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HEATING SYSTEMS

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BACKDRAFTING HEATING EQUIPMENT
BACKUP HEAT for HEAT PUMPS
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BLOWER FAN OPERATION & TESTING
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CIRCULATOR PUMPS & RELAYS
CONDENSING BOILERS/FURNACES
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COOL OFF HEAT, Thermostat Switch

DEFINITION of Heating & Cooling Terms
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DIAGNOSE & FIX HEATING PROBLEMS-FURNACE
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ELECTRIC HEAT, DIAGNOSIS, REPAIR
ELECTRIC MOTOR OVERLOAD RESET SWITCH
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FAN, AIR HANDLER BLOWER UNIT
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LOW VOLTAGE BUILDING WIRING
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MANUALS & PARTS GUIDES - HVAC

NO HEAT - BOILER
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ODORS FROM HEATING SYSTEMS
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OIL FILTERS on HEATING EQUIPMENT
OIL TANKS

PULSE COMBUSTION HEATERS

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RADIATORS
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Reset Switch Broken - Quick Repair
RESET SWITCH - ELECTRIC MOTOR
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STEAM HEATING SYSTEMS

THERMOSTATS, HEATING / COOLING
THERMOSTATS, WATER HEATER
THERMOSTATIC EXPANSION VALVES

WATER HEATERS

ZONE DAMPERS
ZONE VALVES

More Information

Honeywell R8182D control explainedGuide to Heating System Boiler Aquastats
How to buy, replace, install, set-up, wire & troubleshoot heating system aquastats
     

  • AQUASTAT CONTROL Functions
    • Guide to the functions of a typical heating boiler combination control aquastat like the Honeywell R8182D, the Honeywell L8124A, and the Honeywell L8151A. Installation Manuals
    • Guide to the Honeywell 6006 Single Function Boiler Limit Control, How to set the HI LO and DIFF on a heating boiler control
    • How to disable the Aquastat LO circuit when abandoning a tankless coil
    • How to save money by setting the Honeywell R8182D and similar controls to their best adjustment positions
    • How to replace obsolete aquastats such as the Honeywell L8024B,D with the L8124-series controllers
    • Guide to the Honeywell L7224U1002 Universal Oil Heating Boiler Electronic Aquastat Controller
  • Aquastat control HI LO settings & Optimal LO/DIFF settings save fuel & Aquastat control DIFF settings & Disabling LO & DIFF - separate article
  • ELECTRIC WATER HEATER THERMOSTATS - separate article
  • L7224U Universal Aquastat - separate article
  • Single Function Limit Switches & Strap-On Limit Controls - separate article
  • THERMOSTATS, HEATING / COOLING separate article
  • Questions & Answers about the HI, LO, and DIFF Controls on Aquastats Used on Heating Boilers
  • References

Click to Show or Hide Related Topics

  • HEATING SYSTEMS - home
  • BOILER CONTROLS & SWITCHES
    • AIR BLEEDER VALVES
    • AIR SCOOPS PURGERS SEPARATORS
    • AQUASTAT CONTROL
    • BACKFLOW PREVENTER VALVE, HEATING
    • CAD CELL RELAY SWITCH
    • CHECK VALVES, HEATING SYSTEM
    • ELECTRICAL POWER SWITCH FOR HEAT
    • EXPANSION TANKS
    • FIRE SAFETY CONTROLS
    • LIMIT SWITCH, BOILER
    • LOW WATER CUTOFF VALVE, BOILER
    • MIXING / ANTI-SCALD VALVES
    • OIL LINE QUICK STOP VALVES
    • OIL LINE SAFETY VALVES
    • PRESSURE & TEMPERATURE SETTINGS, CONTROLS
    • RESET SWITCH, PRIMARY CONTROL
    • RESET SWITCH, ELECTRIC MOTOR
    • SPILL SWITCHES
    • STACK RELAYS
  • BOILER LEAKS CORROSION STAINS
  • BOILER NOISE SMOKE ODORS
  • BOILER OPERATION DETAILS
  • BOILER OPERATING PROBLEMS
  • CHECK VALVES, HEATING SYSTEM
  • CIRCULATOR PUMPS & RELAYS
  • DIAGNOSE & FIX AIR CONDITIONER / HEAT PUMP
  • DIAGNOSE & FIX HEATING PROBLEMS-BOILER
  • DIAGNOSE & FIX HEATING PROBLEMS-FURNACE
  • DRAFT HOODS - gas fired
  • DRAFT REGULATORS, DAMPERS, BOOSTERS
  • ELECTRIC HEAT, DIAGNOSIS, REPAIR
  • FAN AUTO ON Thermostat Switch
  • FURNACES, HEATING
  • FURNACE CONTROLS & SWITCHES
  • GAUGES ON HEATING EQUIPMENT
  • GAS PIPING, VALVES, CONTROLS
  • HEAT PUMPS, DIAGNOSIS, REPAIR
  • LOW VOLTAGE TRANSFORMER TEST
  • OIL BURNER INSPECTION & REPAIR
  • OIL LINE QUICK STOP VALVES
  • OIL LINE SAFETY VALVES
  • PRESSURE REDUCING VALVES
  • PRESSURE REGULATOR, WATER
  • RADIATORS
  • RELIEF VALVES, BOILERS
  • RELIEF VALVES, STEAM BOILERS
  • RESET SWITCH, Primary
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  • STEAM HEATING SYSTEMS & Controls - home
  • THERMOSTATS, HEATING / COOLING
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  • ZONE VALVES
InspectAPedia tolerates no conflicts of interest. We have no relationship with advertisers, products, or services discussed at this website.

Guide to aquastat controls on heating equipment: this article explains how aquastats work and what the different aquastat controls are, what they do, and how they are set. We define the HI LO and DIFF controls on heating boiler aquastats and explains what they do and how they work. We explain the location and use of the heating boiler reset button found on aquastats. We discuss relationship among HI, LO, DIFF, and heating burner cut-in, cut-out, and circulator lockout that are provided on the combination control. We explain how the Aquastat controls hot water production via a tankless coil on the heating boiler. We explain how to disable the LO control when a tankless coil is not in use on a boiler. After explaining the operation of an aquastat's Hi, Lo, and Diff controls we review the newer universal replacement aquastat from Honeywell, the L7224U Universal Aquastat, followed by a discussion of the simpler single-limit control switches. We discuss aquastat problems such as improper adjustment, improper wiring, and relay buzzing or failures.

Green links show where you are. © Copyright 2013 InspectAPedia.com, All Rights Reserved. Author Daniel Friedman.

Aquastat Guide to the Reset Button & HI LO & DIFF Temperature Settings on Heating Boiler Controls - Aquastats & Primary Controllers

Photograph of a multi function combination control on a heating boilerThe photo at page top shows a Honeywell R8182D combination heating control, also called an "aquastat".

But with the cover on you can't see much. Here at left is part of an inside view of a typical aquastat showing the three controls that need to be correctly set.

If you just want to set the HI LO and DIFF controls and don't care how they work or what they do, see our separate article on Aquastat control HI LO settings and Aquastat control DIFF settings.

This website answers most questions about Heating System Boiler Controls on central heating systems to aid in troubleshooting, inspection, diagnosis, and repairs.

Here we explain how to set and adjust the heating system controls to preserve this cold marriage. CONTACT us to suggest text changes and additions and, if you wish, to receive online listing and credit for that contribution.

How to Find and Use the Reset Button on the Aquastat Combination Control on a Boiler

Aquastat with reset button (C) Daniel FriedmanSummary of the Functions of a Typical Combination Protectorelay™ Primary Control and Aquastat® Controller

Our photo (left) shows an older aquastat type primary controller on an oil fired heating boiler. You can see the gray box covering the control in the right in our photo.

Depending on wiring hookup choices, this control operates the heating system oil burner, circulator, and zone circulators. It can also be configured (factory default) to keep the heating boiler hot to provide domestic hot water through a tankless coil even when the building room thermostats are not calling for heat.

The aquastat controller often also includes connections to a flame sensing device [typically a cad-cell (CAD CELL RELAY SWITCH) or on older heating systems a stack relay (Stack Relay Switch)] to shut down the boiler if the burner is not operating properly, and a "reset" button (Reset Switch - Primary Control) to re-start the heating system if it has shut down for safety. We discuss all of these controls in detail below.

The coiled "wire" leaving the upper right corner of this control is routed to a thermal sensor mounted in a well inserted into the water of the heating boiler.

Unlike the aquastat shown at the top of this page, poking through the upper-center of the cover of this heating system control you'll see a red "reset button" in the center of the upper portion of the gray control box.

If this heating boiler has turned itself off on SAFETY OFF you'll see that the button will have popped up higher out of the control cover.

If the red "reset" button on the this safety control is sticking up and the oil burner has shut down, the homeowner is permitted to try ONCE to "reset" the system by pressing the red reset button. Please be sure to read our more detailed instructions for using the reset button on heating equipment at our article: CAD CELL RELAY SWITCH.

Watch out: sometimes the red plastic button on older heating equipment primary controls can break off. At Reset Switch Broken - Quick Repair we show how to reset the equipment safely if this happens to you.

Where are all the heating system reset buttons? If you are looking for the main reset button on heating equipment you'll want to see: AQUASTAT CONTROL Functions and CAD CELL RELAY SWITCH (hot water boilers and some water heaters), Stack Relay Switch on older oil fired boilers and furnaces, SPILL SWITCHES (gas fired equipment), and also Low Water Cutoff Controls on steam heating systems. At ELECTRIC MOTOR OVERLOAD RESET SWITCH we discuss the thermal overload switch and reset button that is found on many electric motors including those operating air conditioning fans, heating system oil burners, and furnace blowers and motors.

Guide to Function & Settings on Combination or Multi Function Primary Controls (Aquastats) for Heating Boilers

Here we explain how to find and use the Aquastat reset button and how to find the HI LO and DIFF controls on aquastats. We explain how the HI LO and DIFF controls function to turn the burner on and off for both heating and for systems where a tankless coil is in use, also for making domestic hot water. This website answers most questions about Heating System Boiler Controls on central heating systems to aid in troubleshooting, inspection, diagnosis, and repairs.

At night we turn down the thermostat to 55degF to try to save on our heating cost. But our hot water is made with a tankless coil. This morning my wife got out of bed and stepped into the shower for a nice hot wake up. She turned on the water, pretty hot, and stepped in to its comforting stream.

I walked over to the thermostat and turned it up to 90 - thinking (in error) that the thermostat is like an accelerator, and the higher I set it the faster the house would reach a comfortable 72 degrees (wrong). I figured my wife would be able to step out of the shower into a nice warm house. Moments later I heard screaming from the shower as my wife got hit with freezing cold water. What happened? -- anonymous.

Basic Boiler Operation & Control Sequence using an Aquastat

On a call for heat from the thermostat, the zone circulator starts when water temperature is above Low Limit setting (if applicable - that is, if this feature is enabled - the default). The heating boiler temperature is checked. The burner starts when the water temperature is below High Limit setting.

When the boiler temperature reaches or exceeds the High Limit, the burner is turned off. The burner restarts when the
water temperature drops back below the High Limit setting minus the differential. As long as the circulator is continuing to call for heat and provided the control has not "locked out" the circulator (as we discussed above) the zone circulator will continue to circulate hot water through the heating zone.

When the thermostat is satisfied - that is room temperature has reached the thermostat setting, the circulator and burner are turned off. Stated with a bit of simplification, on most common boiler control set-ups in the U.S. the thermostat turns the circulator on or off, and the temperature of water in the boiler turns the burner on and off. (Heating systems in Canada operate differently: there most techs set up the circulator to run continuously if the boiler is "on" and a call for more heat at the thermostat turns the boiler's burner on until the thermostat is satisfied.)

  • Photograph of a multi function combination control on a heating boiler Combination control or primary control on heating boilers: this control, such as a Honeywell R8182D combine High Limit and "Low Limit" boiler controls (The dial marked "low limit" on a combination control may or may not be in use depending on presence of a tankless coil).

  • This primary control or aquastat is the most common type on modern heating boilers in North America. It controls the oil burner operation, turning the burner on or off as the boiler low limit or high limit temperatures are reached respectively.

  • This control may switch on and off a single circulator pump, and if a tankless coil is installed on the boiler, it may also turn the oil burner on and off as needed to maintain temperature in the boiler to provide domestic hot water as well. This control can also be used to control the burner and the first circulator of a multi-circulator zoned hot water heating system. The other circulators are controlled by individual circulator relays and thermostats.

What are the Three HI LO DIFF Controls & Dials We See Inside the Cover of the Honeywell R8182D Aquastat

Heating Control Operation Sequence: With some simplifications, the room thermostat calls for heat. The circulators start running, hot water leaves the boiler and heads for radiators or baseboards, cooler water returns from the building into the boiler. Boiler temperature drops to the cut-on or cut-in temperature. The burner turns on and re-heats the heating water inside the boiler until boiler temperature reaches the cut-off or cut-out temperature. The circulators keep running, and the boiler burner may cycle on and off in this manner, until the room thermostat is satisfied. Then the thermostat turns off the circulators and the burner, if running, will shut off when the boiler reaches the HI limit.

In Canada boilers operate a bit differently: the circulator pump may be set to run continuously, and the thermostat just turns the burner on and off. This gives more even heat and helps avoid a frozen heating zone pipe in very cold climates. Our aquastat function explanation below is bases on the "American" model or as the Canadians say, "the Yanks".

How the Aquastat HI Limit Settings and Functions Work to Control Building Heat

Honeywell R8182D internal (C) Honeywell

HI Limit: Combination Control High Limit:

The HI cut off temperature for the burner: on a typical aquastat or combination control, the "Hi Limit" setting specifies the cut-off temperature for the heating boiler's burner on a call for heat. That means that when the burner is running it will heat water inside the heating boiler until that water temperature reaches the HI or cut-off point. Then the burner is turned off.

The HI cut-on temperature for the burner is hard wired in this HI Limit control at 10 degF below the "Hi Limit" setting.

Example: Hi set to 200. Thermostat calls for heat. Circulators turn on. Hot water leaves the boiler, cooler water returns to the boiler, boiler temperature drops to 190, burner turns on and stays on until boiler temperature reaches 200 F.

The internal view of the Honeywell R8182D (left) can be found along with additional details about this control in the Honeywell R8182D,H Combination Protectorelay™ Primary Control and Aquastat® Controller Installation Instructions (link to copy below at References).

Following wiring details in the instruction manual, the R8182D,H can replace other aquastat controls such as the Tradeline R8182B, R8182E, R8182F, R8182H, R8182J, or White Rogers 6C92.

A newer combination control from Honeywell, the Honeywell L7224U Oil Electronic Aquastat Controller can replace more than 40 older hydronic controls.

How the Aquastat LO Limit Settings and Functions Work to Provide Domestic Hot Water & Circulator Lockout

Low Limit setting on an aquastat

During the summer, because the thermostat never calls for heat, the HI control will never turn on the boiler. The HI limit operates a relay that is turned on by the thermostat and turned off by the boiler reaching the HI or cutoff point.

Out of heating season, your thermostat stops asking for heat, so the HI goes to sleep.

Out of the heating season, the LO gets to work, as we describe here.

What the LO limit actually does: The LO limit is a setting which is intended to maintain heat inside the boiler in order to assure that the boiler can produce hot water when a tankless coil is installed and when the room thermostat's calls for heat are not already keeping the boiler nice and hot.

During warm months when the boiler is not being called-on to heat the building itself, the "Low Limit" keeps heat in the boiler for the tankless coil. So the "Low Limit" is actually a "low range" operating upper limit on boiler temperature that applies out of the heating season or when the thermostat is not calling for heat.

On typical aquastat heating control the LO or "Low Limit" is NOT the "cut on" point for heat (we explained the heat cut-on just above).

It is helpful in understanding the LO limit to call this the "circulator" controller. Provided that DIFF is set to 10 (its smallest value), then

when boiler temperature falls 10 degF below the LO setting, the burner turns on and the circulator is forced to turn off - we call this "circulator lockout" - we are re-heating water in the boiler and we are preventing boiler water from being sent out to the baseboards or radiators - giving priority to heating the tankless coil.

when boiler temperature rises back up to the LO setting, the burner turns off and the circulator is allowed to turn on - we are unlocking the circulator and allowing the building to be heated again - and taking priority away from giving heat to the tankless coil.

We say the circulator is allowed to turn on because if the room thermostat is not calling for heat, the circulator may have permission to turn on, but the thermostat is leaving the circulator(s) turned off (in the U.S., not on many Canadian heating systems).

And note that we say that the burner turns off as the boiler temp rises up through the LO setting. But if the boiler is being turned on from a fully cooled-down "cold" condition and the room thermostat is calling for heat, the burner will turn on and keep running right up through the LO and on to the HI. Why? Because the thermostat was calling for heat.

Circulator Lockout: The LO limit works in concert with the DIFF setting to control the operating temperatures of the boiler when it is being asked to heat the tankless coil (used for making domestic hot water for washing and bathing), and together they also control when the circulator pump should be locked out so that priority is given to keeping the boiler itself hot - presumably because you're in the shower and the tankless coil is in use. At Avoiding Circulator Lockout we provide more detail about this function.

How the Aquastat DIFF Settings Work - DIFF, the Combination Control Differential

Blue jumper disables low limit controlThe DIFF or "differential" setting on an aquastat adjusts the LO range temperature cut-off point when boiler temperature is rising (the burner is on). The DIFF ONLY talks to the LO control, it has nothing to say to the HI control.

Even though the LO and DIFF settings will allow the circulator to run at certain temperatures, the circulator pump(s) still won't run unless the room thermostat is calling for heat.

When boiler temperature is falling: DIFF settings at values other than 10 do not affect the temperature at which the burner turns on and the circulator locks out when boiler temperature is falling.

When boiler temperature is rising: on this control, the "DIFF" or differential control dial specifies the amount above the "Low Limit" to which boiler temperature must rise before the burner will turn off and the circulator will be allowed to run.

We said the circulator pump is allowed to run because if the thermostat is not calling for heat, even though the DIFF + LO are allowing it, the circulators will not run (in the U.S.).

Watch out: as we explain below, realizing that tankless coils on heating boilers, especially modern small high-efficiency boilers, have rather limited ability to deliver much hot water to the building, most users set the "DIFF" control to its smallest number, 10, thinking that means the burner will come on as soon as possible when it's needed to make hot water out of the heating season. As Damian pointed out in email, that's a mistake if you want as much hot water as possible out of your tankless coil.

At this "lowest" DIFF setting of 10, on a boiler temperature rise, the burner turns off (R-B breaks) and the circulator turns on (R-W makes, to deliver heat) at the LO limit (and "circulator setting" setpoint. So if the LO is set to 120 and the DIFF is set to 10, when the boiler temperature rises to 120 the burner turns off and the circulator is allowed to run - that is to circulate water out of the boiler to the baseboards or radiators.

We call the LO the the "circulator lockout" control or the "tankless coil control" to try to make this more clear. In other words, when the LO is satisfied (we have hot water for the tankless coil), then we can go back to delivering heat to the building IF the building room thermostat is asking for heat.

At any DIFF setting above 10, the (R-B make - burner on) and (R-W break - circulator off) temperatures remain the same as we just described above. LO control setting minus ten degrees.

But the (R-B break - burner off) and the (R-W make - circulator on) temperature will now change to be the LO set point temperature plus the difference between the DIFF set point number (for example 20) and ten degrees. Honeywell gives a helpful example: (refer to the yellow area in the sketch to help understand this feature) [we edited the original text slightly for clarity]:

If the LO is set to 140 degF, and DIFF is set to 25 degF, on a temperature rise, the oil burner turns off (R-B breaks) and the circulator is allowed to run if the room thermostat is asking for heat (R-W makes) at 155 degF (25 degF - 10 deg = 15 degrees; 140 + 15 = 155).

And when the boiler temperature falls, the burner turns on (R-B makes) and the circulator will not be allowed to run (R-W breaks) at 130 degF (LO of 140 - 10 degF).

Adjusting the DIFF to numbers higher than 10 does not change the boiler turn-on temperature ("R-B make") nor the circulator turn-off temperature ("R-W break"). But it does affect the boiler turn-off temperature (R-B break) and the circulator turn-on temperature (R-W make) as follows: the new boiler-off and circulator-on temperatures will be equal to the LO setting plus (DIFF-10).

More HI LO DIFF Setting Examples:

LO = 120 F, DIFF = 10 F: when the boiler temperature drops to 110 the burner turns on and the circulator is turned off. As the burner re-heats the boiler and the boiler temperature rises back up to 120, the burner turns off and the circulator is allowed to turn on.

LO = 120 F, DIFF = 25 F: when the boiler temperature drops to 110 the burner turns on and the circulator is turned off, just as before. But as the burner re-heats the boiler and the boiler temperature rises back up to 135 F, the burner turns off and the circulator is allowed to turn on. We calculated the 135F as follows: LO setpoint of 120 is added to (DIFF minus 10) or 120 + (25-10) = 135.

LO= 140 F, DIFF = 25 F: when the boiler temperature drops to 130 F the burner turns on and the circulator is turned off, because the burner-on temperature is always fixed at 10 below the LO, just as before. But as the burner re-heats the boiler and the boiler temperature rises back up to 155 F, the burner turns off and the circulator is allowed to turn on. We calculated the 155F as follows: LO setpoint of 140 is added to (DIFF minus 10) or 140 + (25-10) = 155.

The effect of setting the DIFF up from 10 to 25 is that when the burner is re-heating the boiler (for example while the tankless coil is in use and you're in the shower), the burner heats the boiler temperature up to a higher level before the burner is turned off and the circulator is allowed to turn back on. This gives more heat to TANKLESS COILS and therefore more domestic hot water to the building occupants.

This Honeywell Aquastat Chart Further Explains of How the HI & LO Limit & DIFF Controls Work on an Aquastat

Chart of function of HI LO and DIFF on an aquastat (C) HoneywellEven many heating service technicians (those who failed to read the installation instructions for the control they are servicing) are confused about the relationship among the three adjustable controls on the aquastat: the High Limit Setting, Low Limit Setting, and Differential or "Circulator Setting". Our text (below) and Honeywell's sketch (left) explain these functions.

Here we reiterate the explanation above, trying a little different approach that may help some readers.

On primary controls (aquastats like the like the Honeywell R8182D, the Honeywell L8124A, and the Honeywell L8151A) the HI Limit control (and dial) operates at a heating boiler water temperature range defined as follows:

HI (High Limit) sets the boiler Cut-off temperature or burner turn-off temperature on a call for heat - the temperature to which the HI dial is set.

The boiler Cut-on temperature or burner turn-on temperature for the boiler, AS LONG AS THE THERMOSTAT IS CALLING FOR HEAT is fixed at 10 deg.F. below wherever the HI is set. (Green in our edited version of Honeywell's drawing.) On some controls this hard-wired fixed gap may be 15 degF.

So if HI is set to 200 degF that's the cutout temperature, and the cut-on temperature for the boiler, as long as the thermostat is asking for heat, will be (200 - 10) = 190 deg.F. (or 185 degF on controls with a 15 degree fixed gap.)

See details at Aquastat control HI LO settings

The "LO" is set at least 20 deg F. below the "HI" limit on a combination control. If we set the "LO" any closer top "HI" the control, trying to give priority to making domestic hot water for someone in the shower, will simply lock out the circulator pump entirely - the heating circulator will never run.

DIFF (Differential or Circulator): the Cut-OFF for the burner when the system is operating in the LO range (i.e. the room thermostat is not calling for heat) is adjustable by the DIFF or differential dial. (Yellow on our edited version of Honeywell's drawing, above). Thanks to reader powderfinger5 for careful reading of this text. DIFF specifies the number of degrees above the LO setting at which the burner will turn OFF and the circulator will be allowed to turn ON when the burner has been on and water temperature in the boiler is rising.

We explain more about the DIFF function in detail at Aquastat control DIFF settings.

Abandon or disable the LO setting if a tankless coil is removed from use?

For boilers that do not use a tankless coil to make domestic hot water, at Disabling the LO and DIFF settings we explain in detail how and why you might want to disable these controls.

But first review the details at Aquastat control HI LO settings.


Frequently Asked Questions (FAQs) about Heating System Aquastat Troubleshooting, Settings, & Diagnostic Suggestions

What are the Optimal Settings for the Aquastat HI, LO, & DIFF Controls for Heating Fuel Savings?

Question: What are the Optimal LO & DIFF settings for moderate hot water use in summer?

What would be the optimal setting for the LO & DIFF settings for fuel savings with low and with moderate hot water usage in the summer months when the boiler functioning for heat does not come into play. If you would please identify the low usage from the moderate usage settings it would be greatly appreciated. - Mark

This is an excellent article on the DIFF setting as it pertains to using a Tankless Coil. During the summer in North Carolina when outside temperatures are in the 90's and my system never calls for heat, I am only running my Burnham boiler to provide hot water. It is not unusual to burn 1 gal of oil/day (30 gals / month) just for residential hot water. With oil prices well above $3.50/gal, $100/ month for hot water is a little extreme.

I am curious if some combination of LO Limit / DIFF might cause the burner to run less while still maintaining adequate heat to provide hot water. For example, if my current settings are LO 160/ HI 180/ DIFF 10, might adjusting the LO/DIFF settings either up or down lower oil consumption? I suppose another option could be to use an electric hot water heater with a tank during the summer months. - Tony

I have a VERY old system. Have two separate aquastats, one used for LO and one used for High. No Diff. I have a separate hot water heater. Because of the old system the oil company technician feels that I should keep the furnace on during the summer so that there isn't a "shock" to the system when it is turned on in the fall. Question: What are the best HI-LO settings in the summer and in the heating season.? - Steve

Reply: Summer Aquastat Setting Recommendations

Mark and Tony and Steve: For summer use, if you set the LO to its lowest temperature setting (typically 102 F) you will be keeping minimal heat in the boiler to support the tankless coil in summer and will lower your heating fuel consumption by as much as 30%.

For summer use, if you set the DIFF to its lowest setting you will also lower your fuel consumption.

The result of these settings will also be a reduction in the quantity and also the maximum temperature of hot water supplied to the home - which may be OK for cases when hot water use is only moderate.

If you have an automatic tempering valve or mixing valve installed on your hot water supply that will increase the total hot water quantity available by drawing heated hot water from the boiler only at the rate needed.

Tony: You can leave the HI setting on your Aquastat alone in summer; since the system will never be calling for heat, the HI will be asleep all summer.

If you set the LO down to a lower number in summer you will be keeping less heat in the boiler, and in that sense burning less oil; but if your mixing valve is a MANUAL one you may need to adjust it so that water at the tap is hot enough.

If you keep the DIFF to its lowest number in summer you're also minimizing the oil burner on-time. Or conversely, if you set the DIFF to a higher number (say in summer), quoting from the article above:

The effect of setting the DIFF up from 10 to 25 is that when the burner is re-heating the boiler (for example while the tankless coil is in use and you're in the shower), the burner heats the boiler temperature up to a higher level before the burner is turned off.

Steve,

Given that you are not using your heating boiler for making domestic hot water, the reason a service tech would recommend keeping it on in summer is most likely because some older cast iron boilers can develop leaks between the boiler sections if the boiler is allowed to cool off to stone cold. Such a leak may not "heal" on its own when heat is restored, and it can lead to worse boiler damage.

For summer use on such a system, keeping just about any heat at all in the system, say 100 degF should be sufficient. If your LO is currently set above that number, try setting it down for the summer - but don't forget to restore it at the start of the heating season.

I am inferring that the HI on your system is an upper limit on a call for heat and won't be operating in summer. If I'm mistaken, just keep the HI 20 degF above the LO.

Question: What are the best Hi Lo DIFF settings on an aquastat?

Right now I have baseboard heat and I have the boiler set at HI-170 LO-150 and DIFF at 10. Is that a good Setting. I'm trying to save money on oil. thank you - Matt

I'm still not 100% sure on what my settings should be. I have a Weil Mclain boiler that's about 6 years old with a DHW coil installed. I had a 30 gallon electric hot water heater installed after the coil, and during the summer I would shut off the boiler and use only the hot water heater. During heating season the water would be pre-warmed by the coil and the electric heater wouldn't be doing much.

Problem is, we seem to be using a lot of oil. The boiler is constantly running, every time we use the shower, run the dishwasher, wash our hands, etc. It's also constantly kicking on to keep hot water in standby. During the early heating season, it's a waster, since the boiler isn't on very much to provide heat to the house. What should my settings be? Will I save more money by just not using the coil and telling the aquastat there's no coil? - Matthew

I live in Maine and the winter season is here. What would be a good Hi and Low setting for my aquastat? Its is starting to dip below 10 degrees at night. Thanks. - Nick

Reply:

Nick and Matt:

Under AQUASTAT CONTROL Functions (the article above on this page) you'll find good aquastat HI LO and DIFF setting recommendations in the article titled  Optimal LO/DIFF settings save fuel

Matt: you can significantly save on heating costs by lots of other measures including using a thermostat setback to lower temperatures at night or when the home is unoccupied. See HEATING COST SAVINGS for our suggestions of a variety of ways to save on heating costs, and importantly some priorities: what heat cost savings steps should we address first at a building?

Question: What are Normal Boiler Temperatures When the Aquastat has Turned off the System?

Our aquastat shuts off burner at 190 degrees but old and new temp gauge continues to rise to 215 degrees. is this normal? - Warren G.

Reply: It is normal for boiler temperatures to sometimes rise a bit after the burner has shut down

Warren: it is normal for temperatures inside a heating boiler to continue to rise a bit after the Aquastat has turned off the oil burner at the HI or when the thermostat has stopped calling for heat.

This temperature rise may occur because:

  • The latent heat in the heating boiler combustion chamber and in the steel or cast iron body of the boiler itself continues to heat the water inside the boiler even after the oil or gas burner has stopped firing

and

  • The circulator pump(s) have simultaneously stopped sending hot boiler water out into the heating zones.

As long as boiler temperature does not rise high enough to cause the pressure/temperature relief valve to spill you should be fine.

Question: When Abandoning a Tankless Coil: Should We Change the Aquastat Primary Boiler Control Settings

I am currently installing a hot water heater to replace a tankless coil in my boiler. Do I need a different aquastat to keep my boiler from trying to heat the coil? Can I replace my present aquastat #l8148a with #l8124a??? - John Haines

We installed an electric hot water heater, do we have to change anything to make the boiler function just for heat and not hot water (for bathing, dishes etc) ? - Ernie

I have replaced the tankless coil in the boiler with a gas water heater thus eliminating the need for the boiler to heat water for bathing,washing etc. question does the aquastat still needs to be connected for my boiler to run to heat the house? - jorge gonzalez

Reply: Disable the LO & DIFF settings OR set them to their lowest setting when abandoning a tankless coil

John:

Take a look at the instructions that come with the aquastat and you'll see a list of devices it can replace. But most likely you do NOT have to replace your aquastat with a different model just because you are ceasing to use the tankless coil for domestic hot water.

On the aquastats discussed here, the instructions (at Disabling LO & DIFF) describe a simple process for disconnecting a wire that will disable the low-limit control, thus eliminating that function when a tankless coil is no longer in use.

Ernie, When you abandon or stop using a tankless coil on a heating boiler, you can save on heating fuel consumption by disabling the LO / DIFF feature on your aquastat. The effect is that the aquastat (primary boiler controller) will stop keeping the boiler hot when there is no call for heating the home itself.

If you leave the LO/DIFF working, the boiler will keep heating itself even in summer when there is no call for building heat - because it thinks it's staying hot to support use of the (now abandoned) tankless coil.

Jorge, you still need the aquastat control, since it has to manage the boiler on and off temperatures when the wall thermostat(s) call for heat in the home itself. But as we explain above, the aquastat controls can be changed to stop keeping heat in the boiler to support the tankless coil that is no longer in use.

The procedure for disabling the tankless coil heating system is in our Aquastat Settings article at Disabling LO & DIFF

Question: How Much Will I Save on Heating Cost by Lowering the LO/DIFF Settings on the Aquastat?

Dan, thanks for answering my questions on my recent hot water heater installation. I disconnected the differential wire (see Disabling LO & DIFF) on my aquastat and now my system works perfectly. - Tony

Hi Dan. ..Thanks for answering my question from June 28, 2011. I did, in fact, reduce the LO limit setting this summer from 160 to 120 and it reduced my oil consumption for heating hot water by about 30 percent. I left the DIFF setting unchanged at 10. To be honest, I was a little unclear from your response about the effect raising/lowering the DIFF setting would have on overall oil consumption during the summer months. However, adjusting the LO setting definitely had the desired effect. It was not necessary to adjust my manual mixing valve because the shower water was at a comfortable level. Thanks for taking the time to answer my question and for the valuable information contained on this website! - Tony

Reply: Oil Consumption Savings Reported to be 30% When LO set Back

Thanks for the feedback that lowering the LO setting will save heating fuel during summer months. We have edited the HI, LO, and DIFF functions above to make that text more clear.

Basically, by lowering the LO to its lowest point (120) you reduced that amount of heat kept in the boiler during the summer (when the only function of the boiler is to stay hot in order to heat the tankless coil used to make domestic hot water). Like you I'd have also set the DIFF to 10 as well.

If you are continuing to use a tankless coil for your home hot water supply, you might want to set the LO back up to 20 degrees below the HI in winter because in cold weather the tankless coil is receiving colder incoming water from the building public or private water supply.

Reader Comment: heating cost savings from aquastat settings

Hi Dan. ..I just wanted to clear up that the 30% savings you mentioned in the article were those that I reported in my post as a follow up to the June 28, 2011 post. ...

I can confirm the excellent point you made about setting the LO back up to 20 degrees below the HI in winter because of colder incoming water from the public water supply. It is now late October in NC and I still have the LO limit setting from this summer at 120 with the DIFF setting unchanged at 10. I have not begun to use the system for heat yet and am only running the boiler for hot water.

I have noticed a definite decrease in shower water temperature and will shortly need to reset the LO back up to 20 degrees below the HI. Again, thanks for all the valuable information you provide on your website! - Tony [October 2011]

Question: sorting out HI LO and DIFF - what setting does what?

There seems to be some conflicting info on the site. In some articles, you say that the DIFF is the temperature rise over the LO setting. For example, DIFF 15 and LO 120 would mean you'd have a range of 120-135. In this article, it's explained that there always a 10 degree drop below LO and a rise above LO of DIFF-10, meaning DIFF 15 and LO 120 would give you a range of 110-125. Which is true? And what about aquastats that have a 5 degree DIFF setting? - Brian

Reply: summary of HI LO DIFF definitions and functions on an aquastat

Thank you for the clarification request, Brian. We've reviewed our HI LO DIFF setting articles to be sure that the text is now self-consistent.

Summarizing the definitions of HI, LO, & DIFF controls on an aquastat control

HI Limit Definition: The HI is the cut off point on a call for heat. You can think of the HI dial as the "heat control" in this regard: as long as the room thermostat is calling for heat, when the boiler temperature falls 10 degrees below the HI the burner will (normally) turn on. That 10 degrees is hard-wired into the control - it's not adjustable.

LO Limit Definition: the LO is a control function added to keep heat in the boiler when the room thermostat is not calling for heat. This feature is important on heating boilers that use a tankless coil immersed in the boiler to produce domestic hot water.

The DIFF Definition: the DIFF is an added control that defines the cut-off temperature (above the LO) during a burner-on cycle initiated by the LO control - that is, we are not calling for heat, and we're keeping heat in the boiler to make domestic hot water. It works as you described.

Circulator lockout: There is an interaction between the LO and DIFF settings and the delivery of heat to the building however. That is that the LO operating range on an aquastat also will lock out the heating circulator pump - stopping delivery of hot water out of the boiler and into baseboards or radiators - if the boiler temperature is too low. (That's why aquastat instructions specify that the LO should always be at least 20 degF below the HI setting).

The intent is to give priority to the tankless coil and thus the person in the shower. For heating boilers at homes that do not use a tankless coil to make domestic hot water, it is sometimes (not always) reasonable (and a savings on fuel during summer months) to disable the LO/DIFF controls - as we explain at Disabling LO & DIFF

See Aquastat control HI LO settings for details about how the HI and LO settings work.

See Aquastat control DIFF settings for details about the DIFF setting and how it works

See Optimal LO/DIFF settings save fuel for some recommended settings to save on heating fuel cost

Question: Buzzing sounds from heating controls

When my oil burner is starting up I hear a loud buzzing from the boiler room.

Reply: check for a bad relay or a relay that is being impeded by the control cover

Buzzing noisy aquastats, also any other heating controls that use relays, such as some cad cells, stack relays, and circulator relays: if you hear a buzzing sound coming from your aquastat check to see if the control cover is pressing down on one of its relays. Details, photographs, and an explanation are at HEATING SYSTEM NOISES.

Question/Comment: Rusty crud found on the bottom of the heating boiler firebox

As Tony said in his comment above, I also was using about 1 gal of oil per day during the non-heating months. In Connecticut, we are paying close to $4.00 per gal now. I installed an electric water heater in parallel (NOT series) with the boiler's tankless heater. Either the tankless or the electric can be used since the water does not go through one and then the other. (Glad I still had the tankless piped up since I could still have hot water during the recent 10 day power outage in Connecticut. The 4000 watt generator could run the boiler but not the 4500 watt electric heater.) I found that we are using about 11 kwh/day for domestic hot water by timing how long the 4500 watt heater elements were on each day - a 240 volt relay activating a battery powered clock.

The cost at $0.17/kwh is about $1.90/day - better than 1 gal/day at $4.00. I turned off the boiler when I turned on the electric water heater. My concern is that when I went to tune-up the boiler for the 2012 heating season, I found about one cup of rust (some of the material was magnetic) on the bottom of the firebox below the cast iron boiler sections. I open the firebox for cleaning each year and have not seen this much rust before. I have brush cleaned the flue passageways twice since new and don't recall seeing this type of material. The boiler is a Dunkirk that was new in 2001. Water leakage does not appear to be a problem. Should I be worried about damaging the boiler (corrosion) by letting it go stone cold during the non-heating season? - Buddy 1/12/12

Reply:

Buddy, thanks for the important comments & question. Indeed on many boilers, if you leave the unit shut down for months there can be problems with rust and also with solidification of soot and crud deposits that make seasonal cleaning more difficult (and perhaps costly).

If the boiler and tankless coil is left "on" but not in use, it will run only very little, as it runs just to keep itself hot - it's never cooled down to a longer on-cycle by having moved its hot water out into heating zones.

Alternatively at least it's a good idea to have the annual service/cleanout done in the spring at the end of heating season - don't let it sit over the summer.

Question: retrofitting a 15 year old boiler with a new Honeywell Electronic Aquastat

I am thinking about retrofitting my 15 years old oil burner with new Honeywell electronic aquastat which includes Outside Temperature Reset module. Has anybody done it ? This would allow me to adjust HI water temperature as a function of outside air temperature. They say this would result in 10-20% fuel savings. Has anybody done it ? Is it worth doing it ? Thank you. - Pavel 2/13/12

Reply:

The retrofit aquastat control you describe will function properly if properly connected. the actual heating fuel savings ... well that depends on quite a few variables. "Up to" claims, in advertising law, need be true only about 10% of the time.

Question:

I have a 17 year old Rheem boiler which works just fine. However the temperature differential between on and off has become too great despite my setting the thermostat to 5 degrees. It is time for a new thermostat, but I don't know what to buy. The cover on my thermostat says honeywell aquastat type l8100. eco thermostat. The body says L4005A2080. another part of the body says C0704. I have a blue and white wire to connect to the gas control. There is one bare copper wire going from the center of the thermostat screw on to the left side. That's all the description I have. - Alan 8/21/12

Question:

i had an issue with my boiler , i figured it out it was my aquastats l8124,any icalled my local place and was told a used one was 190.00 rebuilt?? i was told by another place there are no rebuilt aquastats.help!!!!!!
ptsd1969@hotmail.com - Anon 10/3/12

Questions & Answers About How to Diagnose & Fix an Aquastat Control on a Heating Boiler

Question: Boiler won't run: when one of my three thermostats calls for heat the circulator runs but the boiler does not

I have a three zone hot water baseboard heating system. I have three zone valves and only one circulator pump. My zone valves are made by honeywell and I believe they are the newer version. When I raise the thermostat (upstairs zone) I can hear the circulator pump kick on, the switch on top of the zone valve is in open position and I can hear a click come from the boiler.

The problem is that the boiler never comes on to heat the water to a sufficient temperature. When I put my hand on the pipe directly coming out of this zone valve the it is warm at best. My baseboards upstairs never really get that hot and are unable to raise the temperature in the upstairs of the house. When I operate the other thermostats in the other zones of the house, the furnace kicks on and heats the the water to temperature. What could be causing the furnace to not kick on in the in the one zone? - Joe.

Reply: from reader Joe P.

If it is only in the one zone you describe: it may be that the boiler is up to temperature and does not need to "kick on". Observe the temperature on the gauge. Small loops/zones do not take the heat away as fast. Also, there could be blockage. I have also seen in homes that set the thermostats to low, that freezing occurs in the loop, and thus, poor heat output. You also may have air in the lines which will have to be purged. Turn down t-stat to lower temperature so that all heating goes to the troubled loop and see what happens.

Clarification: Turn down the t-stats to the two other loops (that are working) so that all heat goes to the troubled loop that you have activated (via t-stat for troubled loop).

Reply-DF:

Joe, from your description we can exclude the case that the boiler does not run because it's already up to temperature - since you say that you feel no heat in the problem circulator piping and baseboards. We like Joe P's advice to see what happens when you turn down or up thermostats to the other zones. Here are more diagnostics:

Heating zone air bound or stuck zone valve: Joe P. refers to a possible blockage in the problem heating zone. Indeed if the zone is air-bound (see AIRBOUND HEAT SYSTEM REPAIRS) or if the zone valve motor is itself stuck (see ZONE VALVES) then even though the system circulator runs, it never pushes hot boiler water out into the problem heating zone and therefore it never pushes cold water back from the problem heating zone into the boiler where that cooler water would cause the boiler to turn on.

Question: Boiler sometimes won't run": some of my zone thermostats call for heat, the circulator runs, but the boiler won't come

When one or sometimes two of my three heating zone thermostats call for heat, the circulator runs, but for two of the zones, the boiler won't come on until the third zone thermostat is also calling for heat. - DF

Reply: check for a bad control, switch, or relay

This problem could be due to a wiring error or a control problem, as we detail below.

Burn-up on Honeywell Type L8182A, C L8151A Aquastat control board leaves one or two heating zones inoperative

Honeywell L8124A control board burnup (C) D FriedmanWe recently observed the symptoms, debugging, and solution to a similar no-heat in one zone problem. The zone was not air bound. Three thermostats control three individual zone circulators (Taco brand).

The thermostat for zone 3 in a house would call for heat, trip on the circulator, but the boiler would not turn on unless one of the other zones was calling for heat.

The second service tech (from Bottini Fuel, Poughkeepsie, the first fellow said he couldn't see anything wrong), traced the problem to a burned-out circuit on the aquastat control board. We replaced the aquastat and indeed now any thermostat that calls for heat can both turn on the circulator and if appropriate (based on temperatures at the boiler) turn on the boiler's oil or gas burner when it should.

Our photo of this very Honeywell L8124A aquastat control circuit board, with the wires removed, shows brown burn marks around the ZC terminal on the device. (Photo above left). Aside from more sophisticated circuit testing, you might spot this kind of trouble by simple visual inspection of electrical controls and components. Nothing should look "burned-up".

Watch out: a mis-wired multiple zone or multiple circulator pump system can also prevent one or more of the zones from operating correctly. So can a mix of different brands of zone valves that require different wiring.

Question: Boiler will run but the circulator pump(s) do not ever start.

Aquastat with improper control settings HI and LO (C) D FriedmanWhen any of my three heating zone thermostats call for heat, the boiler will run, but it seems to take forever for the baseboards to get warm, especially on the longer runs.

I finally figured that none of the circulators is running. Because there are three circulator pumps and circulator relays, each controlled by an individual wall thermostat, it seems unlikely that all of them are bad. What should I check? - Charlie G., Calais, Maine.

Reply: check the aquastat control settings for crossed or reversed HI LO controls, then check primary control relays

The photo (above left) illustrates Charlie's aquastat with improper settings for the HI and LO. The HI is set to 180 and the LO is set to just under 200!. Sorry Charlie G. but that's not going to work right.

Photograph of a multi function combination control on a heating boilerWe have found this problem lots of times when a homeowner or someone else messed around with the HI, LO, and DIFF settings on the aquastat without having a good idea of what those dials do. Aquastat manufacturers such as Honeywell make clear that

The HI should always be set at least 20 degF. above the LO.

If you "cross the controls" - that is, if you set the LO to a temperature that is less than 20 degrees lower than the HI setting, you have basically locked out the circulators.

The oil burner runs, but the LO control is preventing the circulator from coming on. Take a look at the definitions of HI and LO above and this will be more obvious.

Our photo immediately above shows settings that OK - the HI is set to a little over 180 and the LO is set to 160.

Question: my heating boiler won't start

this morning the boiler was not heating. It worked very well during the night. No light in the furnace. I turn off and turn on the gas igntion and nothing happened. What can be the problem? has the damper related to this issue? I change the button from one side to another side and nothing. Also, how can I switch on the spill gas? I think that the problem is the sensor, because it was smoke near the boiler area and maybe the sensor shut off the gas but I do not know where is it. My boiler is UTICA model. - Anon 11/7/12

Reply:

Anon, with just the information you state, I'd start at the beginning of our no-heat for boilers, see DIAGNOSE & FIX HEATING PROBLEMS-BOILER - troubleshooting. Indeed there could be a bad flue gas spill sensor, but I wouldn't start there.

Question: Indirect fired water heater operation when a tankless coil is also available

I have a strange config. My DHW tank is a zone (tank was added after the fact), but only triggers the LO setting, so it doesn't get the the hotter water that my heating zones get. To complicate things, the water still passes through the tankless and the "Temp-A-Rator" mixing valve. So, in effect, I pre-heat my hot water. Bypassing the tankless would be expensive and I guess I'd need to then have the tank wired so that it triggers a higher water temp (additional aquastat?). I also don't understand this [apparently obsolete] mixing valve. Is it manual? Should I replace it? Ok, I'm rambling. Would appreciate any and all thoughts. - Chris - Chris 5/10/12

Reply:

Chris,

When domestic hot water is made by a separate tank heated by a zone on the heating boiler, we call that an indirect-fired water heater system. The LO and DIFF settings have nothing to do with that water heating method - the LO and DIFF make sense and are used when there is a tankless coil in use.

The heating zone, control, and circulator pump (or zone valve) that heats your separate hot water tank just looks like another heating zone as far as the heating boiler and its controls are concerned. Hot water from inside the boiler itself circulates through a heating coil in the bottom of the hot water tank in response to a thermostat on the hot water tank.

But if a heating boiler uses a tankless coil as a pre-heater or post-heater for the water entering the hot water tank, then indeed you've got two water heating methods in parallel - which can be confusing. In fact, you can think of them separately, and controlled separately.

Take a look at the water piping that brings cold water from the building water supply into your hot water heating tank. If the cold water runs first through the tankless coil, then yes you are pre-heating water entering the hot water heater tank. Some plumbers pipe in the opposite direction, that is, allowing hot water leaving the hot water tank to pass through the tankless coil for a boost that takes effect when the hot water in the separate tank is nearly used up or is cool.

See INDIRECT FIRED WATER HEATERS for details of how these systems work.

Question: L4081B aquastat doesn't seem to be behaving like it should

Great information here. I had to read a few times to put it all together, but I think I finally got it. I have an L4081B aquastat and it doesn't seem to be behaving like it should.

From a cold start with no call for heat (I turned down the thermostats) the burner stayed on all the way to the HI setting (in my case 180°). Shouldn't it cut off at the upper limit of the LO setting?

My Hi is set to 180° and LO at 130 with a 20° DIFF. I have a tankless coil. - Steve 11/7/2012

Reply:

If there is no call for heat but the boiler cycles on, I'd expect that ON cycle to be driven by the LO and DIFF controls just as you describe.

Question: my heater won't turn off; replacing the thermostat did no good, what do I try next?

my heater just don't stop heating my house i tried a new thermostat what should i try next please - Frank Carr 11/12/2012

Reply: things to check when the heat won't turn off, & some Safety Warnings

Buddy said: Frank, You may have a problem with your boiler controls or a check valve in the hot water piping system.

Take a look at "Guide to Heating System Boiler Check Valves & Flow Control Valves" [found at CHECK VALVES, HEATING SYSTEM ] to see if this information helps you determine if a check valve is sticking open. In any case, you will probably need the services of a service technician to check out the controls or a plumber to replace a check valve if it is sticking open. - Buddy 11/12/2012

Daniel (Moderator) said:
Frank: in addition to Buddy's suggestion just above, some other reasons that heat may not turn off in a building include:

  • The thermostat is continuing to call for heat because it is in a draft, is damaged, or stuck
  • The thermostat wires are shorted together anywhere in their run - this is the same as leaving the thermostat set to its highest setting.
  • The aquastat or high limit temperature sensors are not properly sensing boiler water temperature because of a bad sensor or because the sensor was not properly mounted in its well on the boiler. The manufacturers recommend using a temperature-conducting grease, though some techs I know like to leave the grease off.
  • The heating system is unable to adequately warm the room where the thermostat is located
  • If the heating boiler keeps running but is unable to satisfy the thermostat, that is it can't get the room temperature up to the thermostat SET temperature there could be other problems such as
    • An air-bound heating pipe, baseboard or radiator that is just not delivering heat to the room where the thermostat is located. See AIRBOUND HEAT SYSTEM REPAIRS
    • The thermostat is on a cold exterior wall or is in a cold draft and is not properly sensing room temperature. See THERMOSTATS, HEATING / COOLING for details on thermostat installation, wiring, and setting.
  • Watch Out: some safety things to check when your heat won't turn off include
    • Check the heating boiler temperature gauge - if the boiler temperature is at or above the HI limit set on your boiler aquastat or upper limit control switch then something is abormal and unsafe and you should turn the system OFF immediately and call for heating system service and repair. See GAUGES ON HEATING EQUIPMENT
    • Check for discharge, drips, leaks, or spillage at the boiler's temperature/pressure relief valve. If if the boiler temperature is at or above the HI limit set on your boiler aquastat or upper limit control switch and the relief valve is not dumping hot water and pressure then something is abormal and unsafe and you should turn the system OFF immediately and call for heating system service and repair. See RELIEF VALVES, BOILERS or for steam boilers see RELIEF VALVES, STEAM BOILERS
    In any case you should call a heating service technician to inspect and repair the system promptly.

Question: how do I find a replacement Aquastat for a L8024B1048 (triple aquastat) ?

Honeywell L8024B,D triple aquastat heater controller (C) InspectAPediaI have a Gas Hydrotherm 86000 Model R108 furnace. I cannot find a replacement Aquastat. I have called Hydrotherm they say call Honeywell. Honeywell say its discontinued they have no information for a universal replacement.The hot water tankless is disconnected as I have a gas hot water tank.

I heat most of the time with a coal stove so the only time the furnace runs is if I go away for a few days. I'm 73 retired firefighter (36 yrs) . The furnace is in good shape hate to replace just because cant find aquastat. Do you have any Ideas for a replacement universal aquastat relay.attached is all I have on unit.

Any suggestion is welcome.I usually have to clean contacts to get it running when I use it. - J.M. 12/28/2012

Photo (left) of a Honeywell L8024B & the wiring diagram below were provided by reader J.M.

Reply: parts substitution & replacements for the Honeywell L80241048B,D triple aquastat

J.M.

Contact your local heating supplier with the part number (inside the cover check that you correctly identified your Honeywell Aquastat as the Honeywell L8024B1048 (triple aquastat, also the L8024D) - that's probably all they need) from the original aquastat; there are tables of substitution and changeout part numbers and names for just about every control ever made. I'm sure they'll be glad to help you select the correct one. In fact I'm confused that you report not obtaining help from Honeywell themselves; we have usually found that the company's technical support personnel to be informed and helpful.

Honeywell L8024B aquastat wiring instructionsI'm not sure about the L8024B series information you've received, and I understand that there is not necessarily "universal" replacement for all applications, but in fact the Honeywell L8124 series (AQS8124B1039 or the Honeywell Multi Function Aquastat L8124B1039) can substitute for many of the controllers in the L8124 and L8024 aquastat line.

We regularly see that controller advertised as replacing the Aquastat models with part numbers L8124B1039, L8124B1021, L8024B, and L8024D. indeed it might work for you as well. Also check out the Honeywell, the L7224U Universal Aquastat controller.

Be sure to review your control and how it was used with your heating service supplier;

I would be quite surprised if they couldn't immediately give you the part you need, but if you don't have success let us know and we will research further.

The wiring schematic for the Honeywell L8024B triple aquastat (thanks to your photos) is reproduced at left.

Your aquastat, the L8024B controller, also sold in the L8024D model, is being used in your case to control a Hydro-Therm natural gas-fired heater and possibly a circulator pump; often a review of exactly how a controller is being used in a given application can make more clear just what replacement aquastat will work best.

If you cannot find a suitable replacement control such as the 8124B 1039, we may find a "new old stock" (NOS) L8024B,D, etc. series control available from a reseller.

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    • Commercial Building Inspection Courses - protocol ASTM Standard E 2018-08 for Property Condition Assessments
    • Home Inspection Education Courses including home study & live classes at eleven colleges & universities.
    • Home Inspection Education Home Study Courses - ASHI@Home Training 10-course program.
      Special Offer: Carson Dunlop Associates offers InspectAPedia readers in the U.S.A. a 5% discount on these courses: Enter INSPECTAHITP in the order payment page "Promo/Redemption" space. InspectAPedia.com editor Daniel Friedman is a contributing author.
    • The Home Reference Book, a reference & inspection report product for building owners & inspectors.
      Special Offer: For a 10% discount on any number of copies of the Home Reference Book purchased as a single order. Enter INSPECTAHRB in the order payment page "Promo/Redemption" space. InspectAPedia.com editor Daniel Friedman is a contributing author.
    • The Home Reference eBook, an electronic version for PCs, the iPad, iPhone, & Android smart phones.
      Special Offer: For a 5% discount on any number of copies of the Home Reference eBook purchased as a single order. Enter inspectaehrb in the order payment page "Promo/Redemption" space.
    • The Illustrated Home illustrates construction details and building components, a reference for owners & inspectors.
      Special Offer: For a 5% discount on any number of copies of the Illustrated Home purchased as a single order Enter INSPECTAILL in the order payment page "Promo/Redemption" space.
    • The Horizon Software System manages business operations,scheduling, & inspection report writing using Carson Dunlop's knowledge base & color images. The Horizon system runs on always-available cloud-based software for office computers, laptops, tablets, iPad, Android, & other smartphones.
  • Thanks to Bottini Fuel service manager Ron Thomas for discussing aquastat functions, low limit controls, oil burner short cycling causes, and boiler maintenance, reliability, and service contracts 4/13/2010. Bottini Fuel is a residential and commercial heating oil distributor and oil heat service company in Wappingers Falls, NY and with offices in other New York locations. Bottini Fuel, 2785 W Main St, Wappingers Falls NY, 12590-1576 (845) 297-5580 more contact information for Bottini Fuel
  • Thanks to reader powderfinger5 for careful reading of this text and suggesting clarifications - August 2011
  • Thanks to reader Gary (Buddy Cat) for careful reading & editing - November 2012

We provide links just below to several aquastat installation, setting, and adjustment documents in response to reader requests and comments that people sometimes have difficulty finding this information. But readers looking for specific aquastat control information should always first try the control manufacturer.

  • Armstrong 24-hour time and aquastat control accessory: provides on/off pump control according to preset operating times, designed only for use with specified Armstrong Astro series wet roto circulators installed in indoor hot water re circulation applications. Typical timer applications will cycle the pump at preset times, allowing the user to select operation of the circulating pump during high peak usage periods in order to decrease the delivery time to outlet fixtures and reduce wasted water, also available at www.honeywell.com
  • Honeywell Corporation, control installation guides for Honeywell aquastats and other heating and cooling controls: see http://customer.honeywell.com
  • Honeywell L4008E Aquastat high limit,manual reset, aquastat controller instructions
  • Honeywell L4041A,C Pool Heater Aquastat Controller Instructions, also available at www.honeywell.com
  • Honeywell L4006, Manual Reset Strap-On Aquastat (high limit control, 100 to 240 degF) [we consider strap on controls less accurate and reliable than immersion type sensor controls; these were commonly found on older heating boilers including the GE series downfired boilers]
  • Honeywell L4026B Aquastat control instructions (contact Honeywell Corporation) Here is some basic description of the Honeywell L4026B control, also available at www.honeywell.com
  • Honeywell L4029 Reset Limit Control, also available at www.honeywell.com
  • Honeywell L4103A,B,C Combination Aquastat and High Limit Controller Instructions, also available at www.honeywell.com
  • Honeywell L6006A Aquastat Controller installation instructions, also available at www.honeywell.com
  • Honeywell L6006 and L6007 Aquastat Controllers, installation instructions for the trained service technician, these controls combine low or high limit and circulator control, with or without an immersion well depending on the control model A,B, C etc., also available at www.honeywell.com
  • Honeywell L6191 Dual aquastat immersion thermostat, also available at www.honeywell.com
  • Honeywell L7224 Aquastat Controller, oil electronic controls allowing high limit, high limit differential, low limit, and separate low limit differential settings - set to the specifications of your oil heating equipment manufacturer - 69-1957-1 L7224 Series controls, also available at www.honeywell.com
  • Honeywell L7224U Oil Electronic Aquastat Controller - 69-1720-2 series instructions. These newer aquastat controllers are often used to replace the older Honeywell L8124A series that was and remains widely used, also available at www.honeywell.com.
    • L7224U1002- is a universal electronic aquastat (replacing over 40 other aquastat models) that provides circulator, burner and boiler temperature control with electronic temperature sensing. The L7224U1002 provides status and diagnostic information through an LED display to enhance the diagnostic process.
      In "Run" mode the LED displays the boiler temperature followed by the ambient temperature. Buttons inside the control permit the service tech to scan through the control's settings as well as to change them, much like the functions on a programmable room thermostat. Using the "I" button, the LED display can be cycled through: boiler temperature, high limit, low limit, high differential, low differential, local thermostat status, EnviraCOM thermostat status, Burner status, Circulator status, Zone control, Zone request, Error code, degF/degC.
      Five diagnostic LEDs inside the control provide additional diagnostic features, indicating (counterclockwise from upper left) EnviraCOM network active, Thermostat calling for heat, Burner on, Power to zone circulator interrupted (lockout), Circulator powered.
      This is a "triple aquastat" providing High, Low, and circulator controls, as well as advanced features permitting electronic configuration and an LED display for diagnostics. This aquastat can provide multiple zone control as well. The L7224U1002 supports Honeywell's EnviraCOM™ communications that permits remote diagnosis as well as OnWatch diagnostics. The low-limit can be disabled for "cold-start" boiler applications such as where no tankless coil is in use.
    • Eight error codes: 1=sensor fault (check sensor), 2=ECOM fault, check EnviraCOM wiring, 3=Hardware fault, replace the control, 4=B1 fault, check B1 wiring/voltage, 5=Low line voltage, check L1/L2 110VAC, 6=Fuse, check ECOM wires, replace fuse, 7=EEPROM limit and differential settings, restore to desired settings, 8=Repeated B1 fault, (voltage present at B1 when output is turned off); check B1 wiring/voltage
    • Honeywell link for a powerpoint training session on this aquastat: http://customer.honeywell.com/NR/rdonlyres/5C67D10A-631C-4404-9149-25BA61F5D8BB/4041/L7224UUNIVERSALAQUASTATTrainingModule.ppt
    • See L7224U1002 Technicians Quick Reference Guide #69-1957
  • Honeywell L8124A,B,C,E,G,LO,M Aquastat Relays immersion type controllers for forced hydronic heating systems that include domestic hot water service (such as a tankless coil), also available at www.honeywell.com
  • Honeywell R8182D,H Combination Protectorelay™ Primary Control and Aquastat® Controller Installation Instructions combination protectorelay Primary Control installation and operations manual, also available at www.honeywell.com

Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair

  • Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.
  • Home Reference Book - Carson DunlopThe Home Reference Book - the Encyclopedia of Homes, Carson Dunlop & Associates, Toronto, Ontario, 25th Ed., 2012, is a bound volume of more than 450 illustrated pages that assist home inspectors and home owners in the inspection and detection of problems on buildings. The text is intended as a reference guide to help building owners operate and maintain their home effectively. Field inspection worksheets are included at the back of the volume. Special Offer: For a 10% discount on any number of copies of the Home Reference Book purchased as a single order. Enter INSPECTAHRB in the order payment page "Promo/Redemption" space. InspectAPedia.com editor Daniel Friedman is a contributing author.

    Or choose the The Home Reference eBook for PCs, Macs, Kindle, iPad, iPhone, or Android Smart Phones. Special Offer: For a 5% discount on any number of copies of the Home Reference eBook purchased as a single order. Enter INSPECTAEHRB in the order payment page "Promo/Redemption" space.

  • GO TO Carson Dunlop's Home Study Course Information - How to Become a Home Inspector: Carson Dunlop's nationally recognized Home Study Course, selected by ASHI the American Society of Home Inspectors and other professionals and associations. This website author is a contributor to this course.
  • GO TO Carson Dunlop's Home Study Course Information - How to Become a Home Inspector: Carson Dunlop's nationally recognized Home Study Course, selected by ASHI the American Society of Home Inspectors and other professionals and associations. This website author is a contributor to this course.
  • GO TO Carson Dunlop's Home Study Course Information - How to Become a Home Inspector: Carson Dunlop's nationally recognized Home Study Course, selected by ASHI the American Society of Home Inspectors and other professionals and associations. This website author is a contributor to this course.
    Building inspection education & report writing systems from Carson, Dunlop & Associates Ltd
  • Carson Dunlop, Associates, Toronto, have provided us with (and we recommend) Carson Dunlop Weldon & Associates' Technical Reference Guide to manufacturer's model and serial number information for heating and cooling equipment
    Special Offer
    : Carson Dunlop Associates offers InspectAPedia readers in the U.S.A. a 5% discount on any number of copies of the Technical Reference Guide purchased as a single order. Just enter INSPECTATRG in the order payment page "Promo/Redemption" space.

  • Domestic and Commercial Oil Burners, Charles H. Burkhardt, McGraw Hill Book Company, New York 3rd Ed 1969.
  • National Fuel Gas Code (Z223.1) $16.00 and National Fuel Gas Code Handbook (Z223.2) $47.00 American Gas Association (A.G.A.), 1515 Wilson Boulevard, Arlington, VA 22209 also available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Fundamentals of Gas Appliance Venting and Ventilation, 1985, American Gas Association Laboratories, Engineering Services Department. American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209. Catalog #XHO585. Reprinted 1989.
  • The Steam Book, 1984, Training and Education Department, Fluid Handling Division, ITT [probably out of print, possibly available from several home inspection supply companies] Fuel Oil and Oil Heat Magazine, October 1990, offers an update,
  • Principles of Steam Heating, $13.25 includes postage. Fuel oil & Oil Heat Magazine, 389 Passaic Ave., Fairfield, NJ 07004.
  • The Lost Art of Steam Heating, Dan Holohan, 516-579-3046 FAX
  • Principles of Steam Heating, Dan Holohan, technical editor of Fuel Oil and Oil Heat magazine, 389 Passaic Ave., Fairfield, NJ 07004 ($12.+1.25 postage/handling).
  • "Residential Steam Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
  • "Residential Hydronic (circulating hot water) Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
  • "Warm Air Heating Systems". Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
  • Heating, Ventilating, and Air Conditioning Volume I, Heating Fundamentals,
  • Boilers, Boiler Conversions, James E. Brumbaugh, ISBN 0-672-23389-4 (v. 1) Volume II, Oil, Gas, and Coal Burners, Controls, Ducts, Piping, Valves, James E. Brumbaugh, ISBN 0-672-23390-7 (v. 2) Volume III, Radiant Heating, Water Heaters, Ventilation, Air Conditioning, Heat Pumps, Air Cleaners, James E. Brumbaugh, ISBN 0-672-23383-5 (v. 3) or ISBN 0-672-23380-0 (set) Special Sales Director, Macmillan Publishing Co., 866 Third Ave., New York, NY 10022. Macmillan Publishing Co., NY
  • Installation Guide for Residential Hydronic Heating Systems
  • Installation Guide #200, The Hydronics Institute, 35 Russo Place, Berkeley Heights, NJ 07922
  • The ABC's of Retention Head Oil Burners, National Association of Oil Heat Service Managers, TM 115, National Old Timers' Association of the Energy Industry, PO Box 168, Mineola, NY 11501. (Excellent tips on spotting problems on oil-fired heating equipment. Booklet.)
  • ...

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