® Sensor3 CE Rack (ESR3 Series) Installation Manual Revision F 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 .
E T C p e r m i ts t h e r e p r o d u c t i o n o f m a t e r i a l s i n t h i s m a n u a l o n l y f o r n o n - c o m me r c i a l p u r p o s e s . A l l o t h e r r i g ht s a r e r e s e r v e d b y E T C . ET C ® a n d S e n s o r ® a r e e i t h e r r e g i s t e r e d t r a d e m a r k s o r t r a d e m a r k s o f E l e c t r o n i c T h e a t r e C o n t r o l s , I n c . i n t h e U n i t e d S t a t e s a n d o t h e r c o u n tr i e s .
Table of Contents Warnings. . . . . . . . . . . . . . . . . . . . . . . iii Introduction . . . . . . . . . . . . . . . . . . . . . .1 How to use this Guide. . . . . . . . . . . . . . . . . . . . . . . . . . .1 Warning and Notice Conventions . . . . . . . . . . . . . . . . . .1 Contacting ETC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Prepare for Installation . . . . . . . . . . . . .3 Unpack and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet Network Termination - RJ45 Connector. . . . . 23 Panic Circuit Connections (Optional) . . . . . . . . . . . . . . . . . 23 Panic Circuit backplane connection . . . . . . . . . . . . . . . 23 Dual Tracking Remote Select Switch connection (Optional)24 Station Connection (Optional) . . . . . . . . . . . . . . . . . . . . . . . 25 Connecting Station Wiring . . . . . . . . . . . . . . . . . . . . . . 25 Connect ESD Ground. . . . . . . . . . . . . . . . . . . . . . . . . . 25 Finishing Installation . .
Warnings WARNING: (GB) • INCORRECT CONNECTION MAY CAUSE DAMAGE OR INJURY. • FOR PROFESSIONAL USE ONLY. • THIS EQUIPMENT MUST ONLY BE CONNECTED AND OPERATED BY AUTHORISED PERSONNEL. • READ NOTICES AND WARNINGS IN PRODUCT DOCUMENTATION BEFORE USE. • WARNING: HIGH LEAKAGE CURRENT; THIS EQUIPMENT MUST BE GROUNDED. • ISOLATE POWER BEFORE REMOVING COVERS. WARNUNG: (DE) • FALSCHER ANSCHLUSS KANN ZU BESCHÄDIGUNGEN ODER VERLETZUNGEN FÜHREN. • NUR FÜR PROFESSIONELLEN EINSATZ.
VAROITUS: (FI) • KYTKENTÄVIRHE VOI AIHEUTTAA LAITTEEN RIKKOUTUMISEN TAI HENGENVAARAN. • VAIN AMMATTIKÄYTTÖÖN. • LAITTEEN SAA KYTKEÄ AINOASTAAN KOULUTETTU, ASIANSA OSAAVA HENKILÖ. • LUE VARIOTUKSET LAITTEEN KÄYTTÖOHJEISTA ENNEN KÄYTTÖÄ. • VAROITUS: SUURI VUOTOVIRTA, LAITE ON EHDOTTOMASTI MAADOITETTAVA. • KYTKE VIRRANSYÖTTÖ POIS AINA ENNENKUIN POISTAT LAITTEEN SUOJUKSET. ATTENTION: (FR) • DES ERREURS DE CONNEXION ELECTRIQUE POURRAIT PROVOQUER DES DOMMAGES OU BLESSURES.
WAARSCHUWING: (NL) • VERKEERD AANSLUITEN KAN RESULTEREN IN SCHADE OF LETSEL. • ALLEEN VOOR PROFESIONEEL GEBRUIK. • DEZE APPARATUUR MAG ALLEEN DOOR GESPECIALISEERD PERSONEEL AANGESLOTEN WORDEN. • LEES EERST DE GEBRUIKSAANWIJZING VOOR HET APPARAAT TE GEBRUIKEN. • WAARSCHUWING: DIT APPARAAT MOET GEAARD ZIJN! • SCHAKEL DE VOEDINGSSPANNING UIT VOOR OPENEN VAN DE KAST. ADVARSEL: (NO) • FEIL KOBLING KAN FORÅRSAKE STOR SKADE. • KUN FOR PROFESJONELT BRUK.
DIKKAT: (TR) • YANLIŞ BAĞLANTI, HASAR VEYA YARALANMALARA SEBEP OLABİLİR. • YALNIZCA PROFESYONEL KULLANIM İÇİNDİR. • BU CİHAZ, YALNIZCA YETKİLİ BİR KİŞİ TARAFINDAN BAĞLANMALI VE KULLANILMALIDIR. • CİHAZI KULLANMADAN ÖNCE KULLANMA KILAVUZUNDAKİ UYARILAR BÖLÜMÜNÜ DİKKATLİCE OKUUN • DİKKAT: YÜKSEK KAÇAK AKIM. CİHAZ MUTLAKA TOPRAKLANMALIDIR. • KAPAKLARI AÇMADAN ÖNCE ENERJİ BAĞLANTISINI MUHAKKAK KESİN. VAROVÁNÍ: (CZ) • Nesprávné připojení může způsobit škodu nebo zranění.
Introduction Welcome to the installation manual for Sensor®3 CE racks. This manual contains the procedures for safe and efficient installation of Sensor3 rack dimming systems.
Contacting ETC If you are having difficulties, your most convenient resources are provided in this installation manual. To search more widely, try the ETC website at www.etcconnect.com. If none of these resources is sufficient, contact ETC Technical Services directly at one of the offices identified below. Americas Electronic Theatre Controls Inc. Technical Services Department 3031 Pleasant View Road Middleton, WI 53562 800-775-4382 (USA, toll-free) +1-608 831-4116 service@etcconnect.
Chapter 1 Prepare for Installation Unpack and Inspect Before you begin installation, check your shipment and confirm it arrived complete and undamaged. Step 1: Check the shipping container for physical damage. Step 2: If you find damage, document it to help with a claim against your shipper. Step 3: Unpack your order and check the contents against the packing list to be sure your order is complete. Step 4: If you discover a problem, contact your dealer or nearest ETC office.
. CAUTION: A two-wire circuit with separate phase and neutral conductors is required for every branch circuit that will be connected to the dimmer rack. Shared neutral circuit arrangements are not recommended for phase-control dimming systems due to harmonics and potentially elevated neutral currents in a shared neutral arrangement.
Chapter 2 Installation of Racks Mounting the Rack • ESR3-12 racks are normally wall-mounted. • ESR3-24 racks can be mounted to a wall or floor-mounted on an optional pedestal. • ESR3-36 and ESR3-48 racks are floor standing. Mounting Racks on a Wall (ESR3-12 and ESR3-24) The wall must be strong enough to hold the racks. Please see Appendix A: Sensor3 CE Rack Specifications, page 34 for rack and module weights.
Installing ESR3-36 and ESR3-48 Racks on the Floor Step 1: Note: Determine where your rack will be installed using Figure 1: Sensor3 rack clearances on page 4 and use the appropriate diagram from Figure 3 to mark your mounting holes. Sensor3 racks of the same size are the single exception to the 15cm left clearance requirement. They can be installed side by side without problems. Step 2: Drill the holes and install your own M10 mounting hardware. Step 3: Position the rack in the desired location.
32mm 294mm 79mm 32mm 480mm 294mm 79mm 511mm 404mm Dia. 10mm 436mm Dia. 10mm 373mm 373mm ESR3-48 Floor mount hole diagram ESR3-36 / ESR3-24 Floor mount hole Figure 3: Hole diagrams for mounting racks to the floor Securing Sensor3 Racks to a Wall Racks installed on the floor or a pedestal can also be secured to a wall for greater stability.
Wall Mounting Racks Using Vibration Pads Align the center of the fitting over the diagram hole location and mark the position of the fitting bolts ETC Part# HW6111 Vibration damping fittings are available as an option for wall mounted racks. The wall must be strong enough to hold the racks. Please see Appendix A: Sensor3 CE Rack Specifications, page 34 for rack and module weights. Note: 50cm Be sure this mounting method complies with your countries building and electrical codes.
to the floor on page 7 to mark your hole locations. Step 3: Align the center of the vibration fitting over the hole locations from the diagram. Mark the positions for two bolts for each vibration pad. Step 4: Drill the holes and secure the pads to the floor. You must supply your own M8 mounting hardware. Step 5: Remove the included bolt and washer from each vibration pad. Step 6: Position the rack on the pads so the center holes of the pads align with the mounting holes in the base of the rack.
Securing Multiple Racks (Optional) Multiple racks can be connected to each other for greater stability. Note: If you want to install the control cable through the side of the racks, you should remove the side cable knockouts before connecting the rack. Step 1: Use M8 spin lock bolts and lock nuts in the front and at the back to bolt the racks together at the bottom.
Rack Cabling Access ESR3 racks have removable top and bottom access panels. Bottom access panel Top access panel Figure 8: ESR3 access panels Conduit Connections Step 1: Remove the desired access panel from the rack. Step 2: Cut access holes in the top and bottom access panels. Step 3: Install your cabling into the holes. Step 4: Re-install the access panel so that there are minimal air gaps. See “Sealing Rack Air Leaks” on page 28. for more information .
Connect Li ne Power Wiring ETC recommends routing line (feeder) cables first, load neutral and load earth wires next, and load phase wires last. CAUTION: Line and load wires used with Sensor3 dimming systems must be copper. Do not use wire containing aluminium or other metals. CAUTION: Dress wires neatly and avoid leaving extra wire inside the rack. Too much clutter (especially along the right side of the rack) can restrict air circulation and reduce cooling efficiency.
Chapter 3 Land Load Wires Land Load Wires Each dimmer has three sets of lugs connected to phase, neutral and earth. Phase and earth lugs are on the right side of the rack, neutral lugs are on the left. Lugs can be single 6/ 10/15/25 amp, paired 15/25 amp fluorescent, or doubleheight 50 amp. Dress and connect load wires neatly without leaving extra wire in the rack.
that phase, neutral and earth can be corrected to the relevant lugs as shown. Load Neutral (blue wires) are landed on load neutral lugs attached to the main neutral bus plate Load Phase (brown wire) Each dimmer’s load lug set is at the same height. Load Earth (green wire with yellow stripe) Figure 12: Load cable connection to lugs Step 3: Fit load earth wires into the earth lugs as shown below and torque to the recommended value from Table 1.
Cut Key Slots for Modules Sensor3 dimming and control modules are easily slid into place by hand. Each module slot is keyed to accept only a module with the correct current rating for the slot. Cutting Key Slots for 25A and 50A Modules Modules with current capacities higher than 15A are prevented from fitting into incorrect slots by the module cutout bar to the left of the rack.
Converting Neutral Disconnect Slots There are two classes of modules available for Sensor3 CE racks - modules which break the neutral, such as RCD or ND modules, and single pole modules that do not. Normally your rack will be configured by ETC at the factory for the correct module types, however if you have a mixture of modules or you have not been able to supply details of slot allocations you may need to configure some slots on site. Step 1: Determine which dimmer slots you will be converting.
Installing Three-Slot Dimmer Lug Strips Step 1: Use a Phillips screwdriver to remove the two screws securing the lug strip to the left side of the rack. Step 2: Remove the lug strip and replace it with one containing a three-slot Neutral jumper. Step 3: Secure the strip to the rack with the screws you removed in Step 1. Secure the jumper to the main Neutral bus PEM inserts using the two screws provided with the jumper.
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Chapter 4 Control and Data Connections Sensor3 racks support a variety of control and data connections on the CEM3 backplane. CEM3 backplanes have connectors for: • Two DMX512 Cables (Universes) • External Panic Circuit Activation and Indication • Remote Redundant Tracking selection switch (Dual Backplane Only) • Ethernet Network • Station Wiring Dual and Single Backplane Differences To use dual control modules your rack must be fitted with a dual tracking backplane.
Running DMX Cable to Racks Note: If the system includes a Panic circuit, stations or Remote Tracking Selection, pull the necessary wires with the data cables to all required racks. Step 1: Remove the desired top, bottom or side conduit knockout from the first rack on the left or right of the group of racks. See Figure 20:Side data knockouts for knockout locations. Step 2: Remove the 25mm side data conduit knockouts between the first rack and the other racks in the group.
with the rack and should be ordered separately. ORG W/BRN Data - COM GRN BRN Data + W/ORG W/GRN BLU W/BRN COM From source DMX A W/BLU ORG Data - GRN BRN Data + W/ORG W/GRN BLU W/BRN COM From source DMX B W/BLU ORG Data - ORG COM W/BRN Data + W/ORG Data - n/c n/c Data + W/ORG DMX A Thru 1 2 3 4 5 6 7 8 DMX B Thru 1 2 3 4 5 6 7 8 If daisy-chaining to another rack or DMX device...
Running Ethernet to Racks Sensor3 racks use Ethernet for communication with each other and sometimes for communication with the lighting console. It is therefore important that all racks are linked via Ethernet. This may either be done using an NEFM (Network Electronics Filler Module A network switch built into the lower slot of one of the racks) or using an external network hub or switch.
Ethernet Network Termination - RJ45 Connector Step 1: Follow the directions provided in the Ethernet Termination Kit to terminate the incoming CAT5 cable in the RJ45 UTP connector in the surface mounting box. The kit is included with the dimmer rack door. Use the instructions provided with the kit for proper Category 5 cable termination. Step 2: Step 3: The surface mount box should be installed with the double-sided tape inside the rack.
Dual Tracki ng Remote Select Switch connection (Optional) If desired, a remote switch can be wired to the CEM3 backplane to control CEM3 selection in racks equipped with ETC’s Redundant Tracking CEM3 option. Note: You must supply your own enclosed single-pole double-throw center-off switch to install a remote select switch. You may optionally use an external 24V DC power supply, or use the power supply from the rack backplane. Step 1: Pull 1.
Stati on Connection (Optional) Sensor3 racks support ETC’s range of stations. The station network should be wired in Belden 8471 or an equivalent cable. Stations are topology-free. Wiring may be bus, star, loop, home run or any combination of these. to stations SEND B e ld en 84 71 Figure 27: Connection of station wiring C o n n e c t i n g S ta t i o n W i r i n g Step 1: Cut the Belden 8471 cable so that a 20cm tail extends from the edge of the backplane. Step 2: Strip 18cm of the outer jacket off.
26 Sensor3 CE Rack (ESR3) Installation Manual
Chapter 5 Finishing Installation The steps in this chapter should only be performed by, or after receiving approval from, an authorised ETC representative. Check Backplane DIP Switches The backplane of your rack features a set of eight DIP switches allowing configuration of the rack type. The CEM3 reads these DIP switches to determine the rack type, phasing and available modules.
Sensor3 Installation Checklist A checklist is provided in Appendix B: Sensor3 Installation Checklist, page 35. Following this checklist will help ensure that your Sensor3 system operates reliably and without problems. The checklist is a summary version of the steps in this chapter. Sealing Rack Air Leaks After you have installed all conduit, trunking and cables to the rack and connected all wiring, you must seal any air leaks in the rack cabinet created during the installation process.
with two Phillips head screws (included). Top hinge being inserted Top hinge in place Figure 28: Attaching the top door hinge Step 2: The bottom hinge on the ESR3-12 is a different design from the one used on the ESR3-24, ESR3-26 and ESR3-48. • ESR3-12 – Insert the bottom hinge into the slot on the bottom of the rack and attach it to the frame with two Phillips head screws (included).
taper pin through the washers and into the hole on the lower hinge. Door Door Washers Taper pin Taper pin ESR3-48 lower hinge ESR3-12 lower hinge Figure 31: Installing the bottom taper pin Step 3: Hold the door in place and insert the other taper pin, narrow end down, through the top hinge and washer.
Checking Rack Installation before Installing Modul es It is a good idea to check the installation before applying power to the rack. Before Applying Power to the Rack WARNING: Step 1: RISK OF ELECTRIC SHOCK! Power must be turned OFF when you perform this procedure. Clean out dust, metal scraps or other debris from the rack interior. • ETC recommends vacuuming the rack interior before installing modules. Step 2: Check for loose connections, bare wires or damaged insulation.
Installing Dimmer Modules Step 1: Inspect each dimmer module for loosened components or shipping damage. Step 2: Slide dimmer modules into the rack. If you are installing a mix of module types, consult the included project drawings for the correct module order. Step 3: Push each module into its slot until it is flush with the front of the rack. Installing Module Locking Bars CAUTION: The module locking bars should always be installed once installation is complete.
Testing an Installed Sensor3 Rack After finishing installation, use this procedure to perform a functional check. Note: Go over the Sensor3 installation checklist in Appendix B: Sensor3 Installation Checklist, page 35 before energising the rack. Step 1: Make sure power is disconnected at the main circuit breaker. Step 2: Open the door and set all the dimmer module circuit breakers to Off. Step 3: Remove the CEM3 and set the test switch to TEST.
Appendix A Sensor3 CE Rack Specifications All of the rack specifications apply to all of the ESR3 series of racks unless otherwise noted.
Appendix B Sensor3 Installation Checklist CAUTION: Job Number Job Name Rack This checklist is for use by authorised ETC trained personnel when energising ETC Sensor3 racks. Do not attempt to energise a Sensor3 system unless you are authorised and qualified to do so. of Place a tick in each box to confirm item has been checked and is OK. Write NA if Not Applicable. B e fo r e h a n d All material on site. Advise ETC of shortages ASAP.
Appendix C Emergency Modules About Emergency Modules Sensor3 CE Emergency modules provide two live outputs, one of which is dimmed or switched, and one of which is live whenever the breaker is turned on. This allows the modules to control battery backed lighting which requires a constant and a switched or dimmed feed.
Step 5: CAUTION: Terminate the neutral as described below dependant on your rack type. It is important to correctly identify the Constant Live, Dimmed Live and Neutral wires, as incorrect termination can cause damage to the fixture and/or dimmer rack. Single Pole Racks For racks which have neutral jumpers fitted, the neutral of the load fed by the emergency module should be connected to the neutral terminal of an adjacent module.
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