Honeywell AQ255 Series, AQ257 Series Product Information Sheet

AQ255 and AQ257 Series

Expansion Zoning Panels

PRODUCT DATA

AQ25742B

AQ25582B

PRODUCT DESCRIPTION

The AQ255/AQ257 Series Expansion Zoning Panels provide additional zoning capacity for an existing hydronic installation controlled by an AQ2000 Series Boiler Control Panel such as an AQ250 Relay Boiler Control, an AQ251 Reset Boiler Control, or an AQ252 Universal Injection/Mixing Boiler Reset Control.

FEATURES

The AQ255/AQ257 Series Expansion Zoning Panels have the following features:

•Availability of 4 Expansion Zoning Panels.

•Zone control of either pumps or zone valves, in multiples of 4 zones

•4-zone or 8-zone models for pump zoning; 4-zone models for zone valves

•Ability to use both zone valve models and zone pump models in the same installation

•Zone valve panels contain an AQ10X38 transformer (power supply module), which connects to 120 Vac power and supplies 24 Vac power to the Zoning Module.

•Communications between components via the AQUATROL® network, using communication bus wiring.

•Any panel can be configured to activate a group pump when zones are active

•Zone valve models can be used with Normally Open or Normally closed valves

•Can be installed up to 500 ft. away from main AQ2000 Control Panel, for convenient operation of remote zoning equipment

IMPORTANT

To ensure correct installation and proper operation of the zoning panel, perform the 7 installation steps in the order numbered in the “Contents” below.

	Contents
Specifications ...................................................................		2
1	Installation Preparation ..................................................	2
2	Mounting ........................................................................	4
3	Wiring Procedure ...........................................................	5
4	Configure the Expansion Zoning Panel(s) DIP Switches	5
5	Test and Check Out the Installation ...............................	7
6	Purge Air from all System and Zone Piping ..................	8
7	Document and Keep a record of all System Settings ....	9
Troubleshooting ................................................................		10
Appendix ..........................................................................		11
	Wiring Diagrams ...................................................	11

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AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS

SPECIFICATIONS

The AQ2000 Series Expansion Zoning Panels are listed in Table 1.

Table 1. AQ2000 Series Expansion Zoning Panels.

Expansion	Zoning	# of Zoning	Transformer
Zoning Panel	Module	Modules	included
AQ25542B	AQ15540B	1	No
AQ25582B	AQ15540B	2	No
AQ25742B	AQ15540B	1	Yes
AQ25744B	AQ15740B	1	Yes

Application: Controls zoning operations for hydronic zoning systems.

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

B–B Communication Bus Terminals: Low voltage, Class II, 2-wire polarity-insensitive, digital communicating link to other Control or Zoning modules

Zone Pump Output Rating: 120 Vac, 5A, 1/3 HP Zone Valve Output Rating: 24 Vac, 0.5A, 12VA

Electrical Connections (Line Voltage): Wire-clamp screw terminals; maximum 2 x 14 AWG each on line voltage terminals

Environmental Ratings:

Temperature Rating: 32°F to 130°F (0°C to 55°C)

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

Temperature Ratings:

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

Inputs/Outputs:

R–C Input: 24 Vac Class II

R–C Output (on transformer; AQ25742B and AQ25744B only): 38 VA, 24 Vac Class II

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

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

1INSTALLATION 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.

—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, or -44B Expansion Zoning Panels, the full model number is used

(e.g., AQ25744B).

—AQ2000 Series Control Panel is used when the information applies to any of the AQ2000 Series Boiler Control Panels, including AQ25A, AQ250, AQ251, AQ252, etc.

—Control Module refers to the component within the AQ2000 Series Control Panel that performs the master control operations.

—Control Panel refers to an assembled product, consisting of a transformer, Control Module and (if applicable) a 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 Module refers to the component within the AQ2000 Series Control Panel that controls zoning operations. Zoning Modules are available in either 4-zone or 8-zone configurations.

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 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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2

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 Series Control Panel – already installed

—AQ Expansion Zoning Panel(s)

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

•Low voltage thermostat wire

•Zoning equipment (zone valves or pumps)

AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS

Read All Instructions Carefully Before Proceeding

The AQ2000 Series 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. Take a moment to read through this document before beginning the installation. Failure to follow these instructions could damage the product or cause a hazardous condition.

Familiarize Yourself With the AQ255 / AQ257 Expansion Zoning Panel

Refer to Fig. 1 on page 3. In general, the top terminals of all AQ255 / AQ257 Expansion Zoning Panels carry low voltage (24Vac) power and the bottom terminals carry either line voltage (120 Vac) power for the AQ25542B and AQ25582B models, or low voltage (24 Vac) power for the AQ25742B and AQ25744B models. The two exceptions to this are:

1.AQ25744B Expansion Zoning Panel for use with zone valves with end switches.

2.AQ25742B Expansion Zoning Panel when used with low voltage zone valves without end switches.

For these the two exceptions, the bottom terminals of the AQ10X38 Transformer carry line voltage (120 Vac), but the bottom terminals of the Zoning Module will carry low voltage (24 Vac) power.

ZONING MODULE ZONING MODULE

Zone 1

Zone 2

Zone 3

Zone 4

Zone 1

Zone 2

Zone 3

Zone 4

LOW VOLTAGE (24 V)

LINE VOLTAGE (120 V)

M27831A

Fig. 1. AQ255 Expansion Zoning Panel Layout (AQ25582B shown).

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AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS

TRANSFORMER	ZONING MODULE
LOW
VOLTAGE
(24 V)				LOW VOLTAGE
				(24 V)
	Zone 1	Zone 2	Zone 3	Zone 4
LINE
VOLTAGE
(120 V)				LOW VOLTAGE
				(24 V)
				M27832A

Fig. 2. AQ257 Expansion Zoning Panel Layout (AQ25744B shown).

2 MOUNTING	3.	Reverse wire channel plugs and re-insert them into their
		slot to from a wiring channel between the Main Control
This section describes how to mount the Expansion Zoning		Panel and the Expansion Zoning Panel (see Fig. 3) and
Panels and thermostats.	4.	to connect the two panels together.
		Install two top screws of the Expansion Zoning Panel,
Mount Expansion Zoning Panel(s)		ensuring it is level with the adjoining Main Control Panel,
	5.	and install two lower screws.
1. Remove wire channel plugs from the Control Panel and		Repeat steps 1–4 for any additional Expansion Zoning

any Expansion Panels (see Fig. 3).	Panels.

2.Mount Expansion Zoning Panel on the right-hand end of the Main Control Panel.

M13757

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

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4

Mount and Wire Thermostats in the Zones

Install the thermostats on the walls in the zones that are to be controlled by the AQ2000 Control Panels and Expansion Zoning Panels.

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

If not done already, run low voltage thermostat wire (24 gauge or heavier) from the thermostats back to the Expansion Zoning Panel for use in section 3, “Wiring Procedure” .

NOTE: 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 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 AQ255 / AQ257 Expansion Zoning Panels are pre-wired at the factory, making for faster installation.

•For the AQ25742B and AQ25744B models, the low voltage output terminals located at the top of the transformer are wired to the R and C input terminals at the top of the Zoning Module. In addition, for the AQ25742B model, the low voltage output terminals located at the top of the transformer are wired to the R and C input terminals at the bottom of the Zoning Module.

•For the AQ25582B model, which contains two AQ15540B Zoning Modules, the B-B “Exp.Bus OUT” terminals of the Zoning Module on the left side are wired to the B-B “Exp.Bus IN” terminals of the Zoning Module on the right side.

NOTE: For examples of wiring Expansion Zoning Panels to AQ2000 Series Control Panels and wiring additional low voltage VA capacity, refer to the “Wiring Diagrams” section in the “Appendix” beginning on page 11.

Wiring the AQ255 / AQ257 Expansion Zoning Panel to an AQ2000 Series Control Panel

To wire the Expansion Zoning Panel to an AQ2000 Series Control Panel or another AQ255 / AQ257 Expansion Zoning Panel:

1.Ensure the power to the AQ2000 Series Main Control Panel is disconnected before proceeding.

2.For each zone to be added to the existing AQ2000 system, connect one zone thermostat to its corresponding TH input terminals on the top of the Expansion Zoning Panel being installed.

3.The B-B “Exp.Bus IN” terminals of the Expansion Zoning Panel being installed connect to the B-B “Exp.Bus OUT” terminals on the Control Module or previously installed Zoning Module on the furthest right side of the AQ2000 Series installation. These connections are polarity insen-

AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS

sitive, so it does not matter which of the BB “Exp.Bus OUT” terminals is connected to which of the B-B “Exp.Bus IN” terminals.

4.Wire the zoning equipment to the output terminals (bottom edge) of the Expansion Zoning Panel – line voltage circulators or valves for the AQ25542B and AQ25582B and low voltage zone valves for the AQ25742B and AQ25744B.

5.Bring power to the Expansion Zoning Panel as follows:

a.AQ25542B: run 14 AWG jumper wires from the N and L terminals on the bottom of the AQ2000 Series Control Panel’s AQ10X38 transformer to the N and L terminals on the bottom of the AQ15540B module.

b.AQ25582B: run 14 AWG jumper wires from the N and L terminals on the bottom of the AQ2000 Series Control Panel’s AQ10X38 transformer to the N and L terminals on the bottom of EACH AQ15540B Zoning Module.

c.AQ25742B: run 14 AWG jumper wires from the N and L terminals on the bottom of the AQ2000 Series Control Panel’s AQ10X38 transformer to the N and L terminals on the bottom of the AQ25742B’s transformer module (AQ10X38).

d.AQ25744B: run 14 AWG jumper wires from the N and L terminals on the bottom of the AQ2000 Series Control Panel’s AQ10X38 transformer to the N and L terminals on the bottom of the AQ25744B’s transformer module (AQ10X38).

The AQ255 / AQ257 Expansion Zoning Panels can control up to 4 space heating zones (or 8, for the AQ25582B Expansion Zoning Panel). The heart of each Expansion Zoning Panel is its Zoning Module. The corresponding Panels and Modules are shown in Table 1 on page 2.

For the -42B and -82B Panels, line voltage pumps are used for the zoning equipment so low voltage (24 Vac) power is not required. That’s why there isn't a transformer included with these Panels. A small amount of low voltage power is required to power the electronic components inside the Zoning Modules, and this is supplied by jumper wires connecting the R and C terminals of the AQ2000 Series Control Panel’s AQ10X38 transformer with the R and C terminals on the AQ15540B Zoning Module.

For the -42B and -44B Valve Panels, an AQ10X38 transformer is included to provide sufficient low voltage power to drive the zone valves.

4CONFIGURE THE EXPANSION ZONING PANEL(S) DIP

SWITCHES

Setting up the AQ255 / AQ257 Expansion Zoning Panels is quick, simple and straightforward. All that's needed is to check and if necessary adjust, the DIP switch settings.

For all Expansion Zoning Panels, DIP switches are located behind the blank cover in the left most section of the Zoning Module (beside the section labeled Zone 1). Refer to Fig. 4. The DIP switches come pre-set from the factory with default settings that are the most commonly-used by hydronics contractors across North America. That means that most of the settings only need to be checked by the installing contractor to make sure they’re suitable for the job, rather than having to adjust the DIP switch settings from scratch, which is a great time savings.

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