Lighting Controls Blue Box LT Maintenance Manual
®
™
THE BLUE BOX
LT
OPERATION
& MAINTENANCE
MANUAL
LCDBBO&M03Sept08
®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com
THE BLUE BOX LT OPERATION & MAINTENANCE MANUAL 3
TABLE OF CONTENTS
OVERVIEW..........................................................................5
GR1404LT / GR1408LT Drawings & Details......................................................7
Relay Overview ..........................................................................10
GR1416 LT Drawings & Details.................................................................11
Introduction to The Blue Box LT™ Series......................................................15
The Blue Box LT™ vs. Lighting Contactors .....................................................16
Build Your System in 3 Steps ................................................................17
Most Popular Accessories ..................................................................20
Applications...........................................................................22-23
MAINTENANCE & TROUBLESHOOTING ..............................................25
Making Up Cat. 5 Cable With RJ45 Connectors ................................................27
How To Make Proper Crimps...............................................................35
Adding a New Device ..........................................................................39
Parts Replacement & Installation Guide...............................................47
Hardware Troubleshooting .........................................................59
Troubleshooting with An Oscilloscope................................................63
Programming ....................................................................67
DTC Clock Navigation Basics ...............................................................69
Manual Control of Relays ..................................................................70
Programming Switches or DI Inputs..........................................................71
Time Schedules...........................................................................73
Programming a Blue Box LT Photocell........................................................76
To Add a Holiday List to a Schedule .........................................................77
More Data on Scheduled Events ............................................................78
Group Types .............................................................................80
Programming Groups......................................................................81
Additional Groups Parameters ..............................................................82
Group FAQs .............................................................................83
Other System / Set up Programming.........................................................86
LCDBBO&M04Sept08
Daylight Saving Time .......................................................................86
Keyboard Lock Code ......................................................................87
4 THE BLUE BOX LT OPERATION & MAINTENANCE MANUAL
TABLE OF CONTENTS (Continued)
Time Schedule Programming Examples...........................................................88
Exercise #1- Contact Closure Device Controlling 4 Relays ......................................88
Exercise #2 - Contact Closure Device Controlling 10 Relays ....................................88
Exercise #3 - Time Schedules with Override Switches ..........................................88
Exercise #4 - Retail Store ..................................................................89
System Diagnostics Tools...........................................................91
System Start Up & Cabling Guide ...................................................95
Frequently Asked Questions .......................................................103
APPENDIX ........................................................................111
Installation Guide GR1404 LT & GR1408 LT ..........................................113
Installation Guide GR1416 ........................................................117
Chelsea Installation Guide ........................................................121
PCO Installation (Out Door Photocell) Installation Guide ..............................123
Digital Input Card Installation Guide (For Contact Closures)............................125
Occupant Sensors (Hook-Up and Programming)......................................129
Novitas® Brand Occupant Sensors .............................................................131
Sensor Switch® Brand Occupant Sensors ........................................................132
Wattstopper® Brand Occupant Sensors .........................................................133
Hubbell® Brand Occupant Sensors .............................................................134
LC&D® Brand Occupant Sensors...............................................................135
Clock /Programming Navigation Tree ...........................................137-139
Technical Glossary ...........................................................141-143
LCDBBO&M04Sept08
®
™
THE BLUE BOX
OVERVIEW
LT
LCDBBO03Sept08
®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com
6 THE BLUE BOX LT OVERVIEW
TABLE OF CONTENTS
GR1404LT / GR1408LT Drawings & Details..........................................................7
Relay Overview ..................................................................................10
GR1416LT Drawings & Details .....................................................................11
Introduction to The Blue Box™ LT Series ...........................................................15
The Blue Box™ LT VS. Lighting Contactors .........................................................16
Build Your System In 3 Steps .......................................................................17
3 Enclosure Sizes ..................................................................................18
2 Panel Configurations.............................................................................19
Master Relay Panel ................................................................................19
Slave Relay Panel..................................................................................19
Most Popular Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Applications .......................................................................................22
Small Parking Lot (Single Control Panel) ..............................................................22
Retail Stores (With 6 Override Zones)...............................................................22
Warehouse (Multiple Control Panels)................................................................23
Blue Box Technical Support ........................................................................24
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 7
GR1404LT / GR1408LT DRAWINGS & DETAILS
1
3
2
4
LCDBBO03Sept08
5
NEMA 1 surface mount enclosure with hinged door and key lock;
8.375” h x 8.375” w x 3.125” d (GR1404 LT)•
13.5” h x 8.5” w x 3.125” d (GR1408 LT)•
GR1404/08 LT (FRONT DOOR OPEN)
Screw fastener secures white door (Master only).1.
White door provides a barrier between Control 2.
Interface and High Voltage connections beneath
(Master only).
Hinged locking blue door.3.
DTC Clock / Display & Programming Interface: 4.
32-channel, 365-day astronomical clock with
Scroll and Tab to access control features for entire system (Master only).
Door pocket contains the following documenta-5.
tion: Refer to the Blue Box LT Installation Guide
for more information on these documents.
Panel Schedulea)
(optional) DI Card schedule.b)
If this is a Master panel, the System Device c)
Schedule on the back of the Panel Schedule
should also be filled-out.. It lists out all of the
digital lighting controls devices, where they are
and what they do. (see System Star t-Up Guide
for more information.
8 THE BLUE BOX LT OVERVIEW
low voltage only line voltage only
2
1
8
3
4
12
6
9
7
10
5
11
55
GR1404/08 LT (WHITE DOOR OPEN)
Screw fastener secures hinged Control Panel 1.
Door (Master only).
White door provides barrier between human 2.
interface and line voltage connections beneath
(Master only).
Optional Modem. Free factory dial-up programming.3.
Optional DI contact closure interface card.4.
Ø1/4" mounting holes at 4 places.5.
Optional: Unfasten two screws to remove chassis 6.
assembly from enclosure providing full access to
mounting holes if required.
SnapLink7.
LED is ON when relay is OFF.
DTC Clock / Display & Programming Interface: 8.
™
relays, Normally-Closed (NC). Status
32-channel, 365-day astronomical clock with
Scroll and Tab to access control features for entire system (Master only).
Voltage barrier separates line voltage (class 1) & 9.
low (class 2) connections.
Dual Voltage Power Supply Input: Blue Box LT10.
operates on either 120V or 277V.
Ground Lug for equipment grounding.11.
Relay Control Card provides interface between 12.
control network and relays. The Relay Control
Card in the Master panel also holds time schedules and system mapping.
™
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 9
GR1404/08 SLAvE PANEL RELAY CONTROL CARD
4
7
1
9
11
8
10
7
7
12
GR1404/08 MASTER PANEL RELAY CONTROL CARD
5
4
7
1
9
11
8
6
10
7
7
LCDBBO03Sept08
2
13
Relay Drivers. Opto-isolated to prevent line volt-1.
age back-feed and to help prevent RF and EMF
noise interference. Relay drivers will close latching
relays upon loss of power to the Control Card.
RJ45 sockets for digital bus. Digital devices (relay 2.
panels, digital switches, etc) connect to this panel
using a bus (daisy-chain) topology.
Photocell port (master panel only). +V output 3.
with a photocell input. Photocells are polarized follow color code.
Power/data connector for DI Card.4.
Power/data connector for modem (master panel).5.
Power/data connector for DTC clock/display 6.
(master panel only).
Removal slots for control card. Used with a flat 7.
blade screw driver to remove the Control Card.
3
Terminator pins. Add terminator here if this is the 8.
first or last item on a bus (follow the “System
Start-Up & Cabling Guide”).
Online LED indicates the communications mi-9.
cro-processor is functioning, not that the panel
can see the digital bus.
Power ON LED indicates the control card is re-10.
ceiving power from the transformer and has successfully converted it to DC.
Error/Boot LED. Flashes continuously if system 11.
failed to boot.
Hand/Auto Switch (slave panel only). In Auto 12.
mode, relays will react to schedules and switches.
In Hand mode, relays will remain closed.
Power input from transformer.13.
2
13
10 THE BLUE BOX LT OVERVIEW
BLUE BOX LT 1404/1408
INTERNAL SCHEMATIC
3#18 AWG. Supplies power from trans-1.
former to relay control card.
14 conductor ribbon cable: carries control 2.
signal between DTC and relay control card
(master panel only).
2 conductor ribbon cable: carries control 3.
signal from smacker strip to relays - one
per relay.
5 conductor ribbon cable: carries digital 4.
signal from relay control card to (optional)
digital input card.
4#22AWG carries RS-232 signal from 5.
(optional) modem to relay control card
(master panel only).
Terminator pins. Add terminator here if this 6.
is the first or last item on a bus (follow the
“System Start-Up & Cabling Guide”).
For more information about external hook-ups,
refer to GR 1404 LT Installation Guide.
To optional
Modem
master panels
only
5
To DTC
2
To optional
DI Card
4
6
3
1
RELAY OvERvIEW
Low voltage connector.1.
Status indicator LED.2.
Quick removal slot.3.
High conductivity terminal block.4.
SnapLink
ing (NCL), UL listed for 30 amps lighting (ballast,
HID) at 277v, 20 amps at 347v and 20 amps
Tungsten at 120v, 18,000 amp SCCR at 277v,
rated 250,000 on/off cycles, 3 yr. warranty.
™
Latching Relay: Normally closed latch-
1
3
4
2
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 11
GR1416LT DRAWINGS & DETAILS
1
2
LCDBBO03Sept08
1
3
4
GR1416 LT (FRONT DOOR OPEN)
Screw fastener secures hinged Control Panel Door (Master only).1.
Hinged Door Panel provides a barrier between Control Interface and High Voltage connections beneath 2.
(Master only).
NEMA 1 surface mount enclosure with hinged door and key lock; Ø1/4" mounting holes at 4 places 3.
(hardware not included).
DTC Clock / Display & Programming Interface: 32-channel, 365-day astronomical clock with Scroll and Tab 4.
to access control features for entire system (Master only).
12 THE BLUE BOX LT OVERVIEW
1
1
2
8
6
3
9
4
11
6
9
7
6
10
5
GR1416 LT (WHITE DOOR OPEN)
Screw fastener secures hinged Control Panel 1.
Door (Master only).
Hinged Door Panel provides a barrier between 2.
Control Interface and High Voltage connections
beneath (Master only).
Optional Modem. Free factory dial-up programming3.
Optional DI contact closure interface card.4.
NEMA 1 surface mount enclosure with hinged 5.
door and key lock; Ø1/4" mounting holes at 4
places (hardware not included).
Optional: Unfasten three screws to remove chas-6.
sis assembly from enclosure providing full access
to mounting holes if required.
SnapLink7.
LED: ON when relay is OFF (NC).
DTC Clock / Display & Programming Interface: 8.
32-channel, 365-day astronomical clock with
Scroll and Tab to access control features for en-
.
tire system (Master only).
Voltage barrier separates low & line voltage con-9.
nections.
Dual Voltage Input: Blue Box LT10.
ther 120V or 277V.
Ground Lug for equipment grounding.11.
™
relays, Normally-Closed (NC). Status
™
operates on ei-
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 13
GR1416 LT SLAvE PANEL RELAY CONTROL CARD GR1416 LT MASTER PANEL RELAY CONTROL CARD
7
7
12
11
9
4
2
10
8
13
1
7
7
7
3
6
5
11
9
4
1
8
10
7
2
13
LCDBBO03Sept08
Relay Drivers connect to Smacker Strip. Relay 1.
drivers will close latching relays upon loss of
power to the Control Card.
RJ45 sockets for digital bus. Digital devices (re-2.
lay panels, digital switches, etc) connect to this
panel using a bus (daisy-chain) topology.
Photocell por t (master panel only). +V output 3.
with a photocell input. Photocells are polarized
- follow color code.
Power/data connector for DI Card.4.
Power/data connector for modem (master panel).5 .
Power/data connector for DTC clock/display 6.
(master panel only).
Removal slots for control card. Used with a flat 7 .
blade screw driver to remove the Control Card.
Terminator pins. Add terminator here if this is 8.
an end-of-bus panel (per “System Star t-Up &
Cabling Guide”).
Online LED indicates the communications mi-9.
cro-processor is functioning, not that the panel
can see the digital bus.
Power ON LED indicates the control card is 10.
receiving power from the transformer and has
successfully converted it to DC.
Error/Boot LED. Flashing constantly if card can-11.
not boot on start up.
Hand/Auto Switch. (slave panel only) In Auto 12.
mode, relays will react to schedules and switches. In Hand mode, relays will remain closed.
Power input from transformer.13.
14 THE BLUE BOX LT OVERVIEW
3
5
6
4
7
2
8
9
GR1416 LT (DOOR OPEN) INTERNAL SCHEMATIC
3#18 AWG. Supplies power from transformer 1.
to relay control card.
14 conductor ribbon cable: carries control signal 2.
between DTC and relay control card (master
panel only).
2 conductor ribbon cable: carries control signal 3.
from smacker strip to relays - one per relay.
10 conductor ribbon cable: carries digital signal 4.
from relay control card to smacker strip.
5 conductor ribbon cable: carries digital signal 5.
from relay control card to (optional) digital input
card.
4#22 AWG carries RS-232 signal from (optional) 6 .
modem to relay control card (master panel only).
10
12
1
11
Terminator/terminator pins to terminate bus line.7.
External Connections
4#24 flat cable from modem to analog phone 8.
jack. Always note phone number of modem.
2#18 AWG to Blue Box photocell. Up to 300 feet.9.
Cat. 5 cable with RJ45 connectors links Blue Box 10.
to other digital devices (other blue box panels or
digital switches).
Contact closure inputs & DI card common 11.
“GND” + 1 #18 per input.
Line and load relay lugs.12.
For information about cabling for contact closure
switches or occupant sensors. Refer to DI Card
Installation Guide for options and details.
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 15
INTRODUCTION TO THE BLUE BOX™ LT SERIES
The only panel you will ever need for small to medium projects - quicker to install than traditional lighting contactors and
much easier to configure. The Blue Box™ LT Series is UL Listed and complies with every energy code in the USA.
LCDBBO03Sept08
16 THE BLUE BOX LT OVERVIEW
THE BLUE BOX™ LT vS. LIGHTING CONTACTORS
SMART RELAY PANEL
The Blue Box™ LT Series is the only panel you will ever
need for small to medium projects.
It is quicker to install than traditional lighting contactors as
well as more flexible.
With purchase of the optional modem you receive free
lifetime dial-up programming support from the factory.
Or you can connect remotely using our free software.
The Blue Box™ LT is part of the GR 2400 lighting control
system, from LC&D.
Control up to 16 devices.
DITCH THE OLD WAY OF DOING THINGS
Traditional lighting contactor panels require an electrical-mechanical assembly specific to the job at hand. This
means parts and pieces must be field-assembled and
field-programmed.
Any programming or hard-wire changes made to lighting
contactor panels require you to go back to the site.
Outdoor Photocell
Breaker Panel
Digital Override Switch
Master Relay Panel
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 17
BUILD YOUR SYSTEM IN 3 STEPS
Every system must have a Master Panel which contains
the clock and photocell inputs and connections for the
optional modem.
STEP 1: MASTER PANEL
How many circuits (relays) do you need to control? (See
pgs. 6-7 for enclosure sizes).
Do you need a modem for remote dial-up programming?
(See pg. 10, “Modem”).
Do you need inputs for occupant sensors, or contact closure switches? (See pg. 10, “Digital Input Card”)
Each system needs one master panel. Use one Blue Box
for each electric room you are controlling lighting circuits in.
Slave Relay Panel
Master Relay Panel
™
STEP 2: SLAvE PANELS
For each additional Blue Box™ LT, how many circuits (relays) do you need to control? (See pgs. 6-7).
™
For each additional Blue Box
puts for occupant sensors, or contact closure switches?
(See pg. 10, “Digital Input Card”)
Up to 16 panels and switches may be controlled on the bus.
LT Series, do you need in-
STEP 3: SWITCHES, OUTDOOR PHOTOCELLS &
ACCESSORIES
How many override switches do you need?
How many buttons on each switch? (1 to 6 buttons cost
the same).
Will you need a photocell to supplement the DTC astro-
LCDBBO03Sept08
nomical clock? (See pg. 10, “Digital Photocell”).
Add other accessories as shown on pages 10-11.
Control up to 16 devices.
Slave Relay Panel
Slave Relay Panel
Chelsea
Digital Switch
Master Relay Panel
Outdoor Photocell
Slave Relay Panel
Master
Relay Panel
18 THE BLUE BOX LT OVERVIEW
3 ENCLOSURE SIzES
DESIGNING WITH LIMITED SPACE?
The Blue Box™ LT Series comes pre-assembled and ready
for installation in three compact enclosure sizes!
This 100% digital panel can be programmed to operate
any lighting scenario and is equipped with a number of
accessory devices:
Easy energy code compliance•
277V, 30a relays UL Listed for 18,000 SCCR•
Competitively priced against lighting contactors •
and astronomical or multi-channel clocks
Digital Switches can turn relays on or off or over-•
ride time schedules for energy code compliance
Our simple, intuitive network connects multiple •
panels and switches using Cat. 5 with RJ45s
Panels can share the same time schedules and •
photocell
Additional relays can be purchased for partially •
filled panels.
Hinged locking door•
GR1404LT
Shipped with 2 or 4 relays•
Master or slave configuration•
8.4”H x 8.4”W x 3”D•
GR1408LT
Shipped with 4 or 8 relays•
Master or slave configuration•
13.4”H x 8.4”W x 3”D•
GR1416LT
Shipped with 8 or 16 relays•
Master or slave configuration•
17.1”H x 10.6”W x 3”D•
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 19
2 PANEL CONFIGURATIONS
MASTER RELAY PANEL
Each system needs one master panel equipped with: DTC
clock/programmer. Program schedules, switches and photocells for multiple panels.
365-day/7-day/astronomical 32 channel clock•
Plain English command prompts•
Non-volatile memory for all programming, 10 year •
battery back-up for time of day
Photocell Input: One photocell can control any relay in
any panel.
Optional modem and Digital Input Card (See pgs. 10-11,
“Accessories”).
Control up to 16 devices.
SLAvE RELAY PANEL
The slave panel is a fully programmable panel that networks to the DTC, modem, and photocell from the master panel.
No DTC, photocell input, or modem is required in a slave
panel, as it uses the master panel.
Option: Digital Input Card allows dry-contact closure
switches to control any relay in any panel – wall switches,
momentary switches, occupant sensors or any other dry
contact switch
(See pgs. 10-11, “Accessories”).
Master Relay Panel
Modem for remote programming
Optional Hand/Auto Switch
DTC clock/programmer
• 32 channel 365 day, 7
day astronomical clock
• Programming access for
time schedules, switches,
photocell etc.
• Large format screen
Slave Relay Panel
Lighting relays:
• 30A @ 277V Ballast
• 20A @ 120V Tungsten
• 20A @ 347V Ballast
• SCCR 18,000 Amps
Power supply:
• 120V/277V
RJ45s inputs for digital bus
LCDBBO03Sept08
Chelsea Digital SwitchChelsea Digital Switch
Master Relay Panel Slave Relay Panel
20 THE BLUE BOX LT OVERVIEW
MOST POPULAR ACCESSORIES
These represent the most popular LC&D accessories. For a complete list of accessories refer to the LC&D Catalog.
Product: Description:
Digital Outdoor Photocell (PCO): Connects to the master panel. Recommended for stormy
regions (where it may darken early) to supplement the astronomical clock.
Product Code: PCO
Chelsea Digital Switch: With 1, 2, 3, 4 and 6 buttons and free factory engraving. Ideal for override of automatic controls and manual control of lighting. Link with Cat. 5 cable with RJ45s.
Product Code: CH-1, 2, 3, 4 and 6
Modem: Allows you to make changes to the Blue Box™ LT remotely over dial-up. Or call our
technical support line and have us do it for you (for free) for the life of the system.
Product Code: MOD
Digital Input Card: Plugs into master or slave panels. For projects that require non-digital
switches, including: standard wall switches, center-off momentary switches, occupant sensors,
or any dry-contact closure. DI 6 inputs may be enabled / disabled over the bus.
Product Code: DI 6 or DI 14
SnapLink™ Latching Relay: Normally closed latching (NCL), UL listed for 30 amps lighting
(ballast, HID) at 277v, 20 amps at 347v and 20 amps Tungsten at 120v, 18,000 amp SCCR at
277v, rated 250,000 on/off cycles, 3 yr. warranty.
Product Code: SLNC or SLNO
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 21
The accessories below may not be available as a stocking product, but can be ordered.
Product: Description:
SwitchBolt: One or two vandal resistance buttons per gang. Switches can be mounted outdoors or almost any location.
Product Code: SB-1 or 2
Link-To PC/Ethernet: Connect multiple computers to the GR 2400 system from any RS232,
USB port or an ethernet network connection.
Product Code: L2-PC
LCDBBO03Sept08
Occupant Sensors: A full line of sensors. One sensor can control any relay(s) in any panel(s).
Occupant sensors require a Digital Input Card.
Product Code: (Contact LC&D factory)
Digital Rocker Switch: Looks like a regular decora style switch; operates like a 2-button digital
switch.
Product Code: RS
Digital Thermostats/T-Link: A single T-Link card can control up to 32 digital thermostats (heatpump or multi-stage).
Product Code: T-LINK (Contact factory for T-STAT ordering.)
22 THE BLUE BOX LT OVERVIEW
APPLICATIONS
See how easy it is to design and install the Blue Box™ LT in
different applications. We stand behind each of our products with a 3 year warranty.
SMALL PARkING LOT (SINGLE CONTROL PANEL)
Select a master panel with the correct number of relays.
The DTC astronomical clock does the rest. Order an outdoor photocell (PCO) as a back up for stormy days (not
required for code compliance).
GR1408LT master was compared to a equivalent
assembly of lighting contactors and a multi-channel astronomical clock. The Blue Box
less expensive than the lighting contactors!
Outdoor Photocell
Master
Relay Panel
™
LT was 50%
RETAIL STORES (WITH 6 OvERRIDE zONES)
Separately zone lighting circuits to comply with local
codes, and use the DTC clock to schedule the off-sweeps.
A multi-button digital switch is the override and manual
control, and complies with energy codes.
Master Relay Panel
Digital Override Switches
The Blue Box™ LT was compared to similar package of (4) 2-pole lighting contactors, a multichannel clock and twist-timers: The Blue Box™ LT
Series was 60% less expensive than the lighting
contactors!
LCDBBO03Sept08
THE BLUE BOX LT OVERVIEW 23
APPLICATIONS (Continued)
How Does the Blue Box™ LT Series Stack-up? In a nationwide survey of Electrical Contractors, the cost to
purchase and field-assemble lighting contactor panels was
compared to the cost of the Blue Box™ LT Series.
WAREHOUSE (MULTIPLE CONTROL PANELS)
Locate multiple Blue Box™ LT panels and digital switches
where you need them and then link them with Cat. 5 cable.
One Blue Box™ LT master (with a Digital Time Clock
(DTC) can control relays in multiple slave panels and digital switches (up to 16 digital devices).
Digital switches are used for manual control and afterhours override.
A photocell can be used as back up for outdoor lighting, or
even as a simple daylight harvesting system for skylights.
Check your local codes for how large an area each switch
can override.
If you are unsure, visit www.lightingcontrols.com for a free
code excerpt for your state.
Slave Relay Panel
Slave Relay Panel
Chelsea
Digital Switch
The Blue Box™ LT Series system shown above was
compared to multiple lighting contactor panels
(each with a multi-channel clock), manual switches,
twist-timers, and photocells.
The Blue Box™ LT Series was 64% less expensive!
Outdoor Photocell
Master
Relay Panel
LCDBBO03Sept08
24 THE BLUE BOX LT OVERVIEW
BLUE BOX TECHNICAL SUPPORT
AFTER-MARkET SUPPORT
The Blue Box™ LT Series comes with LC&D’s top-notch
customer suppor t and, when connected to a phone line,
includes free lifetime dial-up programming.
Make changes to the Blue Box™ LT Series remotely (with
purchase of a modem) over dial-up. Or call our Technical
Support line and have us do it for you (for free) for the
life of the system.
DITCH THE OLD WAY OF DOING THINGS
Traditional lighting contactor panels require an electrical-mechanical assembly specific to the job at hand. This
means design, parts/pieces and assembly time. Any customer changes require re-wiring and re-assembly.
LIGHTING CONTROL & DESIGN
905AllenAve•Glendale,CA91201•Support800-345-4448•www.lightingcontrols.com
LCDBBO03Sept08
MAINTENANCE
& TROUBLESHOOTING
MAINTENANCE & TROUBLESHOOTING
Making Up Cat. 5 with RJ45 Connectorsa)
Adding a New Deviceb)
Parts Replacement Guidec)
Hardware Troubleshootingd)
LCDBBO&M03Sept08
LCDBBO&M03Sept08
®
™
THE BLUE BOX
LT
MAKING UP CAT.5
CABLE WITH RJ45
CONNECTORS
LCDBBMUCAT03Sept08
®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
•
Tel: 800-345-4448
www.lightingcontrols.com
28 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS
TABLE OF CONTENTS
Introduction .......................................................................................29
Ethernet Network ................................................................................29
The GR 2400 Bus and RS485 Communications Protocol................................................30
Cable and Crimping Quality .......................................................................31
The Importance of a Proper Crimp..................................................................31
Type of Wire .....................................................................................31
The Ideal Scene: Professionally Made Commercial Cables ...............................................32
Reasons Why It’s Hard to Make Good Crimps on RJ45s ............................................33
Solid Wire is Ductile...............................................................................33
The Right Crimping Tool ...........................................................................33
The Right Modular Connector ......................................................................34
How to Make Proper Crimps ......................................................................35
Sequence of Actions ..............................................................................35
Miscellaneous Information .........................................................................37
Cable Kinks ......................................................................................37
Dirty RJ45 Sockets ................................................................................37
Summary ........................................................................................38
Stable Datums on Crimping Cat. 5...................................................................38
LCDBBMUCAT03Sept08
THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS 29
INTRODUCTION
All Lighting Control & Design systems use Cat. 5 cable with
RJ45 connectors to network devices. While both our system & Ethernet networks use Cat. 5 cabling, there are huge
differences between the two (Note: Cat. 6 is often substituted for Cat. 5. Our system accepts either type of cable.)
ETHERNET NETWORk
Typically Ethernet networks have multiple devices connected to a central point, this design scheme is called a
star topology (Figure 1.1 illustrates a multi-level star topology). In this example, the four workstations are connected directly to a switch/hub, which is connected to another
star to access either the file server, printer or router.
The hub/switch receives the data sent by the four workstations; upon receipt of the data, the hub/switch checks
the data for errors and re-transmits to another switch to
access the other devices on the network. The data travels
only one section of the cable before it gets cleaned up or
repeated and forwarded to another point. Thus any incon-
Figure 1.1 - Typical Ethernet Network Setup
Ethernet uses Cat. 5 cables,
each cable does not exceed
100 meters (330ft).
Router
sistent quality in the Cat. 5 cable or crimp will not severely
impact this network’s stability. It may slow the data transmission on one leg of the network, but not as to affect the
other nodes on the network.
In an Ethernet network, one cable is connected to the
switch, workstation, printer, etc. and terminated at a jack
socket in the wall (Figure 1.2a and 1.2b). This socket has
insulation displacement connections, which do not require
crimping. The cable from the wall socket to the device is
typically a factory-manufactured cable. These cables use
flexible stranded wires and crimps made on pneumatic
crimping machines, which exert several hundred pounds
of pressure to ensure an excellent crimp.
Figure 1.2a: Insulation
Displacement Socket
LCDBBMUCAT03Sept08
Switch
File Server
Switch/Hub
Workstation 1 Workstation 2 Workstation 3 Workstation 4
Printer
Figure 1.2b
30 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS
INTRODUCTION (Continued)
THE GR 2400 BUS AND RS485
COMMUNICATIONS PROTOCOL
LC&D devices communicate using a method known simply as half duplex RS485. This data communication method uses one twisted pair of the stranded Cat. 5 cable to
transmit data; and the other three pairs to carry power to
the switches.
All devices are connected in a single line (or bus). This
RS485 network allows multiple items on a bus to be connected in parallel, also called “Daisy Chain” wiring.
Each item on our system has two RJ45 jacks that allow the
cabling to come in on one side and go out the other.
To illustrate the “daisy chain” method, Figure 1.3 shows a
diagram of an LC&D GR2400 lighting control system.
One can see how a bad connection, say at the digital
switch, can prevent communication from the Master Panel
/DTC from reaching the rest of the bus.
Small imperfections in the Cat. 5 cable crimps tend to be
the most common “bad connections.”
Though a single imperfection may only slow down the
communication by a small margin it gets multiplied up
over the length of the chain.
RJ45 connectors simplify the wiring and connections of
our system, but the impor tance of having a good crimp
is paramount.
Figure 1.3
Uplink
™
Card
GR 2400
™
Master Panel
Chelsea
DigitalSwitch
GR 2400™ Slave Panel
MicroPanel
™
SmartBreaker
™
GR 2400 Master Panel GR 2400 Slave Panel SmartBreaker Panel
™
Panel
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