Xylem McDonnell & Miller 42S-N Series Bedienungsanleitung

INSTRUCTION MANUAL

MM-231G

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 13/8(35) 3/4(19)

Pump On 5/8(16)

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

Burner Off 0 (0)

NORMAL BOILER

WATER LINE

BURNER

CUT-OFF LEVEL

AT CAST LINE

7/8" (22 mm)

BURNER ON

BURNER OFF CUT-OFF

LEVEL

NORMAL BOILER

WATER LINE

PUMP

OFF

BURNER

OFF BURNER

CUT-OFF LEVEL

AT CAST LINE

1 3/8" (35mm)

CUT-OFF

LEVEL

NORMAL BOILER

WATER LINE

CUT-OFF

LEVEL

PUMP OFF

PUMP ON

3/4" (19mm)

OPERATION

Maximum Pressure: 50 psi (3.5 kg/cm2)

Electrical Ratings

Settings and Differential Pressures

Values are ± 8” (3.2mm).

Series 42S

50 psi

(3.5 kg/

cm2)

Pressure

Motor Horsepower

Voltage Hp

120 VAC 1/3

240 VAC 1/3

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.



•

The 42S and 42S-N controls are

installed so that the horizontal cast line

on the body is 1aa” (35mm) below the

boiler’s normal water level, but not

lower than the lowest, safe permissi-

ble water level, as determined by the

boiler manufacturer.

The 42S-A controls are installed in boil-

er’s gauge glass tappings. The horizontal

cast line should be approximately 1” (25

mm) above the bottom of the glass.

Verify that this level is not below the

lowest, safe permissible water level,

as determined by the boiler manufac-

turer.

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) flathead 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

BLOW DOWN VALVE

NORMAL BOILER

WATER LINE

LOW WATER

CUT-OFF/PUMP CONTROLLER

BURNER CUT-OFF

LEVEL AT CAST LINE

LOWEST

PERMISSIBLE

WATER LEVEL

(35mm)

WATER

EQUALIZING

PIPE

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

BLOW DOWN VALVE

LOW WATER

CUT-OFF/PUMP CONTROLLER

BURNER CUT-OFF

LEVEL AT CAST LINE

WATER

EQUALIZING

PIPE

13/8"

NORMAL BOILER

WATER LINE

LOWEST

PERMISSIBLE

WATER LEVEL

(35mm)

Series 42S

Series 42S-N

For 42S-A Control

INVERTED “Y” CASTING

Note:

Reverse union

nuts, packing

and plug.

Tighten top

nut securely.

c. Determine the position of the black ‘Y’ casting (H).

If gauge glass tappings (F) and (G) are less

than 10 5⁄8" (270 mm) apart, install the black

‘Y’ casting (H) as depicted in the diagram to the

top right.

If gauge glass tappings (F) and (G) are

greater than 10 5⁄8" (270 mm) apart, invert

the black ‘Y’ casting (H) as depicted in the

diagram to the bottom right.

If gauge glass tappings (F) and (G) are

greater than 14" (356 mm) apart, invert the

black ‘Y’ casting (H) as depicted in the diagram

to the bottom right and install a longer brass nipple (J).

a. Drain the water in the boiler until the level falls below the lower

gauge glass connection (C). Allow the boiler to cool to 80˚F

(27 ˚C) and allow the pressure to release to 0 psi (0 bar).

b. Remove the water glass (D) and gauge glass connections (E)

from the boiler.

STEP 2 - Installation

a. Using a pipe wrench, unscrew shipping block (A) from

upper 1” NPT tapping (B) of the control body.

f. Reinstall gauge glass and trim to ‘Y’ fittings (K, L).

Note: Make sure gauge glass valves are fully open.

d. • Install upper ‘Y’ fitting (K) into upper 1/2” NPT

gauge glass tapping on boiler.

• Install lower ‘Y’ fitting (L) into 1/2” NPT gauge

glass tapping on boiler.

YAA

e. • Screw reducer bushing (O) and nipple (N) into top 1” NPT

tapping (P).

• Screw reducer bushing (Q), nipple (R) and blow-off

valve (S) into bottom 1” NPT tapping (T).

• Screw lower union tailpiece (V) with nut (U) into either

1/2” NPT lower tapping (W, X). Screw 1/2” NPT pipe

plug into unused lower tapping.

• Screw upper union tailpiece (Z) with nut (Y) into ‘Y’

casting (M) 1/2” NPT tapping (AA).

• Slide ‘Y’ casting (M) and compression nut (BB) over

nipple (N).

• Connect upper and lower union nuts (U, Y) to ‘Y’ fittings

(K, L) installed in boiler gauge glass tappings.

Note: ‘Y’ fitting (M) will have to be moved up or down

nipple (N) to mate union halves.

• Tighten compression nut (BB).

For 42S Control

a. Mount and pipe control (CC) on vertical equalizing

pipes (DD) at the required elevation as determined

in Step 1.

b. Install a full ported ball valve (NN) directly below the

lower cross of the water (lower) equalizing line.

For 42S-N Control

a. Install fitting (EE) provided in top 1” NPT tapping.

Orient 1/2” NPT tapping (FF) with 1/2” tapping on

control (GG).

b. Mount and pipe control (HH) on vertical equalizing

pipes (JJ) at the required elevation as

determined in Step 1.

c. Install gauge glass and other trim such as

pressure gauges or pressure controls following

manufacturer’s instructions. Note: These items

are not provided and must be purchased

separately.

d. Install pipe plugs in all unused tappings on

control body and fittings.

e. Install a full ported ball valve (NN) directly below

the lower cross of the water (lower) equalizing line.

STEP 3 - 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.

• 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

Boiler feed pump off,

burner on.

Boiler feed pump on,

burner on.

Boiler feed pump on,

burner off.

12 5 6 12 5 6 12 5 6

b. Following the appropriate wiring

diagram, (refer to page 8)

based on your application

requirements, and using BX

armored cable or Thinwall elec-

trical metal tubing connector fit-

tings, make electrical connec-

tions to the junction box (LL).

Note: Follow local codes and stan-

dards when selecting the types of

electrical fittings and conduit to

connect to control.

Snap Switches

(Series 42S)

IMPORTANT: There must be a

minimum space of 1/2” (13mm)

between connector fittings and

electrical live metal parts.

a. Using a flathead screwdriver, remove the

junction box cover (KK).

WIRING DIAGRAMS

Low Water Cut-Off Only

1. Main Line Switch - For burner circuits within the

switch’s electrical rating.

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.

NOTE: To help insure most effective operation,

balance boiler feed pump(s) to deliver required water

feed rate to match boiler steaming requirements.

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 56

SEE PUMP

CONTROL

CIRCUIT

TO BURNER CONTROL CIRCUIT

HOT

12 56

LOAD

LINE

SEE PUMP

CONTROL

CIRCUIT

12 56

LOAD

LINE

12 56

LOAD

LINE

Combination Pump Control, Low Water Cut-Off and Alarm

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

the burner circuit exceeds the switch’s electrical

rating.

LINE LOAD

12 56

STEP 4 - Testing

a. Turn on the electric power to the boiler. With the boiler empty

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 applicable

codes and ordinances.

This control is factory calibrated for specific applica-

tions. The following testing procedure is only meant

to serve as a verification of proper operating

sequence.

Dimensions provided are typical for a boiler not being

fired and/or not at pressure. Actual operating ranges

are shown on page 2 in the "Operation" section.

OFF

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

(22mm)

7/8"MM

b. The boiler should begin to fill with water.

Watch the gauge glass (D) until the water

level reaches approximately d” (22mm)

above the horizontal cast line (MM) on the

low water cut-off. When the water level

reaches approximately d” (22mm) the

burner should come on.

IMPORTANT: If water does not start filling the

boiler, immediately turn off the the boiler and

make the necessary corrections.

c. Re-attach the junction box cover (KK).

To prevent serious personal injury from steam and hot water during blow-down, connect piping to

the discharge side of the blow-down valve to avoid exposure to steam discharge.

Failure to follow this caution could cause personal injury.

CAUTION

When the water level is at its normal level

and the burner is on, slowly open the blow

down valve (NN) until it is fully open. Watch

the gauge glass (D) to see that the water

level drops. Close the valve after verifying

that the pump comes on and the burner

shuts off. If this does not occur, immediately

shut off the boiler and correct the problem

and retest.

INSTALLATION COMPLETE

13/8"

(35 mm)

DMM

c. Continue watching the gauge glass (D)

to see that the water continues to rise to

approximately 1a” (35mm) above the

horizontal cast line (MM). The pump

should shut off.

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