Table Of Contents

Cleaver-Brooks
CBLM
Level Master
Installation and Operation Manual

750-193 4-04
 ! WARNING
DANGER

Do not operate, service, or repair this equipment unless you fully understand all
applicable sections of this manual.
Do not allow others to operate, service, or repair this equipment unless they fully
understand all applicable sections of this manual.
Failure to follow all applicable warnings and instructions may result in severe per-
sonal injury or death.

To: Owners, Operators and/or Maintenance Personnel

This manual presents information that will help to properly operate and care for the equipment. Study its contents carefully.
The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No
attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly under-
stood.
Failure to follow all applicable instructions and warnings may result in severe personal injury or death.
It is the responsibility of the owner to train and advise not only his or her personnel, but also the contractors' personnel who
are servicing, repairing, or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and
mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper oper-
ating techniques and maintenance procedures must be followed at all times. Although these components afford a high degree
of protection and safety, operation of equipment is not to be considered free from all dangers and hazards inherent in the oper-
ation of a boiler system.
"Automatic" features included in the design do not relieve the operator of any responsibility. Such features merely free him of
certain repetitive chores and give him more time to devote to the proper upkeep of equipment.
It is solely the operator's responsibility to properly operate and maintain the equipment. No amount of written instructions can
replace intelligent thinking and reasoning, and this manual is not intended to relieve operating personnel of the responsibility
for proper operation.
Operating controls will normally function for long periods of time. Do not become lax in daily or monthly testing, assuming
that normal operation will continue indefinitely. Malfunctions of controls lead to uneconomical operation and damage and, in
most cases; these conditions can be traced directly to carelessness and deficiencies in testing and maintenance.
Operation of the equipment by the owner and his operating personnel must comply with all requirements or regulations of his
insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between such
requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

2
 Table Of Contents
Section 1
Primary Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Level Sensor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Water Column Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2
Installation and Initial Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Part1: Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Part 2: Wiring of the Controller and Level Sensor . . . . . . . . . . . . . . . . . . . . . . . 2-4

Section 3
Sensitivity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section 4
Commissioning and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Set Time/Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Alarm/Warning Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Section 5
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Format Serial Port Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Status Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Section 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section 7
Display Message Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

3
 Notes

4
Features and Specifications Section 1

Section 1
Features and Specifications
The Cleaver-Brooks Level Master is a microprocessor based, primary safety
water level control for watertube and firetube steam boilers.

Primary Safety Features: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Controller Features: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Level Sensor Features:- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Water Column Features: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Specifications: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Level Sensor: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Note: This control is not intended for

use on Hot Water boilers.

The system consists of four parts: a controller, an in-situ continuous reading water level sensor, a water
column and 25 feet of sensor cable and three connectors. The Level Master is UL recognized (file #
MH27829).
The controller has operator selectable level and sensitivity settings as well as routines for blowdown and
auxiliary low water cutoff testing.
The sensor top mounts in a water column and can be easily removed for periodic inspection or cleaning.
The water column is rated for 250 psig steam and has connections for gauge glass, level sensor, and tri-
cocks.
The data link between the controller and sensor is RS-485 that is highly resistant to electrical noise and
interference.

750-193 1-1
Section 1 Features and Specifications

Primary Safety Features:

• Low Water Cut-Off (LWCO).
• Independent watchdog system for shutdown in
the event of microprocessor failure.
• Internal redundant LWCO relays with current
monitoring.
• Contacts for external alarms for LWCO viola-
tion conditions.
• Eight user selectable pre-configured water
level settings.
• Float non-movement detection and alarm.
• High water alarm function.
• Water column blowdown routine.
• Real time clock for time stamped event log-
ging for all blowdown cycles and alarm occur-
rences.
Figure 1-1: Low Water Cut Off Controller • Auxiliary low water cut-off check routine.
• Display is user configurable for on-off or mod-
ulating (4-20ma) water level control.
• Non-volatile memory for all logged events.

Controller Features: (Figure 1-1)

• Bargraph style continuous display of water
level.
• Two row by 16 character, backlit LCD for all
controller messages.
• Dual color Power/Error indicator on the front
panel.
• Reset/Menu Button for easy diagnostic
retrieval.
• Expanded programming parameters via RS-
232 computer connection.
• Operator configuration via external "MODE"
switch.
• Nema 1 enclosure, panel mounted.
• Removable terminal strips for easy field wir-
ing.
Figure 1-2: Low Water Cut Off Sensor Circuit
Board Level Sensor Features: (Figure 1-2)
• High speed, noise immune RS-485 link to con-
troller.
• Nema 4x enclosure with sealed conduit con-
nection.
• Titanium float for long life, independent of
feedwater quality.
• Red brass tube and chamber connection.
• Easy installation using five conductor shielded
cable.
1-2 750-193
Features and Specifications Section 1

Water Column Features:

• Made from cast steel.
• ASME Rating to 250 PSI Steam.
• Connections for sight glass, level sensor, and
tri-cocks.
• Casting mark for low water cut-off point.

Specifications:

Controller
120 VAC, 50/60 Hz. input power
Power consumption 20 VA
Operating temperature maximum of 122°F
Panel mounting dimensions of 5.39 ± 0.015 inches
(1/2 DIN)
Minimum panel depth of 6.0 inches
One piece front panel with integral membrane push
button
10 Amp relay contacts for controls
UL recognized

Level Sensor
RS-485 link to controller
Nema 4x enclosure
Operating temperature maximum of 130°F for
electronics, 400°F for sensor
Sensor stroke length of 16 inches
Resolution greater than 0.050 inches
Accuracy of 0.025 inches
Repeatability of 0.010 inches
Update rate of 10.0 milliseconds
Red brass tube and chamber connection
Titanium float

Figure 1-3: Level Master Water Column

750-193 1-3
Section 1 Features and Specifications

Notes

1-4 750-193
 Section 2
Installation and Initial Testing

Installation of the Level Master water level control

system is straightforward provided the installer
takes care to insure all wiring and piping ! CAUTION
DANGER
connections are performed correctly. The system
installation is described in two parts; first, the Only qualified personnel may install or service
mechanical installation of the controller, water the controller, water column or sensor.
column, level sensor, and second, the wiring of the
controller and level sensor.
Part1: Mechanical Installation ! CAUTION
DANGER
Ensure the boiler is off-line, at zero pressure,
! WARNING
DANGER and at ambient temperature before installing
the water column or level sensor.
Disconnect all power prior to installing the
controller in a control enclosure. Failure to
follow this warning could result in serious Note: Perform a leak test on all piping
personal injury or death. connections before firing the boiler.

Figure 2-1: Enclosure Cut Out Dimensions

750-193 2-1
 Installation and Initial Testing

Note: The controller is designed to be flush

mounted in a panel or enclosure that has a Mount the water column in equalizing piping so
minimum depth of 6.0 inches to allow for that the low water cut-off mark on the water
rear wiring connections. Figure 2-1 shows
the enclosure cut-out dimensions.
column corresponds to the desired level. Piping
must include a proper blowdown valve and sight
glass connections. Ensure all connections are tight
Install the controller in the cutout using the and horizontal and vertical runs are plumb.
supplied clamps. Do not over-tighten, only Install the sensor in the pressure chamber orienting
moderate pressure is required to fix the controller the enclosure front in a convenient direction for
to the enclosure door. ease of wiring. Remove the plug on the bottom of
Humidity - Install the Level Master controller the chamber to ensure that the bottom of the sensor
where the relative humidity never reaches the is properly positioned in the chamber. Sensor
saturation point. Condensation of moisture may wiring to the controller must be run in conduit.
cause controller shutdown. Maximum cable distance from the sensor to the
Vibration - Do not install the Level Master controller - 100ft.
controller where it could be subject to excessive Note: controller shall be mounted at the
vibration location where the water column can be
seen.
Weather - The Level Master controller is not
designed to be weather tight. If it is installed
outdoors it must be protected.

CASTING MARK

LWCO Point

TOP ROW OF TUBES

Figure 2-2: Piping Layout

2-2 750-193
Installation and Initial Testing

1/4" 4

2
3

1/2"
1/4"

CONTROL POWER ON
MENU

PANEL
ERROR
RESET

1. Sensor 3
5
2. Water column
3. 1 inch Blowdown valve
4. Vent valve
5. Level master panel
6. Gauge glass

Figure 2-3: Typical Level Master Installation

750-193 2-3
 Installation and Initial Testing

Part 2: Wiring of the Controller and

Level Sensor

! WARNING
DANGER
Disconnect and lock out all power prior to
wiring the controller or level sensor. Failure
to follow this warning could result in severe
personal injury or death.
Note: The low water cut-off contact must be
wired in series with all other boiler limits to
effect a boiler shutdown on low water
condition.
The wiring connections for the sensor are shown
below in Figure 2-4.
Four #18 AWG conductor shielded cable is
required C/B Part # 826-104 (General Cable
#C02543 or equal) from the level sensor to the
controller.

! CAUTION
DANGER
It is recommended to use a grounding wrist
strap when wiring the system.
STATUS LED
J1
CONTROLLER P/S +24 VOLTS
CONTROLLER P/S GROUND
CONTROLLER DATA A (-)
CONTROLLER DATA B (+)
N/C
CONTROLLER SHIELD

Figure 2-4: Wiring connections for the sensor

Note: The cable MUST be run in separate Figure 2-6 is an interconnection diagram showing
conduit, away from the ignition wires.
sample wiring without the 4-20ma level output
Wiring connections for the controller are shown in option.
Figure 2-5.
Depending on configuration settings and job site
requirements not all terminals are used.

2-4 750-193
Installation and Initial Testing

1 GROUND
2 SERIAL RX RS232
3 SERIAL TX
21 PUMP 4 -
22 5 + 4-20 ma LEVEL OUTPUT
23 HW ALARM 6 JUMPER 5-6 IF NOT USED
24 7 -
25 ALARM 8 + 4-20 ma CONTROL OUTPUT
26 9 JUMPER 8-9 IF NOT USED
27 NEUTRAL 10
28 LWCO IN 11
29 LWCO ALARM 12
30 LWCO OUT 13 MODE SWITCH
31 BURNER STATUS 14
(L2) 32 120V AC NEUTRAL 15 BLOWDOWN SWITCH
(L1) 33 120V AC LINE 16 P/S GND
(G) 34 GND 17 P/S +24V
LEVEL
18 DATA B(+)
19 SHIELD SENSOR
JUMPER 20 DATA A(-)

Figure 2-5: Wiring connections for the controller

TerminalFunction
1,2,3 RS 232 Interface, for communication to the controller from a computer.
4,5,6 Water level re-transmit signal (4-20 ma). (default 4ma @ LWCO 20MA @ HWA)
7,8,9 Modulating control output for feed water valve (4-20 ma).
10,11 For low fire input for float check
12,13 Mode switch, used to access user configuration parameters.
14,15 Blow down switch, allows blowdown without boiler shutdown.
16,17,18,19,20 Connections to level probe.
21,22 On-off control for feed water valve or pump contactor/starter.
23,24 Normally open high water alarm contact.
25,26 Normally open general alarm contact.
27 Jumper to 120VAC neutral
28 Supply LWCO
29 LWCO Alarm
30 Return LWCO, wired in burner safety shutdown circuit.
31 Burner status, wired to flame safeguard blower terminal.
32,33,34 AC line in connections. (See note below)

Note: 120 volt power supply to terminals 32 (L2) and 33 (L1)

shall be from the boiler/burner control panel.

750-193 2-5
 Installation and Initial Testing

Note: Do not use this product to switch currents over 10 amp

at 115 VAC resistive load.
Note: Do not power feed pump motor directly from the
controller. Always use pilot relay or starter.

Figure 2-6: Sample Wiring Diagram

2-6 750-193
 Installation and Initial Testing

Initial Testing
Display Description
Prior to re-applying power please check all wiring. Check that the on-off switch for
the boiler/burner is off. Turn power on to boiler/burner.
On initial power-up the Level Master will run its self-start routine. During this pro-
cess the controller will cycle the level indication LED’s to verify their operation. The
green power on LED will be on, and the on board alarm will beep. The LCD will
display the following:
Note:The low water cut-off contact remains de-energized during this period

Cleaver-Brooks
Copyright @YYYY
Waiting On Sensor
Providing that the water level is within the normal water level limits the display will
indicate how far above low water cut-off the sensor is at. Depending on the actual
level a corresponding number of green level indicating LED’s on the face of the
controller will be lit.

[Link]” >LWCO
Boiler Off
If the water level is below low water warning point the controller will enter the low
water alarm countdown period and after expired will enter a low level warning
alarm condition. The lower orange level indicating LED will be lit and the general
alarm relay will be energized.
The LCD will display the following.

Low Lvl Wrn Timer

X Sec
[Link]” >LWCO Low
Lvl Wrn
If the water level is below low water cut-off point the controller will enter the low
water cut-off countdown period and after it expires will enter a shutdown condition.
The lower red level indicating LED will be lit. The red LED above the Reset/Menu
button will be on. This LED will flash red/green for the newest version of software.
The LCD will display the following.

LW Shutdown Timer
X Sec
LW Shutdown Date
Time
The low water cut-off relay and the alarm output relay will be in the alarm state until
the water level is restored to normal operating levels.
Note: On manual reset models the controller low water cut-off limit contact will remain open until
the reset button is pressed.

750-193 2-7
 Installation and Initial Testing

Initial Testing
Display Description

If the water level is above high water warning point the controller will enter the
high water warning countdown period and after it expires it will enter an alarm con-
dition. The upper orange level indicating LED will be lit and the general alarm
relay will be energized. The LCD will display the following.

High Lvl Wrn Timer

X Sec
[Link]” >LWCO High
Lvl Wrn
If the water level is above high water alarm point the controller will enter the high
water warning countdown period and after expired will enter an alarm condition.
The upper red level indicating LED will be lit. The high water alarm relay and the
general alarm relay will be energized. The red LED above the Reset/Menu button
will be lit or flashing.
The LCD will display the following.

High Water Alarm

Timer X Sec

High Water Alarm

Date Time
Note: The alarm conditions will remain on the LCD until the Reset/Menu button is depressed. The
warning conditions will clear on the LCD when the water returns to normal level. All warning and
alarm conditions are logged into the controller history.
If the sensor is not wired properly or if it is defective the controller will display the
following.

Waiting On Sensor
Followed by -

Sensor Not Found

Date Time
The alarm relay will be energized and the low water cut-off relay will be de-ener-
gized and the red LED above the Reset/Menu button will be lit. The sensor has a
LED on the left side of the control board. The LED will be green for normal opera-
tion or red indicating an on board failure.

2-8 750-193
 Installation and Initial Testing

Initial Testing
Display Description

Configuration
The Level Master has configuration parameters that should be set at installation.
Below are the parameters.
Name Default
Sensitivity Table 1
Alarm/Warning Timer 5
Set Date/Time XX/XX/XX XX:XX
Display Format On/Off
Exit To Previous Menu
To enter the configuration mode on the Level Master, press and release the menu
switch. This places the controller in configuration mode. The display will scroll
through the available options.
Note: Configuration mode can only be entered when the water level is within normal operating range. (no
low or high alarm message is displayed).

Sensitivity Table 1
Alarm/Warning
Timer 5
Set Date/Time MM/
DD/YY HH:MM
Display Format On/
Off
Exit to previous
Menu
When the desired parameter appears, press the Reset/Menu button on the front of
the controller. The controller will then start to display the available options under
that menu item. The controller will cycle twice through menu options, if no items are
selected the controller automatically exits configuration mode.

750-193 2-9
 Installation and Initial Testing

Notes

2-10 750-193
 SECTION 3
Sensitivity Tables

The sensitivity table refers to the preset levels that changes to the parameter in that menu, don't press
the sensor and the controller are set to. The type, the Reset/Menu button. The controller will cycle
size, and design pressure of the boiler determine through the available parameters twice and then
what the sensitivity setting should be. Below are move to the next menu item.
the recommended settings.
The recommended sensitivity level selections for
When in commissioning mode and the sensitivity various type and sizes of Cleaver-Brooks boilers
table is selected the controller starts scrolling 1 are shown in Table 3.1
through 9. When the desired value appears, press
the Reset/Menu button. When the desired
parameter is selected the controller will go to the
next menu item. If you do not wish to make any

Table: 3-1 Firetube Boilers

Recommended Sensitivity Selection
CB,CBLE
Diameter 15# Steam 150# Steam 151-250# Steam
36 2 1 2
48 2 1 2
60 2 1 2
78 2 2 2
96 2 2 2

CBE
Diameter 15# Steam 150# Steam 151-250# Steam
48 1 1 2
60 1 1 2
78 2 1 2

CBW,CEW
Diameter 15# Steam 150# Steam 151-250# Steam
60 1 1 2
78 2 1 2
750-193 96 2 1 2 3-1
Section 3 Sensitivity Tables

Table: 3-1 Watertube Boilers

Recommended Sensitivity Selection
FLX M4/M5 M5LWV
15# Steam 150# Steam 15# Steam 150# Steam 15# Steam 150# Steam
3 6 3 4 3 2

Table: 3-2 Sensitivity

Sensitivity 1 2 3 4 5 6 7 8 9
High Water Alarm 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
High Water Warning 4.5 4.65 4.81 4.62 4.87 4.81 5.0 4.87 4.5
Pump Off 1.5 2.12 2.75 2.0 3.0 2.75 3.5 3.0 1.5
Pump On 0.75 1.12 2.0 0.75 0.75 1.5 2.0 1.75 0.75
Low Water Warning 0.3 0.45 0.8 0.3 0.3 0.6 0.8 0.7 0.3
Low Water Cut-Off 0 0 0 0 0 0 0 0 0

All values given in the table above are in inches

and are with respect to the casting mark on the
Level Master chamber.

3-2 750-193
 Chapter 4
Commissioning and Operation

Mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Set Date/Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Alarm/Warning Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Display Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Check Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Display History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
View Blowdown History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 9
View Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 9
Warning and Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
View ALWCO History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
ALWCO Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Milwaukee, Wisconsin

[Link]
Chapter 4 — Commissioning and Operation

Programming
Programming of the Level Master is defined by two distinct areas,
Commissioning and Operation.
Commissioning
Commissioning is designed to enable the installer or owner/opera-
tor to setup the system in accordance to the plant requirements and
local codes. The Mode switch is used to toggle through the various
commissioning modes required by the controller. The commis-
sioning modes are Sensitivity, Alarm/Warning, Set Date/Time
and Display format.
To make a mode selection press the Mode switch once, see Figure
4-1. This will initiate the Mode change menu. The display will
return to normal after cycling through the menu choices two times.
When commissioning the boiler and controller first set the Alarm/
Warning Timer and the Date/Time in the controller.
1. Alarm/Warning Timer
This is a timer that delays the actuation of the alarms or warnings
from the controller, see Figure 4-2. This timer also delays activa-
tion of the Low Water Cutoff relay. The timer helps prevent nui-
sance alarms caused by bouncing water level in the boiler. The
minimum time is zero seconds and the maximum time is 20 sec-
onds. The factory default = 5 seconds. Press the reset/menu button
when the alarm/warning item appears. The controller starts to
scroll through the available values. When the desired value is dis-
played press the Reset/Menu and the controller will go to the next
menu item. If you do not wish to make any changes to the parame-
Figure 4-1. Mode Button ter in that menu, don't press the Reset/Menu button. The controller
will cycle through the available parameters twice and then move
to the next menu item.

Figure 4-2.
2. Set Date/Time
This menu item allows setting of the date and time, see Figure 4-3.
The controller uses this time to time stamp blowdown cycles and
alarms. To change the date and time, press the Reset/Menu button
when Set Date/Time appears. The display cursor will move to the
Figure 4-3.
first character in the date field. To change the value press the
Reset/Menu button until the desired value appears. The controller
will move the cursor to the next value. If no change is required do
not press the Reset/Menu button and the controller will move to
the next field.

4-2 Part No. 750-193

Chapter 4 — Commissioning and Operation

Commissioning Flow Chart.

Pressing the Mode switch will

begin cycling the display
through the various Mode
selection options.
Press Reset/Menu switch to select item or value

Sensitivity Sensitivity * Sensitivity

Table 1 Table ( 1, 2 ...9) Table X

Alarm/Warning Alarm/Warning ** Alarm/Warning

Timer 5 Timer (0,1,2 ... 20) Timer X

Set Date/Time Set Date/Time *** Set Date/Time

mm/dd/yy hh:mm mm/dd/yy hh:mm mm/dd/yy hh:mm

Display Format Display Format **** Display Format

On/Off (On/Off Modulating) Modulating

Exit to previous
menu?

* Sensitivity table values will scroll from 1 to 9. Once the desired number appears, press
Reset/Menu to select.
** Alarm/Warning delay timer values will scroll from 0 to 20 (seconds). Once the desired number
appears, press Reset/Menu to select
*** Cursor will advance through one field at the time. Once the cursor is on the field to be
changed, press Reset/Menu to advance one digit at a time.
**** Display format will alternate between On/Off and Modulating. To select display format
press Reset/Menu once the desired selection appears.

Part No. 750-193 4-3

Chapter 4 — Commissioning and Operation

Operational Flow Chart.

The Reset/Menu button is used to select the operational display

and change operational settings. Pressing the Reset/Menu but-
ton once starts the controller scrolling through the operational
settings; Perform Blowdown, Display History, Perform ALWCO,
etc. When the required operational parameter appears on the dis-
play, push the Reset/Menu button to gain access to that particular
operational parameter.

Press Reset/Menu switch to select the display

Perform Perform Blowdown Blowdown Successful

Blowdown? Blowdown Now? Timer 85 Sec 08/14/03 10:05 08/14/03 10:05

Display View Blowdown H: Good Blowdown

21 Recent Events #1
History History? 08/14/03 10:05

View Alarm 20 Recent Events #1 H: LW Shutdown

History? 08/14/03 10:25

View ALWCO 5 Recent Events #1 H: ALWCO Good

History? 08/14/03 11:25

Exit to previous
menu?

Perform Perform ALWCO -0.52>LWCO ALWCO Check Good

ALWCO? Now? Timer 105 sec. 08/14/03 11:25

Control 85 F
Sensor 145 F

View Date/Time
08/14/03 14:05

Exit to previous
menu?

4-4 Part No. 750-193

Chapter 4 — Commissioning and Operation

3. Display Format
The controller can show either pump on/off or percent output of
the level control signal on the second line of the display while the
boiler is running. When the boiler is off the display will indicate
Boiler Off, see Figure 4-4.
Figure 4-4.
When the display is set to on/off the second line of the display will
indicate either pump on or pump off this is based on the water
level while the boiler is running, see Figure 4-5.

Figure 4-5.
When the display is set to modulating, the second line of the dis-
play will indicate the percent of control output to the modulating
feedwater control valve while the boiler is running, see Figure 4-6.
To change the display format, press the Reset/Menu button when
Display Format appears. The display will toggle On/Off or Modu- Figure 4-6.
lating. To change the value press the Reset/Menu button when the
desired value appears. If no change is required do not press the
Reset/Menu button.
Stuck Float Detection
The Level Master has built in stuck float detection. The controller
will watch for float movement when the boiler/burner is running
(terminal 31 energized). If the float does not move after the pre-
determined time limits the controller will indicate Slow Float,
Figure 4-7. Figure 4-7.
If the warning time has expired and the float has not moved the
controller will open the LWCO contact output and annunciate
Float Check Fail, see Figure 4-8.
The display will toggle with the message Requires Column Blow-
down after a float check fail, see Figure 4-9. Figure 4-8.
Refer to the Perform Blowdown section of this chapter for instruc-
tions on performing water column blowdown.

Note: Boiler cannot be restarted until a proper blowdown is

performed and Successful Blowdown is displayed. Figure 4-9.

Part No. 750-193 4-5

Chapter 4 — Commissioning and Operation

Operation
Check-Out
With the boiler off and the water level in the boiler within normal
limits the controller should display as Figure 4-10.
Start the boiler. The second line of the display should change to
either Pump On/Off or percent output. If the second line of the dis-
Figure 4-10. play does not change, check that the burner status terminal (31) is
wired correctly, see Figure 2-6.

Note: Shut the boiler off immediately and correct wiring. Verify
before proceeding.
To verify low water cut-off wiring, during the pre-purge cycle of
the boiler, open the blowdown valve on the water column. The
boiler should shutdown on low water and a low water message
with the time stamp should appear.
If shutdown does not occur, open the burner switch, verify wiring
and re-check. The operation/wiring of the feed water system can
also be checked with this process.

Note: Do not attempt to fire the boiler unless low water shutdown has
been proven to operate properly.
Normal Operation
Under normal operation the Level Master controller will indicate
on the display, actual water level above low water cut-off. The
green LED's on the controller indicate a relative water level in the
water column depending on the sensitivity table setting, see Figure
4-11.

Operational Menu
Pressing the Reset/Menu button during normal operation, cycles
the controller through the following menu items.
Perform Blowdown, Display History, Perform ALWCO, View
Figure 4-11. Normal Operation Date/Time, Exit to previous menu, see Operational Flow chart on
Display Page 4-4.
The last three items are display only. Pressing the Reset/Menu but-
ton while these are displayed takes the controller back to normal
display. Perform blowdown and perform ALWCO are described in
the maintenance section of this manual. The controller will cycle
through the above choices a couple of times and then return to
normal display if no selection is made.

4-6 Part No. 750-193

Chapter 4 — Commissioning and Operation

4. Display History
Pressing the Reset/Menu button while the display history selection
is displayed will offer the following three choices.
View Blowdown History? Figure 4-12.
View Alarm History? Figure 4-13.
View Alwco History? Figure 4-14. Figure 4-12.

Figure 4-13.

Figure 4-14.

5. View Blowdown History

View Blowdown History will display the twenty one (21) most
recent events, see Figure 4-15.

First the event number is displayed followed by the event. Each

event is date and time stamped with the most recent event dis- Figure 4-15.
played first. Figures 4-16 through 4-19 are examples of the blow-
down history display.

Part No. 750-193 4-7

Chapter 4 — Commissioning and Operation

Figure 4-16.

Figure 4-17.

Figure 4-18.

The controller will cycle through the events 6 times or until the
Reset/Menu button is pressed, which will then display the previ-
ous menu.

Figure 4-19.

6. View Alarm History

View Alarm History will display the twenty (20) most recent
events. First the event number is displayed followed by the event.
Each event is date and time stamped with the most recent event
displayed first. Figure 4-20 through 4-24 are examples of a the
Figure 4-20. Alarm history.

#1 is displayed followed by the event description and time/date

stamp

Figure 4-21.
#2 is displayed with the description and time/date stamp.

Figure 4-22.

Figure 4-23.

4-8 Part No. 750-193

Chapter 4 — Commissioning and Operation

The controller will cycle through the events 6 times or until the
Reset/Menu button is pressed, which will then display the previ-
ous menu.

Figure 4-24.
7. Warning and Alarm Messages Note: See the
Below is a listing of the alarm messages the controller can indi- Troubleshooting section
cate. for more detail on each of
Warnings: the Warnings and Alarms
• Low Lvl Wrn (Low Level Warning)
• High Lvl Wrn (High Level Warning)
• Warning Slow Float Movement

Alarms:
• LW Shutdown (Low Water Shutdown)
• High Water Alarm
• Float Check Fail
• LWCO Relay Fail
• LWCO Relay Short
• Sensor Not Found

8. View ALWCO History

View Alwco History will display the five most recent events. First
the event number is displayed followed by the event. Each event is
date and time stamped with the most recent event displayed first.
Figures 4-25 through 4-29 are examples Alwco histories.
The display indicates (event #1, #2...etc) followed by the descrip- Figure 4-25.
tion with date and time stamp.

Part No. 750-193 4-9

Chapter 4 — Commissioning and Operation

Figure 4-26.

Figure 4-27.

Figure 4-28.

The controller will cycle through the events 6 times or until the
Reset/Menu button is pressed, which will then display the previ-
ous menu.

Figure 4-29. Perform Blowdown

The Level Master will provide years of safe operation providing
that the control is periodically checked and operation is verified. It
is this reliability which may lead to laxity in this very important
preventive maintenance check.
It is recommended that the water column be blown down daily (or
more often, depending on the water quality). The Level Master
controller helps simplify this process by providing a reminder
routine that will notify the operator at least once every 24 hours that
the water column requires blowdown or if a successful blowdown
has not been performed during that period. The period for
notification can be changed anywhere from 4 to 24 hours via
software configuration (refer to appendix A for software
configuration parameters).
Note: The controller has connections for a by-pass switch to allow
blowdown while the boiler is running (refer to Figure 2-6).
Figure 4-30 is an example of the message to inform the operator to
perform a blowdown (Requires Column Blowdown).

Figure 4-30.

To clear the display, press the Reset/Menu button.

4-10 Part No. 750-193

Chapter 4 — Commissioning and Operation

To perform a blowdown, press the Reset/Menu button, the control-

ler will respond with the display in Figure 4-31.
Press Reset/Menu again and the controller will respond with the
display in Figure 4-32.
Figure 4-31.
Press Reset/Menu again and the controller will respond with the
display shown in Figure 4-33.

Figure 4-32.
The water column timer display toggles with Figure 4-34.

Figure 4-33.
The controller will begin a countdown period of 90 seconds. Dur-
ing this period of time, open the Blowdown Valve and wait until
the RED low water light (LED) on the right side of the controller
is illuminated. Then close the blowdown valve.
Connections for a blowdown by-pass switch are provided to allow Figure 4-34.
the boiler to continue running during a blowdown. The blowdown
switch should be located close to the blowdown valve so that the
operator can operate the valve and the switch simultaneously.
Upon completion of a successful blowdown the controller will
respond with the message in Figure 4-35 & 4-36.

Figure 4-35.

The message has the time and date of the blowdown and the event
is logged in the blowdown history.
If the blowdown was not successful the message displayed in Fig-
ure 4-37 & 4-38 will be displayed.

Figure 4-36.

Figure 4-37.

Part No. 750-193 4-11

Chapter 4 — Commissioning and Operation

This message in Figure 4-38 will appear for 5 minutes and the dis-
play will then toggle with the display in Figure 4-39.

Figure 4-38.

Note: Time between blowdowns cannot be less than 1 minute.

If the water level remains below the low water cutoff point for
more than 30 seconds the Level Master will open the low water
Figure 4-39. cutoff contacts and shutdown the boiler (even with the
Blowdown Bypass switch pressed).
The message has the time and date of the unsuccessful blowdown
and the event is logged in the blowdown history. The alarm relay
on the controller will be energized until a successful blowdown
has been completed.
If a another blowdown cycle is attempted before the 1 minute
period has expired the controller will respond with the display in
Figure 4-40.
After which the controller will cycle through the available menu
Figure 4-40. options.
In addition to performing a water column blowdown at least daily
it is recommended that a slow drain test be performed at least
semi-annually. To perform this test, either stop the flow of feed
water to the boiler or drain the boiler manually while running at
low fire. Observe the water level in the sight glass and check for
proper burner cut-off. If unsuccessful, repair or replace the control
at once.

9. ALWCO Check
The Level Master controller has provisions to test the Auxiliary
Low Water Cut-Off device on the boiler. This check allows the
water level in the boiler to drop below the setting of the low water
cut-off without shutting the boiler down. The controller does safe-
guard in case the ALWCO fails. If the water level drops below the
recommended ALWCO point and the boiler has not shut-off the
Level Master will shut down the boiler. The ALWCO check must
be run with the boiler/burner running.
To perform a ALWCO check, press the Reset/Menu button, the
controller will cycle through the menus, when the display in Fig-
ure 4-41 appears, press Reset/Menu again.

Figure 4-41.

4-12 Part No. 750-193

Chapter 4 — Commissioning and Operation

Press Reset/Menu again and the controller will respond with the
display in Figure 4-42.

Figure 4-42.
If the boiler is not running or the Level Master is not wired prop-
erly, when the ALWCO check is initiated, the controller will
respond with the message in Figure 4-44. Correct the wiring or
turn the boiler on and re-initiate ALWCO.
Figure 4-43.

Figure 4-44.

Once initiated the ALWCO check cycle will be complete when the
boiler/burner shuts down. The controller will indicate a successful
ALWCO check and immediately go into LW Shutdown. Once
water level is restored the Reset/Menu button must be pressed to
reset the controller.
If the ALWCO check is not performed within the allotted time or
the level drops below the point at which the ALWCO should have
shut the boiler down the controller will respond with the display in
Figure 4-45.
The Low Water Shutdown screen toggles with the display in Figure Figure 4-45.
4-46.
The controller must be reset at this point and the event is logged
into the ALWCO history file.
Note: Auxiliary low water cutoff check must be performed with
operator present at all times.

Figure 4-46.

Part No. 750-193 4-13

Chapter 4 — Commissioning and Operation

Notes

4-14 Part No. 750-193

 Section 5
Software Configuration

The Level Master controller has additional The following procedure describes communication
parameters that can be configured via computer. with Cleaver-Brooks level master controller using
The controller communicates through the use of an Hyper Terminal communication software.
RS232 serial connection. The computer needs
1. Start hyperterminal.
terminal emulation software such as Windows
Hyperterminal to communicate. Below is how to 2. Enter a name and select icon.
wire the RS232 connection.
3. Connect using Com 1.

Transmit Ground

Recieve

123

Figure 5-1: RS 232 connector

750-193 5-1
Section 5 Software Configuration

4. Set port settings to 19200, 8, N, 1, None. The following parameters require a password in
order to be changed. Only authorized personal
Press the Esc key twice. The computer screen will familiar with boiler burner operation should change
display a message similar to <Cleaver-Brooks parameters
Copyright @YYYY>

At this point communication with the controller is

established.
The serial port task provides a number of
commands that can set and/or read system
parameters that control basic operation and enable
or disable features.
The following commands can be used without a
password:

A date set/read system date

B time set/read system time
C ver read system name, copyright and software version
D temp read controller and sensor temperature
E stat read system statistics
F dispalarms display history alarm/warning/information data on PC connection
G Dispalarms, x display history alarm/warning/information for x number of previous events
All other commands require a valid password prior
to use the password is "Fielduser". The remaining
commands are listed on the following pages.

Resetting the controller removes any previous

password authorization, and will require a
password again.

Format of serial port commands:

1) Enter the command name followed by a 'enter'
to view the current value.
2) Enter the command name followed by a comma
and parameters to set a new value.

5-2 750-193
Software Configuration Section 5

Status Command
Command Format Description Default value
pass pass,password
On a new unit (version 0.40), if you type 420 you should see:
420 = 49,87,51, 66
alarm alarm View current value 5 seconds
alarm,x Alarm/warning countdown time, in
seconds
alwcobelow alwcobelow View current value 120 seconds
alwcobelow,x Maximum time water level can can be 0 to 255 seconds
remain below LWCO during
ALWCO test, in seconds
alwcototal alwcototal View current value 200 seconds
alwcototal,x Maximum time for ALWCO test, in can be 0 to 600 seconds
seconds
bdmin bdmin View current value 0 seconds
bdmin,x Minimum time water level must
remain below LWCO during test,
in seconds
bdnotify bdnotify View current value 24 hours
bdnotify,x Time after previous blowdown
before operator is notified a new
blowdown is required, in hours (4-
24 hours)
bdtotal bdtotal View current value 90 seconds
bdtotal,x Maximum time for blowdown test,
in seconds
bdwait bdwait View current value 1 minute
bdwait,x Minimum time required between
successive blowdowns, in min-
utes (Range)
date date,mm/dd/yy Set or view date
display display View current value 1 (modulating)
display,x Set on/off (0) or modulating (1)
control
lvlzero lvlzero Water level 4mA point, in inches 0 (not used)
lvlzero, 1234 sets the (i.e., water level above LWCO for
4ma point at 1.234" 4mA point)
lvlspan lvlspan Water level 20mA point, in inches 0 (not used)
lvlspan, 2345 sets the (i.e., water level above LWCO for
20mA point at 2.345" 20mA point)
setpass setpass,xxx,1 Set operator password, 10 char-
xxx = password acters maximum.

750-193 5-3
Section 5 Software Configuration

Command Format Description Default value

time time Set or view time
time,HH:MM
usetable usetable View current table used and This perform the same
usetable,x change to a new table. operation as changing the
Select water sensitivity table 1 to water table number in the
9 front panel menu.
valvelimit valvelimit View or change the valve velocity 0
valvelimit, 10 limiter from 0 to 30 seconds. 0 is
disabled.
valvepoint valvepoint Lists the 11 point valve point table 100, 90, 80, 70, 60, 50, 40,
valvepoint,x,# Sets any of the 11 points in the 30, 20, 10, 0
Where x = point # valve point table this is a linear table that
From 1 to 11 and corresponds to the 20mA
# = the number at valve open (pump on)
from 0 to 100 and 4mA at valve closed
valvepoint,1,100 sets (pump off)
the 1st point in the table
to 100.

The 'stat' command returns the Level Master controller status. Alarms, warnings, relay conditions,
water level and feedwater valve position are returned.
The controller responds with:

stat = HAHWLALWSABFAFLFLSHRLRGRFR xx.x yyy.y'[cr])

+-------Current water level in inches

+------------Current valve position% output
+----------------FR = feedwater pump relay on
+--------------------GR = general purpose relay on
+------------------------LR = LWCO relay energized
+----------------------------HR = high water alarm relay on
+--------------------------------LS = LWCO relay short error
+-----------------------------------LF = LWCO relay fail error
+---------------------------------------AF = ALWCO test fail
+-------------------------------------------BF = blowdown test fail
+-----------------------------------------------SA = sensor alarm (sensor not found)
+---------------------------------------------------LW = low water warning
+--------------------------------------------------------LA = low water alarm
+------------------------------------------------------------HW = high water warning
+----------------------------------------------------------------HA = high water alarm
5-4 750-193
 SECTION 6
Troubleshooting and Parts

Note: All McDonnnell & Miller models 193 The installation must conform to the local electrical
and 194 are longer than model 157 and codes. Code compliance is the responsibility of the
modifications to the piping will be customer or his contractor.
necessary in order to install the Level
Master Water Column. Models 193 are 17 1/ Disconnect power to the boiler prior to installation.
2" in length a models 194 are 17 1/4" in
length. Also the gauge glass for model 194
are 1/8" longer than corresponding ! WARNING
DANGER
replacement.
Make sure that all screw terminal
To mount the panel use bracket part number 8- connectors are tightened to the proper
3267. Use additional union per Figure 6-1. torque, and all electrical connectors are
made. Loose or stripped screw terminals
will increase the resistivity of the related
When installing the level master system or when circuit and will generate high temperature in
the controller; this could cause serious
problems occur during the initial installation, damage to the product, or lead to personal
please adhere to the following guidelines: injury or death.

4
4
1

1/2"
1/4" 1. Sensor 1/4"
2. Water column
3. 1 inch Blowdown valve
4. Vent valve CONTROL POWER ON
MENU

PANEL
ERROR
RESET

5. Level master panel

3 6. Gauge glass 3
5

Figure 6-1: Water Column Piping

750-193 6-1
Section 6 Troubleshooting and Parts

! WARNING
DANGER
If a system malfunction is detected, make sure to
check all electrical wiring and connections.
Confirm that all connections are wired pin-to-pin
in accordance with the Level Master manual.
Incorrect wiring can cause a short, which can
damage the product, produce a system
malfunction or result in severe personal injury or
death.

Figure 6-2: Do not use sharp tools on

circuit board
! CAUTION
DANGER
Do not insert a screwdriver or sharp object into the
circuit boards in the system. This can cause electrical
component failures and system malfunctions.

! CAUTION
DANGER
It is recommended to use a wrist strap that is connect-
ed to ground when wiring the system.

If the battery is removed from the controller while power

is disconnected, the time and date will have to be reset.
See Section 4, Commissioning and Operation in this
Figure 6-3: Battery location Level Master manual for instructions.
Do not use magnetized tools during installation.

! WARNING
DANGER
Do not remove the water column when boiler is
pressurized or hot. This can cause damage to the
product, produce a system malfunction or result
in severe injuries or death.

Note: When Level Master components are newly

installed check for proper system operation and
make sure the installation and wiring complies
with the Cleaver-Brooks Level Master and boiler
Installation and Operation manuals.

Figure 6-4: Level Master Float

and Shaft

6-2 750-193
Troubleshooting and Parts Section 6

Table 6-1: Troubleshooting

Problem Display Message Possible Cause Corrective Measures

Water level is not main- Low Lvl Wrn Improper sizing of feedwa- Check sizing and piping
tained. Frequent shut- LW Shutdown ter pump, control valve or configuration.
downs and warnings High Lvl Wrn piping.
High Water Alarm Select different table.
Sensitivity table selection
is wrong Make sure that power is
present at the terminals 21
No power to the pump and 22 when display
starter shows "Pump On"

No control output to the Using a multimeter, check

valve the current ma output on
the terminals 7 and 8. Out-
put shall vary from 4 to 20
ma (4 ma at the "Pump
On" point and 20 ma at
"Pump Off" point).
Unsuccessful auxiliary Alwco Check Bad ALWCO shuts down the Adjust position of ALWCO
low water cut off test burner before level master. to be located below level
master cut off point.

Level master shuts down Timing allocated for

the burner before ALWCO ALWCO test is too short.
does. Adjust time using serial
port connection and PC.

ALWCO position is too

low. Level master allows
for water level to drop
below low water cutoff
point by no more than 1.8".
Water column cannot Blowdown Unsuccessful Improper Piping Follow piping recommen-
blowdown properly. dations in this manual.
Water level does not drop
below low water cutoff Allow water level to drop
point below low water cutoff
point by fully opening col-
Blowdown procedure umn blowdown valve and
takes too long. allowing sufficient time.

Level master allows a total

of 90 seconds for blow-
down from the time it was
initiated via front display.
Water level cannot be
below low water cutoff for
more than 30 seconds.

750-193 6-3
Section 6 Troubleshooting and Parts

Problem Display Message Possible Cause Corrective Measures

Boiler shuts down on the Float Check Fail Impulse lines to the water With no steam pressure,
float check failure. column are plugged. remove piping and clean.
(Also Wrn Slow Float
Movement) Sensor well has sludge Remove probe assembly
build up and prevents float and clean sensor well.
movement.
Contact Cleaver-Brooks
Boiler operates at low fire Incorporate low fire relay
for a long period of time. circuit.
Controller display indi- LWCO Relay Fail Improper wiring Make sure that terminal 28
cates low water cutoff is wired before terminal 30
relay failure. in the burner limit circuit.

Make sure that voltage is

not present at terminal 30
when power is removed
from the terminal 28.
Display indicates that LWCO Relay Short Jumper between terminal With water level below low
low water cutoff relay is 28 and 30. water cut off, check the
shorted. voltage at terminals 28 and
30.
If voltage is present at both
terminals, shut off the
burner immediately and
look for short circuits.
Communications Sensor not found Improper wiring Make sure that the wiring
between the sensor and between the sensor and
the controller cannot be the controller is done in
established accordance with this man-
ual.

Make sure that no loose

wires are present. Check
all of the connections and
wire connections are tight
and secure

Table 2: Parts List

Description Part No. Comments
Controller 623-00035 Auto Reset
Controller 623-00102 Manual Reset
Sensor 623-00036 Replacement Only
Battery CR 2032 3.0V Panasonic
Sensor Flange 623-00118

6-4 750-193
 SECTION 7
Displayed Message Details

January 12, 2003

Ta b l e 7 - 1 - F ro n t P a n e l A l a r m , E r ro r, Level Master Controller, Version 0.59f and later
Informational, and Warning Messages

Displayed Message
Type Where Displayed Meaning
Details
Informational Front Panel Alwco test performed, was unsuccessful at
Alwco Check Bad indicated date and time.
Alwco Check Good Informational Front Panel Alwco test performed, was successful at
indicated date and time.
Blowdown Now ? Informational Front Panel Displayed after a float failure has occurred
when the operator confirms the previous
float fail message.
Blowdown Successful Informational Front Panel Blowdown test performed, was successful at
indicated date and time.
Blowdown Unsuccessful Informational Front Panel Blowdown test performed, was unsuccessful
at indicated date and time. This is part of
the blowdown message sequence shown at
the end of this table. Also see "Requires
Column Blowdown".
Boiler Off Informational Front Panel Displayed on 2nd line of Front Panel if boiler
burner input is NOT powered. 1st line of dis-
play contains
"xx.x " > LWCO" See related messages
"Pump On", "Pump Off" and "Output [Link] %".
Call CB Service Error Front Panel This is alternately displayed with the follow-
ing messages:
a) LWCO Relay Fail
b) Clock Failed
c) Clock Failed 2
Change Battery Informational Front Panel Displayed when the system battery needs to
be changed. This message will be displayed
once each day after 8am until the battery
has been changed. This is a low priority
message, other alarm and warning mes-
sages will be displayed first.
Cleaver Brooks Copy- Informational Front Panel Displayed at system power-up.
right @2003

750-193 7-1
Section 7

Displayed Message
Type Where Displayed Meaning
Details
Clock Failed 1 Warning Front Panel Displayed if the clock has failed in the unit.
The 2nd line displayed is:
Call CB Service.
Clock Failed 2 Warning Front Panel Displayed if the clock has failed in the unit.
The 2nd line displayed is:
Call CB Service.
Clock Not Set Warning Front Panel Clock not set detected at indicated date and
time, this is tested each hour.
Err: Informational Front Panel Displayed when in debug mode while view-
ing the sensor errors. This indicates that the
displayed sensor error has occurred but that
the system is still operational.
Float Check Fail Error Front Panel Float check test detected no float movement
for full test time, error message, at indicated
date and time (see Wrn Slow Float).
High Lvl Wrn Warning Front Panel High water level warning occurred at indi-
cated date and time.
High Water Alarm Alarm Front Panel High water level alarm occurred at indicated
date and time.
Low Lvl Warning Warning Front Panel Low water warning occurred at indicated
date and time.
LW Shutdown Error, Alarm Front Panel LW Shutdown occurred at indicated date
and time.
LWCO Relay Fail Error Front Panel LWCO relay fail occurred at indicated date
and time.
LWCO Relay Short Error Front Panel LWCO relay short occurred at indicated date
and time.
Output [Link] % Informational Front Panel Displayed on 2nd line of Front Panel if boiler
burner input is powered and modulating con-
trol is selected. 1st line of display contains
"xx.x " > LWCO" See related messages
"Boiler Off", "Pump On" and "Pump Off".
Pump Off Informational Front Panel Displayed on 2nd line of Front Panel if boiler
burner input is powered and pump is OFF
during pump on/off control. 1st line of dis-
play contains
"xx.x " > LWCO" See related messages
"Boiler Off", "Pump On" and "Output [Link] %".
Pump On Informational Front Panel Displayed on 2nd line of Front Panel if boiler
burner input is powered and pump is ON
during pump on/off control. 1st line of dis-
play contains
"xx.x " > LWCO" See related messages
"Boiler Off", "Pump Off" and "Output [Link] %".
Req Col Blowdown Informational Front Panel Displayed as part of the "Float Check Fail"
message.

7-2 750-193
 Section 7

Displayed Message
Type Where Displayed Meaning
Details
Requires Column Blow- Informational Front Panel Blowdown test performed, was unsuccessful
down at indicated date and time. This is part of
the blowdown message sequence shown at
the end of this table. Also see "Blowdown
Unsuccessful".
Sensor Not Found Error Front Panel ensor communications are not detected for
12 seconds, system is shutdown. The sen-
sor errors could be any of the following:
a) below null,
b) above maximum,
c) checksum error,
d) data failure (noise),
e) AGC too high,
f) No data
g) No sensor connected
Shut: Informational Front Panel Displayed when in debug mode while view-
ing the sensor errors. This indicates that the
displayed sensor error has shut down the
system.
Too soon for next Informational Front Panel Displayed when the operator tries to initiate
ALWCO the Alwco test too soon after a previous test
Too soon for next blow- Informational Front Panel Displayed when the operator tries to initiate
down the Blowdown test too soon after a previous
test.

Turn Boiler Off Informational Front Panel Displayed and alternates with the message
"LWCO Relay Short".
Waiting On Sensor Informational Front Panel Seen only at power-up when waiting on ini-
tial sensor connection. If no connection is
found after 12 seconds, a "Sensor Not
Found" message will be displayed.
Wrn Check Burner Sta- Warning Front Panel Boiler is off and float movement detected,
tus Input check burner input power, warning message
at indicated date and time. (Note: This mes-
sage is removed on software Version 060
and later).
Wrn Slow Float Move- Warning Front Panel Float check test detected no float movement
ment for 1/2 of test time, warning message, at
indicated date and time (see Float Check
Fail).
xx.x " > LWCO Informational Front Panel Displayed on 1st line of Front Panel during
normal boiler operation (no alarm, error or
informational messages). Displays current
water level. 2nd line of Front Panel is
"Pump ON", "Pump OFF", or modulating
percentage
"Output [Link] %".

750-193 7-3
Section 7

Displayed Message
Type Where Displayed Meaning
Details
Blowdown Unsuccessful Informational Front Panel Displayed for 1 minute
then then
Requires Column Blow- Displayed for 3 seconds
down alternates with
alternates with Blowdown Unsuccessful
Blowdown Unsuccessful indefinitely.
indefinitely until con-
firmed by keypress

Table 7-2: Front Panel Menu Messages

Displayed Message Type Where Displayed Meaning
Adj Battery Date Menu Front Panel Displayed at the beginning of the battery
date adjustment menu.
Alarm / Warning Menu Front Panel Beginning of the alarm / warning time menu.
ALWCO Ignored Menu Front Panel Displayed if operator initiates the ALWCO
test sequence when the water level is
already below the LWCO (can't perform the
test).
Bat Date Changed Menu Front Panel Displayed when the operator updated the
battery date using the front panel keys (in
response to the system indicating that the
clock battery needs to be changed). This
message indicates that the entered date
was accepted.
Bat Date NOT Chg Menu Front Panel Displayed when the operator updated the
battery date using the front panel keys (in
response to the system indicating that the
clock battery needs to be changed). This
message indicates that the entered date
was NOT accepted because the date was
already set.
Blowdown Ignored Menu Front Panel Displayed if operator initiates the Blowdown
test sequence when the water level is
already below the LWCO (can't perform the
test).
Chk LWCO pwr/lvl Menu Front Panel Displayed if operator initiates the ALWCO
test sequence when the burner input is not
powered (can't perform the test).
Control xx.x °C Menu Front Panel The displayed controller temperature in °C
or or °F. The units depend on the metricdata
Control xx.x °F command setting. The display units default
to °F.
Display Format Menu Front Panel The beginning of the display format menu.
Display History ? Menu Front Panel The beginning of the display history (display
alarm, display alwco, display blowdown)
menus.

7-4 750-193
Section 7

Table 7-2: Front Panel Menu Messages

Displayed Message Type Where Displayed Meaning
Exit to previous menu Menu Front Panel Displayed at then end of each menu list to
allow the operator to return to the previous
menu.
Modulating On / Off Menu Front Panel Displayed to indicate whether modulating
control is on or off.
No more history Menu Front Panel Displayed when viewing the alarm, alwco or
blowdown history file when no more items
remain.
Perform ALWCO ? Menu Front Panel 1st prompt before performing the ALWCO
test.
Perform ALWCO Now ? Menu Front Panel 2nd prompt before performing the ALWCO
test.
Perform Blowdown ? Menu Front Panel 1st prompt before performing the Blowdown
test.
Perform Blowdown Now Menu Front Panel 2nd prompt before performing the Blow-
? down test.
xx Recent Events Menu Front Panel Displays the number of alarms, alwco, and
blowdown messages in the history file.
Sensitivity Menu Front Panel Displayed to indicate which water table is
currently being used. See "Table x" mes-
sage for additional details.
Set Date / Time Menu Front Panel The beginning of the set date and time
menu.
Sensor xx.x °C Menu Front Panel The displayed sensor temperature in °C or
or °F. The units depend on the metricdata
Sensor xx.x °F command setting. The display units default
to °F.
Table x Menu Front Panel Displays the current water table number
(from 1 to 9).
Timer x Menu Front Panel Displays the current alarm / warning time in
seconds (from 1 to 20).
Timer xx Sec Menu Front Panel Displays the current remaining time in sec-
onds.
View Alarm History ? Menu Front Panel Beginning of the view alarm history menu.
View Alwco History ? Menu Front Panel Beginning of the view alwco history menu.
View Blowdown History Menu Front Panel Beginning of the view blowdown history
? menu.
View Date / Time Menu Front Panel Beginning of the view date / time menu.
Water Below LWCO Menu Front Panel
Displayed if operator initiates the Blowdown
test sequence when the water level is
already below the LWCO (can't perform the
test).

7-5 750-193
Section 7

Table 7-3: History Messages

Displayed History
Type Where Displayed Meaning
Message
Alwco Bad History Front Panel or Alwco test performed, was unsuccessful at
Serial Port indicated date and time.
Alwco Good History Front Panel or Alwco test performed, was successful at
Serial Port indicated date and time.
Bad Blowdown History Front Panel or Blowdown test performed, was unsuccess-
Serial Port ful at indicated date and time.
Batt Replaced History Front Panel or Battery was replaced at indicated date and
Serial Port time.
BD Notify History Front Panel or Blowdown notification was displayed at indi-
Serial Port cated date and time.
Clock Failed History Front Panel or Time of Day Clock failure detected at indi-
Serial Port cated date and time.
Clock Not Set History Front Panel or Clock not set detected at indicated date and
Serial Port time, this is tested each hour.
Clock Stopped History Front Panel or Time of Day Clock stop detected at indi-
Serial Port cated date and time.
Float Fail History Front Panel or Float check test detected no float movement
Serial Port for full test time, error message, at indicated
date and time (see Slow Float).
Good Blowdown History Front Panel or Blowdown test performed, was successful
Serial Port at indicated date and time.
High Lvl Al History Front Panel or High water level alarm occurred at indicated
Serial Port date and time.
High Lvl Wrn History Front Panel or High water level warning occurred at indi-
Serial Port cated date and time.
Low Water Wrn History Front Panel or Low water warning occurred at indicated
Serial Port date and time.
LW Shutdown History Front Panel or LW Shutdown occurred at indicated date
Serial Port and time.
LWCO Rel Fail History Front Panel or LWCO relay fail occurred at indicated date
Serial Port and time.
LWCO Rel Shrt History Front Panel or LWCO relay short occurred at indicated
Serial Port date and time.
Sensor Error History Front Panel or Sensor Error occurred at indicated date and
Serial Port time.
Slow Float History Front Panel or Float check test detected no float movement
Serial Port for 1/2 of test time, warning message, at
indicated date and time (see Float Fail).
Watchdog Pwr History Front Panel or System was reset due to watchdog timeout
Serial Port at indicated date and time.

7-6 750-193
NOTES
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