Max channels for Ion

From the Ion product page here http://www.etcconnect.com/product.overview.aspx?ID=20351 "Ion is available in five basic configurations –1024, 1536, 2048, 2560 or 3072 outputs."

yeah if you have a movie that will require that many outputs, I would recommend a different board for your rig.  The ion maxes out at 3072 outputs (6 universes), when it's fully upgraded.  you need just over 6 universes, if you want to stick with ETC boards, the Gio or Eos both are able to handle that many unique outputs.

Another option might be to double up LEDs or using a more course control for the LEDs, I'm assuming that you're looking at something like 6ft color blazes set in 4in segments with 16b control, each fixture would be over 200 outputs!  But you can creatively work around these limitations without sacrificing too much flexibility.