Xylem MM 404J User Manual
Series 93/193 and Series 94/194
WARNING
CAUTION
!
Low Water Cut-Off/Pump Controllers
For Steam Boilers and Level Control Applications
Typical Applications:
– Primary or secondary pump controller/
low water fuel cut-off
for steam boilers
– Motorized valve controller
– Proportional valve controller
– Low water cut-off
– High water cut-off
– Alarm actuation
Series 93 or Series 94
INSTRUCTION MANUAL
MM-404J
Series 193 or Series 194
WARNING
• Before using this product read and understand instructions.
• Save these instructions for future reference.
• All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of plumbing, steam, and electrical equipment and/or systems in
accordance with all applicable codes and ordinances.
• To prevent serious burns, the boiler must be cooled to 80˚F (27˚C) and the pressure must be
0 psi (0 bar) before servicing.
• To prevent electrical shock, turn off the electrical power before making electrical connections.
• This low water cut-off must be installed in series with all other limit and operating controls
installed on the boiler. After installation, check for proper operation of all of the limit and
operating controls, before leaving the site.
We recommend that secondary (redundant) Low Water Cut-Off controls be installed on all
•
steam boilers with heat input greater than 400,000 BTU/hour or operating above 15 psi of
steam pressure. At least two controls should be connected in series with the burner
control circuit to provide safety redundancy protection should the boiler experience a
low-water condition. Moreover, at each annual outage, the low water cutoffs should be
dismantled, inspected, cleaned, and checked for proper calibration and performance.
• To prevent serious personal injury from steam blow down, connect a drain pipe to the control
opening to avoid exposure to steam discharge.
• To prevent a fire, do not exceed the switch contact rating.
California Proposition 65 warning! This product contains chemicals known to the
•
state of California to cause cancer and birth defects or other reproductive harm.
Previous controls should never be installed on a new system. Always install new
•
controls on a new boiler or system.
Failure to follow this warning could cause property damage, personal inj ury or death.
CAUTION:
•
A more frequent replacement interval may be necessary based on the condition of
the unit at time of inspection. McDonnell Miller s warranty is one (1) year from date
of installation or two (2) years from the date of manufacture.
!
&
'
OPERATION
PUMP
OFF
BURNER
OFF
BURNER
“CUT-OFF LEVEL”
AT CAST LINE
2
3
/16"
(56mm)
PUMP OFF
PUMP ON
(27mm)
1
1
/16"
BURNER
“CUT-OFF LEVEL”
AT CAST LINE
BURNER OFF
(35mm)
BURNER ON
1
3
/8"
BURNER
“CUT-OFF LEVEL”
AT CAST LINE
BURNER OFF
(35mm)
BURNER ON
1
3
/8"
MOTORIZED
VALVE
CLOSED
BURNER
OFF
BURNER
“CUT-OFF LEVEL”
AT CAST LINE
2
3
/16"
(56mm)
MOTORIZED
VALVE
CLOSED
MOTORIZED
VALVE
OPEN
(27mm)
1
1
/16"
W
A
R
N
I
N
G
C
A
U
T
ION
!
®
Electrical Ratings
Models with 5 or 5-M Switch
Maximum Pressure:
Series 93/193: 150 psi (10.5 kg/cm
Series 94/194: 250 psi (17.6kg/cm
Models with 7B or 7B-M Switch
2
)
2
)
Pump and Burner Switch Contact Ratings
Voltage Pilot Duty Only
120 VA
C
345 VA
240 VAC
Switch Settings
1
/8
Values are ±
Models with 5 or 5-M Switches
Setting In. (mm) In. (mm)
Pump Off 23/
Pump On 11/8(29)
Burner On 13/8(35) 13/8(35)
Burner Off 0
” (3mm)
Approximate
Distance Above
Cast Line Differential
(56) 11/16(27)
16
Switch Ratings
Burner Valve
120 VAC
VA 0 - 135 ohms @ 24 VAC
345
240 VAC
Models with 7B or 7B-M Switches
Approximate
Distance Above
Cast Line Differential
Setting In. (mm) In. (mm)
Valve Full 23/
16
(56) 11/16(27)
Closed
Valve Full 11/8(29)
Open
Burner On 13/8(35) 13/8(35)
Burner Off 0
2
NOTE: Due to the slower operation of some
motorized valves, complete valve opening or
closing may occur at slightly different
levels than indicated above.
INSTALLATION –
11/2"
STEAM EQUALIZING PIPE
V
ERTICAL EQUALIZING PIPE
BLOW DOWN VALVE
NORMAL BOILER WATER LINE
AS A PRIMARY
LOW WATER CUT-OFF/PUMP
CONTROLLER
BURNER “CUT-OFF LEVEL”
A
T CAST LINE
LOWEST
PERMISSIBLE
W
ATER LEVEL
WATER
EQUALIZING
PIPE
STEAM EQUALIZING PIPE
VERTICAL EQUALIZING PIPE
BLOW DOWN VALVE
AS A SECONDARY
LOW WATER CUT-OFF/PUMP
CONTROLLER
BURNER “CUT-OFF LEVEL”
AT CAST LINE
LOWEST
PERMISSIBLE
WATER LEVEL
BURNER OFF
WATER
EQUALIZING
PIPE
TOOLS NEEDED:
o (2) pipe wrenches, one (1) flathead screw
Tw
driver, and pipe thread dope.
IMPORTANT: Follow the boiler manufacturer's
uctions along with all applicable codes and
instr
ordinances for piping, blow-down valve, water
gauge glass, tri-cock and electrical requirements.
STEP 1 - Determine the Position of the Low Water Cut-Off/Pump Controller
If the control will be the primary low
water fuel cut-off, size the steam (top) and
ater (bottom) equalizing pipe lengths so
w
that the horizontal cast line on the body is
1 1/2” (38mm) belo
water level, but not lower than the lowest
e permissible water level, as deter-
saf
mined by the boiler manufacturer.
If the control will be the secondary low
water fuel cut-off, size the steam (top) and
ater (bottom) equalizing pipe lengths so
w
that the horizontal cast line on the body is
at or above the lowest safe permissible
water le
vel, as determined by the boiler
manufacturer.
w the boiler’s normal
OR
3
A
B
C
STEP 2 - Installing the Low Water Cut-Off/Pump Controller
A
E
C
D
A
C
G
11/2"
STEAM EQUALIZING PIPE
V
ERTICAL EQUALIZING PIPE
BLOW DOWN VALVE
NORMAL BOILER WATER LINE
AS A PRIMARY
LOW WATER CUT-OFF/PUMP
CONTROLLER
BURNER “CUT-OFF LEVEL”
A
T CAST LINE
LOWEST
PERMISSIBLE
W
ATER LEVEL
WATER
EQUALIZING
PIPE
STEAM EQUALIZING PIPE
VERTICAL EQUALIZING PIPE
BLOW DOWN VALVE
AS A SECONDARY
LOW WATER CUT-OFF/PUMP
CONTROLLER
BURNER “CUT-OFF LEVEL”
AT CAST LINE
LOWEST
PERMISSIBLE
WATER LEVEL
BURNER OFF
WATER
EQUALIZING
PIPE
For Series 93/193 or 94/194 (except 94-A, 193-D and 193-G Models)
a. Mount and pipe the control (A) on vertical equalizing
pipes (B) at the required ele
vation as determined in
Step 1.
Install a full-ported blow-down valve (C) directly
w the lower cross.
belo
NOTE:
1” (25mm) NPT tappings are provided on Series
93/193 controls.
1 1/4” (32mm) NPT tappings are provided for Series
94/194 controls and 193-B Model.
For 94-A and 193-G Models
a. Mount and pipe the control (A) with a vertical upper
(D) and horizontal lower (E) equalizing piping at the
required ele
Install a full-ported blow-down valve (C) on the low
body connection.
vation as determined in Step 1.
er
NOTE:
1 1/4” (32mm) NPT tappings are provided for 94-A
Model control.
1” (25mm) NPT tappings are provided for 193-G
Model control.
For 193-D Models
a. Mount and pipe the control (A) with a horizontal
upper and lower (G) equalizing piping at the
vation as determined in Step 1.
required ele
Install a full-ported blow-down valve (C) on the lo
body connection.
NOTE:
1” (25mm) NPT tappings are provided for 193-D
Model control.
wer
4
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