Honeywell Aquatrol W964F User manual

Honeywell
THE W964F AQUATROL PROVIDES RESET
CONTROLOF HYDRONIC BOILERS IN COM-
MERCIAL BUILDINGS, MULTI-FAMILY
DWELUNGS, OFFICES, SCHOOLS AND GAR¬
DEN APARTMENTS. THE W964F CAN BE
USED EITHER IN THE ON-OFF MODE TO
DIRECTLY CONTROL THE BURNER, OR IN
THE PROPORTIONAL PLUS INTEGRAL
(P+l) MODE TO CONTROL A MOTORIZED
3-WAY MIXING VALVE.
FEATURES
□ Field selection of on-off or proportional +
integral (P+l) operation. P+l provides stable
temperature control without offset.
□ Selectable outdoor reset ratio from 1:3 to
2.5:1.
□ Selectable parallel adjustment to accom¬
modate individual building construction.
□ 7-day quartz clock with 50-hr battery
backup for programmable setback
schedules.
□ Adjustable differential, from 7 F to 30 F
[4 C to 16 C] in on-off mode, to match burner
operation with boiler characteristics.
□ Adjustable motor timing to 1 or 4 minutes
in P+l mode.
□ Line or low voltage output, no external
transformer needed to power motor.
□ Indicating LEDs on panel show when
valve is opening or closing.
□ Solid state balance circuit provides P+l
control for use with Modutrol motors without
balance relays, or with S684 Step Controller.
□ Options include remote control panel or
space temperature compensating sensor.
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Rev. 2-89
Form Number 63-2036—4
© Honeywell Inc. 1989

MODELS:
W964F1037 Aquatrol panel with 7-day programmable
timer.
W964F1045 Aquatrol panel without programmable
timer.
AMBIENT TEMPERATURE RATING: 36 F to 122 F [2 C to
50 C].
AMBIENT RELATIVE HUMDITIY RATING: 20 to 90% RH.
ELECTRICAL RATINGS:
Input Voltage—120 Vac
Output Voltage—24 Vac or 120 Vac
Frequency—50/60 Hz
Power—2.5 VA
Relay Output Rating—1.25 AFL at 120 Vac
Internal Low Voltage Transformer Output—20 VA at 24
Vac, 60 Hz.
RESET RATIO: Adjustable from 1:3 to 2.5:1 (ratio of
change in outdoor air temperature to change in
heating water temperature).
INITIAL CONTROL POINT: 70 F [21 C].
NIGHT SETBACK OF DISCHARGE WATER: Adjustable
from 0 F to 75 F [0 C to 42 C].
OUTDOOR TEMPERATURE RANGE: -22 F to 68 F [-30 C
to 20 C].
PARALLEL SHIFT: Adjustable from +35 F to -35 F [-19 C
to +19 C].
ACTUATOR MOTOR SPEED: Selectable, 1 or 4 minutes
in P+l mode.
DIFFERENTIAL: Adjustable from 7 F to 30 F [4 C to 17 C] in
on-off mode.
TIMER/PROGRAMMER: Programmable setback
periods; 7-day or 24-hour available. Accuracy ±5 sec
per month.
Battery backup time—50 hr.
Minimum stage operation—3 hr.
SENSORS: See Table 1.
DIMENSIONS: See Fig. 1.
FIG. 1—W964F DIMENSIONS IN in. [mm IN
BRACKETS].
TABLE 1—SENSOR CHARACTERISTICS
MODEL
DESCRIPTION
TEMPERATURE RANGE
F[C]
RESISTANCE
Ohms @ 77 F [25 C]
T7043B1013
Outdoor Sensor
680
T7044A1014
Indoor Sensor (strap-on)
68 to 212 [20 to 100]
4100
T7043A1023
Indoor Sensor (immersion)
68 to 212 [20 to 100]
4100
continued on page 3
WHEN PURCHASING REPLACEMENT AND MODERNIZATION PRODUCTS FROM YOUR TRADELINE
WHOLESALER OR YOUR DISTRIBUTOR, REFER TO THE TRADELINE CATALOG OR PRICE SHEETS FOR
COMPLETE ORDERING NUMBER, OR SPECIFY—
1. Order number. 4. Indoor sensor, immersion or strap-on type.
2. With or without clock. 5. Additional accessories.
3. Outdoor Sensor.
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 BUILDING CONTROLS SALES OFFICE (CHECK WHITE PAGES OF YOUR PHONE
DIRECTORY).
2. BUILDING CONTROLS DIVISION CUSTOMER SERVICE
HONEYWELL INC., 1885 DOUGLAS DRIVE NORTH
MINNEAPOLIS, MINNESOTA 55422-4386 [phone]
(IN CANADA—HONEYWELL LIMITED/HONEYWELL LIMITEE, 740 ELLESMERE ROAD, SCARBOROUGH, ONTARIO M1P
2V9) INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD.
2

ACCESSORIES:
1. W9260A1014 Digital Remote Control Unit with
digital 24-hour clock.
2. T7160A1004 Space Compensation Sensor.
3. 197918 Concealed Set Point Cover for
T7160A1004.
4. 7617ADR Conduit Adapters (2), convert com¬
pression fittings on sensors to 1 /2 in. conduit.
5. 197943 24-hour Quartz Timer/Programmer.
6. T 238 Outdoor Thermostat controls circulating
pump in response to outdoor temperature.
REPLACEMENT PARTS:
1. F u s es (Purchase from electrical wholesaler.)
Main, 1/4 amp slow-blow—MDL 1/4 (Littlefuse
213.250 or equivalent). See Fig. 18 for location.
Output, 1 amp slow-blow—MDL 1 (Littlefuse
213.001 or equivalent). See Fig. 18 for location.
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 your
application.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out product
operation as provided in these instructions.
CAUTION
Disconnect power supply before making wiring
connections to prevent electrical shock and
equipment damage.
NSTALLING SENSORS
To properly install and check out the T7043A1023
(immersion, indoor), T7043B1013 (outdoor) or
T7044A1014 (strap-on, indoor) sensors, refer to the
instructions provided with the sensors or the instructions
supplied with the W964F. The following graphical in¬
formation provides resistance versus temperature data
for measuring the sensor’s thermistor resistance (see
Figures 2 and 3).
INSTALLING W964F AQUATROL
PANEL (Figs. 4,5)
Perform the following installation steps in sequence.
Where additional information is required, references are
given to appropriate sections of this specification.
1. Select a location for the Aquatrol panel that will
provide access to controls for adjustment and service.
2. Detach Aquatrol panel and barrier plate from
subbase.
3. For surface mounting, attach subbase to wall using
two No. 10 screws provided. For flush mounting, cut
panel hole (Fig. 5) and mount Aquatrol using two special
clamps provided.
4. Connect wiring as shown in appropriate system
diagram (Figs. 6-18) in Wiring section. Knockouts are
provided in subbase for 1 /2 and 3/4 in. conduit.
BEFORE APPLYING POWER
TO SYSTEM
5. On back of Aquatrol panel, select mode of
operation (on-off or P+l). Set boiler water differential if in
on-off mode; select motor timing if in P+l mode. See Mode
Selection, Boiler Water Differential Selection, and motor
timing in Settings and Adjustments section.
6. On subbase, select mode of operation (on-off or
P+l) and voltage (line or low). See Mode Selection in
Settings and Adjustments section.
7. After settings and adjustments are made on
subbase, attach barrier plate to subbase (single screw
through center).
3
63 - 203 6—4

FIG. 4—W964F SURFACE MOUNTING.
FIG. 5—W964F FLUSH MOUNTING.
8. Attach Aquatrol panel to subbase (two screws Adjustments section.
through panel). 10. Attach cover to panel and if restriction of function
9. Before securing cover to panel, set timer/pro- knob is desired, engage locking pin.
grammer, reset ratio, function switch, parallel shift and 11. Check operation of system as shown in Checkout
setback. Refer to appropriate portion of Settings and section.
4

Disconnect power supply before making wiring con¬
nections to prevent electrical shock and equipment
damage. All wiring must comply with applicable electrical
codes, ordinances and regulations.
Connect W964F Aquatrol Panel, sensors and acces¬
sories as shown in typical system diagrams. For on-off
control applications, refer to Figs. 6-8. For 3-way mixing
valve (P+l) applications, refer to Figs. 9-16. For hookup of
optional W9260A Remote Control Panel and T7160A
Space Temperature Compensating Unit, refer to Fig. 16.
When replacing a Honeywell W902 Panel with a W964F
Panel, refer to Fig. 17. In systems with valve ports A and B
reversed, refer to Fig. 18.
W9260A
(OPTION)
SYSTEM.
FIG. 8—HOOKUP OF W964F TO TYPICAL FLAME
SAFEGUARD DEVICE ON-OFF SYSTEM.
A
A\ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
— PROTECTION AS REQUIRED.
/2\ ADD LINK FOR ON/OFF MODE.
/3\ THERMOSTAT TERMINALS ON BOILER CONNECTION PANEL.
/4\ TERMINALS B TO A MAKE ON TEMPERATURE FALL. E1040B
r=-1 W9260A
I'- 1 »— I (OPTION)
AQUATROL I l/vj T7160A
OUTDOOR RESET] |-^(OPTION)
SENSOR CONTROLLER I j
T7043B W964F I |
FIG. 7—HOOKUP OF W964F TO TYPICAL BOILER 1-1
WITH LOW VOLTAGE THERMOSTAT TERM- FIG. 9—HOOKUP FOR W964F IN TYPICAL 3-WAY
INALS—ON-OFF SYSTEM. MIXING VALVE SYSTEM.
5
63 - 20 3 6 —4

E>
W964F
MAX. 15 V
FIG. 10—HOOKUP FOR W964F AND M944B LOW
VOLTAGE MOTORS.
FIG. 12-HOOKUP FOR W964F AND M644A,C,D,E
LOW VOLTAGE MOTORS USING TRANS¬
FORMER IN W964F.
FIG. 11—HOOKUP FOR W964F AND M644A,C,D,E LOW
VOLTAGE MOTORS USING SEPARATE TRANS¬
FORMER.
FIG. 13—HOOKUP FOR W964F AND M644B LINE
VOLTAGE MOTORS—MOTOR POWERED
FROM SEPARATE LINE VOLTAGE SUPPLY.
6

/l\ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
— PROTECTION AS REQUIRED.
A MOVE LINK BD TO BL.
/3\ TERMINALS B TO A MAKE ON TEMPERATURE FALL. TERMINALS B TO C
MAKE ON TEMPERATURE RISE. E1Q34
FIG. 14—HOOKUP FOR W964F AND M644B LINE VOLTAGE MOTORS—MOTOR POWERED FROM W964F.
l ~3||£-24 V, 20 VA MAX.~] !
ji + ° f - A | i
1 1 1 D = MAX. j
1 PfWcnQ 1 120 V,
! 1 1 I I 1 1 125 afl
W964F
l|n D | C | B | A | 3 2 1 4 4A 5 6 7 T2 T2 T3 T3
HEATING STAGES *
12 3 4 ZlA 5
■ 1
W R B G T V NC NO NC NO NC NO NC NO NC NO 6 LI L2 3 4 P N
24 V
-1 A
FM 770438
n\ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
/2\ SWITCHES SHOWN WITH DEVICE DEENERGIZED.
A S684F HAS 10 SWITCHES.
/A\ HOOK UP SHOWN IS FOR HEATING.
/5\ REMOVE JUMPER AND CONNECT ON-OFF SWITCH HERE IF S684 MUST
RETURN TO START POSITION DURING OFF CYCLE.
/6\ IF SEPARATION OF SWITCHING STAGES AND CONTROL OPERATION IS
DESIRED, CLIPOUT JUMPER (TERMINAL 6 TO LI) AND CONNECT
SEPARATE POWER SUPPLY.
, DIRECTION OF MOTOR ROTATION IS AS VIEWED FROM THE MOTOR OR
POTENTIOMETER END.
1L — CW LIMIT SWITCH
2L - CCW LIMIT SWITCH
1M - CW MOTOR WINDING
2M - CCW MOTOR WINDING
1 R-- RECYCLING RELAY
^ TERMINALS G. T AND Y NOT USED.
^ REMOVE LINK B TO D.
k TERMINALS B TO A MAKE ON TEMPERATURE FALL. TERMINALS B TO C
MAKE ON TEMPERATURE RISE.
y, V4044 DIVERTING VALVES BYPASS RETURN WATER AROUND
BOILER NOT FIRING. E1033
FIG. 15—W964F USED WITH S684D,F STEP CONTROLLER IN MULTISTAGE HEATING SYSTEM.
7
63 - 2 0 3 6 —4

NOTE: THE W9260A AND
T7160A CANNOT BE
USED TOGETHER.
24 N L I 2 3
j <k> i
• 1
LoqJ
A\ WHEN INSTALLING THE OPTIONAL W9260A DIGITAL REMOTE CONTROL
THE RESISTOR AND LINK MUST BE SNIPPED OFF THE SUBBASE
TERMINALS 5, 6 AND 7.
/2\ WHEN INSTALLING THE OPTIONAL T7160A ROOM TEMPERATURE SENSOR
THE RESISTOR MUST BE SNIPPED OFF THE SUBBASE TERMINALS 6 AND 7.
/3\ TO W964F TERMINALS.
FIG. 16—HOOKUPS FOR OPTIONAL W9260A REMOTE
CONTROL OR T7160A ROOM TEMPER¬
ATURE SENSOR.
FIG. 17—HOOKUP FOR REPLACING HONEYWELL
W902 PANEL WITH W964F PANEL
OUTDOOR
SENSOR
T7043B
AQUATROL
RESET
CONTROLLER
W964F
AQUATROL RESET
CONTROLLER
DISCHARGE
SENSOR
M644,
M944.M945
MOTOR
ON A CALL FOR HEAT IN A NORMAL V50I3A OR B HOOKUP, THE
VALVE STEM TRAVELS UPWARD OPENING PORT B (SUPPLY LINE
FROM BOILER). WITH REVERSED PORT HOOKUP, MOTOR CON¬
TROLLER WIRING MUST BE REVERSED SO THAT ON A CALL FOR
HEAT PORT A OPENS AND PORT B CLOSES. E1047
FIG. 18—HOOKUP FOR W964F AND V5013A,B IN SYSTEM WITH VALVE PORTS A AND B REVERSED.
8

FRONT PANEL ADJUSTMENTS (Fig. 19)
TIMER/
PROGRAMMER
FUNCTION
SWITCH —
RATIO
ADJUSTMENT
PARALLEL
SHIFT
ADJUSTMENT
■ SETBACK
TEMPERATURE
ADJUSTMENT
SKETCH ABOVE SHOWS A PROPORTIONAL +
INTEGRAL (P + I) CONTROLLER. WHEN THE
AQUATROL IS CONVERTED TO AN ON/OFF
CONTROLLER THE DECAL (LEFT, SUPPLIED)
MUST BE APPLIED OVER THE EXISTING
DECAL.
El 055
FIG. 19—AQUATROL FRONT PANEL ADJUSTMENTS.
TIMER/PROGRAMMER
-IMPORTANT-
ALWAYS TURN TIMER CLOCKWISE.
Timer programming is based on a 24-hour or a 24-hour,
7-day system.
1. Insert red (1) pins in grooves opposite day and hour
that each occupied period is to start.
2. Insert blue (0) pins opposite day and hour that each
setback (unoccupied) period is to start.
3. Turn the outer ring CLOCKWISE to set the day and
time (24-hour scale) opposite the white triangle.
4. Turn center knob CLOCKWISE to set exact time on
the 12-hour inner dial.
FUNCTION SWITCH
In the proportional plus integral mode, the function
switch provides a choice of manual or automatic valve
operation, and manual override of the timer program as
follows:
1. Valve closed-boiler side of valve is closed, pro¬
ducing continuous bypass of the system (heat off).
2. Valve stop—power is removed from the actuator,
leaving the valve in an intermediate position.
3. Valve opened—actuator is driven to the open
position, providing no mixing of return water (heat on).
4. Automatic—normal operating position, allowing the
timer/programmer to switch between occupied and
unoccupied settings.
5. Continuous occupied setting—overrides setback,
providing constant comfort discharge water tem¬
perature.
6. Continuous unoccupied setting—overrides tim¬
er/programmer, providing constant setback discharge
water temperature.
9
63 - 2 03 6—4

In the on-off mode, the function switch provides a
choice of manual or automatic contact operation, and
manual override of the timer program as follows:
1. Contact open—burner off.
2. Standby.
3. Contact closed—burner on.
4. Automatic—normal operating position, allowing the
timer/programmer to switch between occupied and
unoccupied settings.
5. Continuous occupied setting—overrides setback,
providing constant comfort discharge water tem¬
perature.
6. Continuous unoccupied setting—overrides tim¬
er/programmer, providing constant setback discharge
water temperature.
RESET RATIO
The reset ratio is the ratio of outdoor temperature
change to the resulting change in discharge water
temperature. Reset automatically adjusts the boiler dis¬
charge water temperature in response to changes in
outdoor temperature. When outdoor temperature rises,
water temperature is automatically lowered, and when
outdoor temperature falls, water temperature is raised.
This saves energy by reducing transmission losses,
stack losses, and heat losses resulting from open
window control.
The W964F provides continuously adjustable reset
ratios from 1:3 to 2.5:1. The 1:3 ratio has the greatest
resetting effect on water temperature in that a 1 degree
change in outdoor temperature causes a 3 degree
change in water temperature. The 2.5:1 ratio has the least
resetting effect since it requires a 2.5 degree outdoor
temperature change to produce 1 degree change in
water temperature. Note on the ratio graph (behind ratio
dial) that the curve with the 1:3 ratio has the steepest
slope, while the 2.5:1 ratio has the shallowest slope.
Reset is adjusted by means of the front panel ratio dial.
The ratios marked on the dial are shown as curves on the
graph behind the dial. However, the dial can be set
between marked numbers and those ratios must be
interpolated between curves on the graph. Suggested
ratios for several different heating systems and design
temperatures are shown in Table 2.
PARALLEL SHIFT
Parallel shift provides fine tuning of reset by creating a
reset ratio curve parallel to the curve originally deter¬
mined by the selected reset ratio. The amount of parallel
shift is adjustable ±35 F [±19 C].
With the parallel shift set at 0 F, all reset ratio curves
relate to an initial set point of 70 F for both outdoor
temperature and discharge temperature. The parallel
shift setting allows the initial control point of the dis¬
charge temperature (70 F) to be shifted by a maximum of
±35 F [±19 C]. For example, with the parallel shift setting
at +10 F, the initial control point of the discharge
temperature would be 80 F (refer to chart on ratio
adjustment dial on face of W964F).
Suggested values of parallel shift for several different
heating systems and design temperatures are shown in
Table 2.
TABLE 2—RESET RATIO AND PARALLEL SHIFT SELECTION GUIDE
TYPE
RADIATION
HEATING
MEDIUM
TEMPER¬
ATURE
AT
DESIGN
TEMP. (°F)
DESIGN TEMPERATURE
-20 F 1
OF_1
+20 F
RESET
RATIO
PARALLEL
SHIFT
RESET
RATIO
PARALLEL
SHIFT
RESET
RATIO
PARALLEL
SHIFT
Direct
Standing
170-190
1:1
+10 F
1:1.5
+10 F 1:2
+15 F
Convector or
Baseboard
180-200
1:1.5
0
1:2.5
+10 F
1:2.5
+5 F
Fan Coil
Heating Only
165-180
1:1
+5 F
1:1.5
+10 F
1:2
0
Heating/Cooling
130-140 1:5.1
+10 F
1:1
0
1:1
+10
Indirect
Floor
Radiant
90
Not
Recom.
—
2.5:1
-25 F
2.5:1
-15 F
Ceiling
Radiant
110
2.5:1
-15 F
2.5:1
-5 F
2.5:1
0
NOTE ON SETBACK TEMPERATURE ADJUSTMENT
The Aquatrol panel is a water temperature controller—the scale of the setback adjustment being calibrated in degrees of
water temperature. A change of ±4 F in water temperature is equivalent to a change of ±1 F in space temperature.
SETBACK TEMPERATURE
ADJUSTMENT
The Aquatrol maintains boiler discharge water at
control point temperature during occupied periods. The
control point is determined by the reset ratio adjustment,
parallel shift adjustment and by outdoor temperature.
Additional energy can be saved by setting back
(decreasing) the control point during unoccupied
periods. The time of each setback period is determined
by the placement of the blue (0) pins on the tim¬
er/programmer.
To obtain the desired amount of setback, turn the
discharge water temperature setback adjustment to the
10