Leviton EZ-MAX User manual

User Guide
EZ-MAXTM
LIGHTING CONTROL RELAY PANELS
...another Z-MAXTM product by Leviton Manufacturing.
Software revision 1.00 and up

.

Table of Contents,
EZ-MAX User Guide Page i
Revision A - April 2005
Table of Contents
Overview
Inspection..................................................................................................... 1
Description.................................................................................................... 1
Control Overview ........................................................................................... 1
Feed and Load Wiring .................................................................................... 2
Control Input Wiring ...................................................................................... 2
Turn On ........................................................................................................ 2
Warnings
Installation
Installation Checklist ...................................................................................... 5
Mounting ...................................................................................................... 6
Suggested Mounting Heights: .................................................................... 7
Location of cabinets .................................................................................. 8
Mounting Cabinet ..................................................................................... 8
Feed and Load Wiring
Overview of Power Wiring - Feed\Line Wiring ................................................ 11
Control Electronics Power Wiring................................................................... 13
Line and Load Circuit Wiring ......................................................................... 13
Testing the Circuits ................................................................................. 13
Wiring the relays .................................................................................... 14
Circuit Schedule...................................................................................... 17
Low Voltage Control Wiring
Control Input Wiring .................................................................................... 19
Configuring Low Voltage Inputs ............................................................... 19
Switch Input Schedule............................................................................. 21
Low Voltage Input Terminals & Connections ............................................. 22
Connecting Low Voltage Switches ............................................................ 25
Occupancy Sensors................................................................................. 27
Photocells .............................................................................................. 29
............................................................................................................. 30
Wiring with an External Power Supply ...................................................... 31
Power Considerations for Control Systems ..................................................... 33
Terminology ........................................................................................... 33
Power Requirements & Maximum Run Length........................................... 33
Power Wire - Run Length ........................................................................ 36
Modem Installation/Phone Line Connection.................................................... 37
Modem Module Installation...................................................................... 37

Table of Contents,
Page ii
Operation
LCD Display .................................................................................................39
Navigation Buttons ..................................................................................40
Turning Relays On/Off & Relay Overrides..................................................41
To Override a Relay On or Off ..................................................................41
To Override a Relay On or Off for a specified time .....................................42
Determine the Firmware/Software Build.........................................................43
Factory Defaults...........................................................................................45
Setting the Date, Time, & Astronomical Time Clock.........................................47
Set the Date & Time................................................................................47
Set the Astronomical Time Clock ..............................................................48
Configuration the Simple Way
Panel Configuration in Simple Mode...............................................................51
Simple Mode Menu Structure ........................................................................52
Configure Inputs ..........................................................................................52
Low Voltage Switch Inputs.......................................................................53
Photocell Configuration............................................................................54
Occupancy Sensor Configuration ..............................................................57
Quick Schedule .......................................................................................59
Advanced Mode Configuration
Warranty Information 65
Limited Warranty .........................................................................................65

Overview, Inspection
EZ-MAX User Guide Page 1
Revision A - April 2005
Overview
Inspection
Carefully unpack the relay cabinet, and inspect to make sure there has been no hidden
shipping damage. Report all damage to the freight carrier who delivered the system. Claims
for damages are filed with the freight carrier as all freight is shipped FOB Tualatin, Oregon.
In case of damaged components, your EZ-MAX relay cabinet can be serviced in the field with
factory replacement parts.
Description
The compact physical design of your EZ-MAX Relay cabinet takes up a minimum of wall space.
The product is only designed for surface mounting. The properties of your cabinet are as
follows:
Cabinet Properties
Some of the relay features are:
•UL & cUL Listed for use in USA and Canada
•Compliant with NEMA requirements
•Easy to install
•Quick & Easy to Configure
The control portion of the relay cabinet employs all digital circuitry for accuracy and for
minimum wiring requirements between the relay cabinet and its control systems.
Control Overview
The Leviton EZ-MAX relay Cabinet uses an intelligent central control card (Digital Main Control
Module), enabling the relays in this system to control the loads connected to it as well as
respond to a variety of inputs. These inputs include:
•Low Voltage (constant voltage)
•Photocell 0-10VDC or Switched
•Occupancy sensor
•0-10VDC analog
•Dry Contacts
The LCD display provides an easy user interface with full configuration from the front panel.
Cabinet Size # of Relays Weight Dimensions - in. (CM)
44 10.6 lbs. (4.83 Kg) 10" W x 10" H x 4 9/32" D
(25.4 x 25.4 x 10.44)

Overview, Feed and Load Wiring
Page 2
Feed and Load Wiring
The cabinets have been designed for multiple entry and exit points for feed (from branch
circuit breaker) and load wiring. Refer to the appropriate section in this guide which discusses
this topic.
Control Input Wiring
The cabinets have been designed for multiple entry and exit points for low voltage control
wiring. Refer to the appropriate section in this guide which discusses this topic.
Turn On
Prior to turn on, verify the following is installed correctly:
•Feed wiring
•Load wiring
•Control wiring

Warnings, Turn On
EZ-MAX User Guide Page 3
Revision A - April 2005
Warnings
•To be installed and/or used in accordance with appropriate electrical codes and regulations.
•To be installed by a qualified Electrician.
•DO NOT CONNECT line voltage wires to low voltage terminals.
•Mount in a location where audible noise is acceptable.
•When using with fluorescent ballasts, both lighting fixture and ballast must be grounded.
•Use this relay cabinet only with minimum 75oC copper wire at 75oC ampacity.
•Disconnect power when servicing the relay cabinet, fixture 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 qualified personnel ONLY!. Heed all
caution markings indicating the presence of High Voltage. High voltage may be up to 600V.
•Test each circuit to make sure it is free of short circuits before connecting it to relay.

Warnings, Turn On
Page 4

Installation, Installation Checklist
EZ-MAX User Guide Page 5
Revision A - April 2005
Installation
Installation Checklist
Install the cabinets by following these simple steps:
Step 1: Unpack the system
Step 2: Report any damages to the freight carrier
Step 3: Remove the cover
Step 4: Remove the mounting plate assembly and store where damage will not occur
to the electronics
Step 5: Attach the cabinet to the wall (note the "UP" orientation as indicated on the
sticker)
Step 6: Drill holes and attach conduit where appropriate
Step 7: Pull all wire into the cabinet
Step 8: Blow out any dust, dirt, or debris which has accumulated in the cabinet
Step 9: Test & Verify all wiring by directly connecting line to load - Correct any faults
and re-test wiring prior to proceeding.
Step 10: Install the mounting plate assembly
Step 11: Terminate the feed & load wiring to each relay
Step 12: Terminate control wiring
Step 13: Verify the feed wiring
Step 14: Verify the load wiring
Step 15: Verify the remote control wiring
Step 16: The firmware of the cabinet is constantly updated by the Lighting Control
Division. Check the website, www.leviton.com, for the latest version of the
firmware and see Appendix B for instructions on how to update your cabinets
firmware
Step 17: Setup & Program the Cabinet

Installation, Mounting
Page 6
Mounting
The cabinets can be mounted only on the surface of the wall. The EZ-MAX Relay Cabinet is
not designed for any flush mounting method.
Prior to the consideration of any mounting location, please pay special attention to the allowed
locations for conduit entry.
All cabinets have ample location for conduit entry for feed, load
output, and control wiring. Ensure that conduit entry is only in
the allowed locations. Refer to the above figures in the
proceeding pages for possible locations. Also please ensure
that the power and control electronics are removed prior to
drilling or punching holes for conduit entry.
1A 2AG
SLOW BLO WFUSE
Grounding
Screws
(typ)
Control
Power
Input
2¼"
Low or High
Voltage
(not both)
Wiring/Conduit
Entry Area
Low Voltage
Wiring/Conduit
Entry Area
High Voltage
Wiring Area
for Conduit Entry
USB
Connector
NO CONDUIT
ENTRY!
NO CONDUIT
ENTRY!

Installation, Mounting
EZ-MAX User Guide Page 7
Revision A - April 2005
Suggested Mounting
Suggested Mounting Heights:
Leviton recommends the following mounting heights in order for the control module to be at a
reasonable height:
Front View
Feed and/or
switch legs
to loads
Feed wiring to relays
W
A
L
L
Side View
Distribution panel
Surface Mounting Shown
Wiring to Loads
Low
Voltage
Control
Wiring
NO LINE VOLTAGE
WIRING BEYOND
THIS POINT

Installation, Mounting
Page 8
Location of cabinets
•Cabinets generate heat (see table below). Make sure they are mounted in a conditioned
space where the temperature will be 0-40oC (32-104oF)
•Reinforce the wall for strength as required for weight and local code
•Clearance on left and right side of the panel should be maintained at 1 1/2" or greater
•Relays will click while in operation. Please locate the panels where audible noise is
acceptable.
Mounting Cabinet
Step 1: Locate where the cabinet will be hung on the wall. Choose a location in a dry area
that is convenient to the branch circuit panel.
Step 2: Leviton recommends that cabinet mounting hardware reach through the drywall
and attaches to wall studs or other suitable solid backing. However, properly
sized struts and suitable drywall hardware can also be used. They must distribute
the load to the anchors without exceeding the recommended anchor limit. Using
drywall screws directly through drywall without a stud is not recommended. Make
sure that there is adequate support
Step 3: Loosen the (4) cover screws and remove the cover by sliding the cover up and off.
Appropriately store the cover for future use.
Step 4: Locate the mounting plate assembly attached to the back wall of the enclosure.
Locate the 4 mounting screws in the 4 corners of the rear plate. Loosen these 4
screws. Lift the entire electrical assembly up and out of the enclosure. Do not
attempt to remove the keyboard separately from its mounting bracket. Store the
assembly in a protected, clean, dry place. Tighten the 4 screws so they don't get
lost.
Step 5: Prior to proceeding, reference the figures below which show the location of the
mounting holes and allowed conduit entry locations.
Step 6: Orient the enclosure so that the "UP" arrow on the label inside the enclosure is
pointing up. Note that the high-voltage conduit access is through the right end of
the bottom, the right side and the right end of the top. Note that the low-voltage
(Class 2) conduit access is through the top end of the left side and the left end of
the top. Cut or punch the desired conduit openings. Do not cut openings in the
back of the enclosure or the bottom end of the left side or the left end of the
bottom as it will no longer be possible to re-install the electrical assembly.
Step 7: Mount to a substantial indoor vertical surface with hardware supplied by others
through the 4 - 0.24 holes in the back wall for #10 hardware. The enclosure is
Type 1 for indoor use only
Cabinet Suggested Mounting height to bottom of
cabinet
4 Relay Panel 62" (157 cm)
Cabinet MAX BTU/HR
4 Relay Cabinet 97

Installation, Mounting
EZ-MAX User Guide Page 9
Revision A - April 2005
Step 8: Cut or Punch holes for conduit only in areas indicated on the product labeling as
appropriate.
Step 9: Install Conduit and pull wire
Step 10: Blow out any dust, dirt, or debris from the enclosure.
Step 11: Re-Install the Mounting Plate Assembly
Step 12: Proceed to Feed and Load Wiring Section.
Cabinet Dimensions and Mounting Hole locations and knockout locations
FRONT VIEW
(all dimensions in inches)
SIDE VIEW
(all dimensions in inches)
MOUNTING HOLES VIEW
(all dimensions in inches)
10.13
10.13
4.34
8.63
8.13
1.00
0.75

Installation, Mounting
Page 10
Allowed Wiring/Conduit Entry Areas
1A2AG
SLOW BLO WFUSE
Conduit Entry
Grounding
Screws
(typ)
Control
Power
Input
2¼"
Low or High
Voltage
(not both)
Wiring/Conduit
Entry Area
Low Voltage
Wiring/Conduit
Entry Area
High Voltage
Wiring Area
for Conduit Entry
USB
Connector
NO CONDUIT
ENTRY!
NO CONDUIT
ENTRY!

Feed and Load Wiring, Overview of Power Wiring -
EZ-MAX User Guide Page 11
Revision A - April 2005
Feed and Load Wiring
Overview of Power Wiring - Feed\Line Wiring
Wiring is simple. All you need is the following:
•Dedicated circuit for control power - Hot, Neutral and Ground
•Individual feeds from branch circuit breakers, input circuits
•Individual load wires leaving relays, output circuits.
Since the panel is fed from multiple circuits, locate each one and lock-out
each feed in the OFF position.
All cabinets have ample location for conduit entry for feed, load output, and control wiring.
Ensure that conduit entry is only in the allowed locations. Refer to the above figures in the
proceeding pages for possible locations. Also please ensure that the power and control
electronics are removed prior to drilling or punching holes for conduit entry.

Feed and Load Wiring, Overview of Power Wiring - Feed\Line Wiring
Page 12
Cabinet Connections & Orientation
1A 2AG
SLOW BLO WFUSE
Relay
Input &
Outputs
Relay #1
Relay #2
Relay #3
Relay #4
(Typical o
f
all relays)
USB
Connector
Control
Power
Input
Dedicated Photocell
and Occupancy
Sensor Inputs
Dedicated
Common
& Switch Inputs

Feed and Load Wiring, Control Electronics Power Wiring
EZ-MAX User Guide Page 13
Revision A - April 2005
Control Electronics Power Wiring
Your relay cabinet requires specific power circuit for the control electronics. Leviton
recommends that this power circuit be dedicated specifically and used only for power to the
control electronics.
If the control electronics must function during a power outage or other
interruption, the control electronics power must be fed from a UPS, generator,
or other guaranteed source.
To connect your relay cabinet’s control electronics to power, please follow the following steps:
Step 1: Connect the relay cabinet to the circuit breaker panel using conduit.
Step 2: Remove all cuttings and dirt.
Step 3: Run a dedicated circuit from the circuit panel or distribution panel to the relay
panel for the control electronics. Make sure the power is off at the breaker.
Step 4: Wire the circuit as shown in the following figure:
Step 5: Connect the circuits ground wire to the relay cabinet
Step 6: Keep the circuit off until all wires are landed in the cabinet.
Line and Load Circuit Wiring
Your relay cabinet has multiple relay circuits of a specific type depending on your relay cabinet
model. For specifications of the different relay types, please reference the chart below.
Testing the Circuits
Prior to connecting any circuit to a relay, and after all load and feed connections have been
made opposite the relay cabinet, test the circuit by following this procedure:
Step 1: Turn off the breaker feeding the circuit
Step 2: Ensure that all connections and wiring between the relay cabinet and the circuit
breaker panel are complete
Control
Power
Input
277VAC (347V on 347V models)
120VAC
Neutral
13W Required
Control Input Power

Feed and Load Wiring, Line and Load Circuit Wiring
Page 14
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 feed(s) for relay #1 to the load for relay #1 with
a wire nut or other appropriate means.
Step 5: Energize the circuit by turning on the circuit breaker.
Step 6: Resolve any mis-wiring, shorts, etc. for the connected circuit
Step 7: Repeat the above steps for all circuits in this relay panel. When all circuits have
been tested, disconnect all Line’s from Loads and proceed to the next section.
Wiring the relays
Step 1: Connect the line (feed/circuit breaker) side of the circuit to the "input" terminal(s)
on the relay card.
Step 2: Connect the load side of the circuit to the "output" terminal(s) on the relay card.
Step 3: Please note that relay card terminals accept the following wire sizes:
Wire Sizes for Relays
Wire the relay cards by following the wiring diagrams.
Model Relay Wire Size Wire Type Torque
re4bd-104 Z-MAX(Standard, 1-Pole) 20-8 AWG Copper Solid or Stranded 7 in-lbs
re4bd-204 2-Pole 20-6 AWG Copper Solid or Stranded 20.5 in-lbs
re4bd-C04 347V 20-6 AWG Copper Solid or Stranded 20.5 in-lbs

Feed and Load Wiring, Line and Load Circuit Wiring
EZ-MAX User Guide Page 15
Revision A - April 2005
Wiring Diagram for EZ-MAX Standard 1-Pole Relay (re4bd-104)
1A2AG
SLOW BLO WFUSE
Relay #1
Relay #2
Relay #3
Relay #4
Load
Line (from
Distribution
Panel)
(Typical of
all relays)
USB
Connector

Feed and Load Wiring, Line and Load Circuit Wiring
Page 16
Wiring Diagram for 2-Pole Relay Card (re4bd-204)
Wiring Diagram for 347V Canadaian Relay (re4bd-C04)
Load (Pole 1 & 2)
Line (Poles 1 & 2)
(from Dist. Panel)
Wiring Typical for
all relays
WARNING: Miswiring of relays
may result in product damage
or personal injury.
Load (Pole 1 & 2)
Line (Poles 1 & 2)
(from Dist. Panel)
Wiring Typical for
all relays
WARNING: Miswiring of relays
may result in product damage
or personal injury.
N/C
N/C