Page 1
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.
The probe may be installed in the boiler above
the lowest safe water level established by the
boiler manufacturer. Most manufacturers provide a suitable opening in the side of the boiler.
Allow 1/4" clearance from the probe to any boiler
surface, tube or baffle. NOTE: Excessive use of
Teflon tape to seal probe piping threads may
insulate the control from boiler ground. This
could result in the control not operating.
Low Water Cut-Offs
For Steam Boilers
24 VAC Operating Voltage
Max. Pressure 15 psi
U.S. Patent No. 5,739,504
with
HOW TO INSTALL
1 2 3
5
1/4"
SAFE
WATER
LINE
P.O. Box 1847
New Haven, CT 06508
Phone: (203) 776-0473
FAX: (203) 773-1019
Low maintenance. No moving parts to wear stick or hang up,
as in float devices.
Solid state circuitry. Designed for the highest level of performance and reliability.
Automatically shuts off burner, after delay, in a low water
condition to prevent dry firing.
Time delay allows water to feed above the probe to a safe
operating level.
INTERMITTENT LEVEL TEST – periodically monitors settled
water level for added protection of today’s smaller steam
boilers.
CG400 Series
Loosen the two control cover binding head
screws and remove the cover. Assemble the
chassis to the probe flange and secure with the
screws provided with the probe.
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, proceed with installation and wiring
according to the instructions on page 2. Upon
completion of wiring replace control cover.
4
REMOTE MOUNTED MODELS ONLY
A. To secure mounting plate to boiler jacket,* pre-drill two 3/32" pilot holes using the mounting plate as a template. Secure plate with sheet metal screws provided. Attach control to
mounting plate by slipping keyholes in back of chassis over pre-mounted screws on plate.
Tighten screws.
B. Using a wire nut, attach a wire (min 90°C) to the pigtail lead in the control box. Attach the
other end to the probe terminal in the remote probe housing. Attach a second wire between
the ground screw on the control chassis and one of the four screws in the remote probe
housing. Note: Wires and wire nuts not provided.
*Or other suitable surface
BA
Page 2
HOW TO WIRE
MODEL CG400
1
AP2P112
BURNER
BURNER
COMMON
POWER
SOURCE
24VAC
Connect input voltage (24 VAC,
60 HZ) to terminals 1 and 2.
FACTORY
INSTALLED
JUMPER.
HOT
DO NOT
REMOVE
2
BURNER
AP2P112
BURNER
POWER
SOURCE
24VAC
COMMON
Connect terminal 2 to burner circuit
common. Connect terminal P2 to
burner Circuit in series with and
before other limit controls. Consult
boiler manufacturer instructions for
proper terminal connections.
C
GAS
VALVE*
LIMIT
HOT
CONTROLS
+
0
H
*or Intermittent Ignition
3
BURNER
POWER
SOURCE
24VAC
Optional water feeder connection.
Connect feeder N to terminal 2.
Connect Feeder H to terminal 1.
Connect feeder “FEED” or “W” to
terminal A. For water feeders with
2 leads, connect feeder common
to terminal 2 and feeder hot to terminal A. Note: Use of a solenoid
valve or McDonnell & Miller Model
101A water feeder may cause
flooding and is not recommended
for use with this low water cut-off.
MODEL CG400 — ALTERNATE WIRING METHOD USING PLUG CONNECTOR
C
VALVE*
VALVE*
4
AP2P112
AP2P112
BURNER
BURNER
POWER
SOURCE
24V
AC
LIMIT
CONTROLS
GAS
GAS
+
0
H
WATER
FEEDER
C
VALVE*
LIMIT
CONTROLS
0
GAS
H
WATER
FEEDER
OPTIONAL
ACTIVATION
Standing pilot boilers: Connect
“Burner” terminal to hot leg of
24VAC connection on gas valve.
Pilotless ignition boilers:
“Burner” terminal to hot leg of
24VAC connection on intermittent
ignition (spark) module.
See boiler manufacturer’s
installation instructions for correct
connection to 24VAC hot.
BURNER
+
Connect
1
2
3
WATER
FEEDER
WATER
FEEDER
AP2P112 BURNER
BURNER
AP2P112
BURNER
AP2P112
C H
GAS
VALVE*
Plug wire harness connector into matching end on circuit board.
IMPORTANT: Factory installed jumper must be in place between
P2
2
1
terminals 1 and P1.
Optional water feeder connection. Connect feeder N to terminal 2.
Connect Feeder H to terminal 1. Connect feeder “FEED” or “W” to terminal A. For water feeders with 2 leads, connect feeder common to
terminal 2 and feeder hot to terminal A. Note: Use of a solenoid valve
or McDonnell & Miller Model 101A water feeder may cause flooding
and is not recommended for use with this low water cut-off.
OPTIONAL
ACTIVATION
Standing pilot boilers: Connect “Burner” terminal to hot leg of 24VAC
connection on gas valve.
Pilotless ignition boilers:
Connect “Burner” terminal to hot leg of
24VAC connection on intermittent ignition (spark) module.
See boiler manufacturer’s installation instructions for correct
*or Intermittent Ignition
connection to 24VAC hot.
Page 3
Operating Instructions
NOTE
For proper low water cut-off operation, the boiler should be cleaned at
initial installation and periodically thereafter. Refer to the boiler manufacturer’s instructions for cleaning procedures.
OPERATING TEST PROCEDURE
1. After installation, bring the boiler water to a safe operating level, turn
on power and set the thermostat to call for heat. The amber LED
lamp should be off. The boiler will fire immediately.
2. Slowly
lower the boiler water to a point below the probe. The amber
LED lamp on the control will light. The lamp may begin to flicker with
the bouncing water level. Stop draining the boiler when the lamp
glows steadily. NOTE: The water should not be lowered beyond a
visible point in the gauge glass.
3. The boiler will shut down within 15 seconds.
IF BURNER DOES NOT SHUT DOWN IN LOW WATER
1. Check terminal block wiring to insure that all connections are correct.
2. Check the probe installation to insure that there is 1/4" clearance
from any surface within the boiler or pipe. (Refer to Step 3 on page 1
of this instruction sheet.
3. Clean the boiler in accordance to the manufacturer’s instructions.
Machining oils, grease, rust and other contaminants in the boiler
water can cause foaming or surging and make a low water condition
difficult to detect during burner operation.
IF THE AMBER LED LAMP IS ON
The amber LED lamp indicates that the water is below the probe. If the
gauge glass shows that the water is at the correct operating level and
the amber LED is lit check the following:
1. Check for plugged gauge glass.
2. Make sure probe lead wire is properly secured to the terminal.
3. Check for proper ground between probe and boiler shell. Excessive
use of Teflon tape or sealing compound may isolate the probe from
the boiler shell.
4. Remove probe and examine for oily residue. Clean probe with steel
wool and skim boiler.
IF THE GREEN LED LIGHT IS ON
The green LED lamp indicates that the control is in a 90 second test
mode. The burner does not fire during the test period. See Intermittent
Level Test Feature on this page for more details.
Maintenance
To ensure optimum performance remove and inspect probe annually.
Clean any sediment or scale from the probe using a scouring pad or
steel wool. Re-install the probe and perform the Operating Test
Procedure described above.
To provide added protection to today’s smaller boilers, the
CycleGard low water cut-off is equipped with an Intermittent
Level Test feature. This feature removes power from the burner circuit for 90 seconds at 10 minute intervals to allow foam
and volatile water to settle giving a very accurate measurement of the boiler water level.
The optional SmartCycle feature
allows the control to initiate the
test time sequence only when the
burner fires enabling full 10
minute run times.
CycleGard
Intermittent Level Test
Feature
Page 4
The Safgard VXT water feeder (available separately) is fully programmable to accommodate
any steam system. By simply arranging a series
of rocker switches the delay time before feed
can be adjusted to allow condensate to return to
the boiler. Settings from 30 seconds to ten min-
utes are available. The amount of feed can also
be set from one to five gallons. If necessary, a
second delay/feed cycle is permitted. If the low
water condition still exists after the second cycle
the control will lock-out to prevent flooding of
the system.
VXT WATER FEEDER
PROBES
Test Pressure: 1000 PSI, All Models
THE PROBE MAKES THE DIFFERENCE
The probe used in all Hydrolevel controls offers
you distinctive advantages. Unlike float devices,
there are no moving parts to wear stick, or
“hang-up” the in harsh boiler environment .
A stuck or “hung-up” float can cause dangerous
low water conditions. And if suddenly released, a
float can feed cold water into overheated tubes
or plates and cause explosive results.
The Hydrolevel control has no float bowl so sediment cannot collect. The reliable solid state circuitry and low maintenance probe are designed
to provide years of troublefree operation.
MAXIMUM PRESSURE: 15 PSI
INPUT VOLTAGE: 24 VAC, 60 HZ
SWITCH CONTACTS: SPDT
SWITCH RATINGS
AND ALARM CIRCUIT: 50 VA @ 24 VAC
Pilot Duty
EL1214 – STANDARD MODEL – 3/4" NPT
For 1/2”, order Model No. EL-1220
EL1214-P – 3/4" NPT
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: (203) 776-0473
FAX: (203) 773-1019
2"
SQUARE
17/8"
313/16"
15
/16"
1"
3
/4" NPT
5
/16"
2"
SQUARE
17/8"
49/16"
1"
3
/4" NPT
5
/16"
111/16"
EL1214-R
REMOTE PROBE
225/32
37/8
15/8
11/8
15/8
23/8
BOTTOM
59/16
51/2
1.00
BACK
11/8
23/8
15/8
TOP
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