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Summary of Contents for SkyTracker STX-1-2000
- Page 1 MOTORIZED SEARCHLIGHTS Models STX-1, STX-4 INSTRUCTION MANUAL Rev. August 2007 4350 McKinley Street • Omaha, Nebraska 68112 USA Tel (402) 453-4444 • Fax (402) 453-7238 • www.skytracker.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ....................1 Model Designation .................1 SAFETY ....................1 OPERATION OF THE SKY-TRACKER ............3 Input Power Requirements ..............3 Startup and Shutdown ................3 3.2.1 Lights “ON” ..................4 3.2.2 Selective Operation ..............5 3.2.3 Motion “ON” .................5 3.2.4 Shutdown ..................5 Hour Meter .....................5 Electrical Protection ................6 Transporting ...................6 BASE ASSEMBLY - ELECTRICAL COMPONENTS ........7... - Page 3 BASE ASSEMBLY - MECHANICAL COMPONENTS (STX-1) .....15 Motion Drive Train ................15 Motion Assembly ..................16 Drive Chain Tension Adjustment ............16 LAMPHEAD ELECTRICAL COMPONENTS ..........16 Igniter System ..................16 6.1.1 Primary Transformer ..............17 6.1.2 R.F. Igniter Transformer ............17 6.1.3 Spark Gap and Related Components ........17 DC Power Cables ................17 Cooling Blowers ...................17 Thermal Switch ..................18...
- Page 4 PATENT POSITION The SkyTracker is a motorized, high-intensity, single or multiple head searchlight system, which was originated by SkyTracker of America, Inc. and is proprietary to Ballantyne of Omaha, Inc. Patents, owned by SkyTracker or Ballantyne of Omaha are either issued or pending in this and related concepts.
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Page 5: Introduction
The concept of achieving maximum safety through knowledge and understanding is basic to SkyTracker equipment. This is applicable to its own personnel, those of the dealer, represen- tative, operator, servicing agency or to any member of the general public who may be exposed to or associated with the operation of a SkyTracker/Strong Entertainment Lighting product. - Page 6 The normal warranty will be voided in instances where it is determined that any component of the SkyTracker has been damaged or has failed due to failure to follow procedures or instructions contained in this manual.
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Page 7: Operation Of The Sky-Tracker
* Recommended wire sizes; conform to local codes STARTUP AND SHUTDOWN The operation of the SkyTracker controls will be explained in this section. The SkyTracker control panel (see Figures 2 & 3) is protected from weather, vandalism, and unauthorized access by means of a locking cover panel (STX-4 models only). The STX-1 control panel is enclosed by a screw cover. -
Page 8: Lights "On
STX-4 – 2000’s), the unit is “powered” and ready to function. STX-1 units do not have pilot lights. NOTE: It is not detrimental to the SkyTracker units to leave the input power connected (with the pilot lights lit) when the unit is not being used, as long as the “Master”... -
Page 9: Selective Operation
STX-1 systems offer speed and direction control on the front panel. If desired, the motion of the SkyTracker may be stopped in any position by turning off the motion switch at the appropriate time. Because of the inertia of the drive mechanism, a small degree of “coasting”... -
Page 10: Electrical Protection
The SkyTracker can also be moved by the use of “optional” casters. It can then be winch- loaded onto a trailer or easily placed or relocated at point of use. -
Page 11: Base Assembly - Electrical Components
jarring, shock or excessive vibration exists, AND IN ALL INSTANCES OF TRANSPORT VIA COMMON CARRIER, the bulbs must be removed from the lampheads. The bulbs should be carefully packed in their original containers and transported vertically. Damage to a xenon bulb during transportation, whether in place in a lamp- head or separately packed, is not covered under warranty, nor is any consequential damage. -
Page 12: Main Wire Harness Assembly
The various input power cord receptacles, switches, circuit breakers, and hour meter are mounted to the panel and all electrical connections are accessible from the rear of the panel. Details of operation are covered in section 3.2. MAIN WIRE HARNESS ASSEMBLY The Wire Harness Assembly provides interconnection between the Control Panel and all electrical components within the base assembly. -
Page 13: Dc Power Supplies
The taps are set at the factory for optimum performance with normal input voltages (see section 3.1). For optimum SkyTracker performance consistent with long bulb life, the input should be measured while the SkyTracker is in operation. If the input voltages vary below or above the levels specified in section 3.1, the taps should be reset. - Page 14 CAUTION If input voltages (measured with the SkyTracker in full operation with all lights and motion on) are found to be BELOW the minimum levels specified in sec- tion 3.1, damage to components may result and in particular the motion motor may burn out. If voltages are found to be below the minimum levels, DO NOT OPERATE THE SKYTRACKER.
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Page 15: Power Diodes
INPUT FROM CONTACTOR VOLTAGE ADJUSTMENT TAPS (Three Phase) FIGURE 6 Changing the letter taps (W, X, Y, Z) has a greater effect on voltage. Also, changing the number taps (1, 2, 3, 4) has a small “fine tuning” effect. The highest setting (Z-4) gives the highest lamp output and the lowest setting (W-1) gives the lowest lamp output. Taps on the (6) terminal boards MUST be changed in unison (i.e. -
Page 16: Timer Pcb Assembly
AC control voltage, igniter operation and fan power. BASE ASSEMBLY, MECHANICAL COMPONENTS – STX-4 (5.1 to 5.5) Components that are required to provide the unique motion of the SkyTracker STX-4 are contained within the base assembly. -
Page 17: Timing Belt Idler
Each spring assembly consists of pairs of springs that counterbalance the lamphouses. The SkyTracker should not be operated with a broken spring for prolonged periods of time, as this will cause extraordinary wear on the drive system that may result in failure. - Page 18 STX-4 MOTION DRIVE SYSTEM FIGURE 7...
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Page 19: Base Assembly - Mechanical Components (Stx-1)
BASE ASSEMBLY – MECHANICAL COMPONENTS - STX-1 (5.6 to 5.9) Components that are required to provide the unique motion of the SkyTracker STX-1 are contained within the base assembly. MOTION DRIVE TRAIN The motion drive train provides mounting for the lamphouse by the motion assembly. The assembly is driven by the reduction gear master by a chain drive (see Figure 7a). -
Page 20: Motion Assembly
MOTION ASSEMBLY The motion assembly provides for both the oscillating motion of the SkyTracker and mount- ing support for the lamphouse. The assembly consists of a “bent shaft”, shaft seal, drive pulley, and lower & upper bearings. Bearings within the assembly are permanently lubri- cated and do not require regular maintenance. -
Page 21: Primary Transformer
6.1.1 PRIMARY TRANSFORMER The Primary Transformer receives an input pulse when either the autostrike assembly or the manual start button is actuated, and raises this voltage to approximately 6,000 V.AC, 50/60 Hz. If replacement is required, it may be easily removed by unplugging the two (2) pin input connector, disconnecting the single output wire from the capacitor and removing the two (2) screws which hold it to the right hand Plenum Support Bracket. -
Page 22: Thermal Switch
THERMAL SWITCH Each lamphead is equipped with a Thermal Switch that will detect “High Temperature” conditions. The switch is located on the upper bulb support spider (see Figure 9, Item 7). When the temperature in a lamphead reaches a level that may be harmful to the system, the Thermal Switch will open –... -
Page 23: Reflector Assembly
The xenon lamphead has been designed and constructed for ease of operation and ser- viceability in extreme weather conditions and operates satisfactorily in rain or snow. In op- eration, the lamphead is slightly pressurized as a result of the cooling air inflow, thus aiding in the exclusion of dust or moisture. The basic components are shown in Figure 9. The two primary components of the lamphead are the deep dish electroformed parabolic reflector and the xenon bulb (light source). To function efficiently, these components must be mounted in such a manner that the bulb can be carefully positioned with its radi-... -
Page 24: Upper Bulb Support Spider And Adjustment Assembly
BULB INSTALLATION Upon original delivery or subsequent common carrier transportation of the SkyTracker, the customer will be required to install the xenon bulb into the lampheads. The procedure is as follows:... - Page 25 BULB INSTALLATION STEPS Place the lamphead in the upright vertical position. Remove the housing and set aside. Remove the two 1/4-20 bolts that secure the power jumper cables to the upper bulb adapter (Figure 9, Item 8). Remove the central bolt., washer, and spring assembly that secures the front bulb adapter to the anode support “spider”...
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Page 26: Final Focus And Beam Alignment
BULB INSTALLATION STEPS (continued) bulb into the lower bulb receiver. Rotate the bulb so that all three leads of the threaded bulb ferrule start. Tighten until the spring pins of the receiver engage the bulb. Apply one-quarter turn to the bulb. Do not overtighten the bulb. - Page 27 LAMP FOCUS PROCEDURE Operate the motion until the lampheads swing outward and shut off the motion with the lampheads extended in the outermost position. This provides easier access to the focus adjustments. The two bulb centering movements (normally described as X and Y adjust- ments, see Figure 9) are located in the sides of the lamphead.
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Page 28: Bulb Removal
BULB REMOVAL DANGER Wear all required protective clothing and follow prescribed steps carefully. If the xenon bulb has been in operation, wait at least 15 minutes after Lamp shutdown (with blowers operating), before opening the lamp- head. This will allow the internal lamp pressure to reduce to a level that is permissible for handling, provided that the specified protective clothing is worn. - Page 29 Clean reflectors and windows. Clean bulb ends. Clean inside contact area of Upper Bulb Adapters, clean contact points on upper bulb support spider. Tighten DC cables. Inspect blower motors for proper air flow; clean impellors. Reinstall bulbs and replace housings. Operate the system – Check automatic ignition, thermal switch operation, motion (timing belt and motor) function and pilot lights.
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Page 30: Troubleshooting Guide
TROUBLESHOOTING GUIDE PROBLEM PROBABLE CAUSE WHAT TO CHECK ONE LAMP Auto Strike is non-operational. Try manual “Ignite” switch. IS OUT Igniter circuit is out. Try manual “Ignite” and listen for arcing sound. Bulb has failed. Inspect bulb for damage. AC Input power is out or AC power Check indicator light on cord is out. - Page 31 PROBLEM PROBABLE CAUSE WHAT TO CHECK LAMPHEADS Timing belt has slipped (continued). COLLIDE Gear belt pulley has slipped. Loosen hub and re-time (continued) bent shafts. Turnbuckles are not evenly adjusted. Loosen #1 and #3 mounts and re-adjust turnbuckles. REPLACEMENT OF STX-4 TIMING BELT (Part No. 3105001; see Parts List Fig. 3, Item 27) Loosen lower bearing housings #1 and #3 (see Parts List Fig.
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Page 32: Wiring Diagrams
WIRING SCHEMATICS XENON POWER SUPPLY Drawing 1 of 5... - Page 33 Jumpers configured for 380/440 V.AC Jumpers configured for 208/230 V.AC CONTROL PANEL Drawing 2 of 5...
- Page 34 LAMPHEAD Drawing 3 of 5...
- Page 35 STX-4 SYSTEM WIRING DIAGRAM Drawing 4 of 5...
- Page 36 STX-1 TIMER PC BOARD (Part No.3200578) Drawing 5 of 5...
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Page 37: Bulb History Record
XENON BULB HISTORY RECORD Strong Entertainment Lighting Date Installed Mfr. & Serial No. Date Removed Elapsed Hours... -
Page 38: Lighting Product Warranty
EQUIPMENT WARRANTY SkyTracker/Strong Entertainment Lighting agrees that its products shall be free from defects in materials and workmanship for a period of one (1) year, from the date of original shipment from its factory. This warranty is nontransferable and applies to the original purchaser only. -
Page 39: Bulb Return Policy
LAMP POLICY To avoid unnecessary down time because of bulb failure, it is suggested that all Sky- Tracker users keep at least one spare bulb, of each type required, on hand. To return a bulb, the owner must first obtain a Returned Materials Authorization Number (RMA) from Strong Entertainment Lighting’s Customer Service Department in Omaha, Nebraska. -
Page 40: Parts Drawings
SkyTracker Lamphead Assembly 23 24 FIGURE 1... - Page 41 PARTS LIST Figure 1 Item Part No. Description 3198097 Cover Lens, Glass 1198062 RTV Silicone Sealant (3 oz. Tube) 3250024 Lamphead Housing, Fiberglass 3118035 Latch (2 req’d.) 3240463 Nut Plate, Latch (not shown) 4 3240462 Catch (mounts to Item 32; 2 req’d.) 3198098 Lower Gasket, Trimlock 4151767 Shoulder Bolt, 5/16 x 3/4"...
- Page 42 PARTS LIST, Figure 1 (continued) Item Part No. Description 3240083 Support Bracket, Left 3240092 Blower Input Cover 3240091 Blower Port Cover (not shown), 2 kW only 3130241 Xenon Bulb, 2 kW 3130242 Xenon Bulb, 4 kW 3250244 Positive Lead - 3198078 Negative Lead (to Power Supply; not shown) 3198075 Snap Ring...
- Page 43 FIGURE 2...
- Page 44 3220088 Thumb Screw 6139001 Name & Data Plate 3240212 End Panel, Welded Assembly 3240263 Side Panel, with Logo (2 req’d.) 3134024 SkyTracker Logo, Self-Adhesive 3240264 Left Side Panel, Motor Housing 3200615 Gear Motor, 90 V.DC 2140249 Brass Breather Cap, Gearbox...
- Page 45 PARTS LIST, Figure 3 (continued) Item Part No. Description 3250023 Expansion Spring Assembly 33a 3198635 Eyebolt & Ball Joint Assembly 3220077 Spring Retainer, Threaded 3220076 Cap, Black Plastic 3250502 Tension Assembly (Items 26,27 & 31-33) STX-1 only 3240220 Stand-Off Bracket 3270137 Timer Control PC Board (replace with 32-00578) 71307000 Blower Grille 71627000 Blower, 220 V.AC, 50/60 Hz.
- Page 46 FIGURE 3...
- Page 47 PARTS LIST Figure 3 Item Part No. Description 3240550 Hinged Access Door 3172002 Toggle Switch 3240545 Instrument Panel Plate (less Components) 3270242 Printed Circuit Board Assembly (208/230 V.AC) 3270322 Printed Circuit Board Assembly (380/440 V.AC) 2121016 Fuse, 1 A. 250 V. (4 req’d.) 3240549 Operator’s Side Panel 85109000 Air Flow Switch 2240854 Switch Mounting Bracket...
- Page 48 PARTS LIST, Figure 3 (continued) 42,43 (ref.) Item Part No. Description 3148001 Retaining Ring 3104005 Ball Bearing 3220098 Upper Bearing Housing* 4253000 Mounting Screw, 1/4-20 x 3" Hex Head 4257000 Split Lockwasher, 1/4" 4257102 Flatwasher, 1/4" 3200422 Bent Shaft, Short (3 req’d) 3200421 Bent Shaft, Long (1 req’d.) - 3136005...
- Page 49 Xenon Power Supply FIGURE 4...
- Page 50 PARTS LIST Figure 4 Item Part No. Description 8240047 Terminal Board Mounting Plate, Phenolic 3121005 Fuse, 20 A. 250 V. (replace with same rated fuse) 3121038 Fuse, 30 A. 250 V. (replace with same rated fuse) 3121054 Fuse Block 3108133 Power Factor Capacitor (3 req’d.) 3110001 Capacitor Clamp (3 req’d.) 3240538 Capacitor Mounting Bracket...
- Page 51 PARTS LIST Figure 5 The 3200301 “Architectural” feature is a factory-installed STX-4 option which permits extinguishing the lampheads and initiating a timed, forced-air lamp cooling cycle from a remote location. The (4) lampheads also “park” in the upright position. The sequence is actuated by closure of a customer-supplied switch connected to J1-3 and J1-4.
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