Miura LX Series Installation instructions

1
STEAM BOILER INSPECTION MANUAL
MIURA BOILER Co.,LTD
MIURA MANUFACTURING AMERICA Co.,LTD
Boiler Inspection Manual Number : T519-998-9031 Date of issue : Sep. 15, 2009

2
Table of Contents
Introduction......................................................................................................4
Basic Cautions.................................................................................................5
Inspection Flow Chart......................................................................................9
Bottom Blowdown Method.............................................................................10
1 BOILER VESSEL AND WINDBOX............................................................................. 14
1.1 Condition of Water-tube (Fire Side).................................................................. 15
1.2 Condition of Castable ........................................................................................ 16
1.3 Condition of Windbox Insulation Material........................................................ 17
1.4 Condition of Air Diffuser (EX Type Only) ......................................................... 18
1.5 Tightening the Windbox..................................................................................... 19
1.6 Inspection for Gas Leakage............................................................................... 20
1.7 Leakage from Joints (Water, Steam)................................................................. 22
1.8 Leakage of Exhaust Gas.................................................................................... 23
1.9 Inspecting the Safety Valve............................................................................... 24
2 BLOWER..................................................................................................................... 25
2.1 Condition of Air Filter......................................................................................... 26
2.2 Damper Operation.............................................................................................. 27
3 BURNER ..................................................................................................................... 29
3.1 Inspecting the Ignition Spark Cable.................................................................. 30
3.2 Inspecting the UV Sensor.................................................................................. 31
3.3 Inspecting the Pilot Burner................................................................................ 33
3.4 Inspecting the Main Burner ............................................................................... 35
4 FEED WATER............................................................................................................. 36
4.1 Cleaning the Feed-water Strainer...................................................................... 37
4.2 Cleaning the Surface-blowdown Strainer......................................................... 38
4.3 Inspecting the Electrode.................................................................................... 39
4.4 Leakage Test for the Feed-water Pump............................................................ 40
4.5 Checking Surface Blowdown Operation (Short-circuit Test).......................... 41
4.6 Checking for Check Valve Counterflow............................................................ 42
5 CONTROL................................................................................................................... 44
5.1 Checking the Steam-Pressure Switch Operation ............................................ 45
5.2 Checking Gas Pressure Switch and Airflow Switch Operations.................... 46

3
5.3 Checking Feed-water Control Operation (Liquid Volume Control) ................ 47
5.4 Checking Safety Operations During Misfiring ................................................. 50
6 WATER ....................................................................................................................... 51
6.1 Collecting Boiler Water...................................................................................... 52
6.2 Measuring pH and Conductivity........................................................................ 53
7 MEASUREMENTS...................................................................................................... 54
7.1 Inspection for Boiler Interior ............................................................................. 55
7.2 Combustion Adjustment Procedure ................................................................. 58
7.3 Pilot Adjustment................................................................................................. 59
7.4 External Adjustment of the Pilot Burner .......................................................... 62
7.5 Main Burner Adjustment.................................................................................... 64
7.6 Adjustment of O2% and CO% in Exhaust Gas ................................................. 66
7.7 Measuring the Furnace Pressure...................................................................... 69
7.8 Inspection in Monitor Mode............................................................................... 70
7.9 Checking Smoke from Chimney........................................................................ 73
7.10 Measuring the Feed-water Pump Capacity .................................................... 74
7.11 Measuring the Supply Voltage ........................................................................ 75
7.12 Measuring the Motor Current .......................................................................... 76
8 OIL-FIRED BOILER.................................................................................................... 77
8.1 Checking Soot Deposits on the Water Pipes (Oil-fired Boiler Only).............. 78
8.2 Inspecting the Economizer (Oil-fired Boiler Only)........................................... 79
8.3 Removing the Burner (Oil-fired Boiler Only).................................................... 80
8.4 Inspecting the Burner (Oil-fired Boiler Only) ................................................... 81
8.5 Check Leakage from the Solenoid Valves (Oil-fired Boiler Only)................... 84
8.6 Testing the Ignition Transformer Capacity (EX-100 only)............................... 85
8.7 Cleaning the Oil Strainer.................................................................................... 87
8.8 Cleaning the Oil-Pump Filter ............................................................................. 88

4
Introduction
Periodic boiler inspection shall be conducted to maintain safe and optimal operating conditions. This is the
most essential aspect of boiler maintenance. The inspector shall be experienced in the all operating
procedures and evaluation criteria. The inspector shall fulfill the true purpose of the inspection, without
omissions or errors. This manual is intended to integrate the operating procedures and evaluation criteria for
the main inspection items.
Boilers subject to inspection: the popular XJ1-specific microcomputer and BL boilers. The contents apply
to any model. This manual should be used in conjunction with the operator’s
manual to learn the inspection procedures.
The items relating to microcomputer specifications are limited to indications in the operator’s manual. Refer
to the specifications of respective boilers for details of evaluation criteria for the microcomputer.
Flow Sheet
SOFTENER
The feed water is normally hard
water. This is a device that softens
the hard water.
FEED-WATER TANK OR
DEAERATOR
Soft-water tank or deaerator
COLORMETRY
(HARD-WATER ALARM)
This is a device that monitors the soft
water treated by the water softener.
Remote alarm indication is available.
CHEMICAL PUMP
This is a device that feeds chemicals
to the feed-water tank or deaerator in
order to prevent boiler corrosion.
STEAM BOILER
The burner heats the treated water
which is fed into the water tube. The
heated boiler water evaporates
continuously and becomes steam,
which is supplied to the load side.
VENT CONDENSATE
RETURN STEAM
SOFTENER
COLORMETRY
(HARD-WATER ALARM) CHEMICAL PUMP FEED-WATER PUMP
ECONOMIZER
STEAM BOILER
FEED-WATER TANK
OR DEAERATOR

5
Basic Cautions
I. Wear appropriate clothing and protective gear.
1) Do not wear bulky clothing or accessories that may
be caught by the valves or mechanical parts during
maintenance.
2) Do not wear clothing that contains flammable oil.
3) A clean working cloth makes a good impression and
helps prevent accidents.
4) Be sure to wear safety gear, including a hard hat,
safety shoes and gloves that are appropriate for the
nature of the work.
5) When handling chemicals (such as when repairing a
chemical feeder), be sure to wear protective glasses
and rubber gloves, etc.
II. Make sure you know the dangers inherent with a boiler before you work on it.
1) Inappropriate operation on the boiler may result in
death or serious injury. Be aware of high-
temperature and high-voltage areas, and explain the
risks to the user in order to prevent accidents.
Examples of Hazard
•Danger of burns
•Danger of breakage
•Disassembly prohibited
•Danger of electric shock
•Proper operation
•Inspection of safety valve
•Beware of rotating parts
WARNING
CAUTION

6
III. Check the boiler installation conditions
Boiler room
1) Ensure that a ventilation fan and vent are providing
adequate air supply to and outlet for the boiler
exhaust.
Failure to provide adequate ventilation may cause
incomplete combustion and carbon monoxide
poisoning.
Boiler main unit
1) Ensure that the unit is properly secured with anchor
bolts at four locations.
Failure to secure the unit may allow the unit to tip
over or cause other accident.
2) Ensure that the unit is mounted on non-combustible
flooring material.
A floor made of wood or other combustible materials
may cause fire easily.
3) Ensure that flammable hazardous materials (i.e.
kerosene, gasoline) are not used in the boiler room.
4) Ensure that the boiler is located at the minimum
distance away from combustible materials according
to local code. As a rule, one shall instruct the user
not to place any combustible materials near the
boiler.
Fuel piping
1) Ensure that there is no leakage of fuel from the fuel
pipes.
2) Recommend that a gas-leakage alarm be installed
for LPG-fired boilers. As LPG is heavier than air, it
can accumulate on the floor and cause a gas
explosion.
The installation of an alarm is also recommended
for other types of gas.
Ventilation fan Air supply and
exhaust opening
Anchor bolt
Combustible material
Minimum distance
required by local
code
Combustibles
Gas-leakage alarm
Approx. 10"

7
Safety-valve outlet
1) Ensure that the end of the outlet pipe is directed
to a safe area for steam discharge.
If the end directs a walkway or other equipment,
blowing steam may cause injury or damage to
the equipment.
2) Ensure that the pipe is properly secured during a
discharge.
Failure to secure the unit properly may allow the
pipe to move in reaction to a blowout, resulting in
bodily injury or damage to surrounding equipment.
Steam pipe
1) Reliable heat-insulation must be provided where
the steam pipe passes through a combustible
wall, etc. Failure to provide sufficient heat-
insulation may result in a fire.
Blowdown pipe
1) Physically touch the blowpipe to check that it is
properly secured.
Failure to secure the unit properly may allow the
pipe to move in reaction to a blowout, resulting in
bodily injury or damage to surrounding equipment.
2) Before draining the blowdown water, allow it to
cool to the temperature specified by local code.
Check the condition of the blowdown tank or
blowdown separator.
Check that the end of the blowout pipe opens into
a pit or other safe area.
DRAIN
SAFETY
RELIEF
VALVE
VENT-PIPE
SUPPORT
SLIP ONTO THE
DRIP PAN
ELBOW
DRIP PAN
ELBOW
UNION
UNION/FLANGE
OUTDOORS
Heat insulation
Wall
Pit
Blowdown pipe

8
Electrical work
Failure to follow the warning signals for electrical work
may result in a short circuit, electrical shock, or fire.
1) Ensure the power source for the boiler has a
dedicated circuit breaker.
2) Ensure the power wire diameter and breaker
capacity meet the specifications.
3) Ensure the grounding wire is connected to the
grounding terminal inside the boiler control box.
Exhaust tube
1) Ensure the materials are non-combustible where the
exhaust tube passes through.
Use of combustible materials may result in a fire.
2) Ensure that there are no combustible materials
around the end of the exhaust tube. Use of
combustible materials may result in a fire.
3) Ensure the hole is sealed and secured where the
exhaust tube passes through.
Inadequate sealing may result in carbon monoxide
poisoning due to the leakage of exhaust gas.
The precautions mentioned above are basic precautions.
Be aware of all relevant factors in the field. Moreover,
consent to all local codes.
Ground
Grounding
terminal
6" all round Exhaust tube
Non-combustible
materials
3 ft.
3 ft.
or more
2 ft.
or more

9
Inspection Flow Chart
Clean the
oil-pump filter
Clean tip of
burner nozzle
Cracking of
ignition insulator
Check nozzle
tip standard
Adjust burner
nozzle dimensions
Check set value of
chemical feeder dial
Check chemical
and salt amounts
Clean boiler area
Prepare inspection
report
User questions and
training
End
Dial set value
Clean inlet-port
filter
Chemicals
1
3
B
C
C
A to E
dimensions
For regenerating water
softener operation
*
*
* * Only for OIL-FIRED BOILER
YES
NO
NO
OK
OK
OK
P.89
P.82
P.30
P.82
P.73
P.52
P.85
P.53
P.19
P.40
P.79
P.38
P.27
P.58
P.52
P.45
P.39
P.42
P.74
P.36
P.42, 53
P.15
P.30
P.31
P.50
P.20
P.24
P.18
P.17
P.16
P.26
P.25
P.54
P.74
P.72
Replace
YES
Clean after
disassembly and
replacement
NO
OK Check and
replace
Check non-ignition
operation
Check abnormal
quenching operation
Check gas-leakage
condition
Check safety
valve
Install burner
nozzle
Tighten windbox
bolt
Clean chimney
elbow
Condition of dust
on economizer
Run boiler
Check damper
operation
Check for abnormal
noise in blower
Regulate burning
Check operation of
TDS controller
Check operation of
steam pressure
switch
Check for leakage
from electrode
Check for leakage
of check valve
Measure capacity
of feed-water pump
Check safety
starting operation
Check UV
sensor
voltage
Timing until
Alarm
Check Hi limit
TC and scale
monitor TC
Pre-purge
Post-purge
Su
pp
l
y
volta
g
e
Gas differential
pressure, oil
pressure, CO2,
smoke, furnace,
pressure,
exhaust
temperature
Ignition
frequency
Burn timer
Temperature of
feed water
Ignition trial
timing
Safety-switch
timing
Safety-switch
timing
Soft-water
check
Check discharge
condition of
chemical feeder
Ignition-transformer
spark test
Clean ejector after
disassembly
Check operational
condition of salt-
water valve
Check regeneration
operation (manual)
2
2
Leakage from the
shutoff valves

10
Bottom Blowdown Method
Difference between Complete Bottom Blowdown and Partial Blowdown
Two methods are available for removing boiler sludge. To properly evaluate which method to use, the
operator needs to consider a number of factors, including water quality, potential increase or decrease in pH,
timing of blowdown, hours of operation, and operating requirements. After conducting a complete bottom
blowdown, the pH and conductivity inside the boiler become the same as the feed water. This low pH and
low conductivity situation can cause corrosion. Therefore, a complete bottom blowdown should be conducted
only before running the boiler.
Complete Bottom Blowdown
Timing of blowdown
Conduct this process when the “B-BLOW Required” lamp on the control panel lights. The XJ1 calculates this
caution according to the equivalent high-fire operation hours. The timing setting can be changed under
“Setting data” on the XJ1.