Leviton EZ-MAX PLUS series User manual

Installation Guide
EZ-MAX PLUSTM RELAY PANELS
Covering EZ-MAX Plus 8, 16 & 24 Relay Panels
So tware Revision 1.0 and above.

i
Table of Contents
Read this efore You egin!
Sa ety Precautions!................................................................................................ 1
Warnings!............................................................................................................. 1
Overview
Introduction.......................................................................................................... 3
Product Speci ications and Capabilities.................................................................... 4
Installation Overview ............................................................................................. 5
Installation Checklist.............................................................................................. 6
Relay Cabinet Mounting
Selection o a Mounting Location ............................................................................ 7
Suggested Mounting Heights............................................................................. 7
Environmental Considerations ........................................................................... 7
Pre erred Areas or Conduit Entry ........................................................................... 8
Sample Electrical Room Layouts ............................................................................. 9
Mounting Provisions and Dimensions .....................................................................10
Line Voltage and Control Power Termination
Overview o Power Wiring - Feed\Line Wiring .........................................................15
Line and Load Circuit Wiring..................................................................................17
Testing the Circuits..........................................................................................17
Installing Relay Cards ......................................................................................17
Wiring the Relays ............................................................................................18
Wiring Diagrams..............................................................................................19
Control Electronics Power Wiring ...........................................................................21
Low Voltage Control Wiring
Control Overview..................................................................................................25
Input Trigger-What Determines an “ON” ...........................................................26
Low Voltage Switches
Connecting to a Low Voltage Input ...................................................................30
Occupancy Sensors
Occupancy Sensor Wiring......................................................................................33
Photocells
Photocell Wiring ...................................................................................................35

ii
Luma-Net III
Wiring Speci ications ............................................................................................39
Wiring the Phoenix Connector ..........................................................................40
Emergency
Inputs and Outputs ..............................................................................................45
Terminal Locations ...............................................................................................46
Appendix A
Power-Up and Installation Veri ication Checklist.................................................... A-1
Appendix
Power Considerations or Control Systems............................................................ B-1
Terminology ................................................................................................. B-1
Power Requirements and Maximum Run Length .............................................. B-2
Power Wire - Run Length............................................................................... B-4

EZ-MAX Plus Installation Guide
Page 1
Read this efore You egin!
Safety Precautions!
Read and ollow all sa ety instructions.
Apply the “Emergency Circuits” label (provided) to the ront o the
door.
When using electrical equipment, basic sa ety precautions should
always be ollowed.
Do not use outdoors.
Do not mount near gas or electric heaters.
Equipment should be mounted in locations and at heights where it
will not readily be subjected to tampering by authorized personnel.
The use o accessory equipment not recommended by manu acturer
may cause an unsa e condition.
Do not use this equipment or other than intended use.
All servicing shall be per ormed by quali ied service personnel.
SAVE THESE INSTRUCTIONS!
Leviton Service and Support:
www.leviton.com 1-800-959-6004
Warnings!
Conduit Entry Locations: The cabinets have been designed with
speci ic locations supporting conduit entry or line and low voltage
circuits. There are speci ic areas o the cabinet that are restricted
rom some or all types o conduit access. See the Installation
sections o this manual or speci ic details.
Line and load circuit wiring: The line wiring should come rom an
over-current device and the load circuit wiring should go to the
speci ic load to be controlled. On some models that have
integrated branch circuit protection, the line side o the relay has
been pre-wired to a circuit breaker. Only the load side o the circuits
needs to be connected with these products.
To be installed and/or used in accordance with appropriate electrical
codes and regulations.
To be installed by a quali ied Electrician.
DO NOT CONNECT line voltage wires to low voltage terminals.
Mount in a location where audible noise is acceptable.
When using with luorescent ballasts, both lighting ixture and
ballast must be grounded.

Read this Be ore You Begin! Warnings!
Page 2
Use this relay cabinet only with minimum 75o C copper wire at 75%
ampacity.
Disconnect power when servicing the relay cabinet, ixture or when
changing lamps.
Indoor use only.
TO AVOID FIRE, SHOCK OR DEATH: TURN OFF POWER AT MAIN
CIRCUIT BREAKER, OR FUSE, AND TEST THAT THE POWER IS OFF
BEFORE WIRING, OPENING THE PANEL, OR REPLACING ANY
COMPONENT!
During operation, cabinet cover is to be removed by quali ied
personnel ONLY! Heed all caution markings indicating the presence
o High Voltage. High voltage may be up to 600V.
Test each circuit or short circuits be ore connecting it to relay so
damage to the relay and it’s electronics can be avoided.
Veri y that all un-used power supply leads are insulated with wire
nuts.

EZ-MAX Plus Installation Guide Page 3
Overview
Introduction
Thank you or choosing Leviton’s EZ-MAX Plus line o products or your relay needs.
The EZ-MAX Plus product line o ers a scalable solution o relay and relay controls that
can it any application with 2 or 3-circuit needs with time clock control.
This manual is designed to assist you in the installation o your product. It includes
guidelines, requirements, and instructions that are required only or the installation
and low voltage termination o your product. The ollowing resources are also
available to you:
•Quick Start Programming Guide (included with every panel)
•Programming Guide (included with every panel)
•Additional resources located at our website at http://www.leviton.com/lms
A hard copy o the Programming Guide is included with your system purchase. Please
contact Leviton Technical Support at [phone] to request additional copies.
This manual covers all products in the EZ-MAX Plus product line, however, the steps
shown are somewhat generic in nature. The particular requirements or your product,
especially as related to termination, may di er slightly rom the steps in this manual.
Please review all markings and labels on your product to ensure that your actions are
correct.
Leviton recommends always checking our website
at http://www.leviton.com/lms or late breaking
notes, requirements, application in ormation, and
irmware updates.

Overview Product Speci ications and Capabilities
Page 4
Product Specifications and Capabilities
The table below gives a general overview o the speci ications o all EZ-Max Plus relay
products. The table uses the ollowing abbreviations:
Y = Yes
N = No
O = Optional
* = A single asterisk in any column indicates that there is support or this eature,
however, there are conditions that you should be aware o . Consult the speci ic
sections o the manual dealing with this eature or additional in ormation and
requirements.
Figure 1: EZ-MAX Plus Product Capabilities Chart
EZ-Max Plus
Product Type
Min-Max Relays Relay Types Weight (lbs (Kg))
Size
W", H", D"
(Wcm,Hcm,Dcm)
Flush Mount Option # discrete Inputs Sw. Input oard Avail. Luma-Net Network Emergency Input Emergency Output Touch-Tone Phone Data Modem Front Panel Program Event Scheduler
Master Panel, 8 relays* 0-8 ** 16
(7.26)
13" x 13" x 4-9/32"
(33 x 33 x 10.9)
Y 8 N Y Y Y O* O* Y Y
Master Panel, 16 relays* 0-16 ** 44
(19.96)
20-1/4"x34"x4-9/32"
(54.4 x 86.4 x 10.9)
Y 12 Y Y Y Y O* O* Y Y
Master Panel, 24 relays* 0-24 ** 44
(19.96)
20-1/4"x34"x4-9/32"
(54.4 x 86.4 x 10.9)
Y 12 Y Y Y Y O* O* Y Y
Note: Voltage:120v/277v/347 @20A, 240v @20/30A
** Relay Types: 30A Latching, 2-Pole, 1-Pole (optional)

EZ-MAX Plus Installation Guide Page 5
Inspection
Care ully unpack the relay cabinet, and inspect to make sure there is no hidden
shipping damage. Report any damage to the reight carrier who delivered the system.
Claims or damages are iled with the reight carrier.
In case o damaged components, your relay cabinet may be serviced in the ield with
actory replacement parts.
Installation Overview
Follow the steps below to install a remote relay cabinet:
Step 1: Mount the relay cabinet to the wall, install conduit, and pull all wire
(See “Relay Cabinet Mounting” on page 7.).
Step 2: Terminate line voltage wiring (See “Line Voltage and Control Power
Termination” on page 15.).
Step 3: Terminate any low voltage discrete input wiring (See “Low Voltage” on
page 23.).
Step 4: Terminate any network wiring (See “Wiring the Phoenix Connector” on
page 40.).
Step 5: Inspect your work (REQUIRED FOR ALL CABINETS) (See “Power-Up
and Installation Veri ication Checklist” on page 1.).
Step 6: Power-up and test the system.
Step 7: Install latest so tware/ irmware rom Leviton website,
www.leviton.com/lms.
Step 8: Per orm all necessary con iguration. (See the EZ-MAX Plus
Programming Guide)
Each o the above steps is covered in detail throughout the rest o this installation
guide. Each section contains notes, warnings, requirements, suggestions, and
procedures that will help you success ully install and use your system.

Overview Installation Checklist
Page 6
Installation
Installation Checklist
Follow these simple steps to install the cabinet:
Step 1: Unpack the system.
Step 2: Report any damage to the reight carrier.
Step 3: I appropriate, remove any covers and/or doors.
Step 4: I appropriate, remove the mounting plate assembly and store where
damage will not occur to the electronics.
Step 5: Attach the cabinet to the wall (re erence stickers inside the cabinet or
proper orientation i it is in question).
Step 6: Drill conduit entry holes i KO’s are not provided and attach conduit
where appropriate.
Step 7: Pull all wire into the cabinet.
Step 8: Test and veri y all wiring by directly connecting line to load. Correct any
aults and re-test wiring be ore you proceed.
Step 9: I applicable, re-install any control electronics removed in Step #4.
Step 10: Terminate discrete input control wiring.
Step 11: Terminate network control wiring.
Step 12: Test each Line/Load circuit or shorts.
Step 13: Terminate the eed and load wiring to each relay.
Step 14: Blow out dust, dirt, or debris which has accumulated in the cabinet.
Step 15: Apply power to the system.
Step 16: Veri y proper operation o each relay using the override buttons.
Step 17: Con igure cabinet per owner’s requirements.

EZ-MAX Plus Installation Guide Page 7
Relay Cabinet Mounting
There are several steps required when mounting your relay cabinet:
Step 1: Install the lush mounting kit i appropriate.
Step 2: Plan your conduit runs and electrical room layout.
Step 3: Determine the appropriate methods or mounting your cabinet to the
wall.
Step 4: Mount the cabinet to the wall.
Step 5: Install conduit, pull wire, and other items as required.
Step 6: Proceed to “Line Voltage and Control Power Termination” on page 15.
Selection of a Mounting Location
Choosing a mounting location or your cabinet is critical to the overall success and
ease o installation. Each style o cabinet has its own unique wiring requirements
which must be observed. Please review the next ew pages, which describe and
illustrate these requirements.
Suggested Mounting Heights
Although success ul operation is completely independent o mounting height, the
suggested mounting heights below were selected to locate the cabinet at a
reasonable and accessible working height.
Environmental Considerations
•Cabinets generate heat (see table below). Make sure they are mounted in a
climate controlled space where the temperature will be 0-40o C (32-104oF) or
20-30o C (68-86oF) i used as Emergency Lighting Power Equipment.
•Rein orce the wall or strength as required or weight and local code.
•Clearance on le t and right side o the panel should be maintained at 1 1/2" or
greater.
•Relays will click while in operation. Locate the panels where audible noise is
acceptable.
Cabinet Suggested Mounting height to bottom o cabinet
8-Relay Cabinet 53" (1,359 mm)
16/24-Relay Cabinet 32" (826 mm)
Cabinet MAX BTU/HR
8-Relay Cabinet 583
16/24 Relay Cabinet 583

Relay Cabinet Mounting Pre erred Areas or Conduit Entry
Page 8
Preferred Areas for Conduit Entry
Your relay cabinet has been designed or easy installation, with a variety o installation
options. Please pay close attention to the “allowed” and disallowed” areas or conduit
entry. Disallowed areas are areas where conduit entry is impossible due to physical
limitations or code limitations. These areas are clearly marked in the illustrations that
ollow. Each cabinet style has designated areas or low voltage and line voltage
conduit entry. You must adhere to these requirements to ensure a success ul
installation and continued code compliance.
Figure 2: 24-Relay Cabinet Conduit Entry
Transformer and
Grounding
Points
High Voltage Pass
Through below
control module
mounting plate
Transformer Connections
located directly below
Control Module
Low Voltage Area
High Voltage Area

EZ-MAX Plus Installation Guide Page 9
Sample Electrical Room Layouts
The "right" layout or your application is a decision only you can make. The layouts
depicted in the ollowing illustrations show some simple and e ective systems which
you’re welcome to use and adapt to your particular installation.
Figure 3: Sample Electrical Room Layouts for all cabinets
Front View
Wiring Raceway
Class 2/PELV
Wiring to
Controls -
2 locations
Feed and/or
switch legs
to loads
Feed and/or
switch legs
to loads
Feed wiring to relays
W
A
L
L
Side View
Distribution panel
Top and Bottom Feed
and /or switch legs to loads
Surface Mounting Shown
front3

Relay Cabinet Mounting Mounting Provisions and Dimensions
Page 10
Mounting Provisions and Dimensions
Figure 4: EZ-Max Plus 8 Cabinet mounting provisions and dimensions.
3/4
[19.05]
11
279.4
27/32
[21.5]
10 3/64
[255.14]
19/32
[15.28]
8 3/4
[222.25]
3 1/2
[88.9]
11 21/32
[295.87]
19/32
15.28
13
[330.2]
4
[101.6]
SIDE VIEW
13
[330.2]
TOP VIEW
BOTTOM VIEW
(9/32)
[7.05]
(4 9/32)
[108.65]
SIDE VIEW
with door
All Dimensions are in inches
[ ] are mm
LINE / LOAD
CONDUIT ENTRY
LOW VOLTAGE
CONDUIT ENTRY
1" & 1-1/4"
LINE / LOAD
CONDUIT ENTRY
1-1/4" & 1-1/2"
4 PLACES
LINE / LOAD
CONDUIT
ENTRY
LOW VOLTAGE
CONDUIT ENTRY
1" & 1-1/4"
4 PLACES

EZ-MAX Plus Installation Guide Page 11
Figure 5: EZ-MAX Plus 16/24 relay cabinet mounting provisions and
dimensions.
20 1/4
[514.35]
34
[863.6]
4
[101.6]
14 11/64
[359.83]
16 5/8
[422.4]
16 5/8
[422.4]
14 11/64
[359.83]
16
[406.4]
1 27/32
[46.8]
16
[406.4]
1 27/32
[46.8]
All Dimensions are in inches
[ ] are mm
LOW
VOLTAGE
CONDUIT
ENTRY
1-1/4" & 1-1/2"
6 PLACES
LINE / LOAD
CONDUIT
ENTRY
1" & 1-1/4"
6 PLACES
LOW VOLTAGE
CONDUIT ENTRY
1" & 1-1/4"
6 PLACES
LINE / LOAD
CONDUIT ENTRY
1" & 1-1/4", 2
PLACES PLUS
1-1/4" & 1-1/2", 3
PLACES
LINE / LOAD
CONDUIT ENTRY
1" & 1-1/4", 2
PLACES PLUS
1-1/4" & 1-1/2", 3
PLACES
LINE / LOAD
CONDUIT
ENTRY
1" & 1-1/4"
6 PLACES
LINE / LOAD CONDUIT ENTRY: 1" &
1-1/4", 4 PLACES PLUS 1-1/4" & 1-
1/2", 6 PLACES

Relay Cabinet Mounting Mounting Provisions and Dimensions
Page 12
Step-by-step Mounting Instructions
Step 1: Choose a location to mount the cabinet. Make sure the location in a dry
area that is convenient to the branch circuit panel.
Step 2: Leviton requires that cabinet mounting hardware reach through the
drywall to wall studs or other suitable solid backing. However, properly
sized struts and suitable hardware can also be used. The load must be
evenly distributed to the anchors without exceeding the recommended
anchor limit. Using drywall screws directly through drywall without a
stud is not acceptable. Make sure that adequate support at all points is
provided. For ully loaded cabinet weights, see “Product Speci ications
and Capabilities Chart” on page 3.
Step 3: Remove the cover. Some cabinets may also require the removal o data
and/or grounding wires. Make sure that this occurs prior to removal o
the door and that they are reconnected when reinstalling the door. On
cabinets with hinges, simply li t the door o the hinges. On cabinets
with screws, remove the cover screws. Appropriately store the cover or
uture use.
Step 4: Be ore you proceed any urther, see “Pre erred Areas or Conduit Entry”
on page 8. This section shows the location o the mounting holes and
allowed conduit entry locations or each cabinet type.
Step 5: Veri y which end o the cabinet is the top be ore you attach the cabinet
to any sur ace. Some cabinets have “up” arrows to indicate the top end.
Step 6: Attach the cabinet to its prepared mounting sur ace as appropriate.
Step 7: Cut, punch, or remove knockouts or the desired conduit openings. Pay
special attention to any disallowed areas or conduit entry.
Step 8: Pull all wire, both line and low voltage as appropriate.
Step 9: Care ully and completely remove any dust, debris, metal particles, etc.
rom inside the cabinet in preparation or wire termination and eventual
power up.
Step 10: Proceed to “Line Voltage and Control Power Termination” on page 15.

Line Voltage

Page 14

EZ-MAX Plus Installation Guide Page 15
LINE VOLTAGE
Line Voltage and Control Power Termination
Overview of Power Wiring - Feed\Line
Wiring
Wiring is simple. All you need is the ollowing:
•Dedicated circuit or control power - Hot, Neutral and Ground
•Individual load wires leaving relays, output circuits.
All cabinets have ample area or conduit entries or eed, load, and control wiring.
Ensure that conduit entry is only in the allowed locations. See “Pre erred Areas or
Conduit Entry” on page 8 or permitted locations.
Each relay panel has areas dedicated or line voltage wiring and similar orientation.
The igures on the next ew pages illustrate line voltage wiring.
Since the panel is ed rom multiple circuits, locate each one
and lock-out each eed in the OFF position.

Line Voltage and Control Power Termination Overview o Power Wiring - Feed\Line Wiring
Page 16
Figure 6: EZ-MAX Plus 8 Line Voltage Wiring Areas.
High Voltage
Connections
Transformer
Ground Point
Control Power Connections
This Area

EZ-MAX Plus Installation Guide Page 17
LINE VOLTAGE
Line and Load Circuit Wiring
EZ-MAX Plus relay cabinets have multiple relay circuits o a speci ic type depending on
the cabinet model. For details o the di erent relay types, their capacities, and
permitted wire sizes, please see “Wire Sizes and Capacities or Relays” on page 18.
Testing the Circuits
Veri y that all load and eed connections have been made be ore you attempt to
connect any circuit to a relay. Test each circuit in the cabinet by ollowing this
procedure:
Step 1: Turn o the breaker eeding the circuit
Step 2: Ensure that all connections and wiring between the relay cabinet and
the circuit breaker panel are complete
Step 3: Ensure that all connections and wiring between the relay cabinet and
the load are complete.
Step 4: At the relay cabinet, connect the eed(s) or relay #1 to the load or
relay #1 with a wire nut or other appropriate means.
Step 5: Turn on the circuit breaker to energize the circuit.
Step 6: Resolve any mis-wiring, shorts, etc. or the connected circuit.
Step 7: Repeat the above steps or all circuits in all relay panels or your
system. When all circuits have been tested, disconnect all Lines rom
Loads and proceed to the next section.
Installing Relay Cards
On several relay cabinet models, the relays are removable. I you have one o these
cabinets and need to add or remove relay modules, please ollow these instructions:
Step 1: Locate the appropriate location or the relay card
Step 2: Align the connector rom the relay card with the relay bus board and
gently push the two together.
Step 3: Once irmly seated, use a phillips screwdriver to tighten the mounting
screw.
30-Amp Relay
Mounting Screw