Miura EX-100G, EX-200G, EX-250G, EX-300, EX-300G Installation Manual

Miura EX-200G is a high-efficiency boiler that provides reliable steam for a variety of applications. It features a compact design, easy installation, and low maintenance requirements. With its advanced technology, the Miura EX-200G delivers exceptional performance and energy savings.

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MIURA

EX BOILER

170/250 PSI Designs

APPROVED

EX - HIGH EFFICIENCY SERIES

IUR

BOILER WEST, INC.

* IN OUR CONTINUING EFFORT TO IMPROVE OUR PRODUCT,

INFORMATION IN THIS MANUAL MAY BE CHANGED WITHOUT NOTICE

OWNER SHALL MAINTAIN THIS MANUAL IN LEGIBLE CONDITION FOR FUTURE REFERENCE

PUBLICATION REVISED MARCH 2000

ENGINEERING REVISED FEBRUARY 2000

&

ECONOMIZER

FLUE

GAS PA

FLUE GAS

OUTLET

TO ECONO

MIZER

STEAM OUTLET VALVE

STEAM SEPARATOR

SAFETY VALVE OUTLET

INSPECTION PORT

SECONDARY LOW WATER CUT OFF

SOOT BLOWER PIPE

SECONDARY WATER PUMP CONTROL

FLAME PORT

FLAME EYE

MAIN GAS INLET

BAFFLE PLATE

EXPANSION RING

INSULATION

AUTO “SURFACE” BLOWDOWN VALVE

FLUE GAS

OUTLET

SAMPLE WATER

THERMOCOUPLE

CONDUCTIVITY SENSOR

FEEDWATER INLET

CASTABLE

INSPECTION PORT

INNER FEEDWATER PIPE

HIGH LIMIT STEAM PRESSURE SWITCH

HIGH STEAM PRESSURE SWITCH

(LOW FIRE CONTROL)

LOW STEAM PRESSURE SWITCH

(HIGH FIRE CONTROL)

PRESSURE GAUGE

DAMPER

AIR INLET

CASTABLE

LIQUID VOLUME CONTROLLER

(PRIMARY PUMP CONTROL)

STOPS FEEDWATER PUMP

STARTS FEEDWATER PUMP

LOW WATER CUT OFF

MANUAL BOTTOM BLOWOFF

Figure 1 Functional Outline of EX-300 and Economizer

1 SECTION ONE - INTRODUCTION 1

1.2 NATIONAL REGULATORY ORGANIZATIONS

1.2.1 MIURA BOILER STEAM GENERATORS (INSPECTOR BRIEFING)

EQUIPMENT 5

2 SECTION TWO - SPECIFICATIONS 8

3.2.1 WATER

3.2.2 WATER

3.3 BOILER POSITIONING AND ANCHORING 19

PROPER 19

3.3.2 ECONOMIZER INSTALLATION 19

3.5 WATER

3.6 PUMP

3.6.1 FEED WATER CONTROL VALVES

3.7 SAFETY RELIEF VALVES, INSTALLATION

3.9 FUEL SUPPLY ARRANGEMENTS

3.10.2 BOILER INTERFACE CAPABILITIES 36

4 SECTION FOUR - OPERATION

4.1 SAFETY FEATURES AND OPERATING CONTROLS

4.1.1 LOW WATER VOLUME CUT-OFF

4.1.4 HIGH PRESSURE LIMIT CUT-OFF

42 iii

SIGNALS 43

4.1.9 GAS

4.1.10 OIL

4.2.3.2 AUTOMATIC BOTTOM BLOW DOWN (OPTION) 46

CARRY 48

4.2.9 MAKE-UP WATER MAINTENANCE CHECK 49

MAINTENANCE 50

5.1 MAINTENANCE & CLEANING SCHEDULE 50

5.2.1 PHYSICAL PROBLEM AND CORRECTIVE ACTION 51

5.4 RECOMMENDED SPARE PARTS LIST 55 iv

LIST OF ILLUSTRATION FIGURES

Figure 1 Functional Outline of EX-300 and Economizer ii and 15

Figure 3 Feed Water Pump Foundation and Installation 15

4 Base 16

Dimensions 17

Figure 6 Blower and Air Duct Assembly

Figure 7 EX-250~300 Steam Separator Assembly

Conductivity 18

Figure 10 EX Series Boiler Base Plate 19

Mounting 20

12 Line

Figure 13 Recommended Feed Water Piping Arrangement

Figure 14 Economizer Safety Relief Valve Installation

15 Safety

Figure 16 Blow Down Piping Arrangement

Figure 17 Double Blow Down Isolation Valve Options

Figure 18 Automatic Blow Down System Check Valve

Figure 19 Typical EX Series Gas Train and Vent Points

Figure 20 Main Gas Pressure Regulator Vent Piping

Figure 21 Pilot Gas Regulator Vent Line Connection

Figure 22 Gas or Air Pressure Switch Connection

Figure Pump

Figure 24 EX Series Boiler Electrical Connection

25 Control

26 38

27 38

Figure 28 Stack and Economizer Bolting Dimensions

29 Volume

39 v

LIST OF TABLES

Table 3 EX Series Specifi cations Flue Gas Re-Circulation 10 cations 11

Table 7 EX Series Feed Pump Foundation Dimensions

Table 8 EX Series Blower Foundation Dimensions

Table 9 Main Steam Outlet Connection Size

Table 10 Feed Water Pump Suction Strainer Size

Table 11 Feed Water Pump Recommendations

12 Down

Table 13 EX Gas Piping Sizes

Table Inlet 32

Table 16 Boiler Minimum Clearance Requirements

Table 17 Minimum Boiler Ventilation Opening Requirements

Table 18 Floatless Switches and Probes

Table 20 Recommended Periodic Maintenance Schedule

Table 21 Motor Service and Lubrication Schedule

Table 22 Physical Problem and Corrective Action Chart

Table 23 Recommended Spare Parts List

40 vi

1 SECTION ONE - INTRODUCTION

Muira Boiler Co., Ltd. began North American activities in 1988 when the manufacturing plant in Brantford,

Ontario, was established. Their engineering department developed procedures to meet ASME codes and listing approval from IRI/FM, UL, and pre-approval for the SCAQMD (Southern California Air Quality Management

District). The United States corporate sales offi ce, Miura Boiler West, Inc., was established and has developed relationships with national, state, and city inspectors and agencies.

The North American network consists of branches in Chicago, Los Angeles, and Ontario. The parent company,

Miura Boiler, Ltd. in Japan, is the leading manufacturer of boilers and other thermal equipment in the Pacifi c

Rim holding more than 55% of the market. With factories in fi ve countries, production now exceeds 14,000 units per year.

As a result of design necessities in Japan, such as limited space and total dependence on foreign energy, the

MIURA STEAM BOILER has been engineered as a highly effi cient, vertical water tube, once-through forced-fl ow design. The MIURA Boiler features a compact unit with a low-water content and is designed to run with a minimum amount of maintenance with simple push-button controls. Operation is quiet, radiant heat losses are minimal, and steam quality is second to none. Miura Boilers are often installed in a multiple boiler network.

MIURA Boilers, along with the patented MIURA Multiple Installation panel, allow appropriate horsepower to be brought on and off line quickly to meet sophisticated production needs with maximum fuel economy. The

35-year, fi eld-proven ‘Miura Advantage’ is the ability to reach full output steam from cold start in less than fi ve minutes using the least amount of energy and having the lowest environmental impact. The high effi ciency

Miura Boiler has won numerous awards from engineering societies and gas associations because it is a compact, safe, cost-effective boiler.

1.1 CODE AND REGULATORY AGENCIES

There are a number of codes, standards, laws, and regulations covering boilers and related equipment that should be considered when designing a system. Regulatory requirements are dictated by a variety of sources and are all focused primarily on safety. The equipment shall be installed in accordance with the current regulations, codes, and specifi cations of the applicable city, county, state, and federal agencies. Authorities having jurisdiction should be consulted before installations are made. 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 fi rm designing the boiler installation. Here are some essential rules to consider:

• The boiler industry is tightly regulated by the American Society of Mechanical Engineers (ASME)

and the ASME codes, which control boiler design, inspection, and quality assurance. The boiler’s pressure

vessel must have an ASME stamp. (Deaerators, economizers, and other pressure vessels must also be ASME

stamped.)

• The insurance company insuring the facility or boiler may dictate additional requirements. Boiler

manufacturers provide special boiler trim according to the requirements of the major insurance

companies. Special boiler trim items usually pertain to 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 the boiler room.

• UL and /or ASME-CSD1 specifi cations may be required. State or local authorities may require data

on the boiler controls or basic design criteria.

• Most areas have established a maximum temperature at which water can be discharged to the sewer. In

this case, a blow down separator after cooler is required.

• Most state, local, or provincial authorities require a permit to install and /or operate a boiler. Additional

restrictions may apply in non-attainment areas where air quality does not meet the national ambient

air quality standards, and emission regulations are more stringent. Be sure to investigate this before

buying a boiler.

• For all new boilers with inputs over 10 Million Btu/Hr, U.S. Federal emission standards apply,

including permitting and reporting procedures.

• A full-time boiler operator may be required. Operator requirement depends on the boiler’s size, pressure,

heating surface area, and volume of water. Boilers can be selected which minimize the requirements, either by

falling under the requirements and being exempt, or with special equipment with special equipment that

gives the operator more freedom in the facility. Contact the local boiler inspector for details.

• Most states or provinces require an annual boiler inspection. There may be other requirements on

piping as well.

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.

United States Environmental Protection Agency

A.S.M.E. Codes and Standards

National Board Licensing Requirements

American Gas Association Standards

Underwriters Laboratories, Inc.

Factory Mutual Insurers

Industrial Risk Insurers

Occupational Safety and Health Administration

Food and Drug Administration

Local, City, and State Fire Marshall

State Boiler Inspection Division

Division of Labor and Industry for the Local State or City

Local Building and Construction Code Inspectors

MIURA Boiler recommends contacting your actual insurance provider as well as the utility companies for assistance in identifying and complying with codes.

1.2 NATIONAL REGULATORY ORGANIZATIONS

A.S.M.E.

345 East 47th Street

New York, NY 10017

PHONE: (212) 705-7800

ASME - C.S.D.1

345 East 47th Street

New York, NY 10017

PHONE: (212) 705-7800

NATIONAL UNDERWRITERS

505 Gest Street

Cincinnati, OH 45203

NATIONAL BOARD

1055 Crupper Avenue

Columbus, OH 43229

PHONE: (614) 888-8320

N.F.P.A.

P.O. Box 9146

Quincy, MA 02169

PHONE: (800) 344-3555

UNDERWRITERS LABORATORIES

333 Pfi ngsten Road

Northbrook, IL 60062

PHONE: (847) 272-8800

1.2.1 MIURA BOILER STEAM GENERATORS (Inspector briefi ng)

The Miura steam generator is an unfamiliar design to most inspectors in the fi eld. The purpose of this section is to address common questions and familiarize the inspector with the Miura steam generator through a general overview of the design and operational characteristics.

The Miura boiler EX design consists of straight water tubes between upper and lower annular 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 in the steam generator. Water volume is exclusively in the tubes with only incidental bubbling in the upper header. Therefore, the design has no natural circulation such as a riser, down-comer 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 fl ashed into steam in the tubes, forming a dynamic bubbling system that 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 fi nal separation in the external separator. Condensate dropped by the external separator is fed back into the lower header.

Because of the steam gradient, there is no defi ned stream/water level and thus no sight glass. Special modifi cations are incorporated into the boiler construction and safety system to accommodate this.

First, probes are inserted directly into the top of the tubes. One probe is long, for low water cut out; and one probe is shorter for feed water control. This water volume control relies on electrical resistance and the bubbling action is what cools the tubes. As the volume of water in the steam generator is consumed, there is less bubbling at the top of the tubes, increasing the amount of electrical resistance. Once the effective electrical resistance reaches a pre-determined level, a ten-second-time delay is tripped, after which the feed water pump is turned on.

It continues to run until the bubbles re-establish effective contact with the probe. Should the water volume ever become so low as to lose effective contact with the low water cutout probe, the boiler will shut down.

Secondly, probes are inserted into a water column on the side of the boiler. This water control system relies on a conventional electrical conductance system. When water contacts a probe, a circuit is formed. Three probes control the boiler feed; the short probe controls the pump in Low Fire, the medium-length probe controls the pump in High Fire. The long probe is the primary low water cut out. This safety can be confusing for the inspector who encounters the Miura steam generator in the fi eld for the fi rst time, because a water column typically equals a “fi xed water level”. This is not true, however, for the Miura EX Series steam generator because of the low water content and the fi erce boiling action of the steam gradient. This dynamic system is stabilized by a special modifi cation of the water column to create an artifi cial level. The fl anged pipe leading form the boiler body runs through the column with three holes drilled in the pipe to create an orifi ce effect. Yet, even with this orifi ce effect, the artifi cial “level” formed is not the level in the boiler; and oscillates - especially with load swings on the system. This oscillation is normal and is directly proportional to the volume of water in the boiler tubes.

Either of these feed water control systems can operate without the other for proper feed water control. However, the combination of these two systems provides for double low water safety and is called the “two-way water volume control system.”

Thirdly, thermocouples are attached directly to the tubes. The thermocouples measure the temperature of the tube and will shut the boiler down if a low water volume condition is detected due to insuffi cient bubbling, dry fi re, or if scale build-up is detected. Scale formation is monitored directly by the rise in tube surface temperature because of lower heat transfer rates. This temperature sensing method can detect a formation of scale of less than 1/64” and will shut down the boiler. The early detection of scale formation is an important factor in maintaining a high effi ciency boiler. According to the US National Bureau of Standards, ¼” of scale build upon heating units requires up to 55% more energy to attain the same temperature. Other methods of detecting scale, such as a pressure gage on the discharge of the feed water pump, are much less sensitive. The MIURA XJ1 Intelligent

Steam Management microcomputer automatically adjusts the alarm settings for the scale monitor based on current boiler steam pressure and boiler fi ring rate.

The boiler will not operate should any low water safeties fail. Only through tampering could the boiler operate without safeties and develop a dry fi re condition. Even in the unlikely event this condition should ever be created, before the tubes superheat enough to destroy the tensile strength of the metal, the amount of energy contained in the remaining water is so small that the possibility of a pressure explosion is negligible. The Miura Steam

Generator design has been used for more than thirty-fi ve years with over 200,000 units presently in operation worldwide. There is no record of ANY pressure vessel explosions.

Steam is produced within fi ve minutes from cold start-up and selected tubes can be visually inspected through two-inch openings located on the top and bottom headers. A complete inspection is typically accomplished in a thirty-minute period.

All Miura EX steam generators are annotated as a forced fl ow steam generator (with no fi xed steam or water level) on the pressure vessel’s P-3 form and registered with the National Board. The complete packaged steam generator is listed with UL as a standard and can be built to IRI, FM and /or ASME-CSD1 at customer request.

Please note that all fl anges and fi ttings identifi ed in this manual as 150# ASA comply with ASME/ANSI standard B16.5. The 150# stamping refers to a standard classifi cation not Maximum Allowable Working Pressure

(MAWP). As specifi ed in Table A-361 of ASME codes, Section I, 1995 edition, the MAWP for 150# fl anges is

205 psig for saturated steam service and 170 psig for Boiler Feed and Blow-off line service. This specifi cation matches the 170psi MAWP rating of the MIURA boiler.

Miura is dedicated to reliable and safe operation of its steam generators through sound engineering principles and years of in-the-fi eld experience. Please contact us at our Chicago offi ce at (847) 465-0001 or the Los Angeles offi ce at (626) 305-6622 should you have any further questions or comments.

1.3 STANDARD EQUIPMENT

A fully Packaged Forced Draft Steam Boiler, the EX series receives complete operational testing at our factory to insure trouble free installation. (Service Parts are non-proprietary.) The EX has the following items as standard equipment:

• Boiler Design is UL approved and labeled

• A.S.M.E. “S” stamped - A.S.M.E. CSD-1, IRI or FM Available

• Mounted Control Panel - wired with all necessary components (No Main Electrical Disconnect included)

• Microprocessor based integrated burner controller with UV fl ame sensor

• MIURA XJ1 micro-processor boiler control with fault history

• Computer interface capability for remote monitoring by factory service department (Requires optional

equipment)(Monitoring contract required)

• Service parts are non-proprietary

• Centrifugal forced draft blower and motor

• Combustion air proving switch

• Automatic combustion air damper and motor

• Thermocouples on water tubes prevent overheat condition caused by low water volume or scale build up

• Thermocouples for feed water temperature, stack temperature and gas meter available as options

• Two independent water volume controls and low water cut-off safety devices, plus manual reset

• Liquid volume control column and bottom blow down valves

• Steam pressure sensor and control switches, plus an independent high-pressure safety requiring manual reset

• Gas regulator with threaded connections for main burner and pilot fl ame

• High and low gas pressure switches

• Dual pilot gas solenoid valves for natural gas

• Dual fl uid actuated main gas valves and plugged leak test port (vent valve optional)

• Soot blower ports for fast convenient cleaning of soot

• External steam separator

• Ports for direct visual inspection of internals

• A.S.M.E. approved safety relief valves for boiler and optional economizer (if installed)

• Intermittent blow down system with strainer and manual shut off valve

• Boiler water test valve

• Operating hours display with start cycle aggregate and fi ve-fault history display

• Heavy duty galvanized economizer (“S” series) (optional)

• Completely enclosed heavy gauge casing

• Steam (and oil on “O” series) pressure gauges installed

• Oil pump and motor (“O”, “GO,” or “SGO” series)

• Triplex, high-low-off, main oil valves (“O,” “GO,” or “SGO” series)

• Multi-stage feed water pump and motor with stainless steel impellers and ceramic bearings (optional)

1.4 GUARANTEE:

• Refer to warranty documents for specifi c details.

• SIX-MONTH labor warranty from boiler start up may be available, contact Local Sales and Service representa

tives for details. This labor warranty covers routine inspection and repairs at the job site. Travel and lodging

expenses are not covered except within local representative service area.

• ONE YEAR Standard warranty for parts from boiler commissioning date or 18 months from shipping date,

whichever occurs fi rst. Express shipping cost for overnight or next day delivery of parts is not included.

Damage to the boiler or parts of the boiler after leaving the factory is not covered. Parts replaced under

this warranty must be returned to MIURA. If the failed part is not returned, the customer will be charged

for the new item.

• SEVEN-YEAR limited factory warranty on pressure vessel against material or workmanship defects.

1.5 DEFINITIONS AND SYMBOLS

“Note,” “Caution,” and “Danger” are used throughout this manual with the following defi nitions and symbols.

NOTE:

Note

indicates an area or subject of special merit, emphasizing either the product capabilities or common errors in operation or maintenance.

CAUTION:

Caution

indicates possible damage to equipment. It also indicates any condition or practice, which, if not observed or remedied, could result in damage or destruction of the equipment.

DANGER:

Danger

indicates any condition or practice, which, if not observed, could result in personal injury or possible death.

CAUTION: All steam engines require proper water treatment. This treatment is mandatory from the time the MIURA BOILER is started. Failure to follow the recommended water treatment and maintenance procedures could shorten the life (as well as the effi ciency) of the boiler. None of the Miura warranties cover repair due to improper water treatment.

1.6 ABOUT THIS MANUAL

This manual is written to support engineering and mechanical contractor fi rms. Some basic information is given for the operator and maintenance personnel. More specifi c information on operation and maintenance of the unit is given in the MIURA OPERATION AND MAINTENANCE MANUAL.

If a question about boiler installation is not contained in the text of this manual and is not answered by one of the drawings, please call the MIURA representative or the company offi ces in Chicago or Los Angeles. We will be glad to help.

This manual is available on disk for Microsoft Word 2000 and Word 95/97. In addtion, detailed drawings are available on disk in Auto CAD 14 fi les. If computer copies are desired, please contact the Chicago Offi ce of

MIURA Boiler. A small fee is required for shipping and handling.

1.7 OFFICES

MIURA BOILER CO., LTD.

(Factory)

8 Copernicus Boulevard

Brantford, Ontario

Canada N3P 1Y4

PHONE: (519) 758-8111

FAX: (519) 758-5294 e-mail: Canada@ miuraboiler.com

MIURA BOILER WEST, INC. (Chicago Offi ce)

600 Northgate Parkway, Suite M

Wheeling, IL 60090-3201

PHONE: (847) 465-0001

FAX: (847) 465-0011 e-mail: [email protected]

MIURA BOILER WEST, INC. (LA Offi ce)

1945 South Myrtle Avenue

Monrovia, CA 91016-4854

PHONE: (626) 305-6622

FAX: (626) 305-6624 e-mail: [email protected]

2 SECTION TWO - SPECIFICATIONS

Table 1 EX Series Specifi cations (without Economizer)

ITEM EX-100G(O) EX-200G(O) EX-250G(O) EX-300G(O)

Utilization Horsepower

Maximum Pressure

Equivalent Output

Fuel Gas Heat Input

Steam Heat Output

Effi ciency (Fuel to Steam)

Heating Surface Area

Full Water Content

Operational Water Content

Operational Weight

Shipping Weight

Combustion Control

Combustion System

Ignition System

Spark System

Power Supply

Max. Electrical Consumption

Blower Motor Output

Gas Consumption

No. 2 Oil

Gas Supply Pressure

Air Changes (Pre-purge)

Flue Gas Volume (Wet)

Flue Gas Volume (Dry)

Flue Gas Velocity

Flue Gas Temperature

Emissions, Oil Fired

Emissions, Gas Fired

Main Steam Outlet Valve

Safety Valve Outlet

Main Water Inlet

Fuel Gas Inlet

Fuel Oil Inlet

Automatic Surface Blow Down

Manual Blow Down

Stack Diameter (ID)

Flame Detector

Pressure Control

Liquid Volume Control

Overheat Protection

100 HP 200 HP 250 HP

170 PSIG Design, 150 PSIG Maximum Operating

3,450 LB/HR 6,900 LB/HR

4,185,000 BTU/HR Gas

4,083,000 BTU/HR Oil

8,369,000 BTU/HR Gas

8,165,000 BTU/HR Oil

300 HP

8,625 LB/HR 10,350 LB/HR

10,461,000 BTU/HR Gas 12,563,000 BTU/HR Gas

10,206,000 BTU/HR Oil 12,256,000 BTU/HR Oil

3,348,000 BTU/HR

193 FT²

100 GAL

54 GAL

5,500 LBS

5,000 LBS

6,695,000 BTU/HR 8,369,000 BTU/HR

80% Gas Fired, 82% Oil Fired

323 FT²

170 GAL

75 GAL

407 FT²

265 GAL

80 GAL

9,700 LBS

9,000 LBS

15,000 LBS

13,800 LBS

3 Position Step Burner HIGH-LOW-OFF

Proprietary Forced Draft

Electric Spark Ignited, Interrupted Gas Pilot

13 KVA (14 for Oil)

10 HP

4,170 SCFH

29.2 GAL/HR

55,900 SCFH Gas

54,700 SCFH Oil

47,700 SCFH Gas

49,700 SCFH Oil

26.0 FT/Sec Gas

25.4 FT/Sec Oil

470°

2”

One 2”

1”

2”

3/4”

One 3/8”

Two 1”

14”

15,000 V

230 or 460 V, 3 PHASE, 60 HZ

24 KVA (14 for Oil) 32 KVA (34 for Oil)

20 HP 25 HP

8,340 SCFH 10,420 SCFH

58.3 GAL/HR 72.9 GAL/HR

3-5 PSIG (Natural Gas or Propane)

>4 (>8*)

111,700 SCFH Gas 139,600 SCFH Gas

136,500 SCFH Oil 109,100 SCFH Oil

95,500 SCFH Gas

99,200 SCFH Oil

25.4 FT/Sec Gas

24.8 FT/Sec Oil

470°

119,300 SCFH Gas

124,000 SCFH Oil

31.8 FT/Sec Gas

31.1 FT/Sec Oil

470°

Smoke=<2 on Bacharach Scale, <300 PPM CO

Max. 20 PPM SOx, Max. 120 PPM NOx

Max. 20 PPM CO, Max. 100 PPM NOx

3”

One 2 1/2”

4”

One 2 1/2”

1”

2”

1 1/4”

2 1/2”

3/4”

One 3/8”

Two 1”

3/4”

Two 3/8”

Two 1”

20”

Ultraviolet Sensor

20”

Adjustable Pressure Switches and Transducer

Electrolytic Conductive Type

Low Water Cut-Off & Thermocouple

10,050,000 BTU/HR

390 FT²

265 GAL

80 GAL

15,000 LBS

13,800 LBS

32 KVA (34 for Oil)

25 HP

12,500 SCFH

87.5 GAL/HR

167,500 SCFH Gas

163,800 SCFH Oil

143,000 SCFH Gas

148,900 SCFH Oil

22.6 FT/Sec Gas

22.1 FT/Sec Oil

470°

4”

Two 2 1/2”

1 1/4”

2 1/2”

3/4”

Two 3/8”

Two 1”

26” i) Equivalent output calculated from and at 212°F (100°C)

feed water at 212°F (100°C) steam.

NOTE: iv) Flue gas temperature & velocity are calculated for Natural Gas

with 68°F (20°C) feed water.

ii) Gas consumption based on Natural Gas with high heating

1004 BTU/SCF when operating at 70 psig.

iii) Thermal effi ciencies are based on high heating values

of fuels.

v) “S” - Economizer, “G” - Natural gas or Propane fi red, “O” - #2

Oil Fired.

* Optional IRI requires 8+ air changes for pre purge.

ITEM

Table 2 EX Series Specifi cations (with Economizer)

EX-100SG(O) EX-200SG(O) EX-250SG(O) EX-300SG(O)

Utilization Horsepower

Maximum Pressure

Equivalent Output

Fuel Gas Heat Input

Steam Heat Output

Effi ciency (Fuel to Steam)

Heating Surface Area

Full Water Content

Operational Water Content

Operational Weight

Shipping Weight

Combustion Control

Combustion System

Ignition System

Spark System

Power Supply

Max. Electrical Consumption

Blower Motor Output

Gas Consumption

No. 2 Oil

Gas Supply Pressure

Air Changes (Pre-purge)

Flue Gas Volume (Wet)

Flue Gas Volume (Dry)

Flue Gas Velocity

Flue Gas Temperature

Emissions, Oil Fired

Emissions, Gas Fired

Main Steam Outlet Valve

Safety Valve Outlet

Main Water Inlet

Fuel Gas Inlet

Fuel Oil Inlet

Automatic Surface Blow Down

Manual Blow Down

Stack Diameter (ID)

Flame Detector

Pressure Control

Liquid Volume Control

Overheat Protection

100 HP 200 HP 250 HP

170 PSIG Design, 150 PSIG Maximum Operating

3,450 LB/HR

3,939,000 BTU/HR Gas

3,848,000 BTU/HR Oil

6,900 LB/HR

7,876,000 BTU/HR Gas

7,695,000 BTU/HR Oil

8,625 LB/HR

9,846,000 BTU/HR Gas

9,620,000 BTU/HR Oil

300 HP

10,350 LB/HR

11,824,000 BTU/HR Gas

11,552,000 BTU/HR Oil

10,050,000 BTU/HR 3,348,000 BTU/HR

193 FT²

110 GAL

64 GAL

7,250 LBS

6,750 LBS

6,695,000 BTU/HR 8,369,000 BTU/HR

85% Gas Fired, 87% Oil Fired

323 FT²

180 GAL

407 FT²

277 GAL

85 GAL

11,500 LBS

92 GAL

17,500 LBS

10,650 LBS 16,600 LBS

3 Position Step Fire Burner HIGH-LOW-OFF

Proprietary Forced Draft

Electric Spark Ignited, Interrupted Gas Pilot

13 KVA (14 for Oil)

10 HP

3,920 SCFH

27.5 GAL/HR

15,000 V

230 or 460 V, 3 PHASE, 60 HZ

24 KVA (25 for Oil) 32 KVA (34 for Oil)

20 HP

7,850 SCFH

25 HP

9,810 SCFH

55.0 GAL/HR 68.7 GAL/HR

3-5 PSIG (Natural Gas or Propane)

390 FT²

280 GAL

94 GAL

18,000 LBS

17,100 LBS

32 KVA (34 for Oil)

25 HP

11,780 SCFH

82.5 GAL/HR

52,500 SCFH Gas

51,500 SCFH Oil

44,900 SCFH Gas

46,800 SCFH Oil

19.1 FT/Sec Gas

18.8 FT/Sec Oil

270°F

105,200 SCFH Gas

103,000 SCFH Oil

89,900 SCFH Gas

93,600 SCFH Oil

18.8 FT/Sec Gas

18.4 FT/Sec Oil

270°F

>4 (>8*)

131,400 SCFH Gas

128,600 SCFH Oil

112,300 SCFH Gas

116,900 SCFH Oil

23.5 FT/Sec Gas

23.0 FT/Sec Oil

270°F

157,800 SCFH Gas

154,500 SCFH Oil

134,800 SCFH Gas

140,300 SCFH Oil

16.7 FT/Sec Gas

16.3 FT/Sec Oil

270°F

2”

Smoke=<2 on Bacharach Scale, <300 PPM CO

Max. 120 PPM NOx, Max. 20 PPM SOx

Max. 100 PPM CO, Max. 100 PPM NOx

3” 4” 4”

One 1” & One 2”

1”

2”

3/4”

One 3/8”

Two 1”

14”

One 1” & One 2 1/2”

1”

One 1” & One 2 1/2”

1 1/4”

2”

3/4”

One 3/8”

2 1/2”

3/4”

Two 3/8”

Two 1”

20”

Two 1”

20”

Ultraviolet Sensor

Adjustable Pressure Switches and Transducer

Electrolytic Conductive Type

Low Water Cut-Off & Thermocouple

One 1” & Two 2 1/2”

1 1/4”

2 1/2”

3/4”

Two 3/8”

Two 1”

26” i) Equivalent output calculated from and at 212°F (100°C)

feed water at 212°F (100°C) steam.

NOTE: iv) Flue gas temperature & velocity are calculated for Natural Gas

with 68°F (20°C) feed water.

ii) Gas consumption based on Natural Gas with high heating

1004 BTU/SCF when operating at 70 psig.

iii) Thermal effi ciencies are based on high heating values

of fuels.

v) “S” - Economizer, “G” - Natural gas or Propane fi red, “O” - #2

Oil Fired.

* Optional IRI requires 8+ air changes for pre purge.

Table 3 EX Series Specifi cations Flue Gas Re-Circulation

EX-100 SG(0)F EX-200 SG(0)F EX-250 SG(0)F ITEM

Utilization Horsepower

Maximum Pressure

Equivalent Output

Fuel Gas Heat Input

Steam Heat Output

Effi ciency (Fuel to Steam)

Heating Surface Area

Full Water Content

Operational Water Content

Operational Weight

Shipping Weight

Combustion Control

Combustion System

Ignition System

Spark System

Power Supply

Max. Electrical Consumption

Blower Motor Output

Gas Consumption

No. 2 Oil

Gas Supply Pressure

Air Changes (Pre-purge)

Flue Gas Volume (Wet)

Flue Gas Volume (Dry)

Flue Gas Velocity

Flue Gas Temperature

Emissions, Oil Fired

Emissions, Gas Fired

Main Steam Outlet Valve

Safety Valve Outlet

Main Water Inlet

Fuel Gas Inlet

Fuel Oil Inlet

Automatic Surface Blow Down

Manual Blow Down

Stack Diameter (ID)

Flame Detector

Pressure Control

Liquid Volume Control

Overheat Protection

100 HP 200 HP 250 HP

170 PSIG Design, 150 PSIG Maximum Operating

3,450 LB/HR 6,900 LB/HR 8,625 LB/HR

3,939,000 BTU/HR Gas

3,848,000 BTU/HR Oil

7,876,000 BTU/HR Gas

7,695,000 BTU/HR Oil

9,846,000 BTU/HR Gas

9,620,000 BTU/HR Oil

3,348,000 BTU/HR 6,695,000 BTU/HR 8,369,000 BTU/HR

85% Gas Fired, 87% Oil Fired

193 FT²

110 GAL

323 FT²

180 GAL

390 FT²

277 GAL

64 GAL

7,300 LBS

6,800 LBS

85 GAL

11,550 LBS

10,700 LBS

92 GAL

18,100 LBS

17,200 LBS

3 Position Step Fire Burner HIGH-LOW-OFF

Proprietary Forced Draft

Electric Spark Ignited, Interrupted Gas Pilot

15,000 V

230 or 460 V, 3 PHASE, 60 HZ

23 KVA (24 for Oil) 30 KVA (31 for Oil) 32 KVA (34 for Oil)

20 HP 25 HP 25 HP

3,920 SCFH 7,850 SCFH 9,810 SCFH

27.5 GAL/HR 55.0 GAL/HR 68.7 GAL/HR

3-5 PSIG (Natural Gas or Propane)

52,500 SCFH Gas

51,500 SCFH Oil

44,900 SCFH Gas

46,800 SCFH Oil

19.1 FT/Sec Gas

18.8 FT/Sec Oil

270°F

>4 (>8*)

105,200 SCFH Gas

103,000 SCFH Oil

89,900 SCFH Gas

93,600 SCFH Oil

18.8 FT/Sec Gas

18.4 FT/Sec Oil

270°F

131,400 SCFH Gas

128,600 SCFH Oil

112,300 SCFH Gas

116,900 SCFH Oil

13.9 FT/Sec Gas

13.6 FT/Sec Oil

270°F

Smoke=<2 on Bacharach Scale, <300 PPM CO

Max. 80 PPM NOx, Max. 20 PPM SOx

Max. 40 PPM CO, Max. 40 PPM NOx

2” 3” 4”

One 1” & One 2”

1”

One 1” & One 2 1/2”

1”

One 1” & One 2 1/2”

1 1/4”

2” 2” 2 1/2”

3/4”

One 3/8”

3/4”

One 3/8”

3/4”

Two 3/8”

Two 1”

14”

Two 1”

20”

Two 1”

26”

Ultraviolet Sensor

Adjustable Pressure Switches and Transducer

Electrolytic Conductive Type

Low Water Cut-Off & Thermocouple

NOTE: i) Equivalent output calculated from and at 212°F (100°C)

feed water at 212°F (100°C) steam.

iv) Flue gas temperature & velocity are calculated for Natural Gas

with 68°F (20°C) feed water.

ii) Gas consumption based on Natural Gas with high heating

1004 BTU/SCF when operating at 70 psig.

iii) Thermal effi ciencies are based on high heating values

of fuels.

10 v) “S” - Economizer, “G” - Natural gas or Propane fi red, “O” - #2

Oil Fired.

* Optional IRI requires 8+ air changes for pre purge.

ITEM

Table 4 EXH-100(S)G(O) Specifi cations

EXH-100G(O) EXH-100(S)G(O)

Utilization Horsepower

Maximum Pressure

Equivalent Output

Fuel Gas Heat Input

100 HP 100 HP

250 PSIG Design, 225 PSIG Maximum Operating

3,450 LB/HR

4,185,000 BTU/HR

3,450 LB/HR

3,939,000 BTU/HR

Steam Heat Output

Effi ciency (Fuel to Steam)

Heating Surface Area

Full Water Content

Operational Water Content

Operational Weight

Shipping Weight

Combustion Control

Combustion System

Ignition System

Spark System

Power Supply

Max. Electrical Consumption

Blower Motor Output

Gas Consumption

No. 2 Oil

Gas Supply Pressure

Air Changes (Pre-purge)

Flue Gas Volume (Wet)

Flue Gas Volume (Dry)

Flue Gas Velocity

Flue Gas Temperature

Emissions, Oil Fired

Emissions, Gas Fired

Main Steam Outlet Valve

Safety Valve Outlet

Main Water Inlet

Fuel Gas Inlet

Fuel Oil Inlet

Automatic Surface Blow Down

Manual Blow Down

Stack Diameter (ID)

Flame Detector

Pressure Control

Liquid Volume Control

Overheat Protection

3,348,000 BTU/HR

80% Gas Fired, 82% Oil Fired

193 FT²

100 GAL

54 GAL

7,600 LBS

3,348,000 BTU/HR

85% Gas Fired, 87% Oil Fired

193 FT²

100 GAL

54 GAL

7,400 LBS

5,100 LBS 6,900 LBS

3 Position Step Fire Burner HIGH-LOW-OFF

Proprietary Forced Draft

Electric Spark Ignited, Interrupted Gas Pilot

15,000 V

230 or 460 V, 3 PHASE, 60 HZ

15 KVA (16 for Oil)

10 HP

15 KVA (16 for Oil)

10 HP

4,170 SCFH 3,920 SCFH

29.2 GAL/HR 27.5 GAL/HR

3-5 PSIG (Natural Gas or Propane)

>4 (>8*)

55,900 SCFH Gas

54,700 SCFH Oil

47,700 SCFH Gas

49,700 SCFH Oil

27.5 FT/Sec Gas

26.9 FT/Sec Oil

470°F

52,500 SCFH Gas

51,500 SCFH Oil

44,900 SCFH Gas

46,800 SCFH Oil

20.2 FT/Sec Gas

19.9 FT/Sec Oil

270°F

Smoke=<2 on Bacharach Scale, <300 PPM CO

Max. 20 PPM SOx, Max. 120 PPM NOx

Max. 100 PPM CO, Max. 100 PPM NOx

2” 2”

One 2”

1”

2”

3/4”

One 1” & One 2”

1”

2”

3/4”

3/8” 3/8”

Two 1”

14”

Two 1”

14”

Ultraviolet Sensor

Adjustable Pressure Switches and Transducer

Electrolytic Conductive Type

Low Water Cut-Off & Thermocouple

NOTE: i) Equivalent output calculated from and at 212°F (100°C)

feed water at 212°F (100°C) steam.

iv) Flue gas temperature & velocity are calculated for Natural Gas

with 68°F (20°C) feed water.

ii) Gas consumption based on Natural Gas with high heating

1004 BTU/SCF when operating at 170 psig.

iii) Thermal effi ciencies are based on high heating values

of fuels.

11 v) “S” - Economizer, “G” - Natural gas or Propane fi red, “O” - #2

Oil Fired.

* Optional IRI requires 8+ air changes for pre purge.

ITEM

Table 5 EXH-200(S)G(O) Specifi cations

EXH-200 G(O) EXH-200 (S)G(O)

Utilization Horsepower

Maximum Pressure

Equivalent Output

Fuel Gas Heat Input

200 HP 200 HP

250 PSIG Design, 225 PSIG Maximum Operating

6,900 LB/HR

8,369,000 BTU/HR

6,900 LB/HR

7,876,000 BTU/HR

Steam Heat Output

Effi ciency (Fuel to Steam)

Heating Surface Area

Full Water Content

Operational Water Content

Operational Weight

Shipping Weight

Combustion Control

Combustion System

Ignition System

Spark System

Power Supply

Max. Electrical Consumption

Blower Motor Output

Gas Consumption

No. 2 Oil

Gas Supply Pressure

Air Changes (Pre-purge)

Flue Gas Volume (Wet)

Flue Gas Volume (Dry)

Flue Gas Velocity

Flue Gas Temperature

Emissions, Oil Fired

Emissions, Gas Fired

Main Steam Outlet Valve

Safety Valve Outlet

Main Water Inlet

Fuel Gas Inlet

Fuel Oil Inlet

Automatic Surface Blow Down

Manual Blow Down

Stack Diameter (ID)

Flame Detector

Pressure Control

Liquid Volume Control

Overheat Protection

6,695,000 BTU/HR

80% Gas Fired, 82% Oil Fired

323 FT²

170 GAL

75 GAL

10,000 LBS

6,695,000 BTU/HR

85% Gas Fired, 87% Oil Fired

323 FT²

170 GAL

75 GAL

11,800 LBS

9,300 LBS 10,950 LBS

3 Position Step Fire Burner HIGH-LOW-OFF

Proprietary Forced Draft

Electric Spark Ignited, Interrupted Gas Pilot

15,000 V

230 or 460 V, 3 PHASE, 60 HZ

28 KVA (29 for Oil)

20 HP

28 KVA (29 for Oil)

20 HP

8,340 SCFH 7,850 SCFH

58.3 GAL/HR 55.0 GAL/HR

3-5 PSIG (Natural Gas or Propane)

>4 (>8*)

111,700 SCFH Gas

109,100 SCFH Oil

95,500 SCFH Gas

99,200 SCFH Oil

26.9 FT/Sec Gas

26.3 FT/Sec Oil

470°F

105,200 SCFH Gas

103,000 SCFH Oil

89,900 SCFH Gas

93,600 SCFH Oil

19.9 FT/Sec Gas

19.5 FT/Sec Oil

270°F

Smoke=<2 on Bacharach Scale, <300 PPM CO

Max. 20 PPM SOx, Max. 120 PPM NOx

Max. 100 PPM CO, Max. 100 PPM NOx

3” 3”

One 2 1/2”

1”

2”

3/4”

One 1” & One 2 1/2”

1”

2”

3/4”

One 3/8” One 3/8”

Two 1”

20”

Two 1”

20”

Ultraviolet Sensor

Adjustable Pressure Switches and Transducer

Electrolytic Conductive Type

Low Water Cut-Off & Thermocouple

NOTE: i) Equivalent output calculated from and at 212°F (100°C)

feed water at 212°F (100°C) steam.

iv) Flue gas temperature & velocity are calculated for Natural Gas

with 68°F (20°C) feed water.

ii) Gas consumption based on Natural Gas with high heating

1004 BTU/SCF when operating at 70 psig.

iii) Thermal effi ciencies are based on high heating values

of fuels.

12 v) “S” - Economizer, “G” - Natural gas or Propane fi red, “O” - #2

Oil Fired.

* Optional IRI requires 8+ air changes for pre purge.

ITEM

Table 6 EXH-300(S)G(O) Specifi cations

EXH-300G(O) EXH-300SG(O)

Utilization Horsepower

Maximum Pressure

Equivalent Output

Fuel Gas Heat Input

300 HP 300 HP

250 PSIG Design, 225 PSIG Maximum Operating

10,350 LB/HR

12,722,000 BTU/HR

10,350 LB/HR

11,964,000 BTU/HR

Steam Heat Output

Effi ciency (Fuel to Steam)

Heating Surface Area

Full Water Content

Operational Water Content

Operational Weight

Shipping Weight

Combustion Control

Combustion System

Ignition System

Spark System

Power Supply

Max. Electrical Consumption

Blower Motor Output

Gas Consumption

No. 2 Oil

Gas Supply Pressure

Air Changes (Pre-purge)

Flue Gas Volume (Wet)

Flue Gas Volume (Dry)

Flue Gas Velocity

Flue Gas Temperature

Emissions, Oil Fired

Emissions, Gas Fired

Main Steam Outlet Valve

Safety Valve Outlet

Main Water Inlet

Fuel Gas Inlet

Fuel Oil Inlet

Automatic Surface Blow Down

Manual Blow Down

Stack Diameter (ID)

Flame Detector

Pressure Control

Liquid Volume Control

Overheat Protection

10,050,000 BTU/HR

79% Gas Fired, 81% Oil Fired

390 FT²

265 GAL

80 GAL

15,300 LBS

10,050,000 BTU/HR

84% Gas Fired, 86% Oil Fired

390 FT²

265 GAL

80 GAL

18,300 LBS

14,100 LBS 17,400 LBS

3 Position Step Fire Burner HIGH-LOW-OFF

Proprietary Forced Draft

Electric Spark Ignited, Interrupted Gas Pilot

15,000 V

230 or 460 V, 3 PHASE, 60 HZ

38.7 KVA (41 for Oil)

25 HP

38.7 KVA (41 for Oil)

25 HP

12,670 SCFH 11,920 SCFH

88.6 GAL/HR 83.5 GAL/HR

3-5 PSIG (Natural Gas or Propane)

>4 (>8*)

169,700 SCFH Gas

165,900 SCFH Oil

145,000 SCFH Gas

150,700 SCFH Oil

23.6 FT/Sec Gas

23.1 FT/Sec Oil

500°F

159,700 SCFH Gas

156,300 SCFH Oil

136,400 SCFH Gas

142,000 SCFH Oil

17.6 FT/Sec Gas

17.2 FT/Sec Oil

300°F

Smoke=<2 on Bacharach Scale, <300 PPM CO

Max. 20 PPM SOx, Max. 120 PPM NOx

Max. 100 PPM CO, Max. 100 PPM NOx

4” 4”

2 1/2”

1 1/4”

2 1/2”

3/4”

One 1” & 2 1/2”

1 1/4”

2 1/2”

3/4”

One 3/8” One 3/8”

Two 1”

26”

Two 1”

26”

Ultraviolet Sensor

Adjustable Pressure Switches and Transducer

Electrolytic Conductive Type

Low Water Cut-Off & Thermocouple

NOTE: i) Equivalent output calculated from and at 212°F (100°C)

feed water at 212°F (100°C) steam.

iv) Flue gas temperature & velocity are calculated for Natural Gas

with 68°F (20°C) feed water.

ii) Gas consumption based on Natural Gas with high heating

1004 BTU/SCF when operating at 170 psig.

iii) Thermal effi ciencies are based on high heating values

of fuels.

13 v) “S” - Economizer, “G” - Natural gas or Propane fi red, “O” - #2

Oil Fired.

* Optional IRI requires 8+ air changes for pre purge.

3 SECTION THREE - INSTALLATION

3.1 UNLOADING

For transportation the LX boiler will be disassembled and shipped in separate crates as follows:

• Boiler Proper.

• Optional Economizer (S series)

• Steam Separator (EX-250/300 only)

• Optional Feed Water Pump Assembly (if purchased)

• Blower Assembly

• Automatic Blow Down sensor electrode (may be shipped inside electrical cabinet door for safety on

some models)

NOTE: Electric parts may be packaged in a separate container as warranted by their nature or options selected by the customer. Some small parts, such as bolts for economizer to boiler fl ange, steam seperator fl ange bolts etc. may be shipped inside the associated control panel for the boiler

The boiler proper and economizer have lifting lugs as shown in Figure 2. EX-250/300 moisture separators must be lifted with slings.

Shipping weights are as listed on Specifi cation Table.

CAUTION: All boiler prices are F.O.B. the factory at Brantford Ontario. This means that MIURA

Boiler West, Inc. is not responsible for damage to the boiler occuring during shipping. We strongly recommend a complete inspection of all boiler shipments at place of delivery. This inspection should include photographs of the boiler and ancillary equipment packing crates. If any damage is found, do not release the driver or unload the equipment until a satisfactory arrangement is made with shipping company to cover the damage. MIURA Boiler makes reasonable effort to ensure that no vibration or shock damage will occur. However, if such damage occurs and is not discovered and noted at the time of delivery, MIURA Boiler is not responsible to pay for the cost of repairs and any damaged parts will not be under warranty.

(2) - 1 3/8” (2) - 1 3/8” (2) - 1” -EX-100~300

EX-100 EX-200/250/300

Figure 2 Lifting an Handling Points

ECONOMIZER

3.2 ASSEMBLING

3.2.1 Feed Water Pump

(OPTIONAL EQUIPMENT)

All Feed Water Pump foundations, if used, should have four (4) 5/8” holes for 1/2” anchor bolts. See Figure 3.

These pump foundations are not supplied by MIURA.

Place the Feed Water Pump on a foundation equivalent to Figure 4 and tighten mounting bolts. Note that the pump should be located under or close to the feed water tank. See Figure 4 and Table 7 for details.

FROM FEED WATER

TANK

4 HOLES 1/2”

(8 on EXH)

4 HOLES 5/8”

for Anchor Bolts

PUMP BASE

Figure 3 Feed Water Pump Foundation and Installation

B A

Figure 4 Pump Base Mounting Holes

DIMENSION (IN INCHES)

MODEL

A B

EX-100 1/2

EX-200/25 9 7 1/2

EX-300

EXH-300

9 1/2

12 1/2

14 15 1/2

Table 7 EX Series Feed Pump Foundation Dimensions

OVERALL

HEIGHT

45 3/4

51 7/16

3.2.2 Feed Water Control Valves

In the application where the customer does not want to operate the feed pump in frequent start/stop cycles, other options are available. Again, the feed system operates in a simple On-Off manner. If control valves are used, they MUST be quick acting (within 5 seconds). MIURA Boiler recommends

Ball Valves with pneumatic actuators (preferred) or electric actuators (acceptable). Note that the pneumatic actuators operate in 1 second, open to shut, and the electric actuators are 5 seconds open to shut. Refer to sections 3.5 and 3.6.1 for detailed discussion and suggestions. Electric feed water control valves are available as an option on all boiler models.

3.2.3 Blower Assembly

Place the Blower on the Foundation. Tighten foundation bolts. Install air hose ducts between blower outlet and burner wind box as shown in Figure 6. Do not bend the fl exible air duct. If necessary, trim the length of the air duct to fi t the installation. Do not allow excessive bends in the hose. Ensure that the hose is placed over the air duct as far as possible to minimize leakage and the chance that it will blow off. Tighten hose clamps.

All blower foundations have four (4) 5/8” holes for 1/2” anchor bolts. See Figure 5 and Table 8 for details.

B A

Figure 5 Blower Foundation Dimensions

MODEL

EX-250~300

A B

DIMENSION

EX-100 19” 11 7/8”

EX-200 19” 11 7/8”

C D

17”

19”

11 1/2”

20” 13” 19 12”

Table 8 EX Series Blower Foundation Dimensions

(2) - Hose Clamps

(4) - 1/2” dia Holes for Anchor Bolt

Figure 6 Blower and Air Duct Assembly

3.2.4 Steam Separator Assembly

EX-250/300 Only - attach steam separator to pressure vessel as shown in Figure 7. Torque bolts to 61.5 ft/lbs.

3/4” UNC x 3 1/2” L

Conductivity sensor will be removed for shipping. Install when re-assembling separator.

Minimum Torque; Approx 62 ft/lbs

5/8” UNC x 3” L

Figure 7 EX-250~300 Steam Separator Assembly

All EX series boilers may be shipped with the conductivity sensors packed separately and a pipe plug installed in its place. Remove the plug and discard. Install the sensor and connect wires provided. See Figure 7 for typical separator arrangement. Connect Automatic Surface Blow Down wiring as shown in typical arrangement illustrations Figure 8 and Figure 9.

Rear Junction Box

WIRING TO REAR J. BOX

8”

J. BOX

(REAR)

10”

20 17

SEPARATOR

RETURN PIPE

Sensor Electrode

Probe Wire E-6

(GRAY) Ground Wire

(GREEN)

Figure 9 Conductivity Sensor E-6

Figure 8 Junction Box

3.3 BOILER POSITIONING AND ANCHORING

3.3.1 Boiler Proper

Mark boiler center line and boiler foundation corners on foundation. Recommended foundation is 6” concrete slab.

Re-enforcement of slab is not necessary if fl oor is solid. Details of the boiler foundation and clearance dimensions are given on BOILER ASSEMBLY OUTSIDE VIEW drawing. Clearances are listed in Table 16.

All EX model boilers have four (4) anchor bolt holes for 5/8” anchor bolts. After positioning, anchor the boiler to the foundation. See Figure 10.

Bolier Pressure

Vessel

Bolier Base Frame

4 5/8” Anchor Bolt Holes

Figure 10 EX Series Boiler Base Plate

3.3.2 Economizer Installation

(OPTIONAL EQUIPMENT)

1. This section does not apply to EX-G or EX-GO boilers. These models do not include an economizer.

2. Flue gas fl anges must be sealed. Adjust the economizer as necessary to match the boiler fl ange by using the

four adjusting bolts mounted on economizer base plate.

3. Adjustment of the economizer to the boiler may result in loss of vertical alignment of the economizer outlet

fl ue. This adjustment will be compensated by fl ue gas stack.

4. Install and tighten bolts for fl ange between boiler and economizer. When boiler to economizer joint is tight,

place shims under economizer base and bolt to foundation slab.

5. See Figure 11.

6. All economizers have a 2” drain hole on the bottom. This drain can be piped to a fl oor drain if desired.

ECONOMIZER

EX - 100

12 Bolts

EX - 200/300

16 Bolts

BOILER

(4) Height

Adjusting

Bolts 3/4”

GASKET

Figure 11 Economizer Mounting

DANGER: INSTALLER AND OPERATOR MUST IDENTIFY EMERGENCY SHUT-

OFF DEVICES - INCLUDING POWER SWITCH, MAIN GAS (AND OIL) AND

WATER COCK.

EX-100

2” NPT

EX-200

3” 150# ASA

FLANGE

EX-250/300

4” 150#

ASA FLANGE

EXH-300

4” 300# ASA

FLANGE

3.4 STEAM PIPING

MIURA Boiler recommends a check valve between the boiler outlet valve and the header isolation valve. Install the main steam check valve horizontally to prevent condensate build up above the check valve.

MIURA Boilers do not have a manhole. All openings into the waterside of the pressure vessel are 2” standard pipe plugs. Consequently, most jurisdictions do not require a “NON RETURN VALVE” in multiple boiler installations. Therefore, less expensive standard globe valves and fl apper type check valves may be used instead of the Non-Return stop-check type.

Install the horizontal piping with suffi cient slope and condensate drainage to prevent water accumulation in process steam supply piping. Recommended slope is 1” for every 200” to300” horizontal pipe run. For piping runs of more than 50 feet, consideration should be given to expansion joints in the steam piping to minimize piping stress on the boiler and process equipment as a result of thermal expansion of the steam piping.

When the amount of condensate return is insuffi cient to maintain feed water tank or hotwell tank temperature, a pre-heater steam system maybe installed if desired. A feed water pre-heat system is NOT required for the

MIURA boiler. However, a pre-heat of the feed water will reduce the amount of oxygen scavenging chemicals required.

Install a steam condensate drain trap on the main steam header to remove condensate prior to distribution to process steam lines. All low points in the steam piping should also have a condensate removal trap installed.

This will minimize the chances of damage caused by water hammer or poor temperature control of the process due to water slugs in the steam system. Standard steam system practice is to install a steam trap every 75 feet of piping run.

See Figure 12 for system diagram and Table 9 for outlet valve connections.

Steam Outlets

Steam Header

Condensate Return

Steam Trap

Feed Water

Tank

Figure 12 Steam Line and Trap Arrangement

3.5 FEED WATER SYSTEM PIPING

Table 10 Feed Water Pump Suction Strainer Size

ITEM EX-100 EX-200

Water Inlet pipe size (nominal) 1” NPT

Feed water pump strainer size (nominal) 1 1/4” NPT

EX-250 EX-300

1 1/4” NPT

1 1/2” NPT

Vent

Condensate Return

Feed Water

Tank

EX Series

MIURA BOILER

Softener

Chemical Pump

Feed Water Pump

Figure 13 Recommended Feed Water Piping Arrangement

NOTE: Prior to installing pump, softener and other equipment, review applicable instruction books.

For the recommended system, refer to Table 10 and Figure 13 for the following discussion.

• Zero PPM hardness and daily sampling are required at the Feed Water tank. Do not connect the hard water line to the condensate return line.

• Install softener in series. Dual units are recommended. If water softeners are not installed in series, a full- size polishing unit is recommended. Do not use a fl oat-actuated make-up water control valve. Such a system may result in low fl ow rates through softener resulting in channeling of ion exchange medium. Use a make-up water control system that will only allow specifi ed fl ow through the Softener. The rule of thumb is ½ gpm minimum fl ow for each 1 cubic foot of resin in the softener tank. Consult chemical treatment company for specifi cs.

• Test cocks for individual softener and Feed Water Tank water quality testing are strongly recommended.

NOTE: To properly size the water softener, raw water hardness and conductivity, make-up water volume, boiler operating hours and water iron content are important factors. For details and assistance please contact your nearest MIURA representative or Boiler Water Treatment Chemical company.

• Collect condensate from process as feasible. Return condensate to Feed Water tank. Do not connect any piping that would allow hardness or product to enter Feed Water tank. Thermal insulation is recommended for all piping between Feed Water Tank and Boiler to conserve heat.

• Install the Feed Water Pump under or near the Feed Water Tank. The suction pipe should be adequately sized and confi gured to minimize friction losses. MIURA requires at least six feet of water above the suction of the pump to prevent cavitation.

• Use a gate valve in the Feed Water Pump suction line, followed by the specifi ed strainer.

• Ensure the height of the water level in the feed water tank is suffi cient to prevent cavitation of the Feed

Water Pump under normal operating conditions. As an example, the EX-300 boiler using the GRUNDFOS model CR8-100U pump will require at least 6 feet of water height above the pump suction connection if the feed water temperature is at the boiling point. In general, MIURA Boiler recommends installing the

Feed Water Supply Tank as high as possible in the boiler room to prevent any possibility of Feed Water

Pump damage due to cavitation. Specifi cally, MIURA requests that the tank water level be at least 6 feet above the pump suction.

• In some cases, a fl ow restricting plate on the discharge side may be necessary to prevent cavitation of the

Feed Pump when re-fi lling the boiler after a bottom blow down. If the boiler will not be operated over about

100 psi, the plate may also be necessary. If the tank supplying water to the boiler is not more than 6 feet above the pump, a plate will be required.

• Avoid high points in the pump suction piping that would allow air to collect and result in loss of pump priming.

• Run all drains and overfl ows to fl oor level or well with an air gap to provide inspection capability.

CAUTION: DO NOT ALLOW THE PUMP TO RUN DRY. DO NOT ALLOW THE PUMP TO VAPOR

LOCK. SEVERE AND IMMEDIATE DAMAGE TO THE PUMP WILL RESULT.

• Chemical feed can be made to Feed Tank and/or Feed Water Line. All MIURA Boilers are provided with a set of “DRY” contacts through terminal strip connections 30 and 34. These wires connect a Normally

Open contact on the feed water pump magnetic contactor. MIURA recommends wiring the chemical injection pumps through this contact. This allows the chemical injection pumps to operate only when the feed pump is running. This type of operation allows the chemical company to adjust chemical usage directly to the boiler water usage. Due to the very small water content of the boiler, any difference between chemical injection rate and steaming rate will result in erratic chemistry control. Operating the chemical pumps concurrently with the feed pump will provide a more consistent use of chemicals.

• Chemical Treatment procedures should be based on recommendations of a reputable boiler water chemical treatment company. NONE of the MIURA Boiler Warranties covers damage to the pressure vessel due to corrosion or formation of scale.

• Dual Pump Feed Water Systems are available as an additional option.

• Insulation of the Feed Water piping is recommended between the condensate return tank and the boiler.

• Some jurisdictions require a pressure gage on the discharge of the pump.

• Follow all local regulations.

3.6 FEEDWATER PUMP

(NOT INCLUDED WITH BOILER UNLESS ORDERED FROM MIURA)

CAUTION: The Feed Water Pump is vital to satisfactory operation of your new MIURA boiler.

Review this section carefully for pump selection criteria if the customer has chosen to purchase a pump from other than MIURA. All pumps, regardless of the manufacturer, require a positive pressure on the pump suction to prevent cavitation damage to the pump. Any damage to the pump resulting from installation errors or cavitation is NOT covered by MIURA.

NOTE: Ensure the height of the water level in the Feed Water Tank is suffi cient to prevent cavitation of the Feed Water Pump under normal operating conditions. As an example, the

EX-300 boiler using the GRUNDFOS model CR8-100U pump will require at least 6 feet of water height above the pump suction connection if the Feed Water Temperature is at the boiling point.

In general, MIURA boiler recommends installing the Feed Water supply tank as high as possible in the boiler room to prevent any possibility of Feed Water Pump Damage due to cavitation.

Specifi cally, MIURA boiler requests that the water level in the pump supply tank be AT LEAST

6 feet vertically ABOVE the pump suction fl ange. MIURA strongly recommends installing the pump directly under the feed water supply tank. If necessary to achieve six-foot vertical height, the pump may be installed in a pit and piping arranged as necessary.

Danger: Improper sizing of the feed water pump will severely impact the performance of the MIURA

Boiler. Under-sizing of the pump, either by fl ow or by pressure will result in frequent Low Water Alarms and Boiler Lockouts. If this condition is allowed to continue, the Manufacturer’s Warranty on the pressure vessel DOES NOT COVER any tube damage that may result. Review and FOLLOW the pump sizing criteria below and this condition will not occur.

NOTE: THE MIURA Boiler is a unique design. Common pump sizing criteria do not apply.

MIURA Boiler recommends that a pump be purchased with the boiler rather than using an existing pump. The reason for this is that MIURA Boilers run with intermittent feed water pump operation. MIURA Boilers start the feed pump on call for water and turn it off when call for water stops. This is due in part to the boiler having no fi xed steam/water level to maintain and in part as a side effect of the pressure vessel design. Some boilers use a modulating feed water control system such as McDonnell Miller fl oat valves and operate the pump continuously.

This is done partly because of a fi xed steam/water level and mostly to reduce thermal stresses on the boiler shell that result from the introduction of relatively cold water to the hot boiler. The MIURA Design Advantage eliminates the need for this type of system. MIURA simply turns the pump on and off as needed based on actual boiler steam demand. This allows the pump to always run at optimum effi ciency and prevents pump-overheating problems. The MIURA Boiler is designed, tested, and CERTIFIED to operate this way. Experience has shown there is no advantage to operating a MIURA Boiler with a modulating feed water control system.

Therefore, if a pump other than that provided by MIURA is used, the following selection criteria are provided:

Size the pump to deliver Twice (2X) or preferable Three times (3X) the steady state evaporation rate of the boiler. This fl ow MUST be delivered to the boiler at a pressure AT LEAST 30-psi ABOVE the Boiler operating pressure. Also, ensure that the pump motor is able to handle frequent start/stop cycles without overheating the motor windings.

For example, an EX-300 operating at 100% capacity for one hour will evaporate 10,350 pounds of water (at 0 psig) each hour. This is the steady state evaporation rate. Converting this evaporation rate to gallons per minute gives 21.6 gpm. As a result, MIURA recommends a pump capable of providing at least 43.2 gpm. If the boiler is operating at 150 psi, the pump should deliver between 43.2 and 64.8 gpm at 170 psi. The GRUNDFOS

CR8-100U, which is the pump recommended, will provide 54 gpm under these conditions.

MIURA recommends a pump equivalent to the GRUNDFOS pumps listed below for each Boiler model.

MIURA BOILER

MODEL

EX-100

EX-200

EX-250

EX-300

EXH-100

EXH-200

EXH-300

Table 11 Feed Water Pump Recommendations

GRUNDFOS

PUMP MODEL

CR2-120U

CR4-120U

CR8-100U

CR2-180U

CR8-120U

CR8-140U

MOTOR HORSE

POWER

3 hp

5 hp

7.5 hp

5 hp

10 hp

15 hp

PUMP CAPACITY

DESIRED

12 GPM

30 GPM

46 GPM

13 GPM (@ 250 psi)

30 GPM (@ 250 psi)

51 GPM (@ 250 psi)

These pumps are available through MIURA and if purchased with the boiler they may be provided with an optional mounting foundation as described below.

MIURA recommends installing a feed water suction strainer of at least 20 mesh. Install a strainer one size larger than pump suction piping. Pump fl ange kits are available from MIURA as an option. Also, install an isolation valve on the supply side of the strainer to allow cleaning the strainer without draining the feed water supply tank.

The suction side isolation valve and feed water strainer are NOT provided by MIURA and must be installed in order to include the pump in the One-Year Parts Warranty. The One-Year Warranty applies to the pump ONLY if it is purchased through MIURA.

Water is automatically fed to the boiler from the feed tank by traveling through a manual shut off valve, “Y” type strainer, pump, economizer (if equipped), then through two (2) check valves to the bottom header to the internal water distribution tube.

GRUNDFOS series C Multi-Stage centrifugal pumps installed in accordance with the manufacturers instruction booklet will operate effi ciently and provide years of service. The pumps are water lubricated and do not require any external lubrication or inspection. The motors will require periodic lubrication as noted in the maintenance schedule section.

The pump is a close coupled, multistage high-pressure centrifugal type. Pump models vary with the horsepower of the boiler and are selected for operation at 150-psi steam pressure. If lower pressure is desired, a fl ow restricting plate or smaller pump may be appropriate.

CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE PUMP BE OPERATED FOR ANY PRO-

LONGED PERIOD OF TIME WITHOUT FLOW THROUGH THE PUMP.

Dry operation of the pump can result in motor and pump damage due to overheating. A properly sized recirculation fl ow fi tting may be obtained from GRUNDFOS and installed to prevent this damage if the pump is run with an isolation valve shut. On a boiler equipped with an economizer, the economizer safety relief will open and spray hot water onto the boiler room fl oor if the boiler feed isolation valve is shut during pump operation.

GRUNDFOS Installation and operating instructions specify the number of start/stop cycles for the pumps.

MIURA Boiler operations exceed these values. The number of start/stop cycles in conjunction with the short running times in our application is approved by GRUNDFOS and MIURA Boiler engineering sections and will not result in motor overheating problems.

For detailed installation data, refer to “GRUNDFOS” installation and operating instructions that were supplied with the pump. The pump is in a separate crate from the boiler.

Before starting the pump after initial installation or maintenance, please check the following:

• All piping connections are tight and the pipes are adequately supported.

• Any isolation valves on the suction of the pump are open.

• Pump is primed and vented through the vent fi tting located at the top of the pump.

• Open main power disconnect. Remove the coupling guard and rotate the pump shaft to be certain it turns freely. Replace the coupling guard.

• Insure that all feed water isolation valves are open.

• Shut the main power disconnect to the boiler.

• While observing the top of the pump, cycle the boiler “ON-OFF” switch located on the front of the boiler. This will start the pump and allow verifi cation of the direction of rotation. Direction of rotation is counterclockwise when viewed from the top. The pump will not run if the control switch is in the “OFF” position.

3.6.1 Feed Water Control Valves

In the application where the customer does not want to operate the Feed Water Pump in frequent start/stop cycles, other options are available. Again, the feed system operates in a simple On-Off manner. If control valves are used, they MUST be quick acting. MIURA Boiler recommends the Motorized Feed Water Control Valve Option be purchased from MIURA at the time of purchase. If the customer elects to install other types of controls, MIURA recommends pneumatic valves or fast operating electric valve actuators. Note that the pneumatic actuators operate in 1 second open to shut, and the electric actuators are 5 seconds open to shut.

DANGER: ANY PROPORTIONAL VALVE ACTUATOR OR CONTROL VALVE MUST MOVE FULL

TRAVEL WITHIN 5 SECONDS TO BE ACCEPTABLE UNDER ALL MIURA WARRANTIES.

3.6.2 Piping Flushing

After installation is completed but before the boiler is fi red, fl ush all water piping. MIURA is not responsible for damage as a result of stuck open check valves that result from debris in the piping.

Figure 14 Economizer Safety Relief Valve Installation

Safety Relief

Valve for

Economizer

1” NPT

Open Drain to

Floor/Waste

3.7 SAFETY RELIEF VALVES, INSTALLATION

EX-100 EX-200 ITEM

Boiler Safety Valve Outlet

Economizer Safety Valve

Outlet

2” NPT 2 1/2” NPT

To Roof

Slip on the Drip Pan

Elbow

EX-250 EX-300 EXH-300

2 1/2” NPT 2x2 1/2” NPT 2x2 1/2” NPT

1” NPT

Vent Pipe

Support

Safety Relief

Valve

Drip Pan

Elbow

Union

Union/Flange

Drain

Figure 15 Boiler Safety Valve Installation

Drip panels should be used for boiler safety valves. Water that collects in the elbow and valve body after the valve lifts, any rain water or valve leakage should be drained off and not allowed to stagnate. Failure to drain the water may result in valve corrosion or water hammer if the valve lifts. This arrangement is shown in Figure 15.

The optional economizer is also equipped from the factory with a safety valve. The installation is illustrated in

Figure 14. The economizer safety valve may not be required to be piped to the roof depending on local codes.

Piping should be directed to a fl ood drain or other collection points as specifi ed by the local codes concerning boiler wastewater. If a de-aerator is used, the water discharged by this safety may be near the boiling point and could cause a potential for personnel injury. Arrange the piping accordingly.

3.8 BLOWDOWN PIPING

ITEM EX-100

LVC blow off outlet

Bottom blow off outlets

Automatic blow down outlet

1” NPT

3/8” NPT

EX-200

1” NPT

3/8” NPT

EX-250 EX-300

1” NPT

2 x 3/8” NPT

1” NPT

2 x 3/8” NPT

EXH-300

1” NPT

3/8” NPT

DANGER: Be sure to install blow down piping separately from overfl ow and drainage piping. Piping shall be arranged to prevent any possibility of boiler water splashing and causing personnel injury.

• All piping subject to pressure from the boiler during blow down must be securely anchored to prevent piping

vibration and shock during blow down of the boiler. Due to the large number of different piping arrangements

possible, MIURA recommends a maximum pressure for manual bottom blow down of 30 psi. Information

on piping sizes is given in Table 12.

• Note that the Automatic Surface Blow Down Line operates automatically when the boiler is at high pressure

and temperature. Therefore, the 3/8” pipeline must be piped to the blow down tank to avoid personnel

hazards.

• Do not allow siphoning back into the boiler from wastewater drains.

• Standard equipment includes on (1) “quick operation” type globe valve for blow down isolation. Double blow

down isolation valves may be installed at customer request and as required by local regulations. The second

blow down valve is an additional option (See Figure 17.)

• Install an additional check valve between the automatic blow down solenoid valve and the blow down separator.

(See Figure 18.) Check valve is not included with boiler.

• Blow down separator after cooler for boiler water may be supplied by MIURA Boiler at customer request.

Insure local regulations for disposal of boiler wastewater are followed.

• In an installation where multiple boilers share a common blow down separator, install a check valve in the

piping between each automatic and manual blow down isolation valve and the blow down separator. See

Figure 16 as an example.

• In a situation where all blow down water is collected in a sump, size the sump for at least fi ve times the

operational water content of the boiler. This will allow collecting the boiler water and the cooling water

used by the blow down separator. The operational water content is provided in the general specifi cation

tables.

• Follow all local regulations.

From other Boiler

To Roof Vent

Blow Down

Separator

Cooling Water

From

Intermittent

Automatic

Surface

Blow Down

Drain If an Automatic

Temperature Control Valve is used instead of a Manual

Valve, install a Strainer upstream of the Control Valve.

Figure 16 Blow Down Piping Arrangement

Option Valves

From Bottom Blow and L.V.C.

MIURA Standard

Quick Operating

Valve

To Blow Down Separator

Figure 17 Double Blow Down Isolation Valve Options

3/8” Solenoid Valve

(Note: EX-250~300 have t

Solenoid Valves.)

Union

Sampling Valve

To Blow Down

Separator

Figure 18 Automatic Blow Down System Check Valve

3.9 FUEL SUPPLY ARRANGEMENTS

3.9.1 Gas Piping

FUEL TYPE: Natural & Propane Gas

SUPPLY PRESSURE: Steady pressure between 3-5 PSIG required at boiler regulator inlet at full fi ring rate and when boiler combustion is stopped. Installation of a pressure gage to monitor gas supply pressure is recommended. If the boiler is operated with propane fuel, MIURA Boiler STRONGLY recommends use of a vaporizer. Collecting the propane gas from the top of the tank is possible but not recommended due to variations in vapor space pressure depending on ambient air temperature. Also, ensure the vaporizer is sized for full boiler capacity even if the normal load is less than the maximum capacity of the boiler. This recommendation is based on the boiler operating at full rated fuel fl ow during the start up period.

ITEM

Gas Inlet

Main Regulator Vent

Pilot Regulator Vent

Pressure Switch Vents

Automatic Vent Valve

(IRI) Option

Table 13 EX Gas Piping Sizes

EX-100 EX-200 EX-250 EX-300

2” NPT

1” NPT

2” NPT

1” NPT

2 1/2” NPT

1” NPT

1/4” NPT 1/4” NPT 1/4” NPT

1/8” NPT

(2 switches)

1/8” NPT

(2 switches)

1/8” NPT

(2 switches)

1” NPT 1” NPT 1 1/4” NPT

2 1/2” NPT

1” NPT

1/4” NPT

1/8” NPT

(2 switches)

1 1/4” NPT

Use an approved reducing valve to meet the required specifi cations if the supply gas pressure is above 5 PSIG.

Use an approved booster pump if necessary to meet the required minimum pressure specifi cations of 3 PSIG. 3

PSIG minimum is required at the inlet to the Fisher model 133L regulator supplied with the boiler to ensure an adequate volume of fuel is available to support combustion during fi ring rate changes. Specifi cally, a change from burner “Off” to “Low Fire,” which is approximately 40% of rated fuel usage, occurs over a 10 - 15 second period. The fuel usage then goes from 40% to 100% rated consumption when the boiler goes to high fi re. This change occurs in less than one second. Fuel consumption then changes from 100% to zero in less than one second when the boiler turns off when running in high fi re. The Utility Gas regulator must maintain at least

3 PSIG and not exceed 5 PSIG under these conditions, and needs to be placed as far away from the boiler regulator as possible. The maximum pressure of 5 PSIG is determined by Underwriter’s Laboratory approval of the MIURA Gas train.

Install a dirt pocket on main gas inlet piping immediately up stream of boiler.

NOTE: Maintain stamped gas supply pressure during operation. This pressure must be at the regulator supplied with the EX-Series boiler gas piping. If necessary, use larger pipe for long piping runs. Failure to maintain required gas fl ow rate and pressure will result in frequent boiler misfi res!

• All main gas train piping to the burner is included, (with the exception of individual regulator and pressure switch vents). Do not attempt to change any part of this gas train without fi rst consulting the nearest

authorized MIURA dealer.

• Do not use any gas piping with a diameter smaller than the gas inlet piping to the boiler.

• Use one reducing station to the boiler room. Do not use a separate reducing valve to supply each boiler.

This can result in pressure oscillations that could result in boiler fl ame failures or momentary over fi ring

conditions. Consult pressure regulator application engineers for correct sizing and regulator model selection.

• See specifi cation tables for fuel consumption.

• The copper gas line to the pilot regulator is lined with aluminum and does not require replacement in jurisdictions that prohibit using copper for natural gas.

• Two pressure switches, HIGH and LOW gas pressure, may be required to be vented to atmosphere outside the

boiler room in some jurisdictions. Contact your local insurance provider and the gas company for specifi c

requirements. Some jurisdictions may require the pilot gas regulator to be vented. See Figure 19 for a

typical vent line arrangement and Figure 20, Figure21, and Figure 22 for connection points. Note that

some boiler models may have ANTUNES RLGP-G 5~30’ switches on the gas train which do not require

venting to atmosphere.

• Gas vent lines, when manifolded, shall be connected to a common vent line having a cross-sectional area not less than the area of the largest vent line plus 50% of the areas of all the additional vent lines.

• An automatic solenoid operated automatic vent valve located between the main gas blocking valves may be required for insurance purposes and is an additional cost option to meet IRI specifi cations. Insure IRI is specifi ed on the purchase order if necessary.

Natural gas vent line from switch and regulator leakage ports to outside boiler room.

Pilot Gas Regulator

Do not allow vent pipe to be kinked.

This will result in pilot fl ame failures.

Pilot Gas Train

High Gas Pressure

Switch

Solenoid Valve (for IRI )

Low Gas Pressure Switch

Main Gas Train

Main Gas

Regulator

Figure 19 Typical EX Series Gas Train and Vent Points

To exterior vent

1” NPT

Union

Fitting

Main Gas Regulator

Use drip leg or rain cap on vent line. Do not allow vent line to be blocked or to fi ll with rain water. Boiler operation will be adversely affected.

Figure 20 Main Gas Pressure Regulator Vent Piping

To exterior vent. Do not allow line to be krimped.

Frequent pilot fl ame failures will result.

1/4” aluminum pipe

Pilot Gas Regulator

Figure 21 Pilot Gas Regulator Vent Line Connection

To exterior vent

Gas Pressure Switch

1/4” Aluminum

Tube

Figure 22 Gas or Air Pressure Switch Connection

3.9.2 Oil Piping

FUEL TYPE: No. 2 Oil

ITEM

OIL INLET

Table 14 Oil Inlet Pipe Sizing

EX-100 EX-200/250

3/4” NPT - UNION

EX-300

1. All oil piping to the burner is included. Do not attempt to change any part of this oil train without fi rst

consulting the nearest authorized MIURA dealer. See Table 14 and Figure 23.

2. See specifi cation tables for fuel consumption.

3. Fuel pump suction pressure should not exceed 3 psig in order to comply with National Fire Protection Code.

4. Fuel pressure at pump suction must NOT be at a vacuum. Do not use the MIURA supplied oil pump to draw

oil up from the tank, through the overhead, and down to the boiler. This arrangement usually allows air

to leak into the pump suction connection and results in very poor combustion.

5. Install a manual fuel oil shut off valve at the boiler.

6. Avoid high points in the pump suction piping that would allow air to collect and result in loss of pump priming.

7. If necessary to prevent loss of oil pump priming, install a re-circulation pump.

8. Vent all air from the piping to prevent damage to the oil pump seal before running the pump.

9. Follow all local regulations.

To Burner

Oil Strainer

Oil Pump Suction

Piping Connection

Oil Pump

Figure 23 Oil Pump Piping

NOTE: Ex-200/250 and EX 300 Oil fi red burners require Natural or Propane gas for the Pilot. The Gas

Pilot is required for ignition when running on oil.

3.1 ELECTRICAL INSTALLATION

ELECTRICAL TABLE

Table 15 Electrical Specifi cations

EX-100SGO EX-200SGO

VOLTAGE

Amperage

Power Usage (KVA)

Wire Size (AWG)

Disconnect Amps

460 230

17 34

13 (14 for oil fi red)

#10 x 3c +

#10(G)

#8 x 3c +

#10(G)

460 230

31 63

24 (25 for oil fi red)

#8 x 3c +

#10(G)

#4 x 3c +

#8(G)

100

EX-250~300SGO

460 230

38 77

32 (34 for oil fi red)

#6 x 3c +

#10(G)

#3 x 3c +

#8(G)

120

1. Other voltages are available by special order.

2. Specifi cations for FGR option are not covered by this table. Contact Miura for details.

3. Optional equipment such as the MIURA remote communications system or the MIURA Multiple Installation

(MI) system must be wired as specifi ed in the individual instruction books.

4. After installation of the feed water pump and blower to the foundations, the motors must be wired to the boiler power distribution box using customer provided cable for the blower and customer supplied cables for the pump. If the pump or blower is located some distance from the boiler, an emergency stop/start or disconnect switch may be required near the motors.

5. For details of wiring, see individual wiring diagrams.

6. Comply with local building electrical codes.

1” Rigid

Conduit

Connection

(Drill to Suit customer job site)

R S T G

33W1

33WL2 7800

T1 T2 T3 X1 X3 X4 X5

88 F

CB4 CB2

88W

49F

Figure 24 EX Series Boiler Electrical Connection

All EX series boilers include as optional equipment a GRUNDFOS feed water pump. This pump is shipped in a separate crate form the boiler. All boilers include a magnetic contactor and circuit breaker pre-wired into the power box for the pump. If the pump is located at a distance from the boiler, use a connection box and comply with local wiring codes to extend the wiring to the pump. Some installations, for example a pump located in a different room from the boiler, may require a local disconnect/emergency stop switch at the pump.

In this situation, it is not necessary to provide an interlock between the pump and boiler to ensure that the local disconnect is shut. The boiler starts and stops the pump automatically as necessary to maintain the required water volume. If the pump does not start, the boiler safety circuits will shut down the boiler on low water volume and prevent damage. If desired, an indicating lamp may be installed near the boiler control panel to indicate that the local disconnect/emergency stop switch at the remote feed pump location is shut.

3.10.1 Panel Layout

Display Window.

Current Status and

Information.

CAUTION/WARNING

Information Button (Push to read message before resetting Alarm)

Menu/Setting

Scroll Buttons

Data

Change/Set

Button

Alarm

Reset

Boiler Combustion

START/STOP

Boiler Operation

Switch/Circuit

Breaker (to left of panel)

Boiler

Steam

Pressure

Figure 25 Boiler Control Panel

3.10.2 Boiler Interface Capabilities

The MIURA boiler has several options for remote monitoring. The standard equipment supplied with the boiler is a Honeywell S7896D Burner Control.

The Honeywell 7800 series is a microprocessor based integrated burner control for automatically fi red gas or oil fi red single burner applications. Functions provided by the S7800 series include automatic burner sequencing,

fl ame supervision, system status indication and system or self-diagnostics and troubleshooting. The 7800 series as installed on the Miura Boiler consists of a Relay Module, Flamed Amplifi er, Universal mounting sub-base,

Plug-In Purge Timer, and Keyboard Display Module. A Communications interface for integrating personal computer networking for burner status is available through Honeywell. The optional interface is the Q7700

Communications system.

Also included as standard equipment on the MIURA Boiler, is a MIURA XJ1 Intelligent Steam Management

Micro-Computer. The XJ1 is a microprocessor-based device designed to monitor the status of a series string of limit, control, and interlock contacts for The MIURA Boiler. The XJ1 acts as a system monitor and enhances fault and status messages of the S7800 series Burner Control. The SJ1 is included as standard equipment, and can provide detailed status on the boiler. Remote communication between the boiler and MIURA Factory

Level Service Department is standard equipment. This allows MIURA Factory Level Service, monitoring, and troubleshooting via modem. A monthly report detailing operating hours, start/stop cycles, actual boiler evaporation (requires optional gas meter), feed water pump performance and the number of times any alarm occurred is available for a small fee. This remote monitoring program is not equaled by ANY boiler control system. Contact your local MIURA Representative for more details.

The MIURA Boiler is capable of providing status information such as burner operating or burner off, steam pressure above or below set value, feed water pump energized or off. This information is provided by the addition of 120VAC control circuits inside the control cabinet. The additional circuits are available as an option from

MIURA or may be fi eld installed. The MIURA XJ1 system is not compatible with standard building automation

/monitoring systems. Individual customer needs vary as well as the information required. Analog information, such as steam pressure or feed water temperature requires separate sensors not included with the MIURA Boiler.

For specifi c information and wiring connections please contact your nearest MIURA Boiler representative.

3.11 CLEARANCE

The EX-Series was designed for use on noncombustible fl oors with minimum clearances from the unit and the fl ue connections to fl ammable materials of:

Table 16 Boiler Minimum Clearance Requirements

ITEM

BOILER TOP

BOILER SIDE

BOILER REAR

BOILER FRONT

SIZE

40”

18”

Follow local regulations.

3.12 VENTILATION

Ventilation of space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The total cross-sectional area of the opening(s) shall be at least equal to the dimensions of Table 17 below.

When air supply is provided by a natural fl ow from outdoors for the boiler, in addition to the opening for ventilation air required, there shall be a permanent air supply opening having a total cross-sectional area not less than recommended from table below and the location of the opening shall not interfere with the intended purpose of the opening for the ventilation air. The supply air opening shall be either located at or ducted to a point not more than 18 inches or less than 6 inches above the fl oor level.

Table 17 Minimum Boiler Ventilation Opening Requirements

EX-100

EX-200

EX-250

EX-300

SUPPLY AIR AREA

(EACH BOILER)

131.5 SQ. IN.

263.0 SQ. IN.

328.5 SQ. IN.

394.0 SQ. IN.

VENTILATION AIR AREA

(EACH BOILER)

13.0 SQ. IN.

26.5 SQ. IN.

33.25 SQ. IN.

40.0 SQ. IN.

This previous table gives factory recommended minimums for each boiler. The recommendation is based on

Canadian Gas Association standards. Boiler room ventilation requirements vary by signifi cant amounts depending on local building and safety codes. For multiple boiler installations, multiply the above areas by the number of boilers installed in the boiler room.

Follow all local regulations.

3.13 STACKS AND BREACHING

Proper installation of the stack is required for high boiler effi ciency and safe operation. The following principles should be followed at all times when designing stacks.

NOTE: Consultation with your Engineering Company, Exhaust Stack Provider or MIURA Representative will ensure a long lasting, trouble free stack design. The stack MUST be designed to maintain available draft at the outlet of the boiler at ZERO or MINUS 0.05 inches of water. Failure to maintain these values will adversely affect boiler performance and is not the responsibility of MIURA.

1. Chimneys should be straight. Bends or offsets have a greater resistance to fl ow with consequent adverse

affects on burner performance and should be avoided whenever possible.

2. A stack should be higher than nearby structures to avoid downdrafts or eddy currents. If this is not

possible, a stack hood designed to prevent downdrafts should be considered. See Figure 26.

3. The stack should project at least:

a) Two feet above the horizontal plane, drawn from a point at least 10 feet away from the stack.

b) Three feet above the lower side of the roof slope.

c) Figure 27 provides examples.

4. Include a rain hood for all stacks. Also, be sure to add a rain shield for straight stacks through the roof.

5. Do not make the stack diameter smaller than the fl ue gas outlet on the boiler.

6. Provide supports if the stack exceeds 100lbs. Also, clamp the stack fi rmly to the fl ue gas outlet.

7. Install the stack away from any combustible material and utilize insulation at the opening in the wall

or roof.

8. Follow all local regulations. Check your building, fi re, and mechanical codes as a minimum guide line.

9. Flue gas sample fi ttings are provided from the factory on boilers ordered with economizers. In addition,

fl ue drain connections are provided on the exhaust elbow and economizer. Ensure these connections are

plugged or piped into drains. Please do not cover these fi ttings when insulating the exhaust stack.

10. One ½” drain plug fi tting is installed on the optional MIURA fl ue elbow, and one 2” drain plug is provided

on the optional economizer. The 2” drain plug is intended to allow piping of condensation to a fl oor drain

through a “J” type water trap. If drain piping is not used, please install a 2” plug to prevent to prevent

fl ue gas escape to the boiler room.

11. When the boiler is installed in regions where temperatures fall to the freezing point, a stack damper should

be installed to prevent down drafts from freezing the boiler tubes when it is not in operation.

12. All boilers are equipped with a fl ange on the fl ue gas outlet. Dimensions and bolt patterns are given in

Figure 28.

13. A chimney down draft will have a positive effect on main burner ignition reliability and boiler stack emissions.

Positive pressure at the boiler stack connection is not allowed.

14. Excessive available draft will result in lower boiler effi ciency and also affect pilot burner and main burner

fl ame stability. Excessive available draft is a negative pressure at the boiler connection to the stack.

NOTE: The relationship between a stack draft and pressure drop of fl ue gas is given in the following equation. Miura boilers require a draft of zero inches w.c. to a maximum of -0.05 inches w.c. for proper operation. Operation outside these values will seriously impact boiler performance.

0.82H > 0.49L + 1.5N + 1.5

H: Height of chimney rain cap (FT)

L: Total length of chimney (FT)

N: Quantity of knuckle points

Insure that the above equation is satisfi ed, in order to obtain full boiler capacity.

RAIN

CAP

RAIN

SHIELD

WATER RECEIVER

SUPPORT

Figure 26 Stack Installation

BOILER

2’ OR MORE

3’ OR MORE

10’

KNUCKLE

POINT

L = L1 + L2 + L3

Figure 27 Stack Design

B” x C”, (D) Holes @ E”

ID A

Flue Gas

Sample Plug

ID H

0.1046”

ID I

0.1046”

EX-G/GO without

Economizer

EX-G/GO with Adaptor

(Option)

Drain

Flue Gas

Sample Plug

EX-SG/SGO with

Economizer

ID A (inches)

B x C (inches)

D holes

E PD (inches)

F fl ange OD (inches)

H, I ID

EX-100

13 1/2

200~250

19 1/2

5/8 x 1 1/8

1 1/2

Figure 28 Stack and Economizer Bolting Dimensions

EX-300

25 1/2

28 3/8

4 SECTION FOUR - OPERATION

DANGER: All cover plates, enclosures, and guards must be in place at all times, except during maintenance and servicing.

4.1 SAFETY FEATURES AND OPERATING CONTROLS

4.1.1 LOW WATER VOLUME CUT-OFF

If the water volume, for any reason, fall below the pre-determined water volume, combustion will immediately be stopped, a warning alarm will be activated, and the display will read, “Low

WATER LEVEL.”

After complete BLOW DOWN of the boiler, all the red lights on the Floatless Switch(es) will be off. With the main power turned on at the boiler and the “ON-OFF” switch “ON,” the Feed Water

Pump will start. After a few minutes, the red LED of Floatless Switch #33WL1 will then come on, and the red LED of Floatless Switch #33WL2 will come on. The Feed Water Pump will continue running until the required water volume is reached.

At this point, the Feed Water Pump will stop. If

The red LED of any of the fl oatless switches does not come on in the above sequence, please check the electrodes and the wiring to the electrodes.

XJ1

Pump

Control

33WL2

Low

Water

Burner

Cut Out

(Auto

Reset)

XJ1

Pump

Control

88W

33WL

33WL1

LWCO

Manual Reset

With Alarm

Feed Water

Pump

The labels 33WL1 and 33WL2 refer to the physical switch. The wiring schematics list the probes as follows:

PROBE

WIRE

E 5

E 4

E 3

E 2

E 1

SWITCH CONTACT

BGI-200-CPU (9)

33WL2 (option)

BGI-200-CPU (7)

BGI-200-CPU (5)

33WL1

Table 18 Floatless Switches and Probes

Please note that probe “B” (E 5) is optional on some models.

Figure 29 Water Volume

Control Illustration

4.1.2 OVERHEAT MONITOR TEMPERATURE

If temperature at the overheat thermocouple on the water tubes should, for any reason, rise above the pre-set temperature (660°F), the overheat protection will be activated, thus shutting down the boiler and activating the alarm. The display will also show “HIGH W TUBE TEMP.”

For testing this function, use the “Set Clock” menu. Set the temperature to lower than the factory value. It will shut down the boiler when the tube temperature reaches the new set value. After testing, do not forget to return to original setting. We suggest changing only the “hundred’s” value. An example would be to reset the temperature controller from 475°F down to 300°F. After the boiler shuts down, the “Set Clock” menu item must be reset to the factory shop test value, or the boiler will not run.

4.1.3 SCALE MONITOR TEMPERATURE

If temperature at the scale monitor thermocouple on the water tubes should, for any reason, rise above the pre-set temperature (maximum 660°F, typically around 450°F), the overheat protection will be activated, thus shutting down the boiler and activating the alarm. The display will also show “HIGH W TUBE TEMP.” Note that there are two different settings for the scale monitor alarm. One setting is used during High Fire and the other during

Low Fire. The computer waits 40 seconds after a change in fi ring rate to evaluate the current temperature against the alarm set point. The XJ1 also adjusts the alarm set point internally based on boiler steam pressure. Therefore, it is not necessary to set the alarm point at boiler start up. DO NOT CHANGE THESE SETTINGS FROM

THE FACTORY NUMBERS.

For testing these functions, use the “Set Clock” menu. Set the temperature to lower than the factory value. It will shut down the boiler when the tube temperature reaches the new set value. After testing, do not forget to return to original setting. We suggest changing only the “hundred’s” value. An example would be to reset the temperature controller from 475°F down to 300°F. After the boiler shuts down, the “Set Clock” menu item must be reset to the factory shop test value, or the boiler will not run.

4.1.4 HIGH PRESSURE LIMIT CUT-OFF

Reset Lever

If the boiler pressure should, for any reason, rise above the pre-set pressure

(Max.170 PSIG), the High Pressure Limit protection will be activated, shutting down the boiler, activating the alarm. The display will show

“EMERGENCY STOP.”

If the boiler shuts down because of high pressure and you need to press the reset on the pressure switch to restart, please check the Control Pressure settings of the XJ1 for any incorrect setting. The Control Pressure should have a lower setting than the Limit Pressure switch.

Honeywell PRESSURE TROL

For testing High Pressure Limit, set it lower than the Control Pressure. It will shut down the boiler when the boiler pressure reaches the set pressure. After testing, do not forget to set it Back to the original setting and reset the High Pressure Limit Switch.

4.1.5 MIS-FIRE

If ignition is not achieved after the ignition period, burner operation will immediately be stopped. After a purge cycle, the safety switch of the

Flame Safeguard will be activated, and a warning alarm will sound. The display will indicate “FLAME FAILURE.”

For testing the Flame Safeguard, close the pilot gas valve, then start the boiler. Mis-fi re will occur after the fi rst or second attempt for pilot.

After testing, do not forget to open the pilot valve and reset the Flame

Safeguard.

4.1.6 FALSE SIGNALS

Should there be any false signals emitted during ignition, pre-purge, or should pre-purge timing be off, the safety switch of the Flame Safeguard will be activated, the boiler will be shut down, a warning alarm will sound, and the INTERLOCK lamp will be illuminated. The display will show the reason for interlock.

For testing during pre-purge, take the fl ame eye out and point it to a fl ame (of a cigarette lighter, for example). The boiler will continue to purge and pilot will not come on. After testing, do not forget to put the fl ame eye back to its original position and reset the Flame Safeguard.

4.1.7 POWER OVERLOAD

POWER

PILOT

FLAME

MAIN

ALARM

RESET

BURNER CONTROL

UV Flame

Sensor

Overload or short-circuiting of the blower motor will result in boiler shutdown and sounding of the warning alarm. Most blower motors have a stator winding thermal overload feature. If the thermal overload,

(49°F) has not tripped in the boiler control panel, operation will not resume until the blower motor has cooled down.

Thermal overload of the blower motor, both internal stator winding and

49°F, will be indicated as “AIR PRESS FAULT” on the XJ1.

4.1.8 AIR PRESSURE

R-SET test man auto

If the air pressure in the air duct, for any reason, falls below the predetermined pressure, combustion will be immediately stopped and a warning alarm will sound. The display will show “AIR PRESS FAULT.”

For testing, turn the setting of overload protector #88 to “TEST.” During combustion press and hold the reset button of overload protector #88F.

The blower will slow down to a stop; there will not be enough airfl ow, and the boiler will shut down. Release the reset button, set overload protection #88F back to manual, and reset the boiler. Also test the airfl ow by noting the setting of the air pressure switch and then adjusting it to a higher setting. After the alarm sounds, reset the switch to the original value.

4.1.9 FUEL GAS PRESSURE

When the “START” button is pushed prior to combustion when there is not enough gas pressure, the burner cannot ignite and the warning alarm will sound. If, during the process of boiler operation, the gas pressure falls below the required range, combustion will stop, and the alarm will sound. In addition, the display will show “LOW

GAS PRESS.” or “HIGH GAS PRESS.”

For testing the Low Gas Pressure alarm, close the main gas valve up-stream of the gas train during combustion.

The boiler will shut off because of low gas pressure. After resetting the Flame Safeguard, the boiler still cannot restart because of low gas pressure, until the main gas valve is opened again.

For testing the High Gas Pressure alarm, close the main gas burner inlet valve down-stream of the gas train during combustion. The boiler will shut off because of high gas pressure. After resetting the Flame Safeguard, the boiler still cannot restart because of main fl ame ignition failure. Open the burner inlet gas valve.

4.1.10 Fuel Oil Pressure

(Standard on UL boiler, optional on others)

If, during the process of boiler operation, the oil pressure falls below the required range, combustion will stop, the alarm will sound and the lamp will be illuminated. In addition, the display will show “LOW OIL PRESS.”

For testing, open the circuit breaker of oil pump during combustion. The boiler will shut off because of low oil pressure and Mis-fi re. After resetting the Flame Safeguard, the boiler still cannot restart because of low oil pressure, until the oil circuit breaker is closed again.

4.2 ROUTINE BOILER OPERATION

DANGER: All cover plates, enclosures, and guards must be in place at all times, except during maintenance and servicing.

NOTE: This is a shop-tested, assembled, and fully packaged boiler, Each unit and assembly have been well adjusted in the factory. It is very important not to make any adjustments without fi rst consulting you nearest authorized MIURA dealer.

Daily, or every shift, water analysis should be performed to see if additional treatment is needed. Use a tester of 1ppm or less sensitivity.

4.2.1 PREPARATION BEFORE START-UP

Check the following every day before boiler start-up:

1. Make sure all gages are operating correctly.

2. Make sure there is water in the feed water tank (hotwell or deaerator).

3. Make sure the boiler water is soft. Use a test kit with at least one ppm sensitivity. (For instructions on

checking for soft water, refer to your water softener instruction manual).

4. Make sure there are chemicals in the chemical feed tank.

4.2.2 Start-Up

CAUTION: The following start-up routine must be followed in sequence (1-7).

1. Open feed water inlet valves.

2. Open the main fuel valve and check that the required gas pressure (3-5 PSIG} on gas fi ring is

available.

3. Turn the power source on. The lamp in the “ON-OFF” switch on the control panel should

illuminate.

4. Make sure the manual blow down valves are closed.

5. Turn the “ON-OFF” switch to “ON” and the display on the panel will change from

“DISABLE” to “ENABLE”. The RM7800 display inside the cabinet will read, “Initiate” for

10 seconds. The feed water pump will start automatically if the water volume is low. The

water volume bar graph will not light up.

6. Once the feed water pump has stopped and the display shows “ENABLE”, push the

“COMBUSTION” button. After a pre-purge cycle (for about 10 seconds), combustion

will begin automatically.

7. When desired steam pressure is reached, open the steam outlet valve.

Note: If the water volume is low, or if there is anything wrong with the gas pressure switch and/or overheat protection system, the alarm will sound after pushing the “COMBUSTION” button.

Combustion sequence to full fi re for all boilers is as follows:

1) Pre-purge

2) Pilot gas ignition

3) Pilot fl ame confi rmation

4) Main burner ignition

5) Main burner confi rmation

6) Pilot gas shut-off

7) Low fi re confi rmation

8) High fi re operation if required

4.2.3 BLOW DOWN

4.2.3.1 BOTTOM BLOW DOWN

In the following discussion, “Blow Down” is defi ned as a complete drain and fi ll of the boiler water content.

Partial opening of the blow down isolation valves for a short time during boiler operation does not satisfy the manufacturer’s requirement for boiler blow down.

It is recommended that Blow Down be performed just after daily start-up. This allows boiler water to remain at high pH while the boiler is not in operation to minimize corrosion to the boiler pressure vessel.

CAUTION: During Blow Down:

Be sure that the main steam valve is closed before beginning Blow Down. Do not perform Blow Down with a steam pressure greater than 30 PSIG unless the BLOW DOWN piping was specifi cally designed for a high pressure. Blow Down the boiler upon start-up rather than just after shutdown whenever possible.

This will maintain boiler chemicals and pH in the boiler while it is shut down. DO NOT MANUALLY

BLOW DOWN DURING OPERATION. Manual Blow Down during operation will result in boiler shut down due to low water content.

It is recommended that Blow Down be performed just after daily start-up: a) Close the main steam valve, raise the steam pressure to 20-30 PSIG, and push the “COMBUSTION” button. Wait for the post purge cycle to fi nish and the blower to stop. Then fl ip the “ON-OFF” switch b) Open the Blow Down Valves slowly and begin blow down.

c) Since the frequency of full blow down is dependent upon running hours and water quality in you area, please follow the advice of the water treatment representative.

d) Once blow down is complete (should take only 5 to 15 minutes depending on the blow down piping

arrangements), continue the blow down until the boiler is completely dry. This will ensure all sludge is removed. Complete draining of the Miura boiler is not dangerous to the boiler.

e) When the boiler is completely drained, shut the blow down valves.

f) Open the control cabinet door and locate the water level control fl oatless switches.

g) Turn on the power switch. The feed water pump should start, and all fl oatless switch LED’s should be out, indicating a low water condition.

h) Push the “COMBUSTION” button after the control panel display reads “ENABLE.” The display should bottom three bars on the water volume display bar graph should be out. This indicates that the boiler was i) Wait for the boiler to fi ll to normal levels. During the fi ll process, observe the red LED’s on the Floatless

Switches. The red LED should be out on both switches when the pump starts.

j) The boiler will initiate combustion if boiler pressure is below the control settings. Combustion may not start if connected to the Multiple Installation Controller. If this is the case, place the boiler in

“MANUAL” or “LOCAL” operation by pushing the “AUTO” button on the MT1 located inside the boiler control panel door.

k) When required steam pressure is reached, slowly open the main steam valve.

l) Return the boiler to Automatic Operation on the MT1, if applicable.

4.2.3.2 Automatic Bottom Blow Down (Option)

This is optional equipment, which is only recommended when the boiler feed water has no hardness , and the silica is removed. The water must also be free of any thick sludge and a non-precipitation hardness modifi er is used. Phosphate treatment is not recommended . This can be further discussed with your water treatment supplier of chemicals.

a) The optional automatic BOTTOM BLOW DOWN valve will reduce the manual full BLOW DOWN sequence of the boiler to once every two weeks.

b) The Bottom BLOW DOWN valve automatically opens for 30 seconds based on Blown Time interval as determined by the Set Clock menu of the XJ1. The time is based on equivalent High Fire Hours. The frequency of BLOW DOWN is determined by the quality of the Feed Water. The Feed water quality to be maintained must be less than 0.5 PPM of hardness. In addition, the boiler water quality must be maintained so that the boiler water conductivity is kept below 4000 mhos. The automatic bottom

blow down valve will not open unless the feed water pump if OFF, and water volume is normal.

c) The optional automatic BLOW DOWN valve and piping arrangement must be secured properly, as this line will be under full operating steam pressure.

d) A full manual blow down must be conducted at least once every 2 weeks to prevent sludge build up.

CAUTION: The following shutdown routine must be followed in sequence.

4.2.4 Shutdown a) b) c) d) e) f)

Push the “COMBUSTION” button. Combustion will stop and post-purge will begin.

Once post-purge has fi nished, turn the “ON-OFF” switch to “OFF” position.

Close all water inlet and outlet valves.

Close the fuel valves.

Turn off the main power supply to the boiler.

After prolonged shutdown, follow the correct start-up procedure to restart the boiler.

4.2.5 Cautions During Operation a) Always open the main inlet and outlet valves before running the boiler. b) If there is a misfi re or fl ame failure, locate the cause of the problem (as discussed in Section 5.2, Trouble

Shooting), fi x it, push the reset button on the panel, and re-fi re the boiler. If the same problem persists,

shut the boiler down and call the nearest MIURA representative or distributor.

c) If a circuit breaker tripped, check the setting and reset it. If the circuit breaker trips again, shut down the

boiler. Call an electrician or the nearest MIURA representative or distributor.

d) Proper balance of gas and airfl ow is needed to assure complete combustion and optimum effi ciency.

Contact your nearest MIURA representative or distributor to adjust the air fl ow. MIURA recommends a

combustion test every three months to ensure maximum combustion effi ciency. e) Do not change the setting on the high temperature limits.

f) When unsure of any boiler trouble, shut down the boiler, turn the power off, and contact your nearest

MIURA representative or distributor.

g) If you smell gas, immediately shut down the boiler, turn off all power sources, and contact your

gas company or MIURA representative.

h ) Be careful when you take a sample of water from the boiler. Please be sure to open the valve very slowly.

A boiler water sample cooler is STRONGLY recommended.

i) Do not re-light the pilot or start burner with the combustion chamber full of gas or with a very

hot combustion chamber.

j) In an emergency, push the “COMBUSTION” button and close the GAS VALVE fi rst, then

cut out the main power supply to the boiler.

4.2.6 Extended Shutdown

To prevent internal corrosion during periods of extended showdown (7 days or more), one of the following must be done: a) Raise the boiler water pH level to between 11-12 to reduce corrosion.

b) Drain the water and dry the boiler completely. Add inert gas or deoxidizing agent.

Since the EX is a low water content boiler, keeping the water in the boiler and raising the pH may be preferred.

However, in places where freezing may occur and shutdown may be more than 7 days, use alternative (b) above.

4.2.7 Carry Over

The Miura Boiler is tested and produces steam with less than 0.25% moisture. This steam quality can be adversely affected by several factors.

1. Poor water quality can produce “carry over.” The indications are foaming, priming, and misting.

Energy loss, fouling blockage of components, and corrosion will result. The LX-Series steam boiler

has automatic surface blow down equipment to minimize the concentration of solids during

operation. However, daily manual blow down is necessary. Follow the recommendations of a reputable

water treatment company to limit conductivity.

2. Over steam demand: Exceeding the steam production rating of the boiler can overwhelm the moisture

separator and allow boiler water carry over.

3. Over fi ring. Exceeding design heat input rate would result in steam production exceeding the capacity

of the boiler and result in boiler water carry over. This condition will also shorten the life of the

boiler and could cause tube damage that would not be covered by warranty.

4. Steam demand surges. This is the normal cause of boiler water carry over for all types of boilers. This

situation occurs when there is a sudden demand for steam that can be caused by types of equipment that

use an on-off steam control system. This situation can be illustrated by a steam load that normally

draws 25% boiler capacity and then “steps up” to 100% boiler capacity very quickly. This results

in “fl ashing” of the water in the boiler, as steam pressure drops, and a momentary steam production

rate that is above nominal capacity. This “fl ashing” can carry boiler water with it. This type of

carry over is easily corrected by shutting the steam outlet valve and then opening it 1 ½ turns.

This does not affect the steam production capacity of the boiler. The effect is to restrict the rate of

change of the steam fl ow and will stop carry over caused by “Surging.”

5. Water level control system faults: Such as an open circuit on the water level probes. This is

extremely rare.

4.2.8 Make-Up Water

Following is a typical example of a good operating discipline. This will prevent expensive repairs. Proper water treatment MUST be used from the time the boiler if fi rst operated. Any damage caused by lack of correct treatment is not covered by Warranty.

4.2.9 Make Up Water Maintenance Check

Be sure to perform the following daily: iii) No air in the chemical feed pump or lines i) ii)

Boiler make-up water is completely soft. Use reagents with at least 1ppm sensitivity

Make sure the water softener timer or fl ow meter is working iii) Make sure there is no hardening of the salt. In case of salt hardening, break into small

pieces.

iv) Make sure the by-pass valve is closed, and inlet and outlet valves are open.

4.2.10 Water Specifi cations

The chemistry values given in Table 15 are specifi c guidelines established by MIURA Boiler. Analysis is to be performed by the customer or a Boiler Water Treatment company. Failure to maintain these specifi cations will affect the Boiler Warranty. MIURA Boiler recommends Polymer type treatment. Phosphate type treatment results in soft sludge that is not water-soluble. This results in higher solids and more frequent bottom blow downs.

ITEM

pH (AT 25.)

HARDNESS

OXYGEN

P ALKALINITY

M ALKALINITY

SULFITES

CONDUCTIVITY

(AT 25°C)

CHLORIDE

SILICA

IRON AND

MANGANESE

Table 19 Boiler Water Chemistry Specifi cations

UNITS ppm ppm

µS/cm

Cl- mg/L

Fe & Mn mg/L

BOILER WATER

STANDARD RANGE

11.0 - 11.8

-0.0-

Below 0.5

150 - 600

250 - 800

DETECTABLE

1,500 - 4,000

MAKE UP WATER

STANDARD RANGE

7 - 9

-0.0-

DETECTABLE

BELOW 400

BELOW 250

BELOW 1.0

BELOW 30

TOTAL BELOW 0.5

5 SECTION FIVE - MAINTENANCE

5.1 MAINTENANCE & CLEANING SCHEDULE

In order to maintain the high effi ciency and to prevent costly breakdowns, perform the following maintenance and cleaning at the intervals shown below:

Table 20 Recommended Periodic Maintenance Schedule

3-4

MONTHS

ITEM

CHECK SOFTENER

FULL BLOW DOWN

COMBUSTION

CONDITIONS

DAILY

Visual

Tune up

Analyzer

NEEDED

CHECK POINTS

REMARKS ON

OPERATION

IS WATER SOFT? SCALE PREVENTION

REFER TO BLOW CARRY OVER,

DOWN SECTION SLUDGE, SCALE

CHECK COMBUS- MIS-FIRE AND

TION, SOUND AND ABNORMAL

FLAME COLOR CONDITIONS

LOW WATER CUT-OFF X

REFER TO BLOW OVERHEAT

DOWN SECTION PROTECTION

FAN COVER

CLEAN BURNER

BOILER SOOT BLOW

GAS PRESSURE

INTERNAL INSPECTION

(UPPER AND LOWER

PORT)

WATER CONTROLLER

RODS

FEED WATER TANK

STRAINERS

ELECTRICAL WIRING

PRESSURE GAUGE

DAMPER SETTING BOLTS

PILOT BURNER

DAMPER MOTOR AND

DAMPER LIMIT SWITCH

OIL PUMP MOTOR

OIL

GAS

ANNUAL

CLEAN FAN COVER POOR COMBUSTION

SOOT AND DIRT POOR COMBUSTION

HIGH STACK TEMP. EFFICIENCY

READ GAS PRESSURE POOR COMBUSTION

OVERHEATING, (DIS- WATER

COLORATION) PITTING, TREATMENT

RUST FORMATION, EFFECTIVENESS

SCALE

CLEAN WITH SAND- LOW WATER CUTOUT

PAPER ALARMS

CLEAN INSIDE

MONTHLY CLEAN INSIDE

X LOOSE WIRES

CALIBRATION

BLOCKED PIPING

LOW WATER FLOW

VIBRATION

PROPER OPERATION

FOR TIGHTNESS POOR COMBUSTION

ELECTRODE WEAR & CAUSE OF POOR

CERAMIC CONDITION IGNITION

COUPLING & RUBBER VIBRATION,

INSERT (SPIDER) INTERLOCK ALARMS

MOVEMENT, TIGHTNESS

COUPLING & RUBBER VIBRATION

INSERT (SPIDER) WEAR

Electric motors are pre-lubricated at the factory and do not require additional lubrication at start-up. Motors containing sealed bearings do not require additional lubrication during the fi rst 15,000 hours of operation.

Operating hours on the motor should be measured by the operating hour meter on the Boiler. Motors with grease fi ttings should only be lubricated with lithium-based grease at the time intervals given in Table 21.

Table 21 Motor Service and Lubrication Schedule

TYPE OF SERVICE FREQUENCY OG GREASING

Seasonal (Motor/Boiler is idle for more than 6 months)

Intermittently (normal daily operation of the Boiler)

Continuous

Yearly

Semi-annually

Quarterly

Do not over grease the bearings. Over greasing will cause increased bearing heat and can result in bearing and motor failure.

This is a basic maintenance schedule. If the fuel or water is of exceptionally poor quality, increase the frequency of these checks. Compare the water quality with our standards and adjust the schedule accordingly.

5.2 TROUBLE SHOOTING

5.2.1 Physical Problem and Corrective Action

Table 22 Physical Problems and Corrective Action Chart

PROBLEM ITEM TO CHECK CAUSE REMEDY

1. With main power “on,”

power lamp (inside

ON-OFF switch) is not

lit

2. The feed water pump does

not come on even though

the pre-set water volume

is not reached

1. circuit breaker(s) tripped?

CB1 or CB4

A) Yes Short circuit

B) No Switch is bad or wires are loose

1. Make sure water volume Rod is grounding out

probes are not bent

Locate and correct short, reset circuit breaker

Replace switch or tighten terminal wires

Straighten probe

2. Is probe insulator cracked? Insulation failure Replace

3. Check probe switch Switch is faulty Replace

3. Feed water pump runs,

but water is not fed into

boiler, or amount of water

is insuffi cient.

4. Boiler fl ooding

4. Is feed water pump over- Motor is faulty

load tripped?

1. Is main feed water valve

and feed water stop cock

open?

Replace

Open all feed water valves

completely

2. Is water level correct in feed Tank feed piping blocked Clean the piping

water tank?

3. Has air been bled at feed Air bound pump

water pump?

Bleed air completely

4. Pump motors direction

of rotation

5. Is water strainer plugged?

Reverse wires at feed water

pump

Clean strainer

6. If not 1-5

1. Is insulator or water volume Insulation failure

probe cracked?

Pump capacity is too low Overhaul the pump

Replace

2. Electrical connection at Poor connection

probe

Tighten properly

3. Are probes dirty? Scale, scum, etc., has broken Clean with sandpaper or

the circuit

4. Is fl oatless switch operating? Faulty switch

other abrasive material

Replace switch

Table 22 Physical Problems and Corrective Action Chart (continued)

PROBLEM

5. Even after start button

is pushed, fan motor

doesn’t start

6. Combustion will not start

7. Ignition starts, but fl ame

dies out

8. Excess smoke from stack;

frequent mis-fi re

ITEM TO CHECK CAUSE REMEDY

1. Steam pressure above set None

point

Wait for steam pressure to

lower

2. Is thermal overload tripped? Faulty wires or faulty device Repair or replace

3. High gas pressure limit Faulty switch, wiring, or Replace or tighten wires

switch plugged pipe and clean piping

4. Motor power failure Faulty electric relay or loose Replace relay or tighten

wiring wires

5. Low gas pressure switch Wrong setting or faulty Replace switch or adjust

pressure switch adjust setting

6. Burner control relay or fl ame eye Faulty Replace

7. High-pressure safety switch tripped Push reset lever

1. Is main gas/oil valve open?

2. Damper position Incorrect setting

Determine and correct cause. Most

likely adjust set point.

Open main gas/oil valve

Adjust to proper airfl ow

3. Fan cover

4. Spark rod

Dust build-up Clean

Carbon on spark rods or Clean or replace

porcelain on rod is broken

Loose wire connection Tighten connection

Faulty cord Replace cord

5. Is pilot gas valve open? Do Loose wiring or faulty gas Tighten wire connection

pilot gas solenoids open? regulator/solenoid valve or replace valves

1. Is gas/oil valve open? Open the gas/oil valve

2. Is UV fl ame eye sensing Faulty fl ame eye or loose Tighten wires or replace

the fl ame? wiring UV sensor

3. Is combustion adjusted Loose stop bolts on air damper Adjust combustion with

correctly? Combustion Analyzer

1. Gas/oil pressure Pressure is too high Adjust pressure setting

2. Damper setting is off or Not enough air

retainer is loose

Adjust or replace

damper motor

3. Oil nozzle

4. Air in nozzles

Broken or worn Replace nozzle

Oil dripping from nozzle Replace nozzles or

solenoid valves

Table 22 Physical Problems and Corrective Action Chart (continued)

PROBLEM

9. Steam is escaping from

Safety Valve

10. Popping sound occurs

during high fi re

11. Flame fails when going

from high to low fi re

12. Burner will not change

from low to high fi re

13. Fan motor runs, but

ignition does not occur

ITEM TO CHECK CAUSE REMEDY

1. High limit switch Limit switch is set too high Adjust limit setting or

or broken replace

2. Pipe leading to steam Poor water condition or Clean pipe

pressure switch is plugged freezing at start-up

3. Safety valve Improper setting

1. Low gas/oil pressure Excess air

2. Damper adjustment

1. Damper position Excess air

Replace or have valve re-set

Adjust pressure

Adjust damper

2. Gas/oil pressure

1. Damper position

Insuffi cient fl ow

Insuffi cient air

Adjust pressure

Adjust damper

2. Gas/oil pressure Insuffi cient pressure Adjust pressure

3. High fi re solenoid fuel Insuffi cient fuel fl ow for high Check electrical wiring

valve or two-stage fuel valve fi re or re-set limits

4. Air duct connection Air leakage Tighten or replace connection

5. Hi or low steam pressure Faulty wiring or pressure has Check electrical wiring or

switches reached the limit setting re-set limits

1. Combustion air proving Incorrect setting, broken or Manual re-set, tighten

switch loose wiring terminal contacts or replace

switch

2. Fan rotation

3. Spark rod

4. Flame safeguard

Incorrect wiring

Faulty

Reverse polarity

Replace

5.3 OPERATING DISCIPLINES

DANGER: The following points MUST be followed to avoid damage or injury.

j) k) l) m) n) e) f) g) h) i) a) Always open the main steam outlet valve slowly to prevent carry over or hammering.

b) If a misfi re or fl ame failure occurs, locate the cause of the problem. (See Table 22) After correcting the problem, push the manual reset button on the fl ame safeguard and re-start the boiler. If the problem persists, shut down the boiler or call an authorized

IUR

Service Agency.

c) Whenever fuses need replacing, use only specifi ed ratings. When replacing a circuit breaker, or magnetic contactor, ensure that trip settings are set on the new component.

d) When testing the low water interlock, perform blow down as described earlier to lower the water level in the boiler. If the alarm does not sound when tested, see Trouble Shooting Guide.

Proper balance of gas and airfl ow is needed to insure complete combustion and optimum effi ciency.

Adjust the airfl ow as needed. (see Damper Adjustment in Operation and Maintenance Manual.)

The overheat protection thermostat setting must never be changed without written authorization from

MIURA. Failure to obtain authorization will result in voiding of all warranties. Changing this temperature setting may be required if the customer chooses to raise or lower the boiler operating pressure.

When any boiler problem occurs, shut down at the control panel and turn the main electrical power off.

If there is a gas or oil smell in the boiler room, immediately shut down the boiler and turn off all power.

Shut the main gas and oil valves. Immediately locate and repair the source of the leak.

Be careful when taking a water sample from the boiler and be sure to open the valve slowly. A water sample cooler is strongly recommended.

Do not re-light the pilot, or start the burner when the combustion chamber is fi lled with gas or is very hot.

In an emergency, push the “STOP” button and close the GAS VALVE fi rst, then cut off main electrical power to the boiler.

The economizer (optional) feed water valves should be left open under normal conditions. The by-pass valve should be used only during maintenance.

Do not close the feed water valves to the economizer (if applicable). Only in the event of an economizer problem can the by-pass valve be used.

If frequent Low Water Level alarms occur, clean the fi ve (5) water level probes and the feed water strainer prior to calling for service on the boiler. Over 90% of the Low Water Alarms are caused by dirty probes.

5.4 RECOMMENDED SPARE PARTS LIST

Table 23 Recommended Spare Parts List

NO.

PART NAME

Damper Coupling

Rubber Assembly

Flame Eye

3 Floatless Switch

11* Level Sensor Probe

Indicator Lamp

Pressure Gage

Relay

Magnetic Contactor for Blower

Magnetic Contactor for Water

Pump

Magnetic Contactor for Oil

Pump (GO Series)

Spark Rod Assembly

Feed Pump Seal Repair Kit

DESCRIPTION/PART #

Lovejoy 5/8” x 7/16” L070

CL101100

Honeywell C7035A1031

FL100401

26A1B0-03

SW102700

16B1A0-00-10

SW102800

32R-2911T (red)

LA100100

Trerice No. 800, 0-300 PSIG

3 1/2” diameter

GA100700

LY-2, CSA, 120V

RE100100

Sprecher CA6-85-11-120

CT100200

Sprecher CA7-72-11-120

CT102700

Sprecher CA7-60-10-120

CT102600

Sprecher CA7-30-10-120

CT102300

Sprecher CA7-37-11-120

CT102400

Sprecher CA7-16-10-120

CT102100

Sprecher CA7-12-10-120

CT102000

Sprecher CA7-23-10-120

CT102200

Sprecher CA7-30-10-120

CT102300

Sprecher CA7-16-10-120

CT102100

Sprecher CA7-12-10-120

CT102000

Sprecher CA7-12-10-120

CT102000

I-18

SR100300

Warrick 3H1C

EL3H1C11108 23 1/2”

985167

985201

EX-100

(1) 230V

(1) 208V

(1) 460V

(1) 575V

(1) 208V

(1) 230V

(1) 460V

(1) 575V

EX-200

(1) 208V

(1) 230V

(1) 460V

(1) 575V

(1) 208V

(1) 230V

(1) 460V

(1) 575V

EX-300

(1) 208V

(1) 230V

(1) 208V

(1) 460V

(1) 575V

*This is the longest level sensor probe. This probe may be shortened if necessary to replace probes in the LVC.

The above listed spare parts are not initially included with the boiler.

5.4 RECOMMENDED SPARE PARTS LIST

After the end of the parts warranty, it is not necessary to order replacement parts from MIURA. One of our design advantages is the use of non-proprietary parts. The electrical control components and assorted valves may be purchased from any industrial parts house.

The list below is not all-inclusive and in general is more than required. If the customer does not have a stand-by boiler, is some distance away from the service representative, or simply desires to maintain a more comprehensive selection of spare parts, contact MIURA for a more customized list.

The customer is reminded that standard ground shipment of a Warranty Replacement Part is a MIURA expense.

Express shipping charges will be billed to the customer. In addition, return of the defective part to MIURA must be done at customer expense. If a Warranty Replacement defective part is not returned to MIURA, the customer will be invoiced for the replacement sent. In addition, if the defective part failure is determined to NOT be a manufacturing defect, the customer will be invoiced by MIURA.

MIURA BOILER WEST, INC. (Chicago )

600 Northgate Parkway, Suite M

Wheeling, IL 60090-3201

REPRESENTED BY:

INDUSTRIAL HEATER

8400 Wolf Lake Dr.

Suite 1

Bartlett, TN 38133

Tel (888) 541-4328

Fax (901) 382-4766

The descriptions and specifi cations are approximate.

Specifi cations subject to change to incorporate engineering advances. Manufacturer reserves the right to change specifi cations and dimensions at any time without liability for equipment previously or subsequently sold.

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Key features

Compact design for space-saving installation
Easy installation for quick setup
Low maintenance requirements for reduced downtime
High-efficiency operation for energy savings
Advanced technology for reliable performance
Automatic water level control for safety and efficiency
Built-in safety features for peace of mind
Versatile fuel options for adaptability
Durable construction for long-lasting operation
Economical operation for cost savings

Frequently asked questions

The fuel consumption of the Miura EX-200G varies depending on the specific model and fuel type. Please refer to the product specifications for more information.

The dimensions of the Miura EX-200G vary depending on the specific model. Please refer to the product specifications for more information.

The warranty for the Miura EX-200G varies depending on the specific model and location. Please contact your local Miura representative for more information.