CALEFFI Z-one ZVR103 User manual

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.
t Compatible with low voltage 2, 3, or 4 wire thermostats
t R, W, C and TT Comm dual labeling at thermostat terminals
t Z-oneLink™ unlimited zone expansion to ZVR and ZSR series
t Selectable priority with 1 hour time-out feature
t System and secondary pump status selectable during ZONE 1 demand
t Circulator will start only after the zone valve end switch is closed
t Dry contact for ZONE 1 (DHW), capable of switching line voltage
t Dry contact AUX for signaling a variable speed self regulated pump or other 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 voltage fuse
t Controls system pump, secondary pump, and priority pump
t Front LED Lights
t 100% Factory tested with 3 year warranty, ETL Listed / CSA Certified
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 / Certified 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 ZVR103 Z-one™ Relay zone valve control...........................................................three zone
Code ZVR104 Z-one™ Relay zone valve control.............................................................four zone
Code ZVR106 Z-one™ Relay zone valve control...............................................................six zone
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873

SAFETY INSTRUCTION
This safety alert symbol will be used in this manual to draw attention to safety
related instructions. When used, the safety alert symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.
CAUTION: All work must be performed by qualified personnel trained in the
proper application, installation, and maintenance of systems in accordance
with all applicable codes and ordinances.
CAUTION: Electrical shock hazard. Disconnect power before installation to
prevent electrical shock or equipment damage. Make sure all connections
are in accordance with 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 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.
Dimensions
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
ZVR106
Six zone switching - Input: 120VAC 50/60Hz 20A MAX
Conforms
to UL 873
4009064
CAUTION: RISKOF ELECTRIC SHOCK - DISCONNECT ALL
INPUTPOWER PRIOR TO SERVICING
Milwaukee,WI 53208 USA
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
T-STAT
CALL
VALVE
OPEN
Code Zones A B C Wgt. (lbs)
ZVR103 3 9 1/4"11"3"3.2
ZVR104 4 9 1/4"11"3"3.2
ZVR106 6 9 1/4"11"3"3.2
A
BC
C

Inspect packages for damage. If damaged, notify the appropriate carrier immediately. If undamaged,
open the package and inspect the device for obvious damage. Return damaged products.
r Use only copper conductor supply wire suitable for at least 105° C
r All circuits must have a common disconnect and be connected to the same pole of the disconnect
Maintenance and Repair
The Caleffi Z-one™multi-zone valve control comes with a automatic resettable low voltage fuse
and requires no maintenance. If control fails or is damaged, replace control with functional one.
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.
Cover removal
Hold either the left or the right
end of the box up and at an
angle.
Insert screwdriver and push
tab inward, cover should
release from base.
Roll cover off base.
Transformer installation
Mount box on stable surface
using level.
Remove transformer(s) from
packaging. Slide bottom end of transformer
into bottom 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 six valve relay
box.
Installation
CAUTION: If unit is below 32 ° F (0 ° C), expose to room temperature for 15 minutes before
pressing cover release tabs. Failure to do so could cause damage to the enclosure.

When a zone has a demand from
a thermostat (T T / R W) the
control will send 24 VAC to the
corresponding zone valve. When
the zone valve end switch closes,
the system and secondary pump
will switch on and the (X X) dry
contact will close to signal the boiler of a heating demand. AUX dry contact will also close as a
signal to a variable speed self regulated pump or other controls. ZONE 1 can be used for priority
(either a priority pump or valve). When the priority dip switch is ON, a demand from T-STAT 1 will
activate 24VAC to VALVE 1 and the ZONE 1 pump relay, 120 VAC will switch on after the end switch
closes (requires a jumper in the end switch terminals if a valve is not used). The DHW (ZONE 1) dry
contact will also close.
Depending upon "Status During Zone 1 Demand" jumpers, the secondary and / or system pump
will either be ON or OFF.
Status During Zone 1 Demand ON / OFF: When
status jumper is placed on ON pins, the secondary
and / or system pump will continue to operate during
ZONE 1 demand. When jumper is placed on OFF pins,
the corresponding pump will be OFF during ZONE 1
demand.
XX = Dry contact rated up to 120 VAC, 2 Amps, which is typically
connected to T T on boiler control, closes when any zone calls including
priority. ZONE 1 / ES (DHW) = Dry contact, rated up to 120 VAC, 2
Amps, close 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 Amps, close when any zone calls and can be used
as signal to a variable speed self regulated
pump. When there is a priority demand, then AUX will follow the selection of the AUX dip switch.
The ZVR series of controls is programmed by
positioning four dip switches for the following
operations.
Master / Slave: allows for unlimited expansion to
additional ZVR or ZSR relays boards.
Pump Exercise ON / OFF: When exercise mode is
ON, each circulator is switched on for 30 seconds
following 72 hours of inactivity.
Priority ON / OFF: When priority switch is ON, upon
demand to TSTAT 1 , ZONE 1 will operate as priority
and all other zones are temporarily switched off (with 1 hour time-out). When priority is OFF, any
zones that were active when ZONE 1 was switched on will remain on.
AUX ON / OFF: When AUX switch is ON, AUX dry contact is activated with a demand to any zone
including priority. When AUX is OFF, AUX dry contact is activated during any demand except priority.
L
ZONE #1
PUMP
NL
SEC
PUMP
N
STATUS DURING
ZONE #1 DEMAND
L
SYSTEM
PUMP
N
0
/
0
'
'
0
/
0
'
'
MASTER
PUMP EXERCISE ON
PRIORITY ON
AUX ON
SLAVE
OFF
OFF
OFF
DURING PRIORITY DEMAND
Dip switch settings
ZONE 1
E / S
XX AUX
Boiler Connections
T-STAT 2
C
RW
TTCOM
T-STAT 3
C
RW
T T COM
T-STAT 1
C
RW
T T COM
T-STAT 4
C
RW
T T COM
Thermostats

Large screw terminals connections makes wiring easy with three pump screw terminal connections.
Pump terminals connection have 120 VAC outputs for simplified pump connections. Zone valve
connections can be 2, 3 or 4 wire.
Z-oneLink™ unlimited expansion allows connecting additional ZVR & ZSR
series relay controls to a Master 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 /
Slave position. A demand for heat from any zone will fire the boiler and start the
pump. Only one relay board can be the Master and Priority, Slave is used for subsequent boards.
L
POWER IN
N
L
ZONE #1
PUMP
NL
SEC
PUMP
N
ZONE 1
EN
SWI
T
MOTOR
L
SYSTEM
PUMP
N
COMMS
DP
Wiring terminals
ZONE 1
END
SWITCH
MOTOR
Z
O
MOTO
R
Wiring 2 wire, 3 wire & 4 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 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 terminal 3 on the zone valve. Failure to
follow schematic will lead to damage of product.
Since a two wire actuator does not have an end switch for
feedback to the relay box, the end switch terminals must have
a jumper to simulate the end switch. If the end switch jumper
is not installed, no demand will be sent to the boiler and the
pumps will not turn on
1
2
3
2 1 3
The four wire zone valve is the most straight forward of the three
types of valves to wire. Simply connect the two motor leads to
motor leads, and the two end switches to end switches.
NE 2
END
SWITCH
ZONE 3
END
SWITCH
MOTOR M
O
ZONE 1
END
SWITCH
T
OR
ZONE 2
END
SWITCH
MOTOR
M

Example Wiring Diagram
VENT
L
N
SYSTEM pump
SECONDARY
pump
ZV1 ZV4ZV3ZV2 ZV5 ZV6
ZV1 ZV4ZV3ZV2 ZV5 ZV6
SYSTEM
pump
SECONDARY
pump
mod/con
boiler
6 Zone
ZVR106
L
POWER IN
N
POWER
T-SAT
CALL
ZONE 6
L
ZONE #1
PUMP
NL
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
RW
TTCOM COMMS
DP
ZONE 1
E / S
XX
T-STAT 3
C
RW
TTCOM
T-STAT 1
C
RW
TTCOM
T-STAT 4
C
RW
TTCOM
T-STAT 5
C
RW
TTCOM
T-STAT 6
C
RW
TTCOM
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
set to ON


Please reference Z-one™ Relay wiring guide for complete listing of wiring diagrams.
Mod-Con boiler with
Primary/Secondary

L
N
G
TT
ZR
ZC
outdoor
temperature
sensor
boiler
reset
controller
space heating thermostats
DHW
aquastat
space
heating
demand
domestic water
heating demand
SYSTEM
pump
ZV1 ZV2 ZV4ZV5 ZV6ZV3
indirectDHW tank
DHW
aquastat
VENT
ZV1
ZV2 ZV4 ZV5 ZV6 ZV3
SYSTEM
pump
6 Zone
ZVR106
L
POWER IN
N
POWER
T-SAT
CALL
ZONE 6
L
ZONE #1
PUMP
NL
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
RW
T T COM COMMS
DP
ZONE 1
E / S
XX
T-STAT 3
C
RW
T T COM
T-STAT 1
C
RW
T T COM
T-STAT 4
C
RW
TTCOM
T-STAT 5
C
RW
TTCOM
T-STAT 6
C
RW
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
set to ON
L
N
Non-condensing boiler with
outdoor reset and indirect DHW

Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208 USA
T: 414.238.2360 F: 414.238.2366
CALEFFI
L
N
"A"
pump
SYSTEM
pump "B"
pump
SYSTEM
pump
A4A3A2 A5 A6
"A"
pump
"B"
pump
A10A9A8 A11 A12A7
A1
A4A3A2 A5 A6A1 A10A9A8 A11 A12A7
L
N
6 Zone
ZVR106
L
POWER IN
N
POWER
T-SAT
CALL
ZONE 6
L
ZONE #1
PUMP
NL
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
RW
TTCOM COMMS
DP
ZONE 1
E / S
XX
T-STAT 3
C
RW
TTCOM
T-STAT 1
C
RW
TTCOM
T-STAT 4
C
RW
TTCOM
T-STAT 5
C
RW
TTCOM
T-STAT 6
C
RW
TTCOM
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
POWER IN
N
POWER
T-SAT
CALL
ZONE 6
L
ZONE #1
PUMP
NL
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
RW
TTCOM COMMS
DP
ZONE 1
E / S
XX
T-STAT 3
C
RW
TTCOM
T-STAT 1
C
RW
TTCOM
T-STAT 4
C
RW
TTCOM
T-STAT 5
C
RW
TTCOM
T-STAT 6
C
RW
TTCOM
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
set to ON set to ON
Mod-Con boiler with Primary/Secondary and
two secondary pumps

1
1

WIRING GUIDE
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
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.
The ZSR Series of controls is for zoning using pumps. Up to 6 zone pumps (model dependent) along with a primary pump
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 simplifi ed 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 selectable with 1-hour
time-out feature. System pump and secondary pump status (on/off) during priority is also selectable. Replaceable snap-fi t 40
VA transformer standard for 3 & 4 zone models – expandable to 80 VA with 2nd transformer. 6 zone model has two 40 VA
(80 VA) transformers.
Form 031914 rev.2