Hydrolevel CG470 Series - Manual (Page 3)

OPERATING TEST PROCEDURE
1. After installation, bring the boiler water to
a safe operating level, turn on power and
set the thermostat to call for heat. The
amber LED lamp should be off. The boiler
will fire immediately.
2. Slowly lower the boiler water to a point
below the probe. The amber LED lamp on
the control will light. The lamp may begin
to flicker with the bouncing water level.
Stop draining the boiler when the lamp
glows steadily. NOTE: The water should
not be lowered beyond a visible point in
the gauge glass.
3. The boiler will shut down within 15
seconds.
TEST BUTTON
The CG470 is equipped with a button to test
wiring and control operation. To use the test
button, remove the cover and press the but-
ton located on the circuit board. The burner
will shut off for the length of time the button
is pressed. If the burner does not shut off,
remove power and recheck wiring. Note:
Hydrolevel recommends lowering the water
level (as described in “Operating Test
Procedure”) to functionally test the control
and probe operation on an annual basis.
IF BURNER DOES NOT SHUT DOWN IN
LOW WATER
1. Check terminal block wiring to insure that
all connections are correct.
2. Check the probe installation to insure that
there is 1/4" clearance from any surface
within the boiler or pipe. (Refer to Step 1
on page 1 of this instruction sheet.
3. Clean the boiler in accordance with the
manufacturer’s instructions. Machining
oils, grease, rust and other contaminants
in the boiler water can cause foaming or
surging and make a low water condition
difficult to detect during burner operation.
IF THE AMBER LED LAMP IS ON
The amber LED lamp indicates that the water
is below the probe. If the gauge glass shows
that the water is at the correct operating level
and the amber LED is lit, check the following:
1. Check for plugged gauge glass.
2. Make sure probe lead wire is properly
secured to the terminal.
3. Check for proper ground between probe
and boiler shell. Excessive use of Teflon
tape or sealing compound may isolate the
probe from the boiler shell.
4. Remove probe and examine for oily
residue. Clean probe with steel wool and
skim boiler.
IF THE RED LED LAMP IS ON
The red LED lamp indicates that the boiler
has experienced an unsafe temperature
(250°F). The control will lock out the burner
circuit and illuminate the LED when this
occurs. DANGER: Adding water to an over-
heated boiler can cause an explosion. The
boiler must be allowed to fully cool before
adding water. The boiler should be evaluated
by a qualified service technician before
restoring operation. The CycleGard control
should be replaced.
IF THE RED LED LAMP IS BLINKING
A blinking red LED lamp indicates that the
control has been locked out on an unsafe
temperature at some point in its history. The
CycleGard control should be replaced.
IF THE GREEN LED LAMP IS ON
The green LED lamp indicates that the control
is conducting an Intermittent Level Test. The
burner does not fire during the test period.
See Intermittent Level Test Feature on this
page for more details.
Enhanced Intermittent
Level Test Feature
To provide added protection to today’s small-
er boilers, CycleGard Model CG470 is
equipped with an enhanced Intermittent Level
Test (ILT) feature. Fifteen minutes after the
boiler reaches boiling temperature, the ILT
feature removes power from the burner for
60 seconds. During this ILT test, foam dissi-
pates and the water level quickly stabilizes,
allowing the CG470 to monitor the true water
level in the boiler. If the water in the boiler is
at a safe level, the control will re-energize the
burner. If the water level has dropped to a
level below the probe, the control will keep
the burner off (and send power to an optional
water feeder) until the water level is replen-
ished. The 60 second ILT test will repeat
every 15 minutes as long as the boiler
remains at boiling temperature. The ILT fea-
ture disengages when the boiler temperature
is below the boiling point.
The optional Smart Cycle feature is designed to
prevent unnecessary ILT tests in the event the
burner cycles off for other reasons (ex. pres-
sure limit or thermostat calls). When activated
(see wiring on previous page), the Smart Cycle
feature restarts the 15 minute timing sequence
each time the burner fires. So, for example, if
the pressure control shuts down the burner,
the Smart Cycle feature will reset the 15
minute clock once the pressure control re-
energizes the burner. This prevents an ILT
from occurring sooner than is needed as the
control was able to monitor the settled water
level during the pressure limit interruption.
Hi Temp Lock-Out
Unlike any other steam low water cut-off, the
CG470 monitors boiler temperature in addi-
tion to water level. This feature will shut
down and lock out the burner circuit if the
boiler reaches an unsafe level (250°F).
3
OPERATING INSTRUCTIONS
NOTE: For proper low water cut-off operation, the boiler should be cleaned at initial installation and periodically thereafter. Refer to the boiler
manufacturer’s instructions for cleaning procedures.