Owen T. Heisler

Last updated 2019-10-09

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This document lists the required parts and steps for building System Design 3.

Please note, these steps have not been tested from beginning to end, but were written while building the system. There may be some inconsistencies here. If you notice any inconsistencies or other problems, please let me know (see Feedback).

Parts List

The following parts are necessary to build the rack part of the system:

For the custom 70V transformer boxes:

You will also need this bulk cable (for both the rack part of the system and the 70V transformer boxes):

These accessories are also necessary (must be stored and transported in a separate container):

Also consider the following (not tested):

Building the Main System

  1. Install the CyberPower power supply in the bottom space of the rack. Connect four power cables (for the other devices) to the first four (black) outlets on the rear.

  2. Open the DA-250FH amplifier and set the input sensitivity and high-pass filter jumpers. Input sensitivity should be set to -10 and the high pass filter should be set to ON. See page 13 of the manual. The three rear switches (near the inputs) should be OFF (out).

  3. Install the DA-250FH amplifier above the power supply, and connect the power cable.

  4. Install the dbx equalizer above the amplifier, and connect the power cable.

  5. On the rear of the M-633D mixer, switch all 6 input selector switches to LINE.

  6. Install the M-633D mixer above the equalizer, and connect the power cable.

  7. On the rear of the Revolabs receiver, switch all configuration DIP switches to the OFF (upward) position.

  8. Important: update the Revolabs firmware (base unit and all microphones) using the HD Control Panel software.

  9. Install the Revolabs receiver at the top space of the case and connect the power cable.

  10. Install 10 Neutrik D-size panel receptacles in the patch panel:

    1. XLR female (marked with F and has a PUSH release tab)
    2. XLR male (marked with M)
    3. speakON (twist connector)
    4. XLR male
    5. speakON
    6. XLR male
    7. speakON
    8. XLR male
    9. XLR male
    10. speakON
    11. (empty)
    12. (empty)
  11. Cut cable to 60 cm (2 ft) lengths. You need:

    • 14 pieces of Belden 9451 and
    • 6 pieces of Wes Penn 25225B.
  12. Connect the first 6 Revolabs outputs to the corresponding M-633D mixer inputs.

    Signal Connections

    Signal Connections

  13. Use cables to connect equipment according to the following signal diagram. Note, XLR connections are 1=earth/ground, 2=hot, and 3=cold.

    Signal Connections

    Signal Connections

  14. Use power cables to connect equipment according to the following diagram. The CyberPower BB outlets are battery-backed in case of a power outage, and are also controlled by the front switch. The S outlets are not battery-backed and are always on. It is important to connect these correctly so the charger base is powered while the system is off.

    Power Connections

    Power Connections

  15. Install the rear patch panel to the rear rack.

  16. Place labels. See Labels (PDF) (Inkscape SVG source).

Building the Custom Transformer/Splitter Boxes

Follow these instructions once for each of the two transformer boxes.

  1. Screw the top cover onto the Polycase enclosure, if it is not already.

  2. Use this template (PDF) (LibreCAD DXF source) to drill six small holes and three large holes on the front side of the Polycase enclosure. It may help to print extra templates, and to tape the template onto the enclosure while drilling.

  3. Use the same template to drill two small holes and one large hole on the rear side of the enclosure.

  4. Remove the top cover and drill two small holes in the bottom of the box for mounting the Atlas Sound T-20 transformer. Be sure to leave room for the speakON connectors; insert a speakON connector in each of the four holes to be sure.

  5. Make the following connections. The transformer connections must be soldered. It may be helpful to use a plastic tie strap around the transformer to stabilize the wires during soldering, as well as for handling in the next step. For more information about the Atlas T20 transformer, see the datasheet (PDF).

    Transformer Box Connections

    Transformer Box Connections

    Inside the 70V transformer/splitter box

    Inside the 70V transformer/splitter box

  6. Use the #4-40 x 1 inch screws/nuts to mount the transformer and speakON panel connectors. It might be easier to start with the front left connector and work around counter-clockwise before mounting the transformer last.

  7. Screw the top cover onto the enclosure again.

  8. Place the label on the top cover. See the Labels (PDF) (Inkscape SVG source).