Development and manufacture of controllers, LED modules, interface technology and electronic ballasts for dynamic lighting systems

Toni Maroni GmbH

Haselund (Brooker Strasse 10)New on Amplifa

GmbH, HRB 1421 HU, Flensburg Local CourtLegal form / Register

Custom build from 1 pieceMinimum lot size

IP 65 (potted housing)Protection rating dimmer box

990 V / 80 mA per output (type 80/1)Dimmer box secondary data

-10 to +65 °CAmbient temperature range

About Toni Maroni

Toni Maroni GmbH, based in Haselund (Schleswig-Holstein), develops and manufactures controllers for operating various types of lamps with a focus on additive color mixing. The product portfolio includes controllable LED modules and LED boards, freely programmable controllers (including DIN-rail designs with PWM, 0-10V and DMX outputs), interface technology for converting DMX signals, and electronic ballasts for neon tubes that are fully potted as dimmer boxes with three separately dimmable outputs. Housings are made of rigid PVC and polyurethane potting compounds are used; the cable connections come pre-assembled and are hermetically sealed with potting (protection rating IP 65 on the potted housing). In addition to standard products, the company offers custom builds from 1 piece, including customer-specific LED boards, car alarm control units, motor controllers, signage, info displays and exhibit labeling. Development takes place in-house, complemented by PC software for creating animations and live support via remote maintenance. Customers are found in illuminated advertising, light art, architectural and facade lighting, stage/show technology, and automotive supply.

Site: Haselund
Processes: Development and manufacture of custom LED boards (LED strips, area boards, flexible, Potting of LED boards into plastic housings/profiles (moisture protection for outdoor use), Assembly and manufacture of electronic controllers (freely programmable controllers,, Manufacture of electronic ballasts for neon tubes (three separate outputs, fully, Development and manufacture of interface technology (DMX converters, PWM modules, DMX line, Custom builds: development of customer-specific devices (alarm systems, motor controllers, signage,, Development of custom solutions and bespoke development, Custom build from 1 piece
Materials: Rigid PVC, Polyurethane, PVC (high-voltage cable), Plastic housing, PVC
Certificates: EN 55015 (VDE 0875 2A1), VDE 0100 (installation standard)
Industries: Illuminated advertising, Light art, Stage/show technology, Architectural and facade lighting, Trade fairs/exhibit labeling, Automotive supply (alarm systems)

01
Development (hardware and software, board layout)
02
Prototype production
03
Assembly and manufacture of the electronics
04
Potting into plastic housing/profile
05
Finishing and shipping
06
Live support / remote maintenance

Materials and Processes

PUR

Polyurethane

Potting compound for moisture protection of LED boards and ballast housings for outdoor use.

PVC-hart

Rigid PVC

Housing shells of the electronic ballasts, standard color white.

PVC

Insulation of the high-voltage cables (4.0 mm diameter) at the ballast outputs.

Location

Haselund

Development, production and sales

Lot size: Custom build from 1 piece
Materials: Plastics (rigid PVC, polyurethane, PVC)

Components and Products

**LED-Control Coleen (controller with touchscreen display)**Assembly/Mounting · Illuminated advertising and show technology

**LED board Anja (RGB, potted in plastic housing)**Potting · Illuminated advertising / outdoor area

**Dimmer box 3x80/1 (electronic ballast for neon tubes)**Potting · Neon lighting / illuminated advertising

**Interface DMX (interface technology)**Assembly/Mounting · Show technology

**Custom LED board**Engineering · Light art / exhibit labeling

**Radio receiver module with 0-10V output**Assembly/Mounting · Lighting control

Inside the production

Industries

Illuminated advertisingLight artStage/show technologyArchitectural and facade lightingTrade fairs/exhibit labelingAutomotive supply (alarm systems)Automotive supply (alarm system control unit)

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Development and manufacture of custom LED boards (LED strips, area boards, flexibleEngineering	–	–	–	1 pc.	Plastics
Potting of LED boards into plastic housings/profiles (moisture protection for outdoor use)Plastics	–	–	–	–	Plastics, Polyurethane (potting compound)
Assembly and manufacture of electronic controllers (freely programmable controllers,Assembly	–	–	–	1 pc.	Plastics
Manufacture of electronic ballasts for neon tubes (three separate outputs, fullyAssembly	–	–	–	–	Rigid PVC (housing shell), Polyurethane (potting compound), PVC (high-voltage cable)
Development and manufacture of interface technology (DMX converters, PWM modules, DMX lineAssembly	–	–	–	1 pc.	–
Custom builds: development of customer-specific devices (alarm systems, motor controllers, signage,Engineering	–	–	–	1 pc.	–

Additional services

Development of custom solutions and bespoke developmentCustom build from 1 piecePlanning support from planning to implementationPC software for creating animationsLive support (remote maintenance via TeamViewer)Consulting and individual quotation

Quality

The electronic ballasts are equipped with fuses and optionally with earth-fault and open-circuit protection switches; radio interference suppression is carried out in accordance with VDE 0875 Part 2A1 (EN 55015). Installation is carried out in accordance with VDE 0100, and the control input is galvanically isolated from mains potential.

Evidence	Haselund
EN 55015 (VDE 0875 2A1)
VDE 0100 (installation standard)

History

2000
Introduction of the 8-bit dimmer box protocol (from October 2000) as a replacement for the 6-bit protocol with 64 dimming steps.
2003
Introduction of dimmer box protocol version 2.0 (from July 2003) with improved data security.