XENON POWER SUPPLY
Compact Model
Type 62-80100
Issue 12/98
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 INTERNATIONAL switching power supply Type 62-80100 is
designed to operate a xenon bulb in all theatrical lighting applications for Strong lamphouses. This
unit will operate all xenon bulbs rated from 1000 to 3000 watts throughout their full operating ranges
(20-35 V.DC, 40-100 A.DC). The power requirement for this unit is 208/230 (200-240) V.AC, 30
amperes single or three phase, 50/60 Hertz.
INCOMING LINE POWER is transformed from 208/230 volts AC to a low voltage,
high current DC output. The incoming AC line is filtered to eliminate noise and is then converted to
DC. This DC voltage is switched on and off by a solid state switching circuit, and converted to a 60
kHz. square wave. The square wave is fed into output transformers to provide low voltage and high
current. Rectifiers convert the 60 kHz. signal to DC, and the output is filtered to eliminate noise and
ripple. Output to the xenon bulb is adjustable through use of potentiometers.
A STEPDOWN TRANSFORMER reduces the incoming line to 120 V.AC to power
the lamphouse igniter and blower(s). A separate three ampere circuit breaker protects the control
circuit in the event of a lamphouse component malfunction.
PROTECTIVE CIRCUITS include a high temperature limit switch and under- and
overvoltage detection. The thermal switch will open and interrupt power supply operation if internal
temperatures exceed 175° F. (80° C.). A drop in AC line voltage, reducing AC supply to inadequate
levels, or a high voltage AC spike, will also disable the power supply until the voltage is corrected.
A MULTI-PIN MS RECEPTACLE is standard on units supplied for use with Strong
follow spotlights and projection consoles. A lamphouse termination panel may be ordered as an
option for motion picture or studio applications using Strong lamphouses without the corresponding
MS plug.
NOTICE
REFER ALL SERVICING of this unit to an authorized Strong International
Equipment Dealer. The 62-80100 Switching Xenon Power Supply employs
solid state circuitry requiring sophisticated diagnostic equipment not generally available to field service personnel. Hazardous high voltages exist within
the power supply cabinet.
1
INSTALLATION - OPERATION
CAUTION: This equipment operates at hazardous v oltages, and
should be operated by qualified, trained personnel
only.
Do not
remove power supply cover panels when the unit is energized.
When positioning the power supply, allow several inches clearance around the power
supply cabinet for unobstructed air flow. If the intake or outlet grilles are blocked, thermal switches
will shut the unit off to prevent heat damage.
Connect the lamphouse DC and control leads to the output side of the power supply
prior to connecting to AC power. Lamphouse to power supply connections, when not terminated in
a MS plug, are illustrated on the INTERCONNECTION DIAGRAM in the lamphouse instruction
manual. Make certain the lamphouse ground lead is connected.
Power leads run to the unit must be of the correct size and type to conform to local
codes. Shield in conduit as required. The power supply will not energize until the circuit breakers
on the side of the cabinet are placed in the ON position.
A four-prong, female plug is furnished to mate to the AC receptacle
mounted to the power supply. Connect 208/230 V.AC three phase input to
terminals X, Y, and Z. Connect single phase input to terminals X and Z only.
Single or three phase neutral is not required for installation of this unit. Attach
an adequate earth ground to the green ground terminal.
In areas using 380/440 V.AC three phase power (Europe, etc.),
connect the unit for single phase operation only, using (1) phase line on X and
a neutral on Z. AC input as measured across connector terminals X and Z
Ground prong
keyed
must not exceed 240 V.AC. Attach an adequate earth ground to the green
ground terminal.
See the warranty information packed with the xenon bulb for correct operating cur-
rent. Do not, at any time, exceed the maximum current level specified by the bulb manufacturer.
Current output to the bulb is set through use of the adjustment potentiometer(s). If
installed in a Strong Xenon Projection Console, the adjustment potentiometer (62-70032) is gener-
ally remoted to the console control panel. When the remote option is not utilized, a potentiometer
printed circuit board assembly (62-70028) is connected directly to the current control receptacle.
2
Check the lamphouse ammeter upon the first bulb ignition, and adjust the current con-
trol potentiometer to set the desired bulb current. On Strong projection consoles, this potentiometer
is usually remoted to the lamphouse control panel adjacent to the ammeter. Rotate the potentiometer
clockwise to increase current, or counterclockwise to reduce current. When the potentiometer printed
circuit board assembly is used in place of a remote control assembly, a second (fine) adjustment poten-
tiometer is included for output changes in small increments. The PC board is marked coarse and fine
to identify the (2) potentiometers.
The stepdown transformer for the lamphouse control circuit is factory prewired.
Terminals 2 & 4 supply 120 V.AC to the lamphouse. After completing the lamphouse interlock circuit,
the 120 V.AC returns to the power supply on wires 5 & 6 to energize the control printed circuit board
at plug PL5 upon closure of the LAMP ON switch. The same circuit (5 & 6) energizes the AC
lamphouse igniter.
A second, two-terminal barrier strip located next to the DC output terminals is in-
cluded in spotlight power supplies. Wires 7 & 8 (220 V.AC) terminate at this position, and supply
voltage to lamphouse blowers in Gladiator III spotlights through MS connector Pins I & J. These
wires are unused in Super Trouper and other spotlights, but are included to permit interchanging
power supplies between Super Troupers and Gladiators. DC output must be re-set after changing
a power supply from one system type to another. See the spotlight manual for current requirement.
The DC Pulse Igniter used in some Strong lamphouses does not require the AC control
voltage supplied on 5 & 6, but will be actuated from the high DC open circuit (no load) voltage
normally generated by the power supply. The DC voltage will fall to a lower sustaining level (20 - 35
V.DC) after the xenon bulb ignites, and the DC Pulse Igniter will cease operation when the DC voltage
drops below 130 V.DC.
Optional Lamphouse
Te rmination Panel as
supplied for units without
MS Connector Assembly.
Assembly No. 62-70030
PC Board 62-70028
Fine Coarse
DC DC
Control Circuit
Terminals
Current Control Receptacle
3
MAINTENANCE
The power supply requires very little service to insure correct operation. Periodically
check all electrical connections for tightness and condition, especially those in the DC circuit. Dis-
colored terminals may indicate oxidation which will increase resistance.
Clean the ventilation inlet and outlet grilles on a regular basis to insure good air flow.
Thermal switches mounted to the power supply will interrupt operation of the power supply in the
event of overheating.
The blower motors are permanently lubricated. The 62-80100 power supply includes
(2) blowers and requires operation of both fully functional blowers for correct operation. In the
event of a blower failure, a replacement blower must be installed immediately.
Service interruptions because of low (below 200 V.) or high (over 240 V.) AC input
require adjustments to the AC supply line. To protect the equipment, voltage level protection cannot
be bypassed.
4
INDICATOR LIGHTS
2
0
V
D
C
F
U
V
S
I
E
N
T
G
O
M
O
E
M
P
D
V
U
I
L
N
I
T
P
R
P
I
L
K
E
E
E
R
S
RESET
GREEN
RED
WHEN ALL FOUR of the green indicator lights are glowing, the power supply is
operating trouble-free. One or more red lights, when glowing, indicates that a problem exists, and
disables operation of the power supply. The red light(s) latches and remains glowing until the RESET
button is depressed after the problem has been corrected.
GREEN LIGHTS:
20 VDC: Indicates that the control board is receiving the correct DC input.
VIN: Indicates that the AC input voltage is within the correct range (200-240 V.AC).
FUSE: Indicates that the fuses on the primary boards are good.
GO: Indicates that the lamphouse interlock circuit is complete, and that DC power is being
applied to the xenon bulb.
RED LIGHTS:
TEMP: Indicates that the unit is overheated.
VIN: Indicates that AC input voltage is above or below the correct range (200-240 V.AC).
MODULE: Indicates that one or more fuses on the primary boards have opened.
STRIKE: Indicates that the xenon bulb is requiring an excessive number of ignition pulses.
RIPPLE: Indicates excessive ripple in the output current.
5
TROUBLESHOOTING
See Lamphouse Manual Before Troubleshooting Power Supply
Lamphouse Blower(s) Not Operating; Power Light ON, Circuit Breaker ON
1. Lamphouse interlock switch open. See lamphouse manual.
2. Three ampere circuit breaker is tripped. Press to reset.
3. Improper AC input connection. Check AC voltage at contactor terminals; should read 200 - 240
V.AC across input terminals (X, Y, Z for three phase; X & Z only for single phase).
4. Miswired output on terminals 2 & 4. Should read 100 - 120 V.AC; check wire numbers.
5. Defective circuit breaker. Check resistance across circuit breaker CB1 with supply OFF; should
measure 0 Ohms. Replace as required.
6. Defective filter board. Check across each leg of the filter board input and output; voltage should
measure 200 - 240 V.AC. Replace as required.
7. Defective stepdown transformer T6. Check input voltage at X & Z; should measure 200 - 240
V.AC. Check output voltage at 2 & 4; should measure 100 - 120 V.AC. Replace if defective.
8. Improper AC connections in lamphouse. Check AC voltage at 2 & 4 in lamphouse; voltage
should measure 100 - 120 V.AC; check wire numbers.
8a. Gladiator III & Ultra 80 lamphouse: wires 7 & 8 should measure 220 V.AC.
9. Lamphouse blower fuse blown (if applicable). See schematic in lamphouse manual.
10. Defective lamphouse blower. Check AC voltage at blower motor inputs; should measure 100 -
120 V.AC (Gladiator III & Ultra 80 lamphouse blower: 220 V.AC). Replace if defective.
Lamphouse Blower(s) Operate, but Power Supply GO Indicator does not glow
1. No voltage on terminals 5 & 6. Possible open interlock switch in lamphouse or power supply;
check air flow and interlock switches and interlock connections.
2. Incorrect setting of lamphouse MODE (AUTO - MAN.) switch. See lamphouse manual.
3. Faulty remote or automation contact (if using lamphouse in AUTO mode).
4. No voltage on terminals 5 & 6. Check for 120 V.AC at control PC board PL5. If no volyage,
check for loose connection or broken wire.
5. Defective control PC board. Check for 20 V.DC at U14 pin 2 & ground test point on power
supply control board. Check for 120 V.AC on PL5. If voltages present and GO light does not
glow, consult factory.
6. Power supply overheated (red TEMP light glowing; open thermal switches). Check for correct
blower operation and unobstructed air flow in power supply cabinet. Thermal switches will open
if temperatures inside the power supply cabinet exceed 175° Fahrenheit (80° Celsius).
6
TROUBLESHOOTING (continued)
Xenon Bulb Fails to Ignite; Blowers Operating, GO Indicator glowing
1. Defective or expired xenon bulb. Replace as required.
2. Incorrect igniter printed circuit board. Strong AC type igniters should be connected to high
voltage igniter PC board (Part No. 40913, 65992B, or equivalent).
3. Check DC no load output voltage. Should measure 150 - 180 V.DC; if lower, consult factory.
4. Faulty DC output connection. Check and correct as required. Tighten connections securely.
5. No DC voltage output. Blown fuse on primary board; allow power supply twenty minutes (power
OFF) to discharge capacitors before removing fuse. Good fuse should measure 0 Ohms; replace
as required. If fuse blows repeatedly, consult factory.
6. Defective igniter. Allow unit to cool and attempt re-ignition. Check DC voltage at output;
should measure 150 V.DC or higher. If voltage is correct, check DC connections in lamphouse
and power supply; tighten securely. Attempt re-ignition; if no ping is audible in the lamphouse,
replace igniter. If ping is audible, but no flash is apparent, check for lamphouse DC lead shorting
to ground. If ping is heard and arc is visible between bulb electrodes, and bulb fails to ignite,
replace bulb.
Xenon Bulb Goes Out During Operation (Intermittent Operation)
1. Defective or expired xenon bulb. Replace as required.
2. Fault in lamphouse interlock circuit (loose access door, inadequate exhaust draft). See lamp-
house manual.
3. Power supply overheated. Check for blower operation and unobstructed air flow in power
supply enclosure. Thermal switches will open if heat sink temperatures exceed 175° Fahrenheit
(80° Celsius).
4. Brown-out (voltage drop) or spike (voltage surge) in AC supply. Measure AC source.
No Output Current Adjustment
1. Defective power module. Consult factory.
Xenon Power Supplies, Lamphouse Igniters, and other components shipped to the
factory for credit, repair or repair/exchange must be returned through an authorized
Strong International Equipment Dealer. Contact your Strong International Dealer
for a Return Authorization and instructions prior to shipping any goods to Strong.
7
FIGURE 1
5
See Figure 3
1
2
3
4
6
7
8
9
10
11
12
13
8
(+)
(-)
PARTS LIST
Figure 1
Item Part No. Description
1 62-40121 Top Cover Panel
2 62-40095 Side Panel (Left)
3 62-40123 Vented Panel, Rear
4 62-40101 Rear Panel Bracket
5 62-80105 Power Module (See Figure 2)
6 62-40096 Base Plate
7 62-40098 Brace Panel
8 62-40102 Vented Panel, Front
9 62-40118 Side Panel (Right)
10 77271000 Handle, Spring-Loaded
11 62-40097 Front Panel Bracket
12 41-51540 Panel Mounting Screw, 8-32 x 3/8"
13 62-80036 Name & Data Plate
9
FIGURE 2
1
2
3
4
5
6
7
8
9
10
11
12
13
5
14
15
16
17
18
17
19
10
PARTS LIST
Figure 2
Item Part No. Description
1 62-00006 Upper Shield, Silk Screened
2 41-51032 Screw, 6-32 x 1/4" Bind Head
- 41-70012 Lockwasher, #6
3 61-98031 Spacer, #6 x 1/4"
4 41-51728 Screw, 6-32 x 1" Brass
5 62-20021 Insulated Support
6 41-51197 Screw, 8-32 x 1/2" Socket Head
7 62-70015 Primary Module Assembly
- 81-21001 Fuse, 15 Ampere (2 reqd.)
8 62-20027 Primary Buss Bar
9 62-70020 Secondary Module Assembly
10 62-20028 Output Buss Bar
11 41-35060 Locknut, 1/4-20
- 61-70002 Spring Washer
12 41-51032 Screw, 6-32 x 1/4" Bind Head
13 62-40093 Lower Shield
14 41-51413 Screw, 6-32 x 5/8" Phillips Head
15 62-40094 Fan Panel
16 61127000 Fan Clip, 6-32
17 61-98002 Fan, 115 V.AC, 50/60 Hz.
18 88253000 Cord & Molded Plug
19 41-51540 Screw, 8-32 x 3/8" Phillips Head
11
FIGURE 3
1
2
3
5
6
7
87
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
4
12
CURRENT CONTROL (to Item 18):
62-70028 Plug-In PC Board Assembly (no Cable)
62-70032 Potentiometer & Cable Assembly (Remote)
PARTS LIST
Figure 3
Item Part No. Description
1 61-71013 Ribbon Cable Assembly
2 61-72015 Control Printed Circuit Board Assembly
3 62-40120 Chassis, Control PCB
4 21-10003 Wire Tie Mount, Self-Adhesive
5 61-61002 Circuit Breaker, 3 Ampere 1 phase
6 61-30001 Indicator Light, Red
7 61-61001 Circuit Breaker, 30 Ampere 3 phase
8 62-40116 Circuit Breaker Mounting Panel
9 41-10029 Cable Clamp, Nylon
10 61-17001 Diode Bridge
11 41-51078 Screw, 8-32 x 7/8" Bind Head
12 62-40122 Chassis Bracket
13 62-70023 Stepdown Transformer, AC Control
14 61-98035 Line Filter
15 41-98045 Grommet
16 62-70026 LEM Harness
17 62-40128 MS Receptacle Mounting Panel
18 61-13007 Amphenol Plug, (15) Pin
19 62-70025 MS Connector, Wired Assembly
- 88319000 MS Receptacle, (14) Pin Female
20 62-40116 Mounting Plate
21 61-40007 AC Input Receptacle, 30 Ampere Hubbell
22 41-51540 Screw, 8-32 x 3/8" Phillips Head
23 41-51413 Screw, 6-32 x 5/8" Phillips Head
24 41-51021 Screw, 4-40 x 1/2" Bind Head
25 51-56002 Nylon Spacer
26 41-35003 Hexnut, 4-40
- 41-70011 Lockwasher, #4
NOT SHOWN
62-70021 Wire Harness Assembly
62-70030 Lamphouse Termination Panel (see Page 3)
62-40109 Cover, Lamphouse Termination Panel
61-98039 Strain Relief Bushing, Cover
41-35088 Locknut for Bushing
13
FIGURE 4
DB 15 Connector
Pin #
1. Com Signal
2. I Signal (20mv/a)
3. GO Signal Input
4. Power Section Fault
5. Inhibit Fault
6. (not used)
7. +9 V.
8. +9 V. Return
9. V Signal (20 mv/v)
10. +9 V. Return
11. +9 V.
12. Enable Fault
13. (not used)
14. I Adjust Fine
15. I Adjust Coarse
CONTROL PC BOARD, Component Functions
14
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