4100/4120/UT Back Box

Installation Instructions

Cautions and Warnings DO NOT INSTALL ANY SIMPLEX PRODUCT THAT APPEARS DAMAGED.
Upon unpacking your Simplex product, inspect the contents of the carton for
shipping damage. If damage is apparent, immediately file a claim with the carrier
and notify Simplex.

Introduction System back boxes come in three different sizes. There are two-unit, four-unit, and
six-unit back boxes. These back boxes are shipped in large containers separate
from the system electronics. If system electronic containers are shipped with the
back box containers, store these system electronics containers in a safe, clean, and
dry location until the back box installation is completed, and you are ready to install
the system electronic bay(s).
The installation is summarized in the steps listed below. When you finish a step,
check the appropriate box.

STEP # ACTION REQUIRED

Open the back box shipping container and remove the back box
1
from the container.

2 Mount the system back box(es).

3 Install the system electronics bay(s) in the back box(es).

Call your local Simplex branch office and notify them that your
4 system is ready for system card installation. DO NOT APPLY
POWER TO THE SYSTEM.

Note: Conductor entrance and routing restrictions apply to power-

limited systems. Before installation, refer to the “Installation”
section of this document for information on power-limited
systems.

 1997 Simplex Time Recorder Co.

All specifications and information shown were current as of publication, and are subject to change without notice.
574-020
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 Requirements

Related Documentation
The following is a list of additional documentation that may assist you in the
installation.
• 4100+ Contractor Installation Instructions ............................. 574-019
• UT Contractor Installation Instructions ................................... 574-901
• 4100+/4120/UT System Cards Installation Instructions .......... 574-038
• 4100/4120 Interconnect Diagram (Wall-Mount Panel) ............ 841-869
• 4100 Field Wiring Diagram (Domestic US) ............................. 841-731
• 4100 Field Wiring Diagram (Domestic US) ............................. 841-731

Installation Requirements Table 1 lists the specifications for the various back boxes.

Table 1. Back Box Specifications

PRODUCT
DESCRIPTION HEIGHT WIDTH ROUGH OPENING
IDENTIFICATION
NUMBER SIZE WEIGHT BOX TRIM DOOR BOX HEIGHT WIDTH
3
2001 2-Unit 55 lb. 20-¾ in. 23-½ in. 26- /8 in. 25-¾ in. 21-¼ in. 26 ¼ in.
1 3
2002 4-Unit 125 lb. 36-¼ in. 39- /8 in. 26- /8 in. 25-¾ in. 36-¾ in. 26 ¼ in.
1 3 5
2003 6-Unit 185 lb. 52- /8 in. 55 in. 26- /8 in. 25-¾ in. 52 /8 in. 26 ¼ in.

Make certain that you have the necessary hardware before you begin the
installation procedure. The 4120/UT Back Box Mounting Hardware Kit should
have all of the items listed in Table 2.

Table 2. Contents of the Back Box Mounting Hardware Kit

QUANTITY PER BACK BOX

9 ITEM PART NO. DESCRIPTION
TWO-UNIT BOX FOUR-UNIT BOX SIX-UNIT BOX

1 268-010 Lockwasher (No. 8) 6 8 10

2 490-011 Washer 6 8 10
3 426-033 Screw (No. 8 Torx, 6 8 10
5
/16 in.)

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 Installation

About System Cards All system electronics shipments include a small cardboard box (or boxes)
containing the system printed circuit boards (or system cards). Each box is marked
as shown in Figure 1.

- CAUTION -
INSTALLER

THIS PACKAGE CONTAINS

CRITICAL COMPONENTS
FOR INSTALLATION INTO,
AND OPERATION OF,
THIS UNIT

Figure 1. System Card Box Label

Note: System card boxes must be opened, inventoried, and installed

by Simplex personnel.

Remove the system card box (or boxes) from the shipping container and place each
box in a clean, dry, and safe location. Simplex personnel will install the system
cards in the box(es) at a later time.

Continued on next page

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 Installation, Continued

Installing the Back Box(es) The following instructions provide a systematic method for installing a 4100, 4120
or Universal Transponder (UT) back box. Common hand tools are required to
perform this installation.
Perform the following procedure to install the back box.

1. Carefully open the back box shipping container.

2. Remove the back box from the shipping container.
3. Lay the unit on a flat surface.
4. Install the back box as shown in Figure 2. Use the precut holes in the back
box to secure it to the wall.

Note: The enclosure must be level and plumb when installed. The front surface
of back box must protrude at least three inches from the wall surface for
semi-flush installations. For semi-flush back box installations, refer to
Table 1 and the “Rough Opening” section of the table.

Continued on next page

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 Installation, Continued

Installing the Back Box(es) Note: Power-limited systems have back box entrance and routing restrictions for
(Continued) field wiring. Do not locate power-limited wiring in the areas of the back
box shown shaded in Figure 2. Do not use the upper right, right, or
bottom knockouts for entrance of power-limited wiring. Those areas are
reserved for non power-limited circuitry such as ac power, batteries, and
the City connection.
SEE NOTES 3, 4, & 6
6 3/4"
TRIM
"B" "A" "B"

TOP TOP

SEE TABLE 1
FOR BOX USE 4 HOLES TO USE 4 HOLES TO
HEIGHT SECURE BACKBOX SECURE BACKBOX
TO THE WALL TO THE WALL

RESERVED
FOR ADDITIONAL
BATTERIES BACK BOX
(SEE NOTE 6)

1 5/8"
SEE NOTES 1 & 2
3" 1 7/16"
3 1/4"

Notes for Figure 2

1. Dimensions shown are typical for all surface and semi-flush installations.
2. Use suitable punch when conduit is required and no knockout is present.
3. Conduit A denotes internal panel interconnect harnesses and non power-limited wiring.
Conduit B denotes contractor wiring.
• Use a 2-inch knockout.
• Minimum distance between boxes is 3 ¼ inches.
• Maximum distance between boxes is 6 inches.
4. When two back boxes are mounted side-by-side, remove the hinge and the lock catch
on the second back box (shown on the right in Figure 2). Remount the hinges on the
right side of the second back box. Remount the lock catch on the left side of the second
back box. Mount the door upside down so the locks on both boxes are side-by-side.
5. Weight shown in Table 1 does not include the weight of the batteries.
6. Do not install any power-limited wiring in the shaded area of the back box as shown in
Figure 2. This area is reserved for non power-limited devices and circuits (for example,
ac power, batteries, and city circuits). The non power-limited area is determined by the
internal barriers, but is always below and to the right of these barriers.

Figure 2. Back Box Installation Diagram

Continued on next page

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 Installation, Continued
Installing the System
Electronics Bays
SYSTEM ELECTRONICS
VERTICAL RAIL
TOP OF CONTAINER
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The system electronics bays for each back box are mounted on two rails. These
rails are secured inside a cardboard shipping container when shipped from the
factory.
Perform the following procedure to install the system electronics bays.
1. Lay the system electronics shipping container on a flat surface near the back
box where the installation is to take place.
2. Carefully remove the plastic bands from the container and remove the
container cover.
3. Inventory the container. (Refer to the factory documentation that accompanies
the shipment.)
4. Remove the panel door box from the container and set it aside.
5. Remove the cardboard and foam protective sheet from the container.
6. Remove the retainer panel from the container.
7. Remove the system card box (or boxes) from the container.
8. Remove the two 8-2 shipping screws that secure the 635-852 interconnect
distribution block (terminal block) to the shipping container; save the two
lockwashers and nuts. (See Figure 3.)
TERMINAL BLOCK
TERMINAL BLOCK SCREW
TERMINAL BLOCK
LOCKWASHER
TERMINAL BLOCK NUT
SYSTEM ELECTRONICS
SHIPPING CONTAINER
SHIPPING STUD
Figure 3. Removing the Shipping Studs
Continued on next page
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 Installation, Continued

Installing the System
Electronics Bays (Continued)
9. Remove the 10-32 shipping studs that secure the vertical rails to the shipping
container. (See Figure 3.)
10. Using the hardware provided (as referenced in Table 2), insert a mounting
screw in both the top right and top left track support holes in the back box.
(See Figure 4.)

BACK BOX

MOUNTING SCREWS

Figure 4. Inserting the Mounting Screws

Continued on next page

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 Installation, Continued

Installing the System
Electronics Bays (Continued)
11. Tighten the two mounting screws, but leave a 1/8-inch gap from the seated
position of each screw.
12. Using the vertical rails as handles, carefully lift the system electronics bay
assembly (and the terminal block) from the shipping container.
13. Install the system electronics bay assembly in the back box by carefully
placing the rail teardrop holes (located at the top of the rails) onto the two
extended screws in the back box; allow the electronics bay assembly to hang
from the screws. (See Figure 5.)

Note: Make certain that you do not pinch the terminal block wiring behind the
rails as you mount the bay assembly in the back box.

BACK BOX

PREMOUNTED SCREWS

TEARDROP HOLES

NUT
LOCKWASHER
TERMINAL
BLOCK
SYSTEM ELECTRONICS
BAY ASSEMBLY

SCREW HOLES

Figure 5. Installing the System Electronics Bay Assembly

Continued on next page

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 Installation, Continued

Installing the System 14. Insert the remaining mounting screws through the screw holes in the rails.
Electronics Bays (Continued)
15. Securely tighten all mounting screws. (Refer to Table 3 for the recommended
torque.)

Table 3. Recommended Torque for Mounting Hardware

SCREW / NUT SIZE RECOMMENDED TORQUE

No. 6 7.9 to 8.7 inch/ounces

No. 8 16.1 to 17.8 inch/ounces
No. 10 26.8 to 29.7 inch/ounces

16. Place the 635-852 terminal block on the two mounting studs on the right side
of the back box. (See Figure 5.)
17. Secure the 635-852 terminal block using the two lockwashers and nuts that
you set aside in Step 8.

Note: Do not torque the nuts securing the 635-852 terminal block.

18. Call your local Simplex branch office and notify them that your system is
ready for system card installation. Do not apply power to the system.
Publication FA4-21-305 (574-038) describes the system card installation
procedure.

Note: For more detailed system installation instructions, refer to one of the
following publications:
• 4100+ Contractor Installation Instructions: FA4-21-202 (574-019)
• UT Contractor Installation: FA4-21-300 (574-901).

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574-020
Rev. A
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