Recommendations for Resolving Controller Overheating Issues with AlphaPix and HinksPix Controllers

Recommendations for Resolving Controller Overheating Issues with AlphaPix and HinksPix Controllers

ISSUE:  A HinksPix PRO or AlphaPix Evolution controller overheats and results in either shut down or reduced output.

BACKGROUND:  All pixel controllers have power supplies that reduce the power from a higher voltage (usually 120v or 240v) to a lower voltage (usually 5v, 12v or 24v) so that the controller and pixels connected to the controller can operate.  During the process of converting the voltages, heat is generated by the power supplies and the amount of heat generated is a function of how much power is being converted.  So this means that during periods where a show is only outputting single colors or has periods of black output, the heat generation will be low and during periods of extended output or white output, the output will be higher and thus the heat output will be higher.

Heat build up can be dissipated by conductive means without fans in an enclosure in most cases but the amount of heat that can be dissipated will vary based on the internal and external temperature differences.  In some cases, HolidayCoro controllers will have built-in fans and vents to expel that heat.  Generally speaking, HolidayCoro does not recommend fans in controllers where possible, as fans can and do pull in moisture and particulates (dust, pollen, dirt, salt air, etc) that cause damage to the controller and power supplies.  If a controller is operating without shutdown, we do not recommend installing fans.

Multiple safeties within HolidayCoro controllers exist to ensure that the temperature of the controller and housing do not reach combustible temperatures.  Note that some of these safe temperatures may feel hot to a human, such as 120F but are well within the suitable range of operation for the controller and power supply, so it should not be assumed that just because the controller is "hot" from a human scale that this is outside the operating temperature of the hardware.

Listed below are details about how to configure and view temperature related settings in both controller types:
  1. Fans
    1. The HinksPix and AlphaPix both support and can control 3 wire PWM (e.g. computer CPU) fans at 12v.  See our assembly instructions for configuration and wiring.
  2. Meanwell Power Supplies
    1. All HolidayCoro controllers ship using genuine Meanwell power supplies
    2. Power supply fans are normally "off" and triggered to turn on by temperature at 122F and turn off at 104F
    3. The power supply will shut down completely at 158F
  3. Flex Expansion Boards
    1. All SPI boards (16 outputs) have built in temperature sensors
    2. Long range boards do not contain temperature sensors
  4. AlphaPix Evolution
    1. Web Interface
      1. Under the section "Fan Temperature Trigger", if a fan is connected, the trigger temperature can be selected:

        This can range from 80 to 135F
      1. Under the Temperature / Voltage / Output Shutdown, the current temperatures and the temperature at which the outputs will stop outputting data to the pixels (the controller will still remain on) can be viewed and configured:

        The shut down range is from 110 to 165F
    1. Screen Interface
      1. The idle screen will show the current temps on supported expansion boards.  Note that Differential boards and ports that do not have an expansion board will show "NONE":
  1. HinksPix PRO
    1. Web Interface
      1. On the Status Page tab of the web interface, there are a number of temperatures
        1. NTC - This is the temperature of the CPU board itself (shown here as 75F)
        2. SPIx - This the temp of the SPI board(s) (shown here at 71F) - where x is the SPI board port

      2. On the Misc Settings | Fan Control tab, configuration of the fan settings can be made to V2 and V3 controllers

        1. Ranges from OFF to 130F can be configured for the fan trigger
      3. It should be noted that the HinksPix does not shut off output but instead lowers the output % as the temperature rises
RESOLUTIONS:  Assuming a controller is reaching a shutdown temperature, there are a number of suggestions to resolve this issue:
  1. Confirm that the reported temperatures are correct.  Using the information above, see if the temperatures are within a range you would expect.  For example, if the controller is at idle and ambient temperature is 80F but the controller indicates 120F, determine if the SPI or CPU board is reporting the wrong temp due to a defect.
    1. If an incorrect temperature is showing, contact HolidayCoro for technical assistance.
  2. Reduce the output % to a lower amount.  Within your application or on the controller, adjust the output percentage from 100% down to a lower amount as this will reduce the amount of power consumed by the pixels and thus the heat generated by the power supplies.
  3. Adjust the sequence so that the amount of time the controller is outputting all pixels on and white output is reduced.
  4. Adjust the shutdown / trigger temperature to a higher temperature.
  5. Adjust the duty cycle so that props are balanced among different controllers if there are multiple controllers/receivers that are suitable.
  6. Install a forced air fan and vent into the controller if the above solutions do not resolve the issue.
  7. Do not leave doors on a controller open if a controller is located outside and exposed to the elements.