Table of Contents Table of Contents 2 - Introduction – The Syncrolite System 3 - Features 3 - Technical / Power Specifications 4 - Fixture Overview 5 - Technical Overview 6 – Syncrolite Series 3 Profile Information 7 - System Cables...
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Introduction The Syncrolite System The Syncrolite Automated Xenon Entertainment lighting system is designed for years of trouble‐free service when properly operated and maintained. All components are arranged in an efficient package for easy maintenance access to allow for concise and systematic troubleshooting. Learning the basics of this process, in addition to proper programming and operating procedures, is essential before attempting to operate the system. This manual is designed for the field technician to use while setting up and running a show. It is also intended for the maintenance of installed systems. This manual does not contain all information about the Syncrolite Automated Xenon Entertainment lighting system. For further documentation or technical support contact Syncrolite, LP. Syncrolite Entertainment Technology 2025 Royal Lane Suite 370 Dallas, TX 75229 Phone: 214‐350‐7696 Fax: 214‐350‐8051 www.syncrolite.com ...
Technical Overview The Syncrolite instruments employ Syncrolite custom microprocessors as the principal components in the unit CPU for DMX operations. Each Xenon unit has seven computer‐ controlled variable parameters employing servo motors with attached optical encoders. Each motor receives positional data via the Syncrolite motor control microprocessor on individually corresponding motor drivers mounted in the electronics box of the unit. These seven motors and motor drivers control: 1. Beam size 2. Douser 3. Scroller 1 4. Scroller 2 5. Scroller 3 6. Pan 7. Tilt ...
Syncrolite Series 3 Profile Information MX, SXL, XL 1 Pan Course 2 Pan Fine 3 Tilt Course 4 Tilt Fine 5 Douser 6 Beam (0=wide, 255=tight) 7 Color 8 Command Word (43=lamp on, 85=off, 169=reset) 9 Command Execute (86=set up, 171=execute) 10 Color 2 11 Color 3 12 Strobe (electronic ballast) 13 Beam Over Drive (0‐254=OFF, 255=ON) 14 (nothing at this time) Our color is achieved using Dichro Tech Thin Film scrollable color in scrolls. The frame numbers can be any number of frames up to 11 full frames. ...
System Cables DMX Cables All Syncrolite products use DMX protocol. We recommend a maximum DMX cable length of 2000’, though the system will operate up to 1 mile from the DMX source with quality cable and a DMX splitter. For architectural Series units, Syncrolite provides a 6‐way and 12‐way DMX splitter. These are necessary in systems in which Syncrolite status monitor products are used‐ normally in large fixed installations. AC Power Cables/Feeder Syncrolite power distros accept standard Camloc five wire input (3 phases, ground, neutral) and distribute output to Syncrolite ballasts via 8/5 wire with a Hubbell twist lock connector. Euro power distros accept Powerlock mains inputs and are equipped with ground fault protection. CAUTION: make sure you use the correct color input with the correct output. Failure to do so could cause a fire or other serious injuries. Lamphead Power Cables DC lamp power is provided between the ballast and lamphead via a pair of Camloc connectors on #1 AWG entertainment cable, triped with a proprietary Syncrolite cable employing 9‐pin Amp male and female line connections providing data and AC for robot and electronics power. ST Series lampheads in fixed or permanent installations can also be hard wired via appropriate cabling and conduit. AC Power The 8/5 AC provides power from the distro to the ballast. It contains five inputs (3 phases, ground, neutral) and distributes output to the ballasts with a Hubbell twist lock connector. Tail The tails will normally be hanging down from the generator or house power for you to connect the female feeder into the tail. ...
Syncrolite Mounting MX4 fixtures are weatherproof outdoor fixtures and may be flown or ground mounted using certified mounting hardware and proper ESTA safety procedures. Flown Syncrolites are designed to mount to standard 20.5” or 12” truss via four 2” half couplers. A safety is provided with each unit. Ballasts are on the ground in individual cases or racks and may be placed up to 200’ from the lamphead. Raked For certain stadium, architectural or event applications it is desirable to ground mount the MX4 with a 30‐45° forward rake. This allows light cues a more acute downward angle to cover all of a performance area and still retain the ability to do beam effects and ballyhoos in the sky. Units mount via four industry standard 2” half couplers. Ballasts are on the ground in individual cases or racks and may be placed up to 200’ from the lamphead. Ground Mount Syncrolites may be ground mounted to a Syncrolite ground mount base which connects via four industry standard 2” half couplers. Ballasts may be placed adjacent to or remote up to 200’ from the lampheads in individual cases or in racks. ...
Metering Power CAUTION: Syncrolite ballasts are high current devices and carelessness may result in electrocution or death. Do not touch the terminals or heat sinks with your hands or with a non‐insulated metallic instrument. Do not allow any conductive device to bridge the terminals. It is essential that power is metered before powering‐up the system and that the taps are set correctly‐ particularly when operating overseas. Syncrolite power distros provide test points for metering incoming power. Before powering up the system, confirm that Camlocs are firmly seated and twisted to full locking position. All Syncrolite ballasts are breaker protected. In the event that the breaker trips immediately determine the source of the interruption of power or phase imbalance and correct the problem. Once the problem is corrected, reset the unit by depressing the phase imbalance reset switch on the rear of the unit. ...
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(Phase Imbalance Switch) Syncrolite ballast taps may be set to accommodate a variety of voltages. To confirm that the tap settings are correct, meter amperage and voltage and calculate wattage (A x V=W). Amperage may be determined by use of an amp probe clamped around the positive of the lamphead cable lead from the ballast. ...
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If calculated voltage is higher or lower than expected, reset the taps for the voltage in your location. ...
Powering Up the System Proper initialization is critical to successful operations of the Syncrolite product. We advise the operator to carefully and systematically follow the recommended start‐up procedures. If there is a problem, it usually starts here. Only certified Syncrolite technicians or personnel trained by a certified Syncrolite technician should carry out system operation and maintenance. Once your system is properly setup, we recommend the following steps: 1. Power up. All units will initialize upon power up. The units will not strike until a strike command is given from the DMX controller, laptop or from the onboard menu. At this point, each unit should have fans running and be in the home position‐ 50% pan and 50% tilt ‐ with all motors active and douser closed. Check each unit’s ID and make a note of its channel number, its physical position or location in the lighting system and its corresponding AC distro channel. If necessary, make a written chart or console map of this for each show to eliminate confusion between the AC distro channel and the control channel number. The units ID can be any number from 1‐36 as the operator requires for programming. The fixtures have digital switches on the skid. 2. Turn on your DMX controller‐ check to make sure the proper DMX profile has been loaded into the controller. 3. You may turn on each individual unit at the distro and watch it go through its initialization routine. The Syncrolite units have specific calibration routines. The calibration routine will take ...
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each of the seven motors to its sensor marks and to the home position after calibration. The calibration routine usually takes 30 seconds. 4. If a particular parameter does not calibrate properly, issue a reset command. Maximum time out for a function is 2.0 minutes. After this, if a parameter is not calibrating you should refer to the Trouble Shooting Section. 5. WATCH AND LISTEN CAREFULLY AS YOU STRIKE EACH UNIT‐ YOU SHOULD HEAR THE LAMP TRY TO STRIKE If any unit does not properly strike‐ then reset. If the unit still does not properly strike‐ refer to the Trouble Shooting Section. Due to the high voltage surge required to energize the arc in a Xenon lamp, our micro‐ processor shuts down momentarily during lamp strike and thereafter reinitializes the system to counteract any loss of function in the processor caused by the RF generated. 6. When all lamps are struck, each until will calibrate in the home position. At this time the lamp will go to whatever DMX is being sent to it. You can select channels and test the individual motor functions (color, beam, douser, pan and tilt) at the console for each unit to ascertain if all units are receiving and responding to commands. ...
Menu Functions Diagnostic functions are accessed via the multifunction buttons and liquid crystal display on the electronics box of the lampheads. On power‐up, the display will read “CALIBRATING” and display the software version. Once calibration is complete, “CALIBRATING” will be replaced with the unit ID #, which will be an integer representing a range of DMX or unit #’s, the number of which channels is determined by the type of unit. 1 2 3 4 5 To access the on‐board menu, simultaneously press button 1 and 5. The first screen should read “SET ID”. Buttons 4 and 5 will map to (+) and (‐) in the display window. Use buttons 4(+) and 5(‐) to increase or decrease to the desired value. ...
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Once the desired value is set, use button 3, which maps to “BACK” in the display, to return to operation. Selecting “Nxt” from the “SET ID” menu will take you to the “MOVE MOTOR?” menu. Pressing button 3, which is now mapped to “YES”, will take you to the motor control menu. Use buttons 1 and 2 to select the desired motor, and buttons 4 and 5 to input the desired value for that motor. When you are finished, press button 3 “BACK” to return to the previous menu. Then press button 2 “Nxt” to proceed to the next menu. ...
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The next menu is the “CAL MOTOR?” menu. Pressing button 3, which is now mapped to “YES”, will take you to the menu. Use buttons 1 and 2 to select the motor to be calibrated, button 4 “GO” to calibrate and button 3 “BACK” to return to the previous menu. Selecting “Nxt” by pressing button 3 takes you to the “OFFSET MOTOR?” menu. This menu allows adjustment of beam, pan and tilt for precise alignment. Again pressing button 3 “Yes” will take you into the menu. The top line will display the parameter being adjusted and the percentage of offset. Buttons 1 and 2 are used to scroll between beam, pan and tilt. Buttons 4(+) and 5(‐) will adjust the offset. Once the adjustments are completed, use button 3 “BACK” to return to the previous menu. Selecting “Nxt” again will take you to the “LOOK ENCODERS?” menu. Select button 3 “YES” to enter the menu. This menu provided a listing of each encoder and its current numerical value and can be used to verify feedback from each encoder. This menu acts as a monitor of encoder function and no input or adjustment is possible. All motors are disengaged. You can manually ...
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move any axis to look for encoder feedback. You will note that there is no button labeled as “BACK”. Use button 3 to return to the previous menu. The next menu is the “RESET” menu. This allows you to re‐initialize the robot. The next menu is the “STRIKE/KILL” menu. This allows you to strike or kill the Xenon lamp. Select button 3 “Yes” to enter the menu. In this menu, selecting button 4 “GO” will either strike or kill the lamp, depending on its current state. Selecting 3 “BACK” will return you to the previous menu. ...
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The final menu is the “LOOK DMX” menu. Selecting button 3 “YES” takes you into the menu. This menu is almost identical to the “LOOK ENCODERS?” menu, except that the values given for each function are DMX values being transmitted to the unit. As with the “LOOK ENCODERS?” menu, there is no “BACK” button. Press button 3 to return to the previous menu. The “Prv/Nxt” buttons will always take you through all other possible menus. The number 3 button will always represent “YES” or “BACK” taking you into or out of a given menu. ...
Component Functions and Operations Pan and Tilt Motor/Encoders Periodically check belt tension and surface of encoder wheel for impurities. Impurities or dings on the encoder wheel will cause pan or tilt function to shudder or move erratically. Sometimes this is mistaken for missing or broken teeth on the belt. Belt tension must be maintained to drive the encoder wheel. All units employ optical sensors to calibrate and establish limits of pan/tilt. Familiarize yourself with these components and where the encoder calibrates. Douser Syncrolite utilizes a Venetian blind type with vanes attached to levers linked by a common shaft turned by a Syncrolite custom servo motor with optical encoder. All vanes should open and close together. Check adjustment of each vane periodically. Closure can be adjusted by loosening the set screw on each vane pivot. The douser assembly calibrates first, and stays shut after lamp strike so as to avoid undesired revealing of the lamp beam. The Venetian blind douser is an effective fader for our Xenon product. The douser is driven by a servo motor attached to a linkage assembly that calibrates to a mechanical stop. The douser assembly calibrates first. DMX Values 0‐255 are the proportional equivalent of dousing values 0‐100%, with 0% being blackout and 100% being full open. Beam The MX4 uses a linear actuator stepper motor to affect beam width. This mechanism attaches the lamp socket assembly to the linear actuator, which moves in or out to change beam width. ...
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The beam motor is coupled to the carrier plate which moves the lamp up and down to change the beam width. Color Changer The Syncrolite type mechanism uses opaque scroll tags traveling though an optical sensor to read beginning and end of strings at calibration. Once length of scroll is known, DMX channel values from 0‐100% or 0‐255 are set to correspond to each color panel or split panel and loaded into libraries. Check optical sensor for impurities in the peep hole and make sure your scroll is in the track at all times. ...
Lamp Installation 1. Take the 8‐32 x 1/2 pan phillips out of the back door so that it can be opened as shown below. 2. Take the lamp and, leaving the wrap on; put the bullet on with the provided screws as shown. 3. Carefully thread the lamp clamp assembly to the lamp. ...
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4. Remove the wrap and place the lamp through the center of the lamp assembly and into the spider bullet first as shown. NOTE: Take care not to touch anything, especially the envelope. ...
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5. Insert the lamp through the beam bracket and seat the bullet into the spider. Connect the H08 cable from the igniter to the lamp clamp using (1) 1/4‐28 x 1/2 hex bolt and tightening with a 7/16 socket wrench as shown below. 6. Using (3) 8‐32 x 1/2 pan phillips, attach the lamp clamp to the beam bracket as shown below. ...
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7. Close the back door and reconnect with the screws removed in step 1. 8. Connect the lamp ground wire to the stud on the spider with (1) 10‐32 flex top nut using a 3/8 socket. ...
Replacing the Reflector To replace the reflector you have to first safely remove the lamp. Remove both of the lamphead covers. Using a 3/8 socket wrench remove the #10 flex top nut from the spider. Remove the (4) back door screws. ...
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Remove the H08 lamp to igniter cable by removing 1/4 ‐ 28 x 1/2 hex bolt using a 7/16 socket wrench. Remove (3) 8/32 x ½” pan head screws from the lamp clamp. ...
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Grabbing the lamp clamp slowly and carefully remove the lamp from the unit. Be careful not to touch the lamp to the fixture when removing. Secure the lamp in a cloth cover or hard shell case. ...
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Put one screw back into the lamphead rear access door so the fixture can be tilted upright without the door swinging open. Remove (3) #6 hex nuts using a 5/16 wrench. ...
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Remove the reflector. Follow the steps backwards to install a new reflector. ...
Replacing the Igniter Remove the lamphead covers to access the igniter. (See page _______) Remove the Xenon lamp using all necessary safety precautions. (See page _______) Remove the negative lamp HO8 and the lead to the lamp as shown below. Remove the two 8/32 screws securing the igniter box. ...
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Remove the two screws holding the HVPSI Box. Remove the igniter and box. Follow the steps backwards to install a new igniter. ...
Color Changer Cartridge Access and Removal 1. Remove (2) 6‐32 x ¼” pan head screws, unlatch (2) latches and remove the cover. 2. Pull out each cartridge. ...
Scroll Installation 1. Find the tag on the scroll and locate the fasteners in the FIXED roller tube to use as your guide. Place the scroll end on the roller making sure that the scroll does not touch either side, the tag faces up and will run through the sensor when rolled through as shown below. Scroll should attach to fixed side with tag facing up 2. Using (2) 3” pieces of gel tape, attach the scroll to the fixed roller. 3. Pull the belt and roll the scroll onto the roller to which it was just taped. Take the loose end and thread it through the guides and then the sensor. 4. Make sure that there is no slack in the gel and hold it tightly in place while you find the fasteners in the SPRING roller tube. Turn the color changer shell with the sensor away from you and roll the spring roller backward four times to “load” it. ...
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5. Using (2) 3” pieces of gel tape, attach the gel to the spring roller as shown below. 6. Repeat steps above for the two remaining color changers. 7. Re‐insert the cartridges in the same order as removed. ...
Scroller Troubleshooting Drive motors for the scroller are mounted behind the fixed roller. Each motor is connected via a DC power wires consisting of a red and a black wire attached to a mini‐fit junior modular connector that plugs to the corresponding connector on the motor lead and an encoder cable consisting of a blue, brown, green and yellow wire connected to a C‐Grid 6‐position connector that plugs into the encoder socket near the shaft end of the motor. The color motors are mounted with 2 4‐40 x 1/2 screws. *If you suspect motor failure, try rotating the motor shaft with the power off. If the shaft rotates evenly and smoothly, the motor is probably not the problem. Bad motors generally exhibit roughness or excessive resistance when turned by hand. The scroller employs two drive belts. A short belt connects the fixed (non‐spring loaded) roller to the drive motor. On the opposite side of the unit, a long belt links the fixed motor to the spring loaded roller. In the event that one of the scroller belts must be changed, follow the steps below. To replace the short belt which couples the scroller drive motor to the fixed roller, remove the motor mount screws and pull the motor out to remove the belt. The belt may then be slipped on or off. Once replaced, the motor should be rotated to restore tension and securely tightened into place. There must be 1/8” slack on the short belt at all times. Never remove all of the slack from this belt or you will have premature motor failure. To replace the long belt that couples the two rollers, the pulleys attached to the rollers must be removed. Each pulley is secured with a set screw. In removing or replacing the pulleys, care should be taken to remove or replace the pulleys simultaneously so as to avoid binding on the ...
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roller shafts and stretching the belt. Never stretch the belt over the pulleys to put it on. You will damage it. ...
Pan and Tilt Troubleshooting Pan and tilt motors and drive belts are unlikely to fail, but in the event of failure, replacement is fairly simple. Both pan and tilt motors attach to the yoke via four 10/32 socket cap screws in the mounting plate to which each motor is attached. Unscrew the (6) 8‐32 x 3/8” screws to remove the arm covers. Unscrew the (12) 8‐32 x 3/8 pan screws to remove the yoke base cover (bow tie) to give more efficient overhead access to motors for removal. ...
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Loosen the belt tension screws (10‐32 thumb screws w/ lock nut). To remove a motor, unscrew the four socket cap screws securing the motor assembly to the yoke. ...
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Once there is sufficient slack, slip the drive belt from the drive pulley. ...
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Unplug the motor from the red and black DC motor power cable, which is attached via a mini‐fit junior 2‐position modular connector, and the blue, brown, green and yellow encoder cable, which attaches via a mini‐fit junior 4‐position cable to the rear of the motor assembly. ...
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The above pictures are of the tilt motor. Although the directions are similar for the pan yoke assembly…please notice the differences in each assembly below. Tilt Pan To place the new motor, insert it through the yoke assembly and loosely insert the allen screws. Slip the belt over the drive pulley. Using the thumb screw tension to the belt tightening the ...
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four allen screws. Reconnect the new motor to the motor cable, coiling and zip tying the excess cable and attach the encoder cable. In the event of sensor failure, both the pan and tilt half‐moon sensors are mounted to the yoke via two Phillips screws and connected to the yoke cable via a mini‐fit junior 3‐position modular connector attached to a green, brown and white wire. Unplug the sensor, remove the Phillips screws and slide the sensor free of the half moon pulley assembly. Slip the new sensor into position making sure the plate is centered in the sensor. Attach screws and plug into the modular connector. ...
Replacing the Douser Motor Follow the step on page ____ to remove the scroll cartridges to access the douser motor. Using an allen wrench loosen (1) 6‐32 x 1/4 socket cap. ...
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Remove the (3) 4‐40 x 3/8” screws. Unplug the mini‐fit junior 6 position receptacle on the outside of where the motor is located. Pull the mini‐fit junior 6 position chassis through the hole as shown below. Install the new motor by following the steps backwards making sure the set screw is fastened to the flat on the motor shaft. ...
Replacing the Beam Motor Remove the lamphead covers to access the beam motor. (See page _______) Remove the Xenon lamp using all necessary safety precautions. (See page _______) Unplug the motor harness mini‐fit junior 8 position connector. ...
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Remove the (4) 8/32 x ½” flat head screws that attach the beam assembly to the lamphead. Remove the beam assembly from the lamphead. Remove (2) 8/32 x ½ pan head screws opposite of the motor to remove the beam block to give access to the nut securing the motor. ...
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Remove the nut using a 7 mm nut driver. Remove the other (2) 8/32 x ½” pan head screws to remove the beam block that contains the motor. ...
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Remove the (4) socket cap screws using a metric 2.5 allen wrench to remove the motor from the beam block. Follow the steps backwards to install a new beam motor. ...
Beam Drive Troubleshooting In the event that the beam drive should fail, take the following steps to determine the source of the failure: 1. Determine whether the motor is moving. Remove the lamphead covers. Have someone power the lamphead while you monitor the calibration of the assembly. 2. If the assembly does not move at all try replacing the beam driver board. 3. If replacing the beam driver board does not solve the problem, replace the skid. 4. If replacing the skid does not solve the problem replace the motor. ...
Cleaning and Maintenance There are several maintenance procedures that are common to all Syncrolite fixtures. The units will operate optimally if kept clean. This is particularly true of glass and reflector surfaces. Glass ‐ Clean lamphead glass with Windex or similar streak‐free glass cleaner. Dichroic Scrolls ‐ When handling DichroFlex HT or installing scrolls, cotton gloves or other protection should be worn in order to avoid direct contact between the filter film and skin. In the event that fingerprints, oils or other contaminants come into contact with the filters, they should be gently removed with a dry microfiber cloth. In the event that a contaminant cannot be removed with a dry microfiber cloth, a mild non‐ammonia window cleaner may be used sparingly, but should be removed with a microfiber or other abrasion‐free cloth. Do not use paper towels as they will scratch the surface and shorten the life of the filters. Please note that ammonia‐based products will damage the DichroFlex HT substrate and should never be used. In operation, DichroFlex HT Scrolls should be kept as clean as possible by routinely changing and cleaning air filters on the color/douser head and cleaning the inside of the filter chamber of any contaminants that may bypass the filter and collect on surfaces. If your units do not have air filters, please immediately contact Syncrolite for replacements. Reflectors ‐ Reflectors should be cleaned only with denatured alcohol and a lint free cloth or wipe. When cleaning reflectors with the Xenon lamp installed, use the same precautions and protective gear as when changing the Xenon lamp. ...
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Lamps ‐ Xenon lamps generate a great amount of heat. This being the case, good airflow is essential to proper operation of the units and maximum life of the Xenon lamp. Clean the lamphead filters as shown in the next section. Some conditions will require an increase in the frequency of required cleaning. Such conditions include damp or dusty conditions, pyrotechnics and smoke machines. Ash from pyrotechnics can block air filters and can form a layer on glass and reflector surfaces, thereby reducing lamp efficiency. Be sure to clean the air filters often. ...
Cleaning the Lamphead Air Filter 1. Remove (4) 8‐32 x 3/8” pan head screws from “Frisbee” to gain access to the air filter. 2. Remove the air filter and either blow out with a high pressured air hose or wash with a mild detergent such as Dawn Dishwashing Detergent. ...
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Troubleshooting Syncrolite Diagnostics There are several means of running diagnostics on Syncrolite units. The onboard status display can be accessed via the display screen and 5 buttons on the face of the electronics box. In the field, technicians may employ the MiroTech DMX PLUS or other DMX device for diagnostic purposes. Onboard Menu Diagnostics (For individual menu item details, see page ________________) 1. To access the menu with the power on (with or without DMX), press buttons 1 and 5 simultaneously. This will access the menus. Reverse (button 1) and forward (button 2) will take you through the menu options. Button 3 will enter a menu function such as pan, tilt, beam, douser, color, strike and kill. Buttons 4 and 5 will increase or decrease the function value. 2. The unit ID# is set by entering the menu and using buttons 4 and 5 to increase or decrease the ID#. 3. The onboard diagnostics are useful in tweaking the values for menu functions where there are perceived differences in them due to mechanical variations. Because usual Xenon applications are long throw, small deviations in pan and tilt and collimated beam can be noticeable. Use the onboard diagnostics to tweak values as needed. 4. When DMX is being received, the onboard diagnostics will show DMX values in real time for each function. ...
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Other Troubleshooting Ensure power cable is properly connected to HBL 2815 connector. Ensure power is coming out of nine pin No power to fixture 1 to 3 pin 120 VAC 2 to 3 pin 63 VAC 1 to 2 pin 120 VAC Make sure the ballast power is ramping up to 90‐100 VDC. Lamp does not strike Make sure you are getting power to all three phases. Check for overheating. Ensure that the fan is running. Overheating will trigger the temp Ballast turns off after running for less than 30 sensor. minutes Check for phase imbalance. Make sure you have all three phases going to the ballast. ...
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