TAC Erie VL500. Application. Features. Zone Valve Control Center General Instructions

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1 TAC Erie VL500 Zone Valve Control Center General Instructions Application The VL500 zone control system provides control of up to five zone valves, a circulator and boiler control in a multi-zone hydronic heating system. Field selectable priority for zone 1 eliminates the need for additional relays to provide domestic hot water priority. Additional zones can be added. Features Field selectable priority or Priority Plus zone Unlimited zone expansion. Maximum load on any serially linked VL500 slave module should not exceed 50 VA Field replaceable relay LED status window Common 24 Vac transformer terminal Field replaceable fuse VL500 Printed in U.S.A Copyright 2008 TAC All Rights Reserved. F

2 SPECIFICATIONS Inputs Power (N-L1): 120 Vac, 50/60 Hz, 100 VA. Main Fuse (F2): 10A, 250 Vac slow blow (Bussman MDA-10 or equal) Thermostat/Heat Demand Dry Contacts (- through T5-T5): 24 Vac, Class 2 Switched load is 0.05A plus load current at corresponding "1-2" terminals. (Power supplied by this unit - do not connect external power source). Set thermostat anticipator per thermostat instructions to measured current. Zone in Terminals: External dry contacts rated for 24 Vac, 2.2 A (58VA), Class 2 Outputs Environment Line Voltage Circulator Output (C1-N): Motor: 1/3 120 Vac Boiler Output (Dry Contact X1-X2): General Purpose: 24 Vac, Class 2 Transformer: 24 Vac, 75 VA Class 2 (total external loads limited as specified below) Secondary Fuse (F1): 3.2A, 250 Vac slow blow (Bussman MDQ-3 2/10 or equal) Zone Valve Outputs (5 pair of terminals 1-2): 24 Vac, Class 2 Any Single Zone : 0.9A (22VA), Maximum Total for Master Zone Valves and Thermostats: 2.7A (65VA), Maximum Total for Slave Zone Valves and Thermostats: 2.1A (50VA), Zone Out Terminals: Switching capacity: 24 Vac, 2.2A (58VA), Class 2 Operating Temperature Limits: 32 to 104 F (0 to 40 C). Humidity: Up to 85% RH non-condensing. Shipping Weight: 6 lbs (2718 g). Location: NEMA Type 1 (IP20). 2 Copyright 2008 TAC All Rights Reserved. F

3 TYPICAL APPLICATIONS (wiring diagram) 4-WIRE JUMPER 3 & 4 WHEN USING S 2 WIRE JUMPER 3& VAC (Hot) 12:00 RWC Switched 24VAC (Com) COM T2 T T3 T T4 T T5 T PRIORITY 1 24VAC Fuse 2 3.2A/250V Slo-Blo Fuse F1 IN 10A/250V Slo-Blo Fuse F2 OUT 3 T2 T3 T4 T5 PL 120VAC Fuse 4 OFF P P+ S M Z1 Z2 Z3 Z4 Z5 ES/CIRC SYSTEM STATUS X T X T BOILER CONTROL C1 N CIRCULATOR (HOT) L1 N (COM) 120VAC Figure-1 Typical Wiring VL500 Series. DHW Controller DOMESTIC HOT WATER 4-WIRE END SWITCH R W JUMPER 3 & 4 WHEN USING S 2 WIRE JUMPER 3& VAC (Hot) 12:00 RWC Switched 24VAC (Com) COM T2 T T3 T T4 T T5 T PRIORITY 1 24VAC Fuse 2 3.2A/250V Slo-Blo Fuse F1 IN 10A/250V Slo-Blo Fuse F2 OUT 3 T2 T3 T4 T5 PL 120VAC Fuse 4 OFF P P+ S M Z1 Z2 Z3 Z4 Z5 ES/CIRC SYSTEM STATUS X X C1 N L1 N T T BOILER CONTROL (HOT) (COM) CIRCULATOR 120VAC Figure-2 Typical Wiring VL500 Series with Domestic Hot Water Priority Zone, Boiler Controller and Circulator. F Copyright 2008 TAC All Rights Reserved. 3

4 VL500 #2 (Slave) VL500 #1 (Master) NOTE: JUMPER 3&4WHEN USING S NOTE: JUMPER 3&4WHEN USING S DHW CONTROLLER 12:00 4-WIRE 12:00 4-WIRE RWC RWC END SWITCH VAC (COM) END SWITCH JUMPER 3&4 SWITCH 24 VAC (HOT) JUMPER 3&4 COM. COM. T5 T T2 T T3 T T4 T PRIORITY T5 T VAC Fuse 24VAC Fuse T2 T T3 T T4 T PRIORITY 3.2A/250V Slo-Blo Fuse F1 3.2A/250V Slo-Blo Fuse IN OUT A/250V Slo-Blo Fuse IN OUT 1 2 F2 10A/250V Slo-Blo Fuse 120VAC Fuse 120VAC Fuse T2 T3 T4 T5 PL T2 T3 T4 T5 PL C1 N L1 N X X 3 4 C1 N L1 N X X 3 4 ES/CIRC Z1 Z2 Z3 Z4 Z5 SYSTEM STATUS S M OFF P P+ ES/CIRC Z1 Z2 Z3 Z4 Z5 S M OFF P P+ SYSTEM STATUS To zone in additional slave units. CIRC. #2 CIRC. #1 T T BOILER CONTROL Master/Slave switch (COM) (HOT) 120 VAC Figure-3 Two VL500 series with Domestic Hot Water Priority, Nine Heating Zones, Boiler and Circulator Control. 4 Copyright 2008 TAC All Rights Reserved. F

5 INSTALLATION Inspection Precautions Inspect the package for damage. If damaged, notify the appropriate carrier immediately. If undamaged, open the package and inspect the device for obvious damage. Return damaged products. Requirements Tools (not provided) Digital multimeter Screw driver Wire stripper Training: Installer must be a qualified, experienced technician General W A R N I N G Electrical shock hazard! Disconnect power before installation to prevent electrical shock or equipment damage. Make all connections in accordance with the electrical wiring diagram and in accordance with national and local electrical codes. C A U T I O N Avoid locations where excessive moisture, corrosive fumes, explosive vapors, or vibration are present. Avoid electrical noise interference. Do not install near large conductors, electrical machinery, or welding equipment. Mounting Status Indicators Mount the VL500 to a solid vertical surface. Slotted keyholes and standard holes are provided for mounting purposes. Do not mount on a surface that exceeds 104 F (40 C). Avoid high humidity and overhead dripping liquids. - T5-T5 Red LEDs Lit Indicates zone 1 through zone 5 heat demand is present. Z1-Z1 Z5-Z5 Green LEDs Lit Indicates zone 1 through zone 5 valves are powered. ES/CIRC Green LED Lit Indicates end switch has closed and circulator has been powered. PL Yellow LED Lit Priority plus lock out has occurred. Domestic Hot Water zone (DHW) has called for more than 1 hour. Move the priority selection switch momentarily to the off position and reposition the DHW switch to the Priority Plus position to reset the DHW circuit. F Copyright 2008 TAC All Rights Reserved. 5

6 Wiring Requirements Terminal Descriptions (Figures 1, 2 and 3) Line Voltage Terminals: L1, 120 Vac hot. N, 120 Vac neutral input. C1, 120 Vac circulator power. N, 120 Vac Circulator neutral. Dry Contact Terminals: X, Dry contact heat demand. X, Dry contact heat demand. ZoneLink Expansion Domestic Hot Water (DHW) Priority Thermostat Anticipator Setting Low Voltage Terminals: COM, 24 Vac transformer common (for electronic thermostats). R, 24 Vac hot., (left), Zone 1 thermostat, (24V hot or R)., (right), Zone 1 thermostat, (W). 1, Zone valve 24 Vac (common). 2, Zone valve switched 24 Vac (hot). 3, Zone valve end switch (heat demand). 4, Zone valve end switch (24 Vac hot). The VL500 series is shipped from the factory with the master/slave switch in the M (master) position. To link one or more additional VL500 series: 1. Connect the OUT terminals of the master unit to the IN terminals of the slave unit. 2. Place the M/S switch of the master VL500 to the M position. 3. Place the M/S switch of the slave VL500 to the S position. 4. Additional VL500 series can be linked in a similar manner (refer to Figure-3). Move the OFF/PR/P+ switch to one of the following positions. Off no DHW priority. PR (Priority) Unlimited DHW priority. P+ (Priority Plus) 1 hour time limit DHW priority. N O T E Zone 1 must be used for Domestic Hot Water priority or Priority Plus. Refer to thermostat manufacturer s anticipator setting instructions and to the Specifications in this document. 6 Copyright 2008 TAC All Rights Reserved. F

7 CHECKOUT 1. Verify presence of 120 Vac power across L1 and N. 2. Verify presence of 24 Vac power across left side terminal and common C terminal. 3. Verify priority selection and master/slave switch positions. 4. Jumper - terminal. 5. Verify presence of 24 Vac power across zone valve terminals 1 and Jumper end switch terminal pair 3 and Verify contact closure across normally open dry contacts X and X. 8. Verify presence of 120 Vac power across circulator output terminals C1 and N. 9. Repeat steps 4 thru 9 for each zone if necessary. THEORY OF OPERATION The VL500 is a zone valve control relay capable of handling up to five heating zones or one priority Domestic Hot Water (DHW) zone, and four heating zones. See the Specifications in this document for load limitations. The VL500 zone input terminals - thru T5-T5 each receive a pair of thermostat wires. When a call for heat occurs on the zone thermostat, the VL500 supplies 24 V to the zone valves, routing this power on terminals 1 and 2. When the normally closed valve strokes open, the normally open end switch on the valve closes. Closure of the end switch completes a circuit through terminals 3 and 4 of the VL500 zone input terminals. During a call for heat, and once contact closure has occurred across terminals 3 and 4 of the zone, the normally open dry contacts for terminals X-X will go to the closed state. The X-X terminals are wired to the heat source, such as a boiler. Also occurring with any or all zone heat demands, power is routed to a circulator on VL500 terminals C1- N, which provide 120 Vac power to the main loop circulator. MAINTENANCE FIELD REPAIR Regular maintenance of the total system is recommended to assure sustained, optimum performance. The EXP-10 relay cube is replaceable. Replace any damaged or failed units with functional replacements. F Copyright 2008 TAC All Rights Reserved. 7

8 DIMENSIONAL DATA 7/8 (21) 5/16 (8) 5/16 (8) 6-1/2 (165) 3/16 (5) 1-7/8 (48) 2-7/8 (73) 12-3/8 (314) Figure-4 VL500 Series. Copyright 2008, TAC All brand names, trademarks and registered trademarks are the property of their respective owners. Information contained within this document is subject to change without notice. TAC 1354 Clifford Avenue P.O. Box 2940 Loves Park, IL F