AQ255 / AQ257 Series Quick Installation Guide

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Table Of Contents

PRODUCT DATA

69-1981-06

AQ255 and AQ257 Series

Expansion Zoning Panels

PRODUCT DESCRIPTION

The AQ255/AQ257 Series Expansion Zoning Panels provide

additional zoning capacity for an existing hydronic installation

controlled by an AQ2000 Series Boiler Control Panel such as

an AQ250 Relay Boiler Control, an AQ251 Reset Boiler

Control, or an AQ252 Universal Injection/Mixing Boiler Reset

Control.

FEATURES

The AQ255/AQ257 Series Expansion Zoning Panels have the

following features:

• Availability of 4 Expansion Zoning Panels.

• Zone control of either pumps or zone valves, in

multiples of 4 zones

• 4-zone or 8-zone models for pump zoning; 4-zone

models for zone valves

• Ability to use both zone valve models and zone pump

models in the same installation

• Zone valve panels contain an AQ10X38 transformer

(power supply module), which connects to 120 Vac

power and supplies 24 Vac power to the Zoning

Module.

• Communications between components via the

AQUATROL® network, using communication bus

wiring.

• Any panel can be configured to activate a group pump

when zones are active

• Zone valve models can be used with Normally Open or

Normally closed valves

• Can be installed up to 500 ft. away from main AQ2000

Control Panel, for convenient operation of remote

zoning equipment

IMPORTANT

To ensure correct installation and proper operation of

the zoning panel, perform the 7 installation steps in

the order numbered in the “Contents” below.

AQ25742B

AQ25582B

Contents

Specifications ................................................................... 2

1 Installation Preparation .................................................. 2

2 Mounting ........................................................................ 4

3 Wiring Procedure ........................................................... 5

4 Configure the Expansion Zoning Panel(s) DIP Switches 5

5 Test and Check Out the Installation ............................... 7

6 Purge Air from all System and Zone Piping .................. 8

7 Document and Keep a record of all System Settings .... 9

Troubleshooting ................................................................ 10

Appendix .......................................................................... 11

Wiring Diagrams ................................................... 11

Summary of content (16 pages)

PAGE 1
AQ255 and AQ257 Series Expansion Zoning Panels PRODUCT DATA AQ25742B AQ25582B PRODUCT DESCRIPTION The AQ255/AQ257 Series Expansion Zoning Panels provide additional zoning capacity for an existing hydronic installation controlled by an AQ2000 Series Boiler Control Panel such as an AQ250 Relay Boiler Control, an AQ251 Reset Boiler Control, or an AQ252 Universal Injection/Mixing Boiler Reset Control.
PAGE 2
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS SPECIFICATIONS Thermostat Compatibility: Digital non-communicating thermostats and/or AQ1000 Series 2-wire communicating thermostats The AQ2000 Series Expansion Zoning Panels are listed in Table 1. Dimensions (HxWxD): 8.0 x 9.4 x 3.3 in. (20.3 x 23.8 x 8.5 cm) approximate Table 1. AQ2000 Series Expansion Zoning Panels. Expansion Zoning Panel Zoning Module Weight: 3.9 lb. (1.
PAGE 3
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS When Installing this Product… Read All Instructions Carefully Before Proceeding 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.
PAGE 4
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS ZONING MODULE TRANSFORMER LOW VOLTAGE (24 V) LOW VOLTAGE (24 V) Zone 1 Zone 2 Zone 3 Zone 4 LINE VOLTAGE (120 V) LOW VOLTAGE (24 V) M27832A Fig. 2. AQ257 Expansion Zoning Panel Layout (AQ25744B shown). 2 MOUNTING 3. This section describes how to mount the Expansion Zoning Panels and thermostats. 4. Mount Expansion Zoning Panel(s) 1. 2. 5. Remove wire channel plugs from the Control Panel and any Expansion Panels (see Fig. 3).
PAGE 5
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS Mount and Wire Thermostats in the Zones 4. Install the thermostats on the walls in the zones that are to be controlled by the AQ2000 Control Panels and Expansion Zoning Panels. When using AQ1000 thermostats, refer to the included installation instructions included with that model. 5. If not done already, run low voltage thermostat wire (24 gauge or heavier) from the thermostats back to the Expansion Zoning Panel for use in section 3, “Wiring Procedure” .
PAGE 6
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS Although for many installations, these factory default DIP switch settings will be suitable, Honeywell recommends that they be reviewed and changed, as necessary, to get optimal performance of the hydronic system controlled by the AQ2000 Series products.
PAGE 7
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS Table 2. AQ15540B Zoning Module (Pump Zoning Module) DIP Switch Arrangement. DIP Switch 1 2 3 4 Switch Description Label and Factory Settings Zone Address: The positions of these 4 DIP switches define the unique address for each zone on the AQUATROL network. For each group of 4 zones, there can be only one DIP switch in the right hand (ON) position. AQ15540B Diagnostic • If set to SYNC, zone synchronization is enabled.
PAGE 8
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS STATUS LEDS Every status LED light (Zone 1, Zone 2, Zone 3, Zone 4) will be turned on for 15 seconds when its corresponding output is activated during Auto Test. If zones are tested simultaneously (TEST: ALL ZONES), zone pumps energize immediately (with a delay of 1/10th of a second delay between each pump to minimize the effect of inrush currents from the pumps' motors) along with the main boiler pump.
PAGE 9
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS 6. 7. 8. SAVE Feature (AQ25A, AQ251, and AQ252 Control Panels) loop does not need to be purged, or there is not a pump connected to the AUX relay, press the TEST button again to advance to the next step in the test sequence. When the DHW device energizes, its LED lights up. Quickly press the TEST button to pause the Auto Test routine and purge the DHW loop for as long as necessary The DIAGNOSTIC LED blinks slowly while the Auto Test is paused.
PAGE 10
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS TROUBLESHOOTING 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 Control Module to operate.
PAGE 11
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS APPENDIX This appendix provides examples for wiring Expansion Zoning Panels to AQ2000 Series Control Panels and wiring additional low voltage VA capacity. Wiring Diagrams Fig. 5. Wiring of AQ25542B Expansion Zoning Panel to AQ2000 Series Control Panel.
PAGE 12
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS ZONING MODULE OF AN EXISTING AQ2000 SERIES CONTROL PANEL THERMOSTATS AQ25582B FROM “C” ON AQ10X38 FROM “R” TRANSFORMER ON AQ10X38 FROM B-B TRANSFORMER “EXP.BUS OUT” TO B-B CONNECTION “EXP.
PAGE 13
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS 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 AQ2000 Series Control Panel.
PAGE 14
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS ZONING MODULE OF AN EXISTING AQ2000 SERIES CONTROL PANEL THERMOSTATS AQ25742B FROM B-B “EXP.BUS OUT” CONNECTION THERMOSTATS ON AQ15540B (#1) ZONE 1 ZONE 2 ZONE 3 ZONE 4 TO B-B “EXP.BUS IN” ZONE 1 ZONE 2 ZONE 3 ZONE 4 CONNECTION ON AQ15540B (#2) TH { SENSOR{ AQ15100B OK AQ15540B (#1) Zone 1 Zone 2 M 1 AQ15540B (#2) AQ10X38 Zone 3 M M Zone 1 Zone 4 1 N 120 VAC L M M Zone 2 Zone 3 Zone 4 M M M POWER SUPPLY.
PAGE 15
AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS 15 69-1981—06
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AQ255 AND AQ257 SERIES EXPANSION ZONING PANELS 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. 69-1981—06 M.S. Rev.