7/29/2019 Series 193 and 194 LWCO

1/12

Series 93/193 and Series 94/194

Low Water Cut-Off/Pump ControllersFor Steam Boilers and Level Control Applications

Typical Applications:

Primary or secondary pump controller/low water fuel cut-offfor steam boilers

Motorized valve controller

Proportional valve controller

Low water cut-off

High water cut-off

Alarm actuation

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 inaccordance with all applicable codes and ordinances.

To prevent serious burns, the boiler must be cooled to 80F (27C) and the pressure must be0 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 controlsinstalled on the boiler. After installation, check for proper operation of all of the limit andoperating controls, before leaving the site.

We recommend that secondary (redundant) Low Water Cut-Off controls be installed on allsteam boilers with heat input greater than 400,000 BTU/hour or operating above 15 psi ofsteam pressure. At least two controls should be connected in series with the burner

control circuit to provide safety redundancy protection should the boiler experience alow-water condition. Moreover, at each annual outage, the low water cutoffs should bedismantled, inspected, cleaned, and checked for proper calibration and performance.

To prevent serious personal injury from steam blow down, connect a drain pipe to the controlopening to avoid exposure to steam discharge.

To prevent a fire, do not exceed the switch contact rating.

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

WARNIN

G

CAUTION

! WARNING

Series 93 or Series 94 Series 193 or Series 194

McDonnell & MillerInstallation & Maintenance

InstructionsMM-404(H)

7/29/2019 Series 193 and 194 LWCO

2/122

Electrical RatingsModels with 5 or 5-M Switch Models with 7B or 7B-M Switch

ApproximateDistance Above

Cast Line DifferentialSetting In. (mm) In. (mm)

Pump Off 23/16 (56) 11/16 (27)

Pump On 11/8 (29)

Burner On 13/8 (35) 13/8 (35)

Burner Off 0

Switch Settings

Values are 1/8 (3mm)

NOTE: Due to the slower operation of somemotorized valves, complete valve opening orclosing may occur at slightly differentlevels than indicated above.

Models with 5 or 5-M Switches

ApproximateDistance Above

Cast Line DifferentialSetting In. (mm) In. (mm)

Valve Full 23/16 (56) 11/16 (27)

ClosedValve Full 11/8 (29)

Open

Burner On 13/8 (35) 13/8 (35)

Burner Off 0

Models with 7B or 7B-M Switches

OPERATION Maximum Pressure:Series 93/193: 150 psi (10.5 kg/cm2)Series 94/194: 250 psi (17.6kg/cm2)

PUMPOFF

BURNEROFF BURNER

CUT-OFF LEVELAT CAST LINE

23/16"(56mm)

PUMP OFFPUMP ON

(27mm)11/16"

BURNERCUT-OFF LEVELAT CAST LINE

BURNER OFF

(35mm)

BURNER ON

13/8"BURNERCUT-OFF LEVELAT CAST LINE

BURNER OFF

(35mm)

BURNER ON

13/8"

MOTORIZEDVALVE

CLOSED

BURNER

OFF BURNERCUT-OFF LEVELAT CAST LINE

23/16"(56mm)

MOTORIZEDVALVE

CLOSED

MOTORIZEDVALVEOPEN

(27mm)11/16"

Pump and Burner Switch Contact Ratings

Voltage Pilot Duty Only

120 VAC 345 VA240 VAC

Switch Ratings

Burner Valve

120 VAC 345 VA 0 - 135 ohms @ 24 VAC240 VAC

7/29/2019 Series 193 and 194 LWCO

3/12

If the control will be the primary lowwater fuel cut-off, size the steam (top) andwater (bottom) equalizing pipe lengths sothat the horizontal cast line on the body is1 1/2 (38mm) below the boilers normalwater level, but not lower than the lowestsafe permissible water level, as deter-mined by the boiler manufacturer.

OR

If the control will be the secondary lowwater fuel cut-off, size the steam (top) andwater (bottom) equalizing pipe lengths sothat the horizontal cast line on the body isat or above the lowest safe permissiblewater level, as determined by the boilermanufacturer.

STEP 1 - Determine the Position of the Low Water Cut-Off/Pump Controller

INSTALLATION

TOOLS NEEDED:Two (2) pipe wrenches, one (1) flathead screwdriver, and pipe thread dope.

IMPORTANT: Follow the boiler manufacturer'sinstructions along with all applicable codes andordinances for piping, blow-down valve, watergauge glass, tri-cock and electrical requirements.

11/2"

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

BLOW DOWN VALVE

NORMAL BOILER WATER LINE

AS A PRIMARYLOW WATER CUT-OFF/PUMPCONTROLLER

BURNER CUT-OFF LEVELAT CAST LINE

LOWESTPERMISSIBLEWATER LEVEL

WATEREQUALIZING

PIPE

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

BLOW DOWN VALVE

AS A SECONDARYLOW WATER CUT-OFF/PUMPCONTROLLER

BURNER CUT-OFF LEVELAT CAST LINE

LOWESTPERMISSIBLEWATER LEVEL

BURNER OFF

WATEREQUALIZING

PIPE

7/29/2019 Series 193 and 194 LWCO

4/124

AB

C

a. Mount and pipe the control (A) on vertical equalizingpipes (B) at the required elevation as determined inStep 1.

Install a full-ported blow-down valve (C) directly

below the lower cross.

NOTE:1 (25mm) NPT tappings are provided on Series93/193 controls.

1 1/4 (32mm) NPT tappings are provided for Series94/194 controls and 193-B Model.

STEP 2 - Installing the Low Water Cut-Off/Pump ControllerFor Series 93/193 or 94/194 (except 94-A, 193-D and 193-G Models)

A

E

C

D

a. Mount and pipe the control (A) with a vertical upper(D) and horizontal lower (E) equalizing piping at therequired elevation as determined in Step 1.

Install a full-ported blow-down valve (C) on the lowerbody connection.

NOTE:1 1/4 (32mm) NPT tappings are provided for 94-AModel control.

1 (25mm) NPT tappings are provided for 193-GModel control.

For 94-A and 193-G Models

A

C

G

a. Mount and pipe the control (A) with a horizontalupper and lower (G) equalizing piping at therequired elevation as determined in Step 1.

Install a full-ported blow-down valve (C) on the lowerbody connection.

NOTE:1 (25mm) NPT tappings are provided for 193-DModel control.

For 193-D Models

7/29/2019 Series 193 and 194 LWCO

5/12

a. Using a pipe wrench, remove the float blocking plugs (I)and dowels (H) from the control as shown below.

b. Using a pipe wrench, screw the pipe plugs provided withcontrol into the open tappings.

STEP 3 - Removing Float Blocking Plugs and Dowels

I

H

I

H

Series 93 / 94Series 193 / 194

CAUTIONThe plug and rod must be reinstalled before control is shipped installed on theboiler, and removed after boiler is placed and installed.

Failure to follow this caution may damage the float and operating mechanism.

!

7/29/2019 Series 193 and 194 LWCO

6/126

STEP 4 - Installing a Water Gauge Glass and Tri-Cocks

Tri-Cock Gauge Glass Tapping Gauge Glass Tapping

Tapping Pipe Size Center Distance

Unit B C D E F H J K L

193 12 (15) 12 (15) 12 (15) 12 (15) 12 (15) 1234 (324)

193-A1

2 (15)1

2 (15)1

2 (15)1

2 (15)1

2 (15) 111

2 (292)193-B 34 (20) 34 (20) 34 (20) 34 (20) 34 (20) 1234 (324)

193-D 12 (15) 12 (15) 12 (15) 1112 (292)

193-G 12 (15) 12 (15) 12 (15) 1112 (292)

194 12 (15) 12 (15) 12 (15) 12 (15) 12 (15) 1158 (295)

194-A 12 (15) 12 (15) 12 (15) 12 (15) 12 (15) 1278 (327)

194-B 34 (20) 34 (20) 34 (20) 34 (20) 34 (20) 1278 (327)

CUT-OFF LEVEL

CUT-OFFLEVEL

3"

3"

B

D

FE

C

KL

JH

a. Determine pipe size of tri-cock andsight glass tappings for the controlbeing installed including center

distance of sight glass tappings.NOTE:These items are not provided withcontrol and must be purchasedseparately

b. Install tri-cocks and gauge glass following

manufacturers instructions.

NOTE: A separate water column for installation ofgauge glass and tri-cocks may be required for boilers

with a Series 93 or Series 94 control. Follow themanufacturers instructions to install the water column.

GAUGE GLASS

(TYPICAL)

TRI-COCK

(TYPICAL)

7/29/2019 Series 193 and 194 LWCO

7/12

STEP 5 - Electrical Wiring

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 theboiler. After installation, check for proper operation of all of the limit and operating controls, before leavingthe site.

Failure to follow this warning could cause electrical shock, an explosion and/or a fire, which could result in

property damage, personal injury or death.

! WARNING

2 4

1 3

BLUE

BOILER FEED PUMP OFFBURNER ONALARM OFF

BOILER FEED PUMP ONBURNER ONALARM OFF

BOILER FEED PUMP ONBURNER OFFALARM ON

RED

3 1

4 2

2 4

1 3

BLUE RED

3 1

4 2

2 4

1 3

BLUE RED

3 1

4 2

Switch OperationFor Series 93/193 or 94/194 with 5 or 5-M Switch

Wiring Diagrams

NOTE: The following diagrams are provided for refer-ence only. If available, manufacturers wiring diagrams

should always be followed to connect the devicebeing operated.

Red switch terminals 1 and 2 are for burner circuit contacts, terminals 3 and 4 are for the low level alarmcircuit contacts.

Blue switch terminals 3 and 4 are for feeder/pump control contacts, terminals 1 and 2 are for high levelalarm circuit contacts.

BLUE

NO. 5SWITCH

TO BURNERTO PUMP

LINE

1

2

3

4

4

3

RED

LINE

ALARM

TRANS.

Pump Control, Low Water Cut-Off and Alarm

7/29/2019 Series 193 and 194 LWCO

8/128

LOW WATER CUT-OFF CIRCUIT

BLUE

NO. 5SWITCH

BURNERSTARTER

1

2

RED

LINE

Low Water Cut-Off Only

PUMP CONTROL CIRCUIT

BLUE

NO. 5SWITCH

PUMPSTARTER

4

3

RED

LINE

Pump Control Only

ALARM CIRCUIT

BLUE

NO. 5SWITCH

ALARM

TRANS.

NEUTRAL

3

4

RED

LINE

Low Water Alarm Only

7/29/2019 Series 193 and 194 LWCO

9/12

TO BURNER

LINE

13

4

4

3

2

1

COMMON

CLOSING CIRCUIT

OPENING CIRCUIT

NO. 7BSWITCH

BLUERED

Proportional Control, Low Water Cut-Off and Alarm

2 4

1 3

BLUE

BURNER ONALARM OFFVALVE CLOSED

BURNER ONALARM OFFVALVE OPEN

BURNER OFFALARM ONVALVE OPEN

RED

3 1

4

2 4

1 3

BLUERED

3 1

4

2 4

1 3

BLUERED

3 1

4

NOTE: The 7B switch is a 135 ohm potentiometer slidewire control for use with an electric valve operator withthe same rating.

For Series 93/193 or 94/194 with 7B or 7B-M

Red terminals 1 and 2 are the burner circuit contacts, terminals 3 and 4 are the low level alarm circuitcontacts.

Blue terminal 3 is the common contact, terminals 1 and 4 are the output contacts.

7/29/2019 Series 193 and 194 LWCO

10/1210

A

SWITCHCOVER

a. Remove two screws (A) and lift off switchcover.

b. Connect BX armored cable or Thinwall electricalmetal tubing to the integral fitting hub. Connectwires to terminals following appropriate wiringdiagram from pages 8 and 9 for your application.

NOTE: Follow local codes and standards whenselecting the types of electrical fittings and conduitto connect to control.

A

SWITCHCOVER

c. Replace switch cover and fasten with twoscrews (A).

Wiring Connections

7/29/2019 Series 193 and 194 LWCO

11/12

STEP 6 - Testing

a. Turn on power to boiler and pump circuits.With the boiler empty, the pump should turn on (5or 5-M switch models) or the valve open (7B or

7B-M switch models). The burner should remain offand boiler should begin to fill with water.

b. For Automatic Reset ModelsWhen water level in the gauge glass is approximately1 3/8 (35mm) above the horizontal cast line, theburner should turn on.

For Manual Reset ModelsWhen water level in the gauge glass is approximately1 3/8 (35mm) above the horizontal cast line, pressthe manual reset button and the burner should turn on.

c. For 5 or 5-M Switch ModelsWhen water level in the gauge glass is approximately2 3/16 (56mm) above the horizontal cast line, thepump should turn off.

For 7B or 7B-M Switch ModelsWhen water level in the gauge glass is approximately2 3/16 (56mm) above the horizontal cast line, thevalve should be closed.

d. With the water in the boiler at its normal level andburner on, SLOWLY open the blow-down valveuntil it is fully open. As the water level in the gaugeglass begins to drop, verify that the following occurs.For 5 or 5-M Switch ModelsWhen water level drops to approximately 1 1/8(29mm) above the horizontal cast line, the pumpshould turn on. When water level drops to the horizontal cast line, the burner should turn off.

For 7B or 7B-M Switch Models

As the water level drops, the valve should begin toopen. When the water level drops to approximately1 1/8 (29mm) above the horizontal cast line, thevalve should be full open.When the water level drops to the horizontal castline, the burner should turn off.

e. Close the blow-down valve after burner turns offand restore water level to normal operating level.

f. Repeat testing procedure several times to ensureproper operation of control.

g. After testing and verification of control operation,the boiler can be returned to service.

Dimensions shown are typical. The following testing procedure is only meant to serve

as a verification of proper operating sequence.

CAUTIONImmediately turn off all power if the burner turns onwith no water in the gauge glass. Investigate furtherbefore continuing procedure.

!

CAUTIONIf pump does not turn off or valve close, turn off

water supply to boiler. Investigate further beforecontinuing procedure.

!

TROUBLESHOOTING

Erratic operation of the control is the most common symptothat occurs.Erratic operation can be defined as pump and/o

burner switches not switching at proper levels. Refer to thefollowing list of items to check if the control is not operatingproperly.

1. Float Ball is CrushedCrushed floats are typically caused by improper blow-

down. Drain piping from blow-down valve to drain shouldbe checked for proper pitch and the blow-down procedu

followed when blowing down the control. Purchase andinstall a new float ball after investigating and correctingthe problem.

2. Float Ball is Filled with WaterThe seam weld on the float can sometimes deteriorate.

This can be caused by the type of chemical treatmentused in the boiler.While this is a rare occurrence, thechemical treatment supplier should be consulted to dete

mine if a reaction could occur. Purchase and install a nefloat ball after investigating and correcting the problem.

3. Float Arm Springs are BentThe pivot springs located on either side of the float rod

should be flat and straight. If they become bent, the usucause is mishandling of the unit during installation orimproper blow-down.The control should never be picked

up by the float ball or allowed to hang from the bowl by tfloat. Drain piping from blow-down valve to drain should bchecked for proper pitch and the blow-down procedurefollowed when blowing down control. Purchase and insta

new control or head mechanism after investigating andcorrecting the problem.

4. Switch Contact Springs BrokenThe contact springs can break if the electrical rating is

exceeded. Purchase and install new switch assembly orhead mechanism after investigating and correcting theproblem.

5. Switch Contact Springs MisalignedMisalignment of the contact arms is usually associatedwith damage to the control during shipment or installatio

Purchase and install new switch assembly or headmechanism after investigating and correcting the proble

6. Internal (Wetted) Parts DirtyThe internal parts can operate improperly if dirt, scale orust is allowed to build.This condition can be a result of

not blowing down the control as recommended and/orimproper boiler water chemical treatment. Purchase and

install new control or head mechanism after investigatingand correcting the problem.

7/29/2019 Series 193 and 194 LWCO

12/12

2008 ITT Corporation

Printed in U.S.A. 12-08 246043ITT

8200 N. Austin Ave.

Morton Grove, IL 60053

tel: 847-966-3700

fax: 847-966-9052

www.mcdonnellmiller.com

MAINTENANCE

SCHEDULE:Blow down control as follows when boiler isin operation.

Daily if operating pressure is above 15 psi. Weekly if operating pressure is below 15 psi.

Remove head assembly and inspect waterside components annually. Replace headassembly if any of the internal components areworn, corroded or damaged or if control no longeroperates properly.

Inspect the float chamber and equalizing pipingannually. Remove all sediment and debris.

Replace head mechanism every 5 years.More frequent replacement may be required whensevere conditions exist.Replacement parts are available from your localauthorized McDonnell & Miller Distributor.The use of parts or components other than thosemanufactured by McDonnell & Miller will void allwarranties and may affect the units compliance withlistings or regulating agencies.

BLOW DOWN PROCEDURE:

When blowing down a control at pressure, the blowdown valves should be opened slowly.The pipingneeds to be warmed up and stagnant water in thedrain piping needs to be pushed out. Suddenlyopening a blow down valve causes steam tocondense, which creates water hammer. Damage tocomponents can occur when water hammer occursdue to improper blow down piping.For these reasons,McDonnell & Miller recommendsa dual valve blow-down system for each control.Blow down the control when the water in the boileris at its normal level and the burner is on.

NOTE: Refer to page 2 for switch operating points. Open upper valve (#1) Slowly open the lower valve (#2) Water in the sight glass should lower. As the water in the sight glass lowers, the

pump should turn on. As the water continues to lower in the sight

glass, the burner should turn off. Slowly close the lower valve (#2). Close the upper valve (#1) The water level in the sight glass should rise, firstturning on the burner and then turning off the pump.NOTE: On manual reset models, the reset buttonwill need to be pressed after the water level hasbeen restored before the burner will operate.

To prevent serious personal injury from steampipe blow down, connect a drain pipe to thecontrol opening to avoid exposure to steamdischarge.

Failure to follow this caution could causepersonal injury.

! CAUTION

NOTEMore frequent blow-down may be necessarydue to dirty boiler water and/or local codes.

Valve #2

Valve #1

NOTEThe control may need to be inspected andcleaned more frequently on systems where thereis the potential of excessive scale or sludgebuild-up.This includes systems:

With high raw water make-up With no condensate return With untreated boiler water Where significant changes have been

made to the boiler-water chemicaltreatment process

With oil in the boiler water

NOTEIf this sequence of operation does not occur asdescribed, immediately close all the valves, turn off theboiler and correct the problem. Inspection/cleaning ofthe float mechanism may be required to determine whythe control was not working properly. Retest the controlafter the problem has been identified and corrected.