CALEFFI Z-one Relay Multi-Zone Valve Control ZVR10X Series Hot Rod are you out there

cutter

I am using the control panel listed above. It appears the light comes on saying a zone needs heat but the pump controlling the zone does. That same pump supply's water to 4 zones. So if another zone wants heat at the same time the pump supply's water to both zones. But if the other 3 zones are satisfied the pump does not run. the indicator red light on the panel says the zone needs heat but the pump does not run. I have sensors showing the supply and return water temperature. I noticed today the supply and return was the same temperature.. Only one zone was calling for heat, I then turned up another thermostat and the return temp went down. I could hear the pump run then. when the supply and return was the same temperature I could not hear the pump. I would say the control panel is getting tired. I am not as sharp as most of you folks. I changed that pump last week think the pump was the problem. being as how the pump was new I figured something else was the problem so now I feel the control panel is not doing it's job 100%. Anybody have suggestions or comments.

hot_rod

Which pump connection are you using? Is there a priority zone? If not dip switch for priority to no.

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cutter

I don't remember when I re-piped this system and used all Caleffi controls. At least 6 years ago. the system has worked flawless until now. The screen shots and the information confuses me. When a zone calls for heat and the zone valve opens but the pump does not come on something is wacko. if another zone calls for heat the second zone valve opens and the pump comes on and supply's water for both zones. so something is not working quite right.

pedmec

Your zone valve is most likely not functioning. Zone valves have end switches to relay back to the ZVC to indicate the valve is opened and you can turn the circulator on. it's to prevent your circulator from deadheading. are you getting heat to all zones when the working zones are functioning. does the second zone light come on when you turn the thermostat up?

hot_rod

With the cover off you can see both lights. One light indicates the thermostat is calling. The second will come on after the zone valve end switch closes. Depending on the zone valve it could take 45 seconds with a motorized valve, or maybe 3 minutes with a thermal actuator.

If the second light does not come on, the end switch is not closing.

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cutter

https://forum.heatinghelp.com/discussion/comment/1832131#Comment_1832131

I should have got back to thin long ago. I get heat to all zones that are calling for heat if zone 1 is calling for heat. Today I tried to heat an area that I don't normally heat. I turned down the thermostat for zone 1 and turned up the thermostat for zone 4. The pump would not run. I turned up the thermostat for zone 1 and the pump started. On the panel the second light comes on after the first one calls for heat for all the zones. I currently run zone one at a higher temp so the other zones get hot water. The zone valves were new when I replumbed this system about six years ago.

hot_rod

do you have zone 1 set to priority. If so no other zone will operate until #1 satisfies. Send a pic of the board with cover off so I can see the dip switches.
If priority is off, do both lights for zone 4 come on? If not it might be mis-wired or the end switch is not closing

cutter

The green light on top indicates the system is powered up after I get a fire hot enough for an aqua stat to send power to the panel. The green light on the left comes on saying opening the zone need heat. Then the green light on the left comes on saying the pump has power. The pump is not coming on because there is no power to it for some reason. I have zone 4 doing the same thing now. not sending power to the pump. both green lights are on.

hot_rod

To be sure we are on the same page, you have this control a ZVC relay?

Green light is on whenever it is powered up. It is not a "pump on" indicator. I just put a cord on mine and plug it into a receptacle. This allows easy service. Also I can connect a generator easily in a power outage. And the pump exercise function can be used over the summer if it is always powered.

Inside there are two red lights for every zone.

One light comes on when the thermostat calls. This sends power to the zone valve.

After a period of time, depending on what type of zone valve you have, the second light comes on, this indicates the pump relay is activated. Zone pump relay #1 should have 120V now.

45 seconds for a Z-one, Honeywell etc to make the end switch. Thermal zone valves can take several minutes to open.

Two additional relays, secondary pump and system pump, require you to move the jumper to use them. These are for primary secondary piping systems that use multiple pumps.

So basically two red lights need to be on for a pump to start.

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cutter

https://forum.heatinghelp.com/discussion/comment/1837118#Comment_1837118

I have a ZVR10X series as stated when i first posted. Green light comes on when powered up. The thermostats are below temperature settings. So the left red light comes on and a second or two later the right red light comes on. If zone one is satisfied and both red lights are off and zone 2 and 4 red lights are on the pump will not run. I do have two pumps the other pump is the one that pumps water through the boiler until and after the boiler water reaches 140 degrees and a valve of some sort opens gradually and allows the water to go to zones.

hot_rod

are you wired to the first set of pump connections?

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if so maybe tech support has other ideas?

414 348 6338 is the direct line. Matt or Ryan are full time support. Greg and Cody know the control also. All 4 were heating techs, so you get experienced help.

It helps if you are at the control when you call in.

cutter

The picture you posted above does not resemble my control at all. I have taken a picture of my control but for some reason I can not get it to the computer I have to get my son to help me with the picture. I will post it when I get it on the computer.

hot_rod

So basically a ZVR-10 and the last number will be 3,4 or 6

ZVR 103, 104 or 106. Which is 3,4 or 6 zones

The one I showed is a 3 zone ZVR-103

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cutter

https://forum.heatinghelp.com/discussion/comment/1837435#Comment_1837435

This is 4 zone system. this is the wiring. Don't know if you can make it out. The directions for the wiring was simple I thought. I could have made a mistake.

I will try to send it again

cutter

I had a network error

cutter

trying to send picture again

cutter

I was finally able to send the picture of the control. the phone numbers you sent earlier I will call if you can't give suggestions.

hot_rod

gosh, the wiring looks fine. I can’t make out where you have the pins above the relays set?

The boys in Milwaukee might have more current info. It looks like a Rev. 4 board, it should be current with upgrades.

cutter

https://forum.heatinghelp.com/discussion/comment/1837550#Comment_1837550

The pins above the relays are set to on. I feel my mistake is the pump connections. The wood boiler pump that circulates the water until it gets hot enough to keep the controls powered up and the pump from shutting off and on is connected to system pump. The pump that supply's water to the zones is connected to zone #1 pump. That is the mistake, I think now it should be connected to the the secondary pump connections. I think then it would run whenever any zone called for heat. Does that make sense. or does it need a jumper connection from zone #1pump connection to secondary pump connection?

hot_rod

Maybe a piping drawing would help see what control logic you need?

You mentioned the WB pump runs until it gets hot enough? What gets hot a buffer tank? Or just a secondary loop? The boiler itself?

Do you have two pumps, the wb pump and the system pump flowing the zone valves?

So if the wood boiler heats itself or a buffer tank, when it gets to a temperature, say 180, the relay box powers on from a separate control? If the tank or wb drops too cold, maybe 140° the wb pump is off, via the wb control, until the wb catches up? So no heat is available during that time period?

If so a separate setpoint control wired N.O. normally open on the tank, or wb. When it, the tank or wb reaches the temperature you want, it closes and powers 120V to the relay box. So no zones can get heat until the tank is hot?

A Ranco setpoint control would do that , adjustable differential, nice digital display to see what the temperature is.

What controls the boiler. Does it have it's own control to start a fan, control a damper? Does it power the wb pump? It is always powered?

The relay in the ZCV can only switch the zone pump, and system and secondary pumps on/ off. It cannot run two pumps based on two different temperature or thermostat calls.

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cutter

https://forum.heatinghelp.com/discussion/comment/1837605#Comment_1837605

Yes I have two pumps one pump is the pump that moves water through the boiler when water temperature reaches 140 degrees and continues to run as long as the water is above 140 degrees. that first pump runs so the boiler controls do not turn off and on as the boiler gets hot. The second pump is the zone valve pump that comes on at the same time as the first pump that water is circulated through the hydraulic separator until that valve on the boiler lets water go through it to the system.

I do not have a buffer tank. I have very limited room where the boiler is at so a lot of piping is crowded into a small space.

I have a simple Buderus boiler. A sampson firing control, controls the draft damper. There are no fans on the boiler. The ZVR10X Caleffi control, controls the WB pump. When the boiler gets hot (140 degrees) a aquastat sends power to the Caleffi control. The house is normally below 70 degrees when I build a fire. So the caleffi control powers up the wood boiler pump and the zone valve pump at the same time.

The wood boiler pump is always on if the water temperature is above 140 degrees.

I am going to call the number you gave me and see what those men tell me. Thanks for the help.