Honeywell L4081 Installation Manual

Page 1

L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

INSTALLATION

When Installing This Product…

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.

3. Installer must be a trained, experienced service technician.

4. After installation is complete, check out product operation as provided in these instructions.

CAUTION: EXCESSIVE HANDLING OR SHARP BENDS CAN DAMAGE THE CAPILLARY.

WARNING

Electrical Shock Hazard. Can cause serious injury, death or equipment damage.

Disconnect power supply before installation to prevent electrical shock or equipment damage.

NOTE: These devices can be installed in any position.

Proper location, sizing and threaded boiler tapping are required.

1. Maximum pressure rating for these models is

200 psi (1380 kPa)

2. Maximum permissible ambient temperature as

sensing bulb is 265°F (130°C); at switches, 150°F (66°C).

3. The L6081C is without enclosure or well

assembly.

Mounting

Followinstructions provided by system manufacturer, if available. Otherwise, proceed as follows:

1. Drain the boiler if the system is filled with water.

2. Place the front of the controller down on a horizontal

surface and gently raise the sensing bulb until it is at a right angle with the back of the case and centered with the alrge hole in the case. This requires bending the capillary tube, but be sure to make no sharp bends and no bends near the bulb.

NOTE: Some models have an adjustable tubing length to

3 in. (76 mm). In these models, extra tubing inside the case can be pulled out, if needed. See Fig. 3.

SENSING ELEMENT IS FACTORY FORMED FOR 1.5 IN.

INSULATION WELL ASSEMBLIES. FOR 3 IN. INSULATION WELL ASSEMBLIES, PULL OUT

SUFFICIENT CAPILLARY TO ASSURE THAT THE CAPSULE BOTTOMS IN THE WELL.

STRAIGHTEN CAPILLARY SUFFICIENTLY SO IT DOES NOT

INTERFERE WITH INSERTION OF THE CAPSULE INTO THE WELL.

M888

Fig. 3. Adjusting the capillary length.

3. Adjust the position of the bulb so tht the bulb projects

4-7/8 in. (124 mm) from the back of the case for immersion well designed for 1-1/2 in. (38 mm) insulation; or 6-3/8 in. (162 mm), if designed for 3 in. (76 mm) insulation. If this requires bending the tube inside the case, insert the end of your index finger through the hole and carefully mold the tube into the correct shape as you gently pull (or push) the bulb to the correct position. The bulb must project the right distance so that after the case in installed, the spring force of the capillary tube holds the bulb against the inner end of the well for good thermal contact. The tube must be straight for at least 3/8 in. (10 mm) inside the case so the end of the well spud does not strike the coiled tube and pull the bulb away from contact with the inner end of the well.

4. Remove the plug from a properly located boiler tapping.

5. Apply pipe dope sparingly to the threads of the well,

then screw the well tightly into the boiler tapping.

6. Fill the system with water, then carefully examine around the threads for leakage. Tighten the well if necessary to stop any leakage.

7. Loosen the wallclamp screw three or four turns., move the screw in and out and not how it moves the well clamp. See Fig. 4. Loosen the screw enough so that when the screw is pushed inward, the T-shaped clamp guide is at the far end of the slot in the case.

8. Mount the case on the well spud in any position that facilitates wiring. With the case in final position, carefully insert the sensing bulb into the well until the case slips over the end of the well spud and fits squarely against the shoulder of the spud.

60-2105—6 4

NOTE: Open the clamp to receive the spud by pushing in

the well clamp screw.

9. While holding the case in the correct position, firmly tighten the well clamp screw.

Page 2

STRIP

2 T

GAUGE

WELL CLAMP SCREW

L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

3. Insert a screwdriver into the rectangular slot near the terminal and hold it in the slot while inserting the wire into the terminal hole as far as possible.

4. Remove the screwdriver when complete.

LOW LIMIT/ CIRCULATOR DIFFERENTIA ADJUSTMENT

LOW LIMIT SETPOINT ADJUSTMENT

HIGH LIMIT SETPOINT ADJUSTMENT

JUMPER SLOT

M8848

Fig. 4. L6081A with cover removed to show adjustments.

WIRING

WARNING

Electrical Shock Hazard. Can cause serious injury, death or equipment damage.

Disconnect the power supply to prevent electrical shock or equipment damage.

IMPORTANT

Use care to avoid strain on the control case when using cable or conduit.

Jumper

When using the controller field addable jumper (Fig. 4), connect terminals R-R. When the jumper is added, make sure

that the two prongs of the jumper face the center of the controller.

CIRCULATOR

2431

4V HERMOSTAT

RA832A SWITCHING RELAY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND

OVERLOAD PROTECTION AS REQUIRED. B TERMINALS ARE TAB TERMINALS.

L1 (HOT)

L4081A

1R2

BRB

HIGH LIMIT

LOW LIMIT

JUMPER REMOVED

VR8300 LOW VOLTAGE GAS VALVE

M8846

WARNING

Fig. 5. L4081A used with gas burner (line voltage limit).

Explosion Hazard. Can cause serious injury, death or property damage.

Use this product only in a system with a pressure relief valve.

Alll wiring must comply with all applicable local codes and ordinances. See cover insert for electrical load ratings. Refer to Fig. 5 through 9 for typical wiring diagrams.

Use the following procedure when connecting wires to the B-B tab terminals (Fig. 4):

1. Connect no. 14, 16, or 18 solid, or no. 14 or 16 unistranded wire to the tab terminals.

2. Strip insulation from the end of each wire.

3. use the included wire nut from the bag assemblyh to

connect the tab terminal connector to the wire.

4. Connect the wire to the tab terminal.

Use the following procedures when connecting wires to the R-R terminals (Fig. 4):

1. Use no. 14, 16, or 18 solid, or no. 14 or 16 unistranded wire for connecting the push-in terminals.

Fig. 6. L4081B used to prevent circulator opertion with

2. Strip the insulation from the end of each wire.

5 60-2105—6

L1 (HOT)

BRW

L4081B

BURNER CONTROL

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

B IS A TAB TERMINAL.

HIGH LIMIT

CIRCULATOR

JUMPER REMOVED

CIRCULATOR RELAY

CIRCULATOR MOTOR

M8787

boiler water temperature below low limit setting.

Page 3

L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

2 T S

)

2 T

CIRCULATOR

4V HERMOTAT

1R1

RA89A SWITCHING RELAY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

B TERMINALS ARE TAB TERMINALS.

(HOT)

PILOTSTAT® CONTROL

HIGH LIMIT

L4081A

LOW LIMIT

GAS VALVE

M8788

L1 (HOT

Fig. 7. L4081A used with burner cycled from the water temperature.

(HOT)

BLACK

L1 (HO

4V HERMOSTAT

CIRCULATOR

RA832A SWITCHING RELAY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

B TERMINALS ARE TAB TERMINALS.

1R1

1R2

HIGH LIMIT

L4081A

LOW LIMIT

OIL PRIMARY CONTROL

WHITE

JUNCTION BOX

M8786

Fig. 8. L4081A used with oil burner.

60-2105—6 6

Page 4

M8855

R4184D PROTECTORELAY™ CONTROL

JUNCTION BOX

L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

BLACK

CAD CELL

1K2

SOLID STATE

SWITCH

SAFETY SWITCH HEATER

24V THERMOSTAT

1K1

4 3 1

RA89A SWITCHING RELAY

1R1

ORANGE

WHITE

L1 (HOT)

BURNER MOTOR

OIL VALVE

IGNITION

CIRCULATOR

L6081A

POWER SUPPLY. PROVIDE DISCONNECT

MEANS AND OVERLOAD PROTECTION AS REQUIRED.

B TERMINALS ARE TAB TERMINALS.

JUMPER ADDED

Fig. 9. L6081A used with oil burner.

OPERATION

High Limit

The high limit opens and turns off the burner when the water temperature reaches the setpoint. The high limit automatically resets after the water temperature drops past the setpoint and through the 10°F (6°C) differential.

Low Limit and Circulator

On a temperature rise, with the adjustable differential at the minimum setting of 10°F (6°C) (also applies to fixed 10°F [6°C] differential models), the burner circuit (R-B) breaks and the circulator circuit (R-W) makes at the control setpoint. On a temperature drop of 10°F (6°C) below the setpoint, the R-B circuit makes and the R-W circuit breaks.

At any differential setting greater than 10°F (6°C), the R-B make temperature and R-W break temperature remain the same control setting minus 10°F (6°C). The R-B break and R-W make temperatures are the setpoint temperature plus the difference between the differential setting and 10°F (6°C).

Examples:

L4081A: Setpoint of 140°F (60°C); differential set at 25°F (14°C). On a temperature rise, the switch breaks at 155°F (69°C). On a temperature fall, the switch makes at 130°F (55°C).

L4081B: Setpoint of 140°F (60°C); differential set at 25°F (14°C). On a temperature rise, the switch makes at 155°F (69°C). On a temperature fall, the switch breaks at 130°F (55°C).

L6081A,B: Setpoint of 140°F (60°C); differential set at 25°F (14°C). On a temperature rise, R-B breaks and R-W makes at 155°F (69°C). On a temperature fall, R-B makes and R-W breaks at 130°F (55°C).

7 60-2105—6

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L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

L S

C S

H S

L C S

H S

L6081A,C

SETTINGS

240°F (116°C)

Because heating systems differ, follow the boiler manufacturer recommendations when selecting temperature settings.

Study the applicable chart in Fig. 10, which shows the switching response to temperature changes.

With the cover off, set the high limit adjustment at the temperature desired but not higher than recommended by the boiler manufacturer (Fig. 4).

Set the low limit and/or circulator adjustment to obtain temperature desired but not less than 20°F (11°C) below the high setting.

HIGH LIMIT SETTING

OW LIMIT

ETTING

10°F (5.6°C) DIFFERENTIAL

25°F (13.9°C) DIFFERENTIAL

10°F (5.6°C) DIFFERENTIAL

SWITCH BREAKS ON RISE. BURNER TURNS OFF.

SWITCH MAKES ON FALL. BURNER OPERATES ON A CALL FOR HEAT.

SWITCH BREAKS ON RISE. (25°F (13.9°C) DIFFERENTIAL

SWITCH BREAKS ON RISE. (10°F (5.6°C) DIFFERENTIAL)

SWITCH MAKES ON FALL. BURNER ON.

The differential adjustment applies to only the low-limit and/or circulator switch(es). Minimum differential adjustment provided is 10°F (6°C) nominal; maximum is 25°F (14°C)

110°F (43°C)

L4081A

nominal. Set as desired.

240°F (116°C)

Setting Stop

Install the 126580 Setting Stop on the adjusting knob to prevent turning the knob beyond a predetermined point. Fig. 11 shows stops installed on the knob of the high limit switch to prevent setting higher than 180°F (82°C).

IGH LIMIT ETTING

10°F (5.6°C) DIFFERENTIAL

To install the setting stop, proceed as follows:

1. Turn the knob to the setting that is to be established as the limit.

2. Place the setting stop over the knob in position to arm of setting stop (after the stop is pressed into place) strikes projection A and prevents turning the knob beyond the

IRCULATOR ETTING

25°F (13.9°C) DIFFERENTIAL

10°F (5.6°C) DIFFERENTIAL

desired limit setting.

SWITCH BREAKS ON RISE. BURNER TURNS OFF.

SWITCH MAKES ON FALL. BURNER OPERATES ON CALL FOR HEAT.

SWITCH MAKES ON RISE. (25°F (13.9°C) DIFFERENTIAL)

SWITCH MAKES ON RISE. (10°F (5.6°C) DIFFERENTIAL).

SWITCH BREAKS ON FALL. CIRCULATOR OFF.

3. Press the setting stop tightly onto the knob so that its inner teeth securely engage the knob.

4. Turn knob back and forth several times to make sure the stop functions properly.

5. When all settings are made, replace the cover.

IGH LIMIT ETTING

OW LIMIT AND

IRCULATOR ETTING

110°F (43°C)

L4081B

240°F (116°C)

10°F (5.6°C) DIFFERENTIAL

25°F (13.9°C) DIFFERENTIAL

10°F (5.6°C) DIFFERENTIAL

110°F (43°C)

SWITCH BREAKS ON RISE. BURNER TURNS OFF. CIRCULATOR OPERATES ON CALL FOR HEAT.

SWITCH MAKES ON FALL. BURNER OPERATES ON CALL FOR HEAT.

SWITCH MAKES R-W AND BREAKS R-B ON RISE. 25°F (13.9°C) DIFFERENTIAL.

SWITCH MAKES R-W AND BREAKS R-B ON RISE. (10°F (5.6°C) DIFFERENTIAL)

SWITCH MAKES R-B ON FALL,BREAKS R-W ON FALL. BURNER ON,CIRCULATOR OFF.

M8847

Fig. 10. Charts showing switching

response to temperature changes.

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L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

KNOB SET AT 180°F (82°C)

SETTING STOP

SETTING STOP ARM

ROJECTION "A"

SCALE MARKINGS IN FAHRENHEIT ONLY.

220

200

180

160

140

M2844

Fig. 11. Setting stop shown in position to limit

the high limit setting to 180°F (82°C).

CHECKOUT

After completing installation and controller settings, operate the system. Carefully observe the operation of all components through at least one complete cycle. Be sure to include a check of the high limit switch operation. Make any correction needed; then repeat the checkout. Repeat until system operates properly.

9 60-2105—6

Page 7

L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

MATERIAL SAFETY DATA SHEET

Section 1. Product and

Manufacturer: Honeywell Inc., 1985 Douglas Drive North, Minneapolis, MN 55422.

Company Identification.

Product Name: Heat conductive compound.

MSDS ID: DS9021.

Synonyms: MS1699.

Product Use: Heat conductive material used to enhance contact and heat transfer in temperature sensor applications.

Date Released: October 8, 1999.

NFPA Ratings:

Health 0; Flammability 1; Reactivity 0; Personal Protection B.

Section 2. Composition, Information on Ingredients (Table 3).

Table 3. Ingredients of Heat Conductive Compounda.

Ingredients CAS Number Percent PEL TLV

No. 2 Lithium Complex Grease (70%):

Mineral Oil 64742-65-0 35-50

Mineral Oil 64742-62-7 20-25

Lithium Hydrostearate/Sebacate Complex 68815-49-6 4-9 — —

Zinc Alkyldithiophosphate 68649-42-3 0-2 — —

Aluminum Paste (30%):

Aluminum, as Al 7429-90-5 20-25

Aliphatic Petroleum Distillates 8052-41-3 10-15

Stearic Acid 57-11-4 1-2 — —

Aromatic Petroleum Distillates 64742-95-6 1-2

Additional Information: Part No. 120650 (0.5 oz. tube); Part No. 107408 (4 oz. can); Part number 197007 (5 gallon container).

May also contain minute amounts of lithium and molybdenum lubricant compounds.

5 mg/m

15 mg/m

2900 mg/m

5 mg/m

10 mg/m

525 mg/m

5 mg/m

60-2105—6 10

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L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

Section 3. Hazard Identification

Acute Health Effects:

Skin—Excessive contact can cause skin irritation and dermatitis.

Eye—Direct contact with eye will cause irritation.

Inhalation—No adverse effects are expected.

Ingestion—Ingestion of product may cause nausea, vomiting and diarrhea.

Chronic Health Effects:

Existing skin rash or dermatitis may be aggravated by repeated contact.

OSHA Hazard Classifications:

None.

Carcinogenicity:

Not considered to be a carcinogen by either OSHA, NTP, IARC, or ACGIH.

Target Organs:

None known.

Section 4. First Aid Measures

Explosion Hazards:

None. Aluminum powder can react with water to release flammable hydrogen gas. In the form of this product, this reaction is not expected.

Section 6. Accidental Release Measures

Scrape up and dispose as solid waste in accordance with state and federal regulations.

Section 7. Handling and Storage

Store in dry place. Keep container closed when not in use.

Section 8. Exposure Controls and Personal Protection

Ventilation:

No special ventilation is required when working with this product.

Respiratory Protection:

None required.

Eye Protection:

Not normally required. However, use chemical safety goggles or faceshield if potential for eye contact exists, especially if material is heated.

Eye Contact:

Flush eyes with water for 15 minutes. Remove any contact lenses and continue to flush. Obtain medical attention if irritation develops and persists.

Skin Contact:

Remove excess with cloth or paper. Wash thoroughly with mild soap and water. Obtain medical attention if irritation develops and persists.

Ingestion:

Contact physician or local poison control center immediately.

Inhalation:

Remove patient to fresh air and obtain medical attention if symptoms develop.

Section 5. Fire Fighting Measures

Flash Point:

>383°F (195°C). Will burn if exposed to flame.

Extinguishing Media:

Carbon dioxide, dry chemical or foam.

Special Fire Fighting Procedures:

None.

Hand/Clothing Protection:

Not normally required. Protective gloves and clothing are recommended, as material is difficult to remove from skin and clothing.

Other Protective Equipment:

None required.

Section 9. Physical and Chemical Properties

Appearance/Odor:

Aluminum color, semi-solid material, pleasant odor.

Solubility in Water:

Negligible.

Specific Gravity:

0.86.

Section 10. Stability and Reactivity

Stability:

Stable.

Reactivity:

Hazardous polymerization will not occur.

11 60-2105—6

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L4081A,B AND L6081A,C MULTIPLE AQUASTAT® CONTROLLERS

Incompatibilities:

Strong oxidizing agents and halogens.

Hazardous Decomposition Products:

Carbon dioxide, carbon monoxide.

Section 11. Toxicology Information

No data available.

Section 12. Ecological Information

Chemical Fate Information:

Hydrocarbon components will biodegrade in soil; relatively persistent in water.

Section 13. Disposal Consideration

Dispose of as solid waste in accordance with Local, State and Federal regulations.

Section 14. Transportation Information

DOT Classification:

Not classified as hazardous.

Section 15. Regulatory Information

SARA Title III Supplier Notification:

Include in Section 311/312 inventory reports if amounts exceed 10,000 pounds. Aluminum compounds are subject to the reporting requirements under Section 313 of Emergency Planning and Community Right-to-Know Act of 1986 (40 CFR 372). Ingredients listed in TSCA Inventory.

Section 16. Other Information

This information is furnished without warranty, expressed or implied, except that it is accurate to the best of our knowledge.

Prepared By:

PROSAR, 1295 Bandana Boulevard, Suite 335, St. Paul, MN 55108 (651-917-6100).

Automation and Control Solutions Automation and Control Solutions

Honeywell Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Scarborough, Ontario

60-2105—6 G.R. Rev. 12-01 www.honeywell.com

M1V 4Z9

Printed in U.S.A. on recycled paper containing at least 10% post-consumer paper fibers.