Caleffi Switching Relays ZSR104 Circulator Pump Relay ZSR104 4 Zones
NA10334 www.caleffi.com Z-oneTM Relay Multi-Zone Pump Control © Copyright 2014 Caleffi ZSR10X series Function The ZSR series is multi-zone pump and boiler operating control for multiple zone hydronic heating or cooling systems. The ZSR series interfaces with low voltage thermostats, or any other low voltage controllers having a switching action. The ZSR series controls up to 3, 4, 5 or 6 heating circulator pumps (depending on model selected) a primary pump and has LED indicators to provide functional status and easy system troubleshooting. In addition, a primary pump system circulator is switched on whenever any zone calls for heat. · Compatible with low voltage 2, 3, or 4 wire thermostats · R, W, C and TT Comm dual labeling at thermostat terminals · Z-oneLink unlimited zone expansion · 120 VAC pump outputs · Selectable Priority with 1 hour time-out feature · Selectable Post Purge and excercise · Dry contacts for DHW (ZR/ZC), capable of switching line voltage · High capacity transformer · Large terminal connections · Simplified wiring with extra ground terminals · Heavy duty sealed relays · Fuse protected (with spare fuse) · Front LED Lights · 100% Factory tested with 3 year warranty · ETL Approved Product Range Code ZSR103 Z-oneTM Relay switching relays...............................................................three zone Code ZSR104 Z-oneTM Relay switching relays.................................................................four zone Code ZSR106 Z-oneTM Relay switching relays...................................................................six zone Technical specifications Materials Housing plastic: Front display lights: Electrical knockouts: Performance Power supply: Transformer voltage: Maximum transformer load: Electrical switch rating: Electrical switch rating pump output: Dry contact rating, ZR/ZC, DHW, XX: Replaceable fuses: Temperature limits for: Shipping and storage max: Maximum Operating: Maximum Humidity: Approvals: ABS LED (12) 1/2" size 120 VAC, 50/60 Hz 24 VAC 12 VA (ZSR103/4), 20 VA (ZSR106) 20A max combined 120 VAC, 5A each 120 VAC max, 2A each Type 2AG, 5A slow blow 110°F (43°C) 110°F (43°C) 90% non-condensing Certified to CSA C22-2 No.24 Conforms to UL Standard 873 Dimensions ZSR106 Six switching relays - Input: 120VAC 50/60Hz 20A MAX CAUTION: RISK OF ELECTRIC SHOCK - DISCONNECT ALL INPUT POWER PRIOR TO SERVICING Conforms 4009064 to UL 873 Milwaukee, WI 53208 USA POWER ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 PUMP ON A B C C Code Zones A B ZSR103 3 9 1/4" 11" ZSR104 4 9 1/4" 11" ZSR106 6 9 1/4" 11" C Wgt. (lbs) 3" 3.2 3" 3.2 3" 3.2 SAFETY INSTRUCTION This safety alert symbol will be used in this manual to draw attention to safety related instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD. CAUTION: All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of systems in accordance with all applicable codes and ordinances. CAUTION: Electrical shock hazard. Disconnect power before installation to prevent electrical shock or equipment damage. Make sure all connections are in accordance with the electrical wiring diagram and in accordance with national and local electrical codes. WARNING: Avoid electrical noise interference. Do not install near large conductors, electrical machinery, or welding equipment. Avoid locations where excessive moisture, corrosive fumes, vibration, or explosive vapors are present. Caleffi shall not be liable for damages resulting from misapplication or misuse of it products. X X ZR/ZC R WC R WC R W T T COM T T COM T T CO T-STAT 1 T-STAT 2 T-STAT Installation The DIP Switches on the ZSR series can be positioned for the following operations. Dip Switches 6 Zone Master / Slave: allows for unlimited expansion to additional ZSR relays. Priority OFF / Priority ON: When priority ZSR106 mode is ON, upon demand, zone 1 will oarpeertaetmepaosrTarpRilryioAsrwitNyitcSahnFeddOaolRflf o(MwthitEehrR1zohnoeusr Master Priority OFF Primary OFF Exercise OFF Post Purge OFF Slave Priority ON Primary ON 6 Zon Exercise ON Post Purge ON ZSR1 time-out). When priority mode is OFF, all zones remain active. Primary OFF / Primary ON: When primary mode is ON, the primary pump will continue to operate during priority. Exercise OFF / Exercise ON: When exercise mode is ON, each circulator is switched on for 30 seconds following 72 hours of inactivity. Post Purge OFF / Post Purge ON: When post purge is ON, the priority pump continues operating for 2 minutes after the priority zone is switched off. PRIORITY PUMP 1 LN PUMP 2 PUMP 3 PUMP 4 L POWNER IN L GNROUNLDS N LN PUPMRPIO5RITY PUMP 6 L PUNMP 1 L PUMNP 2 PU L N L N L Large screw terminal connections makes wiring easy. Three extra ground screw terminals connection allows fast grounding of pumps. Pump terminals have 120 VAC outputs for simplified pump connection. X X DHW ZR/ZC R WC R WC R WC R W T T COM T T COM T T COM T T T-STAT 1 T-STAT 2 T-STAT 3 T-STA When a zone has a demand from a thermostat (T T or R W) the relay will close sending 120 VAC to the corresponding zone pump, primary pump and closes 6 Zone (X X) dry contacts signaling the boiler of a heating demand. Zone 1 can be used for priority by positioning the Priority dip switch to ON, a demand from T-Stat 1 will activaTteRpAriNorSityFpOumRpM1EaRnd all other zone pumps will be switched OFF, plus ZSR106 DHW (ZR/ZC dry contact rated to switch max 120 VAC, 2A) will close during priority. Depending on Primary pump dip switch position, the primary pump will remain either ON or OFF. WC T COM AT 3 Z-oneLink unlimited expansion allows adding addition ZSR series relay controls to a Master ZSR. Communication is accomplished by connecting three wires (bell or thermostat R W C wirRe) to thWe commCunicatRion termWinals lCocated T T COM T-STAT 4 iidnsetmTphTLoea-snuSiPdtpiOopTfnWeoTeNrrAEdrhiRgTetChoIaNtOt5hMfMaraonsmdtecraoTTnr/nGy-eSRSzrl.OoaTnvUTTeehNAeDwpTdoSCililspOift6isiroMewni.tthcAhe boiler and start the pump. PRIODRITY P PUMPC1OMMPUSMP 2 L N L N PUMP 3 LN PW PU L ZON Installation Inspection Inspect packages for damage. If damaged, notify the appropriate carrier immediately. If undamaged, open the package and inspect the device for obvious damage. Return damaged products. · Use only copper conductor supply wire suitable for at least 105° C · All circuits must have a common disconnect and be connected to the same pole of the disconnect Maintenance and Repair The Caleffi Z-oneTM switching relay box contains a spare fuse and requires no maintenance. If any product fails or is damaged, replace product with functional one. Mounting Mount the Caleffi Z-oneTM switching relay box to a suitable surface. Slotted holes are provided for mounting purposes. Do not mount to a surface that exceeds 115°F (45°C). The unit must be only located in dry interior locations. It is not suitable for installation in hazardous locations and should not be placed close to any electromagnetic fields. · · Remove cover of relay box. Identify the four mounting holes on relay box, mark on the wall the desired location of mounting. · Drill, anchor, and fasten four screws for mounting. · Hang relay box and fasten tight to desired locations. · Complete wiring connections in accordance with terminal locations. · Place cover back on relay box. Cover removal Hold either the left or the right end of the box up and at an angle. Use body for stabilizing relay box. Insert screwdriver and push tabs inward, cover should release from base. Roll cover off base. Example Wiring Diagram Please reference Z-oneTM Relay wiring guide for complete listing of wiring diagrams. ModCon boiler with primary/secondary space heating thermostats X X DHW ZR/ZC R WC T T COM THM 1 R WC T T COM THM 2 R WC T T COM THM 3 R WC T T COM THM 4 R WC T T COM THM 5 R WC T T COM THM 6 DP COMMS TRANSFORMER 12/20VA ZZ46SSZRZRZ61oo1Pn0n0ee46! DipSwitches Master Priority OFF Primary OFF Exercise OFF Post Purge OFF Slave Priority ON Primary ON Exercise ON Post Purge ON POWER IN LN GROUNDS PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PUMP 5 LN PUMP 6 LN PRIMARY PUMP LN PWR ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 LNG C2 C4 C1 C3 PRIMARY! PUMP C1 C2 C3 C4 VENT PRIMARY! PUMP Non-Condensing boiler with indirect DHW DHW! aquastat space heating thermostats space heating demand domestic water heating demand boiler! reset! controller L ZC T T ZR N G outdoor! temperature! sensor X X DHW ZR/ZC R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 DP COMMS TRANSFORMER 12/20VA 6 Zone ZSZR61P06 DipSwitches Master Priority OFF Primary OFF Exercise OFF Post Purge OFF Slave Priority ON Primary ON Exercise ON Post Purge ON POWER IN LN GROUNDS PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PUMP 5 LN PUMP 6 LN PRIMARY PUMP LN PWR ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 LNG C2 C4 C1 C3 C5 C1 C2 C3 C4 C5 VENT TT ModCon boiler with primary/secondary and zone expansion high flow resistance heat source to / from zone loads C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 temperature! sensor! (in well) PRIMARY! PUMP VENT space heating thermostats X X DHW ZR/ZC R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 DP COMMS TRANSFORMER 12/20VA 6 Zone ZSZR61P06 DipSwitches Master Priority OFF Primary OFF Exercise OFF Post Purge OFF Slave Priority ON Primary ON Exercise ON Post Purge ON POWER IN LN GROUNDS PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PUMP 5 LN PUMP 6 LN PRIMARY PUMP LN PWR ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 L NG C2 C4 C6 C1 C3 C5 space heating thermostats X X DHW ZR/ZC R WC T T COM THM 1 R WC T T COM THM 2 R WC T T COM THM 3 R WC T T COM THM 4 R WC T T COM THM 5 R WC T T COM THM 6 DP COMMS TRANSFORMER 12/20VA 6 Zone ZSZR61P06 DipSwitches Master Priority OFF Primary OFF Exercise OFF Post Purge OFF Slave Priority ON Primary ON Exercise ON Post Purge ON POWER IN LN GROUNDS PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PUMP 5 LN PUMP 6 LN PRIMARY PUMP LN PWR ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 L NG C8 C10 C12 C7 C9 C11 CALEFFI Caleffi North America, Inc. 3883 West Milwaukee Road Milwaukee, WI 53208 T: 414.238.2360 F: 414.238.2366 1 WIRING GUIDE The ZSR101 is a versatile single relay control with two outputs for operating a 120 VAC pump with boiler enable, or two 120 VAC devices without boiler enable. Features include rear knock outs for 4x4 junction box mounting, convenient pre-installed jumper for pump operation, and 10 amp total load rating. The ZSR Series of controls is for zoning using pumps. Up to 6 zone pumps (model dependent) along with a primary pump can be operated. Zone priority is selectable with 1-hour time-out feature. Other features include pump exercising, selectable post purge, and 3 pump ground terminals for simplified wiring. The ZVR Series of controls is for zoning using zone valves. Up to 6 valves (model dependent), along with a system pump, secondary pump and zone 1 pump (typically used for DHW priority) can be operated. Zone priority is selectable with 1-hour time-out feature. System pump and secondary pump status (on/off) during priority is also selectable. Replaceable snap-fit 40 VA transformer standard for 3 & 4 zone models expandable to 80 VA with 2nd transformer. 6 zone model has two 40 VA (80 VA) transformers. Certified to CSA C22-2 No.24 Conforms to UL Standard 873 4009064 Form 031914 rev.2 INDEX Z-one Relay thermostat connections Thermostat wiring ........................................................................................................................................................................... 4 Zone valve wiring to ZVR series....................................................................................................................................................... 5 ZSR101 - single zone relay Product overview ............................................................................................................................................................................ 6 Operation and cover removal ........................................................................................................................................................................7 A1 - Single thermostat ...................................................................................................................................................................................8 A2 - Multiple thermostats...................................................................................................................................................................10 A3 - Single master thermostat, with TRVs, variable speed pump.................................................................................................... 12 ZSR103, ZSR104 & ZSR106 - multi-zone pump relay Product overview ........................................................................................................................................................................... 14 Circuit board .................................................................................................................................................................................. 15 Cover removal................................................................................................................................................................................ 16 Product details............................................................................................................................................................................... 17 B1 - Mod/Con boiler, hydro separator or buffer tank, zone pumps ................................................................................................. 18 B2 - Traditional boiler, indirect DHW w/ priority, zone pumps .......................................................................................................... 20 B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps............................................................................................ 22 B4 - Mod/Con boiler, hydro separator or buffer tank, zone pumps with remote enable................................................................... 24 ZVR103, ZVR104 & ZVR106 - multi-zone valve control Product overview ........................................................................................................................................................................... 26 Circuit board .................................................................................................................................................................................. 27 Cover removal, Transformer Installation .................................................................................................................................................28 Product details............................................................................................................................................................................... 29 C1 - Mod/Con boiler, hydro separator, zone valves ........................................................................................................................ 30 C2 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves ............................................................................... 32 C3 - Mod/Con boiler, indirect DHW on load side of hydro sep, zone valves.................................................................................... 34 C4 - Mod/Con boiler, indirect DHW on primary side of hydro sep, master and slave control ........................................................... 36 C5 - Traditional boiler, indirect DHW (no priority) with valve ............................................................................................................. 38 C6 - Traditional boiler with reset control, priority indirect DHW with valve........................................................................................ 40 C7 - Mod/Con boiler, hydro separator, zone valve (more than 6), multiple secondary pumps.......................................................... 42 C8 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves with ECM pump enabling....................................... 44 C9 - Mod/Con boiler, hydro separator, zone 1 low temp, 2 - 6 high temp zone valves.................................................................... 46 Caleffi shall not be liable for damages resulting from misapplication or misuse of it products. 3 Z-one Thermostat Connections 2-Wire Thermostats 4-Wire Thermostats 4 All Caleffi Z-one controls use the same interface to connect to thermostats. This interface is very flexible and allows many different types of thermostats to be connected to the control including 2, 3 and 4 wire versions. In addition, any type of switching device can be used to signal a heat demand by connecting the R & W (T & T) terminals together. The terminals are dual labeled to help simplify wiring. There are a few different types of 2 wire thermostats including bi-metallic, power stealing and battery powered. All of these thermostats connect in the same manner to the Caleffi Z-one series of controls. Connect R to R and W to W. See below. To connect a 4-wire thermostat to the Z-one series controls, connect R to R, W to W and C to C. A jumper in the thermostat is also required between R & Rh as shown below. Similar to a 3-wire thermostat, R & C from the Z-one Control supply constant 24 VAC to the thermostat. Z-one T-stat interface C R Rh W1 X X DHW ZR/ZC R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM DP COMMS PWR R WC T T COM T-STAT 1 R WC T T COM T-STAT 2 X X DHW R W ZCR/ZC T T COM T-STAT 3 R W C R W C R W C R W C R W C R W CTHM 1 R W T CT COMRT TWCOM CT TRCOM WT T CCOM T T COM T D T COPM THM 1 THM 2 THM 3 THM 4 THM 5 T T COM T T COM T T COM THCMO6MMS T-STAT 4 T-STAT 5 T-STAT 6 D TPHM 2 COMMS THM 3 THM 4 PWR THM 5 ZODNrE1y Contacts THM 6 ZONE1 ZONE2 Description R = 24 VAC Supply TRANSFORMER 12/20VA 3-Wire Thermostats TRDAipNSSwFitOchReMs ER 6 Zone A heat demand can also be initiated by any type ZONE2 DipSwitches Master Priority OFF Slave Priority ON ZONE3 Primary OFF Primary ON Three6wZiroentehermostats get their power from the MASTER Master 12/20VA Priority OFF SLAVE Primary OFF Slave Priority ON Primary ON POWER Z6P control they are connected to. R & C from the ExerciseOFF Post Purge OFF Exercise ON Post Purge ON Z-onePRCIOoRnITtrYoOl Nsupply 24 VOAFCF to the thermostat at Z6P of device that has dry contacts (dry contacts are ZONE3 Exercise OFF Post Purge OFF Exercise ON Post Purge ON ZONE4 a set of contacts that open and close but do not ZONE4 have any voltage present until supplied from ZaOnNE5 W = Heat Call C = 24 VAC Common Function POWER IN GROUNDS LN R&W: When connected, signals a heat demand. RaElMl tOimTEeEsNAwBhLEileONthe W lead OsFigFnals a heat deZmOaNnEd1. ZoONuEt5side source). The end switch on a Z-one series EXERCISE ON OFF POPRSIOTRITPYURGE ZONE#1 ON POWER IN OFFGROUNDS PUMP 1 PUMP 2 PUMP 3 PULMP 4 N PUMP 5 PUMP 6 PRIMARY PUMP PRIORITY PUZMOP 1NEP2UMP 2 LN LN ZzOoNEn6e valve is an example of a dry contact. UsZinOgNE6 aPUdMrPy3 coPnUMtPa4ct tPoUMcP 5onnPeUMcPt6 R to W will PRIMARY PUMP initiate a heat dLemNandL. N L N L N L N L N L N L N L N L N L N LN ZONE3 R&C: Provides 24 VAC to powered thermostats. NDS ZSR106 ZONE4 6 Zone WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct shoXrtXon tZhDReH/ZW2C 4 VAC supR plyW TT C COM R T WC R T COM T WC R T COM T WC R T COM T X X DHW W C R W ZRC/ZC T COM T T COM THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 R WC R WC R WC R WC R WC R WC ZONE5 D P COMTMS T COM T PTWRCOM T T COM T T COM T T COM T T COM THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 DP COMMS P ZONE1 ZO Always refer to the thermostat manufaZcOtNuEre6r's inZOsNtEr2uctions. ZO DipSwitches DipSwitches Master Slave 6 ZZ6oPne 6 ZZ6oPne REMOTE ENABLE 24 - 120 VAC SThAisFEsTaYfetIyNSalTeRrtUsCymTIbOoNl TwRilAl 1Nb2S/e2F0OuVRsAMedERin this manual to draw attention to Master Priority OFF safety Primary OFF Exercise OFF Post Purge OFF related instructions. When used, the safety alert symbol means ATTENTION! Slave Priority ON Primary ON Exercise ON Post Purge ON BEPCROIOMREITAYLERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE PRIMARY INSPTURMUPCT1IONSPMUAMYP R2ESULPTUIMNPA3SAFETPYUMHPAZ4ARD.PUMP 5 PUMP 6 PUMP TRA1N2S/2F0OVRAMERCeleAcUtrTicIOalNs:hEolcekctoZZrirOOceaNNqlEEus34hipomceknhtadzaamrda.gDei.sMcoanknPeoEsePxtPrePsricmriuocrariusgitrteyey rOOOOpeFFFFFFFFoawll ecEPPPrxroroiiemsortrbcainPtirysyueeOrnOgONeNfNeOoNcretioinnsstaarlleatiinonactocoprdreavnecnet with the electrical wiring diagram and in accordance with national and local electrical STATUScodes. DURING ZONE5 ZO ZO ZO L N L N L N L N L N LN L N CAUTION: All work must be performed by qualifPiReIdORITpYersonnel trained in the proper application, instaPllOaWtiEoRnI,N and mGRaOinUNteDSnance of syPUsMtePm1 s inPUaMcP c2 ordPaUnMcPe3 witPhUMaPll4 applicable codes and oLrdinNances. LN L N L N L N LN PUMP 5 LN PRIORITY POWER PLUMP 6N LN IN ONPLRPIUMMAPRNGYROCemUOFF NleAoDcSUistrtTuicIrOaelN, c:moAarvrPcPoLRohUIsiOMidZniRvPOIeeTNe1NYrlyefEu,c6mtPLroUiecrMsaP,lwN2vneiboldirsaPLineUtigMoiPnnNt3e,eqorfureiPLrepeUxmMnpPcelN4oens.ti.vDePLoAUvMvnaoPopNi5dtoirnslsoPLatcUarMaellPtiNn6openreassr ePlLwanRPrIUthMg.MAeePRNrYecoenxdcuecstsoirvse, ZO Caleffi shall not be liable for damages resulting from misapplication or misuse of it products. Wiring zone valve to Caleffi ZVR control Wiring a standard zone valve to Caleffi Z-one Relay Since a two wire actuator does not have an end switch for feedback to the ZVR control, the end switch terminals must have a jumper to simulate the end switch. If the end switch jumper is not installed, no demand will be sent to the boiler and the pumps will not turn on. Wiring a Taco 570 valve to Caleffi Z-one Relay When connecting the Taco 570 zone valve to the Caleffi Z-one Relay, the wiring of this valve can only be done in one way. The left motor terminal on the ZVR series control must be connected to terminal 2 on the zone valve. The right motor terminal must be connected to terminal 1 on the zone valve. Lastly, the left end switch terminal must be connected to terminal 3 on the zone valve. Failure to follow schematic will lead to damage of product. Wiring a White Rogers 1361 valve to Caleffi Z-one Relay The White Rogers 1361 zone valve requires 24 VAC to terminal 2 at all times, therefor connect to the R terminal of the associated T-STAT on the ZVR control. The left motor terminal on the ZVR series control must be connected to terminal 4 on the zone valve. The right motor terminal must be connected to terminal 1 on the zone valve. Lastly, the left end switch terminal must be connected to terminal 3 on the zone valve. The 1361 can not be used on any zone when the ZVR control is set for priority. AUX XX ZONE 1 E / S R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER POWER IN LN ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH 4 1 3 2 2 1 3 22 5 4 1 1 3 2 3 White Rogers 1361 Zone Valve 4 wire Zone Valve 2 wire Taco 570 5 Certified to CSA C22-2 No.24 Conforms to UL Standard 873 4009064 6 ZSR101 - Single Zone Switching Relay Overview · Compatible with 2, 3 and 4-wire thermostats or other low voltage controllers with switching action · 120 VAC input · Heavy duty, sealed, DPDT, fuse protected relay (with spare fuse) · Two dry contact outputs (Relay 1 and Relay 2) for operating 120 VAC pump with boiler enable or two devices without boiler enable · 5 A capacity each relay - 10 A total · Rear knock-outs for mounting onto 4"x4" junction box · High capacity 6VA transformer · Simplified wiring with pre-installed jumper · 100% factory tested with 3 year warranty · ETL certified See technical brochure 01284 NA for more product information. Operating Principles When a zone has a demand from a thermostat (TT or R W) the relay will close sending 120 VAC to Relay #1 NO terminal RW and switching the pump on, and the C to NO dry contact on relay #2 closes, R TW CT T T COM signaling the boiler of a heating demand. C COM PWR R, W, C and T T Comm dual labeling at thermostat terminals. ComTpRaAtibNlSe FwOithRlMowERvoltage 2, 3, or 4 wire thermostats or any ZS1 ZZRo1Sn0eR1 101 TRotAheNr lSowFvOoltRagMe dEevRices having a switching action. ZONE 1 Zone Supply 120 VAC hot to terminal L and 120 VAC neutral to N. A factory installed jumper from L terminal to the C terminal of Relay 1 is supplied for simplified pump connection. 6 VA Transformer. PWR ZONE Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Replaceable fuses. POWER IN NL RELAY #1 RELAY #2 C NO NC C NO NC 120VAC input power connection POWER IN RELAY #1 RELAY #2 If dry N L contacts are C desired fromNreOlay #1,NreCmove thCe factoNry O NC installed jumper between L and C. Cover removal Keyhole mounting which fits a 4X4 junction box. Pre-installed jumper. Hold either the left or the right end of the box up and at an angle. Use body for stabilizing relay box. Insert screwdriver and push tab inward. Turn box and repeat inserting screwdriver and pushing tab inward on opposite side, cover should release from base. Slide cover off base. Rear knockout for 4X4 junction box. Mounting: Do not mount to a surface that exceeds 115°F (45°C). The unit must be only located in dry interior locations. Use only copper conductor supply wire suitable for at least 105° C. All circuits must have a common disconnect and be connected to the same pole of the disconnect. It is not suitable for installation in hazardous locations. 7 8 A1 - Single thermostat R WC T T com transformer power zone CalefÞ! single zone relay N L RELAY 1 RELAY 2 C N/O N/C C N/O N/C N T L T Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (live leg of 120 VAC) C = Common terminal NO = Normally Open terminal NC = Normally Closed terminal Note: There is a factory installed jumper between the 120 VAC line (L) and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings · A demand occurs from the thermostat closing R to W on the ZSR101 control. The "ZONE" LED illuminates. · The ZSR101 control will power relay #1 and #2 closing C to NO. · The NO terminal of relay #1 will send out 120 VAC to your pump. Relay #2 provides a dry contact closure to signal the boiler of a demand. · NOTE: Relay #1 can be used as a dry contact as well by removing the factory installed jumper between L and C. · When the thermostat demand is satisfied R to W will open and the "ZONE" LED will turn off. · The control will remove power from relays #1 and #2 opening C to NO. This will drop 120 VAC to your pump and terminate the demand to your boiler. 9 A2 - Multiple thermostats 10 4-wire zone valve 4-wire zone valve 4-wire zone valve End switch wires R WC T T com power zone transformer CalefÞ! RW single zone relay RW RW N L RELAY 1 RELAY 2 C N/O N/C C N/O N/C 24 VAC N T L T Hydronic diagram is for illustration purposes only and could be missing system components. Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (live leg of 120 VAC) C = Common terminal NO = Normally Open terminal NC = Normally Closed terminal Note: There is a factory installed jumper between the 120 VAC line (L) and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings · A demand occurs from one of the thermostats which sends power (from a separately sourced transformer) to the corresponding zone valve. · When the zone valve opens the end switch will close R to W on the ZSR101 control. The "ZONE" LED illuminates. · The ZSR101 control will power relay #1 and #2 closing C to NO. · The NO terminal of relay #1 will send out 120 VAC to your pump. Relay #2 provides a dry contact closure to signal the boiler of a demand. · NOTE: Relay #1 can be used as a dry contact as well by removing the factory installed jumper between L and C. · When all the thermostat demands are satisfied the zone valves will close and the end switch will open R to W. The "ZONE" LED will turn off. · The control will remove power from relays #1 and #2 opening C to NO. This will drop 120 VAC to your pump and terminate the demand to your boiler. 11 A3 - Single master thermostat, panel radiators with TRVs, variable speed pump 12 TRV thermostatic radiator valves (TRV) on each radiator TRV TRV TRV TRV TRV bu er tank R WC T T com transformer power zone ZSR101 N L RELAY 1 RELAY 2 C N/ON/C C N/ON/C N T L T Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (live leg of 120 VAC) C = Common terminal NO = Normally Open terminal NC = Normally Closed terminal Note: There is a factory installed jumper between the 120 VAC line (L) and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings · A demand occurs from the thermostat closing R to W on the ZSR101 control. The "ZONE" LED illuminates. · The ZSR101 control will power relay #1 and #2 closing C to NO. · The NO terminal of relay #1 will send out 120 VAC to your pumps. Relay #2 provides a dry contact closure to signal the boiler of a demand. · NOTE: Relay #1 can be used as a dry contact as well by removing the factory installed jumper between L and C. · When the thermostat demand is satisfied R to W will open and the "ZONE" LED will turn off. · The control will remove power from relays #1 and #2 opening C to NO. This will drop 120 VAC to your pumps and terminate the demand to your boiler. · NOTE: In this application, the single thermostat will be set to a slightly higher temperature than the desired room temperatures. The room temperatures will then be controlled by each individual thermostatic radiator valve by adjusting the flow through the radiator making this a fitting application for a variable speed (ECM) pump (between the buffer tank and radiators). When the temperature drops below the set point of the thermostat the boiler will maintain the buffer tank at its target temperature. Ideally, the boiler will operate on an outdoor reset curve to maximize efficiency and use a system temperature sensor located in the upper portion of the buffer tank. 13 Certified to CSA C22-2 No.24 Conforms to UL Standard 873 4009064 14 ZSR10X - Multi-Zone Pump Control Overview · Compatible with low voltage 2, 3, or 4 wire thermostats · R, W, C and TT Comm dual labeling at thermostat terminals · Z-oneLink unlimited zone expansion · 120 VAC pump outputs · Selectable priority with 1 hour time-out feature · Selectable post purge and exercise · Dry contacts (X X , AUX, ZONE 1 E/S) capable of switching line voltage · High capacity transformer · Large terminal connections · Simplified wiring with extra ground terminals · Heavy duty sealed relays · Fuse protected (with spare fuse) · Front LED lights · 100% Factory tested with 3 year warranty · ETL approved See technical brochure 01286 NA for more product information. AUX closes on a demand for heat from any zone. Rated for 120 VAC 2 Amps. X X closes on a demand for heat from any zone. Rated for 120 VAC 2 Amps. ZONE1 /ES closes only during a demand from zone 1. Rated for 120 VAC 2 Amps. Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Selectable DIP switches. 3 wire communications to expansion board. Power ON LED. 120 VAC input power connection Multiple ground connections for easy wiring. 120 VAC zone pump outputs. LED for each zone. Replaceable fuses (2 extra included under cover). 120 VAC primary pump output. 15 Cover removal 16 Hold either the left or the right end of the box up and at an angle. Use body for stabilizing relay box. Insert screwdriver and push tab inward, cover should release from base. Roll cover off base. Mounting: Do not mount to a surface that exceeds 115°F (45°C). The unit must be only located in dry interior locations. Use only copper conductor supply wire suitable for at least 105° C. All circuits must have a common disconnect and be connected to the same pole of the disconnect. It is not suitable for installation in hazardous locations. E / S T T COMT T T TCOCMOMTT T TT CTCOOMCMOMTT T TT CTCOOMCMOMTT T TT TCCOOCMOMMTT T TTTCCOCOMOMM TT TT CCOOMMCTOMMST COMCOMM T-STAT 1 T-TS-TSATTAT1 2 TT-S-TST-TSAATTTA1T2 3 TT-S-TST-STAATTAT2T34 TT--STS-TSTAATTAT3T45 TT-S-TS-TSTATATAT4T56 TT-S-STTAATT56 T-STAT 6 Maintenance and Repair: The Caleffi Z-oneTM multi-zone pump control The ZSR series of control is comes with two spare fuses. If control fails or is damaged, replace control with programmed by positioning five dip MASTER MASTESRLAVE MASTESRLAVPE OWE functional one. switches for the following operations. PRIORITY ON PRIORITY OONFFPRIORITY OONFF X X X X ZS6 RZo1n0Ze6SR10Z6SR106 AUX AUX BXwcZAbZwwleOOmXooihhtheisiNeNpcleenn=EhsEtsrah,ab1eicDwws1nsolerEihyeytlnEdlye/ncSpf/zncaeSeloiooscaccansnat=aatnZeueitlnOloyEarypDeNwcnc/brzEsScriatsiooeyt.1olh:lrnrsAinucateaynsUotaneeceznnXyddacotdaltncl=etscueaTocdtp,liDRalncrtttnrcyaAltooyoopltRTuNesbTiZcTcdedSe1-oOaTiSn2nFaluNlugWyT0tOoTpaDsEAunpcTeRHVtsT1trdCRo,bMAeiW.oOCd1oArCar1EMaiZiNtcsl,2fteRyooeo0Sr.2rndsnRTTFhceiVtguaAeo-OA1npScanmCRatttTWcitrplTnT,oMoaoAsgnRt2nlTo,,E1CdAb2ORC2ooaN0MmilSeVverFaAsRTTcrOtCiioac-,RSnbh2tMTlWeroToAAtElsswmTCRpeaOCp3eqtMseeuZ,rdOiE.cpNRT/lTpToEsSeh-es1SdeelfTWTATCOC4MerPsTsaRheMwwxcoSrealpiatlTiiomdisttvyacAcrtRReTTsnTooeihhTTt.srf-eytw-fOSieRdSo1/iahEsnTnOWWTSEleoTT,lMlAynNAltnzfZaOOofTooaTCCvZOT(NnnwbaE/eOOEOCC5PN1ee,dXl:MMiRONEetsEEdhaMINuEORFiwlOtlA1p1MiCaoFRRRoTTa1BTTNoswI:AInwSiThLtt--nSwaiesYEESoSniW/TllrlaugOOOTT.WfEWOZdToThsrRNNNAAoVfeerFPotspmTiTRnFCOCmurweOOn:SCCaa62oireptTlaMnMRnWic-rmrtdoEPhieZeohMuUietxSreReTtaRdOitTt)tRndoe.sGyT-oErEWSErnpnXeEaTZWrSOOOEhPmTiwNOloLAReFFFO2AANoriFFFnCTlSiCl4BVttEITyeRSrOLpEC#3De-EEE1PrMaemiC1MUoOOOnn2OaRrOdNNNai0itRGTMTnbTPyEaEElVM-eXoliSlsEZAEnSoPmNOTCWR.TtOAONAChoBSvEeIFdTSCLTo#RrFPeEE1OlCE4PtZ,zOaOOOMMiUosOagOOONNNWROnneNOFFFGeTyRETFFFETEfsNEErzXRo-,E1ZoaESmNOnrtRTheWANeCTetABsEhtISeL#TebtCEEm1hoOCb5PaOOOpaMoROOOtNNNroidIFFFlwOreFFFaMrReRwTr.TriAIlTiey-lZZZZSlYSTOOOOOTWETNNNNRNAEEEETC 6 Zone 6 Zone regulated pump or other controls. ExePrOcSisTePUORNGE/ OZOFNFE:#W1 OhNen exercise mOoFdFe is ON, each cirZcOulaNtoEr2RisEsMwOiTtcEhEeNdAoBLnZEOONNE for 30 seconds following 72 hours of inactivity. EXERCISE ON Communication connections: C RCDotTnoWnReDAc,NtCtSPeFrmtORoinRPaM,lWsEGtoRroCmuantdcRhtiongWGterormuCninda.lRoUfsseWla1ve8 boards Cgauge DP PopoesrtaPtiungrgfeorZ2onmein#u1tOesNa/ftOeFr Fth:eWphreionritpyozsot npeurigseswisiOtcNhe, dZoZOnOFeFPN1.OEpS3uTmPUpRcGoEntZinOuNeEs#Z1OONNE COM 2 TthermT oCsOtaMt wTire aTndCOitMshoTuld TbeCsOhMieldTed ifT loCcOaMted in COMMS ZONE4 ZSR106 Tc-loSsTeApTro3ximTity-StToAhTig4h volTta-SgeTAwTiri5ng. T-STAT 6 TRANSFORMER Primary pump output: 6 Zone ZS6 RZo1n0e6 ILNNcnoopn=t=u=etrtL:NoGiPnlwesroeu,ohwtuea(rhenanllolrdct:ocolfoenn1gtn2r)oe0olcsfVt1imAn2LgCu0sP2VtOAbWoCNeRrEERsmpMuIoNOopwLTrpeEEePlXPyrREEZeOINORd-WAoMCRNBEnbIAISGTLReySEYERTIOOOONEthRNNNUeNLDsPSaOmWeGNER1RO2R2IUE0N4SOOOMLN-OLVFFFD1ATFFFAE2SV0ECENVNAAcBCLiGrEcRRu2OEi4tMPLU.-OPLRN1TUIE2DOM0ESRNPPVNAIZATNOB1YCLOEWNEER2ERPPL41MPLLRU-OUIM1TOPsuLNSME2PtsRrt0aEP=ia=iNmIN2ntVTNtN1AugLuAYNBasiCLsnrteEyhdeueDupPLt(rPLhrUuujaPiuUonMmrPLlRmiMgtlUPneIpOlPpMNgeg3pRNerg2PruoIri)PTNon1fpoYrrs1iiiftnoPLy2w1srPLU02i.h(UtMoPL0yeVMnPUnAV\PNM4OoCaAN3PfNnfC)Nt2yoct/zoapPLoOnUoPLpnMwUFoebPLMPFweeUpN:Pr5MeupNtr4PImhrftoNe3hpgpeprrPLraiuuopUPLmmnruMUisPLtmmpPMy.UNpP6eIMtidNss5P PRIMARY STATUS 4 N PUPZMUOMPNPE5 5 LPULMPN6 N L ZONNE6 PLPLRPPUIDUONMRMUMIAOPRPRNRIN6NYITGYOFF enabled and the jumper is PRIM PSU LD PR O N POST PURGE ZONE#1 ON OFF ZONE2 placed on the ON pins, the primary pump will continue to operate during ZONE Zone pump outputs: REMOTE ENABLE PRIORITY 1 demand. When jumper is placePdRIoMnAROYFF pins, SthTAeTpUrSimary pump will be OFF ZPoOnWeER IpNumps GrRuOnUNDwShen 24 - 120 VAC PUMP 1 PUMP 2 PUMPZ3ONEP3UMdPur4ing ZOPUNMEP15 demPaUndM.P 6 PUMP DURING L corrNesponding thermostat L N L N L N L N L N L N L N LN PRIORITY initiates a demand. ZSR106 GROUND = Connect the POWER IN GZROUNNED4S g6rouZndofnroem the pump to the ground terminal. PRIORITY PUMP = Runs when L zone N #1 calls. Can ZbOeNE5 REMOTE ENABLE 24 - 12W0AVRANCING: PRIORITY NPEUVMERPC1ONNEPCUT MRP& 2C O N DIREPCUTLMYP, t3his will O F bPeUF aMdPire4ct shorPt UonMtPhe524 VAPCUMP 6 L supNply. L N L N L N L N L N L N programmed to be the priority zone. L = Line (hot leg) of 120 VAC to power the pump, N = Neutral leg of 120 VAC to power the pump. Remote EnabZlOeNE6 WARNING: When connecting 2 or more Z-one controls, all controls must be powered by the same 120 VAC circuit. allows for input of 24-120 VAC from a boiler to allow the zone pumps to operate. When power is removed from Remote Enable, zone pumps will not be allowed to operate. This is useful during warm weather shut down to WARNING: When replacing fuses, make sure power is disconnected to control box. stop zone pumps from running or if your boiler conPRtrIoMlAsRaYre usedSTtoAThUaSndle PUpMrPio2rity (DPUHMWP )3demPaUnMdPa4nd nePeUdMPth5e zonPUeMpPu6mps toPbUeMoPff during DthUeRIpNrGiority L demN andL. EveNn witLh poNwer rLemovNed frLom RNemoteL EnaNble, stays powered to supply power to the thermostats. the PRIORITY ZSR O N boO ard F F 17 18 B1 - Mod/con boiler, hydro separator or buffer tank, zone pumps Pump 1 Pump 2 Pump 3 Pump 4 Bu er tank- Optional hydraulic separator L N AUX XX ZONE 1 E / S TRANSFORMER R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE#1 ON ZSR106 6 Zone SLAVE OFF OFF OFF OFF POWER ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 POWER IN LN GROUNDS REMOTE ENABLE 24 - 120 VAC LN PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PUMP 5 LN PUMP 6 LN PRIMARY PUMP LN STATUS DURING PRIORITY O N O F F Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. Description of terminals Sequence of Operation / Settings = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC · Master / Slave switch: Master · Priority Switch: OFF · Remote Enable Switch: OFF · Exercise Switch: OFF W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. · Post Purge Zone 1 Switch: OFF · Status During Priority Jumper: OFF · A demand occurs from any thermostat closing R to W. The "PUMP ON" LED illuminates for the corresponding zone. · ZSR control sends 120 VAC to corresponding zone pump and the primary pump output. The control will close the X X contacts to signal the boiler of a demand. · When the demand from the last thermostat calling is satisfied (thermostat opens R to W), the X X contacts are opened and the "PUMP ON" LED turns off. The 120 VAC to the zone pump and primary pump outputs are dropped. Dip switch description Master / Slave: allows for unlimited expansion to additional ZVR or ZSR relays. Only one Master. Priority ON / OFF: When priority switch is ON, upon demand to TSTAT 1, ZONE 1 will operate as priority and all other zones are temporarily switched off (with 1 hour time-out). When priority is OFF, any zones that were active when ZONE 1 was switched on will remain on. Remote Enable ON / OFF: When remote enable mode is ON, the board will hold off all zones waiting for an external 24 - 120 VAC voltage from the boiler. Exercise ON / OFF: When exercise mode is ON, each circulator is switched on for 30 seconds following 72 hours of inactivity. Post Purge Zone #1 ON / OFF: When post purge is ON, Zone 1 pump continues operating for 2 minutes after the priority zone is switched OFF. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply 19 B2 - Traditional boiler, indirect DHW w/ priority, zone pumps Pump 2 Pump 3 Pump 4 Pump 5 Pump 6 boiler high limit control Pump 1 DHW aquastat DHW aquastat TT DHW outdoor temperature sensor AUX XX ZONE 1 E / S TRANSFORMER R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 ZSR106 6 Zone MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE#1 ON DP COMMS POWER SLAVE OFF OFF OFF OFF ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 L N POWER IN LN GROUNDS REMOTE ENABLE 24 - 120 VAC LN PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PUMP 5 LN PUMP 6 LN PRIMARY PUMP LN STATUS DURING PRIORITY O N O F F Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. 20 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Dip switch description Master / Slave: allows for unlimited expansion to additional ZVR or ZSR relays. Only one Master. Priority ON / OFF: When priority switch is ON, upon demand to TSTAT 1, ZONE 1 will operate as priority and all other zones are temporarily switched off (with 1 hour time-out). When priority is OFF, any zones that were active when ZONE 1 was switched on will remain on. Remote Enable ON / OFF: When remote enable mode is ON, the board will hold off all zones waiting for an external 24 - 120 VAC voltage from the boiler. Exercise ON / OFF: When exercise mode is ON, each circulator is switched on for 30 seconds following 72 hours of inactivity. Post Purge Zone #1 ON / OFF: When post purge is ON, Zone 1 pump continues operating for 2 minutes after the priority zone is switched OFF. Sequence of Operation / Settings · Master / Slave switch: Master · Priority Switch: ON · Remote Enable Switch: OFF · Exercise Switch: OFF · Post Purge Zone 1 Switch: OFF · Status During Priority Jumper: OFF · A demand occurs from a thermostat on zones 2-6 closing R to W. The "PUMP ON" LED illuminates for the corresponding zone. · ZSR control sends 120 VAC to corresponding zone pump. The control will close the X X contacts to signal the boiler of a demand. The PRIMARY PUMP output will also deliver 120 VAC even if no pump is wired to it. · When the demand from the thermostat is satisfied R to W will open and the "PUMP ON" LED for the corresponding zone will turn off. · 120 VAC is dropped to the corresponding zone pump terminals. · If no other zones are calling for heat, 120 VAC is dropped to the PRIMARY PUMP and the XX contacts will open terminating the demand for heat to the boiler. · If a demand occurs from the DHW aquastat (T-STAT 1), the "PUMP ON" LED illuminates for zone 1. · If any other zone was calling for heat (zones 2-6) when zone 1 is calling 120 VAC is dropped to the pumps on zones 2-6. · The X X and the ZONE 1 E/S contacts close to signal a DHW demand to the boiler. · The PRIORITY PUMP 1 output delivers 120 VAC. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to PRIORITY PUMP 1 is dropped. The ZONE 1 E/S contacts open. · If a call for heat exists from zones 2-6 the corresponding "PUMP ON" LED will illuminate and 120 VAC will be delivered to those zone pumps. The XX contacts will remain closed to signal a heating demand to the boiler. · When all the thermostat demands are satisfied R to W will open and the "PUMP ON" LEDs will turn off. The X X contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to all of the zone pumps. DHW Time Out \ Freeze Prevention Feature · After one hour of a priority demand, the control will open the ZONE 1 E/S contacts and drop power to PRIORITY PUMP 1. · If a call for heat exists from zones 2-6, the control will satisfy those demands before going back to the priority demand. · After zones 2-6 have been satisfied, the control will go back to the priority demand and reset the one hour timer. 21 22 B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps Pump 1 Pump 2 Pump 3 boiler pump Primary pump AUX XX ZONE 1 E / S R WC R WC R WC T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 TRANSFORMER ZSR103 3 Zone MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE#1 ON DP COMMS POWER SLAVE OFF OFF OFF OFF ZONE1 ZONE2 ZONE3 L N POWER IN LN GROUNDS REMOTE ENABLE 24 - 120 VAC LN PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN Pump 1 Pump 2 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. Pump 3 PRIMARY PUMP LN STATUS DURING PRIORITY O N O F F boiler pump Primary pump Description of terminals Sequence of Operation / Settings = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals · Master / Slave switch: Master · Priority Switch: OFF · Remote Enable Switch: OFF R = 24 VAC · Exercise Switch: OFF W = Heat call · Post Purge Zone 1 Switch: OFF C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Dip switch description Master / Slave: allows for unlimited expansion to additional ZVR or ZSR relays. Only one Master. · Status During Priority Jumper: OFF · A demand occurs from any thermostat closing R to W. The "PUMP ON" LED illuminates for the corresponding zone. · ZSR control sends 120 VAC to corresponding zone pump and the primary pump output. The control will close the XX contacts to signal the boiler of a demand. · When the demand from the last thermostat calling is satisfied (thermostat opens R to W), the XX contacts are opened and the "PUMP ON" LED turns off. The 120 VAC to the zone pump and primary pump outputs are dropped. · ALTERNATE WIRING: The boiler pump can be controlled by the boiler if it is equipped to do so. Priority ON / OFF: When priority switch is ON, upon demand to TSTAT 1, ZONE 1 will operate as priority and all other zones are temporarily switched off (with 1 hour time-out). When priority is OFF, any zones that were active when ZONE 1 was switched on will remain on. Remote Enable ON / OFF: When remote enable mode is ON, the board will hold off all zones waiting for an external 24 - 120 VAC voltage from the boiler. Exercise ON / OFF: When exercise mode is ON, each circulator is switched on for 30 seconds following 72 hours of inactivity. Post Purge Zone #1 ON / OFF: When post purge is ON, Zone 1 pump continues operating for 2 minutes after the priority zone is switched OFF. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply 23 24 B4 - Mod/con boiler with warm weather shut down, hydro separator or buffer tank, zone pumps Pump 1 Pump 2 Pump 3 Pump 4 Bu er tank- Optional hydraulic separator Boiler with outdoor reset/ warm weather shut down and pump control AUX XX ZONE 1 E / S Boiler Pump Output 120VAC TRANSFORMER R WC R WC R WC R WC T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE#1 ON ZSR104 4 Zone DP COMMS SLAVE OFF OFF OFF OFF POWER ZONE1 ZONE2 ZONE3 ZONE4 L N POWER IN LN GROUNDS REMOTE ENABLE 24 - 120 VAC LN PRIORITY PUMP 1 LN PUMP 2 LN PUMP 3 LN PUMP 4 LN PRIMARY PUMP LN STATUS DURING PRIORITY O N O F F Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Dip switch description Master / Slave: allows for unlimited expansion to additional ZVR or ZSR relays. Only one Master. Priority ON / OFF: When priority switch is ON, upon demand to TSTAT 1, ZONE 1 will operate as priority and all other zones are temporarily switched off (with 1 hour time-out). When priority is OFF, any zones that were active when ZONE 1 was switched on will remain on. Remote Enable ON / OFF: When remote enable mode is ON, the board will hold off all zones waiting for an external 24 - 120 VAC voltage from the boiler. Exercise ON / OFF: When exercise mode is ON, each circulator is switched on for 30 seconds following 72 hours of inactivity. Post Purge Zone #1 ON / OFF: When post purge is ON, Zone 1 pump continues operating for 2 minutes after the priority zone is switched OFF. Sequence of Operation / Settings · Master / Slave switch: Master · Priority Switch: OFF · Remote Enable Switch: ON · Exercise Switch: ON · Post Purge Zone 1 Switch: OFF · Status During Priority Jumper: OFF · A demand occurs from any thermostat closing R to W. · ZSR control closes XX contacts to signal the boiler of a demand. Boiler receives demand and fires. Boiler control sends 120 VAC to boiler pump output. · ZSR control receives 120 VAC at REMOTE ENABLE terminals from boiler pump output. The "PUMP ON" LED illuminates for the corresponding zone. ZSR control sends 120 VAC to corresponding zone pumps and the primary pump output. · NOTE: Boilers equipped with a warm weather shutdown feature will not power the boiler pump output if outdoor temperature is above the warm weather shutdown setpoint. In this case the ZSR control will not receive 120 VAC at the REMOTE ENABLE terminals. Without power (24 120 VAC) at the REMOTE ENABLE terminals the ZSR control will not send 120 VAC to any pumps wired to the ZSR control. · NOTE: The REMOTE ENABLE terminals are only using the power applied to them as a signal to allow the pumps wired to the ZSR control to operate. The power applied to the REMOTE ENABLE terminals is not used to power any of the pumps wired to the ZSR control. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · When the demand from the last thermostat calling is satisfied (thermostat opens R to W), the XX contacts are opened and the "PUMP ON" LED turns off. The 120 VAC to the zone pump and primary pump outputs are dropped. 25 Certified to CSA C22-2 No.24 Conforms to UL Standard 873 4009064 26 ZVR10X - Multi-Zone Valve Control Overview · Compatible with low voltage 2, 3, or 4 wire thermostats · R, W, C and TT Comm dual labeling at thermostat terminals · Z-oneLink unlimited zone expansion · Selectable priority with 1 hour time-out feature · System pump and Secondary pump status selectable during priority · Pumps will start only after the zone valve end switch is closed · Dry contacts (XX, AUX, ZONE 1 E/S) capable of switching line voltage · Large terminal connections · High capacity 40 VA transformer standard for 3 and 4 zone models-expandable to 80 VA, and 80 VA for the 6 zone model · Automatic resettable fuse · Controls system pump, secondary pump, and zone #1 pump · Front LED Lights · 100% Factory tested with 3 year warranty · ETL approved See technical brochure 01285 NA for more product information. AUX closes on a demand for heat from any zone. Rated for 120 VAC 2 Amps. X X closes on a demand for heat from any zone. Rated for 120 VAC 2 Amps. ZONE1 /ES closes only during a demand from zone 1. Rated for 120 VAC 2 Amps. Dip switches Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. 3 wire communications to expansion board. Power ON LED. Transformer connections. 120 VAC input power connection. 120 VAC output to pumps. System pump (boiler pump) status during priority can be changed with jumper. ZONE #1 priority. LED illuminates when end switch closes. LED illuminates with call for heat. Zone valve motor connections. Zone valve end switch connection. 27 Cover removal 28 Hold either the left or the right end of the box up and at an angle. Use body for stabilizing relay box. Transformer Installation Insert screwdriver and push tab inward, cover should release from base. Roll cover off base. Mount box on stable surface using level. Remove transformer(s) from packaging. Slide bottom end of transformer into bottom latch. Snap top of transformer into latch arms. Mounting: Do not mount to a surface that exceeds 115°F (45°C). The unit must be only located in dry interior locations. Use only copper conductor supply wire suitable for at least 105° C. All circuits must have a common disconnect and be connected to the same pole of the disconnect. It is not suitable for installation in hazardous locations. Feed wiring through hole near the top of the transformer and insert transformer plug into the socket. Repeat process for 2nd transformer if using six valve relay box. AUX ON E / S OFF DURING PRIORITY DEMAND T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-SZTOANTE4 Maintenance and Repair: The Caleffi Z-oneTM multi-zone valve relay comes with a automatic resettable fuse and requires no maintenance. If control fails or is damaged, replace control with functional one. Thermostat connections ZVR106 6 Zone R = 24 VAC. W = Heat call C = Common of 24 VAC ZONE ZONE Boiler connections: XX = Dry contact rated up to 120 VAC, 2 Amps, which AUXAXUXX X X ZONE 1 ZONE 1 R W RC WR WC CR RW WC CHReatR dWemWaCndC isRRinitWiaWtedCCby cRRlosinWWg RZCCONER E / S E / S T T CTOM TT COTMCOTM T T CTOMCOtoMTWT. T TCOCMOM T T TT CCOOMM TT TT CCOOMM T is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = AUX XX ZONE 1 E / S Dry contact rated up to 120 VAC, 2 Amps, will close STATUS DURING with any call to ZONE 1. Zone 1 can be enabled as a prioriZtyOzNoEn#e1,DtyEpMicAaNlDly used for a DHW heating contact domestic on boiler hot water. The ZONE 1 controls equipped with Eth/SesecafneabtON uereuss. eAOFFdUtXoON close = Dry O F F ZSR106 TRT-TS-TSTAWTRTTAAT1TNC-OCSS1MFTTOA-RRTSTTMT-1SAETTWRTA2TTC-OC2SMTT-ASRTTTTA-2STTWT2&3A4CTTC-.VOC3STAM-TCSATRTTTiAs-T3Sa4TlWwTAaTTyCs-TOC4S-MpSTrTAeAsRTTTeT-n4S5tTWTbAeMTTtCTAw-O-C5STSSeMT-TeTESnRAAARTTTTRZ-65OSNTWTAETVTC Zone valve connectionMsASTER SLAVE PRIORITYCOANLL PUMP EXERCISE ON 6 Zone MotoOr F=F 24 VAC tRoEMpOoTwEeErNtAhBeLEzOoNnMeASTER contact, rated up to 120 VACPO, W2 EARmIpNs, close whZeOnNaEn#y1zone cSaElCls and cSaYnSTbEeM used as signal to a variablLe speeNd self regulated pLPuUmMpPNor othLPeUr McPoNntrols.LPUMPN Communication connections: AUX X X Connect terminals toZOmNEa1tching terminRal oWf slavCe boRardsW C R W C R W CD tRo DW, P Cto RP, GWEro/ uS Cnd tRo GWrounTCd. URTseCWO1M8 CgTaugeT COMD T P T COM T ZONE 1 ZPORNIOER2ITY ON ZONEv3alveOmFFotZoOr NE 4 ZEOXNEREC5ISPEROIONRITZYOONNE 6 MOTOR END SWITCH MOTOR END SWAITUCXHOMNOTOR SWEENInTDCdHSOMwFOFitTcOhR =SCWEPNIoTODnCSnHTePMcUOtRsTGOtRoEREZeMOSnWONEdETNIT#EsDC1wHEOiNtNMcAOhBTLOERONSWE WC R T COM T WC T COM R T DUWRTINCGOCPMRIORITouYsnDinzEgoMnaAeDN2DCvOawlMvPierMe. SzoMnuesPtvOabSlveTe.PjuUmRpGEeEXreZEOdRNCiEfIS#E1 ON ON T COMtherTmosTtatCOwMireTandTit CsOhMoulTd beT sChOTieM-ldSeTTdATif T1locCaOtMeTd-SinTAT 2TRACNTO-MSSMFTOSARTM3ER T-STIAnTpu4t poTw-SerTAT 5 T-STAT 6 STAT 2closTe-SpTroAxTim3ity tTo-hSiTgAhTvo4ltagTe-wSTirAinTg 5 T-STAT 6 The ZVR series of controls is programmed by the dip switches MASTER MASTER SLTAVREANSFSOLARVMEPEORWER which can be positioned for thePRIORITY ON OFF PUMP EXERCISE ON OFF POWER IN LN REMOTELENA=BLELinePR(hIOoRtITleYg) of 120 VAC supply ZSR106 ZV6 RZo1n0e6 6 Zone GROUNDS 24 L 12N0 VN==ACGNreouutPLrnUadlMsoPfN1P1O20WVPLEUARMCP 2 N PUMP 3 LN PUM L ZSR106 following operations. REMOTE ENABLE ON OFF Master / Slave: allows for unlimitedEXERCISE OPNRIORITY ON OFF ZONE1 OFF Pump outputs 6 Zone ZONE 1 expansion to additional ZVRPOoSTr PZUSRRGE ZONE#1 ON AUX ON OFF relays. OFF ZONE2 STATUS DURING SYSTEM PUMP = Runs when any zone calls for heZatO. NE 2 Pump Exercise ON / OFF: When exercise mode is ON, each circulator DURING PRIORITY DEMAND POWER IN ZONE3 GROUNDS REMOTE ENABLE 24 - 120 VAC O N ZONE #1 DEMAND PRIORO ITY PUMPFF 1 O N O PUMP F F 2 SEC PUMP = Runs when any zone PR PcUaMllsP f3or hePaUt.MP 4ZONEPU3MP 5 PUMP 6 P is switched ZSR106 ZVR106 Priority ON / on for 30 OFF: When seconds following 72 hoursLof inaNctivity. priority switch is ON, upon demand, PZOonWeER1 IwZNOill NE4 opera6te Zasopnrieority and all 6 Zone time-out). When priority is other zones are temporarily OFF, any zones that were switched oLff (withN1 activPeOwWhEeRnINZone 1 hwGoZRauOOsrNUNED5S LN L N L N LZONNE 1 PLUMPN = RLuns wN hen LzoneN1 L ZONE #1 SEC SYSTEM PUMP PUMP PUMP L REMOTNE L ENABLE PRNIORITYL N 24 - 120 VAC PUMP 1 PUMP 2 tehMneOdrTmOZsORowsNitStEacWEth1NITDcChaHallssMZOOcfoTloONZr sOREehNdeSE4a.WE2tNITDaCAHndjuMmOzTopOZneORer NSi1EsWE3NITDCH requPirUeMdP b3etwePeUnMPth4e ZOPNUEMP15 ENDPUMP M 6 switched on will remain on. LN ZONE6 LN L N L N SWITLCH tNerminaLZlsOwNhENe5n usLing aNpumpL N AUX ON / OFF During Priority Demand: When AUX switch is ON, the AUX for ZONE 1 instead of a zone valve. dry contacts will close during a priority demand. When switch is OFF, the AUX dry contacts will remain open during a priority demand. STATUS DURING ZONE 1 DEMAND ON / OFF = ZWOhNenE s6tatus jumper is placed on ON pins, the secondary and / or system pump will continue to ORITY MP 1 N STATUS DURING WARNING: NEVER CONNECT R & CZDOIRNEEC#TL1YD, EthMisAPwNRilIDlMbAeRaYdirect shoSrTtAoTnUtShe 24 PUMP 2 LN PVUAMCPsu3pply. PUMP 4 L N L N PUMP 5 L N O N PUMPO 6 L FN F O N PUMO P L FN F POWER IN ZONE #1 SEC SYSTEM DURING PRIORITY O N O F F L WARNING: When connPeUcMtinPg 2 Nby the same 120 VACLcircuit.N or moPrUe MZ-Pone LN contrPolUs,MaPll controls LN must ZbOe NpEow1ered END operate during ZONE 1 demand. When jumperTi-sSpAlTaced oVnAOLVFFE pins, the corresponding pump will be OFF during ZONE 1 dCeAmLaLnd. OPEN ZONE 2 END ZONE 3 END ZONE 4 END ZONE 5 END ZONE 6 END 29 MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH C1 - Mod/Con boiler, hydro separator, zone valves mod/con boiler SYSTEM pump ZV1 ZV2 ZV3 ZV4 ZV5 ZV6 SECONDARY pump L N AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH SYSTEM pump SECONDARY pump Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. ZV1 ZV2 ZV3 ZV4 ZV5 ZV6 30 Description of terminals Sequence of Operation / Settings = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals · Master / Slave switch: Master · Pump Exercise: OFF · Priority: OFF R = 24 VAC · AUX During Priority Demand: OFF W = Heat call C = Common of 24 VAC · System Pump Status During Zone 1 Demand Jumper: OFF Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler · Sec Pump Status During Zone 1 Demand Jumper: OFF · A demand occurs from any thermostat closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. controls equipped with these features. · When the zone valve end switch closes, AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the XX contacts to signal the boiler of a demand. SYSTEM PUMP = Runs when any zone calls for · When the thermostat demand is satisfied R heat. to W will open and the "T-STAT CALL" and SEC PUMP = Runs when any zone calls for heat. "VALVE OPEN" LEDs will turn off. 24 VAC is ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. dropped to the corresponding zone MOTOR terminals. A jumper is required between the ZONE 1 END · If no other zones are calling for heat the XX SWITCH terminals when using a pump for ZONE contacts will open terminating the demand for 1 instead of a zone valve. heat to the boiler. The 120 VAC is dropped to STATUS DURING ZONE 1 DEMAND ON / OFF: the SYSTEM PUMP and SEC PUMP. When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone WARNING: NEVER CONNECT R & C DIRECTLY, valve. Must be jumped if using a 2wire zone valve. this will be a direct short on the 24 VAC supply 31 C2 - Mod/Con boiler, priority indirect DHW on primary side of hydro sep, zone valves mod/con boiler DHW aquastat DHW PRIORITY pump SYSTEM pump ZV2 ZV3 ZV4 ZV5 ZV6 SECONDARY pump DHW AQUASTAT Bu er tank- Optional hydraulic separator L N AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH DHW PRIORITY pump SECONDARY pump ZV2 ZV3 ZV4 ZV5 ZV6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. SYSTEM pump 32 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings · Master / Slave switch: Master · Pump Exercise: OFF · Priority: ON · AUX During Priority Demand: OFF · System Pump Status During Zone 1 Demand Jumper: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · A demand occurs from a thermostat on zones 2-6 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the X X contacts to signal the boiler of a demand. · When the thermostat demand is satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. · If no other zones are calling for heat the X X contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. · If a demand occurs from the DHW aquastat (T-STAT 1), the "T-STAT CALL" and the "VALVE OPEN" LEDs illuminate for zone 1. (When using a pump for zone 1 instead of a zone valve a jumper must be installed on the ZONE 1 END SWITCH terminals.) WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · If any other zone was calling for heat (zones 2-6) when zone 1 is calling 24 VAC is dropped to those zone's MOTOR terminals. The "T-STAT CALL" and "VALVE OPEN" LED will also turn off. · The XX and the ZONE 1 E/S contacts close to signal a DHW demand to the boiler. · The ZONE 1 PUMP output delivers 120 VAC. · 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. · Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to ZONE 1 PUMP is dropped. The ZONE 1 E/S and X X contacts open. · If a call for heat exists from zones 2-6 the corresponding "T-STAT CALL" will illuminate again and 24 VAC will be delivered to their zone MOTOR terminals. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the X X contacts to signal the boiler of a demand. · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The X X contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. DHW Time Out \ Freeze Prevention Feature · After one hour of a priority demand, the control will open the ZONE 1 E/S contacts and drop power to ZONE #1 PUMP and ZONE 1 MOTOR terminals. · If a call for heat exists from zones 2-6, the control will satisfy those demands before going back to the priority demand. · After zones 2-6 have been satisfied, the control will go back to the priority demand and reset the one hour timer. 33 C3 - Mod/Con boiler, priority indirect DHW on load side of hydro sep, zone valves Bu er tank- optional hydraulic separator ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM pump DHW AQUASTAT SECONDARY pump DHW PRIORITY pump DHW AQUASTAT L N AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER ZONE #1 PUMP LN MASTER PUMP EXERCISE ON SLAVE OFF ZONE 1 ZONE 2 PRIORITY ON AUX ON OFF OFF DURING PRIORITY DEMAND ZONE 3 ZONE 4 STATUS DURING ZONE #1 DEMAND O N O F F O N O F F ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN SEC PUMP LN SYSTEM PUMP LN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH SECONDARY pump DHW PRIORITY pump ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM pump Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. 34 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings · Master / Slave switch: Master · Pump Exercise: OFF · Priority: ON · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: ON · A demand occurs from a thermostat on zones 2-6 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the XX contacts to signal the boiler of a demand. · When the thermostat demand is satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. · If no other zones are calling for heat the XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. · If a demand occurs from the DHW aquastat (T-STAT 1), the "T-STAT CALL" and the "VALVE OPEN" LEDs illuminate for zone 1. (When using a pump for zone 1 instead of a zone valve a jumper must be installed on the ZONE 1 END SWITCH terminals.) WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · If any other zone was calling for heat (zones 2-6) when zone 1 is calling 24 VAC is dropped to those zone's MOTOR terminals. The "T-STAT CALL" and "VALVE OPEN" LED will also turn off. · The XX and the ZONE 1 E/S contacts close to signal a DHW demand to the boiler. · The ZONE 1 PUMP and SYSTEM PUMP outputs deliver 120 VAC. · 120 VAC is dropped to the SEC PUMP. · Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to ZONE 1 PUMP and SYSTEM PUMP is dropped. The ZONE 1 E/S and X X contacts open. · If a call for heat exists from zones 2-6 the corresponding "T-STAT CALL" will illuminate again and 24 VAC will be delivered to their zone MOTOR terminals. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the XX contacts to signal the boiler of a demand. · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. DHW Time Out \ Freeze Prevention Feature · After one hour of a priority demand, the control will open the ZONE 1 E/S contacts and drop power to ZONE #1 PUMP and ZONE 1 MOTOR terminals. · If a call for heat exists from zones 2-6, the control will satisfy those demands before going back to the priority demand. · After zones 2-6 have been satisfied, the control will go back to the priority demand and reset the one hour timer. 35 36 C4- Mod/Con boiler, priority indirect DHW on primary side of hydro sep, expansion control NOTE: 120 VAC is only sent to the SEC PUMP terminals on the control that receives the call for heat. For instance, if a zone from the Master control calls, the SEC PUMP on the Master control sends 120 VAC and SEC PUMP on the Slave control does not. When using a single secondary pump with 2 (or more) controls you must wire the secondary pump to the SEC PUMP terminals on all of the controls. Bu er tank - optional hydraulic separator DHW AQUASTAT DHW PRIORITY pump SYSTEM pump DHW AQUASTAT ZV2 ZV3 ZV4 ZV5 ZV6 ZV7 ZV8 ZV9 ZV10 ZV11 ZV12 SECONDARY pump AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER ZONE #1 PUMP LN MASTER PUMP EXERCISE ON SLAVE OFF ZONE 1 ZONE 2 PRIORITY ON AUX ON OFF OFF DURING PRIORITY DEMAND ZONE 3 ZONE 4 STATUS DURING ZONE #1 DEMAND O N O F F O N O F F ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN SEC PUMP LN SYSTEM PUMP LN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH L N DHW PRIORITY SYSTEM pump pump ZV2 ZV3 ZV4 ZV5 ZV6 AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER ZONE #1 PUMP LN MASTER PUMP EXERCISE ON SLAVE OFF ZONE 1 ZONE 2 PRIORITY ON AUX ON OFF OFF DURING PRIORITY DEMAND ZONE 3 ZONE 4 STATUS DURING ZONE #1 DEMAND O N O F F O N O F F ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN SEC PUMP LN SYSTEM PUMP LN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH ZV7 ZV8 ZV9 ZV10 ZV11 ZV12 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. SECONDARY pump Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings Control #1 · Master / Slave switch: Master · Pump Exercise: OFF · Priority: ON · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: OFF Control #2 · Master / Slave switch: Slave · Pump Exercise: OFF · Priority: OFF · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: OFF · A demand occurs from a thermostat on zones 2-12 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. The Master ZVR control sends 120 VAC to SYSTEM PUMP and the control (Master or Slave) which received the call for heat will send 120 VAC to its SEC PUMP. The Master control will close the XX contacts to signal the boiler of a demand. · When the thermostat demand is satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · If no other zones are calling for heat the XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. · If a demand occurs from the DHW aquastat (T-STAT 1), the "T-STAT CALL" and the "VALVE OPEN" LEDs illuminate for zone 1. (When using a pump for zone 1 instead of a zone valve a jumper must be installed on the ZONE 1 END SWITCH terminals.) · If any other zone was calling for heat (zones 2-12) when zone 1 is calling 24 VAC is dropped to those zone's MOTOR terminals. The "T-STAT CALL" and "VALVE OPEN" LED will also turn off. · The XX and the ZONE 1 E/S contacts on the Master control close to signal a DHW demand to the boiler. · The ZONE 1 PUMP output on the Master control delivers 120 VAC. · 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP on all controls. · Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to ZONE 1 PUMP is dropped. The ZONE 1 E/S and X X contacts open. · If a call for heat exists from zones 2-12 the corresponding "T-STAT CALL" will illuminate again and 24 VAC will be delivered to their zone MOTOR terminals. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control #1 sends 120 VAC to SYSTEM PUMP and the corresponding control SEC PUMP outputs. The Master control will close the XX contacts to signal the boiler of a demand. · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP on all controls. 37 ZV2 ZV3 ZV4 ZV5 ZV6 C5 - Traditional boiler, indirect DHW (no priority) with pump, zone valves SYSTEM pump DHW PRIORITY pump DHW aquastat DHW aquastat TT DHW outdoor temperature sensor AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH L N DHW PRIORITY pump Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. SYSTEM pump ZV2 ZV3 ZV4 ZV5 ZV6 38 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings · Master / Slave switch: Master · Pump Exercise: OFF · Priority: OFF · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · A demand occurs from a thermostat on zones 2-6 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP output. The control will close the XX contacts to signal the boiler of a demand. · If a demand occurs from the DHW aquastat (T-STAT 1), the "T-STAT CALL" LED and the "VALVE OPEN" LED will illuminate for zone 1. (When using a pump for zone 1 instead of a zone valve a jumper must be installed on the ZONE 1 END SWITCH terminals.) ZVR control sends 120 VAC to the ZONE #1 PUMP. The XX and ZONE 1 E/S contacts close to signal a DHW demand to the boiler. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · NOTE: At this point, the control has signaled the boiler of a DHW demand which (in most cases) will override any outdoor reset controls and raise the temperature of the boiler. Because priority is not enabled on the control, you will now be allowing high temperature fluid to zones 2-6. Be certain that these zones are capable of handling this high temperature fluid. If not, priority will need to be enabled to hold off zones 2-6 during a demand from the DHW aquastat. · When the thermostat demands from zones 2-6 are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. · If the DHW aquastat (T-STAT 1) is still calling for heat the XX and ZONE 1 E/S contacts will remain closed and the ZONE #1 PUMP will remain powered. 120 VAC will be dropped to the SYSTEM PUMP. (This is due to the jumper position of the SYSTEM PUMP for STATUS DURING ZONE #1 DEMAND.) · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The XX and ZONE 1 E/S contacts will open terminating any demands to the boiler. The 120 VAC is dropped to all of the pump outputs (SYSTEM PUMP and ZONE #1 PUMP). 39 ZV2 ZV3 ZV4 ZV5 ZV6 C6- Traditional boiler with priority indirect DHW with valve, zone valves SYSTEM pump DHW ZV1 DHW aquastat DHW aquastat AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH L N Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. SYSTEM DHW ZV1 ZV2 ZV3 ZV4 ZV5 ZV6 pump 40 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation · Master / Slave switch: Master · Pump Exercise: OFF · Priority: ON · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: ON · A demand occurs from a thermostat on zones 2-6 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP output. The control will close the XX contacts to signal the boiler of a demand. · When the thermostat demand is satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. · If no other zones are calling for heat the XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP. · If a demand occurs from the DHW aquastat (T-STAT 1), the "T-STAT CALL" LED illuminates for zone 1. · ZVR control sends 24 VAC to ZONE 1 MOTOR terminals. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · When the ZONE 1 zone valve end switch closes, the "VALVE OPEN" LED illuminates for ZONE 1. · If any other zone was calling for heat (zones 2-6) when zone 1 is calling 24 VAC is dropped to those zone's MOTOR terminals. The "T-STAT CALL" and "VALVE OPEN" LED will also turn off. · The XX contacts close to signal a demand to the boiler. · The SYSTEM PUMP output delivers 120 VAC. · Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to the SYSTEM PUMP is dropped. The XX contacts open. · If a call for heat exists from zones 2-6 the corresponding "T-STAT CALL" will illuminate again and 24 VAC will be delivered to their zone MOTOR terminals. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the XX contacts to signal the boiler of a demand. · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. DHW Time Out \ Freeze Prevention Feature · After one hour of a priority demand, the control will drop power to the ZONE 1 MOTOR terminals. · If a call for heat exists from zones 2-6, the control will satisfy those demands before going back to the priority demand. · After zones 2-6 have been satisfied, the control will go back to the priority demand and reset the one hour timer. 41 C7 - Mod/Con boiler, hydro separator, zone valves (more than 6), multiple secondary pumps 42 SYSTEM pump "A" pump A1 A2 A3 A4 A5 A6 "B" pump A7 A8 A9 A10 A11 A12 AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER ZONE #1 PUMP LN MASTER PUMP EXERCISE ON SLAVE OFF ZONE 1 ZONE 2 PRIORITY ON AUX ON OFF OFF DURING PRIORITY DEMAND ZONE 3 ZONE 4 STATUS DURING ZONE #1 DEMAND O N O F F O N O F F ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN SEC PUMP LN SYSTEM PUMP LN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH L N SYSTEM pump "A" pump A1 A2 A3 A4 A5 A6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH "B" pump A7 A8 A9 A10 A11 A12 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings Control #1 · Master / Slave switch: Master · Pump Exercise: OFF · Priority: OFF · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: OFF Control #2 · Master / Slave switch: Slave · Pump Exercise: OFF · Priority: OFF · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: OFF · A demand occurs from a thermostat on zones 1-12 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. The Master ZVR control sends 120 VAC to SYSTEM PUMP and the control (Master or Slave) which received the call for heat will send 120 VAC to its SEC PUMP. The Master control will close the XX contacts to signal the boiler of a demand. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · NOTE: 120 VAC is only sent to the SEC PUMP terminals on the control that receives the call for heat. For instance, if a zone from the Master control calls, the SEC PUMP on the Master control sends 120 VAC and SEC PUMP on the Slave control does not. · When the thermostat demand is satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. · If no other zones are calling for heat the XX contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP. 43 C8 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves, ECM pump enable 44 mod/con boiler DHW aquastat DHW PRIORITY pump SYSTEM pump ZV2 ZV3 ZV4 SECONDARY pump DHW AQUASTAT NOTE: The AUX contact status during priority demand from Zone 1 can be changed using the dip switch. L N AUX XX ZONE 1 E / S R WC R WC R WC R WC T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 POWER IN LN MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR104 4 Zone ZONE 1 ZONE 2 ZONE 3 ZONE 4 END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH DP COMMS POWER ZONE 1 ZONE 2 ZONE 3 ZONE 4 T-SAT CALL VALVE OPEN DHW PRIORITY pump NOTE: ECM seconday pump requires power at all times and a dry contact closure to start. SECONDARY pump Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. SYSTEM pump ZV2 ZV3 ZV4 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings · Master / Slave switch: Master · Pump Exercise: OFF · Priority: ON · AUX During Priority Demand: OFF · System Pump Status During Zone 1 Demand Jumper: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · A demand occurs from a thermostat on zones 2-6 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP output. The control will close the XX contacts to signal the boiler of a demand and close the AUX contacts to signal the ECM pump to start. · When the thermostat demand is satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. · If no other zones are calling for heat the XX contacts will open terminating the demand for heat to the boiler. The AUX contacts will also open terminating the demand to the ECM pump. The 120 VAC is dropped to the SYSTEM PUMP. · If a demand occurs from the DHW aquastat (T-STAT 1), the "T-STAT CALL" and the "VALVE OPEN" LEDs illuminate for zone 1. (When using a pump for zone 1 instead of a zone valve a jumper must be installed on the ZONE 1 END SWITCH terminals.) · If any other zone was calling for heat (zones WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply 2-6) when zone 1 is calling 24 VAC is dropped to those zone's MOTOR terminals. The "T-STAT CALL" and "VALVE OPEN" LED will also turn off. The AUX contacts will also open terminating the demand to the ECM pump. · The XX and the ZONE 1 E/S contacts close to signal a DHW demand to the boiler. · The ZONE 1 PUMP output delivers 120 VAC. · 120 VAC is dropped to the SYSTEM PUMP. · Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to ZONE 1 PUMP is dropped. The ZONE 1 E/S and XX contacts open. · If a call for heat exists from zones 2-6 the corresponding "T-STAT CALL" LED will illuminate again and 24 VAC will be delivered to their zone MOTOR terminals. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP output. The control will close the XX contacts to signal the boiler of a demand and close the AUX contacts to signal the ECM pump to start. · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The XX contacts will open terminating the demand for heat to the boiler. The AUX contacts will also open terminating the demand to the ECM pump. The 120 VAC is dropped to the SYSTEM PUMP. DHW Time Out \ Freeze Prevention Feature · After one hour of a priority demand, the control will open the ZONE 1 E/S contacts and drop power to ZONE #1 PUMP and ZONE 1 MOTOR terminals. · If a call for heat exists from zones 2-6, the control will satisfy those demands before going back to the priority demand. · After zones 2-6 have been satisfied, the control will go back to the priority demand and reset the one hour timer. 45 C9 - Mod/Con boiler, hydro separator, Zone 1 low temp pump, zones 2 - 6 high temp zone valves 46 mod/con boiler ZONE 1 Pump ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM pump SECONDARY pump L N AUX XX ZONE 1 E / S POWER IN LN R WC R WC R WC R WC R WC R WC T T COM T T COM T T COM T T COM T T COM T T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 DP COMMS POWER MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE #1 PUMP LN STATUS DURING ZONE #1 DEMAND O N O F F O N O F F SEC PUMP LN SYSTEM PUMP LN ZVR106 6 Zone ZONE 5 ZONE 6 T-SAT CALL VALVE OPEN ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 END END END END END END MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH ZONE 1 Pump SYSTEM pump SECONDARY pump Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. ZV2 ZV3 ZV4 ZV5 ZV6 Description of terminals = Ground N = Neutral (Common leg of 120 VAC) L = Line (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically connected to TT on boiler control, closes when any zone calls including priority. ZONE 1 E/S = Dry contact rated up to 120 VAC, 2 Amps, will close with any call to ZONE 1. Zone 1 can be enabled as a priority zone, typically used for heating domestic hot water. The ZONE 1 E/S can be used to close a DHW contact on boiler controls equipped with these features. AUX = Dry contact, rated up to 120 VAC, 2 Amps, close when any zone calls and can be used as signal to a variable speed self regulated pump or other controls. Pump terminals SYSTEM PUMP = Runs when any zone calls for heat. SEC PUMP = Runs when any zone calls for heat. ZONE 1 PUMP = Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed. A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve. STATUS DURING ZONE 1 DEMAND ON / OFF: When status jumper is placed on ON pins, the secondary and / or system pump will continue to operate during Zone 1 demand. When jumper is placed on OFF pins, the corresponding pump will be OFF during Zone 1 demand. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumped if using a 2wire zone valve. Sequence of Operation / Settings · Master / Slave switch: Master · Pump Exercise: OFF · Priority: OFF · AUX During Priority Demand: OFF · Sec Pump Status During Zone 1 Demand Jumper: OFF · System Pump Status During Zone 1 Demand Jumper: ON · A demand occurs from a thermostat on zones 2-6 closing R to W. The "T-STAT CALL" LED illuminates for the corresponding zone. · ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. · When the zone valve end switch closes, the "VALVE OPEN" LED illuminates for the corresponding zone. ZVR control sends 120 VAC to SYSTEM PUMP and SEC PUMP outputs. The control will close the XX contacts to signal the boiler of a demand. · If a demand occurs from the thermostat on zone 1 closing R to W. The "T-STAT CALL" LED and the "VALVE OPEN" LED will illuminate. (When using a pump for zone 1 instead of a zone valve a jumper must be installed on the ZONE 1 END SWITCH terminals.) ZVR control sends 120 VAC to the ZONE #1 PUMP. · When the thermostat demands from zones 2-6 are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. 24 VAC is dropped to the corresponding zone MOTOR terminals. WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC supply · If zone 1 thermostat is still calling for heat the XX contacts will remain closed and the SYSTEM PUMP and the ZONE #1 PUMP will remain powered. 120 VAC will be dropped to the SEC PUMP. (This is due to the jumper position of the SEC PUMP for STATUS DURING ZONE #1 DEMAND.) · When all the thermostat demands are satisfied R to W will open and the "T-STAT CALL" and "VALVE OPEN" LEDs will turn off. The X X contacts will open terminating the demand for heat to the boiler. The 120 VAC is dropped to all of the PUMP outputs (SYSTEM PUMP, SEC PUMP and ZONE #1 PUMP). 47 48 Caleffi North America, Inc. / 3883 W Milwaukee Rd / Milwaukee, WI 53208 Tel: 414.238.2360 / Fax: 44.238.2366 www.caleffi.com / Ask.Us@caleffi.com ©Copyright 2016 Caleffi North America, IncAdobe PDF Library 10.0.1 Adobe InDesign CS6 (Windows)