Johnson Systems CD-3000 User Manual

User Manual

CD-3000 Series

Retroﬁt Control System

Model Application

CD-3000-AE Strand CD80® AMX or Advanced Electronic (AE) permanent installation racks. CD-3000-AE-48RR Strand CD80® AMX or Advanced Electronic (AE) 48 channel rolling racks CD-3000-AE-96RR Strand CD80® AMX or Advanced Electronic (AE) 96 channel rolling racks CD-3000-SV Strand CD80® Supervisor (SV) permanent installation racks CD-3000-SV-48RR Strand CD80® Supervisor (SV) 48 channel rolling racks CD-3000-SV-96RR Strand CD80® Supervisor (SV) 96 channel rolling racks CD-3000-C21 Strand C21 permanent installation racks

JOHNSON SYSTEMS INC.

www.johnsonsystems.com

2002161

Contents

Warranty ..........................................................................................................2

Introduction ......................................................................................................3

Packaging & Contents .....................................................................................4

Installation .......................................................................................................4

CD-3000 Backplane ......................................................................................12

Control Input/Output Connections .................................................................13

Control Module • MADD-96 ...........................................................................15

User Interface ................................................................................................16

System Status • LED Indicators ....................................................................17

System Status • LCD Display ........................................................................17

Quick Programming Reference to System Conguration Menu Items ..........19

Detailed Programming of System Conguration Menu Items........................20

Important Hard-key Information .....................................................................35

Troubleshooting Reference ...........................................................................36

Warranty

The CD-3000 comes with a standard one (1) year limited warranty. Extended warranties of up to ten (10) years are available at the time of purchase.

For details visit www.johnsonsystems.com/warranties.htm.

For Technical Assistance

1. Refer to your product user manual. The most current revision is available online: www.johnsonsystems.com/literature.htm

2. Contact the “point-of-sale” dealer or distributor from which this product was originally purchased, and ask for technical assistance.

3. If neither of the above can provide you with the necessary information, please contact our factory via email (info@johnsonsystems.com) or phone (403-287-8003) during business hours (Monday to Friday, 8:00AM to 5:00PM MST).

www.johnsonsystems.com

Introduction

The JSI CD-3000 is a next

generation retrot electronics package designed specically for

any vintage of Strand CD80® dimmer rack. The CD-3000 will replace the aging control electronics of the existing CD80® dimmer rack making system replacement unnecessary. This full- featured, ETL listed state-

of-the-art unit provides a low cost digital interface to any of today’s modern

lighting communication protocols.

Designed to install in minutes with only a single screw driver, this elegant package has been designed for longevity and reliability with the end-user in mind. Intuitive LCD user interface combined with a

single modular design makes the CD-3000 extremely user-friendly and easily serviceable. Advanced next generation hardware and software designs reduce stand-by power consumption to less than 1 Watt, allowing for

compliance with the International Energy Agency’s “One Watt Initiative” for

standby power consumption.

CD-80® Supervisor

96 Channel Dimmer Rack

with CD-3000-SV Installed

Full featured, hi-resolution dimming with lightning fast response. Exclusive “lamp warming” techniques extends lamp life considerably. An

environmentally and nancially responsible solution that offers unsurpassed

high performance in a matter in minutes!

CD-3000-AE CD-3000-SV

Model Application

www.johnsonsystems.com 3

Packaging & Contents

Each CD-3000 Series retrot system is shipped in a custom designed box for protection of the

unit. Keep the box and packaging stored in a safe place. In the unlikely event that the system needs to be returned to the JSI Factory, the packaging will be required to prevent shipping damage and maintain warranty.

Each CD-3000 Series system includes all of the hardware required to complete the retrot.

Installation

CD-3000-AE

• Disconnect (turn off) the power supply to the Strand CD80® dimmer rack(s) and rack processor electronics. Some systems may have their processor electronics powered by an isolated (separate) feed.

WARNING! Verify all power is disconnected (turned off) before proceeding.

Removal of the Old Processor Housing

• Remove the upper ventilation grill and lower air lter grill from the CD-80® rack and set them

aside.

• Inspect the lower portion of the dimmer rack for any wiring, AC line voltage bussing, conduit, etc. that could prevent the smooth removal of the old processor housing. Take the appropriate measures to remove any obstructions being careful not to strain or remove any of the control wiring that terminates on the rear of the existing processor housing.

• Inspect the upper portion of the dimmer rack for any similar obstructions. Pay particular attention to the upper left side of the dimmer rack. This portion of the rack contains

hardware, circuitry and wiring that must be retained in order to retrot the rack as designed.

www.johnsonsystems.com

• Unscrew the two mounting (thumb) screws that hold the old processor housing in place. Slowly remove the old card cage, taking care not to strain or disconnect any of the original CD-80® wiring. Carefully observe and label as necessary all wiring as to its location and polarity.

• If you are not familiar with the Strand CD-80® dimmer rack processor electronics and wiring, it is strongly advised that you take a few minutes to look at the back of the processor housing connections and compare it to the backplane on the CD-3000-AE. Do not disconnect any wiring until

you are satised with how easy this is going to be.

NOTE: Never pull directly on the wires to remove connectors.

• Disconnect the power connector. This connector is a 9-position CPC (Circular Plastic Connector) plug (female - cable mount) and receptacle (male - chassis mount). It is black in color and approximately two (2) inches in length. It is located at the lower (rear) right-hand side of the old processor housing. Turn the locking ring counterclockwise to disconnect.

• Disconnect the four (4) 27-conductor control output cables. Do not pull on the wire to disconnect. Carefully apply pressure to the connector

itself with either your ngers or preferably a small at head screwdriver.

Do not mix up the cable order or polarity.

• Disconnect the smaller 10-conductor connector. This connector and

cable is not required on the CD-3000 retrot and should be coiled up

and wire-tied. Carefully set it aside inside the rack and keep it isolated from any AC line voltage.

• The old processor housing can now be set aside.

Installation of the new CD-3000-AE System

• Remove your new CD-3000-AE system from the box. Leave the foam end caps in place to protect the unit from damage.

• Familiarize yourself with the backplane, and low voltage control input/ output connections. Refer to page 12 for details.

• Dress out all DMX and other low voltage connections to the backplane using the breakaway connectors provided. Be sure to isolate and protect all shield wires.

• Place the CD-3000-AE in front of the rack face down / backplane up.

Leave the foam end caps left in place to protect the unit from damage.

• Connect the four (4) 27-conductor control output cables to the backplane in the same order and polarity in which they were removed. Extra care should be taken not to bend or break any of the connector/header pins. Damage to these pins may require replacement of the entire CD-3000 assembly and will not be considered warranty! Refer to page 10 for the connector pinout.

• Connect all other applicable low voltage control input/output connections to the backplane.

• Connect the 9-position CPC power connector. The connector is keyed, so the plug and receptacle must be aligned to mate properly. Once aligned, turn the locking ring clockwise until a “click” is heard and felt indicating that the connector is fully seated. Refer to page 10 for the connector pinout.

www.johnsonsystems.com 5

• Remove the protective foam caps.

• Place the CD-3000-AE onto the CD-80® dimmer rack guide rails located on each side and carefully slide the unit into place. Ensure that the CD-3000-AE is fully seated.

• Tighten the mounting (thumb) screws into the threaded speed clips mounted on the end of each of the guide rails. Replacement speed clips are provided in case the original ones are worn out or missing.

• Install the CD-3000-AE air lter grill assembly. Start the upper two (2) mounting (thumb) screws, located on the upper arms of the air lter

grill assembly and screw into the CD-3000-AE chassis. Start the lower two (2) mounting (thumb) screws located on the lower portion of the air

lter grill assembly and screw into the brackets at the bottom CD-80®

dimmer rack. Once all four (4) mounting (thumb) screws are started, tighten them down and verify the assembly is fully seated. Be sure not

to over-tighten or cross-thread the mounting screws. The air lter should

be removed from the rack and cleaned annually using compressed air.

The air lter grill assembly is precisely engineered to allow for safe air

ow and ltration. The air lter and frame can be easily removed for cleaning and maintenance. Pushing up on the lter frame will free it to be pivoted out. Always ensure the lter frame is fully seated and secure before installing the CD-3000 air lter grill assembly. The air lter should

be removed from the rack and cleaned annually using compressed air.

WARNING! Never connect power with the air lter grill assembly removed.

• Reinstall the upper ventilation grill assembly onto the dimmer rack.

• Connect (turn on) the power supply to the Strand CD80® dimmer rack(s) and CD-3000.

• Verify system status LED indicators and LCD display. Refer to page 17 and 18 for details.

• Refer to the programming section of this manual for system setup. Refer to page 19 to 34 for details.

• Test the system thoroughly to ensure all wiring terminations are functioning and the control signals to the dimmers have the correct phase referencing.

• Verify fan operation. The fans are triggered on at 3% DMX input control, and stay on as long as the DMX is at 3% or greater. When the DMX input is brought down below 3%, there is a 5 minute timeout for the fans to turn off.

CD-3000-AE-48RR

• Follow the same installation procedure as CD-3000-AE.

CD-3000-AE-96RR

• Follow the same installation procedure as CD-3000-AE for the primary processor side of the rack.

• The CD-3000-AE-96RR is supplied with a fan housing assembly used to cool the secondary side of the rolling rack.

• The CD-3000-AE-96RR is supplied with a fan wiring harness used to supply power to the fans in the fan housing assembly.

www.johnsonsystems.com

• Remove the old fan housing similarly to the processor housing and set aside.

• Place the fan housing assembly in front of the rack with the foam end caps left in place to protect the unit from damage.

• Connect the fan wiring harness to the connectors supplied on the fan housing assembly.

• Remove the protective foam caps.

• Install the fan housing assembly and ventilation grill assembly similarly to the CD-3000-AE.

CD-3000-SV

WARNING! Verify all power is disconnected

Removal of the Old Processor Housing

•

Remove the screws located on left and right sides of the processor housing.

• Slowly pull the processor housing partway out to expose the control cable connections.

•

If you are not familiar with the Strand CD-80® dimmer rack processor electronics and wiring, it is strongly advised that you take a few minutes to look at the control cables connected to the circuit board on top of the processor housing and compare it to the backplane on the CD-3000-SV.

NOTE: Never pull directly on the wires to remove connectors.

Do not disconnect any wiring until you are satised with how easy this is going to be.

www.johnsonsystems.com 7

(turned off)

before proceeding.

• Note the location and function of all control cables landed on the circuit board on top of the processor housing. Label cables if necessary. These control cables may now be disconnected from the circuit board. Disconnect the “TOP COLUMNS” and “BOTTOM COLUMNS” control cables making sure they have their respective labels.

• The processor housing can now be carefully withdrawn from the rack, threading the control cables out from under the plexiglass cover. The back end must be supported as it is withdrawn so the power connector (square, white, 12-position connector) located at the left rear can be disconnected. To disconnect, squeeze the tabs on both sides of the connector together and pull out. The processor housing may now be

fully removed and set aside.

• Unscrew and remove the blank panel located under the slot for the processor housing.

• Unscrew and remove the air lter grill on the fan housing located above

the slot for the processor housing.

• Unscrew and remove the fan housing. There is a Molex connector at the rear of the fan housing that must be disconnected. This connector

and cable is not required on the CD-3000 retrot and should be coiled

up and wire-tied to the wiring harness it emerges from. Keep it isolated from any AC line voltage.

• With everything removed, look at the fuse block in the back of the rack and check the phasing. The wires landed on the bottom of the fuse block lead to the processor power connector. The black wire should be on Phase “A”, red on Phase “B”, and blue on Phase “C”. Correct if necessary.

Installation of the new CD-3000-SV System

• Remove your new CD-3000-SV system from the box. Leave the foam end caps in place to protect the unit from damage.

• Familiarize yourself with the backplane, and low voltage control input/ output connections. Refer to page 12 for details.

• Dress out all DMX and other low voltage connections to the backplane using the breakaway connectors provided. Be sure to isolate and protect all shield wires.

• Place the CD-3000-AE in front of the rack face down / backplane up.

Leave the foam end caps left in place to protect the unit from damage.

• Connect the “TOP COLUMNS” and “BOTTOM COLUMNS” control cables to their designated locations on the backplane. Lock in place using the ejection clamps on the connector. Refer to page 11 for the connector pinout.

www.johnsonsystems.com

• Connect all other applicable low voltage control input/output connections to the backplane.

• Connect the power connector (square, white, 12-position connector) into its mate mounted on the CD-3000-SV chassis. The connector is keyed so it can only be inserted one way. Push the connector in until a “click” is heard and the clamps locked indicating that the connector is fully seated. Refer to page 11 for the connector pinout.

• Carefully slide the CD-3000-SV into the rack using the rails for the old fan housing. Be sure not to pinch or stress any wires or cables. Secure in place using the four (4) 10-32 x 3/8” screws provided.

• Place the new air lter grill assembly over the bottom opening of the

rack. Secure in place using the four (4) 10-32 x 1 3/4” screws provided.

The air lter grill assembly is precisely engineered to allow for safe air

be removed from the rack and cleaned annually using compressed air.

WARNING! Never connect power with the air lter grill assembly removed.

• Connect (turn on) the power supply to the Strand CD80® dimmer rack(s) and CD-3000.

• Verify system status LED indicators and LCD display. Refer to page 17 and 18 for details.

• Refer to the programming section of this manual for system setup. Refer to page 19 to 34 for details.

• Test the system thoroughly to ensure all wiring terminations are functioning and the control signals to the dimmers have the correct phase referencing.

• Verify fan operation. The fans are triggered on at 6% DMX input control, and stay on as long as the DMX is at 6% or greater. When the DMX input is brought down below 6%, there is a 5 minute timeout for the fans to turn off.

CD-3000-SV-48RR

• In development.

CD-3000-SV-96RR

• In development.

CD-3000-C21

• In development.

www.johnsonsystems.com 9

CD-3000-AE Dimmer Control Cable Pinout

J1AE Connector J2AE Connector J3AE Connector J4AE Connector

PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION

1 Dimmer 24 1 Dimmer 48 1 Dimmer 72 1 Dimmer 96 2 Dimmer 23 2 Dimmer 47 2 Dimmer 71 2 Dimmer 95 3 Dimmer 18 3 Dimmer 42 3 Dimmer 66 3 Dimmer 90 4 Dimmer 17 4 Dimmer 41 4 Dimmer 65 4 Dimmer 89 5 Dimmer 12 5 Dimmer 36 5 Dimmer 60 5 Dimmer 84 6 Dimmer 11 6 Dimmer 35 6 Dimmer 59 6 Dimmer 83 7 Dimmer 6 7 Dimmer 30 7 Dimmer 54 7 Dimmer 78 8 Dimmer 5 8 Dimmer 29 8 Dimmer 53 8 Dimmer 77

9 Dimmer 22 9 Dimmer 46 9 Dimmer 70 9 Dimmer 94 10 Dimmer 21 10 Dimmer 45 10 Dimmer 69 10 Dimmer 93 11 Dimmer 16 11 Dimmer 40 11 Dimmer 64 11 Dimmer 88 12 Dimmer 15 12 Dimmer 39 12 Dimmer 63 12 Dimmer 87 13 Common 13 Common 13 Common 13 Common 14 Common 14 Common 14 Common 14 Common 15 Common 15 Common 15 Common 15 Common 16 Dimmer 10 16 Dimmer 34 16 Dimmer 58 16 Dimmer 82 17 Dimmer 9 17 Dimmer 33 17 Dimmer 57 17 Dimmer 81 18 Dimmer 4 18 Dimmer 28 18 Dimmer 52 18 Dimmer 76 19 Dimmer 3 19 Dimmer 27 19 Dimmer 51 19 Dimmer 75 20 Dimmer 20 20 Dimmer 44 20 Dimmer 68 20 Dimmer 92 21 Dimmer 19 21 Dimmer 43 21 Dimmer 67 21 Dimmer 91 22 Dimmer 14 22 Dimmer 38 22 Dimmer 62 22 Dimmer 86 23 Dimmer 13 23 Dimmer 37 23 Dimmer 61 23 Dimmer 85 24 Dimmer 8 24 Dimmer 32 24 Dimmer 56 24 Dimmer 80 25 Dimmer 7 25 Dimmer 31 25 Dimmer 55 25 Dimmer 79 26 Dimmer 2 26 Dimmer 26 26 Dimmer 50 26 Dimmer 74 27 Dimmer 1 27 Dimmer 25 27 Dimmer 49 27 Dimmer 73

CD-3000-AE Power Connector Pinout

PIN FUNCTION

1 Ground

2 No Connect

3 Neutral

4 No Connect

5 Phase C

6 No Connect

7 Phase A

8 No Connect

9 Phase B

www.johnsonsystems.com

CD-3000-SV Dimmer Control Cable Pinout

#1 Top Columns #2 Top Columns #3 Top Columns

PIN FUNCTION PIN FUNCTION PIN FUNCTION

1 Dimmer 1 1 Dimmer 3 1 Dimmer 5 2 Dimmer 2 2 Dimmer 4 2 Dimmer 6 3 Dimmer 13 3 Dimmer 15 3 Dimmer 17 4 Dimmer 14 4 Dimmer 16 4 Dimmer 18 5 Dimmer 25 5 Dimmer 27 5 Dimmer 29 6 Dimmer 26 6 Dimmer 28 6 Dimmer 30 7 Dimmer 37 7 Dimmer 39 7 Dimmer 41 8 Dimmer 38 8 Dimmer 40 8 Dimmer 42 9 V+ 9 V+ 9 V+

10 NC 10 NC 10 NC

#4 Top Columns #5 Top Columns #6 Top Columns

PIN FUNCTION PIN FUNCTION PIN FUNCTION

1 Dimmer 7 1 Dimmer 9 1 Dimmer 11 2 Dimmer 8 2 Dimmer 10 2 Dimmer 12 3 Dimmer 19 3 Dimmer 21 3 Dimmer 23 4 Dimmer 20 4 Dimmer 22 4 Dimmer 24 5 Dimmer 31 5 Dimmer 33 5 Dimmer 35 6 Dimmer 32 6 Dimmer 34 6 Dimmer 36 7 Dimmer 43 7 Dimmer 45 7 Dimmer 47 8 Dimmer 44 8 Dimmer 46 8 Dimmer 48 9 V+ 9 V+ 9 V+

10 NC 10 NC 10 NC

#1 Bottom Columns #2 Bottom Columns #3 Bottom Columns

PIN FUNCTION PIN FUNCTION PIN FUNCTION

1 Dimmer 49 1 Dimmer 51 1 Dimmer 53 2 Dimmer 50 2 Dimmer 52 2 Dimmer 54 3 Dimmer 61 3 Dimmer 63 3 Dimmer 65 4 Dimmer 62 4 Dimmer 64 4 Dimmer 66 5 Dimmer 73 5 Dimmer 75 5 Dimmer 77 6 Dimmer 74 6 Dimmer 76 6 Dimmer 78 7 Dimmer 85 7 Dimmer 87 7 Dimmer 89 8 Dimmer 86 8 Dimmer 88 8 Dimmer 90 9 V+ 9 V+ 9 V+

10 NC 10 NC 10 NC

#4 Bottom Columns #5 Bottom Columns #6 Bottom Columns

PIN FUNCTION PIN FUNCTION PIN FUNCTION

1 Dimmer 55 1 Dimmer 57 1 Dimmer 59 2 Dimmer 56 2 Dimmer 58 2 Dimmer 60 3 Dimmer 67 3 Dimmer 69 3 Dimmer 71 4 Dimmer 68 4 Dimmer 70 4 Dimmer 72 5 Dimmer 79 5 Dimmer 81 5 Dimmer 83 6 Dimmer 80 6 Dimmer 82 6 Dimmer 84 7 Dimmer 91 7 Dimmer 93 7 Dimmer 95 8 Dimmer 93 8 Dimmer 94 8 Dimmer 96 9 V+ 9 V+ 9 V+

10 NC 10 NC 10 NC

CD-3000-SV Power Connector Pinout

PIN FUNCTION

1 Phase C 2 Phase B 3 Phase A 4 Neutral 5 No Connect 6 Ground 7 O/T N.C. (V+) 8 O/T N.C.

9 O/T N.O. 10 O/T N.C. (COM) 11 No Connect 12 No Connect

www.johnsonsystems.com 11

J3AE J1AE J2AE J4AE

J1SV J10SV

J11SV

J12SV

J2SV

J3SV

J4SV

J5SV

J6SV

J7SV

J8SV

J9SV

J17

J18

J16

J15

J12

J11

J10

J4 J5

J14

J13

JP1

J2 J1

1-24 25-48 49-72 73-96

TOP COLUMNS BOTTOM COLUMNS

FAN FAN

LINE NEUTRAL

DATA+

DATA-

SHIELD

COMMON

ANALOG

+12V

FIRE ALARM INPUT (NORMALLY OPEN)

SECURITY ALARM INPUT (NORMALLY OPEN)

AUXILIALY INPUT (NORMALLY OPEN)

+12V PS

+12V O/T

COM PS

COM O/T

O/T N.O.

O/T N.C.

COMMON

+12V

DMX A

INPUT

DMX A

THRU

DMX B

INPUT

DMX B

THRU

DMX I O

REMOTE

COM

FAN+

COM

+5V

TEMP

AE SV

1 1

FAN

LINE

FAN

LINE

FAN

NEUTRAL

FAN

NEUTRAL

1 1 1 1

N.C.

F1 F2 F3

 A

 B  C

 A

 B

 C

NEUTRAL

IN PS

COMMON

DATA+

DATA-

DATA+

DATA-

DATA+

DATA-

OVERTEMP INPUT (NORMALLY CLOSED)

OPEN COLLECTOR OUTPUT

OVERTEMP INPUT (NORMALLY OPEN) (TS1)

SHIELD /

COMMON

SHIELD /

COMMON

SHIELD /

COMMON

INPUT 1

INPUT 2

INPUT 3

INPUT 4

SSR1

PLC T  

STCTN US ONL

CUTON C LN OLT

REV.1 1024

BACKPLANE BOARD

+ 

CD-3000

WWW.JOHNSONSYSTEMS.COM

SERIAL

NUMBER



CD-3000 Backplane

Internal Fuses (3) Replace with 5A 250V Fast-Acting Fuse Only!

WARNING! Verify all power is disconnected (turned off) before checking or servicing fuses.

CD-3000-SV Control Output Connectors (12)

CD-3000-AE Control Output Connectors (4)

Input / Output Contacts Connector

+12VDC Power Supply Output Connector

0-10VDC Analog Input Connector

RJ45 DMX I/O Connectors (2). Used to connect (daisychain) DMX A and DMX B between CD-3000 systems in multi-rack installations.

Dual DMX Input and Thru Connectors

www.johnsonsystems.com

+ 26 hidden pages