CALEFFI Z-one ZSR10X Series Manual

Relay multi-zone pump control

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Z-one

Relay Multi-Zone Pump Control

™

Certified to CSA C22-2 No.24

Conforms to UL Standard 873

4009064

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

R, W, C and T T COM dual labeling at thermostat terminals

Z-oneLink™ unlimited zone expansion

120 VAC pump outputs

Remote Enable input 24 - 120 VAC

Selectable Priority with 1 hour time-out

Selectable Post Purge and Exercise

Dry contacts for ZONE 1 (DHW), capable of switching line voltage

High capacity transformer

Large terminal connections

Simpliﬁ ed wiring with extra ground terminals

Heavy duty sealed relays

All pumps fuse protected (with spare fuse)

Front LED Lights

100% Factory tested with 3 year warranty, ETL Approved

Product Range

Code ZSR103 Z-one™ Relay pump control.................................................................three zone

Code ZSR104 Z-one™ Relay pump control...................................................................four zone

Code ZSR106 Z-one™ Relay pump control.....................................................................six zone

Technical specifications

Materials

Housing plastic:

Front display lights:

Electrical knockouts:

Performance

Power supply:

Transformer voltage:

Maximum transformer load:

Electrical switch rating pump output:

Dry contact rating, Zone 1 ES, XX, AUX:

Replaceable fuses:

Working temperature range:

Maximum humidity:

Approvals:

Function

The ZSR series is a multi-zone pump and boiler

operating control for multiple zone hydronic heating or

cooling systems. The ZSR series interfaces with low

voltage thermostats, or any other low voltage controllers

having a switching action. The ZSR series controls up

to 3, 4, 5 or 6 heating circulator pumps (depending

on model selected), a primary pump and has LED

indicators to provide functional status and easy system

troubleshooting.

Conforms to UL873 / Certiﬁ ed to CSA C22 No 24, listed by ETL

www.caleffi.com

ZSR10X series

12 VA (ZSR103/4), 20 VA (ZSR106)

120 VAC, 5A each

120 VAC max, 2A each

Type 2AG, 5A slow blow

32°F (0°C)—115°F (45°C)

90% non-condensing

NA10334 G2.01

ABS

LED

(12) 1/2" size

120 VAC, 50/60 Hz

24 VAC

(20A max combined)

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Questions and answers

Summary of Contents for CALEFFI Z-one ZSR10X Series

Page 1 NA10334 G2.01 www.caleffi.com Z-one Relay Multi-Zone Pump Control ™ © Copyright 2018 Caleffi ZSR10X series Function The ZSR series is a multi-zone pump and boiler operating control for multiple zone hydronic heating or cooling systems. The ZSR series interfaces with low voltage thermostats, or any other low voltage controllers having a switching action.
Page 2 Dimensions POWER ZONE 1 ZONE 2 ZSR106 Six switching relays - Input: 120VAC 50/60Hz 20A MAX ZONE 3 CAUTION: RISK OF ELECTRIC SHOCK - DISCONNECT ALL INPUT POWER PRIOR TO SERVICING ZONE 4 Conforms ZONE 5 4009064 to UL 873 Milwaukee, WI 53208 USA ZONE 6 PUMP...
Page 3 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.
Page 4 Dip switch settings The ZSR series of control is programmed by positioning five dip switches for the following operations. MASTER SLAVE Master / Slave: allows for unlimited expansion to additional ZSR or ZVR relays boards. PRIORITY ON Priority ON / OFF: When priority switch is ON, upon REMOTE ENABLE ON demand to TSTAT 1 , ZONE 1 will operate as priority EXERCISE ON...
Page 5 Communication terminals Z-oneLink™ unlimited expansion allows connecting additional ZSR & ZVR series relay controls to a Master ZSR or 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 / COMMS Slave position.
Page 6 Example Wiring Diagram Please reference Z-one™ Relay wiring guide for complete listing of wiring diagrams. space heating thermostats ModCon boiler with primary/secondary ZONE 1 E / S COMMS T COM T COM T COM T COM T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 POWER...
Page 7 Non-Condensing boiler with indirect DHW space heating thermostats aquastat 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 space heating POWER MASTER...
Page 8 REMOTE ENABLE PRIMARY POWER GROUNDS 24 - 120 VAC DURING PUMP 1 PUMP 2 PUMP 3 PUMP 4 PUMP 5 PUMP 6 PUMP PRIORITY CALEFFI Caleffi North America, Inc. 3883 West Milwaukee Road Milwaukee, WI 53208 T: 414.238.2360 F: 414.238.2366 4-16-18...
Page 10 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 11 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 12 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 13 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 14 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 15 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 16 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 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 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 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 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 29 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 30 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 31 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 32 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 33 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 34 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 35 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 36 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 37 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 38 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 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 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 54 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 55 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.

This manual is also suitable for:

Z-one zsr103 Z-one zsr104 Z-one zsr106