instructions for zone pump relay control

ARTICLE NO. 281721-001
Fully fuse protected and with four standard "ice-cube" snap out relays, this junction box is feature rich with a
priority switch for four zones. There is a convenient 24 VAC terminal available and a master/slave switch allowing for the ganging together of multiple boxes for control of up to 20 zones. External LED indicator ights indicate
system power and zone pump operation. Three power port terminals are available and can receive plug-in
cards, which can add additional features, such as post purge, priority protection and universal timer/pump
exercise. Controls up to four zone pumps.
Cold Start Boiler Application
Tankless Coil Boiler Application
(Alternative Wiring)
For Cold Start Boiler Application
Mode Operation: When the dip switch is set to NORMAL, the end switch relay will
Operation: When any thermostat calls for heat, the appropriate circulating pump is
be energized if any zone is in operation. When the switch is set to RESET, the end
energized and the isolated end switch (X and X) will start the boiler.
switch relay will only be energized if the priority zone is in operation, or through the
operation of a plug-in reset control.
For Tankless Coil Boiler Application (Alternative Wiring)
Operation: When any thermostat calls for heat, the boiler will be enabled and
Primary Pump Operation: When the dip switch is set to OFF, the primary circu-
appropriate circulating pump is energized when the boiler temperature is above the
lating pump output will energize when any zone calls for heat, except the priority
set low limit and low limit (ZC) dip switch is set to on.
zone. When the dip switch is set to ON, the primary circulating pump output will
energize when any zone calls for heat.
ZC and ZR Terminals: Connect terminal ZC to ZC terminal on the aquastat
control. Connect ZR to ZR terminal on the aquastat control. Confirm polarity is
Post Purge Operation: When the dip switch is set to ON, the priority zone output
consistent between boiler aquastat and switching relay.
will stay energized for 2 minutes after its thermostat or aquastat is satisfied, but not
operate the boiler.
WARNING: Power must originate from the boiler aquastat when using
Alternative Wiring diagram. Failure to follow these wiring instructions may
Priority Protection Operation: When the dip switch is set to on, and if the priority
result in a secondary source of power being connected to the boiler that may
zone calls continuously for more than one hour, power is returned to all the other
activate it under certain circumstances, causing injury or death.
zones, allowing each zone to function independently. Once the priority zone is
satisfied, the control's auto-reset is activated and the priority zone is again allowed
For Both Cold Start Boiler Application and Tankless Coil Boiler Application
to have priority for up to one hour starting from when it calls next.
(Alternative Wiring)
Priority Operation: When the priority dip switch is set to ON and the priority zone
Pump Exercise Operation: When the dip switch is set to on, the solid state timer
is actuated, all other zones will stop operation until priority zone is satisfied. When
cycles all the circulating pumps that are attached to the Expandable Switching
not switched to priority, all zones will operate independently.
Relay at the selected time interval. The time interval can be set for the pumps to
run for either 30 seconds every 2 weeks or for 4 minutes every 24 hours.
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The information contained herein is believed to be reliable, but no representations, guarantees or warranties of any kind are made as to its accuracy, suitability for particular applications or the results to be obtained therefrom.
Before using, the user will determine suitability of the information for the user’s intended use and shall assume all risk and liability in connection therewith. © 2012 REHAU
855.627 10.12
Low Limit (ZC) Operation: When the dip switch is set to on and the boiler drops
120 VAC Connections (N is Neutral, H is Hot):
below the set low limit (terminal ZC connected to boiler), all zone circulating pumps
Power Input
Connect 120 Volt AC power
will stop. When the boiler rises above the set low limit, the zone circulating pumps
Primary Pump (optional)
are allowed to operate.
Zone 1-3
Circulator Zones
Priority Zone 4
Priority Zone (if enabled) or Zone 4
End Switches (Dry Contacts): The main end switch closes when any zone
N/C Zone 4
Normally closed terminals for the Priority Zone
thermostat calls for heat and the mode switch is set to normal. The main end
Will deactivate on a Priority Zone call.
switch also closes when the mode switch is set to reset and a PC Series boiler
reset power control is calling for heat. The priority end switch closes only when the
This device complies with part 15 of the FCC Rules. Operation is subject to the
priority zone thermostat or aquastat is calling for heat.
following two conditions: (1) This device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that
Expansion Connections: Set the expansion switch to MASTER on the switching
may cause undesired operation.
relay that has the designated priority zone or is utilizing the PC Series plug-in
option. Set all other daisy chained controls to SLAVE. Using thermostat wire
External Diagnostics: Externally visible lights show full functionality of the switch-
(18-22 gauge) connect between terminals A, B, C on the master control to the
ing relay. The green light should always be on, indicating that power is connected.
corresponding A, B, C on the slave control(s). Controls may be daisy chained up to
When the thermostat calls for heat, both the appropriate circulator and red indicat-
20 zoning panels using any combination of -EXP controls (120 zones if all are six
ing light are energized.
zone panels).
Wiring connections must be made in accordance with all applicable electrical
Thermostat Input (24 vac):
codes. Use copper wire only. Recommendations for wiring:
- 12 to 18 gauge wire for 120 VAC connections (120 VAC wiring must have a
Hot side of transformer. Connect to R on thermostat.
Switched R signal from thermostat. Connect to W on thermostat.
Common side of transformer. Connect to COM on thermostat (optional).
- 14 to 22 gauge wire for thermostat connections
Network terminals 1 and 2 are tied together for wiring convenience when
- 14 to 22 gauge wire for 24 VAC source connections
minimum temperature rating of 167°F (75°C)
using communicating style thermostats (optional).
WARNING: Failure to follow applicable electrical codes can result in
personal injury or death due to electrocution or shock and/or property
- Front External Indicator Lights
- Two Isolated End Switchs
- Plug-In Power Port Cards
- Expandable to 20 Zones
- Ideal for Retrofitting
- Simplified Wiring
- Contractor-Friendly PC Board Layout
- Primary Circulator Output
- Universal Thermostat Compatibility
- 100% Factory Tested
- Compact Design
- Fuse Protected
- 24 Volt Power Input/Output Terminal
- UL Approved
damage due to fire.
Dip Switch Settings
- Expandable to 20 Zoning Panels
Article No.
Number of Zones
4 with priority
Input Voltage
120/60/1 VAC
Maximum Combined Load
20 amps
Type 1 Enclosure
10 3/4 in.
7 in.
2 3/4 in.
All circulator relay connections, including ZC/ZR, are rated 1/3 hp (6 FLA, 36 LRA) at 120 VAC. End switch connections are rated 24 VAC, 1 amp. All thermostat connections supply a 24 VAC class 2 output.
2 Expandable Switching Relays Connected Together