SOFTWARE VERSION 3.1 WWW.PRG.
AutoPar®, Bad Boy®, Best Boy 4000®, PRG Series 400®, Mbox Extreme®, OHM™, V476®, V676®, Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and VL6C+™ are trademarks of Production Resource Group, LLC, registered in the U.S. and other countries. Mac®, QuickTime® and FireWire® are registered trademarks of Apple Computer, Inc. All other brand names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies.
FOREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product. WARNING advising of potential injury or death to persons.
Revision History This manual has been revised as follows: Version Release Date Notes BASIC April 28, 2006 Initial Release A May 30, 2006 Updated Rack Configuration drawing p.18. Added “Software Upgrades” p.39. B II May 13, 2008 Updated “Additional Documentation” section on p. 1. Incorporated Series 400 400 Amp Disconnect information and warnings. Incorporated Series 400 10-Port and 7-Port Ethernet Switch descriptions, features and installation information. C.
TABLE OF CONTENTS Introduction About This Manual........................................................................................................................................................................ 1 Additional Documentation ............................................................................................................................................................ 1 Customer Service ............................................................................................
Menu Details ............................................................................................................................................................................... Input/Output Summary – Rack Module............................................................................................................................... Input/Output Summary – Front of House Module ...............................................................................................................
INTRODUCTION About This Manual This manual provides necessary information regarding product safety, installation, and operation for the following PRG equipment: + PRG Series 400® Power and Data Distribution System - 120/208V Model (U.S. / Canada) This manual applies to S400 software version 3.1. Familiarizing yourself with this information will help you get the most out of your PRG product.
Customer Service For technical assistance, contact the PRG International Service Center or contact your nearest PRG office. Contact information for all PRG office locations can be found on our website at: www.prg.com/about-us/locations/ PRG Dallas (International Service) 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 USA Phone: 214.630.1963 Fax: 214.630.5867 Service Fax: 214.638.2125 Service Email: orders@prg.com For additional resources and documentation, please visit our website at: www.prg.
1. OVERVIEW This chapter provides an overview of product features, components, and system configurations.
DESCRIPTION Overview The standard V676 Console consists of a Rolling Rack unit, up to six 3U Breaker Modules, and associated Breakout Boxes connected by Trunk Cables. The rack is designed to distribute house power service and control signals for the purpose of operating automated luminaires or other remote devices up to 500 feet away.
Depending on the application, there are several model types available for Series 400 Breaker Modules and Breakout Boxes. Models are as follows: Breaker Modules 30A 208V Breaker Module 20.9680.2630 2.38380-18 15A 120V Breaker Module 20.9680.1915 2.38380-05 15A 208V Soca Output Breaker Module 20.9680.2715 2.38380-16 15/30A 208V (mixed) Breaker Module 20.9680.2815 2.38380-17 15A 208V Breaker Module 20.9680.2915 2.38380-15 Breakout Boxes 15A 208V Breakout Box 20.9680.6615 2.
Several types of data distribution devices are available for expansion of the Series 400 System. Ethernet Switches The Series 400 Ethernet Switches provide a powerful and convenient interface between Virtuoso® or DMX512 control consoles and their control equipment. For complete installation and operation instructions, refer to the following manual: + Series 400 Ethernet Switch User Manual (02.9801.0001).
Features Overview The Series 400 System offers a significant amount of features, both standard and superior to other power distribution systems. Features Summary + Supports up to 72, 1.
Features By Component Rolling Rack Unit • Supports up to 72, 1.
A 208V Breaker Module • Twelve 15A 208V Outputs • Two DMX512 Inputs • Two 100BaseT Ethernet Inputs • Signal Routing Control and Display • Front Panel Flush Rocker Circuit Breakers • Hot-Swapping Capability • Safety Interlock with Breakout Boxes 15A 208V Breakout Box • Power and Signal for up to Six Devices • Six L6-20 Output Connectors • DMX512 and 100BaseT Ethernet Outputs • Compact Package for Truss Mounting • Rugged Construction • Safety Interlock with Breaker Modules 30A 208V Breaker Module • Six 20
15A 208V Soca Output Breaker Module • Twelve 15A 208V Outputs • Two VEAM VSC 19-Pin Connectors • 15A Long-Time Delay Trip Curve Circuit Breakers designed to handle Strobes • Compatible with Standard Socapex Trunk Cables and FanOuts • Neon Power Indicators for each of Three Phases • Master Switch Controls Contactors • Front Panel Flush Rocker Circuit Breakers • Hot-Swapping Capability Front of House Trunk DC Adapter • Used in place of standard Trunk Cable to power internal circuit boards in all versions of
Virtuoso Node Plus • Accepts both Virtuoso and Art-Net control protocols. • Compatible with 10Base-T or 100Base-TX standard signals. • Automatic detection and mode configuration according to input signal type. • One Ethernet (Art-Net) output port supporting up to six DMX512 universes. • Six DMX512 serial output ports supporting one DMX512 universe each. • LEDs indicating Link, TX data, and RX data status for all Ethernet ports. • LEDs indicating DMX Tx, RDM Tx, and RDM Rx data status for all DMX ports.
Accessories The following optional and/or replacement items can be ordered directly from PRG. (Please order by PRG part number.) PRG P/N TEAM eCode Accessory 22.9620.0194 2.38380-75 Safety Cable Assembly 55.6841.0001 2.38380-72 Mega-Claw Truss Hook (for 2" Round Pipe) 21.9680.0661 - 1U Safety Cover Plate Assembly 21.9680.0662 - 2U Safety Cover Plate Assembly 21.9680.0660 - 3U Safety Cover Plate Assembly 25.9680.9001 2.38380-48 Ethernet Patch Cable, 1 Ft., Black Shark Fin 25.9680.
CONTROLS AND INDICATORS Series 400 Rack The PRG Series 400 Rack unit is the main power and data distribution hub for the system. The Rack houses up to six Breaker Modules of any type, which can include a Front of House Breaker Module. The Rack provides a built-in LED Meter Module that monitors system current and voltage, and additional space for installing optional expansion components such as Series 400 Ethernet Switches and/or Virtuoso® Nodes.
Rear Rack Light - provides illumination for rear side of rolling rack. Pilot Light - indicates when power is applied to rack system. Provides a Push-To-Test function. Rack Light On/Off Switches - on/off switches for front and rear rack lights. Master On Switch - powers up entire rack system.
Breaker Module The Breaker Module provides two trunk outputs, with each circuit protected by an individual circuit breaker, for the purpose of routing power and control to the system. The total number of circuits depends on the model. The module accepts 100BaseT Ethernet and DMX512 inputs, and features a Menu Display which provides control and configuration of the signal routing to all connected Breakout components. The Breaker Module is installed directly into the Rack unit.
Soca Output Breaker Module The Soca Output Breaker Module allows Socapex-compatible trunk cables and fan-outs to be used with the Series 400 system. The module provides twelve 15A outputs for two Socapex-compatible trunk cables (six circuits each). During operation, all trunk outputs will be on if the Rack Master Switch is enabled, since there are no key lines to disable the outputs.
Breakout Box The Breakout Box supplies power and control signal for three, four or six devices, depending on the model. LEDs provide verification of the power and data signals. The Breakout Box can be installed in a truss with a choice of several mounting hardware options, providing a convenient location for connecting system devices. The following illustration provides a detailed description of the Breakout Box connections, indicators and mounting hardware options.
Front of House Breakout Module The Front of House (FOH) Breakout Module provides a convenient method for connecting consoles and accessories at the mix riser position. It provides power outlets for up to 12 devices, each of which are protected by an individual circuit breaker. Using the FOH Breakout Module, both a primary and backup console can be connected to the system.
Front of House Breaker Module The Front of House (FOH) Breaker Module provides two trunk outputs, with each circuit protected by an individual circuit breaker, for the purpose of routing power and control to FOH Breakout Modules. Unlike the standard Breaker Modules, the FOH Breaker Module does not offer a Menu Display, which is instead located at the FOH Breakout Module itself. The FOH Breaker Module is installed directly into the Rack unit.
Front of House A/B Switch This component requires software version 2.0 or greater. The Front of House A/B Switch is connected to a FOH Breakout Module to provide a convenient method for switching between two sets of DMX512 universes (A and B). With software v2.0, all input universes are given a Source Identifier, in addition to a Universe Number. The default is Source A. Sources A, B, C or * can be selected at a Breaker Module’s Menu Display (refer to "Menu Display Features" on page 39).
10-Port Ethernet Switch The PRG Series 400 10-Port Ethernet Switch provides a powerful and convenient interface between Virtuoso® or DMX512 control consoles and their control equipment. The 10-Port Ethernet Switch offers two types of connections: isolated copper Ethernet ports and fiber optic ports. The fiber optic ports provide the ability to send fast and reliable information up to 2 kilometers away without the need for repeaters using Virtuoso Fiber Optic Cable.
7-Port Ethernet Switch The PRG Series 400 7-Port Ethernet Switch provides a powerful and convenient interface between Virtuoso® or DMX512 control consoles and their control equipment. The 7-Port Ethernet Switch provides seven isolated copper Ethernet ports. Note: Copper connections are limited to a maximum distance of 300 feet.
THEORY OF OPERATION Rack System A Rolling Rack houses an internal 3-phase, 400 Amp bus bar system which is connected to the house power service by 4/0 Cam-Lok cables. The Rack accepts hot-swappable chassis modules that automatically connect to the internal power bus. These Breaker Modules supply various types of AC power to individually protected branch circuits.
FIBER OPTIC CABLE FROM REMOTE RACKS 8 DMX UNIVERSE CABLES FIBER OPTIC CABLE TO REMOTE RACKS DMX DATA CABLE CAT5e CABLE TO LOCAL RACKS A B A B DMX CONSOLE PRIMARY AutoPar AC POWER A A B B AutoPar AutoPar AC POWER A VL3000 B VL3000 VL3000 15A BREAKOUT BOX (A) FRONT OF HOUSE BREAKOUT MODULE A UP TO 500 FT. B FOH A/B SWITCH FRONT VIEW S-400 TRUNK CABLE S-400 TRUNK CABLE DMX512 S-400 RACK UP TO 500 FT.
2. INSTALLATION This chapter provides instructions for connecting rack components and powering up the system.
SYSTEM INSTALLATION AND POWER UP Load Distribution Consideration for proper load distribution should be followed when connecting devices. Be sure to evenly distribute the load across the phases. Refer to the following charts.
Component and Power Connections For examples of basic system configurations, refer to "Theory of Operation" on page 23. Use the following procedure to connect rack components: Step 1. Place rack in desired location and remove front and back covers (Figure 2-2). Figure 2-2: Removing Rack Covers Step 2. Turn OFF all breakers at Rack and Breakout Boxes. Step 3. Turn OFF Mater Switch. CAUTION: Always use safety cables when installing Breakout Boxes in truss. Step 4.
Step 8. Connect console and other auxiliary devices to Front of House Breakout Box. Refer to "Front of House Breakout Module" on page 18 for detailed connection diagram.
Installing an Ethernet Switch A Series 400 Ethernet Switch can be used independently or installed directly in a Series 400 rack chassis, using any blank space above the LED Meter Module. To install in Series 400 rack: Step 1. Install Ethernet Switch as required in top portion of rack chassis (Figure 2-6). Step 2. At Ethernet Switch rear panel, connect AC Line Cord 208V PowerCon® Cable (supplied) to Neutrik® connector. Step 3. After power is applied, verify that ON indicator is lit. Step 4.
The following example system diagrams illustrate an Ethernet Switch being used with a Series 400 Power and Data Distribution Rack. Note: Fiber optic connections are available only with the 10-Port Ethernet Switch.
Power Up Sequence Use the following procedure to power up rack system: Step 1. At house service mains breaker (or 400 Amp Disconnect), turn power ON. Step 2. At rear of rack, verify all phase indicators are lit (Figure 2-10). Phase Indicators Test Points Figure 2-10: Phase Indicator and Test Point Locations Step 3. Using AC voltmeter, check voltages at test points.
Notes: + When properly connected, a click inside the Breaker Module will be heard as the Trunk Cable key engages. + When properly connected, the green Trunk Data LINK indicator will be lit. + Connecting or disconnecting an A/B Switch while the system is powered up can cause an apparent switch closure resulting in a change to the source system. + Connector numbers on the Breakout Boxes correspond to breaker switch numbers on the associated Breaker Module.
Breakout Box Mounting Options Breakout Boxes can be hung horizontally or vertically from any appropriate truss or structure. The Breakout Box provides threaded holes for mounting by wingbolts, along with two additional holes for attaching a clamp bracket or a variety of other hooks. The Mega-Claw truss hook is shown in these examples, however, other compatible truss hooks are available from different manufacturers. CAUTION: A safety cable should be used in all mounting configurations. Attach as shown.
Mega-Claw A Mega-Claw truss hook can be attached by several methods: directly onto the Breakout Box mounting flange or onto a clamp bracket. Refer to previous procedure for installing the clamp bracket.
POWER DOWN Power Down Sequence Use the following procedure to power down and disconnect rack components: Step 1. At Series 400 Rack, turn Master Switch OFF. To disengage Master Switch, pull down red protective cover and press red button (Figure 2-5). Step 2. At house service mains breaker (or 400 Amp Disconnect), turn power OFF. Step 3. At rear of rack, verify all phase indicators are off (Figure 2-10).
Notes 36 PRG SERIES 400® POWER AND DATA DISTRIBUTION SYSTEM USER MANUAL
3. OPERATION This chapter provides detailed instructions for configuring source inputs and using the Menu Display features.
SYSTEM SUPPORT Multiple DMX512 Input Sources The Series 400 rack supports multiple input sources (software v2.0 or greater) and DMX merging (software v3.0 or greater). All DMX512 inputs are configured with a Universe Number and a Source Identifier (A, B, C, *). (Outputs are only assigned with a Universe Number.) The output device will send the numbered universe for the currently selected source, i.e.
MENU DISPLAY FEATURES Overview The Menu Display, located on each Rack Breaker Module, is used to configure, test and access internal status information for the PRG Series 400 Comm System. The soft-programmable buttons are used with the dynamic menu options, while the Reset button performs a hard rest of the module’s processor. Note: Pressing the Reset button may interrupt any DMX512 universes on the network briefly, since the switch will also go into a reset state while the button is held down.
Menu Structure The entire v3.
Menu Details Input/Output Summary – Rack Module This menu shows the configuration of the two DMX512 rack inputs and the two DMX512 outputs on each of the two Trunk Breakout Boxes. In this case, Input 1 (Ca) is Universe 1 from Source A and Input 2 (Cb) is Universe 2 from Source B. The system source default is Source A, indicated by src:a in the last line.
Source-Assignable Art-Net Input An Ethernet input on a Front of House (FOH) module can be mapped to a particular system source. Standard Art-Net corresponds to System A, so it doesn't need to be re-mapped. A standard Art-Net output can be mapped to a different system (B, C, or *) by enabling that option on the FOH module. When Ethernet remapping is enabled on a module, the corresponding DMX inputs are disabled due to the increased processing requirements for handling the network packets.
Configure Outputs – Rack Module This menu allows configuration of the two DMX512 outputs on each of the two Trunk Breakout Boxes. The highlighted universe can be changed by selecting the down arrow () or up arrow (). Move to the next universe by selecting next. Pressing done will prompt a confirmation screen that allows for changes to be committed or discarded.
System: Universes This menu shows all active universes on the network. Up to four universes are displayed at a time. The display consists of the universe number and source (Aa), the module where that universe is defined as an input (FOH1), and the port used for the input to be connected to the device (p0). The left (<) and right (>) arrows allow the previous and subsequent universes to be displayed. Pressing exit will return to the SYSTEM OVERVIEW menu.
Setup 1 and 2 These menus allow configuration of system options and reset to defaults. The highlighted option can be changed by selecting the down arrow () or up arrow (). Move to the next universe by selecting next. Pressing done will save changes and return to the main menu. Name + Displays the current module device name. + To edit the device name, first select one of the arrow buttons, () or (), while the Name menu entry is selected.
Config + Allows the device to be switched between rack and foh modes. Note: The interface will automatically switch to foh mode if a DMX512 input board is detected on one of the Ethernet ports. S/N + Displays the module’s Serial Number. Network Info This menu displays errors, status information and network identification information. The menu will display information for Ethernet (mod), Trunk 1 (out1) and Trunk 2 (out2) communications. DMX Monitor This menu shows the current data for a DMX512 universe.
Software Info This menu shows the current software version and boot version for the Series 400 system. Note: The following is an example screen and may differ from the current released software version. The Version field shows the system software version number. The top Date field shows the system software date and time. The Boot field shows the version number and date for the boot loader module. The bottom Date field shows the boot loader date and time.
Ethernet Tests This menu provides the ability to test Trunk and Ethernet cables. + A Trunk test (trA and trB) sends a round-trip test packet to the attached Breakout Box and back over the specified trunk cable. + Cable test (cable) is used to verify a RJ-45 style cable using the connectors on the front panel. It sends a test packet from one of the ports on the front panel and expects to receive it on the other port.
SOFTWARE UPGRADES Installing a New S400 Software Version The S400Tools Utility should be used for all system software updates. S400Tools allows a system-wide software update with a single button press. Unlike previous versions of S400 software, v3.0 allows software update for all devices in a single packet (instead of updating devices one-by-one). The S400Tools Utility application can be run on any Macintosh® or Java-enabled Windows® computer.
Step 2. At S400 Configuration Manager window, click Load Software button. Click to launch S400 Loader window. Step 3. At S400 Loader window, click Start Download button. The software downloads will be sent sequentially. Progress of the update will be shown via the text display and the progress bar. Step 4. Press Done button when update is complete.
4. TROUBLESHOOTING & MAINTENANCE This chapter provides a basic troubleshooting guide, along with procedures for reconfiguration and extended care of the rack.
TROUBLESHOOTING Basic Troubleshooting Guide Symptom(s) Solution(s) No power to rack. Phase indicators not lit. 1. Ensure Mains Cable Cam-Loks are connected to Inputs. 2. Turn on breaker at 400 Amp Disconnect. 3. Check for LVS failure (see below). No power to connected devices or convenience outlets. 1. Engage green Master Switch button. Power to convenience outlets, but not to connected fixtures (via Trunk Cable). 1. Switch breakers at front of Breaker Module(s) to ON position. 2.
ROUTINE MAINTENANCE Cleaning/Replacing Air Filters Air filters are located on the bottom of the rack tower and in each Breaker Module. These filters may need to be cleaned periodically, depending on amount of use and/or exposure to dusty environments. Rack Filter Parts: 40.7153.0001.0 AIR FILTER, SERIES 400 RACK Tools: #2 Phillips screwdriver WARNING: Remove power from rack before performing any maintenance procedures. To clean the rack air filter: Step 1. Disconnect power to rack. Step 2.
Breaker Module Filter Parts: 40.7154.0001.0 FILTER, FAN Tools: Screwdriver WARNING: Remove power from rack before performing any maintenance procedures. To clean a Breaker Module air filter: Step 1. Disconnect power to rack. Step 2. If required, remove Breaker Module from rack. Refer to "Swapping a Breaker Module" on page 55. Step 3. Using screwdriver, remove filter as shown. Step 4. Clean filter with soap and water. Dry thoroughly. Step 5. Re-install filter.
RECONFIGURING COMPONENTS About Reconfiguring The rack and other system components are configurable depending on system requirements. For example, the rack can contain various types and quantities of Breaker Modules such as 120V and/or 208V or additional auxiliary equipment. The Front of House Breakout Module can be installed independently or in a rack unit itself. WARNING: In any configuration, the rack should never have any unfilled gaps.
Repositioning Front of House Trunk Connector The trunk connector on the Front of House Breakout Module can be positioned in one of two locations depending on whether the unit is to be installed in a rack or used as a stand-alone enclosure. Parts: none Tools: #2 Phillips screwdriver WARNING: Remove power before performing any maintenance procedures. To reposition FOH trunk connector: Step 1. Disconnect power from Front of House Breakout Module. Step 2.
Installing Safety Cover Plates In the event there are gaps in rack components, an appropriate safety cover plate(s) must be installed to prevent contact with the live bus bars. The size of the safety cover is dependent upon the size of the unused rack space. For example, if there is 3U of empty space, then a 3U cover plate is used. If there is 4U of empty space, then both a 3U and 1U cover would be used. Parts: 21.9680.0661 21.9680.0662 21.9680.
Notes 58 PRG SERIES 400® POWER AND DATA DISTRIBUTION SYSTEM USER MANUAL
PRG Series 400® Power and Data Distribution System User Manual Version as of: July 6, 2012 PRG part number: 02.9680.0001.
Production Resource Group, LLC Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.
