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Instruction Manual – WLF Models 9.

5 HP to 50 HP February 2005

Lattner Boiler Company 1411 9th St. S.W. Cedar Rapids, IA 52404 (800) 345-1527 www.lattner.com

INDEX
General Description………………..…..……….……………………………………………………………….....1 A. Boiler Design ……………………..…..……….………………………...…………………………….....1 B. Boiler Connections ……………………..…..……….……………………………………………….....2 C. Boiler Trim ……………………..…..……….…………………………………………………………....2 D. Fuel Burning System ……………………..…..……….……………………………………………....3 E. Fuel/Air Control ……………………..…..……….……………………………………………………4 F. Fuel Trains ……………………..…..……….…………………………………………………………4 G. Control Panel ……………………..…..……….………………………………………………………4 H. Combustion Safeguard ……………………..…..……….……………………………………………5 I. Guarantees ……………………..…..……….…………………………………………………………..5 J. Factory Tests ……………………..…..……….……………………………………………………….5 K. Nameplates, Stamping ……………………..…..……….…………………………………………….5 Section 1: Installation Instructions …..………………………………………………………………….....7 A. Unloading ………………………………………….…………………………………………………….7 B. Rigging ……………...……………………………………………………………………………………7 C. Placement of Boiler ………………………………..…………………………………………………...7 D. Combustion Air ……………………………………………….………………………………………...8 E. Stack ……………………………………….……………………………………………………………..8 F. If Boiler Shipping with Controls ………………………………………………………………………..9 G. Steam Outlet …………….……………………………………………………………………………...9 H. Blowdown Piping ……………………………………………………………………………………….10 I. Safety Valve ……………………………………………………………………………………………12 J. Gas Train Piping ….……………………………………………………………………………………12 K. Boiler Feed Systems ….……………………………………………………………………………13 L. Electrical Connections ………………………………………………………………………………..14 M. Before Firing the Boiler ………………..………………………………………………………………15 N. Pressuretrols: Controller and Limit …………………………………………………………………16 O. Firing The Boiler ……………………………………………………………………………………….18 P. Cleanout Compound ……………………..……………………………………………………………18 Q. After The Boiler Has Operated ……………………………………………………………………….19 R. Standard Maintenance Items ………………………………………………………………………...19 S. Start-Up of Low NOx Boilers ………………………………………………………………………….19 Section 2: Boiler Care …………………..……………………………………………………………………25 A. General ………………………………………………………………………………………………...25 B. New Boiler Cleanout …………………….……………………………………………………………..25 C. Water Treatments …………………………………………………………………...…………………25 D. Water Treatment Chemicals ………………………………………………………………………….26 E. Water Softener …………………………………………………………………………………………26 F. Foaming / Bouncing / Carryover ………………………………………………………………………26 G. Summary ……………………………………………………………………………………………….27 H. Blowdown ………………………………………………………………………………………………27 I. Feed Water System …………………………………………………………………………………….27 J. Burner Adjustment ……………………………………………………………………………………...28 K. Sight Glass …………………………………………………………………………………………28 L. External Inspections ……………………………………………………………………………………28 M. Internal Inspections ……………………………………………………………………………………29 N. Dust and Debris ………………………………………………………………………………………..30 Water Quality Limits for Steam Boilers ………..…………………………………………………………..31 Section 3: Maintenance ……………………………………………………………………………………...32 A. Daily Blowdown ………………………………………………………………………………………..32 B. Weekly Maintenance …..…………………………………………………………………………….32 C. General Maintenance …….…………………………………………………………………………..32 D. Handhole Plate Removal and Installation ……………………………………………………………36 E. Sight Glass Removal and Installation ……………..………………………………………………..38 F. McDonnell Miller Servicing ..………………………………………………………………………….39 G. Cleaning Interconnecting Pipe ……………………………………………………………………….40 H. Warrick Relay Replacement ………………………………………………………………………...40 I. Auxiliary Low Water Cut-Off Probe Cleaning ………………………………………………………..40

Section 4: Troubleshooting …………………………………………………………………………………42 A. Normal Operation …………...…………………………………………………………………………42 B. Basic Service Tools ……………………………………………………………………………………42 C. Before You Begin ……………………………………………………………………………………...42 D. Troubleshooting ………………………………………………………………………………………..43 Warranty ………………………………………………………………………………………………………..46 Standard Terms & Conditions ………………………………………………………………………………47 Additional Product Literature ……………………………………………………………………………..48

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GENERAL DESCRIPTION
WARNING: All installation procedures must be followed completely by a competent installer familiar with boilers and boiler accessories. CAUTION: Read and follow all instructions before installing any boiler equipment. All cover plates, enclosures and guards must be maintained and in place at all times, except during maintenance and servicing.
A. BOILER DESIGN The Model WLF is a 4-pass carbon steel vertical boiler of the water-leg tubeless design that includes an integral furnace and extended convective heat transfer surfaces. The furnace is completely submerged within the normal operating water level. In accordance with the latest edition of the ASME Code, the boiler is constructed for either low-pressure steam or high-pressure steam to 150 psig. 1. Gas Flow Heat transfer design of the Model WLF Boiler provides four pass vertical heated gas flow to ensure maximum heated gas travel and heat transfer. Limited refractory lined steel exhaust ports are incorporated for heated gas flow direction from the furnace to the finned convection surfaces. Symmetrical finned design and layout provides equalized flow of heat into each convection section from the furnace and successive gas passes, ensuring high efficiency. 2. Water Circulation Feedwater make-up and/or returns enter the bottom of the vessel well below the steaming surface. By directing the makeup into a non-steaming portion of the boiler, we eliminate the possibility of collapsing steam bubbles and thereby work in harmony with the natural watercirculating pattern within the boiler. 3. Tubeless Boiler tubes are eliminated with the use of extended finned heat transfer surfaces. These fins are seal welded to the pressure vessel to enhance heat absorption into the boiler water. Fouling, plugging and replacement of tubes are eliminated with the use of extended finned surfaces. 4. Furnace The combustion chamber or furnace is centrally located within the pressure vessel. It consists of a single cylindrical tube attached to the top of the pressure vessel with ASME Code required stay rods, and strength welded to the bottom of the vessel's water-leg. It is symmetrical in layout, completely water backed, thus, assuring a balanced flow circulating pattern under all load conditions. 5. Inner Casing A non-metallic heat barrier encases the heat transfer fins, to ensure proper gas travel from the combustion chamber into each heat transfer zone. This barrier is covered with a steel wrapper that is in turn covered with a minimum 3 ½” ceramic blanket, minimizing heat loss and ensuring high fuel to steam efficiency. Blanket density exceeds 8 Ib./cf. The steel inner wrapper ensures that the combustion byproducts will not diffuse through the blanket insulation and into the boiler room. 6. Outer Casing The removable outer casing is fabricated of four 16 gauge octagonal steel panels.
Lattner Boiler Company Instruction Manual – WLF Models February 2005

the nozzle connection may be flanged. B. a sight port is provided in the burner housing.2 Each panel is painted by a powder coating process on the inner and outer surfaces. Feedwater Make-up A tapping is provided on the bottom of the pressure vessel near the front. The minimum height of the structural base is 4 inches and the boiler is welded to the base at four points. Waterside Inspection Two 3" x 4" hand hole inspection plates are provided in the pressure vessel near the bottom for visual inspection of the waterside internals. 8. 4. 3. and the extra thick inner insulation provides a jacket temperature near ambient conditions. and main flame ignition. This is a sleeve connection. Boiler Blowdown/Drain A screwed fitting is provided on the bottom centerline at the side of the pressure vessel to completely drain the boiler as required. for connection to the system make-up and/or condensate return. Strategically spaced air space between the insulation and outer casing. short base extension may be incorporated to provide mounting for a separate oil pump for oil-fired boilers or for burners with longer extensions. 2. BOILER TRIM The following are factory installed standard trim and control items. Heat transfer extended finned surfaces can be cleaned by the removal of access plates at the top of the boiler. Exhaust Gas Vent The connection for the stack or breaching is located at the rear near the top of the boiler. A flue brush can then be used to scrub the heating surfaces clean as needed. The lug(s) is located on the top centerline of the pressure vessel. Flame Observation Port For visual inspection of the pilot. 11. Trim items are in accordance with the ASME Code and the controls are UL listed and in accordance with the ASME/CSD-1 requirements. A The system supply connection is located on the top of the boiler and is threaded as standard. Fireside Inspection and Cleaning 1. 9. Steam Connection Combustion chamber access is accomplished by the removal of the burner head. Boiler Lifting Lugs One lug for 10 to 20 horsepower and two lugs on larger units are provided to facilitate lifting and rigging the boiler into place. BOILER CONNECTIONS The following connections are factory installed in accordance with the ASME: Lattner Boiler Company Instruction Manual – WLF Models February 2005 . 7. One hand hole inspection plate is located on the top of the boiler for additional waterside inspection. and for periodic bottom blowdown. with the opening in accordance with the nominal dimension and rating sheets. 10. Boiler Base Frame A structural steel welded base is provided upon which the pressure vessel (boiler) is placed. ensuring corrosion resistance and longevity. C. In some instances or for specific project requirements.

and a minimum of 1 inch equalized piping and crosses for inspection and clean-out. if the column is a float-actuated device. Relief Valve(s) In compliance with the ASME Code. a snap acting single pole single throw switch activates a pump contactor for on/off pump or solenoid valve operation. gauge glass isolation valves. This device is an internal probe control located on the top centerline of the pressure vessel. 7. oil only. This device is wired in series to the burner combustion safeguard control to prevent burner operation whenever a low water condition occurs. or a combination style can be provided to Lattner Boiler Company Instruction Manual – WLF Models February 2005 6. valve capacity. These may be shipped loose to prevent possible damage during shipment. 3. Auxiliary Low Water Cut-off An additional control. These probes are wired to an electronic interlock relay for pump or water valve control. 1. one for on/off operation while the other is to prevent burner operation if excess steam pressure is sensed and requires a manual reset. The burner can be equipped to burn only gas. Low Water Cutoff To prevent burner operation whenever a low water condition occurs. D. 4. One control provides for on/off operation in response to system demand and one is provided as a safety lockout with a manual reset requirement. two stainless steel probes are furnished in the water column to provide pump on/off operation for water make-up. FUEL BURNING SYSTEM The factory-assembled boiler is furnished with an UL-approved and labeled fuel burning forced draft packaged system. steam boiler pressure relief valves are provided. Water Column 10 to 25 Horsepower Factory mounted and piped complete with gauge glass. Burner Type Our forced draft design is of the high radiant multi-port type for LP or Natural gas and of the mechanical pressure atomizing type for light No. 5. column drain valve. Size and quantity determined by the valve setting. The third control is for burner positioning at either low fire or high fire relative to steam demand. 2 fuel oil. Valves for larger sizes are not provided unless required by Code or as requested. The packaged system is mounted and wired integral with the front centerline of the boiler. (1) Quick Open Bottom Blowdown. 2.5 times the valve setting for high-pressure units. 30 to 50 Horsepower . gauge glass drain valve. or float operated control is furnished in the water column. Valves Standard valve piping package. Three (3) controls are supplied as standard. separate from the primary low water control is provided to prevent burner operation if a low-low water condition exists. Pump Control When a probe sensing main level control is furnished. and requires manual reset whenever a low-low water condition occurs. Steam Pressure Controls Two controls are furnished. 10 to 30 Horsepower consists of: (1) Main Steam Stop Valve. Boiler Steam Pressure Gauge A 3 ½" dial pressure gauge is furnished as standard. (1) Feedwater Stop Valve. 8. However. and the ASME Code. and two times the design pressure of low-pressure units. an electronic probe-sensing device. (1) Feedwater Check Valve [spring-loaded type].3 1. based on 1. The range of the gauge will be in accordance with the safety valve setting. and (1) Slow Open Bottom Blowdown.

As standard. gas pressure regulator. and gas pilot pressure gauge. Gas Assembly Lattner Boiler Company Instruction Manual – WLF Models February 2005 . This pump requires twice the burner firing delivery for suction line sizing. The standard burner is not designed to burn both fuels simultaneously. G. Forced Draft Fan An integral fan assembly direct connected to a NEMA foot mounted fan motor supplies the required combustion air. piped and wired gas piping assembly. Provided to interrupt control power to the 120-volt control circuit. in accordance with the latest UL and CSD-1 requirements. pilot safety shutoff valve. The oil pump is direct driven from the fan motor assembly and is used for mechanical pressure atomization of the fuel oil for proper combustion. oil discharge filter. Pump On/Off Switch Mechanically fixed for the correct combustion air to fuel ratio for on/off firing. Burner On/Off Switch The control of combustion air is managed with an integral inlet air damper operating as follows: 10 to 25 Horsepower 2. 30 to 50 Horsepower Mechanically linked with the fuel valve and air damper to provide fuel/air ratio at low fire and high fire. ignition transformer. fuel input control valve. 3. manual shutoff valve. manual shutoff cocks. safety shutoff valves. Provided to isolate the pump control circuit. Gas-fired units are equipped with a spark ignited gas pilot assembly. 3. Air Proving Switch An air pressure-sensing switch is mounted on the burner to prevent fan or burner operation if sufficient air is not available for proper combustion or pilot ignition. FUEL/AIR CONTROL 1. 4. Ignition/Pilot For oil-fired units a 10. 5.) Boiler base rail mounted. 2. Heated heavy oil is not available nor recommended for use with the Model WLF boiler.4 manually switch between gas and oil fuels. the boiler is equipped with dual safety shutoff valves. CONTROL PANEL A NEMA 1A enclosed (powder coated finish) control panel is mounted integral to the burner or as an independent bracket mounted unit on the boiler. Burner Operation The burner is designed to operate in an on-off mode for sizes at and below 25 horsepower. E. and an oil pump. operating at 3450 RPM. 2. Terminals Provided for the connection of the 120/1/60 volt supply and for external connections for field wiring. (Does not disconnect the main power source. as a minimum with the following: 1. consisting of main gas pressure regulator. high efficiency type. and low/high/low – off for boilers at 30 to 50 horsepower. Each fuel piping assembly is equipped.000-volt ignition transformer is furnished for direct spark ignition. The gas pilot assembly includes a pilot gas cock. the fan motor is an open dripproof. FUEL TRAINS The burner is equipped with factory mounted fuel safety control and safety shutoff valves for either natural gas or LP gas fuel or Light unheated oil fuel. This panel contains as a minimum the following components: F. 2 Fuel Oil Assembly For burners equipped to burn fuel oil. No.

2. Burner/Controls To ensure proper operation of the combustion safeguard control. All burner and boiler controls are checked for circuit continuity and operation after mounting and wiring the burner onto the boiler. and provides for the safe start sequencing of the burner from start-up. or operating the unit beyond its' capacity and rating. normal shutdown. ignition. This guarantee does not include items that are damaged due to circumstances carelessness. neglect. Refer to the Warranty Statement for more detailed information. This pre-programmed solid-state control is mounted adjacent to the burner. and main fuel light off the burner manufacturer subjects the packaged burner to a preliminary factory fire test. Efficiency The boiler package is guaranteed to operate at a minimum of 80 or greater. 3. Pressure Vessel The boiler is submitted to an ASME certified hydrostatic pressure test to ensure the pressure vessel meets the standards of the ASME. Wiring/Controls All devices and wiring are in accordance with the latest UL/NFPA 70 requirements. COMBUSTION SAFEGUARD 1. H. K. run. Each device is UL listed or recognized. is submitted to an additional hydrostatic pressure test. GUARANTEES 1. STAMPING 1. the unit is stamped with the "H" symbol for 15 psig design units and with the "S" symbol for 150 psig and greater designs. thinwall or rigid and seal tight may be used. Upon acceptance of the test by the authorized independent inspector. Boiler Piping Hydro Each Section I High Pressure Boiler ("S" stamped). FACTORY TESTS 1. 5. flexible conduit is used and as deemed necessary or in accordance with specifications. Warranty The complete package is warranted for a period of one (1) year from the date of initial start-up or 18 months from the date of shipment or notice to ship. A flame-sensing device of the UV scanning principle is furnished on all boilers. fuel input to steam pounds per hour output efficiency. 2. I. This test includes the integral steam and water trim piping and the trim valves. The burner is guaranteed to provide an efficiency of 97 or greater. and bears the UL label or stamp. NAMEPLATES. Status indicating lights are furnished on the front face of this control for visual indication of the burner/boiler operation. built in accordance with the ASME Code for high pressure steam boilers.5 4. 3. In accordance with the ASME Code (Section IV Heating Boilers or Section I Power Boilers). J. The National Board of Pressure Vessel Inspectors registration number is stamped on the pressure vessel along with the boiler serial number. year built. this test is supervised by an independent inspection agency. Relays Water level control relays as described above. and safety shutdown. Conduit As standard. 2. maximum boiler output and minimum safety valve capacity. One copy of the ASME data sheets is provided to the purchaser. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . whichever shall occur first. 6.

near the upper rear of the boiler. A facsimile nameplate of this data stamping is mounted near or on the front door of the boiler control panel. Boiler Feedwater care and maintenance information is provided on a nameplate located on the boiler near the water column. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . 2.6 beyond the control of Lattner Boiler. A "tag-line" mark is located on the front panel door or on the boiler casing near the water level control. 3. This information is located on the pressure vessel beneath an inspection plate. indicative of the lowest permissible water level within the boiler.

carpet.e. When moving or lifting the unit. or boom. C. Therefore. cement or cinder block walls). boiler piping. B. If the entry way is too narrow for the boiler and controls to pass through. FLOOR Boiler must be placed on a level.. PLACEMENT OF BOILER 1. If the unit will be moved into the permanent location with a forklift. or burner. Lifting – The boiler will arrive secured to a wooden skid/pallet and will include a lifting lug (top of the boiler). NEVER install boiler on a wood floor or any other combustible surface (i. 1.36 inches 3. enclosures and guards must be maintained and in place at all times. UNLOADING The boiler was loaded by Lattner (including any accessories) and accepted by the transport company as undamaged. 3. determine whether any shipping damage is apparent. etc. If lifting with a forklift. maintain 18 inches around the boiler Lattner Boiler Company Instruction Manual – WLF Models February 2005 . DO NOT attach slings or chains to any part of the boiler. A. linoleum). extended forks should be used and placed beneath the skid.7 SECTION 1: INSTALLATION WARNING: All installation procedures must be followed completely by a competent installer familiar with boilers and boiler accessories. if moving the unit through a tight space or into an area that will not permit a forklift. NON-COMBUSTIBLE SURFACE When placing boiler near non-combustible surfaces (i. attach chains to the base frame only. RIGGING Always use a competent rigger that has experience moving and setting boilers. One should properly denote all wiring and piping connections and match mark accordingly for attachment after the boiler is placed. attach the hook to the lifting lug on top of the boiler. Once the equipment is lifted from the trailer. Care must be taken to ensure that the boiler sits correctly on the forks such that the unit does not topple.. DO NOT attach slings around the boiler or to the burner in an attempt to pull the boiler. any damage sustained during transit and not filed with the transport company will be the responsibility of the rigger or purchaser.48 inches Sides . before unloading the equipment. All cover plates. It may be helpful to use a digital camera to record the location of trim items for reference. CAUTION: DO NOT lay the boiler on its side as the panels will not support the weight of the boiler without sustaining damage. crane. noncombustible surface. When lifting with a crane or boom. COMBUSTIBLE SURFACE UL specifies the following minimum clearance to combustible surfaces: ƒ ƒ ƒ Top . place the boiler on rollers or on 2 inch pipes and roll the boiler into place.36 inches Flue Pipe . Always note the weight of the boiler relative to the lifting capacity of the forklift. removal of the trim and controls can be executed. 2. If the unit is dragged. CAUTION: Read and follow all instructions before installing any boiler equipment.e.. follow the directions in section A. However. except during maintenance and servicing. 2.

The vent must be opened to the outside to allow air to flow into the room. if the stack is 6 inch in diameter then the overall stack should not exceed 90 feet (6x15) in length and height combined. per 1. SPECIFICATIONS Install all stacks in compliance with state and local codes. a draft inducer may be required to properly vent combustion gases. appliance category III for positive . D. 2. NOTE: Any equipment with a forced draft burner must be vented separately from equipment with atmospheric burners. WALLS OR CEILINGS When passing through combustible walls or ceilings. NEVER tie these stacks together. Lattner Boiler Company Instruction Manual – WLF Models February 2005 3. A general rule is not to exceed 15 feet for every inch of stack diameter. Chart based on 1 sq. etc.000 BTU input. other boilers. The entire stack must be the same size as the stack outlet on the boiler or one size larger. a stack thimble is required. per 1. If the boiler stack is connected to other equipment. 2. The thimble must be double wall stack. If there is other equipment in the room that uses air (large water heaters. in. Lattner recommends double wall stack per ANSI Z2231. STACK SIZE a. STACK 1. b. If unavoidable. NOTE: Any state or local fire and building codes requiring additional clearances take precedence over the above requirements. If a long horizontal run (4 feet or more) cannot be avoided. HORIZONTAL STACK Avoid any horizontal runs of stack. 5.). VENT SIZE Use the following chart to determine vent size for Lattner boilers. CONNECTIONS Limit connections to one of the following combinations: ƒ ƒ ƒ ƒ Two 90 degree elbows or One 90 degree elbow and one tee or One 90 degree elbow and two 45 degree elbows or Four 45 degree elbows. 3. the stack size must be increased. E.1. in. For example. horizontal runs should have a minimum incline of 3 inches per foot. VENTILATION The boiler room must be adequately ventilated to supply combustion air to the boiler. air compressors. additional venting capacity is required.000 BTU input 4. OVERALL LENGTH Avoid long runs of stack. 1 1/2 9" x 9" 3 13" x 13" 5 15" x 15" 7 18" x 18" 9 1/2 22" x 22" 10 23" x 23" 15 27" x 27" 20 31" x 31" 25 33" x 33" 35 40" x 40" 50 47" x 47" *1 sq. ADDITIONAL VENTILATION The above chart shows vent sizes for one gas fired boiler. exhaust fans. 6. COMBUSTION AIR 1. Proper sizing of the vent is important to ensure that sufficient free air is available for complete combustion and proper venting of the flue gases. HP Opening size Square inches required 2 81 in 2 160 in 2 230 in 2 325 in 2 499 in 2 525 in 2 690 in 2 970 in 2 1080 in 2 1600 in 2 2160 in vent pressure systems for boilers operating with a maximum continuous temperature not exceeding 500°F.8 for servicing.

DO NOT connect the power supply at this time. CODES AND STANDARDS Piping must comply with all industry standards (especially ANSI B31. F. Required by ASME Code if the boiler is operated over 15 psi. the steam line should slope downward. IF BOILER SHIPPED WITH CONTROLS REMOVED 1. STEAM PIPING Steam line should be pitched downward slightly away from the boiler and toward a steam trap. 4. 3. p. PIPE SIZE Size steam pipe according to system requirements. 2. If using a steam solenoid valve. G. and after the solenoid valve.9 6 inches larger in diameter than the vent stack. NOTE: All wiring should be done by a competent electrician. OUTLET SIZE Refer to product literature sheet for steam outlet size on a particular boiler model. ƒ ƒ ƒ Allows boiler to be isolated from the system during service work and May be helpful in throttling steam flow. The material used to close the opening between the stack and the stack thimble must be non-combustible. WIRING Re-wiring the controls will be covered in section K: ELECTRICAL CONNECTIONS. STEAM OUTLET 1. 15. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . 5.1) and all state and local codes. STEAM STOP VALVE Install a steam stop valve in the steam line as close to the boiler as is practical. REASSEMBLE See assembly print in this section. 2. the steam line should slope upward slightly to the solenoid valve.

The pressure rating of the valve must be equal to or greater than the pressure of the boiler safety valve but not lower than 30 psi. or a bronze valve have a WSP rating of at least 150. a WSP rating of at least 200. class 125 cast iron. rating and piping must be rated at 125% of the boiler safety valve setting. ƒ ƒ ƒ ƒ ƒ Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Boilers operating 101 psi to 150 psi require piping designed for a pressure of 125% of the boiler safety valve set pressure (schedule 80 blowdown piping) and two slow opening blowdown valves. Blowdown piping and all fittings must be the same size as the boiler blowdown connection (refer to product literature sheets). Boilers operating 16 PSI to 100 psi inclusive require a single blowdown form a pocket inside the valve are not acceptable blowdown valves. Y-type and ball valves are acceptable blowdown valves. Electric boilers not exceeding a volume of 100 gallons require only a single blowdown valve. or if steel.1 code and all city and state codes.10 Vent Lattner Blowdown Separator (Optional) Automatic Temperature Control Valve (Optional) Steam Boiler Motorized Ball Valve (Optional) Strainer Lattner Aftercooler (Optional) Stop Valve City Water Supply Dead Boiler Drain Valve Sewer Bottom Blowdown Valve Blowdown System Piping Diagram H. ƒ valve. class 150 steel. Standard globe and gate valves that form a pocket inside the valve are not acceptable blowdown valves. All blowdown piping must meet ANSI B31. BLOWDOWN PIPING (See Diagram Above) 1. Boilers built to the miniature section of the ASME code and stamped with a cloverleaf M symbol require a blowdown valve rated at least 125 psi. A Ytype or a ball valve is acceptable blowdown valves. require one blowdown or drain valve. If cast iron. or if bronze. these valves must be class 250. operating at 15 psi or less. BOILER BOTTOM BLOWDOWN DO NOT REDUCE. ƒ Low pressure boilers. these valves must be class 150.

NEVER connect the vent pipe from the condensate tank to the separator vent. CODES AND STANDARDS All blowdown piping. The inspection opening will be plugged. AFTERCOOLER If the water must be cooled before entering the sewer (required by some codes). ƒ 4. ƒ SEPARATOR MODELS: 810 uses 205A (auto) or 205M (manual) aftercooler. specifically to a blow-down separator. COOLING WATER SUPPLY Connect cold water supply pipe to aftercooler: ƒ ƒ Model 205A or 205M uses 1/2 inch NPT. the entire drain line must be lower than the bottom of the boiler. BLOWDOWN DISCHARGE All boiler blowdown water must be discharged to a safe location. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . BLOWDOWN SEPARATOR Select a Lattner Blowdown Separator according to the size of the boiler blowdown connection. Pipe to sewer or floor drain. SEPARATOR MODELS: 1410. 11. 7. Select the aftercooler according to separator drain size. then an aftercooler must be used. Some codes require the water to pass through an air gap before entering the sewer. 2. 1600. DEAD BOILER DRAIN VALVE For draining the boiler when it is cool and not under pressure. drain and sewer connections. AUTO BOTTOM BLOWDOWN VALVE A Lattner automatic bottom blowdown valve may be used in place of one of the manual blowdown valves. water piping and separator connections must be done in strict compliance with all applicable codes.11 ƒ Galvanized piping is not acceptable for boiler blowdown piping. 8. CONTROL BLOWDOWN VALVE ƒ A McDonnell Miller level control is supplied with the blowdown valves. DO NOT reduce the vent pipe size. 9. SEPARATOR DRAIN The water leaving the separator through the drain should be piped to the sewer. 1450. Valve must be rated up to the MAWP of the boiler. 6. 1800 use 301A or 301M aftercooler. Connect the control blowdown lines into the bottom blowdown line after the second bottom blowdown valve. Units may be either manual or automatic. INSPECTION OPENING The extra coupling in the separator vessel is an inspection opening. 3. 5. Vent pipe must discharge outside through the roof. 12. VENT ƒ ƒ ƒ ƒ The blowdown separator must be vented to atmosphere. 1 inch 1 ½ inch 2 inch 2 ½ inch Model 810 or 1410 Model 1450 Model 1600 Model 1800 ƒ 10. Model 301 A or 301 M uses 1 inch NPT. The aftercooler attaches to the separator drain connection and mixes cold water with the hot drain water.

GAS TRAIN PIPING 1. SUPPORTS Safety valve piping should be secured by clamps or braces to a wall or structural member. MOTORIZED GAS VALVE ƒ The gas train using a motorized gas valve is similar to that with a diaphragm valve. the boiler will have a sparkignited pilot. or S8660 flame safeguard control and a ignition transformer. the main gas valve and pressure regulator are two separate components. SAFETY VALVE 1. The motorized gas valve is a two-piece valve. and has no other functions. DIAPHRAGM GAS VALVE ƒ This valve combines the main gas valve and main pressure regulator into a single unit. With the motorized gas valve. in which all the above functions are combined into a single unit. As an option. INSTALLATION Be sure safety valve is threaded securely into the boiler or into the elbow supplied with boiler. 3. The boiler may be supplied with a Honeywell RM7895. This system has a Lattner Boiler Company Instruction Manual – WLF Models February 2005 NOTE: For additional information on the gas train refer to the assembly prints and product literature sheets. The upper section is the actuator. This system will shut off the main and pilot gas within four seconds of a pilot failure. With these controls. The lower section is the valve body. COMPONENTS In general. R8895. ƒ . 4. the combination gas valve can be supplied with an intermittent pilot. This system has a spark-ignited pilot and will shut off the gas within four seconds of a flame failure.12 I. The safety valve will always be installed in the upright position. 2. DO NOT reduce the safety valve discharge piping. pilot gas pressure regulator and pilot valve. CODES AND STANDARDS All safety valve piping and supports must conform to all applicable codes. J. This gas train requires a separate main gas pressure regulator. A separate pilot gas pressure regulator must be used. Do not allow the discharge piping to hang on the safety valve. 3. The actuator has a small built-in hydraulic system. As an option. the combination gas valve can be supplied with an intermittent pilot. 4. The motorized gas valve is a gas valve only. which is a plunger valve. DISCHARGE ƒ ƒ ƒ Pipe the safety valve outlet to a safe point of discharge. COMBINATION GAS VALVE ƒ Most Lattner gas trains include a combination gas valve. R4795. NEVER plug the safety valve outlet. a gas train should include the following: ƒ ƒ ƒ ƒ ƒ ƒ manual gas cock main gas pressure regulator main gas valve pilot gas pressure regulator pilot gas valve flame failure control ƒ 2. The hydraulic system opens and closes the valve. ƒ spark-ignited pilot and will shut off the gas within four seconds of a flame failure.

Manifold pressure when the boiler is operating should be 4. thru R2 use 1 inch NPT LV60 thru LV100 and R3 thru R12 use 1 1/2 inches NPT ƒ WARNING: NEVER use Teflon tape on any part of the gas train piping. 7. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . CODES AND STANDARDS All gas piping must be done in accordance with all applicable codes (National Fuel Gas Code. ƒ ƒ LV5 thru LV35 and R1-Jr thru R5 use ½ inch NPT LV60 thru LV100 and R7 thru R12 use ¾ inch NPT f. 1 inch NPT line is sufficient. Do not reduce the vent pipe size. d. CONDENSATE RETURN LINE Condensate from all steam traps should be tied into a common return line.5 inches water column. Vent should discharge through the roof or through a wall to the outside. GAS SUPPLY PRESSURE ƒ Natural Gas: Supply pressure should be between 6 to 11 inches water column ahead of the gas pressure regulator when the boiler is running. K. local building codes etc. Liquid Propane (LP): Gas supply pressure should be 11 inches water column. Use 1 inch NPT pipe and fittings between pump and boiler. Keep the number of elbows and fittings to a minimum. CONDENSATE RETURN SYSTEMS a. A pressure regulator will not be supplied with a propane fired boiler. GAS SUPPLY PIPE The gas pipe to the boiler must be at least the same size as the gas train supplied with the boiler. Overflow connection should be at least as large as the condensate return. ƒ LV5 thru LV35 and R1-Jr. b. ƒ OVERFLOW Pipe to floor drain. Install two spring-loaded check valves. utility company requirements.). VENT Condensate return tank must be properly vented to atmosphere. Install a hand shut-off valve between the last check valve and the boiler. DRIP LEG Gas supply piping must be installed with a proper drip leg ahead of any gas train components. ƒ Install a manual shut-off valve in the water line. 8.13 5. Install a valve in the line. This will void any warranty on the gas train assembly. The condensate return line should be pitched downward toward the condensate return tank. 6. BOILER FEED SYSTEMS 1. DRAIN CONNECTION Pipe to floor drain. PUMP SUCTION LINE This is pre-piped from the factory with an isolation valve and strainer. DO NOT reduce. PUMP DISCHARGE LINE DO NOT reduce. e.25 to 4. g. c. Make-Up Water Supply Connect city water line to the float valve provided with the boiler feed system.

WATER INLET Refer to the boiler assembly print for correct connection and location of feedwater inlet. ELECTRICAL CONNECTIONS CAUTION: All electrical work shall be done by a competent electrician. operating at 100 psi or less. Install a hand shut-off valve between the last check valve and the boiler. ƒ Use a 15 amp circuit breaker or fused disconnect if the boiler has a solenoid water feed valve or a pump motor 1/2 hp or less or a motor starter for a three phase pump. ELECTRICAL SUPPLY Supply 120 volt single phase from a separate fused disconnect. solenoid valve. e. Install two springloaded check valves. Maximum water temperature is 170° F. All pipe is 1/2 inch NPT. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . with no condensate return. WATER SUPPLY Connect water supply to the strainer. POWER SUPPLY Install pump raised at least one inch off the floor. Connect the power supply to the terminals in the panel box as shown on the wiring diagram. This pump is normally used on electric boilers only. globe valve. 1. boiler feed pump or pump motor starter as indicated on the wiring diagram. L. b. All wires that need to be re-connected will have a tag indicating the control or terminals to which they must be connected. springloaded check valve. 120 volt single phase. d. 3. PIPING The solenoid water valve assembly shall be piped in the following order: Y-type strainer. APPLICATIONS This feed system is used with boilers 7 hp or smaller. c. Wire the solenoid water valve. ƒ f. WATER SUPPLY Connect the water supply to the solenoid water valve inlet. SOLENOID WATER VALVE a. All wiring must be done in strict accordance with the National Electrical Code and any state or local codes.14 2. RECONNECTING CONTROLS If the boiler was shipped with controls removed. b. re-connect the wires according to the wiring diagram. 2. WATER PRESSURE This system will work only if the water supply pressure is at least 10 psi higher than the boiler pressure. WATER INLET 3. PUMP DISCHARGE DO NOT reduce. c. COMPONENTS System is preassembled with a solenoid water valve and strainer. Use a 20 amp circuit breaker or fused disconnect if the boiler has a 3/4 hp pump motor. d. WIRING WATER FEED Refer to the boiler assembly print for correct connection and location of feedwater inlet. INSTALLATION 4. and boiler. MODEL 1 PUMP a.

make sure the water supply is connected. CHECK FOR LEAKS Lattner Boiler Company Instruction Manual – WLF Models February 2005 . 5. 3. If not. make sure the water supply is connected. check for leaks in the piping and around the boiler. FLOAT BLOCK Remove the float block screwed into the body of the McDonnell Miller level control. If there are leaks. SECURE CONNECTIONS After all wiring is complete and before any power is supplied to the boiler. 6. 5. SPARE FITTINGS Check that all unused pipe nipples are plugged or capped. check for leaks in the piping and around boiler. 4. Make sure there is water in the tank. turn off the pump switch and fix all leaks before continuing. TURN ON Turn on the pump switch.15 ƒ ƒ "Hot" side will be marked L1. CONDENSATE RETURN SYSTEM ƒ If a solenoid water valve or Model 1 pump is used. BEFORE FIRING BOILER 1. If there are leaks. see troubleshooting section. M. 6. MODEL 1 PUMP OR SOLENOID 4. ƒ Make sure there is make-up water supply to the tank. be sure all wiring connections are tight. Replace with a malleable iron plug (supplied with the boiler). While the boiler is filling. TURN ON Turn on the pump switch. Pump or solenoid valve should start immediately. If not. 2. CHECK FOR LEAKS While the boiler is filling. Pump or solenoid valve should start immediately. MODEL 1 PUMP OR SOLENOID If a solenoid water valve or Model 1 pump is used. 5. turn off the pump switch and fix all leaks before continuing. see the troubleshooting section of this manual. Neutral will be marked L2.

When steam pressure drops enough. When the steam pressure reaches the controller's set point. When the boiler switch is turned on. The controller will continue to operate in this manner to maintain boiler pressure. Lattner Boiler Company Instruction Manual – WLF Models February 2005 .16 Differential Adjusting Screw Main Scale Adjusting Screw Manual Reset Lever Mercury Switch Screw plates Differential Setting Indicator Main Scale Indicator Index Mark Diaphragm Assembly Leveling Indicator Pointer Pressuretrol N. CONTROLLER Before the boiler is started. a "controller" and a "limit”. STANDARD All Lattner steam boilers will have at least two pressure switches. the steam pressure will rise. the steam pressure is 0 psi. 2. As steam is used. At this point. the pressure will begin to drop. the boiler will fire and start generating steam. PRESSURETROLS: CONTROLLER AND LIMIT (See Diagram Above) 1. the controller is in the "on" condition and is calling for heat. the controller will shut off the burner. the controller will start the burner again. As the boiler fires.

The differential is adjustable. the limit switch shuts off the boiler. High pressure boilers: Set the limit switch at least 10 psi higher than the controller and 5 psi lower than the safety valve setting. When the switch is turned to Hi. Lattner Boiler Company Instruction Manual – WLF Models February 2005 6. burner will fire. If for some reason the steam pressure should rise to 90 psi. The limit switch is supplied with a manual reset function. When the pressure drops to 70-72 psi the burner re-starts. . ƒ ƒ A minimum differential will maintain the boiler pressure closer to the set point. The controller is an operating switch. The boiler continues to cycle to maintain 80 psi. 8. Set the limit switch at 90 psi. ƒ Low pressure boilers (15 psi and less): Set the limit switch 4 psi higher than the controller and 3 psi lower than the safety valve setting. the night operating switch is by-passed and the boiler operates at the normal operating pressure. The boiler panel box will also be wired with a Hi/Lo selector switch. MORE INFORMATION For any additional information on the Honeywell Pressuretrols. the limit switch will shut down the boiler. EXAMPLE Boiler with a 100 psi safety valve. 5. 9. Set the controller at 80 psi with an 8-10 psi differential. 7. SETTING THE LIMIT This is done using the same procedure as for the controller. the controller shuts down the burner. refer to the Honeywell product sheet in the back of this manual. If the steam pressure trips the high limit switch. Turn on the boiler. 4. NIGHT OPERATING PRESSURE SWITCH A third pressure switch may be supplied as an option.17 3. Set the night operating pressure switch at approximately 10 psi. The limit setting will be slightly higher than the controller's set point. SETTING THE CONTROLLER (See Pressuretrol Diagram Page 10) On the left side of the pressuretrol is the set point indicating scale labeled "MAIN". Turn the main scale adjustment screw until the set point indicator aligns with the desired operating pressure. Turn the differential adjusting screw until the indicator aligns with the desired differential. A larger differential will help prevent rapid on and off cycling of the boiler. 10. Setting the selector switch at Lo. When the steam pressure reaches 80 psi. That amount is called the differential. The manual reset on the limit switch must then be reset before the boiler will operate again. If the controller fails to shut off the boiler and the steam pressure continues to rise. SETTING THE DIFFERENTIAL (See Diagram Page 10) On the far left side of the pressuretrols is the differential indicating scale labeled "DIFF". Turn screw clockwise to increase pressure. the boiler will operate at 10 psi. The pressure must drop by a set amount before the controller will turn on the burner again. the limit serves as an auxiliary safety cut-off. DIFFERENTIAL ƒ When the boiler pressure reaches the set point the controller shuts off the burner. counterclockwise to decrease pressure. the limit locks in the off position. This switch allows the boiler to operate at low pressure at night for heating the building. LIMIT The limit switch is similar in operation to the controller but has a slightly higher set point. The limit switch will not reset until the manual reset lever is pressed.

LEAVE BOILER SWITCH OFF 2. PRESSURETROLS Allow the boiler to reach its operating pressure. shut off the main gas supply and fix any leaks before continuing. . Refer to the burner manual in the product literature section for proper carbon monoxide. ADJUST PRESSURE If the burner head pressure is not within that range. CLEANOUT COMPOUND 1. 7. 2. For boilers with combination gas valve. If there are any gas leaks. and then turn the pressure adjusting screw underneath. ADJUST THE BURNERS Forced draft burners can only be properly set up by using combustion test equipment. 1. CHECK FOR GAS LEAKS Brush a soapy water solution on each connection in the main gas and pilot gas lines. BURNER HEAD PRESSURE ƒ Check gas pressure at burner head. 8. Do not use a match or other types of fire to locate a gas leak. Remove slotted head screw. NOT FOR WATER TREATMENT Lattner compound is intended to be a cleaning compound for new boilers only. 6. GAS SUPPLY Turn on the main gas supply cock.18 O. Look for bubbles. This odor will generally go away within two days. PURGE GAS LINE 3. FIRING THE BOILER CAUTION: All work performed on gas-fired equipment or gas train components must be done by qualified personnel. TURN BOILER SWITCH ON 5. Refer to Honeywell product sheet for proper instructions. ODORS It is normal for a new boiler to give an odor when it first fires. Repeat steps 1 through 6. P. Check the pressuretrols to be certain they’re are set as described and functioning properly. 4. 9. 11. carbon dioxide. These burners cannot be set up on how the flame looks. INSTRUCTIONS ƒ Motorized or Diaphragm gas train: has a separate gas pressure regulator. Burner head pressure should be as specified in the burner manual. 12. 10. ƒ Combination gas valve: has a built in regulator. turn knob to ON position. See also Boiler Care section. Refer to Maxitrol product sheet for complete instructions. BURNER SHOULD FIRE If not. adjust the gas pressure regulator. Remove large slotted cover screw and turn the adjusting screw underneath. and excess oxygen levels. Use according to instructions on the container. LEVEL CONTROLS Make certain the level control feeds water into the boiler and maintains a proper water level. It is NOT a boiler water treatment. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . refer to the troubleshooting section in this manual.

R. Replace the sight glass with new gaskets and washers. ROUTINE SERVICE These standard maintenance items are considered routine repair parts and are not covered under warranty. STANDARD MAINTENANCE ITEMS 1. SIGHT GLASS A sight glass with gaskets and washers should be in stock. START-UP OF LOW NOX BOILERS The burner system of the Lattner low NOx boiler consists of a gas valve with built-in pressure regulator. Thermocouples used for water heaters and furnaces are not nickel-plated and will not last. If any leaks are present around the gasket surfaces. 5. the actual volume of gas in cubic feet per hour is calculated using the formula for calculating the BTU input to the burner. GENERAL There are three standard maintenance items which should be kept in stock at all times to avoid unnecessary shut down. keep a thermocouple on hand at all times. 2. It is absolutely necessary to determine the firing rate of the boiler by actually determining the volume of fuel gas supplied to the boiler. 7. 8. 4. It is necessary to make sure the voltage to the boiler is correct. the exact firing rate can be determined. premix burner tubes and electronic ignition and flame monitoring. Formula for calculating BTU input to the burner Formula for calculating NOx corrected to 3% CO2 / O2 / Excess Air ratio curve chart Carbon monoxide tester “U” tube manometer or aneroid gas pressure gauge Before attempting to actually start the boiler. In order to properly start the burner you will need the following items: 1. High pressure water and steam leaks will erode the metal surfaces and cause expensive repairs. check the function of the low water cutoffs and pressure controls. After this check is confirmed. Lattner uses a nickel-plated thermocouple to withstand higher temperatures. the gas valve to the burner train can be opened and the burner started. GASKETS The handhole gaskets and the McDonnell Miller head gasket must be replaced after each internal inspection. Thermocouple replacement is described in the maintenance section. Further calculation using the actual BTU per cubic foot of gas. Keep a full set of handhole and McDonnell Miller head gaskets in stock at all times. 3. The system is basically similar to any boiler with a forced draft power burner and must be started in a similar fashion to any boiler with this type burner. 2. 4. Combustion analyzer Stop watch Calculator Knowledge of BTU content of the fuel gas Method of measuring the fuel gas input in cubic feet per hour. The boiler should then be started with the fuel gas shut off to make sure no valves will open during the burner pre-purge cycle. AFTER BOILER HAS OPERATED Check thoroughly for steam and water leaks around the boiler and all pipe fittings while the boiler is under pressure. Using a stop-watch and reading the fuel gas volume in cubic feet for a specific period of time at the gas meter. 5. THERMOCOUPLES For boilers with a standing pilot.19 Q. 6. 3. (Contact the gas utility supplier to determine the BTU per cubic foot Lattner Boiler Company Instruction Manual – WLF Models February 2005 . replace the gasket immediately. S. The gas piping must be properly purged up to the point of connection to the gas train. Purchase thermocouples from Lattner Boiler or a Lattner representative. motor driven blower. 9. 10.

Any pressure regulator readjustment may also require minor changes in the air shutter adjustment.20 content of the fuel gas). Adjust the air shutter on the burner blower to change the readings. As air shutter adjustments are made. The finalized burner adjustments are those that will produce the lowest corrected NOx readings using the formula for calculating NOx corrected to 3% calculation. After any adjustments are finalized. In general. readjustment of the air shutter will be required to prevent the loss of burner flame. Check the flue gas content for carbon monoxide. the 02 reading obtained on the combustion analyzer may be around 4% or slightly higher. Adjust the air shutter to obtain low NOx readings. Adjust the fuel gas pressure regulator on the combination gas valve until the BTU input matches the BTU input rating of the boiler. The “U” tube manometer or aneroid gas pressure gauge is used only to observe any changes in the manifold gas pressure as adjustments are being made. Adjust the air shutter while observing the NOx readings on the analyzer. Use the combustion analyzer probe to sample the flue gas below any draft regulator (if used). These readings will probably be about 2 Inches water column pressure. The reading must be below 400parts per million but preferably around 40 parts per million. record these readings for future use. the fuel gas pressure regulator will require minor adjustments to maintain the correct fuel gas BTU input to the burner. As the fuel gas input is changed. Lattner Boiler Company Instruction Manual – WLF Models February 2005 .

6807” Pressure Ounces 8.5000 BTUs per gallon 4.156 1.514 8.260 BTUs per cubic foot 21. the volume shall be figured on the basis of a ceiling height of 8 feet.180 BTUs per pound 102. provide a louver with a minimum free area of one square inch for each 1000 BTUs (4000 BTUs for power burners) input to the boiler and other fuelfired appliances in the room.560 12.624 5.5 Cubic feet per pound 1.092 Pressure Water Column Inches 15” 16” 17” 18” 19” 20” 21” 22” 23” 24” 25” 26” 27” 27.890 3.826 10.606 16.55 Cubic feet per pound 1.028 15. 2.599 2.5” 5” 6” 7” 8” 9” 10” 11” 12” 13” 14” Pressure Ounces .138 12.780 6.358 6.84 LBS per gallon at 60°F 31. 3.670 9. each sized as above.24 LBS per gallon at 60°F 36.468 4.982 11.450 15.202 5.936 7. When the boiler is located in a confined space.248 9.046 4.560 BTUs per pound 91.000 AIR VENT OR LOUVER – FREE AREA FOR BOILER ROOM 1. If air is taken from well ventilated surrounding rooms (not equipped with exhaust fans) a minimum of one square inch of area is required for each 1000 BTUs input to the boiler and other fuel-fired appliances in the room. Confined space: Any room or enclosure space which has a volume of less than 16 times the total volume of the boiler or boilers located in such space. Lattner Boiler Company Instruction Manual – WLF Models February 2005 .21 MISCELLANEOUS GAS INFORMATION Propane Gas 2.530 BTUs per cubic foot 21.734 2.28 Cubic feet per gallon 8.312 2.578 1. provide two permanent openings.01 Specific gravity GAS PRESSURE COMPARISON CHART Pressure Water Column Inches 1” 2” 3” 4” 4. If ceiling height is greater than 8 feet.500 BTUs per gallon 4.95 or 2.64 Cubic feet per gallon 6.716 13.294 13. one in or near the top of the boiler room and one in or near the bottom of the room.404 10.52 specific gravity Butane Gas 3.872 14. If air is taken directly form outside the building.

After adding the boil-out solution. failure to remove these coatings will result in your unit foaming. Continue the process until the overflow water appears clear. E. Do not allow it to produce any steam pressure. Dissolve these compounds in water and add dissolved chemicals through an opening at the top of the boiler. the use of a suitable face mask. H. NOTE: Prior to draining the boiler. F. G. DO NOT permit the dry chemicals or the concentrated solution to come in contact with skin or clothing. Failure to follow initial boiler warm-up procedures and burner adjustment using a combustion analyzer may cause damage to the refractory and/or the burner. nor is it time consuming. The procedure for correct operation and care of your unit is not complicated. The safety valves must be removed to prevent any contaminants or boil-out solution from entering them. The boil-out operation is easily accomplished by following the procedure as outlined below: A. Preparations prior to use: NOTE: The boiler should be started only by personnel completely familiar with burner start-up procedures. NOTE: When dissolving and mixing the boil-out chemicals. D. It is necessary to connect an overflow pipe from the safety valve opening in the boiler to a safe point of discharge. During this procedure. C. Tri-sodium phosphate and caustic soda each in the amount of one pound per 50 gallons of water are the suggested chemicals for cleaning boilers. If is necessary to clean the inside of the new boiler of oil and grease used as tube rolling lubricants. goggles. In this bulletin.22 BOIL-OUT RECOMMENDATIONS FOR YOUR NEW LATTNER BOILER With proper operation and maintenance you can expect years of trouble free service from your new Lattner boiler. Remove safety valves at the top of the boiler. Close boiler steam stop valve in the steam line. Maintain just enough heat to hold the solution at the boiler point. rubber gloves. threading. Fire the boiler intermittently at a low rate for 4 to 5 hours. Fill the boiler to the normal water line. and protective clothing is mandatory. and/or other various reasons beyond the manufacturer’s control. Drain the boiler while the water is still warm. Since these coatings may lower the heat transfer rate of the heating surfaces. Stop the burner and allow the water to cool to about 120°F. carry-over or other damage. priming. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . allow just a small amount of water to enter the boiler to carry off any surface impurities through the overflow pipe. we outline the proper boil-out procedure for you boiler prior to placing it into service. check with local water treatment facilities to determine whether special instructions or permits are required to dispose of the water. I. B. add water to the boiler until it is completely filled.

and applicable procedures. If not clean. On a hot water system. L. Wash until all evidence of dirt. mud. Consult a water treatment company for recommendations. After closing the openings and reinstalling the safety valves. Follow the advice of you water treating company. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . fill the boiler to its normal water level and fire it until the water temperature is at least 180°F to drive off any dissolves gasses and oxygen which might otherwise corrode the metal. chemical cleaning of the entire system is generally necessary and the entire system should be drained after treatment. attention must be given to the treatment of the raw water used as make up so that an accumulation of unwanted materials or corrosion does not occur. the condensate should be wasted until test show the elimination of undesirable impurities. cleaning compounds. K. repeat the boil-out procedure. Inspect the internal surfaces. and impurities are removed through the bottom handhole openings. Remove the handhole (and manhole) plates from the boiler and wash the interior with tap water at full pressure through a nozzle. On a steam system.23 J. During the period the condensate is wasted.

24 Lattner Boiler Company Instruction Manual – WLF Models February 2005 .

B. the dissolved minerals will separate from the water and attach to the boiler shell forming scale deposits. When using a condensate return system with a boiler. use the supply of Lattner Boiler Compound sent with the boiler. To remove oil and grease from a new boiler. The condition of the water inside the boiler is probably the most important single factor in determining the life of the boiler. PURPOSE Regardless of the care used in the manufacture of steel boilers. Pour in a mixture of Lattner Boiler Compound with water. C. This creates an unstable water line and causes water to carry over in the steam lines. Follow instructions on the label of the boiler compound and use initial dose as outlined. 2. Scale will deposit on all surfaces below the water line. remove the safety valve or use any capped or plugged opening above the water line. a certain amount of oil. the burners operate correctly. and the boiler be inspected periodically. it is advisable to waste all of the condensate for the first day or two. the heat will cause the oxygen to separate from the water. To ensure continuous reliable operation. Fire the boiler and maintain steam pressure of at least 20 psi for a minimum of two hours. SCALE DEPOSITS As the water boils. grease and pipe dope will still be in the boiler when shipped from the factory. Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 . The oxygen will then attack exposed metal surfaces. WATER TREATMENTS 1. GENERAL 1. This leads to corrosion and localized pitting of the metal. it is also important that the water feed system be maintained. A. This will keep the oils not taken care of by the boiler compound from going back through the pump and into the boiler.25 SECTION II: BOILER CARE CAUTION: Read and follow all instructions before working on any boiler. The new boiler must be cleaned. Then shut off the boiler switch. 2. NEW BOILER CLEAN OUT 1. and a regular blowdown schedule must be followed. If this is not possible then the new boiler clean out procedure becomes imperative. Oil in a boiler can cause water to foam and bounce. Allow boiler to cool to approximately room temperature before filling with cool water. DIRECTIONS When installation is complete and boiler has been filled with water. OXYGEN SCAVENGING Generally. This permits the boiler compound to cook and loosen the oil and grease from all metal surfaces. allowing the boiler to cool for one hour and the steam pressure to drop to 15 psi or less. Scale deposits will plug the piping and damage the controls. proper water treatment must be used over the life of the boiler. The life expectancy of any boiler will depend on the routine care given to the boiler. NOTE: Never fill a hot. boiler feedwater will contain oxygen and dissolved minerals. empty boiler with cold water. Inside the boiler. Open the blowdown valve to the wide open position allowing all water and steam to be blown out of the boiler.

3. WATER TREATMENT CHEMICALS 1. water carryover may occur. Secondly. NEW BOILER FOAMING In a new boiler. Some water treatment companies will ask for more samples after the boiler has been in use. as described before. The presence of oil or grease in the boiler water will cause serious foaming. CARRYOVER Carryover (often called priming) is simply small droplets of water leaving the boiler with steam. Foaming. foaming has two primary causes. D. This prevents the solids and the oxygen from attacking the boiler. 2.26 Layers of scale on the boiler shell act as an insulator. however. If the system uses steam faster than the boiler can make steam. Scale deposits inside the boiler can retain enough heat to cause the pressure to continue to rise after the burner is shut off. if left in the boiler. will raise the alkalinity. Never use zero grain soft water without additional chemical treatment. E. CAUSES OF FOAMING It is normal for the water line of Lattner boilers to fluctuate about one inch. Trisodium phosphate. Lattner clean-out compound contains trisodium phosphate. This must be thoroughly flushed out of the boiler. This will lower the boiler efficiency and cause the boiler shell to retain heat. analyze. A softener controls a substantial portion of the dissolved solids. is a key cause of carryover. preventing heat transfer to the water. PURPOSE OF WATER TREATMENT Water treatment chemicals are added to the boiler water to prevent the damaging effects of scale and oxygen corrosion. The pressure may rise enough to lift the safety valve. There are several competent water treatment companies that can test. SELECTING WATER TREATMENT The boiler feedwater should always be tested by a competent water treatment company that can analyze the boiler water and recommend the best water treatment program for the boiler based on water quality. a softener does not remove dissolved oxygen nor does it control the pH level. FOAMING / BOUNCING / CARRYOVER 1. foaming will occur. Overheating the boiler shell will cause permanent damage to the pressure vessel. 2. to make sure that the water treatment used is adequate. A third cause is excessive alkalinity (high pH level). A complete chemical treatment program must also control the pH level in addition to providing both an oxygen scavenger and control of dissolved solids. In dry cleaning applications. Oil from the steam piping and the boiler metal has accumulated at the water line. F. if perchloroethylene appears in the boiler water. If the foaming problem is eliminated. Be certain that all steam traps function properly. recommend and supply a boiler feedwater treatment program. causing foaming. WATER SOFTNER A water softener by itself is not a complete treatment program. Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 . Foaming can also be caused by excessive concentrations of boiler water solids. the carryover should stop as well. all piping is insulated and there are no leaks in the steam piping. chemical treatment is still necessary for oxygen scavenging and controlling pH. The chemicals react with the dissolved solids and dissolved oxygen. excessive foaming and bouncing (an unstable water line) can be caused by several different conditions. However. Whenever a softener is used.

FEED WATER SYSTEM 1. NEVER blowdown a hot boiler to a level where no water is visible in the sight glass. If there is an abnormally high steam flow from the vent. this water flashes to steam. Chloride = less than 500 PPM. the concentration of these substances increases and must be removed. 2. When the boiler water level drops about one inch. Swing check valves (even when new) are not suitable for boiler feed applications. GENERAL A boiler cannot operate without water. Blowdown will also remove some of the loose deposits that may be in the boiler. cavitation becomes more likely and prevents the pump from working properly. PURPOSE OF BLOWDOWN The boiler and the boiler level controls should be blown down at least DAILY.5 to 10. look at the vent pipe from the condensate return tank. Dry firing the boiler will permanently damage the boiler shell. When the pump starts. BLOWDOWN INSTRUCTIONS The boiler may be blown down at any pressure. causes the pump to sound like there are ball bearings in the water and prevents the pump from working properly. BLOWDOWN 1. known as cavitation. The purpose of water treatment is to protect the boiler shell from substances dissolved in the water. The water treatment chemicals keep these substances suspended in the water. PUMP CAVITATION Always use spring-loaded check valves in the feedwater piping. CHECK VALVES / STEAM TRAPS To check for bad steam traps or check valves. Sodium Phosphate = less than 100 PPM. open the boiler bottom blowdown valve (see assembly print) to the fully open position. Bad steam traps may also cause the pump to cavitate. Bad traps allow steam to return to the condensate tank and heat the water in the tank. Eventually.27 G. the boiler may dry fire. Contact a qualified company with experience in this field to provide a treatment program for your installation. 3. pH value = 8.8 grains maximum. Blowdown removes a portion of the water in the boiler in order to reduce the amount of dissolved solids. CONTROL BLOWDOWN Scale can also deposit in the water level controls and piping. If scale blocks these controls or the piping connected to them. a complete water treatment program must be used. H. Alkalinity = less than 300 PPM. Watch the sight glass. As the water temperature gets above 180° F. This condition. just as it can deposit in the boiler. A bad check valve will allow hot water from the boiler to back-feed to the pump. provided the blowdown piping is piped to a safe location (see Installation Instructions). either the traps or check valves are leaking. SUMMARY These are general guidelines for water treatment.000 PPM or 116. close the blowdown valve. the boiler must have a reliable water supply. The following are guidelines for boiler water quality: I. To ensure proper operation and extend the life of the boiler. Insufficient chemical treatment or even too much chemical treatment can damage your boiler. The McDonnell Miller level control and auxiliary low water cut-off water column MUST also be blown down daily. This is done by blowdown. 3. Lattner is not a water treatment company and cannot make specific recommendations for each boiler installation. Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 . Total dissolved solids = 2. For proper operation. To blowdown. 2.

SIGHT GLASS 1. replace the section of pipe. PROPER INSTALLATION Always be certain the sight glass is cut to proper length. feedwater pipes. 2. If leaks are found. Open the bottom drain cock (on the lower sight glass fixture) periodically to flush scale and sediment out of the sight glass. If the brass washers are not in place. The combined effects of wear and high pressure cause small cracks to develop in the sight glass over a period of time. L. Refer to the burner manual for proper settings of the forced draft burner. PIPING Check the piping for leaks. 2. This includes steam pipes. draft conditions and the actual gas input according to the gas meter. causing the glass to break. 3. 2. If these two conditions are not checked. BURNERS Occasionally the burners may need to be cleaned. GASKETS AND WASHERS When installing a new sight glass. Too much air will cause the burners to backfire when lighting. Remove the burners as described in the Maintenance section of this manual. BURNER ADJUSTMENT 1. When burners backfire. the glass may crack. Remember. DANGER Only competent personnel familiar with forced draft burners and having proper test equipment to measure burner input and analyze floe gases should attempt adjusting the burner. proper gas pressure. many problems can be detected before they become serious. tighten the fittings or connections. EXTERNAL INSPECTIONS 1. Check burner adjustment. 3. REGULAR PLACEMENT Replace the sight glass about every six months with new gaskets and brass washers. If the pipe threads show extensive corrosion. INSUFFICIENT AIR A properly adjusted burner will burn with an orange-blue flame. A yellow flame will deposit soot on the boiler heating surfaces and decrease efficiency. blowdown pipes and all fittings on the boiler. the gasket will twist. MAINTENANCE External inspections are routine observations of the visible portions of the boiler. Heat is wasted warming the excess air instead of making steam. efficiency declines. By noticing the normal boiler operation. 3. they frequently extinguish the pilot flame. air supply to the room. Make sure the fixtures are plumb. NEVER use galvanized pipe for a steam system or for condensate lines. condensate pipes. soak the burners in a mild solvent Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 . Eventually the sight glass will shatter. If the flame burns brilliant yellow. A yellow flame in general terms is caused by too much gas or too little air. it is also important not to open them too far. The continual movement of water through the water gauge set wears the sight glass. K. incomplete combustion is occurring.28 J. This is avoided by replacing the sight glass regularly. Use pressurized air to blow dust or lint out of the burners. when there is excess combustion air. 4. If the burner ports are blocked. MAINTENANCE The sight glass and water gauge set must be properly maintained in order to observe the boiler water level. EXCESS AIR In adjusting the burner air shutters. This will shut down the boiler and is also a nuisance. also replace the gaskets and brass washers. Additionally.

Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 .. NEVER store paper. The Uloops can be cleaned by removing the flue cap and spraying water over the loops. closed loop systems) and the water is treated. If the loops are covered with soot or dirt. DUST AND DEBRIS If dust. If the boiler uses minimal quantities of makeup water (i. Also clean the gas orifices so they are not blocked. it is very important to remove dust and debris that accumulate inside the boiler panel box. the boiler may need to be inspected only once a year. If a water spray cannot clean the loops. M. 3. INTERNAL INSPECTIONS 1. SAFETY VALVE Check that steam is not leaking from the safety valve. a normal product of combustion. and the high temperatures present will cause rust. PURPOSE OF INSPECTIONS Internal boiler inspections are required to check the structural integrity of the boiler shell and look for scale accumulations inside the boiler. If the boiler uses large quantities of untreated hard water. Many state and/or city codes require annual internal boiler inspections. Perchloroethylene. This depends on the amount and the quality of the boiler feedwater. Remove the auxiliary low water cut-off probe and remove any scale that has deposited on the probe. Check the float for leaks. Check the entire length of the stack to be sure there is no leakage of combustion gases. the pressure vessel must be removed from the jacketing and thoroughly cleaned with solvents and water. or other debris collect on and around the boiler. Any rust appearing on the boiler jacket will only affect the boiler's appearance and should not harm the boiler operation. 7. Use an air hose to blow out the panel box and controls. boxes or other combustibles near the boiler combustion chamber. Also. If the float leaks or is damaged. it must be replaced. 4. will accelerate corrosion. used in dry cleaning. lint. then replace it with a new valve. the boiler loses efficiency.e. When working in and around the panel box always shut the power off at the circuit breaker or disconnect switch (do not use the boiler switch). especially near the stack. it is also necessary to inspect the McDonnell Miller and auxiliary low water cut-off level controls. Depending on the condition of the boiler at that time. Important: Inspect and clean all interconnecting piping on the auxiliary low water cut-off and the McDonnell Miller. have a second inspection in six months or less. Be sure the boiler is near a floor drain. The time between inspections will vary from 30 days to one year. the boiler may need to be inspected every 30 days. Disassemble the McDonnell Miller control per instructions in the Maintenance section.29 to loosen debris. SURFACE RUST Occasionally sheet metal surfaces will rust. Water. and also on how the boiler is being used. These U-loops form the boiler heating surface. 6. rags. LEVEL CONTROLS When making an internal boiler inspection. then use pressurized air or a rag to clean the exterior surfaces. HEATING SURFACE The U-loops welded to the side of the vertical boiler shell must remain clean. 5. Check for scale build-up in the float chamber. NEW BOILER INSPECTION Make the initial inspection of a new boiler within 30 days of start-up. If the safety valve is not seating properly. around the float ball and the float rod. Hold the float completely submerged in a bucket of water and look for air bubbles. 2. The results of these internal inspections can be used to set a time interval for future internal inspections.

4. Replace the sight glass with new gaskets and washers. Keep a full set of handhole gaskets and a McDonnell Miller head gasket in stock at all times. High pressure water and steam leaks will erode the metal surfaces and cause damage to the boiler which will require expensive repairs. CAUTION: Read and follow all directions in the Maintenance section when repairing or replacing any parts on the boiler. Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 . ROUTINE SERVICE These standard maintenance items are considered routine and are not covered under warranty. DUST AND DEBRIS 1. 3.30 N. GENERAL There are a few standard maintenance items which should be kept in stock at all times to avoid unnecessary shut down. 2. replace the gasket immediately. If any leaks are present around the gasket surfaces. GASKETS The handhole gaskets and the McDonnell Miller head gasket must be replaced after each internal inspection. SIGHT GLASS A sight glass with gaskets and washers should be kept in stock.

200 – 2.500 umho/cm non-neutralized < 150 parts per million < 0.1 parts per million 3.0 1 part per million as CaCO3 600 parts per million as CaCO3 2.1 parts per million Lattner Boiler Company Instruction Manual – WLF Models Febraury 2005 .0 – 10.31 WATER QUALITY LIMITS FOR STEAM BOILERS Constituent Oxygen Carbon Dioxide pH Total Hardness Total Alkalinity Total Dissolved Solids Total Iron Specific Conductance Silica Oily Matter Recommended Value/Limit 0 parts per million 0 parts per million 9.500 parts per million < 0.

Shut the McDonnell Miller blowdown valve. By opening the blowdown valves with the boiler firing. the burners must shut off during this test. 1. NOTE: Certain maintenance items concerning specific components may be found in the product literature specifications section of this manual. This would indicate bad steam traps or check valves. 3. AUXILIAY LOW WATER BLOWDOWN. 5. Test the McDonnell Miller and auxiliary low water cut-off for proper operation. Reassemble each handhole with a new gasket. Visually inspect the boiler and water feed system for any water or steam leaks in the piping. the control may require immediate servicing. WEEKLY MAINTENANCE 1. 2. 3. Clean McDonnell Miller float chamber. Shut the boiler blowdown valve. IF APPLICABLE ƒ Turn the auxiliary low water column blowdown valve to the full open position. on water quality: ƒ ƒ ƒ ƒ ƒ Remove handhole plate and clean inside boiler. A. BOILER BLOWDOWN ƒ ƒ ƒ Turn the boiler blowdown valve to the full open position. Drain the sight glass. Shut the low water column blowdown valve. 2. DAILY BLOWDOWN The boiler and controls may be blown down at any pressure but he blowdown lines must be piped to a safe location.32 SECTION III: MAINTENANCE WARNING: All maintenance procedure must be followed completely by competent personnel familiar with boilers and boiler accessories. Check the vent pipe from the condensate return tank for excessive steam loss. Leave the valve open for 3 to 5 seconds. If the burners do not shut off. Clean scale off the auxiliary low water cut-off probe. 4. Check the sight glass for excessive wear or leaks. GENERAL MAINTENANCE 1. Leave the valve open for 3 to 5 seconds. MCDONNELL MILLER BLOWDOWN ƒ ƒ ƒ Turn the McDonnell Miller blowdown valve to the full open position. Reassemble the operating mechanism with a new head gasket. Do the following every two to six months depending. Clean the interconnecting piping between the boiler and auxiliary low water column if applicable. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . C. ƒ ƒ B. Watch the sight glass. CAUTION: Read and follow all instructions thoroughly before working on any boiler equipment. Let the water drop one inch in the sight glass. Clean the interconnecting piping between the boiler and McDonnell Miller.

4. 6. Make sure burners are clean and adjusted correctly. Inspect the burners. Replace the sight glass with gaskets and washers every six months or less if signs of wear appear.33 2. Inspect the pilot burner and thermocouple for soot or dirt accumulations. 3. 5. Rebuild or replace the check valves in the water feed line at least once a year. Always use spring-loaded check valves. Open the boiler for a complete internal inspection at least once a year. Lattner Boiler Company Instruction Manual – WLF Models February 2005 .

Refer to product literature. Vent. check safety shutdown timing. Refer to manufacturers instructions Perform slow drain test in accordance with ASME Boiler and Pressure Vessel Code Section VI. or gas pressure. Make visual check against manufacturers recommended specifications. In accordance with ASME Boiler and Pressure Vessel Code Section VI. verify annually. for both pilot and main flames. pilot burner. notify service organization if readings are very high. or fluctuating. Recommended Rules for care and operation of Heating Boilers. refer to product literature. Stack Pilot and Main Fuel Valves Pilot and Main Gas Valves Flame Failure Response Time Flame Signal Strength when Using Flamerod Weekly Monthly Annually Weekly Weekly Weekly Pilot Turndown Test Low Water Fuel Cut-Off As Required / Annually Daily / Weekly Semiannually Service Technician Operator High Limit Safety Control Operating Control Safety Valve Annually Annually As Required Service Technician Service Technician Operator Lattner Boiler Company Instruction Manual – WLF Models February 2005 . very low. Semiannually Annually Service Technician Operator Operator Operator Service Technician Operator Operator Ignitor and/or Pilot Flue. Close manual fuel valve supply. Refer to product literature. Verify BTU input and gas pressure and check with combustion test. Make aural and visual check. Perform leak test.34 7. Verify BTU input and gas pressure. read and log results. Refer to product literature sheets. If appropriate equipment is installed to measure flame signal. Make visual inspection and check flame strength with appropriate equipment. RECOMMENDED TESTING SCHEDULE Item Gauges and Sight Glass Instrument and Boiler Settings Firing Rate Control Frequency Daily Daily Performed By: Operator Operator Remarks Make visual inspection and record readings in a log. Required after any adjustments to flamerod. log results. Make visual inspection and check for proper operation.

Thursday P. Wednesday P.M. Friday P. .WATER Burner Fuel Supply Remarks Water Treatment Boiler Blowdown Feed Operator Water on Duty Make Up PRESSURE TEMPERATURE DAY TIME Level Control Water Column Gauge Glass Feed Pump Feed Pump or Feed Condensate if Flue Steam or Solenoid Solenoid Req'd Gas Water Level Low Water Cut Off BOILER LOG A. 35 A. A.M.M. Sunday Lattner Boiler Company Instruction Manual – WLF Models February 2005 P.M. A.M.M. A.M. Saturday P.M.M.M.M.M. A. National Board Serial Number: ______________________ Monday P.M.M. A. Tuesday P.

If the plate rocks back and forth. 3. 10. Scrape the old gasket material off the handhole plate. DO NOT LEAVE THE HANDHOLE PLATE INSTALLED IN THE BOILER WITHOUT THE GASKET. 5. 7. 8. Use a 7/8" socket. 9. 2. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . See assembly print for handhole location. 4. Remove arch over handhole plate. Sometimes it is necessary to tap on the handhole plate to loosen it. Remove the handhole plate nut. Remove any burrs with a file. use a 1-1/16" socket. Place the handhole plate back into the boiler handhole plate opening without the gasket. Disconnect all power to the boiler. Remove handhole plate. Make sure the handhole plate does not fall inside the boiler. Scrape the inside of the boiler around the handhole area to remove any scale or old gasket material. Figure 2 D.36 Figure 1 Stud Nut Arch Boiler Gasket Handhole Plate Figure 2 Over-compressed Gasket Handhole Plate Assembly NOTE: NEVER over-tighten gasket. HANDHOLE PLATE REMOVAL AND INSTALLATION (See Diagram Above) 1. 6. The boiler must be cool and drained of all water. except 10 and 15 HP SteamEase boilers. Make sure there are no burrs around the handhole opening. remove the high spots on the handhole plate with a file.

14. Replace the arch over the stud of the handhole plate. 16.37 11. 15. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Check the handhole plate for leakage with pressure on the boiler. This will only shorten the life of the gasket. let the boiler cool and drain to reposition the handhole plate. Reconnect the power to the boiler. DO NOT COMPRESS THE GASKET EXCESSIVELY. Install the gasket on the handhole plate. LUBRICANTS OR ADHESIVES WHEN INSTALLING HANDHOLE GASKETS. If leaks are noted. Tighten the nut hand tight. remove the pressure from the boiler. Repeat steps 12 through 16. The arch should extend across the width (short way) of the handhole opening. Reinstall the handhole plate into the boiler. 13. then turn the nut ¼ turn with a socket. DO NOT USE ANY GREASE. 12. Replace the nut on the handhole plate stud. Make sure the gasket is pressed firmly down on to the handhole plate.

Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Close the upper and lower water gauge valves. 10. Assemble the new sightglass as shown. 13. 12. 4. Slide the new glass into the upper fixture. Tighten the sightglass packing nuts hand tight. NEVER over tighten the sightglass. 9. Be careful not to break the sightglass when removing. Boiler and pump should be switched off. 7. Open the upper and lower gauge valves. Loosen both sightglass packing nuts (top and bottom) with a wrench. 8. Switch on boiler and pump. Use a wrench to tighten 1/4 turn past hand tight. 5. 11. 3. Glass should lift out of the lower fixture. Glass should clear the lower fixture and tilt into position. Pull glass down. 6. Slide glass carefully upward into the upper fixture. Slide the sightglass down into the lower fixture. out of the upper fixture tilting the glass slightly to clear the lower fixture. This will crack the glass and cause it to shatter under pressure. Boiler should be cool and the water level should be below the lower water gauge fixture. SIGHTGLASS REMOVAL AND INSTALLATION (See Diagram Above) 1. ALWAYS replace the gaskets and brass washers when installing a new sight glass.38 E. 2. Equalize the gap between the upper and lower fixtures.

body or operating mechanism. 4. Always check the operating mechanism for any scale that might be blocking the float or float arm. Draw up the bolts evenly to prevent damage to the gasket. 14. 5. Reinstall the eight bolts to the operating mechanism. 2. Carefully scrape the old gasket from the body and the operating mechanism of the McDonnell Miller. Check the float for any holes. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Tag all wires to ensure they are reconnected properly. 3. Use a 9/16" wrench or a crescent wrench. Disconnect all power to the boiler. MCDONNELL MILLER SERVICING (See Diagram Above) 1. Remove the eight bolts holding the operating mechanism to the McDonnell Miller body. It may be necessary to tap near the base of the operating mechanism to free it from the body. Reconnect the McDonnell Miller per wiring diagram. 13. 12.39 Steel Plug Gasket Terminal Strip and Mercury Switch Housing 8 Bolts Req’d Steel Plug Operating Mechanism 8 Bolts Req’d Body Float Body McDonnell Miller Assemblies Model 157 (Left). Model 150 (Right) Operating Mechanism Gasket F. The boiler should be cool and drained of all water just below the McDonnell Miller control. Disconnect the wiring and conduit connection to the McDonnell Miller. 8. 9. 10. Reconnect all power to the boiler. Be careful to avoid damaging the float and float arm which extend into the body of the McDonnell Miller. Always reassemble the McDonnell Miller operating mechanism to the body with a new gasket. 6. Hold the float submerged in a bucket of water and look for any air bubbles coming from the float. Remove any scale in the McDonnell Miller body. 7. Make sure all water is drained from the McDonnell Miller control by opening the control blowdown valve. 11. Lift the McDonnell Miller operating mechanism out of the body. Do not over tighten the bolts.

8. Replace all pipe plugs and pipe caps. Flush out all piping with water after cleaning. 5. Remove the pipe caps with a pipe wrench. Clean all interconnecting piping by removing the pipe plugs or pipe caps. 6. Disconnect all power to the boiler. Make sure all water is drained from the McDonnell Miller or auxiliary low water cut-off control by opening the blowdown valve. 7. Tighten with a wrench enough to prevent water or steam leaks. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Reconnect power to the boiler. 4. Use a steel rod or a hard brush and clean inside of the piping. Remove all 1" pipe plugs with a 13/16" wrench or a crescent wrench. CLEANING INTERCONNECTING PIPE (SEE ASSEMBLY PRINT) 1.40 G. The boiler must be cool and drained of water below the level controls. 3. 2.

2. Only tighten the probe enough to stop any steam leaks. Only the wire on the probe is to be removed. Clean the stainless steel probe and probe fitting. The relay has a small tab so that it can be installed only one way. Remove the four screws on top of the 3. 2. 4. 8.41 H. Remove the wire from the probe using a 5/16" wrench or a crescent wrench. Reconnect the power to the boiler. 7. Use a 13/16" spark plug socket and remove the probe. Disconnect all power to the boiler. Replace the Warrick with a new 26M series Warrick. AUXILIARY LOW WATER CUT-OFF PROBE CLEANING 1. I. 5. probe enclosure with a Phillips screwdriver. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Pull relay out by hand. Reinstall the probe wire to the probe. Over tightening will destroy the threads of the enclosure. 3. 6. This may take a little force but be careful. Reconnect power to the boiler. 4. Reassemble the cover to the enclosure with the four Phillips screws. Disconnect all power to the boiler. Reinsert the probe using a 13/16" spark plug socket. WARRICK RELAY REPLACEMENT (See Diagram Right) 1. 9.

Gas valve opens and main burners light. are reset. Turn boiler switch to the on position. 2. check the following: 1. If the McDonnell Miller does not shut down the boiler. Note: Generally. 9. Turn the pump switch on. If the pump cannot fill the boiler. Schematic diagram of the boiler. If the boiler has optional controls. the boiler should fire. refer to the wiring diagram. Continuity tester. Check if breaker is tripped or if fuse is blown. 5. 6. Ammeter. all Lattner boiler controls are wired in series. 2. When the boiler calls for water. NORMAL OPERATION All Lattner forced draft gas-fired boilers follow the same operating sequence: 1. 6. 3. 2. 3. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . McDonnell Miller shuts off the pump or solenoid water valve when water is at normal operating level. 7. Gas pressure gauge. Boiler pressure will rise to the pressure controller’s set point. 10. BEFORE YOU BEGIN Before you begin any troubleshooting procedures. the McDonnell Miller low water cut-off will shut down the boiler. McDonnell Miller pump control turns on the pump or solenoid water valve. A. When all switches close. Be certain manual gas cock is open and that gas is supplied to the boiler. B. 8. Be certain boiler switch is on and that there are 115 volts supplied to the boiler control circuit. BASIC SERVICE TOOLS The following basic equipment will aid in troubleshooting Lattner boilers. Be certain pump switch is on and check for proper pump switch is on and check for proper pump voltage and phase if different from boiler circuit. 7. 4. 7. Carbon monoxide sampler. if supplied with the boiler. 5. 3. the McDonnell Miller level control will turn on the pump or solenoid water valve. 6. Volt/ohm meter. The then controller will shut off the gas valve. Not all equipment is needed for every repair: 1. 4. 8.42 SECTION IV: TROUBLESHOOTING WARNING: All troubleshooting procedures must be followed completely by competent personnel familiar with boilers and accessories. Be certain that all manual resets. the auxiliary low water cut-off will shut down the boiler. Flame simulator. The boiler operating controls and limits form a series circuit. Pump or solenoid valve fills boiler. C. If boiler has a combination gas valve. 5. be sure knob is in the on position. Make sure the pilot is lit. Flue gas analyzer. CAUTION: Read and follow all instructions before troubleshooting any boiler equipment. Make sure there is water in the boiler. 4.

6. No water is supplied to the pump. 3. pump does not run. 1. TROUBLESHOOTING The chart below is a general chart that shows common problems that may occur in boiler operation. 3. Water temperature is too hot. Pump out of adjustment. 8. 1. 3. Solenoid is not opening (model #1 pump). If the problem and/or cause is not on the chart below. McDonnell Miller float is stuck. Solenoid water valve is not seating properly. 4. 1. McDonnell Miller mercury tube is malfunctioning. Pump or solenoid water valve is wired incorrectly. The causes are arranged with the most common first. Strainer is plugged. 5. Pump or solenoid over fills the boiler. 7. 3. Circuit breaker tripped or fuse is blown. Pump isolation valve is closed. Insufficient quantity of gas supplied to the boiler. 5. 5. Bad check valve. Boiler flue passages need to be cleaned. Problem Boiler and pump switch is on. 4. read down the side of the chart from the problem. Burners out of adjustment. Always replace with a spring-loaded check valve. 9. To us this chart. This chart is only to be used by competent service personnel familiar with Lattner boiler equipment and controls. Pump is wired incorrectly. Gas valves firing on low fire only. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Bad steam traps. McDonnell Miller piping is plugged. Cause 1. 5. 2. 6. Scale build-up inside boiler. Improper gas pressure. Bas burner heads (primarily with cast iron burners). McDonnell Miller is wired incorrectly. Pump runs but does not maintain water level in boiler. McDonnell Miller float is operating incorrectly. 2. then read the right side for possible causes. Hand valve between pump and boiler is closed. 7. 2.43 D. 2. Boiler takes excessive time to reach pressure. McDonnell Miller is wired incorrectly. 4. low water level in the boiler. consult a trained boiler service company. 4.

Probe is out of probe socket. 7. 12. Main or pilot gas line not purged. Thermocouple not functioning properly. 3. 8. Incoming gas line to gas valve is too small. 9. Pump switch is turned off. Pilot tubing is blocked or kinked. Pressure regulator not functioning properly. Water in boiler is too soft. Air shutters on the burner are open too wide. 10. Auxiliary level control relay wired incorrectly. 1. Scale build-up inside of the boiler. 3. Thermocouple too tight or loose in the gas valve or pilot safety switch. 2. 11. Pilot safety switch. Bad check valve. Pilot burner not functioning properly. Pilot gas valve not functioning properly. 1. 9. 6. 7. Boiler shuts down with auxiliary low water cutoff. Lack of free air in the boiler room. Gas valve not functioning properly. Pilot fails to light or stay lit. 2. Lattner Boiler Company Instruction Manual – WLF Models February 2005 . 1. 8. Excessive draft around the boiler. 2. 3. No water is supplied to the pump. Probe wired incorrectly. 7. McDonnell Miller is not operating correctly. Pilot burner is not in correct location. 1. dirt or debris on it. 4. Pump is not functioning properly. 5. Operating pressure switch is set higher than limit switch. Pilot gas pressure too high or too low.44 Limit switch always shuts down boiler. Pilot tubing blocked or kinked. 11. Always replace with spring-loaded check valve. 4. Blocked orifices on main or pilot burner. Probe has scale. 2. Drafty conditions around the boiler. 5. 4. 5. Operating pressure switch is not operating correctly. 6. 10. Flashback or rough light-off of main burners. 3. 6. Pressure switch differential set too close. Foaming problem in boiler.

Once the problem has a possible cause. refer to Maintenance or product literature section for the proper procedures to repair or replace defective parts. Operating and/or limit switch set higher than safety valve. Scale build-up inside boiler. 3. 2. Operating and/or limit switch wired incorrectly. Gas valve wired incorrectly. 4. 1.45 Safety valve lifts. 5. Pressure in boiler exceeds pressure setting of safety valve. Lattner Boiler Company Instruction Manual – WLF Models February 2005 .

No allowance will be granted for any repairs or alterations made by Purchaser without Lattner’s prior verbal or written consent. has not been operated in accordance with Lattner’s printed instructions or specifications. has been subject to misuse. but not later than the one-year guarantee period. ANSI and NFPA Codes and all applicable local. Lattner shall not be liable for any loss or damage resulting. Lattner shall not be liable for special. Such authorization may be obtained by calling the factory at 319/366-0778 or by writing to P. has been operated under conditions more severe than or otherwise exceeding those set forth in the specifications for such boiler.O. state and national codes. and the liability of Lattner with respect to any contract or sale shall no exceed the cost of repair or replacement of the boiler or other equipment manufactured by Lattner. Lattner will not be responsible for labor charges. ANSI and NFPA Codes and applicable local. Items returned to Lattner must be accompanied by a factory-supplied return goods authorization (RGA). provided the boiler is operated under normal use and service for which it was intended. such claims shall be deemed waived. An independent ASME boiler inspector inspects the construction of each boiler and (1) checks mill test reports on all materials used to insure that the chemical and physical analysis of such materials complies with the ASME Code. or has not been properly installed by a qualified technical in accordance with but not limited to ASME. LATTNER MAKES NO WARRANTLY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE. The above Warranty shall not apply to any boiler or other equipment manufactured by Lattner which: 1) 2) 3) 4) 5) 6) has been repaired or altered without Lattner’s written consent. IA 52406. directly or indirectly. and (3) witnesses the final hydrostatic test and then places the ASME stamp on the boiler shell and signs an ASME data report certifying the boiler is ASME approved. indirect. (2) inspects each boiler shell during construction to see that workmanship complies with the Code. EXPRESS OR IMPLIED. to replacing or repairing any defective part of the boiler or other equipment of it manufacture. LATTNER BOILER COMPANY Cedar Rapids. This exclusion from liability includes the purchaser’s expenses for downtime or for making up downtime. from the use or loss of use of the boiler. Lattner warrants the boiler and any other equipment of its manufacture to be free form defects in material and workmanship for one year from the date of shipment from the factory.46 LATTNER BOILER LIMITED WARRANTY A Lattner boiler shell is guaranteed to be constructed in accordance with the ASME Code. or damages to property. and only if the boiler has been properly installed by a qualified technician in accordance with but not limited to ASME. has been altered in any way so as. The remedies set forth in this Warranty are exclusive. or consequential damages. state and national codes. loss or damages caused by defective parts not manufactured by Lattner. and there are no oral agreements or warranties collateral to or affecting this Agreement. in the judgment of Lattner. at Lattner’s option. Lattner neither assumes nor authorizes any person to assume for it any other liability in connection with the sale or use of the boiler or other equipment manufactured by Lattner. negligence or accident. Cedar Rapids. damages for which the Purchaser may be liable to other persons. THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF ALL OTHER WARRANTIES. otherwise. Box 1527. Purchaser must notify Lattner of a breach of warranty within thirty (30) days after discovery thereof. to adversely affect the stability or reliability of the boiler. IA USA Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Lattner’s obligation under this Warranty is limited.

from its headquarters in Cedar Rapids. Beginning thirty (30) days after the invoice date. IA. IA – USA. CANCELLATION AND DELAYS Subsequent to the receipt of Purchaser’s Purchase Order and the Company’s issued order acknowledgement. SHIPMENT Any shipping date shown in the body of the quotation or order acknowledgement. The Company’s sole warranty statement and this paragraph contain the Company’s sole warranty and the Company makes no implied warranty. without causing a breach or incurring liability. flood. Upon receipt of payment in full. DAMAGE LIMITATION Under no circumstance shall the Company be held liable for any loss of profits. and a minimum 15% restocking charge. storage. or any incidental or consequential damages of any kind with respect to its products or the transaction by which its products are sold. unauthorized modification or service. TAXES Purchaser shall be liable for all Federal. EXCLUSION OF OTHER TERMS This constitutes an offer on behalf of Lattner Boiler Manufacturing (the Company). art of war. The Company’s warranty shall be voiced by any abuse.O. whichever is lower. down time. extended warranty or local delivery charges. If an event occurs that is beyond the control of the Company. types. the Company will rescind the lien. the quotation will remain valid for a period of thirty (30) days from the date hereof. capacities. Warranty shall also be voided if water treatment has not been provided or by improper start-up of the equipment. EQUIPMENT SELECTION The Purchasers selection of sizes. purchasing. and specifications and suitability thereof for the specific application shall be the unshared responsibility of the Purchaser or Purchaser’s representative or consultant. civil disorder. PRICES Unless defined otherwise in the quotation. the equipment shall be place in storage at the Purchaser’s risk and expense. SERVICE Unless otherwise noted herein. the cost of the equipment does not include service or installation. installation. or to offset costs incurred by the Company in order preparation. shall be governed by the interpreted and construed in accordance with the laws of the State of Iowa. The Courts in the State of Iowa will have the sole jurisdiction over any claim arising under this contract of sale. Consent. and there is no implied warranty of merchantability or fitness for any particular purpose. neglect. and the only if the so authorized material is in new and . SECURITY INTEREST For the purposes of securing payment. on any unpaid portion of the purchase price. ASSIGNMENT All sales as evidenced by the Company’s acknowledgement hall be binding up on and inure to the benefit of the Purchaser and the Company and their respective heirs. will be upon the condition the purchaser assumes all carrier charges. or use not in accordance with the Company’s instructions. which are subject hereof. engineering. PAYMENT Purchaser shall pay with US funds. if any. at which time it will automatically expire unless extended by a signed document issued by the Company. only upon prior written authorization of the Company. to sell the goods described in the quotation. the Purchaser may not change nor cancel the order in whole or in part. or any cause not within the reasonable control of the Company. The Company may. The credit will be based on the original invoice price or the current price. start-up. the full amount of the invoiced purchase price within 30 (30) days of the Company’s invoice. act of God. and or in actual production of the order in the event of a cancellation. lack of maintenance and service. and is subject o change as determined by shop loading if and when this quotation should be realized as an actual sale.B. allocate goods which are in short supply irrespective of the reasons therefore among customers in any manner which the Company in its sole discretion deems advisable. delay or default in transportation. which is an annual rate of 24%. service. RETURNS AND RESTOCKING Equipment may be returned to Lattner at 1411 9th Street SW. revolution. whether the equipment has shipped or has been delayed through no fault of the Company and subject to approved credit. fire. The Courts in the State of the Iowa. and transfer to storage shall occasion shipment and the order shall be invoice as if shipped. The Company shall no incur any liability of any kind for failure to ship on any particular date unless a firm shipping date has been expressly agreed to by an officer of the Company. and local taxes with respect to the purchase of the equipment proposed. misuse. exclusively on the terms and conditions stated. WARRANTY AND PERFORMANCE Products shall be warranted in accordance with the Company’s standard warranty statement. GOVERNING LAW The transaction with respect to the goods. the Company may pass such increased cost(s) on to the Purchaser. Acceptance of this by the Purchaser is hereby expressly limited to these Terms and Conditions and shall be applicable to any order issued by the Purchaser unless other terms have been agreed to in a written document issued by the Company. form No. loss or damage that is the proximate result of any act of government authority. prices are F. or assigns. and that even delays the Company’s performance and causes its cost of production to increase because of the delay. The Company reserves the right to revoke or modify these credit terms. the Company may issue a lien on the equipment. Lattner Boiler Company Instruction Manual – WLF Models February 2005 .47 STANDARD TERMS & CONDITIONS LIMITATION ON QUOTATION Unless otherwise stated in the quotation. in a separate written document. responsibility for damages in transit. FORCE MAJEURE In no event shall the Company be liable for loss or damage resulting from any delay or failure to ship or other failure. exclusive of freight. unless exclusively exempted from any taxes and proof thereof is on file with the Company. if given. IA 52406. All services performed by the Company are subject to purchaser’s payment of the Company’s prevailing charges plus necessary travel and living expenses. less the applicable restocking charge. Purchaser shall pay a late payment charge of two percent (2%) per month. please refer to Lattner’s Service Policy for specific details. off-loading. The price change to reflect the Company’s cost to implement the change.unused condition and returned within one year from original date of shipment. riot. successors. Cedar Rapids. and until such time that payment has been received in full. Cedar Rapids. following the invoice 30 days time. 2-98. represents the Company’s approximated schedule as of the date of the quotation. In the event that Purchaser delays shipment of the equipment up the Company’s notice to ship. without the written approval and acceptance by the Company of such cancellation or change. inability to obtain materials or facilities from normal sources. State. Whenever service is quoted.

After cover plate is in boiler and gasket is in place. 2. Remove old gasket and thoroughly clean the surface on boiler and on cover plate. Then. tighten only enough to stop leakage.48 Easy Topog-E® Boiler Installation Instructions 1. Gaskets on the bottom of a boiler shell are usually hard to install without leaking because particles of scale or sand tend to run down onto the mating surface between the time the surface is cleaned and the handhole cover plate is put into place ready • Lattner Boiler Company Instruction Manual – WLF Models February 2005 . make one last cleaning swipe of the mating surface in the boiler. Use a rag wrapped around your finger. then center plate in opening and tighten nut enough to give a snug fit. Set crab. snug up with 1/4 turn of wrench. lubricant. Never over-compress a gasket. Be sure the gasket is pushed down tight on the plate. or adhesive. 4. Do not use any grease. SPECIAL NOTES: • If gasket leaks while pressure is being built up. Sometimes it is necessary to buff each surface. Place Topog-E® Gasket on handhole cover plate. 3.

When this happens. • As pressure builds up in the boiler the bolt and crab will loosen. It takes some time for the gasket to reach its ultimate compression.com Lattner Boiler Company Instruction Manual – WLF Models February 2005 . Recommendations for use of Topog-E Gaskets are based on tests believed to be reliable and on actual customer experience. OK 74110-4682 1-800-587-7123 918-587-6649 Fax: 918-587-6961 topogesales@topog-e. This is especially true if the boiler is operated intermittently. or expect to replace the gasket in a very short time. In this case. We disclaim any responsibility. Topog-E® Gaskets are sold for use in steam. so the operator should watch this for several days and keep the bolt tight until it no longer loosens. and other selected applications only. vacuum pressure in the boiler would suck the cover plate in and allow the water to leak out of the boiler. whether or not such use is in accordance with directions. drain the boiler again and start over. 1224 North Utica Tulsa. Since their installation and use is beyond our control we cannot guarantee the results. air. i. Re-using gaskets after they have been in service is not recommended! • Topog-E® Bolt Gaskets (when required) should be used with Topog-E® Handhole Gaskets. shut off at night to allow pressure to drop. water.49 to be tightened..e.

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..... s Can be used with steam........ s Scaleplates marked in English (psi) and Metric (kg/cm2) units.....1 kg/cm2 or 2068 kpa)... s Surface mount is available using screws through holes (knockouts) in case backing.. 1995 60-2150-10 ...... s Dustproof..L404A-D.. s Stainless steel diaphragm (except 300 psi [21...... s L404F models available with European enclosure......... 10 L............. or dpst switching and in variety of operating ranges........ s Trip-free mechanism on manual reset models assures that limit function of controller cannot be defeated by jamming reset lever...... ground screw. s Leveling indicator visible through cover... automatic limit protection.. s Automatic reset models have adjustable......M Pressuretrol® Controllers L404 and L604 Pressuretrol® Controllers are line voltage pressure controllers that provide operating control............ 3-95 • ©Honeywell Inc. trouble-free mercury switches (all models except L404F....... 5 Setting and Checkout .. oxygen.. spdt........... s L404B is recommended for supervision of atomizing medium pressure in oil burner systems.... Z..............1 kg/ cm2 (2068 kPa)] models) also allows use with ammonia.. s Clear plastic cover on case to observe pressure settings and switch action......... distilled water.... and similar media.......... 8 Service Information .... s Screw adjustments made on top of case.. 2 Installation . which has snap-acting switch)... subtractive differential (except L604M). non-combustible gases.... or manual reset limit protection for pressure systems of up to 300 psi (21...................... 2 Ordering Information .. CONTENTS Specifications ........... air. British Standard Pipe Threads. L604A.....F... s Hexagonal fitting with 1/4-18 NPT internal threads for direct mounting to 14026 Steam Trap (siphon loop).L.............. • Rev.. or fluids non-corrosive to the pressure sensing element....... s Models are available with spst.. and scaleplates marked in kg/cm2 and either psi or kPa.

please write or phone: 1. if desired and available (see Table 1. except where noted in Table 1. Accessories. Replacement parts. .4 to 3.14 to 1. 5 to 50. See Table 1. 1885 Douglas Drive North Minneapolis. 4. Manufacturing in Australia.0 kg/cm2 [138 to 2068 kPa]) . or would like to comment on our products or services. MAXIMUM AMBIENT TEMPERATURE: 150°F (66°C). SWITCH(ES): Mercury switch(es) in all models except the L404F. U. hole in side of case for 1/2 in.M SPECIFICATIONS • ORDERING INFORMATION Specifications TRADELINE® models are selected and packaged to provide ease of stocking. Mexico. which has a Micro Switch snap-acting switch. Note b). ADDITIONAL FEATURES: TRADELINE® pack with cross-reference label. United Kingdom. Taiwan. conduit. 2. 3. and 1.1 kg/cm2 [14 to 103 kPa].A. 2. Scales are marked in psi and kPa. Canada. Operating range (see Table 1). TRADELINE® MODELS STANDARD MODELS MODELS: L404A-D. also refer to the note in the Location and Mounting section. if desired. .4 to 21. Also can be surface-mounted using screws through two holes (knockouts) in back of case.S. Optional specifications. Netherlands. The steam trap is necessary for boiler installations.M Pressuretrol® Controllers. 740 Ellesmere Road. Home and Building Control Customer Logistics Honeywell Inc. refer to the Tradeline Catalog or price sheets for complete ordering number. Model without steam trap.5 kg/cm2 [34 to 345 kPa]. ADJUSTMENT MEANS: Screws on top of controller case.. Ordering Information When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor. Spain. if desired). (2068 kPa)] models). Scarborough. 60-2150—10 2 . France. 5. MINIMUM AMBIENT TEMPERATURE: Minus 35°F (minus 37°C). Germany. Japan. 6.F and L604A. A 14026 Steam Trap (siphon loop) is available. Order number (TRADELINE® model. TRADELINE® MODELS AVAILABLE: L604A Pressuretrol® Controllers—Available in 2 to 15. 10 to 150. ELECTRICAL CONNECTIONS: Internal screw terminals. or specify— 1.L404A-D.7 to 10.L. International Sales and Service Offices in all principal cities of the world. Your local Home and Building Control Sales Office (please check the white pages of your phone directory). ease of handling. MOUNTING MEANS: Hexagonal fitting on diaphragm has 1/4-18 NPT internal threads for mounting on a pipe or steam trap (siphon loop). and maximum replacement value. if desired (see Table 1). L604A. Finland. and 20 to 300 psi (. If you have additional questions. Specifications of TRADELINE® controls are the same as those of standard models except as noted below. if desired.6 kg/ cm2 [69 to 1034 kPa].L. Minnesota 55422-4386 (612) 951-1000 In Canada—Honeywell Limited/Honeywell Limitée.F. PRESSURE SENSING ELEMENT: Stainless steel diaphragm (brass bellows in 300 psi [21. need further information.1 kg/cm2. Ontario M1P2V9.

0 .97 . L404F only.2 35 15.76 kPa 14 to 4 127 to 83 55 to 110 103 to 276 14 to 41 27 to 83 55 to 110 103 to 276 Maximum Surge Pressure psi 50 85 225 500 50 85 225 500 50 85 225 500 50 225 50 85 225 500 25 85 225 500 25 kg/cm2 3.66 to 10 1.5 L604M a b L404F (snap-acting) does not have non-inductive or dc ratings.L404A-D.66 to 10 .j makes R1W.14 to .0 kPa 14 to 103 34 to 345 69 to 1034 138 to 2068 14 to 103 24 to 345 69 to 1034 138 to 2068 14 to 103 34 to 345 69 to 1034 138 to 2068 14 to 103 69 to 1068 14 to 103 34 to 345 69 to 1034 138 to 2068 14 to 103 34 to 345 69 to 1034 138 to 2068 14 to 103 Midscale Subtractive Differentiala (Adjustable) psi 2 to 6 4 to 12 8 to 16 15 to 40 2 to 6 4 to 12 8 to 16 15 to 40 kg/cm2 .14 to 1.82 .f 5 to 50 10 to 150e.0 10. breaks circuit manual reset (fixed.0 15.35 to 3.4 to21.62 kPa) and minimum subtractive differential of 0.5 .56 to 1.45 kPa).1 kPa) L604M 10 to 150 . makes circuit spdt snap-acting switch.0 . plus 250 VA pilot duty at 120 Vac.0 1. subtractive differential) L404D L404F spst.0 . subtractive differential) 2 to 6 6 to 14 10 to 22 20 to 50 2 to 6 4 to 12 8 to 16 15 to 40 .41 to .0 . Also recommended for supervision of atomizing medium pressure (air or steam) in an oil burner system.0 5.) and breaking (not making) a load with a total rating of 9.0 240 Vdc 1.04 to 2.5 psi (24.14 to 1.5 psi (0.2 1. makes circuit L404C spst.66 to 10.Lb Load Full Load Locked Rotor a Noninductive Full Load Locked Rotor Noninductive Full Load 120 Vac 8.8 35. L404C.0 48.M SPECIFICATIONS TABLE 1—MODELS AVAILABLE.0 15.5 6.5 6.4 to21.76 . Model available with minimum operating pressure of 1. Not suitable for use with ammonia.14 to . Spst switches operate in unison. The subtractive differential is fixed at the minimum value of the adjustable differential of the L404A for each corresponding operating range.04 to 2.66 to 10 1.6 1.5 120 Vdc 2.1 .6 1.B and L604A models are available with 1 to 6 psi midscale subtractive differential in 2 to 15 psi models.2 1.8 35. all other models have mercury switches. SWITCH CONTACT RATING (in amperes at 50/60 Hz): Model L404A L604A. plus 360 VA ignition.28 to .0 0.8 35. or other corrosive materials.F.0 20.0 8. oxygen.14 to .0 .41 .8 1550 a b c d e f g h i j k Scaleplates are marked in both psi and kg/cm2 Model available with special fixed low differential.1 69 to 1034 225 15.14 to 1.14 to 1. breaks R-B manual resetg (fixed.L.0 15.6 5.09 kg/cm2 or 8.5 6.2 3.0 10. breaks R2-B spdt circuit makes R-W.25 psi (0.5 .5 .0 1.0 .2 1. Switching Action on Pressure Rise to Setpoint spst.10 1.0 8.4 to 21. spdt action when jumper is installed between R1 and R2.6 5. Model available with special fixed low differential. breaks R-B 2 isolated spst circuits.c.35 to 3.41 .D and L604L models are designated as Manual Reset 2 controllers.0 . Brass bellows replaces stainless steel diaphragm.66 to 10.0 .8 kPa 345 586 1550 3445 345 586 1550 3445 345 586 1550 3445 345 1550 345 586 1550 3445 172 586 1550 3445 172 Model L404A L404Bi spst. breaks R-B spdt circuit makes R-W.0 2.28 to.0 240 Vac 5. 3 60-2150—10 .82 .8 A full load.35 to 3.0 15.14 to 1.69 to 15.0 10.0 1.035 kg/cm2 or 3. breaks circuit Operating Rangesa psi 2 to 5 to 50 10 to 150b 20 to 300d 2 to 15d.41 .0 0.b 20 to 300d 2 to 15 5 to 50 10 to 150 20 to 300d 2 to 15 10 to 150 2 to 15 5 to 50i 10 to 150 20 to 300d 2 to 15c 5 to 50 10 to 150 20 to 300d 2 to 15 15b.e.4 to 3.5 .0 .10 1.14 to 1.66 to 10. Switch rated for 0.2 12. the trip-free reset mechanism does not permit the controller to function as an automatic-reset device when the manual reset lever is held in the reset position. subtractive differential) fixed: 3.5 .0 5.c kg/cm2 .56 to 1.35 to 3. L604A.14 to .8 35.5 .1 30.66 to 10.8 3. Switch rated for 0. Model available with sealed bell crank adjustment.56 to 1.0 48.6 1.28 to .10 1.41 .2 3.4 24.8 35.4 to 21.76 14 to 41 41 to 97 60 to 152 138 to 345 14 to 41 27 to 83 55 to 110 103 to 276 L604A L604L manual resetg (fixed.14 to 1.h makes R-W.5A at 120 Vac.1 30.0 2.0 15.0 . or 1 spdt.4 to 21.5 6.5A at 120 Vac. L604A and L have also been tested (and listed by Underwriters Laboratories Inc.04 to 2. L404A.8 6.82 .0 4.35 to 3.

TABLE 2—CONVERSION TABLE (psi to kPa).14 TO 1.3) KNOCKOUT (2) 2-1/8 (54.D.C.L.0) 1/4-18 NPT 1-3/16 (30.6) 3/16 (4.L. M8933 3 60-2150—10 4 .) THIS DIMENSION IS 4-27/32 IN.5 69 to 152 15 to 40 1.1) 1 2 RESET LEVER (ON MANUAL RESET MODELS ONLY.10.0) 3 7/8 (22.4 to 20.8 28 to 83 5 to 14 .B.5) 4-31/32 (126.3) (COVER) 2-3/4 (69. fits on main scale pressure adjusting screw.7 to 1. 1.2) DIA.2) 2 1-13/16 (46.7 34 to 345 34 to 1034 69 to 1034 138 to 2068 Subtractive Differential Equivalent Scale-Plate 2) (psi) (kg/cm (kPa) — — — 1 to 6 07 to 4 7 to 41 2 to 6 .2) 1-1/16 (27.0) 13/16 (20.D. L604A. guide no.0 MM) ON L604 MODELS WITH A 2 TO 15 PSI (.4 to 1. APPROVALS: Underwriters Laboratories Inc.14 to .8 103 to 276 20 to 50 1.4) 1 1-61/64 (49.A MM) ON L604 MODELS WITH A 20 TO 300 PSI (1. L604A. See Fig. black iron pipe. MP466.C.3 . 4074BWJ Limit Stop Assembly—to limit set point ranges. 2 for mounting steam trap (siphon loop).91 kg).8) X 21/64 (8.F.C. Necessary for boiler installations.4) 3-23/32 (94.0 to 2.M SPECIFICATIONS DIMENSIONS: See Fig.0 kg/cm2 (14 TO 103 kPa)) OPERATING RANGE. and 23466 Wrench.F.0) 1-1/2 (38.B.B. in in.4 to 3. (146.L only): file no.L.3 to 3. (123. FINISH: Gray. LR1620.0 41 to 97 — — — 8 to 16 .7 kg/cm2 (138 TO 2068 kPa) OPERATING RANGE. L604A. ONLY ON L604 MODELS WITH A 2 TO 15 PSI (.L.6) 1 1-1/16 (27.F and L604A. L604A.3 to . vol.6) 1/2 (12.400-E-0. AND 5-3/4 IN. (0.F.3) (CASE) 1-15/16 (49.3 to 10. Canadian Standards Association certified (L404A. WEIGHT: 2 IBC.1 55 to 110 10 to 22 .0 14 to 103 .0 kg/cm2 (14 TO 103 kPa)) OPERATING RANGE.4 TO 20.7) 3-7/8 (98.14 to1.6 to 1. 13/16 (20. 14026 Steam Trap (siphon loop)—1/4 in. REPLACEMENT PARTS: 129178 Thermoplastic Cover.0) 1-5/32 (29. 1—Mounting dimensions of the L404A.4 14 to 41 4 to 12 .M Pressuretrol® Controllers.M only): file no. MBPR.14 TO 1.L404A-D. (mm). listed (L404A. guide no.F. includes 129564 Range Stop.5 .2) 3-3/16 (81. Scale-Plate (psi) 0 to 15 2 to 15 5 to 50 5 to 150 10 to 150 20 to 300 Operating Range Equivalent 2) (kPa) (kg/cm 0 to 10 0 to 103 .3 1. ACCESSORIES: 33312B Knurled Adjustment Knob—with setscrew.5 138 to 345 Fig.D.7 to 10. L404A-D.M 4-1/2 (114. 107194 Range Stop Screw.9) 4-11/32 (110.

BLACK IRON PIPE WITH 1/4 . because mercury in the switch freezes at this temperature. install a steam trap (siphon loop) with a tee on top. The loop on the steam trap must always be perpendicular to the face of the controller. 5 60-2150—10 . expansion or contraction of the loop tips the controller and causes the switch to operate inaccurately. 11) hangs freely with its pointer directly over the index mark inside the back of the case. Failure to follow them could damage the product or cause a hazardous condition. CORRECT INCORRECT BOILER BOILER 1 1/4 IN. M8934 Make all pipe connections in accordance with approved standards. 2.F. (3) at a remote location in case of excessive vibration. 3. 2—Right and wrong mounting of a steam trap (siphon loop). LOCATION AND MOUNTING NOTE: For most accurate operation. header. PRESSUR CONTROLLER PRESSURE GAUGE TEE CAUTION 1. IMPORTANT: 1. 3. Do not tighten the controller by hand by holding the case.M INSTALLATION Installation WHEN INSTALLING THIS PRODUCT. remove the gauge. 2. use a parallel jaw wrench on the controller’s hexagonal fitting.7) 1 14026 STEAM TRAP (SIPHON LOOP) 2-1/4 (57. After installation is complete.L. 2. When used with steam boilers. In its place. . or (4) in a special mounting on a low water cutoff. Installer must be a trained. 4. Do not tighten the controller by hand by holding the case. L604A. install a dampening device (such as a needle valve. with approximate dimensions in in. Mounting Alongside a Pressure Gauge To mount the controller alongside a pressure gauge (Fig. 4.L404A-D. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application. Use pipe compound sparingly to avoid clogging the hole in the pipe or diaphragm fitting. . It is level when the leveling indicator (Fig. Leveling A controller with a mercury switch must be accurately leveled for proper operation. always mount the controller above the water line in the boiler. Using elbows and pipe nipples. Locate the controller where the ambient temperature will not exceed 150°F (66°C). Accurately level the controller for proper operation. 2) to prevent boiler scale and corrosive vapors from attacking the diaphragm. (2) in a fitting on the boiler provided by the manufacturer. flame safeguard control technician. Use only a small amount of pipe compound to seal the connection joints. When using the controller with a compressor. (mm). experienced.2) DIA. To avoid leaks and damage to the case. 4-1/2 TO 5-1/2 (114. The controller can be mounted (1) alongside the pressure gauge. 2). mount the controller and pressure gauge on the ends of the tee. check out product operation as provided in these instructions. add supplemental heat to installations where the temperature falls below minus 20°F (minus 29°C). BEND THE STEAM TRAP (SIPHON LOOP) TO LEVEL THE CONTROLLER. 1. Excess pipe compound can clog the small hole in the fitting and prevent the controller from operating properly. Fig. Level the controller by carefully bending the steam trap (siphon loop). Level the controller after installation.3 TO 139. Disconnect power supply before beginning installation to prevent possible equipment damage or electrical shock.18 NPT EXTERNAL TRHEADS ON BOTH ENDS. A steam trap (siphon loop) must always be connected between the controller and the boiler (Fig. or surge tank) to dampen pulsations that can damage the controller or reduce its life. Never locate the controller where the temperature falls below minus 35°F (minus 37°C). Read these instructions carefully. If the loop is parallel to the controller.

2 mm) hole in one side for 1/2 in. 7. LOW LIMIT—L404B BREAKS WHEN PRESSURE FALLS TO SETPOINT MINUS DIFFERENTIAL. Use NEC Class 1 (line voltage) wiring. and breaks when the pressure falls to the set point minus the differential (Fig. WIRING 1.M SPDT SWITCH ACTION WITH JUMPER INSTALLED. All piping from the boiler must be suitable and solidly mounted. and regulations. use moisture-resistant No. 14 wire suitable for at least 167°F (75°C) when you are using the controller with a flame safeguard primary control. Mounting at a Remote Location If there is excessive vibration at the boiler that can adversely affect the operation of the controller. All models have a terminal block inside the cover (Fig. (22. Fig.D MAKES ON PRESSURE RISE TO SETPOINT L404F (SNAP-ACTING) BREAKS R-B. RISE RISE B 1 JUMPER R2 R1 W B R W L604A MAKES R1-W BREAKS R2-B ON PRESSURE RISE TO SETPOINT. W M8935 Fig. 6. SPST CONTROLLER 2 FLAME SAFEGUARD CONTROL. or at least 194°F (90°C) when using it with a programming control. M8936 2 60-2150—10 6 . Make sure the loads do not exceed the Switch Contact Ratings in the Specifications section. ordinances. 3. 5. It makes a circuit when the pressure rises to the set point. Refer to Fig. use moisture-resistant No. install a steam trap (siphon loop) in the fitting provided by the boiler manufacturer. If there is no fitting. cable. Remove the front cover by loosening the screw at the bottom of the main scale. Level the controller after installation. Assume all wiring complies with applicable electrical codes. OTHERWISE. Disconnect the power supply before beginning wiring to prevent electrical shock or equipment damage. MOTOR. AND MAKES AGAIN WHEN PRESSURE FALLS TO SETPOINT MINUS DIFFERENTIAL.C BREAKS ON PRESSURE RISE TO SETPOINT L404B. 10). mount the steam trap at a location recommended by the boiler manufacturer. 5—L404 used as a limit or as an operating controller. For high temperature installations. TWO ISOLATED SPST SWITCHES. 4—L404 terminal block and internal schematic. selected for a temperature rating above the maximum operating temperature. MAKES R-W ON PRESSURE RISE TO SETPOINT Fig.L. The L404B is recommended for this application. mount the controller at a remote location. For normal installations. authorities having jurisdiction (approval bodies and codes) often require a low limit to prevent opening the main oil valve until sufficient atomizing pressure is present. Follow the burner or boiler manufacturer’s wiring diagram if provided . 4. or wires. 3 and 4) and a 7/8 in. L604A. A steam trap (siphon loop) must be mounted between the remote piping and the controller.F. OPERATING CONTROLLER—L404A BREAKS WHEN PRESSURE RISES TO SETPOINT. and level the controller. conduit. 2. Screw the controller directly to the steam trap. 1 L604L. Replace the front cover when wiring is completed. 8. 3—L404 terminal blocks and internal schematics. OR OTHER LOAD R W B L1 (HOT) POWER SUPPLY L2 1 L2 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. 5 through 9 for typical hookups. 14 wire. Supervision of Atomizing Medium Pressure (Air or Steam)—L404B When air or steam is used as an atomizing medium in an oil burner system. HIGH LIMIT—L404A OR C BREAKS WHEN PRESSURE RISES TO SETPOINT. and to shut down the system when the atomizing pressure falls too low.L404A-D. The piping must be properly pitched to drain all condensation back to the boiler. RISE RISE RISE B W R R B M8941 L404A.M INSTALLATION Mounting on a Boiler If it is not convenient to mount the controller alongside the pressure gauge.

2 M8939 7 60-2150—10 . BREAKS R TO B AND MAKES R TO W WHEN PRESSURE RISES TO SETPOINT. SPDT CONTROLLER (LOW LIMIT) 2 W R B SPDT CONTROLLER W 2 R B WHITE RED BLUE LINE VOLTAGE TWO-POSITION MOTOR W1 CLOSED (LOW FIRE) R1 B1 OPEN (HIGH FIRE) L1 (HOT) POWER SUPPLY L2 1 L2 FLAME SAFEGUARD CONTROL. 8—L404F. 7—L404F. Fig. M8938 2 Fig. 9—L404F. OR OTHER LOAD LOAD ALARM 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. Fig.L404A-D.L. OR OTHER LOAD L1 (HOT) ALARM BLACK 1 L1 POWER SUPPLY L2 BLACK L2 M644B 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. BREAKS R TO B AND MAKES R TO W WHEN PRESSURE RISES TO SETPOINT. L604A (jumper installed) used as a high limit. MOTOR. with an alarm circuit. 6—L404 with a low voltage relay. MOTOR. L604A. controlling an M644B motor. M8940 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M8937 2 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. BREAKS R TO W AND MAKES R TO B WHEN PRESSURE FALLS TO SETPOINT MINUS DIFFERENTIAL.F. L604A (with jumper installed) or L604M. or L604 with jumper installed.M INSTALLATION Fig. with an alarm circuit. used as a low limit. L1 (HOT) POWER SUPPLY 1 L2 W R L1 (HOT) POWER SUPPLY L2 1 L2 SPDT CONTROLLER (HIGH LIMIT) 2 B LOW VOLTAGE RELAY 1 24 VOLT THERMOSTAT L404 2 THERM FLAME SAFEGUARD CONTROL.

D AND L604L MODELS ONLY. Also check the make and break points of the controller. adjust the differential setting by turning the differential adjusting screw (Fig. FIXED DIFFERENTIAL OF 3. TRIP-FREE MANUAL RESET LEVER ON THE L404C. MAKES R-W) 1 12 10 8 6 1 4 2 . The scaleplates are marked psi and kg/cm2. the differential is subtractive from the main scale set point. They will not automatically return to their former positions.34 TO 10.7 . Fig.6 .1 3 2. a slight adjustment of the scaleplate(s) may be necessary. L404C. MAIN SCALE SETPOINT (SWITCH BREAKS) main scale setpoint. AND L604A MODELS ONLY. DIFFERENTIAL ADJUSTING 1 SCREW SCALEPLATES MAIN SCALE ADJUSTING SCREW 2 MERCURY SWITCH MANUAL RESET LEVER L404A. 10—L404 and L604 operating points.F with a 5 to 150 psi (.F.M have spdt switching action.D AND L604L MANUAL RESET MODELS HAVE A SMALL. test it with the system in operation. Then depress the manual reset lever (Fig.5 1 .4 . Pressure should increase when the setpoint is raised and decrease when the set point is lowered.3 kg/cm2 [34 to 1034 kPa]) operating range. 10.5 50 40 30 20 10 0 DIFFERENTIAL SETTING (SWITCH BREAKS) MAIN SCALE SETPOINT (BREAKS R-B. On an L404A.M PRESSURE RISE SUBTRACTIVE DIFFERENTIAL DIFFERENTIAL SETTING (MAKES R-B. and set. wired. Fig. 11) on the top of the case until the main scale setting indicator is at the desired value.2 . L. MAKES R2-B) MAIN SCALE SETTING INDICATOR DIAPHRAGM ASSEMBLY 1 INDEX MARK POINTER LEVELING INDICATOR 1 L404C.8 . FIXED DIFFERENTIAL.B. First allow the system to stabilize. L404L WITH A 5 TO 150 PSI (0. Operating points are shown in Fig.3 kg/cm2 [34 TO 134 kPa] OPERATING RANGE. 10). and the L604L makes R-W and breaks R-B when the pressure rises to the CHECKOUT After the controller has is installed. Then observe the operation of the controller while raising and lowering its setpoint. 11) and release it. The upper operating point is determined by the main scale set point. while the lower operating point is determined by the main scale setting less the differential setting.F. Trip-Free Manual Reset Feature (L404C.3 . THEY CAN BE MANUALLY RESET WHEN THE PRESSURE FALLS TO THE MAIN SCALE SETPOINT MINUS THE DIFFERENTIAL.D PRESSURE RISE SUBTRACTIVE DIFFERENTIAL DIFF. 60-2150—10 8 .5 . The controller will not be reset until you release the manual reset lever.5 PSI (0. This prevents the controller from becoming an automatic-reset device if the reset lever is stuck.5 2 1. Do not rely on inexpensive gauges.M SETTING AND CHECKOUT Setting and Checkout SETTING In all models. L604L. or an L604A.D and L604L are manual reset models: see the next paragraph.D and L604L only) The L404C breaks.25 kg/cm2) OR 24. 11—Setting a Pressuretrol® Controller.L404A-D. the L404D makes. If they do not agree with a separate. The L604M has a fixed differential. The controllers are carefully calibrated at the factory. BREAKS R2-B) 2 DIFFERENTIAL SETTING INDICATOR PSI L604A PRESSURE RISE SUBTRACTIVE DIFFERENTIAL DIFFERENTIAL SETTING (BREAKS R1-W. To reset one of these controllers. held in. or tied down. wait until the pressure falls to the set point minus the differential (Fig. Use accurate pressure testing equipment when checking out the controller.1 kPa. accurately calibrated pressure gauge.C PRESSURE RISE SUBTRACTIVE DIFFERENTIAL DIFFERENTIAL SETTING (SWITCH MAKES) MAIN SCALE SETPOINT (SWITCH MAKES) 1 L404B.B. L604M HAS A SMALL.3 to 10.L. BREAKS R-W) MAIN SCALE SETPOINT (MAKES R1-W. MAIN 3. L604A.) M8942 ADJUSTABLE DIFFERENTIAL ON THE L404A. M8943 2 2 Adjust the main scale set point for the desired operating pressure by turning the main scale adjusting screw (Fig. The L404F and L604A (with jumper installed).5 0 L404F. 11) until the differential setting indicator is at the desired value.

Connect an ohmmeter between the switch terminals. 2. an L404B or D should make. L604A.6 . the ohmmeter reads zero. 5.) If it makes. Note the boiler pressure by checking the boiler pressure gauge. IS SUBTRACTIVE OHMMETER SETPOINT DECREASE INPUT OUTPUT 0 W B 1 ZERO ADJ R ZERO OHMS (INFINITY WHEN R-B BREAKS) 1 AN L604. 4.L404A-D.1 3 2. 6. and remove the cover. Disconnect the wires from the controller. When the controller is operating properly. reconnect the wires to the terminal block.5 2 1. just the opposite of its action in step 4 (except for the L404C. 11) until the main scale setting indicator on the controller corresponds to the boiler pressure gauge reading. MAIN 3.5 50 40 30 20 10 0 PSI 12 10 8 6 4 2 DIFFERENTIAL SETTING INDICATOR . Disconnect all power to the controller.5 0 B R1 R2 W PSI KG CM 2 KG CM 2 MAIN SCALE SETTING INDICATOR DIFF. 12): 1.8 . AN L404A OR C BREAKS AND L404B OR D MAKES WHEN THE SETPOINT IS DECREASED FAR ENOUGH. If the controller is operating properly. Raise the set point of the controller (simulating a pressure decrease) through a range greater than the differential. NOTE: An approximation of the differential can be made by observing the change in set point required for a resistance change from zero to infinity. and an L604A should break R2-B and make R1-W. L604L.M should break R-B and make R-W. depending on the model of the controller. B. L604L. replace it. 3.M should make the R-W circuit and break the R-B circuit under the same circumstances. C OR D HAS ONLY TWO TERMINALS (SPST SWITCHING). 11) until the main scale setting indicator is at the desired set point.5 .F. and any others required by the burner and boiler manufacturers. if it breaks. The L404B or D should make the circuit under the same circumstances. 7.5 1 . it may be further checked as follows (Fig.7 .L.2 . Turn the main scale adjusting screw (Fig. replace the cover and tighten the cover screw. If the controller operates improperly. If a Controller Seems to Operate Improperly If the controller is suspected of operating improperly. M8944 9 60-2150—10 . 12—Checking controller operation using an ohmmeter. the ohmmeter reads infinity.3 . Lower the set point of the controller (simulating a pressure increase) through a range greater than the differential. turn the main scale adjusting screw (Fig. AN L404F OPERATES SIMILARLY (SPDT SWITCHING). The L404F. IS SHOWN. MAIN SCALE ADJUSTING SCREW DIFF. loosen the cover screw. 4. (To perform this test properly. 3. Fig. test it as follows: 1. The switch should either make or break. the boiler should have a pressure reading near the middle of the controller’s main scale range. (An L404A or C should break.) 2. an L404F. The L604A should make the R1-W circuit and break the R2-B circuit under the same circumstances.M SETTING AND CHECKOUT Boiler Installation If the controller is being used on a boiler installation. and reconnect the power. The L404A or C should break the control circuit(s) automatically when the boiler pressure gauge reading equals or slightly exceeds the controller setting.D and L604L manual reset models).4 . CAUTION Do not put the system into service until you have satisfactorily completed all applicable tests described in this Checkout section. AN L404A. in the Checkout section of the applicable instructions for the flame safeguard control. WITH JUMPER INSTALLED BETWEEN R1 AND R2. The switch should break or make.

M SERVICE INFORMATION Service Information CALIBRATION The controller was carefully calibrated during manufacturing and should not require recalibration. L604A. carefully bend the steam trap (siphon loop) until the controller switches properly.L404A-D. perform an operational check of the entire system during routine maintenance checks. and physical damage. MAINTENANCE The cover of the controller should be in place at all times to protect the internal components from dirt. the leveling indicator may not be accurate enough. Routine maintenance should consist of occasional inspection and blowing or brushing away any accumulated dirt and dust. The pointer may be over the index mark. In this case. but the controller still may not be operating within the tolerance of its scale setting. dust. The controller should be level when the pointer on the leveling indicator is directly over the index mark (Fig. Most calibration errors are caused by improper leveling.L.F. 60-2150—10 10 . In some cases. 11). To ensure proper functioning of the controller at all times.

11 60-2150—10 .

MN 55422 Home and Building Control Honeywell Limited—Honeywell Limitée 740 Ellesmere Road Scarborough.S.Home and Building Control Honeywell Inc. 12 . 1985 Douglas Drive North Golden Valley. Ontario M1P 2V9 Helping You Control Your World QUALITY IS KEY 60-2150—10 Printed in U.A.

and do not overtighten. Do not plug any bonnet vent openings. When hand operating the valve. Discharge piping. Do not use the valve body or bonnet for installing the valve in threaded connections. to prevent sealing compound from entering and damaging the valve. 1. the inspection interval may be decreased or increased. personal injury. 2. Do not use the safety valve as a control valve to regulate system operating pressure. care should be exercised so that lifting straps do not contact the valve lift lever. Boiler & Pressure Vessel Code requirements. ASME Section IV valves may be operated at any set pressure. For threaded valves. hold it open long enough to purge any foreign matter from the seat area. WARNING! Removal of the seal wires or any attempt to adjust. It should be installed correctly per A. An initial inspection interval of 12 months is recommended. and protected to prevent contamination from getting inside. When hoisting the valve into position for installation.S. This will help to limit the inlet pressure drop to 3% or less when the valve is relieving. due to thermal expansion. 3. Failure to do so could result in property damage or serious injury to personnel. NC 28711 Rev B 01/14/2002 Fax: 828-669-4017 . For steam service. and death. including safety glasses and ear protection. If a body drain port is provided. Installation Always wear proper safety equipment. The inlet piping should be as short as possible. 2. and equal to or greater than the size of the pressure relief valve inlet connection. a drip pan elbow or flexible connection between the valve and the pipe should be used to prevent excessive pipe stress. whichever is greater. Maintenance Maintenance should be performed on a regular basis. To do so may cause valve leakage. To do so may cause the sealing compound to enter the valve and cause seat leakage. Kunkle Valve is not liable for any damage resulting from misuse or misapplication of its products. Use only Kunkle parts for repair. from being imposed on the valve body. make sure the direction of pull is the same as it would be if the lever were pulled directly by hand. apply a small amount of pipe thread sealing compound to external threads only. with no elbows. 3. Maintain a system operating pressure at least 5 psig or 10% below the set pressure of the valve.E.M. The valve should be handled with care. Depending on the service conditions and the condition of the valve. ASME Section I and VIII valves equipped with lift levers are designed to be operated only when the system pressure is 75% of set pressure or greater. Operating too close to the valve set pressure will cause seat leakage and will shorten the time between valve maintenance. make sure it is open when required by the ASME code. repairs may have to be made by a repair facility holding a VR stamp. 4. other than a short tailpipe. If a cable or wire is attached to the lift lever for remote actuation. For flanged valves. When discharge piping is connected to valve outlet. Do not put any sealing compound on the first thread or on any internal threads. must be supported. repair or modify this product by non-qualified or non-authorized persons voids the product guarantee and may cause serious damage to equipment. Excessive operation will cause the seat to leak and will require more frequent valve maintenance. Kunkle Valve Division Phone: 828-669-5515 953 Old US 70. not subjected to heavy shock loads. make sure it is self draining if a body drain port is not used. The valve should not be connected to any discharge pipe that contains pressure before the valve opens or to any pipe where the pressure build-up is greater than 10% of the set pressure when the valve is open and relieving. use new gaskets and tighten the mounting studs evenly. Use the wrench flats provided to tighten the valve to the connecting pipe. Depending on the local jurisdictional requirements where the valve is installed. Black Mountain. Mount the valve in a vertical position so that the valve body is self-draining. Operation 1.KUNKLE PRESSURE RELIEF VALVES Installation and Operating Instructions Pre-Installation Handling This pressure relief valve is designed to protect equipment from overpressure.

.... & RV111 .. S-T-F Series ........ 2". RV91..... 1"............ RV61. RV91 & RV111 . mixed. GASES: Natural........... 1¼"............... 1½".......... 15 psi (1050 mbar) RV61..... 25 psi (1750 mbar) * Please note that internal damage may occur when exposed to these pressures................ RV111........... 3" & 4" design certified Maximum Pressure CSA Rated (except RV131) ..... & RV131 ....... RV81....... 3 psi (210 mbar) RV61.. RV91......... or LP gas-air mixture...... RV81.... 1/2 psi (35 mbar) RV61.. RV53.... and RV131 1/2"..... RV91 & RV111 ... manufactured................... RV81......... RV111. RV81........... 1 psi (70 mbar) RV131 ............BULLETIN MS2056. 5 psi (350 mbar) RV131 .. 2 psi (140 mbar) * Do not use if inlet pressure is more than 10 times desired outlet pressure EMERGENCY EXPOSURE LIMITS (Maxitrol Tested) RV52 & RV53 .......04/04 Gas Appliance Pressure Regulators Straight-Thru-Flow Design RV52.... RV91....... -40° to 205° F (-40° to 96° C) RV131 ...................... 1/2 psi (35 mbar) Maxitrol Tested* RV52 & RV53 ............ 2½".... RV53............. RV61. 3/4"... liquefied petroleum..... 15 psi (1050 mbar) GAS CONTAINMENT EXPOSURE LIMITS* RV 52 & RV53 ........... RV81.............. -40 to 125° F (-40 to 52° C) ... AMBIENT TEMPERATURE LIMITS RV52...

non-lockup type. commercial and industrial gas-fired appliances and equipment used on low pressure gas supply. See Maxitrol’s ”Spring Selection Chart“ for part numbers. Typical applications include all types of residential. Refer to other Maxitrol sales bulletins for proper types. and may also be used with air or other noncorrosive gases within their pressure limits. RV91. The improved flow pattern provides accurate sensitive regulation at extremely low pressure differentials. construction.c. 3”.Straight-Thru-Flow Design RV series RV52. Use only where downstream controls can operate at line pressure. The cone principal permits gas to flow straight through the regulator without changing directions. RV91. The 2 RV131 four inch model is of cast iron and steel construction. 3/4”. The basic difference between S-T-F design and other type regulators lies in the conical valve. RV91. there may be no regulation. They are main burner only. Models up to the three inch pipe size have high strength pressure cast aluminum housings. 1-1/4”. • RV131 only. They should not be used as a line gas pressure regulator ahead of low pressure controls. NOTE: All Maxitrol appliance regulators should be installed in accordance with Maxitrol’s “Safety Warning” bulletin. the 4" RV131 is flanged. color and size of springs. and CSA listed to certify compliance with nationally published safety. RV61. & RV131 internal conical valves are coated with Teflon® for long life. & RV61 are suitable for multipoise mounting. RV111. Maxitrol's original Straight-Thru-Flow design meets your needs for high capacities at low inlet pressures. RV61. resulting in greater capacity. Straight-Thru-Flow appliance regulators are intended for use with all fuel gases. The ability of the regulator to handle large capacity appliances with limited supply pressure offers a definite advantage to designers of commercial and industrial gas-fired equipment. and RV131 FEATURES • Greater accuracy—higher pressure drop capacity • Outlet pressures available to 42” w. The RV81. & RV131 are recommended for normal horizontal position only. sensitive regulation at inlet pressures as low as 3” w. At the emergency exposure limits. and 4” are available. Teflon is a registered trademark of DuPont Corporation. RV53. The RV52. RV53. They will suffer no internal damage and will resume regulation when normal pressure is restored. but all models will contain gas. Pipe sizes of 1/2”. All other parts are carefully specified corrosion-resistant or plated material. RV81. 1”. Frictional flow resistance is reduced. RV111.c. provides bonus benefits of high capacity and good performance at pressures of 1 psi or higher • Ease of installation and replacement All models except RV131 are CSA design certified for 1/ 2 psi rated pressure under the ANSI standard for gas pressure regulators. . • Available in full range of pipe sizes from 1/2" to 4" • All models tapped with NPT vent bosses • CSA Design Certified (except RV131) BENEFITS • Unique conical valve design fills need of combining good regulation with high capacity in low to intermediate pressure range • Allows more pressure drop to be assigned to piping and valves—permits reduction in manifold size • Provides accurate. 1-1/2”. 2-1/2". RV111. Models through the 3" size are threaded. 2”. and performance standards. Diaphragm material is cut from the finest synthetic coated fabrics available. RV81.

Capacities and Pressure Drop CAPACITIES—expressed in CFH (m3/h)—0.7) 2464 (69.7) 780 (22. Subtract outlet pressure .c.c.1) 6718 (190) 11596 (328) 0.8) 4929 (139) 7668 (217) 17161 (486) 29942 (848) RV53 RV61 RV81 RV91 RV111 RV131 4x4 -- Sizing Instructions In order to select the proper size regulator.4) 1185 (33.1) 2424 (68.4) 1742 (49.c.c.3 262 (7. 4.3) 1073 (30.A.2) 1714 (48. 3.7) 5422 (153) 12134 (343) 21172 (600) 3 828 (23.1) 1369 (38.8) 7256 (205) 12525 (354) 0. pressure drop. you must know the available inlet pressure. The RV111 meets these standards with a flow rate of 12.5) 484 (13. Check Capacity Chart to determine which regulator has a pressure drop of 2" w.5) 2711 (76.172 CFH the pressure drop is 2" w.134 CFH for the 2-1/2" pipe size at 2" w.c.5) 3878 (110) 6695 (190) 0.c.000 CFH (0. 3.1) 612 (17.1) 1350 (38.1) 968 (27.5) 2134 (60. CSA MAX 0. pressure drop.5" w.7 400 (11.7) 710 (20. 1—To select a regulator of ample capacity to handle flow. Therefore.4) 375 (10.7) 6132 (175) 10586 (300) Pressure DropÑinches w. Subtract 4" differential pressure from 10" w. Determine differential pressure available: Inlet pressure 9" w.2) 2100 (59.64 sp gr gas Model Number and Pipe Size A.2 214 (6.8 427 (12.5) 530 (15) 929 (26.1) 1102 (31.64 sp gr).2) 2339 (66.2) 759 (21. and the required maximum flow rate.4) 2204 (62. When determining capacity Maxitrol recommends that the pressure drop not exceed 1/2 of available differential pressure (1/2 of 4" w.5) 433 (12. 4.3) 2742 (78) 4734 (134) 0. inlet pressure 9" w.9 453 (12. 2.000 CFH.6 370 (10. Multiply this by two to obtain recommended differential pressure (4" w.c.3) 573 (16.6) 536 (15.7) 7500 (212) 151 (4.8) 650 (18.1 RV52 1/2 x 1/2 3/4 x 3/4 3/4 x 3/4 1x1 1x1 1-1/4 x 1-1/4 1-1/4 x 1-1/4 1-1/2 x 1-1/2 2x2 2-1/2 x 2-1/2 2-1/2 x 2-1/2 3x3 450 (12. The 2-1/2" RV91 flows 5422 CFH at 2" w.c.c.3) 1909 (54) 2969 (84. flow rate 8.5) 1559 (44. or less at a flow rate of 8.5 338 (9.c.G.3) 3485 (98. SOLUTION: 1.c. KNOWN: Pipe size 4".4) 2062 (58.2) 3637 (103) 8227 (233) 14202 (402) 1 478 (13.1) 2500 (70. inlet pressure to obtain maximum recommended outlet pressure setting of 6" w. 2.4) 1138 (32.0) 2465 (69.4) 3208 (90.2) 217 (6.2) 1004 (28.4 302 (8.1) 379 (10.). inlet pressure 10" w.c.c. Example No. desired outlet pressure 5" w.4) 4750 (134) 8200 (232) 0.000 CFH.4) 3429 (97.5) 684 (19. SOLUTION: 1. KNOWN: Pipe size 2-1/2".1) 306 (8.).c.1) 7757 (219) 13390 (380) 0. (mbar) 0. 2—To determine maximum recommended operating outlet pressure. desired outlet pressure. flow rate 21.6) 5485 (155) 9468 (268) 0. the RV111—2-1/2" is the correct regulator to use.4) 4269 (120) 6640 (188) 14862 (420) 25930 (734) 4 956 (27.1) 1212 (34. Check capacity Chart above for 4" regulator.1) 1100 (31.c..6) 675 (19.3) 1200 (34. Pressure Drop Chart 3 . Note that at a flow rate of 21.c.8) 3834 (108) 8572 (243) 14971 (424) 2 676 (19. RV131.7) 848 (24) 1743 (49.8) 3275 (92. Available differential pressure 4" w. = 2" w. Example No.

9 (99) 5. (mbar) Model Number RV52 RV53 RV61 RV81 RV91 RV111 RV131 CSA Certified Springs A.5 (2.1 (232) 13.maxitrol.0 • Fax 49.1 (373) 23.5 (284) 18.5 (2.5) 3-8 (7.5 (2. A copyrighted publication of www.5-9) 1-3. SPRING SELECTION CHART—inches w.5-30) 5-12 (12.1 (232) 9.5" pipe RV111 RV131 Vent Tap 1/8" NPT 1/8" NPT 1/8" NPT 3/8" NPT 1/2" NPT 1/4" NPT 3/4" NPT 3/4" NPT Swing Radius 3.25 (590) B 3.4 (213) 10.5) 2-5 (5-12.0 • Fax 49. Germany 49.5-9) 1-3.5-38) 5-15 (12.5-20) 3-8 (7.1 (181) 9 (229) 13.5-20) 3-8 (7.4 (324) 18 (458) D 1.5-15) 3 to 6 (7.2 (81) 3.5) 2-5 (5-12.5 (267) 15.5-15) 3 to 6 (7.6 (41) 2 (51) 2.4 (62) 3.4 (162) 8.356. 248.356.5-20) 3-8 (7.5-20) 4-12 (10-30) 4-12 (10-30) -4-12 (10-30) 4-12 (10-30) 4-12 (10-30) 4-12 (10-30) ---5-15 (12.3 (33) 1.c. P.200 Industriestrasse 1 48308 Senden.Dimensions and Spring Ranges RV81 & 91 RV52 & 53 A RV61 A A C C C D B D D B B DIMENSIONS*—inches (millimeters) Model & Illustration Number RV52 RV53 RV61 RV81 RV91 2" pipe RV91 2.3947.5) 2-5 (5-12.5-9) 1-3.5) 2-5 (5-12.5-9) 1-3. Germany 49.3 (212) 11.A.1400 • Fax 248.75 (95) 4. MI 48037-2230 U..com Maxitrol Company 23555 Telegraph Rd.5-30) 5-12 (12.400.A.400.9 (99) 4.5 (2.O. Box 2230 Southfield.5 (89) 5.5-30) 5-12 (12.99 .25 (32) 1.4 (164) 8.9632.5-38) 5-15 (12.G.5-30) 5-12 (12.5-15) 4-8 (10-20) 4-8 (10-20) 4-8 (10-20) 4-8 (10-20) 4-8 (10-20) 4-8 (10-20) -- 5-12 (12.5-9) -2-5 (5-12. Actual production dimensions may vary somewhat from those shown.2 (462) Call-Outs A 4.5) 2-5 (5-12.5-38) ---10-22 (25-55) 10-22 (25-55) 10-22 (25-55) 10-22 (25-55) 10-22 (25-55) ------15-30 (38-75) ------20-42 (50-105) 3 to 6 (7.1 (129) D B C C RV111 A D B RV131 A * Dimensions are to be used only as an aid in designing clearance for the valve.9632.5 (216) 8.5-30) NOTE: The area within the heavy line indicates CSA certified springs.5-30) 5-12 (12.4 (111) 6 (153) 6.5 (165) 7.5-15) 3 to 6 (7.25 (83) 3.9 (124) 5.3947.5-15) 3 to 6 (7.2 (132) 6.8 (275) 10.5 (2.4 (138) 7 (178) 9.5-20) 3-8 (7.5-9) 1-3.5 (2.9 (353) C 3.2597.5-20) 3-8 (7. Other Springs Available 1-3.2597.5-15) 3 to 6 (7.5-20) 3-8 (7.S.5-15) 3 to 6 (7.6 (91) 3.5-30) 5-12 (12.3 (60) 2.8 (122) 6.5) 2-5 (5-12.0829 European Representatives Warnstedter Strasse 3 06502 Thale.

3. a. Absolutely no leakage should occur.356. INSTALAR EL REGULADOR EXTERNO ENTRE EL SUMINISTRO DE PROPANO Y EL REGULADOR MAXITROL 5.O. damaged in any way. (a la vuelta) 23555 Telegraph Rd. INSTALL THE EXTERNAL REGULATOR BETWEEN THE PROPANE SUPPLY SOURCE AND MAXITROL REGULATOR. a. usando los códigos y reglamentos gubernamentales así como los códigos y prácticas de plomería. Absolutamente no deberá haber ninguna fuga. incluyendo los reguladores de presión de gas.com . Install the regulator properly with gas flowing as indicated by the arrow on the casting. Do not use a gas pressure regulator if it appears to have been subjected to high temperatures. 5. MAXITROL REGULATORS REQUIRE AN EXTERNAL REGULATOR (NOT SUPPLIED). used with combustible gas must be installed and used strictly in accordance with the instructions of the manufacturer.A. properly threaded pipes and careful assembly procedure so that there is no cross threading. 2. INSTRUCCIONES PARA PRECAUCIONES DE SEGURIDAD PARA REGULADORES DE PRESION DE GAS MAXITROL NOTA: LOS REGULADORES DE PRESION DE GAS NO CORTAN EL FLUJO DE GAS SPECIAL WARNINGS IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY. If you suspect that a Maxitrol regulator has been exposed to more than twice the maximum operating inlet pressure. asegurándose de que no haya trasroscados. P. It is a good practice to periodically check for leakage during use of the appliance. MI U. Aumentos grandes de presión en la línea de suministro de gas (o como resultado de exponer el sistema a alta presión) pueden resultar en daños internos y causar fugas o afectar el funcionamiento del regulador. which might cause damage or leakage. 2. and plumbing codes and practices. Usar un compuesto sellador de tubería o hilo sellador de rosca.1400 Fax 248. PERSONAL INJURY OR LOSS OF LIFE. c. To minimize the possibility of FIRE. No usar un regulador de presión de gas si parece haber estado expuesto a altas temperaturas.0829 www. Asegurarse de que no se pinten o tachen las marcas o escritura en el regulador. Limpiar con un trapo húmedo. Cualquiera de éstas pueden ser señales de posibles fugas u otros daños que pueden afectar el funcionamiento correcto y causar problemas de combustión potencialmente peligrosos. Apply wrench or vise pressure only to the flat areas around the pipe tappings at the end being threaded to the pipe to avoid possible fracture of the regulator body which could result in leakage d. EXPLOSION Y OTROS RIESGOS: 1. Very high pressure surges in the gas supply line (or as a result of exposing the system to high pressure) may result in serious internal damage and cause leakage or affect regulator operation.. lo cual podría causar daños o fugas. Verificar inmediatamente que no haya fugas de gas después de que el regulador haya sido instalado y se haya abierto el paso del gas. pipe connections. A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE. EXPLOSION. (over) ¡PRECAUCION! NUNCA CONECTAR EL REGULADOR DIRECTAMENTE AL SUMINISTRO DE PROPANO. Nunca deberá usarse si se detectan fugas. b. NADIE QUE NO HAYA SIDO ENTRENADO DEBERA DE TRATAR DE INSTALAR. Wipe clean with a damp rag. All products. que se usan con gases combustibles deberán instalarse y usarse estrictamente de acuerdo con las instrucciones del fabricante. Box 2230 Southfield. Es una buena práctica verificar periódicamente que no haya fugas durante el uso del aparato electrodoméstico. CAUSANDO DAÑOS A LA PROPIEDAD. el fondo del plato. 4.maxitrol. la apertura de ventilación. Any of these may be signs of possible leakage or other damage that may affect proper operation and cause potentially dangerous combustion problems 3. Usar una solución espesa de jabón (u otro probador de fugas aceptado) alrededor de las bridas del diafragma. como se muestra en la tabla siguiente.356. with government codes and regulations. Todos los productos. c. tuberías correctamente roscadas y procedimientos de ensamble cuidadoso. Esto deberá hacerse antes de tratar de operar el aparato electrodoméstico o cualquier otro dispositivo quemador de gas. 48037-2230 Phone 248. Use a rich soap solution (or other accepted leak tester) around the diaphragm flanges. Check carefully for gas leaks immediately after the regulator has been installed and the gas turned on. DAR SERVICIO O DAR MANTENIMIENTO A LOS REGULADORES DE PRESION DE GAS Para reducir la posibilidad de INCENDIO. Make sure markings or wording on regulator are not painted over or obliterated. CAUTION NEVER CONNECT REGULATOR DIRECTLY TO THE PROPANE SUPPLY SOURCE. Aplicar únicamente la presión de una llave o tornillo de banco en las áreas planas alrededor de las roscas de la tubería del extremo a enroscar para evitar la posible rotura del cuerpo del regulador que podría resultar en fugas. including gas pressure regulators. as shown in the following chart. Si usted sospecha que un regulador Maxitrol ha sido expuesto a más del doble de la presión máxima de entrada. la tapa selladora y las conexiones de la tubería y todas las demás juntas. 4. LESIONES PERSONALES O PERDIDA DE VIDAS. turn off the gas and have the system checked by an expert. PUEDE OCURRIR UN INCENDIO O UNA EXPLOSION. seal cap. etc. b. Use pipe compound or thread sealant. dañado en alguna forma o que se haya desmantelado o maltratado. MAINTAIN OR SERVICE GAS PRESSURE REGULATORS. and OTHER HAZARDS: 1.S. otherwise there is a danger of fire or explosion depending upon conditions. d. Instalar el regulador correctamente con el gas fluyendo como se indica en la flecha en la carcasa de fundición. ¡PRECAUCIONES ESPECIALES! SI USTED NO SIGUE ESTAS INSTRUCCIONES EXACTAMENTE. or to have been taken apart or tampered with. De otra forma hay peligro de incendio o explosión dependiendo de las condiciones. cierre el paso del gas y haga que el sistema sea verificado por un experto. Never use if leakage is detected. LOS REGULADORES MAXITROL REQUIEREN UN REGULADOR EXTERNO (NO PROVISTO). bottom plate. NO UNTRAINED PERSON SHOULD ATTEMPT TO INSTALL.BULLETIN MI2010-5/00 SAFETY WARNING INSTRUCTIONS FOR MAXITROL GAS PRESSURE REGULATORS NOTE: GAS PRESSURE REGULATORS WILL NOT TURN OFF THE FLOW OF GAS. Do this before attempting to operate the appliance or other gas burning device. and all other joints. vent opening.

R600Z 210D. C. 8. Los tubos de ventilación deberán estar abiertos y el extremo abierto deberá estar protegido contra cualquier materia extraña. Un regulador MAXITROL deberá usarse dentro del rango de temperatura y no deberá excederse la presión máxima de entrada que se muestra en la tabla siguiente 9. B. C. 110MMP . R500Z. (*1) A only (únicamente) A only (únicamente) A only (únicamente) A. (*1) RV61.A. C. 12A09. (*1) R400Z. (*1) A only (únicamente) A only (únicamente) A only (únicamente) A. Inlet pressures exceeding 2 psi (LP) or 5 psi (natural) require a vent line. favor de comunicarse con el Service Manager (Gerente de with all fuel gases. where applicable. Si se necesita cambiar un resorte para accordance with intended usage. (*1) Para estar seguro que el regulador responde con rapidez cuando está equipado con un dispositivo limitador de ventilación automático tipo bola (12A04. Caution should be used to guarantee that there is sufficient inlet pressure to achieve the desired outlet pressure and no readjustment of the outlet pressure setting should be made unless the inlet pressure is within the proper limits for the regulator. B. C. D. Vent pipes must be open and the open end protected against entry of foreign matter. 6. (*1) A. GZ. el resorte deberá ser especificado por the required outlet pressure. D. EZ. Deberá consultarse el boletín MAXITROL para el regulador para ver la relación específica entre la presión de entrada y la de salida. (*1) Mounting Position (Posición de Montaje) A RV12LT. Venting must be controlled in accordance with government and plumbing codes and regulations to avoid the danger of escaping gas should there be internal leakage. (*1) A. The outlet pressure of the regulator must be measured to make sure it is in acuerdo para el uso que se pretende. B. G. (*1) A.6. (*1) A. Maxitrol Company. Los reguladores MAXITROL not in excess of the maximum inlet pressure shown in the following table and pueden usarse con todo tipo de gases combustibles. D. should be in the mounting position indicated. Deberá usarse precaución para garantizar que hay suficiente presión interna para alcanzar la presión de salida deseada y no deberá hacerse ningún reajuste en la presión de salida a menos que la presión interna esté dentro de los límites correctos para el regulador. MI USA. Model Number (Número de Modelo) Maximum Operating Inlet Pressure (Presión Máxima de Entrada para Operación) 1/2 psi (34 mbar) 2 psi (138 mbar) 1/2 psi (34 mbar) 1/2 psi (34 mbar) 1/2 psi (34 mbar) 1 psi (69 mbar) 1 psi (69 mbar) 1 psi (69 mbar) 2 psi (138 mbar) 1 psi (69 mbar) 5 psi (345 mbar) 1psi (69 mbar) 10 psi (690 mbar) 5 psi (345 mbar) 10 psi (690 mbar) 10 psi (690 mbar) (*1) Ambient Temperature Range (Rango de Temperatura Ambiente) Mounting Position [see below] (Posiciónde Montaje) [ver abajo] A. (*1) RV81. Southfield. En caso de dudas. B. C. R500. Failure to follow this may result in overfiring of the appliance or other gas burning device. D. La presión de salida del regulador deberá medirse para asegurarse que está de 7. J 325-3 (*1). including water. 10. La ventilación deberá estar controlada de acuerdo con los códigos y reglamentos gubernamentales de plomería para evitar el peligro de que se escape el gas en caso de una fuga interna. (*1) R400S. RV53. 325-5A (*1). B. C. J 210DZ. Teléfono: 248-356-1400. C. D A. MI USA. 7. 9. esto podrá interferir con el cierre o causar que el piloto se apague. 12A39). B. E. In case of any doubt. C.12A39). A MAXITROL regulator must be used within the temperature range and y deberá estar en la posición indicada de montaje. D. If a spring change is required to develop desarrollar la presión de salida requerida. Maximum inlet pressure for regulators with 12A09 or 12A39 is 2 psi (LP) or 5 psi (natural). D. Las presiones de admisión que excedan 2 psi (gas licuado) o 5 psi (gas natural) requerirán una línea de ventilación. Si esto no se lleva a cabo podría resultar en una llama excesiva del aparato electrodoméstico u otro dispositivo quemador de gas. the spring must be one specified by MAXITROL MAXITROL y la nueva presión de salida deberá anotarse en el regulador. G. D B B Vertical Flow (Flujo Vertical) C Horizontal Flow (Flujo Horizontal) LITHO IN U. (*1) A. incluyendo el agua. RV48 (*1) RV48T (*1) RV52. C. 12A09. C. R500S. Any other mounting position may interfere with lockup or cause pilot outage. RV20LT RV20L RV47. regulators must be in upright position (A) with non-integral vent limiter installed directly into vent threads. R600. D. B. Maxitrol regulators can be used 10. 325-7 -40° to 275° F (-40° to 135° C) -40° to 225° F (-40° to 107° C) 32° to 225° F (0° to 107° C) 32° to 275° F (0° to 135° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 125° F (-40° to 52° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) -40° to 205° F (-40° to 96° C) (*1) When equipped with a ball-check type automatic vent limiting device (12A04. 8. Maxitrol Company. RV91 RV111 RV131 R400. JZ 220D. B. please contact the Service Manager. Southfield.S. Servicio). Si se usa cualquier otra posición durante su instalación. Phone: 248/356-1400. B. E. D A. D. The MAXITROL bulletin for the regulator should be consulted for specific inlet and outlet pressure relationships. los reguladores deberán estar en posición vertical (A) con el limitador de ventilación instalado directamente a las roscas del tubo de ventilación. R600S. B. La presión máxima de admisión para reguladores con los dispositivos 12A09 o 12A39 es de 2 psi (gas licuado) o 5 psi (gas natural).

• To prevent serious personal injury from steam blow down. installation. check for proper operation of all of the limit and operating controls. • To prevent a fire. turn off the electrical power before making electrical connections. • To prevent serious burns. the low water cut-offs should be dismantled. All Models except 157S-RB-P) Low Water Cut-Off/Pump Controllers For Steam Boilers and Other Level Control Applications Series 150 and 150S Typical Applications: – Primary or secondary pump controller/ low water fuel cut-off for steam boilers – Motorized valve controller – Low water cut-off – High water cut-off – Alarm actuator Series 157 and 157S ! WARNING ION CAUT ING WARN • • Before using this product read and understand instructions. do not use this low water cut-off to switch currents over 7. 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. 1/3 Hp at 240 VAC. . • All work must be performed by qualified personnel trained in the proper application. the boiler must be cooled to 80˚F (27˚C) and the pressure must be 0 psi (0 bar) before servicing. Moreover.4A. before leaving the site. • To prevent electrical shock. Failure to follow this warning could cause property damage. and checked for proper calibration and performance. personal injury or death. • Save these instructions for future reference. 1/3 Hp at 120 VAC or 3. at each annual outage. After installation.000 BTU/hour or operating above 15 psi of steam pressure. • This low water cut-off must be installed in series with all other limit and operating controls installed on the boiler.Installation & Maintenance Instructions MM-217(F) Series 150 and 157 (Mercury Switch) ® Series 150S and 157S (Snap Switch. • We recommend that secondary (redundant) Low Water Cut-Off controls be installed on all steam boilers with heat input greater than 400.7A. inspected. steam. and electrical equipment and/or systems in accordance with all applicable codes and ordinances. connect a drain pipe to the control opening to avoid exposure to steam discharge. unless a starter or relay is used in conjunction with it. cleaned. and maintenance of plumbing.

(mm) 15/16 9/16 Pressure Setting Pump Off Pump On Burner On Burner Off Pump Off Pump On Pressure Setting Pump Off Pump On Burner Off 0 psi (0 kg/ cm2) (24) (16) (16) (6. Series 150.2mm).5 kg/cm2) Electrical Ratings Voltage 120 VAC 240 VAC PumpCircuit Rating (Amperes) Full Load Locked Rotor 7. 150S-MD. 150S. (mm) In. 157 and 157S Approximate Distance Above Cast Line Differential In.5 kg/cm2) Levels 13/8" DIFFERENTIAL (35mm) PUMP OFF BURNER OFF NORMAL BOILER WATER LINE 113/16" DIFFERENTIAL (46mm) PUMP OFF NORMAL BOILER WATER LINE BURNER “CUT-OFF LEVEL” AT CAST LINE BURNER OFF 3/4" DIFFERENTIAL (19mm) PUMP OFF PUMP ON BURNER CUT-OFF LEVEL 3/8" (9.2 Pilot Duty 345 VA at 120 or 240 VAC Alarm Circuit Rating Voltage Amps 120 VAC 240 VAC 1 1/2 Motor Horsepower Voltage Hp 120 VAC 240 VAC 1/3 1/3 Enclosure rating: NEMA 1 General Purpose Settings and Differential Pressures Values are ± 8” (3.3/8 (-16) N/A 0 7/8 150 psi (10.4 3.OPERATION Maximum Pressure: 150 psi (10.5 kg/cm2) Levels 150 psi (10.4) (41) (16) (22) (0) 5/16 (8) (16) (19) (22) 3/8 0 psi (0 kg/ cm2) (24) (14) (0) (37) (17) 3/8 (16) 0 17/16 11/16 N/A 3/4 150 psi (10.5 kg/ Burner On cm2) Burner Off 13/8 5/8 7/8 3/4 150 psi Pump Off (10.5mm) BELOW CAST LINE 3/4" DIFFERENTIAL (19mm) PUMP OFF PUMP ON 7/8" DIFFERENTIAL (22mm) BURNER ON BURNER OFF 2 .7 22. 157-MD and 157S-MD Approximate Distance Above Cast Line Differential In.4 44.5 kg/ Pump On cm2) Burner Off (19) . (mm) In. (mm) 15/16 5/8 5/8 1/4 Model 150-MD.

complete valve opening or closing will occur at slightly different levels than indicated above.5 kg/ Pump On cm2) Burner Off 17/16 (37) .3/8 (-16) (19) N/A (19) 150 psi (10. (mm) In.5 kg/cm2) Levels 150 psi Pump Off (10.5 kg/ Motorized Valve Open cm2) 7/8 Burner On Burner Off 0 150 psi (10.5 kg/cm2) Levels 7/8 (22) 113/16" DIFFERENTIAL (46mm) MOTORIZED VALVE CLOSED BURNER OFF NORMAL BOILER WATER LINE 13/8" DIFFERENTIAL (35mm) MOTORIZED VALVE CLOSED BURNER OFF NORMAL BOILER WATER LINE BURNER “CUT-OFF LEVEL” AT CAST LINE BURNER CUT-OFF LEVEL 3/8" (9.4) (41) (16) (22) (0) 3/4 5/16 0 psi (0 kg/ cm2) (8) 0 psi (0 kg/ cm2) (24) (14) (0) (17) 3/8 (16) 0 11/16 N/A 3/4 5/8 1/4 3/8 (16) Motorized 13/8 Valve Closed 150 psi 5/8 (10.5mm) BELOW CAST LINE 3/4" DIFFERENTIAL MOTORIZED (19mm) VALVE CLOSED MOTORIZED VALVE OPEN 3/4" DIFFERENTIAL MOTORIZED (19mm) VALVE OPEN CLOSED NOTE: Due to the slower operation of some motorized valves. (mm) 15/16 5/8 Model 158-MD/158S-MD Approximate Distance Above Cast Line Differential In.2mm). complete valve opening or closing will occur at slightly different levels than indicated above. 7/8" DIFFERENTIAL (22mm) BURNER ON BURNER OFF NOTE: Due to the slower operation of some motorized valves. (mm) 15/16 9/16 Pressure Setting Motorized Valve Closed Motorized Valve Open Burner On Burner Off Pressure Setting Pump Off Pump On Burner Off (24) (16) (16) (6. Model 158/158S Approximate Distance Above Cast Line Differential In. (mm) In. 3 .Settings and Differential Pressures (continued) Values are ± 8” (3.

(mm) 15/16 5/8 5/8 1/4 Pressure Setting Pump #1 Off Pump #1 On Pump #2 Off Pump #2 On 0 psi (0 kg/ cm2) (24) (16) (16) (6. (mm) In. Model 159/159S Approximate Distance Above Cast Line Differential In.5 kg/cm2) Levels 13/8" DIFFERENTIAL (35mm) PUMP #1 OFF PUMP #2 ON NORMAL BOILER WATER LINE PUMP #2 ON AT CAST LINE 3/4" DIFFERENTIAL (19mm) PUMP #1 OFF PUMP #1 ON NORMAL BOILER WATER LINE 7/8" DIFFERENTIAL (22mm) PUMP #2 OFF PUMP #2 ON PUMP #2 ON AT CAST LINE 4 .5 kg/ Pump #2 Off cm2) Pump #2 On Pump #1 Off 13/8 (41) 5/8 (16) 7/8 3/4 0 (22) (0) 7/8 150 psi (10.Settings and Differential Pressures (continued) Values are ± 8” (3.2mm).4) 5/16 (8) (16) (19) (22) 3/8 150 psi Pump #1 On (10.

blow down valve and water gauge glass requirements. but not lower than the lowest.Installing the Low Water Cut-Off a.INSTALLATION TOOLS NEEDED: Two (2) pipe wrenches. IMPORTANT: Follow the boiler manufacturer's instructions along with all applicable codes and ordinances for piping. as determined by the boiler manufacturer. Using a pipe wrench. size the steam (top) and water (bottom) equalizing pipe lengths so that the horizontal cast line on the body is 1a” (35mm) below the boiler’s normal water level. the lowest. STEP 1 . safe permissible water level. as determined by the boiler manufacturer. Series 150 and 150S (except Model 150-B and 150S-B) Models 150-B and 150S-B Series 157 and 157S A B A A B B 5 . size the steam (top) and water (bottom) equalizing pipe lengths so that the horizontal cast line on the body is at or above. 13/8" (35mm) AS A PRIMARY LOW WATER CUT-OFF/PUMP CONTROLLER NORMAL BOILER WATER LINE LOWEST PERMISSIBLE WATER LEVEL BURNER “CUT-OFF LEVEL” AT CAST LINE WATER EQUALIZING PIPE VERTICAL EQUALIZING PIPE BLOW DOWN VALVE STEAM EQUALIZING PIPE AS A SECONDARY LOW WATER CUT-OFF/PUMP CONTROLLER BURNER OFF LOWEST PERMISSIBLE WATER LEVEL BURNER “CUT-OFF LEVEL” AT CAST LINE WATER EQUALIZING PIPE VERTICAL EQUALIZING PIPE BLOW DOWN VALVE STEP 2 . OR If the control will be the secondary low water fuel cut-off. safe permissible water level. one (1) flathead screw driver. and pipe sealing compound. unscrew the plastic float blocking plug (A) from the low water cut-off body (B).Determine the Elevation at Which the Low Water Cut-Off/Pump Controller Must be Installed STEAM EQUALIZING PIPE If the control will be the primary low water fuel cut-off.

Models 150-B and 150S-B Series 157 and 157S C A C A ! CAUTION The plug must be reinstalled before control is shipped installed on the boiler. Screw the w” NPT steel plug (C) (provided) in tapping (A). c. Failure to follow this caution may damage float and operating mechanism. Note: 1” NPT tappings are provided. and removed when boiler is installed after shipment.Installing a Water Gauge Glass (Required on all steam boilers) a. b. with the exception of some 157 and 157S models which are 14” NPT. Series 157 and 157S All Other Models J J H 6 . Install a full ported blow down valve (G) directly below the lower cross of the water equalizing pipe (F). Install a water gauge glass (J). For Models 150-B and 150S-B and Series 157 and 157S (For all other models. Note: Gauge glass and tri-cocks not included with product. Mount and pipe the low water cut-off (D) on a vertical equalizing pipe (E) at the required elevation level. as determined in Step 1.b. F E D G STEP 3 . Install a water column (H) (not included with product) for all models except Series 157 and 157S (with integral water column). proceed to Step 3).

pump #2 on. alarm off. burner off. alarm on. alarm off. alarm off. pump #2 off. burner off. Pump #1 on.STEP 4 . do not use this product to switch currents over 7. burner on. 1/3 Hp at 120 VAC or 3. 1 2 4 5 6 1 2 4 5 6 1 2 4 5 6 For Models 158 and 158S Motorized valve closed. alarm off. After installation. burner on. • Modification of the switch assembly before or after installation could cause damage to the boiler and/or boiler system. an explosion and/or a fire. burner on. • This low water cut-off must be installed in series with all other limit and operating controls installed on the boiler. 1 2 5 6 1 2 5 6 1 2 5 6 a. burner on. 1/3 Hp at 240 VAC. turn off the electrical power before making electrical connections. check for proper operation of all of the limit and operating controls. unless a starter or relay is used in conjunction with it. remove the junction box cover (K). Boiler feed pump on.7A. personal injury or death. Using a flathead screwdriver. Boiler feed pump on. 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 For Models 159 and 159S Pump #1 off. Motorized valve open.Electrical Wiring ! WARNING • To prevent a fire. • To prevent electrical shock.4A. Failure to follow this warning could cause electrical shock. K 7 . Motorized valve open. before leaving the site. Switch Operation For all Models except 158/158S and 159/159S Boiler feed pump off. which could result in property damage. alarm on. Pump #1 on. pump #2 off.

b. (refer to page 9) based on your application requirements. 2 PUMP CIRCUIT 1 2 3 4 5 6 1 2 5 6 L PUMP SWITCH CUT-OFF AND ALARM SWITCH L L (All models except 158 and 159) 8 Model 158 Model 159 . 1 PUMP CIRCUIT NO. make electrical connections to the junction box (L). and using BX armored cable or Thinwall electrical metal tubing connector fittings. MOTORIZED VALVE TERMINALS ALARM CIRCUIT TERMINALS LOW WATER CUT-OFF TERMINALS PUMP #1 CIRCUIT TERMINALS PUMP #2 CIRCUIT TERMINALS 1 2 3 4 5 6 L L PUMP SWITCH LOW WATER CUT-OFF AND ALARM SWITCH L PUMP #1 SWITCH MOTORIZED VALVE SWITCH LOW WATER CUT-OFF AND ALARM SWITCH PUMP #2 SWITCH Automatic Reset (All models except 158S and 159S) Automatic Reset Model 158S Automatic Reset Model 159S PUMP CIRCUIT TERMINALS ALARM CIRCUIT TERMINALS LOW WATER CUT-OFF TERMINALS PUMP CIRCUIT TERMINALS ALARM CIRCUIT TERMINALS LOW WATER CUT-OFF TERMINALS L PUMP SWITCH L PUMP SWITCH LOW WATER CUT-OFF AND ALARM SWITCH LOW WATER CUT-OFF AND ALARM SWITCH Manual Reset (All models except 158S) Mercury Switches (Series 150 and 157) ALARM LOW WATER PUMP CIRCUIT CUT-OFF CIRCUIT TERMINALS TERMINALS TERMINALS Manual Reset Model 158S-M TO TO TO ELECTRIC LOW WATER LOW WATER VALVE ALARM CUT-OFF NO. Following the appropriate wiring diagram. Snap Switches (Series 150S and 157S) PUMP CIRCUIT TERMINALS ALARM CIRCUIT TERMINALS LOW WATER CUT-OFF TERMINALS IMPORTANT: There must be a minimum space of 1/2” (13mm) between connector fittings and electrical live metal parts.

WIRING DIAGRAMS
For Motorized Valves, refer to the valve manufacturer's wiring instructions. Low Water Cut-Off Only 1. Main Line Switch - For burner circuits within the switch’s electrical rating. 2. Pilot Switch - To holding coil of a starter when the burner circuit exceeds the switch’s electrical rating.
LINE LINE LOAD

OR

1 2

4 5 6 1 2 4 5 6 LOAD

Pump Control Only 1. Main Line Switch - For pump motors within the switch’s electrical rating. 2. Pilot Switch - To holding coil of a starter when the pump circuit exceeds the switch’s electrical rating.
LINE

LINE

LOAD

1 2

4 5 6

OR

Note: For Models 159 and 159S, use terminals 5 and 6 for pump #2. Alarm Circuit Only 1. Low Water Alarm
ALARM NEUTRAL HOT 1 2 4 5 6

1 2

4 5 6 LOAD

2. High Water Alarm
ALARM

OR

NEUTRAL HOT 1 2 4 5 6

Combination Pump Control, Low Water Cut-Off and Alarm 1. Main Line Switch - For burner circuits within the switch’s electrical rating. 2. Pilot Switch - To holding coil of a starter when the burner circuit exceeds the switch’s electrical rating.
SEE PUMP CONTROL CIRCUIT ALARM LINE (3 PHASE)

SEE PUMP CONTROL CIRCUIT

HOT ALARM TO NEUTRAL TO BURNER CONTROL CIRCUIT

OR

1 2

4 5 6

1 2

4 5 6 LOAD

9

6. Re-attach the junction box cover (K).
Note: Cover must be installed correctly as shown

K

STEP 5 - Testing
This control is factory calibrated for specific applications. The following testing procedure is only meant to serve as a verification of proper operating sequence. Dimensions provided are typical for a boiler not being fired and/or not at pressure. Actual operating ranges are shown on page 2 in the "Operation" section.

IMPORTANT: Follow the boiler manufacturer’s start-up and operating instructions along with all applicable codes and ordinances. Note: Water levels stated below are only for 150 psi (10.5 kg/cm2) operation.

a. Turn on the electric power to the boiler. With the boiler empty the pump should go on and the burner must remain off.

ON

!

WARNING
OFF

If the burner comes on, immediately turn the boiler off and make the necessary corrections. Failure to follow this warning could cause an explosion or fire and result in property damage, personal injury or death.

b. The boiler should begin to fill with water. Watch the gauge glass (J) until the water level reaches approximately d” (22mm) above the horizontal cast line (M) on the low water cut-off. IMPORTANT: If water does not start filling the boiler, immediately turn off the the boiler and make the necessary corrections.

J

78 (22mm)

/"

M

10

c. For automatic reset models only. When the water level reaches approximately d” (22mm) above the horizontal cast line (lower for MD models) the burner should come on (pump #2 should shut off with Models 159 and 159S). OR For manual reset models only. When the water level reaches approximately d” (22mm) above the horizontal cast line press the reset button (N). The burner should then come on.

Snap Switch Models

N

Mercury Switch Models
N

d. Continue watching the gauge glass (J) to see that the water continues to rise to approximately 1a” (35mm) (17/16” (37mm) for MD models) above the horizontal cast line (M). The pump should shut off (the motorized valve should close with Models 158 and 158S, or with Models 159 and 159S, pump #1 should shut off).

J

78 (22mm)

/"

M

!

CAUTION

To prevent serious personal injury from steam pipe blow down, connect a pipe to avoid exposure to steam discharge. Failure to follow this caution could cause personal injury.

e. Blow down the control when the water in the boiler is at its normal level and the burner is on. Follow Blow Down Procedure found in Maintenance Section on the last page of these instructions.

INSTALLATION COMPLETE
11

MAINTENANCE
SCHEDULE:
• Blow down control as follows when boiler is in operation. – Daily if operating pressure is above 15 psi. – Weekly if operating pressure is below 15 psi. NOTE More frequent blow-down may be necessary due to dirty boiler water and/or local codes. • Disassemble and inspect annually. Replace the low water cut-off/pump controller if it is worn, corroded, or if components no longer operate properly. • Inspect the float chamber and equalizing piping annually. Remove all sediment and debris. • Replace head mechanism every 5 years. More frequent replacement may be required when severe conditions exist such as rapid switch cycling, surging water levels, and use of water treatment chemicals. • We recommend head mechanism replacement when the switch(es) no longer operate properly. If you choose to replace the switch(es), order the proper McDonnell & Miller replacement switch or switch assembly and follow the Repair Procedure provided.

BLOW DOWN PROCEDURE:

!

CAUTION

To prevent serious personal injury from steam pipe blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge. Failure to follow this caution could cause personal injury.

Blow down the control when the water in the boiler is at its normal level and the burner is on. Slowly open the upper then the lower blow-down valves and observe the water level fall in the sight glass. Close the valves (lower first then upper) after verifying that the pump contacts have closed and the burner shuts off. If this does not happen, immediately shut off the boiler, correct the problem and retest. For Models 158 and 158S, close the blow down valve after the motorized valve opens and the burner shuts off. For Models 159 and 159S, close the blow down valve after both pumps come on. If this does not happen, immediately shut off the boiler and correct the problem.

2-Wire Pump Replacement Switch Assembly

3-Wire Burner

Replacement Mercury Tubes
Valve #1

!

CAUTION

Valve #2

Snap switches must be replaced as an assembly.

3500 N. Spaulding Avenue Chicago, Illinois 60618 tel: 773 267-1600 fax: 773 267-0991 www.mcdonnellmiller.com

©2003 ITT Industries Inc. Printed in U.S.A. 10-03 210341

2. limit control recognized. Sensitivity: Models operate from 4. 240 VAC (120°F) Contact Life : Mechanical. Listings: U. Selection or installation of equipment should always be accompanied by competent technical assistance. and local codes 3. Contact Ratings : 10 A @ 120.4 VA Secondary Circuit: 12 VAC RMS Voltage on probes. Install octal socket in appropriate enclosure using two #6 or #8 metal screws. 5/8” . H Warrick® Series 26M Controls Installation and Operation Bulletin This bulletin should be used by experienced personnel as a guide to the installation of series 26M controls. 240 VAC resistive (150°F). Specifications Control Design: Solid State components enclosed in clear lexan plug-in style housing. Install control module in socket. Sensitivities vs Maximum Probe Wire Distance* SENSITIVITY CHARACTER A B C D E SENSITIVITY (KOHMS) 4.C. 1A. Wire control per wiring diagram. 1/3 H.7 10 26 50 100 DISTANCE (FT) 900 600 250 100 50 * Based on type MTW or THHN wire.) powered contacts.240 VAC resistive (120°F). 1A @ 120. Time Delays : Standard – LLCO probe.E.5 million operations Electrical100.5 milli-amp Current. 1. @ 120. following N. Temperature: -40 TO 150°F ambient Terminals: All connections #6-32 screw type terminals with pressure clamps.O.L.L. Installation 1.) and one normally closed (N. Housing carries no NEMA ratings.7K to 100K maximum specific resistance. Contact Design : SPDT (1 form C): One normally open (N.Form 261 Sheet P/N 100204-1 Rev. Install rail mount socket on appropriate rail (DIN mount) in appropriate enclosure if applicable. We encourage you to contact Gems Sensors or its local representative if further information is required. VAC 50/60Hz Supply Current : Relay energized at 4.0” 3-1/2” 1-11/16” 11/64” Dia. Supply Voltage: 120. 240 and 208 volt units are not U. 3 seconds standard for lowering level.000 operations minimum at rated load. #14 or #16 Awg Dimensional Diagram 2-3/8” 2-5/16” 1-5/32” 2-3/4” 2. 240 or 24 VAC models: +10% -15% 50/ 60 Hz. 208/240 model: 187 Vmin to 255 Vmax. limit control recognition (353).C.P.

With liquid above electrode on terminal 6. Unless otherwise specified. At which time the LED and relay contact return to the dry state.module only Supply Voltage: 1=120VAC. Such a condition may suggest electrode maintance is required. TANK MAY BE USED Reference Probe INSTEAD OF REFERENCE PROBE pressed. changReset ing state of the load contacts. 2=240VAC. (LED will not be lit) returning load contacts to their original state. 4=NEMA 4 Socket Style: A=11 Pin Octal. E=100K N. Manual Reset with Optional Power Outage Feature: (Normally closed pushbutton across reset terminals) Control will ignore power loss to control. a power outage will cause the control to de-energize.Wiring Diagram AC Power Options: Automatic Reset: (Reset terminals not used): When the liquid rises to the electrode on terminal 6. 1=NEMA 1. Holding down the reset button for 3 seconds will allow the LLCO circuit to trip which simulates the loss of water. there is a three second time delay on decreasing 3 9 level. M=None.7K. 26M X X X X X XX XX X Optional Character Chart Dirty Probe: Blank = No Dirty Probe. 3=24VAC. D=50K. The control then de-energizes. the control will remain de-energized until the pushbutton is deIF METALLIC. loss of liquid will cause control to de-energize and remain so until liquid again rises to electrode and pushbutton is depressed. (LED will be lit) changing the state of the contacts. but will automatically energize upon return of power. Unless otherwise specified. B=10K. The relay state will not change until it exceeds the nominal sensitivity by more than 25% (typically) at nominal input voltage. B=DIN mount. One Cowles Road Plainville. (LED 1 will not be lit) returning load contacts to origi2 11 L2 10 nal state. The control will then energize. Liquid must be below probe on termi8 4 7 nal 6 for a full three seconds before control 5 6 de-energizes. (LED will be NC L1 lit) The control remains energized until the liquid level recedes below electrode on terNO minal 6.C. without the need of draining the water level in the boiler. C=26K. there is a three second time delay on decreasing level. Dirty Electrode Detection: The LED will flash every half-second once the probe resistance reaches a value greater than the nominal control sensitivity rating. A = With Dirty Probe Time Delay Increasing Level: 00-90 seconds. The control then de-energizes. the control energizes. Manual Reset : (Normally closed pushbutton installed across terminals #7 G LWCO and #8): When the liquid rises to the elecLow Level Cut-0ff Probe trode on terminal 6. The control will return to normal operation once the reset button is pressed a second time. Test Feature Allows LLCO circuit to be tested. 8=208/240VAC Sensitivity : A=4. The control remains energized until the liquid level recedes below electrode on terminal 6. Liquid must be below probe on terminal 6 for full three seconds before control de-energizes. Blank = 3 seconds Optional Character: Optional character chart Enclosure: 0=None. Blank = 0 seconds Time Delay Decreasing Level: 03-90 seconds. Pushbutton A B C E F Y Z X X X Power Outage X Test Feature X X X X X No Option X X X X Gems Sensors Inc. CT 06062-1198 Tel: 860-793-4579 Fax: 860-793-4580 . However.