installation guide - zendesk · gr 2400 relay panel installation guide to remove the panel...

Step 1. Mount relay panel (LCP) in the location stated in the construction documents. To keep the relays and electronics clean during rough-in, you can remove the panel interior.

Mounting hole dimensions. . . . . . . . . . . . . . . . . Pg 2How to remove panel interior . . . . . . . . . . . . . . Pg 3

Step 2. Make up conduit and gutters to breaker panels.

Diagram of KOs. . . . . . . . . . . . . . . . . . . . . . . . . Pg 3Suggested conduit and gutter pathways. . . . . . . Pg 4

Step 3. Prior to pulling cables from the breaker panels, review the customer-approved Panel Schedule on the door of the panel. For systems not factory pre-programmed, create a Panel Schedule.

! Are you controlling emergency loads? What you need to know. . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 4Mixing normal and emergency loads. . . . . . . . . Pg 4How to read the Panel Schedule . . . . . . . . . . . . Pg 6How to create a new Panel Schedule . . . . . . . . . Pg 7

Step 4. Land conductors per the Panel Schedule. Use the Fault Check Procedure to detect and prevent faults from damaging relays during start-up.

Fault Check Procedure. . . . . . . . . . . . . . . . . . . . Pg 5 Torque Specifi cations for Relays Lugs . . . . . . . Pg 5

Lighting Control & DesignSupport (800) 345-4448 • www.lightingcontrols.com

INSTALLATION GUIDE

GR 2400 RELAY PANEL

(Read this Installation Guide completely before starting and reduce your installation time by 50%)

Step 5. Connect power supply to 120v or 277v (use ap-propriate lug) neutral and ground. Use a dedicated breaker.

If controlling emergency loads . . . . . . . . . . . . . Pg 4

! Do not power-up the panel electronics until the bus has been activated (see the System Start-Up Guide).

Step 6. Make up Cat. 5 cable per the Quick Start Guide or System Start-Up Guide.

Appendix

Line and Low Voltage Connections . . . . . . . . . . Pg 8Panel Schematics . . . . . . . . . . . . . . . . . . . . . . . . Pg 9Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Pg 10Panel Call-Outs . . . . . . . . . . . . . . . . . . . . . . . . Pg 11Blank Panel Schedule . . . . . . . . . . . . . . .Back Cover

LCD

GR2400RPIG

27Mar08

LCDGR2400RPIG27Mar08

GR 2400 RELAY PANEL INSTALLATION GUIDE

"H" "A"19.5”31.5”

25.5"37.5”

3248

2



To Remove the Panel Interior:If the rough-in is going to create a lot of dust or metal shavings, it may prove best to remove the chassis prior to installation. To remove the chassis:

Remove the four mounting screws.1.

Grab the top and bottom of the back plate and gen-2. tly lift out of the enclosure.

Recommended: Re-mount the screws and washers 3. in the threaded holes on the back of the enclosure.

Store the panel interior in the original shipping box.4.

Upon request, the factory will ship the enclosure separately from the back plate.

Mounting the EnclosureEnclosure must be mounted on something sub-1. stantial like plywood or a 2x4 stud.

Use (customer supplied) 1/4” lag bolts.2.

Knock-OutsNote that the center section of the panel is reserved 1. for low voltage. While all KOs on the end-cap may be used for line voltage conduit, if the center KOs are used, those line voltage conductors will be bent on a sharp radius.

Panels can be ordered with no KOs.2.

The pattern shown on the right is true for both the 3. 32 and the 48 relay panel enclosures. Note that the end cap on the bottom is reversed from the end cap on the top (see drawing to the left for clarifi cation).

3



Planning Your Conduit and GutterGutter tray or conduit used for interconnects

120

VN

orm

al27

7 V

Nor

mal

120

VE

mer

genc

y27

7 V

Em

erge

ncy

Optional Horizontal BarrierSupplied by LC&D

Mixed Voltage/Mixed SourceMixing sources (normal and emergency), even though separated by barriers and in separate compartments, may not be allowed in your jurisdiction. When in doubt, use separate panels for normal and emergency.

The GR 2400 panel is listed for controlling emergency circuits (ETL Listed to UL 924), and may control both normal and emergency loads in the same enclosure.

If mixing sources is allowed, try to keep emergency loads on the right side of the panel (even-numbered re-lays). Since power-supply is top-left, keep normal power on the left side of the panels (odd-numbered relays).

Electronics Power Supply

Normal Power Distribution Panel

Emergency Power Distribution Panel

Blue BoxRelay Panel

4

120

V

277

V

Single Voltage. Mount Panels side-by-side (preferred) or ver-tically. A gutter provides plenty of room for make-up work.

Mixed/Multiple Voltages. If possible, we recom-mend splitting the panel left and right. The low volt-age section of the panel acts as a natural barrier. Our panels are numbered like a breaker panel: odd-num-bered relays are on the left and even-numbered on the right. (See How to Read a Panel Schedule, pg. 6)

Controlling Emergency PowerWhen controlling emergency loads, use normal power to supply panel electronics, and the (NC) relays will automatically close in the event of any normal power loss. When power is restored, relays will return to the appropriate status (on or off).



Fault Check Procedure:Land “line” and “load” conductors on the same termi-1. nal lug. Label “line” conductor with the breaker ID.

Check the line. Switch breakers on and clear any 2. faults. Switch breakers off.

Move the load conductors to the load terminal lug 3. on each relay once tested.

5

Torque Specs and Instructions The Torque spec for the relay terminal block is 16in-lbs. With a 1” diameter = ½” radius screw driver, this means a turning force of 32 lbs.

Tighten and WiggleCopper is “ductile.” That means that it can compress and fl ow. To ensure a good connection in the termi-nal lug, follow this procedure.

Tighten the terminal to the specifi ed torque.1.

“Wiggle” the wire; Move it slowly from side to 2. side while pulling gently.

Tighten again to the specifi ed torque. Usually this 3. takes 1/16 to 1/4 of a turn or more.

Repeat as needed.4.

32 lbs

1" DiameterScrew Driver

1/2"

Breaker ID



Job Name:LCP Location:

Model #:LCP Name:

Supply Circuit: Voltage:

Comments:Joe's GarageElectrical Room 100GR 2432/26-DTC MODEM-HL-SMLCP 1HA-10 120V Normal

Relay Line Feed Zone Type Voltage Load Name Relay Line Feed Zone Type Voltage Load Name

R1 HA 1 NC 277V-N Hallway R2 LA 5 NC 120V-N Track CenterR3 HA 2 NC 277V-N Foyer R4 LA 6 NC 120V-N Track LeftR5 HA 3 NC 277V-N Sales Floor "a" R6 LA 7 NC 120V-N Track RightR7 HA 4 NC 277V-N Sales Floor "b" R8 LA 8 NC 120V-N Track FrontR9 HA 5 NC 277V-N Sales Flr Daylit R10 LA 9 NC 120V-N Track BackR11 HA 6 NC 277V-N Office 103 R12 LA 10 NC 120V-N Track EntryR13 HA 7 NC 277V-N Office 104 R14 LA 11 NC 120V-N ReceptsR15 HA 8 NC 277V-N Office 105 R16 LA 1 NC 120V-N ReceptsR17 HA 9 DP 480V-N Parking Lot R18 NC 120V-N SpareR19 HA 10 DP 480V-N Parking Lot R20 NC 120V-N SpareR21 HA 11 DP 480V-N Parking Lot R22 NC 120V-N SpareR23 HA 12 DP 480V-N Parking Lot R24 NC 120V-N SpareR25 HA 13 NC 277V-N Spare R26 /// 120V-N SPACE ONLYR27 NC 277V-E Spare R28 /// 120V-N SPACE ONLYR29 EHA 2 NC 277V-E Hall/Foyer Emer R30 /// 120V-N SPACE ONLYR31 EHA 4 NC 277V-E Sales Flr Emer R32 /// 120V-N SPACE ONLY

Enclosure:Dimensions:

Mounting:NEMA Rating:

Door Type:

Accessories: Relay Summary:Active Relays:Spare Relays:Total Relays:

Spaces:

Relay Types:Normally Closed:Two Poles (NC):

25.5"H x 20"W x 6"DSurface1Hinged, Locking

DTC ClockModem

206264

242

Programming Section OnlyCard Mode: Serial #:

Control Card Address:Discrete

1-4

A. Note the odd-numbered relays on the left and even-numbered relays on the right column

B. NC stands for Normally Closed Relay. LC&D offers a number of relay types. For more information go to www.lightingcontrols.com.

C. Cards can be in Discrete, 8-Zone or 16-Zone Mode.

Discrete Mode means that every relay is separately controlled.

Zone Mode means that the relays are controlled together - like a lighting contactor. When a panel is in Zone Mode, the zones are controlled or scheduled, and the relays on the panel are manually assigned to the zone.

6

How to Read a Panel ScheduleThis panel schedule was generated by Unity™ Lighing Control Software in only a few minutes. You can download Unity (www.lightingcontrols.com) and make schedule

changes on the fl y. Follow your panel schedule and reduce installation time by eliminating re-documentation. All changes must be documented for after-market support.

D. DP stands for “double-pole” relays.

E. Accessories: This panel has a DTC clock (master) and a modem. All other panels linked to this will not have clocks (slave panels).

F. Note the emergency loads (ensure this is allowed locally). The thick line on the panel schedule indicates a barrier (thin lines are used to count every four relays).

G. Panels use one address for every 8 zones or relays. Since this panel is in Discrete Mode, the 32 relays use four addresses (in this case 1-4).

H. Panel summary generated by Unity.

A A

B

CE

D

F

G

H

H



How to Create a New Panel ScheduleLC&D offers a simplifi ed version of the panel schedule (pg. 6), which can be fi lled out by hand. It’s mounted on the door of all non-programmed panels and at the back of this manual. Download a new one at: www.lightingcontrols.com/panel_schedule.pdf.

TM

Design Program Manage Integrate

Lighting Control Software

GR 2400 TM

Relay Panel ScheduleJob Name: ____________________________

LCP Location: __________________________

Modem #: _____________________________

Supply Circuit: ________ Voltage: _________

Comments:

Relay Line Feed Voltage Load Name

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

____________________________________________________________________________________


___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

Master Panel Modem Slave Panel

32 Relays 48 Relays

Hardware specs

___-____ _____ ________________ ___-____ _____ ________________

R1R3R5R7R9

R11R13R15R17

R2R4R6R8

R10R12R14R16R18

___-____ _____ ________________ ___-____ _____ ________________

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

R35R37R39R41R43R45R47

R36R38R40R42R44R46R48 ___-____ _____ ___________________-____ _____ ________________

Lighting Control & Design800-345-4448 www.lightingcontrols.com

Panel ID: ____________

Input Card ID: ________

Discrete Mode Zone Mode

Programming Section Only

Serial #: __________

7

Creating Programmable Panel SchedulesYou can download Unity Lighting Control Software which will allow you to document your panel sched-ules. Unity is free and easy to use.



Danger! This dual-tap transform-er generates an output voltage on the unused line voltage lug.

Example: If the 120v lug is used, the 277v lug will have a live

voltage of 277v.

8

Overview - Line & Low Voltage Connections



9

Internal Wiring SchematicInternal Jumpers and connector cables for the GR 2400 are shown and listed below. All internal wiring connections use depluggable connectors. Gently tug connectors after connection to ensure a firm fit and visually inspect to see it it seated properly.

Internal Connectors:1. QTY: 3 – #18AWG: Supplies power & neutral from input card to transformer.

2. QTY: 4 – #18AWG: Supplies power & reference ground from Transformer to Control Card.

3. QTY: 4 – 14-conductor ribbon cable: carries control signal between Control Card & Smacker Strips.

4. Up to QTY: 32 (GR 2432) / 50 (GR 2448) – 2-conductor ribbon cable: Carries control signal from Smacker Strip to Relays (QTY: 2 cables used on GR 2448 Card - GR 2448 only).

5. QTY: 1 – 8-conductor CAT.5 / RJ45 cable: Carries signal between Control Card & DTC Clock.

6. Terminator (QTY: 2 – provided inside sealed bag attached to DTC Clock bracket) – Terminated bus line.

7. QTY: 1 – 20-conductor ribbon cable: Connects GR 2448 Card to Control Card (for GR 2448 only).



Troubleshooting: What Do Flashing LEDs Mean?1. The online LED flashes ON once per second when the panel can see the clock or another panel is Master on the bus. If flashing about 10 times per second, the card is storing data to memory, so do not de-power the board.

If it is flashing slowly, but is mostly ON with a flash OFF, the card is trying to master the bus as it cannot see the DTC clock. If this is the Master Panel (with a DTC) check the cable con-nection to the DTC or try swapping out the flat cable. If it is a slave panel check that the Cat. 5 is plugged in and that your crimping is OK. Perform a bus scan. Can the clock “see” the panel? Worst case: the control card may need to be replaced.

2. If the Assign LED is flashing, at least one of the relay drivers has gone into Protect mode. There may be a short on the driver or a power spike may have caused it to trigger.

Press the ASSIGN button and it should clear. If it does not clear, toggle each relay with the manual override and observe which relay does not operate. Disconnect the relay jumper cable. If it still does not clear, transfer the load to a spare relay. If the control card has been damaged, and it is not pos-sible to clear the problem, the card may need to be replaced.

3. A blinking Relay LED on the control card means the relay is in Timer Mode and will perform an automatic shut-off within the specified timer value. Timer Mode is initiated when a clock schedule sweeps off relays in a group which is programmed as Maintain+Timer or Maintain+Blink (see page 10 of the Basic Programming Guide). If it is blinking

rapidly, shut-off is immi-nent (usually within 5 minutes - but check your blink timer value) and unless an override switch

Online

Zone2

Zone4

Zone6

Zone8

Zone1

Zone3

Zone5

Zone7

Assig

ns re

lays t

o a zo

ne

Push

"Assi

gn" f

or 3

Sec

onds

to ch

eck

Mode

AssignButton

Zones 1-8Active

2

Zones 9-16Active

4

6

8

10Discrete

Mode

128 ZoneMode

1416 Zone

Mode

16

1

3

5

7

9

11

13

15

1

2

3

is activated the relay will turn off. To initiate an override (re-start the timer) from the control card, press the relay button once. Or use an override switch.

Lights Won’t Turn Off

1. Is the panel ON and receiving power? Check that the breaker feeding the panel electronics is ON; check the input voltage with a meter. Relays are normally closed so no power to the electronics will change them to the ON state.

2. Check that the Hand-Auto switch is set to “Auto.”

3. Check that the jumpers from the control cards to the relays are properly seated and plugged in.

4. Press the Toggle buttons for each relay and listen for a clicking sound. If the relays sound like they are responding, then check the relay contacts. Check for continuity with the power removed when the relay is ON and then OFF. If the relay continuity is correct, the problem lies with the wiring (no neutrals, wrong circuits, etc).

Lights Won’t Turn On

1. Check that the breakers feeding the relays are powered up. Check the Line side of each relay with a volt meter for proper voltage.

2. Press the Toggle buttons for each relay and listen for a clicking sound. If the relays sound like they are responding, then check continuity with a meter (ensure that breaker is de-powered) when the relay is ON and then OFF. If the relay is responding, and the lights are not turning ON or OFF, then the problem lies within the wiring (no neutrals, wrong circuits, etc).

Can’t See the Clock DisplayAdjust the contrast level on the DTC Clock.



GR 2400 Panel with Call-Outs

11

The GR 2400 relay panel is a programmable panel with up to 32 or 48 relays. A master panel can stand alone or be the controller for a system of up to 128 digital devices: photocell cards, digital switches, contact closure input cards, slave panels or any other digital devices.

• Mix normal and emergency power if allowed by local codes.

• Mix voltages (up to 480v)

• On-board manual override for each relay

• 32 individual 365 day astronomical and time-of-day schedules can control any relay(s)

• Clock schedules can be overridden by digital switches through simple programming steps

GR 2400 TM

Relay Panel ScheduleJob Name: ____________________________

LCP Location: __________________________

Modem #: _____________________________

Supply Circuit: ________ Voltage: _________

Comments:


___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

____________________________________________________________________________________


___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

Master Panel Modem Slave Panel

32 Relays 48 Relays

Hardware specs

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

___-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ___________________-____ _____ ________________

R1R3R5R7R9

R11R13R15R17R19R21R23R25R27R29R31R33R35R37R39R41R43R45R47

R2R4R6R8

R10R12R14R16R18R20R22R24R26R28R30R32R34R36R38R40R42R44R46R48

___-____ _____ ________________

___-____ _____ ________________ ___-____ _____ ________________

___-____ _____ ________________

___-____ _____ ___________________-____ _____ ________________

Panel ID: ____________

Input Card ID: ________

Discrete Mode Zone Mode

Programming Section Only

Serial #: __________Lighting Control & DesignSupport (800) 345-4448

installation guide - zendesk · gr 2400 relay panel installation guide to remove the panel...

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