4 Blue Box LTD Parts Replacement Guide
RELAY REPLACEMENT AND INSTALLATION
To remove a relay:
1. For master panels: Unscrew and open the hinged display-panel door
to expose the low-voltage section.
2. De-energize all breakers feeding relays and disconnect the AC power
from transformer to the control card.
3. Disconnect the low voltage jumper that connects the relay to the
control card.
4. Unscrew and open the dead-front cover to expose the high-voltage
section.
5. Disconnect line and load wires from the terminals on the relay to be
replaced.
6. Apply a flat head screw driver to the white tab at the bottom of
the relay, high voltage side. Pull the tab away from the relay until it
“clicks” un-securing the relay from the DIN rail.
7. Multiple connections and clips may need to be removed for multi-
pole relays.
To install a relay:
1. Align the relay on the DIN rail. Push in the white tab on the high
voltage side until it “clicks”.
2. Reconnect the low voltage jumper between the relay and the relay
driver pins on the control card.
3. Reconnect Line and Load conductors to the connection lugs.
WARNING: Tighten down relay terminal screws per torque spec, located
in the high voltage compartment. Failure to do so may result in loose
contact, electrical shock, overheating and/or permanent component
damage!
4. Re-apply low voltage and high voltage dead fronts and screw down.
5. After the part replacement installation is complete, return the part
using the prepaid UPS return label to factory.
[Note: If the part is not returned within a 30-day period, your account will
be automatically billed for the part. ]
To test the replacement relay:
1. Switch the breakers powering all the relays and the transformer back
ON.
2. Navigate on the DTC to USER MENU > MANUAL OVERRIDE and TAB
or SCROLL to the correct LCP and Load (relay) and press ENTER
to cycle the relay on and o 3 or 4 times, allowing a second or
two between cycles. Visually confirm that the relay is functioning
properly.
DI CARD REPLACEMENT AND INSTALLATION
To remove a DI Card:
1. Note the programming and the address of the existing DI Card. Refer
to the Panel Schedule located in the master panel or use the READ
ADDRESS function (Refer to Blue Box LTD Hardware Troubleshooting
manual).
2. Disconnect the RJ45 jumper cable from the DI card (leave it
connected to the control card).
3. Label and remove all low voltage conductors for contact closure
devices from the input/output terminals by pushing down the
release button next to the wire.
4. Remove the DI card out of the plastic track by inserting a flat-blade
screw driver into the slot on the side of the card and twisting to
release the board.
To install a DI card:
1. Snap the new DI card into the upper slot of the plastic track .
2. Reconnect all low voltage conductors for contact closure devices to
the input/output terminals.
3. Re-connect the RJ45 jumper cable to the DI card.
4. Proceed to addressing the DI card.
5. After the part replacement installation is complete, return the part
using the prepaid UPS return label to factory.
[Note: If the part is not returned within a 30-day period, your account will
be automatically billed for the part. ]
To address the replacement DI card
1. Navigate to the AUTO-ADDRESSING screen: USER MENU> SETUP
MENU> RESTRICTED (PASSCODE: 900001) > ADDRESSING-BUS
SCAN > AUTO ADDRESSING.
2. SCROLL UP until the address of the previous DI is displayed.
3. Press the address button on the DI card.
4. If the DI “takes” the address, the display will increment by one (e.g.
from “3” to “4”).
To verify the bus recognizes the replacement DI card:
1. Navigate to SCAN BY SERIAL NUMBER screen: USER MENU >
SETUP MENU > RESTRICTED (PASSCODE 900001) > ADDRESSING
– BUS SCAN> BUS DIAGNOSTICS > MORE DIAGNOSTICS > DEVICE
MANAGEMENT > SCAN BY SERIAL#
2. ENTER to begin a system scan.
3. The screen should show no collisions or “0” addressed devices.
If
collisions are present, refer to the “Scan by Serial Number” section of
PARTS REPLACEMENT INSTRUCTIONS
