ITT Bell & Gossett ZoneTrol II Z-2 Manual

• PRIORITY: This is typically used in domestic hot water
applications where it may be desirable to give hot water
production a priority over space heating requirements for a
certain period of time. Zone 1 is the priority zone and the
functionality is enabled via DIP switch 1. The priority timer is
selectable for 30 or 60 minutes, via DIP switch 3.
• PURGE: In normal operation, the last circulator will stop and
the boiler will shut down as soon as there is no longer a call
for heat. If the purge functionality is enabled via DIP switch
2, the boiler will shut down, but the circulator will continue
to run for 90 seconds to extract additional BTUs from the
boiler.
• EXERCISE: When the exercise functionality is enabled via
DIP switch 4, each circulator will run for 10 seconds after
every 72 hours of inactivity. This prevents scale and other
deposits from accumulating around the rotating parts and
ensures a trouble free start up at the beginning of each
heating season.
DIP SWITCH SETTINGS
Switch ON OFF
1 Priority OFF Priority ON
2 Purge On Purge Off
3 Priority 30 minutes Priority 60 minutes
4 Exercise On Exercise Off
5 Not Used Not Used
6 Power Delay On Power Delay Off
MECHANICAL INSTALLATION
INSTRUCTIONS
The pump controller should be securely mounted on a wall
near the pumps using four #8 screws (not included).
DESCRIPTION
The Bell & Gossett ZoneTrol II and McDonnell & Miller Zone-
Smart Pump Controllers are designed to control 120 VAC
circulating pumps in hydronic systems.
Max.
T-stat Number of Max. HP
Model Current Zones per Pump
Z-2 / ZS-2 0.085 21/3
Z-3 / ZS-3 3
FEATURES
• Indicator lights visible without removing cover.
Power ED will illuminate when input power is applied to the
controller. Zone EDs will illuminate when relay is energized.
Installation, Operation and Service Instructions
Bell & Gossett®ZoneTrol II™
Models Z-2, Z-3
McDonnell & Miller ZoneSmart™
Models ZS-2, ZS-3
SAFET
INSTRUCTION
This safety alert symbol will be used in this manual and on the
unit safety instructions decal to draw attention to safety related
instructions. When used, the safety alert symbol means ATTEN-
TION! BECOME ALERT! OUR SAFET IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTIONS MA RESULT
IN A SAFET HAZARD.
INSTALLER: P EASE EAVE THIS MANUA FOR THE OWNER’S USE.
Instruction Manual 210712
REVISION B
UL
®
C US
LISTED
15 amps maximum combined load.

ELECTRICAL INSTALLATION
INSTRUCTIONS
1. Disconnect the electrical supply to the pump before
installing the controller.
2. Refer to the applicable wiring diagram
- Figure 1: Cold Start Boiler
- Figure 2: Tankless Coil
3. Verify that the circulator(s) do not exceed the electrical rat-
ing of the controller.
4. Make electrical connections according to the applicable
wiring diagram. Run the pump power through the holes in
the controller chassis to the applicable /N terminals. Keep
120 VAC and 24 VAC wiring separate. All 120 VAC wiring
should be 14 AWG (minimum) copper electrical wire.
Perform all wiring in accordance with applicable codes.
5. If the priority function is to be enabled, the priority zone
(e.g., Domestic Hot Water) pump should be wired to the
Zone 1 /N terminals.
6. Run the thermostat wires through the grommet(s) in the
controller chassis and connect to the appropriate R/W ter-
minals. If the priority function is to be enabled, the priority
zone (e.g., Domestic Hot Water) T-Stat should be wired to
the Zone 1 R/W terminals. Keep 24 VAC wiring separate
from 120 VAC wiring.
NOTE: During the initial power-up of the zone controller,
some “power stealing” thermostats may require up to 3
minutes to function properly. If the installation requires the
pump relays and X-X relay to be held open during this
power-up sequence, the installer can position DIP switch
6 to the “
ON” position . This will cause the controller to
suspend relay operation during the thermostat power-up
period. Normal operation and cycling of the heating system
will resume after the 3 minute time period. This affects ini-
tial power-up only and does not impact normal system
operation.
WARNING: Electrical Shock Hazard
Electrical connections are to be made by a qualified
electrician in accordance with all applicable codes, ordi-
nances and good practices. Disconnect and lock out the
power before making electrical connections. Failure to fol-
low these instructions could result in serious personal injury
and/or death.
ITT
8200 N. Austin Avenue
Morton Grove, I 60053
Phone: [phone]
Fax: [phone]
www.bellgossett.com
www.mcdonnellmiller.com
© COPYRIGHT 2008 BY
ITT CORPORATION
PRINTED IN U.S.A. 8-08
THE ITT ENGINEERED B OCKS SYMBO AND
ENGINEERED FOR IFE ARE REGISTERED
TRADEMARKS OF ITT CORPORATION
END SWITCH
X X ZC ZR
ZONE 1
L N
ZONE 2
L N
ZONE 3
L N
R W
ZONE 1
R W
ZONE 2
R W
ZONE 324 VAC
120 VAC
LNG
HN
THERMOSTATS
Note: Use these terminals for
3& 4 wire thermostats Thermostat(s)
To TT Boiler
Terminals
Factory
Installed
jumper
120 VAC to
Circulator(s)
120 VAC
Input Power
Note: Use these terminals for
3 & 4 wire thermostats Thermostat(s)
To ZC on boiler aquastat
To ZR on boiler aquastat
120 VAC to
Circulator(s)
120 VAC
Input Power
END SWITCH
X X ZC ZR
ZONE 1
L N
ZONE 2
L N
ZONE 3
L N
R W
ZONE 1
R W
ZONE 2
R W
ZONE 324 VAC
120 VAC
LNG
HN
THERMOSTATS
GENERAL WIRING DIAGRAM
Figure 1: Cold Start Boiler
When a thermostat calls for heat,
the corresponding circulator will
start and the XX end switch will
close to enable the boiler.
Figure 2: Tankless Coil
(Remove ZC/ZR Jumper)
When a thermostat calls for heat,
the corresponding circulator will
start when the boiler temperature
reaches the low limit setting.
WARNING: Electrical Shock Hazard
When wiring per the Tankless Coil Application,
pump controller and boiler aquastat must be on the
same circuit and have a common disconnect. Failure to
follow these instructions may introduce a secondary
source of power resulting in personal injury or death.