Xylem MM 415C User Manual

Replacement Head Mechanism

150E-HD

Replacement head mechanisms can be installed without disturbing existing equalizing connections or disassembly of components, making repair simple and easy.

The Series 150E is a microprocessor based control which utilizes the conductive properties of the boiler water to operate relays. All units include redundant low water cut-off and pump off features to guard against shorted or fouled probe conditions.

INSTRUCTION MANUAL

MM-415C

Series 150E

WARNING

CAUTION

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, instal-

lation, 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 cut-offs 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 use this low water cut-off to switch currents over 16A, 1 Hp at 120 VAC or 8A, 1 Hp at 240 VAC, unless a starter or relay is used in conjunction with it.

Failure to follow this warning could cause property damage, personal injury or death.

SPECIFICATIONS

Maximum Pressure: 150 psi (10.5 kg/cm2)

ELECTRICAL RATINGS & SWITCH RATINGS

Supply Probe Full Load (Amps) Locked Rotor (Amps) Pilot Duty (VA) Motor (HP) Voltage Voltage NO (NC), VAC NO (NC), VAC NO (NC), VAC NO (NC), VAC

120 VAC 5 VAC 16 (5.8), 120 96 (34.8), 120 470 (290), 120 1 (1/4), 120 50/60 HZ maximum 8 (2.9), 240 48 (17.4), 240 470 (290), 240 1 (1/4), 240

Burner Delay (DOB): 0 to 60 seconds (Field Adjustable)

Ambient Temp: 120˚F Max.

NOTE: The circuit board is protected with a sensor which will shut down the unit if the temperature at the board exceeds 176˚F (80˚C). The board will reset when the temperature at the board drops below 167˚F (75˚C).

FEATURES

Burner Relay Time Delay

There is a field-adjustable time delay (DOB) to prevent nuisance burner shut-down. The number of seconds water needs to be off the bottom probe before the burner relay is reactivated can be set between 0 and 60 seconds.

Redundant Low Water Cut-Off

When the boiler water drops below the middle probe, a 3 minute timing circuit will be activated. If water does not return to the middle probe within three minutes, the burner relay will reactivate. The Red LED will flash once every second if this condition occurs.

•Automatic Reset units will automatically reset when the water level is restored to the middle probe.

• The reset button on Manual Reset units will have to be pressed after water is restored to the middle probe.

NOTE: The timing circuit will automatically reset if the water level is restored to the middle probe within 3 minutes.

Redundant Pump Off

The pump relay will be activated after water drops below the middle probe. If the water level is not restored to the top probe within 3 minutes the pump relay will be deactivated. After the pump relay is deactivated, normal operation is resumed. Water must again drop off the middle probe to activate the pump relay. There is no LED signal for this occurance.

CSD-1 Code Compliance

On Manual Reset units, if the control is in a low water condition (burner relay deactivated) prior to an interruption of power, the control will remain in a low water condition when power is restored. The reset button will need to be pressed when the water level again covers the middle probe.

Adjustable Pump Differentials

BURNER

CUT-OFF LEVEL

AT CAST LINE

(22mm)

BURNER OFF

BURNER ON

/8"

PUMP

OFF

BURNER

OFF

BURNER

CUT-OFF LEVEL

AT CAST LINE

/16"

(52 mm)

NORMAL BOILER

WATER LINE

/16"

(30 mm)

PUMP OFF

PUMP ON

NORMAL BOILER

WATER LINE

SWITCH SETTINGS:

BURNER

CUT-OFF LEVEL

AT CAST LINE

(22mm)

BURNER OFF

BURNER ON

/8"

PUMP

OFF

BURNER

OFF

BURNER

CUT-OFF LEVEL

AT CAST LINE

/8"

(41mm)

NORMAL BOILER

WATER LINE

/4" (19 mm)

PUMP OFF

PUMP ON

NORMAL BOILER

WATER LINE

Values are ±

/16” (6mm).

When the water level in the boiler drops below the middle probe, the circuit is broken which will activate the pump relay. When the water level rises above the top probe, the circuit is made and the pump relay is deactivated.

The distance between the top and middle probes is adjustable. By turning the flange one bolt hole clockwise, the distance can be increased by 7/16”.

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 15/8 (41) Pump On

Burner On

/8 (22)

Burner Off 0 (0)

/4(19)

/8(22)

When the water level in the boiler drops below the bottom probe, the circuit is broken which will deactivate the burner relay. When the water level is restored to the middle probe, the burner relay will be activated for auto reset controls only.

Flange in “B” PositionFlange in “A” Position

Approximate

Distance Above

Cast Line Differential

Setting In. (mm) In. (mm)

Pump Off 2 Pump On

Burner On Burner Off 0 (0)

/16 (52)

/8 (22)

/16(30)

/8(22)

Burner Off has adjustable 0-60 second time delay.

INSTALLATION –

TOOLS NEEDED:

One (1) pipe wrench, one (1) flatblade screwdriver, one (1) scraper, and one (1) 9/16" socket or wrench.

STEP 1 - Preparation

WARNING

•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 disconnecting or making electrical connections.

Failure to follow this warning could cause property damage, personal injury or death.

a. Drain water in the boiler to a level

which is below the float chamber (A). Allow the boiler to cool to 80˚F (27˚C) and release the boiler pressure to 0 psi (0 bar).

b. Using a flatblade screwdriver, remove the

junction box cover (B). Disconnect, mark, and remove the supply wires and conduit connections.

CAUTION

There may be more than one source of power to the control.

c. Remove the existing head mechanism (C)

from the body (D).

d. Using a scraper, remove the old gasket (E).

Clean all debris from the float chamber. The gasket sealing surface (F) must be smooth and clean.

STEP 2 - Installing the Replacement Head Mechanism

a. Carefully remove the new replacement head

mechanism from the carton. Handle it carefully to prevent damage to the probes.

CAUTION

If probes are loose and/or damaged, the control may leak or not work properly.

b. Align the bolt holes of the new head gasket (J)

on the sealing surface of the control body.

c. Install the new replacement head (K) on the

body (D) by guiding the probes into the control body and aligning the bolt holes. NOTE: For increased pump differential locate tab “B” down (see page 3 Flange Positioning).

d. Using a wrench, insert the eight (8) bolts and

tighten them to approximately 14-20 ft•lb (19-27 N•m) in an alternating star pattern.

+ 11 hidden pages