Etec Congo Jr Service Documents

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

Face Panel Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

MIDI, Telephone, and Remote Macro Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Congo jr Service Documents - Page i

Congo jr Service Documents - Page ii

ETC® Service Note

Congo™ jr Face Panel Diagnostics

Tools Needed:

DVI Monitor, or VGA w/ DVI adapters
USB Keyboard
USB Mouse

Procedure:

Step 1: Connect all USB cables to the Congo jr USB ports
Step 2: Turn on the console

Step 3: At the main Congo screen press [Crtl]+[Alt]+[Delete] from the USB Keyboard
Step 4: Select Task Manager
Step 5: Select the Processes Tab
Step 6: Locate “CongoShell” Right click on it and click on End Task, then click OK
Step 7: Locate “Congo” Right click on it and click on End Task, then click OK

Face Panel Diagnostics

Face Panel Diagnostics

Corporate Headquarters
London, UK
Rome, IT 
Holzkirchen, DE
Hong Kong  Room 1801, 18/F, Tower 1 Phase 1, Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Kowloon, Hong Kong
Service:
Web:
Pending

Congo™ jr Face Panel Diagnostics Page 1

 Unit 26-28, Victoria Industrial Estate, Victoria Road, London W3 6UU, UK  Tel [phone]  Fax [phone]

Via Ennio Quirino Visconti, 11, 00193 Rome, Italy  Tel [phone]  Fax [phone]

(Americas) [e-mail] 

www.etcconnect.com 

 Rev A  Released 02/2007

 3031 Pleasant View Road, P.O. Box 620979, Middleton, Wisconsin 53562-0979 USA  Tel [phone]  Fax [phone]

 Ohmstrasse 3, 83607 Holzkirchen, Germany  Tel [phone]  Fax [phone]



Copyright © 2006 ETC. All Rights Reserved.  Product information and specifications subject to change.

(UK) [e-mail]  (DE) [e-mail] 

Tel [phone]  Fax [phone]

(Asia) [e-mail]

ETC Service Note

Congo™ jr Face Panel Diagnostics

Step 8: Select File -> New Task (run)
Step 9: Type “cjtest.exe” [ENTER]

Step 10: The following program will pop up:

Click here for face panel diagnostics

Step 11: Click on either the Congo jr Face button or the Congo jr Wing button.

Congo™ jr Face Panel Diagnostic s Page 2 Electronic Theatre Controls, Inc.

Click here for wing diagnostics

ETC Service Note

Congo™ jr Face Panel Diagnostics

Step 12: The following window will pop up if you click the Congo jr Face button:

Congo™ jr Face Panel Diagnostic s Page 3 Electronic Theatre Controls, Inc.

ETC Service Note

Congo™ jr Face Panel Diagnostics

Step 13: The following window 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.

Congo™ jr Face Panel Diagnostic s Page 4 Electronic Theatre Controls, Inc.

ETC® Service Note

Congo™ jr MIDI, Phone and Macro Test

Tools Needed:

Remote Macro Test board
Standard telephone and cable
MIDI cable (5 Pin Din)
DVI monitor, or VGA w/ DVI adapters
USB Keyboard
USB Mouse

Procedure :

Step 1: Connect all cables to the Congo jr Console
Step 2: Turn on the console

Step 3: At the main Congo screen press [Crtl]+[Alt]+[Delete] from the USB keyboard.
Step 4: Select Task Manager
Step 5: Select the Processes Tab
Step 6: Locate “CongoShell” Right click on it and click on End Task, then click Yes
Step 7: Locate “Congo” Right click on it and click on End Task, then click Yes

MIDI, Telephone, and Remote Macro Test

Corporate Headquarters
London, UK
Rome, IT 
Holzkirchen, DE
Hong Kong  Room 1801, 18/F, Tower 1 Phase 1, Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Kowloon, Hong Kong
Service:
Web:
Pending

 Unit 26-28, Victoria Industrial Estate, Victoria Road, London W3 6UU, UK  Tel [phone]  Fax [phone]

Via Ennio Quirino Visconti, 11, 00193 Rome, Italy  Tel [phone]  Fax [phone]

(Americas) [e-mail] 

www.etcconnect.com 

 Rev A  Released 02/2007

 3031 Pleasant View Road, P.O. Box 620979, Middleton, Wisconsin 53562-0979 USA  Tel [phone]  Fax [phone]

 Ohmstrasse 3, 83607 Holzkirchen, Germany  Tel [phone]  Fax [phone]

Congo™ jr MIDI, Phone and Macro Test Page 5 Electronic Theatre Controls, Inc.



Copyright © 2006 ETC. All Rights Reserved.  Product information and specifications subject to change.

(UK) [e-mail]  (DE) [e-mail] 

Tel [phone]  Fax [phone]

(Asia) [e-mail]

ETC Service Note

Congo™ jr MIDI, Phone and Macro Test

Step 8: Select File -> New Task (run)
Step 9: Type “test2” in the text field, then click the “OK” button]

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 window
Step 16: Shut the console down.

Congo™ jr MIDI, Phone and Macro Te st Page 6 of 6 Electronic Theatre Controls, Inc.

ETC® Service Note

Congo™ jr LCD Replacement

Tools Required:

#1 Phillips Screwdriver
#2 Phillips Screwdriver
Side Cutter
4" replacement zip ties

Procedure:

Step 1: Remove the protective side panels from the Congo jr Console.
Step 2: Remove the 7 screws indicated in Red below.
Step 3: Loosen the 3 screws indicated in Blue below.

NOTE: DO NOT remove the 3 screws.

Remove these screws

Loosen these screws

2 full turns

LCD Replacement

Corporate Headquarters
London, UK
Rome, IT 
Holzkirchen, DE
Hong Kong  Room 1801, 18/F, Tower 1 Phase 1, Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Kowloon, Hong Kong
Service:
Web:
Pending

 Unit 26-28, Victoria Industrial Estate, Victoria Road, London W3 6UU, UK  Tel [phone]  Fax [phone]

Via Ennio Quirino Visconti, 11, 00193 Rome, Italy  Tel [phone]  Fax [phone]

(Americas) [e-mail] 

www.etcconnect.com 

 Rev A  Released 02/2007

Congo™ jr LCD Replacement Page 7 Electronic Theatre Controls, Inc.

 3031 Pleasant View Road, P.O. Box 620979, Middleton, Wisconsin 53562-0979 USA  Tel [phone]  Fax [phone]

 Ohmstrasse 3, 83607 Holzkirchen, Germany  Tel [phone]  Fax [phone]

Copyright © 2006 ETC. All Rights Reserved.  Product information and specifications subject to change.

(UK) [e-mail]  (DE) [e-mail] 



Tel [phone]  Fax [phone]

(Asia) [e-mail]

ETC Service Note

Step 4: Carefully flip over the console 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.

2. Slide face panel forwards

Congo™ jr LCD Replacement

Loosen these screws

1. Tilt face panel upwards

Congo™ jr LCD Replacement Page 8 Electronic Theatre Controls, Inc.

Base Pressure Plate

ETC Service Note

Step 8: Disconnect the J1 USB Uplink from the I/O card.
Step 9: Disconnect the face panel USB 1&2 connectors from the Congo jr motherboard.
Step 10: Clip the zip ties holding the face panel cables to the base of the unit.

Congo™ jr LCD Replacement

FP USB 1

FP USB 2

J1 - USB Uplink

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.

Congo™ jr LCD Replacement Page 9 Electronic Theatre Controls, Inc.

ETC Service Note

Step 13: Remove the 8 face panel LCD Jumper screws

Congo™ jr LCD Replacement

Step 14: Lightly lift each side of the LCD Screen socket circuit 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 short screws

back into the standoffs.

Congo™ jr LCD Replacement Page 10 Electronic Theatre Controls, Inc.

ETC Service Note

Step 18: Re-attach the USB Connectors to the motherboard.

Congo™ jr LCD Replacement

FP USB 1

FP USB 2

J1 - USB Uplink

Step 19: Slide the face panel back under the base pressure plate.

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.

Congo™ jr LCD Replacement Page 11 Electronic Theatre Controls, Inc.

ETC Service Note

Congo™ jr LCD Replacement

Congo™ jr LCD Replacement Page 12 Electronic Theatre Controls, Inc.

ETC® Service Note

Congo™ jr Encoder Replacement

Tools Required:

#2 Phillips Screwdriver
#1 Phillips Screwdriver
Side Cutter
Needle Nose Pliers
Soldering Iron
Lead Free Solder
4" Replacement zip ties
.050 angled Hex key

Procedure:

Step 1: Remove the protective side panels from the Congo jr Console.
Step 2: Remove the 7 screws indicated in Red below.
Step 3: Loosen the 3 screws indicated in Blue below.

NOTE: DO NOT remove the 3 screws.

Remove these screws

Encoder Replacement

Corporate Headquarters
London, UK
Rome, IT 
Holzkirchen, DE
Hong Kong  Room 1801, 18/F, Tower 1 Phase 1, Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Kowloon, Hong Kong
Service:
Web:
Pending

 Unit 26-28, Victoria Industrial Estate, Victoria Road, London W3 6UU, UK  Tel [phone]  Fax [phone]

Via Ennio Quirino Visconti, 11, 00193 Rome, Italy  Tel [phone]  Fax [phone]

(Americas) [e-mail] 

www.etcconnect.com 

 Rev A  Released 02/2007

Congo™ jr Encoder Replacement Page 13 Electronic Theatre Controls, Inc.

 3031 Pleasant View Road, P.O. Box 620979, Middleton, Wisconsin 53562-0979 USA  Tel [phone]  Fax [phone]

 Ohmstrasse 3, 83607 Holzkirchen, Germany  Tel [phone]  Fax [phone]

Loosen these screws

2 full turns



Copyright © 2006 ETC. All Rights Reserved.  Product information and specifications subject to change.

(UK) [e-mail]  (DE) [e-mail] 

Tel [phone]  Fax [phone]

(Asia) [e-mail]

ETC Service Note

Congo™ jr Encoder Replacement

Step 4: Carefully flip over the console 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

2. Slide face panel forwards

1. Tilt face panel upwards

Congo™ jr Encoder Replacement Page 14 Electronic Theatre Controls, Inc.

Base Pressure Plate

ETC Service Note

Congo™ jr Encoder Replacement

Step 8: Disconnect the J1 USB uplink from the I/O card.
Step 9: Disconnect the face panel USB 1&2 connectors from the Congo jr Motherboard.

FP USB 1

FP USB 2

J1 - USB Uplink

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 others.

Congo™ jr Encoder Replacement Page 15 Electronic Theatre Controls, Inc.