MK1 Series Relay Card Fitting
Product Information
Specifications:
- Model: Chilli Pro MK3
- Supported Cards: 6 cards (2 primary, up to 4 secondary)
- Upgrade Kits: 0095-000108-00 – Primary Relay Card & PSU
Kit, 0095-000109-00 – Secondary Relay Card Kit
Product Usage Instructions
Configure Relay Channels:
- Prior to fitting the relay cards, configure the channels you
wish to convert to relays in the dimmer settings using the User
Interface. - Remove the front cover(s) by removing the screws on the front
of the unit. Retain all screws for reassembly. - Fit the required wires to the power supply of the Primary Card
before assembling it to the unit. - Screw Live and Neutral wires into the first circuit
breaker. - For non-bypass variants, fit the PSU at the top of the DIN
rail.
Removal of Triac Boards:
- Unscrew the Triac connectors on the boards to be replaced from
the unit. - Cut cable ties on Live and Load wires for each channel to be
replaced. - Disconnect wires, mark their positions, and remove the Triac
Boards. - Lift the Triac Clip and remove the Triac.
Fitting Relay Cards:
- Slide the Relay Board into position ensuring correct alignment
and insert screws but do not fully tighten. - If needed, handle thermal sensors based on the assembly
position of the relay card.
FAQ
Q: How do I confirm my Chilli dimmer version?
A: You can confirm your Chilli dimmer version by visiting the
link provided in the manual:
https://zero88.com/manuals/chillipro/introduction-105/chilli-pro-versions
Q: What precautions should I take before commencing the relay
card fitting procedure?
A: Ensure that the power supply to the dimmer is isolated and
observe precautions for handling Electrostatic Sensitive
Devices.
Relay Card Fitting Instructions
Introduction Chilli dimmers can have blocks of 4 dimmer channels replaced with relays. Chilli Pro MK3 support six cards (2 primary and up to 4 secondary). The secondary cards must be placed directly above or below a primary card. Chilli MK1 & MK2 support three cards (1 primary, and up to 2 secondary). These instructions are for the following upgrade kits:
0095-000108-00 – Primary Relay Card & PSU Kit 0095-000109-00 – Secondary Relay Card Kit
To confirm your version of Chilli dimmer, see the link below… https://zero88.com/manuals/chillipro/introduction-105/chilli-pro-versions
Chilli Channel Outputs
Zero 88 – Chilli Pro – Page 1 of 6
Printed: 02/08/2025
Ensure the power supply to the dimmer is isolated before commencing this procedure.
Observe precautions for handling Electrostatic Sensitive Devices
Instructions for Chilli Pro MK3
Configure Relay Channels 1 . Prior to fitting the relay cards, configure the channels you wish to convert to relays in the dimmer settings. Using the User Interface:
1. Press Enter to get to the Menu 2. Use the Up/Down Arrows to select Dimmer Laws 3. Press Enter 4. Use the Up/Down Arrows to get to Set Laws 5. Press Enter 6. Use the Up/Down Arrows to Select the Channel 7. Press Enter to confirm 8. Use the Up/Down Arrows to Select the law [Switch] 9. Press Enter to confirm and repeat for all necessary channels.
2 . Remove the front cover(s) by removing the screws on the front of the unit.
Retain all screws as they will be required for reassembly.
3 . Before assembling it to the unit, fit the following wires to the power supply of the Primary Card:
1. Fit the brown Live wire to Live PSU terminal. 2. Fit blue Neutral wire to Neutral PSU terminal. 3. Fit terminated end of black wire on the long DC supply cable to
a terminal on the PSU 4. Fit terminated end of red wire on the long DC supply cable to a
+ terminal on the PSU
4 . For non-bypass variants, the PSU can be fitted at the top of the DIN rail where the Bypass switches would be fitted.
5 . Screw the other end of the brown Live wire into the first circuit breaker. Screw the other end of the blue Neutral wire into the first circuit breaker.
Removal of Triac Boards
Zero 88 – Chilli Pro – Page 2 of 6
Printed: 02/08/2025
6 . Unscrew the Triac connectors on the boards to be replaced from the unit.
7 . Working through each individual channel to be replaced, cut the cable ties on the Live and Load wires. Disconnect each wire, untangle any wires that are twisted together (as you may need the length later) and mark up where the wire came from.
8 . Disconnect the ribbon cable(s) attached to the Triac Board and remove the PCB by unscrewing the 3 screws. Slide the board away from the Triacs then lift out.
9 . Lift the Triac Clip and slide out the Triac. With the Triac removed the clip is no longer tensioned and can be removed.
Fitting Relay Cards 10 . If a relay card is to be assembled at the middle position, then the thermal sensor is required. If a relay card is to be assembled to the top or bottom position, then the thermal sensor must be removed from the board by cutting its pins.
11 . Slide the Relay Board into position ensuring the side of the PCB is located in the retaining slot and insert the screws but do not fully tighten.
12 . Apply pressure to the (screw) side of the PCB to ensure that it is fully located in the slot and while maintaining the pressure, tighten the screws (if you don’t do this it can pop out of the slot when you are pushing the connectors on).
13 . If the central board has been replaced, then you must fit the Triac clip to the thermal sensor.
14 . Fit the coil wires first, running them around each side of the relay, then the Live and Load wires. Note: The coil connections are not electrically connected to the circuit, they are physically connected to the PCB, and are there to secure the wires only.
15 . Fit the DC supply cable to the furthest/lowest board closest to the PCB and use the link wires to connect the others.
Reassembly 16 . Refit all covers, reusing the screws that have been retained.
If you hear a relay buzzing, the channel dimmer law hasn’t been set to Switch. See step 1.
Zero 88 – Chilli Pro – Page 3 of 6
Printed: 02/08/2025
Instructions for Chilli MK1 & MK2
Configure Relay Channels 1 . Prior to fitting the relay cards, configure the channels you wish to convert to relays in the dimmer settings. Using the User Interface:
1. Press Enter to get to the Menu 2. Use the Up/Down Arrows to select Dimmer Laws 3. Press Enter 4. Use the Up/Down Arrows to get to Set Laws 5. Press Enter 6. Use the Up/Down Arrows to Select the Channel 7. Press Enter to confirm 8. Use the Up/Down Arrows to Select the law [Switch] 9. Press Enter to confirm and repeat for all necessary channels.
2 . Remove the front cover(s) by removing the screws on the front of the unit.
Retain all screws as they will be required for reassembly.
3 . Before assembling it to the unit, fit the following wires to the power supply of the Primary Card:
1. Fit the brown Live wire to Live PSU terminal. 2. Fit blue Neutral wire to Neutral PSU terminal. 3. Fit terminated end of black wire on the long DC supply cable to
a terminal on the PSU 4. Fit terminated end of red wire on the long DC supply cable to a
+ terminal on the PSU
4 . Assemble the metal bracket to the unit in the position shown. Do this by removing the two screws holding the circuit breaker bracket to the enclosure, putting the metal bracket into position and refitting the screws. Once the bracket is in place clip the power supply to the metal bracket such that the N and L terminals are facing to the right.
5 . Screw the other end of the brown Live wire into the first circuit breaker. Screw the other end of the blue Neutral wire into:
1. One of the Neutral DIN terminal blocks if a non-RCD version Chilli
2. The phase one RCD if the Chilli has RCDs fitted
Removal of Triac Boards
Zero 88 – Chilli Pro – Page 4 of 6
Printed: 02/08/2025
6 . Unscrew the Triac connectors on the boards to be replaced from the left-hand side of the unit.
7 . Working through each individual channel to be replaced, cut the cable ties on the Live and Load wires. Disconnect each wire, untangle any wires that are twisted together (as you may need the length later) and mark up where the wire came from.
8 . Disconnect the ribbon cable(s) attached to the Triac Board and remove the PCB by unscrewing the 3 screws. Slide the board away from the Triacs then lift out.
9 . Lift the Triac Clip and slide out the Triac. With the Triac removed the clip is no longer tensioned and can be removed.
Fitting Relay Cards 10 . Relay cards are to be assembled to the left-hand side of the enclosure only.
If a relay card is to be assembled at the middle position, then the thermal sensor is required. If a relay card is to be assembled to the top or bottom position, then the thermal sensor must be removed from the board by cutting its pins.
11 . Slide the Relay Board into position ensuring the side of the PCB is located in the retaining slot and insert the screws but do not fully tighten.
12 . Apply pressure to the (screw) side of the PCB to ensure that it is fully located in the slot and while maintaining the pressure, tighten the screws (if you don’t do this it can pop out of the slot when you are pushing the connectors on).
13 . If the central board has been replaced, then you must fit the Triac clip to the thermal sensor.
14 . Fit the coil wires first, running them around each side of the relay, then the Live and Load wires. Note: The coil connections are not electrically connected to the circuit, they are physically connected to the PCB, and are there to secure the wires only.
15 . Fit the DC supply cable to the furthest/lowest board closest to the PCB and use the link wires to connect the others.
Reassembly 16 . Refit all covers, reusing the screws that have been retained.
Zero 88 – Chilli Pro – Page 5 of 6
Printed: 02/08/2025
If you hear a relay buzzing, the channel dimmer law hasn’t been set to Switch. See step 1. Doc. No. 9850-000377-00 (Version 2)
Zero 88 – Chilli Pro – Page 6 of 6
Printed: 02/08/2025
Documents / Resources
 |
Zero 88 MK1 Series Relay Card Fitting [pdf] Instructions MK1 Series Relay Card Fitting, MK1 Series, Relay Card Fitting, Card Fitting, Fitting |