User Manual CD-3000 Series Retrofit Control System Model CD-3000-AE CD-3000-AE-48RR CD-3000-AE-96RR CD-3000-SV CD-3000-SV-48RR CD-3000-SV-96RR CD-3000-C21 Application Strand CD80® AMX or Advanced Electronic (AE) permanent installation racks.
R O FI Contents T Y CL EU REC SE ! R ET Warranty...........................................................................................................2 Introduction.......................................................................................................3 Packaging & Contents......................................................................................4 E R Installation....................................................................................................
Introduction The JSI CD-3000 is a next generation retrofit electronics package designed specifically 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 stateof-the-art unit provides a low cost digital interface to any of today’s modern lighting communication protocols.
Packaging & Contents Each CD-3000 Series retrofit 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 retrofit.
• 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.
• 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 filter grill assembly.
• • • • • 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.
• • • • • • 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.
• • • • 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.
CD-3000-AE Dimmer Control Cable Pinout J1AE Connector PIN FUNCTION 1 Dimmer 24 2 Dimmer 23 3 Dimmer 18 4 Dimmer 17 5 Dimmer 12 6 Dimmer 11 7 Dimmer 6 8 Dimmer 5 9 Dimmer 22 10 Dimmer 21 11 Dimmer 16 12 Dimmer 15 13 Common 14 Common 15 Common 16 Dimmer 10 17 Dimmer 9 18 Dimmer 4 19 Dimmer 3 20 Dimmer 20 21 Dimmer 19 22 Dimmer 14 23 Dimmer 13 24 Dimmer 8 25 Dimmer 7 26 Dimmer 2 27 Dimmer 1 J2AE Connector PIN FUNCTION 1 Dimmer 48 2 Dimmer 47 3 Dimmer 42 4 Dimmer 41 5 Dimmer 36 6 Dimmer 35 7 Dimmer 30 8 Dimmer
CD-3000-SV Dimmer Control Cable Pinout #1 Top Columns FUNCTION Dimmer 1 Dimmer 2 Dimmer 13 Dimmer 14 Dimmer 25 Dimmer 26 Dimmer 37 Dimmer 38 V+ NC #4 Top Columns PIN FUNCTION 1 Dimmer 7 2 Dimmer 8 3 Dimmer 19 4 Dimmer 20 5 Dimmer 31 6 Dimmer 32 7 Dimmer 43 8 Dimmer 44 9 V+ 10 NC #1 Bottom Columns PIN FUNCTION 1 Dimmer 49 2 Dimmer 50 3 Dimmer 61 4 Dimmer 62 5 Dimmer 73 6 Dimmer 74 7 Dimmer 85 8 Dimmer 86 9 V+ 10 NC #4 Bottom Columns PIN FUNCTION 1 Dimmer 55 2 Dimmer 56 3 Dimmer 67 4 Dimmer 68 5 Dimmer 79 6 D
J12 DMX B THRU J11 DMX B INPUT J10 DMX A THRU J13 J14 J15 DMX I O DMX I O REMOTE J17 J16 ANALOG INPUT 1 ANALOG INPUT 2 ANALOG INPUT 3 ANALOG INPUT 4 +12V COMMON +12V +12V +12V COMMON SERIAL NUMBER WWW.JOHNSONSYSTEMS.COM DATA+ DATA- SHIELD / COMMON DATA+ DATA- SHIELD / COMMON DATA+ DATA- SHIELD / COMMON DATA+ SV AE JP1 J8 J7 J18 +5V COM TEMP COM FAN+ N.C.
Control Input/Output Connections All CD-3000 systems come with a variety of control input and output (I/O) capabilities. All I/O connections are terminated on the Backplane. Breakaway type connectors are supplied for all I/O connections. • • Use wire size #28 to #12 AWG. Strip insulation length to 0.3” (7.5mm). Torque terminations to 3.6 IN-LBS (0.4 NM). NOTE: For connection use copper wire only, rated for 167°F (75°C) minimum.
+12V Normally Closed Thermostat Switch Overtemp Input Normally Closed Overtemp Input Normally Open Normally Open Thermostat Switch Common Over-Temperature Input (Normally Closed) • Terminate (OVERTEMP INPUT (NORMALLY CLOSED)) on J18 connector. • Disables all dimmer outputs when contact/switch is opened. • Controlled via a maintained contact/switch to +12V. • Connects to OEM wiring in Strand CD80® Supervisor (SV) racks via the power connector.
Control Module • MADD-96 (Multiple Application Dimmer Driver) The MADD-96 is the central electronic control system (brain) for all CD-3000 Series retrofit systems. The MADD-96 is mounted in the Control Module. The Control Module can be removed by releasing the two (2) quarter-turn fasteners on each side. To release the fasteners, turn them a quarter-turn counter-clockwise using a flathead screwdriver. Once the fasteners are released, pull the module outwards using the two (2) handles on each side.
User Interface LCD Display All CD-3000 Series retrofit systems are equipped with a user interface. The user interface provides access to all programming and configuration settings. System status is easily visible on the LCD display and LED indicators. An infrared LED allows for printout of all system configuration settings when used with a hand held infrared printer (Johnson System Inc., Part Number: JS-IP).
System Status • LED Indicators RUN (Green) Illuminates when the power is on and the microcontroller status is in normal run mode. The LED flashes once every 2 seconds when the system is in STANDBY mode. ØA, ØB and ØC (Green) Illuminates when the line voltage power is within the acceptable range of 100-130 VAC for each phase and the zero-cross reference circuitry is functioning properly.
INF HOLD Displayed when DMX is disconnected and the systems predetermined DMX status hold (SH) time is set for infinite (INF) hold. Refer to menu item “SH TIME” on page 25 for further details. SCENE:XX Displays the scene (1 to 20) that is currently activated. The colon in front of the scene number flashed twice per second during fading. Refer to menu item “SCENEMOD” on page 28 for further details. A-SCENE! Displayed when the auxiliary input is triggered.
Quick Programming Reference 1. SCENESET 2. FADETIME 3. SNAPSHOT 4. DIM TEST 5. MONITOR 6. ADDRESS 7. DMX MODE 8. 2 RM SET 9. DMXA TRM 10. DMXB TRM 11. DMX O/P 12. DMXA PAT 13. DMXB PAT 14. SH TIME 15. DC PATCH 16. DIM CURV 17. VOUT LIM 18. REGULATE 19. ANA MODE 20. ANA PAT 21. ANA TEST 22. ANA FLTR 23. ANA BLOC 24. STANDBY 25. TEST INC 26. OC MODE 27. AUX IN 28. SCENEMOD 29. S-ALARM 30. F-ALARM 31. Ø-PATCH 32. WARMING 33. POLARITY 34. LINE V 35. LINE F 36. REM TEMP 37. CTL TEMP 38. RTIME 39. HARD-KEY 40.
Detailed Programming of System Configuration Menu Items NOTE: The programming switches can be locked out to prevent inadvertent configuration changes. To toggle between “LOCKED!!” and “UNLOCKED” press and hold down the EXECUTE and then ESCAPE switches at the same time for 4-5 seconds. The sequence of the following system configuration menu items appear as the MENU DOWN ( ) switch is pressed. Pressing the MENU UP ( ) switch will sequence the system configuration menu items in the opposite order.
3. SNAPSHOT SAVE >01 SCENE>20 SURE ??? DONE !!! NO RX! 4. DIM TEST Record DMX levels into the backup scenes. Provides a quick and easy way to save control channel levels into each of the 01 to 20 backup scenes using a DMX source. Press EXECUTE to enter the menu and activate snapshot mode. Press MENU ( ) to select a different scene from 01 to 20. Press EXECUTE to store DMX levels in the selected scene. Press EXECUTE if you are sure the DMX levels are set as intended.
7. DMX MODE PTY A PTY B MERGE DMX A+B 2 ROOM Configure the mode of the on-board DMX protocol manager. There are five different mode settings for the DMX protocol manager. Priority A (PTY A) and Priority B (PTY B) modes are intended for the implementation of a backup DMX source. Priority A (PTY A) sets the DMX A input as the priority, and ignores the DMX B input when the DMX A input is active.
9. DMXA TRM ENABLED DISABLED Enable or disable termination on the DMX A input. Activates and deactivates a 120Ω termination resistor. DMX termination is indicated on the LCD display when DMX is being received. When the DMX A input is not terminated (DISABLED) the LCD display will read AXXXBXXX. When the DMX A input is terminated (ENABLED) the LCD display will read MT XXXBXXX. Press EXECUTE to toggle termination from ENABLED to DISABLED. Press EXECUTE to toggle termination from DISABLED to ENABLED.
MANUAL? DIM DMXA 001<999? 096<999? 001<999? 001 999? 001 999? 001 999? 001 999? 001 999? 001 999? 001 512 001 999? BLOCK? DIM#:001 DIM#:096 DIM#:001 DMXA:001 DMXA:512 DMXA:001 #DIM:001 #DIM:096 #DIM:001 PROCEED? SURE ??? DONE !!! CLEAR??? SURE ??? DONE !!! For a more complex example, if DIM# is 049, DMX is 321, and #DIM is 024, then dimmer outputs 049 thru 073 are addressed sequentially to DMX channels 321 thru 344.
13. DMXB PAT Patch the 96 dimmer (PWM) outputs to any DMX B input channel. Refer to the DMXA PAT menu for further information. The DMXA PAT menu is used to patch dimmers to DMX A input channels, while the DMXB PAT menu is used to patch dimmers to DMX B input channels. 14. SH TIME Set the DMX status hold time from 0 to 99 minutes or infinite. When DMX is disconnected the system will hold the status of the last received DMX levels for the selected amount of time.
17. VOUT LIM 01<127.5 96<127.5 96>127.5 96>100.0 96<100.0 Set the maximum RMS output voltage for each dimmer. Limiting the maximum RMS voltage can greatly improve lamp life. Press EXECUTE to enter the menu. Displays the dimmer (01) and its current maximum output voltage level (127.5). Press MENU ( ) to select the desired dimmer number from 01 to 96. Press EXECUTE to toggle the pointer (< >) to select the output voltage level. Press MENU ( ) to adjust the output voltage level in 0.
21. ANA TEST AI>01=00 AI>04=00 AI>04=FL 22. ANA FLTR LEV:00% LEV:00%< LEV:10%< 23. ANA BLOC ENABLED DISABLED 24. STANDBY ENABLED DISABLED 25. TEST INC PERCENT HEX VAL View the control level for each of the analog inputs. The analog voltage level for the 4 analog inputs can be tested and viewed as a percentage or hexadecimal value. The level displayed is proportional to the 0-10VDC analog input where 5VDC is 50%.
26. OC MODE A+D< 001 A+D> 001 A+D> 512 A+D< 512 DMX< 512 ANA< OFF< 27. AUX IN SCENE:01 SCENE>01 SCENE>20 28. SCENEMOD ENABLED DISABLED 29. S-ALARM L>FL:01* L>00:01* L>FL:01* L:FL>01* L:FL>96* L:FL>96 28 Configure the input trigger parameters for the open collector output. The on-board open collector output is used to sink up to 100mA of current. It can be configured to be triggered via a selected DMX channel, analog input 4, or both.
30. F-ALARM L>FL:01* L>00:01* L>FL:01* L:FL>01* L:FL>96* L:FL>96 31. Ø-PATCH CH 01 ØA CH 96 ØA CH 96 ØB CH 96 ØC 32. WARMING DISABLED ENABLED ON OFF Select the level and control channels triggered by the fire alarm input. When a contact is sensed on the fire alarm input, the selected control channels are triggered on to the selected output level from 0% to 100%.
33. POLARITY DISABLED ENABLED POSITIVE NEGATIVE Set the PWM output control polarity. Locked for factory use only! This menu is only used when swapping control modules between CD-3000-AE and CD-3000-SV retrofit systems. CD-3000-AE systems utilize a positive going PWM output control signal while the CD-3000-SV systems utilize a negative going PWM output control signal. Press EXECUTE to enter the menu and configure the polarity mode.
K>XXXXXX K>XXXXXX K:>XXXXX K:>XXXXX K:X>XXXX K:X>XXXX K:XX>XXX K:XX>XXX K:XXX>XX K:XXX>XX K:XXXX>X K:XXXX>X A pointer (>) appears to indicate hard-key modification is activated. Press MENU ( ) to modify the first hard-key character. Press EXECUTE to advance to the second hard-key character. Press MENU ( ) to modify the second hard-key character. Press EXECUTE to advance to the third hard-key character. Press MENU ( ) to modify the third hard-key character.
CRC-TEST >>>>>>>> VER X.X UPDATE?? SURE ??? UPDATING WILL AUTO RESTART PLEASE WAIT.... NO MEM! WRONG MEM TYPE WRONG PRODUCT CRC ERR! WARNING: Do not reset or turn the power off while the firmware is being updated. Doing so will cause unrecoverable loss of firmware data that is being loaded into the MADD-96 microcontroller. 44. RESTORE Restore parameters saved in the EEPROM memory module. DISABLED ENABLED MEMCHECK OKAY....
45. BACKUP DISABLED ENABLED MEMCHECK SURE ??? WAIT VERIFY DONE!! NO MEM! WRONG MEM TYPE WRONG PRODUCT DATA ERR Backup parameters and save them in the EEPROM memory module. All of the configuration setting parameters can be saved in the EEPROM memory module for backup. The backup parameters can then be restored if they have been inadvertently changed or corrupted. Once backup is complete the EEPROM memory module may be removed for safe storage.
47. DEFAULTS ØPATCH1? ØPATCH2? CURVES? ANA-OFF? V-LIMIT? DCPATCH? FD-TIME? 2 ROOM? SURE??? DONE!!! Set various system configuration settings to the factory default. Press EXECUTE to enter the menu. Press MENU ( ) to scroll through and select which item(s) to default. Sets the dimmer phase patch to AABBCC. This is the default setting. Sets the dimmer phase patch to AAAAAA. Sets all 96 dimmer curve profiles to Square Law curve. Clears the control channel patch for all 4 analog inputs.
Important Hard-key Information CD-3000 Series retrofit systems may be shipped with an invalid hard-key code of 000000. A valid hard-key must be entered before the run time (RTIME) counter reaches 2160 hours / 90 days. If the run time expires without a valid hard-key, the LCD display will show a runtime counter error (RTC ERR!) and all dimmer control outputs will be disabled. Refer to menu item “HARD-KEY” on page 30 of the user manual for detailed instructions on how to enter a valid hard-key code.
Troubleshooting Reference This manual is accurate at time of printing and subject to revisions and technical updates as required without prior notice. Please visit www.johnsonsystems.com for applicable updates. 36 www.johnsonsystems.
Troubleshooting Reference This manual is accurate at time of printing and subject to revisions and technical updates as required without prior notice. Please visit www.johnsonsystems.com for applicable updates. www.johnsonsystems.
User Manual CD-3000 Series Retrofit Control System Rev. 4 ET R O FI T Y CL EU REC SE ! R www.johnsonsystems.
