CEM+ Sensor Rack (SR Series)
Retrofit Manual
Revision A
C o p y r i g h t © E le c tr o n i c T h e a t r e C o n t r o l s , I n c .
All Rights reserved.
P r o d u c t in f o r m a t i on a n d s p e c i f i c a t i o n s s u bj e c t t o c h a n g e .
P a r t N u m b e r : 7150M2300 R e v A
Released: June 2004
ET C ®, E m p h a s i s ™ , E x p r e s s i o n ®, I n s i gh t ™ , I m a g i n e ™ , F o c u s ™ , E x p r e s s ™ , U n i s o n ®,
O b s e s s i o n ® I I , E T C N e t 2 ™ , E D M X ™ , S e n s o r ®, a n d W Y S I L i n k ™ a r e e i t h e r r e g i s t e r e d t r ad e m a r k s
o r t r a d em a r k s o f E l e c t r o n ic T h e a t r e C o n t r o l s , I n c . i n th e U n it e d S t at e s a n d o t h e r c o u n t r i e s .
M i c r o s o f t ® a n d W i n d o w s ® a r e r e g i s t e r e d t r a d e m a r k s o f M i c ro s o f t C o r p o r a t i o n in t h e U n i t e d
S t a t e s a n d o th e r c o u n t r i e s .
Introduction
This manual is intended to guide ETC Service Technicians through the process of
upgrading existing Sensor rack installations to Sensor+ racks with an CEM+ control
module. This manual covers SR6, SR12, SR24 and SR48 permanent installation dimming
racks.
If you have questions about the retrofit process that are not answered in this manual, please
contact ETC Technical Services.
Americas
ETC International
Technical Services Department
3031 Pleasant View Road
Middleton, WI 53562
+1 800 775 4382
+1 608 831 4116
service@etcconnect.com
Please email comments about this manual to: TechComm@etcconnect.com
Warnings and Notice Conventions
These symbols are used in Sensor documentation to alert you to danger or important
information:
Note:
Notes are helpful hints and information that is supplemental to the main text.
CAUTION:
A Caution statement indicates situations where there may be undefined or
unwanted consequences of an action, potential for data loss or an equipment
problem.
WARNING:
A Warning statement indicates situations where damage may occur, people
may be harmed, or there are serious or dangerous consequences of an
action.
WARNING:
RISK OF ELECTRIC SHOCK! This warning statement indicates situations
where there is a risk of electric shock.
Introduction
1
Safety
Please note the following safety warnings before use:
•
Disconnect power from the racks before all maintenance.
WARNING:
Dimmer racks without an accessible power disconnect device cannot be
serviced safely.
Overview of this Manual
Reference this manual throughout the retrofit procedure.
•
Preparation, page 5 - before you open the rack.
•
Remove the Old, page 5 - labeling and remove the existing equipment.
•
Install the New Backplane, page 9 - transfer the wiring and install new components.
•
Change out the AF Cards (if present), page 10 - remove the existing Advanced Feature
cards and install the new ones.
•
Change out the Beacon PCB, page 10 - replace the beacon pcb with the new one.
•
Verify the Retrofit, page 11 - put the dimmers back in the rack and power up the rack.
•
Configure the CEM+, page 11 - put a configuration in the CEM+.
•
Finishing Touches, page 11 - replace rack stickers and the acrylic beacon in the door.
•
Quick Reference Sheet, page 13 - is an illustrated overview of the retrofit procedure.
When viewing this document in electronic form (pdf file) with Adobe Acrobat Reader, blue
italicized text followed by a page number such as “Overview of this Manual, page 2” is a
link within the document. If you click on the link, it will jump to that section or topic.
2
CEM+ Sensor Rack Retrofit Manual
Section 1
Unpack and Organize
1
Unpack and Organize
SR24
7150K1003
SR48
7150K1004
CEM+ Backplane Bracket
7150A3002
CEM+ Backplane PCB Assy
7150B5003
CEM+ Backplane Label
7150A4005
Stand-off (4-40x.375 M-F 3/16-HX AL)
HW9322
CEM+ Backplane Short Shield
7150A3007
Screw (4-40X1/4 SEMS PhPHMS)
HW183
CEM+ Sensor Rack Retrofit Manual (this manual)
7150M2300
Backplane Screw (8-32X3/8 PhPHMS)
HW377
CEM+ Backplane 1/8” #8 screw spacer
HW9343
Wire tie - 4”
HW7121
Tie-mount (sticky-back)
HW741
Ethernet Termination Kit
4101A2003
CAT5 Cable RJ45/RJ45 UTP 1FT
N4036
Sensor+ Beacon (Blue LED) PCB Assy
7050B5109
Beacon PCB Screw (6-32X3/8 PhPHMS)
HW222
Sensor+ Beacon Door Acylic
7051A4116
Terminal Block 8F Plug Screw
J3407
CEM+ UPGRADE 16-PIN Power Cable
7150B7002
PCB Upgrade 16-Pin Power
7150B4009A
CEM+ Lower Ribbon Card Assy
7150B5006
CEM+ Upper Ribbon Card Assy
7150B5007
Sensor+ Door Label
7151A4001
Heat shrink - 4.5” x 1.5” dia.
W682
Heat shrink - 6” x 3/16” dia.
W606
SR12
7150K1002
Shipped as Individual Parts
Parts Included in the Kits
Shipped Assembled
Parts/Components
ETC Part Number
SR6
7150K1001
The table below lists the parts and components needed to retrofit a Sensor rack up to a
Sensor+ rack with a CEM+. Each part is listed to reflect the different quantities for the
different kits and types of racks.
1
1
1
1
1
1
1
1
1
1
1
1
6
6
6
6
1
1
1
1
8
8
8
8
1
1
1
1
2
2
2
2
2
2
2
2
8
8
10
14
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
3
SR12
7150K1002
SR24
7150K1003
SR48
7150K1004
Sensor+ AF Cards (Optional)
7150B5005
Terminal Block 8F Plug IDC (Optional)
J3409
CEM+
7150A1001
SR6
7150K1001
Additional
Line Items
Parts/Components
ETC Part Number
1
1
2
4
3
3
3
3
1
1
1
1
Required Tools
#1 Phillips screwdriver
#2 Phillips screwdriver
3/8” Socket
Diagonal wire cutter
Permanent marker
Heat shink gun
4
CEM+ Sensor Rack Retrofit Manual
Section 2
The Retrofit
Preparation
Step 1:
Use Sensor Configuration Editor and a SLTA to download and save the current
Sensor configuration out of racks for later reference.
Step 2:
Turn off main power to the rack(s).
Step 3:
Pull the modules out of the rack. Note and document the module’s order/
positioning in the rack for proper insertion and configuration later.
Step 4:
Use a digital voltmeter and VERIFY that power is off by checking voltages for
all combinations between the phase bars, neutral and ground.
Remove the Old
Step 1:
Mark the edge connector of each dimmer output ribbon cable (1, 2, 3 & 4) as
illustrated below in the hexagons. There may be stickers on the ribbon cables
already, however these refer to cable length and not dimmer outputs. They
should not be used as a reference to these instructions.
CEM SR6/12 Ribbon Cable Layout
1
1
2
3
4
5
6
7
8
9 10 11 12 13 14
J1
J2
CEM SR48 Ribbon Cable Layout
1
2
(25-48)
9 10 11 12 13 14
(1-24)
8
1
7
2
3
4
5
J3
1
6
J1
J2
5
6
7
8
9 10 11 12 13 14
2
(73-96)
4
Note:
4
3
J2
CEM SR24 Ribbon Cable Layout
(49-72)
2
J1
(1-24)
2
1
3
J3
J3
(1-24)
(25-48)
The order/layout of the dimmer output edge connectors is different on the CEM+
backplane.
Step 2:
Document and/or label each wire that is currently landed on the J2 edge
connector.
Step 3:
Unscrew the dimmer output edge connectors from the backplane metal.
Step 4:
Carefully feed the dimmer output ribbon cables through the backplane.
Step 5:
Examine each ribbon cable for any nicks or cuts due to backplane scrapes.
Step 6:
Unscrew the power edge connector (J1). Remove it from the back plane by
sliding it out of the notch in the rack and carefully pushing it through the
backplane metal. This connector will be used in the upgrade.
Step 7:
Unscrew the backplane metal from the rack. (One screw in each side uppercorner - two screws total.) Discard these screws. Replacement screws with
thread locker are provided (ETC Part# HW377).
The Retrofit
5
7 Remove the
backplane screws
1
2
10
3
4
5
6
7
8
9 10 11 12 13 14
9
9
8
Step 8:
Push the backplane towards the back of the rack to free the backplane side tabs
Step 9:
Bend the sides into the center (out of the sides of the rack).
Step 10: Slide backplane metal forward in order to allow easier working space while
removing data terminations.
Data and Power Terminations
Note:
Transfer all wire groups (except those designated as ETCLink) to
the new connectors one at a time. Clip tie-wraps as needed to free
wires from the old backplane. See Quick Reference Sheet, page 13
for detailed data wiring instructions and pin-outs.
a: In most cases stranded wire has been used for the data
terminations. If so, land the DMX wiring on the new connectors in
the same manner as they were on the old backplane (physically
landed on the same connector and no need to use the DMX Thru
connector).
1 2 3
Step 1:
Black
Blue
Red
There are two different connectors available for CEM+ data terminations. One is
for stranded wire as found in Belden 9729 and contains screw terminals (ETC
Part# J3407- included with the kits). The other style is an IDC connector (ETC
Part# J3409 - an additional line item) for solid-core wire such as Category 5
cabling.
J16
Beacon
Pin-out
b: If Category 5 type cabling is used, use IDC connectors and land the rack-torack jumper connections on the separate DMX Thru connector on the
backplane (J15).
CAUTION:
If using the IDC connector for Cat5 solid-core wiring, you must start with clean wire
ends (clip the old punched end. Re-punching the old ends could result with an
intermittent or failed connection.
Step 2:
If present, cap the ETCLink wiring.
a: Clip the bare ends.
b: Cap the ends of the wires with the provided UL recognized heat shrink and a
heatgun.
c:
Wire-tie the wires back to the cable.
d: Secure the cabling to the side or back of the rack with tie mounts and wire ties.
Note:
6
Complete removal of the ETCLink wiring may not be possible, and isn't necessary
if properly capped as described in Step 2.
Step 3:
Finish removing the old backplane metalwork. Discard the old backplane.
Step 4:
Clip the first wire-tie behind the existing J1 power connector to give the harness
more room to move while you work.
CEM+ Sensor Rack Retrofit Manual
Step 5:
Install the power adapter harness to edge connector (straight thru PCB) to old
power connector (match the wire colors)
.
The PCB is the same on
both sides, top and bottom.
Oh, I wish
I were an
Oscar Meyer®
wiener...
Wire-tie the
connectors
together
Match the
wire colors
Step 6:
Secure the power connectors together with provided 4"wire-ties. Clip wire tie ends for neatness.
Step 7:
Center the provided 4 1/2” x 1/2” dia. heat shrink tubing over
the power harness connectors (leaving at least 1 1/4” past
each connector) and heat shrink it with a heat shrink gun.
Step 8:
Secure the power harness to the rack:
•
4 1/2"
1-1/4"
Min.
SR6, SR12 & SR24 racks
a: Use a pair of sticky-back tie mounts and wire ties to secure
the power harness to the rear or left side of the rack. The
new power connector should be facing out of the rack (near where the old
harness used to be installed) and the power harness needs to be kept back
from the phase bars.
•
SR48 racks only.
a: Remove the screw near the bottom of B phase bar
that connects the red sense wire to the phase bar.
b: Use a 3/8” socket to remove the five bolts holding the
B phase bar in place and push the phase bar towards
the center of the rack. You only need enough room
to mount the power harness. Do not remove the
power feeder.
c:
Using a couple sticky-back tie-mounts, mount the
power harness to the left side of the rack (see detail
below). The new power connector should be facing
out of the rack (near where the old harness used to
be installed) and the power harness needs to be kept
back from the phase bars.
next to
t
n
u
o
M
al
eetmet
h
s
f
o
edge
3"
1/2"
nt
p mou ic.
a
r
w
last
st tie
the fir e middle G
e
c
a
l
P
th
bove
1/2" a
2
The Retrofit
7
d: Use a 3/8” socket to re-install the B phase bar with the five bolts.
e: Re-attach the red sense wire to the B phase bar with the previously used screw.
Step 9:
Identify the different dimmer output ribbon cable transition cards. An SR6 and
SR12 will only have a single “lower” card.
This is an “Upper”
transition board
(7150B5007)
2
1
4
3
This is an “Lower”
transition board
(7150B5006)
Note:
There are two different types. An “upper” card and a “lower” card. The PCB card
is marked for both the type and which side is up when installed.
Step 10: Mate the transition cards with the ribbon cable edge connectors as indicated
below. Secure the ribbon cable connectors to the transition cards with wire ties.
The tie wrap binding needs to be on the top for an Upper board and on the
bottom for a Lower board for clearance. Clip wire tie ends for neatness.
Wire tie the
connectors
together
Match
the red
wire to
pin-1
and be
sure the
proper
side is
up
Position of the
tie wraps
On top for Upper
On bottom for Lower
Step 11: Terminate the Ethernet cable with the provided Ethernet Termination Kit (ETC
Part# 4101A2003). Follow the wire preparation and termination instructions
included with the kit.
8
CEM+ Sensor Rack Retrofit Manual
Install the New Backplane
Step 1:
Set the DMX termination switches.
Termination should be turned on for the
last physical rack in the DMX daisychain (No DMX wiring goes back out for
that port.) The switches and their
location are shown here.
Step 2:
Bend one arm of the backplane metal in
towards the opposite arm (about 30 deg).
Step 3:
Insert the backplane metal on an angle. Then
straighten it once it is past the face of the rack.
Push it into the rack far enough that it stays in
place, but leave yourself some room to make
the power and data connections.
Step 4:
Make the power and data connections on the
backplane.
a: Dimmer output ribbon cables/transition
cards. The order/layout is not the same as
on the old backplane. See the illustration
below. Make sure the proper side is
facing up on each connector and that
each connector is fully seated.
b: Power harness (Look at the pin shapes for proper orientation. It will only fit one
way.)
c:
DMX connections. (The wires come out the top on both styles of connectors.)
d: Beacon connector (The wires come out the top.)
e: Use the 1' Cat5 Ethernet cable to connect the biscuit box to the backplane. (Not
shown on the drawing below for clarity.)
• In an SR6, SR12 and SR24, use the double-stick tape (on the box) to secure
the biscuit box to the bottom of the rack behind the backplane.
• In an SR48, use the double-stick tape (on the box) to secure the biscuit box
to the bottom of the backplane.
2
1
Power
Beacon
Step 5:
2
The Retrofit
CEM+ Ribbon Cable Layout
DMX Thru
DMX B
DMX A
4
3
(25-48)
(73-96)
(1-24)
(49-72)
Push the backplane the rest of the way into the rack. Be careful of the power and
data connections you just made. Don’t let any of the wiring become stressed or
get pinched.
9
Step 6:
Insert tabs in the side of the
rack.
Step 7:
With the tabs fully inserted in the
sides of the rack, pull the
backplane towards the front of
the rack to line up the screw
holes in the upper side corners
to line up.
Step 8:
Install one screw with a sleeve in each side upper-corner of the backplane.
Note:
Screw with
sleeve
You cannot use the old screws without the additional shoulder-sleeve as they will
block the CEM+ from being fully inserted.
Change out the AF Cards (if present)
Step 1:
Remove the old AF cards (pull the plastic tabs)
Step 2:
Address the new AF cards (mini-switches) as
shown below.
Step 3:
AF Card Addressing
S
W
1
Sensor+
1 SR6+
SR12+
Install the cards in the slots. Make sure they are
completely and securely seated. Card #1 at the
top, down to 4 at the bottom for SR48. (SR6, SR12
& SR24 have fewer cards. Always start with #1 at
the top.)
2
SR24+
3
4
SR48+
S
W
2
S
W
3
S
W
4
Card 1
Card 2
Card 3
Card 4
Change out the Beacon PCB
Step 1:
Note:
10
Remove the two screws that hold the beacon PCB in the face of the rack.
Be sure to use a properly sized screw driver (#2 Phillips) and a good amount of
force as those screws are kept in place with a thread locker. Don’t worry about
damaging the existing screws (replacements are provided) or shearing off the
heads of the screws (the screw shanks are threaded into the PCB’s standoffs).
Step 2:
Pull the PCB down and around the rack New blue-LED
case. (The wire harness will only let it go beacon PCB
so far.)
Step 3:
Note the orientation of the connector. and
unplug the wire harness from the old
Beacon PCB.
Step 4:
Attach the wire harness to the new
beacon PCB with the connector in the
same orientation.
Step 5:
Install the new beacon PCB (ETC Part #
7050B5109) with two screws (ETC Part #
HW222) (two new screws of the same type are provided in case the old ones get
damaged during the removal process).
CEM+ Sensor Rack Retrofit Manual
F i n i s h i ng T o u c h e s
Step 1:
Remove the old Sensor beacon acrylic in the door and discard.
Step 2:
Install the Sensor+ beacon acrylic in
the door.
Step 3:
Remove old Sensor label from the front
of the door and discard.
Step 4:
Clean the door surface to remove any
dirt or old adhesive.
Step 5:
Apply the new Sensor+ label to the
front of the door. Line up the label
around the opening for the acrylic in the
door and be sure the label is straight.
Use a piece of cloth or paper towel to
make sure the label is flat & smooth
and properly adhered to the rack door.
Repeat the above steps for the remainder of connected racks.
Verify the Retrofit
Step 1:
Put the dimmer modules back in the rack in the correct/original order.
Step 2:
Put the CEM+ in the rack.
Step 3:
Power up the rack.
Step 4:
Check that the CEM+ powers up and the rack fan turns on. (The only rack errors
should be a lack of DMX on the ports if the DMX source is not present.)
Configure the CEM+
2
Step 1:
Configuration of the CEM+ is done via the front face panel interface or via a
graphical HTML interface called Sensor+ Connect that is resident in the CEM+.
Step 2:
Configure the rack to reflect the rack type and dimmer module types installed.
Step 3:
Configure the data types that will be used (DMX and EDMX) including the rack
patch.
Step 4:
For detailed configuration information, please refer to the CEM+ Configuration
Manual.
The Retrofit
11
12
CEM+ Sensor Rack Retrofit Manual
7
8
9 10 11 12 13 14
(1-24)
J3
(1-24)
1
J3
1
3
(1-24)
(49-72)
2
4
(25-48)
(73-96)
(25-48)
2
3
2
7
8
9
PANIC OUT
DMX B DMX B +
DMX COM
ETCLink V+
ETCLink Common
ETCLink (B2)
ETCLink (B1)
5
6
BEACON
+10V
COMMON
12
13
14
11
10
3
4
PANIC IN
Red
Blue
Black
1
2
3
1
2
3
DMX COM
DMX B DMX B +
+12V
BEACON
COMMON
DMX COM
DMX A DMX A +
and Tie back.
Heat shrink,
Clip ends,
3
1
2
J11
3
1
2
J16
J10
J2
DMX A DMX A +
DMX COM
CEM+
BEACON
+12V
8
DMX A +
DMX COM
DMX B DMX B +
N/C
N/C
4
5
6
7
8
DMX A 2
3
DMX COM
1
DMX Thru for Cat5
with IDC connector
J15
PANIC IN
7
PANIC OUT
6
N/C
5
N/C
4
COM/GND
3
COM/GND
2
1
J3
2
4
3
J15
J16
J11
J10
J3
CEM+
CEM
Physical Overview
1 2 3
to
3
backplane screws
1 Remove the
Start to remove the old backplane
Label the data wiring
(use the pin-out from #4)
1 2 3 4 5 6 7 8
CEM
Transfer wire groups one at a time to the new backplane data connectors.
6
4
5
9 10 11 12 13 14
J2
4
8
J1
3
CEM SR48 Ribbon Cable Layout
2
7
J2
1
6
J1
J3
1
CEM SR24 Ribbon Cable Layout
5
CEM
Ribbon Cable
Layouts
4
J2
3
9 10 11 12 13 14
J1
2
8
1
1
6
Number the
ribbon cables
5
CEM SR6/12 Ribbon Cable Layout
4
7
Quick Reference Sheet
3
Section 3 2
Quick Reference Sheet
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1
3
13
14
CEM+ Sensor Rack Retrofit Manual
I were an
Oscar Meyer®
wiener...
1-1/4" minimum
past both ends
Sensor+
4
3
2
SR48+
SR24+
1 SR6+
SR12+
Card 1
Card 2
Card 3
Card 4
S
W
1
S
W
2
S
W
3
AF Card Addressing
S
W
4
6
13
Install new beacon PCB
"Lower" Transition board
(7150B5006)
"Upper" Transition board
(7150B5007)
Identify the ribbon cable
transition cards for
correct use and placement
New blue-LED
beacon PCB
Bend &
insert
the new
backplane
9
Install backplane screws (2)
Set the DMX
termination
Oh, I wish
Assemble the power
harness adapter &
heat shrink it
Address
AF cards
12
11
8
5
Power
10
side up.
correct
check for
pin-1 and
wire to
Match red
15
14
DMX B
DMX A
(1-24)
(25-48)
(49-72)
(73-96)
CEM+ Ribbon Cable Layout
Install new beacon acrylic
DMX Thru
Apply new
Sensor+
label
Beacon
1
2
3
4
Mate the transition card(s) with the
correct ribbon cable connector.
Note the markings for proper
orientation to both the ribbon cable
and the backplane.
Make the power & data connections
7
Notes:
3
Quick Reference Sheet
15
Notes:
16
CEM+ Sensor Rack Retrofit Manual
Americas „ 3031 Pleasant View Road, P.O. Box 620979, Middleton, Wisconsin 53562-0979 USA „ Tel: +1 608 831 4116 „ 800 688 4116 „ Fax: +1 608 836 1736 „ 800 555 8912
Europe „ Unit 5, Victoria Industrial Estate, Victoria Road, London W3 6UU, UK „ Tel: +44 (0)20 8896 1000 „ Fax: +44 (0)20 8896 2000
Asia „ Room 605-606, Tower III Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Kowloon, Hong Kong „ Tel: +852 2799 1220 „ Fax: +852 2799 9325
Web: www.etcconnect.com „ Email: (US) mail@etcconnect.com „ (UK) mail@etceurope.com „ (Asia) mail@etcasia.com
Service: service@etcconnect.com „ Toll free: 800 775 4382 „ Comments about this document: techcomm@etcconnect.com
7150M2300 „ Rev A „ Released 06/2004 „ Copyright © 2004 Electronic Theatre Controls, Inc. All Rights Reserved. Product information and specifications subject to change.