Strong Ultra 80 Instruction Manual
ULTRA 80
Xenon Lamphouse
Type 40001, 40002
Rev. 5/99
STRONG INTERNATIONAL
a division of Ballantyne of Omaha, Inc.
4350 McKinley Street
Omaha, Nebraska 68112 USA
Tel 402/453-4444 • Fax 402/453-7238
PREFACE
THE STRONG ULTRA 80 is a reflector type, direct current lamphouse for large format (70mm+) motion picture projection which uses a horizontally mounted xenon bulb as the light
source. Type 40001 is designed for use with the XH7000HS xenon bulb, and Type 40002, for the
XH10000V(H) bulb. Both type bulbs are manufactured by the Hanovia Division, ORC Lighting
Products, Azusa, California. The lamphouse reflector is a metal, deep ellipse type, with a “cold”
(dichroic) coating to reduce aperture heat and prolong bulb life. The reflector is designed to operate
in a fixed position 34½ to 35 inches from the projection film plane.
USE ONLY THE SPECIAL XENON POWER SUPPLIES manufactured by Strong
International. The 40001 lamphouse requires a power supply capable of providing 120-160 DC amperes at 43-49 V.DC. Nominal operating current for a 7000 watt bulb is 150 amperes; do not exceed
160 amperes. The xenon power supply used with the 40002 lamphouse must be capable of producing
135-200 DC amperes at 52-58 V.DC. The nominal operating current of a 10,000 watt bulb is 180
amperes; do not exceed 200 amperes. The xenon power supply must also include a 120 V.AC
lamphouse control circuit.
THE ADJUSTMENT CONTROL to position the xenon bulb in relation to the reflector is located on the rear of the lamphouse, behind the removable cover panel. This control permits
horizontal and vertical movement and focus control of the xenon bulb.
A TERMINAL STUD, located near the bulb anode support on the base pan of the
lamphouse, is provided as a connecting point for the lamphouse DC (+) lead and the anode lead
attached to the xenon bulb.
THE LAMPHOUSE CONTROL PANEL includes a DC ammeter to display the
operating current of the lamp. A pushbutton switch above the ammeter changes the reading to indicate the DC voltage at the arc. This capability permits calculation of the lamp power while the lamp
is operating (amperes x volts = wattage). Pressing the switch at ignition will also briefly display the
“no load” DC voltage.
AN ELAPSED TIME METER indicates the total number of hours the lamp has been
in service and provides a means of noting the number of hours each xenon bulb has operated. It is
advisable to replace the xenon bulb upon expiration of warranty hours. See the warranty information
provided by the manufacturer of the xenon bulb.
THE LAMP BLOWER(S), internally wired in the lamphouse, operate on AC voltage
and are required to maintain the seals of the bulb at a safe operating temperature. The top blower is
fused at 3 amperes. A second side-mounted blower is used on the T ype 40002 to cool the reflector for
10,000 watt operation. The blowers will operate continuously until control voltage is turned off at the
xenon power supply .
U80/001
TWO AIR FLOW SWITCHES, mounted to the exhaust duct and the blower intake,
will prevent ignition of the lamp if the top blower is not operating, or the exhaust air flow is inadequate. The eight-inch lamphouse exhaust stack connects to an externally installed exhaust system.
The exhaust system must be capable of removing 700 cubic feet per minute (c.f.m.) of free air from the
lamphouse, as measured at the lamphouse exhaust outlet.
THE LAMPHOUSE has an interlock switch on the side access door and one under the
igniter cover on the top of the lamphouse. Opening the side door or removing the plastic igniter cover
will open the AC control circuit and prevent operation of the xenon lamp. The lamphouse door has a
viewing port to permit observation of the xenon arc.
THE IGNITER is equipped with an emergency ignition switch, located beneath the
plug button on the igniter access panel on the top of the lamphouse.
THE “MODE” rocker type switch on the rear of the lamphouse provides the means of
operating the equipment from a remote AUTO system, or when placed in the “MAN.” position, from
the lamphouse.
THE LAMP “ON - OFF” SWITCH on the lamphouse instrument panel is used for bulb
ignition when the MODE switch is in the “MAN.” position. For AUTO operation, the LAMP switch
remains in the “ON” position.
THE LAMPHOUSE DOUSER is provided to permit shutting off the light to the projector at changeover. The lamp should not be operated for any extended time with the douser closed.
The small intense spot of light on the douser plate may cause deterioration of the plate. An Electric
Douser Kit, connected to the projector motor, is available as an option. This option automatically
closes the douser when the projector motor is switched OFF.
THE ULTRA 80 is not designed for use with 35mm projection. The highly intense
radiant energy generated by high wattage xenon bulbs will damage 35mm prints.
IF AT ANY TIME you have a suggestion, or desire aid in securing anticipated results,
write STRONG INTERNATIONAL, 4350 McKinley Street, Omaha, Nebraska 68112.
U80/002
ULTRA 80 LAMPHOUSE
1. Exhaust Stack, 8 inch 6. Lamphouse Access Door
2. Douser Plate 7. Rear Casting & Instrument Panel
3. Douser Control Handle 8. Magnetic Door Catch (early models)
4. Tamperproof Screw 9. Emergency Ignition Switch*
5. Arc Viewing Port 10. Bulb Seal Blower
* Emergency Ignition Switch located below Plug Button on Access Plate.
U80/003
MECHANICAL LAMPHOUSE ALIGNMENT
ONE ALIGNING KIT consisting of an aligning cord, aperture plate, dummy lens, and
centering plug is supplied with each lamphouse to provide an accurate and reliable method of optical
alignment of the lamphouse to the projector mechanism. Because of the relatively small arc produced
by the xenon bulb, good screen results can be obtained only by the careful use of this aligning kit.
PLACE THE LAMPHOUSE on the projection pedestal, making certain that it is centered between the ways. Open the side access door.
IF USING the optional Heat Filter, the filter holder bracket should be installed onto
the lamphouse before aligning the lamphouse to the projector. Do not insert the filter until the following aligning procedure has been completed.
POSITION THE LAMPHOUSE on the table so the center of the reflector measures as
near 34.5 inches from the projector aperture as the projector design will permit.
IN PREP ARATION for optical alignment, bolt the lamphouse temporarily to the pedestal table using the 5/16-18 cap screws shipped with the lamphouse accesssory kit.
U80/004
INSERT THE CENTERING PLUG into the reflector opening, and secure the cord
behind it as illustrated. Place the aligning tube on the anode support yoke and run the cord through it.
Open the douser.
REMOVE THE PROJECTION LENS and pull the cord through the lens barrel. Pass
the cord through the dummy lens and tie the cord to an object of sufficient weight to hold the cord
taut. Position the test aperture as illustrated in the film trap of the projector. Close the film gate to
hold the test aperture in place.
MOST PROJECTOR BASES have adjustable lamphouse tables so the lamp can be
brought into optical alignment with the projector mechanism. If the lamphouse table is not adjustable,
use shims or washers at the front, rear, or at both ends of the lamphouse to obtain optical alignment to
the projector.
ALIGN THE LAMPHOUSE in relation to the projector so the cord passes through
the center of the hole in the test aperture, and the correct cord image is seen on the reflector. Set the
anode support yoke as illustrated and tighten the set screw in the air duct. DO NOT reposition the
reflector, as it is factory prealigned for maximum optical ef ficiency .
ONCE CORRECT ALIGNMENT is achieved, tighten the lamphouse mounting screws
to secure the lamphouse to the table. Remove the cord and associated fixtures and restore the operation of the fire shutter.
STORE THE ALIGNING KIT in a secure location in the projection booth. If the
Ultra 80 reflector is ever removed or replaced, it is necessary to repeat the entire cord alignment
procedure, Likewise, if a different type or wattage bulb is used in a subsequent relampment, it may be
necessary to re-align the anode yoke to position it for the optical center of the replacement bulb.
U80/005
EXHAUST SYSTEM INSTALLATION
THE EXHAUST DUCT of the Ultra 80 is designed to fit an eight inch diameter
exhaust duct. This size ducting, either rigid or heat-resistant flexible, must be used throughout the
complete exhaust system. The exhaust system must be vented to outside air, and installed in such a
manner as to eliminate any possibility of downdraft or rain dripping into the lamphouse.
THE EXHAUST F AN must be capable of removing 700 cubic feet per minute (cfm) of
air, as measured at the exhaust outlet of the lamphouse. If more than one lamphouse is connected to
a common exhaust system, each individual lamphouse must meet the 700 cfm requirement.
IF THE EXHAUST AIR FLOW must be restricted for any reason, install bypasses
rather then dampers in the exhaust line.
Bypass
(as req’d.)
(700 cfm) (700 cfm)
CHECK EACH LAMPHOUSE for correct exhaust air flow . Insufficient exhaust draft
can severely shorten bulb life, and no credit will be allowed bulbs damaged in this manner . Inadequate
exhaust may also cause possible injury to personnel by overheating the lamphouse enclosure.
THE XENON BULBS approved for use in the Ultra 80 are designated as ozone free.
See “BULB INSTALLATION AND OPERATION.”
U80/006
LAMPHOUSE - POWER SUPPLY INTERCONNECTION DIAGRAM
Ultra 80
U80/007
WIRING INST ALLATION
THE LAMPHOUSE LEADS must be connected to the xenon power supply as illustrated on the Installation Diagram.
CONNECT THE TWO HEAVY FIBREGLASS INSULATED LEADS to the DC
outputs in the power supply. Observe correct polarity; red to positive (+), black to negative (-).
Tighten connections securely to prevent overheating. Leads 2, 4, 5, and 6 provide the 115 V.AC
control circuit between the lamphouse and power supply, and wires 7 & 8 (220 V.AC) power the
lamphouse blower. Connect them to their corresponding numbered terminals on the barrier strip in
the power supply cabinet.
COLOR CODE:
Brown #2
Red #3
Orange #4
Blue #5
Yellow #6
Grey #7
Black #8
BECAUSE OF HIGH VOLTAGES impressed during the ignition cycle, the xenon
lamphouse must be grounded. Connect the ground lead in the cable assembly (#8 AWG green) to the
terminal lug in the power supply cabinet. Make certain that the power supply is connected to an
adequate earth ground.
IF AUTOMATED or remote lamphouse switching is desired, it is generally more convenient to make such connections to the power supply barrier strip (3 & 6) as illustrated. See the
“AUTOMATION SYSTEMS” section following for detailed instructions.
ALL LEADS may be run in conduit or greenfield if desired, or if required by local
code. This may also be necessary as shielding to prevent electrical interference in the theatre sound
system.
IT IS RECOMMENDED to establish a routine of periodically checking all electrical
connections for tightness. Loose connections, particularly in the DC circuit, are subject to hazardous
overheating.
U80/008
SAFETY PROCEDURES
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 mishandled.
REFER bulb 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:
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 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 shorten bulb life. If fingermarks are made,
they should be carefully removed with methyl alcohol and cotton prior to bulb operation.
5. Never view an ignited bulb directly. BLINDNESS OR PERMANENT EYE DAMAGE MAY BE
INCURRED.
6. Use only xenon bulbs designated as OZONE FREE. When possible, vent the lamphouse exhaust to
outside atmosphere.
7. Maintain the lamphouse blower in good operating condition. Keep the blower inlet clean for unre-
stricted air flow .
8. To insure maximum bulb life, operate the lamphouse blower and the exhaust system for at least ten
minutes after extinguishing the bulb.
9. If returning a bulb for warranty adjustment, pack it in its original shipping container. Complete and
return all required warranty information.
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 A TTEMPT ANY PHASE
OF XENON BULB HANDLING OR SERVICE.
Cathode Pin
Cathode
Seal
Cathode End Cap
U80/009
Anode
Envelope
Anode End Cap
Seal
Anode Pin
BULB INSTALLATION AND OPERATION
OBSERVE ALL SAFETY PROCEDURES. Bulb installation and replacement must
be performed by QUALIFIED PERSONNEL with protective clothing and face shield.
THE XENON BULB requires no adapters to mount in the Ultra 80. All bulb mounting fixtures and electrical connections are designed for use with the designated xenon bulb (7000 watt
for 40001; 10,000 watt for 40002). A silastic rubber tube is supplied with each lamp to permit insulating the bulb anode lead from the lamphouse base or other grounded metal components.
INSERT THE CATHODE (-) end of the bulb through the hole in the center of the
reflector. Seat the cathode pin into the cathode support collet as far as possible to permit full focus
travel of the bulb. Rest the anode (+) stem in the front support yoke and dress the anode lead directly
in front of the air duct. Securely tighten the socket head screw in the cathode clamp, taking care not
to apply any mechanical strain to the bulb vessel. Remove the hexnut, washer, and lockwasher from
the anode binding post in front of the reflector. Connect the anode lead to the binding post and tighten
securely .
Igniter Lead
Cathode Clamp
Cathode
Clamping Screw
Anode
Front Bulb Support Yoke
Bulb Anode Lead
Air Duct Casting
TOWARD
SCREEN
Set Screw
OBSER VE CORRECT POLARITY
REMOVE THE PLASTIC PROTECTIVE COVER (when applicable) from the bulb.
Close and secure the lamphouse door. Turn on the exhaust system. Place the MODE switch in the
“MAN.” position and close the douser.
U80/010
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