Sensor3 Rack (SR3 and HSR3 Series) Installation Manual
Contents
1. amp amp Make sure that the lugs bolt is left unobstructed for access to tighten it later Two lugs can be connected per bus bar side Dual side bars can hold four lugs single left or right bars can hold two Lugs can be positioned for top or bottom cable entry N 0 0 0 o 99 o o lolo 000 000900000 ooo 000 000 Bottom entry Figure 28 Aux Bay dual bus bar detail dual bar shown cables max 5 16 inch hex Allen lug driver e AU 350 Two 350 kcmil cables max 3 8 inch hex Allen lug driver e AU 600 Two 600 kcmil cables max 1 2 inch hex Allen lug driver Sensor3 Rack Installation Manual Note If a custom lug is used to connect line cables follow the lug manufacturer s torque recommendations Cable size Table 4 Line lug torque Torque inch Ibs Torque foot Ibs Torque N m 4 6AWG 110 Ib in 9 2 lb ft 12 N m 1 2 AWG 150 Ib in 12 5 Ib ft 17 N m 1 0 2 0 AWG 180 Ib in 15 Ib ft 20 N m 3 0 4 0 AWG 250 Ib in 20 8 Ib ft 28 N m 250 450 kcmil 325 Ib in 27 1 Ib ft 36 5 N m 500 750 kcmil 375 Ib in 31 3 Ib ft 42 52. Note Pull the line phase neutral and ground cables to the rack through the openings dro oro you prepared previously o o o See Using a Wire Trough for Line Power Wire it Access page 12 A o om lt 3 Figure 29 Line lug locations Note Phase neutral and ground lug orientation is reversible to make top or bottom connections easier Lugs are shipped in top entry orientation Be sure to leave access to the lugs bolt for tightening later Step 2 Cut each cable so it reaches the desired lug without any excess Line cables must be dressed neatly with a minimum of excess wire Sensor3 Rack Installation Manual A CAUTION Dress wires neatly and avoid leaving extra wire inside the rack Too much clutter especially along the right side of the rack can restrict air circulation and reduce cooling efficiency If cabling interferes with airflow during operation the rack may shut down due to overheating Step 3 Strip 1 inch of insulation from the end of the line phase neutral and ground cables and attach them to the correct lugs Each phase is labeled either A B C N and Equipment Grounding Lug Labels are attached to the phase neutral and ground distribution plates not
3. Step 1 Determine where your rack will be installed using Figure 1 Sensor3 wall mounted rack clearances on page 5 and use the appropriate diagram from Figure 2 to mark your mounting holes Note Sensor3 racks of the same size are the single exception to the 6 inch left clearance requirement They can be installed side by side without problems Step 2 Use the mounting slot dimensions to mark the 14 6 hole locations You must supply your own 3 8 an inch mounting hardware lag bolts recommended Step 3 Drill the holes and install the hardware Step 4 Attach the rack to the wall 14 6 HSR3 24 lt gt racks do not SR3 12 amp de 33 95 14 6 oot OOF A lt i 18 93 DE OOA 25 5 21 75 66 7 94 12 83 7 94 sa 9 83 16 4 A ui bot 6 69 A aa 6 69 5 38 69 ii su Bd Y y Figure 2 6 12 and 24 module rack wall mount hole diagrams Ea Installation of Individual Racks 6 Installing 48 Module Racks on the Floor Step 1 Determine where your rack will be installed using Figure 3 and use the appropriate diagram from Figure 4 to mark your mounting holes Sensor3 racks of the same size are the single exception to the 6 inch left clearance requirement They can be installed side by side without problems Step 2 Step 3 Step 4 Drill the holes and install your own 3 8 inch mounting hardware Lag bolts recommende
4. Top View Bottom View Clo Knockout sizes ij Size Conduit Hole size r il Large 2inch 2 5 inch fil i TT Medium 1 5inch 2 0 inch i T Small 0 75inch 0 9inch Figure 27 Aux Bay wire access Step 1 Remove the desired access panel from the rack Step 2 Punch out the desired knockouts consult the table in Figure 27 for knockout sizes or cut access holes in the top and bottom access panels Note 19 inch Aux Bays Figure 27 have three conduit knockouts per panel 30 inch Aux Bay panels have five conduit knockouts Step 3 Install your conduit fittings into the holes Step 4 Re install the access panel Using a Wire Trough for Line and Load Wire Access Step 1 Remove the access panel Step 2 Create the desired openings in the access panel by removing conduit knockout or cutting openings and reinstall the panel Step 3 Install a fiche paper lining or grommeting material in the access panel opening Note Wire openings must have fittings or linings to protect wire and cable insulation from damage by sharp metal edges Step 4 Position the wire trough above the prepared opening EJ Installation of Bussed Racks 30 Connecting the Aux Bay Line Feed Wires Line feed wires are terminated on the bay s line phase neutral and ground lugs Phase and neutral lugs are located on bus bars The ground lug is shipped
5. provided with the jumper strip Figure 43 Removing or installing a Neutral lug strip B Converting Discrete Neutral Dimmer Lugs 46 Appendix C 120V GFCI Circuit Troubleshooting Ground Fault Circuit Interrupt GFCI circuits provide extra protection for people and equipment by comparing current on the Hot supply and Neutral return wires of each dimmer circuit In a properly functioning circuit the current on these wires will be equal because all the current carried to the loads by the hot wire returns on the Neutral wire to complete the circuit In the event of a ground fault some or all of the current leaks from the circuit to ground This leakage reduces the amount of current that returns on the neutral wire The GFCI electronics detect this difference and trip the circuit breaker Requirements for GFCI circuits GFCI circuit wires cannot be longer than 125 feet measured from dimmer lugs The neutral and hot wires for each GFCI protected circuit must run in the same dedicated conduit No splitting of load and neutral wires between conduits No ganging of neutral return wires at any point in circuit No including non GFCI load or neutrals in GFCI conduits Low voltage loads need special transformer or GFCI won t trip on fault GFCI compatible fluorescent ballasts must be used Typical causes of GFCI circuit faults Circuit immediately trips when powered up Load and neutral wires from
6. sensor 3 Sensor3 Rack SR3 and HSR3 Series Installation Manual Revision C Copyright 2014 Electronic Theatre Controls Inc All rights reserved Product information and specifications subject to change Part Number 7141M2100 Rev C Released 2014 01 ETC permits the reproduction of materials in this manual only for non commercial purposes All other rights are reserved by ETC ETC intends this document whether printed or electronic to be provided in its entirety ETC and Sensor are registered trademarks of Electronic Theatre Controls Inc in the United States and other countries All other trademarks both marked and not marked are the property of their respective owners Table of Contents Chapter 1 Chapter 2 Chapter 3 Table of Contents INMOGUCION esi isdn edt cada ashes d 1 How To Use This Guide 0 0 00 c ee eae 1 Warnings and Notice Conventions eee eee 1 Contacting ETCai ios eta seen te deeds deat outed cena 2 Prepare for Installation 4 Unpack and Inspect 000 eee eee eee 4 Main Circuit Breaker Protection 4 Obtain ETC Approval to Energize the System 4 Wiring Requirements 0 000 c eee ee eee 4 Line Feed WINING 0354 29 esata pe EEG ast saan 4 Load WINING 6220 ie che ba ee E bee ae ed 5 Wire ROUTING sura A Rede Ae a a ee eae fae ke 5 Where to Mount the Rack 5 Dimmer Room Requirements 5 Installation of Individual Ra
7. 1 2 and 3 until you ve secured all of the racks EJ Installation of Bussed Racks 18 Making the Bus Connections Between Racks Bussed racks are shipped with as much of the bussing connections completed as possible Connections between separately shipped racks cannot be finished until the racks are secured together See Secure Racks Together page 18 for instructions A CAUTION Bus bars connected between unsecured racks are subject to physical stresses that may damage or destroy bus bar components Finish securing racks together before making bussing connections Begin installing your bussing components in the rack where the line power connections will be made These bus connections will carry the most current and may use multiple bus bars to handle current load Installing the Neutral Bus Plates The neutral bus plate is loosely installed in the rack at time of shipping It may need to be removed for bus bar installation I pee 4 er n Neutral bus plate pa L 7 ia AD i Nomex air baffle AD a a lt DD ssaa S55 T a Step 4 _ Pi Se ae hace oD Bus bar s o a ao Figure 19 Installing the I neutral plate with bus bar Step 1 Remove the neutral plate and bolts and set aside They will be reinstalled later in the process Step 2 Consult your job drawings to determine how many bus bars are needed between your neutral plates Step 3 Slide b
8. Conduit Access These racks have removable conduit knockouts SR3 6 SR3 12 Top Only Top Only SR3 24 Top Bottom Knockout sizes Type Conduit Hole size A 1 1 178 2 18 5 1 4 2 2 B 1 1 Pie 1 Figure 9 Conduit knockouts Step 1 Remove the desired top or bottom wire knockouts Step 2 Install the appropriate conduit in the holes Sensor3 Rack Installation Manual 48 Module Wire and Conduit Access 48 module racks have removable top and bottom access panels Step 1 Step 2 Step 3 Step 4 Top access panel ia a Bottom access panel Figure 10 48 module access panels Remove the desired access panel from the rack Cut access holes in the top and bottom access panels Install your conduit fittings into the holes Re install the access panel so that there are minimal air gaps See Sealing Rack Air Leaks on page 40 for more information Using a Wire Trough for Line Power Wire Access Step 1 Remove the desired wire knockouts 6 12 or 24 module racks or access panel 48 module rack Step 2 6 12 and 24 module racks Install conduit fittings or grommets in the openings Step 3 48 module Cut the necessary opening in the access panel and reinstall it Note Wire openings must have fittings or linings to protect wire and cable insulation from damage by sharp metal edges Step 4 Position the wire trough above
9. Step 4 Step 5 Unscrew the lower two bolts holding the ground plate into the rack Insert the bolt through the lug on the pre assembled cable supplied Run the cable to the adjacent rack and connect the lug to the ground plate in the same manner Repeat for any additional racks requiring ground bussing Torque the cable lugs using the values in on the Torque values sticker on the bottom of the rack or see Table 3 on page 17 Sensor3 Rack Installation Manual Making Bus Connections to an Auxiliary Bay Auxiliary Bays are available in 19 and 30 inch widths Except for the length of the bus bars the installation procedure for both sizes are the same Bussing connections cannot be finished until all racks are secured together See Secure Racks Together page 18 for instructions CAUTION Bus bars connected between unsecured racks are subject to physical stresses that may damage or destroy bus bar components Finish securing racks together before making bussing connections Begin installing your bussing components in the Auxiliary Bay where the line power connections will be made These bus connections will carry the most current and may use multiple bus bars to handle current load Before installation confirm your dimmer rack and Aux Bay load rating with Dimmer Rack and Aux Bay Ratings page 29 Installing the Aux Bay Bus Bars Bus bars bolt directly to the Glastic standoffs on the back of the Aux Bay The rack connection
10. attached installed in the Aux Bay cabinet Aux Bay bus bars ship with one dual hole lug but can accommodate additional lugs depending on whether the bars are single left or right or dual side connectors Work with your ETC representative for system requirements Step 1 Install the connection lugs on the phase and neutral bus bars Lugs can be installed in up or down position as desired Install lugs so the entire back of the lug makes contact with the bus bar This creates the best electrical contact Step 2 Pull the line phase neutral and ground cables to the rack to their respective lugs Step 3 Strip 1 inch of insulation from the end of the line phase neutral and ground cables and attach them to the correct lugs Line connections are labeled A B C N and Equipment Grounding Lug The example in Figure 28 shows a three phase 48 module Aux Bay Single phase Aux Bays only available for the 12 and 24 module racks are shipped with two phase bus bars labeled L1and L2 31 Step 4 Tighten the lugs to the correct torque based on cable size e AU 250 Two 250 kcmil Phase C bus Ground lug Phase B bus Neutral bus Phase A bus o ejo a D REE
11. dissipation include service ampacity as well as how the dimmers are used and typical loads Dimmer Rack and Aux Bay Ratings Standard ETC Sensor Rack Options with Maximum Current Ratings Dimmer Racks SR3 48 and HSR3 48 SR3 24 and HSR3 24 SR3 12 and HSR3 12 SR3 6 Suggested Max of bussed racks Max Current Max Current Max Current Rating of Max Current Rating of Rating of 3 Rating of 18 3 19 Aux 36 30 Aux Rack Aluminum Copper Aluminum Copper 1200A MCB 1600A MCB 800A CU 3 600A 800A 600A AL 1600A ML 2000A ML 400A 600A 800A 800A N A N A 200A 300A 400A 400A N A N A 100A 150A N A N A N A N A Must use copper feeds when using 100 rated breakers and breakers rated greater than 1200A Aluminum feeds suitable for 80 rated breakers at 1200A and less and main lugs 1600A and less 3SR 48 is rated at 600A for aluminum feeds D Sensor3 Rack Specifications 52 53 Sensor3 Rack Installation Manual 54 Corporate Headquarters m 3031 Pleasant View Road P O Box 620979 Middleton Wisconsin 53562 0979 USA m Tel 608 831 4116 m Fax 608 836 1736 London UK Unit 26 28 Victoria Industrial Estate Victoria Road London W3 6UU UK m Tel 44 0 20 8896 1000 m Fax 44 0 20 8896 2000 Rome IT m Via Pieve Torina 48 00156 Rome Italy m Tel 39 06 32 111 683 m Fax 44 0 20 8752 8486 Holzkirchen DE Ohmstrasse 3 83607 Holzkirchen Germany m Tel 49 80 24 47 00 0 m
12. for instructions 48 Module Racks Bussed 48 module racks are available connected to a 19 or 30 inch Auxiliary Bay or bussed together There is no physical limit to how many racks can be bussed together but usually four is the maximum due to power feed limitations If an Auxiliary Bay is included in the bussed assembly it can contain a Main Circuit Breaker MCB for the racks Both19 inch and 30 inch bays can house one MCB The 19 inch bays are limited to 800A maximum and NN Figure 13 SR3 48 and HSR3 48 bussing options 15 Sensor3 Rack Installation Manual Two 48 module racks or one rack and one Aux Bay can be shipped with all bussing connections complete Racks that are shipped assembled can be mounted without further assembly See nstalling 48 Module Racks on the Floor page 27 for instructions Racks shipped separately must be bolted together and bussing connections between the racks must be completed before the racks can be secured in their installation location See Secure Racks Together page 18 for instructions Putting Racks in Installation Order It is important that bussed racks are connected in proper order Bussing order is called out in job drawings and is also indicated by rack number You can also often determine a rack s position based on the configuration of side access pane
13. order should be called out on your job drawings and the necessary bus bar types for connecting through the left right or both sides of the Aux Bay will be included Note Your Aux bay may or may not have an internal Main Circuit Breaker MCB The presence of an MCB does not affect bus bar installation Step 1 Remove the Aux Bay front access panels with a 2 Phillips screwdriver Step 2 Use the job drawings for your installation to determine how many bars will be needed per phase Note Make sure all your installation complies with applicable local electrical codes Step 3 Install the bus bars on the standoff using the included 3 8 inch bolts with washers and lock washers Step 4 Install the provided lugs on the phase bus bars Step 5 Torque all Aux Bay fasteners except those securing bus assemblies to Glastic standoffs using the values in on the Torque values sticker on the bottom of the installation racks or see Table 3 on page 17 e 9 16 inch bolts 20 Ib ft 27 N m maximum e 7 16 inch bolts 15 Ib ft 20 N m maximum Note Bolts securing the bus assemblies to Glastic standoffs on the back of the rack must not be overtightened or the standoffs will break Eq Installation of Bussed Racks 24 Connecting an Internal Main Circuit Breaker MCB The optional internal MCB s are shipped completely installed and ready to connect to Aux Bay bus bars e An MCB less than 800A will use cable
14. power to your dimming system You can get pre approval for some installations during the purchase process or pass a wiring inspection by an authorized ETC representative after the system is installed Wiring errors in unauthorized installations 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 A CAUTION Energizing your system without ETC approval may result in equipment damage that may not be covered under your warranty Wiring Requirements Line Feed Wiring You may feed your rack with either copper or aluminium feeder wire See the table Rack Line Lug Sizes page 13 for information on possible feed wire sizes using the standard lugs provided by ETC Other lugs or termination methods may be acceptable contact ETC s applications engineering department for details SeeContacting ETC page 2 for contact information I Note When feeding an SR48 or HSR48 with aluminium wire you will need to derate the rack from 800A to 600A maximum current This is due to the available space for wire termination 1 Prepare for Installation 4 Load Wiring The output load wiring from your rack must be 90 C rated copper wire only In order to determine the correct conductor sizing for your rack use 90 C conductors at the 75 C ampacities based on your local electrical cod
15. the prepared opening 2 Installation of Individual Racks 12 Connect Line Feed Cable Line feed cables are terminated on the rack s line phase neutral and ground lugs Phase and neutral lugs are located on bus bars Table 1 Rack Line Lug Sizes Phase A lug Phase B lug Phase C lug Rack Type Hot and Neutral Lugs Ground Lugs o SR3 6 2 x 2 0 2 x 250 kcmil to 6 AWG SR3 12 and HSR3 12 2 2 to 14 AWG 120 to 16mm 2 SR3 24 and HSR3 24 2 300 kemil to 6 AWG 25 to 2 5mm 150 to 16mm SR3 48 and HSR3 48 2 600 komil to 2 AWG T 98 i 7 2 300 to 35mm 120 to 16mm2 Note The lugs are not suitable for fine stranded wire JO Note The Neutral Disconnect bussing used by Ground Fault Interrupt racks have different line connection orientations See Connecting Ground S Fault Circuit Interrupt Racks 120V GFCI on page 38 for line connection points Neutral yg Equipment grounding lug 1 Figure 11 Line cable lug locations Step 1 Pull the line phase neutral and ground cables to the rack through the openings you prepared previously See Attaching Line Power Wire and Conduit on page 11 Note Phase neutral and ground lug orientation is reversible to make top or bottom line cable easier Lugs are shipped in top entry orientation Be sure j3
16. your dimmer rack without a door installed Table 7 Loose parts shipped with Sensor3 rack doors 12 Module 24Module 48 Module ETC Part Descriptions Qty Qty Qty Number 1 1 1 7051A4116 Acrylic door beacon 2 2 1 7051A3006 Bracket Rack door hinge i 1 7051A2009 48 module Bottom hinge 4 4 2 HW486 Screw 10 32x PhTHMS 2 2 2 HW253 Screw 6 32x3 8 truss SS 3 3 3 HW757 Pin Taper 5 32x1 0 6 6 6 HW327 Washer Flat 8 188x 375x 049 SS 1 1 1 HW8146 Keylatch with Keeper 93 10 202 50 SR3 6 racks ship with their doors assembled and attached ea Finishing Installation 40 A CAUTION Dimmer rack doors filter and regulate ventilation airflow Operating without the door can contaminate the rack interior with dust and cause rack modules to overheat Step 1 Insert the top hinge into the slot on the top of the rack and attach it to the frame with two 10 32 x 1 2 inch Phillips head screws included Top hinge being inserted Top hinge in place Figure 35 Attaching the top door hinge Step 2 The bottom hinge on the 48 module rack is a different design from the one used on the smaller racks to compensate for the heavier door e 12 and 24 module rack Insert the bottom hinge into the slot on the bottom of the rack and attach it to the frame with two 10 32 x 1 2 inch Phillips head screws included Bottom hinge Bottom hinge being inserted in place Q Figu
17. 0 amp lugs fluorescent oo Figure 31 Load lug types Figure 30 Line and load wiring example When using D20F modules connected to dimmable fluorescent 3 wire ballasts wire the top lug in each slot to the ballast s non dimmed power lead and the bottom lug to the dimmed ballast control lead When using D20FB modules connected to dimmable fluorescent 2 wire ballasts with integral battery back up use the same terminations as listed above for 3 wire ballasts A CAUTION Dress and terminate wires neatly and avoid leaving extra wire inside the rack Too much clutter especially along the right side of the rack can restrict air circulation and reduce cooling efficiency If cabling interferes with airflow during operation the rack may shut down due to overheating Load wires should not cross between racks They should enter the rack in which they will be terminated Hot and neutral load wiring must follow the same conduit path for each circuit Step 1 Route the load wires to the rack s The Discrete Neutral bussing used by Ground Fault Interrupt racks have different load wire connection requirements See Connecting Ground Fault Circuit Interrupt Racks 120V GFCI page 38 for more information 14 Land Load Wires 36 A A CAUTION A two wire circuit with separate hot and neutral conductors is required for ever
18. 200 Ib in 22 5 N m 2 0 4 0 N A 250 Ib in 28 N m 5 16 inch 275 Ib in 31 N m 250 350 kcmil N A 325 Ib in 36 5 N m 3 8 inch 375 Ib in 42 N m 500 600 kcmil N A 375 Ib in 42 N m 1 2 inch 500 Ib in 56 5 N m 9 16 inch 600 Ib in 68 N m 17 Sensor3 Rack Installation Manual Secure Racks Together After the racks are in their installation order they must be secured together before connecting bussing to maintain correct tolerances and avoid stress to power components during installation Step 1 Use 1 4 inch bolts and lock nuts in the front and at the back to bolt the racks together at the bottom 7 Aux Bays provide Connecting one the easiest access rack to another for installing nut TI O a Connecting an install rack to an Aux Bay Figure 17 Placing connecting bolts between install racks or Aux Bays Note The front bolt is difficult to reach you may need a magnetic bolt driver or socket extension Step 1 Remove 6 screws from the tops of adjacent racks or Auxiliary Bays Install the rack splice and replace the screws to secure it Temporarily remove six screws from this area Figure 18 Screws to remove to connect two racks Step 2 Place a rack splice plate over the empty screw holes and replace the screws you removed in Step 1 as shown above Step 3 Repeat Steps
19. 40 contains sealing the rack and installing the rack door When viewing this document in electronic form PDF file with Adobe Acrobat Reader blue italicized text followed by a page number such as How To Use This Guide page 1 is a link within the document If you click on the link it will jump to that section or topic Warnings and Notice Conventions These symbols are used in Sensor3 documentation to alert you to danger or important information Note Notes are helpful hints and information that is supplemental to the main text CAUTION A Caution statement indicates situations where there may be undefined or unwanted consequences of an action potential for data loss or an equipment problem WARNING A Warning statement indicates situations where damage may occur people may be harmed or there are serious or dangerous consequences of an action Sensor3 Rack Installation Manual WARNING RISK OF ELECTRIC SHOCK This warning statement indicates situations where there is a risk of electric shock Contacting ETC For questions about Sensor3 rack system delivery contact ETC Systems Group For general information technical questions about Sensor3 rack systems contact ETC Technical Services Americas Europe Asia ETC International ETC Europe Ltd ETC Asia Ltd Technical Services Department Technical Services Department Technical Services Department 3031 Pleasant View Road Unit 5 Victoria Industrial
20. Check Power Installation 44 Appendix B Converting Discrete Neutral Dimmer Lugs If you need to place a non GFCI protected circuit and use a non GFCI dimmer module such as a standard D20 in a GFCI rack you need to perform this conversion This conversion needs to be done per slot to accommodate an entire module ETC does not make a module that is half GFCI and half standard Converting GFCI dimmer slots Step 1 Shut off rack power at the main circuit breaker WARNING Servicing a dimmer rack with power on may result in death or injury from electrical shock Before removing dimmer or control modules for service de energize main feed to dimmer rack and follow appropriate Lockout Tagout procedures as described in NFPA Standard 70E It is important to note that electrical equipment such as dimmer racks can present an arc flash safety hazard if improperly serviced This is due to available large short circuit currents on the feeders of the equipment Any work on energized equipment must comply with OSHA Electrical Safe Working Practices Step 2 Step 3 Determine which dimmer slots you will be converting You can convert either individual slots or a three slot strip at a time Gently bend the neutral lug retraining tab out with a small standard screwdriver until the lug releases and you are able to pull it out See Figure 41 A CAUTION Lug catches will break ifbent too far Only bend the catch until the l
21. Estate Room 605 606 Middleton WI 53562 Victoria Road Tower Ill Enterprise Square 800 775 4382 USA toll free London W3 6UU England 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong 1 608 831 4116 44 0 20 8896 1000 852 2799 1220 service etcconnect com service etceurope com service etcasia com Please email comments about this manual to TechComm etcconnect com Introduction Chapter 1 Prepare for Installation Unpack and Inspect Before you begin installation check your shipment and confirm it arrived complete and undamaged Step 1 Check the shipping container for physical damage Step 2 If you find damage document it to help with a claim against your shipper Step 3 Unpack your order and check the contents against the packing list to be sure your order is complete Step 4 If you discover a problem call ETC Systems Group Refer to Contacting ETC page 2 Main Circuit Breaker Protection Before beginning installation of your Sensor3 dimmer rack s make sure you have installed a main circuit breaker cabinet or other readily accessible input power disconnect device See Appendix D Sensor3 Rack Specifications page 49 for individual rack power requirements For bussed rack installations this may be in the Auxiliary Bay WARNING Dimmer racks installed without an accessible power disconnect device cannot be serviced or operated safely Obtain ETC Approval to Energize the System You need ETC approval to apply
22. Fax 49 80 24 47 00 3 00 Hong Kong Rm 1801 18 F Tower 1 Phase 1 Enterprise Square 9 Sheung Yuet Road Kowloon Bay Kowloon Hong Kong m Tel 852 2799 1220 m Fax 852 2799 9325 Service Americas service etcconnect com m UK service etceurope com m DE techserv hoki etcconnect com m Asia service etcasia com Web www etcconnect com m Copyright 2014 ETC All Rights Reserved m Product information and specifications subject to change 7141M2100 m Rev C m Released 2014 01
23. N m Step 5 Tighten the lug fasteners using the values in on the Torque Values sticker on the bottom of the installation racks or see Table 3 on page 17 EJ Installation of Bussed Racks 32 Connecting Line Power Directly to Bussed Dimmer Racks If the bussed rack assembly does not include an Auxiliary Bay line connections are made to one rack Note Copper and aluminum are both acceptable for line and load wiring but have restrictions Reference the Dimmer Rack and Aux Bay Ratings page 29 before installation to ensure your system does not void UL This is done in the same manner as standard racks Please see Connect Line Power Wiring page 11 Connecting the Line Feed Cables Line feed cables are terminated Phase C bus on the rack s line phase neutral and ground lugs Phase neutral and ground lugs are located the bus bars Neutral bus Phase A bus Phase B bus Ground lug Step 1 If necessary install phase lugs on the ES PA See ead Ee connection rack bus Ara bars Use the i i MMI procedure in i Connecting the Aux Bay Line Feed Wires page 31 oo Note Bussed racks with direct i power connections are normally shipped with phase lugs installed on o the connection rack s bus HAMI bars If installation of custom lugs is desired follow lug manufacturers installation recommendations o 0 0
24. Sensor3 Rack Specifications page 49 for rack and module weights Note Be sure this mounting method complies with local building and electrical codes Step 1 Mark the hole locations on the wall from Figure 4 Hole diagrams for mounting racks to the floor or a pedestal on page 7 Note ETC s wall mount vibration pads ETC Part HW6111 attach to racks with 1 2 inch bolts that are slightly larger than the top of Fi 5 Positionii ibrati d the keyhole slots The bolt works fine ME el RR installed in the lower portion of the slot but the rack will mount slightly higher approximately 1 2 inch than the diagram Indicates Step 2 Align the center of the fitting over the hole locations from the diagram Mark the position for two fitting bolts for each vibration pad the middle holes are recommended 2 Installation of Individual Racks 8 A Step 3 Drill the holes and secure the fittings to the wall You must supply your own 7 16 inch mounting hardware lag bolts recommended Step 4 Remove the included 1 2 inch bolt and washer from each vibration fitting Step 5 Position the rack on the wall so the centers of the vibration fittings align with the wall mounting slots Step 6 Secure the rack to its vibration pad with the 1 2 inch bolts and washer CAUTION Unless mounting is done and connections are made in a flexible manner the effectiveness of the vibration pads will be reduced or completely n
25. Tagout procedures as described in NFPA Standard 70E It is important to note that electrical equipment such as dimmer racks can present an arc flash safety hazard if improperly serviced This is due to available large short circuit currents on the feeders of the equipment Any work on energized equipment must comply with OSHA Electrical Safe Working Practices Step 1 Clean out dust metal scraps or other debris from the rack interior o I Note ETC recommends vacuuming the rack interior after the installation of the wiring Step 2 Check for loose connections bare wires or damaged insulation Step 3 Spin the top cooling fan in both directions to be sure it is not obstructed Correct stop air leaks left in conduit openings empty screw holes or misaligned panels Checking Main Power Wiring Check resistance between phases neutral and ground busses with a digital voltmeter DVM e Phase to phase resistance should be 10M Ohm or higher e Phases to ground resistance should be 10M Ohm or higher e Neutral to ground resistance should be 0 Ohm e Phase to neutral resistance should be 10M Ohm or higher Checking Load Wiring Check resistance between the load terminals and the neutral buss Above 1M Ohm Normal when no load is connected e Between 1 1000 Ohm Normal when loads are connected e Below 1 Ohm Indicates a dead short in the load wiring WARNING A dead short can cause dimmer module damage FAT
26. V GFCI devices UL File E92134 Control Sensor3 Control Electronics Module CEM3 electronics Hardware rear Ethernet control signal input Front Cat5 Ethernet uplink to the Net3 Lighting network Two DMX512 inputs USB quick load Supports Dimmer Doubling in 120V systems Web Interface Allows remote users to browse into the power control system to activate locally set levels check circuit and rack status and perform adjustments to mode settings Options Advanced Features dimmer specific load and diagnostic reporting included with SRA3F and SRA3FN racks Amp Trap fuses to allow feeding individual racks from oversize mains All copper bus kits available Auxiliary Racks Vibration reduction kits available for all racks Sensor3 Rack Installation Manual Empty Rack Weights Wiring Charts SR3 and HSR3 Models Weight Primary Feed Lug Capacity 5 ss da HSR3 Wire Size Wire Size 12 45 0 21 0 6 Single 2 0 to 14 AWG 2mm to 60mm 12 Door 11 0 5 0 12 Dual 250 kcmil to 6 15mm to dual 24 107 0 49 0 AWG 125mm 24 Door 17 0 8 0 24 Dual 350 kcmil to 4 25mm to dual 48 188 0 86 0 AWG 170mm S48 Door 31 0 14 0 48 Dual 600 kcmil to 2 35mm to dual Rack doors ship separately AWG 300mm Note Installed rack weights are dependent upon number and type of installed modules To calculate approximate installed Load Wiring Lug Capacity weight m
27. ane aerosol foam or conduit duct seal to fill air gaps in conduit Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Seal all conduit access holes Re install access panels removed during installation or completely cover their openings with fiche paper and urethane aerosol foam or duct seal Seal any air gaps caused by bent access panels Fill in any gaps inside partially filled wiring conduit Fill in other gaps or holes in the cabinet created during installation Any racks that are installed side by side bolted together should only have minimal airflow between them e Bussed racks shipped from ETC should have the proper baffling in place Check to make sure it hasn t moved during shipping or installation e Racks that are bussed in the field need to have the airflow between the racks restricted to a minimum A CAUTION Air leaks can cause dimmer racks to overheat during operation and shut down Air leaks can also cause a rack to shut down via an Airflow Error meaning that too little air is going through the front of the rack where it is needed to cool the dimmers Attaching the door All Sensor3 racks except the SR3 6 are delivered with the doors separated This improves access to the rack interior for wiring and other installation work Some loose door installation parts are bundled with the doors as detailed below in Table 7 When interior wiring is completed attach the rack door Do not operate
28. cks 6 Mounting the Rack 6 Mounting Racks on a Wall 6 12 and 24 Module Racks 6 Installing 48 Module Racks on the Floor 7 Pedestal Mounting a 24 Module Rack 7 Securing 24 and 48 Module Racks to a Wall 8 Wall Mounting Racks Using Vibration Pads 8 Floor Mounting Racks Using Vibration Pads 9 Securing Multiple Racks Optional 10 Connect Line Power Wiring 0000 eee eee eee 11 Attaching Line Power Wire and Conduit 11 Connect Line Feed Cable 0 0c ee 13 Installation of Bussed Racks 15 Configurations of Bussed Racks_ cee eee eee 15 12 Module RackS LL 15 24 Module Racks 0 15 48 Module Racks iii lia 15 Putting Racks in Installation Order 16 Access Panel Configurations by Rack Position 16 Chapter 4 Chapter 5 Appendix A Appendix B Rack Numbering and Torque Information Stickers 17 Secure Racks Together L eee 18 Making the Bus Connections Between Racks 19 Installing the Neutral Bus Plates 0 0 0 0 00 000 19 Bussing Between Phase Bus Plates 21 Soft Bussing Between Ground Bus Plates 23 Making Bus Connections to an Auxiliary Bay 24 Installing the Aux Bay Bus Bars 24 Connecting an Internal Main Circuit Breaker MCB 25 Mounting the Rack 26 Moun
29. d Position the rack in the desired location Adjust the leveling feet with an open end 1 2 inch wrench until the rack is level and plumb 48 module installation racks are tall narrow and heavy Use caution to keep racks stable until conduit is installed Leveling Step 5 feet Secure the rack to the floor using your mounting hardware 13 38 Dia 0 39 Figure 3 Floor mounted rack clearances 14 0 y lt gt 14 6 14 7 H SR3 48 floor mount hole diagram H SR3 24 pedestal mount hole diagram Figure 4 Hole diagrams for mounting racks to the floor or a pedestal Pedestal Mounting a 24 Module Rack Step 1 Use Figure 4 to mark the location of the 24 module rack mounting holes The 24 module pedestal has the same floor mounting dimensions as the 24 module rack Note You must supply 1 4 inch mounting hardware The pedestal has four mounting holes into the floor and four securing the rack Step 2 Drill holes or mount floor hardware and position the pedestal on them Step 3 Secure the pedestal base to the floor Step 4 Position the rack on the pedestal and align the mounting holes Step 5 Bolt the rack into place Sensor3 Rack Installation Manual Securing 24 and 48 Module Racks to a Wall Racks installed on the floor or a pedestal can also be secured to a wall for greater stability Step 1 Prepare the rack for f
30. different circuits are connected to GFCI dimmer Neutral wires are ganged with other dissimilar loads There is a real GFCI circuit fault Circuit intermittently trips when powered up Load and neutral wires from different but associated circuits are connected to GFCI dimmer Neutral wires are ganged with associated dimmer circuits There is an intermittent GFCI circuit fault Circuit does not trip during a GFCI fault GFCI dimmer is connected to the wrong fault free dimmer circuit GFCI circuit load is an incompatible low voltage transformer or fluorescent ballast type GFCI dimmer module is faulty WARNING GFCI dimmer modules cannot be repaired on site Defective modules must be replaced and returned to ETC for evaluation or repair Do not allow anyone to attempt to repair a GFCI module in the field A GFCI module that has been tampered with does not provide UL 943 compliant GFCI circuit protection 47 Sensor3 Rack Installation Manual Appendix D sensor3 Rack Specifications All of the rack specifications apply to all of the SR3 series of racks unless otherwise noted General Racks available in four sizes SR3 6 6 modules 12 dimmers maximum SR3 12 and HSR3 12 12 modules 24 dimmers maximum SR3 24 and HSR3 24 24 modules 48 dimmers maximum SR3 48 and HSR3 48 48 modules 96 dimmers maximum Dual density two dimmers per module single density and half density dimmer modules available Environme
31. e See Rack Numbering and Torque Information Stickers page 17 for the torque values for load connections Wire Routing Sensor3 racks have conduit knockouts or access panels at the top and bottom Line and load wiring can enter from the top or bottom Control cables can enter from the top bottom or side Signal and power wiring must be run in separate conduit A CAUTION A two wire circuit with separate hot and neutral conductors is required for every branch circuit that will be connected to the dimmer rack Shared neutral multiwire branch circuit arrangements are not recommended for phase control dimming systems due to harmonics and potentially elevated neutral currents in a shared neutral arrangement For retrofit installations where shared neutral circuits are already installed or track lighting installations where the track has a shared neutral consult ETC Technical Services for rack installation guidelines Where to Mount the Rack Sensor3 dimmer racks require 10 inches 254mm of top clearance for proper airflow through the cabinet To allow the door to open sufficiently to install and remove modules install the rack with 17 inches 432mm of front clearance and 6 inches 152mm clearance to the left of the door hinge from walls or other equipment Note Additional Sensor3 racks of the same size are the single exception to the 6 inches left clearance rule They can be installed side by side without problems D
32. e rack Use Figure 33 to locate line connections WARNING A Ground Fault Circuit Interrupt load circuit will not function unless its Hot and Neutral wires are connected to the same dimmer and run in the same conduit wire path Step 3 Follow the instructions in Load lugs are on 39 the right side of the rack Lugs can be single 15 20 amp paired 15 20 amp fluorescent double height 50 amp or dual slot 100 amp page 36 to connect load wires to the rack Refer to Figure 34 to locate Ground Fault Circuit Interrupt load wire connections Phase A line connections N Ground line connection p Neutral line connection Phase B line connections Phase C line connections Neutral load wire connection bus Phase load wire connection bus J o ay rm Figure 33 Ground Fault Interrupt line and load connections Sensor3 Rack Installation Manual Chapter 5 Finishing Installation Sealing Rack Air Leaks After you have attached all the conduit to the rack and connected all wiring you must seal any air leaks in the rack cabinet created during the installation process Use ureth
33. e hole locations You must supply your own 3 8 inch mounting hardware lag bolts recommended Note If you are installing racks without attached Aux Bays use the rack measurements on the left Step 2 Drill the holes and install the hardware Step 3 Attach the rack s to the wall 36 5 lt 14 6 21 9 a te gt lt gt A 24 Module Rack 24 Module Aux Bay 7 94 22 54 33 64 6 697 TI gt T 18 977 66 x 6 on 2 94 45 2 12 Module Rack 12 Module Aux Bay 33 95 36 5 E 14 6 21 9 gt lt gt lt gt 00 6 OA A 7 94 17 54 33 54 p gt gt gt m 25 5 2175 6 69 D o 18 94 2 94 18 93 00 0 on SE di SA 12 83 ae 56 0 on 5 38 Y Y ydy Figure 23 24 module and 12 module rack and Aux Bay wall mount hole diagrams EJ Installation of Bussed Racks 26 Pedestal Mounting 24 Module Racks 24 module racks bussed to each other can be mounted 13 38 on pedestals however there is no pedestal for the 24 module Aux Bay 24 module racks bussed to Aux Bays must be wall mounted Step 1 o o Use 24 module pedestal mount dimensions page 27 to mark the location of the 24 module and mounting holes The 24 module pedestal has the same floor mounting dimensions as Diao 209 the 24 module rack You must supply 1 4 inch mounting hardware The pedestal has four mounting holes into the floor and fo
34. e holes in the bus bar and slide the spacer plate over the bolt ends Step 4 Secure the bar to the plate assembly with the included nut washer sets Step 5 Torque the fasteners except the bolts securing bus assemblies to Glastic standoffs using the values in on the Torque values sticker on the bottom of the rack or see Table 3 on page 17 e 9 16 inch bolts 20 Ib ft 27 N m maximum e 7 16 inch bolts 15 Ib ft 20 N m maximum CAUTION Bolts securing the bus assemblies to Glastic standoffs on the back of the rack must not be overtightened or the standoffs will break qu 4 Ay 4 4 A I il di Step 2 Step 2 Angle plates Figure 20 Attaching bus bars in a rack with fuses 21 Sensor3 Rack Installation Manual EJ Installation of Bussed Racks Figure 21 Connecting bus bars in a rack without fuses 22 23 The bus bar configuration for racks at the end of a line have a slightly different appearance when installed correctly See below for reference If additional racks are added this plate will need to be removed to accommodate additional bussing Soft Bussing Between Ground Bus Plates Ground bus plates are shipped installed in the rack Soft bus cables are included with the rack for bussing ground plates together To in stall the soft bus cables Step 1 Step 2 Step 3
35. egated Proper connections include the use of a minimum of 1 of flexible conduit for all electrical connections to the rack s Floor Mounting Racks Using Vibration Pads 48 module racks can be floor mounted on optional Center the fitting over the mount hole location vibration damping fittings ETC Part HW6109 lille Step 1 Determine where your rack will be installed i e using Figure 3 Floor mounted rack clearances on page 7 Note Be sure this mounting method complies with local building and electrical codes Level 48 module racks before marking the hole positions Step 2 Use the appropriate diagram from ai Figure 4 Hole diagrams for mounting racks Figure 6 Floor vibration pad to the floor or a pedestal on page 7 to mark your hole locations Step 3 Align the center of the vibration fitting over the hole locations from the diagram Mark the positions for two bolts for each vibration pad Step 4 Drill the holes and secure the pads to the floor You must supply your own 11 32 inch mounting hardware lag bolts recommended Step 5 Remove the included 3 8 inch bolt and washer from each vibration pad Step 6 Position the rack on the pads so the center holes of the pads align with the mounting holes in the base of the rack Step 7 Optional If required secure the rack to a wall using wall mount vibration pads ETC Part HW61 11 If the vibration pads are requested for the installation they are included wit
36. er the screw The Right way Insert the wire between the pressure plate and the back of the lug and clamp the plate on top of the wire The Wrong way Don t clamp the wire on top of the pressure plate with the lug screw Pressure Plate Figure 32 Connecting 15 50 amp load lug wires e 100 amp load lugs tighten the screw lug directly on the cable see Figure 31 Tighten all load connections to the torque specified in the table below Table 6 Line lug torque 37 Connection Cable size Torque Torque Torque 20 to 50 amp 14 to 10 AWG 1 5 6mm 35 Ib in 2 9 Ib ft 4 N m and fluorescent g ne e CSM oli 3 3 Ib ft 4 5 N m Load lugs eal age 45 Ib in 3 8 lb ft 5 N m 4 to 6 AWG 16mm 100 amp 14 to 8 AWG 1 5 10mm 75 Ib in 6 3 Ib ft 8 5 N m Load lugs 2 110 Ib in 9 2 lb ft 12 N m 6 to 4 AWG 16 25mm 150 Ib in 12 5 lb ft 17 N m 2 to 1 AWG 35 50mm 180 Ib in 15 Ib ft 20 N m 1 0 to 2 0 70mm Neutral bus 14 to 8 AWG 1 5 10mm 25 Ib in 2 lb ft 3 N m Equipment 14 to 8 AWG 1 5 10mm 75 Ib in 6 3 Ib ft 8 5 N m grounding hee ANG pira folbin 9 2 lb ft 12 N m y 150 Ib in 12 5 lb ft 17 N m 2 to 3 AWG 35mm Sensor3 Rack Installation Manual Connecting Ground Fault Circuit Interrupt Racks 120V GFCI Sensor3 GFCI racks have discrete Neutral bussing for using GFCI dimmer modules which provide extra safeguards in hazardous environments CAUTION GFCI protec
37. h the rack e Follow instructions from Securing 24 and 48 Module Racks to a Wall page 8 to drill holes in the back of the rack for wall mounting e Mount the rack to the wall using the procedure from Wall Mounting Racks Using Vibration Pads page 8 above Step 8 Secure the rack to the pads with the 3 8 inch bolts CAUTION Unless mounting is done and connections are made in a flexible manner the effectiveness of the vibration pads will be reduced or completely negated Proper connections include the use of a minimum of 1 of flexible conduit for all electrical connections to the rack s Sensor3 Rack Installation Manual Securing Multiple Racks Optional Multiple racks can be connected to each other for greater stability This is not the same as bussed racks Bussed racks include hard bussing copper to physically connect the line power through multiple racks For proper bussed rack installation please see nstallation of Bussed Racks page 15 Note If you want to install the control cable through the side of the racks remove the side cable knockouts before connecting the racks Step 1 Use 1 2 inch long bolts and lock nuts in the front and at the back to bolt the racks together at the bottom Hole for bolting racks together WAAAY Hole for bolting racks together recessed Figure 7 Placement of rack connecting holes Note The front bolt is diffic
38. immer Room Requirements e A main circuit breaker cabinet or other readily accessible input power disconnect device can be in the Auxiliary Bay for bussed racks Main breakers not in the same room must have a physical means to be locked off e A clean not dusty temperature controlled environment Figure 1 Sensor3 wall mounted rack clearances e Restricted public access to prevent tampering e Soundproofing or performance area separation to muffle ventilation fan noise Please see Appendix D Sensor3 Rack Specifications page 49 for environmental details 6 and 12 module racks are normally wall mounted 24 module racks can be wall or pedestal mounted 48 module racks are designed to be free standing When wall mounting racks install racks with the Control Electronics Module CEM3 between two and five feet from the floor In 6 12 and 24 module racks the CEM3 is in the bottom slot In the 48 module rack the CEM83 slot is in the middle 5 Sensor3 Rack Installation Manaul Chapter 2 Installation of Individual Racks Mounting the Rack 6 and 12 module racks are normally wall mounted e 24 module racks can be mounted to a wall or floor mounted on an optional pedestal e 48 module racks are floor standing Mounting Racks on a Wall 6 12 and 24 Module Racks The wall must be strong enough to hold the racks Please see Appendix D Sensor3 Rack Specifications page 49 for rack and module weights
39. leave access to the lug s bolt for tightening ater Step 2 Strip one inch of insulation from the end of the line phase neutral and ground cables and attach them to the correct lugs Line connections are labeled A B C N and Equipment Grounding Lug Note The example in Figure 11 shows a three phase rack On 120 V single phase racks are shipped with two phase bus bars labeled L1and L2 WARNING Do not try to modify any Sensor3 rack to use a single line feed by jumpering between phase bars Single feed operations will result in overcurrents on the neutral bus and may cause fire or equipment failure 13 Sensor3 Rack Installation Manual Neutral bus bar Figure 12 Line cable bus connections Step 3 Tighten the lugs to the correct torque based on cable size Table 2 Line lug torque Cable size Torque Pound Inches Torque Pound feet Torque N m 4 to 6 AWG 110 Ib in 9 2 Ib ft 12 4 N m 25 to 16mm 1 to 2 AWG 150 Ib in 12 5 lb ft 16 9 N m 35mm 1 0 to 2 0 AWG 180 Ib in 15 Ib ft 20 3 N m 50 to 70mm 3 0 to 4 0 AWG 250 Ib in 20 8 Ib ft 28 2 N m 95mm 250 to 450 kcmil 325 Ib in 27 1 Ib ft 36 7 N m 120 to 185mm 500 to 750 kcmil 375 Ib in 31 3 Ib ft 56 5 N m 240 to 300mm If you are not installing bussed racks please skip ahead to Section 4 Land Load Wires page 36 2 Installation of Individual Racks Chapter 3 Installation of Bus
40. loor or pedestal mounting nstalling 48 Module Racks on the Floor page 7 or Pedestal Mounting a 24 Module Rack page 7 WARNING Make sure the holes for the mounting hardware are located where the hardware cannot come into contact with electrical wiring Bussing and wire configurations will vary depending on installation types Make all modifications in accordance with applicable local electrical codes o I Note 48 module rack enclosures do not have wall mounting holes Drill two or more securing holes through the top third of the cabinet Step 2 Mark the locations for your securing hardware on the wall e For 24 module racks use the diagram in Figure 4 to determine where you need to install your hardware e For 48 module racks put the rack in position and mark the holes directly Note Be sure to level 48 module racks before marking the hole positions Step 3 Drill holes or install mounting hardware in the marked locations Step 4 Finish mounting the rack to the floor or pedestal Step 5 Attach the rack to the wall with your securing hardware Wall Mounting Racks Using Vibration Pads Align the center of the fitting over the diagram hole location and mark the position of the fitting i agg bolts Vibration damping fittings are available as an option ETC Part HW6111 for wall mounted racks 6 12 and 24 module racks The wall must be strong enough to hold the racks Please see Appendix D
41. ls and bussing preparation Access Panel Configurations by Rack Position Dimmer racks are shipped with bussing access panels prepared for installation You can use the panel configuration to help identify racks positions in bussed assemblies e Racks on the left side of an assembly have the left side access panel in place and right side panel replaced by a fiche paper Nomex air baffle e Racks in the middle have the right panel replaced by an air baffle and the left panel removed e Racks on the right side of the assembly have the right access panel in place and the left removed Access panel Access panel replaced Access panel Nomex baffle Panel removed Panel in place in place by Nomex air baffles removed i A USA _ ESE e Left side racks Middle racks Right side racks Figure 14 Rack access panel configuration Note Some installations will have separate groups of bussed racks resulting in multiple left and right side racks Always check your job drawings and rack ID labels to confirm a rack s installation position eq Installation of Bussed Racks 16 Rack Numbering and Torque Information Stickers Each dimmer rack has a rack identification label Use the label to identify the rack in the configuration Rack numbering begins on the left and goes on to the right Auxiliary Bays are not numbered Note in the job drawing
42. ntal Operating temperature 0 to 40 C 32 to 104 F Dimmer room HVAC systems must at all times maintain the specified ambient temperature at the dimmer rack Dimming systems operating within 10 degrees F of the upper or lower temperature limits must strictly follow installation and operation guidelines to operate reliably Relative humidity 10 to 90 non condensing GFCI Load Wiring Requirements Up to 125 foot load wire length Can use standard load wiring type XHHW recommended Load and neutral wires for each circuit installed in same conduit No ganging of neutral return wires at any point GFCI Restrictions GFCI modules do not support ETC s Dimmer Doubling GFCI modules may not detect ground faults across a transformer Contact ETC for applications requiring longer branch circuit runs or non resistive loads such as motors or electronic magnetic ballasts Mechanical 49 Rugged 16 gauge steel construction Fine textured scratch resistant epoxy paint 6 and 12 module racks use wall mount installation 24 module racks can be wall or pedestal mounted 48 module racks are floor mounted Top and bottom conduit access through removable panels 48 module racks or knockouts 6 12 and 24 module racks No tools required for module removal or installation Keyed module slots prevent insertion of inappropriate module types Front access to all wiring and terminations Full height locking door Electrostatic air filte
43. ovides information on the thermal efficiency of ETC Sensor3 dimmer modules All dimmer efficiencies are measured at maximum current full load Note that the watt and BTU figures shown below apply to single dimmers not dimmer modules and a module often contains more than one dimmer Table 8 Dimmer Module Efficiency Module Type Dimmers per Full Load in Watts BTUs Dimmer Module Watts Dissipated Dissipated Efficiency CEM CEM3 lt 4 lt 10 D15 2 1 800 56 190 96 9 D15AF D15E 2 1 800 70 237 96 1 D20 2 2 400 77 261 96 8 D20AF D20E 2 2 400 119 405 95 1 D20HR 1 2 400 259 883 89 2 D50AF 1 6 000 237 808 96 1 D50HR 1 6 000 543 1 853 90 9 D100AF 1 12 000 446 1 521 96 3 HD15 2 3 600 65 222 97 2 HD25 2 6 000 238 810 96 9 Although Sensor3 dimmers are designed to operate safely in environments with ambient temperatures of up to 104 F 40 C as with all electronic equipment keeping the operating environment at cooler temperatures will help improve the service life of the equipment In order to maximize the efficiency of your dimming system dimmer room air conditioning should maintain an ambient dimmer room temperature of 68 F 20 C or less Note When calculating air conditioning requirements keep in mind that the BTU outputs cited in the table above are maximums The heat actually dissipated may be less depending on the size of the loads Factors that influence actual heat
44. p 5 27 Secure the rack to the floor using your mounting hardware Figure 25 Floor mounted rack clearances Sensor3 Rack Installation Manual gt E 14 7 21 9 48 module rack AN connected to a 19 inch Auxiliary Bay i PN 20 1 3 13 17 83 33 52 gi TIT 18 829 b 1 25 47 6 lt 14 7 32 9 a gt lt il A o fe Si 18 88 48 module rack x connected to a Dia 0 39 30 inch Auxiliary Bay na 20 1 3 13 17 83 44 52 gk 3 13 3 29 82 eu 1 25 i Y Figure 26 Hole diagrams for mounting 48 module racks to the floor Securing 48 Module Racks to a Wall Racks installed on the floor can also be secured to a wall for greater stability Step 1 Prepare the rack for floor mounting see the previous page Note 48 module rack enclosures do not have wall mounting holes Drill two or more securing holes through the top third of the cabinet CAUTION Mounting hardware should not come in contact with electrical wiring Drill holes appropriately Bussing and wire configurations will vary depending on installation types Make all modifications in accordance with applicable local electrical codes Step 2 Position the rack against the wall and mark the holes directly Note Level the 48 module racks before marking the hole positions Step 3 Drill hole
45. r easily removed from door for periodic cleaning High efficiency cooling system with airflow sensor High visibility LED status beacon Electrical See Dimmer Rack and Aux Bay Ratings page 52 for specifics on rack feeder amperage SR3 series line feed voltage range is 91 to 139 VAC HSR3 series line feed voltage range 190 to 265 VAC 6 12 and 24 module 120 V SR3 racks accept Three phase 120 208 VAC Single phase 120 240 VAC 48 module rack accepts Three phase 120 208 VAC Single phase 120 240 VAC up to 600 amps Line feed frequencies from 47 to 63 Hz Maximum current ratings 3 phase SR3 6 100 amps per phase SR3 12 and HSR3 12 200 amps per phase SR3 24 and HSR3 24 400 amps per phase SR3 48 and HSR3 48 800 amps per phase SR3 48 and HSR3 48 with Aux Bay 2000 amps per phase 3 phase max 1600 amps max with main breaker Maximum current ratings Single phase SR3 6 150 amps per phase SR3 12 and HSR3 12 300 amps per phase SR3 24 and HSR3 24 600 amps per phase SR3 48 and HSR3 48 600 amps per phase See Dimmer Rack and Aux Bay Ratings page 52 for limitations when using aluminum and copper feeders Load terminals accept up to 4 AWG 16mm wire see chart 100 000 SCCR symmetrical rack rating at 120V 10 000 SCCR symmetrical at 240V Auxiliary Equipment Racks and switchgear distribution available Call ETC for details All racks UL and cUL Listed SR3AFN racks UL and cUL 943 compliant Class A 120
46. r3 Rack Specifications 49 Introdu ction Welcome to the installation manual for Sensor 3 racks This manual contains the procedures for safe and efficient UL UL LISTED C installation of individual and bussed Sensor3 SR3 and HSR3 series dimming systems SR3 series racks are designed for 120V phase to neutral and are sold in North America HSR3 racks are designed for 240V phase to AC Lighting Loads Only neutral and are sold in South America Asia and the Pacific e For Indoor Use Only Rim There are four sizes of installation racks SR3 6 120V only Six dimmer slots up to 12 UL File E92134 circuits SR3 12 and HSR3 12 Twelve dimmer slots up to 24 circuits SR3 24 and HSR3 24 Twenty four dimmer slots up to 48 circuits SR3 48 and HSR3 48 Forty eight dimmer slots up to 96 circuits SR3 6 racks cannot be bussed while the 12 24 and 48 module racks listed above can be bussed A bussed SR3 24 or SR3 48 installation may also include an Auxiliary Bay equipped with main circuit breakers How To Use This Guide Use this guide during system installation It contains complete installation instructions Introduction page 1 describes general requirements for installation Installation of Individual Racks page 6 contains procedures for installing your rack Installation of Bussed Racks page 15 contains procedures for installing your bussed rack Finishing Installation page
47. re 36 Attaching the 12 and 24 module rack bottom hinge 7 e 48 module rack Remove the 10 32 x 1 2 inch Phillips head screw insert the hinge into the slot and secure it by replacing the screw Bottom hinge Bottom hinge z in place being inserted Figure 37 Attaching the 48 module rack bottom hinge 41 Sensor3 Rack Installation Manual e Drive the narrow end of one taper pin into the bottom of the door Put the taper pin through the washers and into the hole on the lower hinge Door Washers Taper pin 48 module rack lower hinge 12 and 24 module rack lower hinge Figure 38 Installing the bottom taper pin Step 3 Hold the door in place and insert the other taper pin narrow end down through the top hinge and washer Taper pin Washers Figure 39 Installing the top taper pin Step 4 Take the Sensor3 beacon block insert it through the slot on the upper left corner of the door and secure it with two 10 32 x 1 2 inch Phillips head screws included Figure 40 Installing the beacon block ea Finishing Installation 42 43 Sensor3 Rack Installation Manual Appendix A Check Power Installation It is a good idea to review the installation before applying power to the rack WARNING Power must be turned OFF when you perform this procedure Before removing dimmer or control modules for service de energize main feed to dimmer rack and follow appropriate Lockout
48. s or install mounting hardware in the marked locations Step 4 Finish mounting the rack to the floor Step 5 Attach the rack to the wall with your securing hardware Eq Installation of Bussed Racks 28 Connecting Main Power Through an Auxiliary Bay Line cable access to the Auxiliary Bay is through the removable top and bottom access panels Copper and aluminum are both acceptable for line and load wiring but have restrictions Reference the Dimmer Rack and Aux Bay Ratings Chart below before installation to ensure your system does not void UL Dimmer Rack and Aux Bay Ratings Standard ETC Sensor Rack Options with Maximum Current Ratings Dimmer Racks SR3 48 and HSR3 48 SR3 24 and HSR3 24 SR3 12 and HSR3 12 Suggested Max Current Max of bussed racks Rating of 30 Rack 800A CU 600A AL Max Current Max Current Rating of Max Current Rating of Rating of 1 39 19 Aux 39 30 Aux Rec atuminum copper aluminum copper 1200A MCB 1600A MCB 1600A ML 2000A ML DONO 800A 00A 00A 00A N A Must use copper feeds when using 100 rated breakers and breakers rated greater than 1200A Aluminum feeds suitable for 80 rated breakers at 1200A and less and main lugs 1600A and less 29 3SR 48 is rated at 600A for aluminum feeds Sensor3 Rack Installation Manual Attaching Line and Load Wire Conduit Aux Bay access panels have conduit knockouts for installing conduit
49. s or specified to installers Some customers specify non standard rack numbering based on special installation requirements Custom numbering arrangements should be called out Customer Rack number Job Rack numbering is ordered from left to right Model Artist s Theatre 114042 S O 114042 SR3 48 1 Serial Of 999 999 6 M E E Date 6 02 11 Figure 15 Rack identification labels The identification label is located on the phase A bus in each SR3 48 rack It is on the base of each SR3 12 and SR3 24 rack SR3 12 and SR3 24 rack ID stickers are on the bottom of the rack A bolt and wire torque table sticker is on the bottom of all dimmer racks SR3 48 rack ID sticker is on Phase A bus Figure 16 Locating the rack ID sticker Each rack has a sticker on the bottom with a table of torque values Table 3 Bolt and wire torque values Wire Tightening Torque Values Bolt Tightening Torque Values Internal socket size Maximum tightening AWG or kcmil size Screwdriver External drive across flats torque wrench 1 8 inch 45 Ib in 5 N m 14 12 10 8 35 Ib in 4 N m 75 Ib in 8 5 N m 5 32 inch 100 Ib in 11 N m 6 4 45 Ib in 5 N m 110 Ib in 12 5 N m 3 16 inch 120 Ib in 13 5 N m 2 1 50 Ib in 5 5 N m 150 Ib in 17 N m 7 32 inch 150 Ib in 17 N m 1 0 2 50 Ib in 5 5 N m 180 Ib in 20 N m 1 4 inch
50. s to connect to the bus bars These cables are provided with the bus kit e Main Circuit Breakers over 800A use only the pre bent multilayer copper plates Step 1 Install the bus bars according to the instructions in Installing the Aux Bay Bus Bars page 24 Step 2 If you have an MCB less than 800A connect the provided cables from the MCB to their respective bus bars and torque them using the values in the following table Cable size Torque Ib in Torque Ib ft Table 5 Line lug torque Torque N m 4 6AWG 110 Ib in 1 2 AWG 9 2 Ib ft 12 5 Ib ft 12 N m 1 0 2 0 AWG 15 Ib ft 3 0 4 0 AWG 20 8 Ib ft 250 450 kcmil 27 1 Ib ft 31 3 Ib ft 500 750 kcmil 375 Ib in 800 1000 kcmil 500 Ib in 25 41 7 Ib ft Sensor3 Rack Installation Manual Mounting the Rack e 12 module racks are normally wall mounted e 24 module racks can be mounted to a wall or on an optional pedestal e 48 module racks are floor standing For stability these racks must also be secured to the floor or wall after installation Note Store unsecured racks where they cannot fall over and use caution to keep racks stable during installation Mounting Bussed Racks on a Wall 12 and 24 Module The wall must be strong enough to hold the racks See Sensor3 Rack Specifications page 49 for rack and module weights Step 1 Use the mounting slot dimensions to mark th
51. sed Racks Configurations of Bussed Racks 12 Module Racks Bussed 12 module racks are available connected to an Auxiliary Bay only It is recommended that no more than two racks and an Auxiliary Bay be bussed together The Auxiliary Bay can contain a Main Circuit Breaker MCB for the racks Racks can be shipped with all bussing connections complete or as two racks and one Auxiliary Bay Racks that are shipped assembled can be mounted immediately on a wall or pedestal without further assembly See Mounting Bussed Racks on a Wall 12 and 24 Module on page 26 for instructions 24 Module Racks Bussed 24 module racks are available connected to an Auxiliary Bay or bussed together There is no physical limit to how many racks can be bussed together but usually four is the maximum due to power feed limitations If an Auxiliary Bay is included in the bussed assembly it can contain a Main Circuit Breaker MCB for the racks Up to three 24 module racks can be shipped with all bussing connections complete or two racks and one Auxiliary Bay Racks that are shipped assembled can be mounted immediately on a wall or pedestal without further assembly See Mounting Bussed Racks on a Wall 12 and 24 Module on page 26 for instructions Racks shipped separated must be bolted together and bussing connections between the racks must be completed before the racks can be secured in their installation location See Secure Racks Together page 18
52. ting Bussed Racks on a Wall 12 and 24 Module 26 Pedestal Mounting 24 Module Racks 27 Installing 48 Module Racks on the Floor 27 Securing 48 Module Racks to a Wall 28 Connecting Main Power Through an Auxiliary Bay 29 Dimmer Rack and Aux Bay Ratings 000 29 Attaching Line and Load Wire Conduit 30 Using a Wire Trough for Line and Load Wire Access 30 Connecting the Aux Bay Line Feed Wires 31 Connecting Line Power Directly to Bussed Dimmer Racks 33 Connecting the Line Feed Cables 0000 33 Land Load Wires 05 36 Connecting Ground Fault Circuit Interrupt Racks A20V GPCI erate ie ade ae ei 38 Making Discrete Neutral Load Connections 39 Finishing Installation 40 Sealing Rack Air Leaks 0 0 eee 40 Attaching the door aufer deora ica LEALE 40 Check Power Installation 44 Checking Main Power Wiring LL 44 Checking Load Wiring 0 cece ee 44 Converting Discrete Neutral Dimmer Lugs 45 Converting GFCI dimmer slots 45 Installing Three Slot Dimmer Lug Strips 46 Sensor3 Rack Installation Manual Appendix C Appendix D Table of Contents 120V GFCI Circuit Troubleshooting 47 Requirements for GFCI circuits 00s 47 Typical causes of GFCI circuit faults 47 Senso
53. tion does not increase sensitivity to overcurrent conditions caused by shorts between a circuit s neutral and load wires Overcurrent protection provided by the dimmer module circuit breaker is identical to equally rated standard Sensor3 dimmer modules gt Note GFCI rack slots can be modified to use standard Sensor3 dimmer modules For information on converting module slots from GFCI to standard see Appendix B Converting Discrete Neutral Dimmer Lugs page 45 Converted slots have the same discrete Load Neutral wire connections as GFCI slots 14 Land Load Wires 38 Making Discrete Neutral Load Connections GFCI racks have a larger line Neutral bus with individual Load Neutral lugs for each dimmer circuit Neutral and Hot wires from GFCI circuits must be matched to the same GFCI dimmer to work correctly Load Load Hot wires Neutral usually black white Each dimmer circuit s Hot and Neutral lugs are directly Load Neutral and across from Hot wires must be each other identified by circuit labels and Load matched to the Ca d correct dimmer roun lugs wires usually Ground wire bus plate green Grounds do not need 5 7 ral Figure 34 Neutral Disconnect Hot and Neutral lugs Step 1 Follow the instructions in Connect Line Feed Cable page 13 to prepare line cables for connection Step 2 Follow the instructions in Connect Line Feed Cable page 13 to connect line cables to th
54. to the bus bars The example in Figure 29 shows a three phase 48 module rack Single phase racks only available for the 12 module and 24 module racks are shipped with two phase bus bars labeled L1and L2 Step 4 Tighten the lugs to the correct torque based on cable size e AU 250 Two 250 kcmil cables max 5 16 inch hex Allen lug driver e AU 350 Two 350 kcmil cables max 3 8 inch hex Allen lug driver e AU 600 Two 600 kcmil cables max 1 2 inch hex Allen lug driver If a custom lug is used to connect line cables follow the lug manufacturer s torque recommendations Table 5 Line lug torque Torque inch Ib Torque foot Ib Torque N m 4 6AWG 3 9 2 Ib ft 1 2AWG i 12 5 Ib ft 1 0 2 0 AWG 15 Ib ft 3 0 4 0 AWG 20 8 Ib ft 250 450 kcmil 27 1 Ib ft 500 750 kcmil 31 3 Ib ft EJ Installation of Bussed Racks 34 35 Sensor3 Rack Installation Manual Chapter 4 Land Load Wires Load lugs are on the right side of the rack Lugs can be Use just enough wire to ma single 15 20 amp paired 15 20 amp fluorescent double the connections height 50 amp or dual slot 100 amp Use wire ties to keep wire bundles tight J Do not terminate more than one conductor per lug oo Double height 50 amp lug Dual slot 100 amp lug eo 0 oo Switched or Constant A tf Control or Dimmed Dual 15 2
55. ug releases Step 4 Step 5 Step 6 Step 7 Step 8 45 Use a 2 flat screwdriver to loosen the threaded Use a small flat screwdriver inserts until the contact plates can slide out of both to lift the lug tab enough to lugs release the lug from the strip and pull it out Repeat Step 3 and Step 4 for the other dimmer slot lug Figure 41 Removing a lug Install a Neutral lug jumper into the lugs and tighten the threaded inserts Slide the jumpers into the plastic lug strip until the lug tab clicks into place Secure the jumper to the PEM insert on the main Neutral bus using the provided 4 40 screw Sensor3 Rack Installation Manual Step 9 Repeat Steps 1 through 6 for any other lugs you want to convert Slide the lugs Slide the lugs onto the jumper onto the jumper 7 Secure the jumper with the screw s Insert the jumper CO into the slot Figure 42 Converting Neutral Disconnect lugs to use standard dimmers Installing Three Slot Dimmer Lug Strips Step 1 Use a 2 Phillips screwdriver to remove the two 4 40 screws securing the lug strip to the e left side of the rack A 2 Step 2 Remove the lug strip and replace it with one gt containing a three slot Neutral jumper 8 O SI Step 3 Secure the strip to the rack with the screws Q S you removed in Step 1 S Step 4 Secure the jumper to the main Neutral bus O S PEM inserts using the two 4 40 screws
56. ult to reach you may need a magnetic bolt driver or socket extension Step 2 Remove six screws from the tops of adjacent racks as shown below Temporarily remove six screws from this area Install the rack splice and replace the screws to secure it Figure 8 Screws to remove to connect two racks Step 3 48 module only Place a rack splice plate over the empty screw holes and replace the screws you removed in Step 2 as shown above Step 4 Repeat Steps 1 2 and 3 until you ve secured all of the racks 2 Installation of Individual Racks 10 Connect Line Power Wiring ETC recommends routing line feeder wires first load neutral and load ground wires next and load phase wires last A CAUTION Copper and aluminum are both acceptable for line and load wiring but have restrictions Reference the Dimmer Rack and Aux Bay Ratings page 29 before installation to ensure your system does not void UL A CAUTION Dress wires neatly and avoid leaving extra wire inside the rack Too much clutter especially along the right side of the rack can restrict air circulation and reduce cooling efficiency If cabling interferes with airflow during operation the rack may shut down due to overheating Attaching Line Power Wire and Conduit Line cable and power wire conduits should enter the rack through the designated top and bottom access points 6 12 and 24 Module Rack Wire and
57. ultiply the module weight times the number of Connection Wire Size modules add the result with the CEM3 weight and the above weights for rack and door Final weight will also include weight of installed line and load wiring Maximum D20DHR modules 5 71bs 2 6kg per slot Typical D20 and HD15 or 20 modules 5 0 Ibs 2 3kg per slot Refer to module data sheets to calculate total module weight for other module types D Sensor3 Rack Specifications 10A 15A 20A and 50A lugs 4 AWG Max 16mm 100A lugs 2 0 Max 60mm 50 Rack Dimensions SR3 6 Series not avail as AFN Wall or other barrier all racks Installation Rack Dimensions 6 omm 51 6 somm SR3 and HSR3 Models Height Width Depth inches cm inches cm inches cm 6 16 4 42 14 6 37 13 3 34 12 25 8 66 14 6 37 13 3 34 24 45 8 116 14 6 37 16 8 43 48 83 1 211 14 6 37 22 8 58 Clearance above fan 10 0 250mm SR3 48 Series Y Clearance above fan 10 0 250mm SR3 24 Series Y e i A Clearance 8341 above fan 2110mm 10 0 Clearance Seo above fan n Ey SR3 12 Series Y ae ti PS rari 10 0 m A LI 250mm LI 25 8 16 4 660mm 420mm i N N N 14 6 14 6 14 6 370mm gt lt 370mm lt 370mm Sensor3 Rack Installation Manual Dimmer Module Efficiency The following table pr
58. ur securing the rack Step 2 Step 3 Step 4 Step 5 Drill holes or mount floor hardware and position the pedestal on them Figure 24 24 module pedestal Secure the pedestal base to the floor mountdimensions Position the rack on the pedestal so the mounting holes align Bolt the rack into place Securing Pedestal Mounted 24 Module Racks to a Wall 24 module racks installed on pedestals can also be secured to a wall for greater stability Step 1 Step 2 Step 3 Step 4 Step 5 Installing 48 Module Racks on the Floor Step 1 Step 2 Step 3 Step 4 Prepare the racks for pedestal mounting see above Mark the locations for your securing hardware on the wall Use the 24 module diagram in Figure 23 to determine where you need to install your hardware Drill holes or install mounting hardware in the marked locations Finish mounting the rack to the floor or pedestal Attach the rack to the wall with your securing hardware Determine where your racks will be installed using Figure 25 and use the appropriate diagram from Figure 26 to mark your mounting holes Drill the holes and install your own 3 8 inch mounting hardware Position the rack in the desired location Adjust the leveling feet with an open end 1 2 inch wrench until the rack is level 48 module installation racks are tall narrow and heavy Use caution to keep racks stable until conduit is installed Leveling Ste
59. us bar s in through the Nomex air baffle on the side of the rack Step 4 Connect the neutral bus plate to the neutral bus bar s with the included carriage bolts Note If the line power is connected at the center rack only connect the bus bar s to one side of the neutral plate Connect the bus bar s on the other side after completing Step 6 19 Sensor3 Rack Installation Manual Step 5 Reattach the neutral plate assembly to the Glastic standoffs on the back of the rack with the included hardware Do not overtighten Step 6 Repeat steps 4 and 5 with any additional racks until all are installed and bussed together Step 7 Tighten all neutral bus hardware except the bolts securing the neutral bus assembly to Glastic standoffs to the values on the Torque Values sticker on the bottom of the rack or in Table 3 on page 17 e 9 16 inch bolts 20 Ib ft 27 N m maximum e 7 16 inch bolts 15 Ib ft 20 N m maximum Note Bolts securing the neutral bus assembly to the Glastic standoffs on the back of the rack must not be overtightened or the standoffs will break EJ Installation of Bussed Racks 20 Bussing Between Phase Bus Plates Step 1 Place the bus bar through the side openings provided on the rack and position behind the copper angle plates Step 2 Lightly secure it to the Glastic standoffs with the included bolt washer combination Step 3 Insert the two securing carriage bolts through the squar
60. y branch circuit that will be connected to the dimmer rack Shared neutral multiwire branch circuit arrangements are not recommended for phase control dimming systems due to harmonics and potentially elevated neutral currents in a shared neutral arrangement For retrofit installations where shared neutral circuits are already installed or track lighting installations where the track has a shared neutral consult ETC Technical Services for rack installation guidelines Step 2 Combine load ground wires into the Equipment grounding lug and torque to the recommended value from Figure 6 above Step 3 Step 4 Use the combined diameter of the ground wires to determine the torque needed If there are too many load ground wires to fit into the equipment grounding lug replace it with a larger lug or bus and torque to manufacturer s specification It is acceptable to land multiple ground wires in the same lug Separate the neutral load wires from the other cables route them to the neutral bus in each rack and terminate them Route each hot load wire to its individual load output connection CAUTION To prevent interference with cooling airflow do not run load wires from one rack through a different rack See Sealing Rack Air Leaks page 40 for more information Step 5 e 15 50 amp load lugs Insert the wire under the pressure plate and tighten it onto the wire with the screw Do not clamp the wire directly und
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