ETC SMARTRACK User manual

smartrack
USER MANUAL
Electronic Theatre Controls Ltd.
5 Victoria Industrial Estate, Victoria Road
London W3 6UU, England
([phone] FAX [phone]
Copyright 1995 Electronic Theatre Controls Ltd.
Specifications subject to change. Revised 8/95
2000M1001

smartrack
User Manual
page i
Introduction – Please read this first
Thank you for choosing ETC Smartrack digital dimmers. We are
sure that you will be pleased with Smartrack, and wish you a
long and happy association with our company and its products.
We at ETC 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 arising from the
guidelines in this manual not being followed.

Table of contents
1. Digital dimming explained ...................................................1
2. About Smartrack..................................................................2
2.1 Mechanical............................................................................2
2.2 Electrical................................................................................4
2.3 Filtering.................................................................................4
2.3.1 Standard risetime choke ..........................................................4
2.3.2 High risetime choke ................................................................5
2.4 Rack control...........................................................................5
2.4.1 Dimmer profile .......................................................................5
2.4.2 Response speed......................................................................5
2.4.3 Dimmer test............................................................................6
2.4.4 Reference voltage ...................................................................6
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-phase systems ..................................17
4.5.3 Connecting Delta systems ......................................................17
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Smartrack User Manual ETC Ltd

4.5.4 Cascading a stack of Smartracks ...........................................17
4.6. Load wiring..........................................................................19
4.6.1 Installing load wires ..............................................................19
4.7. Identifying and testing power and load wiring..........................19
4.8. Signal wiring .......................................................................20
4.9. Power assemblies .................................................................21
4.9.1 Installation ...........................................................................21
4.9.2 Connecting load wiring.........................................................21
4.9.3 Connecting power wiring – RCD option fitted...........................23
4.9.4 Connecting power wiring – without RCD option .......................25
4.9.5 The power assembly signal looms...........................................25
4.10 Smartrack door ....................................................................27
4.10.1 Mounting the door ................................................................27
4.10.2 Connecting earth and power wiring........................................27
4.10.3 Smartrack 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
5.5. Using offline mode................................................................33
5.5.1 Verifying rms line voltage in offline mode ................................34
5.5.2 Setting the output voltage range in offline mode .......................34
5.6. Testing dimmer circuits with the rotary potentiometer.................35
5.7. DMX control.........................................................................35
5.7.1 Terminating the DMX line.......................................................36
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Smartrack User ManualVersion 1.2

5.7.2 Good/bad data ...................................................................36
5.7.3 Setting the rack address ........................................................36
5.7.4 Large installations .................................................................37
5.7.5 Testing dimmers with DMX.....................................................37
5.8. Dimmer profiles ....................................................................37
5.8.1 What is a profile?.................................................................37
5.8.2 Smartrack standard profiles ...................................................38
5.8.3 Dimmer and console set profiles .............................................39
5.8.4 Setting profiles .....................................................................39
5.9. Response speed....................................................................40
5.9.1 Setting response speed..........................................................41
5.10 Important note – Exiting 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 .....................................................................47 ...
7.2. Cleaning .............................................................................47
7.3. Inspecting dimmer module connectors .....................................48
7.4. Control fuse ratings...............................................................48
7.5. Battery replacement ..............................................................48
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Smartrack User Manual ETC Ltd

8. Technical support ...............................................................49
8.1. Who to call..........................................................................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
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Smartrack User ManualVersion 1.2

Notes:
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Smartrack User Manual ETC Ltd

smartrack
USER MANUAL
1. Digital dimming explained
There are good reasons why users of professional dimming equipment are now only
willing to accept true digital dimming equipment, such as ETC Smartrack and
Smartpack. They are:
●Accuracy – digital dimmers are able to regulate output levels to reproduce precisely
recorded intensities, even when mains power is fluctuating.
●Reliability – with fewer electronic components, digital dimmers literally have less
things to go wrong.
●Smarts – with processing power on board, digital dimmers can perform tasks previ-
ously impossible with analogue techniques. These include diagnostic functions, indi-
vidual dimmer profile and response speed settings, and more.
●Cost – a well designed 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 this information, the power devices are pre-
cisely controlled, to compensate for any mains voltage fluctuations and produce a con-
stant voltage output for any given control level.
Of course, in an age where virtually all lighting control consoles output the same inter-
nationally accepted digital control signal (USITT DMX512), another plus with digital
dimmers is that no expensive demultiplexer stage is required. The digital signals from
the lighting console are simply connected directly to the dimmers.
page 1

2. About Smartrack
Smartrack is a revolutionary concept in professional digital dimming equipment, offer-
ing a very wide range of system options in an extremely compact package, with many
significant advantages over its competitors:
●Compact size
●Competitive price
●Easy and economical installation
●Highly flexible configuration options
●Basic or modular variants
●All-digital – high reliability, high accuracy
Smartrack is unique in that it offers competitive system solutions at all levels of the market,
and versions exist to cover all requirements, right up to top level broadcast applications.
2.1 Mechanical
Each Smartrack is a proprietary wall mounting steel cabinet, measuring 85cm
wide, 65cm high and 30cm deep, designed 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
three high, side by side, or back to back. Smartrack may also be fitted into flight-
cases with custom rear connector panels, for highly cost-effective mobile dimming
systems.
All power, load and signal cables may enter from top, bottom, or through rear
panels and sufficient space is provided for through wiring in a stack of three
Smartracks. Front access only is required for installation and maintenance, and
all terminal screwheads face forward, for easy re-tensioning in service.
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Smartrack User Manual ETC Ltd

Power Assemblies are available either with plug-in modules containing power
devices and LED level indicators, or with power devices mounted on a perma-
nent heatsink. Power assemblies of different ratings may be mixed in a rack, but
basic and modular power assemblies may not be mounted in the same rack.
All 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.
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Smartrack User ManualVersion 1.2
DIGITAL
SmartRack
2.5 2.5 2.5
2.5 2.5 2.5
2.5 2.5 2.5
0205 490 850
0
84
290
496
650
mcb centre
mcb centre
mcb centre
Front view of a modular
Smartrack, showing key
dimensions.
Note that Smartrack is
300mm deep, plus 30mm
for dimmer module handles
on the modular version only.
smartrack
215 630 990

2.2 Electrical
Smartrack is designed for operation on single or three phase supplies at 230Vac
±12.5%. Delta versions are also available to special order.
Each Smartrack may optionally be supplied with a 4-pole 125A or 160A circuit
breaker fitted, and earth leakage (RCD) protection may be fitted at power assem-
bly level (single phase to special order).
Power devices are generously overrated solid state switching devices, encapsu-
lated into quad 2.5kW, dual 5kW and single 10kW modules.
Individual dimmer circuits are normally protected by single pole miniature circuit
breakers, rated at 13A (2.5kW), 25A (5kW) and 50A (10kW). Single pole with
neutral disconnect mcbs and double pole mcbs are also available to special
order. See the Smartrack specification for more detailed electrical information.
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-
ferent types of work. Generally speaking, the higher the risetime the more the
interference generated by the dimmer is suppressed, but it is unwise to specify a
higher risetime than that actually required, since there are weight, thermal and
cost penalties as you go up the scale.
2.3.1 Standard risetime choke
The standard choke is wound on a 2.5” toroidal iron powder core, and
produces a risetime in excess of 200µS. This should be adequate for the-
atre and most video production work, and complies with the BBC’s
PID171 standard for 2.5kW dimmers.
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Smartrack User Manual ETC Ltd

2.3.2High risetime choke
The High Risetime choke is wound on a 4” toroidal iron powder core, and
produces a risetime in excess of 400µS. This is a requirement of the
Nordic Television Authorities for 2.5kW dimmers, and complies with the
BBC PID171 standard for 5kW and 10kW dimmers. It is recommended
for front of house lighting circuits in theatres and in concert halls, where
acoustic requirements may be critical.
2.4. Rack control
Smartracks receive USITT DMX512/1990 dimmer drive signals from a very wide
range of lighting controllers, including all ETC Expression, Impression, Insight,
MicroVision, Connection and Reflection systems.
The control panel on each Smartrack enables the user to set and display a start
address for the rack, as well as to select, for each or all 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 to
arrive at a new level, following the reception of a new level instruction by
the dimmer’s control electronics, and is measured in milliseconds. Don’t
confuse response speed (in milliseconds) with risetime (in microseconds).
Smartrack ships with a default 100mS response speed set for all dimmers,
but allows the user the choice, for any or all dimmers in a rack, of 30,
100, 300 or 500mS.
Thus, a studio with RCDs and a lot of 5kW loads might function happily
with all dimmers set to 300mS response time, while individual circuits for
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Smartrack User ManualVersion 1.2

chasers or practicals might be set to 30mS for special effects work. A tour-
ing rack used for concert lighting, on the other hand, might be set globally
to 30mS, but with the odd 10kW dimmer at 500mS.
IMPORTANT: A slower response speed will also have beneficial effects on
lamp life, since the shock to cold filaments will be reduced, as the time
period required to ramp them to full brightness is increased.
2.4.3Dimmer test
Any or all dimmers may be selected and set to a level, using the rotary
potentiometer on the front panel. The dimmers in a rack may be ‘flashed
through’ to a level, by setting the pot to the desired intensity, 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 and maximum fan life. One fan is incorporated into
the end of each power assembly, and air is drawn very efficiently over the
chokes and power device heatsinks before being exhausted through the front
panel.
Since Smartrack’s air inlet and exhaust vents are all on the front panel, there is
no problem stacking Smartracks vertically and horizontally, or mounting in sim-
ple flightcases.
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Smartrack User Manual ETC Ltd

One thermal sensor is provided for each power device, and constantly feeds
back temperature status information to the central processor (CPU). The CPU uses
this information to decide when it is necessary to switch on the fan for any given
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.
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Smartrack User ManualVersion 1.2

3. Getting started – what’s in the box
3.1. Smartrack
Smartrack systems are shipped broken down into racks and power assemblies
(up to three per rack). Please check carefully to verify that you have everything
you need before starting the installation.
3.1.1Rack
Each rack is shipped separately as an empty enclosure, with separately
wrapped door assembly and a number of internal fittings kits, namely:
Metalwork Kit
2 x power cable entry cover
2 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 taptite screw
Remove the door assembly from the carton and store it separately while
the racks are installed and wired. It’s not needed until the installation of
the wiring and power assemblies is complete.
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Smartrack User Manual ETC Ltd

3.1.2Power assemblies
Power assemblies are packed individually, and are of two main types –
basic or modular. Basic power assemblies come with the power devices
permanently mounted on a single heatsink on the front of the assembly.
Modular power assemblies are each provided with three plug-in dimmer
modules containing the power devices and level indicators.
When installing modular power assemblies, first remove the plug-in mod-
ules and store separately in a safe place until ready.
Each power assembly is also shipped with
Power Loom Kit
1 x 2.5mm2cable. Brown ident L1
1 x 2.5mm2cable. Brown ident L2
1 x 2.5mm2cable. Brown ident L3
1 x 2.5mm2cable. Blue ident N
1 x 2.5mm2cable. 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 10mm2uninsulated bootlace ferrules
Note that the power assemblies are not required for the first stages of
installation, and should be left in their packing, especially if there is a risk
of builders’ dust on site.
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Smartrack User ManualVersion 1.2

4. Installation
Smartracks are intended for mounting either against a wall, back to back in an island
formation or in a flightcase. This section deals with wallmount or island installation –
see the next section for information on flightcasing.
4.1. Environmental considerations
Care must be taken to ensure that the ambient temperature in the dimmer room
stays within the range 0 – 35° Celsius. In some cases, this will require air extrac-
tion or air conditioning.
In order to calculate worst case air handling requirements, you need to know the
thermal losses in the dimmer, as well as estimating the actual maximum continu-
ous load. Since lighting loads vary enormously, it may be reasonable to apply a
diversity 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 result is that up to 3.75kW of
heat may be anticipated in the dimmer room, which may then need additional
extraction or cooling.
Relative humidity should be kept below 80%, non-condensing.
4.2 Planning and marking out
Smartracks are intended to be mounted up to three racks high, and as wide as
may be required, with no air gap between racks.
Wiring access may be from above, from below or through the rear, and only
front access is required for installation and service.
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Smartrack User Manual ETC Ltd

We recommend using a large cable duct running across the top of a bank of
Smartracks, carrying power and load wiring. Alternatively, power wires may be
run in from below, and load wires from above, or vice versa.
Note that DMX signal wires should be run in separate cableways from the power
and load cables, outside the racks, though it is permissible to mix them in the
immediate 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:
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Smartrack User ManualVersion 1.2
850
760
90
45
850
760
560
560
560
90
90
58
663 650 650
Fixing
Centres
Stack 1 Stack 2
Two stacks of three
Smartracks, showing posi-
tions of fixing holes. 13mm
has been allowed for the
feet at the bottom of each
stack, which are optional.
Rack:
h 650mm,
w 850mm
Mounting centres:
h 560mm,
w 760mm

4.2.2Planning an island installation
Smartracks may be mounted back to back, either in an island, or, with
one end of each bay against a wall, in a peninsula configuration.
On a solid floor, all wiring will normally be taken out through the top
wiring access ports. Where raised computer type flooring is used, some or
all of the wiring may enter through the base of the racks.
Note that the ‘keyhole’ fixing positions in the back of each rack must be
used in back-to-back installations, to provide stability. Use M6 nuts and
bolts to fix back-to-back racks together.
A knockout panel is provided in the centre of Smartrack’s rear panel,
which may be removed if interwiring between back-to-back racks is
required. If using the knockout panels, use a grommet strip around the
inside edges to prevent chafing.
4.3. Wall fixings
Each 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 plugs, should be more than sufficient.
On uneven surfaces, it may be necessary to mount 50 x 50mm wooden battens
to the wall, and fix the Smartracks to the battens. In this case, ensure that the bat-
ten fixings are sufficient to take the total weight of all the Smartracks to be so
mounted.
Having marked out the wall, drill, plug and fit mounting screws, protruding about
20mm from the wall.
4.4. Assembly and mounting
a) If the bottom Smartrack in a stack will stand on the floor, fit the four plastic
feet provided by screwing them up into the threaded inserts on the base of
the rack.
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Smartrack User ManualVersion 1.2
How to fix 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)