ETC IRIDEON AR500 User manual

AR500™Remote Ballast Rack
Installation Manual
Revision A
Copyright © Electronic Theatre Controls, Inc.
All Rights reserved.
Product information and specifications subject to change.
Part Number:
7091M2100 Rev A
Released: April 2003

ETC
®
, Irideon
®
, Composer
™
, Composer Lite
™
, AR50
™
, AR6
™
, AR500
™
, Building with Light
™
,
and the Building Designs are registered trademarks owned by Electronic Theatre Controls, Inc.,
3030 Laura Lane, Middleton, Wisconsin, USA, registered in the United States and other
countries.
Microsoft
®
and Windows
®
are registered trademarks or the Microsoft Corporation in the United
States and other countries.

Table of Contents i
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Contacting ETC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Warnings and notice conventions . . . . . . . . . . . . . . . . . . . . 1
System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Circuit breaker protection . . . . . . . . . . . . . . . . . . . . . . 3
Obtaining ETC approval to energize the system . . . . . . . . . 4
Clearance and Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Weight Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Input Power and Control Cable Preparation . . . . . . . . . . . . 5
Cable Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Install the remote ballast rack. . . . . . . . . . . . . . . . . . . . . . . . 7
Cable Access Preparation . . . . . . . . . . . . . . . . . . . . . . . . .8
Prepare cable access to the rack . . . . . . . . . . . . . . . . . . . . . 8
AC and Data input wiring . . . . . . . . . . . . . . . . . . . . . . . . .10
Connect AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect Data-in and Data-through. . . . . . . . . . . . . . . . . . . 11
Lamp Power and Motor Control wiring . . . . . . . . . . . . . .15
Connect Lamp Power Out . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connect Motor Control Out. . . . . . . . . . . . . . . . . . . . . . . . . 17
Addressing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Address the Composer CPU . . . . . . . . . . . . . . . . . . . . . . . 19

ii AR500 Remote Ballast Rack Installation Manual
Ballast Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Install ballast plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ballast Rack installation checklist. . . . . . . . . . . . . . . . . .22
Finishing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contact ETC for System Energization . . . . . . . . . . . . . . . . 22

Introduction 1
Introduction
Welcome to the Irideon®AR500™Remote Ballast Rack Installation Manual. This manual
contains the procedures for safe and efficient installation of the remote ballast rack system.
AR500 remote ballast racks may be populated with up to six ballast and control electronics
for control of up to six AR500 remote luminaires:
• AR500 BR-2 – Ballast rack including control electronics for two AR500 luminaires
• AR500 BR-3– Ballast rack including control electronics for three AR500 luminaires
• AR500 BR-4– Ballast rack including control electronics for four AR500 luminaires
• AR500 BR-5– Ballast rack including control electronics for five AR500 luminaires
• AR500 BR-6– Ballast rack including control electronics for six AR500 luminaires
How to use this manual
Use this manual during system installation. This manual contains complete step by step
installation instructions which are very important to follow:
•System Layout, page 2 displays general system risers for installation.
•Preparing for installation, page 3 details installation requirements in preparation of
your installation.
•Installation, page 7 provides step by step instructions for installation of the remote
ballast rack including all cabling, addressing and ballast installation.
Contacting ETC
®
For general information about the Irideon remote ballast rack system, contact ETC
Technical Support at 608.831.4116.
Warnings and notice conventions
These symbols are used in the Irideon AR500 Remote Ballast Rack documentation and on
equipment to alert you to danger or important information:
WARNING: Warns you when electricity may cause injury.
CAUTION: Alerts you to important information relating to equipment performance or reliability.
Note: Provides you with additional helpful information.

2Remote Ballast Rack Installation Manual
System Layout
The Irideon AR500 remote ballast rack is a compact alternative power and signal
distribution method for the AR500 remote luminaire. Each remote ballast rack provides
space for a maximum of six individual ballast assemblies and six control electronic
assemblies. This rack is intended for installations where there is an interior space, within
300 feet of the AR500 exterior luminaires, allowing field wiring to be installed between the
rack and the luminaires.
Lamp Power: 3-#12AWG Wires
Motor Control: Belden 9160
Typical for each luminaire.
To
3
Ø
4 Wire (or 1
Ø
3-Wire
)
+ Ground
(
A
C
P
o
w
e
r
Sou
r
ce
with
Main Circuit Breaker
(
B
y
Others
)
To
3
Ø
4 Wire (or 1
Ø
3-Wire) + Ground
AC Power Source with
(
))
T
o
A
C
P
o
w
e
r
Sou
r
ce
8
R
S
-
W
MRP
-
W
s
Rack to Rack
Data jumper
Lamp Power: 3-#12AWG Wires
Motor Control: Belden 9160
Typical for each luminaire.
To
3
Ø
4 Wire (or 1
Ø
3-Wire
)
+ Ground
(
A
C
Power
S
ource wit
h
Main Circuit Breaker
(
B
y
Others
)
To
3
Ø
4 Wire (or 1
Ø
3
-Wire +
G
roun
d
AC Power Source with
(
T
o
A
C
P
o
w
e
r
Sou
r
ce
Rack to Rack
Data jumper

Preparing for installation 3
Preparing for installation
Before you begin installation, check your shipment.
Step 1: Check the shipping container for physical damage.
Step 2: If you find damage, document it to help with the claim against your shipper.
Step 3: Unpack your order and check the contents against the packing list provided with
the shipment to ensure the order is complete.
Step 4: If you discover a problem please contact ETC Customer Service at 608.831.4116
Installation requirements
Note: The installation contractor is responsible for compliance with local electrical codes.
The AR500 remote ballast rack is not weatherproof and must be installed in an interior
location, such as an equipment room, with the following environment requirements:
• clean (not dusty), temperature controlled environment (32°-104°F)
• Humidity between 30-95%, non-condensing
• restricted public access to prevent tampering
ETC provides the following for this installation:
• (2) Data Termination Preparation Kit
• (1) Hex key 3/16"X9" Looped Thandle (for AR500 luminaire adjustment)
The following tools and supplies are required, but not supplied by ETC, to complete the
installation:
• #2 Phillips screwdriver
• #2 Straight slot screwdriver
• Conduit punch
• Wire cutters and strippers
• Adjustable wrench
Main Circuit breaker protection
Before beginning installation of your remote ballast rack(s), make sure you have installed
a main circuit breaker cabinet or other readily available accessible input power disconnect
device. See AC Power Requirements, found on page 5 for individual rack power
requirements.
WARNING: Ballast Racks installed without an accessible power disconnect device cannot be
serviced or operated safely.

4Remote Ballast Rack Installation Manual
Obtaining ETC approval to energize the system
ETC approval is required to apply power to your Irideon AR500 remote ballast rack and
AR500 luminaires. You may obtain pre-approval for some installations during the
purchasing process, or pass a wiring inspection by an authorized ETC representative after
the system is installed. Wiring errors in unauthorized energization of your system may
endanger operators or cause system damage and failure.
WARNING: Do not attempt to energize the system without proper approval. Energizing the
system without ETC approval may result in serious injuries due to improper
wiring.
CAUTION: Energizing your system without ETC approval may result in equipment damage
that will void your warranty.
Clearance and Access
The remote ballast rack is 31.25” wide, 26.75” deep and 35.125” tall. When installing the
rack, provide sufficient access to the front and side door panels for maintenance, including
provisions for AC and data-in, AC and data-out to the luminaires, and at least 6” clearance
on the left and back sides for proper air flow with 12-27” for the front and right sides for
proper maintenance access.
Weight Specification
A single remote ballast rack weighs 160 pounds without ballast plates installed. A loaded
remote ballast rack, including six ballast plates, weighs approximately 380 pounds.
CAUTION: Ensure that the floor space you have chosen for this installation can support this
product.
27"
6"
12" to nearest
structure for access
to the right panel.
6"

Preparing for installation 5
AC Power Requirements
Note: The installation contractor is responsible for compliance with local electrical codes.
The AR500 remote ballast rack is available in voltages ranging from 100VAC to 277VAC
@ 60Hz. Each AR500 luminaire requires 700 watts of power at the specified voltage and
frequency. A fully loaded remote ballast rack (up to six ballasts / two ballast per phase)
would require 4200 watts of power at the specified voltage and frequency.
Each remote ballast rack also requires a Main Breaker, not supplied by ETC.
Input Power and Control Cable Preparation
The installation contractor must provide cabling for incoming power, incoming data,
outgoing lamp power, outgoing motor control cable, and data through (if required) All
conduit knockouts must be drilled on the removable covers provided. All drilling must be
completed with the covers removed from the rack.
WARNING: Drilling with the covers installed may cause damage to the rack which will negate
warranty for this installation.
VAC / Hz Phase Current at Run
120VAC/60Hz
A 15A
B 15A
C 15A
208VAC/60Hz
A 13A
B 13A
C 13A
220/240VAC/
60Hz
A7A
B7A
C7A
277VAC/60Hz
A7A
B7A
C7A
Removeable covers
for strain relief and
hole punching.
Knock-outs for
Lamp Power out to
Luminaires (Typical)
Knock-out for
data in
Knock-out for
power in

6Remote Ballast Rack Installation Manual
Cable Specification
Note: The installation contractor is responsible for compliance with local electrical codes.
The maximum length of lamp power and motor control cable from the remote ballast rack
to the AR500 luminaire cannot exceed 300 feet.
Per UL regulation, Lamp Power and Motor control cable are to be routed through separate
conduit. When terminating data and AC power in a common junction box, wiring must be
separated by a dividing panel.
Signal Type Cable Specification Conduit
(required)
AC Power to Remote Ballast
Rack
3PH/5w or 1PH/4wire
rated Per local code Per local code
Lamp Power from Remote
Ballast Rack to AR500
luminaire
3- #12AWG YES
Data to Remote Ballast Rack Belden 9729 (or
equivalent) YES
Data through (to daisy chain
two or more remote ballast
racks)
Belden 9729 (or
equivalent) YES
Motor control cable from the
Remote Ballast Rack to AR500
luminaire
Belden 9160 (or
equivalent) YES