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Blue Giant BLUE GENIUS CONTROL PANEL Owner's Manual

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ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN
WARNING
Do not operate or service this product unless you have
read and fully understand the entire contents of this
manual. Failure to do so may result in bodily injury or
death.
STARTING FROM MARch 7, 2025 / SERIAL #
OwNER'S MANUAL
BLUE GENiUS
BLUE GENiUS
BLUE GENiUS
ISSUE DATE: MARch 4, 2025 REv. 1.0 (PART # 038-1169E)
®
CONTROL PANEL
CONNECT
®
CONNECT PLUS
®

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  • Page 1 OwNER'S MANUAL BLUE GENiUS ® CONTROL PANEL BLUE GENiUS CONNECT ® BLUE GENiUS CONNECT PLUS ® ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN WARNING Do not operate or service this product unless you have read and fully understand the entire contents of this manual.

  • Page 3: Table Of Contents

    Blue Genius ® ConneCt Master Controls—owner's Manual Table of Contents 1.0 BLUE GENIUS CONNECT MASTER CONTROL PANELS ® 1.1 OWNER’S PURCHASE RECORD 2.0 INTRODUCTION 2.1 WARRANTY INFORMATION 2.2 EXCLUSION OF LIABILITY 2.3 MANUFACTURER’S NOTE 2.4 OWNER’S RESPONSIBILITY 3.0 SAFETY MESSAGE COLOR IDENTIFICATION 3.1 OPERATIONAL SAFETY WARNINGS 4.0 LOCKOUT / TAGOUT PROCEDURE AND RULES 4.1 ROTARY DISCONNECT: BLUE GENIUS CONNECT PLUS...
  • Page 4 Blue Genius ® ConneCt Master Controls—owner's Manual 13.0 WIRING DIAGRAMS 13.1 BLUE GENIUS ® CONNECT WITH HVR 13.2 BLUE GENIUS ® CONNECT WITH SVR AND FHE COMBO issue Date: MarCH 4, 2025 rev. 1.0 (Part # 038-1169e)

  • Page 5: Blue Genius Connect Master Control Pan Els

    BLUE GENIUS ® CONNECT MASTER CONTROLS—OWNER'S MANUAL 1.0 Blue Genius ConneCt MAsteR ContRol PAn els ® Blue Genius ® Connect and Blue Genius ® Connect Plus Control Panels represent the highest level in loading dock safety and productivity. An interior and exterior lights communication system keeps truck drivers and warehouse personnel advised of safety conditions during dock operations.

  • Page 6: Introduction

    2.1 WARRANTY INFORMATION Thank you for purchasing Blue Giant products. We appreciate your business, and are confident that our product will serve you for many years to come. In the event that you experience a problem with our product, our Customer Support Team is here to support the Blue Giant Product(s) that you have purchased.

  • Page 7: Manufacturer's Note

    Any observed transport damage is to be listed on the signed copy of the freight document. There are many configurations or custom designs whose specifications may not be fully reflected in this manual. Contact your Blue Giant Dealer to obtain the General Arrangement drawing for application specific designs.
  • Page 8 BLUE GENIUS ® CONNECT MASTER CONTROLS—OWNER'S MANUAL Unless specifically agreed to in writing by Blue Giant Equipment Corporation at the time of order (and prior to manufacture), all Blue Genius ® Control Panels are sold as a complete offering and must not be altered or added to in any manner (which includes configuration and function) without written permission from an authorized manufacturer’s representative.

  • Page 9: Safety Message Color Identification

    BlUE GENIUS ® CONNECT MASTER CONTROlS—OwNER'S MANUAl 3.0 SAFETY MESSAGE COLOR IDENTIFICATION This manual includes color-coded safety messages that clarify instructions and specify areas where potential hazard exists. To reduce the possibility of equipment damage and serious injury or death, please follow the instructions and understand the warnings contained in the messages.
  • Page 10 Always clean up dry and liquid spills immediately after they occur. • Always maintain proper lighting in the work area. • If a procedure is not clearly defined in this manual, contact your Blue Giant Dealer. 10 ISSUE DATE: MARCH 4, 2025 REV. 1.0 (PART # 038-1169E)

  • Page 11: Lockout / Tagout Procedure And Rules

    The machine or equipment power supply shall be locked in the OFF position or disconnected from the energy source. Blue Giant strongly recommends that only OSHA-approved and/or local jurisdiction lockout devices and procedures be utilized. The energy isolating device must bear a prominent warning tag indicating that work is being done on the equipment and the name of the authorized employee responsible for the lockout.

  • Page 12: Rotary Disconnect: Blue Genius Connect Plus

    FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES DO NOT DISCARD. Any components shipped back to Blue Giant must be in their original packaging (along with completed RGA form taped to the OUTSIDE of the static bag) or warranty may be voided. 038-850E Prior to handling PCBs, wear a static grounding wrist strap and clip it to an electrical ground.

  • Page 13: Control Station Operation

    BlUE GENIUS ® CONNECT MASTER CONTROlS—OWNER'S MANUAl 5.0 CONTROL STATION OPERATION Depending on the specific installation, the control station may be mounted on an adjacent wall. See “6.0 OPERATING INSTRUCTIONS” on page 15 for more information. 5.1 TOUCH BUTTON CONTROLS Controls one individual vehicle Control Panel only, equipped with touch buttons, inside forklift operator traffic lights, operator menu screen, and keypad for coded features.
  • Page 14 BlUE GENIUS ® CONNECT MASTER CONTROlS—OWNER'S MANUAl Control buttons are momentary contact: a single tap will activate the engage or release features based on situation. Audible touch #038-451 14 ISSUE DATE: MARCH 4, 2025 REv. 1.0 (PART # 038-1169E)

  • Page 15: Operating Instructions

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.0 OPERATING INSTRUCTIONS Follow the safe operating instructions to ensure personnel, load, and equipment safety. WARNING • Do not operate the Blue Genius ® Connect or Blue Genius ® Connect Plus unless you have been trained and authorized to do so, and have read and understood all of the safety information and instructions contained in this manual.

  • Page 16: Arrival

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.2 ARRIVAL operating instructions are not always listed this order. Perform steps as necessary. The following steps apply to pit-style dock levelers only. Before the truck enters the driveway, the exterior traffic light will be GREEN and the control panel indicator screen will be RED. The truck may now enter the driveway.

  • Page 17: Engaging The Vehicle Restraint

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.3 ENGAGING THE VEHICLE RESTRAINT select the required option • Tap the ENGAGE RESTRAINT to activate vehicle restraint. exterior traffic light will change to RED and the control panel indicator screen displays RED. The exterior traffic light will be GREEN.
  • Page 18 Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl • Tap the BYPASS RESTRAINT button to activate bypass vehicle restraint screens. exterior traffic light displays RED and the control panel indicator screen displays RED. 18 Issue DATe: MARCH 4, 2025 Rev. 1.0 (PART # 038-1169e)

  • Page 19: Deploy Seal

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.4 DEPLOY SEAL If available, tap INFLATE SEAL or OVERRIDE THE SEAL to activate feature. seal inflates during this screen. The seal finishes inflating. exterior traffic light displays RED and the control panel indicator screen displays RED. Issue DATe: MARCH 4, 2025 Rev.

  • Page 20: Open Automated Door

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.5 OPEN AUTOMATED DOOR Tap OPEN button to raise the overhead door when the door is not in automatic mode. Door opens during this screen. 20 Issue DATe: MARCH 4, 2025 Rev. 1.0 (PART # 038-1169e)

  • Page 21: Deploying Dock

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl If the door is slightly open, these additional options may be available: CLOSE DOOR to lower the door or STOP DOOR to pause an automated door. Door is now open. exterior traffic light displays RED and the control panel indicator screen displays RED. 6.6 DEPLOYING DOCK Tap and hold RAISE LEVELER.

  • Page 22: Load Transfer

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.7 LOAD TRANSFER once the restraint and leveler are deployed correctly, perform loading and unloading. 22 Issue DATe: MARCH 4, 2025 Rev. 1.0 (PART # 038-1169e)

  • Page 23: Departing

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.8 DEPARTING once load transfer is complete, tap COMPLETE to begin the releasing process. 6.9 RAISE THE DOCK LEVELER Tap and hold RAISE LEVELER. exterior traffic light displays RED and the control panel indicator screen displays RED. •...

  • Page 24: Close Automated Door

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.10 CLOSE AUTOMATED DOOR Tap CLOSE to lower the overhead door when the door is not in automatic mode. If the door is slightly open, these additional options may be available: OPEN DOOR to raise door or STOP DOOR to pause an automated door.

  • Page 25: Remove Seal

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.11 REMOVE SEAL If available, tap DEFLATE SEAL or OVERRIDE THE SEAL to activate feature. seal deflates during this screen. exterior traffic light displays RED and the control panel indicator screen displays RED. Issue DATe: MARCH 4, 2025 Rev.

  • Page 26: Releasing The Vehicle Restraint

    Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl 6.12 RELEASING THE VEHICLE RESTRAINT Tap the DISENGAGE RESTRAINT to disengage the vehicle restraint or release the bypass on the vehicle restraint. The restraint returns to home during this screen. 26 Issue DATe: MARCH 4, 2025 Rev. 1.0 (PART # 038-1169e)
  • Page 27 Blue GenIus ® ConneCT MAsTeR ConTRols—owneR's MAnuAl when the restraint is fully released, the exterior traffic light will change to GREEN and the control panel indicator screen displays RED. Issue DATe: MARCH 4, 2025 Rev. 1.0 (PART # 038-1169e)

  • Page 28: Maintenance

    Recommended procedures for a periodic planned maintenance program that covers inspections, operational checks, cleaning, and minor adjustments are outlined in the Owner’s Manual for this product. Contact your Blue Giant Dealer regarding for assistance with a planned maintenance program by offering trained service personnel with expertise in Control Panel maintenance requirements.

  • Page 29: Daily Maintenance Procedures (Dmp) Checklist

    BLUE GENIUS ® CONNECT MASTER CONTROLS—OwNER'S MANUAL 7.6 DAILY MAINTENANCE PROCEDURES (DMP) CHECKLIST Use checklist to aid the daily maintenance inspection. Photocopy or scan to storage then print from stored copy as needed. DANGER • when repairing or conducting maintenance procedures on electrical components, perform lockout / tagout steps according to OSHA regulations and approved electrical codes.

  • Page 30: Recommended Spare Parts

    Blue Genius ® ConneCt Master Controls—owner's Manual 8.0 RECOMMENDED SPARE PARTS Blue Genius ® Connect Blue Genius ® Connect Plus STANDARD OPERATIONAL COMPONENTS Blue Genius ® Connect ITEM PART # DESCRIPTION QTY REQ’D BGC-1115 1PH,115V, CONTROL BOX BGC-1230 1PH,230V, CONTROL BOX BGC-3230 3PH,230V, CONTROL BOX BGC-3460...
  • Page 31 Blue Genius ® ConneCt Master Controls—owner's Manual STANDARD OPERATIONAL COMPONENTS Blue Genius ® Connect Plus ITEM PART # DESCRIPTION QTY REQ’D BGCP-1115 1PH,115V, CONTROL BOX BGCP-1230 1PH,230V, CONTROL BOX BGCP-3230 3PH,230V, CONTROL BOX BGCP-3460 3PH,460V, CONTROL BOX BGCP-3575 3PH,575V, CONTROL BOX issue Date: MarCH 4, 2025 rev.

  • Page 32: Decal Identification And Location

    DE RETENUE, ET COMBOS ÉQUIPEMENTS DE QUAI. Défaut de suivre les instructions ci-dessus peut causer des blessures graves et/ou la mort. 038-853EF ATTACHED TO DIVIDER PLATE IN CONNECT PLUS SERIES BLUE GIANT EQUIPMENT E353795 CORPORATION Model No. No De Modele Serial No.
  • Page 33 RED. En ter Do No t En ter Do No t When the door is fully open, the Blue Genius Control Panel remains Ca ut io n Ca ut io n d W ith d W ith Pr oc ee Pr oc ee solid RED.

  • Page 34: Equipment Component Illustrations

    Blue Genius ® ConneCT MasTer ConTrols—owner's Manual 10.0 EQUIPMENT COMPONENT ILLUSTRATIONS This section displays the various hardware components. 10.1 COMPONENTS AS SHIPPED CHECKLIST This section displays the shipped hardware components. CONTROL AND COMPONENTS OWNER'S MANUAL INSTALLATION & TECHNICAL MANUAL PARTS LIST BLUE GENiUS®...

  • Page 35: Exterior Driver Traffic Light Installation

    BluE GENius ® CONNECT MAsTEr CONTrOls—OwNEr's MANuAl 11.0 EXTERIOR DRIVER TRAFFIC LIGHT INSTALLATION This procedure describes the wall mounting of the exterior traffic light Mount the exterior traffic light approximately 84in. - 96in. 5" (127 mm) (2134 - 2438mm) above the driveway surface on the right hand side of The loading bay entrance and easily viewed in the driver’s rear view side 4 3/8"...

  • Page 36: Exterior Driver Warning Sign Installation

    BluE GENius ® CONNECT MAsTEr CONTrOls—OwNEr's MANuAl 11.1 EXTERIOR DRIVER WARNING SIGN INSTALLATION This procedure describes the mounting of the exterior warning sign for drivers. NOTE: when fastening the sign to the wall, do not warp or twist the sign while tightening the anchors. (use shim washer if needed.) Do not over-tighten fastenings, as damage to the sign may occur.

  • Page 37: Troubleshooting

    OSHA regulations and approved electrical codes. The following description of operating principles is intended as a guide when trouble shooting and making adjustments or repairs. If no fault can be found and equipment fails to operate properly, contact your Blue Giant Dealer. MESSAGE...

  • Page 38: Wiring Diagrams

    Blue Genius ® ConneCT MasTer ConTrols—owner's Manual 13.0 WIRING DIAGRAMS NOTICE The following wiring diagrams are sample configurations only. Wiring diagrams specific to your needs will be provided inside the control panel and/or as part of your submittal package. This section describes how the modules are installed, wired, and electrically powered. 13.1 Blue GeNIuS ®...
  • Page 39 Blue Genius ® ConneCT MasTer ConTrols—owner's Manual issue DaTe: MarCH 4, 2025 rev. 1.0 (ParT # 038-1169e)
  • Page 40 Blue Genius ® ConneCT MasTer ConTrols—owner's Manual WHITE BLACK GREEN ORANGE WHITE/BLACK BLUE WHITE BLACK GREEN 40 issue DaTe: MarCH 4, 2025 rev. 1.0 (ParT # 038-1169e)
  • Page 41 Blue Genius ® ConneCT MasTer ConTrols—owner's Manual 13.2 Blue GeNIuS CoNNeCt WItH SVR AND FHe CoMBo ® issue DaTe: MarCH 4, 2025 rev. 1.0 (ParT # 038-1169e)
  • Page 42 Blue Genius ® ConneCT MasTer ConTrols—owner's Manual GREEN BLACK +24V DIL1 GREEN DIL1 +24V DIL2 WHITE DIL2 STOP STOP OPEN MAIN POWER IN OPEN CLOSE CLOSE RELAY COM SECURITY B SECURITY A DECK DOCK SHELTER RESTRAINT SECONDARY LIGHT /FAN POWER IN OPTION GREEN WHITE...
  • Page 43 Blue Genius ® ConneCT MasTer ConTrols—owner's Manual issue DaTe: MarCH 4, 2025 rev. 1.0 (ParT # 038-1169e)
  • Page 44 Corporate 410 Admiral Blvd USA 6350 Burnt Poplar Road Mississauga, ON, Canada L5T 2N6 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.bluegiant.com If calling within North America: t 1.800.872.2583 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2025...

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