Honeywell R8182D, R8182H Installation Manual

R8182D,H Combination

Protectorelay™ Primary Control

®

and Aquastat

Controller

INSTALLATION INSTRUCTIONS

APPLICATION

The R8182D,H Controllers combine a Protectorelay™
Primary Control and an Aquastat® Controller for use in
oil-fired, hydronic heating systems. The Aquastat
Controller provides high and low limit protection,
circulator control, and minimum water temperature
control for tankless domestic hot water service.

The Protectorelay Primary Control provides control of a
line voltage, intermittent ignition oil burner when used
with a C554A Cadmium Sulfide Flame Detector and a
24V thermostat.

The auxiliary ZC and ZR terminals provide zone control
through an R845A Switching Relay. Each additional zone
requires a separate 24V thermostat and an R845A Relay.

The R8182D,H also provide zone control using zone
valves. Each additional zone requires a separate 24V
thermostat and a V8043 or V8044 Zone Valve. The
R8182D,H can be converted to provide only the high-limit
to replace an R8182B,E or only the limit and circulator
function to replace of the R8182C,F.

The R8182D mounts directly on the boiler. The R8182H
mounts on a 4 by 4 in. junction box and has a 5 ft. (1.5m)
capillary that allows a remote sensor location.

The R8182D includes

• Bag of heat-conductive compound for better heat
transfer.

• High- and low-limit setting stops.

• One wire nut.

To order an immersion well or a well adapter, see form
68-0440, Wells and Fittings for Temperature Controllers,
for part numbers and descriptions.

INSTALLATION

WARNING

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

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

When Installing this Product…

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

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

3. Be sure the installer is a trained, experienced ser­vice technician.

4. After completing installation, use these instructions
to check product operation.

WARNING

Electrical Shock Hazard and Explosion
Hazard.
Can cause severe injury, death or equipment
damage.

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

2. Be sure that combustion chamber is clear of oil
or oil vapor before starting burner.

3. Be sure that the ambient temperature at the
element does not exceed 250°F (121°C).

IMPORTANT

Be sure that the sensing bulb fits snugly inside
the immersion well and that the sensing bulb
rests against the bottom of the immersion well.
If the sensing bulb does not fit snugly inside the
immersion well, use the heat-conductive
compound as described below. See Fig. 3.

Mounting the R8182D

See Fig. 1 for R8182D installation dimensions and Fig. 4
for an internal view of the R8182D.

If existing immersion well does not fit the R8182D
immersion well clamp, use a 124904 Immersion Well
Adapter, ordered separately from form 68-0040.

1. Disconnect power supply.

2. Drain all water from boiler.

3. Fasten R8182D immersion well clamp to flange on

immersion well adapter. See Fig. 3.

4. Place adapter on capillary tube.

5. Put adapter end into hole in controller case and

tighten clamp screw.

® U.S. Registered Trademark
Copyright © 2002 Honeywell • All Rights Reserved

69-0599-2

R8182D,H COMBINATION PROTECTORELAY™ PRIMARY CONTROL AND AQUASTAT® CONTROLLER

6. Insert sensing bulb into the immersion well and, if
necessary, bend capillary tubing to hold sensing
bulb against bottom of immersion well.

NOTE: Do not make sharp bends in capillary tubing. In

models with an adjustable tubing length, pull the
extra tubing out of the controller case.

7. If necessary, apply heat-conductive compound into
the immersion well.
a. Fold plastic bag of heat-conductive compound

lengthwise and twist it gently.

b. Cut off end of plastic bag and work open end of

bag all the way into immersion well.

c. Slowly pull bag out of immersion well while

squeezing it firmly to distribute compound.

8. Wipe off any excess heat-conductive compound
and tighten set screw against adapter.

If the existing immersion well is not usable, remove the
existing immersion well and order a new one using form
68-0040.

1. Disconnect power supply.

2. Drain all water from boiler.

3. Install the new immersion well by threading it into

the threaded hole.

4. Loosen the immersion well clamp screw. See Fig.

3.

5. Insert sensing bulb into the immersion well and, if
necessary, bend capillary tubing to hold sensing
bulb against bottom of immersion well.

NOTE: Do not make sharp turns while bending the

capillary tubing. In models with an adjustable
tubing length, pull the extra tubing out of the
controller case.

6. If necessary, apply heat-conductive compound into
immersion well.
a. Fold plastic bag of heat-conductive compound

lengthwise and twist it gently.

b. Cut off end of plastic bag and work open end of

bag all the way into immersion well.

c. Slowly pull bag out of immersion well while

squeezing firmly to distribute compound.

7. Be sure immersion well fits hole in controller case.

8. Position immersion well clamp snugly over

immersion well flange. Tighten clamp screw
securely.

9. Refill boiler and check for water leakage.

7-1/8
(181)

3-9/16

(91)

3/16

(5)

Fig. 1. R8182D installation dimensions in in. (mm).

1/2 (13)

7/8
(22)

3-7/16

(87)

7-1/8

(181)

KNOCKOUTS
FOR 1/2 IN.
(13 MM)
CONDUIT (5)

2-7/16

(62)

1-5/16

(33)

VERTICAL
MOUNT
ONLY

HORIZONTIAL
MOUNT ONLY

5-1/4 (133)

1 VERTICAL MOUNT SHOWN.

3-3/8 (86)

1

KNOCKOUTS
FOR 1/2 IN. (13 MM)
CONDUIT (5)

3-1/4 (83)

M4517

1

Mounting the R8182H

See Fig. 2 for R8182H installation dimensions and Fig. 5
for an internal view of R8182H.

1. Disconnect power supply.

2. Drain all water from boiler.

3. Most boilers are equipped with a tapping that

allows horizontal mounting of immersion well
where average temperature boiler water circulates
freely. If no tapping is provided, prepare one.

4. Install immersion well or compression fitting
(ordered separately) by threading into tapped hole.

5. Loosen screw holding hinged backplate to
controller case and swing backplate away from
case.

6. Screw backplate to 4 by 4 inch junction box.

69-0599—2 2

1 SIDE MOUNTED HINGE SHOWN.

5-1/4 (133)

3-7/16 (87)

M4518

Fig. 2. R8182H installation dimensions in in. (mm).

7. Insert sensing bulb into immersion well and, if

necessary, bend capillary tubing to hold sensing
bulb against bottom of immersion well.

NOTE: Do not make sharp turns while bending the

capillary tubing. In models with an adjustable
tubing length, pull the extra tubing out of the
controller case.

R8182D,H COMBINATION PROTECTORELAY™ PRIMARY CONTROL AND AQUASTAT® CONTROLLER

8. If necessary, apply heat-conductive compound into
the immersion well.
a. Fold plastic bag of heat-conductive compound

lengthwise and twist it gently.

b. Cut off end of plastic bag and work open end of

bag all the way into the immersion well.

c. Slowly pull bag out of the immersion well while

squeezing it firmly to distribute compound.

9. Tighten the immersion well screw over brass collar.

10. After wiring, swing control case against backplate

and refasten it with screw.

11. Refill the boiler and check for water leakage.

(C)

2

CONTROLLER
CASE

ADAPTER

CAPILLARY
TUBE

SETSCREW

IMMERSION
WELL CLAMP SCREW

IMMERSION
WELL CLAMP

IMMERSION
WELL SPUD

BOILER

1

SHORT TUBE
FITS IN CENTRAL
RECESS OF ADAPTER

(A)

Fig. 3. Positioning the sensing bulb in the immersion well.

SAFETY SWITCH
RESET BUTTON

TRANSFORMER
FOR THERMOSTAT
CIRCUIT

WIRING

IMPORTANT

• Use Underwriters Laboratories Inc. listed
connectors when making external circuit
connections to the orange and white line votage
burner and ignition leadwires of the R8182H.

• Terminals on the R8182 are approved for
copper wire only.

BACK OF

CONTROLLER

CASE

IMMERSION
OLD IMMERSION
WELL ASSEMBLY

HEAT-CONDUCTIVE COMPOUND

1

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

2

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).

WELL CLAMP

SCREW

GROUNDING SCREW

ADAPTER

IMMERSION
WELL CLAMP

SENSING
BULB

SAFETY SWITCH
RESET BUTTON

(D)

(B)

TRANSFORMER
FOR THERMOSTAT
CIRCUIT

M8830

HIGH LIMIT
SETTING

CAD CELL
LEADS (YELLOW)

TRANSFORMER FOR
CAD CELL CIRCUIT

Fig. 4. Internal view of R8182D.

DIFFERENTIAL
SETTING

CIRCULATOR
RELAY (1K)

BURNER MOTOR
AND IGNITION
RELAY (2K)

LOW LIMIT
SETTING

VOLTAGE BARRIER

M4524

DIFFERENTIAL
SETTING

CIRCULATOR
RELAY (1K)

BURNER MOTOR
AND IGNITION
RELAY (2K)

LOW LIMIT
SETTING

VOLTAGE BARRIER

HIGH LIMIT
SETTING

TRANSFORMER FOR
CAD CELL CIRCUIT

M4525

Fig. 5. Internal view of R8182H.

3 69-0599—2

R8182D,H COMBINATION PROTECTORELAY™ PRIMARY CONTROL AND AQUASTAT® CONTROLLER

A

WARNING

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

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

All wiring must comply with local codes, regulations, and
ordinances.

Follow the wiring instructions furnished by the appliance
manufacturer, if available, or see Fig. 6 through 9. For
wiring multiple zoning systems, see Fig. 8 and 9.

The R8182 is equipped with special wiring terminals.
Wires can be wrapped around the terminal screw or
inserted from side.

Method 1

1. Strip 7/16 in. of insulation from
wire end.

2. Wrap wire 3/4 of distance
around screw as shown.

3. Using a standard, flat-head
screwdriver, tighten screw until
wire is snugly contacting screw
and contact plate.

4. Tighten screw an additional half turn.

USING THE TRADELINE® R8182D
TO REPLACE R8182F:

1. REMOVE BLUE WIRE FROM
THIS TERMINAL AND INSULATE
END TO PREVENT CONTACT.

2. REMOVE OTHER BLUE WIRE
FROM THIS TERMINAL AND
CONNECT AS SHOWN BELOW.

3. CONNECT CIRCULATOR TO
ZC AND C2.

BLUE

COMPLETED
WIRING TO
REPLACE
R8182C,F

H

I

WHITE

L

O

M8843

Method 2

1. Strip 5/16 in. of insulation from
wire end.

2. Insert wire beneath screw as
shown.

3. Follow steps 3 and 4 in Method

1.

NOTE: Do not use a push-type

ratchet screwdriver.

The TRADELINE® R8182D,H can be converted to
replace an R8182B,C,E,F or a White Rodgers 6C92-2 or
6C92-3. When replacing a White Rodgers model, the
immersion well must also be replaced. See Fig.5 for
Aquastat limit connections necessary for each R8182D,H
conversion.

To release the wires from the R8182, insert a screwdriver
into the rectangular hole adjacent to the wire, push
inward to release the locking-grip on the wire, and pull
the wire out of the terminal hole.

To reinsert the wire into a new terminal hole, simply push
the wire into the new slot.

USING THE TRADELINE® R8182D
TO REPLACE R8182B,E OR
WHITE RODGERS 6C92:

1. REMOVE WHITE ABD BLACK
LEADS FROM THEIR TERMINAL
AND CONNECT WITH A
SODDERLESS CONNECTOR.

TO USE TRADELINE® R8182H
TO REPLACE R8182J:

1. REMOVE RED AND WHITE
LEADS FROM THEIR TERMINALS
AND CONNECT WITH A
SOLDERLESS CONNECTOR.

H

I

BLUEBLUE

COMPLETED WIRING
TO REPLACE
R8182B,E AND

WHITE RODGERS 6C92
L
O

M4516

YELLOW

BLACK

Fig. 6. Converting R8182D,H to replace other controls.

69-0599—2 4

YELLOW

BLACK
OR RED

M4526