Aquatrol emperature Compensators AQ675A for Floating Control s AQ775A for Injection Pumps FEAURES PRODUC DAA Automatic reset curve calculation. Adjustable settings for mixing maximum temperature, boiler minimum return temperature and outdoor air low (design) temperature. Optional 70 F ( C) Warm Weather Shut Down () to prevent summer heating operation. Optional Setpoint Control mode for constant loop temperature control. Replacement circulator relay common to other Honeywell replacement controls., outdoor and return sensors included. Long-life DC relay drive control technology. roubleshooting LEDs. Push-to-test button. Full size screw terminals. APPLICAIO he AQ675A Aquatrol emperature Compensator for floating control valves provides full outdoor reset with a proportional-integral-derivative (PID) floating signal to a mixing or injection valve. he AQ775A Aquatrol emperature Compensator for injection pumps provides full outdoor reset through variable speed control of an injection pump. By using the optional boiler return sensor, both controls can provide boiler shock or flue gas condensation protection. AQ675A: PID floating output to Vac -, -, or -way mixing or injection valve actuator. Warm weather mixing valve and circulator exercise functions. Functional replacement for Honeywell W96F Aquatrol (mixing mode). AQ775A: 0 Vac modulating output to variable speed circulator. A standard circulator can be used as an injection circulator. Warm weather mixing injection circulator exercise functions. Contents Application... Features... Specifications... Ordering Information... Installation... Wiring... Settings... Operation... 7 Checkout and est... roubleshooting... Copyright 999 Honeywell Inc All Rights Reserved 6-0-
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS SPECIFICAIOS ORDER IFORAIO Specifications Important he 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. odels: he AQ675A emperature Compensator for s automatically positions a proportional control valve to regulate heating loop supply water temperature using an outdoor reset curve. he AQ775A emperature Compensator for Injection s automatically controls the speed of a wet rotor circulation pump to regulate heating loop supply water temperature using an outdoor reset curve. he AQ675A and AQ775A both include a supply, return and outdoor temperature sensor, tie-clamp, mounting bracket and wire-nuts. Electrical Ratings: AQ675A, AQ775A: L-L Power : 0 Vac 60 Hz, 00 VA. C-C Output: 0 Vac, 0 A; / hp (7. AFL,. ALR); 0 VA pilot duty powered contact with minute minimum O time. - Output: to 0 Vac,.7 AFL,. ALR maximum ; 0 VA pilot duty, isolated (dry) contact. R-W hermostat input: Dry contacts from thermostat or end switches; Vac, 0.0 A. AQ675A: ixing and Injection / output: Vac, 60 Hz, 0.7A ( VA) powered contacts (timing for either VC series valve, or for -way mixing or -way globe valve). AQ775A: P-P Variable Speed Injection output: 0 Vac, 60 Hz,.A, /6 hp, (nominal /6 hp). emperature Control Ranges: ixing () aximum: 0 F to 00 F (7 C to 9 C). Low (Design):, 50 F to 0 F (, 5 C to C). inimum:, 70 F to 0 F (, C to C). emperature Ratings: Panel: F to F (0 C to 50 C). s: 50 F to 55 F ( 5 C to 5 C). Humidity Ratings: Less than 90% RH, non-condensing. Electrical Connections: o. 6 captivated wire clamp screw terminals., and s: 0 kilohm at 77 F (5 C), C ±%, beta = 950. Lead Length: in. (067 mm). Approvals: Canadian Standards Association C/US Certified, LR5. Dimensions: See Fig.. Cross Reference: AQ675 functionally replaces Honeywell W96F Aquatrol configured in mixing mode. hermostat Compatibility: Contemporary Honeywell electromechanical and electronic -wire thermostats. Replacement Parts: 0090-00 Replacement Relay. 9799H, and emperature s. Fig.. AQ675A, AQ775A mounting dimensions in in. (mm). -/ (9) 7/ (6) Diameter ounting Hole Knockout for / () Conduit () Ordering Information When purchasing replacement or modernization products from your wholesaler or distributor, refer to the 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:. Your local Home and Building Control Sales Office (check white pages of your phone directory.). Home and Building Control Customer Logistics Honeywell Inc. 5 Douglas Drive orth inneapolis, innesota 55-6 (6) 95-000 In Canada - Honeywell Limited/HoneywellLimitée, 55 Gordon Baker Road, orth York, Ontario H 7. -00-565-6 International Sales and Service Offices in all principal cities of the world. anufacturing in Australia, Canada, Finland, France, Germany, Japan, exico, etherlands, Spain, aiwan, United Kingdom, U.S.A. 6-0- -5/ (9) 5/ (0) -/ (5) -/ (0) / () Diameter /() Diameter -7/ () 7/ () Diameter Keyhole ype ounting Hole / (0) -7/ () -/ () / (0) -5/6 (75) 5-/ ()
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS ISALLAIO Installation When Installing this Product. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.. Installer must be a trained, experienced service technician.. After installation is complete, check out product operation as provided in these instructions. 5. Follow local codes for installation and application. Wiring Control. Start a screw in the upper right corner for the keyhole type mounting hole. Screw it down within about / in. ( mm) of the surface.or until keyhole slot slides tightly on screw.. Hang the control on the keyhole screw, position the case, and install the bottom screw. : 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 orth side of the house. See Fig. for typical placement. Fig.. sensor mounting location 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. through 9 for typical mechanical, wiring diagrams for the AQ675/AQ775. Route wiring away from LEDs to avoid pinching wires under the bezel when reinstalling the cover Important Use a maximum of AWG wire for wiring terminals. All wiring must be rated for 00 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 OLY at the AQ675/AQ775 panel. DO O connect the shield (or conduit if used as a shield) to earth ground at any other location or electromagnetic shielding will be ineffective. Connect AWG (or larger) wire to the two sensor wires using the wire nuts provided. Wiring must be rated for 00 V. LOCAIO Control Locate the control on a panel or wall near the equipment to be controlled. ake sure the location is accessible for installation and service and that the ambient temperature at the selected location does not exceed 0 F (50 C).. Position the control on the wall at the selected location and mark the mounting holes. See Fig.. o mount the outdoor sensor ount the sensor in the desired location using the sensor in the plastic mounting clamp provided. Insert the screw provided through the hole in the mounting clamp and fasten the sensor in place. Run an extension wire from the sensor lead wires to the control. :. ount the sensor ft. (m) downstream from the zone circulator, in a well at an elbow, or at the beginning of a distribution manifold or other location where the heating supply water can adequately mix with the return water.. Secure the sensor with the tie-wrap (included).. Wrap the sensor with insulation and secure with high quality electrical or duct tape. 6-0-
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS s cont d (if used):. ount the sensor on the return water pipe of the boiler loop a minimum of ft (m) downstream from the return loop of the controlled zone.. Secure the sensor with the tie-wrap (included).. Wrap the sensor with insulation and secure with high quality electrical or duct tape. SEIGS Reset Ratio ISALLAIO SEIGS It is not necessary to calculate the reset ratio. o adjust it:. Set the Low dial to the coldest actual winter temperature (available from your local weather service).. Set the ixing Upper Limit dial to the maximum for the desired heating supplywater temperature (refer to manufacturer and industry recommendations for various heating distribution systems, see able ). Fig.. ypical mechanical, wiring hookup for AQ675A with outdoor compensation through -way mixing valve system, optional boiler return protection. Fig.. ypical mechanical, wiring hookup for AQ675A with outdoor compensation through -way valve, without and with boiler return protection. A. ECHAICAL--Way Direct ixing Configuration - C - C ` V5 ixing C - C ` hermostat A. ECHAICAL - -Way ixing Configuration - Bypass VC6 ixing C- C hermostat B. ECHAICAL - -Way Injection Configuration - C - C ` V5 ixing C - C ` hermostat - C- C VC6 ixing C- C hermostat Generic configuration does not show all accessories that can be used or Generic configuration does not show all accessories that can be used or C. ELECRICAL AQ675 C. ELECRICAL AQ675 6-0- Power L ULAORS ER Power/est in. L L (HO) C C /" /" 50% 0% IXIG/IJ.VALVE V~ OHER VA ES HEROSA VC600 Series Boil. ix REUR HEROSA OR ZOE VALVE ED SWICH(ES) Use 50% setting for systems with high mass and/or domestic hot water. 0.A anticipator current. See text for setting guidelines. Ensure boiler circulator is running when loop circulator is turned on. L ULAORS Power ER Power/est in. L L (HO) C C /" /" 50% 0% IXIG/IJ.VALVE V~ VA ES OHER HEROSA VC600 Series Boil. ix REUR (IJECIO OLY) HEROSA OR ZOE VALVE ED SWICH(ES) Use 50% setting for systems with high mass and/or domestic hot water. 0.A anticipator current. See text for setting guidelines. Ensure boiler circulator is running when loop circulator is turned on.
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS able. ypical Aquatrol Settings for Heating Distribution Systems. Distribution ype ype aximum ixing emperature Direct Free-standing Radiator 70-90 F (75-5 C) Baseboard Convector 0-00 F (0-90 C) Fan Coil Heating Only 50-0 F (65-0 C) Heating/Cooling 0-0 F (50-60 C) Low emperature Floor Radiant 90-0 F (- C) Ceiling Radiant 0-0 F (5-60 C) he values of these two settings determine the maximum operating temperature for the heating system based on an assumed balance point of 7 F ( C) for both supply water temperature and outdoor temperature. If the outdoor temperature falls below the Low setting, mixed temperature is limited to 0 F (5.5 C) above the aximum ixing emperature setting. ISALLAIO hermostat Anticipator hermostat anticipator settings are based on the rate of temperature rise in the space. he hotter the supply water relative to outdoor temperature, the faster the thermostat needs to cycle to maintain accurate temperature control. he AQ675A/AQ775A Aquatrol supplies water just hot enough to heat the space. (Re)set electromechanical zone thermostat anticipators to longest, and the electronic thermostat cycle rate to the lowest setting to prevent system short cycling. hermostatic Radiator s (RVs) If the AQ675A/AQ775A is used with non-electric loop controls such as thermostatic radiator valves, jumper the R-W thermostat input to simulate a constant call for heat; the RVs control space temperature in each zone. Limit Protection return temperature control is activated automatically when the return sensor is installed and a emperature is selected (not ). Choose a setting based on the boiler manufacturer recommendations. cont d Fig. 5. ypical mechanical, wiring hookup for AQ675A with outdoor compensation through -way valve, without and with boiler return protection. Fig. 6. ypical mechanical, wiring hookup for AQ775A with outdoor temperature compensation through variable speed injection control, boiler return protection. A. ECHAICAL - C - C ` VC6A Injection C - C ` hermostat A. ECHAICAL - C - C Injection ` Pump C - C ` hermostat BALACIG VALVE BALACIG VALVE Generic configuration does not show all accessories that can be used or B. ELECRICAL Power L ULAORS ER Power/est in. L L (HO) C C /" /" 50% 0% AQ675 IXIG/IJ.VALVE V~ OHER VA ES HEROSA VC600 Series Boil. ix REUR HEROSA OR ZOE VALVE ED SWICH(ES) Generic configuration does not show all accessories that can be used o B. ELECRICAL Power L ULAORS ER Power/est in. % Out L L (HO) C C P P IJ. PUP AQ775 ES 50% HEROSA 0% Boil ix. REUR HEROSA OR ZOE VALVE ED SWICH(ES) IJECIO PUP Use 50% setting for systems with high mass and/or domestic hot water. Use 50% setting for systems with high mass and/or domestic hot water. 0.A anticipator current. See text for setting guidelines. 0.A anticipator current. See text for setting guidelines. Ensure boiler circulator is running when loop circulator is turned on. 5 Ensure boiler circulator is running when loop circulator is turned on. 6-0-
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS ISALLAIO Fig. 7. ypical system with secondary loop outdoor temperature compensation (OC) control integrated with primary loop boiler OC control. A. ECHAICAL s s - DHW Aquastat Pump and Check C - C ` Injection Pump VC6A Injection C - C ` Balancing C - C ` Balancing hermostat hermostat Generic configuration does not show all accessories that can be used or Limit Protection cont d otes: temperature control is not available when using -way mixing valves in a non-injection configuration (see Fig. A) because there is no way to directly control return water temperature. See Fig. B for an example of return temperature control with a -way mixing valve, or Fig. 5A with a -way injection valve. Since the emperature can be set above the ixing emperature, install the return sensor on the primary boiler loop. If primary/secondary piping is not used, such as with a V5 -way mixing valve, or if the sensor is mounted on the primary to secondary return connection, ensure that the return temperature is set to a temperature that the system can maintain at design load conditions. Activation he - boiler output can be set to activate either when the valve (AQ675A) or circulator (AQ775A) is at 0% flow (default setting), or at 50% flow. Set the 0%-50% switch to 50% to delay boiler operation. See the Operation section, Operation, to determine when to use this feature. B. ELECRICAL AQ75 O DHW VALVE AQ775 SELECIO Power/ est DHW DE ER L L (HO) POWER 7 DR DHW PUP AQUASA L LOOP ULAOR L Power/est in. % Out L L (HO) C C P P IJ. PUP ES 50% HEROSA 0% Boil ix. 5 REUR ULAOR IJECIO PUP HEROSA OR ZOE VALVE ED SWICH(ES) 5 6 7 Use 0% setting to keep main circulator running 0.A anticipator current. See text for setting guidelines. he DHW in the circulator position shuts down the boiler circulator on a call for domestic hot water. Set all es the same. Set boiler maximum temperature at least 0 F [0 K] higher than highest loop temperature setting. 0-0 minute time delay optional to limit DHW priority over space heating. Each unit must have its own sensors, do not wire sensors together. L LOOP ULAOR Power/est in. L L (HO) C C /" /" 50% 0% AQ675 V~ OHER VA ES HEROSA VC600 Series Boil. ix 5 REUR 6-0- 6 IXIG / IJ.VALVE HEROSA OR ZOE VALVE ED SWICH(ES)
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS Warm Weather Shut Down () does not allow the circulator or the boiler to run, even when a call for heat (R-W) is present. is enabled with a slide switch and occurs whenever the outdoor air temperature is warmer than 70 F ( C). he LED turns on when it is selected and the outdoor temperature is warmer than 70 F ( C). If a call for heat is made during, the Call for Heat LED also turns on. Setpoint Control ode If the Low emperature setting is set to, the reset control action is disabled, the loop is controlled at the ixing aximum emperature setting and is disabled. ote: In setpoint control mode, set the thermostat anticipator to the value recommended by the manufacturer for the type of heating system installed. ight Setback ight setback control may be added to the system using a programmable thermostat. o 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 compensator accurately calculates the heat required based on the outdoor temperature, allow at least two hours for recovery to the desired comfort temperature. ote: he recovery time needed for high mass systems, such as thick slab radiant floor heating, is too long to make night setback practical. AQ675A Settings When using VC series floating valves with 00 or 600 series cartridges, set the VC600 slide switch to the VC600 Series setting. his setting matches AQ675A operation to the linear flow characteristic of the valve. Set the / in.- / in. slide switch to / in. when using injection -way, or mixing -way, / in. VC600 series valves. Fig.. Wiring hookup for replacing W96F when wired for mixing valve control. L L 0 V~60 HZ L L L POWER D C W96F B A V O SERIES 60 ACUAOR CLOSE OPE CO IXIG/IJ. VALVE AQ675A W96F power supply may be 0 Vac or Vac depending on model. AQ675A requires 0 V 60 Hz. AQ675A sources Vac power, VA maximum. Rewire actuator to accept power from AQ675; use isolating relays and separate power supply if more power or higher voltage switching capability is needed. Replace sensors and reuse wiring. OPERAIO Basic Functions ISALLAIO he thermostat R-W heat input provides 0.0A at Vac for power stealing thermostats or thermostats with heat anticipators. If using a zone control relay box, use an isolated end switch to create a call for heat. he circulator output is 0V switched from the power supply of the Aquatrol. he - boiler Aquastat Control output is an isolated (dry) contact closure rated from to 0 Vac. he valve open/closed outputs are powered relay contact closures supplying Vac. If the mixing valve has not been run through its full stroke in hours, the AQ675A control runs the mixing valve fully open and fully closed to exercise and lubricate the valve seals and recalibrate the actuator to the control. his exercising and calibration is done when there is no call for heat. If a demand for heat is introduced during an exercise, the control completes the exercise before activating the system. On a call for heat, the thermostat, zone valve end switch, or zone panel closes the R-W input. he circulator relay turns on if the system is not in. he mixing valve position or injection pump speed is adjusted until the supply sensor is satisfied according to the calculated reset curve. he - boiler Aquastat Control contact makes to start the burner when the call for heat exceeds a minimum value. See the Operation section. prevents the circulator and boiler relays from turning on and prevents the mixing valve from opening. is enabled with a slide switch and occurs whenever the outdoor air temperature is warmer than 70 F ( C). he LED (hermostat On) may still turn on during. is not active when the control is operating in setpoint mode (when the Out Low setting is ). Operation (AQ675A) he heating curve (reset ratio) is determined by the adjustments Low, ix ax. emperature and Limit and a preset outdoor high temperature of 7 F ( C). Once a call for heat is present, the control turns on the loop circulator relay and operates the mixing or injection valve to provide outdoor reset. he boiler enable relay turns on when the valve is above 0% flow and stays on until the valve is below 5% for three minutes, or until the call for heat is removed, whichever occurs first. If boiler minimum return protection is selected, the boiler relay turns off when the valve is below 5% for three minutes and the boiler return limit has been satisfied for three minutes. he installer should make sure there is enough thermal mass in the boiler loop to prevent short cycling. When the 50% option is selected, the boiler contact is closed when the mixing output is above 50%. When the boiler relay turns on, it remains on for at least three minutes and turns off if the mixing output remains below 0% flow, or until the call for heat is removed. his setting should be used when the boiler has a triple Aquastat Control, if the system has tankless hot water, or if the system has multiple temperature loops and the primary circulator runs continuously. See Fig. 7 for an example of a multiple loop system with boiler OC control. 7 6-0-
AQ675A, AQ775A AQUAROL EPERAURE COPESAORS Injection Operation (AQ775A) he heating curve (reset ratio) is determined by the adjustments Low, ix ax. emperature and Limit and a preset outdoor high temperature of 7 F ( C). Once a call for heat is present, the control turns on the system circulator relay and varies the injection circulator speed to provide outdoor reset. he boiler enable relay turns on when the injection circulator is above 0% flow and stays on until the injection circulator is below 5% flow for three minutes, or until the call for heat is removed, whichever occurs first. When the 50% option is selected, the boiler contact is closed when the injection circulator speed is above 50%. When the boiler relay turns on, it remains on for at least three minutes and turns off if the mixing output remains below 0% flow, or until the call for heat is removed. his setting should be used when the boiler has a triple Aquastat Control, if the system has tankless hot water, or if the system has multiple temperature loops and the primary circulator runs continuously. See Fig. 7 for an example of a multiple loop system with boiler OC control. Exercising If the circulator has not been operated in the past 7 hours, the AQ675A/775A turns on the C-C output for ten seconds to reduce the chance of circulator seizure during the summer CHECKOU AD ES Caution Electrical Shock or Equipment Damage Hazard. Can shock individuals or short equipment circuitry. Disconnect all power before removing cover for service Press the est button as follows to cycle the control through the test routine:. First press Control enters the test mode and Power/est LED flashes. able. LED Status. LED Power/est (Summer Off) (hermostat On) inimum (Heating Override) AQ675A Only: AQ775A Only: Action ISALLAIO CHECKOU months. he AQ775A also turns on the P-P outputs to exercise the injection pump. LED Operation Refer to able to determine LED status. urns on when compensator is powered. Flashes during ES mode. urns on when outdoor temperature is above 70 F ( C). Flashes if either supply or outdoor sensor fails. urns on when R-W input is shorted. Flashes if supply sensor fails or if control fails self-test. urns on when operation is modified by minimum return temperature program. Flashes if return sensor fails when return limit is active, or if control fails self-test. urns on when power is supplied to circulator(s). urns on when - output is made. urns on when mixing/injection valve is opening. urns on when mixing/injection valve is closing. % Out (Injection) Flashes at a rate proportional to the injection pump speed.. Second press relay turns on.. hird press relay turns on.. Fourth press and boiler relays turn off and the valve opens to 00% (AQ675A), or the injection pump is turned on to 00% (AQ775A). 5. Fifth press closes (AQ675A), or injection pump is turned off (AQ775), and control panel exits the test routine (AQ775A). OE: If the est button is not pressed for five minutes during the test mode, the control automatically resumes normal operation. ROUBLESHOOIG Error Results Action fails (open or short circuit). fails (open or short circuit). water sensor fails (open or short circuit) and Lower Limit dial is off. Self-test sequence error. he control continues to operate assuming the outdoor temperature is F (0 C) and the LED flashes. emperature may be too hot or too cold depending on outdoor temperature. he control turns on the circulator relay and boiler and opens the valve (AQ675) to 0% flow (55% flowif 50% option selected), or runs the injection pump (AQ775A) at 0% speed. Both the and LEDs flash. emperature may be too hot or too cold depending on outdoor temperature. he control continues to operate without boiler return protection. he inimum LED flashes. he control attempts to operate normally. Both the and LEDs flash. Check wiring for open or short circuit; if wiring is okay, replace the outdoor sensor. Check wiring for open or short circuit; if wiring is okay, replace the supply sensor. Check wiring for open or short circuit; if wiring is okay, replace the return sensor. Replace the control. Home and Building Control Honeywell Inc. 95 Douglas Drive orth Golden Valley, 55 6-0- RJ /99 Honeywell Limited - Honeywell Limitée 55 Gordon Baker Road oronto, O H 7 www.honeywell.com