XENON SUPER TROUPER
Follo w Spotlight
Type 83050, 83070
Rev. 11/99
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 XENON SUPER TROUPER is a direct current follow spotlight
system complete with a xenon lamphouse, power supply, optical system, base and yoke assembly,
and six-color boomerang.
ONLY THE SPECIAL XENON POWER SUPPLIES manufactured by Strong
International can be used with the xenon spotlight. For installation and operation of the power supply,
see the manual furnished separately.
THE XENON LAMPHOUSE utilizes a deep ellipse dichroic metal reflector designed
to operate in a fixed position with a horizontally mounted xenon bulb as the light source. A heat filter
is located in the front of the lamphouse to reduce the heat at the optical system and color boomerang.
ONLY XENON BULBS designed for horizontal operation should be used in this spotlight. The presently approved ratings for bulbs used in this spotlight are 1000, 1600, and 2000 watt.
See the listing in this manual for the approved types and necessary adapters.
ADJUSTMENT CONTROL for positioning the xenon bulb is located at the rear of
the lamphouse. The adjustments are for the horizontal, vertical, and focus control of the bulb.
THE LAMPHOUSE INSTRUMENT PANEL is equipped with an ammeter and
running time meter. The ammeter indicates the operating current of the lamp, and the running time
meter records the number of hours the lamp has operated.
THE BULB is ignited and extinguished by use of the LAMP switch mounted on the
instrument panel. Remote ignition switching is accommodated by wiring a five ampere dry contact
across wires 3 & 6. See the Interconnection Wiring Diagram.
THE LAMP BLOWER, internally wired in the lamp, operates on 115 V.AC and is
required to keep the seals on the bulb at a safe operating temperature. This blower will operate
continuously until power is turned off at the main line switch to the xenon power supply. An air flow
switch in the lamphouse prevents operation of the xenon lamp if the blower is not operating, or the
airflow is inadequate.
THE LAMPHOUSE is supplied with a 13 foot cable containing the two DC leads, the
ground lead, and all AC control leads. The cable terminates in a multiple pin MS connector to mate to
the receptacle on the power supply.
WHEN TRANSPORTING the follow spotlight, it is recommended that the xenon bulb
be removed from the lamphouse and placed in its original shipping carton with the cover on the bulb to
prevent breakage.
XST/001
LAMPHOUSE - POWER SUPPLY
LAMPHOUSE
(Connections Pre-wired)
Interconnection Diagram
MS CONNECTOR
Pin Wire No,
A DC B DC+
C 2
D 3
E 4
F 5
G 6
I 7
J 8
M Grnd
Lamphouse
Cable Assembly
SYSTEM MUST BE GROUNDED
All wiring must conform to local
codes; shield lamphouse cable in
conduit if required.
Grn
Conduit
XENON
POWER
SUPPLY
MS Connector (pre-wired)
DC+
DC-
Ground Lug
(as req’d. for older units)
Remote - Auto
Sustained 5 Amp.
Dry Contact
(by Installer)
XST/002
INSTALLATION AND SETTING UP SPOTLIGHT
THE XENON SUPER TROUPER is shipped in sections which must be assembled.
The Folding Base Stand Assembly 65826 (if supplied; see Figure 6A) is shipped collapsed, and requires only folding down and pinning the base legs. The following paragraph applies only to the rigid
base assembly 83793 (see Figure 6).
ASSEMBLE the four base legs to the square section of the center tube using the 3/816 x 2-3/4 inch hex head cap screws and lock washers supplied. Insert a leveling foot and locknut in
each of the four leg brackets and level the base before proceeding with the installation.
WHEN INSTALLED in a permanent location, the leveling feet must be removed, and
the clearance holes in the base leg brackets used for hardware (user supplied) to bolt the base to the
floor or platform. If it is desired to have the unit portable, when operating, the leveling feet must be
adjusted down until the weight of the spotlight has been shifted from the casters to the leveling feet.
THE INNER TUBE and support yoke has three holes to permit adjusting the height of
the spotlight. The three holes are on four inch centers and will allow an optical height of approximately
53 inches, 57 inches, and 61 inches above floor level to the optical center of the lamphouse and lens
system. The leveling feet may be adjusted 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 lamphouse and lens system on the support yoke.
PLACE THE LAMPHOUSE and lens system on the yoke assembly, with the spot size
control handle to the right hand (operating) side, the same as the locking controls on the yoke. Line up
the four mounting holes in the bottom of the base rail with the four mating holes in the support yoke
and secure with the four 5/16-18 wing screws.
ATTACH THE COLOR BOOMERANG to the front of the optical system by inserting
the hinge pin through the hinge on the boomerang and optical system. Fasten the boomerang yoke to
the slotted angle bracket on the underside of the optical system pan. Adjust and securely tighten the
wing nut and lock nuts to hold the boomerang parallel with the front of the optical system housing.
ATTACH THE LAMPHOUSE CABLE connector to the receptacle on the power
supply. Align the pins before tightening the locking ring. Early model lamphouse cables include a
separate ground lead; secure the green ground lead to the ground terminal on the outside of the
power supply housing. Do not energize the xenon power supply before first installing the xenon
bulb into the lamphouse.
XST/003
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 ATTEMPT ANY PHASE
OF XENON BULB HANDLING OR SERVICE.
Anode End Cap
Envelope
Anode Pin
Seal
Anode
XST/004
Cathode End Cap
Seal
Cathode
Trigger Wire
Cathode Pin
1. Fade-Out Mechanism Control Lever
2. Masking Shutter (Chopper) Control Lever
3. Iris Control Lever
4. Spot Size Control Handle
5. Color Boomerang
6. Spot Focus Knob
7. Leveling Foot
8. Horizontal Swing Control Lever
9. Vertical Tilt Control Lever
10. Lifting Strap
11. Cap, Exhaust Stack
XST/005
EXHAUST SYSTEM INSTALLATION
IF THE SPOTLIGHT is installed in a closed booth, it is recommended to vent the
lamphouse exhaust to outside atmosphere to remove the heat from the booth.
THE EXHAUST STACK of the lamphouse is designed to fit a six-inch diameter duct.
The exhaust system must be designed and installed is a way to eliminate any possibility of a down draft
or of rain dripping into the lamphouse. The exhaust fan must be capable of removing 750 lineal feet
(150 cfm) of air per minute at each lamphouse.
TO PERMIT MOVEMENT of the follow spotlight, install a section of six-inch diameter flexible tubing between the lamphouse exhaust stack and the projection booth exhaust system.
The two holes in the stack exposed by removing the vent cap can be used to secure the tubing.
IF THE INSTALLATION is to be made in a location where it is not possible to install
an exhaust system, leave the vent cap mounted to the exhaust stack.
THE RADIATION from some xenon bulbs can convert the oxygen in the surrounding
air to ozone. In large quantities, ozone can endanger health, but it spontaneously changes back into
oxygen in a very short time, especially if it mixes with a large volume of air (as in an auditorium, arena,
or outdoors). Most currently manufactured xenon bulbs are classified as ozone free and do not release
ozone.
XST/006
1. Cap, Exhaust Stack
2. Top Cover, Lamphouse
3. Access Panel, Igniter
4. Cover, Bulb Adjust
5. Current Control (early models)
6. Elapsed Time Meter
7. Ammeter
8. MODE Switch (AUTO-MAN.)
9. LAMP Switch (ON-OFF)
XST/007
BULB ADAPTERS, 1000 & 1600 WATT BULBS
XST/008
1 65199 65199 65259 65403
2 00720 00720 00720 00720
3 XBO1000W/HS XBO1600W/HS XH1000HS XH1600HS
Item No. OSRAM 1 kW OSRAM 1.6 kW Hanovia 1 kW Hanovia 1.6 kW
4 65198 65198 65198 65198
BULB INSTALLATION
CAUTION: OBSERVE ALL SAFETY PROCEDURES. Put on the protective face
mask. Wear clean cotton gloves to prevent marking the quartz envelope of the bulb with fingerprints.
REMOVE THE TOP COVER of the lamphouse by removing the four Holt head
(tamperproof) screws with the special screwdriver provided.
NO BULB ADAPTERS are required to install the 2000 watt bulb in the 83070 Xenon
Super Trouper lamphouse. Adapters used to install the 1000 watt or 1600 watt bulb in the 83050
lamphouse are supplied in the accessory kit. See the Bulb Adapter Chart for the correct adapters and
sequence of assembly.
ASSEMBLE THE REQUIRED ADAPTERS to the 1000 or 1600 watt bulb prior to
inserting the bulb into the lamphouse. Be very careful not to apply any strain on the quartz envelope
when installing adapters. Screw the threaded cathode adapter on the negative stud so it seats firmly
against the shoulder of the (-) end cap. Slip the anode adapter with set screw over the positive stud,
up to the shoulder of the (+) end cap. Tighten all fasteners securely to insure a good electrical connection.
REMOVE THE PLASTIC PROTECTIVE COVER from the xenon bulb only if necessary. Insert the bulb through the top of the lamphouse, between the reflector support and the front
casting. Pass the anode (+) end of the bulb through the hole in the reflector, taking care not to touch
the surface of the reflector.
INSERT THE ANODE ADAPTER STEM of 1000 and 1600 watt bulbs into the rear
support collet. The stem must be inserted as far as possible to permit full focus travel of the bulb.
Place the cathode adapter into front bulb support, pivot the retaining plate to its closed position, and
tighten the (2) thumb screws. Tighten the socket head clamping screw in the anode contact securely
to insure a good electrical contact.
INSTALL THE CATHODE LEAD CONTACT over the end of the cathode adapter
up to the shoulder of the contact and tighten the clamping screw securely. Lay the lead in front of the
air duct to minimize the shadow.
THE 2000 WATT bulb mounting components include a shock mount support at the
front of the lamphouse. Insert the 2000 watt bulb through the top of the lamphouse, passing the anode
(+) end through the hole in the reflector. Pass the anode pin as far as possible to the rear of the
lamphouse to permit sliding the cathode (-) end cap through the ring of the shock mount. Insert the
anode pin into the bulb support collet and firmly tighten the socket head clamping screw. Slide the
cathode contact clamp over the cathode pin and tighten securely.
XST/009
AN ALTERNATE METHOD of installing the 2000 watt bulb is to dismount the shock
mount ring from the front bulb support assembly by removing the socket head screw. Slide the ring
over the cathode (-) end cap of the bulb, and install the bulb by inserting the anode (+) end cap through
the reflector center hole and seating the anode pin into the rear support collet. Re-mount the ring to
the base of the front bulb support using the socket head screw. Secure the anode (+) clamping screw;
install and tighten the cathode (-) contact clamp.
THE SOCKET HEAD SCREW which mounts the bulb support ring to its support
bracket must be tightened securely enough to clamp the upright bulb support ring in a vertical (90°)
position and prevent its tilting forward or back as the bulb is focused. The end cap of the bulb should
touch only the coils of the shock mount spring to allow the bulb to slide forward and back with a
minimum of friction and no stress on the quartz envelope.
OBSERVE THE POSITION of the Trigger Wire on the 2 kW xenon bulb relative to
the point where the bulb passes through the center hole of the reflector. Some bulb manufacturers
attach one end of the trigger wire to the anode end cap; if this trigger wire approaches the reflector too
closely, the DC current will follow this path to ground and prevent bulb ignition. To avoid this, detach
the trigger wire from the anode end cap and loop it around the bulbous portion of the envelope as
illustrated on the line drawing at the end of the SAFETY PROCEDURES page.
XENON BULBS WITH LEADS may be used in the lamphouse. A terminal stud
located on the air duct casting has been provided for connecting a bulb cathode lead with the negative
lamphouse lead. Remove the contact and clamp from the negative lamphouse lead. Attach the lamphouse lead and bulb lead in contact with each other, under the hex nut on one side of the terminal stud.
This stud should not be used as a feed-through terminal.
AN ANODE LEAD attached to a bulb must be coiled around the bulb adapter and
secured to the igniter lead with the 1/4-20 x 3/8" head head cap screw used to connect the igniter lead
to the contact clamp. The socket head clamping screw must be tightened to fix the position of the bulb.
IT IS RECOMMENDED to establish a routine for periodically checking all electrical
connections for tightness, particularly those at the bulb. A loose connection in the DC circuit will
cause failure of the contacts and leads, and may destroy the bulb.
THE REFLECTOR is optically positioned at the factory. Do not alter the position of
the reflector by adjusting the tie rod located in the upper corner of the lamphouse.
XST/010
65198
XBO1000W/HSC;
XBO1600W/HSC
(with Anode Lead)
BULB MOUNTING - OSRAM TYPE “HSC”
Two Turns
Bulb Anode Lead
NOTE:
00805 Hexnut
00710 Set Screw
Clamp
65359 Adapter
over brass socket in rear support collet.
1. Dismount Contact Clamp from Igniter Lead. Slide Clamp
Igniter
from grounded
Igniter Output Lead
CAUTION: Dress lead
away
lamphouse components
both 00710 Set Screws.
2. Attach Adapters (65198 & 65359) to Bulb. Securely tighten
3. Install Bulb as instucted in preceding section.
Adapter using Two Turns.
4. Tighten rear clamping screw; wrap Bulb Lead around 65359
1/4-20 screw removed from the Contact Clamp (Step 1)
and a 00805 Hexnut. Dress well away from back casting.
5. Connect Igniter Lead to ring terminal of Bulb Lead using the
XST/011
01532
65410
83747
00687
Position Ring at 90° (as shown)
00389
and tighten Clamping Screw
2000 WATT BULB INSTALLATION
65131
OBSERVE CORRECT POLARITY
REAR OF LAMPHOUSE
65844
01532
2000 Watt Operation: 75 Amperes Nominal
DO NOT EXCEED 90 AMPERES
00687 Lead Mounting Screw
01532 Clamping Screw
00389 Bulb Support Mounting Screw
65131 Anode (+) Contact Clamp
65410 Cathode (-) Contact Clamp
65844 Rear Bulb Support Collet, 2 kW
Part No. Description
83747 Front Bulb Support Assembly
NOT SHOWN
65948 Negative (-) Lead Assembly
65966 Positive (+) Lead Assembly
XST/012
OPERATION
REMOVE THE PLASTIC COVER from the xenon bulb. Do not ignite the lamp with
the cover on the bulb.
A GLASS HEAT FILTER is supplied to reduce the temperature at the optical system
and color gels. Insert the heat filter in the bracket provided on the inside of the lamphouse at the front
opening. Place the filter in position with the coated surface facing the bulb. The coated surface is
indicated by a small XX or other marking. This filter is a narrow strip that covers only the center
portion of the beam. To prevent damage to optical system components, do not operate the spotlight
with the filter removed or reversed.
SECURE THE LAMPHOUSE COVER with the (4) tamperproof screws using the
special screwdriver provided. The cover must be securely in position to actuate the interlock switch
and permit lamp ignition.
PLACE THE MODE SWITCH (on units so equipped) in the “MAN.” position and
energize the xenon power supply. The lamphouse blower will start and actuate the blower interlock
switch to permit bulb ignition. This lamp blower will operate continuously until the xenon power
supply is de-energized.
PLACE THE LAMP SWITCH in the ON position and the xenon bulb will ignite.
Allow a few minutes for the current to stabilize, and read the lamphouse ammeter. The bulb must be
operated within the current range specified by the bulb manufacturer. The ranges for the Hanovia bulb
supplied with the unit are as follow:
WATTAGE NOMINAL CURRENT DO NOT EXCEED
1000 50 A. 58 A.
1600 65 A. 70 A.
2000 75 A. 90 A.
ADJUST THE POWER SUPPLY as instructed in the power supply manual for the
correct operating current. The current setting must be increased in time to compensate for bulb aging,
but do not, at any time, exceed the maximum current rating.
REMOVE THE REAR COVER PANEL (two pull-type knobs) to expose the bulb
position adjustment control.
THE CENTER SECTION of the control is a threaded member that focuses the bulb in
relation to the reflector. Turning this adjustment moves the bulb on the horizontal plane, into or out of
the reflector. Rotating this section clockwise moves the bulb away from the reflector. The small
knurled screw to the left of this section can be tightened to lock the focusing mechanism in place after
the bulb alignment procedure has been completed.
XST/013
THE THUMB SCREWS to the left and right of the focusing control lock the horizon-
tal and vertical position of the bulb.
BULB ADJUSTMENT CONTROLS
Thumb Screw Focus Control
Focus Lockscrew
TWO METHODS, detailed following, are recommended to align the bulb in order to
project the best light to the stage.
MOVE THE SPOT SIZE CONTROL HANDLE on the large lens carriage to the
forwardmost position to project the smallest spot possible with the iris, choppers, and dimming control in the full open position. Project the spot to a wall or similar flat perpendicular surface opposite
the spotlight.
TURN THE CENTER FOCUS CONTROL counterclockwise until a small black spot
is projected on the wall. It may be well to run this adjustment both directions to permit positive
identification of the dark spot.
LOOSEN THE TWO THUMB SCREWS to the left and right of the focus control just
enough to permit manual movement of complete control assembly. Move the control assembly around
the two thumb screws and observe the smooth dark shadow of the bulb electrode inside the shaded
circle of the reflector center opening. The shadow of the electrode must be centered in the projected
opening of the reflector.
MOVE THE CONTROL ASSEMBLY around the thumb screws until the dark electrode shadow is as round as possible to project. It may be necessary to again rotate the focus control
to define the electrode shadow.
AFTER THE ELECTRODE SHADOW is as even around the outside as possible,
tighten the two thumb screws to lock this adjustment in place, and rotate the focus control to obtain
the brightest light with the best light distribution. Turn the spot focus control knob, located on the
front of the lens mechanism, to sharpen the edge of the spot.
THE SECOND METHOD of aligning the xenon bulb is to project the spot to the
stage, and using the bulb adjustment controls, obtain a “hot spot” in the projected spot. Center this
“hot spot” in the projected spot by moving the entire control section around the two thumb screws.
XST/014
Once the “hot spot” is centered in the projected spot, lock the adjustment control in position with the
two thumb screws and rotate the focus control to obtain a spot with an even distribution of light. Turn
the spot focus control knob at the front of the lens mechanism to sharpen the edge of the spot.
THIS ADJUSTMENT should not be disturbed until the xenon bulb is replaced. At this
time it will be necessary to repeat the alignment procedure.
REPLACE THE REAR COVER PANEL over the bulb adjustment control mecha-
nism. Secure using the plastic fasteners.
BECAUSE OF MANUFACTURING TOLERANCES and normal bulb aging, it may
be necessary to operate one lamp at slightly higher or lower current than others to obtain equal light
balance between units. These adjustments are made at the xenon power supply.
TO EXTINGUISH THE ARC, place the LAMP switch in the OFF position. The
blower in the lamphouse will continue running until the xenon power supply is de-energized. Allow
the blower to operate and cool the bulb for at least five minutes after extinguishing. This measure will
prolong bulb life.
TO OPERATE THE SPOTLIGHT from a remote location or an automation controller, the lamphouse must be equipped with the MODE (Auto-Man.) switch. With the MODE
switch in the “AUTO” position, and the LAMP switch “ON,” the lamphouse will ignite by means of
a dry contact across terminals 3 and 6 at the lamphouse or power supply (See Lamphouse-Power
Supply Interconnection Diagram). This type of installation is intended for use only if the spotlight is
“locked down” as a fixed spot without an operator at the unit.
XST/015
HANDLING THE SPOTLIGHT
GENERALLY THE BEST POSITION for the operator to stand is near the center of
the spotlight, on the right hand side, although the angle of tilt and the size of the porthole may alter the
position for the most convenient operation.
EACH OPERATOR will, after a few minutes of operation, generally develop his own
system and position for operating the unit.
THE HORIZONTAL SWING LOCK LEVER and vertical tilt lock lever located on
the base assembly can be set to give the desired amount of friction on the spotlight swing to suit the
individual operator.
THE LENS CARRIAGE FRICTION BRAKE is a nylon drag screw located on the
outrider of the large lens carriage, and is preset at the factory for most satisfactory operation. Individual requirements may vary, and the brake can be adjusted to best suit the operator or allow for a
severe “down” angle. Remove the color boomerang and lens mechanism housing, loosen the nylon
lock nut and adjust the screw on the friction brake to apply the desired tension. Tighten the lock nut
and replace the housing and boomerang.
XST/016
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 right.
THE SPOT SIZE CONTROL HANDLE is located on the right hand side of the optical system just above the base rail. A variation of spot sizes from full flood to small spot can be
obtained by moving the spot size control handle from one extreme to the other. Beam intensity is
increased by this optical system when reducing from flood to spot, and maximum intensity is reached
when the spot size control handle is in the extreme forward position.
THE MAXIMUM FLOOD SPOT is obtained with the iris control lever to the left
(away from operating side) for the largest aperture and with the spot size control handle moved as far
to the rear as possible.
SMALLER SIZED SPOTS are projected as the spot size control handle is moved
forward. Most of the spot sizes needed will be produced with the iris in its maximum open position.
FOR A “HEAD SPOT,” or any spot smaller than can be obtained with the spot size
control handle in its extreme forward position, shift the iris control lever to the right (toward operating
side) for a smaller aperture. The iris control lever should always be returned to its extreme left
position before the spot size control handle 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 to complete cutoff are obtained by moving
the lever to the left (away from operating side).
THE ANGLE of the masking shutter blades can be adjusted to compensate for the
horizontal projection angle. Remove the color boomerang and optical system housing, and loosen the
screws holding each of the masking shutter blades enough to allow movement. Ignite the bulb and
adjust the angle of the bottom blade by tapping with a screwdriver so its projected edge lies parallel to
the footlights. Tighten the screw. Operate the masking shutter lever to close the blades. Adjust the
upper blade to close in line with the bottom blade and tighten the screw.
THE FADEOUT MECHANISM AND DOUSER CONTROL is the rear lever projecting through the top of the optical system cover. This lever controls the intensity of light from
complete fadeout when the lever is to the left, to full intensity when the lever is to the right.
XST/017
THE SPOT FOCUSING CONTROL KNOB is located on the operating side of the
optical system at the forward end above the base rail. This control is used to position the lenses of the
optical system for the length of throw. When making an adjustment, rotate the spot focusing control
knob until the sharpest edge is obtained on the projected spot.
A SLOT in the lens mechanism housing, between the optical system controls and the
front lens, allows insertion of special media such as frost gels. Additional frame holders (83746) may
be ordered from Strong International dealers.
OPERATION OF COLOR BOOMERANG
THE COLOR BOOMERANG is equipped with six color filters and provision has been
made for installation of an optional ultraviolet filter. The ultraviolet filter may be purchased as an
accessory (Order No. 51829) and is easily mounted to the front of the boomerang. Additional filter
holders (51928 & 51376) can be supplied by your Strong International Dealer.
TO OPERATE INDIVIDUAL COLOR FILTERS, lower the desired filter selector
lever. A rocker catch located in the color disc housing holds the filter in position.
TO RELEASE A COLOR, push the filter release arm up or engage another color, thus
releasing the previous color automatically.
TO REPLACE A FILTER HOLDER, open the hinged top of the color disc housing
and lift out the desired filter holder.
NOTE: WHEN PLACING COLOR FILTERS in the boomerang, the less dense colors should be placed in the holders toward the rear of the boomerang (toward arc), and those of
greater density should be placed in the holders toward the front of the boomerang (away from the
arc).
COLOR TEMPERATURE REDUCTION FILTERS, required for use with television
and videotape, are available from theatrical supply dealers.
XST/018
MAINTENANCE
THE XENON SUPER TROUPER SPOTLIGHT requires very little maintenance to
keep it in good working order.
THE REFLECTOR should be cleaned periodically with a clean, soft, lint free cloth to
remove any dust from the reflective surface. Do not use abrasive cleaners.
CHECK ALL ELECTRICAL CONNECTIONS periodically for tightness, especially
the bulb connections and other leads in the DC circuit.
THE XENON LAMPHOUSE requires no lubrication other than the blower motor.
This should be lubricated with two or three drops of non-detergent oil at each oil hole every six
months. The lamphouse cover must be removed to expose the oil holes.
THE XENON BULB should be checked occasionally for presence of foreign material
on the envelope. Any dirt or other foreign material must be removed immediately. CAUTION:
Observe all safety procedures when working around the exposed bulb.
THE INSIDE OF THE LAMPHOUSE and the blower should be cleaned periodically,
depending on the dust conditions at each installation. The blower requires cleaning to remove dust
build up which accumulates over a period of time. Keep the air inlet grille clean to permit free air flow.
THE OPTICAL SYSTEM LENSES must be kept clean to prevent any light reduction
in the projected spot. To gain access to the lenses, tighten the horizontal swing and vertical tilt locking
clamps, and remove the color boomerang and optical system housing.
CLEAN THE PROJECTION LENS and large lens with any cleaner approved for use
on coated projection lenses. If the small lens is removed for cleaning, the end of the lens with the FL
marking ring must be toward the iris when replaced in its support.
WHEN TRANSPORTING the spotlight, it is recommended that the xenon bulb be
removed and placed in its original shipping carton with the cover on to insure against breakage. If the
spotlight is equipped with a bulb shock mount, the unit may be transported with the bulb installed,
assuming reasonable caution is exercised. Under no circumstances should the unit be moved until the
bulb has cooled to room temperature.
XST/019
LAMPHOUSE SCHEMATIC
XST/020
SCHEMATIC DIAGRAM
Parts List
Ref.
Desig. Part No. Description
- 65938A Igniter (See Figure 3)
B1 65932 Blower, 115 V.AC, 50/60 Hz.
C1,2 76132 Capacitor, .005 µf, 600 WVDC
C3 76133 Capacitor, .01 µf, 400 WVDC
C4A,B 80177 Capacitor, 1.0-1.0 µf, 600 WVDC
C5 81947 Capacitor, .01 µf, 500 WVDC
DS1 - Xenon Bulb
M1 65891 Elapsed Time Meter (60 Hz.)
- 65870 Elapsed Time Meter (50 Hz.)
M2 65142 Ammeter, 0-150 A.
R1 82167 Shunt, 150 A. 50 mV.
R2 88122 Potentiometer *
S1 80168 Cover Interlock Switch
S2 81275 LAMP Switch, “ON-OFF”
S3 81276 MODE Switch, “AUTO-MAN.”
S4 85109 Air Flow Switch
S5 80168 Access Panel Interlock Switch
- 65935 Lamphouse/Power Supply Interconnect Cable
(with MS Connector)
* 88122 used with Type 88000 Power Supplies only
Specify Equipment Type and Serial Number when ordering replacement parts.
XST/021
See Figure 3 for Parts List
XENON SUPER TROUPER IGNITION CIRCUIT
5 - AC Ref Desig. (100) in 65998X Igniter Box
6 - AC Ref. Desig. (200) on 65992B Circuit Board
10 - DC-
15 - DC+ Complete Assembly: 65938A
XST/022
Move to adjacent unused ter minal “10A.”
Installation of 65938 Ignition Enhancement Resistors
(required for use with 62-80100 Power Supplies)
1. Locate #10 lamphouse lead on igniter terminal block.
15 as shown.
2. Connect Resistor Kit leads to terminals 10A, 10, and
65938
IGNITER PRINTED CIRCUIT BOARD
Assembly No. 65992B
Ref.
Desig. Part No. Description
C201 65204 Capacitor, 3 µf, 400 V.
C202 65222 Capacitor, .68 µf, 100 V.
C203 79127 Capacitor, .01 µf, 1000 V.
C204 65960 RF Bypass Capacitor Assembly
D201 65223 Silicon Diode, 1N2071
D202 65223 Silicon Diode, 1N2071
DS201 65224 Neon Glow Lamp
PCB 65221 Printed Circuit Board (less Components)
R201 65226 Resistor, 82k Ohm
R202 65227 Resistor, 400 Ohm
R203 65228 Resistor, 33k Ohm
R204 65229 Resistor, 1000 Ohm
R205 65228 Resistor, 33k Ohm
R206 65250 Resistor, 16k Ohm
R207 65250 Resistor, 16k Ohm
R208 65348 Trim Potentiometer, 100k Ohm
T201 65993 Isolation Transformer
- 01378 Screw, 6-32 x 3/8"
- 01494 Lockwasher, #6
- 00793A Order 41-35005 Hexnut
- 00828 Flatwasher, #6
T202 65220 Pulse Transformer
TB 65268 Barrier Strip, (5) Terminal
- 65238 Transformer Bracket (early models)
- 65938 Strike Enhancement Kit (with 62-80100 Power Supplies)
XST/023
TROUBLESHOOTING FLOW CHART
Xenon Super Trouper
XST/024
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 light on
the xenon power supply will glow. The lamphouse blower will start. The blower in the power supply,
if an older high reactance type (61000, 61001) or current production switching type, will operate.
OPERATION OF THE LAMPHOUSE BLOWER will close the air flow interlock
switch, and if the lamphouse top cover and access panel are correctly installed, the control circuit to
the LAMP switch will be completed.
THE MODE SWITCH, located on the lamphouse instrument panel, should be in the
“MAN.” (manual) position. This is the normal setting for spotlight opertion, as it allows direct ignition control by the operator.
WHEN THE “LAMP” SWITCH is placed in the ON position, the AC control circuit in
the lamphouse will energize the power supply circuitry providing DC current to the igniter and bulb.
THERE WILL BE a distinctly audible high voltage arc ping at the igniter 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 SHOOTING
IF THE XENON BULB does not ignite, observe the following operational sequences
for assistance in locating and isolating the trouble area.
WHEN THE FAN(S) and the indicator light on the power supply are on, the AC
circuit in the power supply is trouble free up to the terminal block in the power supply.
AT THIS TIME, the lamphouse blower should operate. If this does not occur, the
trouble is in the cover interlock switch, the access panel interlock switch, the blower motor, a loose
connection, or a broken #2 or #4 lead. CAUTION: To prevent bulb ignition when checking the AC
control circuit in the lamphouse, remove lead #10 from the igniter terminal strip. Check at this time
for 115 V.AC Control Voltage at the cover interlock switch (wires 2 & 4), the side access panel
(wires 13 & 14), and the blower terminals (9 & 12). The cover interlock switch must be manually
actuated to energize the blower. Replace #10 lead before proceeding.
XST/025
TROUBLE SHOOTING (continued)
THE VANE on the air flow switch should raise. With the MODE switch in the “MAN.”
position and the LAMP switch in the “ON” position, the running time meter should start and indicate
elapsed time. If this meter does not operate, check for continuity at the MODE and LAMP switches.
A DEFECTIVE RUNNING TIME METER will not prevent bulb ignition.
WITH THE “LAMP” SWITCH in the “ON” position, a distinct high voltage arc ping
should be heard at the spark gap in the igniter, and the flash of the xenon bulb should be visible through
the ammeter as a high DC voltage pulse is applied across the bulb electrodes.
IF THE HIGH VOLTAGE PING or the flash at the ammeter is not apparent, check for
115 V.AC at terminals 5 & 6 at the igniter terminal board. If 115 V.AC is present, and terminals are
tight, check then the “No Load” DC Voltage between the lamphouse and power supply. Remove
either lead #5 or #6 at the igniter terminal board to prevent bulb ignition and defeat the cover interlock
switch. Check the DC voltage across terminals #10 (-) and #15 (+). A reading of 85-150 V.DC should
be measured if using a high reactance power supply; 120-170 V.DC if using a switching type. If this
voltage is not indicated, the problem is in the leads between the lamphouse and power supply, or in the
power supply boost circuit. See the trouble shooting section of the power supply manual for additional instructions. Replace lead #5 or #6 at the igniter before proceeding.
IF THE HIGH VOLTAGE ARC is audible at the lamphouse and the bulb does not
flash, check for a lamphouse DC lead arcing to ground. If no ground fault is detected, replace the bulb
and attempt ignition with the new bulb.
IF THE HIGH VOLTAGE ARC is audible at the lamphouse, the flash of the bulb is
visible in the ammeter, 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 Super Troupers to aid in diagnosis of a problem is encouraged. This will not lead to equipment
damage, and will not void equipment warranty.
CAUTION - HIGH VOLTAGE
THE IGNITER SPARK GAP (SEE FIGURE 3, ITEM 7) MUST
BE SHORTED OUT WITH AN INSULATED HANDLE
SCREWDRIVER BEFORE SERVICING OR BENCH TESTING
THE IGNITER.
XST/026
XENON SUPER TROUPER TROUBLESHOOTING
Bulb fails to ignite.
1. MODE switch S3 set to “AUTO.” Place in “MAN.” position when not employing automated or
remote lamphouse operation.
2. AC power not on to lamphouse. Turn switching power supply 30 A. circuit breaker ON. If 115
V.AC not read at 2 & 4, see power supply manual.
3. Top cover or side access panel interlock switch (S1, S5) open. Close and secure lamphouse top
cover. Tighten all four mounting screws; check switch actuating screw. Tighten side access panel
screws.
4. Faulty interlock switch(s). Check for 115 V.AC at 9 & 12; replace switch(s) if defective.
5. Air vane switch S4 not closing. Check for unobstructed operation; clean if required. Check
continuity between “NO” and “COM;” replace if defective.
6. Faulty S2 “ON-OFF” switch. Check for voltage at 3 & 5; check for loose terminals or wiring.
Replace if defective.
Bulb fails to ignite; ping audible, bulb flash visible.
1. Inadequate DC output from xenon power supply. Set power supply output to correct range
required for bulb wattage (65 A. for 1.6 kW, 75 A. for 2 kW).
2. If bulb flash is visible but faint, check for defective glass capacitor 65216 in igniter (capacitor
body cracked or leaking oil). 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 leads away from
grounded metal components.
No high voltage ping audible; MODE switch in “MAN.” and LAMP switch in “ON.”
1. Loss of AC control voltage. Check xenon power supply for tripped circuit breaker or open
thermal switch. See power supply manual.
2. Little or no DC “No Load” voltage. Measure DC “No Load” voltage at 10 & 15. See power
supply manual.
3. Open fuse F1 (600 V.) on 62-80000 switching power supply. SEE POWER SUPPLY MANUAL.
Allow (10) minutes for capacitor discharge before replacing.
4. Faulty igniter printed circuit board. If neon glow lamp on igniter PCB does not light, replace
printed circuit board.
5. Diode 65857 in igniter (Fig. 3, Item 10) loose or defective. Replace as required.
6. Loose or defective spark gap. Correct or replace as required.
7. Faulty igniter. Check for 115 V.AC at 5 & 6; adequate DC “No Load” at 10 & 15. If present, and
igniter does not fire, replace igniter.
XST/027
Bulb goes out during operation.
1. Xenon power supply overheated; thermal switch open. Check power supply blower(s), air inlets
and outlets unobstructed. See power supply manual.
2. Xenon bulb depressurizing. Check for envelope discoloration; replace if defective.
3. Lamphouse blower B1 not moving adequate air. Clean and lubricate blower.
4. Lamphouse blower B1 failed or obstructed. Clean dust and dirt from blower inlet grille. Check
for 115 V.AC at 9 & 12; replace blower if defective.
5. Lamphouse air vane switch S4 faulty. Check for vane actuation; adjust or replace as required.
6. Power supply brown-out protection actuated by voltage drop. See power supply manual.
7. Phase loss detected by power supply (3 phase units only). See power supply manual.
Power supply does not energize when actuated.
1. S1 or S5 cover interlock switch, B1 blower, S4 air vane switch, S2 power switch, S3 MODE
switch. Check for 115 V.AC at each station; 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.
Excessive light flicker.
1. Faulty or aged bulb. Check for cracked or sagging 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 side. Check with
compass if required.
Reduced light output.
1. Normal bulb aging. Increase output current. DO NOT EXCEED MAXIMUM CURRENT
SPECIFIED BY BULB MANUFACTURER.
2. Soiled reflector. Clean using commercial glass cleaner. USE NO ABRASIVES.
3. Soiled heat filter, projection lens or large lens. Clean as required.
Extremely long duration between ignition pulses.
1. Low DC “No Load” from xenon power supply. Check “No Load” voltage; see power supply
manual.
XST/028
Extremely long duration between ignition pulses (continued).
2. Defective spark gap. A “Ping” sound is normal; excessive “Hissing” is abnormal. Replace if
defective.
3. Low AC voltage to lamphouse. Check for 115 V.AC at 2 & 4; if below 95 volts, check stepdown
or isolation transformer in xenon power supply. See power supply manual.
4. Potentiometer R208 on igniter printed circuit board incorrectly set. Set R208 to fire DS201 neon
glow lamp at 80-85 V.DC. Turn clockwise to increase voltage, counterclockwise to decrease.
5. Faulty SCR201 or DS201 neon glow lamp on igniter printed circuit board. Remove and test
PCB; replace if defective.
Igniter continues to fire after bulb ignites.
1. Faulty igniter printed circuit board assembly. 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 coating
peeled.
3. Reflector coating peeled. Replace if defective.
XST/029
FIGURE 1
XST/030
PARTS LIST
Figure 1
Item Part No. Description
1 65866 Cap, Exhaust Stack
- 01303 Screw, #6 Self-Tapping
2 81282 CAUTION Plate
- 01639-2 Pop Rivet, Aluminum
3 65864 Igniter Access Panel
- 01736-1 Screw, 10-32 x 1/2" Holt Head (Tamperproof)
- 01715 Flatwasher, #10
4 65865 Lamphouse Base Pan
- 65969 Base Adapter, Black Enamel (not shown)
- 00687 Screw, 1/4-20 x 1/2" Hex Head
- 00852 Flatwasher, 1/4"
- 00889 Lockwasher, 1/4"
5 65100 Name & Data Plate
- 01639-2 Pop Rivet, Aluminum
6 65968 Cover Assembly, Bulb Adjust Controls
- 65140 Cover Plate
- 65166 Plunger, Black Plastic
- 65167 Grommet, Black Plastic
7 65880 Control Panel Assembly (See Figures 4 & 5)
8 65895 Top Cover Assembly
- 01716 Screw, Switch Actuator, 10-24 x 5/8"
- 41-35014 Hexnut, 10-24
- 01736-1 Screw, 10-32 x 1/2" Holt Head (Tamperproof)
- 01715 Flatwasher, #10
- 65149A Screwdriver (for 1736-1 Screw)
XST/031
FIGURE 2
XST/032
PARTS LIST
Figure 2
Item Part No. Description
1 85109 Air Flow Switch (S4)
- 01565 Screw, 4-40 x 3/4" Round Head
- 41-70011 Lockwasher, #4
2 81143 Cable Connector, 90°
- 65935 Lamphouse/Power Supply Interconnect Cable Assembly
- 88318 MS Connector to Power Supply
- 62153 Cable Clamp (for 88318)
3 65932 Blower Assembly (B1) w/ Switch Bracket
- 01312 Screw, 8-32 x 1/2" Pan Head
- 65158 Switch Bracket
- 01639-2 Pop Rivet
4 83131 Blower Intake Grille
- 01304 Screw, 8-32 x 1/4" Pan Head
5 65936 Reflector, 10" dia.
- 01432 Screw, 1/4-20 x 1/2" Socket Head
- 00889 Lockwasher, 1/4"
6 65171 Insulator Bushing
- 00262 Screw, 8-32 x 1" Fillister Head
- 41-70002 Flatwasher, #8
7 65261 Cathode Lead Connector Stud
- 41-35016 Hexnut, 1/4-20
- 00876 Split Lockwasher, 1/4"
8 65164 Tie Rod (Factory Aligned - Do Not Adjust)
- 41-35016 Hexnut, 1/4-20
9 65115 Air Duct
- 65175 Insulator Plate
10 65933 Heat Filter Bracket Assembly
- 00377 Screw, 10-24 x 1/4" Fillister Head
- 00885 Lockwasher, #10
- 65122 Heat Filter, Glass
11 65156 Inner Heat Shield, Right
- 65155 Inner Heat Shield, Left
- 01304 Screw, 8-32 x 5/16" Pan Head
12 65111 Front Casting
- 76329 Plug Button
XST/033
PARTS LIST, Figure 2 (continued)
Item Part No. Description
13 65148 Contact & Clamp (as shown; 1, 1.6 kW)
- 65410 Contact & Clamp (2 kW)
- 41-51556 Clamping Screw, 8-32 x 1/2" Socket Head
- 00687 Screw, 1/4-20 x 1/2" Hex Head
- 00876 Split Lockwasher, 1/4"
- 65948 Negative Lead Wire Assembly (to Shunt)
14 65152 Thumb Screw (not req’d. for 2 kW)
- 65151 Retainer Plate (not req’d. for 2 kW)
- 65117 Support Yoke (1, 1.6 kW)
- 00387 Screw, 10-24 x 3/4" Bind Head
14 83747 Cathode Shock Mount Assembly (2 kW only)
- 83748 Ring Assembly
- 83364 Base Mount Bracket
- 41-51134 Clamping Screw, 10-32 x 5/8" Socket Head
- 83410 Coil Spring, Shock Mount
15 65114 Reflector Support Casting
- 41-51122 Screw, 1/4-20 x 3/4" Hex Head
- 00876 Split Lockwasher, 1/4"
- 41-35016 Hexnut, 1/4-20
16 65248 Igniter Hold-Down Strap (early models)
17 65938A Igniter Assembly (See Figure 3)
- 41-51387 Screw, 10-32 x 7/8" Hex Head
- 41-35013 Hexnut, 10-32
- 01715 Flatwasher, #10
- 00875 Split Lockwasher, #10
65847B Magnetic Arc Stabilization Kit
39215 Permanent Magnet
41-10004 Clamp
NOT SHOWN
XST/034
CURRENT MODELS of the Xenon Super Trouper igniter incorporate a small rectangular potentiometer (R208) located next to the large capacitor on the igniter printed circuit board.
This component replaces a fixed resistor, and permits adjustment of the voltage level at which the
neon glow lamp (DS201) will flash-over. Adjustment of this potentiometer will therefore increase or
decrease the DC voltage level at which the igniter will fire. This affects the pulse rate of the igniter and
limits the time for the boost capacitors in the power supply to build up a charge for the ignition pulse.
THIS FLASH-OVER VOLTAGE at the neon glow lamp can be decreased to a point
where the ignition pulses are so rapid that the boost capacitors do not have time to build up to full
capacity. The voltage can also be increased to a level beyond the capacity of some xenon power
supplies, at which point the igniter will not fire.
BEFORE ADJUSTING THE POTENTIOMETER, check the DC “No Load” voltage
of the installed xenon power supply to determine that ignition difficulties are not caused by inadequate
DC open circuit voltage. The Strong switching power supply should develop 150-180 V.DC open
circuit, whereas an older high reactance type (i.e. Type 61001) provides around 120 V.DC. The R208
potentiometer on the PC board is factory set to fire the neon glow lamp at 80-85 V.DC.
TURNING THE POTENTIOMETER clockwise will increase the voltage, and counterclockwise rotation will decrease the voltage. One or two revolutions of the adjusting screw alters
the voltage by approximately (1) volt. The setting of this potentiometer should be changed only if
aging of the neon glow lamp has changed its firing point, or if a xenon bulb becomes hard to ignite
after extended hours of operation.
THE IGNITER ASSEMBLY will hold an electrical charge, and care should be exercised when handling or servicing. After removing the igniter from the lamphouse, remove the black
plastic cover from the side of the igniter case. Place the blade of an insulated-handle screwdriver
across the spark gap (Figure 3, Item 7) to discharge the capacitor. Make contact with the metal
screwdriver blade on the diode end first, and then short to the opposite end of the spark gap.
AN EARLIER MODEL of this igniter had a diode (65231) in the circuit. This diode,
located outside the igniter case, may be removed with no adverse effect on the operation of the igniter
or the lamp, if it is suspected as a source of trouble. The lead, from the terminal board to the same post
as the diode, must remain connected into the circuit.
AN ACCESS PANEL, located on the side of the lamphouse, allows easy access to the
igniter. This permits servicing the igniter without removing it from the lamphouse. An interlock
switch is positioned behind this panel, so make certain that the panel is replaced correctly and secured
with the fasteners provided.
IGNITERS AND IGNITER PRINTED CIRCUIT BOARDS may be returned to the
factory for repairs. Items returned to Strong International must display a Return Authorization
Number, and all returns must be arranged through an authorized Strong International Equipment
Dealer.
XST/035
FIGURE 3
XST/036
PARTS LIST
Figure 3A
Item Part No. Description
1 65992B Igniter Printed Circuit Board Assembly
2 65384 PCB Stand-Off Bracket
- 41-51028 Screw, 6-32 x 1/4" Pan Head
3 65390 Capacitor Mounting Bracket
- 01761 Nylon Screw, 1/4-20 x 1/2" Hex Head
- 01754 Nylon Hexnut, 1/4-20
4 65394 Ceramic Insulator
- 41-51539 Screw, 8-32 x 3/16"
- 00886 Split Lockwasher, #8
5 65392 Spark Gap Holder
- 01311 Screw, 8-32 x 3/8"
6 65858 Igniter Case, Potted Assembly
7 65237 Spark Gap
8 65393 Bracket, Spark Gap
9 65216 Discharge Capacitor, Oil Filled
- 41-35070 Hexnut, 8-32
- 00891A Lockwasher, #8
10 65857 Diode Assembly
- 65938A Igniter & PC Board Assembly, Complete
Not Shown
65395 Cover, Igniter Case
01306 Cover Mounting Screw, 6-32 x 5/16" (4 req’d.)
XST/037
FIGURE 4
XST/038
PARTS LIST
Figure 4
Item Part No. Description
1 65142 Ammeter (M2), 0-150 A.
2 81276 MODE Switch (S3), “Auto - Man”
3 81275 LAMP Switch (S2), “On - Off”
4 65116 Casting, Bulb Adjust Control
5 65132 Thumb Screw
- 15010 Compression Spring
- 65150 Fender Washer
6 65112 Rear Lamphouse Casting
7 65959 Focus Screw & Bearing
8 65153 Focus Lock Screw
- 65154 Nylon Ball, 3/16" Diameter
9 76329 Plug Button, Chromed
10 65891 Elapsed Time Meter (M1), 60 Hz.
- 65870 Elapsed Time Meter (M1), 50 Hz.
- 00953 Screw, 4-40 x 1/2" Round Head
- 01343 Lockwasher, #4
- 01620 Hexnut, 4-40 Brass
11 01382 Screw, 8-32 x 3/16" Bind Head
12 65107 Instrument Panel (less Components)
XST/039
FIGURE 5
XST/040
PARTS LIST
Figure 5
Item Part No. Description
1 80168 Cover Interlock Switch (S1)
- 01741 Lockwasher, 7/16"
- 65185 Switch Mounting Bracket
- 00254 Screw, 8-32 x 1/4" Fillister Head
- 00891A Lockwasher, #8
2 65876 Current Control Ass’y. (early models)
3 79131 Ground Terminal
4 65960 Anode Support Collet (1, 1.6 kW)
4 65844 Anode Support Collet (2 kW)
5 M4361 Cable Clamp
- 00377 Screw, 10-24 x 1/4" Fillister Head
6 82167 Shunt (R1)
- 00385 Screw, 10-24 x 1/2" Fillister Head
- 00875 Split Lockwasher, #10
7 65935 Lamphouse/Power Supply Interconnect Cable
- 95119 Bushing, 1-1/4"
- 95120 Lock Nut, 1-1/4"
8 81947 Capacitor (C5)
- 00381 Ground Screw, 10-24 x 5/8" Fillister Head
9 80177 Capacitor (C4A & C4B)
- 00375 Screw, 10-24 x 3/16" Fillister Head
- 00885 Lockwasher, #10
10 65966 Positive Cable & Clamp Assembly
- 00685 Screw, 1/4-20 x 3/8" Hex Head
- 00876 Split Lockwasher, 1/4"
11 65131 Anode Clamp
- 01532 Clamping Screw, 8-32 x 7/8" Socket Head
12 65951 Lamphouse Wire Harness Assembly
13 65134 Barrier Strip, (10) Terminal
- 00182 Screw, 6-32 x 7/16" Fillister Head
- 65160 Barrier Strip Mounting Bracket
- 00255 Screw, 8-32 x 5/16" Fillister Head
- 00891A Lockwasher, #8
14 65890 Capacitor Assembly (C1, C2, C3)
- 00182 Screw, 6-32 x 7/16" Fillister Head
XST/041
FIGURE 6
XST/042
PARTS LIST
Figure 6
Item Part No. Description
1 49943 Lifting Strap
2 00854 Washer, 3/8" S.A.E.
3 49120 Tilt Axis Bolt
4 01319 Nut, 3/8-16 NyLock
5 02411 Washer, .640" I.D. x 1¼” O.D.
6 49126 Clamp Plate
7 49125 Compression Spring, Clamp
8 49124 Bushing
9 49223 Clamping Shaft
10 49130 Handle
11 10048A Knob, Plastic
12 49290 Swivel Clamp Shaft
- 49291 Plate, Swivel Stop
- 01523 Bolt, 3/8-16 x 2-1/2" Square Head
13 49130 Handle
14 83799 Column & Outer Tube, Welded Assembly
15 83297 Bolt, Leg Mounting
- 00878 Split Lockwasher, 3/8"
16 83979 Base Leg, Welded Assembly
- 49208 Caster (not shown)
17 49226 Leveling Foot
- 00992 Hexnut, 1/2-13
18 83294A Height Adjustment Pin
19 83794 Inner Tube Assembly
20 83113 Needle Bearing
21 83114 Race, Needle Bearing
22 49213 Collar, Swivel Clamp
- 00687 Screw, 1/4-20 x 1/2" Hex Head
- 00876 Split Lockwasher, 1/4"
23 01307 Screw, 10-32 x 3/8" Pan Head
24 49224 Cover Plate
25 83112 Top Collar, Inner Tube
- 01759 Set Screw, 1/4-28 x 3/8" Dog Point
26 83770 Yoke, Welded Assembly
27 01525 Screw, 5/16-18 x 3/4" Wing Head
- 01502 Lockwasher, 5/16"
- 00853 Flatwasher, 5/16"
28 49955 Saddle & Quadrant, Welded Assembly
29 83341 Cable Clamp
- 41-51121 Screw, 1/4-20 x 5/8" Hex Head
XST/043
FIGURE 6A
XST/044
PARTS LIST
Figure 6A
Item Part No. Description
1 49120 Tilt Axis Bolt
2 49943 Lifting Strap
- 01319 Hexnut, 3/8-16 NyLock
3 83743 Yoke, Welded Assembly
4 49955 Saddle & Quadrant, Welded Assembly
5 83341 Cable Clamp
6 65431 Inner Retaining Collar
- 65824 Inner Tube Welded Assembly
7 83357 Cover Panel
8 83381 Swivel Clamp Collar
- 83386 Thrust Bearing
- 83388 Bearing Race
9 49291 Swivel Stop Plate
10 49226 Leveling Pad
11 83744 Base Leg Welded Assembly
12 49226 Leveling Pad
13 49208 Caster
14 83745 T-Bolt Leg Pin, Welded Assembly
- 41-51399 Bolt, 7/16-14 x 3" Hex Head
- 41-35056 Elastic Stop Nut
- 41-70007 Washer, 7/16"
15 83742 Base Support Column Welded Assembly
16 48395 Height Adjusting Pin
17 10048A Knob
18 49130 Handle, Swivel Lock
19 49290 Swivel Lock Clamping Shaft
20 49130 Handle, Tilt Lock
21 49223 Tilt Lock Clamping Shaft
22 49125 Compression Spring
- 49124 Spring Bushing
23 49126 Tilt Lock Clamping Plate
24 02411 Negative Spider Washer
NOT SHOWN
01525 Thumb Screw, 5/16-18 x 3/4" (Head Mounting)
01502 Lockwasher, 5/16"
00853 Flatwasher, 5/16"
XST/045
FIGURE 7
XST/046
PARTS LIST
Figure 7
Item Part No. Description
1 83309 Lens Retainer Spinning (pre-1981 units)
2 83864 Lens Ring, Welded Assembly *
- 83107 Lens Retaining Ring *
3 83306 Rubber Gasket, Large Lens *
4 83302 Large Lens *
* 83775 Large Lens & Ring Assembly (All above parts marked *)
5 01305 Screw, 6-32 x 1/4" Pan Head
6 51133 Block, Lens Focus
7 51352 End Casting, Front
8 51454 Focus Adjusting Screw
9 51202 Shoulder Screw, Focus Knob
10 51168 Focus Adjusting Control Knob
11 51114 Stop Collar & Set Screw
12 51910 Focus Adjusting Ribbon Assembly
13 00381 Screw, 10-32 x 3/8" Fillister Head
- 83863 Large Lens Carriage Casting
14 51509 Handle
15 51441 Shaft, Trombone
- 00795 Retaining Ring
16 01754 Hexnut, 1/4-20 Nylon
17 01752 Friction Brake Screw, 1/4-20 x 1" Hex Head Nylon
18 83789 Base Pan, Lens Mechanism
19 00720 Set Screw, 10-32 x 3/16" Cup Point
20 51114 Stop Collar & Set Screw
- 51479 Rubber Bumper
21 51453 Slide Rod
- 48127 Retaining Ring, Slide Rod
22 51162 Expansion Spring, Focus Adjusting Ribbon
23 51158 Pulley, Small
24 51354 Slide Rod Support Casting
25 51120 Spring & Ribbon Clip
26 51353 End Casting, Rear
27 83163 Pulley, Rear
28 51160 Pulley Stud
29 83784 Lens Mechanism Housing, Complete
- 83783 Lens Mechanism Housing, Welded Assembly
- 83328 Slotted Top Cover Plate, Control Shafts
- 83777 Rubber Light Shield, Trombone Shaft
- 83327 Front Frame, Mechanism Housing
- 83309 Front Frame Trim
- 83102 Chrome Trim Strip (Fasteners: 83103)
SST/047
PARTS LIST, Figure 7 (continued)
Item Part No. Description
30 83144 Support Tube, Projection Lens
31 83160 Rear Lens Carriage Casting
32 44239 Projection Lens
33 83155 Lens Retaining Ring
34 47210 Pulley, Large Lens Carriage
35 83774 Large Lens Support Frame (pre-1981 units)
NOT SHOWN
83795 Base Rail, Lamphouse & Optical System
01525 Mounting Screw, Wing Head (see Figure 6, Item 27)
01502 Lockwasher, 5/16" Shakeproof
00853 Flatwasher, 5/16"
49342 Handle, Base Rail
01346 Screw, 5/16-18 x 1/2" Hex Head
00877 Lockwasher, 5/16" Split Ring
XST/048
FIGURE 8
XST/049
PARTS LIST
Figure 8
Item Part No. Description
1 10048A Knob
2 51451 Shaft, Iris Handle
3 00179 Screw, 6-32 x 1/4" Fillister Head
4 00892 Lockwasher, #6
5 51978 Friction Spring, Iris (as shown; see Item 8 below)
- 51229 Friction Pad (as shown)
6 00184 Screw, 6-32 x 5/8" Fillister Head
7 00892 Lockwasher, #6
8 51979 Iris (Old Style, as shown)
8 51641 Iris Assembly, (not shown; used 1992-1997)
8 24374 Iris (current production) See Figure 8A
9 51226 Stud, Chopper Blade
10 83773 Aperture Support Plate
11 51160 Pulley Stud
12 83163 Pulley (Small)
13 00830 Washer, #8
14 47191 Chopper Blade
15 47191 Chopper Blade
16 47982 Chopper Blade Slide Assembly
17 00253 Screw, 8-32 x 3/16" Fillister Head
- 00891A Lockwasher, #8
18 00853 Washer, 1/4" S.A.E.
19 51156 Friction Plate (Replace with 00843A Friction Washer)
20 83134 Pull Rod, Lower Fade-Out Blade
21 00876 Lockwasher, 1/4" Split
22 00805 Hex Nut, 1/4-20
23 00831 Washer, #10, .036" Thick Brass
24 001344 Lockwasher, #10
25 00378 Screw, 10-32 x 1/4" Fillister Head
26 00831 Washer, #10, .036" Thick Brass
27 01344 Lockwasher, #10
28 00378 Screw, 10-32 x 1/4" Fillister Head
29 83135 Retainer Plate, Fade-Out Pivots
30 51226 Pivot Stud, Fade-Out Control
31 83890 Fade out Bracket, Welded Assembly
32 83892 Lower Fade-Out Blade Assembly
33 83891 Upper Fade-Out Blade Assembly
34 51153 Spacer Bushing, Fade-Out Control
35 83133 Pull Rod, Upper Fade-Out Blade
36 00919 Cotter Pin, 1/16" x 1/2"
XST/050
PARTS LIST, Figure 8 (continued)
Item Part No. Description
37 83143 Fade-Out Control Bracket
38 51450 Shaft Handle, Fade-Out Control
39 01406 Hex Nut, 5/16-18, Flexlock
40 00853 Washer, 1/4" S.A.E.
41 51156 Friction Plate (Replace with 00843A Friction Washer)
42 51498 Chopper Pull Rod (Short)
43 51452 Control Shaft, Choppers
44 10048A Knob
45 00254 Screw, 8-32 x 1/4" Fillister Head
46 00891 Lockwasher, #8
47 47170 Iris Stop (as shown)
48 51488 Chopper Control Bracket
49 51153 Spacer Bushing, Chopper Control
50 00876 Lockwasher, 1/4" Split
51 00805 Hex Nut, 1/4-20
52 01406 Hex Nut, 5/16-18 Flexlock
53 51497 Chopper Pull Rod (Long)
XST/051
FIGURE 8A
Part No. Description
01306 Screw, 6-32 x 5/16"
21-70029 Spring Washer
24369 Bell Crank
24372 Adapter Ring
24374 Iris
25034 Iris Clamp
25035 Link with Pins
41-51252 Screw, 8-32 x 5/8"
41-50325 Screw, 6-32 x 3/8"
41-51530 Shoulder Bolt
51451 Iris Control Handle
83773 Aperture Support
41-51530
41-51325
51451
24369
01306
24374
21-70029
25035
83773
(ref. Fig.8,
Item 10)
41-51252
25034
24372
XST/052
51850 BOOMERANG ASSEMBLY
XST/053
BOOMERANG PARTS LIST
Part No. Description
51850 Boomerang Assembly
00180 Screw, 6-32 x 5/16" Fillister Head
00255 Screw, 8-32 x 5/16" Fillister Head
00793 Nut, 6-32, Steel
00829 Washer, #8 Brass, 3/8" O.D.
00831 Washer, #10 Brass, 7/16" O.D.
00837 Washer, 5/16" Brass, 3/4" O.D.
00839 Washer, 3/8" Brass, 7/8" O.D.
00856 Washer, 1/2" S.A.E.
00886 Lockwasher, #8 Split Ring
01309 Order 41-35065 Wing Nut 1/2-13
01310 Hex Half Nut, 1/2-13
01406 Locknut, 5/16-18 x 1/4"
01419 Screw, 5/16-18 x 3/4" Hex Head Cap
01456 Paper Fastener
01515 Screw, 4-40 x 1/4" Round Head
01566 Screw, 10-24 x 5/16" Pan Head
01573 Jam Nut, 1/4-20
45209 “E” Ring, 3/16"
49226* Adjusting Screw (Replace with 51347*)
51166 Shoulder Screw
51192 Ultra Violet Filter
51196 Hinge Pin
51347* Adjusting Screw (Mfr. 1991 and Later)
51376 Cover Plate, Color Frame
51396 Catch
51398 Nylon Spacer Washer
51399 Spacer
51406 Clip, U.V. Filter
51522 Frame, Color Disc Housing
51526 Shaft, Rocker Catch Pivot
51527 Shaft, Color Disc Pivot
51530 Yoke
51535 Screw, U.V. Filter Pivot
51591 Latch, Color Disc Housing
51842 U.V. Filter Support Frame Assembly
51845 Rocker Catch Assembly
51848 Housing, Welded Assembly
51928 Color Frame Slide Channel Assembly
51932 Arm Assembly (5-3/16")
51933 Arm Assembly (4-11/16")
51934 Arm Assembly (4-3/16")
90473 Spring
91199 “E” Ring, 5/16"
XST/054
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