IDEAL EXALT Combi 155 User manual

1
See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
EXALT COMBI AND SOLO

2See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
Features & specification
INDUSTRY LEADING
WARRANTY PROGRAM
- Standard – 2-year parts and 10-year
primary heat exchanger warranty
- Plus – 5-year parts, 2-year labor
allowance, and 10-year primary
heat exchanger warranty with
registration
- Elite – 6-year parts, 3-years labor
and 12-year heat exchanger
warranty oered with registration,
combustion analysis and hydronic
system treatment. See warranty
for details.
STAINLESS STEEL FIRE TUBE
HEAT EXCHANGER
-ASME Certified
- 50 PSI Maximum working pressure
VENTING
- 2” Vent Exalt 110 & 155 up to 28’
- 3” Vent all models up to 100’
- 3 in 1 Universal vent adapter directly
accepts PVC, Polypropylene and
Stainless Steel
COMBI FEATURES
- Endless hot water
- Large brazed plate heat exchanger
to maximize eciency
- Condensing in DHW Mode
CTRLMAX CONTROL SYSTEM
- EZ Setup allows for quick
60 second setup
- Easy
troubleshooting in plain text,no
codes
-Operate up to 3 circulators
-Outdoor reset to optimize efficiency
- Domestic hot water priority to
maximize hot water production
- Accepts 0-10 VDC signal
- ModBus ready
-Multiple heating curves
INTEGRATED CASCADE
- Integrated cascade function
for up to 6 Exalt Solo boilers
Technical Specification
EXALT MODEL Solo 110 Solo 155 Solo 199 Combi 155 Combi 199
Min Input (BTU) 13,75019,37524,875 19,375 24,875
Max Input (BTU) 110,000 155,000 199,000 155,000 199,000
Turndown Ratio 8:1 8:1 8:1 8:1 8:1
AFUE 95%95% 95%95% 95%
DOE Heating Capacity (MBH) 102 142 184 142 184
AHRI Net Rating (MBH) 89 123 159 123 159
Fuel NG & LP NG & LP NG & LP NG & LP NG & LP
Gas Connection 3/4" 3/4" 3/4" 3/4" 3/4"
Supply / Return Connections 1” 1” 1” 1” 1”
Domestic Inlet/Outlet Connections ---3/4" 3/4"
Vent/Air Connections* 3” 3” 3” 3” 3”
2” Maximum Vent Length 28’ 28’-28’ -
3” Maximum Vent Length 100’ 100’ 100’ 100’ 100’
Water Volume (Gallons)23434
DHW Output GPM (70°F Rise) ---4.0 5.3
DHW Output GPM (75°F Rise) ---3.7 4.9
DHW Output GPM (80°F Rise) ---3.5 4.6
DHW Minimum Flow Rate (GPM) ---0.50.5
DHW Maximum Operating Pressure (PSI) ---150 150
CH Maximum Temperature (°F[°C]) 185 (85) 185 (85) 185 (85) 185 (85) 185 (85)
DHW Maximum Temperature (°F[°C]) ---150 (65) 150 (65)
Cabinet Height 26” 26” 26” 33” 33”
Cabinet Width 21 3/4" 21 3/4" 21 3/4" 21 3/4" 21 3/4"
Cabinet Depth 16 1/2" 16 1/2" 16 1/2" 16 1/2" 16 1/2"
Weight (Lbs)8899 119 110 128
FEATURES & SPECIFICATIONS
Ideal USA reserves the right to change the technical characteristics, components and features of its products without prior notice.
Check for an updated version of this quick reference guide at www.idealusa.com.
This quick reference guide is not a substitute for the installation manuals included with the boiler.
Boiler installation must be in accordance with the boiler manuals and the local authority having jurisdiction.

3See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
COMBI USING A LOW LOSS HEADER
COMBI USING CLOSELY SPACED TEES
COMBI BOILERS
COMBI BOILERS

4See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
WATE R
SUPP LY
O S
COMBI BOILER
SINGLE ZONE WITH CLOSELY SPACE TEES
Power
120VAC
* No Pump Setting Changes Needed With This Configuration
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
WATE R
SUPP LY
O S
COMBI BOILER
SINGLE ZONE WITH CLOSELY SPACE TEES
Power
120VAC
* No Pump Setting Changes Needed With This Configuration
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
WATE R
SUPP LY
O S
COMBI BOILER
SINGLE ZONE WITH CLOSELY SPACE TEES
Power
120VAC
* No Pump Setting Changes Needed With This Configuration

5See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
WATE R
SUPP LY
COMBI BOILER
SINGLE ZONE WITH LOW LOSS HEADER
O S
Power
120VAC
* No Pump Setting Changes Needed With This Configuration
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
WATE R
SUPP LY
COMBI BOILER
SINGLE ZONE WITH LOW LOSS HEADER
O S
Power
120VAC
* No Pump Setting Changes Needed With This Configuration
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
WATE R
SUPP LY
COMBI BOILER
SINGLE ZONE WITH LOW LOSS HEADER
O S
Power
120VAC
* No Pump Setting Changes Needed With This Configuration

6See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
6See appendix for listing of additional components.
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
N G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
LN G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
L
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
OF F
ON
ZONE 4
PRIORITY
OF F
ON
WWRR
ZONE 1ZONE 1
WR
ZONE 1
WWRR
ZONE 2ZONE 2
WR
ZONE 2
WWRR
ZONE 3ZONE 3
WR
ZONE 3
WWRR
ZONE 4ZONE 4
WR
ZONE 4
PRIORI TYPRIORI TYTHERMOSTATS (24 VAC)THERMOSTATS (24 VAC)
XXXX
ISOLATED
EN D
SW IT CH
ISOLATED
EN D
SW IT CH
XX
ISOLATED
EN D
SW IT CH
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORS12 0 VAC CIRCULATORSINPUT
12 0 VAC
INPUT
12 0 VAC
INPUT
12 0 VAC
HHNN
INPUT
12 0 VAC
HNHHNN
ZONE 4ZONE 4
PRIORI TYPRIORI TY
HN
ZONE 4
PRIORI TY
HHNN
ZONE 3ZONE 3
HN
ZONE 3ZONE 2ZONE 2
HHNN
ZONE 2
HN
ZONE 1ZONE 1
HHNN
ZONE 1
HN
12 0 VAC12 0 VAC
ZCZC ZRZR
HH HH
12 0 VAC
ZC ZR
H H
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
WATE R
SUPP LY
O S
COMBI BOILER
WITH MULTIPLE PUMPS
* No Pump Setting Changes Needed With This Configuration
Power
120VAC
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
N G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
LN G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
L
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
OF F
ON
ZONE 4
PRIORITY
OF F
ON
WWRR
ZONE 1ZONE 1
WR
ZONE 1
WWRR
ZONE 2ZONE 2
WR
ZONE 2
WWRR
ZONE 3ZONE 3
WR
ZONE 3
WWRR
ZONE 4ZONE 4
WR
ZONE 4
PRIORI TYPRIORI TYTHERMOSTATS (24 VAC)THERMOSTATS (24 VAC)
XXXX
ISOLATED
EN D
SW IT CH
ISOLATED
EN D
SW IT CH
XX
ISOLATED
EN D
SW IT CH
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORS12 0 VAC CIRCULATORSINPUT
12 0 VAC
INPUT
12 0 VAC
INPUT
12 0 VAC
HHNN
INPUT
12 0 VAC
HNHHNN
ZONE 4ZONE 4
PRIORI TYPRIORI TY
HN
ZONE 4
PRIORI TY
HHNN
ZONE 3ZONE 3
HN
ZONE 3ZONE 2ZONE 2
HHNN
ZONE 2
HN
ZONE 1ZONE 1
HHNN
ZONE 1
HN
12 0 VAC12 0 VAC
ZCZC ZRZR
HH HH
12 0 VAC
ZC ZR
H H
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
WATE R
SUPP LY
O S
COMBI BOILER
WITH MULTIPLE PUMPS
* No Pump Setting Changes Needed With This Configuration
Power
120VAC
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
N G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
LN G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
L
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
OF F
ON
ZONE 4
PRIORITY
OF F
ON
WWRR
ZONE 1ZONE 1
WR
ZONE 1
WWRR
ZONE 2ZONE 2
WR
ZONE 2
WWRR
ZONE 3ZONE 3
WR
ZONE 3
WWRR
ZONE 4ZONE 4
WR
ZONE 4
PRIORI TYPRIORI TYTHERMOSTATS (24 VAC)THERMOSTATS (24 VAC)
XXXX
ISOLATED
EN D
SW IT CH
ISOLATED
EN D
SW IT CH
XX
ISOLATED
EN D
SW IT CH
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORS12 0 VAC CIRCULATORSINPUT
12 0 VAC
INPUT
12 0 VAC
INPUT
12 0 VAC
HHNN
INPUT
12 0 VAC
HNHHNN
ZONE 4ZONE 4
PRIORI TYPRIORI TY
HN
ZONE 4
PRIORI TY
HHNN
ZONE 3ZONE 3
HN
ZONE 3ZONE 2ZONE 2
HHNN
ZONE 2
HN
ZONE 1ZONE 1
HHNN
ZONE 1
HN
12 0 VAC12 0 VAC
ZCZC ZRZR
HH HH
12 0 VAC
ZC ZR
H H
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
FOUR ZONE SWITCHING RELAY
SR 50 4-4
24 VA C
COM
LED
INDICATO RS
POWER
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
FU SE
6 AMP
ZONE 4
PRIORITY
OF F
ON
WR
ZONE 1
WR
ZONE 2
WR
ZONE 3
WR
ZONE 4
PRIORI TYTHERMOSTATS (24 VAC)
XX
ISOLATED
EN D
SW IT CH
12 0 VAC CIRCULATORSINPUT
12 0 VAC
HNHN
ZONE 4
PRIORI TY
HN
ZONE 3ZONE 2
HN
ZONE 1
HN
12 0 VAC
ZC ZR
H H
WATE R
SUPP LY
O S
COMBI BOILER
WITH MULTIPLE PUMPS
* No Pump Setting Changes Needed With This Configuration
Power
120VAC

7See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
7See appendix for listing of additional components.
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
Thermo stat
6 5
Sy stem
Sensor
4 3
Modulation
Si gnal
- +
2 1
CH 2
Thermo sta
t
CH1
Thermo stat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
N G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
LN G L N G L N G L N G
FLAM ESU PPLY CH PUMP DHW PUMP
L
WATE R
SUPP LY
O S
COMBI BOILER
USING ZONE VALVES
POWER INPOWER IN
SLAVE MASTER
PRIORITY OFF
RESE TNORMAL
POSTPURGEOF F
PRIOR. PROT EC TOF F
PUMP EXERCISE OF F
30 SE C / 2 WK 4 MIN / 24HR
SLAVEMASTER
PRIORITY OFF
RESE TNORMAL
POSTPURGEOF F
PRIOR. PROT EC TOF F
PUMP EXERCISE OF F
30 SE C / 2 WK 4 MIN / 24HR
PRIORI TYPRIORI TY
ZONE 1
1 2 3 4
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZONE VALVE S24 VAC ZONE VALVE SPRIORITY
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZONE VALVE S
FO UR ZO NE EXPANDABL E
ZO NE VA LVE CONTROL
ZVC 40 4-EXP-4
FO UR ZO NE EXPANDABL E
ZO NE VA LVE CONTROL
ZVC 40 4-EXP-4
LED
INDICATO RS
VALVE 1
VALVE 2
VALVE 3
VALVE 4
VALVE 1
VALVE 2
VALVE 3
VALVE 4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
LED
INDICATO RS
VALVE 1
VALVE 2
VALVE 3
VALVE 4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
ZONE 3ZONE 3ZONE 2ZONE 2ZONE 1
THERMOSTATS (24 VAC)THERMOSTATS (24 VAC)
R W CR W CR W CR W CR W CR W C
EXP ANSI ON
A B CA B CX XX XX XX X
MAINMAIN PR IORITY
END SWIT CHEND SWIT CH
1 21 2
NE TNE T
R W C
ZONE 4
PRIORITY
ZONE 3ZONE 2ZONE 1
THERMOSTATS (24 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PR IORITY
END SWIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
SW IT CH
X X
PU MP EN D
SW IT CH
N/ O COM N/C
ZONE 4 PUMP
EN D SW ITCH
X X
PU MP EN D
SW IT CH
N/ O COM N/C
ZONE 4 PUMP
EN D SW ITCH
POWER IN
SLAVE MASTER
PRIORITY OFF
RESE TNORMAL
POSTPURGEOF F
PRIOR. PROT EC TOF F
PUMP EXERCISE OF F
30 SE C / 2 WK 4 MIN / 24HR
PRIORI TY
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZONE VALVE S
FO UR ZO NE EXPANDABL E
ZO NE VA LVE CONTROL
ZVC 40 4-EXP-4
LED
INDICATO RS
VALVE 1
VALVE 2
VALVE 3
VALVE 4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (24 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PR IORITY
END SWIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
SW IT CH
N/ O COM N/C
ZONE 4 PUMP
EN D SW ITCH
FU SE
5 AMP
FU SE
5 AMP
FU SE
5 AMP
FU SE
5 AMP
POWER IN
SLAVE MASTER
PRIORITY OFF
RESE TNORMAL
POSTPURGEOF F
PRIOR. PROT EC TOF F
PUMP EXERCISE OF F
30 SE C / 2 WK 4 MIN / 24HR
PRIORI TY
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZONE VALVE S
FO UR ZO NE EXPANDABL E
ZO NE VA LVE CONTROL
ZVC 40 4-EXP-4
LED
INDICATO RS
VALVE 1
VALVE 2
VALVE 3
VALVE 4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (24 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PR IORITY
END SWIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
SW IT CH
N/ O COM N/C
ZONE 4 PUMP
EN D SW ITCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
PORT
ACCESSORY
PORT
POWER
CONTROLS
POWER
CONTROLS
POWER
CONTROLS
POWER IN
SLAVE MASTER
PRIORITY OFF
RESE TNORMAL
POSTPURGEOF F
PRIOR. PROT EC TOF F
PUMP EXERCISE OF F
30 SE C / 2 WK 4 MIN / 24HR
PRIORI TY
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZONE VALVE S
FO UR ZO NE EXPANDABL E
ZO NE VA LVE CONTROL
ZVC 40 4-EXP-4
LED
INDICATO RS
VALVE 1
VALVE 2
VALVE 3
VALVE 4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (24 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PR IORITY
END SWIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
SW IT CH
N/ O COM N/C
ZONE 4 PUMP
EN D SW ITCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
PORT
POWER
CONTROLS
POWER IN
SLAVE MASTER
PRIORITY OFF
RESE TNORMAL
POSTPURGEOF F
PRIOR. PROT EC TOF F
PUMP EXERCISE OF F
30 SE C / 2 WK 4 MIN / 24HR
PRIORI TY
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZONE VALVE S
FO UR ZO NE EXPANDABL E
ZO NE VA LVE CONTROL
ZVC 40 4-EXP-4
LED
INDICATO RS
VALVE 1
VALVE 2
VALVE 3
VALVE 4
POWER
T ST AT1
T ST AT2
T ST AT3
T ST AT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (24 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PR IORITY
END SWIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
SW IT CH
N/ O COM N/C
ZONE 4 PUMP
EN D SW ITCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
PORT
POWER
CONTROLS
* No Pump Setting Changes Needed With This Configuration
Power
120VAC
CH2
Thermostat
6 5
Sy s t e m
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
T hermo sta
t
CH1
Thermostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
M od b us
+ G -
3 2 1
X7X4
X6X5
CH2
Thermostat
6 5
Sy s t e m
Sensor
4 3
Modulation
Signal
-+
2 1
CH 2
T hermo sta
t
CH1
Thermostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
M od b us
+ G -
3 2 1
X7X4
X6X5
N G L N G L N G L N G
FL AM E SU P PL Y CH PUMP DHW PUMP
LN G L N G L N G L N G
FL AM E SU P PL Y CH PUMP DHW PUMP
L
WATE R
S U P P LY
O S
COMBI BOILER
USING ZONE VALVES
POWER INPOWERIN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T YP R IO RI T Y
ZONE 1
1 2 3 4
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S24 VAC ZONE VALVE S PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
ZV C 40 4 -E XP-4
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
ZV C 40 4 -E XP-4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 3ZONE 2ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)THERMOSTATS (2 4 VAC)
R W CR W CR W CR W CR W CR W C
EXP ANSI ON
A B CA B CX XX XX XX X
MAINMAIN PRIORITY
END S WIT CHEND SWITCH
1 21 2
NE TNE T
R W C
ZONE 4
PRIORITY
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
ZV C 40 4 -E XP-4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
FU SE
5 AMP
FU SE
5 AMP
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
ZV C 40 4 -E XP-4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
POR T
ACCESSORY
POR T
POWER
CONTROLS
POWER
CONTROLS
POWER
CONTROLS
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
ZV C 40 4 -E XP-4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
POR T
POWER
CONTROLS
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
ZV C 40 4 -E XP-4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
POR T
POWER
CONTROLS
*No Pump Setting Changes Needed With This Configuration
Pow er
120VAC
CH2
Thermostat
6 5
Sy s t e m
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
T hermo sta
t
CH1
Thermostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
M od b us
+ G -
3 2 1
X7X4
X6X5
CH2
Thermostat
6 5
Sy s t e m
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
T hermo sta
t
CH1
Thermostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
M od b us
+ G -
3 2 1
X7X4
X6X5
N G L N G L N G L N G
FL AM E SU P PL Y CH PUMP DHW PUMP
LN G L N G L N G L N G
FL AM E SU P PL Y CH PUMP DHW PUMP
L
WATE R
S U P P LY
O S
COMBI BOILER
USING ZONE VALVES
POWER INPOWERIN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T YP R IO RI T Y
ZONE 1
1 2 3 4
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S24 VAC ZONE VALVE S PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
Z V C 40 4 -E XP -4
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
Z V C 40 4 -E XP -4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 3ZONE 2ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)THERMOSTATS (2 4 VAC)
R W CR W CR W CR W CR W CR W C
EXP ANSI ON
A B CA B CX XX XX XX X
MAINMAIN PRIORITY
END S WIT CHEND SWITCH
1 21 2
NE TNE T
R W C
ZONE 4
PRIORITY
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
Z V C 40 4 -E XP -4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
FU SE
5 AMP
FU SE
5 AMP
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
Z V C 40 4 -E XP -4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
POR T
ACCESSORY
POR T
POWER
CONTROLS
POWER
CONTROLS
POWER
CONTROLS
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
Z V C 40 4 -E XP -4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
POR T
POWER
CONTROLS
POWER IN
SLAVE MASTER
PR IORIT Y OF F
RESET NORMAL
POSTPURGE OF F
PRIOR. PROTECT OF F
PUMP EXERCISE OF F
30 SEC / 2 WK 4 M IN / 2 4 H R
PR IO RI T Y
ZONE 1
1 2 3 4
ZONE 2
1 2 3 4
ZONE 3
1 2 3 4
ZONE 4
1 2 3 4
24 VAC ZON E VALVE S
FO UR Z O N E EX P AN DA BL E
ZONE VALVE CONTRO L
Z V C 40 4 -E XP -4
LED
INDICATO RS
V AL VE 1
V AL VE 2
V AL VE 3
V AL VE 4
POWER
T STAT1
T STAT2
T STAT3
T STAT4
ZONE 3ZONE 2ZONE 1
THERMOSTATS (2 4 VAC)
R W CR W CR W C
EXP ANSI ON
A B CX XX X
MAIN PRIORITY
END S WIT CH
1 2
NE T
R W C
ZONE 4
PRIORITY
X X
PU MP EN D
S W IT C H
N/O COM N/C
ZO NE 4 P UM P
EN D SW I TCH
FU SE
5 AMP
FU SE
5 AMP
ACCESSORY
POR T
POWER
CONTROLS
* No Pump Setting Changes Needed With This Configuration
Pow er
120VAC

8See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
8See appendix for listing of additional components.
Ch-2 H ig h Te m p
CH2
6 5
System
Sen sor
4 3
Modulation
Signal
- +
2 1
CH 2
T hermo sta
t
CH1
Th er mosta
t
4 3
Outd oor
Sen sor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sen sor
4 3
Modulation
Signal
- +
2 1
CH 2
T hermo sta
t
CH1
Th er mosta
t
4 3
Outd oor
Sen sor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Th er mos ta t
N G L N G L N G L N G
CH-2 P U MP
P OW ER CH PUMP DHW
PUMP
FL AME
LN G L N G L N G L N G
CH-2 P U MP
P OW ER CH PUMP DHW
PUMP
FL AME
L
Ch-1 L ow TempCh-1 L ow Temp
COMBI BOILER
USING 2 TEMPS / 2 HEATING CURVES
WATE R
SU PP LY
O S
Power
120VAC
* Pump Setting Changes Needed With This Configuration
* *
*(OFF)
Ch-2 H ig h Te m p
CH2
6 5
System
Sen sor
4 3
Modulation
Signal
- +
2 1
CH 2
T hermo sta
t
CH1
Th er mosta
t
4 3
Outd oor
Sen sor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sen sor
4 3
Modulation
Signal
- +
2 1
CH 2
T hermo sta
t
CH1
Th er mosta
t
4 3
Outd oor
Sen sor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Th er mos ta t
N G L N G L N G L N G
CH-2 P U MP
P OW ER CH PUMP DHW
PUMP
FL AME
LN G L N G L N G L N G
CH-2 P U MP
P OW ER CH PUMP DHW
PUMP
FL AME
L
Ch-1 L ow TempCh-1 L ow Temp
COMBI BOILER
USING 2 TEMPS / 2 HEATING CURVES
WATE R
SU PP LY
O S
Power
120VAC
* Pump Setting Changes Needed With This Configuration
* *
* (OFF)
Ch-2 H ig h T em p
CH2
6 5
System
Sen sor
4 3
Modulation
Signal
-+
2 1
CH 2
T hermo sta
t
CH1
Th er most a
t
4 3
Outdoo r
Sen sor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sen sor
4 3
Modulation
Signal
-+
2 1
CH 2
T hermo sta
t
CH1
Th er most a
t
4 3
Outdoo r
Sen sor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Th er mosta t
N G L N G L N G L N G
CH-2 P UMP
P OW ER CH PUMP DHW
PUMP
FLAME
LN G L N G L N G L N G
CH-2 P UMP
P OW ER CH PUMP DHW
PUMP
FLAME
L
Ch-1 L ow TempCh-1 L ow Temp
COMBI BOILER
USING 2 TEMPS / 2 HEATING CURVES
WATE R
SU PP LY
O S
Power
120VAC
* Pump Setting Changes Needed With This Configuration
* *
*(OFF)
**(ON)
**(OFF)

9See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
9See appendix for listing of additional components.
HEAT ONLY BOILER USING A LOW LOSS HEADER
HEAT ONLY BOILER USING CLOSELY SPACED TEES
WATE R
SUPP LY
WATE R
SUPP LY
WATE R
SUPP LY
HEAT ONLY BOILERS
P1
P1
PUMP SELECTION GUIDE (P1)
HEAT ONLY BOILER USING A LOW LOSS HEADER
HEAT ONLY BOILER USING CLOSELY SPACED TEES
WATE R
SUPP LY
WATE R
SUPP LY
WATE R
SUPP LY
HEAT ONLY BOILERS
P1
P1
PUMP SELECTION GUIDE (P1)
HEAT ONLY BOILER USING A LOW LOSS HEADER
HEAT ONLY BOILER USING CLOSELY SPACED TEES
WATE R
SUPP LY
WATE R
SUPP LY
WATE R
SUPP LY
HEAT ONLY BOILERS
P1
P1
PUMP SELECTION GUIDE (P1)
HEAT ONLY BOILER USING A LOW LOSS HEADER
HEAT ONLY BOILER USING CLOSELY SPACED TEES
WATE R
SUPP LY
WATE R
SUPP LY
WATE R
SUPP LY
HEAT ONLY BOILERS
P1
P1
PUMP SELECTION GUIDE (P1)
HEAT ONLY BOILER USING A LOW LOSS HEADER
HEAT ONLY BOILER USING CLOSELY SPACED TEES
WATE R
SUPP LY
WATE R
SUPP LY
WATE R
SUPP LY
HEAT ONLY BOILERS
P1
P1
PUMP SELECTION GUIDE (P1)
HEAT ONLY BOILER USING A LOW LOSS HEADER
HEAT ONLY BOILER USING CLOSELY SPACED TEES
WATE R
SUPP LY
WATE R
SUPP LY
WATE R
SUPP LY
HEAT ONLY BOILERS
P1
P1
PUMP SELECTION GUIDE (P1)
HEAT ONLY BOILERS

10 See appendix for listing of additional components.
Quick Reference Boiler Piping and Wiring Guide
10 See appendix for listing of additional components.
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
O S
HEAT ONLY BOILER
SINGLE ZONE WITH CLOSELY SPACED TEES
WATE R
SUPP LY
Power
120VAC
* No Pump Setting Changes Needed With This Configuration
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
O S
HEAT ONLY BOILER
SINGLE ZONE WITH CLOSELY SPACED TEES
WATE R
SUPP LY
Power
120VAC
* No Pump Setting Changes Needed With This Configuration
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
CH2
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH 2
Thermo sta
t
CH1
Ther mostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor
or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
Ther mostat
N G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
LN G L N G L N G L N G
CH-2 PUMP
POWERCH PUMP DHW PUMP
FLAM E
L
O S
HEAT ONLY BOILER
SINGLE ZONE WITH CLOSELY SPACED TEES
WATE R
SUPP LY
Power
120VAC
* No Pump Setting Changes Needed With This Configuration