CALEFFI Z-one ZSR101 Series Wiring Manual Download Page 4

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Caleffi North America, Inc.

3883 West Milwaukee Road

Milwaukee, WI 53208

T: 414.238.2360 F: 414.238.2366

CALEFFI

Application Wiring Diagram

Installation

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. Please

pay attention to routing of power

supply cables.

•

Remove cover of relay box.

•

Identify the four mounting

holes on relay box, mark on

the wall the desired location of

mounting.

•

Predrill, anchor, and fasten four

screws for mounting.

•

Hang relay box and fasten tight

to desired locations.

•

Complete wiring connections

in accordance with terminal

locations.

•

Place cover back on relay box.

FUSE

T com

power

zone

transformer

N L

N LL

RELAY 1

C N/O N/C C N/O N/C

RELAY 2

thermostat

L
N

space

heating

demand

variable-speed

pressure-regulated

distribution circulator

mod/con boiler

ZSR101

1 Zone

4-16-18

Summary of Contents for Z-one ZSR101 Series

Page 1: ...LED Electrical Knockouts 6 1 2 size Performance Power Supply 120 VAC 50 60 Hz Transformer Voltage 24 VAC Maximum transformer load VA Maximum operating temperature 110 F 43 C Maximum Humidity 90 non condensing Electrical Switch Rating 10A Max Combined Replaceable Fuses Type 2AG 5A Slow Blow Approvals Technical specifications Features Compatible with low voltage 2 3 or 4 wire thermostat R W C and TT...

Page 2: ...th 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 stress corrosion misapplication or misuse of it products Dimensions ZSR101 PWR ZONE ...

Page 3: ...naling the boiler of a heating demand Operating principles Supply 120 VAC hot to termilan 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 1 Zone ZSR101 T T COM L POWER IN N C RELAY 1 NO NC C RELAY 2 NO NC TRANSFORMER PWR ZONE 1 Zone ZSR101 C R W T T COM L ER IN N C RELAY 1 NO NC C RELAY 2 NO NC SFORMER PW...

Page 4: ...upply cables Remove cover of relay box Identify the four mounting holes on relay box mark on the wall the desired location of mounting Predrill anchor and fasten four screws for mounting Hang relay box and fasten tight to desired locations Complete wiring connections in accordance with terminal locations Place cover back on relay box FUSE FUSE R W C T T com power zone transformer N L G L G N L L R...

Page 5: ...1 1 ...

Page 6: ...ump 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 and zone 1 pump typically used for DHW priority can be operated Zone priority is se...

Page 7: ... zone valve control Product overview 26 Circuit board 27 Cover removal Transformer Installation 28 Product details 29 C1 Mod Con boiler hydro separator zone valves 30 C2 Mod Con boiler indirect DHW on primary side of hydro sep zone valves 32 C3 Mod Con boiler indirect DHW on load side of hydro sep zone valves 34 C4 Mod Con boiler indirect DHW on primary side of hydro sep master and slave control 3...

Page 8: ...UMP 4 N L PUMP 5 N L PUMP 6 N THM 5 C R W T T COM THM 6 C R W T T COM PWR ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 ZONE6 DipSwitches Master Slave Priority OFF Priority ON Primary OFF Primary ON Exercise OFF Exercise ON Post Purge OFF Post Purge ON 6 Zone Z6P THM 2 C R W T T COM COMMS D P DHW ZR ZC X X THM 3 C R W T T COM THM 1 C R W T T COM L PUMP 2 N PRIMARY PUMP L PRIORITY PUMP 1 N L POWER IN N GROUNDS L P...

Page 9: ...ng a Taco 570 valve to Caleffi Z one Relay When connecting the Taco 570 zone valve to the Caleffi Z one Relay 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 termi...

Page 10: ...20 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 NA for more product information 4009064 Certified to CSA C22 2 No 24 Conforms to UL Stan...

Page 11: ...mp connection Dual labeled T stat terminals Compatible with 2 3 and 4 wire T stats Replaceable fuses 6 VA Transformer Keyhole mounting which fits a 4X4 junction box Pre installed jumper Rear knockout for 4X4 junction box If dry contacts are desired from relay 1 remove the factory installed jumper between L and C Cover removal Hold either the left or the right end of the box up and at an angle Use ...

Page 12: ...com power zone transformer N L L RELAY 1 C N O N C C N O N C RELAY 2 CalefÞ single zone relay L N A1 Single thermostat Hydronic diagram is for illustration purposes only some components have been removed for simplicity ...

Page 13: ... the thermostat demand is satisfied R to W will open and the ZONE LED will turn off The control will remove power from relays 1 and 2 opening C to NO This will drop 120 VAC to your pump and terminate the demand to your boiler Description of terminals Ground N Neutral Common leg of 120 VAC L Line live leg of 120 VAC C Common terminal NO Normally Open terminal NC Normally Closed terminal Note There ...

Page 14: ...O N C C N O N C RELAY 2 CalefÞ single zone relay 4 wire zone valve 4 wire zone valve 4 wire zone valve R W 24 VAC T T R W R W End switch wires L N A2 Multiple thermostats Hydronic diagram is for illustration purposes only and could be missing system components ...

Page 15: ... factory installed jumper between L and C When all the thermostat demands are satisfied the zone valves will close and the end switch will open R to W The ZONE LED will turn off The control will remove power from relays 1 and 2 opening C to NO This will drop 120 VAC to your pump and terminate the demand to your boiler WARNING NEVER CONNECT R C DIRECTLY this will be a direct short on the 24 VAC sup...

Page 16: ... TRV TRV TRV R W C T T com power zone transformer N L L RELAY 1 C N ON C C N ON C RELAY 2 ZSR101 T T L N A3 Single master thermostat panel radiators with TRVs variable speed pump Hydronic diagram is for illustration purposes only some components have been removed for simplicity ...

Page 17: ...ired room temperatures The room temperatures will then be controlled by each individual thermostatic radiator valve by adjusting the flow through the radiator making this a fitting application for a variable speed ECM pump between the buffer tank and radiators When the temperature drops below the set point of the thermostat the boiler will maintain the buffer tank at its target temperature Ideally...

Page 18: ...ure Selectable post purge and exercise Dry contacts X X AUX ZONE 1 E S 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 NA for more product information 4009064 C...

Page 19: ...l labeled T stat terminals Compatible with 2 3 and 4 wire T stats Selectable DIP switches LED for each zone 120 VAC zone pump outputs 120 VAC input power connection ZONE1 ES closes only during a demand from zone 1 Rated for 120 VAC 2 Amps X X closes on a demand for heat from any zone Rated for 120 VAC 2 Amps AUX closes on a demand for heat from any zone Rated for 120 VAC 2 Amps ...

Page 20: ... release from base Roll cover off 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 ...

Page 21: ...ne 1 calls Can be programmed to be the priority zone L Line hot leg of 120 VAC to power the pump N Neutral leg of 120 VAC to power the pump Remote Enable allows for input of 24 120 VAC from a boiler to allow the zone pumps to operate When power is removed from Remote Enable zone pumps will not be allowed to operate This is useful during warm weather shut down to stop zone pumps from running or if ...

Page 22: ...OMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX 6 Zone ZSR106 MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE 1 ON SLAVE OFF OFF OFF OFF REMOTE ENABLE 24 120 VAC L N O N O F F STATUS DURING PRIORITY B1 Mod con boiler hydro separator or buffer tank zone pumps Hydronic diagram is for illust...

Page 23: ... close with any call to ZONE 1 Zone 1 can be enabled as a priority zone typically used for heating domestic hot water The ZONE 1 E S can be used to close a 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 or other controls Dip switch description Master S...

Page 24: ... ZONE6 T STAT 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX 6 Zone ZSR106 MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE 1 ON SLAVE OFF OFF OFF OFF REMOTE ENABLE 24 120 VAC L N O N O F F STATUS DURING PRIORITY B2 Traditional boiler indirect DHW w priority zone pumps Hy...

Page 25: ... Freeze Prevention Feature After one hour of a priority demand the control will open the ZONE 1 E S contacts and drop power to PRIORITY PUMP 1 If a call for heat exists from zones 2 6 the control will satisfy those demands before going back to the priority demand After zones 2 6 have been satisfied the control will go back to the priority demand and reset the one hour timer WARNING NEVER CONNECT R...

Page 26: ...ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM AUX 3 Zone ZSR103 MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE 1 ON SLAVE OFF OFF OFF OFF REMOTE ENABLE 24 120 VAC L N O N O F F STATUS DURING PRIORITY Pump 3 Pump 1 Pump 2 Pump 3 B3 Mod Con boiler primary loop closely spaced tees zone pumps Hydronic diagram is for illustration purposes only some components have been r...

Page 27: ...cted to TT on boiler control closes when any zone calls including priority ZONE 1 E S Dry contact rated up to 120 VAC 2 Amps will close with any call to ZONE 1 Zone 1 can be enabled as a priority zone typically used for heating domestic hot water The ZONE 1 E S can be used to close a DHW contact on boiler controls equipped with these features AUX Dry contact rated up to 120 VAC 2 Amps close when a...

Page 28: ...1 C R W T T COM T STAT 4 C R W T T COM AUX 4 Zone ZSR104 MASTER PRIORITY ON REMOTE ENABLE ON EXERCISE ON POST PURGE ZONE 1 ON SLAVE OFF OFF OFF OFF REMOTE ENABLE 24 120 VAC L N O N O F F STATUS DURING PRIORITY Boiler Pump Output 120VAC Boiler with outdoor reset warm weather shut down and pump control B4 Mod con boiler with warm weather shut down hydro separator or buffer tank zone pumps Hydronic d...

Page 29: ...tact rated up to 120 VAC 2 Amps which is typically connected to TT on boiler control closes when any zone calls including priority ZONE 1 E S Dry contact rated up to 120 VAC 2 Amps will close with any call to ZONE 1 Zone 1 can be enabled as a priority zone typically used for heating domestic hot water The ZONE 1 E S can be used to close a DHW contact on boiler controls equipped with these features...

Page 30: ... closed Dry contacts XX AUX ZONE 1 E S 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 zone 1 pump Front LED Lights 100 Factory tested with 3 year warranty ETL approved See technical brochure 01285 NA for ...

Page 31: ...rd Power ON LED Dual labeled T stat terminals Compatible with 2 3 and 4 wire T stats Dip switches 120 VAC input power connection Zone valve end switch connection Zone valve motor connections Transformer connections ZONE1 ES closes only during a demand from zone 1 Rated for 120 VAC 2 Amps X X closes on a demand for heat from any zone Rated for 120 VAC 2 Amps AUX closes on a demand for heat from any...

Page 32: ...ottom 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 using six valve relay 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 Al...

Page 33: ...ZSR106 REMOTE ENABLE 24 120 VAC L N L Line hot leg of 120 VAC supply N Neutral of 120 VAC Grounds Input power Pump outputs 6 Zone ZVR106 L POWER IN N L ZONE 1 PUMP N L SEC PUMP N STATUS DURING ZONE 1 DEMAND ZONE 1 END SWITCH MOTOR ZONE 2 END SWITCH MOTOR ZONE 3 END SWITCH MOTOR M L SYSTEM PUMP N T STAT 2 C R W T T COM ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T ...

Page 34: ... SYSTEM PUMP N T STAT 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 5 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND SYSTEM pump SECONDARY pump ZV1 ZV4 ZV3 ZV2 ZV5 ZV6 C1 Mod Con boiler...

Page 35: ...s XX Dry contact rated up to 120 VAC 2 Amps which is typically connected to TT on boiler control closes when any zone calls including priority ZONE 1 E S Dry contact rated up to 120 VAC 2 Amps will close with any call to ZONE 1 Zone 1 can be enabled as a priority zone typically used for heating domestic hot water The ZONE 1 E S can be used to close a DHW contact on boiler controls equipped with th...

Page 36: ...H MOTOR ZONE 4 END SWITCH MOTOR ZONE 5 END SWITCH MOTOR ZONE 6 END SWITCH MOTOR L SYSTEM PUMP N T STAT 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 5 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRI...

Page 37: ...l close the X X contacts to signal the boiler of a demand When all the thermostat demands are satisfied R to W will open and the T STAT CALL and VALVE OPEN LEDs will turn off The X X contacts will open terminating the demand for heat to the boiler The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP DHW Time Out Freeze Prevention Feature After one hour of a priority demand the control will open ...

Page 38: ...CH MOTOR L SYSTEM PUMP N T STAT 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 5 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND DHW PRIORITY pump SYSTEM pump SECONDARY pump ZV4 ZV3 ZV2 Z...

Page 39: ...he control will close the XX contacts to signal the boiler of a demand When all the thermostat demands are satisfied R toWwillopenandthe T STATCALL and VALVE OPEN LEDs will turn off The XX contacts will open terminating the demand for heat to the boiler The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP DHW Time Out Freeze Prevention Feature After one hour of a priority demand the control will...

Page 40: ...C PUMP N 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 L SYSTEM PUMP N T STAT 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE ...

Page 41: ... The ZONE 1 E S and X X contacts open If a call for heat exists from zones 2 12 the corresponding T STAT CALL will illuminate again and 24 VAC will be delivered to their zone MOTOR terminals When the zone valve end switch closes the VALVE OPEN LED illuminates for the corresponding zone ZVR control 1 sends 120 VAC to SYSTEM PUMP and the corresponding control SEC PUMP outputs The Master control will...

Page 42: ...E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 5 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND DHW aquastat SYSTEM pump ZV2 ZV4 ZV5 ZV6 ZV3 DHW PRIORITY pump DHW PRIORITY pump T T DHW outdoor temperature sensor C5 Trad...

Page 43: ...ump terminals SYSTEM PUMP Runs when any zone calls for heat SEC PUMP Runs when any zone calls for heat ZONE 1 PUMP Runs when zone 1 thermostat calls for heat and zone 1 end switch has closed A jumper is required between the ZONE 1 END SWITCH terminals when using a pump for ZONE 1 instead of a zone valve STATUS DURING ZONE 1 DEMAND ON OFF When status jumper is placed on ON pins the secondary and or...

Page 44: ... 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 5 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND DHW aquastat SYSTEM pump DHW ZV1 ZV2 ZV4 ZV5 ZV6 ZV3 C6 Traditional boiler with priority ...

Page 45: ... boiler of a demand When all the thermostat demands are satisfied R to W will open and the T STAT CALL and VALVE OPEN LEDs will turn off The XX contacts will open terminating the demand for heat to the boiler The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP DHW Time Out Freeze Prevention Feature After one hour of a priority demand the control will drop power to the ZONE 1 MOTOR terminals If ...

Page 46: ... PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND 6 Zone ZVR106 L POWER IN N POWER T SAT CALL ZONE 6 L ZONE 1 PUMP N L SEC PUMP N 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 L SYSTEM PUMP N T STAT 2 C R W T T COM COMMS D P ZONE 1 E S X X T STAT...

Page 47: ...s will open terminating the demand for heat to the boiler The 120 VAC is dropped to the SYSTEM PUMP and SEC PUMP Description of terminals Ground N Neutral Common leg of 120 VAC L Line Hot leg of 120 VAC Thermostat terminals R 24 VAC W Heat call C Common of 24 VAC Boiler terminals XX Dry contact rated up to 120 VAC 2 Amps which is typically connected to TT on boiler control closes when any zone cal...

Page 48: ... P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND NOTE ECM seconday pump requires power at all times and a dry contact closure to start NOTE The AUX contact status during priority demand from Zone 1 can be changed us...

Page 49: ...tput The control will close the XX contacts to signal the boiler of a demand and close the AUX contacts to signal the ECM pump to start When all the thermostat demands are satisfied R to W will open and the T STAT CALL and VALVE OPEN LEDs will turn off The XX contacts will open terminating the demand for heat to the boiler The AUX contacts will also open terminating the demand to the ECM pump The ...

Page 50: ... COM COMMS D P ZONE 1 E S X X T STAT 3 C R W T T COM T STAT 1 C R W T T COM T STAT 4 C R W T T COM T STAT 5 C R W T T COM T STAT 6 C R W T T COM AUX O N O F F O N O F F VALVE OPEN ZONE 1 ZONE 2 ZONE 4 ZONE 5 ZONE 3 MASTER PUMP EXERCISE ON PRIORITY ON AUX ON SLAVE OFF OFF OFF DURING PRIORITY DEMAND SYSTEM pump SECONDARY pump ZV4 ZV3 ZV2 ZV5 ZV6 ZONE 1 Pump ZONE 1 Pump C9 Mod Con boiler hydro separa...

Page 51: ...lose with any call to ZONE 1 Zone 1 can be enabled as a priority zone typically used for heating domestic hot water The ZONE 1 E S can be used to close a 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 or other controls Pump terminals SYSTEM PUMP Runs w...

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