Honeywell AQ25400B Product Information Sheet
AQ25400B “Add-A-Temperature”
Expansion Control Panel
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.
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
• 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.
PRODUCT DATA
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-toinstall”).
• 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 exist-
ing 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
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
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, non-
condensing
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 2
1 INSTALLATION PREPARATION
A
AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL 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.
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 pro-
vide 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.
Product Data sheet before
follow them could damage the product or cause a hazardous
condition.
beginning the installation. Failure to
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
LOW
VOLTAGE
(24V)
CONTACTS
SYMBOL
LINE
VOLTAGE
(120V)
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.
CONTROL MODULE
M27808
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
3 69-1987—02
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
nals 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)
be applied to the low voltage termi-
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.
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 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-Temperature” Control Panel.
4. Install the 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 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
Fig. 2. Orientation of wire channel plugs for creating pass-through wire channel and
for joining Control Panel to Expansion Zoning Panels.
69-1987—02 4
M23733A
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 1-800318-0815.
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
3A FUSE
SPARE
FUSE
Fig. 3. Location of spare fuse for AQ254
Expansion Control Panel
M13884
5 69-1987—02
AQ25400B “ADD-A-TEMPERATURE” EXPANSION CONTROL PANEL
STEP 3
120V TO
ELECTRICAL
PAN EL
STEP 1 STEP 2
24 VAC TO
EXPANSION
ZONING PANELS
(IF INSTALLED)
120V TO
EXPANSION
ZONING PANELS
(IF INSTALLED)
SECONDARY
SENSOR
SECONDARY
LOOP PUMP
FLOATING
ACTION
VALV E
10 VDC
AUX DEVICE
(OPTIONAL)
INJECTION
PUMP
STEP 5 STEP 4
FACTORY WIRING
(LOW VOLTAGE)
FIELD WIRING
(LOW VOLTAGE)
FACTORY WIRING
(LINE VOLTAGE)
FIELD WIRING
(LINE VOLTAGE)
M27809A
Fig. 4. Wiring sequence.
69-1987—02 6
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