The Single Dimmer Board
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- Blaze Wilcox
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1 The Single Dimmer Board Introduction This electronic system has been designed as an interface unit between a Cronapress illuminated press strip and an external system such as a security alarm system; a typical use being in Police custody suites. The Cronapress illuminated press strip has a pair of contacts which are shorted when pressed. The illumination is provided by a string of LEDs down the strip terminating in a pair of wires. The LED strip is polarity sensitive and voltage sensitive where as the press strip can be operated at any voltage and polarity. The connection to the external system is by means of a pair of relays which enable complete electrical isolation of this unit. One relay is normally-off and is turned on when the strip is pressed; 3 isolated terminals area available as outputs (Common, N/O and N/C). The second relay is normally on when power is applied to the system and turns off if: 1. The power is turned off to the board, or 2. There is an open-circuit in the series connection formed by the 2 lines of the press strip and a end-of-line terminating resistor, or 3. The LED strip goes open circuit. These conditions are fault conditions and the relay is used to inform the external system that a fault has occurred. 3 isolated terminals are provided for the external system to detect this condition. Local indication of the state of the system is provided by a red/green bi-colur LED on the front of the unit. Green is used to indicate all is well i.e. no press has occurred and no faults. If a press is detected then the LED strip flashes and the coloured LED flashes red. If an open circuit occurs in the lines of the press strip, the coloured LED flashes green (the LED strip continues with steady illumination). If the LED strip goes open-circuit then the coloured LED flashes green and the LED strip extinguishes of course. Loss of power leads to extinguishing of both the strip and the coloured LED. Should a press occur, the system operates the press relay and starts flashing the LED strip and the coloured LED. The system has to be reset by applying a short cross the Reset terminals. These terminals operate at the local system voltage (5V) and the external system should provide an isolated pair of contacts if the reset is to be done remotely. No provision has been made for local reset in this unit. However, it could be done quite simply. The Cronapress LED strip is manufactured for use with a 12V supply and this supply voltage has been used for the system since PSUs for this voltage are readily available. However, because many users find the resultant LED strip intensity too bright, the voltage to the LED strip is reduced within the system to create a more
2 acceptable intensity. The level used is controlled digitally within the system and is normally a pre-set value controlled by the software of the microprocessor running the system. This allows the intensity to be altered without any hardware changes should the need arise for a given application. Provision for some local intensity adjustment has been made by 2 shorting links. 4 combinations of Link/no Link is available with these and which give 4 different intensity values; the installer can thus select an intensity from the 4 available The circuit is manufactured on a single PCB and is mounted on a blanking plate of a 1-G patress box with the coloured LED in the centre. Wiring Interface The diagram below shows how the unit is wired in. The Press relay P and Fault relay F have independent commons but will normally be connected together. The relay condition can be detected with the normally-open or normally-closed contacts. The relays give isolation between the external system and the dimmer suystem. The reset connection will normally be connected to an isolated normally-open switch S (a relay) within the external system to give the required isolation. Circuit: The full circuit is shown below. The 12V supply feeds a voltage regulator to generate the 5V local system voltage. The supply to the LED strip is created by use of a series dropping transistor so that the output voltage to the LED strip is set by the difference between the 12V and the output of a DAC. The DAC is controlled by the microprocessor running the system. The microprocessor continuously monitors the voltage on the press strip and the current through the LED strip so that a press can be detected, an open-circuit of the LED or an open circuit of the press strip. The microprocessor then controls the 2 relays and the bi-coloured LED. When a press occurs, the intensity of the LED strip is switched between the normal
3 level and the minimum level that the DAC can achieve to create a flashing of the strip; the software controls the flash rate. The condition of the shorting links is detected and is used to select a different quiescent intensity level. PCB Size:
4 Mounting on 1-G Patress Blanking Plate The 75mm square PCB is mounted on the back of a standard patress blanking plate using 4 M3X20 CSK screws and 8mm nylon spacers. The hole spacing should match the PCB holes and fix the board centrally. An 8mm central hole is for the LED holder and the LED leads should pass through the central hole in the PCB so that they can be connected with TB5. Testing of the System A simple functional test of each system is required and a 12V DC supply is needed. Connections: Connect the 12V supply to the terminals TB6 observing the correct polarity and connect a simple on/off switch to the reset terminals TB4. A length of LED strip will be provided to be connected to terminals TB1 with the correct orientation. A 1k2 resistor should be connected across the profile terminals TB2 and both shorting jumpers should be inserted. 1. With these connections the LED strip should be on and the coloured LED showing green. Relay 1 should be on and relay 2 off (measure NO contacts shorted to com alternatively, NC contact and com are open circuit). This is the normal waiting state
5 2. Short the 1k2 resistor momentarily: Response should be the green LED and the LED strip start to flash. 3. Momentary operation of the reset switch should turn the flashing off and restore the constant green and lighted strip. To the normal state. 4. Check that relay 1 (TB3) is on and relay 2 (TB7) is off Short the 1k2 resistor and check the relay 1 and 2 are both on. 5. Reset to normal state. Check that relay 1 turns off if the 1k2 resistor is open-circuited and led flashes red. 6. Reset. Check that open-circuiting the LED strip turns relay 1 off and the coloured LED shows continuous red. Operating Characteristics Speed of response: Although a press is detected rapidly, it is the operating time of the relay which is the critical factor as far as output response to the external system. Maximum operating time is quoted as 10ms and maximum release time of 5ms for the relays used. Supply Current: The current drawn from the 12V supply is determined primarily by the LED strip and hence depends upon the length of strip; the control electronics draws a very small current in comparison. The LED current also depends upon which of the 4 brightness levels (set by the shorting links) is used. The table below shows the value of supply current at the 4 settings with a 5m, 10m and 15m lengths of LED strip. It should be noted that because of the volt drop along the length of a strip, current values do not scale with length as can be seen by comparing values at each link setting. This drop along the length causes the LED light intensity to reduce with length. Link 5m 10m 15m 00 (both in) 60mA 65mA 80mA mA 160mA 200mA mA 275mA 325mA 11 (both out) 380mA 470mA 530mA Increased lengths of LED strip will produce little increase in supply current; the loss of brightness at the remote end compared with that at the start will become more noticeable. However, this may not be a problem as it will still be easy to distinguish a steady light form a flashing light (after a press ).
6 The results above suggest that a 1A-rated 12V supply will be sufficient for a single dimmer unit. Other Versions 1. Auto-reset: The software for a version of this sytem which automatically resets after 10 on/off flashes is also included. File: 1Glight_Dimmer_PCB4setRevAR.asm 7. Normally Off: A version in which the strip is normally off but flashes when pressed. File: 1Glight_Dimmer_PCB4setR.asm 3. Adjustable: This version utilises the link pins to allow 2 N/O switches to be connected temporarily. The initial part of the program allows the steady intensity of the LED strip to be lowered and raised (up to a set limit). Removal of the switches then gives normal running with the intensity set. File: 1Glight_Dimmer_DAC_Adj.asm
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