SUPERSEDES: New
Plant ID# 9300-2880
Wiring Diagram
WHITE
120 VAC
INPUT
BLACK
WHITE
120 VAC
INPUT
BLACK
Optional System
and/or DHW and/or
Secondary Circulators
PUMP END
ZONE 4 PUMP
SWITCH
END SWITCH
X
X
N/O COM N/C
HOT
120
SYSTEM
VAC
PUMP
DHW
PUMP
NEUTRAL
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.
Operation/External Diagnostics: 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.
Priority Operation: 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.
Mode Operation: 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.
Post Purge Operation: 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.
Priority Protection Operation: 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 Operation: 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 Contacts): 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.
Specifications:
PRODUCT
NUMBER
INPUT
NUMBER
OF ZONES
VOLTAGE
ZVC404-EXP-4
4 with Priority
120/60/1 VAC, 3A
1
The pump end switches are rated
⁄
hp, 5 amps at 120 VAC. The main and priority end switch connections
6
are rated 24 VAC, 1 amp. All thermostat and zone valve connections supply a 24 VAC class 2 output.
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.
Instruction Sheet
ZVC404-EXP-4 Zone Valve Control
TO: "TT" ON BOILER WITH
TO: "TT" ON BOILER
POWER
CONTROLS
FUSE
A
5 AMP
24 VAC
FUSE
5 AMP
ACCESSORY
B
24 VAC
PUMP END
ZONE 4 PUMP
SWITCH
END SWITCH
X
X
N/O COM N/C
TO
CIRCULATOR
DRY
CONTACTS
SECONDARY
PUMP
MAX 24 VAC
TYPE 1 ENCLOSURE
OUTPUT @ 25°C
WIDTH HEIGHT
1
24 VA per Zone
12
⁄
"
8"
4
40 VA per Transformer
Powered from Transformer A
DHW "TT" INPUT
X X X X
A B C R W C R W C R W C R W C 1 2
MAIN
PRIORITY
EXPANSION
END SWITCH
MASTER
SLAVE
PRIORITY ON
OFF
PORT
RESET
NORMAL
POST PURGE ON
OFF
PRIORITY PROTECTION ON
OFF
PUMP EXERCISE ON
OFF
30 SEC/2 WK
4 MIN/24 HOUR
24 VAC ZONE VALVES
ZONE 1
1 2 3 4
JUMPER
3 & 4
1
2
3
2 WIRE
ZONE VALVE
TACO
(NO END SWITCH)
3 WIRE
MUST USE JUMPER
ZONE VALVE
Powered from Transformer A
Expansion Connections: 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 (18-22 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).
Thermostat Input (24 vac):
R
Hot side of transformer. Connect to R on thermostat.
W
Switched R signal from thermostat. Connect to W on
thermostat.
C
Common 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).
Power 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 Contacts):
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.
Zone 4 Pump End Switches (Dry Contacts): 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 Connections:
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
DEPTH
a minimum temperature rating of 75°C. Failure to follow this instruction
3"
can result in personal injury or death and/or property damage. 12-18 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.
EFFECTIVE: May 1, 2010
Powered from Transformer B
THERMOSTATS (24 VAC)
ZONE 1 ZONE 2 ZONE 3 ZONE 4 NET
THERMOSTATS (24 VAC) PRIORITY
ZVC 404-EXP-4
FOUR ZONE EXPANDABLE
ZONE VALVE CONTROL
PRIORITY
ZONE 2
ZONE 3
ZONE 4
1 2 3 4
1 2 3 4
1 2 3 4
JUMPER
3 & 4
PRIORITY
ZONE
MOTOR
END
SWITCH
NOTE: When a circulator is used
on the priority zone instead of a
zone valve, jumper 3 and 4 of
the priority zone.
4 WIRE
ZONE VALVE
(POWER OPEN,
SELF CLOSING)
Powered from Transformer B
102-399
INDIRECT
WATER HEATER
AQUASTAT OR
THERMOSTAT
LED
INDICATORS
POWER
VALVE 1
T STAT 1
T STAT 2
VALVE 2
VALVE 3
T STAT 3
T STAT 4
VALVE 4
SEE NOTE
