CALEFFI Z-one ZSR10X Series User manual

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

3
INDEX
Z-one Relay thermostat connections
Thermostat wiring ........................................................................................................................................................................... 4
Zone valve wiring to ZVR series....................................................................................................................................................... 5
ZSR101 - single zone relay
Product overview ............................................................................................................................................................................ 6
Operation and cover removal ........................................................................................................................................................................7
A1 - Single thermostat ...................................................................................................................................................................................8
A2 - Multiple thermostats...................................................................................................................................................................10
A3 - Single master thermostat, with TRVs, variable speed pump.................................................................................................... 12
ZSR103, ZSR104 & ZSR106 - multi-zone pump relay
Product overview ........................................................................................................................................................................... 14
Circuit board .................................................................................................................................................................................. 15
Cover removal................................................................................................................................................................................ 16
Product details............................................................................................................................................................................... 17
B1 - Mod/Con boiler, hydro separator or buffer tank, zone pumps ................................................................................................. 18
B2 - Traditional boiler, indirect DHW w/ priority, zone pumps .......................................................................................................... 20
B3 - Mod/Con boiler, primary loop, closely spaced tees, zone pumps............................................................................................ 22
B4 - Mod/Con boiler, hydro separator or buffer tank, zone pumps with remote enable................................................................... 24
ZVR103, ZVR104 & ZVR106 - multi-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........................................................... 36
C5 - Traditional boiler, indirect DHW (no priority) with valve ............................................................................................................. 38
C6 - Traditional boiler with reset control, priority indirect DHW with valve........................................................................................ 40
C7 - Mod/Con boiler, hydro separator, zone valve (more than 6), multiple secondary pumps.......................................................... 42
C8 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves with ECM pump enabling....................................... 44
C9 - Mod/Con boiler, hydro separator, zone 1 low temp, 2 - 6 high temp zone valves.................................................................... 46
Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.

4
All Caleffi Z-one controls use the same interface
to connect to thermostats. This interface is
very flexible and allows many different types
of thermostats to be connected to the control
including 2, 3 and 4 wire versions. In addition, any
type of switching device can be used to signal a
heat demand by connecting the R & W (T & T)
terminals together. The terminals are dual labeled
to help simplify wiring.
Z-one Thermostat Connections
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
T T COM COMMS
DP
ZONE 1
E / S
X X
T-STAT 3
C
RW
T T COM
T-STAT 1
C
RW
T T COM
T-STAT 4
C
RW
T T COM
T-STAT 5
C
RW
T T COM
T-STAT 6
C
RW
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
LN
ON
OFF
STATUS
DURING
PRIORITY
Z-one T-stat interface
Description
R = 24 VAC Supply
W = Heat Call
C = 24 VAC Common
Function
R&W: When connected, signals a heat demand.
R&C: Provides 24 VAC to powered thermostats.
There are a few different types of 2 wire thermostats
including bi-metallic, power stealing and battery
powered. All of these thermostats connect in
the same manner to the Caleffi Z-one series of
controls. Connect R to R and W to W. See below.
2-Wire Thermostats
6 Zone
Z6P
T
HM 2
C
R
W
T
T COM COMMS
DP
DHW
ZR/ZC
X X
THM 3
C
RW
T T COM
THM 1
C
RW
T T COM
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
LPOWER IN
NGROUNDS
L
PUMP 3
N
TRANSFORMER
12/20VA
LN
THM 4
C
RW
T T COM
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
THM 5
C
RW
T T COM THM 6
C
RW
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
To connect a 4-wire thermostat to the Z-one
series controls, connect R to R, W to W and C
to C. A jumper in the thermostat is also required
between R & Rh as shown below. Similar to a
3-wire thermostat, R & C from the Z-one Control
supply constant 24 VAC to the thermostat.
4-Wire Thermostats
Three wire thermostats get their power from the
control they are connected to. R & C from the
Z-one Control supply 24 VAC to the thermostat at
all times while the W lead signals a heat demand.
3-Wire Thermostats
6 Zone
Z6P
TH
M 2
C
R
W
T
T COM COMMS
DP
DHW
ZR/ZC
X X
THM 3
C
RW
T T COM
THM 1
C
RW
T T COM
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
LPOWER IN
NGROUNDS
L
PUMP 3
N
TRANSFORMER
12/20VA
LN
THM 4
C
RW
T T COM
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
THM 5
C
RW
T T COM THM 6
C
RW
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
TH
M 2
C
R
W
T
T COM COMMS
DP
DHW
ZR/ZC
X X
THM 3
C
RW
T T COM
THM 1
C
RW
T T COM
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
LPOWER IN
NGROUNDS
L
PUMP 3
N
TRANSFORMER
12/20VA
LN
THM 4
C
RW
T T COM
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
THM 5
C
RW
T T COM THM 6
C
RW
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
RW
T T COM
COMMS
DP
DHW
ZR/ZC
X X THM
3
C
RW
T T
COM
THM 1
C
RW
T T COM
L
PUMP 2
N
PRIMARY
PUMP
L
PRIORITY
PUMP 1
N
LPOWER IN
NGROUNDS
L
PUMP 3
N
TRANSFORMER
12/20VA
LN
THM 4
C
RW
T T COM
L
PUMP 4
NL
PUMP 5
NL
PUMP 6
N
THM 5
C
RW
T T COM THM 6
C
RW
T T COM P
WR
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
C R Rh W1
A heat demand can also be initiated by any type
of device that has dry contacts (dry contacts are
a set of contacts that open and close but do not
have any voltage present until supplied from an
outside source). The end switch on a Z-one series
zone valve is an example of a dry contact. Using
a dry contact to connect R to W will initiate a heat
demand.
Dry Contacts
Always refer to the thermostat manufacturer’s instructions.
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.
CAUTION: 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.
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply

5
1
2
3
LPOWER IN
N
POWER
T-SAT
CALL
ZONE 6
L
ZONE #1
PUMP
NL
SEC
PUMPN
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
X X
T-STAT 3
C
RW
T T COM
T-STAT 1
C
RW
T T COM T-STAT 4
C
RW
T T COM T-STAT 5
C
RW
T T COM T-STAT 6
C
RW
T T COM
AUX
ON
OFF
ON
OFF
VALVE
OPEN
1
2
3
4
52
2 1 3
4 1 3
White Rogers
1361 Zone Valve 4 wire Zone Valve 2 wire Taco 570
2
Wiring a standard zone valve to Calef Z-one Relay
Since a two wire actuator does not have an end switch for feedback
to the ZVR control, 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.
Wiring a Taco 570 valve to Calef 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 terminal 3 on the zone valve. Failure to follow
schematic will lead to damage of product.
Wiring a White Rogers 1361 valve to Calef Z-one Relay
The White Rogers 1361 zone valve requires 24 VAC to terminal 2
at all times, therefor connect to the R terminal of the associated
T-STAT on the ZVR control. The left motor terminal on the ZVR
series control must be connected to terminal 4 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. The 1361 can not be used on any
zone when the ZVR control is set for priority.
Wiring zone valve to Calef ZVR control

6
Overview
•Compatiblewith2,3and4-wirethermostatsorother
low voltage controllers with switching action
•120VACinput
•Heavyduty,sealed,DPDT,fuseprotectedrelay 
(with spare fuse)
•Twodrycontactoutputs(Relay1andRelay2)for
operating 120 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
•Simpliedwiringwithpre-installedjumper
•100%factorytestedwith3yearwarranty
•ETLcertied
See technical brochure 01284 NA for more product
information.
4009064
Certified to CSA C22-2 No.24
Conforms to UL Standard 873
ZSR101 - Single Zone Switching Relay

7
When a zone has a
demand from a thermostat
(TT or R W) the relay will
close sending 120 VAC
to Relay #1 NO terminal
and switching the pump
on, and the C to NO dry
contact on relay #2 closes,
signaling the boiler of a heating demand.
1 Zone
ZSR101
C
RW
T T COM
L
POWER IN
NC
RELAY #1
NO NC C
RELAY #2
NO NC
TRANSFORMER
PWR
ZONE
1 Zone
ZSR101
C
RW
T T COM
L
POWER IN
NCRELAY #1
NO NC CRELAY #2 NO NC
TRANSFORMER
PWR
ZONE
Operating Principles
R, W, C and T T Comm dual labeling at thermostat terminals.
Compatible with low voltage 2, 3, or 4 wire thermostats or any
other low voltage devices having a switching action.
Supply 120 VAC hot to terminal 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.
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
body for stabilizing relay box. Insert
screwdriver and push tab inward.
Turn box and repeat inserting
screwdriver and pushing tab inward
on opposite side, cover should
release from base.
Slide 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.
120VAC input
power connection

8
T
T
RWC
TTcom
power
zone
transformer
N LL 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.

9
Sequence of Operation / Settings
• A demand occurs from the thermostat closing
RtoWontheZSR101control.The“ZONE”
LED illuminates.
• The ZSR101 control will power relay #1 and
#2 closing C to NO.
• The NO terminal of relay #1 will send out
120 VAC to your pump. Relay #2 provides
a dry contact closure to signal the boiler of a
demand.
• NOTE: Relay #1 can be used as a dry contact
as well by removing the factory installed
jumper between L and C.
• When 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 is a factory installed jumper between the 120
VAC line (L) and the common terminal of relay #1 (C).
Thermostat terminals
R = 24 VAC
W = Heat call
C = Common of 24 VAC
WARNING: NEVER CONNECT R & C DIRECTLY,
this will be a direct short on the 24 VAC supply

10
RWC
TTcom
power
zone
transformer
N LL RELAY 1
C N/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
RWRW
End switch wires
L
N
A2 - Multiple thermostats
Hydronic diagram is for illustration purposes only and could be missing system components.

11
Sequence of Operation / Settings
• A demand occurs from one of the thermostats
which sends power (from a separately sourced
transformer) to the corresponding zone valve.
• When the zone valve opens the end switch
will close R to W on the ZSR101 control. The
“ZONE”LEDilluminates.
• The ZSR101 control will power relay #1 and
#2 closing C to NO.
• The NO terminal of relay #1 will send out
120 VAC to your pump. Relay #2 provides
a dry contact closure to signal the boiler of a
demand.
• NOTE: Relay #1 can be used as a dry contact
as well by removing the 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 supply
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 is a factory installed jumper between the 120
VAC line (L) and the common terminal of relay #1 (C).
Thermostat terminals
R = 24 VAC
W = Heat call
C = Common of 24 VAC

12
buer tank
thermostatic
radiator valves
(TRV) on each
radiator
TRV
TRV
TRV
TRV
TRV TRV
RWC
TTcom
power
zone
transformer
NLLRELAY 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.