Gems Sensors & Controls DF Operating Manual

Form 222B

Sheet P/N 100205-1

Rev. F

Warrick Dual Function Control

®

Installation and Operation Bulletin

This bulletin should be used by experienced personnel as a guide to the installation of Dual Function Controls. Selection or
installation of equipment should always be accompanied by competent technical assistance. We encourage you to contact
Gems Sensors or a representative if further information is required.

Specifications

Control Design: Open-board design (no housing)
Contact Design:

Limit Control - 1 SPDT (1 form C), dry contacts
Level Control - 1 SPDT (1 form C), dry contacts

Contact Ratings: 10A @120/220/240-VAC resistive (120°F),
1A @ 120, 208/240,240 resistive (150°F), 1/3 Hp @ 120,
208/240, 240 VAC
Contact Life: Mechanical - 5 million operations
Electrical - 100,000 operations minimum at rated load
Supply Voltage: 24, 120, 220, or 240 VAC models,+10%/-15%,
50/60 Hz. 208/240 Model: 187V Min to 242V Max, VAC 50/60
Hz
Power Consumption: 24/120/208/220/240-VAC with both
relays energized ~ 4.4 VA.
Secondary Circuit: 2.3 VAC RMS voltage on probes,
< 1 milliampere source capability.
Sensitivity: Factory programmed to 4.7K, 10K, 26K, 50K, or
100K Ohms

Operating Ambient Temperature Range: -40°F to +150°F
(-40°C to +65°C)
Terminals: Probe connections 3/16" male quick connects, Line

and Power connections 1/4" male quick connects
Time Delays: Standard, 0.5 seconds rising level, LLCO probe,
3 seconds lowering level.
Listings: Entire control carries U.L. Limit Control Listing (UL-

353) for supply voltages of 120-VAC and below.

Standoff Options

There are 5 standoff styles offered by Gems to
connect circuit boards to panels.

PCB Mount Side

1/8”

Panel

1/16”
Panel

Retrofit

Standoff

Panel Mount Side

Circuit
Board

Standoff

Standoff

Screw
Mount

Installation

1. Drill five 0.187” holes in customer supplied back plate
using stick on template supplied with control.
Standard standoffs are designed for back plate
thickness of 0.062 (1/16"). Standoffs are available for
back plates of 0.125 (1/8") nominal thickness. If
retrofit plate standoffs are used, drill 5 (five) 0.250 dia.
Holes in proper locations.

2. Install five standoffs into back plate. Install two
support standoffs into circuit board. CAUTION: Be
careful not to bend or flex the circuit board during
installation as this can damage the control. Do not
push down on transformer or relays during installation.
Install circuit board onto standoffs by gently pushing
down on circuit board at board edges near standoff
locations until board is fully seated. See sketch for
proper installation. Install control in appropriate
enclosure.

3. Wire controls per wiring diagram, following N.E.C. and
local codes. Use appropriately sized spade terminals.

mm]

]
m

.5
3

6m

[ 0
"
0 6
0

.5

" [46.3

2

5
2

.8
1

0.200" [5.08mm]

Dimensional Drawing

m
m ]

8

5.0
[

"
00

2

0.

0.950" [24.13mm]

2.433" [61.80mm]

3.180" [80.77mm]

4.185" [106.30mm]

4.400" [111.76mm]

Support
Standoff
Locations

Wiring Diagram

L1

AC Power

L2

Second before control energizes. This function can be wired
for single level service by using only the H terminal.

L1

LLCO

G

Note: For single level service, only High Probe is required

H

L

FILL RELAY

NC

COM

RESET SW.

NO

RESET/TEST Switch Optional

L2

LLCO Probe

Low Probe
High Probe

G

LLCO RELAY

NC

COM

NO

IF METALLIC, TANK MAY BE USED
INSTEAD OF REFERENCE PROBE

Reference Probe

Operation

AUTOMATIC RESET (Reset Switch terminals not wired) When the liquid rises to the

electrode on terminal LLCO, the control energizes, changing state of the load contacts.
(LED will be lit) The control remains energized until the liquid level recedes below
electrode on terminal LLCO. The control then de-energizes, (LED will not be lit) returning
load contacts to original state. Unless otherwise specified, there is a three second time
delay on decreasing level. Liquid must be below probe on terminal LLCO for a full three
seconds before control de-energizes.
MANUAL RESET (Normally closed pushbutton installed across reset terminals) When
the liquid rises to the electrode on terminal LLCO, the control will remain de-energized until
the pushbutton is depressed. Upon Reset Swtich activation, the control will energize, (LED
will be lit) changing the state of the contacts. The control remains energized until the liquid
level recedes below electrode on terminal LLCO. The control then de-energizes, (LED will
not be lit) returning load contacts to their original state. Unless otherwise specified, there is
a three second time delay on decreasing level. Liquid must be below probe on terminal
LLCO for full three seconds before control de-energizes.
H-L Function: When the liquid rises to the electrode on terminal H, the associated
relay energizes, changing the state of the load contacts. (LED will be lit). The relay
remains energized until the liquid level recedes below electrode on terminal L. The
associated relay then de-energizes, (LED will not be lit) returning load contacts to
original state. Unless otherwise specified, there is a one half second time delay on
increasing level. Liquid must be in contact with probe on terminal H for a full half-

DF XXXXX XX XX XX

DIRECT MODE BOTH FUNCTIONS

Time Delay: (Decreasing Level) LLCO level function 3 sec.
Standard.

Time Delay: (Decreasing Level) H-L level function 1-20 sec.

Time Delay: (Increasing Level) H-L level function 1-20 sec.

Optional Character: see Chart

Enclosure: 0-none, 1-NEMA 1, 4-NEMA 4, 7-NEMA 7, 12-

NEMA

Standoff Style: A-1/16” panel, B-1/8” panel, C-screw
mount, D-retrofit

Supply Voltage: 1-120VAC (+10%/-15%), 2-240VAC
(+10%/-15%), 3-24VAC (+10%/-15%), 5-220VAC (+10%/­15%), 8-208/240VAC (187 to 242 VAC Absolute Range)

Mode/Sensitivity: LLCO, H/L-Direct A-4.7K, B-10K, C-26K,
D-50K, E-100K --- LLCO, H/L-Inverse K-4.7K, L-10K, M-

26K, N-50K, P-100K

Gems Sensors Inc.
One Cowles Road
Plainville, CT 06062-1198
Tel: [phone]

LLCO Function: LLCO always functions in direct mode

INVERSE MODE

only see above for operation.

H-L Function: Associated relay energizes with power,
(LED will be lit) changing the state of the load contacts.
When the liquid rises to the electrode on terminal H,

relay de-energizes, returning load contacts to shelf

the
state. (LED will not be lit). The associated relay remains
de-energized until the liquid level recedes below electrode
on terminal L. The relay then energizes.

TEST FEATURE

Allows LLCO circuit to be tested without the need to drop the
water level in the boiler to create a dry probe condition.
Holding down the reset button for 3 seconds will allow the
LLCO circuit to trip, simulating a dry probe. The controller will
return to normal operation once the reset button is pressed a
second time.

LED Status Indicator In normal operation, the LED on the
control will either be on or off depending on the controller
state. On-board microprocessors continuously monitor for
fault conditions. In the event a fault is detected, the LED
will blink a pattern indicating the fault type. If you
experience an inoperable control and the LED is blinking,
attempt to leave the control in the blinking state and
contact the factory for assistance.

Options

Manual Reset with optional Power Outage Feature: The
Power Outage option, used in conjunction with the Manual
Reset option, eliminates the need for a manual reset in the
event of a power outage during normal boiler operation.
With the Power Outage option, if there is a loss of power
with liquid present on the LLCO probe, the control will self­reset (energize) IF liquid is still present on the LLCO probe
at the time when power is re-established. If the control did
not have liquid on the LLCO probe at the time of the power
outage, or if there is no liquid present at the time power is
re-established, the control will de-energize and remain so
until liquid again rises to the LLCO probe and the Manual
Reset pushbutton is depressed.
Time Delays associated with terminals H and L : With
time delay on increasing level, the liquid must be in contact
with the high electrode for the full duration of the time delay
before control will operate. With delay on decreasing level,
the liquid must be below the low electrode for the full
duration of the time delay before control will operate.
Time Delays associated with terminal LLCO: 3 Second
time delay on decreasing level is standard.

D

G

J

K

L

R

S

T

W

Reset

Function

x

x

x

x

x

x

x

x

N.C.

Pushbutton

x

x

Power

Outage

x

x

x

x

Retrofit

Plate

x

x

x

x

x