Broadcast Tools Box O' Relays 6 User manual

Installation and Operation Manual
PROBLEM SOLVED
Due to the dynamic nature of product design, the information contained in this
document is subject to change without notice. Broadcast Tools, Inc., assumes no
responsibility for errors and/or omissions contained in this document. Revisions
of this information or new editions may be issued to incorporate such changes.
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Copyright® 1989 - 2023 by Broadcast Tools,Inc. All rights reserved.
No part of this document may be reproduced or distributed without permission.
Visit www.broadcasttools.com for important product update information.
Manual update: 5/17/2023
If you need a firmware upgrade, contact Broadcast Tools®
No part of this document may be reproduced or distributed without permission.
ALL SPECIFICATIONS AND FEATURES FOR THIS PRODUCT ARE SUBJECT TO
CHANGE WITHOUT NOTICE
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Box O’ Relays 6
Six channel optically isolated relay module.
INC
®

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BOR-6 Installation and Operation Manual
Table of Contents
Section Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page #
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Who to Contact for Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation/Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting the BOX O’ RELAYS 6 . . . . . . . . . . . . . . . . . . . . . . 5
Surge Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UPS standby power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Terminal Block Wiring Instructions . . . . . . . . . . . . . . . . . . . . . 6
Terminal Block Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . 6
RJ45 Jack Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Optically Isolated Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Input Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting to GPOs from WheatNet Blade . . . . . . . . . . . . . . . 8
Connecting to GPOs from an GPIO xNode . . . . . . . . . . . . . . . 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front and rear panel drawings . . . . . . . . . . . . . . . . . . . . . . . . Appendix
Connector layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix
Fractional schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix
WEBSITE:
Visit our web site for
product updates and
additional information.
2
CONTENTS

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BOR-6 Installation and Operation Manual
INTRODUCTION
INTRODUCTION
Thank you for your purchase of the BOX O’ RELAYS 6 optically isolated relay
interface, which we will refer to throughout the manual as the BOX O’ RELAYS 6.
We’re confident this product will give you many years of dependable service. This
manual is intended to give you all the information needed to install and operate the
Broadcast Tools® BOX O’ RELAYS 6.
SAFETY INFORMATION
Only qualified technical personnel should install the BOX O’ RELAYS 6. Any
attempt to install this device by a person who is not technically qualified could result
in a hazardous condition for the installer or other personnel or damage to the BOX
O’ RELAYS 6 or other equipment. Please ensure that proper safety precautions have
been taken before installing this device. If you are unfamiliar with this type of equip-
ment, please contact a properly qualified engineer to handle the installation and set-
up of BOX O’ RELAYS 6. Broadcast Tools, Inc., is unable to support NON-
Broadcast Tools software, hardware, or NON-Broadcast Tools
computer/hardware/software problems. If you experience these problems, please
research your hardware/software instruction manuals, or contact the manufacturers
technical support department.
WHO TO CONTACT FOR HELP
If you have any questions regarding your product or you need assistance, please con-
tact your distributor from whom you purchased this equipment. If you would like
more information about BROADCAST TOOLS® products, you may reach us at:
Broadcast Tools, Inc.
131 State Street
Sedro-Woolley, WA 98284-1503 USA
Voice: 360.854.9559
Fax: [phone]
Internet Home Page: www.broadcasttools.com
E-mail:[email protected]
THANK YOU FOR CHOOSING
BROADCAST TOOLS® BRAND PRODUCTS!
CAUTION!
Broadcast Tools®
Products, as with any
electronic device, can
fail without warning.
Do not use this product
in applications where a
life threatening condition
could result due to failure.
NOTE:
This manual should be
read thoroughly before
installation and operation.
WEBSITE:
Visit our web site for
product updates and
additional information.
Broadcast Tools is a Veteran Owned Business
Designed, Assembled and Supported in WA State, USA

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BOR-6 Installation and Operation Manual
OVERVIEW
Product Overview
The BOX O’ RELAYS 6 is a six channel optically isolated relay module, following
in the footsteps of the original Box O’ Relays 4 from over twelve years ago. The new
design of the BOX O’ RELAYS 6 is perfect for converting GPO outputs from AoIP
systems and other devices to dry contact closures. All six SPDT relay outputs are
available via pluggable screw terminal block connectors for ease of installation. The
BOX O’ RELAYS 6’s SPDT relays are rated up to 30V at 1 amp, perfect for con-
trolling on-air lights, LED indicators, and other externally powered devices. All six
optically isolated inputs are available via an RJ45 input jack as well as pluggable
screw terminal block connectors and can be configured via to interface with dry con-
tact closures, open collector outputs, as well as voltages from 3.3-24 VDC, or 25-48
VDC via an external resistor.
Convert Wheatstone Blade Logic Outputs (GPOs) to Contact Closures
The RJ45 input jack on the BOX O’ RELAYS 6 is compatible with the RJ45 logic
jacks on Wheatstone Blades. The BOX O’ RELAYS 6 allows the user to easily con-
vert six WheatNet Blade logic outputs (GPOs), on one Cat5/6 cable to 6 isolated
SPDT dry contact closure outputs on pluggable screw terminal blocks. Because the
Logic ports on Blades can be switched between inputs and outputs in software, it’s
important that the logic port connected to the BOX O’ RELAYS 6’s Input jack be
configured as outputs.
Convert GPIO xNode General Purpose Outputs (GPOs) to Contact Closures
Using the optional Broadcast Tools COA-15/RJ, DB-15 to dual RJ45 adapter you
can easily interface an xNode GPIO port with the BOX O’ RELAYS 6 via standard
Cat5/6 cabling converting the port’s 5 GPOs to 5 isolated SPDT dry contact closure
outputs on pluggable screw terminal blocks. The COA-15/RJ also breaks out the
GPIs to their own RJ45 jack for ease of installation.
Inspection
Please examine your BOX O’ RELAYS 6 carefully for any damage that may have
been sustained during shipping. If any damage is present, please notify the shipper
immediately and retain the packaging for inspection by the shipper. The package
should contain the BOX O’ RELAYS 6, and a 9 VDC power supply. Manuals can
be downloaded from our web site.
WEBSITE:
Visit our web site for
product updates and
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BOR-6 Installation and Operation Manual
OPERATION
Installation/Operation
The BOX O’ RELAYS 6 provides an easy way to convert GPOs from an AoIP sys-
tem to isolated SPDT relay contact closures. All six of the GPO relay trigger inputs
on the BOX O’ RELAYS 6 are designed to be controlled by GPO outputs from an
AoIP system but will work equally well with other devices. Each trigger input is
opto-isolated and configured to be controlled from a dry contact closure or open col-
lector output.
For example: pulling input 1 low (to ground) and holding it there will activate
(close) the K1 relay output and light the K1 indicator LED, they will stay active as-
long-as the input 1 is held low. Releasing the trigger input back to its normal high
level will de-activate (open) the relay and turn the LED off. The GPO relay trigger
inputs are connected in parallel to the RJ45 jack J2 as well as to pins on the TB1-3
pluggable screw terminal block connectors.
The BOX O’ RELAYS 6 connects with your equipment through a standard RJ45
Cat5/6 patch cable and/or six removable euro-block screw terminals. Follow the
labels in this manual and on the circuit board for all connections.
Mounting the BOX O’ RELAYS 6
Mounting options for the BOX O’ RELAYS 6 are numerous: The plastic enclosure
can be screwed, cable tied or Velcroed to most surfaces. The optional RA-1 Rack
Shelf may be used to rack mount up to three units.
Surge Protection
The BOX O’ RELAYS 6 has built-in resistance to voltage changes; we recommend
that you use a power surge protector or line conditioner on the incoming AC line.
Lightning strikes and/or other high voltage surges may damage your BOX O’
RELAYS 6 and connected equipment if it is not properly protected. For lightning
protection devices, check out www.polyphaser.com and www.itwlinx.com.
UPS Standby Power System
We recommend that you power your BOX O’ RELAYS 6 from an uninterruptable
power supply (UPS) system. A UPS, like the BE600M1 from APC, helps minimize
the risk to the
BOX O’ RELAYS 6 and provides power during a power outage.
Power
Connect the 2.1mm barrel type power connector into the unit and the 9 VDC universal
switching power supply with domestic AC connector into a 120 Vac 50-60 Hz power
source.
NOTE:
Never use any type of
power supply other
than the specified/sup-
plied power supply.
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BOR-6 Installation and Operation Manual
OPERATION
LED Indicators
• “PWR” Power LED: Illuminates when power is applied. (Green)
• “K1-K6” Relay LEDs: Lit when each respective relay output is active.
(Yellow, Red, Green, Yellow, Red, Green)
Terminal Block Wiring Instructions:
The BOX O’ RELAYS 6 interfaces to external equipment through removable euro-
block screw terminals. The terminals accommodate wire sizes from 16 - 28 AWG
solid or stranded wire. Before installing a wire, remove the euro-block screw termi-
nal plug and turn each capture screw fully counterclockwise. Strip each conductor
to a length of 0.25” and insert the conductor fully into the terminal. Turn the capture
screw fully clockwise to secure the conductor.
Terminal Block Connector Pinouts
Input/Relay 1 (TB1 Bottom)
Optically isolated Input 1 K1 Relay Output
Input/Relay 2 (TB1 Top)
Optically isolated Input 2 K2 Relay Output
Input/Relay 3 (TB2 Bottom)
Optically isolated Input 3 K3 Relay Output
Input/Relay 4 (TB2 Top)
Optically isolated Input 4 K4 Relay Output
Input/Relay 5 (TB3 Bottom)
Optically isolated Input 5 K5 Relay Output
Input/Relay 6 (TB3 Bottom)
Optically isolated Input 6 K6 Relay Output
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BOR-6 Installation and Operation Manual
OPERATION
RJ45 Jack Pinout (J2):
Function: Wire Pair: RJ45 Pins:
Ground White/Orange 1
Input 1B Orange/White 2
Input 2B White/Green 3
Input 3B Green/White 6
Input 4B White/Blue 5
Input 5B Blue/White 4
Input 6B White/Brown 7
+5V In* Brown/White 8
* See JP7 Power Jumper Configuration
Optically Isolated Inputs
Each optically isolated input has a terminal labelled “xA” and a terminal labelled
“xB”. Inputs can be configured for either wet or dry operation via internal jumpers. The fac-
tory default configuration is dry, where the “A” side of the input is ground (GND) and the
“B” side of the input is the cathode (-) of the opto-isolator. In this configuration, 5V is
applied internally to the anode (+) of the opto-isolator. This configuration is best for inter-
facing external dry contact relay outputs, switches, and open collector outputs.
In the “wet” configuration an external voltage must be applied to the input to acti-
vate the opto-isolator. When configured for wet operation the “A” side of the input is the
anode (+) and the “B” side of the input is the cathode (-). This configuration is best where
full isolation is preferred or when interfacing with external voltage/logic level outputs.
Each optically isolated input is connected through an internal 2.2k ohm series cur-
rent-limiting resistor directly to an opto-coupler circuit so no external resistor is necessary if
the input voltage is between 3.3 VDC and 24 VDC. Higher DC voltages, from 25 to 48 VDC,
can be used but must be reduced with an additional external resistor of the appropriate value
and power rating to limit the input current.
Here is how to calculate the value and power rating of an external current limiting
resistor for DC voltages up to 48 VDC: Each optically isolated input has an internal 2.2K
ohm series resistor. The opto-isolator works well with an input current of 9 mA and has a
voltage drop of around 1.2V. With this information we can determine the correct external
series current limiting resistor value needed for other voltages using the equation:
R = ((Vin-1.2)/0.009)-2200
Where:
R = External resistor value required
Vin = Desired input voltage
1.2 V = Forward voltage drop of the LED in the opto-isolator
0.009 A = Nominal LED current
2200 ohms = Internal resistor
For example:
To connect a 48 VDC signal voltage to an input on the BOX O’ RELAYS 6 in “wet” con-
figuration, the completed equation for the external resistor value would be:
R = ((48-1.2)/0.009)-2200 = 3000 ohms
To calculate the power dissipated by the external resistor, the equation would be:
P = I x I x R, so the resistor must be at least .009 x .009 x 2200 = 0.243 Watts,
we recommend the use of a 1/2 Watt rated resistor.
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BOR-6 Installation and Operation Manual
OPERATION
Input Jumper Configuration
Each optically isolated input is equipped with an internal four-position header and
two jumpers. The headers are labeled JP1-6. The factory default configuration is for
a DRY input (relay contact, switch, open collector) with a jumper over pins 1 & 2
and another jumper over pins 3 & 4. To change the input to WET (user supplied volt-
age between 3.3-24 VDC, or 25-48 VDC with an external resistor), remove both
jumpers and place ONE jumper over pins 2 & 3.
NOTE: When using this product with WheatNet Blade or GPIO xNode GPO’s, ALL
inputs MUST be configured for DRY operation.
JP7 Power Jumper Configuration
From the factory the BOX O’ RELAYS 6 is powered from the supplied external 9
VDC power supply. Alternatively, the internal JP7 header/jumper allows you to
power the BOX O’ RELAYS 6 from a user supplied external +5 VDC sourced via
pin 8 (+5V IN) on the RJ45 jack (J2.) See the component layout drawing for more
information.
Connecting to GPOs from a WheatNet Blade:
1. Configure one of the Logic ports on your Blade so that all six logic pins on the
port are configured as GPOs.
2. Use a standard Cat5 or Cat6 Ethernet patch cable to connect the RJ45 jack on the
BOX O’ RELAYS 6 (J2) to the Logic port on the Blade.
3. Wire the devices you wish to control (on-air lights, LED indicators, etc.) to the
K1-K6 dry contact closure relay outputs on the 5-position terminal blocks on the
top and bottom of the headers labelled TB 1-3.
4. Apply power to the BOX O’ RELAYS 6 using the supplied 9 VDC power supply
and test the GPOs from your WheatNet-IP system.
Connecting to GPOs from a GPIO xNode or Engine:
1. Connect the optional Broadcast Tools COA-15/RJ DB15 the dual RJ45 adapter to
the one of the DB15 GPIO ports on the Node/Engine.
2. Use a standard Cat5 or Cat6 Ethernet patch cable to connect the RJ45 jack
(Output, J2) on the BOX O’ RELAYS 6 to the RJ45 jack on the COA-15/RJ
labelled “J2, Output.”
3. Wire the devices you wish to control (on-air lights, LED indicators, etc.) to the
K1-K5 dry contact closure relay outputs on the 5-position terminal blocks on the
top and bottom of the headers labelled TB 1-3.
4. Apply power to the BOX O’ RELAYS 6 using the supplied 9 VDC power supply
and test the GPOs from your Livewire system.
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BOR-6 Installation and Operation Manual
SPECIFICATIONS
Specifications
Optically isolated Inputs: (6) Optically isolated (3.3 -24 VDC, or 25-48 VDC via an exter-
nal resistor). Wet or Dry inputs. Default = Dry (5 volts internally
sourced and current at 2ma).
Relay Outputs: (6) SPDT, 1 amp @ 30 VDC maximum relays. Sealed relays uti-
lizing 2 - form – C, Bifurcated-Crossbar silver alloy with gold
overlay contacts, with front panel LED indicators.
CAUTION! For safety, never connect 120 Vac circuits to these relays!
Connectors: Inputs and Relay Outputs: (6) 5-position pluggable screw termi-
nal blocks. (1) RJ45 input jack.
Power: 9 to 12 VDC only, greater than 350 mA. 2.1mm ID x 5.5mm OD
coaxial connector, center positive, surge protected. Universal
switching power supply with domestic connector supplied. This
product may be powered by an external 5-volt DC source
that can source => 350ma at 5-volts DC via the RJ45 jack.
Dimensions: 6 x 5.25 x 1.63 in (W x L x H)
Options: RA-1 Rack Shelf – 1 RU. Accommodates up to 3
units, filler panels supplied. Note: Velcro is supplied to secure
the product to the RA-1 shelf.
COA-15/RJ – DB-15M to RJ45 Breakout Adapter for GPIO
xNodes.
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10
BOR-6 Installation and Operation Manual
LIMITED WARRANTY
LIMITED WARRANTY
The term “Buyer” as used in this document refers to and includes both (but only) (a) any person or entity who acquires such an item for
the purpose of resale to others (i.e., a dealer or distributor of an item), and (b) the first person or entity who acquires such an item for
such person’s or entity’s own use.
Broadcast Tools warrants to each Buyer of any item manufactured by Broadcast Tools that the item will be free from defects in materials
and workmanship at the time it is shipped by Broadcast Tools if the item is properly installed, used and maintained.
EXCLUSIVE REMEDIES
If Broadcast Tools is notified, in writing, of a failure of any item manufactured by Broadcast Tools to conform to the foregoing Limited
Warranty within one (1) year following the date of the Buyer’s acquisition of the item, and if the item is returned to Broadcast Tools in
accordance with Broadcast Tools’ instructions for confirmation by inspection of the defect (which at Broadcast Tools’ election may
include, without limitation, a requirement that the Buyer first obtain a Return Authorization number from Broadcast Tools, that the Buyer
furnish proof of purchase in the form of an invoice and/or receipt, and that the Buyer prepay all freight charges associated with any return
of the item to Broadcast Tools using such freight service as Broadcast Tools reasonably may specify), Broadcast Tools will repair or
replace the defective item, or will refund the purchase price paid by the Buyer for the item. Broadcast Tools shall have the exclusive
right to choose between these alternative remedies.
NO OTHER WARRANTIES OR REMEDIES
TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, BROADCAST TOOLS AND ITS SUPPLIERS DISCLAIM ALL OTHER
WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABIL-
ITY OR FITNESS FOR A PARTICULAR PURPOSE; AND THE FOREGOING ALTERNATIVE REMEDIES SHALL BE EXCLUSIVE OF
ALL OTHER REMEDIES. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. YOU MAY HAVE OTHER RIGHTS,
WHICH VARY FROM STATE/JURISDICTION TO STATE/JURISDICTION.
NO LIABILITY FOR CONSEQUENTIAL DAMAGES
TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, NEITHER BROADCAST TOOLS NOR ANY OF ITS SUPPLIERS
SHALL HAVE ANY LIABILITY FOR ANY SPECIAL, INCIDENTAL, INDIRECT, CONSEQUENTIAL OR PUNITIVE DAMAGES WHATSO-
EVER (INCLUDING, WITHOUT LIMITATION, ANY DAMAGES FOR LOST PROFITS, BUSINESS INTERRUPTION, LOSS OF DATA OR
INFORMATION, COST OF CAPITAL, CLAIMS OF CUSTOMERS, OR ANY OTHER PECUNIARY LOSS) ARISING OUT OF THE USE
OF OR THE INABILITY TO USE ANY ITEM SUPPLIED BY BROADCAST TOOLS, EVEN IF BROADCAST TOOLS HAS BEEN
ADVISED OF THE POSSIBILITY OF SUCH DAMAGES HAVE ANY LIABILITY FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL,
EXEMPLARY OR PUNITIVE DAMAGES. THIS LIMITATION OF LIABILITY APPLIES WHETHER A CLAIM IS ONE ALLEGING
BREACH OF A CONTRACT OR WARRANTY, NEGLIGENCE OR OTHER TORT, FOR THE VIOLATION OF ANY STATUTORY DUTY,
THE FAILURE OF ANY LIMITED OR EXCLUSIVE REMEDY TO ACHIEVE ITS ESSENTIAL PURPOSE, OR ANY OTHER CLAIM OF
ANY NATURE. BECAUSE SOME STATES AND JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, THIS LIMITATION MAY NOT APPLY TO YOU.
Broadcast Tools, Inc.
131 State Street
Sedro-Woolley, WA 98284 • USA
360.854.9559 voice •866.783.1742 fax
[email protected] e-mail
www.broadcasttools.com website
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PWR 9-12VDCRJ-45 Input
1A
2A
1B
2B
1NO
2NO
1CM
2CM
1NC
2NC
5NO
6NO
5B
6B
5A
6A
5CM
6CM
5NC
6NC
3NO
4NO
3B
4B
3A
4A
3CM
4CM
3NC
4NC
K1
K2
K3
K4
K5
K6 Power
Box O’ Relays 6
RELAYS
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Product_Name Installation and Operation Manual
11
APPENDIX

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Product_Name Installation and Operation Manual
Box O’
R
Component Lay
o
Power LEDRelay Output LED
s
R
elays 6
o
ut
s
Optically
Isolated
Isolated
Input
Configuration
Jumpers
Wet
JP1-4
Dry
(
Default
)
JP7: Power Jumper
Power from J1
power jack (default)
+5VDC (MAX)
power infrom J2
( )
Input/Relay
1/2
Input/Relay
3/4
Input/Relay
5/6
Power
9-12VDC
RJ 45
Input Jack
12
APPENDIX

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Product_Name Installation and Operation Manual
B
Fractio
n
B
ox O’ Relays 6
n
al Schematic
13
APPENDIX