C-TEC CAST ZFP Operating and maintenance manual

CAST ZFP
Analogue Addressable
Fire Alarm Control Panel
Standard 1 to 4 Loop Panel
Installation,
Maintenance &
Programming Manual
Approved Document No. DFU5030000 Rev 4

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 2 of 60
CAST ZFP Access Levels 1 & 2 Menu Structure

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 3 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
CAST ZFP Access Level 3 Menu Structure

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 4 of 60
Ensure you have attended C-TEC’s Authorised
Training Course before installing this panel.
Contents
NOTE:A GLOSSARY OF TERMS USED IN THESE INSTRUCTIONS IS LISTED IN APPENDIX 7.
1IMPORTANT NOTES ...............................................................................................................................7
1.1 STANDARDS ..............................................................................................................................................7
1.2 ITEMS SUPPLIED........................................................................................................................................7
1.3 NOTICES....................................................................................................................................................7
1.4 SYSTEM DESIGN........................................................................................................................................8
1.5 EQUIPMENT GUARANTEE ..........................................................................................................................8
2CAST ZFP KEY FEATURES....................................................................................................................8
2.1 EN54 COMPLIANCE STATEMENT ..............................................................................................................8
3TYPICAL 4 LOOP CAST ZFP PANEL BLOCK DIAGRAM.............................................................10
4CABLING REQUIREMENTS ................................................................................................................11
4.1 MAINS WIRING .......................................................................................................................................11
4.2 FIELD WIRING.........................................................................................................................................11
4.3 TESTING OF FIELD WIRING......................................................................................................................11
5INSTALLATION......................................................................................................................................12
5.1 ENCLOSURE DESCRIPTION ......................................................................................................................12
5.2 MOUNTING LOCATION ............................................................................................................................13
5.3 REMOVING THE LID AND PCB CHASSIS ..................................................................................................13
5.4 PLANNING THE CABLE LAYOUT IN THE PANEL AND REMOVING KNOCKOUTS ........................................13
5.5 WALL MOUNTING THE BACK BOX..........................................................................................................13
5.6 REINSTALLING THE PCB CHASSIS AND LID ............................................................................................14
5.7 INSERTING THE ‘SLIDE-IN’LABELS..........................................................................................................14
5.8 FITTING THE 2-LOOP PCB (OPTIONAL)...................................................................................................14
5.9 ANALOGUE ADDRESSABLE LOOP WIRING ..............................................................................................15
5.10 ANALOGUE ADDRESSABLE LOOP(S)WIRING .....................................................................................16
5.11 CONVENTIONAL SOUNDER CIRCUIT(S)WIRING .................................................................................17
CAUTION !
DO NOT connect or disconnect the panel’s
internal wiring / looms, or terminate field wiring
at the PCBs, with the panel’s power applied
(either mains or battery). Failure to observe this
will destroy the panel’s electronic components
and the warranty will be void.

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 5 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
5.12 AUXILIARY INPUT WIRING.................................................................................................................17
5.13 24V AUXILIARY POWER OUTPUT.......................................................................................................18
5.14 RELAY OUTPUT WIRING.....................................................................................................................18
5.15 REMOTE PC CONNECTION..................................................................................................................18
5.16 CONNECTING MAINS TO THE PANEL’S PSU .......................................................................................19
5.17 CONNECTING THE STANDBY BATTERIES ............................................................................................20
6A-BUS (OPTIONAL)................................................................................................................................21
6.1 Z11/Z12 RELAY PCB AND Z13/Z14 DIGITAL I/O PCB FEATURES .........................................................21
6.2 A-BUS DIP SWITCH ADDRESS SETTINGS ................................................................................................22
6.3 Z15 SOUNDER PCB FEATURES ...............................................................................................................23
6.4 Z16 ZONE &CONVENTIONAL SOUNDER PCB FEATURES .......................................................................24
6.5 FITTING A-BUS PCBS.............................................................................................................................25
6.6 A-BUS WIRING .......................................................................................................................................26
6.7 Z15 AND Z16 CONVENTIONAL SOUNDER CIRCUIT(S)WIRING................................................................28
6.8 Z16 CONVENTIONAL ZONE CIRCUIT(S)WIRING .....................................................................................28
7TOUCHSCREEN, INDICATORS & CONTROLS...............................................................................29
8COMMISSIONING & PROGRAMMING.............................................................................................29
8.1 EN54 COMPLIANCE STATEMENT ............................................................................................................29
8.2 RECOMMENDED SHORTFORM INSTALLATION &COMMISSIONING PROCEDURE ......................................30
8.3 ACCESS LEVEL 3MENU STRUCTURE ......................................................................................................32
8.4 HOW TO ENTER ACCESS LEVEL 3(AL3).................................................................................................32
8.5 ENGINEERING FUNCTIONS.......................................................................................................................33
8.5.1 Device Manager ....................................................................................................................................33
8.5.2 Contamination Check ........................................................................................................................... 37
8.5.3 Show PSU Status ......................................................................................................................................38
8.5.4 Test Input Group......................................................................................................................................38
8.5.5 Test Output Group .................................................................................................................................. 38
8.5.6 Walk Test.................................................................................................................................................. 38
8.5.7 Clear All Tests .......................................................................................................................................... 38
8.5.8 Show Loop Status.................................................................................................................................... 39
8.5.9 Find Loop Break ...................................................................................................................................... 39
8.5.10 Change Access Level 2 (AL2) Code..................................................................................................... 40
8.5.11 Change Access Level 3 (AL3) Code..................................................................................................... 40
8.5.12 Panel Notes .............................................................................................................................................40
8.5.13 Show System Details ............................................................................................................................... 41
8.5.14 Safe Mode............................................................................................................................................... 41
8.5.15 Clean Start .............................................................................................................................................. 41
8.5.16 Sync Network Data................................................................................................................................. 41
8.5.17 Diagnostics.............................................................................................................................................. 42
8.5.18 Firmware Update ....................................................................................................................................42
8.6 COMMISSIONING FUNCTIONS ..................................................................................................................43
8.6.1 Loop Learn ..............................................................................................................................................43
8.6.2 Auto Address........................................................................................................................................... 44
8.6.3 Fix Address Faults ....................................................................................................................................45
8.6.4 Verify Loop .............................................................................................................................................. 45
8.6.5 Device Manager .................................................................................................................................... 45
8.6.6 Add New Device .................................................................................................................................... 46
8.6.7 Add/Delete/Edit a Device..................................................................................................................... 46
8.6.8 Edit Zone Name ...................................................................................................................................... 46
8.6.9 Edit Input Group Name .......................................................................................................................... 47
8.6.10 Edit Output Group Name....................................................................................................................... 47
8.6.11 Setup Panel Printer..................................................................................................................................47
8.6.12 Setup Networking ................................................................................................................................... 47
8.6.13 Select Language .................................................................................................................................... 47
8.6.14 Synchronise Network Data..................................................................................................................... 47

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Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 6 of 60
8.6.15 LCD Auto-Dimming................................................................................................................................. 47
8.6.16 Set Loops Fitted....................................................................................................................................... 48
8.6.17 System Configuration ............................................................................................................................. 48
8.6.18 Setup Polling LED..................................................................................................................................... 48
8.7 EVENT LOG FUNCTIONS..........................................................................................................................48
8.8 DISABLEMENT FUNCTIONS......................................................................................................................49
8.8.1 Supervisory Disablements....................................................................................................................... 49
8.8.2 Enable/Disable Zones............................................................................................................................. 50
8.8.3 Enable/Disable Devices ......................................................................................................................... 50
8.8.4 Enable/Disable Input Groups................................................................................................................. 50
8.8.5 Enable/Disable Output Groups ............................................................................................................. 51
8.8.6 Enable/Disable Panel Printer.................................................................................................................. 51
8.8.7 Clear All Disablements ........................................................................................................................... 51
8.9 SET THE PANEL’S TIME AND DATE..........................................................................................................51
8.10 SHOW SUPERVISORY EVENTS.............................................................................................................51
9MAINTENANCE......................................................................................................................................52
APPENDIX 1 –ENCLOSUREDIMENSIONSAND FIXING DETAILS.........................................................53
APPENDIX 2 –BEZELS (FLUSH-MOUNT)..................................................................................................54
APPENDIX 3 –CHASSIS..................................................................................................................................55
APPENDIX 4 –LIST OF MODULES..............................................................................................................56
APPENDIX 5 –STANDBY BATTERY CALCULATION GUIDE...............................................................57
APPENDIX 6 –CAST ZFP TECHNICAL SPECIFICATION......................................................................58
APPENDIX 7 –GLOSSARY OF TERMS.......................................................................................................60
Figures
Fig.1 –Typical 4 Loop CAST ZFP Panel Block Diagram...................................................................................10
Fig.2 –Location of Standard 1 to 4 Loop Version Components ..........................................................................12
Fig.3 –Typical Analogue Addressable Loop Overview.......................................................................................15
Fig.4 –Analogue Addressable Loop Connections ...............................................................................................16
Fig.5 –Conventional Sounder Circuit Connections .............................................................................................17
Fig.6 –Auxiliary Input Connections ....................................................................................................................17
Fig.7 –24V Auxiliary Output Connections..........................................................................................................18
Fig.8 –Relay Output Detail..................................................................................................................................18
Fig.9 –PC Connection..........................................................................................................................................18
Fig.10 –5A PSU Layout and Mains Connection Details .....................................................................................19
Fig.11 –Battery Connection Details.....................................................................................................................20
Fig.12 –Z11/Z12 Relay PCB and Z13/Z14 Digital I/O PCB Wiring ..................................................................26
Fig.13 –Z15 Sounder PCB Wiring ......................................................................................................................26
Fig.14 –Z16 Zone Sounder PCB Wiring .............................................................................................................27
Fig.15 –Z16 Conventional Sounder Circuit Connections....................................................................................28
Fig.16 –Z16 Conventional Zone Circuit Connections.........................................................................................28
Fig.17 –Access Level 3 Menu Structure..............................................................................................................31
Manufacturer: Computionics Limited (C-TEC), Challenge Way, Martland Park, Wigan, Lancashire WN5 0LD. www.c-tec.com

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 7 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
Symbols
General Warning Sign Danger Electrical Hazard
Read these instructions thoroughly before installation and operation
1IMPORTANT NOTES
1.1 Standards
1.2 Items Supplied
CAST ZFP Fire Alarm Control Panel, as ordered.
Installation, Maintenance & Programming manual (this manual) –Explains how to install, commission
and maintain the fire alarm control panel. This manual must not be left accessible to the user.
User Manual and Log Book (Document No. DFU5030050) –Gives detailed operational information
and details about the panel’s touchscreen, indicators and controls.
Quick start guides for users (Document No. DFU5030060) and engineers(Document No. DFU5030010)
–Summarize key information provided in the main manuals.
Key for unfastening / securing the panel lid (key number 801).
Electrical accessory pack, containing:
1 x 20mm T 2 A H 230 V ceramic fuse (spare primary fuse)
1 x 7.5 A MINI®automotive blade fuse (spare battery fuse)
1 x set of battery link wires and nylon cable ties
4 x 6K8 0.25W EOL resistors for conventional sounder circuits (2) and auxiliary inputs (2)
2 x 470R 0.25W trigger resistors for auxiliary inputs I/P1 & I/P2.
1.3 Notices
Anti-static handling guidelines
Make sure that handling precautions for electro-static devices (ESD) are taken immediately
before handling PCBs and other ESD components. Before handling any ESD items,
engineers should get rid of any electro-static charge by touching a sound safety earth.
Always handle PCBs by their sides and avoid touching any electronic components. PCBs
should be stored in a clean, dry place that is free from vibration, dust and excessive heat.
Disclaimer
Errors and omissions excepted (E&OE). No responsibility can be accepted by the manufacturer
or distributors of this range of fire panels for any misinterpretation of an instruction or guidance
note or for the compliance of the system as a whole. The manufacturer’s policy is one of
continuous improvement and we reserve the right to make changes to product specifications at
our discretion and without prior notice.
WARNINGS!
This equipment must only be installed and maintained by a suitably skilled and
technically competent person. Ensure you have attended C-TEC’s Authorised
Training Course before handling the panel.
This equipment is a piece of Class 1 permanently connected equipment and MUST
BE EARTHED.
ALWAYS isolate the panel’s Mains and battery backup supplies before making
connections to its PCBs.
ZFP1/CA 2831-CPR-F4508
ZFP2/CA 2831-CPR-F4509
ZFP4/CA 2831-CPR-F4510
ZFP1/40/CA 2831-CPR-F4511
ZFP2/40/CA 2831-CPR-F4512
ZFP4/40/CA 2831-CPR-F4513
DOP0000076

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 8 of 60
1.4 System Design
Fire alarm system design is beyond the scope of this document. A basic understanding of general fire alarm
system components and their use is assumed.
Contact the Fire Officer concerned with the property at an early stage in case he has any special requirements.
We strongly recommend that a suitably qualified and competent person is consulted in connection with the
design of the fire alarm system.
The equipment must be installed, operated and maintained in accordance with these instructions and the
appropriate national, regional or local regulations. If in doubt please consult your distributor.
We recommend you read BS 5839-1, Fire detection and alarm systems for buildings: Code of practice for system
design, installation and maintenance, available at your local reference library or from the BSI. Other national
standards of installation should be referenced where applicable.
1.5 Equipment Guarantee
This equipment is not guaranteed unless the complete installation is installed and commissioned in accordance
with the laid down national, regional or local standards (in the UK BS 5839 Part 1) by an approved and
competent person or organisation.
2CAST ZFP KEY FEATURES
2.1 EN54 Compliance Statement
The ‘out-of-the-box’ fire alarm panel is fully compliant with the requirements of EN54-2 (Fire detection and fire
alarm systems, control and indicating equipment) and EN54-4 (Fire detection and fire alarm systems, power supply
equipment) and is 3rd party certified as meeting these standards.
Please note, some of the Key Features listed below, go beyond the scope of EN54-2, i.e. Non-EN54-2
approved. DO NOT affix the EN54 approval label (supplied) to the front of the panel if it has been
configured to operate in a way that would make it non-compliant with the requirements of EN54-2.
Dependant on the model purchased, the CAST ZFP fire alarm control panel includes the following features:
Certification by the LPCB to EN54 parts 2 and 4
Full compatibility with C-TEC’s CAST® (C-TEC Addressable System Technology) - a powerful,
proprietary communication protocol
Short-circuit protected loop driver (rated at 450mA, 40V), capable of supporting up to 255 addressable
CAST detectors and CAST call points per loop, with a maximum of 512 detectors / call points per panel.
Each CAST loop device is fitted with a short-circuit isolator
Three cabinet sizes are available:
Standard –1 chassis c/w 2 modules (1, 2 or 4 addressable loops)
Medium –2 chassis c/w 4 modules (1, 2, 4, 6 or 8 addressable loops). Non-EN54-2 approved
Large –3 chassis c/w 6 modules (1, 2, 4, 6 or 8 addressable loops). Non-EN54-2 approved
Modular construction
5A EN 54-4/A2 PSU and battery charger included in all panels
Up to 17Ah batteries in a standard cabinet, up to 38Ah in the medium and larger cabinets
4.3 inch, 480 x 272 pixel, 24 Bit, 16M colour LCD touchscreen
Separate distinct LEDs for mandatory EN 54 indications plus programmable LEDs
One RS232 port - for ancillary devices, e.g. pagers / DECT telephone systems / Graphics Interface
Two RS485 ports –one for A-Bus (connects peripheral PCBs), one for Graphics Interface / Diagnostics
Integrated ‘galvanically - isolated’ USB connection to a PC running programming tools
Two independently programmable 1A conventional sounder circuits –monitored

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 9 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
Up to 200 programmable and indicatable system zones per panel. Note: The panel has been tested and
approved as a 40 zone panel; however, the panel is capable of accommodating up to 200 zones.
10,000 event memory for all fire, fault and system events - all filterable
Three access levels –access level 1 (general user), access level 2 (authorised user) and access level 3
(authorised systems engineer) with keyswitch entry to access level 2
A day/night function (building occupied/unoccupied) including detector sensitivity (high/low) and zone
dependency settings. Non-EN54-2 approved.
An investigation delay period function (programmable for length of time, which zone(s) it applies to and
whether or not it operates in day/night mode)
Individual sensitivity settings for each device
Real-time clock with automatic daylight saving time
Standard upload download software includes facility to upload company logos –even from a simple .gif
file from a camera
Up to 16 GB internal micro SD memory card.
In addition to the mandatory requirements of EN 54-2, the panel meets the following criteria:
EN 54-2 Clause 7.8 ‘Output to fire alarm devices (option with requirements)’ to enable an audible warning
to be sounded throughout the premises upon the detection of a fire condition or the operation of a manual
call point.
EN 54-2 Clause 7.11 ‘Delays to outputs (option with requirements)’ of fire alarm devices (sounders) so
that an alarm may be verified before a premises is evacuated.
A selection of zone dependency functions (EN 54-2 Clause 7.12, Type A or B) as detailed below:
-Clause 7.12.1 ‘Type A dependency (option with requirement)’- If there is an alarm from a detector,
the panel will look for a confirmatory alarm from the same or another detector in the same zone
before a full alarm is established. If there is no confirmatory alarm, the first alarm will automatically
reset.
-Clause 7.12.2 ‘Type B dependency (option with requirement)’- As Type A except the confirmatory
alarm from another detector in the same zone or a different zone.
-Important Note: Type A & B dependencies should not be selected to operate together at the
same panel as the initiation of an alarm in one zone will cause a Type B dependency on another
zone, even if a Type A dependency has been set. Dependencies are selected using the panel’s
ZTOOLS.
EN 54-2 Clause 7.13 ‘Alarm counter (option with requirements)’ to record the number of instances the
panel enters the fire alarm condition. Note: The maximum number of instances the alarm counter can
store is 1000.
EN 54-2 Clause 8.3 ‘Fault signals from points (option with requirements)’.
EN 54-2 Clause 9.5 ‘Disablement of addressable points (option with requirements)’.
EN 54-2 Clause 10 ‘Test condition (option with requirements)’ to allow the automatic resetting of zones
in alarm for testing purposes.

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 10 of 60
3TYPICAL 4 LOOP CAST ZFP PANEL BLOCK DIAGRAM
Fig.1 –Typical 4 Loop CAST ZFP Panel Block Diagram

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 11 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
4CABLING REQUIREMENTS
All installation wiring must be checked and tested before termination at the panel. Always isolate the
panel’s mains and battery backup supplies before cable termination at the panel.
4.1 Mains Wiring
Mains wiring must be installed in accordance with all applicable national, regional or local standards. In the
UK this is BS 7671 IET Wiring Regulations and BS 5839-1, Fire detection and alarm systems for buildings: Code
of practice for system design, installation and maintenance.
Mains wiring should be fire resistant and segregated from extra low voltage field wiring.
The general requirement for the 230V, 50Hz mains supply to the CAST ZFP panel is fixed wiring, using 3 core
cable (no less than 1mm2and no more than 2.5mm2), or a suitable three conductor system fed from an isolating
switched fused spur, fused at 3A or a 6A Type B circuit breaker to IEC/EN 60898-1.
The mains supply MUST be exclusive to the panel and be reliably earthed at the indicated earthing post.
As an alternative to a switched fused spur, a double-pole isolating switch (S), with 3mm air gaps on the contacts
& switching L & N only, may be used in the mains feed from the Main Distribution Board (A) to the Panel
(C), providing it meets the appropriate wiring regulations (see drawing below).
Hint! C-TEC’s Fire Alarm Control
Panel Mains Keyswitch (Part No.
BF319) is a lockable, double-pole
keyswitch that provides secure
switching of mains supply to a fire
alarm panel (The BF319 is
available @ www.c-tec.com).
4.2 Field Wiring
Separated or Safety Extra-Low Voltage (SELV) field wiring includes loop circuits, sounder circuits and
auxiliary inputs/outputs. SELV field wiring must be installed in accordance with the relevant national, regional
or local regulations (in the UK this is the IET Wiring Regulations BS 7671 and BS 5839 Part 1).
Fire resistant, screened cable should be used throughout the installation. This not only shields the data moving
up and down the cables from outside interference but is essential to ensure compliance with EMC regulations.
All screens must only be terminated to the earth bar provided in the panel’s back box.
Screened cables such as FP 200™, Firetuff™, Firecel™ and MICC may be acceptable provided they meet
national standards / the system specification as applicable. Consult Clause 26 of BS 5839 Part 1 for more
detailed information on cables, wiring and other interconnections.
4.3 Testing of Field Wiring
Check the continuity of the loops (including screens), loop earth faults, loop crossover faults, the resistance of the
conventional sounder circuits and all other field wiring as appropriate to ensure they are free from faults.
Note: Only the continuity on the negative (-ve) line of the device loop can be tested to ensure it is fault free. Loop
isolators are in the positive (+ve) line, therefore continuity cannot be tested.
DO NOT test wiring with an insulation tester (Megger) with any electronic equipment connected as the
500V test will destroy these devices and invalidate the warranty.

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 12 of 60
5INSTALLATION
Note: See section 8.2 for a recommended shortform installation procedure.
5.1 Enclosure Description
The panel’s enclosure comprises of a hinged steel lid and a steel back box which houses a power supply unit
(PSU) and several printed circuit boards (PCBs) mounted on a metal chassis, as shown in Fig.2 below. Space
is available inside the back box for the backup batteries.
The panel can be surface or semi-flush wall mounted (a bezel is required for semi-flush mounting). The
standard ZBOXS, 1 to 4 loop version enclosure, is shown below.
Fig.2 –Location of Standard 1 to 4 Loop Version Components
Fig.2 key:
A
Lid Hinge Pins –2 off
G
PSU
B
Module (Part No. Z48) 40 zone, 5 switches, 10 LEDs
H
PCB Stepped Chassis
C
20-way heavy duty brass earth bar.
DO NOT operate equipment without connecting cable screens to this bar.
I
Main 1 or 2-Loop PCB
D
Control/Display Module (Part No. Z41) incorporates the touchscreen
J
2-Loop PCB adds two additional loops
(Part No. Z02LOOP/CA).
E
Lid Aperture
K
A-Bus PCB. Optional.
ZHN Network PCB. Optional.
F
Lid (requires Key No. 801)
L
Space for up to 2 x 12V, 17Ah batteries

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 13 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
5.2 Mounting Location
Each panel must wall mounted, indoors and positioned to avoid accidental damage, and MUST NOT be subjected
to excessive dust, conductive or corrosive gases or liquids, nor subject to temperatures, input voltages and electrical
loads outside the stated operating range. They should be sited at an easily accessible height and in a prominent
position within the building. The ambient light and sound levels should allow the indicators and touchscreen to be
clearlyvisible and the internal buzzer clearlyheard. Typical locations for the panel are in the entrance foyer / hallway
at ground floor level (the first and most obvious point of contact for emergency services) or in a permanently manned
security office.
5.3 Removing the Lid and PCB Chassis
To protect the panel’s electronic components from damage and also to expose the back box mounting holes,
the panel’s lid and PCB chassis should be removed prior to initial installation. Note: The PSU should not be
removed.
All removed panel components should be stored in a clean, dry place which is free from vibration, dust and
excessive heat.
Hint! Retaining the components in a suitable cardboard box will also guard them against mechanical
damage.
To remove the lid:
Use the supplied key to unlock the lid (key number 801).
Open the lid 180°to the left (do not overbend the hinges), then disconnect the lid’s earth strap.
By hand, or by using a screwdriver, push out the lid’s two plastic hinge pins (shown right)
and lift off the lid.
To remove the PCB chassis:
See ‘Anti-static handling guidelines’in section 1.3
Disconnect the earth strap from the PCB chassis. Remove the four retaining screws that secure the PCB
chassis in the back box and carefully remove the chassis to expose the PSU.
5.4 Planning the Cable Layout in the Panel and Removing Knockouts
Mains wiring should be segregated from extra low voltage field wiring. Leave sufficient tails
inside the panel to ensure straightforward connection of wiring to the panel’s terminals.
All cables should be fed into the panel through the knockouts provided in the back box.
Knockouts should be removed with a sharp, light tap using a 6mm flat-bladed screwdriver
as shown in the diagram (right). Ensure any swarf is removed from the enclosure.
Always ensure if a knockout is removed, the hole is filled with a good quality 20mm strain
relief, cable gland. Any unused knockouts must be securely blanked off.
5.5 Wall Mounting the Back Box
Note: The panel can be surface or semi-flush mounted on a wall (note optional bezels are available for semi-
flush mounting).
CAUTION: The enclosures are heavy! Therefore, use suitable screw fixings for wall mounting
the enclosures.
Securely fix the panel to a vertical wall, ≤2m mounting height, using the four (ø4.7mm) mounting holes
provided in the back box. The mounting holes are suitable for use with countersunk screws.
See Appendix 1 for enclosure fixing details.
Always assess the condition and construction of the wall and use suitable screw fixings for the in-service weight
of the product. Any dust or swarf created during the fixing process must be removed from the inside of the back
box. Ensure there is sufficient space to allow the lid to be fitted / removed when the panel is wall mounted.

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 14 of 60
5.6 Reinstalling the PCB Chassis and Lid
Refit the panel’s PCB chassis and lid by following the removal procedure (section 5.3) in reverse order.
Note: Connections to the panel’s PSU will have to be made before the chassis is refitted. See Connecting Mains
–section 5.16 and Connecting the Standby Batteries –section 5.17.
5.7 Inserting the ‘slide-in’ labels
A ‘slide in’ label system is employed by the CAST ZFP for customizing language
labels and description of zones / programmable LEDs. The label inserted for the
module’s control buttons depends on how the unit has been configured.
Insert the slide-in labels (supplied in the accessory pack) for the ancillary
modules), as shown right.
Important Note:
Before inserting the horizontal ‘Fire/Fault/Disablement/Test’ label in the Z41
Control/Display module, create a ‘slight’ bend (NOT A FOLD!) at the left-hand
side of the label (approx. 20mm). Gently push the label through the slot provided
into its housing using the hinge on the module’s rack to assist with finding its
path, as shown below.
5.8 Fitting the 2-Loop PCB (Optional)
An optional 2-Loop PCB (Part No. Z02LOOP/CA) provides two additional analogue loop connections (Loop3
& Loop4) if required. Note this PCB is not available for the 1 loop panel version.
With reference to the diagram below:
Take the 2-Loop PCB and carefully align its holes up
with the four mounting holes on the Main 2-Loop PCB.
Insert the four PCB ‘plug-on’ pillars (supplied with the
2-Loop PCB) through the holes on the 2-Loop PCB and
into the holes on the Main 2-Loop PCB. Push the pillars
until they click and lock in position.
Refer to section 5.10, Fig.4 for analogue loop
connections.

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 15 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
5.9 Analogue Addressable Loop Wiring
Fig.3 below shows a typical analogue addressable loop complete with detectors, manual call points, loop-powered
sounders and ancillary devices. Connect the loop to the relevant connector block on the panel’s Main 1 or 2-Loop
PCB (dependent on model) and terminate screens at the panel’s earth bar as shown in section 5.10, Fig.4.
Fig.3 –Typical Analogue Addressable Loop Overview
Design issues - reducing faults and their consequences
To ensure a reliable system, it should be designed and maintained to local design and installation regulations. The
CAST ZFP panel has a short circuit protected loop driver fitted and also short circuit isolators fitted in every
CAST loop device. A single short circuit or open circuit fault will have no detrimental effect on the operation of
the system.
Note a critical design issue with any analogue fire system is the combined effect of loop resistance, loop
capacitance and the current demand of loop devices. Factors that influence this include loop length, cable diameter,
cable type and the number/type of devices. There are no strict rules regarding these factors as every situation is
unique. However, if the following general rules of thumb are followed, the loop WILL almost certainly work.
Absolute maximum loop length = 1km using either 1mm2or 1.5mm2cable.
Maximum of 255 devices per loop (maximum of 512 detectors / call points per panel)
If sounders are used DO NOT fit more than the maximum circuit rating detailed in the technical
specification (see Appendix 6).
The above SHOULD NOT be considered the maximum operating conditions for the panel as many other
permutations are possible. Always refer to the supplied device instructions before installation.
Hint! ZFP Loop & Battery Calculator Tools are available for download on C-TEC’s website in the
Support Hub to assist with system designs (available @ www.c-tec.com).
Hint! Refer to www.c-tec.com for C-TEC’s
CAST range of compatible devices.

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 16 of 60
Important Note: Remember to isolate the panel’s mains and battery backup supplies before terminating wiring
at the panel.
5.10 Analogue Addressable Loop(s) Wiring
Two analogue loop connections (Loop1 & Loop2) are available on a Main 2-Loop PCB, as shown in Fig.4
below. One analogue loop connection (Loop1) is available on a Main 1-Loop PCB.
An optional 2-Loop PCB (not available for the 1 loop panel version) provides two additional analogue loop
connections (Loop3 & Loop4), if required (see section 5.8).
The maximum number of addressable detectors and call points per loop is 255 with a maximum of 512
devices per panel. This includes a maximum of 40 sounders per loop, or 30 sounder VADs per loop.
Plug-on 5mm connectors accept up to 2.5mm2cable.
The loop’s earth screens should be adequately insulated and ONLY terminated at the earth bar in the back box
to ensure earth continuity. Check for loop earth faults and loop crossover faults.
The back box earth bar is provided for terminating earth screens or drains and is NOT the panel’s
main earth point. The installer must review the external earth bonding (if required) with respect to
the national, regional or local wiring rules. If the installation requires protective earth bonding, then
this must be applied externally and in conjunction with the type of earth system employed on site.
Fig.4 –Analogue Addressable Loop Connections
Figure 4 key:
A
Analogue Loop 1 Cable (fire resistant).
D
Analogue Loop 1 Connector (A+, A-, B+, B-).
Plug-on connector type.
B
20-way heavy duty brass earth bar.
DO NOT operate the equipment without
connecting cable screens to this bar.
E
Additional Analogue Loop 2 Connector (A+, A-, B+, B-).
Plug-on connector type. Wiring not shown.
NOT APPLICABLE FOR A 1 LOOP PANEL.
C
Cable Earth Screens.
F
Main 2-Loop PCB.

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 17 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
5.11 Conventional Sounder Circuit(s) Wiring
Two conventional sounder circuits are provided on the Main 1 or 2-Loop PCB (dependent on model), each
circuit has a maximum rating of 1A. IF A FULL COMPLEMENT OF SOUNDERS ARE TO BE USED,
SPLIT THEM EQUALLY ACROSS BOTH CIRCUITS.
Each sounder circuit should be connected to the terminals marked SNDR1 & SNDR2 as shown in Fig.5 below
and its earth screens terminated at the back box earth bar. Plug-on 5mm connectors are provided that accept up
to 2.5mm2cable.
Note: ALWAYS make sure the two 6k8 EOL resistors (supplied) are fitted across the terminals of the last
sounder on each circuit to allow the wiring to be monitored for open and short circuit faults. If a sounder circuit
is unused, you must still connect the resistor at the panel terminals.
Fig.5 –Conventional Sounder Circuit Connections
Fig.5 key:
A –Sounder Circuit Cable (fire resistant)
B –Earth Bar for terminating cable screens
C –Cable Earth Screen
D –Sounder Circuit 1 Connector (0, +). Plug-on
connector type.
E–AdditionalSounderCircuit2Connector (0, +). Plug-
on connector type. Wiring not shown.
F –Main 2-Loop PCB
5.12 Auxiliary Input Wiring
Fig.6 –Auxiliary Input Connections Two programmable auxiliary input
connections are provided on the Main 1
or 2-Loop PCB (which are set up
standard as Class Change & Alert).
The wiring for each input should be
connected to the terminal block marked
IP/1 & IP/2 with a 470R 0.25W trigger
resistor (supplied) in each leg, as shown
in Fig.6, left.
If required, input wiring screens can be
terminated at the earth bar in the same
way as the analogue loop earth screens.
Note: ALWAYS make sure the two 6k8 EOL resistors (supplied) are fitted across the terminals of the last
device on each input to allow the wiring to be monitored for open and short circuit faults. If an input is unused,
you must still connect the resistor at the panel terminals.

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 18 of 60
5.13 24V Auxiliary Power Output
Fig.7 –24V Auxiliary Output Connections
One fused 24Vdc output, rated at 100mA, is provided on the Main 1 or 2-Loop
PCB and can be used for supplying power to ancillary fire alarm equipment, e.g.
relays. The output wiring should be connected to the terminal block marked
+24V, as shown in Fig.7 left.
5.14 Relay Output Wiring
Three volt-free relay output connections are provided on the Main 1 or 2-Loop PCB - a failsafe fault output*
which switches under any fault condition or total power failure and two programmable auxiliary relay outputs.
All three relays are capable of switching 1A @ 30Vdc.
DO NOT use these relays for switching mains voltages.
*In the event of total de-energisation of the fire panel the fault relay will change state.
Fig.8 –Relay Output Detail The two auxiliary outputs can be programmed using CAST ZFP
Programming Tools (Part No. ZTOOLS) to operate as required
but their default operations are:
RLY1: Switches when any zone goes into fire; switches back
when the panel is silenced.
RLY2: Switches when any zone goes into fire; switches back
when the panel is reset.
The wiring for each output should be connected to the relevant connector block on the Main 1 or 2-Loop PCB
(dependent on model), as shown in Fig.8 above.
5.15 Remote PC Connection
Fig.9 –PC Connection
A ‘galvanically - isolated’ USB connector
(CONN3) is provided on the Control/Display
Module PCB for the connection of a Windows
based PC, running programming software.
The recommended cable is a USB Type A male
connector to USB Type B male connector.
CAST ZFP Programming Tools (Part No.
ZTOOLS) are available that allow quick and easy
input of data, cause and effect programming,
device and zone naming.

CAST ZFP Analogue Addressable Fire Alarm Panel
Page 19 of 60 Approved Document No. DFU5030000 Rev 4 Installation and Programming Manual
5.16 Connecting Mains to the Panel’s PSU
THE PSU IS CLASS 1EQUIPMENT AND MUST BE EARTHED.
The panel’s EN 54-4 PSU is a mains to regulated DC power supply providing 5A @ 24Vdc nominal. Combining
the functions of a PSU, battery charging unit and battery monitoring unit, it is fullycompliant withEN 54-4:1997
+ A1:2002 + A2:2006. For compliance with EN 54-4 the PSU must be closely coupled with the CIE.
Remove the protective cover of the PSU and terminate the mains cable at the power supply’s PCB connector
block CONN1 (see Fig.10 below). After terminating, refit and secure the cover.
DO NOT CONNECT MAINS SUPPLY TO THE PSU UNTIL THE INSTALLATION IS COMPLETE
AND THE PANEL IS READY TO BE TESTED.
Fig.10 –5A PSU Layout and Mains Connection Details
Fig.10 key:
A
Mains Cable
Must be fire resistant, segregated from extra low voltage cables and only
enter the panel through the top knockouts.
H
Battery Fuse (F2)
B
Mains Connector (CONN1)
L=Live, N=Neutral, =Earth. Terminate mains cable to this connector.
I
Supply Output (CONN3)
C
Earth Distribution Tag
DO NOT operate the PSU without first connecting this strap to the base
earth distribution post
J
Battery Connector (CONN7)
D
Mains Fuse (F1) Exposed live parts under fuse cover. Isolate before removal.
K
DIP Switches 1, 2, 3, 4 (SW1)
OFF (Down) = Defaults
E
Cable Cover
Exposed live parts under cable cover. Isolate first, then remove the small
cover by loosening its single retaining screw which is retained in the cover.
Only operate the PSU with this cover securely fitted
L
Cat 5 Connector (PL1)
Connects to PL10 on Main 1 or 2-Loop PCB
F
Display & Data Connector (PL2)
M
Battery Charge Inhibit (CONN6)
Configurable Input/Output (CONN6)
G
Hazardous Voltage Present LED
When lit red, hazardous voltages are present on the components
and copper under the PSU’s cover. Allow to discharge for at
least 5 minutes before removal & handling. DO NOT TOUCH
UNTIL EXTINGUISHED!
N
Fault Relay (CONN4)

CAST ZFP Analogue Addressable Fire Alarm Panel
Installation and Programming Manual Approved Document No. DFU5030000 Rev 4 Page 20 of 60
5.17 Connecting the Standby Batteries
CAUTION: There is a risk of explosion if an incorrect battery type is used. Always dispose of
used batteries in accordance with the battery manufacturers’instructions.
Do not make the final battery connections until the installation wiring is complete and the
panel is ready to be tested. One method of isolating battery power is to disconnect the battery
link wire.
Two new, good quality and fully charged 12V valve regulated lead acid (VRLA) batteries are required as the
emergency standby power supply for the panel.
The batteries should be connected in series and located in the bottom of the panel’s enclosure, as shown in Fig.11
below. Connect the ‘Red’ (+ve) and ‘Black’ (-ve) battery wires from the battery terminals to connector block
CONN7 on the power supply’s PCB. The (red and black) battery wires, (green) link wire and nylon cable ties are
supplied in the panel’s accessory pack. Secure the batteries into position using the cable ties.
The panel’s sophisticated battery monitoring unit protects the batteries against deep discharge by activating a
cut off circuit when the standby supply voltage reaches 21V approx. If batteries are not fitted, are discharged
or in poor condition, a PSU fault will show at the panel.
The capacity of the batteries used will depend upon the required standby time. To calculate the batteries
required for any given standby period, see the battery calculation guide in Appendix 5.
Fig.11 –Battery Connection Details
CAUTION! Inferior and New Batteries stored over 6 months.
The panel’s PSU is an EN 54-4/A2 power supply and as such measures
accurately the internal battery resistance down to a fraction of an ohm.
The fault threshold is a function of EN 54-4 and as such cannot be
changed, otherwise, it would NOT be a certifiable power supply.
Batteries stored for long periods of time before use (especially new
ones!), suffer a progressive degradation of internal resistance the
longer they are kept off charge after manufacture. Contrary to popular
opinion they DO NOT recover this degradation once re-charged. In
order for the battery to recover it MUST be discharged and charged
several times (more than once), each time you will see a reduction in
the internal resistance.
Therefore, if you install one of these batteries AND it shows a fault
AND you just leave it AND expect the fault to go away, it will not! In
this instance it is not the charger at fault, it is the battery.