Taco ZVC404-EXP-4 User manual

1234
ZONE 1
1234
ZONE 2
1234
ZONE 3
1234
ZONE 4
PRIORITY
ZONE
2 WIRE
ZONE VALVE
(NO END SWITCH)
MUST USE JUMPER
TACO
3 WIRE
ZONE VALVE
1
2
3
JUMPER
3 & 4
MOTOR END
SWITCH
4 WIRE
ZONE VALVE
(POWER OPEN,
SELF CLOSING)
JUMPER
3 & 4
POWER
CONTROLS
ZVC 404-EXP-4
FOUR ZONE EXPANDABLE
ZONE VALVE CONTROL
24 VAC
FACTORY
INSTALLED
TRANSFORMER
120 VAC
INPUT
WHITE
BLACK
POWER IN
24 VAC
24 VAC
FACTORY
INSTALLED
TRANSFORMER
120 VAC
INPUT
WHITE
BLACK
N/O COM N/C
PUMP END
SWITCH
ZONE 4 PUMP
END SWITCH
SLAVE
PRIORITY ON
RESET
POST PURGE ON
PRIORITY PROTECTION ON
PUMP EXERCISE ON
30 SEC/2 WK
MASTER
OFF
NORMAL
OFF
OFF
OFF
4 MIN/24 HOUR
NOTE 3: When a circulator is used
on the priority zone instead of a
zone valve, jumper 3 and 4 of
the priority zone.
INDIRECT
WATER HEATER
AQUASTAT OR
THERMOSTAT
T STAT 1 VALVE 1
T STAT 2 VALVE 2
T STAT 3 VALVE 3
T STAT 4 VALVE 4
POWER
LED
INDICATORS
TO: "TT" ON BOILER
TO: "TT" ON BOILER WITH
DHW "TT" INPUT
ZONE 1 ZONE 2 ZONE 3 ZONE 4 NET
EXPANSION
MAIN PRIORITY
XX X X ABCRWC R W C R W CRWC12
END SWITCH THERMOSTATS (24 VAC) PRIORITY
24 VAC ZONE VALVES
ACCESSORY
PORT
PRIORITY
XX
FUSE
5 AMP
FUSE
5 AMP
A
B
Powered from Transformer APowered from Transformer B
120 VAC
INPUT
DHW
PUMP
SYSTEM PUMP AND BOILER TURN ON WHEN ANY ZONE VALVE OPENS.
DHW PUMP TURNS ON ONLY WHEN PRIORITY ZONE CALLS.
SECONDARY PUMP COMES ON WHEN ANY ZONE CALLS EXCEPT PRIORITY ZONE.
SYSTEM
PUMP SECONDARY
PUMP
HOT
NEUTRAL
N
H
THERMOSTATS
(24 VAC) Powered from
Transformer A
Powered from
Transformer B
See NOTE 1
See
NOTE 2
NOTE 1: Terminals Care for
optional 24V thermostat
COMMON connections.
NOTE 2: Resistor (1K , 1⁄2W)
may be needed between
Wand Cterminals.
Operati n/External Diagn stics: When any thermostat calls for heat,
the appropriate zone valve is energized and the yellow light goes on.
When the zone valve is fully open, the red light goes on and energizes
the end switch relay. The green light should always be on, indicating
that power is connected.
Pri rity Operati n: When the priority dip switch is set to ON and the
priority zone is actuated, all other zones will stop operation until pri-
ority zone is satisfied. When not switched to priority, all zones will
operate independently.
M de Operati n: When the dip switch is set to NORMAL, the end
switch relay will be energized if any zone is in operation. When the switch
is set to RESET, the end switch relay will only be energized if the priority
zone is in operation, or through the operation of a plug-in reset control.
P st Purge Operati n: When the dip switch is set to ON, the priori-
ty zone output will stay energized for 2 minutes after its thermostat or
aquastat is satisfied, but not operate the boiler.
Pri rity Pr tecti n Operati n: When the dip switch is set to ON, and
if the priority zone calls continuously for more than one hour, power
is returned to all the other zones, allowing each zone to function inde-
pendently. Once the priority zone is satisfied, the control's auto-reset is
activated and the priority zone is again allowed to have priority for up
to one hour starting from when it calls next.
Pump Exercise Operati n: When the dip switch is set to ON, the solid
state timer cycles all the zone valves and circulating pumps that are
attached to the Expandable Zone Valve Control at the selected time
interval. The time interval can be set for the valves and pumps to run
for either 30 seconds every 2 weeks or for 4 minutes every 24 hours.
End Switches (Dry C ntacts): The main end switch closes when any
zone thermostat calls for heat and the mode switch is set to NORMAL.
The main end switch also closes when the mode switch is set to RESET
and a PC Series boiler reset power control is calling for heat. The priori-
ty end switch closes only when the priority zone thermostat or aquastat
is calling for heat.
Expansi n C nnecti ns: Set the expansion switch to MASTER on the
switching relay that has the designated priority zone or is utilizing the
PC Series plug-in option. Set all other daisy chained controls to SLAVE.
Using thermostat wire (1 -22 gauge) connect between terminals A, B,
C on the master control to the corresponding A, B, C on the SLAVE con-
trol(s). Controls may be daisy chained up to 20 zoning panels using any
combination of -EXP controls (120 zones if all are 6 zone panels).
Therm stat Input (24 vac):
RHot side of transformer. Connect to Ron thermostat.
WSwitched R signal from thermostat. Connect to W on
thermostat.
CCommon side of transformer. Connect to COM on
thermostat (optional).
NET Network terminals 1 & 2 are tied together for wiring convenience
when using communicating style thermostats (optional).
P wer Input (120 vac):
Connect neutral (white) leads on transformers to 120 volts ac
neutral power supply.
Connect hot (black) leads on transformers to 120 volts ac
hot power supply.
Pump End Switch (Dry C ntacts):
Connect hot power supply to the right side of the pump end switch
terminal on board.
Connect hot input lead of the circulator to the left side of the pump
end switch terminal on board.
Z ne 4 Pump End Switches (Dry C ntacts): See Diagram.
N/O Normally open terminal of the priority zone relay.
COM Common terminal of the priority zone relay.
N/C Normally closed terminal of the priority zone relay.
End Switch Pump Neutral C nnecti ns:
Connect neutral power supply directly to neutral lead on circulator(s).
WARNING: Wiring connections must be made in accordance with all
applicable electrical codes. Use copper wire only. 120 VAC wiring must have
a minimum temperature rating of 75°C. Failure to follow this instruction
can result in personal injury or death and/or property damage. 12-1 gauge
wire recommended for 120 VAC connections, 14-22 gauge wire for thermo-
stat connections, and 14-22 gauge wire for 24 VAC source connections.
Wiring Diagram:
Instruction Sheet
ZVC404-EXP-4 Zone Valve Control
102-399
SUPERSEDES: March 1, 2013 EFFECTIVE: D c mb r 20, 2013
Plant ID# 9300-2880
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that
may cause undesired operation.
Specificati ns:
PRODUCT NUMBER INPUT MAX 24 VAC TYPE 1 ENCLOSURE
NUMBER OF ZONES VOLTAGE OUTPUT @ 25°C WIDTH HEIGHT DEPTH
ZVC404-EXP-4 4 with Priority 120/60/1 VAC, 3A 24 VA per Zone 121⁄4" " 3"
40 VA per Transformer
The pump end switches are rated 1⁄6hp, 5 amps at 120 VAC. The main and priority end switch connections
are rated 24 VAC, 1 amp. All thermostat and zone valve connections supply a 24 VAC class 2 output.

SLAVE
PRIORITY ON
RESET
POST PURGE ON
PRIORITY PROTECTION ON
PUMP EXERCISE ON
30 SEC/2 WK
MASTER
OFF
NORMAL
OFF
OFF
OFF
4 MIN/24 HOUR
Dip Switch Settings
Tr ublesh ting:
• Pr blem: Digital thermostats do not work cor-
rectly when connected to a zone valve control.
• S luti n: Some thermostats are a “Power
Stealing” type which means they are powered by
the zone control with just 2 wires (R& W). A
resistor may be needed in order to have the ther-
mostat work properly. This resistor should be
placed between the W& C(c mm n) terminals
of the zone control. If the thermostat manufac-
turer does not supply a resistor, a 1000 ohm ½
watt resistor has proven to work with most mod-
els and is readily available at electronic supply
outlets (e.g. Radio Shack). If the thermostat is bat-
tery powered, then check that the batteries are
fresh and installed correctly.
• Pr blem: No heat in a zone or room of build-
ing.
• S luti n: LED diagnostic lights will help find a
component that is not working properly. The
green LED should always be on, indicating that
power is connected and the fuse is good. When
there is a call for heat, the yellow LED will come
on indicating power to the zone valve. This
indicates the thermostat is working correctly.
When the zone valve fully opens and its end
switch makes contact, the red LED will come
on, the boiler turns on and a circulator will start
if connected to the zone control.
For information on Taco’s Zone
Valve Controls (ZVC) including
catalog sheet, instruction sheets,
Visio stencils and our highly
praised Zone Controls Wiring
Guide, scan the QR code to the
right or go to our website:
http://www.taco-hvac.com.
CONTROLS MADE EASY.®
TACO, INC., 1160 Cranston Str t, Cranston, RI 02920 T l phon : [phone] FAX: [phone].
TACO (Canada), Ltd., 8450 Lawson Road, Unit #3, Milton, Ontario L9T 0J8. T l phon : 905/564-9422. FAX: [phone].
Visit o r web site at: http://www.taco-hvac.com
Print d in USA
Copyright 2013
TACO, Inc.
Taco, Inc. will r pair or r plac without charg
(at th company’s option) any product or part
which is prov n d f ctiv und r normal us
within thr (3) y ars from th dat of start-up or
thr (3) y ars and six (6) months from dat of
shipm nt (which v r occurs first).
In ord r to obtain s rvic und r this warranty, it
is th r sponsibility of th purchas r to promptly
notify th local Taco stocking distributor or Taco
in writing and promptly d liv r th subj ct prod-
uct or part, d liv ry pr paid, to th stocking dis-
tributor. For assistanc on warranty r turns, th
purchas r may ith r contact th local Taco
stocking distributor or Taco. If th subj ct prod-
uct or part contains no d f ct as cov r d in this
warranty, th purchas r will b bill d for parts
and labor charg s in ff ct at tim of factory
xamination and r pair.
Any Taco product or part not install d or op rat-
d in conformity with Taco instructions or which
has b n subj ct to misus , misapplication, th
addition of p trol um-bas d fluids or c rtain
ch mical additiv s to th syst ms, or oth r
abus , will not b cov r d by this warranty.
If in doubt as to wh th r a particular substanc
is suitabl for us with a Taco product or part, or
for any application r strictions, consult th
applicabl Taco instruction sh ts or contact
Taco at [401-942-8000].
Taco r s rv s th right to provid r plac m nt
products and parts which ar substantially simi-
lar in d sign and functionally quival nt to th
d f ctiv product or part. Taco r s rv s th right
to mak chang s in d tails of d sign, construc-
tion, or arrang m nt of mat rials of its products
without notification.
TACO OFFERS THIS WARRANTY IN LIEU OF
ALL OTHER EXPRESS WARRANTIES. ANY
WARRANTY IMPLIED BY LAW INCLUDING
WARRANTIES OF MERCHANTABILITY OR FIT-
NESS IS IN EFFECT ONLY FOR THE DURATION
OF THE EXPRESS WARRANTY SET FORTH IN
THE FIRST PARAGRAPH ABOVE.
THE ABOVE WARRANTIES ARE IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR STATU-
TORY, OR ANY OTHER WARRANTY OBLIGA-
TION ON THE PART OF TACO.
TACO WILL NOT BE LIABLE FOR ANY SPE-
CIAL, INCIDENTAL, INDIRECT OR CONSE-
QUENTIAL DAMAGES RESULTING FROM THE
USE OF ITS PRODUCTS OR ANY INCIDENTAL
COSTS OF REMOVING OR REPLACING
DEFECTIVE PRODUCTS.
This warranty giv s th purchas r sp cific
rights, and th purchas r may hav oth r rights
which vary from stat to stat . Som stat s do
not allow limitations on how long an impli d war-
ranty lasts or on th xclusion of incid ntal or
cons qu ntial damag s, so th s limitations or
xclusions may not apply to you.
LIMITED WARRANTY STATEMENT
Optional power stealing thermostat resistor part number: SRTR-001RP
(Value: 1000 Ohms, 1/2 watt or higher)
Replacement Zone Valve Controls fuses part number: SR5A-005RP
(Manufacture: Littlefuse, Part Number: 229005)
24 VAC
FACTORY
INSTALLED
TRANSFORMER
120 VAC
INPUT
WHITE
BLACK
H
N
BOILER
24 VAC
FACTORY
INSTALLED
TRANSFORMER
120 VAC
INPUT
WHITE
BLACK
24 VAC
FACTORY
INSTALLED
TRANSFORMER
120 VAC
INPUT
WHITE
BLACK
24 VAC
FACTORY
INSTALLED
TRANSFORMER
120 VAC
INPUT
WHITE
BLACK
Note: When a circulator is used on the
priority zone instead of a zone valve,
jumper 3 and 4 of the priority zone.
SWITCH SETTINGS
Master/Slave: Master
Reset/Normal: Normal
Priority Zone: On
SWITCH SETTINGS
Master/Slave: Slave
Reset/Normal: Normal
Priority Zone: Off
120 VAC
INPUT
MASTER
SLAVE
SYSTEM PUMP AND BOILER TURN ON
WHEN ANY ZONE VALVE OPENS.
SYSTEM
PUMP
DRY
CONTACTS
DRY
CONTACTS
TO: "TT" ON BOILER
TO: "TT" ON BOILER WITH
DHW "TT" INPUT
1234
ZONE 1
1234
ZONE 2
1234
ZONE 3
1234
ZONE 4
1234
ZONE 5
1234
ZONE 6
PRIORITY
ZONE
2 WIRE ZONE VALVE
(NO END SWITCH)
MUST USE JUMPER
TACO
3 WIRE
ZONE VALVE
1
2
3
JUMPER
3 & 4
MOTOR END
SWITCH
4 WIRE ZONE VALVE
(POWER OPEN,
SELF CLOSING)
JUMPER
3 & 4 SEE NOTE
ZVC 406-EXP-4
SIX ZONE EXPANDABLE
ZONE VALVE CONTROL
POWER IN
24 VAC
N/O COM N/C
ZONE 6 PUMP
END SWITCH
SLAVE
PRIORITY ON
RESET
POST PURGE ON
PRIORITY PROTECTION ON
PUMP EXERCISE ON
30 SEC/2 WK
MASTER
OFF
NORMAL
OFF
OFF
OFF
4 MIN/24 HOUR
THERMOSTATS
24 VAC
T STAT 1 VALVE 1
T STAT 2 VALVE 2
T STAT 3 VALVE 3
T STAT 4 VALVE 4
VALVE 5
T STAT 6 VALVE 6
POWER
LED
INDICATORS
T STAT 5
ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 NET
EXPANSION
MAIN PRIORITY
X X X X A B C RWCRWCRWCRWCRWCRWC 1 2
END SWITCH THERMOSTATS (24 VAC) PRIORITY
24 VAC ZONE VALVES
1234
ZONE 1
1234
ZONE 2
1234
ZONE 3
1234
ZONE 4
1234
ZONE 5
1234
ZONE 6
PRIORITY
ZONE
2 WIRE ZONE VALVE
(NO END SWITCH)
MUST USE JUMPER
TACO
3 WIRE
ZONE VALVE
1
2
3
JUMPER
3 & 4
MOTOR END
SWITCH
4 WIRE ZONE VALVE
(POWER OPEN,
SELF CLOSING)
JUMPER
3 & 4 SEE NOTE
ZVC 406-EXP-4
SIX ZONE EXPANDABLE
ZONE VALVE CONTROL
POWER IN
24 VAC
N/O COM N/C
PUMP END
SWITCH
ZONE 6 PUMP
END SWITCH
SLAVE
PRIORITY ON
RESET
POST PURGE ON
PRIORITY PROTECTION ON
PUMP EXERCISE ON
30 SEC/2 WK
MASTER
OFF
NORMAL
OFF
OFF
OFF
4 MIN/24 HOUR
THERMOSTATS
24 VAC
INDIRECT
WATER HEATER
AQUASTAT OR
THERMOSTAT
T STAT 1 VALVE 1
T STAT 2 VALVE 2
T STAT 3 VALVE 3
T STAT 4 VALVE 4
VALVE 5
T STAT 6 VALVE 6
POWER
LED
INDICATORS
T STAT 5
ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 NET
EXPANSION
MAIN PRIORITY
X X XX A B CRWCRWCRWCRWCRWCRWC 1 2
END SWITCH THERMOSTATS (24 VAC) PRIORITY
24 VAC ZONE VALVES
PRIORITY
PRIORITY
XX
PUMP END
SWITCH
XX
POWER
CONTROLS
ACCESSORY
PORT
FUSE
5 AMP
FUSE
5 AMP
POWER
CONTROLS
ACCESSORY
PORT
FUSE
5 AMP
FUSE
5 AMP
2 EXP Z ne Valve C ntr ls C nnected T gether
with System Pump