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Jands HP6 Technical Manual

Digitally controlled dimmer rack
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HP6/HP12
D i g i t a l l y C o n t r o l l e d D i m m e r R a c k
T T E E C C H H N N I I C C A A L L M M A A N N U U A A L L

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Summary of Contents for Jands HP6

  • Page 1 HP6/HP12 D i g i t a l l y C o n t r o l l e d D i m m e r R a c k T T E E C C H H N N I I C C A A L L M M A A N N U U A A L L...
  • Page 2 It is recommended that all service and repairs on this product be carried out by JANDS ELECTRONICS P/L or it’s authorised service agents.

  • Page 3: Table Of Contents

    Equipment Description Table of Contents Table of Contents 1.0 Introduction Mains supply wiring .................... 1-1 Phase failure......................1-2 Circuit breakers....................1-2 1.3.1 Overloads and Inrush ................1-3 1.3.2 Short Circuits.................... 1-3 Outdoor Systems....................1-3 2.0 Equipment Description Front panel layout ....................2-1 3.0 Circuit Descriptions Mains and Low Voltage power supplies ..............
  • Page 4 Equipment Description Load & drive indicators..................3-6 3.5.1 Drive LEDs ....................3-6 3.5.2 Load LEDs ....................3-6 3.5.3 Load Detecting ..................3-7 CPU card ......................3-8 3.6.1 Microprocessor..................3-8 3.6.2 Memory....................3-8 3.6.3 DMX input / output .................. 3-9 3.6.4 Zero crossing detector ................3-9 3.6.5 Analog to digital converter (ADC) ............
  • Page 5 Equipment Description 4.1.7 BUILD menu..................4-10 4.1.8 RUN menu....................4-11 4.1.9 TEST function ..................4-14 Deep clear......................4-14 4.2.1 Quick deep clear ..................4-14 Channel disable ....................4-15 Software update....................4-15 5.0 Fault Diagnosis Protection ......................5-1 5.1.1 Output protection ..................5-1 5.1.2 Thermal protection..................
  • Page 6 Equipment Description 7.0 Test and Configuration Settings CPU self-tests ..................... 7-1 Output card testing....................7-2 Phase Compensation ................... 7-2 Dimmer Re-calibration ..................7-3 8.0 Technical Data and Specifications Multipin output connector pin-outs ..............8-3 DMX connector pin-outs ..................8-5 DMX bank allocations..................8-5 Mains wiring colour codes...................

  • Page 7: Introduction

    In Australia the HP6-C is normally fitted with a flexible supply cable and 50 amp Clipsal plug. The incoming mains supply must be protected at not more than 63 amps. The dimmer’s circuit breakers are not rated to correctly clear faults if the supply protection is...

  • Page 8: Phase Failure

    OVERVOLTAGE if connected to the 415V wye or star three-phase supply of most countries. The three active lines must each be protected at not more than 50 amps [63 amps: HP6- C]. The dimmers' breakers are not rated to clear faults if the supply is protected at currents of over 50 amps [63 amps: HP6-C].

  • Page 9: Overloads And Inrush

    Equipment Description 1.3.1 Overloads and Inrush Cold lamp filaments consume considerably more power than warm filaments. This means that the first time the lamp is turned on to full, the surge current can be several times greater than the rated current for the lamp. This cold surge current may be enough to trip the output circuit breakers.

  • Page 11: Equipment Description

    Jands recommend the maximum load connected to a channel be limited to 10 amps. The HP6-C breakers are rated at 25 amps but Jands recommend the maximum channel load be limited to 20 amps. If nuisance tripping occurs, enable the Preheat option (see section 4.1.4.5).
  • Page 12 Equipment Description LOAD LED: This red LED serves two functions. In normal operation, it acts as an output mimic. When the channel drive is at zero, it indicates whether that channel’s load is disconnected (or open-circuit). To check a load, set the channel drive to zero. The LOAD LED will turn ON if there is no load.
  • Page 13 Equipment Description [ BLANK PAGE ] Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...

  • Page 17: Circuit Descriptions

    The dimmer should be supplied with three same-phase actives and three neutrals. The three active lines must each be protected at not more than 50 amps [63 amps: HP6-C]. The three neutral conductors must each be rated at the same current as the actives. The earth conductor should be similarly rated.

  • Page 18: Mains Radio Frequency Suppression

    Equipment Description DELTA SUPPLY OPERATION (ILLEGAL IN MOST COUNTRIES!) The available venue mains supply in some countries (eg. the Phillipines) is in the form of three phases (220 volts between phases) with no neutral connection. The dimmer may be configured for operation from 220V delta supplies. The bridge between the three neutral terminal poles (N1, N2, N3) must be removed before the three incoming active lines are connected.

  • Page 19: Low Voltage Transformers

    WILL trip if a low voltage fault occurs. Thermistor cutout will turn off the frontpanel PHASE LED. HP12-SC, HP6-C: The transformers are nominally rated at 240V (primary), 15V (secondary). The primary windings are protected against secondary-side overloads by card-mounted 30mA PTC thermistors. These thermistors will trip during continuous mains overvoltages of more than 340V.

  • Page 20: Fan Control

    Equipment Description 3.1.7 Fan Control Temperatures are sensed by LM35DZ sensors mounted at the exhaust ("hot") ends of the heatsinks. These sensors have an output voltage of 10mV per degree Celsius (ie. 300mV at 30°C). Their output voltage is summed and fed to the frontpanel CPU card for temperature display, and to the 12 volt dc fan control.
  • Page 21 The SCRs used in the HP6-C are 65 amp, 600 volt devices (type S6065) with 2500 volt isolation to the mounting tab. They have a surge current rating of 800 amps for 10 milliseconds.

  • Page 22: Output Chokes And Filtering

    The HP12-TR uses 100nF snubber and filter capacitors, and will pass up to 15mA to the load; the HP12-SC uses 47nF capacitors and will pass up to 7mA. The HP6-C uses 100nF snubber and filter capacitors, and will pass up to 22mA to the load.

  • Page 23: Load Detecting

    When no load is connected, the Load LED will light. The snubber and filter capacitors (100nF for HP12-TR and HP6-C, 47nF for HP12-SC) will pass an ac current of 7mA to 22mA, which is sensed by the Load LED as an output voltage.

  • Page 25: Cpu Card

    Equipment Description CPU card Figure 3.2 The HP Series dimmers are fully digital. The CPU reads all inputs and generates all outputs. The one exception to this is the fan control system which is intended to operate without CPU intervention - if the CPU were to stop operating the cooling system will continue to operate normally.

  • Page 26: Dmx Input / Output

    Equipment Description Read and Write control lines for the SRAM are generated by the GAL16V8 (IC7). A MAX691 “watchdog“ chip (IC8) supplies power to the RAM ICs from the 5V supply rail, but changes over to the 3V Lithium backup battery when the 5V supply drops below a set level.

  • Page 27: Volt Power Supply

    Equipment Description 3-10 3.6.7 5 volt power supply All electronic circuits other than the fan controller are run from a 5 volt supply, regulated from the 15 V supply with a LM2576-5 switching regulator (REG1) operating as a continuous-mode buck converter at approx 52kHz.. The demand on the 5 V rail is around 750 mA.

  • Page 29: Front Panel Card

    Equipment Description 3-11 Front panel card Figure 3.4 The front panel PCB holds all front panel switches and LEDs, including the LOAD and DRIVE LEDs which are fed by the Output PCB. Additionally, the control electronics for the switches and LEDs and the encoder circuitry are also on the front panel PCB. To minimise flat cable size, the CPU data bus and required CPU select lines are connected to the front panel card to control the latches for the LEDs and buffers for the switches/encoder circuitry.

  • Page 31: Dimmer Operation

    Dimmer Operation 4.0 Dimmer Operation This section assumes the dimmer has been correctly connected to three phase power and a source of DMX input signals. Menu structure The HP dimmers feature a “tree” menu structure. This means that an option is chosen from the display with the LEVEL/FUNCTION encoder wheel, and the ENTER keypad button is then pressed to confirm the selection.
  • Page 32 NORMAL button on the keypad will clear the display to “OK”. Note The HP12-TR / HP12-SC / HP6-C dimmers are designed to be installed in standard 19-inch wide racks. These racks should have adequate ventilation allowing for the side-to-side airflow of the dimmers. Fully enclosed racks that obstruct side-to-side ventilation may cause overheating problems.
  • Page 33 Fault Diagnosis 4.1.4.3 “LAW” - Dimmer law Figure 4.1A Selecting “LAW” gives the option of either a linear power curve - “Lin P” - or a switch curve - “Swch”. The linear power curve gives even fade characteristics for lamps, while the switch curve may be used for switching other devices (eg. fans, strobes, motors, etc) on or off, with the switching points set at 55% for upfades and 45% for downfades.
  • Page 34 Dimmer Operation 4.1.4.5 “P. FLT” - Mains Power Fault Figure 4.1A The HP series dimmers will detect two types of mains supply problems: • Mains undervoltages • Neutral-to-earth overvoltage In some venues the three phase power supply may be less than ideal, and one or more of the above fault conditions may occur without the wiring being truly “faulty”.
  • Page 35 Fault Diagnosis [ BLANK PAGE ] Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...
  • Page 37 Dimmer Operation 4.1.4.6 “TERM” DMX Signal Terminate Figure 4.1B Selecting “TERM” allows the DMX signal to be correctly terminated, as is required for the last dimmer in a DMX line. Note that when set to “ON” the DMX Loop connector in unused. Pressing the NORMAL button on the keypad will change the display to “OK”...
  • Page 38 Dimmer Operation When “MAX” has been selected: • Adjust the displayed voltage using the FUNCTION encoder wheel until it is equal to the desired maximum output voltage from the dimmer when driven to full. eg to avoid running 220 volt lamps above their rated voltage set this parameter to 220V.
  • Page 39 Fault Diagnosis [ BLANK PAGE ] Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...

  • Page 41: Dmx Channel Menu

    Dimmer Operation 4.1.5 DMX CHannel menu Figure 4.2 The dimmer’s DMX start channel can be selected anywhere from channel 1 to channel 512. By selecting DMX start channel 1, the dimmer will respond to DMX channels 1 through 12 inclusive. When using racks of looped dimmers, the next dimmer should start at channel 13, the next at channel 25, and so on.

  • Page 43: Build Menu

    Fault Diagnosis 4-10 4.1.7 BUILD menu Figure 4.3 The BUILD menu is used to record DMX Snapshots or user-defined Scenes. • Press the BUILD keypad button. • Select a flashing Snapshot number (“SP1 - SP3”) or a Scene number (“SC1 - SC2”) to record, using the FUNCTION encoder wheel.

  • Page 45: Run Menu

    Fault Diagnosis 4-11 4.1.8 RUN menu Figure 4.4 The HP dimmers offer a range of pre-recorded Snapshots, Scenes and Chases that may be used for testing purposes or for when the dimmer rack is used in stand-alone (no control desk) applications. The Snapshots and Scenes must be recorded via the Build menu (see section 4.1.7).
  • Page 46 • Once the SELECT button is released, the encoder wheel becomes the chase rate control once more. There is no master level control for this function. The factory Preset Chase patterns for HP12 [HP6] are as follows: Channels 1 to 12 [6] in sequence (12 [6] step chase) Channels 12 [6] to 1 in sequence (12 [6] step reverse chase) Channels 1 to 12 [6] in sequence (12 [6] step shadow chase) ie.
  • Page 47 Fault Diagnosis 4-13 [ BLANK PAGE ] Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...

  • Page 49: Test Function

    MODE menu (see section 4.1.4.1). • Next use the encoder wheel to select “12ch” output for HP12-TR / HP12-SC (“6ch” output for HP6-SC), and press ENTER. • The display will change to “OK” to indicate the dimmer is now back in normal operating mode.

  • Page 50: Channel Disable

    Dimmer Operation 4-15 Channel disable When the dimmer is in normal operating mode (“OK” showing on the display), any channel may be taken off-line by pressing its SELECT button. Pressing the button a second time will bring that channel back on-line. The STATUS LED will be on (red or green) for all active channels, and be off for all disabled channels.

  • Page 51: Fault Diagnosis

    5.0 Fault Diagnosis NOTE Contact your authorised JANDS Distributor for repairs or servicing. In Australia refer all repairs to an authorised JANDS service agent or return the faulty unit in suitable packaging to: JANDS ELECTRONICS Service Dept, 40 KENT Rd...

  • Page 52: Supply Power Fault Protection

    The electronic shutdown at 85°C is backed up by a 90°C buried cutout, which shuts down power to all electronics other than the cooling fan. Note that the HP6-C / HP12-SC's two fans will run slower and quieter under average operating conditions than the HP12-TR's single fan, due to the increased airflow capacity.

  • Page 53: Output Faults

    If a message should appear scrolling across the display: “ADDRESS EXCEPTION ERROR XXXXXXXX XXXXXXXX XXXXXXXX” where the Xs represent different characters, write down the characters and contact JANDS Service Department or your local JANDS Distributor, giving details of the dimmer’s operating conditions that caused the error, and software version (see section 4.1.4.3).

  • Page 54: Phase Fault Indication

    Disassembly Phase fault indication The three green PHASE LEDs will light when all three power input phases are present. WARNING If one or more PHASE LEDs is off, IMMEDIATELY disconnect power to the dimmer and check the mains supplies and wiring before re-connecting power to the dimmer.

  • Page 55: Fault Finding Guide

    Disassembly Fault finding guide FAULT SYMPTOM POSSIBLE CAUSE REMEDY Over-temperature indication Poor intake ventilation Use racks with side ventilation Poor exhaust ventilation Use racks with side ventilation Damaged fan Replace fan Ambient temp above 40°C Keep ambient temp below 40°C Breaker trips when channel flashed Large incandescent load Use Preheat facility...

  • Page 56: Disassembly

    Technical Data and Specifications 6.0 Disassembly Should it become necessary to repair or replace a PCB, the following procedures should be used. The numbers below refer to the sequence of operations. CPU card removal OUTPUT CARD CPU CARD Figure 6.1 HP12-TR with CPU card exposed Figure 6.1 1.

  • Page 57: Front Panel Card Removal

    Technical Data and Specifications Front Panel card removal OUTPUT CARD FRONT PANEL CARD Figure 6.2 HP12-TR with CPU card removed Figure 6.2 1. First remove the CPU card using the procedures in section 6.1. 2. Undo the screws and threaded spacers that hold the Front Panel card to the front panel, noting the location of the spacers.

  • Page 58: Triac / Scr Replacement

    Technical Data and Specifications Triac / SCR replacement TRIACS Figure 6.3 HP12-TR showing access to triacs Figure 6.3 1. Remove the sixteen lid screws and the lid. 2. Remove the front panel as in section 6.1 for access to the front triacs/SCRs. 3.

  • Page 59: Engine Block" Removal

    “Engine Block” removal 1. Remove the sixteen lid screws and the lid. 2. Remove all 24 wires [12 wires on HP6] to the circuit breakers. 3. Remove the screws holding the front panel in place (3 underneath, 2 pairs each side).

  • Page 60: Test And Configuration Settings

    Test and Configuration Settings 7.0 Test and Configuration Settings CPU self-tests A number of CPU test routines are contained in the EPROM. To run these tests set DIP switch 3 on, DIP switch 4 off, and set DIP Switches 1 and 2 as required (see below) and apply power.

  • Page 61: Output Card Testing

    Phase Compensation DIP switches 1 and 2 on the CPU card are used to specify the amount of phase compensation for different generations of Jands HP dimmers as follows: Product Switch #2 Switch #1...

  • Page 62: Dimmer Re-Calibration

    Test and Configuration Settings The DIP switch is checked at startup and the dimmer configured accordingly. The status of the DIP switch is indicated in the software version – this is accessed by holding down the “Normal” button for 2 seconds when “OK” is displayed. The following table indicates the displayed version for the various DIP switch combinations: Switch #2 Switch #1...
  • Page 63 Test and Configuration Settings [ BLANK PAGE ] Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...

  • Page 64: Technical Data And Specifications

    Test and Configuration Settings 8.0 Technical Data and Specifications PARAMETER HP12-TR HP12-SC HP12-WMTR HP12-WMSC HP6-C No. of Channels: Input Power 3 Phases plus Neutral and Earth Requirements: 200-265 volts phase-to-neutral 345-460 Volts AC Phase-Phase +/-10% 46 Amps / Phase 50 Amps / Phase...
  • Page 65 Technical Data and Specifications channel channel (Australia) HPM CAT38 per channel (parallel) PARAMETER HP12-TR HP12-SC HP12-WMTR HP12-WMSC HP6-C Output Options: Clipsal 415 Clipsal 415 Clipsal 415 Clipsal 415 HPM CAT38 19 pin Socapex 19 pin Socapex 3x Wieland 3x Wieland...

  • Page 66: Multipin Output Connector Pin-Outs

    Technical Data and Specifications Multipin output connector pin-outs 19 PIN SOCAPEX CONNECTORS PIN No OUTPUTS 1-6 OUTPUTS 7-12 ACTIVE ACTIVE NEUTRAL 1 NEUTRAL 7 ACTIVE ACTIVE NEUTRAL 2 NEUTRAL 8 ACTIVE ACTIVE NEUTRAL 3 NEUTRAL 9 ACTIVE ACTIVE NEUTRAL 4 NEUTRAL 10 ACTIVE ACTIVE...
  • Page 67 Technical Data and Specifications 19 PIN SERIES-WIRED SOCAPEX OUTPUTS 1-6 (OUTPUTS 7-12) CONNECTOR “A” CONNECTOR “B” PIN No CONNECTION PIN No CONNECTION ACTIVE LINK LINK NEUTRAL 1 ACTIVE LINK LINK NEUTRAL 2 ACTIVE LINK LINK NEUTRAL 3 ACTIVE 4 (10) LINK 4 (10) LINK...

  • Page 68: Dmx Connector Pin-Outs

    Technical Data and Specifications DMX connector pin-outs CONNECTION CONNECTION (DMX IN) (LOOP) SHIELD SHIELD OUT- OUT+ DMX bank allocations BANK CHANNELS BANK CHANNELS 1 – 12 [6] 265 – 276 [270] 13 – 24 [18] 277 – 288 [282] 25 – 36 [30] 289 –...

  • Page 69: Mains Wiring Colour Codes

    Technical Data and Specifications Mains wiring colour codes FLEX TAILS INSTALLED WIRING PHASE A BROWN PHASE B WHITE WHITE PHASE C BLACK BLUE NEUTRAL BLUE BLACK EARTH GREEN / YELLOW GREEN / YELLOW Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...

  • Page 70: Appendix A History Of Modifications

    Appendix A A -1 Appendix A History of Modifications HP12-TR Serial Number Modification J94281 Version: V1.0 K94733 Software version V1.1 R27 on CPU card changed from 3K3 to 4K7 for wider zc pulses L94188 Software version V1.1A B95176 Software version V1.1D R1, R2, R3 on Output card changed from 5R6 to 15R for mains tone filtering CF3, CF4, CF5 on Output card changed from 47uF bipolar to 33uF bipolar R27 on CPU card changed from 4K7 to 6K8 for wider zc pulses...
  • Page 71 Appendix A A -2 Visit JANDS’ Website to download all related Technical Bulletins: http://www.jands.com.au/jands_elec/Download/Tech_Bulletins/tech_bulletins.html Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...
  • Page 72 Appendix B B -1 Appendix B Connector Pinouts All connectors viewed from component side of PCB. CPU card POWER CONNECTOR FRONT PANEL CONNECTOR DMX CONNECTOR Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...
  • Page 73 Appendix B B -2 Front panel card CPU CONNECTOR Output card CPU CONNECTOR TEMP SENSE CONNECTOR Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...
  • Page 74 Appendix C C -1 Appendix C Spare Parts The following spare parts for HP Series dimmers are available from the JANDS Service Department: ITEM PART No. Circuit breaker 11.5 amp (HP12-TR / HP12-SC) ZEB0200 Circuit breaker 25 amp (HP6-C) ZEB0250...
  • Page 75 Appendix C C -2 Flat cable (CPU card to Output card) ZPL2550 5 pin chassis mount AXR - male ZPG2200 5 pin chassis mount AXR - female ZPG2100 Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL...
  • Page 76 HP12-SC OUTPUT/POWER CARD HPSCHDF2 HP12-SC SCR FIRING CIRCUIT DIMCPU8 HP DIMMER CPU CARD HPCEFPN2 HP DIMMER FRONT PANEL CARD HP6CPWR0 HP6 OUTPUT CARD HPWMFPN2 HP WALL-MOUNT FRONT PANEL CARD SUPERSEDED 12CHOP3 HP12 OUTPUT CARD DIMFP5 HP12 FRONT PANEL CARD DIMCPU4...

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