Hydrolevel CG400 User Manual
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
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.
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