HYDROLEVEL CG450 Low Water Cut Offs For Steam Boilers Owner’s Manual

HYDROLEVEL CG450 Low Water Cut Offs For Steam Boilers

Product Information

The CG450 Series and CGT450 Series are low water cut-offs designed for steam boilers. They operate at a voltage of 120 VAC and have a maximum pressure of 15 psi. These products feature solid-state circuitry, ensuring high performance and reliability. With no moving parts, they require low maintenance and are not prone to wear, sticking, or hanging up like float devices. The product is equipped with patented technology (U.S. Patent Nos. 5,739,504 & 6,390,027) for enhanced functionality.

The low water cut-off automatically shuts off the burner in a low water condition to prevent dry firing. It includes a time delay feature that allows water to feed above the probe to reach a safe operating level. This ensures the safety and longevity of the boiler.

Product Usage Instructions

Installation

1. The probe should be installed in the boiler above the lowest safe water level specified by the boiler manufacturer. Most manufacturers provide a suitable opening on the side of the boiler.
2. Ensure that there is a 1/4 inch clearance between the probe and any boiler surface, tube, or baffle.
3. When sealing probe piping threads, avoid excessive use of Teflon tape as it may insulate the control from boiler ground, potentially causing it to malfunction.
4. Loosen the two control cover binding head screws and remove the cover.
5. Assemble the chassis to the probe flange using the screws provided with the probe.
6. Connect the ring terminal wire lead to the probe terminal stud and secure it with the lock washer and wing nut provided.
7. Ensure that power is disconnected before proceeding with installation and wiring. Follow the instructions on pages 3-4 for wiring and installation details.
8. After completing the wiring, replace the control cover.

Installation of Remote Mounted Models (optional)
Warning: To prevent electrical shock, death, or equipment damage, disconnect the power supply before installing or servicing the control. Install the control in accordance with al  local codes and authorities having jurisdiction. Regulations of these authorities take precedence over the general instructions provided in this manual.

1. Ensure that the factory-installed jumper is not removed.
2. Connect the input voltage (120 VAC, 60 HZ) to terminals 1 and 2.
3. Connect terminal 2 to the burner circuit neutral.
4. Connect terminal P2 to the burner circuit in series with other limit controls. Refer to the boiler manufacturer’s instructions for proper terminal connections. The control should be wired in series with and before other limit controls.
5. Optionally, connect a water feeder to the control using the provided terminals. Note that the 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.
6. To activate the control, connect the BURNER terminal on the CycleGard control to the orange burner wire (120VAC) located under the oil burner transformer. Refer to page 5 for schematic wiring diagram and additional SmartCycle description.

Usage for Models CGT450 (for boilers with tankless coil)

1. Connect the input voltage (120 VAC, 60 HZ) to terminals 1 and 2.
2. Connect the LOW LIMIT terminals on the CycleGard control to the terminals on the tankless aquastat.
3. Connect terminal 2 to the burner circuit neutral.
4. Connect terminal P2 to the burner circuit in series with other limit controls. Refer to the boiler manufacturer’s instructions for proper terminal connections. The control should be wired in series with and before other limit controls.

CG450 Series CGT450 Series

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

• Low maintenance. No moving parts to wear stick or hang up, as in float devices.
• Solid state circuitry. Designed for the highest level of perfor-mance 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.

HOW TO INSTALL

1. WARNING – To prevent electrical shock or equip-ment damage, power must be off during installa-tion or servicing of the control. To prevent serious burns, the boiler should be thoroughly cooled before installing or servicing control. Only quali-fied personnel may install or service the control in accordance with local codes and ordinances. Read instructions completely before proceeding.

2. The probe may be installed in the boiler above the lowest safe water level established by the boiler manufacturer. Most manu-facturers provide a suitable open-ing in the side of the boiler.
   Allow 1/4″ clearance from the probe to any boil-er 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.

3. 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.

4. 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 pages 3-4. Upon completion of wiring replace control cover.

126 Bailey Road

• North Haven, CT 06473
• Phone: 203-776-0473 
• FAX: 203-764-1711
• www.hydrolevel.com

INSTALLATION OF 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

Wiring
WARNING Electrical shock hazard. To prevent electrical shock, death or equipment

NOTICE
Install this control in accordance with all local codes and authorities having jurisdiction. Regulations of these authorities take precedence over the general instructions provided in this manual.

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. 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.

4. Connect “BURNER” terminal on the CycleGard control to the orange burner wire (120VAC) located under the oil burner transformer. See page 5 for schematic wiring diagram and additional SmartCycle description.

MODEL CGT450 (for boilers with tankless coil)

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. 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 cutoff.

4. Connect “LOW LIMIT” terminals on CycleGard control to the ter-minals on the tankless aquastat.

5. Connect “THERMOSTAT” terminals on CycleGard control to T-T terminals on burner primary control.

6. Connect “BURNER” terminal on the CycleGard control to the orange burner wire (120VAC) located under the oil burner trans-former.

See next page for schematic wiring diagram and additional SmartCycle description.

CycleGard Intermittent

Level Test 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.

When the optional SmartCycle feature is activated (see wiring instructions on pages 4 & 5), the CycleGard’s test time sequencing is restarted each 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.

Burner/SmartCycle Wiring Connection

• Model CG450 and CGT450
• Diagram shows how the signal is sent to the Cyclegard from the primary control.

See page 4 & 5 for limit and LWCO wiring.

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 to see if a foaming condition in the boiler is preventing the control from accurately detecting the water level. With power to the system on, and water above the probe level, set the thermo-stat so there is no call for heat and allow the burner to shut down. Then, slowly lower the water in the boiler to a point below the probe. The amber LED lamp should turn on and the relay will open after a 15 second delay. Once this has occurred, reestablish a call for heat and the boiler should not fire. Now raise the water level to an operating level. The amber light should turn off and the control should reenergize the burner circuit after a 30 second delay. If the control functions normally during this test, but allows water to drop below the level of the probe when the test is con-ducted with the burner on (as described in the Operating Test Procedure above), the boiler is foaming. The CycleGard provides protection for foaming boilers (see CycleGard Intermittent Level

Maintenance

1. To insure optimum performance, remove and inspect the probe annually.
   • Clean any sediment or scale from the probe using a scouring pad or steel wool.
   • Test Feature on page 5). However, to provide optimal steaming performance, it is still recommended that you clean the boiler in accordance with the manufacturer’s instructions. The foaming condition is caused by machining oils, elevated mineral content from make-up water, grease and other contaminants in the boiler water. Cleaning the boiler will eliminate foaming conditions in the boiler and provide for optimal steaming performance.
2. Check terminal block wiring to insure that all connections are correct.
3. 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.

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 conducting an Intermittent Level Test. The burner does not fire during the test peri-od. See Intermittent Level Test Feature on page 5 for more details.

NOTE: Do not use caustic chemicals that could damage the probe.
Reinstall the probe and perform the Operating Test Procedure described above.

VXT Water Feeder

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 the boiler before starting a feed cycle. The VXT Feeder’s 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.

Probes

• Test Pressure : 1000 PSI, All Models

The Probe Makes the Difference

• The probe used in all Hydrolevel controls offers you dis-tinctive 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.

Dimensions

Specifications

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

WARNING Frozen pipes/water damage. Central heating systems are prone to shut down as a result of power or fuel outages, safety related fault conditions or equipment failure. Installation of freeze protection monitoring or other precautions is recommended for unattended dwellings in climates subject to sustained below-freezing temperatures.

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 guaran-tee, 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.

• 126 Bailey Road 
• North Haven, CT 06473
• Phone: 203-776-0473 
• FAX: 203-764-1711
• www.hydrolevel.com

References

• Home | Hydrolevel

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