Honeywell Boiler aq475a User's Manual
Contents
1. Control 32 F to 122 F 0 C to 50 C Sensors 50 F to 255 F 45 C to 125 C Humidity Ratings Less than 90 RH non condensing Electrical Connections No 6 wire clamp screw terminals Outdoor and Supply Sensors 10 kQ 77 F 25 C NTC 1 beta 3950 Lead Length 42 in 1067 mm Approvals Canadian Standards Association C US Certified LR 95329 1 Dimensions See Fig 1 Cross Reference Functionally replaces Honeywell T475A Outdoor Reset Controller and W964F Aquatrol configured in on off mode Thermostat Compatibility Contemporary Honeywell electromechanical and electronic 2 wire thermostats Replacement Parts 32002190 001 Circulator Replacement Relay 32002100 001 Outdoor or Supply Sensor Fig 1 AQ475A Approx mounting dimensions in inches mm Fig 1 Dimensions in inches mm 1 5 32 108 29 ee 4 1 4 i HE Diameter 3 32 n 2 Diameter Keyhole Type Mounting Hole 1 2 13 Diameter 3 1 2 3 8 in 89 io A 7 32 6 Diameter Mounting Hole 10 2 15 16 75 Knockout for 1 2 13 Conduit 3 Ordering Information When purchasing replacement or modernization products from your wholesaler or distributor refer to the price sheets for com plete 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 Home and Building Control Sales Office2. The boiler only responds to DHW Demand in warm weather Domestic Hot Water Priority DHW Supplying 24 to 240 Vac power to the DHW Demand input sets the boiler control point to the Boiler Maximum Temperature setting until the DHW call is satisfied If DHW has its own circulator and requires absolute priority over space heating set the DHW switch to PUMP to disable the main circulator during a call for domestic hot water If DHW is controlled by a zone valve set the DHW switch to VALVE Note If domestic hot water has priority over heating space temperature will not be maintained while there is a DHW call To maintain comfort level in the event of DHW failure use a normally closed 20 to 30 minute time delay on relay in series with the DHW input to limit the operation of DHW See Fig 5 for a typical wiring diagram Night Setback Night setback control may be added to the system using a programmable thermostat To minimize thermal stresses in the system during recovery periods use a thermostat with a gradual warm up such as the Honeywell Chronotherm III or Chronotherm IV thermostat with the Adaptive Intelligent Recovery feature Because the outdoor temperature com pensator accurately calculates the heat required based on the outdoor temperature allow at least two hours for recovery to the desired comfort temperature Note The recovery time needed for high mass systems such as thick slab radiant floor heating is too long
3. a Troubleshooting cceceeteeeseeeeeeeeeeeeeeeeeeseneeeseneeeseneeeeeeee 68 0217 1 MBONARWWWNH AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS SPECIFICATIONS ORDER INFORMATION Specifications Important The specifications given in this publication do not include normal manufacturing tolerances therefore an individual unit may not exactly match the listed specifications Also this product is tested and calibrated under closely controlled conditions and some minor differences in performance can be expected if those conditions are changed Model The AQ475A Aquatrol Outdoor Temperature Compensator automatically cycles the boiler to regulate heating supply water temperature using an outdoor reset curve The AQ475A includes a supply and outdoor sensor tie clamp mounting bracket and wire nuts Electrical Ratings L1 L2 Power Supply 120 Vac 60 Hz 1200 VA C1 C2 Circulator Output 120 Vac 10 A 1 3 hp 7 4 AFL 44 4 ALR 240 VA pilot duty powered contact T T Boiler Output 24 to 120 Vac 3 7 AFL 22 2 ALR maximum 240 VA pilot duty isolated dry contact DHW Demand input opto isolated 24 to 240 Vac R W Thermostat input Dry contacts from thermostat or end switches 24 Vac 0 10 A Temperature Control Ranges Boiler Supply Maximum 120 F to 225 F 50 C to 107 C Outdoor Low Design 50 F to 30 F 46 C to 1 C Boiler Minimum OFF 80 F to 180 F OFF 27 C to 82 C Temperature Ratings
4. check white pages of your phone directory 2 Home and Building Control Customer Logistics Honeywell Inc 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 612 951 1000 In Canada Honeywell Limited HoneywellLimit e 155 Gordon Baker Road North York Ontario M2H 3N7 1 800 565 6282 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 68 0217 1 AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS INSTALLATION Installation When Installing this Product 1 Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condition 2 Check the ratings given in the instructions and on the product to make sure the product is suitable for your application 3 Installer must be a trained experienced service technician 4 After installation is complete check out product operation as provided in these instructions 5 Follow local codes for installation and application Wiring Control N Caution Electrical Shock or Equipment Damage Hazard Can shock individuals or short equipment circuitry Disconnect all power supplies before installation All wiring must comply with applicable local codes ordinances and regulations Refer to Fig 3 through 9 for typical mechanical wiring diagrams for the AQ475A Ro
5. A AQUASTAT DR1 Fig 8 Typical mechanical wiring hookups for AQ475A R8888 Hydronic Circulator Zone Panel with DHW priority Thermostats A MECHANICAL x X AQUASTAT 4 Outdoor TT PUMP AND N x Sensor 7 CHECK Boiler VALVE amp 4 K es Be Re T TE AAAA Supply Zone Check Radiators Sensor Circulators Valves Generic configuration does not show all accessories that can be used or that are required by local codes B ELECTRICAL AQ475 lt wwsD oN H OFF E DHW varve M cire SELECTION BOILER MAX Power Test TEMPERATURE i BOILER BOILER MIN TEMPERATURE Circulator OUTDOOR LOW Boiler O Thermostat 24Vac 0 1A w Supply SUPPLY i Sensor A SENSOR Sensor OUTDOOR SENSOR Outdoor Sensor CIRCULATOR 4 A Power supply Provide disconnect means and overload protection as required Slide Priority Enable switch to ON for DHW priority INSTALLATION SETTINGS AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS INSTALLATION SETTINGS Fig 9 Typical wiring hookups for replacing T475A Outdoor Reset Controller or W964F Aquatrol Outdoor Reset Controller configured for on off control SUPPLY OUTDOOR TO BURNER SENSOR SENSOR W964F Mode Supply Outdoor TO BURNER A Jumper Sensor Sensor A Sensor Outdoor Supply Sensor Common Sensor BOILER Power supply Provide disconnect means and overload protect
6. to make night setback practical OPERATION The thermostat R W heat input provides 0 10A at 24 Vac for power stealing thermostats or thermostats with heat anticipa tors If the thermostat anticipator cannot be set lower than 0 15A replace the thermostat or install a R8845U Universal Switching Relay to power the thermostat If using a zone control relay box use an isolated end switch to create the call for heat The DHW Demand input requires 24 to 240 Vac from either a zone control relay box zone valve or Aquastat Control If using a relay box the signal is provided from the zone output terminals and is typically 24 Vac The circulator output is 120V switched from the power supply of the Aquatrol The T T boiler Aquatrol control output is an isolated and unpowered dry relay contact closure rated up to 120 Vac Note The AQ475A performs the function of an operating non limit Aquastat Control For consistent operation set the existing operating control on the boiler to its highest setpoint if the boiler is started by zone thermostat s or zone valve end switches If the existing boiler is not integrated to space temperature demand for example if the boiler runs at constant temperature and the thermostats control the circulators set the operating control to its lowest setpoint and wire the AQ475A T T outputs in parallel Call for Heat Domestic Hot Water DHW Demand On a call for heat the thermostat zone valve end switch o
7. 200 F 80 90 C Fan Coil Heating Only 150 180 F 65 80 C Heating Cooling 120 140 F 50 60 C Low Temperature Floor Radiant 90 110 F 32 43 C Ceiling Radiant 110 140 F 45 60 C The values of these two settings determine the maximum operating point for the heating system based on an as sumed balance point of 72 F 22 C for both supply water temperature and outdoor temperature The reset curve will be overriden by either the Boiler Minimum Temperature setting or the DHW Demand input which ever is active If the outdoor temperature falls below the Outdoor Low setting the boiler operating temperature is limited to 10 F 5 5 C above the Boiler Maximum Temperature setting Fig 4 Typical mechanical wiring hookups for AQ475A with multiple zones and domestic hot water valve A MECHANICAL y og N outdoor T T N Sensor Boiler N 4 4 ee E E EE EN C1 C2 Supply Zone Radiators Circulator Sensor Valves Generic configuration does not show all accessories that can be used or that are required by local codes B ELECTRICAL AQ475 lt wwsD oN E oFF E DHW vatve E cinc SELECTION BOILER MAX TEMPERATURE wp Power Test wwsD Call for Heat DHW DEM Circulator Boiler BOILER BOILER MIN TEMPERATURE VALVE END SWITCHES SUPPLY SENSOR L1 HoT POWER OUTDOOR SENSOR Power supply Provide disconnect CIRCULATOR means and overload protectio
8. Honeywell AQ475A Aquatrol Outdoor Temperature Compensator for Boilers Application The AQ475A Aquatrol Outdoor Temperature Compen sator automatically regulates boiler water temperature to provide outdoor reset The DHW Priority option operates the boiler at the Boiler Maximum Temperature setting to heat domestic hot water and can operate or shut down the system circulator The boiler High Limit safety function must still be provided by the boiler manufacturer s high limit Copyright 1999 Honeywell Inc All Rights Reserved PRODUCT DATA Features e Adjustable settings for boiler maximum temperature boiler minimum temperature and outdoor low design temperature e Selectable Warm Weather Shut Down WWSD at 70 F 21 C to prevent summer boiler operation e Domestic Hot Water DHW priority e Replaceable circulator relay common to other Honeywell replacement controls e Supply and outdoor sensors included e Automatic boiler operating differential e Automatic system circulator exercising e Long life DC relay drive control technology e Troubleshooting LEDs e Push to test button e Full size screw terminals e Functional replacement for Honeywell T475A Outdoor Reset Controller and W964F Aquatrol on off mode Contents Application Features Specifications Ordering Information Installation Wiring Settings Operation Checkout and Test
9. ac 1 3 HP ZONE 1 He a AQUASTAT L INVA ALIdOldd PRIORITY ZONE 2 THERMOSTAT ZONE 3 ZONE 4 Power supply Provide disconnect means and overload protection as required A Slide PriorityEnable switch to ON for DHW priority 68 0217 1 AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS Fig 7 Typical mechanical wiring hookups for AQ475A DHW circulator with priority R8889 Hydronic Valve Zone Panel A MECHANICAL DHW Aquastat Pump and N Check Valve N Outdoor T T X Sensor Boiler N Supply C1 C2 Check Zone Radiators Sensor Circulator Valve Valves Generic configuration does not show all accessories that can be used or that are required by local codes B ELECTRICAL AQ475 lt wwsp oN L oFF om DHW varve M circ SELECTION BOILER MAX Power Test TEMPERATURE wwsD BOILER Call for Heat BOILER MIN DHW DEM TEMPERATURE Circulator Boiler OUTDOOR SUPPLY SENSOR OUTDOOR SENSOR Circulator 120 Vac 1 3 HP Zs Of zone OJ 3 mi THERMOSTAT Eion PRIORITY ENABLE z INVA lt ZONE 3 THERMOSTAT o Power supply Provide disconnect means and overload protection as required Set DHW switch to CIRC to disable main circulator for DHW priority 20 30 minute time delay optional to limit DHW priority over space heating 68 0217 1
10. ang the control on the keyhole screw position the case and install the bottom screw Outdoor Sensor Locate the sensor 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 house See Fig 2 for typical placement Fig 2 Outdoor sensor mounting location IK N i F l o NN LU N Ss YY A AAN OTe To mount the outdoor sensor 1 Place the sensor in the plastic mounting clamp provided 2 Insert the screw provided through the hole in the mounting clamp and fasten the sensor in place 3 Run an extension wire from the sensor lead wires to the control Insulate all connections and strain relief wires 68 0217 1 AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS INSTALLATION SETTINGS Location cont d Supply Sensor The ideal supply sensor mounting location is in a well in the boiler shell The supply sensor may also be mounted on the main supply pipe as follows 1 Mount the sensor 3 feet 1 m downstream from the main or primary circulator to ensure adequate water mixing If the circulator is on the boiler return mount the sensor after the first elbow away from the boiler supply outlet 2 Secure the sensor with the tie wrap included 3 Wrap the sensor with insulation and secure w
11. ere is a demand for domestic hot water FLASHES if control fails self test e Circulator ON when power supplied to circulator s e Boiler ON when T T output made CHECKOUT AND TEST N Caution Electrical Shock or Equipment Damage Hazard Can shock individuals or short equipment circuitry Disconnect all power supplies before installation Press the Test button as follows to cycle the control through the test routine e First press Conirol enters the test mode and Power Test LED flashes e Second press Circulator relay turns on e Third press Boiler relay turns on e Fourth press Circulator and boiler relays turn off and control exits the test routine NOTE If the Test button is not pressed for five minutes during the test mode the control automatically resumes normal operation Action Outdoor Sensor fails open or short circuit The control continues to operate assuming the outdoor temperature is 32 F 0 C and the WWSD LED flashes Space temperature may be too hot or too cold depending on outdoor temperature Check wiring for open or short circuit if wiring is okay replace the outdoor sensor Supply Sensor fails open or short circuit The control turns on the circulator relay and boiler for up to 50 of a 20 minute cycle depending on the thermostat setting and DHW Demand Both the WWSD and Call for Heat LEDs flash Temperature may be too hot or too cold depending on outdoor tempera
12. ion as required A W964F power supply may be 120Vac or 24Vac depending on model AQ475A requires 120V 60Hz A Burner contact may be line or low voltage AQ475A has isolated contacts for compatibility with either style A Replace sensors and reuse wiring Boiler Minimum Temperature Boiler minimum temperature control is activated when the Boiler Minimum Temperature dial is not set to OFF Determine the setting based on the boiler manufacturer recommenda tions This operation is only active when there is a call for heat from the space thermostat Notes To prevent condensation of flue gases do not set the Boiler Minimum Temperature dial lower than the manufacturer s recommendation It is important that the supply sensor accurately reflects boiler temperature See the Mounting section Supply Sensor The AQ475A Boiler Minimum Temperature setting does NOT replace the low limit function of a Triple Aquastat Control Make sure that the Boiler Minimum Temperature setting is less than the Boiler Maximum Temperature setting or reset control will be disabled Burner Differential The AQ475A automatically calculates the best operating differential for the boiler No installer setting is necessary or supplied Warm Weather Shut Down WWSD Slide the WWSD slide switch to ON to activate warm weather shut down When selected the boiler will not turn on for a heat call if the outdoor temperature is above 70 F 21 C
13. ith high quality electrical or duct tape Settings Reset Curve It is not necessary to calculate the reset curve the AQ475A calculates this automatically To adjust it 1 Set the Outdoor Low dial to the coldest actual winter temperature design temperature available from your local weather service Set the Boiler Maximum Temperature dial to the maximum for the desired heating supply water temperature refer to manufacturer and industry recommendations for heating distribution see Table 1 Fig 3 Typical mechanical wiring hookups for AQ475A with one zone no domestic hot water A MECHANICAL Outdoor Sensor T T Boller Thermostat SS SY C1 C2 Supply Radiators Circulator Sensor Generic configuration does not show all accessories that can be used or that are required by local codes B ELECTRICAL lt E SELECTION AQ475 wwsD ON H oFF DHW varve E circ BOILER MAX TEMPERATURE Power Test BOILER BOILER MIN TEMPERATURE Circulator Boiler Supply Sensor SUPPLY SENSOR OUTDOOR SENSOR CIRCULATOR Power supply Provide disconnect means and overload protection as required A Anticipator Current 0 1A 68 0217 1 Table 1 Typical Aquatrol settings for Heating Distribution Systems Distribution Type Radiation Type Boiler Maximum Temperature Direct Free standing Radiator 170 190 F 75 85 C Baseboard Convector 180
14. n as required A Anticipator Current 0 1A AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS INSTALLATION SETTINGS Notes Radiators are a potential burn hazard if the exposed surface temperature is allowed to exceed 140 F 60 C Discomfort results if radiant floor heating surface termperature is above 87 F 31 C Building materials can also be damaged at high temperatures Thermostat Anticipator Thermostat anticipator settings are based on the rate of temperature rise in the space The hotter the supply water the faster the thermostat needs to cycle to maintain accurate temperature control The AQ475A Aquatrol supplies water just hot enough to heat the space except when overridden by DHW Demand input or the Boiler Minimum setting If neither feature is used re set the electromechanical thermostat anticipator to longest and the electronic thermostat cycle rate to the lowest setting to prevent system short cycling Thermostatic Radiator Valves TRVs If the AQ475A is used with non electric room controls such as thermostatic radiator valves jumper the R W thermostat input to simulate a constant call for heat the TRVs will trim the space temperature for each zone Fig 5 Typical mechanical wiring hookups for AQ475A with multiple zones domestic hot water circulator with priority A MECHANICAL DHW Aquastat Pump and a Check Valve Outdoor Sensor T T Boiler LA h Suppl
15. r zone panel closes the R W input The circulator relay turns on if the system is not in WWSD The T T boiler Aquastat Control output contact makes to start the burner until the supply sensor is satisfied according to the calculated reset curve 24 to 240 Vac supplied to the DHW Demand input forces the AQ475A to control the boiler at the Boiler Maximum cont d 68 0217 1 AQ475A AQUATROL OUTDOOR TEMPERATURE COMPENSATOR FOR BOILERS INSTALLATION SETTINGS Heat Domestic Hot Water DHW Demand cont d Temperature setting and either turns the system circulator on if the DHW switch is set to VALVE or off if the DHW switch is set to PUMP WWSD WWSD does not allow the circulator or the boiler to run even when a call for heat R W is present WWSD is enabled with a slide switch and occurs whenever the outdoor air temperature is warmer than 70 F 21 C The WWSD LED turns on when it is selected and the outdoor temperature is warmer than 70 F 21 C If a call for heat is made during WWSD the Call for Heat LED also turns on While in WWSD if a DHW Demand occurs the boiler operates at the Boiler Maximum Temperature setting until the demand is satisfied Boiler Operation The reset ratio is determined by the adjustments Outdoor Low Boiler Maximum Temperature Boiler Minimum Tempera ture and a preset outdoor high temperature of 72 F 22 C Once a call for heat is present the control operates the boiler to reset the
16. supply water temperature to a lower value that corresponds to the observed outdoor air temperature When a DHW Demand is present the control operates the boiler at the temperature set by the Boiler Maximum Temperature dial The minimum boiler operating temperature is equal to the Boiler Minimum Temperature setting During the summer months if the WWSD is turned off and a call for heat is present the control operates the boiler at the Boiler Minimum Temperature setting When a thermostat call for heat ends the circulator runs for ten seconds to remove excess heat from the boiler Note Factory supplied boiler controls can also ener gize the boiler independently from the AQ475A The boiler switching differential is automatically determined by the auto differential algorithm to optimize boiler cycling fre quency Troubleshooting Error Results Circulator Exercising If the circulator has not been operated in the past 72 hours the AQ475A turns on the C1 C2 output for ten seconds to reduce the chance of circulator seizure during the summer months LED Operation e Power Test ON when power on to Compensator FLASHES during TEST mode e WWSD Summer Off ON when Outdoor Temperature is above 70 F 21 C FLASHES if either supply or outdoor sensor fails e Call for Heat Thermostat On ON when R W input is shorted FLASHES if supply sensor fails or if control fails self test e DHW Dem Hot Water On ON when th
17. ture Check wiring for open or short circuit if wiring is okay replace the supply sensor Self test sequence error Home and Building Control Honeywell Inc 1985 Douglas Drive North Golden Valley MN 55422 68 0217 1 RJ 7 99 The control attempts to operate normally Both the Boiler and Call for Heat LEDs flash Honeywell Limited Honeywell Limit e 155 Gordon Baker Road Toronto ON M2H 3N7 Printed in U S A Replace the control Honeywell wwwhoneywell com
18. ute wiring away from LEDs to avoid pinching wires under the bezel when reinstalling the cover Important Use a maximum of 14 AWG wire for wiring terminals All wiring must be rated for 300 V Important Do not run sensor wires parallel or close to telephone or power cables Cross all power and telephone wiring at right angles If sensor wires are located in an area with strong sources of electromagnetic interference use twisted pair shielded cable or run wires in a grounded metal conduit When using shielded cable or conduit connect the shield wire to earth ground ONLY at the AQ475A panel DO NOT connect the shield or conduit if used as a shield to earth ground at any other location or electromagnetic shielding will be ineffective Connect 18 AWG or larger wire to the two sensor wires using the wire nuts provided Wiring must be rated for 300 V Location Control Locate the AQ475A on a panel or wall near the equipment to be controlled Make sure the location is accessible for installa tion and service and that the ambient temperature at the selected location does not exceed 120 F 50 C Mounting Tomountthe AQ475A control 1 Position the control on the wall at the selected location and mark the mounting holes See Fig 2 2 Start a screw in the upper right corner for the keyhole type mounting hole Screw it down within about 1 8 in 3 mm of the surface or until the keyhole slot slides tightly on the screw 3 H
19. y C1 C2 Check Zone Radiators Sensor Circulator Valve Valves Generic configuration does not show all accessories that can be used or that are required by local codes B ELECTRICAL os CE DHW varve M circ SELECTION AQ475 wwsD oN Cli OFF BOILER MAX TEMPERATURE BOILER BOILER MIN il TEMPERATURE O Power Test Circulator VALVE END SWITCHES SUPPLY SENSOR OUTDOOR SENSOR Circulator 120 Vac 1 3 HP CIRCULATOR Power supply Provide disconnect means and overload protection as required A Anticipator Current 0 1A 20 30 minute time delay optional to limit DHW priority over space heating Fig 6 Typical mechanical wiring hookups for AQ475A R8889 Hydronic Valve Zone Panel with DHW priority A MECHANICAL DHW Aquastat FON amp and Valve N ue ve N sete Sensor Boiler N N WL wed So TTT LL Le N SSS T TE TE T T T E T T T T T T T T T T T TR T T G C1 C2 Supply Zone Radiators Circulator Sensor Valves Generic configuration does not show all accessories that can be used or that are required by local codes B ELECTRICAL AQ475 lt WWSD on EI OFF E DHW varve LH circ SELECTION BOILER MAX Power Test TEMPERATURE wwsD BOILER Call for Heat BOILER MIN DHW DEM TEMPERATURE Circulator Boiler OUTDOOR LOW Thermostat 24Vac 0 1A SUPPLY SENSOR OUTDOOR SENSOR Circulator 120 V
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