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CALEFFI Z-one ZSR10 Series Manual

CALEFFI Z-one ZSR10 Series Manual

Relay multi-zone pump control

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Z-one
Relay Multi-Zone Pump Control
© Copyright 2014 Caleffi
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 excercise
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
Product Range
Code ZSR103 Z-one™ Relay switching relays...............................................................three zone
Code ZSR104 Z-one™ Relay switching relays.................................................................four zone
Code ZSR106 Z-one™ Relay switching relays...................................................................six zone
Technical specifications
Materials
Housing plastic:
Front display lights:
Electrical knockouts:
Performance
Power supply:
Transformer voltage:
Maximum transformer load:
Electrical switch rating:
Electrical switch rating pump output:
Dry contact rating, ZR/ZC, DHW, XX:
Replaceable fuses:
Temperature limits for:
Shipping and storage max:
Maximum Operating:
Maximum Humidity:
Approvals:
www.caleffi.com
Function
The ZSR series is 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. In addition, a primary pump system
circulator is switched on whenever any zone calls for
heat.
12 VA (ZSR103/4), 20 VA (ZSR106)
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
NA10334
ZSR10X series
ABS
LED
(12) 1/2" size
120 VAC, 50/60 Hz
24 VAC
20A max combined
120 VAC, 5A each
120 VAC max, 2A each
Type 2AG, 5A slow blow
110°F (43°C)
110°F (43°C)
90% non-condensing

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Summary of Contents for CALEFFI Z-one ZSR10 Series

  • Page 1 Z-one Relay Multi-Zone Pump Control ™ ZSR10X series © Copyright 2014 Caleffi Function The ZSR series is 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 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.
  • Page 3 ZR/ZC T COM T COM T CO T-STAT 1 T-STAT 2 T-STAT Installation The DIP Switches on the ZSR series can DipSwitches be positioned for the following operations. 6 Zone Master / Slave: allows for unlimited Master Slave expansion to additional ZSR relays. Priority ON Priority OFF Priority OFF / Priority ON: When priority...
  • Page 4 All circuits must have a common disconnect and be connected to the same pole of the disconnect Maintenance and Repair The Caleffi Z-one™ switching relay box contains a spare fuse and requires no maintenance. If any product fails or is damaged, replace product with functional one.
  • Page 5 Cover removal Insert screwdriver and push tabs Hold either the left or the right inward, cover should release from end of the box up and at an base. angle. Use body for stabilizing relay box. Roll cover off base.
  • 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 ZR/ZC COMMS T COM T COM T COM T COM T COM T COM THM 1 THM 2 THM 3 THM 4 THM 5...
  • Page 7 Non-Condensing boiler with indirect DHW space heating thermostats DHW! aquastat space heating demand domestic water heating demand ZR/ZC COMMS T COM T COM T COM T COM T COM T COM THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 boiler! ZONE1...
  • Page 8 ZONE4 ZONE5 ZONE6 PRIORITY PRIMARY POWER IN GROUNDS PUMP 2 PUMP 3 PUMP 4 PUMP 5 PUMP 6 PUMP 1 PUMP L N G CALEFFI Caleffi North America, Inc. 3883 West Milwaukee Road Milwaukee, WI 53208 T: 414.238.2360 F: 414.238.2366...
  • Page 9 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 10 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.
  • Page 11 PUMP 2 PUMP 3 PUMP 4 PUMP 5 PUMP 6 PUMP 1 PUMP 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 12 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 4009064...
  • Page 13 Operating Principles Dual labeled T-stat terminals. When a zone has a 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 14 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 15 Description of terminals Sequence of Operation / Settings = Ground • A demand occurs and closes RW (TT) = Neutral (Common leg of 120 VAC) • Relay #1 and relay #2 both fire connecting the common terminal to the NO terminal. = Line (live leg of 120 VAC) • If the factory installed jumper has not been = Common terminal...
  • Page 16 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 17 Description of terminals Sequence of Operation / Settings = Ground • There is a demand by one of the t-stats which sends power to the corresponding zone valve. = Neutral (Common leg of 120 VAC) • When the zone valve opens, its end switch = Line (live leg of 120 VAC) contacts close and signal a demand to the RW (TT) contacts on the single zone relay control.
  • Page 18 A3 - Single master thermostat, panel radiators with TRVs, variable speed pump thermostatic! radiator valves! (TRV) on each! radiator R W C buffer tank T com power zone CalefÞ! transformer single zone relay N L L RELAY 1 RELAY 2 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 19 Description of terminals Sequence of Operation / Settings • The relay contacts return to their normal position turning off power to the variable = Ground • A single “master” thermostat is wired to the speed circulator and opening the RW (TT) ZSR101 control.
  • Page 20 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 for DHW (ZR/ZC), capable of switching line voltage...
  • Page 21 DHW (ZR/ZC) Dual labeled XX Closes for closes only T-stat terminals. heat demand during priority Compatible with and DHW call. Rated 3 wire 2, 3 and 4 wire demand. Rated Selectable DIP for 120 VAC, communications to T-stats. Power ON LED. for 120 VAC, switches.
  • Page 22 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 23 The DIP Switches on the ZSR series Maintenance and Repair: The Caleffi Z-one™ multi-zone pump control ZR/ZC can be positioned for the following COMMS T COM T COM T COM T COM T COM T COM comes with two spare fuses. If control fails or is damaged, replace control with...
  • Page 24 B1 - Mod/con boiler, hydro separator or buffer tank, zone pumps Buffer tank- Optional hydraulic separator ZR/ZC 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 ZONE1 ZONE2...
  • Page 25 Description of terminals Sequence of Operation / Settings = Ground Priority switch: OFF = Neutral (Common leg of 120 VAC) Master / Slave switch: Master = Line (Hot leg of 120 VAC) Status During Priority switch: OFF Thermostat terminals • A demand occurs from any T-stat (T-stat = 24 VAC closes TT terminals). The “PUMP ON” LED = Heat call...
  • Page 26 B2 - Traditional boiler, indirect DHW w/ priority, zone pumps boiler! high limit! control DHW! aquastat DHW! aquastat ZR/ZC COMMS T COM T COM T COM T COM T COM T COM THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 ZONE1...
  • Page 27 Description of terminals Sequence of Operation / Settings • Once the Zone #1 DHW demand is satisfied, = Ground Priority switch: ON (Zone #1 becomes priority) power to the PRIORITY PUMP is dropped, the = Neutral (Common leg of 120 VAC) Master/Slave switch: Master DHW contacts open.
  • Page 28 B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps boiler pump Primary pump ZR/ZC T COM COMMS 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 ZONE1 ZONE2 DipSwitches...
  • Page 29 Description of terminals Sequence of Operation / Settings = Ground Priority switch OFF = Neutral (Common leg of 120 VAC) Master / Slave switch: Master = Line (Hot leg of 120 VAC) Status During Priority switch: OFF Thermostat terminals • A demand occurs from any T-stat (T-stat = 24 VAC closes TT terminals). The “PUMP ON” LED = Heat call...
  • Page 30 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 status selectable during priority • Pump will start only after the zone valve end switch is closed...
  • Page 31 DHW (ZR/ZC) XX Closes for Dual labeled closes only heat demand T-stat terminals. during priority and DHW Compatible with 3 wire call. Rated demand. Rated 2, 3 and 4 wire communications Master/Slave for 120 VAC, for 120 VAC T-stats. to expansion jumper.
  • Page 32 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 T COM T COM T COM T COM T COM T COM Thermostat connections Maintenance and Repair: The Caleffi Z-one™ multi-zone valve relay comes with T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 R = 24 VAC. T-STAT 6 a resettable fuse and requires no maintenance.
  • Page 34 C1 - Mod/Con boiler, hydro separator, zone valves mod/con! boiler PRIORITY! SYSTEM SECONDARY! pump pump ZR/ZC 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 TSAT1 ZONE1 MASTER SLAVE...
  • Page 35 Description of terminals Sequence of Operation / Settings = Ground Priority Jumper: OFF = Neutral (common leg of 120 VAC) Master / Slave Jumper: Master = Line (live leg of 120 VAC) Status During Priority: OFF Thermostat terminals • A demand occurs from any T-stat (T-stat = 24 VAC closes TT terminals). The “T-STAT CALL” LED illuminates for that zone.
  • Page 36 C2 - Mod/Con boiler, priority indirect DHW on primary side of hydro sep, zone valves mod/con! boiler DHW! aquastat PRIORITY! SECONDARY! pump pump SYSTEM! pump DHW! AQUASTAT ZR/ZC COMMS T COM T COM T COM T COM T COM T COM T-STAT 1 T-STAT 2 T-STAT 3...
  • Page 37 Description of terminals Sequence of Operation / Settings • The XX and DHW contacts close. = Ground • Priority Jumper: ON (Zone #1 becomes priority) • The PRIORITY PUMP contacts deliver 120 = Neutral (common leg of 120 VAC) • Master/Slave Jumper: Master = Line (live leg of 120 VAC) • The SEC PUMP and SYSTEM PUMP are off.
  • Page 38 C3 - Mod/Con boiler, priority indirect DHW on load side of hydro sep, zone valves Buffer tank- Optional hydraulic separator SECONDARY! pump SYSTEM! pump PRIORITY! pump DHW! AQUASTAT DHW! AQUASTAT ZR/ZC COMMS T COM T COM T COM T COM T COM T COM T-STAT 1...
  • Page 39 Description of terminals Sequence of Operation / Settings • The PRIORITY PUMP and SYSTEM PUMP = Ground Priority Jumper: ON (Zone #1 becomes priority) contacts deliver 120 VAC = Neutral (common leg of 120 VAC) Master/Slave Jumper: Master • The SEC PUMP is off. = Line (live leg of 120 VAC) Status During Priority: ON • Once the Zone #1 DHW demand is satisfied,...
  • Page 40 C4- Mod/Con boiler, priority indirect DHW on primary side of hydro sep, expansion control Buffer tank - Optional hydraulic separator ZV10 ZV11 ZV12 SECONDARY! pump PRIORITY! DHW! pump AQUASTAT SYSTEM! pump DHW! AQUASTAT ZR/ZC COMMS ZR/ZC COMMS T COM T COM T COM T COM T COM...
  • Page 41 Description of terminals Sequence of Operation / Settings • If no other zones are calling, power is dropped to the SEC PUMP and SYSTEM PUMP and = Ground Control #1 (Master) the XX contacts are opened. Priority Jumper: ON (Zone #1 becomes priority) = Neutral (common leg of 120 VAC) • If a demand occurs from the DHW aquastat (zone #1), The “T-STAT CALL” LED illuminates...
  • Page 42 C5 - Traditional boiler, indirect DHW (no priority) with valve, zone valves SYSTEM! pump DHW! aquastat ZR/ZC T COM T COM T COM T COM T COM T COM COMMS THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 Master/Slave THM1 ZONE1...
  • Page 43 Description of terminals Sequence of Operation / Settings = Ground Priority Jumper: OFF = Neutral (common leg of 120 VAC) Master/Slave Jumper: Master = Line (live leg of 120 VAC) Status During Priority: OFF Thermostat terminals • A demand occurs from a T-stat (T-stat = 24 VAC closes TT terminals) in zones 2 thru 6 otr the aquastat on zone #1. The “T-STAT CALL” LED...
  • Page 44 C6- Traditional boiler with reset control, priority indirect DHW with valve, zone valves SYSTEM! pump DHW! aquastat DHW! aquastat ZR/ZC T COM T COM T COM T COM T COM T COM COMMS THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 Master/Slave...
  • Page 45 Description of terminals Sequence of Operation • The PRIORITY PUMP and SYSTEM PUMP = Ground Priority Jumper: ON (Zone #1 becomes priority) contacts deliver 120 VAC = Neutral (common leg of 120 VAC) Master/Slave Jumper: Master • The SEC PUMP is off. = Line (live leg of 120 VAC) Status During Priority: ON • Once the Zone #1 DHW demand is satisfied,...
  • Page 46 C7 - Mod/Con boiler, hydro separator, zone valves (more than 6), multiple secondary pumps "B"! "A"! pump pump A11A12 A5 A6 SYSTEM! pump ZR/ZC COMMS ZR/ZC T COM T COM T COM T COM T COM T COM T COM T COM T COM T COM...
  • Page 47 Description of terminals Sequence of Operation / Settings • If no other zones are calling, power is turned = Ground Control #1 (Master) off to the SEC PUMP and SYSTEM PUMP and = Neutral (common leg of 120 VAC) Priority Jumper: OFF the XX contacts are opened.
  • Page 48 Calef North America, Inc. / 3883 W Milwaukee Rd / Milwaukee, WI 53208 Tel: 414.238.2360 / Fax: 44.238.2366 www.calef .com/usa / sales@calef .com ©Copyright 2014 Calef North America, Inc...

This manual is also suitable for:

Z-one zsr103Z-one zsr104Z-one zsr106