Taco Comfort Solutions ZVC406-5 Zone Valve Control Instructions

Taco Comfort Solutions ZVC406-5 Zone Valve Control

For information on Taco’s Zone Valve Controls (ZVC’s) including catalog sheet, instruction sheets, Visio stencils and our highly praised Zone Controls Wiring Guide, scan the QR code to the left or go to our website:
www.TacoComfort.com

Overview:

The ZVC406-5 is a six zone valve control that can have up to 6 thermostats connected and will operate up to 6 zone valves, plus 3 auxiliary outputs (AUX) to control circulators; like boiler and primary loops.
The ZVC406-5 has a priority zone option, allowing zone 1 to operate and deactivate zones 2 through 6 during a priority call; this is ideal for when using an indirect water heater.
The ZVC406-5 includes timing options for Post Purge, Pump Exercise and Priority Protection. The ZVC406-5 includes an energy-saving program that can adjust the temperature of a modulating-condensing boiler or conventual On/Off boiler to increase the comfort level and use less fuel, without the need to install an outdoor sensor

Warnings & Safety Information

FCC Regulatory Statements
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.
2.  This device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the Federal Communication Commission (FCC) rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment causes harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by doing one or more of the following measures:

• Reorient or relocate the receiving antenna.
•  Increase the separation between the equipment and receiver.
•  Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
•  Consult the dealer or an experienced radio/TV technician for help.

NOTE: THE GRANTEE IS NOT RESPONSIBLE FOR ANY CHANGES OR MODIFICATIONS NOT EXPRESSLY APPROVED BY THE PARTY RESPONSIBLE FOR COMPLIANCE. SUCH MODIFICATIONS COULD VOID THE USER’S AUTHORITY TO OPERATE THE EQUIPMENT.

RF Exposure Warning
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. In order to avoid the possibility of exceeding the FCC radio frequency exposure limits, human proximity to the antenna shall not be less than 20 cm during normal operation and must not be co-located or operating in conjunction with any other antenna or transmitter.
ISED Regulatory StatementsThis device complies with ISED Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

RF Exposure Information
This equipment complies with ISED RSS-102 radiation exposure limits set forth for an uncontrolled environment. This transmitter must be installed to provide a separation distance of at least 20 cm from all persons and must not be co- located or operating in conjunction with any other antenna or transmitter.

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. Based on the current draw; 12-18 gauge wire is recommended for 120 VAC connections, 14-22 gauge wire for thermostat connections, and 14-22 gauge wire for 24 VAC source connections.

Location & Installation

Planning:

Included in Package:

• ZVC406-5 zone valve control: 6 zone Instruction sheet
• 2 Spare fuses attached to inner cover: Strap-on temperature sensor

Tools & Material Needed:

• Small straight blade screwdriver: Screws or hardware for mounting
• Phillips screwdriver:Electrical connectors for field wiring
• Torpedo level: Low and live voltage wiring (per code)  Wire strippers

Location: Do not mount to a surface that exceeds 104°F (40°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. The product is not suitable for installation in hazardous locations.

Installation

1.  Hang the panel on a wall with one mounting screw.
2.  Level the panel.
3. Install other 3 mounting screws.
   

 Operation & Dip Switch Settings

General Operation: 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 boiler end switch relay and AUX circulator relay(s).

Expansion Connections: Set dip switch (#1) to MASTER on the switching relay that is designated as the priority zone control. Set all other daisy- chained zone controls to EXPANSION. Using thermostat wire (18-22 gauge) connect between terminals 1, 2, 3 on the master control to the corresponding 1, 2, 3 on the expansion zone control(s). Zone controls may be daisy-chained up to 20 Taco zoning panels using any combination of SR and ZVC controls (120 zones if all are 6 zone panels).

Priority Operation: When the priority dip switch (#2) is set to ON and the priority zone (zone 1) is actuated, all other zones will stop operation until priority zone is satisfied. When not switched to priority, all zones will operate independently. More adjustments are available when using the Taco eLink mobile app.

Priority Protection Operation: If the priority zone calls continuously for more than one hour, power is returned to all the other zones, allowing each zone to function independently. 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.

Primary Pump Operation: When the dip switch (#3) is set to OFF, the AUX 2 circulating pump output will energize when any zone calls for heat, except the priority zone. When the dip switch is set to ON, the AUX 2 circulating pump output will energize when any zone calls for heat.

Post Purge Operation: When the dip switch (#4) is set to ON, the priority zone output will stay energized for 2 minutes after its thermostat or aquastat is satisfied, but not operate the boiler. More adjustments are available when using the Taco eLink mobile app.

Pump Exercise Operation: When the dip switch (#5) is set to ON, the solid-state timer cycles all the zone valves a nd circulating pump outputs that are attached to the Zone Valve Control t o run for 30 seconds every 2 weeks. More adjustments are available when using the Taco eLink mobile app.

Time Delay for Zone Valves without End Switches: When the dip switch (#6) is set to ON, the boiler end switch relay(s) and AUX 1, AUX 2, and AUX 3 circulating pump outputs are delayed operating by 1 minute. When dip switch (#6) is set to OFF, then either zone valve with an end switch or jumper between terminals 3 and 4 of zone output is required. More adjustments are available when using the Taco eLink mobile app.

AUX 1; Secondary Circulator Output: The AUX 1 output is energized when any zone calls for heat and the zone valve end switch is closed. More adjustments are available when using the Taco eLink mobile app.

AUX 2; Primary Circulator Output: The AUX 2 output follows dip switch setting # 3 listed above. More adjustments are available when using the Taco eLink mobile app.

AUX 3; Priority Zone Circulator Output: The AUX 3 output is energized when zone 1 calls for heat and the zone valve end switch is closed. More adjustments are available when using the Taco eLink mobile app.

Wiring Procedure

End Switches (Low Voltage Dry Contacts):

Main The main end switch closes when any zone thermostat calls for heat and connects to T-T on boiler operating control.
Priority The priority end switch closes only when the priority zone thermostat or aquastat is calling for heat and connects to DHW T-T on boiler (optional).

Thermostat Input (24 vac):

• R :  Hot side of the transformer. Connect to R on the thermostat.
• W : Switched R signal from the thermostat. Connect to W on the thermostat.
• C : Common side of the transformer. Connect to COM on the thermostat (optional).

Zone Valve Connections (24 vac):

1. Connect terminal 1 on ZVC to one of the motor connections on the zone valve.
2. Connect terminal 2 on ZVC to the other motor connections on the zone valve.
3. Connect terminal 3 on ZVC to one of the end switch connections on the zone valve.
4. Connect terminal 4 on ZVC to the other end switch connections on the zone valve.

Expansion Connections: (optional)

1. Connect 1 on Master zone control to 1 on all Expansion zone control(s).
2.  Connect 2 on Master zone control to 2 on all Expansion zone control(s).
3.  Connect 3 on Master zone control to 3 on all Expansion zone control(s).

Power Input (120 vac):

• H : Connect to 120 vac Hot side of power supply to zone control.
• N : Connect to 120 vac Neutral side of power supply to zone control.
• G : Connect the ground wire to ground screws on the base of zone control.

Circulator Output; Secondary / AUX 1 (120 vac):

• H : Connect the Hot output to Hot power input on the circulator.
• N : Connect the Neutral output to Neutral power input on the circulator.
• G : Connect the ground wire to ground screws on base of zone control.

Circulator Output; Primary / AUX 2 (120 vac):

• H : Connect the Hot output to Hot power input on the circulator.
• N : Connect the Neutral output to Neutral power input on the circulator.
• G : Connect the ground wire to ground screws on base of zone control.

Circulator Output; Priority Zone / AUX 3 (120 vac):

• H : Connect the Hot output to Hot power input on the circulator.
• N : Connect the Neutral output to Neutral power input on the circulator.
• G : Connect ground wire to ground screws on base of zone control

 Product & Applications Diagrams

PA01-V – ZVC406-5 with 5 Zone Valves & Indirect DHW; Supply & Return Headers

Mechanical Diagram

Electrical Diagram

PA02-V – SR506-5 with 5 Zone Circulators & Indirect DHW; Primary/Secondary

Mechanical Diagram

Electrical Diagram

PA03-V –High & Low Temp Temperature Zones + Indirect DHW; Primary/Secondary

Mechanical Diagram

Electrical Diagram

PA04-V – Oil Fired Boiler with Tankless Coil; Supply & Return Headers

Mechanical Diagram

Electrical Diagram

Reset Control Setup & Wiring (Optional)

Boiler Reset Types: The ZVC406-5 includes two types of boiler reset control logic:
Indoor Reset Control (Load Reset) uses the thermostat cycling information to determine the supply water temperature. Thermostat short cycling usually indicates supply water temperature is too high and long on cycles usually is too low of water temperature.
Outdoor Reset Control uses an outdoor sensor to compare it against the a reset ratio
(configured by the installer) to determine the appropriate supply water temperature.

General Operation: 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 circulator relay(s). The boiler end switch relay and modulating output will be controlled by the reset algorithm. either based on indoor thermostat operation or on outdoor temperature.
Control Setup: The Taco eLink mobile app is required to set type of reset control and parameters to operate. See section 7 for more information on the Taco eLink mobile app.

Wiring of Reset Control:
Remove the inner cover as shown in section 9 of this manual on page X to have access to wire.

Sensor Connections:

Boiler Sensor:
A boiler supply sensor is required for either indoor or outdoor reset. Mount the supplied strap-on sensor to the supply piping of boiler and wire the sensor to the Boiler Sensor terminal block on zone control.

Outdoor Sensor:
An outdoor sensor is required when utilizing the outdoor reset function. Mount the Taco outdoor sensor P# 9300-2052RP on the north side of the building and wire to the Outdoor Sensor terminal block on zone control

Boiler Connections:

Modulating Output:
Most Mod-Con boilers have an input for an external modulating signal (0-10 vdc or 4-20 ma) to control boiler. Connect the modulating output to appropriate input terminals on the boiler; noting that the polarity is correct. Some Mod-Con boilers also require a T T call for heat to activate the boiler. In this case, wire the Main Boiler End Switch to T T input on the boiler.

Dry Contact End Switch:
ON/OFF boilers are controlled by the Main Boiler End Switch on zone control. Wire the Main Boiler End Switch to T T input on the boiler.

The Taco eLink APP (Optional)

Note: The Taco eLink mobile app is not required for standard installations.

Advanced Control & Monitoring Options: The Taco APP is required for advanced control functions and parameters to operate. Use the QR code to download APP for either iOS or Android mobile devices.

Follow the app menu to configure advanced features that the Taco new zone controls have to offer, including;

• Different levels of access
• Zone naming
• Programmable output naming
• Alerts & messages
• Post purge time delay adjustment
• Pump exercise time delay adjustment
• Priority protection time delay adjustment
• Indoor boiler reset
• Outdoor boiler reset
• AUX 1 output behavior
• AUX 2 output behavior
• AUX 3 output behavior
• Cooling function
• Zone association

Trouble Shooting & FAQ’s

For your convenience, the Taco Tech Support team is available anytime 24/7. Just call 401-
942- 8000 for help.

Problem: Digital thermostats do not work correctly when connected to a switching relay. Solution: Some thermostats are a “Power Stealing” type which means they are powered by the switching relay with just 2 wires (R & W). A resistor may be needed in order to have the thermostat work properly. This resistor should be placed between the W & C (common) terminals of the switching relay. If the thermostat manufacturer does not supply a resistor, a 1000 ohm ½ watt resistor has proven to work with most.

Problem: No heat in a zone or room of the building.

Solution: 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 solid-state fuse is good. When there is a call for heat, the red LED will come on indicating power to the zone circulator. This indicates the thermostat is working correctly. If the red LED does not come on, then check the thermostat and thermostat wiring for errors.
Problem:
Solution:

Inner Cover Removal & Fuses:

1.  Gently push in tab in with finger on side of inner cover.
   

2.  Lift cover and hinge up to remove it.

3.  Fuses are replaceable; with 2 spare fuses attached to inner cover near the transformer.

Specifications

• Power and Electrical Ratings:

• Power Supply: 120VAC ±10%, 60Hz, 20A

• Zone Valve Output Rating:
  24 Vac, 1A,

• AUX(s) Pump Output Rating:
  120 Vac, 1/6 HP

• Boiler End Switch Contact Rating:
  24 Vac, 1A,

• Boiler Modulating Output Rating:
  0-10 VDC Mode; 500 Ω min impedance
  4-20 mA Mode; 1k Ω max impedance?

• Expansion Terminals: Low voltage, 3-wire polarity-sensitive, digital communications that link other Switching Relays (SR-5), Zone Valve Controls (ZVC-5), and other Modbus equipment.

• Electrical Terminals (Line Voltage):
  Wire Range Min / Max: 12-24AWG Torque: 7.0 lbs-in. Max.
  Electrical Terminals (Low Voltage):
  Wire Range Min / Max: 12-28AWG Torque: 3.5 lbs-in. Max.

• Transformer Rating:
  3 & 4 zone; 1 @ 40 VA, 24 Vac Class II
  5 & 6 zone; 2 @ 40 VA, 24 Vac Class II

• Environmental Ratings:

• Ambient Temperature Rating:
  32°F to 104°F (0°C to 40°C)

• Operating Humidity Range (% RH):
  5 to 90% RH, noncondensing

• Sensor Temperature Rating:
  -58°F to 230°F (-50°C to110°C)

• DIP Switch Timing Settings:

• Post Purge: 30 seconds; adjustable with mobile app

• Pump Exercise: 30 seconds per 2 weeks of space heating inactivity; adjustable with mobile app

• Thermostat Compatibility: Compatible with most mechanical, battery operated, power-stealing (power-robbing), hardwired and “Smart” thermostats. Temperature Sensor: 10K ohm NTC thermistor at 77°F (25°C) ± 0.5°F (±0.3°C). Lead length: ?ft. (m); up to 500 ft. (150 m) using 18 AWG or larger wire, beta=3892. Dimensions (HxWxD): 15.6 x 8.7 x 2.7 in.(39.5 x 22.0 x 6.8 cm)

• approximate Weight: l b. (kg)

• Approvals: UL, FCC, ISED

 Accessories & Replacement Parts

Item Part Number
Strap-on sensor for boiler reset control or SmartPlus logic —————— 9300-2044RP
Outdoor sensor for outdoor boiler reset and smart pump exercise ——- 9300-2052RP
Circulator output fuses; slow blow, 6 amp, 2AG (5mm X 15mm) ———– SR6A-001RP
Low voltage fuses; slow blow, ? amp, 2AG (5mm X 15mm) —————— ?
Transformer; 40 VA at 24 VAC with connectors to plug into board ——– 9300-4107RP

LIMITED WARRANTY STATEMENT

(at the company’s option) any product or part which is proven defective under normal use within three (3) years from the date of  In order to obtain service under this warranty, it is the responsibility of the purchaser to promptly notify the local Taco stocking distributor or Taco in writing and promptly deliver the subject product or part, delivery prepaid, to the stocking distributor. For assistance on warranty returns, the purchaser may either contact the local Taco stocking distributor or Taco. If the subject product or part contains no defect as covered in this warranty, the purchaser will be billed for parts and labor charges in effect at time of factory examination and repair.

Any Taco product or part not installed or operated in conformity with Taco instructions or which has been subject to misuse, misapplication, the addition of petroleum-based fluids or certain chemical additives to the systems, or other abuse, will not be covered by this warranty.

If in doubt as to whether a particular substance is suitable for use with a Taco product or part, or for any application restrictions, consult the applicable Taco instruction sheets or contact Taco at
[401-942-8000].

Taco reserves the right to provide replacement products and parts that are substantially similar in design and functionally equivalent to the defective product or part. Taco reserves the right to make changes in details of design, construction, or arrangement of materials 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 FITNESS 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 STATUTORY, OR ANY OTHER WARRANTY OBLIGATION ON THE PART OF TACO.

TACO WILL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF ITS PRODUCTS OR ANY INCIDENTAL COSTS OF REMOVING OR REPLACING DEFECTIVE PRODUCTS.

This warranty gives the purchaser specific rights, and the purchaser may have other rights which vary from state to state. Some states do not allow limitations on how long an implied warranty lasts or on the exclusion of incidental or consequential damages, so these limitations or exclusions may not apply to you.

References

• Taco Comfort Solutions | Leader in Hydronics and Pump Solutions

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