XENON TROUPER
Follow Spotlight
Type 48057
Issue 4/98
PRELIMINARY
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 TROUPER, Type 48057, is a direct current follow spotlight complete with a xenon lamphouse, power supply, optical system, base and yoke assembly, and color boomerang. It
utilizes proven design features of the Strong Xenon Super Trouper combined with advanced properties of the
Strong Super Trouper II. Using a 700 watt xenon bulb as a light source, the Xenon Trouper meets or exceeds
all professional requirements for short- to medium-throw follow spotlight applications.
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 (“cold”) coated metal reflector
designed to operate in a fixed position with a horizontally mounted xenon bulb as the light source. The dichroic
reflector coating reduces heat at the aperture and optical system.
BULB ADAPTERS, required to mount the 700 watt bulb into the lamphouse, are included in
the spotlight accessory kit. Two anode adapters are supplied; the 65259 adapter, measuring 2-5/8 inches in
length, is used with the Hanovia XH0700HS bulb, and the shorter 65199 adapter is used with the OSRAM
XBO700W/HS OFR bulb.
ADJUSTMENT CONTROL for positioning the xenon bulb is located at the rear of the lamphouse. The adjustments are for the horizontal and vertical positioning, 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. A DC Pulse Igniter Assembly requires no AC control circuit; it operates from DC open circuit voltage
normally generated by the xenon power supply. Remote ignition switching is accommodated by wiring a 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.
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 spotlight, it is recommended that the xenon bulb be removed
and placed in its original shipping carton with the cover on the bulb to insure against breakage.
XTR/001
LAMPHOUSE - PO WER SUPPLY
LAMPHOUSE
(Connections Pre-wired)
Lamphouse
Cable Assembly
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
Remote - Auto
Sustained 5 Amp.
Dry Contact
(by Installer)
Conduit
SYSTEM MUST BE GROUNDED
All wiring must conform to local
codes; shield lamphouse cable in
conduit if required.
Grn
XTR/002
XENON
POWER
SUPPLY
MS Connector (pre-wired)
DC+
DC-
Ground Lug
(as req’d. for older units)
INSTALLATION & SET-UP
THE XENON TROUPER is shipped in sections which must be assembled. The Folding Base
Stand Assembly 65838 is shipped collapsed, and requires only unfolding and securing the (4) base legs using the
T-bolts supplied.
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 cover 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. Do not energize the xenon power supply before first installing
the xenon bulb into the lamphouse.
EARLIER MODELS of Strong xenon spotlights included a heavy-gauge green ground wire in
the lamphouse cable assembly. This ground wire was attached to a ground stud connected to the power supply
cabinet. Current models of Strong power supplies include a 1/4-20 stud in the cabinet adjacent to the MS
connector to allow ground termination of older spotlights.
SAFETY PROCEDURES
READ CAREFULLY BEFORE INSTALLING XENON BULB
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. Breakage resulting from transport and handling is not covered by the bulb manufacturer’s warrranty,
and it is strongly recommended to dismaount the xenon bulb when transporting the spotlight.
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.
XG2/005
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 Pin
Seal
Anode End Cap
Envelope
Anode
Cathode End Cap
Seal
Cathode
Cathode Pin
700 WATT XENON BULB INSTALLATION
Type 48057 Trouper
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. Loosen the two knurled-head thumb screws (65152) on the front
bulb support yoke and pivot the retaining plate (65151) aside. Slide the 65131 clamp on the end of the igniter
lead over the brass socket of the rear bulb support collet (65844).
ASSEMBLE THE ADAPTERS to the 700 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
cathode adapter (65198) onto the threaded negative stud so it seats firmly against the shoulder of the (-) end cap.
Slip the 65259 anode adapter over the positive pin up to the shoulder of the (+) end cap. Tighten the set screw
(00720) securely to insure a good electrical connection.
Set Screw 00720
Anode Clamp
65131
Hanovia XH0700HS
Thumb Screw 65152
Retainer Plate 65151
Anode Adapter 65259*
Clamping Screw 01532
Rear Bulb Support Collet 65960
* Use short adapter (65199) with OSRAM bulb
Cathode Adapter 65198
Front Bulb Support 65117
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 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 the 65117 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.
A GLASS STRIP HEAT FILTER is supplied to reduce the thermal energy 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.
REMOVE THE PLASTIC COVER from the xenon bulb. Store the protective cover and the
original bulb packing in a secure location. The spare anode adapter (65199) is for use with an OSRAM 700
watt bulb (XBO700W/HS OFR) should such a bulb be used as a replacement.
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.
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 damage the bulb.
OPERATION
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 700 watt xenon bulb must be
operated within the current range specified by the bulb manufacturer, normally 36 amperes nominal; maximum
current 40 amperes. Refer to the manufacturer’s documents shipped with the bulb for the exact figures.
ADJUST THE POWER SUPPLY as instructed in the power supply manual for the correct
operating current. New 700 watt bulbs are normally first operated at their nominal current level (36 A.). The
current setting must be increased in time to compensate for bulb aging, but do not, at any time, exceed the
maximum current rating (40 A.).
REMOVE THE REAR COVER PANEL (two pull type knobs) located below the instrument
panel. This will expose the bulb position adjustment controls.
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.
THE THUMB SCREWS to the left and right of the focusing control lock the horizontal and
vertical position of the bulb. These thumb screws are spring-loaded to apply a degree of friction against the
lamphouse back casting.
TWO METHODS 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 controls in their full open
positions. 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. 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 rotated or replaced. At
this time it will be necessary to repeat the alignment procedure.
REPLACE THE REAR COVER PANEL over the bulb adjustment control mechanism.
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
two or more spotlights. 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.
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.
REMOTE/AUTO OPERATION
TO IGNITE 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.
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 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.
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 adjustments. 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.
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 adjust 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.
OPERATION OF COLOR BOOMERANG
THE COLOR BOOMERANG is equipped with six color holders and an ultraviolet filter.
Additional filter holders can be supplied by an authorized 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 lever 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.
HIGH TEMPERATURE FILTERS (RoscoLux
®
or equivalent) cut to nine inch diameter are
required, and are secured in the filter holders with paper fasteners.
NOTE: WHEN PLACING COLOR FILTERS in the boomerang, the less dense colors (pink,
amber) should be placed in the holders toward the rear of the boomerang (toward arc), and those of greater
density (red, green) 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.
MAINTENANCE
THE STRONG XENON TROUPER SPOTLIGHT requires very little maintenance to keep it
in good working order.
THE REFLECTOR should be cleaned periodically with a soft, clean, lint-free cloth to remove
dust from the reflecting surface. If excessively soiled, the reflector may be cleaned with Windex
®
or an equivalent glass cleaner. DO NOT use abrasive cleaners of any kind. Clean the heat filter glass; replace with the
coated surface toward the lamphouse.
CHECK ALL ELECTRICAL CONNECTIONS for tightness on a regular basis. Loose con-
nections, particularly in the DC circuit, may cause premature bulb failure and damage lamphouse components.
THE XENON BULB should be checked occasionally for the presence of dust or foreign materials. If necessary, clean the quartz envelope of the bulb with alcohol, and wipe dry with a clean, lint-free cloth.
Observe all safety procedures when working with the exposed bulb.
THE INSIDE OF THE LAMPHOUSE and the blower should be cleaned periodically, depending on the dust conditions at each installation. Keep the blower inlet grille clean to permit free air flow. The
blower is permanently lubricated and requires no oil.
THE LENS SYSTEM should be kept clean to prevent any light reduction in the projected spot.
Tighten the horizontal swing and vertical tilt locking clamps. Remove the boomerang and the optical system
cover to reach and clean the back surface of the large lens. Remove the cover casting over the fadeout, chopper,
and iris controls to remove the small projection lens which is held in place with a large spring-type retainer ring
at the front of the lens barrel.
CLEAN THE PROJECTION LENS and large lens with with any cleaner approved for use on
coated projection lenses. Replace the projection lens with the end with the FL marking ring toward the iris;
secure with the retainer ring.
BEFORE TRANSPORTING the spotlight, remove the xenon bulb from the lamphouse. Place
the bulb in its plastic cover and original shipping container.
MS CONNECTOR
to Trouper
not connected
A = BLK DC- B = RED DC+
C = BRN # 2 D = PINK #3
E = ORN #4 F = BLU #5
G = YEL #6 I = GRY #7
J = BLK #8 M = GRN Gnd
Wires 7 & 8
LAMPHOUSE WIRING DIAGRAM
Xenon Trouper
PARTS LIST
Wiring Diagram
Ref,
Desig. Part No. Description
B1 62-98002 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, 600 WVDC
DS1 - Xenon Bulb, 700 Watt
M1 65891 Elapsed Time Meter, 60 Hz.
- 39195 Elapsed Time Meter, 50 Hz. (Export)
M2 65142 Ammeter, 0-150 A.
R1 82167 Shunt, 150 A. 50 mV.
S1 80168 Top Cover Interlock Switch
S2 81275 LAMP Switch, ON-OFF
S3 81276 MODE Switch, AUTO-MAN.
S5 80168 Side Cover Interlock Switch
J1 37990 Fan Cord & Plug Assembly
65503 DC Pulse Igniter Assembly
65935 Lamphouse/Power Supply Cable Assembly
88318 MS Connector (incl. with 65935)
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 a older Strong
high reactance type (61000, 61001) or current production switching type, will operate.
IF THE LAMPHOUSE TOP COVER and access panel are correctly installed, the top and side
panel interlock switches will close. At this time, 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 contactor circuit and provide DC current to the igniter and bulb. The
high DC open circuit voltage generated upon start-up of the power supply will actuate the DC Pulse Igniter.
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. 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. Observe caution when taking voltage readings in a power ON
condition.
THE VANE on the air flow switch should actuate. 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 RF voltage pulse is applied across the bulb electrodes.
IF THE HIGH VOLTAGE PING or the flash at the ammeter is not apparent, check the “No
Load” DC Voltage between the lamphouse and power supply. 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; 140-170
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.
THE SWITCHING-TYPE xenon power supply normally furnished with the spotlight system
contains thermal overload switches and circuits to protect the power supply from high or low AC input voltage.
A lack of open circuit voltage, or interruptions in sustaining DC current, may be traced to these circuits.
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, power supplies) between similar Strong Xenon
Troupers to aid in diagnosis of a problem is encouraged. This will not lead to equipment damage, and will not
void equipment warranty.
XENON 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. 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 switching power supply. SEE POWER SUPPLY MANUAL. Allow (20)
minutes for capacitor discharge before replacing.
4. Faulty igniter. Check for adequate DC “No Load” at 10 & 15. If present, and igniter does not fire, replace
igniter.
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.
Bulb goes out during operation (continued)
2. Xenon bulb depressurizing. Check for envelope discoloration; replace if defective.
3. Power supply brown-out protection actuated by voltage drop. See power supply manual.
4. 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, 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.
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.
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.
1234
6
5
8
7
9
10
11121314
FIGURE 1
23
22
21
20
19
18
17
16
15
PARTS LIST
Figure 1
Item Part No. Description
1 65114 Reflector Bulkhead Casting
2 00805 Tie Rod Lock Nut, 1/4-20 Hex
3 65164 Tie Rod, Bulkhead to Front Casting
4 65111 Lamphouse Front Casting
5 65865 Lamphouse Base Pan & Lower Side
6 65155 Inner Heat Shield, Left
- 65156 Inner Heat Shield, Right (not shown)
7 65117 Front Bulb Support Yoke
- 65151 Retainer Plate
- 65152A Thumb Screw, Retainer Plate (2 req’d.)
- 01567 Mounting Screw, 10-24 x 1/2" Bind Head
8 65115 Air Duct Casting
9 00262 Screw, 8-32 x 1" Fillister Head
- 65171 Insulator Bushing
10 65175 Insulator Plate
11 41-51122 Screw, 1/4-20 x 3/4" Hex Head
- 00876 Lockwasher, 1/4" Split Ring
- 00805 Hexnut, 1/4-20
12 01432 Screw, 1/4-20 x 1/2" Socket Head
13 65503 DC Pulse Igniter Assembly
14 80168 Side Cover Interlock Switch (S5)
- 72178 Switch Mounting Bracket
15 65112 Lamphouse Back Casting
16 61-98002 Blower (B1), 115 V.AC, 50/60 Hz.
17 65966 Igniter Lead & Clamp Assembly
18 65827 Bulb Positioning Assembly (less Collet)
19 65960 Rear Support Collet
- 21-48027 Collet Retaining Ring
20 65131 Contact Clamp (incl. with Item 17)
21 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
22 80168 Top Cover Interlock Switch (S1)
- 65185 Switch Mounting Bracket
- 00254 Screw, 8-32 x 1/4" Fillister Head
23 23756 Flanged Reflector, 10" Dichroic
65895 Lamphouse Top Cover Assembly
65866 Cap, Exhaust Stack
01736-1 Tamperproof Screw, 10-32 x 1/2" Holt Head
65149A Screwdriver (for 1736-1)
NOT SHOWN
FIGURE 2
PARTS LIST
Figure 2
Item Part No. Description
1 65142 Ammeter (M2)
2 81276 MODE Switch (S3), AUTO-MAN.
3 81275 LAMP Switch (S2), ON-OFF
4 65116 Casting, Bulb Positioning Control
- 65197 Fender Washer, Inner
5 37985 Thumb Screw
- 15010 Compression Spring
- 65150 Fender Washer. Outer
6 65112 Lamphouse Back 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, 50 Hz. (Export)
- 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)
FIGURE 3
PARTS LIST
Figure 3
Item Part No. Description
1 80168 Top 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 Potentiometer (early models*)
3 79131 Ground Terminal
4 65960 Rear Bulb Support Collet
- 21-48027 Collet Retaining Ring
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 Cable Assembly
- 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 Igniter Lead & Clamp Assembly
- 00685 Screw, 1/4-20 x 3/8" Hex Head
- 00876 Split Lockwasher, 1/4"
11 65131 Contact Clamp (incl. with Item 10)
- 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 Mointing 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
FIGURE 4
not shown;
Small Lens
see Parts List, Item 23
for clarity. See Figure 5, Items 11-13.
offset
Items 20 & 21 shown
PARTS LIST
Figure 4
Item Part No. Description
1 51875 Carriage Casting, Large Lens
2 51493 Lens Retaining Ring
- 51492 Rubber Lens Cushion
- 00217 Screw, 8-32 x 5/16" Round Head
- 00830 Flatwasher, #8 Brass
- 00866 Flatwasher, #10
3 51102 Large Lens
4 51133 Lens Focus Block
5 51489 Lens Focus Shaft
- 00866 Flatwasher, #10
- 01475 Cotter Pin, 1/16" x 3/8"
6 41-51170 Set Screw, Focus Knob
7 51168 Focus Knob, Lens Mechanism
8 51167 Post, Focus Ribbon
- 00490 Mounting Screw, 1/4-20 x 1/2" Flat Head
9 51114 Stop Collar
10 51992 Lens Focus Ribbon
11 51509 Handle, Red Plastic
12 48410 Handle Shaft
13 01752 Lock Nut, 1/4-20 Nylon Hex
14 01754 Friction Brake Screw, 1/4-20 x 1" Hex Head Nylon
15 48899 Base Pan, Welded Assembly
16 51162 Tension Spring
17 41-51178 Set Screw, 10-32 x 1/4"
18 51114 Stop Collar
19 51485 Slide Rod (Left & Right)
- 48127 Truarc Ring, #5100-56
- 48147 Truarc Ring, #5101-56
20 51157 Pulley, Focus Ribbon
21 51160 Pulley Stud
- 00830 Flatwasher, #8 Brass
22 48895 Lens Housing Welded Assembly
- 01307 Screw, 10-32 x 3/8" Pan Head
- 00541 Screw, 1/4-20 x 1/2" Pan Head
23 48896 Small Lens Carriage Welded Assembly
- 51101 Small Lens (not shown; mounts to 48896)
- 48404 Small Lens Mounting Plate (not shown; 2 req’d.)
- 48042 Mounting Tube (for Item 24 Lens)
- 00241 Tube Mounting Screw, 8-32 x 5/8" Flat Head
PARTS LIST, Figure 4 (continued)
Item Part No. Description
24 44239A Projection Lens
25 83155 Retaining Clip, Projection Lens
26 51160 Pulley Stud
- 00830 Flatwasher, #8 Brass
48891 Base Rail, Lamphouse & Lens Mechanism
49342 Hand Rail
01346 Screw, 5/16-18 x 1/2" Hex Head
00877 Split Lockwasher, 5/16"
NOT SHOWN
FIGURE 5
PARTS LIST
Figure 5
Item Part No. Description
1 10048A Knob, Red Plastic
2 48402 Iris Shaft
3 00179 Screw, 6-32 x 1/4" Fillister Head
4 00892 Lockwasher, #6
5 51978 Friction Spring & Pad (for 51979)
6 00184 Screw, 6-32 x 5/8" Fillister Head
7 00892 Lockwasher, #6
8 51979 Iris (as shown; also see Figure 5A)
See Figure 5A for current configuration
9 51226 Stud, Chopper Blade
10 51871 Aperture Support Plate, Welded Assembly
11 51160 Pulley Stud
12 51157 Small Pulley
13 00830 Flatwasher, #8 Brass
14 47191 Chopper Blade
15 47191 Chopper Blade
16 47982 Slide Assembly, Chopper Blade
17 00253 Screw, 8-32 x 3/16" Fillister Head
- 00891A Lockwasher, #8
18 00853 Washer, 1/4" Steel, S.A.E.
19 51156 Friction Plate
20 51602 Pull Rod, Lower Fadeout Blade
21 00876 Split Lockwasher, 1/4"
22 00805 Hexnut, 1/4-20
23 51517 Spacer
24 00866 Flatwasher, #10
25 00400 Screw, 10-32 x 1-1/2" Fillister Head
26 00831 Flatwasher, #10; .036" Thick
27 01344 Lockwasher, #10
28 00378 Screw, 10-32 x 1/4" Fillister Head
29 51443 Pivot Shaft Retainer
30 51226 Stud, Chopper Blade
31 48898 Fadeout Mechanism Bracket, Welded Assembly
32 48878 Lower Fadeout Blade
33 48879 Upper Fadeout Blade
34 51153 Pivot Bushing
35 51515 Pull Rod, Upper Fadeout Blade
36 00919 Cotter Pin, 1/16" x 1/2"
37 51520 Fadeout Control Handle Bracket
38 51452 Handle, Fadeout Control
39 01406 Nut, 5-16-18 FlexLock Hex
PARTS LIST, Figure 5 (continued)
Item Part No. Description
40 00853 Washer, 1/4" Steel, S.A.E.
41 51156 Friction Plate
42 51498 Chopper Pull Rod, Short
43 51155 Handle, Chopper Control
44 10048A Knob, Red Plastic
45 00254 Screw, 8-32 x 1/4" Fillister Head
46 00891 Lockwasher, #8
47 47170 Iris Stop Bracket
48 48406 Bracket, Chopper Control Handle
49 51153 Pivot Bushing
50 00876 Split Lockwasher, 1/4"
51 00805 Hexnut, 1/4-20
52 01406 Locknut, 5/16-18
53 51497 Chopper Pull Rod, Long
FIGURE 5A
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
48402 Iris Control Handle
41-51530
41-51325
48402
24369
01306
24374
21-70029
25035
41-51252
25034
24372
51850 BOOMERANG ASSEMBLY
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"
1
2
3
33
32
31
30
29
28
27
26
25
24
23
22
4
5
6
7
8
9
10
11
12
13
14
21
20
17
19
16
18
15
FOLDING BASE & STAND
Assembly No. 65838
PARTS LIST
Folding Base & Stand
Item Part No. Description
1 49120 Tilt Axis Bolt
2 02411 Washer, 1.25" O.D. x .640" I.D.
3 49121 Washer, Tilt Axis
4 41-35020 Hexnut, 3/8-16
5 00845 Flatwasher, 3/8" S.A.E.
6 49126 Clamping Plate
7 49125 Clamping Spring, Compression
8 49124 Clamp Bushing
9 49129 Shaft, Tilt Clamp
10 49130 Handle, Clamp Shaft
11 10048A Knob, Red Plastic
12 49179 Swivel Clamping Nut
13 49114 Handle Stud, Swivel Clamp
- 10048A Knob, Red Plastic
14 83742 Base Column, Welded Assembly
15 49208 Swivel Caster
16 00854 Flatwasher, 3/8" S.A.E.
17 41-51397 Screw, 7/16-14 x 3" Hex Head
- 41-70007 Flatwasher, 7/16"
- 41-35056 Nut, 7/16-14 FlexLock
18 83745 Leg T-Bolt, Welded Assembly
19 83744 Base Leg, Welded Assembly
20 49226 Leveling Foot
- 00919 Lock Nut, 1/2-13 Hex
21 48395 Height Adjust Pin, 3/8" Diameter
22 65824 Inner Tube & Ring Welded Assembly
23 48399 Bronze Washer
24 83381 Collar, Swivel Clamp
25 00687 Screw, 1/4-20 x 1/2" Hex Head
26 01304 Screw, 8-32 x 5/16" Pan Head
27 48394 Yoke Cover Plate
28 65431 Inner Tube Retaining Collar
29 01317 Screw, 1/2-13 x 2-1/2" Hex Head
30 65823 Yoke, Welded Assembly
31 00689 Screw, 1/4-20 x 5/8" Hex Head
32 83341 Cable Clamp
33 48884 Saddle & Quadrant Plate, Welded Assembly
65838 Base & Stand, Complete (Items 1-33)
18765 Folding Base Assembly (Items 14-20)
ASSEMBLIES
Loading...