Install Instructions

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.
OPERATING TEST PROCEDURE
1. After installation, bring the boiler water to a safe operating level, turn on
power and set the thermostat to call for heat. The amber LED lamp should be
off. The boiler will fire immediately.
2. Slowly lower the boiler water to a point below the probe. The amber LED lamp
on the control will light. The lamp may begin to flicker with the bouncing
water level. Stop draining the boiler when the lamp glows steadily. NOTE: The
water should not be lowered beyond a visible point in the gauge glass.
3. The boiler will shut down within 15 seconds.
IF BURNER DOES NOT SHUT DOWN IN LOW WATER
1. Check to see if a foaming condition in the boiler is preventing the control from
accurately detecting the water level. With power to the system on, and water
above the probe level, set the thermostat so there is no call for heat and allow
the burner to shut down. Then, slowly lower the water in the boiler to a point
below the probe. The amber LED lamp should turn on and the relay will open
after a 15 second delay. Once this has occurred, reestablish a call for heat
and the boiler should not fire. Now raise the water level to an operating level.
The amber light should turn off and the control should reenergize the burner
circuit after a 30 second delay. If the control functions normally during this
test, but allows water to drop below the level of the probe when the test is
conducted with the burner on (as described in the Operating Test Procedure
above), the boiler is foaming. The CycleGard provides protection for foaming
boilers (see CycleGard Intermittent Level Test Feature above). However, to pro-
vide optimal steaming performance, it is still recommended that you clean the
boiler in accordance with the manufacturer's instructions. The foaming condi-
tion is caused by machining oils, elevated mineral content from make-up
water, grease and other contaminants in the boiler water. Cleaning the boiler
will eliminate foaming conditions in the boiler and provide for optimal steam-
ing performance.
2. Check terminal block wiring to insure that all connections are correct.
3. Check the probe installation to insure that there is 1/4" clearance from any
surface within the boiler or pipe. (Refer to Step 3 on page 1 of this instruction
sheet.
IF THE AMBER LED LAMP IS ON
The amber LED lamp indicates that the water is below the probe. If the gauge
glass shows that the water is at the correct operating level and the amber LED
is lit check the following:
1. Check for plugged gauge glass.
2. Make sure probe lead wire is properly secured to the terminal.
3. Check for proper ground between probe and boiler shell. Excessive use of
Teflon tape or sealing compound may isolate the probe from the boiler shell.
4. Remove probe and examine for oily residue. Clean probe with steel wool and
skim boiler.
IF THE GREEN LED LIGHT IS ON
The green LED lamp indicates that the control is 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.
To provide added protection to today’s
smaller boilers, the CycleGard low water
cut-off is equipped with an Intermittent Level Test. This important
feature adds protection against false signals that can be caused by
foam and volatile water conditions inside the boiler. The
Intermittent Level Test removes power from the burner at preset
intervals. During the test, foam dissipates and the water level sta-
bilizes – allowing CycleGard to monitor the true water level in the
boiler assuring safe and accurate operation.
The last four digits
of the CycleGard
model number
determine the fre-
quency and duration
of the Intermittent
Level Test (ILT) as
shown in the table.
When the optional SmartCycle feature is
activated (see wiring instruction on pre-
vious page), the CycleGard’s test time
sequencing is restarted each time the
burner fires. This feature enables a full
burner run cycle (10 or 20 minutes, depending on model) prior to
the first Intermittent Level Test. On CGT450 models (designed for
boilers equipped with tankless coils), SmartCycle suspends the
Intermittent Level Test during a call for domestic hot water allow-
ing the boiler to deliver its full BTU capacity to the production of
hot water.
Burner Connection
Model CG450 and CGT450
CycleGard
Intermittent
Level Test
Feature
Last 4 digits Frequency Duration
of Model No. of ILT of ILT
1090 10 Minutes 90 Seconds
1560 15 Minutes 60 Seconds
2060 20 Minutes 60 Seconds
2090 20 Minutes 90 Seconds
MAINTENANCE
To insure optimum performance, remove and inspect the probe annually.
Clean any sediment or scale from the probe using a scouring pad or steel wool.
Note: Do not use caustic chemicals that could damage the probe. Reinstall
the probe and perform the Operating Test Procedure described above.