Building AutomationDatasheet for Honeywell models including: AQ25A Series, Programmable Boiler Control Panels
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 ...
This is a legacy product document supported by Resideo. This product is no longer manufactured. 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. PRODUCT DATA 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 69-2119-05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS SPECIFICATIONS The AQ25A Programmable Boiler Control Panels and corresponding attached equipment are listed in Table 1. Table 1. AQ25A Series Control Panel Models. Control Panel AQ25A42B AQ25A44B Corresponding Control Module AQ15A10B AQ15A10B Corresponding Zoning Module AQ15540B AQ15740B Application: Controls zoning operations, and provide boiler and DHW management for hydronic zoning systems. Power and Electrical Ratings: Power Supply: 120 Vac / 60Hz Auxiliary Pump Output Rating: Dry contact output, 120 to 240 Vac, 5A, 1/3 HP Auxiliary Low Voltage Output Rating: 24 Vac, 0.5A, 12VA Boiler (T-T) Output Rating: 24 Vac, 0.5A, 12VA Boiler Pump (C1-C2) Output Rating: 120 Vac 5A, 1/3HP DHW Pump/Valve Output Rating: 120 Vac 5A, 1/3HP BB Communication Bus Terminals: Low voltage, Class II, 2-wire polarity-insensitive, digital communicating link to other Control or Zoning modules Electrical Connections (Line Voltage): Wire-clamp screw terminals; maximum 2 x 14 AWG each on line voltage terminals Environmental Ratings: Control and Zoning Panel Temperature Rating: 32°F to 130°F (0°C to 55°C) Operating Humidity Range (% RH): 5 to 90% RH, noncondensing Temperature Ratings: Boiler Differential: 2° to 41° F (1° to 23° C), or AUTO Boiler (Supply) Minimum Control Temperature: OFF, 59° to 180° F (OFF, 15° to 82° C) Boiler (Supply) Maximum Control Temperature: OFF, 120°F to 225°F (OFF, 49°C to 107°C) Return Minimum Control Temperature: OFF, 80°F to 180°F (OFF, 27°C to 82°C) Sensor Temperature Rating: -58°F to 230°F (-50°C to 110°C) 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 RC Input (on Control and Zoning Modules): 24 Vac Class II RC Output (on transformer): 38 VA, 24 Vac Class II Interface and Timings: User Interface (Setting, Programming): LCD Display and a 7-button keypad Setback Program: 7 day, up to 2 setback periods/day. DHW Valve Open: 0-230 seconds, before boiler loop pump is energized. DHW Purge: Yes/No; selects whether purge is applied after a DHW demand is served Boiler Heat Post Purge: Off, 10 seconds to 30 minutes (factory default is 30 seconds) Pump/Valve exercise: 30 seconds per 2 weeks of space heating inactivity Thermostat Compatibility: Digital thermostats and/or AQ1000 Series 2-wire communicating thermostats Supply/Return Sensor: 10K ohm NTC thermistor at 77°F (25°C) ± 0.5°F (±0.3°C). Lead Length: 10 ft. (3.0 m); up to 500 ft. (150 m) using 18 AWG or larger wire, beta=3892. Outdoor Sensor: 10K ohm NTC thermistor at 77°F (25°C) ± 0.5°F (±0.3°C). Lead Length: 15 ft. (4.6 m); up to 500 ft. (150 m) using 18 AWG or larger wire, beta=3892 ORDERING INFORMATION When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number. If you have additional questions, need further information, or would like to comment on our products or services, please write or phone: 1. Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory). 2. Honeywell Customer Care 1885 Douglas Drive North Minneapolis, Minnesota 55422-4386 In Canada--Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9. International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A. 69-2119--05 2 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Dimensions (HxWxD): 8 x 16 1/2 x 3 3/8 in. (20.3 x 42 x 8.5 cm) approximate Weight: 4.9 lb. (2.3 kg) Approvals: Canadian Standards Association: Certified, File No. LR76030 1 INSTALLATION PREPARATION NOTES: Throughout these instructions, the following terminology conventions are used: -- AQ155 refers to the AQ15540B Zoning Module -- AQ157 refers to the AQ15740B Zoning Modules. -- AQ15A refers to the AQ15A10B Control Module within an AQ25A Series Control Panel. -- AQ25A refers to the AQ25A42B and AQ25A44B Control Panels. Where there are specific instructions or details relating to the -42B or -44B Control Panels, the full model number (i.e., AQ25A44B) is used. -- AQ255 refers to all of the AQ25542B, AQ25582B and AQ25742B Expansion Zoning Panels -- AQ257 refers to the AQ25744B Expansion Zoning Panel Where there are specific instructions or details, the full model number (i.e., AQ25744B) is used; -- Control Module refers to the component within an AQ25A Series Control Panel that performs the master control operations. See Table 1 on page 2 for specific models. -- Control Panel refers to an assembled product, consisting of a transformer, Control Module and Zoning Module, all contained within an AQ2000 panel enclosure; -- Expansion Zoning Panel refers to an assembled product, consisting of a Zoning Module and (if applicable) a transformer, contained within an AQ2000 panel enclosure. Expansion Zoning Panels are available in either 4-zone or 8-zone configurations. -- Zoning Module refers to the component within the AQ25A Series Control Panel that controls zoning operations. When Installing this Product... 1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition. 2. Check the ratings given in the instructions and on the product to make sure the product is suitable for the application. 3. Installers must be trained, experienced, and licensed service technicians. 4. Follow local codes for installation and application. 5. After installation is complete, check out the product operation as printed in these instructions. WARNING Risk of electrical shock. Can cause severe injury, property damage or death. Disconnect power supply before installation and before servicing. Check That You Have All the Necessary Equipment For a Successful Installation · AQ2000 Series components -- AQ25A Control Panel -- AQ Expansion Zoning Panels (if more than four space heating zones in the system) -- Digital thermostats (one for every space heating zone being controlled) · Boiler supply and return temperature sensors (included with the AQ25A Control Panel) · Outdoor temperature sensor (included with AQ25A Control Panel) · Low voltage thermostat wire · Zoning equipment (zone valves or pumps) Read All Instructions Carefully Before Proceeding The AQ25A Control Panels are a part of a totally new family of hydronic controls. And although they - and other AQ2000 system components - are very easy to install and operate, they are different than other hydronic controls that you have previously installed. Take a moment to read through this quick installation guide before beginning the installation. Failure to follow them could damage the product or cause a hazardous condition. Familiarize Yourself With the AQ25A Control Panel Layout Refer to Fig. 1 on page 4. All AQ25A Control Panels consist of three functional components: 1. the AQ10X38 transformer (power supply module), which connects to 120 Vac power and supplies 24 Vac power to the Control Module and Zoning Modules; and 2. the AQ15A boiler/DHW Control Module, which controls the boiler and DHW functions as well as coordinating the overall operation of the hydronic system, and 3. One of two different 4-zone Zoning Modules: · AQ15740B (part of the AQ25A44B Control Panel) for zoning with 24 Vac zone valves with end switches. · AQ15540B (part of the AQ25A42B Control Panel) for zoning with either line voltage circulators or 24 Vac zone valves without end switches. AQ25A Control Panels can control a maximum of 16 zones by connecting additional Expansion Zoning Panels to the AQ25A Control Panel. Each Expansion Zoning Panel is configured with its own bank of DIP switches, located in the left-most section of each Zoning Module. 3 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS In general, the top terminals of the AQ2000 Series components carry low voltage (24 Vac) power and the bottom terminals carry line voltage (120 Vac) power. This is illustrated in Fig. 1. The two exceptions to this are: 1. AQ15740B Zoning Module for use with zone valves with end switches. 2. AQ15540B Zoning Module when used with low voltage zone valves without end switches. For these the two exceptions, the bottom terminals of the Transformer and Control Module carry line voltage (120 Vac), but the bottom terminals of the Zoning Module will carry low voltage (24 Vac) power. The powered terminals on the bottom of the AQ2000 Series Control Modules and Zoning Modules are connected internally as shown in Fig. 2. The voltage supplied to the N and L terminals is also available at the adjacent terminal pairs when the hot ( ) relays are switched. TRANSFORMER CONTROL MODULE ZONING MODULE LOW VOLTAGE (24 V) Menu OK Home Zone 1 Zone 2 Zone 3 Zone 4 1 FOR THE AQ25A42B TERMINALS CAN BE LINE VOLTAGE (IF USED WITH PUMPS) OR LOW VOLTAGE (IF USED WITH ZONE VALVES) Fig. 1. AQ25A Series Programmable Boiler Control Panel layout (AQ25A42B shown). LINE VOLTAGE (120 V) 1 M27753A CONTACTS SYMBOL Menu OK Home Zone 1 Zone 2 Zone 3 Zone 4 Fig. 2. Internal wiring for AQ2000 Series components line voltage relays. M27754A 69-2119--05 4 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS 2 MOUNTING This section describes how to mount the Control Panel, Expansion Zoning Panels, and the Thermostats. Mount AQ25A Control Panel Mount the control panel on the wall: 1. Use the template supplied with the AQ25A Series Programmable Boiler Control Panel to mark mounting holes for panels. 2. Install two top screws, mount the panel, and install the two lower screws. Mount Expansion Zoning Panel(s) If there are Expansion Zoning Panels to install, they should be mounted on the wall now. 1. Remove wire channel plugs from the AQ25A Control Panel and any Expansion Panels (see Fig. 3). 2. Mount Expansion Zoning Panel on the right-hand end of the AQ25A Control Panel. Install two top screws of the Expansion Zoning Panel, ensuring it is level with the adjoining Control Panel, and install two lower screws. 3. Reverse wire channel plugs and re-insert them into their slot to from a wiring channel between the Control Panel and the Expansion Zoning Panel (see Fig. 3) and to connect the two panels together. 4. Repeat steps 13 for any additional Expansion Zoning Panels. WIRE CHANNEL PLUGS WIRE CHANNEL PLUGS M23733A Fig. 3. Orientation of wire channel plugs for creating pass-through wire channel and for joining Control Panel to Expansion Zoning Panels. Mount and Wire Thermostats in the Zones Install the thermostats on the walls in the zones that are to be controlled by the AQ251 Control Panel. When using AQ1000 thermostats, refer to the installation instructions included with the AQ1000 thermostats. If not done already, run low voltage thermostat wire (24 gauge or heavier) from the thermostats back to the AQ25A Control Panel. NOTE: If not otherwise specified, low voltage wiring should be run with 18 gauge thermostat wire and line voltage wiring should be run with 14 gauge wire. AQUATROL line voltage screw terminals are approved for use with 22 to 12 gauge copper conductors. Several wiring diagrams are included in this document. For additional information, refer to http://customer.honeywell.com or your local distributor. 3 WIRING PROCEDURE The AQ25A Control Panel is pre-wired at the factory, making for faster installation. For all models, the low voltage output terminals located at the top of the transformer secondary are wired to the R and C input terminals of the Control Module, as well as the R and C inputs of the Zoning Module. The B-B Exp. Bus terminals (21 and 22) of the Control Module are wired to the B-B Exp. Bus IN terminals of the Zoning Module. Beginning with the top left of Fig. 4 on page 6 and moving clockwise around the panel, wire components to the AQ25A Control Panel and Expansion Zoning Panels (if installed) in the following six steps: · "Step 1 Transformer Wiring" on page 6 · "Step 2 Control Panel Wiring" on page 6 · "Step 3 Thermostats Wiring" on page 9 · "Step 4 Zoning Equipment Wiring" on page 9 · "Step 5 Line Voltage System Outputs" on page 12 · "Step 6 Connection to Line Voltage Power" on page 13 5 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS STEP 1 TO EXPANSION ZONING MODULES (IF INSTALLED) STEP 2 STEP 3 Menu OK Home Zone 1 Zone 2 Zone 3 Zone 4 STEP 6 STEP 5 STEP 4 M27755A Fig. 4. Wiring sequence. Step 1 Transformer Wiring Factory pre-wiring of the Control Panels is shown as dotted lines in Fig. 4. In addition to the pre-wiring, run low voltage jumper wires from available R and C terminals to the R and C terminals of any Expansion Zoning Panel. 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 IN FROM "R" TERMINAL ON TRANSFORMER MODULE (FACTORY-WIRED) IN FROM "C" TERMINAL ON TRANSFORMER MODULE (FACTORY-WIRED) TO BOILER SUPPLY SENSOR TO BOILER RETURN SENSOR TO OUTDOOR SENSOR TO AUXILIARY INPUT SWITCH (OPTIONAL) TO SETPOINT LOAD (OPTIONAL) TO DHW AQUASTAT TO MODULATING INPUT ON BOILER TO "T-T" TERMINALS ON BOILER AQUASTAT TO LOW VOLTAGE AUXILIARY DEVICE (OPTIONAL) TO B-B "EXP.BUS IN" TERMINALS ON CONNECTED ZONING MODULE Fig. 5. Low voltage wiring for the AQ15A10B Control Module. M27756A 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). 69-2119--05 6 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS The Boiler Return sensor should be installed on the return piping as close to the entrance port to the boiler as practical, using the other AQ12C11 strap-on sensor supplied with the AQ25A. The correct location is one that will measure the temperature of all combined sources of water returning back to the boiler. Insulate strap-on sensors with pipe wrap to ensure accurate boiler temperature sensing. The Boiler Supply and Return water sensors come with 10 ft. (3m) of wire to minimize the need for splicing. M13763 Fig. 6. Strap-on temperature sensor installation. OUTDOOR SENSOR: FOR USE WITH AQ1000 THERMOSTATS IMPORTANT The AQ25A is not an Outdoor Reset Boiler Control Panel. The purpose of the outdoor sensor is to communicate the outdoor temperature to the AQUATROL network for display on all AQ1000 thermostats. The outdoor sensor should be located: · in a shady location out of direct sunlight · at least three feet from dryer, bathroom, or other vents · above the expected snow line where ice and debris cannot cover it · on the North side of the building. See Fig. 7 for typical placement. Outdoor sensor comes with 10 ft. (3 m) of wire to facilitate splicing the sensor on the interior of the building. Alternatively, if the building is equipped with a continuous fresh air supply using, for example, an air-to-air heat exchanger, the outdoor sensor may be installed in the insulated portion of the ventilation intake duct, taking care not to expose the sensor to direct or indirect sunlight. M13775 Fig. 7. Outdoor temperature sensor installation. IMPORTANT Do not run sensor wires parallel, or close, to telephone, Ethernet, or power cables. Cross all power, Ethernet, and telephone wiring at right angles. If sensor wires are located in an area with strong sources of electromagnetic interference, or EMI, (e.g., if sensor wires are run in the same electrical chase as line voltage wiring) use twisted pair, shielded cable, or run wires in a grounded metal conduit. This is important, since the calculated temperature - based on the sensor's resistance reading - can be distorted by high EMI, potentially causing the AQ25A to not operate properly. If using shielded cable or conduit, connect the shield wire to earth ground only at the AQ25A panel. do not ground the shield or conduit at any other location or electromagnetic shielding will be ineffective. If shielded cable is used, Honeywell recommends the use of shielded cable with a continuous ground plane, such as foil, with an integral drain wire for bonding to earth ground. System Demands Wiring Additional information about settings for the various System Demands is discussed in Table 6 on page 30. AUX-IN If the optional Aux In. contacts (terminals 9 and 10) will be used, wire them now. These inputs are powered with 24 Vdc and must connect only to a dry closure contact (unpowered switch). The Aux-In contact closure sets the system into a specific state as determined by the installer setup using the EQUIPMENT SETUP > AUXILIARY I/O sub-menu (see Fig. 25 on page 38). HEAT DEMAND If the optional Heat Demand (terminals 11 and 12) will be used, wire them to a system setpoint demand (dry contact closure), such as a pool or spa Aquastat®. The HEAT contact closure drives the system to control either at the Reset temperature or the Setpoint temperature as determined by the installer setup using the EQUIPMENT SETUP > ZONING > HEAT DMND selection (see Fig. 25 on page 38). Heat Demand priority allows only heat for the first 30 7 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS minutes of a call for heat and then allows the space heating needs to be added in for the next 30 minutes. This cycle continues until the call for heat is satisfied. DOMESTIC HOT WATER Wire the DHW (terminals 13 and 14) to the Aquastat or thermostat on the domestic hot water tank. DHW priority allows only DHW heat for the first 30 minutes of a call for DHW and then allows the space heating needs to be added in for the next 30 minutes. This cycle continues until the call for DHW is satisfied. NOTE: If the AQ25A is connected to a modulating condensing boiler with built-in DHW management, the DHW tank's Aquastat should be connected to the AQ25A's DHW (terminals 13 and 14). The AQ25A's Aux. Out (terminals 19 and 20) should be wired to the boiler's DHW input terminals to the AQ25A. Low Voltage Outputs Wiring 10 VDC The 10 Vdc terminals (15 and 16) of the AQ25A produce a modulating (0-10 Vdc or 2-10 Vdc) signal that can drive a modulating boiler's combustion fan to maintain a constant supply temperature from the boiler (generally equal to the Boiler High Limit setting in the EQUIPMENT SETUP > BOILER SETTINGS sub-menu). Boiler Signal: If the AQ25A panel is configured to send a 0-10V or 2-10V signal to a modulating/condensing boiler, connect the AQ25A's modulating output terminals (15 and 16) to the modulating signal input on the boiler control. BOILER Wire the Boiler dry contact output (terminals 17 and 18) to the T-T terminals on the boiler Aquastat or the boiler's control panel. See Fig. 15 on page 12 for wiring connections to a typical boiler Aquastat. These contacts are made any time the system has a request for boiler operation, unless the water supply temperature is above the target temp at that time, at which time the system primary boiler pump would come on. AUX-OUT If the Auxiliary Out low voltage output will be used, wire it now to the device that will be switched when the Auxiliary Out's dry contacts close. Wire the hot leg of the device through the Aux. Out connection (terminals 19 and 20). The Aux-Out relay contacts close to correspond with an action as determined by the installer setup using the EQUIPMENT SETUP > AUXILIARY I/O sub-menu (see Fig. 25 on page 38). NOTE: The Aux. Out contacts are rated for low voltage devices only. Communication Bus Wiring All AQ2000 components communicate with each other on the AQUATROL network using communication bus wiring. This wiring must connect all AQ2000 components. Otherwise features that depend on this networked communication (e.g., zone synchronization, outdoor temperature displayed on thermostats, etc.) will not function. The communication bus wiring is polarity insensitive. The installer does not need to worry about a +ve or ve orientation of the wires. If there are two wires connected between the B-B Bus Exp. In on one module and B-B Bus Exp. Out on another module, there will be communication. See example in Fig. 8 for how this wiring is to be installed. The communication bus connections are pre-wired at the factory for AQ25A Control Panels. DATA BUS COMMUNICATION WIRING Menu OK Home Zone 1 Zone 2 Zone 3 Zone 4 AQ25242B Fig. 8. Wiring for communication bus. Zone 1 Zone 2 Zone 3 Zone 4 AQ25744B M27757A 69-2119--05 8 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Step 3 Thermostats Wiring NOTE: The new AQ2000 panels will work with digital (electronic) non-communicating thermostats. AQ1000 thermostats are not required. WHEN USING AQ1000 THERMOSTATS: 1. Using low voltage thermostat wire, connect one AQ1000 communicating thermostat from each zone to the corresponding TH inputs on top of the Zoning Module (see Fig. 9 on page 9). 2. If there are additional zones (on Expansion Zoning Panels) connected to this Zoning Module, run low voltage thermostat wiring from the B-B Exp. Bus Out connection (terminals 13 and 14) of the Zoning Module to the B-B Exp. Bus. In connection (terminals 3 and 4) on the Expansion Zoning Panel. IMPORTANT Do not run thermostat wires parallel, or close, to telephone, Ethernet, or power cables. Cross all power, Ethernet, and telephone wiring at right angles. If thermostat wires are located in an area with strong sources of electromagnetic interference, or EMI, (e.g., if thermostat wires are run in the same electrical chase as line voltage wiring) use twisted pair, shielded cable, or run wires in a grounded metal conduit. This is important because the AQ1000 thermostats are communicating thermostats which send and received data via the two wires connecting them to the Zoning Module. This data can be distorted by the EMI, potentially causing the AQ25A to not operate properly. 3. Run low voltage thermostat wiring from the R and C terminals on the AQ25A Control Panel's transformer to the R and C terminals on the Expansion Zoning Panel. As an alternative, you can run low voltage thermostat wiring from the R and C terminals on the Zoning Module to the R and C terminals on the Expansion Zoning Panel. Step 4 Zoning Equipment Wiring Because the Zoning Module of the AQ25A Control Panel can be used with either line voltage pumps or valves, or low voltage zone valves (with or without end switches), field installed wiring of the correct voltage needs to be connected to the zoning equipment terminals on the bottom left portion of the Zoning Module. Line Voltage Circulators or Zone Valves Refer to Fig. 10. Remove the plastic wiring barrier that is located in the bottom wiring channel between the AQ15A Control Module and the Zoning Module. Run jumper wires from the N and L terminals on the bottom of the AQ25A Control Panel's transformer, through the wiring channel across the bottom of the Control Panel, and to the corresponding N and L terminals of the Zoning Module. FROM LINE VOLTAGE 120V TERMINALS (N AND L) ON BOTTOM OF TRANSFORMER M27687A Fig. 10. Wiring an AQ15540B Zoning Module for use with line voltage circulators. Low Voltage Zone Valves With or Without End Switches Wire using step 1 for zone valves without end switches or use step 2 for zone valves with end switches: 1. Low voltage zone valves without end switches: Using Fig. 12 as a guide, run jumper wires from the R and C terminals on the top left of the AQ25A's transformer through the wiring channel across the top of the Control Panel, down through the wiring channel on the right side of the panel and over to the R and C terminals on the bottom of the Zoning Module IMPORTANT If low voltage zone valves are used with the AQ25A Control Panel, the supplied Low Voltage Output sticker (shown in Fig. 11) must be applied over the line voltage output sticker (see Fig. 10) that is already attached to the Zoning Module. FROM B-B "EXP. BUS" TERMINALS ON CONTROL MODULE THERMOSTAT ON ZONE 1 THERMOSTAT ON ZONE 2 THERMOSTAT ON ZONE 3 THERMOSTAT ON ZONE 4 TO B-B "EXP. BUS IN" TERMINALS ON CONNECTED ZONING MODULE (IF AN EXPANSION ZONING PANEL IS CONNECTED) M13776C Fig. 9. Connecting AQ1000 thermostats. M27688A Fig. 11. Low voltage output sticker. 9 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS M M M M FROM LOW VOLTAGE 24 VAC TERMINALS (C AND R) ON TOP OF TRANSFORMER M27689A Fig. 12. Wiring an AQ15540B Zoning Module for use with low voltage zone valves without end switches. 2. Low voltage zone valves with end switches: See Fig. 13 on page 10. 24 Vac power is pre-wired between the transformer secondary at the top left of the AQ25A's transformer and the AQ15740B Zoning Module. No field wiring is required. M M M M M27690A Fig. 13. Wiring an AQ15740B Zoning Module for use with low voltage zone valves with end switches. NOTE: When wiring zone valves with end switches, note the transformer's VA: If low voltage zone valves with end switches are used for zone control, make sure the selected zone valves do not draw more power (VA) than the 38 VA capacity of the AQ10X38 transformer supplied with the AQ25A Control Panel. This integral transformer has enough power to operate 4 motorized zone valves (such as Honeywell V8043E valves or 4 valves using lowamperage draw, heat motor actuators such as Honeywell MV100 actuators), plus power the electronics of the AQ25A's Control Module and up to 16 AQ1000 thermostats. If zone valves with high-amperage draw, heat motor actuators are used, such as Taco 500 series zone valves, additional 24 Vac transformer capacity will need to be wired to the Zoning Module to power the valves. See Fig. 14 on page 11 for recommended wiring of additional low voltage VA capacity to AQ2000 Series Zoning Modules. CAUTION Equipment Damage Hazard. Can damage internal circuitry of Zoning Module. The ES1 and ES2 terminals of the AQ15740B Zoning Module are powered terminals and must only be connected to a set of dry contacts, such as a zone valve motor's end switch. If power is applied to these contacts (for example, by running line voltage through the zone valves' end switches to bring on a circulator feeding those valves), the internal circuitry of the Zoning Module will be damaged, in which case the warranty for this product will be voided. 69-2119--05 10 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS 115 VAC 100 VA TRANSFORMER 24 VAC 1 1 115 VAC THERMOSTATS ZONE 1 ZONE 2 ZONE 3 ZONE 4 100 VA TRANSFORMER THERMOSTATS ZONE 1 ZONE 2 ZONE 3 ZONE 4 USING AN AQ15740B VALVE ZONING MODULE Zone 1 Zone 2 Zone 3 Zone 4 USING AN AQ15540B PUMP ZONING MODULE Zone 1 Zone 2 Zone 3 Zone 4 1 2 3 1 2 3 1 2 3 1 2 3 24 VAC 1 2 3 1 2 3 1 2 3 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. Fig. 14. Wiring of additional low voltage VA capacity. 1 2 3 M27691 11 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Step 5 Line Voltage System Outputs Refer to Fig. 15 and follow the steps in this section to wire these devices to the AQ25A Control Module. "1. Boiler Pump" "2. DHW Device" "3. Line Voltage Rated Aux Output (Aux. Pump)" on page 13 FROM LINE VOLTAGE 120V TERMINALS (N AND L) ON BOTTOM OF TRANSFORMER TO BOILER TERMINALS 22-23 ON TOP OF AQ15200B CONTROL MODULE TT TO LINE VOLTAGE 120V TERMINALS (N AND L) ON BOTTOM OF TRANSFORMER NL L8148, L7148 ZC ZR G L2 L1 C2 C1 B2 B1 L2 1 L1 (HOT) TO AUXILIARY DEVICE (INSTALLER-DEFINED) BOILER PUMP R8184A, R7184 T F T F C554 BLACK ORANGE BURNER AND IGNITION WHITE 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M27763A Fig. 15. Line Voltage Connections for AQ25A. 1. Boiler Pump Connect the N and L wires of the boiler loop pump to the N and switched hot ( ) terminals of the line voltage Boiler output, shown in Fig. 17 on page 13. The ground wire of the pump can be connected to any of the 8 ground screw terminals located on the back surface of the Control Panel enclosure. The boiler pump contacts are made after any one of the following occur: · A call for heat has occurred from any heating zone. · The Heat input is shorted on terminals 11 and 12. · The DHW input is shorted and the DHW type is configured as a valve. The pump is delayed for the FIRE DELAY programmed in the EQUIPMENT SETUP > BOILER OPERATION sub-menu (see Fig. 25 on page 38). The boiler pump and the last zone calling remain on in order to move heat out of the boiler for the period of time programmed in the Purge time menu under the fire delay. Manually adjusting thermostats affects the operation of this software so it can not be tested manually, you must observe it under normal operating conditions. NOTE: If the AQ25A is connected to a modulating condensing boiler, the boiler pump may need to be connected to the boiler, not the AQ25A. Confirm this with the boiler's installation manual. 2. DHW Device Wire the DHW pump or line voltage zone valve to the N and switched hot ( ) terminals of the DHW output as shown in Fig. 17 on page 13. If using a low voltage zone valve, wire the primary of a spud-mounted transformer (115V to 24V) to the DHW line voltage contacts and connect the low voltage zone valve to the secondary terminals of this transformer. A spudmounted transformer may be located in one of the conduit knockouts on the bottom of the AQ25A Control Panel. Alternatively, a 24 Vac zone valve can be connected to the Aux. pump line voltage-rated dry contacts which can be configured to close on a DHW call. This configuration is defined in the Installer Equipment Setup menu beginning on page 30. The DHW contacts are made when the DHW inputs on terminals 13 and 14 are shorted by the controlling Aquastat. This is a line voltage output designed to go to the DHW pump. If 24 Vac is needed for a low voltage valve, you can mount a step-down transformer on the conduit opening and wire the valve from the transformer. When DHW is enabled, the system has a 30 minute priority over all calls for heat. After 30 minutes, calls for heat are added back in to the operation for 30 minutes and then turned off again. This repeats until the DHW is satisfied. NOTE: If the AQ25A is connected to a modulating condensing boiler, the DHW pump will probably need to be connected to the boiler, not the AQ25A. Confirm this with the boiler's installation manual. 69-2119--05 12 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS 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. BY-PASS PUMP M27764A Fig. 16. Wiring of the Aux. pump line voltage rated dry contacts [example shown is for a by-pass pump]. AQ25A FROM LINE VOLTAGE 120V TERMINALS (N AND L) ON BOTTOM OF TRANSFORMER TO AUXILIARY DEVICE (INSTALLER-DEFINED) Fig. 17. Wiring for Boiler Pump, DHW Device, and Aux Output. M27765A 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). Menu OK Home Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4 Fig. 18. Connections for multiple Zoning Panels - parallel wiring. M27766A 13 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Menu OK Home Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4 Fig. 19. Alternate Connections for multiple Zoning Panels - daisy chain wiring. M27767A CAUTION AQ15540B 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. M23731A 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. 2. · 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. DIP Switch 5 enables or disables Zone Synchronization: The factory setting enables Zone Synchronization, which is an energy saving feature of the AQ2000 panels. Zone Synchronization coordinates zone demands to start at the same time when the boiler cycle begins. The AQ2000 functions as activating valves. The valve logic induces a delay before activating the boiler pump even when zone pumps are used. When Zone Synchronization is not selected, the zone demands are served whenever they call for heat. 69-2119--05 14 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS · The Zone Synchronization feature replaces the pump/valve selection of previous AQ2000 versions. Review the settings of all DIP switches for each Zoning Module connected to an AQ15A, to ensure they are correct before system start-up. When you finish setting the DIP switches for all the Zoning Modules, replace the front cover of the AQ25A Control Panel and the cover of each Expansion Zoning Panel. NOTE: The snap-on DIP switch covers are designed so they cannot be removed (exposing the DIP switches) when the front cover of the AQ25A Control Panel is in place. Table 2. AQ15540B Zoning Module (Pump Zoning Module) DIP Switch Arrangement. DIP Switch Switch Description 1 Zone Address: The positions of these 4 DIP switches define the unique address for 2 each zone on the AQUATROL network. For each group of 4 zones, there can be only 3 one DIP switch in the right hand (ON) position. 4 The correct DIP switch settings for each zone module are: · First Zone (1-4) Module: 1 = ON position; 2, 3, and 4 = OFF position · Second Zone (5-8) Module: 2 = ON position; 1, 3, and 4 = OFF position · Third Zone (9-12) Module: 3 = ON position; 1, 2, and 4 = OFF position · Fourth Zone (13-16) Module: 4 = ON position; 1, 2, and 3 = OFF position · If set to SYNC, zone synchronization is enabled. 5 · If set to NOT, zone synchronization is disabled. · If zone valves are normally closed (N.C.), set the NC/NO DIP switch to the OFF position. · If zone valves are normally open (N.O.), set the NC/NO DIP switch to the ON 6 position. · If set to Group (ON position), the AUX Pump contacts on the Control Module are switched when any of the zones on this Zoning Module are active. · If set to - (OFF position), the AUX Pump contacts are not affected by activity on 7 these zones. · If set to 2-stage (ON position), then 2-stage operation is activated on thermostat inputs. The zoning module operates as two 2-stage zones. 8 · If set to 1-stage (OFF position), then operates as four 1-stage zones. Label and Factory Settings AQ15540B Diagnostic TTeest ON 1 2345678 M23720A M34972 15 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS AQ25A System Programming This section describes how to navigate the user interface using the keypad and LCD display, and how to program the AQ25A Control Panel, which begins on page 17. Keypad The AQ25A User Interface consists of an LCD screen (16 characters by 3 rows) and a 7-button keypad for navigating the menus, as illustrated in Fig. 22. Fig. 21 provides an isolated view of the keypad. Menu Home OK M23538 Fig. 21. AQ25A keypad. Press this button to access the User Menu. When pressed while in a sub-menu, the sub-menu's values are saved before going up one level in the current menu. Press this button to leave the User or Installer Menu and return to the Home Page display screen. Press this button to enter a sub-menu of the active menu item. A menu item is active when the indicator arrow is positioned beside the item. ^ and v and + Press these buttons to scroll up/down in the menu items. Pressing one of these buttons automatically saves your current selection, exits the edit mode, and moves to the previous or next menu item. Press these buttons to decrease/increase the value of a selected menu item, or to scroll through a list of pre-defined options. - If the menu item being modified is a number, the displayed value will decrease/increase by pressing these buttons. When holding the or + button for more than a second, the values automatically decrease/increase at a faster pace, similar to setting the time on a digital clock radio. - If the menu item is an option, pressing these buttons scrolls through the list of available options one at a time. LCD Display The LCD on the AQ25A Control Panel is used to: -- Monitor system status and performance. -- Select and/or modify control settings for the hydronic system. -- Diagnose and troubleshoot system problems. The layout of the display is logical and simple to navigate. The information displays so that the installer can see at a glance the system's operating temperatures as well as the status of the system equipment such as a Call for heat, DHW pump On, Boiler T-T terminals energized, etc. In addition, all system information displays in simple, straightforward English for quick system diagnosis. Fig. 22 illustrates the layout and features of the LCD display panel and keypad. STATUS OF SYSTEM DEMANDS - CALL FOR HEAT - CALL FOR DHW - SIGNAL ON AUXILIARY INPUT STATUS OF SYSTEM OUTPUTS - AUXILIARY OUTPUT ACTIVE - BOILER T-T OUTPUT ACTIVE DISPLAY AREA SHOWING SYSTEM STATUS AND MENU OPTIONS AND SELECTIONS MADE GRAPHIC SHOWING THE PERCENTAGE OF THE BOILER'S HEATING CAPACITY AT WHICH IT'S : OPERATING; ARROWS ABOVE AND BELOW THE BAR SHOW THE : TREND OF THE BOILER'S TEMPERATURE (UP OR DOWN) STATUS OF LINE VOLTAGE OUTPUTS - PRIMARY (BOILER) HEAT - DHW PUMP - SECONDARY PUMP - AUXILIARY "PUMP" OUTPUT GRAPHIC SHOWING THE DEGREE OF MIXING IN THE SECONDARY LOOP: # OF BARS INCREASES AS A) THE INJECTION PUMP SPEED INCREASES, B) THE VOLTAGE OF THE MODULATING DOWN ARROW, IF DISPLAYED, INDICATES THAT OTHER MENU ITEMS EXIST BELOW AND CAN BE VIEWED BY SCROLLING DOWN WITH THE BUTTON. VALVE SIGNAL INCREASES OR C) THE ACTUAL MIX TEMPERATURE APPROACHES THE MAXIMUM MIX TEMPERATURE Fig. 22. LCD display and keypad layout. UP ARROW, IF DISPLAYED, INDICATES THAT OTHER MENU ITEMS EXIST ABOVE AND CAN BE VIEWED BY SCROLLING UP WITH THE BUTTON. ARROW INDICATES THE CURRENTLY SELECTED "ACTIVE" MENU ITEM. M27698 69-2119--05 16 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS LCD Display Navigation This section describes how the keypad is used to navigate the LCD display and menus. · The LCD displays up to three lines of text at a time. For menus with more than three lines, use the up and down buttons (^ or v) to scroll through the menu options. · As the menu is scrolled up or down, the indicator arrow shows which menu item is active. · If the active menu item is part of a list of predefined options (e.g., Day of the Week) press the or + button to scroll through the available options until the preferred option is displayed. The option is automatically saved when the indicator arrow is scrolled away from the value being edited. · If the active menu item requires you to define a value (e.g., a setpoint), use the or + button to decrease or increase the value until the desired value is displayed. The selection will be saved when the indicator arrow is scrolled up or down. NOTES: 1. 2. When setting times for the setback schedule, you must use the or + button to change the time. The OK button, when pressed, defaults the time setting to "--:--" (midnight). · If the active menu item leads to a further sub-menu, pressing the OK button displays the sub-menu options on the LCD. Scroll through this sub-menu to position the indicator arrow beside the desired menu item to input or modify. Choose one of the options provided or input the desired value for the menu item. When satisfied, scroll to another item and your selection will be saved. · To define or modify another item within the same menu, scroll the up and down buttons (^ or v) until the indicator arrow is beside the desired option. Use the or + buttons to set the value for that item. · To move back (up) one level within a menu, press the Menu button. · To return to the Home Page display, press the Home button. NOTE: The AQ25A automatically returns to the Home Page display after 60 minutes of inactivity on the keypad. HOME PAGE DISPLAY The Home Page is the default view displayed on the AQ25A Control Panel's LCD screen. There are two Home Page views - Simple and Detail. · Simple view shows 3 lines of text and is a brief description of the system operation: Day, Time of Day, Current Program and Outdoor temperature. · Detail view includes the same 3 lines plus up to 10 lines of additional information, including Boiler Supply and Return temperatures, Secondary (Mixed loop) temperature, Boiler Supply Target temperature, Secondary Loop Target temperature, Zone Count, and DHW temperature (if configured for DHW sensor use). Detail view is the factory default setting for the Home Page. The choice of the Simple or Detail Home Page view is made from the USER MENU > PREFERENCES/TIME menu option. The Home Page together with the System Status information (a selection from the User Menu), provide a service contractor extensive diagnostic information for troubleshooting the installation. NOTES: Home Page display upon restart after a power failure of more than four hours: 1. Upon restarting the AQ25A following a power disruption of greater than 4 hours, the message PLS SET DAY/TIME OF DAY displays on the top line of the Home Page screen. The message disappears after the DAY and TIME OF DAY are updated. -- If the power failure parameter is set to Backlight (USER MENU > PREFERENCES), the LCD backlight flashes repeatedly, along with the message. 2. The AQ25A starts up with its clock settings as: DAY = MONDAY, TIME OF DAY = 12:00 midnight, and program = OCCupied. 3. Until the DAY and TIME OF DAY settings are adjusted, the control remains in permanent setpoint (comfort) mode. 4. When the DAY and TIME OF DAY settings are adjusted, the AQ25A follows the four programs of WAKE, LEAVE, RETRN (return), and SLEEP. Refer to "Home Page" on page 23 in the "Appendix" for illustrations of the Simple and Detail displays. Programming the AQ25A Program the AQ25A by using the keypad and LCD display to select parameters from the User and Installer menus. Refer to to Fig. 22 on page 16 for an illustration of the LCD screen and keypad. NOTE: The figures in "Menu Structure" on page 37 provide a graphical layout of the AQ25A's User and Installer menus. When a new AQ2000 component is connected on the AQUATROL network, it is seamlessly integrated in the system after a few seconds. If one or more components are disconnected or stop providing data to the network, a message will appear on the System Status display until the fault is corrected. User Menu The User Menu is intended for use by the building owner to choose the LCD display preferences, Zone Settings (including setpoint temperatures and setback times for each zone), and temperatures for the WAKE, LEAVE, RETRN (return), and SLEEP programs. The Home Page and User Menu allow the building owner to: · View the status of the system. · Set up preferences for how the system information is displayed. · Set target temperatures for each zone. · Program times of the day when the system will set back the temperatures for all zones. NOTE: If there are any problems with the system's operation, the AQ25A displays error codes on the System Status Page display of the LCD panel. For details on these, refer to "Troubleshooting" on page 20. TO ACCESS THE USER MENU: Press the Menu button on the keypad at any time to access the User Menu. 17 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Refer to Table 5 on page 24 in the "Appendix" for all of the User Menu options for the AQ25A Control Panel, the factory default values and permissible ranges for each option, and a brief description of each setting. Installer Menu The Installer Menu is used to: -- Set up and modify the Equipment Settings (for boiler operation, DHW management, zoning, auxiliary input/output operation, and options such as pump/valve exercise, freeze protection, and Save/Restore settings) -- Access the Test and Purge functions to facilitate quick and simple commissioning of the hydronic system. TO ACCESS THE INSTALLER MENU: 1. Press the Home button to return to the Home Page display. 2. Press and hold the OK button for 3 seconds until the message, INSTALLER MODE ARE YOU SURE?, displays. 3. Select YES. 4. Press and release the OK button to display the Installer Menu. Refer to Table 6 on page 30 in the "Appendix" for all of the Installer Menu options for the Control Panel, the factory default values and permissible ranges for each option, and a brief description of how each setting affects the AQ25A's operation. 5 TEST AND CHECK OUT THE INSTALLATION Startup IMPORTANT Apply power to the AQ25A Control Panel only after all of the AQ2000 SERIES components (Control Panel, thermostats, sensors, Zoning Panels) have been connected to the other equipment in the hydronic heating system (boiler, zone valves or pumps, DHW, Aquastat, etc.). When powered, the AQ25A Control Panel begins its start-up routine, establishing communication with all other AQ2000 Series components on the AQUATROL network. Test The TEST feature enables the installer to checkout all of the system's outputs, sensors, and zone equipment as part of system commissioning (Checkout). The TEST operation is accessed from the Installer Menu option EQUIPMENT SETUP >TEST AND PURGE. To begin testing the installation, position the indicator arrow beside the equipment group to be tested (OUTPUTS, SENSORS, or ZONES) and press the OK button. TEST OUTPUTS · When TEST OUTPUTS is selected, the AQ25A LCD displays a list of all outputs that can be tested. To select an output to test, position the indicator arrow beside that output and press the + button to activate the output's relay. As each output is activated, a word icon for that output is displayed at the top or bottom of the LCD display (refer to Fig. 22 on page 16). The test routine activates the output relay until the "" button is pressed to turn off that output. · To test additional outputs, navigate the list using the up and down arrows (^ or v), position the indicator arrow beside that output and press the + button to begin testing. Press the "" button to de-activate the output relay and stop its test. · Any combination of outputs can be activated at the same time when testing the outputs. · When finished testing the outputs, press the Menu button to return to the TEST AND PURGE sub-menu. TEST SENSORS When TEST SENSORS is selected, the AQ25A LCD displays the temperature that each of the SUPPLY, RETURN, SECONDARY and OUTDOOR sensors is measuring. If a sensor is malfunctioning or is not properly connected to the AQUATROL network, the value "- -" displays beside that sensor on the LCD, instead of its temperature. If any of the sensors reports a temperature that is illogical, investigate further by referring to "Troubleshooting" on page 20. TEST ZONES · When TEST ZONES is selected, the Installer can test all space heating zones connected to the AQ25A simultaneously or individually. · If zones are tested simultaneously (TEST ALL ZONES), all zone outputs energize immediately (with a delay of 1/10th of a second between each pump or valve to minimize the chance of electrical circuit overloads caused by the inrush currents from the pumps' motors). · A zero (0) displayed after a zone's ID address (e.g., Zone A1 0, A2 0, A16 0) indicates that the AQ25A Control Module has received confirmation that the zone's pump or valve is closed, or OFF. Similarly, a one (1) displayed after a zone's ID address (e.g., Zone A1 1, A2 1, A16 1) indicates that the AQ25A has received confirmation that the zone's pump or valve is open, or ON. · For zone pumps or zone valves without endswitches, a 1 is displayed as soon as the pump is energized. · For zone valves with end-switches, a 1 is displayed only after the valve's end switch makes or the valve's Time To Open delay has expired (for use with 2-wire valves). · To test zones individually, position the indicator arrow beside a selected zone and press the + button to energize it, and press the button to de-energize it. As each zone is tested, the Status LED on the Zoning Module associated with that zone illuminates. To test additional zones, position the indicator arrow beside the zone to be tested, press the "+" button to energize the zone's pump or valve, and then press the "" button to de-energize it. · Any combination of zones can be activated at the same time when testing the zones. · When finished testing the zones, press the MENU button to return to the SETUP >TEST AND PURGE menu. Checkout 1. From the Installer Menu, select Boiler Settings and reduce the Warm Weather Shut Down (WWSD) temperature setting until it is disabled and the display shows "- -". This way, the WWSD will not interfere with the zone operation during checkout. 2. Turn down the DHW Aquastat, if present, to avoid interfering with space heating control operation. 69-2119--05 18 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS 3. Turn up the setpoint of one of the thermostats. a. The zone valve or pump associated with that zone turns on. b. The Boiler T-T relay activates (Boiler displays in the demands section of the LCD screen and the Boiler pump relay activates (PRIMary displays in the outputs section of the LCD screen). NOTE: See Fig. 22 on page 16 for the demands and outputs display areas on the LCD. c. Depending on the settings for the AUX.PUMP (line voltage rated dry contacts) and the AUX OUT (low voltage rated dry contacts), either or both of these relays may also close. 4. Turn down the set point of one thermostat. The zone valve or pump associated with that zone should turn off. The Boiler T-T and Boiler pump relay outputs should deactivate. 5. Repeat steps 3 and 4 for all zones to verify each zone is operating correctly. Thermostats may be exercised individually or all together to accelerate the check out process. 6. Turn up the DHW Aquastat to simulate a call for hot water. a. If the DHW device is a pump, the DHW relay output energizes immediately. The Boiler pump relay remains off. b. If the DHW device is a valve, the Boiler pump relay energizes after a delay to allow the zone valve to fully open. This delay is selected from the EQUIPMENT SETUP>DHW>DHW VLV.OP menu option. c. Turn up the set point of one thermostat. (1) If the DHW relay is configured to control a pump, and DHW PRIOrity is selected, the Boiler and the associated zone pump's relay remain off. (2) If the DHW relay is configured to control a valve, and DHW PRIOrity is selected, the Boiler pump activates after a delay for the DHW zone valve to open, but the associated zone relays remain off. (3) If DHW PRIOrity is disabled, space heating zone pumps and valves should operate during a call for DHW. 7. Turn down the DHW Aquastat to end the call for hot water. Space heating operation should continue (if DHW priority is disabled) or resume (if DHW PRIOrity is enabled). 6 PURGE AIR FROM ALL SYSTEM AND ZONE PIPING The PURGE operation on the AQ25A Control Panel allows the installer to purge all zones (loops) sequentially, or each zone individually, for a period of time, PURGE TIME, which selected from the EQUIPMENT SETUP>TEST AND PURGE>PURGE sub-menu. The purge time can be adjusted in increments of 1 minute, up to a maximum of 30 minutes per loop to be purged. After you have defined which loops to purge (all loops, or an individual loop) and for how long (using the AQ25A's menus), position the indicator arrow beside the START PURGE option and press the OK button. The START PURGE display will change to STOP PURGE and the AQ25A display begins counting down the time remaining for the purge cycle. 19 Purging All Loops When the purge time has elapsed for the first loop, the control proceeds to the next loop and performs the purge operation on each loop in sequential order. After all selected loops have been purged, the display shows PURGE COMPLETED. 7 DOCUMENT AND KEEP A RECORD OF ALL SYSTEM SETTINGS After the AQ25A Series Control Panel has been set up, and the entire hydronic installation is operating properly, it is important to document all the system settings for future reference. Job Records All AQ2000 Series Panels are shipped with Installation Job Records for documenting these settings. These should be filled out completely and saved in the Installing Contractor's files. NOTES: There are two classes of settings used by the AQ25A to control the operation of the heating system, Zone Settings and System (or Equipment) Settings. Both types of settings are stored in non-volatile memory and are not lost following an extended power disruption. WHEN USING AQ1000 THERMOSTATS 1. Zone Settings are designed to be adjustable by the user or the installer and are stored in the faceplate of each zone's AQ1000 thermostat. These settings are not saved with the SAVE SETUP operation. If the faceplates of two AQ1000 thermostats are switched, the settings (setpoints, zone minimum, zone maximum, etc.) will also be switched. 2. System Settings are designed to be adjustable only by the system installer and are stored in the AQ15A Control Module. These are the settings that are saved with the SAVE SETUP operation. SAVE Feature In addition to the hardcopy Installation Job Records, the AQ25A Control Panel has a convenient SAVE feature that allows the installing contractor to save the specific equipment setting for this installation in the AQ25A's memory for future recall, in case the system's settings are inadvertently changed. This feature is found in the EQUIPMENT SETUP > SAVE/RESTORE sub-menu. There are three levels of settings in the AQ25A's memory CURRENT, FACTORY and SETUP. · CURRENT settings are the settings that are currently displayed in any of the menus and are the settings that the AQ25A uses to operate. Any time a value is changed in any of the menus, the CURRENT settings are changed and these new settings are instantly used by the AQ25A Control Panel. · FACTORY settings are the default values loaded at the factory and are the starting point for programming the AQ25A. These values are permanently stored in memory and cannot be over-written or erased. The AQ25A can be restored to factory settings through the RESTORE FACTORY option in the SAVE / RESTORE sub-menu. A warning prompt, RESTORE FACTORY--ARE YOU SURE?, displays and YES or NO must be chosen before proceeding. If YES is selected, the FACTORY settings are 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS be copied to the AQ25A's CURRENT settings and the Control Panel begins to operate with these values immediately. · SETUP settings are the specific settings for this installation which an installer has saved after the AQ25A is set up and operating well. These are saved for future recall, in case the system's settings are inadvertently changed. -- To save this installation's settings for the first time, go to the EQUIPMENT SETUP > SAVE/RESTORE submenu. Position the indicator arrow beside SAVE SETUP and press OK. This saves the current system settings to the SETUP values. -- To retrieve the SETUP values at any time in the future, go to the EQUIPMENT SETUP > SAVE/RESTORE sub-menu and select RESTORE SETUP to load those values into the AQ25A as the CURRENT settings. The system will now operate according to these retrieved settings. -- If the current settings are modified after a RESTORE SETUP operation is performed, simply select SAVE SETUP again to overwrite these new settings into the SAVE settings memory. CAUTION If you change any system settings after a RESTORE SETUP operation, you change the current settings that the AQ25A uses as its basis of operation. TROUBLESHOOTING The following information helps the installer correctly identify system problems, making troubleshooting much faster. Table 3 and Table 4, beginning on page 21, describe the possible error codes and status notices that can be communicated on the AQ155 / AQ157 Zoning Modules' diagnostic LEDs. System Status Information To aid in troubleshooting hydronic systems controlled by an AQ25A, the operational status of the system is shown on the System Status page. Status notices and error messages display here as appropriate, i.e., only those that are pertinent to the system's current operation will be displayed. See Table 4 on page 21 for a complete list of status notices and error messages. The System Status page is available from the User Menu. When a new AQ2000 component is connected on the AQUATROL network, its settings are communicated to the AQ25A Control Module within 10 seconds of being connected. If the component is an AQ1000 thermostat, the setpoints for that zone thermostat can be modified from the AQ25A Control Module as soon as it is recognized. When an AQ1000 thermostat is disconnected from the AQUATROL network, a message displays on the System Status page of the AQ25A indicating "Lost Zone A-xx", where "xx" is the specific identity, or address, of the lost zone. This helps the servicing contractor quickly identify the lost zone and fix its wiring to re-establish communication with the AQ25A Control Module. This diagnostic information is very valuable and the System Status page is the first place a contractor should look for information when troubleshooting system problems. Communications Loss Because all AQ2000 Series components communicate with each other via the dedicated AQUATROL network when controlling a hydronic system, one possible failure mode of the AQ25A would be loss of communication between the AQ15A Control Module and any connected Zoning Modules, or between a Zoning Module and any zone thermostats connected to the AQUATROL network. In general, the Control Module: · Periodically tries to re-establish communication with any lost components on the network. · Initializes any component that re-establishes its communication. · Displays an error code on the AQ25A's System Status page, until the error is corrected and/or communication is re-established. Control Module Reaction When the AQ15A Control Module loses communication with any number of zones for more than one minute (as long as there's still at least one zone communicating on the AQUATROL network), the AQ25A continues to deliver heat to the other non-communicating zones and the address of each lost zone (e.g., A-7, B-4) displays on the System Status page. When communication is lost with all zones, the AQ25A enters BOILER FREEZE PROTECTION mode, in which it fires the boiler and then activates the Boiler (supply) pump and zone equipment for a period of 10 minutes every hour. This should provide sufficient heat to the system to prevent a building from freezing up until communication is re-established between the AQ2000 Series components. BOILER FREEZE PROTECTION mode is disabled when the outdoor temperature is above the warm weather shutdown (WWSD) temperature setting. Zoning Module Reaction When a Zoning Module loses communication with the Control Module (as long as there is at least one other Zoning Module communicating with the Control Module), the Zoning Module operates its pumps or valves in a conventional, nonsynchronized zoning fashion. That is, it operates according to the demands from the thermostats, without zone synchronization or waiting for permission from the AQ15A Control Module to operate. This allows the zones to extract any heat provided by the boiler. When using AQ1000 thermostats and communication is lost between a Zoning Module and any of its thermostats, that zone enters Single Zone Freeze Protection mode. In this mode, the zoning equipment is operated for an amount of time equal to one-half of the maximum demand of all other zones on the network. This helps prevent the lost zone from freezing. This is especially helpful if a zone's thermostat is removed from the wall while a room is being painted. When used with 2-stage thermostat operation, only the first stage will be activated in the freeze protection mode. When using digital, non-communicating thermostats other than the AQ1000, the Single Zone Freeze Protection is disabled for those zones. 69-2119--05 20 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Single Zone Freeze Protection mode is disabled when the outdoor temperature is above the warm weather shutdown (WWSD) temperature setting. The AQ25A provides Zoning Module diagnostic information via the DIAGNOSTIC LEDs located above the DIP switches on its Zoning Module(s), as well as on the System Status menu of the LCD display. If a zone becomes disconnected from the Control Module or is malfunctioning (i.e., lost), this can be seen in the ZONE COUNT value on the AQ25A's Home Page display (Detail view only). The ZONE COUNT represents the number of zones on the AQUATROL network at any given time. When a zone is lost, the ZONE COUNT decreases by one. Because an installer knows how many zones are installed, if there is a difference between the actual number of installed zones and the ZONE COUNT, the installer will know to look for the zone(s). The identity of lost zones displays in the System Status page as LOST ZONE A-X: · A identifies the Control Module of the lost zone, and B, C, or D identify an AQ25400B Add-A-Temperature Expansion Control Panel. This prefix can be set or changed on the AQ254 Panels. · X identifies the lost zone (1 through 16). Boiler Freeze Protection (not network communication related) If the boiler supply temperature sensor measures 50°F (10°F) or less, the boiler fires and the boiler pump, secondary pump etc. operate until the target temperature is achieved, as measured by the supply temperature sensor. This target temperature is the reset temp (if the boiler RESET parameter = OUTDOOR). Or it is the AQ25A's BOILER HIGH LIMIT (if the boiler RESET parameter = LOAD or NONE). DHW and Heat Demand calls are ignored when the system is in freeze protection mode. Power Disruption The AQ25A's system and thermostat parameters are stored in non-volatile memory and are updated as they are changed. When a power disruption occurs, the system configuration is retained in memory. When power is restored, the AQ25A Control Panel enters auto-detection mode, reads its previously-stored settings, and initializes all AQUATROL network components according to their saved parameters. Power Disruption Greater Than 2 Hours If a power disruption lasts for more than 2 hours, the AQ25A will have discharged its internal super capacitor, and the DATE and TIME OF DAY settings will need to be reset. Upon restart, the AQ25A displays its clock settings as: YEAR = 2008, MONTH = JAN, DATE = 1. The message PLS SET DAY/ TIME displays and optionally, the AQ25A's backlight flashes repeatedly. This displayed message continues until the DATE and TIME OF DAY are updated. The AQ25A remains permanently in OCCUPIED (or Comfort) mode until the DATE and TIME OF DAY are updated. Table 3. AQ155 / AQ157 Zoning Module LED Display and System Condition. DIAGNOSTIC LED Status Steady (no blinking) Fast blinking (4 blinks per second) Slow blinking (2 blinks every 3 seconds) Coded blinking = ERROR 2 blinks, then pause 3 blinks, then pause System Condition No system problem detected Auto Test is in operation Auto Test has been paused. Freeze protection activated across the entire AQUATROL network Communication lost with all thermostats on the Zoning Module Action Required None None. Allow the control to finish its Auto Test routine. Press the Test button to resume the Auto Test routine. All zones have lost communication with the Control Module. Check BB wiring between the Control Module and each Zoning Module. Check thermostat wiring to each Zoning Module. LCD Display AUX IN EM. SHUT BOILER: Table 4. LCD Status Notices and Error Messages. Parameter n/a EM SHUT FRZ PROT HEAT DHW Meaning Auxiliary Input's Emergency Shut Down is active. Boiler is disabled, because the AQ25A is in Emergency Shut Down mode. Boiler freeze protection activated: · Communication between Control Module and Zoning Module has been lost for more than 1 minute or · Boiler supply temperature is less than 50°F (10°C) Boiler is active to serve DHW. 21 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 4. LCD Status Notices and Error Messages. (Continued) LCD Display Parameter Meaning HEATING Boiler is active to serve zones. IDLE Boiler is not active. BOILER: (continued) INIT Boiler contacts (terminals 22-23) on the AQ152A, which are connected to the boiler's T-T terminals, have been shorted and the boiler is beginning its firing sequence. INST PURG Boiler is active while the AQ25A is conducting the PURGE operation in the Installer Setup. INSTALL Boiler is in ready mode during Installer Setup. PMP EXER Boiler is disabled while the AQ25A is exercising all pumps and valves connected to the AQUATROL network. POST PURG Boiler is active with Post Purge operation and is sending the purged water to the Boiler (Primary) loop. PURGE DHW Boiler is active with Post Purge operation and is sending the purged water to the DHW tank. CALL FOR COOL n/a At least one zone with a programmable thermostat requires cooling. CALL FOR DHW n/a The DHW requires heat. CALL FOR HEAT n/a At least one zone requires heat. CWSD ACTIVE n/a Zone calls for cooling are not served because CWSD (Cold Weather Shutdown) is in progress. DHW DISABLE n/a DHW call is not served because it is disabled. LOST ZONE A-1 ... n/a Lost communication with a zone (A-1 to A-16, B-1 to B-16, C-1 to C-16, or D-1 to D-16). LOST ZONE D-16 NO DHW PROBE n/a No DHW sensor connected or it is defective. NO OUTDOOR PROBE n/a No outdoor sensor connected or it is defective. NO RETURN PROBE n/a No return sensor connected or it is defective. NO SUPPLY PROBE n/a No supply sensor connected or it is defective. SHORT CYCLE PROT n/a There is a call for heat, but less than two minutes have elapsed since the last firing of the boiler (prevents short cycling). VALVE INIT n/a Motorized mixing valve controlling the secondary loop is being initialized and repositioned (opening or closing) to meet the secondary loop target temperature. WATER READY n/a Boiler Supply Water temperature is at or above the target temperature calculated by the AQ25A. WWSD ACTIVE n/a Zone calls for heat is not served because WWSD (Warm Weather Shutdown) is in progress. 69-2119--05 22 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS APPENDIX The appendix provides AQ25A Control Panel user interface information for the: -- The Home Page -- Programming menus (User and Installer) -- Programming menu structure (User and Installer). See page 37. Home Page The Home Page is the default display for the control panel. It provides general information on system water and outdoor temperatures, and program schedule mode and day and time. The Home Page display may be Simple (3-line) or Detailed (8-line), as illustrated in Fig. 23. The Home Page display type is configured from the Installer Menu. Press the Home button on the keypad to display the Home Page. NOTES: 1. 2. 3. 4. PLS SET DAY/TIME displays after a power outage of more than 4 hours. PROGRAM displays the current active program (Leave, Return, Sleep, Wake, Occ, or Unocc). TARGET displays the current temperature or indicates the system is in a warm water shutdown (WWSD) status. When "- -" is displayed instead of a temperature value (e.g., TARGET: - -), this means that there is no call for heat from either space heating, DHW, or Heat Demand zones at the moment. LCD DISPLAY HOME PAGE (SIMPLE) WEDNESDAY PROGRAM: OUTDOOR: 9:30A LEAVE -5 HOME PAGE (DETAIL) WEDNESDAY PROGRAM: OUTDOOR: TARGET: BOILER: RETURN: DHW: ZONE COUNT: 9:30A LEAVE -5 180 180 160 100 31 KEYPAD Menu RETRN SLEEP WAKE OCC UNOCC WWSD - - Home Fig. 23. Home Page display (Simple and Detail) and keypad. M27769 Programming Menus There are two programming menus, User and Installer. The Installer Menu begins on page 30. User Menu The User Menu can be accessed at any time by pressing the Menu button on the keypad. This menu allows the building owner to: · View the System Status and Statistics. · Set the display preferences, date, and time. · Edit the Zone settings, including setpoint temperatures for each zone. · Edit the Setback temperatures for each zone for the WAKE, LEAVE, RETRN (return), and SLEEP programs. Refer to Table 5 beginning on page 24 for the following User Menu selections: -- System Status (page 24) -- Preferences/Time (page 24) -- Zone Settings (page 24) · All zones · Single zone for Ambient, Floor, or Ambient/Floor settings -- Program Settings (page 28) NOTE: An illustration of the complete User Menu is on page 37. 23 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS . Menu Option SYSTEM STATUS See Table 4 on page 21 PREFERENCES/TIME BOILER UNITS ZONE UNITS TIME DISP D.S.T. YEAR MONTH DATE DAY TIME HOMEPAGE BACKLIGHT POWER FAILURE NOTICE Range Table 5. User Menu. Factory Default Description Identifies what is happening within the system. Multiple status and alarm messages can display on this n/a n/a page. This diagnostic information is for troubleshooting purposes. However, only the status and messages pertinent to the system's current operating condition will display. Allows you to set up the AQ25A Control Panel with preferred display, time, date, and temperature settings. °F or °F °C Choice of temperature units (F or C) for displaying temperatures on the AQ25A LCD display. °F or °F °C Choice of temperature units (F or C) for displaying temperatures (on the AQ1000 zone thermostats). 12H or 12H 24H Choice of time format display: 12 hour format (e.g., 2:00 P) or 24 hour format (e.g., 14:00). ENABLE or DISABLE ENABLE Enables / disables automatic change to and from Daylight Savings Time. 2000 - 2099 2008 Select the year when the control is commissioned. JAN, FEB, MAR, JAN APR, MAY, JUN, JUL, AUG, SEP, OCT, NOV, DEC Select the month of the year when the control is commissioned. 01 to 31 01 Select the date (01-31) of the month when the control is commissioned. MONDAY, TUESDAY, WEDNESDAY, ... SUNDAY MONDAY Select the day of the week when the control is commissioned. 00:00A to 12:59P 12:00A (00:00 to 23:59) (midnight) Select the time of day when the control is commissioned. You can change the time with the + and buttons, just as with a clock radio. SIMPLE or DETAIL DETAIL Select the 3 line (Simple) display or the 10 line (Detail) display for the Home Page. AUTO or ON AUTO · Auto mode = backlight illuminates when any button on the display is pressed. It turns off after 1 hour. · ON mode = backlight stays on constantly. BACKLIGHT or MSG.ONLY BACKLIGHT The building owner can be notified in one of two ways that the AQ25A's DATE and TIME OF DAY settings need to be reset: 1. By displaying the message, PLS SET DAY/TIME, on the first line of the Home Page 2. By repeated flashing of the AQ25A's LCD backlight and displaying the message PLS SET DAY/TIME, on the first line of the Home Page 69-2119--05 24 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Menu Option Range Table 5. User Menu. (Continued) Factory Default Description ZONE SETTINGS Displays all information pertaining to the selected zone(s). There are four possible submenu displays: 1. EDIT ALL ZONES 2. EDIT SINGLE ZONE - Ambient Style (see page 26) 3. EDIT SINGLE ZONE - Floor Style (see page 27) 4. EDIT SINGLE ZONE - Ambient/Floor Style (see page 27) EDIT ALL ZONES YES or NO NO Prompts with EDIT ALL ZONES ARE YOU SURE? Selecting YES displays the following options: SETPOINT Between SETPOINT MIN and SETPOINT MAX 70°F (21°C) Target temperature set for the zone. SETBACK 0°F to 16°F (0ºC to 9°C) 7°F (4°C) Amount of temperature (number of degrees) setback from occupied to unoccupied modes for this zone. SETPOINT MAX 41°F to 100°F (5ºC to 38 °C) 100°F (38°C) Maximum setpoint temperature allowed for this zone's thermostat. The SETPOINT MAX cannot be set below the SETPOINT MIN setting. SETPOINT MIN 41°F to 100°F (5ºC to 38 °C) 41°F (5°C) Minimum setpoint temperature allowed for this zone's thermostat. The SETPOINT MIN cannot be set above the SETPOINT MAX setting. FLOOR LIMIT HIa 41°F to 100°F (5ºC to 38 °C) 100°F (38°C) Maximum floor temperature allowed for a given zone that is controlled by a floor / slab sensor connected to that zone's AQ1000 thermostat. At Floor MAX, the zone equip is turned off. The FLOOR MAX cannot be set below the FLOOR MIN setting. FLOOR LIMIT LOa 41°F to 100°F (5ºC to 38 °C) 41°F (5°C) Minimum floor temperature allowed for a given zone that is controlled by a floor / slab sensor connected to that zone's AQ1000 thermostat. At Floor MIN, the zone equip is energized. The FLOOR MIN cannot be set above the FLOOR MAX setting). SETPOINT VACANCY Between HEAT SETPOINT MIN and SETPOINT MAX 41°F (5°C) Target heating temperature for the zone when system is in VACANCY mode. SETPOINT VACANCY Between COOL SETPOINT MIN and SETPOINT MAX 100°F (38°C) Target cooling temperature for the zone when system is in VACANCY mode. Only displays when cooling is enabled for that zone. CHANGEOVER 2°F to 9ºF (1ºC to 5ºC) 2°F (1ºC) Temperature deadband that determines the changeover from heating to cooling and from cooling to heating: · The thermostat switches from heating to cooling mode when the indoor temperature is higher than the setpoint by more than the changeover band setting for 15 minutes. · The thermostat switches from cooling to heating mode when the indoor temperature is lower than the setpoint by more than the changeover band setting for 15 minutes. KEYBOARD LOCK or UNLOCK UNLOCK Controls the zone thermostat's keyboard. · If set to LOCK, settings cannot be changed at that zone's thermostat. · If set to UNLOCK, the thermostat's settings can be changed within the respective limits. 25 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Menu Option EDIT SINGLE ZONE ZONE #A-X Table 5. User Menu. (Continued) Range Factory Default Description Ambient Style -- Selecting this menu item displays the following options: A-1 to A-16 A-1 ... D-1 to D-16 Each zone on the AQUATROL network has a unique identity (address). This address consists of a Control Module ID and the Zone related to that controller. · Module ID: The Boiler Controller is A, and the 1st through 3rd Add-A-Temperature Expansion Control Modules (i.e., AQ25400B) are B, C, and D. · Zone: From 1 to 16 for each Module ID. ROOM TEMP SETPOINT H/C STATUS SETBACK SETPOINT MAX 32°F to 158°F (0ºC to 70°C) Between SETPOINT MIN and SETPOINT MAX HEAT or COOL 0°F to 16°F (0ºC to 9°C) 41°F to 100°F (5ºC to 38 °C) n/a 70°F (21°C) n/a 7°F (4°C) 100°F (38°C) SETPOINT MIN 41°F to 100°F (5ºC to 38 °C) 41°F (5°C) SETPOINT VACANCY 41°F to 100°F HEAT (5ºC to 38 °C) SETPOINT VACANCY 41°F to 100°F COOL (5°C to 38°C) 41°F (5°C) 100°F (38°C) CHANGEOVER 2°F to 9ºF (1ºC to 5ºC) 2°F (1ºC) KEYBOARD LOCK or UNLOCK UNLOCK A total of four controllers (one Boiler Control Module and up to three Add-A-Temperature Expansion Control Modules), each having 16 associated zones can be connected on the AQUATROL network. The AQ25A Control Panel itself can control one Boiler loop water temperature and one secondary loop water temperature. Display only Temperature measured by the zone thermostat. Target temperature set for the zone. Display only Status is received from each programmable zone thermostat every 10 seconds. Amount of temperature (number of degrees) setback from occupied to unoccupied modes for this zone Maximum setpoint temperature allowed for this zone's thermostat. The SETPOINT MAX cannot be set below the SETPOINT MIN setting. Minimum setpoint temperature allowed for this zone's thermostat. The SETPOINT MIN cannot be set above the SETPOINT MAX setting. Target HEATING temperature for the zone when system is in VACANCY mode Target COOLING temperature for the zone when system is in VACANCY mode. Only displayed when cooling is enabled for that zone. Temperature deadband that determines the changeover from heating to cooling and from cooling to heating: · The thermostat switches from heating to cooling mode when the indoor temperature is higher than the setpoint by more than the changeover band setting for 15 minutes. · The thermostat switches from cooling to heating mode when the indoor temperature is lower than the setpoint by more than the changeover band setting for 15 minutes. Controls the zone thermostat's keyboard. · If set to LOCK, settings cannot be changed at that zone's thermostat. · If set to UNLOCK, the thermostat's settings can be changed within the respective limits. 69-2119--05 26 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 5. User Menu. (Continued) Menu Option Range Factory Default Description EDIT SINGLE ZONE Floor Style -- Selecting this menu item displays the following options: FLOOR TEMP 32°F to 158°F (0ºC to 70°C) n/a Display only. This is the temperature measured by the floor temperature sensor. FLOOR SETPT 41°F to 100°F (5ºC to 38 °C) 70°F (21°C) This menu option displays only when the AQ1000 thermostat is set to FLOOR ONLY mode. SETBACK 0°F to 16°F (0ºC to 9°C) 7°F (4°C) Amount of temperature (number of degrees) setback from occupied to unoccupied modes for this zone. SETPOINT MAX 41°F to 100°F (5ºC to 38 °C) 100°F (38°C) Maximum setpoint temperature allowed for this zone's thermostat. The SETPOINT MAX cannot be set below the SETPOINT MIN setting. SETPOINT MIN 41°F to 100°F (5ºC to 38 °C) 41°F (5°C) Minimum setpoint temperature allowed for this zone's thermostat. The SETPOINT MIN cannot be set above the SETPOINT MAX setting. SETPOINT VACANCY 41°F to 100°F HEAT (5ºC to 38 °C) 41°F (5°C) Target HEATING temperature for the zone when system is in VACANCY mode. KEYBOARD LOCK or UNLOCK UNLOCK Controls the zone thermostat's keyboard. · If set to LOCK, settings cannot be changed at that zone's thermostat. · If set to UNLOCK, the thermostat's settings can be changed within the SETPOINT MAX and SETPOINT MIN limits. EDIT SINGLE ZONE Ambient/Floor Style -- Selecting this menu item displays the following options: ZONE #A-X A-1 to A-16 A-1 ... D-1 to D-16 Each zone on the AQUATROL network has a unique identity (address). This address consists of a Control Module ID and the Zone related to that controller. · Module ID: The Boiler Controller is A, and the 1st through 3rd Add-A-Temperature Expansion Control Modules (i.e., AQ25400B) are B, C, and D. · Zone: From 1 to 16 for each Module ID. ROOM TEMP FLOOR TEMP SETPOINT H/C STATUS SETBACK SETPOINT MAX SETPOINT MIN 32°F to 158°F (0ºC to 70°C) 32°F to 158°F (0ºC to 70°C) Between SETPOINT MIN and SETPOINT MAX HEAT or COOL 0°F to 16°F (0ºC to 9°C) 41°F to 100°F (5ºC to 38 °C) n/a n/a 70°F (21°C) n/a 7°F (4°C) 100°F (38°C) 41°F to 100°F (5ºC to 38 °C) 41°F (5°C) A total of four controllers (one Boiler Control Module and up to three Add-A-Temperature Expansion Control Modules) each having 16 associated zones can be connected on the AQUATROL network. The AQ25A Control Panel itself can control one Boiler loop water temperature and one secondary loop water temperature. Display only. This is the temperature measured by the zone thermostat. Display only Temperature measured by the floor temperature sensor. Target temperature set for the zone. Display only Status is received from each zone thermostat every 10 seconds. Amount of temperature (number of degrees) setback from occupied to unoccupied modes for this zone. Maximum setpoint temperature allowed for this zone's thermostat. The SETPOINT MAX cannot be set below the SETPOINT MIN setting. Minimum setpoint temperature allowed for this zone's thermostat. The SETPOINT MIN cannot be set above the SETPOINT MAX setting. 27 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 5. User Menu. (Continued) Menu Option EDIT SINGLE ZONE FLOOR LIMIT HIa Range Factory Default Ambient/Floor Style (continued) 41°F to 100°F (5ºC to 38 °C) 100°F (38°C) FLOOR LIMIT LOa 41°F to 100°F (5ºC to 38 °C) 41°F (5°C) SETPOINT VACANCY 41°F to 100°F HEAT (5ºC to 38 °C) SETPOINT VACANCY 41°F to 100°F COOL (5°C to 38°C) CHANGEOVER 2°F to 9ºF (1ºC to 5ºC) 41°F (5°C) 100°F (38°C) 2°F (1ºC) KEYBOARD LOCK or UNLOCK UNLOCK Description Maximum floor temperature allowed for a given zone that is controlled by a floor / slab sensor connected to that zone's AQ1000 thermostat. At floor maximum, the zone equipment is turned off. The FLOOR MAX cannot be set below the FLOOR MIN setting. Minimum floor temperature allowed for a given zone that is controlled by a floor / slab sensor connected to that zone's AQ1000 thermostat. At Floor MIN, the zone equip is energized. The FLOOR MIN cannot be set above the FLOOR MAX setting. Target HEATING temperature for the zone when system is in VACANCY mode. Target COOLING temperature for the zone when system is in VACANCY mode. Only displays when cooling is enabled for that zone. Temperature deadband that determines the changeover from heating to cooling and from cooling to heating: · The thermostat switches from heating to cooling mode when the indoor temperature is higher than the setpoint by more than the changeover band setting for 15 minutes. · The thermostat switches from cooling to heating mode when the indoor temperature is lower than the setpoint by more than the changeover band setting for 15 minutes. Controls the zone thermostat's keyboard. · If set to LOCK, settings cannot be changed at that zone's thermostat. · If set to UNLOCK, the floor thermostat's settings can be changed within the FLOOR MAX and FLOOR MIN limits. PROGRAM SETTINGS MODE EDIT ALL DAYS EDIT DAILY Displays, and allows for editing of, the temperature setpoints for each of the four time periods (or programs) within a 24-hour period (WAKE, LEAVE, RETRN (return), and SLEEP). AUTO, OCC, or UNOCC AUTO · AUTO = Automatically follow the four time periods (or programs) within a 24 hour period, as set up in the Edit All Days or Edit Daily sub-menus. The four programs are WAKE, LEAVE, RETRN (return), and SLEEP. · OCC = Observe the program settings only for WAKE and RETRN (return). · UNOCC = Observe the program settings only for LEAVE and SLEEP. ALL WAKE, ALL LEAVE, ALL RETRN, or ALL SLEEP WAKE=6:00AM Allows Installer to set the WAKE, LEAVE, RETRN (return), LEAVE=8:00AM and SLEEP times once, and apply the settings to all 7 RETRN=6:00PM days. SLEEP=10:00PM NOTE: The programs will be copied to the individual days only when the COPY TO ALL DAYS option is selected. WAKE, LEAVE, RETRN, or SLEEP WAKE=6:00AM Allows Installer to set the WAKE, LEAVE, RETRN (return), LEAVE=8:00AM and SLEEP times for all 7 days individually. RETRN=6:00PM SLEEP=10:00PM 69-2119--05 28 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Menu Option Range Table 5. User Menu. (Continued) Factory Default Description STATISTICS Displays the summary and zone relay activity (hours of operation or cycles since last reset). LAST DATA RESET Max. 24,855 days 2000 JAN 01 (68 years) Date of last reset formatted as YYYY MMM DD. BOILER FIRE ACTIV Maximum of 0H 596,523 hours (68 years) Hours of operation of the relay since last reset. BOILER PUMP ACTIV Maximum of 0H 596,523 hours (68 years) Hours of operation of the relay since last reset. DHW PUMP ACTIV Maximum of 0H 596,523 hours (68 years) Hours of operation of the relay since last reset. AUX PUMP ACTIV Maximum of 0H 596,523 hours (68 years) Hours of operation of the relay since last reset. AUX OUT ACTIV Maximum of 0H 596,523 hours (68 years) Hours of operation of the relay since last reset. ZONE A-1 ACTIV Maximum of 0H 596,523 hours (68 years) Hours of operation of the zone's relay (e.g., zone A-1) since last reset. The zone Identifier is A-1 through D-16. a The FLOOR LIMIT values can be set in the User Menu of AQ25A Control Panel or the Installer Menu of the AQ1000 thermostat. These programming options only display when an AQ1000 thermostat is configured for Air/ Floor or Floor control operation. Refer to the AQ1000 thermostat Instruction Sheet. 29 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Installer Menu The Installer Menu allows you to set up and modify system settings that typically would be adjusted by a trained installer. These include equipment settings (for boiler operation, DHW management, zoning, auxiliary input/output operation) and option settings, such as pump/valve exercise, freeze protection, and Save/Restore settings. System statistics and the installer tools (Test and Purge) are also available from the Installer Menu. The two Installer Menu options are: · Equipment Setup (including Statistics) refer to Table 6 · Test and Purge refer to Table 7 on page 35 NOTE: Illustrations of the complete Installer Menu begin on page 38. To access the Installer Menu: 1. Press the Home button to return to the Home Page display. 2. Press and hold the OK button for 3 seconds until the message, INSTALLER MODE ARE YOU SURE?, displays. 3. Select YES, then press and release the OK button to display the Installer Menu. NOTE: To exit Installer Mode, select the Installer Exit menu option. Menu Option BOILER SETTINGS HIGH LIMIT LOW LIMIT BOILER DIFF W.W.S.D. MIN. RETURN Table 6. Installer Menu Equipment Setup. EQUIPMENT SETUP Range Factory Default Description Installer-defined settings for the system design parameters (e.g., boiler supply and return temperatures, reset mode, and outdoor low temperature) 120°F to 225°F (49°C to 107°C) 190°F (88°C) Maximum temperature that the control can use as a target for the boiler supply water (HIGH LIMIT cannot be set below the LOW LIMIT setting). 60°F to 180°F (15°C to 82°C) 150°F Minimum temperature that the control can use as a target for the boiler supply water (LOW LIMIT cannot be set above the HIGH LIMIT setting). 2°F to 41°F (1°C to 23°C) / AUTO AUTO The temperature differential used by the control when operating the boiler. The same differential is used for both the HIGH LIMIT and the LOW LIMIT. · If AUTO is selected, the differential is calculated automatically by the AQ25A to maximize comfort and minimize boiler short cycling. · If a specific boiler differential (BOILER DIFF) is selected, the AQ25A will apply 1/2 of this differential above the AQ25A's HIGH LIMIT boiler setting and the other 1/2 below the HIGH LIMIT setting when controlling the boiler supply water temperature. · For example, if the High Limit = 190°F and the Boiler Diff = 10°F, the High Limit range becomes 185-195°F. NOTE: This formula also applies to the boiler differential around the AQ25A's LOW LIMIT. - - 70 °F 35°F to 100°F (2°C to 38°C) (21°C) Warm Weather Shut Down is the outdoor temperature above which the AQ25A will not allow hot water to be sent to a space heating zone. The boiler still operates to supply hot water to DHW or a setpoint (HEAT) demand. The WWSD feature can be disabled by reducing the WWSD temperature below 35°F (2°C), at which point the display will read "- - ". - - / 80°F to 180°F (27°C to 140 °F 82°C) (60°C) NOTE: Disabling WWSD is not advisable. This will increase the average reset temperature for the Boiler Supply water, resulting in higher energy consumption and less even heating. Minimum temperature (or OFF) that the control allows for water returning to the boiler. If the temperature of the boiler return water is below the selected temperature, and the AUX pump is set to operate as a boiler bypass pump (EQUIPMENT SETUP > AUXILIARY I/O > AUX.PUMP option is set to BYPASS), the AUX dry contacts close, allowing the separatelypowered AUX pump to energize. · "- -" means Off (not used). 69-2119--05 30 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 6. Installer Menu Equipment Setup. (Continued) EQUIPMENT SETUP Menu Option Range Factory Default Description BOILER OPERATION CYCLES/HOUR 2 to 6 4 The number of heating cycles per hour that the control will operate the boiler FIRE DELAY 0 seconds to 3 minutes (in 5 second increments) 10 (seconds) Time period that AQ25A control expects between closing the T-T relay and the boiler firing up. Referring to the boiler's instruction manual, set this value equal to the boiler's pre-purge time, if available for the boiler. PURGE TIME OFF, 10 seconds to 30 minutes (in 10 second increments) 30 (seconds) Length of time the Boiler pump (or Boiler pump plus zone valve) will continue to operate (remain open) after the boiler stops firing. Adjustable from 10 seconds to 30 minutes or OFF. EXERCISE YES / NO YES Option can be set to YES or NO. When set to YES, all pumps and valves in the system are energized for 30 seconds following a period of 2 weeks of no zone equipment activity. The boiler is not fired during this operation. FREEZE PROT YES / NO YES Option can be set to YES or NO. When set to YES, all pumps and valves in the system are energized for 4 minutes every hour. The boiler is operated at high fire during this operation. 10V MOD. SELECT Operating settings for the analog 0-10V (2-10V) modulating signal 10V MOD 0-10V / 2-10V 0-10V The analog signal provided by the control to the boiler is proportional to the target firing rate of the boiler calculated by the AQ25A. This firing rate will produce a constant boiler supply water temperature (typically equal to the BOILER HIGH LIMIT) for as long as any zone is calling for heat. USAGE NONE / BOILER NONE This setting assigns the device which the analog signal will drive. The NONE option disables a signal from the 10V output. DOMEST.HOT WATER Settings that the AQ25A uses to manage Domestic Hot Water generation DHW ENABLE / DISABLE ENABLE Identifies whether Domestic Hot Water Management function is enabled. DHW is typically disabled only if a separate source of domestic hot water (e.g., oil, or gasfired hot water heater) is used. DHW PRIO YES / NO NO Displays only if DHW = ENABLE. Selects whether DHW generation can take priority over space heating. If yes, set to YES; if not, set to NO. PRIO.OVER. YES / NO YES Displays only if DHW PRIO = YES. Selects whether (following a 30 minute uninterrupted call for DHW Demand) the priority given to DHW generation can be overridden to minimize the chance of freeze up or excessive cool down of the space heating zones. · YES = On = Allow DHW Priority override. · NO = Off = Do not allow DHW Priority override. If DHW Priority is selected, Honeywell strongly recommends setting the DHW PRIOR.OVER to YES. DHW DEVICE PUMP / VALVE PUMP Displays only if DHW = ENABLE. Selects whether the DHW loop is supplied by a zone valve or zone pump. DHW VLV.OP 0 - 230 seconds (in 5 second increments) 15 (seconds) Displays only if DHW DEVICE = VALVE. Time required for the DHW zone valve to fully open before boiler loop pump is energized. The 15 second default is typical for motorized valves. 31 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 6. Installer Menu Equipment Setup. (Continued) EQUIPMENT SETUP Menu Option Range Factory Default Description DOMEST.HOT WATER (continued) DHW PURGE YES / NO YES Displays only if DHW = ENABLE. Selects whether or not a purge should be applied after a DHW demand has been served. If YES is selected, the DHW pump or valve is kept running for the amount of time programmed in the PURGE TIME option of the BOILER OPERATION menu. DHW SENSOR YES / NO NO Selects whether or not the Return sensor will be used as a DHW tank sensor. YES = use as the DHW sensor. DHW SETPOINT - - 140°F 60°F to 160°F (16°C to 71°C) (60°C) Displays only if DHW SENSOR = YES. Target temperature set for the DHW tank. · "- -" means Off (not used). DHW DIFF - - 20°F 5°F to 40°F (2.5°C to 22°C) (-7°C) Displays only if DHW SENSOR = YES. · "- -" means Off (not used). · A call for DHW begins when the measured DHW temperature = DHW SETPOINT - DHW DIFF and ends when the DHW temperature = DHW SETPOINT. · For example, if the DHW setpoint = 140°F and the DHW Diff = 20°F, a call for DHW begins when the DHW temperature falls below 120°F and ends when the DHW temperature increases to 140°F. DHW VACANCY - - 45°F [41°F + DHW DIFF] to 160°F (7°C) ([5°C + DHW DIFF] to 71°C) Displays only if DHW SENSOR = YES. Target DHW temperature when system is in VACANCY mode. · "- -" means Off (not used). ZONING Settings which the AQ25A uses specifically for Zone operation HT DMND PRIO YES / NO NO Selects whether a HEAT DEMAND (device connected to the Heat terminals on the AQ control module) can take priority over space heating. If yes, set to YES; if not, set to NO. · If both DHW Priority and Heat Demand Priority are set to YES and both are active at the same time, DHW Priority takes priority over Heat Demand Priority. PRIO.OVER YES / NO NO Displays only if HT DMND PRIO = YES. Selects whether (following a 30 minute uninterrupted call for Heat Demand) the priority given to the Heat Demand can be overridden to minimize the chance of freeze up or excessive cool down of the space heating zones. · YES = On = Allow Heat Demand Priority override. · NO = Off = Do not allow Heat Demand Priority override. ZONING VALVES 5 - 230 TIME TO OPEN (seconds) 15 Time required for the zone valves installed on space (seconds) heating zones to fully open. 69-2119--05 32 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Menu Option AUXILIARY I/O AUX.IN (optional) AUX.OUT (optional) AUX.PUMP (optional) A/C SETTINGS CYCLES/HOUR MIN.OFF TIME C.W.S.D. FAN MODE Table 6. Installer Menu Equipment Setup. (Continued) EQUIPMENT SETUP Range Factory Default Description Settings which the AQ25A uses to control the system based on input to the AUX. IN terminals or to control the activation of the AUX.OUT and AUX.PUMP outputs. SETBACK / VACANCY / EM. SHUT / NONE SETBACK Based on the setting chosen, the AQ25A sets the system in one of 3 different levels of setback for as long as the Aux. In terminals are shorted. Refer to instruction sheet for AQ1000 thermostat (69- 2005EF) for setting the Vacancy (Freeze Protection) temperature setpoint. BOILER / SETBACK / BOILER ZONE OP. / ALARM / AUX.IN / DHW IN / HEAT IN / HT DMND / COOL / NONE Based on the setting chosen, the AQ25A closes the AUX. Out dry contact terminals when: · BOILER: The boiler pump energizes. · SETBACK: The system program is in setback mode (either SLEEP or LEAVE). · ZONE OP.: The end switch of a zone valve connected to a Zoning Module closes or a zone pump energizes. · ALARM: An alarm is detected on the system. · AUX.IN, DHW IN, HEAT IN, or HEAT DMND: An input signal is detected on the respective terminals. · COOL: There is a call for cooling from a programmable AQ1000 thermostat. The COOL option is available only if central A/C is present; see the "A/C SETTINGS" and "A/C EQUIP CONFIG" menu options in this table. · NONE: indicates that the Aux Out terminals are not used. BOILER / GROUP / OCC / BOILER BYPASS / FAN / NONE / AUX.IN / DHW IN / HEAT IN / HT DMND Based on the setting chosen, the AQ25A closes the Aux. Pump dry contacts when: · BOILER: The boiler pump energizes. · GROUP: Any of the thermostats in a Group of zones (identified by the Zoning Module's DIP switch #7 [AUX] being switched to YES) energize. · OCC: The system program is in Occupied mode (either WAKE or RETRN). · BYPASS: The boiler return sensor measures a water temperature less than the value defined for the EQUIPMENT SETUP > BOILER SETTING > MIN RETURN setting. · FAN: There is a call for cooling from a programmable AQ1000 thermostat. The FAN option is available only if central A/C is present; see the "A/C SETTINGS" and "A/C EQUIP CONFIG" menu options in this table · AUX.IN, DHW IN, HEAT IN, or HEAT DMND: An input signal is detected on the respective terminals. · NONE: indicates that the Aux Pump terminals are not used. Central A/C Available only if no AQ158 controller is present on the network. 2 / 3 / 4 / 5 / 6 4 The maximum number of times the controller will permit the central A/C to cycle in each hour. 2 to 10 (minutes) 5M The length of time that must elapse after the AC compressor shuts off before the Aux. Out relay is permitted to close, to energize the compressor again. - - 65°F 32°F to 100°F (0°C to 38°C) (18°C) The temperature at which cold weather shutdown is activated. · "- -" means Off (not used). AUTO / ON AUTO Selects whether or not the fan serving the A/C system operates constantly (ON) or operates only when there is a call for cooling (AUTO). FAN MODE displays only if the FAN option is selected for AUX.PUMP. See "AUX.PUMP" menu option in this table. 33 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Menu Option A/C EQUIP CONFIG ZONE A/C UNIT COOLING Table 6. Installer Menu Equipment Setup. (Continued) EQUIPMENT SETUP Range Factory Default Description Central A/C Available only if no AQ158 controller is present on the network. A-1 to D-16 A-1 Selects the desired zone. NONE / 1 1 Defines which A/C compressor is associated with each zone thermostat. NOTE: At this time, only one zone of A/C can be handled by the AQ2000 controls. The options are 1 (if the zone uses an AQ1000TP2 programmable thermostat and can call for cooling), or NONE. ENABLE / DISABLE ENABLE Enables or disables the cooling functions of the zone's programmable thermostat (AQ1000TP2). NOTE: This item is always set to DISABLE when a nonprogrammable thermostat (AQ1000TN2) is used in the selected zone. STATISTICS Displays the summary and Zone relay activity (hours of operation or cycles since last reset) LAST DATA RESET Max. 24,855 days (68 years) 2000 JAN 01 Date of last reset formatted as YYYY MMM DD. RESET ALL DATA YES / NO ARE YOU SURE? NO Selecting YES resets all of the summary and zone activity values to zero. BOILER FIRE ACTIV Maximum of 596,523 hours 0H (68 years) Hours of operation of the relay since last reset. BOILER PUMP Maximum of 596,523 hours 0H ACTIV (68 years) Hours of operation of the relay since last reset. DHW PUMP ACTIV Maximum of 596,523 hours 0H (68 years) Hours of operation of the relay since last reset. AUX PUMP ACTIV Maximum of 596,523 hours 0H (68 years) Hours of operation of the relay since last reset. AUX OUT ACTIV Maximum of 596,523 hours 0H (68 years) Hours of operation of the relay since last reset. ZONE A-1 ACTIV Maximum of 596,523 hours 0H (68 years) Hours of operation of the zone's relay (e.g., zone A-1) since last reset. The zone Identifier is A-1 through D-16. ENVIRACOM Not used - reserved for future use. Modules ID: n/a n/a n/a SAVE / RESTORE Options for saving settings or restoring previously-saved settings RESTORE n/a FACTORY n/a Selecting this option restores all settings to their factory defaults RESTORE n/a SETUP n/a Selecting this option restores all settings to those saved by the Installer with the SAVE SETUP operation. RESTORE SETUP is only displayed as a menu option if installer settings have previously been saved using the SAVE SETUP menu option. Only displays if the installer has previously saved his (non- factory default) settings using the SAVE SETUP feature. SAVE SETUP n/a n/a Enables installer to SAVE system settings once the system has been set up and is working well; Designed to facilitate quick recovery to proper system operation in the event of inadvertently changing control settings (e.g., tampering with the system settings by an inexperienced user). 69-2119--05 34 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 7. Installer Menu Test and Purge. TEST and PURGE Menu Option Range Factory Default Description TEST OUTPUTS Tests the individual system outputs to ensure correct operation. BOILER PUMP ON / OFF OFF Energizes / de-energizes the line voltage terminals marked Boiler when switched to ON / OFF respectively. AUX PUMP ON / OFF (close / open) OFF (open) Closes / opens the line voltage rated dry contacts marked Aux. when switched to ON / OFF, respectively. DHW PUMP ON / OFF OFF Energizes / de-energizes the line voltage rated terminals marked DHW when switched to ON / OFF respectively. BOILER T-T ON / OFF (close / open) OFF (open) Closes / opens the low voltage rated dry contacts (terminals 17 and 18) marked Boiler T-T when switched to ON / OFF respectively. AUX OUT ON / OFF (close / open) OFF (open) Closes / opens the low voltage rated dry contacts (terminals 19 and 20) marked Aux. Out. when switched to ON / OFF respectively. 10V MOD 0V to 10V 0V Produces voltage on the 10 Vdc low voltage terminals (15 and 16), according to the setting chosen (0V to 10V), in increments of 1V. TEST SENSORS Tests the supply, return and outdoor temperature sensors to ensure correct operation OUTDOOR - LO -58° to 212°F (-50° to 100°C) HI n/a Displays the temperature measured by the outdoor sensor. "- -" means sensor is disconnected LO means temperature reading is below -55°F (-50°C) HI means temperature reading is above 212°F (100°C) BOILER - LO -49° to 257°F (-45° to 125°C) HI n/a Displays the temperature measured by the boiler supply sensor. "- -" means sensor is disconnected LO means temperature reading is below -49°F (-45°C) HI means temperature reading is above 257°F (125°C) RETURN - LO -49° to 257°F (-45° to 125°C) HI n/a Displays the temperature measured by the Return/DHW sensor. "- -" means sensor is disconnected LO means temperature reading is below -49°F (-45°C) HI means temperature reading is above 257°F (125°C) DHW - LO -49° to 257°F (-45° to 125°C) HI Does not display when the RETURN/DHW sensor is configured as a DHW sensor. n/a Displays the temperature measured by the sensor configured for DHW (the sensor wired to the Return/DHW terminals 5 and 6). "- -" means sensor is disconnected LO means temperature reading is below -49°F (-45°C) HI means temperature reading is above 257°F (125°C) Displays only when the sensor is configured as a DHW sensor. 35 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Table 7. Installer Menu Test and Purge. (Continued) TEST and PURGE Menu Option Range Factory Default Description TEST ZONES Tests the zone equipment individually, or sequentially, to ensure correct operation ALL ZONES n/a OFF Sequentially energizes / de-energizes all zones connected to the AQUATROL network. · 0 displays when the Control Module has confirmation that the pump/valve is closed. · 1 displays when the Control Module has confirmation that the pump/valve is fully open. In the case of pump zoning, the 1 displays no more than 5 seconds after the activation of the relay. In the case of valve zoning, the 1 displays either when the zone valve operating time (defined in EQUIPMENT SETUP > ZONING > ZONE VALVES TIME TO OPEN) has elapsed (AQ15540B) or when the valve's end switch is closed (AQ15740B). ZONE A-1 0/1 0 / 1 ... ZONE A-16 0/1 0 Energizes / de-energizes each zone individually. · 0 displays when the Control Module has confirmation that the pump/valve is closed. · 1 displays when the Control Module has confirmation that the pump/valve is fully open. PURGE Purges all (or individual) zones for the period of time selected in the PURGE TIME menu option PURGE TIME 1 to 30 (minutes) 5:00 (minutes) Duration of purge for each zone selected. PURGE ALL / DHW / ALL ZONE A-1 ... ZONE D-16 Installer selects which zones to purge (all, only DHW, or individual zones). START PURGE START PURGE / STOP PURGE n/a Starts and Stops purge operation. PURGE OFF WAIT VALVE / PURGE COMPLETED n/a Indicates status of the system during a Purge operation. Displays only if START PURGE is active. 69-2119--05 36 Menu Structure This section illustrates the complete menu structure for: · User Menu · Installer Menu (see Fig. 25 on page 38) AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS User Menu Structure Press the Menu button on the keypad to display the User Menu. Fig. 24 illustrates all possible User Menu selections. USER MENU SYSTEM STATUS PREFERENCES/TIME ZONE SETTINGS PROGRAM SETTINGS STATISTICS SYSTEM STATUS PREFERENCES / TIME 1 ZONE SETTINGS (All or Single) PROGRAM SETTINGS STATISTICS AUX IN EM.SHUT BOILER: IDLE CALL FOR DHW BOILER UNITS: °F ZONE UNITS: °F TIME DISP: 12H EDIT ALL ZONES EDIT SINGLE ZONE MODE: EDIT ALL DAYS EDIT DAILY AUTO CALL FOR HEAT DHW DISABLE LOST ZONE A-1 ... LOST ZONE D-16 NO DHW PROBE NO OUTDOOR PROBE NO RETURN PROBE NO SUPPLY PROBE SHORT CYCLE PROT VALVE INIT WATER READY WWSD ACTIVE D.S.T.: ENABLE YEAR: 2008 MONTH: JAN DATE: 1 DAY: MONDAY TIME: 12:00A HOMEPAGE: DETAIL BACKLIGHT: AUTO POWER FAILURE NOTICE: BACKLIGHT ARE YOU SURE? NO YES ZONE A-1 ROOM TEMP FLOOR TEMP SETPOINT: 70 2 FLOOR SETPT: 70 HEAT/COOL STATUS 3 SETBACK: 7 SETPOINT MAX: 100 SETPOINT MIN: 41 FLOOR LIM HI: 100 FLOOR LIM LO: 41 SETPOINT VACANCY HEAT: 41 SETPOINT VACANCY EDIT ALL DAYS ALL WAKE 6:00A ALL LEAVE 8:00A ALL RETRN 4:30P ALL SLEEP 10:00P COPY TO ALL DAYS COPY WAKE COPY LEAVE COPY RETRN COPY SLEEP COOL: 100 CHANGEOVER: 2 KEYBOARD: UNLOCK EDIT DAILY MON WAKE 6:00A 1 THE t SYMBOLS INDICATE ADDITIONAL SELECTIONS ARE POSSIBLE. THE FACTORY DEFAULT VALUES ARE SHOWN. MON LEAVE MON RETRN 8:00A 4:30P MON SLEEP 2 TEMPERATURE VALUES ARE SHOWN IN DEGREES FAHRENHEIT, WHICH IS THE FACTORY DEFAULT TEMPERATURE UNIT. ... 10:00P SUN WAKE 6:00A 3 EITHER HEAT OR COOL DISPLAYS DEPENDING ON THE SYSTEM'S STATUS. SUN LEAVE --:-- SUN RETRN --:-- 4 FACTORY DEFAULT TIMES FOR MON THROUGH FRI. SUN SLEEP 10:00P LAST DATA RESET: 2000 JAN 01 BOILER FIRE ACTIV: 0H BOILER PUMP ACTIV: 0H DHW PUMP ACTIV: 0H AUX PUMP ACTIV: 0H AUX OUT ACTIV: 0H ZONE A-1 ACTIV: 0H ARE YOU SURE? NO YES 4 5 5 FACTORY DEFAULT TIMES FOR SAT AND SUN. M27770 Fig. 24. User Menu Structure. 37 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS Installer Menu Structure To display the Installer Menu, go to the Home Page, press and hold the OK button for 3 seconds until the message INSTALLER MODE ARE YOU SURE? displays. Select YES and press the OK button. Fig. 25 and Fig. 26 on page 39 illustrate all possible Installer Menu selections. INSTALLER MODE INSTALLER MODE ARE YOU SURE? NO YES INSTALLER MENU EQUIPMENT SETUP TEST AND PURGE EXIT INSTALLER EQUIPMENT SETUP BOILER SETTING BOILER OPERATION 10V MOD. SELECT DOMESTIC HOT WATER ZONING AUXILIARY I/O A/C SETTINGS A/C EQUIP CONFIG STATISTICS ENVIRACOM SAVE/RESTORE 1 BOILER SETTING HIGH LIMIT: 190 2 LOW LIMIT: 150 BOILER DIFF: AUTO W.W.S.D.: 70 MIN.RETURN: 140 BOILER OPERATION CYCLES/HOUR: FIRE DELAY: PURGE TIME: EXERCISE: FREEZE PROT: 4 0:10 0:30 YES YES 10V MOD. SELECT 10V MOD: USAGE: 0-10V NONE DOMESTIC HOT WATER DHW: ENABLE DHW PRIO.: NO PRIO.OVER.: YES 3 DHW DEVICE: PUMP DHW VLV.OP: 15 DHW PURGE: YES DHW SENSOR: NO DHW SETPOINT: 140 DHW DIFF: 20 DHW VACANCY: 45 ZONING HT DMND PRIO: NO PRIO.OVER.: YES ZONING VALVES TIME TO OPEN: 15 AUXILIARY I/O AUX.IN: AUX.OUT: AUX.PUMP: SETBACK BOILER BOILER STATISTICS LAST DATA RESET: 2000 JAN 01 RESET ALL DATA: ARE YOU SURE? NO YES BOILER FIRE ACTIV: 0H BOILER PUMP ACTIV: 0H DHW PUMP ACTIV: 0H AUX PUMP ACTIV: 0H AUX OUT ACTIV: 0H ZONE A-1 ACTIV: 0H 1 THE SYMBOLS INDICATE ADDITIONAL SELECTIONS ARE POSSIBLE. THE FACTORY DEFAULT VALUES ARE SHOWN. A VALUE OF "- -" INDICATES THE ITEM IS DISABLED OR NOT USED. 2 TEMPERATURE VALUES ARE SHOWN IN DEGREES FAHRENHEIT, WHICH IS THE FACTORY DEFAULT TEMPERATURE UNIT. 3 SOME ITEMS DISPLAY BASED ON PRIOR SELECTIONS. FOR EXAMPLE, IF DHW PRIO = YES, THEN THE PRIO. OVER SELECTION DISPLAYS. 4 THE ENVIRACOM SUB-MENU IS NOT USED. A/C SETTINGS CYCLES/HOUR: MIN.OFF TIME: C.W.S.D: FAN MODE: 4 5M 65 AUTO A/C EQUIP CONFIG ZONE: A/C UNIT: COOLING: A-1 1 ENABLE Fig. 25. Installer Menu Structure. Equipment Setup. ENVIRACOM 4 MODULES ID: 0 SAVE/RESTORE SAVE SETUP RESTORE FACTORY RESTORE SETUP M27771 69-2119--05 38 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS INSTALLER MODE INSTALLER MODE ARE YOU SURE? NO YES INSTALLER MENU EQUIPMENT SETUP TEST AND PURGE EXIT INSTALLER TEST AND PURGE TEST OUTPUTS TEST SENSORS TEST ZONES PURGE TEST OUTPUTS BOILER PUMP: AUX. PUMP: DHW PUMP: BOILER T-T: AUX OUT: 1 OFF OFF OFF OFF 0FF TEST SENSORS OUTDOOR: BOILER: RETURN: DHW: TEST ZONES ALL ZONES: ZONE A-1: ... ZONE D-16: OFF 0 OFF 0 OFF 1 THE SYMBOLS INDICATE ADDITIONAL SELECTIONS ARE POSSIBLE. THE FACTORY DEFAULT VALUES ARE SHOWN. PURGE PURGE TIME: PURGE: START PURGE: PURGE OFF: 5:00 ALL Fig. 26. Installer Menu Structure. Test and Purge. M27772 39 69-2119--05 AQ25A SERIES PROGRAMMABLE BOILER CONTROL PANELS AQUATROL® is a registered trademark of Honeywell International Inc. Aquastat® is a registered trademark of Honeywell International Inc. Automation and Control Solutions Honeywell International Inc. 1985 Douglas Drive North Golden Valley, MN 55422 customer.honeywell.com ® U.S. Registered Trademark © 2013 Honeywell International Inc. 69-2119--05 L.L. Rev. 10-13 Printed in United States