Page 1
Low maintenance. No moving parts to wear stick or hang up,
as in float devices.
CG450 Series
CGT450 Series
Solid state circuitry. Designed for the highest level of performance and reliability.
Automatically shuts off burner, after delay, in a low water
Low Water Cut-Offs
For Steam Boilers
120 VAC Operating Voltage
Max. Pressure 15 psi
U.S. Patent Nos. 5,739,504 & 6,390,027
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.
HOW TO INSTALL
1 2 3
SAFE
WATER
LINE
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.
1/4"
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.
4
R E M O TE M O U N TE D M O DE L S O N LY
BA
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
83 Water Street
New Haven, CT 06511
Phone: (203) 776-0473 • FAX: (203) 773-1019
www.hydrolevel.com
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.
5
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.
Page 2
HOW TO WIRE
FACTORY
INSTALLED
JUMPER.
DO NOT
REMOVE
BURNER
POWER
SOURCE
120V
AC
+
0
LIMIT
CONTROLS
AP2P112
BURNER
WATER
FEEDER
MODEL CG450
1
Connect input voltage (120 VAC,
60 HZ) to terminals 1 and 2.
2
Connect terminal 2 to burner circuit
neutral. Connect terminal P2 to
burner Circuit in series with other
limit controls. Consult boiler manufacturer instructions for proper terminal connections. Control should
be wired in series with and before
other limit controls.
3 4
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 neutral
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 CGT450 (for boilers with tankless coil)
1 2 3
OPTIONAL
ACTIVATION
Connect “BURNER” terminal on the
CycleGard control to the orange
burner wire (120VAC) located
under the oil burner transformer.
See opposite page for schematic
wiring diagram and additional
SmartCycle description.
Connect input voltage (120 VAC, 60 HZ) to terminals 1 and 2.
OPTIONAL ACTIVATION
4 5 6
Connect “LOW LIMIT” terminals on CycleGard
control to the terminals on the tankless aquastat.
Connect terminal 2 to burner circuit neutral.
Connect terminal P2 to burner Circuit in series
with other limit controls. Consult boiler manufacturer instructions for proper terminal connections. Control should be wired in series with and
before other limit controls.
Connect”THERMOSTAT” terminals on
CycleGard control to T-T terminals on burner
primary control.
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 neutral
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.
Connect “BURNER” terminal on the CycleGard
control to the orange burner wire (120VAC)
located under the oil burner transformer. See
opposite page for schematic wiring diagram
and additional SmartCycle description.
Page 3
CycleGard
Intermittent
Level Test
Operating Instructions
Feature
To provide added protection to today’s smaller boilers, the
CycleGard low water cut-off is equipped with an Intermittent
Level Test. This important feature adds protection against
false signals that can be caused by foam and volatile water
conditions inside the boiler. The Intermittent Level Test
removes power from the burner at preset intervals. During the
test, foam dissipates and the water level stabilizes – allowing
CycleGard to monitor the true water level in the boiler assuring safe and accurate operation.
The last four digits
of the CycleGard
model number
determine the frequency and duration of the Intermittent Level Test (ILT) as shown in the table.
time the burner fires. This feature enables a full burner run
cycle (10 or 20 minutes, depending on model) prior to the
first Intermittent Level Test. On CGT450 models (designed for
boilers equipped with tankless coils), SmartCycle suspends
the Intermittent Level Test during a call for domestic hot water
allowing the boiler to deliver its full BTU capacity to the production of hot water.
Last 4 digits Frequency Duration
of Model No. of ILT of ILT
1090 10 Minutes 90 Seconds
1560 15 Minutes 60 Seconds
2060 20 Minutes 60 Seconds
2090 20 Minutes 90 Seconds
When the optional SmartCycle feature
is activated (see wiring instruction on
previous page), the CycleGard’s test
time sequencing is restarted each
Burner Connection
Model CG450 and CGT450
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
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 cor-
2. Check the probe installation to insure that there is 1/4" clearance
3. Clean the boiler in accordance to the manufacturer’s instructions.
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
4. Remove probe and examine for oily residue. Clean probe with steel
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.
rect.
from any surface within the boiler or pipe. (Refer to Step 3 on page 1
of this instruction sheet.
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.
use of Teflon tape or sealing compound may isolate the probe from
the boiler shell.
wool and skim boiler.
IF THE GREEN LED LIGHT IS ON
The green LED lamp indicates that the control is conducting an
Intermittent Level Test. 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.
Page 4
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"
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
VXT WATER FEEDER
PROBES
Test Pressure: 1000 PSI, All Models
EL1214 – STANDARD MODEL – 3/4" NPT
For 1/2”, order Model No. EL-1220
The VXT Water Feeder (available separately) can be installed with Hydrolevel or
other low water cut-offs to automatically
replenish boiler water in the event of a low
water condition. The VXT offers programmable
feed amount
and
feed delay
settings. These can easily be set to ensure
the proper feed amount and to provide
adequate time for condensate to return to
EL1214-P – 3/4" NPT
the boiler before starting a feed cycle. The
VXT Feederʼs
Digital Feed Counter
tracks
the amount of water added to the boiler
exposing system leaks, which can significantly shorten the life of a cast iron boiler.
Additional features including a manual feed
button, underfeed and flood protection
make the VXT an ideal choice for safety
and convenience.
EL1214-R
REMOTE PROBE
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 .
LIMITED MANUFACTURERʼS WARRANTY
We wa rran t p rod uct s manuf act ure d 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
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.
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.
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: 120 VAC, 60 HZ
SWITCH RATINGS: 5.8 FLA, 34.8 LRA
SWITCH CONTACTS: SPDT
ALARM CIRCUIT: 125 VA @ 120 VAC
Pilot Duty
83 Water Street
New Haven, CT 06511
Phone: (203) 776-0473
FAX: (203) 773-1019
www.hydrolevel.com
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