Bulletin MM-856

McDonnell
& Miller
Service
Guide
Fast Facts Testing Tips
Troubleshooting Proper Hook-ups

IT T
McDonnell & Miller
Service Guide
In this service guide, you will find many helpful
tips concerning installation, maintenance and
troubleshooting boiler controls.
It is intended to highlight factors that should be
considered in boiler installation, operation, main-
tenance, and servicing.
Only qualified individuals trained in accordance
with all applicable codes should perform installa-
tion and repair of boiler controls.

CONTENTS
Electronic Controls
Low Water Cut-offs for Residential
Hot Water and Steam Boilers… ……………………… 3
Locating an LWCO Probe on a Hot Water Boiler……… 3
Locating an LWCO in a Pipe Tee above the
Hot Water Boiler… …………………………………… 4
Common Mistakes… …………………………………… 5
Testing Tips… …………………………………………… 7
Service Guidelines………………………………………… 8
Steam Boilers with Remote Sensors… ………………… 9
150E Tips… ……………………………………………… 9
Blow Down Procedure………………………………… 12

Electro-Mechanical Controls
Locating Controls on a Steam Boiler………………… 15
Common Installation Errors with Boiler Controls…… 16
Operation Tips… ……………………………………… 18
Blow Down… ………………………………………… 20
Servicing Switches on Cut-offs… …………………… 22
Special Service Points… ……………………………… 24
Servicing Combination Water Feeder/Cut-offs……… 25

Make-up Feeders
Electric Water Feeders… ……………………………… 27
Mechanical Feeders… ………………………………… 28
The Broken Union Test………………………………… 31

Hot Water Boiler Mechanical Controls

Flow Switches as Cut-offs… ………………………… 32
Mechanical Cut-offs and Accessories………………… 33

Replacement Mechanisms… ……………………… 35

Appendices… ………………………………………… 36

2
Electronic Controls
Low Water Cut-Offs for Residential
Hot Water and Steam Boilers
Electronic Low Water Cut-Off (LWCO) controls used
on residential hot water and steam boilers oper-
ate on electrical conductance principals. When an
electrical current passes from the probe tip through
the water and returns to the control unit, the con-
trol determines that water is present and it is safe
for the boiler’s burner to fire. Proper location and
maintenance are required to help insure safe opera-
tion of the boiler.

750
LWCO RB-24E

PS850 RB-122-E
LWCO

Locating a LWCO Probe on a

Hot Water Boiler
All boiler manufacturers designate the preferred
primary (and sometimes secondary) location for
installation of the LWCO probe on the boiler. They
have determined that this location is above the
minimum safe water level and provides the ¼”
probe tip clearance needed to ensure the probe
is not grounded. It is best to install the probe in
these locations. If installed in other locations on a
hot water boiler, make sure the area is not prone to
develop an air pocket.

3
 TYPICAL BOILER LOW WATER CUT OFF
PROBE INSTALLATION LOCATIONS
To System
Circulating
Pump

3/4” (20 mm) NPT

Tapping Minimum
Safe Water
Level (as
determined
by the boiler
manufacturer)
Install
Here Hot Water Boiler
On the Boiler (RECOMMENDED)
Figure 1
Locating a LWCO in a Pipe Tee above the Hot
Water Boiler
The LWCO probe may also be installed in piping ex-
ternal to the boiler on hot water systems (Figure 2).
To System
Circulating Install Here
Pump
Use a Reduced-branch
Tee 11/4 x 11/4 x 3/4
(minimum)
Optional
Isolation
Valve
Never install the Low
(Must be Water Cutoff in extensions
installed
above tee)
from the boiler.
Minimum Safe
Water Level
(as determined
by the boiler
manufacturer)

Hot Water Boiler

Figure 2
The probe installation in Figure 3 is CORRECT
for either a hot water or steam system

Figure 3

4
• Directly in the boiler or large pipe
• Sufficient clearance around the probe
• Teflon® insulator extends past the wall or pipe
• Good continuity path through the wall and probe
body to ground

The probe installation in Figure 4 is

incorrect!!

WRONG

WRONG

Figure 4
Insulating sealant or Teflon® tape blocks the conti-
nuity path, resulting in a weak electrical signal and
a false low-water-level indication.

Common Mistakes with LWCO Probe

Installations in Hot Water Boilers
Installing the LWCO in the piping external to the
boiler can have pitfalls:

Figure 5
Probe too long - One potential problem may be
the probe is too long for the installed location and
the probe lacks proper clearance. Contact between
the probe and pipe results in a shorted electrical
path (Figure 5). If the probe touches the wall of
the pipe, the circuit is completed and the LWCO
“thinks” there is water in the system whether there
is or not. If the water level drops below the level of
the probe in this situation, the burner circuit will
not be interrupted and a dry fire could occur.

5
 AIR POCKET

Figure 6
Probe not in water path way - In hot water sys-
tems with copper tube piping, locating the probe
in sweat-to-thread adapters can cause the probe to
be out of the path of flowing water. Figure 6 shows
a probe installed in an extension. Air in the water
will escape, collect around the probe and form an
air pocket. This leads to a loss of continuity and a
false low water condition, resulting in a nuisance
shutdown. Removing the probe from the extension
allows the air to escape, and the probe to function
properly when reinstalled, until air collects again.
This may lead to the opinion that the control is
faulty when the real problem is the air pocket.

DEBRIS

Figure 7
Debris build up in adaptor - Installations in exten-
sions can also allow scale or debris to settle in the
adaptor (Figure 7). If the debris is conductive, it can
create an electrical bridge. Here, the control cannot
discern the difference between water and debris
and a false-level signal condition is created, allow-
ing the burner to continue to run, even without
water! This can create a possible dry fire. Always
make sure the probe Teflon® insulator extends into
the run of the system supply pipe to ensure proper
operation.

6
Testing Tips for Series 750, PS-800,
PSE-800 and PS-850 LWCO
• On a regular schedule, perform an operational
test on the LWCO control while the system is run-
ning.
• On controls with a TEST button, press and hold
the button for at least 30 seconds. The electronic
control will go into a low water cut-off condition
and turn the system off.
• For steam systems, occasionally perform an
actual low water test by draining the system to
just below the probe level as it is running. This
will determine whether the probe will sense the
absence of water in the system. If the system has
an electronic time delayed make-up water feeder,
press and hold the test button for at least 2 min-
utes to allow the feeder to actuate.

If the system fails to shut off during any of

these tests, immediately turn off the boiler.
Determine the reason for the failure and
correct the problem. Failure to correct may
result in serious property damage, personal
injury or death.

Series PS800 and PS850 cut-offs manufactured

prior to December 2007 have a shorted probe
diagnostic feature. For controls with this feature,
if the LWCO senses 5 ohms or less resistance levels
between the probe and ground, the control shuts
down the boiler and displays alternately-flashing-
red-and-green LED’s. This indicates there is a prob-
lem at the probe - the probe is in contact with or
grounded to the boiler piping. Another possibility is
boiler water chemistry. Aggressive cleaning agents
in the boiler can affect the conductivity level and
result in a nuisance shorted probe cut-off.

7
Service guidelines for steam or hot
water applications with low water
cut-off controls and probes

Inspect the probe annually or more frequently for

scale build-up or oily residue, and clean or replace
the probe if necessary. If the McDonnell & Miller
probe has the patented self-cleaning feature, the
inspection and cleaning is required only every five
years, unless performance problems indicate more
frequent cleaning is required.
• Check annually for damaged probe wire insula-
tion or loose power wiring and grounding con-
nections.
• Make certain there is no scale or build-up on the
central metal probe rod or its Teflon® insulator.
• Clean the probe only by wiping with a non-abra-
sive cloth and rinsing with clean water.
• Do not use sharp instruments to remove scale or
rust accumulations.
• Be careful not to damage the Teflon insulator.
• Replace the probe if the Teflon insulator is
cracked or the probe rod is loose in the assembly.
• Replace the probe every 10 years or more fre-
quently if applications have significant water
treatment or high make-up water requirements.
Appendix B lists available replacement probes.
• Replace the low water cut-off control unit every
15 years.

8
Steam Boilers with Remote Sensors
Probes must be installed vertically if they are more
than 6” (152mm) long. The end of the probe rod
or extension must be installed above the minimum
safe water level, as determined by the boiler manu-
facturer. A false low-water signal can occur
if the probe extension rod loosens due to
improper assembly or excessive vibration.
Vertically mounted
Low Water Cut- Remote Sensor
off Control

Figure 8

Series 1575 and 150E Combination

Pump Controller and Low Water Cut-off
Diagnostic Tips
The Series 1575 and 150E LWCO lets the operator
diagnose what is happening with the boiler water
level and the condition of the probes by means of
internal and external LED’s.

External LEDs

Figure 9

9
The Green and Red LEDs on the outside of the
control box (Figure 9) can be used to diagnose
the 1575 and 150E’s condition:
• Green LED on solid indicates the unit is powered
• Red LED on solid means a low water condition
exists
• Red LED flashing indicates water has been below
the middle probe for more than three minutes
• Green and red LED flashing alternately every 1/2
second means an out-of-sequence condition
(probes detecting water in other than the normal
sequence has occurred [check the status of the
middle probe (internal yellow LED) to verify]
• Green and red LED flashing together indicates
the circuit board is too hot. (The control box may
need to be relocated remotely away from the
probe head to a cooler spot.)

BCC
Burner Cut-off
Timing Delay
BNC
Adjustment
BNO
60

PCC
Secs.
30

PNC

PNO

N Internal
H
LEDs

Figure 10
The internal Green, Red and Yellow LEDs (Figure
10) turn on as water touches each probe:
• Green LED – Top probe status – Controls Pump
OFF
• Yellow LED – Middle probe status – Controls
Pump ON / Burner ON
• Red LED – Bottom probe status – Controls Burner
OFF
When these LEDs are flashing it indicates fouling
and/or continuity threshold-level changes -- a sign
to clean the probes of surface contaminants. The
middle probe may require more frequent atten-
tion because oil, mud and scale accumulate more
readily on this probe since the water level normally
operates at this level more often. Heavy accumula-

10
tions of scale may result in an out-of-sequence
shut down due to fouling of the middle or lower
probe.

The 1575 and 150E control also has a Burner Cut-

off Timing Delay Adjustment (Figure 10). If the
factory-set, zero delay is too short, make changes in
small increments. Test the boiler cut-off after each
setting change. While pressing the “TEST” button,
the external green LED will flash once per second of
time delay.

As with all remotely-mounted electronic controls,

proper grounding techniques should be followed.
Always run a separate ground wire from the con-
trol box to the sensor body for best operation.

CAUTION: In applications that require high vol-

ume make-up water, scaling of the probes and
internal chamber surfaces becomes a problem.

Proper, Periodic Blow downs Are Required

Periodic flushing of the control, referred to as blow
down, is an essential component of an effective
boiler maintenance program. The purposes of a
blow down test are to verify proper control opera-
tion and to clear the LWCO chamber of sediment
and debris. Sediment or debris in the chamber and
on the probes may cause the probe(s) to incor-
rectly sense the water level due to accumulation of
deposits that can affect probe conductivity.

Blow downs must be done while the boiler is

operating. The frequency of LWCO blow down
is determined by the operating pressure of the
boiler:
• Daily, if the boiler operating pressure is above 15
psi
• Weekly, if the boiler operating pressure is below
15 psi
• Primary and secondary controls should be blown
down independently
NOTE: More frequent blow down may be neces-
sary due to dirty boiler water and/or local code
requirements.

11
Caution must be exercised when doing a blow
down to prevent serious injury. A drain pipe must
be connected to the lower control piping opening
to avoid exposure to steam discharge during the
blow down process. Refer to Figure 11 and steps
below for proper blow down procedure.

Valve #1

Valve #2

Figure 11

Blow Down Procedure

When blowing down the control at pressure, the
blow down valves should be opened slowly. The
piping needs to be warmed up and the stagnant
water in the drain piping needs to be pushed out.
Suddenly operating a blow down valve causes
steam to condense which creates water hammer.
Damage to LWCO components and piping is pos-
sible when water hammer occurs due to improper
blow down piping and procedures. For this reason,
McDonnell & Miller recommends a dual valve blow
down system (Figure 11) for each LWCO control.
Blow down the low water cut-off/pump controller
when the water level is at its normal level (pump/
valve off) and the burner is on.

• Verify that the pump or valve turns on when the

water falls below the level of the middle probe

12
• Verify that the burner turns off when the water
level falls below the level of the bottom probe
and is still visible in the sight glass
• Slowly close the lower “Throttling Gate Valve”
(#2). The water level should begin to rise:
• Verify that the burner turns on when the water
level reaches the middle probe level
• Verify the pump or valve turns off when the
water level rises above the top probe position.
If the above sequence of actions does not occur
as described, immediately close all valves, turn
off the boiler and correct the problem. Inspec-
tion/cleaning of the LWCO probes by disman-
tling the control may be required.
If the LWCO performs per these instructions, close
both blow down valves and return boiler to normal
operation.

Periodic LWCO Dismantle Inspections are

Required
At least annually, disassembly, inspection and
cleaning of the LWCO components and piping are
required.
• During the inspection/cleaning, the float bowl/
probe chamber and equalizing piping must be
examined and cleaned to ensure all sediment or
debris is removed.
• The LWCO/pump control unit should be replaced
if it is worn, corroded, or if components no lon-
ger operate properly.
• Inspect the probe for scale build-up or oily resi-
due and clean or replace if necessary.
• Check for damaged probe wire insulation or loose
power wiring and grounding connections.
• Make certain there is no scale or build-up on the
central metal probe rod or its Teflon® insulator.
• Clean the probe only by wiping with a non-abra-
sive cloth and rinsing with clean water.
• Do not use sharp instruments to remove scale or
rust accumulations.
• Be careful not to damage the Teflon insulator.
• Replace the probe flange assembly if the Teflon
insulator on any probe is cracked or the probe
rod is loose in the assembly.

13
• Replace the probe assembly every 10 years, or
more frequently if applications have significant
water treatment or high make-up water require-
ments.
• Replace the low water cut-off control unit every
15 years.

NOTE
The probes may need to be inspected and
cleaned more frequently on systems where
there is the potential of coating build-up on the
probes. This includes systems:
• With high quantities of raw water make-up
• With no condensate return
• With untreated boiler water
• With inconsistent or infrequent boiler-water
chemical treatment
• Where significant changes have been made to
the boiler-water chemical treatment process
• With oil in the boiler water

Excessive scale or sludge should trigger a reassess-

ment of boiler water treatment, as well as more
frequent dismantle inspections of the LWCO.
See the Installation and Maintenance Bulletins for
full explanation of operation and test procedures:
Series 1575 – MM-286
Series 150E – MM-414

Electro-Mechanical
LWCO Controls
Float-Actuated Burner Switches and Feeder
Valves
Electro-Mechanical LWCO controls use a float to
monitor the water level in the boiler to determine if
it is safe for the boiler’s burner to fire. Proper loca-
tion and maintenance are required to help insure
safe operation of the boiler.

14
Locating Controls on a Steam Boiler
Electro-Mechanical controls include Low Water Cut-
Offs (LWCO) and combination LWCO with feeder
valves or pump controllers. Check to be sure that
the cut-off/feeder is correctly installed before check-
ing control function. Some controls are mounted
in the gauge glass tappings (Figure 12); others are
mounted in equalizing piping (Figure 13).

Figure 12

1” STEAM
EQUALIZING PIPE

INDEPENDENT
WATER COLUMN MODEL 63
LOW WATER
CUT-OFF

CUT-OFF
LEVEL

1” BLOW DOWN
VALVE
1” WATER
EQUALIZING PIPE

Figure 13

15
A Correctly Installed Control – Look For These
Characteristics
• The steam equalizing leg is properly connected
directly into the boiler.
• The water equalizing leg is connected into a tap-
ping in the water space of the front of the boiler,
at or below the bottom of the water glass (but
above the firebox of the boiler). In this boiler
section there is a large volume of water and slow
circulation.
• Cross fittings installed for clean out and inspec-
tion.
• Blow down piping installed for each control.
When the boiler has an independent water col-
umn, equalizing pipe should be connected from
top and bottom tappings of the boiler control to
corresponding steam and water equalizing pipes of
the water column. This duplicates the water level
conditions in the boiler in the float chamber of the
LWCO or feeder.

Common Installation Errors with Boiler

Controls
The following figures point out common instal-
lation errors – errors that can cause an incorrect
reproduction of the boiler water level in the float
chamber of the feeder or cut-off.

Casting ByPass
Line Valve
Series 247
Water
Feeder

Burner
Boiler Return
Header

Figure 14

Equalizing pipe connected to header – Figure 14

shows the steam-equalizing piping connected into
the steam header. The velocity of the steam in the

16
larger line causes water level in float chamber to be
higher than boiler water level.

CAUTION: Never connect a system line to the

steam leg of the LWCO control. It will produce
an incorrect water level in the control.

ASME Boiler Code only allows connections of the

water column to the boiler and/or to another
control. (Connecting a sight glass water column
into the float chamber the does not violate the
code because in effect it simply adds another water
column.)

City Water Supply

Casting
Line ByPass
Valve

Burner
Boiler Return
Header

Figure 15

Connecting to feed line – Figure 15 shows the

water equalizing pipe incorrectly connected into
the direct feed line. A surprising, but common
mistake! Equalizing and feed pipes must be totally
independent.

City Water Supply

Casting
Line ByPass
Valve
Series 247
Water
Feeder

Burner
Boiler Return
Header

Figure 16

17
Equalizing pipe connected too low – Figure 16
shows the water-equalizing pipe connected down
too low into the bottom part of the boiler. Circula-
tion in the water leg of boiler exerts a downward
pull through the pipe that often causes water level
in float chamber to be 2 to 11 inches below the
actual boiler water level. If this occurs, the water
feeder will tend to ‘overfeed’ water into the boiler –
causing boiler flooding.

Operation Tips
Examining the system as a whole can identify
sources of potential problems. Boiler operating
pressure must not exceed the pressure rating of
the control. Some codes require that controls meet
or exceed the maximum boiler rating. Relief valves
must be able to handle the boiler capacity, should a
high pressure condition occur.
Once it has been determined that the control
installation is correct, a step-by-step functional
test should determine correct control operation
or the sources of problems.
• Start with a normal water level in the boiler.
Slowly drain the boiler while the burner is run-
ning. Drain the boiler via its lowest drain connec-
tion rather than the blow down valves. If neces-
sary, mark and unwire the terminals and use an
electric test meter to indicate switch operation.
• Note the indicating line on the control’s float
chamber. This is a reference point.
• Using a spirit level, transfer this reference level
to and mark the sight/gauge glass. If the control,
such as the Model 150, 150S or 67, has a switch
for feeder or pump control, it will close about
1/2” to 1/4” above the reference level. On some
high-pressure models, such as the Model 93, this
action point is as much as 1” above the refer-
ence line. To continue lowering the water level,
increase the rate of draining the boiler or throttle
back the automatic feed.

18
• The most important point of action, the burner
cut-off, should occur at the reference line, but no
more than 1/2” below the reference line! ASME
Boiler Code mandates there must be water still
visible in the sight/gauge glass at the point of
burner cut-off.
• Once the burner cut-off level has been reached
and boiler cut-off has occurred, stop draining the
boiler and slowly feed water into the boiler - up
to the normal water level. The burner should re-
start at a level about 1/2” to 3/4” above the cut-
off level. The feeder or pump controller switch
should not open before the burner switch closes,
except on manual reset models. The manual reset
units maintain burner cut-off until an adequate
water level has been re-established in the boiler
and a physical reset action occurs.
• If the stated actions do not occur as described,
immediately turn off the boiler, investigate and
correct the cause.
Periodic testing and consistent performance
determines a control’s operation as a safety
control.
Keep a log of the daily or weekly test of operation
to track a control’s performance over time. The log
will help identify changes in water conditions and
component response time.
Whether the system has separate controls for low
water cut-off and feeder/pump operation or all-
in-one controls, the internal condition of the float
chamber must be maintained free of sediment and
debris for best performance. The Model 67 and
64 controls have float mechanism on the same
plane as the switch mechanism. Sediment can ac-
cumulate around and between the convolutions of
the seal, or bellows of these controls. Over time,
enough debris builds up affecting the movement of
the control which delays or prohibits the reaction
of the float to water level changes.
Proper and regular blow down of the control mini-
mizes sediment accumulation.
In some cases, the debris can produce a physical
obstruction to the mechanical action. Sediment
around the float can also cause the float to dete-
riorate and the float to take on water, resulting in

19
a false low water reaction and uncontrolled feeder/
pump operation. Clean out of the chamber around
the bellows using as gentle flushing water as pos-
sible so as not to damage the thin bellows. If clean-
ing is not practical, replacing the entire assembly is
recommended.
LWCO Models 63, 42 or 150 have bellows which
are above the waterline. These models are subject
to floating debris and corrosive gases. An annual
inspection is important to maximize control life. If
the bellows develops a pinhole or fracture, steam
and water leakage can cause significant damage to
the electrical switch.
Changes of control set points should not be ig-
nored. Replacement parts are available to bring the
operation back to like-new condition.

Blow Down: A Key Maintenance Point

Periodic flushing of the control, referred to as blow
down, is an essential component of an effective
boiler maintenance program. The purposes of a
blow down test are to verify proper control opera-
tion and to clear the LWCO chamber of sediment
and debris. Sediment or debris in the chamber may
prevent the float from traveling through its normal
operating range.
Blow downs must be done while the boiler is
operating. The frequency of LWCO blow down is
determined by the operating pressure of the boiler:
• Daily, if the boiler operating pressure is above 15
psi
• Weekly, if the boiler operating pressure is below
15 psi
• Primary and secondary controls should be blow
down independently
NOTE: More frequent blow down may be neces-
sary due to dirty boiler water and/or local code
requirements.
Caution must be exercised when doing a blow
down to prevent serious injury. A drain pipe must
be connected to the lower control piping opening
to avoid exposure to steam discharge during the
blow down process. Refer to the illustration and
steps below for proper blow down procedure.

20
Blow Down Procedure
When blowing down the control at pressure, the
blow down valves should be opened slowly. The
piping needs to be warmed up and the stagnant
water in the drain piping needs to be pushed out.
Suddenly operating a blow down valve causes
steam to condense which creates water hammer.

Valve #1

Valve #2

Figure 17
Damage to LWCO components and piping is pos-
sible when water hammer occurs due to improper
blow down piping and procedures. For this reason,
McDonnell & Miller recommends a dual valve blow
down system (Figure 17) for each LWCO control.
Blow down the low water cut-off/pump controller
when the water level is at its normal level (pump/
valve off) and the burner is on.
• Open the upper “Positive Shut-off Valve” (#1)
• Slowly open the lower “Throttling Gate Valve”
(#2)
• With both valves open, the water level in the
control will drop in the sight glass
o Verify that the pump switch contacts close
o Verify that the burner shuts off when water
falls to the cast-in low water cut-off line and is
still visible in the sight glass

21
• Slowly close the lower “Throttling Gate Valve”
(#2). The water level should begin to rise:
o Verify the burner turns on when the water level
in the sight glass rises above the cast-in low
water cut-off line
o Verify the pump turns off
If the above sequence of actions does not occur
as described, immediately close all valves, turn
off the boiler and correct the problem. Inspec-
tion/cleaning of the LWCO float mechanism
or probes by dismantling the control may be
required.
If the LWCO performs per these instructions, close
both blow down valves and return boiler to normal
operation.

Series 47 and 67 Controls with 14B valves

Blow down the low water cut-off when the water

level is at its normal level and the burner is on.
Slowly open the blow down valve until it is fully
open, and observe the water level falls in the gauge
glass. After verifying the burner shuts off, close the
valve. If the boiler does not shut off or restart as
described, immediately shut off the boiler and cor-
rect the problem.

Servicing Switches on the Cut-Off

Electrical switches can deteriorate over time. In
mercury switch units with glass tubes, dull, stretchy
or separated mercury is a sign of aging. In snap
switches, a visual examination provides little help.
A continuity test must be performed to deter-
mine whether a switch is functioning. Snap switch
contacts can fuse from current overload or short

22
cycling resulting in system damage from boiler
flooding or dry firing. Using a relay in the pump
motor circuit can help reduce current overload on
switch contacts.

What Causes LWCO and Pump Switches To

Malfunction
The switches used in McDonnell & Miller controls
are conservatively rated, and, when applied in ac-
cordance with these ratings, they should operate
dependably for many years. Determining the cause
of failed switches can be difficult, but here are a
few helpful hints and possible causes:
• Burner motor having greater power requirements
than the LWCO switch ratings
• Feed pump is not properly balanced for required
boiler fill rate resulting in rapid cycling of switch-
es
• Shorting of power wiring in control circuit
• Switch submerged in water
• Lightning striking electrical service to building,
causing tremendous electrical overload
• Overloaded circuit in building, resulting in low
voltage conditions which in turn causes higher
amperage draw and consequent switch failure
• Other limiting devices, like pressure controls,
relays, thermostats, etc., may short circuit, over-
loading all switches in the same electrical line
• Pump motor having a dead spot, may stall and
generates heat, causing overloading of switch
As previously stated, the most common cause of
switch overload is incorrect application. Check Mc-
Donnell & Miller electrical ratings against ratings of
the equipment controlled.
If there is any doubt about product selection, ask
for recommendations by contacting your McDon-
nell & Miller Representative or the factory.
23
Special Service Points
Boiler Piping Considerations
Feeder Cut-Off
Pump Controller Combination

Steam
Boiler

Figure 18

Make connections between boiler and control

as short as possible, and make all piping not less
than 1” pipe size. Always provide separate blow
down valves in straightaway connection from each
control and be sure there are no trapped discharge
lines.
Feeder Cut-Off
Pump Controller Combination

XX

Steam
Boiler

Figure 19

24
Improper water column piping may create a water
pocket in the lower equalizing connections, as
shown by the X’s in Figure 19. Such a water pocket
often causes abnormal fluctuations when the
control is blown down – particularly when boilers
are operated above 100 PSI. This can subjected the
floats to violent hammering with subsequent dam-
age.

Surge Columns
Applications where the boiler water level fluctuates
rapidly may lead to inconsistent operation. It could
also cause unnecessary stopping and starting of
burner. The addition of a surge column, next to the
cut-off control (as shown in Figure 20), effectively
overcomes this condition.

Surge
Column

Figure 20

Gaskets
Keep fresh gasket sets on hand but no longer than
1 year -- gaskets will become brittle in heated, dry
boiler rooms. See Appendix C for commonly used
gaskets.

Servicing Combination Water Feeder /

Cut-Offs
On a mechanical feeder valve/cut-off unit, the refer-
ence line (see Figure 21) is the valve shut-off level.
So the valve will start to feed at or just below the
reference line. The feeder must be sized with ad-
equate capacity to efficiently meet the peak steam-
ing load of the boiler.

25
The burner cut-off level of these units is 3/4” to 1”
below the reference line. To reach the cut-off level
in testing this type of control, the feedwater supply
should be throttled back while the boiler is slowly
drained. If the cut-off level is too easily reached,
there may be a blockage in the make-up water pip-
ing or the feeder itself.
Once the cut-off level has been reached, stop drain-
ing the boiler and allow the feeder to restore the
water level. At 1/2” to 1/4” below the reference
line, the burner switch should fire the burner on
automatic switch models. Then the feeder valve
will slowly close off until the water level is at or just
above the reference line. On models with manual
reset features, the burner cut-off switch should be
reset when the water level in the sight glass reach-
es the reference line.

IMPORTANT: When boiler water level fluctuates

constantly causing the feeder to operate, this
is a danger signal that the system needs atten-
tion due to excessive feeding – even though the
feeder has kept the boiler out of trouble. This
could indicate the boiler has a leak or the sys-
tem is losing condensate.

REFERENCE LINE

Figure 21

26
Make-up Feeders –
Electric and Mechanical
Electric Water Feeders
Electric water feeders rely on a signal from the boil-
er’s low water cut-off control to function. Water
feeders only function when the LWCO control turns
them on and off. The feeder should have adequate
water feeding capacity for the application. McDon-
nell & Miller makes two types: the WFE-2 Series and
the 101A Series.

Strainer Cap
WF
UNI-MATCH®
Figure 22

The Uni-Match® Series WFE water feeder is used

primarily with the probe type cut-offs and has a
selectable time delay. The factory setting of the
Series WF is a feed rate of 2 gal/min. Every unit is
packaged with 2 other orifice discs -- 1 GPM and
4 GPM. This allows the feeder to be used in a wide
range of systems. The water feed time delay allows
the system condensate to return to the boiler be-
fore adding any fresh water to the system. The ad-
justable time delay feature allows for a wide range
of compatibility with various styles of cut-offs. The
WF water feeder also has a manual feed option
that allows the operator to manually add water to
the boiler by depressing the manual feed button.
The WF has a strainer that should be cleaned or
changed annually. The broken union test (page
31) can be used for troubleshooting if leakage is
suspected.

27
 5/8” Manual Feed
max.

101A &
Cartridge

Linkage adjustment
access window

Figure 23

The series 101A is another electrical water feeder.

This model has a replaceable valve cartridge, which
should be removed, inspected, cleaned or replaced
annually. NOTE: When removing and installing
the cartridge from the valve body, depress and
hold the manual feed button to remove added
pressure on the cartridge seal.
Repeated or excessive on-off cycling of an electron-
ic feeder will shorten its life dramatically. Examine
the height of the red manual fill button above the
cover (Figure 23). If it exceeds 5/8”, the linkage is
wearing out or starting to lose adjustment. Just
above the valve body are the access holes to the
linkage adjustment. An adjustment can be made
to reposition the linkage so that the height of the
manual fill button is about 1/2”.

Mechanical Feeders
Mechanical feeders from M&M include the car-
tridge valve design (Models 47, 247, 847, 51, 551 &
851) as well as the removable seat and stem design
(Models 21, 221 & 25A). A basic and patented
feature of the M&M Boiler Make-up Water Feeders
is the “cool feed valve”. It is designed to operate
“cool” to prevent water at the valve from reaching
the critical temperature at which lime and scale can
form. Connecting it to a hot water line defeats this
purpose. Scale can be precipitated from hot water,

28
causing the feed valve to stick. Cold water from city
or regular, unsoftened source is best.
Models 47, 247, 51, 53 & 51S feeders have a bel-
lows seal between the float chamber and the valve
housing. Frequent cycling or rapid level fluctuations
in these models can cause premature failure and
an external leak. Regardless of the type of make-up
feeder, an annual inspection and cleaning is re-
quired. The strainers at the inlet line should always
be cleaned or replaced annually.

Adequate Water Feeding Capacity

Too often feeders have been selected based on the
size of the water supply pipe. Remember that it is
the opening size of the orifice in the feeder that
determines the feeder capacity. Feeding capacity
tables of McDonnell & Miller Boiler Water Feeders
are found in the General Catalog MM-825. These
capacities were determined under rated water sup-
ply pressure and boiler pressure conditions.

If Boiler Is Getting Too Little Water

Reasons for too little water include:
• A plugged strainer may prevent water flow
• Priming and foaming due to dirty boiler water
• Condensate hung up in system
• Faulty operation of boiler feed pumps
• City water pressures less than boiler pressure
• Faulty swing-check in return header (allowing
water to be pushed out into return)

On float-controlled feeders, the float chamber may

be filled with sediment due to poor blow down.
To verify this, open blow down valve under float
chamber. With blow down valve open, if little or
no water flows, you can assume the float chamber

29
is loaded with mud or sediment. The float cannot
move far enough to open the valve fully. Remove,
inspect, clean and replace, if required.

NOTE: Using a feeder/cut-off combination in

process boilers, larger boilers, or boilers with
low differential pressures, may result in a low
water level. These types of applications can be
better handled by an independent feeder and
cut-off.

For boilers which have larger make-up needs, the

closely set operating levels of a feeder/cut-off
combination may stop the burner before the feeder
has caught up with the make-up requirements.
By using a separate feeder and a separate cut-off,
operating levels can be set so that the feeders will
feed at its maximum rate before the cut-off stops
the burner.

If Boiler Is Getting Too Much Water

Common causes of flooding include:
• Feeder pump not balanced to boiler requirements
• Faulty swing-check in return header
• Plugged equalizing pipe connection
• Leaking tankless hot water coil in boiler
• Attendant over-filling boiler through the hand
by-pass valve
• Dirty water resulting in priming and carry-over
• Too small difference between level of dry return
and boiler water level
• City water pressure above 150 lbs. (May need
pressure reducing valve in feed line)

Faulty installation can cause flooding. Remember

that the closing level of make-up feeders on heat-
ing boilers should be set 2” to 2½ “ below the
manufacturer’s recommended boiler water line.
This allows the system return to properly balance
varying steaming rates without adding make-up.

In all of these cases, perform a broken union test

below to pinpoint or eliminate the feeder as the
source of the problem.

30
The Broken Union Test
The Broken Union Test is a diagnostic procedure.
All feeders properly piped as shown below can be
examined for leak-through or blockage by perform-
ing the following steps. Annual examination is
recommended.

Check Valve

Feed WATER
Valve Bypass SUPPLY
Valve
X
Y

Z
TO BOILER

Figure 24

• Make sure the water level in the boiler is above

the closing level of the feeder
• Close valve “X” in the feed pipe running from the
feeder to the boiler
• Uncouple (break) the union “Z”
o Lower the water level in the boiler to observe
water flow through the feeder.
o Raise the water level in the boiler back to the
shutoff level to verify that no water flows out.
If water does come out the union, the water
feeder is leaking and needs to be repaired or
replaced
o Open valve “X” to verify that there is a steady
stream of water coming back from the boiler.
If there is not, check the feed line for lime or
scale, which can hold the feeder open due to
back pressure
• Check for leakage past the by-pass valve “Y” by
opening the union below the by-pass valve.
o If water is leaking past the by-pass valve, repair
or replace it

31
Hot Water Boiler
Mechanical Controls
Flow Switches as Cut-Offs
Some hot water systems use Finned or Copper
Tube boilers. On these systems there is no large
“vessel or tank”, only a manifold that passes the
water continuously through the boiler heating area.
Circulation is critical to prevent damage in these
systems. The manufacturers of these types of boil-
ers use flow switches as part of the control system
to protect the copper tubes from damage due to
reduced flow.
M&M Flow Switches can be found on many of
these systems. It is very important that the flow
switch is sized correctly for the flow rate in the
system and properly installed. If the flow switch is
not pre-installed by the manufacturer, follow M&M
recommendations to choose the best model, to
locate the switch and to size the paddle for the run
of pipe. The control is meant to be a safety device
and proper wiring of the flow switch in series in
the limiting circuit is crucial. If the water flow in the
system falls below the manufacturer’s minimum
specification, burner operation must be stopped
to avoid a dangerous condition and possible boiler
damage.
To service a flow switch you can test the operation
by throttling the circulation down below the No-
Flow Limit and observing the burner cut-off. Also
examine the paddles for deterioration annually and
replace, if necessary.

Copper Fin
Tube Boiler
Figure 25

32
Mechanical Cut-Offs and Accessories
Many municipalities require Low Water Cut-off
controls on commercial and residential hot water
boilers. Probe type models dominate this market.
However, larger and older systems may have float
type models. Since there is no water level to follow
in the float chamber or in the hot water boiler, the
float is in a fully buoyant position until testing or
annual draining. Codes dictate a functional test
of the cut-off to verify it turns off the burner in
the event of a low water situation. Switch opera-
tion must be tested. To do this, the operators must
drain the water in the control’s float chamber.
On some installations the cut-off is mounted in an
equalizing parallel pipe arrangement on or next to
the supply riser. Consider using the M&M Test-N-
Check® valves in place of the cross fittings above
and below the unit. This allows the low water cut-
off to be tested without draining the entire system.

TC-4
VERTICAL RISER TO RADIATION
OR COMPRESSION TANK

HOT WATER
BOILER MODEL
63

TC-4

Figure 26

TC-4 Installation Tips

• EXACTLY follow the installation instructions for
the proper connections of the TC-4 valves. Piping
the equalizing lines to boiler return piping could
result in nuisance shut downs due to backward
water flow.
• The blow down piping MUST be full 1” NPT size
and as short as possible. Smaller pipe size and
longer pipe runs result in slow draining of water
which does not allow the ‘flappers’ inside the
TC-4 valves to close properly.

33
• Blow down valve should be ‘quick-opening’ type
such as a lever-type ball valve. Using a slow-open-
ing valve, such as a globe or gate valve, allows
the boiler water to drain slowly while the valve is
being opened and does not provide the required
quick action for the ‘flappers’ in the TC-4 valves
to open.
• When connecting the upper equalizing piping to
the top of the boiler, install an air vent to the pip-
ing to remove any accumulated air.
• The LWCO should ALWAYS be installed below the
top of the boiler, but NEVER below the mini-
mum safe water line recommended by the boiler
manufacturer.

34
Replacement
Mechanisms
Replacement mechanisms are available for many
McDonnell & Miller controls. The McDonnell &
Miller Replacement Parts Catalog MM-701 can
be viewed on line at www.mcdonnellmiller.com
or is available from your local distributor or McDon-
nell & Miller Representative. It includes exploded
views of all controls with lists of available parts and
replacement head assembly diagrams.

In most cases these replacement heads represent the

best way to repair controls in the field, since they:
• Save labor and expense required for individual
component replacement
• Eliminate risk of disturbing critical factory adjust-
ment
• Incorporate all of the latest refinements in design
and materials
McDonnell & Miller replacement heads also serve
as spare mechanisms to be kept on hand ready for
immediate use to avoid expensive plant shutdown.
They include all operating parts – everything but
the float or probe chamber. They are shipped with
all necessary components, gaskets and installation
instructions.
A recommended replacement schedule of controls
is found in Appendix A.
Mercury switches from older controls that are
replaced should be removed and recycled in accor-
dance with Local State and Federal Regulations so
mercury does not find its way into the environment.

35
 Appendix A

Recommended Replacement
Intervals - Low Water Cut-offs
Recommended
Recommended
Series Replacement
Maintenance
Interval (max.)
*150, 150S
*157, 157S
*158, 158S Blow down
15 years
*159, 159S and test daily;
93, 193, inspect annually
94, 194
*42, 42S 10 years
67, 767, Blow down
61, 63, and test weekly; 10 years
64, 764 inspect annually
69, 169, Test and
269, 369, inspect annually 10 years
469, 569
750,
PS-800, Test
PSE-800, and
PS-850, inspect 15 years
750B, annually
RB120,
RB122E
Test and
RB24E 10 years
inspect annually
1575, Test daily and
15 years
150E inspect annually
*Mercury Units are no longer available.

Replacement Head Mechanisms for

Commercial/Industrial Applications
Recommended
Recommended
Series Replacement
Maintenance
Interval (max.)
*150-HD, 150S-HD,
Test and
93-HD, 94-HD,
42-HD, 42S-HD, inspect annually 15 years
63-HD, 64-HD,
6667, 150E-HD

36
Recommended Replacement
Intervals - Water Feeders
Recommended
Recommended
Series Replacement
Maintenance
Interval (max.)
WFE Inspect and test
Uni- annually; Replace 10 years
Match strainer annually
Inspect, test and
101-A replace cartridge 10 years
annually
47, 47-2, Blow down weekly;
247, Inspect, test and
247-2, 51, replace cartridge 10 years
51-2, 551S, annually
847, 851
51S,
51S-2, 53, Test
53-2, 21, and 15 years
221, 25A, inspect
851S, annually
3155
Test and
27-W 5 years
inspect annually

Flow Switches, Liquid Level

Controls and Probes
Recommended
Recommended
Series Replacement
Maintenance
Interval (max.)
FS4-3,
FS8-W,
Test and
FS7-4, 5 years
inspect annually
FS251,
FS254
LPC-2000,
PCH, PCL, Test and
15 years
65, 165, inspect annually
PFC
RS & AS
Sensors Inspect
5 years
PA800, annually
PA750

37
Appendix B

Probe Assemblies

Replacement
Model Where Used
Probe

PS801, PS802, Residential PA-800

PS851, PS852 Steam and 354081
Hot Water

750P-MT-120 Commercial PA-800

Hot Water 354081

RB-120, Residential PA-RB-122

RB-122, Hot Water 354083
PS851-SP,
PS852-SP

PS851- RX2, Commercial PA-800-RX2

PS802-RX2 and Residential 354140
Hot Water
and Steam

PS801-U, Residential PA-800 -U

PS802-U, Steam and 354141
PS851-U Hot Water

RS, Commercial EA-RS

750B-C, High Pressure 354401
1575 Steam PA-750-HP
176319

150E Commercial 150E

High Pressure 310492
Steam (Flange/Probe
Assembly)

For the most accurate replacement probe information, visit

McDonnell & Miller website, www.mcdonnellmiller.com.

38
Appendix C

Common Gaskets

Gasket
Model Where Used
Part Number

47, 67 Blow Down 313200

Valve

47 Body, Upper 312700

and Lower

51, 51S, Body-Head 304100

53, 25A

61, 63, Body-Head 302600

64

61, 67, Float Flange- 318800

69 (old) Body

150, 157, Body-Head 325400

150S, 157S, (flat face
93, 193 head flange)

150, 157, Body-Head 325500

150S, 157S, (raised face
150E, 157E head flange)

94, 194 Body-Head 323300

21, 47, Flange 335400

851, 851S

For the most accurate replacement probe information, visit

McDonnell & Miller website, www.mcdonnellmiller.com.

39
 ITT
8200 N. Austin Avenue
Morton Grove, IL 60053
Phone: 847-966-3700
FAX: 847-983-5954
www.mcdonnellmiller.com

Your Local Distributor /

Representative

IT T 3/09