Honeywell L8148J1009 Aquastat Relays

INSTALLATION INSTRUCTIONS - Transcript

• Page 1 - English - : US Registered Trademark Copyright 2002 Honeywell All Rights Reserved INSTALLATION INSTRUCTIONS 95 6940 12 L8148AEJ Aquastat Relays APPLICATION The L8148AEJ Aquastat Relays are immersiontype controllers for use with forced hydronic heating systems The combination high limit and intermediate switching relay works with a low voltage 24V thermostat to control burner and circulator circuits A call for heat by the thermostat starts both the burner and the circulator When boilerwater temperature exceeds the highlimit settings the burner circuit is broken the circulator continues to operate during the thermostat call for heat The L8148A controls linevoltage burner circuits the L8148EJ control lowvoltage burner circuits the L8148J controls millivoltage burner circuits All models control linevoltage circulator circuits L8148AEJ have provisions for adding lowlimit controllers L8148EJ can power valves in multizone systems L8148E is available with a plug and 50 VA transformer for use with Honeywell Smart Valve SV9500SV9600 SPECIFICATIONS Electrical Ratings Table 1 Circulator Control Circuit A Table 2 Burner Control Circuit Scale Range 140F to 240F 60C to 116C or 180F to 240F 82C to 116C Differential Nonadjustable High Limit Dial Stop Adjustable Maximum Pressure on Immersion Well 255 psi 1758 kPa Maximum Ambient Temperature 150F 66C with 12A 24V load 77F 25C with 14A 24V load Maximum Bulb Temperature 40F over setpoint up to 265F 4C over setpoint up to 129C Thermostat Heat Anticipator Setting 02A Material Safety Data Sheets MSDS For information on heatconductive compound see form number 690955 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 severe injury death or property damage This product is intended for use only in systems with a pressure relief valve Type 120 Vac 240 Vac Full Load 74 37 Locked Rotor 444 227 Model No Voltage Electrical Rating L8148A Line Same as circulator control circuit L8148EJ Low 08A maximum at 24 Vac
• Page 2 - English - : L8148AEJ AQUASTAT RELAYS 95694012 WARNING Electrical Shock Hazard Can cause severe injury death or property damage 1 Disconnect power supply before beginning installation to prevent electrical shock or equipment damage 2 Never apply a jumper across or short terminals B1 B2 or B3 This burns out the transformer Mounting The L8148AJ has a case that can be converted to either horizontal or vertical mounting Fig 1 Fig 1 Case is designed for vertical or horizontal mounting New Installation Order well assemblies and 124904 Well Adapter for the Aquastat Relay separately refer to form 680040 Wells and Fittings for Temperature Controllers Boilers usually have tappings that allow the well to be mounted horizontally so boiler water of average temperature can circulate freely 1 Turn off all power and drain the boiler 2 If no tapping is provided prepare properly sized and threaded tapping near the top of the boiler 3 Coat the well threads sparingly with pipe dope install the well in the boiler tapping and tighten securely NOTE Do not attempt to tighten by using the case as a handle 4 Refill boiler and check for water leakage 5 Insert the bulb element into the well until it bottoms If necessary slightly bend the tube inside the case to hold the bulb against the bottom of the well 6 Center the loop of excess tubing in front of the immersion well so it cannot touch any electrical parts NOTE Some models have an adjustable tubing length to 3 in 76 mm For these models pull out extra tubing from inside the case if needed 7 Fit the case into the well so the clamp on the case slides over the flange on the well IMPORTANT Best thermal response is obtained with a well that snugly fits the sensing bulb Insert the bulb until it rests against the bottom of the well Use a well of correct length and bend the tubing if necessary to hold the bulb against the bottom of the well but do not make a sharp bend in the tubing If the well is not a snug fit on the bulb use the heatconductive compound furnished with TRADELINE models as follows Fold the plastic bag of compound lengthwise and twist it gently Then snip off end of bag and work the open end of bag all the way into the well Slowly pull the bag out while squeezing it firmly to distribute compound evenly in the well Bend the tubing if necessary to hold the bulb against the bottom of the well and to hold outer end of the bulb in firm contact with the side of the well See Fig 2 Wipe excess compound from the outer end of the well Replacement Installation Turn off all power and remove the old control Refer to the cover insert of the old control to identify and tag each external lead as it is disconnected If old well is unsuitable for new installation remove it and proceed with instructions for new installation If old well is suitable use it and a 124904 immersion well adapter ordered separately from form 680040 Wells and Fittings for Temperature Controllers for the installation If the well clamp fits directly over the flange of the existing well spud adapter use is not necessary The adapter has a flange at the wide end that fits into the well clamp and is slotted lengthwise to accommodate both the capillary tube and the short length of tube extending from the bulb 1 Loosen but do not remove the well clamp screw on the side of the control case 2 Pull out the capillary until the bulb bottoms in the well Place adapter if used around the capillary tube so it fits into the slot See Fig 2 Center the loop of excess capillary tubing in front of the immersion well so it cannot touch any electrical parts NOTE Some models have a tubing length adjustable to 3 in 76 mm For these models extra tubing inside the case can be pulled out if needed 3 Make sure the wide end of the adapter fits into the hole in the case Position immersion well clamp snugly over the flange on the adapter and tighten the clamp screw 4 Insert sensing bulb into well as shown in Fig 2 Distribute the heatconductive compound in the tube prior to bulb insertion 5 Securely tighten setscrew if present on old well against adapter BRACKET POSITION FOR VERTICAL MOUNTING BRACKET POSITION FOR HORIZONTAL MOUNTING M8890
• Page 3 - English - : L8148AEJ AQUASTAT RELAYS 3 95694012 Fig 2 Proper position of sensing bulb in immersion well and use of well adapter in existing well WIRING IMPORTANT The terminals of these Aquastat Relays are approved for use with copper wire only WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before making wiring connections to prevent electrical shock or equipment damage All wiring must comply with local electrical codes and ordinances Do not exceed the specifications in the Application section when applying this control L8148J can power up to two V8043 Zone Valves Additional valves in groups of two or less require an additional transformer Follow the appropriate wiring diagrams when using zone valves or a low limit controller See Fig 3 through 7 If the B1 terminal on the device being replaced is a 14 in tab terminal use the existing wiring harness terminals to install the replacement device If the B1 terminal on the device being replaced is a screw terminal insert the provided tab terminal to screw terminal adapter onto the 14 in tab terminal of the replacement device After the adapter is installed reuse the existing wraparound wire end to make an electrical connection to the B1 terminal CAUTION Equipment Damage Hazard Can cause incorrect operation 1If L8148EJ are used to power zone valves low voltage 24 Vac load must not exceed 14A a 12A load is the maximum permissible when ambient temperature exceeds 77F 25C Use additional transformers when load exceeds these ratings 2When L8148E is used to power SV9500 SV9600 use separate transformer to power zone valves CONTROLLER CASE IMMERSION WELL CLAMP ADAPTER IMMERSION WELL SPUD BOILER OLD IMMERSION WELL ASSEMBLY BACK OF CONTROLLER CASE IMMERSION WELL CLAMP SCREW ADAPTER SENSING BULB HEATCONDUCTIVE COMPOUND SETSCREW CAPILLARY TUBE C IMMERSION WELL CLAMP IMMERSION WELL CLAMP SCREW SHORT TUBE FITS IN CENTRAL RECESS OF ADAPTER 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 M8830 D B A
• Page 4 - English - : L8148AEJ AQUASTAT RELAYS 95694012 Fig 3 External connections and internal schematic for L8148A Fig 4 Internal schematic and external connections for L8148J with either low voltage or millivoltage gas valves Low limit added in hookup with 24V gas valve C1 C2 B1 B2 R W B G L1 L2 T T B R L1 L2 G T T3 C1 C2 B2 B1 JUMPER 1K 1K2 1K1 B R L6006 LOW LIMIT CONTROLLER L1 HOT L2 24V THERMOSTAT L8148A HIGH LIMIT TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE CIRCULATOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOADPROTECTION AS REQUIRED REMOVE JUMPER WHEN ADDING L6006 LOW LIMIT CONTROLLER CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED B1 IS 14 IN TAB TERMINAL M2842A L8148A L1 HOT L2 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED REMOVE ZW JUMPER IF SERIES 60 LOW LIMIT IS USED WIRE LOW LIMIT CONTROLLER OR ZONE VALVES AS SHOWN USE WITH 24V B1B3 CIRCUIT ONLY FOR 24V BURNER WIRE B1B3 AND USE JUMPER ZW AND TPZ FOR POWERPILE MILLIVOLTAGE GAS VALVES REMOVE JUMPER TPZ AND WIRE BURNER B1B2 JUMPER ZW REMAINS IN POSITION CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED B1 IS 14 IN TAB TERMINAL L6006 LOW LIMIT CONTROLLER POWERPILE MILLIVOLTAGE GAS VALVE PP PP TH2 TH1 W R R R B B B 24V THERMOSTAT L8148J CIRCULATOR G G L1 L1 L2B3B2B1 HIGH LIMIT TP TV T W Z C1 C2 TR TH THTR LOW VOLTAGE GAS VALVE eg VR8300 1K3 TP Z WT TV 1K2 AUTO MANUAL SWITCH 1K1 C1 C2 B3 B2 B1 L2 L8148J M1793B
• Page 5 - English - : L8148AEJ AQUASTAT RELAYS 5 95694012 Fig 5 Wiring L8148A in oilfired forced hot water tankless zoned pump system Fig 6 Wiring L8148E1265 with internal plug directly to vent damper in hydronic intermittent pilot system TT TT TT GL2L1 T T C1 C2 B2 B1 F F T T L1 HOT L2 PUMP PUMP PUMP T87F T87F T87F R845 RELAY R845 R845 C554 R8184G BURNER AND IGNITION ORANGE WHITE BLACK POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED B1 IS 14 IN TAB TERMINAL L8148A M2843A 24V GND 24V S8600 L1 HOT L2 L8148E1265 FUSE 6PRONG FEMALE MOLEX RECEPTABLE IN L8148E AND 5PRONG MALE MOLEX PLUG ON CABLE 1K1 B1 B2 L1 C1 C2 L2 CIRCULATOR POLARIZED 4PRONG MALE MOLEX PLUG AND 4PRONG FEMALE MATING PLUG ON CABLE 24 VAC THERMOSTAT D892M892 4 197516A CABLE POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED REMOVE PLUGIN THAT JUMPERS PINS 2 AND 3 WHEN USING VENT DAMPER AFTER VENT DAMPER IS PLUGGED INTO L8148E1265 FUSE BLOWS WHEN THERMOSTAT FIRST CLOSES AFTER FUSE BLOWS L8148E1265 OPERATES ONLY WHEN VENT DAMPER IS CONNECTED SEE VENT DAMPER PRODUCT SPECIFICATIONS FOR INTERNAL SCHEMATICS B1 IS 14 IN TAB TERMINAL M2763C 1K2 HIGH LIMIT CONTROLLER R B TV W T 1K Z
• Page 6 - English - : L8148AEJ AQUASTAT RELAYS 95694012 Fig 7 Wiring L8148J for multizone control OPERATION AND SETTING High Limit The high limit switch shuts off the burner when the boiler temperature exceeds highlimit setting Because heating systems differ the correct temperature setting for one system might not be correct for another Follow the boiler manufacturer recommendation for proper setting To set remove cover and turn dial until the desired setting is directly below the pointer The dial stop is factoryset at the high end of the limit scale To adjust use a small screwdriver to hold the stop away from the dial face and turn the dial until the desired setting is below the pointer See Fig 8 Release pressure on screwdriver and make sure the stop rests flat against the dial face WARNING Explosion Hazard Can cause severe injury death or property damage This product is intended for use only in systems with a pressure relief valve Switching Relay The switching relay is controlled by the room thermostat On a call for heat the relay coil is energized completing the line voltage circulator circuit and also the burner circuit if the boiler water temperature is below the high limit setting AutoManual Switch The AUTOMANUAL switch only L8148J millivolt models makes it possible to operate the burner in a system with a millivoltage gas valve during an electrical power failure With switch at MANUAL the burner operates continuously until either the high limit setting is reached or the switch is reset to AUTO The circulator requiring line voltage is inoperative When power is restored the switch must be set to AUTO to resume automatic burner operation L1 HOT L2 END SWITCH END SWITCH END SWITCH TV TP W Z T B1 B2 B3 C1 C2 L1 L2 G 4 4 TH1 PP TH2 PP TR TH THTR LOW VOLTAGE GAS VALVE eg VR8300 MILLIVOLTAGE GAS VALVE POWERPILE L1 HOT L2 CIRCULATOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED L8184J POWERS TWO V8043E OR F ZONE VALVES OR ONLY ONE V8043 WHEN AMBIENT TEMPERATURE EXCEEDS 77 o F 25 o C USE AN ADDITIONAL TRANSFORMERS TO POWER ADDITIONAL VALVES LINK MUST BE USED WHEN USING 24 VOLT GAS VALVE HOOKUP B1B3 REMOVE LINK WHEN MILLIVOLTAGE GAS VALVE IS USED B1B2 ADD JUMPER CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED B1 IS 14 IN TAB TERMINAL 24 VOLT THERMOSTAT 24 VOLT THERMOSTAT 24 VOLT THERMOSTAT ZONE 3 ZONE 2 ZONE 1 L8148J V8043F V8043F V8043F M2887A
• Page 7 - English - : L8148AEJ AQUASTAT RELAYS 7 95694012 Fig 8 Setting high limit stop CAUTION Equipment Damage Hazard Improper procedure will damage equipment Never apply a jumper across or short terminals B1 B2 or B3 This burns out the transformer CHECKOUT Put the system into operation and observe through at least one complete cycle to be sure control operates as described above INSERT CORNER OF SMALL SCREWDRIVER IN THIS NOTCH AND PRY STOP UPWARD FROM DIAL FACE WHILE HOLDING STOP AWAY FROM DIAL FACE WITH SCREWDRIVER TURN DIAL UNTIL DESIRED HIGH LIMIT SETTING IS ALIGNED WITH POINTER RELEASE SCREWDRIVER MAKE SURE HIGHLIMIT STOP RESTS FLAT AGAINST DIAL FACE POINTER HIGH LIMIT STOP DIAL FACE M8889