LION KING JR // MASTER TECH PORTAL
Wireless-only build · 6 cast channels + flexible music source · dual mono PA · 2 lights + 2 pedals.
All pans center · L+R faders together · single-fault tolerant via hot-spare packs.
REFBuild Profile & Signal Flow
Whole system on one chart — print, tape inside the road case lid
★Show Identity
Production
Show Title: Disney's THE LION KING JR · 60 min runtime
Tech Lead:
Show Date:
Doors / Curtain:
Venue:
Quick Stats — Live from Inventory
| Total wireless channels | — |
| Total wired mics | — |
| Mixers on hand | — |
| Speakers / PA | — |
| Light fixtures | — |
| Foot pedals | — |
⚡Operator's Mantra
Faders down → trim with PFL + PEAK LED → channel faders to unity → mix with MAIN.
Phantom only for condensers. Cut before boost on EQ. Watch the meters, not the room.
INVEquipment Inventory · Live Manifest
How this works
Edit any quantity, model, or status. Changes save automatically and propagate to the Dashboard, the Channel Map, the Hookup SOP, and the Sign-Off page. Click + Add to extend a category. Click × to remove. Click a category header to collapse.
CHMixer Channel Assignment Map
Channel rows scale with your wireless channel count. Fill in cast member names during mic-up.
| CH | Source | Cast Member | Capsule | Pack # | Battery Fresh |
|---|
$Lean Buy Reference
| # | Item | Spec | Qty | Total |
|---|---|---|---|---|
| 1 | Wired vocal mic | Shure SM58 (not purchased — wireless-only build) | 0 | — |
| 2 | XLR 25 ft | Hosa HXX-025 | 1 | $18 |
| 3 | Boom mic stand | On-Stage MS7701B | 1 | $30 |
| 4 | Cable ramp 5-ch | 36" rubber drop-over, 18000 lb | 1 | $55 |
| 5 | Gaff tape 2" | Pro-Gaff black (NOT duct) | 1 | $22 |
| 6 | Battery brick | AA 24-pack + 9V 4-pack | 1 | $25 |
| TOTAL OUT-OF-POCKET (revised) | $150 | |||
0Pre-Flight (Day Before · Bench Test)
Wireless out-of-box & sync
- PTU-7000-4B unboxed: 1 receiver, 4 bodypacks, 4 headsets, 4 lavs, 4 antennas, 8 AA, power adapter, 1/4" cable — all present.
- Both BNC antennas snapped onto receiver, vertical orientation.
- Receiver powered, all channels light up.
- 2× AA installed in each bodypack with correct polarity (verify yourself — don't trust the kid).
- Each bodypack IR-synced to its receiver channel (frequency match confirmed).
- Headset/lav capsules plugged into bodypacks (mini 3-pin TA4F XLR, screw collar tight).
- Auto-scan run on each channel; clear UHF frequency locked with SET.
- NEW WIRELESS PAIR: 2 added bodypacks IR-synced to clean frequencies (no overlap with existing 4 channels).
- Shure BLX bodypacks (from carry case): TA4F connector confirmed clean, no bent pins. Mute slide tested.
Bench audio test
- Each receiver channel XLR out tested — audio passes to mixer/headphone amp.
- Mute switch on every bodypack tested.
- Range test — talk while walking 50 ft from receiver, no dropouts.
- Deep-backup gear (Phenyx 4ch + Shure BLX) stored offstage and accessible if 8ch rcvr fails catastrophically.
- Existing portable battery PA fully charged (24-hour soak) and tested at half-volume.
- Existing 8-ch powered mixer — every channel passes signal, no scratchy faders, no idle hum.
- Cast monitor combo amp — clean signal at low level, no buzz.
- Chauvet 4BAR Quad + SlimPar bar fixture power on; both foot pedals respond (tap test).
- All XLR cables continuity-tested; bad ones flagged & set aside.
- Music source bench-tested: phone playlist plays through Ch 6/7 line input, stereo verified.
- USB/SD media playback tested on mixer's onboard player (FAT32 stick, MP3/WAV).
1Position Gear · Load-In T-3:00
| Position | Place | Why |
|---|---|---|
| Portable battery PA | Stage center-front, top of speaker at standing-audience head height (~6 ft) | Direct line-of-sight to seats. Higher = better throw to back row. |
| Mixer (FOH) | Same plane as last row of audience seating, off to one side aisle | You mix what the audience hears. Never mix from under the speaker throw. |
| Wireless receiver(s) | Next to mixer at FOH, antennas vertical, line-of-sight to stage | RF needs sight to bodypacks. Behind cinder-block wall = drops. |
| Combo amp (cast monitor) | Upstage center, tilted up at performers, behind playing area | Cast hears themselves; audience does not. |
| Chauvet SlimPars (light #1) | Front-of-stage on floor or short stand, 45° to talent | Front wash from below = lit faces. |
| Chauvet 4BAR Quad (light #2) | Upstage on T-bar stand, sandbagged | Back/depth color wash. Sound-active or pedal-controlled. |
| Foot pedal #1 (4BAR RF) | FOH or backstage operator station, in 100 ft RF range | Blackout for speeches. |
| Foot pedal #2 (DMX/lighting) | FOH operator position | Manual control on second light fixture. |
| Power strip | FOH location, cable taped down to seat-aisle floor | Single point for all FOH gear power. |
Wireless Receiver Rack
Bodypack · TA4F (Mini-XLR) Connection
2Connect Cables · All Gear OFF
2A — Wireless receiver(s) → mixer
- Take 6× XLR 25 ft (M-F). Label with masking tape:
RCVR CH1,RCVR CH2,RCVR CH3,RCVR CH4,WL CH5,WL CH6. - Phenyx receiver back panel has 4 individual XLR outputs — one per channel. Plug male end into rcvr Ch 1 XLR out.
- Run cable to mixer. Plug female end into mixer Ch 1 XLR/mic input.
- Repeat for Ch 2, 3, 4. Each Phenyx channel gets its own mixer channel — never combine.
- Two new wireless bodypacks (additional set): receivers feed mixer Ch 5 + Ch 6 if you have channels free; otherwise reassign per channel map.
2B — 8-Channel Receiver → Mixer (Ch 1-6 all at once)
- Position the 8-channel receiver at FOH on stable surface, all 4 antennas vertical, line of sight to stage.
- Connect 6 XLR cables: receiver Ch 1 OUT → mixer Ch 1 MIC in, receiver Ch 2 OUT → mixer Ch 2, and so on through Ch 6. Use the two NEW 6ft XLR cables for the two shortest runs (typically Ch 1 + Ch 2); longer 25ft XLRs for the rest.
- Receiver Ch 7 and Ch 8 OUTs are left disconnected at the mixer — these channels hold spare bodypacks ready for IR re-sync if any of Ch 1-6 fails.
- Plug in receiver DC power. Power up. Confirm all 8 channel displays show their assigned frequency.
- If the receiver has a MIC/LINE switch (some have it, some do not): set to MIC since we are going into the mixer MIC XLR jacks.
- Verify pans on mixer Ch 1-6 are all at center detent for dual-mono operation.
2C — Music source → mixer
- Stereo 1/8" → 2× 1/4" TS cable.
- 1/8" end into headphone jack of phone/tablet/laptop running playlist.
- Two 1/4" ends into mixer Ch 6 (left/red) and Ch 7 (right/white) LINE inputs.
- Pan Ch 6 hard left, Ch 7 hard right.
- Alternate: Use the mixer's onboard USB/SD slot — see Music Playback tab.
2D — Mixer → portable PA
- XLR 25 ft, male into mixer Main Out (Mono XLR if available, otherwise use Left only).
- Female end into portable PA Mic/Line input (XLR or 1/4" combo jack on rear panel).
- Stereo XLR Mains: use Left only for mono PA — running mono is fine for speech.
2E — Mixer → combo amp (cast monitor)
- 1/4" TRS instrument cable, 10 ft.
- Mixer Aux 1 Send output → combo amp 1/4" line input. NOT speaker out. NOT headphone jack.
- Combo amp tone knobs: bass at 12 o'clock, mids at 12, treble at 11 (cut highs to reduce feedback).
2F — Lighting power & foot pedals
- 4BAR Quad: IEC into surge-protected outlet on a separate circuit from mixer (if available).
- SlimPars: same — separate circuit prevents 60 Hz hum bleed-through.
- Foot pedal #1 (Chauvet RF wireless): 9 V battery fresh, station within 100 ft of 4BAR.
- Foot pedal #2 (DMX/auxiliary): connect per fixture-specific run.
3Power-On Sequence (Order Matters)
| # | Power on | Why this order |
|---|---|---|
| 1 | Mixer (master fader DOWN, all channel faders DOWN, phantom OFF) | Mixer comes up clean before downstream gear can hear it. |
| 2 | Wireless receiver(s) | Source first, ready to feed signal. |
| 3 | Bodypacks (one at a time, confirm each on rcvr RF + AF meters) | Watch each channel's meters light up. |
| 4 | Combo amp (volume knob at 0) | Monitor amp on, but silent. |
| 5 | Portable PA (volume knob at 0) | Main PA on LAST. Always. |
| 6 | Lighting fixtures + foot pedals | Independent circuit, doesn't affect audio. |
4Gain Staging · Per Channel
Sequence — execute for every active channel
- Press PFL button IN on the channel being set.
- Talent speaks/performs at full performance volume.
- Slowly rotate TRIM CW until the PEAK LED flickers red on loudest peaks.
- Back off TRIM ~3 dB. PEAK should rarely flash, never stay solid.
- Release PFL (button OUT).
- Repeat for every active channel.
- Set each active channel fader to 0 dB unity.
- Set HPF / low-cut at 80 Hz on every vocal channel.
- Adjust LEFT and RIGHT MAIN faders together to set room volume.
5Ring Out the Room
- House at show level. All cast mics live, faders at unity.
- One channel at a time, slowly bring channel up beyond unity until it just begins to feedback.
- Identify the freq (sharp ringing tone — usually 2–4 kHz in a gym).
- Pull that frequency 3–6 dB on the channel EQ (use mid-sweep on the mixer if available).
- Bring channel back to unity. Repeat for each channel.
Feedback Frequency Map (squeal → cut here)
- HIGH squeal (~2 kHz): cut 1 kHz / 4 kHz sliders
- MID honk (~500 Hz): cut 350 Hz slider
- LOW howl (<150 Hz): cut 80 Hz slider
- Always first: pull mic away from monitor.
M8-Channel Powered Mixer · Operator Manual
Channel Strip Anatomy · Top to Bottom
Field Condition Reference · This Unit
Master Section · Graphic EQ · Output
Field Condition Flags · This Unit
- EFFECT return fader is taped over with NO MIC / NO MORE tag — treat as DISABLED. Do not raise. Run dry if FX needed.
- LEFT MAIN fader cap is missing — metal stub functional. Match RIGHT visually using dB scale.
- PHANTOM is GLOBAL across all 8 XLRs. NEVER engage with ribbon or older bodypack capsules connected.
- Channel labels (Ch 1–4) are tape labels — verify before each event.
Pre-Flight Checklist · Before Power-On
- All channel faders 1–8 → ∞ (bottom)
- EFFECT, LEFT MAIN, RIGHT MAIN faders → ∞
- All TRIM (red) → fully CCW (minimum gain)
- All SEND/EFF (blue) → 0
- All PAN (yellow) → center detent
- HI / LOW EQ knobs → 0 (flat)
- Graphic EQ (5 sliders) → 0 dB (flat)
- AUX / EFF RETURN / DELAY → 0
- PHANTOM (+48V) OFF — LED dark
- PHONE LEVEL → 0
- Speaker cables landed BEFORE applying power
EQ Reference · Per Source Type
| Source | LOW 80 Hz | HI 12 kHz | Graphic EQ Tweak |
|---|---|---|---|
| Male vocal | 0 to -3 | +2 to +4 | Pull 350 Hz down 2-3 dB if muddy |
| Female vocal | 0 | +3 to +5 | Pull 1 kHz down 2 dB if honky |
| Speech / lectern | -4 (cut rumble) | +3 (presence) | Push 4 kHz +2 for intelligibility |
| Acoustic guitar (DI) | 0 | +2 | Pull 80 Hz on Graphic if boomy |
| Music playback (USB/SD) | 0 (flat) | 0 (flat) | Flat — let the source do its work |
Always cut before you boost. Boosting eats headroom and invites feedback.
Effects Routing
- Channel SEND/EFF (blue) routes that channel's signal to the onboard FX engine.
- Master EFF RETURN sets the wet signal level returned to the mix.
- Master DELAY sets the delay time / mix.
- Vocal reverb starting point: channel SEND/EFF at 2-3, master EFF RETURN at 3, master AUX RETURN at 0.
- This unit's EFFECT return fader is disabled. Verify wet signal via PFL before relying on FX live. If no wet signal, run vocals dry.
Master Output & Level Targets
- L/R LED meter target: signal averages in green +0 zone, peaks tickle yellow +4. Sustained red +7 = clipping at master bus, correct immediately.
- LEFT and RIGHT MAIN faders run together at approximately 0 dB unity for normal operation.
- To reduce room volume, pull MAIN L/R together. Do NOT pull individual channel faders for room volume.
📐Mixer Anatomy · Labeled Controls
Eight identical channel strips feed a master section
Mental model: Sound flows top-down on each channel — input at the back panel → preamp (TRIM) → EQ → FX send → fader → MAIN bus → master output. Master section sums everything, applies graphic EQ, sends to speakers.
Learn one channel — you know all eight
0 = dry (no FX), 10 = full wet send. Vocal reverb starting point: 2-3.0 dB mark (about 3/4 up). Mix the room from MAIN — leave channels at unity once gain-staged.Signal flow within the strip: XLR/Line input → TRIM (gain) → HI/LOW EQ shelves → SEND tap (parallel to FX) → PAN → Channel Fader → MAIN bus. PFL listens after EQ but before fader (so you can stage independent of mix volume).
FX returns · graphic EQ · phantom · monitoring · main faders
3 (~30%).0 = off. 2 = subtle slap echo on vocals.2, raise to comfortable listening level.Inputs along the back edge · USB/SD media player at the top right
Media player vs CH8/USB: The USB IN at the top of the master section is for stick playback (MP3/WAV → onboard player). A separate CH8/USB port (if present) accepts USB-B from a laptop for digital audio input. Different ports, different jobs.
🎯Operator's Mantra
FADERS DOWN → TRIM W/ PFL+PEAK → CHANNEL FADERS TO UNITY → MIX W/ MAIN
Phantom only for condensers · Cut before boost on EQ · Watch the meters, not the room
★ SMART CONFIG // OPTIMAL SOP
5 wireless leads + wired MC/backup + stereo iPhone music. Hot spares staged at FOH.
The Decision (and why)
Real rig confirmed: single 8-channel UHF wireless receiver as primary, 8 matching bodypacks, 2 speakers, 2 lights. Peak 5–6 cast on mic simultaneously. Music source remains TBD per show day. The single-brand wireless system replaces the mixed Phenyx + Shure setup we originally planned around — same hardware, much simpler workflow.
5 wireless + 1 spare ch + 2 music · DUAL MONO
Five cast leads on Mixer Ch 1-5 from 8ch Rcvr Ch 1-5. Mixer Ch 6 stays as a floating emergency slot, muted at startup. Receiver Ch 6, 7, and 8 each hold a pre-synced spare bodypack. Music channels labeled generic — works with iPhone Lightning, laptop 1/8″, USB-C dongle, or stay muted. All pans CENTER. Both speakers play identical mono mix.
5 wireless + spare ch + 2 music
Wastes a channel. Does not cover the peak scenes where 6 leads are on mic at once.
True stereo PA
Music gets L/R imaging. In a wide gym with kids walking across stage, voices would seem to shift between speakers. Not worth the trade.
Why dual mono wins for the gym: wide audience spread means no single "stereo sweet spot," kids in seat 1 hear the same mix as kids in seat 40. Why generic music channels: source device is not locked yet — patching is identical no matter what plugs in. Failover: 3 hot-spare wireless packs at FOH (2 new + Shure BLX#2 if available). Drop = mute, swap pack at next break.
CHOptimal Channel Allocation
| CH | Source | Cable | Role | PAN | Gain |
|---|---|---|---|---|---|
| 1 | 8ch Rcvr Ch 1 XLR out | NEW XLR 6ft | Lead 1 | CTR | PFL+PEAK · unity |
| 2 | 8ch Rcvr Ch 2 XLR out | NEW XLR 6ft | Lead 2 | CTR | PFL+PEAK · unity |
| 3 | 8ch Rcvr Ch 3 XLR out | XLR 25ft | Lead 3 | CTR | PFL+PEAK · unity |
| 4 | 8ch Rcvr Ch 4 XLR out | XLR 25ft | Lead 4 | CTR | PFL+PEAK · unity |
| 5 | 8ch Rcvr Ch 5 XLR out | XLR 25ft | Lead 5 | CTR | PFL+PEAK · unity |
| 6 | (SPARE — unused at startup) | No cable patched | Floating emergency slot | CTR | Fader DOWN · muted |
| 7 | Music source · L tip (iPhone, laptop, or device TBD) | Match to device · see Music Playback tab | Music L | CTR | TRIM ~9 o'clock |
| 8 | Music source · R tip (iPhone, laptop, or device TBD) | Match to device · see Music Playback tab | Music R | CTR | TRIM ~9 o'clock |
SPKSpeaker Output · Dual Mono Setup
Two speakers, identical signal in each. No L/R imaging weirdness, no fader-balance riding.
| From | Cable | To |
|---|---|---|
| Mixer MAIN OUT L | XLR or 1/4" (per speaker input) | Speaker A (audience left) |
| Mixer MAIN OUT R | XLR or 1/4" (per speaker input) | Speaker B (audience right) |
SPAREHot Spare Strategy
These packs sit at FOH, batteries fresh, IR-synced and ready. If any of CH 1-5 fails, swap in <30 sec.
| Spare | Synced To | Covers If… |
|---|---|---|
| Spare pack A (parked on Rcvr Ch 6) | Pre-synced to Ch 6 frequency | Any of Ch 1-5 cast fails — IR re-sync to failed channel in seconds |
| Spare pack B (parked on Rcvr Ch 7) | Pre-synced to Ch 7 frequency | Second simultaneous failure OR pre-positioned for scene-change handoff |
| Spare pack C (parked on Rcvr Ch 8) | Pre-synced to Ch 8 frequency | Third spare — triple-fault tolerance OR cast addition mid-show |
| Spare headset/lav capsule | TA4F connector ready | Capsule failure separate from pack failure |
♪Music Source · Plug-In Day Of
Source device is not locked. Whoever brings music plugs in at sound check. Channel 7 and 8 LINE inputs are ready for any of these:
| If the source is... | Use this cable | Path |
|---|---|---|
| iPhone with Lightning port | NEW Lightning → Dual 1/4″ TS | Direct digital out of phone, no headphone-jack DAC |
| iPhone with USB-C, iPad, or laptop | 3.5mm headphone jack → 1/8″ → Dual 1/4″ TS (existing) | Analog out of device, into mixer LINE in |
| Laptop with USB audio out | USB-B cable into mixer CH8/USB rear port if available | Pure digital path, no analog conversion |
| No music source brought | Leave Ch 7 & 8 muted | Show runs on cast dialogue + ensemble singing alone |
If iPhone or iPad — Lock These Settings Before Doors
If Laptop — Lock These Settings
PWRPower-On Sequence · Optimal Order
- Mixer — all faders DOWN, all TRIM CCW, PHANTOM OFF. Verify field-flag tape on EFFECT fader.
- Phenyx 4ch wireless receiver — confirm all 4 channels show frequency on display.
- Shure BLX receiver — confirm RF + AF when bodypack hot.
- All bodypacks — power one at a time, watch corresponding receiver meters light up.
- Combo amp (cast monitor) — volume knob at 0, power on.
- Portable PA (mains) — volume at 0, power on LAST in the audio chain.
- 4BAR Quad rear switch ON — IR enabled, Snd2 mode, SEnS u 50, dimmer L.255.
- SlimPar rear switch ON — sound-active mode OR scene color.
- Both foot pedals — 9V batteries fresh, range-test within 100 ft of fixtures.
- iPhone — Lightning cable seated, airplane mode + DND on, playlist loaded, volume 75%.
- Bench-test music — play 5 sec, confirm L/R hit Ch 7/8 LINE inputs (PFL each).
- Gain stage each cast channel using PFL + PEAK LED method (Faders Down → TRIM until PEAK flickers → -3 dB → fader to unity).
💡Lighting Configuration · Both Pedals Mapped
| Fixture | Position | Mode | Pedal Control |
|---|---|---|---|
| 4BAR Quad | Upstage on T-bar stand, sandbagged | Snd2 (smooth multi-color), SEnS u 50, L.255 | Pedal #1 (Chauvet RF 4-pedal): Pedal 4 = BLACKOUT during speeches |
| SlimPar | Downstage floor, 45° to talent — front wash | Sound-active OR static white/scene color per cue | Pedal #2: Static dim / blackout for the front wash independently |
→Aux Send Routing · Use the Y-Splitter
Smart use for one of the new 1/4" TS Y-splitters:
- Mixer Aux 1 SEND (1/4" TRS) → male end of Y-splitter.
- Y-splitter dual outputs → (a) combo amp for cast monitor, (b) recording device (digital recorder or laptop audio interface) for show capture.
- Single Aux send feeds both monitor AND recording. No extra hardware. Free archival of every show.
🎯Final Verification · Pre-Doors Gate
All 10 boxes Pass before doors open. Any Fail = blocker.
- Phenyx 4 channels: RF + AF on every receiver display. Talent walked stage edges — no dropouts.
- Shure BLX (CH 5): RF + AF confirmed, mute tested.
- 2nd wireless system (CH 6): RF + AF confirmed, mute tested.
- Music source identified for tonight (iPhone / laptop / none). Correct cable selected and patched into Ch 7/8 LINE in — OR channels muted if no music.
- Source device settings locked per Music Source tab (Airplane Mode / sleep off / vol 75% / etc.).
- All PAN knobs on Ch 1-5 (cast) and Ch 7-8 (music) set to CENTER detent. Ch 6 fader DOWN and muted. Verified visually.
- LEFT MAIN and RIGHT MAIN faders matched at same dB position.
- Hot spares staged at FOH: 3 bodypacks with fresh AA, IR-sync verified.
- 4BAR Quad: Snd2 active, Pedal #1 tested, blackout in <1 sec.
- SlimPar: front wash on, Pedal #2 dim/blackout independent.
- Cable safety: every audience walking path clear, ramps placed, gaff tape down.
Single 8ch wireless rcvr · 5 cast leads + 3 hot spares · music flexible · dual mono PA · 2 lights · 2 pedals.
All pans center. L+R faders together. Mix from MAIN.
♪Music Playback · Three Paths
Path A · Onboard USB/SD Media Player (easiest)
- Format a USB stick or SD card to FAT32.
- Drop MP3 or WAV files onto it. Number them
01_intro.mp3,02_scene1.mp3, etc. for predictable order. - Insert stick/card into slot at the top of the master section.
- Press PLAY/PAUSE.
- PREV / NEXT skips tracks.
- EQ button cycles preset EQ profiles for the player only — does NOT affect mic channels.
Path B · Phone / Laptop Line-In (most flexible)
- Stereo 1/8" → dual 1/4" TS cable.
- 1/8" end into headphone jack of phone/tablet/laptop.
- Two 1/4" ends into mixer Ch 6 (left) + Ch 7 (right) LINE inputs on the back panel (not the front XLR/mic).
- Pan Ch 6 hard L, Ch 7 hard R.
- Set TRIM as you would any other channel — but don't expect PEAK to flicker on quiet music. Aim for steady -6 dBFS on transients.
- Mute Ch 6/7 at the board between music cues.
Path C · USB Audio (CH8/USB · digital)
- Many of these powered consoles route Ch 8 through a USB-B port labeled CH8/USB on the back panel.
- USB-B cable from mixer to laptop USB-A.
- Laptop sees the mixer as USB Audio output device. Select it in the OS sound settings.
- Audio routes to mixer Ch 8 — set the channel fader and trim like any line source.
Where the Media Player Lives
CUEShow-Day Music Cue Sequence
| Cue | Action | Mixer State |
|---|---|---|
| Doors | Preshow playlist on aux input @ -10 dB below show level | Music channel at -10 dB, all cast mics MUTED |
| House to half | Preshow music fade out over 8 seconds | Pull music channel slowly to -∞ |
| Cue 1 | Narrator enters | Music muted; unmute Narrator channel |
| Mid-show transition | Cue track 2, fade in -10 dB | Music up to -10, dialogue mics still live for cross-fade |
| Curtain call | Bow music to 0 dB | Music up to unity, cast mics ride balance |
| End | Outro music; mute all cast mics | Music continues, all mic channels muted |
L1Chauvet 4BAR Quad · Sound-Active SOP
Step 1 · Verify Model on the Bar
MODEL: 4BARQUAD on the top of the bar before proceeding.Control Panel Anatomy
MENU, UP, DOWN, ENTER. All menu sequences in this SOP use these four. Mic grille is on the front face — keep clear of dust/tape/stickers.Rear Panel Reference
Equipment Identification
- Model: Chauvet DJ 4BAR Quad (item code 10031614). Verify label on top of bar reads
MODEL: 4BARQUAD. - LED engine: 28 × Quad-color RGBA LEDs, 3.5 W each (7 LEDs per pod × 4 pods).
- Power draw: 80 W @ 120 V / 60 Hz.
- Voltage range: 100-240 VAC, 50/60 Hz auto-ranging.
- Fuse: F 1.6 A, 250 V — REPLACE WITH IDENTICAL TYPE ONLY.
- Beam: 14° / Field: 23°.
- Strobe rate: 0-20 Hz; PWM 1310 Hz.
- Weight: 12.2 lb · Dimensions: 46.7 × 12.8 × 4.8 in.
- Max ambient: 104°F (40°C). Convection cooled, IP20 indoor only.
- Required clearance: ≥20 in (50 cm) ventilation around fixture.
Field Condition Flags
Mode Configuration · 4 Sub-Procedures (~3 min total)
Step 1 · Enable IR / Footswitch Reception
MENU → SEt → ENTER → ir → ENTER → on → ENTER
Step 2 · Set Sound-Active Program
MENU → Snd → ENTER → (UP/DOWN to Snd2) → ENTER
Snd2 = recommended for student events (smooth multi-color wash). Snd5-Snd6 for high-energy dance segments only.
Step 3 · Set Sensitivity
MENU → SEnS → ENTER → (UP/DOWN to u 50) → ENTER
Adjust during sound check: barely reacts → raise to u 70-80. Pulses on every minor sound → drop to u 30-40.
Step 4 · Set Master Dimmer
MENU → d-- → ENTER → (UP to L.255) → ENTER
L.255 = full output (gym/large room) · L.180 = ~70% (smaller rooms) · L. 1 = nearly off.
Blackout · Foot Pedal Operation
- Operator stands within 100 ft of fixture with footswitch pedal accessible.
- Display shows current mode (e.g.
Snd2) — fixture in normal sound-active operation. - MC steps to microphone — operator TAPS Pedal 4.
- Lights extinguish in <1 second; display shows
FOOtindicating footswitch capture. - After speech, operator TAPS Pedal 4 again; lights resume immediately.
L2Operational Scenarios
| Scenario | Light state |
|---|---|
| Pre-event (house open) | Snd2 active, sensitivity u 50, dimmer L.255. Background music ~70 dB; lights provide subtle motion. |
| Speech / announcement | BLACKOUT via Pedal 4 (or IRC-6) BEFORE MC begins speaking. Hold for entire speech. Release after MC concludes. |
| High-energy dance segment | Switch to Snd5 or Snd6 for faster chase. Raise sensitivity to u 75 if needed. Dimmer L.255. |
| Speech-to-music transition | Lights blacked out during speech → MC says "now welcome the DJ" → operator releases blackout → DJ drops track → lights immediately reactive. |
Practice the speech-to-music handoff once before doors open.
RoSLion King JR · Show-Run Cue Sheet
| CUE | SCENE / SONG | LIGHT | SOUND |
|---|---|---|---|
| GO | House to half · pre-show music fade | House -50% | Music ↓ -∞ over 8s |
| CUE 1 | Circle of Life — Rafiki entrance, Pride Rock reveal | SlimPar warm wash 100% · 4BAR Snd2 sunrise colors | Music UP (track 01) · Unmute Cast Ch 1-5 as principals enter |
| CUE 2 | Grasslands Chant · Mufasa & Young Simba scene | Hold wash, 4BAR amber/gold | Mufasa CH 1 · Young Simba CH 2 · cast hot |
| CUE 3 | I Just Can't Wait to Be King | 4BAR Snd5 (high-energy chase), SlimPar bright | Music track 02 · Simba + Nala + zazu mics live |
| CUE 4 | Be Prepared · Scar & hyenas | 4BAR green/red ominous · SlimPar dim | Music track 03 · Scar CH 3 · Hyenas CH 4-5 |
| CUE 5 | Stampede sequence · Mufasa dies | BOTH PEDALS — full blackout on impact | Track 04 (loud, stinger ending) · all 6 cast mics MUTE on blackout |
| INT | INTERMISSION (if used) or seamless transition | House up 50% · stage out | Pre-recorded intermission music · ALL cast mics MUTED |
| CUE 6 | Hakuna Matata · Timon, Pumbaa, Simba grow up | Sunny wash · 4BAR Snd2 cheerful | Music track 05 · Timon CH · Pumbaa CH · adult Simba |
| CUE 7 | Can You Feel the Love Tonight | SlimPar romantic warm · 4BAR low purple | Music track 06 · Simba + Nala duet · ensemble support |
| CUE 8 | He Lives in You · Rafiki/Mufasa spirit | 4BAR ethereal blue/white · SlimPar dim | Music track 07 · Rafiki + Simba live · reverb on if available |
| CUE 9 | Final Battle · Pride Rock reclaim | 4BAR Snd6 dramatic chase · SlimPar red | Track 08 · all 5 cast hot · monitor for safety call |
| CUE 10 | Circle of Life (reprise) · finale + bows | Full warm wash · house up 50% | Music track 09 · all cast mics on for bows |
| END | House full · stage out · exit music | House 100% · stage dark | Track 10 outro · MUTE all cast mics |
RoSPre-Doors Verify · 5-Minute Check
- RF — walked stage with each pack hot; receiver shows solid 4-5 RF bars on all channels.
- Audio — each cast mic clear at FOH and back row; no hum, buzz, or crackle.
- Music — phone playlist plays through PA in stereo, no distortion.
- Monitor — cast on stage hears themselves clearly from upstage combo amp.
- CH 6 (2nd wireless system): RF + AF confirmed, mute tested.
- Lighting — 4BAR + SlimPars on; both foot pedals tested; sound-active chasing.
- Cable safety — every audience walking path checked; zero exposed cables.
- Spare batteries staged at FOH (ready for pack swap-out).
- All 6 wireless channels confirmed live, gain-staged. 3 hot spare packs at FOH.
- Show file / cue sheet in hand at FOH.
⊞Master Troubleshooting Matrix
Symptom × Likely Cause × First Action (≤30 sec) × If Fails × Severity. Five categories, 31 entries. Reference card during live show — first column matches what you hear, third column is what you do next.
| Symptom | Likely Cause | First Action (≤30 sec) | If That Fails | Sev |
|---|---|---|---|---|
| No sound, single channel | Channel muted at fader, TRIM at min, PFL stuck on another ch, cable unseated | Fader up, TRIM CW until PEAK flickers, release any held PFL, reseat XLR at both ends | Swap XLR cable. Try same mic in different channel to isolate strip vs source. | 1 |
| No sound, all channels | Master fader down, PA powered off, MAIN cable unplugged, +48V never engaged on condensers | Verify MAIN L/R faders at unity. PA powered + volume up. Cable from MAIN OUT seated. | Headphones into PHONES jack — if heard there, PA chain is bad, not mixer. | 3 |
| Quiet voice + loud handling thump | INVERTED gain staging: TRIM too low, master fader pushed too hot to compensate | Run 5-step Sound Fix (above). Reset → PFL → TRIM to PEAK → fader to unity. | If line-level rcvr feeding XLR mic input — switch rcvr to LINE or move cable to LINE jack. | 2 |
| Distortion / fuzz on a channel | TRIM clipping the preamp, source already overdriven before the board, bad cable | Reduce TRIM. Watch PEAK LED — should rarely flicker. Re-gain at lower input level. | Check phone/laptop output volume — if at 100%, drop to 75%. Swap XLR cable. | 2 |
| PEAK LED solid red | Channel clipping continuously | Reduce TRIM 6 dB IMMEDIATELY. Re-gain stage that channel from scratch. | If trim already at min and still clips — source level too hot at the source. | 3 |
| Output meter pinning red constantly | Master bus clipping — too many open channels at unity, or graphic EQ boosted everything | Pull MAIN L/R together by 6 dB. Verify graphic EQ sliders centered (0 dB), not pushed up. | Reduce channel faders globally — never compensate by pulling MAIN further down. | 2 |
| Volume jumps when fader moved | Scratchy/dirty fader contacts, fader cap stuck | Run fader full travel 10× to clean. Mark for service if persistent. | Move source to spare channel. Schedule fader replacement off-show. | 1 |
| Symptom | Likely Cause | First Action (≤30 sec) | If That Fails | Sev |
|---|---|---|---|---|
| Hum / 60-cycle buzz | +48V engaged on dynamic mic, ground loop from laptop, bad XLR shield | PHANTOM OFF unless condenser plugged. Lift ground on PA if switch present. Swap XLR. | Plug laptop into same circuit as PA, not separate outlets. DI box for laptop line-in. | 2 |
| Hiss / white noise floor | TRIM too high (preamp gain noise), cheap unbalanced 1/4" cable on long run | Re-gain stage to drop TRIM. Replace 1/4" lines with TRS balanced or XLR runs. | Pull HI 12kHz shelf -3 dB on idle channels. Mute unused channels. | 1 |
| Feedback HIGH squeal (~2 kHz) | Stage monitor wash hitting open mic, mic too close to PA | Pull mic away from monitor. Cut graphic EQ 1 kHz / 4 kHz sliders -3 dB. | Reduce monitor send level. Check mic position relative to PA throw axis. | 3 |
| Feedback MID honk (~500 Hz) | Room resonance, omnidirectional pickup, mic in corner reflection | Cut graphic EQ 350 Hz slider -3 dB. Reposition mic. | Move mic 6" off the wall. Switch to cardioid pattern if mic supports. | 2 |
| Feedback LOW howl (<150 Hz) | Boomy room, mic too close to subwoofer, wireless rcvr line-level into mic preamp | Cut graphic EQ 80 Hz slider -3 dB. HPF on channel (LOW shelf -4). | Reposition mic away from sub. Verify rcvr LINE/MIC switch. | 2 |
| Mic cuts in/out intermittently | XLR cable failing, loose TA4F on bodypack, RF dropout | Swap XLR cable FIRST (9 of 10 fixes). Reseat TA4F at bodypack. | Walk talent into clear RF sight-line of receiver. Check antenna orientation. | 3 |
| One side dead (L or R) | MAIN fader mismatch, PA cable, channel pan stuck | Match LEFT and RIGHT MAIN faders. Check pan knob center detent on stereo sources. | Swap PA L/R cables — if dead side moves, cable is bad. | 2 |
| Symptom | Likely Cause | First Action (≤30 sec) | If That Fails | Sev |
|---|---|---|---|---|
| No reverb / FX missing | EFFECT fader DISABLED on this unit (taped). SEND/EFF assign released. | Run vocals dry. Do NOT chase FX mid-event. Verify SEND assign button engaged. | Note for post-event repair. Bench-test FX path before next show. | 1 |
| FX wet but no dry signal | Channel routed only to FX bus, fader for that channel down | Channel fader to unity. Verify channel sends to MAIN, not solo to FX. | Hard-pull SEND/EFF knob to 0 to confirm dry signal returns. | 2 |
| Music plays but vocals don't over PA | Mic channels muted at board, PFL switch IN (only soloed channels heard) | Verify PFL/L-R switch OUT (not solo). Unmute mic channels at fader. | Confirm cast mics have RF + AF on receiver. | 3 |
| USB/SD media player skips or stutters | Cheap stick failing, file format incompatible, media drive corrupt | Re-format stick to FAT32, re-encode files as 320 kbps MP3. | Switch to phone line-in via Ch 6/7 instead. Bench-test new media before next show. | 2 |
| Symptom | Likely Cause | First Action (≤30 sec) | If That Fails | Sev |
|---|---|---|---|---|
| Lights won't turn on | Outlet dead, IEC unseated, rear power switch off, blown fuse | Verify outlet hot (test lamp). Reseat IEC both ends. Rear switch fully ON. | Check fuse F 1.6A 250V — replace with IDENTICAL only. If repeats, INTERNAL SHORT — stop. | 3 |
| Lights on but no music reactivity | Sound-active mode disabled, mic grille clogged, sensitivity too low | Confirm Snd2-Snd6 mode active (not C-- static). Check mic grille is clear. | Raise SEnS to u 70-80. Test by clapping near grille. | 2 |
| Lights stuck on one color | Custom color set in C-- or u-- mode, IRC-6 blackout latch | Power-cycle (off 5 sec, on). PRESS BLACK OUT button on remote first. | Re-enter SEt → ir → on. Rerun Snd2 mode set. | 1 |
| IRC-6 remote dead | Battery dead, remote latched in blackout, IR receiver blocked | Press BLACK OUT — most "broken remote" calls are inadvertent blackout. | Replace remote 9V battery. Confirm line-of-sight to fixture IR sensor. | 1 |
| Footswitch not responding | 9V battery dead, ir mode disabled in menu, RF range exceeded (>100 ft) | SEt → ir → on. Replace 9V. Move within 100 ft, line-of-sight. | Display should show FOOt when pedal received. If not — pedal pairing lost. | 2 |
| Wrong colors / dim output | Master dimmer not L.255, custom u-- mode active, single LED pod failing | d-- → L.255. Power-cycle. If still dim — single pod LED driver fault. | Single-pod fault = warranty claim. Chauvet US: 1-800-762-1084. | 2 |
| Repeated fuse blow | INTERNAL SHORT — do NOT re-fuse, do not power on | STOP. Tag fixture. Pull from inventory. | Warranty claim required. Document fuse rating + circumstances. | 3 |
| Smoke or burning smell | Catastrophic internal failure | UNPLUG IMMEDIATELY at wall. Do not power on. | Warranty claim. Discard if out of warranty — do not attempt repair. | 3 |
| Symptom | Likely Cause | First Action (≤30 sec) | If That Fails | Sev |
|---|---|---|---|---|
| No RF on receiver display | Bodypack off, battery dead, frequency mismatch | Power bodypack, fresh AA batteries, IR-sync to receiver channel. | Run auto-scan to find clean frequency, re-sync pack. | 3 |
| RF present but no audio (AF bars dead) | Bodypack mute switch ON, capsule unseated, mic gain at min | Slide mute OFF. Reseat TA4F connector with screw collar tight. | Check bodypack input gain menu (some units have variable gain). | 3 |
| Audio drops when talent moves stage left | RF shadow — receiver behind cinder block, antenna mis-oriented | Reposition receiver for line-of-sight. Antennas vertical, V-shape (not parallel). | Add active antenna distro if multi-channel system in same venue. | 2 |
| Multiple channels share same noise burst | Frequency conflict between bodypacks, or external RF interference (Wi-Fi, Bluetooth) | Re-scan all channels for clean frequencies. Space frequencies ≥250 kHz apart. | Identify external RF source. Move venue Wi-Fi router away from receiver. | 2 |
| TA4F connector pins bent or broken | Connector force-fit, dropped pack, corrosion | Inspect under light. Pin spacing must be uniform. | Replace bodypack OR repair connector at bench. Do NOT power-on with bent pins. | 3 |
🔧5-Step Sound Fix · Quiet Voice + Loud Handling Noise
Root cause: TRIM is too low and master fader pushed too hot to compensate. Master meter shows yellow+red. This amplifies handling noise more than voice.
Possible second issue: Wireless receiver outputting line level into a mic input — same exact symptom.
What to look for
- All channels show a frequency on display (e.g.,
553.000 MHz) - When someone talks into a wireless mic, that channel's AF (audio) bars move
- RF (radio) bars are lit on each active channel
Identify receiver's output type
- Look at the back of the wireless receiver at the cable connection
- Look for a MIC / LINE switch on the receiver — set it to LINE
- Note whether the cable is XLR (3-pin) or 1/4" (single jack)
Match the input type on the mixer
- Receiver is LINE on 1/4": plug into the BOTTOM jack (LINE) on CH1
- Receiver is MIC on XLR: plug into the TOP jack (XLR) on CH1
- NEVER plug both jacks at once on the same channel
Reset the channel
- Channel 1 fader → all the way down (∞)
- LEFT MAIN + RIGHT MAIN faders → all the way down
- TRIM (red, top) → fully CCW (minimum)
- HI 12k + LOW 80 (white) → 12 o'clock (flat)
- SEND/EFF (blue) → 0
- PAN (yellow) → center
Gain stage the channel
- Press PFL on CH1 (button IN)
- Talk into mic at performance volume, 6 inches away
- Slowly rotate TRIM CW until PEAK LED just barely flickers on loudest words
- Back off TRIM about 3 dB (tiny tick CCW)
- Release PFL (button OUT)
- CH1 fader → 0 dB unity (about 3/4 up)
- LEFT + RIGHT MAIN → 0 dB unity together
Test for partial connection
- With audio playing quietly, gently wiggle the 1/4" plug at the speaker end
- Then wiggle at the amp end (back of mixer)
- If volume jumps, drops, or crackles → cable or jack is bad
- Replace cable first (cheaper than re-soldering)
Healthy mixer state checklist
- TRIM around 10 o'clock (not min, not max)
- Channel fader at 0 dB unity (about 3/4 up)
- LEFT and RIGHT MAIN at 0 dB unity (matching positions)
- Master meter green +0 average, yellow +4 on peaks
- PEAK LED rarely flickers, never solid red
- Voice clear and present, not thin or distorted
- Tap on mic = loud but normal, not jarring
- No buzz, hum, or hiss when no one is talking
If it's STILL broken after all 5 steps
- Swap the suspect wireless pack with a hot spare bodypack. If spare works in same channel, the original pack is the issue. If spare also fails, the issue is in the rcvr, the cable, or the mixer channel.
- Check receiver's audio level/squelch menu — some units have output level that may be turned down.
- Bypass the speaker — plug headphones into the PHONES jack. If headphones sound great but speaker quiet, amp section or speaker cable is the problem.
- Check speaker impedance — back of speaker says 8Ω, amp says 4Ω-16Ω = compatible. Verify nothing else paralleled to that output dropping below 4Ω.
- Check the SEND/EFF Assign button (top of master section) — if pushed in when you don't want FX, can route signal weirdly.
90% of "quiet + noisy" sound problems are gain staging, not broken gear.
⚠Failure Protocols · Mid-Show
9Strike · Show + 0:30
- Master fader to -∞; all channels muted.
- Power-DOWN order: PA off → combo amp off → bodypacks off → wireless rcvr off → mixer off.
- PHANTOM (+48V) OFF — wait 10 seconds before unplugging condenser mics.
- Pull bodypacks from cast. Switch OFF. Pull batteries (corrosion kills packs in storage).
- Disconnect cables at gear end first, then run end. Coil over-under, velcro, label.
- Lighting: last song fades — operator activates blackout via pedal/remote.
- Wait minimum 60 seconds for LED housing to cool before powering off lighting.
- Lighting power off: rear switch OFF → unplug IEC at WALL FIRST, then at fixture.
- Coil cable in figure-8 pattern (prevents kinking).
- Inspect 4BAR mic grille for confetti/dust; gently clear with compressed air if needed.
- Foot pedals: remove batteries (9V from 4BAR pedal, batteries from 2nd pedal if applicable).
- Cable ramp rolled, gaff tape onto end-tab, stands packed.
- Inventory check vs Step 0 list — anything missing flagged.
- Photos of all packed cases taken for next-show reference.
Post-Event Log
Anomalies to log:
WIRELESS SYSTEM REFERENCE
Primary wireless rig — single 8-channel UHF receiver with 8 matching bodypacks. Phenyx 4ch and Shure BLX kept offstage as deep backup only.
📷Photo Reference Library
Mixer · Overall & Anatomy
Mixer · Field Condition Walkthroughs
Mixer · Training Deck Step Diagrams
Wireless · Receiver Rack & Bodypacks
Lights · Chauvet 4BAR Quad
Image Sources
Photos consolidated from: bench-test uploads (May 2026), Mixer_Fix_Walkthrough.html, Mixer_Interactive.html, Lights_4BAR_Walkthrough.html, and Mixer_Training_Deck.pptx. All images compressed to ≤700px max dimension at JPEG 78% quality for offline embedding.
✓Operator Certification & Sign-Off
Operator competency demonstration
Each operator must demonstrate competency before independent operation. The training officer signs below to certify.
| Operator Name | |
| Date Trained | |
| Foot pedals located & tested | |
| Successfully demonstrated sound check | |
| Successfully demonstrated gain stage on every channel | |
| Successfully demonstrated blackout (foot pedal) | |
| Successfully demonstrated music playback (USB and line-in) | |
| Successfully demonstrated shutdown / strike sequence | |
| Operator Signature | |
| Training Officer Name | |
| Training Officer Signature |
Final readiness summary
| Pre-Flight checklist complete | — |
| Mixer pre-flight complete | — |
| Pre-doors verify complete | — |
| Strike checklist complete | — |
| Total wireless channels in inventory | — |
| Total light fixtures | — |
| Total foot pedals | — |
Operator's Bottom Line
Faders down → trim with PFL and PEAK LED → channel faders to unity (0 dB) → mix with MAIN.
Phantom only for condensers, only after the mic is plugged.
Cut before boost on EQ. Watch the meters, not the room.
Two foot pedals, two lights, six wireless channels — own them.