Jands HP6 User manual

HP6/HP12
Digitally Controlled Dimmer Rack
TTEECCHHNNIICCAALLMMAANNUUAALL

Equipment Description ii
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
JANDS ELECTRONICS PTY LTD 1997
All rights reserved
DISCLAIMER
Information contained in this manual is subject to change without notice and does not
represent a commitment on the part of the vendor. JANDS ELECTRONICS P/L shall
not be liable for any loss or damage whatsoever arising from the use of information or
any error contained in this manual.
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.
JANDS HP Series dimmers must only be used for the purpose they were intended by
the manufacturer and in conjunction with the operating manual.
JANDS ELECTRONICS P/L cannot accept any liability whatsoever for any loss or
damage caused by service, maintenance or repair by unauthorised personnel, or by use
other than that intended by the manufacturer.
Manufactured in Australia by:
JANDS ELECTRONICS PTY LTD ACN 001 187 837
40 KENT Rd
Locked Bag 15
MASCOT NSW 2020
AUSTRALIA
PHONE: [phone]
FAX: [phone]
EMAIL: Internet: [e-mail]

Equipment Description iii
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
Table of Contents
Table of Contents
1.0 Introduction
1.1 Mains supply wiring............................................................................................1-1
1.2 Phase failure........................................................................................................ 1-2
1.3 Circuit breakers................................................................................................... 1-2
1.3.1 Overloads and Inrush................................................................................1-3
1.3.2 Short Circuits............................................................................................1-3
1.4 Outdoor Systems.................................................................................................1-3
2.0 Equipment Description
2.1 Front panel layout ............................................................................................... 2-1
3.0 Circuit Descriptions
3.1 Mains and Low Voltage power supplies..............................................................3-1
3.1.1 Mains Circuit Wiring:................................................................................ 3-1
3.1.2 Mains Radio Frequency Suppression......................................................... 3-2
3.1.3 Neutral - Earth Voltage Detection............................................................. 3-2
3.1.4 Low Voltage Transformers.......................................................................3-3
3.1.5 Control Tone Rejection............................................................................. 3-3
3.1.6 Low Voltage DC Supplies ........................................................................ 3-3
3.1.7 Fan Control............................................................................................... 3-4
3.2 Phase control...................................................................................................... 3-4
3.3 SCRs and triggering circuits................................................................................3-4
3.4 Output chokes and filtering .................................................................................3-6

Equipment Description iv
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
3.5 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
3.6 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)............................................................ 3-9
3.6.6 Optocoupler drive..................................................................................... 3-9
3.6.7 5 volt power supply ................................................................................ 3-10
3.6.8 Reset generator....................................................................................... 3-10
3.6.9 Rotary encoder ....................................................................................... 3-10
3.7 Front panel card................................................................................................ 3-11
3.7.1 Switches................................................................................................. 3-11
3.7.2 LEDs...................................................................................................... 3-11
3.7.3 Encoder.................................................................................................. 3-11
4.0 Dimmer Operation
4.1 Menu structure.................................................................................................... 4-1
4.1.1 ENTER ....................................................................................................4-1
4.1.2 NORMAL ................................................................................................4-1
4.1.3 CLEAR .................................................................................................... 4-1
4.1.4 MODE menu ............................................................................................ 4-1
4.1.5 DMX CHannel menu ................................................................................4-9
4.1.6 DMX BANK menu................................................................................... 4-9

Equipment Description v
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
4.1.7 BUILD menu.......................................................................................... 4-10
4.1.8 RUN menu.............................................................................................. 4-11
4.1.9 TEST function........................................................................................ 4-14
4.2 Deep clear......................................................................................................... 4-14
4.2.1 Quick deep clear..................................................................................... 4-14
4.3 Channel disable ................................................................................................. 4-15
4.4 Software update................................................................................................ 4-15
5.0 Fault Diagnosis
5.1 Protection........................................................................................................... 5-1
5.1.1 Output protection ..................................................................................... 5-1
5.1.2 Thermal protection....................................................................................5-1
5.1.3 Supply Power fault protection................................................................... 5-2
5.2 Output faults....................................................................................................... 5-3
5.3 Operating faults...................................................................................................5-3
5.4 DMX faults......................................................................................................... 5-3
5.5 Phase fault indication...........................................................................................5-4
5.6 Cold lamp filaments.............................................................................................5-4
5.7 Memory failure.................................................................................................... 5-4
5.7 Fault finding guide .............................................................................................. 5-5
6.0 Disassembly
6.1 CPU card removal...............................................................................................6-1
6.2 Front Panel card removal..................................................................................... 6-2
6.3 Triac / SCR replacement .....................................................................................6-3
6.4 “Engine Block” removal......................................................................................6-4

Equipment Description vi
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
7.0 Test and Configuration Settings
7.1 CPU self-tests..................................................................................................... 7-1
7.2 Output card testing..............................................................................................7-2
7.3 Phase Compensation ........................................................................................... 7-2
7.4 Dimmer Re-calibration ........................................................................................7-3
8.0 Technical Data and Specifications
8.1 Multipin output connector pin-outs..................................................................... 8-3
8.2 DMX connector pin-outs ....................................................................................8-5
8.3 DMX bank allocations.........................................................................................8-5
8.4 Mains wiring colour codes...................................................................................8-6
Appendix A History of Modifications
Appendix B Connector Pinouts
Appendix C Spare Parts
Appendix D Circuit Diagrams

Equipment Description 1-1
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
1.0 Introduction
1.1 Mains supply wiring
THREE PHASE OPERATION ("NORMAL"):
In Australia the HP12-TR / HP12-SC is normally fitted with a flexible supply cable and
32 amp Clipsal plug. The cable has 6mm2(40 amp) conductors for the three phases, the
neutral and the earth.
The 32 amp Clipsal plug suits the majority of 3 phase venue outlets in Australia, and will
provide sufficient power to run twelve pairs of 1000 watt PAR64 lamps, assumimg
normal duty cycles.
The incoming mains supply must be protected at not more than 50 amps. The dimmers'
circuit breakers are not rated to correctly clear faults if the supply protection is in excess
of this. Mains supplies are generally protected at lower currents (32 amps or 40 amps at
most Australian venues). It is up to the user to ensure that the dimmer is used in a
manner that does not exceed the available supply capacity.
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
in excess of this.
The power cable is terminated within the dimmer at a six-way terminal block and an
earthing stud. The six-way terminal block has three poles for the three live mains phases
(labelled A1, A2, A3), and three poles for the mains neutral (N1, N2, N3). The three
neutral poles are bridged with a copper link, with the mains neutral connected to terminal
N2.
If the supply cable is damaged, it must be replaced with a cable available from JANDS or
its service agents.
SINGLE PHASE OPERATION:
The dimmers may be configured for single phase operation where three phase mains
supply is unavailable.
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.
The bridge between the three neutral terminal poles (N1, N2, N3) must be removed
before the three incoming neutral lines are connected.
Although it is possible to supply the dimmer with one large single phase feed, the
dimmers' breakers are not rated to clear faults if the supply is protected at currents of
over 50 amps [63 amps: HP6-C].
The neutral-earth detection will act if all three neutrals have more than 15 volts to earth,
or if any one neutral has more than 45 volts to earth.

Equipment Description 1-2
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
DELTA SUPPLY OPERATION (ILLEGAL IN MOST COUNTRIES!)
The available venue mains supply in some countries (eg. the Philippines) 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.
•The first incoming active is connected to terminals A1 and N3.
•The second incoming active is connected to terminals A2 and N1.
•The third incoming active is connected to terminals A3 and N2.
Note that this connection is ILLEGAL in Australia, Europe and the U.K..
Note that this connection renders the output sockets' neutral pins LIVE.
Note that a dimmer wired in this fashion will be subjected to CONTINUOUS
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]. The earth conductor must be similarly
rated.
The neutral-earth voltage detector will sense whether the "centre" (average) voltage of
the three phases deviates more than 15 volts from earth.
Once again -
DELTA CONNECTION IS ILLEGAL AND DANGEROUS IN MOST COUNTRIES!
1.2 Phase failure
If one power phase should fail, the dimmer will turn off the outputs associated with that
phase. This function can be disabled by the operator. See section 4.1.4.5.
1.3 Circuit breakers
The circuit breakers protect the HP dimmers' output devices and the user’s output wiring
against overloads and short circuits. The breakers have a "type 32" delay characteristic,
which is similar to standard switchboard breakers.
The delay characteristics of the circuit breaker are a delicate balance between high speed
(required for adequate semiconductor protection) and surge tolerance (to pass the inrush
current demanded by large incandescent lamps).
Each of the twelve output circuits is protected by a 11.5 amp [25 amp: HP6-C] fast-
acting magnetic circuit breaker. These breakers are designed to pass the rated current,
but will disconnect the output circuit for any overload condition (the larger the overload,
the quicker the disconnection).
NOTE: The dimmer outlet sockets are rated at 10 amps [20 amps: HP6-C]. Avoid
loading the dimmer outputs beyond the socket capacity.
The breakers protect the dimmer’s output devices from short-circuit loads and faulty
wiring looms, and save on expensive dimmer repairs. A tripped circuit breaker indicates a
load fault that requires immediate attention.

Equipment Description 1-3
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
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. If this
“nuisance-tripping” of the circuit breakers is a problem, the filament Preheat facility may
be utilised. See section 4.1.4.5 for instructions on enabling the Preheat facility.
Lamp filament resistance is roughly proportional to temperature. A filament preheated to
900°K (630°C) has a resistance about three times higher than a filament at room
temperature (300°K, 30°C).
Preheat turns on the selected channels a very small amount (around 1% at 240 volts and
4% at 110 volts) which heats the lamp filaments and increases their electrical resistance.
When the lamp is then turned on full, the surge current is much less and the circuit
breaker will not trip.
Other advantages of using Preheat are an increase in lamp life (due to the reduction of
thermal shock to the filaments), and a reduction of lamp heat up time (the lamps will
flash slightly quicker).
1.3.2 Short Circuits
The SCRs and triacs are protected by the circuit breakers during shorts produced by
damaged wiring or blown lamp filament fragments across the filament supports.
The stress on SCRs and triacs during short circuits depends on:
•The operating temperature of the devices prior to application of the short
•The impedances of the mains supply, dimmer chokes and output cables
•The let-through energy of the circuit breaker when breaking the fault
•The moment during the mains waveform when the short is applied
The triacs in the HP12-TR will survive output short circuits under most conditions. The
more rugged SCR pairs in the HP12-SC, aided by higher choke impedance, will survive
output shorts under extreme conditions (high operating temperatures, high supply fault
current availability, zero cable length from dimmer to short).
1.4 Outdoor Systems
It is recommended that at outdoor shows where the power is locally generated the
following steps be taken to ensure a trouble-free show:
1. Run the console from an extension cord that is plugged into the same power
source as the dimmers. If this is not possible a DMX isolating unit should be
inserted between the lighting console and the dimmers.
2. Disable the neutral detect system. Generators often have poor regulation on
their output power and it is very likely that under certain circumstances this can
cause the neutral detect feature to trip.

SELECTSELECT
TR
1 7 6253
4
891110
Figure 2.1

Equipment Description 2-1
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
2.0 Equipment Description
2.1 Front panel layout
(
Figure 2.1
1. Channel output circuit breakers: The circuit breakers are rated at 11.5 amps
continuous, however 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). See also section 5.6 for a full explanation of
nuisance tripping.
2. Display: A red four digit alpha-numeric display is used to show dimmer status and
option menus.
3. LEVEL/FUNCTION encoder wheel: This detent action control knob is used to
select items from the menus, and to select the channel levels or chase rate (depending on
the operating mode).
4. DMX IN/LOOP connectors: A standard five pin AXR connector inputs control
desk DMX-512 signals and outputs them to other dimmers via the Loop connector. See
section 8.2 for wiring details.
5. DMX IN LED: A green LED indicates the presence of DMX signals.
6. Keypad: These switches are used to select different options and operating modes. A
red LED is associated with each switch to indicate activation of selected function.
7. PHASE LEDs: Three green LEDs (one for each phase) indicate that the three phase
mains supply is available.
8. Channel SELECT switch: These select or deselect options for each channel, or
switch a channel between “on-line” and “off-line”. If a channel is “off-line”, it will not
respond to the DMX input signals.
9. Channel STATUS LED: A bi-colour LED indicates channel status, ie.
Red = channel set for 110V output
Green = channel set for 240V output
Off = channel disabled
Orange = voltage change selected but not yet confirmed
Flashing = channel selected for changes to be made
10. DRIVE LED: This green LED indicates a control signal is being applied to
that channel.

Equipment Description 2-2
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
11. 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.
For levels above zero, the LOAD LED will mimic the channel output whenever a load is
connected.
Note that the channel circuit breaker must be ON for the LOAD LED circuitry to work.
BREAKER LOAD CHANNEL DRIVE LOAD LED STATUS
on not connected off ON
on connected off OFF
on connected on OUTPUT MIMIC
off doesn’t matter doesn’t matter OFF

Equipment Description 2-3
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
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MAINS, FAN CONTROL & POWER SUPPLY
HPTRPWR4
OPTO DRIVE CIRCUIT from CPU: Open-collector switches (ULN2003 ICs) to common.
FRONTPANEL LED CIRCUITS: Output mimic (load) LEDs are fed by 470R; LED cathodes connected to common. Drive LEDs fed by 470R; LED anodes connected to +5 volts.
C18 4n7-Y
C19 4n7-Y
C17 4n7-Y C16
4n7-Y
C15 4n7-Y
C14 4n7-Y
TR2
Q6040K7
TR1
Q6040K7
R16
10K
RD2
470R
CF2 100nF
OPDIAC2
BRT11
BR2
DB102
RL2
47K
CS2 100nF
RT2
220R
RS2
100R
L2
CB2 11.5A
OPTRAN2
CNY17
OPTRANS13 CNY17
BR16 DB102 RG3 47K RG2 47K RG1 47K
D6
D5
D4
D3
D2
D1
C4
100nF
BR13 DB102
BR15
DB102
BR14
DB102
OPTRAN1
CNY17
CB1 11.5A
PTC3
30mA
PTC2
30mA
PTC1
30mA
C3 1uF
C2 1uF
C1 1uF
FAN-A
12V
TEMP1
LM35
C9 2200uF
TX1 TX2 TX3
L1
RS1
100R
RT1
220R
CS1 100nF
RL1
47K
BR1
DB102
R1
15R
R2
15R
R3
15R
C13 33uF
C11 33uF C12
33uF
GPO1 GPO2
C7 100uF
OPDIAC1
BRT11
CF1 100nF
OTEMP
90DEG
U1B
LM358 Q2
BC557
R5 470R
R6
470R
R7 22K
R8
10K
U1A
LM358
R13
10K
RD1
470R
C8 10uF
TEMP2
LM35
C5
100nF
C6
100nF
R14
470R
R15
470R
Q1 TIP42
R4 1R
TPD
TPN
FL4
FL3
FL2
FL1
TRACKS
FUSIBLE
THREE
240v:14v
PHASE 3 NEUTRAL to CHANNELS 9 - 12 PHASE 2 NEUTRAL to CHANNELS 5 - 8
(STAR or WYE) OPERATION.
LINKED for NORMAL NEUTRALS 1-2-3 INPUT WIRING OPTIONS REFER TO MANUAL for
PHASE 1 NEUTRAL to CHANNELS 1 - 4
NEUT1
NEUT3
NEUT2
ACTIVES to BREAKERS NEUTRALS to OUTLETS GROUNDS to OUTLETS
CH3 - CH12
LOAD MIMICS
CHANNEL 2 LOAD MIMIC
CHANNEL 1 LOAD MIMIC
OUTPUT MIMIC (LOAD)
10
11
12
1
2
3
4
5
6
7
8
9
+5V to CH3 - CH12
CHANNEL 2 DRIVE
CHANNEL 1 DRIVE
5
42
1
Two channels of twelve shown.
OP2
LO2
LI2
CB2A2K2 G2
1
2
4
5
1
2
4
6
6
4
2
1
5
42
1
LEDs
DRIVE/OUTPUT
FRONTPANEL
TO
CARD
CPU TO
12
11
10
9
8
7
6
5
4
3
2
1
+5
+5
Temp
V-Faults
COM
+Vs
A
B
C
G1K1 A1
NEUTRAL 3
NEUTRAL 2
CB1
PHASE 1
PHASE 2
CHANNEL DRIVE
EARTH
NEUTRAL 1
PHASE 3
1
2
3
4
5
6
7
8
9
10
11
12
CIRCUIT CARD:
HPCEPWR4
HP-12TR TOURING DIMMER
LI1
LO1
OP1
A
E
NA
E
N
4 87
6 5
1
2 3
TP+
TP5
TP-
TPT
Ch.1-4 Ch.5-8 Ch.9-12

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FRONTPANEL LED CIRCUITS: Output mimic (load) LEDs are fed by 470R; LED cathodes connected to common. Drive LEDs fed by 470R; LED anodes connected to +5 volts. OPTO DRIVE CIRCUIT from CPU:
Open-collector switches (ULN2003 ICs) to common.
CON3
Q1
TIP42
C19
4n7-Y
C18
4n7-Y
C17
4n7-Y
C16
4n7-Y
C15
4n7-Y
C14
4n7-Y
CHASSIS
CHASSIS
CON3
CON3
CON3
CON3
R15 470R
R14 470R
C6
100nF C5
100nF
TEMP2
LM35
C8
10uF
R13
10K
U1B
R8
10K
R7(A-C)
3x10K
R6
470R
R5(A-D)
4x2K2
Q2
BCX17
U1A
CON3CON3
FAN-B
12V
OTEMP 110DEG
C7
100uF
GPO2GPO1
C12A,B
2x33uF
C11A,B
2x33uF
C13A,B
2x33uF
R3
4R7
R2
4R7
R1
4R7
TX3TX2TX1
C92200uF
TEMP1
LM35
FAN-A
12V
CON3CON3
C1 1uF
C2 1uF C3
1uF
PTC1
30mA
PTC2
30mA
PTC3
30mA
CB1
11.5A
C4
100nF
D1
D2 D3
D4
D5
D6
RG1 100K RG2 100K
RG3
100K
OPTRANS13 CNY17
CB2
11.5A
CON3
CON3
CON3
CON3
R16
4K7
CON1CON1 CON1CON1
L1 L2
CON1CON1CON1CON1
D8 D9
D10 D11
C202200uF
D12D13
D14D15
D16
D17 D18
D19D20
D21
D22
D23
C21
2200uF
C22
100uF
LP1
220uH
D24
HER303
R18
470R
R19
1K
ARROW ARROW
R4 1R
CON3
R17
2K2
R20
10K
R21
470R
R22
470R
C10 2n2
TPD
U2
LM2575-5
FUSIBLE
TRACKS
FL1
FL2
FL3
FL4
EARTH BAR
TPT
TP-
TP5
TP+
3 215
6
7
8 4
N
E
AN
E
A
TOURING DIMMERHP12-SC FAN CONTROLMAINS WIRING, and POWER SUPPLY 6.0
HPSCPWR6
12
11
10
9
8
7
6
5
4
3
2
1
PHASE 3
NEUTRAL
EARTH
CHANNEL DRIVE
PHASE 2
PHASE 1
D.FORD
NEUTRAL
NEUTRAL
3 4
5 6 7 8
9
10 11 12
1
2
3
C
B
A
+Vs
COM
Temp
+5
+5
1
2
3
4
5
6
7
8
9
10
11
12
TO
CPU
CARD
TO FRONTPANEL
DRIVE/OUTPUT LEDs
Two channels oftwelve shown.
1
24
5
CHANNEL 1 DRIVE
CHANNEL 2 DRIVE
+5V to CH3 - CH12
9
8
7
6
5
4
3
2
1
12
11
10
OUTPUT MIMIC (LOAD)
CHANNEL 1 LOAD MIMIC
CHANNEL 2 LOAD MIMIC
GROUNDS to OUTLETS NEUTRALS to OUTLETS ACTIVES to BREAKERS
NEUT2
NEUT3
NEUT1
PHASE 1 NEUTRAL to CHANNELS 1 - 4
REFER TO MANUAL for INPUT WIRING OPTIONS NEUTRALS 1-2-3 LINKED for NORMAL (STAR or WYE) OPERATION.
PHASE 2 NEUTRAL to CHANNELS 5 - 8 PHASE 3 NEUTRAL to CHANNELS 9 - 12
240:14V
THREE
NN
OP1
LO1
LI1
CB1
OP2
LO2
LI2
CB2
MIMIC1
DRIVE1
+5V
COMMON
+10V
+10V
COMMON
+5V
DRIVE2
MIMIC2
+7.6V to CH3-CH12
COMMON to CH3-CH12
MAINS VOLTAGES LOW VOLTAGES
THYRISTOR CONTROL CIRCUITS: REFER TO DIAGRAM HPSCHDF4
Refer to diagramHPSCHDF5 for thyristor firing circuits.
TPN
3 4
5 6 7 8
9
10 11 12 3
4
5 6 7 8
9
10 11 12
+Vs
+7.6V
Neutral
Detect

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ARROWARROW
ARROW
ARROW ARROW
ARROW
ARROW
ARROW
OPTRAN1 CNY17
DP1
DN1 DM1
DL1
RL1 47K
RS1
100R
CS1
47nF
CF1
47nF
SCRB1
SCRA1
L1
CON1 CON1 CON1 CON1
RY1 2R7
RX1 68R RW1 68R
RP1
10K
RA1
10K
RB1
4K7
RC1
2K2
QA1
BCX19
QB1
BCX19
QC1
BCX19
QE1
BCX19
QG1
BCX19
QD1
BCX17
QH1 BCX17
CA1
100uF
CB1 1uF
TX1
DA1 DB1
DC1
DD1
DE1
DF1
DG1
DH1
DJ1
DK1
RD1
100K
RE1
100K
RF1
100K
RH1
4K7
RJ1
4K7
CC1
2n2
RK1
4K7
RM1
4K7
RN1
4K7
RQ1
2K2
RR1
4K7
ARROW
CD1
100nF
CE1
100nF
RU1
68R
RV1 68R
3 D.FORD
HPSCHDF3
LOW VOLTAGES MAINS VOLTAGES
LEDs
MIMIC
LOAD
to
SUPPLY
+5V
SUPPLY
+10V
NEUTRAL
MAINS
LOAD
to
OUTPUT
BREAKER
POWER MAINS
from
NEUT1 OP1 LO1 LI1 CB1
HP12-SC SCR FIRING & OUTPUT
CHANNEL 1 SHOWN
from
ULN2003
on CPU
CARD
One of twelve circuits per unit shown.
This diagram is a part of diagram
2W
3W
Q6035K
Q6035K
All diodes BAV103.
All resistors 1/16W
SMT unless stated.
HPSCPWR3.

Equipment Description 3-1
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
3.0 Circuit Descriptions
(
Figure 3.1
The Output PCB contains the circuitry for the output devices (triacs in the HP12-TR and
SCRs in the HP12-SC and HP6-C), the temperature-controlled fan, and the 15 volt
power supply.
3.1 Mains and Low Voltage power supplies
The dimmer electronics uses low voltage dc power at 15 volts (unregulated) and 5 volts
(regulated). The HP12-SC also uses a 10V regulated supply for the gate drive
oscillators. The unregulated DC power is supplied by three transformers mounted on the
output PCB.
3.1.1 Mains Circuit Wiring:
The mains circuits of the HP dimmers are configured as three separate phase circuits,
with four channels per circuit. The three active mains inputs and three separate mains
neutral inputs appear at a terminal block, labelled A1, A2, A3 and N1, N2, N3
respectively. The ground terminal is an adjacent M4 stud.
This wiring allows the dimmer to be configured for three-phase star (wye) mains
supplies, three-phase delta supplies or single-phase supplies.
THREE PHASE OPERATION ("NORMAL"):
The rack mount HP dimmers are normally supplied with a three-phase power cable and
plug attached, suiting the vast majority of available mains supplies (ie. three phase and
neutral). The three live mains phases are connected to terminals A1, A2, A3. The three
neutral poles are bridged with a copper link, with the mains neutral connected to terminal
A2.
SINGLE PHASE OPERATION:
The dimmers may be configured for single phase operation where three phase mains
supply is unavailable.
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.
The bridge between the three neutral terminal poles (N1, N2, N3) must be removed
before the three incoming neutral lines are connected to these terminals. The three
incoming actives are connected to A1, A2, A3.

Equipment Description 3-2
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
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.
•The first incoming active is connected to terminals A1 and N3.
•The second incoming active is connected to terminals A2 and N1.
•The third incoming active is connected to terminals A3 and N2.
Note that this connection is ILLEGAL in Australia, Europe and the U.K. since this
connection renders the output sockets' neutral pins LIVE.
Note that a dimmer wired in this fashion will be subjected to CONTINUOUS OVER-
VOLTAGE if connected to the 415V wye or star three-phase supply of most countries.
3.1.2 Mains Radio Frequency Suppression
Radio-frequency interference generated by phase-controlled dimming is heavily
attenuated before it can contaminate the mains supply.
Capacitors C1, C2 and C3 (1uF 275VAC X2 rated) are connected from each incoming
active (A1, A2, A3) to the corresponding neutral (N1, N2, N3).
Capacitors C14 thru C19 (4700pF 275VAC Y2 rated) are connected from each incoming
active and neutral to ground.
The mains circuits are protected from (improbable) catastrophic failure of these
capacitors by fusible PCB track links (labelled FL1 thru FL4). Failure of these links will
remove power from the low-voltage transformer associated with that phase. The links
may be renewed during repairs by wire links (a single strand of flexible wire, not more
than 0.2mm dia).
3.1.3 Neutral - Earth Voltage Detection
Voltages of more than 15V (AC average) between neutral and earth are a strong
indicator of mains supply problems (eg missing or weak neutral connection, or missing
earth).
The voltage from the dimmers' earth to each of the three neutrals is sensed by three 100K
resistors (RG1, RG2, RG3), full-wave rectified and fed to the input LED of an
optoisolator.
When the dimmer is configured for normal three-phase star connection, the three
incoming neutrals are bridged, yielding an impedance of 33K from neutral to ground and
a sensitivity of 15V AC average.
If the dimmer is configured for three same-phase inputs, each neutral has a sensitivity of
45V (or 15V for all three neutrals).
If the dimmer is configured for delta operation (with no incoming neutral) the circuit will
detect when the "centre average" of the three phases deviates more than 15V from earth.

Equipment Description 3-3
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
3.1.4 Low Voltage Transformers
HP12-TR: The transformers are nominally rated at 375V (primary), 23V (secondary).
The primary windings of these transformers will tolerate 415 volts without overheating.
They are protected against secondary-side overloads by card-mounted 30mA PTC
thermistors. These thermistors are sized NOT to trip during mains overvoltages, but
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. Thermistor cutout will turn off the frontpanel
PHASE LED.
If thermistor cutout occurs, they may be reset by turning off power to the dimmer for
five seconds. However, since thermistor cutout will never occur during normal
operation, the cause of cutout should be investigated.
3.1.5 Control Tone Rejection
Control tones are superimposed on mains voltages by supply authorities to control off-
peak heaters etc. Tone frequencies of 750 Hz and 1050 Hz are common, although
frequencies from 167 Hz to 1750 Hz are in use. Amplitudes are typically less than 5
volts, although higher levels have been reported at some locations.
These tones may cause flicker in dimmed lamps, due to jitter in the detected zero-
crossing position.
The effect of control tones is minimised by filtering at the secondary windings of the low
voltage transformers. Resistor-capacitor networks (R1-CF3, R2-CF4, R3-CF5), in
conjunction with inherent transformer inductances, form a 12 dB/oct filter at 400 Hz.
Control tones at levels up to 15 volts at 750 Hz, or 25 volts at 1050 Hz, have little effect
on performance.
3.1.6 Low Voltage DC Supplies
Each of the three transformers has two associated rectifiers. One set of rectifiers feeds
the common DC supply filter capacitors, while the other provides full-wave rectified
waveforms to the zero-crossing detectors and three phase indicator LEDs via the Front
Panel PCB.
The dimmers’ unregulated supply is filtered by C9 (2200uF) and directly feeds the fan
controller, the overvoltage detector and the temperature sensors. All other circuits are
supplied via the OTEMP overtemperature cutout.
The dimmer will shut down under software control at 85°C. If the dimmer manages to
reach higher temperatures than this, the OTEMP cutout will remove power from all
circuits except the fan controller and associated circuits. The fan speed will increase due
to lighter supply loading.
The unregulated dc voltage at the common supply filter capacitor (C9) is normally
around 14 ~ 15 volts but may drop as low as 11 volts with low mains voltages, or rise in
excess of 20V during severe mains overvoltages.
Mains overvoltages are sensed as high unregulated DC voltages by op-amp U1b. Since
the DC supply voltage is dependent on dimmer loading as well as mains voltage, the trip
point of this circuit may vary from 260V to 280V AC mains voltage.

Equipment Description 3-4
Revision 2 - 26 April, 2000 HP SERIES DIMMER TECHNICAL MANUAL
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.
The fan speed controller is a DC amplifier formed by op-amp U1a and transistor Q1. The
fan is "held off" until sensor temperatures reach 30°C by resistor R16 from the 5V rail.
The fan voltage reaches 12V at temperatures of 50°C.
The circuit is protected against shorts in the fan or its wires by transistor Q2, which
clamps the output current at 0.6 amps.
3.2 Phase control
The power applied to a load is varied by controlling the point of thyristor firing in each
mains half-cycle.
The convention used here is that firing angles of 0°(0 radians) occurs at the end of each
half cycle, and give zero output. Firing angles of 180°(πradians) occurs at the beginning
of each half cycle, giving maximum (unity) output.
The traditional method of achieving phase control (ie. firing position control) has been to
generate a "ramp" voltage in each half-cycle, which is then compared to the dc control
signal.
Key elements in this technique are:
•The ramp begins just after the start of the half cycle, at a voltage equal to the
maximum control voltage.
•The ramp ends just before the finish of the half cycle, at a voltage equal to the
minimum control voltage.
•The beginning and end of the ramp are determined by zero crossings of the
mains waveform.
•The shape of the ramp determines the control law (CV to P law).
Note that the finite width of the zero-crossing pulse causes the dimmer to jump from no
firing to some small firing angle as soon as control voltage is applied. The snap-on firing
angle is defined by the zero crossing pulse width.
This is actually a very minor problem since zero crossing pulses of 2.2 ms (±1100 µs
around true zero crossing) give a snap-on power of less than 1%. The HP has a zero-
crossing pulse width less than 2 ms.
The HP microprocessor (µP) generates its "ramp" digitally, and specifically shapes the
ramp to provide linear control-to-power characteristics. The µP then compares the DMX
channel information with the generated ramp information and turns on the appropriate
output device at the required point on each mains half-cycle.
3.3 SCRs and triggering circuits
HP12-TR:
The triacs used in the HP12-TR are 40 amp, 600 volt devices (type Q6040K) with 2500
volt isolation to the mounting tab. They have a surge current rating of 335 amps for 10
milliseconds. The dimmer will function with replacement triacs of lower ratings but its
ability to survive short circuits and overvoltages will be jeopardised.