McDonnell & Miller 150E Series Montage- und Bedienungsanleitung

Series 150E and 157E

Low Water Cut-Off/Pump Controllers

For Steam Boilers and Other Level Control Applications

Typical Applications:

– Primary or secondary pump controller/

low water fuel cut-off

for steam boilers

– Motorized valve controller

– Low water and high water cut-off

– Dual pump control

– Alarm actuator

• Before using this product read and understand instructions.

• Save these instructions for future reference.

• All work must be performed by qualified personnel trained in the proper application, instal-

lation, and maintenance of plumbing, steam, and electrical equipment and/or systems in

accordance with all applicable codes and ordinances.

• To prevent serious burns, the boiler must be cooled to 80˚F (27˚C) and the pressure must be

0 psi (0 bar) before servicing.

• To prevent electrical shock, turn off the electrical power before making electrical connections.

• This low water cut-off must be installed in series with all other limit and operating controls

installed on the boiler. After installation, check for proper operation of all of the limit and

operating controls, before leaving the site.

• To prevent serious personal injury from steam blow down, connect a drain pipe to the control

opening to avoid exposure to steam discharge.

• To prevent a fire, do not use this low water cut-off to switch currents over 16A, 1 Hp at

120 VAC or 8A, 1 Hp at 240 VAC, unless a starter or relay is used in conjunction with it.

Failure to follow this warning could cause property damage, personal injury or death.

WARNINGCAUTION

WARNING

Series 150E

Series 157E

with

MERCURY

FREE

1 HP

Relays

Installation & Maintenance

Instructions MM-414

SPECIFICATIONS

Maximum Pressure: 150 psi (10.5 kg/cm2)

FEATURES

Burner Delay (DOB): 0 to 60 seconds (Field Adjustable)

Ambient Temp: 120˚F Max.

NOTE:The circuit board is protected with a sensor which will

shut down the unit if the temperature at the board exceeds

176˚F (80˚C).The board will reset when the temperature at

the board drops below 167˚F (75˚C).

Burner RelayTime Delay

There is a field-adjustable time delay (DOB) to

prevent nuisance burner shut-down.The number

of seconds water needs to be off the bottom probe

before the burner relay is deactivated can be set

between 0 and 60 seconds.

Redundant Low Water Cut-Off

When the boiler water drops below the middle

probe, a 3 minute timing circuit will be activated. If

water does not return to the middle probe within

three minutes, the burner relay will deactivate.The

Red LED will flash once every second if this

condition occurs.

• Automatic Reset units will automatically reset

when the water level is restored to the middle

probe.

• The reset button on Manual Reset units will

have to be pressed after water is restored to

the middle probe.

NOTE:The timing circuit will automatically reset

if the water level is restored to the middle probe

within 3 minutes.

Redundant Pump Off

The pump relay will be activated after water drops

below the middle probe. If the water level is not

restored to the top probe within 3 minutes the pump

relay will be deactivated. After the pump relay is

deactivated, normal operation is resumed.Water

must again drop off the middle probe to activate the

pump relay.There is no LED signal for this

occurance.

CSD-1 Code Compliance

On Manual Reset units, if the control is in a low

water condition (burner relay deactivated) prior to

an interruption of power, the control will remain in a

low water condition when power is restored.The

reset button will need to be pressed when the water

level again covers the middle probe.

Adjustable Pump Differentials

ELECTRICAL RATINGS & SWITCH RATINGS

Supply Probe Full Load (Amps) Locked Rotor (Amps) Pilot Duty (VA) Motor (HP)

Voltage Voltage NO (NC), VAC NO (NC), VAC NO (NC),VAC NO (NC),VAC

120 VAC 5 VAC 16 (5.8), 120 96 (34.8), 120 470 (290),120 1 (1/4), 120

50/60 HZ maximum 8 (2.9), 240 48 (17.4), 240 470 (290),240 1 (1/4), 240

BURNER

CUT-OFF LEVEL

AT CAST LINE

(22mm)

BURNER OFF

BURNER ON

7/8"

PUMP

OFF

BURNER

OFF BURNER

CUT-OFF LEVEL

AT CAST LINE

21/16"

(52 mm) NORMAL BOILER

WATER LINE

13/16"

(30 mm)

PUMP OFF

PUMP ON

NORMAL BOILER

WATER LINE

When the water level in the boiler drops below the

middle probe, the circuit is broken which will acti-

vate the pump relay.When the water level rises

above the top probe, the circuit is made and the

pump relay is deactivated.

The distance between the top and middle probes is

adjustable. By turning the flange one bolt hole

clockwise, the distance can be increased by 7/16”.

When the water level in the boiler drops below the

bottom probe, the circuit is broken which will deacti-

vate the burner relay.When the water level is

restored to the middle probe, the burner relay will

be activated for auto reset controls only.

SWITCH SETTINGS:

Values are ± 3/16”(6mm).

Flange in “B”PositionFlange in “A”Position

Burner Off has adjustable 0-60 second time delay.

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 15/8(41) 3/4(19)

Pump On 7/8(22)

Burner On 7/8(22) 7/8(22)

Burner Off 0 (0)

BURNER

CUT-OFF LEVEL

AT CAST LINE

(22mm)

BURNER OFF

BURNER ON

7/8"

PUMP

OFF

BURNER

OFF BURNER

CUT-OFF LEVEL

AT CAST LINE

15/8"

(41mm)

NORMAL BOILER

WATER LINE

3/4"(19 mm)

PUMP OFF

PUMP ON

NORMAL BOILER

WATER LINE

Burner Off has adjustable 0-60 second time delay.

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 21/16 (52) 13/16(30)

Pump On 7/8(22)

Burner On 7/8(22) 7/8(22)

Burner Off 0 (0)

If the control will be the primary low

water fuel cut-off, size the steam (top)

and water (bottom) equalizing pipe lengths

so that the horizontal cast line on the body

is 13/8”(35mm) below the boiler’s normal

water level, but not lower than the

lowest safe permissible water level, as

determined by the boiler manufacturer.

If the control will be the secondary low

water fuel cut-off, size the steam (top) and

water (bottom) equalizing pipe lengths so

that the horizontal cast line on the body is

at or above, the lowest safe permissible

water level, as determined by the boiler

manufacturer.

STEP 1 - Determine the Elevation at Which the

Low Water Cut-Off/Pump Controller Must be Installed

INSTALLATION –

TOOLS NEEDED:

Two (2) pipe wrenches, one (1) flatblade screw-

driver, and pipe sealing compound. IMPORTANT: Follow the boiler manufacturer's

instructions along with all applicable codes and

ordinances for piping, blow down valve and water

gauge glass requirements.

13/8"

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

NORMAL BOILER WATER LINE

AS A PRIMARY

LOW WATER CUT-OFF/PUMP

CONTROLLER

BURNER CUT-OFF LEVEL AT CAST LINE

LOWEST

PERMISSIBLE

WATER LEVEL

(35mm)

WATER

EQUALIZING

PIPE

BLOW DOWNVALVE

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

BLOW DOWNVALVE

BURNER CUT-OFF LEVEL AT CAST LINE

LOWEST

PERMISSIBLE

WATER LEVEL

BURNER OFF

WATER

EQUALIZING

PIPE

AS A SECONDARY

LOW WATER CUT-OFF/PUMP

CONTROLLER

BLOW DOWNVALVE

b. Install a water gauge glass (J).

Note: Gauge glass and tri-cocks

not included with product.

a. Mount and pipe the low water cut-off (D) on a

vertical equalizing pipe (E) at the required ele-

vation level, as determined in Step 1.

Install blow down valves directly below the

lower cross of the water equalizing pipe (F).

STEP 2 - Installing the Low Water Cut-Off

a. Install a water column (H) (not included with

product) for all models except Series 157E,

(with integral water column).

STEP 3 - Installing a Water Gauge Glass (Required on all steam boilers)

Series 157E All Other Models

GAUGE GLASS

(TYPICAL) TRI-COCK

(TYPICAL)

Cover

Loosen screws (A) and remove cover.

BCOM

BNC

BNO

PCOM

PNC

PNO

BCOM

BNC

BNO

PCOM

PNC

PNO

Secs.

060

Secs.

Probe Wires

Control Box

•Disconnect probe wires (red, blue, yellow) from

circuit board.

•Remove 4 screws (B) connecting control box to

brackets, lifting control box from brackets.

Remote Mounting of the Control Box

Probes

Disconnect wires from probes.

Cover Plate

Brackets

Offset Connector

•Remove 6 screws (C) connecting brackets

and cover plate to probe housing.

•Remove offset connector from cover plate.

Only loosen upper nut to remove probe wire.

NOTE

Upper Nut

•Mount Control Box in a suitable location near

the boiler’s main electrical panel.

•Install electrical conduit between Probe

Housing and Control Box.

•Pull four (4) wires through conduit.

Boiler sight glass must be visible from location of

Control Box and must be within 25 feet of Control

Box.

NOTE

Refer to and follow local codes and standards

when selecting conduit and electrical fittings.

Wires from Probe Housing to Control Box must be

in their own conduit. If they are run in conduit with

other wires, there may be interference that can

affect the performance of the control.

NOTE

Wire must be 18 AWG stranded with glass braided

silicone jacket (UL 3071) suitable for high temper-

ature (200˚C) service.

NOTE

Screws

Plate Ground

Blue/Top

Yellow/Middle

Red/Bottom

Connect wires between Control Box and Probes

as follows.

Probes Control

Top/Blue Top/Blue

Middle/Yellow Middle/Yellow

Bottom/Red Bottom/Red

Plate Ground Chassis Ground

•Attach cover plate to probe housing.

•Use knockout plug from probe housing to plug

the hole in the cover plate.

•Proceed to Electrical Wiring Section to complete

wiring to Burner and Pump/Valve circuits.

Wire connections at Probes (1/4”Ring Terminal) and

Control Panel (22-18 Female Spade) must be made

with connectors suitable for high temperature (200˚C)

service.

NOTE

BCOM

BNC

BNO

PCOM

PNC

PNO

BCOM

BNC

BNO

PCOM

PNC

PNO

Secs.

060

Secs.

BCOMBCOM

BNCBNC

BNOBNO

PCOMPCOM

PNCPNC

PNOPNO

BCOM

BNC

BNO

PCOM

PNC

PNO

6060

3030

SecsSecs.

06060

3030

SecsSecs.

Probe wires

Control Box

Chassis Ground

STEP 4 - Electrical Wiring

•To prevent electrical shock, turn off the electrical power before making electrical connections.

•This low water cut-off must be installed in series with all other limit and operating controls installed on the

boiler. After installation, check for proper operation of all of the limit and operating controls, before leaving

the site.

•Boiler manufacturer schematics should always be followed. In the event that the boiler manufacturer’s

schematic does not exist, or is not available from the boiler manufacturer, refer to the schematics provided

in this document.

Failure to follow this warning could cause electrical shock, an explosion and/or a fire, which could result in

property damage, personal injury or death.

WARNING

Cover Removal and Installation Procedure

a. To remove cover, use a flatblade screwdriver to

loosen screws and remove the cover (K).

b. To reconnect cover, slide over brackets and tighten

screws using a flatblade screwdriver.

c. Following the appropriate wiring diagram (refer to

page 11) based on your application requirements,

and using BX armored cable or Thinwall electrical

metal tubing connector fittings, make electrical

connections to the junction box (L).

IMPORTANT: There must be a minimum space

of 2”(13mm) between connector fittings and

electrical live metal parts.

Circuit Board Layout

BCOM

BNC

BNO

PCOM

PNC

PNO

BCOM

BNC

BNO

PCOM

PNC

PNO

Secs.

060

Secs.

BCOM

BNC

BNO

PCOM

PNC

PNO

060

Secs.

Probe Connections Bottom

Red

Middle

Yellow

Top

Blue

0-60 Second Adjustable

Burner Off Delay

110Volt Input

from Boiler

Circuit Manual Reset

(If applicable)

LowWater

LED

Red

Power

LED

Green

Test

Switch

Burner

Terminals

Pump

Terminals

BCOM

BNC

BNO

PCOM

PNC

PNO

Probe LED's

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