Xylem McDonnell & Miller 150S Series Bedienungsanleitung

Enclosure rating: NEMA 1 General Purpose

Pump Circuit Rating (Amperes)

Voltage Full Load Locked Rotor Pilot Duty

120 VAC 7.4 44.4 345 VA at

240 VAC 3.7 22.2 120 or 240 VAC

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 15/16 (24) 5/16 (8)

Pump On 5/8(16)

Burner On 5/8(16) 3/8(16)

Burner Off 1/4(6.4)

Pump Off 13/8(41) 3/4(19)

Pump On 5/8(16)

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

Burner Off 0 (0)

BURNER OFF

BURNER ON

7/8"

DIFFERENTIAL

(22mm)

PUMP

OFF

BURNER

OFF

NORMAL BOILER

WATER LINE

13/8"

DIFFERENTIAL

(35mm)

PUMP OFF

PUMP ON

3/4"

DIFFERENTIAL

(19mm)

PUMP OFF

PUMP ON

3/4"

DIFFERENTIAL

(19mm)

PUMP

OFF

BURNER

OFF

NORMAL BOILER

WATER LINE

113/16"

DIFFERENTIAL

(46mm)

OPERATION

Maximum Pressure: 150 psi (10.5 kg/cm2)

Electrical Ratings

Settings and Differential Pressures

Values are ± 8" (3.2mm).

Series 150S and 157S

150 psi (10.5 kg/cm2) Levels 150 psi (10.5 kg/cm2) Levels

0 psi

(0 kg/

cm2)

150 psi

(10.5 kg/

cm2)

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 15/16 (24) 3/8(16)

Pump On 9/16 (14)

Burner Off 0 (0) N/A

Pump Off 17/16 (37) 3/4(19)

Pump On 11/16 (17)

Burner Off - 3/8(-16) N/A

Model 150S-MD and 157S-MD

0 psi

(0 kg/

cm2)

150 psi

(10.5 kg/

cm2)

Pressure

Alarm Circuit Rating

Voltage Amps

120 VAC 1

240 VAC 1/2

Motor Horsepower

Voltage Hp

120 VAC 1/3

240 VAC 1/3

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Motorized 15/16 (24)

Valve Closed 5/16 (8)

Motorized 5/8(16)

Valve Open

Burner On 5/8(16) 3/8(16)

Burner Off 1/4(6.4)

Motorized 13/8(41)

3/4(19)

Valve Closed

Motorized 5/8(16)

Valve Open

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

Burner Off 0 (0)

BURNER OFF

BURNER ON

7/8"

DIFFERENTIAL

(22mm)

MOTORIZED

VALVE

CLOSED

BURNER

OFF

NORMAL BOILER

WATER LINE

13/8"

DIFFERENTIAL

(35mm)

MOTORIZED

VALVE

CLOSED

MOTORIZED

VALVE

OPEN

3/4"

DIFFERENTIAL

(19mm)

Values are ± 8" (3.2mm).

NOTE: Due to the slower operation of some

motorized valves, complete valve opening

or closing will occur at slightly different

levels than indicated above.

Model 158S

150 psi (10.5 kg/cm2) Levels

0 psi

(0 kg/

cm2)

150 psi

(10.5 kg/

cm2)

Pressure

Settings and Differential Pressures (continued)

150 psi

(10.5 kg/

cm2)

MOTORIZED

VALVE

OPEN

CLOSED

3/4"

DIFFERENTIAL

(19mm)

MOTORIZED

VALVE

CLOSED

BURNER

OFF

NORMAL BOILER

WATER LINE

113/16"

DIFFERENTIAL

(46mm)

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 15/16 (24) 3/8(16)

Pump On 9/16 (14)

Burner Off 0 (0) N/A

Pump Off 17/16 (37) 3/4(19)

Pump On 11/16 (17)

Burner Off - 3/8(-16) N/A

Model 158S-MD

0 psi

(0 kg/

cm2)

Pressure

150 psi (10.5 kg/cm2) Levels

NOTE: Due to the slower operation of some

motorized valves, complete valve opening

or closing will occur at slightly different

levels than indicated above.

PUMP #1

OFF

PUMP #1

NORMAL BOILER

WATER LINE

(19mm)

3/4"

DIFFERENTIAL

PUMP #2 ON

AT CAST LINE

7/8"

DIFFERENTIAL

(22mm)

PUMP #2

OFF

PUMP #1

OFF

PUMP #2

ON PUMP #2 ON

AT CAST LINE

NORMAL BOILER

WATER LINE

13/8"

DIFFERENTIAL

(35mm)

Values are ± 8" (3.2mm).

150 psi (10.5 kg/cm2) Levels

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump #1 Off 15/16 (24) 5/16 (8)

Pump #1 On 5/8(16)

Pump #2 Off

5/8(16) 3/8(16)

Pump #2 On

1/4(6.4)

Pump #1 Off 13/8(41) 3/4(19)

Pump #1 On 5/8(16)

Pump #2 Off

7/8(22) 7/8(22)

Pump #2 On

0 (0)

Model 159S

0 psi

(0 kg/

cm2)

150 psi

(10.5 kg/

cm2)

Pressure

Settings and Differential Pressures (continued)

• 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 disconnecting or making electrical connections.

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

WARNING

c. Remove the existing head mechanism (C)

from the body (D).

a. Drain water in the boiler to a level which is

below the float chamber (A). Allow the boiler

to cool to 80˚F (27˚C) and release the boiler

pressure to 0 psi (0 bar).

b. Using a flathead screwdriver, remove the junction

box cover (B). Disconnect, mark, and remove the

supply wires and conduit connections.

d. Using a scraper, remove the old gasket (E).

Clean all debris from the float chamber. The

gasket sealing surface (F) must be smooth

and clean.

STEP 1 - Preparation

INSTALLATION

TOOLS NEEDED:

One (1) pipe wrench, one (1) flathead screwdriver, one (1) scraper, and one (1) 9/16" socket or wrench.

There may be more than one source of power to the boiler.

CAUTION

d. Using a wrench, insert the eight (8) bolts and

tighten them to approximately 14-20 ft•lb

(19-27 N•m) in an alternating star pattern.

b. Align the bolt holes of the new head gasket (J)

on the sealing surface of the control body.

a. Carefully remove the new replacement head

mechanism from the carton. Handle it carefully

to prevent damage to the float rod (G).

c. Install the new replacement head (K) on the

body (D) by guiding the float into the control

body and aligning the bolt holes.

STEP 2 - Installing the Replacement Head Mechanism

IMPORTANT: There must be a

minimum space of 1/2" (13mm)

between connector fittings and

electrical live metal parts.

STEP 3 - Electrical Wiring

a. Reconnect conduit and wires which were disconnected prior to head removal.

b. Re-attach the junction box cover (B).

Note:

Cover must be installed correctly as shown

• To prevent a fire, do not use this product to switch currents over 7.4A, 1/3 Hp at 120 VAC or 3.7A, 1/3 Hp at 240

VAC, unless a starter or relay is used in conjunction with it.

• 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.

• Modification of the switch assembly before or after installation could cause damage to the boiler and/or

boiler system.

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

Switch Operation

For all Models except 158S and 159S

For Model 158S

Boiler feed pump off,

burner on, alarm off.

Boiler feed pump on,

burner on, alarm off.

Boiler feed pump on,

burner off, alarm on.

12 4 5 6 12 4 5 6 12 4 5 6

Motorized valve closed,

burner on, alarm off.

Motorized valve open,

burner on, alarm off.

Motorized valve open,

burner off, alarm on.

4 5 6

12 3 4 5

12 3

6 6

For Model 159S

Pump #1 off,

pump #2 off.

Pump #1 on,

pump #2 off.

Pump #1 on,

pump #2 on.

12 5 6 12 5 6 12 5 6

WIRING DIAGRAMS

For Motorized Valves, refer to the valve manufacturer's wiring instructions.

Pump Control Only

1. Install a starter or relay in pump control circuit,

as shown, to prevent damage to snap switch

and help insure proper switch/control operation.

Failure to do so may shorten the life of the switch

when actual amperage exceeds switch rating.

2. Connect wires from holding coil of pump starter

or relay to terminals 1 and 2 as shown.

1. Main Line Switch - For burner circuits within

the switch’s electrical rating.

2. Pilot Switch - To holding coil of a starter when

the burner circuit exceeds the switch’s electrical

rating.

12 456

ALARM

NEUTRAL

HOT

ALARM

NEUTRAL

HOT

12 4 56

12 456

SEE PUMP

CONTROL

CIRCUIT

TO NEUTRAL

TO BURNER CONTROL CIRCUIT

HOT

ALARM

12 456

LOAD

LINE (3 PHASE)

SEE PUMP

CONTROL

CIRCUIT

ALARM

12 456

LOAD

LINE

Combination Pump Control, Low Water Cut-Off and Alarm

Alarm Circuit Only

1. Low Water Alarm 2. High Water Alarm

NOTE

To help insure most effective operation,

balance boiler feed pump(s) to deliver

required water feed rate to match boiler

steaming requirements.

NOTE

For Model 159S, use terminals 5 and 6 from

starter or relay for pump #2.

Low Water Cut-Off Only

1. Main Line Switch - For burner circuits within the

switch’s electrical rating.

LINE LOAD

12 456

LOAD

LINE

2. Pilot Switch - To holding coil of a starter when

the burner circuit exceeds the switch’s electrical

rating.

To prevent serious personal injury from steam pipe blow

down, connect a drain pipe to the control opening to

avoid exposure to steam discharge.

Failure to follow this caution could cause personal injury.

CAUTION

INSTALLATION COMPLETE

Snap Switch Models

STEP 4 - Testing

OFF

a. Turn on the electric power to the boiler.The pump should go on

and the burner must remain off.

IMPORTANT: Follow the boiler manufacturer’s start-up and operating instructions along with all applica-

ble codes and ordinances.

This control is factory calibrated for specific level

settings as shown on pages 2-4 in the “Operation”

section.

The following testing procedure is only meant to

serve as a verification of proper operating

sequence.

If the burner comes on, immediately turn the boiler off and make the

necessary corrections.

Failure to follow this warning could cause an explosion or fire and

result in property damage, personal injury or death.

WARNING

b. The boiler should begin to fill with water.

As the water level rises in the sight glass,

the burner should turn on and then the

pump should turn off at appropriate levels.

For manual reset models, press the reset

button (K) when the water reaches appro-

priate level.

If the burner does not turn on or pump

turn off at appropriate levels, immediately

turn off the boiler and make necessary

corrections.

Location of Manual Reset Button

c. Blow down the control when the water in the boiler is at

its normal level and the burner is on. Follow Blow Down

Procedure found in Maintenance Section on page 11 of

these instructions.

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