water tube, once through, forced flow, steam boiler BHP 200 PSIG (Kg/cm²) 170 (11.95) design Lb/Hr (Kg/Hr) 6,900 (3,129) 6,695,000 (1,687,000) Btu/Hr (KCal/Hr) 8,369,000 (2,109,000) 7,876,000 (1,985,000) % 80 85 Ft² (m²) 387.7 (36.0) Lb (Kg) 7,650 (3,470) 8,620 (3,910) Lb (Kg) 6,850 (3,110) 7,820 (3,550) 3 position step burner HIGH-LOW-OFF Forced draft, pre-mixed burner Electric spark ignited interrupted gas pilot 575, 460, 230 or 208V, 3 phase, 60 Hz KVA 24.3 or w/o MI Check Valve option Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Main Steam Outlet Safety Valve Outlet Feedwater Inlet Fuel Gas Inlet Automatic "Surface" Blowdown Boiler & LVC Drain Chimney Diameter Flame Detector Overheat Protection NOTE: i. ii. iii. iv. v. vi. HP (KW) SCFH (Nm3/Hr) PSIG 15 (11.2) 8,340 (223.4) 7,850 (211.0) 3 - 5 (natural gas or propane) 112,000 (2,999) 105,000 (2,813) SCFH (Nm3/Hr) 95,500 (2,559) 89,900 (2,409) Ft/s (m/s) 25.5 (7.8) 18.8 (5.7) 470 (240) 270 (130) F (C) 3" FLG 2½" NPT 1" NPT 2" NPT Inches 3 /8" NPT 2 x 1" NPT 20" ID Ultraviolet flame eye sensor High temperature & Low water cut-off. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. Thermal efficiencies are based on high heating values of fuels. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. Boiler Safety valve Outlet size may increase if set below 170 PSIG. With the inverter option (12ppm Low NOx package model) the input is derated to 190BHP(95%) and the heat in & output, fuel consumption, and the flue gas numbers are reduced accordingly. Page 86 Specifications for LXL-200 ITEM Boiler Type Boiler Horsepower Rating Maximum Pressure Equivalent Output Heat Output Heat Input Efficiency (fuel to steam) UNITS LXL-200 G LXL-200 SG Multiple water tube, once through, forced flow, steam boiler BHP 200 PSIG (Kg/cm²) Lb/Hr (Kg/Hr) 15 (1.05) design 6,900 (3,129) Btu/Hr (KCal/Hr) 6,695,000 (1,687,000) % 8,369,000 (2,109,000) 7,876,000 (1,985,000) 80 85 Boiler Heating Surface Area Ft² (m²) 387.7 (36.0) Operational Weight Lb (Kg) Shipping Weight Combustion Control Lb (Kg) Combustion System Ignition System 10,150 (4,600) 8,950 (4,060) 9,920 (4,500) 3 position step burner HIGH-LOW-OFF Forced draft, pre-mixed burner Electric spark ignited interrupted gas pilot Power Supply Max. Electrical Consumption 11,120 (5,040) 575, 460, 230 or 208V, 3 phase, 60 Hz KVA 19.0 – with or w/o MI Check Valve option Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature HP (KW) 15 (11.2) 3 SCFH (Nm /Hr) PSIG SCFH (Nm3/Hr) Ft/s (m/s) F (C) Main Steam Outlet Safety Valve Outlet Feedwater Inlet Fuel Gas Inlet 8,340 (223.4) 7,850 (211.0) 3 - 5 (natural gas or propane) 112,000 (2,999) 105,000 (2,813) 95,500 (2,559) 25.5 (7.8) 470 (240) 89,900 (2,409) 18.8 (5.7) 270 (130) 8" FLG 2 x 4" FLG 1" NPT 2" NPT /8" NPT Inches 3 Automatic "Surface" Blowdown Boiler & LVC Drain 2 x 1" NPT Chimney Diameter 20" ID Flame Detector Overheat Protection Ultraviolet flame eye sensor High temperature & Low water cut-off. NOTE: i. ii. iii. iv. v. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. Thermal efficiencies are based on high heating values of fuels. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. With the inverter option (12ppm Low NOx package model) the input is derated to 190BHP(95%) and the heat in & output, fuel consumption, and the flue gas numbers are reduced accordingly. Page 87 Specifications for LXH-200 (Special) ITEM UNITS LXH-200 SG Boiler Type Multiple water tube, once through, forced flow, steam boiler Boiler Horsepower Rating BHP 200 Maximum Pressure PSIG (Kg/cm²) 250 (17.6) design Equivalent Output Lb/Hr (Kg/Hr) 6,900 (3,129) Heat Output 6,695,000 (1,687,000) Btu/Hr (KCal/Hr) Heat Input 7,970,000 (2,008,000) Efficiency (fuel to steam) % 84 Boiler Heating Surface Area Ft² (m²) 397 (36.9) Operational Weight Lb (Kg) 10,400 (4,720) Shipping Weight Lb (Kg) 9,600 (4,360) Combustion Control 3 position step burner HIGH-LOW-OFF Combustion System Forced draft, pre-mixed burner Ignition System Electric spark ignited interrupted gas pilot Power Supply 575, 460, 230 or 208V, 3 phase, 60 Hz Max. Electrical Consumption – KVA 24.3 with or w/o MI Check Valve option Blower Motor Output HP 15 3 Fuel Consumption SCFH (Nm /Hr) 7,940 (205) Fuel Supply Pressure PSIG 3 - 5 (natural gas or propane) Flue Gas Volume (Wet) 106,000 (2,846) SCFH (Nm3/Hr) Flue Gas Volume (Dry) 90,900 (2,438) Flue Gas Velocity Ft/s (m/s) 19.0 (5.8) Flue Gas Temperature 270 (130) F (C) Main Steam Outlet 3" FLG Safety Valve Outlet 2½‖ for boiler and optional 1¼‖ for economizer Feedwater Inlet 1‖ NPT Fuel Gas Inlet 2‖ NPT Inches 3 Automatic "Surface" /8" NPT Blowdown Boiler & LVC Drain 2 x 1" NPT Chimney Diameter 20" ID Flame Detector Ultraviolet flame eye sensor Overheat Protection High tube temperature & Low water cut-off. NOTE: i. Equivalent Output is calculated base on the conversion of 212F (100C) feedwater to 212F (100C) steam. ii. Gas consumption based on Natural Gas with High heating value 1,004 Btu/SCF. iii. Thermal efficiencies are based on high heating values of fuels. iv. Flue gas temperature & velocity are calculated for Natural Gas with 68F (20C) feedwater. v. Boiler Safety valve Outlet size may increase if set below 250 PSIG. vi. With the inverter option (12ppm Low NOx package model) the input is derated to 190BHP(95%) and the heat in & output, fuel consumption, and the flue gas numbers are reduced accordingly. Page 88 STANDARD EMISSION FOR MIURA LX SERIES BOILER LX-G Stack Temperature ** 500°F LX-SG 300°F LXL-G 500°F LXL-SG 300°F LX-GI** 500°F LX-SGI** 300°F LXL-GI** 500°F LXL-SGI** 300°F O2 NOx CO 5% ± 1% < 20 PPM (< 25 PPM*) < 100 PPM 5% ± 1% < 12 PPM (< 15 PPM*) < 50 PPM These data are based on shop test boiler with 70°F feed water temperature and 70 PSI steam pressure at high-fire rates. NOx and CO are corrected to 3% O2 based on Natural Gas combustion. * the NOx rating based on Propane Gas combustion is shown in brackets. ** with Low NOx Inverter option. *** stack temperature for reference for chimney design. With the dual fuel option (natural gas + propane gas train), the NOx level increases due to adjustment complexity. Page 89 Required wire gauge for power supply LX-50 LX-100 LX-150 LX-200 LX-300 LXL-50 LXL-100 LXL-150 LXL-200 LXH-200 LXH-300 VOLTAGE (V) INPUT CURRENT (A) 575 6.9 480 8.5 230 17.0 575 13.1 480 16.8 230 32.6 575 19.7 480 25.1 230 49.2 #6 × 3 + #8G 60 575 30.6 #8 × 3 + #10G 40 480 38.1 #6 × 3 + #10G 60 230 77.2 #3 × 3 + #8G 100 575 5.2 #14 × 3 + #14G 15 480 6.3 230 12.6 575 11.4 480 14.6 230 28.2 575 17.0 480 21.4 230 42.0 #6 × 3 + #8G 60 575 25.1 #10 × 3 + #10G 30 480 30.0 #8 × 3 + #10G 40 230 62.7 #4 × 3 + #8G 90 575 39.7 #8 × 3 + #10G 40 480 48.4 #6 × 3 + #8G 60 230 97.8 #2 × 3 + #6G 120 WIRE GAUGE (AWG) DISCONNECT AMPERAGE (A) #14 × 3 + #14G 15 ELECTRICAL CONSUMPTION (kVA) 6.8 #10 × 3 + #14G 30 13.4 #8 × 3 + #10G 40 #10 × 3 + #10G 30 20.0 30.4 5.0 #10 × 3 + #12G 30 11.6 #8 × 3 + #10G 40 #10 × 3 + #10G 30 17.0 Page 90 25.0 36.7 12 APPENDIX Purchasing individual operating manuals ...................................... 92 Page 91 Purchasing individual operating manuals: If an extra operating manual for this steam boiler should be required, please contact a MIURA sales office or your local dealer. Also, please have your operation manual number ready when you call. MIURA BOILER OFFICES WWW.MIURABOILER.COM ATLANTA: CHICAGO: 1900 THE EXCHANGE SE, SUITE 330 ATLANTA, GA 30339-2022 PHONE: (770) 916-1695 FAX: (770) 916-1858 [email protected] 600 NORTHGATE PARKWAY, UNIT M WHEELING, ILLINOIS 60090-3201 PHONE: (847) 465-0001 FAX: (847) 465-0011 [email protected] LOS ANGELES: NEW YORK: 1945 SOUTH MYRTLE AVE. MONROVIA, CALIFORNIA 91016-4854 PHONE: (626) 305-6622 FAX: (626) 305-6624 [email protected] 120 SYLVAN AVE., SUITE 4 ENGELWOOD CLIFFS, NJ 07632 PHONE: (201) 592-1260 FAX: (201) 592-1262 [email protected] MIURA BOILER FACTORY: MISSISSAUGA: 8 COPERNICUS BLVD., BRANTFORD, ONTARIO N3P 1Y4 PHONE: (519) 758-8111 FAX: (519) 758-5294 [email protected] 6315 SHAWSON DRIVE, UNIT #17, MISSISSAUGA, ONTARIO L5T 1J2 PHONE: (905) 564-9199 Page 92 1 Description of Functionality 1) Combustion Control 2) 1. Purging Purging is the process whereby the blower operates for a certain period of time prior to ignition in order to discharge any residual gas from the combustion chamber. Specifically, this is referred to as a ―pre-purge.‖ Meanwhile, the term ―post-purge‖ is used to refer to a similar process carried out after boiler stops, with the blower again operating for a certain period of time to purge residual gas from the combustion chamber. If a false flame is identified in the combustion chamber during purging, the purge is continued and will take place for a certain period of time after extinguishing this false flame. Furthermore, an alarm is activated if the false flame continues to burn for longer than a predefined time. The set period for pre-purging is timed from the detection of air pressure following the start of operation of the blower. 2. Ignition and combustion [Gas-fired] Following pre-purge, ignition sparks are generated and the pilot burner is lit. After a specific period of pilot burn, the main burner is lit. After another predetermined period, the boiler transitions to high fire combustion. If the ―OPERATION‖ switch is turned off during high fire combustion, low fire burn is carried out for a specific period of time, and then the system performs a post-purge. 3. Pressure control If the steam pressure rises over the low-pressure setting during high fire combustion, the system will switch to low fire combustion. If the pressure then rises over the high-pressure setting, combustion is ended and the system goes into standby mode. It should be noted if steam pressure drops during low fire combustion to less than the low pressure setting’s differential portion, high fire combustion will be restarted. Similarly, if the steam pressure drops during standby to less than the high pressure setting’s differential portion, the control system will repeat pre-purging and will then perform ignition. Feed Water Control 1. 3) 4) Feed water control is carried out using electrode-type water level detection rods. Blowdown Control 1. Automatically modifying the equivalent blowdown time based on combustion conditions, the control system will perform surface blowdown control in order to maintain a high degree of steam quality. 2. The control system constantly monitors the pressure vessel’s conductivity sensor and the surface blowdown rate in order to perform self-diagnosis. 3. Timing for blowdown is displayed in accordance with the level of concentration of the boiler water and the duration of combustion. The system automatically resets this value after blowdown has been completed. 4. If the system detects the maximum water level upon startup, it activates blowdown control in order to adjust to a suitable water level. Optional Laborsaving Control 1. The fitting of an automatic bottom blowdown valve makes automatic bottom blowdown control possible, thus reducing the work required for blowdown-related activities. 2. Automatic control of the feed-water valve opening and closing is made possible by the fitting of an automatic feed-water shutoff valve. Page 93 5) Safety Devices 1. If any of the following abnormalities should occur, the system will lockout combustion and activate an alarm. (1) Solenoid-valve leakage or false flame - If the flame sensor confirms the presence of a flame during purging (2) Emergency stop - If the emergency stop button is pressed (3) Misfire or flame failure - If the pilot burner does not light, or if the flame goes out after lighting of the pilot burner or main burner (4) Air pressure problem - If the air pressure is continuous low during blower operation (5) Gas pressure problem (gas-fired) - If gas pressure is not in the set level (6) Low water level - If water remains below the normal level when firing is requested (7) Water level probe problem - If a serious problem preventing ongoing control occurs, even if the water level control method has been changed (8) Triggering of the overheat thermocouple - If the overheat thermocouple’s temperature rises to a preset level or beyond (9) Wire breakage in overheat thermocouple - If an open circuit is detected in the overheat thermostat (10) Exhaust-gas temperature problem - If the temperature of the exhaust gas remains constantly above a preset level. (11) Power failure - If the supply of power is interrupted while the ―OPERATION‖ switch is on. (12) Short circuit - If a ground fault is detected in the ignition transformer or the solenoid fuel valve while the ―OPERATION‖ switch is turned on. (13) Overcurrent - If the thermal relay in the electric motor’s switching device has tripped while the ―OPERATION‖ switch is turned on 2. A caution will be issued whenever any of the following situations arise. At this time, the boiler can continue to operate in the current mode of combustion, or if necessary, the control method can be changed to a new combustion mode. (1) Insufficient air supply during low fire or high fire combustion (2) Flame sensor degradation (3) Degradation of feed-water pump capacity or water supply shortage (4) Reverse flow (5) Freeze alert (6) Problem with water level probe (7) Broken wire in thermocouple (with the exception of the overheat thermostat) (8) High circuit-board temperature (9) Problem with water softener (Optional specification) (10) Problem with steam pressure sensor (11) Air-pressure sensor problem (12) Blowdown timing reached or buildup of scale (13) Battery replacement (14) Inspection of surface blowdown required or problem with conductivity sensor (15) Communication error Page 94 3. The display will show the following whenever an alarm is activated in response to an abnormality or whenever a caution is issued. (1) Details of the abnormality (2) Instructions for required action 4. Self-checking The control system hardware constantly monitors its own operation, and it will immediately shutdown operation when an abnormality occurs. 6) Status Display The display indicates the boiler’s current operation status using the following text strings. (1) DISABLE (2) STAND-BY (3) FEED WATER (4) PREPURGE (5) IGNITION (6) PILOT (7) MAIN IGNITION (8) LOW FIRE (9) HIGH FIRE (10) POSTPURGE (11) PILOT HOLD (12) LOW FIRE HOLD (13) PREPURGE HOLD 7) Monitoring The following parameters can be output and monitored on the display. (1) Steam Pressure (2) Exhaust Gas Temperature (3) Feed Water Temperature (4) Scale Monitor Temperature (5) Overheat Thermostat Temperature (6) Flame Current (7) Remaining Blowdown Time (8) Surface Blowdown Valve On / Off (9) Water Conductivity (10) Water Level Condition (11) Date & Time 8) Heat Management Data The display can output the current day’s boiler management data in terms of the following parameters. (1) Ignition Cycles (2) Gas-fired Low Fire Duration (3) Gas-fired High Fire Duration (4) Gas-fired Average Exhaust-Gas Temperature (low fire) (5) Gas-fired Average Exhaust-Gas Temperature (high fire) (6) Average Feed Water Temperature (7) Gas-fired Boiler Efficiency (8) Gas Consumption Level (9) Boiler Makeup Water (10) Steam Generated (11) Surface Blowdown Volume Page 95 9) 10) Warning Logs The following details on the seven most recent alarms and cautions can be called up and output on the display. 1. Details of the abnormality 2. Date and time of occurrence 3. Boiler operating status when abnormality occurred Communication Functionality The boiler can be fitted with a communications port as an option, allowing remote communication with external devices. Using this functionality, online maintenance can be carried out from a MIURA technical center and the boiler can be remotely monitored. 1. 2 Communicated information (1) Notification of abnormalities Whenever an abnormality occurs, the control system will send notification containing a description of the abnormality and other associated information. Specifically, data transfer is achieved by automatic dialing on the connected telephone line. (2) Monitoring The control system outputs data necessary for the regular monitoring of boiler conditions. (3) Control data - Heat management data (for current and previous days) - Abnormality log (seven most recent items) - Operation log (4) Setting of control data An external device can use the communication function to read and overwrite settings. Guarantee Refer to your warranty documents for specific details. A six-month labor warranty from boiler startup may be available. Contact local sales and service representatives for details. This labor warranty covers routine inspection and repairs at the installation site. Travel and lodging expenses are not covered, except within local representative service area. This product is covered by a one-year standard parts warranty from the boiler commissioning date or for 18 months from the shipping date, whichever occurs first. Express shipping costs for overnight or next-day delivery of parts are not included. Damage to the boiler or any of its component parts after leaving the factory is not covered. Parts replaced under this warranty must be returned to MIURA. If any defective parts are not returned, the customer will be charged for the corresponding item. The pressure vessel of this boiler is covered by a seven-year limited factory warranty against material or workmanship defects. Page 96
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