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INSTALLATION & OPERATING INSTRUCTIONS FOR THE FLW CONTROL
This document should be used by trained personnel as a guide
to install the ProtoDesign Inc. Dual-Function control. Follow
necessary wiring practices as defined by the national electric
code (NEC). Installation or selection of equipment should
always be accompanied by trained technical personnel. Reset
and probe wires runs should be separated from high voltage wire
runs.
We recommend that secondary (redundant) Low Water Cut-Off
controls be installed on all steam boilers with heat input greater
than 400,000 BTU/hour or operating above 15 psi of steam
pressure. At least two controls should be connected in series
with the burner control circuit to provide safety redundancy
protection should the boiler experience a low water condition.
Moreover, at each annual outage, the low water cut-offs and
probes should be dismantled, inspected, cleaned, and checked
for proper calibration and performance. If used as a LWCO, the
control must be installed in series with all other limit and
operating controls.
SPECIFICATIONS:
Ambient Operation Temp: 0 to 150 deg. F.
Humidity: 85% (non-condensing)
UL Approval: UL353 limit control (FW function rated as an
operating control, non-limit)
Supply Voltage: 120/220/240/24 VAC 50/60 Hz.,
+10/- 15% line variation.
Contact Ratings: SPDT, 10A, 1/3H.P. 120/240VAC. Rated
100,000 cycles rated load.
Power Consumption: 1.5VA
Wiring Terminals: Open board design ¼" quick connects on
high voltage and 3/16" quick connects on low voltage.
Probe wire distances: 500 feet max. using MTW or THHN
#14 or #16 AWG wire.
Reset terminal wires: 50 feet max. using same wire type
described above.
OPERATION:
Test Feature (Option A) Allows the LLCO circuit to be
tested. Holding down the reset button for 3 seconds will allow
the LLCO circuit to trip, which simulates the loss of water
without the need to drain the water in the boiler. The control
will return to normal operation once the reset button is pressed
a second time or after a one-minute timeout.
Manual Reset With a normally closed pushbutton installed
across RESET terminals TB9 & TB10, and after a low water
condition, the relay will remain de-energized until the
pushbutton is pressed after the liquid rises to the level of the
probe. With no pushbutton installed control will be in
Automatic Reset.
•
Inspect probe annually for scale build-up and clean if necessary. Make certain there is no scale or build-up on the probe or its white
insulator.
•
Replace probe every 10 years. More frequent replacement of the probe is required if it is used in locales where significant water
treatment is required, where more frequent cleaning is necessary, or in applications with high make-up water requirements.
•
Replace the FLW Control every 15 years or after 100,000 cycles on the relay.
ProtoDesign Inc.
50495 Corporate Dr. Suite 106 Utica MI. 48315
Phone: 586-739-4340
www.teampdi.com
Single Level Service - Direct Mode: When the liquid rises to the
HIGH electrode on terminal TB3, the control energizes (LED1 will
be lit). The control remains energized until the liquid leaves the high
electrode on terminal TB3 de-energizing the load contacts (LED1 will
not be lit). In Inverse Mode: the control logic is reversed.
Differential Service – Direct Mode: When the liquid rises to the
HIGH electrode on terminal TB3, the control energizes (LED1 will
be lit). The control remains energized until the liquid leaves the LOW
electrode on terminal TB4 de-energizing the load contacts (LED1 will
not be lit). In Inverse Mode: the control logic is reversed.
LWCO - When the liquid rises to the LLCO electrode on terminal
TB11, the control energizes, changing state of the (LW) load contacts
(LED2 will be lit). The control remains energized until the liquid
level recedes below LLCO electrode on terminal TB11. The control
then de-energizes, (LED2 will not be lit) returning load contacts to
original state. Unless otherwise specified, there is a three-second time
delay on decreasing level. Liquid must be below probe on terminal
TB11 for a full three seconds before control de-energizes.
POWER OUTAGE FEATURE The power outage feature is a
standard feature for the FLW. When using the manual reset feature, if
power interruption occurs when the probes are in liquid the relay will
de-energize. When power is restored if the liquid is in contact with
the probe the relay will energize without a manual reset. This feature
eliminates boiler lockouts due to power outages when using the reset
function.
CSD-1 CODE COMPLIANCE On Manual Reset units, if the
control is in a low-water condition (water off probe) when there is
an interruption of power, the control will remain in a low-water
condition when power is restored. The reset button will need to
be pressed when the water level is restored to a level above the
probe.
:
PROBE BUILD UP DETECTION If the resistance of the LLCO
probe to ground increases to approximately 10K above sensitivity
set point the control will turn off and indicate probe buildup (LED
blinking). To clear error, clean or replace probes. In manual reset
mode, probe must be in liquid and reset button pushed for 30
seconds. In automatic reset mode, error will clear 30 seconds after
probe is in liquid. (Detection not available in Non-Limit Control
version, Option E)
Time Delays: In Differential Service, rising level time delays begin
upon liquid level contacting the high probe and falling level time
delays begin upon leaving the low probe. In Single Level Service that
uses the high probe and requires time delays on increasing and
decreasing levels, terminals TB3 (high) & TB4 (low) must be jumped
together. Otherwise, Single Level Service time delay will only be on
decreasing level.
Maintenance Schedule
Fax: 586-739-4341
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