Etec Congo Jr Service Documents

Lighting control console

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Lighting Control Console

Service Documents

C o p y r i g h t © E le c tr o n i c T h e a t r e C o n t r o l s , I n c .

A l l R i g h t s r e s e r v e d .

P r o d u c t in f o r m a t i on a n d s p e c i f i c a t i o n s s u bj e c t t o c h a n g e .

P a r t N u m b e r : P e n d i n g

R e l e a s e d : M a y 2 0 0 7

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Page 1 Lighting Control Console Service Documents C o p y r i g h t © E le c tr o n i c T h e a t r e C o n t r o l s , I n c . A l l R i g h t s r e s e r v e d .
Page 3: Table Of Contents
Congo™ jr v4.3 I/O Software Code Installation ......... . 53 Congo jr Service Documents - Page i...
Page 4 Congo jr Service Documents - Page ii...
Page 5: Face Panel Diagnostics
DVI Monitor, or VGA w/ DVI adapters USB Keyboard USB Mouse Pr ocedure: Step 1: Connect all USB cables to the Congo jr USB ports Step 2: Turn on the console Step 3: At the main Congo screen press [Crtl]+[Alt]+[Delete] from the USB Keyboard...
Page 6 Click here for face panel diagnostics Click here for wing diagnostics Step 11: Click on either the Congo jr Face button or the Congo jr Wing button. Con go ™ jr Fa ce Pan el Di ag no st ic s Pag e 2 El ect r on ic T he at r e Con tr o ls , I nc.
Page 7 E T C S e r v i c e N o t e Congo™ jr Face Panel Diagnostics Step 12: The following window will pop up if you click the Congo jr Face button: Con go ™ jr Fa ce Pan el Di ag no st ic s Pag e 3 El ect r on ic T he at r e Con tr o ls , I nc.
Page 8 Step 15: Every slider move will indicate a range from 0-255. Step 16: When each button and slider tests out ok; close the window and power the Congo jr down.
Page 9: Midi, Telephone, And Remote Macro Test
DVI monitor, or VGA w/ DVI adapters USB Keyboard USB Mouse Pr ocedure : Step 1: Connect all cables to the Congo jr Console Step 2: Turn on the console Step 3: At the main Congo screen press [Crtl]+[Alt]+[Delete] from the USB keyboard.
Page 10 E T C S e r v i c e N o t e Congo™ jr MIDI, Phone and Macro Test Step 8: Select File -> New Task (run) Step 9: Type “test2” in the text field, then click the “OK” button] Step 10: The following window will pop up: Step 11: Watch for the 2 LEDS to flash on the Remote Macro Test Board Step 12: Press the 4 buttons on the LED Remote Macro Test Board (if present), look for...
Page 11: Lcd Replacement
#2 Phillips Screwdriver Side Cutter 4" replacement zip ties Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 12 E T C S e r v i c e N o t e Congo™ jr LCD Replacement Step 4: Carefully flip over the console and loosen the 3 screws in blue below: NOTE: DO NOT remove the 3 screws. Loosen these screws Step 5: Flip the console back onto the base.
Page 13 FP USB 1 FP USB 2 J1 - USB Uplink Step 11: Carefully set the Congo jr face panel face down exposing the back side of the face panel PCB. Step 12: Remove the 8 short screws from the LCD pressure plate.
Page 14 Step 14: Lightly lift each side of the LCD Screen socket circuit board to remove the LCD screen from the Congo jr face panel. Step 15: Replace the LCD screen by removing each of the 2 face panel LCD Jumper circuit boards.
Page 15 E T C S e r v i c e N o t e Congo™ jr LCD Replacement Step 18: Re-attach the USB Connectors to the motherboard. FP USB 1 FP USB 2 J1 - USB Uplink Step 19: Slide the face panel back under the base pressure plate. Base Pressure Plate Step 20: Re-attach all 7 screws from each side of the console face panel.
Page 16 E T C S e r v i c e N o t e Congo™ jr LCD Replacement Con go ™ jr LCD Re pl ac eme nt Pa ge 1 2 El ect r on ic T he at r e Con tr o ls , I nc.
Page 17: Encoder Replacement
Lead Free Solder 4" Replacement zip ties .050 angled Hex key Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 18 E T C S e r v i c e N o t e Congo™ jr Encoder Replacement Step 4: Carefully flip over the console and loosen the 3 screws in blue below: NOTE: DO NOT remove the 3 screws. Loosen these screws Step 5: Flip the console back onto the base.
Page 19 J1 - USB Uplink Step 10: Clip the zip ties holding the face panel cables to the base of the unit. Step 11: Carefully set the Congo jr face panel face down exposing the back side of the face panel PCB.
Page 20 Step 14: Lightly lift each side of the LCD screen socket circuit board to remove the LCD Screen from the Congo jr face panel. Step 15: With the LCD screen removed from the face panel, you can now access the encoder knob shafts.
Page 21 E T C S e r v i c e N o t e Congo™ jr Encoder Replacement Step 19: Replace encoders as needed on PCB or replace the whole board. NOTE: Pins on this board are soldered, not socketed. You will need to de- solder each of the 16 pins.
Page 22 E T C S e r v i c e N o t e Congo™ jr Encoder Replacement Step 24: Slide the face panel back under the Base pressure plate. Base Pressure Plate Step 25: Re-attach all 7 screws from each side of the console face panel. Step 26: Flip the face panel over and tighten the 3 screws on the base of the console.
Page 23: Video Card Replacement
Congo™ jr Video Card Replacement Tools Required: #2 Phillips Screwdriver #1 Phillips Screwdriver Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 24 E T C S e r v i c e N o t e Congo™ jr Video Card Replacement Step 5: Flip the console back onto the base. Step 6: Lift the back side of the face panel upwards away from the base. Step 7: Slide the face panel towards the front of the console.
Page 25 E T C S e r v i c e N o t e Congo™ jr Video Card Replacement Step 9: Remove all 5 screws from both sides and the rear of the base. Remove these screws (located on side of chassis) Remove this screw Step 10: Remove the base cover, and set aside.
Page 26 E T C S e r v i c e N o t e Congo™ jr Video Card Replacement Step 13: Set the defective/damaged video card aside. Step 14: Insert the new video card into the motherboard. There should be a click heard/felt when the video card is seated all the way into the AGP Slot.
Page 27: Hard Drive Replacement
#1 Phillips Screwdriver Side Cutter (3) 4" Replacement zip ties Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 28 E T C S e r v i c e N o t e Congo™ jr Hard Drive Replacement Step 4: Carefully flip over the console and loosen the 3 screws in blue below: NOTE: DO NOT remove the 3 screws. Loosen these screws Step 5: Flip the console back onto the base.
Page 29 E T C S e r v i c e N o t e Congo™ jr Hard Drive Replacement Step 8: Rest the face panel off to the left side of the base unit. (the side with the DMX connectors) There is no need to remove the face panel cables when replacing the hard drive.
Page 30 E T C S e r v i c e N o t e Congo™ jr Hard Drive Replacement Step 11: Using a 5/16” nut driver, remove both nuts from the hard drive plate. Remove both 5/16” nuts Step 12: Remove all 4 Hard Drive Plate Screws. Step 13: Swap the old Hard Drive fo rthe one one.
Page 31 E T C S e r v i c e N o t e Congo™ jr Hard Drive Replacement Step 18: Slide the face panel back under the pressure plate.. Base Pressure Plate Step 19: Re-attach all 7 screws from each side of the console face panel. Step 20: Flip the face panel over and tighten the 3 screws on the base of the console.
Page 32 E T C S e r v i c e N o t e Congo™ jr Hard Drive Replacement Con go ™ jr Har d Dr ive Re pl ac eme nt Pa ge 2 8 El ect r on ic T he at r e Con tr o ls , I nc.
Page 33: Dmx Driver Chip Replacement
Congo™ jr DMX Driver Chip Replacement Tools Required: #2 Phillips Screwdriver #1 Phillips Screwdriver Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 34 E T C S e r v i c e N o t e Congo™ jr DMX Driver Chip Replacement Step 5: Flip the console back onto the base. Step 6: Lift the back side of the face panel upwards away from the base. Step 7: Slide the face panel towards the front of the console.
Page 35 E T C S e r v i c e N o t e Congo™ jr DMX Driver Chip Replacement Step 10: Remove the base cover, and set aside. Step 11: Locate the MIDI riser card near the Video Card, and above the DMX I/O Card. Step 12: Remove the ribbon cable from the MIDI riser card, and remove the 3 screws.
Page 36 E T C S e r v i c e N o t e Congo™ jr DMX Driver Chip Replacement Step 16: Replace the desired DMX driver chip. (75LBC182) ETC Part Number Z1458-F. Step 17: Re-connect the MIDI riser card to the DMX I/O card. Line up all 14 pins with the I/O socket.
Page 37 E T C S e r v i c e N o t e Congo™ jr DMX Driver Chip Replacement Step 19: Slide the face panel back under the base pressure plate. Base Pressure Plate Step 20: Re-attach all 7 screws from each side of the console face panel. Step 21: Flip the face panel over and tighten the 3 screws on the base of the console.
Page 38 E T C S e r v i c e N o t e Congo™ jr DMX Driver Chip Replacement Con go ™ jr DMX Dr iv er Ch ip Re pl ac emen t Pa ge 3 4 El ect r on ic T he at r e Con tr o ls , I nc.
Page 39: Power Supply Replacement
#1 Phillips Screwdriver Side Cutter 4 Replacement zip ties Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 40 E T C S e r v i c e N o t e Congo™ jr Power Supply Replacement Step 5: Flip the console back onto the base. Step 6: Lift the back side of the face panel upwards away from the base. Step 7: Slide the face panel towards the front of the console.
Page 41 E T C S e r v i c e N o t e Congo™ jr Power Supply Replacement Step 10: Remove the base cover and set aside. Step 11: Locate the Power Supply and cut the zip tie around the large bundle of cable. Step 12: Disconnect the motherboard power connector.
Page 42 E T C S e r v i c e N o t e Congo™ jr Power Supply Replacement Step 14: Cut both zip-ties and disconnect the Motherboard Aux Power. Step 15: Remove the 4 Screws holding the Power Supply in place. Remove these 4 screws Step 16: Swap out the power supply for a new power supply.
Page 43 E T C S e r v i c e N o t e Congo™ jr Power Supply Replacement Step 20: Re-connect the 2 Power connectors back into the power supply. Re-connect these 2 power connectors Step 21: Re-connect the large Motherboard connector into the Motherboard. Step 22: Place a 4"...
Page 44 E T C S e r v i c e N o t e Congo™ jr Power Supply Replacement C on go ™ jr P ow er S upp ly R e pl ace men t Pa ge 4 0 E l ect r on ic T he at r e C on tr o ls , I nc.
Page 45: Main Board Replacement
5/16" nut driver Right angle hex key (0.050) 4" Replacement zip ties Pr ocedure: Step 1: Remove the protective side panels from the Congo JR Console. Step 2: Remove the 7 screws indicated in below. Step 3: Loosen the 3 screws indicated in Blue below.
Page 46 E T C S e r v i c e N o t e Congo™ jr Main Board Replacement Step 4: Carefully flip over the console and loosen the 3 screws in blue below: NOTE: DO NOT remove the 3 screws. Loosen these screws Step 5: Flip the console back onto the base.
Page 47 J1 USB Uplink Step 10: Clip the zip ties holding the face panel cables to the base of the unit. Step 11: Carefully set the Congo jr face panel face down exposing the back side of the face panel PCB.
Page 48 Step 14: Lightly lift each side of the LCD screen socket circuit board to remove the LCD screen from the Congo jr face panel and set it aside. Step 15: With the LCD screen removed from the face panel, you can now access the encoder knob shafts.
Page 49 E T C S e r v i c e N o t e Congo™ jr Main Board Replacement Step 23: Remove the level wheel ribbon cable from the encoder board. Step 24: Clip the 2 zip ties attached to sticky backs on the keypad reinforcement plate. Step 25: Disconnect the following headers from the motherboard.
Page 50 E T C S e r v i c e N o t e Congo™ jr Main Board Replacement Step 30: Move the USB key to the new face panel and replace the zip tie. Step 31: Replace all 32 screws that hold the face panel motherboard in place. Step 32: Re-connect the encoder board and encoders.
Page 51 E T C S e r v i c e N o t e Congo™ jr Main Board Replacement Step 38: Slide the face panel back under the base pressure plate. Base Pressure Plate Step 39: Re-attach all 7 screws from each side of the console face panel. Step 40: Flip the face panel over and tighten the 3 screws on the base of the console.
Page 52 E T C S e r v i c e N o t e Congo™ jr Main Board Replacement Con go ™ jr Mai n Boa r d Repl ac eme nt Pa ge 4 8 El ect r on ic T he at r e Con tr o ls , I nc.
Page 53: Master Wing Lcd Replacement
Soldering Iron Lead Free Solder Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Master Wing. Step 2: Place the master wing face down exposing the back side. Step 3: Remove the 20 screws indicated in below.
Page 54 E T C S e r v i c e N o t e Congo™ jr Master Wing LCD Replacement Step 7: Remove the 6 screws holding the LCD Jumper board in place. Step 8: Gently lift up all 3 Master LCD jumper boards; removing all the pins from each socket. Step 9: Lift both LCD screens from the center and gently lift the screens away from the master wing.
Page 55: Master Wing Main Board Replacement
Tools Required: #1 Phillips Screwdriver Pr ocedure: Step 1: Remove the protective side panels from the Congo jr Master Wing. Step 2: Place the master wing face down exposing the back side. Step 3: Remove the 20 screws indicated in below.
Page 56 E T C S e r v i c e N o t e Congo™ jr Master Wing Main Board Replacement Step 7: Remove the 6 screws holding the LCD Jumper board in-place. Step 8: Gently lift up all 3 Master LCD jumper boards; removing all the pins from each socket. Step 9: Lift both LCD Screens from the center and gently lift the screens away from the master wing.
Page 57: Congo™ Jr V4.3 I/O Software Code Installation
Congo™ jr v4.3 I/O Software Code Installation Description: This service note describes how to install new I/O firmware for your Congo jr console. This version of firmware fixes a software bug that caused the DMX power supply to be under powered; resulting in flickering levels or loss of control of some DMX devices.
Page 58 E T C S e r v i c e N o t e Congo™ jr v4.3 I/O Software Code Installation Step 9: At the Main login Screen, click on the System Settings button Step 10: The following window will pop up: Step 11: Click on the software update button Step 12: The following window will pop up: C on go ™...
Page 59 E T C S e r v i c e N o t e Congo™ jr v4.3 I/O Software Code Installation Step 13: Wait until the window displays "Please load Firmware File" Note: It may take up to 10 seconds for this message to be displayed Step 14: Click on the File button Step 15: Browse to the USB Flash Drive's software folder Step 16: Select the file labeled"...
Page 60 Step 21: Remove the USB flash drive while the Congo jr is rebooting Step 22: After the Congo jr has rebooted, at the main login screen, select shut down. Physically switch off the desk and back on.
Page 62 Americas 3031 Pleasant View Road, P.O. Box 620979, Middleton, Wisconsin 53562-0979 USA Tel: +1 608 831 4116 800 688 4116 Fax: +1 608 836 1736 800 555 8912 Europe Unit 5, Victoria Industrial Estate, Victoria Road, London W3 6UU, UK Tel: +44 (0)20 8896 1000 Fax: +44 (0)20 8896 2000 Asia Room 605-606, Tower III Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Kowloon, Hong Kong Tel: +852 2799 1220 Fax: +852 2799 9325 Web: www.etcconnect.com...