Blue Box LT Operation,

Programming and
Maintenance Manual

Project Name:
Project Location:
Acuity Agency:
Order #:
PO #:
Project ID:
Date:

Controls Tech Support:

1-800-535-2465 - option 1: nLight; option 2: SSI; option 3: Fresco; option 4: Synergy; option 5: LC&D/Bluebox; option 6 ROAM
To preschedule a call with tech support (providing a 4 hour business lead time) go to the following
link: http://www.acuitybrands.com/resources/schedule-support-request

Additional Technical Literature:

https://www.acuitybrands.com/products/controls/blue-box

1
 Table of Contents

Blue Box LT O&M ..................................................................................................................... 3

Chelsea Digital Switch Programming Guide ........................................................................ 151

Additional Resources (Product specific user guides, Programming documents, etc) ………171

2
 ®

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

3
4
 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
Daylight Saving Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LCDBBO&M04Sept08

Keyboard Lock Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5
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

6
 ®

THE BLUE BOX LT

™

OVERVIEW
LCDBBO03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

7
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

8
 THE BLUE BOX LT OVERVIEW 7

GR1404LT / GR1408LT DRAWINGS & DETAILS

4
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)

1. Screw fastener secures white door (Master only). tion: Refer to the Blue Box LT Installation Guide
2. White door provides a barrier between Control for more information on these documents.
Interface and High Voltage connections beneath a) Panel Schedule
(Master only). b) (optional) DI Card schedule.
3. Hinged locking blue door. c) If this is a Master panel, the System Device
4. DTC Clock / Display & Programming Interface: Schedule on the back of the Panel Schedule
32-channel, 365-day astronomical clock with should also be filled-out.. It lists out all of the
Scroll and Tab to access control features for en- digital lighting controls devices, where they are
LCDBBO03Sept08

tire system (Master only). and what they do. (see System Start-Up Guide
5. Door pocket contains the following documenta- for more information.

9
8 THE BLUE BOX LT OVERVIEW

low voltage only line voltage only

6
2
1
3 7 5

12
11

10
5 5

gr1404/08 lt (white DOOR OPEN)

1. Screw fastener secures hinged Control Panel 32-channel, 365-day astronomical clock with
Door (Master only). Scroll and Tab to access control features for en-
2. White door provides barrier between human tire system (Master only).
interface and line voltage connections beneath 9. Voltage barrier separates line voltage (class 1) &
(Master only). low (class 2) connections.
3. Optional Modem. Free factory dial-up programming. 10. Dual Voltage Power Supply Input: Blue Box LT™
4. Optional DI contact closure interface card. operates on either 120V or 277V.
5. Ø1/4" mounting holes at 4 places. 11. Ground Lug for equipment grounding.
6. Optional: Unfasten two screws to remove chassis 12. Relay Control Card provides interface between
assembly from enclosure providing full access to control network and relays. The Relay Control
mounting holes if required. Card in the Master panel also holds time sched-
7. SnapLink™ relays, Normally-Closed (NC). Status ules and system mapping.
LCDBBO03Sept08

LED is ON when relay is OFF.

8. DTC Clock / Display & Programming Interface:

10
 THE BLUE BOX LT OVERVIEW 9

gr1404/08 Slave PANEL RELAY CONTROL CARD gr1404/08 MASTER PANEL RELAY CONTROL CARD

4 4
5

7 7

1 1

9 9
8 8
11 11
6
10 10

7 7
7 12 7

2
13 3 2 13

1. Relay Drivers. Opto-isolated to prevent line volt- 8. Terminator pins. Add terminator here if this is the
age back-feed and to help prevent RF and EMF first or last item on a bus (follow the “System
noise interference. Relay drivers will close latching Start-Up & Cabling Guide”).
relays upon loss of power to the Control Card. 9. Online LED indicates the communications mi-
2. RJ45 sockets for digital bus. Digital devices (relay cro-processor is functioning, not that the panel
panels, digital switches, etc) connect to this panel can see the digital bus.
using a bus (daisy-chain) topology. 10. Power ON LED indicates the control card is re-
3. Photocell port (master panel only). +V output ceiving power from the transformer and has suc-
with a photocell input. Photocells are polarized - cessfully converted it to DC.
follow color code. 11. Error/Boot LED. Flashes continuously if system
4. Power/data connector for DI Card. failed to boot.
5. Power/data connector for modem (master panel). 12. Hand/Auto Switch (slave panel only). In Auto
6. Power/data connector for DTC clock/display mode, relays will react to schedules and switches.
(master panel only). In Hand mode, relays will remain closed.
LCDBBO03Sept08

7. Removal slots for control card. Used with a flat 13. Power input from transformer.
blade screw driver to remove the Control Card.

11
10 THE BLUE BOX LT OVERVIEW

To optional To optional
Blue box lt 1404/1408 Modem DI Card
master panels
Internal schematic only 4
1. 3#18 AWG. Supplies power from trans-
former to relay control card. 5
2. 14 conductor ribbon cable: carries control
signal between DTC and relay control card
(master panel only).
3. 2 conductor ribbon cable: carries control
signal from smacker strip to relays - one
per relay.
4. 5 conductor ribbon cable: carries digital
signal from relay control card to (optional)
3
digital input card.
5. 4#22AWG carries RS-232 signal from To DTC
(optional) modem to relay control card
6 1
(master panel only).
2
6. Terminator pins. Add terminator here if this
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.

3 4
Relay overview

1. Low voltage connector.

2. Status indicator LED.
3. Quick removal slot.
4. High conductivity terminal block.

SnapLink™ Latching Relay: Normally closed latch-

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.
LCDBBO03Sept08

2
1

12
 THE BLUE BOX LT OVERVIEW 11

GR1416LT drawings & details

3
4

gr1416 lt (front DOOR open)

1. Screw fastener secures hinged Control Panel Door (Master only).

2. Hinged Door Panel provides a barrier between Control Interface and High Voltage connections beneath
(Master only).
3. NEMA 1 surface mount enclosure with hinged door and key lock; Ø1/4" mounting holes at 4 places
(hardware not included).
4. DTC Clock / Display & Programming Interface: 32-channel, 365-day astronomical clock with Scroll and Tab
to access control features for entire system (Master only).
LCDBBO03Sept08

13
12 THE BLUE BOX LT OVERVIEW

6 9
6
1

7
2

1 6

3 10

8
11 5
4

gr1416 lt (white DOOR OPEN)

1. Screw fastener secures hinged Control Panel 7. SnapLink™ relays, Normally-Closed (NC). Status
Door (Master only). LED: ON when relay is OFF (NC).
2. Hinged Door Panel provides a barrier between 8. DTC Clock / Display & Programming Interface:
Control Interface and High Voltage connections 32-channel, 365-day astronomical clock with
beneath (Master only). Scroll and Tab to access control features for en-
3. Optional Modem. Free factory dial-up programming. tire system (Master only).
4. Optional DI contact closure interface card. 9. Voltage barrier separates low & line voltage con-
5. NEMA 1 surface mount enclosure with hinged nections.
door and key lock; Ø1/4" mounting holes at 4 10. Dual Voltage Input: Blue Box LT™ operates on ei-
places (hardware not included). ther 120V or 277V.
6. Optional: Unfasten three screws to remove chas- 11. Ground Lug for equipment grounding.
LCDBBO03Sept08

sis assembly from enclosure providing full access

to mounting holes if required.

14
 THE BLUE BOX LT OVERVIEW 13

gr1416 lt Slave PANEL RELAY CONTROL CARD gr1416 lt MASTER PANEL RELAY CONTROL CARD

4
4
5
1 1
7 7

9 9 8
8

11 11
6
10
10

7 7 7
7 12

2
2
13 3 13

1. Relay Drivers connect to Smacker Strip. Relay 8. Terminator pins. Add terminator here if this is
drivers will close latching relays upon loss of an end-of-bus panel (per “System Start-Up &
power to the Control Card. Cabling Guide”).
2. RJ45 sockets for digital bus. Digital devices (re- 9. Online LED indicates the communications mi-
lay panels, digital switches, etc) connect to this cro-processor is functioning, not that the panel
panel using a bus (daisy-chain) topology. can see the digital bus.
3. Photocell port (master panel only). +V output 10. Power ON LED indicates the control card is
with a photocell input. Photocells are polarized receiving power from the transformer and has
- follow color code. successfully converted it to DC.
4. Power/data connector for DI Card. 11. Error/Boot LED. Flashing constantly if card can-
5. Power/data connector for modem (master panel). not boot on start up.
6. Power/data connector for DTC clock/display 12. Hand/Auto Switch. (slave panel only) In Auto
(master panel only). mode, relays will react to schedules and switch-
LCDBBO03Sept08

7. Removal slots for control card. Used with a flat es. In Hand mode, relays will remain closed.
blade screw driver to remove the Control Card. 13. Power input from transformer.

15
14 THE BLUE BOX LT OVERVIEW

12
3

5
6 4

2 1

8 11
9 10

gr1416 lt (DOOR OPEN) internal schematic

1. 3#18 AWG. Supplies power from transformer 7. Terminator/terminator pins to terminate bus line.
to relay control card. External Connections
2. 14 conductor ribbon cable: carries control signal 8. 4#24 flat cable from modem to analog phone
between DTC and relay control card (master jack. Always note phone number of modem.
panel only). 9. 2#18 AWG to Blue Box photocell. Up to 300 feet.
3. 2 conductor ribbon cable: carries control signal 10. Cat. 5 cable with RJ45 connectors links Blue Box
from smacker strip to relays - one per relay. to other digital devices (other blue box panels or
4. 10 conductor ribbon cable: carries digital signal digital switches).
from relay control card to smacker strip. 11. Contact closure inputs & DI card common
5. 5 conductor ribbon cable: carries digital signal “GND” + 1 #18 per input.
from relay control card to (optional) digital input 12. Line and load relay lugs.
card. For information about cabling for contact closure
LCDBBO03Sept08

6. 4#22 AWG carries RS-232 signal from (optional) switches or occupant sensors. Refer to DI Card
modem to relay control card (master panel only). Installation Guide for options and details.

16
 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

17
16 THE BLUE BOX LT OVERVIEW

The Blue Box LT vs. Lighting Contactors™

Smart Relay Panel Outdoor Photocell

The Blue Box™ LT Series is the only panel you will ever
need for small to medium projects. Breaker Panel
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. Digital Override Switch

The Blue Box™ LT is part of the GR 2400 lighting control

system, from LC&D.
Control up to 16 devices.
Master Relay Panel

Ditch the Old Way of Doing Things

Traditional lighting contactor panels require an electri-
cal-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.

LCDBBO03Sept08

18
 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”). Master Relay Panel

Do you need inputs for occupant sensors, or contact clo- Each system needs one master panel. Use one Blue Box™
for each electric room you are controlling lighting circuits in.
sure switches? (See pg. 10, “Digital Input Card”)

Slave Relay Panel

Step 2: Slave Panels
For each additional Blue Box™ LT, how many circuits (re-
lays) do you need to control? (See pgs. 6-7).
For each additional Blue Box™ LT Series, do you need in-
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.
Slave Relay Panel Master Relay Panel

Slave Relay Panel Outdoor Photocell

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). Slave Relay Panel
Will you need a photocell to supplement the DTC astro-
nomical clock? (See pg. 10, “Digital Photocell”).
LCDBBO03Sept08

Add other accessories as shown on pages 10-11. Chelsea Master

Digital Switch Relay Panel
Control up to 16 devices.

19
18 THE BLUE BOX LT OVERVIEW

3 Enclosure Sizes

Designing with limited space? GR1404LT

The Blue Box™ LT Series comes pre-assembled and ready
• Shipped with 2 or 4 relays
for installation in three compact enclosure sizes!
• Master or slave configuration
This 100% digital panel can be programmed to operate • 8.4”H x 8.4”W x 3”D
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-
GR1408LT
ride time schedules for energy code compliance
• Our simple, intuitive network connects multiple • Shipped with 4 or 8 relays
panels and switches using Cat. 5 with RJ45s • Master or slave configuration
• Panels can share the same time schedules and • 13.4”H x 8.4”W x 3”D
photocell
• Additional relays can be purchased for partially
filled panels.
• Hinged locking door

GR1416LT

• Shipped with 8 or 16 relays

• Master or slave configuration
• 17.1”H x 10.6”W x 3”D
LCDBBO03Sept08

20
 THE BLUE BOX LT OVERVIEW 19

2 panel Configurations

Master Relay Panel Master Relay Panel

Each system needs one master panel equipped with: DTC Modem for remote pro-
clock/programmer. Program schedules, switches and pho- gramming
tocells for multiple panels. Optional Hand/Auto Switch
• 365-day/7-day/astronomical 32 channel clock DTC clock/programmer
• Plain English command prompts • 32 channel 365 day, 7
• Non-volatile memory for all programming, 10 year day astronomical clock
battery back-up for time of day • Programming access for
Photocell Input: One photocell can control any relay in time schedules, switches,
any panel. photocell etc.
• Large format screen
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 net- Slave Relay Panel
works to the DTC, modem, and photocell from the mas-
Lighting relays:
ter panel.
• 30A @ 277V Ballast
No DTC, photocell input, or modem is required in a slave
• 20A @ 120V Tungsten
panel, as it uses the master panel.
• 20A @ 347V Ballast
Option: Digital Input Card allows dry-contact closure • SCCR 18,000 Amps
switches to control any relay in any panel – wall switches,
Power supply:
momentary switches, occupant sensors or any other dry
contact switch • 120V/277V
RJ45s inputs for digital bus
(See pgs. 10-11, “Accessories”).

Chelsea Digital Switch Chelsea Digital Switch

LCDBBO03Sept08

Master Relay Panel Slave Relay Panel

21
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 over-
ride 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

22
 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 out-
doors 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

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 (heat-
pump or multi-stage).
Product Code: T-LINK (Contact factory for T-STAT ordering.)
LCDBBO03Sept08

23
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 prod-
ucts with a 3 year warranty.

Small Parking Lot (single control panel)

Select a master panel with the correct number of relays. Outdoor Photocell
The DTC astronomical clock does the rest. Order an out-
door photocell (PCO) as a back up for stormy days (not Master
required for code compliance). Relay Panel

GR1408LT master was compared to a equivalent

assembly of lighting contactors and a multi-chan-
nel astronomical clock. The Blue Box™ LT was 50%
less expensive than the lighting contactors!

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. Master Relay Panel
A multi-button digital switch is the override and manual
Digital Override Switches
control, and complies with energy codes.

The Blue Box™ LT was compared to similar pack-

age of (4) 2-pole lighting contactors, a multi-
channel clock and twist-timers: The Blue Box™ LT
Series was 60% less expensive than the lighting
contactors!
LCDBBO03Sept08

24
 THE BLUE BOX LT OVERVIEW 23

APPLICATIONS (Continued)

How Does the Blue Box™ LT Series Stack-up? In a na-

tionwide 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 Slave Relay Panel Outdoor Photocell
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 digi-
tal switches (up to 16 digital devices).
Slave Relay Panel
Digital switches are used for manual control and after-
hours override.
A photocell can be used as back up for outdoor lighting, or Chelsea Master
even as a simple daylight harvesting system for skylights. Digital Switch Relay Panel
Check your local codes for how large an area each switch
can override. The Blue Box™ LT Series system shown above was
If you are unsure, visit www.lightingcontrols.com for a free compared to multiple lighting contactor panels
code excerpt for your state. (each with a multi-channel clock), manual switches,
twist-timers, and photocells.
The Blue Box™ LT Series was 64% less expensive!
LCDBBO03Sept08

25
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 support 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 electri-
cal-mechanical assembly specific to the job at hand. This
means design, parts/pieces and assembly time. Any cus-
tomer changes require re-wiring and re-assembly.

LCDBBO03Sept08

Lighting Control & Design

905 Allen Ave • Glendale, CA 91201 • Support 800-345-4448 • www.lightingcontrols.com

26
 MAINTENANCE
& TROUBLESHOOTING
MAINTENANCE & TROUBLESHOOTING

a) Making Up Cat. 5 with RJ45 Connectors

b) Adding a New Device
c) Parts Replacement Guide
d) Hardware Troubleshooting
LCDBBO&M03Sept08

27
28
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

29
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

30
 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS 29

INTRODUCTION

All Lighting Control & Design systems use Cat. 5 cable with sistent quality in the Cat. 5 cable or crimp will not severely
RJ45 connectors to network devices. While both our sys- impact this network’s stability. It may slow the data trans-
tem & Ethernet networks use Cat. 5 cabling, there are huge mission on one leg of the network, but not as to affect the
differences between the two (Note: Cat. 6 is often substi- other nodes on the network.
tuted for Cat. 5. Our system accepts either type of cable.) In an Ethernet network, one cable is connected to the
switch, workstation, printer, etc. and terminated at a jack
Ethernet Network
socket in the wall (Figure 1.2a and 1.2b). This socket has
Typically Ethernet networks have multiple devices con-
insulation displacement connections, which do not require
nected to a central point, this design scheme is called a
crimping. The cable from the wall socket to the device is
star topology (Figure 1.1 illustrates a multi-level star topol-
typically a factory-manufactured cable. These cables use
ogy). In this example, the four workstations are connect-
flexible stranded wires and crimps made on pneumatic
ed directly to a switch/hub, which is connected to another
crimping machines, which exert several hundred pounds
star to access either the file server, printer or router.
of pressure to ensure an excellent crimp.
The hub/switch receives the data sent by the four work-
stations; 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 Eth-

ernet Network Setup Figure 1.2a: Insulation
Ethernet uses Cat. 5 cables, Displacement Socket
each cable does not exceed
100 meters (330ft). Router

Switch Figure 1.2b

File Server
Printer

Switch/Hub
LCDBBMUCAT03Sept08

Workstation 1 Workstation 2 Workstation 3 Workstation 4

31
30 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS

INTRODUCTION (Continued)

The GR 2400 Bus and RS485 Though a single imperfection may only slow down the
Communications protocol communication by a small margin it gets multiplied up
LC&D devices communicate using a method known sim- over the length of the chain.
ply as half duplex RS485. This data communication meth- RJ45 connectors simplify the wiring and connections of
od uses one twisted pair of the stranded Cat. 5 cable to our system, but the importance of having a good crimp
transmit data; and the other three pairs to carry power to is paramount.
the switches.
All devices are connected in a single line (or bus). This
RS485 network allows multiple items on a bus to be con-
nected 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.”
Figure 1.3

SmartBreaker™
GR 2400™ Master Panel GR 2400™ Slave Panel
Panel

Chelsea MicroPanel™
DigitalSwitch™
Uplink™ Card

LCDBBMUCAT03Sept08

GR 2400 Master Panel GR 2400 Slave Panel SmartBreaker Panel

32
 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS 31

Cable and crimping quality

The importance of a proper crimp direction and create multiple echo effects. This results in
Imperfections in a crimp adds a resistive and capacitive load an “unstable bus” because these reflections or echoes
at that point in the network. For example, if the voltage is make it difficult for our devices to receive data.
dropped to 75% of its previous value at each crimp, the Figure 1. 4 shows a daisy-chained network; if there are bad
signal voltage will drop from 5V to 3.75V on the first crimp crimps as described above the transmitted signal from the
and 2.8V after the second. relay panel can lose strength with every device.
Therefore, multiple bad crimps can cause the signal to be
lost in the noise threshold after consecutive voltage drops; Type of Wire
this loss of signal through the length of a cable is called There are three types of wire that use RJ45 crimped
attenuation. Impedance is the measurement of cable connectors. The first is a flat telephone cable, made of 26
resistance to a signal, measured in ohms. gauge wires. It is not Cat. 5 since the wires all run parallel to
each other and are not twisted and thus lack immunity to
If the RJ45 connectors are improperly terminated, the noise. We use this type cable for low frequency signals and
additional resistance and capacitance at the connector short distances, such as to provide power to the clock.
changes the “character” of the wire causing what is called
an impedance mismatch. The other two cables are round in form. They come in
stranded and solid varieties. The stranded wires are used
Impedance mismatch causes signal attenuation because for “patch cables” from a computer to a wall socket.
part of the transmitted signal is reflected back much like
an echo and does not reach the receiver. Inconsistent
crimps compound these effects and cause a larger part of
the signal to be reflected back.
When these reflected signals collide with the first
discontinuity, part of the signal will return to the original

Figure 1.4
LCDBBMUCAT03Sept08

33
32 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS

Cable and crimping quality (Continued)

Stranded wire does not fatigue as easily and break. Solid The Ideal Scene: professionally made
wire is usually used as “building wire.” The reason being commercial cables
that it used to be cheaper and is not usually flexed after Common attributes of commercially made cables include:
it has been installed. LC&D only recommends the use of
a) They always use stranded cable.
stranded Cat. 5 wire.
b) The pneumatically crimped connectors have per-
The three types of wire have three types of crimps fectly flat contacts.
(Figures 1.5a & 1.5b show an RJ45 connector and three
cable crimp types): c) The strain reliefs are usually injection molded.

Contacts for Stranded wires

Figure 1.6 illustrates an example of a commercial cable.
Contacts for Solid/Stranded wires Take note of the injection molded strain relief. This pre-
Contacts for Solid wires. vents any move-
ment of the connec-
tor from the cable
to ensure the cable
Figure 1.5a
crimp stays engaged.

Figure 1.6

Stranded Only Solid / Stranded Solid Only

Figure 1.5b

(Note: It is very important that the correct crimps/

contacts are used for the right wire! The contacts that
mate with the wires have different shapes for the different
LCDBBMUCAT03Sept08

types of wire).

34
 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS 33

Reasons why it’s hard to make

good crimps on rj45s
There are two components needed to crimp a Cat. 5 cable:
a “crimper” and a “RJ45 modular connector.” A crimper is
the tool used to make a crimp and seal the cable to the
connector. RJ45 connectors create the interface for a con-
nection and come in four sizes : 4-, 6-, 8-, and 10-position
(position is the placement in the connector that holds a
contact [pin]).
It is important to note, all crimpers and connectors are
not created equal. We have performed many trials to de- Figure 1.9a: Contacts are seated properly.
termine a recommended crimper tool and connectors for
our systems; these products will be discussed in a later
section.
Note that no matter what brand of connector or crimp
tool used, just the action of crimping a connector to a
cable can cause it to deform and splay the connections.

Figure 1.7a Figure 1.7b

Figure 1.9b: Contacts are not seated properly.

center pins is to crimp multiple times (Note: we suggest

5-10 crimps for a successful Cat. 5 cable crimp) (Figure 1.9a
and 1.9b are examples of properly seated and non-properly
seated contacts).

Solid Wire is Ductile

The action of pulling a cable side to side does two things: a) pulls
Figure 1.7a illustrates how the crimper head pushes the the side wires out of the crimp and/or b) squashes the copper
contacts down by the same distance but deforms the wire, first one way and then another. The copper “flows” into
plastic case under the pressure; as you see in Figure 1.7b a new shape and stays there as if it has been hammered
the contact causes the center crimp to not be adequately flat. An example of this pulling occurs unintentionally when a
supported or seated. Figure 1.8 shows a crimp after switch is pushed/forced into a tight space or wall enclosure.
release; notice how it has a “bowed” appearance. This can result in an “open” connection.This is why we do not
recommend solid wire cable.
Figure 1.8 A bowed crimp is a recipe for
disaster. The two center pins The right crimping tool
do not have adequate contact Choosing the right crimping tool is the most critical part
with the wire. And for the of a cable crimping job. All crimping tools do pretty
purpose of LC&D lighting much the same thing, they force the contacts within the
LCDBBMUCAT03Sept08

systems, the two center pins connectors onto the cable. But as we mentioned earlier,
carry the data! The ONLY there is a big difference in the quality of crimps on different
way to completely flush the types of crimping tools. In trial testing, we found even the

35
34 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS

Reasons why it’s hard to make

good crimps on rj45s (Continued)
expensive, solidly made crimping tools did not make good Care must be taken to
crimps. The best and recommended crimper is provided prevent any excess wire
in the LC&D Crimping Kit.This crimping tool has no “stop” protruding from the end
feature. The no “stop” feature allows “over-crimping” of the connector since
to ensure the wires are seated correctly; and thus it is this will prevent the
possible to get the center contacts properly engaged. connector from seating
properly in the jack.
The right modular connector
There are two wiring Figure 1.12a
After much research, we found a modular connector that is
standards used for mak-
easy to setup and makes it possible to crimp a perfect Cat.5
ing Cat.5 cables; 568A and 568B. Either one may be used,
cable every time. The brand is “EZ RJ45” (shown in figure
as long as it is consistent along the bus. This manual refer-
1.11). It allows for faster terminations and is compatible
ences the 568B convention in the examples and images.
with our crimper tool.
The EZ RJ45 crimp has holes in the front of the connector
which allow the 24AWG wire to protrude from the end
prior to crimping. (shown in figure 1.11) This will ensure
proper wire color arrangement and will also ensure that
the wires will be pushed all the way into the end of the
RJ45 connector.

White/Orange
Orange
White/Green
Blue
White/Blue Patented Taiwan
Green
White/Brown
Brown This crimper is available in the LC&D Figure 1.12b
Figure 1.11 crimper kit. It is also private labeled
under many brand names.
The “EZ RJ45 Crimping Tool” (shown in Figures 1.12a and
1.12b) is specifically designed for these connectors and
will cut through the excess wires protruding from the end
of the RJ45 connector when crimped down.
It has some professional features such as the large crimp-
ing head but it is not capable of “over-crimping” to ensure
that the center conductors have really been engaged.
Though this crimper is very convenient; it will NOT make
good crimps. Use only the ratcheting crimper provided in
the LC&D Crimping Kits.Thus it may ONLY be used as an
initial crimper/cutter and then give the crimp multiple hits
LCDBBMUCAT03Sept08

with our recommended ratcheting crimper.

One can use the “EZ-RJ45” connectors with any crimper. It
just requires that the excess wire is cut off very close to the
end of the connector; this can be done with flush cutters.

36
 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS 35

How to make PROPER crimps

Sequence of actions
a) Always use STRANDED cable!
b) Only use “EZ-RJ45” brand connectors!
c) P
 roper preparation of the wires is very important.
Our kit comes with a wire stripper and cutter that
is separate from the crimper (Figure 1.13 shows a
standard wire stripper/cutter)

Figure 1.13

Figure 1.15

Now put the wires in order. It is really easy to remember

the order with the following stable datums.
i. Every white/color wire is followed by a solid
color wire.
d) Use a very light touch with the wire jacket stripper
tool. Inspect the conductors for nicks, it is easy to ii. Start with White/Orange.
nick the wires inside the jacket. This is especially iii. The two center pairs (Green and Blue) straddle
true with stranded cables. each other with the blue in the middle.
iv. The order goes as follows:
White/Orange
Orange
White/Green
Blue
White/Blue
Green
White/Brown
Brown.
Once the wires are all in line, hold them solidly about ½
Figure 1.14 inch from the insulation and cut straight across the wires
to get even ends. The twists in the wires are hard to
LCDBBMUCAT03Sept08

smooth out at the very end so cutting prevents the wires

e) Untwist all four pairs and straighten/smooth out the
crossing up once inside the connector.
kinks (as shown in Figure 1.15).
After cutting the wires do not let go of the insulation be-
fore pushing the wires into an EZ-RJ45 connector - make

37
36 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS

How to make PROPER crimps (Continued)

sure the locking prongs are facing down. Make sure that j) A
 ssemble the other end the same way for a straight
the insulation is well under the strain relief and that the through cable.Test each cable for continuity using a
wires are in the right order. LAN tester. While testing, wiggle and tug to verify
a solid crimp.
Brown
White/Brown
Green
White/Blue
Blue
White/Green
Orange
White/Orange

Figure 1.16
Figure 1.16 shows an example of the proper wire se-
quence (from right to left):
f) Depending on preference one can cut the ends of
the wires off at this point or after they have been
crimped. The positive of cutting the ends off right Figure 1.17
now is that one can use flush cutters and then pull
the wires back into the connector so that they are
just inside prior to crimping. This may be easier
than cutting the wire after being crimped. Having
the wires protrude before being cut off allows one
to do a double check to make sure that the color
code is correct.
g) C
 rimp the connector multiple times, we
recommend at least 5 to 10 times. (Note: Fast
hard crimps will help the contacts seat better than
slow crimps. )
h) V
 isually inspect the crimp! Crimps must NOT
be bowed or arched. If they are, hit them again
multiple times with the ratcheting crimper.
i) If the wires have not been cut short as shown in Figure 1.18
figure 1.16, the excess wire has to be cut off right
next to the connector. We want to make sure there
are no stubs protruding that prevent the crimp from
latching into a jack (see figure 1.17).
LCDBBMUCAT03Sept08

Figure 1.18 shows front view of a correctly made

Cat. 5 cable. Observe that none of the strands
are in a position to short to another strand or
cause problems.

38
 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS 37

Miscellaneous information

Our cables are made up as “Straight Through” cables. The

connectors at each end look identical. Notice that the
green pair straddles the blue while the orange and brown
take up the edges.

White/Orange
Orange
White/Green
Blue
White/Blue
Green
White/Brown Dirty RJ45 Sockets
Brown
A panel can be installed and sit in a dusty electrical room
for days or months while the building is being readied. In this
Never ever have a mixed pair on pins (4) and (5). Such as
way the sockets can get dirty. The grit inside the socket can
Blue on (4) and White Green on (5). This will cause major
prevent a proper electri-
data loss. It is hard to find since the cable tester will tell
cal connection. It may
you that the cable is OK.
allow some contact but
An additional comment on cable testers. They only tell eventually this connection
you if the wires have continuity from one end of the cable can cause problems.
to the other and that they are in the same order at each
Be aware of this and make
sure that the socket plugs
White/Orange
Orange provided are replaced if a
White/Blue cable is removed.
Blue
White/Green Additionally one can push the RJ45 connector into the
Green
White/Brown socket upside down; this causes the gold plated spring
Brown contacts to be deformed. The only solution in this case is
to replace the entire card.
end. They do not tell you if you have good crimps or if
your cables will work. The cables are part of the GR 2400
system. They are the part of the system that is manufac-
tured in the field. Thus LC&D has the least amount of
control over it. We have had cables that were tested with
high end, high frequency equipment that pass individually
but when plugged in end to end, the system did not work.
visual inspection of each crimp however showed bowed
crimps. When corrected the system was fine.

Cable Kinks
Cable kinks cause loss of data! Cat. 5 specifications say a
LCDBBMUCAT03Sept08

cable must have a radius of 1" going round a corner. Wires

that have been tightened up and then straightened out
cause data loss on our bus. If an electrician pulls a kink it
must be cut out and the wires pulled again.

39
38 THE BLUE BOX LT MAKING UP CAT. 5 CABLE WITH RJ45 CONNECTORS

Miscellaneous information (Continued)

LC&D ships all relay panels with caps for the RJ45 connec- 8. When you crimp an RJ45, always crimp it down multi-
tors to get rid of the possibility of contamination. ple times to ensure properly aligned and evenly seated
contacts on the connector.
Summary 9. Never bend Cat. 5 with a radius of less than 1". Cut out
There is a lot to know about making good Cat.5 cables and throw away sections of cables that have been kinked
with RJ45 connectors. The purpose of this guide is to and straightened out. They can cause drop outs.
cover the basics of crimping Cat.5 cable; which is vital to
10. Always VISUALLY inspect crimps. This one action can
LC&D system installation, operation and maintenance.
save a lot of work. Always follow up with a cable tester
Please follow the steps outlined in this guide thoroughly; if
once both ends of the cable have been crimped.
you have any questions or need assistance call Tech Sup-
port (800) 345-4448.

Stable Datums on Crimping CAT.5

1. Ethernet cabling standards are different from our GR
2400 Cat. 5 cabling. Ethernet cables max out at 100m
(330ft). RS485 can go to 4000ft.
2. A cable can pass a LAN cable test but still cause an un-
stable bus, no matter how expensive the cable tester.
3. Inconsistent crimping causes problems in a network.The
expression “weakest link in the chain” really applies on a
DAISY CHAINED system. If there is a bad connection in
the chain, nothing on the far side of that connection can RECOMMENDED CRIMPER - Patented Taiwan
communicate back to the beginning of the chain.
4. Inconsistent crimps that may work fine on an Ethernet
network may yet cause problems on a “multi-drop” or
“daisy chained” bus.
5. Professionally made wires use stranded RJ45 cable. Al-
ways use stranded wire. It is only slightly more expen-
sive than solid cable and yet can save hours and hours
of tracking down and correcting bad crimps.
6. LC&D can only recommend EZ-RJ45 brand modular
connectors.
7. The EZ-RJ45 brand crimper that also cuts off the wires is
NOT recommended since it still produces bowed crimps
no matter how many times you hit the crimp.The recom-
mended crimper is provided in the LC&D crimper kit.
It’s also widely available from other suppliers who private LC&D CRIMP KIT - Ships with 50EZ RJ45 Connectors and
label the same crimper.They all look the same. is provided at LC&D cost.
LCDBBMUCAT03Sept08

Lighting Control & Design

905 Allen Ave • Glendale, CA 91201 • Support 800-345-4448 • www.lightingcontrols.com

40
 ®

the Blue Box LT

™

adding a new device

INSTRUCTIONS:
Step 1: Step 5:
Install new devices and note down their serial numbers on Verify proper connections and cabling for the entire bus using
the “System Device Schedule” in the Master Panel (Refer to the Hardware Activation Tests . . . . . . . . . . . . . . . . . . . . . Pg.42
Installation Guides)
Step 6:
Step 2: Make up low voltage cabling and connections for contact
Remove terminators from both ends of the bus. closure devices and photocells. . . . (See Installation Guides)

Step 3: Step 7:
Pull Cat. 5 cable in a daisy-chain to new devices. If convenient Power-up and auto-address new devices . . . . . . . . . . Pg.43
new devices can be added to the middle of the existing bus.
(Never splice Cat. 5 cable!). Add “EZ“ brand RJ 45 connec- Step 8:
tors to cable ends using the proper color code. . . . . Pg.41 Verify the system is operating without errors . . . . Pg.45-46

Step 4: Step 9:
Test new cables with a LAN tester and once passed plug each Begin Programming. . . . . . . . . . . . . . . . . (See O&M Manual)
in. Do not power-up devices until Step 7 . . . . . . . Pgs.41-42

Slave Relay Panel Outdoor Photocell

Digital Network:
Locate multiple Blue Box LTs and
control stations where you need
them and then link them all with
Cat. 5 cable. One master panel
(with a Digital Time Clock) for 16
digital devices. Control stations
provide combined manual control Chelsea Digital Switch
LCDBBAND04Sept08

and after-hours override.

Note: The photocell is not on the
digital bus and should not be con-
nected until Step 5.
Slave Relay Panel Master Relay Panel

41
40 THE BLUE BOX LT ADDING A NEW DEVICE

LOW VOLTAGE CABLING

Digital devices have two RJ45 connectors and are daisy-

chained using Cat. 5 (see cover). Non-digital devices (pho- Bus-Powered Devices Allowed
tosensors, toggle switches, etc.) are cabled per their instal- for Each Active Device
lation guides (not daisy-chained). 1000 ft.

Total Feet of Cable from

! Adhere to 568A or 568B standards for Cat. 5 cables.
Always use a dedicated pair for the center pins.

One Active Device

900 ft.
Refer to individual product installation guides for line-volt-
age cabling details and low voltage connection details Do 800 ft.
not “home run” digital switches back to a relay panel. No
spurs or T-Taps are allowed. Do not exceed 16 devices on
any system with a Blue Box LT Master. 700 ft.

12
Eliminate Interference; Isolate cat. 5 Number of Bus-Powered Devices
cables Active Device - Device with power supply (a transformer). It
acts as a source of electrical energy for the bus.
…From Line Voltage Cable: Cat. 5 cable must be at least
Bus-Powered Device - Any device that relies on the 12v
12” from all line voltage conductors, except to cross or supplied by the bus for its power. Example: digital switches,
make terminations. and photosensor cards.
Low Voltage Cable
Photosensor
Input The more feet of Cat. 5 cable used, the fewer bus-pow-
Photosensor ered devices before adding another active device.
Relay
Line Voltage Cable Examples: Per the above chart, up to 3 bus-powered de-
Relay Panel vices may be powered across 1,000 feet of Cat. 5 cable.
Low voltage cabling must not be run in parallel with
line voltage cable, and must not share the same conduit,
whether digital cable (Cat. 5) or low voltage cable (3#18 Bus-Powered Devices Active Device Anywhere
from a photosensor). in the 1000 ft. zone
Power Cat. 5 Cable
…From Line Voltage Devices: Low voltage cabling must avoid
Active Device Active Device Power
EMF or RF from ballasts, arc welders or other “noisy” loads.
EMF or RF interference can create an unstable bus. The active device may be located anywhere within the
1,000 foot region.
Low Voltage
Cable Photosensor Multiple active devices in the same location will not in-
Input crease the distance allowed.
Photosensor 1000 ft. Insufficient Power
Relay
12" or more
Relay Panel
Bus-Powered Devices Bus-Powered Devices
Power
Power
Active Devices Cat. 5 Cable
Line Voltage Cable
LCDBBAND04Sept08

For the above, the correct solution is to connect the ac-

Don’t CAUSE Voltage Drop! tive devices (relay panels) as the center of the network
There is a limit to how many switches and photocell cards and have two runs of cable. Call the Tech Support if cable
you can add in a row over long runs of Cat. 5 cabling. runs exceed 1000ft without active devices.

42
 THE BLUE BOX LT ADDING A NEW DEVICE 41

MAKING UP RJ45 CONNECTORS

Never made up RJ45 connectors before? Its easy. Just fol-

low the steps below. For a short lesson on making RJ45
connectors, refer to The Blue Box LT “O&M Manual”.
To be successful, only use the ratcheting crimping tool rec-
ommended by LC&D and a Local Area Network (LAN)
cable tester that allows remote testing — the ends of the
cable will be remote from each other.

! Only use stranded Cat. 5 cable.

Contacts were not correctly cut off - will prevent
proper seating in socket.

!  nly use EZ RJ45 brand connectors provided by Light-

O
ing Control & Design (LC&D). 7. Visually inspect each connector. Contacts should be
1. Remove two inches of the Cat. 5 jacket - use the pushed into the insulation of each conductor.
wire stripper and cutter provided in our kit. Carefully 8. Repeat on the other end of the cable for a straight-
inspect the conductors for nicks. through cable.
2. Untwist all four pairs, and straighten/smooth out
each conductor.
3. Reorganize the conductors in the order shown in the
illustration below. Bring all conductors together until
they touch.

Brown
Brown/White
Green
Blue/White
Contacts not seated properly (bowed crimping).
Blue
Green/White
Orange 9. Test every cable for continuity with a LAN cable tes-
Orange/White ter. While testing, wiggle and tug on each connector
to test for a solid crimp.
4. Place an EZ connector on the end of the cable with Never make “hot” RJ45 crimps (crimping the other end of
the locking prong facing down. a cable that has been plugged into a powered device).This
5. Push conductors completely through and (using flush can damage equipment.
cutters or box cutters) trim-off all excess cable. Con-
ductors should butt up to the end of the connector
– they must not protrude or be too short.

!  lways follow acceptable safety procedures when using a

A
sharp cutting tool. Tools must be sharp; dull tools cause
more hazards than sharp ones.
6. Using the recommended ratcheting crimp tool, crimp
at least five times for the best possible connection.
LCDBBAND04Sept08

Contacts properly seated (flat crimping).

43
42 THE BLUE BOX LT ADDING A NEW DEVICE

HARDWARE ACTIVATION TESTS

Before starting, note total approximate bus cable length: 6. All test values should be greater than 1K ohm!
Gnd to A ____ohms A to B ____ohms
Once each cable has been checked with a LAN cable Gnd to B ____ohms A to +12 ____ohms
tester and plugged-in, it is still possible for the entire con- Gnd to +12 ____ohms B to +12 ____ohms
nected cable structure to be problematic. For instance,
dirt may have accumulated inside the RJ45 sockets, the
Earth Ground Test
strain on the Cat. 5 when pushing switches into the wall
This test is intended to detect any pathways to earth
may weaken connections or even break the conductors,
ground.
or the bus length may exceed 4000 ft.
7. M
 easure resistance between the terminals mentioned be-
Each test must be passed before moving onto the next. If
low, and “Earth ground” (a metallic enclosure or conduit).
any readings are out of range, refer to “Hardware Activa-
tion Troubleshooting” section at the end of this document Gnd A
or call Technical Support at 1-800-345-4448. +12 B
CONTINUITY Test 8. A
 ll readings between each terminal and “Earth ground”
This test is intended to verify bus length, continuity, and should be infinite or “Open”!
detect crossed data-pair wires.
1. D
 e-power every item on the bus and check the voltage Terminator Test
at both ends to ensure a reading of 0vdc. Remove any This test is intended to ensure that only 2 terminators
terminators. exist, one at each end of the bus. If the readings are out of
range, it would indicate a missing, misplaced, or an extra
2. At one end of the bus, plug in the “Data/Power Jumper.” terminator.
3. A
 t the other end of the bus, plug in the “Bus Checker Card” 9. A
 dd a “Terminator” on the first and last device. On the
and measure resistance across the following terminals: “Bus Checker Card“, measure
Gnd to A ____ohms B to +12 ____ohms A to B ____ohms
4. A
 ll test values must be within 10% of the values in the 10. Test reading should be within 62 Ω to 92 Ω!
chart below to be considered valid!
11. Remove the bus checker card and call our Tech Sup-
Continuity Test Results (Gnd to A & B to +12) port with your results at: 1-800-345-4448 x391.
Length Ohms Length Ohms
100 ft 3 Ω to 6 Ω 2000 ft 68 Ω to 80 Ω
Figure A:
500 ft 12 Ω to 20 Ω 3000 ft 102 Ω to 120 Ω
1000 ft 34 Ω to 40 Ω 4000 ft 130 Ω to 160 Ω
Bus Checker Card Data/Power Jumper

SHORT CIRCUIT TEST

This test is intended to detect any short circuits along the
bus. Please use the lowest resistance range (200 Ω) setting
LCDBBAND04Sept08

on your multimeter. DO NOT use a “beep” test.

5. Remove the “Data Power Jumper.” On the “Bus Checker
Card,” measure the resistance across the following terminals:

44
 THE BLUE BOX LT ADDING A NEW DEVICE 43

AUTO-ASSIGNING ADDRESSES
TO A NEW DEVICE SYSTEM DEVICE SCHEDULE: (for Master Panels)
Any newly added digital device (switch, relay panel, DI (Master)
(Master)LCP1
LCP1 3 btn sw 6 btn sw LCP 2
card, etc) to any system with a Blue Box LT Master panels Device Type Device Type Device Type Device Type
may be auto-addressed as follows: elec rm Hallway lobby telecom
Location Location Location Location
ce80 8875 4685 af97

R
1. After completing the product Installation Guide(s), Serial # Serial # Serial # Serial #
1 5

E
power up all Slave Panels, and active devices (any de- Address Address Address Address

T
vice with an onboard - 120 or 277 - power supply) first

S
and then power up the Master Panel. Check that the DI-6

A Y
power-indicator LEDs on all digital devices are lit-up. Device Type Device Type Device Type Device Type

L
LCP 1

M
2. The main screen will be displayed for a few seconds, Location Location Location Location

N
after which the following will be displayed.TAB to YES 4055

R
Serial # Serial # Serial # Serial #

O
and press ENTER to auto-address the new device(s). 7

O
Address Address Address Address
If the number of devices detected do not match the

F S
number of devices present on the bus, proceed to

L
Not sure what the serial numbers are? Each device has a

E
trouble-shooting section.
unique Serial Number
Device Type label
Device or do the following
Type Device Typeto “read” Device Type

N
the Serial Number from
Location the DTC clock:Location
Location Location
Found 1 device on the

A
system that are not used. a. Serial #
Navigate Serial # Address” screen:
to the “Read SerialUSER
# MENU Serial #

P
Would you like to
auto-assign them? > SETUP MENUAddress
Address > RESTRICTED >Address ADDRESSING- Address
BUS SCAN > READ ADDRESS. The password to
YES / NO / -> enter the RESTRICTED area is 900001.
Never Ask Again
Device Type Device Type Device Type Device Type
b Press the first button on a switch or the “Address/
Assign” button. The
Location screen will display
Location the “Address”
Location Location
3. To view address assignment, TAB to YES and press and “Serial number”. Record this data on#the System
Serial # Serial # Serial Serial #
ENTER to go to the “Serial Number Scan” screen. Device Schedule.
Address Address Address Address
Error Check
Assigned 1 device. The “Serial Number
Review assignments by The system is now ready for Error Checking. EXIT repeat-
Scan” screen displays the
scanning all serial
numbers?
serial number, address,
and device-type of any
LIGHTING CONTROL & DESIGN
edly to navigate to the main menu.
905 Allen Ave s Glendale, CA 91201 s Support 800-345-4448 s www.lightingcontrols.com
YES / NO newly added device(s) 6. Navigate to the Error Statistics Screen. Use the path
LCDBBIG13Aug08

USER MENU > SETUP MENU > RESTRICTED >

4. If adding more than one device, TAB to “Serial#” field ADDRESSING-BUS SCAN > ERROR STATISTICS.
and SCROLL UP or DOWN to review each device. 7. Tab to the field that says CLEAR and press ENTER to
clear errors. If after 3 minutes no errors accumulate
BB Panel Schedule.indd 4 8/13/2008 1:37:4
SCAN by serial# on this screen, your system is stable.
Serial# CE80 8. If errors continue to accumulate, refer to the “Error
Adr: 6
Item Type: Switch
Check Troubleshooting” section in the Blue Box LT
Mapd: 6 Btn. Switch O&M Manual or System Start-Up and Cabling Guide
Address: OK or call Technical Support: 1-800-345-4448.
SAVE ADDRESS CHANGES
LCDBBAND04Sept08

5. Add the new device(s) to the “System Device Sched-

ule” on the back of the “Panel Schedule” located inside
the Blue Box LT Master Panel for future programming.

45
44 THE BLUE BOX LT ADDING A NEW DEVICE

digital time clock (DTC) NAVIGATION BASICS

DTC CLOCk NAvIGATION BASICS TAB moves the cursor through a screen
Most devices can be programmed from the DTC
DTC Clock Navigation Basics SWITCHES PAGE 1-1
(Digital Time Clock) in the master Lighting Control
All devices can be programmed from the DTC (Digital #04: SWITCH 4
Panel (LCP) .in the master Lighting Control Panel (LCP).
Time Clock) #05: SWITCH 5
#06: SWITCH 6
#07: SWITCH 7
#08: SWITCH 8
#09: SWITCH 9
#10: SWITCH 10
TAB moves the cursor through a screen

SCROLL to choose one item from a field .*

SWITCHES PAGE 1-1
USER MENU #04: SWITCH 4
Load 4
#05: SWITCH 5
MANUAL OVERRIDE SWI ID05-5 TOGGLE
#06:LCP-2
EDIT: SWITCH 6
LOAD-1
Load 3
REVIEW SCHEDULE
GROUP LOADS #07: SWITCH 7 Load 2
PROGRAM SWITCH #08: SWITCH 8
SETUP MENU #09: SWITCH 9
Load 1
#10: SWITCH 10

SCROLL to choose one item from a field.*

Load 4
1 2 SWI ID05-5 toggle
Load 3
5 EDIT: LCP-2 LOAD-1
This“field” contains a list of possible
Load 2
4 selections, but only displays one
Loaditem
1
3 from that list at a time.

This“field” contains a list of possible

CALL OUT LEGEND:
selections, but only displays one item
1 . SCROLL through choices in one field* from that list at a time.
2 . TAB to position the cursor
3 . DELETE information or programming about
an item . Use caution .
4 . ENTER to select
5 . EXIT to leave a screen .
LCDBBAND04Sept08

* A“field” contains a list of possible selections, but only displayed one item from that list at a time.

* A “field” is a display in which many items can be selected.

46
 THE BLUE BOX LT ADDING A NEW DEVICE 45

HARDWARE ACTIVATION TROUBLESHOOTING

! Always re-check “failed” results. If improperly set or

connected a meter can display unusual readings during
testing.
Earth Ground TroubleShooting
LAN-tested cables can still have a path to earth ground.
1. An abraded or “folded” cable inside the conduit will

! The “Bus-Splitting Technique” is the fastest way to find

a bad cable and/or damaged device. Be sure to docu-
ment the cable path!
cause a short to earth ground.
2. Other low voltage or high voltage wires touching
any device on the bus will cause continuity to earth

! Cat. 5cables that pass a LAN cable test can still short ground
or break from stress and strain during installation. If re- Use the Bus Splitting Technique to locate the problem.
testing a suspected cable with a LAN tester, roughly wiggle
Terminator Trouble-Shooting
and tug the conductors (cable wires) near the RJ45 con-
nector to ensure the conductors are properly engaged. 1. Ensure that the Data/Power Jumper is removed.
2. Visually inspect both terminators are present and
Continuity test TroubleShooting properly seated on each bus-end device.
1. Fluctuating resistance readings indicate one or more
“active” devices are still “hot”. De-power all devices ERROR CHECK Troubleshooting:
and re-test. If the hardware activation tests have just been completed
2. High resistance readings indicate broken or resistive and the bus is unstable, consider the following causes:
connections. Use the “Bus-splitting” technique to find: 1. Failure to follow the 568A or 568B color code (or
• RJ45 connectors not properly pushed into sockets minimally to use a dedicated pair for the center pins)
(check to make sure that the wires are not extended will cause the Error Check test to fail. Visually inspect
beyond the end of the RJ45 connector) RJ45 connectors.
• Cable strain can break conductors or pull conduc- 2. Occasionally the flat-cable connecting the clock to
tors out of RJ45 contacts (visually inspect cable and the Master panel can become damaged. Visually in-
connector). spect the Cat. 5 cable – if damaged, replace it with a
• Unseated RJ45 sockets (rough install environment) new cable.
3. An external source of EMF (electro-magnetic fre-
• Damaged device (rare) quency) or RF (radio frequency) interference may
• Dirt or paint on RJ45s (rare) be affecting the bus (or digital devices). Refer to the
beginning of this guide on running low voltage cables
• Bad data/power jumper cable (rare)
across or parallel to line voltage cables or exposing
Short Circuit Test TroubleShooting low voltage cables to EMF or RF sources (e.g. welders,
1. A low resistance reading indicates a crossed or short- ballasts, improperly grounded wireless devices, etc.);
ed pair or (rarely) a damaged device. Cable strain any of which can interfere with the bus operation
when pushing switches into a wall can short nicked and stability.
conductors. Use the bus splitting technique to find Visually inspect and handle any external sources of signal
the bad cable, crimp or device. noise - a digital device can also become damaged and cre-
2. Resistance readings below 300Ω on A-B only indicate ate signal noise.
an extra terminator. Use the bus splitting technique
An oscilloscope can be used to locate the source of the
to find the short or extra terminator.
3. After the problem has been resolved, please com- bus failure.The Oscilloscope Test procedures can be found
LCDBBAND04Sept08

plete the “Continuity Test” again. in The Blue Box LT “O&M Manual”. If unfamiliar with how
to use an oscilloscope or if one is unavailable on-site, con-
unstable bus troubleshooting tact Tech Support: 1-800-345-4448.
1. Ensure terminators are present at both ends of the bus.

47
HARDWARE ACTIVATION TROUBLESHOOTING
(Continued)
Bus Splitting Technique

! Note:To speed up troubleshooting when readings are

less than 200Ω on the Continuity or Short-Circuit test,
refer to the “Bus Length Chart” earlier in this document
before splitting the bus; this can provide an approximate
distance to a shorted pair or extra terminator from the
test point.

1. On the middle device of the bus, disconnect one Cat. Bus Checker Card Data/Power Jumper
5 cable to create two smaller “half-buses”.
2. Test each “half-bus” to find the side with the out-of-
range values.
3. Repeat steps 1 & 2 on the out-of-range “half-bus,”
to create another “half-bus” until the cable, crimp or
device creating the out of range measurements is lo-
cated.
The idea is to split a bus in half and then half again – over and
over until the bad area has been located. It is OK to visually
inspect each cable, crimp or device to detect the problem.

Bus Checker Card Data/Power Jumper

Data/Power Jumper Bus Checker Card

LCDBBAND04Sept08

Lighting Control & Design

905 Allen Ave • Glendale, CA 91201 • Support 800-345-4448 • www.lightingcontrols.com

48
 ®

THE BLUE BOX LT

™

PARTS REPLACEMENT &

installation guide
LCDBBPRIG03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

49
48 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE

LC&D recommends that any suspect circuit be fault- 6. Pry the relay out of the plastic track by applying a
checked prior to re-energizing. flat-blade screw driver to the slot located at the
relay card’s edge near the line and load lugs.
rELAY REPLACEMENT AND INSTALLATION
To replace a defective relay
Screw/ Lockwasher 7. Push the replacement relay back into the track
fasteners until it “snaps” securely in place – use a flat-blade
screw driver to snap in one or both ends.
Relays
Low Voltage jumper 8. Reconnect the low voltage jumper between the
connector relay and the relay driver pins on the control card
(LT4 and LT8) or the smacker strip (LT16).
Line/Load Connection
lugs 9. Re-install the line/low voltage barrier and the screw
and lockwasher fasteners. If necessary, break out
line/low voltage
barrier the “break-away“ tab(s) (one for each new relay)
on the voltage barrier for the replacement relay(s).
10. Reconnect Line and Load conductors to the
connection lugs.
To remove a defective relay: 11. For master panels: Close and screw down the
hinged display-panel door.
1. Switch off all breakers feeding relays and the
transformer in the Blue Box LT. 12. After the defective part replacement installation
is complete, return the part using the prepaid
2. For master panels: Unscrew and open the hinged USP return label and envelope to LC&D.
display-panel door to expose the high-volatge section.
3. Remove the screw and lockwasher fasteners that [Note: If the defective part is not returned within a
hold the line/low voltage barrier over the relays. 30-day period, your account will be automatically billed
4. Pull off the low voltage jumper that connects the relay to for the part. ]
the control card (LT 4 & 8) or the smacker strip (LT 16).
5. Loosen the LINE and LOAD connection lugs on To exercise and test the replacement relay:
the relay and remove the conductors. [Note: For 13. Switch the breakers powering all the relays and
safety reasons, use a wire nut to tie the two wires the transformer back ON
together] 14. Navigate on the DTC to USER MENU >
MANUAL OVERRIDE and TAB or SCROLL to
the correct LCP and Load (relay) and ENTER to
exercise the relay by switching it on and off 3 or 4
times. If possible, listen to hear the relay contacts
clicking as they open and close.
Line Lug
MANUAL CONTROL AU SCROLL to select LCP
Removal Slot LCP-1 LOAD-1
Load Log TAB to LOAD
LCDBBPRIG03Sept08

1- 3■ 5■ 7■ 9- 11- 13- 15- SCROLL to select

LOAD
Low voltage connector pins 2- 4- 6- 8■ 10- 12- 14- 16-
ENTER to toggle
status

50
 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE 49

Refer to the Digital Input Card Installation Guide

section of the Blue Box LT “O&M Manual” for more
details.
DI Card
DI CARD REPLACEMENT AND INSTALLATION
Input/output
To remove a defective DI Card: terminals
1. Note the address of the existing DI Card. Refer to
the SYSTEM DEVICE SCHEDULE in the master
panel or by process of elimination - the READ Power
ADDRESS screen.
2. De-power the Blue Box LT by switching off the
breaker feeding the power supply (the relays in

24V 3.3V Gnd

that panel will close).
3. Disconnect the power/data jumper cable from
the DI card (leave it connected to the control
card). To replace a defective DI Card
6. Snap the new DI card into the plastic track .
4. Remove all low voltage conductors for contact
closure devices from the input/output terminals. 7. Re-connect the power/data jumper cable to the
DI card.
5. Pry the DI Card out of the plastic track by
applying a flat-blade screw driver to the slot on 8. Reconnect all low voltage conductors for contact
the side of the card. closure devices to the input/output terminals.
9. Re-power the Blue Box LT.
10. If this is a master panel, the main screen will
be displayed for a few seconds, after which the
DI Card “device detection” screen will be displayed. DO
Input/output NOT ASSIGN THIS DEVICE A NEW ADDRESS!
terminals TAB to NO and ENTER
11. When the screen prompts: ”Are you sure?” TAB
to YES and ENTER.
12. After the defective part replacement installation
is complete, return the part using the prepaid
USP return label and envelope to LC&D.

[Note: If the defective part is not returned within a

30-day period, your account will be automatically billed
for the part. ]

To address the replacement DI Card

LCDBBPRIG03Sept08

13. Navigate to the AUTO-ADDRESSING screen:

USER MENU> SETUP MENU> RESTRICTED
(PASSCODE: 900001) > ADDRESSING-BUS
SCAN > AUTO ADDRESSING.

51
50 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE

DEVICE MANAGEMENT that panel will close).

SCAN BY SERIAL # 2. Once the panel is de-powered, disconnect all
ERASE ALL ADDRESSING
AUTO ADDRESSING
cables connected to the control card.
SCAN FOR ZERO ID ON 3. Pry the Control Card out of the plastic track by
POWER UP: YES
applying a flat-blade screw driver to the slot on
the side of the card.
14. SCROLL UP until the address of the previous DI
is displayed. To replace a defective Control Card
15. Press the address button on the DI CARD. 4. Snap the new control card into the plastic track.
16. If the DI “takes” the address, the display will 5. Re-connect all cables and conductors to the
increment by one (e.g. from “3” to “4”). control card.
6. Re-power the Blue Box LT
To verify the bus recognizes the replacement DI 7. After the defective part replacement installation
Card: is complete, return the part using the prepaid
17. Navigate to SCAN BY SERIAL NUMBER screen: USP return label and envelope to LC&D.
USER MENU > SETUP MENU > RESTRICTED
(PASSCODE 900001) > ADDRESSING –
[Note: If the defective part is not returned within a
BUS SCAN> BUS DIAGNOSTICS > MORE
DIAGNOSTICS > DEVICE MANAGEMENT > 30-day period, your account will be automatically billed
SCAN BY SERIAL# for the part. ]

SERIAL# SCAN
BACK FWD |SAVE|
SERIAL# ce80
ADR: 1
LCP
No address collision found
on this card

18. ENTER to begin a system scan.

Master Control Card
19. If the screen shows no collisions, DI Card
replacement is complete.
Power
20. If collisions exist, contact Technical Support.
21. Reconnect all low voltage conductors for contact
closure devices to the low voltage input/output
terminals.
22. Program the new DI card.

Control Card [Master] Replacement and

installation
LCDBBPRIG03Sept08

To remove a defective Control Card

1. De-power the Blue Box LT by switching off the
breaker feeding the power supply (the relays in

52
 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE 51

11. If collisions exist, contact Technical Support.

12. If no collisions exist or collisions have been
resolved, the bus needs to be mapped so that
the devices can be programmed. Navigate to
the BUS MAP screen: USER MENU > SETUP
MENU > RESTRICTED (PASSCODE 900001) >
ADDRESSING – BUS SCAN> BUS MAP.
Master Control Card
ADDRESSING PAGE 1-19
ID1 : UNUSED
ID2 : UNUSED
ID3 : UNUSED
ID4 : UNUSED
Power ID5 : UNUSED
ID6 : UNUSED
ID7 : UNUSED

To address and verify the bus recognizes replace- 13. To define the Master Blue Box, TAB to ID1 and
ment Control Card SCROLL to select Panel LCP 1 (4 or 8 relay
The Blue Box master Control Card contains the time panels). For a 16 relay panel, TAB to ID2 and
clock for the system.To save time, the time, date and SCROLL to “Panel LCP 1” also. Every 8 relays
take up an address, so a 16 relay panel will take
location settings can be pre-loaded at the factory - if up 2 addresses.
requested.Time schedules and any groups which had
Loads (relays) in LCP 1 (master panel) will need to be ADDRESSING PAGE 2-19
ID1 : Panel LCP1
re-programmed. ID2 : Panel LCP1
If your system has a modem, contact Technical Support ID3 : UNUSED
ID4 : UNUSED
to have all of the programming (listed below) done. ID5 : UNUSED
ID6 : UNUSED
8. Navigate to SCAN BY SERIAL NUMBER screen: ID7 : UNUSED
USER MENU > SET UP MENU > RESTRICTED
(PASSCODE 900001) > ADDRESSING –
BUS SCAN> BUS DIAGNOSTICS > MORE 14. Map the remaining devices into the BUS MAP
DIAGNOSTICS > DEVICE MANAGEMENT > screen using the data from the SCAN BY SERIAL
SCAN BY SERIAL# NUMBER screen
9. ENTER to begin a system scan. Item Bus Map Name
SCAN BY SERIAL# Blue Box LT-4 Panel LCP X (1-32)
Scanning complete. Blue Box LT-8 Panel LCP Y (1-32)
Found 3 items.
Not addressed: 0
Blue Box LT-16 Panel LCP Z (1-32)
(Blue Box LT 16 requires Panel LCP Z (1-32)
Hit ENTER when ready

two addresses)
LCDBBPRIG03Sept08

10. If the Screen shows no collisions SCROLL through 1 button digital switch 1 Btn. Switch, etc
each device noting down the address (ID) and DI-14 14 Btn. Switch
the device type (3 button switch, etc)

53
52 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE

Item Bus Map Name [Note: If the defective part is not returned within a
30-day period, your account will be automatically billed
DI-6 14 Btn. Switch
for the part. ]
Any Digital Switch that is 14 Btn. Switch
enabled or disabled

Re-program schedules and groups

15. Since the master panel control card is also Slave Control Card
the system clock, all programs will need to be
programmed back into the clock.
16. Any groups which had relays in LCP 1 will need
to be modified to add back the relays from LCP 1.
Relays from other LCPs will automatically appear
on the Groups screens.
Power
Control Card [SLAVE] Replacement and
installation

To remove a defective Control Card

1. Note the address of the LCP (lighting control
panel). Refer to the SYSTEM DEVICE SCHEDULE
in the Master Panel or use the READ ADDRESS
screen.
2. De-power the Blue Box LT by switching off the
breaker feeding the power supply (the relays in Slave Control Card
that panel will close).
3. Once the panel is de-powered, disconnect all
cables connected to the control card.
4. Pry the Control Card out of the plastic track by Power
applying a flat-blade screw driver to the slot on
the side of the card. [Note: If this is a warranty
replacement, do not forget to ship relay back to To address and verify the bus recognizes replace-
LC&D.] ment Control Card
9. Navigate to the AUTO ADDRESS screen:
To replace a defective Control Card USER MENU> SET UP MENU> RESTRICTED
5. Snap the new control card into the plastic track. (PASSCODE: 900001) > ADDRESSING BUS
6. Re-connect all cables and conductors to the SCAN > AUTO ADDRESSING.
Control Card. 10. SCROLL UP until the address of the LCP is
7. Re-power the Blue Box LT. displayed.
LCDBBPRIG03Sept08

8. After the defective part replacement installation 11. Press the address button on the Control Card.
is complete, return the part using the prepaid 12. If the address “takes” the address on the display
USP return label and envelope to LC&D. will increase by one for an LT4 and LT-8, or 2 for
an LT-16) (e.g. from “3” to “4”).

54
 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE 53

13. Navigate to SCAN BY SERIAL NUMBER screen: 7. After the defective part replacement installation
USER MENU > SETUP MENU > RESTRICTED is complete, return the part using the prepaid
(PASSCODE 900001) > ADDRESSING – USP return label and envelope to LC&D.
BUS SCAN> BUS DIAGNOSTICS > MORE
DIAGNOSTICS > DEVICE MANAGEMENT > [Note: If the defective part is not returned within a
SCAN BY SERIAL# 30-day period, your account will be automatically billed
for the part. ]
SERIAL# SCAN
BACK FWD |SAVE|
SERIAL# ce80
ADR: 1
LCP1
No address collision found on
this card

14. ENTER to begin a system scan.

15. If collisions exist, contact Technical Support.
16. If no collisions exist or collisions have been
Modem

resolved, the bus needs to be mapped so that

the devices can be programmed. Navigate to
the BUS MAP screen: USER MENU > SETUP
MENU > RESTRICTED (PASSCODE 900001) >
ADDRESSING – BUS SCAN> BUS MAP.

Re-program Groups
17. Any Groups which had relays in the LCP with the
new control card will need to be modified to add
back the relays from that LCP. Relays from other
LCPs remain unaffected.
To verify replacement modem is operational:
Replacing a Modem (Master panels only) 8. Navigate to the DIAL UP HOST screen: USER
MENU > SETUP MENU > RESTRICTED
To remove a defective modem (PASSCODE 900001) > REMOTE SYSTEM
1. Disconnect the power/data cable connected to MENU > DIAL UP HOST
the modem. DIALING UP HOST
2. Disconnect the RJ-12 (phone line) Enter the complete
phone number of the
3. Pry the modem out of the plastic track by applying HOST and hit enter.
a flat-blade screw driver to the slot located on
the side of the card.
9. Refer to the DIAL UP HOST section in the O&M
To replace a defective Modem
manual to place an outbound call to a cell phone
4. Snap the new modem into the plastic track .
LCDBBPRIG03Sept08

or land line.
5. Re-connect cables.
10. A successful call means installation is complete.
6. Re-power the Blue Box LT If the call was not successful, contact Technical
Support for assistance.

55
54 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE

DTC Display Replacement and Smacker Strip

Installation
1. Unplug the jumper cable at the back of the
DTC.
2. Unscrew the four fasteners on the back of the
DTC.
3. Mount the new DTC.
4. Re-connect the new DTC.
5. After the defective part replacement installation
is complete, return the part using the prepaid
USP return label and envelope to LC&D.
[Note: If the defective part is not returned within a
30-day period, your account will be automatically billed
for the part. ]
smacker strip (blue box Lt16)
Replacement and Installation

To remove a defective smacker strip

1. De-power the Blue Box LT by switching off the
breaker feeding the power supply (the relays in
that panel will close).
2. Once the panel is de-powered, disconnect all
cables connected to the smacker strip.
3. Remove the three screws and lift the smacker
strip out of the panel. To verify proper connections:
8. To exercise and test the newly added smacker
To replace a defective smacker strip strip, navigate to the MANUAL OVERRIDE
4. Mount the new Smacker Strip using the three screen: USER MENU > MANUAL OVERRIDE
screws.
MANUAL CONTROL AU SCROLL to select LCP
5. Re-connect all flat cables and relay jumpers. LCP-1 LOAD-1
Refer to the Blue Box LT 16 schematic drawing if TAB to LOAD
uncertain about cable placement. SCROLL to select
1- 3■ 5■ 7■ 9- 11- 13- 15-
6. Re-power the Blue Box LT. LOAD
2- 4- 6- 8■ 10- 12- 14- 16-
7. After the defective part replacement installation ENTER to toggle status
is complete, return the part using the prepaid
USP return label and envelope to LC&D. 9. TAB or SCROLL to the correct LCP. Exercise each
relay by manually switching it on and off 3 or 4
LCDBBPRIG03Sept08

[Note: If the defective part is not returned within a times. Make sure the relay corresponds to the Load
30-day period, your account will be automatically billed number on the MANUAL OVERRIDE screen.
for the part. ] 10. Correct any mis-connections.

56
 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE 55

Transformer Replacement and 6. For LT 4 and 8: Pry the transformer out of the
installation plastic track by applying a flat-blade screw driver
to the slot located at the card’s edge near the
To remove a defective Transformer hot and neutral lugs. For LT 16: Remove the four
1. De-power the Blue Box LT by switching off the screws at the base of the transformer.
breaker feeding the power supply (the relays
in that panel will close). De-power any other To replace a defective Transformer
breakers that may present a hazard during 7. For LT 4 and 8: Push the new replacement
installation. transformer into the track until it “snaps” securely
2. For master panels: Unscrew and open the hinged in place. You may need to use a flat-blade
display-panel door to expose the high-voltage screw driver to snap in one or both ends. For
section. LT 16: Mount the new transformer with the four
screws.
3. Remove the screw and lockwasher fasteners
that hold the line/low voltage barrier on top of 8. Reconnect the low voltage connectors.
the power supply (transformer) and remove the 9. Reconnect hot and neutral conductors
barrier to free it up.
10. Re-install the line/low voltage barrier and the
Low Voltage/High Voltage Barrier screw and lockwasher fasteners.
11. For master panels: Close and screw down the
To optional DI Card
hinged display -panel door.
To optional Modem
master panels only
12. Re-power any breakers.
13. After the defective part replacement installation
5 is complete, return the part using the prepaid
4 USP return label and envelope to LC&D.
[Note: If the defective part is not returned within a
30-day period, your account will be automatically billed
for the part. ]

To exercise the replacement Transformer

3
14. Visually inspect that the ONLINE LED on the
control card is blinking and the clock is powered
up and displaying correctly.
2 15. Navigate on the DTC to USER MENU >
6
MANUAL OVERRIDE and TAB or SCROLL to
To DTC 1 the correct LCP and Load (relay). Exercise each
relay by manually switching it on and off 3 or 4
Low Voltage High Voltage times. If possible, listen to hear the relay contacts
clicking as they open and close.
4. Loosen the hot and neutral connection lugs on the trans-
LCDBBPRIG03Sept08

former’s terminal block and remove the conductors.

5. Pull off the low voltage connector(s) (one wire
3#18 AWG. Supplies power and neutral from transformer
1 for LT 4 and 8 and three wires for LT 16) that
to relay control card.
connects the transformer to the control card.
2 14 Conductor ribbon cable: carries control signal
between DTC and relay control card (master panel only).

3 2 conductor ribbon cable: carries control signal from

relay control card to relays - onbe per relay.

4 _____ cable: carries digital siganl from relay control card

to (optional) digital input card
57
56 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE

BLUE BOX LT 1404/1408

low voltage only line voltage only

7 5 2 1

10 6

7
2
4 3
9

4 2
5

1. 3#18 AWG. Supplies power and neu- 1. Blue Box mounting holes (4).
tral from transformer to relay control 2. Back plate mounting screws.
card. 3. RJ45 sockets for GR 2400 bus.
2. 1-14 conductor ribbon cable: carries 4. Photocell input (master only). The Pho-
control signal between DTC and relay tocell may control any relay(s) in any
control card (master panel only). panel(s).
5. Optional modem. Analog phone line con-
3. 4(1404LT)/ 8 (1408) 2 conductor rib- nects to RJ-12 socket.
bon cable: carries control signal from 6. Relays (line and load lugs).
smacker strip to relays - one per relay. 7. Dual-voltage (120V or 277V)power
4. Terminator / terminator pin-outs. (pro- supply.
vided inside master panel) - terminates 8. (Optional) Digital Input Card. [DI] 14
bus line. (or 6 enable/disable) inputs.
9. Terminator pins. Terminate the bus only
after the “System Start-Up and Cabling
Guide” has been completed.
10. Clock backplate and back of DTC clock
LCDBBPRIG03Sept08

(for the master panel only).

58
 THE BLUE BOX LT PARTS REPLACEMENT & INSTALLATION GUIDE 57

BLUE BOX LT 1416

2 1

5 6 6
6 4

1 5 7
2

10
9
4 8
3
1. 3#18 AWG. Supplies power and neu-
tral from transformer to relay control
card.
2. 14 conductor ribbon cable: carries
control signal between DTC and relay 1. Blue Box mounting holes (4).
control card (master panel only). 2. Back plate mounting screws. (Retaining
3. 2 conductor ribbon cable: carries con- pin located at bottom, lift up and out to
remove)
trol signal from smacker strip to relays
3. RJ45 sockets for GR 2400 bus.
- one per relay. 4. Photocell input (master only). The Pho-
4. P10 conductor ribbon cable: carries tocell may control any relay(s) in any
digital signal from relay control card to panel(s).
smacker strip 5. Optional modem. Analog phone line con-
5. 5 conductor ribbon cable: carries digital nects to RJ-12 socket.
signal from relay control card to (op- 6. Relays (line and load lugs).
tional) digital input card 7. Dual-voltage (120V or 277V)power
6. 4#22AWG carries rs-232 signal from supply.
(optional) modem to relay control card 8. (Optional) Digital Input Card. [DI] 14
(master panel only) Dual-voltage (120V (or 6 enable/disable) inputs.
9. Terminator pins. Terminate the bus only
or 277V)power supply.
after the “System Start-Up and Cabling
LCDBBPRIG03Sept08

7. Terminator / terminator pin-outs. (pro- Guide” has been completed.

vided inside master panel) - terminates 10. Clock backplate and back of DTC clock
bus line. (for the master panel only).

59
LCDBBPRIG03Sept08

60
 ®

BLUE BOX LT
™

HARDWARE
TROUBLESHOOTING
LCDBBHTS03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

61
60 THE BLUE BOX LT HARDWARE TROUBLESHOOTING

HARDWARE TROUBLESHOOTING

relay troubleshooting Is the relay “Stuck Closed”?

This section contains the most common problems, causes Stuck Closed – Lights are constantly ON, there’s continuity
and solutions for troubleshooting relays. These specific across the relay when you measure across line & load, and
issues will be covered in depth: there’s voltage (120/277) going to the load side of the relay
• Relay(s) stuck open / stuck closed a) If the relay is “Stuck Closed” and it is a Normally
• Light turns OFF by itself after a certain period of time Open Relay:
• Light turns ON by itself after a certain period of time • Unplug the relay jumper to cut the power to the
relay; if the relay is “Normally Open” it should go
• Relay(s) chattering
to its fail state, it should fail open.
PROBLEM: Relay(s) not working: • The red LED on the relay should be OFF, if not
Relay may be stuck to its previous state and need to be cycled
Troubleshooting to check:
• Go to “Manual Override” screen
...If the relay is bad:
• Try to cycle the relay ON/OFF
• Swap relay with a known working relay or use a spare
• If successful, the physical relay status and the on-
• Then cycle the relay ON & OFF
screen status indicator will change, in addition the
relay should start clicking • If spare relay works, the relay may be bad; contact
LC&D Technical Support for a replacement.
QUESTION:
• If not, there is a possible loose ribbon cable.
Is the relay “Stuck Open”?
i. Unplug, then plug the ribbon cable back
Stuck Open – Lights are constantly OFF, no continuity
across the relay when you measure across line & load, and ii. Cycle the relays ON & OFF
no voltage going to the load side of the relay ...If the Relay Jumper is bad:
a) Check the circuit breaker: • Change the relay jumper cable by using the jumper
• Verify the breaker is set to the ON position cable from a known working relay
• If necessary, measure voltage on Line Side of relay. • Cycle the relay ON & OFF
b) Next, find out what type of relay it is: • If not fixed, the relay jumper cable is bad; contact
LC&D Technical Support for a replacement.
• “Normally Open Relay”
...If the Ribbon Cable is bad:
• “Normally Closed Relay”
• Change ribbon cable using a cable from another
c) If the relay is “Stuck Open” and it is a Normally
panel if available
Closed Relay (relays are defaulted to the “Nor-
mally Closed” position): • Then cycle the relay ON & OFF
• Unplug the relay jumper to cut the power of the • If not fixed, this is a bad Ribbon Cable; contact
relay and it should go to its failed state LC&D Technical Support for a replacement.
• The relay is “Normally Closed” so it should fail closed ...If the Smacker Strip is bad:
• The red LED on the relay should be OFF • Change the smacker strip using a known working
LCDBBHTS03Sept08

smacker strip
• There should be continuity if you measured across
the relay. There should be voltage going to the • Cycle the relay ON & OFF
load side

62
 THE BLUE BOX LT HARDWARE TROUBLESHOOTING 61

HARDWARE TROUBLESHOOTING (Continued)

• If not fixed, this is a bad smacker strip; contact LC&D 4. If voltage is present on all pins except for the one that
for a replacement. controls the relay in question, relay driver is bad and
smacker strip will need to be replaced.
...If the relay is in Timer Mode:
5. If voltage is present on all pins, transformer is supply-
• Go to “Manual Override Screen.”
ing correct voltage on the secondary side, and power
• The status indicator on the screen will have an to smacker strip has been reset, disconnect the con-
extra leg, if the relay is in timer mode. trol card power cable, then disconnect smacker strip
• If not in relay timer mode, the relay may be in a power cable, and then the relay jumper. Reconnect
Maintain + Timer or Maintain + Blink Group control card power cable first, then smacker strip
power cable, and finally the relay jumper. Exercise re-
• Find out if and which Group controls that relay. lay and listen for clicking sound. Repeat Step 2. If relay
• Go to the “What and When” menu or refer to the does not respond, replace smacker strip.
system Bus file. 6. If replacing the Smacker Strip does not work, the prob-
• If the relay is not supposed to be on a Maintain + lem lies on the card; contact LC&D for a replacement.
Timer or Maintain + Blink Group, remove it from
Group. control card troubleshooting
Check to see if the “Online” LED is ON.
...If the relay(s) are chattering it may be caused by insuf-
ficient voltage driving the relay: If “Online” LED is ON (blinking or solid):
• Check for any loose connections with the relay 1. Navigate to the “Read Address” screen. Read the address.
jumpers or the ribbon cable. 2. Screen should display either an address or a “0” address.
• Unplug, and then plug the relay jumper cable back. 3. If the screen displays an address:
Smacker Strip Troubleshooting Use the “Scan by Serial Number” screen, to check if any
If relays do not turn ON or OFF and the relay trouble- address collisions exist with another device on the bus.
shooting procedure does not help resolve a relay related If collision exists, re-address card to an unassigned address
issue, follow the steps below: and define it in the “Bus Map”.
1. Check the voltage between the smacker strip relay If no collision exists, but the card was already assigned to an
driver pins (24V and Gnd) for the relay in question: address in a previous location (where it was causing a collision
For Normally Closed Relays with another device) on the bus map, eliminate device from
If 24V and LED on relay button is OFF bus map and define the correct device on that address.
4. If the screen display’s a “0”
For Normally Open Relays
Address the card through the “AUTO-ADDRESSING”
If 24V and LED on relay button is ON
screen and define it in the “Bus Map” screen.
2. If correct voltage is present, connect a different relay
to the driver pins and exercise relay – listen for a If unable to read address:
clicking sound. 1. Remove the control card from the bus (disconnect
3. If 24 V ac is not present on the pins, check other pins all Cat.5),
for voltage. If no relay driver has 24 V ac, disconnect • Connect directly to the master control card with
LCDBBHTS03Sept08

power cable at the bottom of the strip and recon- a LAN tested cable
nect. Measure voltage on each driver pin. If no voltage • Read the address of the card through the read
is present, refer to the transformer troubleshooting address screen
procedure.

63
62 THE BLUE BOX LT HARDWARE TROUBLESHOOTING

HARDWARE TROUBLESHOOTING (Continued)

2. If address is displayed, a problem exists somewhere 7. Replace clock cable with a new one
along the bus. • Disconnect clock cable
• Troubleshoot the bus using the “Bus splitting tech- • R
 eplace with a new cable and wait a few seconds
nique” for a powered bus – refer to the “System for display to show up
Diagnostics Tools” section of the O&M
8. If replacing the clock cable does not fix the problem,
• If a “0” is displayed, address the card using the DTC needs to be replaced; contact LC&D for a re-
“AUTO-ADDRESSING” screen and define it in placement.
the “Bus Map” screen
If the DTC displays the message: “Upload in Progress,” the
3. If unable to read the address, power cycle the card clock is either in the middle of a software upgrade or it
and read address again. was interrupted and got stuck. The fix to this problem is
• If address is displayed, a problem exists some- to re-upload the DTC software, if this does not correct
where along the bus the problem, the DTC will need to be replaced. Contact
• If a “0” is displayed, address the card through the LC&D for a replacement.
“AUTO-ADDRESSING” screen and define it in
the “Bus Map” screen transformer troubleshooting
The transformer should have 120/277 V ac on the prima-
• If address is not displayed still, control card needs ry side and the secondary side should have 20 V between
to be replaced; contact LC&D for a replacement. the two outer terminals and 10 V between the center and
either outer terminal.
dtc troubleshooting
If the DTC shows no display, follow the steps below: 1. If the voltage on the primary side is not 120/277 Vac,
Check for power to the DTC. • Check to see if the breaker is in the ON position
and that there is voltage from the breaker to the
4. Vary contrast to the darkest setting.
transformer
• O
 pen low-voltage panel door. On the back of the
2. If the voltage on the primary side is correct (120/277
display clock, the “contrast” dial can be used to
Vac) and any of the devices in the panel are not re-
vary the display contrast
ceiving appropriate voltage:
• U
 sing a small Phillips screw driver to turn the con-
• Check the voltage on the secondary side terminals
trast dial:
3. If there is a 120/227 Vac supply from the breaker to
- Clockwise to turn up the contrast
the transformer, but not sufficient or steady voltage
- Counter-clockwise to turn down the contrast supply on the secondary side:
5. Power cycle the DTC. • Transformer needs to be replaced: contact LC&D
• D
 isconnect the clock cable on the back side of the for a replacement.
clock display that connects to the control card
• R
 e-connect cables and wait for a few seconds for
the clock display to show up
6. Disconnect master panel from the bus:
• D
 isconnect both Cat. 5 cables connected to the
LCDBBHTS03Sept08

master panel and wait for a few seconds

• If the display shows up, the problem on the bus
exists with the Cat. 5 cabling

64
 ®

THE BLUE BOX LT

™

TROUBLESHOOTING
WITH AN OSCILLOSCOPE
LCDBBTSWO03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

65
64 THE BLUE BOX LT TROUBLESHOOTING WITH AN OSCILLOSCOPE

using an oscilloscope to test

A DIGITAL bus
In troubleshooting a system or a bus, the “Final Activation 5. If the bus is not terminated properly, some “ringing”
Checklist” is always the first and most important step. An Os- may be seen. With less loading, the Vpp is higher. If
cilloscope is a visual aid to troubleshoot the bus better. there are not bad devices, the baseline is still at Zero.
The Oscilloscope will let one test the stability of the bus
while everything is powered up. This will show if the bus
is getting noise, how clean the bus signal is, if the bus is
properly terminated, if there is a bad device present on
the bus, and give an indication of crimp quality.
Below are some examples where the use of an Oscillo- +V = -V
scope is definitely needed:
1. The Hardware Activation Tests included the “System
Startup and Cabling Guide” passed, but when the sys-
tem is powered up, devices appear/disappear on the
bus scan.
2. The Hardware Activation Tests passed, but some de-
vices don’t seem to be working if the bus is connect-
ed, and the same devices work perfectly fine when
connected directly to a master panel.
3. Everything else was checked (The Hardware Activa-
tion Tests” passed and all devices are good) but the +V = -V
bus is still unstable.

How to setup the scope for testing

Make sure the Oscilloscope is not earth grounded in any
way. A battery powered scope is best.
1. Connect the probe leads to the system’s A & B ter- Ideal wave form; Square waves with no ring or dampen-
minals; A “Bus Checker Card” may be used to make ing means the bus is terminated. +V = -V means no bad
the testing easier. Attach the alligator clip (which is the devices.
ground lead of the probe) to the bus checker card’s
B terminal, then connect the main probe lead (which
is usually a retractable hook tip) to the bus checker
card’s A terminal.
2. Adjust the vertical & horizontal controls accordingly
and set the input coupling to DC. You should be able +V = -V
to see your bus signal which is a “Square Wave Sig-
nal.”
3. The advisable setting would be “1.0 volts/div” & “(20
µs to 50 µs) sec/div” this should be able to let one see
LCDBBTSWO03Sept08

a decent size waveform on the screen. (10-1 Probe).

Problematic: Dampened square wave means the bus is
4. A completely “Stable Bus” should show a clean & bal- missing one or both terminators. +V = -V means no bad
anced square wave signal. The baseline is centered at devices.
“0” and never changes.

66
 THE BLUE BOX LT TROUBLESHOOTING WITH AN OSCILLOSCOPE 65

using an oscilloscope to test

A DIGITAL bus (Continued)
6. With a partially bad device, it is sometimes hard to
distinguish because it looks very similar to a good bus.
One has to carefully examine the waveform and see
if the baseline is centered at Zero.
7. A bad device causes the baseline to shift and become +V ≠ -V
unbalanced. (Baseline is not at Zero anymore). Below
are three examples where A & B are not equal.
8. Use the Bus-Splitting technique to find the problem.

Problematic: Ringing and dampened square wave means

that the bus is missing one or both terminators. +V ≠ -V
means damaged devices. Usually caused by over-voltage:
static, lightning, or line voltage.

+V = -V

+V ≠ -V
Problematic: Ringing on peak of square wave means the bus
is missing one or both terminators. +V = -V means no bad
devices.

Problematic: Ringing and extremely dampened square wave

means the bus is missing one or both terminators. +V ≠
-V means damaged devices. Usually caused by over-voltage:
static, lightning, or line voltage.
+V ≠ -V

Problematic: Clean square waves mean the bus is termi-

nated. But +V ≠ -V means damaged devices. Usually caused
by over-voltage: static, lightning, or line voltage.
LCDBBTSWO03Sept08

67
66 THE BLUE BOX LT TROUBLESHOOTING WITH AN OSCILLOSCOPE

Bus Splitting Technique

! Note:To speed up troubleshooting when readings are

less than 200Ω on the Continuity or Short-Circuit test,
refer to the “Bus Length Chart” on page 4 before splitting
the bus; this can provide an approximate distance to a
shorted pair or extra terminator from the test point.
1. On the middle device of the bus, disconnect one Cat.
5 cable to create two smaller “half-buses”.
2. Test each “half-bus” to find the side with the out-of- Bus Checker Card Data/Power Jumper
range values.
3. Repeat steps 1 & 2 on the out-of-range “half-bus,”
to create another “half-bus” until the cable, crimp or
device creating the out of range measurements is lo-
cated.
The idea is to split a bus in half and then half again – over
and over until the bad area has been located. It is also OK
to visually inspect each cable, crimp or device to detect the
problem.
Bus Checker Card Data/Power Jumper

Data/Power Jumper Bus Checker Card LCDBBTSWO03Sept08

68
 ®

THE BLUE BOX LT

™

PROGRAMMING
LCDBBP03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

69
68 THE BLUE BOX LT PROGRAMMING

TABLE OF CONTENTS

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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
Daylight Saving Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Keyboard Lock Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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

LCDBBP03Sept08

70
 THE BLUE BOX LT PROGRAMMING 69

PROGRAMMING

DTC CLOCk
CLOCK NAVIGATION
NAvIGATION BASICS
CLOCk NAvIGATION TAB moves
TAB moves the
the cursor
cursor through
through aa screen
screen
Most devices can be programmed from the DTC
(Digital Time Clock)inininthe
Time Clock)
Clock) themaster
the master
master LCP (Lighting
Lighting Control SWITCHES
SWITCHES PAGE 1-1
PAGE 1-1
(Digital Lighting Control #04: SWITCH
SWITCH 44
#04:
Control
Panel Panel).
(LCP) .
Panel (LCP) . #05: SWITCH
#05: SWITCH 55
#06: SWITCH
#06: SWITCH 66
#07: SWITCH
#07: SWITCH 77
#08: SWITCH
#08: SWITCH 88
#09: SWITCH
#09: SWITCH 99
#10: SWITCH
#10: SWITCH 10
10

SCROLL to
SCROLL to choose
choose one
one item
item from
from aa fifield .
eld .**
USER MENU
USER MENU
Load 44
Load
MANUAL OVERRIDE
OVERRIDE SWI ID05-5
SWI ID05-5 TOGGLE
TOGGLE
MANUAL
EDIT: LCP-2
LCP-2 LOAD-1
LOAD-1
Load 33
Load
REVIEW SCHEDULE
REVIEW SCHEDULE EDIT:
GROUP LOADS
GROUP LOADS Load 22
Load
PROGRAM SWITCH
PROGRAM SWITCH
SETUP MENU
Load 11
Load
SETUP MENU

1
1 2
2
5
5 This“field”
This“fi eld”contains
contains aa list
list ofof possible
possible
4
4 selections,but
selections, but only
only displays
displays one one item
item
3
3 from that
from that list
list at
at aa time.
time.

CALL OUT
CALL OUT LEGEND:
LEGEND:

1 .1 . SCROLL
SCROLL throughthrough choices
choices inin one
one fifield*
eld*
2 .2 . TAB
TAB to to position
position thethe cursor
cursor
3 .3 . DELETE
DELETE information
information or or programming
programming about about
an item .
an item .Use
Use caution .
caution .
4 .4 . ENTER
ENTER to to select
select
5 .5 . EXIT
EXIT to to leave
leave aa screen .
screen .
LCDBBP03Sept08

***AA“fi
A“fi eld”contains
eld”
“field” contains aa list
list ofof possible
possible selections,
selections,but
but only
only displayed
displayed one
one item
item from
from that
thatlist
the listat
list ataaatime.
at time.
time.

71
70 THE BLUE BOX LT PROGRAMMING

Manual control of relays To Control a LOAD (Relay):

Manually control and visually check the (on/off) status 8. ENTER to toggle the status of the LOAD “off ”
of any relays(s) in any panel(s). or “on”.
MANUAL CONTROL AU
To Start LCP-1 LOAD-1
1. TAB once or twice to get started. The USER 1■ 3■ 5■ 7■ 9■ 11- 13- 15■ LOAD 15 is on. .
MENU will display. 2- 4- 6- 8■ 10- 12- 14- 16- LOAD 16 is off.
2. TAB to MANUAL OVERRIDE.

USER MENU - indicates the LOAD is off

MANUAL OVERRIDE ■ indicates the LOAD is on
REVIEW SCHEDULE
GROUP LOADS
PROGRAM SWITCH There are other relays statuses. Refer to “Groups
SETUP MENU FAQ” for a more complete description of all of the
different relay statuses.
MANUAL CONTROL AU AU indicates LCP 1 is
3. ENTER to select the MANUAL CONTROL screen. LCP-1 LOAD-1 in AUTOMATIC mode.
1■ 3■ 5■ 7■ 9- 11- 13- 15-
“MN” indicates LCP 1
To Navigate to a LOAD (Relay) 2- 4- 6- 8■ 10- 12- 14- 16- is in HAND mode
MANUAL CONTROL AU SCROLL to select LCP
LCP-1 LOAD-1
TAB to LOAD
SCROLL to select LOAD 9. Press EXIT several times to get back to the main
1- 3■ 5■ 7■ 9- 11- 13- 15-
screen.
ENTER to toggle status
2- 4- 6- 8■ 10- 12- 14- 16-

4. TAB to LCP-1(Lighting Control Panel 1).

5. SCROLL to select the correct LCP (for systems
with multiple LCPs).
6. TAB to LOAD-1.
7. SCROLL up or down to select the LOAD (relay)
to control.
LCDBBP03Sept08

72
 THE BLUE BOX LT PROGRAMMING 71

Programming Switches or di inputs To Select Control Type

To Navigate to Digital Switch or DI Card Before adding or deleting loads it is important to
1. TAB to start. determine the Control Type (see the Control Types
section of this manual).
2. TAB to PROGRAM SWITCH and ENTER to
select. Tip: Most common Control Types for switches are
TOGGLE, ON, and OFF.
USER MENU
1. SCROLL to select Control Type.
MANUAL OVERRIDE
REVIEW SCHEDULE SWI ID11-6 TOGGLE Indicates Control Type
GROUP LOADS EDIT: LCP-1 LOAD-1
PROGRAM SWITCH
SETUP MENU

Note: Switches may control any number of loads. If

3. If needed SCROLL to the correct Page.
more than 8 loads are selected, the system will create
SWITCHES PAGE 1-2 Indicates Page 1 of 2 a Group upon exiting. When prompted to create a
#04: switch 4
#05: switch 5 If cursor starts here, new Group, select “YES” (See Groups Section for
#06: switch 6 multiple pages exist
#07: switch 7
more information).
with switches on each.
#08: switch 8
SCROLL to navigate
#09: switch 9
to the correct page. To Add or Delete Loads for all Control Types
#10: switch 10
(except Mixed Mode)
1. TAB to LCP 1.
4. TAB to the correct Switch. 2. SCROLL to select LCP (1,2,3 etc.).
5. ENTER to select (Switch 11). 3. TAB to LOAD 1.
SWITCHES PAGE 2-2
SWI ID11-6 TOGGLE “Toggle” Control Type
#11: Switch 11
#12: switch 12
This is the name of EDIT: LCP-1 LOAD-1 has been selected
#16: switch 13 the switch.
LCP1 Relay1 has been
This is the address of LCP1: 1
added to the Load
the switch. Summary
6. TAB to the correct Button/Input.
7. ENTER to select. 4. SCROLL to the LOAD you want to add or
delete.
SELECT BTN SWI ID#11 Switch ID#11
SETUP PAGE 1-1 5. ENTER once to select LOAD - it will be added to the
B1: BUTTON 1 Load Summary.
B2: BUTTON 2 SETUP is for advanced
B3: BUTTON 3 programming only! 6. ENTER again to delete LOAD from the Load
B4: BUTTON 4
B5: BUTTON 5 Button6, Switch ID11 Summary.
B6: BUTTON 6
7. Repeat to add or delete more LOADs.
LCDBBP03Sept08

8. EXIT up to main menu.

To Add or Delete Loads for Mixed Mode:

73
72 THE BLUE BOX LT PROGRAMMING

1. SCROLL to select LCP (1,2,3, etc.). Programming an Occupant Sensor

2. TAB to LOAD 1. Once the occupant sensor has been connected to
the low-voltage dry contact inputs in the DI card, the
3. SCROLL to the LOAD you want to add or
delete. inputs must be programmed.
4. ENTER once to add to ON Load Summary. Occupant sensor contacts send a “Maintain”
type closure to the inputs on the DI card and are
SWI ID13-1 MIXED MODE Mixed Mode
EDIT: LCP-2 LOAD-3
therefore programmed as a “Maintain” Control Type
Load Summary
shows LOADS to be (or Maintain Group for more than 8 relays).
ON LCP1: 1-3 switched ON and
OFF LCP2: 1-3 switched OFF To program a DI Input:
1. Navigate to the DI card inputs: USER MENU > PRO-
GRAM SWITCH > SWITCH # > BUTTON #.
5. ENTER twice to add to OFF Load Summary. 2. SCROLL to select MAINTAIN as the Control Type.
6. ENTER third time to delete LOAD from Load SWI ID13-1 MAINTAIN Occupant Sensors
Summary. EDIT: LCP-2 LOAD-5 use a MAINTAIN
7. Repeat to add or delete more LOADs. Control Type
LCP2: 4,5
8. EXIT up to main menu.

To Delete a Load:
1. TAB and SCROLL to select LOAD.
3. Add/delete LOADs (refer to Add or Delete Loads
2. ENTER until the LOAD is deleted from the Load section).
Summary.
If more than 8 relays are added, accept the
Delete LCP2:4 from creation of a new Group upon EXITing.
SWI ID13-1 TOGGLE
Load Summary
EDIT: LCP-2 LOAD-4 1.TAB to LCP 1 To use an existing Group SCROLL to the Control
LCP1: 2-5,12 2. SCROLL to LCP 2 Type and select the Group.
LCP2: 1,4
3. TAB to LOAD 1 For more information on Control Types, Groups and
4. SCROLL to LOAD 4 Group types, refer to the relevant sections in the
5. ENTER to remove O&M.
from Load Summary

SWI ID13-1 MIXED MODE Delete “LCP1:3” from

EDIT: LCP-2 LOAD-3 “ON” Load Summary
ON LCP1: 1-3
1. TAB to LOAD 1
OFF LCP2: 1-3 2. SCROLL to LOAD 3
5. ENTER until
removed from (ON &
LCDBBP03Sept08

OFF) Load Summary

74
 THE BLUE BOX LT PROGRAMMING 73

Time Schedules SCHEDULES PAGE 1-6 Page 1 of 6. SCROLL

Name: SCHEDULE 1
SCH 1 UNUSED
to view more pages
Introduction to Time Schedules
SCH 2 UNUSED “UNUSED” means
There are a few important things to note before SCH 3 UNUSED sch unprogrammed
programming a Time Schedule: SCH 4 ===> NO LOADS
SCH 5 UNUSED “NO LOADS” means
SCH 6 UNUSED sch is programmed -
Time Schedules DO NOT control relays – they
no loads assigned
control Groups and have Scheduled Events (when ..

things are on and off). Groups contain Loads (relays)

and describe “behaviors” pertaining to the schedule. 4. TAB to a new or existing SCHEDULE and
For more information about groups refer to Groups ENTER to select.
Section. 5. TAB to EVERY DAY (default) and SCROLL to
When creating or modifying a schedule. select one of three schedule types:
1. Scheduled the Events. 1. Every Day.
2. Add a group which contains loads (relays) and 2. Mon-Fri, Sat Sun.
their behaviors. 3. By Day.
Example: For more information on the three schedule types
What it refer to Scheduled Types Section.
Name Its Behaviors
Controls
SCH 1 EXCEPT NONE SCROLL to adjust
On 9am EVERY DAY
ON TIME: 09:00 AM • EVERY DAY
Schedule 1 Group 1 Off 5pm OFF TIME: 05:00 PM
• M-F, S, S
Mon-Fri • BY DAY
When the group is “off ”,
LCP1: relays may only be turned For Every Day or Mon-Fri-Sat-Sun Schedules:
relays 1-5
Group 1 on for 2 hours (relay-timer)
LCP2: 1. TAB to each ON TIME and OFF TIME.
Prior to shutting lights off,
relays 3 & 9 relays issue a blink warning. 2. SCROLL to adjust the Scheduled Event (refer to
“Scheduled Events” Section for more information).
To Navigate to Any Schedule (up to 32).
1. TAB to start. SCH 1 EXCEPT NONE To Add or to edit
EVERY DAY
2. TAB to REVIEW SCHEDULE and ENTER to ON DUSK -30mins Holiday Lists refer to
OFF DAWN +30mins Holiday Section
select.
SCROLL to adjust
USER MENU Scheduled Event
MANUAL OVERRIDE Every Day Schedule - same on & off times 7 days/wk.
REVIEW SCHEDULE
GROUP LOADS SCH 1 EXCEPT NONE
PROGRAM SWITCH MONDAY - FRIDAY Tab to each Scheduled
SETUP MENU ON TIME: 09:00 AM Event and SCROLL to
OFF TIME: 05:00 AM adjust.
SAT ON TIME: 11:00 AM
LCDBBP03Sept08

OFF TIME: 03:00 PM

3. A list of the first 6 (of 32) schedules will be SUN none
displayed. If needed SCROLL to the correct Page none

75
74 THE BLUE BOX LT PROGRAMMING

For “By Day” Schedule 2. TAB to 1 and Scroll to adjust.

With different Scheduled Events for each day of 3. Repeat as above to edit the end-date.
the week, the “BY DAY” schedule offers the most
comprehensive feature set of all schedule types. 4. EXIT when complete.
SCH 1
SCH 1
BY DAY H1 H2
BY DAY H1 H2
Monday is highlighted Mo Tu We Th Fr Sa Su
Mo Tu We Th Fr Sa Su
This is the summary ON TIME: 09:00:00a
ON TIME: 09:00:00a
of Monday’s OFF TIME: 05:00:00p
OFF TIME: 05:00:00p Edit Schedule start
Scheduled Events
from Sep 1 to Jun 15 date and end date
from Jan 1 to Dec 31
here.

1. Tab to any day and ENTER to edit that day. Sample Schedules:
SCH 1 EXCEPT NONE
2. TAB to ON TIME or OFF TIME and SCROLL to MONDAY - FRIDAY These lights will be
adjust Scheduled Events. ON dusk -30 mins switched on 30 mins
OFF TIME: 01:00 am prior to dusk Mon-Sat.
ON TIME: 11:30:00 am This is the summary SAT dusk -30 mins Off time on Saturday
OFF TIME: 02:00:00 pm OFF TIME: 10:00 pm
of Monday’s SUN NONE
is earlier (10pm).
ADJUST THESE DAYS: Scheduled Events in NONE Lights are off Sunday.
Mon editing mode
every day
SCH 1 EXCEPT NONE These two schedules
EVERY DAY when combined will
ON PCEL: 06:00am
OFF PCEL: 09:00am
control outdoor egress
To Add Scheduled Events from one day to multiple and parking lighting
before and after
days (“By Day” schedules only) hours for employees
3. TAB to Every Day (bottom of screen). SCH 2 EXCEPT NONE but only when it is
EVERY DAY dark out (during the
4. SCROLL and ENTER to select the desired day ON PCEL: 03:00pm short daylight hours of
or group of days. Repeat until all desired days OFF PCEL: 07:00pm
winter.
are selected. The list of selected days will be
displayed (see below). SCH 8
BY DAY H1 H2 These two schedules
5. EXIT. Selected days will be updated. Mo Tu We Th Fr Sa Su control lighting at a
school in tandem.
ON TIME: 11:30:00 am This is a list of more ON TIME: 07:00:00a
OFF TIME: 02:00:00 pm days the Scheduled OFF TIME: 07:00:00p During the school year
Events for Monday (Sept 1 to Jun 15)
ADJUST THESE DAYS: from Sep 1 to Jun 15 lights operate on one
Mon, Tue, Wed
will be copied to
schedule (SCH 8)
TAB to here. SCROLL
Thu and ENTER to add SCH 9
days to the above list. BY DAY H1 H2 During summer break
Mo Tu We Th Fr Sa Su (Jun 16 to Aug 31),
lights operate on a
6. Repeat steps 1-5 to edit schedules for other days. ON TIME: 11:00:00a
LCDBBP03Sept08

OFF TIME: 02:00:00p

much shorter schedule
(SCH 9)
To Select a Start-Date and End-Date from jun 16 to aug 31
1. TAB to JAN and SCROLL to adjust.

76
 THE BLUE BOX LT PROGRAMMING 75

To Add Loads to a Schedule GROUP1 MAINTAIN

EDIT: LCP-2 LOAD- 5
When you have completed programming a time LCP1: 1-5 and LCP
schedule, the next step is to add the loads to be LCP1:1-5 3,4 are in the Load
LCP2:3,4 Summary
controlled.
1. To save the schedule press EXIT. TAB to “yes”
and ENTER to save the schedule. The clock will Additional steps for MAINTAIN + TIMER and
take a second to save the changes and exit back
MAINTAIN + BLINK Groups
to the SCHEDULE LIST menu.
These steps are considered best practice for indoor
2. TAB to “NO LOADS” and ENTER to add loads lighting, and include after-hours relay timers.
to the schedule.
MAINTAIN groups can EXIT at this point.
Schedule 1 is
programmed and has 7. With “MNTN + __” highlighted, ENTER to set
no loads advanced options.
SCHEDULES PAGE 1-6
Name: SCHEDULE 1 Schedule 3 is not 8. TAB to AUTOMATIC ON. SCROLL to change
SCH 1 ==> NO LOADS programmed to NO AUTOMATIC ON if desired. NO
SCH 2 UNUSED
SCH 3 UNUSED
Schedule 4 is AUTOMATIC ON means lighting will not
SCH 4 ==> GROUP 4 programmed and automatically be switched on in the morning by
SCH 5 UNUSED controls GROUP 4 the clock but must be manually switched on by
SCH 6 ==> DISABLED
Schedule 6 is an occupant.This is considered an energy savings
programmed, but is feature. AUTOMATIC ON will turn the lights
disabled
on by the clock, whether occupants are present
or not.
3. TAB to MAINTAIN and SCROLL to choose the GROUP1 PARAMETERS
Group Type.
AUTOMATIC ON
Quick Tip: Choose MAINTAIN for outdoor lighting SET TIMER

and MNTN + BLINK for indoor lighting. For a more

complete understanding of Group Types, refer to the 9. TAB to SET TIMER and ENTER to program
Group Section later in this manual. the after-hours relay timers. This features allows
occupants to switch lights on after the scheduled
GROUP1 MAINTAIN Choices are time, but only for a timed duration. This is an
EDIT: LCP-2 LOAD-5 energy savings feature and is required by most
• MAINTAIN
LCP1:1-5 energy codes.
LCP2:3,4
• MNTN + TIMER
• MNTN + BLINK 10. TAB to the Hours/Minutes/Seconds display
and TAB/SCROLL to set the Hours/Minutes
and Seconds of the after-hours timer. 2:00:00 is
4. TAB to LOAD 1. usually recommended.
5. SCROLL to the desired Load (relay) and ENTER
to add to the Load Summary.
6. Repeat the TAB and SCROLL sequence and add
LCDBBP03Sept08

as many loads as required.

77
76 THE BLUE BOX LT PROGRAMMING

TIMER SETTING After Hours Timer is SCH 1 EXCEPT NONE TAB to hours
for all relays in this EVERY DAY and minutes and
REGULAR TIMER MODE
Group - relays will be ON PCEL: 03:00pm SCROLL to select
30:59:59 H/M/S OFF PCEL: 05:00pm
BLINK ONE: 05:00 M/S in a Timer-Mode to “on” time
BLINK TWO DISABLED conserve energy
BLINK is only for
MNTN+BLINK group 6. TAB to the time settings after OFF PCEL and
SCROLL to select an “off ” time. This is the time
that the photocell will be “disabled” (not allowed
11. TAB to 05:00 and TAB and SCROLL to change to operate). When the photocell is disabled, the
the Blink Timer. EXIT twice when complete to group is also switched off.
return to the Groups screen (Load Summary).
SCH 1 EXCEPT NONE TAB to hours
12. EXIT when complete. EVERY DAY and minutes and
ON PCEL: 03:00pm SCROLL to select
OFF PCEL: 10:00pm
Programming a Blue Box LT Photocell “off ” time
When an outdoor photocell is plugged directly
into The Blue Box LT master panel, the photocell is
programmed as part of a time schedule (available for For outdoor lighting, we recommend an “on” time of
schedules 1-8 only). about 3:00 PM and an “off ” time that coincides with
the scheduled “off ” time.
1. Navigate to: USER MENU>REVIEW SCHEDULE.
For daylight harvesting use the PCC3 which offers
2. Use the SCROLL and TAB keys to navigate to
the desired schedule. ENTER to select. settings more appropriate for daylight harvesting.
(See GR2400 system catalog).
3. SCROLL to select schedule type (EVERYDAY,
BY DAY, M-F S S). Adjusting Photocell Triggers
SCH 1 EXCEPT NONE 7. With the cursor on PCEL, ENTER to edit the
EVERY DAY SCROLL to select trigger settings.
ON TIME:09:00am schedule type
OFF TIME:05:00pm SCH 1 EXCEPT NONE
EVERY DAY TAB to either PCEL
ON PCEL: 03:00pm and ENTER to go to
OFF PCEL: 10:00pm trigger settings
4. TAB to ON TIME or OFF TIME for each day or
group of days and SCROLL to select PCEL.
SCH 1 EXCEPT NONE 8. SCROLL to adjust the “off ” Time Delay (10
EVERY DAY SCROLL to select minutes is usually recommended).
ON PCEL:09:00am PCEL
OFF PCEL:05:00pm
On Board Photocell
Reading: 0 In trigger settings you
Delay to off: 10 mins can edit the “on” delay
5. TAB to the time settings after ON PCEL and Off when when light level and the “off ” delay
rises above: 30 and the on and off
SCROLL to select an “on” time. This is the time
Delay to On:5mins triggers
that the photocell will be “enabled.” When On when light level
enabled, the group is switched on only if the light falls below: 20
LCDBBP03Sept08

levels are below the ON trigger, otherwise they

will remain OFF until the light levels drop below 9. The default setting for the “off ” trigger (rises
the ON trigger. above) is 30. The default setting for the “on”

78
 THE BLUE BOX LT PROGRAMMING 77

trigger (falls below) is 20. TAB DOWN to each To Add a Holiday List to a Schedule
trigger and and SCROLL to adjust. The system offers up to 2 separate editable Holiday
Lists. This portion of the menu allows you to select
On Board Photocell from pre-existing holiday lists. See Edit/Create
Reading: 0 TAB DOWN to “off ”
Delay to off: 10Mins trigger (raises above) Holiday List for instructions on how create or edit a
Off when when light level and SCROLL to adjust. new Holiday List.
rises above: 40
ON and OFF triggers
Delay to On:5Mins
On when light level
should remain at least Every Day & Mon-Fri, Sat, Sun Schedule
falls below: 41
10 points apart. These two schedules only allow the Holiday Lists to
be exempt from the schedule.
10. TAB to ”on” trigger (falls below) and SCROLL 1. Follow this path: USER MENU › REVIEW
to adjust. SCHEDULE.
2. SCROLL to the correct page and then TAB to the
On Board Photocell SCHEDULE you wish to add a Holiday List to.
Reading: 0
Delay to off: 10Mins 3. In the Schedule, TAB to EXCEPT NONE.
Off when when light level
rises above: 40 SCH 1 EXCEPT NONE Except None
Delay to On:5Mins EVERY DAY Except H1
On when light level ON TIME: 09:00 AM
falls below: 41 OFF TIME: 05:00 PM Except H2
Except H1 + H2
Tip: A good way to determine the best trigger
settings is to do the above steps at a time when 4. SCROLL to select the desired Holiday Exception.
daylight about matches when you want the lights 5. Continue programming this schedule or Exit and
to go on or off. For example, set the Off (raises Save.
above) trigger in the morning when the sun is
just coming up. Check the light level reading on Holiday List in “By Day” Schedule
the clock when the area is bright enough for the This schedule allows one or both of the Holiday Lists
lights to shut off and use this reading as the “Off ” to be exempt, or even a new schedule created just
value. Similarly, set the On (falls below) trigger in for the days included in the Holiday List.
the evening when it is just getting dark enough 1. Follow this path: USER MENU › REVIEW
so that the lights should come on. Check the SCHEDULE.
light level reading at that time and use it as your 2. SCROLL to the correct page and then TAB to
“On” value. the SCHEDULE you wish to add a Holiday List.
11. EXIT and SAVE. SCH 1
12. To add loads(relays) to this schedule, refer to BY DAY H1 H2 ENTER each
Mo Tu We Th Fr Sa Su
“Adding Loads to a Schedule”. The PCELL Holiday List to
schedule is always programmed as MAINTAIN. ON TIME: 09:00:00a edit the Holiday
OFF TIME: 05:00:00p Options
LCDBBP03Sept08

GROUP 1 MAINTAIN Use a MAINTAIN from Jan 1 to Dec 31

EDIT: LCP-1 LOAD-5 group for
photosensor
LCP1:1,2,5 settings.

79
78 THE BLUE BOX LT PROGRAMMING

3. TAB to either H1 or H2. – the two Holiday Lists. 4. SCROLL to YES to select.
Both can be selected, but only individually. 5. To add new Holidays to a Holiday List, SCROLL
4. ENTER to go to the Holiday options menu. to page 3 and TAB to the first unused date.
5. SCROLL to select the desired Holiday option. HOLIDAY LIST 1 - PAGE 3
There are three choices:
Jan 1 2008: no
• Do Not Omit (default) – the days on this Jan 1 2008: NO
Jan 1 2008: NO
holiday list will be included in this schedule. Jan 1 2008: NO
Jan 1 2008: NO
• Omit - the days on this holiday list will not be Jan 1 2008: NO
included in this schedule.
• ON-OFF schedule - the days on this holiday 6. TAB to month, day and year and SCROLL to
list will have unique schedules. adjust.
6. Program a unique schedule for this Holiday list.
7. EXIT when complete.
7. Continue programming this schedule or Exit & Save.
more data on scheduled events
To Edit a Holiday List There are four types of scheduled events, which when
The Holiday lists contain no Holidays until edited.Two combined, offer an almost limitless set of options and
separate holiday lists may be created and edited. capabilities.
1. Follow this path: USER MENU › SETUP MENU ›
SYSTEM SETUP MENU › EDIT HOLIDAYS. “On Time” & “Off Time” Scheduled Events
ON TIME or OFF TIME are also called Time of Day
system setup menu
(TOD) events.
set time and date
edit HOLIDAYs To edit an ON or OFF TIME:
system options
what and when? 1. TAB to the Hours Minutes, (Seconds for BY
addressing-bus scan DAY schedules only) and am/pm settings after
ON TIME or and SCROLL to adjust.
ON TIME: 09:00 AM
select holiday list OFF TIME: 05:00 PM
to edit

HOLIDAY list 1
Holiday list 2
Astonomical Scheduled Events
2. SCROLL to select page. The DTC clock offers true astonomical programming.
When setting up the clock, the location is entered
3. TAB to the Holiday. (by city or Lat/Long) and from that all dusk and dawn
Holiday list-page 1 times are calculated.
Date: Jan1
New Years :yes The system even compensates for daylight savings
ML King :no
Presidents : no (where applicable).
LCDBBP03Sept08

Easter : no
Memorial : no “DAWN (or DUSK) + or -” means minutes before
Independece : no or after dawn or dusk.

80
 THE BLUE BOX LT PROGRAMMING 79

1. TAB to “+ 0 mins”. need here, contact Technical Support, and they will
2. SCROLL up or down to select. assist you.

ON DUSK -30mins 30 mins. before dusk Control Types

OFF DAWN +30mins
30 mins. after dawn “Control Types” describes how loads are controlled by
schedules, switches, photocells, or DI Cards (via contact
closure switches). When controlling more than 8 relays
No (NONE) Scheduled Event or when any time schedule is used, “Groups” must be
In some cases you may desire that nothing at all used and the Toggle feature is not available.
happen (e.g. no “off time”). In our schedule, this
Scheduled Event is referred to as “NONE”. TOGGLE A momentary contact will toggle up to
8 loads on or off.
NONE is usually used to disable a specific day or set
of days (i.e. Sunday). ON MODE A momentary contact will issue an “on”
command to as many as 8 loads.
1. SCROLL to select NONE.
ON NONE
OFF MODE A momentary contact will issue an “off ”
OFF NONE command to as many as 8 loads.

MIXED A momentary contact will switch one

set of loads “on” and another set of
Photocell Scheduled Events MODE loads “off ” at the same time.
A photocell connected directly to the photocell
input of the Master Blue Box LT, controls relays
only through any of the first 8 time schedules. Each
Schedule may have a unique trigger level, and may MAINTAIN Loads are ON for the duration of a
be applied to any relay(s) in any panel(s), creating a closure and OFF when the closure
global photocell. is opened. Similar to the way a wall
switch makes and then breaks a circuit
Refer to “Programming a Blue Box LT Photocell” for to turn lights on or off.
programming details.
Photosensor Card Triggers are usually
Mixing Scheduled Events - Custom Schedules programmed as maintain, as is any
maintained contact closure device such
SCH 1 EXCEPT NONE
MONDAY - FRIDAY Mix up “on” and “off ” as a wall switch or a relay closure from
ON TIME: DUSK -30mins events to create a (for instance) a security system.
OFF TIME: 10:00 PM truly unique schedule..
SAT ON TIME: DUSK -30mins GROUPs To control more than 8 loads, or when
OFF TIME: 08:00 PM
SUN ON TIME: NONE
(1-32) programming a time schedule, always
OFF TIME: NONE use GROUPs.

Last Input Override

All of the different Scheduled Events (except PCELL)
Your digital lighting controls use a logic structure
may be mixed with each other to create a variety of
LCDBBP03Sept08

called “last input override” and as such, other inputs

scheduling options. If you need help with a particular
can affect the loads too. Example: A load is toggled
scheduling requirement, and do not see what you
on from one location and then switched off by a

81
80 THE BLUE BOX LT PROGRAMMING

time schedule. If activated again, the toggle switch will 3. When a photocell is connected to a photocell
turn the loads back on - last input override. card (not directly to the BLUE BOX panel) and
turns more than 8 relays both on and off.
Group TYPES
A group describes two things: which relays are Used by time schedules or for any
maintained device (eg. photosensor
controlled together, and how they are controlled. (BASIC)
card triggers) controlling more than
Groups MUST BE USED when controlling more MAINTAIN
8 loads. When the GROUP is ON
than 8 relays and with all time schedules. GROUP
the loads are ON, and when the
Up to 32 groups are available. Any relay(s) in any GROUP is OFF, the loads are OFF.
panel(s) can be assigned to a GROUP. Usually used only with Time
Schedules. When the GROUP is
There are two types of GROUPS: ON, the loads are ON. When the
Maintain Style Groups GROUP is OFF and relays in that
MAINTAIN +
GROUP are in Timer Mode, timer
Just like the maintain control, starting a maintain TIMER
duration is programmable. When
contact (or time schedule) will turn a maintain style GROUP
the GROUP is ON, the relays
group on, and when the contact is open or the cannot be in TIMER MODE, when
schedule is off, the group is turned off. the GROUP is OFF, you can place
When a Maintain style group is first switched on, the the relays in TIMER MODE.
relays within that group are switched on too, with Works the same as MAINTAIN +
MAINTAIN +
one exception. (See NO AUTOMATIC ON option TIMER except a “blink” or “flick”
BLINK
under Programming Groups). warning is issued prior to shutting
GROUP
loads off.
While the GROUP is “on” the relays within that
group will respond normally when switched on and Momentary Style Groups
off by a digital wall switch. Any momentary pulse, or any single button press will
trigger a momentary group once.
The relays are switched off when the GROUPS are
switched off, with one exception (see MAINTAIN + Momentary style groups are used in the following two
BLINK below). circumstances to turn relays on or off:
1. When a digital switch, a contact closure, or
When “Maintain+Timer” or “Maintain+Off Sweep”
photocell trigger switches more than 8 relays
Groups are off the relays are in “timer mode”: which either “on” or “off ” only or,
means if the relays are turned on when the Group is
2. When a time schedule only switches relays either
off, they will remain on for a (programmable) timed
“on” or “off,” but not both.(See table below).
period. Maintained Groups are used in the following
circumstances: MOMENTARY “On Mode” - any number of loads
1. Outdoor time schedules usually use a Maintain ON
style group. MOMENTARY “Off Mode” - any number of loads
2. Indoor time schedules usually use a OFF
LCDBBP03Sept08

Maintain+Timer or Maintain+Blink Group which MOMENTARY “Mixed Mode” - any number of

allow relays to be in a “timer mode” when the MIXED loads
group is off.

82
 THE BLUE BOX LT PROGRAMMING 81

For more information on groups, please refer to the After creating, exiting, and saving a schedule, TAB
Groups FAQ. DOWN once to NO LOADS, or GROUP X (X
represents a number 1-32). ENTER to edit or create
Programming Groups the GROUP.
To Access a Group
Within the DTC, there are two paths you can use to To Edit a Group
access a group for programming purposes: 1. SCROLL to select the desired GROUP Type.
GROUP1 MAINTAIN
From USER MENU: EDIT: LCP-1 LOAD-1
1. Navigate to: USER MENU>GROUP LOADS
and ENTER.
USER MENU 3. Add or delete loads.
MANUAL OVERRIDE
REVIEW SCHEDULE
4. EXIT when complete.
GROUP LOADS
PROGRAM SWITCH
SETUP MENU

2. SCROLL to the correct page. (1 through 6) and

TAB to the desired GROUP. ENTER to begin
editing or creating the desired GROUP.
GROUPS PAGE 1-6
This group does not
GROUP 1 UNUSED OFF have any loads
GROUP 2 UNUSED OFF
GROUP 3 USED MOM Momentary Group
GROUP 4 USED ON This Group has loads
GROUP 5 USED ON
GROUP 6 UNUSED OFF
and is on

TAB to a group and SCROLL up or down to change the

status. Enter to edit the group

From the SCHEDULE MENU:

Schedule 1 is
programmed and has
no loads
SCHEDULES PAGE 1-6
Name: SCHEDULE 1 Schedule 3 is not
SCH 1 ==> NO LOADS programmed
SCH 2 UNUSED
SCH 3 UNUSED
Schedule 4 is
SCH 4 ==> GROUP 4 programmed and
SCH 5 UNUSED controls GROUP 4
SCH 6 ==> DISABLED
Schedule 6 is
LCDBBP03Sept08

programmed, but is
disabled

83
82 THE BLUE BOX LT PROGRAMMING

Additional Groups parameters 3. TAB to MNTN + TIMER, and ENTER.

To adjust Group Parameters such as Automatic On,
GROUP1 PARAMETERS
Group Timer, and Blink Warning, navigate to the
AUTOMATIC ON
Group Parameters Screen: SET TIMER
1. USER MENU › GROUP LOADS.
2. SCROLL to the correct page and TAB select a 4. TAB to SET TIMER and ENTER to program
Group to be edited). the after-hours relay timers. This features allows
occupants to switch lights on if the Group is off,
3. TAB to MNTN + TIMER or MNTN + BLINK but only for the timer duration. This is an energy
and ENTER to Group Parameters Screen. savings feature required by most energy codes.
or 5. TAB to the Hours/Minutes/Seconds display
TAB to MAINTAIN and SCROLL to MNTN and TAB/SCROLL to set the Hours/Minutes
+ TIMER or MNTN + BLINK and ENTER to and Seconds of the after-hours timer. 2:00:00 is
Group Parameters Screen. usually recommended. This will determine how
long relays are allowed to be “overrided” to the
Automatic On/No Automatic On “on” state before the timer runs out.
AUTOMATIC ON (the default setting) means that
TIMER SETTING
the Group will switch its relays on when the Group REGULAR TIMER MODE
is turned on. Example: Schedule 1 turns on Group 1 30:59:59 H/M/S
at 9:00AM. If AUTOMATIC ON is selected the relays BLINK ONE: 05:00 M/S
BLINK TWO DISABLED
in Group 1 will all be switched on. AUTOMATIC ON
is recommended for large open areas, such as a sales
floor or open area office. “Blink Timer” is only displayed, in a Maintain+
Blink Group. The default setting of 5 minutes gives
NO AUTOMATIC ON means that the group will
occupants 5 minutes after a “blink” warning to activate
not automatically switch relays on when the group
an override (Momentary On, Toggle, or Momentary
is turned on. Example: Schedule 1 turns on Group
On) switch before lights are shut off.
1 at 9:00AM. If NO AUTOMATIC ON is selected.
the relays in Group 1 will not be automatically If during that 5 minute period, an “on” button is
switched on. Instead relays are turned on by a local pressed, all relays controlled by that button will be
digital control station. NO AUTOMATIC ON is extended for the duration of the timer (02:00:00
recommended for smaller offices which have local for example), and will again blink at that end of that
digital control stations. period. This process repeats itself every time the
1. TAB to AUTOMATIC ON. override switch is activated until the next scheduled
On Time.
2. SCROLL to change to NO AUTOMATIC ON.
TIMER SETTING After Hours Timer is
Relay/Group Timers REGULAR TIMER MODE for all relays in this
30:59:59 H/M/S Group - relays will be
All relays in a Maintain + Timer or Maintained + Blink in a Timer-Mode to
BLINK ONE: 05:00 M/S
group have an “after-hours” timer value when the conserve energy
LCDBBP03Sept08

BLINK TWO DISABLED

group is switched off (usually by a time schedule) the BLINK is only for
timer duration can be adjusted. MNTN+BLINK group

84
 THE BLUE BOX LT PROGRAMMING 83

6. TAB to 05:00 and TAB and SCROLL to change AA: If the relay is on, the manual override screen will
the Blink Timer to select a new countdown. If a show the normal ON square symbol with an
double blink is desired, set the second timer. additional little “leg” on the bottom left corner,
Programming Tip: Blink timers work backwards like this:
from the off time. So if the first blink is 05:00, Relay ON with no TIMER:
and the second blink is 04:55.Then the first blink
will be issued 5 minutes prior to shut off and the Relay ON in TIMER mode:
second blink will be issued 5 seconds later. QQ: What does a MAINTAIN + BLINK group do?
7. EXIT twice when complete to return to the AA: It is identical to a MAINTAIN + TIMER group,
Groups screen (Load Summary). with the only addition being that when you turn
TIMER SETTING a MAINTAIN + BLINK group OFF, the lights
REGULAR TIMER MODE will blink or flick, and then wait for a specified
02:00:00 H/M/S amount of time before the relay turns off. This
BLINK ONE: 05:00 M/S
BLINK TWO: 04:55 M/S
time period is called the “Blink time out.” This
time period is set in the MAINTAIN + BLINK
group under “SET TIMER”.
Group FAQs QQ: How do you take a relay out of timer mode?
QQ: How do you manually turn on a group using the
clock interface? AA: Find out what MAINTAIN + TIMER or
MAINTAIN + BLINK group that relay is in, and
AA: Go to the “Group Loads” screen, highlight the turn that group ON.
group:
QQ: How can you tell if a relay has a “Blink Timer”?
1. F or a MOMENTARY ON group SCROLL UP
to turn the relays in that group on, AA: If you check the relay properties screen for
that relay, it will say BLINK One or BLINK Two:
2. F or a MOMENTARY OFF group SCROLL UP followed by a number, e.g. BLINK One: 20:00
to turn the relays in that group off, M/S.
3. F or a MOMENTARY MIXED group SCROLL QQ: How can you tell if a relay is in a blink warning
UP to control the relays per the ON and OFF time-out?
programming within that group,
AA: The manual override screen will show the relay
4. F or any MAINTAIN group, SCROLL UP to as being on with TWO little legs on the bottom
turn the group on and SCROLL DOWN to corners, as shown here:
turn the group off.
Relay on with no BLINK or TIMER:
QQ: How do you tell if a relay has a timer and what
timer value is on it? Relay in final BLINK Warning Timer:
AA: If you check the relay properties screen for that QQ: What is the purpose of the “Blink time OUT”?
relay, it will say REGULARTIMER MODE: followed AA: It gives the occupants of the area a warning
LCDBBP03Sept08

by a number, e.g. TIMER 00:20:00 H/M/S. that the lights are about to turn off. They can
QQ: How do you tell if a relay timer is active? extend the time that they have light by pushing
any button with a rapidly blinking LED. This is the

85
84 THE BLUE BOX LT PROGRAMMING

indication that the lights are in Blink Time OUT. QQ: How do you find out which group(s) a relay is in?
QQ: Where are the two locations on the DTC that a AA: Look in the “What & When Menu”: SETUP
relay timer can be viewed or programmed? MENU >SYSTEM SETUP MENU >WHAT
AA: USER MENU > GROUP LOADS > TAB AND WHEN? >WHAT CONTROLS RELAYS.
to GROUP > ENTER to select >TAB to Select the relay and press ENTER. Any groups
MAINTAIN+TIMER or MAINTAIN+BLINK that the relay is in will be displayed.
>ENTER to select >. QQ: How do you find out what is turning a group
USER MENU >SETUP MENU >SYSTEM off or on?
RESTRICTED (PASSCODE 900001) >RELAY AA: Look in the “What & When Menu”: SETUP
PROPERTIES >select BOARD >. >SYSTEM SETUP >WHAT AND WHEN?
QQ: You create a new MAINTAIN group or add new >WHAT CONTROLS GROUPS. Select
relays to an existing MAINTAIN group and EXIT. the group and press ENTER. Any schedules,
Upon re-entering the group, you notice it has photocells or switches that control that group
changed itself into MAINTAIN+TIMER. Why? will be displayed.

AA: One or more of the relays in the group QQ: What do you do to sync up the relays in a group,
are also in another MAINTAIN+TIMER or when some of them are on and some are off?
MAINTAIN+BLINK group which has assigned AA: Go to the “group loads” screen and turn on
it or them a timer value. Since the timer value the group again using the SCROLL UP button.
is written into the relay properties, it is carried If the group is already “ON” scrolling up will re-
over into the new MAINTAIN group. reiterate the “ON” command.
QQ: What does MAINTAIN mean in reference to a QQ: How do you get rid of a group you don’t want
wall switch? to use anymore?
AA: It means that the switch concerned is a contact AA: Go to the “GROUP LOADS” screen, highlight
closure switch like an ordinary wall switch. When the group and press the DELETE button.
one flips the switch UP the contacts close and QQ: What should you suspect is happening when you
stay closed and the lights come ON. (They are delete a group but the relays still have a timer?
MAINTAINED that way.) When one flips the
switch down the contacts open and the lights AA: Those relays are in another MAINTAIN+TIMER
go off. Note that both making the circuit and or MAINTAIN+BLINK group which is forcing a
breaking the circuit (from the switch to the timer onto them.
contact input) causes the relay(s) to react. QQ: What should you be careful never to do with
QQ: What does MOMENTARY mean in reference MAINTAIN + TIMER or MAINTAIN + BLINK
to a switch? groups?
AA: It means that it is expecting a pulse as would be AA: Never have the same relay in more than one
received from a push button. The command is MAINTAIN + TIMER or MAINTAIN + BLINK
LCDBBP03Sept08

executed on contact closure.The contact opening group.

does nothing. QQ: What does the “NO AUTOMATIC ON” setting
in a MAINTAIN+TIMER or MAINTAIN+BLINK

86
 THE BLUE BOX LT PROGRAMMING 85

group do? this is that switch buttons turn maintain groups

AA: It makes it so that when you turn ON the group, ON when the button is held down and OFF
the relays don’t come on – only the group when the button is released.
status changes to ON and the relay timers are Having to hold the button down to keep lights
disabled. on is not generally useful!
QQ: Why would someone want to use “NO QQ: If you are having a photocell control more than
AUTOMATIC ON”? 8 relays, what type of group would you assign to
AA: So they can take disable relay-timers without the photocell?
actually turning the relays on. For example, if AA: You would normally use a maintain-type group.
the customer wants to turn lights on with a Remember that only maintain-type groups can
switch early in the morning, and not have them be turned on AND off. If you want the photocell
automatically shut off after an hour (timer to turn lights ON when it is dark and OFF when
mode), they would need to turn the MAINTAIN it is bright, the easiest way is to use a maintain
+ TIMER group on with a schedule. However, if group.
they don’t want the actual lights to turn on until QQ: When would you use a momentary-type group
they use a switch, they would set the group to with a photocell?
“No Auto On”. This would take the relays out
of Timer mode, but not turn them on with the AA: When you only want the photocell to turn the
schedule.This saves energy until someone enters relays OFF, or only want it to turn relays ON.
the room and switches the lights on. Even when using a schedule to turn the lights
QQ: When must a switch button be programmed off (for example at 11:00pm), one would usually
to operate a group instead of just operating the program the Photocell as “Maintain”.This ensures
relays directly? the lights turn off at dawn in the event that an
override “ON” command switched the lights on
AA: When you want the switch to operate more during the night.
than 8 relays, the system will require you to make
them into a group.
QQ: How do you toggle a group on and off using a
single switch button?
AA: You can’t. Groups cannot be toggled. If you
want to turn more than 8 relays on and off
with a switch, you need to use two buttons and
two groups: one MOMENTARY On and one
MOMENTARY OFF.
QQ: What kind of group would you normally NOT
assign to a momentary switch?
LCDBBP03Sept08

AA: You normally do NOT assign any of the maintain-

type groups (MAINTAIN, MAINTAIN+TIMER,
MAINTAIN+BLINK) to a switch. The reason for

87
86 THE BLUE BOX LT PROGRAMMING

other System / Set up Programming The Time Zone is the number of hours negative or
Date, Time and Location positive from Greenwich Mean Time (GMT). For
The DTC in the relay panel is astronomical, and example: the North American Eastern Time Zone
needs to know the date, time, and location. is - 5 GMT, Central Time is - 6, Mountain Time is - 7,
Pacific Time is - 8, and Hawaii is -11.
enter new time/date
8:50:00 AM PAGE 1 Daylight Saving Time
27 June 2008 Fri To save your settings The relay control panel will automatically adjust
Time starts when TAB to here and its time setting forward and backward an hour to
you... hit enter account for Daylight Saving Time.
assembled 3 jan 2008 ENTER to select
To disable Daylight Savings Time
1. In the DTC, navigate to: USER MENU > SETUP 1. Navigate to the Display Options screen:
MENU > SYSTEM SET UP MENU > SET TIME SETUP MENU > SYSTEM SETUP > SYSTEM
AND DATE. OPTIONS > DISPLAY OPTIONS.
2. TAB to the hour and SCROLL to select. Repeat this 2. TAB to Daylight Savings and SCROLL to select
process for minutes, seconds, day, month and year. NO.
3. TAB to “HIT ENTER” and ENTER to save 3. TAB to “HIT ENTER” and ENTER to save
settings. settings.
To Set Location 4. EXIT when complete.
1. In the DTC Clock navigate to USER MENU > Military Time: NO
SETUP MENU > SYSTEM SET UP MENU > Seconds Visible: YES
Daylight Savings: YES
SYSTEM OPTIONS > SELECT LOCATION > Temperature F/C: F
LIST OF CITIES. RS-232 K-BAUD: 57.6
Modem mode: 0
2. SCROLL to select city or nearest city. Photocell mode: NEW
To save: HIT ENTER
3. TAB to “HIT ENTER” and ENTER to save
settings.
Daylight Saving Time will now be disabled.
Detroit MI SCROLL to select
nearest city
latitude: 42 N
Longitude: 83 w
time zone:gmt-5 To save your settings
To accept the above
TAB to here and
settings...hit enter ENTER to select

Optional: If you cannot find any cities within several

hundred miles of your location, EXIT and go to
LATITUDE – LONGITUDE. Use a dependable
resource (internet, etc.) to locate your exact Latitude
LCDBBP03Sept08

and Longitude.

88
 THE BLUE BOX LT PROGRAMMING 87

To Adjust Daylight Savings Change-Over dates: and TAB UP or DOWN to move between digits.
1. Navigate to the Display Options screen: SETUP When the desired value has been entered, EXIT to
MENU > SYSTEM SETUP > SYSTEM OPTIONS save the code and return to the previous menu.
> DAYLIGHT SET UP.
Any user attempting to access the programming
Daylight parameters
interface will now be required to enter the code you
Daylight starts on: set in order to view or change settings.
2nd Sun of Mar.
To remove the keyboard lock code, navigate back to
Daylight ends on:
1st Sun of Nov the screen where the code was originally.
: SETUP MENU > SYSTEM SETUP MENU > SYSTEM
2. TAB to each setting and SCROLL to select the OPTIONS > KEYBOARD LOCK CODE (set the
proper value. Note A strict date-time system is 4-digit number to 0000 and EXIT).
not used.
The DTC will set the time forward one hour on
the start date and backward one hour on the
end date.
3. EXIT when complete. All changes will be
automatically saved.

Keyboard Lock Code

If you are responsible for maintaining and programming
the lighting control system, you may wish to prevent
others from making changes in the clock interface.
To do this, you can set a keyboard lock code that is
required to make any changes to schedules, groups,
switch programming, etc.
To set up the keyboard lock code, navigate the
following menus:
KEYBOARD LOCK CODE
IS: 0000
Set Code ‘0000’ to
disable or any other
code to enable Key Lock
permanently
Hit exit if not sure
and see Users manual.

SETUP MENU > SYSTEM SETUP MENU > SYSTEM

OPTIONS > KEYBOARD LOCK CODE.
LCDBBP03Sept08

You will be prompted to create a 4-digit keyboard

lock code. SCROLL UP or DOWN to change values

89
88 THE BLUE BOX LT PROGRAMMING

TIME SCHEDULE PROGRAMMING EXAMPLES

Exercise #1- Contact Closure Device 6. TAB to YES and ENTER to save as a GROUP.
Controlling 4 Relays 7. To determine the new Group name. TAB to the
The client wants to have a Security System turn on button and ENTER.
LCP1: 1-4 for the duration of an “Alarm Mode” event.
SWI ID05-1 GROUP 2
The Security System will issue a maintained closure Button 1 controls
for the duration of the event through Input 1 of a To edit the loads Group 2.
you must use
contact-closure interface. What do you do? the group menu

Solution:

SWITCHES PAGE 1-2

Address 5 is a Exercise #3 - Time schedules with
#5: 14 BTN SW 5 14 Btn Input. Its
either the Blue override switches
#6: SWITCH 06
#7: SWITCH 07 Box contact inputs The client wants a time schedule for indoor lights
#8: SWITCH 08 or a DigiLink starting at 7:00 am and off at 5:30 pm.
SWI ID05-1 MAINTAIN Select Maintain After hours the digital switches can turn the lights
EDIT: LCP-1 LOAD- 4 (refer to Control on but only for two hours. Also, the clients want to
LCP1:1-4
Types)
warn occupants five minutes to prior shut-off. What
Add LCP 1: 1-4
do you do?
Solution:
1. Navigate to the DI card address (switch), and
the input (button) you want to program (Refer 1. Set up a schedule: ON: 7:00 AM & OFF: 5:30 PM.
to Navigating to a Switch). SCH 4 EXCEPT NONE
EVERY DAY
2. TAB to MAINTAIN and SCROLL to select ON TIME: 07:00 AM
Control Type. Maintain is probably the best OFF TIME: 05:30 PM
choice for a Security System (Refer to Control
Types).
3. TAB to LOAD. SCROLL and ENTER to select 2. The schedule will control a MAINTAIN+BLINK
loads (Refer to Adding a Load). group with a 2 hour timer, and 5 minute blink
warning. Select the relays for this group as
Exercise #2 - Contact Closure Device needed.
Controlling 10 Relays SCHEDULES PAGE 1-6
The same requirements as Exercise #1 but the Name: SCHEDULE 1
SCH 1 ==> GROUP 1
customer wants the security system to control 10 SCH 2 UNUSED
SCH 3 UNUSED
relays (LCP1 1-10) instead of four. SCH 4 ==> NO LOADS
4. Follow the above steps adding more loads. SCH 5 UNUSED
SCH 6 ==> DISABLED
5. EXIT when complete.
GROUP 4 MNTN+BLINK
Your selection is The system EDIT: LCP-1 LOAD-1
more than 8 loads. automatically
Proceed to create a creates a Group LCP1:1-12
LCDBBP03Sept08

group?
more than 8
No / Yes loads.

90
 THE BLUE BOX LT PROGRAMMING 89

Tip: If you wish to prevent the lights from all coming 2. After-hours, all lights (loads) should be on a
on at 7:00 am, select NO AUTOMATIC ON, and then 1-hour timer with a 5-minute blink warning.
the local digital switches will turn the lights on and 3. Employees enter the store as early as 5:00am
the schedule will turn the lights off. (see Additional and need to switch on enough lights to clean
Group Parameters) This is optimal for energy savings and stock the store (called the “entry level”)
when local digital switches are used. without the complications of a timer.
GROUP 4 PARAMETERS Entry level lights are controlled by LCP1:1-7. All
remaining lights are controlled by LCP1:8-24
NO AUTOMATIC ON
TIMER OUT: 1:00:00 Hr
OFF SWEEP: 05:00 Mins Programming Steps
For step-by-step instruction on how to program
3. Program each switch button that will need to these schedules, refer to the sections on adding a
override lighting after-hours with a Toggle or On load, Control Types, Groups, and time schedules.
Mode control type (refer to Control Types) and
1. Set up a Schedule: ON: 5:00 AM & OFF: 10:20 PM.
add loads as appropriate.
Employees coming in any time after 5:00 AM can
SWITCHES PAGE 1-2 Address 6 has switch-on lights manually. The relays will not be
#5: 14 BTN SW 5 been named the
#6: OPEN OFFICE SW1 in timer mode because the Group was switched
#7: OPEN OFFCE SW2
OPEN OFFICE
#8: RECEPTION SW1. on at 5:00 AM with NO AUTOMATIC ON.

SELECT BTN SW ID#06 Refer to Name Controls Behaviors

PAGE 1-1 Navigation Tree
B1: BUTTON 1 for the Naming On 5am
Group 2
B2: BUTTON 2 Menus Schedule 4 Off 10:20pm
B3: BUTTON 3
Entry Lights Every Day
B4: BUTTON 4
B5: BUTTON 5 Maintain + Blink
B6: BUTTON 6 LCP1: NO Automatic On
Group 2 Relays 1-7 1 Hour Timer
SWI ID06-2 ON MODE Select TOGGLE or 5 Minute Blink Warn
EDIT: LCP-1 LOAD-3
ON MODE (refer
LCP1:1,3 to Control Types) 2. Set up a second schedule: ON: 8:45am &
Add any relays in OFF:10:20pm to sweep-on the remaining loads
the group 15 minutes before and 20 minutes after-hours
Name Controls Behaviors
Tip: Remember, the smaller the zone of control of On 9:20am
Schedule 5 Group 3 Off 10:20pm
each button the greater the energy savings. Every Day
Exercise #4 - retail store Maintain + Blink
LCP1: (Yes) Automatic On
Information and customer requirements Group 3 relays 8-24 1 Hour Timer
1. Store hours: 9:00am to 10:00pm pm every day. 5 Minute Blink Warn
LCDBBP03Sept08

Lights should be swept-on 15 minutes before

store opening and off 20 minutes after closing.

91
90 THE BLUE BOX LT PROGRAMMING

Set-up a third schedule to sweep-on the entry lights,

in case they were not manually switched on by a
control station. Note that this schedule simulates a
momentary push button and only turns the lights on.

Name Controls Behaviors

On 8:45am
Schedule 6 Group 4 Off 8:46Am
Every Day
LCP1:
Group 3 Momentary On
relays 1-7

3. Provide a button on a control station that

switches on the “entry” lights on the morning
(On Mode).
4. Program another button on the same station to
allow the last person out to switch off all lights.
SWITCHES PAGE 1-2 Address 6 has
#5: 14 BTN SW 5 been named
#6: ENTRY SWITCH the Entry Switch.
#7: SWITCH 07
#8: SWITCH 08
(Refer to Naming
Switches).
SWI ID06-2 ON MODE Select ON MODE
EDIT: LCP-1 LOAD-8 (refer to Control
LCP1:1-8
Types)
Add LCP 1: 1-7

A second control station in the managers office can

extend other lighting zones for after hours activities,
such as a photo-shoot, or extended store hours.
Tip: Check out our set-back Thermostats. They can
be locally and remotely programmed through the
Blue Box and can generate a very high Return On
Investment.
LCDBBP03Sept08

92
 ®

THE BLUE BOX LT

™

SYSTEM
DIAGNOSTICS
TOOLS
LCDBBSDT03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

93
92 THE BLUE BOX LT SYSTEM DIAGNOSTICS TOOLS

SYSTEM DIAGNOSTICS TOOLS

The DTC contains diagnostics tools which detect and

ERROR STATS. CLEAR
help narrow down any bus stability issues. Overall: 0
Addr1: 0
Cmd0: 0
Dial up Host EEPROM FLAG ERR: 0
To test the operation of a modem, the “Dial up Host” EEPROM WRITE ERR: 0
screen may be used to dial out to a cell phone or land line. DROP-OFF: 0
FATAL-ERR: 0
To do so, navigate to the Dial up Host screen:
USER MENU > SETUP MENU > RESTRICTED (PASS- USER MENU > SETUP MENU > RESTRICTED (PASS-
CODE 900001) > REMOTE SYSTEM MENU > DIAL UP CODE 900001) > ADDRESSING-BUS SCAN > ERROR
HOST STATISTICS

DIALING UP HOST
Bus Scan
This screen displays all recognized devices on a bus. A re-
lay panel displays the number “3” for every 8 or less relays
Enter the complete phone that it contains, any switch or photocell displays a “1”, and
number of the HOST and any “Link-to” device such as Link-to-PC card displays a “2”.
hit ENTER.
The Blue Box LT 16 takes up 2 addresses.
If devices seem to appear and disappear intermittently on
On the screen, SCROLL UP to enter the first digit and TAB
the bus scan, the bus may be unstable. That is, if a switch is
DOWN to enter the next number. Enter the area code and
assigned to address 7 and the display shows a “1”, then a
the phone number and ENTER to begin dialing out.
“0” and a “1” again, there may be a bad Cat. 5 or device in
Error Statistics that area of the bus. To navigate to this screen:
This screen displays any kind of errors that may be accu-
3000000000 0000000000
mulating on the bus. The “overall” errors field is the only 0000000000 0000000000
one of interest during general troubleshooting. 0000000000 0000000000
0000000000 0000000000
This screen must be monitored for approximately 3 min- 0000000000 0000000000
0000000000 0000000000
utes and if no errors accumulate, the bus is stable. 0000000 0-5 0
If errors accumulate in this field, there may be a bus stabil-
ity issue and the “Bus splitting technique for a powered
USER MENU > SETUP MENU > RESTRICTED (PASS-
bus” section at the end of this document may be used to
CODE 900001) > ADDRESSING-BUS SCAN > BUS
resolve the issue.
SCAN DISPLAY
The fastest way to detect a bad device, missing, misplaced 1. To find out which device or devices are appearing
terminator is to use the “Oscilloscope testing procedure” or disappearing, count up to the address(es) of the
in the O&M manual. device(s) and note it down.
If an Oscilloscope is not available, complete all the steps in 2. Refer to the “System Device Schedule” in the master
the “System Start-Up & Cabling Guide” and refer to the panel to find out the device type and location.
“Error Check” and troubleshooting sections at the back of
The next step would be to follow the Bus Splitting tech-
the document.
LCDBBSDT03Sept08

nique for a powered bus.

If all tests have passed and errors continue to accumulate,
contact Tech Support. Bus Map
Every device must be defined in the DTC under the Bus Map
To navigate to this screen:

94
 THE BLUE BOX LT SYSTEM DIAGNOSTICS TOOLS 93

SYSTEM DIAGNOSTICS TOOLS (Continued)

screen for it to be able to communicate with the rest of the

SCAN BY SERIAL#
bus. A device may be assigned a “type” through this screen.
If a device takes more than one address, the first address must
be used to define the device type and the clock will automati- Scanning complete.
Found 3 items.
cally assign all (consecutive) addresses to the device. Not addressed: 0
Hit ENTER when ready.
The address assignment on the bus map must always
match the Bus Scan display. If they do not, errors will ac- USER MENU > SETUP MENU > RESTRICTED (PASSCODE
cumulate and devices may not function properly. 900001) > ADDRESSING-BUS SCAN > MORE DIAGNOS-
If more than one device is assigned the same address, there TICS > DEVICE MANAGEMENT > SCAN BY SERIAL #
may be address collisions that may be causing instability.
Bus Splitting Technique for a powered bus
BUS MAP PAGE 1-19
This method is slightly different from the one in the “Sys-
ID1 : Panel LCP1
ID2 : Panel LCP1
ID3 : UNUSED
ID4 : UNUSED
ID5 : UNUSED
ID6 : UNUSED
ID7 : UNUSED

To check for collisions, refer to the “Scan by Serial Num-

ber” screen. To navigate to this screen:
USER MENU > SETUP MENU > RESTRICTED (PASS-
CODE 900001) > BUS MAP

Scan by Serial Number

When starting up the system, one of the steps includes
filling out the “System Device Schedule” with the help of
this screen. This screen displays the address, device type
and serial number of every device on the bus.
Additionally, this screen detects and displays any “overlap-
ping addresses” or “address collisions” for the devices on
the bus. If more than one device is assigned the same ad-
dress, a collision is displayed on this screen.
To view the serial#, device type and address of every de-
vice on the bus, highlight “ENTER” and press ENTER.
If any collisions are detected, the screen will display the se-
rial number for any device that is colliding with the device
being viewed. One of these devices may then be assigned
a different address to eliminate the collision.
LCDBBSDT03Sept08

To navigate to this screen:

95
94 THE BLUE BOX LT SYSTEM DIAGNOSTICS TOOLS

tem Start-Up & Cabling Guide” in that, we have the added

ERROR STATS. CLEAR
advantage of being able to use the “System Diagnostics Overall: 0
Tools” mentioned above to help narrow or track down Addr1: 0
Cmd0: 0
the problem area. EEPROM FLAG ERR: 0
EEPROM WRITE ERR: 0
The Error Checking Screens (Error Statistics and the Bus DROP-OFF: 0
Scan) must be checked after each of the following steps FATAL-ERR: 0

for accumulating errors and for appearing and disappear-

ing devices respectively.
3000000000 0000000000
1. Disconnect both Cat. 5 cables from the Blue Box LT 0000000000 0000000000
master panel. 0000000000 0000000000
0000000000 0000000000
2. Add the Cat. 5 from the first device only on either side 0000000000 0000000000
of the master panel and terminate both devices. Check 0000000000 0000000000
0000000 0-5 0
the Error Statistics and bus scan screen for errors.
3. If errors accumulate on either or both screens, lo-
cate the Cat. 5 cable connecting the device that was
just added to the bus and check for bad crimps, and ERROR STATS. CLEAR
conduct a LAN cable test and plug it back in. TAB to Overall: 0
Addr1: 0
“Clear” and monitor both screens for errors for a Cmd0: 0
few minutes. If errors continue to accumulate, replace EEPROM FLAG ERR: 0
cable, clear error count, and monitor both screens for EEPROM WRITE ERR: 0
DROP-OFF: 0
errors. If re-testing and replacing cables does not fix FATAL-ERR: 0
the error counts, by-pass the device and add the next
device to the master panel.
4. Continue to add devices one at a time while moni- ERROR STATS. CLEAR
toring for errors on both screens until the bad crimp, Overall: 30
Addr1: 0
cable, or device has been detected. Replace, retest Cmd0: 0
cables, or by-pass devices as needed. EEPROM FLAG ERR: 0
EEPROM WRITE ERR: 0
DROP-OFF: 4
FATAL-ERR: 1

LCDBBSDT03Sept08

96
 ®

the Blue Box LT

™

System Start-up & cabling guide

INSTRUCTIONS:
Step 1: Step 4:
Install all equipment and note down their serial numbers on Verify proper connections and cabling using the Hardware
the “System Device Schedule” in The Blue Box LT Master Activation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.98
Panel. . . . . . . . . . . . . . . . . . . . . . (Refer to Installation Guides)
Step 5:
Step 2:
Make up low voltage cabling and connections for contact
Pull Cat. 5 cable in a daisy-chain between all digital devices.
closure devices or photocells. . . . . (See Installation Guides)
Add “EZ” brand RJ45 connectors to cable ends and crimp
using the proper color code. Note: Do not connect contact Step 6:
switches or photocells until Step 5. . . . . . . . . . . . . Pgs.96-97
Start-up and auto-address the digital bus. . . . . . . . . . . Pg.99
Step 3:
Once the 6 steps are completed you can program sched-
Test each cable with a LAN tester and once passed plug ules, switches, and photocells. Need help? Call Tech Support:
each in. Do not power-up devices until Step 6! . . . . . Pgs.97 (800) 345-4448.

Digital Network:
Locate multiple Blue Box LTs and Slave Relay Panel Outdoor Photocell
control stations where you need
them and then link them all with
Cat. 5 cable. One master panel
(with a Digital Time Clock) for 16
digital devices. Control stations
provide combined manual control
and after-hours override. Chelsea Digital Switch
LCDBBSSU&CG03Sept08

Note: The photocell is not on the

digital bus and should not be con-
nected until Step 5.

Slave Relay Panel Master Relay Panel

97
96 THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE

LOW VOLTAGE CABLING

Digital devices have two RJ45 connectors and are daisy-

Bus-Powered Devices Allowed
chained using Cat. 5 (see cover). Non-digital devices (pho-
for Each Active Device
tosensors, toggle switches, etc.) are cabled per their instal-
lation guides (not daisy-chained). 1000 ft.

Total Feet of Cable from

! Adhere to 568A or 568B standards for Cat. 5 cables.

One Active Device

900 ft.
Always use a dedicated pair for the center pins.
Refer to individual product installation guides for line-volt-
800 ft.
age cabling details and low voltage connection details Do
not “home run” digital switches back to a relay panel. No
spurs or T-Taps are allowed. Do not exceed 16 devices on 700 ft.

12
any system with a Blue Box LT Master. Number of Bus-Powered Devices
Eliminate Interference; Isolate cat. 5 Active Device - Device with power supply (a transformer). It acts as a
source of electrical energy for the bus.
cables Bus-Powered Device - Any device that relies on the 12v supplied by the
…From Line Voltage Cable: Cat. 5 cable must be at least bus for its power. Example: digital switches, and photosensor cards.
12” from all line voltage conductors, except to cross or
make terminations.
The more feet of Cat. 5 cable used, the fewer bus-pow-
Low Voltage Cable
Photosensor ered devices before adding another active device.
Input
Photosensor
Examples: Per the above chart, up to 3 bus-powered de-
Relay vices may be powered across 1,000 feet of Cat. 5 cable.
Line Voltage Cable
Relay Panel

Low voltage cabling must not be run in parallel with Bus-Powered Devices Active Device Anywhere
line voltage cable, and must not share the same conduit, Cat. 5 Cable
in the 1000 ft. zone
Power
whether digital cable (Cat. 5) or low voltage cable (3#18 Active Device Power
Active Device
from a photosensor).
The active device may be located anywhere within the
…From Line Voltage Devices: Low voltage cabling must avoid
1,000 foot region.
EMF or RF from ballasts, arc welders or other “noisy” loads.
EMF or RF interference can create an unstable bus. Multiple active devices in the same location will not in-
crease the distance allowed.
Low Voltage
Cable Photosensor 1000 ft. Insufficient Power
Input
Photosensor
Relay Bus-Powered Devices Bus-Powered Devices
Power
12" or more Power
Relay Panel Active Devices Cat. 5 Cable

For the above, the correct solution is to connect the ac-

LCDBBSSU&CG03Sept08

Line Voltage Cable

tive devices (relay panels) as the center of the network
and have two runs of cable. Call the Tech Support if cable
Don’t CAUSE Voltage Drop! runs exceed 1000ft without active devices.
There is a limit to how many switches and photocell cards
you can add in a row over long runs of Cat. 5 cabling.

98
 THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE 97

MAKING UP RJ45 CONNECTORS

Never made up RJ45 connectors before? Its easy. Just fol-

low the below steps. For a short lesson on making RJ45
connectors, refer to The Blue Box LT “O&M Manual”.
To be successful, only use the ratcheting crimping tool rec-
ommended by LC&D and a Local Area Network (LAN)
cable tester that allows remote testing — the ends of the
cable will be remote from each other.

! Only use stranded Cat. 5 cable. Contacts not seated properly (sticking out 1⁄16
of an inch too far).

!  nly use EZ RJ45 connectors provided by Lighting

O
Control & Design (LC&D). 7. Visually inspect each connector. Contacts should be
pushed into the insulation of each conductor.
1. Remove two inches of the Cat. 5 jacket - use the 8. Repeat on the other end of the cable for a straight-
wire stripper and cutter provided in our kit. Carefully through cable.
inspect the conductors for nicks.
2. Untwist all four pairs, and straighten/smooth out
each conductor.
3. Reorganize the conductors in the order shown in the
illustration below. Bring all conductors together until
they touch.

Brown
Brown/White
Green Contacts not seated properly (bowed crimping).
Blue/White
Blue
9. Test every cable for continuity with a LAN cable tes-
Green/White
Orange ter. While testing, wiggle and tug on each connector
Orange/White to test for a solid crimp.
Never make “hot” RJ45 crimps (crimping the other end of
a cable that has been plugged into a powered device).This
4. Place an EZ connector on the end of the cable with
can damage equipment.
the locking prong facing down.
5. Push conductors completely through and (using flush
cutters or box cutters) trim-off all excess cable. Con-
ductors should butt up to the end of the connector
– they must not protrude or be too short.

!  lways follow acceptable safety procedures when using a

A
sharp cutting tool. Tools must be sharp; dull tools cause
more hazards than sharp ones.
LCDBBSSU&CG03Sept08

6. Using the recommended ratcheting crimp tool, crimp

at least five times for the best possible connection. Contacts properly seated (flat crimping).

99
98 THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE

HARDWARE ACTIVATION TESTS

Before starting, note total approximate bus cable length: Checker Card,”
6. All test values should be greater than 1K ohm!

Once each cable has been checked with a LAN cable tes- Gnd to A ____ohms A to B ____ohms
ter and plugged-in, it is still possible for the entire connect- Gnd to B ____ohms A to +12 ____ohms
ed cable structure to become problematic. For instance,
Gnd to +12 ____ohms B to +12 ____ohms
dirt may accumulate inside the RJ45 sockets, the strain
on the Cat. 5 when pushing switches into the wall may
weaken connections or even break the conductors, or the Earth Ground Test
bus length may exceed 4000 ft. This test is intended to detect any pathways to earth
ground.
Each test must be passed before moving onto the next. If
any readings are out of range, refer to “Hardware Activa- 7. Measure resistance between the terminals mentioned be-
low, and “Earth ground” (a metallic enclosure or conduit).
tion Troubleshooting” section at the end of this document
or call Technical Support at 1-800-345-4448. Gnd A
+12 B
CONTINUITY Test
This test is intended to verify bus length, continuity, and 8. All readings between each terminal and “Earth
detect crossed data-pair wires. ground” should be infinite or “Open”!
Terminator Test
1. De-power every item on the bus and check the volt-
This test is intended to ensure that only 2 terminators
age at both ends to ensure a reading of 0vdc. Re-
move any terminators. exist, one at each end of the bus. If the readings are out of
2. At one end of the bus, plug in the “Data/Power Jumper.” range, it would indicate a missing, misplaced, or an extra
3. At the other end of the bus, plug in the “Bus Checker Card” terminator (terminators are shipped in the Master Panel).
and measure resistance across the following terminals: 9. Add a “Terminator” on the first and last device. On
the “Bus Checker Card“, measure
Gnd to A ____ohms B to +12 ____ohms
A to B ____ohms
4. All test values must be within 10% of the values in the
chart below to be considered valid! 10. Test reading should be within 62 Ω to 92 Ω!
11. Remove the bus checker card and call our Tech Sup-
Continuity Test Results (Gnd to A & B to +12) port with your results at: 1-800-345-4448 x391.
Length Ohms Length Ohms
100 ft. 3 Ω to 6 Ω 2000 ft. 68 Ω to 80 Ω Figure A:
500 ft. 12 Ω to 20 Ω 3000 ft. 102 Ω to 120 Ω
1000 ft. 34 Ω to 40 Ω 4000 ft. 130 Ω to 160 Ω
Bus Checker Card Data/Power Jumper
SHORT CIRCUIT TEST
LCDBBSSU&CG03Sept08

This test is intended to detect any short circuits along the

bus. Please use the lowest resistance range (200 Ω) setting
on your multi-meter. DO NOT use a “beep” test.
5. Remove the “Data Power Jumper” and measure the
resistance across the following terminals on the “Bus

100
 THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE 99

SYSTEM ACTIVATION

AUTO ADDRESS devices Fill out the “System Device Schedule” located on the back
of the “Panel Schedule” inside the master panel.
Starting up a new system requires a few simple steps.
Consider the following steps to set-up and start the sys- If unable to correlate the serial numbers and device loca-
tem (see page 6 for DTC navigation). tions when filling out the “System Device Schedule”, refer
to the serial label on each device or follow the “Read Ad-
1. A
 fter completing the Hardware Activation Tests, power dress” section of the Blue Box LT “O&M Manual”.
up all slave panels, and active devices (any device with
an onboard - 120 or 277 - power supply) first and then
SYSTEM DEVICE SCHEDULE: (for Master Panels)
power up the master panel. Check that the power-indi-
cator LEDs on all digital devices are lit-up. (Master)
(Master)LCP1
LCP1 3 btn sw 6 btn sw LCP 2
Device Type Device Type Device Type Device Type
elec rm Hallway lobby telecom
2. T
 he main screen will be displayed for a few seconds, af- Location Location Location Location
ter which the “device detection” screen will be displayed. ce80 8875 4685 af97

R
Serial # Serial # Serial # Serial #
TAB to YES and ENTER to auto-address devices. 1 3 4 5

E
Address Address Address Address

S T
Found 1 device on the If the number of devices
system that are not used. detected do not match DI-6

A Y
Device Type Device Type Device Type Device Type
Would you like to

L
the number of devices LCP 1
auto-assign them?

M
present on the bus, pro- Location Location Location Location

N
ceed to trouble-shooting 4055
YES / NO / ->

R
Serial # Serial # Serial # Serial #
section.

O
Never Ask Again 7

O
Address Address Address Address

F L S
4. T
 o view address assignments in the “Serial Number
Error
Device TypeCheck

E
Scan” screen TAB to YES and ENTER. Device Type Device Type Device Type
The system is now ready for Error Checking. Press EXIT

N
Location Location Location Location
Assigned 1 device. repeatedly to go back to the main menu.

A
The “Serial Number Serial # Serial # Serial # Serial #
Review assignments by

P
Scan” screen displays the
scanning all serial
serial number, address, 7.Address
Navigate to the “Error
Address Statistics” screen. Use the path Address
Address
numbers?
and device-type of added USER MENU > SETUP MENU > RESTRICTED > AD-
YES / NO device(s)
DRESSING-BUS SCAN > ERROR STATISTICS. The
Device Type Device Type Device Type Device Type
password to enter the RESTRICTED area is 900001.
fill out System Device Schedule Location Location Location Location

8.Serial
TAB# to the field that
Serialsays
# CLEAR and press
Serial # ENTER to Serial #
6. In the “Serial#” field SCROLL to review each device clear errors. If after 3 minutes no errors accumulate on Address
Address Address Address
(including DI cards). If collisions are present or if two this screen, your system is stable.
devices share the same address, contact Tech Support.
SCAN BY SERIAL#
SERIAL# CE80 LIGHTING CONTROL & DESIGN
9. If errors continue to accumulate refer to the Error
Check Troubleshooting section of the Blue Box LT
ADR: 1 905 Allen Ave s Glendale, CA 91201 s Support 800-345-4448 s www.lightingcontrols.com
Item Type: Switch “O&M Manual” or call Technical Support for assistance
LCDBBIG13Aug08
LCDBBSSU&CG03Sept08

Mapd: 6 Btn. Switch at 800-345-4448.

Address OK

SAVE ADDRESS CHANGES verify Date, Time & location

To change the factory programmed settings, refer to the
BB Panel Schedule.indd 4 8/13/2008 1:37:47 P
Blue Box LT “O&M Manual”.

101
100 THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE

DIGITAL TIME CLOCK (DTC) NAVIGATION BASICS

DTC CLOCk
CLOCK NAVIGATION
NAvIGATION BASICS
CLOCk NAvIGATION TAB moves
TAB moves the
the cursor
cursor through
through aa screen
screen
Most
Most devices
devices can
Most devices can can be programmed
be be programmed
programmed from
from from
the DTCthe(Digital
the DTC
DTC
Time Clock)
(Digital Timein the
Time Clock)master LCP
Clock) inin the (Lighting
the master Control
master Lighting Panel).
Lighting Control
Control SWITCHES
SWITCHES PAGE 1-1
PAGE 1-1
(Digital #04: SWITCH
SWITCH 44
#04:
Panel (LCP) .
Panel (LCP) . #05: SWITCH
#05: SWITCH 55
#06: SWITCH
#06: SWITCH 66
#07: SWITCH
#07: SWITCH 77
#08: SWITCH
#08: SWITCH 88
#09: SWITCH
#09: SWITCH 99
#10: SWITCH
#10: SWITCH 10
10

SCROLL to
SCROLL to choose
choose one
one item
item from
from aa fifield .
eld .**
USER MENU
USER MENU
Load 44
Load
MANUAL OVERRIDE
OVERRIDE SWI ID05-5
SWI ID05-5 TOGGLE
TOGGLE
MANUAL
EDIT: LCP-2
LCP-2 LOAD-1
LOAD-1
Load 33
Load
REVIEW SCHEDULE
REVIEW SCHEDULE EDIT:
GROUP LOADS
GROUP LOADS Load 22
Load
PROGRAM SWITCH
PROGRAM SWITCH
SETUP MENU
Load 11
Load
SETUP MENU

1
1 2
2
5
5 This“field”
This“fi eld”contains
contains aa list
list ofof possible
possible
4
4 selections,but
selections, but only
only displays
displays one one item
item
3
3 from that
from that list
list at
at aa time.
time.

CALL OUT
CALL OUT LEGEND:
LEGEND:

1 .1 . SCROLL
SCROLL throughthrough choices
choices inin one
one fifield*
eld*
2 .2 . TAB
TAB to to position
position thethe cursor
cursor
3 .3 . DELETE
DELETE information
information or or programming
programming about about
an item .
an item .Use
Use caution .
caution .
4 .4 . ENTER
ENTER to to select
select
5 .5 . EXIT
EXIT to to leave
leave aa screen .
screen .
LCDBBSSU&CG03Sept08

***AA“fi
A“fi eld”contains
eld”
“field” contains aa list
list ofof possible
possible selections,
selections,but
but only
only displayed
displayed one
one item
item from
from that
thatlist
the listat
list ataaatime.
at time.
time.

102
 THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE 101

HARDWARE ACTIVATION TROUBLESHOOTING

! Always re-check “failed” results. If improperly set or

connected a meter can display unusual readings.
Earth Ground Trouble Shooting
LAN-tested cables can still have a path to earth ground.

! The “Bus-Splitting Technique” is the fastest way to find

a bad cable and/or damaged device. Be sure to docu-
ment the cable path!
1. An abraded or “folded” cable inside the conduit will
cause a short to earth ground.
2. Other low voltage or high voltage wires touching any

! Cat. 5 cables that pass a LAN cable test can still short
or break from stress and strain during installation.
device on the bus will cause continuity to earth ground
Use the Bus Splitting Technique to locate the problem.
If re-testing a suspected cable, roughly wiggle and tug the
conductors near the RJ45 while keeping an eye on the Terminator Trouble-Shooting
LAN tester: conductors should remain properly engaged 1. Ensure that the Data/Power Jumper is removed.
throughout the test. 2. Visually inspect both terminators are present and
properly seated on each bus-end device.
Continuity test Trouble Shooting
1. Fluctuating resistance readings indicate one or more ERROR CHECK Troubleshooting
“active” devices are still “hot”. De-power all devices If the hardware activation tests have just been completed
and re-test. and the bus is unstable, consider the following causes:
2. High resistance readings indicate broken or resis-
tive connections. Use the “Bus-splitting” technique to 1. Failure to follow the 568A or 568B color code (or
find: minimally to use a dedicated pair for the center pins)
• RJ45 connectors not properly pushed into sockets will cause the Error Check test to fail. Visually inspect
(check to make sure that the wires are not ex- RJ45 connectors.
tended beyond the end of the RJ45 connector) 2. Occasionally, the flat-cable connecting the clock to
• Cable strain can break conductors or pull conduc- the master panel can become damaged. Visually in-
tors out of RJ45 contacts (visually inspect cable spect the Cat. 5 cable – if damaged, replace it with a
and connector). new cable.
• Unseated RJ45 sockets (rough install environ- 3. An external source of EMF (electromagnetic fre-
ment) quency) or RF (radio frequency) interference may
• Damaged device (rare) be present and affecting the bus (or digital de-
• Dirt or paint on RJ45s (rare) vices). Refer to the beginning of this guide on run-
• Bad data/power jumper cable (rare) ning low voltage cables across or parallel to line
voltage cables or exposing low voltage cables to
Short Circuit Test Trouble Shooting EMF or RF sources (e.g. welders, ballasts, improp-
1. A low resistance reading indicates a crossed or short- erly grounded wireless devices, etc.); any of which
ed pair or (rarely) a damaged device. Cable strain can interfere with the bus operation and stability.
when pushing switches into a wall can short nicked Visually inspect and handle any external sources of
conductors. Use the bus splitting technique to find signal noise - a digital device can also become dam-
the bad cable, crimp or device. aged and create signal noise.
2. Resistance readings below 300Ω on A-B only indicate
LCDBBSSU&CG03Sept08

an extra terminator. Use the bus splitting technique An oscilloscope can be used to locate the source of the
to find the short or extra terminator. bus failure. The “Oscilloscope Test” can be found in The
3. After the problem has been resolved, please com- Blue Box LT “O&M Manual”.
plete the “Continuity Test” again. If unfamiliar with how to use an oscilloscope or if one is
unavailable on-site, contact Tech Support: 1-800-345-4448.

103
HARDWARE ACTIVATION TROUBLESHOOTING
(Continued)
Bus Splitting Technique

! Note:To speed up troubleshooting when readings are

less than 200Ω on the Continuity or Short-Circuit test,
refer to the “Bus Length Chart” earlier in this document
before splitting the bus; this can provide an approximate
distance to a shorted pair or extra terminator from the
test point.

1. On the middle device of the bus, disconnect one Cat.

Bus Checker Card Data/Power Jumper
5 cable to create two smaller “half-buses”.
2. Test each “half-bus” to find the side with the out-of-
range values.
3. Repeat steps 1 & 2 on the out-of-range “half-bus,” to
create another “half-bus” until the cable, crimp or device
creating the out of range measurements is located.
The idea is to split a bus in half and then half again – over and
over until the bad area has been located. It is OK to visually
inspect each cable, crimp or device to detect the problem.

Bus Checker Card Data/Power Jumper

Data/Power Jumper Bus Checker Card

LCDBBSSU&CG03Sept08

Lighting Control & Design

905 Allen Ave • Glendale, CA 91201 • Support 800-345-4448 • www.lightingcontrols.com

104
 ®

THE BLUE BOX LT

™

Frequently asked
questions
LCDBBFAQ03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

105
104 THE BLUE BOX LT FREQUENTLY ASKED QUESTIONS

GENERAL FAQ

QQ: Where is the modem connected? Blue Box LT 4/8. A maximum of 16 relays may be
AA: The modem is connected to The Blue Box LT mas-
™ installed in a Blue Box LT 8/16.
ter panel using the 4-wire connector provided with QQ: How is the Blue Box photocell programmed?
the modem. One end is connected to the modem AA: Photocells connected directly to the Blue Box LT
card on the 4-pin connector and the other end is master panel may be programmed under any of the
connected to the 4-pin connector on The Blue Box™ first 8 schedules under the REVIEW SCHEDULES
LT card labeled “MODEM”. screen. To get to this screen, do the following: SETUP
QQ: How do you change a schedule? MENU > REVIEW SCHEDULES > SCHEDULE # >
AA: To edit a schedule, navigate to the REVIEW SCHED- ENTER on PCELL ON or PCELL OFF. Change set-
ULES screen: SETUP MENU > REVIEW SCHED- tings as desired. Refer to the “Programming a photo-
ULES > and highlight the schedule that needs to be cell” section.
modified. Change the ON or OFF times as desired. QQ: Why can’t I see the photocell in the bus scan?
For more information, refer to the “Time Schedules” AA: A Blue Box LT photocells are not digital devices and
section. do not sit on the bus - the inputs for Blue Box LT
QQ: What does the Red LED on the relay indicate? photocells are provided on the master panel. Refer
AA: The Red LED indicates the status of a relay. For Nor- to “PCO Installation Guide”.
mally Closed relays, the red LED indicates the relays QQ: What is the DI card?
(lights) are OFF. For Normally Open relays, the red AA: DI cards provide programmable inputs for contact
LED indicates the relays (lights) are ON. closure devices such as analog switches and occupant
QQ: What does the ONLINE LED indicate? sensors.
AA: The ONLINE LED indicates that the card is function- QQ: How do I adjust the contrast level on the Clock?
ing normally, but not necessarily recognized by the AA: The contrast screw is located on the back of the
bus. A solid ONLINE LED indicates that the panel display. Use a small Phillips screwdriver to rotate
is “stuck”, which usually occurs after a power surge, clockwise for increasing and counter-clockwise for
short or storm. decreasing the contrast level.
If ONLINE LED is solid, follow the steps below: QQ: What is the AUTO/HAND switch for and what does
Disconnect card from the bus by disconnecting all it do?
Cat. 5 cables connected to it. AA: When in AUTO mode, relays can be controlled by
Power cycle the card by disconnecting power supply the system (schedules, switches, etc.).
cable connected to the power input connector la- When in HAND mode, all lights will turn ON, i.e.
beled AC Input - located at bottom-right of the card. both Normally Closed and Normally Open relays will
If issue persists after connecting card to the bus, com- close. This feature is generally used for maintenance
plete the steps in the “System Start-Up and Cabling purposes.
Guide” to verify Cat. 5 integrity. Contact Tech Support QQ: Does the Blue Box LT have to be the first device?
with results.
AA: The Blue Box LT, like any digital device, may be placed
LCDBBFAQ03Sept08

QQ: How many relays can fit in the Blue Box? anywhere along the bus. If unsure how or where to
AA: A maximum of 4 relays may be installed in a Blue Box install, refer to the single line drawing in the Blue Box
LT 2/4. A maximum of 8 relays may be installed in a “Installation Guide”.

106
 THE BLUE BOX LT FREQUENTLY ASKED QUESTIONS 105

GENERAL FAQ (Continued)

QQ: Does The Blue Box LT have an astronomical clock?

AA: Yes. The astronomical clock is .accessed by scrolling
on the “time” field in a schedule. Choose DUSK or
DAWN as appropriate.
QQ: Can you have a DUSK to DAWN schedule without
the photocell?
AA: Yes. Refer to the “Time schedules” section to pro-
gram DUSK to DAWN schedules.
LCDBBFAQ03Sept08

107
106 THE BLUE BOX LT FREQUENTLY ASKED QUESTIONS

GROUPS FAQ

QQ: What does a “maintain” type group do? QQ: How do you tell if a relay has a timer and what timer
AA: When the MAINTAIN group is turned ON, it turns value is on it?
its relays ON. When it is turned OFF, it turns its relays AA: If you check the relay properties screen for that relay,
OFF. it will say REGULAR TIMER MODE: followed by a
QQ: What does a “momentary” type group do? number, e.g. TIMER 00:20:00 H/M/S.

AA: Momentary groups are usually used with switch but- QQ: How do you tell if a relay timer is active?
tons. They can be ON, OFF or mixed. AA: If the relay is on, the manual override screen will show
QQ: What is the difference between “maintain” type the normal ON square symbol with an additional lit-
groups and “momentary” type groups? tle “leg” on the bottom left corner, like this:

AA: A MAINTAIN group can be turned ON and OFF. Relay ON with no TIMER:
Once it is turned ON, it stays on until turned OFF. Relay ON in TIMER mode:
When it is turned OFF, it stays OFF until turned ON. QQ: What does a MAINTAIN + BLINK group do?
A MOMENTARY ON group can only turn its relays AA: It is identical to a MAINTAIN + TIMER group, with
ON, never OFF. A MOMENTARY OFF group will al- the only addition being that when you turn a MAIN-
ways turns its relays OFF. A MOMENTARY MIXED TAIN + BLINK group OFF, the lights will blink or flick,
group turns some relays ON and some relays OFF. and then wait for a specified amount of time before
QQ: Which type of group is most commonly used for the relay turns off. This time period is called the “Blink
schedules and why? time out.” This time period is set in the MAINTAIN +
AA: Usually schedules operate “maintain” type groups. BLINK group under “SET TIMER”.
This is because schedules are used to turn lights on QQ: How do you take a relay out of timer mode?
and have them stay on for a period of time, and then AA: Find out what MAINTAIN + TIMER or MAINTAIN
turn them off. Only maintain groups can be turned + BLINK group that relay is in, and turn that group
on and off. ON.
QQ: When would you use a “momentary” type group QQ: How can you tell if a relay has a “Blink Timer”?
with a schedule?
AA: If you check the relay properties screen for that relay,
AA: In those rare instances when a schedule needs to it will say BLINK One or BLINK Two: followed by a
just turn lights on (without a corresponding off com- number, e.g. BLINK One: 20:00 M/S.
mand) or off (without a corresponding on command).
For example, if you wanted the lights turned off by a QQ: How can you tell if a relay is in a blink warning time-
schedule at 8pm every day, but didn’t want any on out?
time, you would create a schedule that activates a AA: The manual override screen will show the relay as
Momentary OFF group. being on with TWO little legs on the bottom corners,
QQ: What does a MAINTAIN + TIMER group do? as shown here:

AA: When it is turned ON, it turns its relays ON. When Relay on with no BLINK or TIMER:
it is turned OFF, it turns off its relays AND enables a Relay in final BLINK Warning Timer:
LCDBBFAQ03Sept08

timer on each relay. If any of the relays in timer mode

QQ: What is the purpose of the “Blink time OUT”.
are flipped on with a switch, etc., they will automati-
cally turn back off again after the timer has expired. AA: It gives the occupants of the area a warning that the
lights are about to turn off. They can extend the time

108
 THE BLUE BOX LT FREQUENTLY ASKED QUESTIONS 107

GROUPS FAQ (Continued)

that they have light by pushing any button with a rap- >WHAT CONTROLS RELAYS. Select the relay and
idly blinking LED. This is the indication that the lights press ENTER. Any groups that the relay is in will be
are in Blink Time OUT. displayed.
QQ: Where are the two locations on the DTC that a relay QQ: How do you find out what is turning a group off or
timer can be viewed or programmed? on?
AA: USER MENU >GROUP LOADS >TAB to GROUP > AA: Look in the “What & When Menu”: SETUP >SYS-
ENTER to select >TAB to MAINTAIN+TIMER or TEM SETUP >WHAT AND WHEN? >WHAT
MAINTAIN+BLINK >ENTER to select > CONTROLS GROUPS. Select the group and press
USER MENU >SETUP MENU >SYSTEM SETUP ENTER. Any schedules, photocells or switches that
MENU >RESTRICTED (PASSCODE 900001) >RE- control that group will be displayed.
LAY PROPERTIES >select BOARD > QQ: How do you manually turn on a group using the clock
QQ: You create a new MAINTAIN group or add new re- interface?
lays to an existing MAINTAIN group and EXIT. Upon AA: Go to the “group loads” screen, highlight the group:
re-entering the group, you notice it has changed itself 1. For a MOMENTARY ON group SCROLL UP to
into MAINTAIN+TIMER. Why? turn the relays in that group on,
AA: One or more of the relays in the group are also in 2. For a MOMENTARY OFF group SCROLL UP to
another MAINTAIN+TIMER or MAINTAIN+BLINK turn the relays in that group off,
group which has assigned it or them a timer value.
Since the timer value is written into the relay prop- 3. For a MOMENTARY MIXED group SCROLL UP
erties, it is carried over into the new MAINTAIN to control the relays per the ON and OFF pro-
group. gramming within that group,

QQ: What does MAINTAIN mean in reference to a wall 4. For any MAINTAIN group, SCROLL UP to turn
switch? the group on and SCROLL DOWN to turn the
group off.
AA: It means that the switch concerned is a contact clo-
sure switch like an ordinary wall switch. When one QQ: What do you do to synch up the relays in a group,
flips the switch UP the contacts close and stay closed when some of them are on and some are off?
and the lights come ON. (They are MAINTAINED AA: Go to the “group loads” screen and turn on the group
that way.) When one flips the switch down the con- again using the SCROLL UP button. If the group is
tacts open and the lights go off. Note that both making already “ON” scrolling up will re-reiterate the “ON”
the circuit and breaking the circuit (from the switch command.
to the contact input) causes the relay(s) to react.
QQ: How do you get rid of a group you don’t want to
QQ: What does MOMENTARY mean in reference to a use anymore?
switch?
AA: Go to the “GROUP LOADS” screen, highlight the
AA: It means that it is expecting a pulse as would be re- group and press the DELETE button.
ceived from a push button. The command is executed
QQ: What should you suspect is happening when you de-
on contact closure. The contact opening does nothing.
lete a group but the relays still have a timer?
LCDBBFAQ03Sept08

QQ: How do you find out which group(s) a relay is in?

AA: Those relays are in another MAINTAIN+TIMER or
AA: Look in the “What & When Menu”: SETUP MENU MAINTAIN+BLINK group which is forcing a timer
>SYSTEM SETUP MENU >WHAT AND WHEN? onto them.

109
108 THE BLUE BOX LT FREQUENTLY ASKED QUESTIONS

QQ: What should you be careful never to do with MAIN- type groups (MAINTAIN, MAINTAIN+TIMER,
TAIN + TIMER or MAINTAIN + BLINK groups? MAINTAIN+BLINK) to a switch. The reason for this
AA: Never have the same relay in more than one MAIN- is that switch buttons turn maintain groups ON when
TAIN + TIMER or MAINTAIN + BLINK group. the button is held down and OFF when the button
is released.
QQ: What does the “NO AUTOMATIC ON” setting in
a MAINTAIN+TIMER or MAINTAIN+BLINK group Having to hold the button down to keep lights on is
do? not generally useful!

AA: It makes it so that when you turn ON the group, the QQ: If you are having a photocell control more than 8
relays don’t come on – only the group status changes relays, what type of group would you assign to the
to ON and the relay timers are disabled. photocell?

QQ: Why would someone want to use “NO AUTOMAT- AA: You would normally use a maintain-type group. Re-
IC ON”? member that only maintain-type groups can be turned
on AND off. If you want the photocell to turn lights
AA: So they can take disable relay-timers without actually ON when it is dark and OFF when it is bright, the
turning the relays on. For example, if the customer easiest way is to use a maintain group.
wants to turn lights on with a switch early in the
morning, and not have them automatically shut off QQ: When would you use a momentary-type group with
after an hour (timer mode), they would need to turn a photocell?
the MAINTAIN + TIMER group on with a schedule. AA: When you only want the photocell to turn the relays
However, if they don’t want the actual lights to turn OFF, or only want it to turn relays ON.
on until they use a switch, they would set the group Even when using a schedule to turn the lights off (for
to “No Auto On”. This would take the relays out of example at 11:00pm), one would usually program the
Timer mode, but not turn them on with the sched- Photocell as “Maintain”. This ensures the lights turn
ule. This saves energy until someone enters the room off at dawn in the event that an override “ON” com-
and switches the lights on. mand switched the lights on during the night.
QQ: When must a switch button be programmed to op-
erate a group instead of just operating the relays di-
rectly?
AA: When you want the switch to operate more than 8
relays, the system will require you to make them into
a group.
QQ: How do you toggle a group on and off using a single
switch button?
AA: You can’t. Groups cannot be toggled. If you want to
turn more than 8 relays on and off with a switch, you
need to use two buttons and two groups: one MO-
MENTARY On and one MOMENTARY OFF.
LCDBBFAQ03Sept08

QQ: What kind of group would you normally NOT assign

to a momentary switch?
AA: You normally do NOT assign any of the maintain-

110
 THE BLUE BOX LT FREQUENTLY ASKED QUESTIONS 109
LCDBBFAQ03Sept08

111
 LCDBBFAQ03Sept08

Lighting Control & Design

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112
 APPENDIX
APPENDIX

a) Installation Guide - GR1404 & 1408

b) Installation Guide - GR1416
c) Installation Guide - Chelsea DigitalSwitch
d) Installation Guide - Photocell
e) Installation Guide - Digital Input (DI)

f) Connecting Occupancy Sensors

g) Clock/Programming Navigation Tree
h) Technical Glossary
LCDBBO&M03Sept08

113
114
LCDBBO&M03Sept08
 ®

THE BLUE BOX LT

™

INSTALLATION GUIDE
GR1404LT & GR1408LT
LCDBB1404/08IG03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

115
114 THE BLUE BOX LT GR1404/08 LT INSTALLATION GUIDE

INSTRUCTIONS

Panel Mounting low voltage only line voltage only

1. Use the drill template to pre-drill
mounting holes for appropriate
screw fasteners and mount panel.
Backplate can be removed at rough-in.
5 2 1
line voltage connections
2. Connect to power (120V or 277V)
neutral and ground lugs. Connect 8
to dedicated breaker (see next
page for emergency loads).
3. Follow the Panel Schedule on
the inside door. If panel is factory 10
pre-programmed connect per
line and load directions. If not,
document field-made connec- 6
tions. (back page)
4. Tighten and then re-tighten lugs
to 18 in/lbs. 9
Tip: Fault-check each circuit prior to en- 11
ergizing relays.
4 3
Low Voltage Connections 7
5. Follow the “System Start-Up &
Cabling Guide” to make bus con- 2
nections using Cat. 5 with RJ45s.
6. Make-up connections to optional
low voltage accessories:
For a complete parts list refer to the Blue Box LT O&M Manual
7. Modem (see back page)
8. Photocell (see next page) 1. Blue Box Mounting Holes (4). 7
7. Dual-voltage (120V or
9. For contact closure devices use 1
277V)power supply.
the optional DI Card (next page). 22. Back Plate Mounting Screws.
8. (Optional) Digital Input
Start Up 3. RJ45 sockets for GR 2400 bus. 8 Card. DI 14 (or DI6 with
3
10. To start-up the panel as part of a
enable/disable) inputs.
new system refer to the “System 4. Photocell Input (master
4
Start-Up & Cabling Guide”. only). The Photocell may 9. Terminator pins. Terminate
To start-up the Blue Box in an control any relay(s) in any 9
the bus only after the “Sys-
existing network, refer to “Add- panel(s). tem Start-Up and Cabling
ing New Devices” in “The Blue Guide” has been completed.
Box LT O&M Manual”. 5. Optional Modem. Analog
5
LCDBB1404/08IG03Sept08

phone line connects to RJ- 10. White door and back of DTC
10
12 socket. clock (master panel only).
6. Relays (line and load lugs).
6 11. Grounding LUG.
11

116
 THE BLUE BOX LT GR1404/08 LT INSTALLATION GUIDE 115

HOOK UP DIAGRAMS

2#18AWG - 4#18AWG
for each contact-closure switch
7
6

DI-14
Modem

TO
GND BUS

1
3

2
Master Blue Box (DTC not shown)
4

Outdoor
Photocell

5 Emergency Loads
To switch relays on in the event of a
Chelsea Digital Switch loss of normal power, feed the power
Slave Blue Box supply with a dedicated normal-pow-
1. Relay lugs may hold up to 5. Daisy-chain switches and er breaker.
1 5 panels using Cat. 5 cable
4#10 or 2 #8 AWG. Neu- To maintain relay status (on or off) in
trals may be run through with RJ45s. the event of a loss of normal power,
Blue Box gutter. feed the power supply with a dedi-
6
6. Wiring details from contact cated emergency-power breaker via
2
2. Power supply lugs may hold closure switches to (optional) a server-quality UPS (load is less than
up to 2#12. Digital Input (DI) Card are 10 watts).
shown in the “DI Installation
3
3. Equipment Ground Lug. Guide.”

4
4. 2#18 AWG from photocell 7
7. Run phone cable from mo-
LCDBB1404/08IG03Sept08

input (master panel only) to dem to an analog phone jack.

outdoor photocell (up to See back for details.
300 ft).

117
 MORE INSTALLATION DETAILS
Modem Installation DETAILS
555- 1. Run an analog phone line to a phone outlet near the
Blue Box LT.
4356 2. Write the modem phone number on the outlet.
3. Connect to the modem using a phone cord.
Note: Do not use Digital Phone lines from a PBX system,
it will not work.

RELAY INFORMATION:
† Master Modem #: _____________________________________ # Relay(s):_________

† Slave Supply Circuit:__________________ Voltage: ___________

FILL OUT THE PANEL SCHEDULE!

In the door of the Blue Box is a Panel Schedule. Use it
Relay Breaker #
Line / Feed
Voltage
120 / 277
Load Name to keep track of load names and the relays that control
them.
Use the Line Feed column to ensure that the correct
R1 ________________ - _______ _____________________ _________________________________________________
breakers are on and off when they need to be. If servicing
R2 -
________________ _______ _____________________ _________________________________________________
the relay or the circuit, for example, the breaker should be
R3 ________________ - _______ _____________________ _________________________________________________
off. If the lights are not turning on, the breaker should be
R4 ________________ - _______ _____________________ _________________________________________________ checked to ensure that it is neither off nor tripped.
R5 -
________________ _______ _____________________ _________________________________________________
Load name is pretty important as it connects the breaker
R6 ________________ - _______ _____________________ _________________________________________________ to the relay to the actual lights being controlled. Make up
R7 ________________ - _______ _____________________ _________________________________________________ any name that is descriptive for you.
R8 ________________ - _______ _____________________ _________________________________________________

R9 ________________ - _______ _____________________ _________________________________________________

R10 ________________ - _______ _____________________ _________________________________________________

LCDBB1404/08IG03Sept08

R11 ________________ - _______ _____________________ _________________________________________________

R12 ________________ - _______ _____________________ _________________________________________________

R13 ________________ - _______ _____________________ _________________________________________________

R14 ________________ -
Lighting Control & Design
_______ _____________________ _________________________________________________
LCDBBPS15Aug08

R15 -
905 Allen Ave • Glendale, CA 91201 • Support 800-345-4448 • www.lightingcontrols.com
________________ _______ _____________________ _________________________________________________

R16 ________________ - _______ _____________________ _________________________________________________

BB Panel Schedule.indd 2 8/26/2008 11:48:34 AM

118
 ®

THE BLUE BOX LT

™

INSTALLATION GUIDE
GR1416LT
LCDBB1416IG03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

119
118 THE BLUE BOX LT 1416 LT NSTALLATION GUIDE

INSTRUCTIONS
Optional Nipple

Panel Mounting 1
1. Use the drill template to pre-drill 2
mounting holes for appropriate 2
screw fasteners and mount panel.
Backplate can be removed at rough-in.

line voltage connections

2. Connect to power (120V or 277V)
neutral and ground lugs. Connect

line voltage only

to dedicated breaker (see next
6 6
page for emergency loads).
3. Follow the Panel Schedule on the
inside door. If panel is factory pre-
programmed connect per line and
load directions. If not, document
field-made connections. (back pg)
4. Tighten and then re-tighten lugs to
18 in/lbs.
5 7
low voltage only

Tip: Fault-check each circuit prior to en-

ergizing relays.
10
Low Voltage Connections 9
5. Follow the “System Start-Up and 4 8
Cabling Guide” to make bus con-
nections using Cat. 5 with RJ45s. 3
6. Make-up connections to optional low voltage only
low voltage accessories:
• Modem (see back pg) 1. Blue Box mounting holes (4). 6. Relays (line and load lugs).
• Photocell (next pg)
2. Back plate mounting screws. 7. Dual-voltage (120V or 277V)
• For contact closure devices use (Retaining pin located at power supply.
the optional DI Card. (next pg) bottom, lift up and out to
remove) 8. (Optional) Digital Input Card.
Start Up
7. To start-up the panel as part of a 3. RJ45 sockets for GR 2400 bus. 9. Terminator pins.
new system refer to the “System 10. White door and back of DTC
4. Photocell input (master only).
Start-Up and Cabling Guide”. clock (master panel only).
The Photocell may control any
To start-up the Blue Box in an relay(s) in any panel(s).
LCDBB1416IG03Sept08

existing network, refer to “Adding

New Devices” in the Blue Box LT 5. Optional modem. Analog phone
line connects to RJ-12 socket.
“O&M Manual”.

120
 THE BLUE BOX LT 1416 LT NSTALLATION GUIDE 119

HOOK UP DIAGRAM

CONNECTIONS details
1 For internal wiring connections refer
to The Blue Box LT “O&M Manual”.
1. Relay lugs may hold up to 4#10 or
2 #8 AWG. Neutrals may be run
through The Blue Box LT gutter.
2. Power supply lugs may hold up
to 2#12. Use a dedicated power
2
supply breaker (see below for
3 controlling emergency loads).
3. Ground Lug - for grounding The
Blue Box LT only.
4. 2#18 AWG from photocell in-
7 6 put (master panel only) to out-
door photocell (up to 300 ft). If
longer, use shielded cable.
4 5. Cat. 5 from RJ45 sockets connect
The Blue Box LT to other digital
Slave Blue Box devices (switches, relay panels,
Outdoor etc.). Refer to “System Start-Up
Photocell Cabling Guide” when making
5
these connections, and before
powering-up The Blue Box LT.
6. Wiring details for optional Digi-
Chelsea Digital Switches tal Input Card are shown on the
Slave Blue Box “DI Installation Guide.”
7. Run 4-conductor, flat cable from
modem to an analog phone jack.
Refer “Modem Installation Guide.”

Emergency Loads
To switch emergency on in the event
of a loss of normal power, feed the
power supply with a dedicated nor-
mal-power breaker (left).
To hold relay status (on or off) in the
LCDBB1416IG03Sept08

event of a loss of normal power, feed

The Blue Box power supply with a
dedicated emergency-power breaker
via a server-quality UPS (load is less
than 10 watts).

121
 LCDBB1416IG03Sept08

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122
 ®

CHELSEA (digital switch)

Installation guide
Field programmed switches only

Chelsea switch
Overview
Manual control - override control
Supposing you have a relay panel that turns the lights on
and off automatically with time schedules and a photo-
cell; How would you extend the lighting (override a time
schedule) when staying late? How would you turn the
lights on first thing in the morning?
The Chelsea DigitalSwitch™ can be programmed to
turn relays on and off during business hours and act as
an override switch with a programmable timer value
for after-hours. It can control one relay, or any combina-
tion of relays in any panel(s).
LCDBBCIG03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: 800-345-4448 • www.lightingcontrols.com

123
 CHELSEA DIGITAL SWITCH INSTALLATION GUIDE 122

CHELSEA INSTALLATION INSTRUCTIONS

For field-programmed switches
These instructions supersede the instructions on the side
of the shipping box for any field-programmed Chelsea
DigitalSwitches™.

Preparation

1. Record the serial number of the Chelsea Digital-

Switch™ onto the System Device Schedule located in
the door of the Master Blue Box. You will need this
later for startup and programming. Conduit
SYSTEM DEVICE SCHEDULE: (for Master Panels) Stud

(Master)
(Master)LCP1
LCP1 3 btn sw 6 btn sw LCP 2
Device Type Device Type Device Type Device Type
elec rm Hallway lobby telecom
Location Location Location Location
ce80 8875 4685 af97 Low Voltage Ring

R
Serial # Serial # Serial # Serial #
1 5

E
Address Address Address Address

T
RJ45 Connectors

S
Note the DI-6
serial number and device type on the back of the (In and Out)

A Y
SYSTEM
Device TypeDEVICE SCHEDULE.
Device Type Device Type Device Type
Chelsea DigitalSwitch™

L
LCP 1

M
Connection
Location Location Location Location

N
4055
2. SerialRun
# Cat. 5 to the
Serial low voltage ring or# switch box.

R
# Serial Serial #

O
7 devices using Cat. 5 with RJ45s*.
Daisy-chain

O
Address Address Address Address
3. Once cables have been properly tested*, connect

F L S
them to the RJ45 sockets on the back of the Chelsea

E
Device DigitalSwitch
Type ™
. Device Type Device Type Device Type Terminator: installed on
bus end devices only.

N
Mounting
Location Location Location Location RJ45 sockets for
digital bus.

PA
4. SerialM#ount the Chelsea
Serial #DigitalSwitch Serial
™
like #any standard Serial #
decorator style switch. It fits in any standard Decora-
Address Address Address Address
tor style wall plate (provided by the installer).
Address/Erase
Programming & Commissioning button.
5. Device
OType
nce the systemDevice
has Type
been poweredDevice Type switch
up* begin Device Type
button
Location programming
Locationper the programming
Location section of Location
The Blue Box “O&M Manual”.
Serial # Serial # Serial # Serial #
6. Once programmed, exercise each button on each
Address Address
switch several times to ensure that itAddress
is operating per Address
customer requirements.

LIGHTING CONTROL & DESIGN Serial Number Label

LCDBBCIG03Sept08

905 Allen Ave s Glendale, CA 91201 s Support 800-345-4448 s www.lightingcontrols.com Note: serial number on the
LCDBBIG13Aug08
System Device Schedule.

* Refer to The Blue Box LT “System Start-Up & Cabling Guide”.

BB Panel Schedule.indd 4 8/13/2008 1:37:47 PM

124
 ®

PCO (OUTDOOR PHOTOCELL)

installation guide
outdoor
photocell (PCO)
Overview
Connected to the Master Blue Box LT Connected to Photocell (PCC- Card)
If connected to the photocell inputs of a master Blue If the PCO is connected to a photocell card (PCC1
Box, the PCO must control relays via one or more of or PCC3), it can be programmed to directly switch
the first 8 clock schedules (photocell on, time clock relays on and off at any analog value (1 – 1020) with
off, etc.); each with a unique “on” or “off ” trigger – a programmable time delay, but can not be included
programmable at any analog value (1 – 1020). in a time schedule.
LCDBBPCOIG03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
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125
124 THE BLUE BOX LT PCO INSTALLATION GUIDE

INSTALLATION INSTRUCTIONS

Figue A:
Red conductor to 8v (common)
Blue conductor to “Input”

8v Red conductor

Input Blue conductor

PCO has a 1/2 threaded
nipple, with a locking ring
(if needed).

roof-Mounting the pco

1. Roof mount the PCO “hood up” COMMISSIONING PROCEDURES
with an as unobstructed view of
the north sky as possible. Avoid 1. Read the Light Level from the 2. If the display reads in the range
aiming at any surfaces that might photocell to ensure placement of 0 – 1020, this test is a pass,
reflect sunlight directly into the and functionality. and programming can be
PCO lens. When connected to a Blue started.
Box LT, navigate to :
Connection 3. If display reads “1020”:
2. Connect the PCO to the photo- MAIN MENU > USER MENU Cover PCO lens and check
cell inputs of a master Blue Box LT, > REVIEW SCHEDULE > readings. If readings drop close
a PCC1 or PCC3 photocell card PCELL ON to “0”, adjust the aim of the
with 2#18, up to 300 feet away. When connected to a PCC photocell to avoid direct or
Card, navigate to: reflected sunlight. If display still
Commissioning reads “1020” , check for re-
3. Once the system has been pow- MAIN MENU > USER MENU
versed connection (see Figure
ered up per the steps of the “Sys- > PROGRAM SWITCH >
PHOTOCELL (1 OR 3) > A above).
tem Start-Up & Cabling Guide”,
complete the following test to ver- TRIGGER (1-10) > ON 4. If reading is stuck at “0”, ensure
ify the photocell is connected and MODE/OFFMODE photocell is securely connect-
aimed correctly — facing North. ed. If reading does not change,
Follow the correct commissioning contact LC&D Tech Support.
LCDBBPCOIG03Sept08

steps in the “Commissioning Pro-

cedures”.

126
 ®

the Blue Box LT

™

digital input card

installation guide
(for contact closures)
DIGITAL INPUT CARD Overview
The Digital Input (DI) Card is mounted inside the DI-14: The DI-14 Card has 14 programmable dry-
Blue Box. It provides a gateway for almost any con- contact inputs that can not be “disabled” or “enabled”.
tact closure switch or occupant sensor to control any DI-6: The DI-6 Card has 6 programmable dry-con-
relay(s) in any Blue Box(es). tact inputs that may be “enabled” and “disabled” - par-
The DI Card is available in two sizes and features sets. ticularly useful when connecting occupant sensors.
LCDBBDICIG03Sept08

®
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
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127
126 THE BLUE BOX LT DIGITAL INPUT CARD INSTALLATION GUIDE

MOUNTING INSTRUCTIONS

2 Mounting/Installation
If your DI Card is already installed in the Bue Box LT, skip
6 5 4 this section and proceed to “Connecting Inputs” on the
next page.
To add the DI Card to any Blue Box LT panel:
1 a) De-power the Master Panel (the relays in that pan-
24V
3.3V
Gnd

3 el will automatically close).

b) If not already done, de-power the panel you are
adding the DI Card to (the relays in that panel will
close).
c) Snap the DI Card into the snap track above the
control card in The Blue Box LT.
d) Connect the board-to-board cable to the control
card.
e) Address the new DI Card, per the addressing steps
on the back of this Installation Guide.
f) Once the addressing stepts are complete, make-up
the contact closure connections (next page).

CALLOUT LEGEND:
For a complete parts list refer to The Blue Box LT
O&M Manual.

1. Board-to-board ribbon cable provides power

and digital signal to the DI Card.
3 2. DI Card snaps into existing snap track on The
Blue Box LT panel.
3. 6 or 14 programmable contact closure inputs
(DI-14 shown). Each input is numbered.
4. Ground input. Use only the on-board Ground
Momentary Switch
as common. Do not use Earth Ground!
4 5. 3V output supplies power to LED pilot lights
(LC&D contact closure switches only).
24V 3.3V Gnd

6. 24 V output (500 mA) for occupant sensors.

LCDBBDICIG03Sept08

INPUT X
SPST Switch
Gnd
3.3V
24V

INPUT X
128
 24V

Momentary Switch
Momentary Switch

24V 3.3V Gnd

INPUT X

24V 3.3V Gnd

THE BLUE BOX LT DIGITAL INPUT CARD INSTALLATION GUIDE
Momentary Switch 127
Gnd
24V
3.3V

CONNECTING
MomentaryINPUTS
INPUT X
SPST Switch
Switch INPUT X
SPST Switch
Gnd with LED Pilot Light
3.3V Gnd
24V 3.3V
making connections & switch types 24V
INPUT X
1. Strip the conductor about
3/8”.
INPUT X
2. Using a flathead screwdriverRelay Contact INPUT X Momentary Switch
Gndpush connector release but- Gnd Relay Contact
24Vton until fully disengaged and 24V
Gnd

24V 3.3V Gnd

3.3Vthen gently add or remove 3.3V
24V
wire. 3.3V
SPST maintained Switch or relay
3. After making any connections, tug wire to verify it is Program as “Maintain” switch type.
engaged properly.
NOTE: Contact connectors can only accept (1) #18 AWG INPUT X
INPUT X Momentary
SPST SwitchSwitch
wire. For Ground Connections with more than 1 input: wire INPUT X
nut all ground wires together, connect to a single wire and Gnd
Gnd 3.3V
insert into the appropriate ground (GND) position.
COM

24V 3.3V Gnd

3.3V Gnd
24V COM
24V
Connect contact-closure devices by followingPWR
the typical 3.3V
24V PWR
diagrams. Programming details are found
Occupant in the O&M Man- Momentary DT switch
ual. Refer to the Switch TypeSensor
for programming. Occupant
Program one input as “Momentary On” and the other input as
INPUT X SensorSPDT switch will “positively”

! Never complete a contact closure circuit with “earth “Momentary Off”. The “center-off”
Relay Contact
ground” or risk system failure turn
Gnd
lights on or
INPUT X off.
INPUT X SPST Switch

!
24V
Only the DI-6 supports the enable and disable feature Gnd INPUT X
3.3V
which is particularly important for occupant sensors.
INPUT Y 3.3V
SPDT Switch 24V INPUT Y
Momentary Contact Closure switch SPDT Switch
Gnd
Any3.3Vpush button switch is acceptable as long as it is de- Gnd
signed
24V for low voltage, low current (non-oxidizing contacts) 3.3V
INPUT X
contact circuits. Program as a “Momentary On”, “Momen- 24V INPUT X
Relay Contact
tary Off ”, or “Toggle” switch type.
Gnd
Generic
Gnd occupant sensor
24V
Program
3.3V
3.3V per the “Occupant Sensor” section COMof the O&M
INPUT X
Momentary Switch 24V
Manual. ReferX to www.lightingcontrols.com forPWR
specific oc-
INPUT
cupant sensor manufacturers’ Momentary
hook-up
Occupant Switch
drawings.
Gnd
24V Gnd Sensor
3.3V 24V
3.3V

tch
Momentary switch with LED pilot light INPUT X
INPUT X
Light This only works with LC&D Momentary
contact closure switches. The in-
Switch
put provides a pilot light signal
withwhen
LED operated.
Pilot Light Program as a Gnd
INPUT Y COM
3.3V
“Momentary On”, “Momentary Off ”, or “Toggle” switch type. 24V SPDT Switch
LCDBBDICIG03Sept08

PWR
Gnd
INPUT X Occupant
3.3V
INPUT X
24V Sensor

Gnd
INPUT X
24V Gnd
3.3V 24V INPUT X
3.3V INPUT Y Momentary Switch
SPDT Switch
Gnd
Gnd
24V
3.3V
3.3V
129 24V
AUTO-ASSIGNING ADDRESSES TO A NEW DEVICE
SYSTEM DEVICE SCHEDULE: (for Master Panels Only)
Auto-addressing any newly added digital device (switch, (Master)
(Master)LCP1
LCP1 3 btn sw 6 btn sw LCP 2
relay panel, DI Card, etc.) to any system with a Blue Box Device Type Device Type Device Type Device Type
elec rm Hallway lobby telecom
LT Master Panel is done as follows: Location Location Location Location
ce80 8875 4685 af97

R
1. After completing the product installation guide(s), Serial # Serial # Serial # Serial #
1 3 4 5

E
power up all Slave Panels and active devices first and Address Address Address Address

T
then power up the Master Panel.

S
2. The main screen will be displayed for a few seconds, DI-6

A Y
Device Type Device Type Device Type Device Type

L
after which the screen below will be displayed. TAB LCP 1

M
Location Location Location Location
to YES and press ENTER to auto-address the new

N
4055

R
device(s). If the number of devices detected does Serial # Serial # Serial # Serial #

O
7
not match the number of devices present on the bus,

O
Address Address Address Address

F S
proceed to troubleshooting section.

L
6. DeviceNot sure whatDevice
the Type
serial numbers are? Each device

E
Found 1 device on the system that are Type Device Type Device Type
not used. has a unique Serial Number label or do the following

N
Location Location Location
Would you like to auto-assign them? to “read” the Serial Number from the DTC clock: Location

PA
Serial # Serial # Serial # Serial #
YES / NO / -> 7. Navigate to the “Read Address” screen: USER MENU
Never Ask Again Address
> SETUP MENU Address
> RESTRICTED Address Address
> ADDRESSING-
BUS SCAN > READ ADDRESS. The password to
3. To view address assignment, TAB to YES and press
enter
Type the RESTRICTED
Device Type area is 900001.
ENTER to go to the “Serial Number Scan” screen. Device Device Type Device Type
8. Location
Press the first button
Locationon a switch orLocation
the “Address/Assign”
Location
Assigned 1 device. button. The screen will display the “Address” and “Se-
Review assignments by Serial # Serial # Serial # Serial #
scanning all serial numbers? rial number”. Record this data on the “System Device
Address Address Address Address
Schedule. “ The system is now ready for Error Checking.
YES / NO EXIT repeatedly to navigate to the main menu.
4. If adding more than one device, TAB to “Serial#” field
and SCROLL UP or DOWN to review each device.
LIGHTING
Error Check CONTROL & DESIGN
905 Allen
9. Ave s Glendale,
Navigate to the CA 91201
Error s SupportScreen.
Statistics 800-345-4448 s www.lightingcontrols.com
Use the path
LCDBBIG13Aug08

The “Serial Num- USER MENU > SETUP MENU > RESTRICTED >
SCAN by serial#
Serial# CE80 ber Scan” screen ADDRESSING-BUS SCAN > ERROR STATISTICS.
Adr: 1 displays the serial
Item Type: Switch number, address, 10. Tab to the field that says CLEAR and press ENTER to
Mapd: 6 Btn. Switch and device-type clear errors. If after 3 minutes no errors accumulate
BB Panel Schedule.indd 4 8/13/2008 1:37:47 PM
Address: OK on this screen, your system is stable.
SAVE ADDRESS CHANGES
of any newly
added device(s) 11. If errors continue to accumulate, refer to the “Error
5. Add the new device(s) to the “System Device Sched- Check Troubleshooting” section in the Blue Box LT
ule” on the back of the “Panel Schedule” located inside “O&M Manual” or “System Start-Up Cabling Guide”
The Blue Box LT Master Panel for future programming. or call Technical Support: 1-800-345-4448.
LCDBBDICIG03Sept08

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130
 ®

BLUE BOX LT
™

Occupant Sensors
HOOK-UP AND PROGRAMMING
LCDBBOSHP03Sept08

®
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131
130 THE BLUE BOX LT OCCUPANT SENSORS

INTRODUCTION

The DI inputs of the Blue Box allow a single occupant sensor To program a DI input
to control multiple relays in a variety of different
Momentary scenarios.
Switch 1. Navigate to the DI card inputs: USER MENU > PRO-
Sensors may be disabled by time of day if the DI6 is used, or GRAM SWITCH > SWITCH # > BUTTON #
may be included as part of a combined occupant sensor / 2. Add/delete LOADs (relays) to the input(s) to which
24V 3.3V Gnd

daylight harvesting controls strategy. the occupant sensor(s) are connected. TAB to the
Sensors from any manufacturer are allowed long as they Control Type and set it to “Maintain.”
have an “-R” (relay option) or dry contact output. Hook 3. If more than 8 relays need to be added, create a new
up is similar to a traditional power pack. Occupant sensors Group you will be asked if you wish to press yes to
may be powered by the regulated 24 V dc/300 mA supply accept.
on theINPUT X
DI card.
SPST Switch 4. Navigate back to the DI input and SCROLL to the
Programming an Occupant Sensor Control Type and select the Group that contains the
Gnd
3.3V the occupant sensor has been connected to the
Once relays.
24V
low-voltage dry contact input on the DI card, the input For more information on Groups and Group types, refer
must be programmed. to the relevant section in the O&M.
All occupant sensors have contacts that send a “maintain”
type closure
INPUT Xto the dry contact inputs on the DI card and
therefore must be programmed asRelay
such.Contact
Gnd
24V
3.3V

Refer to the specific hook-up diagrams on the next

pages. Sensors can use the onboard power supply from
INPUT X
the DI card.

Gnd
COM
3.3V
24V PWR

Occupant
Sensor

INPUT X

INPUT Y
LCDBBOSHP03Sept08

SPDT Switch
Gnd
3.3V
24V

INPUT X
Momentary Switch
Gnd
132
24V
 THE BLUE BOX LT OCCUPANT SENSORS 131

NOVITAS BRAND OCCUPANT SENSORS

®

CONNECTION DETAILS
LCDBBOSHP03Sept08

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132 THE BLUE BOX LT OCCUPANT SENSORS

SENSOR SWITCH BRAND OCCUPANT SENSORS

®

CONNECTION DETAILS

LCDBBOSHP03Sept08

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 THE BLUE BOX LT OCCUPANT SENSORS 133

WATTSTOPPER BRAND OCCUPANT SENSORS

®

CONNECTION DETAILS
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134 THE BLUE BOX LT OCCUPANT SENSORS

HUBBELL BRAND OCCUPANT SENSORS

®

CONNECTION DETAILS

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 THE BLUE BOX LT OCCUPANT SENSORS 135

LC&D BRAND OCCUPANT SENSORS

®

CONNECTION DETAILS
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 LCDBBOSHP03Sept08

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 ®

THE BLUE BOX LT

™

CLOCK/PROGRAMMING
NAVIGATION TREE
LCDBBCPNT03Sept08

®
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139
138 THE BLUE BOX LT CLOCK/PROGRAMMING NAVIGATION TREE

User Menu

Manual Override Review Schedule Group Loads Program Switch Setup Menu

Manual Control Schedules Groups Setup Menu Setup More Menu

Maintain +Timer Define Load Button Setup

or Maintain+ Blink for Buttons Menu Restricted
(Password 90001)

Group Parameters Timer Setting Hi Res

Factory
Setup

Addressing- Remote System

Bus Map Relay Properties Owner Settings Erase options
Bus Scan Menu

Erase by Address
Bus Scan Display Relay Parameters Dial up Host Button

Read Address Remote Password Default Names

Board Settings

Address by Erase Relay

Local Network Boards
Button

(TAB up)
Extra Address
Erase Clock
Error Statistics Memory

Timer Settings
Erase By
More Diagnostics Address

Relay Control

Default to Main HIdden Menu

Drop OFF Stats Reset Counts Device Management
Screen (ON/OFF) (YES/NO)
LCDBBCPNT03Sept08

Scan for Zero IDs

Erase All on Power Up
Scan by Serial # AUTO Address
Addressing (YES/NO)

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 THE BLUE BOX LT CLOCK/PROGRAMMING NAVIGATION TREE 139

System Setup
Relay Properties Menu

Addressing-
Relay Parameters Set Time and Date Edit Holidays System Options WHAT and WHEN?
Bus-Scan

Holiday List 1 Keyboard Lock Scheduled Events Bus Scan Display

Board Settings
Holiday List 2 Code

What Controls
Select Location Read Address
Groups
(TAB up)
Extra Address

What Controls
Display Options Addressing Button
Relays
Timer Settings

Daylight Setup List of Cities

Naming Menu Latitude/Longitude

Daylight Param
Switch-Button
Group Names Schedule Names Panel-Load Names
Names
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 ®

THE BLUE BOX LT

™

TECHNICAL GLOSSARY
LCDBBTG03Sept08

®
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142 THE BLUE BOX LT TECHNICAL GLOSSARY

technical glossary

Active Device up one address for every 8 relays it contains. Therefore,

Any device with an onboard transformer, that acts as a a Blue Box LT 16 would take two addresses and the bus
source of electrical energy for the bus. (e.g. Blue Box LT scan display would show “33” on the two consecutive ad-
panel) dresses that are assigned to the panel.

Address Cat. 5
The associated number that identifies a device on the bus. Category 5 (Cat. 5) is a cabling standard used for high
A Blue Box can have up to 127 unique addresses to which speed data transmission. A Cat. 5 cable consists of 4 twist-
devices must be assigned in order for them to work prop- ed pairs of wire to reduce external interference (e.g. from
erly. Each device must be assigned one address (or more line voltage) and is crimped with a RJ 45 connector. There
for relay panels with more than 8 relays and defined in the are two commonly used wiring standards when making up
Bus Map screen. Cat 5. Cables: 568A and 568B. Either one may be used on
a bus as long as it is uniform all along.
Address Collision
When more than one device on the bus is assigned the Conductor
same address; refer to the “System Diagnostics Tools” sec- Any wire. (e.g. the 8 twisted-pair wires inside a Cat. 5 cable
tion in the O&M for information on resolving this issue. are referred to as conductors).

Bus Contact Closure Devices

A system consisting of digital devices communicating over A device (e.g. low-voltage analog switch) that sends a
Cat. 5 cables. command to a dry contact device (e.g. DI card) input.

Bus Map Digital Time Clock (DTC)

Defines the addresses assigned to the devices on the bus; Contains all programming features for the system (Blue
for example, a relay panel must be defined as “Panel LCP Box LT Master Panels)
x”, a 1 button switch as 1-Btn Switch, etc.
Dry Contact
Bus-Powered Device A device that does not require voltage to function; for
Any device that relies on the 12V supplied by the bus example, a low-voltage analog switch tied to a DI card
(supplied by an active device transformer) for its power input when the switch button is pressed, a closed circuit
(e.g. digital switches, and photosensor cards) is formed between the input pin and ground and finally a
signal is sent to perform a certain function.
Bus Scan
Displays the 1 – 127 addresses available on the bus that “EZ”BRAND connector
can be assigned to LC&D digital device An EZ brand connector is an easy-to-use RJ45 connec-
tor used for crimping Cat. 5 cables. Every LC&D device
The first row in first column displays addresses 1 – 10,
is provided with (at least) 2 RJ45 connectors called “EZ
while the first row in the second column displays address-
connectors”. Instructions on how to crimp Cat. 5 cables
es 11 – 20 and so on. A “0” indicates no device has been
with EZ connectors are included in the “System Startup
assigned to the address, or there is a missing device.
and Cabling Guide.”
Any relay panel assigned to an address will display the
LCDBBTG03Sept08

number “3”, for each 8 relays. A switch, PCC or DI card Ground lug
will display a “1”, and a “Link-to-” card such as a “T-Link” Provides a pathway to “Earth-Ground” connection for
or “Link-2-Ethernet” will display a “2”. A relay panel takes high-voltage cabling.

144
 THE BLUE BOX LT TECHNICAL GLOSSARY 143

technical glossary (Continued)

Group Smacker Strip

Any given switch button, DI input or photocell input may Used to send a signal to control relays (Blue Box LT 16 only)
be programmed to control up to 8 relays. If more than 8
relays need to be programmed, or if any relay(s) need to Stable Bus
be controlled by a schedule, a Group must be used. There When all Cat. 5 cables are functioning and have been
are different types of groups available for programming. crimped properly, both terminators are placed at the two
Refer to the “Group Types” and “Groups FAQ” for details. ends of the bus, and all devices are present on the bus and
communicating and functioning properly.
last input override
When a command is sent to the DTC from a device which Terminator
will override any previous commands that may have been It is a jumper that completes a circuit by shorting a resis-
sent to (e.g. if a switch button is used to turn a relay ON tor, placing it in parallel with the rest of the circuit. When
and a photocell is programmed to control the same relay placed on the two end devices of a bus, terminators elimi-
and it detects a high light level, it will override the ON nate signal reflections along the bus. If installed in the mid-
command sent by the switch and turn OFF the lights). dle of the bus, it blocks signals from going past the point
where it is placed. Therefore, extra care must be taken to
LCP not place a terminator anywhere except at the two end
Acronym for “Lighting Control Panel” - may be a master devices on a bus.
or slave panel (e.g. Blue Box LT master or slave panel)
Time Schedule
Load A programming option in the DTC that is used to turn
Any device that requires power to operate (e.g. Lights); relays ON and OFF at specified times. Relays that need to
and since loads are tied in to relays, the terms “load” and be controlled by a schedule must be placed in a group.
“relay” are used interchangeably in this manual.
Transformer
Occupant Sensor Takes the high-voltage at the “primary side” terminals and
Detects a person moving into a space to control relays. “steps-down” the voltage. In the case of a Blue Box LT,
Certain OCC sensors have dual technology sensing for the transformer accepts 120/277 V ac and outputs 20 V
more reliable operation. ac between the outer terminals and 10 V ac between the
center and either of the two outer terminals.
Oscilloscope
An electronic test device that allows signal voltages to
be viewed, usually as a two-dimensional graph of one or
more electrical potential differences (vertical axis), plotted
as a function of time or of some other voltage (horizontal
axis).
Refer to the “Oscilloscope testing procedure” on how to
use an oscilloscope with the bus to detect bad cables,
devices, misplaced or missing terminators.

Photocell
LCDBBTG03Sept08

A device that measures the light intensity entering the

lens; photocells can be wired to the Blue Box LT to con-
trol relays throughout any of the first 8 time schedules.

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144 THE BLUE BOX LT TECHNICAL GLOSSARY

LCDBBTG03Sept08

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 THE BLUE BOX LT TECHNICAL GLOSSARY 145
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146 THE BLUE BOX LT TECHNICAL GLOSSARY

LCDBBTG03Sept08

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 149
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CHELSEA DIGITAL SWITCH

ADVANCED PROGRAMMING GUIDE

151
 CONTENTS

1. Overview…………………………………………………………………… Page 1

2. Important Programming Notes …………………………………………….. Page 2

3. The Switch Setup Screen (First Screen) …………………………………….Page 3

a. 7 On = ______ …………………………………………………….. Page 4

b. 8 On = ______ ………………………………………………….…. Page 5
c. BTN Beep …………………………………………………….……. Page 6
d. Button 1 Address .…………………………………………….……. Page 6
e. 9-14 disable 1-6 ……………………………………………………. Page 7
f. Debounce …….……………………………………….……………. Page 7

4. The Switch Setup Screen (Second Screen) ………………...…………….... Page 9

a. ALL-OFF logic except groups ……..…………………………...…. Page 9

b. LED logic for other buttons ……………..……………………….. Page 10

5. The Button Edit Screen ………………………………………….……….. Page 11

a. LED mode ………………………………………………….…….. Page 11

b. Toggle mode …………………………………………..…….….… Page 12
c. Debounce …………………………………………….…….…..…. Page 12

6. Common Applications …………………………………………………… Page 13

a. How do I disable a particular switch button? ………………… Page 13

b. How do I set a button to give an audible “error” beep when
someone presses a disabled button? …………...................….…. Page14
c. How do I make a switch give an audible alert during a blink
warning period? ………………………………..…………...……Page 15
d. How do I set up a room with a partition, so that the switches
change their function depending on whether the partition is open
or closed? ………………………………………………………… Page 17

152
 Overview
The Chelsea Digital Switch has been updated with several new programmable features.
In summary, they are:

• Programmable Locator LED. Now the LED at the top of

the switch can be programmed to flash during a blink
warning. It can also be activated by Tech Support, for use
in helping the user identify a particular switch.

• The feature allowing button 1 of the switch to

function as the Address button can now be
enabled or disabled in the programming menu.

• Status LED logic is now programmable. The Status LED

above each button can now have one of 4 types of logic
used to determine whether it should be lit or not. For
example, if a button control 6 relays, and 4 of them are
ON, the user can set whether the LED will be ON or
OFF. This logic can be assigned button-by-button or for
all the Status LEDs on the switch.

• Adjustable debounce time. Debounce is how long a switch

button must be held down before it is recognized as a button
press. Debounce can be set for the whole switch, or button by
button.

• Audible beep alert which can be used to notify users during a blink warning period before the
lights shut off. The beep pattern is programmable and can also be used by Tech Support to
help the customer locate a specific switch on the bus.

• Alternate button programming. Chelsea Digital Switches can now have two sets of programming
for six buttons, or three sets of programming for three buttons. Each set of programming can be
activated by a time schedule, override switch, etc. This feature is useful for setting buttons to
function differently at different times of day, or in partitionable rooms where a switch functions
differently depending on whether a partition is open or closed.

• Programmable Toggle logic. If a button controls multiple relays, it is important to synchronize

them when toggling them all at once. If some of the relays are ON and some are OFF, it is now
possible to specify whether the switch syncs them all ON or all OFF when toggling.

• Enabling and disabling individual switch buttons is still an available feature carried over from the
previous version of the Chelsea. Enabling and disabling buttons can now be allowed or not
allowed for a switch in the programming menu. Additionally, disabled buttons can be set to
trigger a rapid series of beeps when pressed, so the user knows that the button has specifically
been disabled by programming.

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 ! Important Programming Notes !
To use the advanced features of the new Chelsea Digital Switch, please ensure the
following:

• Always set a Chelsea Digital Switch as a “14 Button Switch” in the Panel/Switch
Types screen. This is true even if the switch only has 1, 2 or 3 physical buttons.
The reason for this is because advanced programming requires setting parameters
for buttons 7-14, even though they are “virtual” buttons and not physically present
on the switch.

• To access advanced programming functions of the Chelsea Switch, you must have
DTC clock version 4.48 or later.

• To use advanced programming functions of the Chelsea Switch, you must be

using switch firmware 1.12 or later. The version of firmware a switch has is
displayed in the lower left corner of the SETUP screen for that switch.

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 The Switch Setup Screen
(First Screen)

To access the screen, navigate to the switch you want to program, highlight the word
SETUP and press ENTER.

USER MENU → PROGRAM SWITCH → SWITCH# → SETUP

The Switch Setup Screen has a number of parameters which can be set as shown
below.

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Table 1.1
7 ON = _____________
This field determines what happens when the LED status light associated with
Button 7 is turned ON.

Generally if the button is set to ON MODE and the relay it controls is

ON, the LED will turn ON as well. This also applies to the opposite
mode: if the button is set to OFF MODE and the relay it controls is OFF,
the LED will also generally turn ON (the only exceptions are if the logic
of the Status LEDs are changed as described later in this guide).

Note that there is no physical Button 7 or physical Status LED for Button 7 on a
Chelsea Digital Switch. So Buttons 7-14 are virtual buttons used for
programming purposes only, and the associated Status LEDs are also just virtual
placeholders that are turned on and off. Usually, virtual Buttons 7 and 8 will be
set to operate a spare relay or an empty relay position rather than a relay with a
connected load.
Possible Values Result
Normal None. Setting this value to “Normal” in a Chelsea Digital
(default value) Switch means that nothing will happen when the virtual
LED associated with Button 7 is turned ON.
BTS 1-6 < 9 - 14 When the virtual LED associated with Button 7 is ON, the
programming for buttons 1-6 will be replaced with the
programming for buttons 9-14. When the LED is OFF,
buttons 1-6 will revert to their original programming.
BTS 1-3 < 9 - 11 When the virtual LED associated with Button 7 is ON, the
programming for buttons 1-3 will be replaced with the
programming for buttons 9-11. When the relay is OFF,
buttons 1-3 will revert to their original programming.
BEEP When the virtual LED associated with Button 7 is ON, the
switch will make a beeping sound. Highlighting the word
BEEP and pressing ENTER will allow you to set the beep
pattern.
Locator When the virtual LED associated with Button 7 is ON, the
switch’s Locator LED will flash. Highlighting the word
Locator and pressing ENTER will allow you to set the
flash pattern.
Disable 1-6 When the virtual LED associated with Button 7 is ON,
buttons 1-6 will be disabled.
Disable 1-14 For a Chelsea Switch, this has the same effect as “Disable
1-6”. However, when programming a Digilink, it allows
all Digilink inputs (1-14) to be disabled.
Beep + Locator When the virtual LED associated with Button 7 is ON, the
switch will make a beeping sound and the Locator LED
will flash. Highlighting the words Beep + Locator and
pressing ENTER will allow you to set the beep and flash
pattern.

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Table 1.2
8 ON = _____________
This field determines what happens when the LED status light associated with
Button 8 is turned ON.

The operation of this field is almost identical in operation to the “7 ON = __”.

The parameters are the same as those given in Table 1.1 above with a few
exceptions noted below.

In general, the BTS 1-6 < 9 – 14, BEEP, Locator, and Disable 1-6 functions
assigned to “7 ON = __” take priority over their “8 ON = __” counterparts.

For example:
If a switch is set to “7 ON = BEEP” and “8 ON = BEEP” and both virtual LEDs
are ON, the switch will have the BEEP pattern of “7 ON = BEEP” not the
pattern of “8ON = BEEP”.

If a switch is set to “7 ON = LOCATOR” and “8 ON = BEEP” and both virtual

LEDs are ON, the switch will blink the Locator LED and also beep.
Possible Values Result
Normal None. Setting this value to “Normal” in a Chelsea Digital
(default value) Switch means that nothing will happen when the virtual
LED associated with Button 8 is turned ON.
BTS 1-6 < 9 – 14 These settings operate in the same way as they are
BEEP described in table 1.1
Locator
Disable 1-6
BTS 1-3 < 12-14 When the virtual LED associated with Button 8 is ON, the
programming for buttons 1-3 will be replaced with the
programming for buttons 12-14. When the relay is OFF,
buttons 1-3 will revert to their original programming.
Disable 9-14 Used only in Digilinks to disable higher numbered inputs.

** “8 ON = __” Does not have a “Beep + Locator” option.

Important Note On Using “7 ON = 1-3
9-11” and “8

ON = 1-3
12-14” in tandem:
If the switch has the settings “ 7 ON = 1-3 ← 9-11” and
“ 8 ON= 1-3 ← 12-14”, and the relays operated by Button 7
and Button 8 are BOTH ON, then buttons 1-3 will execute both sets of
programming (9-11 and 12-14) at the same time. Please ensure that
there is no conflicting programming as the behavior of the loads
controlled will become unpredictable. An example of conflicting
programming is Button 9 turning ON a relay and Button 12 turning
OFF a relay.

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Table 1.3
BTN Beep
This field determines when the switch’s buttons will cause a beeping sound.

Possible Values Result

OFF There will never be a beeping sound when a button is
pressed. Note that any beep alerts set to take place using
the “7 On = _____” or “8 On = _____” fields will still be
executed. Setting “BTN Beep” to OFF only effects normal
button presses, not special alerts.
PUSH only The buttons on the switch will beep when pressed. (Note
that operating the same load(s) from another location will
not cause the beep) There will be no rapid series of beeps
when a disabled button is pressed, it will simply cause the
standard single beep.
Disable Buttons will not normally beep when pressed; however, if
the user presses a disabled button, the switch will give a
rapid series of beeps to alert them that the button will not
operate as expected because it has been disabled.
Push + Disa. Buttons on the switch will give a standard single beep
when pressed. If the user presses a button that has been
disabled, the switch will alert them with a rapid series of
beeps.

Table 1.4
Button 1 Address
This field determines whether Button 1 on the switch will act as the Address
Button (meaning that the user can set and read the address by pushing Button 1
instead of having to press the Address Button on the back of the switch). This
is generally set to “Y” (Yes) except on Digilinks, which are always set to “N”.

Possible Values Result

Y Yes, Button 1 will function as the Address Button
N No, Button 1 will not function as the Address Button

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Table 1.5
9-14 disable 1-6
Determines whether “virtual” buttons 9-14 can be used to disable buttons 1-6
on the physical switch. For example, if virtual Button 9 is set to turn on relay
X, then any time relay X is ON, the physical Button 1 will be disabled. If relay
X is OFF, then Button 1 will function normally.

The same correspondence exists between virtual Button 10 and physical Button
2, virtual Button 11 and physical Button 3, etc.

Possible Values Result

Y Yes, virtual Buttons 9-14 will enable and disable physical
Buttons 1-6. This is the normal, default setting. However,
there are times when you should not use this functionality
as described below.
N No, virtual Buttons 9-14 will NOT enable and disable
physical Buttons 1-6. You should use this option in the
following circumstances:

• If you have set up alternate button programming

sets (e.g. you have set “7 ON = BTS 1-6 < 9 – 14”
as described earlier in this section).
• If you are already using other button disable
settings, such as “7 On = Disable 1-14” described
earlier in this section.
• If you are programming a Digilink, which uses any
of the inputs between 9 and 14.

Table 1.6
Debounce
This field sets how long the user must hold down a switch button before the
system recognizes the button press. If the button is released before the full
duration of the debounce time, the press is ignored and no programming is
executed.

Possible Values Result

By Button This value means that the Debounce will be set
individually for each individual Button in the Button’s
“Edit” menu. There will be no overall setting for all the
buttons on the switch.

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Selectable value These are global values that apply to all of the switch’s
between 0.05 sec buttons. Whatever value is selected will be how long the
and 5.00 sec. user must hold down the button before its programming is
activated. For example, setting the value to 2.00 sec means
that when the user first presses a button on the switch,
nothing will happen. However, if the user continues
holding down the button for at least 2 full seconds, the
button will then operate the relays it was set to control.
The default setting is 0.05 sec. Debounce affects button
beeping the same way it affects programming.

Important Note on Debounce:

Use debounce carefully since a long debounce time can make it seem
like a switch is not working. If a switch does not appear to function,
always check for a debounce setting before assuming that the switch
is bad.

MORE
To go to the second page of switch setup options, highlight the field “MORE”
and press ENTER.

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160
 The Switch Setup Screen
(Second Screen)

The Switch Setup Screen has additional parameters shown on a second page in the
DTC screen. Along with the Debounce option on the first screen, these parameters
are global in that they override any local LED logic set in the EDIT menu and apply
to all buttons on a switch. These parameters can be set as shown below:

Table 2.1
ALL-OFF logic except groups
Sets the logic which determines if the Status LED over each of the switch’s
buttons should be on or off. This field applies only to buttons programmed in
OFF MODE. If a button only turns lights OFF, then it is customary to have the
Status LED be lit when all of the controlled relays are in the OFF position.
However, there are some applications when different logic is needed.

Possible Values Result

AND The Status LED on a button set to OFF MODE will light
up only if ALL the controlled relays are OFF. (This is also
called “True” switch logic and is usually used for buttons
in OFF MODE or MIX MODE).
OR The Status LED on a button set to OFF MODE will light
up if one OR more of the controlled relays are OFF.
OR-INVERT The Status LED on a button set to OFF MODE will light
up only if NONE the controlled relays are OFF (i.e. they
are all ON)
AND-INVERT The Status LED on a button set to OFF MODE will light
up if ONE OR MORE of the controlled relays are ON.
Therefore, if they are all OFF, the LED light will not be lit,
but if at least one relay is ON, the LED will be lit.

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161
Table 2.2
LED logic for other buttons
Sets the logic which determines if the Status LED over each of the switch’s
buttons should be on or off. This field applies to buttons in TOGGLE MODE,
ON MODE, MAINTAIN, MIX MODE (all other settings except OFF MODE).

Possible Values Result

AND The Status LED on a button will light up only if ALL the
controlled relays are ON. In MIX MODE the LED will be
lit only if ALL the controlled relays are in the state (ON or
OFF) the button was programmed to set them to. (This is
also called “True” switch logic. It is usually used for MIX
MODE or OFF MODE buttons.)
OR The Status LED on a button will light up if ONE OR
MORE of the controlled relays are ON. In MIX MODE
the LED will be lit if ONE OR MORE of the controlled
relays are in the state (ON or OFF) the button was
programmed to set them to. (Usually this logic in used for
buttons that are set to something other than MIX MODE or
OFF MODE).
OR-INVERT The Status LED on a button will light up only if NONE of
the controlled relays are ON (i.e., they are all OFF). In
MIX MODE the LED will be lit only if NONE of the
controlled relays are in the state (ON or OFF) the button
was programmed to set them to (they must all be in the
opposite state from what the button was assigned to set
them to).
AND-INVERT The Status LED on a button will light up only if ONE OR
MORE of the controlled relays are OFF. In MIX MODE
the LED will be lit only if ONE OR MORE of the
controlled relays are in the opposite state from what the
button was programmed to set them to.

BACK TO PAGE 1
To go back to the first page of switch setup options, highlight the field “BACK
TO PAGE 1” and press ENTER.

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 The Button Edit Screen

To access the Button EDIT screen, navigate to the switch button you want to
program, highlight the word EDIT and press ENTER. These parameters are local,
meaning that they apply to each individual button only, not the entire switch.

USER MENU → PROGRAM SWITCH → SWITCH# → BUTTON# → EDIT

The Button Edit Screen has the parameters which can be set as shown below.

Table 3.1
LED mode
Sets the logic which determines if the Status LED over the button should be on
or off.

The operation of this field is identical in operation to the SETUP second screen
LED logic except these settings apply only to a single button because they are
local settings. The parameters are the same as those given in Table 2.1, if OFF
MODE is used, or Table 2.2 above for all other modes.

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Table 3.2
Toggle mode
Sets how the button synchronizes multiple relays when toggling. For example,
if a switch button is toggling relay X, relay Y and relay Z, the user can decide
what happens when relay Y is ON and relays X and Z are OFF. The least
desirable behavior is to have the relays just flip states so that no matter how the
TOGGLE button is pressed either, relay Y is OFF and relays X and Z are ON,
or relay Y is ON and relays X and Z are OFF. This would make it impossible
to get all the lights ON or OFF at the same time. Therefore, one of the two
types of logic below is used to sync the relays that are being toggled by a
switch button.

Possible Values Result

OFF if any load If any ONE OR MORE of the relays controlled by the
ON switch button are ON, then pressing the toggle button will
turn ALL relays OFF.
OFF only if all If the relays are out of sync, the toggle button will first
ON bring them all ON. Then, once they are all ON, pressing
the toggle button again will turn them all OFF.

Table 3.3
Debounce
Works in the same manner as SETUP menu Debounce except it applies to
individual buttons, has no “By Button” option, and only appears on screen if
SETUP menu Debounce is set as “By Button”.

Important Note on Debounce:

Use debounce carefully since a long debounce time can make it seem
like a switch is not working. If a switch does not appear to function,
always check for a debounce setting before assuming that the switch
is bad.

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 Common Applications

Question:

How do I disable a particular switch button (for example, button 3)?

Answer:

1. Go to the Program Switch screen and select the switch you want to disable the
button for. For physical Button 3, you would use the virtual Button 11 to enable
and disable it. (See table 4.1 below)

Button Enable / Disable Relationships

This virtual button: Disables this physical button:
9 1
10 2
11 3
12 4
13 5
14 6

2. Select Button 11 on the Program Switch Screen. Assign a spare relay or empty
relay position to this button and make sure it is set to ON MODE.

3. Back on the Program Switch screen, again select the switch you want to program
and then go to the “SETUP” field and press ENTER.

4. Ensure that the option “9-14 disable 1-6” is set to “Y” (for Yes). See table 1.5
earlier in this guide for details.

5. Now, when you turn the relay you selected in step 2 above ON, Button 3 will be
disabled and not function. When you turn the relay OFF, Button 3 will function
again. Remember, you can turn this relay ON and OFF using schedules, groups,
other switches, or even photocells that pass a certain light level!

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Question:

How do I set a button to give an audible “error” beep when someone presses a
disabled button?

Answer:

It can be very frustrating or confusing to a user when they press a button that usually
turns certain lights on and off, only to find that nothing is happening. Sometimes, this
happens when a switch button has been programmed to be disabled, but the user has no
way of knowing. Therefore, it is helpful to set up the switch to make and “error” beep if
the user presses a disabled button. To do this, follow the steps below:

1. Go the Program Switch screen and select the switch you want to set up the error
beep for.

2. Highlight the “SETUP” field and press ENTER

3. Set the option labeled “BTN Beep” to “Disable”. This causes the switch to emit
a rapid series of beeps if a user presses a button that has been disabled. See Table
1.3 earlier in this guide for details.

4. If you want the switch to make a standard beep whenever an enabled button is
pressed, and a rapid series of beeps when a disabled button is pressed, set the “BTN
Beep” option to “Push + Disa.” See Table 1.3 earlier in this guide for more
details.

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Question:

How do I make a switch give an audible alert during a blink warning period?

Answer:

It is a fairly common request to have users notified a few minutes before the lights turn
off, so they have an opportunity to override the offsweep. Instead of having the lights
flash, or a separate horn installed, the new switch can be set to generate a beeping alert
pattern as a warning that the lights will be shutting off shortly. To do this:

1. First, create a Maintain+Blink Group containing the relays that are going to be
turned on and off with the schedule. You can use any Timer and Blink Warning
settings you wish; typical values are a 2 hour Timer and a 5 minute Blink
Warning. Make sure that you include one spare relay or empty relay position in
the group. This will be the “Horn Driver relay”

2. Once you have created the Maintain + Blink Group above, go to the Relay
Properties Screen for the individual relay you set as the “Horn Driver relay”.
Change the Horn Driver Mode parameter to “Y” (for Yes). Set the Horn One
parameter to the length of time you want to audible alert to last. Then exit out of
the screen.

3. (Optional) You will probably want to set the “No Blink” option to “Y” (for
Yes) for all the relays in the Group to prevent them from flashing OFF and
then ON again when the Blink Warning starts. Sometimes, the flash is
desirable, but since there is going to be an audible alert, the lights blinking
will most likely not be necessary.

4. Now create a new MOMENTARY ON Group that contains all the same relays as
your group from step 1 above, including the Horn Driver Relay.

5. Assign the MOMENTARY ON Group to the switch and button that you want to
behave as an override, to turn the lights on or keep them on at the end of the
schedule / blink warning period.

6. For the same switch, go to the PROGRAM SWITCH screen, select the switch,
highlight the “SETUP” field and press ENTER.

7. On the switch SETUP screen, set either the “7 ON =” or “8 ON =” field to the

option “BEEP”. (See Tables 1.1 and 1.2 earlier in this guide for full details).

8. In the Program Switch Screen, set either Button 7 or Button 8 (depending on

which you selecting in the previous step) to ON MODE, and have it associated
with the relay you set earlier as the Horn Driver Relay.

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9. That’s it. Now, at the end of the schedule, the switch will start beeping to signal
that the lights will be shutting off shortly. If the user presses the override button
on the switch, the beep alert will stop, and the lights will stay on for an additional
2 hours (or whatever duration the Timer was set to in the Maintain+Blink Group).
At the end of this 2 hour period, the switch will start beeping again to signify the
lights will be shutting off, at which point the user can override the shutoff again
and start the cycle over again, or simply let the lights go off.

** The procedure just described can also be used to make the Locator LED blink. Just
replace “BEEP” in step 7 with “Locator”.

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Question:

How do I set up a room with a partition, so that the switches change their function
depending on whether the partition is open or closed?

Answer:

Let’s take a scenario where a room has a switch on the north wall, a switch on the south
wall, and a partition that can separate the room into a north half and a south half.

Each switch has an ON button and an OFF button. When the partition is open, the
switches control both sets of lights in the room (North and South lights, i.e. Relay 1 and
Relay 2). When the partition is closed, the South Switch turns on and off the South
Lights (Relay 2) only, and the North Switch turns on and off the North Lights (Relay 1)
only.

Here are the steps to accomplish this:

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1. For the North Switch, program Button 1 to ON MODE for Relay 1 and Relay 2.
Program Button 2 to OFF MODE for Relay 1 and Relay 2.

2. While still in the Program Switch screen for the North Switch, set Button 9 to ON
MODE for Relay 1 only. Program Button 10 to OFF MODE for Relay 1 only.

3. Program Button 7 to ON MODE for a spare relay or empty relay position (Relay
X).

4. Now go to the North Switch “SETUP” screen and set the parameter “7 ON =” to
the option “BTS 1-6 < 9 – 14”. (See Table 1.1 for full details).

5. Now, for the South Switch, program Button 1 to ON MODE for Relay 1 and
Relay 2. Program Button 2 to OFF MODE for Relay 1 and Relay 2.

6. While still in the Program Switch screen for the South Switch, set Button 9 to ON
MODE for Relay 2 only. Program Button 10 to OFF MODE for Relay 2 only.

7. Program Button 7 to ON MODE for the same spare or empty relay position you
used in step 3 above (Relay X).

8. Now go to the South Switch “SETUP” screen and set the parameter “7 ON =” to
the option “BTS 1-6 < 9 – 14”. (See Table 1.1 for full details).

9. Set another switch button, or a Digilink with an input coming from a partition
sensor, to turn ON Relay X when the partition is CLOSED and turn OFF Relay X
when the partition is OPEN.

10. That’s it. When the partition is closed or separate switch button is pressed, each
switch will only control the lights in their half of the room. When the partition is
open, each switch controls ALL of the lights in the room.

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ADDITIONAL BLUE BOX RESOURCES
(hyperlinks provided below)

Software Guides

Unity GX2™ Customer Submission Guide

Unity 2.2 Software
Unity VClock Software
BACnet Configurator

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