Hydrolevel 700 User Manual

Low Water Cut-Of fs

500/600/700 Series

24 VAC Operating Voltage

WARNING: To prevent electrical shock or equipment damage, power must be off during installation or servicing of the control. To prevent
serious burns, the boiler should be thoroughly cooled before installing or servicing control. Only qualified personnel may install or service
the control in accordance with local codes and ordinances. Read instructions completely before proceeding.

1. Where To Install

Automatically shuts off burner in a low water condition to prevent
boiler damage.

Low maintenance. No moving parts to wear stick or hang up, as in
float devices.

Test button (500 & 600 Series) allows the burner circuit and
control to be tested without lowering the water level.

Manual reset feature (500 & 700 Series) will not lock out in power
failures.

HOT WATER BOILER
INSTALLATIONS

A

MINIMUM

WATER LEVEL

HOT WATER BOILERS: Probe must be installed at or
above the minimum safe water level established by the
boiler manufacturer. The probe may be installed directly
in the boiler (A) if a suitable tapping is available, in the
riser (B), in the header horizontally (C), or in the header
vertically (D). IMPORTANT: To assure proper drainage,
pipe diameter should be no less than 1" on installations
in vertical piping and no less than 1
horizontal piping.

B

D

C

HOT WATER
BOILER

1

⁄4" on installations in

2. Tee Options

STANDARD

REDUCING TEE

(SV Models Only)

FABRICATED TEE

TYPICAL STEAM BOILER
INSTALLATIONS

SECONDARY

LWCO

AB

STEAM BOILERS (Secondary) : Control must be installed in a suitable tapping provided in
the boiler(A), or in an equalizing line(B). The control should be located below the level of the
primary low water cut-off but above the lowest permissable water line as specified by the
boiler manufacturer.
Note: For installations in equalizing lines, Hydrolevel recommends the use of Safgard Tees
(see step 2).

LOW WATER
CUT-OFF PUMP
CONTROLLER

LOW WATER
CUT-OFF PUMP
CONTROLLER

SECONDARY
LWCO

3. Probe Installation

FOEM-TEE

(160psi)

1214C-2 TEE

(250psi)

TEE MOUNTING: If a field fabricated tee is used, make sure that the tee drains thoroughly when the

water level falls below it, and that it conforms to the spacing requirements described in Step 3.
Models equipped with the shorter EL1214-SV probe can be installed in most standard reducing tees.
Safgard cast iron tees are also available to accommodate all probe models (See page 4).

4. Control Mounting

Loosen the two control box cover bind­ing head screws and remove the cover.

Slide keyhole slots over probe mounting
screws and tighten screws (with either a
1/4" hex head driver or flat screwdriver.

Connect the ring terminal wire lead to the probe terminal
stud and secure with the lock washer and wing nut provided.

With the power removed,

wiring according to Method A or B described on next page.

Check to insure 1/4" clearance from probe to

any

surface within the boiler or tee. When
installed in a tee, the probe tip should extend
fully into the pipe run. Apply pipe sealing com­pound to threads.
Note: Use of Teflon tape is not recommended.

proceed with installation and

WIRING METHOD A: SAME POWER SOURCE FOR CONTROL AND BURNER CIRCUIT.

A1

䊴

A1 Connect the hot lead of the input

A2

voltage (24 VAC, 60 HZ) to terminal 1. Connect
the neutral lead to terminal 2. 24 VAC, 60 HZ
must be supplied to terminals 1 and 2 for inter-

2

1

P1 P2 A

nal operation of the control.

Install a jumper between terminal

A2

䊳

21

P1 P2 A

1 and terminal P1. Power from terminal P1 is
supplied to terminal P2 through the control

BURNER

NEUTRAL

POWER

SOURCE

24VAC

60HZ

HOT

A3 A4

relay when water is at the probe.

䊴

A3 Connect terminal 2 to burner circuit

BURNER

POWER

SOURCE

24VAC

60HZ

neutral. Connect terminal P2 to burner circuit in
series with other limit controls. Consult boiler

21

P1 P2 A

manufacturer instructions for proper terminal
connections. Control should be wired in series
with and before other circuits.

Optional alarm connection.

A4

䊳

1

P1 P2 A

Connect alarm common to terminal 2.
Connect alarm hot to terminal A.

Upon completion of wiring, replace control
box cover.

ALARM

BURNER

+

LIMIT

CONTROLS

NEUTRAL

HOT

0

WIRING METHOD B: SEPARATE POWER SOURCE FOR CONTROL AND BURNER CIRCUIT.

B1

BURNER

POWER

SOURCE

24VAC

60HZ

B3

NEUTRAL

HOT

NEUTRAL

HOT

2 1

BURNER
CIRCUIT

2

1

P1 P2 A

+

LIMIT

CONTROLS

P1 P2 A

0

䊴

B1Connect the hot lead of the input

voltage (24 VAC, 60 HZ) to terminal 1. Connect
the neutral lead to terminal 2. 24 VAC, 60 HZ
must be supplied to terminals 1 and 2 for inter­nal operation of the control.

Connect hot lead from the 24 VAC
or 120 VAC burner power source to

B2

䊳

terminal P1. This terminal supplies power to ter­minal P2 in normal operating conditions when
water is at the probe. Connect neutral to burner
circuit. Note: consult boiler manufacturer
instructions for proper terminal connections.

䊴

B3 Connect terminal P2 to burner

circuit in series with and before other limit con­trols.

Optional alarm connection. Connect

B4

䊳

alarm hot to terminal A. Connect alarm common
to neutral of the burner power source.

Upon completion of wiring, replace control
box cover.

BURNER

POWER

SOURCE

(24 or

120VAC)

HOT

NEUTRAL

HOT

NEUTRAL

21

BURNER
CIRCUIT

21

BURNER
CIRCUIT

P1 P2 A

+

LIMIT

CONTROLS

P1 P2 A

0

B2

B4

ALARM

WIRING METHOD C: SECONDARY CUT-OFF

When a Safgard 500/700 is used as a secondary low water cut-off on a steam boiler, the following wiring instructions should be used. The diagram below
depicts the 500/700 as a secondary control wired in series with a Safgard Model 400/CG400. Consult boiler manufacturer’s instructions for the location of a
tapping recommended for a secondary low water cut-off. CAUTION – Model 500/700 should not be used as a primary cut-off on a steam boiler.

SAME POWER SOURCE FOR CONTROL AND BURNER CIRCUIT

PRIMARY CUTOFF SECONDARY CUTOFF

MODEL 400/CG400 MODEL 500/700

21

P1 P2 A

FEEDER

24 VAC

NEUTRAL

HOT

ALTERNATE WIRING: SECONDARY CUT-OFF WITH

On some installations it may be necessary to mount the secondary cut-off at a
level in close proximity to the primary cut-off level. In these situations, when
the primary low water cut-off shuts down the boiler, the water line can settle
below the secondary cut-off causing nuisance lockouts. The wiring diagram at
the right is designed to prevent these lockouts. NOTE: This wiring method can
only be used if the power supply from the primary cut-off is 24 VAC.

BURNER
CIRCUIT

21

P1 P2 A

+

0

LIMIT CONTROLS

ALARM

CRITICAL DIFFERENTIAL

SEPARATE POWER SOURCE FOR CONTROL AND BURNER CIRCUIT

PRIMARY CUTOFF SECONDARY CUTOFF

MODEL 400/CG400 MODEL 500/70

24 VAC

BURNER

SUPPLY

VOLTAGE

24 VAC

NEUTRAL
HOT

HOT

NEUTRAL

NEUTRAL

HOT

21

P1 P2 A

BURNER
CIRCUIT

+

0

LIMIT CONTROLS

PRIMARY CUTOFF SECONDARY CUTOFF

MODEL 400/CG400

21

P1 P2 A

NEUTRAL

FEEDER

PRIMARY CUT-OFF

POWER FROM

21

MODEL 500/700

21

P1 P2 A

ALARM

P1 P2 A

TO
BURNER

OPERATING INSTRUCTIONS

700 Series:

1. With the water level above the probe, turn on the power and set the thermostat to call for

heat. The burner will fire immediately. The LED lamps should be off.

2. Slowly lower the water level below the probe. The amber light will come on and the burner
will shut down within two seconds.

3. Wait 3O seconds. The red LED lamp will come on indicating that the control is locked-out.

4. Raise the water above the probe. The red LED lamp will remain lit and the burner will

not fire.

5. Push the RESET button to reset the control and restore burner operation.

600 Series:

1. With the water level above the probe, turn on the power and set the thermostat to call for

heat. The burner will fire immediately. The LED lamp should be off.

2. Push the test button on the top of the control to simulate a low water condition. The LED
lamp will light and the burner will shut down within two seconds.

500 Series:

Follow the operating instructions for the 700 & 600 Series above.

Note: To test the manual reset feature on the 500 Series without lowering the water level:

1. Push and hold down the TEST button. The red LED lamp will come on in approximately
3O seconds indicating that the control is locked-out.

2. Once the red LED is lit, release the TEST button. The burner will not fire.

3. Push the RESET button to reset the control and restore burner operation.

Manual Reset

Automatic Reset & Test Button

Manual Reset & Test Button

BURNER
CIRCUIT

+

LIMIT CONTROLS

0

TROUBLE SHOOTING

IF THE BURNER DOES NOT SHUT DOWN

If the burner does not shut down when the water drops
below the probe:

1. Remove power immediately and re-check wiring.

2. Remove power and check for adequate clearance from

the probe to any surface within the boiler or tee.

IF THE BURNER DOES NOT FIRE

1. Make sure water is at probe and probe lead wire is

properly secured to the terminal.

2. Check for proper ground between probe and boiler
shell. Excessive use of Teflon tape or sealing com­pound may insulate the probe from the boiler shell.

3. Re-check wiring and test for correct incoming voltage.

IF THE RED LED LAMP IS ON

The red LED lamp indicates that the control is locked-out.
This feature will activate if the boiler experiences a low
water condition exceeding 30 seconds in duration.
IMPORTANT: Do not reset control until the cause of the
low water condition is corrected. CAUTION: Do not add

water until boiler is cool.

MAINTENANCE

To ensure optimum performance, inspect probe annually.
Clean any scale or build-up from the probe using a scour­ing pad or steel wool. Re-install the probe and test control
in accordance with the Operating Instructions.

FITTINGS

Controls equipped with the EL1214-SV Probe can be mounted in standard reducing tees (supplied by others). Safgard manifolds, listed below, can be used
with all probe models.

MODEL PSI SIZE

FOEM-1 160 1 1/2" x 1 1/2" x 3/4"NPT
FOEM-2 160 1" x 1" x 3/4"NPT
FOEM-3 160 1 1/4" x 1 1/4" x 3/4"NPT

1214C-2 TEE 250 1" x 1" x 3/4"NPT

FOEM MANIFOLD 1214C-2 TEE

PROBE DATA

Test Pressure: 1000 PSI, All Models

15

/16"

17/8"

1"

5

/16"

3

/4" NPT

313/16"

SQUARE

EL1214 – STANDARD MODEL – 3/4" NPT

For 1/2", order Model EL1220

1"

2"

5

/16"

EL1214-SV – 3/4" NPT

For 1/2", order No. EL1220-SV

11/16"

15

/16"

2"

SQUARE

3

/4" NPT

3"

5

/16"

17/8"

1"

49/16"

3

/4" NPT

111/16"

2"

SQUARE

EL1214-P – 3/4" NPT

DIMENSIONS SPECIFICATIONS

MAXIMUM PRESSURE: 250 PSI
INPUT VOLTAGE: 120 VAC, 60 HZ
SWITCH RATINGS: 5.8 FLA, 34.8 LRA

15/8

59/16

15/8

11/16

51/2

31/16

BACK

37/8

BOTTOM

11/8

23/8

SWITCH CONTACTS: SPDT
ALARM CIRCUIT: 50 VA @ 24 VAC

Pilot Duty

LIMITED MANUFACTURER’S WARRANTY

We warrant products manufactured by
Hydrolevel Company to be free from defects in
material and workmanship for a period of two
years from the date of manufacture or one year
from the date of installation, whichever occurs
first. In the event of any claim under this warran­ty or otherwise with respect to our products
which is made within such period, we will, at our
option, repair or replace such products or refund
the purchase price paid to us by you for such
products. In no event shall Hydrolevel Company

be liable for any other loss or damage, whether
direct, indirect, incidental or consequential. This
warranty is your EXCLUSIVE remedy and shall be
IN PLACE OF any other warranty or guarantee,
express or implied, including, without limitation,
any warranty of MERCHANTABILITY or fitness
for a particular purpose. This warranty may not
be assigned or transferred and any unauthorized
transfer or assignment thereof shall be void and
of no force or effect.

P.O. Box 1847
New Haven, CT 06508
Phone: [phone]
FAX: [phone]