Honeywell AQ250 Series Product Information Sheet

68-0306-05

AQ250 Series Hydronic Control Panels

Need new photo of AQ250

PRODUCT DATA

PRODUCT DESCRIPTION

The AQ250 easily converts a single-zone heating system into a room-by-room comfort control system, or upgrades a basic, relay-logic zoning system to intelligent Zone of Greatest Demand control. The boiler control of the AQ250 can ensure ample supply of hot water for both space heating and priority generation of domestic hot water for bathing, dishes and laundry.

FEATURES

The AQ250 Series Hydronic Control Panels have the following features:

• Zoning Control for up to four, single-stage zones or two, two-stage zones as shipped; can be expanded to a total of 16 zones with AQ255 or AQ257 expansion zoning panels, and up to 64 zones by us ing up to thre e AQ254 Add-a-Temperature expansion panels and additional expansion zoning modules.

• Controls one boiler loop.

• Zone synchronization through Zone of Greatest Demand control.

• Domestic hot water (DHW) priority and priority override protection.

• Use with digital non-communicating thermostats or AQ1000 2-wire polarity insensitive communicating thermostats.

• Automated test feature for quick start-up and simplified troubleshooting.

• Boiler freeze protection (in the event of network communication failure).

• Boiler short cycling protection, post purge, and shock prevention from cold water returning to boiler.

• Line or low-voltage output for zoning equipment (pumps or valves).

• Integral 38 VA transformer with self resetting electronic fuse.

IMPORTANT

T o ensure correct installation and proper operation of the control, perform the 7 installation steps in the order numbered in the “Contents” below.

Contents

Specifications ................................................................... 2

1 Installation Preparation .................................................. 3

2 Mounting ........................................................................ 4

3 Wiring Procedure ........................................................... 5

4 Configure the Control Panel DIP Switches .................... 14

5 Test and Check Out the Installation ............................... 17

6 Purge Air from all System and Zone Piping .................. 19

7 Document and Keep a record of all System Settings .... 19

Troubleshooting ................................................................ 19

AQ250 SERIES HYDRONIC CONTROL PANELS

• When using non-communicating thermos tats, the following features are not available:

• Outdoor temperature is not displayed on the thermostat.

• Individual zone freeze protection.

SPECIFICATIONS

The AQ250 Control Panels and corresponding attached equipment are listed in Table 1.

Table 1. AQ250 Series Control Panel Models.

Control Panel

AQ25042B AQ15000B AQ15540B AQ25044B AQ15000B AQ15740B

Application: Controls one boiler loop as well as domestic hot

water (DHW) management and zoning operation in a hydronic zoning system.

Power and Electrical Ratings:

Power Supply: 120 Vac / 60Hz Auxiliary Pump Contact Rating: 120/250 Vac, 5A,

1/3 HP

Boiler (T-T) Contact Rating: 24 Vac, 0.5A, 12 VA Boiler Pump Output Rating: 120 Vac, 5A, 1/3 HP DHW Pump/Valve Output Rating: 120 Vac, 5A, 1/3 HP B–B Communication Bus Terminals: Low voltage,

Class II, 2-wire polarity-insensitive, digital communicating link to other Control or Zoning modules.

Electrical Connections (Line Voltage): Wire-clamp

screw terminals; maximum 2 x 14 AWG each on line voltage terminals

Environmental Ratings:

Control and Zoning Panel Temperature Rating: 32°F to

130°F (0°C to 55°C)

Corresponding

Control Module

Corresponding Zoning Module

Operating Humidity Range (% RH): 5 to 90% RH, non-

condensing

Temperature Ratings:

Return Minimum Control Temperature: 140°F (60°C);

This is the temperature at which the bypass pump (Aux. Pump contacts) is activated.

Sensor Temperature Rating: -58°F to 230°F (-50°C to

110°C)

Inputs/Outputs:

DHW Demand Input: External dry contacts connection

only

Heat Demand (Thermostat R-W) Input: External dry

contacts connection only

R–C Input (on Control and Zoning Modules): 24 Vac

Class II

R–C Output (on transformer): 38 VA, 24 Vac Class II

Interface and Timings:

User Interface: DIP Switch settings Boiler Heat Post Purge: 30 seconds; not adjustable Pump/Valve exercise: 30 seconds per 2 weeks of space

heating inactivity; not adjustable

Thermostat Compatibility: Digital thermostats and/or

AQ1000 Series 2-wire communicating thermostats

Supply/Return Loop Sensor: 10K ohm NTC thermistor at

77°F (25°C) ± 0.5°F (±0.3°C). Lead length: 10 ft. (3.0 m); up to 500 ft. (150 m) using 18 AWG or larger wire, beta=3892.

Dimensions (HxWxD): 8.0 x 13 x 3.3 in. (20.3 x 32.9 x

8.5 cm) approximate

Weight: 4.9 lb. (2.2 kg) Approvals: Canadian Standards Association: Certified, File

No. LR76030

ORDERING INFORMATION

When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number.

If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:

1. Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory).

2. Honeywell Customer Care

1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386 In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9. International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

68-0306—05 2

AQ250 SERIES HYDRONIC CONTROL PANELS

WARNING

1 INSTALLATION PREPARATION

NOTES: Through out these instructions, the following

terminology conventions are used:

— AQ150 refers to the AQ15000B Control Module; — AQ155 refers to the AQ15540B Zoning Module. — AQ157 refers to the AQ15740B Zoning Module. — AQ250 is used when the information applies to both

the AQ25042B and AQ25044B Control Panels. Where there are specific instructions or details relating to the “42B” or “-44B” Control Panels, the full model number (i.e. AQ25044B) is used;

— AQ255 refers to all of the AQ25542B, AQ25582B and

AQ25742B Expansion Zoning Panels

— AQ257 refers to the AQ25744B Expansion Zoning

Panel. Where there are specific instructions or details relating to the “-42B”, “-82B”, “-42B”, or “-44B” Expansion Zoning Panels, the full model number (i.e. AQ25744B) is used;

— Control Module refers to the component within an

AQ2000 Series Control Panel that performs the master control operations. See Table 1 on page 2 for specific models.

— Control Panel refers to an assembled product,

consisting of a transformer, Control Module and Zoning Module, all contained within an AQ2000 panel enclosure;

— Expansion Zoning Panel refers to an assembled

product, consisting of a Zoning Module and, if applicable, a transformer, contained within an AQ2000 panel enclosure. Zoning Modules are available in either 4-zone or 8-zone configurations. Refer to Honeywell literature Form No. 69-1981 for more information on these products.

— Zoning Module refers to the component within an

AQ2000 Series Control Panel or Zoning Expansion Panel.

When Installing this Product…

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and on the product to make sure the product is suitable for the application.

3. Installers must be trained, experienced, and licensed service technicians.

4. Follow local codes for installation and application.

5. After installation is complete, check out the product operation as printed in these instructions.

Risk of electrical shock. Can cause severe injury, property damage or death.

Disconnect power supply before installation and before servicing.

Check That You Have All the Necessary Equipment For a Successful Installation

• AQ2000 Series components: — AQ250 Control Panel — AQ Expansion Zoning Panels (if more than four space

heating zones in the system)

— Digital thermostats (one for every space heating zone

being controlled)

• Boiler supply and return temperature sensors (included with the AQ250 Control Panel)

• Low voltage thermostat wire

• Zoning equipment (zone valves or pumps)

Read All Instructions Carefully Before Proceeding

The AQ250 Control Panels are a part of a totally new series of hydronic controls. And although they - and other AQ2000 system components - are very easy to install and operate, they are different than other hydronic controls that you have previously installed. So take a moment to read through this quick installation guide before Failure to follow them could damage the product or cause a hazardous condition.

beginning the installation.

Familiarize Yourself With the AQ250 Control Panel Layout

Refer to Fig. 1 on page 4. All AQ250 Control Panels consist of three functional components:

1. AQ10X38 transformer (power supply module), which connects to 120 V ac power and supplies 24 V ac power to the Control Module and Zoning Modules

2. AQ15000B boiler / DHW Control Module, which controls the boiler and domestic hot water (DHW) functions as well as coordinating the overall operation of the hydronic system.

3. One of two different 4-zone Zoning Modules:

• AQ15740B (part of the AQ25044B Control Panel) for zoning with 24 Vac zone valves with switches.

• AQ15540B (part of the AQ25042B Control Panel) for zoning with either line voltage circulators or 24 Vac zone valves without

AQ250 Control Panels can control a maximum of 16 zones by connecting additional Expansion Zoning Panels to the AQ250 Control Panel. Each Expansion Zoning Panel is configured with its own bank of DIP switches, located in the left-most section of each Zoning Module. To expand the capacity of an AQ250 Control Panel beyond 16 zones, an AQ254 Add-ATemperature Expansion Control Panel is required. The hydronic system can be expanded by 16 zones for each AQ254 connected to the AQ2000 network. A maximum of three (3) AQ254 Panels may be connected to an existing AQ2000 Control Panel for a maximum of 64 zones connected on the AQUATROL® network

NOTE: If an AQ254 Add-A-Temperature Expansion Control

Panel is used for controlling the temperature in a mixed loop, it can reset the mixed loop temperature using LOAD reset, but not OUTDOOR reset, as the AQ250 panel does not have input terminals for an outdoor sensor.

end switches.

end

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AQ250 SERIES HYDRONIC CONTROL PANELS

In general, the top terminals of the AQ2000 Series components carry low voltage (24 Vac) power and the bottom terminals carry line voltage (120 Vac) power. This is illustrated in Fig. 1. The two exceptions to this are:

1. AQ15740B Zoning Module for use with zone valves with end switches.

2. AQ15540B Zoning Module when used with low voltage zone valves without

LINE VOLTAGE (120 V)

end switches.

TRANSFORMER

CONTROL MODULE

For these the two exceptions, the bottom terminals of the Transformer and Control Module carry line voltage (120 Vac), but the bottom terminals of the Zoning Module will carry low voltage (24 Vac) power.

The powered terminals on the bottom of the AQ2000 Series Control Modules and Zoning Modules are connected internally, as shown in Fig. 2. The voltage supplied to the N and L terminals is also available at the adjacent terminal pairs when the hot ( ) relays are switched.

ZONING MODULE

Boiler

DHW

Aux

Zone 1

Zone 2

Zone 3

Zone 4

M29032A

LOW VOLTAGE (24 V)

Fig. 1. AQ250 Control Panel layout (AQ25044B shown).

CONTACTS SYMBOL

Fig. 2. Internal wiring for AQ2000 Series components line voltage relays.

2MOUNTING

This section describes how to mount the Control Panel, Expansion Zoning Panels, and the Thermostats.

Mount AQ250 Control Panel

Mount the control panel on the wall:

1. Use the template supplied with the AQ250 Series Control Panel to mark the four mounting holes for the panel.

2. Install two top screws, mount the panel, and install the two lower screws.

Boiler

DHW

Aux

Zone 1

Zone 2

Zone 3

Zone 4

M29033

Mount Expansion Zoning Panels

If there are Expansion Zoning Panels to install, mount them to the wall now:

1. Remove wire channel plugs from the AQ250 Control Panel and any Expansion Zoning Panels (see Fig. 3 on page 5).

2. Mount Expansion Zoning Panel on the right-hand end of the AQ250 Control Panel. Install two top screws of the Expansion Zoning Panel, ensuring it is level with the adjoining Control Panel, and install two lower screws.

3. Reverse wire channel plugs and re-insert them into their slot, to form a wiring channel between the Control Panel and the Expansion Zoning Panel (see Fig. 3 on page 5) and to connect the two panels together.

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4. For any additional Expansion Zoning Panels, repeat

M23733A

WIRE CHANNEL PLUGS

steps 1–3.

AQ250 SERIES HYDRONIC CONTROL PANELS

Fig. 3. Orientation of wire channel plugs for creating pass-through wire channel and

for joining Control Panel to Expansion Zoning Panels.

Mount and Wire Thermostats in the Zones

Install the thermostats on the walls in the zones that are to be controlled by the AQ250 Control Panel.

When using AQ1000 thermostats refer to the installation instructions included with the AQ1000 thermostats.

If not done already, run low voltage thermostat wire (24 gauge or heavier) from the thermostats back to the Zoning Modules connected to the AQ250 Control Panel.

NOTES: If not otherwise specified, low voltage wiring should

be run with 18 gauge thermostat wire and line voltage wiring should be run with 14 gauge wire. AQUATROL line voltage screw terminals are only approved for use with 22 to 12 gauge copper conductors.

Several wiring diagrams are included in this document. For additional information, refer to http:// customer.honeywell.com or your local distributor.

3 WIRING PROCEDURE

The AQ250 Control Panel is pre-wired at the factory, making for faster installation.

For all models, the low voltage output terminals located at the top of the transformer secondary are wired to the R and C input terminals of the Control Module, as well as the R and C inputs of the Zoning Module. The B-B Exp. Bus terminals (13 and 14) of the Control Module are wired to the B-B Exp. Bus IN terminals of the Zoning Module.

Beginning with the top left of Fig. 4 on page 6 and moving clockwise around the panel, wire components to the AQ250 Control Panel and Expansion Zoning Panels (if installed) in the following six steps:

• “Step 1 – Transformer Wiring” on page 6

• “Step 2 – Control Panel Wiring” on page 6

• “Step 3 – Thermostats Wiring” on page 8

• “Step 4 – Zoning Equipment Wiring” on page 8

• “Step 5 – Line Volt age System Output s” on p age10

• “Step 6 – Connection To Line Voltage Power” on page 13

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AQ250 SERIES HYDRONIC CONTROL PANELS

STEP 1 STEP 2 STEP 3

TO EXPANSION ZONING MODULES (IF INSTALLED)

Fig. 4. Wiring sequence.

Step 1 – Transformer Wiring

Factory pre-wiring of the Control Panels is shown as dotted lines in Fig. 4.

In addition to the pre-wiring, run low voltage jumper wires from available R and C terminals on the secondary of the transformer to the R and C terminals of any Expansion Zoning Panel.

Step 2 – Control Panel Wiring

Wire the Temperature Sensors, System Demands, Low Voltage Outputs, and Communication Bus (Refer to Fig. 5 for wiring terminals on the top of the AQ250):

• “Temperature Sensor Wiring”

• “System Demands Wiring” on page 7

• “Low Voltage Outputs Wiring” on page 7

• “Communication Bus Wiring” on page 7

DHW

Boiler

Aux

STEP 5STEP 6

ZR Boi l er

STEP 4

Aux.

DHW

M29034

Temperature Sensor Wiring

Connect the lead wires of each sensor to the corresponding terminals on top of the AQ15000B Control Module. See Fig. 5.

The Boiler Supply and Return sensors can be installed either as strap-on sensors or inserted into an immersion well that is packed with thermally-conductive paste.

BOILER SUPPLY AND RETURN SENSORS

the Supply and Return Sensors should be installed on the

Both supply and return piping of the boiler for proper operation of the AQ250 Control Panel. Even if the AQ250 is connected to a modulating condensing boiler with its own supply and/or return sensors, the AQ250’s sensors should still be installed for the control to operate.

The Boiler Supply water sensor should be installed on the supply piping close to the exit port of the boiler, using one of the AQ12C11 strap-on sensors supplied with the AQ250. See Fig. 6 on page 7.

TO DHW AQUASTAT

(OPTIONAL)

TO “T-T” TERMINALS ON

BOILER AQUASTAT

TO B-B “EXP.BUS IN”

TERMINALS ON CONNECTED

ZONING MODULE

M29035A

IN FROM “C” TERMINAL

ON TRANSFORMER MODULE

(FACTORY-WIRED)

IN FROM “R” TERMINAL

TO BOILER SUPPLY SENSOR

TO BOILER RETURN SENSOR

TO SETPOINT LOAD

Fig. 5. Low voltage wiring for the AQ1520M0 Control

Module.

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The Boiler Return sensor should be installed on the return piping as close to the entrance port to the boiler as practical, using the other AQ12C11 strap-on sensor supplied with the AQ250. The correct location is one that will measure the temperature of all combined sources of water returning back to the boiler.

Insulate strap-on sensors with pipe wrap to ensure accurate boiler temperature sensing.

The Boiler Supply and Return water sensors come with 10 ft. (3m) of wire to minimize the need for splicing.

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