Summary of Contents for Strong Lighting SUPER TROUPER III
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FOLLOW SPOTLIGHT INSTRUCTION MANUAL SUPER TROUPER III Rev. March 2018 10533 Chandler Rd, Suite 101 • La Vista, NE 68128 USA Tel (402) 506-9096 • www.strong.lighting...
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ONLY POWER SUPPLIES manufactured by Beamlight, LLC (dba Strong Lighting) 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 potentiometer. For detailed information...
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Reasonable care should be exercised; breakage caused by handling is not covered by the xenon lamp warranty. Transportation of the Super Trouper III from venue to venue with the lamp installed is permitted so long as the road case that the follow spot is stored in is designed to protect the fixture and provide a cushioned ride.
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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 ST3/003...
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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 SUPPLY MS Connector (pre-wired) ST3/004...
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THE SUPER TROUPER III is wired for operation with the “compact” model xenon power supply Equipment Type 62000xx and the new B3 Strong Lighting followspot power supply. If installing the Super Trouper III 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 III with a xenon power supply other than a 62- or B3 series will void safety listing compliance.
SAFETY PROCEDURES THE XENON LAMP is highly pressurized. When ignited, the normal operating temperature of the lamp increases the pressure to a level at which the lamp may explode if not handled in strict accordance to the manufacturer’s operating instructions. The lamp is stable at room temperature, but may still explode if dropped or otherwise mishandled. REFER ALL LAMP 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 lamp 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 lamp in its protective cover when cleaning or servicing the lamphouse interior. The lamp, when outside the lamphouse, must be encased in the cover. Clean the lamp after it has cooled to room temperature. Do not touch the quartz envelope of the lamp; fingerprints will burn in and create hot spots which may shorten bulb life. If fingermarks are made, they should be carefully removed with isopropyl alcohol and cotton prior to operation. Never view an ignited lamp directly. BLINDNESS OR PERMANENT EYE DAMAGE MAY BE INCURRED. Use only xenon lamps designated as OZONE FREE. Maintain the lamphouse blowers in good operating condition. Keep the blower inlets clean for unrestricted air flow.
THE ABOVE XENON LAMPS are designated OZONE FREE, and replacement lamps other than the above must be certified by their manufacturer as being 100% interchangeable. The warranty on the xenon bulb supplied is administered by the lamp manufacturer and is separate from the spotlight warranty issued by Strong Lighting. Retain the warranty documentation packed with the xenon lamp. WHEN ORDERED for 1600 watt operation, the adapters required to install these smaller bulbs in the Super Trouper III lamphouse are supplied in the accessory kit. The front bulb support in the 1600 watt lamphouses is a cast yoke (65117000) which holds the stem of the cathode adapter. A retainer plate (65151000) and two thumb screws (65152000) clamp the stem of the cathode adapter into the yoke.
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XENON LAMP INSTALLATION Note: The reflector is factory laser aligned and should not be adjusted under normal circumstances. Only when a new reflector is installed is adjustment required. Configuration for 1600W Operation NO ADAPTERS REQUIRED FOR 2000 WATT TYPE “HS” LAMP See Parts List, Figure 2 for 2000 watt lamp mounting illustration ST3/008...
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1600 Watt Lamp Installation ASSEMBLE THE REQUIRED ADAPTERS to the 1600 watt lamp as illustrated prior to inserting the lamp into the lamphouse. Be very careful not to apply any mechanical strain to the quartz envelope when installing adapters. SCREW THE THREADED CATHODE ADAPTER (24270000) onto the lamp 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.
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2000 Watt or higher Lamp Installation (continued) NOTE THE TWO NOTCHES at the center hole of the reflector. These notches allow additional clearance between the grounded reflector and the energized lamp trigger wire. Rotate the lamp to align the trigger wire with one of these two notches to prevent the trigger wire from arcing to the grounded reflector.
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LAMP 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 lamp. 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 “LAMP INSTALLATION” SECTION for instructions detailing the above. Failure to remove the lamp's protective cover will damage or destroy the xenon lamp. 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.
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THE TWO LARGE THUMB SCREWS to the left and right of the focusing control secure the horizontal and vertical position of the lamp. These two large thumb screws are spring-loaded to provide a degree of friction against the bulkhead section of the control mechanism. LAMP ADJUSTMENT CONTROLS Thumb Screw Focus Control Focus Lock Screw THE FOLLOWING METHOD is recommended to position the xenon lamp inside the reflector in order to project the best light to the stage. REMOVE THE PROJECTION LENS (item 25, figure 3). To do this you will have to remove the front lens cover on the operator side. Make note of the directional arrows on the lens. CENTER THE LAMP ADJUSTMENT CONTROLS.
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AFTER THE SPOT is correctly positioned, verify that the lamp is at the optical centerline, by turning the focus control clockwise to again project Spot “A.” The dark spot should remain centered in the spot projection as shown. REPLACE PROJECTION LENS and replace front lens housing. Be sure to replace the lens into the original orientation shown by the direction arrows. ROTATE THE LAMP 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.
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HANDLING THE SPOTLIGHT THE SUPER TROUPER III 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.
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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 S POT i s obtained with the iris control l ever t o the left (away from t he 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; reinstall 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...
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It may be necessary to refocus 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 Strong Lighting 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.
MAINTENANCE THE SUPER TROUPER III 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 that does not contain ammonia. THE XENON LAMP 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 lamp. CHECK ALL ELECTRICAL TERMINATIONS periodically for tightness. Note especially the xenon lamps connections and other leads in the DC circuit. 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 impellers, or if obstructed air flow allows the squirrel cage blower motor to overheat, a thermal switch in the blower motor will shut down the blower. If the squirrel cage 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) impellers and lubricate the blower motor in the marked oil holes.
TROUBLESHOOTING NORMAL OPERATION WHEN THE SWITCH for 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 AC Power (“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.
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.
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TROUBLE CHART (continued) Lamp Fails To Ignite No DC current. Switch xenon power supply breaker ON. DC output level too low. Increase power supply output to rated lamp current. Low DC no load voltage from xenon power supply. Check no load voltage by pressing VOLTS/AMPS switch at ignition cycle. Repair or replace power supply if no load voltage is lower than 150 V.DC. Defective xenon lamp. 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 (2 & 4 and 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 (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. Lamp Goes Out During Operation Blocked lamp seal blower intake or defective blower motor. Clean or replace. Overheated thermal switch in xenon power supply. Check for unobstructed air flow through power supply; loose DC connection(s). Squirrel cage blower motor overheated, internal thermal switch open. Allow to cool; clean as required. Faulty xenon lamp. Check for sagging or damaged electrodes, darkened envelope, instability in operating voltage or current. Replace if defective.
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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 Strong Lighting dealer for further information. ST3/021...
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LAMPHOUSE SCHEMATIC J2-1 J2-2 J2-8 J2-9 J2-11 J2-10 12vac J2-7 J5-1 J5-2 K1 through J10 on 7201311 on 7201311 J2-5 J2-3 J2-4 Igniter XENON Shunt J2-11 Responsible dep. Technical reference Drawn by Approved by Production Paul Rabinovitz A. Sawyer Paul Rabinovitz Document type Document status Lamphouse Schematic...
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AMP/VOLTS S101 POWER INTERLOCK Analog Control Panel Printed Circuit Board Assembly No. 3200866 ST3/023...
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Super Trouper III Control Circuit ST3/024...
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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...
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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...
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FIGURE 5A Part No. Description Spring Washer 2170029 24369000 Bell Crank 24372000 Adapter Ring 24374000 Iris 25017000 Bushing (with 4151530) 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,...
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FIGURE 6 24084000 YOKE & STAND ASSEMBLY ST3/040...
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XENON BULB RECORD MACHINE NO. LAMPHOUSE TYPE AMPS. MAX. CURRENT _ _ AMPS. WATTAGE NOM. CURRENT DATE BULB LAMPHOUSE HOURS MFGR. SERIAL NO. INSTALLED ROTATED REPLACED...
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