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to wire CA3750 and GE ZW4004 zwave contactors
How to wire wifi
|Intermatic CA3750 2 channel
120-208-240-277 volt zwave contactor
2 channel operation means contactor can be set for SPST so both relays turn on-off same time, or DPST where each relay can be operated separately
GE zwave contactor
|2 channel operation
Set CA3750 to DPST
Select 240 as operating voltage
Connect Hot 1 and Hot 2 to terminals 1 and 2.
Run jumper wire between terminals 1 and 3.
Connect 240 volt 3 Hp motor to terminal 4 and terminal 2
Connect 120 volt Hot wire to terminal 5.
Connect 120 volt light to terminal 6 and to Neutral.
This wiring lets you operate 2 different loads, with 2 different voltages, each with different amperages.
Do not connect 20 amp load to 30 amp wires.
Always match breaker size and wire.
Resource: Match breaker and wire size
277 and 208 volt are not found in residential homes, and instead found in commercial building depending on the type of electric service specified. Resource: What is 208V
1 channel, with antenna and newer architecture than CA3750
1 channel mean both relays turn on-off at same time.
120 - 208 - 240 - 277 volt
Range 50' indoor, 100' sight line outdoor.
Min temperature 4°F Max temperature 104°F
1 channel operation
Metal outdoor box/ Nema3R
Different brands interoperate with other brands zwave
GE z-wave contactor
Zwave from GE
Zwave from Leviton
Zwave from Aeon
Zwave from Smartthings
GE z-wave contactor manual
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."
More brands Zwave hubs
|Use phone to control pool
and spa equipment, irrigation
Pentair pool equipment
Hayward pool equipment
Zwave door lock
AO Smith/ Century motors
Same wiring applies to 120-208-240-277 volt
|Two loads, each same voltage
Same wiring applies to 120-208-240-277 volt
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.
GE z-wave contactor
Figure volts amps and watts of water heater
Select correct wire size
How to check if electricity is OFF
See inside main breaker box
|Control 2 water heaters with
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
Fuse protection/ trips when heat on line exceeds fuse rating / same as circuit breaker
disconnect -or- Non-fusable
Safety cut off
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.
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
How to wire safety switch
How to wire subpanel
How to change subpanel from 120V to 240V
240 volt with 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
Zwave from Leviton
See materials list and detailed wiring
How to wire WEMo wifi
How to wire wifi switch
Image of PE653 installed
5 channel contactor2016/ Intermatic waterproof PE953 is a z-wave controller that is made to work with PE653 5-channel contactor
PE953 remote controller is waterproof ... but 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 might work with ZW4004.
Older model 950 remote control 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
PE953 Z-wave remote control at Amazon
PE6563 5-channel receiver
PE953 remote control manual
PE953 and PE653 + related multiwave pool equipment
Alternative to Z-wave: X10 relay for resistive loadsRelay 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.
Insteon 240v / 30 amp X10 load controller for resistive loads only
Insteon remote control products at Amazon
ISY home automation devices at Amazon
Insteon load controller manual
X10/ to control gas water heater timer
Does not use ZW4004 contactor.
Use any z-wave or X10 module in place of timer located on top of gas water heater timer
Remote control for gas water heater
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.
Install enclosure directly to structure using 3-4 screws.
GE contactor has Nema 3R metal enclosure that 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.
Code vary. Some outdoor installations, such as metal enclosures, solar panels and pool equipment are required by code to have separate direct bond to nearby ground rod in addition to ground wire to main panel. This for safety and to help suppress surge events. Outdoor motors must absolutely be grounded.
Why you need ground wire
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.
Figure correct wire and breaker
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
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.
|Terminology for wiring
Load = light bulb, motor, fan, heater, pump; Total load = add up all Loads.
Resistive Load: incandescent light bulb, heating element and have uniform voltage and amp draw; Inductive load: motor, pump etc. Inductive loads pull many amps during start up. CA3750 is rated for resistive and inductive.
Load rating... light bulb shows wattage, label on water heater shows volts-watts etc Figure volts amps watts
Volts x amps = watts Water heater formulas .pdf
Hot wire = wire or wires that carry voltage and would shock you if breaker was on Image residential breaker box
Neutral wire = by code, a white wire used for 120V and 277V circuits to complete circuit, and carries no voltage
Ground wire = green or bare copper wire that connects to ground busbar in breaker box Why ground is needed
208 and 240 volt circuits have 2 Hot wires. (US electric) Image residential breaker box
Some countries have 230-240Volt circuits with 1 Hot and 1 Neutral (instead of 2 Hot wires). Unknown if CA3750 works with this power source.
120 and 277 volt circuits have 1 Hot and 1 Neutral / Usually 277volt is found in commercial applications (US)
Other voltages include 12V 24V 230V 380V 440V 480V 600V etc found in various applications worldwide
DC direct current generated by solar panels and batteries. Large arc when switching high voltage DC is fire hazard. Device must show DC rating. CA3750 is not rated for DC. Read about DC vrs AC
AC alternating current produced by power plant, windmill, or portable generator. CA3750 is rated for AC More
Single-phase = residential electrical systems are single phase AC, requiring 2 wires to complete circuit More
Three-phase = commercial wiring requiring 3 Hot wires to complete circuit More
Wire gauge = diameter of wire. The wire size and load rating and breaker must match Select wire and breaker
Breaker: circuit breaker will trip when amp draw from Load overheats wire. Turn breaker fully off and then fully on.
60Hz or 60 cycle = number of times AC generator rotates each second. Americas use 60 Hz power, while other countries use 50Hz. CA3750 is rated 50/60 Hz. Read more
Jumper = short wire used to connect 2 electrical points together.
contactor is single phase. All household wiring is single phase,
meaning two wires are needed to complete any electric circuit. (+ground
Contrast single-phase with commercial 3-phase where 3 wires are needed for a circuit. (+ground wire)
All single-phase circuits require two wires: Single-phase circuits can be turned on-off by switching off 1 wire or 2 wires.
Control 3-phase with GE ZW4004
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.
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
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.
Zwave does not broadcast your information. Z-wave information packets are too small. The 100 foot range too limited.
But do manufacturers and sellers track products to your address?
Certainly your wifi-based controller can send signals to outside parties.
Remember... the purpose of privacy today is to keep your information from being shown to you or your family unless you authorize release of your information to you, which of course you cannot due to terms of service agreement. Of course your information is available to all other interested parties around the globe, for a price.
The real question might be: How important is all that information if it cannot be updated when you change habits or die?
|Duane Paulson of home
2Gig by Linear, and a former utility-industry exec who developed load
management programs, said: “Utilities are incentivizing the wrong
people. Individuals don’t care about saving $5 or $10 per month, but
give those incentives to companies like ADT or AT&T, with their
millions of customers, and the money really adds up.” 1
My opinion: The problem with this thinking, is that people don't like big companies forcing them into packages and treating them with indifference, and misleading the public to gain a dollar. The battle lines are drawn, and we the people are behind the barricades and losing badly as our ownership disappears, wages promised as future benefit magically don't exist (stocks), jobs become temporary, the rich-get-richer, and tabloid facts become reasonable alternatives.
|Are z-wave networks secure? Yes
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 product become
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.
vs wi-fi home automation
Z-wave and wifi are on different radio frequencies and do not interoperate with each other. Zwave standard is 908.4 MHz
Caution: Wifi poses health risk from high radiation levels, but outcomes from radiation generally do not manifest immediately.
Wifi carries large packets of information: for example a movie. Wifi drains batteries very quickly: for example cell phone battery needs to be recharged frequently.
Contrast wi-fi with a TV remote control... the TV remote batteries last many months since the information packets are small, and the device is asleep except when button is pushed. Radiation levels for TV remote control are very low.
Contrast wi-fi and z-wave... Z-wave information packets are small for both battery-operated z-wave devices, and for continually-powered z-wave devices.
For example zwave can be 9700 bits per second. Radiation levels are very small for z-wave.
Choose wi-fi or z-wave? Both systems operate on different wavelength and do not interfere with each other. Both have distance limitations. Both systems can be connected to and controlled by phone or computer. Both systems control electric and electronic devices.
Zwave has advantages. Low radiation. Low amount of information is passed between controller and device, and to possible outside parties.
Zwave is not dependent on a specific brand. Zwave products from any company will interoperate with each other. Zwave devices will not become obsolete in a few years.
Wi-fi is high radiation. Large amounts of information can be passed between controller and device, and possibly to other parties. Broadcast is stronger. Response might be more rapid.
Wi-fi can broadcast security video and record more parameters such as energy usage.
Wi-fi systems are largely brand-specific. And the wi-fi providers usually want to be a partner with your activities.
Your information is worth big money. When wi-fi manufacturers change software or upgrade system or consolidate into one corporation that owns all wi-fi, you might need to replace devices, or upgrade 'package.' Don't forget the software upgrade for your smart TV that includes advertisements and listens to your voice, or the Hi-Def product offered by TV that degraded regular def over several years to differentiate their 'product.' Or Windows 10 upgrade that no longer protects you from spyware... because it is the spyware.
An appliance error code is opportunity to blizzard you with 'ten competitive offers for repair' that come from the same company that operates as ten different companies. Conclusion: zwave home automation offers less long-term chance of interfering with your life than wifi.
This information is for battery-operated devices. The GE contactor does
not use batteries, and is hardwired and fully powered at all times.
How long do z-wave batteries last? As a result of sleeping, battery-operated z-wave remote control, or motion detector, or door-alarm sensor will work for extended time using same batteries. Typical goal is 2-3 year battery life. And 1 year for' frequently listening devices' that awake very briefly once per second.
Battery life calculation: Ordinary AAA battery has 1000mAh (milliamp hours). Z-wave chip consumes .0025 mA during hibernation sleep.; 15-21 mA at wakeup, and 21-36 mA during transmission. If battery-operated z-wave was awake full time, then battery would last 2 days. Math 1000 mAh divided by 21 mA consumption = 47 hours or 2 days. This is why battery-operated z-wave must sleep except when prompted by push of button, or prompted by parameters set during device configuration.
Chance of running battery down is one reason why battery-operated devices must be configured immediately after inclusion.
GE contactor is hardwired, requires no battery, and requires no device configuration after inclusion is complete, and is awake full time, with 3 watt standby consumption.
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.
GE zwave contactor
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:
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.
See wire size and loading charts
See motor HP chart
See ordinary pool timers and manuals
See Intermatic control centers
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.
solar panels using WZ4004
WZ4004 is not rated for heavy-amp DC, but will control 12-24 Volt DC available from power supply
Many project options: Run 120 volt power to WZ4004 and to Power supply
GE zwave contactor
24 volt DC power supply
DC-DC 26 Amp Power relay
DC-DC 200 Amp Power relay
Convert AC water heater to DC water heater
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
40 amp contactor with 240Volt coil at amazon
120Volt coil At Amazon
240Volt Freeze control and contactor in outdoor box
More contactors/ contractors explained
Reassembled Intermatic Freeze control products and manuals
Mars 2-pole and 3-pole contactors at Amazon
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
Resources for 3-pole contactors
Use 30 amp fuse
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
Read about 3-phase electric
How to wire 3-phase timers
Resources for 3-pole contactors
Tools and home improvement
Home and garden
Black and Decker
Irwin Hand tools
Klein hand tools
Fluke electrical testing
Dremel hobby tools
Campbell Hausfeld air powered
Saws and saw blades
Compare box timers
Control water heater w/ Z-wave
Intermatic control centers: and parts
Digital control centers and parts
Tork control centers and parts
All control centers and parts
Off delay timers
On delay timers
Twin & one-shot
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