Solution Cool Dimmer Installation Guide

Transcription

1 Solution Cool Dimmer Installation Guide Document: Revision 4.0 December 2004

2 2 SOLUTION COOL DIMMER INSTALLATION GUIDE Contact Us State Automation Pty Ltd ABN Fonceca Street PO Box 632 Mordialloc VIC 3195 Australia Phone +61 (0) Fax +61 (0) info@stateautomation.com State Automation may have patents and/or pending patent applications covering subject matter in this document. The provision of this document does not provide any license on these patents. State Automation All rights reserved. This manual and any programs described herein are copyrighted by State Automation with all rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, mechanical, photocopying, recording or otherwise, without the prior permission of State Automation. All State Automation product names are trademarks or registered trademarks of State Automation. Other brand or product names are trademarks or registered trademarks of their respective owners. Specifications are subject to change without notice. State Automation October 2006

3 CONTENTS 3 1 About this guide Installation Mounting the dimmer...6 Ventilation and maintenance allowances 6 Mounting without brackets 8 Mounting with optional brackets 9 19 rack mounting 11 Mounting with hook clamps Connecting power Connecting loads Connecting Input Signals DMX input C-Bus input C-Bus remote override input...18 C-Bus power requirements 19 4 Commissioning Visual Inspection Physical checks Applying power Controlling Loads Cleaning and Maintenance How to clean the dimmer externally How to clean the dimmer internally Service Glossary October 2006 State Automation

4 4 SOLUTION COOL DIMMER INSTALLATION GUIDE Appendix A: Product Specifications General limits 28 Input filter specifications 29 General levels 29 Interfaces 29 Remote inputs 30 Status Indicators 30 Load indicators (1-12) 30 Mechanical 30 Appendix B: Physical Dimensions Figure 1: Ventilation and maintenance clearances...7 Figure 2: Mounting without bracket...8 Figure 3: Mounting bracket...9 Figure 4: Shallow mounting bracket...10 Figure 5: Deep mounting bracket...10 Figure 6: Light bar mounting hooks...11 Figure 7: Light rail mounting hooks...12 Figure 8: Internal input wiring...13 Figure 9: Internal input and load wiring...14 Figure 10: Internal close up load wiring...15 Figure 11: Internal DMX terminal...16 Figure 12: Internal C-Bus termination...17 Figure 13: C-Bus remote override input...18 Figure 14: Physical dimensions...31 State Automation October 2006

5 ABOUT THIS GUIDE 5 In this guide: Actions (procedures) performed by the user are set out in three columns: Action provides step by step instructions or simply indicates the button to press. Outcome describes or shows what happens after the step is completed. Notes provide more information about that step, such as valid values to enter. All dimensions are in millimetres. This guide uses the following icons to mean: Refer to another section. Procedure continues over the page. End of procedure. 19 October 2006 State Automation

6 6 SOLUTION COOL DIMMER INSTALLATION GUIDE Installing the Solution COOL dimmer involves the following steps. 1. Mount the dimmer. 2. Connect mains supply. 3. Connect loads. 4. Connect input signals as required: C-Bus input, C-Bus remote override input, DMX-512 input. 5. Reset configuration values. This step is recommended if the dimmer has previously been in service. Refer to the Solution COOL Dimmer User Guide for instructions on how to reset configuration values. The Solution COOL dimmer can be mounted: directly onto a wall without brackets, onto a wall using optional mounting brackets, or on a 50mm bar using mounting brackets or hook clamps. Refer to the mounting template provided with the Solution COOL dimmer. Ventilation and maintenance allowances The following diagram shows the minimum clearances for ventilation and maintenance. Minimum spacing vertically is 100mm to allow for ventilation. Minimum spacing horizontally is 50mm to allow for servicing. Suggested minimum distance from the floor to the first dimmer is 300mm. Consult local electrical standards for any minimum height requirements. Minimum spacing from the top dimmer to the ceiling is 150mm. Consult local electrical standards for maximum working height of circuit breakers. State Automation October 2006

7 INSTALLATION 7 Minimum clearances Figure 1: Ventilation and maintenance clearances 19 October 2006 State Automation

8 8 SOLUTION COOL DIMMER INSTALLATION GUIDE Mounting without brackets All Solution COOL dimmers can be mounted directly onto a wall. Fixing points and cable entry knock-outs are shown in the following diagram. Figure 2: Mounting without bracket State Automation October 2006

9 INSTALLATION 9 Mounting with optional brackets By using the optional mounting brackets system, all cabling can be roughed in on a building site prior to mounting the dimmers. Cable entry points Figure 3: Mounting bracket 19 October 2006 State Automation

10 10 SOLUTION COOL DIMMER INSTALLATION GUIDE Shallow mounting bracket Figure 4: Shallow mounting bracket Deep mounting bracket Figure 5: Deep mounting bracket State Automation October 2006

11 INSTALLATION rack mounting The mounting brackets are designed for 19 rack mounting. The Solution COOL is 12 rack units (RU) high, allowing up to three Solution COOL dimmers to be mounted in a standard 45RU high rack. Recommended spacing between units is 3RU. Consult State Automation or your local agent for additional information on high density installations. Mounting with hook clamps A kit is available from State Automation to allow the use of hook clamps for mounting the Solution COOL dimmer. This allows the dimmer to be: mounted from a 50mm bar, or flown on a 50mm bar in a theatre. Care should be taken when using these clamps to ensure that sufficient support is provided. Figure 6: Light bar mounting hooks 19 October 2006 State Automation

12 12 SOLUTION COOL DIMMER INSTALLATION GUIDE Figure 7: Light rail mounting hooks State Automation October 2006

13 INSTALLATION 13! Megger testing State Automation recommends that Solution COOL dimmers be disconnected before megger testing. Megger testing of an electrical installation incorporating C-Bus units will not damage them. Since C-Bus units contain electronic components, the installer should interpret megger readings with due regard to the nature of the circuit being tested. The dimmer must be connected to a properly rated, three phase mains supply by suitably qualified personnel. The power terminal block is located in the upper right hand corner of the unit, as shown in the diagram below. This terminal block can accommodate power wiring with the following cross-sections. Cross-section 10.00mm mm 2 Models 10A, 12A and 16A 20A and 50A A threaded post connecting to the chassis is provided for the earth wire termination. Figure 8: Internal input wiring The Solution COOL dimmer is fed from a three phase, neutral and earth power supply. The three green phase indicators on the front panel indicate the presence of voltage on each phase. 19 October 2006 State Automation

14 14 SOLUTION COOL DIMMER INSTALLATION GUIDE The diagram below shows the inside of the Solution COOL dimmer. The supply and load terminal block is on the right hand side of the unit. Supply Terminals Load Terminals Figure 9: Internal input and load wiring State Automation October 2006

15 INSTALLATION 15 Each channel has three terminals: Active (A) Neutral (N) Earth ( ). Figure 10: Internal close up load wiring The terminal block can accommodate load wiring up to 4.0mm 2. Earth bar 19 October 2006 State Automation

16 16 SOLUTION COOL DIMMER INSTALLATION GUIDE The DMX input to the Solution COOL dimmer connects to either: the DMX IN socket on the front panel, or the internally mounted three-way connector. The Internal DMX terminal connection on the C-Bus DSP board The DMX signal may be: Figure 11: daisy-chained to the next dimmer, or terminated by: Internal DMX terminal soldering a 120 Ohm resistor across pins two and three of a male XLR plug and connecting to the female DMX OUT socket on the front panel, or connecting a 120 Ohm resister across the DMX+ and DMX- terminals on the internal connector. The DMX input signal should conform to the USITT DMX-512 (1990) specification. The amber DMX LED indicates the presence of DMX signals. If the DMX LED: is lit, then DMX signals are present is not lit, then there is no DMX signal present flashes, then there were DMX signals but they are no longer present. The Solution COOL dimmer features a Last Hold function that remembers the last received DMX message (packet). In the event of a DMX signal cable being unplugged or severed, the dimmer holds the DMX levels until a new DMX message is received. State Automation October 2006

17 CONNECTING INPUT SIGNALS 17!" The Solution COOL dimmer must be connected to the unshielded twisted pair C-Bus Network Cable. State Automation recommends the use of Category 5 data cable. The connection is polarity sensitive. The warranty for the Solution COOL dimmer will be voided by: use of non-specified cable for C-Bus failure to ensure the use of correct conductor pairs. C-Bus can be connected to the Solution COOL dimmer in two places: the internally mounted three way connectors, located on the DSP board, or the front-mounted RJ-45 connector. The diagram below shows the recommended technique for cable termination to give the best electrical performance. Internal C-Bus termination Figure 12: Internal C-Bus termination External C-Bus termination RJ45 8 Pin Pin Allocation Colour 1 Remote ON Green/White 2 Remote ON Green 3 C-Bus Neg (-) Orange/White 4 C-Bus Pos (+) Blue 5 C-Bus Neg (-) Blue/White 6 C-Bus Pos (+) Orange 7 Remote OFF Brown/White 8 Remote OFF Brown 19 October 2006 State Automation

18 18 SOLUTION COOL DIMMER INSTALLATION GUIDE!"# All dimmer channels may be controlled remotely using: the extra pairs of conductors on the C-Bus connector, or the internal four-way connector. The C-Bus interface specification assigns four cores of the 8-core cable for remote override switches. Remote override provides a means to set all dimmer channels to full output or zero output, regardless of the level of data communications via the C- Bus network. Remote override is implemented by SPST ON and OFF switches connected to the dimmers as shown in the diagram below. The diagram also shows switches which may be connected in parallel on any single network, using green and green/white conductors for the remote ON function. Brown and brown/white conductors may be wired in the same way for remote OFF, with these conductors being connected to C-Bus negative via the switch. A Clipsal 30/1/2LM mechanism makes an ideal remote input switch. There can be more than one remote ON switch and more than one remote OFF switch. Additional switches are wired in parallel on the network. Note Bus is a balanced network. At any point where C-Bus negative is taken, C- Bus positive must also be present. Both network conductors must be looped through all remote input switches on the network. Figure 13: C-Bus remote override input State Automation October 2006

19 CONNECTING INPUT SIGNALS 19 C-Bus power requirements The Solution COOL dimmer will draw 22mA from the C-Bus network. Adequate C-Bus power supply units must be installed to support the connected devices. If in doubt use the C-Bus Calculator software available from Clipsal Integrated Systems to verify network design before proceeding. Refer to: for the calculator for information about Clipsal Integrated Systems. 19 October 2006 State Automation

20 20 SOLUTION COOL DIMMER INSTALLATION GUIDE $ $ % There are four main areas to check during a visual inspection of the Solution COOL dimmer. Check all wiring is in the correct terminals. Inspect all spade connectors. Inspect the ribbon cable between the DSP board and the Trigger card. Inspect all hard-wired connections including three-phase input wiring and output load wiring (Solution COOL hard-wired versions only). $ &' ( Pull each wire in turn to ensure it is actually being secured by the terminal. Check the tension on all terminations. Check the ribbon cable between the DSP board and the Trigger card is secure. Check there are no obstructions in the cooling fan. Using a vacuum cleaner or compressed air, remove all swarf and building dust from the unit. State Automation October 2006

21 COMMISSIONING 21 $ '! WARNING Isolate power at the source before connection. Action Outcome Notes 1. 1Ensure the mains supply is protected. 2. 2For units with a mains input lead, connect the power plug. 3. 3Apply mains power to the dimmer. 4. 4Turn on the RCD switch. The dimmer runs through the power up sequence: 1. The green RUN LED turns on. 2. The channel LEDs cycle through green, amber and red. 3. The phase LEDs cycle on and off individually. 4. The display shows the software version number followed by the operating voltage of that software (either 110V or 220V). 5. The DMX, RUN, DMX Address and Level LEDs light briefly. The mains supply to the dimmer must be protected by upstream circuit breakers or fuses rated as specified for the model purchased Connect the power plug to an appropriately rated socket outlet. Ensure the plug s retaining lock ring (if present) is screwed home. If the RCD trips immediately, the input is incorrectly connected. If the dimmer displays a number preceded by the letter E, an internal error occurred. For an explanation of errors, refer to the Solution COOL Dimmer User Guide. 19 October 2006 State Automation

22 22 SOLUTION COOL DIMMER INSTALLATION GUIDE Action Outcome Notes 5. 5Turn on the MCB to apply power to the first load to be checked. 6. 6Observe the load for correct performance over the full dimming range. 7. 7Repeat steps 5 and 6 for all operational channels. 6. The green RUN LED pulses and the DMX address displays or the word Bus appears if running from C-Bus. 7. The three phase indicators are lit. Power will be applied to the load in accordance with control signals. Loads should exhibit smooth flicker-free dimming over their full operating range. If one or more indicators fail to light up, there is either an error in the wiring of the mains input to the dimmer or a missing phase. Refer to the Solution COOL Dimmer User Guide for instructions on how to flash a channel, or use DMX-512 or C-Bus to adjust the output level. State Automation October 2006

23 COMMISSIONING 23 $$ Loads connected to the C-Bus Solution COOL dimmer may be controlled by a combination of C-Bus commands, DMX data and remote override switches. If the dimmer overheats or channels are disabled, loads are turned off. The table below shows the priority ranking of the control inputs. Priority Mode Function 1 (Highest) Max Voltage Scaling Maximum output voltage 2 Channel Isolated Fault condition 3 Channel Disabled User disable 4 Channel Curve Scaling User selectable dimming curves 5 Maximum Level Scaling Max output level 6 Minimum Level Scaling Min output level 7 Flash Channel Flash output to max Then for DMX Channels 8 DMX 512 Control DMX 512 data levels Or C-Bus Channels 8 Remote OFF C-Bus override OFF 9 Remote ON C-Bus override ON 10 Local Toggle Buttons on front panel 11 (Lowest) C-Bus C-Bus input level Local override has priority over normal C-Bus commands received on the bus, such as those generated by pressing a C-Bus key. By default, if any channel is in local override mode and a C-Bus command is received for that channel, the C-Bus command state will be imposed ( Enable C-Bus Priority option). This feature can be disabled in software so that the unit whilst in Local Override Mode will ignore all relevant C-Bus commands. Note When channels of the Solution COOL dimmer are being controlled by DMX rather than C-Bus, the Remote OFF, Remote ON and C-Bus modes are not used. The DMX signal becomes the lowest priority input signal to the unit. 19 October 2006 State Automation

24 24 SOLUTION COOL DIMMER INSTALLATION GUIDE )! WARNING Do not allow liquids of any sort to enter the dimmer body. To comply with safety requirements, all internal protective earth cables must be connected to appropriate dimmer enclosure elements. Installed dimmers need little maintenance; however, if the dimmer is installed in a dusty location then remove built up dust every six to twelve months. For instructions, section 5.2, How to clean the dimmer internally. Transportable dimmers need a more rigorous maintenance routine: Inspect the chassis for evidence of impact damage and physical abuse. Inspect outlets for wear and damage. Inspect the power cable for wear and damage. Check ground integrity from power cable to chassis. Check ground integrity from power cable to outlet grounds. Flush dust build up. For instructions, section 5.2, How to clean the dimmer internally. Test the operation of all front panel switches and breakers. ) * +' Wipe the front panel with a mild detergent on a damp soft cloth. Do not spray liquids onto the front panel. Do not use solvents to clean the front panel. State Automation October 2006

25 CLEANING AND MAINTENANCE 25 ) * ' The Solution COOL dimmer requires little internal maintenance other than periodic dusting with compressed air. This will remove any dust or fluff which may clog the fan and air-path. Action Outcome Notes 1. 1Isolate power to the dimmer. 2. 2Open the cover. 3. 3Blow compressed air over the fan and internals. 4. 4Make sure the protective earth cable is connected to each removable panel or hinged lid. 5. 5Replace the lid and screws. 6. 6Reconnect the power. Any dust or fluff which has built up is removed. Isolate power by: disconnecting the power cable, or locking off the mains supply isolator. NOTE Do not spin the fan with compressed air or the blades may break. 19 October 2006 State Automation

26 26 SOLUTION COOL DIMMER INSTALLATION GUIDE, # Contact your authorised State Automation distributor for repairs or servicing. State Automation Pty Ltd Service Department Fonceca Street MORDIALLOC VIC Phone +61 (0) Fax +61 (0) Service Support phone: State Automation October 2006

27 GLOSSARY 27 -.' C-Bus Channel Dimmer DSP board DMX Megger testing Phase RCD TN-S A communications protocol patented by Clipsal. One circuit of a dimmer/distribution system. A dimmer channel may be connected to one or more lamps in parallel. Also refers to the control value in the DMX system. A device which controls the intensity of a lighting fixture. Digital Signal Processor Board. Located behind the control surface, this printed circuit board is the intelligence of your Solution COOL dimmer. Wiring connector terminals for DMX and C-Bus are located on this board. DMX-512 (1990) is a specification for communication between control desks and dimmers or fixtures. Originally for dimmers, it has been adopted as a control protocol for most lighting systems. It can carry 512 different slots of 8-bit data. Testing between circuit and earth for insulation and isolation. Mains power is supplied in three different live conductors, each called a phase. Consult an electrician for more details. Residual Current Device. This helps to protect the user against electrocution by detecting any imbalance between current leaving the unit down the live conductor and the current returning down the neutral. It isolates the supply if the current differs by more than 30mA. Type of three phase power system with neutral bonded to earth at the substation and a separate earth conductor throughout the system. 19 October 2006 State Automation

28 28 SOLUTION COOL DIMMER INSTALLATION GUIDE +/&. AC supply voltage AC supply frequency Frequency drift 230V+/-10% 40-80Hz 2Hz/sec for normal operation. If exceeded, all loads turn On for 0.5 sec & unit reverts to normal mode Frequency step change 1Hz for normal operation. If exceeded, all loads turn On for 0.5 sec & unit reverts to normal mode Channels &12 6&12 3 Max. load RMS current per channel MCB rating 10A 12A 16A 20A 25A 50A Max I 10A 12A 14.4A 20A 22A 50A Breaker type Operating ambient temperature Operating humidity Switching technology Min. channel peak non-repetitive full cycle surge current RMS surge (non-repetitive) I 2 t for fusing (10mSec Period) Peak repetitive half cycle current Max load shunt capacitance Max. number of units on a single C-Bus network Compatible Loads Minimum Load Standard IP, 6KA interrupt capacity (Neutral disconnect 1P+N [DPN] optional) 0-40 o C 0-95% RH (non-condensing) Dual TRIAC per channel in Advanced Phase Control (APC) configuration 60Hz 420A 50 Hz 400A 450A 2 Sec 55A 5nF per Watt (approx) 100 Suitable for incandescent, low voltage lighting and ceiling sweep fans (contact manufacturer) Suitable for electronic transformers compatible with leading edge dimmers 60 Watts/channel (Resistive load), 100Watts/channel (Inductive or Capacitive load) State Automation October 2006

29 APPENDIX A: PRODUCT SPECIFICATIONS 29 Rated voltage Test voltage (1 min) Line to line Line to earth Rated current Temp range Leakage current Insultation resistance 440/250 VAC 1500 VDC 1500VAC / 2250VDC 65A -25C to +85C < 1.5mA (250VAC / 50 Hz) >1500 MOhm (500 VDC).# Off state power consumption <55 Watts (unloaded) <65Watts (loaded) Off state AC supply current 250mA (unloaded) 750mA (loaded) Output filter Toroidal inductors Rise time (10%-90%) 200 microsecs 440 microsecs (optional) Load terminal off state leakage current 25 o C (heatsink temperature) Load terminal off state voltage Input voltage (open circuit), 0V (with normal load) Power control range 0-99% Warm up time 10 Seconds DMX interface External connection (DMX 512 Std) Internal connection (hardwired) C-Bus interface Network operating voltage range Unit input current AC input impedance Electrical isolation Network clock Network burden C-Bus connection INPUT 5 pin AXR male, OUTPUT 5 pin AXR female Phoenix 3 pin PCB plug with screw terminals 15-36Vdc 22mA 1kHz 3.75 kv RMS from C-Bus to mains (provided external to unit) Software selectable, 2mSec between clock pulses, amplitude 2.5V Software selectable (unit address 01 only) 2 x RJ-45 connectors 1 x 4-way removable terminal block 19 October 2006 State Automation

30 30 SOLUTION COOL DIMMER INSTALLATION GUIDE 0 Open-state voltage (On/Off input) Maximum cable length Remote input to C-Bus isolation voltage Remote override input 5V C-Bus RJ-45 connectors on front panel 1000m Alternately, wire on 4-way Phoenix connector located internally on the processor board 1m Not isolated 2 x RJ-45 connectors; 1 x 4-way removable terminal block C-Bus LED Indicator status C-Bus clock C-Bus voltage ON OK 20V DC FLASH OK < 20V DC OFF No clock n/a OFF n/a < 15V DC Unit LED Indicator status System condition C-Bus power ON Normal operation OK FLASH At least one channel in local or remote override mode OK OFF C-Bus not available Fail 1!2 Load indicator is On (amber) when dimmer output is On at any C-Bus determined dimming level Load indicator is On (green) when dimmer output is On at any DMX determined dimming level Mains supply terminals Accommodates 1 x 6.0mm 2 Load terminals Accommodates 1 x 4.0mm 2 or 2 x 2.5mm 2 Dimensions Weight 533 x 486 x 163mm 30kg State Automation October 2006

31 APPENDIX B: PHYSICAL DIMENSIONS 31 +"/&' Figure 14: Physical dimensions 19 October 2006 State Automation