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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.

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

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

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

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Selectable priority with 1 hour time-out feature

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System and secondary pump status selectable during ZONE 1 demand

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

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

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Dry contact AUX for signaling 

a variable speed self regulated pump or other controls

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Large terminal connections

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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

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Automatic resettable low voltage fuse

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Controls system pump, secondary pump, and priority pump

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Front LED Lights

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100% Factory tested with 3 year warranty, ETL Listed / CSA Certifi ed

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

NA10333 G2

Z-one

™ 

Relay Multi-Zone Valve Control

 

ZVR10X series

www.caleffi.com

© Copyright 2015 Caleffi North America

Product Range

Code ZVR

103

 

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

Code ZVR

104

 

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

Code ZVR

106

 

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

4009064

Certified to CSA C22-2 No.24
Conforms to UL Standard 873

Summary of Contents for Z-one ZVR103

Page 1: ...r 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 voltag...

Page 2: ...th 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 wel...

Page 3: ...ce 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 fiel...

Page 4: ...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...

Page 5: ...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...

Page 6: ...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...

Page 7: ...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...

Page 8: ...COM T STAT 5 C R W T T COM T STAT 6 C R W 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 OFF OFF DURING PRIORITY DEMAND 6 Zone ZVR106 L...

Page 9: ...1 1...

Page 10: ...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 simpli ed wiring The ZVR Serie...

Page 11: ...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...

Page 12: ...MP 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 Exerc...

Page 13: ...g 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 ser...

Page 14: ...0 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 wirin...

Page 15: ...p 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 f...

Page 16: ...om power zone transformer N L L RELAY 1 C N O N C C N O N C RELAY 2 Calef single zone relay L N A1 Single thermostat Hydronic diagram is for illustration purposes only some components have been remove...

Page 17: ...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 t...

Page 18: ...N C C N O N C RELAY 2 Calef 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 illustr...

Page 19: ...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...

Page 20: ...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 fo...

Page 21: ...red 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 va...

Page 22: ...re 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 termina...

Page 23: ...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...

Page 24: ...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...

Page 25: ...l PRIORITY PUMP Runs when zone 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 o...

Page 26: ...MMS 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...

Page 27: ...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...

Page 28: ...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 PRIORI...

Page 29: ...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...

Page 30: ...ONE 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...

Page 31: ...ted 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...

Page 32: ...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...

Page 33: ...act 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...

Page 34: ...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 th...

Page 35: ...d 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 Transforme...

Page 36: ...ttom 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...

Page 37: ...NSFORMER L PUM T STAT 2 T T COM E S T STAT 3 T T COM T STAT 1 T T COM T STAT 4 T T COM 6 Zone ZSR106 REMOTE ENABLE 24 120 VAC L N L Line hot leg of 120 VAC supply N Neutral of 120 VAC Grounds Input po...

Page 38: ...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...

Page 39: ...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 clo...

Page 40: ...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...

Page 41: ...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...

Page 42: ...H 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...

Page 43: ...e 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 wil...

Page 44: ...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 ST...

Page 45: ...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 z...

Page 46: ...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 P...

Page 47: ...mp 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 i...

Page 48: ...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 ZO...

Page 49: ...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...

Page 50: ...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 SWIT...

Page 51: ...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 VA...

Page 52: ...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 OF...

Page 53: ...put 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 an...

Page 54: ...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...

Page 55: ...ose 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...

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