Reimers HLR120 User manual

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
4407MartinsburgPike Phone:5406623811
ClearBrook,VA22624 Fax:5406658101
USA email:[email protected]
web:www.reimersinc.com
_______
MODEL:
________
SERIAL#:
HLR120180kWHydronicBoilerModels
InstructionsManual

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
LimitedWarrantyInformation.............................................................4
ImportantSafetyInformation..............................................................5
Installation..........................................................................................7
Location..............................................................................................7
Installation..........................................................................................7
HeatingLoopPiping...........................................................................8
SafetyReliefValve.............................................................................8
Electrical.............................................................................................8
Operation............................................................................................9
BoilerStartup......................................................................................9
HoneywellControllerT775P2003Setup............................................9
HoneywellControllerT775P2003SettingOperatingParameters......9
BoilerStartup......................................................................................9
BoilerMaintenance.............................................................................10
TighteningtheElectricalTerminalConnections.................................10
TestingtheSafetyReliefValve...........................................................10
ElementInspection,Replacement,andElementCleaning................11
TestingtheLowWaterCutOffDevice...............................................11
TestingtheSafetyReliefValve...........................................................11
Troubleshooting..................................................................................12
PartsLists...........................................................................................13
PartsList(Continued).........................................................................14
TABLEOFCONTENTS

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
PowerSupply
Voltage:
C=208V
E=240V
G=380V
J=415V
K=480V
M=600V
HLR120‐HLR180HOWWATERBOILERS
4407MartinsburgPike Phone:5406623811
ClearBrook,VA22624 Fax:5406658101
USA  email:[email protected]
web:www.reimersinc.com
• Maximumdesign100psi,250°F
• Maximumoperang85psi,235°F
• 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Naonal
BoardStamp“H”.
• Shellfiberglassinsulaonthicknessminimum2".
• Powerrange120kW‐180kWwithupto6heangstages,depending
onmodel.
• Heangstagesmanagedbydigitalstepcontroller.
Features
StandardEquipmentofEachBoilerIncludes:
• A.S.M.E.pressurereliefvalve
• One(1)primaryhightemperaturecutoffcontrolwithautomacreset
and one (1) secondary high temperature cutoff controll with manual
reset
• One(1)lowwatercutoffcontrolwithmanualreset
• PID‐step controller with number of heang stages depending on the
boilerheangpower
• Digitalreadoutoftheoperangtemperature
• Magneccontactors
• Internalbranchcircuitfusing
• Mainsupplypowerdistribuonblock
• Indicator lights for POWER, HEATING, CIRCULATOR PUMP, and
ALARMS
• Pressureandtemperaturegauges
Applications
•SpaceHeang
•TankHeang
•WaterSourceHeatPumps
•SwimmingPools
ModelNumberKey
BoilerPowerinkW
SafetyRelief
ValveSetting:
A=15psi(1.0bar)
B=30psi(2.1bars)
C=50psi(3.4bars)
D=60psi(4.1bars)
E=75psi(5.2bars)
F=100psi(6.9bars)
PowerSupply:
1=1Phase
3=3Phase
Example:HLR180K3B=HLR‐Serieshotwaterboiler,180kW
heangpower,powersupply480V,3ph,safetyvalvesetto
30psi
*Eachboilermodelrequirestwo(2)powersupplies:
Heangpowerandcontrolvoltage.Nominalcontrol
voltageis120VAC.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opon,allboilermodels
can be equipped with control voltage transformers
so that only the heang power supply needs to be
connectedtotheboiler.
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.
•Bio‐DieselReactors
•De‐Icing
H L R

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
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.
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.
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 their application. 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.
ClaimsunderthisLimitedWarrantymustbemadebyobtainingaReturnAuthorizationNumberfromouroffice(PHONE:
5406623811,FAX:5406658101)&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.
ReimersElectraSteam,Inc.,isnotliableforlaborcostsincurredintheremoval,reinstallation,orunauthorizedrepairof
product,orfordamagesofanytypewhatsoever,includingincidentaland/orconsequentialdamages.
LIMITEDWARRANTYHOTWATERBOILERS
WARRANTYPERIOD
LIMITATIONS
REMEDY
CONSEQUENTIALDAMAGES
THISWARRANTYSUPERSEDESALLPRESIOUSWARRANTIES

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
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.
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NonFrancophoneCountriesCanadaandAllOtherFrancophoneCountries
Locatedonelectricalenclosuredoor
Locatedonendcapsofcylindricalboilerpressurevesseljacket
Locatedonendcapsofcylindricalboilerpressurevesseljacket
Thismanualcontainssafetymessages.Eachofthesafetymessagesareprecededbyoneofthefollowingsignalword
panels:
Safety messages preceded by this label contain information, that if not followed will result in death or
seriousinjury.
Safetymessagesprecededbythislabelcontaininformation,thatifnotfollowedcouldresultindeathor
seriousinjury.
Safetymessagesprecededbythislabelcontaininformation,thatifnotfollowedcouldresultinminoror
moderateinjury.
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thismanualbeforeinstallingandusingthisproduct.
Failuretodosocanresultinseriousinjuryordeath.
NOTICE
CAUTION
WARNING
DANGER
WARNING

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
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 lever using pliers and let it
"slapping"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.
WARNING
Read carefully all safety labels attached to the boiler. If any safety label was damaged during shipment, contact the
factoryimmediately:
Ph.5406623811;email:sale[email protected]

PAGE7
ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
REIMERS  ELECTRA  STEAM,  INC.  boilers  are  heated  by  one  or  more  immersion  type  heating  elements.
Automaticcontrolsareprovidedtomaintainpreset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 PRESSURE VESSELBEHINDLABEL STAMPED WITH NATIONAL
BOARDNUMBEROFUNIT.
Whenboilerisreceived,makesureithasnotbeendamagedinshipment.
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NFPA70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.
a.)Workingspace:
ElectricboilerspacingisdictatedbyNFPA70,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.
(a)DeadFrontAssemblies.Workingspaceshallnotberequiredinthebackorsidesofassemblies,suchasdeadfront
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 non
electricalpartsonthebackofenclosedequipment,aminimumhorizontalworkingspace
of762mm(30in.)shallbeprovided.
b.)RegardlessoftheaboveworkingspacerequiredbytheNationalElectricalCod,the
followingcleranesideoftheboilermustbeprovidedforheatingelementservicing:
HLR120HLR180 1.5ft(460mm)onbothsidesofboiler
c.) Alcove or closet installation per UL834: Proper location of this boiler model with
regardtocombustibleandnoncombustiblesurfacesandmaterialsiscodedontheboiler
name plate. The following decoding sketch and description is provided for the user
information:
Descriptionofdimensionsandsymbols
AClearanceabovetopofboiler
BClearancefromfrontof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backofboiler
ELClearancefromleftsideofboiler
ERClearancefromrightsideofboiler
F  Indicates type of flooring: "NC" for noncombustible floor / "C" for combustible floor. Numeral indicates minimum
clearancebelowsuspendedunitstocombustiblefloor
1.1Location
1.Installation
120180

PAGE8
ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
Piping: This hot water boiler is intended to be used in a
closed pressuresystemwith a circulating hotwaterpump.
Theboilersafetyreliefvalvecanhavesettingsfrom30and
up to 150psig.The expansion tank must be sized tomeet
theASMEstandards for the overall water capacity of your
heatingsystem.Thecirculatingsystemshouldalsoinclude
an air trap and bleed, as well as automatic water fill. The
water inlet and outlet are located on top of the boiler as
showninFIGURE2.
Recommendedheatinglooppipingsize,dependingonthe
boilerheatingpower:
HLR210–HLR300:3"NPS
HLR330–HLR510:4"NPS
Installstopvalvesascloseaspossibletotheboilersupply
andreturnports(FIGURE2).
In order to ensure long term troublefree boiler operation,
werecommendthatthewaterusedasboilerfeedwaterto
be tested for hardness. If the water in your area is harder
than 1grain (17mg/L), use a water softener. The main
cause for premature heating element failure in electric
steamboilersiswaterhardness.Ifseverecorrosionduring
inspection of the pressure vessel as indicated in chapter
3.4 of this manual becomes evident, additional tests of
yourboilerfeedwatermustbeperformed.Awateranalysis
should be performed by a qualified and recognized water
treatmentcompanylocatedinyourarea.
Recommendedlevelsforboilerfeedwater:
Recommended levels for boiler water (water inside
pressurevesselwhenboilerisoperating)
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!
Install a fused disconnect switch near the boiler. It should
befusedasmarkedontheboilernameplate.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. 3) should be made by a qualified Electrician. All
wiringmustcomplywithlocalelectricalcodes.
All boiler models that are equipped with a transformer
option (OPT1010 or OPT1011) do not require a separate
externalcontrolvoltagepowersupply.
NOTICE Donotaddanychemicalsto
theboilerfeedwaterunless
specificallyrecommendedbya
qualifiedandrecognizedwater
treatmentcompany.
1.2HeatingLoopPiping
1.3SafetyReliefValve
1.4Electrical
SafetyValve
FIGURE2
ReturnLine
SupplyLine
FIGURE2
MainPower
FIGURE3 Control
Voltage
ROOM/PROCESS
THERMOSTAT
CONNECTION

PAGE9
ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
a.Withallpowerdisconnected,checkthecontrolpanelfor
loose wires caused by vibration in shipping. Review
installationinstructionstobesureboiler
isproperlywiredandinstalled.
b. Be sure that the boiler drain valve is
closed
c.Fillthesystemwithwater
d. Ensure that the selector switch is in
OFFposition(middleposition)
e. Turn on the control voltage power
supply
f. TurntheredPOWERswitchtotheON
position
g. Start the circulating pump, or pumps by throwing the
selector switch of the boiler controller into the PUMP
position.Withpumprunning,bleedairfromsystemand
checkentiresystemforleaks.
h. This hot water boiler is equipped in its standard
configurationwithonetemperaturesensor,placedinside
the boiler pressure vessel near the water outlet nozzle.
Itsensesthewatertemperatureasitexitstheboiler.For
space heating applicationsthat require outdoor reset, a
second sensor can be easily connected to the boiler
controllerinthefield.
NOTE: For all boilers equipped with the Honeywell
T775P2003 controller (standard configuration), please
continue reading this paragraph. For all boilers equipped
with the BACnetTM enabled controller, model OPTHLR
BMS, please refer to the separate instruction manual that
comeswiththeboiler.
TheHoneywellcontrollerT775P2003wassetatthefactory
with its parameters as shown below and to the operating
watertemperatureasordered:
1.1EnteringSetupMode:PressandholdtheMENUbutton
for5secondstodisplaytheSetupmenu
1.2.SettinguptheSensors:
1.2.1.#ofSensors=1
1.2.2.SensorA
1.2.2.1.UNITS=DEGF
1.2.2.2.CALIBRATE=0.0°F
1.2.2.3.LABEL=BOILERA
>EXIT
2.3. SENSOR B = Not set, unless outdoor reset sensor
connectedtocontroller
1.2.4.SENSORC:Notused
>EXIT
1.3.SettinguptheOutputs
1.3.1.NumberofSTAGES=4
1.3.2.SCHEDULE=NO
1.3.3.OPTIONS
1.3.3.1. RESET = NO, unless  outdoor  reset  sensor  is
connectedtocontroller
1.3.3.2.INTEGRAL=0sec.
1.3.3.3.DERIVATIVE=0sec.
1.3.3.4.ONDELAY=0sec.
1.3.3.5.OFFDELAY=0sec.
1.3.3.6.WWSD=NO
1.3.3.8.LEADLAG=FOFO
1.3.3.9.DIOPTIONS=DISABLE
1.3.3.10.SHOWRT=NO
>EXIT
1.3.4.SettinguptheStages=Notset
>EXIT
1.4.SetupAlarms=Notset
>EXIT
PROGRAMMINGOUTPUTSTAGESWITHNORESET
3.1.EnteringProgramMode:PresstheMENUbutton,then
select PROGRAM and press the > button to view the
Programmenu.
3.1.1. SETPOINT = Set value to desired heating loop
temperature
3.1.2. THROTTLING RANGE = recommended range 15 –
25°F
3.1.3.SENSOR=Notset
3.1.4.HEAT/COOL=HEAT
>EXIT
>EXIT
To set the boiler controller for reset mode, please refer to
the Honeywell T775P2003 boiler controller manual that is
attachedtothismanual.
i. TurnthethreephasepowersupplyON
j. TurntheselectorswitchintotheHEATINGposition
a.Assoonastheselectorswitchisinthe
HEATINGpositionandtheRoom/Process
thermostatcallsforheating:
BothlightsremainONaslong
as the Room/Process
thermostatcallsforheating.
b. Depending on the difference between
the programmed temperature set point
and the actual temperature in the boiler
pressure vessel, the boiler controller will
start energizing heating stages. The
energizedheatingstages areindicatedin
thecontrollerdisplayasblackdots.
c. The actual temperature of the boiler is shown in the
middle portion of the display.Tochange the
set point, follow the instructions above
(Honeywell Controller T775P2003 Setting
OperatingParameters)
d. Various status messages may be shown
in the lower portion of the boiler controller
display. As long as the thermostat calls for
heating,DI=OFF,whenthethermostatdoes
notcallforheating,DI=ON.
e. As soon as the temperature in the
pressure vessel approaches the
programmed set point temperature, the
boilercontrollerwillbegintostepoutheating
stages.
If the actual temperature in the pressure
vessel (temperature indicated on the
temperature gauge) is higher than the
programmedtemperaturesetpoint,thenthe
throttling range must be increased. If the
actual temperature in the pressure vessels
swings too high over the programmed set point, the high
temperaturesafetylimitcontrol(s)maytrip.
2.Operation
2.1BoilerStartup
HoneywellControllerT775P2003Setup:
Selector
Switch
FIGURE2
HoneywellControllerT775P2003SettingOperating
Parameters:
2.2BoilerOperation,SequenceofEvents
HEATING
lightON
FIGURE5
PUMPlight
ON
FIGURE6

PAGE10
ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
2.2.2LowWaterCutOffFunction
The low water cutoff function of the boiler control de
energizes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probe.Whenthetipofthe
probe is in contact
with water in the
boiler, the boiler
operates normally.
Whenthewaterlevel
in the boiler falls
below the tip of the
probe the control
senses that water
level is low. The
control will not de
energize the heating
elements when the
probe loses contact
with the boiler water
forshortperiodsoftime.But,whentheprobelosescontact
withtheprobeforasettime,thecontroldeenergizes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.After pressing the "LOW WATER" reset button the
alarm light "LOW WATER" turns off, the lockout is reset
andtheheatingelementsareenergized.
2.2.3HighTemperatureCutoffFunction
Assoonasthewatertemperatureintheboilerreachesthe
high limit setting, the heaters and the HEATINGlight will
turn off. This may occur when the system is brought up
from cold to fully heated
condition. In this case, increase
the throttling range as described
above. However, if the high limit
control actuates repeatedly it
would indicate that the water
temperature setting is too close
to the hilimit setting. Check
these settings and increase the
difference between them. Each
boiler is equipped
with two high limit
temperature safety
limit controls: One
automatic reset control, set to a
lower cutoff temperature and
one manual reset control, set to
a higher cutoff temperature. If
the automatic reset control trips,
the HEATING light on the front
panel of the boiler
controller turns off
and all heating
stages turn off
immediately. If the
manual reset control trips, then
the HEATING light on the front
panel of the boiler controller turns off, the HIGH
TEMPERATURE alarm light will turn on and all heating
stagesturnoffimmediately.
Frequency:
During boiler
installation,
90days after
boilerinstallationandthenannual
Retightentheterminalsofthecontactors,fuseblocksand
heating element terminals inside the electrical enclosure
andpressurevesseljacket,followingthemaximum torque
valueslistedbelow:
Component MaximumTorque
50AContactor 25in*lb
75AContactor 45in*lb
FuseBlock 45in*lb
ElementWirestoCopperLugs20in*lb
CopperLugstoElementTerminals12in*lb
Frequency:Onceeverysixmonths
For this test, the boiler temperature should be near the
boilertemperaturesetpointandatleastoneheatingstage
energized.
3.2.1 Testing theAutomatic Reset Temperature High Limit
SafetyControl
 Readthecurrentboileroperatingtemperaturesetpoint
 Readandmemorize thecurrentsettingoftheautomatic
resettemperaturehighlimitsafetycontrol
 Turnthedialofthetemperaturecontroltowardstheboiler
temperature setpoint until all energized heating stages
turnofftogether.
 Turn the dial of the temperature control to its initial
position. The heating stages should energize staged in
accordance with the programmed ONdelay time in the
Honeywellstepcontroller
3.2.2 Testing the Manual Reset Temperature High Limit
SafetyControl
Read the current boiler temperature boiler operating
temperaturesetpoint
 Read and memorize the current setting of the manual
resettemperaturehighlimitsafetycontrol
 Turnthedialofthetemperaturecontroltowardstheboiler
temperature setpoint until all energized heating stages
turn off together. The HIGH TEMPERATURE alarm
indicatorlightintheboilercontrollerpanelshouldbeON.
 Turn the dial of the temperature control to its initial
position. Press the red RESET button. The heating
stages should energize staged in accordance with the
programmed ONdelay time in the Honeywell step
controller
3.BoilerMaintenance
BleederValve
Lowwatercut
offprobe
FIGURE7
Manualreset
temperaturehigh
limitcontrol
Automaticreset
temperaturehigh
limitcontrol
FIGURE8
WARNING
Donotaddanychemicalstothe
boilerfeedwaterunless
specificallyrecommendedbya
qualifiedandrecognizedwater
treatmentcompany.
3.1ReTighteningtheElectricalTerminalConnections
insidetheElectricalEnclosureandPressureVessel
Jacket
3.2TestingtheHighTemperatureCutOffDevices

PAGE11
ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
Frequency: Under normal operating
conditions test valve every two (2)
months. Under severe service
conditions or if corrosion and/or
depositsarenoticedwithinthevalve
body, testing must be performed
more often. A test must also be
performed at the end of any non
serviceperiod.
Test the safety relief valve
(preferably near its maximum
pressure setting by holding the test
lever fully open for at least 5
seconds to flush the valve seat free of sediment and
debris.Thenreleaseandpermitthevalvetosnapshut.
 Closethewaterinletandoutletstopvalves(FIGURE10)
 Turnoffandlockoutallboilerpowersupplies
 Ensure that the boiler drain valve (FIGURE 10) is piped
toasafepointofdischarge
 Open the boiler drain valve carefully and drain the
pressurevessel.Assoonasthereisnopressurepresent
inthevessel,openthebleedervalve(FIGURE7)slightly
tobreakthevacuum
*WaterInletandOutletStopValvesarenot providedwith
theboiler
 Remove the left pressure vessel jacket end cap to
accesstheheatingelements
 Labelthewiresofheatingelementsanddisconnectfrom
theterminals
 Remove the four (4) nuts from each heating element
flange and pull the elements slowly out of the pressure
vessel
 Inspect and if necessary remove with a stiff wire brush
rust,calciumorotherdepositsfromtheelementrods
 Inserta flashlightthroughoneheatingelementopening
and inspect through the second opening the inner walls
ofthepressurevessel.Itisnormalthattheinnerwallsof
the vessel be covered by a layer of red, brown or black
layer of rust. However,
rough pressure vessel
surface and layers of rust
peelingoffthesurfaceare
an indication for severe
corrosion. In such case,
contact a water treatment
company.
 Installtheheatingelementsbackintotheboilerpressure
vessel,followingtheaboveprocedureinreverseorder.
 After installing the pressure vessel jacket end cap, turn
onallpowersuppliesoftheboiler.
 FliptheredPOWERswitchoftheboilercontrollertothe
ONposition and leave the operating mode selector
switchinthemiddle(OFFposition)
 Observe the LOW WATER alarm light in the boiler
controllerfrontpanel.IfitturnsON,thelowwatercutoff
deviceworksproperly.
 Close the boiler drain valve, open the inlet and outlet
valves and with the bleeder valve open, refill the boiler
pressure vessel. Close the bleeder valve as soon as it
dischargeswater.
 Press the LOW WATER RESET switch. The LOW
WATERalarmlightshouldturnOFF.
 Thehotwaterboilershouldbereadyforoperation.
3.5.1TestingtheElectronicLowWaterCutOffDeviceOnly
Frequency:Anytime.
 PressandholdtheLOWWATERCUTOFFTESTswitch
ontheboilercontrollerpanel
 After 3 seconds, the HEATING indicator light – if it was
ON – will turn OFF; the LOW WATER alarm indicator
lightwillturnON
 PresstheLOWWATERRESETswitchtodeactivatethe
LOWWATERalarm
3.5.2 Testing the Entire Low Water CutOff System
(ElectronicLowwaterCutOffDevice+LowWaterprobe)
Frequency:
90daysafterinstallation,thenonceeveryyear
 Flip the boiler operating mode selector
switchtothemiddle(OFFposition)
 Close the water inlet and outlet stop
valves(FIGURE10)
 Turn off and lock out all boiler power
supplies
 Ensure that the boiler drain valve
(FIGURE10)ispipedtoasafepointof
discharge
 Open the boiler drain valve carefully
and drain the pressure vessel.As soon
as there is no pressure present in the
vessel, open the bleeder valve
(FIGURE 7) slightly to break the
vacuum.
 FliptheredPOWERswitchoftheboilercontrollertothe
ONposition and leave the operating mode selector
switchinthemiddle(OFFposition)
 Observe the LOW WATER alarm light in the boiler
controllerfrontpanel.IfitturnsON,thelowwatercutoff
deviceworksproperly.
 Close the boiler drain valve, open the inlet and outlet
3.4ElementInspection,Replacement,andElement
Cleaning
WARNING
ElementRods
3.5TestingtheLowWaterCutOffDevice
3.3TestingtheSafetyReliefValve
CAUTION
Beforetesting,makecertainthat
thedischargepipeisproperly
connectedtothevalveoutletand
arrangedtocontainandsafely
disposeofboilerdischarge.
Maintenanceworkmustbe
performedbyexperienced
personnelonly.Ensureboileris
coldanddrainedandhasno
pressureorelectricity.
WaterInlet
StopValve*
WaterOutlet
StopValve*
FIGURE9
FIGURE10
BoilerDrain
Valve*
Selector
Switch
FIGURE12
FIGURE11

PAGE12
ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
valves and with the bleeder valve open, refill the boiler
pressure vessel. Close the bleeder valve as soon as it
dischargeswater.
 Press the LOW WATER RESET switch. The LOW
WATERalarmlightshouldturnOFF.
 Thehotwaterboilershouldbereadyforoperation.
4.Troubleshooting
WARNING
Ensurethattheboileriscoldandhasnopressure.
Electricaltroubleshootingmustbeperformedbyaqualifiedelectrician.
Iftroubleshootingdidnotresolveproblem,pleasecontactourservice
techniciansat:
Phone:5406623811
Email:[e-mail]

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
5.PartslistforHLR120180
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.
1
5.1
2
13
12
5
7
10
8
6
9
5
5.1
3
11
4

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ReimersElectraSteam,Inc. 01/10/2022 HLR120‐180Manual‐English REV1
NOTE:Whenorderingparts,pleasegiveboilerModelandSerialNumberanddetailshippinginstructions.