Hydrolevel Company CycleGard CG450 Series User manual

WARNING – To prevent electrical shock or
equipment damage, power must be off during
installation or servicing of the control. To pre-
vent serious burns, the boiler should be thor-
oughly cooled before installing or servicing con-
trol. Only qualified personnel may install or ser-
vice 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 pro-
vide 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
120 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: [phone]
FAX: [phone]
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.
CG450 Series
CGT450 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 mount-
ing 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

MODEL CGT450 (for boilers with tankless coil)
HOW TO WIRE
Connect input voltage (120 VAC,
60 HZ) to terminals 1 and 2.
Connect input voltage (120 VAC, 60 HZ) to ter-
minals 1 and 2. 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 flood-
ing and is not recommended for use with this
low water cut-off.
BURNER
POWER
SOURCE
120VAC
AP2P112
FACTORY
INSTALLED
JUMPER.
DO NOT
REMOVE
BURNER
NEUTRAL
HOT
MODEL CG450
Connect terminal 2 to burner circuit
neutral. Connect terminal P2 to
burner Circuit in series with other
limit controls. Consult boiler manu-
facturer instructions for proper ter-
minal connections. Control should
be wired in series with and before
other limit controls.
Connect terminal 2 to burner circuit neutral.
Connect terminal P2 to burner Circuit in series
with other limit controls. Consult boiler manu-
facturer instructions for proper terminal connec-
tions. Control should be wired in series with and
before other limit controls.
Connect “LOW LIMIT” terminals on CycleGard
control to the terminals on the tankless aquas-
tat.
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 ter-
minal 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.
1
BURNER
POWER
SOURCE
120VAC
2
FACTORY
INSTALLED
JUMPER.
DO NOT
REMOVE
AP2P11 BURNER LOW LIMIT THERMOSTAT
NEUTRAL
HOT
1
AP2P11 BURNER LOW LIMIT THERMOSTAT
BURNER
POWER
SOURCE
120VAC
+ 0
LIMIT
CONTROLS
2
HOTNEUTRAL
BURNER
CIRCUIT
2
AP2P11 BURNER LOW LIMIT THERMOSTAT
BURNER
POWER
SOURCE
120VAC
+ 0
LIMIT
CONTROLS
2
BURNER
CIRCUIT
WATER
FEEDER
3
AP2P11 BURNER LOW LIMIT THERMOSTAT
BURNER
POWER
SOURCE
120VAC
+ 0
LIMIT
CONTROLS
2
BURNER
CIRCUIT TANKLESS
AQUASTAT
WATER
FEEDER
NEUTRAL
HOT
4
BURNER
POWER
SOURCE
120VAC
+ 0
LIMIT
CONTROLS
2
BURNER
CIRCUIT TANKLESS
AQUASTAT PRIMARY
BURNER
CONTROL
TT
AP2P11 BURNER LOW LIMIT THERMOSTAT
WATER
FEEDER
5
AP2P11 BURNER LOW LIMIT THERMOSTAT
BURNER
POWER
SOURCE
120VAC
+ 0
LIMIT
CONTROLS
2
BURNER
CIRCUIT TANKLESS
AQUASTAT PRIMARY
BURNER
CONTROL
TT
WATER
FEEDER
6
BURNER
POWER
SOURCE
120VAC
+ 0
LIMIT
CONTROLS
AP2P112
HOTNEUTRAL
BURNER
CIRCUIT
BURNER
2
BURNER
POWER
SOURCE
120 VAC
+ 0
LIMIT
CONTROLS
AP2P112
GAS
VALVE*
BURNER
GAS
VALVE*
C
H
WATER
FEEDER
3
BURNER
POWER
SOURCE
120 VAC
+ 0
LIMIT
CONTROLS
AP2P112 BURNER
GAS
VALVE*
H
C
WATER
FEEDER
4
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.
OPTIONAL ACTIVATION

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 manu-
facturer’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 terminal block wiring to insure that all connections are cor-
rect.
2. 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.
3. Clean the boiler in accordance to the manufacturer’s instructions.
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.
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 in a 90 second test
mode. 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.
To provide added protection to today’s smaller boilers, the
CycleGard low water cut-off is equipped with an Intermittent
Level Test feature. This feature removes power from the burn-
er circuit for 90 seconds at 10 minute intervals to allow foam
and volatile water to settle giving a very accurate measure-
ment of the boiler water level.
The optional SmartCycle feature
allows the control to initiate the
test time sequence only when the
burner fires enabling full 10
minute run times. 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 pro-
duction of hot water.
CycleGard
Intermittent Level Test
Feature
BURNER
MOTOR
AP2P112 BURNER LOW LIMIT THERMOSTAT
IGNITION
TRANSFORMER
BURNER
PRIMARY
CONTROL
Burner Connection
Model CG450 and CGT450

The Safgard VXT water feeder (available sepa-
rately) is fully programmable to accommodate
any steam system. By simply arranging a series
of rocker switches the delay time before feed
can be adjusted to allow condensate to return to
the boiler. Settings from 30 seconds to ten min-
utes are available. The amount of feed can also
be set from one to five gallons. If necessary, a
second delay/feed cycle is permitted. If the low
water condition still exists after the second cycle
the control will lock-out to prevent flooding of
the system.
VXT WATER FEEDER
PROBES
Test Pressure: 1000 PSI, All Models
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 .
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 sed-
iment cannot collect. The reliable solid state cir-
cuitry 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
EL1214 – STANDARD MODEL – 3/4" NPT
For 1/2”, order Model No. EL-1220 EL1214-P – 3/4" NPT
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 warran-
ty 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 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.
P.O. Box 1847
New Haven, CT 06508
Phone: [phone]
FAX: [phone]
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"
EL1214-R
REMOTE PROBE
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