CALEFFI Z-one ZVR103 Manual de usuario

Function

The ZVR series is a multi-zone zone valve and boiler

operating control for multiple zone hydronic heating

systems. The ZVR series interfaces with low voltage

thermostats, or any other low voltage controllers having

a switching action. The ZVR series controls up to 3, 4,

5 or 6 zones, depending on model selected. In addition,

a system pump, secondary pump and a priority (DHW)

pump can also be controlled. LED indicators provide

functional status and easy system troubleshooting. The

ZVR series is a perfect match with Caleffi’s Z-one™

motorized zone valves.

t Compatible with low voltage 2, 3, or 4 wire thermostats

t R, W, C and TT Comm dual labeling at thermostat terminals

t Z-oneLink™ unlimited zone expansion to ZVR and ZSR series

t Selectable priority with 1 hour time-out feature

t System and secondary pump status selectable during ZONE 1 demand

t Circulator will start only after the zone valve end switch is closed

t Dry contact for ZONE 1 (DHW), capable of switching line voltage

t Dry contact AUX for signaling a variable speed self regulated pump or other controls

t Large terminal connections

t High Capacity 40 VA Transformer standard for 3 and 4 zone models-expandable to 80 VA,

and 80 VA standard for the 6 zone model

t Automatic resettable low voltage fuse

t Controls system pump, secondary pump, and priority pump

t Front LED Lights

t 100% Factory tested with 3 year warranty, ETL Listed / CSA Certiﬁed

Technical specifications

Materials

Housing plastic: ABS

Front display lights: LED

Electrical Knockouts: (12) 1/2" size

Performance

Power supply: 120 VAC, 50/60 Hz

Transformer voltage: 24 VAC

Maximum transformer load: 40 VA (ZVR103/4), 80 VA (ZVR106)

Electrical switch rating: 20A Max Combined

Electrical switch rating, AUX, ZONE 1, XX: 120 VAC, 2A each

Electrical switch rating pumps: 120 VAC, 5A each

Resettable Fuse: automatic

Working temperature range: 32°F (0°C)—115°F (45°C)

Maximum humidity: 90% non-condensing

Approvals: Conforms to UL873 / Certiﬁed to CSA C22 No 24, listed by ETL

NA10333 G2

Z-one™Relay Multi-Zone Valve Control

ZVR10X series

www.caleffi.com

Product Range

Code ZVR103 Z-one™ Relay zone valve control...........................................................three zone

Code ZVR104 Z-one™ Relay zone valve control.............................................................four zone

Code ZVR106 Z-one™ Relay zone valve control...............................................................six zone

4009064

Certified to CSA C22-2 No.24

Conforms to UL Standard 873

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual to draw attention to safety

related instructions. When used, the safety alert symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.

CAUTION: All work must be performed by qualified personnel trained in the

proper application, installation, and maintenance of systems in accordance

with all applicable codes and ordinances.

CAUTION: Electrical shock hazard. Disconnect power before installation to

prevent electrical shock or equipment damage. Make sure all connections

are in accordance with the electrical wiring diagram and in accordance with

national and local electrical codes.

WARNING: Avoid electrical noise interference. Do not install near large

conductors, electrical machinery, or welding equipment. Avoid locations

where excessive moisture, corrosive fumes, vibration, or explosive vapors are

present.

Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.

Dimensions

POWER

ZONE 1

ZONE 2

ZONE 3

ZONE 4

ZONE 5

ZONE 6

ZVR106

Six zone switching - Input: 120VAC 50/60Hz 20A MAX

Conforms

to UL 873

4009064

CAUTION:

RISKOF ELECTRIC SHOCK - DISCONNECT ALL

INPUTPOWER PRIOR TO SERVICING

Milwaukee,WI 53208 USA

POWER

ZONE 1

ZONE 2

ZONE 3

ZONE 4

ZONE 5

ZONE 6

T-STAT

CALL

VALVE

OPEN

Code Zones A B C Wgt. (lbs)

ZVR103 3 9 1/4"11"3"3.2

ZVR104 4 9 1/4"11"3"3.2

ZVR106 6 9 1/4"11"3"3.2

Inspect packages for damage. If damaged, notify the appropriate carrier immediately. If undamaged,

open the package and inspect the device for obvious damage. Return damaged products.

r Use only copper conductor supply wire suitable for at least 105° C

r All circuits must have a common disconnect and be connected to the same pole of the disconnect

Maintenance and Repair

The Caleffi Z-one™multi-zone valve control comes with a automatic resettable low voltage fuse

and requires no maintenance. If control fails or is damaged, replace control with functional one.

Mounting

Mount the Caleffi Z-one™switching relay box to a suitable surface. Slotted holes are provided for

mounting purposes. Do not mount to a surface that exceeds 115°F (45°C). The unit must be only

located in dry interior locations. It is not suitable for installation in hazardous locations and should

not be placed close to any electromagnetic fields.

Cover removal

Hold either the left or the right

end of the box up and at an

angle.

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.

Feed wiring through hole near

the top of the transformer and

insert transformer plug into the

socket.

Repeat process for 2nd

transformer if six valve relay

box.

Installation

CAUTION: If unit is below 32

F (0

C), expose to room temperature for 15 minutes before

pressing cover release tabs. Failure to do so could cause damage to the enclosure.

When a zone has a demand from

a thermostat (T T / R W) the

control will send 24 VAC to the

corresponding zone valve. When

the zone valve end switch closes,

the system and secondary pump

will switch on and the (X X) dry

contact will close to signal the boiler of a heating demand. AUX dry contact will also close as a

signal to a variable speed self regulated pump or other controls. ZONE 1 can be used for priority

(either a priority pump or valve). When the priority dip switch is ON, a demand from T-STAT 1 will

activate 24VAC to VALVE 1 and the ZONE 1 pump relay, 120 VAC will switch on after the end switch

closes (requires a jumper in the end switch terminals if a valve is not used). The DHW (ZONE 1) dry

contact will also close.

Depending upon "Status During Zone 1 Demand" jumpers, the secondary and / or system pump

will either be ON or OFF.

Status During Zone 1 Demand ON / OFF: When

status jumper is placed on ON pins, the secondary

and / or system pump will continue to operate during

ZONE 1 demand. When jumper is placed on OFF pins,

the corresponding pump will be OFF during ZONE 1

demand.

XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically

connected to T T on boiler control, closes when any zone calls including

priority. ZONE 1 / ES (DHW) = Dry contact, rated up to 120 VAC, 2

Amps, close with any call to ZONE 1. When priority is enabled and ZONE

1 is calling, it is typically used to close DHW contact on boiler controls

equipped with these features. AUX = Dry contact, rated up to 120 VAC,

2 Amps, close when any zone calls and can be used

as signal to a variable speed self regulated

pump. When there is a priority demand, then AUX will follow the selection of the AUX dip switch.

The ZVR series of controls is programmed by

positioning four dip switches for the following

operations.

Master / Slave: allows for unlimited expansion to

additional ZVR or ZSR relays boards.

Pump Exercise ON / OFF: When exercise mode is

ON, each circulator is switched on for 30 seconds

following 72 hours of inactivity.

Priority ON / OFF: When priority switch is ON, upon

demand to TSTAT 1 , ZONE 1 will operate as priority

and all other zones are temporarily switched off (with 1 hour time-out). When priority is OFF, any

zones that were active when ZONE 1 was switched on will remain on.

AUX ON / OFF: When AUX switch is ON, AUX dry contact is activated with a demand to any zone

including priority. When AUX is OFF, AUX dry contact is activated during any demand except priority.

ZONE #1

PUMP

SEC

PUMP

STATUS DURING

ZONE #1 DEMAND

SYSTEM

PUMP

MASTER

PUMP EXERCISE ON

PRIORITY ON

AUX ON

SLAVE

OFF

DURING PRIORITY DEMAND

Dip switch settings

ZONE 1

E / S

AUX

Boiler Connections

T-STAT 2

TTCOM

T-STAT 3

T T COM

T-STAT 1

T T COM

T-STAT 4

T T COM

Thermostats

Large screw terminals connections makes wiring easy with three pump screw terminal connections.

Pump terminals connection have 120 VAC outputs for simpliﬁed pump connections. Zone valve

connections can be 2, 3 or 4 wire.

Z-oneLink™ unlimited expansion allows connecting additional ZVR & ZSR

series relay controls to a Master ZVR. Communication is accomplished by

connecting three wires (thermostat wire) to the communication terminals

located in the upper right hand corner. The dip switch is positioned to Master /

Slave position. A demand for heat from any zone will fire the boiler and start the

pump. Only one relay board can be the Master and Priority, Slave is used for subsequent boards.

POWER IN

ZONE #1

PUMP

SEC

PUMP

ZONE 1

SWI

MOTOR

SYSTEM

PUMP

COMMS

Wiring terminals

ZONE 1

END

SWITCH

MOTOR

MOTO

Wiring 2 wire, 3 wire & 4 wire zone valves

The Taco 570 three wire zone valve presents a unique wiring

challenge. When connecting the Taco 570, the wiring of this

valve can only be done in one way. The left motor terminal on

the ZVR series control must be connected to terminal 2 on the

zone valve. The right motor terminal must be connected to

terminal 1 on the zone valve. Lastly, the left end switch terminal

must be connected to terminal 3 on the zone valve. Failure to

follow schematic will lead to damage of product.

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 the end switch. If the end switch jumper

is not installed, no demand will be sent to the boiler and the

pumps will not turn on

2 1 3

The four wire zone valve is the most straight forward of the three

types of valves to wire. Simply connect the two motor leads to

motor leads, and the two end switches to end switches.

NE 2

END

SWITCH

ZONE 3

END

SWITCH

MOTOR M

ZONE 1

END

SWITCH

ZONE 2

END

SWITCH

MOTOR

Example Wiring Diagram

VENT

SYSTEM pump

SECONDARY

pump

ZV1 ZV4ZV3ZV2 ZV5 ZV6

SYSTEM

pump

SECONDARY

pump

mod/con

boiler

6 Zone

ZVR106

POWER IN

POWER

T-SAT

CALL

ZONE 6

ZONE #1

PUMP

SEC

PUMP

STATUS DURING

ZONE #1 DEMAND

ZONE 1

END

SWITCH

MOTOR

ZONE 2

END

SWITCH

MOTOR

ZONE 3

END

SWITCH

MOTOR

ZONE 4

END

SWITCH

MOTOR

ZONE 5

END

SWITCH

MOTOR

ZONE 6

END

SWITCH

MOTOR

SYSTEM

PUMP

T-STAT 2

TTCOM COMMS

ZONE 1

E / S

T-STAT 3

TTCOM

T-STAT 1

TTCOM

T-STAT 4

TTCOM

T-STAT 5

TTCOM

T-STAT 6

TTCOM

AUX













VALVE

OPEN

ZONE 1

ZONE 2

ZONE 4

ZONE 5

ZONE 3

MASTER

PUMP EXERCISE ON

PRIORITY ON

AUX ON

SLAVE

OFF

DURING PRIORITY DEMAND

set to ON





Please reference Z-one™ Relay wiring guide for complete listing of wiring diagrams.

Mod-Con boiler with

Primary/Secondary

outdoor

temperature

sensor

boiler

reset

controller

space heating thermostats

DHW

aquastat

space

heating

demand

domestic water

heating demand

SYSTEM

pump

ZV1 ZV2 ZV4ZV5 ZV6ZV3

indirectDHW tank

DHW

aquastat

VENT

ZV1

ZV2

ZV4

ZV5

ZV6

ZV3

SYSTEM

pump

6 Zone

ZVR106

POWER IN

POWER

T-SAT

CALL

ZONE 6

ZONE #1

PUMP

SEC

PUMP

STATUS DURING

ZONE #1 DEMAND

ZONE 1

END

SWITCH

MOTOR

ZONE 2

END

SWITCH

MOTOR

ZONE 3

END

SWITCH

MOTOR

ZONE 4

END

SWITCH

MOTOR

ZONE 5

END

SWITCH

MOTOR

ZONE 6

END

SWITCH

MOTOR

SYSTEM

PUMP

T-STAT 2

T T COM COMMS

ZONE 1

E / S

T-STAT 3

T T COM

T-STAT 1

T T COM

T-STAT 4

TTCOM

T-STAT 5

TTCOM

T-STAT 6

T T COM

AUX

















VALVE

OPEN

ZONE 1

ZONE 2

ZONE 4

ZONE 5

ZONE 3

MASTER

PUMP EXERCISE ON

PRIORITY ON

AUX ON

SLAVE

OFF

DURING PRIORITY DEMAND

set to ON

Non-condensing boiler with

outdoor reset and indirect DHW

Caleffi North America, Inc.

3883 West Milwaukee Road

Milwaukee, WI 53208 USA

T: 414.238.2360 F: 414.238.2366

CALEFFI

"A"

pump

SYSTEM

pump "B"

pump

SYSTEM

pump

A4A3A2 A5 A6

"A"

pump

"B"

pump

A10A9A8 A11 A12A7

A4A3A2 A5 A6A1 A10A9A8 A11 A12A7

6 Zone

ZVR106

POWER IN

POWER

T-SAT

CALL

ZONE 6

ZONE #1

PUMP

SEC

PUMP

STATUS DURING

ZONE #1 DEMAND

ZONE 1

END

SWITCH

MOTOR

ZONE 2

END

SWITCH

MOTOR

ZONE 3

END

SWITCH

MOTOR

ZONE 4

END

SWITCH

MOTOR

ZONE 5

END

SWITCH

MOTOR

ZONE 6

END

SWITCH

MOTOR

SYSTEM

PUMP

T-STAT 2

TTCOM COMMS

ZONE 1

E / S

T-STAT 3

TTCOM

T-STAT 1

TTCOM

T-STAT 4

TTCOM

T-STAT 5

TTCOM

T-STAT 6

TTCOM

AUX

















VALVE

OPEN

ZONE 1

ZONE 2

ZONE 4

ZONE 5

ZONE 3

MASTER

PUMP EXERCISE ON

PRIORITY ON

AUX ON

SLAVE

OFF

DURING PRIORITY DEMAND

6 Zone

ZVR106

POWER IN

POWER

T-SAT

CALL

ZONE 6

ZONE #1

PUMP

SEC

PUMP

STATUS DURING

ZONE #1 DEMAND

ZONE 1

END

SWITCH

MOTOR

ZONE 2

END

SWITCH

MOTOR

ZONE 3

END

SWITCH

MOTOR

ZONE 4

END

SWITCH

MOTOR

ZONE 5

END

SWITCH

MOTOR

ZONE 6

END

SWITCH

MOTOR

SYSTEM

PUMP

T-STAT 2

TTCOM COMMS

ZONE 1

E / S

T-STAT 3

TTCOM

T-STAT 1

TTCOM

T-STAT 4

TTCOM

T-STAT 5

TTCOM

T-STAT 6

TTCOM

AUX

















VALVE

OPEN

ZONE 1

ZONE 2

ZONE 4

ZONE 5

ZONE 3

MASTER

PUMP EXERCISE ON

PRIORITY ON

AUX ON

SLAVE

OFF

DURING PRIORITY DEMAND

set to ON set to ON

Mod-Con boiler with Primary/Secondary and

two secondary pumps

WIRING GUIDE

4009064

Certified to CSA C22-2 No.24

Conforms to UL Standard 873

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 simpliﬁ ed wiring.

The ZVR Series of controls is for zoning using zone valves. Up to 6 valves (model dependent), along with a system pump,

secondary pump and zone 1 pump (typically used for DHW priority) can be operated. Zone priority is selectable with 1-hour

time-out feature. System pump and secondary pump status (on/off) during priority is also selectable. Replaceable snap-ﬁ t 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.

Form 031914 rev.2

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