Xylem McDonnell & Miller 1575 Series Bedienungsanleitung

INSTRUCTION MANUAL

MM-286D

212634

• Before using this product read and understand instructions.

• Save these instructions for future reference.

• Allworkmustbeperformedbyqualiedpersonneltrainedintheproperapplication,

installation,andmaintenanceofplumbing,steam,andelectrical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.

• Werecommendthatsecondary(redundant)LowWatercut-offcontrolsbeinstalledonallsteam

boilerswithheatinputgreaterthan400,000BTU/houroroperatingabove15psiofsteam

pressure. At least two controls should be connected in series with the burner control circuit to

provide safety redundancy protection should the boiler experience a low water condition.

Moreover,ateachannualoutage,thelowwatercut-offsshouldbedismantled,inspected,

cleaned,andcheckedforpropercalibrationandperformance.

• 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re,donotusethislowwatercut-off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.

• ThisproductcanexposeyoutochemicalsincludingLead,whichisknowntotheStateof

Californiatocausecancerandbirthdefectsorotherreproductiveharm.Formore

informationgoto:www.P65Warnings.ca.gov.

Electronic Control Unit

Burner Relay Time Delay

The field-adjustable time delay (DOB) helps to

p r event nuisance bu r ner shut-dow n . The number

of seconds water needs to be off the longest probe

b e fore the bu r ner will shut down can be set

b e t w een 0 and 60 seconds.

Redundant Low Water Cut-Off

When the boiler water drops below the middle

p r o b e, a 3 minute timing circuit will be activa t e d . I f

water does not return to the middle probe within

three minu t e s, the bu rner relay will shut dow n . T h e

Red LED will flash once eve r y second if this

condition occurs.

• Automatic Reset units will automatically reset

when the water level is restored to the middle probe.

N OT E : The timing circuit will automatically reset

if the water level returns to the middle probe within

3 minu t e s.

Redundant Pump Off

The pump relay will be activated, turning the pump

on after water drops below the middle probe. If the

water level is not restored to the top probe within 3

m i nutes the pump relay will be deactivated, shutting

off the pump. After the pump relay is deactiva t e d ,

n o r mal operation is resumed. Water must again

drop off the middle probe to activate the pump

r e l ay. There is no LED signal for this occura n c e.

A d j u s t a ble Pump Diffe r e n t i a l s

The water level positions for turning the pump on

and off and obtaining the needed pump diffe r e n t i a l s

are changed by cutting the length of the middle and

s h o r test probes.

Previous controls should never be installed on a new system. Always install new

•

controls on a new boiler or system.

CAUTION:

A more frequent replacement interval may be necessary based on the condition of

the unit at time of inspection. McDonnell Miller s warranty is one (1) year from date

of installation or two (2) years from the date of manufacture.



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

•

SPECIFICATIONS

M a x i mum Pressure: 150 psi (10.5 kg/cm2)

Burner Delay (DOB): 0 to 60 seconds (Field Adjustabl e )

Ambient Te m p : 120˚F Max.

N OT E : The circuit board is protected with a sensor which will

shut down the unit if the temperature at the board ex c e e d s

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

the board drops below 167˚F (75˚C).

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

M a x i mum System Water Te m p e r a t u r e : 406˚F (208˚C)

M a x i mum System Water Pressure: 250 psi (17.6 kg/cm2)

M a x i mum System Steam Pressure: 250 psi (17.6 kg/cm2)

All probes in the Series 1575 units are sent from the factory pre-cut to

9" length (229mm). Any of the probes can be used as the low water

cut-off level probe.The 9" length positions the probe at the low water

cut-off cast-in line on the chamber body.The remaining probes can be

‘cut to length’ using a metal cutting saw to achieve desired pump control

(pump on/pump off) and pump differential levels. Approximately 1 inch

of the metal probe rod should be exposed below the PTFE coating.

4-3/16"

(106.4)

4-3/8"

(111)

2-1/2"

(63.5)

3-1/4"

(82.5)

3-1/4"

(82.5)

3-1/8"

(79.4)

1" NPT

11-1/2"

(292)

18-5/8"

(473)

1/2" NPT

CONDUIT

CONNECTION 1"

NPT

1" NPT

1/2" NPT

ELECTRODE

PRE-CUT

9" PROBE ROD

CUT AS

NEEDED

When the water level in the boiler drops below the

middle probe, the circuit is broken which will

a c t i vate the pump relay, turning the pump on. W h e n

the water level rises above the shortest probe, the

circuit is made and the pump relay is deactiva t e d ,

t u r ning the pump off.

When the water level in the boiler drops below the

longest probe, the circuit is broken which will

d e a c t i vate the bu rner relay, turning the bu rner off.

When the water level is restored to the middle

p r o b e, the bu r ner relay will be activated (bu rner on)

for auto reset controls only.

SWITCH SETTINGS:

Chamber

STEP 1 - Installation

TOOLS NEEDED:

One (1) pipe wrench, one (1) flathead screwdriver and/or 11/32" nut driver,

one (1) metal-cutting saw, one (1) 9/16" socket or wrench and pipe sealing compound.

If the control will be the primary low water fuel

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

equalizing pipe lengths to the chamber so that the

cut-off level mark is 11/2" (38mm) 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, s i z e the steam (top) and water (bottom)

equalizing pipe lengths to the chamber so that the

cut-off level mark is at or abov e the lowest safe

p e r m i s s i bl e water level, as determined by the

boiler manufacturer.

• Mount C o n t rol Box in a suitable location near

the boiler’s main electrical panel.

• Install electrical conduit between electrical

enclosure of the P robe Chamber and

C o n t rol 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

R e fer to and fo l l ow local codes and standard s

when selecting conduit and electrical fittings.

Wires from Electrical Enclosure of the Pro b e

Chamber to Control Box must be in their own

c o n d u i t . 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

SPECIFICATIONS (cont.)

Circuit Board Layout

STEP 2 - 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

C o ver Removal and Installation Pro c e d u r e

a . To remove cove r, use a flathead screw d ri ver to

loosen screws and remove the cover (K).

b . To reconnect cove r, slide over bra ckets and tighten

s c r e ws using a flathead screw d ri ve r.

c . Following the appropriate wiring diagram (refer to

page 7) 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).

I M P O RTA N T:There must be a minimum space

of 2 " (13mm) between connector fittings and

electrical live metal parts.

BCOM

BNC

BNO

PCOM

PNC

PNO

BCOM

BNC

BNO

PCOM

PNC

PNO

Secs.

0 60

Secs.

BCOM

BNC

BNO

PCOM

PNC

PNO

060

Secs.

Probe Connections

Bottom

Red

Middle

Yellow

Top

Blue

0-60 Second Adjustable

Burner Off Delay

110 Volt Input

from Boiler

Circuit Manual Reset

(If applicable)

Low Water

LED

Red

Power

LED

Green

Test

Switch

Burner

Te r minals

Pump

Te r minals

BCOM

BNC

BNO

PCOM

PNC

PNO

Probe LED's

• Connect wire “ a ” from power supply to

t e rminal “ H ” .

• Connect wire “ b ” from neutral supply to

t e rminal “ N ” .

• Connect wire “ c ” from pump control circuit

to terminal “ P N O ” .

• Connect wire “ d ” from pump control circuit

to terminal “ P C O M ” .

• Connect wire “ e ” from bu rner control

circuit to terminal “ B N O ” .

• Connect wire “ f ” from alarm control circuit

to terminal “ B N C ” .

• Connect wire “ g ” from bu rner or alarm

control circuit to terminal “ B C O M ” .

WIRING DIAGRAMS

Low Water Cut-Off,Alarm and Pump Up Control

• Connect wire “ a ” from power supply to

t e rminal “ H ” .

• Connect wire “ b ” from neutral supply to

t e rminal “ N ” .

• Connect wire “ c ” from pump #1 control

circuit to terminal “ P N O ” .

• Connect wire “ d ” from pump #1 control

circuit to terminal “ P C O M ” .

• Connect wire “ e ” from pump #2 control

circuit to terminal “ B N C ” .

• Connect wire “ f ” from pump #2 control

circuit to terminal “ B C O M ” .

Dual Pump Control

• Connect wire “ a ” from power supply to

t e r minal “ H ” .

• Connect wire “ b ” from neutral supply to

t e r minal “ N ” .

• Connect wire “ c ” from va l ve control circuit

to terminal “ P N O ” .

• Connect wire “ d ” from va l ve control circuit

to terminal “ P C O M ” .

• Connect wire “ e ” from bu rner control

circuit to terminal “ B N O ” .

• Connect wire “ f ” from alarm control circuit

to terminal “ B N C ” .

• Connect wire “ g ” from bu rner or alarm

control circuit to terminal “ B C O M ” .

Motorized Valve and Low Water Cut-Off

FROM BURNER OR ALARM

CONTROL CIRCUIT

TO ALARM

CONTROL CIRCUIT

TO BURNER

CONTROL CIRCUIT

FROM PUMP UP

CONTROL CIRCUIT

TO PUMP UP

CONTROL CIRCUIT

NEUTRAL

HOT

BCOM

BNC

BNO

PCOM

PNC

PNO

FROM PUMP #1

CONTROL CIRCUIT

FROM PUMP #2

CONTROL CIRCUIT

TO PUMP #2

CONTROL CIRCUIT

TO PUMP #1

CONTROL CIRCUIT

NEUTRAL

HOT

BCOM

BNC

BNO

PCOM

PNC

PNO

FROM VALVE

CONTROL CIRCUIT

TO VALVE

CONTROL CIRCUIT

NEUTRAL

HOT

BCOM

BNC

BNO

PCOM

PNC

PNO

FROM BURNER OR ALARM

CONTROL CIRCUIT

TO ALARM

CONTROL CIRCUIT

TO BURNER

CONTROL CIRCUIT

STEP 3 - Testing

Procedure

Turn on power to the boiler and pump circuits.With the boiler empty,

the control will be activated (Green LED On) and the pump should turn

on. The burner should stay off (Red LED On).

NOTE: If Green and Red LED’s flash alternately, the probes are out of

sequence, indicating they are not working correctly. Turn off power and

check probe wires for proper connection.

•Green light on: Unit has power

•Red light on: Boiler water dropped below the longest probe for longer than the adjustable time delay

setting. The burner has shut down.

•Red light flashing every second: Boiler water was below the middle probe for more than three

minutes and the burner has shut down.

•Auto reset units will automatically reset when the boiler water returns to the middle probe.

•Red light and green light flashing alternately every 1/2 second. Probes are out of sequence.

Unit has shut down. Unit will automatically reset when condition has cleared or been corrected.

•Red light and green light flashing simultaneously every 1/2 second: The PCB is too hot and the unit

has shut down. The unit will automatically restart when the PCB has cooled sufficiently.

•When using the “TEST” button, the green light will flash once per second during the time delay interval.

The time delay setting can be determined by counting the number of flashes.

Green Light – Shows status of shortest probe

Yellow Light – Shows status of middle probe

Red Light – Shows status of longest probe

•If the light is on, the probe is in water and probe resistance is well below the threshold.

•If the light is flashing every 1/2 second, the probe is in water, but probe resistance is near (just below)

the threshold.

•If the light is flashing every 2 seconds, the probe is out of water, but probe resistance is near (just above)

the threshold.

•If the light is off, the probe is out of water and probe resistance is well above the threshold.

I M P O RTA N T:Follow the boiler manufacturer’s start-up and operating instructions along with all applicable

codes and ordinances.

If the burner comes on, i m m e d i a t e ly turn the boiler off and make the

n e c e s s a ry corrections.

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

result in property damage, personal injury or death.

WARNING

Exterior Lights

Interior Lights

OFF

Adjusting Burner Delay (DOB)

The boiler should begin to fill with wa t e r.

N OT E : If water does not start filling the boiler,

immediately turn off the the boiler and make

the necessary corrections.

For Automatic Reset Models:

When the water level reaches the level of the

middle probe, the burner circuit should be acti-

vated and the Red LED should turn off. (Pump

#2 should turn off with Dual Pump Applications).

When the water level rises to the level of the top

p r o b e, the pump relay will be de-activa t e d .

Depending on the application, this will either turn

off the pump or close a va l ve.

The number of seconds that water must be off the

s h o r test probe before the bu rner will turn off is

a d j u s t a ble from 0 to 60 seconds. The unit is fa c t o r y

set at 0 seconds. To adjust, turn the adjusting screw

c l o ckwise using a small flatblade screw d r i ver to the

d e l ay time desired.

Fo l l owthe bl ow down procedure found on page 11

to ve r ify opera t i o n .

I N S TA L L ATION COMPLETE

If the time delay on the primary control set is too long,

the manual reset secondary LWCO may turn off the

boiler before the primary control turns off the boiler.

If this occurs, shorten the time delay by turning the

adjustment screw counter- c l o c kwise from the new setting.

NOTE

BCOM

BNC

BNO

PCOM

PNC

PNO

BCOM

BNC

BNO

PCOM

PNC

PNO

Secs.

0 60

Secs.

BCOM

BNC

BNO

PCOM

PNC

PNO

060

Secs.

Probe Connections

Bottom

Red

Middle

Yellow

Top

Blue

0-60 Second Adjustable

Burner Off Delay

110 Volt Input

from Boiler

Circuit Manual Reset

(If applicable)

Low Water

LED

Red

Power

LED

Green

Test

Switch

Burner

Te r minals

Pump

Te r minals

BCOM

BNC

BNO

PCOM

PNC

PNO

Probe LED's

Green LED does not turn on.

•There may be no power to the unit. Check wiring

connected to ‘H’ and ‘N’ terminals on circuit board.

Verify that the control is being powered when the

boiler power is turned on.

Red & Green LEDs flash alternately every

1/2 second.

•The probes are out of sequence. Check probe

wires and connections.

Red & Green LEDs flash simultaneously every

1/2 second.

•The temperature at the circuit board is higher than

170˚F. Removing the control box cover may cool

the control enough for it to operate.If the control

works with the cover removed, the control box

should then be mounted remotely.

Pump does not turn off when water level is above

shortest probe.

•The probes may be fouled with dirt, scale or rust.

Remove head assembly to inspect probes.

•The wiring connections for the pump may not be

connected properly. Check wiring at terminals.

Pump does not turn on when water level is below

the middle probe.

•The probes may be fouled with dirt, scale or rust.

Remove and inspect probes.

•The wiring connections for the pump may not be

connected properly. Check wiring at terminals.

Burner does not turn off when water level is

below longest probe.

•The probes may be fouled with dirt, scale or rust.

Remove and inspect probes.

•The wiring connections for the burner may not be

connected properly. Check wiring at terminals.

• Make sure the time delay is not causing delay of

burner off.

The 1575 control does not turn off the burner

before the secondary (manual reset LWCO) turns

off the burner.

•The burner off time delay (DOB) may be set for too

long of a delay.

During operation, the burner does not turn off

when the water level is below the longest probe.

•The burner off time delay (DOB) may be set for too

long of a delay.

•The boiler water may be priming or foaming. Clean

boiler water and/or consult with chemical treatment

specialist.

During operation, the burner turns off even when

the pump has turned on or the motorized valve

has opened.

•Pump capacity may not be sufficient or there may

be restrictions in the feedwater piping. Check pump

capacity and piping.

•The motorized valve stroke-to-open time may be

too long. Check valve motor timing.

Troubleshooting

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