Bell and Gossett ZoneTrol II Z-4 User manual

FEATURES
• Indicator lights visible without removing cover.
Power LED will illuminate when input power is applied to the
controller. Zone LEDs will illuminate when relay is energized.
•PRIORITY: This is typically used in domestic hot water
applications where it may be desirable to givehot water
production a priority over space heating requirements for a
certain period of time. Zone 1isthe priority zone and the
functionality is enabled via DIP switch 1. The priority timer is
selectable for 30 or 60 minutes, via DIP switch 3.
• PURGE: In normal operation, the last circulator will stop and
the boiler will shut down as soon as there is no longer a call
for heat. If the purge functionality is enabled via DIP switch
2, the boiler will shut down, but the circulator will continue
to run for 90 seconds to extract additional BTUsfrom the
boiler.
•EXERCISE: Whenthe exercise functionalityis enabled via
DIP switch 4, each circulator willrun for 10 seconds after
every 72 hours of inactivity. This prevents scale and other
deposits fromaccumulating around the rotating partsand
ensures atrouble free start up at the beginning of each
heating season.
DESCRIPTION
The Bell & Gossett ZoneTrol II and McDonnell & Miller Zone-
Smart Pump Controllers are designed to control 120 VAC
circulating pumps in hydronic systems.
Max.
T-stat Number of Max.
Model Current Zones HP/Pump
Z-4 / ZS-4 0.085 41/3
Z-6 / ZS-6 6
Bell & Gossett®ZoneTrol II™
Models Z-4, Z-4B, Z-4M, Z-6, Z-6B, Z-6M
McDonnell &Miller ZoneSmart™
Models ZS-4, ZS-4B, ZS-4M, ZS-6, ZS-6B, ZS-6M
SAFETY
INSTRUCTION
This safety alert symbol will be used in this manual and on the
unit safety instructions decal to draw attention to safety related
instructions. When used, the safety alert symbol meansATTEN-
TION! BECOME ALERT! YOURSAFETY IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT
IN A SAFETY HAZARD.
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
DIP SWITCH SETTINGS
Switch ON OFF
1Slave Master
Priority Off Priority On
2 Purge On Purge Off
3 Priority 30 minutes Priority 60 minutes
4 Exercise On Exercise Off
5 Reset Normal
6 Power Delay On Power Delay Off
OUTDOOR RESET
For controllers with intergal outdoor reset controller,
please refer to Instruction Manual 210668. This document
can be downloaded at www.bellgossett.com or
www.mcdonnellmiller.com.
MECHANICAL INSTALLATION INSTRUCTIONS
The pump controller shouldbe securelymounted on awall
near the pumps using four #8 screws (not included).
ELECTRICAL INSTALLATION INSTRUCTIONS
1. Disconnect the electrical supply to the pump before
installing the controller.
2. Refer to the applicable wiring diagram
- Figure 1A: Cold Start Boiler
- Figure 1B: Tankless Coil
3. Verify that the circulator(s) do not exceed the electrical rat-
ing of the controller.
WARNING: Electrical Shock Hazard
Electrical connections are to be made by a qualified
electrician in accordance with all applicable codes, ordi-
nances and good practices Disconnect and lock out the
power before making electrical connections. Failure to fol-
low theseinstructions could result in serious personal injury
and/or death.
UL
®
C US
LISTED
20 amps maximum combined load.
INSTRUCTION MANUAL
210667C

For connection
of additional
controllers
Used only with optional reset
control - refer to
instruction
manual 210668
for details
To
thermostats
}
Input Power
120/1/60
To zone
circulators
Refer to Fig 1A for cold start or
Fig. 1B for tankless coil application
EXPANSION
BOIL OUT SUP COM HN
24 VAC
RW
ZONE 1
ZONE 1
LN
ZONE 2
LN
ZONE 3
LN
ZONE 4
LN
ZONE 5
LN
ZONE 6
LN
RW
ZONE 2
RW
ZONE 3
RW
ZONE 4
RW
ZONE 5
RW
ZONE 6
THERMOSTATS
INSOLATED END
SWITCH
X X ZC ZR
120 VAC
LNG
CIRCULATORS
}
To TT
on boiler
Jumper
X X ZC ZR ZC ZR
To ZC on
aquastat
To ZR on
aquastat
GENERAL WIRING DIAGRAM
Refer to Instruction Manual 210688 for units with outdoor reset controller.
Figure 1A: Cold Start Boiler
When a thermostat calls for heat,
the corresponding circulator will
start and the XX end switch will
close to enable the boiler.
Figure 1B: Tankless Coil
When a thermostat calls for heat,
the corresponding circulator will
start when the boiler temperature
reaches the low limit setting.
General Wiring Diagram
(6 zone controller shown)
WARNING: Electrical Shock Hazard
When wiring pertheTankless Coil
Application, pump controller and boiler
aquastat mustbe on the samecircuit and
haveacommon disconnect. Failure to fol-
low these instructions may introduce a
secondarysource of power resultingin
personal injury or death.
4. Makeelectricalconnections according to the applicable
wiring diagram. Run the pump power through the holes in
the controller chassis to the applicable L/N terminals. Keep
120 VAC and 24 VAC wiring separate. All 120 VAC wiring
should be 14 AWG (minimum)copper electricalwire.
Perform all wiring in accordance with applicable codes.
5. If the priority function is to be enabled, the priorityzone
(e.g., Domestic Hot Water) pump should be wired to the
Zone 1 L/N terminals.
6. Run the thermostat wires through the grommet(s) in the
controller chassis and connect to the appropriate R/W ter-
minals. If the priority function is to be enabled, the priority
zone (e.g., Domestic Hot Water) T-Stat should be wired to
the Zone 1R/W terminals. Keep 24 VAC wiring separate
from 120 VAC wiring.
NOTE:During the initial power-up of the zone controller,
some“powerstealing” thermostats may require up to 3
minutes to function properly. If the installation requires the
pump relays andX-X relay to be heldopenduring this
power-up sequence, the installer can position DIP switch
6 to the “ON” position. This will cause the controller to
suspendrelayoperation during the thermostat power-up
period. Normal operation and cycling of the heating system
will resume after the 3 minute time period. This applies to
initial power-up onlyand does not affect normal system
operation.
EXPANSION
The 4 and 6 zone controllers can be connected together to
accommodate larger systems. A six conductor straight pinned
cable with two male RJ-11 terminations is required for con-
nection of multiple controllers. This cable can be ordered from
your distributor as McDonnell & Miller part number 109454.
The “master”controller should have DIP switch1setto the
OFF position. “Slave” controllers should have DIP switch 1 set
to theONposition. If the Priority function is to be enabled
(e.g., domestic hot water production) Zone 1 on the Master
controller will be the priority zone.
Xylem Inc.
8200 N. Austin Avenue
Morton Grove, Illinois 60053
Phone: [phone]
Fax: [phone]
www.xyleminc.com/brands/bellgossett
Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries.
© 2012 Xylem Inc. 210667C May 2012