Lighting Controls Blue Box LT Series Installation, Operation & Maintenance Manual page 97

THE BLUE BOX LT SYSTEM START-UP & CABLING GUIDE
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 .
!
Only use EZ RJ45 connectors provided by Lighting
Control & Design (LC&D) .
1 . Remove two inches of the Cat . 5 jacket - use the
wire stripper and cutter provided in our kit . Carefully
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
Blue/White
Blue
Green/White
Orange
Orange/White
4 . Place an EZ connector on the end of the cable with
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 .
!
Always follow acceptable safety procedures when using 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 .
Contacts not seated properly (sticking out 1⁄16
of an inch too far).
7 . Visually inspect each connector . Contacts should be
pushed into the insulation of each conductor .
8 . Repeat on the other end of the cable for a straight-
through cable .
Contacts not seated properly (bowed crimping).
9 . Test every cable for continuity with a LAN cable tes-
ter . While testing, wiggle and tug on each connector
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
can damage equipment .
Contacts properly seated (flat crimping).
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