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TOPAZ 12 PORTABLE PACK
AND
ASSOCIATED CONTROL MODULES
USER GUIDE
(Part # LIT-29433-1A)
© Copyright March 2002 Leviton Manufacturing Co. Inc.
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TABLE OF CONTENTS
CHAPTER I: USING THIS MANUAL……………………………………………... 1
CHAPTER II: PORTABLE PACK INSTALLATION………………………………. 2
CHAPTER III: REMOTE CONTROL MODULE…………………………………… 6
CHAPTER IV: UNIVERSAL CONTROL MODULE……………………………….. 10
CHAPTER V: FINAL ASSEMBLY…………………………………………………. 17
CHAPTER VI: MAINTENANCE AND ADJUSTMENT……………………………. 18
CHAPTER VII: TROUBLE SHOOTING…………………………………………….. 19
APPENDIX A: SPECIFICATIONS………………………………………………….. 20
APPENDIX B: DIMMER PACK FEEDER CABLES………………………………. 21
APPENDIX C: LOAD CONNECTORS……………………………………………... 22
APPENDIX D: DIMMER PHASING………………………………………………… 22
PAGE NO.
WARRANTY …………………….…………………………………………………..
23
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CHAPTER 1: USING THIS MANUAL
The TOPAZ 12 Pack is an extremely versatile piece of equipment which can be tailored to meet the needs of any small to
medium-sized dimming application. This manual is designed to assist you in identifying each of the parts of your system
and to correctly connect each of those parts.
The model number of the pack shell may be found on the back of the pack and the control module model number will be
found on the bottom of the module. Consult your packing list for individual component identification. The information
shown below is in generic terms. For details on 100V or 220V operation, see Chapter VI, Section 2.
TABLE 1
120 VOLT MODELS
MODEL# DESCRIPTION
600-021 TOPAZ 12 Portable Pack: 12 x 1.8kW Dimmers, 2 x 15A U-Ground (NEMA 5-15) outlets per
dimmer
600-001 TOPAZ 12 Portable Pack: 12 x 2.4kW Dimmers, 2 x 20A Pin Plug outlets per dimmer
600-002 TOPAZ 12 Portable Pack: 12 x 2.4kW Dimmers, 2 x 20A U-Ground (NEMA 5-20) outlets per
dimmer
600-004 TOPAZ 12 Portable Pack: 12 x 2.4kW Dimmers, 1 x 20A Locking Blade (NEMA L5-20) outlet
per dimmer
LEC2102 TOPAZ 12 Remote Control Module
600-902 TOPAZ 12 Universal Control Module
240 VOLT MODELS
(Foreign Electrical Service Only)
MODEL# DESCRIPTION
600-011 TOPAZ 12 Portable Pack: 12 x 2.5kW Dimmers, 2 x 15A Pin Plug outlets per dimmer.
600-014 TOPAZ 12 Portable Pack: 12 x 2.5kW Dimmers, 1 x 15A Locking Blade outlet per dimmer
LEC2105 TOPAZ 12 Remote Control Module
600-904 TOPAZ 12 Universal Control Module
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CHAPTER II: PORTABLE PACK INSTALLATION
A. PACK LOCATION
The TOPAZ 12 Pack should be located in a dust-free space with an ambient temperature between 32 - 104°F (0-40°C)
and a relative humidity of 10 - 90% without condensation. It should be located on a stable surface suitable for supporting
the weight indicated in Appendix A, Specifications. If packs are stacked on top of each other using the interlocking
feature, make sure that the stack is stable both before and after all cables are terminated. There must be at least 18
inches (457.2 mm) of clearance at the front and back of the pack to allow for cooling and wire routing. Consideration
should be given to the fact that this equipment will produce a slight noise due to dimmer hum and fan operation. Also, no
sound equipment should be placed in the vicinity of the dimmer pack or its wiring. Failure to observe this practice could
result in excessive buzzing in the sound equipment.
B. LINE WIRING
The feeder cable should enter the pack through the strain relief located in the back of the pack. See Figure 1. This cable
clamp will accept 1.15” to 1.98” diameter (29.21 to 50.292 mm) cable. Suggested cables to U.S.A. standards can be
found in Appendix B. The input power (feeder) requirements are indicated on the back of the pack along with the shell
model number.
Locate the line wire lugs, found inside the rear of the pack. Phases A, B, C, the Neutral and the Ground lug are designed
to accept 14-1/0 AWG (2-50mm
should be tightened to the following torque values:
14-10AWG 35in.lbs.
8 AWG 40in.lbs.
6-4 AWG 45in.lbs.
2-1/0 AWG 50in.lbs.
2
) CU. wire operating at the 90°C ampacity rating. Upon termination, the contact screws
Feeder Cable Inlet
Figure 1 - Feeder Cable Inlet
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The TOPAZ 12 Pack comes wired from the factory to accept a 3 phase, 4 wire, wye service with equipment ground. If
this is the type of service which will be used for your particular installation, connect the line wiring to the A, B, C, Neutral
and Ground Lugs, See Figure 2; then skip down to Part C of this chapter.
Jumper Bars (2)
ØA Terminal
ØB Terminal
Neutral Terminal
Ground Terminal
ØC Terminal
Feed Wire Entry
Figure 2 - 3 Ø Power Hookup
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If the service you have available is a single phase, 3 wire (split phase) service, convert the pack using the
following directions:
Phase Conversion
1. Loosen the four bolts on the dimmer power feed busses using a 7/16" socket wrench. See figure 3.
2. Rotate the Phase B1 jumper bar up so that it connects to the Phase A bus. Be sure that the terminal lug on
the Phase A bus is pointing to the right side of the pack and hand-tighten the Phase A bolt.
3. On the Phase B2 bus, rotate the jumper bar down so that it connects to the Phase C bus. Be sure that the
terminal lugs on the Phase B and C busses are pointing to the right side of the pack and hand-tighten both
bolts.
4. Using a 7/16" socket wrench, tighten all four bolts.
Connect the wiring to the ØA, ØC, Neutral and Ground Lugs. This configuration is also suitable for connection to two
phases of a 3 phase, 4 wire system.
ØA Terminal
ØB1 Jumper
Unused Terminal
N
ØB2 Jumper
ØC Terminal
Figure 3 - Phase Conversion
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C. DIMMER INSTALLATION
The dimmers may now be installed in the pack. The door on the front of the pack must be open to allow for insertion of
the dimmer modules. Also, the module retaining bracket on the right must be moved to the right by loosening the two
thumb screws. Insert the dimmers in the six slots of the pack. Slide the modules in firmly until they stop. The breakers
should be in the off position while inserting the modules. All slots must have a dimmer or airflow module inserted in order
to maintain proper cooling of the pack.
The TOPAZ 12 PACK dimmer module is available in 1.8kW or 2.4kW sizes for 120V operation, and 2.5kW for 240V
operation. The 1.8/2.4/2.5kW modules are dual dimmers. The model number may be found on the bottom of each
dimmer module.
TABLE 2
Model No. Description Voltage Max.
Load
166-361
166-362
166-364
Dual Dimmer Module
Dual Dimmer Module
Dual Dimmer Module
120V
120V
240V
1.8kW
2.4kW
2.5kW
Circuit
Breaker
15A
20A
15A
D. LOAD WIRING
Loads are connected to the portable pack by means of plug-in receptacles on the rear panel of the pack. Dimmer and
load receptacle types and receptacle ampere ratings for the type of pack being used can be found in Table 1 of Chapter I.
Maximum load capacity and branch circuit ratings of the dimmers can be found in Table 2, above. The dimmers are rated
for both incandescent and inductive loads, the latter having a kVA rating equal to the kW rating shown. These dimmers
employ phase-control switching techniques, so inductive loads must be suitable for use with the steep wave front which
this technique produces. The loads should be sized appropriately and mating connectors utilized for proper connections.
Information on load wiring and mating connectors can be found in Appendix C.
E. CONTROL MODULE CONFIGURATION AND INSTALLATION
The electronic control module may now be installed in the pack. There are two types of control modules available which
are designed to work under different conditions. The model number of the control module may be found on the bottom of
its case. Go to the appropriate chapter (Chapter III or IV) for instructions on how to configure the module for your
application.
IMPORTANT. The module must be configured before it is installed to conform to your application.
Please read carefully and make all necessary settings to your control module.
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CHAPTER III: REMOTE CONTROL MODULE MODEL NO. LEC2102 - 120V
and LEC2105 - 240V
The purpose of the Remote Control Module is to control the TOPAZ 12 Pack when only a digital multiplexed control signal
is used. The remote control module automatically detects whether the control signal is DMX512 or CMX (Colortran's
version of DMX) protocol upon power-up, reset or first appearance of a valid control signal.
There are numerous switches and jumpers on or in the control module which provide a large range of configurations in
which the module can operate. The operation of each item will be explained. It should be noted that the functions of all
items may be combined as desired in order to tailor the equipment for the desired application. Refer to Figures 4 and 5
for the physical location of each item.
IMPORTANT. The module must be configured before it is installed to conform to your application.
Please read carefully and make necessary switch settings to your control module.
1. THUMBWHEEL SWITCH (Front Panel, Figure 4)
This switch selects which dimmers the module will control. In this 12 dimmer pack, position "0" represents dimmers 1 thru
12, position "1” represents dimmers 13 thru 24, etc. As the digital cable is routed from pack to pack ("daisy chained"), the
packs do not need to be sequentially assigned. Dimmer numbering is determined only by the "Thumbwheel" setting and
not by the sequence of the control cable daisy chain. It is also possible to set two thumbwheels to the same number if it is
desired to have two dimmers (one per pack) respond to the same control channel.
2. RESET SWITCH (Front Panel, Figure 4)
It a control module becomes inoperative or "freezes", the Reset Switch should be pressed. This will cause a “warm boot"
of the system and it should resume normal operations.
3. TEST SWITCH (Front Panel, Figure 4)
This switch is used to test the individual outputs of each dimmer without the use of a digital signal from the lighting
console. This switch, when in the up position, causes all the dimmers to lock on at full. By shutting off all the breakers
and turning each breaker on individually, you can check the output of each dimmer. This switch overrides any signal
coming into the pack and must be turned off (down) to restore dimmer control to the lighting console.
Thumbwheel Switch Test Switch Signal Indicator Power Indicator Phase Trim Adjustments
Reset Switch Airflow Indicator
Figure 4 - Remote Control Module Front Panel
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Status Control Console Jumper
DIP Switches
4. STATUS CONTROL CONSOLE JUMPER (JP 5, internal, Figure 5)
IMPORTANT: This jumper should ONLY be moved when using a Status control console,
moving the jumper and using any other control console may damage the control console.
By placing the jumper in the "Status" position you are placing 12 volts on pin #4 of the data cable. For all other types of
digital control consoles the "JP5" must be in the "remote” position. The jumper should be checked before a lighting
console is connected.
Figure 5 – Internal Switches/Jumpers
5. DIP SWITCHES (Red Switches Numbered 1 thru 3, internal, Figure 5)
These switches offer a large range of configurations in which the module can operate. The operation of each switch is
explained below.
SWITCH NO. 1: Thumbwheel "+ 16” Switch
In a very large system, dimmers with numbers higher than 192 might be required. There are only 16 positions on
the front panel thumbwheel switch. In these situations, the + 16 switch, number 1 on the dip switch, makes it
possible to have higher numbered packs on the same control line.
The first 16 packs are assigned as normal, with their "+16” switch in the "OFF”, or down, position. The next group
of 16 packs should have their thumbwheel switches set from "0” to "15” and the "+16" switch in the "On” (up)
position. In other words the thumbwheel switch on the seventeenth pack should be set to "0” and the "+16"
switch (numbered 1 on the dip switches) in the "ON” (up) position. This will cause the first dimmer in the
seventeenth pack to be addressed as dimmer 193 and so on up to a maximum of 384.
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SWITCH NOS. 2 and 3: Pack Configuration Switches
These switches tell the control module that it will be controlling a 12 x 1.8 / 2.4 / 2.5kW pack. The table below
explains the setting.
TABLE 3
Switch No.
Pack Description
2 3
Pack with 12 – 1.8 / 2.4 / 2.5kW dimmers UP DOWN
6. FRONT PANEL LED'S (Figure 4, page 6)
SIGNAL INDICATOR (Green):
This LED senses the presence of a digital signal from the lighting console. If a digital signal is correctly applied,
the LED will glow solid green. If a signal is not present or incorrectly applied, the LED will either not turn on or will
flicker.
AIRFLOW INDICATOR (Amber):
This LED, when on, indicates the lack of airflow over the dimmer modules. The Airflow indicator will turn on and
shut down all dimmer output within the pack for several reasons, such as: a fan failure, missing dimmer modules,
or an obstruction in the airflow. To reset a module in Airflow mode, remove any obstruction or replace any
missing modules, and the control module will automatically reset itself. In the event that these actions do not
restore the system, you may need to have the fan circuitry repaired. A failure in any one pack will light its LED,
but not the LED in any other pack.
POWER INDICATOR (Red):
The Power Indicator will blink if any phase is missing or incorrectly wired. The Power Indicator will glow steadily if
all wiring and phasing is correct.
7. PHASE TRIM ADJUSTMENT (Front Panel, Figure 4, page 6)
The control module is preset at the factory for 120 or 240 volts and should not require further phase trim adjusting; but if
you are using the TOPAZ 12 Pack in an environment that has unusually high or low voltage, including 100V or 220V, the
phase trim will need to be adjusted. Refer to Chapter VI, Maintenance and Adjustments.
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After you have made all necessary settings on the Remote Control Module, you can install it into the TOPAZ 12 pack.
Push the module in firmly making sure that the edge connectors are making full contact.
Control wiring to this module is via the 5-pin XLR connectors on the back of the pack. See Figure 6. If LEVITON control
cables are not available, cables must be made using Neutrik NC5MX-B (male) and NC5FX-B (female), or equivalent
connectors, and Belden 9829 or equivalent cable. Connector wiring is per the USITT DMX512 standard.
TABLE 4
Control Connector Wiring
Pin No. Function Wiring
1
2
3
4
5
Common
Data –
Data +
Not Used
Not Used
Shield
Pair 1
Pair 1
Pair 2
Pair 2
Control Out – To next pack
Control In – From console or another pack
Figure 6 - Control Connectors
Plug the control console into the male connector marked "IN" for the first pack. Plug the male connector of a jumper cable
into the pack connector marked "OUT” and the other end of the cable into the next pack. Packs can be connected in any
order without regard to the thumbwheel switch-selected numbers. The complete installation must adhere to the EIA 422A
standard which, in general, limits the total cable length from console to last pack to 1000' (304.8m) and the number of
control modules to 16.
Now go on to the final assembly section of this manual, Chapter V.
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CHAPTER IV: UNIVERSAL CONTROL MODULE, MODEL NO. 600-902 - 120V
The purpose of the Universal Control Module is to control the TOPAZ 12 Pack when a digital or analog multiplexed
control signal and/or standard analog control signals are used. When in the digital multiplex mode, the Universal control
module automatically detects whether the control signal is DMX512 or CMX (Colortran’s version of DMX) protocol upon
power-up, reset or first appearance of a valid control signal. If multiplex and analog signals are both present, the signals
will be "piled onto" each other in a highest takes precedence action.
There are numerous switches on or in the Universal Control Module that provide a large range of configurations in which
the module can operate. The operation of each switch will be explained. It should be noted that the functions of all
switches may be combined as desired in order to tailor the equipment for the desired application. Refer to Fig. # 7, 8 and
9 for the physical location of each switch.
IMPORTANT: The module must be configured before it is installed to conform to your application.
Please read carefully and make all necessary switch settings to your control module.
1. THUMBWHEEL SWITCH (Front Panel, Figure 7)
This switch selects which dimmers the module will control from the incoming control signal. In this 12 dimmer pack,
position "0" represents dimmers 1 thru 12, position "1" represents dimmers 13 thru 24, etc. As the digital cable is routed
from pack to pack ("daisy chained"), the packs do not need to be sequentially assigned. Dimmer numbering is
determined only by the "Thumbwheel” setting and not by the sequence of the control cable daisy chain. It is also possible
to set two thumbwheels to the same number if it is desired to have two dimmers (one per pack) respond to the same
control channel.
Analog Input
Trim Adjustment
Status/Other Console
Selector Switch
AMX/DMX
Selector Switch
Analog Control
Input Connector
600-904 - 240V
Thumbwheel Switch Test Switch Signal Indicator Power Indicator Phase Trim
Adjustments
Reset Switch Airflow Indicator
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Figure 7 - Universal Control Module Front Panel
Page 13
2. RESET SWITCH (Front Panel, Figure 7)
If a control module becomes inoperative or "freezes", the Reset Switch should be pressed. This will cause a "warm boot"
of the system and it should resume normal operations.
3. TEST SWITCH (Front Panel, Figure 7)
This switch is used to test the individual outputs of each dimmer without the use of a signal from a lighting console. This
switch, when in the up position, causes all the dimmers to lock on at full. By shutting off all the breakers and turning each
breaker on individually, you can check the output of each dimmer. This switch overrides any signal coming into the pack
and must be turned off (down) to restore dimmer control to the lighting console.
4. STATUS ONLY / OTHER CONSOLE SWITCH (Front Panel, Figure 7)
IMPORTANT: This switch should be used ONLY when using a Status control console;
moving the switch and using any other control console may damage that control console.
By placing the switch in the "Status Only” position, you are placing 12 volts on pin #4 of the data cable. For all other types
of digital control consoles, the switch must be in the "Other Console” position (down) only. The switch should be checked
before a lighting console is connected.
5. AMX / DMX SWITCH (Front Panel, Figure 7)
This switch is used to switch between DMX512 and AMX192 protocols.
DMX POSITION
In this position, the control module will receive USITT standard DMX512 and will automatically switch
between CMX and DMX512 protocol.
AMX POSITION
In this position, the control module will receive USITT standard AMX192 protocol.
IMPORTANT: This switch extensively changes the function of the control connector on the rear of the pack.
Refer to the end of the chapter for details.
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DIP Switches
Figure 8 - Universal Control Module Internal Switches
Non-Dim Switches
Figure 9 - Universal Control Module Non-Dim Switches
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6. DIP SWITCHES (Red Switches Numbered 1 thru 3, Internal, Figure 8)
These switches offer a large range of configurations in which the module can operate. The operation of each switch is
explained below. Note that switches 1 thru 3 offset only the multiplexed control and not the analog control.
SWITCH NO. 1: Thumbwheel "+16" Switch
In a very large system, dimmers with numbers higher than 192 might be required. There are only 16 positions on
the front panel thumbwheel switch. In these situations, the +16 switch, number 1 on the dip switch, makes it
possible to have higher numbered packs on the same control line.
The first 16 packs are assigned as normal, with their "+16" switch in the "OFF" (down) position. The next group of
16 packs should have their thumb wheel switches set from "0" to "15" and the "+16" switch in the "On" (up)
position. In other words the thumbwheel switch on the seventeenth pack should be set to "0" and the "+16"
switch (numbered 1 on the dip switch) in the "ON" (up) position. This will cause the first dimmer in the
seventeenth pack to be addressed as dimmer 193 and on up to a maximum of 384. Since the AMX-192 protocol
stops at 192, a second console cable will be used in lieu of this switch.
SWITCH NOS. 2 and 3: Pack Configuration Switches
These switches tell the control module that it will be controlling a 12 x 1.8 / 2.4 / 2.5kW pack. The table below
explains the setting.
TABLE 5
Pack Description
Pack with 12 – 1.8 / 2.4 / 2.5kW dimmers UP DOWN
Switch No.
2 3
7. NON-DIM SWITCHES (24 DIP Switches on Top Card, Figure 9)
The Universal Control Module is also equipped to handle non-dims on a per circuit basis. The DIP switches can
individually select which channel is a non-dim. This is done by moving the appropriate dip switch to the "On' position.
The channel then becomes a non-dim and will become active (to Full) only when the control level exceeds 50% on the
control console.
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8. FRONT PANEL LED'S (Front Panel, Figure 7, Page 10)
SIGNAL INDICATOR (Green)
This LED senses the presence of a digital signal from the lighting console. If a digital signal is correctly applied,
the LED will glow solid green. If signal is not present or incorrectly applied, the LED will either not turn on or will
flicker.
AIRFLOW INDICATOR (Amber)
This LED when on indicates the lack of airflow over the dimmer modules. The Airflow indicator will turn on and
shut down all dimmer outputs within the pack for several reasons, such as: a fan failure, missing dimmer
modules, or an obstruction in the airflow. To reset a module in Airflow mode, remove any obstruction or replace
any missing modules, and the control module will automatically reset itself. In the event that these actions do not
restore the system, you may need to have the fan circuitry repaired. A failure in any one Pack will light its LED,
but not the LED in any other Pack.
POWER INDICATOR (Red)
The Power Indicator will blink if any phase is missing or incorrectly wired. The Power Indicator will glow steadily if
all wiring and phasing is correct.
9. ANALOG INPUT CONNECTOR (Front Panel, Figure 7, Page 10)
Connecting your analog control input into the 15 pin "D" connector on the front panel will allow control from a nonmultiplexed analog console to drive dimmers. If both analog and a multiplexed protocol are used at the same time, the
analog levels will pile-on to the multiplexed levels. Cables must be terminated on the pack end with a Cannon DA-15P or
equivalent "D” connector.
10. ANALOG INPUT TRIM ADJUSTMENT SCREW (Front Panel, Figure 7, Page 10)
Your non-multiplexed analog input voltage can be adjusted using the trim adjustment screw on the front panel. The
control module is factory set for 0 to 10V but can be adjusted to accept 0 to 4.5, 0 to 15, or any voltage in between those
values using the trim adjustment screw. Table 6 is a listing of connector pin numbers and their functions in the control
module.
The Control Module will respond to a filtered full wave DC linear voltage or to a linear transition of a pulse-width
modulated DC voltage within the frequency range of 900 Hz to 11 kHz. The input impedance of each dimmer is 21.3 kΩ.
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TABLE 6
Analog Input Connector
Connector Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DIMMER 1 CONTROL
DIMMER 2 CONTROL
DIMMER 3 CONTROL
DIMMER 4 CONTROL
DIMMER 5 CONTROL
DIMMER 6 CONTROL
DIMMER 7 CONTROL
DIMMER 8 CONTROL
DIMMER 9 CONTROL
DIMMER 10 CONTROL
DIMMER 11 CONTROL
DIMMER 12 CONTROL
NOT USED
NOT USED
COMMON
Function
1.8/2.4/2.5kW Pack
11. PHASE TRIM ADJUSTMENT (Front Panel, Figure 7, Page 10)
The control module is preset at the factory for 120 or 240 volts and should not require further phase trim adjusting; but if
you are using the TOPAZ 12 Pack in an environment that has unusually high or low voltage, including I00V or 220V, the
phase trim will need to be adjusted.
Refer to Chapter VI, Maintenance & Adjustment.
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After you have made all necessary settings on the Universal Control Module, you can install it into the TOPAZ 12 pack.
Push the module in firmly making sure that the edge connectors are making full contact.
Multiplex control wiring to this module is via the 5-pin XLR connectors on the back of the Pack. See Figure 10. If
LEVITON control cables are not available, cables can be made using Neutrik NC5MX-B (male) and NC5FX-B (female), or
equivalent connectors and Belden 9829, or equivalent cable. Connector wiring is as shown in Table 7, depending on the
position of the AMX/DMX Switch discussed in Setup Step 5, above.
TABLE 7
Multiplex Control Connector Wiring
Wiring Pin FUNCTION
Shield
Pair 1
Pair 1
Pair 2
Pair 2
1
2
3
4
5
AMUX
C-ND
CLOCK-
CLOCK+
ANALOG MUX.
NOT USED
DMX512/CMX
GND
DATA-
DATA+
NOT USED
NOT USED
*Depends on the setting of the Status/Other Switch - see control module setup, Step 4.
Control Out – To next pack
Control In - From console or another pack
Figure 10 - Control Connectors
Plug the control console into the male connector marked "In" for the first pack. Plug the male end of a jumper cable into
the pack connector marked "Out” and the other end of the cable into the next pack. Packs can be connected in any order
without regard to the thumbwheel switch-selected dimmer numbers. If operating in the DMX mode, the complete
installation must adhere to the EIA 422A standard, which, in general, limits the total cable length to 1000' (304.8m) and
the number of Control Modules to 16. Systems operating in the AMX mode must comply with the USITT AMX-192
standard.
Now you can go on to the Final Assembly section of this manual, Chapter V.
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CHAPTER V: FINAL ASSEMBLY
1. Make sure all breakers are in the "OFF" position on the dimmer pack.
2. Apply power to the pack. The power indicator should be on. If control console is hooked up and running, the signal
indicator will also be on.
3. Turn on the Test Switch.
4. Confirm that the fan is running. If you are using a Universal Control Module, the fan should turn on when power is
applied.
5. Turn on each dimmer breaker individually (one at a time) and confirm that each of the dimmers is working.
6. Turn off the Test Switch.
7. Turn on all dimmer breakers.
8. Close the front door of the pack. The door should latch closed. Move the retaining bracket on the right edge of the
pack to the left and secure with the two thumb screws.
(Note to Canadian users: CSA requires screwdriver-installed screws in lieu of thumb screws. Two 8-32 x 1/2 screws are
provided for this purpose.)
9. Test the dimmers using control console.
THIS COMPLETES THE INSTALLATION OF THE TOPAZ 12 PACK DIMMING SYSTEM. IF THERE ARE ANY
TECHNICAL QUESTIONS OR DIFFICULTIES, SEE CHAPTER VIII: TROUBLESHOOTING.
Figure 11 - Assembled Pack
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CHAPTER VI: MAINTENANCE AND ADJUSTMENT
IMPORTANT: Disconnect Pack from power source before performing any maintenance.
1. MAINTENANCE
The only maintenance which should be required on the TOPAZ 12 Pack is the occasional cleaning of the dimmer
modules and the tightening of the feeder bus bar lugs.
The cleaning of the modules is simply done by removing the module from the pack and blowing the dust out of the module
with compressed air. The modules should be cleaned every six months or sooner when the pack is used in an
environment that is particularly dusty. The control module should also be cleaned in the same manner as the dimmer
module.
The Bus Bar lugs should also be checked at the same time that the modules are cleaned. Using a 7/16” socket, check
the torque of all three phases lugs and the neutral lug.
2. ADJUSTMENT
IMPORTANT: This operation should only be attempted by a qualified electrical technician.
There are three phase trim adjustment screws on the front of the control module. Each of these phase adjustment screws
corresponds with a phase of the incoming feeder. Refer to Appendix D on Dimmer Phasing to find the corresponding
dimmer numbers. The simplest method of adjustment is through the use of an oscilloscope. If split phase, 3 wire, power
is being used, only phases A and C need to be accurately adjusted.
Note: If any phase is considerably out of adjustment with respect to the others, the microprocessor will not run. Take care
that the adjustment process does not render the module temporarily inoperable.
Phase Trim Adjustment Procedure:
1. Connect the scope probe to a Phase A dimmer output. This is best accomplished by using a load
receptacle plug. Note: Be sure to isolate the ground of your scope.
2. Apply power to the dimmer pack.
3. Turn on the Test Switch.
4. Look at dimmer output on scope. The wave should be sinusoidal.
5. While looking at the dimmer output wave form, turn the Phase A trim adjustment screw counter clockwise
until the wave starts to become chopped. Then slowly turn the adjustment screw clockwise until the wave
form becomes sinusoidal again. At this point the adjustment is complete. Continue in this manner to
calibrate the remaining phases.
Control modules are usually adjusted for 120V or 240V operation. For 100V or 220V operation it may be necessary to
readjust your modules. If you operate this Pack at 100V, the dimmer modules are derated to 2KW and 5KW. The ratings
of dimmer modules operating at 220V remain at 2.5KW and 5.0KW.
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CHAPTER VII: TROUBLESHOOTING
Before requesting service for this unit, check the charts below for a possible cause of the problem you are
experiencing. Some simple checks or a minor adjustment on your part may eliminate the problem and restore
proper operation.
If you are in doubt about some of the checkpoints, or if the remedies indicated in the chart do not solve the
problem, consult your local dealer or call the NSI Technical Support line for assistance. 1-800-864-2502
M-F 8 AM – 5 PM PST.
TABLE 8
CONTROL MODULE INDICATOR LEDS
SIGNAL AIRFLOW POWER STATUS
ON
OFF
OFF
ON
ON
FLASHING
OFF
ON
OFF
ON
OFF
OFF
ON
ON
OFF
ON
FLASHING
ON
NORMAL
Console not on, not connected, or control line is miswired.
Power not on, not connected, or control module fuses are blown
Airflow obstructed or dimmers are missing.
Missing a phase of power, control module fuse blown.
Protocol is wrong, not selected, control line is miswired.
.
TABLE 9
OUTPUT AND OPERATION
PROBLEM SUGGESTED CAUSE/REMEDY REFER TO CHAPTER, SECTION
Lights stuck at full.
Dimmer numbering is wrong
Lights don't come on with
Test Switch
Lights don't come on with
console control
Improper dimmer curve
Light bumps to FULL
Dimmer modules 3 + 4 don't
turn on.
Test switch is ON, turn off
Check thumbwheel setting.
Check control module configuration DIP switches
Circuit breakers off.
Loads not connected properly.
Power not on, not connected.
Dimmer modules not inserted.
Airflow obstructed, missing dimmer modules.
Console not connected properly.
Control cable wired improperly.
Protocol selected improperly.
Thumbwheel setting is wrong.
Pack configuration DIP switches set improperly.
Phase trim adjustment is wrong.
Non-Dim switch is ON.
Bussing configured wrong.
III, 3 and IV, 3
III, 1 and IV, 1
III, 5 and IV, 6
II, C and V
II, D
II, B
II, C
II, C
III and IV
III and IV
IV, 5
III, 1 and IV, 1
III, 5 and IV, 5
VI
IV, 7
II, B
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APPENDIX A: SPECIFICATIONS
PACK CAPACITY: 12 CIRCUITS, 20AMP MAX PER CIRCUIT
DIMENSIONS: 13.00"H x 14.65”W x 9.63"D
(33.0cm) x (37.2cm) x (24.4cm)
WEIGHT:
EMPTY:
LOADED:
NOMINAL INPUT:
120V CIRCUITS
240V CIRCUITS
(FOREIGN ELECTRICAL SERVICE ONLY)
POWER FEEDER ENTRY: 2" STRAIN RELIEF - RANGE 1.15” (29.21 mm) to 1.98” (50.292mm)
MAXIMUM FAN NOISE RATING: NC33
MAXIMUM AMBIENT
OPERATING TEMPERATURE:
MAXIMUM OPERATING HUMIDITY 90% W/O CONDENSATION
PHASE-TO-NEUTRAL
OPERATING VOLTAGE:
OPERATING FREQUENCY: 50 ± .5HZ OR 60 ± .5HZ
24.8 LBS. (11.16 Kg)
45.1 LBS. (20.3 Kg)
120/208V, 50/60HZ, 3Ø, 4 WIRE OR
120/240V, 50/60HZ, 1Ø, 3 WIRE
240/415V, 50/60HZ, 3Ø, 4 WIRE OR
240/480V, 50/60HZ, 1Ø, 3 WIRE
40˚C (104˚F)
120V ± I0% OR 220/240V ± 10%
ENCLOSURE TYPE: NEMA TYPE 1 FOR INDOOR USE ONLY (UTILIZER DANS UN
ENDROIT A L'ABRI).
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APPENDIX B: DIMMER PACK FEEDER CABLES
The 2002 National Electrical Code allows for smaller, lighter, less expensive cables, providing the
terminations on each end are capable of dealing with the elevated temperatures. All Pack
terminations are rated to operate at the elevated temperatures at which 90˚C rated cables operate.
Proper selection is dependent on the rating of the terminations on the opposite end of the cable. All
other terminations are rated for 60˚C cable unless specifically marked for the higher rating.
Below are suggested feeder cables based on the 2002 NEC. They all fit the 1.15" to 1.98” range of
the Pack cable clamp and the 1/0 AWG (0 AWG) maximum size of the terminations.
Dimmer Pack
Rating
2.4Kw
2.4kW
2.4kW
2.4kW
2.4kW
2.4kW
Termination
Temperature Rating
60˚C
60˚C
75˚C
75˚C
90˚C
90˚C
Cable Size
and Type
1/4G
1/5W
2/4G
2/5W
3/4G
3/5W
Cable
Diameter
1.68
1.88
1.48
1.61
1.34
1.51
It is also possible to use single-conductor type W feeder cable. The NEC requires a minimum of 1
AWG for use in theatres. Since this cable is over-sized for this application, 1 AWG is good for all
three temperature ratings. The five cables can be bundled or unbundled. It is necessary to use a 6
AWG ground conductor as five 1 AWG conductors will not fit the cable clamp.
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APPENDIX C: LOAD CONNECTORS
APPENDIX D: DIMMER PHASING
For the Topaz 12 portable pack, the dimmers are on the following phases:
DIMMER 3 PHASE SINGLE PHASE
1
2
3
4
5
6
7
8
9
10
11
12
A
A
A
A
B
B
B
B
C
C
C
C
A(LI)
A(LI)
A(LI)
A(LI)
A(LI)
A(LI)
C(L2)
C(L2)
C(L2)
C(L2)
C(L2)
C(L2)
INTERLOCK STACKING CAPABILITIES
The TOPAZ 12 Pack is designed so that several units can be stacked on top of each other. The channel on the bottom of
the packs is designed to fit over the handle on the top and the rubber feet minimize slipping. Numerous packs can be
stacked on top of each other as stability permits. Stability must be verified after all power cables are connected.
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Page 25
LEVITON-NSI DIVISION TWO-YEAR LIMITED WARRANTY
Leviton-NSI warrants new Leviton-NSI electronic control and dimmer products to be free from defective materials and
workmanship for a period of two years from the date of purchase to the original owner when purchased from an
authorized Leviton-NSI dealer.
Fixtures, lamps and gel material are not covered under this warranty.
The purchaser is encouraged to complete and mail to Leviton-NSI the product registration card enclosed with each
product. Leviton-NSI products that have been subjected to accident, alteration, abuse or defacing of the serial number
are not covered by this warranty. The normal wear and tear of items such as knobs, jacks and switches are not covered
under this warranty.
If your Leviton-NSI product requires service during the warranty period, Leviton-NSI will repair, at its option, defective
materials provided you have identified yourself as the original owner of the product to Leviton-NSI or any authorized
Leviton-NSI dealer. Transportation charges to and from an authorized dealer or the Leviton-NSI factory for repair shall be
the responsibility of the owner. All products returned to Leviton-NSI must have a factory return authorization number
issued prior to shipping.
Leviton-NSI is not liable for any incidental or consequential damages resulting from defect or failure other than repairs of
the Leviton-NSI product subject to the terms of this warranty. This warranty gives you specific legal rights, and you may
have other rights which vary from state to state. This warranty is expressly in lieu of all other agreements and warranties
expressed or implied except as may be otherwise required by law.
20497 SW Teton Avenue
Tualatin, OR 97062
503-404-5500
fax: 503-404-5600
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