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

desired value within the range of 0 F to 76 F [0 C to 42 C].
A setback in discharge water temperature of 4 degrees is
approximately equivalent to a setback of 1 degree in
space temperature. To obtain a 10-degree setback in
space temperature, the setback knob should be set to 40
F [22 C].
MOTOR SPEED AND BOILER
DIFFERENTIAL ADJUSTMENTS
(Fig. 20)
(4CT0 16C) ei 049
FIG. 20—W964F PANEL, REAR VIEW.
applications, the mode selector must be turned to the
on-off mode (fully counterclockwise position).
A
l\ JUMPER TERMINALS D AND B.
FIG. 21—W964F SUBBASE.
ON-OFF CONTROL OF BURNER
A. Set mode selector to ON-OFF mode (counter¬
clockwise position).
B. Set boiler water differential to desired value within 7 F
to 30 F [4 C to 16 C] range. An initial differential setting
of 10 F [5.5 C] is recommended as the number of
degrees through which the discharge water must
pass between relay make and break.
C. Select line or low voltage input to motor. The subbase
is shipped with jumper in low voltage position (jumper
between terminals D and B). For low voltage input to
motor, verify that this jumper is in place. For line
voltage input to motor, remove jumper from D and B,
and connect jumper to L and B.
D. Connect jumper between terminals 1 and 2.
MOTOR SPEED SELECTION
In the P+l mode, the motor speed selector screw
provides timing either for 4-minute motors (fully
clockwise ) or for 1 -minute motors (fully counter¬
clockwise ). Determine timing from the motor label.
BOILER WATER
DIFFERENTIAL SELECTION
When Aquatrol is used in on-off system applications,
set the boiler water differential screw to the required
differential—within the range of 7 F to 30 F [4 C to 16 C].
An initial differential setting of 10 F [5.5 C] is recom¬
mended.
MODE SELECTION
(Figs. 20, 21)
The Aquatrol is shipped with the mode selector screw
set in the proportional plus integral mode (fully
clockwise position) to control a motorized 3-way
mixing valve. When aquatrol is used in on-off system
P+l MODE
(For 3-way mixing valve control)
PROPORTIONAL PLUS INTEGRAL
(P+l) CONTROL
Proportional control is corrective valve action that is in
proportion to the error or deviation of the controlled
medium temperature from set point temperature.
Proportional plus integral control moves the valve at a
speed proportional to the error or deviation of controlled
medium temperature from set point temperature. That is,
the valve is moved faster as the error gets larger. This
eliminates the offset error due to load changes.
A. Set mode selector to P+l mode (clockwise
position).
B. Set motor speed selector to desired time (1 or 4
minutes).
C. Verify that no jumper is connected between terminals
1 and 2.
11
63 - 2 036-4

CHECKOUT AND TROUBLE!
CHECKOUT
BEFORE APPLYING POWER TO THE SYSTEM . . .
1. Check to be sure all connections are correct and
secure.
2. Check all settings and adjustments (see Settings
and Adjustments section).
3. T u r n power on and check system operation. If
trouble occurs, refer to the troubleshooting chart, Table
3, for corrective action.
TABLE 3—W964F TROUBLESHOOTING CHART
SYMPTOM
POSSIBLE CAUSE
CHECK
CORRECTIVE ACTION
System shows no
sign of life.
No power to system.
Check fuses and main
disconnects.
Correct and replace main
fuse as necessary
See “Motor does not move at
all” below.
(page 11).
System blows main
Faulty wiring to transformer.
Check line voltage wiring.
tuse (tou mA)
—located on
Aquatrol panel
printed circuit
board (page 11).
Faulty transformer.
Check transformer as follows:
Switch off the unit and remove the
Aquatrol from subbase. Route 2
wires through a wiring knockout in
the subbase and connect them to
terminals D and 3. Connect the
free ends of the wires to a suitable
ac voltmeter. Replace Aquatrol on
subbase and switch unit on. Meter
should read approx. 24 Vac.
Remove wires from unit after
transformer test.
Replace Aquatrol if
necessary.
Panel powered,
LED’s light, but no
power on output
terminals C or A.
Output fuse blown or faulty
wiring.
Check fuse and wiring.
Replace output fuse (see
page 11). Correct wiring.
Motor does not
move at all
(stopped in
midstroke).
Failure in motor.
Use function switch to check motor
action (positions 1 and 3). Use
voltmeter to check voltage at
motor.
Replace motor if
necessary.
No power to motor.
If line voltage is not supplied from
Aquatrol, check power supply.
Repair power supply as
necessary.
Component failure in panel.
Function switch-operates motor
but turning adjustment knobs does
not.
Replace panel.
Linkage is jammed.
Inspect linkage—operate
manually.
Repair linkage, valve
damper, or sequencer.
Loose connections.
Check that Aquatrol terminals C, A
and B are connected to motor.
Correct wiring as
necessary.
continued on next page
12

Table 3 continued
SYMPTOM
POSSIBLE CAUSE
CHECK
CORRECTIVE ACTION
System overheats
in mild weather.
Faulty outdoor sensor.
Check outdoor sensor resistance
(see page 3, Fig. 3).
Replace if necessary.
Parallel shift set too high;
e.g., at +35 F.
Check operation with lower shift
setting ‘’setting reset ratio and
parallel shift” (page 10).
Lower parallel shift
setting if necessary. Do
not alter ratio setting.
Outdoor sensor improperly
located.
Check outdoor sensor for ice or
snow buildup or other reason for
cooling.
Relocate sensor if
necessary.
Too little heat in
very cold weather.
Ratio setting or parallel shift
setting too low; e.g,-35 F
parallel shift.
Check setting of reset ratio and
parallel shift (page 10).
Change ratio schedule
or parallel shift to
increase hot water
temperature in very cold
weather.
Outdoor sensor faulty.
Check outdoor sensor resistance. Replace outdoor sensor
if necessary.
System undersized.
Check for 100% boiler operation. Increase heating
capacity if necessary.
Outdoor sensor not located
properly.
Check to see that sensor can
detect average outdoor air
temperature.
Relocate sensor if
necessary.
No reduction in
flow water
temperature
during night
setback (NSB).
Incorrect function switch
setting.
Check function switch is at position
4 (automatic) and clock is set for
night setback period.
Change function switch
to position 4 if
necessary.
Faulty clock.
Visually inspect for:
( i) incorrect time settings
(ii) no clock movement
(iii) correct positioning of program
override switch (page 9) could
be in (1) position
( i) reset time
(ii) replace clock
(iii) manually adjust
override switch to
(0) position and
check program pins
Component failure. Adjusting NSB control to 76 F has
no effect on flow water
temperature during NSB period.
Replace panel.
Motor closes and
will not open (no
heat).
Function switch set to
position 1
(valve permanently closed).
Check function switch setting.
Change function switch
setting to other position,
if necessary.
Sensors are incorrectly
wired.
Visual inspection, check wiring
diagram.
Correct sensor wiring or
replace if necessary.
Either sensor is shorted out. Measure sensor resistance.
Correct sensor wiring or
replace if necessary.
continued on next page
13
63 - 203 6—4

Table 3 continued
SYMPTOM
POSSIBLE CAUSE
CHECK
CORRECTIVE ACTION
Motor opens and
will not close (full
heat).
Open circuit in either sensor.
Measure sensor resistance.
Correct sensor wiring or
replace if necessary.
Function switch set to
position 3 (valve
permanently open).
Check function switch setting.
Change function switch
setting to other position,
if necessary.
System “short
cycles”
(repositions
between ON and
OFF at very short
intervals).
Hot water sensor improperly
located.
Check positioning of sensor
relative to heat source.
Relocate sensor.
Ratio setting too high.
Check ratio schedule.
Lower ratio setting by
one position and
monitor system
operation. Reduce ratio
setting by one or more
further positions if
required.
Parallel shift control set too
high; e.g., at +35 F.
Check parallel shift setting and
ratio schedule.
Reduce the parallel shift
setting by 10 F. If system
operation does not
improve, reduce setting
further. Do not alter ratio
setting.
Motor speed preadjustment
incorrectly set to match
motor used in system.
Check motor timing (see tag-on
motor).
Set motor speed
preadjustment to
correspond to speed of
motor used in system
(see page 11).
Valve greatly oversized.
Check rated output against
estimated load requirement.
Reduce system capacity
if necessary.
Differential setting.
Check that setting is not too low.
Adjust as recommended
on page 11.
O PE
RATION
■ ".V- ■
GENERAL
Most boiler systems heat water to a constant tempera¬
ture regardless of the outdoor temperature. In fact,
discharge water temperatures in hydronically heated
systems are set sufficiently high to heat a building during
the coldest outdoor temperatures. While this setting is
adequate for extreme settings, it wastes energy during
mild weather by maintaining too much heat in the system
and overheating the building.
Outdoor reset can result in 15% or 20% savings in
heating energy by lowering the boiler discharge water
temperature as the outdoor air temperature increases,
and by programming lower water temperatures during
unoccupied periods. These reset savings are the result of
reduced transmission losses, stack losses, heat losses
from open window control, and use of the timer pro¬
grammer to set back the boiler temperature during
unoccupied periods.
Transmission losses occur when heat is lost through
pipes in non-air conditioned passageways, ceiling and
underground piping routes. Stack losses occur in ail
gas-and oil-fired boilers. Resetting boiler water
discharge temperature downward reduces stack losses. For
optimum savings, return water should be piped around
boilers that are not firing. Open window control losses
occur when occupants attempt to reduce the effects of
overheating by opening windows.
14

Outdoor reset also improves comfort control and
extends the life of the burner and boiler. Without reset,
system temperatures are maintained too high during mild
weather. This produces uncomfortable space temper¬
atures and causes unnecessary cycling of the burner.
Systems without reset are susceptible to expansion
and contraction caused by large changes in water
temperature. This causes annoying noise and excessive
system wear. Outdoor reset reduces these undesirable
effects by maintaining lower and more constant water
temperatures. The W964F Aquatrol System senses both
outdoor temperature and discharge water temperature.
As outdoor temperature changes, the Aquatrol resets the
boiler water, following a selected ratio.
ON-OFF AND PROPORTIONAL +
INTEGRAL (P+l) CONTROL
The Honeywell W964F Aquatrol System is designed to
provide any commercial building with reliable, effective
control over hydronic heating systems. The Aquatrol has
field selectable on-off burner control or P+l control of a
motorized 3-way mixing valve.
ON-OFF CONTROLOF BOILERS WITHOUT DOMESTIC
WATER HEATING COILS
On-off control of burners to reset the boiler water
temperature is used mostly with the smaller commercial
boilers. The W964F directly controls the operation of the
burner through output contacts, thereby controlling the
temperature of the discharge water.
W964F P+l CONTROL OF LARGER BOILERS AND OF
BOILERS WITH DOMESTIC WATER HEATING COILS
P+l control is used to reset the discharge water
temperature by positioning a motorized mixing valve.
This valve bypasses return water around the boiler and
mixes it with the correct amount of water leaving the
boiler to provide the required temperature of water being
discharged from the valve into the heating system. Mixing
valves are used with reset systems for three important
reasons:
1. Boilers with domestic water heating coils must be
maintained at a preset minimum temperature to provide
the capacity to serve the domestic water needs of the
building.
2. The manufacturers of many large fire-tube boilers
require the boiler to be maintained at a present
temperature (usually 170 F to 190 F [77 C to 88 C])
regardless of domestic water heating coils.
3. P+l control of motorized 3-way mixing valves
provides much moreaccurate control of discharge water
temperature than either on-off control of burners or
conventional modulating control of mixing valves.
With P+l control, there is zero offset of the required
discharge water temperature. In other words, the actual
discharge temperature does not fall below or rise above
the discharge temperature required by the reset sys¬
tem. This closer temperature control produces more
comfort and more energy savings than on-off or mod¬
ulating control.
In new installations with the Aquatrol, any of the
Honeywell series 60 actuators, such as the M644A-E, are
used with V5013A.B mixing valves. In retrofit of older
installations using W902 reset systems, the W964F may
be used to control existing series 90 motors without
internal balancing relays (M944B,E or M945B,C,G).
APPLICATION VERSATILITY
All hydronically heated buildings, including those
with uncontrolled radiation, controlled radiation, or
variable air volume can benefit from the W964F
Aquatrol System.
UNCONTROLLED RADIATION
The Aquatrol System can be used to provide out¬
door reset in buildings with uncontrolled radiation,
which includes standing radiators, baseboards and
convectors.
The Aquatrol controls the building’s space tem¬
perature and is less expensive than zone control. The
Aquatrol saves energy by reducing overheating and
providing night setback during unoccupied periods.
CONTROLLED RADIATION
The W964F can also be used to provide outdoor
reset in buildings with controlled radiation, which in¬
cludes fan coils, unit ventilators, unit heaters, radiator
valves, and terminal reheat.
In these applications, the Aquatrol improves space
temperature control by providing water at a tem¬
perature very close to the heating requirements. The
zone and room thermostats fine tune the water flow for
precise temperature control.
Reset ensures lowered heating water temperature as
the weather becomes milder. This can speed the
changeover from heating to cooling on a two-pipe fan
coil system. (Water over 90 F [32 C] must not be sent to
the chiller.)
VARIABLE AIR VOLUME
In variable air volume cooling with perimeter heating
applications, the W964F provides controlled heating
of perimeter zones and reduces the conflict between
the heating and cooling systems. Additional energy
savings can be gained by using the built-in night
setback.
If questions arise regarding this product, contact your local distributor or Honeywell representative.
Honeywell Inc. International Sales Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland,
1885 Douglas Drive N. France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
Golden Valley, MN 55422-4386 PRINTED IN U.S.A.