Reimers SR SRH and SRHC­20­120 Steam Boiler Instruction Manual

Reimers SR SRH and SRHC­20­120 Steam Boiler

Applications

• Process Steam
• Autoclaves/Sterilizers
• Air Humidification
• Dry Cleaning
• Food Service(*)
• Laboratories

Features

• Miniature boiler max. vessel volume 5ft3
• Maximum safety valve setting 100psi
• All boilers are manufactured in accordance with the requirements of the A.S.M.E. Boiler and Pressure Vessel Code and A.S.M.E. CSD‐1. Each boiler bears the National Board Stamp “M”.
• Dry pure saturated steam, operating pressure range 0 – 85psig
• Heavy-duty 304 or 316 stainless steel pressure vessel. Vessel jacket and electrical enclosure 304 stainless steel
• Large selection of optional equipment.

Standard Equipment of Each Boiler Includes

• A.S.M.E. pressure relief valve
• One (1) slow opening boiler boom blowoff valve as per A.S.M.E. Code B31.1
• Stainless steel steam outlet ball valve
• High-pressure feed pump in SRH‐ and SRHC models
• Low water cutoff control with manual reset
• One (1) high-pressure cutoff control with manual reset
• One (1) operating pressure control for all models equipped with two heating elements or two (2) staged operating pressure controls for all models equipped with three or four heating elements
• Magnetic contactors
• Internal branch circuit fusing
• Enable/Disable the switch for each heating element
• Main supply power distribution block
• Indicator lights for POWER, REFILLING, HEATING, ALARMS, and Automatic Boiler Blowoff Status
• Pressure and water level gauge.

DIRECT STEAM APPLICATIONS TO FOOD PRODUCTS: Reimers offers stainless steel boilers or #OPT1032 Steam Filter option (see Page 5). This alone does not guarantee the production of culinary-grade steam. Applicable safety standards (i.e. 3‐A T609) must be considered.

DEIONIZED WATER

• ASME (PEB 5.3) requires that; boilers constructed of austenitic stainless steel be operated on deionized water only, having a minimum specific resistivity of 1 megohm/cm.

Model Number Key

1. Each boiler model requires two (2) power supplies: Primary healing power and secondary control voltage. The nominal control voltage is 120V, 50/60Hz. Boiler models rated for 380V and 415V are equipped with control voltage transformers that require 220/240V applied to their primary side in order to provide the 120V AC control voltage to the] boiler. As an opon, all boiler models can be equipped with control voltage transformers so that only the heang power supply needs to be connected to the boiler.
2. Also available in 240V 1PH
3. On boiler equipped with condensate tank, add 90lbs (41.0kg) to shipping weight
4. The STEAM CAPACITY listed above is based on the evaporation rate from and at 212°F, at 0 psig. If the boiler feed water temperature is 50°F, then the STEAM CAPACITY for each model listed above is approximately 15% lower.

Please note that all information provided within this brochure is approximate and subject to change without notice. Please contact Reimers Electra Steam, Inc. with any questions regarding the specifications or dimensions detailed within.

Read this manual before installing and using this product. Failure to do so can result in serious injury or death

You have just purchased a quality steam boiler designed to the ASME Boiler Code and registered with the National Board of Boiler Inspectors. Treat this industrial equipment with care and respect. It is safe when installed, maintained, and used properly. Read the instruction carefully and contact the factory if you have any questions.

WARNING: Read this manual before installing and using this product. Failure to do so can result in serious injury or death.

Your boiler should be marked with a complete set of WARNING/CAUTION labels shown below. If one of these labels is missing, please contact our factory immediately.

US and All Other NonFrancophone Countries

Located on electrical enclosure door

WARNING

• Risk of electric shock. This boiler is connected to more than one branch circuits.
• Disconnect all power and control circuits before servicing.
• Read and understand the operator’s manual before using this boiler.
• Risk of electric shock.
• Disconnect all branch circuits before removing this cover.

CAUTION: All exposed pipes and valves may be hot. Do not touch.

Canada and All Other Francophone Countries

WARNING

• Risk of electric shock
• Disconnect all branch circuits before removing this cover.

CAUTION: All exposed pipes and valves may be hot. Do not touch.

DANGER: This manual contains safety messages. Each of the safety messages is preceded by one of the following signal word panels:

WARNING: Safety messages preceded by this label contain information, that if not followed will result in death or serious injury.

CAUTION: Safety messages preceded by this label contain information, that if not followed could result in death or serious injury.

NOTICE: Safety messages preceded by this label contain information, that if not followed could result in minor or moderate injury.

WARNING: Messages preceded by this label contain important information, but are not hazard-related.

Ensure that this manual is available to the boiler operator at any time. Read carefully all safety labels attached to the boiler. If any safety label was damaged during shipment, contact the, factory immediately:

• Ph:  5406623811;
• email: sales@reimersinc.com

Important Safety Information

1. BLOWDOWN VALVE: This valve is utilized to blow impurities from the boiler chamber. When opened, a large volume of hot water and steam is discharged. Ensure that this valve is properly piped for such discharge. State and local codes must be met as applicable.
2. ELECTRICAL: All field wiring to the boiler must be in accordance with the National Electric Code and any local codes that may apply. Wiring must be made by a competent certified electrician. Use copper wire only. Ensure that all electrical components are in a dry location, free from any possibility of water soaking. Electric foot switches when supplied must not be placed on a wet floor. They must be placed on dry surface, not subject to steam or water.
3. GAUGE GLASS: The gauge glass protector guards must be on at all times. When replacing the glass, be sure that the unit is not under pressure and is cool to touch. The gauge glass should be replaced once per year. If cracks or wear is evident, replace the gauge glass immediately.
4. MODIFICATION/MISUSE: This boiler has been designed and constructed in accordance with the ASME Boiler and pressure Vessel Code. Any modification or misuse can result in a dangerous situation. Reimers Electra Steam, Inc. is not liable for any product that has been modified or improperly used.
5. PRESSURE GAUGE: The pressure gauge indicates the internal pressure of the boiler. It can fail. Periodically have your boiler inspector compare the gauge with a known gauge utilizing the test valve arrangement provided
6. REGISTRATION: Most states and cities require boiler registration and inspection. Check with your government authorities.
7. INSTALLATION AND REPAIR: Installation and repair work of this unit must be performed only by experienced personnel. Before commencing a repair, ensure that the boiler is cold, not pressurized and electrically disconnected. All standard electrical and steam safety precautions must be taken during testing.
8. SAFETY VALVE: The safety valve is designed to discharge hot steam when the set pressure is exceeded. Ensure that the discharge port is pointing toward the back of the unit away from the operator or any aisles. Test the safety valve periodically to ensure that it is operating properly. Test carefully at full pressure by lifting the lever using pliers and let it “slap” shut. Steam discharge can scald. Ensure no one is exposed.
9. STEAM INSTALLATION: Steam piping must be of black pipe, not galvanized. Work must be done by an experienced steam fitter. All state and local codes must be met as applicable.
10. WATER: Ensure that all electrical components are in a dry location, free from any possibility of water soaking. Electric foot switches when supplied must not be placed on a wet floor. They must be placed on dry surface not subject to steam or water.

Installation

REIMERS ELECTRA STEAM, INC. boilers are heated by one or more immersion-type heating elements. Automatic controls are provided to maintain preset operating pressure and proper water supply. Safety features include automatic low water cutoff, automatic pressure control, safety valve and visible water level gauge. Each boiler is manufactured in accordance with the ASME Power Boiler Code Standards and is individually inspected and stamped by an authorized National Board Insurance Inspector. All boilers are registered with the National Board of Boiler and Pressure Vessel Inspectors. When boiler is received, make sure it has not been damaged in shipment.

NOTE

• ASME DATA PLATE IS LOCATED ON END OF THE PRESSURE VESSEL BEHIND THE LABEL STAMPED WITH THE NATIONAL BOARD NUMBER OF UNIT.
• When a boiler is received, make sure it has not been damaged in shipment.

Location

Place the boiler in a level position, close to the equipment which it is to supply. This will insure minimum heat losses and allow more economical piping arrangements. All steam lines should be insulated. Review the overall dimensions of your boiler model on page 6 to select proper boiler location. Regardless of the NFPA70 working space requirements shown below, provide a minimum of 3ft clearance on both sides of the boiler for element servicing, 3ft of clearance to the front of the boiler and 1.5ft to the rear of the boiler.

Working space

Electric boiler spacing is dictated by NFPA70, Table 110.26 as follows:

Note: Where the conditions are as follows:

Condition 1:  Exposed live parts on one side of the working space and no live or grounded parts on the other side of the working space, or exposed live parts on both sides of the working space that are effectively guarded by insulating materials.
Condition 2 : Exposed live parts on one side of the working space and grounded parts on the other side of the working space. Concrete, brick, or tile walls shall be considered as grounded.

Condition 3 : Exposed live parts on both sides of the working space.

• DeadFront Assemblies. Working space shall not be required in the back or sides of assemblies, such as deadfront\ switchboards or motor control centers, where all connections and all renewable or adjustable parts, such as fuses or switches, are accessible from locations other than the back or sides. Where rear access is required to work on nonelectrical parts on the back of enclosed equipment, a minimum horizontal working space of 762 mm (30 in.) shall be provided.
• Alcove or closet installation per UL834: Proper location of this boiler model with regard to combustible and non-combustible surfaces and materials is coded on the boiler nameplate. The following decoding sketch and description is provided for the user information:

Description of dimensions and symbols

• A – Clearance above the top of boiler
• B – Clearance from front of the boiler
  • Prefix C to numeral indicates suitability for closet or alcove installation
  • Prefix A indicates suitability for alcove but not for closet installation
• D – Clearance from the back of the boiler
• EL – Clearance from the left side of the boiler
• ER – Clearance from the right side of the boiler
• F – Indicates the type of flooring: “NC” for noncombustible floor / “C” for the combustible floor. Numeral indicates minimum clearance below suspended units to a combustible floor.

Water Supply.

On models with a pump and/or solenoid valve, connect the incoming water supply to a strainer on the intake side of the solenoidvalve.

On models furnished with condensate return tank, connect water line to makeup valve located at tank end. (See Instruction Supplement 1 in this manual) SR, SRH and SRHC steam boiler models require four (4) gallons of feed water per hour for each 10 kW of electric heating capacity of the boiler. Lines should be of adequate size and meet local plumbing codes.

CAUTION: On all stainless steel models, the specific resistivity of the boiler feed water must be above 1Mohns*cm. In addition, boiler feed water must be free of chlorine.

Steam Outlet

All piping from and to the boiler must comply with the A.S.M.E. B31.1 Power Piping Code. All-State and local codes must be met. All piping must be done by a qualified steam fitter. Connect steam line of sufficient size from steam line valve to the equipment. Steam piping must be black steel pipe, not galvanized. Work must be done by an experienced steamfitter. All state and local codes must be met.

Condensate Return

If the condensate is to be returned by gravity (no tank) in a], closed system, the load discharge should be at least 2 feet above the boiler level so that the weight of the condensate will actuate the check valve. When applicable, install steam return lines at sufficient height to allow a pitch of 2 inches for every 10 feet of pipe length.

Note: For condensate return systems (with tank), see the special sheet.

Safety Relief Valve

The safety valve is designed to discharge hot steam when the set pressure is exceeded. Ensure that the discharge] port is pointing toward the back of the unit away from the operator and any aisles. If it is required that discharge piping be installed from the safety valve, the pipe should not be smaller than the valve outlet and should be rigidly supported so as not to place weight on the valve itself.

Important: No valve in this line!

Electrical

Install a fused disconnect switch near the boiler. It should be fused as marked on the boiler nameplate. Connect the power supply from the disconnect switch to the terminals in the boiler control panel. A copy of the wiring diagram is in the control panel.

Important: Electrical connections to the boiler control panel (FIG. 7) should be made by a qualified Electrician. All wiring must comply with local electrical codes.

Three Phase Boiler Models Without Power Supply Extension Box

ThreePhase Boiler Models With Power Supply Extension Box

All boiler models that are equipped with a transformer option (OPT1010 or OPT1011) don’t require a separate external control voltage power supply.

Blowdown Valve

CAUTION: When the blowdown valve is utilized, a large volume of hot water and steam is discharged. Ensure that this valve is properly piped for this discharge. State and local codes must be met as applicable.

Operation

Boiler Startup

• Open the steam line valve slightly. This will allow the boiler to be filled without producing back pressure.
• Ensure that the feed water shutoff valve is in the open position
• Close the boiler blow-down valve
• Throw the fused disconnect switch (not provided by the factory) to the ONposition and turn on the boiler control voltage
• After approximately 2 seconds, the WATER FEED light turns on and water enters the boiler. As soon as the water level reaches approximately half height in the gauge glass, the automatic water feed turns off.

NOTICE: Do not let the pump to run dry for an extended time as this will cause damage to the pump.

• If the boiler controller indicates any alarms, then press the corresponding RESET button(s).

As soon as no boiler alarms are indicated, the HEATING light turns on and the boiler starts to build up pressure. Observe the pressure gauge while pressure builds up, until working pressure is reached. The working pressure should have been factory set to your specification. However, if you wish to change the working pressure setting, proceed as follows.

WARNING: Stand clear of scalding water or steam. Disconnect the boiler from all power supplies.

All pressure controls are factory preset and require no adjustment. However, if a change of the operating steam pressure is required, then proceed as follows:

• Disconnect all power supplies from the boiler.
• Close the steam outlet valve
• Remove the cover from the pressure control enclosure.
• Turn the black knob of the operating pressure switch clockwise to increase the pressure and counterclockwise to decrease the pressure.
• Connect all power supplies to the boiler, open the steam outlet valve, and install the pressure control enclosure cover.
• To shut off the boiler, turn the POWER switch on the boiler controller OFF.

Control Functions

See Boiler Control Manual for detailed instructions.

The control provides four basic functions and two optional functions. The following overview describes the functions. Low water cutoff Boiler high- pressure cutoff High water level feed shutoff Automatic boiler refill Automatic boiler blowoff (Optional) Remote controlled boiler ON/OFF and boiler status (Optional)

Low Water CutOff Function

The low water cutoff function of the boiler control deenergizes the heating elements when the water level in the] boiler pressure vessel falls below the minimum acceptable operating level. The control senses the water level in the boiler pressure vessel through a float. When the float is at the correct height on the float rod, the boiler operates normally. When the water level and float falls below the internal sensors, the control senses that water level is low. The control will not deenergize the heating elements when\ the float loses contact with the internal sensors for short periods of time. But, when the float contact with the internal sensors for a set time, the control deenergizes the heating elements and turns on the “LOW WATER” boiler alarm light. Boiler operation can only be resumed after determining why water level is low, restoring normal water level in the boiler and pressing the “LOW WATER” reset button [R]. After pressing the “LOW WATER” reset button the alarm light “LOW WATER” turns off, the lockout is reset and the heating elements are energized. The Low Water CutOff function short cycling timer can be adjusted. See the Boiler Control Manual (Doc. #9101)

High-Pressure Cutoff Function

If the operating pressure control fails, the steam pressure in the boiler can reach the value set on the high limit pressure control. In that case, the high limit pressure control de-energizes the heating elements and locks them out. The boiler alarm light “HIGH PRESSURE” comes on.After the pressure control is replaced the HIGH PRESSURE alarm light turns off.

Automatic Boiler Refill

When the POWER switch is turned on and the water level M float is in contact with the boiler water, the boiler control keeps the boiler water feed pump and/or solenoid valve de-energized. When the water level float loses contact with the boiler water, the boiler control energizes the boiler feed pump and/or the solenoid valve after a set ON delay time. When the water level probe makes contact with the boiler water, the boiler controller deenergizes the boiler water feed pump and/or solenoid valve after a set refills OFF delay time. The ON and OFF delay time can be adjusted. See the] boiler control manual for instructions. If the feedwater pump and/or solenoid valve remains on for longer than the ON delay time the boiler control de-energizes the feed water pump and/or solenoid valve and displays a flashing “0” on the control LED display. Th “E” ;key must be pressed to start a new refilling attempt

Automatic Boiler Blowoff (Optional)

• See Boiler Control Manual for instructions.

Remote-controlled boiler ON/OFF and boiler status. (Optional)

• See Boiler Control Manual for instructions.

Boiler Monitor Definitions

The following are definitions for all boiler monitor indications. See the control manual for details including] adjusting all parameters. Flashing “0”: Boiler feed pump and/or solenoid remained energized longer than the set time. Boiler feed pump and/ or solenoid are de-energized. Press the “E” key to reset the alarm and start a new refilling cycle. Flashing “1”: Following a blowdown cycle, the automatic refill device did not stay on for the set time. Press the”E” key to reset the alarm.

Boiler Maintenance

WARNING: Boiler repairs must be performed by experienced personnel only. Ensure boiler water is cold and drained and that there is no pressure and all electricity to the boiler is shutoff.

Boiler Blowoff

All boilers must be blown off periodically to remove minerals, scale and other foreign matter, which accumulate inside the pressure vessel. The concentration of this deposit depends in part upon the condition of the water in the area. When water is naturally soft, or has been softened chemically, boiler blowoffs are required less often than in areas where hard water is found. Water softeners are suggested in hard water areas to minimize the formation of hard scale on heating elements. Another factor affecting water condition is the amount of condensate if any, that is being returned to the boiler. Since the condensate is essentially clean distilled water, it contains very few impurities. If a large part of the condensate is being returned and little makeup water is used, the boiler need not be blown down as often as when little or no condensate is returned to the boiler. We recommend blowoff of newly installed steam boilers once per day until the first heating element and pressure vessel inspection is performed (refer] to chapter 3.4). If no significant amount of sediment is found on the bottom of the pressure vessel and on the heating element sheaths, then the boiler blowoff frequency can be reduced accordingly. The safest method to blowoff Rseries] steam boilers is to install a Reimers Electra Steam, Inc. properly sized and fully trimmed blowdown tank, model BTANK10. Reimers blowdown tanks are designed and constructed to Section VIII of the A.S.M.E. Code and inspected by a commissioned National Board Boiler inspector.

Boiler Blowoff Frequency

In areas where water is soft or has been softened chemically:

• When little condensate is returned blowdown once every second day
• When a large part of the condensate is returned and little makeup water is used, blowdown once every week

In areas where hard water exists:

• When little or no condensate is returned, blowdown once a day
• When a large part of the condensate is returned and little makeup water is used, blow down once every second day.

Safety Valve Test

WARNING: Stand clear of scalding water or steam. Ensure that the Boiler Bottom Blowoff Valve is properly piped.

This test should be performed once per month. Proceed as follows:

Increase the steam pressure as shown in chapter 2.1. to maximum operating pressure.

• Keep the steam outlet valve closed
• Pull the trip lever and hold it open for five (5) seconds in order to flush off the valve seat.
• Permit the valve to “slap” shut. If] a leak occurs, repeat this test and if necessary, replace the valve.

Element Replacement and Element Cleaning

WARNING: Ensure that the boiler is cold, drained and all power supplies are disconnected.

Clean the element rods every six (6) months. To clean the element rods, or if an element must be replaced, proceed as follows:

• • Remove the element terminal cover from the front of the boiler.
• Disconnect and label the terminal wires
• Remove all four (4) nuts from each element flange and pull out the heating element.
• Use a stiff wire brush to remove all scale and foreign matter from the element rods.
• Clean the element flange surfaces before installing new elements and gaskets.

Gauge Glass Replacement

WARNING: Ensure that the boiler is cold, drained and all power supplies are disconnected.

Steam and boiler water can erode the glass. Therefore inspect the sight glass every 6 months. If the glass thickness becomes less that 5/16” or if the glass looses its transparency, replace it immediately. To replace the bull’s eye water level indicator, use a 213/ 16” hex socket or adjustable wrench with the same minimum opening. Read carefully the bull’s eye water level indicator manual in Instruction Supplement #2.

Troubleshooting

WARNING

• Ensure that the boiler is cold and has no pressure.
• Electrical troubleshooting must be performed by a qualified electrician.

If troubleshooting did not resolve the problem, please contact our service technicians at:

• Phone: 5406623811
• Email: techsupport@reimersinc.com

Parts list for SR, SRH, and SRHC Boiler Models (SRXSeries)

WARNING: Use Reimers replacement parts. All components are designed and approved to be used in this Underwriters Laboratories listed and ASME National Board Stamped boiler. Failure to do so may cause serious injury or death.

Instruction Supplement #1

Condensate Return System

Tank size for Models SRHC40 thru 120 16 gallons

Installation

Connect water supply to the water inlet on the tank.
Note: The water supply should be turned off when the boiler is not in operation.

1. Connect condensate return line from equipment to condensate return intake.
2. Pipe from vent is to be installed to the outside of building, if desired. If this method is used, pipe should be the same size as vent opening. Under no condition should vent be plugged!
3. Install piping from overflow to drain.
4. Pressure-reducing valve is required for city water pressures in excess of 40 PSI.

Maintenance

1. A strainer should be removed and cleaned shortly after the boiler has been in operation to clear away sediment which may have accumulated during startup. This strainer should be periodically inspected and cleaned when necessary.
2. Gauge Glass – Inspect once per year. If the gauge glass inner wall is eroded, then replace it.
3. Pump Motor Maintenance is not normally required on the pump or motor.

LIMITED WARRANTY – STEAM GENERATORS

Reimers Electra Steam, Inc. warrants the following products of its own manufacture against defects in materials and workmanship under normal use and service. This warranty is in lieu and excludes all other expressed or implied warranties or merchantability of fitness for any particular use. No person is authorized to  extend the terms of this warranty or assume any other liability except by written statement signed by an officer of Reimers Electra Steam, Inc. Clear Brook, Virginia 22624.

WARRANTY PERIOD

The pressure vessel and electrical & mechanical components are warranted for one year from date of shipment from Reimers Electra Steam, Inc. in Clear Brook, VA 22624.

LIMITATIONS

Products must be installed, used and maintained in accordance with our instructions, including reasonable & necessary maintenance by the user. Users are responsible for the suitability of the products to theirapplication. There is no warranty for damage resulting from improper installation, abuse, power failure, fire, flood, lightening, improper water, misuse, improper specification, misapplication or other operating conditions beyond our control or parts that are normally expendable in usual course of operation.\ Claims against carriers for damage in transit must be filed by the buyer. Reimers liability, if any, will not exceed the price of Reimers products claimed to be defective. Components manufactured by any supplier other than Reimers shall bear only that warranty made by the manufacturer of that product and service for that warranty shall be the responsibility of that manufacturer and not Reimers.

REMEDY

Claims under this Limited Warranty must be made by obtaining a Return Authorization Number from our office (PHONE: 5406623811, FAX: 5406658101) & returning the defective part, freight prepaid to: Reimers Electra Steam, Inc., 4407 Martinsburg Pike, Clear Brook, Virginia 22624 Defective items will be repaired or replaced as necessary within a reasonable time without charge, other than incidental charges such as freight prepayment. Such repair or replacement within a reasonable time is the exclusive remedy available from Reimers Electra Steam, Inc., under this Limited Warranty.

CONSEQUENTIAL DAMAGES

Reimers Electra Steam, Inc., is not liable for labor costs incurred in the removal, reinstallation, or unauthorized repair of the product, or for damages of any type whatsoever, including incidental and/or consequential damages.

THIS WARRANTY SUPERSEDES ALL PREVIOUS WARRANTIES.

CONTACTS

• 4407 Martinsburg Pike Clear Brook, VA 22624 USA
• Phone: 540-662-38 11
• Fax: 540-665-8101
• email: sales@reimersinc.com
• web: www.reimersinc.com

References

• Reimers Electra Steam – Electric Boiler Manufacturer

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