R88D,E,F,H,J Combination Protectorelay Primary Control and Aquastat Controller APPLICAION he R88 combines a Protectorelay primary control and immersion type Aquastat controller in one unit for use in oil-fired, hydronic heating systems. INSALLAION INSRUCIONS KNOCKOUS FOR / IN. ( MM) CONDUI (5) he Protectorelay primary control provides control of a line voltage, intermittent ignition oil burner when used with a C55A Cadmium Sulfide Flame Detector and a V thermostat. -5/6 () -7/6 (6) he R88 models provide switching as follows: Model R88D R88E R88F R88H (with remote bulb) R88J (with remote bulb) Switching High limit, spst; Low limit/circulator, spdt High limit, spst High limit, spst Circulator, spst High limit, spst Low limit/circulator, spdt High limit, spst he auxiliary and terminals on the R88D,E,H,J provide zone control through an R85A Switching Relay. All models are capable of zone control using zone valves. Each additional zone requires a separate V thermostat and a V80 or V80 Zone Valve. 7-/8 (8) /6 (5) -9/6 (9) VERICAL MOUN SHOWN. VERICAL MOUN ONLY HORIZONIAL MOUN ONLY 5-/ () -/ (8) M57 Fig.. R88D,E,F installation dimensions in inches (millimeters). he R88D,E,F models mount directly on the boiler. he R88H,J models mount directly on a by inch junction box and have a 5 foot (.5 meter) armored capillary for remote sensor location. o order an immersion well, use form 68-000 Wells and Fittings for emperature Controllers, for part numbers and descriptions. Refer to Fig. through for installation dimensions. Refer to Fig. through 8 for internal views of the R88D,E,F,G,J. Copyright 995 Honeywell Inc. All Rights Reserved X-XX UL 69-0600-
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER KNOCKOUS FOR / IN. ( MM) CONDUI (5) GROUNDING SCREW RESE UON RANSFORMER FOR CIRCUI / () -/8 (86) 7/8 () RELAY (K) MOOR RELAY (K) 7-/8 (8) -7/6 (87) LOW LIMI VOLAGE ARRIER RANSFORMER FOR CAD CELL CIRCUI Fig.. Internal view of R88D. M55 5-/ () -7/6 (87) GROUNDING SCREW RESE UON SIDE MOUNED HINGE SHOWN. M58 RANSFORMER FOR CIRCUI Fig.. R88H,J installation dimensions in inches (millimeters). AQUASA RELAY (K) R88D,E,F CONROL MOUN FIS OILER APPED HOLE / OR / NP MOOR RELAY (K) VOLAGE ARRIER INSULAION LENGH -/ OR IN. (8 OR 76 MM) R88H,J SESCREW INSERION LENGH -/8 IN. (86 MM) FIS OILER APPED HOLE / OR / NP RANSFORMER FOR CAD CELL CIRCUI Fig. 5. Internal view of R88E. GROUNDING SCREW M5 RESE UON INSULAION LENGH -/ IN. (8 MM) INSERION LENGH -/8 IN. (86 MM) M50 MOOR RELAY (K) Fig.. Immersion well dimensions in inches (millimeters). LOW LIMI RANSFORMER FOR CAD CELL CIRCUI VOLAGE ARRIER Fig. 6. Internal view of R88F. M55 69-0600
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER RESE UON RELAY (K) LOW LIMI RANSFORMER FOR CAD CELL CIRCUI CAD CELL LEADS () Fig. 7. Internal view of R88H. INSALLAION CAD CELL LEADS () RESE UON RANSFORMER FOR CIRCUI MOOR RELAY (K) VOLAGE ARRIER M5 RANSFORMER FOR CIRCUI AQUASA K RELAY K RELAY VOLAGE ARRIER RANSFORMER FOR CAD CELL CIRCUI Fig. 8. Internal view of R88J. M5 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. e sure the installer is a trained, experienced service technician. After completing installation, use these instructions to check product operation. CAUION. Disconnect the power supply before beginning installation to prevent electrical shock or equipment damage.. e sure that the combustion chamber is clear of oil or oil vapor before starting burner.. e sure that the ambient temperature at the element does not exceed 50 F ( C). IMPORAN e 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.. Mounting the R88 Disconnect power supply. Drain all water from boiler. 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. Install immersion well or compression fitting (ordered separately) by threading immersion well into tapped hole. For R88D,E,F models: a. Loosen immersion well clamp screw on side of R88 case. b. Insert bulb into immersion well until it bottoms. c. If necessary, bend capillary tube to hold bulb against bottom of immersion well. NOE: 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. Fit controller case onto immersion well so that immersion well clamp slides over flange of immersion well. e. Securely tighten immersion well clamp screw. For R88H,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 by inch junction box. c. Insert bulb into immersion well until it bottoms. d. If necessary, bend capillary tube to hold bulb against bottom of immersion well. NOE: 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. ighten immersion well screw over brass collar. f. After wiring, swing the control against the backplate and refasten the screw. Refill the boiler and check for water leakage. 69-0600
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER Wiring IMPORAN Use Underwriters Laboratories Inc. listed connectors when making external circuit connections to the orange and white line voltage burner and ignition leadwires of the R88H,J. CAUION Disconnect power supply before wiring to prevent electrical shock or equipment damage. All wiring must comply with local codes, regulations, and ordinances. G L K LACK L R88D LUE LUE LOW LIMI R W K R WHIE K C C O OIL O WAER IMPORAN erminals on the R88 are approved for copper wire only. Follow the wiring instructions furnished by the appliance manufacturer, if available, or refer to Fig. 9 through 5. For wiring multiple zoning systems, refer to Fig. and 5. he R88 is equipped with special wiring terminals. Wires can be wrapped around the terminal screw or inserted from the side. Method Strip 7/6 inches of insulation from the wire end. Wrap wire / of distance around screw as shown in Method. Use a standard, flat-headed screwdriver to tighten screw until wire is snugly in contact with screw and contact plate. ighten the screw an additional one half turn. Method Strip 5/6 inches of insulation from the wire end. Insert wire beneath screw as shown in method. Using a standard, flatheaded screwdriver, tighten screw until wire is snuggly in contact with screw and contact plate. ighten screw an additional one half turn. NOE: Do not use a push-type ratchet screwdriver. OPERAION M88 M56 R88D A call for heat by the thermostat pulls in relays K and K to turn on the burner. Safety switch starts to heat. If burner ignites within safety switch timing, cad cell sees flame and safety switch heater circuit is bypassed. urner operates until call for heat is satisfied. Circulator operates when relay K pulls in only if R to W is made in the Aquastat controller. When R to (low-limit) is made by a drop in water temperature, it acts as a call for heat, pulling in relay K VOL K ILAERAL K HEAER RIAC C R F F C55A 0 VAC POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. WHEN HE LACK WHIE WIRES ON HE RADELINE R88D AQUASA CONROLLER ASSEMLY ARE DISCONNECED FROM HE ARE INERCONNECED, LOW LIMI CONROL ARE YPASSED. OPERAES WIHY HEROMSA ONLY. O REPLACE R88C,F, REMOVE LUE WIRE INSULAE END. DISCONNEC HE HE OHER LUE WIRE A WIRE O A. WHEN IS CONNECED EWEEN C, LOW LIMI FUNCION IS REMOVED OPERAES WIH CONROL (R O W) ONLY. CONROL CASE MUS E CONNECED O EARH GROUND. USE GROUNDING SCREW PROVIDED. M59 K Fig. 9. R88D internal schematic and wiring diagram. to turn on the burner. Circulator cannot operate. See Fig., 9,, 5, and 7. R88E urner and circulator operate whenever thermostat calls for heat. Relay K pulls in. When cadmium sulfide cell sees flame, the safety switch heater circuit is bypassed. K is held in through K. If temperature rises to high limit setpoint, R to breaks, shutting off burner. Circulator continues operation under direction of thermostat. See Fig. 5, 0, 5, and 6. R88F A thermostat call for heat pulls in relay K to turn on the burner. When cadmium sulfide cell sees flame, safety switch heater circuit is bypassed. Circulator is independent of thermostat circuit, being controlled only by Aquastat controller switch. Refer to Figs. 6,, 5, and 8. R 69-0600
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER G L K L K K R R88E C C O OIL O WAER G L L JUMPER R R W HIGH LIMI K CONROL C R88F C O WAER O K K HEAER RIAC ILAERAL K R VOL K R K HEAER ILAERAL RIAC C R F F F R C F VOL C55A C55A 0 VAC POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. 0 VAC POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. CONROL CASE MUS E CONNECED O EARH GROUND. USE GROUNDING SCREW PROVIDED. M57 CONROL CASE MUS E CONNECED O EARH GROUND. USE GROUNDING SCREW PROVIDED. M58 Fig. 0. R88E internal schematic and wiring diagram. R88H A call for heat by the thermostat pulls in relays K and K to turn on the burner. Safety switch starts to heat. If burner ignites within safety switch timing, cadmium sulfide cell sees flame and safety switch heater circuit is bypassed. urner shuts off when call for heat is satisfied. Circulator operates when relay K pulls in only if R to W in the Aquastat controller is made. When R to (low-limit) is made by a drop in water temperature, it acts as a call for heat, pulling in relay K to turn on the burner. Circulator cannot operate. See Fig. 7,, 5, and 7. R88J urner and circulator operate whenever the thermostat calls for heat. Relay K pulls in. When cadmium sulfide cell sees flame, the safety switch heater circuit is bypassed. K is held in through K. If temperature rises to high-limit setpoint, R to breaks, shutting off burner. Circulator continues operation under direction of thermostat. See Fig. 8,, 5, and 6. Multizone Control In all multizone applications, a call for heat in any zone energizes the safety switch circuit and relay K pulls in. If burner ignites within safety switch timing, cad cell sees flame and safety switch heater is bypassed. Fig.. R88F internal schematic and wiring diagram. In all multizone applications with R88D and H, the low- limit controller in the Aquastat acts independently to turn on the main burner on a drop in water temperature. When R to (low-limit) is made, relay K pulls in to turn on the main burner, the same as for single-zone applications. Zone Circulator Control with R88D,H he relay for each zone is connected to the Aquastat controller through terminals and. he R85 Relay and thermostat for each zone can energize the zone circulator through only if R to W in the Aquastat controller is made. If R to (high-limit) is made, the zone thermostat energizes the burner through. Zone Circulator Control with R88E,J he relay for each zone is connected to the Aquastat controller through terminals and. he R85A Relay and thermostat in each zone can energize the zone circulator through on a call for heat. If R to (high-limit) is made, the zone thermostat energizes the burner through. Zone Valve Control with R88 he valve for each zone is connected to the Aquastat controller by wiring end switches on the zone valve to - on the R88. On a call for heat from any zone, the R88 operates the same as in single-zone applications. 5 69-0600
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER L L R88H L L R88J K LOW LIMI R W K ORANGE R WHIE K C C O OIL O WAER K R ORANGE K WHIE C K C O OIL O WAER K K HEAER K K C HEAER RIAC ILAERAL R K R K RIAC ILAERAL C R F F R VOL C55A 0 VAC POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. M50 Fig.. R88H internal schematic and wiring diagram. SARUP CHECKOU WARNING CAN CAUSE PROPERY DAMAGE, SEVERE INJURY OR DEAH. his product is intended for use only in systems with a pressure relief valve. ecause heating systems differ, the correct temperature setting for one system may not be correct for another. Follow the boiler manufacturer recommendations for proper selection of settings. High-Limit Setting All Models he high-limit opens and turns off the burner when the water temperature reaches the setpoint. he high-limit automatically resets after the water temperature drops past the setpoint and through the 0 F (6 C) (5 F [8 C] with R88E,J) differential. Set the indicator at desired shutoff temperature. Low-Limit/Circulator Setting D and H Models (Fig. 7) On a temperature rise, with the adjustable differential at the minimum setting of 0 F (6 C), the burner circuit (R- ) breaks and the circulator circuit (R-W) makes at the low-limit setpoint. See Fig. 7. On a temperature drop of 0 F (6 C) below the setpoint, the R- circuit makes and the R-W circuit breaks. VOL C55A 0 VAC POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. M59 Fig.. R88J internal schematic and wiring diagram. At any differential setting greater than 0 F (6 C), the R- make temperature and R-W break temperature remain the same control setting minus 0 F (6 C). he R- break and R-W make temperatures are the setpoint temperature plus the difference between the differential setting and 0 F (6 C). EXAMPLE: Setpoint of 0 F (60 C), differential set at 5 F ( C). On a temperature rise, R- breaks and R- W makes at 55 F (68 C). On a temperature fall, R- makes and R-W breaks at 0 F (5 C). Set low-limit indicator at the minimum temperature recommended for domestic hot water supply. he setting must be at least 0 F ( C) below high-limit setting to prevent one switch from locking out the other. Set differential the desired number of degrees. Circulator Setting F MODELS (Fig. 8) Set circulator indicator at the minimum water temperature recommended for hydronic heating comfort. Circulator breaks 0 F (6 C) below setpoint. Startup CAUION e sure combustion chamber is free of oil or vapor. 69-0600 6
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER L L 6 ZONE R85A ING RELAY ZONE K K 5 K G K LOW LIMI LUE R W K R 5 C K R88D C O OIL O WAER 6 ZONE K O ADDIIONAL ZONES,, EC. 0 VAC POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. HEA ANICIPAOR, 0. AMP FOR R88D. HEA ANICIPAOR, 0. AMP FOR R85A. K HEAER RIAC ILAERAL C R F F K R CONROL CASE MUS E CONNECED O EARH GROUND. USE GROUNDING SCREW PROVIDED. 5 6 R88E,H,J CONNECIONS FROM ARE IDENICAL FOR MULIPLE CIRULAOR ZONING APPLICAION. EACH ADDIIONAL ZONE REQUIRES A SEPARAE, FIELD-ADDED V R85 RELAY. VOL Fig.. R88D and R85A in a typical multiple circulator zoning application. C55A M5. 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. 5. Under normal conditions, burner operates until thermostat is satisfied or line switch is opened. Make certain the system operates as described in the OPERAION section. Use the following procedure to verify that the Protectorelay control is controlling properly. Flame Failure Check Shut off oil supply hand valve while burner is on. After 5 seconds, the safety switch locks out, the motor stops, and the oil valve closes. Allow five minutes for burner to cool, then manually reset safety switch. Ignition Failure Check est by closing oil supply while burner is off. Run through starting procedure but do not open the oil supply line hand valve. Safety switch locks out as for flame failure. hen turn oil back on, and reset safety switch. Power Failure Check urn off power supply while burner is on. When burner goes out, restore power and burner will reset. NOE: If operation is not as described, see cover insert for additional information and check wiring. Aquastat Replacement he Aquastat controller section of the Protectorelay control is field replaceable. When ordering a replacement assembly, specify the complete model number of the R88. o Replace the Aquastat Limit:. Disconnect power supply.. Note the position of the connecting wires.. Remove fastening screws and wires.. Remove Aquastat controller and install new assembly. 7 69-0600
R88D,E,F,H,J COMINAION PROECORELAY PRIMARY CONROL AQUASA CONROLLER VOL VOL VOL L L 0 F (6 C) 0 F (6 C) REAKS ON URNS OFF. OPERAES ON A CALL FOR HEA. MAKES ON EMPERAURE FALL. OPERAES ON A CALL FOR HEA. 5 5 5 L C L C O OIL LOW LIMI 5 F ( C) 0 F (6 C) 0 F ( C) MAKES R-W REAKS R- ON MAKES R-W REAKS R- ON MAKES R- REAKS R-W ON EMPERAURE FALL. IS ON O MAINAIN MINIMUM WAER EMPERAURE. IS OFF. POWER SUPPLY. PROVIDE DISCONNEC MEANS OVERLOAD PROECION AS REQUI. R88H J HAVE WHIE ORANGE LEADWIRES FOR OIL CONNECIONS. LEADWIRES PROVIDED ONLY ON MODLES WIH END. WHEN WAER REACHES PROPER EMPERAURE, HE SHUS OFF OR HE PUMP SARS (WHEN CALLING FOR HEA). M5 Fig. 7. R88D,H Aquastat limit switching. 5 CHOOSE A7, A87, OR A88 RANSFORMER O MACH MAXIMUM SYSEM LOAD. USE V80 OR V80 ZONE VALVES WIH AUXILIARY END ONLY. M5 0 F (6 C) Fig. 5. R88D,E,F,H, and J in typical zoning application using zone valves. 0 F (6 C) 0 F (6 C) R- REAKS ON URNS OFF. R- REAKS ON URNS OFF. OPERAES ON A CALL FOR HEA. R- MAKES ON EMPERAURE FALL. OPERAES ON CALL FOR HEA. 5 F (8 C) R- MAKES ON EMPERAURE FALL. OPERAE ON A CALL FOR HEA. 0 F (6 C) R-W MAKES ON URNS ON. R- REAKS ON EMPERAURE FALL. URNS OFF. 80 F (8 C) M50 Fig. 6. R88E,J Aquastat limit switching. 0 F ( C) M509 Fig. 8. R88F Aquastat limit switching. Automation and Control Solutions Honeywell International Inc. 985 Douglas Drive North Golden Valley, MN 55 Honeywell Limited-Honeywell Limitée 5 Dynamic Drive Scarborough, Ontario MV Z9 69-0600 J.H. Rev. 5-95 8