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How
to wire GE ZW4004 zwave contactor
Intermatic CA3750 has been discontinued / Use GE instead The Intermatic CA3750 had older Zwave architecture The GE zwave contactor does not use batteries, and is hardwired and fully powered. |
| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker. 1  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire HOOK UP Wires |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
 600 volt 12 ga Stranded wire ot THHN wire is good for conduit with multiple wires ... but stranded cannot be installed under screw terminals on outlets, switches, timers etc without risk ... of heat causing splayed strands ....that come loose ... and begin to arc. Connect stranded to short piece of solid copper wire, and attach solid to screw terminal. Do not solder residential or commercial wiring. Project wire, extension cords, thermostat, bell and automotive wire are not rated for residential or commercial wiring. Only wire maked 600 volt can be used for permanent household wiring. Buy: Southwire 600 volt stranded wire Rolls of stranded wire HOOK UP Wires |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
  Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point. Buy tools: KLEIN TOOLS Wire strippers at Amazon Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
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 Larger image Both wires MUST be same gauge Straighten each wire Tighten screw very tight against copper wire |
 Larger image Connect stranded and solid with wire connector and run jumper to screw plate. Or add solder to stranded wire to make solid. See example image |
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GE
Z-wave contactor Automatically detects voltage 120 - 208 - 240 - 277 volt 40 amp Range 50' indoor, 100' sight line outdoor. Min temperature 4°F Max temperature 104°F 1 channel operation DPST Metal outdoor box/ Nema3R Different brands interoperate with other brands zwave Buy GE z-wave contactor Zwave from GE Zwave from Leviton Zwave from Aeon Zwave from Smartthings Resource GE z-wave manual |
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SmartThings Hub Zwave requires a hub ... and the hub lets you control zwave using phone or other hand held device SmartThings is a popular brand Smarthings says: "Ethernet-connected Hub plugs directly into Internet router and supports ZigBee, Z-Wave as well as IP-accessible devices." Buy: SmartThings Hub Vera hub More brands Zwave hubs |
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Use phone to control pool
and spa equipment, irrigation
system, etc Buy: Pentair pool equipment Hayward pool equipment Zwave door lock AO Smith/ Century motors |
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120-208-240-277
volt Wiring: When power is connected to terminals 1 and 2, this supplies power to operate z-wave receiver, circuit board and both relays. Use hammer and screwdriver and pliers to remove knockouts to run wire into enclosure. Always use wire connectors to fasten electric cable to enclosure. Electric cables must be tightly secured to enclosure. All cables and conduit must be held tight to structure to preserve installation safety. Resource: Figure correct wire and breaker |
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120
volt/
2 loads Same wiring applies to 120-208-240-277 volt Load rating Contact Ratings: 120-277 VAC, 40A Resistive Single Phase 120-277 VAC, 20A Ballast load (Inductive) Single phase 125 VAC, 15 A Tungsten 250 VAC, 5 A Tungsten 1HP@120VAC, 2HP @ 240VAC DC or direct current volt ratings are not shown in manual 3Hp at 240Volts/ 1-1/2 Hp at 120V Volts x amps = watts. 240V x 24 amps = 5760 watts. Use 10 gauge wire Range 50' indoor, 100' outdoor. |
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Two
loads, each same voltage Same wiring applies to 120-208-240-277 volt |
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Control 30 amp water heater Wire color can be red-black or white-black or black-black etc Wire color does not matter. Add black tape near end of white wire when white wire carries voltage. Buy: GE z-wave contactor Resources: Figure volts amps and watts of water heater Select correct wire size How to check if electricity is OFF See inside main breaker box |
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Control two 30 amp water heaters
with
ZW4004 Turn off each Load by turning off 1 hot wire on each circuit Select 240Volt operation Choose 2xSPST to operate each water heater with different schedule Choose DPST to operate both water heaters at same time Controller assigns 1 Node id for DPST & 2 different Node ids for 2xSPST. 2 separate circuit breakers required. Up to 5500 watt residential non-simultaneous each water heater can be controlled by 30 amp breaker and 30 amp CA3750 Typical residential water heater is 4500 watt non-simultaneous |
 Safety switch Fusable  Fusable pull-out Fuse protection/ trips when heat on line exceeds fuse rating / same as circuit breaker |
Pull-out
disconnect -or- Non-fusable cut off for safety on outdoor
installation: Locate fused cut-off or no-fusable cut-off next to ZW4004 or short reach away. Purpose to protect anyone working on electricity outside ... so person knows power is OFF, and power cannot accidently be turned ON. Instructions: Install on wire from breaker box before wires enter ZW4004 Incoming wire from breaker box has 2 Hot wires Connect these 2 wires to top terminals on cut off. Wire going to ZW4004 has 2 Hot wires. Connect these to lower terminals on cut off. Connect ground wires to ground screw. Check that screws are very tight against copper wire. Move safety switch lever up-and-down to turn power on-off. Fusable vrs non-fusable: Non-fusable means there is no breaker or fuse inside the cut-off box. Non fusable is manually-operated on-off switch for safety. When is fusable cut off required? 1) If incoming wire is not already protected by circuit breaker -or- 2) if 30 amp ZW4004 is being connected to higher amp line, such as 40-60 amp breaker. Buy: Pullout Disconnect at Amazon Fusable pullout disconnect 2-pole outdoor / 60 amp/ non-fusable safety switch 2-pole indoor / 30 amp/ fusable safety switch 2-pole 60 amp non-fusable safety switch Resource: How to wire safety switch How to wire subpanel How to change subpanel from 120V to 240V |
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Control
240 volt with zwave or wi-fi switch 240 Volt Z-wave switch Requires Neutral wire. Use ground wire as temporary neutral to check connection. Bring white neutral wire from any nearby light switch or outlet box Buy: GE zwave Zwave from Leviton Resource See materials list and detailed wiring |
Image of PE653 installed |
Alternative:
Intermatic 5
channel contactor 2016/ Intermatic waterproof PE953 is a z-wave controller that is made to work with PE653 5-channel contactor PE953 controller is NOT a general household zwave controller. It will control 1 additional zwave device 953 5-channel 'Controls any Zwave' according to specifications, but only 1 device outside the PE953 PE953 should work with ZW4004. Older model 950 does not work with z-wave PE series is made to work in swimming pool environment, with low voltage compartment for switching off 24 volt swimming pool light, and control pool pump and spa aerator and interface with freeze control etc Buy: PE953 Z-wave remote control at Amazon PE6563 5-channel receiver Resources: PE953 remote control manual PE953 and PE653 + related multiwave pool equipment |
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Alternative
to Z-wave: X10 relay for resistive loads Relay handles resistive load only: Water heater, incandescent light bulb... yes Motor, CFL, LED.... no 2 year warranty/ must use Insteon X10 compatible controller etc X10 products from different companies generally don't interoperate with each other. X10 is older, open-source software, possibly less reliable than Z-wave. Buy: $120 Insteon 240v / 30 amp X10 load controller for resistive loads only Insteon remote control products at Amazon ISY home automation devices at Amazon Resource: Insteon load controller manual |
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Use
Z-wave, wifi or
X10/ module to control gas water heater timer Does not use ZW4004 contactor. Use any z-wave, wifi or X10 module in place of timer located on top of gas water heater timer Resource: Remote control for gas water heater |
| Choose location
Test location before installation. Inductive loads such as motors, blowers can interfere with Z-wave. Resistive loads such as light bulbs, heating elements do not interfere with Z-wave. Zwave 908.42 MHz and is relatively free from interference with other radio signals. Z-wave is a radio wave. Each country has a specific radio frequency or band of the spectrum allocated for z-wave products. America's use a different band than Europe, etc. Locate in open area so clear communication can take place with controller. Or locate ZW4004 in clear view of other nodes in the network. Max 4 nodes between controller and ZW4004. Do not install GE ZW4004 near motor, air conditioner, furnace or other inductive source of interference. Do not install with metal or aluminum between GE ZW4004 and controller. Signal will travel through walls and floors. Up to 30% loss for each wall. Clear sight-line with controller allows 100' distance. Several walls reduce distance to 30-50 feet. Brick walls reduce distance more than plaster wall. Z-wave signal is not as strong as in-home wi-fi signal, for example. Adding several nodes to network helps since each node communicates with other nodes in the network. Z-wave signal travels outward 360 degrees in all directions like a rock making ripples in a pond. Obstructions and distance weaken the signal.. Metals can stop the signal, making a dead spot. Sending signal horizontally through several joists or rafters can block the signal. Furniture & belongings between controller and Z-wave device can block or weaken signal. Always test network capability before installation. |
| Installation of Nema 3R metal,
weather-resistant Enclosure Metal enclosure must be connected to ground wire for safety. Install enclosure directly to structure using 3-4 screws. Choose location out of direct sun and heat if possible (max 104°). Install away from potential impact or damage from fork lift, lawn mower etc. GE contactor can be used indoor-or-outdoor, and can be exposed to rain, but is not moisture-proof, and not humidity-proof, and cannot be under water. Install at least 12" above anticipated snowfall. Do not work on contactor unless power is off. Keep enclosure door closed to prevent hazard. Resource: Enclosures |
| Ground connection Metal enclosure absolutely must be connected to ground wire for safety. Other electrical requirements vary by locale. Some outdoor installations, such as metal enclosures, solar panels and pool equipment are required by local code to have separate direct bond to nearby ground rod in addition to ground wire to main panel. They might also require any outdoor installation to have safety disconnect. These requirements are for safety and to help suppress surge events from nearby lightning strike, or motor starts etc. Resource: Why you need ground wire |
| Z-wave basics a) More devices result in more routes for communication. Zwave is mesh network. Maximum 232 devices in a network. Each device has a unique Node id that is assigned by the controller during inclusion. When controller sends signal to a device node, the signal can be passed from one device to the next device to find best route. There can be more than one controller, but generally only 1 controller is the master controller. b) Z-wave devices from different companies will communicate with each other. Z-wave is designed for home-use products. Each Z-wave product is tested to ensure it will communicate with all Z-wave-compatible controllers and devices. |
| All
controllers generally find best route to the GE contactor. If the GE
contactor is out of range, then controller can use maximum 4 other
device nodes to repeat signal until it reaches contactor. All Z-wave controllers will re-try signal 3 times if communication fails, then search for 2 alternative routes, and try each new route 3 times... storing successful routes in memory. If all attempts fail, then controller indicates failure. Add repeater node in view of the GE contactor. If communication is successful, controller will indicate success. Steel and other structure can reduce or block signal. Always check location before making final installation. Expect z-wave network to feel more sluggish than flipping on a light switch. |
| How
Z-wave works: Home-id
and Node-id. Each Z-wave network requires 1 main controller. Controllers can be a hand-held controller (portable controller), or wall-mount controller (static controller), or SmartThings Hub (static controller) etc. Controllers can be battery-powered or hardwired. SmartThings Hub is 'hardwired' and continually powered. At the factory, controllers are given unique Home-id number. No two controllers have same Home-id. The Home-id cannot be changed inside the controller. During inclusion of each device, such as the GE Contactor, the controller will assign it's unique Home-id to that device. // Each Z-wave network also requires 1 to 232 devices (actors and sensors). For example the GE Contactor is an example device (or actor), while Z-wave wall switch is another device. During inclusion, each device will be assigned a unique Node id by the controller. To summarize: During inclusion, the controller will assign its Home-id and a unique Node-id to each device. ## GE Contactor arrives new out of the box without Home-id or Node-id. Therefore the GE Contactor device is ready to interoperate with any Z-wave controller. Recommended that each device be excluded before being included. This is to clear any prior inclusions. If a device falls off network, it must be excluded and then included again. Most zwave devices today are auto-inclusion type and will automatically seek the network signal. ++ During inclusion, the device automatically exchanges its node-information-frame to the controller. The information-frame tells the controller what kind of device and what command classes are supported. GE Contactor requires no further configuration after inclusion. The controller knows this after receiving the node information frame from the GE Contactor. While other z-wave devices, such as battery-powered motion detector, can be configured with various parameters such as time interval etc. Battery operated devices should be configured immediately. When battery-operated device is included, it will stay awake while waiting for configuration... and this can drain battery. GE Contactor is powered by electricity and not battery, so battery drain is not as issue. ## After the controller's Home-id is assigned to a device, then the device will not accept signals from any other controller (unless network has secondary controller or bridge to another network). This assures that the GE Contactor cannot be operated through somebody else's controller. == Summary: When inclusion is complete, the GE Contactor is assigned the same Home-id as the controller, and is assigned a unique Node-id. And the controller knows what commands can be sent to the GE Contactor. |
| Are z-wave networks secure? Yes
probably The home or business owner must be in possession of the device and the controller to 'pair' or include each device into network. If you are in possession of the device and controller, and each device responds only to the unique Home-id of the controller, then nobody else can control your Z-wave network. Exception: auto-inclusion devices. This feature makes it easy to set up network. For security, this type device can be excluded and then included by the owner. Exception: large z-wave networks with multiple controllers. While z-wave has limited range, a hand-held controller could disappear, or be operated by unauthorized person. With subscription Z-wave service, then assume security and privacy are available to others. Assume Z-wave standard allows manufacturer to record the unique Home-id of your controller. Zwave is constantly evolving, as are methods to profit from your information. |
| Will
your zwave product become
obsolete? No. All Z-wave is open source standard, and all devices will continue to interoperate with newer zwave devices. Changes in technology will give added capabilities to devices, but suggest that most innovations today are within the terms of service pertaining to collection of your information and conversion to monthly subscription and not changes in the device function. |
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Off
peak water heater
No wires connect to 5-6 Control lower part of tank separately. Upper part of tank runs normally, When 3-4 is ON, whole tank runs normally. When 3-4 is off, lower element is off. Saves money during peak electric. Required; ECO-protected thermostat installed in place of lower thermostat Required: one 30 amp breaker, 10 gauge wires Required: rewire tank, & run 1 additional wire to tank Turn off lower element when electric prices are high. 3-4 OFF Upper part of tank stays hot Lower part of tank is off. Lower part of tank cools over time, or cools when hot water is drawn from tap and cold water enters bottom of water heater You have hot water for shower or washing hands, but less hot is available. Buy: Intermatic CA3750 at Amazon Intermatic CA3750 at Amazon< Resources: How to replace thermostat How to wire water heater thermostats More off-peak water heater wiring and ideas How to adjust temperature on gas and electric heaters Water heater temperature for killing bacteria 140F - options advisories Ordinary box timers that can accomplish same objectives Ways to increase amount of hot water Control gas water heater using Z-wave Thermostats must be covered with insulation or cool room temperature will cause thermostat to misread tank temperature. Thermostat must sit flat against tank wall to correctly read temperature: |
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WZ4004 controls pool pump and pool heater
Control 2 Loads. Rated for 2 HP at 240Volts Up to 24 amps Volts x amps = watts 240Volts x 24 amps = 5760 watts Each electrical device has rating label showing voltage and amperage, and sometimes wattage. Resources: See wire size and loading charts See motor HP chart See ordinary pool timers and manuals See Intermatic control centers |
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Control
2 different voltages 208-240Volt circuit can be turned ON-OFF by cutting power to one of the two hot wires. 120Volt circuit is turned ON-OFF by cutting power to hot wire. It is against code to turn 120V circuit on-off by cutting white neutral wire without also cutting power to black hot wire. |
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Control
solar panels using WZ4004 WZ4004 is not rated for heavy-amp DC, but will control a power supply that produces 24 volt DC. Power supply example: Buy LED driver produces 200-300 watts of 24 volt DC. 24 volt output from power supply is connected to switching terminals on the wifi or zwave contactor to turn the high-amp DC-DC relay on-off. Important to isolate the low voltage wires away from 120 volt household power so an insulation failure will not energize low voltage wires with 120V. Buy: Power supply IP67 weatherproof 24 volt driver Magnecraft relay DC-DC 26 Amp Power relay DC-DC 200 Amp Power relay Resource: Convert AC water heater to DC water heater |
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Freeze
control: works for 120V-277V
Override WZ4004 with freeze control: When pool pump is off, then pump and pipes can freeze. When outdoor or vacation home water heater is off, the water can freeze. Mechanically-operated freeze control thermostat overrides WZ4004 circuit and turns Load ON. Requires purchase DPST contactor with 240Volt coil For 120Volt, purchase contactor with 120V coil See 120V wiring Buy: 40 amp contactor with 240Volt coil at amazon 120Volt coil At Amazon Freeze thermostat 240Volt Freeze control and contactor in outdoor box Resources: More contactors/ contractors explained Reassembled Intermatic Freeze control products and manuals Mars 2-pole and 3-pole contactors at Amazon |
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3-phase
z-wave contactor
Neutral to terminal 1, Hot to terminal 2 Jumper wire from terminal 2 to terminal 3 3-pole contactor coil connects to terminal 1 and terminal 4 Usually buildings with 3-phase also have ordinary 120Volt outlets Code usually requires separate 120Volt breaker box. Single pole breaker can be snapped into 3-phase breaker box. Depending on the 3-phase service voltage: For 3-phase 208-120, then single pole breaker will give 120V If service is 277-480, then a single pole breaker will give 277V If service is 120-240 High leg, the either 120 or 240 are available Fused disconnect required on 3-phase line and timer in commercial applications Resource: Resources for 3-pole contactors 3-phase timers |
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Control
3-phase 277V-480V with WZ4004 Connect white neutral to terminal 1 Connect first Hot leg to terminal 2 ... use 30 amp line fuse Add jumper wire from terminal 2 to terminal 3 Connect other Hot leg to terminal 5 ... use 30 amp line fuse Connect wires going to 3-pole contactor to terminals 4 and 6 Contactor has 480Volt coil Or choose contactor with 277V coil. Difference: Only 277V enters CA3750 and connects to terminals A and B as illustrated. No hot wire connects to terminal 3, contactor wires connect to terminals 1 and 4 Resources: Read about 3-phase electric How to wire 3-phase timers Resources for 3-pole contactors |
 Contactors/ relays |
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