Dove Systems DM 624 RM User Manual

OWNER'S MANUAL

DIMMERMASTER 624

DIGITAL DIMMER

Dove Systems

3563 Sueldo Street Unit E

San Luis Obispo, CA 93401

[phone]

fax [phone]

[e-mail]

www.dovesystems.com

DM624 Rev. 1.10 02/26/98

TABLE OF CONTENTS

1) SETUP AND CONNECTION 1
A) Mechanical Installation 1
B) Rack Mounting 1
C) Electrical Installation 1
D) Grounding 1
E) Load Connections 2
F) Control Connections and Overtemp Sensing 2
G) Channel Selection and Testing 3
H) Indicators 3

2) TROUBLESHOOTING CHART 3

3) WARRANTY INFORMATION 4

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1. SETUP AND CONNECTION

A) MECHANICAL INSTALLATION
Remove all packing material from the unit. Make certain that all holes are free of obstruction on all sides of the unit.

Replace all packing material in the carton and store it for reuse.
For portable use, set the Dimmermaster on a smooth, cool surface. Up to 2 packs may be stacked vertically. Do not

remove the feet when stacking. Do not block any vent holes. Make certain that the vent holes all have at least 6 inches
of free air around them. It is essential that this unit have adequate cooling for safe, reliable performance. Maximum
air temperature must not exceed 40E Centigrade (105E Fahrenheit).

B) RACK MOUNTING
The Dimmermaster may be rack mounted in a standard EIA 19-inch equipment rack. The rubber feet may be

removed. Do not remove the top and bottom panels. The Dimmermaster occupies 5.25 inches of space in the rack,
or three rack units. For best cooling, an additional 1.75 inches, or one rack unit, between packs is recommended. The
rack should be ventilated from the top at a minimum of 120 CFM.

C) ELECTRICAL INSTALLATION
The dimmer must be supplied with an amount of current equal to the combined total current of the lamps it controls.

To calculate this current, use the formula amps = watts ÷ volts. For example, if six 2400-watt, 120 volt lighting units
are connected to the dimmer, it would require 14,400 ÷ 120, or 120 amps total power. This is available from a three
phase 4 wire 40 amp or a single phase 3 wire 60 amp service. Usually this much power is not required and a 30 - 50
amp service may be used with lower power loads plugged in.

The Dimmermaster accepts either three phase or single phase power input and is factory configured for three
phase. Line to neutral voltage is always 120 volts. Line 1 to Line 2 voltage is 208 volts in three phase service
and 240 volts in single phase service. It is very important that the input voltages be checked with a meter to
insure that they are correct. A mistake can place 208 to 240 volts across a 120 volt lamp. The breakers will
protect the unit but may not save the lamps. A double check of voltages before applying power can guard
against such disaster.

The power input connector is a terminal block. Each leg of the power feed connects to one terminal on the dimmer
pack. These are marked "L1", "L2", and "L3". The neutral connection is made on the neutral bar, just to the left of the
power block. The ground connection is made on the ground terminal, just to the right of the power block. The pack has
circuit breakers to protect each dimmer channel, but the primary circuit protection and disconnect is to be provided
by the user.

When single phase service is used switch SW1, located near the center of the board, must be moved from the "6"
position to the "4" position. The power input terminal marked "L3" is not used. The two blue wires wrapped with red
tape must be moved to the terminal marked "L1" and the two wrapped with black tape to "L2". The tiny blue wire stays
in terminal "L3". Please refer to the diagrams at the rear of this manual.

D) GROUNDING
The term GROUNDING refers to a separate wire with green insulation which is connected from the equipment case

to earth ground (often through a properly grounded conduit system). This is not the same as the neutral or common
and must not be confused with them. The neutral is a separate, load-carrying circuit conductor. The ground conductor
should not normally carry current.

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When the Dimmermaster is connected to its power source by a flexible rubber cable, the ground connection is made
through a wire in the cable. For maximum safety and to comply with electrical codes, this connection must be made.
Cables supplied by Dove Systems are pre-wired for this connection and include the necessary green wire. Be sure
this is firmly bonded to a ground connection box, a cold water pipe, or a known earth ground.

When the Dimmermaster is connected to its power source by conduit, the ground connection can be made via the
conduit itself. If flexible conduit is used, a separate bonding conductor will usually be required. Always check your local
codes for hook-up before operating this equipment. It is recommended that power connections to the Dimmermaster
be made by a qualified electrician.

E) LOAD CONNECTIONS
The dimmer pack consists of six dimming channels. The Dimmermaster will dim any load from 1 watt through 2400

watts at 120 volts. The load may be incandescent, inductive, or resistive. This includes conventional incandescent,
quartz incandescent, rain-lights, pin beams, and similar lamp loads. This does not include fluorescent or neon lamps.
Dove Systems offers a solid state transformer to dim other types of loads, such as 12 volt MR16 lamps.

The output connectors can be U-ground receptacles, stage pin receptacles, twist-lock receptacles (L5-20R), or a
terminal block. If your unit has receptacles installed, merely plug the load into the outlet which corresponds to the circuit
you desire to use. For terminal-block-only units, there is one lug for each output and a neutral bar for all neutrals. Lugs
are numbered according to their circuits. There should be a separate neutral returning from each load circuit.

F) CONTROL CONNECTIONS AND OVERTEMPERATURE SENSING
The Dimmermaster 624 can take either of two control protocols: USITT DMX-512 or 0 to +10VDC analog. DMX

control input connections are made through the five pin male XLR on the front of the unit. Analog 0 to +10VDC
control input connections are made through the DB15 male on the front of the unit.

XLR DB15
DMX ANALOG

PIN 1 Common PIN 1 Channel 1 PIN 9
PIN 2 Data PIN 2 Channel 2 PIN 10
PIN 3 Data PIN 3 Channel 3 PIN 11
PIN 4 N/C PIN 4 Channel 4 PIN 12
PIN 5 Overtemp PIN 5 Channel 5 PIN 13 Optional power supply

PIN 6 Channel 6 PIN 14 Optional power supply
PIN 7 PIN 15 Common
PIN 8

Pin 5 of the XLR is the overtemp line. When the temperature of the heatsink exceeds 70E Celsius, pin 5 is
pulled to signal common. Some controllers, including Dove Systems memory controllers, read this and display
an overtemp warning message.

When the temperature of the heatsink exceeds 75E Celsius, the control is cut off. This prevents overheating. When
the heatsink cools, the loads begin to work again. If this happens, the air circulation around the dimmer should be
improved. Check that the internal fan has not failed.

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G) CHANNEL SELECTION AND TESTING
The thumbwheel switch on the front of the unit is the channel selection switch. The number shown is the starting

dimmer. Valid starting dimmer numbers range from 1 to 501. The starting dimmer number determines the setting
for the entire pack of six dimmers. If, for example, the starting dimmer number is 37, the pack reads control
signals for channels 37 through 42.

When the first digit of the thumbwheel switch reads "6", the pack is in load testing mode. The second and third
digits show the dimmer being tested, from 1 to 6. The load test forces the output of the dimmer to full. This is
helpful for focusing and troubleshooting. (e.g. Which channel is that? Is the lamp burnt out?)

H) INDICATORS
The status indicator LED is used to check the Dimmermaster for proper control and power connections. It shines

green when it is receiving power and a valid DMX signal, and both red and green (amber) when it is receiving power
but a bad signal. It also shines both red and green when it is receiving an analog signal only. No light at all means that
it is not receiving power.

2. TROUBLESHOOTING CHART

SYMPTOM: No channels work; no lights at all.

Possible cause: Action to take:

*Improper pinout on controller or cable wires Check pinout. Check cable.

reversed

*Control console incorrectly set up Reread operating instructions;

check setup & protocol on console.
*Defective control card Replace Control Card Assembly.
*Thermostat has opened Improve air circulation or reduce loads. Check internal

fan. Unit will start working when cool.

SYMPTOM: One or more channels are out.

Possible cause: Action to take:

*No load connected or lamp Check instrument in known

burned out good outlet.
*Channel breaker is tripped Check load, reset breaker.
*Power wire not connected Check for proper phasing on power wiring
*Test switch in load test mode Select proper starting channel

SYMPTOM: Channels are stuck on or off or work backwards

Possible cause: Action to take:

*Incorrect power wiring or switch setting Check power wiring and switch SW1
SYMPTOM: Channel breaker keeps tripping.

Possible cause: Action to take:

*Shorted cord or fixture Clear fault and reset breaker.
*Channel overload Reduce wattage connected and reset breaker.

SYMPTOM: One or more channels are up full and won't dim.

Possible cause: Action to take:

*SCR failure Replace SCR module.
*Control console incorrectly set up Reread the operating instructions

(Unplug control line to verify) of console
*Test switch in load test mode Select proper starting channel

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SYMPTOM: Some channels flicker

Possible cause: Action to take:

*Intermittent connection in Recheck all connections.

control or load lines
*SCR or control circuit failure Replace SCR module or card
*Slide controls are broken Have slide control replaced. Treat temporarily

or dirty with WD-40 or Tri-flow.
SYMPTOM: Some channels ghost

Possible cause: Action to take:

*Trim out of adjustment Adjust trimmers R16, R15, or R27

TO CHANGE AN SCR MODULE OR SSR: 1. DISCONNECT POWER FROM DIMMER. 2. REMOVE FIVE
SCREWS BINDING TOP PANEL TO SIDE PANELS AND BACK. 3. REMOVE CONNECTIONS FROM THE
SUSPECT SCR MODULE. THERE ARE SIX MODULES WITH TWO CHANNELS IN EACH. THE MODULE
CLOSEST TO THE FAN IS CHANNELS 1 AND 2. 4. REMOVE SCREWS BINDING MODULE TO HEAT
SINK AND REPLACE MODULE. 5. REASSEMBLE IN REVERSE ORDER OF DISASSEMBLY.

TO CHANGE THE CIRCUIT CARD: 1. DISCONNECT POWER FROM DIMMER. 2. UNSCREW FOUR
CAPTIVE SCREWS HOLDING CIRCUIT BOARD PANEL TO FRONT PANEL. 3. SLIDE CARD OUT. SET
JUMPERS AND SWITCHES ON REPLACEMENT CARD TO MATCH. 4. SLIDE REPLACEMENT CARD IN
UNTIL IT SEATS INTO EDGE CONNECTOR AND SCREW DOWN.

Users with further technical questions may call the factory at [phone]. NOTE: DOVE SYSTEMS DIMMER
PACKS USE TRADE SECRET AND PROPRIETARY CIRCUITY. FOR THIS REASON, SCHEMATICS
CANNOT BE RELEASED FOR THIS PRODUCT. To obtain service, pack the unit with the original packing
materials or crushed newspaper and return it, freight prepaid, to:

Dove Systems (The repair process is expedited when you include: a note
3563 Sueldo Street Unit E describing the problem; your daytime phone number; and your
San Luis Obispo, CA 93401 return UPS shipping address.)

3. WARRANTY INFORMATION

The manufacturer agrees that the Dimmermaster 624 shall be free from defects in material or workmanship from date
of shipment over a period of one year. Said warranty will not apply if equipment is used under conditions of service
for which it is not specifically intended. The manufacturer is not responsible for damage to its apparatus through
improper installation, physical damage, or poor operating practice.

If any device is found unsatisfactory under the warranty, the buyer should notify the manufacturer, and after
receipt of shipping advice, buyer may return it directly to Dove Systems, San Luis Obispo, CA, shipping prepaid.
Such equipment will be replaced or put in proper operating condition, free of all charges except transportation.
The correction of any defects by repair or replacement by the manufacturer shall constitute fulfillment of all
obligations to the purchaser. Manufacturer does not assume responsibility for unauthorized repairs to its
apparatus, even though defective.

Manufacturer shall not be liable for any consequential damage in case of any failure to meet the conditions of
any warranty of shipping schedule, nor will claims for labor, loss of profits, repairs, or other expenses incidental
to replacement be allowed.

No other representations, guarantees or warranties, expressed or implied, are made by the manufacturer in
connection with the manufacture and sale of its equipment. This warranty is non-transferable and applies to the
original buyer only. Copyright Dove Systems 1994

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