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Syncrolite SUPER TROUPER II Instruction Manual

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FOLLOW SPOTLIGHT
INSTRUCTION MANUAL
SUPER TROUPER II
24000-07 (2 kW) • 24000-08 (1, 1.6 kW) • Rev. July 2016
2025 Royal Lane • Dallas, Texas 68154 USA
Tel (214) 350-7696 • www.syncrolite.com

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Summary of Contents for Syncrolite SUPER TROUPER II

  • Page 1 FOLLOW SPOTLIGHT INSTRUCTION MANUAL SUPER TROUPER II 24000-07 (2 kW) • 24000-08 (1, 1.6 kW) • Rev. July 2016 2025 Royal Lane • Dallas, Texas 68154 USA Tel (214) 350-7696 • www.syncrolite.com...
  • Page 3 ONLY THE SPECIAL POWER SUPPLIES manufactured by Syncrolite, LLC can be used with the xenon spotlight. Current level adjustments (DC output to the xenon bulb) are made at the power supply by means of output potentiometers. For detailed information regarding installation and...
  • Page 4 PREFACE (continued) THE LAMPHOUSE is supplied with a 13 foot (4 meter) cable assembly containing the two DC leads, the ground wire, and all AC control leads. The cable assembly is terminated with (2) multiple pin, keyed MS connectors which mate to receptacles on the lamphouse and xenon power supply cabinet. The AC hook-up to the xenon power supply is detailed in the power supply manual; AC connectors must comply with all local electrical codes.
  • Page 5 1. Cover, Lamphouse Compartment 9. Mounting Bracket, Leveling Foot 2. Fade-Out Control Lever 10. “T” Bolt, Folding Leg 3. Masking Blade Control Lever 11 Horizontal Swing Friction Adjust 4. Iris Control Lever 12. Horizontal Tilt Friction Adjust 5. Cover, Optical System 13. Spot Size Control (Trombone) Handle 6. Disc Housing, Color Boomerang 14. Lifting Strap 7. Color Selector Lever, Boomerang 15. Hand Rail 8. Height Adjusting Pin 16. Arc Viewing Port ST2/003...
  • Page 6 LAMPHOUSE - POWER SUPPLY Interconnection Diagram LAMPHOUSE (Connections Pre-wired) MS CONNECTOR Wire No, Grnd SYSTEM MUST BE GROUNDED All wiring must conform to local codes; shield lamphouse cable in conduit if required. Lamphouse Cable Assembly XENON POWER Check Slide Switch (below) on Power SUPPLY Supply for correct “SPOT”...
  • Page 7 ATTACH THE LAMPHOUSE CABLE CONNECTORS to the mating receptacles on the lamphouse and power supply. The lamphouse and power supply connectors are keyed for correct pin align- ment; make certain pins are seated before tightening the locking ring. DO NOT energize the xenon power supply before the xenon bulb is correctly installed into the lamphouse. THE SUPER TROUPER II is wired for operation with the “compact” model xenon power supply Equipment Type 62000xx and the new B3 Syncrolite followspot power supply. If installing the Super Trouper II with an older model or type xenon power supply, a ground wire must be connected to the power supply’s MS connector Pin M. Operation of the Super Trouper II with a xenon power supply other than a 62- or B3 series will void safety listing compliance. ST2/005...

  • Page 8: Safety Procedures

    SAFETY PROCEDURES THE XENON BULB is highly pressurized. When ignited, the normal operating temperature of the bulb increases the pressure to a level at which the bulb may explode if not handled in strict accordance to the manufacturer’s operating instructions. The bulb is stable at room temperature, but may still explode if dropped or otherwise mishandled. REFER ALL BULB REPLACEMENT and service to QUALIFIED PERSONNEL with adequate protective clothing (face shield, clean cotton gloves, welder’s jacket). For routine lamphouse service, observe the following rules: Allow the bulb to cool to room temperature before opening the lamphouse. Put on protective clothing described above. De-energize the xenon power supply at the AC source before opening the lamphouse compartment. When possible, encase the bulb in its protective cover when cleaning or servicing the lamphouse interior. The bulb, when outside the lamphouse, must be encased in the cover. Clean the bulb after it has cooled to room temperature. Do not touch the quartz envelope of the bulb; fingerprints will burn in and create hot spots which may shorten bulb life. If fingermarks are made, they should be carefully removed with methyl alcohol and cotton prior to bulb operation. Never view an ignited bulb directly. BLINDNESS OR PERMANENT EYE DAMAGE MAY BE INCURRED. Use only xenon bulbs designated as OZONE FREE. When possible, vent the lamphouse exhaust to outside atmosphere. Maintain the lamphouse blowers in good operating condition. Keep the blower inlets clean for unrestricted air flow.

  • Page 9: Bulb Installation

    BULB INSTALLATION CAUTION: OBSERVE ALL SAFETY PROCEDURES. Put on protective face mask. Wear clean cotton gloves to prevent marking the quartz envelope of the bulb with fingerprints. Turn the circuit breaker on the side of the xenon power supply cabinet OFF. DISMOUNT THE LAMPHOUSE ACCESS COVER by removing the two phillips head screws and lockwashers; (1) at the rear bulkhead and (1) at the front bulkhead. Open the key lock after first removing the hex head security screw. Do not misplace the security screw. THE SUPER TROUPER II SYSTEM is shipped from the factory with a compatible xenon power supply. The desired bulb wattage and desired input voltage of the spotlight system shipped is specified by the customer when placing the original equipment order. Three wattages are available: 1000, 1600, or 2000 watt. Bulbs approved for use in the Super Trouper II include: Philips. Part No. Ushio OSRAM Nominal DO NOT Wattage Part No. Part No. Current EXCEED XBO1000W/HS OFR LTIX-1000W-HS...

  • Page 10: Xenon Bulb

    XENON BULB INSTALLATION REFLECTOR NEGATIVE CONTACT XENON BULB CLAMP POSITIVE CONTACT HEAT FILTER CLAMP NO ADAPTERS REQUIRED FOR 2000 WATT TYPE “HS” BULB See Parts List, Figure 2 for 2000 watt bulb mounting illustration ST2/008...
  • Page 11 1000, 1600 Watt Bulb Installation ASSEMBLE THE REQUIRED ADAPTERS to the 1000 or 1600 watt bulb as illustrated prior to inserting the bulb into the lamphouse. Be very careful not to apply any mechanical strain to the quartz envelope when installing adapters. Note the (2) different anode adapters; the longer anode adapter (24271000) is for the 1000 watt Hanovia XH1000HS bulb only. SCREW THE CHROMED, THREADED CATHODE ADAPTER (24270000) onto the bulb stud so it seats firmly against the shoulder of the cathode (-) end cap. Slip the correct brass anode adapter with set screw over the stud of the positive end cap in contact with the shoulder of the anode (+) end cap. Tighten all threaded fasteners securely to insure firm mechanical fit and good electrical conduction. LOOSEN THE THUMB SCREWS on the top of the front bulb support yoke and swing the retainer plate clear of the yoke. Slide the contact clamp of the igniter lead over the brass socket of the rear bulb support collet. REMOVE THE PROTECTIVE COVER from the bulb after putting on the face shield. DO NOT touch the clear quartz envelope of the bulb with bare fingers. Natural skin oils will rapidly burn into the quartz and shorten bulb life. The xenon bulb warranty does not cover damage of this nature. If the quartz is accidentally fingermarked, thoroughly remove the fingerprints with isopropyl alcohol before igniting the bulb.
  • Page 12 2000 Watt Bulb Installation (continued) NOTE THE TWO NOTCHES at the center hole of the reflector. These notches allow addi- tional clearance between the grounded reflector and the energized bulb trigger wire. Rotate the bulb to align the trigger wire with one of these two notches to prevent the trigger wire from arcing to the grounded reflector. INSERT THE ANODE (+) PIN of the bulb into the rear support collet. The pin must be inserted as far into the socket as possible to insure good conduction and permit full focus travel of the bulb. Make certain the bulb’s trigger wire is aligned to the center of either reflector notch, and firmly tighten the socket head clamping screw. Slide the negative contact clamp over the cathode (-) pin and dress the negative lead directly in front of the front bulb support to minimize the shadow. Securely tighten the negative clamp. AN ALTERNATE METHOD of installing the 2000 watt bulb is to dismount the shock mount ring and cushion spring from the front bulb support assembly by removing the socket head screw. Slide the ring over the cathode (-) end cap of the bulb, and install the bulb by inserting the anode (+) end cap through the reflector center hole and seating the anode pin into the rear support collet. Re-mount the ring to the base bracket of the front bulb support using the socket head screw. Secure the anode (+) clamping screw; install and tighten the cathode (-) contact clamp. THE SOCKET HEAD SCREW which mounts the bulb support ring to its support bracket must be tightened securely enough to clamp the upright bulb support ring in a vertical (90°) position and prevent its tilting forward or back as the bulb is focused. The end cap of the bulb should touch only the coils of the shock mount spring to allow the bulb to slide forward and back with a minimum of friction and no stress on the envelope. All Bulb Wattages INSERT THE STRIP HEAT FILTER into the bracket in front of the xenon bulb. This filter is a narrow glass strip that covers only the center portion of the beam. One surface of the glass is coated, and marked “XX” and/or imprinted “This Surface Toward Bulb.” The coated glass surface must face the bulb or damaging radiant heat energy will be transmitted to the optical system. DO NOT operate the spotlight with the glass strip heat filter missing or reversed. CHECK THE ARC STABILIZATION MAGNET mounted to an “L” bracket below the reflec- tor. The SOUTH pole of the magnet is marked with paint, and should be pointed toward the off-operator side of the lamphouse (left side, as viewed from rear). If the magnet is reversed, the arc will burn high on the face of the anode electrode, creating severe light flicker and causing ignition problems. This magnet is required for 2000 watt operation, and is in no way detrimental to the operation of 1000 and 1600 watt bulbs. REMOVE THE PLASTIC COVER from the xenon bulb. Do not ignite the lamp with the cover on the bulb. Retain the plastic cover and store in a secure location at or near the spotlight. REPLACE THE LAMPHOUSE COVER. Replace and tighten all (3) phillips head retaining screws and washers. Secure the key lock and install the security screw. The lamphouse cover must be cor- rectly installed and secured to close the cover interlock switches and enable bulb ignition and operation.
  • Page 13 BULB ALIGNMENT & LAMPHOUSE OPERATION PRIOR TO OPERATING THE SPOTLIGHT, verify the following conditions: The protective cover has been removed from the xenon bulb. The strip heat filter is installed with the coated surface facing the bulb. The lamphouse access cover is in place and secured using both Phillips head screws; key lock secured and hex head security screw installed. SEE THE PRECEDING “BULB INSTALLATION” SECTION for instructions detailing the above. Failure to remove the bulb protective cover will damage or destroy the xenon bulb. A missing or reversed heat filter will allow radiant heat damage to the optical mechanism and lens system. The lamphouse cover must be installed correctly and secured to actuate all interlock switches and permit lamp ignition.
  • Page 14 THE TWO LARGE THUMB SCREWS to the left and right of the focusing control secure the horizontal and vertical position of the bulb. These two large thumb screws are spring-loaded to provide a degree of friction against the cast section of the control mechanism. BULB ADJUSTMENT CONTROLS Thumb Screw Focus Control Focus Lock Screw THE FOLLOWING METHOD is recommended to position the xenon bulb inside the reflector in order to project the best light to the stage. SLIDE THE SPOT SIZE CONTROL HANDLE (“trombone”) back to its stop at the the re- armost position to project the smallest spot possible. Place the iris, choppers, and dimming controls in their full open positions. Project the spot to a wall or similar flat perpendicular surface opposite the spotlight. TURN THE CENTER “FOCUS CONTROL” section of the bulb adjustment control, as illustrated above, fully clockwise until a small dark spot is projected on the wall (Spot “A”). At this point, the bulb is defocused at its extreme forward position. Then rotate the focus control counterclockwise until a center “hot” spot is defined (Spot “C”). Spot “A” Spot “B” Spot “C” LOOSEN THE TWO THUMB SCREWS to the left and right of the focus control just enough to permit manual motion of complete control assembly. Move the control assembly around the two thumb screws and observe the movement of the brighter “hot” area within the projected spot.
  • Page 15 AFTER THE “HOT” SPOT is correctly positioned, tighten the two thumb screws to lock this a djustment in place. To verify that the bulb is at the optical centerline, turn the focus control clockwise to again project Spot “A.” The dark spot should remain centered in the spot projection as shown. ROTATE THE BULB FOCUS CONTROL (center section) to obtain the brightest light with even, flat light distribution (Spot “B”). To sharpen the edge of the spot, rotate the spot fine focus control (large knurled knob) located immediately behind the color boomerang. A SECOND METHOD of aligning the xenon bulb is to project the spot to the stage, and using the bulb adjustment controls, obtain a “hot” spot in the projected spot. Center this “hot” spot in the projected spot by moving the entire control section around the two thumb screws. Once the “hot” spot is centered, or slightly above center in the projected spot, lock the adjustment control in position with the two thumb screws and rotate the focus control (center section) to obtain a bright spot with an even distribution of light. To sharpen the edge of the spot, rotate the knurled focus control knob located on either side of the lens mechanism. THIS BULB POSITIONING ADJUSTMENT should not be disturbed until the xenon bulb is either rotated or replaced. At this time it will be necessary to repeat the above bulb alignment procedure. REPLACE THE REAR COVER PLATE over the bulb adjustment control mechanism. Secure in place with the (3) phillips head screws and finish washers. BECAUSE OF MANUFACTURING TOLERANCES and normal bulb aging, it may be neces- sary to operate one lamp at slightly higher or lower current than others to obtain equal light balance between two or more spotlights. These current adjustments are made at the xenon power supply. TO EXTINGUISH THE ARC, place the LAMP switch in the OFF position. The blowers in the lamphouse will continue running until the xenon power supply is de-energized. Allow the blowers to operate and cool the bulb for at least ten minutes after extinguishing. This measure is required to comply with the bulb manufacturer’s warranty conditions. TO PROLONG BULB LIFE, and to encourage rapid bulb starts, it is recommended to douse out using the choppers or the fade-out blades rather than extinguishing the bulb during “dark” periods between cues. Multiple ignition pulses and “warm” re-starts consume more power and cause more bulb electrode wear than sustained operation. While repeated ignitions are frequently unavoidable, and within design parameters, a (20) minute delay between ignitions is desirable. COMPLY WITH THE BULB MANUFACTURER’S INSTRUCTIONS regarding rotation of the xenon bulb at specified intervals. To rotate the bulb, loosen both the positive and negative clamps. Grasp- ing the metal end caps, rotate the bulb 180° and align the trigger wire to the opposite reflector notch. Securely re-tighten both clamps. Adjust the xenon power supply to increase the DC current to a setting at or just below the maximum level specified for the bulb. Project a white spot to check for an even field; correct the bulb positioning as required. Operate the xenon bulb at this higher current level for one or two performances, and then return the power supply setting to its previous level. This temporary operation of the xenon bulb at high current following bulb rotation will restore the cathode tip and enhance ignition at the new arc position. RETURN BULBS upon which a warranty claim is being made to the theatre equipment dealer through whom the unit was purchased. Pack the bulb in its original shipping carton with the pro- tective cover over the bulb. Complete and enclose all warranty forms supplied by the bulb manufacturer.
  • Page 16 HANDLING THE SPOTLIGHT THE SUPER TROUPER II can be operated from either side. Generally, the best position for the operator to stand is near the center of the spotlight, on the right hand side. The angle of tilt and the size or location of the porthole may alter the position for the most convenient operation. Each operator will, after a few minutes of operation, generally develop his or her own system and position for operating the unit. POSITION THE COLOR BOOMERANG with the color arms facing the desired operating side. The boomerang housing can be reversed by removing the three mounting screws, removing and reversing the boomerang, and re-mount using the (3) mounting holes on the opposite side of the housing. It is advisable to check the sequence of color filters and to place the more dense colors (red, green) in the front positions of the boomerang (furthest away from the arc). See the following OPERATION OF THE COLOR BOOMERANG section for detailed instructions. THE HORIZONTAL PAN and vertical tilt tension adjustment levers are located on the yoke a ssembly. Each can be separately set to give the desired degree of friction on spotlight swing, from complete release to total lock-down, to suit the spotlight’s application and the individual operator. THE LENS SYSTEM “ZOOM” BRAKE, which controls the degree of force required to slide the spot size control handle (“trombone”), is located on the outrider of the movable projection lens carriage. Alternately tightening or loosening the nylon brake tension screw will increase or decrease the force required to operate the spot size control handle. Requirements may vary, and the braking can be adjusted to both ac- commodate the angle of tilt and to suit the individual operator. See the following OPERATION OF OPTICAL SYSTEM section for details regarding accessing and setting the friction brake. ST2/014...
  • Page 17 OPERATION OF OPTICAL SYSTEM THE IRIS CONTROL is the front lever which projects through the slots on the top of the optical system housing. When this lever is to the left (as viewed from the rear of the unit), the largest aperture is provided. Smaller apertures are obtained as the lever is moved to the right. THE SPOT SIZE CONTROL HANDLES (“Trombone”) are located on the right and left sides of the optical system just above the base rail. A variation of spot sizes from full flood to small spot can be obtained by moving the spot size control handle from one extreme to the other. Beam intensity is increased by this optical system when reducing from flood to spot, and maximum intensity is reached when the trombone handle is in the extreme rear position. THE MAXIMUM FLOOD SPOT is obtained with the iris control lever to the left (away from the normal operating side) for the largest aperture and with the trombone handle moved as far forward as possible. SMALLER SIZED SPOTS are projected as the trombone handle is pulled back. Most of the spot sizes needed will be produced with the iris in its maximum open position. A “diffused” spot (reduced intensity with a soft edge) is projected by moving the trombone handle forward toward “flood” while closing the iris control. TO ADJUST the degree of force required to slide the spot size control handle, the nylon brake screw in the outrider of the projection lens carriage must be loosened or tightened. The lens mechanism housing (see Figure 3, Item 27) must be dismounted to perform this adjustment. TIGHTEN THE YOKE TILT LOCK and dismount the color boomerang. Remove the (2) spot size control handles and the (2) focus knobs. These items are mounted using socket head screws which can be removed using a 3/16" allen wrench. Unscrew the (3) plastic knobs from the optical system control levers. Remove the (6) phillips head screws retaining the lens mechanism housing. Lift the housing from the spotlight, slightly spreading the bottom of the cover to clear the protruding shafts. THE FRICTION BRAKE is a hex head nylon screw (see Figure 3, Item 4) which bears against the slide rod. Tightening the screw applies tension and loosening the screw relieves tension. A spotlight operated at an extreme down angle will require more brake tension than one operated at a more level angle. Furthermore, the preferred degree of tension may vary between individual operators. Secure the lock nut after setting the desired brake tension; re-install the lens mechanism housing and the color boomerang. THE EDGE OF THE PROJECTED SPOT is focused by rotating the focus control knob. This focus control alters the relative distance between the lenses to adjust the optical system for differing lengths of throw. The degree of torque required to rotate the focus control is adjustable by tightening or loosening the friction screws (Figure 4, Item 17) on the off-operator side of the focus mechanism. When making a focus ad- justment, observe the spot and rotate the focus knob until the sharpest edge on the projected spot is obtained. FOR A “HEAD” SPOT, or any spot smaller than can be obtained with the trombone handle in its extreme rear position, shift the iris control lever to the right (toward operating side) for a smaller aperture. The iris control lever should always be returned to its extreme left (open) position before the spot size control (trombone) handle is again moved forward to obtain larger spots. ST2/015...
  • Page 18 (douse) when the lever is to the left, to full intensity when the lever is to the right. ROTATING THE LARGE KNURLED KNOBS located on the sides of the optical system i mmediately behind the boomerang adjusts the fine focus of the lenses and sharpens the edge of the spot. It may be necessary to re-focus the edge of the spot after zooming from flood to small spot, and from spot to flood. OPERATION OF COLOR BOOMERANG THE COLOR BOOMERANG is equipped with six two-part filter holders (51928000 gel frame with slide channel and 51376000 cover plate). Six sheets of assorted color gels are included in the spotlight accessory kit. Additional colors and filter holders can be supplied by your Syncrolite Dealer. Specify ROSCOLUX ® or equivalent high temperature gels. TO OPERATE INDIVIDUAL COLOR FILTERS, lower the desired filter selector lever. A rocker catch located in the color disc housing holds the filter in position. To release a color, push the filter release arm in or engage another color, thus releasing the previous color automatically. TO REPLACE FILTER HOLDERS, open the front cover of the color disc housing by remov- ing the thumb screw on the top of the housing. The upper portion of the housing is hinged to allow access to the color holders. Slide the filter holders up and off the color arms. Replace gel frames as required and secure...

  • Page 19: Maintenance

    MAINTENANCE THE SUPER TROUPER II SPOTLIGHT SYSTEM requires very little maintenance to keep it in good working order. Routine cleaning is generally sufficient. THE REFLECTOR and the heat filter should be cleaned periodically with a clean, soft, lint free cloth to remove any dust from the coated surfaces. If excessively soiled, use a commercial liquid glass cleaner (i.e. Windex ). Do not use Bon Ami ® ® or other abrasive cleaners. THE XENON BULB should be checked occasionally for presence of any foreign material on the envelope. Any dirt or other foreign material will rapidly burn into the quartz material and possibly shorten bulb life. Use isopropyl alcohol and a clean, lint-free cotton cloth to remove dirt, fingermarks, and other contaminants. CAUTION: Observe all safety procedures when working around the exposed bulb. CHECK ALL ELECTRICAL TERMINATIONS periodically for tightness. Note especially the xenon bulb connections and other leads in the DC circuit. All connections to the MS receptacle on the xenon power supply are accessible below the small panel adjacent to the receptacle. THE INSIDE OF THE LAMPHOUSE COMPARTMENT and the lamphouse cover louvers should be cleaned periodically, depending on the dust conditions at each installation. The blower air inlets in the bottom panel may require cleaning to remove dust build-up which accumulates over a period of time. If dust build-up impedes the blower impellors, or if obstructed air flow allows the squirrelcage blower motor to overheat, a thermal switch in the blower motor will shut down the blower. If the squirrelcage blower shuts down repeatedly, it is necessary to dismount it from the spotlight base rail for a thorough cleaning. Vacuum or blow out the (2) impellors and lubricate the blower motor in the marked oil holes. The six-inch box fan at the rear of the lamphouse requires no lubrication. THE OPTICAL SYSTEM LENSES must be kept clean to prevent any light reduction in the projected spot. To gain access to the lenses, tighten the horizontal pan and vertical tilt locking clamps, and remove the color boomerang and optical system housing. CLEAN THE OPTICAL SYSTEM LENSES using lint-free lens tissues with any cleaner approved for use on coated projection lenses. If the projection lens assembly is removed from its barrel for cleaning, replace the lens with the arrow (engraved on the lens barrel) pointing toward the iris.

  • Page 20: Normal Operation

    TROUBLESHOOTING NORMAL OPERATION WHEN THE SAFETY SWITCH in the main AC supply line to the xenon power supply is in the ON position, and the 30 ampere circuit breaker on the switching power supply is ON, the green VIN (“voltage input”) light on the xenon power supply will glow. The blowers in both the lamphouse and the xenon power supply will start. The PWR and AIR indicator lights on the spotlight lamphouse control panel will glow. OPERATION OF THE LAMPHOUSE BLOWERS will maintain normal temperature in the lamphouse. If the lamphouse top cover is correctly installed and locked, the (4) cover interlock switch closures will complete the control circuit to the LAMP switch, and the lamphouse PANELS light will glow. WHEN THE “LAMP” SWITCH is placed in the ON position, the 115 V.AC control circuit (wires 5 & 6) in the lamphouse will energize the power supply circuitry providing DC current to the igniter and bulb. The green GO indicator light on the xenon power supply will glow, as will the LAMP light on the lamphouse control panel. The power supply will then deliver high open circuit (approximately 180-200 V.DC “no load”) voltage to the lamphouse. This high DC voltage will actuate the DC Pulse Igniter. THERE WILL BE a distinctly audible high voltage arc “ping” at the igniter spark gap and across the bulb electrodes. The bulb should ignite immediately after one or two of these high RF voltage pulses. Once bulb ignition is sustained, the lamp current will adjust to the output setting of the xenon power supply. The DC voltage will fall to the xenon bulb’s sustaining voltage level (30 V.DC or less), and the DC Pulse Igniter will cease generating the RF pulse. MULTIPLE IGNITION PULSES prior to bulb ignition usually indicate a low DC output setting. Adjust lamphouse DC current according to the INSTALLATION - OPERATION section of the Xenon Power Supply manual to the correct level specified by the bulb manufacturer. Operating a xenon bulb below its rated current will not prolong bulb life; sustained operation below rated current will cause ignition problems as the bulb ages. A “warm” or aged xenon bulb might require multiple strikes. A short delay between ignition pulses is normal. The capacitors in the xenon power supply must re-charge between each high voltage “no load” discharge. THE DC PULSE IGNITER will remain out of circuit while the xenon bulb is operating nor- mally. No further ignition pulses will be generated until the xenon power supply again delivers open circuit DC voltage in excess of 140 V.DC. ELAPSED HOURS will begin counting up when the xenon bulb sustains ignition. A faulty hour meter will not prevent bulb ignition. Record the meter reading when first using a new bulb; the hour meter is not resettable, so accurate figures should be used when entering bulb hours to maintain a permanent record of the spotlight system performance. ST2/018...

  • Page 21: Trouble Chart

    TROUBLE CHART IN THE EVENT of an ignition failure, check first the status of the four indicator lights mounted to the lamphouse control panel. INDICATOR LIGHT FUNCTIONS: When lit, AC power is supplied to the lamphouse, and the lamphouse blowers will operate. “PWR” This indicator lights only when the control circuit is complete, meaning all access covers “LAMP” are closed and locked, and the bulb seal blowers are operating and supplying adequate air flow across the xenon bulb. This light also indicates that the xenon power supply is energized and DC current is applied to the xenon bulb. This L.E.D. lights concurrently with the “PWR” indicator. “AIR” “PANELS” The (3) magnetic cover interlock switches, two at the lower lamphouse side cover panels and one at the top cover, plus the pushbutton switch at the door lock, must be closed to actuate this light. The security screw securing the key lock must be installed to insure switch closure. THE “PWR,” “AIR,” and “COVERS” indicators on the control panel must all be lighted to indicate that conditions are correct for ignition of the xenon bulb. The MAIN LINE circuit breaker must be in the ON position. The “LAMP” indicator lights only when the circuit for bulb ignition is complete. BEFORE PRECEDING with the following Trouble Chart, check first that the green VIN indicator light on the xenon power supply is glowing, showing that AC power is present. The PWR and AIR indicators on the lamphouse control panel should also be lighted, showing correct continuity through the lamphouse/power supply interconnect cable.
  • Page 22 TROUBLE CHART (continued) Bulb Fails To Ignite No DC current. Switch xenon power supply breaker ON. DC output level too low. Increase power supply output to rated bulb current. Low DC no load voltage from xenon power supply. Check no load voltage by pressing VOLTS/AMPS switch at igntion cycle. Repair or replace power supply if no load voltage is lower than 140 V.DC. Defective xenon bulb. Check for damaged or scorched electrodes, discolored quartz envelope or end caps. Replace if defective. Loose or faulty terminal connection. Visually inspect connections, particularly in AC circuit (5 & 6) and all DC connections. Ignition pulse arcing to ground. Dress all igniter and bulb leads one-half inch (13mm) or more away from grounded metal lamphouse components. Inadequate AC supply line. Brown-out protection circuit in switching power supply disables operation if line voltage falls below 100 V.AC (120 volt models) or below 195 V.AC (220 volt models). Phase loss (220 volt models) will also disable power supply operation. Check AC voltage at power supply terminals L1 & L3 (see Xenon Power Supply manual, INSTALLATION section). Faulty igniter. Arc at spark gap should be audible, and arc across bulb electrodes should be visible through arc viewing port. Repair or replace as required. Arc gap spacing in igniter is incorrect. If arc is audible inside igniter case but is not seen across bulb electrodes, widen the gap between the two screws. If no arc is audible or observed, shorten the gap. NOTE: Discharge igniter capacitors as directed on preceding page before adjusting. Bulb Fails To Ignite and Power Supply Circuit Breaker Trips Slide switch on power supply (near MS receptacle) in incorrect SPOT/CONS position. Place in SPOT (left) setting. Bulb Goes Out During Operation Blocked bulb seal blower intake or defective blower motor. Clean or replace.
  • Page 23 The switching-type Xenon Power Supply employs solid state circuitry requiring sophisticated diagnostic equipment not generally available to field service personnel. If an operational problem in the TROUBLE CHART section is traced to this unit, contact an authorized Syncrolite dealer for further information. ST2/021...
  • Page 24 Super Trouper II Lamphouse Xenon Bulb Ignition & Monitor Circuit ST2/022...
  • Page 25 AMP/VOLTS S101 POWER INTERLOCK Analog Control Panel Printed Circuit Board Assembly No. 3200866 ST2/023...
  • Page 26 Super Trouper II Control Circuit ST2/024...

  • Page 27: Parts List

    PARTS LIST Wiring Diagrams Ref. Desig. Part No. Description Blower, Dual Squirrelcage; 115 V.AC, 50/60 Hz. B1 23939000 B2 25011000 Blower, 6" Box Fan, Modified; 115 V.AC, 50/60 Hz. RF Suppression Capacitor, 2 x 1.0 µf, 600 WVDC C1 80177000 Fuse, 3 A. Std. (on 3200866 PC Board) F1 2121017 3113231 Connector, (8) Position J1 3113221 Connector, (4) Position J2 3113214 Connector, (3) Position J5 3113011 Connector, (5) Position J10 3140018 Pin Hour Meter, 10-80 V.DC M1 7132005 Ammeter, 1-200 A. 50 mV. M2 8132009 Printed Circuit Board Assembly, Control Panel PCB 3200866 Shunt, 200 Ampere, 50 mV.
  • Page 28 SUPER TROUPER II Parts List FIGURE 1 ST2/026...
  • Page 29 PARTS LIST Figure 1 Item Part No. Description Access Door & Top Cover, Welded Assembly 1 24021000 48930000 Arc Viewing Port 4100501 Screw, 10-32 x 1/2" Phillips Truss Head (3 req’d.) 4107101 Finish Washer, #10 71284000 Cam Lock & Keys 7201309 Security Screw, Hex Head Cover Plate, Bulb Adjust Mechanism 2 24150000 3 4100501 Screw, 10-32 x 1/2" Phillips Truss Head 4107101 Finish Washer, #10 Instrument Panel Assembly, Analog 4 7201289 7201283 Instrument Panel Plate, Formed & Welded (less components) Hour Meter (M1), 10-80 V.DC (incl. with 7201289) 5 7132005 7201308 Spacer Ring, Hour Meter (2 req’d.) Lamphouse Base Panel, Lower Right 6 24029000 4100501 Screw, 10-32 x 1/2" Phillips Truss Head Rocker Switch, “LAMP” (S101 on 3200866)
  • Page 30 ST2/028...
  • Page 31 PARTS LIST Figure 2 Item Part No. Description 1 24317000 Reflector, Dichroic Coated, 10" Diameter 4251250 Screw, 1/4-20 x 1-1/4" Socket Head (4 req’d.) 5158025 Compression Spring (4 req’d.) 4258001 Lock Nut, 1/4-20 Hex (4 req’d.) 2 24073000 Bulkhead, Reflector Support T1050000 Foam Tape, 1/8" x 3/8" Negative Contact Clamp, Bright Chrome 3 39191000 4080870 Clamping Screw, 8-32 x 7/8" Socket Head 24327000 Negative Lead, Clamp to Shunt (see Item 22) 4250373 Screw, 1/4-20 x 3/8" Hex Head Heat Filter Mounting Bracket, Welded Assembly 4 24366000 Bulkhead, Lamphouse Front 5 24072000 T1050000 Foam Tape, 1/8" x 3/8" Heat Filter, Coated Glass 6 65122A00 Lamphouse Nose Cone (Light Shield) 7 24337000...
  • Page 32 FIGURE 2 Parts List (continued) Item Part No. Description Permanent Magnet (Install with painted end toward off-operator side) 19 39215000 65409000 “L” Bracket, Magnet Mount 1110004 Magnet Clamp Bottom Cover, Center (Igniter Access) 20 24364000 DC Pulse Igniter Assembly 21 65503000 24360000 Mounting Bracket, Igniter 24361000 Nylon Insulator, Igniter Post (2 req’d.) Negative Lead, Shunt to Cathode Contact Clamp 22 24327000 23 25011000 Blower (B2), 6" Box Fan, Modified; 115 V.AC, 50/60 Hz. Rear Bottom Cover, Welded Assembly 24 24338000 83131000 Blower Inlet Grille Channel, Base Rail 25 25051000 Cover Interlock Switch (S2; S1 & S3 not shown) 26 2198544 24135000 Switch Mounting Bracket 2198545 Magnetic Switch Actuator (not shown, 3 req’d.)
  • Page 33 FIGURE 3 ST2/031...
  • Page 34 PARTS LIST Figure 3 Item Part No. Description 25221000 Hand Rail, Chromed (4 req’d.) 1 4310752 Screw, 5/16-18 x 3/4" Hex Head 4317000 Lockwasher, 5/16" Split Ring 25051000 Base Channel 2 25081000 Negative Lens Carriage Assembly (incl. Items 4 & 5) 3 25089000 Small Pulley, Focus Control Nylon Screw, Friction Brake; 1/4-20 x 1" Hex Head 4251001 4258015 Locknut, Friction Brake Screw; 1/4-20 Nylon 25063000 Handle, Spot Size Control (2 req’d.) 25053000 Shaft, Spot Size Control Handle 4251002 Handle Mounting Screw, 1/4-20 x 1" Socket Head 23987000 Slide Rod (same as Item 12) 6 2171187 Braided Wire Rope, Focus Control (Order 22 in.) 7 25064000 Knurled Knob, Spot Focus Control 8 25079000 Spot Focus Mechanism (incl. Item 8); See Figure 4 24071000...
  • Page 35 FIGURE 3 Parts List (continued) Item Part No. Description 24095000 Mounting Ring, Negative Lens 26 24161000 Negative Lens, 3.5" Diameter Pyrex (NOTE: Install 24161000 Lens with FLAT Surface facing Front Lens Assembly.) 24094000 Lens Seal, Neoprene 4080502 Screw, 8-32 x 1/2" Socket Head 25090000 Front Lens Assembly (see Figure 4, 25090000 Assembly) 27 4250755 Mounting Screw (Ring Casting to Base Channel), 1/4-20 x 3/4" Lens Mechanism Housing, Right Side 28 7200895 Lens Mechanism Housing, Left Side 28 7200896 4100501 Mounting Screw, 10-32 x 1/2" Phillips Truss Head 4107102 Finish Washer, #10 Black 23059A00 STRONG Insignia 51459000...
  • Page 36 FIGURE 4 25090000 LARGE LENS ASSEMBLY 25079000 FINE FOCUS ASSEMBLY ST2/034...
  • Page 37 PARTS LIST Figure 4 25090000 FRONT LENS ASSEMBLY (ref. Figure 3, Item 26) Item Part No. Description Screw, 8-32 x 3/8" Pan Head (3 req’d.) 1 4080375 Flatwasher, #8 (3 req’d.) 2 4087101 Coated Lens, 8” Diameter, 30" F.L.* 3 25037000 Lens Gasket (2 req’d.) 4 24234000 Casting, Large Lens Ring 5 25087000 Coated Lens, 8” Diameter, 30" F.L.* 6 25037000 Lens Ring (2 req’d.) 7 24233000 Mounting Screw, 1/4-20 x 3/4" Socket Head (2 req’d.) 8 4250755 * Install 8 inch Lenses with FLAT Surfaces facing Lamphouse. 25079000 SPOT FINE FOCUS ASSEMBLY (ref. Figure 3, Item 28) Item Part No. Description Clamp, Focus Cable 9 25067000 4080374 Screw, 8-32 x 3/8" Socket Head...
  • Page 38 ST2/036...
  • Page 39 PARTS LIST Figure 5 Item Part No. Description Knob, Red Plastic 1 10048A00 Shaft, Iris Control Lever 2 48402000 Screw, 6-32 x 5/16" Fillister Head 3 4060310 Lockwasher, #6 Shakeproof 4 4067001 Bell Crank 5 24369000 4151530 Shoulder Screw, Bell Crank Pivot 25017000 Bushing, Shoulder Screw 24371000 Linkage Arm, Bell Crank to Iris Screw, 8-32 x 5/8" Socket Head 6 4080623 Iris Clamp (2 req’d.) 7 25034000 Iris, 101mm (4") Diameter 8 24374000 24372000 Iris Back Plate, Split Ring See Figure 5A for Iris Front View Pivot Stud 9 51226000...
  • Page 40 FIGURE 5 Parts List (continued) Item Part No. Description Lower Fade-Out Blade 32 48878000 Upper Fade-Out Blade 33 48879000 51153000 Spacer Bushing 34 Pull Rod, Upper Fade-Out Blade 35 51515000 Cotter Pin, 1/16" x 1/2" 36 00919000 Bracket, Fade-Out Control Lever 37 51520000 Handle, Fade-Out Control Lever 38 51452000 10048A00 Knob, Red Plastic Hex Nut, 5/16-18 FlexLoc 39 4318004 Flatwasher, 1/4" SAE 40 4257102 Friction Washer, Brass 41 4507106 Chopper Pull Rod, Short 42 51498000 51155000 Handle, Chopper Control Lever 43...
  • Page 41 FIGURE 5A Part No. Description Spring Washer 2170029 24369000 Bell Crank 24372000 Adapter Ring 24374000 Iris 25017000 Bushing (with 41-51350) 25034000 Iris Clamp 48402000 25225000 Base, Aperture Plate 25244000 Aperture Plate Screw, 4-40 x 5/16" 4040310 Screw, 6-32 x 3/8" 406037B Screw, 8-32 x 5/8" 4080621 24369000 Screw, 10-32 x 1/2" 4100500 406037B Shoulder Bolt 4151530 48402000 Iris Control Handle 81432000 Shoulder Screw 24374000 Link 7200075 2170029 4040310 4151530,...
  • Page 42 FIGURE 6 24084000 YOKE & STAND ASSEMBLY ST2/040...
  • Page 43 PARTS LIST Figure 6 Item Part No. Description Tilt Axis Bolt 1 49120000 4378002 Hex Nut, 3/8-16 Lifting Strap (2 req’d.) 2 49943000 Yoke, Welded Assembly 3 83743000 Saddle & Quadrant, Welded Assembly 4 25236000 Cable Clamp 5 83341000 4250623 Mounting Screw, 1/4-20 x 5/8" Hex Head Upper Retaining Collar, Inner Tube 6 65431000 Screw, 1/4-20 x 5/8" Hex Head 7 4250623 4257102 Washer, 1/4" SAE Pan Swivel Stop 8 49291000 Yoke Cover Plate (2 req’d.) 9 83357000 Thrust Bearing 10 83386000 83388000...
  • Page 44 ST2/042...
  • Page 45 PARTS LIST Figure 7 Item Part No. Description Outer Panel, Welded Assembly 1 24141000 Front Panel, Welded Assembly 2 24130000 Rocker Catch Pivot Shaft 3 51526000 Spacer Washer (6 req’d.) 4 51398000 Pivot Shaft, Color Frames 5 51527000 24113000 Mounting Frame, Color Discs 6 Spacer 7 51399000 91199000 Snap Ring, Truarc #5133-31 (2 req’d.) 8 Snap Ring, Truarc #5144-18S (2 req’d.) 9 45209000 Rear Panel, Welded Assembly 10 24131000 Thumb Screw (4 req’d.) 11 31875000 Color Frame & Slide Channel, Welded Assembly (6 req’d.) 12 51928000 51376000*...