Leprecon LP-900 User Manual

Leprecon®
Pro Lighting Equipment

LP-900 and LP-1000 Service Manual

Leprecon/CAE, Inc.

10087 Industrial Drive
PO Box 430
Hamburg, MI 48139 USA
810-231-9373 FAX [phone]

This document is the property of CAE, Inc. and is provided for service and instructional purposes
only. Possession does not imply or convey rights to use any information herein. This information
is proprietary and may relate to patents or patents pending that are the property of CAE, Inc.,
other than the use of products manufactured by CAE, Inc., Inc.

Leprecon®

Pro Lighting Equipment

LEPRECON LP-900 & LP-1000 SERVICE MANUAL

CONTENTS

1 Contents
2 Introduction and Specifications
3 & 4 Operating Precautions
5 Output Adjustment – Trimming
6, 7, 8 Repairs and Maintenance

DOCUMENTATION

10A... .......... .......... ....................Output Connector Pin Assignment

10B... .......... .......... ....................Leprecon Wiring – Internal

10C... .......... .......... ....................Internal Connector Pin Assignment

11A... ..........30-1012.................. Power Supply Schematic

11B... .......... .......... ....................PCB Layout and Parts List

12A... ..........30-1016.................. Grand Master Schematic

12B... .......... .......... ....................PCB Layout and Parts List

13A... ..........30-1017.................. Crossfader Schematic

13B... .......... .......... ....................PCB Layout and Parts List

14A... ..........30-1018.................. Preset Fader Schematic

14B... .......... .......... ....................PCB Layout and Parts List

15A... ..........30-1015.................. Submaster Schematic

15B... .......... .......... ....................PCB Layout and Parts List

16A... ..........30-0001C (6XDM)..Controller Module Schematic

16B... .......... .......... ....................PCB Layout and Parts List

17A... ..........30-0002D (6XEM)..Electronics Module Schematic

17B... .......... .......... ....................Electronics Module Used as Output

Buffer PCB Layout

17C... .......... .......... ....................Electronics Module Used as Preset

Buffer PCB Layout

18A... ..........30-1025.................. Chaser Schematic

18B... .......... .......... ....................PCB Layout and Parts List

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INTRODUCTION

Leprecon Models LP-900 and LP-1000 are portable lighting control consoles that
are compatible with most dimming systems. They are designed for road use,
and with reasonable care should require minimal service. Troubleshooting and
repair are simplified by the use of modular electronics. This manual outlines
procedures for safe and reliable operation of these consoles, and provides the
necessary technical documentation for service.

SPECIFICATIONS

POWER IN: Connector – Male U-ground inlet

105-125 VAC @ 50/60 Hz
Current less than 1 amp

OUTPUT: Connector – 27 pin male “Jones” type

Maximum Out – Adjustable 5-15 volts
Minimum Out – Adjustable 0-3 volts
24 volts available at pin 25 for fan relays
Maximum output current – 15 mA/channel

SIZE: LP-900 – 30 7/8” W x 18 ¼” D x 3 7/8” H

LP-1000 – 29 5/16” W x 25 3/8” D x 4 7/16” H
LP-1001 – 12 ½” W x 25 3/8” D x 4 7/16” H

WEIGHT: LP-900 – 26 lbs.

LP-1000 – 40 lbs.
LP-1001 – 15 lbs.

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OPERATING PRECAUTIONS
PROPER SYSTEM GROUNDING
An essential ingredient to safe, consistent, reliable, and quiet operation of a

lighting system is that the neutral and ground are not connected together at any
point in the lighting system or in the house service except at the main transformer
or service entrance, where the neutral is bonded to earth ground. Except at this
one point, neutral and ground are totally separate, totally isolated, and very
different terminals. The hot legs conduct power from the service through the
dimmers to the load. The neutral conducts current not balanced between the
legs from the load back to the main power source. It is a current carrying
conductor: By definition a potential difference exists between any two points of a
current carrying conductor. Current flows only when a potential difference exists.
The only point at which the neutral and ground are at the same potential when
any current is flowing in the neutral is at the one common point where the neutral
and ground are physically tied together.

The ground serves two purposes: Its primary purpose is to connect all conductive
parts of the system which can be touched by a person to earth ground potential
so that a person with some other part of his body grounded will not become a
conductor of electrical current (get hurt or killed) because of electrical leakage
(perfect insulation doesn’t exist) or because of a fault in equipment wiring.

Its secondary purpose is to shield the current carrying and electrical noise
generating components in a system by connecting chassis and enclosures solidly
to ground potential. In a situation where lots of sensitive audio equipment (much
of it improperly grounded) co-exists, this function is very important.

Connecting the ground to neutral at any point other than the single bonding point
at the main service causes neutral current to flow through the “ground”
conductor; it is no longer at ground potential; it is no longer a ground; its function
for safety and optimum system operation is impaired.

CONTROL GROUNDING
The control common should be totally isolated throughout the system, that is, not

connected to ground or neutral in the board, stage boxes, or dimmers. Some
dimmers have grounded control commons. This won’t be a problem in itself, but
will aggravate other possible faults.

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CONTROL GROUNDING (continued)
Please – before you attach your system to main power, perform this simple test.

Connect an ohmmeter between your neutral and ground. If you read other than
infinite resistance, you have a ground-neutral fault, which you must correct for
your own safety, and for the proper operation of your system.

We have flown thousands of miles, and spent hundreds of hours (and charged
many dollars) chasing down the strangest, most unpredictable and inexplicable
lighting system problems only to find (after being reassured that the grounding
was proper) that the removal of a bonding screw, a jumper wire, or repair of a
shorted connector or instrument cured the problem. Check it out.

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OUTPUT ADJUSTMENT – TRIMMING

The output voltage of Leprecon consoles may be easily adjusted to be
compatible with most dimmer systems. Trim is factory set for an output range of
0-10 volts, and may be readjusted by the trimmers in the upper left corner of the
front panel.

Tools needed are: DC volt meter

Small slot screwdriver – 1/8” blade

Connect meter between control common (pin 26 or 27) and channel one output
(pin 1). Set selector switch for scene X channel one to I (Independent). Set Ind.
Fader to max and channel one fader (scene X) to min. Turn on power. Meter
should read minimum output voltage.

Minimum: If 0 volts minimum is desired, trimmer for minimum is turned fully

counter clockwise. If non-zero minimum is desired, turn minimum
trimmer clockwise until meter shows desired output – 3 volts
maximum.

Maximum: Set scene X channel one fader to full. Meter will read maximum

output. Maximum trimmer can be turned clockwise to increase
output voltage, counter clockwise to decrease it within the range of

5-15 volts. Set as desired.
Once set, output trim is usually stable and should not require adjustment.
Common dimmer requirements are:

Electronics Diversified – scrimmer 2 – 7.6V*
Berkey Colortran 0 – 12V
Skirpan (adjustable) 0 – 10V
Teatronics 0 – 10V
TTI 0 – 10V

*Also requires + 24 volts to activate cooling fan.

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REPAIRS AND MAINTENANCE

The most common repairs in Leprecon consoles will be replacing parts that are
physically damaged. Failure of opamps and LEDs is rare, and easy to diagnose
and repair.

The principal parts of a board subject to serious wear are the slide pots. They
are vulnerable to dirt and other contamination. The grease in a slider that gives it
a nice feel also traps dirt and dust. Unfortunately, there is no real way to remove
the dirt and leave the grease. Cleaning sprays remove dirt but also remove the
damping grease and will make the pots feel rough. Sliders should be spray
cleaned only as a last resort. Never use tuner or contact cleaners, which contain
abrasives on potentiometers! These are suitable for switches only. “BLUE
STUFF” contains abrasive – it’s good for switches and connectors – but do NOT
use it on potentiometers! “JIFI” (from Workman) and “WISSH” (from G.C.) are
good potentiometer and contact cleaners.

Leprecon consoles have a layer of fabric between the front panel and the slide
pots to keep dirt from falling into the pots. Keeping the board clean is the only
solution to prevent wear to the sliders. Ideally, the board should be kept covered
when not in use. Vacuuming the console out occasionally helps too.

Dust and dirt will make the sliders feel gritty and wear more quickly. Spilled soft
drinks leave a sticky caramel lacquer on matrix contacts and sliders. The main
attention a control board needs is keeping contamination out of the electro­mechanical parts.

PLEASE consult with us before cleaning or lubricating the sliders.
Output circuits are not delicate, and can usually stand short circuits on outputs or

even ribbon cables plugged in backwards without damage. Power supply
regulators have current limiting and thermal shut-off, and will usually survive
shorts without damage.

Simple isolated problems, such as a single dead control channel or a short
between two channels, can usually be traced down quickly. Schematics include
opamp pin numbers. DC voltage test will quickly show what’s going on without
removing PC boards.

The most serious problems in a console are those that affect many circuits, such
as defects in the power supply, grand master and scene master or submaster.
Problems in these circuit boards will affect more than one module and must be
isolated to the single defective board.

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REPAIRS AND MAINTENANCE (continued)
The first step in major troubleshooting is to prove the problem is in the board.

With the snake disconnected, if the LEDs function normally from the power
supply to the output indicators and control voltage is verified with a meter at the
output connector, the board by itself is functioning as it should. Snake channels
that are shorted to control common or to another controller will show on the
output LEDs when the snake is plugged in. An LED that jumps to full up when
the slider is moved above minimum, indicates an output shorted to common or
ground. An LED that is off when the fader is partially up can indicate a short
between channels. A comprehensive test for shorts is to bring all outputs full up
and verify with a meter that each channel can be run from maximum to minimum
with the other channels up.

If all LEDs respond normally but no voltage can be read at any of the outputs, the
problem is probably a break in the control common between the power supply
card and the output connector.

The circuit boards in the console are inter-connected by ribbon cables that carry
power and the necessary input and output lines. A defect in one card can affect
everything it is connected to. Faults in a 6XDM can affect the entire scene and a
short to V+ in any card can kill the entire board. Problems are isolated by
removing the ribbon jumpers from suspect modules and then checking the other
modules to see if normal operation is restored.

Modules connected by a continuous ribbon are a functional system. Boards with
an input and an output are connections between systems.

There are three ribbon jumper systems in a board:

Horizontal ribbon jumpers for each scene of 6XDM’s;
These connect to the submaster output, and supply the entire scene.

Vertical jumpers from scene to scene on each 6XDM;
This is 6XDM output/6XEM input jumper.

Submaster input ribbons connecting the scene master output to all
submasters; This ribbon may continue to the grand master and power
supply or those connections may be made through other cables.

The proper function of the power supply, grand master, crossfader, and
submasters can be checked by disconnecting ribbon cables.

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REPAIRS AND MAINTENANCE (continued)
By removing possible defective modules from the circuit you will arrive at the

point where connecting a system ribbon to a particular module that is connected
to nothing else causes the system to malfunction. This pinpoints the problem to
that card. Schematics for each PC card are supplied in the next section.

Easier to spot are single failures where a single circuit stops working without
affecting other modules. Again, the only way to show definitely that the problem
is in a single module is to disconnect it from everything except a “known good”
input.

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THE LP-1000 SERIES OPERATIONAL INSTRUCTIONS

The LP-1000 series is a two scene console with a 12 channel preset configured
through a pin matrix. The LP-1000 also has a 6 channel chase, a bump system
that can change the existing look on stage momentarily, a output trim adjustment,
a minimum trim adjustment, a master section, a dipless crossfade and a
independent channel section. The LP-1000 series also has a 12 volt dimmable
gooseneck work lamp.

This controller uses a power source of 105-125 VAC 50-60 HZ and its output is a
continuous DC voltage to all channels.

POWER UP
When the power is applied to the controller the dimmable gooseneck work lamp

is immediately accessible. The 2.4 watt bulb is standard equipment in all of our
controllers. You can adjust the intensity of the lamp by a clockwise rotation of
the knob marked “lite”.

To engage or disengage the controller simply push the rocker switch marked
“on”. The green LED marked “power”, located beneath the switch, will be
glowing along with the switch itself.

If the LED or switch is not glowing recheck your power cord and be sure the
outlet that you are using is operational. If the outlet is operational and the power
is still not working, you may have an open breaker. The breaker reset is a red
button located next to the AC power cord.

TRIM
Under the “power” LED you will notice another green LED marked “max”. This

LED’s brightness is directly related to the amount of output voltage the controller
has been adjusted to. The factory trim adjustment is 10 volts, and the trim is
accessible from a recessed trim pot located next to the “max” LED. Under the
“max” trim control is another recessed control for the minimum output voltage,
this is marked “min” and is factory adjusted to zero volts. Do not readjust either
of these controls unless there is a reason for the adjustment, such as the
implementation of another brand of dimmer. Do this only in accordance with
factory instructions, which will be covered in detail under the trim adjustment
section.

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CHASER
This is a straight 6 channel chase operating through a preset pin matrix. The

chase “on/off” button is a “winking eye” push-push type switch. Above the switch
are two slide pots for the chaser rate and intensity controls. The rate pot will vary
its speed, the LED located above it will blink at the corresponding rate, and the
intensity pot adjusts output level for all chase channels.

The chase channels are sent to the last 6 sections of the pin matrix, that is
sections 7-8-9-10-11-12. Whatever output channels are assigned to these
sections will be operated by the chase and the corresponding preset controller
channels. Example, if you put a diode pin into the pin matrix so that you connect
channel 12 to preset 7 every time the first (of 1-6) chase channel turns on, that
channel number one will light (See section on pin matrix).

BUMP
In the master section there are two switches and one level pot for the bump

buttons. Above the switches are two yellow LED’s. These switches allow the
operator to use the bump buttons located beneath each of the controller
channels to achieve different results.

The switch marked “on/off” is the bump enable switch. The yellow LED will be
glowing when this switch and bump buttons are on. When pressing a channel’s
bump button, while in the “add” mode, that channel will be added, at the intensity
of the bump level control. The bump button will “add” that channel to the existing
look on stage, it will not effect the scene setup in any other way. If you want you
may deactivate the bumps so accidental channel increases will be avoided.

Next to the “on/off” switch is the “solo/add” switch. When the “solo/add” switch is
in the “solo” position the yellow LED will glow whenever a bump button is
depressed. Also while the button is held down the controller will delete all of the
channels that are in the “X” and “Y” scenes, except the channel whose bump
button is being held down, which will be at maximum intensity. The solo will be
over ridden by the independent and chase functions. This effect will last only as
long as the bump button is depressed and when the button is released the scene
will return to its normal condition.

HINT: When the “solo” feature is activated only that channel will appear,
excluding chase and independent. You may rearrange channels while the bump
button is depressed and return to a new stage look. This will give the effect of
very fast scene changes with a minimum of fader work.

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GRAND MASTER
The “grand master” section has 2 faders and an illuminated blackout switch. The

master fader, marked “M”, the independent fader, marked “I”, and the board
disable switch, marked “black” are grouped together.

The “M”, master, fader controls only the “crossfader” section and the A, B, C sub­masters. The overall level that is set by the “M” fader can be seen with the LED
located directly above it.

The “I”, independent, fader controls only the channels that have been selected “I”
by the “A, B, C, M, I” selector switches located above the individual channels.
The “I” fader also has a level LED located above it.

The switch marked “black” will disable anything assigned to the “M” fader on the
board. This gives the operator instant control over the scene outputs. When the
disable function is activated the red LED above it will be glowing.

NOTE: All of the controls in the “grand master” section can be overridden by the
chase and the bump sections.

CROSSFADER
The “crossfader” section controls the top, “X” scene, and the middle, “Y” scene,

channels. There are two control faders and they operate in reverse order to
accomplish a smooth crossing between the scenes. The leftmost fader is
marked “X” and it operated the top set of controller’s faders. The fader is at its
maximum output when in the upward position. To its right is the “Y” fader, which
operates the middle set of controllers. This fader has a maximum output when in
the downward position. Also in this section is the bottom, “P” scene, preset
master fader. This has a maximum level when in the up position.

With both crossfader controls in the up position the look on stage is
accomplished from the levels of the “X” scene controllers and the “Y” scene fader
is off. The operator sets up the next stage look to be used on the “Y” scene
controls. When it is time to change the look on the stage the operator brings
both “crossfader” controls to the down position. This turns down the “X” scene
and turns up the “Y” scene. Creating a smooth scene transition with a rate
determined by the operator.

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CONTROL CHANNELS
The control section is at the right of the board. This section contains the

individual channel faders, the “A, B, C, I, M” switches, the bump buttons and
output LEDs.

The output LEDs located at the top are directly related to that channels output.
The five position slide switches located beneath the output LEDs select either the
submasters, “A, B, C”, the manual, “M”, or the independent, “I”, as a fader source
for that channel. The momentary switches at the bottom of each channel are for
the bump button operations.

PIN MATRIX
The pin matrix (located in the lower right hand side of the console) is a circuit

board that allows channels to be connected together by the use of diode pins.
This feature will allow the operator to preselect scenes rather then going back
and forth between the “X” and “Y”. The operator will be able to bring up one
preset channel and bring down another to accomplish a crossfade between
scenes.

Horizontally across the top of the pin matrix board are channels 1 thru 24. These
correspond to channels 1-24 in the X-Y scenes. Vertically, on the left side of the
matrix, are numbers 1 thru 12 and these correspond to the preset faders 1-12.
You assign outputs to presets by the use of diode pins, not shorting pins or diode
pins of the wrong polarity.

Example: You have an interesting look in the “X” scene with channels 1, 15, 17,
and 23. You would like to bring them up together with one fader. You open your
matrix lid, take a diode pin and move across the numbers horizontally until you
find #1, you did not have to go far. Then you move down the left side vertically
until you get to preset number 6, this can be any submaster channel. Now put
the diode pin in the location 1-6. Take another diode pin and go horizontally on
the matrix to channel #15, go down vertically to preset channel #6 and insert that
diode pin. You should continue to do this for channels 17 and 23. After you
have finished you will have pins 1, 15, 17, and 23 in the vertical row of preset #6.
If you bring up preset #6, and all other channels down, you will bring up control
outputs #1, 15, 17, and 23. Now you can program the other 11 presets.

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The last 6 preset positions, 7, 8, 9, 10, 11, and 12 are also connected to the
chaser function. The first step in the chase is #7, the second step is #8 and so
on to step #12. Whatever you have pined into these presets can also be
operated by running the chase. You have the option of operating them together
or separately.

ABC-SUBMASTERS
At the beginning of the “X” and “Y” scenes, to the left of channel 1, are

submasters. These submasters are labeled “A”, “B” and “C” and they have a two
position switch located above them. These switches will allow the submaster to
be controlled by either the corresponding “X” or “Y” crossfader, or the “I”
independent master fader.

Above each of the controller channels is a 5 position switch. This switch will
reroute that channel to a different submaster fader. While operating in the “X”
scene if you put the selector switch in the “A” position. This fader will be
controlled by the “A” submaster fader. The level of the channel you are using
needs to be up in order for output to appear on that channel.

TRIM ADJUSTMENT
To adjust the trim of any LEPRECON controller you need a volt meter and a

small flat blade screwdriver. The first item that should be done is to determine
which pin is common with your controller.

On the LP-1000 there is a 27 pin cinch jones type connector. On the 27 pin CJ,
pins 26 and 27 are common and pin 25 is a 28 volt DC source that is used for
another brand of dimmers.

You will need to first turn on your controller. Then with your volt meter’s negative
lead connected to the controller’s common pin and the positive lead connected to
channel number one you then raise all channels to maximum. With all channels
up and a screwdriver in the recessed trim pot you adjust the “max” trim to the
desired level, factory adjustment is 10 volts.

To adjust the minimum voltage you bring only channel one down, all other
channels must remain at maximum output. With the screwdriver in the “min” pot
you turn it counterclockwise to the near zero position.

Once the trim has been adjusted it does not need to be readjusted unless
another brand of dimmers have been introduced.

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Leprecon/CAE, Inc. P.O. Box 430 Hamburg, Michigan 48139 810-231-9373