Related Manuals for Strong 47070-02
Summary of Contents for Strong 47070-02
- Page 1 FOLLOW SPOTLIGHT INSTRUCTION MANUAL XENON GLADIATOR IV Equipment Type 47070-02 • Rev. November 2010 4350 McKinley Street • Omaha, Nebraska 68112 USA Tel (402) 453-4444 • Fax (402) 453-7238 • www.strong-lighting.com...
- Page 2 BULB CURRENT NOMINAL DO NOT WATTAGE RANGE (DC) CURRENT EXCEED 2000 50-90 A. 75 A. 90 A. 2500 70-100 A. 90 A. 100 A. 3000 60-110 A. 100 A. 110 A. 4000 80-150 A. 125 A. 150 A.
- Page 3 PREFACE STRONG INTERNATIONAL’S XENON GLADIATOR IV Model 47070 is a direct current follow spotlight system complete with a lamphouse, xenon power supply, op t ical system, color boomerang, and base stand assembly. The spotlight assembly consists of the arc lamp, variable focus lens system, color boomerang, and base. The separate xenon power supply completes the installation. Only these special power supplies furnished by Strong Entertainment Lighting can be used with the Gladiator IV. For installation and operation of the power supply, see the instruction manual furnished separately. THE XENON LAMPHOUSE utilizes a xenon bulb designed for horizontal operation, and a deep ellipse metal reflector, as a light source. The reflector operates in a fixed position, and is dichroic (“cold”) coated to reduce heat in the projected light. A lens blower and heat filter, mounted in the spotlight optical system, further reduce heat at the projection lens and color media. ONLY XENON BULBS specifically designed for horizontal operation should be used in this follow spot. The Gladiator IV lamphouse is designed to use the LTIX-4500W-HS watt bulb, and replacement bulbs (4000-4500 watt, not exceeding 4500 watts) must be certified as 100% interchangeable with this bulb. Lower wattage (2000-3000 watt Type “HS”) bulbs may be installed in the Gladiator IV using an optional anode support collet and cathode adapter kit supplied by Strong. All required bulb cabling and contact clamps are provided in the xenon lamphouse. ADJUSTMENT CONTROL for the xenon bulb is located at the rear of the lamphouse behind the access cover. The adjustments control the horizontal, vertical and focal movement of the bulb. INSTRUMENTATION of the lamphouse includes a DC ammeter and a running time meter. The ammeter continuously displays the operating current (amperage) applied to the bulb; pressing the VOLTS/ AMPS switch below the ammeter momentarily indicates the DC voltage at the arc. The running time meter records the elapsed hours of the bulb. A second rocker switch controls lamp ON/OFF. TWO LAMPHOUSE COOLING BLOWERS are internally wired and operate on AC voltage derived from the xenon power supply. These blowers are required to maintain a safe operating temperature at the bulb seals. A third blower cools the optical system and the center-mounted color boomerang. These blowers operate continuously until the xenon power supply is de-energized. THE LAMPHOUSE is supplied with a 13 foot (4 meter) cable containing the DC leads, the AC control wires, and the ground wire. The cable terminates in a mul t iple-pin, quick-disconnect plug keyed to mate with the receptacle on the power supply cabinet. WHEN TRANSPORTING THE SPOTLIGHT, it is necessary to remove the xenon bulb and place it in its original shipping container to prevent breakage. See the SAFETY PROCEDURES section fol- lowing, and permit only trained and authorized person n el to handle the xenon bulb. IF AT ANY TIME you have a suggestion, or desire aid in securing an t icipated results, write directly to STRONG ENTERTAINMENT LIGHTING, 4350 McKinley Street, Omaha, Nebraska 68112 USA, or online at www.strong-lighting.com.
- Page 4 XENON GLADIATOR IV Lamphouse Access Cover Fade-Out/Douser Control Lever Masking Shutter (Chopper) Control Lever Iris Control Lever Color Boomerang Control Levers* Lens System Lifting Strap Access Cover Vertical Tilt Control Lever Horizontal Pan Control Lever Height Setting Pin Spot Focus Knob Spot Size Control Handle * Color Boomerang Type 7200264 shown;...
- Page 5 INSTALLATION AND SETTING UP SPOTLIGHT THE XENON GLADIATOR IV is shipped in sections which must be a ssembled. Lifting straps on the yoke assembly permit completely assembling the spotlight on the floor and later hoisting it to an elevated position. ASSEMBLE THE FOUR BASE LEGS to the lower square section of the base column, leg brackets downward, and align the holes. Secure using the (4) T-bolts. Insert a leveling foot with locknuts in each of the four leg brackets and level the base before continuing the installation. WHEN INSTALLED in a permanent location, the casters and leveling feet must be removed, and the clearance holes in the base leg brackets used for hardware (user supplied) to bolt the base to the floor or platform. If it is desired to have the unit portable, when operating, the leveling feet must be adjusted down until the weight of the spotlight has been shifted from the casters to the leveling feet. THE INNER TUBE of the support yoke has three holes to permit adjusting the height of the spotlight. The three holes are on four-inch centers and will al l ow an optical height of approximately 53 inches, 57 inches, and 61 inches above floor level to the optical center of the lamphouse and lens system. Insert the height location pin through the hole in the outer tube and one of the holes in the inner tube. The leveling feet may be adjusted through an additional two-inch range. THE HORIZONTAL SWING and vertical tilt locking knobs are on the right hand (operating) side of the yoke assembly. Level the yoke and tighten both of these locking devices securely before attempting to place the lamphouse and lens system on the support yoke. PLACE THE LAMPHOUSE and lens system on the yoke assembly, with the spot size control handle to the right hand (operating) side, the same as the locking controls on the yoke. Line up four tapped (5/16-18) mounting holes in the bottom of the base rail mounting bracket with mating holes in the yoke saddle and secure using the four 5/16-18 wing screws, lockwashers and flatwashers. Two sets of holes allow setting correct balance for units with or without the front-mounted boomerang; the mounting holes are also slotted to allow fine adjustment for precisely balancing the spotlight. Loosen the tilt lock and test the spotlight balance before permanently tightening the wing screws. ATTACH THE LAMPHOUSE CABLE CONNECTOR to the mating receptacle on the power supply. The lamphouse and power supply connectors are keyed for correct pin alignment; 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. XG4/003...
- Page 6 LAMPHOUSE - POWER SUPPLY Interconnection Diagram LAMPHOUSE (Connections Pre-wired) CONNECTOR Wire No. Grnd Lamphouse Cable Assembly SYSTEM MUST BE GROUNDED All wiring must conform to local codes; shield lamphouse cable in conduit if required. XENON POWER Check Slide Switch (below) on Power SUPPLY Supply for correct “SPOT”...
-
Page 7: Safety Procedures
SAFETY PROCEDURES READ CAREFULLY BEFORE INSTALLING XENON BULB 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 operat i ng instructions. THE BULB is stable at room temperature, but may still explode if dropped or otherwise mis- handled. Breakage resulting from transport and handling is not covered by the bulb manufacturer’s warranty, and it is strongly recommended to dismount the xenon bulb when transporting the spotlight. REFER bulb replacement and service to QUALIFIED PERSONNEL with adequate protec- tive clothing (face shield, clean cotton gloves, welder’s jacket). For routine lamphouse service, observe the following rules: 1. Allow the bulb to cool to room temperature before opening the lamphouse. Put on protective clothing described above. 2. De-energize the xenon power supply at the AC source before opening the lamphouse compartment. 3. 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. - Page 8 10. Dispose of expired bulbs that are beyond warranty in the following manner: Wrap the bulb tightly in several layers of canvas or heavy cloth. Place it on a hard surface and shatter the envelope with a sharp hammer blow. DO NOT place an unshattered bulb in an ordinary refuse container. 11. DO NOT PERMIT UNAUTHORIZED PERSONNEL TO PERFORM OR ATTEMPT ANY PHASE OF XENON BULB HANDLING OR SERVICE. Cathode End Cap Anode End Cap Envelope Seal Anode Pin Cathode Seal Cathode Pin Anode PRIOR TO INSTALLING BULB, PLEASE NOTE: For use in a Gladiator IV lamphouse, it is necessary to remove the anode lead (if attached) from the anode end cap of the xenon bulb.
-
Page 9: Bulb Installation
BULB INSTALLATION OBSERVE ALL SAFETY PROCEDURES when working around the xenon bulb. Open the lamphouse access cover by releasing the clasps and swinging the cover up to its stop. Loosen the (5) captive fasteners and remove the two bulb compartment side covers. Verify that the lamphouse is fitted with the cor- rect support collet appropriate to the desired bulb wattage. The bulb leads and contact clamps are tied down for shipping. Free the clamps and slide the anode clamp over the brass socket of the rear support collet. REMOVE THE PLASTIC PROTECTIVE COVER from the xenon bulb only if necessary. Handle the bulb by the metal end caps only. Dismount the anode lead from the (+) end cap of the bulb if attached. Grasp the bulb by the metal anode (+) end cap only when unscrewing the lead from the bulb; DO NOT hold the bulb at the cathode (-) end cap when removing the anode lead. INSERT THE BULB into the lamphouse, passing the anode (+) end cap through the center hole of the reflector. Take care not to bump or scratch the surface of the reflector. Insert the anode (+) pin into the rear support collet and contact clamp. Rest the cathode (-) end cap in the front bulb support yoke. Seat the anode (+) pin into the rear support collet as far as possible for correct focus travel. Securely tighten the socket head clamping screw in the anode contact. Rear Support Collet Cathode Contact Clamp Bulb Socket Anode Contact Clamp Cathode Adapter (as req’d.)* Cathode Anode Clamping Screw to Igniter Post to Negative Binding Post Front Bulb Support Yoke * Cathode Adapter &... - Page 10 ESTABLISH A ROUTINE of periodically checking all electrical connec t ions for tightness. Loose contacts, particularly in the DC circuit, will cause overheating and damage the xenon bulb and other components. Normal xenon bulb warranties allow no credit for bulb damage caused by overheating. REFER TO THE BULB MANUFACTURER’S INSTRUCTIONS regarding bulb rotation. Most bulb manufacturers recommend rotating the bulb 180° at 50% of warranty hours. After rotating the bulb, operate at maximum allowable current for several hours, and then return to the nominal operating current. IN THE EVENT of a bulb warranty claim, the bulb must be packaged in its original shipping container, and returned with all required warranty forms completed. Contact the dealer through whom the bulb was originally purchased for correct procedures and Return Authorizations. IT IS A COMMON PRACTICE to replace the bulb at the expiration of its warranty period. If a xenon bulb explodes in operation, the reflector and other lamphouse components are frequently damaged. The xenon bulb manufacturer will extend no credit for a replacement reflector if the defective bulb is beyond warranty. Explosion-damaged reflectors are to be returned to the bulb supplier, NOT Strong Entertainment Lighting, unless the bulb was supplied by Strong. ARC STABILIZATION MAGNET THE XENON BULB used in the Gladiator IV lamphouse requires use of an arc stabilization magnet. This magnet is located below and behind the reflector. The magnet is preset at the factory and should not require adjustment. Should it become necessary to adjust the magnet, the following procedure must be followed. Observe all bulb safety procedures when working in the lamphouse compartment. A NORMAL ARC should appear as shown in Figure “A,” and represents the correct magnet position. Figure “B” shows the position of the arc when the magnet is too low; Figure “C” shows the position of the arc when the magnet is too high. Condition “B” or “C” will cause arc flicker. If flicker is apparent in the projected spot, raise or lower the magnet on its slots as required to position the arc as illustrated in Figure “A.” THE MAGNET must always be installed with the longest portion of the magnet uppermost (nearest the bulb), and with the NORTH (N) pole pointing toward the operator side access door. Reversing the magnet will cause bulb flicker, and may inhibit bulb ignition. In new equipment, the magnet is normally in the center of the adjustment range. Changes in the magnet position are required only to correct an improperly burning arc (Figure “B” or “C”). ANY REPLACEMENT MAGNET should first be installed in the center position of the adjustment range. Raise or lower the magnet as required to center the arc as illustrated in Figure “A.” XG4/008...
-
Page 11: Operation
OPERATION OPEN THE BOOMERANG ACCESS COVER and verify that the round glass heat filter and ring assembly (Figure 5, Item 17) is installed into the bracket mounted to the fadeout and douser support housing. NOTE: The followspot should never be operated with this heat filter removed. REMOVE THE PLASTIC COVER from the xenon bulb. DO NOT ignite the lamp with the cover on the bulb. Store the cover for future re-use. Replace and secure the inner bulb enclosure covers. CLOSE THE LAMPHOUSE COVER and secure using both latches. Turn on the main line switch and/or circuit breaker to energize the xenon power supply. The spotlight blowers will start and operate continuously until the xenon power supply is de-energized. PLACE THE LAMP SWITCH in the “ON” position and the lamp will i gnite. Check the reading on the lamphouse ammeter. Nominal current for the 4000/4500 watt xenon bulb is 135 amperes. If using a lower wattage bulb, check the documentation packaged with the bulb for its current ratings. DO NOT, AT ANY TIME, exceed maximum rated amperage. Output current is adjusted at the xenon power supply; see power supply manual for instructions. Operation of a new bulb is normally started at the lower end of its range, and current is gradually increased as the bulb ages to maintain light output. During the ignition cycle, pressing the VOLTS/AMPS switch will briefly indicate the high “no load” (open circuit) DC voltage applied to the xenon bulb for ignition. OPEN THE REAR COVER above the instrument panel by loosening the (2) thumbscrews. This exposes the bulb positioning controls in the lamphouse back casting. To focus the xenon bulb and obtain the best light on the stage, the two methods outlined below are the most suitable. MOVE THE SPOT SIZE CONTROL HANDLE (trombone) on the large lens carriage all the way forward to project the smallest spot possible; place the iris, masking shutters (choppers) and the fadeout douser blades in their full open positions. Project a spot to a wall or similar flat perpendicular surface opposite the spot l ight position. THE CENTER SECTION of the bulb positioning controls is a threaded member that focuses the bulb in relation to the reflector. Turning this adjustment moves the bulb in only one plane,... - Page 12 TURN THE CENTER FOCUSING SECTION of the bulb positioning control counterclock- wise until a small black spot is projected onto the wall. It may be best to run this adjustment both directions to permit positive identification of the spot. LOOSEN THE TWO THUMB SCREWS, one on either side of the center focusing section, just enough to permit manual movement of the complete assembly. The bulb positioning control will now move around these two thumb screws, and as this control is shifted, the smooth shadow of the bulb electrode can be seen ex t ending beyond the projected center hole in the reflector. The shadow of the electrode (black spot) must be centered in the projected hole of the reflector (shaded, less dense dark area). MOVE THE CONTROL SECTION around the two screws until the black spot is as round as possible to project. It may be necessary to again turn the focus control to project a sharply defined black spot. AFTER THE BLACK SPOT is as even around the outside as possible to project, and appears centered in the shaded reflector center hole (Spot “A”), tighten the two large thumb screws to lock the position of the mechanism. Turn the center focus control to obtain the brightest light with the best light distribution (Spot “B”) and continue to the defocused position (Spot “C”) to verify that the bulb is centered in the reflector. IF THE CENTER BRIGHT SPOT tracks off to the left, right, top, or bottom, it may be neces- sary to reposition the front bulb support yoke to compensate. Loosen the set screw in the support casting and reset the yoke as required. The hex nut may be used to lock the height of the yoke. Secure the yoke with the set screw after the bulb tracks on a straight axis. Return the focus control to the desired Spot “B,” and rotate the spot focus control knob, located at the extreme front of the lens mechanism, to obtain the sharpest edge possible on the projected spot. THE SECOND METHOD of focusing the xenon bulb is to project the spot to the stage, and working with the above lamphouse controls, adjust these controls to obtain a “hot spot” on the projected spot. Center this “hot spot” on the projected light by moving the entire control section around the two thumb screws. Once this “hot spot” is centered in the projected light, lock the control in position with the two thumb screws and turn the center section to obtain a spot with an even distribution of light. Rotate the lens spot focus control knob to obtain a sharp edge on the projected spot. THESE ADJUSTMENTS should not be disturbed until after replacing or rotating the xenon bulb. At that time, the procedure on obtaining a smooth, round black spot, or “hot spot,” may have to be re- peated. Replace the cover plate over the bulb positioning controls and tighten the (2) thumbscrews. BECAUSE OF NORMAL BULB AGING, and manufacturing tolerances b etween individual xenon bulbs, it may be necessary to operate different lamps at slightly higher or lower current settings to achieve balanced, uniform light output when two or more spotlights are used in one installation. This entails a slight current output adjustment at the xenon power supplies. See the power supply manual. XG4/010...
- Page 13 TO EXTINGUISH the arc, place the LAMP switch on the instrument panel to “OFF.” The lamphouse blowers will continue to operate until the xenon power supply is de-energized. Allow the blowers to operate for ten minutes before turning off the power supply; a forced-air bulb cooling cycle at shutdown is required by all bulb manufacturers to comply with their warranty terms. BEFORE OPENING the lamphouse enclosure for servicing, allow the blowers to operate for twenty minutes, or until the bulb has cooled to room temperature. HANDLING THE SPOTLIGHT GENERALLY THE BEST POSITION for the operator to stand is near the center of the spot- light on the right side. The angle of tilt, the size of the porthole, and the layout of the spotlight position may dictate another location. EACH OPERATOR will, after a few minutes of operation, generally develop his own system and position for most convenient operation. THE HORIZONTAL SWING and vertical tilt are individually adjustable to give the desired degree of friction to suit the operator. The locking clamps are located on the right side of the yoke assembly. AN EXPERIENCED OPERATOR will usually keep one hand on the spot size control handle. This allows both directing the spot and changing spot sizes immediately upon cue. Compressing the brake lever permits free movement of the large lens forward and back, and releasing the lever locks the spot size at the desired point of travel. Large Lens Spot Size Control Handle Brake Lever XG4/011...
- Page 14 OPERATION OF OPTICAL SYSTEM THE IRIS CONTROL is the front lever that projects through 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 left. THE MAXIMUM FLOOD SPOT is obtained with the iris control lever to the right (near the op- erating side) for the largest aperture and with the spot size con t rol handle moved as far to the rear as possible. SMALLER SIZED SPOTS are projected as the spot size control handle is moved forward. Most of the spot sizes needed will be produced with the iris in its maximum open position. FOR A “HEAD SPOT,” or any spot smaller than can be obtained with the spot size control handle in its extreme forward position, shift the iris control lever to the left (away from operating side) for a smaller aperture. The iris control lever should always be returned to its extreme right position before the spot size control handle is again moved to obtain larger spots. THE MASKING SHUTTER (chopper) lever is the middle lever projecting through the top of the optical system housing. The masking shutter blades are operated by this lever to shape the projected spot to a rectangle, strip spot, or dousing. THE DISENGAGED POSITION of the masking shutter lever is to the ex t reme right (toward operating side) and varying degrees of masking to complete cutoff are obtained by moving the lever to the left (away from operating side). If dousing the spot for a prolonged period with the bulb operating, it is highly recommended to use the Fadeout dousers (below) to prevent heat damage to the masking shutter blades. THE ANGLE of the masking shutter blades can be adjusted to compensate for the horizontal projection angle. Remove the color arm cover plate and dismount the boomerang. Loosen the (4) screws holding each of the masking shutter blades enough to allow adjustments. Ignite the bulb and adjust the angle of the bottom blade by tapping with a screwdriver so its projected edge lies parallel to the footlights. Tighten the screw. Operate the masking shutter lever to close the blades. Adjust the upper blade to close in line with the bottom blade and tighten the screw. THE FADEOUT MECHANISM AND DOUSER CONTROL is the rear lever projecting through the top of the optical system cover. This lever controls the in t ensity of light from complete fadeout when the lever is to the left, to full inten s ity when the lever is to the right.
- Page 15 OPERATION OF COLOR BOOMERANG THE COLOR BOOMERANG supplied with the Gladiator IV is selected when first ordering the spotlight from the factory. The Type 7200264 boomerang is mounted within the optical system and uses (6) 50mm dichroic discs as the color media. Type 7200709 mounts to the front of the lens barrel and uses conventional high-temperature color gels (i.e. Roscolux ) as color media. ® EACH BOOMERANG is equipped with six color arms. A “starter” set of six 50mm dichroic color discs is included with the 7200264 unit. Additional colors, including color temperature reduction filters, are available from most theatrical supply dealers. COLOR FILTERS are controlled by the six color levers of the boomerang. To engage an individual color filter, lower the desired filter selector lever. A rocker catch located in the color disc housing holds the filter in the light beam. To release a color, lower the filter release lever or engage another color, thus releasing the previous color automatically. TO REPLACE A COLOR FILTER in the 7200264 boomerang (see Parts List, Figure 6A), it is recommended to dismount the entire assembly from the optical system and place it on a convenient working surface. Loosen the (2) quarter-turn fasteners and remove the side cover plate. The entire boomerang assembly can then be easily removed by loosening the single captive screw securing the boomerang bracket to the base rail, and lifting the bracket off the (2) locating pins. When re-installing the boomerang, align the holes in the boomerang base plate onto these pins before again securing the captive screw. TO ATTACH A COLOR GEL to the color frame of the front-mounted 7200709 boomerang (see Parts List, Figure 6B), detach the color frame from the selector arm by loosening the set screw on the slide channel and lifting the frame off the arm. Spray the flat surface of the ring (without the channel clip) with an aerosol adhesive. Center the ring over a precut 13½ by 13½ inch (34 x 34cm) gel, and press the adhesive- coated side onto the gel. Allow a few minutes for the adhesive to dry and trim the excess gel material. Install the ring onto the boomerang color arm and tighten the set screw. Old gels can be removed from the color frame by scraping the gel and dried adhesive from the frame using a single-edge razor blade. NOTE: WHEN INSTALLING COLOR FILTERS in either boomerang, the less dense colors (pink, amber) should be placed in the holders toward the rear of the boomerang (close to the arc), and those of greater density (red, green) should be placed in the holders toward the front of the boomerang (away from the arc). This measure will prolong the useful life of the filters. XG4/013...
-
Page 16: Maintenance
MAINTENANCE CAUTION: DISCONNECT AC POWER BEFORE SERVICING THE XENON GLADIATOR IV SPOTLIGHT requires very little maintenance to keep it in good working order. THE REFLECTOR should be cleaned periodically with a soft, clean, lint-free cloth to remove dust from the reflecting surface. If excessively soiled, the reflector may be cleaned with Windex or ® an equivalent glass cleaner. DO NOT use abrasive cleaners of any kind. Remove the heat filter ring and clean both surfaces of the filter glass with a lens cleaning solution formulated for coated lenses. CHECK ALL ELECTRICAL CONNECTIONS for tightness on a regular basis. Loose connections, particularly in the DC circuit, may overheat and cause premature bulb failure and/or damage other lamphouse components. LUBRICATE the (3) squirrelcage blower motors with two or three drops of non-detergent oil once every six months. The oil holes are located on the tops of the motors and are accessed by removing the motor covers from the off-operator side. An injection oiler is required to reach the inner oil holes. - Page 17 LAMPHOUSE WIRING DIAGRAM Barrier Strip 2162012 (see Figure 3, Item 43) XG4/015...
-
Page 18: Wiring Diagram Parts List
WIRING DIAGRAM PARTS LIST Part No. Description 7200280 Blower (B1,B2,B3), 230 V.AC, 50/60 Hz. 3113289 Molex Plug, (3) Pin 7200255 Capacitor (C1), RF Suppression 81247000 Shunt (R1), 200 A. 50 mV. 7201313 Cable Assembly, Shunt to Control Panel J2 3201311 Printed Circuit Board Assembly, Analog Control Panel 2121017 Fuse, 3 A. Std. (F1 on 3201311) 24086000 Rocker Switch, VOLTS/AMPS (S102 on 3201311) 8161028 Rocker Switch, LAMP (S101 on 3201311) 8132009 Ammeter (M2), 0-200 A. 50 mV. 7201317 Cable Assembly, Ammeter to Control Panel J4 7132005 Hour Meter (M1), 10-80 V.DC 7201294 Cable Assembly, Hour Meter to Control Panel J6 7200253 Stepdown Transformer (X1) 7200252 Terminal Board & Molex Connector, Wired Assembly 2162012 Barrier Strip, (10) Terminal 2140014 Molex Receptacle, (12) Pin 39862000 Igniter Assembly 25476000 Igniter Printed Circuit Board Assembly 39875000 Igniter Case & Coil, Potted Assembly... - Page 19 WIRING DIAGRAM, 3201311 PRINTED CIRCUIT BOARD XG4/017...
-
Page 20: Trouble Chart
TROUBLE CHART NORMAL OPERATION WHEN THE SWITCH in the main AC supply line to the xenon power supply is in the ON position, and the 30 A. circuit breaker on the switching power supply is ON, the VIN light on the xenon power supply, and the lamphouse instrument panel POWER and AIR lights will glow. The cooling blowers in the lamphouse and in the power supply will operate. When all lamphouse covers are secured,the magnetic interlock switches will close and the PANELS light on the control panel will glow. WHEN THE CONTROL PANEL LAMP SWITCH is placed in the ON position, the AC c ontrol circuit in the lamphouse will energize the xenon power supply circuitry providing DC current to the igniter and bulb. The green “GO” light on the xenon power supply and the LAMP light on the lamphouse control panel indicate a completed circuit. THERE WILL BE a distinctly audible high voltage arc ping at the i gniter arc gap and across the bulb electrodes. The bulb should ignite immediately after one or two of these high voltage pulses, and the lamp current will adjust to the output setting of the xenon power supply. Multiple ignition pulses prior to bulb ignition normally indicate a low DC output setting. Increase output to the bulb’s initial (“nominal”) current setting; see xenon power supply manual. A “warm” or aged xenon bulb might also require multiple strikes. TROUBLE SHOOTING IF THE XENON BULB does not ignite, observe the following operational sequences for assistance in locating and isolating the trouble area. WHEN THE FANS and the VIN indicator light on the power supply are on, the circuit in the power supply is trouble-free up to the terminal block in the power supply. At this time, the spotlight blowers should operate. If this does not occur, the trouble is in one of the blower motors, a loose connection, or a broken #7 or #8 lead (220 V.AC). Check at this time for 220 V.AC blower voltage at wires 7 & 8, and 220 V.AC at the lamphouse quick-disconnect pins I & J. CAUTION: exercise extreme caution when taking voltage measurements in a power “on” condition. - Page 21 IF THE HIGH VOLTAGE ARC is audible at the lamphouse, the flash of the bulb is apparent, but ignition of the bulb is not sustained, the problem area is in the power supply. See the trouble shooting section of the power supply manual for additional instructions. IF THE HIGH VOLTAGE ARC is not audible or the flash of the bulb visible, the problem is in the igniter assembly. EXCHANGE of components (i.e. known-good igniters, printed circuit boards) between similar Strong Gladiators IV units to aid in diagnosis of a problem is encouraged. This will not lead to equipment damage, and will not void equipment warranty. GLADIATOR IV TROUBLESHOOTING EXERCISE ALL DUE CAUTION WHEN MEASURING VOLTAGES IN A “POWER ON” CONDITION Bulb fails to ignite. 1. AC power not on to lamphouse. Turn switching power supply 30 A. circuit breaker ON. If 230 V.AC not read at 1 & 2, or POWER indicator not glowing, see power supply manual. 2. Faulty “ON-OFF” switch. Check for voltage at terminal block positions 9 & 10; check for loose terminals or wiring. Replace if defective. 3. Low AC source voltage actuating “brownout” protection circuit in xenon power supply. Bulb fails to ignite, power supply circuit breaker trips.
- Page 22 Current display not operating. 1. Check for loose connection on plug J4 on control panel PC board. 2. Defective M2 ammeter. Replace as required. Elapsed bulb hours not recording. 1. Check for loose connection on plug J6 on control panel PC board. 2. Defective M1 hour meter. Replace as required. Bulb goes out during operation. 1. Xenon power supply overheated; thermal switch open. Check power supply blower(s), air inlets and outlets unobstructed. See power supply manual. 2. Lamphouse cover loose or open. Close and secure. 3. Xenon bulb depressurizing. Check for envelope discoloration; replace if defective. 4. Fluctuating AC source voltage actuating brownout or surge protection circuits in xenon power supply. See power supply manual. Noise in theatre sound as bulb ignites. 1. Faulty RF suppression capacitor(s). Remove and test C1. Replace if defective.
- Page 23 FIGURE 1 XG4/021...
-
Page 24: Parts List
PARTS LIST Figure 1 Item Part No. Description 1 7200164 Lamphouse Top Cover & Access Panel - 7200163 Side Cover, Off-Operator Side (not shown) 2 7200247 Cover Plate, Optical System Controls (as shown) 2 7201000 Cover Plate, Optical System Controls (no color arm slots) - 7151008 Captive Fastener (as req’d.) 3 10048A00 Knob 4 7200207 Lens System Cover, Off-Operator Side 5 7200175 Front Cover, Lens System 6 25064000 Lens Focus Knob 7 25221000 Hand Rail - 4310751 Mounting Screw, 5/16-18 x 3/4" - 4317000 Lockwasher, 5/16"... - Page 25 FIGURE 2 XG4/023...
- Page 26 PARTS LIST Figure 2 Item Part No. Description 1 7200160 Bulb Enclosure Top Cover, Rear 2 7200159 Bulb Enclosure Brace - 00M15315 Arc Stabilization Magnet (not shown) - 81137000 Magnet Clamp - 4080259 Set Screw, 8-32 x 1/4" 3 7200166 Bulb Enclosure Top Cover, Front 4 7200173 Mounting Bracket, Fade Out Assembly 5 7200258 Light Shield (see Figure 3, Item 14) 6 7201328 Access Panel Assembly, Front 7 7200165 Bulb Enclosure Lower Cover, Left & Right (2 req’d.) 8 7201327 Access Panel Assembly, Rear 9 7151008 Captive Fastener (incl. with Items 6 & 8) BULB MOUNTING COMPONENTS...
- Page 27 FIGURE 3 XG4/025...
- Page 28 PARTS LIST Figure 3 Item Part No. Description 1 7200658 Access Cover Plate - 4100504 Mounting Screw, 10-32 x 1/2" - 31875000 Thumbscrew, 10-32 2 7200158 Lamphouse Back Cover 3 7200155 Rear Lamphouse Bulkhead Plate - 4250752 Mounting Screw, 1/4-20 x 3/4" - 4257000 Lockwasher, 1/4" 4 2161006 Interlock Switch & Lead Assembly - 4040500 Mounting Screw, 4-40 x 1/2" 5 2198544 Magnet, Switch Actuator (mounts to Figure 1, Item 1) 6 7200159 Bulb Enclosure Brace (see Figure 2, Item 2) - 00M15315 Arc Stabilization Magnet (not shown) -...
- Page 29 PARTS LIST, Figure 3 (continued) Item Part No. Description 19 51914000 Large Lens Ring - 4110371 Mounting Screw, 10-24 x 3/8" Fillister Head (6 req’d.) - 51408000 Large Lens 19a 7200649 Brake Lever - 51417000 Lens Retainer - 7158005 Expansion Spring - 51350000 Large Lens Carriage 19b 7200648 Lever Bracket - 7200641 Large Pulley - 4040500 Screw, 4-40 x 1/2" - 51160000 Pulley Axle, Shoulder Bolt 20 7200202 Slide Rod (2 req’d.) - 51114000...
- Page 30 PARTS LIST, Figure 3 (continued) Item Part No. Description 40 7200165 Bulb Enclosure Panel, Lower (2 req’d.) 41 81247000 Shunt (R1), 200 A. 50 mV. - 4080754 Mounting Screw, 8-32 x 3/4" Pan Head - 7201313 Cable Assembly, Shunt to Control Panel 42 7200209 Mounting Bracket, Terminal Board - 4080250 Mounting Screw, 8-32 x 1/4" Pan Head 43 7200252 Terminal Board & Molex, Wired Assembly - 2162012 Barrier Strip, (10) Terminal (incl. with 7200252) - 4080506 Mounting Screw, 8-32 x 1/2" Pan Head 44 7201315 Control Panel Assembly (see Figure 4) 45 7200213 Spacer, Hand Rail (2 req’d.) - 4311750 Mounting Screw, 5/16-18 x 1-3/4"...
- Page 31 FIGURE 4 7201315 Control Panel Assembly Item Part No. Description 1 7201282 Panel, less Components - 4100501 Mounting Screw, 10-32 x 1/2" 2 7198017 Standoff, 4-40 x 5/8" (4 req’d.) 3 3201311 Printed Circuit Board Assembly 4 4048005 Hexnut, 4-40 Nylon (4 req’d.) 5 8130030 Lens, Green Plastic (4 req’d.) 6 4040251 Screw, 4-40 x 1/4" Button Head (4 req’d.) 7 5161015 Switch Bezel (2 req’d.) 8 8132009 Ammeter (M2), 0-200 A. 50 mV. - 7201317 Plug & Wire Assembly, Ammeter 9 7132005 Hour Meter (M1), 10-80 V.DC -...
- Page 32 FIGURE 5 XG4/030...
- Page 33 PARTS LIST Figure 5 Item Part No. Description 1 7200212 Fade Out Housing, Welded Assembly 2 7200262 Bell Crank, Fade Out Dousers 3 51155000 Control Lever, Fade Out - 4257102 Flatwasher, 1/4" SAE - 4258001 Hexnut, 1/4-20 4 7200268 Lower Douser Blade Assembly 5 7200265 Upper Douser Blade Assembly 6 7200272 Heat Shield, Upper Blade 7 7200271 Heat Shield, Lower Blade 8 83351000 Pivot Adjusting Plate, Douser Blades - 4100503 Mounting Screw, 10-32 x 1/2" 9 24332000 Cover Shield, Heat Filter 10...
- Page 34 FIGURE 6A XG4/032...
- Page 35 PARTS LIST Figure 6A Item Part No. Description 1 7200196 Bottom Plate 2 7200195 Side Plate (2 req’d.) 3 7200186 Pivot Rod 4 7200176 Bronze Bearing (7 req’d.) 5 7200181 Color Holder (6 req’d.) 6 51396000 Color Holder Catch Hook (6 req’d.) 7 7200260 Retainer Clip (18 req’d.) 8 4040252 Screw, 4-40 x 1/4" Socket Head 9 4080250 Screw, 8-32 x 1/4" Pan Head 10 4080255 Screw, 8-32 x 1/4" Flat Head 11 7200177 Stop Plate 12 7200194 Color Arm Catch Plate 13...
- Page 36 FIGURE 6B Color Boomerang Assembly No. 7200709 XG4/034...
- Page 37 PARTS LIST Figure 6B Item Part No. Description 1 7200710 Shroud Assembly 2 7200714 Pivot Shaft 3 7200713 Bearing Block (7 req’d.) 4 51396000 Color Holder Catch Hook (6 req’d.) 5 7200715 Lock & Release Lever 6 7200716 Lock/Release Lever Shaft 7 7200721 Color Arm Assembly (6 req’d.) 8 7158003 Rubber Bumper (6 req’d.) 9 7200717 Gel Ring, 13½" Diameter; Welded Assembly (6 req’d.) 10 4257102 Flatwasher, 1/4" SAE (2 req’d.) 11 4250504 Screw, 1/4-20 x 1/2" Button Head (16 req’d.) 12 4080183 Screw, 8-32 x 3/16" (12 req’d.) 13...
- Page 38 FIGURE 7 Iris, Chopper & Aperture Assembly XG4/036...
- Page 39 PARTS LIST Figure 7 Item Part No. Description 1 7200201 Iris Mount 2 7200263 Iris Bell Crank 3 24374000 Iris 4 7200075 Iris Linkage 5 7200199 Iris Clamp (2 req’d.) 6 48402000 Iris Lever - 4257002 Flatwasher, 1/4" SAE - 4258001 Hexnut, 1/4-20 7 7200200 Iris Back Plate 8 47972000 Upper Chopper Blade Assembly 9 47973000 Lower Chopper Blade Assembly 10 7200197 Guide Plate (2 req’d.) 11...
- Page 40 FIGURE 8 XG4/038...
- Page 41 PARTS LIST Figure 8 Item Part No. Description 1 49943000 Lifting Strap 2 4377102 Flatwasher, 3/8" 3 49120000 Tilt Axis Bolt 4 4378002 Locknut, 3/8-16 Hex 5 02411000 Washer, .640" I.D. x 1-1/4" O.D. 6 7201021 Clamp Plate 7 49125000 Compression Spring, Tilt Clamp 8 49124000 Spring Bushing 9 49223000 Clamp Shaft 10 49130000 Clamp Handle 11 10048A00 Knob, Round Plastic - 4198027 Grommet, Black Rubber 12...
- Page 42 FIGURE 9 LAMPHOUSE CABLE ASSEMBLY Part No. 7200251 See Page XG4/004 for Connector Pinout POWER SUPPLY CABLE ASSEMBLY Part No.6270025 XG4/040...