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(s), and primary pump can be operated. Zone priority is selectable with 1-hour time-out feature. System
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.
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
Form 031914 rev.1
2
INDEX
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 pump..................................................................................................... 10
ZSR103, ZSR104 & ZSR106 - multi-zone pump relay
Product overview............................................................................................................................................................................ 12
Circuit board................................................................................................................................................................................... 13
Cover removal................................................................................................................................................................................. 14
Product details................................................................................................................................................................................ 15
B1 - Mod/Con boiler, hydro separator or buffer tank, zone pumps.................................................................................................. 16
B2 - Traditional boiler, indirect DHW w/ priority, zone pumps........................................................................................................... 18
B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps............................................................................................. 20
ZVR103, ZVR104 & ZVR106 - multi-zone valve control
Product overview............................................................................................................................................................................ 22
Circuit board................................................................................................................................................................................... 23
Cover removal, Transformer Installation..................................................................................................................................................24
Product details................................................................................................................................................................................ 25
C1 - Mod/Con boiler, hydro separator, zone valves......................................................................................................................... 26
C2 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves................................................................................ 28
C3 - Mod/Con boiler, indirect DHW on load side of hydro sep, zone valves..................................................................................... 30
C4 - Mod/Con boiler, indirect DHW on primary side of hydro sep, master and slave control............................................................ 32
C5 - Traditional boiler, indirect DHW (no priority) with valve.............................................................................................................. 34
C6 - Traditional boiler with reset control, priority indirect DHW with valve......................................................................................... 36
C7 - Mod/Con boiler, hydro separator, zone valve (more than 6), multiple secondary pumps........................................................... 38
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
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.
4
Z-one T-stat interface
C
XX
R
T
W
R
C
T COM
T-STAT 1
T
W
C
T COM
T-STAT 2
R
X
Function
X WZR/ZCC
T
R
T COM
T
T-STAT 3
Description
R = 24 VAC Supply
W = Heat Call
MER C = 24 VAC Common
DHW
R
T
W
WT
N
GROUNDS
R&W: When connected, signals a heat demand.
R&C: Provides 24 VAC to powered thermostats.
GROUNDS
COM
T
C
T-STAT 4
6 Zone
ZSR106
POWER IN
R
W
RT
C
R
W
R
C
W
R
ZR/ZC
T
R
C
W
R
C
R
W
C T COM
C
T COM T
T COM T
3
THM 5
T THM T4 COM
T THM
COM
WT
COM
THM
T 1COM THM
T 2
TRANSFORMER
12/20VA
L
C
DHW
T
W
D
W
T COM
CTHM
T COM
R
C
P
1
W
T
D
R
C
T COM
T COM
T
THM
2
P
PWR
PWR
R
C
T COM
W
T
THM 4
C
T COM
R
W
T
R
Rh W1
D
C
P
PWR
COMMS
T COM
THM 6
THM 5
ZONE1
Dry Contacts
T-STAT 6
T-STAT 5
W
T
THM 3
COMMS
THM 6COMMS
R
C
W
ZONE1
3-Wire Thermostats
ZONE2
DipSwitches
ZONE2
ZONE1
ZONE3
A heat demand can also be initiated by any type
6 Zone
ZONE3
of device that has dry contacts (dry contacts ZONE4
are
Three6wire
thermostats get their power from the Z6P
Zone
a set of contacts that open and close but do not
DipSwitches
TRANSFORMER
Master
Slave
12/20VA
Priority ON
Priority OFF
Master
Priority OFF
Primary OFF
Exercise OFF
Post Purge OFF
Slave
Priority ON
Primary ON
Exercise ON
Post Purge ON
Primary ON
Exercise ON
Post Purge ON
Primary OFF
Exercise OFF
Post Purge OFF
controlZ6P
they are connected to. R & C from the ZONE2
ZONE4
have any voltage present until supplied from ZONE5
an
Z-one
Control
DipSwitches supply 24 VAC to the thermostat at ZONE5
outside
source).
The
end
switch
on
a
Z-one
series
all
times
while
the
W
lead
signals
a
heat
demand.
Master
Slave
ZONE6
ZONE3
Priority ON
Priority OFF
zone valve is an example of a dry contact. Using
ZONE6
Primary ON
Primary OFF
PRIORITY
PRIMARY
Exercise ON
Exercise OFF
POWER IN
aPUMP
dry3 contact
to
connect
W will initiate a heat
PUMP 4
GROUNDS
PUMP 2
PUMP
5
PUMP 6 R to
PRIORITY
PUMP
PUMP 1
Post Purge ON
Post
Purge OFF
PRIMARY
N
L
PUMP
PUMP 2
PUMP 3
L
N
L 4 N PUMP 5
L
L
NZONE4
N
N
L
PUMP 6
N
L
N
L
PUMP
PUMP 1
demand.
N
L
WARNING: NEVER CONNECT
R & C DIRECTLY,
DHW
R
W
C
this will be a direct short
24 VAC supply
X Xon the
ZR/ZC
T
T COM
PRIORITY
THM 1
PUMP 1
PUMP 4
PUMP 2
PUMP 3
L
N
L
L
N
N
N
L
L
N
L
N
L
N
L
N
N
L
L
N
ZONE5
R
T
W
C
T COM
THM 2
R
W
T
R
C
T COM
THM 3
PUMP 5
N
L
T
W
C
T COM
THM 4
PUMP 6
N
L
R
T
W
C
XR XW
DHW
C
ZR/ZC
T
T COM
PRIMARY
THM 6
THM 5
PUMP
N
L
T COM
ZONE6
D
R
P
T
W
COMMS
C
T COM
THM 1
R
T
W
C
T COM
PWR
THM 2
R
T
W
C
T COM
THM 3
DipSwitches
Master
Priority OFF
Primary OFF
Exercise OFF
Post Purge OFF
Slave
Priority ON
Primary ON
Exercise ON
Post Purge ON
T
W
C
T COM
THM 4
R
W
T
C
T COM
THM 5
R
W
T
C
T COM
D
P
COMMS
TRANSFORMER
CAUTION:
12/20VA
ZONE3
ZO
6 Zone
ZO
DipSwitches
Master
Priority OFF
Primary OFF
Exercise OFF
Post Purge OFF
Slave
Priority ON
Primary ON
Exercise ON
Post Purge ON
Electrical shock hazard. Disconnect power before installation to prevent
Z6P
electrical shock or
equipment
damage. Make sure all connections are in accordance
ZONE4
with the electrical wiring diagram and in accordance with national and local electrical
codes.
ZONE5
ZONE6
PRIORITY
CAUTION: All work must be performed by qualified
personnel trained in the
POWER IN
PUMP
GROUNDS
2
PUMP 3 with
PUMP 1
proper application, installation,
and maintenance
of systems
inPUMP
accordance
all4
N
L
N
L
L
N
L
N
N
L
applicable codes and ordinances.
Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.
PRIORITY
PUMP 5
L
N
P
THM 6
ZONE1
Always refer to the thermostat manufacturer’s instructions.
ZONE2
SAFETY INSTRUCTIONTRANSFORMER
6 Zone
This safety alert symbol will 12/20VA
be used in this manual to draw attention to safety
Z6P
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.
R
CAUTION: Avoid electrical
noise
interference.
Do
not install
near PRIMARY
large conductors,
POWER IN PRIMARY
PUMP 4
GROUNDS
PUMP 2
PUMP 3
PUMP 5
PUMP 6
PUMP
PUMP 1
PUMP 6
PUMP
electrical machinery,
or welding
equipment.
Avoid
locations
excessive
N
Lwhere
N
L
N
L
L
L
N
N
N
L
N
L
N
L
N
L
N
L
moisture, corrosive fumes, vibration, or explosive vapors are present.
ZO
ZO
ZO
ZO
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
DHW
R end
R
R is not
R
W
C
W
C
W
Cinstalled,
W no
C
simulate X
the
swith. If the
switch
jumper
X end
ZR/ZC
T
T COM T
T COM T
T COM T
T COM
demand will be sent to the T-STAT
boiler and
the pumps
will not
on4.
1
T-STAT
2
T-STAT
3 turn
T-STAT
The Taco 570 zone valve presents a unique wiring challenge. When
connecting the Taco 570 zone valve to the Caleffi Z-one Relay, the
R of Wthis
D
R
C valve can
P
Wwiring
C
only be donePWR
in one way. The left motor
COMMS
T COM
T
T COM T
terminal
on
the
ZVR
series
control
must
be connected to terminal
T-STAT 5 T-STAT 6
2 on the zone valve. The right motor terminal must be connected
TSAT1 ZONE1
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
TSAT2 ZONE2
follow schematic will lead to damage of product.
MASTER
SLAVE
ZVR106
TSAT3 ZONE3
6 Zone
STATUS
DURING
PRIORITY
ON
OFF
TSAT5 ZONE5
PRIORITY
ON
POWER IN
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
TSAT4 ZONE4
TSAT6 ZONE6
OFF
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
M
1
2
3
5
6
ZSR101 - Single Zone Switching Relay
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
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 01284-14 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
R
W
and switching the pump
R
TW C T
on, and the C to NO dry
T
T COM
contact on relay #2 closes,
signaling the boiler of a heating demand.
Dual labeled T-stat terminals.
Compatible with 2, 3 and 4
wire T-stats.
Replaceable fuses.
6 VA Transformer.
C
COM
PWR
R, W, C and T T Comm dual labeling at thermostat terminals.
Compatible
with low voltage 2, 3, or 4 wire thermostats or any
TRANSFORMER
TRANSFORMER
other low voltage devices having a switching action.
ZONE
PWR
ZSR101
ZSR101
1 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.
RELAY #1
POWER IN
N
L
C
L
C
120VAC input
power connection
NO NC
C
RELAY #1
POWER IN
N
NO NC
RELAY #2
RELAY #2
NO NC
C
ZONE
NO NC
If dry contacts are desired from relay #1, remove the factory
installed jumper between L and C.
Keyhole mounting
which fits a 4X4
junction box.
Pre-installed jumper.
Cover removal
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.
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 pushin tab inward on
opposite side, cover should release
from base.
Slide cover off base.
7
8
A1 - Single thermostat
R
T
W C
T com
power
zone
transformer
N L
Caleffi!
single zone relay
RELAY 1
RELAY 2
C N/O N/C C N/O N/C
N
L
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
T
T
Description of terminals
Sequence of Operation / Settings
= Ground
• A demand occurs and closes RW (TT)
N
= Neutral (Common leg of 120 VAC)
L
= Line (live leg of 120 VAC)
• Relay #1 and relay #2 both fire connecting the
common terminal to the NO terminal.
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
W
C
= 24 VAC
= Heat call
= Common of 24 VAC
• If the factory installed jumper has not been
removed, the NO terminal of relay #1 will
deliver the hot leg of 120 VAC. Relay #2 has
dry contacts.
• The zone LED illuminates.
• The demand is satisfied and opens RW (TT).
• The relay contacts return to their normal
position (common to normally closed).
• The zone LED turns off.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
9
10
A2 - Multiple thermostats
power
zone
transformer
N L
R
Caleffi!
single zone relay
RELAY 1
RELAY 2
C N/O N/C C N/O N/C
N
L
Hydronic diagram is for illustration purposes only and could be missing system components.
W
24 VAC
T
T
R
W
R
W
4-wire zone valve
W C
T com
4-wire zone valve
R
T
4-wire zone valve
End switch wires
Description of terminals
Sequence of Operation / Settings
= Ground
N
= Neutral (Common leg of 120 VAC)
• There is a demand by one of the t-stats which
sends power to the corresponding zone valve.
L
= Line (live leg of 120 VAC)
C
= Common terminal
• 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.
NO
= Normally Open terminal
• Relay #1 and relay #2 fire
NC
= Normally Closed terminal
• If the factory installed jumper has not been
removed, the NO terminal of relay #1 will
deliver the hot leg of 120 VAC thus firing the
pump.
Note: There is a factory installed jumper between the 120
VAC line (L) and the common terminal of relay #1 (C).
Thermostat terminals
R
W
C
= 24 VAC
= Heat call
= Common of 24 VAC
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
• Relay #2 closes the TT contacts on the boiler
signally a demand.
• The Zone LED 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 pump
and opening the RW (TT) contacts.
• The Zone LED turns off.
11
12
A3 - Single master thermostat, panel radiators with TRVs, variable speed pump
TRV
TRV
thermostatic!
radiator valves!
(TRV) on each!
radiator
TRV
TRV
TRV
TRV
R W C
T T com
buffer tank
power
zone
transformer
NL
N
L
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
Caleffi!
single zone relay
RELAY 1 RELAY 2
C N/ON/C C N/ON/C
T
T
Description of terminals
Sequence of Operation / Settings
= Ground
N
= Neutral (Common leg of 120 VAC)
L
= Line (live leg of 120 VAC)
C
= Common terminal
• 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.
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
W
C
= 24 VAC
= Heat call
= Common of 24 VAC
• 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 pump are
no longer enabled.
• The Zone LED turns off.
• 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 NO 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 LED illuminates.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
• 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.
13
14
ZSR10X - Multi-Zone Pump Control
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
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 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
See technical brochure 01286-14 NA for more product
information.
XX Closes for
heat demand
and DHW
demand. Rated
for 120 VAC,
2 amps.
DHW (ZR/ZC)
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 ON LED.
LED for each
zone.
120 VAC input
power connection
Multiple ground
connections for
easy wiring.
Replaceable
fuses (2 extra
included under
cover).
120 VAC zone
pump outputs.
120 VAC primary
pump output.
15
16
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, cover should release from
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.
Roll cover off base.
DHW
R
R
R
R
R
R
D
W
C
P
W
C
C
W
C
DIP Switches
on theWZSRCseries W C
Maintenance and Repair: The X Caleffi
Z-one™ multi-zone pump
control W The
X ZR/ZC
COMMS
T COM
T
T COM T
T COM T
T COM T
T COM T
T COM T
can be positioned for the following
DipSwitches
comes with two spare fuses. If control fails or is damaged, replace control with
T-STAT
6 Slave
T-STAT
1
T-STAT
2
T-STAT
3
T-STAT
4
T-STAT
5
operations.
Master
functional one.
Priority ON
Priority OFF
MasterR/ Slave:
allows
forWunlimited
Primary ON
Primary
OFF
DHW
TRANSFORMER
R
R
R
R OFF
R ON W
W
W
C
C
W
C Exercise
W
CExercise
C
expansion
toT additional
ZSR
relays.
X X ZR/ZC
Post Purge
Post Purge
T
T
COM T
T COM T
T COM
T OFFT COM
T ONT COM T
Boiler connections:
Priority T-STAT
OFF / Priority
ON: When
T-ST
1
T-STAT
2
T-STAT
3
T-STAT
4
T-STAT
5
XX = Dry contacts rated up to 120 VAC, 2 Amps.
priority mode is ON, upon demand,
Closes when any zone calls including priority. Typically
DHW
R
R as priority
R
R are
R
DipSwitches
W
C
W
C and
W temporarily
C
W
C
zoneR1 willW operate
all W
otherC zones
switched
off
X X ZR/ZC
connected to TT on boiler control.
Master
Slave
T
T
T time-out).
COM T When
T COM
T
T COM
T
T
COM
T
T
COM
(with T1 hour
priority
mode
is
OFF,
all
zones
remain
active.
Priority ON
Priority OFF
Primary
ON
Primary
OFF
TRANSFORMER
T-STAT
Primary
OFF / 1Primary
ON: 2
When
primaryExercise
is ON, the
pump
T-STAT
T-STAT
T-STAT
3mode
T-STAT
4 primary
T-STAT
5 will
DHW (ZR/ZC) = Dry contacts rated up
to 120 VAC, 2
ON
Exercise OFF
Post Purge ON
Post Purge OFF
continue to operate during priority.
Amps.
Closes
only
when
priority
is
enabled
and
calling.
DHW
R
D
R
R
R
R
R
W
C
P
W
C
W
C
W
C
W
C
W
C
DipSwitches
used to close ZR\ZC (120 VAC) or DHW contacts (24 VAC) on boiler
Exercise OFF / Exercise ON: When exercise mode isPWR
ON, each
circulator is
X X Typically
Master
Slave
ZR/ZC
COMMS
T COM
T
T COM T
T COM T
T COM T
T COM T
T COM T
Priority ON
Priority
OFF
controls equipped with these features.
switched
on
for
30
seconds
following
72
hours
of
inactivity.
PRIORITY
P
Primary ON
Primary OFF
T-STAT
6
T-STAT 1
T-STATPOWER
2
T-STAT
3
T-STAT
4
T-STAT
5
TRANSFORMER
GROUNDS
IN
Exercise
ON
Exercise
OFF
Post
Purge
/ Post
ON:3 When
post4purgePUMP
is ON,
PUMP
1 OFF
PUMP
PUMP
2 Purge
PUMP
5 the priority
PUMP 6pump
Post Purge ON
Post Purge OFF
ZONE1
L
continues
forN 2 minutes
after
the
N
L priority
N zone
L
L
N
L
N DipSwitches
L is switched
L off. N
Noperating
L
Communication connections:
Master
Slave
Connect terminals to matching terminal of slave boards
Priority ON
Priority OFF
Primary ON
Primary OFF
Primary pump output:
R
D TRANSFORMER
R D to
R
W
C
P
W D,CP to RP, Ground
W
C to Ground
W
C
ZONE2
Exercise ON
Exercise OFF
PWR pump runs when any zone pump runs. Its status Post Purge OFF
PRIORITY
PRIMARY
Post Purge ON
COMMS
Primary
M T
T COM T
T COM T
T COM
GROUNDS
POWERT IN T COM
PUMP
PUMP
1
PUMP 4
PUMP 2
PUMP 3
PUMP 5
PUMP 6
DipSwitches
during
priorityL (on\off)
canL be programmed
usingL the N
DIP
2
T-STAT 3
T-STAT 4
T-STAT
N
N
L 5 N T-STAT 6
L Slave N
N
N
L
Master
N
L
ZONE3 L
Priority ON
switches.
Priority OFF
Primary ON
Primary OFF ZONE1
TRANSFORMER
Input Power:
Exercise OFF
L =Exercise
Line ON(hot leg) ofPRIORITY
120 VAC to power the pump
Post Purge ON
Post Purge OFF
L = Line (hot leg) of 120 VAC supply
GROUNDS
POWER IN
N = Neutral leg of 120
VAC
PUMP
1 to power
PUMP 4
PUMP 2the pump
PUMP 3 ZONE4
PUMP 5
PUMP 6
N = Neutral of 120 VAC
ZONE2
N
L
N
L
L
L
N
N
N
L
N
L
N
L
= Ground
DipSwitches
ZONE5
Note: when connecting Master
2 or more
Z-one controls, all
PRIORITY
Slave
ZONE3 WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24 VAC
GROUNDS
POWER IN
Priority ON
Priorityby
OFFthe same
PUMP 1
PUMP 4
PUMP 2
PUMP 3
PUMP 5
PUMP 6
controls must be powered
120 VAC circuit.
Primary ON
Primary OFF
supply.
Exercise ON
Exercise OFF
N
L
N
L
L
L
N
N
N
L
N
L
ZONE6
N
L
Post Purge ON
Post Purge OFF
ZONE4
Zone pump outputs:
PRIORITY
WARNING: When PRIMARY
connecting 2 or more Z-one controls, all controls must be powered by
GROUNDS
POWER
IN
PUMP
Zone
pumps
run when
PUMP 1
PUMP 4
PUMP 2
PUMP 3
PUMP 5
PUMP
6
the same
120 VAC circuit.
ZONE5
N
L
Ncorresponding thermostat
L
N
L
L
L
N
N
N
L
N
L
N
L
initiates a demand.
GROUND = Connect the
ZONE6 WARNING: When replacing fuses, make sure power is disconnected to control box.
ground from the pump to the
ground terminal.
PRIMARY
PUMP
PUMP
4
PUMP 2PRIORITY
PUMP 3
PUMP
5
PUMP
6
PUMP = Runs when zone #1 calls. Can be programmed
to be the
N
L
L
N
L
L
N
N
N
L
N
L
priority zone.
L = Line (hot leg) of 120 VAC to power the pump
N = Neutral leg of 120 VAC to power the pump
6 Zone
ZSR106
6 Zone
ZSR106
6 Zone
ZSR106
6 Zone
ZSR106
6 Zone
ZSR106
6 Zone
ZSR106
17
18
Pump 4
Pump 3
Pump 1
Pump 2
B1 - Mod/con boiler, hydro separator or buffer tank, zone pumps
Buffer tank- Optional hydraulic
separator
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
T
T-STAT 1
W
C
T COM
T-STAT 2
R
T
W
C
T COM
T-STAT 3
R
T
W
C
T COM
T-STAT 4
R
W
T
C
T COM
T-STAT 5
R
T
W
C
D
P
COMMS
T COM
PWR
T-STAT 6
ZONE1
ZONE2
6 Zone
ZSR106
TRANSFORMER
DipSwitches
Master
Priority OFF
Primary OFF
Exercise OFF
Post Purge OFF
ZONE3
Slave
Priority ON
Primary ON
Exercise ON
Post Purge ON
ZONE4
ZONE5
ZONE6
POWER IN
L
GROUNDS
N
L
N
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
PRIORITY
PUMP 1
L
N
PUMP 2
L
N
PUMP 3
L
N
PUMP 4
L
N
PUMP 5
N
L
PUMP 6
N
L
PRIMARY
PUMP
N
L
Description of terminals
Sequence of Operation / Settings
= Ground
Priority switch: OFF
N
L
= Neutral (Common leg of 120 VAC)
= Line (Hot leg of 120 VAC)
Master / Slave switch: Master
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.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Status During Priority switch: OFF
• A demand occurs from any T-stat (T-stat
closes TT terminals). The “PUMP ON” LED
illuminates for that zone.
• ZSR control sends 120 VAC to the
corresponding zone pump and the primary
pump 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 “PUMP ON” LED
turns off and the 120 VAC to the zone pump
and primary pump outputs are dropped.
Dip switch description
Master / Slave: Used when joining 2 or more
controls together. Only one Master per group
Priority OFF / Priority ON: 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 ON: Sets the status of the
primary pump when there is a priority call. This
allows the DHW pump to be on either side of a
hydro separator.
Exercise OFF / Exercise ON: When enabled the
pumps will rub for 30 seconds after 72 hours
without a demand.
Post Purge OFF / Post Purge ON: Allows the DHW
pump to run for 2 minutes after the DHW demand
has been satisfied.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
19
20
Pump 6
Pump 5
Pump 1
boiler!
high limit!
control
Pump 4
Pump 2
Pump 3
B2 - Traditional boiler, indirect DHW w/ priority, zone pumps
DHW!
aquastat
DHW!
aquastat
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
T
THM 1
W
R
C
T COM
THM 2
W
T
R
C
T COM
T
THM 3
W
C
T COM
THM 4
R
W
T
R
C
W
T
T COM
D
C
T COM
P
COMMS
PWR
THM 6
THM 5
ZONE1
ZONE2
6 Zone
Z6P
ZSR106
TRANSFORMER
12/20VA
TT
ZC
ZR
DipSwitches
Master
Priority OFF
Primary OFF
Exercise OFF
Post Purge OFF
ZONE3
Slave
Priority ON
Primary ON
Exercise ON
Post Purge ON
ZONE4
ZONE5
ZONE6
PRIORITY
outdoor!
temperature!
sensor
POWER IN
L
GROUNDS
N
L
N
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
PUMP 1
L
N
PUMP 2
PUMP 3
PUMP 4
PUMP 5
L
L
L
L
N
N
N
N
PUMP 6
L
N
PRIMARY
PUMP
N
L
Description of terminals
Sequence of Operation / Settings
= Ground
Priority switch: ON (Zone #1 becomes priority)
N
L
= Neutral (Common leg of 120 VAC)
= Line (Hot leg of 120 VAC)
Master/Slave switch: Master
Thermostat terminals
R
= 24 VAC
W
= Heat call
C
= Common of 24 VAC
Primary Status During Priority switch: OFF
• A demand occurs from a T-stat (T-stat closes
TT terminals) in zones 2 thru 6.
• The “PUMP ON” LED illuminates for that zone.
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.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
• ZSR control sends 120 VAC to the
corresponding zone pump terminals to fire
the zone pump and closes the XX contacts
to signal a heat demand to the boiler. The
PRIMARY PUMP output will also deliver 120
VAC even if no pump is connected.
Dip switch description
Master / Slave: Used when joining 2 or more
controls together. Only one Master per group
Priority OFF / Priority ON: 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 ON: Sets the status of the
primary pump when there is a priority call. This
allows the DHW pump to be on either side of a
hydro separator.
Exercise OFF / Exercise ON: When enabled the
pumps will rub for 30 seconds after 72 hours
without a demand.
Post Purge OFF / Post Purge ON: Allows the DHW
pump to run for 2 minutes after the DHW demand
has been satisfied.
• 120 VAC is dropped from the corresponding
zone pump terminals.
• When the demand from the T-stat is satisfied
(T-stat opens TT terminals), the “PUMP ON”
LED turns off.
• If no other zones are calling, power is dropped
to the SEC PUMP and SYSTEM PUMP and
the XX contacts are opened.
• If a demand occurs from the DHW aquastat
(zone #1), The “PUMP ON” LED illuminates for
Zone #1.
• Once the Zone #1 DHW demand is satisfied,
power to the PRIORITY PUMP is dropped, the
DHW contacts open.
• If a demand from zones 2 thru 6 is present,
120 VAC is delivered to the corresponding
zone pump(s) and the “PUMP ON” LED 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 pumps.
DHW Time Out \ Freeze Prevention Feature
• After one hour of a priority demand, the control
will open the DHW contacts and turn off power
to the DHW pump.
• If a heating demand is present from Zones
#2- 6, the control will satisfy those demands
before going back to the DHW call.
• After the heating demands are met, the control
will go back to DHW and re-set the one hour
timer.
• If any other zone was calling (Zones 2 thru
6) when Zone #1 called, power (120 VAC) is
dropped to those zone pumps.
• The XX and DHW contacts close.
• The PRIORITY PUMP contacts deliver 120
VAC
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
21
22
Pump 3
Pump 1
Pump 2
B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps
boiler pump
Primary pump
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
T
T-STAT 1
W
C
T COM
T-STAT 2
R
T
W
C
T COM
T-STAT 3
R
T
W
C
T COM
T-STAT 4
R
W
T
C
T COM
T-STAT 5
R
T
W
C
D
P
COMMS
T COM
PWR
T-STAT 6
ZONE1
ZONE2
36 Zone
ZSR106
3
TRANSFORMER
DipSwitches
Master
Priority OFF
Primary OFF
Exercise OFF
Post Purge OFF
ZONE3
Slave
Priority ON
Primary ON
Exercise ON
Post Purge ON
ZONE4
ZONE5
ZONE6
POWER IN
L
N
GROUNDS
PRIORITY
PUMP 1
L
N
PUMP 2
L
N
PUMP 3
N
L
PUMP 4
L
N
PUMP 5
N
L
PUMP 6
N
L
PRIMARY
PUMP
N
L
L
N
boiler pump
Primary pump
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
Description of terminals
Sequence of Operation / Settings
= Ground
Priority switch OFF
N
L
= Neutral (Common leg of 120 VAC)
= Line (Hot leg of 120 VAC)
Master / Slave switch: Master
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.
DHW (ZR/ZC) = 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 DHW 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 ON: 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 ON: Sets the status of the
primary pump when there is a priority call. This
allows the DHW pump to be on either side of a
hydro separator.
Exercise OFF / Exercise ON: When enabled the
pumps will rub for 30 seconds after 72 hours
without a demand.
Post Purge OFF / Post Purge ON: Allows the DHW
pump to run for 2 minutes after the DHW demand
has been satisfied.
Status During Priority switch: OFF
• A demand occurs from any T-stat (T-stat
closes TT terminals). The “PUMP ON” LED
illuminates for that zone.
• ZSR control sends 120 VAC to the
corresponding zone pump and the primary
pump 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 “PUMP ON” LED turns off and
the 120 VAC to the zone pump and primary
pump outputs are turned off.
• ALTERNATE WIRING: The boiler pump can be
controlled by the Mod/Con boiler if equiped to
do so.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
23
24
ZVR10X - Multi-Zone Valve Control
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
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 status selectable during priority
• Pump will start only after the zone valve end switch
is closed
• Dry contacts for DHW (ZR/ZC), 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 priority
pump
• Front LED Lights
• 100% Factory tested with 3 year warranty
• ETL approved
See technical brochure 01285-14 NA for more product
information.
XX Closes for
heat demand
and DHW
demand. Rated
for 120 VAC
2 amps.
DHW (ZR/ZC)
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 ON LED.
Transformer
connections.
LED illuminates
when end switch
closes.
120 VAC input
power connection.
120 VAC output
to pumps.
System pump
(boiler pump)
status during
priority can be
changed with
jumper.
LED illuminates
with call for
heat.
ZONE #1
priority.
Zone valve motor
connections.
Zone valve
end switch
connection.
25
Cover removal
Hold either the left or the right end
of the box up and at an angle. Use
body for stabilizing relay box.
26
Insert screwdriver and push tab
inward, cover should release from
base.
Roll cover off base.
Remove transformer(s)
packaging.
Slide bottom end of transformer
into bottom latch.
Transformer Installation
Mount box on stable surface using
level.
from
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.
T-STAT 1
DHW
XX
R
W
C
R
W
T-STAT 2
C
ZR/ZC
T
T COM T
T COM
Maintenance and Repair: The Caleffi Z-one™ multi-zone valve relay comes with
T-STAT 1 T-STAT 2
a resettable fuse and requires no maintenance. If control fails or is damaged,
replace control with functional one.
R
T
6 Zone
W
R
C
T-STAT 4
W
T-STAT 5
R
C
T COM T
T COM
Thermostat connections
T-STAT 3
ZVR106
DHW
T-STAT 3
DHW
T-STAT 4
T
SLAVE
C
T COM
R
W
T
MASTER
C
TSAT2
T COM
SLAVE
T-STAT 6
T-STAT
5
R = 24 VAC.
T
D
ZON
T
R
R
R
R
W
C
W
C
W
C
W=
Heat
call
ZON
T
T COM T
T COM TSAT3
T
T COM
TT
C = Common of 24 VAC
R
R
R
R
R
W 4C T
W 1C T-STAT
W
C
W
C T-STAT
W 2 C T-STAT
W 3 C T-STAT
6
Zone
HeatRdemand
is initiated
by closing
R
MASTERT SLAVE
T COM T
T COM T
T
T COM T
T COM T
T COM T
T COM
to W.
T-STATZON
6
T-STAT 1 T-STAT 2
T-STAT 3 T-STAT 4
T-STAT 5 TSAT4
24 VAC is always present between R
& C.R W C R W C R W C T
R
R
W
C
W
C
XX
ZVR106
ZR/ZC
R
MASTER
W
TSAT1 ZON
T-STAT 6
T
W
C
T COM
The ZVR series of controls is programmed
X X ZR/ZC
by positioning a series of jumpers. Example
photo to right shows jumper in off position
STATUS
(left photo) and on position (right photo).
DURING
DHW
STATUS
PRIORITY
Jumpers are used for the following
ZON
X X ZR/ZC PRIORITY T T COM T T COM T T COM T T COMTSAT5
Dip
DURING
T
T COM
ON OFF
operations.
Mas
PRIORITY
T-STAT 1
T-STAT 2
T-STAT 3
T-STAT 4
T-STATPriority
5 OT
ON OFF connections
Zone valve
Primary O
Priority ON / Priority OFF: When priority
TRANSFORMER
PRIORITY
DipSwitches
Exercise O
ON
OFF
Post
Purge O
jumper is ON, upon demand, zone
1
will
Motor
=
24
VAC
to
power
the
zone
TSAT6
ZON
Master
Slave
PRIORITY SEC PUMP SYSTEM
POWER IN
Priority ON
Priority OFF
ON
OFF
ZONE
1
ZONE
2
ZONE
5
ZONE
ZONE
3
ZONE
4
PUMP
PUMP
operate as priority and all other zones are
Primary ON
valve motor Primary OFF
TRANSFORMER
Exercise END
ON
N
L
Exercise
L
N
N
L
END
END
END
ENDOFF
N
L
Purge
ON
Purge OFF MOTOR
temporarily switched off (with 1 hour timeSWITCH
SWITCH
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
MOTOR S
MOTOR
End Switch
=Post
Connects
toPostend
switch
SYSTEM
PRIORITY
SEC is
PUMP
ER IN out). When
priority mode
OFF, any
zones
on zone valve. Must be jumpered if
STATUS
ZONE
1
ZONE 2
ZONE 5
ZONE 6
ZONE 3
ZONE 4
PUMP
PUMP
that
were
active
when
zone
1
was
switched
N W C L R NW CL
END
ENDzone valve. END
END
END using a 2 –wire
D
RN W L C N R
W
C DURING
P END
on will remain on.
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
PWRMOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
PRIORITY
COMMS Input power
T COM
T Status
COM During
T
T COM
T During
COM T
Priority
ON /TStatus
PRIORITY
LPRIORITY
= Line 6
(hotZone
leg) of 120 VAC supply
GROUNDS
Priority
When 4
status T-STAT
jumper is 5
ON, T-STAT 6 ON OFF
POWER IN
T-STAT
3 OFF:
T-STAT
PUMP 1
PUMP 4
PUMP 2
PUMP 3
P
NL= Neutral
of 120
VACL
N
L
N
L
N
N
the system pump will continue to operate
L
ON OFFL
N
PRIORITY STATUS
= Ground
TSAT1 ZONE1
during priority.
GROUNDS
POWER IN
PUMP 1
PUMP 4
PUMP 2
PUMP 3
PUMP 5
PUMP 6
DURING
Master / POWER
Slave: allows
expansion
N
L
N
L
L
L
N
N
N
L
N
L
N PRIORITY
L
SYSTEM
PRIORITY
SEC PUMP MASTER
IN for unlimited
SLAVE
ZONE 1
ZONE 2 ON OFF ZONEPRIORITY
ZONE 5
to additional ZVR relays.
3
ZONE 4
PUMP
PUMP
N
L
TSAT2
ZONE2END
L
N
N
L
Pump
ENDoutputs
END
END
END
N
L
ON OFF
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITC
SYSTEM PUMP = Runs when any
Boiler Connections
PRIORITY SEC PUMP SYSTEM
POWER IN
zone
calls
When
priority
ZONE
1 for heat.
ZONE
2
ZONEis3
PUMP
PUMP
TSAT3
ZONE3
N
L
XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone
calls
L
N
N
L
END
END
N
L
enabled,
the
status
of
the
pump
(on\END
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH M
including priority. Typically connected to TT on boiler control.
off) during a priority call is selected via
DHW (ZR/ZC) = 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 ZONE4
SEC PUMP = Runs when any zone
or DHW contacts (24 VAC) on boiler controls equipped with these features.
calls for heat except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone calls. A jumper is required
Communication connections
TSAT5 ZONE5
between the END SWITCH terminals when using a pump for DHW.
Connect terminals to matching terminal of
boards
R
D
R
R
W
C
P
W slave
C
W
C
W
C
WARNING: NEVER CONNECT R & C DIRECTLY, this will be a direct short on the 24
ORITY
PWR
supply.
COMMS
T COM
T D
COM
COM
T
T Ground
COM T
TSAT6 VAC
ZONE6
to D,T P toT P,
Ground
to
OFF
T-STAT
T-STATUse
3 18
T-STAT
4 thermostat
T-STAT 5 wire.
gauge
Wire6
should be shielded if located in close proximity to high voltage wiring.
ZONE1
WARNING: When connecting 2 or more Z-one controls, all controls must be powered
ZVR106
6 Zone
6 Zone
ZSR106
6 Zone
ZSR106
ZVR106
ZVR106
6 Zone
ONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
END
END
END
END
END
END
ZONE2
SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
Zone
DipSwitches
Master
Priority OFF
Primary OFF
Slave
Priority ON
Primary ON
ZONE3
by the same 120 VAC circuit.
27
28
C1 - Mod/Con boiler, hydro separator, zone valves
mod/con!
boiler
ZV1
PRIORITY!
SYSTEM
ZV2
ZV3
ZV4
ZV5
ZV6
SECONDARY!
pump
pump
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
T
W
C
T COM
T-STAT 3
R
T
W
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
P
PWR
COMMS
T COM
T-STAT 6
TSAT1 ZONE1
MASTER
SLAVE
TSAT2 ZONE2
ZVR106
TSAT3 ZONE3
6 Zone
STATUS
DURING
PRIORITY
ON
OFF
TSAT5 ZONE5
PRIORITY
ON
POWER IN
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
L
N
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
N
SYSTEM
PUMP
L
N
TSAT4 ZONE4
TSAT6 ZONE6
OFF
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
Description of terminals
Sequence of Operation / Settings
= Ground
Priority Jumper: OFF
N
= Neutral (common leg of 120 VAC)
Master / Slave Jumper: Master
L
= Line (live leg of 120 VAC)
Status During Priority: OFF
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.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
• A demand occurs from any T-stat (T-stat
closes TT terminals). The “T-STAT CALL” LED
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 PUMP and
SYSTEM PUMP. The “VALVE OPEN” LED
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
CALL” and “VALVE OPEN” LED’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 PUMP and SYSTEM PUMP and
the XX contacts are opened.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
29
30
C2 - Mod/Con boiler, priority indirect DHW on primary side of hydro sep, zone valves
mod/con!
boiler
ZV2
ZV3
ZV4
ZV5
ZV6
DHW!
aquastat
PRIORITY!
pump
SECONDARY!
pump
SYSTEM!
pump
DHW!
AQUASTAT
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
T
W
C
T COM
T-STAT 3
R
W
T
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
P
PWR
COMMS
T COM
T-STAT 6
TSAT1 ZONE1
MASTER
SLAVE
TSAT2 ZONE2
ZVR106
TSAT3 ZONE3
6 Zone
STATUS
DURING
PRIORITY
ON
OFF
TSAT5 ZONE5
PRIORITY
ON
POWER IN
L
Buffer tank- Optional hydraulic
separator
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
TSAT4 ZONE4
TSAT6 ZONE6
OFF
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
ZV2
ZV3
ZV4
ZV5
ZV6
END
END
END
END
END
END
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
L
N
PRIORITY!
pump
SECONDARY!
pump
SYSTEM!
pump
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)
• Priority Jumper: ON (Zone #1 becomes
priority)
• The XX and DHW contacts close.
• Master/Slave Jumper: Master
• The PRIORITY PUMP contacts deliver 120
VAC
Thermostat terminals
R
= 24 VAC
W
= Heat call
C
= Common of 24 VAC
• Status During Priority: OFF
• The SEC PUMP and SYSTEM PUMP are off.
• A demand occurs from a T-stat (T-stat closes
TT terminals) in zones 2 thru 6. The “T-STAT
CALL” LED illuminates for that zone.
• Once the Zone #1 DHW demand is satisfied,
power to the PRIORITY PUMP is dropped, the
DHW contacts open.
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.
• ZVR control sends 24 VAC to the corresponding
zone MOTOR terminals to open the zone
valve.
• If a demand from zones 2 thru 6 is present,
24 VAC is delivered to the corresponding
zone valve(s) and the “T-STAT CALL” LED’s
illuminate.
L
= Line (live leg of 120 VAC)
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
• When the end switch on the zone valve closes,
the control sends 120 VAC to SEC PUMP and
SYSTEM PUMP. The “VALVE OPEN” LED
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
CALL” and “VALVE OPEN” LED’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 PUMP and SYSTEM PUMP and
the XX contacts are opened.
• If a demand occurs from the DHW aquastat
(zone #1), The “T-STAT CALL” LED illuminates
for Zone #1 and the “VALVE OPEN” LED
will illuminate. (When using a DHW pump,
a jumper must be installed on Zone #1 end
switch terminals.)
• When the zone valve end switch closes,
the “VALVE OPEN” LED illuminates, the XX
contacts close, the SEC PUMP and SYSTEM
PUMP terminals deliver 120 VAC.
DHW Time Out \ Freeze Prevention Feature
• After one hour of a priority demand, the control
will open the DHW contacts and turn off power
to the DHW pump 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 DHW call.
• After the heating demands are met, the control
will go back to DHW and re-set the one hour
timer.
• If any other zone was calling (Zones 2 thru
6) when Zone #1 called, power (24 VAC) is
dropped to those zones.
31
32
C3 - Mod/Con boiler, priority indirect DHW on load side of hydro sep, zone valves
Buffer tank- Optional hydraulic
separator
ZV2
SECONDARY!
pump
SYSTEM!
pump
PRIORITY!
pump
DHW!
AQUASTAT
DHW!
AQUASTAT
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
T
W
C
T COM
T-STAT 3
R
T
W
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
P
PWR
COMMS
T COM
T-STAT 6
TSAT1 ZONE1
MASTER
SLAVE
TSAT2 ZONE2
ZVR106
TSAT3 ZONE3
6 Zone
STATUS
DURING
PRIORITY
ON
OFF
TSAT5 ZONE5
PRIORITY
ON
POWER IN
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
TSAT4 ZONE4
TSAT6 ZONE6
OFF
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.
ZV3
ZV4
ZV5
ZV6
Description of terminals
Sequence of Operation / Settings
= Ground
Priority Jumper: ON (Zone #1 becomes priority)
N
= Neutral (common leg of 120 VAC)
Master/Slave Jumper: Master
L
= Line (live leg of 120 VAC)
Status During Priority: ON
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.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
• A demand occurs from a T-stat (T-stat closes
TT terminals) in zones 2 thru 6. The “T-STAT
CALL” LED illuminates for that zone.
• The PRIORITY PUMP and SYSTEM PUMP
contacts deliver 120 VAC
• The SEC PUMP is off.
• Once the Zone #1 DHW demand is satisfied,
power to the PRIORITY PUMP and SYSTEM
PUMP is dropped, the DHW contacts open.
• ZVR control sends 24 VAC to the corresponding
zone MOTOR terminals to open the zone
valve.
• If a demand from zones 2 thru 6 is present,
24 VAC is delivered to the corresponding
zone valve(s) and the “T-STAT CALL” LED’s
illuminate.
• When the end switch on the zone valve closes,
the control sends 120 VAC to SEC PUMP and
SYSTEM PUMP. The “VALVE OPEN” LED
illuminates for that zone and the XX contacts
close to signal a heat demand to the boiler.
• When the zone valve end switch closes,
the “VALVE OPEN” LED illuminates, the XX
contacts close, the SEC PUMP and SYSTEM
PUMP terminals deliver 120 VAC.
• When the demand from the T-stat is satisfied
(T-stat opens TT terminals), both the “T-STAT
CALL” and “VALVE OPEN” LED’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 PUMP and SYSTEM PUMP and
the XX contacts are opened.
• If a demand occurs from the DHW aquastat
(zone #1), The “T-STAT CALL” LED illuminates
for Zone #1 and the “VALVE OPEN” LED
will illuminate. (When using a DHW pump,
a jumper must be installed on Zone #1 end
switch terminals.)
DHW Time Out \ Freeze Prevention Feature
• After one hour of a priority demand, the control
will open the DHW contacts and turn off power
to the DHW pump 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 DHW call.
• After the heating demands are met, the control
will go back to DHW for and re-set the one
hour timer.
• 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 DHW contacts close.
33
34
C4- Mod/Con boiler, priority indirect DHW on primary side of hydro sep, expansion control
Buffer tank - Optional hydraulic
separator
ZV2
ZV3
ZV4
ZV8
ZV7
ZV6
ZV5
ZV9
ZV12
ZV11
ZV10
SECONDARY!
pump
PRIORITY!
pump
DHW!
AQUASTAT
SYSTEM!
pump
DHW!
AQUASTAT
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
T
W
C
T COM
T-STAT 3
R
W
T
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
P
XX
PWR
COMMS
T COM
DHW
R
ZR/ZC
T
T-STAT 6
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
W
T
C
T COM
T-STAT 3
R
W
T
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
TSAT1 ZONE1
MASTER
MASTER
SLAVE
TSAT2 ZONE2
STATUS
DURING
PRIORITY
ON
OFF
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
ZVR106
PRIORITY
STATUS
DURING
PRIORITY
TSAT6 ZONE6
OFF
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
L
N
ON
OFF
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
TSAT4 ZONE4
TSAT5 ZONE5
PRIORITY
ON
POWER IN
END
END
END
END
END
END
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
TSAT3 ZONE3
6 Zone
TSAT4 ZONE4
TSAT5 ZONE5
ON
POWER IN
TSAT2 ZONE2
TSAT3 ZONE3
6 Zone
PWR
TSAT1 ZONE1
SLAVE
ZVR106
P
COMMS
T COM
T-STAT 6
TSAT6 ZONE6
OFF
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
ZV7
ZV8
ZV9
ZV10
ZV11
ZV12
END
END
END
END
END
END
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
L
N
PRIORITY!
pump
SECONDARY
SECONDARY!
pump
pump
SYSTEM! SYSTEM
pump
pump
ZV2
ZV3
ZV4
ZV5
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
ZV6
Description of terminals
Sequence of Operation / Settings
= Ground
Control #1 (Master)
N
= Neutral (common leg of 120 VAC)
Priority Jumper: ON (Zone #1 becomes priority)
L
= Line (live leg of 120 VAC)
Master/Slave Jumper: Master
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.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
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
CALL” LED 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 PUMP and
SYSTEM PUMP. The “VALVE OPEN” LED
illuminates for that zone and the XX contacts
close to signal a heat demand to the boiler.
NOTE: The SEC PUMP output is only fired on the
control that receives the t-stat call. For instance,
if a zone from control #1 calls, the SEC PUMP on
control #1 fires but SEC PUMP on control #2 does
not. When using a single secondary pump with 2
controls, the secondary pump must be connected
to the “SYSTEM PUMP” terminals. (An alternative
wiring option for secondary pump is to wire the
secondary pump to the “SEC PUMP” terminals of
both controls).
• When the demand from the T-stat is satisfied
(T-stat opens TT terminals), both the “T-STAT
CALL” and “VALVE OPEN” LED’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 PUMP and SYSTEM PUMP and
the XX contacts are opened.
• If a demand occurs from the DHW aquastat
(zone #1), The “T-STAT CALL” LED illuminates
for Zone #1 and the “VALVE OPEN” LED
will illuminate. (When using a DHW pump,
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 DHW contacts close.
• The PRIORITY PUMP contacts deliver 120
VAC
• The SEC PUMP and SYSTEM PUMP are off.
• Once the Zone #1 DHW demand is satisfied,
power to the PRIORITY PUMP is dropped, the
DHW 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 CALL” LED’s
illuminate.
• When the zone valve end switch closes,
the “VALVE OPEN” LED illuminates, the XX
contacts close, the SEC PUMP and SYSTEM
PUMP terminals deliver 120 VAC.
• DHW Time Out \ Freeze Prevention Feature
• After one hour of a priority demand, the control
will open the DHW contacts and turn off power
to the DHW pump 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 DHW call.
• After the heating demands are met, the control
will go back to DHW for and re-set the one
hour timer.
35
36
ZV6
ZV5
ZV4
SYSTEM!
pump
ZV3
ZV2
C5 - Traditional boiler, indirect DHW (no priority) with valve, zone valves
ZV1
DHW!
aquastat
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
THM 1
W
T
R
C
T COM
THM 2
T
W
C
T COM
THM 3
R
W
T
C
T COM
THM 4
R
T
W
C
T COM
THM 5
R
T
W
C
D
P
PWR
COMMS
T COM
THM 6
Master/Slave
ZRV106
6 Zone
Z6V
THM1 ZONE1
THM2 ZONE2
THM3 ZONE3
THM4 ZONE4
THM5 ZONE5
STATUS
DURING
PRIORITY
POWER IN
L
N
PRIORITY
PUMP
L
N
SEC PUMP
L
L
N
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
N
SYSTEM
PUMP
THM6 ZONE6
PRIORITY
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
Description of terminals
Sequence of Operation / Settings
= Ground
Priority Jumper: OFF
N
= Neutral (common leg of 120 VAC)
Master/Slave Jumper: Master
L
= Line (live leg of 120 VAC)
Status During Priority: OFF
Thermostat terminals
R
= 24 VAC
W
= Heat call
C
= Common of 24 VAC
• 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 CALL” LED
illuminates for that zone.
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.
• ZVR control sends 24 VAC to the corresponding
zone MOTOR terminals to open the zone
valve.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
• When the end switch on the zone valve closes,
the control sends 120 VAC to SEC PUMP and
SYSTEM PUMP. The “VALVE OPEN” LED
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
CALL” and “VALVE OPEN” LED’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 PUMP and SYSTEM PUMP and
the XX contacts are opened.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
37
ZV6
ZV5
ZV4
SYSTEM!
pump
ZV3
ZV2
C6- Traditional boiler with reset control, priority indirect DHW with valve, zone valves
ZV1
DHW!
aquastat
DHW!
aquastat
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
THM 1
W
T
R
C
T COM
THM 2
T
W
C
T COM
THM 3
R
W
T
C
T COM
THM 4
R
T
W
C
T COM
THM 5
R
T
W
C
D
P
Master/Slave
ZRV106
6 Zone
Z6V
ZC ZR T T
PWR
COMMS
T COM
THM 6
THM1 ZONE1
THM2 ZONE2
THM3 ZONE3
THM4 ZONE4
THM5 ZONE5
STATUS
DURING
PRIORITY
POWER IN
L
N
PRIORITY
PUMP
L
N
SEC PUMP
L
N
L
N
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
SYSTEM
PUMP
THM6 ZONE6
PRIORITY
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
38
Description of terminals
Sequence of Operation
= Ground
Priority Jumper: ON (Zone #1 becomes priority)
N
= Neutral (common leg of 120 VAC)
Master/Slave Jumper: Master
L
= Line (live leg of 120 VAC)
Status During Priority: ON
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.
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
• A demand occurs from a T-stat (T-stat closes
TT terminals) in zones 2 thru 6. The “T-STAT
CALL” LED illuminates for that zone.
• The PRIORITY PUMP and SYSTEM PUMP
contacts deliver 120 VAC
• The SEC PUMP is off.
• Once the Zone #1 DHW demand is satisfied,
power to the PRIORITY PUMP and SYSTEM
PUMP is dropped, the DHW contacts open.
• ZVR control sends 24 VAC to the corresponding
zone MOTOR terminals to open the zone
valve.
• If a demand from zones 2 thru 6 is present,
24 VAC is delivered to the corresponding
zone valve(s) and the “T-STAT CALL” LED’s
illuminate.
• When the end switch on the zone valve closes,
the control sends 120 VAC to SEC PUMP and
SYSTEM PUMP. The “VALVE OPEN” LED
illuminates for that zone and the XX contacts
close to signal a heat demand to the boiler.
• When the zone valve end switch closes,
the “VALVE OPEN” LED illuminates, the XX
contacts close, the SEC PUMP and SYSTEM
PUMP terminals deliver 120 VAC.
• When the demand from the T-stat is satisfied
(T-stat opens TT terminals), both the “T-STAT
CALL” and “VALVE OPEN” LED’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 PUMP and SYSTEM PUMP and
the XX contacts are opened.
• If a demand occurs from the DHW aquastat
(zone #1), The “T-STAT CALL” LED illuminates
for Zone #1 and the “VALVE OPEN” LED
will illuminate. (When using a DHW pump,
a jumper must be installed on Zone #1 end
switch terminals.)
DHW Time Out \ Freeze Prevention Feature
• After one hour of a priority demand, the control
will open the DHW contacts and turn off power
to the DHW pump 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 DHW call.
• After the heating demands are met, the control
will go back to DHW and re-set the one hour
timer.
• 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 DHW contacts close.
39
C7 - Mod/Con boiler, hydro separator, zone valves (more than 6), multiple secondary pumps
40
"B"!
pump
"A"!
pump
A7 A8 A9 A10 A11A12
A1 A2 A3 A4 A5 A6
SYSTEM!
pump
XX
DHW
R
ZR/ZC
T
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
W
T
C
T COM
T-STAT 3
R
W
T
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
P
XX
PWR
COMMS
T COM
DHW
R
ZR/ZC
T
T-STAT 6
W
R
C
T COM
W
T
T-STAT 1
R
C
T COM
T-STAT 2
W
T
C
T COM
T-STAT 3
R
W
T
C
T COM
T-STAT 4
R
T
W
C
T COM
T-STAT 5
R
T
W
D
C
TSAT1 ZONE1
MASTER
MASTER
SLAVE
TSAT2 ZONE2
STATUS
DURING
PRIORITY
ON
OFF
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
ZVR106
PRIORITY
STATUS
DURING
PRIORITY
TSAT6 ZONE6
OFF
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
L
N
ON
OFF
L
N
PRIORITY
PUMP
N
L
SEC PUMP
L
N
SYSTEM
PUMP
L
N
TSAT4 ZONE4
TSAT5 ZONE5
PRIORITY
ON
POWER IN
END
END
END
END
END
END
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
TSAT3 ZONE3
6 Zone
TSAT4 ZONE4
TSAT5 ZONE5
ON
POWER IN
TSAT2 ZONE2
TSAT3 ZONE3
6 Zone
PWR
TSAT1 ZONE1
SLAVE
ZVR106
P
COMMS
T COM
T-STAT 6
TSAT6 ZONE6
OFF
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
A7
A8
A9
A10
A11
A12
END
END
END
END
END
END
MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH
L
N
"B"!
pump
SYSTEM!
pump
"A"!
pump
A1
A2
A3
A4
A5
Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
A6
Description of terminals
Sequence of Operation / Settings
= Ground
Control #1 (Master)
N
= Neutral (common leg of 120 VAC)
Priority Jumper: OFF
L
= Line (live leg of 120 VAC)
Master/Slave Jumper: Master
Thermostat terminals
R
= 24 VAC
W
= Heat call
C
= Common of 24 VAC
Status During Priority: OFF
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.
Master/Slave Jumper: Slave
DHW (ZR/ZC) = 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 DHW contacts (24 VAC) on boiler controls
equipped with these features.
Pump terminals
SYSTEM PUMP = Runs when any zone calls for
heat. When priority is enabled, the status of the
pump (on\off) during a priority call is selected via
a jumper
SEC PUMP = Runs when any zone calls for heat
except the priority zone when it is enabled.
PRIORITY PUMP = Runs when the priority zone
calls. A jumper is required between the END
SWITCH terminals when using a pump.
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.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply
• If no other zones are calling, power is turned
off to the SEC PUMP and SYSTEM PUMP and
the XX contacts are opened.
Control #2 (Slave)
Priority Jumper: OFF
Status During Priority: OFF
• A demand occurs from a T-stat (T-stat closes
TT terminals) in zones 1 thru 12. The “T-STAT
CALL” LED 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 PUMP
and to the SEC PUMP located on the ZVR
control that is seeing the demand. The “VALVE
OPEN” LED illuminates for that zone and the
XX contacts close to signal a heat demand to
the boiler.
NOTE: The SEC PUMP output is only fired on the
control that receives the t-stat call. For instance,
if a zone from control #1 calls, the SEC PUMP on
control #1 fires but SEC PUMP on control #2 does
not.
• When the demand from the T-stat is satisfied
(T-stat opens TT terminals), both the “T-STAT
CALL” and “VALVE OPEN” LED’s turn off.
• 24 VAC is dropped from the corresponding
zone MOTOR terminals.
41
42
Caleffi North America, Inc. / 3883 W Milwaukee Rd / Milwaukee, WI 53208
Tel: 414.238.2360 / Fax: 44.238.2366
www.caleffi.com/usa / sales@caleffi.com
©Copyright 2014 Caleffi North America, Inc