WIRING GUIDE. Form rev.1. Certified to CSA C22-2 No.24 Conforms to UL Standard 873

Transcription

1 WIRIG GUIDE The ZSR101 is a versatile single relay control with two outputs for operating a 120 VAC 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 operation, and 10 amp total load rating. The ZSR Series of controls is for zoning using s. Up to 6 zone s (model dependent) along with a primary can be operated. Zone priority is selectable with 1-hour time-out feature. Other features include exercising, selectable post purge, and 3 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, secondary (s), and primary can be operated. Zone priority is selectable with 1-hour time-out feature. System 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 o.24 Conforms to U Standard 873 Form rev.1

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3 IDEX Z-one Relay thermostat connections Thermostat wiring... 3 ZSR101 - single zone relay Product overview... 4 Operation and cover removal...5 A1 - Single thermostat...6 A2 - Multiple thermostats...8 A3 - Single master thermostat, with TRVs, variable speed ZSR103, ZSR104 & ZSR106 - multi-zone relay Product overview Circuit board Cover removal Product details B1 - Mod/Con boiler, hydro separator or buffer tank, zone s B2 - Traditional boiler, indirect w/ priority, zone s B3 - Mod/Con boiler, primary loop, closely spaced tees, zone s ZVR103, ZVR104 & ZVR106 - multi-zone valve control Product overview Circuit board Cover removal, Transformer Installation...24 Product details C1 - Mod/Con boiler, hydro separator, zone valves C2 - Mod/Con boiler, indirect on primary side of hydro sep, zone valves C3 - Mod/Con boiler, indirect on load side of hydro sep, zone valves C4 - Mod/Con boiler, indirect on primary side of hydro sep, master and slave control C5 - Traditional boiler, indirect (no priority) with valve C6 - Traditional boiler with reset control, priority indirect with valve C7 - Mod/Con boiler, hydro separator, zone valve (more than 6), multiple secondary s Caleffi shall not be liable for damages resulting from misapplication or misuse of it products. 3

4 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. Z-one T-stat interface R W C T T COM T-STAT 1 R W C R W C R W C R W C R W C R W CTHM 1 R W C RX X W C R W R W C W C D P T T COM T T COM T T COM T T COM T T COM T T COM T T COM T THM T 1COM THM T 2 T THM COM3 T THM T4 COMTHM 5 THM 6COMMS T-STAT 2 T-STAT 3 T-STAT 4 Description TRASFORMER 12/20VA R = 24 VAC Supply W = Heat Call ER C = 24 VAC Common POWER I Function GROUDS ZSR106 R&W: When connected, signals a heat demand. R&C: Provides 24 VAC to powered thermostats. 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. C R Rh W1 R W C R W C R W C R W C R W C R W C D P X X T T COM T T COM T T COM T T COM T T COM T T COM COMMS D THM P 2 THM 3 THM 4 THM 5 THM 6 PWR T T COM COMMS T-STAT 5 T-STAT 6 3-Wire Thermostats TRASFORMER DipSwitches Master Slave Three wire thermostats Priority OFF 12/20VA get Priority O their power from the Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O control Z6P they are connected to. R & C from the DipSwitches Z-one Control supply 24 VAC to the thermostat at all times while the W lead signals a heat demand. Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O POWER I Post Purge OFF Post Purge O GROUDS 6 PRIMARY 1 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. PWR ZOE1 Dry Contacts DipSwitches ZOE1 ZOE2 Master Slave A heat demand Priority OFF can Priority O also be initiated by any type Primary OFF Primary O Exercise OFF Exercise O ZOE3 of device that Post Purge OFF has Post dry Purge Ocontacts (dry contacts are Z6P ZOE2 a set of contacts that open and close but do not ZOE4 have any voltage present until supplied from an ZOE5 outside source). The end switch on a Z-one series ZOE3 zone valve is an example of a dry contact. Using ZOE6 PRIMARY a dry 3 contact 4 to connect 5 6 R to W will initiate a heat ZOE4 demand. 2 ZOE5 PWR ZOE1 ZOE2 ZOE3 ZOE4 ZOE5 ZOE6 ROUDS WARIG: EVER COECT R & C DIRECTY, R W C this will be a direct short X Xon the 24 VAC supply T T COM THM THM 2 THM 3 THM Z6P SAFETY ISTRUCTIO TRASFORMER This safety alert symbol will 12/20VA be used in this manual to draw attention to safety related instructions. When used, the safety alert symbol means ATTETIO! BECOME AERT! YOUR SAFETY IS IVOVED! FAIURE TO FOOW THESE ISTRUCTIOS MAY RESUT I A SAFETY HAZARD. CAUTIO: All work must be performed by qualified personnel trained in the POWER I proper application, installation, and maintenance GROUDS of systems 1 in accordance 2 3 with all 4 applicable codes and ordinances. W C X R XW PRIMARY THM 5 THM 6 R W C R W C R W C R W C R C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS THM 1 Master Priority OFF Primary OFF Exercise OFF Post Purge OFF DipSwitches 5 Slave Priority O Primary O Exercise O Post Purge O ZOE6 R W C R W C R W C R W C R W C D P T PWR T COM T T COM T T COM T T COM T T COM COMMS THM 2 THM 3 THM 4 THM 5 THM 6 ZOE1 Always refer to the thermostat manufacturer s instructions. ZOE2 DipSwitches Master Slave TRASFORMER ZOE3 Priority OFF Priority O Primary OFF Primary O 12/20VA CAUTIO: Electrical shock hazard. Disconnect Exercise OFF power Exercise before O installation to prevent Post Purge OFF Post Purge O electrical shock or ZOE4 equipment Z6P damage. Make sure all connections are in accordance with the electrical wiring diagram and in accordance with national and local electrical codes. ZOE5 ZOE6 PRIMARY POWER I CAUTIO: Avoid electrical noise interference. Do not install near large conductors, PRIMARY GROUDS electrical machinery, or welding equipment. Avoid locations where excessive moisture, corrosive fumes, vibration, or explosive vapors are present. P ZO ZO ZO ZO ZO ZO Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.

5 Wiring of 2 wire or 3 zone valve to Caleffi Z-one Relay Wiring a 2 wire zone valve to Caleffi Z-one Relay Wiring a 3 wire zone valve to Caleffi Z-one Relay Since a two wire actuator does not have an end switch for feedback to the relay box, the end switch terminals must have a jumper to simulate R W C D P Xthe Xend swith. If the R end W Cswitch jumper Ris not W Cinstalled, R W no C R W C R W C T T COM T T COM T T COM T T COM T T COM T T COM COMMS demand will be sent to the boiler and the s will not turn on. T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 ZVR106 The Taco 570 zone valve presents a unique wiring challenge. When connecting the Taco 570 zone valve to the Caleffi Z-one Relay, the wiring of this valve can only be done PWR in one way. The left motor terminal on the ZVR series control must be connected to terminal T-STAT 6 2 on the zone valve. The right motor terminal must be connected TSAT1 ZOE1 to terminal 1 on the zone valve. astly, the left end switch terminal T-STAT 5 MASTER SAVE must be connected to terminal 3 on the zone valve. Failure to TSAT2 ZOE2 follow schematic will lead to damage of product. TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 M

6 Certified to CSA C22-2 o.24 Conforms to U Standard 873 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 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 ET certified See technical brochure A for more product information.

7 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 O terminal and switching the on, and the C to O dry R R TW W CT C COM contact on relay #2 closes, T T COM signaling the boiler of a heating demand. PWR R, W, C and T T Comm dual labeling at thermostat terminals. Compatible TRASFORMER with low voltage 2, 3, or 4 wire thermostats or any other low voltage devices having a switching ZOE 1 ZSR101 action. Zone Supply 120 VAC hot to terminal and 120 VAC neutral to. A factory installed jumper from terminal to the 1 C terminal Zone of Relay 1 is supplied for simplified connection. TRASFORMER 6 VA Transformer. PWR ZOE Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Replaceable fuses. POWER I REAY #1 REAY #2 C O C C O C 120VAC input power connection POWER I C REAY #1 O C C REAY #2 If dry contacts are desired from relay #1, remove the factory installed jumper between and C. 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 tab inward. O C Turn box and repeat inserting screwdriver and pushin tab inward on opposite side, cover should release from base. Keyhole mounting which fits a 4X4 junction box. Pre-installed jumper. 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 8 R W C T T com power zone transformer Caleffi! single zone relay REAY 1 REAY 2 C /O /C C /O /C T T Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

9 Description of terminals C O C = Ground = eutral (Common leg of 120 VAC) = ine (live leg of 120 VAC) = Common terminal = ormally Open terminal = ormally Closed terminal ote: There is a factory installed jumper between the 120 VAC line () and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Sequence of Operation / Settings A demand occurs and closes RW (TT) Relay #1 and relay #2 both fire connecting the common terminal to the O terminal. If the factory installed jumper has not been removed, the O terminal of relay #1 will deliver the hot leg of 120 VAC. Relay #2 has dry contacts. The zone ED illuminates. The demand is satisfied and opens RW (TT). The relay contacts return to their normal position (common to normally closed). The zone ED turns off. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply 9

10 A2 - Multiple thermostats 10 End switch wires transformer R W C T T com power zone Caleffi! single zone relay R W 4-wire zone valve 4-wire zone valve R W R W 4-wire zone valve REAY 1 REAY 2 C /O /C C /O /C 24 VAC T T Hydronic diagram is for illustration purposes only and could be missing system components.

11 Description of terminals C O C = Ground = eutral (Common leg of 120 VAC) = ine (live leg of 120 VAC) = Common terminal = ormally Open terminal = ormally Closed terminal ote: There is a factory installed jumper between the 120 VAC line () and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings There is a demand by one of the t-stats which sends power to the corresponding zone valve. When the zone valve opens, its end switch contacts close and signal a demand to the RW (TT) contacts on the single zone relay control. Relay #1 and relay #2 fire If the factory installed jumper has not been removed, the O terminal of relay #1 will deliver the hot leg of 120 VAC thus firing the. Relay #2 closes the TT contacts on the boiler signally a demand. The Zone ED illuminates. When the last of the T-stats is satisfied, the corresponding zone valves closes which opens the end switch contacts. The relay contacts return to their normal position turning off power to the system and opening the RW (TT) contacts. The Zone ED turns off. 11

12 A3 - Single master thermostat, panel radiators with TRVs, variable speed 12 TRV TRV thermostatic! radiator valves! (TRV) on each! radiator TRV TRV TRV TRV buffer tank R W C T T com power transformer zone Caleffi! single zone relay REAY 1 REAY 2 C /O/C C /O/C T T Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

13 Description of terminals C O C = Ground = eutral (Common leg of 120 VAC) = ine (live leg of 120 VAC) = Common terminal = ormally Open terminal = ormally Closed terminal ote: There is a factory installed jumper between the 120 VAC line () and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings A single master thermostat is wired to the ZSR101 control. The master thermostat is set to a slightly higher set point than the desired room temperatures on the thermostatic radiator valves. When the temperature drops below the thermostat s set point, a heat demand is initiated by closing the R & W terminals. Relay #1 and relay #2 both fire. If the factory installed jumper has not been removed, the O terminal of relay #1 will deliver 120 VAC line to the variable speed circulator. Relay #2 closes the TT contacts on the boiler signaling a demand. The Zone ED illuminates. Using an outside air sensor and system temperature sensor located in the buffer tank, the boiler determines if the water in the boiler meets the target temperature based off the outside air reset curve. As long as the master thermostat is calling, the boiler will maintain the buffer tank to the target temperature. The thermostatic radiator valves modulate the flow through the panel radiators because the variable speed circulator is enabled. When the master thermostat reaches set point, the master thermostat will open the contact between R & W. The relay contacts return to their normal position turning off power to the variable speed circulator and opening the RW (TT) contacts. Both the boiler and are no longer enabled. The Zone ED turns off. 13

14 Certified to CSA C22-2 o.24 Conforms to U Standard 873 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-oneink unlimited zone expansion 120 VAC outputs Selectable priority with 1 hour time-out feature Selectable post purge and exercise Dry contacts for (), capable of switching line voltage High capacity transformer arge terminal connections Simplified wiring with extra ground terminals Heavy duty sealed relays Fuse protected (with spare fuse) Front ED lights 100% Factory tested with 3 year warranty ET approved See technical brochure A for more product information.

15 XX Closes for heat demand and demand. Rated for 120 VAC, 2 amps. () closes only during priority call. 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 O ED. ED for each zone. 120 VAC input power connection Multiple ground connections for easy wiring. Replaceable fuses (2 extra included under cover). 120 VAC zone outputs. 120 VAC primary output. 15

16 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.

17 Maintenance and Repair: The Caleffi Z-one multi-zone control The DIP Switches on the ZSR series T T COM T T COM T T COM T T COM T T COM T T COM COMMS comes with two spare fuses. If control fails or is damaged, replace control with can be positioned for the following DipSwitches functional one. T-STAT 1 T-STAT operations. 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 Master Slave Master / Slave: allows Priority OFF Priority O TRASFORMER for unlimited R R W C R Primary W C W C R OFF Primary O W C R W C R W Exercise OFF Exercise O X X expansion to additional relays. T T COM T T COM T T COM Post Purge T OFFT COMPost Purge T OT COM T T Boiler connections: Priority XX = Dry contacts rated up to 120 VAC, 2 Amps. T-STAT OFF / Priority 1ZSR106 T-STAT O: When 2 T-STAT 3 T-STAT 4 T-STAT 5 T-ST priority mode is O, upon demand, Closes when any zone calls including priority. Typically zone R1 will W operate C Ras priority W C and RDipSwitches all Wother Czones R are W temporarily C R switched W C off R W connected to TT on boiler control. X X (with T1 hour T time-out). COM T When T COM priority TMaster mode T COM Slave is OFF, T all Tzones COM remain T Tactive. COM T T Priority OFF Priority O () = Dry contacts rated up TRASFORMER Primary OFF Primary O to 120 VAC, 2 Primary T-STAT OFF / 1Primary T-STAT O: 2When T-STAT primary 3 T-STAT 4 T-STAT 5 T-STAT Exercise OFF Exercise mode O is O, the primary will Post Purge OFF Post Purge O Amps. Closes only when priority is enabled and calling. continue to operate during priority. R W C R W C R W C R W C R W C R W C D P Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler Exercise ZSR106 OFF / Exercise O: When exercise mode is DipSwitches PWR O, each circulator is T T COM T T COM T T COM T T COM T T COM T T COM COMMS Master Slave controls equipped with these features. switched on for 30 seconds following 6 72 Zone hours of inactivity. Priority OFF Priority O P T-STAT 1 T-STAT TRASFORMER Primary OFF Primary O POWER 2 T-STAT I 3 GROUDS T-STAT 4 T-STAT 5 T-STAT 6 Post Purge 1 OFF / Post 2 Purge O: 3 When post 4purge is O, 5Exercise the OFF priority 6 Exercise O Post Purge OFF Post Purge O Communication connections: continues operating for 2 minutes ZSR106 after the priority zone ZOE1 is switched DipSwitches off. Master Slave Connect terminals to matching terminal of slave boards Priority OFF Priority O TRASFORMER Primary OFF Primary O R D to W D, CP to RP, Ground W C to Ground R W C R W C D P Primary output: Exercise OFF Exercise O PWR ZOE2 COMMS Post Purge OFF Post Purge O T T COM T T COM T T COM T T COM Primary runs when any zone runs. Its status PRIMARY POWER I GROUDS DipSwitches T-STAT 3 T-STAT 4 T-STAT 5 T-STAT ZSR during priority (on\off) can be programmed using the DIP Master Slave ZOE3 Priority OFF switches. Priority O TRASFORMER Primary OFF Input Power: ZOE1 Primary O Exercise OFF = Exercise ine O (hot leg) of Post Purge OFF Post Purge O 120 VAC to power the = ine (hot leg) of 120 VAC supply POWER I GROUDS ZSR106 = eutral leg of 120 VAC 1 to power 2the 3 ZOE = eutral of 120 VAC ZOE2 = Ground DipSwitches ZOE5 ote: when connecting 2 or more Z-one controls, all Master Slave POWER I GROUDS ZOE3 Priority OFF Priority O WARIG: controls must be powered by the same 120 VAC circuit. EVER 1 COECT R 2& C DIRECTY, 3 this will be a 4direct short on 5 the 24 VAC 6 Primary OFF Primary O supply. Exercise OFF Exercise O ZOE6 Post Purge OFF Post Purge O ZOE4 Zone outputs: WARIG: When PRIMARY connecting 2 or more Z-one controls, all controls must be powered by Zone s GROUDS run when the same VAC circuit. corresponding thermostat ZOE5 initiates a demand. GROUD = Connect the ZOE6 WARIG: When replacing fuses, make sure power is disconnected to control box. ground from the to the ground terminal. PRIMARY 3 = Runs 4 when zone 5 #1 calls. 6 Can be programmed to be the priority zone. = ine (hot leg) of 120 VAC to power the = eutral leg of 120 VAC to power the X ZSR106 POWER I UMP 2 X X R W C R W C R W C R W C R W C R W C D P 17

18 B1 - Mod/con boiler, hydro separator or buffer tank, zone s 18 Pump 1 Pump 2 Pump 3 Pump 4 Buffer tank- Optional hydraulic separator X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR ZOE1 ZOE2 TRASFORMER ZSR106 DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O ZOE3 ZOE4 ZOE5 ZOE6 POWER I GROUDS PRIMARY Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

19 Description of terminals = Ground = eutral (Common leg of 120 VAC) = ine (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Dip switch description Master / Slave: Used when joining 2 or more controls together. Only one Master per group Priority OFF / Priority O: Used to set Zone #1 as the priority zone. All other zones will hold off during priority. Priority has a one hour time out feature to prevent freeze up. Primary OFF / Primary O: Sets the status of the primary when there is a priority call. This allows the to be on either side of a hydro separator. Exercise OFF / Exercise O: When enabled the s will rub for 30 seconds after 72 hours without a demand. Post Purge OFF / Post Purge O: Allows the to run for 2 minutes after the demand has been satisfied. Sequence of Operation / Settings Priority switch: OFF Master / Slave switch: Master Status During Priority switch: OFF A demand occurs from any T-stat (T-stat closes TT terminals). The O ED illuminates for that zone. ZSR control sends 120 VAC to the corresponding zone and the primary outputs, XX contacts close to signal boiler of a demand. When the demand from the last T-stat calling is satisfied (T-stat opens TT terminals), the XX contacts are opened, the O ED turns off and the 120 VAC to the zone and primary outputs are dropped. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply 19

20 B2 - Traditional boiler, indirect w/ priority, zone s 20 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6 boiler! high limit! control Pump 1! aquastat! aquastat X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 PWR ZOE1 ZOE2 ZC ZR T T TRASFORMER 12/20VA ZSR106 Z6P DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O ZOE3 ZOE4 ZOE5 ZOE6 outdoor! temperature! sensor POWER I GROUDS PRIMARY Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

21 Description of terminals = Ground = eutral (Common leg of 120 VAC) = ine (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Dip switch description Master / Slave: Used when joining 2 or more controls together. Only one Master per group Priority OFF / Priority O: Used to set Zone #1 as the priority zone. All other zones will hold off during priority. Priority has a one hour time out feature to prevent freeze up. Primary OFF / Primary O: Sets the status of the primary when there is a priority call. This allows the to be on either side of a hydro separator. Exercise OFF / Exercise O: When enabled the s will rub for 30 seconds after 72 hours without a demand. Post Purge OFF / Post Purge O: Allows the to run for 2 minutes after the demand has been satisfied. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Priority switch: O (Zone #1 becomes priority) Master/Slave switch: Master Primary Status During Priority switch: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6. The O ED illuminates for that zone. ZSR control sends 120 VAC to the corresponding zone terminals to fire the zone and closes the XX contacts to signal a heat demand to the boiler. The PRIMARY output will also deliver 120 VAC even if no is connected. When the demand from the T-stat is satisfied (T-stat opens TT terminals), the O ED turns off. 120 VAC is dropped from the corresponding zone terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the aquastat (zone #1), The O ED illuminates for Zone #1. If any other zone was calling (Zones 2 thru 6) when Zone #1 called, power (120 VAC) is dropped to those zone s. The XX and contacts close. The contacts deliver 120 VAC Once the Zone #1 demand is satisfied, power to the is dropped, the contacts open. If a demand from zones 2 thru 6 is present, 120 VAC is delivered to the corresponding zone (s) and the O ED for those zones will illuminate. The XX contacts close to signal a heat demand to the boiler. When all zones are satisfied, the XX contacts open and power (120 VAC) is turned off to all of the zone s. Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the contacts and turn off power to the. If a heating demand is present from Zones #2-6, the control will satisfy those demands before going back to the call. After the heating demands are met, the control will go back to and re-set the one hour timer. 21

22 B3 - Mod/Con boiler, primary loop, closely spaced tees, zone s 22 Pump 1 Pump 2 Pump 3 boiler Primary X X R W C T T COM T-STAT 1 R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR ZOE1 ZOE2 TRASFORMER 3 ZSR106 3 DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O ZOE3 ZOE4 ZOE5 ZOE6 POWER I GROUDS PRIMARY Primary boiler Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

23 Description of terminals = Ground = eutral (Common leg of 120 VAC) = ine (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Dip switch description Master / Slave: Used when joining 2 or more controls together. Only one Master per group Priority OFF / Priority O: Used to set Zone #1 as the priority zone. All other zones will hold off during priority. Priority has a one hour time out feature to prevent freeze up. Primary OFF / Primary O: Sets the status of the primary when there is a priority call. This allows the to be on either side of a hydro separator. Exercise OFF / Exercise O: When enabled the s will rub for 30 seconds after 72 hours without a demand. Post Purge OFF / Post Purge O: Allows the to run for 2 minutes after the demand has been satisfied. Sequence of Operation / Settings Priority switch OFF Master / Slave switch: Master Status During Priority switch: OFF A demand occurs from any T-stat (T-stat closes TT terminals). The O ED illuminates for that zone. ZSR control sends 120 VAC to the corresponding zone and the primary outputs, XX contacts close to signal boiler of a demand. When the demand from the T-stat is satisfied (T-stat opens TT terminals), the XX contacts are opened, the O ED turns off and the 120 VAC to the zone and primary outputs are turned off. ATERATE WIRIG: The boiler can be controlled by the Mod/Con boiler if equiped to do so. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply 23

24 Certified to CSA C22-2 o.24 Conforms to U Standard 873 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-oneink unlimited zone expansion Selectable priority with 1 hour time-out feature System status selectable during priority Pump will start only after the zone valve end switch is closed Dry contacts for (), capable of switching line voltage arge 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, secondary, and priority Front ED ights 100% Factory tested with 3 year warranty ET approved See technical brochure A for more product information.

25 XX Closes for heat demand and demand. Rated for 120 VAC 2 amps. () closes only during priority call. Rated for 120 VAC, 2 amps. Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Master/Slave jumper. 3 wire communications to expansion board. Power O ED. Transformer connections. ED illuminates when end switch closes. 120 VAC input power connection. 120 VAC output to s. System (boiler ) status during priority can be changed with jumper. ZOE #1 priority. Zone valve motor connections. Zone valve end switch connection. ED illuminates with call for heat. 25

26 Cover removal 26 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. Transformer Installation 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.

27 TSAT1 ZO T R W C R W C R W C R W C R MASTER W SAVE C R W C D X X MASTER SAVE T T COM T T COM T T COM T T COM T T COM T T COMTSAT2 ZO Maintenance and Repair: The Caleffi Z-one multi-zone valve relay comes with Thermostat connections T T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT R = 24 VAC. 5 T-STAT 6 a resettable fuse and requires no maintenance. If control fails or is damaged, R W C R W C R W C R W C R replace control with functional one. X X W = Heat call T T COM T T COM T T COM TSAT3 T T COM ZO TT ZVR106 ZVR106 C = Common of 24 VAC R W C R W C T-STAT R W 1C T-STAT R W 2C T-STAT R W 3C T-STAT R W 4 C T The ZVR series of controls is programmed X6 X Zone Heat demand is initiated by closing R T T COM T T COM T T COM T T COM T T COM MASTER T SAVE T COM T by positioning a series of jumpers. Example to W. T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5TSAT4 T-STAT ZO 6 photo to right shows jumper in off position STATUS 24 VAC is always present between R (left photo) and on position (right photo). DURIG STATUS & C. T Jumpers are used for the following R W C R W C R W C R W C R W C DURIG X X TSAT5 ZO T T COM T T COM T T COM T T COM T T COM Dip operations. O OFF Mas Priority O / Priority OFF: When priority ZVR106 T-STAT 1 T-STAT 2 T-STAT 36 T-STAT Zone4 T-STAT Priority 5 T O Zone valve O OFF TRASFORMER connections Primary O DipSwitches Exercise O jumper is O, upon demand, zone O 1 will OFF Master Slave Motor = 24 VAC to power TSAT6 the zone Post ZO Purge O POWER I SEC SYSTEM Priority OFF Priority operate as priority and all other zones are O OFF TRASFORMER ZOE 1 ZOE 2 ZOE valve 3 motorzoe ZSR106 Primary 4 OFF ZOE Primary O5 ZOE Exercise OFF Exercise O temporarily switched off (with 1 hour time- When priority mode SEC is OFF, any SYSTEM zones ZSR106 End Switch MOTOR= Post Connects SWITCH Purge OFF MOTOR to Post end Purge SWITCH switch O MOTOR S R Iout). that were ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 active when zone 1 was switched STATUS on zone valve. Must be jumpered if DURIG using a 2 wire zone valve. W C R W C R W C R W C D P on will remain on. PWR ZVR106 TStatus COMDuring T Priority T COMO / TStatus T During COM T T COM COMMS Input power -STAT Priority 3 OFF: T-STAT When 4status T-STAT jumper is 5O, = ine 6 (hot Zone leg) of 120 VAC supply T-STAT 6 O OFF POWER I GROUDS P the system will continue to operate O OFF = eutral of 120 VAC during priority. TSAT1 ZOE1 STATUS = Ground POWER I GROUDS 1 DURIG Master / POWER Slave: allows I for unlimited expansion SEC SYSTEM MASTER SAVE to additional ZVR relays. ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 O OFF Pump TSAT2 outputs ZOE2 O OFF MOTOR SWITC SYSTEM = Runs when any Boiler Connections POWER I SEC SYSTEM zone ZOE calls 1 for heat. ZOEWhen 2 priority ZOEis 3 XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls TSAT3 ZOE3 ZVR106 enabled, the status of the (on\ M including priority. Typically connected to TT on boiler control. off) during a priority call is selected via 6 Zone () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only a jumper when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) TSAT4 ZOE4 or contacts (24 VAC) on boiler controls equipped with these features. SEC = Runs when any zone calls for heat except the priority zone when it is enabled. Communication connections = Runs when the priority zone calls. A jumper is required TSAT5 ZOE5 between the SWITCH terminals when using a for. Connect terminals to matching terminal of RITY W slave C boards R W C R W C R W C D P WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 PWR T D COM to D, T P to T P, COM Ground T to T Ground COM T T COM COMMS TSAT6 VAC ZOE6 supply. -STAT OFF Use 3 18 T-STAT gauge 4 thermostat T-STAT 5 wire. T-STAT Wire 6 should be shielded if located in close proximity to high voltage wiring. ZOE1 E 1 SWITCH Zone ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 ZOE2 DipSwitches Master Slave ZOE3 Priority OFF Primary OFF Priority O Primary O T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 WARIG: When connecting 2 or more Z-one controls, all controls must be powered by the same 120 VAC circuit. 27

28 C1 - Mod/Con boiler, hydro separator, zone valves 28 mod/con! boiler ZV1 ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM! SECODARY! X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 ZVR106 MASTER SAVE TSAT2 ZOE2 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

29 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. Sequence of Operation / Settings Priority Jumper: OFF Master / Slave Jumper: Master Status During Priority: OFF A demand occurs from any T-stat (T-stat closes TT terminals). The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is turned off to the SEC and SYSTEM and the XX contacts are opened. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply 29

30 C2 - Mod/Con boiler, priority indirect on primary side of hydro sep, zone valves 30 mod/con! boiler ZV2 ZV3 ZV4 ZV5 ZV6! aquastat! SYSTEM! SECODARY!! AQUASTAT X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 ZVR106 MASTER SAVE TSAT2 ZOE2 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 Buffer tank- Optional hydraulic separator! SECODARY! ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM! Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

31 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Priority Jumper: O (Zone #1 becomes priority) Master/Slave Jumper: Master Status During Priority: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the aquastat (zone #1), The T-STAT CA ED illuminates for Zone #1 and the VAVE OPE ED will illuminate. (When using a, a jumper must be installed on Zone #1 end switch terminals.) If any other zone was calling (Zones 2 thru 6) when Zone #1 called, power (24 VAC) is dropped to those zones. The XX and contacts close. The contacts deliver 120 VAC The SEC and SYSTEM are off. Once the Zone #1 demand is satisfied, power to the is dropped, the contacts open. If a demand from zones 2 thru 6 is present, 24 VAC is delivered to the corresponding zone valve(s) and the T-STAT CA ED s illuminate. When the zone valve end switch closes, the VAVE OPE ED illuminates, the XX contacts close, the SEC and SYSTEM terminals deliver 120 VAC. Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the contacts and turn off power to the and Zone Valve #1. If a heating demand is present from Zones #2-6, the control will satisfy those demands before going back to the call. After the heating demands are met, the control will go back to and re-set the one hour timer. 31

32 C3 - Mod/Con boiler, priority indirect on load side of hydro sep, zone valves 32 Buffer tank- Optional hydraulic separator ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM! SECODARY!!! AQUASTAT! AQUASTAT X X R W C R W C R W C R W C R W C R W C D P T T COM COMMS 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 PWR TSAT1 ZOE1 ZVR106 MASTER SAVE TSAT2 ZOE2 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

33 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Priority Jumper: O (Zone #1 becomes priority) Master/Slave Jumper: Master Status During Priority: O A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the aquastat (zone #1), The T-STAT CA ED illuminates for Zone #1 and the VAVE OPE ED will illuminate. (When using a, a jumper must be installed on Zone #1 end switch terminals.) If any other zone was calling (Zones 2 thru 6) when Zone #1 called, power (24 VAC) is dropped to those zones. The XX and contacts close. The and SYSTEM contacts deliver 120 VAC The SEC is off. Once the Zone #1 demand is satisfied, power to the and SYSTEM is dropped, the contacts open. If a demand from zones 2 thru 6 is present, 24 VAC is delivered to the corresponding zone valve(s) and the T-STAT CA ED s illuminate. When the zone valve end switch closes, the VAVE OPE ED illuminates, the XX contacts close, the SEC and SYSTEM terminals deliver 120 VAC. Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the contacts and turn off power to the and Zone Valve #1. If a heating demand is present from Zones #2-6, the control will satisfy those demands before going back to the call. After the heating demands are met, the control will go back to for and re-set the one hour timer. 33

34 C4- Mod/Con boiler, priority indirect on primary side of hydro sep, expansion control 34 Buffer tank - Optional hydraulic separator ZV2 ZV3 ZV4 ZV5 ZV6 ZV7 ZV8 ZV9 ZV10 ZV11 ZV12 SECODARY!! AQUASTAT! SYSTEM!! AQUASTAT X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 MASTER SAVE TSAT2 ZOE2 MASTER SAVE TSAT2 ZOE2 ZVR106 TSAT3 ZOE3 TSAT4 ZOE4 ZVR106 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6! SECODARY! SECODARY SYSTEM! SYSTEM ZV2 ZV3 ZV4 ZV5 ZV6 ZV7 ZV8 ZV9 ZV10 ZV11 ZV12 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

35 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Control #1 (Master) Priority Jumper: O (Zone #1 becomes priority) Master/Slave Jumper: Master Status During Priority: OFF Control #2 (Slave) Priority Jumper: OFF Master/Slave Jumper: Slave Status During Priority: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 12. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. OTE: The SEC output is only fired on the control that receives the t-stat call. For instance, if a zone from control #1 calls, the SEC on control #1 fires but SEC on control #2 does not. When using a single secondary with 2 controls, the secondary must be connected to the SYSTEM terminals. (An alternative wiring option for secondary is to wire the secondary to the SEC terminals of both controls). When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the aquastat (zone #1), The T-STAT CA ED illuminates for Zone #1 and the VAVE OPE ED will illuminate. (When using a, a jumper must be installed on Zone #1 end switch terminals.) If any other zone was calling (Zones 2 thru 12) when Zone #1 called, power (24 VAC) is dropped to those zones. The XX and contacts close. The contacts deliver 120 VAC The SEC and SYSTEM are off. Once the Zone #1 demand is satisfied, power to the is dropped, the contacts open. If a demand from zones 2 thru 12 is present, 24 VAC is delivered to the corresponding zone valve(s) and the T-STAT CA ED s illuminate. When the zone valve end switch closes, the VAVE OPE ED illuminates, the XX contacts close, the SEC and SYSTEM terminals deliver 120 VAC. Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the contacts and turn off power to the and Zone Valve #1. If a heating demand is present from Zones #2-12, the control will satisfy those demands before going back to the call. After the heating demands are met, the control will go back to for and re-set the one hour timer. 35

36 C5 - Traditional boiler, indirect (no priority) with valve, zone valves 36 SYSTEM! ZV2 ZV3 ZV4 ZV5 ZV6 ZV1! aquastat X X R W C T T COM THM 1 R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM COMMS THM 2 THM 3 THM 4 THM 5 THM 6 Master/Slave PWR THM1 ZOE1 ZRV106 Z6V THM2 ZOE2 THM3 ZOE3 THM4 ZOE4 THM5 ZOE5 STATUS DURIG THM6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

37 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. Sequence of Operation / Settings Priority Jumper: OFF Master/Slave Jumper: Master Status During Priority: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6 otr the aquastat on zone #1. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is turned off to the SEC and SYSTEM and the XX contacts are opened. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply 37

38 C6- Traditional boiler with reset control, priority indirect with valve, zone valves 38 SYSTEM! ZV2 ZV3 ZV4 ZV5 ZV6 ZV1! aquastat! aquastat X X R W C T T COM THM 1 R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM COMMS THM 2 THM 3 THM 4 THM 5 THM 6 Master/Slave THM1 PWR ZOE1 ZCZR T T ZRV106 Z6V THM2 THM3 THM4 ZOE2 ZOE3 ZOE4 THM5 ZOE5 STATUS DURIG THM6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

39 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation Priority Jumper: O (Zone #1 becomes priority) Master/Slave Jumper: Master Status During Priority: O A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the aquastat (zone #1), The T-STAT CA ED illuminates for Zone #1 and the VAVE OPE ED will illuminate. (When using a, a jumper must be installed on Zone #1 end switch terminals.) If any other zone was calling (Zones 2 thru 6) when Zone #1 called, power (24 VAC) is dropped to those zones. The XX and contacts close. The and SYSTEM contacts deliver 120 VAC The SEC is off. Once the Zone #1 demand is satisfied, power to the and SYSTEM is dropped, the contacts open. If a demand from zones 2 thru 6 is present, 24 VAC is delivered to the corresponding zone valve(s) and the T-STAT CA ED s illuminate. When the zone valve end switch closes, the VAVE OPE ED illuminates, the XX contacts close, the SEC and SYSTEM terminals deliver 120 VAC. Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the contacts and turn off power to the and Zone Valve #1. If a heating demand is present from Zones #2-6, the control will satisfy those demands before going back to the call. After the heating demands are met, the control will go back to and re-set the one hour timer. 39

40 C7 - Mod/Con boiler, hydro separator, zone valves (more than 6), multiple secondary s 40 "A"! "B"! A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11A12 SYSTEM! X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 X X R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 MASTER SAVE TSAT2 ZOE2 MASTER SAVE TSAT2 ZOE2 ZVR106 TSAT3 ZOE3 TSAT4 ZOE4 ZVR106 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 SYSTEM! "B"! "A"! A1 A2 A3 A4 A5 A6 Hydronic diagram is for illustration purposes only, some components have been removed for simplicity. A7 A8 A9 A10 A11 A12

41 Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. () = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Control #1 (Master) Priority Jumper: OFF Master/Slave Jumper: Master Status During Priority: OFF Control #2 (Slave) Priority Jumper: OFF Master/Slave Jumper: Slave Status During Priority: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 1 thru 12. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SYSTEM and to the SEC located on the ZVR control that is seeing the demand. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. OTE: The SEC output is only fired on the control that receives the t-stat call. For instance, if a zone from control #1 calls, the SEC on control #1 fires but SEC on control #2 does not. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is turned off to the SEC and SYSTEM and the XX contacts are opened. 41

42 Caleffi orth America, Inc. / 3883 W Milwaukee Rd / Milwaukee, WI Tel: / Fax: / [email protected] Copyright 2014 Caleffi orth America, Inc 42