Materials Housing plastic: Front display lights: Transformer voltage: Electrical switch rating, ZR/ZC, DHW, XX:

A10333 Z-one Relay Multi-Zone Valve Control Copyright 2014 Caleffi ZVR10X series Function The ZVR series is a multi-zone zone valve and boiler operating control for multiple zone hydronic heating or cooling systems. The ZVR series interfaces with low voltage thermostats, or any other low voltage controllers having a switching action. The ZVR series controls up to 3, 4, 5 or 6 zones, depending on model selected. In addition, a system circulator and secondary is turned on whenever any zone calls for heat. ED indicators provide functional status and easy system troubleshooting. The ZVR series is a perfect match with Caleffi s Z-one motorized zone valves. Compatible with low voltage 2, 3, or 4 wire thermostats R, W, C and TT Comm dual labeling at thermostat terminals Z-oneink unlimited zone expansion Selectable priority with 1 hour time-out feature System status selectable during priority Circulator will start only after the zone valve end switch is closed Dry contacts for DHW (ZR/ZC), capable of switching line voltage arge terminal connections High Capacity 40 VA Transformer standard for 3 and 4 zone models-expandable to 80 VA, and 80 VA for the 6 zone model Automatic resettable fuse Controls system, secondary, and priority Front ED ights 100% Factory tested with 3 year warranty ET Approved Product Range Technical specifications www.caleffi.com Code ZVR103 Z-one Relay switching relays...three zone Code ZVR104 Z-one Relay switching relays...four zone Code ZVR106 Z-one Relay switching relays...six zone Materials Housing plastic: Front display lights: Electrical Knockouts: Performance Power supply: Transformer voltage: Maximum transformer load: Electrical switch rating: Electrical switch rating, ZR/ZC, DHW, XX: Electrical switch rating s: Resettable Fuse: Maximum temperature: Maximum humidity: Approvals: ABS CD (12) 1/2" size 120 VAC, 50/60 Hz 24 VAC 40 VA (ZVR103/4), 80 VA (ZVR106) 20A Max Combined 120 VAC, 2A each 120 VAC, 5A each automatic 110 F (43 C) 90% non-condensing Certified to CSA C22-2 o.24 Conforms to U Standard 873

Conforms 4009064 to U 873 Milwaukee, WI 53208 USA T-STAT CA ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 VAVE OPE Dimensions POWER ZVR106 Six zone switching - Input: 120VAC 50/60Hz 20A MAX CAUTIO: RISK OF EECTRIC SHOCK - DISCOECT A IPUT POWER PRIOR TO SERVICIG A B C C Code Zones A B C Wgt. (lbs) ZVR103 3 9 1/4" 11" 3" 3.2 ZVR104 4 9 1/4" 11" 3" 3.2 ZVR106 6 9 1/4" 11" 3" 3.2 SAFETY ISTRUCTIO This safety alert symbol will be used in this manual to draw attention to safety related instructions. When used, the safety alert symbol means ATTETIO! BECOME AERT! YOUR SAFETY IS IVOVED! FAIURE TO FOOW THESE ISTRUCTIOS MAY RESUT I A SAFETY HAZARD. CAUTIO: 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. CAUTIO: 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. WARIG: 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.

Installation Inspection 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. 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 Maintenance and Repair The Caleffi Z-one multi-zone valve control comes with a resettable fuse and requires no maintenance. 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. Use body for stabilizing relay box. Insert screwdriver and push tab inward, cover should release from base. Roll cover off base.

Transformer Installation Mount box on stable surface using level. Remove transformer(s) from packaging. Slide bottom end of transformer into bottom latch. Snap top of transformer into latch arms. Feed wiring through hole near the top of the transformer and insert transformer plug into the socket. Repeat process for 2nd transformer if six valve relay box.

The jumpers on the ZVR series can be positioned for the following operations. Priority O / Priority OFF: When priority jumper is O, upon demand, zone 1 will operate as priority and all other zones are O OFF C R temporarily W Cswitched R off W(with 1 Chour Rtime-out). W When C priority R W C STATUS D P OM T mode T is COM OFF, any T zones T that COM were active T when T COM zone 1 was T T COMDURIG COMMS switched on will remain on. 2 T-STAT Status During 3 Priority T-STAT O / Status 4 During T-STAT Priority OFF: 5 When T-STAT 6 P status jumper is O, the system will continue to operate O OFF R W during C priority. R W C R W C R W C R W C D P T T Master COM / Slave: T allows T COM for unlimited T expansion T COM to Tadditional T ZVR COM T T COM relays. MASTER SAVE COMMS T-STAT 2 Jumper set up T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 Wiring terminals MASTER SAVE ATUS RIG IORITY OFF TEM MP X X DHW R W C ZR/ZC T T COM ZVR106 6 Zone T-STAT 1 R W C T T COM T-STAT 2 R W C T T COM T-STAT 3 R W C T T COM T-STAT 4 When a zone has a demand from a thermostat (T T or R W) the control will send 24 VAC to the corresponding zone valve. When the zone valve end switch closes, the primary will switch on and the (X X) dry contacts will close to signal the boiler of a heating demand. Zone 1 can be used for priority (either a priority or valve). When the priority jumper is O, a demand from T-Stat1 will activate 24VAC to valve 1 and the priority will switch on after the end switch closes (requires a jumper in the end switch terminals if a valve is not used). The DHW (ZR/ZC) dry contact will also close. Depending upon "Status During Priority" jumper, the system will O OFF either be O or OFF. ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR S arge screw terminals connections makes wiring easy with three screw terminal connections. Pump terminals connection have 120 VAC outputs for simplified connections. Zone valve connections can be 2, 3 or 4 wire. C COM 3 Z-oneink unlimited expansion allows adding addition ZVR series relay controls to a Master ZVR. Communication is accomplished by connecting three wires (bell or thermostat wire) to the communication terminals located in the upper R right Whand corner. C RThe jumper W is Cpositioned R to Master W C/ Slave T position. T COM A demand Tfor heat T from COM any zone T will Tfire the COM boiler and start the. T-STAT 4 T-STAT 5 T-STAT 6 D P COMMS PWR ZOE

VET Example Wiring Diagram Please reference Z-one Relay wiring guide for complete listing of wiring diagrams. ModCon boiler with Primary/Secondary mod/con! boiler ZV1 ZV2 ZV3 ZV4 ZV5 ZV6! SECODARY! X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 ZVR106 6 Zone MASTER SAVE TSAT2 ZOE2 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH SECODARY!! ZV1 ZV2 ZV3 ZV4 ZV5 ZV6

VET oncondensing boiler with outdoor reset and indirect DHW SYSTEM! ZV2 ZV3 ZV4 ZV5 ZV6 ZV1 DHW! aquastat low flow resistance boiler indirect DHW tank DHW! aquastat space heating thermostats space heating demand domestic water heating demand G boiler! reset! controller outdoor! temperature! sensor ZC ZR T T DHW R W C R W C R W C R W C R W C R W C D P X X PWR ZR/ZC T T COM T T COM T T COM T T COM T T COM T T COM COMMS THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 Master/Slave THM1 ZOE1 ZRV106 6 Zone Z6V set to O STATUS DURIG POWER I SEC SYSTEM ZOE 1 ZOE 2 MOTOR SWITCH MOTOR SWITCH THM2 ZOE2 THM3 ZOE3 THM4 ZOE4 THM5 ZOE5 THM6 ZOE6 ZOE 3 ZOE 4 ZOE 5 ZOE 6 MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH G SYSTEM! ZV1 ZV2 ZV3 ZV4 ZV5 ZV6

O OFF O OFF MASTER SAVE O OFF O OFF MASTER SAVE Modern boiler with Primary/Secondary and two secondary s "A"! "B"! A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 SYSTEM! X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 TSAT1 ZOE1 TSAT2 ZOE2 TSAT2 ZOE2 ZVR106 6 Zone TSAT3 ZOE3 TSAT4 ZOE4 ZVR106 6 Zone TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG TSAT5 ZOE5 TSAT6 ZOE6 STATUS DURIG TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH "B"! SYSTEM! "A"! A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 CAEFFI Caleffi orth America, Inc. 3883 West Milwaukee Road Milwaukee, WI 53208 T: 414.238.2360 F: 414.238.2366

WIRIG GUIDE The ZSR101 is a versatile single relay control with two outputs for operating a 120 VAC 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 operation, and 10 amp total load rating. The ZSR Series of controls is for zoning using s. Up to 6 zone s (model dependent) along with a primary can be operated. Zone priority is selectable with 1-hour time-out feature. Other features include exercising, selectable post purge, and 3 ground terminals for simplified wiring. The ZVR Series of controls is for zoning using zone valves. Up to 6 valves (model dependent), along with a system, secondary (s), and primary can be operated. Zone priority is selectable with 1-hour time-out feature. System status (on\off) during priority is also selectable. Replaceable snap-fit 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. 4009064 Certified to CSA C22-2 o.24 Conforms to U Standard 873 Form 031914 rev.1

IDEX Z-one Relay thermostat connections Thermostat wiring... 3 ZSR101 - single zone relay Product overview... 4 Operation and cover removal...5 A1 - Single thermostat...6 A2 - Multiple thermostats...8 A3 - Single master thermostat, with TRVs, variable speed... 10 ZSR103, ZSR104 & ZSR106 - multi-zone relay Product overview... 12 Circuit board... 13 Cover removal... 14 Product details... 15 B1 - Mod/Con boiler, hydro separator or buffer tank, zone s... 16 B2 - Traditional boiler, indirect DHW w/ priority, zone s... 18 B3 - Mod/Con boiler, primary loop, closely spaced tees, zone s... 20 ZVR103, ZVR104 & ZVR106 - multi-zone valve control Product overview... 22 Circuit board... 23 Cover removal, Transformer Installation...24 Product details... 25 C1 - Mod/Con boiler, hydro separator, zone valves... 26 C2 - Mod/Con boiler, indirect DHW on primary side of hydro sep, zone valves... 28 C3 - Mod/Con boiler, indirect DHW on load side of hydro sep, zone valves... 30 C4 - Mod/Con boiler, indirect DHW on primary side of hydro sep, master and slave control... 32 C5 - Traditional boiler, indirect DHW (no priority) with valve... 34 C6 - Traditional boiler with reset control, priority indirect DHW with valve... 36 C7 - Mod/Con boiler, hydro separator, zone valve (more than 6), multiple secondary s... 38 Caleffi shall not be liable for damages resulting from misapplication or misuse of it products. 3

Z-one Thermostat Connections 2-Wire Thermostats 4-Wire Thermostats 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 T-stat interface R W C T T COM T-STAT 1 R W C T T COM T-STAT 2 R W C T T COM T-STAT 3 R W T T C T-STAT 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. 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. C R Rh W1 DHW R W C R W C R W C R W C R W C R W C D P X X ZR/ZC T T COM T T COM T T COM T T COM T T COM T T COM COMMS W C R W C R W C R W C R W CTHM 1 D THM P 2 THM 3 THM 4 THM 5 THM 6 T COM T T COM T T COM T T COM T T COM COMMS THM 2 THM 3 THM 4 THM 5 THM 6 3-Wire Thermostats TRASFORMER Three wire thermostats 12/20VA 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. POWER I GROUDS 1 6 Zone Z6P 2 Dry Contacts DipSwitches PWR ZOE1 ZOE2 Master Slave A heat demand Priority OFF can Priority O also be initiated by any type Primary OFF Primary O Exercise OFF Exercise O of device that Post Purge OFF has Post dry Purge Ocontacts (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 PRIMARY a dry 3 contact 4 to connect 5 6 R to W will initiate a heat demand. ZOE3 ZOE4 ZOE5 ZOE6 WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply SAFETY ISTRUCTIO This safety alert symbol will be used in this manual to draw attention to safety related instructions. When used, the safety alert symbol means ATTETIO! BECOME AERT! YOUR SAFETY IS IVOVED! FAIURE TO FOOW THESE ISTRUCTIOS MAY RESUT I A SAFETY HAZARD. CAUTIO: 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. DHW R W C W C R W C R W C R W C R W C D P ZR/ZC T T COM T COM T T COM T T COM T T COM T T COM COMMS THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 4 Master Priority OFF Primary OFF Exercise OFF Post Purge OFF DipSwitches 5 X X Slave Priority O Primary O Exercise O Post Purge O POWER I 6 R W C R W C R W C R W C R W C D P T PWR T COM T T COM T T COM T T COM T T COM COMMS THM 2 THM 3 THM 4 THM 5 THM 6 ZOE1 Always refer to the thermostat manufacturer s instructions. ZOE2 DipSwitches Master Slave TRASFORMER ZOE3 6 Zone Priority OFF Priority O Primary OFF Primary O 12/20VA CAUTIO: Electrical shock hazard. Disconnect Exercise OFF power Exercise before O installation to prevent Post Purge OFF Post Purge O electrical shock or ZOE4 equipment Z6P damage. Make sure all connections are in accordance with the electrical wiring diagram and in accordance with national and local electrical codes. ZOE5 ZOE6 CAUTIO: Avoid electrical noise interference. Do not install near PRIMARY large conductors, GROUDS 1 2 3 4 5 6 electrical machinery, or welding equipment. Avoid locations where excessive moisture, corrosive fumes, vibration, or explosive vapors are present. P ZO ZO ZO ZO ZO ZO Caleffi shall not be liable for damages resulting from misapplication or misuse of it products.

Wiring of 2 wire or 3 zone valve to Caleffi Z-one Relay Wiring a 2 wire zone valve to Caleffi Z-one Relay Since a two wire actuator does not have an end switch for feedback to the relay box, the end switch terminals must have a jumper to simulate the end swith. If the end switch jumper is not installed, no demand will be sent to the boiler and the s will not turn on. Wiring a 3 wire zone valve to Caleffi Z-one Relay The Taco 570 zone valve presents a unique wiring challenge. 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. astly, 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. 6 Zone TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 MOTOR SWITCH ZOE 2 MOTOR SWITCH ZOE 3 MOTOR SWITCH ZOE 4 MOTOR SWITCH ZOE 5 MOTOR SWITCH ZOE 6 MOTOR SWITCH M 1 2 3 5

6 4009064 Certified to CSA C22-2 o.24 Conforms to U Standard 873 ZSR101 - Single Zone Switching Relay 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 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 Simplified wiring with pre-installed jumper 100% factory tested with 3 year warranty ET certified See technical brochure 01284-14 A for more product information.

Operating Principles When a zone has a demand from a thermostat (TT or R W) the relay will close sending 120 VAC to Relay #1 O terminal R and switching the on, and the C to O dry contact on relay #2 closes, signaling the boiler of a heating demand. W C T T COM 6 VA Transformer. Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Replaceable fuses. 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 and 120 VAC neutral to. A factory installed jumper from terminal to the C terminal of Relay 1 is supplied for simplified connection. POWER I REAY #1 REAY #2 C O C C O C 120VAC input power connection If dry contacts are desired from relay #1, remove the factory installed jumper between 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 pushin tab inward on opposite side, cover should release from base. Keyhole mounting which fits a 4X4 junction box. Pre-installed jumper. Slide cover off base. Rear knockout for 4X4 junction box. 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. 7

A1 - Single thermostat 8 R W C T T com power zone transformer Caleffi! single zone relay REAY 1 REAY 2 C /O /C C /O /C T T Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

A2 - Multiple thermostats 10 End switch wires transformer R W C T T com power zone Caleffi! single zone relay R W 4-wire zone valve 4-wire zone valve R W R W 4-wire zone valve REAY 1 REAY 2 C /O /C C /O /C 24 VAC T T Hydronic diagram is for illustration purposes only and could be missing system components.

A3 - Single master thermostat, panel radiators with TRVs, variable speed 12 TRV TRV thermostatic! radiator valves! (TRV) on each! radiator TRV TRV TRV TRV buffer tank R W C T T com power transformer zone Caleffi! single zone relay REAY 1 REAY 2 C /O/C C /O/C T T Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

Description of terminals C O C = Ground = eutral (Common leg of 120 VAC) = ine (live leg of 120 VAC) = Common terminal = ormally Open terminal = ormally Closed terminal ote: There is a factory installed jumper between the 120 VAC line () and the common terminal of relay #1 (C). Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings A single master thermostat is wired to the ZSR101 control. The master thermostat is set to a slightly higher set point than the desired room temperatures on the thermostatic radiator valves. When the temperature drops below the thermostat s set point, a heat demand is initiated by closing the R & W terminals. Relay #1 and relay #2 both fire. If the factory installed jumper has not been removed, the O terminal of relay #1 will deliver 120 VAC line to the variable speed circulator. Relay #2 closes the TT contacts on the boiler signaling a demand. The Zone ED illuminates. Using an outside air sensor and system temperature sensor located in the buffer tank, the boiler determines if the water in the boiler meets the target temperature based off the outside air reset curve. As long as the master thermostat is calling, the boiler will maintain the buffer tank to the target temperature. The thermostatic radiator valves modulate the flow through the panel radiators because the variable speed circulator is enabled. When the master thermostat reaches set point, the master thermostat will open the contact between R & W. The relay contacts return to their normal position turning off power to the variable speed circulator and opening the RW (TT) contacts. Both the boiler and are no longer enabled. The Zone ED turns off. 13

14 4009064 Certified to CSA C22-2 o.24 Conforms to U Standard 873 ZSR10X - Multi-Zone Pump Control Overview Compatible with low voltage 2, 3, or 4 wire thermostats R, W, C and TT Comm dual labeling at thermostat terminals Z-oneink unlimited zone expansion 120 VAC outputs Selectable priority with 1 hour time-out feature Selectable post purge and exercise Dry contacts for DHW (ZR/ZC), capable of switching line voltage High capacity transformer arge terminal connections Simplified wiring with extra ground terminals Heavy duty sealed relays Fuse protected (with spare fuse) Front ED lights 100% Factory tested with 3 year warranty ET approved See technical brochure 01286-14 A for more product information.

XX Closes for heat demand and DHW demand. Rated for 120 VAC, 2 amps. DHW (ZR/ZC) closes only during priority call. Rated for 120 VAC, 2 amps. Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Selectable DIP switches. 3 wire communications to expansion board. Power O ED. ED for each zone. 120 VAC input power connection Multiple ground connections for easy wiring. Replaceable fuses (2 extra included under cover). 120 VAC zone outputs. 120 VAC primary output. 15

Cover removal 16 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, cover should release from base. Roll 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.

X Maintenance and Repair: The Caleffi Z-one multi-zone control The DIP Switches on the ZSR series ZR/ZC T T COM T T COM T T COM T T COM T T COM T T COM COMMS comes with two spare fuses. If control fails or is damaged, replace control with can be positioned for the following DipSwitches functional one. T-STAT 1 T-STAT operations. 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 Master Slave Master / Slave: allows 6 Zone Priority OFF Priority O TRASFORMER for unlimited Primary R OFF Primary O W C R W C R W Exercise OFF Exercise O expansion to additional relays. Post Purge T OFFT COMPost Purge T OT COM T T Boiler connections: Priority OFF / Priority ZSR106 O: When XX = Dry contacts rated up to 120 VAC, 2 Amps. T-STAT 4 T-STAT 5 T-ST priority mode is O, upon demand, Closes when any zone calls including priority. Typically DHW zone 1 will operate as priority and DipSwitches all other zones are temporarily switched off connected to TT on boiler control. X X ZR/ZC (with 1 hour time-out). When priority Master mode Slave is OFF, all zones remain active. 6 Zone Priority OFF Priority O DHW (ZR/ZC) = Dry contacts rated up TRASFORMER Primary OFF Primary O to 120 VAC, 2 Primary OFF / Primary O: When primary Exercise OFF Exercise mode O is O, the primary will Post Purge OFF Post Purge O Amps. Closes only when priority is enabled and calling. continue to operate during priority. DHW R W C R W C R W C R W C R W C R W C D P Typically used to close ZR\ZC (120 VAC) or DHW contacts (24 VAC) on boiler Exercise ZSR106 OFF / Exercise O: When exercise mode is DipSwitches PWR O, each circulator is ZR/ZC T T COM T T COM T T COM T T COM T T COM T T COM COMMS Master Slave controls equipped with these features. switched on for 30 seconds following 72 hours of inactivity. Priority OFF Priority O P T-STAT 1 T-STAT 2 T-STAT 3 T-STAT TRASFORMER 4 T-STAT 5 T-STAT 6 Primary OFF Primary O POWER I GROUDS Post Purge 1 OFF / Post 2 Purge O: 3 When post 4purge is O, 5Exercise the OFF priority 6 Exercise O Post Purge OFF Post Purge O Communication connections: continues operating for 2 minutes ZSR106 after the priority zone ZOE1 is switched off. Connect terminals to matching terminal of slave boards D to D, P to P, Ground to Ground Primary output: ZOE2 6 Zone ZSR106 TRASFORMER Input Power: = ine (hot leg) of 120 VAC supply = eutral of 120 VAC = Ground ote: when connecting 2 or more Z-one controls, all controls must be powered by the same 120 VAC circuit. POWER I X X POWER I DHW GROUDS D P COMMS POWER I Primary runs when any zone runs. Its status DipSwitches 2 3 4 5 6 during priority (on\off) can be programmed using the DIP Master Slave switches. ZOE3 Priority O Primary O = Exercise ine O (hot leg) of 120 VAC to power the Post Purge O GROUDS = eutral leg of 120 VAC to power the ZOE4 Priority OFF Primary OFF Exercise OFF Post Purge OFF Zone outputs: Zone s GROUDS run when 1 2 3 4 corresponding thermostat initiates a demand. GROUD = Connect the ground from the to the ground terminal. = Runs when zone #1 calls. Can be programmed to be the priority zone. = ine (hot leg) of 120 VAC to power the = eutral leg of 120 VAC to power the R W C R W 1 C 5 R W C R W C R W 3 4 ZOE5 ZOE6 5 WARIG: When PRIMARY connecting 2 or more Z-one controls, all controls must be powered by the same 6 120 VAC circuit. C R W C D PRIMARY WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply. WARIG: When replacing fuses, make sure power is disconnected to control box. P 6 17

B1 - Mod/con boiler, hydro separator or buffer tank, zone s 18 Pump 1 Pump 2 Pump 3 Pump 4 Buffer tank- Optional hydraulic separator X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR ZOE1 ZOE2 TRASFORMER 6 Zone ZSR106 DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O ZOE3 ZOE4 ZOE5 ZOE6 POWER I GROUDS 1 2 3 4 5 6 PRIMARY Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

B2 - Traditional boiler, indirect DHW w/ priority, zone s 20 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6 boiler! high limit! control Pump 1 DHW! aquastat DHW! aquastat X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS THM 1 THM 2 THM 3 THM 4 THM 5 THM 6 PWR ZOE1 ZOE2 ZC ZR T T TRASFORMER 12/20VA 6 Zone ZSR106 Z6P DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O ZOE3 ZOE4 ZOE5 ZOE6 outdoor! temperature! sensor POWER I GROUDS 1 2 3 4 5 6 PRIMARY Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

Description of terminals = Ground = eutral (Common leg of 120 VAC) = ine (Hot leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. DHW (ZR/ZC) = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or DHW contacts (24 VAC) on boiler controls equipped with these features. Dip switch description Master / Slave: Used when joining 2 or more controls together. Only one Master per group Priority OFF / Priority O: Used to set Zone #1 as the priority zone. All other zones will hold off during priority. Priority has a one hour time out feature to prevent freeze up. Primary OFF / Primary O: Sets the status of the primary when there is a priority call. This allows the DHW to be on either side of a hydro separator. Exercise OFF / Exercise O: When enabled the s will rub for 30 seconds after 72 hours without a demand. Post Purge OFF / Post Purge O: Allows the DHW to run for 2 minutes after the DHW demand has been satisfied. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Priority switch: O (Zone #1 becomes priority) Master/Slave switch: Master Primary Status During Priority switch: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6. The O ED illuminates for that zone. ZSR control sends 120 VAC to the corresponding zone terminals to fire the zone and closes the XX contacts to signal a heat demand to the boiler. The PRIMARY output will also deliver 120 VAC even if no is connected. When the demand from the T-stat is satisfied (T-stat opens TT terminals), the O ED turns off. 120 VAC is dropped from the corresponding zone terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the DHW aquastat (zone #1), The O ED illuminates for Zone #1. If any other zone was calling (Zones 2 thru 6) when Zone #1 called, power (120 VAC) is dropped to those zone s. The XX and DHW contacts close. The contacts deliver 120 VAC Once the Zone #1 DHW demand is satisfied, power to the is dropped, the DHW contacts open. If a demand from zones 2 thru 6 is present, 120 VAC is delivered to the corresponding zone (s) and the O ED for those zones will illuminate. The XX contacts close to signal a heat demand to the boiler. When all zones are satisfied, the XX contacts open and power (120 VAC) is turned off to all of the zone s. DHW Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the DHW contacts and turn off power to the DHW. If a heating demand is present from Zones #2-6, the control will satisfy those demands before going back to the DHW call. After the heating demands are met, the control will go back to DHW and re-set the one hour timer. 21

B3 - Mod/Con boiler, primary loop, closely spaced tees, zone s 22 Pump 1 Pump 2 Pump 3 boiler Primary X X DHW ZR/ZC R W C T T COM T-STAT 1 R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR ZOE1 ZOE2 TRASFORMER 36 Zone ZSR106 3 DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O Exercise OFF Exercise O Post Purge OFF Post Purge O ZOE3 ZOE4 ZOE5 ZOE6 POWER I GROUDS 1 2 3 4 5 6 PRIMARY Primary boiler Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

24 4009064 Certified to CSA C22-2 o.24 Conforms to U Standard 873 ZVR10X - Multi-Zone Valve Control Overview Compatible with low voltage 2, 3, or 4 wire thermostats R, W, C and TT Comm dual labeling at thermostat terminals Z-oneink unlimited zone expansion Selectable priority with 1 hour time-out feature System status selectable during priority Pump will start only after the zone valve end switch is closed Dry contacts for DHW (ZR/ZC), capable of switching line voltage arge terminal connections High capacity 40 VA transformer standard for 3 and 4 zone models-expandable to 80 VA, and 80 VA for the 6 zone model Automatic resettable fuse Controls system, secondary, and priority Front ED ights 100% Factory tested with 3 year warranty ET approved See technical brochure 01285-14 A for more product information.

XX Closes for heat demand and DHW demand. Rated for 120 VAC 2 amps. DHW (ZR/ZC) closes only during priority call. Rated for 120 VAC, 2 amps. Dual labeled T-stat terminals. Compatible with 2, 3 and 4 wire T-stats. Master/Slave jumper. 3 wire communications to expansion board. Power O ED. Transformer connections. ED illuminates when end switch closes. 120 VAC input power connection. 120 VAC output to s. System (boiler ) status during priority can be changed with jumper. ZOE #1 priority. Zone valve motor connections. Zone valve end switch connection. ED illuminates with call for heat. 25

Cover removal 26 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, cover should release from base. Roll cover off base. Transformer Installation Mount box on stable surface using level. Remove transformer(s) from packaging. Slide bottom end of transformer into bottom latch. Snap top of transformer into latch arms. 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. Feed wiring through hole near the top of the transformer and insert transformer plug into the socket. Repeat process for 2nd transformer if using six valve relay box.

T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 T Maintenance and Repair: The Caleffi Z-one multi-zone valve relay comes with a resettable fuse and requires no maintenance. If control fails or is damaged, replace control with functional one. The ZVR series of controls is programmed by positioning a series of jumpers. Example photo to right shows jumper in off position (left photo) and on position (right photo). Jumpers are used for the following operations. Y Priority O / Priority OFF: When priority jumper is O, upon demand, zone 1 will POWER I operate as priority and all other zones are O OFF temporarily switched off (with 1 hour timeout). When priority mode is OFF, any zones STATUS that were active when zone 1 was switched W C R W C R W C R W C DURIG on will remain on. TStatus COMDuring T Priority T COMO / TStatus T During COM T T COM Priority OFF: T-STAT When 4status T-STAT jumper is 5O, T-STAT 6 O OFF the system will continue to operate during priority. Master / Slave: allows for unlimited expansion to additional ZVR relays. MASTER SAVE -STAT 3 SEC Boiler Connections XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. DHW (ZR/ZC) = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or DHW contacts (24 VAC) on boiler controls equipped with these features. Communication connections Connect terminals to matching terminal of W slave C boards R W C R W C R W C D P T D COM to D, T P to T P, COM Ground T to T Ground COM T T COM COMMS -STAT Use 3 18 T-STAT gauge 4 thermostat T-STAT 5 wire. T-STAT Wire 6 should be shielded if located in close proximity to high voltage wiring. Thermostat connections T R = 24 VAC. DHW R W C R W C R W C R W C R X X W = Heat call ZR/ZC T T COM T T COM T T COM T T COM TT ZVR106 C = Common of 24 VAC R W C R W C T-STAT R W 1 T-STAT 2 T-STAT 3 T-STAT 4 T 6 Zone Heat demand is initiated by closing R T T COM T T COM T T T to W. T-STAT 1 T-STAT 2 T-STA STATUS 24 VAC is always present between R DURIG & C. T DHW R W C R W C R W C R W C R W C ZR/ZC T T COM T T COM T T COM T T COM T T COM Dip O OFF Mas T-STAT 1 T-STAT 2 T-STAT 36 T-STAT Zone4 T-STAT Priority 5 T O Zone valve O OFF TRASFORMER connections Primary O Exercise O Motor = 24 VAC to power the zone Post Purge O SYSTEM ZOE 1 ZOE 2 ZOE valve 3 motorzoe ZSR106 4 ZOE 5 ZOE MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH End Switch MOTOR= Connects SWITCH MOTOR to end SWITCH switch MOTOR S on zone valve. Must be jumpered if using a 2 wire zone valve. D P ZVR106 COMMS Input power P = ine 6 (hot Zone leg) of 120 VAC supply POWER I GROUDS 1 2 3 4 P = eutral of 120 VAC = Ground X X POWER I PWR ZOE1 STATUS DURIG O OFF MASTER Pump outputs O OFF SYSTEM = Runs when any SEC SYSTEM zone ZOE calls 1 for heat. ZOEWhen 2 priority ZOEis 3 enabled, the status of the (on\ MOTOR SWITCH MOTOR SWITCH MOTOR off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a for DHW. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply. WARIG: When connecting 2 or more Z-one controls, all controls must be powered by the same 120 VAC circuit. SAVE SWITCH M Zone DipSwitches Master Slave Priority OFF Priority O Primary OFF Primary O ZOE2 ZOE3 27

C1 - Mod/Con boiler, hydro separator, zone valves 28 mod/con! boiler ZV1 ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM! SECODARY! X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 ZVR106 6 Zone MASTER SAVE TSAT2 ZOE2 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 MOTOR SWITCH ZOE 2 MOTOR SWITCH ZOE 3 MOTOR SWITCH ZOE 4 MOTOR SWITCH ZOE 5 MOTOR SWITCH ZOE 6 MOTOR SWITCH Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

C2 - Mod/Con boiler, priority indirect DHW on primary side of hydro sep, zone valves 30 mod/con! boiler ZV2 ZV3 ZV4 ZV5 ZV6 DHW! aquastat! SYSTEM! SECODARY! DHW! AQUASTAT X X DHW ZR/ZC R W C R W C R W C R W C R W C R W C D P T T COM T T COM T T COM T T COM T T COM T T COM COMMS T-STAT 1 T-STAT 2 T-STAT 3 T-STAT 4 T-STAT 5 T-STAT 6 PWR TSAT1 ZOE1 ZVR106 6 Zone MASTER SAVE TSAT2 ZOE2 TSAT3 ZOE3 TSAT4 ZOE4 STATUS DURIG O OFF O OFF TSAT5 ZOE5 TSAT6 ZOE6 POWER I SEC SYSTEM ZOE 1 ZOE 2 ZOE 3 ZOE 4 ZOE 5 ZOE 6 MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH MOTOR SWITCH Buffer tank- Optional hydraulic separator! SECODARY! ZV2 ZV3 ZV4 ZV5 ZV6 SYSTEM! Hydronic diagram is for illustration purposes only, some components have been removed for simplicity.

Description of terminals = Ground = eutral (common leg of 120 VAC) = ine (live leg of 120 VAC) Thermostat terminals R = 24 VAC W = Heat call C = Common of 24 VAC Boiler terminals XX = Dry contacts rated up to 120 VAC, 2 Amps. Closes when any zone calls including priority. Typically connected to TT on boiler control. DHW (ZR/ZC) = Dry contacts rated up to 120 VAC, 2 Amps. Closes only when priority is enabled and calling. Typically used to close ZR\ZC (120 VAC) or DHW contacts (24 VAC) on boiler controls equipped with these features. Pump terminals SYSTEM = Runs when any zone calls for heat. When priority is enabled, the status of the (on\off) during a priority call is selected via a jumper SEC = Runs when any zone calls for heat except the priority zone when it is enabled. = Runs when the priority zone calls. A jumper is required between the SWITCH terminals when using a. Valve terminals Motor = 24 VAC to power the zone valve motor End Switch = Connects to end switch on zone valve. Must be jumpered if using a 2 wire zone valve. WARIG: EVER COECT R & C DIRECTY, this will be a direct short on the 24 VAC supply Sequence of Operation / Settings Priority Jumper: O (Zone #1 becomes priority) Master/Slave Jumper: Master Status During Priority: OFF A demand occurs from a T-stat (T-stat closes TT terminals) in zones 2 thru 6. The T-STAT CA ED illuminates for that zone. ZVR control sends 24 VAC to the corresponding zone MOTOR terminals to open the zone valve. When the end switch on the zone valve closes, the control sends 120 VAC to SEC and SYSTEM. The VAVE OPE ED illuminates for that zone and the XX contacts close to signal a heat demand to the boiler. When the demand from the T-stat is satisfied (T-stat opens TT terminals), both the T-STAT CA and VAVE OPE ED s turn off. 24 VAC is dropped from the corresponding zone MOTOR terminals. If no other zones are calling, power is dropped to the SEC and SYSTEM and the XX contacts are opened. If a demand occurs from the DHW aquastat (zone #1), The T-STAT CA ED illuminates for Zone #1 and the VAVE OPE ED will illuminate. (When using a DHW, a jumper must be installed on Zone #1 end switch terminals.) If any other zone was calling (Zones 2 thru 6) when Zone #1 called, power (24 VAC) is dropped to those zones. The XX and DHW contacts close. The contacts deliver 120 VAC The SEC and SYSTEM are off. Once the Zone #1 DHW demand is satisfied, power to the is dropped, the DHW contacts open. If a demand from zones 2 thru 6 is present, 24 VAC is delivered to the corresponding zone valve(s) and the T-STAT CA ED s illuminate. When the zone valve end switch closes, the VAVE OPE ED illuminates, the XX contacts close, the SEC and SYSTEM terminals deliver 120 VAC. DHW Time Out \ Freeze Prevention Feature After one hour of a priority demand, the control will open the DHW contacts and turn off power to the DHW and Zone Valve #1. If a heating demand is present from Zones #2-6, the control will satisfy those demands before going back to the DHW call. After the heating demands are met, the control will go back to DHW and re-set the one hour timer. 31