DMX dimmer pack

http://www.hoelscher-hi.de/hendrik/english/dimmer.htm

8ch DMX dimmer pack

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This single phase diy dimmer pack was designed for small size and maximum stability. Though it is
quite cheap because of its few parts, it has a firing table for power linearization and a 'switch mode'
option for each channel integrated. An internal heat control prevents failures in the power units.
A dimmer pack consists of:
1 DMX-Transceiver
1 zc detection
1-8 power units
DMX-Transceiver (Rev. 3.01)
With this modul DMX data can be received or transmitted.
Because of the complete usage of the RS485 converter, a bidirectional transfer
of data is possible (i.e: RDM as described in ANSI E1.20). Till now this feature
is only supported by a few expensive devices.

high voltage
tesla coil
twin

Though the circuit is only made of an AVR and few other parts I recommend a
diy etched board.

misc
pics
links
imprint
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parts

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27/06/2012 12:12

DMX dimmer pack

http://www.hoelscher-hi.de/hendrik/english/dimmer.htm

IC1
IC2
IC3
B1
LED1
LED2
R1
R2,3,4
C1,2
C7
C5,6
SW1
Q1
connectors

ATmega8515-16PU
75176B
7805
rectifier (round)
LED 5mm red
LED 5mm green
10k (PT10-S)
390 Ohm
27pF
100nF
100F
DIP-Switch (10)
8MHz (HC49)
pin header (single)

As you can see, the schematic is quite simple: The heart of the controller is the firmware of the mcu
(IC1). The start address is set with SW1. The LEDs indicate the status of the controller. The parts
around IC3 are responsable for an exact Vcc of 5.0Vdc. IC2 is the RS485-Transceiver. It allows our
controller to communicate via DMX512 with other equipment.
For a dimmer- or switchpack you have to connect the pins of "output" with the "-"pins of the
dimmer-/switchmodules because a mcu can drive bigger loads as a current sink. The "+"inputs of
all modules must be connected to vcc.
The "spare" port is used for additional pins or to jumper different modes.
AC1&2 have to be connected with a power supply of 9-12V ac or dc. 3-5W should be sufficient.
The following schematic shows you how to connect the transceiver with the DMX bus:

this is the layout:

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27/06/2012 12:12

DMX dimmer pack

http://www.hoelscher-hi.de/hendrik/english/dimmer.htm

The board is 48 * 76 mm^2. The resolution of the picture above is 300dpi.

placement:

On the resources site you can find a manual for programming AVRs. The 8MHz crystal has to be
selected as clock source by changing the fuse bits.
After setting up the clock source, the dimmer firmware should be written to the AVR's flash.
zc detection
This zero crossing detection is needed for syncing a microcontroller with the mains. The more
precise the circuit works, the better is the resolution of the dimmer pack. Because of this, I tested
lots of such devices...
In my opinion, this simple circuit is one of the best:

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27/06/2012 12:12

DMX dimmer pack

http://www.hoelscher-hi.de/hendrik/english/dimmer.htm

parts:
OK1
D1
R1A
R1B
R3

4N33
1N4007
27k / 1W
27k / 1W
10k

The OK1-LED is powered via R1 in the positive part of the ac cycle. (D1 is for limiting the reverse
voltage in the negative part.) If OK1 is conductive, it pulls ZC to GND otherwise ZC is pulled to VCC
via R3. At the output, there should be a square wave with 50% duty-cycle. The edges indicate a
zero crossing (but only the falling edges are used in the firmware).
The zc detection is part of the new power modules.
And here's the placement :

power units
With this dimmer modul you can dimm inductive loads up to 1kW or resistive loads up to 3kW per
channel. (depends only on the used triacs)
The temperature must be between -20C and +80C.
The schematic is based on application notes of Teccor and was enhanced with information
published by ON-Semiconductor.
schematic:

parts for the dimmer modul:

OK1
T1
R1
R2
R3

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MOC3022
TIC 2XX
390
360
470

27/06/2012 12:12

DMX dimmer pack

http://www.hoelscher-hi.de/hendrik/english/dimmer.htm

R4
R5-S
C1-D
C2
OUT

39 / 0,5W
not used
47nF / 630Vdc (MKS4 / RM7,5)
10nF / 630Vdc (MKS4 / RM7,5)
6.35mm Ribbon con. (Print, vert.)

If the LED of OK1 is turned on, the optotriac discharges instantly C1-D into the gate of the main
triac. A snubber network to limit inductive surges is made of C2 and R4. The optotriac is filtered by
R3 and C1-D. The modul is powered via the common heat sink (similar to the switch). This way we
can handle large currents without heavy wires. Of cause such a heat sink must not be directly
connected to parts you can touch!!
I routed a combi pcb for the power modules of the dimmer and switch packs with 4 channels and an
on-board zero crossing detection. Dimmer and switch modules use different parts.
pcb:

The board is 37mm x 111mm. The picture has a resolution of 300dpi.

placement:

To reduce EMI a toroidal choke (iron powder core) with 1-2mH for each channel is recommended.
temperature monitor
Switching large amounts of current, we have to make sure that the power modules won't get to hot.
This is done with an NTC (6k8 @20C) connected to A-In of the transceiver. For calibration move the
poti R1 to the right stop and set the NTC to the shut down temperature. Now move R1 back until
the red LED goes on and the pack shuts down.
switch mode
To use some channels in switch mode, you have to do the following steps:
1.) shut down the pack
2.) switch on DIP10 and the DIPs of the 'to be switched channels' (1-8).
3.) Start the pack again and wait 2sec.
4.) Choose the start address of the pack (DIP1-9) and switch DIP10 off.

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27/06/2012 12:12

DMX dimmer pack

http://www.hoelscher-hi.de/hendrik/english/dimmer.htm

60Hz mode
If your mains are 60Hz (USA), you have to jumper Spare1 to get the correct firing angles.
Debugging
To make the assembling of the dimmer easier, there is a wiring plan of the whole pack.
The change of a relevant channel is indicated by a flashing green LED. The red one repeats error
codes until the bug is fixed:
Pattern
flashing
double
flashing
fast
flashing
constant

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Error
Solution
There is no signal connected to the
Connect the transceiver to the DMX bus.
transceiver.
The signal is not accepted as DMX.
Swap D+ and D- at the DMX connector.
The transceiver cannot receive all Transmit more channels or choose a lower
required channels.
start address.
The ZC-Detection is not connected to
Connect the ZCD or repair it.
the transceiver.
Wait until the temperature is OK again.
Improve the heat sink.
on The power modules are too hot.
Build the temperature monitor and the A-In
of the transceiver.

27/06/2012 12:12