Honeywell AQ252 Product Information Sheet

AQ252 Universal Injection/Mixing

Boiler Reset Control Panels

PRODUCT DATA

PRODUCT DESCRIPTION

The AQ252 family of AQUATROL® Universal Injection/Mixing Boiler Reset Controls provides simplified, energy-efficient outdoor temperature compensated control of a hightemperature boiler loop and a lower temperature mixed loop in residential hydronic heating systems. The AQ252 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, with outdoor reset for increased energy efficiency with reduced boiler cycling. The boiler controls of the AQ252 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 AQ252 family have the following features:

•Controls one boiler loop and one mixed temperature loop.

•Outdoor temperature compensation (reset), or Load reset based on indoor temperature feedback, or none.

•Zone synchronization through Zone of Greatest Demand control.

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

•Customizable control settings and schedules allow for greater level of control and comfort.

•Use of variable speed injection pump or motorized mixing valve for mixed temperature loop control.

•Central set-back schedules available.

•Zoning Control for up to four, single-stage or two, twostage 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 using up to three AQ254 Add-a-Temperature expansion panels and additional expansion zoning modules.

IMPORTANT

To 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 ........................................................................	5
3	Wiring Procedure ...........................................................	7
4	Program and Configure the Control Panel .....................	15
5	Test and Check Out the Installation ...............................	20
6	Purge Air from all System and Zone Piping ..................	21
7	Document and Keep a record of all System Settings ....	21
Troubleshooting ................................................................		22
Appendix ..........................................................................		25
	User Menu ..............................................................	25
	Installer Menu .........................................................	32

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•Use with digital non-communicating thermostats or AQ1000 2-wire polarity insensitive communicating thermostats. Note: When using non-communicating thermostats, the following features are not available:

•Outdoor temperature is not displayed on the thermostat.

•Time clock on AQ1000TP2 will not synchronize with the Control Module.

•Central programming, vacancy and setback schedules of AQ1000 from AQ panel are not enabled.

•AQ panel will not display individual zone temperatures.

•Individual zone freeze protection.

•Allows display of outdoor temperature on all AQ1000 thermostats when used with an AQ12C10 outdoor sensor (included).

•Intuitive programming interface (can be programmed at your shop and taken to the job site “ready-to- install”).

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

•Boiler freeze protection and single-zone freeze protection.

•Pump/valve exercise.

•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.

•4 hour power supply (super capacitor) retains day and time settings during power outage and a non-volatile EPROM memory retains program settings during power outage.

ORDERING INFORMATION

SPECIFICATIONS

The AQ252 Control Panels and corresponding attached equipment are listed in Table 1.

Table 1. AQ252 Series Control Panel Models.

	Corresponding	Corresponding
Control Panel	Control Module	Zoning Module
AQ25242B	AQ15200B	AQ15540B
AQ25244B	AQ15200B	AQ15740B

Application: Controls one boiler and one mixed temperature loop (using either a variable-speed injection pump or motorized valve mixing), 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 Output Rating: Dry contact output, 120/250 Vac 5A, 1/3 HP

Auxiliary Low Voltage Output Rating: 24 Vac, 0.5A, 12VA

Boiler (T-T) Output Rating: 24 Vac, 0.5A, 12VA

Boiler Pump (C1-C2) Output Rating: 120 Vac 5A, 1/3HP DHW Pump/Valve Output Rating: 120 Vac 5A, 1/3HP Secondary Pump Output Rating: 120 Vac 5A, 1/3HP

Variable-Speed Injection Pump Output: Triac modulated; 120 Vac 2.1A, 1/6HP

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)

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

Temperature Ratings:

Boiler Design Temperature: 80°F to 210°F (26°C to 99°C)

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 Environmental and Combustion Controls Sales Office (check white pages of your phone directory).

2.Honeywell Customer Care 1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386

3.http://customer.honeywell.com or http://customer.honeywell.ca

International Sales and Service Offices in all principal cities of the world. Manufacturing in Belgium, Canada, China, Czech Republic, Germany, Hungary, Italy, Mexico, Netherlands, United Kingdom, and United States.

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Boiler Differential: 2°F to 41°F (1°C to 23°C), or Auto

Boiler (Supply) Minimum Control Temperature: OFF, 59°F to 180°F (OFF, 15°C to 82°C)

Boiler (Supply) Maximum Control Temperature: OFF, 120°F to 225°F (OFF, 49°C to 107°C)

Outdoor Low Design Control Temperature: -60°F to 32°F (-51°C to 0°C)

Return Minimum Control Temperature: OFF, 80°F to 180°F (OFF, 27°C to 82°C)

Secondary Loop Mixing (Supply) Design Temp Range: 70°F to 210°F (21°C to 99°C)

Secondary Loop Mixing (Supply) Min. Control Temp Range: OFF, 35°F to 150°F (OFF, 2°C to 66°C)

Secondary Loop Mixing (Supply) Max. Control Temp Range: OFF, 80°F to 210°F (OFF, 27°C to 99°C)

Sensor Temperature Rating: -58°F to 230°F (-50°C to 110°C)

Warm Weather Shut Down (WWSD) Temperature: OFF, 35°F to 100°F (OFF, 1°C to 38°C)

Cold Weather Shut Down (CWSD) Temperature: OFF, 32°F to 100°F (OFF, 0°C to 38°C)

Inputs/Outputs:

Auxiliary (Demand) Input: External dry contacts connection only

DHW Demand Input: External dry contacts connection only

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

Modulating Output: )-10 or 2-10 Vdc for variable speed pump or modulating boiler

Mixing Valve (Com, O, C): 324 Vac, 0.5A, 12VA

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 (Setting, Programming): LCD Display and a 7-button keypad

Setback Program: 7 day, up to 2 setback periods/day.

Boiler Heat Post Purge: Off, 10 seconds to 30 minutes (factory default is 30 seconds)

Pump/Valve exercise: 30 seconds per 2 weeks of space heating inactivity

Thermostat Compatibility: Digital non-communicating thermostats and/or AQ1000 Series 2-wire communicating thermostats

Supply/Return/Secondary (Mixed) 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.

Outdoor Sensor: 10K ohm NTC thermistor at 77°F (25°C) ± 0.5°F (±0.3°C). Lead length: 15 ft. (4.6 m); up to 500 ft. (150 m) using 18 AWG or larger wire, beta=3892

Dimensions (HxWxD): 8 x 16 1/2 x 3 3/8 in. (20.3 x 42 x 8.5 cm) approximate

Weight: 4.9 lb. (2.3 kg)

Approvals: Canadian Standards Association: Certified, File

No. LR76030

1 INSTALLATION PREPARATION

NOTES: Throughout these instructions, the following terminology conventions are used:

—AQ155 refers to the AQ15540B Zoning Module.

—AQ157 refers to the AQ15740B Zoning Module.

—AQ1520 refers to the AQ15200B Control Module within an AQ252 Series Control Panel.

—AQ252 refers to the AQ25242B and AQ25244B Control Panels. Where there are specific instructions or details relating to the -42B or -44B Control Panels, the full model number (i.e., AQ25244B) 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 -542B, -582B, -742B, or - 744B Expansion Zoning Panels, the full model number (i.e., AQ25744B) is used.

—Control Module refers to the component within an AQ252 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. Expansion Zoning Panels are available in either 4-zone or 8-zone configurations.

—Zoning Module refers to the component within the AQ252 Series Control Panel that controls zoning operations.

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.

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WARNING

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:

—AQ252 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 and secondary loop sensor (included with the AQ252 Control Panel)

•Outdoor temperature sensor (included with AQ252 Control Panel)

•Low voltage thermostat wire

•Zoning equipment (zone valves or pumps)

Read All Instructions Carefully Before Proceeding

The AQ252 Control Panels are a part of a totally new family 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 beginning the installation. Failure to follow them could damage the product or cause a hazardous condition.

Familiarize Yourself With the AQ252 Control Panel Layout

Refer to Fig. 1. All AQ252 Control Panels consist of three functional components:

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

2.AQ15200B boiler/DHW Control Module, which controls the boiler and domestic hot water (DHW) functions, mixing operation for the secondary loop, as well as coordinating the overall operation of the hydronic system.

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

•AQ15740B (part of the AQ25244B Control Panel) for zoning with 24 Vac zone valves with end switches.

•AQ15540B (part of the AQ25242B Control Panel) for zoning with either line voltage circulators or 24 Vac zone valves without end switches.

AQ252 Control Panels can control a maximum of 16 zones by connecting additional Expansion Zoning Panels to the AQ252 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 AQ252 Control Module beyond 16 zones, an AQ254 Add-A- Temperature 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.

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 end switches.

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 on page 5. The voltage supplied to the N and L terminals is also available at the adjacent terminal pairs when the hot ( ) relays are switched.

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TRANSFORMER CONTROL MODULE ZONING MODULE

			LOW
			VOLTAGE
			(24 V)
Zone 1	Zone 2	Zone 3	Zone 4
			LINE
			VOLTAGE
			(120 V)
			1

1 FOR THE AQ25242B TERMINALS CAN BE LINE VOLTAGE (IF USED WITH PUMPS) OR LOW VOLTAGE (IF USED WITH ZONE VALVES)

M27682A

Fig. 1. AQ252 Control Panel layout (AQ25242B shown).

CONTACTS
SYMBOL
Zone 1	Zone 2	Zone 3	Zone 4
			M27683A

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

2 MOUNTING

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

Mount AQ252 Control Panel

Mount the control panel on the wall:

1.Use the template supplied with the AQ252 Series Control Panel to mark mounting holes for panels.

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

Mount Expansion Zoning Panel(s)

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

1.Remove wire channel plugs from the AQ252 Control Panel and any Expansion Zoning Panels (see Fig. 3).

2.Mount Expansion Zoning Panel on the right-hand end of the AQ252 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) and to connect the two panels together.

4.Repeat steps 1–3 for any additional Expansion Zoning Panels.

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WIRE

CHANNEL

PLUGS

WIRE

CHANNEL

PLUGS

M23733A

Fig. 3. Orientation of wire channel plugs for creating pass-through wire channel and for joining Control Panel to Expansion Zoning Panels.

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Mount and Wire Thermostats in the Zones

Install the thermostats on the walls in the zones that are to be controlled by the AQ252 Control Panel.

When using AQ1000 thermostats refer to the installation instructions (form #69-2005) 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 AQ252 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 AQ252 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 (26 and 27) 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 and moving clockwise around the panel, wire components to the AQ252 Control Panel and Expansion Zoning Panels (if installed) in the following six steps:

•“Step 1 – Transformer Wiring”

•“Step 2 – Control Panel Wiring”

•“Step 3 – Thermostats Wiring” on page 9

•“Step 4 – Zoning Equipment Wiring” on page 10

•“Step 5 – Line Voltage System Outputs” on page 13

•“Step 6 – Connection To Line Voltage Power” on page 14

TO EXPANSION ZONING MODULES (IF INSTALLED)

STEP 1

STEP 2

STEP 3

	Zone 1	Zone 2	Zone 3	Zone 4
STEP 6	STEP 5	STEP 4		M27684A

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 on page 8 for wiring terminals on the top of the AQ252):

•“Temperature Sensor Wiring” on page 8

•“System Demands Wiring” on page 9

•“Low Voltage Outputs Wiring” on page 9

•“Communication Bus Wiring” on page 10

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<![if ! IE]> <![endif]>IN FROM “R” TERMINAL ON TRANSFORMER MODULE (FACTORY-WIRED)

<![if ! IE]> <![endif]>IN FROM “C” TERMINAL ON TRANSFORMER MODULE (FACTORY-WIRED)

<![if ! IE]> <![endif]>TO BOILER SUPPLY SENSOR

<![if ! IE]> <![endif]>TO BOILER RETURN SENSOR

<![if ! IE]> <![endif]>TO OUTDOOR SENSOR

<![if ! IE]> <![endif]>TO SECONDARY SENSOR

<![if ! IE]> <![endif]>TO AUXILIARY INPUT SWITCH (OPTIONAL)

<![if ! IE]> <![endif]>TO SETPOINT LOAD (OPTIONAL)

<![if ! IE]> <![endif]>TO DHW AQUASTAT

<![if ! IE]> <![endif]>TO MODULATING MIXING VALVE OR VARIABLE SPEED PUMP

<![if ! IE]> <![endif]>TO FLOATING ACTION MIXING VALVE

<![if ! IE]> <![endif]>TO “T-T” TERMINALS ON BOILER AQUASTAT

<![if ! IE]> <![endif]>TO LOW VOLTAGE AUXILIARY DEVICE (OPTIONAL)

<![if ! IE]> <![endif]>TO B-B “EXP.BUS IN” TERMINALS ON CONNECTED ZONING MODULE

M27685A

Fig. 5. Low voltage wiring for the AQ15200B Control Module.

Temperature Sensor Wiring

Connect the lead wires of each sensor to the corresponding terminals on top of the AQ1520 Control Module. See Fig. 5.

The Boiler Supply, Return and Secondary loop 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.

Both the Supply and Return Sensors should be installed on the supply and return piping of the boiler for proper operation of the AQ252 Control Panel. Even if the AQ252 is connected to a modulating condensing boiler with its own supply and/or return sensors, the AQ252’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 AQ252. See Fig. 6 on page 8.

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 AQ252.

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.

SECONDARY (MIXED) LOOP SUPPLY SENSOR

The secondary sensor should be installed on the secondary (mixed) water piping, far enough downstream of the mixing device that the return water from the mixed loop and the boiler loop water are sufficiently well mixed, but before it flows through a branch leading to a zoning pump, zoning valve or manifold. The sensor used for the secondary loop is the same type of sensor (AQ12C11) as the Boiler Supply and Return sensors. See Fig. 6.

M13763

Fig. 6. Strap-on temperature sensor installation.

OUTDOOR SENSOR

The outdoor sensor should be located:

•in a shady location out of direct sunlight

•at least three feet from dryer, bathroom, or other vents

•above the expected snow line where ice and debris cannot cover it

•on the north side of the building.

See Fig. 7 on page 9 for typical placement. Outdoor sensor comes with 10 ft. (3m) of wire to facilitate splicing the sensor on the interior of the building. Alternatively, if the building is equipped with a continuous fresh air supply using, for example, an air-to-air heat exchanger, the outdoor sensor may be installed in the insulated portion of the ventilation intake duct, taking care not to expose the sensor to direct or indirect sunlight.

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M13775

Fig. 7. Outdoor temperature sensor installation.

IMPORTANT

Do not run sensor wires parallel, or close, to telephone, Ethernet, or power cables. Cross all power, Ethernet, and telephone wiring at right angles.

If sensor wires are located in an area with strong sources of electromagnetic interference, or EMI, (e.g., if sensor wires are run in the same electrical chase as line voltage wiring) use twisted pair, shielded cable, or run wires in a grounded metal conduit.

This is important because the calculated temperature - based on the sensor's resistance reading - can be distorted by high EMI, potentially causing the AQ252 to not operate properly.

If using shielded cable or conduit, connect the shield wire to earth ground only at the AQ252 panel. Do not ground the shield or conduit at any other location or electromagnetic shielding will be ineffective. If shielded cable is used, Honeywell recommends the use of shielded cable with a continuous ground plane, such as foil, with an integral drain wire for bonding to earth ground.

System Demands Wiring

Additional information about settings for the various System Demands is discussed in Table 6 on page 33.

AUX-IN

If the optional Aux In. contacts (terminals 11 and 12) will be used, wire them now. These inputs are powered with 24 Vdc and must connect only to a dry closure contact (unpowered switch).

The Aux-In contact closure sets the system into a specific state, as determined by the installer setup using the EQUIPMENT SETUP > AUXILIARY I/O sub-menu (see Fig. 25 on page 42).

HEAT DEMAND

If the optional Heat Demand (terminals 13 and 14) will be used, wire them to a system setpoint demand (dry contact closure), such as a pool or spa Aquastat®.

The HEAT contact closure drives the system to control either at the Reset temperature or the Setpoint temperature, as determined by the installer setup using the EQUIPMENT

SETUP > ZONING > HEAT DMND selection (see Fig. 25 on page 42). Heat Demand priority allows only heat for the first 30 minutes of a call for heat and then allows the space heating needs to be added in for the next 30 minutes. This cycle continues until the call for heat is satisfied.

DOMESTIC HOT WATER

Wire the DHW (terminals 15 and16) to the Aquastat or thermostat on the domestic hot water tank.

DHW priority allows only DHW heat for the first 30 minutes of a call for DHW and then allows the space heating needs to be added in for the next 30 minutes. This cycle continues until the call for DHW is satisfied.

NOTE: If the AQ252 is connected to a modulating condensing boiler with built-in DHW management, the DHW tank’s Aquastat should be connected to the AQ252's DHW (terminals 15 and 16). The AQ252's Aux. Out (terminals 24 and 25) should be wired to the boiler's DHW input terminals to the AQ252.

Low Voltage Outputs Wiring

10 VDC

The 10 Vdc terminals (17 and 18) of the AQ252 produce a modulating (0-10 Vdc or 2-10 Vdc) signal that can drive a modulating boiler’s combustion fan or a modulating mixing device, such as a motorized mixing valve or a variable-speed injection pump.

Boiler Signal: If the AQ252 panel is configured to send a 0-10V or 2-10V signal to a modulating/condensing boiler, connect the AQ252’s modulating output terminals (17 and 18) to the modulating signal input on the boiler control.

Secondary Loop Control: If a 0-10V or 2-10V driven variable speed injection pump or a modulating mixing valve is used for controlling the temperature of the secondary loop, wire the mixing device to the - and + terminals (17 and 18) of the AQ252.

FLOATING ACTION OUTPUT

Floating action valve: If a floating action valve is used for controlling the temperature of the secondary (mixed) loop, wire the Common (Com), Open (O), and Close (C) (terminals 19, 20, and 21) of the AQ252 to the corresponding terminals on the mixing valve’s actuator.

BOILER

Wire the Boiler dry contact output (terminals 22 and 23) to the T-T terminals on the boiler Aquastat or the boiler's control panel. See Fig. 15 on page 13 for wiring connections to a typical boiler Aquastat.

These contacts are made any time the system has a request for boiler operation, unless the water supply temperature is above the target temp at that time. If this occurs, the system primary boiler pump would come on.

AUX-OUT

If the Auxiliary Out low voltage output will be used, wire it now to the device (e.g., A/C compressor) that will be switched when the Auxiliary Out’s dry contacts close. Wire the hot leg of the device through the Aux. Out connection (terminals 24 and 25).

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The Aux-Out relay contacts close to correspond with an action, as determined by the installer setup using the EQUIPMENT SETUP > AUXILIARY I/O sub-menu (see Fig. 25 on page 42).

NOTE: The Aux. Out contacts are rated for low voltage devices only.

Communication Bus Wiring

All AQ2000 components communicate with each other on the AQUATROL network using communication bus wiring. This wiring must connect all AQ2000 components. Otherwise,

features that depend on this networked communication (e.g., zone synchronization, outdoor temperature displayed on thermostats, etc.) will not function.

The communication bus wiring is polarity insensitive. The installer does not need to worry about a +ve or –ve orientation of the wires. If there are two wires connected between the B-B Bus Exp. In on one module and B-B Bus Exp. Out on another module, there will be communication. See example in Fig. 8 for how this wiring is to be installed.

The communication bus connections for AQ252 Control Panels are pre-wired at the factory.

DATA BUS
COMMUNICATION
WIRING
Zone 1	Zone 2	Zone 3	Zone 4	Zone 1	Zone 2	Zone 3	Zone 4
AQ25242B				AQ25744B
						M27686A

Fig. 8. Wiring for communication bus.

Step 3 – Thermostats Wiring

NOTE: The new AQ2000 panels will work with either digital (electronic) non-communicating thermostats or AQ1000 communicating thermostats.

1.Using low voltage thermostat wire, connect one thermostat from each zone to the corresponding THERMOSTATS Zone X inputs on top of the Zoning Module (see Fig. 9).

2.If there are additional zones (on Expansion Zoning Panels) connected to this Zoning Module, run low voltage thermostat wiring from the B-B Exp. Bus Out connection (terminals 13 and 14) of the Zoning Module to the B-B Exp. Bus. In connection (terminals 3 and 4) on the Expansion Zoning Panel.

IMPORTANT

Do not run thermostat wires parallel, or close, to telephone, Ethernet, or power cables. Cross all power, Ethernet, and telephone wiring at right angles.

If thermostat wires are located in an area with strong sources of electromagnetic interference, or EMI, (e.g., if thermostat wires are run in the same electrical chase as line voltage wiring) use twisted pair, shielded cable, or run wires in a grounded metal conduit.

This is important, because the AQ1000 thermostats are communicating thermostats which send and received data via the two wires connecting them to the Zoning Module. This data can be distorted by the EMI, potentially causing the AQ252 to not operate properly.

3.Run low voltage thermostat wiring from the R and C output terminals on the secondary of the AQ252 Control Panel’s transformer to the R and C input terminals on the Expansion Zoning Panel. As an alternative, you can run low voltage thermostat wiring from the R and C terminals on the Zoning Module to the R and C terminals on the Expansion Zoning Panel.

<![if ! IE]> <![endif]>FROM B-B “EXP. BUS” TERMINALS ON CONTROL MODULE

<![if ! IE]> <![endif]>THERMOSTAT ON ZONE 1

<![if ! IE]> <![endif]>THERMOSTAT ON ZONE 2

<![if ! IE]> <![endif]>THERMOSTAT ON ZONE 3

<![if ! IE]> <![endif]>THERMOSTAT ON ZONE 4

<![if ! IE]> <![endif]>TO B-B “EXP. BUS IN” TERMINALS ON CONNECTED ZONING MODULE (IF AN EXPANSION ZONING PANEL IS CONNECTED)

M13776C

Fig. 9. Connecting thermostats.

Step 4 – Zoning Equipment Wiring

Because the Zoning Module of the AQ25242B Control Panel can be used with either line voltage pumps or valves, or low voltage zone valves (with or without end switches), field

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installed wiring of the correct voltage needs to be connected to the zoning equipment terminals on the bottom left portion of the Zoning Module.

Line Voltage – Circulators or Zone Valves

Refer to Fig. 10. Remove the plastic wiring barrier that is located in the bottom wiring channel between the AQ15200B Control Module and the Zoning Module. Run jumper wires from the N and L terminals on the bottom of the AQ252 Control Panel’s transformer, through the wiring channel across the bottom of the Control Panel, and to the corresponding N and L terminals of the Zoning Module.

FROM LINE VOLTAGE
120V TERMINALS
(N AND L) ON BOTTOM
OF TRANSFORMER	M27687A

Fig. 10. Wiring an AQ15540B Zoning Module for use with line voltage circulators.

Low Voltage – Zone Valves With or Without End Switches

Wire using step 1 for zone valves without end switches, or use step 2 for zone valves with end switches:

•Low voltage zone valves without end switches: Using Fig. 12 on page 11 as a guide, run jumper wires from the R and C terminals on the secondary of the AQ252’s transformer, through the wiring channel across the top of the Control Panel, and down through the wiring channel on the right side of the panel and over to the R and C terminals on the bottom of the Zoning Module.

IMPORTANT

If low voltage zone valves are used with the AQ25242B Control Panel, the supplied Low Voltage Output sticker (shown in Fig. 11) must be applied over the line voltage output sticker (see Fig. 10) that is already attached to the Zoning Module.

M27688A

Fig. 11. Low voltage output sticker.

M

M

M

M

FROM LOW VOLTAGE
24 VAC TERMINALS
(C AND R) ON TOP
OF TRANSFORMER	M27689A

Fig. 12. Wiring an AQ15540B Zoning Module for use with low voltage zone valves without end switches.

4.Low voltage zone valves with end switches:

See Fig. 13. 24 Vac power is pre-wired between the transformer secondary at the top left of the AQ252’s transformer and the AQ15740B Zoning Module. No field wiring is required.

M

M

M

M

M27690A

Fig. 13. Wiring an AQ15740B Zoning Module for use with low voltage zone valves with end switches.

NOTE: When wiring zone valves with end switches, note the transformer's VA:

If low voltage zone valves with end switches are used for zone control, make sure the selected zone valves do not draw more power (VA) than the 38 VA capacity of the AQ10X38 transformer supplied with the AQ252 Control Panel. This integral transformer has enough power to operate 4 motorized zone valves (such as Honeywell V8043E valves or 4 valves using low-amperage draw, heat motor actuators, such as Honeywell MV100 actuators), plus power the electronics of the AQ252's Control Module and up to 16 AQ1000 thermostats. If zone valves with high-amperage draw heat-motor actuators are used (such as Taco 500 series zone valves), additional 24 Vac transformer capacity will need to be wired to the Zoning Module to power the valves. See

Fig. 14 on page 12 for recommended wiring of additional low voltage VA capacity to AQ2000 Series Zoning Modules.

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CAUTION

Equipment Damage Hazard.

Can damage internal circuitry of Zoning Module.

The ES1 and ES2 terminals of the AQ15740B Zoning Module are powered terminals and must only be connected to a set of dry contacts, such as a zone valve motor's end switch. If power is applied to these contacts (for example, by running line voltage through the zone valves’ end switches to bring on a circulator feeding those valves), the internal circuitry of the Zoning Module will be damaged, in which case the warranty for this product will be voided.

				1
		115 VAC
	100 VA
	TRANSFORMER	THERMOSTATS
	ZONE 1 ZONE 2 ZONE 3 ZONE 4
115 VAC	24 VAC
	1
	USING AN AQ15740B
	VALVE ZONING MODULE
	Zone 1	Zone 2	Zone 3	Zone 4
	1
	2
	3
	1
	2
	3
		1
		2
		3
			1
			2
			3

100 VA
TRANSFORMER
THERMOSTATS
ZONE 1	ZONE 2 ZONE 3 ZONE 4
USING AN AQ15540B
PUMP ZONING MODULE
Zone 1	Zone 2	Zone 3	Zone 4
24 VAC
1
2
3
1
2
3
	1
	2
	3

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.	1
	2
	3

M27691A

Fig. 14. Wiring of additional low voltage VA capacity.

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12

Step 5 – Line Voltage System Outputs

Refer to Fig. 15 and follow these steps to wire the devices to the AQ252 Control Module.

“1. Boiler Pump”

“2. DHW Device”

“3. Line Voltage Rated Variable Injection Pump”

“4. Line Voltage Rated Aux Output (Aux. Pump)” on page 14 “5. Secondary Pump” on page 14

TO BOILER TERMINALS 22-23 ON TOP OF AQ15200B CONTROL MODULE

FROM LINE VOLTAGE 120V TERMINALS (N AND L) ON BOTTOM OF TRANSFORMER

TO LINE VOLTAGE 120V TERMINALS (N AND L) ON BOTTOM OF TRANSFORMER

N L

L8148, L7148

T

T

ZC

ZR

G L2 L1 C2 C1 B2 B1

1 L2

L1

(HOT)

TO AUXILIARY DEVICE (INSTALLER-DEFINED)

BOILER

PUMP

	R8184A, R7184
	T	F
		C554
	T	F
BLACK	<![if ! IE]> <![endif]>WHITE	ORANGE

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

BURNER AND

IGNITION

M27692A

Fig. 15. Line Voltage Connections for AQ252.

1. Boiler Pump

Connect the N and L wires of the boiler loop pump to the N and switched hot ( ) terminals of the line voltage Boiler output, shown in Fig. 17 on page 14. The ground wire of the pump can be connected to any of the 8 ground screw terminals located on the back surface of the Control Panel enclosure.

The boiler pump contacts are made after any one of the following occur:

•A call for heat has occurred from any heating zone.

•The Heat input is shorted on terminals 13 and 14.

•The DHW input is shorted and the DHW type is configured as a valve.

The pump is delayed for the FIRE DELAY programmed in the EQUIPMENT SETUP > BOILER OPERATION sub-menu (see Fig. 25 on page 42). The boiler pump and the last zone calling remain “On,” in order to move heat out of the boiler for the period of time programmed in the Purge time menu under the fire delay. Manually adjusting thermostats affects the operation of this software, so it can not be tested manually. You must observe it under normal operating conditions.

NOTE: If the AQ252 is connected to a modulating condensing boiler, the boiler pump may need to be connected to the boiler, not the AQ252. Confirm this with the boiler’s installation manual.

If using a low voltage zone valve, wire the primary of a spudmounted transformer (115V to 24V) to the DHW line voltage contacts and connect the low voltage zone valve to the secondary terminals of this transformer. A spud-mounted transformer may be located in one of the conduit knockouts on the bottom of the AQ252 Control Panel.

Alternatively, a 24 Vac zone valve can be connected to the Aux. pump line voltage-rated dry contacts, which can be configured to close on a DHW call. This configuration is defined in the Installer Equipment Setup menu beginning on page 33.

The DHW contacts are made when the DHW inputs on terminals 15 and 16 are shorted by the controlling Aquastat. This is a line voltage output designed to go to the DHW pump. If 24 Vac is needed for a low voltage valve, you can mount a step-down transformer on the conduit opening and wire the valve from the transformer. When DHW is enabled, the system has a 30 minute priority over all calls for heat. After 30 minutes, calls for heat are added back in to the operation for 30 minutes and then turned off again. This repeats until the DHW is satisfied.

NOTE: If the AQ252 is connected to a modulating condensing boiler, the DHW pump will probably need to be connected to the boiler, not the AQ252. Confirm this with the boiler’s installation manual.

2. DHW Device

Wire the DHW pump or line voltage zone valve to the N and switched hot ( ) terminals of the DHW output, as shown in Fig. 17 on page 14.

3. Line Voltage Rated Variable Injection Pump

The terminals for the variable injection pump are line voltage rated and protected by an external fuse. A standard pump is controlled by the output of these terminals.

13	69-1986—05

Setup is enabled in the EQUIPMENT SETUP > SECONDARY LOOP sub-menu when the INJECT parameter is set to ENABLE (see Fig. 25 on page 42). The pump remains off (drive is off) whenever the Return temperature is below the Boiler Minimum Return temperature.

4. Line Voltage Rated Aux Output (Aux. Pump)

To connect a line voltage auxiliary device to these contacts, such as a group pump or a boiler bypass pump, power the device from the N and L terminals on the bottom of the Control Module, running the hot (L) lead through the Aux. Pump contacts. See Fig. 16 for details. The exact wiring schematic will depend on what is connected to these dry contacts.

The Aux Pump is a line voltage rated dry contact that is controlled by the selection in the EQUIPMENT SETUP > AUXILIARY I/O sub-menu (see Fig. 25 on page 42).

NOTE: Use of this output is optional. The Aux. pump dry contacts are line voltage-rated but unpowered. A low voltage device can be connected to these programmable contacts, but the wire's insulation must meet applicable codes for use in line voltage enclosures.

See page 33 for programming options for the Aux. Pump dry contacts.

5. Secondary Pump

Connect the N and L wires of the secondary (mixed) loop pump to the N and switched terminals of the line voltage Sec. output. shown in Fig. 17. The ground wire of the pump can be connected to any of the 8 ground screw terminals located on the back surface of the Control Panel enclosure.

The secondary pump terminals energize only when a zone that has been designated as a secondary zone has a call for heat. This enables the pump and the mixing device you have chosen for the loop control. Set-up is enabled in the EQUIPMENT SETUP > PRI/SEC sub-menu (see Fig. 25 on page 42).

M27693A

BY-PASS PUMP

Fig. 16. Wiring of the Aux. pump line voltage rated dry contacts (example shown is a by-pass pump).

	TO AUXILIARY DEVICE
FROM LINE VOLTAGE	(INSTALLER-DEFINED)
120V TERMINALS
(N AND L) ON BOTTOM
OF TRANSFORMER	M27694A

Fig. 17. Wiring for Boiler Pump, Secondary (Mixed) Loop Pump, DHW Device, Injection Pump, and Aux Output.

Step 6 – Connection To Line Voltage Power

Connect the N and L line voltage inputs of the primary on the AQ252 transformer to the electrical distribution panel and power up the Control. A service switch should be installed on the hot (L) lead to the distribution panel.

If multiple Zoning Modules are connected to the AQ252 Control Panel, the line voltage wiring can either be run directly from the N and L terminals on the primary of the transformer to each Zoning Module (Fig. 18), or run in a daisy chain from the N and L terminals of one AQ2000 module to the N and L terminals of the next AQ2000 module (see Fig. 19 on page 15).

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14