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7. Routine maintenance

The following simple maintenance procedures are recommended to keep your
Smartrack installation in perfect working order throughout its life.

7.1. Torque settings

Following first installation, and at regular intervals in situations where dimmers
are subjected to vibration, we strongly recommend that all terminal screw torque
settings be checked for tightness, using the torque setting table below:

Power Terminal hex-headed screws

2Nm

RCD and Circuit breaker terminals

2Nm

Earth and neutral terminals – 10mm

2

2Nm

Earth and neutral terminals – 2.5mm

2

1.5Nm

2.5kW load terminals

1Nm

5kW load terminals

2Nm

10kW load terminals

1.2Nm

To retorque terminals, open the front door of the rack, by releasing the three cap-
tive screws on the front panel, and use a torque setting screwdriver. Note that all
terminal screwheads face forwards, for ease of access.

7.2. Cleaning

In average conditions of use, cleaning should be carried out on an annual basis.

a) Using a vacuum cleaner with a soft furniture nozzle, clean the outside of the

Smartrack enclosure. Then use a damp or spirit-soaked rag to remove grease
or stains.

b) Switch off supply power and open the rack. Using an air blower, blow dust

out of the electronics, behind the aluminium protective cover.

page 47

Smartrack User Manual

Version 1.2

Summary of Contents for SMARTRACK

Page 1: ...onic Theatre Controls Ltd 5 Victoria Industrial Estate Victoria Road London W3 6UU England 44 181 896 1000 FAX 44 181 896 2000 Copyright 1995 Electronic Theatre Controls Ltd Specifications subject to change Revised 8 95 2000M1001 ...

Page 2: ... have done everything we can to ensure that your new dimming system will function perfectly will be easy to install and will give you many years of reliable service This manual contains detailed instructions for installing using and maintaining ETC Smartrack dimmers Please follow them carefully to guarantee best results Neither ETC Ltd nor its distributors can accept any liability whatsoever arisi...

Page 3: ... 2 5 Thermal management 6 3 Getting Started What s in the box 8 3 1 Smartrack 8 3 1 1 Rack 8 3 1 2 Power assemblies 9 4 Installation 10 4 1 Environmental considerations 10 4 2 Planning and marking out 10 4 2 1 Marking out a wall 11 4 2 2 Planning an island installation 12 4 3 Wall fixings 12 4 4 Assembly and mounting 12 4 5 Power wiring 14 4 5 1 Standard Smartrack 16 4 5 2 Connecting single and bi...

Page 4: ...martrack CPU jumper settings 27 4 10 4 Connecting power assembly signal looms 28 4 10 5 Connecting DMX input output wiring 29 4 10 6 Fitting blanking plates 29 4 10 7 Closing the door 29 4 10 8 Fitting dimmer number strips 30 5 Commissioning and configuration 31 5 1 Switching on 31 5 2 Power and signal indicators 31 5 3 Modular Smartrack dimmer level indicators 32 5 4 Battery supported memory 33 5...

Page 5: ...ing from user interface mode 41 6 Smartrack operational summary 42 6 1 Accessing the control panel 42 6 2 Address setting 43 6 3 Dimmer mode 43 6 3 1 Testing dimmers at levels 43 6 3 2 Profile mode 44 6 3 3 Speed mode 44 6 4 Offline mode 45 6 4 1 Checking line voltage 46 6 4 2 Setting the output voltage scale 46 6 4 3 Clearing configuration settings 46 7 Routine maintenance 47 7 1 Torque settings ...

Page 6: ...ll 49 8 2 What to tell them 49 9 Accessories and options 50 9 1 RCD protection 50 9 2 Single phase adapter kit 50 9 3 Spare numbering sheets 51 9 4 Load terminal extender kits 51 10 Spare parts 52 page v Smartrack User Manual Version 1 2 ...

Page 7: ...Notes page vi Smartrack User Manual ETC Ltd ...

Page 8: ...d digital dimmer typically uses fewer electronic components and is therefore cheaper to manufacture The key to the accuracy of digital dimmers is regulation This means that the dimmer is constantly measuring the rms voltage of each supply phase a total of 12 800 times per second in the case of ETC Smartrack to build up an accurate picture of the condition of the mains supply to each dimmer Using t...

Page 9: ...signed to house up to three power assem blies supplied separately each of which comprises 30kW of dimming as either 12 x 2 5kW 6 x 5kW or 3 x 10kW A hinged steel front door supports all the system electronics and the rack is available in two versions to accept either basic hard wired or plug in modular power assemblies Smartrack is primarily intended for wall mounting and may be installed up to th...

Page 10: ...controls for rack configuration are mounted on the front panel and the start address of the rack is normally displayed along with power DMX and thermal status indicators page 3 Smartrack User Manual Version 1 2 DIGITAL SmartRack 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 0 205 490 850 0 84 290 496 650 mcb centre mcb centre mcb centre Front view of a modular Smartrack showing key dimensions Note that Smar...

Page 11: ...mation 2 3 Filtering Smartrack dimmers are designed to conform to the EMC requirements of EN55014 and EN55022 the usually accepted European norms specifying RFI interference suppression requirements In addition low frequency filtering is achieved to different levels depending on the choke specified Two different choke styles are available offering different current risetimes as required for dif fe...

Page 12: ...l dimmers 2 4 1Dimmer profile Any dimmer may be set to any one of 12 preprogrammed curves includ ing three non dims and a hot setting permanently on This should take care of the requirements of the vast majority of entertainment and architec tural applications and custom profiles may be generated if required 2 4 2Response speed A dimmer s response speed is the time it takes for the dimmer s output...

Page 13: ...sity and stepping through the dimmers using the or buttons 2 4 4Reference Voltage Smartrack needs to know the voltage expected by the user for full on 100 to which all other levels are scaled This reference voltage is set by the user or installer using the rack controls 2 5 Thermal Management Smartrack runs remarkably cool and uses computer controlled brushless dc fans to do so with minimum noise ...

Page 14: ...ven power assembly In the event that a power device should run hot an amber warning signal is lit on the front panel If the device overheats it will be shut down and the warning LED will flash red The thermal indicator LED may be wired to a remote panel or incorporated in control room furniture to provide a simple geographic dimmer room mimic panel showing rack power and temperature status page 7 ...

Page 15: ... x load cable entry cover Hardware Kit Door Kit 2 x M4 black washer 1 x M4 shakeproof washer 1 x M4 10 Pan Posi Screw 1 x graphics layer number sheet Entry Cover Kit 32 x M4 6 taptite screw 32 x M4 spring washer Fan Kit 3 x M5 10 Pan Posi screw 3 x M5 nylon washer Foot Kit 4 x plastic feet 4 x M5 16 csk screws 4 x plastic plugs Power Terminal Safety Cover Kit 1 x Plastic Safety Cover 3 x M5 12 tap...

Page 16: ... mod ules and store separately in a safe place until ready Each power assembly is also shipped with Power Loom Kit 1 x 2 5mm2 cable Brown ident L1 1 x 2 5mm2 cable Brown ident L2 1 x 2 5mm2 cable Brown ident L3 1 x 2 5mm2 cable Blue ident N 1 x 2 5mm2 cable Yellow green ident Hardware Kit 5 x M5 10 Hex head screw 6 x M5 shakeproof washer 1 x M5 10 Pan Posi screw 2 x 10mm2 uninsulated bootlace ferr...

Page 17: ...sity factor of between 0 5 0 8 to the actual connected load to represent worst case The formula for calculating the heat generated by the dimmers in watts is there fore Total connected load x diversity factor x 100 efficiency Or for example 250 000 x 0 6 x 100 98 3 750 watts Here a diversity factor of 0 6 is applied to a 250kW load assuming 98 effi ciency at the dimmers which is reasonable The res...

Page 18: ...ate vicinity and inside the racks themselves 4 2 1Marking out a wall Use the dimensions below to mark out a grid on the wall where the Smartracks are to be installed Note the height and width of the racks and the mounting centres page 11 Smartrack User Manual Version 1 2 850 760 90 45 850 760 560 560 560 90 90 58 663 650 650 F i x i n g C e n t r e s Stack 1 Stack 2 Two stacks of three Smartracks ...

Page 19: ... Smartrack weighs between 75 85kg depending on version used and is fixed to the wall at four points Making an allowance for cable of 20 25kg per rack this means that each fixing has to support no more than 30kg The actual fixing used will depend very much on the wall material and condition but on a brick or concrete wall 50 x 5mm woodscrews used in conjunction with correctly installed plastic wall...

Page 20: ... two Smartrack enclosures together Fit power and load cable entry cover plates to top and bottom of the stack as required but not in between Smartracks in a stack Plastic plugs f M5 Fixing screws d Plastic feet a and M5 fixing screws Mounting keyholes c ...

Page 21: ... Smartrack in each stack g If required fit the top cable entry cover plates to the top surface of the top Smartrack using the taptite screws provided These plates should be used if forming or glanding is required or unworked to blank unused cable entry ports 4 5 Power wiring Smartrack is primarily intended for use on five wire services where the phase to neutral voltage is 230Vac 12 5 However sing...

Page 22: ...Manual Version 1 2 L1 L3 L2 N Wiring in power feeder cables to a standard Smartrack Note that power wiring to other Smartracks in a stack should be tied back to the cable way provided down the inner left wall of the enclosure ...

Page 23: ... wires into the power terminal block via the top or bot tom cable entry on the left side of the rack Cable tie anchors are pro vided just inside the cable entry ports Note that a cable way with slots for cable ties is provided to lead power wires up and down the left side of the enclosure to feed other Smartracks above or below b Trim to length and terminate with M12 clearance lugs Do not fit the ...

Page 24: ...l block located to the right of the channel circuit breakers with the three heavy cables provided in the adaptor kit Having fitted the plates installation is as for standard Smartracks see above Y2 SR002 0 contents 2 x plates 3 x neutral cables 35mm2 3 x earth cables 16mm2 4 5 3Connecting Delta systems Power wiring is as for standard Smartracks except that the neutral termi nal is unused Warning o...

Page 25: ...page 18 Smartrack User Manual ETC Ltd L1 L3 L2 N Wiring a standard Smartrack for single phase operation using the Smartrack single phase adaptor kit ...

Page 26: ...ribute them evenly across the cable tie anchors provided and allow enough length at each power assembly level to strip back the outer sheath sufficient to reach all terminals allow 80cm Ensure that all wires are correctly labelled with circuit number and function phase neutral or earth 4 7 Identifying and testing power and load wiring It is essential that all power and load wiring be correctly ide...

Page 27: ...slack for termina tion in each rack L1 L3 L2 N Laying in the load wires Note the arrangement of wires into Earth Neutral and phase wires according to the phase of the load circuit P1 P2 or P3 Laying the wires in this way makes connection to the load terminals on the power assembly easy and quick If using three core or multicore cables spread them evenly across the nine cable bunches and strip back...

Page 28: ... and do not fall behind it d Fix the power assembly in place by screwing the left side into the threaded hole in the back of the rack s power assembly slot using the M5 screw provided Do not fix the right side for the time being e Repeat steps b to d for the middle and top power assemblies f Slide the fan plate back into position ensuring that the tabs on the three blades of the fan plate locate i...

Page 29: ... Note that bootlace ferrules are required to be fitted to the earth and neu tral wires if stranded cable is used a Terminate load earth wires into the earth busbar on the left side of the power assembly Recommended tightening torque 1 5Nm 2 5mm2 cable to 2Nm 10mm2 cable L1 L3 L2 N 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 Terminating load wiring Note that numbering is always from left to right ie Earth ...

Page 30: ...s depending on whether the power assembly is fitted with RCD pro tection or not If not skip to the next section a Terminate the five wires to the appropriate terminals on the power ter minal block using the M5 hex head screws provided Recommended tightening torque 2Nm The colour code is L1 L3 brown Neutral light blue Earth green yellow Form the five wires into a loom and run to the top of the powe...

Page 31: ...r Manual ETC Ltd L1 L3 L2 N Wiring the power feeds from the power terminals to the Power Assembly RCD Note the order of connection to the RCD For the sake of clarity only one Power Assembly connection is shown L1 L2 L3 E N ...

Page 32: ...sequence from the left L1 L2 L3 Recommended tightening torque 2Nm c Trim to length and terminate the earth wire into the left position of the earth bar entering from below Use the bootlace ferrule provided to protect the stranded cable and ensure good earth contact Recommended tightening torque 2Nm d Trim to length and terminate the neutral wire into the DIN terminal to the left of the circuit bre...

Page 33: ...embly The three phase wires are terminated into the caged terminals on the three blocks of dimmer circuit breakers For the sake of clarity only one Power Assembly connection is shown L1 L2 L3 E N Tip Run the three phase wires past the neutral terminal as shown this makes it easy to retrofit RCDs later if required ...

Page 34: ... is deliberately loose This tightens automati cally when the door is closed and screwed shut 4 10 2 Connecting earth and power wiring a Connect front door earthing wire to the adjacent stud in the chassis using an M4 nut runner b Route the CPU power loom and terminate to the power terminal block following the coding labels on the loom wires c Fix the clear plastic cover of the power terminal block...

Page 35: ...at ribbon cable clips mounted inside the Smartrack run the rib bon cable from the top power assembly around the top of the rack and terminate to the top position on the Smartrack CPU Fold any excess cable flat inside one of the cable clips In the same way run the ribbon cables from the middle and lower power assemblies around the bottom of the rack and terminate to the middle and lower positions o...

Page 36: ...r assembly position remains unused you must fit a power assembly blanking plate part no 2000A1500 To fit blanking plates a Offer blanking plate into position inside door b Using an M3 nut runner remove the M3 nuts and washers from the studs required to fit the blanking plates c Fit the blanking plate s in position then replace and tighten the M3 washers and nuts Note if Smartrack is only partially...

Page 37: ...2 481 720 2000A4003 721 960 a Simply peel off the numbers required and cut strips to length with a pair of scissors as necessary b Press into place above the appropriate circuit breakers in the detent left by the cutout in the door s graphic layer c Fill any gaps to the right of the circuit breakers on 5kW and 10kW dimmers with the blank strips provided page 30 Smartrack User Manual ETC Ltd 181 18...

Page 38: ...ring and repeat c If RCDs are fitted switch them on If any RCDs trip at this stage there is an earth wiring fault in the dimmer rack d Switch on MCBs one by one If any RCDs trip at this stage there is a power fault in the power assembly 5 2 Power and signal indicators The following status indicators are provided on the control panel Check that their status is correct before continuing page 31 Smar...

Page 39: ...X source is not on a red DMX indicator is fine d Temperature status LED tricolour This LED should normally show green indi cating that all power devices are within a safe temperature range and oper ation is normal The three states of this LED are Green Normal operation Amber One or more power devices are getting hot but operation is safe Flashing red One or more power devices are over temperature ...

Page 40: ...ear configuration settings To enter offline mode it is first necessary to unlock the control panel a Press enter for three seconds The enter LED lights indicating that the con trol panel is unlocked Note that the control panel has a three minute time out This means that the control panel will lock up if no buttons are pressed in normal operating mode after a period of three minutes This time out d...

Page 41: ...nction has a very useful by product for example in a TV studio where the dimmers are being fed from their own transformer it may make sense to specify say a 240V supply where 220V lamps are to be used in the studio Given that a loss in the region of 4V rms can be expected at the dimmer dependent on choke type plus an average cable loss say 3V rms dependent on installation the highest voltage that ...

Page 42: ...sses to a new dimmer the dimmer previously under control is set to zero Important Note In Dimmer mode the display only scrolls through dimmer addresses used in the rack This means that a rack with one each 12 6 and 3 channel dimmer assem blies would have a total of 21 dimmers and if its starting address were to be set to 201 would only scroll through the range 201 221 in Dimmer mode When selecting...

Page 43: ...g should be a 5 pin XLR male plug with a 120Ω 0 25 watt resistor connected between pins 2 and 3 When using other untermi nated devices downstream of the Smartracks the terminating plug should be connected to the Data Out socket of the last device in the DMX line 5 7 2 Good bad data Check the DMX cable connection to the Smartrack s and switch on the control console Check that the DMX status LEDs on...

Page 44: ... and the actual dimmer output For this there is no real substitute for going round the installation with a known good light and plugging it into each of the tested sockets in turn 5 8 Dimmer profiles 5 8 1 What is a profile A dimmer profile is a table of dimmer output levels corresponding to DMX input levels Using different profiles allows different types of load to be connected to the outputs of ...

Page 45: ...ld Cathode Use for cold cathode or neon lighting loads Lin Linear Volts Linear rms voltage output in relation to DMX512 levels 120 120 volt scale Provides 0 120v output scaled to 0 100 DMX512 input P03 Preheat 3 Any DMX512 level 3 or below results in 3 output Above 3 as IES square law P05 Preheat 5 Any DMX512 level 5 or below results in 5 output Above 5 as IES square law N05 Non Dim 5 Non dim dimm...

Page 46: ...l result in a significantly chopped wave form being seen by the load Smartrack does not regulate non dim or hot profiles so by setting the non dims at the rack a full output wave form can be guaranteed for sensitive loads 5 8 4 Setting profiles a If the control panel is locked enter LED off press enter for three sec onds to gain access b Press dimmer to enter dimmer mode c Select all dimmers by pr...

Page 47: ...level in an installation with exceptionally low loop impedance 100mS Response speed Factory default setting gives acceptably fast response in most situations eliminates nuisance tripping in all but most severe circumstances and pro longs lamp life by reducing thermal shock to cold filaments 300mS Response Time Used mainly in TV studios where most loads are 5kW further prolongs lamp life by reducin...

Page 48: ...l panel back to dimmer mode for the selection of the next dimmer to be set f To exit without saving press dimmer or profile 5 10 Important note Exiting from the user interface When exiting from the user interface either following a press on enter or Smartrack s automatic timeout it is important that the rack should not be switched off for at least 2 seconds When returning to normal operation Smart...

Page 49: ...rol panel user mode a Press enter for three seconds When the enter LED lights you are in user mode with access to the main control panel functions b To lock the control panel again press enter any time the enter LED is on but not flashing NOTE For security reasons the control panel will automatically lock up if no key is pressed for a three minute period page 42 Smartrack User Manual ETC Ltd L1 DM...

Page 50: ... pressing enter The enter LED stops flash ing indicating that the new address has been recorded 6 3 Dimmer mode In dimmer mode you can test dimmers at levels set dimmer profiles set dimmer response speeds Having accessed the control panel press dimmer to enter dimmer mode The dimmer LED is now lit In dimmer mode when using the and keys note that Smartrack limits the range of dimmer numbers display...

Page 51: ...Select one or all dimmers using the and keys c Press profile to enter profile mode The profile LED is lit and the pro file for the selected dimmer s is displayed d Select a new profile using the and keys The enter LED flashes indicating that the profile displayed is not that recorded for the select ed dimmer s e Press enter to record or dimmer to return to dimmer mode without changing the profile ...

Page 52: ... to zero Normal DMX512 operation will be resumed upon exiting offline mode Note that there is no timeout from offline mode You have to exit in order to return to normal operation In offline mode you can View rms voltage of the main supply Set the output rms voltage scale for the rack Clear down all configuration settings to factory defaults To enter offline mode a Access the control panel by press...

Page 53: ...etting the output voltage scale For a full explanation of this function see section 6 5 2 a From the offline menu Select CAL and press enter The display shows the present rms voltage set for 100 dimmer output eg 220 b Use the and keys to change the rms voltage output scale in steps of one volt c Press enter to save the new value and exit to the offline menu 6 4 3 Clearing configuration settings a ...

Page 54: ...l terminals 2 5mm2 1 5Nm 2 5kW load terminals 1Nm 5kW load terminals 2Nm 10kW load terminals 1 2Nm To retorque terminals open the front door of the rack by releasing the three cap tive screws on the front panel and use a torque setting screwdriver Note that all terminal screwheads face forwards for ease of access 7 2 Cleaning In average conditions of use cleaning should be carried out on an annual...

Page 55: ...r modules b Check that all power contacts are bright and clean in the modules and in the power assembly bases If any evidence of arcing is seen contact your ETC authorised service dealer c Check that the earth pins are tightly mounted d Close rack and replace modules 7 4 Control fuse ratings 1 6amp T 20mm 7 5 Battery replacement It will be necessary to replace the battery on the Smartrack CPU whic...

Page 56: ... with a sketch if appro priate to ETC Ltd Lighting Control Division Technical Support Fax no 44 181 896 2000 Or call us on 44 181 896 1000 8 2 What to tell them We need to know a The serial number of the rack or power assembly concerned b Who you bought it from c The software version being run look for the sticker on the electronics protec tive cover d The nature of the fault or difficulty We shal...

Page 57: ... When ordering Smartrack you can specify Residual Current Device RCD pro tection as a factory fitted item If not supplied as original equipment RCDs may be easily retrofitted to Smartracks in service Part Number 2000A1520 9 2 Single phase adapter kit Smartracks are supplied to run on three phase 220 380v or 240 415v sup plies However with a simple adaptor kit see section 4 5 3 single phase sup pli...

Page 58: ...s It will in some cases be necessary to use cable with a larger cross sectional area than the capacity of the standard load phase terminals provided where very long cable runs are required In this case the following extender kits are available for 2 5kW and 5kW dim mers only Note that 10kW dimmers are already provided with terminals for 35mm2 cable Part Number 2000A1565 4 x 2 5kW Output terminal e...

Page 59: ...teristic circuit breaker MCB 024 Single pole 50amp C characteristic circuit breaker FAN 008 Smartrack Fan 2000A5001 CPU circuit board assembly 2000A5002 Operator interface circuit board assembly SWI 032 Push button switch body and cap POT 006 Rotary potentiometer KNO 007 Rotary potentiometer knob KNO 007 1 Rotary potentiometer collet cap FUS 008 20mm Fuseholder HDD 001 Dimmer module handle MDD 023...

Page 60: ...Notes page 53 Smartrack User Manual Version 1 2 ...

Page 61: ...page 54 Smartrack User Manual ETC Ltd ...

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