Honeywell AQ25A Series User manual

PRODUCT DATA
69-2119-05
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—05 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°Fto
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—05
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.