Honeywell Water Heater B User Manual

L4188A,B; L4189A,B; L6188A-C;  
®
L6189A-C Aquastat Controllers  
PRODUCT DATA  
FEATURES  
L4188 and L4189 provide spst switching for high and  
low limit control.  
L6188 and L6189 provide spst switching for low limit  
and circulator control.  
L4188, L6188 models are direct-mounted.  
L4189, L6189 models are remote bulb.  
Diaphragm-operated switch breaks on temperature  
rise (spst and normally closed spdt contacts).  
Compact controller case for application flexibility.  
3/16 in. diameter bulb for faster response.  
Remote Bulb with  
Screwdriver Slot  
All models available with or without setting knob.  
Models without knob are adjusted with screwdriver.  
Choice of manual or auto reset. Auto reset models  
available with fixed or adjustable differential.  
1/4 in. male quick-connects standard; combination  
screw and 1/4 in. quick-connects available.  
Field adjustable high or low limit stop available.  
Bracket for surface mounting available on remote bulb  
models.  
Capillary on remote bulb models available in several  
lengths.  
Direct Mount with  
Setting Knob  
Immersion well with 1/2 in. NPT spud available as  
accessory.  
APPLICATION  
®
Aquastat Controllers are bulb-type providing operating or  
limit control of water temperature in hot water heating systems  
and water heaters.  
Contents  
Application.........................................................................  
Features ............................................................................  
Specifications ....................................................................  
Ordering Information .........................................................  
Installation .........................................................................  
Wiring ................................................................................  
Operation...........................................................................  
Adjustments.......................................................................  
Checkout ...........................................................................  
1
1
2
2
4
6
7
7
8
68-0061—1  
 
L4188A,B; L4189A,B; L6188A-C; L6189A-C AQUASTAT® CONTROLLERS  
Ambient Temperature Range: 32° to 158° F (0° to 70° C).  
Dimensions: See Fig. 1.  
Mounting: Must be mounted in an enclosure that meets local  
electrical codes.  
Sensing Bulb: Liquid-filled copper (See Fig. 1).  
Direct: Unit mounts on immersion well at desired sensing  
location.  
Underwriters Laboratories Inc. Component Recognized:  
File No. MP466, Guide No. MBPR.  
Remote bulb: Sensing bulb is inserted into immersion well  
at desired sensing location. Controller case mounts  
behind remote panel with two self-tapping M4 or No. 8  
sheetmetal screws (supplied). Optional mounting bracket  
allows mounting on front of panel. Specify bracket when  
ordering.  
Canadian Standards Association Listed: File No. LR62051-1.  
KNOB MODEL  
2-11/16  
(68)  
19/32  
(15)  
1-1/4  
(32)  
11/16  
1/2  
(17)  
(13)  
7/16  
(11)  
3/16  
(5)  
19/32  
(15)  
5/8  
(16)  
1-7/8  
(48)  
1
HOLE FOR  
UP TO NO. 10  
SCREW  
4 (101)  
3/8  
(9)  
SEE  
TABLE  
1-7/8  
(48)  
1-7/8  
(48)  
SCREWDRIVER SLOT MODEL  
SEE  
4 (101)  
TABLE  
1-1/4  
(32)  
1/2  
(13)  
5/8  
(16)  
1-7/8  
(48)  
3/16  
(5)  
1-7/8  
(48)  
3/8  
(9)  
1-7/8  
(48)  
1-7/8  
(48)  
IMMERSION WELLS  
INSULATION  
INSERTION  
OPTIONAL MOUNTING BRACKET  
1
PART NO.  
SPUD  
INSULATION INSERTION  
45900409-003B  
45900409-009B  
45900409-010B  
1/2 in. BSPT  
1/2 in. NPT  
3/4 in. NPT  
1 in.  
3-1/2 in.  
3 in.  
1-1/2 in.  
1-1/2 in.  
3 in.  
MODEL  
CAPILLARY LENGTH  
MOUNTING  
DIRECT MOUNT  
L4188, L5188  
1-3/16 IN.  
30 MM  
USE IMMERSION WELLS SHOWN AT RIGHT  
2-5/16 IN.  
39-3/8 IN.  
50 IN.  
50 MM  
1000 MM  
1500 MM  
2000 MM  
REMOTE MOUNT  
L4189, L5189  
USE IMMERSION WELLS SHOWN AT RIGHT  
OR CAPILLARY COMPRESSION FITTINGS  
78-11/16 IN.  
M25414  
Fig. 1. Dimensions in in. [mm in brackets] of Aquastat Controller and Immersion Well.  
3
68-0061—1  
 
L4188A,B; L4189A,B; L6188A-C; L6189A-C AQUASTAT® CONTROLLERS  
Accessories (order separately):  
3. Refill the system. Check for and correct any leaks.  
Capillary compression fittings.  
USE MODERATE AMOUNT  
OF PIPE COMPOUND  
Part No. 104484A: 1/2 in. NPT spud.  
Part No. 104484B: 3/4 in. NPT spud.  
Immersion well: Pressure rating 255 psi [1760 kPa].  
Part No. 45900409-003B: 1/2 in. BSPT spud, 1 in.  
insulation, 3-1/2 in. insertion.  
Part No. 45900409-009B: 1/2 in. NPT spud, 1-1/2 in.  
insulation, 3 in. insertion.  
LEAVE 2 END THREADS BARE  
M25415  
Part No. 45900409-010B: 3/4 in. NPT spud, 1-1/2 in.  
insulation, 3 in. insertion.  
Fig. 2. Use good Piping Practice when Installing  
Immersion Well.  
Optional Specifications (Specify when ordering):  
Combination screw and 1/4 in. male quick-connect  
terminals.  
To Install Direct Mount Controller  
High or low limit stop (models with knob only).  
Mounting bracket (remote bulb models only).  
1. Slide the sensing bulb all the way into the well. The metal  
collar around the capillary should slip into the well spud.  
2. Line up the case so the setting indicator is on top.  
3. Tighten the setscrew in the well spud snugly against the  
metal collar.  
INSTALLATION  
CONTROLLER  
SETSCREW  
SPUD  
When Installing This Product...  
1. Read these instructions carefully. Failure to follow them  
could damage the product or cause a hazardous  
condition.  
WELL  
2. Check the ratings given in the instructions and on the  
product to make sure the product is suitable for your  
application.  
BULB  
METAL  
CAPILLARY  
COLLAR  
3. Installer must be a trained, experienced service  
technician.  
M25416  
4. After installation is complete, check out product  
operation as provided in these instructions.  
Fig. 3. The Direct Mount Model is held in place by the  
Setscrew in the Well Spud.  
CAUTION  
Disconnect power supply before wiring to avoid  
electrical shock or equipment damage.  
Terminal connections must be inside an enclosure  
that meets local electrical codes.  
To Mount Remote Bulb Controller  
Insert Sensing Bulb in Well  
1. Slide sensing bulb into well. Make sure bulb rests  
against the bottom of the well. Don’t bend the capillary  
where it connects to the bulb.  
2. Hold bulb in place and tighten setscrew all the way  
down. It won’t fit tight against the capillary, but it will keep  
the bulb from sliding out.  
Location  
The equipment manufacturer generally provides a tapping for  
insertion of the temperature controller sensing element. The  
tapping should be located at a point where average system  
temperature will be measured. Never locate the sensing  
element close to a hot or cold water inlet or a steam coil, or  
where the well’s pressure rating will be exceeded.  
SETSCREW  
SPUD  
CAPILLARY  
Turn off power and, if the system is filled, drain to a point below  
the boiler tapping or wherever the sensing element is to be  
located. If no tapping is provided, prepare one, properly  
threaded, at the desired location.  
SETSCREW  
SPUD  
WELL  
BULB  
If this is a remote bulb unit, the controller case can be mounted  
in a panel or, with the optional bracket, on any flat surface.  
Choose a location within reach of the sensing element. Allow  
for gradual bends and some slack in the capillary.  
CAPILLARY  
M25417  
Fig. 4. The Setscrew keeps the Remote Sensing Bulb in  
the Well.  
Mount the Immersion Well  
1. Coat the well threads with a moderate amount of pipe  
®
dope, leaving two end threads bare. Teflon tape may  
also be used.  
2. Screw the immersion well into the tapping and tighten  
securely.  
68-0061—1  
4
 
L4188A,B; L4189A,B; L6188A-C; L6189A-C AQUASTAT® CONTROLLERS  
4. ADJUSTABLE DIFFERENTIAL MODELS ONLY: Set  
Mounting Behind Panel-Controller with Knob  
differential. See Adjustment and Checkout section.  
5. Using setting indicator as a template, mark and drill  
holes in the panel for the mounting screws and for the  
knob shaft.  
6. Mount the controller behind, and the setting indicator in  
front of, the panel using the two screws removed earlier  
(See Fig. 5).  
7. MODELS WITH TEMPERATURE LIMIT STOP ONLY:  
Adjust to desired setting, as described under “To Set  
Temperature Limit Stop,” page 8.  
NOTE: The panel can be up to 5/64 in. thick.  
1. Uncoil capillary, starting at bulb. Avoid sharp bends or  
kinks in the capillary. Leave excess capillary loosely  
coiled below controller case.  
2. Remove the setting knob by pulling straight off.  
3. Remove the two screws that hold the setting indicator in  
place and remove the setting indicator (See Fig. 5).  
8. Replace knob on shaft.  
SETTING  
INDICATOR  
CONTROLLER  
PANEL  
NO. 8  
(MAX. 5/64 IN. THICK)  
MOUNTING  
SCREWS (2)  
KNOB  
M25418  
Fig. 5. The Mounting Screws hold the Setting Indicator and Controller in place.  
Mounting Behind Panel-Controller with Screwdriver Slot  
1. Mark and drill three holes in the panel, using the tem-  
plate in Fig. 6 as a guide.  
2. MANUAL RESET MODELS ONLY: Drill a fourth hole to  
make the manual reset button accessible.  
3. ADJUSTABLE DIFFERENTIAL MODELS ONLY: Drill a  
hole for the differential dial, if desired, Set the differential.  
See Adjustment and Checkout section.  
4. Hold controller against back of panel with terminals  
pointed down and fasten with two No. 8 sheetmetal  
screws (not supplied) (Refer to Fig. 6).  
5
68-0061—1  
 
L4188A,B; L4189A,B; L6188A-C; L6189A-C AQUASTAT® CONTROLLERS  
MOUNTING TEMPLATE  
NO. 10  
3/4  
SHEETMETAL  
SCREWS (2)  
(OBTAIN LOCALLY)  
3/16  
5/16  
3/16  
1
1
PANEL  
2
MOUNTING  
BRACKET  
5/8  
3/16  
3
1
2
DRILL 2 MOUNTING SCREW HOLES.  
DRILL HOLE FOR SLOTTED SHAFT. USE SMALL HOLE FOR SHAFT  
ONLY; LARGE HOLE SHAFT PLUS SETTING SCALE.  
3
DRILL SMALL HOLE FOR MODEL WITH MANUAL RESET BUTTON OR  
LARGE HOLE FOR MODEL WITH DIFFERENTIAL ADJUSTMENT.  
CONTROLLER  
CAPILLARY  
CONTROLLER  
M25420  
SLOTTED  
SHAFT  
Fig. 7. The Controller with Bracket Mounts on the Front of  
the Panel.  
WIRING  
All wiring must comply with applicable codes and ordinances,  
Disconnect power before beginning wiring.  
MANUAL  
RESET  
BUTTON  
NO. 8  
MOUNTING SCREWS (2)  
(OBTAIN LOCALLY)  
Connect as shown in equipment manufacturer’s instructions, if  
provided. Otherwise, use the typical hookups shown  
(See Fig. 8) (refer to Figures 9 and 10).  
PANEL  
M25419  
24V  
Fig. 6. Drill holes in the Panel as shown.  
THERMOSTAT  
Mounting on Panel-Controller with Bracket  
1. Using controller bracket as a template, mark and drill two  
holes in the panel.  
LOW WATER  
CUTOFF  
2. Mount controller with terminals down.  
3. Run capillary neatly along panel, avoiding sharp bends  
and interference with other components on the panel.  
4. MODELS WITH TEMPERATURE LIMIT STOP ONLY:  
Adjust to desired setting, as described under “To Set  
Temperature Limit Stop,” page 8.  
L4188.9  
PRESSURE  
L4188.9  
LOW LIMIT  
CONTROLLER  
HIGH LIMIT  
2
L1  
(HOT)  
L2  
1
TH-TR  
24V  
GAS VALVE  
TH  
TR  
1
2
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD  
PROTECTION AS REQUIRED.  
USE L6188.9C (C-1 CONTACTS) IF MANUAL RESET IS REQUIRED.  
M25421  
Fig. 8. Low and High Limit Application on a Gas-Fired  
System with Domestic Hot Water.  
68-0061—1  
6
 
L4188A,B; L4189A,B; L6188A-C; L6189A-C AQUASTAT® CONTROLLERS  
OPERATION  
24V THERMOSTAT  
As the liquid filing the sensing bulb and capillary expands and  
contracts, it moves a diaphragm. Movement of the diaphragm  
is transferred by a lever to the snap-acting switch in the  
controller.  
RELAY CENTER  
L1  
R
G
(HOT)  
High or Low Limit Action (L4188, L4189)  
PROTECTORELAY  
CONTROL  
L2  
The normally closed C-1 contacts open on temperature rise to  
the set point, shutting off power to the controlled circuit. On  
auto recycle models, the switch closes C-1 after the  
temperature falls past the set point and through the differential  
(See Fig. 11).  
2
HIGH LIMIT  
BLACK  
BURNER MOTOR  
3
LOW LIMIT  
1
ORANGE  
C
2
CIRCULATOR  
MOTOR  
Low Limit/Circulator Action (L6188, L6189)  
CIRCULATOR  
The low limit is connected to the normally closed C-1 contacts,  
and the circulator to the normally open C-2 contacts. As long  
as the temperature at the sensing bulb is above set point, the  
circulator runs. If sensing bulb temperature falls past the set  
point and through the differential, the switch breaks C-2 to turn  
off the circulator, and makes C-1 to turn on the burner. When  
the temperature rises to the set point, C-2 makes to turn on the  
circulator, and C-1 breaks to turn off the burner.  
IGNITION  
WHITE  
T
T
On manual reset models, the reset button must be pushed  
before contacts C-1 will close (See Fig. 11).  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD  
PROTECTION AS REQUIRED.  
2
3
L4188 OR L4189 USED AS HIGH LIMIT.  
TEMPERATURE  
SETTING  
L6188 OR L6189 USED AS LOW LIMIT/CIRCULATOR CONTROLLER.  
M25422  
SCALE  
L4188.9  
L6188.9  
HIGH OR LOW  
LIMIT  
LOW LIMIT/  
CIRCULATOR  
220 F  
Fig. 9. High Limit and Low Limit/Circulator Application in  
an Oil-Fired Hydronic System with domestic hot water.  
2
SET POINT  
SET POINT  
MANUAL  
C
1
C
24V  
1
RESET  
THERMOSTAT  
1
BREAKS  
MAKES C-1  
C-1 BREAKS  
C-2 MAKES  
L1 L2  
DIFFERENTIAL  
2
1
(HOT)  
SWITCHING RELAY  
AUTO  
RA832A  
RECYCLE  
L4188.9  
C
HIGH LIMIT  
2
T
X
T
2
1
SET POINT  
BLACK  
C
1
LESS  
C
1
DIFFER-  
ENTIAL  
MAKES  
C-1 MAKES  
WHITE  
C-2 BREAKS  
IGNITION  
X
4
ORANGE  
L4188.9  
CIRCULATOR  
100 F  
M25424  
L4188.9  
T
T
LOW LIMIT  
CIRCULATOR BURNER  
Fig. 11. Aquastat Controller Switch Action on Temperature  
Change.  
PROTECTORELAY  
CONTROL  
LINE VOLTAGE  
LOW VOLTAGE  
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS  
REQUIRED.  
ADJUSTMENTS  
M25423  
Fig. 10. High Limit and Separate Low Limit and Circulator  
Application in an Oil-Fired Hydronic System with  
Domestic Hot Water.  
To Set Temperature  
KNOB MODELS  
Line up the desired temperature setting with the temperature  
setting indicator behind the knob.  
SCREWDRIVER SLOT MODELS  
Line up the pointer on the shaft with the desired temperature  
setting printed on the case.  
7
68-0061—1  
 
L4188A,B; L4189A,B; L6188A-C; L6189A-C AQUASTAT® CONTROLLERS  
To Set Adjustable Differential (if provided)  
Use a screwdriver to turn the differential dial until the slot  
molded into the case lines up with the desired degrees of  
differential.  
AJUST LIMIT STOP  
LIFT AND PUSH  
TO CHANGE LIMIT  
SETTING  
CONTROLLER  
LIMIT STOP  
POINTER  
KNOB  
DIFFERENTIAL  
ADJUSTMENT  
DIAL  
REPLACE KNOB ON SHAFT  
SETTING  
INDICATOR  
M25425  
SETTING INDICATOR:  
LIMIT STOP MUST  
BE ON RIGHT SIDE OF  
SETTING INDICATOR FOR  
HIGH LIMIT; ON LEFT  
SIDE FOR LOW LIMIT  
Fig. 12. Twist the Screwdriver Slightly to turn the  
Differential Dial.  
To Set Temperature Limit Stop (if provided)  
SHAFT  
CAUTION  
FOR LOW LIMIT STOP:  
Follow these instructions carefully to avoid  
placing the limit stop pointer on the wrong side of  
the setting indicator. In a high limit application,  
incorrect positioning of the pointer will cause  
system operation above the limit stop setting,  
potentially resulting in overheating or related  
conditions.  
TURN SHAFT  
FULL COUNTERCLOCKWISE  
(SHOWN) BEFORE  
REPLACING KNOB.  
KNOB  
FOR HIGH LIMIT STOP:  
TURN SHAFT  
FULL CLOCKWISE  
BEFORE REPLACING  
KNOB.  
M25426  
Fig. 13. Adjust the Limit Stop with a Screwdriver and  
check Orientation when Replacing Knob on Shaft.  
Remove the knob.  
Turn the controller shaft all the way counterclockwise  
when setting a high limit. Turn it all the way  
clockwise  
when setting a low limit.  
CHECKOUT  
Find the metal limit stop on the back of the knob.  
Lift the limit stop slightly with a pencil or screwdriver and  
push to move to desired setting.  
Read the setting from the front of the knob.  
Place the knob on the shaft.  
Turn the knob to make sure it: (1) turns through the desired  
adjustment range, and (2) stops at the limit setting.  
DO NOT FORCE.  
Turn the system on and observe it through several cycles to  
make sure the controller operates as desired.  
Return knob to desired setting.  
Teflon® is a registered trademark for E.I. Du Pont De Nemours and Company.  
Automation and Control Solutions  
Honeywell International Inc.  
1985 Douglas Drive North  
Golden Valley, MN 55422  
customer.honeywell.com  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Toronto, Ontario M1V 4Z9  
® U.S. Registered Trademark  
© 2007 Honeywell International Inc.  
68-0061—1 J.I. Rev. 10-07  
 

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