Honeywell AQ25A Series Product Information Sheet

AQ25A Series Programmable Boiler

Control Panels

PRODUCT DATA

FEATURES

PRODUCT DESCRIPTION

The AQ25A Series of Programmable Boiler Control Panels consists of a transformer, a boiler/DHW Control Module, and a 4-zone Zoning Module, all contained within an AQ2000 panel enclosure. The boiler/DHW Control Module, controls the boiler and domestic hot water (DHW) functions, as well as coordinating the overall operation of the hydronic system.

AQ25A Control Panels can control a maximum of 16 zones by connecting additional Expansion Zoning Panels to the AQ25A Control Panel. Each Expansion Zoning Panel is configured with its own bank of DIP switches.

The AQ25A Series Programmable Boiler Control Panels have the following features:

•Boiler supply and return temperature sensors

•Outdoor temperature sensor

•Zoning equipment (zone valves or pumps)

•Availability of two Zoning Modules: the AQ15740B, for zoning with 24 Vac zone valves with end switches, and the AQ15540B, for zoning with either line voltage circulators or 24 Vac zone valves without end switches.

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

•4-zone or 8-zone Expansion Zoning Panels, up to a maximum of 16 zones

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

•AQ15A Boiler/Domestic Hot Water Control Module, which controls boiler and DHW functions, as well as provides overall management of the hydronics system

	Contents
Specifications ...................................................................		2
1	Installation Preparation ..................................................	3
2	Mounting ........................................................................	5
3	Wiring Procedure ...........................................................	5
4	Program and Configure the Control Panel ....................	14
5	Test and Check Out the Installation ...............................	18
6	Purge Air from all System and Zone Piping ..................	19
7	Document and Keep a record of all System Settings ....	19
Troubleshooting ................................................................		20
Appendix ..........................................................................		23
	User Menu ..............................................................	23
	Installer Menu .........................................................	30

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

SPECIFICATIONS

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

The AQ25A Programmable Boiler Control Panels and corresponding attached equipment are listed in Table 1.

Table 1. AQ25A Series Control Panel Models.

	Corresponding	Corresponding
Control Panel	Control Module	Zoning Module
AQ25A42B	AQ15A10B	AQ15540B
AQ25A44B	AQ15A10B	AQ15740B

Application: Controls zoning operations, and provide boiler and DHW management for hydronic zoning systems.

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

Auxiliary Pump Output Rating: Dry contact output, 120 to 240 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

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

Boiler (Supply) Minimum Control Temperature:

OFF, 59° to 180° F (OFF, 15° to 82° C)

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

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

Heat Demand Input External dry contacts connection only

Modulating Output: 0-10 or 2-10 Vdc for modulating boiler

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.

DHW Valve Open: 0-230 seconds, before boiler loop pump is energized.

DHW Purge: Yes/No; selects whether purge is applied after a DHW demand is served

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 thermostats and/or AQ1000 Series 2-wire communicating thermostats

Supply/Return 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

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.

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

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 Modules.

—AQ15A refers to the AQ15A10B Control Module within an AQ25A Series Control Panel.

—AQ25A refers to the AQ25A42B and AQ25A44B Control Panels. Where there are specific instructions or details relating to the -42B or -44B Control Panels, the full model number (i.e., AQ25A44B) 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, the full model number (i.e., AQ25744B) is used;

—Control Module refers to the component within an AQ25A 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 AQ25A 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.

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

—AQ25A 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 AQ25A Control Panel)

•Outdoor temperature sensor (included with AQ25A Control Panel)

•Low voltage thermostat wire

•Zoning equipment (zone valves or pumps)

Read All Instructions Carefully Before Proceeding

The AQ25A 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 quick installation guide before beginning the installation. Failure to follow them could damage the product or cause a hazardous condition.

Familiarize Yourself With the AQ25A Control Panel Layout

Refer to Fig. 1 on page 4. All AQ25A Control Panels consist of three functional components:

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

2.the AQ15A boiler/DHW Control Module, which controls the boiler and DHW functions as well as coordinating the overall operation of the hydronic system, and

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

•AQ15740B (part of the AQ25A44B Control Panel) for zoning with 24 Vac zone valves with end switches.

•AQ15540B (part of the AQ25A42B Control Panel) for zoning with either line voltage circulators or 24 Vac zone valves without end switches.

AQ25A Control Panels can control a maximum of 16 zones by connecting additional Expansion Zoning Panels to the AQ25A 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.

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AQ25A SERIES PROGRAMMABLE BOILER 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 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. The voltage supplied to the N and L terminals is also available at the adjacent terminal pairs when the hot ( ) relays are switched.

TRANSFORMER CONTROL MODULE ZONING MODULE

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

1 FOR THE AQ25A42B TERMINALS CAN BE LINE VOLTAGE (IF USED WITH PUMPS) OR LOW VOLTAGE (IF USED WITH ZONE VALVES)

M27753A

Fig. 1. AQ25A Series Programmable Boiler Control Panel layout (AQ25A42B shown).

CONTACTS
SYMBOL
Menu
OK
Zone 1	Zone 2	Zone 3	Zone 4
Home
			M27754A

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

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

2 MOUNTING

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

Mount AQ25A Control Panel

Mount the control panel on the wall:

1.Use the template supplied with the AQ25A Series Programmable Boiler 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, they should be mounted on the wall now.

1.Remove wire channel plugs from the AQ25A Control Panel and any Expansion Panels (see Fig. 3).

2.Mount Expansion Zoning Panel on the right-hand end of the AQ25A 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 from 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.

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.

Mount and Wire Thermostats in the Zones

Install the thermostats on the walls in the zones that are to be controlled by the AQ251 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 AQ25A Control Panel.

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 AQ25A 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 (21 and 22) 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 AQ25A 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 9

•“Step 4 – Zoning Equipment Wiring” on page 9

•“Step 5 – Line Voltage System Outputs” on page 12

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

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

TO EXPANSION ZONING MODULES (IF INSTALLED)

STEP 1

STEP 2

STEP 3

	Menu
	OK
	Zone 1	Zone 2	Zone 3	Zone 4
	Home
STEP 6	STEP 5	STEP 4		M27755A

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 to the R and C terminals of any Expansion Zoning Panel.

<![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 AUXILIARY INPUT SWITCH (OPTIONAL)

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

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

<![if ! IE]> <![endif]>TO MODULATING INPUT ON BOILER

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 AQ25A):

•“Temperature Sensor Wiring”

•“System Demands Wiring” on page 7

•“Low Voltage Outputs Wiring” on page 8

•“Communication Bus Wiring” on page 8

<![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

M27756A

Fig. 5. Low voltage wiring for the AQ15A10B Control Module.

Temperature Sensor Wiring

Connect the lead wires of each sensor to the corresponding terminals on top of the AQ15A 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.

Both the Supply and Return Sensors should be installed on the supply and return piping of the boiler for proper operation of the AQ25A Control Panel. Even if the AQ25A is connected to a modulating condensing boiler with its own supply and/or return sensors, the AQ25A’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 AQ25A (see Fig. 6 on page 7).

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

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 AQ25A.

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.

M13763

Fig. 6. Strap-on temperature sensor installation.

OUTDOOR SENSOR: FOR USE WITH AQ1000 THERMOSTATS

IMPORTANT

The AQ25A is not an Outdoor Reset Boiler Control Panel. The purpose of the outdoor sensor is to communicate the outdoor temperature to the AQUATROL network for display on all AQ1000 thermostats.

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 for typical placement. Outdoor sensor comes with 10 ft. (3 m) 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.

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, since the calculated temperature - based on the sensor's resistance reading - can be distorted by high EMI, potentially causing the AQ25A to not operate properly. If using shielded cable or conduit, connect the shield wire to earth ground only at the AQ25A 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 30.

AUX-IN

If the optional Aux In. contacts (terminals 9 and 10) 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 38).

HEAT DEMAND

If the optional Heat Demand (terminals 11 and 12) 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 38). Heat Demand priority allows only heat for the first 30

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

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 13 and 14) 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 AQ25A is connected to a modulating condensing boiler with built-in DHW management, the DHW tank’s Aquastat should be connected to the AQ25A's DHW (terminals 13 and 14). The AQ25A's Aux. Out (terminals 19 and 20) should be wired to the boiler's DHW input terminals to the AQ25A.

Low Voltage Outputs Wiring

10 VDC

The 10 Vdc terminals (15 and 16) of the AQ25A produce a modulating (0-10 Vdc or 2-10 Vdc) signal that can drive a modulating boiler’s combustion fan to maintain a constant supply temperature from the boiler (generally equal to the Boiler High Limit setting in the EQUIPMENT SETUP > BOILER SETTINGS sub-menu).

Boiler Signal: If the AQ25A panel is configured to send a 0-10V or 2-10V signal to a modulating/condensing boiler, connect the AQ25A’s modulating output terminals (15 and 16) to the modulating signal input on the boiler control.

BOILER

Wire the Boiler dry contact output (terminals 17 and 18) to the T-T terminals on the boiler Aquastat or the boiler's control panel. See Fig. 15 on page 12 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, at which time 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 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 19 and 20).

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 38).

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 are pre-wired at the factory for AQ25A Control Panels.

DATA BUS
COMMUNICATION
WIRING
Menu
OK
Zone 1	Zone 2	Zone 3	Zone 4	Zone 1	Zone 2	Zone 3	Zone 4
Home
AQ25242B				AQ25744B
						M27757A

Fig. 8. Wiring for communication bus.

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

Step 3 – Thermostats Wiring

NOTE: The new AQ2000 panels will work with digital (electronic) non-communicating thermostats. AQ1000 thermostats are not required.

WHEN USING AQ1000 THERMOSTATS:

1.Using low voltage thermostat wire, connect one AQ1000 communicating thermostat from each zone to the corresponding TH inputs on top of the Zoning Module (see Fig. 9 on page 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 AQ25A to not operate properly.

3.Run low voltage thermostat wiring from the R and C terminals on the AQ25A Control Panel’s transformer to the R and C 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)

Step 4 – Zoning Equipment Wiring

Because the Zoning Module of the AQ25A Control Panel can be used with either line voltage pumps or valves, or low voltage zone valves (with or without end switches), field 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 AQ15A Control Module and the Zoning Module. Run jumper wires from the N and L terminals on the bottom of the AQ25A 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:

1.Low voltage zone valves without end switches: Using Fig. 12 as a guide, run jumper wires from the R and C terminals on the top left of the AQ25A’s

transformer through the wiring channel across the top of the Control Panel, 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 AQ25A 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.

M13776C

Fig. 9. Connecting AQ1000 thermostats.

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

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.

2.Low voltage zone valves with end switches:

See Fig. 13 on page 10. 24 Vac power is pre-wired between the transformer secondary at the top left of the AQ25A’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 AQ25A Control Panel. This integral transformer has enough power to operate 4 motorized zone valves (such as Honeywell V8043E valves or 4 valves using lowamperage draw, heat motor actuators such as Honeywell MV100 actuators), plus power the electronics of the AQ25A'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 11 for recommended wiring of additional low voltage VA capacity to AQ2000 Series Zoning Modules.

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.

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AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

					1
			115 VAC
	100 VA
	TRANSFORMER	THERMOSTATS
115 VAC		ZONE 1	ZONE 2 ZONE 3 ZONE 4
	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

M27691

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

11	69-2119—05

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS

Step 5 – Line Voltage System Outputs

Refer to Fig. 15 and follow the steps in this section to wire these devices to the AQ25A Control Module.

“1. Boiler Pump”

“2. DHW Device”

“3. Line Voltage Rated Aux Output (Aux. Pump)” on page 13

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

L2

1

L1

(HOT)

TO AUXILIARY DEVICE (INSTALLER-DEFINED)

BOILER

PUMP

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

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

M27763A

Fig. 15. Line Voltage Connections for AQ25A.

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 13. 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 11 and 12.

•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 38). 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 AQ25A is connected to a modulating condensing boiler, the boiler pump may need to be connected to the boiler, not the AQ25A. 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 13. If using a low voltage zone valve, wire the primary of a spud-mounted 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 spudmounted transformer may be located in one of the conduit knockouts on the bottom of the AQ25A 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 30.

The DHW contacts are made when the DHW inputs on terminals 13 and 14 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 AQ25A is connected to a modulating condensing boiler, the DHW pump will probably need to be connected to the boiler, not the AQ25A. Confirm this with the boiler’s installation manual.

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12