Honeywell AQ25400B Product Information Sheet

AQ25400B “Add-A-Temperature”

Expansion Control Panel

PRODUCT DATA

PRODUCT DESCRIPTION

The AQ25400B “Add-A-Temperature” Expansion Control Panel provides additional zoning capacity for an existing hydronic installation controlled by an AQ2000 Series Boiler Control Panel such as an AQ250 Relay Boiler Control, an AQ25A Programmable Boiler Control, an AQ251 Reset Boiler Control, or an AQ252 Universal Injection/Mixing Boiler Reset Control. The AQ254, which can control up to 16 zones of heating in addition to the zones connected to the Master AQ2000 Series boiler control, maintains the water temperature in a secondary loop of a hydronic system by

mixing higher temperature water from the primary (boiler) loop with cooler water returning from the heat emitters in the secondary loop that is being controlled by the AQ254.

The mixing action is accomplished by one of three outputs on the AQ254’s Control Module:

•a line voltage injection pump,

•a 24 Vac floating action motorized mixing valve, or

•a 0-10 Vdc (or 2-10 Vdc) modulating output (for a motorized mixing valve or variable speed pump). The floating action mixing valve can be either a rotary or globe style design.

FEATURES

The AQ25400B has the following features:

•Controls 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.

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

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

________________________________________________

IMPORTANT

To ensure correct installation and proper operation of the control, perform the 6 installation steps in the order numbered in the “Contents” below.

	Contents
Specifications ...................................................................		2
1	Installation Preparation ..................................................	3
2	Wiring Procedure ...........................................................	5
3	Program and Configure the Expansion Control Panel ...	9
4	Test and Check Out the Installation ...............................	11
5	Purge Air from all System and Zone Piping ..................	12
6	Document and Keep a record of all System Settings ....	12
Troubleshooting ................................................................		13
Appendix ..........................................................................		14
	Home Page and System Status Page ....................	14
	Installer Programming Menu ..................................	15

69-1987-02

AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL PANEL

•Extends the capacity of an existing AQ2000 hydronic control panel by up to 16 zones and one reset mixed temperature loop.

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

•Integral 38 VA transformer with self resetting electronic fuse.

•Equipment settings are stored in a non-volatile EPROM memory so the AQ254 retains all program settings during a power outage.

SPECIFICATIONS

Application: Provides additional zoning capacity for an existing hydronic installation controlled by an AQ2000 Series Boiler Control Panel.

Power and Electrical Ratings: Power Supply: 120 Vac / 60Hz

Auxiliary Pump Output Rating: Dry contact output, 120 to 240 Vac 5A, 1/3 HP

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:

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)

Inputs/Outputs:

Auxiliary (Demand) Input: External dry contacts connection only

DHW Demand Input: External dry contacts connection only

Secondary Sensor Input: External dry contacts connection only

Mixing Valve (Com, O, C) Output: 24 Vac, 0.5A, 12VA

Modulating Output: 0-10 or 2-10 Vdc for variable speed pump or modulating mixing valve

User Interface (Setting, Programming): 8-character, 3-line LCD Display with a 3 button keypad

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

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

Dimensions (HxWxD): 8.0 x 9.4 x 3.3 in. (20.3 x 23.8 x 8.5 cm) approximate

Weight: 3.9 lb. (1.8 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.

69-1987—02

AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL PANEL

1 INSTALLATION PREPARATION

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.

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:

—AQ2000 boiler Control Panel (such as AQ250, AQ25A, AQ251, or AQ252)

—AQ254 “Add-A-Temperature” Expansion Control Panel

—AQ Expansion Zoning Panel (at least one Expansion Zoning Panel must be connected to an AQ254 to provide input from zone thermostats associated with the mixed temperature loop controlled by the AQ254)

—Digital thermostats (one for every space heating zone being controlled)

•Secondary loop supply temperature sensor (included with the AQ254 control panel)

•Mixing device (injection pump, floating 2-, 3- or 4-way motorized mixing valve, modulating 0-10 Vdc [or 2-10 Vdc] motorized mixing valve or variable speed pump

•Secondary loop pump

•Low voltage thermostat wire

•Zoning equipment (zone valves or pumps)

The AQ254 is designed to be connected to an AQ2000 boiler Control Panel - it cannot be operated as a standalone device.

The AQ254 Control Panel can control a maximum of 16 zones by connecting additional Expansion Zoning Panels to the AQ254 Control Panel. 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.

Read All Instructions Carefully Before Proceeding

The AQ254 Control Panel is 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

Product Data sheet before beginning the installation. Failure to follow them could damage the product or cause a hazardous condition.

Familiarize Yourself With the AQ254 Control Panel Layout

The AQ254 “Add-A-Temperature” Expansion Control Panel consists of two functional components (see Fig. 1 on page 3):

•The AQ10X38 transformer (power supply module), which connects to 120 Vac power and supplies 24 Vac power to the Expansion Control Module and any connected Zoning Modules.

•The Mixing Control Module, AQ15400B, which controls the mixing device (pump or valve) to maintain the secondary loop temperature according to the method of reset (outdoor or load adaptive reset).

TRANSFORMER CONTROL MODULE

LOW VOLTAGE (24V)

CONTACTS

SYMBOL

LINE

VOLTAGE

(120V)

M27808A

Fig. 1. AQ254 Expansion Control Panel layout.

The top terminals of the AQ254 carry low voltage (24 Vac) power and the bottom terminals carry line voltage (120 Vac) power. This is illustrated in Fig. 1.

The powered terminals on the bottom of the AQ254 are connected internally, as shown in by the dashed lines in Fig. 1. The voltage supplied to the N and L terminals is also available at the SEC pump and variable speed injection pump terminal pairs when the hot ( ) relays are switched.

The 38 VA transformer included with the AQ254 has sufficient capacity to provide low voltage power to the AQ15400B Control Module as well as up to 16, AQ1000 thermostats.

All low voltage contacts (terminals 3 to14) on the top of the AQ15400B Control Module are internally-powered.

IMPORTANT

Voltage must not be applied to the low voltage terminals or the internal electronics of the AQ15400B could be damaged.

The 10kΩ sensor for measuring the secondary loop (mixed) temperature is the only low voltage input on the AQ254 Control Panel (besides the 24 Vac R and C supply terminals). There are two low voltage outputs: a 0-10Vdc (or 2-10Vdc)

3	69-1987—02

Honeywell AQ25400B Product Information Sheet

AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL PANEL

modulating signal to drive a modulating mixing valve or a variable speed pump, and a 24 Vac set of terminals that provides a floating signal to a motorized mixing valve.

Line voltage outputs include a secondary pump relay and a variable speed injection output which drives a fixed speed circulating pump at a varying speed depending on the heat input required for the secondary mixed loop.

On the bottom of the Control Module, there is a set of line voltage-rated auxiliary (AUX.) dry contacts that can be programmed to close under several predefined conditions, making this Control Panel a very versatile mixing controller for hydronic systems.

Mount AQ254 Control Panel

Mount the control panel on the wall using Fig. 2 as a guide:

1.Remove the wire channel plugs from the AQ254.

2.Mount the AQ254 on the right hand end of the main AQ2000 Series Control Panel (or Expansion Zoning Panel).

3.Reverse the wire channel plugs and re-insert them into the groove from where they were removed to form a wiring channel between the main AQ2000 Series Control Panel (or Expansion Zoning Panel) and the “Add-A-Tem- perature” Control Panel.

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

MOUNTING

Since the AQ254 “Add-A-Temperature” Panel is an Expansion Control Panel, it functions as an “add-on” control to an existing Main AQ2000 Series Boiler Control. The AQ254 is designed to be connected to an AQ2000 boiler Control Panel - it cannot be operated as a standalone device.

IMPORTANT

The Main AQ2000 Series Control Panel (an AQ250, AQ25A, AQ251, or AQ252), and any Expansion Zoning Panels connected to the Main panel) must be mounted on the wall of the mechanical room before the AQ254 can be installed.

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 AQ254 Control Panel and any Expansion Zoning Panels (see Fig. 2).

2.Mount Expansion Zoning Panel on the right-hand end of the AQ254 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. Refer to Figure

Fig. 5 on page 7 for an example of an installation with multiple AQ254 Expansion Control Panels

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

WIRE

CHANNEL

PLUGS

WIRE

CHANNEL

PLUGS

M23733A

Fig. 2. Orientation of wire channel plugs for creating pass-through wire channel and for joining Control Panel to Expansion Zoning Panels.

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AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL PANEL

Mount and Wire Thermostats in the Zones

Install the thermostats on the walls in the zones that are to be controlled by the AQ2000 Series panels, and (if not done already) run low voltage thermostat wire (24 gauge or heavier) from the thermostats back to the Zoning Modules connected to the AQ254 Control Panel.

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

Connect floor sensors (part # AQ12C20) to the thermostats for any space heating zones with in-floor heating, where temperature regulation of the floor is required.

Spare Fuse

The AQ254 includes a fuse to protect the electronic circuit that drives the variable speed injection pump output. Although it is unlikely that the fuse will be blown – as injection pumps rarely if ever exceed the 1/6 HP rating for this output – there is a spare fuse attached to the side of the AQ254 housing. See Fig. 3 for location of this spare fuse. If additional replacement fuses are needed, please contact Honeywell Technical Support at 1-800- 318-0815.

3A FUSE

SPARE

FUSE

M13884

Fig. 3. Location of spare fuse for AQ254

Expansion Control Panel

2 WIRING PROCEDURE

The AQ254 Control Panel is pre-wired at the factory, making for faster installation:

•The low voltage output terminals located at the top of the AQ10X38 transformer are wired to the R and C input terminals of the AQ15400B Control Module, and

•The line voltage terminals on the bottom of the AQ10X38 transformer are connected to the N and L terminals on the bottom of the AQ15400B Control Module.

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 14 gauge copper conductors.

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

Beginning with the top left of Fig. 4 on page 6 and moving clockwise around the panel, wire components to the AQ254 Expansion Control Panel and Expansion Zoning Panels (if installed) in the following six steps:

•“Step 1 – Low Voltage Transformer Wiring” on page 7

•“Step 2 – Low Voltage Control Panel Wiring” on page 7

•“Step 3 – Communications Bus Wiring” on page 8

•“Step 4 – Line Voltage Wiring” on page 8

•“Step 5 – Connection to Expansion Zoning Panels” on page 8

•“Step 6 – Connection to Line Voltage Power” on page 8

5	69-1987—02

AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL PANEL

STEP 3

STEP 1	24 VAC TO		STEP 2 FLOATING
	EXPANSION			ACTION
	ZONING PANELS	SECONDARY		VALVE
	(IF INSTALLED)	SECONDARY
	(IF INSTALLED)	SENSOR
		SENSOR
			10 VDC
120V TO		SECONDARY
ELECTRICAL		SECONDARY		INJECTION
PANEL	120V TO	LOOP PUMP		PUMP
	EXPANSION		AUX DEVICE
	ZONING PANELS		AUX DEVICE
	(IF INSTALLED)		(OPTIONAL)
STEP 5				STEP 4

Fig. 4. Wiring sequence.

FACTORY WIRING (LOW VOLTAGE)

FIELD WIRING (LOW VOLTAGE)

FACTORY WIRING (LINE VOLTAGE)

FIELD WIRING (LINE VOLTAGE)

M27809A

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