Leviton Z-MAX Series User manual

User Guide
Z-MAXTM REMOTE RELAY PANELS
LIGHTING CONTROL RELAY PANELS
...another Z-MAXTM product by Leviton Manufacturing
.
WEB VERSION

WEB VERSION

Table of Contents,
Pageiii
Table of Contents
Overview
Introduction.............................................................................. 1
Installation Overview ................................................................. 1
Inspection................................................................................. 2
Physical Description................................................................... 2
Control Overview....................................................................... 3
Conduit Entry Locations ............................................................. 4
Line & Load Circuit Wiring.......................................................... 4
Turn On.................................................................................... 4
Warnings ........................................................................................... 5
Installation ......................................................................................... 6
Installation Checklist.................................................................. 6
Relay Cabinet Mounting ...................................................................... 9
Flush Mounting.......................................................................... 9
Special Instructions for Flush Mount Kit Installation............... 10
Selection of a Mounting Location .............................................. 12
Suggested Mounting Heights ............................................... 12
Environmental Considerations.............................................. 12
Preferred areas for conduit entry .............................................. 13
Suggested Layouts................................................................... 16
Physical Mounting Requirements............................................... 17
Step-by-step Mounting............................................................. 20
Master/Slave Network Topology
Network Topology ............................................................................ 22
Network Layout Planning .................................................................. 23
Relay Numbering Chart ....................................................... 25
Relay Numbering Chart ..................................................................... 26
Feed and Load Wiring
Overview of Power Wiring - Feed\Line Wiring ............................ 27
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Table of Contents,
Page iv
Line and Load Circuit Wiring .....................................................30
Testing the Circuits..............................................................30
Installing Relay Cards..........................................................30
Wiring the relays.................................................................31
Control Electronics Power Wiring...............................................38
Circuit Schedule ..................................................................41
Master/Remote Network Interconnection
RJ-45 Pinout.......................................................................46
Termination........................................................................47
How to Terminate Relay Cabinets.........................................49
Low Voltage Control Wiring
Input Trigger - What determines an "ON" .............................52
Low Voltage Input Terminals & Connections..........................54
Connecting Low Voltage Switches
Connecting Low Voltage Switch............................................58
Occupancy Sensors
Occupancy Sensor Wiring .........................................................61
Photocells
Photocell Wiring.......................................................................63
Wiring with an External Power Supply...................................65
Power Considerations for Control Systems..................................67
Terminology .......................................................................67
Power Requirements & Maximum Run Length .......................68
Power Wire - Run Length.....................................................73
Configuration ....................................................................................75
Out of the Box Configuration................................................75
Remote/Slave Cabinet Configuration..........................................75
Comments & Examples on Relay Numbering .........................76
Configuration of Remote Relay Cabinets with Dipswitches......76
Table of MRN Codes & Starting Relay Number.......................77
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Table of Contents,
Pagev
Configuration of Remote Relay Cabinets without Dipswitches or via
USB................................................................................... 78
Configuration of Master Control Panel ....................................... 79
Enable Master/Slave Communication.................................... 79
Enabling Master/Slave Communication ................................. 80
Setting the Total number of Remote Relays.......................... 80
Communication Verification ...................................................... 82
Conclusion .............................................................................. 82
Warranty Information ........................................................................ 85
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Table of Contents,
Page vi
WEB VERSION

Overview, Introduction
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 1
Overview
Introduction
The Z-MAX Remote Relay Panels, also referred to as Z-MAX Slave
Relay Cabinets, are designed for remote installation and
mounting where relay switching from 4 to 48 load circuits is
desired, but control intelligence, programming, and interface to
other systems is required at a central location. This system of
remote relay panels has the following benefits over the traditional
configurations:
•Remote mounting of relays where control electronics are
inconvenient
•Single point of programming when a continuous extension of
an existing relay panel is desired
•Other unique applications where configuring at the relay itself
is not desired
Installation Overview
Installing a remote relay cabinets involves only a few steps:
Step 1: Mounting the relay cabinet to the wall, install
conduit, and pull all wire.
Step 2: Terminate line voltage wiring
Step 3: Terminate any low voltage wiring
Step 4: Terminate the Master/Slave networking wiring
Step 5: Inspect your work
Step 6: Power-up, configure, and test the system
Each of the above steps are covered in detail throughout the rest
of this user’s guide. In each section notes, warnings,
requirements, suggestions, and procedures are included which
will help you be successful in the installation and use of your
system.
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Page 2
Inspection
Carefully unpack the relay cabinet, and inspect to make sure
there is no hidden shipping damage. Report any damage to the
freight carrier who delivered the system. Claims for damages are
filed with the freight carrier.
In case of damaged components, your relay cabinet may be
serviced in the field with factory replacement parts.
Physical Description
Remote relay panels are classified by the number of load circuits
they can switch. The fewer the number of controlled circuits, the
smaller the overall cabinet dimensions, and the larger the
number of controlled circuits, the larger the overall cabinet
dimensions. The physical properties of the cabinets 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
Model # of Relays Flush
Option Weight Dimensions - in. (CM)
re4sd 4
(fixed relays) No 10.6 lbs. (4.83 Kg) 10" W x 10" H x 4 9/32" D
(25.4 x 25.4 x 10.44)
r24sd 0-24
(accepts Z-
MAX relay
modules)
Yes 44 lbs.
(19.96 Kg) 20 1/4" W x 34" H x 4 9/32" D
(54.4 x 86.4 x 10.9)
r48sd 0-48
(accepts Z-
MAX relay
modules)
Yes 65 lbs
(29.48 Kg) 20 1/4" W x 54" H x 4 9/32" D
(54.4 x 137.2 x 10.9)*
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Overview, Control Overview
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 3
•Quick & Easy to Configure
The control portion of the relay cabinet employs all digital
circuitry for accuracy and minimum wiring requirements between
the relay cabinet and its control systems.
Control Overview
The Leviton Z-MAX remote relay cabinets use an intelligent
central control card (Digital Main Control Module) and a
dedicated system of networking wiring, allowing for control of the
relays in the remote cabinet from any control source connected
to the master relay cabinet and from any low voltage source
connected to the remote relay cabinet.
Control input to a remote relay cabinet can be any combination of
the following:
•Low Voltage momentary or maintained
•Momentary 2-Pole On/Off
•Photocell 0-10VDC or Switched
•Occupancy sensor
•0-10VDC analog
•Dry Contacts
Following the basic premise of remote relay cabinet, even though
each remote relay cabinet can accept control inputs, these inputs
are processed by the master control panel for configuration and
relay control.
Remote relay cabinets require a dedicated physical network of
certified category-5 wiring utilizing RJ-45 connectors at each end.
The panels should be laid out in a linear "daisy-chained" fashion.
In the event that this network topology is not convenient, hubs
and/or routers may be available to facilitate this topology.
Contact the factory for additional information.
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Page 4
Conduit Entry Locations
The cabinets have been designed with specific locations
supporting conduit entry for line and low voltage circuits. There
are specific areas of the cabinet which are restricted from some
or all types of conduit access. Reference the Physical Installation
section of this manual for specific details.
Line & Load Circuit Wiring
Each relay requires line & load circuit wiring. The line wiring
should come from an over-current device and the load circuit
wiring shall go to the specific load to be controlled. On some
models which have integrated branch circuit protection, the line
side of the relay has been pre-wired to a circuit breaker. With
these products, only the load side of the circuits needs to be
connected.
Turn On
Prior to turn on, verify the following is installed correctly:
•Feed wiring
•Load wiring
•Control wiring
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Overview, Turn On
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 5
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
75%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 for short circuits before connecting it to relay
so damage to the relay and it’s electronics can be avoided.
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Page 6
Installation
Installation Checklist
Install the cabinets by following these simple steps:
Step 1: Unpack the system
Step 2: Report any damage to the freight carrier
Step 3: If appropriate, remove any covers and/or doors
Step 4: If appropriate, remove the mounting plate
assembly and store where damage will not
occur to the electronics
Step 5: Attach the cabinet to the wall (reference stickers
inside the cabinet for proper orientation if it is
in question)
Step 6: Drill conduit entry holes if KO’s are not provided
and attach conduit where appropriate
Step 7: Pull all wire into the cabinet
Step 8: Test & Verify all wiring by directly connecting line
to load - Correct any faults and re-test wiring
prior to proceeding
Step 9: Re-install any control electronics removed in step
#4
Step 10: Terminate the feed & load wiring to each relay
Step 11: Terminate control wiring
Step 12: Verify feed wiring
Step 13: Verify load wiring
Step 14: Verify master/slave network wiring
Step 15: Blow out dust, dirt, or debris which has
accumulated in the cabinet
Step 16: Apply power to the system
Step 17: Verify proper operation of each relay using the
override buttons
Step 18: Make adjustments to remote slave starting relay
number if necessary and reset the system
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Overview, Installation Checklist
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 7
Step 19: Make programming adjustments at the master
control module so that newly installed remote
relays usage correctly.
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Page 8
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, Flush Mounting
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 9
Relay Cabinet Mounting
There are several steps required when mounting your relay
cabinet:
Step 1: Install the flush mounting kit if appropriate
Step 2: Plan your conduit runs & layout
Step 3: Plan your physical mounting, the connection
between the cabinet and the wall
Step 4: Mount the cabinet to the wall
Flush Mounting
The 4 relay cabinet is designed only for surface mounting.
However, the other relay cabinets have a flush mount kit option
which is available as an accessory. The part numbers for these
kits are as follows:
Cabinet Size/Type Flush Trim Kit Part
Numbers
8 RAC00-08F
24 RAC00-24F
48 RAC00-48F
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Page 10
Special Instructions for Flush Mount Kit
Installation
Step 1: Locate where the cabinet will be hung in the wall.
Choose a location in a dry area that is convenient to
the branch circuit panel
Step 2: Be careful to remove the ground wire from the door.
It is attached using a spade connector. No tools are
required
Step 3: Remove the door by sliding the door up and off its
hinges. You will have to unlock the door first using
the supplied key
Step 4: On the 8 Cabinet you will also have to remove the
ribbon cable from the LCD display
Step 5: Set the door aside in a safe place
Step 6: Cut out the drywall if needed
Step 7: Tap out the mounting hole knockouts located on the
sides of the cabinet. See the figure on the next page
for the location of the knockouts on each cabinet
Step 8: Attach the unit to the wall. Use #10 (with washer)
hardware. 1/4" hardware can be used, but the
mounting holes will need to be drilled out to 5/16"
Step 9: Install the flush frames as shown in the figure below
using the screws provided
The 24 cabinet is shown, but the process is similar
for the 8 and 48 cabinet.
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, Flush Mounting
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 11
Step 10: Remove the nut holding the door lock in place
Step 11: Remove the lock and its trim ring (Looks like a
washer)
Step 12: Discard the trim ring and reinstall the lock
Step 13: Loosen the screws holding the door hinges to the
cabinet. This will allow the hinges to move in their
slotted holes
Step 14: Install the door onto its hinges
Step 15: Open the door 90 degrees and insert a quarter (or
something with similar thickness) between the door
and the frame
Step 16: Push the door against this spacer and tighten the
hinge screw
Step 17: Remove the spacer
Step 18: Remove the door and proceed to the next section
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Page 12
Selection of a Mounting
Location
Choosing a mounting location for your cabinet is critical to the
overall success and ease of installation. Each style of cabinet has
it’s unique wiring requirements which must be observed. Please
review the next few pages, which describe and illustrate these
mounting requirements.
Suggested Mounting Heights
Although successful operation is completely independent of
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 which follows). Make sure
they are mounted in a climate controlled 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. Locate the panels where
audible noise is acceptable.
Cabinet Suggested Mounting height to bottom of
cabinet
4 Relay Cabinet 62" (157 cm)
8 Relay Cabinet 53" (1,359 mm)
24 Relay Cabinet 32" (826 mm)
48 Relay Cabinet 12" (318 mm)
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, Preferred areas for conduit entry
Z-MAX Remote Relay Panel User Guide, Revision A 8/2005
PK-93194-10-00-0A Page 13
Preferred areas for conduit
entry
Your relay cabinet has been designed to be easy to install with a
variety of installation options to fit many applications. However,
there still are specific considerations which must be made. One of
these is the allowed, and in some cases disallowed, areas for
conduit entry. Disallowed areas are areas where conduit entry is
impossible. These areas are clearly marked in the following
illustrations. Once you recognize the disallowed areas for conduit
entry, you can look at the allowed areas. Each cabinet style has
designated areas for low voltage and line voltage conduit entry.
This must be observed for proper code compliance.
Please review the following illustrations which indicate preferred,
allowed, and disalllowed areas for conduit entry.
Cabinet MAX BTU/HR
4 Relay Cabinet 97
8 Relay Cabinet 245
24 Relay Cabinet 583
48 Relay Cabinet 1166
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Page 14
4 Relay Cabinet Conduit Entry
1A 2AG
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!
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