Strong XENON GLADIATOR II, Instruction Manual

Page 1: ...STRONG INTERNATIONAL a division of Ballantyne of Omaha Inc 4350 McKinley Street Omaha Nebraska 68112 USA Tel 402 453 4444 Fax 402 453 7238 XENON GLADIATOR II Follow Spotlight Type 47050 Rev June 2001 ...

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Page 3: ...horizontal vertical and focal movement of the bulb INSTRUMENTATION of the lamphouse includes a running time meter and a DC ammeter The running time meter indicates the number of hours the bulb has been in operation The ammeter displays the operating current of the lamp A push button switch located below the ammeter changes the meter reading to indicate the DC voltage at the arc THE LAMPHOUSE COOLI...

Page 4: ... 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 following 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 Neb...

Page 5: ...sted through an additional two inch range Insert the height location pin through the hole in the outer tube and one of the holes in the inner tube THE HORIZONTAL SWING and vertical tilt locking knobs are on the right hand operating side of the yoke assembly Tighten both of these locking devices securely before attempting to place the lamp house and lens system on the support yoke PLACE THE LAMPHOU...

Page 6: ... A DC B DC C 2 D 3 E 4 F 5 G 6 I 7 J 8 M Grnd Lamphouse Cable Assembly Conduit Remote Auto Sustained 5 Amp Dry Contact by Installer as req d XENON POWER SUPPLY MS Connector pre wired DC DC SYSTEM MUST BE GROUNDED All wiring must conform to local codes shield lamphouse cable in conduit if required XG2 004 ...

Page 7: ...ower 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 inte rior 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 may...

Page 8: ...h 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 Pin Cathode Anode Anode Pin Cathode End Cap Seal Seal Envelope Anode End Cap XG2 006 ...

Page 9: ...SERT 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 REST THE CATHODE END CAP in the V of the bulb yoke Install the cathode contact clamp over the cathode pin Firmly tigh...

Page 10: ...upplied by Strong XG2 008 ARC STABILIZATION MAGNET THE XENON BULB used in the Gladiator II lamphouse requires an arc stabilization magnet This magnet is located on the lamp base behind the reflector This 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 w...

Page 11: ...hold more than one second release immediately upon lamp ignition Use of the emergency ignition switch indicates an abnormal condition see the TROUBLESHOOTING section following CHECK THE READING on the lamphouse ammeter Nominal current for the 2500 watt xenon bulb is 90 amperes DO NOT AT ANY TIME exceed 100 amperes Output current is adjusted at the power supply see power supply manual for instructi...

Page 12: ...r 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 ap...

Page 13: ... the LAMP switch to ON The lamp will ignite when a sustained dry contact is made between the automation leads 3 and 6 and extinguish when the contact is opened See the INSTALLATION DIAGRAM in the power supply manual The lamphouse blowers will operate until the xenon power supply is de energized allow for ten minutes bulb cooling BEFORE OPENING the lamphouse enclosure for servicing allow the blower...

Page 14: ...e 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 extreme right toward operating side and varying degrees of masking ...

Page 15: ... TO REPLACE A FILTER HOLDER open the hinged top of the color disc housing and lift out the desired filter holder HIGH TEMPERATURE FILTERS RoscoLux or equivalent cut to nine inch diameter are required and are secured in the filter holders with paper fasteners NOTE WHEN PLACING COLOR FILTERS in the boomerang the less dense colors pink amber should be placed in the holders toward the rear of the boom...

Page 16: ... clean lint free cloth Observe all safety procedures 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 Clean the actuator arms of the air flow switches to prevent dust build up THE LENS SYSTEM should b...

Page 17: ... Pos C BRN No 2 D RED No 3 E ORN No 4 F BLU No 5 G YEL No 6 I GRY No 7 J BLK No 8 M GRN Ground Lamp ON OFF Exhaust Lens Bulb Seal Access Door Interlock Air Flow Intake Air Flow Exhaust LAMPHOUSE SCHEMATIC 47050 4 00 XG2 015 ...

Page 18: ... 1200 V DC DS1 Xenon Bulb M1 39976 Elapsed Time Meter 60 Hz 39974 Elapsed Time Meter 50 Hz M2 65142 Ammeter 0 150 A R1 82167 Shunt 150 A 50 mV R2 39151 Resistor 150k Ohm Watt Order 21 46059 S1 80168 Door Interlock Switch S2 81275 LAMP Switch Rocker Type S3 81276 MODE Switch Rocker Type S4 78133 Air Flow Switch Exhaust 81545 Air Vane Actuator Exhaust Switch S5 72275 VOLTAGE Switch Pushbutton S6 851...

Page 19: ...power supply energizing the 12 V DC coil and closing the contacts of K201 relay completing the AC circuit through the igniter to the T102 high voltage 10 kV transformer High voltage boost capacitor C107 is charged to a voltage sufficient to cause breakdown across the E101 spark gap Approximately 35 kV is supplied to the xenon bulb for ignition S101 is the igniter cover interlock switch and S102 is...

Page 20: ...00 pf 20 kV DC C108 39110 Capacitor 2400 pf 20 kV DC E101 39923 Spark Gap Assembly S101 80168 Cover Interlock Switch S102 80168 Emergency Ignite Switch T101 39937 High Voltage Transformer 39998 Case Coil Potted Assembly IGNITER ASSEMBLY SCHEMATIC XG2 018 ...

Page 21: ...1 39157 Resistor 1k Ohm 12 Watt R202 39158 Resistor 100k Ohm Watt Ref Desig Part No Description R203 39159 Resistor 200k Ohm Watt U201 72185 Timer IC Motorola MC11455P1 39164 IC Socket 6 Pin VR201 39211 Zener Diode 1N5377A 40913 VR201 39167 Zener Diode 1N5369A 39966 VR202 39162 Zener Diode 1N4742 39145 PC Board less Components 40913 PCB Assembly Standard 39966 PCB Assembly Older Models using High ...

Page 22: ...er 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 See xenon power supply manual A warm or aged xenon bulb might also require multiple strikes TROUBLE SHOOTI...

Page 23: ...al instructions Replace lead 5 or 6 at the igniter before proceeding THE SWITCHING TYPE XENON POWER SUPPLY furnished with the spotlight system includes thermal overload switches and protection circuits to prevent damage resulting from high or low input voltage Loss of DC open circuit voltage or an interruption of DC sustaining current may be traced to these circuits See the power supply manual IGN...

Page 24: ...ominal for 2500 watt 2 If bulb flash is visible but faint check for defective HV capacitor s in igniter Replace if defective 3 Faulty or expired xenon bulb Replace as required Bulb fails to ignite ping audible no bulb flash 1 Faulty xenon bulb Check for cracked electrodes or darkened envelope Replace if defective 2 Ignition pulse shorting to ground Inspect DC leads for burned insulation dress lead...

Page 25: ...replace defective component SEE POWER SUPPLY TROUBLESHOOTING UNDER SAME HEADING Noise in theatre sound as bulb ignites 1 Faulty RF suppression capacitor s Remove and test C1 C2 C3 C4A or C4B Replace if defective 2 Lamphouse power supply or sound system not properly grounded Connect to adequate earth ground 3 Leads between lamphouse and automation contact not shielded Shield leads in conduit AUTO M...

Page 26: ...ive Igniter continues to fire after bulb ignites 1 Faulty igniter printed circuit board Replace circuit board IMMEDIATELY to prevent bulb damage Color gels burning or fading prematurely 1 Bulb focused to hot spot Refocus bulb to flat field with iris fully open and spot size control handle trombone fully forward 2 Heat filter glass reversed or peeled Check for coated surface toward bulb replace if ...

Page 27: ...1 2 3 4 5 6 7 8 9 10 11 12 13 FIGURE 1 XG2 025 ...

Page 28: ... Center 4250623 Screw 1 4 20 x 5 8 Hex Head 4257000 Lockwasher 1 4 Split Ring 8 4100502 Tamperproof Screw 10 32 x 1 2 Holt Head 4107101 Flatwasher 10 4108021 Tinnerman Nut 10 Clip On 65149A Screwdriver for 4100502 9 39219 Name Data Plate Super Lume X 01639 2 Pop Rivet 1 8 10 65968 Cover Assembly Bulb Adjust Controls 65140 Cover Plate 65166 Plunger Black Plastic 65167 Grommet Black Plastic 11 39954...

Page 29: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 FIGURE 2 XG2 027 ...

Page 30: ...apter not required in Gladiator Lamphouse 11 39978 Reflector Assembly Potted Assembly as shown 11 39876 Flanged Reflector 11 Dichroic current production 65435 Reflector Adapter Ring Black Enamel incl with 39876 21 58001 Compression Spring Long 18194 Shoulder Bolt P 3055 Compression Spring Short 4250870 Ring Mounting Screw 1 4 20 x 7 8 Hex Head 12 65114 Reflector Bulkhead Casting 4250752 Mounting S...

Page 31: ...Clamp Gladiator II 16 39933 RF Suppression Capacitor Assembly C1 C2 C3 17 39165 Shield Printed Circuit Board 4080252 Screw 8 32 x 1 4 Socket Head 4087000 Lockwasher 8 18 39949A Igniter Assembly see Figure 5 19 39954 Back Casting Assembly See Figures 3 4 PARTS LIST Figure 2 continued XG2 029 ...

Page 32: ...1 2 3 4 5 6 7 8 9 10 11 12 13 FIGURE 3 XG2 030 ...

Page 33: ...Ring Bulb Collet 8 65153 Knurled Lockscrew 9 41 98013 Plug Button 3 8 10 39970 VOLTAGE Switch Assembly 72275 Switch Pushbutton S5 39151 Resistor R2 39152 Label Press for Voltage 11 39976 Elapsed Time Meter M1 60 Hz 39974 Elasped Time Meter 50 Hz Export 4040500 Mounting Screw 4 40 x 1 2 Round Head 4048003 Hexnut 4 40 4047001 Lockwasher 4 12 4080310 Screw 8 32 x 5 16 Pan Head 4087004 Lockwasher 8 13...

Page 34: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 FIGURE 4 XG2 032 ...

Page 35: ...53 Insulation Marker Strip 8 39921 Wire Harness Assembly incl Item 7 9 81947 Capacitor Assembly C5 4110250 Grounding Screw 10 24 x 1 4 Socket Head 4107000 Lockwasher 10 10 39986 Capacitor Assembly 80177 Capacitor C4A 11 80168 Door Interlock Switch 39622 Bracket 4060501 Screw 6 32 x 1 2 Flat Head 4067001 Lockwasher 6 4098001 Hexnut 6 32 12 39194 Anode Clamp 4080870 Clamping Screw 8 32 x 7 8 Socket ...

Page 36: ...1 2 3 4 5 6 7 8 9 10 FIGURE 5 IGNITER ASSEMBLY XG2 034 ...

Page 37: ...20 Nylon 5 4080250 Screw 8 32 x 1 4 Pan Head 4087001 Lockwasher 8 6 39998 Case Current Coil Potted Assembly 65353 DANGER Label 7 39201 Spark Gap Body Nylon 4110501 Screw 10 24 x 1 2 Pan Head 8 39107 Contact Screw Tungsten 39109 Terminal Tab 4107100 Flatwasher 10 Brass 4088001 Hexnut 8 32 39923 Spark Gap Assembly Items 7 8 Gapped 9 39937 High Voltage Transformer T102 4087101 Flatwasher 8 4088001 He...

Page 38: ...witch Bracket 47936 Blower Housing Welded Assembly 71220 Blower B2 115 V AC 50 60 Hz 40937 Plug Cord Assembly 72375 Barrier Strip 2 Terminal 78133 Air Flow Switch S4 81545 Actuator Air Flow Switch XG2 036 72375 71220 81545 78133 39173 47936 Switch Location earlier models ...

Page 39: ...FIGURE 6 XG2 037 ...

Page 40: ...lit Ring 16 83797 Base Leg Welded Assembly 47238 Tandem Caster Locking not shown 17 49226 Leveling Foot 4508001 Locknut 1 2 13 Hex 18 83294A Height Adjustment Pin 19 83794 Tube Collar Assembly 20 83113 Needle Bearing 21 83114 Race Needle Bearing 22 49213 Swivel Clamp Collar 4250503 Screw 1 4 20 x 1 2 Hex Head 4257000 Lockwasher 1 4 Split Ring 23 83357 Yoke Cover Plate 4080375 Screw 8 32 x 3 8 Pan ...

Page 41: ...FIGURE 7 XG2 039 ...

Page 42: ...44191 Blower Motor Squirrelcage 115 V AC 21 40011 Plug 2 Pin Male 31 62007 Molex Pin Male 21 40019 Receptacle 2 Pin Female 31 62006 Molex Pin Female 3 4080375 Screw 8 32 x 3 8 Pan Head as req d 4 47177 Receptacle Bracket not req d in current units 5 21 71066 Cable 18 2 Type SJ incl with Item 2 6 47965 Base Rail Welded Assembly PARTS LIST Figure 7 XG2 040 ...

Page 43: ...FIGURE 8 XG2 041 ...

Page 44: ...ining Ring 12 4250508 Screw 1 4 20 x 1 2 Pan Head 4257004 Lockwasher 1 4 13 4080120 Set Screw Focus Adjust Knob 14 51168 Focus Adjust Knob 15 51114 Stop Collar Slide Rod 4100180 Set Screw 10 32 x 3 16 16 51479 Rubber Bumper 17 51910 Ribbon Assembly Lens Focus 18 4110371 Screw 10 24 x 3 8 Socket Head 4107000 Lockwasher 10 Split Ring 19 51509 Handle Red Plastic 20 51441 Handle Shaft 51428 Retaining ...

Page 45: ...r 1 4 32 51353 End Casting Rear 33 83163 Small Pulley 34 51160 Pulley Stud 4087100 Flatwasher 8 Brass 35 47967 Lens Mechanism Housing Welded Assembly 23059A STRONG Insignia 47168 GLADIATOR Insignia 45237 Insignia Roman Numeral II 47962 Rubber Light Baffle for Item 20 Shaft 36 83160 Support Casting Projection Lens 37 4080372 Screw 8 32 x 3 8 Flat Head 38 83144 Mounting Tube Projection Lens 39 44239...

Page 46: ...58 59 FIGURE 9 Item 58 Bracket mounts to back surface of Item 31 XG2 044 ...

Page 47: ...ing Blade 15 47982 Slide Assembly Masking Blade 16 4087000 Lockwasher 8 Split Ring 17 4080375 Screw 8 32 x 3 16 Pan Head 18 4257102 Flatwasher 1 4 19 51156 Friction Plate Replace with 4507106 Friction Washer 20 83134 Fadeout Pull Rod Long 21 4257000 Lockwasher 1 4 Split Ring 22 4258001 Hexnut 1 4 20 23 4107100 Flatwasher 10 Brass 24 4107001 Lockwasher 10 25 4080250 Screw 10 32 x 1 4 Pan Head 26 40...

Page 48: ... 64 Spacer early models only 49 4257000 Lockwasher 1 4 Split Ring 4257102 Flatwasher 1 4 50 4258001 Hexnut 1 4 20 51 4318004 Hexnut 5 16 18 FlexLock 52 48406 Bracket Masking Blade Control Lever 53 51153 Spacer Bushing 54 51497 Masking Blade Pull Rod Long 55 47170 Stop Bracket Iris Lever 56 4087004 Lockwasher 8 Split Ring 57 4080250 Screw 8 32 x 1 4 Pan Head 58 47966 Mounting Bracket Heat Filter Gl...

Page 49: ...on 21 37001 Roll Pin 3 32 x 9 16 21 70029 Spring Washer 24369 Bell Crank 24372 Adapter Ring 24374 Iris 25017 Bushing with 41 51530 25034 Iris Clamp 406037B Screw 6 32 x 3 8 4080621 Screw 8 32 x 5 8 41 51530 Shoulder Bolt 51451 Iris Control Handle 81432 Shoulder Screw 72 00075 Link 21 37011 81432 83773 ref Figure 9 Item 10 ...

Page 50: ...FIGURE 10 47 XG2 048 ...

Page 51: ... Screw 10 24 x 1 2 Pan Head 18 51398 Nylon Washer 19 51402 Torsion Spring UV Filter 20 51927 UV Arm Assembly 21 408037A Screw 8 32 x 3 8 Pan Head 4087000 Lockwasher 8 Split Ring 22 51465 Torsion Spring Color Arm 23 51929 Color Arm Assembly 6 11 16 24 51403 Pivot Shaft Color Arms 25 00919 Cotter Pin 1 16 x 1 2 26 4107101 Flatwasher 10 S A E 27 51922 Rocker Catch Assembly Short 51506 Rubber Pad Shor...

Page 52: ... Shaft 46 51401 Rubber Stop 47 19893 Boomerang Heat Filter Assembly 47231 Bracket 47232 Heat Filter Mounting Disc 47233 Heat Filter 46150 Assembly Clip PARTS NOT SHOWN 51913 Boomerang Housing Hinge 51471 Rubber Bumper Pad 7 x 8 4080310 Screw 8 32 x 5 16 Pan Head 4088001 Hexnut 8 32 4087004 Lockwasher 8 51355 Boomerang Housing Support Casting Rear 4080372 Screw 8 32 x 3 8 Flat Head 51864 Auxiliary ...

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