Installation Guide EZ-MAX PLUSTM RELAY PANELS Covering EZ-MAX Plus 8, 16 & 24 Relay Panels Software Revision 1.0 and above.
Table of Contents Read this Before You Begin! Safety Precautions!................................................................................................ 1 Warnings! ............................................................................................................. 1 Overview Introduction.......................................................................................................... 3 Product Specifications and Capabilities ........................................................
Luma-Net III Wiring Specifications ............................................................................................39 Wiring the Phoenix Connector ..........................................................................40 Emergency Inputs and Outputs ..............................................................................................45 Terminal Locations ...............................................................................................
Read this Before You Begin! Safety Precautions! Read and follow all safety instructions. Apply the “Emergency Circuits” label (provided) to the front of the door. When using electrical equipment, basic safety precautions should always be followed. 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.
Read this Before You Begin! Warnings! Use this relay cabinet only with minimum 75o C copper wire at 75% ampacity. Disconnect power when servicing the relay cabinet, fixture or when changing lamps. Indoor use only.
Overview Introduction Thank you for choosing Leviton’s EZ-MAX Plus line of products for your relay needs. The EZ-MAX Plus product line offers a scalable solution of relay and relay controls that can fit any application with 2 or 3-circuit needs with time clock control. This manual is designed to assist you in the installation of your product. It includes guidelines, requirements, and instructions that are required only for the installation and low voltage termination of your product.
Overview Product Specifications and Capabilities Product Specifications and Capabilities The table below gives a general overview of the specifications of all EZ-Max Plus relay products. The table uses the following abbreviations: Y = Yes N = No O = Optional # discrete Inputs Sw. Input Board Avail. Luma-Net Network Emergency Input Emergency Output Touch-Tone Phone Data Modem Front Panel Program Event Scheduler 0-8 ** 16 (7.26) 13" x 13" x 4-9/32" (33 x 33 x 10.
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.
Overview Installation Checklist Installation Installation Checklist Follow these simple steps to install the cabinet: 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).
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 and electrical room layout. Step 3: Determine the appropriate methods for 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.
Relay Cabinet Mounting Preferred Areas for Conduit Entry Preferred Areas for Conduit Entry Your relay cabinet has been designed for easy installation, with a variety of installation options. Please pay close attention to the “allowed” and disallowed” areas for 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 follow.
Sample Electrical Room Layouts The "right" layout for your application is a decision only you can make. The layouts depicted in the following illustrations show some simple and effective systems which you’re welcome to use and adapt to your particular installation.
Relay Cabinet Mounting Mounting Provisions and Dimensions Mounting Provisions and Dimensions TOP VIEW LOW VOLTAGE CONDUIT ENTRY 1" & 1-1/4" LINE / LOAD CONDUIT ENTRY 13 [330.2] SIDE VIEW with door 3/4 [19.05] SIDE VIEW 19/32 15.28 4 [101.6] 11 21/32 [295.87] 27/32 [21.5] (9/32) [7.05] (4 9/32) [108.65] 19/32 [15.28] LOW VOLTAGE CONDUIT ENTRY 1" & 1-1/4" 4 PLACES 13 [330.2] 10 3/64 [255.14] 11 279.4 3 1/2 [88.9] LINE / LOAD CONDUIT ENTRY 1-1/4" & 1-1/2" 4 PLACES 8 3/4 [222.
LINE / LOAD CONDUIT ENTRY 1" & 1-1/4", 2 PLACES PLUS 1-1/4" & 1-1/2", 3 PLACES LOW VOLTAGE CONDUIT ENTRY 1-1/4" & 1-1/2" 6 PLACES LINE / LOAD CONDUIT ENTRY 1" & 1-1/4", 2 PLACES PLUS 1-1/4" & 1-1/2", 3 PLACES 20 1/4 [514.35] 1 27/32 [46.8] 4 [101.6] 16 [406.4] 14 11/64 [359.83] LOW VOLTAGE CONDUIT ENTRY 1" & 1-1/4" 6 PLACES 14 11/64 [359.83] 34 [863.6] LINE / LOAD CONDUIT ENTRY 1" & 1-1/4" 6 PLACES 16 5/8 [422.4] 1 27/32 [46.8] 16 5/8 [422.
Relay Cabinet Mounting Mounting Provisions and Dimensions 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.
Line Voltage
Page 14
LINE VOLTAGE Line Voltage and Control Power Termination 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 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 area for conduit entries for feed, load, and control wiring.
Line Voltage and Control Power Termination Overview of Power Wiring - Feed\Line Wiring Ground Point Transformer High Voltage Connections Control Power Connections This Area Figure 6: EZ-MAX Plus 8 Line Voltage Wiring Areas.
EZ-MAX Plus relay cabinets have multiple relay circuits of a specific type depending on the cabinet model. For details of the different relay types, their capacities, and permitted wire sizes, please see “Wire Sizes and Capacities for Relays” on page 18. Testing the Circuits Verify that all load and feed connections have been made before you attempt to connect any circuit to a relay.
Line Voltage and Control Power Termination Line and Load Circuit Wiring If you need to remove the installed relay cards that shipped from the factory, remove the shipping screw located near the connector and discard. This screw is only required for shipping and not for installation. Wiring the Relays Step 2: Connect the load side of the circuit to the "output" terminal(s) on the relay card.
LINE VOLTAGE Wiring Diagrams The diagrams on the following pages show how to wire the relay circuits.
Line Voltage and Control Power Termination Line and Load Circuit Wiring Load Line (From Distribution Panel) Figure 11: Wiring Diagram for EZ-Max Plus 347 V Relay Card Load Load Line (From Distribution Panel) Load Figure 12: Wiring of Multiple Relays to Common Branch Circuit Breaker Page 20
Your relay cabinet requires a 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 any Emergency Circuits are fed or controlled from this panel, it must be located electrically where fed from a UPS, a generator, or other guaranteed source of power during emergency and power outage situations.
Line Voltage and Control Power Termination Page 22 Control Electronics Power Wiring
Low Voltage
Page 24
Low Voltage Control Wiring Once the power wiring has been completed, you can begin the control wiring. Control wiring can be divided into two categories: analog and digital. Remote relay panels only support analog control inputs. Control Overview • Low Voltage momentary or maintained through a discrete input. • Momentary 2-Pole On/Off through a discrete input. • Photocell 0-10VDC or Switched through a discrete input. • Occupancy sensor through a discrete input.
Low Voltage Control Wiring Control Overview Control Wiring Termination This section gives instructions for terminating all types of low voltage inputs. • Leviton recommends minimum 18AWG stranded wire for all low voltage wiring. • Terminate all control wiring directly to the terminal blocks on the printed circuit board. Use a small 1/8-in. flat screwdriver on these terminals. • Terminal blocks are 2-part terminals and can be removed for ease of termination.
General Requirements for Connecting any Device to Low Voltage Inputs Connect leads per wiring diagram as illustrated in the figures on the following pages. Step 2: Twist strands of each lead tightly (making sure that there are no stray strands) and push firmly into appropriate plug connector location. Step 3: Tighten the screws on the plug connector—making sure that no bare conductor is showing.
Low Voltage Control Wiring Page 28 Control Overview
Low Voltage Switches • Momentary: provides momentary contacts, triggering alternating On/Off actions. • Maintained: triggers On action when connection is made, Off action when removed. • Momentary On/Off with On & Off terminals provided: provides momentary connection to the “On” terminal to trigger an On action, momentary connection to the “Off”. Used with single pole double throw center off (SPDT-CO) switches.
Low Voltage Switches Typical terminal designations for all products are shown below. Please confirm the function of each pin on your device with the labeling on the circuit board prior to any termination. Pin Label Function +24V Supplies +24Vdc power to devices, usually unregulated COM Connection to DC Common of the cabinet IN Switch Input or signal from device. Usually expecting +V to trigger. OUT Used for connection to device LED indicating on/off state of that input.
COM +24V OUT IN COM +24V OUT IN S2 COM +24V TB3 OUT S3 IN COM +24V TB4 OUT S4 IN D7 D2 D4 D6 D3 D8 D1 D12 D27 RELAY 1 TB16 COM +24V TB7 OUT S7 IN 1 JP35 CAN 2 TERM RELAY 2 EMERGENCY HEARTBEAT-C LUMANET DMX CAN1 CAN2 RELAY ETH/MODEM 5V POWER HEARTBEAT-R 3 LEVITON ASSEMBLY OX-70129-00-00-01 NETWORK OX-70129-00-00-02 BASIC SELECTOR S1 THRU S8 COM +24V TB6 OUT S6 IN ANALOG/SWITCH I/O* COM +24V TB5 OUT S5 IN 1 EMERGENCY RELAY } Switch Inputs TB13 LOW VOLTAGE EMERGENCY - TB17* COM. EMERG.
Low Voltage Switches Page 32 Step 4: Plug the terminal block back into the cabinet with the screws facing toward you and the wires exiting toward the side or top of the cabinet. Alternatively, the connector can be inserted with the screws parallel to the circuit board and the wires exiting toward you. Step 5: Verify that the wires land on the correct terminals.
Occupancy Sensors One of the control input types that your relay cabinet can accept is Occupancy Sensors. When using an occupancy sensor, the cabinet is expecting a DC voltage between +9V & +24V to trigger an occupied state, or a floating input to indicate an unoccupied state. The specific function of what happens in each of these states is set via software configuration. This section only deals with connecting your Occupancy Sensor to your relay cabinet.
Occupancy Sensors Page 34 Occupancy Sensor Wiring
Photocells The relay cabinet is capable of supporting the following types of photocells: • Switched Photocell (On/Off, trigger point set at photocell). • 0-10V Photocell. The configuration and behavior of your photocell is set via software (see the EZ-MAX Plus Programmer’s Guide for details). This section only covers installation.
Photocells Photocell Wiring AC Power Switch Leg PhotoCell Switch Leg IN +V COM Note: Switch Legs must be completly isolated from Photocell AC power and should be connected to either side of the switching relay at the photocell. Note: If your switching photocell requires +24VDC power, this power can be sourced from the cabinet just like a 0-10VDC photocell.
Digital
Page 38
Luma-Net III Luma-Net is Leviton’s proprietary digital architectural lighting control protocol. Luma-Net can be used for the following items: • Optional Communication and control by Dimensions 8000 control stations and accessories. • Optional Communication and control by Dimensions 4200 control stations and accessories.
Luma-Net III Wiring Specifications Wiring the Phoenix Connector Step 1: Connect leads per the wiring diagram below. Step 2: Twist strands of each lead tightly (making sure that there are no stray strands) and push firmly into appropriate plug connector location. Step 3: Tighten the screws on the plug connector—making sure that no bare conductor is showing. Step 4: Tie the Drain/Shield wires together and insulate using a small piece of heat shrink tubing.
Install termination jumpers as required. Termination jumpers are required at the two ends of the Luma-Net run. The termination can be accomplished on the Luma-Net connector with a jumper wire as shown below. Termination can also be accomplished on the control board by jumpering the 2 pin header to the left of the Luma-Net connector.
Luma-Net III Page 42 Wiring Specifications
Emergency
Page 44
Emergency Inputs and Outputs The control card has both an emergency input and output. The input can be driven by a contact closure such as one from a fire alarm or by a low voltage signal capable of sinking 5 mA (3 - 5 volts is emergency off and 0 - 2 volts is emergency on). Emergency output has a common contact and both NO and NC contacts. In the nonemergency state, the NO contact is closed.
Emergency Terminal Locations Terminal Locations Emergency terminal locations for the EZ-Max Plus 8 and 16/24 relay cabinets are shown. COM +24V OUT IN TB2 S2 NC COM +24V OUT IN COM +24V OUT IN TB1 S1 TB3 S3 COM +24V OUT IN COM +24V OUT IN TB7 S7 TB8 S8 TB9 S9 TB10 S10 TB11 S11 ON PULLS INPUT HIGH } JUMPER JUMPER OFF IS DEFAULT C 2004 LEVITON MFG. CO.
COM +24V OUT IN TB2 S2 NC NO From contact closure or other source COM +24V OUT IN COM +24V OUT IN TB1 S1 TB3 S3 EMERGENCY RELAY (OUTPUT) COMMON COM EMERG EMERGENCY INPUT - TB21 * Cabinet One J15 COM +24V OUT IN TB2 S2 NC NO COM +24V OUT IN COM +24V OUT IN TB1 S1 TB3 S3 EMERGENCY RELAY (OUTPUT) COMMON COM EMERG EMERGENCY INPUT - TB21 * Cabinet Two J15 (Upper left hand corner of control module shown) EMERGENCY Figure 23: Wiring Diagram for 16/24 relay cabinets showing (2) interconnected
Emergency Page 48 Terminal Locations
Appendix A Power-Up and Installation Verification Checklist Prior to the application of power to your relay cabinet, all of the following steps must have been successfully executed. Inspect each relay load wiring for incomplete termination Inspect each relay’s load wiring for terminals not completely tightened With each relay in the “off” position, check for voltage between the Line & Load terminals; there should be none. Inspect all low voltage wiring and ensure that it is complete.
Power-Up and Installation Verification Checklist Page A-2
Appendix B Power Considerations for Control Systems The control system should be carefully planned to take these important issues into consideration: • Power Supply for connected devices. • Wire Size for Power Runs. On systems where full factory drawings have been provided, our Applications Engineering department has already managed these calculations for you so you only need to follow the instructions on the system drawings.
Power Considerations for Control Systems Power Requirements and Maximum Run Length Each Control Device used in your system has a different load (draw) and each PCD can support a different total load (supply.) There are logical steps for determining the total load of your network and verifying that the supply is sufficient: Step 1: Determine the maximum available current of your supply, be it a PCD or other Power Supply. Convert this to the maximum number of Unit Loads if necessary.
Control Device Loads Control Devices Unit Load @12VDC Unit Load @24VDC D4200 LCD 5 2 D4200 Entry (Button), 2 D4200 Room Combine Station Station Type Unit Load @ 12VDC Unit Load @ 24VDC EZ-MAX Plus Digital Switch, 1 Button N/A 0.6 1 EZ-MAX Plus Digital Switch, 2 Buttons N/A 0.8 3 1 Z-AX Digital Switch, 3 Buttons N/A 1.0 D4200 Remote I/R 2 1 EZ-MAX Plus Digital Sw., 4 Buttons N/A 1.1 Luma-Net Hub 6 3 EZ-MAX Plus Digital Switch, 5 Button N/A 1.
Power Considerations for Control Systems Power Wire - Run Length The maximum total run length of each segment is a function of the total number of unit loads. A run becomes too long when the voltage drop, due to wire size and run length, increases to a point where the station does not have sufficient voltage to operate. The maximum run length, in feet, based on the total number of unit loads is shown below: (2) Tables are provided, (1) @ 12VDC and (1) at 24VDC.
Warranty Information Limited Warranty Leviton Manufacturing Co Inc. warrants the products represented in this manual to be free of material and workmanship defects for a period of two years after system acceptance or 26 months after shipment from Leviton, whichever comes first. The EZ-MAX Plus relay cards are covered for a period of ten (10) years. Lighting fixtures manufactured by Leviton are covered for a period of one year.
Leviton Lighting Management Systems Division Headquarters 20497 SW Teton Avenue, Tualatin, OR 97062 Customer Service Telephone: 1-800-736-6682 • FAX: 1-503-404-5600 Tech Line: 1-800-959-6004 Leviton Manufacturing Co., Inc. 59-25 Little Neck Parkway, Little Neck, NY 11362-2591 Telephone: 1-800-323-8920 • FAX: 1-800-832-9538 Visit Leviton’s Web site at http://www.leviton.com © 2005 Leviton Manufacturing Co., Inc.
