Miura EX Series Installation and operation manual

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EX BOILER START UP MANUAL
MIURA CANADA Co.,LTD
MIURA MANUFACTURING AMERICA Co.,LTD
Boiler Start up Manual Number : T539-998-9022 Date of issue : Mar. 20, 2013

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1 REQUIRED TOOLS & MEASURING DEVICES

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1.1 Tools
A set of standard tools
1.2 Measuring Devices
Manometer (for measurement of orifice differential pressure and combustion-chamber pressure)
Multimeter (with temperature measurement functionality)
O
2meter
Smoke tester
CO meter and detecting tube
Megaohmmeter (Insulation Tester or Meggar)
Clamp tester
Tester (capable of measuring voltage, current, and resistance)
Flame simulator
Inspection lamp
Plastic tubing (for measurement of orifice differential pressure and gas-leak checks)
Soapy solution (for gas-leak checks)
Gas leak detector
NOx meter (if required)
Fiber scope (if required)

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2 TRIAL OPERATION PROCEDURE

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2.1 Boiler Installation Inspection
1) Confirm that feed water piping is suitable for your application.
You must be able to easily bleed air from the piping and you must be able to drain water from the
boiler in order to prevent freezing.
The diameter of the piping must be sufficiently large to ensure cavitation does not occur.
2) Confirm that gas piping is suitable for your application.
3) Confirm that blowdown piping is suitable for your application.
Make sure blowdown piping drains horizontally or downward without elevation of the piping to avoid
water buildup.
In addition, blowdown piping must be securely fixed in place.
4) Confirm that water softeners, chemical feeders, drain recovery devices are installed and connected in
a suitable manner for your application.
5) Confirm that the boiler unit has been installed correctly.
6) Confirm that the exhaust system (flue configuration) is suitable for your application.
Confirm that the chimney passing through the wall is properly sealed to prevent rain leakage, and that
the section of the wall is made of non-inflammable material.
Confirm that no combustible materials are present near chimney stacks.
7) Confirm that safety valve piping is suitable for your application.
Confirm that the safety valve can be easily replaced. Make sure the entire piping connecting to the
safety valve has the same diameter or more as the safety valve outlet.
8) Confirm that steam piping does not come into direct contact with combustible materials.
2.2 Inspection of Accessories
1) Water softening equipment
1. Confirm that water softening equipment has been installed and connected correctly. (Examine
piping, power supply, capability for 24-hour operation, etc.)
2. Confirm that the pressure of water is as required by the softner specification.
3. Confirm that all regenerative system is operating normally.
4. Confirm that salt-water suction is proceeding normally.
5. Confirm that the equipment is providing soft water as required.
2) Chemical feeders
1. Confirm that chemical feeders have been installed and connected correctly.
2. Confirm that chemicals are being added in the correct volume.
3. Bleed air from chemical feed pumps.
3) Drain recovery devices
1. Confirm that drain recovery devices have been installed and connected correctly.
2. Confirm that piping has been installed and connected correctly.
3. Confirm that overflow piping, ventilation piping, and other piping have been provided as required.
4. Oil, grease, and other substances can enter the drain upon installation of new drain piping. For
this reason, it is preferable that discharge be continued with the drain bypassed until no
contamination remains in the system.

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2.3 Inspecting the Boiler Unit
1) Inspecting the interior of the boiler shell
Open the upper and lower inspection holes and visually inspect the inside of the boiler shell (for corrosion,
pitting, and the like) using an inspection lamp and a work light.
2) Inspecting the interior of the combustion chamber
Remove the burner assembly and inspect the inside of the combustion chamber using an inspection lamp
and a work light.
Examine the lower castable section for cracking and take the appropriate action if identified.
Ensure that the wind-box heat insulator has not shifted or become detached.
3) Inspecting the exterior
Examine the casing and other exterior parts for scratching or indentation.
If any damage is confirmed, carry out the required painting or repair work.
4) Inspecting wind-box bolts
Wind-box bolts must always be tightened.
Tighten in a diagonal fashion in order to avoid incomplete or non-uniform tightening.
INSPECTION LAMP
WATER TUBE
DETACHMENT
DETACHMENT
ENLARGED VIEW
WORK LIGHT
Wrench
Wind box
Boiler unit
UPPER HEADER
TOP, CENTER, AND BOTTOM OF
WATER TUBE
LOWER HEADER

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5) Inspecting the safety valve
Confirm that the safety valve’s steam discharge outlet is directed toward a safe area for discharge.
Take the appropriate action if this is not the case.
6) Inspecting the feed water system
1. Disassemble and clean the Y-type strainer’s filter.
2. Inspect the probes in boiler.
(Water level control probes (L, M, S), low/high water cutoff probe (D))
Inspect the electrode’s insulation and ensure that it is free of scratch and cracking.
Ensure that wirings are securely fastened. In addition, confirm there is no peeling or dislocation of
the wiring.
Ensure that the full complement of the electrode has been assembled.
Ensure that connector end is free of insulation problems and wire breakage. Use a tester to check
continuity and a megaohmmeter to perform an insulation test.
Confirm that the water-level detection rods are straight and oriented vertically.
Tester
* Must be 1 or less.
* Must be 0.1 Mor more.
Megaohmmeter
Measure after wetting.
(red) (white) (blue)

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“SELECT” switch“DATA” switch
Operation switch
2.4 Preparing for Operation
1) Power supply lines
1. Confirm that power supply lines for each terminal strip (i.e., within the control panel, motor
terminal box, etc.) are securely fastened by manually pulling each terminal line. Tighten if any
looseness is confirmed.
2. Measure the inter-terminal and ground-to-terminal voltages within the main power breaker.
3. After confirming that the boiler switch is in the off position, turn on the power supply.
4. If the motor rotates in reverse, switch any two of the three phases on the power side.
2) Fuel lines (oil-pump air bleed)
1. Confirm that the oil tank contains oil.
2. Open the oil-tank valve and allow oil to pass as
far as the oil strainer.
3. Loosen the oil strainer’s air-bleed screw and
bleed air from the piping.
4. Place the tip of the plastic hose attached to the
oil pump’s oil and air bleed port inside a
container.
5. Open the oil pump’s oil and air bleed port.
6. Press the “DATA” switch and select “INI SET
MODE.” Next, press and hold this switch (for at
least two seconds).
7. Press the “DATA” switch and select “AIR
REMOVAL OIL PIPING”. Use the “SELECT”
switch to set “START”.
8. In this condition, the pump can be started by
setting the operation switch to “ON”.
9. Operate the oil pump and discharge any air from
the system.
10. When air bleeding has been completed, close the
air-bleed port.
11. Set the operation switch to “OFF” in order to stop
the oil pump, and to cancel air and oil bleed
operation. Press and hold the “DATA” switch to
return to the normal monitor display.
Tester
Tester
INI SET MODE
PRESS&HOLD“DATA”
AIR REMOVAL
OIL PIPING STOP
AIR REMOVAL
OIL PIPING START

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3) Bleeding air from the feed water system
1. Fill the feed water tank with water.
2. Open the feed-water supply valve and bleed air completely from the air-bleed ports located on
the top of the pump. Use the following method if air cannot easily be bled from the system.
Open the feed-water valve, located downstream of the pump, slightly from the fully closed
position, and also open the air-bleed port. As air bleeds from the system, the discharge
pressure increases gradually.
When the discharged water from the air-bleed ports does not contain bubbles, this indicates the
bleeding of air has been completed.
3. Fully open the boiler’s feed-water valve.
4. Run the feed water pump and confirm that its direction of rotation is correct.
Note that even if the multi-stage centrifugal pump is rotating in the opposite direction, water will
be discharged at approximately half the normal level. Accordingly, any attempt to determine the
direction of rotation by simply confirming whether or not water is being discharged could result
in an erroneous judgement.
If the feed water pump is confirmed to be rotating in the opposite direction, switch the power
supplies (R-phase and T-phase).

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4) Checking for gas leaks
i) Leaks from piping
Inspect the connection points of all piping to confirm there is no leakage.
1. Close the main gas valve and the pilot gas valve.
2. Open the gas supply valve, apply gas pressure, and after taking a reading from the gas
pressure gage, close the gas supply valve. Allow the system to stand for at least five minutes,
and then confirm whether the pressure-gage reading has dropped.
3. If the reading has dropped, inspect the section leading to the main gas valve for leaks.
(Use a soapy solution or a gas leak detector for this purpose.)
ii) Leaks from valves
With shutoff valves and solenoid valves closed off, inspect for valve leakage due to physical damage, the
adherence of foreign material, etc.
Checking for Gas Leaks by Observing Pressure Drops
1) Stop the boiler.
2) Close the manual main gas valve and the manual pilot gas valve.
3) Remove the plug from between the shutoff valves.
4) Open the manual main gas valve and apply pressure to the shutoff valves. *: A significant volume of
gas may leak at this time, and extra caution is required.
5) Close the manual main gas valve and simultaneously start a stopwatch. Monitor the pressure
displayed by the gas pressure gage.
6) Determine the degree to which the gas pressure drops over a period of five minutes.
7) If five minutes is not sufficient to reach a definitive judgement, extend the measurement period
accordingly.

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Checking for Gas Leaks Using a Measuring Cylinder
1) Close the manual main gas valve and the manual pilot gas valve.
2) Remove the plug from between the shutoff valves and install an inspection nipple. (See the previous
page for the pressure inspection point.)
3) Connect a plastic hose to the inspection nipple, and as shown in the figure below, place the other end
of the hose under a graduated cylinder that has been filled with water in a bucket or container.
4) Open the gas supply valve and hold the tip of the hose approximately 0.39 inch below the surface of
the water. Over a period of one minute, measure the volume of gas that collects in the graduated
cylinder or count the number of bubbles that emerge from the hose.
In situations where a direct reading cannot be taken using a measuring cylinder, the volume of gas can be
calculated as follows based on the number of bubbles that emerge. With the tip of the hose placed
approximately 0.39 inch below the water surface as shown above;
the volume of one bubble is 0.30 ml for a bore diameter of 0.39 inch, or
0.22 ml for a bore diameter of 0.24 inch.
Any valve that leaks must be either repaired or replaced.
With the measurement method described above, the volume of gas corresponding to the maximum amount
of bubbles that can be visually counted is approximately 40 ml per minute. If the flow of gas is such that the
number of bubbles cannot be visually counted, the valve in question must be replaced immediately.
Gas
Gas supply valve
(open)
shutoff valve (primary side)
(closed) (closed)
(closed)
Main gas valve
Plastic hose
No leakage
Approximately 0.39 inch
Bucket or container
Water

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3 ADJUSTMENT

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Condition display lamp
Display
“DATA” switch
Operation switch
“SELECT” switch
Precautions
If multiple installation control (MI Control) is to be carried out, set the boilers to manual combustion-
adjustment mode and optimize boiler combustion conditions.
Note)
1. Boilers that have been set to manual combustion-adjustment mode will be controlled at the
corresponding steam pressure settings. Care should therefore be taken with regard to changes in
steam pressure.
2. When combustion adjustment has been completed, return the boilers from “MANUAL” (manual
adjustment mode) to “AUTO” (automatic adjustment mode). Any boiler that is in “MANUAL” will not be
included in MI-control.
If performing MI-control using MP1 and MT1;
1. Set the boilers’ “OPERATION” switches to “ON”, press the “AUTO” button on the MT1, and
confirm that the “AUTO” lamp turns off.
Note) The “AUTO” lamp is ON for automatic MI System control and OFF for manual control.
3.1 Maintenance Display Mode
In order to adjust combustion, it is necessary to switch to Maintenance mode.
Maintenance display mode
In order to adjust combustion, it is necessary to set “MAINTENANCE
MODE” to “YES”.
1. Set “SW1” to “ON”.
2. Press the “DATA” switch and set to “MAINTENANCE
MODE”.
3. Turn the rotary switch and select “YES”.
4. Set “SW1” to “OFF” (to confirm the new setting).
Note) During a setup session as described above,
M
will flash on the display and the beeping alarm
will sound.
3.2 Setting Procedure in Combustion-Adjustment Mode
Setting procedure for combustion-adjustment mode
Use the following procedure to setup or cancel forced
pilot fire, forced low fire, and forced pre-purge.
1. Set “MAINTENANCE MODE” to “YES”.
2. In “BURNER ADJUST”, turn the rotary
switch and make the following settings.
Pre-purge hold : PREPURGE
Pilot hold : PILOT
Low fire hold : LOW
FIRE
Normal control : AUTO
3. Press and hold the “DATA”
switch to confirm these
settings.

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3.3 BL11 Controller Setting Procedure
Normal Display: “SW1” set to “OFF”
Condition monitor: Basic screen
Steam Pressure
Exhaust Gas Temperature
Feed Water Temperature
Scale Monitor Temperature
Overheat Thermostat Temperature
···
Ignition cycles
Combustion time
Average exhaust gas temperature
Average feed water temperature
Boiler efficiency
···
SELECT
STEAM SET (L)
100PSI
Setting the
steam pressure
To next item
To condition monitor
Press and hold
DATA
DATA
NO FLAME
COMBUSTION STAGE
NO FUEL OR UV
SENSOR ERROR
To the previous
warning
To condition monitor
Cause
Press and hold
Combustion
stage setting
Confirm
To condition monitor Asterisk (*) displayed when
“MAINTENANCE MODE” set to “YES”.
Heat management
Switching of user operation mode
Switching of warning display mode
* Switching of combustion adjustment mode
SELECT
DATA
HIGH FIRE
STEAM 70PSI
HIGH FIRE
IGN CYCLE 10
DATA
DATA
SELECT
DATA DATA
DATA
DATA
Press and hold
SELECT
DATA
* Data
DATA
BURNER AJUST
PRESS&HOLD “DATA”
SELECT
Press and hold
DATA
Press and hold
DATA
Press and hold
HI FIRE
BURNER ALARM 5
INI SET MODE
PRESS&HOLD “DATA”
FAULT HISTORY
PRESS&HOLD “DATA”
BURNER STAGE
AUTO

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Maintenance Setting Screen: “SW1” set to “ON”
To next item
NO
YES
Select “YES” for combustion adjustment
A beeping alarm will sound when “YES”
is selected, and “M” will be displayed on-
screen.
Setting the date
BURNER CONTORL
GAS
GAS/OIL
GAS
OIL (PILOT)
OIL (DIRECT)
B/DOWN SCHEDULE
10Hr
To maintenance mode
Press and hold
DATA SELECT
Change date
DATA SELECT
MAINTENANCE MODE
NO
CHANGE DATA DATE
04/01/07
Specification setting
DATA
SELECT
SPEC SET MODE
PRESS&HOLD “DATA”
Model data setting
DATA
DATA1 SET MODE
PRESS&HOLD “DATA”
Heat management data setting
DATA DATA
SELECT
DATA DATA
Press and hold
To next item
To maintenance mode
Press and hold
DATA
Press and hold
DATA
Setting
SELECT
DATA DATA
To next item
To maintenance mode
Press and hold
DATA
DATA2 SET MODE
PRESS&HOLD “DATA”
MEAS START TIME
0Hr
Press and hold
DATA
Maintenance mode
Setting

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3.4 Adjustment Flowchart
* Adjustment Flowchart: Oil-fired combustion adjustment is to be carried out after the completion of gas-
fired combustion adjustment.
Gas-fired Combustion Adjustment
PILOT AIR
PILOT GAS PROVISIONAL DIFFERENTIAL
PRESSURE SETTING
FLOW-RATE ADJUSTMENT
FOR LOW-FIRE GAS
PROVISIONAL AIRFLOW SETTING
TRANSITION TO LOW FIRE
LOW-FIRE (AIRFLOW)
ADJUSTMENT
YES
NO
Low-fire hold
Pilot hold
HIGH-FIRE (AIRFLOW)
ADJUSTMENT
NO
YES
NO
YES
CO MEASUREMENT
CO<100ppm
NO
YES
NO
YES
NO
YES
NO
YES
NO MISFIRE
FLAME CURRENT
MEASUREMENT
RATED VAL
U
E
O2MEASUREMENT
WITHIN RATED RANGE
FLOW-RATE ADJUSTMENT FOR HIGH-FIRE GAS
CO MEASUREMENT
CO<100ppm
O2MEASUREMENT
WITHIN RATED RANGE
IGNITION
PILOT AIR
PILOT GAS DIFFERENTIAL PRESSURE SETTING

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Oil-fired Combustion Adjustment
“OPERATION” SWITCH: OFF
FUEL SELECTOR SWITCH: OIL-FIRED
IGNITION
TRANSITION TO HIGH FIRE
OIL PRESSURE ADJUSTMENT
TRANSITION TO LOW FIRE
Low-fire hold
Automatic
O2MEASUREMENT
WITHIN RATED
RANGE
SMOKE LEVEL
MEASUREMENT
WITHIN RATED
END
O2MEASUREMENT
WITHIN RATED
RANGE
SMOKE LEVEL
MEASUREMENT
WITHIN RATED
NO
YES
NO
YES
NO
YES
NO
YES
YES
NO
NO MISFIRE

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3.5 Gas Flow-Rate Adjustment Method
As the boiler is tested at the factory prior to shipment, no significant adjustment is required in terms of
combustion. However, the basic procedure for adjustment of the combustion is as follows.
1. Move the combustion switch to “ON” and set the boiler to high fire operation.
2. Check the gas regulator pressure (for high fire).
* The gas regulator pressure will vary slightly as a result of changes in combustion-chamber
pressures, exhaust-gas O2settings, etc.
* During low fire operation, the regulator pressure varies in response to the gas supply pressure.
3. Adjustment of gas flow rate using differential pressure (for high fire)
The gas flow volume can be adjusted by referring to the differential pressure between the regulator
pressure and the manifold pressure. If the gas differential pressure is not at the rated level, adjust the
regulator to the rated level. The gas differential pressures in the list of combustion adjustment values
represent rough targets. During commissioning, therefore, adjust to the pre-shipment values indicated
on the factory shop test data sheet.
In situations where the gas flow rate can be measured using a gas flow meter, a measurement should
be taken after adjusting the differential pressure. If the measured gas flow rate differs from the rated
flow rate, calculate the gas differential pressure using the following formula for readjustment.
2
g
g
gg Q
'Q
P'P 








Pg' : Gas differential pressure for rated flow rate (in WC inches)
Pg : Gas differential pressure upon measurement of gas flow rate (in WC inches)
Qg' : Rated gas flow rate (SCFH)
Qg : Measured gas flow rate (SCFH)
After adjustment of the gas flow rate, confirm that the exhaust-gas O2level is within the rated range.

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Regulator adjustment method
Adjust the regulator to correct any significant deviation of the gas regulator pressure and orifice
differential pressure from the corresponding entries in the list of adjustment values.
4. Measurement of gas flow rate during low fire operation
After adjusting the gas flow rate and exhaust-gas O2level during high fire operation, switch to low fire
operation, adjust the exhaust-gas O2level to within the rated range*, and measure the gas differential
pressure in the same way as described in (3) above. (*: As differences in gas supply pressure cause
the gas flow rate for low-fire operation to vary, the level of exhaust-gas O2may have deviated from
that following factory adjustment.) If a gas flow meter has been installed, the gas flow rate should also
be measured.
Increase gas flow

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3.6 Gas Flow Rates
1. Standard-condition conversion for gas flow rates
14.7
(PSI)pressureGas14.7
F)(etemperaturGas459.7
519.7
(CFH)readingrate-Flow(SCFH)rateflowcondition-Standard  


3.7 Adjustment Standards for Gas Flow Rates
The adjustment of flow rates should be carried out in accordance with the following priority sequence.
1. Adjustment using a gas flow meter
If gas flow rates can be measured on an individual boiler basis, use a gas flow meter to confirm the
current flow rate.
Be sure to always convert to standard condition.
2. Adjustment using the factory shop test sheet
When correction is required in accordance with the supplied gas type, refer to “Correction of factory
adjustment values” in order to do so.