The Reimers HLR 120-180 Hydronic Boiler is a hot water boiler designed for various applications, including space heating, tank heating, water source heat pumps, bio-diesel reactors, swimming pools, and de-icing. It is manufactured in accordance with ASME Boiler and Pressure Vessel Code and ASME CSD-1, bearing the National Board Stamp "H".
Function Description:
The HLR 120-180 series boilers utilize immersion-type heating elements to heat water, with automatic controls maintaining pre-set operating temperature and proper water supply. Safety features include a low water cutoff, automatic temperature control, safety relief valve, and a visible water level gauge. The boiler's heating stages are managed by a digital step controller, which energizes elements based on the difference between the programmed set point and the actual water temperature. The system includes both automatic and manual reset high-temperature limit controls to prevent overheating.
Important Technical Specifications:
- Design: Maximum design 100psi, 250°F.
- Operation: Maximum operating 85psi, 235°F.
- Power Range: 120kW - 180kW.
- Heating Stages: Up to 6 heating stages, depending on the model.
- Insulation: Shell fiberglass insulation with a minimum thickness of 2 inches.
- Voltage Options: Available in 240V, 380V, 415V, 480V, and 600V (3-phase).
- Water Capacity: 33 gallons (125 liters).
- Inlet & Outlet Size: 2-1/2" NPT.
- Temperature Range: 35°F (1°C) to 235°F (113°C).
- Weight: Ranges from 910 lbs (413 kg) for 120kW to 940 lbs (427 kg) for 180kW models.
- Control Voltage: Nominal 120V AC. Models rated for 380V and 415V require 220/240V applied to control voltage transformers.
Standard Equipment:
- ASME pressure relief valve.
- One (1) primary high temperature cutoff control with automatic reset.
- One (1) secondary high temperature cutoff control with manual reset.
- One (1) low water cutoff control with manual reset.
- PID-step controller for managing heating stages.
- Digital readout of operating temperature.
- Magnetic contactors.
- Internal branch circuit fusing.
- Main supply power distribution block.
- Indicator lights for POWER, HEATING, CIRCULATOR PUMP, and ALARMS.
- Pressure and temperature gauges.
Usage Features:
- Installation: Boilers should be placed in a level position, close to the equipment they supply to minimize heat losses. Minimum clearances are required for servicing: 3ft on both sides for element servicing, 3ft to the front, and 1.5ft to the rear. Electrical working space requirements are dictated by NFPA-70, with clearances ranging from 3ft to 4ft depending on voltage and conditions.
- Water Quality: Maintaining proper water quality is crucial for boiler longevity. Recommended water properties include: Total Dissolved Solids <3500 ppm, Suspended Solids <300 ppm, Total Alkalinity <700 ppm, and pH >8.5. For hard water, an ion exchange softener is recommended.
- Startup Procedure: Involves checking for loose wires, ensuring the drain valve is closed, filling the system with water, setting the selector switch to OFF, turning on control voltage, activating the red POWER switch, starting the circulating pump to bleed air, and finally turning on the three-phase power supply and setting the selector switch to HEATING.
- Controller Setup: The Honeywell T775P2003 controller allows programming of setpoint, throttling range, and other parameters. It displays current temperature and indicates energized heating stages.
- Safety Controls:
- Low Water Cut-Off: De-energizes heating elements and activates a "LOW WATER" alarm if water level drops below the probe. Operation resumes after restoring water level and pressing the reset button.
- High Temperature Cut-Off: Two controls are present: an automatic reset control (lower cut-off temperature) and a manual reset control (higher cut-off temperature). If either trips, heating elements are de-energized. The manual reset also triggers a "HIGH TEMPERATURE" alarm.
Maintenance Features:
- Electrical Connections: Re-tighten terminals of contactors, fuse blocks, and heating element terminals annually, following specified torque values (e.g., 25 inlb for 50A-Contactor, 45 inlb for 75A-Contactor and fuse block).
- Safety Relief Valve Testing: Test every six months by manually lifting the lever to ensure discharge.
- High Temperature Cut-Off Testing: Test every six months by adjusting the temperature control dial to simulate an over-temperature condition and verify proper cutoff and alarm activation.
- Element Inspection, Replacement, and Cleaning: Inspect heating elements annually for scale buildup. Clean elements by removing the pressure vessel jacket and elements, then brushing off deposits.
- Low Water Cut-Off Device Testing: Test every six months by draining water from the boiler to activate the low water cutoff and verify the alarm.
- Troubleshooting: A dedicated section in the manual provides quick fixes for common issues like no power, "Low Water" alarm, and "High Temperature" alarm.
- Parts List: A comprehensive list of replacement parts is provided, including descriptions and applicable boiler models, to facilitate maintenance and repairs.
Warranty:
Reimers Electra Steam, Inc. provides a one-year warranty on the pressure vessel and electrical & mechanical components from the date of shipment, covering defects in materials and workmanship under normal use and service. The warranty is subject to limitations, including proper installation, use, and maintenance. Claims require a Return Authorization Number and return of the defective part freight prepaid.
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