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E T C S e r v i c e N o t e

Congo™ jr Power Supply Replacement

Congo™ jr Power Supply Replacement

Page 37

Electronic Theatre Controls, Inc.

Step 10: Remove the base cover and set aside.

Step 11: Locate the Power Supply and cut the zip tie around the large bundle of cable.

Step 12: Disconnect the motherboard power connector.

Step 13: Remove the 2 power connectors attached to the Power Supply.

Cut this zip tie

Motherboard Power Connector

Remove these 2

power connectors

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Summary of Contents for Congo Jr

Page 1: ...Lighting Control Console Service Documents Copyright Electronic Theatre Controls Inc All Rights reserved Product information and specifications subject to change Part Number Pending Released May 2007 ...

Page 2: ......

Page 3: ... 5 LCD Replacement 7 Encoder Replacement 13 Video Card Replacement 19 Hard Drive Replacement 23 DMX Driver Chip Replacement 29 Power Supply Replacement 35 Main Board Replacement 41 Master Wing LCD Replacement 49 Master Wing Main Board Replacement 51 Congo jr v4 3 I O Software Code Installation 53 ...

Page 4: ...Congo jr Service Documents Page ii ...

Page 5: ...n Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Needed DVI Monitor or VGA w DVI adapters USB Keyboard U...

Page 6: ...cs Page 2 Electronic Theatre Controls Inc Step 8 Select File New Task run Step 9 Type cjtest exe ENTER Step 10 The following program will pop up Step 11 Click on either the Congo jr Face button or the Congo jr Wing button Click here for face panel diagnostics Click here for wing diagnostics ...

Page 7: ...C S e r v i c e N o t e Congo jr Face Panel Diagnostics Congo jr Face Panel Diagnostics Page 3 Electronic Theatre Controls Inc Step 12 The following window will pop up if you click the Congo jr Face button ...

Page 8: ...ow will pop up if you click the Congo JR Wing button Step 14 Move every slider and press every button on the face panel master wing Each button will change color to indicate that the hardware is functional Step 15 Every slider move will indicate a range from 0 255 Step 16 When each button and slider tests out ok close the window and power the Congo jr down ...

Page 9: ...n Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Needed Remote Macro Test board Standard telephone and cable MIDI ca...

Page 10: ...Step 10 The following window will pop up Step 11 Watch for the 2 LEDS to flash on the Remote Macro Test Board Step 12 Press the 4 buttons on the LED Remote Macro Test Board if present look for ACTIVE on the screen Step 13 Look for MIDI IN messages of 32 and 33 repeating Step 14 Press all 12 buttons on the phone individually and look for corresponding numbers on the screen Step 15 Close the command...

Page 11: ... 1801 18 F Tower 1 Phase 1 Enterprise Square 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released...

Page 12: ...crews in blue below NOTE DO NOT remove the 3 screws Step 5 Flip the console back onto the base Step 6 Lift the back side of the face panel upwards away from the base Step 7 Slide the face panel towards the front of the console The face panel will slip under the base pressure plate Loosen these screws 1 Tilt face panel upwards 2 Slide face panel forwards Base Pressure Plate ...

Page 13: ...rs from the Congo jr motherboard Step 10 Clip the zip ties holding the face panel cables to the base of the unit Step 11 Carefully set the Congo jr face panel face down exposing the back side of the face panel PCB Step 12 Remove the 8 short screws from the LCD pressure plate NOTE Be sure that you keep these 8 screws separated from the other FP screws as these are shorter than the others FP USB 1 F...

Page 14: ... board to remove the LCD screen from the Congo jr face panel Step 15 Replace the LCD screen by removing each of the 2 face panel LCD Jumper circuit boards Re attach the LCD jumper circuit boards to the new LCD screen Step 16 Place the LCD screen back into the face panel and screw the circuit board into the standoffs Step 17 Place the LCD pressure plate back over the LCD screen and screw the 8 shor...

Page 15: ...oard Step 19 Slide the face panel back under the base pressure plate Step 20 Re attach all 7 screws from each side of the console face panel Step 21 Flip the face panel over and tighten the 3 screws on the base of the console Step 22 Power the console up and verify correct face panel operation and LCD screen operation FP USB 1 FP USB 2 J1 USB Uplink Base Pressure Plate ...

Page 16: ...E T C S e r v i c e N o t e Congo jr LCD Replacement Congo jr LCD Replacement Page 12 Electronic Theatre Controls Inc ...

Page 17: ...rise Square 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 2 Phillip...

Page 18: ...e 3 screws in blue below NOTE DO NOT remove the 3 screws Step 5 Flip the console back onto the base Step 6 Lift the back side of the face panel upwards away from the base Step 7 Slide the face panel towards the front of the console The face panel will slip under the base pressure plate Loosen these screws 1 Tilt face panel upwards 2 Slide face panel forwards Base Pressure Plate ...

Page 19: ...from the Congo jr Motherboard Step 10 Clip the zip ties holding the face panel cables to the base of the unit Step 11 Carefully set the Congo jr face panel face down exposing the back side of the face panel PCB Step 12 Remove the 8 short screws from the LCD pressure plate NOTE Be sure that you keep these 8 screws separated from the other face panel screws as these are shorter screws than the other...

Page 20: ... each side of the LCD screen socket circuit board to remove the LCD Screen from the Congo jr face panel Step 15 With the LCD screen removed from the face panel you can now access the encoder knob shafts Step 16 Spin the encoder shaft until the hex nut is visible Step 17 Loosen the hex nut until the encoder falls from the shaft Step 18 Loosen all 10 screws from the encoder PCB board Soldered Pins ...

Page 21: ... board has been replaced re solder the 16 pins on the left side of this board Re attach all 10 screws of the encoder board to the appropriate stand off NOTE The stand offs used on this board are plastic DO NOT OVER TIGHTEN doing so will strip the standoff Attach these screws with a manual screw driver only Step 21 Replace the LCD Screen and attach all 8 of the screws on either side of the LCD Jump...

Page 22: ...ntrols Inc Step 24 Slide the face panel back under the Base pressure plate Step 25 Re attach all 7 screws from each side of the console face panel Step 26 Flip the face panel over and tighten the 3 screws on the base of the console Step 27 Power the console up and verify correct console operation Base Pressure Plate ...

Page 23: ...e 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 2 Phillips Screwdri...

Page 24: ...he face panel upwards away from the base Step 7 Slide the face panel towards the front of the console The face panel will slip under the base pressure plate Step 8 Rest the face panel off to the left side of the base unit the side with the DMX connectors There is no need to remove the face panel cables when replacing the video card 1 Tilt face panel upwards 2 Slide face panel forwards Base Pressur...

Page 25: ...es and the rear of the base Step 10 Remove the base cover and set aside Step 11 Locate the AGP video card near the MIDI and DMX connectors Step 12 Pull back the AGP slot locking tab towards the DMX I O Card At the same time pull the video card up and out of the AGP slot Remove these screws located on side of chassis Remove this screw Pull APG slot tab towards DMX I O Card ...

Page 26: ...k heard felt when the video card is seated all the way into the AGP Slot Step 15 Place the base cover back onto the base of the console and re attach all 5 screws Step 16 Slide the face panel back under the base pressure plate Step 17 Re attach all 7 screws from each side of the console face panel Step 18 Flip the face panel over and tighten the 3 screws on the base of the console Step 19 Power th...

Page 27: ...oom 1801 18 F Tower 1 Phase 1 Enterprise Square 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Relea...

Page 28: ... the 3 screws in blue below NOTE DO NOT remove the 3 screws Step 5 Flip the console back onto the base Step 6 Lift the back side of the face panel upwards away from the base Step 7 Slide the face panel towards the front of the console The face panel will slip under the base pressure plate Loosen these screws 1 Tilt face panel upwards 2 Slide face panel forwards Base Pressure Plate ...

Page 29: ...the face panel off to the left side of the base unit the side with the DMX connectors There is no need to remove the face panel cables when replacing the hard drive Step 9 Clip all 3 zip ties holding the Power supply and SATA cables Step 10 Disconnect the Power and SATA connectors from the hard drive Remove these zip ties Power Cable SATA Cable ...

Page 30: ...4 Hard Drive Plate Screws Step 13 Swap the old Hard Drive fo rthe one one Replace all four screws holding it to the Hard Drive Mounting plate Step 14 Place the Hard Drive Plate over the screws and tighten down both 5 16 nuts Step 15 Re attach the Hard Drive Power and SATA cables back into the hard drive Step 16 Replace all 3 zip ties around the sticky backs Step 17 Trim the excess tail off the zip...

Page 31: ...ce panel back under the pressure plate Step 19 Re attach all 7 screws from each side of the console face panel Step 20 Flip the face panel over and tighten the 3 screws on the base of the console Step 21 Power the console up and verify correct face panel operation and LCD screen operation Step 22 Update console software as necessary Base Pressure Plate ...

Page 32: ...E T C S e r v i c e N o t e Congo jr Hard Drive Replacement Congo jr Hard Drive Replacement Page 28 Electronic Theatre Controls Inc ...

Page 33: ...are 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 2 Phillips Screwd...

Page 34: ...Slide the face panel towards the front of the console The face panel will slip under the base pressure plate Step 8 Rest the face panel off to the left side of the base unit The side with the DMX connectors There is no need to remove the face panel cables when replacing the DMX connectors Step 9 Remove all 4 screws from both sides of the base 1 Tilt face panel upwards 2 Slide face panel forwards B...

Page 35: ...IDI riser card near the Video Card and above the DMX I O Card Step 12 Remove the ribbon cable from the MIDI riser card and remove the 3 screws Step 13 Lift up on 2 sides of the MIDI card being careful not to bend any of the pins below the card Step 14 Set the MIDI card aside Step 15 Locate either DMX Driver Chip U11 DMX Port 1 U12 DMX Port 2 Remove these 3 Screws Disconnect this ribbon cable DMX P...

Page 36: ...the desired DMX driver chip 75LBC182 ETC Part Number Z1458 F Step 17 Re connect the MIDI riser card to the DMX I O card Line up all 14 pins with the I O socket Once the pins are aligned gently push down on the MIDI riser card to seat it into the socket Step 18 Place the base cover back onto the base of the console and re attach all 4 screws MIDI Riser Socket ...

Page 37: ...Step 19 Slide the face panel back under the base pressure plate Step 20 Re attach all 7 screws from each side of the console face panel Step 21 Flip the face panel over and tighten the 3 screws on the base of the console Step 22 Power the console up and verify correct console operation and verify DMX outputs on both ports Base Pressure Plate ...

Page 38: ...E T C S e r v i c e N o t e Congo jr DMX Driver Chip Replacement Congo jr DMX Driver Chip Replacement Page 34 Electronic Theatre Controls Inc ...

Page 39: ...oad Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 2 Phillips Screwdriver 1 Phillips Sc...

Page 40: ...e the face panel towards the front of the console The face panel will slip under the base pressure plate Step 8 Rest the face panel off to the left side of the base unit the side with the DMX connectors There is no need to remove the face panel cables when replacing the power supply Step 9 Remove all 4 screws from both sides of the base 1 Tilt face panel upwards 2 Slide face panel forwards Base Pr...

Page 41: ...ls Inc Step 10 Remove the base cover and set aside Step 11 Locate the Power Supply and cut the zip tie around the large bundle of cable Step 12 Disconnect the motherboard power connector Step 13 Remove the 2 power connectors attached to the Power Supply Cut this zip tie Motherboard Power Connector Remove these 2 power connectors ...

Page 42: ...d Aux Power Step 15 Remove the 4 Screws holding the Power Supply in place Step 16 Swap out the power supply for a new power supply Step 17 Attach the power supply by screwing in the 4 screws from the back of the console Step 18 Re connect the 12v motherboard aux power Step 19 Place 2 zip ties around the 12v motherboard aux power supply and the soft power switch cables Remove these 4 screws ...

Page 43: ...dle of wire and thru the sticky back on the base of the console Step 23 Place the base cover back onto the base of the console and re attach all 4 screws Step 24 Slide the face panel back under the base pressure plate Step 25 Re attach all 7 screws from each side of the console face panel Step 26 Flip the face panel over and tighten the 3 screws on the base of the console Step 27 Power the console...

Page 44: ...E T C S e r v i c e N o t e Congo jr Power Supply Replacement Congo jr Power Supply Replacement Page 40 Electronic Theatre Controls Inc ...

Page 45: ...Enterprise Square 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 2 P...

Page 46: ...and loosen the 3 screws in blue below NOTE DO NOT remove the 3 screws Step 5 Flip the console back onto the base Step 6 Lift the back side of the face panel upwards away from the base Step 7 Slide the face panel towards the front of the console The face panel will slip under the base pressure plate Loosen these screws 1 Tilt face panel upwards 2 Slide face panel forwards ...

Page 47: ...ectors from the Congo jr motherboard Step 10 Clip the zip ties holding the face panel cables to the base of the unit Step 11 Carefully set the Congo jr face panel face down exposing the back side of the face panel PCB Step 12 Remove the 8 short screws from the LCD pressure plate NOTE Be sure that you keep these 8 screws separated from the other FP Screws as these are shorter screws than the others...

Page 48: ... encoder knob shafts Step 16 Spin the encoder shaft until the hex nut is visible Step 17 Loosen the hex nut until the encoder falls from the shaft Step 18 Flip the face panel back over exposing the keypad and faders Step 19 Lift up the Independents and BO ON FREEZE knob caps NOTE You can lift these caps up with the tip of your fingernail Step 20 Once you expose the inside of the knob you can remov...

Page 49: ...ky backs on the keypad reinforcement plate Step 25 Disconnect the following headers from the motherboard J5 Right Fader J8 Left Fader J11 USB Uplink J4 Power Step 26 Set the face panel wire harness aside Step 27 Remove all 32 screws holding the face panel main board in place Step 28 Swap out the main board for the new one Step 29 Clip the zip ties from the USB key attached to the old board J4 Powe...

Page 50: ...nel motherboard in place Step 32 Re connect the encoder board and encoders Step 33 Re connect the LCD screen screws and pressure plate Step 34 Re connect the level wheel ribbon cable Step 35 Connect the J4 J5 J8 J11 connectors back on the main board Step 36 Place 2 zip ties around the face panel wire harness through the sticky backs Trim off the excess zip tie tails Step 37 Re attach the USB conne...

Page 51: ... Controls Inc Step 38 Slide the face panel back under the base pressure plate Step 39 Re attach all 7 screws from each side of the console face panel Step 40 Flip the face panel over and tighten the 3 screws on the base of the console Step 41 Power the console up and verify correct console operation Base Pressure Plate ...

Page 52: ...E T C S e r v i c e N o t e Congo jr Main Board Replacement Congo jr Main Board Replacement Page 48 Electronic Theatre Controls Inc ...

Page 53: ...1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 1 Phillips Screwdriver Soldering Iron Lead Free Solder Procedure Step 1 Remove the ...

Page 54: ...ed Line up the above pictures 8 pins and solder the 2 LCD screens Step 13 Once the pins are aligned with the Master Wing Main Board gently press each board into its socket Step 14 Secure each of the 6 screws back into the LCD jumper board connecting them to the sandoffs Step 15 Place each of the LCD pressure plates back over the LCD screens and tighten all 8 screws back into the appropriate holes ...

Page 55: ...ng Tel 852 2799 1220 Fax 852 2799 9325 Service Americas service etcconnect com UK service etceurope com DE techserv hoki etcetcconnect com com Asia service etcasia com Web www etcconnect com Copyright 2006 ETC All Rights Reserved Product information and specifications subject to change Pending Rev A Released 02 2007 Tools Required 1 Phillips Screwdriver Procedure Step 1 Remove the protective side ...

Page 56: ...into the master wing Step 15 Re connect each of the J9 J12 and J8 headers at the master wing main board Note the cable orientation pictured above Step 16 Place the 2 screens back into the Master Wing Line up all of the pins on each of the 3 LCD jumper boards Step 17 Once the pins are aligned with the Master Wing main board gently press each board into the socket Step 18 Secure each of the 6 screws...

Page 57: ...ibes how to install new I O firmware for your Congo jr console This version of firmware fixes a software bug that caused the DMX power supply to be under powered resulting in flickering levels or loss of control of some DMX devices This firmware update should be performed after the 4 3 software installation Tools Needed Computer Congo jr Console DVI Monitor or VGA with DVI adapters USB Keyboard US...

Page 58: ...ngo jr v4 3 I O Software Code Installation Page 54 Electronic Theatre Controls Inc Step 9 At the Main login Screen click on the System Settings button Step 10 The following window will pop up Step 11 Click on the software update button Step 12 The following window will pop up ...

Page 59: ...nic Theatre Controls Inc Step 13 Wait until the window displays Please load Firmware File Note It may take up to 10 seconds for this message to be displayed Step 14 Click on the File button Step 15 Browse to the USB Flash Drive s software folder Step 16 Select the file labeled CNGOJRIO_v1_0_0_9_0_026 src Step 17 Click the Open button ...

Page 60: ...conds The progress bar will show the installation status Step 20 The status will indicate that the progress has finished and display Download Complete When this message is displayed click the Exit button The Congo jr console will reboot Step 21 Remove the USB flash drive while the Congo jr is rebooting Step 22 After the Congo jr has rebooted at the main login screen select shut down Physically swi...

Page 61: ......

Page 62: ...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 Rev Released 05 2007 Copyright 2005 Electron...

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