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Strong International XENON GLADIATOR IV Instruction Manual

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XENON GLADIATOR IV
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Type 47070
Rev. September 2006
STRONG INTERNATIONAL
a division of Ballantyne of Omaha, Inc.
4350 McKinley Street
Omaha, Nebraska 68112 USA
Tel 402/453-4444 • Fax 402/453-7238
www.strong-lighting.com

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Summary of Contents for Strong International XENON GLADIATOR IV

  • Page 1 XENON GLADIATOR IV Follow Spotlight Type 47070 Rev. September 2006 STRONG INTERNATIONAL a division of Ballantyne of Omaha, Inc. 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 THE LAMPHOUSE is supplied with a 13 foot cable containing the DC leads, the AC control wires, and the ground wire. The cable terminates in a multiple-pin, quick-disconnect plug keyed to mate with the receptacle on the power supply. 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 authorized personnel to handle the xenon bulb. IF AT ANY TIME you have a suggestion, or desire aid in securing anticipated results, write directly to STRONG INTERNATIONAL, 4350 McKinley Street, Omaha, Nebraska 68112 USA, or online at www.strong-lighting.com. XG4/001...
  • 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...
  • Page 5 INSTALLATION AND SETTING UP SPOTLIGHT THE XENON GLADIATOR IV is shipped in sections which must be assembled. 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 using the 3/8-16 x 2-3/4 inch hex head cap screws and lockwashers provided. Insert a leveling foot and locknut in each of the four leg brackets and level the base before continuing the installation.
  • Page 6 LAMPHOUSE - POWER SUPPLY Interconnection Diagram LAMPHOUSE (Connections Pre-wired) MS 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 positioning.

  • 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 operating 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: Allow the bulb to cool to room temperature before opening the lamphouse. Put on protective clothing described above.
  • Page 8 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. 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...

  • 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) quarter- turn fasteners and remove the two bulb compartment side covers. Verify that the lamphouse is fitted with the correct 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.
  • Page 10 ESTABLISH A ROUTINE of periodically checking all electrical connections 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.

  • Page 11: Operation

    OPERATION OPEN THE BOOMERANG ACCESS COVER and verify that the round glass heat filter and ring assembly is installed into the bracket mounted to the fadeout and douser support housing. NOTE: The coated side of the filter, with the XX or other marking, must be facing the reflector. 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 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 ignite. Check the reading on the lamphouse ammeter.
  • 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 extending 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.
  • 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 which 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 control handle moved as far to the rear as possible.
  • 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 72-00264 boomerang is mounted within the optical system and uses (6) 50mm dichroic discs as the color media. Type 72-00709 mounts to the front of the lens barrel and uses conventional high-temperature color gels (i.e.

  • Page 16: Digital Display

    DIGITAL DISPLAY UPON ENERGIZING the LAMP circuit, the backlighting will illuminate the LCD screen. The display CHECK TOP COVER will appear if the top cover if not secured. When the lamphouse access cover is closed and correctly secured, and the blowers are operating, the display will appear as shown: 000V 000A 0000W 1234BLB 12345HR * FOR PURPOSES OF ILLUSTRATION, the above display indicates a non-operating bulb with 1,234 hours of use installed into a spotlight with 12,345 hours of operation. The asterisk (*) at the end of the second line, when flashing, indicates that the display is active and awaiting input. Upon bulb ignition, the upper line will display the arc voltage (V), the DC current (A), and the operating wattage (W) of the bulb.
  • Page 17 DIAGNOSTIC MESSAGES serve as prompts and suggestions but do not replace traditional troubleshooting procedures. If the top cover is closed and secured but transmits an error message, check the subject cover interlock switch with an ohmmeter and replace if defective. Dirt or dust fouling an air vane switch will cause a “blower” error message. A “power supply” or “igniter” error message might be caused by a loose or oxidized connection. XG4/015...

  • Page 18: 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 re- move 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. Clean the heat filter glass; replace with the coated surface toward the lamphouse.
  • Page 19 LAMPHOUSE WIRING DIAGRAM Barrier Strip 21-62012 (see Figure 3, Item 44) XG4/017...

  • Page 20: Wiring Diagram Parts List

    WIRING DIAGRAM PARTS LIST Part No. Description 72-00280 Blower, 230 V.AC, 50/60 Hz. (B1,B2,B3) 72-00255 Capacitor, RF Suppression (C1) 81247000 Shunt (R1), 200 A. 50 mV. 24086000 Rocker Switch, ON/OFF 72-00253 Transformer (X1) 39862000 Igniter Assembly 24275000 Printed Circuit Board Assembly, Voltage Divider (mounts to R1) 25098000 Digital Display Assembly (see Figure 3, Item 45) 23976S00...
  • Page 21 XG4/019...
  • Page 22 XG4/020...
  • Page 23 XG4/021...
  • Page 24 VOLTAGE DIVIDER ASSEMBLY Cut this Jumper Wire before installing 24275 PC Board in Gladiator IV Lamphouse 24275 VOLTAGE DIVIDER BOARD mounts to R1 Shunt Ref. Desig. Part No. Description C1-C5 61-08025 Capacitor, .005µf, 3 kV. D1-D4 51-17001 Diode, 1N4007 61-46002 Resistor, 100 Ohm, ¼ W. 5% 61-46045 Resistor, 100k Ohm, ¼...

  • Page 25: 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 POWER lights on the xenon power supply and the lamphouse instrument panel will glow. The lamphouse blowers will start. The blowers in the power supply will operate. WHEN THE LAMP SWITCH is placed in the ON position, the AC control circuit (2 & 6) in the lamphouse will energize the power supply circuitry providing DC current to the igniter and bulb. The green “GO”...
  • Page 26 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. igniters, printed circuit boards) between similar Strong Xenon Gladiators to aid in diagnosis of a problem is encouraged. This will not lead to equipment damage, and will not void equipment warranty.
  • Page 27 Digital Display not ON. Check for loose connection on plug J5. Check for 230 V.AC on terminal block positions 1 & 2. If correct, check X1 transformer output for 115 V.AC. If not measured, replace transformer. Bulb goes out during operation. Xenon power supply overheated;...
  • Page 28 FIGURE 1 XG4/026...

  • Page 29: Parts List

    PARTS LIST Figure 1 Item Part No. Description 72-00164 Lamphouse Top Cover & Access Panel 72-00163 Side Cover, Off-Operator Side (not shown) 72-00247 Cover Plate, Optical System Controls (as shown) 72-01000 Cover Plate, Optical System Controls (no color arm slots) 10048A00 Knob 72-00207 Lens System Cover, Off-Operator Side...
  • Page 30 FIGURE 2 XG4/028...
  • Page 31 PARTS LIST Figure 2 Item Part No. Description 72-00160 Bulb Enclosure Top Cover, Rear 72-00159 Bulb Enclosure Brace 00M15315 Arc Stabilization Magnet (not shown) 81137000 Magnet Clamp 4080259 Set Screw, 8-32 x 1/4" 72-00166 Bulb Enclosure Top Cover, Front 72-00173 Mounting Bracket, Fade Out Assembly 72-00258 Light Shield (see Figure 3, Item 14) 72-00167...
  • Page 32 FIGURE 3 XG4/030...
  • Page 33 PARTS LIST Figure 3 Item Part No. Description 72-00658 Access Cover Plate 4100504 Mounting Screw, 10-32 x 1/2" 31875000 Thumbscrew, 10-32 72-00158 Lamphouse Back Cover 72-00155 Rear Lamphouse Bulkhead Plate 4250752 Mounting Screw, 1/4-20 x 3/4" 4257000 Lockwasher, 1/4" 21-61006 Interlock Switch & Lead Assembly 4040500 Mounting Screw, 4-40 x 1/2"...
  • Page 34 PARTS LIST, Figure 3 (continued) Item Part No. Description 51914000 Large Lens Ring 4110371 Mounting Screw, 10-24 x 3/8" Fillister Head (6 req’d.) 51408000 Large Lens 19a 72-00649 Brake Lever 51417000 Lens Retainer 71-58005 Expansion Spring 51350000 Large Lens Carriage 19b 72-00648 Lever Bracket 72-00641 Large Pulley...
  • Page 35 PARTS LIST, Figure 3 (continued) Item Part No. Description 72-00165 Bulb Enclosure Panel, Lower (2 req’d.) 24275000 Voltage Divider PC Board Assembly 81247000 Shunt (R1), 200 A. 50 mV. 4080754 Mounting Screw, 8-32 x 3/4" Pan Head 72-00209 Mounting Bracket, Terminal Board 4080250 Mounting Screw, 8-32 x 1/4" Pan Head 72-00252 Terminal Board &...
  • Page 36 FIGURE 4 XG4/034...
  • Page 37 PARTS LIST Figure 4 Item Part No. Description 72-00212 Fade Out Housing, Welded Assembly 72-00262 Bell Crank, Fade Out Dousers 51155000 Control Lever, Fade Out 4257102 Flatwasher, 1/4" SAE 4258001 Hexnut, 1/4-20 72-00268 Lower Douser Blade Assembly 72-00265 Upper Douser Blade Assembly 72-00272 Heat Shield, Upper Blade 72-00271 Heat Shield, Lower Blade...
  • Page 38 FIGURE 5A XG4/036...
  • Page 39 PARTS LIST Figure 5A Item Part No. Description 72-00196 Bottom Plate 72-00195 Side Plate (2 req’d.) 72-00186 Pivot Rod 72-00176 Bronze Bearing (7 req’d.) 72-00181 Color Holder (6 req’d.) 51396000 Color Holder Catch Hook (6 req’d.) 72-00260 Retainer Clip (18 req’d.) 4040252 Screw, 4-40 x 1/4" Socket Head 4080250 Screw, 8-32 x 1/4" Pan Head...
  • Page 40 FIGURE 5B Color Boomerang Assembly No. 72-00709 XG4/038...
  • Page 41 PARTS LIST Figure 5B Item Part No. Description 72-00710 Shroud Assembly 72-00714 Pivot Shaft 72-00713 Bearing Block (7 req’d.) 51396000 Color Holder Catch Hook (6 req’d.) 72-00715 Lock & Release Lever 72-00716 Lock/Release Lever Shaft 72-00721 Color Arm Assembly (6 req’d.) 71-58003 Rubber Bumper (6 req’d.) 72-00717 Gel Ring, 13½"...
  • Page 42 FIGURE 6 Iris, Chopper & Aperture Assembly XG4/040...
  • Page 43 PARTS LIST Figure 6 Item Part No. Description 72-00201 Iris Mount 72-00263 Iris Bell Crank 24374000 Iris 72-00075 Iris Linkage 72-00199 Iris Clamp (2 req’d.) 48402000 Iris Lever 4257002 Flatwasher, 1/4" SAE 4258001 Hexnut, 1/4-20 72-00200 Iris Back Plate 47972000 Upper Chopper Blade Assembly 47973000 Lower Chopper Blade Assembly 72-00197...
  • Page 44 FIGURE 7 XG4/042...
  • Page 45 PARTS LIST Figure 7 Item Part No. Description 49943000 Lifting Strap 4377102 Flatwasher, 3/8" 49120000 Tilt Axis Bolt 4378002 Locknut, 3/8-16 Hex 02411000 Washer, .640" I.D. x 1-1/4" O.D. 72-01021 Clamp Plate 49125000 Compression Spring, Tilt Clamp 49124000 Spring Bushing 49223000 Clamp Shaft 49130000 Clamp Handle 10048A00...
  • Page 46 FIGURE 8 LAMPHOUSE CABLE ASSEMBLY Part No. 72-00251 See Page XG4/004 for Connector Pinout POWER SUPPLY CABLE ASSEMBLY Part No.62-70025 XG4/044...

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