Honeywell R8182F User's Manual
Contents
1. Device Description Part Number R8182F 1 1 2 in 38 mm insulation horizontal or vertical 3 in 76 mm insulation horizontal 125017AAB 3 in 76 mm insulation vertical 125017AAC R8182H 1 1 2 in 38 mm insulation 125026AAJ R8182J 123726AT Dial Stop For restricting range part no 4074BRR for R8182D F H SAFETY SWITCH Optional Specifications R8182D E F Case with long dimension horizontal R8182H J End mounted hinge SAFETY SWITCH ES GROUNDING SCREW RESET BUTTON g7 TRANSFORMER FOR THERMOSTAT CIRCUIT SETTING RELAY 1K RELAY 2K DIFFERENTIAL CIRCULATOR BURNER MOTOR AND IGNITION A GROUNDING SCREW 5 Em GA Zi 1 Ac 1 a RESET BUTTON TRANSFORMER FOR THERMOSTAT CIRCUIT AQUASTAT SWITCH CIRCULATOR RELAY 1K BURNER MOTOR AND IGNITION RELAY 2K YES voca BARRIER Cf LOW LIMIT SETTING VOLTAGE BARRIER TRANSFORMER FOR CAD CELL CIRCUIT HIGH LIMIT SETTING M4532 Fig 5 Internal view of R8182E HIGH LIMIT SETTING TRANSFORMER FOR CAD CELL CIRCUIT M4525 Fig 4 Internal view of R8182D 68 0105 2 GROUNDING SCREW SAFETY SWITCH RESET BUTTON HIGH LIMIT SETTING BURNER MOTOR AND IGNITION RELAY 2K LOW LIMIT SETTING TRANSFORMER FOR CAD CELL CIRCUIT VOLTAGE BARRIER M4515 Fig 6 Internal2. STARTUP AND CHECKOUT A 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 Because heating systems differ the correct temperature setting for one system may not be correct for another Follow the boiler manufacturers recommendations for proper selection of settings High Limit Setting All Models 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 15 F 8 C with R8182E J differential Set the indicator at the desired shutoff temperature 68 0105 2 14 Low Limit Circulator Setting D And H Models 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 circuit R W makes at the low limit setpoint See Fig 19 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 remains the same 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 EXAMPLE Setpoint of 140 F 60 C differential set at 2
3. SWITCH BREAKS ON TEMPERATURE RISE BURNER TURNS OFF CIRCULATOR OPERATES lt ON A CALL FOR HEAT SWITCH MAKES ON TEMPERATURE FALL lt BURNER OPERATES ON A CALL FOR HEAT lt SWITCH MAKES R W AND BREAKS R B ON TEMPERATURE RISE lt SWITCH MAKES R W AND BREAKS R B ON TEMPERATURE RISE SWITCH MAKES R B AND BREAKS R W ON TEMPERATURE FALL BURNER IS ON TO MAINTAIN MINIMUM WATER TEMPERATURE CIRCULATOR IS OFF M1523 Fig 18 R8182D H Aquastat limit switching 240 F 116 C HIGH LIMIT SETTING 15 F 8 C DIFFERENTIAL 180 F 82 C R B BREAKS ON TEMPERATURE RISE BURNER TURNS OFF CIRCULATOR OPERATES lt 4 ON A CALL FOR HEAT lt R B MAKES ON TEMPERATURE FALL BURNER AND CIRCULATOR OPERATE ON A CALL FOR HEAT M1510 Fig 19 R8182E J Aquastat limit switching 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS 240 F 116 C 10 F j DIFFERENTIAL 10 F DIFFERENTIAL 110 F 43 C HIGH LIMIT SETTING lt q R B BREAKS ON TEMPERATURE RISE BURNER TURNS OFF lt q R B MAKES ON TEMPERATURE FALL BURNER OPERATES ON CALL FOR HEAT CIRCULATOR SETTING J R W MAKES ON TEMPERATURE RISE CIRCULATOR TURNS ON lt R B BREAKS ON TEMPERATURE FALL CIRCULATOR TURNS OFF M1509 Fig 20 R8182F Aquastat limit switching
4. pull the extra tubing out of the controller case Apply heat conductive compound into the immersion well if necessary a Fold the plastic bag of heat conductive compound lengthwise and twist it gently b Cutoffthe end of the plastic bag and work the open end of the bag all the way into the immersion well c Slowly pull the bag out of the immersion well while squeezing it firmly to evenly distribute the heat conductive compound Be sure the immersion well fits the hole in the controller case Position the immersion well clamp snugly over the immersion well flange Securely tighten the clamp Screw Refill the boiler and check for water leakage R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS CONTROLLER Pa CASE IMMERSION WELL CLAMP i IMMERSION UA S WELL DON estia n T NSNR IR RE IS 4 o CAPILLARY TUBE 7 rem ED ZZZzZ2zz SETSCREW 4 IMMERSION WELL CLAMP SCREW SHORT TUBE FITS IN CENTRAL E RECESS OF ADAPTER IEEE KK RO LOOK KIS OX X XX XC XXX XXX XXX XXX KIYOD BACK OF IMMERSION CONTROLLER WELL CLAMP CASE Ni A ADAPTER IMMERSION OLD IMMERSION WELL CLAMP SENSING WELL ASSEMBLY SCREW BULB TNX RISSA ee NG HEAT CONDUCTIVE COMPOUND 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
5. TENSION OF THE CAPILLARY TUBE AT POINT C HOLDS THE SENSING BULB IN GOOD THERMAL CONTACT WITH THE IMMERSION WELL AT POINT D M8830 Fig 9 Positioning the sensing bulb in the immersion well WIRING IMPORTANT Use Underwriters Laboratories Inc listed connectors when making external circuit connections to the orange and white line voltage burner and ignition leadwires of the R8182H J A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before wiring to prevent electrical shock or equipment damage All wiring must comply with local codes regulations and ordinances IMPORTANT Terminals on the R8182 are approved for copper wire only Follow the wiring instructions furnished by the appliance manufacturer if available or refer to Fig 11 through 17 For wiring multiple zoning systems refer to Fig 16 and 17 The R8182 is equipped with special wiring terminals Wires can be wrapped around the terminal screw or inserted from the side Method 1 1 Strip 7 16 in of insulation from the wire end 2 Wrap the wire 3 4 of the distance around the screw as shown in method 1 3 Using a standard flat headed screwdriver tighten the screw until the wipe is snugly in contact with the screw and contact plate 4 Tighten the screw pin an additional one half turn Method 2 1 Strip 5 16 in of insulation from the wire end 2 Insert wire beneath the screw as sho
6. the best of our knowledge Prepared By PROSAR 1295 Bandana Boulevard Suite 335 St Paul MN 55108 651 917 6100 68 0105 2 68 0105 2 18 19 68 0105 2 Honeywell Automation and Control Solutions Honeywell Honeywell Limited Honeywell Limit e 1985 Douglas Drive North 35 Dynamic Drive Golden Valley MN 55422 Scarborough Ontario MIV 4Z9 Printed in U S A on recycled 68 0105 2 G R Rev 1 02 paper containing at least 10 post consumer paper fibers www honeywell com building components
7. 5 F 14 C On a temperature rise R B breaks and R W makes at 155 F 68 C On a temperature fall R B makes and R W breaks at 130 F 54 C Set the low limit indicator at the minimum temperature recommended for domestic hot water supply This setting must be at least 20 F 11 C below the high limit setting to prevent one switch from locking out the other Set the differential the desired number of degrees Circulator Setting F Models Set the circulator indicator at the minimum water temperature recommended for hydronic heating comfort Setting Stops R8182D H TRADELINE Part no 126580 Setting Stops can be installed on the low and high limit adjusting knobs to prevent turning the knobs beyond a predetermined point To install the setting stops proceed as follows IMPORTANT Once the setting stops are in place they cannot be replaced If they must be removed cut off with cutters do not twist off 1 On low limit knob turn the knob to the setting that is to be established as the limit 2 Place the setting stop over the knob so that the arm of the setting stop after the stop is pressed into place strikes projection A and prevents turning the knob beyond the chosen limit setting See Fig 21 3 Press the setting stop tightly onto the knob so its inner teeth securely engage the knob 4 Turn knob back and forth several times to make sure stop functions properly 5 Repeat steps 1 to 4 for the high limit kno
8. AVE WHITE AND ORANGE LEADWIRES FOR OIL BURNER AND IGNITION CONNECTIONS A RED LEADWIRES PROVIDED ONLY ON MODLES WITH END SWITCH CHOOSE AT72 AT87 OR AT88 TRANSFORMER TO MATCH MAXIMUM SYSTEM LOAD 24 VOLT A USE V8043 OR V8044 ZONE VALVES WITH AUXILIARY END SWITCH ONLY M4522 THERMOSTAT C554A A 120 VAC POWER SUPPLY PROVIDE DISCONNECT MEANS i AND OVERLOAD PROTECTION AS REQUIRED Fig 16 R8182D E F H and J in a typical zoning M4529 PI application using zone valves Fig 15 R8182J internal schematic and wiring diagram 11 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS A ZONE 2 THERMOSTAT R845A SWITCHING RELAY ZONE 2 CIRCULATOR TO ADDITIONAL VANE VAC POWER SUPPLY PROVIDE DISCONNECT ZONES 3 4 ETC MEANS AND OVERLOAD PROTECTION AS REQUIRED ZA THERMOSTAT HEAT ANTICIPATOR SETTING 0 2 AMP FOR R8182D Z ATHERMOSTAT HEAT ANTICIPATOR SETTING 0 4 AMP FOR R845A Z ACONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED R8182E H J CONNECTIONS FROM ZC AND ZR ARE IDENTICAL FOR MULTIPLE CIRULATOR ZONING APPLICAITON EACH ADDITIONAL ZONE REQUIRES A SEPARATE FIELD ADDED 24V THERMOSTAT AND R845 RELAY 24 VOLT THERMOSTAT R8182D TO OIL BURNER AND IGNITION TO WATER CIRCULATOR SAFETY SWITCH HEATER M4521 Fig 17 R8182D and R845A in a typical multiple circulator zoning application OPERA
9. D CONNECT WITH A SO COMPLETED WIRING TO REPLACE R8182C F YELLOW YELLOW LDERLESS CONNECTOR BLUE COMPLETED WIRING TO REPLACE R8182B E AND WHITE RODGERS 6C92 M4526 Fig 10 Converting TRADELINE R8182D H to replace other controls 68 0105 2 8 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS R8182D TO OIL BURNER TO WATER CIRCULATOR ir IGNITION CIRCULATOR SSW CONTACTS SAFETY SWITCH HEATER 24 VOLT THERMOSTAT Gama A 120 VAC POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED WHEN THE BLACK AND WHITE WIRES ON THE TRADELINE R8182D AQUASTAT CONTROLLER ASSEMBLY ARE DISCONNECTED FROM THE CIRCULATOR SWITCH AND ARE INTERCONNECTED LOW LIMIT AND CIRCULATOR CONTROL ARE BYPASSED CIRCULATOR OPERATES WITHY THEROMSTAT ONLY A TO REPLACE R8182C F REMOVE BLUE WIRE AND INSULATE END DISCONNECT THE THE OTHER BLUE WIRE AT 4 AND WIRE TO B AT 3 WHEN CIRCULATOR IS CONNECTED BETWEEN ZC AND C2 LOW LIMIT FUNCTION IS REMOVED AND CIRCULATOR OPERATES WITH CIRCULATOR CONTROL R TO W ONLY A CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED M4519 Fig 11 R8182D internal schematic and wiring diagram R8182E TO OIL BURNER IGNITION TO WATER CIRCULATOR CONTACTS SAFETY SWITCH HEATER TRIAC BILATERAL SWITCH 24 VOLT 554A THERMOSTAT A 120 VAC POWER SUPPLY PROVIDE DISCO
10. 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 will 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 Refer to Fig 9 Mounting the R8182 1 Disconnect the power supply 2 Drain all water from the boiler 3 Generally boilers are equipped with a tapping that allows horizontal mounting of the immersion well where average temperature boiler water circulates freely If no tapping is provided prepare one 4 Install the immersion well or compression fitting ordered separately by threading the immersion well into the tapped hole 5 For R8182D E F models a Loosen the immersion well clamp screw on the side of the R8182 case b Insert the bulb into the immersion well until it bottoms c If necessary bend the capillary tube to hold the bulb against the bottom of the immersion well 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS NOTE Do not make sharp bends in the tubing A sharp bend can break the tubing and cause a loss of fill In models with an adjustable tubing length pull the extra tubing out of the controller case d Fitthe controller c
11. Honeywell R8182D E F H J Combination Protectorelay and Hydronic GENERAL The R8182 is a combination Protectorelay intermittent ignition oil burner primary and immersion type Aquastat controller for oil fired hydronic heating systems U S Registered Trademark Copyright 2002 Honeywell All Rights Reserved Heating Controls PRODUCT DATA FEATURES Depending on model these single unit devices provide combinations of high limit low limit and circulator control All models use a 24V thermostat and C554A Cadmium Sulfide Flame Detector R8182D E H and J have auxiliary terminals ZC and ZR for circulator zone control Additional zones require a separate 24V thermostat and R845 Relay All models have capability for zone control with zone valves Each additional zone requires a separate 24V thermostat and a V8043 or V8044 Zone Valve Ideal for packaged boiler systems requiring compact multipurpose controls R8182D E F mode R8182H J models mount on a 4 x 4 inch junction box and have a 5 ft 1 5m armored capillary for remote sensor location Aquastat Controller section is field replaceable Oil burner circuit includes an improved safety shutoff in the event the burner fails to start Flame failure during the running cycle results in a 45 second attempt to restart If unsuccessful safety shutoff occurs requiring manual reset before burner can be restarted Contents General d Rome eo t
12. NNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED M4527 Fig 12 R8182E internal schematic and wiring diagram 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS A R8182F TO WATER CIRCULATOR CIRCULATOR CONTROL TO AND IGNITION SAFETY SWITCH CONTACTS SAFETY SWITCH j HEATER 24 VOLT THERMOSTAT BILATERAL SWITCH NNV 120 VAC POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED M4528 Fig 13 R8182F internal schematic and wiring diagram 68 0105 2 10 L1 L2 HOT R8182H HIGH LIMIT TO OIL BURNER AND IGNITION TO WATER CIRCULATOR CONTACTS SAFETY SWITCH HEATER C554A 24 VOLT THERMOSTAT 120 VAC POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED M4520 Fig 14 R8182H internal schematic and wiring diagram R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS 24 VOLT 24 VOLT 24 VOLT THERMOSTAT THERMOSTAT THERMOSTAT R8182J HIGH LIMIT TO WATER CIRCULATOR E gz zZ 552 om MOTISA MOTISA ES TO OIL BURNER AND IGNITION CONTACTS SAFETY SWITCH HEATER CIRCULATOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED R8182H AND J H
13. Number Percent PEL TLV No 2 Lithium Complex Grease 7090 Mineral Oil 64742 65 0 35 50 5 mg m 5 mg m Mineral Oil 64742 62 7 20 25 5 mg m 5 mg m 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 15 mg m 10 mg m Aliphatic Petroleum Distillates 8052 41 3 10 15 2900 mg m 525 mg m Stearic Acid 57 11 4 1 2 Aromatic Petroleum Distillates 64742 95 6 1 2 5 mg m 5 mg m 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 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 lIngestion 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 Eye Contact Flush eyes with water for 15 minutes Remove any contact lenses and continue to flush Obtain medical attention if irritati
14. TION R8182D A call for heat by the thermostat pulls in relay 1K which energizes the safety switch circuit and relay 2K to turn on the burner Safety switch starts to heat If burner ignites within safety switch timing the cadmium sulfide flame detector sees flame and the safety switch heater circuit is bypassed The burner operates until the call for heat is satisfied The circulator operates when relay 1K pulls in only if R to W is made in the Aquastat limit When R to B low limit is made by a drop in water temperature it acts as a call for heat pulling in relay 2K to turn on the burner The circulator cannot operate See Fig 11 16 17 and 19 R8182E The burner and circulator operate whenever the thermostat calls for heat Relay 2K pulls in When the cadmium sulfide flame detector sees flame the safety switch heater circuit is bypassed and 2K is held in through 2K1 If temperature rises to a high limit setpoint R to B breaks shutting off the burner The circulator continues operation under the thermostat direction See Fig 12 16 17 and 20 68 0105 2 12 R8182F The thermostat call for heat pulls in relay 2K to turn on the burner When the cadmium sulfide the flame detector sees flame safety switch the heater circuit is bypassed The circulator is independent of the thermostat circuit being controlled only by the Aquastat limit switch See Fig 13 17 and 20 R8182H A call for heat by the thermostat pulls in r
15. 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 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 lll 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
16. ase onto the immersion well so that the immersion well clamp slides over the flange of the immersion well e Securely tighten the immersion well clamp screw 6 For R8182H J models a Loosen the screw holding the hinged backplate to the controller case and swing the backplate away from the controller case b Screw the backplate to a 4 by 4 inch junction box c Insert the bulb into the immersion well until it bottoms d If necessary bend the capillary tube to hold the bulb against the bottom of the immersion well NOTE Do not make sharp bends in the tubing A sharp bend can break the tubing and cause a loss of fill In models with an adjustable tubing length pull the extra tubing out of the controller case e Tighten the immersion well screw over the brass collar f After wiring swing control against the backplate and refasten with the screw 7T Refill the boiler and check for water leakage Mounting the R8182D TRADELINEG If the existing immersion well does not fit the R8182D immersion well clamp use a 1249094 immersion well adapter order separately see form 68 0040 Wells and Fittings for Temperature Controllers nA No 9 68 0105 2 Disconnect the power supply Drain all water from the boiler Fasten the R8182D immersion well clamp to the flange on the immersion well adapter Refer to Fig 9 Place the adapter on the capillary tube Put the adapter end into the hole in the controller case and tight
17. astat amp Controller Conversion to R8182E or F TRADELINE pack with special instructions Wire nut Mounting Means R8182D E F Case clamps to horizontal immersion well installed through boiler wall R8182H J Mounts on standard 4 x 4 inch junction box Dimensions Refer to Fig 1 and 2 Table 1 Standard Models Adjustable Control Range Differential Model Switching F C F C R8182D8 High Limit Spst 130 to 240 54 to 116 10 Fixed 6 Fixed High Limit Circulator Spdt 110 to 220 43 to 104 10 to 25 Adj 6 to 14 Adj R8182E High Limit Spst 180 to 240 82 to 116 15 Fixed 8 Fixed R8182F High Limit Spst 130 to 240 54 to 116 10 Fixed 6 Fixed Circulator Spst 110 to 220 43 to 104 10 Fixed 6 Fixed R8182H Remote Bulb High Limit Spst 130 to 240 54 to 116 10 Fixed 6 Fixed Low Limit Circulator Spdt 110 to 220 43 to 104 10 to 25 Adj 6 to 14 Adj R8182J Remote Bulb High Limit Spst 180 to 240 82 to 116 15 Fixed 8 Fixed Auxiliary ZC and ZR terminals can be used to provide circulator zone control through an R845A Switching Relay Electrical Ratings Power Supply 120 Vac 60 Hz Ignition 360 VA in addition to motor load rating Maximum Power Consumption R8182D E H and J 9W R89182F 5 5W Burner Circulator Contact Rating 4 4A full load 26 4A locked rotor at 120 Vac Safety Switch Timing Approximately 45 seconds Flame Detector Required C554A Cadmium Sulfide F
18. b After settings are made replace the cover R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS STOP ARM SETTING PROJECTION A ET SETTING STOP KNOB SET AT 140 F 60 C A SCALE MARKINGS IN FAHRENHEIT ONLY M4523 Fig 21 Setting stop in position to restrict low limit setting to 180 F 82 C or lower Startup A WARNING Explosion Hazard Can cause severe injury death or property damage Be sure combustion chamber is free of oil or vapor Push red reset button and release Open hand valve on oil supply line Set thermostat to call for heat Close line switch burner will start Under normal conditions burner operates until thermostat is satisfied or line switch is opened NANA MATERIAL SAFETY DATA SHEET MSDS SECTION 1 PRODUCT AND 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 15 Make certain the system operates as described in the OPERATION section Use the following procedure to verify that the Protectorelay burner sequencing relay is controlling properly Flame Failure Check Shut off the oil supply hand valve while the burner is on After 45 seconds the safety switch locks out the motor stops and the oil valve closes Allow five minutes for the burner to cool then manually reset
19. ee pp 1 uU e d 1 Specifications S e eee i eis 2 Ordering Information eker 2 Installation lt f dun Ieri tnr Citt 5 WINING iiiter cete ang E rr des ance Am an 7 ieozrudn 12 Startup and Checkout sseeeene 14 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS SPECIFICATIONS IMPORTANT The specifications given in this publication do not include normal manufacturing tolerances Therefore this unit may not exactly match the listed specifications Also this product is tested and calibrated under closely controlled conditions and some minor differences in performance can be expected if those conditions are changed TRADELINE Models TRADELINE models are selected and packaged for ease of handling ease of stocking and maximum replacement value TRADELINE model specifications are the same as those of standard models except as noted below TRADELINE Models Available R8182D Combination Protectorelay Primary Control and Aquastat Controller R8182H Combination Protectorelay Primary Control and Aquastat Controller Additional Features Well not included To order wells or well adapters refer to form 68 0040 Wells and Fittings for Temperature Controllers for part numbers and descriptions Heat conductive compound supplied for better bulb response in oversized well Field addable stops for Aqu
20. elay 1K which energizes the safety switch circuit and relay 2K to turn on the burner The safety switch starts to heat If the burner ignites within the safety switch timing the cadmium sulfide flame detector sees the flame and the safety switch heater circuit is bypassed The burner shuts Off when a call for heat is satisfied The circulator operates when relay 1K pulls in only if R to W in the Aquastat limit is made When R to B low limit is made by a drop in water temperature it acts as a call for heat pulling in relay 2K to turn on the burner The circulator cannot operate See Fig 14 16 17 and 18 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS R8182J The burner and circulator operate whenever the thermostat calls for heat Relay 2K pulls in When the cadmium sulfide flame detector sees flame the safety switch heater circuit is bypassed and 2K is held in through 2K1 If temperature rises to a high limit setpoint R to B breaks shutting off the burner The circulator continues operation under direction of the thermostat See Fig 15 16 17 and 19 Multizone Control In all multizone applications a call for heat in any zone energizes the safety switch circuit and relay 2K pulls in If the burner ignites within the safety switch timing the cadmium sulfide flame detector sees flame and the safety switch heater is bypassed In all multizone applications with R8182D and H the low limit contro
21. en the clamp screw Insert the sensing bulb into the immersion well and bend the capillary tubing if necessary to hold the sensing bulb against the bottom of the immersion well NOTE Do not make sharp turns while bending the capillary 8 tubing In models with an adjustable tubing length pull the extra tubing out of the controller case Apply the heat conductive compound into the immersion well if necessary a Fold the plastic bag of heat conductive compound lengthwise and twist it gently b Cutoffthe end of the plastic bag and work the open end of the bag all the way into the immersion well c Slowly pull the bag out of the immersion well while squeezing it firmly to evenly distribute the heat conductive compound Wipe off any excess grease and tighten the set screw against the adapter If the existing immersion well is not usable remove the existing immersion well and order a new one using form 68 0040 Wells and Fittings for Temperature Controllers ec o BR Disconnect the power supply Drain all water from the boiler Install the new immersion well by threading it into the threaded hole Loosen the immersion well clamp screw See Fig 9 Insert the sensing bulb into the immersion well and bend the capillary tubing if necessary to hold the sensing bulb against the bottom of the immersion well NOTE Do not make sharp turns while bending the capillary tubing In models with an adjustable tubing length
22. l in the Aquastat limit acts independently to turn on the main burner on a drop in water temperature When R to B low limit is made relay 2K pulls in to turn on the main burner the same as for single zone application Zone Circulator Control with R8182D H The relay for each zone is connected to the Aquastat limit through terminals ZC and ZR The R845 Relay and thermostat for each zone can energize the zone circulator through ZC only if R to W in the Aquastat limit is made If R to B high limit is made the zone thermostat energizes the burner through ZR Zone Circulator Control with R8182E J The relay for each zone is connected to the Aquastat limit through terminals ZC and ZR The R845A Relay and thermostat in each zone can energize the zone circulator through ZC on a call for heat If R to B high limit is made the zone thermostat energizes the burner through ZR Zone Valve Control with R8182 The valve for each zone is connected to the Aquastat limit by wiring end switches on the zone valve to T T on the R8182 On a call for heat from any zone the R8182 operates the same as for single zone applications 13 240 F 116 C 10 F 6 C DIFFERENTIAL 25 F 14 C DIFFERENTIAL HIGH LIMIT SETTING LOW LIMIT AND CIRCULATOR SETTING 10 F 6 C DIFFERENTIAL 110 F 43 C A WHEN WATER REACHES PROPER TEMPERATURE THE BURNER SHUTS OFF OR THE CIRCULATOR PUMP STARTS WHEN CALLING FOR HEAT
23. lame Detector ordered separately Thermostat Required 24V 2 wire thermostat such as the T87F ORDERING INFORMATION When purchasing replacement and modernization products from your TRADELINE wholesaler or distributor refer to the TRADELINE Catalog or price sheets for complete ordering number If you have additional questions need further information or would like to comment on our products or services please write or phone 1 Your local Home and Building Control Sales Office check white pages of your phone directory 2 Home and Building Control Customer Relations Honeywell 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 In Canada Honeywell Limited Honeywell Limit e 35 Dynamic Drive Scarborough Ontario M1V 4Z9 International Sales and Service Offices in all principal cities of the world Manufacturing in Australia Canada Finland France Germany Japan Mexico Netherlands Spain Taiwan United Kingdom U S A 68 0105 2 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS KNOCKOUTS FOR 1 2 IN 13 MM CONDUIT 5 HORIZONTIAL MOUNT ONLY as EM 5 1 4 133 a lee 3 1 4 PE PA VERTICAL MOUNT SHOWN M4517 Fig 1 R8182D E F installation dimensions in in mm Thermostat Anticipator Setting 0 2A for R8182 0 4A for each R845A Switching Relay used Maximum Ambient Temperature at Element 250 F 121 C Maximum Pressure Rating 200 psi 1379 kPa on i
24. mmersion well 100 psi 689 5 kPa direct immersion Internal Views Refer to Fig 4 through 8 Well Insertion Length 3 3 8 in 86 mm Immersion Well Dimensions Order Well Separately Refer to Fig 3 Aquastat Assembly Repair Parts 125026AAE Aquastat Assembly Replaces R8182D F Sensing Bulb Replacement Well Assemblies Refer to form 68 0040 Wells and Fittings for Temperature Controllers for part numbers and descriptions KNOCKOUTS FOR 1 2 IN 13 MM CONDUIT 5 Pas 5 1 4 133 3 E 3 7 16 87 A SIDE MOUNTED HINGE SHOWN M4518 Fig 2 R8182H J installation dimensions in in mm R8182D E F A ua MOUNT Pr BOILER TAPPED HOLE Lorn OR 3 4 NPT INSERTION 3 3 8 IN 86 MM FITS BOILER TAPPED HOLE p OR 3 4 NPT n INSULATION LENGTH gt 1 1 2 OR 3 IN 38 OR 76 MM R8182H J x SETSCREW ba INSULATION LENGTH INSERTION LENGTH 1 1 2 IN 38 MM 3 3 8 IN 86 MM M4530 Fig 3 Approximate immersion well dimensions Device Description Part Number R8182D 1 1 2 in 38 mm insulation horizontal or vertical 3 in 76 mm insulation horizontal 125026AAD 3 in 76 mm insulation vertical 1250266AAE R8182E 1 1 2 in 38 mm insulation horizontal or vertical 3 in 76 mm insulation horizontal 123726AV 3 in 76 mm insulation vertical 123726AW 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS
25. on develops and persists 68 0105 2 16 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 gt 383 F 195 C Will burn if exposed to flame Extinguishing Media Carbon dioxide dry chemical or foam Special Fire Fighting Procedures None 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 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS 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 Hand Clothing Protection Not normally required Protective gloves
26. the safety switch Ignition Failure Check Test by closing the oil supply while the burner is off Run through the starting procedure but do not open the oil supply line hand valve The safety switch locks out as in flame failure Then turn the oil back on and reset the safety switch Power Failure Check Turn off the power supply while the burner is on When the burner goes out restore power and the burner will restart NOTE If operation is not as described see cover insert for additional information and check wiring Aquastat Controller Replacement The Aquastat limit section of the Protectorelay control is field replaceable When ordering a replacement assembly specify the complete model number of the R8182 Replace the Aquastat Limit Disconnect power supply ni On all models Note the position of the connecting wires 3 Remove fastening screws and wires 4 Remove Aquastat limit and install the new assembly Manufacturer Honeywell Inc 1985 Douglas Drive North Minneapolis MN 55422 Date Released October 8 1999 Emergency Telephone Information 1 888 809 3787 NFPA Ratings Health 0 Flammability 1 Reactivity 0 Personal Protection B 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS Section 2 Composition Information on Ingredients Table 3 Table 2 Ingredients of Heat Conductive Compound Ingredients CAS
27. view of R8182F R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS SAFETY SWITCH RESET BUTTON TRANSFORMER FOR THERMOSTAT CIRCUIT DIFFERENTIAL SETTING CIRCULATOR RELAY 1K BURNER MOTOR AND IGNITION RELAY 2K LOW LIMIT SETTING VOLTAGE BARRIER TRANSFORMER FOR HIGH LIMIT CAD CELL CIRCUIT SETTING CAD CELL LEADS YELLOW M4524 Fig 7 Internal view of R8182H SAFETY SWITCH RESET BUTTON AG AZ TRANSFORMER FOR THERMOSTAT CIRCUIT AQUASTAT SWITCH 2K RELAY 1K RELAY VOLTAGE BARRIER TRANSFORMER FOR CAD CELL CIRCUIT HIGH LIMIT SETTING CAD CELL LEADS YELLOW M4531 Fig 8 Internal view of R8182J INSTALLATION A 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 When Installing this Product Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condition Check the ratings given in these instructions and on the product to be sure the product is suitable for your application 1 T he installer must be a trained experienced service technician After completing installation use these instructions to check product operation A WARNING Explosion or Electrical Shock Hazard Can cause severe injury death or property damage 1
28. wn in method 2 3 Using a standard flat heat screwdriver tighten the screw until the wire is snugly in contact with the screw and contact plate 4 Tighten the screw an additional one half turn 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 Refer to Fig 10 for Aquastat limit connections necessary for each R8182D 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 68 0105 2 R8182D E EH J COMBINATION PROTECTORELAY AND HYDRONIC HEATING CONTROLS USING THE TRADELINE R8182D USING TO REPLACE R8182F TO RE WHITE 1 REMOVE BLUE WIRE FROM THIS TERMINAL AND INSULATE END TO PREVENT CONTACT AN 2 REMOVE OTHER BLUE WIRE SO FROM THIS TERMINAL AND CONNECT AS SHOWN BELOW TORE 3 CONNECT CIRCULATOR TO ZC AND C2 BLUE AN THE TRADELINE R8182D PLACE R8182B E OR RODGERS 6C92 1 REMOVE WHITE ABD BLACK LEADS FROM THEIR TERMINAL D CONNECT WITH A DDERLESS CONNECTOR TO USE TRADELINE R8182H PLACE R8182J 1 REMOVE RED AND WHITE LEADS FROM THEIR TERMINALS
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