CDSO 1.2Kw Pack
Price: $20.00
.~
Strand Lighting
Operator's Reference
Part#: 2-450064-010
Document Revision: CO
By: D. Lammers
Date: 08/29/89
Information contained in this document is disclosed in confidence and may not be
duplicated in full or in part by any person without prior written approval of Strand
Lighting. It's sole purpose is to provide the user with adequately detailed
documentation so as to efficiently install, operate, maintain, and order spare parts
for the system supplied. The use of this document for all other purposes is
specifically prohibited .
The material in this manual is for information purposes and is subject to change
without notice. Strand Lighting assumes no responsibility for any errors or omissions which may appear in this manual.
Comments and suggestions for corrections and/or updates to this manual are
appreciated and will be considered for the next printing if forwarded in writing
(red-lined photocopy preferred} to the Documentation Manager or Applications
Engineering Manager at the West Coast facility of Strand Lighting North America.
Copyright 1989, Strand Lighting. All rights reserved.
West Coast Office (All Services):
18111 South Santa Fe Ave.
Aancho Dominguez, CA 90221
East Coast Office (Field Service, Sales):
20 Bushes Lane
Elmwood Park, NJ 07407
Canadian Office (All Services):
6490 Viscount Road
Missisauga, Ontario L4V
Canada
1 H3
(213) 637-7500
(201) 791-7000
(416) 677-7130
Maintenance
This section provides trouble-shooting and maintenance information for the COBO 1.2Kw Pack.
For electronic repair information, see
(Strand part #8-700193-000) .
•coao 1.2Kw Pack Electronics Repair Procedures•
7. Basic Trouble-Shooting ................................................................................... 35
7.1 Component Removal ................................................................................................... 35
7.2 System Malfunctions Common to One or More Power Supplies ............................ 36
7.3 Dimmer Problems Common to a Single Ramp Card ............................................ 38
7.4 Dimmer Problems Not Related by Phase or a Common Phase ............................ 39
8. Periodic System Maintenance .......................................................................... 41
Appendices
A. Spare Parts ................................................................................................. 43
References
List of Figures
1. COBO 1.2Kw Pack ........................................................................................................ 15
2. COBO 1.2Kw Pack Exploded View ............................................................................. 16
3. COBO 1.2Kw Pack Wall Mounting ............................................................................. 20
4. XLR To mini-SwitchCraft Adapter ............................................................................. 21
5. 1.2Kw Pack Power Connection ................................................................................... 25
6. Multiplexed 1.2Kw Pack Control Hookup .................................................................. 26
7. COBO 1.2Kw Pack (Hardwired Control) Installation .................................................. 27
8. Analog 1.2Kw Pack Hookup to Strand Analog Console ....................................... 28
9. Analog 1.2Kw Pack Hookup to Non-Strand Analog Console ................................. 29
1 O. Analog 1.2Kw Pack Hookup to Strand Multiplexed Console .................................. 30
11. Reference Adjustment Locations ............................................................................. 31
12. COBO Dimmer Output Curves ................................................................................... 32
Index ........................................................................................................................ 47
iii
Table of Contents
CD80 1.2Kw Pack Operator's Reference
Introduction
This section provides information on manual organization. It also details procedures for getting
your suggestions to Strand Lighting, and receiving help if necessary.
1. About this Manual .............................................................................................. 3
1.1 Manual Organization ..................................................................................................... 3
2. Technical Assistance .......................................................................................... 5
2.1 In Case of Problems ..................................................................................................... 5
2.2 Technical Questions ..................................................................................................... 5
2.3 Parts Purchases ........................................................................................................... 5
2.4 Comments and Suggestions .......................................................................................... 5
System Information
This section provides specifications and basic layout information for the COBO 1.2Kw Pack.
3. Dimmer Pack Description ................................................................................. 9
3.1 General ........................................................................................................................... 9
3.2 Environmental ................................................................................................................ 9
3.3 Servicing ........................................................................................................................... 9
3.4 A.C. Power ..................................................................................................................... 9
3.5 Control Signal ..............................................................................................................
3.6 Dimming Characteristics .............................................................................................. 1 D
3.7 Dimmer Output ........................................................................................................ 10
3.8 Protection ................................................................................................................... 1 D
1 D
4. Basic Co,nponint Layout .............................................................................. 11
4.1 Chassis ......................................................................................................................... 11
4.2 Control Electronics (Multiplexed Analog Input) ....................................................... 12
4.3 Control Module (Discreet Analog Input) .................................................................. 13
4.4 Power Control and Cooling Assemblies .................................................................. 13
Operation
This section provides information on installation and operation of COBO 1.2Kw Packs.
5. Installation ...................................................................................................... 19
5.1 Install Packs - Portable COBO 1.2Kw Pack .................................................................. 19
5.2 Install Packs
5.3 Connect Control Signal ............................................................................................. 21
5.4 Set Thumbwheel Switches ........................................................................................ 22
5.5 Systems with Multiple Control Cables ........................................................................ 22
5.6 Mixing COBO Packs ................................................................................................... 23
5.7 Analog Control Module Hookup ............................................................................. 23
5.8 Set Phase Changer ................................................................................................... 24
5.9 Connect Power ........................................................................................................ 24
o Fault Protection ........................................................................................................ 24
5.1
5.11 Test Controller .............................................................................................................. 24
-Wall Mounted COBO 1.2Kw Pack ....................................................... 20
6. Di,nmer Pack Calibration .............................................................................. 31
6.1 Ramp Card Calibration .............................................................................................. 31
6.2 Power Supply Card Calibration ................................................................................... 31
ii
Introduction
CD80 1.2Kw Pack Operator's Reference
This section provides information on manual organization. It also details procedures for
getting your suggestions to Strand Lighting, and receiving help if necessary.
1. About this Manual
This manual provides information on the operating and maintenance procedures
for CD80 1.2Kw Packs. Circuit descriptions are included in the CD80 1.2Kw
Pack Repair Procedures Manual for those who wish to do their own circuit level
maintenance of this equipment.
1.1 Manual Organization
This manual contains 5 major sections as shown below.
INTRODUCTION
Manual organization (chapter 1)
How to get help (chapter 2)
SYSTEM INFORMATION
Specifications (chapter 3)
Basic Description (chapter
OPERATION
4)
Installation (chapter 5)
Calibration (chapter 6)
MAINTENANCE
CD80 1.2Kw Pack trouble-shooting (chapter 7)
Periodic maintenance procedures (chapter 8)
APPENDICES
Appendix A
3
2. Technical Assistance
COBO 1.2Kw Packs are designed to require a minimum of maintenance and servicing. Circuit descriptions are included in the COBO
dures Manual for those who wish to to do all of their their own repair and maintenance work. Other documentation may be purchased through Strand Lighting
Customer Service.
2.1 In Case of Problems
If equipment fails to operate properly upon installation, or under normal load and
temperature conditions, and basic trouble-shooting procedures are not effective,
please contact Strand Lighting Field Service at the office serving your area.
Strand Lighting will issue an RGA (Return Goods Authorization) before the return
of any defective materials. This allows tracking of returned equipment, and
speeds its return to you.
2.2 Technical Questions
For technical questions regarding setup, operation, or maintenance of this
equipment, please contact the Strand Lighting Field Service office serving your
area (see reverse side of manual title sheet for addresses and phone numbers).
1.2Kw Pack Repair Proce-
2.3 Parts Purchases
For purchase of spare parts or documentation, Please contact Strand Lighting
Customer Service in the Rancho Dominguez office.
2.4 Comments and Suggestions
For comments regarding equipment functions and/or suggested enhancements,
please call or write to the Control and Dimming Product Manager at the Rancho
Dominguez office.
For comments on this manual, please write to the Technical Publications
Manager at the Rancho Dominguez office.
5
System Information
CDBO J .2Kw Pack Operator's Reference
This section provides specifications and basic layout information for COBO 1.2Kw Packs.
7
3.
Dimmer Pack Description
The COBO 1.2Kw Pack is a lightweight portable performance dimming pack containing 24 1.2Kw dimmers.
3.1 General
Size - 23.25" x 20.00' x 7.75'
Weight - 65 pounds
.125' (3mm) aluminum alloy housing.
Baked enamel finish, black semi-gloss, with off-white silkscreened
graphics .
Integral carrying handles for transporting.
Optional wall mounting .
3.2 Environmental
Operating Temperature - 40 degree maximum ambient.
Low noise fan for efficient cooling.
3.3 Servicing
Rapidly replaceable electronics.
Rapidly replaceable SSA modules.
3.4 A.C. Power
100-140VAC, 50/60Hz.
Three phase power requirements:
Single phase power requirements:
Internally field changeable between three phase and single phase
power input configurations.
1.2Kw Pack - 120V/208 VAC, 80 Amps, 4-wire plus ground.
2.4Kw - 120V/240
VAC, 120 Amps, 3-wire plus ground.
9
3.5 Control Signal
Compatible with USITT AMX 192 control signals.
Input Control Voltage - Multiplexed Oto 5.0V DC level
Input Control Current - Less than
Signal Input Impedance - Line terminated by 1.8K in series with .001 uF
Optional 0-1 0VDC input electronics module (switchable between
AMX192 and analog).
3.6 Dimming Characteristics
Input vs. output - IES square law characteristics.
Output Response Time - Better than 0.1 seconds
Line Regulation - + 2% with changes in line from 1 oav to 132 VAC.
Load Regulation - Better than +2% with changes in load from 10 watts
to full load any point in the dimming curve.
3.7 Dimmer Output
Output Waveform -Variable conduction angle 120 VAC Sine Wave.
Rise Time - Greater than 320 micro-seconds.
Efficiency - Better than 95% at full load.
Load Range Output Capacity - Twenty four 1.2Kw channels.
Available with Grounded Twist Lock, Pin Plug, U-Ground, or terminal
strip outputs.
1 ow to 1.2Kw.
1 ma
3.8 Protection
Overvoltage Protection - fuses on Motherboard and Power Supply.
Front panel overtemperature and power indication.
Solid State Relay Peak Surge Rating: - 600 AMPS.
Short Circuit Protection - fully magnetic circuit breakers.
10
4.
Basic Component Layout
4.1
Chassis
The COBO 1.2Kw Pack chassis consists of a main structural chassis (bottom
housing and front panel), a removable top, and an interchangeable rear connector panel. The heavy gauge structural panels create a rugged container even
though assembled with only four pieces.
The main structural chassis consists of the bottom housing and front panel fastened rigidly together. The front panel is recessed to protect the circuit breakers
and panel components.
The front panel, constructed of .090 thick aluminum alloy, contains cutouts for
the U.L. listed circuit breakers and a removable panel which hides the plug-in
printed circuit boards.
The bottom housing, constructed of .125 thick aluminum alloy, supports a heat
sink subassembly (mounting the solid state relays and an overheat thermostat),
a fan, a fan guard, a circuit breaker/torroidal choke subassembly (with chokes
solidly mounted in a
knock-out, for input power wiring wiring. The rear panel is attached to the bottom housing and recessed to protect the connectors. Four large diameter feet,
approximately 3/4' high, are attached to the underside of the bottom housing
and existing feet mount holes are accessible for easy wall mounting.
The rear connector panel, constructed of .090 thick aluminum alloy, is manufactured in four customer options:
'clamshell" Lexan retaining channel), and a power-in
1) Pin connectors
2) Twist lock GTL connectors
3) Straight blade (Duplex) connectors
4) A terminal block for hard wiring of outputs plus control
The top cover, constructed of .125 aluminum alloy, fastens to the main chassis
by four screws, and allows easy access for servicing. Recessed handles are in-
tegrated into the top housing for easy one man carry capability. Instruction
labels are affixed to the underside of the top cover and a warning label ... ,
'Disconnect power before removing
top~ ... attached to the top of the cover.
4.2 Control Electronics (Multiplexed Analog Input)
The control electronics for the 1.2Kw Pack consists of a Motherboard, four COBO
Rack Ramp Cards, one COBO Rack Power Supply Card, and a Control Panel
assembly which is screwed on in front of the other control components, and
hides them.
A. Motherboard
The Motherboard serves to connect the control components together. It
also contains the phase references for phases B and C, and a clock circuit which allows testing the pack by bringing all dimmers in the pack to
FULL
B. Ramp Card
Ramp Cards provide control signal demultiplexing and analog to pulse
width conversion.
Up to 192 dimmer levels are time multiplexed on the ANA (analog) line of
the control cable (control terminal
senting dimmer output levels of 0-100%. A differential clock on the CLK-
(minus clock) and CLK+ (plus clock) lines (control terminals
synchronizes the dimmer rack with the control console. The multiplexing scheme conforms to the USITT AMX192 Dimmer Signal Specifica-
6W and 12W dimmers require 2 clock cycles or dimmer posi-
tion.
tions.
4). Levels vary from 0-SVDC, repre-
1 and 3)
12
Each Ramp Card contains the following circuitry:
1) clock receiver and reset detector
2) counter/decoder circuit
3) analog buffer
4) analog demultiplexer
5) A.C. zero crossover detector
6) square law curve generator
7) output solid state relay driver
8) power supply
C. Power Supply Card
The Power Supply Card conditions AC power from power phase A, and
supplies the AC line reference source for the phase A Ramp Card.
The Power Supply Card also has an SSA for fan power, which is ener-
gized from the Ramp Card when system clock signals are present. A
fuse on the Power Supply Card provides overload and short circuit
protection for this SSA.
D. Control Panel
The contains input plugs for the AMX192 signal, the thumbwheel switch
for pack number selection, a slider controller for testing the dimmers, a
'NORMAL/TEST' switch to activate the slider control, and 'POWER' and
'OVERTEMP' indicators.
4.3 Control Module (Discreet Analog Input)
A discreet analog input version of the pack is available. This pack contains an
analog to multiplex converter in addition to the other control circuitry.
This converter plugs into the Motherboard, and requires a different removable
control panel from the 'Multiplex Only' version. The 'Multiplex/Analog• version of
the control panel allows selection of AMX192 or analog signals from a front
panel switch.
4.4 Power Control and Cooling Assemblies
The following circuit and thermal elements in the bottom housing serve to control and dissipate power in the CD80 1.2Kw Pack:
A. 12 SSAs (1 for each 2 dimmers), rated appropriately for the dimmer
power rating, and mounted on a common
to the bottom housing. Each dual SSA is field replaceable.
18' long heat sink anchored
B. One torroidal choke for each dimmer is mounted in a common assembly
adjacent to the heat sink.
C. One primary, fully magnetic circuit breaker for each dimmer is mounted
in front of the torroidal chokes.
D. A fan mounted on the positive pressure side of the heat sink provides
approximately 70 CFM (derated) of cooling air through the enclosure.
E. A phase changing/terminal block assembly on the bottom housing
provides termination of either 3 phase 4-wire plus ground 120/208 VAC
80 AMPS, or single phase 3-wire plug ground 120/240
VAC 120 AMPS.
13
1 ______ 20.37
15A Primary Circuit Breakers (24)
(Fully magnetic)
AMX192 Control Input
AMX192 Control Output
Power Light
Air Outlet Vent
Dimmer Pack Select
est Controller
nalog Input (ANA/MPX units only)
TEST/NORMAL Switch
MPX/ANA Switch (MPX/ANA uinits only)
Cover for access with 4 flat head screws
(See exploded view for options)
Figure 1. CD80 1.2Kw Pack
Knockout for
Power Cord
Air Inlet
an Guard
15
Rear Panel Assembly
1 3 Pole 20A Pin Conn. (3-283359-01-0)
2 3 Pole 15A GTL Conn. i3-283369-01 b)
2 3 Pole 20A GTL Conn. 3-283355-010)
3 3 Pole 20A U-Ground -283356-010
4 Teminal
Removable
Control Panel
(Multiplex
(Analog/MPX
- Hard Wired 3-283357 -01 o
- 3-283358-010)
- 3-283360-010)
Cover Ass'y (3-151004-010)
1.2Kw Choke/Breaker Ass'y
(3-169006-01 0)
Fan w/Fan Guard
(4" dia., 100CFM)
(1-260014-000)
Main Chassis Assem
(2-190137-010)
Power Input
Terminal Block
I
Figure 2. CD80 1.2Kw Pack Exploded View
-----
-----
-----
-------J
I
Card Cage
(3-254004-010)
I
I
Control PCBs
I
16
Operation
CDBO J .2Kw Pack Operator's Reference
This section provides information on installation and operation of COBO 1.2Kw Packs.
17
5. Installation
The location of wiring runs may affect dimmer performance and should be
planned before laying out the control and dimming equipment.
DO NOT run power feed or load wires in the same cable
bundle, conduit or wireway as control wiring. Where control and
power wiring must cross, they should cross at as close to a right angle
as possible.
DO NOT run wiring from other manufacturers' equipment in
the same cable bundle, conduit, or wireway with CDS0 1.2Kw
Pack wiring.
DO NOT run wiring from unrelated Strand Lighting or Strand
Electro Controls equipment in the same cable bundle, conduit,
or wireway with CD80 1.2Kw Pack wiring.
DO NOT run wiring in ways other than shown on system riser
diagram in permanent installations.
DO NOT substitute plastic conduit for metal where conduit is
called for in permanent installation. Metal conduit acts as a ground and
shield.
Since this is portable equipment, and installed under many circumstances, following all of the above constraints in all installations may not be possible.
However, following these constraints where possible will help insure consistent
and stable system operation.
5.1 Install Packs - Portable CD80 J .2Kw Pack
The CD80 1.2Kw Pack may be placed on any flat surface for normal operation.
Up to 8 units may be stacked vertically if required. No more than 2 units should
be placed side to side unless at least 24 inches is provided between packs.
Otherwise, the hot air exhaust from each unit will simply feed into the next. In
permanent or semi-permanent installations, build shelves to hold two packs
separated by at least 24 inches horizontally. Vertical shelf spacing should allow
removal of the CDBO 1.2Kw Pack top covers for access to SSR modules if required.
19
5.2 Install Packs- Wall Mounted CDBO 1.2Kw Pack
The wall mounted COBO 1.2Kw Pack (Terminal Strip 1.2Kw Pack) provides load
and control terminal strips on the rear panel of the pack, and provides a termination for remote overtemp indication.
A. Set mounting hardware in wall according to the figure.
B. Remove top of pack and mount on wall. Make certain that the fan is at
the bottom of the unit as mounted.
C. Attach conduit as indicated for power, load, and control wires, and pull
wiring. Bring wires into pack as shown. This configuration is designed
for minimum crosstalk between the AC line and the control wiring.
-Ami:~~•~, .. I
Keep Clear
LEFT
SIDE
20.5' (52.1 cm)~
1-16' (40.6cm)---t--j I
T* ~-1
nockout For \ /
Power Wirr Mounting Holes
23.5' 20.25'
(59.7cm) +
TOP (COVER REMOVED)
l-=10--:--I-Air Intake Area
I (25.4cm) I Keep Clear
~~II~~
T c::J
8.5'
(29.85cm)
l_ '--,I'--='-----=--'
Air Inlet Fan
Jj-lom)
Knockout For
Power Wires
Knockout For
Control Wires
-++,[}
;- Control
RIGHT
SIDE
Panel
Primary
Circuit
Breakers
20
Figure 3. CD80 1.2Kw Pack Wall Mounting
5.3 Connect Control Signal
COBO Dimmer Racks accept control signals conforming to the USITT AMX192
Dimmer Signal Specification.
Short extensions of the multiplex signal, where
are made with Belden cable #8723 (2 pairs of shielded 24 gauge wire). All other
runs (in or out of conduit) are made with Belden #9156 (2 pairs of unshielded
gauge wire). Maximum allowable distance from control console to last dimmer
cabinet is 1000 feet.
The three types of connections provided in Strand Lighting equipment for the
AMX192 signal are the XLR style connector, the TA4{fY4 Series Mini-SwitchCraft
connector, and terminal blocks. COBO 1.2Kw Packs use XLR connectors for
control signal connection. Pin assignments are shown below.
TA4{fY4 connectors are used,
18
COBO
XLR
Function
-CLOCK
+ CLOCK
COMMON
ANALOG
Interconnection between equipment with different plug types requires an
adapter cable.
See figure below for proper adapter wiring.
The plugs on this adapter are not connected pin to pin.
Pin#
4
2
1 2 2
3
TA4{TY4
Pin# Pin#
1
3 3
4 4
Term. Block
1
"XLR" Style
Connector
TA4/TY4 Series
Connector
-CLK -Clock
4
~
Multi lexed Analo
COM Common
+CLK +Clock
Figure 4. XLR To mini-SwitchCraft Adapter
21
5.4 Set Thumbwheel Switches
Set the dimmer numbers for each pack by setting the thumbwheel switch and
expansion switch on the front of the control module to the appropriate group of
dimmers on the control cable. Switch settings are as follows:
Thumbwheel
Switch Setting
1
2
3
4
5
6
7
8
Dimmer Numbers
1-24
25-48
49-72
73-96
97-120
121-144
145-168
169-192
5.5 Systems with Multiple Control Cables
When there is more than one control cable, dimmer numbers on cable 2 will be
offset by 96 or 192, depending on the console, and cables after cable #2 will
have dimmer numbers offset from cable #2 by 192.
The following Strand Lighting control consoles output only 96 dimmer signals
from Dimmer Output #1, and 192 dimmer signals from all other outputs.
Remember that each dimmer patched as a 6Kw dimmer in the console takes up
two dimmer signals.
22
All versions of Mantrix
Mantrix Memory
miniPalette consoles, when set for 288 dimmer signals or less. When
set for more than 288 dimmer signals, these consoles output
192 dimmer signals from Dimmer Output
Lightboard M with AMX select jumper installed. Without this jumper, the
console outputs 192 dimmer signals from Dimmer Output #1.
minilight Palette Series consoles, when set for 288 dimmer signals or
less. When set for more than 288 dimmer signals, these consoles output 192 dimmer signals from Dimmer Output #1.
Light Palette Series consoles with software revisions above V6E, when
set for 288 dimmer signals or less. When set for more than 288
dimmer signals, these consoles output 192 dimmer signals from
Dimmer Output #1.
Strand Lighting Light Palette Series consoles with software revisions V5A, V5B,
V6A and V6B output 96 dimmer signals from all Dimmer Outputs when set for
384 dimmer signals or less. When set for more than 384 dimmer signals, these
consoles output 192 dimmer signals from each output.
#1.
5.6 Mixing CDBO Packs
Combinations of 1.2Kw, 2.4Kw, 6Kw, and 12Kw packs may be used in the same
installation. Care must be taken to properly set the thumbwheel group switches,
and identify 6Kw/12Kw dimmers in the patching operation when setting up the
control console.
5.7 Analog Control Module Hookup
For use with discreet analog output control consoles, the Analog Control Module
inputs twelve 0 to + 1 0VDC signals through a standard male D825 connector.
The thumbwheel switch has no effect on signals input through this connector.
Control consoles with outputs which are not pure D.C. (i.e., Manual Micro-Q), will
require a filter choke box (part #3-069017-010 or 3-069018-010) between the
console and any splitter arrangement for proper operation. The connector
pinout for the D825 connector is shown below.
PIN FUNCTION
1 COM
2 Analog signal #23
3
4 Analog Signal #19
5 Analog Signal #17
6 Analog Signal #15
7
8 Analog Signal
9 Analog Signal #9
10 Analog Signal #7
11 Analog Signal #5
12 Analog Signal #3
13 Analog Signal #1
14 Analog Signal #24
15 Analog Signal #22
16 Analog Signal #20
17 Analog Signal #18
18
19 Analog Signal #14
20 Analog Signal #12
21
22
23 Analog Signal #6
24 Analog Signal #4
25 Analog Signal #2
Analog Signal #21
Analog Signal #13 .
#11
Analog Signal #16
Analog Signal #10
Analog Signal #8
23
5.8 Set Phase Changer
For maximum flexibility, a phase changing terminal assembly (consisting of a terminal block and a connector pair assembly} provides termination for a 3-phase
4-wire 240/208 VAC 80 AMP power source, or a single phase 3-wire 120/240
VAC 120 AMP power source.
For 3 phase operation, place the connection plug in the 3 phase (3cf,} position.
For single phase operation, place connector plug in the 1 phase (1 cf,} position.
Changing from three phase to single phase operation also requires changing
the position of the reference source switch
re-routes the ramp generators to the proper SSR drive.
5.9 Connect Power
Connect power to the COBO 1.2Kw Pack by attaching the appropriate customer
supplied connector to the manufacturer supplied power cable. If no cable is
supplied, install customer cable by removing the top of the unit, connecting the
phase connector for split single phase or three phase operation, and attaching
cable to the power terminal block. In the event of an improper power connec-
tion, the overvoltage circuit disables the power supply regulator and flashes the
power supply indicator, protecting the electronics.
(3cf,/1 cf,} on the Motherboard . This
5.10 Fault Protection
If the SSR heat sink overheats, the OverTemp Indicator will turn ON. This shows
that air flow has been blocked or the fan has failed.
Electromagnetic circuit breakers protect the SSAs if there is a short circuit. A
short on any dimmer in the pack will trip the circuit breaker for the dimmer OFF.
Restore circuit operation by clearing the short and turning the circuit breaker
back ON.
5.11 Test Controller
Use the Test Controller on the Control Panel to test loads without using a control
console. Set the
raise the Test Controller to the required level. All 24 dimmers will be active at the
set level. To turn individual dimmers OFF while using this feature, turn their circuit breaker OFF.
To activate all dimmers at full, push the PANIC switch on the rear panel next to
the dimmer 24 output.
'NORMAL/TEST" switch on the Control Panel to 'TEST" and
24
Loads House Power Loads
3 phase 4 wire
200 Amps per phase per pack
Pack #12
j() •
I<~ •
II~ e
- -
.
0 .
Q e
e
.
(~ e
e
.
e
.ill
DJ
ill
01
y
.ill
DI
-
-
-
Pack #4
Dimmers 73-96
Pack #2
Dimmers 25-48
Daisy chain cable
Pack #1
Dimmers 1-24
I<~ e
-.=--
10 •
Dimmers 265-288
Pack #9
Dimmers 193-216
Pack #8
Dimmers 169-192
.
0 .
e
.
.
( ~
(~ e
e
.
.ill.
Of
_.:::n.
DI
.ill
Pack #5
Dimmers 97-120
NOTE: Figure shows console with 96 dimmer signals from Output
with 192 signals from Output
drives packs #9-16.
Figure 6. Multiplexed 1.2Kw Pack Control Hookup
.
I<~ •
I~
.ill
e
Of
e
\ wire MUX cable
Output 2
-
Multiplex
Control Console
#1, packs 1-8 are on Output #1 and Output #2
Output1
DI
11
~
#1 . For consoles
26
RECEPTACLES
PHASE
POWER
CABLE
POWER
TERMINAL BLOCK
Warning: Disconnect power before removing any parts.
Connect only to a system that is properly grounded/earthed .
Installation for:
1ct, 120/240VAC, 3 wire+ GND.
1. Plug phase connector into •1 q,•
phase receptacle ("3cp not used).
2. Connect power cable wires to power
terminal block:
a. "L 1 • wire to "q,A" terminal
"q,B" terminal not used
b.
"L2" wire to •q,c• terminal
c.
"N" wire (white) to •N• terminal
d.
e. •G• wire (green) to
•G• terminal
Installation for:
3ct, 120/208VAC, 4 wire + GND.
1. Plug phase connector into "3cp"
phase receptacle ("1 q, not used).
2. Connect power cable wires to power
terminal block:
a. "</JA"wire to "q,A" terminal
"</JB" wire to "</JB" terminal
b.
c.
"</JC" wire to "</JC" terminal
d.
•N• wire (white) to •N• terminal
e. •G• wire (green) to
CARD CAGE
•G• terminal
3. Place phase switch in •1
Figure 5. 1.2Kw Pack Power Connection
q,• position
3. Place phase switch in
"3</J" position
25
NOTE 2
2
RECEPTACLE
STATION
~-+------l CD8 0
3-229015-010
1 2
0 0
RC OT
0 0
9 9 9
I I I
I I I
I I I
I I I
o
r ___ .o_CJ.._.o.. ___ 7
□ □
'-----+---; C D8 0
I 1 2 OT I
I CONTROL I
L ___________ _J
I CONSOLE I
SYSTEM HOOKUP
INTERNAL WIRING
( 2) 20
PACK
1
DIM
1-24
PACK
5
DIM
97-120
5 -------
2
6 -------
PAIR
PAIR
Receptacle Station note:
Splice to leads 601, 602, A 1, A2,
A3, A4 in receptacle station for
first 4 1.2Kw Packs (dimmers
1-96). Use leads 81, 82, 83, 84
for 1 .2Kw packs 5 to 12
(dimmers 97-288) . Leads
marked RF1-RF4 are not used.
"TWISTED PAIR
"TWISTED PAIR
-----;;=:;:----112
NOTE 2
All AC wires must be run in separate conduit,
and may not be combined with control wires or
cables. See inside top cover of pack for input
power wiring instructions.
1.
Note:
II
II
3</J 4 wire 120/208VAC or 1</> 3 wire 120/240VAC main feed (bottom entry only).
2.
To loads as required (left side conduit entry only). 2 wire circuits .
Air entry
3.
Warm air exhaust• keep clear.
4.
5.
Two (2) twisted pair
in conduit (for
6.
Two (2) twisted pair BELDEN #9744 or #9156 (81, 82, 83, 84) and two (2) #20 AWG (601,602)
in conduit for COBO
(II)
Use BELDEN #9744 cable up to 1000 feet, and BELDEN /19156 cable up to 2000 feet.
BELDEN #9744 or #9156 (A 1, A2, A3, A4) and two (2) #20 AWG (601,602)
COBO 1.2Kw Packs 111-4).
1.2Kw Packs #5-12).
Figure 7. CD80 1.2Kw Pack (Hardwired Control) Installation
CONTROL
·TERMINALS
LOAD
TERM! NALS
NEUTRAL
BUSS
27
CUSTOM
SPLITTER
BOX
4 - COBO 1.2Kw Packs with Analog Option
(96 dimmer system)
I I I
Part #3-069018-01 o Filter Box
I
~
·~~iER
)----<(I"--
(I)
96 CHANNEL
*
Figure 8. Analog 1.2Kw Pack Hookup to Strand Analog Console
~
CONSOLE
(ANALOG)
When used in
~
I
___/I)1---(3) Control Cables
Multi-O
Light Palette
M1cro-Q (*)
Manual Mode, use the filter box in addition to the splitter box.
(Required for Micro-a Manual Mode use only)
#3-262931- 1 1 o {25') or
#3-262931-090 100') or
#3-262931-100 200')
28
CUSTOM
INTERFACE
BOX
4
- COBO 1.2Kw Packs with Analog Option
(96 dimmer system)
>------- Custom cable to mate with other
manufacturer's console as
specified by customer.
-
CONSOLE
(ANALOG)
Figure 9. Analog 1.2Kw Pack Hookup to Non-Strand Analog Console
29
8 - COBO 2.4Kw Packs with Analog Option
CUSTOM
SPLITTER
BOX
I I I
(96 dimmer system)
(3) Control Cables
#3-262931-11 o t25') or
#3-262931-090
#3-262931-100 200')
100') or
I I I
+lOV INTERFACE
~Multiplex Control Cable
To 120VAC source
t
-
STRAND
MULTIPLEXED
CONSOLE
Figure 10. Analog 1.2Kw Pack Hookup to Strand Multiplexed Console
30
6.
Dimmer Pack Calibration
6.1
Ramp Card Calibration
Calibration of COBO Ramp Cards is beyond the scope of this chapter. Calibra-
tion is done in the factory before shipment of the COBO 1.2Kw Pack and should
not be necessary in the field. All field adjustments relating to curve or to maximum output level should be accomplished with the Power Supply adjustment.
6.2 Power Supply Card Calibration
COBO Ramp Cards require a specific reference voltage from the Power Supply to
generate their 5 Volt reference ramp (5V •s• curve). The Power Supply is then
used to make any required adjustments in dimmer output curve using a true
RMS (AC+OC) meter. Adjustment is made with the Power Supply Card installed
in the
1.2Kw Pack.
60Hz systems require a 10.96VAC RMS reference and 50Hz systems require a
9.13VAC RMS reference from the power supply. For the phase A reference in
1.2Kw Packs, measure this voltage between J2 (Common) and J3 (Ref.) on the
Power Supply Card. For phase B and C, measure this voltage between J2 on
the Power Supply Card and the center tap of the adjustment potentiometer.
Compensation for different line voltages frequencies is by adjusting the Power
Supply, not the Ramp Card.
n
"
"
"
"
:: Card Cage
"
"
"
Phase A Adjust
(on Power Supply Card)
Figure 11. Reference Adjustment Locations
31
COBO 1.2Kw Pack electronics virtually eliminates the need for on-site calibration.
•coao Dimmer Output• drawing below shows the effects of line voltage
The
shifts in a system calibrated for 120VAC, and typical output curves of COBO
1.2Kw Packs when power supplies are calibrated to the actual incoming line voltage. Once calibrated, the output is held to the ideal output curve for the
calibrated voltage until it reaches incoming line voltage level, at which time it flattens out. Systems with greater than calibrated voltage as power line voltage will
maintain a square law curve to the calibrated voltage. Systems with lower than
calibrated voltage as incoming line voltage should be recalibrated in the field.
Recalibration for this purpose is on the Power Supply Cards, not on the Ramp
Cards.
Where line voltages vary significantly from calibration voltage, a standard square
law output can be obtained by adjusting the Power Supply reference voltage to
10.96VAC RMS (for 60Hz systems) or 9.13VAC RMS (for SOHz systems) on-site.
This results in a square law output curve with a maximum output voltage 3-SVAC
below the incoming line voltage. Though adjustment to boost output voltage
slightly (or limit output to a specific level) is possible, it is not recommended, as it
will change the output curve.
130V
120V
,,ov
100V
90V
BCV
t 70V
60V
Ql 50V
g> 40V
-
g 30V
S 20V
& 10V
:,
0
10% 20% 30% 40% 50% BO% 70% BO% 90% 100%
Controller Setting-
c urves shown are with power supply cal ibrated
120VAC. Each curve rep resents a different
to
incoming line voltage .
Incoming voltages over
120VAC maximum.
120VAC are held to
Q)
C)
n,
.=:
g
Q)
C:
:.:J
C)
C:
.E
0
(.J
,f;
130V
120V
,,ov
100V
90V
BCV
t 70V
60V
Ql 50V
g> 40V
-
g 30V
S 20V
& 10V
:,
0
10% 20% 30% 40% 50% BO% 70% 80% 90% 100%
Controller Setting-
Curves shown are for powe r supply calibrated
to incoming line voltage . Each curve represents
a different incoming line voltage .
Dimmer output is a square law output to the
incom ing line voltage minus
3-SVAC.
Q)
C:
:.:J
C)
C:
.E
0
(.)
,f;
32
Figure 12. CD80 Dimmer Output Curves
Maintenance
CD80 J .2Kw Pack Operator's Reference
This section provides trouble-shooting and maintenance information for CD80 1.2Kw
Packs. For electronic repair information, see 'COBO 1.2Kw Pack Electronics Repair Procedures· (8-700193-000).
33
7.
Basic Trouble-Shooting
7.1
Component Removal
The COBO 1.2Kw Pack has been designed to be serviced easily and quickly by
the customer.
The plug-in electronics are designed to be removed by first removing the Control Panel (4 screws), and then removing the suspect printed circuit board.
The Motherboard is removed as a part of the card cage. Remove the top cover,
then unplug all cards and cables from the Motherborard, making sure to note
where they go back, remove the screws holding the Card Cage to the Bottom
Housing, and remove the Card Cage.
The electrical and mechanical components, relays, chokes, breakers, connec-
tors, fan and phase changer are accessible by simply removing the top cover.
The relays are fastened from above into the heat sink by two screws and are
easily replaced by the customer by removing the two screws and disconnecting
the electical connections .
For best operation, do a routine check and cleaning about once each year unless the operating environment is unusually harsh or dirty. Service and main-
tenance other than this cleaning are seldom required. In case of problems , and
in order to save time and aggravation, follow the procedures outlined here
before calling Strand Lighting. Observe what happens at each step. These
steps represent the questions you will first be asked by Strand Lighting Service
Representatives.
Strand
Lighting to minimize errors in translation and other misun-
derstandings.
The person actually doing the tests should contact
In case of failures in the system, fault isolation is expedited by considering the
system subject to the following categories of possible malfunctions :
A. Major system malfunctions common either to all dimmers or to a
single phase.
B. Dimmer problems common to a single Ramp Card.
C. Dimmer problems not related by phase or Ramp Card.
Establish fault location by interchanging Ramp Cards, or SSAs as required.
Correct the problem by card or SSA replacement. Always turn dimmer rack
power OFF when removing or replacing a PCB from the Motherboard.
35
7.2 System Malfunctions Common to One or More Power Phases
A) POWER SUPPLY INDICATOR IS OFF.
POSSIBLE CAUSE
1) Main power feed off.
SOLUTION
Check main power feed.
POSSIBLE CAUSE
1) Blown fuse in power supply.
SOLUTION
Replace fuse.
B) POWER SUPPLY INDICATOR ON, FANS OFF.
POSSIBLE CAUSE
1) Control cable disconnected, or broken.
SOLUTION
Repair, connect, or replace control cable.
POSSIBLE CAUSE
2) Incorrect patch in console.
SOLUTION
Check console patch to make certain it is correct.
POSSIBLE CAUSE
3) Clock leads reversed.
SOLUTION
Reverse clock leads to coao Pack at control signal input ter-
minal block (TB1) or control input connector.
36
C) INDICATOR ON, FAN ON. LIGHTS FLOAT TO FULL.
POSSIBLE CAUSE
1) Analog line broken or no analog output from console.
SOLUTION
Try control cable for defective pack in a different console output.
Remember that this changes the dimmer numbers, and repatching may be necessary, as well as resetting the number of dimmers. If problem persists, check analog line for breaks. Otherwise, problem is probably in console.
D) INDICATOR ON. FAN ON. ALL LIGHTS OFF.
POSSIBLE CAUSE
1) Analog line shorted or reversed.
SOLUTION
Repair or clear shorts on analog line, or replace defective con-
trol cable.
E) INDICATOR ON, FAN ON, CONSOLE NOT ADDRESSING DIM-
MERS CORRECTLY
OFF BY A CERTAIN NUMBER).
(I.E. DIMMER NUMBERS ARE CONSISTENTLY
POSSIBLE CAUSE
1) Patch problem in console.
SOLUTION
Check 6kW/12kW assignments in patch.
F) ALL DIMMERS IN ONE PACK WILL ONLY GO TO 90%.
POSSIBLE CAUSE
1) Control wiring error.
SOLUTION
+ Clock and common probably reversed in control wiring.
G) ALL DIMMERS IN ONE PACK WILL NOT GO TO ZERO.
POSSIBLE CAUSE
1) Control wiring error.
SOLUTION
- Clock and common probably reversed in control wiring.
37
7.3 Dimmer Problems Common to a Single Ramp Card
The dimmer pack must be powered down before removing or insert-
ing Ramp
A) FOUR OR EIGHT CONSECUTIVE DIMMERS DO NOT
8) A PAIR OF CONSECUTIVELY NUMBER DIMMERS DO NOT
C) FOUR OR EIGHT CONSECUTIVELY NUMBERED DIMMERS
Cards
RESPOND TO COMMANDS.
POSSIBLE CAUSE
1) Ramp Card failure.
SOLUTION
Replace Ramp Card and return faulty card to factory for repair.
RESPOND TO CONTROLS.
POSSIBLE CAUSE
1) Ramp Card driver output failure.
SOLUTION
Replace Ramp Card and return faulty card to factory for repair.
DO NOT COME UP TO FULL BRIGHTNESS OR DO NOT
TRACK SYSTEM.
POSSIBLE CAUSE
1) Motherboard phase switch (1 cp/3cp) not in correct position for 3
phase operation.
SOLUTION
Place phase switch in 3cp position.
POSSIBLE CAUSE
2) Ramp Card improperly calibrated.
SOLUTION
Replace Ramp Card and return faulty card to factory for
recalibration.
D) ONE OR MORE LIGHTS COME ON WHEN CONSOLE IS
TURNED OFF OVERNIGHT.
POSSIBLE CAUSE
1) Output driver or sample and hold malfunction.
SOLUTION
Replace Ramp Card and return faulty card to factory for repair.
38
7.4 Dimmer Problems Not Related by Phase or a Common Ramp Card
The dimmer pack must be powered down before removing or inserting Ramp Cards.
A) DIMMER FLICKERS AS SYSTEM IS BROUGHT UP.
POSSIBLE CAUSE
1) Defective Ramp Card or SSR.
SOLUTION
Swap Ramp Card with a known good unit. If problem moves,
Ramp Card is defective. Replace Ramp Card and return defective unit to factory for repair.
Swap SSR with a known good unit. If problem moves, SSR is
defective. Replace SSR.
B) DIMMER DOES NOT FOLLOW COMMANDS.
POSSIBLE CAUSE
1) Defective Ramp Card or SSR.
SOLUTION
Swap Ramp Card with a known good unit. If problem moves,
Ramp Card is defective. Replace Ramp Card and return defec-
tive unit to factory for repair.
Swap SSR with a known good unit. If problem moves, SSR is
defective. Replace SSR.
POSSIBLE
2) Control circuitry open.
CAUSE
SOLUTION
Check and repair control circuitry, motherboard connectors .
39
8.
Periodic System Maintenance
Perform Periodic Maintenance every six (6) to twelve (12) months, depending on
the environmental conditions.
A. Turn power to the dimmer pack OFF.
B. Remove Ramp Cards and Power Supply Card from the Motherboard,
dust them off with a soft natural bristle brush, and clean their edge connectors with a mixture of 70% denatured alcohol and 30% distilled water
(or other cleaning compound intended for gold edge connectors).
C. Inspect the dimmer pack for loose connections, build-up of dust, and
(for permanent or semi-permanent installations) placement of obstructions around it which may impede air flow. Tighten any loose connections found at this time.
D. Vacuum out any excessive dust build-up in the dimmer pack while
power to the pack is shut down.
D. Exercise all circuit breakers by turning them ON and OFF several times.
E. Replace Power Supply Cards and Ramp Cards.
F. Turn power to the system ON and verify Power Supply reference volt-
ages and adjust as required.
41
Appendix A
Spare Parts
CD80 1.2Kw Pack Operator's Reference
43
CD80 J.2Kw Pack Spare Parts List
DESCRIPTION
COBO Ramp Card
COBO Power Supply Card
COBO 1.2Kw Pack Motherboard
Analog Interface PCB
Analog Splitter Box
Analog Filter Box (32 dimmer)
Analog Filter Box (96 dimmer)
Torroidal Choke
Circuit Breaker (15A)
Heat Sink Assembly with SSA (1.2Kw)
Solid State Relay (dual 1.2Kw)
Fan for 1.2Kw Pack
PART#
3-722776-010
3-722777-010
3-723041-010
3-723045-010
3-060008-010
3-069017-010
3-069018-010
2-169032-010
1-132247-000
3-189013-010
1-377161-000
1-260014-000
45
Index
A
About This Manual, 3
8
Basic Trouble-shooting, 35
C
Calibration
Power Supply Card, 31
Ramp Card, 31
Chassis,
Circuit Breaker, 24
Circuit Description, 5
Comments, 5
Component Removal, 35
Conduit
Control Electronics, 12
Control Module
Control Panel, 13
Control Signal, 10
Control Wires
Cooling, 13
D
Description
Dimmer Output, 10
Dimmers
Dimming Characteristics, 1 0
Documentation, 5
E
Environment, 9
11
Type, 19
Analog Input, 13
Installation,
Analog Control Module, 13
chassis, 11
Cooling, 13
Power Section, 13
Output Curve,
21
32
CDBO J .2Kw Pack Operator's Reference
In Case Of Problems, 5
Installation
Analog COBO Pack, 23
Control Cable Adapter, 21
Control Cable Type, 21
Control Wires, 21
Mixed COBO Pack Types, 23
Multiple Control Lines, 22
Phase Changer, 24
Portable COBO Pack, 19
Power Connection,
Thumbwheel Switch Setting, 22
Wall Mounting, 20
M
Manual Organization, 3
Motherboard, 12
0
Overtemperature, 24
Overvoltage, 24
p
Parts, 45
Parts Purchases, 5
Peak Surge Rating, 1 0
Periodic maintenance, 41
Power
Phase Changer, 24
Power Requirements, 9
Power Section, 13
Power Supply Card
Calibration, 31
Specification,
Protection
Circuit Breaker, 24
Overtemperature, 1 o, 24
Overvoltage, 24
Short Circuit, 1 0
Purchase
Parts, 5
Purchase Documentation, 5
24
12
47
R
Ramp Card
Calibration, 31
Specification, 12
Routing
Control Wires, 19
Load Wires, 19
Power Feeds,
19
s
Servicing, 9
Spare Parts List, 45
Specification
AC Power, 9
Control Signal, 10
Dimmer Output, 10
Dimming Characteristics, 1 O
Environmental, 9
General, 9
Power Supply Card, 12
Protection, 10
Ramp Card, 12
Servicing, 9
SSR
Peak Surge Rating, 10
Suggestions, 5
T
Technical Questions, 5
Test Controller,
Thumbwheel Switch Setting, 22
Trouble-shooting
Periodic Maintenance, 41
Phase Related Problems, 36
24
w
Wall Mounting, 20
Wiring
Routing, 19
48
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