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Installation, Operating and Maintenance of Air Break

Vertical Controls for Industrial Steam Boilers


1 9
1. Top Cover
10
2 11
2. Switch Box
3. Lower Cover
3
12 4. Top Flange
4 5. Float Chamber
13
6. Steam Side Flange
14 7. Water Side Flange
6
8. Reducer
5 9. S. S. Pipe
10. Magnet Of Float Rod
15 11. Air Break Switch
7 12. Spacer Pipe
13. Stopper Nut
14. Float Rod
8 15. S. S. Float

Introduction
Magnetically - operated controls of the vertical type in float chambers for external mounting on
steam boilers and pressure vessels, are designed to meet all requirements for automatic on/off
control of boiler feed pump, burner cut-out or lock-out high and / or low level alarm or a combination
of these.

Operation
A primary permanent magnet attached to the float rod slides vertically inside a non-magnetic
stainless steel centre tube and transmits the movement of the float to a secondary magnet in each
switch unit, which are operated with a snap action.

SWITCH UNITS
Electrical Characteristics
Single-pole double-throw operation capable of carrying the following currents :
AC (25 to 60 c.p.s.) Power Factor 1 to 0.4
4 A at 110 V 2 A at 250 V 1 A at 440 V
DC Inductive Loads —Time Constant L/R = 40 milisec. max.
0.25 A at 250 V 0.17 A at 110 V 0.17 A at 250 V

Switches must not be used for the direct starting of motors. Contacts should be wired in series with
the operating coils of relays, contactor starters or solenoid valves, and fused separately.

A four-way terminal block labelled A-A and B-B is provided for each switch unit. The A-A circuit makes on a rise of water
level and the B-B circuit makes on a fall of water level.

Important : Blow- Down the Air Break Vertical Control Twice daily.
NOTE
The temperature of the switch head may at times approach the temperature of
the boiler and suitable heat resisting cables should therefore be used.
Switch mechanisms are interchangeable and may be fitted with any float chamber provided the control range does not
exceed the maximum for which the float chamber is designed.
Each switch unit has a nominal differential of 25 mm (1") If a differential greater than 25 mm is required for pump control,
two switch units must be used and a holding circuit arranged for the starter control circuit. Wider differential may
obtained by increasing the separation between the switches.
Switches must be positioned with centres not less than 8 mm (5/16") apart to avoid simultaneous operation.

Adjustments
Any required adjustment to the operating level(s) of controls is made
entirely within the switch head.
The switch units allow variable adjustment between the circlip stops on
the support rods and are secured in position by clamp screws.

To avoid two switches operating together, their centres must be at least 8


mm (5/16") apart.

Control Range
Switch should always remain between circlips. Control range is 6" (150
mm).

Switches can be moved up & down and water level controlled in the
boiler as desired.Adjustments

Any required adjustment to the operating level(s) of controls is made


entirely within the switch head.

INSTALLATION
1. A horizontal raised band is provided externally on the float chambers of all Air Break Vertical
Controls. This raised band indicates the lowest level at which the control can operate and the
range of the control is measured upwards from this band.

IT IS IMPORTANT THAT AIR BREAK VERTICAL CONTROLS OPERATE WITHIN THE VISUAL
LIMITS OF THE GAUGE GLASS AT ALL TIMES.

2. The steam and water connections between the boiler and the float chamber of the control must
be independent of any other boiler mounting, relatively short and free from sharp bends or packets.

If Boiler connecting Pads and valves have any obstruction , then the differential pressure is
created which can effect the up and down movements of float assembly, hence the working of
Mobray.

It is Important that the controls should be mounted vertically, close to the Boiler guage glasses and
with the water leg as short as possible.

This will minimise any differences in water level between the guage glass and the control float
chamber.

3. Steam and water stop valves must be provided so that the chamber can be isolated from the
boiler for inspection purposes. All mounting arrangements should include a blow-down valve
provided at the lowest point in the water connection.

Important : Blow- Down the Air Break Vertical Control Twice daily.
Float and Float Rod Assembly
S
N 10

10. Magnet of Float Rod


14
12. Spacer Pipe
13. Stopper Nut
L (See the table 1)
14. Float Rod
4 MM
15. S. S. Float
12

13
63mm
152mm

70.5mm
15

Type Of Mobray Standard Length of Float rod (L)


1. CC 216 mm side & side 310 mm
2. CC 295 mm side & side 395 mm
2. CC 300 mm side & side 400 mm
3. CC 370 mm side & bottom 365 mm
3. CC 400 mm side & side 500 mm
4. CC 450 mm side & side 550 mm
5. CC 500 mm side & side 600 mm
Table 1

Note : Length of the Float Rod as well as weight of the Float and Rod assembly is set as such ,
when the pump on/off Switch is fixed in the centre of the Control Box then Pump should starts
from 1/2” ( 12.5 mm ) below the centre of guage glass and stops 1/2” above the centre of
guage glass.

If in case , the Pump On is desired from 60-65 % of Guage Glass , then the length of the Float
Rod should be shortened , accordingly.

Float
Size : (i) Outer Dia - 63 mm
(ii) Outer Dia of Welding Part - 70.5 mm
(iii) Length - 152 mm
(iv) Cap Internal Threading -6 mm

Important : Blow- Down the Air Break Vertical Control Twice daily.
High Level Alarm
Pump Off N W L
Pump On
Low Level Alarm

SIDE AND SIDE ENTRY


CHAMBER ON STEAM DRUM
1. Pump should start from 1/2” ( 12.5 mm ) below the centre of guage glass and stops 1/2” above the centre
of guage glass
Each switch unit has a nominal differential of 25 mm (1") If a differential greater than 25 mm is required for
pump control, two switch units must be used and a holding circuit arranged for the starter control circuit.
Wider differential may obtained by increasing the separation between the switches.

To avoid two switches operating together , their centres must be at least 8 mm (5/16”) apart.

2 . Low Level Alarm switch should be set 1.1/2” ( 28 mm ) below the Pump on/off switch.

3. High Level Alarm switch ( If provided ) should be set 1.1/2” ( 28 mm ) above the Pump on/off
switch.

To test pump control switch


Under normal operating conditions :
(a) Allow the water level to rise until the 'Pump Cut-out" level is reached.
At this point the pump should stop.
(b) Allow the water level to fall until the 'Pump Cut-in'level is reached.
At this point the pump should start.

To test low water alarm and cut-out switch.

Shut off the feed water to the boiler, either by closing down the feed pump or in certain cases closing the feed valve.

WITH A COMPETENT ATTENDANS STANDING BY, allow the water level to fall by evaporation until the low alarm level
is reached. At this point the machine should operate the low alarm and the firing apparatus should cease to operate.
With the feed pump under hand control, restore the feed water to the boiler. Upon a short rise in water level the low
alarm should re-set and the firing apparatus should commence to operate. Restore normal feed water control to the
boiler. Any change in operating level from the set position may be indicative either of blocked connections to the float
chamber, a waterlogged float or a loose switch unit and should be investigated immediately.
Warning : Any unauthorised interference or modification to the mechanisms of these machines can be detrimental to
their correct operation.

Important : Blow- Down the Air Break Vertical Control Twice daily.
ELECLRICAL CONNECTIONS AND APPLICATIONS

SINGLE-SWITCH CONTROL TWO-SWITCH CONTROL TWO-SWITCH CONTROL


Combined Pump Control and Low Level Alarm High and Low Level Alarm

A Alarm ON A
High Level Alarm A Alarm ON
A A High Level Alarm
Switch A
B Pump Control B Switch
Pump ON B
B Switch B B
A
A
Pump Control B A
Switch Pump ON A Firing OFF
B Firing OFF A
A Low Level Alarm
Low Level Alarm Switch B
A B Alarm ON
Firing OFF Switch Alarm ON B
A B
Low Level Alarm
Switch B
Alarm ON
B

THREE-SWITCH CONTROL THREE-SWITCH CONTROL FOUR-SWITCH CONTROL

A Alarm ON A A
High Level Alarm Pump Control High Level Alarm Alarm ON
A A Switch A
Switch Switch
B B Pump Trip B
B B B

A A A
A A A
Pump Control B Pump Control B Pump Control B
Switch Pump ON Switch Pump On Pump Trip
B B Switch B

A A Firing OFF A
Firing OFF
A A A
Low Level Alarm Low Level Alarm Pump Control
Switch B Switch B Alarm ON B
Alarm ON Switch Pump On
B B B

A Firing OFF
Low Level Alarm A
Switch B Alarm On
B

Type Available : Flanges machined to BS 10, IBR.


Centre to Centre Max. Working Chamber Connection Blow
Type distance of side Down No. of Type No.
Pressure Steam Water Switches
flanges Connection

Side & Side 400 mm 250 psig Side Side 1/2”BSP TWO 400-6253-7376
(17.5 kg/cm2 ) (Holes) (Holes)
Side & Side 400 mm 350 psig Side Side 1/2”BSP TWO 5783-6253-7376
(24.6 kg/cm2 ) (Holes) (Holes)
Side & Side 216 mm 250 psig Side Side 1/2”BSP TWO 216-6253-7376
(17.5 kg/cm2 ) (Holes) (Holes)
Side & Side 295 mm 250 psig Side Side 1/2”BSP TWO 295-6253-7376
(17.5 kg/cm2 ) (Holes) (Holes)
Side & Side 300 mm 250 psig Side Side 1/2”BSP TWO 300-6253-7376
(17.5 kg/cm2 ) (Holes) (Holes)
Side & Bottom _ 250 psig Side Bottom _ TWO 5742-6253-7374
(17.5 kg/cm2 ) (Holes) (Holes)
Top Mounted _ 250 psig _ _ _ TWO TOP-6253-7376
(17.5 kg/cm2 )

Types also availables against order with flanges machined to


BS 10 R,B 16.5 #150,#300,#600,ND-40,DIN etc.
Electrical Wiring diagram
N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter OFF ON
A A
B B
Auto Pump On/Off
( 1” Differential )
Pump
Start/Stop
Switch

Pump Motor

Diagram Shows Starter Fitted With 250 V Coil

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter OFF ON
A A
B B
Auto Pump On/Off
( 1-4” Differential )
A

B
Pump Motor
B

A A
B B

Two Switch Pump Control Circuit Using


Auxillary Contacts On Starter

A Relay
B
R1
B
Pump
Stop A A
Switch B B

B
Pump
Start A A Live Supply From
B B 2 A Fuse
Switch Pump Starter
To Pump
Motor Starter

Two Switch Pump Control Circut Using


Holding Relay For Starters Without Auxiliary Contacts

Important : Blow- Down the Air Break Vertical Control Twice daily.
Applications
One Switch Operation
N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter OFF ON
A A
B B
Auto Pump On/Off
( 1” Differential )
Pump
Start/Stop
Switch

Pump Motor

Two Switch Operation

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter OFF ON
A A
B B
Auto Pump On/Off
( 1” Differential )
Pump
Start/Stop
Switch

Pump Motor

Upper Switch

Solenoid
Valve
A 2A Fuse

B
X P
N
Low
Level
Trip { In Oil
Fired
Boilers

2A Fuse
P
B
Low Level
Alarm
A A N
B B Hooter

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.
Applications
Three Switch Operation- I

A
P High
A Hooter
Level
2A Fuse
Alarm
B
N
B

A A
B B

Upper Switch

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter OFF ON
A A
B B
Auto Pump On/Off
( 1” Differential )
Pump
Start/Stop
Switch

Pump Motor

Middle Switch

Solenoid
Valve
A 2A Fuse

B
X P
N
Low
Level
Trip { In Oil
Fired
Boilers

2A Fuse
P
B
Low Level
Alarm
A A N
B B Hooter

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.
Applications
Three Switch Operation - II

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter OFF ON
A A
B B

Auto Pump On / Off


A
(1"-4" Differential)
A

B
Pump Motor
B

A A
B B

Middle Switch

Solenoid
Valve
A 2A Fuse

B
X P
N
Low
Level
Trip { In Oil
Fired
Boilers

2A Fuse
P
B
Low Level
Alarm
A A N
B B Hooter

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.
Applications
Four Switch Operation

A
P High
A Hooter
Level
B 2A Fuse
N Alarm
B

A A
B B

Upper Switch

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
Starter
A
B
A
B
OFF ON Auto Pump On / Off
(1"-4" Differential)
A

B
Pump Motor
B

A A
B B

Middle Switches

Solenoid
Valve
A 2A Fuse

B
X P
N
Low
Level
Trip
{ In Oil
Fired
Boilers

2A Fuse
P
B
Low Level
Alarm
A A N
B B Hooter

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.
Trouble Shooting
1. Mobray not maintaing level.
Move the switch up and down to achieve the required level.
2. Pump is running and filling water in the boiler , but not stopping.
A. Check the SS Float
i If puncture, replace the same with a new one.
ii Strucking in the float chamber
Isolate the Mobray open the top flange, clean the chamber and fit it again.

B. Check the Float Rod


If bend either make it straight or replace the same
C. Check the Top flange SS Pipe , it should be perpendicular with the flange.
If tilting on one side, either get it set on lathe machine or send it to our works.
D. Check the Spacer Pipe.
If missing
Put it in the float rod above the brass Stopper Nut.
E. Check the water side valve , If closed , open it.

3. Pump is not filling water in the boiler.


A. Check electrical connections of mobray and pump motor
B. Check the Air Break Switch.
If faulty replace the same with a new one.
C. Check the pump Motor.
D. Check the water and steam connecting valves.
If closed , open it.
E. Check the water in the Tank.

4. Mobray maintaing level out side the visible range of gauge glass.
A. Check the Padding of Mobray , it should coincide with the Padding of gauge
Glass.

i. If maintaing level outside the upper limit of Gauge Glass


Shorten the length of float rod, accordingly.
ii. If maintaing level outside the lower limit of Gauge Glass
Increase the length of float rod, accordingly.
B. Check the obstruction in the water and steam side mounting of the boiler
connecting mobray.

5. Float rod is climbing upward , but not coming down.


A. Check the Steam connecting valve
If closed, open it.
6. Low Level Alarm not working.
A. Check the alarm unit ( Hooter ) and its electrical wiring.
B. Check the Lower Air Break Switch BB point and its continuity by Multimeter.
If the continuity shows its open , replace the same with a new switch.

Important : Blow- Down the Air Break Vertical Control Twice daily.
Possible Various Faults In The Mobray
And Their Corresponding Effects
Two Switch Operation
Lower Switch BB Circuit Open - Low Level Alarm / Indication would not work
Lower Switch AA Circuit Open - ID Fan would not work (husk, coal fired Boilers)
- Solenoid Valve would not work ( oil fired Boiler )
Upper Switch BB Circuit Open - Pump would not start
Upper Switch AA Circuit Open - No Action because not connected

Three Switch Operation - I


Lower Switch BB Circuit Open - Low Level Alarm / Indication would not work
Lower Switch AA Circuit Open - ID Fan would not work (husk, coal fired Boilers)
- Solenoid Valve would not work ( oil fired Boiler )
Middle Switch BB Circuit Open - Pump would not start
Middle Switch AA Circuit Open - No Action because not connected
Upper Switch BB Circuit Open - Pump would not start ( in holding circuit for
differential 1”- 4 “ )
Upper Switch AA Circuit Open - No Action because not connected

Three Switch Operation - II


Lower Switch BB Circuit Open - Low Level Alarm / Indication would not work
Lower Switch AA Circuit Open - ID Fan would not work (husk, coal fired Boilers)
- Solenoid Valve would not work (oil fired Boiler)
Middle Switch BB Circuit Open - Pump would not start
Middle Switch AA Circuit Open - No Action because not connected
Upper Switch BB Circuit Open - No Action because not connected
Upper Switch AA Circuit Open - High Level Alarm / Indication would not work

Four Switch Operation


Lower Switch BB Circuit Open - Low Level Alarm / Indication would not work
Lower Switch AA Circuit Open - ID Fan would not work (husk, coal fired Boilers)
- Solenoid Valve would not work ( oil fired Boiler )
Middle Switch BB Circuit Open - Pump would not start
Middle Switch AA Circuit Open - No Action because not connected
Middle Switch BB Circuit Open - Pump would not start
Middle Switch AA Circuit Open - No Action because not connected
Upper Switch BB Circuit Open - No Action because not connected
Upper Switch AA Circuit Open - High Level Alarm / Indication would not work

Important : Blow- Down the Air Break Vertical Control Twice daily.
SS Float Puncture -i Pump is running & filling water in the boiler, but not stopping.
ii Low Level Alarm would sound
Float Rod having Bend - Float with Rod assembly cannot move up and down.
Mobray is not fitted Vertical - Float with Rod assembly cannot move up and down.
Top SS Tube has a Bend - Float with Rod assembly cannot move up and down
Steam side connecting Padding/Valve has an obstruction - Pump will not start even after water
level in the Guage glass goes down because of partial vaccum in the float chamber.
Water side connecting Padding/Valve has an obstruction - Pump is running but not stopping even
after water level in the Guage glass goes up because float chamber does not have sufficient
water
Float Rod Magnet Polarity is Reverse - all operation related to switches get reversed.
Float Rod Magnet Strength goes down - Air Break Switch will not actuate on passing of primary
Magnet.of Float Rod.
Mobray fitted with shorter length of Float rod than standard length------
Mobray will maintain the water level and low level alarm out side the upper range of guage glass.
Mobray fitted with larger length of Float rod than standard length--------
Mobray will maintain the water level and low level alarm out side the lower range of guage glass.

Blow Downing The Control-


While blow downing the control first comes the hot water and then steam this way the whole
float assembly will go down tripping the firing and sounding the alarm and as soon as closing
the blow-down valve the float assembly will move up resuming the firing and stopping theS alarm
this way the low level alarm/trip switch got tested ,automatically

SPARES N

TOP CONTROL BOX AIR BREAK SWITCH S. S. FLOAT ROD ASSEMBLY


Important : Blow- Down the Air Break Vertical Control Twice daily.
TYPICAL MOUNTING ARRANGEMENTS OF
AIR BREAK VERTICAL CONTROLS ON VARIOUS TYPES OF BOILER

N W L N W L

SIDE AND BOTTOM ENTRY SIDE AND SIDE ENTRY


CHAMBER WITH SEQUENCING
BLOW - DOWN VALVE CONTINENTAL CHAMBER

N W L

SIDE AND BOTTOM ENTRY


SIDE AND SIDE ENTRY
CHAMBER WITH SEQUENCING
CHAMBER ON STEAM DRUM
BLOW - DOWN VALVE ON
OF WATER TUBE BOILER
VERTICAL BOILER

Malhotra Bros & Co.


Registered Office :
EA-198, Tagore Garden, New Delhi - 110027
Ph. : Office : 42133632, Works : 25461405
Tel. / Fax : 5417828 Mobile : 098100 52558
E-mail : mobray@vsnl.com,
mobrays@gmail.com

Important : Blow- Down the Air Break Vertical Control Twice daily.

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