Strong International XENON GLADIATOR IV, Instruction Manual

Page 1: ...ATIONAL 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 XENON GLADIATOR IV Follow Spotlight Type 47070 Rev September 2006 ...

Page 2: ...BULB WATTAGE CURRENT RANGE DC NOMINAL CURRENT DO NOT 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: ...and bulb adapters are not required 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 digital running time meter with DC volt age and amperage display A wattage readout on the digital display is an approximate figure and shoul...

Page 4: ...Lever Horizontal Pan Control Lever Vertical Tilt Control Lever Height Setting Pin Lifting Strap Spot Size Control Handle Color Boomerang Control Levers Spot Focus Knob Leveling Feet not shown Lens System Access Cover XENON GLADIATOR IV XG4 002 Boomerang Type 72 00264 Type 72 00709 not shown see Figure 5B ...

Page 5: ...hes 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 yo...

Page 6: ...DC B DC C 2 D 3 E 4 F 5 G 6 I 7 J 8 M Grnd Lamphouse Cable Assembly XENON POWER SUPPLY Connector pre wired DC DC SYSTEM MUST BE GROUNDED All wiring must conform to local codes shield lamphouse cable in conduit if required Check Slide Switch below on Power Supply for correct positioning Slide to LEFT XG4 004 ...

Page 7: ...on 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 4 Clean the bulb after it has cooled to room temperature Do not touch the quartz envelope of the bulb fingerprints will burn in and create hot spots which ...

Page 8: ...tective cover Grasp the bulb by the anode end cap Use small channel locks or slip joint pliers and grip the bulb lead fitting at the crimp joint nearest the end cap and unscrew the lead If the bulb manufacturer uses a brazed rather than threaded connection cut the lead from the end cap cutting as close as possible to the end cap The standard bulb support collet 72 00285 measures 4 11 16 inches 120...

Page 9: ...e 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 REST THE CATHODE END CAP in the V of the bulb yoke Dress the bulb lead directly in front of the bulb support yoke to minimize the projected sha...

Page 10: ...bulb was supplied by Strong XG4 008 ARC STABILIZATION MAGNET THE XENON BULB used in the Gladiator IV lamphouse requires an arc stabilization mag net 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 whe...

Page 11: ...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 the display will also briefly indicate the high no load open circuit DC voltage applied to the xenon bulb for ignition REMOVE THE REAR COVER above the instrument panel by releasing the 3 quarter turn fasteners This exposes the bulb positionin...

Page 12: ...e 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 s...

Page 13: ...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 lock...

Page 14: ...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 o...

Page 15: ...re 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 boom...

Page 16: ... open circuit DC voltage will ignite the bulb The voltage reading V will then fall to the bulb s sustaining level and the DC amperes A and wattage W will be displayed continuously until the bulb is extinguished ELAPSED HOURS will begin counting upon bulb ignition Bulb hours BLB are limited to four digits and must be re set when the xenon bulb is replaced To re set bulb hours press the RESET button...

Page 17: ...s 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 ...

Page 18: ...cloth Observe all safety pro cedures when working with the exposed bulb THE INSIDE OF THE LAMPHOUSE and the blower squirrelcages should be cleaned peri odically depending on the dust conditions at each installation Keep the blower inlet and outlet grilles clean to permit free air flow THE LENS SYSTEM should be kept clean to prevent any light reduction in the projected spot Tighten the horizontal s...

Page 19: ...LAMPHOUSE WIRING DIAGRAM Barrier Strip 21 62012 see Figure 3 Item 44 XG4 017 ...

Page 20: ...2000 Igniter Assembly 24275000 Printed Circuit Board Assembly Voltage Divider mounts to R1 25098000 Digital Display Assembly see Figure 3 Item 45 23976S00 Printed Circuit Board Assembly Digital Display Control 25044000 LCD Display Screen 31 30231 Xenon Bulb LTIX 4500W HS 72 00251 Interconnect Cable Assembly Lamphouse Power Supply see Figure 8 72 00252 Terminal Board Molex Wired Assembly 21 62012 B...

Page 21: ...23976S DIGITAL DISPLAY CONTROL CIRCUIT Page 1 0f 3 XG4 019 ...

Page 22: ...23976S DIGITAL DISPLAY CONTROL CIRCUIT Page 2 0f 3 XG4 020 ...

Page 23: ...23976S DIGITAL DISPLAY CONTROL CIRCUIT Page 3 0f 3 XG4 021 ...

Page 24: ...17001 Diode 1N4007 R1 61 46002 Resistor 100 Ohm W 5 R2 61 46045 Resistor 100k Ohm W 5 J1 21 37051 Connector 5 Position NOTE Replacement Board must be modified as shown above cut jumper or board will not function VOLTAGE DIVIDER ASSEMBLY Cut this Jumper Wire before installing 24275 PC Board in Gladiator IV Lamphouse XG4 022 ...

Page 25: ...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 9 10 CA...

Page 26: ...s of AC control voltage Check xenon power supply for tripped circuit breaker or open thermal switch See power supply manual 2 Lamphouse top cover interlock switch open Top cover must be closed and both latches secured 3 Xenon power supply GO light not glowing See power supply manual 4 Little or no DC No Load voltage Measure DC No Load voltage at 6 7 See power supply manual 5 Open fuse F1 10A on sw...

Page 27: ...ng electrodes replace if defective 2 Excessive ripple in DC output See power supply manual 3 Arc stabilization magnet reversed NORTH pole should point toward operator s side Check with compass if required Reduced light output 1 Normal bulb aging Increase output current DO NOT EXCEED MAXIMUM CURRENT LEVEL SPECIFIED BY BULB MANUFACTURER 2 Soiled reflector Clean using commercial glass cleaner USE NO ...

Page 28: ...1 2 3 4 5 6 7 8 9 10 12 13 7 14 15 11 XG4 026 FIGURE 1 ...

Page 29: ...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 8 51509000 Handle Spot Size Control 9 72 00246 Access Panel 31 98209 Quarter Turn Fastener 4 req d 31 98200 Receptacle Quarter Turn Fastener not shown 10 72 00206 Lens System Cover Operator Side 11 72 00397 Bottom Cover Front 12 4310753 Wing Screw 5 16 18 4 req d 431...

Page 30: ...FIGURE 2 1 2 3 4 5 6 7 8 XG4 028 ...

Page 31: ...e Adapter 2 3 kW Item Part No Description 1 72 00160 Bulb Enclosure Top Cover Rear 2 72 00159 Bulb Enclosure Brace 00M15315 Arc Stabilization Magnet not shown 81137000 Magnet Clamp 4080259 Set Screw 8 32 x 1 4 3 72 00166 Bulb Enclosure Top Cover Front 4 72 00173 Mounting Bracket Fade Out Assembly 5 72 00258 Light Shield see Figure 3 Item 14 6 72 00167 Access Panel Front 7 72 00161 Access Panel Rea...

Page 32: ...1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 33 FIGURE 3 38 39 40 41 42 43 44 45 49 50 51 52 53 54 46 47 48 27 30 37 XG4 030 19b 28a Detail 19a ...

Page 33: ...Mounting Screw 1 4 20 x 3 4 4257000 Lockwasher 1 4 9 72 00157 Front Lamphouse Bulkhead Plate 4250752 Mounting Screw 1 4 20 x 1 2 4257000 Lockwasher 1 4 10 31 30231 Xenon Bulb 4 kW Type HS 11 72 00173 Support Bracket Fade Out Assembly 4080375 Mounting Screw 8 32 x 3 8 Pan Head 12 72 00261 Fade Out Heat Filter Assembly see Figure 4 4250752 Mounting Screw 1 4 20 x 3 4 4258007 Locking Hexnut 1 4 20 42...

Page 34: ...5 16 18 x 3 4 4311750 Mounting Screw 5 16 18 x 1 3 4 with Item 46 4317000 Lockwasher 5 16 28 72 00647 Shaft Spot Size Handle 21 48011 Retaining Ring 3 8 External 28a 51509000 Handle 29 81143000 Bushing Xenon Power Supply Cable 72 00251 Interconnect Cable Assembly Lamphouse Power Supply Figure 8 30 25089000 Small Pulley 2 req d 51160000 Shoulder Bolt Pulley Axle 31 72 00168 Base Channel 32 72 00286...

Page 35: ...nd Rail 2 req d 4311750 Mounting Screw 5 16 18 x 1 3 4 47 81301000 Insulator Negative Binding Post 4080506 Mounting Screw 8 32 x 1 2 Pan Head 81300000 Binding Post 3 8 16 Brass with 72 00251 Assembly 4378003 Hexnut 3 8 16 Brass 4377000 Lockwasher 3 8 48 40107000 Air Duct Casting 4250503 Duct Mounting Screw 1 4 20 x 1 2 Hex Head 72 00287 Insulator Spacer Plate 4250752 Insulator Mounting Screw 1 4 2...

Page 36: ...FIGURE 4 Fade Out Heat Filter Assembly XG4 034 ...

Page 37: ... Cover Shield Heat Filter 10 81847000 Heat Filter Holder Welded Assembly 11 72 00273 Pull Rod Short 12 72 00274 Pull Rod Long 01704000 Hitch Pin Pull Rods not shown 4 req d 13 51153000 Spacer Bushing 14 4318004 Lock Nut 5 16 18 Hex 15 4507106 Washer 1 2 Brass 16 4317102 Washer 5 16 SAE 2 req d 17 72 00504 Heat Filter Ring Assembly 18 41 98003 Stand Off 1 4 Hex 4 req d 19 51 56016 Stand Off 7 8 4 r...

Page 38: ...FIGURE 5A Color Boomerang Assembly No 72 00264 XG4 036 ...

Page 39: ...Color Arm 20 2 req d 18 72 00184 Color Arm 30 19 4060500 Screw 6 32 x 1 2 Pan Head 20 72 00259 Release Arm 21 71 98011 Dichroic Filter Flame Red 22 71 98014 Dichroic Filter Lavender 23 71 98012 Dichroic Filter Wheat Yellow 24 71 98012 Dichroic Filter Jade Green 25 71 98010 Dichroic Filter Navy Blue 26 71 98009 Dichroic Filter Magenta Purple 27 4100623 Screw 10 32 x 5 8 Flat Head 28 51 58018 Expans...

Page 40: ...FIGURE 5B Color Boomerang Assembly No 72 00709 XG4 038 ...

Page 41: ...00721 Color Arm Assembly 6 req d 8 71 58003 Rubber Bumper 6 req d 9 72 00717 Gel Ring 13 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 4268003 Acorn Nut 1 4 28 14 2468006 Jam Nut 1 4 28 Hex 15 01704000 Hitch Pin 3 req d 16 71 58004 Torsion Spring NOT SHOWN 71 34001 Magnetic Label Dr...

Page 42: ...FIGURE 6 Iris Chopper Aperture Assembly XG4 040 ...

Page 43: ...o Holder 16 81432000 Shoulder Screw 10 24 17 21 37011 Roll Pin 3 32 x 9 16 18 25017000 Shim Spacer 19 4251002 Screw 1 4 20 x 1 Socket Head 20 4257102 Flatwasher 1 4 SAE 2 req d 21 51 35013 Stop Nut 22 4060250 Screw 6 32 x 1 4 Pan Head 2 req d 23 4080501 Screw 8 32 x 1 2 Flat Head 2 req d 24 4250251 Set Screw 1 4 20 x 1 4 2 req d 25 72 00275 Chopper Blade Pull Rod Short 26 72 00276 Chopper Blade Pu...

Page 44: ...FIGURE 7 XG4 042 ...

Page 45: ...Ring 16 83797000 Base Leg Welded Assembly 11 09013 Caster Locking not shown 17 49226000 Leveling Foot 4508001 Locknut 1 2 13 Hex 18 83294A00 Height Adjustment Pin 7 16 Dia 21 71187 Lanyard Wire Rope 9 req d 11 98230 Lanyard Clamp 2 req d 19 83794000 Tube Collar Assembly 20 83113000 Needle Bearing 21 83114000 Race Needle Bearing 22 49213000 Swivel Clamp Collar 4250503 Screw 1 4 20 x 1 2 Hex Head 42...

Page 46: ...FIGURE 8 LAMPHOUSE CABLE ASSEMBLY Part No 72 00251 POWER SUPPLY CABLE ASSEMBLY Part No 62 70025 See Page XG4 004 for Connector Pinout XG4 044 ...

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