Honeywell L6081 Installation Manual

Page 1

L6081A

Aquastat® Controller

INSTALLATION INSTRUCTIONS

APPLICATION

The L6081A is a triple function controller; it is used as a high limit, low limit, and circulator control. This controller is designed to replace the controls listed in Table 1.

Table 1. Controls L6081A Replaces.

Honeywell General Controls

L401A L4010B L4062A L4062B L4081A,B L6062A L6081A,C

All require a 124904 Well Adapter to fit L6081A case to well (order separately, see form 68-0040, Wells and Fittings for Temperature Controllers).

Well for L6081A must be added when replacing these models.

L52F L52G L52H L52J L52K L52L

480 DA-36-153

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.

WARNING

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

Use this product only in systems with pressure relief valves.

When replacing some of these controls, only 1 or 2 of the L6081A switching functions may be needed. Refer to Fig. 2 to determine which terminals are used in a given application.

Mercoid

443AT 447G 4432X 4420 4433 4420X 4433X 4422 4436 4422X 4437

Penn

4432

White Rodgers

11A61 11C61

1131 1135 11C30 1115 11C31

WARNING

Electrical Shock Hazard. Can cause serious injury or death.

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

NOTE: If new immersion well is needed, refer to form

68-0040 Wells and Fittings for Temperature Controllers for ordering information.

Mounting

Follow the mounting system manufacturer instructions if available; otherwise, proceed as follows:

1. Turn off power and drain the system if necessary.

2. Remove old control.

3. loosen the captive cover mounting screw on the

L6081A and pull off the cover.

95- 6701- 5

Page 2

L6081A AQUASTAT® CONTROLLER

IMPORTANT:

Best thermal response is obtained with a well that snugly fits the sensing bulb.

If well does not snugly fit bulb, use the heat-conductive grease. Fold the plastic bag of grease lengthwise and twist it gently. Then snip off end of bag and work the open end all the way into the well. Slowly pull out bag while squeezing it firmly to distribute grease evenly in the well. Insert bulb all the way to the bottom of the well. Bend the tubing, if necessary, to hold the bulb against the bottom of the well and to hold the outer end of the bulb in firmly to the side of the well (Fig. 1). Wipe excess grease off outer end of the well.

CONTROLLER CASE

IMMERSION WELL CLAMP

IMMERSION WELL SPUD

ADAPTER

(C)

CAPILLARY TUBE

SETSCREW

IMMERSION WELL CLAMP SCREW

BEND THE CAPILLARY TUBE TO HOLD THE SENSING BULB IN GOOD THERMAL CONTACT WITH THE IMMERSION WELL AT POINTS (A) AND (B).

ASSURE THAT CAPILLARY TUBE FITS FREELY IN THE ADAPTER SO THE TENSION OF THE CAPILLARY TUBE AT POINT (C) HOLDS THE SENSING BULB IN GOOD THERMAL CONTACT WITH THE IMMERSION WELL AT POINT (D).

BOILER

SHORT TUBE FITS IN CENTRAL RECESS OF ADAPTER

Fig. 1. Use of adapter and proper position of sensing bulb in immersion well.

6. If the immersion well from the old control does not

fit into the clamp on the back of L6081A case, use the 124904 Well Adapter (order separately, see form 68-0040, Wells and Fittings for Temperature Controllers). a. Fit sensing element capillary into the adapter

groove (Fig. 1).

b. Fasten the adapter to the case. Make certain

that the clamp is properly positioned on the adapter and the adapter flange fits snugly into the opening in the case.

c. Apply heat-conductive grease as instructed

above.

d. Insert the bulb and adapter into the well. The

sensing element bulb must bottom in the well for best temperature response. (A slight bend in the tubing will hold the bulb against the well.) See Fig. 1.

e. Tighten the setscrew. Make certain that the

adapter groove is on the opposite side of the setscrew (Fig. 1).

4. Loosen the insertion well clamp screw (Fig. 1).

5. If the immersion well from the old control fits into

the clamp on the back of the L6081 case, proceed as follows. If it does not, go to step 6 below. a. Apply heat-conductive grease as instructed

above. b. Insert the sensing element into the well. c. Fasten the case to the well with the clamp

screw. Make certain that the clamp is properly

positioned on the well and the well flange fits

snugly into the opening in the case. The

sensing element bulb must bottom in the well

for best temperature response. (A slight bend

in the tubing holds the bulb against the well.)

See Fig. 1.

(A)

BACK OF

CONTROLLER

CASE

OLD IMMERSION WELL ASSEMBLY

IMMERSION WELL CLAMP SCREW

HEAT-CONDUCTIVE COMPOUND

ADAPTER

IMMERSION WELL CLAMP

SENSING BULB

(B)

M8830

(D)

WIRING

WARNING

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

Disconnect power supply to prevent electrical shock or equipment damage.

All wiring must comply with local electrical codes. Make certain that the electrical requirement of the controlled equipment does not exceed the rating shown inside the L6081A cover. Follow the hookup instructions furnished by the system manufacturer.

IMPORTANT:

L6081A terminals are approved for copper wire only.

Use Fig. 2 to determine which switches to use when replacing the existing control. For example, if the existing control has high limit and circulator control switch terminals, use terminals R and B on the left side of the switch for the high limit and the R and W terminals on the right side of the switch to control the circulator.

95-6701—5 2

Page 3

L6081A AQUASTAT® CONTROLLER

Fig. 3 shows a typical L6081A hookup.

NOTE: If the 128975 Field Addable Jumper (included)

is used (Fig. 2 and 3), make sure that the two prongs of the jumper face the center of the controller.

OPERATION AND SETTING

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.

R4184D PROTECTORELAY™ CONTROL

CAD CELL

SOLID STATE

SWITCH

SAFETY SWITCH

HEATER

1K1

HIGH LIMIT

MAKES R-B, BREAKS R-W ON TEMPERATURE FALL.

BREAKS ON TEMPERATURE RISE.

B TERMINALS ARE TAB TERMINALS.

LOW LIMIT/CIRCULATOR

JUMPER

M8874A

Fig. 2. Internal wiring of L6081A.

JUNCTION BOX

BLACK

1K2

ORANGE

WHITE

L1 (HOT)

BURNER MOTOR

OIL VALVE

IGNITION

CIRCULATOR

24V THERMOSTAT

2 4 3 1

RA89A SWITCHING RELAY

Fig. 3. Typical L6081A hookup.

WARNING

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

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

Low Limit and Circulator Controls

On a temperature rise, with the adjustable differential at the minimum setting of 10°F (6°C), the burner circuit R-B breaks and the circulator control R-W makes at the

1R1

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 temperature are the setpoint temperature plus the difference between the differential setting and 10°F (6°C).

L6081A

POWER SUPPLY. PROVIDE DISCONNECT

MEANS AND OVERLOAD PROTECTION AS REQUIRED.

B TERMINALS ARE TAB TERMINALS.

JUMPER ADDED

3 95-6701—5

M8855

Page 4

L6081A AQUASTAT® CONTROLLER

WELL CLAMP

STRIP

SCREW

GAUGE

LOW LIMIT/ CIRCULATOR DIFFERENTIAL ADJUSTMENT

LOW LIMIT SETPOINT ADJUSTMENT

HIGH LIMIT SETPOINT ADJUSTMENT

JUMPER SLOT

M8848

Fig. 4. Internal view of L6081A.

Example: 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).

Setting Stop

The 126580 Setting Stop may be installed on the adjusting knob to prevent turning the knob beyond a predetermined point. Fig. 6 shows the stop installed on the knob of a high limit switch at a setpoint of 180°F (82°C). 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 so the arm of the setting stop (after stop is pressed into place) strikes projection A and prevents turning the knob beyond the desired limit setting.

IMPORTANT:

Be extremely careful when installing the setting stop. It cannot be reset once it is in place. If the stop must be removed, snip it off with cutters; do not twist off.

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

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

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

240°F (116°C)

SWITCH BREAKS ON

HIGH LIMIT SETTING

LOW LIMIT AND CIRCULATOR SETTING

10°F (6°C) DIFFERENTIAL

25°F (14°C) DIFFERENTIAL

10°F (6°C) DIFFERENTIAL

110°F (43°C)

L6081A,C

Fig. 5. Relationship of setpoints and differential

SETTING STOP

SETTING STOP ARM

adjustments.

KNOB SET AT 180°F (82°C)

RISE. BURNER TURNS OFF. CIRCULATOR OPERATES ON A CALL FOR HEAT.

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

SWITCH MAKES R-W AND BREAKS R-B ON RISE. 25°F (14°C) DIFFERENTIAL.

SWITCH MAKES R-W AND BREAKS R-B ON RISE. 10 DIFFERENTIAL.

SWITCH MAKES R-B AND BREAKS R-W ON FALL. BURNER IS ON; CIRCULATOR IS OFF.

200

220

°F (6°C)

M8875

180

160

PROJECTION "A"

SCALE MARKINGS IN FAHRENHEIT ONLY.

Fig. 6. Setting stop installed to prevent turning high

limit setting beyond 180°F (82°C).

140

M2844

CHECKOUT

Put system into operation. Carefully observe the operation of all components for at least one complete cycle.

$XWRPDWLRQDQG&RQWURO6ROXWLRQV $XWRPDWLRQDQG&RQWURO6ROXWLRQV

+RQH\ZHOO +RQH\ZHOO/LPLWHG+RQH\ZHOO/LPLWpH 'RXJODV'ULYH1RUWK '\QDPLF'ULYH *ROGHQ9DOOH\01 6FDUERURXJK2QWDULR

95-6701—5 G.R. Rev. 12-01 www.honeywell.com

09=

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