JOHNSON SYSTEMS J-PACK Series User manual

User Manual
J-PACK Series
Hi-Power Relay Pack
JOHNSON SYSTEMS INC.
WWW.JOHNSONSYSTEMS.COM

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Warranty
J-PACK Series relay packs come with a standard two (2) year limited
warranty. Extended warranties of up to ten (10) years are available at the
time of purchase.
For details visit: www.johnsonsystems.com/warranties.htm
For Technical Assistance
1. Refer to your product user manual. The most current revision is
available online: www.johnsonsystems.com/literature.htm
2. Contact the “point-of-sale” dealer or distributor from which this product
was originally purchased, and ask for technical assistance.
3. If neither of the above can provide you with the necessary information,
please contact our factory via email ([email protected])
or phone [phone]) during business hours (Monday to Friday,
8:00AM to 5:00PM MST).
Contents
Warranty ..........................................................................................................2
Introduction......................................................................................................3
Characteristics.................................................................................................4
Installation .......................................................................................................6
Mounting Options ............................................................................................6
AC Power Supply Input Options......................................................................8
Output Connector/Receptacle Options..........................................................10
Output Connector/Receptacle Diagrams.......................................................13
Control Input..................................................................................................14
DRD-6 Controller...........................................................................................15
DRD Relay PDB ............................................................................................15
User Interface................................................................................................16
System Status • LED Indicators ...................................................................17
System Status • LCD Display ........................................................................18
Quick Programming Reference to System Conguration Menu Items..........19
Detailed Programming of System Conguration Menu Items............... 20
Important Hard-key Information.....................................................................28
J-Pack Relay Pack (RP) Ordering Information..............................................29

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Introduction
J-PACK Relay Packs are a universal hi-power series of 3 and 6 channel relay
packs rated at a full 20 Amps per circuit. Designed for dry contact and/or DMX
power control of LED xtures, distributed commercial uorescent installations or
any environment where fast, precise hi-power control is demanded. J-PACK's
offer versatility in virtually any environment; these commercial grade units
include 120, 208, 240, and 277 volt models. These unique and compact units
can be wall-mounted for permanent installations, 19" rack mounted, pipe
mounted or used as portable units. Multiple units can be easily “ganged”
together for fast system expansion. Long distance communication via DMX512
protocol lowers electrical installation costs and allows for centralized control.
Next generation “system-on-a-chip” technology provides unsurpassed value in
professional grade hi-power switching. Standby power consumption of less than
1 Watt, allows for compliance with the International Energy Agency’s “One Watt
Initiative” for standby power consumption. This makes J-PACK’s truly “green”
with minimal possible impact on the environment!
All circuits contain fully isolated output power relays rated to 50 Amps! Self-
contained units with premium UL489 rated hydraulic magnetic circuit breakers
provide optimum safety while eliminating the need for separate branch circuit
breakers and relay panels. Intuitive LCD user interface combined analog
inputs and contact closure inputs allow for industry wide application. This next-
generation product helps save our environment as well as time and money.
Features
• Power control via dry contact or DMX512 lighting control protocol.
• Designed for LED xture power switching.
• Unique power saving standby mode reduces power consumption to less
than 1 Watt, a “green” power management product.
• Heavy-duty “airgap” output relays rated to 50 Amps!
• DMX512 start addressable in single channel (offset) or individually (patch).
• Programmable DMX Status Hold timeout.
• Dual auxiliary contact inputs permits power management interface with
BMS, photocells, occupancy sensors, HVAC, security and audio.
• Dry contact activated relay sequencing for special effects.
• LCD user interface for easy setup and monitoring.
• Keypad lockout prevents unauthorized access.
• Over-heat and over-current protected.
• Available in various voltages, output and mounting congurations.
• ETL Listed, compliance with UL508 and CSA 22.2.
• Up to 10 year product warranty available.
J-PACK Series
Hi-Power Relay Pack

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Front View
User Interface
Refer to page 16 for details
Circuit Breakers
Control Input
XLR Connectors
Refer to
page 14 for details
Characteristics
• Power Termination & Maximum Feeder Capacity:
RP-120-ED-*XX 6 circuits totaling 1,800W
RP-120HO-ED-*XX 6 circuits totaling 3,600W
RP-120/240-SP-XX 6 circuits totaling 14,400W
RP-120/240-TL-XX 6 circuits totaling 14,400W
RP-120/240-SO-XX 6 circuits totaling 14,400W
RP-120/240-TB-XX 6 circuits totaling 14,400W
RP-120/208-SP-XX 6 circuits totaling 14,400W
RP-120/208-TL-XX 6 circuits totaling 14,400W
RP-120/208-SO-XX 6 circuits totaling 14,400W
RP-120/208-TB-XX 6 circuits totaling 14,400W
RP-120/208-TL208-XX 3 circuits totaling 12,480W
RP-120/208-SO208-XX 3 circuits totaling 12,480W
RP-120/208-TB208-XX 3 circuits totaling 12,480W
RP-120/240-TL240-XX 3 circuits totaling 14,400W
RP-120/240-SO240-XX 3 circuits totaling 14,400W
RP-120/240-TB240-XX 3 circuits totaling 14,400W
RP-277/480-TB277-WM 3 circuits totaling 16,620W
* Not available in wall mount (WM)
• Environment
• Temperature Range: 23°F (-5°C) to 104°F (40°C) ambient.
• Humidity Range: 0% to 90% non-condensing.
• Load Type:
• Six 120V single phase 50/60 Hz circuits for AC Loads Only.
• Rated for 20A General Purpose and 20A Tungsten.
• Switch Type: “Airgap” power relay rated 1 million operations minimum at 50 Amps 240VAC.
• Isolation: 4,000 Volts minimum per circuit.
• Physical: 10" x 17" x 3.4" (25.4 cm x 43 cm x 8.5 cm).
• Weight: 12 - 13 lbs. (5.5 - 6.0 Kg) depending on model.
• Material: 18-gauge steel CRS.
• Finish: Hammer texture black powder coat.

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Rubber Feet
(For RF model only)
Left Side View
Right Side View
Top View
Air Intake Fan
Handle
Four (4) Safety Cable Mounting Holes
(For PM model only)
Four (4) Indents
(For vertical stacking)
Air
Exhaust
Air
Intake
Ten (10) SEMS #6-32 x 3/8" Philips Pan Head, Top Panel (Lid) Mounting Screws
Six (6) #6-32 x 3/8" Philips Flat Head, Top Panel (Lid) Mounting Screws
Four (4) SEMS #6-32 x 3/8" Philips Pan Head, Rack Mount Bracket Mounting Screws
Air Exhaust
Ventilation
Safety Cable supplied
on PM model

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Installation
J-Pack Series relay packs are intended for indoor use only, in a controlled environment at a room
temperature.
• Mount in a suitable location.
Refer to the Mounting Options section on page 6 for applicable details.
• Connect the applicable AC power supply input.
Refer to the AC Power Supply Input Options section on page 8 for applicable details.
• Connect the relay output receptacles/terminals.
Refer to the Relay Output Connection Options section on page 10 for applicable details.
• Connect DMX and/or dry contact control input(s).
Refer to the Control Input section on page 14 for details.
• Program, setup, test and verify functionality.
Refer to the Detailed Programming of System Conguration Menu Items section on page
20 for details.
WARNING: For indoor use only!
Mounting Options
J-PACK Series relay packs are capable of various mounting options to suit the application required.
A cooling fan mounted inside the relay pack is used to move air through the chassis and cool the
internal components. The fan automatically turns on whenever a relay is on and automatically turns
off when all relays are off. There is a 5 minute timeout for the fan to turn off to ensure the internal
components are cooled sufciently. It is important to mount the dimmer pack in the orientation
intended with unobstructed ventilation to ensure adequate cooling.
RF = Rubber Feet
For portable applications, the relay pack can be
set on any at surface. Rubber feet are mounted
on the bottom of the relay pack, with indents on
the top cover panel to facilitate vertical stacking
of up to 6 units high.
WARNING: Never place the relay packs side
by side (horizontally) without
a minimum of 12” of clearance
between them. Always leave a
minimum of 6” of clearance from
the relay packs air intake and
exhaust. Failure to comply may
cause thermal overheating.

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PM = Pipe Mount
For pipe mounting, a bracket, C-clamp and safety cable
are provided and must be used to secure the relay pack to
standard pipe sizes from 1" to 2" (1.25" to 2.375" outside
diameter).
WARNING: Ensure the pipe is secure and rated
adequately for local rigging codes.
Ensure the safety cable is fastened correctly
to secure the relay pack.
WM = Wall Mount
For permanent applications, the relay pack can be
mounted to any wall surface capable of supporting its
weight. Using the four (4) mounting holes provided, 1/4"
(6mm) screws or bolts are required to fasten and secure
the rack safely to the wall.
WARNING: Never place the relay packs side by side
(vertically) without a minimum of 12” of
clearance between them. Always leave a
minimum of 6” of clearance from the relay
packs air intake and exhaust. Failure to
comply may cause thermal overheating.
RM = Rack Mount
For rack mounting, brackets are provided and used to
secure the relay pack in a standard 19" rack.
WARNING: Ensure there is sufcient ventilation
provided when mounting multiple relay
packs within a 19" rack. The internal
ambient temperature of the rack must not
exceed 104°F (40°C). Failure to comply may
cause thermal overheating.
WARNING: Ensure there is adequate rear support
provided to maintain the relay pack position
inside the 19" rack.

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AC Power Supply Input Options
J-PACK Series relay packs are capable of various AC power supply input
congurations.
Remove the top panel (lid) of the relay pack chassis to access the contractor
termination area, where the required AC power supply input terminals are
located. To remove the top panel (lid), remove the ten (10) SEMS #6-32 x 3/8"
Philips pan head mountings screws located on the sides and the six (6) #6-32
x 3/8" Philips at head mounting screws located on the top, using a Philips
#2 screwdriver, and carefully lift the lid up. The cooling fan is mounted on the
lid, so be careful not to strain the fan wiring cable. If the fan cable needs to
be disconnected, carefully cut off the strain relief wire tie and unplug the fan
connector from the J5 PCB connector. Be sure to save the mounting screws to
secure the top panel (lid) once the AC power supply input wiring termination is
complete.
A 1.109" knockout (suitable for 0.75" conduit) located on the rear panel of the
relay pack chassis is provided for wire/conduit entry to the AC power supply
input terminals. Ensure an adequate tting is used to secure the conduit to the
rear panel. Only use wire rated for the specications provided. Route the wire
directly from the conduit entry into the power terminals. Use a 3/16" athead
screwdriver to torque the power terminals to the specications provided.
Once the AC power supply input wiring termination is complete, carefully
reinstall the top panel (lid). If the cooling fan cable was disconnected, be sure
to reconnect it to the J5 PCB connector, and install a wire tie for strain relief.
Carefully slide the lid down into place, making sure the fan cable does not get
pinched in the metalwork. Secure the lid using the mounting screws previously
removed. To ensure ground continuity between all chassis panels, be sure to
use the SEMS mounting screws with integral star washers on the sides.
WARNING: All wiring must comply with local electrical codes and be
completed by qualied personnel only!
WARNING: For connection use copper wire only, rated for 167ºF (75ºC)
minimum!
WARNING: All AC power supply input options require an external disconnect!
WARNING: Ensure the AC power supply external disconnect is turned off and
locked out while wiring terminations are completed!
WARNING: For permanent installations, the external disconnect must be
located adjacent to the equipment.
AVERTISSMENT: Pour les installations permanentes, le débrancher externe
doit être trouvé adjacent à l'équipement.
AC Power Supply
Input Terminals

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120 = 120VAC 1Ø 3-Wire via a Single 5' Edison Power Cord
Includes a single factory installed 5' (1.5m) Edison power cord. Connect the
cables to a standard Edison (NEMA 5-15) receptacle, protected with a circuit
breaker rated at a maximum of 15 Amps.
• Up to 15 Amps – maximum 1,800W total.
• Internal electrical wiring termination is not required.
• Available only with Duplex Edison output connectors/receptacles.
120 = 120VAC 1Ø 3-Wire via Dual 5' Edison Power Cord
Includes two (2) factory installed 5' (1.5m) Edison power cords. Connect the
cables to standard Edison (NEMA 5-15) receptacles, each protected with a
circuit breaker rated at a maximum of 15 Amps.
• 2 circuits of up to 15 Amps – maximum 3,600W total.
• Internal electrical wiring termination is not required.
• Relays 1, 3 and 5 are powered from a single power cord.
• Relays 2, 4 and 6 are powered from a single power cord.
• Available only with Duplex Edison (NEMA 5-15) output connectors/
receptacles.
120/240 = 120/240VAC 1Ø 4-Wire Terminal Block
• Up to 60 Amps per phase – maximum 14,400W total.
• Use wire size #12 to #4 AWG copper wire only, rated for 300V and
167°F (75°C) minimum.
• Strip insulation length to 0.44" (11mm).
• Torque power terminals (A, B, N, ) to 10.5 IN-LBS (1.2 NM).
• Relays 1, 3 and 5 are powered from Phase A.
• Relays 2, 4 and 6 are powered from Phase B.
120/240 = 120/240VAC 1Ø 3-Wire Terminal Block
• Applicable for 240VAC output models only.
• Up to 60 Amps per phase – maximum 14,400W total.
• Use wire size #12 to #4 AWG copper wire only, rated for 300V and
167°F (75°C) minimum.
• Strip insulation length to 0.44" (11mm).
• Torque power terminals (A, B, ) to 10.5 IN-LBS (1.2 NM).
• Relays 1, 3 and 5 are powered from Phase A.
• Relays 2, 4 and 6 are powered from Phase B.
120/208 = 120/208VAC 3Ø 5-Wire Terminal Block
• Up to 40 Amps per phase – maximum 14,400W total.
• Use wire size #12 to #4 AWG copper wire only, rated for 300V and
167°F (75°C) minimum.
• Strip insulation length to 0.44" (11mm).
• Torque power terminals (A, B, C, N, ) to 10.5 IN-LBS (1.2 NM).
• Relays 1 and 4 are powered from Phase A.
• Relays 2 and 5 are powered from Phase B.
• Relays 3 and 6 are powered from Phase C.

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120/208 = 120/208VAC 3Ø 4-Wire Terminal Block
• Applicable for 208VAC output models only.
• Up to 40 Amps per phase – maximum 12,480W total.
• Use wire size #12 to #4 AWG copper wire only, rated for 300V
and 167°F (75°C) minimum.
• Strip insulation length to 0.44" (11mm).
• Torque power terminals (A, B, C, ) to 10.5 IN-LBS (1.2 NM).
• Relays 1 and 4 are powered from Phase A.
• Relays 2 and 5 are powered from Phase B.
• Relays 3 and 6 are powered from Phase C.
277/480 = 277/480VAC 3Ø 5-Wire Terminal Block
• Up to 20 Amps per phase – maximum 16,620W total.
• Use wire size #12 to #4 AWG copper wire only, rated for 300V
and 167°F (75°C) minimum.
• Strip insulation length to 0.44" (11mm).
• Torque power terminals (A, B, C, N, ) to 10.5 IN-LBS (1.2 NM).
• Relay 1 is powered from Phase A.
• Relay 2 is powered from Phase B.
• Relay 3 is powered from Phase C.
WARNING: Ensure all AC power supply connections are tightened to the torque specication
provided, before turning on the AC power supply!
WARNING: Ensure all chassis panels are secure before turning on the AC power supply!
Output Connector/Receptacle Options
J-PACK Series relay packs are designed for high performance switching for general purpose and
tungsten loads at 120VAC, 208VAC, 240VAC or 277VAC.
120VAC Operation with Factory Installed Single or Dual Edison Power Cord
Capable of switching six (6) 1,800 Watt relay output circuits, fully protected by premium 15 Amp
hydraulic magnetic circuit breakers. Powered with 120VAC 1Ø 3-Wire, each hot leg is switched
independently through six (6) relays, providing 120VAC on each of the output connectors.
J-PACK Series relay packs supplied with a factory installed single (1) Edison power cord are
capable of switching a total of 1,800 Watts shared between the six (6) Duplex Edison output
connectors. J-PACK Series relay packs supplied with factory installed dual (2) Edison power
cords are capable of switching a total of 3,600 Watts shared between the six (6) Duplex Edison
output receptacles.
120VAC Output Receptacle with Factory Installed Single or Dual Edison Power Cord
• ED = 15A Duplex Edison (NEMA 5-15)
120VAC Operation
Capable of switching six (6) 2,400 Watt relay output circuits, fully protected by premium 20 Amp
hydraulic magnetic circuit breakers. Powered with 120/240VAC 1Ø 4-Wire or 120/208VAC 3Ø
5-Wire, each hot leg is switched independently through a relay, providing 120VAC on each of the
output connectors/receptacles.