Leviton Z-MAX r24sd User manual

Installation Guide
Z-MAXTM RELAY PANELS
Covering Z-Max 24 & 48 Relay Panels with Master Control Module
Software Revision 1.40 and above.

Page i
Table of Contents
Overview
Introduction.......................................................................................................... 1
Product Specifications & Capabilities ....................................................................... 1
Product Specifications & Capabilities Chart ......................................................... 2
Inspection ................................................................................................................. 4
Installation Overview ............................................................................................. 4
Warnings - READ ME FIRST
Installation
Installation Checklist.............................................................................................. 6
Relay Cabinet Mounting
Selection of a Mounting Location ............................................................................ 7
Suggested Mounting Heights............................................................................. 7
Environmental Considerations ........................................................................... 7
Preferred areas for conduit entry ............................................................................ 8
Sample Electrical Room Layouts ............................................................................. 9
Mounting Provisions & Dimensions.........................................................................10
Step-by-step Mounting Instructions ............................................................................12
Line Voltage & Control Power Termination
Overview of Power Wiring - Feed\Line Wiring .........................................................13
Line and Load Circuit Wiring..................................................................................14
Testing the Circuits..........................................................................................14
Installing Relay Cards ......................................................................................15
Wiring the relays .............................................................................................15
Control Electronics Power Wiring ...........................................................................18
Low Voltage Control Wiring
Control Overview..................................................................................................19
Input Trigger-What determines an "ON" ...........................................................20
General Requirements for Connecting any Device to Low Voltage Inputs ........21
Connecting Low Voltage Switches
Connecting Low Voltage Switch ........................................................................24
Occupancy Sensors
Occupancy Sensor Wiring......................................................................................25
Photocells
Photocell Wiring ...................................................................................................27
Emergency ...............................................................................................................29
Master/Remote Network Interconnection
RJ-45 Pinout ...................................................................................................33

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Page ii
Termination ....................................................................................................34
How to Terminate Relay Cabinets.....................................................................35
Luma-Net III ............................................................................................................37
Requirements .................................................................................................37
Wiring the Phoenix Connector ..........................................................................37
DMX 512 .................................................................................................................39
Requirements .................................................................................................39
Wiring the DMX Connector ..........................................................................39
Modem Module Installation/Phone Line Connection.................................................41
Modem Module Installation ..............................................................................41
Pinout ............................................................................................................42
Ethernet Network Module Installation ....................................................................43
Connection Methods ...................................................................................44
RJ-45 Plug Connection................................................................................44
......................................................................................................................45
Power-Up & Installation Verification Checklist
Warranty Information

Page iii
List of Figures & Tables
Figure 1-1:Product line product capabilities Chart (all products shown) ............................... 3
Figure 2-1:Relay Cabinet Max head load (BTU/hr.) ............................................................ 7
Figure 2-2:24 & 48 Relay Cabinets Conduit Entry (24 relay cabinet shown, 48 similar) ......... 8
Figure 2-3:Sample Electrical Room Layouts for all cabinets................................................. 9
Figure 2-4:Z-MAX 24 Master & Remote relay cabinet mounting provisions and dimensions ..10
Figure 2-5:Z-Max 48 Relay cabinet mounting provisions and dimensions ............................11
Figure 3-1:24 Cabinet Low Voltage and High Voltage Wire Connections (48 similar)............14
Figure 3-1:Wire Sizes & Capacities for Relays ...................................................................16
Figure 3-1:Wiring Diagram for Z-MAX Standard 1 Pole Relay Card (latching relay card similar)
16
Figure 3-2:Wiring Diagram for Standard 2-Pole Relay Card................................................17
Figure 3-3:Wiring Diagram for Z-Max 347 V Relay Card.....................................................17
Figure 3-4:Wiring of Multiple Relays to Common Branch Circuit Breaker .............................17
Figure 3-1:24 & 48 Relay Cabinets Control Electronics Power Wiring ..................................18
Figure 4-1:Control Wire Type and Size.............................................................................20
Figure 5-1:Low voltage terminaly layout, 24 & 48 relay cabintes........................................23
Figure 5-2:Discreet input terminal labels and their meaning - applies to all Leviton products23
Figure 6-1:Occupancy Sensor Termination using Dedicated Occ Sensor Terminal ................25
Figure 7-1:0-10VDC Photocell Wiring ...............................................................................27
Figure 7-2:Switching Photocell ........................................................................................28
Figure 8-1:Emergency Input and Output Connectors 24 & 48 relay cabinets .......................30
Figure 8-2:Wiring Diagram for 24 & 48 relay cabinets showing (2) interconneted Emergency
Cabinets. 31
Figure 9-3:Master/Slave Connections Z-MAX 24, & 48 Relay Panel .....................................33
Figure 9-4:Cabinets requiring termination ........................................................................35
Figure 9-1:24/48 relay panel control module shown, others similar ....................................35
Figure 10-1:Typical termination jumper location ...............................................................38
Figure 11-1:Z-Max DMX connector wiring.........................................................................39
Figure 12-1:Modem Module Installation, 24 & 48 relay cabinets.........................................41
Figure 12-2:Telephone plug pinout ..................................................................................42
Figure 13-1:Ethernet Module Installation, 24 & 48 relay cabinets .......................................44

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Page iv

Overview Introduction
Z-MAX Installation Guide
Revision C 11/2005 Page 1
Overview
Introduction
Thank you for choosing Leviton’s Z-MAX line of products for your relay needs. The Z-
MAX product line offers a scalable solution of relay and relay control which can fit any
application from the simple 2 or 3-circuit needs with time clock control, to a complete
campus solution, fully integrated with your building management system products.
This manual is designed to assist you in the installation of your product. Included are
guidelines, requirements, and instructions which are required only for the installation
and low voltage termination of your product. Other resources available to you are as
follows:
•Quick Start Programming Guide (included with every panel)
•Supplemental addendum released in-between user’s guide revisions
•Programming & System Planning Guide
•Additional resources located at our website at http://www.leviton.com/lms
The programming and system planning guide was supplied in print with your system
purchase. The guide also can be found on the enclosed compact disc. In the event
that an additional printed copy is required, please contact Leviton Technical Support
at [phone] and we will send one to you.
This manual covers all products in the Z-Max product line; however the steps given
are somewhat generic in nature. The particular requirements for your product,
especially as related to termination, may differ slightly from that shown. Please review
all markings and labels on your product to ensure that your actions are correct.
Product Specifications & Capabilities
The specifications and capabilities for each product are shown in the table on page 3,
however, generally your product will fit into one of four categories. As the four
categories are used throughout this manual, it’s helpful to recognize which category
your product fits in so you know which sections of the manual apply to each product
type.
Master
"Master" relay panels offer the full suite of capabilities of the Z-Max products including
all networking functionality and modular relays. Relay panel sizes range from as few
as 8 relays per panel up to 96 relays per panel.
L
ev
it
on recommen
d
s a
l
ways c
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ec
ki
ng our
website at http://www.leviton.com/lms for late
breaking notes, requirements, application
information, and firmware upates.

Page 2
Basic
The "Basic" relay panel is very similar to the Master except the feature set has been
reduced. It is designed to be used in stand alone installations where only basic
capabilities are desired.
Remote
"Remote" relay panels 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. Exactly (1) Master
panel must exist on the same network as the remote relay cabinets, and the remote
panels can control relays, accept discreet inputs, and accept an emergency input.
EZ-Max
Panels designated as "EZ-Max" panels are very similar to a "Basic" relay panel except
that in addition to the feature set being reduced, the hardware has also undergone
change to make it a more econmical and easy to install package. For example, on an
EZ-Max panel, the relays are not modular. You still get the superior switching
technology of the Z-Max panels, just in a non-modular format.
Product Specifications & Capabilities Chart
The table on page 3 gives a generalized overview of the specifications of all Z-Max
relay products. In the table, the following abbreviations are used:
Y = Yes
N = No
O = Optional
* = An asterisk in any column indicates that there is support for this feature, however,
there are conditions with which you should be aware. Consult the specific sections of
the manual dealing with this feature for additional information and requirements.

Overview Product Specifications & Capabilities
Z-MAX Installation Guide
Revision C 11/2005 Page 3
Figure 1-1: Product line product capabilities Chart (all products shown)
Z-Max Product
Type
Min-Max Relays Relay Types Weight (lbs (Kg))
Size
W", H", D"
(Wcm,Hcm,Dcm)
Flush Mount Option # Discreet Inputs Sw. Input Board Avai Luma-Net Network DMX Network Master/Slave Net Emergency Input Emergency Output Touch-Tone Phone Data Modem Ethernet Network Front Panel Program Event Scheduler
Master Panel, 8 relays 0-8 Any 16
(7.26)
13" x 13" x 4-9/32"
(33 x 33 x 10.9)
Y8NYYYYYO*O*O*YY
Master Panel, 24 relays 0-24 Any 44
(19.96)
20-1/4"x34"x4-9/32"
(54.4 x 86.4 x 10.9)
Y12YYYYYYO*O*O*YY
Master Panel, 48 relays 0-48 Any 65
(29.48)
20-1/4"x54"x4-9/32"
(54.4 x 86.4 x 10.9)
Y12YYYYYYO*O*O*YY
Basic Panel, 8 relays 0-8 Any 16
(7.26)
13" x 13" x 4-9/32"
(33 x 33 x 10.9)
Y8NNNNNNO*O*NYY
EZ-Max, 4 Standard
relays
4Std10.6
(4.83)
10" x 10" x 4-9/32"
(25.4 x 25.4 x 10.44)
N6*NNNNNNO*NNYY
EZ-Max, 4 2-Pole relays 4 2PL 10.6
(4.83)
10" x 10" x 4-9/32"
(25.4 x 25.4 x 10.44)
N6*NNNNNNO*NNYY
EZ-Max, 4 347V relays 4 347 10.6
(4.83)
10" x 10" x 4-9/32"
(25.4 x 25.4 x 10.44)
N6*NNNNNNO*NNYY
Remote, 4 Standard
relays
4Std10.6
(4.83)
10" x 10" x 4-9/32"
(25.4 x 25.4 x 10.44)
N4NNNYYYNNNNN
Remote, 4 2-Pole relays 4 2PL 10.6
(4.83)
10" x 10" x 4-9/32"
(25.4 x 25.4 x 10.44)
N4NNNYYYNNNNN
Remote, 4 347V relays 4 347 10.6
(4.83)
10" x 10" x 4-9/32"
(25.4 x 25.4 x 10.44)
N4NNNYYYNNNNN
Remote, 24 Max Relays 0-24 Any 44
(19.96)
20-1/4"x34"x4-9/32"
(54.4 x 86.4 x 10.9)
Y12YNNY YYNNNNN
Remote, 48 Max Relays 0-48 Any 65
(29.48)
20-1/4"x54"x4-9/32"
(54.4 x 86.4 x 10.9)
Y12YNNY YYNNNNN
Z-Max with Breakers,
120V Cabinets and 48
Master or Remote Panel
0-48 Any 195
(88.45)
24"x87"x4-9/32"
(61 x 220 x 10.9)
N
Features are defined based on the Z-Max relay cabinet to which it is paired
Z-Max with Breakers,
120V Cabinets and 24
Master or Remote Panel
0-24 Any 174
(78.93)
24" x 67" x 4-9/32"
(61 x 170 x 10.9)
N
Z-Max with Breakers,
277V Cabinets and 48
Master or Remote Panel
0-48 Any 335
(152)
60" x 40-1/2" x 6"
(152 x 103 x 15.2)
N
Z-Max with Breakers,
347V Cabinets and 48
Master or Remote Panel
0-48 347
&
Lat
only
335
(152)
60" x 40-1/2" x 6"
(152 x 103 x 15.2)
N

Page 4
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.
Installation Overview
Installing a remote relay cabinet involves only a few steps:
Step 1: Mount the relay cabinet to the wall, install conduit, and pull all wire
(page 7)
Step 2: Terminate line voltage wiring (page 13)
Step 3: Terminate any low voltage discreet input wiring (page 19)
Step 4: Terminate any network wiring (page 53)
Step 5: Inspect your work (REQUIRED FOR ALL CABINETS) (page 47)
Step 6: Power-up and test the system
Step 7: Install latest software/firmware from Leviton website, www.leviton.com/
lms
Step 8: Perform all necessary configuration
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.