Lighting Controls Blue Box LT Series Instruction manual

LCDBBO&M03Sept08
OPERATION
& MAINTENANCE
MANUAL
THE BLUE BOX™LT
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: [phone] •www.lightingcontrols.com
®
®

THE BLUE BOX LT OPERATION & MAINTENANCE MANUAL 3
LCDBBO&M04Sept08
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
Keyboard Lock Code ......................................................................87

4 THE BLUE BOX LT OPERATION & MAINTENANCE MANUAL
LCDBBO&M04Sept08
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
TABLE OF CONTENTS (Continued)

LCDBBO03Sept08
OVERVIEW
THE BLUE BOX™LT
Lighting Control & Design
905 Allen Ave, Glendale CA 91201
Tel: [phone] •www.lightingcontrols.com
®
®

6 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
TABLE OF CONTENTS
GR1404LT / GR1408LT Drawings & Details..........................................................7
Relay Overview ..................................................................................10
GR1416LT Drawings & Details .....................................................................11
Introduction toThe Blue Box™LT Series ...........................................................15
The Blue Box™LT VS. Lighting Contactors .........................................................16
BuildYour 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

THE BLUE BOX LT OVERVIEW 7
LCDBBO03Sept08
GR1404LT / GR1408LT DRAWINGS & DETAILS
Screw fastener secures white door (Master only).1.
White door provides a barrier between Control2.
Interface and High Voltage connections beneath
(Master only).
Hinged locking blue door.3.
DTC Clock / Display & Programming Interface:4.
32-channel, 365-day astronomical clock with
Scroll and Tab to access control features for en-
tire system (Master only).
Door pocket contains the following documenta-5.
tion: Refer to the Blue Box LT Installation Guide
for more information on these documents.
Panel Schedulea)
(optional) DI Card schedule.b)
If this is a Master panel, the System Devicec)
Schedule on the back of the Panel Schedule
should also be filled-out.. It lists out all of the
digital lighting controls devices, where they are
and what they do. (see System Start-Up Guide
for more information.
GR1404/08 LT (FRONT DOOR OPEN)
1
3
2
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)•

8 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
Screw fastener secures hinged Control Panel1.
Door (Master only).
White door provides barrier between human2.
interface and line voltage connections beneath
(Master only).
Optional Modem. Free factory dial-up programming.3.
Optional DI contact closure interface card.4.
Ø1/4" mounting holes at 4 places.5.
Optional: Unfasten two screws to remove chassis6.
assembly from enclosure providing full access to
mounting holes if required.
SnapLink7. ™relays, Normally-Closed (NC). Status
LED is ON when relay is OFF.
DTC Clock / Display & Programming Interface:8.
32-channel, 365-day astronomical clock with
Scroll and Tab to access control features for en-
tire system (Master only).
Voltage barrier separates line voltage (class 1) &9.
low (class 2) connections.
Dual Voltage Power Supply Input: Blue Box LT10. ™
operates on either 120V or 277V.
Ground Lug for equipment grounding.11.
Relay Control Card provides interface between12.
control network and relays. The Relay Control
Card in the Master panel also holds time sched-
ules and system mapping.
GR1404/08 LT (WHITE DOOR OPEN)
1
3
2
4
10
11
5
6
7
8
low voltage only line voltage only
9
55
12

THE BLUE BOX LT OVERVIEW 9
LCDBBO03Sept08
GR1404/08 SLAvE PANEL RELAY CONTROL CARD
1
2
4
10
11
7
8
9
77
12
13
GR1404/08 MASTER PANEL RELAY CONTROL CARD
3
5
6
7
7
2
4
1
10
11
8
9
7
13
Relay Drivers. Opto-isolated to prevent line volt-1.
age back-feed and to help prevent RF and EMF
noise interference. Relay drivers will close latching
relays upon loss of power to the Control Card.
RJ45 sockets for digital bus. Digital devices (relay2.
panels, digital switches, etc) connect to this panel
using a bus (daisy-chain) topology.
Photocell port (master panel only). +V output3.
with a photocell input. Photocells are polarized -
follow color code.
Power/data connector for DI Card.4.
Power/data connector for modem (master panel).5.
Power/data connector for DTC clock/display6.
(master panel only).
Removal slots for control card. Used with a flat7.
blade screw driver to remove the Control Card.
Terminator pins.Add terminator here if this is the8.
first or last item on a bus (follow the “System
Start-Up & Cabling Guide”).
Online LED indicates the communications mi-9.
cro-processor is functioning, not that the panel
can see the digital bus.
Power ON LED indicates the control card is re-10.
ceiving power from the transformer and has suc-
cessfully converted it to DC.
Error/Boot LED. Flashes continuously if system11.
failed to boot.
Hand/Auto Switch (slave panel only). In Auto12.
mode, relays will react to schedules and switches.
In Hand mode, relays will remain closed.
Power input from transformer.13.

10 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
Low voltage connector.1.
Status indicator LED.2.
Quick removal slot.3.
High conductivity terminal block.4.
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.
RELAY OvERvIEW
3#18 AWG. Supplies power from trans-1.
former to relay control card.
14 conductor ribbon cable: carries control2.
signal between DTC and relay control card
(master panel only).
2 conductor ribbon cable: carries control3.
signal from smacker strip to relays - one
per relay.
5 conductor ribbon cable: carries digital4.
signal from relay control card to (optional)
digital input card.
4#22AWG carries RS-232 signal from5.
(optional) modem to relay control card
(master panel only).
Terminator pins.Add terminator here if this6.
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.
BLUE BOX LT 1404/1408
INTERNAL SCHEMATIC
1
2
34
2
3
6
4
5
1
To optional
DI Card
To optional
Modem
master panels
only
To DTC

THE BLUE BOX LT OVERVIEW 11
LCDBBO03Sept08
GR1416LT DRAWINGS & DETAILS
Screw fastener secures hinged Control Panel Door (Master only).1.
Hinged Door Panel provides a barrier between Control Interface and High Voltage connections beneath2.
(Master only).
NEMA 1 surface mount enclosure with hinged door and key lock; Ø1/4" mounting holes at 4 places3.
(hardware not included).
DTC Clock / Display & Programming Interface: 32-channel, 365-day astronomical clock with Scroll andTab4.
to access control features for entire system (Master only).
GR1416 LT (FRONT DOOR OPEN)
2
3
4
1
1

12 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
Screw fastener secures hinged Control Panel1.
Door (Master only).
Hinged Door Panel provides a barrier between2.
Control Interface and High Voltage connections
beneath (Master only).
Optional Modem. Free factory dial-up programming3.
.
Optional DI contact closure interface card.4.
NEMA 1 surface mount enclosure with hinged5.
door and key lock; Ø1/4" mounting holes at 4
places (hardware not included).
Optional: Unfasten three screws to remove chas-6.
sis assembly from enclosure providing full access
to mounting holes if required.
SnapLink7. ™relays, Normally-Closed (NC). Status
LED: ON when relay is OFF (NC).
DTC Clock / Display & Programming Interface:8.
32-channel, 365-day astronomical clock with
Scroll and Tab to access control features for en-
tire system (Master only).
Voltage barrier separates low & line voltage con-9.
nections.
Dual Voltage Input: Blue Box LT10. ™operates on ei-
ther 120V or 277V.
Ground Lug for equipment grounding.11.
GR1416 LT (WHITE DOOR OPEN)
1
3
2
4
10
11
6
7
8
5
6
6
1
9
9

THE BLUE BOX LT OVERVIEW 13
LCDBBO03Sept08
Relay Drivers connect to Smacker Strip. Relay1.
drivers will close latching relays upon loss of
power to the Control Card.
RJ45 sockets for digital bus. Digital devices (re-2.
lay panels, digital switches, etc) connect to this
panel using a bus (daisy-chain) topology.
Photocell port (master panel only). +V output3.
with a photocell input. Photocells are polarized
- follow color code.
Power/data connector for DI Card.4.
Power/data connector for modem (master panel).5.
Power/data connector for DTC clock/display6.
(master panel only).
Removal slots for control card. Used with a flat7.
blade screw driver to remove the Control Card.
Terminator pins. Add terminator here if this is8.
an end-of-bus panel (per “System Start-Up &
Cabling Guide”).
Online LED indicates the communications mi-9.
cro-processor is functioning, not that the panel
can see the digital bus.
Power ON LED indicates the control card is10.
receiving power from the transformer and has
successfully converted it to DC.
Error/Boot LED. Flashing constantly if card can-11.
not boot on start up.
Hand/Auto Switch. (slave panel only) In Auto12.
mode, relays will react to schedules and switch-
es. In Hand mode, relays will remain closed.
Power input from transformer.13.
1
3
2
4
10
11
5
6
7
8
9
7
7
7
2
4
1
10
11
8
9
77
12
13
13
GR1416 LT SLAvE PANEL RELAY CONTROL CARD GR1416 LT MASTER PANEL RELAY CONTROL CARD

14 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
3#18 AWG. Supplies power from transformer1.
to relay control card.
14 conductor ribbon cable: carries control signal2.
between DTC and relay control card (master
panel only).
2 conductor ribbon cable: carries control signal3.
from smacker strip to relays - one per relay.
10 conductor ribbon cable: carries digital signal4.
from relay control card to smacker strip.
5 conductor ribbon cable: carries digital signal5.
from relay control card to (optional) digital input
card.
4#22 AWG carries RS-232 signal from (optional)6.
modem to relay control card (master panel only).
Terminator/terminator pins to terminate bus line.7.
External Connections
4#24 flat cable from modem to analog phone8.
jack. Always note phone number of modem.
2#18 AWG to Blue Box photocell. Up to 300 feet.9.
Cat. 5 cable with RJ45 connectors links Blue Box10.
to other digital devices (other blue box panels or
digital switches).
Contact closure inputs & DI card common11.
“GND” + 1 #18 per input.
Line and load relay lugs.12.
For information about cabling for contact closure
switches or occupant sensors. Refer to DI Card
Installation Guide for options and details.
GR1416 LT (DOOR OPEN) INTERNAL SCHEMATIC
1
2
4
10
11
12
6
8
9
7
3
5

THE BLUE BOX LT OVERVIEW 15
LCDBBO03Sept08
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.
INTRODUCTION TO THE BLUE BOX™LT SERIES

16 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
THE BLUE BOX™LT vS. LIGHTING CONTACTORS
Outdoor Photocell
Master Relay Panel
Digital Override Switch
SMART RELAY PANEL
The Blue Box™LT Series is the only panel you will ever
need for small to medium projects.
It is quicker to install than traditional lighting contactors as
well as more flexible.
With purchase of the optional modem you receive free
lifetime dial-up programming support from the factory.
Or you can connect remotely using our free software.
The Blue Box™LT is part of the GR 2400 lighting control
system, from LC&D.
Control up to 16 devices.
DITCH THE OLD WAY OF DOING THINGS
Traditional lighting contactor panels require an 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.
Breaker Panel

THE BLUE BOX LT OVERVIEW 17
LCDBBO03Sept08
STEP 1: MASTER PANEL
How many circuits (relays) do you need to control? (See
pgs. 6-7 for enclosure sizes).
Do you need a modem for remote dial-up programming?
(See pg. 10,“Modem”).
Do you need inputs for occupant sensors, or contact clo-
sure switches? (See pg. 10,“Digital Input Card”)
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.
STEP 3: SWITCHES, OUTDOOR PHOTOCELLS &
ACCESSORIES
How many override switches do you need?
How many buttons on each switch? (1 to 6 buttons cost
the same).
Will you need a photocell to supplement the DTC astro-
nomical clock? (See pg. 10,“Digital Photocell”).
Add other accessories as shown on pages 10-11.
Control up to 16 devices.
Every system must have a Master Panel which contains
the clock and photocell inputs and connections for the
optional modem.
BUILD YOUR SYSTEM IN 3 STEPS
Master Relay Panel
Each system needs one master panel. Use one Blue Box™
for each electric room you are controlling lighting circuits in.
Slave Relay Panel
Slave Relay Panel Outdoor Photocell
Chelsea
Digital Switch
Master
Relay Panel
Slave Relay Panel
Slave Relay Panel Master Relay Panel

18 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
DESIGNING WITH LIMITED SPACE?
The Blue Box™LT Series comes pre-assembled and ready
for installation in three compact enclosure sizes!
This 100% digital panel can be programmed to operate
any lighting scenario and is equipped with a number of
accessory devices:
Easy energy code compliance•
277V, 30a relays UL Listed for 18,000 SCCR•
Competitively priced against lighting contactors•
and astronomical or multi-channel clocks
Digital Switches can turn relays on or off or over-•
ride time schedules for energy code compliance
Our simple, intuitive network connects multiple•
panels and switches using Cat. 5 with RJ45s
Panels can share the same time schedules and•
photocell
Additional relays can be purchased for partially•
filled panels.
Hinged locking door•
3 ENCLOSURE SIzES
GR1408LT
Shipped with 4 or 8 relays•
Master or slave configuration•
13.4”H x 8.4”W x 3”D•
GR1416LT
Shipped with 8 or 16 relays•
Master or slave configuration•
17.1”H x 10.6”W x 3”D•
GR1404LT
Shipped with 2 or 4 relays•
Master or slave configuration•
8.4”H x 8.4”W x 3”D•

THE BLUE BOX LT OVERVIEW 19
LCDBBO03Sept08
2 PANEL CONFIGURATIONS
Master Relay Panel
Modem for remote pro-
gramming
Optional Hand/Auto Switch
DTC clock/programmer
• 32 channel 365 day, 7
day astronomical clock
• Programming access for
time schedules, switches,
photocell etc.
• Large format screen
Slave Relay Panel
Lighting relays:
• 30A @ 277V Ballast
• 20A @ 120V Tungsten
• 20A @ 347V Ballast
• SCCR 18,000 Amps
Power supply:
• 120V/277V
RJ45s inputs for digital bus
MASTER RELAY PANEL
Each system needs one master panel equipped with: DTC
clock/programmer. Program schedules, switches and pho-
tocells for multiple panels.
365-day/7-day/astronomical 32 channel clock•
Plain English command prompts•
Non-volatile memory for all programming, 10 year•
battery back-up for time of day
Photocell Input: One photocell can control any relay in
any panel.
Optional modem and Digital Input Card (See pgs. 10-11,
“Accessories”).
Control up to 16 devices.
SLAvE RELAY PANEL
The slave panel is a fully programmable panel that net-
works to the DTC, modem, and photocell from the mas-
ter panel.
No DTC, photocell input, or modem is required in a slave
panel, as it uses the master panel.
Option: Digital Input Card allows dry-contact closure
switches to control any relay in any panel – wall switches,
momentary switches, occupant sensors or any other dry
contact switch
(See pgs. 10-11,“Accessories”).
Chelsea Digital SwitchChelsea Digital Switch
Master Relay Panel Slave Relay Panel

20 THE BLUE BOX LT OVERVIEW
LCDBBO03Sept08
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
MOST POPULAR ACCESSORIES
These represent the most popular LC&D accessories. For a complete list of accessories refer to the LC&D Catalog.