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CALEFFI Z-one ZSR10X Series User manual

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NA10334 G2.01
Z-one™ Relay Multi-Zone Pump Control
ZSR10X series
www.caleffi.com
© Copyright 2018Caleffi
Function
The ZSR series is a 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.
t Compatible with low voltage 2, 3, or 4 wire thermostats
t R, W, C and T T COM dual labeling at thermostat terminals
t Z-oneLink™ unlimited zone expansion
t 120 VAC pump outputs
t Remote Enable input 24 - 120 VAC
t Selectable Priority with 1 hour time-out
t Selectable Post Purge and Exercise
t Dry contacts for ZONE 1 (DHW), capable of switching line voltage
t High capacity transformer
t Large terminal connections
t Simplified wiring with extra ground terminals
t Heavy duty sealed relays
t All pumps fuse protected (with spare fuse)
t Front LED Lights
t 100% Factory tested with 3 year warranty, ETL Approved
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: 12 VA (ZSR103/4), 20 VA (ZSR106)
Electrical switch rating pump output: 120 VAC, 5A each (20A max combined)
Dry contact rating, Zone 1 ES, XX, AUX: 120 VAC max, 2A each
Replaceable fuses: Type 2AG, 5A slow blow
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
Product Range
Code ZSR103 Z-one™Relay pump control.................................................................three zone
Code ZSR104 Z-one™Relay pump control...................................................................four zone
Code ZSR106 Z-one™Relay pump 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
ZSR106
Six switching relays - Input: 120VAC 50/60Hz 20A MAX
Conforms
toUL 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
PUMP
ON
Code Zones ABC Wgt. (lbs)
ZSR103 3 9 1/4"11"3"3.2
ZSR104 4 9 1/4"11"3"3.2
ZSR106 6 9 1/4"11"3"3.2
A
B C
C
WARNING: This product can expose you to chemicals including lead, which is known to the
State of California to cause cancer and birth defects or other reproductive harm. For more
information go to www.P65Warnings.ca.gov.
Remove cover of relay box.
Identify the four mounting
holes on relay box, mark on
the wall the desired location of
mounting.
Drill, anchor, and fasten four
screws for mounting.
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 pump control comes with a resettable fuse on the low voltage
side and replaceable fuses on each 120 VAC output 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.
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.
Hang relay box and fasten
tight to desired locations.
Complete wiring connections
in accordance with terminal
locations.
Place cover back on relay box.
When a zone has a demand
from a thermostat (T T / R W )
the control will send 120 VAC to
the corresponding zone pump,
primary pump 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. When the priority dip switch is ON, a demand from T-STAT 1 will
activate PRIORITY PUMP 1 and all other zone pumps will be switched OFF. The Priority has a 1
hour time out and will go back to operating zones 2 - 6. The ZONE 1 (DHW) dry contact will also
close. Depending upon "Status During Priority" jumper, the primary pump will either be ON or OFF.
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, 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 or other controls.
The ZSR series of control is programmed by positioning
five dip switches for the following operations.
Master / Slave: allows for unlimited expansion to
additional ZSR or ZVR relays boards.
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.
Remote Enable ON / OFF: When remote enable mode is ON, the ZSR board will hold off all zones
until it receives an external 24 - 120 VAC signal to the Remote Enable terminals.
Exercise ON / OFF: When exercise mode is ON, each circulator is switched on for 30 seconds
following 72 hours of inactivity.
Post Purge Zone #1 ON / OFF: When post purge is ON, Zone 1 pump continues operating for 2
minutes after the priority zone is switched off.
MASTER
PRIORITY ON
REMOTE ENABLE ON
EXERCISE ON
POST PURGE ZONE#1 ON
SLAVE
OFF
OFF
OFF
OFF
Dip switch settings
ZONE 1
E / S
XX
AUX
Boiler Connections
T-STAT 2
C
RW
T T COM
T-STAT 3
C
RW
T T COM
T-STAT 1
C
RW
T T COM
T-STAT 4
C
RW
TTCOM
Thermostats
Status During Priority ON / OFF: When status jumper
is placed on the ON pins, the primary pump will
continue to operate during ZONE 1 priority demand.
When jumper is placed on the OFF pins, the primary
pump will be OFF during ZONE 1 priority demand.
PRIMARY
PUMP
LN
0
/
0
'
'
STATUS
DURING
PRIORITY
Jumper
Z-oneLink™ unlimited expansion allows connecting additional ZSR & ZVR
series relay controls to a Master ZSR or 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.
COMMS
DP
Communication terminals
L
PUMP 2
N
L
PRIORITY
PUMP 1
N
L
POWER IN
N
GROUNDS
REMOTE ENABLE
24 - 120 VAC
LN
Large screw terminal connections makes wiring easy. Three extra ground screw terminals
connection allows fast grounding of pumps eliminating the need for extra wire connectors. Pump
terminals have 120 VAC outputs for simplified pump connection.
The Remove Enable feature allows the ZSR to be controlled from an external power source. If the
Remove Enable dip switch is positioned to ON, the ZSR must have 24 - 120 VAC supplied to the
Remote Enable terminals in order for the zone pumps to run. A typical application is to connect
the boiler’s circulator output to the Remote Enable terminals so the zone pumps will not run during
warm weather shutdown. This feature can also be used to hold off the zone pumps if the boiler is
equipped with a DHW pump output.
Pump 1 will be become the Priority pump when the Priority dip switch is positioned to ON.
Wiring terminals
Example Wiring Diagram
VENT
C1
C2
C3
C4
space heating thermostats
PRIMARY
PUMP
C1 C2 C3 C4
PRIMARY
PUMP
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
L
POWER IN
N
GROUNDS
L
PUMP 3
N
TRANSFORMER
LN
L
PUMP 4
N
POWER
ZONE1
ZONE2
ZONE3
ZONE4
T-STAT 2
C
RW
TTCOM COMMS
DP
ZONE 1
E / S
XX
T-STAT 3
C
RW
T T COM
T-STAT 1
C
RW
TTCOM
T-STAT 4
C
RW
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
LN





STATUS
DURING
PRIORITY
L
N
ModCon boiler
with primary/secondary
Please reference Z-one™ Relay wiring guide for complete listing of wiring diagrams.
TT
C1
C2
C3
C4
space heating thermostats
C1 C2 C3 C4
L
N
G
TT
ZR
ZC
outdoor
temperature
sensor
boiler
reset
controller
DHW
aquastat
space
heating
demand
domestic water
heating demand
VENT
C5
C5
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
L
POWER IN
N
GROUNDS
L
PUMP 3
N
TRANSFORMER
LN
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
POWER
ZONE1
ZONE2
ZONE3
ZONE4
ZONE5
ZONE6
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
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
LN





STATUS
DURING
PRIORITY
L
N
Non-Condensing boiler with
indirect DHW
Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
CALEFFI
L
N
VENT
resistance heat
source
temperature
sensor
(in well)
to / from zone loads
C1
C2
C3
C4
space heating thermostats
C7
C8
C9
C10
space heating thermostats
C5
C6
C11
C12
C1 C2 C3 C4 C5 C6 C7C8 C9 C10 C11 C12
PRIMARY
PUMP
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
L
POWER IN
N
GROUNDS
L
PUMP 3
N
TRANSFORMER
LN
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
POWER
ZONE1
ZONE2
ZONE3
ZONE4
ZONE5
ZONE6
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
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
LN





STATUS
DURING
PRIORITY
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
L
POWER IN
N
GROUNDS
L
PUMP 3
N
TRANSFORMER
LN
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
POWER
ZONE1
ZONE2
ZONE3
ZONE4
ZONE5
ZONE6
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
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
LN





STATUS
DURING
PRIORITY
L
N
ModCon boiler with
primary/secondary and
zone expansion
4-16-18
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