Johnson Systems DPC-24-3000 User Manual
User Manual
DPC-12 & DPC-24
3000 Series Digital Pack Controller
Control Retrofit for CD80 Portable Dimmer Packs
Model Description
DPC-12 CD80 12 x 2.4kW, 6 x 6kW and 6 x 12kW Portable Dimmer Packs.
DPC-24 CD80 24 x 1.2 kW and 24 x 2.4kW Portable Dimmer Packs
CD80 48 x 2.4kW Compact Rolling Racks (requires 2 per rack).
JOHNSON SYSTEMS INC.
www.johnsonsystems.com
Table of Contents
Warranty ..........................................................................................................2
Introduction ......................................................................................................3
Packaging & Contents .....................................................................................3
Installation .......................................................................................................3
DPC-24/12 Circuit Board .................................................................................5
DPC-12 and DPC-24 Control Module Face Panels.........................................6
Dual DMX Input and Thru Connectors ............................................................7
User Interface ..................................................................................................7
LCD Display.....................................................................................................8
Programming Switches....................................................................................8
12 or 24 Local Buttons/Switches .....................................................................8
System Status - LED Indicators.......................................................................9
System Status - LCD Display ..........................................................................9
Quick Programming Reference to System Conguration Menu Items .......... 11
Detailed Programming of System Conguration Menu Items........................12
Troubleshooting Reference ...........................................................................23
Important Hard-key Information .....................................................................23
Warranty
DPC-12 and DPC-24 retrot control modules comes with a standard one (1)
year limited warranty against defects in parts and workmanship.
Extended warranties of up to ten (10) years are available at the time of
purchase. For details visit www.johnsonsystems.com/warranties.htm
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DPC-12
Introduction
Digital Pack Controllers (DPC’s) are a next generation retrot electronics
package designed specically for upgrading Strand CD80 12 channel and 24
channel portable dimmer packs, as well as 48 channel compact rolling racks.
This direct plug-in replacement control module supersedes all previous
generations of OEM and aftermarket controllers in both reliability and
features.
“Basic Mode”, on power up, was designed specically at the request of
major U.S. studios and rental houses. Advanced features for the more
selective user allow customization of over 30 additional features. Advanced
next generation “3000 Series” hardware and software designs reduce
stand-by power consumption to less than 1 Watt. Exclusive “lamp warming”
techniques extends lamp life considerably.
DPC-24
Packaging & Contents
DPC-12 and DPC-24 retrot control modules are shipped in a custom
designed box and packaging for protection of the unit. It is recommended to
keep the box and packaging stored in a safe place. In the unlikely event that
the system needs to be returned to the JSI Factory, the packaging will help
prevent shipping damage and maintain warranty.
Installation
DPC-12 and DPC-24 retrot control modules are a “plug-and-play”
replacement for the OEM (Original Equipment Manufacturer) CD80 dimmer
pack control module.
• Disconnect (turn off) the power supply to the CD80 dimmer pack.
WARNING! Verify all power is disconnected (turned off) before proceeding.
Removal of the old CD80 pack control module
• Loosen the two (2) thumbscrews located on each end of the control
module.
• Carefully pull straight out on the thumbscrews to remove the control
module.
• Determine if the DMX input is connected internally, on a terminal block
mounted inside the CD80 dimmer pack. If it is, determine which rear
connector the DMX comes in though.
Installation of the new DPC-12 or DPC-24 retrofit control
module
• Remove your new DPC-12 or DPC-24 retrot control module from the
box.
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(EDGE3) (EDGE2)
CD80 DIGITAL PACK CONTROLLER
REV.1 1132
SERIAL NUMBER
3000 SERIES
DPC-24/12
FAN FUSE
REPLACE WITH
2A 250V
FAST-ACTING
GMA TYPE
FUSE ONLY!
CAUTION: AC LINE VOLTAGE!
MOVE JUMPERS (x3)
TO LEFT-HAND SIDE POSITION
TO ENABLE INTERNAL DMX-B INPUT
EDGE2, 16-Pin
Edge Connector
PIN FUNCTION
13 DMX-B Input Data+
15 DMX-B Input Data-
16 DMX-B Input Shield / Common
EDGE3, 20-Pin
Edge Connector
PIN FUNCTION
1 DMX-B Input Shield / Common
2 DMX-B Input Data+
4 DMX-B Input Data-
• If the DMX input is connected internally, on a terminal block mounted
inside the CD80 dimmer pack, jumpers will need to be moved on the
DPC-24/12 circuit board to enable the DMX-B input. To enable the internal
DMX through the EDGE2 connector on the DPC-24/12 circuit board, move
the three (3) jumpers on JP2 to the left-hand side position. To enable the
internal DMX through the EDGE3 connector on the DPC-24/12 circuit
board, move the three (3) jumpers on JP3 to the left-hand side position.
• Line up the DPC-12 or DPC-24 control module with the guide rails on each
end of the control module slot.
• Carefully slide the DPC-12 or DPC-24 control module in until the
connectors on the DPC-24/12 circuit board touch the rear connectors
inside the CD80 dimmer pack.
• Line up the two (2) thumbscrews on the DPC-12 or DPC-24 with the
mounting holes on the CD80 dimmer pack.
• Firmly push the DPC-12 or DPC-24 in on both ends until the control
module is fully seated.
NOTE: If it feels like the control module isn’t fully seated or doesn’t slide in
easily, it may be necessary to re-align the rear connectors inside
the CD80 dimmer pack to their upper most position, due to the
inconsistencies in the assembly of the CD80 dimmer pack. This can
be accomplished by loosening the two (2) mounting screws on each
end of the rear connectors by half a turn, sliding the connectors up as
much as possible and then re-tightening the mounting screws.
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• Tighten the two (2) thumbscrews to secure the DPC-12 or DPC-24 in the
CD80 dimmer pack.
Turn on and test the new DPC-12 or DPC-24 retrofit control
module
• Connect (turn on) the power supply to the to the CD80 dimmer pack.
• Verify the operation of the system status LED indicators, LCD display and
programming switches.
• Refer to the programming section of this manual for system conguration.
• Test the system thoroughly to ensure everything is functioning properly.
• Verify all of the dimmer control outputs have the correct phase referencing.
If a dimmer control output is patched to the incorrect phase reference, the
dimmer will not dim correctly and will go to full output at around 1% DMX
input. The factory conguration for DPC-12 and DPC-24 control modules
is for standard three-phase applications, with the dimmer phase reference
patch set at AAAABBBBCCCC… For standard single-phase applications,
set the default (DEFAULT) menu for single-phase (1ØPATCH) operation,
with the dimmer phase reference patch set at AAAAAAAACCCCCCCC…
The phase patch (Ø-PATCH) menu must be used to congure non-
standard applications.
• Verify the fan inside the CD80 dimmer pack is operating properly. The fan
should turn on with between 6-7% DMX (or other) control – when DMX (or
other) control drops below 6-7%, there is a 5 minute timeout on the fan to
ensure the dimmers have been cooled sufciently. If required, replacement
fans are available (Johnson System Inc., Part Number: CF-CD80P).
www.johnsonsystems.com
DPC-24/12 Circuit Board
The DPC-24/12 circuit board is the central electronic control system (a.k.a. brain) for DPC-12 and
DPC-24 retrot control modules. The edge connectors (EDGE1, EDGE2, EDGE3 and EDGE5 (for
DPC-24 only)) located on the upper edge of the DPC-24/12 circuit board connects with the OEM
connectors inside the CD80 dimmer pack.
There are three (3) items of interest located on the DPC-24/12 circuit board:
• Located on the upper left-hand side of the board, there is a removable EEPROM memory
module. The EEPROM memory module slides into the PORT1 connector located on
the upper left-hand side of the board. The EEPROM memory module is used to backup
important conguration settings and may be removed for safe storage. The EEPROM
memory module can also be used for rmware updates. Refer to menu items “EEPROM”,
“FW-LOAD”, “RESTORE” and “BACKUP” on page 19, 20 and 21 for further details.
• Located on the upper-central left-hand side of the board, there are two sets of jumpers. If
the DMX input is connected internally, on a terminal block mounted inside the CD80 dimmer
pack, the jumpers will need to be moved on the DPC-24/12 circuit board to enable the
DMX-B input. To enable the internal DMX through the EDGE2 connector on the DPC-24/12
circuit board, move the three (3) jumpers on JP2 to the left-hand side position. To enable the
internal DMX through the EDGE3 connector on the DPC-24/12 circuit board, move the three
(3) jumpers on JP3 to the left-hand side position.
• Located on the upper right-hand side of the board, there is a fan fuse. The fuse is required
for safety and protects the fan control circuitry on the DPC-24/12 circuit board. If the fuse
is blown (open), the “FAN” LED illuminates. A blown (open) fuse suggests the fan may
be defective and needs to be replaced (Johnson System Inc., Part Number: CF-CD80P).
Replace the fuse with a 2A, 250V, fast-acting, GMA type fuse only!
EEPROM Memory Module Enable Internal DMX-B Input Jumpers Fan Fuse
EEPROM
MEMORY
MODULE
MADE IN CANADA
EEPROM
BACKUP &
FIRMWARE
UPDATE
(EDGE3) (EDGE2)
MOVE JUMPERS (x3)
TO LEFT-HAND SIDE POSITION
TO ENABLE INTERNAL DMX-B INPUT
WWW.JOHNSONSYSTEMS.COM
DPC-24/12
CD80 DIGITAL PACK CONTROLLER
SERIAL NUMBER
3000 SERIES
REV.1 1132
FAN FUSE
REPLACE WITH
2A 250V
FAST-ACTING
GMA TYPE
FUSE ONLY!
CAUTION: AC LINE VOLTAGE!
www.johnsonsystems.com 5
DPC-12 and DPC-24 Control Module Face Panels
Dual DMX Input and Thru Connectors (5-Pin XLR)
System Status - LED Indicators
LCD Display
Programming Switches
Infrared (I/R) LED for Printer
Local Button/Switches
(a.k.a. Bump Buttons)
Dual DMX Input and Thru Connectors (5-Pin XLR)
System Status - LED Indicators
Infrared (I/R) LED for Printer
LCD Display
Programming Switches
Local Button/Switches
(a.k.a. Bump Buttons)
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DMX Input and Thru
5-Pin XLR Connectors
PIN FUNCTION
1 DMX Shield / Common
2 DMX Data3 DMX Data+
4 Pass Thru Connection
5 Pass Thru Connection
Dual DMX Input and Thru Connectors
DPC-12 and DPC-24 control modules are equipped with dual (2) optoisolated DMX inputs. The DMX-A and DMX-B input and thru connectors (5pin XLR) are located on the front panel of the control module. A built-in DMX
protocol manager can be congured for various applications. Refer to menu
item “DMX MODE” on page 14 for further details.
NOTE: If DMX is connected internally, on a terminal block mounted inside
the CD80 dimmer pack, the DMX-B input is utilized, and the front
panel DMX-B input should not be used or data collision will occur.
• Complies with USITT DMX512-A (ANSI E1.11 - 2008), standard protocol
for digital data control.
• Recommended cable is Beldon 9829, 9842, Cat 5 or equivalent (lowcapacitance, twisted pair).
• Wiring must follow a daisy-chain topology.
• Maximum of 32 receiving devices on a single DMX line.
• Maximum cable length is 1,500 feet (455 meters).
• For more information, Google DMX, or visit:
http://www.usitt.org/DMX512FAQ.aspx
NOTE: Ensure only the last (end-of-line) DMX receiving device is
terminated!
User Interface
DPC-12 and DPC-24 retrot control modules are equipped with a user
interface. The user interface provides access to all programming and
conguration settings. System status is easily visible on the LCD display
and LED indicators. An infrared (I/R) LED allows for printout of all system
conguration settings when used with a hand held infrared printer (Johnson
System Inc., Part Number: JS-IP).
All of the programming is accomplished using four (4) switches. Within a few
minutes most users will nd the menu structure very intuitive and easy to
navigate. All conguration settings are automatically stored in the on-board
EEPROM.
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LCD Display
The LCD display is capable of displaying 2 lines of 8 characters. A backlight automatically comes
on when activity is sensed. The LCD contrast can be easily adjusted for optimum viewing.
Refer to menu item “LCD VIEW” on page 22 for further details.
Programming Switches
The MENU UP/DOWN ( ) switches are used for navigating through the various system
conguration menu items. They also allow for programming of other specic parameters within
a selected menu. Pressing and holding either switch will speed up the scroll rate, which can be
helpful to speed up the conguration time.
The EXECUTE ( ) switch is normally used to select/enter a menu item, advance forward within
a selected menu item, or toggle between parameters within a selected menu item.
The ESCAPE ( ) switch is normally used to back up within a selected menu item one step at a
time or exit the menu completely.
The RESET switch has two purposes. First, it allows for quick exit from a menu item after a
programming change and automatically puts the system into normal run mode. Second, it provides
a soft reboot for the systems microcontroller.
The programming switches are backlit with blue LED’s. The LED’s automatically turn on when
activity is sensed. The LED intensity can be adjusted in the “LED INT” menu. Refer to page 24 for
further details.
NOTE: When the DPC-12 or DPC-24 is powered up, the menus are “LOCKED!!” with access
only to the basic system conguration menus, which includes setting the DMX start
address as well as enabling or disabling the end-of-line DMX termination. The menus
need to be “UNLOCKED” to access the advanced system conguration menus. To
toggle between “LOCKED!!” and “UNLOCKED” press and hold down the EXECUTE and
then ESCAPE switches at the same time for 4-5 seconds.
NOTE: A detailed procedure for programming all system conguration menu items can be found
on page 11 to 22.
12 or 24 Local Buttons/Switches
The 12 or 24 local buttons/switches (a.k.a. bump buttons) can be congured for two different
modes. They can either be congured as bump buttons or to activate scenes. Refer to menu item
“L-BUTTON” on page 17 for conguration details.
The local buttons are backlit with blue LED’s. The LED’s indicate the approximate control level for
each of the 12 or 24 dimmers. As the control level for a dimmer is increased, the intensity of the
LED increases.
For a 6 dimmer circuit CD80 pack, button 1 controls and indicates dimmer 1, button 3 controls
and indicates dimmer 2, button 5 controls and indicates dimmer 3, button 7 controls and indicates
dimmer 4, button 9 controls and indicates dimmer 5 and button 11 controls and indicates dimmer 6.
NOTE: To congure a DPC-12 for 6 PACK (6 dimmer circuit CD80 pack) operation,
select 6 PACK in the DEFAULTS menu..
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