CALEFFI Z-one ZSR101 Series Wiring Manual
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CALEFFI Z-one ZSR101 Series Wiring Manual

Zone control relay
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Zone Control Relay
© Copyright 2018 Caleffi
Certified to C
Conforms to UL Standard 873
4009064
Product range
Code ZSR101 Z-one ™ Relay switching relay .................................................... single zone
Technical specifications
Materials
Housing plastic:
Front display lights:
Electrical Knockouts:
Performance
Power Supply:
Transformer Voltage:
Maximum transformer load:
Maximum operating temperature:
Maximum Humidity:
Electrical Switch Rating:
Replaceable Fuses:
Approvals:
Function
The ZSR101 single zone switching relay is operated by low
voltage thermostats. The ZSR101 single zone switching
relay incorporates Power In, Relay 1 and Relay 2 connection
terminals to provide a convenient and cost effective way to
control a circulator and a boiler operating control in a single
zone hydronic heating system. The ZSR101 single zone
switching relay saves hours in installation time and provide a
clean and professional installation.
Features
•
Compatible with low voltage 2, 3, or 4 wire thermostat
•
R, W, C and TT Comm dual labeling at thermostat
terminals
•
120 VAC pump outputs
•
High capacity transformer
•
Large screw terminal connections
C22-2 No.24
•
Simplified wiring with pre-installed jumper
•
Heavy duty sealed relay
•
Relay 1 and Relay 2 connection terminals
•
Fuse protected relays (with spare fuse)
•
Easy to read PC board layout
•
Compact modern design
•
Front LED Lights
•
100% Factory tested with 3 year warranty
•
ETL Approved
Certified to CSA C22-2 No.24, Conforms to UL Standard 873
www.caleffi.com
ZSR101 Series
120 VAC, 50/60 Hz
90% non-condensing
10A Max Combined
Type 2AG, 5A Slow Blow
NA10331.01
ABS
LED
(6) 1/2" size
24 VAC
6 VA
110°F (43°C)

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  • Page 1 NA10331.01 www.caleffi.com Zone Control Relay ZSR101 Series © Copyright 2018 Caleffi Function The ZSR101 single zone switching relay is operated by low voltage thermostats. The ZSR101 single zone switching relay incorporates Power In, Relay 1 and Relay 2 connection terminals to provide a convenient and cost effective way to control a circulator and a boiler operating control in a single zone hydronic heating system.
  • Page 2 Dimensions ZSR101 ZSR101 Single DPDT relay - Input: 120VAC 50/60Hz 10A MAX CAUTION: RISK OF ELECTRIC SHOCK - DISCONNECT ALL ZONE Single DPDT relay INPUT POWER PRIOR TO SERVICING Conforms 4009064 to UL 873 Milwaukee, WI 53208 USA Code Zones Wgt.
  • Page 3 ZSR101 TRANSFORMER Operating principles 1 Zone Supply 120 VAC hot to termilan L and 120 VAC neutral to N. When a zone has a demand A factory installed jumper from L terminal to the C terminal of from a thermostat (T T or R W) Relay 1 is supplied for simplified pump connection.
  • Page 4 1 Zone RELAY 1 RELAY 2 N L L C N/O N/C C N/O N/C variable-speed pressure-regulated mod/con boiler distribution circulator CALEFFI Caleffi North America, Inc. 3883 West Milwaukee Road Milwaukee, WI 53208 T: 414.238.2360 F: 414.238.2366 4-16-18...
  • Page 6 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.

  • Page 7: Table Of Contents

    C8 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves with ECM pump enabling ........44 C9 - Mod/Con boiler, hydro separator, zone 1 low temp, 2 - 6 high temp zone valves ..............46 Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.

  • Page 8: Z-One Relay Thermostat Connections Thermostat Wiring

    PUMP 2 PUMP 3 PUMP 4 PUMP 5 PUMP 6 PUMP PUMP 1 applicable codes and ordinances. moisture, corrosive fumes, vibration, or explosive vapors are present. Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.

  • Page 9: Zone Valve Wiring To Zvr Series

    Wiring a Taco 570 valve to Caleffi Z-one Relay series control must be connected to terminal 4 on the zone valve. When connecting the Taco 570 zone valve to the Caleffi Z-one Relay, The right motor terminal must be connected to terminal 1 on the the wiring of this valve can only be done in one way.

  • Page 10: Zsr101 - Single Zone Relay Product Overview

    ZSR101 Single Zone Switching Relay Overview • Compatible with 2, 3 and 4-wire thermostats or other low voltage controllers with switching action • 120 VAC input • Heavy duty, sealed, DPDT, fuse protected relay (with spare fuse) • Two dry contact outputs (Relay 1 and Relay 2) for operating 120 VAC pump with boiler enable or two devices without boiler enable • 5 A capacity each relay - 10 A total • Rear knock-outs for mounting onto 4”x4” junction box • High capacity 6VA transformer • Simplifi ed wiring with pre-installed jumper Certified to CSA C22-2 No.24 • 100% factory tested with 3 year warranty Conforms to UL Standard 873 • ETL certifi ed...

  • Page 11: Operation And Cover Removal

    Operating Principles Dual labeled T-stat terminals. When zone Compatible with 2, 3 and 4 Replaceable fuses. demand from a thermostat wire T-stats. (TT or R W) the relay will close sending 120 VAC 6 VA Transformer. to Relay #1 NO terminal and switching the pump on, and the C to NO dry contact on relay #2 closes,...

  • Page 12: A1 - Single Thermostat

    A1 - Single thermostat T com power zone transformer CalefÞ! single zone relay RELAY 1 RELAY 2 N L L C N/O N/C C N/O N/C Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
  • Page 13 Description of terminals Sequence of Operation / Settings = Ground • A demand occurs from the thermostat closing R to W on the ZSR101 control. The “ZONE” = Neutral (Common leg of 120 VAC) LED illuminates. = Line (live leg of 120 VAC) • The ZSR101 control will power relay #1 and #2 closing C to NO.

  • Page 14: A2 - Multiple Thermostats

    A2 - Multiple thermostats End switch wires T com power zone transformer CalefÞ! single zone relay RELAY 1 RELAY 2 N L L 24 VAC C N/O N/C C N/O N/C Hydronic diagram is for illustration purposes only and could be missing system components.
  • Page 15 Description of terminals Sequence of Operation / Settings = Ground • A demand occurs from one of the thermostats which sends power (from a separately sourced = Neutral (Common leg of 120 VAC) transformer) to the corresponding zone valve. = Line (live leg of 120 VAC) • When the zone valve opens the end switch will close R to W on the ZSR101 control.

  • Page 16: A3 - Single Master Thermostat, With Trvs, Variable Speed Pump

    A3 - Single master thermostat, panel radiators with TRVs, variable speed pump thermostatic radiator valves (TRV) on each radiator bu er tank T com power zone transformer ZSR101 RELAY 1 RELAY 2 C N/ON/C C N/ON/C Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.
  • Page 17 Description of terminals Sequence of Operation / Settings = Ground • A demand occurs from the thermostat closing R to W on the ZSR101 control. The “ZONE” = Neutral (Common leg of 120 VAC) LED illuminates. = Line (live leg of 120 VAC) • The ZSR101 control will power relay #1 and #2 closing C to NO.

  • Page 18: Zsr103, Zsr104 & Zsr106 - Multi-Zone Pump Relay Product Overview

    ZSR10X Multi-Zone Pump Control Overview • Compatible with low voltage 2, 3, or 4 wire thermostats • R, W, C and TT Comm dual labeling at thermostat terminals • Z-oneLink unlimited zone expansion • 120 VAC pump outputs • Selectable priority with 1 hour time-out feature • Selectable post purge and exercise • Dry contacts (X X , AUX, ZONE 1 E/S) capable of switching line voltage...

  • Page 19: Circuit Board

    AUX closes on a X X closes on a ZONE1 /ES closes Dual labeled demand for heat demand for heat only during a T-stat terminals. from any zone. demand from zone 1. Compatible with from any zone. 3 wire Rated for Rated for Rated for 2, 3 and 4 wire...

  • Page 20: Cover Removal

    Cover removal Roll cover off base. Hold either the left or the right end Insert screwdriver and push tab of the box up and at an angle. Use inward, cover should release from body for stabilizing relay box. base. Mounting: Do not mount to a surface that exceeds 115°F (45°C). The unit must be only located in dry interior locations.

  • Page 21: Product Details

    T-STAT 4 T-STAT 5 The ZSR series of control is Maintenance and Repair: The Caleffi Z-one™ multi-zone pump control programmed by positioning five dip comes with two spare fuses. If control fails or is damaged, replace control with POWE MASTER...

  • Page 22: B1 - Mod/Con Boiler, Hydro Separator Or Buffer Tank, Zone Pumps

    B1 - Mod/con boiler, hydro separator or buffer tank, zone pumps Bu er tank- Optional hydraulic separator ZONE 1 E / S COMMS T COM T COM T COM T COM T COM T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6...
  • Page 23 Description of terminals Sequence of Operation / Settings = Ground • Master / Slave switch: Master = Neutral (Common leg of 120 VAC) • Priority Switch: OFF = Line (Hot leg of 120 VAC) • Remote Enable Switch: OFF Thermostat terminals • Exercise Switch: OFF = 24 VAC = Heat call...

  • Page 24: B2 - Traditional Boiler, Indirect Dhw W/ Priority, Zone Pumps

    B2 - Traditional boiler, indirect DHW w/ priority, zone pumps boiler high limit control aquastat DHW aquastat ZONE 1 E / S T COM T COM T COM T COM T COM T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6...
  • Page 25 Description of terminals Sequence of Operation / Settings • Once the DHW aquastat (T-STAT 1) is satisfied it will open R to W and 120 VAC to PRIORITY = Ground • Master / Slave switch: Master PUMP 1 is dropped. The ZONE 1 E/S contacts = Neutral (Common leg of 120 VAC) • Priority Switch: ON open.

  • Page 26: B3 - Mod/Con Boiler, Primary Loop, Closely Spaced Tees, Zone Pumps

    B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps boiler pump Primary pump ZONE 1 E / S T COM T COM T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 POWER MASTER SLAVE ZONE1 PRIORITY ON REMOTE ENABLE ON ZONE2 EXERCISE ON TRANSFORMER...
  • Page 27 Description of terminals Sequence of Operation / Settings = Ground • Master / Slave switch: Master = Neutral (Common leg of 120 VAC) • Priority Switch: OFF = Line (Hot leg of 120 VAC) • Remote Enable Switch: OFF Thermostat terminals • Exercise Switch: OFF = 24 VAC = Heat call...

  • Page 28: B4 - Mod/Con Boiler, Hydro Separator Or Buffer Tank, Zone Pumps With Remote Enable

    B4 - Mod/con boiler with warm weather shut down, hydro separator or buffer tank, zone pumps Bu er tank- Optional hydraulic separator Boiler with outdoor reset/ warm weather shut down ZONE 1 and pump control E / S COMMS T COM T COM T COM T COM...
  • Page 29 Description of terminals Sequence of Operation / Settings • When the demand from the last thermostat calling is satisfied (thermostat opens R to W), = Ground • Master / Slave switch: Master the XX contacts are opened and the “PUMP = Neutral (Common leg of 120 VAC) • Priority Switch: OFF ON” LED turns off. The 120 VAC to the zone...

  • Page 30: Zvr103, Zvr104 & Zvr106 - Multi-Zone Valve Control Product Overview

    ZVR10X Multi-Zone Valve Control Overview • Compatible with low voltage 2, 3, or 4 wire thermostats • R, W, C and TT Comm dual labeling at thermostat terminals • Z-oneLink unlimited zone expansion • Selectable priority with 1 hour time-out feature • System pump and Secondary pump status selectable during priority • Pumps will start only after the zone valve end switch...

  • Page 31: Circuit Board

    Dual labeled AUX closes on a X X closes on a ZONE1 /ES closes demand for heat only during a T-stat terminals. demand for heat Compatible with from any zone. from any zone. demand from zone 1. 2, 3 and 4 wire Rated for Rated for Rated for...

  • Page 32: Cover Removal, Transformer Installation

    Cover removal Roll cover off base. Hold either the left or the right end Insert screwdriver and push tab of the box up and at an angle. Use inward, cover should release from body for stabilizing relay box. base. Transformer Installation Remove transformer(s) from...

  • Page 33: Product Details

    T-STAT 4 ZONE DURING PRIORITY DEMAND ZONE Thermostat connections Maintenance and Repair: The Caleffi Z-one™ multi-zone valve relay comes R = 24 VAC. ZVR106 with a automatic resettable fuse and requires no maintenance. If control fails or W = Heat call ZONE is damaged, replace control with functional one.

  • Page 34: C1 - Mod/Con Boiler, Hydro Separator, Zone Valves

    C1 - Mod/Con boiler, hydro separator, zone valves mod/con boiler SYSTEM pump SECONDARY pump ZONE 1 E / S COMMS T COM T COM T COM T COM T COM T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 POWER...
  • Page 35 Description of terminals Sequence of Operation / Settings = Ground • Master / Slave switch: Master = Neutral (Common leg of 120 VAC) • Pump Exercise: OFF = Line (Hot leg of 120 VAC) • Priority: OFF Thermostat terminals • AUX During Priority Demand: OFF = 24 VAC = Heat call • System Pump Status During Zone 1 Demand...

  • Page 36: C2 - Mod/Con Boiler, Indirect Dhw On Primary Side Of Hydro Sep, Zone Valves

    C2 - Mod/Con boiler, priority indirect DHW on primary side of hydro sep, zone valves mod/con boiler aquastat DHW PRIORITY SECONDARY pump pump SYSTEM pump AQUASTAT ZONE 1 E / S T COM T COM T COM T COM T COM T COM COMMS T-STAT 1...
  • Page 37 Description of terminals Sequence of Operation / Settings • If any other zone was calling for heat (zones 2-6) when zone 1 is calling 24 VAC is dropped = Ground Master • Master / Slave switch: to those zone’s MOTOR terminals. = Neutral (Common leg of 120 VAC) • Pump Exercise: “T-STAT CALL” and “VALVE OPEN” LED will...

  • Page 38: C3 - Mod/Con Boiler, Indirect Dhw On Load Side Of Hydro Sep, Zone Valves

    C3 - Mod/Con boiler, priority indirect DHW on load side of hydro sep, zone valves Bu er tank- optional hydraulic separator SECONDARY pump SYSTEM pump DHW PRIORITY pump AQUASTAT AQUASTAT ZONE 1 E / S COMMS T COM T COM T COM T COM T COM...
  • Page 39 Description of terminals Sequence of Operation / Settings • If any other zone was calling for heat (zones 2-6) when zone 1 is calling 24 VAC is dropped = Ground • Master / Slave switch: Master to those zone’s MOTOR terminals. The “T-STAT = Neutral (Common leg of 120 VAC) • Pump Exercise: CALL” and “VALVE OPEN” LED will also turn off.

  • Page 40: C4 - Mod/Con Boiler, Indirect Dhw On Primary Side Of Hydro Sep, Master And Slave Control

    C4- Mod/Con boiler, priority indirect DHW on primary side of hydro sep, expansion control NOTE: 120 VAC is only sent to the SEC PUMP terminals on the control that receives the call for heat. For instance, if a zone from the Master control calls, the SEC PUMP on the Master control sends 120 VAC and SEC PUMP on the Slave control does not.
  • Page 41 Description of terminals Sequence of Operation / Settings • If no other zones are calling for heat the XX contacts will open terminating the demand for = Ground Control #1 heat to the boiler. The 120 VAC is dropped to = Neutral (Common leg of 120 VAC) • Master / Slave switch: Master the SYSTEM PUMP and SEC PUMP.

  • Page 42: C5 - Traditional Boiler, Indirect Dhw (No Priority) With Valve

    C5 - Traditional boiler, indirect DHW (no priority) with pump, zone valves SYSTEM pump DHW PRIORITY pump aquastat aquastat ZONE 1 E / S T COM T COM T COM T COM T COM T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5...
  • Page 43 Description of terminals Sequence of Operation / Settings • NOTE: At this point, the control has signaled the boiler of a DHW demand which (in most = Ground • Master / Slave switch: Master cases) will override any outdoor reset controls = Neutral (Common leg of 120 VAC) • Pump Exercise: OFF and raise the temperature of the boiler.

  • Page 44: C6 - Traditional Boiler With Reset Control, Priority Indirect Dhw With Valve

    C6- Traditional boiler with priority indirect DHW with valve, zone valves SYSTEM pump DHW ZV1 aquastat aquastat ZONE 1 E / S T COM T COM T COM T COM T COM T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6...
  • Page 45 Description of terminals Sequence of Operation • When the ZONE 1 zone valve end switch closes, the “VALVE OPEN” LED illuminates for = Ground • Master / Slave switch: Master ZONE 1. = Neutral (Common leg of 120 VAC) • Pump Exercise: OFF • If any other zone was calling for heat (zones = Line (Hot leg of 120 VAC) • Priority: ON 2-6) when zone 1 is calling 24 VAC is dropped...

  • Page 46: C7 - Mod/Con Boiler, Hydro Separator, Zone Valve (More Than 6), Multiple Secondary Pumps

    C7 - Mod/Con boiler, hydro separator, zone valves (more than 6), multiple secondary pumps "B" "A" pump pump A11 A12 A5 A6 SYSTEM pump ZONE 1 ZONE 1 E / S COMMS E / S COMMS T COM T COM T COM T COM T COM...
  • Page 47 Description of terminals Sequence of Operation / Settings • NOTE: 120 VAC is only sent to the SEC PUMP terminals on the control that receives = Ground Control #1 the call for heat. For instance, if a zone from = Neutral (Common leg of 120 VAC) • Master / Slave switch: Master the Master control calls, the SEC PUMP on = Line (Hot leg of 120 VAC)

  • Page 48: C8 - Mod/Con Boiler, Indirect Dhw On Primary Side Of Hydro Sep, Zone Valves With Ecm Pump Enabling

    C8 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves, ECM pump enable mod/con boiler aquastat DHW PRIORITY SECONDARY pump pump SYSTEM pump AQUASTAT ZONE 1 E / S T COM T COM T COM T COM COMMS T-STAT 1 T-STAT 2...
  • Page 49 Description of terminals Sequence of Operation / Settings 2-6) when zone 1 is calling 24 VAC is dropped to those zone’s MOTOR terminals. The “T-STAT = Ground Master • Master / Slave switch: CALL” and “VALVE OPEN” LED will also turn off. = Neutral (Common leg of 120 VAC) • Pump Exercise: The AUX contacts will also open terminating the = Line (Hot leg of 120 VAC)

  • Page 50: C9 - Mod/Con Boiler, Hydro Separator, Zone 1 Low Temp, 2 - 6 High Temp Zone Valves

    C9 - Mod/Con boiler, hydro separator, Zone 1 low temp pump, zones 2 - 6 high temp zone valves mod/con boiler ZONE 1 Pump SYSTEM pump SECONDARY pump ZONE 1 E / S COMMS T COM T COM T COM T COM T COM T COM...
  • Page 51 Description of terminals Sequence of Operation / Settings • If zone 1 thermostat is still calling for heat the XX contacts will remain closed and the = Ground • Master / Slave switch: Master SYSTEM PUMP and the ZONE #1 PUMP will = Neutral (Common leg of 120 VAC) • Pump Exercise: OFF remain powered.
  • Page 52 Caleffi North America, Inc. / 3883 W Milwaukee Rd / Milwaukee, WI 53208 Tel: 414.238.2360 / Fax: 44.238.2366 www.caleffi.com / Ask.Us@caleffi.com ©Copyright 2016 Caleffi North America, Inc...

This manual is also suitable for:

Z-one zsr103Z-one zvr104Z-one zvr106Z-one zsr104Z-one zsr106Z-one zvr103

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