Honeywell AQ25A Series Use and care manual

Hydronics Technical Reference Book
Aquatrol Hydronic Boiler Controls
63-9963_Tech_Ref_Cover_5_10.indd 1 5/7/10 11:20:58 AM

63-9963 Rev. 05-10

Rev. 05-10 63-9963
Hydronic Technical Reference Book Contents
Aquatrol Hydronic Boiler Controls
Form Number Page
Control Modules
AQ25A Series Programmable Boiler Control Panels Product Data 69-2119-02 5
AQ250 Series Hydronic Control Panels Product Data 68-0306-02 45
AQ251 Series Boiler Reset Control Panels Product Data 69-1974-04 65
AQ252 Universal Injection/Mixing Boiler Reset Control Panels
Product Data 69-1986-02 105
Expansion Relays
AQ254 “Add-A-Temperature” Expansion Control Panel
Product Data 69-1987-02 151
AQ255, AQ257 Series Expansion Zoning Panels Product Data 69-1981-03 171
Thermostats
AQ1000TN2 Hydronic Zoning Thermostat Owner’s Guide 69-2005EF 189
AQ1000TP2 7-day Programmable Hydronic Thermostat
Owner’s Guide 69-2245EF 225
Sales Literature
Aquatrol AQ2000 Series Brochure 63-9686BW 283
AQ2511 Outdoor Reset Control Panel Sell Sheet 67-7175 299

63-9963 Rev. 05-10

Rev. 05-10 63-9963
Control Modules

63-9963 Rev. 05-10

PRODUCT DATA
69-2119-02
AQ25A Series Programmable Boiler
Control Panels
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.
FEATURES
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

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 2
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.
SPECIFICATIONS
The AQ25A Programmable Boiler Control Panels and
corresponding attached equipment are listed in Table 1.
Table 1. AQ25A Series Control Panel Models.
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, non-
condensing
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)
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
Control Panel
Corresponding
Control Module
Corresponding
Zoning Module
AQ25A42B AQ15A10B AQ15540B
AQ25A44B AQ15A10B AQ15740B

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
369-2119—02
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.

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 4
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.
Fig. 1. AQ25A Series Programmable Boiler Control Panel layout (AQ25A42B shown).
Fig. 2. Internal wiring for AQ2000 Series components line voltage relays.
Menu
Home
OK
M27753
A
Zone 1 Zone 2 Zone 3 Zone 4
LOW
VOLTAGE
(24 V)
LINE
VOLTAGE
(120 V)
ZONING MODULE
TRANSFORMER CONTROL MODULE
FOR THE AQ25A42B TERMINALS CAN BE LINE VOLTAGE (IF USED WITH PUMPS) OR LOW VOLTAGE (IF USED WITH ZONE VALVES)
1
1
M27754A
Zone 1 Zone 2 Zone 3 Zone 4
CONTACTS
SYMBOL
Menu
Home
OK

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
569-2119—02
2MOUNTING
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.
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
M23733A
WIRE
CHANNEL
PLUGS
WIRE
CHANNEL
PLUGS

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 6
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.
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
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).
M27755
A
Zone 1 Zone 2 Zone 3 Zone 4
STEP 1 STEP 2 STEP 3
STEP 4STEP 5STEP 6
TO EXPANSION ZONING MODULES
(IF INSTALLED)
Menu
Home
OK
M27756
A
TO BOILER SUPPLY SENSOR
TO BOILER RETURN SENSOR
TO OUTDOOR SENSOR
IN FROM “R” TERMINAL ON TRANSFORMER MODULE (FACTORY-WIRED)
TO “T-T” TERMINALS ON BOILER AQUASTAT
TO B-B “EXP.BUS IN” TERMINALS ON CONNECTED ZONING MODULE
TO SETPOINT LOAD (OPTIONAL)
TO DHW AQUASTAT
IN FROM “C” TERMINAL ON TRANSFORMER MODULE (FACTORY-WIRED)
TO LOW VOLTAGE AUXILIAR
Y
DEVICE (OPTIONAL)
TO AUXILIARY INPUT SWITCH (OPTIONAL)
TO MODULATING INPUT ON BOILER

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
769-2119—02
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.
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.
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
M13763
M13775

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 8
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.
Fig. 8. Wiring for communication bus.
Zone 1 Zone 2 Zone 3 Zone 4
Zone 1 Zone 2 Zone 3 Zone 4
M27757A
DATA BUS
COMMUNICATION
WIRING
AQ25744B
AQ25242B
Menu
Home
OK

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
969-2119—02
Step 3 – Thermostats Wiring
NOTE: The new AQ2000 panels will work with digital (elec-
tronic) 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.
Fig. 9. Connecting AQ1000 thermostats.
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.
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.
Fig. 11. Low voltage output sticker.
FROM B-B “EXP. BUS” TERMINALS ON CONTROL MODULE
TO B-B “EXP. BUS IN” TERMINALS ON CONNECTED ZONING MODULE (IF AN EXPANSION ZONING PANEL IS CONNECTED)
THERMOSTAT ON ZONE 1 THERMOSTAT ON ZONE 2 THERMOSTAT ON ZONE 3 THERMOSTAT ON ZONE 4
M13776C
FROM LINE VOLTAGE
120V TERMINALS
(N AND L) ON BOTTOM
OF TRANSFORMER
M27687
A
M27688A

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 10
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.
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 low-
amperage 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.
FROM LOW VOLTAGE
24 VAC TERMINALS
(C AND R) ON TOP
OF TRANSFORMER
MMMM
M27689A
M
M27690A
MMM

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
11 69-2119—02
Fig. 14. Wiring of additional low voltage VA capacity.
THERMOSTATS
ZONE 1 ZONE 2 ZONE 3 ZONE 4
M27691
THERMOSTATS
ZONE 1 ZONE 2 ZONE 3 ZONE 4
Zone 1 Zone 2 Zone 3 Zone 4
USING AN AQ15740B
VALVE ZONING MODULE
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
1
Zone 1 Zone 2 Zone 3 Zone 4
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
24 VAC
100 VA
TRANSFORMER
115 VAC
115 VAC
24 VAC
100 VA
TRANSFORMER
1
1
USING AN AQ15540B
PUMP ZONING MODULE

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 12
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
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 spud-
mounted 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.
ZC
ZR
B1
B2
C1C2
L1L2
T
T
G
L8148, L7148
R8184A, R7184
BURNER AND
IGNITION
C554
F
F
T
T
BLACK
WHITE
ORANGE
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
L1
(HOT)
L2
1
1
TO AUXILIARY DEVICE
(INSTALLER-DEFINED)
BOILER
PUMP
M27763A
NL
TO LINE VOLTAGE 120V
TERMINALS (N AND L) ON
BOTTOM OF TRANSFORMER
FROM LINE VOLTAGE 120V
TERMINALS (N AND L) ON
BOTTOM OF TRANSFORMER
TO BOILER
TERMINALS 22-23
ON TOP OF AQ15200B
CONTROL MODULE

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
13 69-2119—02
3. 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
pump from the N and L terminals on the bottom of the AQ15A
Control Module, running the L (hot) lead through the
AUX.Pump contacts. See Fig. 16 for details.
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 38).
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 30 for programming options for the Aux.
Pump dry contacts.
Wire the Installer-defined AUXiliary output to the line voltage
AUX terminals, as shown in Fig. 17. The exact wiring
schematic will depend on what is connected to these dry
contacts.
Fig. 16. Wiring of the Aux. pump line voltage rated dry contacts [example shown is for a by-pass pump].
Fig. 17. Wiring for Boiler Pump, DHW Device, and Aux Output.
Step 6 – Connection to Line Voltage Power
Connect the N and L line voltage inputs of the primary on the
AQ25A 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 AQ25A
Control Panel, the line voltage wiring can either be run directly
from the N and L terminals on the transformer to each Zoning
Module (Fig. 18) or run in a daisy chain fashion from the N and
L terminals of one AQ2000 component to the N and L
terminals of the next AQ2000 (see Fig. 19 on page 14).
Fig. 18. Connections for multiple Zoning Panels - parallel wiring.
BY-PASS PUMP
M27764A
TO AUXILIARY DEVICE
(INSTALLER-DEFINED)
FROM LINE VOLTAGE
120V TERMINALS
(N AND L) ON BOTTOM
OF TRANSFORMER
M27765A
AQ25A
Zone 1 Zone 2 Zone 3 Zone 4
Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4
M27766A
Menu
Home
OK

AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS
69-2119—02 14
Fig. 19. Alternate Connections for multiple Zoning Panels - daisy chain wiring.
CAUTION
Electrical Shock or Equipment Damage Hazard.
Can shock individuals or short equipment circuitry.
When line voltage is applied to the AQ25A Control
Panel and the front cover of the Panel is removed,
there is a risk of electrocution. Be careful to avoid
contact with the line voltage (N and L) terminals, either
with your fingers or with metal tools (such as a
screwdriver) when power is applied to the Control
Panel.
4 PROGRAM AND CONFIGURE THE
CONTROL PANEL
Only two steps are required to set up the AQ25A Series
Control Panel:
1. Check the program settings for the Control Module:
Operation of the AQ25A's Control Module is set by the
menu selections accessible through the Control
Module’s LCD screen. See “AQ25A – System
Programming” on page 16 for instructions.
2. Check the DIP switch settings for each Zoning Module.
Control Panel Defaults
Operation of the AQ25A Control Module is set by the menu
selections accessible through the Control Module’s LCD
screen. See “AQ25A – System Programming” on page 16 for
instructions.
The AQ25A Control Panels are shipped from the factory with
pre-defined values for all program settings. These factory
default settings are commonly used by hydronics contractors
across North America. Usually, most of the settings only need
to be checked by the installing contractor to make sure they
are suitable for the job, rather than having to input all the
settings from scratch.
Although these factory default values for the Control Module
and each Zoning Module are suitable for many installations,
Honeywell recommends that they be reviewed, and changed
as necessary, to get optimal performance of the hydronic
system controlled by the AQ2000 Series products.
Zoning Module DIP Switch Location
The AQ15540B (pump Zoning Module) and AQ15740B (valves
with end switches Zoning Module) both have DIP switches in
8-switch banks and are concealed behind snap-on covers as
shown in Fig. 20.
Fig. 20. Location of Zoning Modules DIP switches.
Zoning Module DIP Switch Settings
A chart of the different settings for each DIP switch is attached
to the inside of each DIP switch cover.
Refer to Table 2 on page 15, and check all DIP switch settings.
If necessary, change the switch settings to suit the desired
operation of the hydronic installation.
NOTES:
1. To set DIP switches 1 through 4, which identify the
unique address of each zone on the AQUATROL
network):
Refer to the descriptions in Table 2 for the correct
DIP switch settings for the Pump or Valve Zoning
Module.
Unpredictable zone behavior may occur if more
than one Zoning Module has DIP switches (1-4)
set to the same address.
2. To set DIP switch 5:
AQ15540B Zoning Module – DIP switch 5 must be
set to PUMP or VALVE, according to whether this
Zoning Module will be used for zoning with pumps
or zone valves without end switches.
AQ15740B Zoning Module – DIP Switch 5 is not
used on this Zoning Module, as this Module can
only be used for valve zoning.
Review the settings of all DIP switches for each Zoning Module
connected to an AQ15A, to ensure they are correct before
system start-up.
Zone 1 Zone 2 Zone 3 Zone 4
Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4
M27767A
Menu
Home
OK
M23731
A
AQ15540B