ETC Source Four Zoom User manual

Assembly Guide
Source Four™ Zoom

2 Electronic Theatre Controls, Inc.

Source Four Zoom Assembly Guide 3
Table of Contents
15º–30º Final assembly ................................................5
25º–50º Final assembly ................................................6
Lamp socket assembly ................................................7
Reflector housing assembly .........................................10
Gate housing assembly ................................................12
15º–30º lens tube assembly .........................................15
Gel frame endcap assembly ..............................16
Front lens assembly ..........................................16
Rear lens asembly .............................................16
25º–50º lens tube assembly .........................................17
Gel frame endcap assembly ..............................17
Front lens assembly ..........................................17
Rear lens assembly ...........................................17
15º–30º and 25º–50º assembly instructions .................18
Cleaning glass lenses ...................................................19

4 Electronic Theatre Controls, Inc.
1
4
2
36
5
7
8
15º - 30º Final assembly
Reference Part Description Quantity
Number Number Required
1 7060A2030 15°-30° lens tube 1
2 7060A2020 Rear housing assembly, double clutch 1
3 7060A2408 Lamp socket assembly 1
4 7060A4008-01 Knob set with male insert 1
5 7060A4037 Handle, insulated rear 1
6 HW5197 Screw, 1/4-20 x 5/8, black zinc 1
7 HW2181 Screw, 6-32x3/4, black Taptite 4
Optional equipment
8 7060A2028 Balance yoke 1
Figure 1
Figure 2

Source Four Zoom Assembly Guide 5
25º - 50º Final assembly
Reference Part Description Quantity
Number Number Required
1 7060A2032 25°-50° lens tube 1
2 7060A2020 Rear housing assembly, double clutch 1
3 7060A2408 Lamp socket assembly 1
4 7060A4008-01 Knob set with male insert 1
5 7060A4037 Handle, insulated rear 1
6 HW5197 Screw, 1/4-20 x 5/8, black zinc 1
7 HW2181 Screw, 6-32x3/4, black Taptite 4
1
4
2
36
5
7
Figure 3

6 Electronic Theatre Controls, Inc.
Lamp socket assembly
Reference Part Description Quantity
Number Number Required
1 7060A3055 Housing, socket, casting, painted 1
2 7060A3057 Socket, light baffle casting, painted 1
3 7060A4007 Knob, X-Y, lamp set 1
4 7060A4008-02 Knob, Z, lamp set w/female insert 1
5 7060A4011 Bushing, cup 1
6 7060A3011 Hub, index, casting 1
7 7060A3012 Spring, lamp retainer 1
8 HW748 Spring, compression 1
9-11 M718 Complete TP22 CLCM assembly 1
9 W330-03 TP22 CLCM assembly, mica 1
10 W330-04 TP22 CLCM 16-gauge, 1/4" semi-striped, Ni-gold contacts,
600V, 450˚C 2
11 W330-02 TP22 CLCM assembly, ceramic 1
12 HW534 Nut, hex, 1/4-20, black zinc 1
13 7060A3025 Screw, 1/4-20 knurled head 1
14 HW746 Retaining ring, flat, Southco 1
15 HW5123 Nut, hex, 9/16-18, black zinc 1
16 HW747 Washer, wave 1
17 7060A3056 Clamp, strain relief, painted 1
18 HW3103 Screw, 8-32 x 5/8 PhFHMS, black zinc 2
19 HW5122 Bolt, 1/4-20 x 1.75, full thread, black zinc 1
20 HW2125 Screw, self tap, 6-32 x 1/4, black zinc 1
21 7060B7003 48" W420 wire, 16 gauge, 200° C/300V, green
UL 1180/CSA AWM with lug J490T installed 1
22 W689 36" sleeve, fiberglass (not pictured) 1
23 HW749 Spring, ground 1
24 7060B7007 4" W420 wire, 16 gauge, 200° C/300V, green,
UL 1180/CSA AWM with two J490T lugs installed 1
25 7060A4037 Insulated rear handle 1
26 HW2181 Screw, 6-32x3/4, black Taptite 4
6
20
1
24 23
17
18
13
4
15
16
3
5
2
21
11
24
9
8
7
10
12
14
19
Figure 4
Tab
25
26
Lamp burner
assembly

Source Four Zoom Assembly Guide 7
Lamp socket assembly
Tools required: Open-end adjustable wrench or a 7/16" socket,
needle-nose pliers, screwdriver.
1. Install the screw (20) into the light socket baffle casting as
shown in figure 5. (Also see figure 12 on page 9.)
Note: Do not install the screw if the fixture will be used with
77V lamps and ETC’s Dimmer Doubler. This screw prevents 77V
lamps from being installed.
2. Insert the bolt (19) through the light baffle socket casting (2).
3. Install the green ground wire assemblies (21 and 24) on the bolt
(19) with the prongs on the crimped connectors toward the
casting. Run both wires through the indent in the lip around the
bolt hole. Secure with nut (12) and torque to 60 inch pounds.
4. Place the ceramic TP22 socket (11) into the light baffle socket
casting (2) as shown in figure 6. Be sure it is well seated. Firmly
push the connectors on the white TP22 leads (10) into the
grooves in the socket.
5. Place the TP22 mica (9) over the leads, then install the lamp
retainer spring (7). The lamp retainer spring secures the mica.
Insert the spring one end at a time, making sure the rectangular
slot in each side of the spring seats on the corresponding tab in
the casting.
Important: If the spring does not seat correctly, coax it into
place with a screwdriver or needle-nose pliers.
6. Install the bushing cup (5) into the housing socket casting (1) as
shown in figure 7. The cup should slide smoothly up and down,
but not side to side.
7. Insert the threaded end of the index hub (6) through the holes in
the bushing cup and the back of the housing socket casting (1).
8. Slide the X-Y knob (3) over the exposed index hub bolt (6), then
insert the wave washer (16) on the bolt and secure with the 9/16
hex nut (15). Hand tighten the X-Y knob (3).
Note: Install the wave washer with the upward curve toward
the hex nut.
9. Lay the leads in the bottom half of the cable clamp, making sure
that the fiberglass sleeving extends slightly past the screw holes
in the housing socket casting, (install new sleeving if necessary)
2
2
1
12
21
19
24
20
Figure 5
10
11
9
7
Figure 6
16
4
3
5
15
6
Figure 7

8 Electronic Theatre Controls, Inc.
10. Insert the knurled head screw (13) through the housing socket
casting (1) as shown in figure 8.
11. Install the shorter green ground wire (24) with the prongs on the
crimped connector toward the casting onto the screw.
12. Install the ground spring (23) onto the screw and secure it with
the Southco flat retaining ring (14). Install the Southco ring with
its prongs away from the casting.
Note: Use pliers to straighten the Southco retaining ring (14) if it
bends when you install it on the bolt.
13. Lay the leads in the bottom half of the cable clamp, making sure
that the fiberglass sleeving extends slightly past the screw holes
in the housing socket casting. Install new sleeving if necessary.
Then, route the wires as shown in figure 9.
Important: You must follow the wire routing diagram to ensure
that the socket leads do not interfere with the lamp focus
mechanism.
14. Install the top half of the cable clamp (17) and secure it with the
two screws (18) as shown in figure 10. Tighten the screws
alternately to ensure a solid connection.
Note: To ensure that the clamp holds the cable tightly, flatten
the cable, then fold over the sleeving before you install the top
half of the clamp. Make sure the top edge of the cable clamp is
even with the edge of the socket to prevent interference with
lamp focus movement. Make sure sleeving is not pinched.
White
wire
Green
wires
White
wire
14
23
13 24
4
1
13
Figure 8
Figure 10
Figure 9
1
3
17
8
12 2
19
18

Source Four Zoom Assembly Guide 9
26
25
20
Figure 12
15. Using the four screws (25), attach the handle (26) to the lamp
socket assembly.
16. Place the spring (8) on the protrusion on the inside of the index
hub (6).
17. Insert bolt (19) through the light socket baffle (2), thread nut
(12), through spring (8) and through the index hub (6) of the
housing socket (1), joining the two castings. Make sure wires
are not pinched between the two pieces.
18. Before proceeding, check again to make sure the wires are still
positioned as indicated in figure 9. Adjust if necessary.
19. Press the two castings together firmly so the bottom of the light
baffle (2) sits on top of the cable clamp (17), then install the X-Y
lampset (3) and Z lamp knob (4). Hand tighten the knob all the
way to the right.
Important: You must install Z knob as described above to
ensure proper lamp focus travel.
20. Set the crossbar of the retainer clip (25) under the two hooks on
the clip bracket as shown in figure 11.
21. Place the Tinnerman clip (26) over the retainer clip crossbar
between the two hooks and press it down firmly until it snaps
into place.
25
26
Lamp burner
assembly
Figure 11

10 Electronic Theatre Controls, Inc.
SOURCE FOUR
UL
Reflector housing assembly
Reference Part Description Quantity
Number Number Required
1 7060A3054 Housing, reflector casting, painted black 1
2 7060A3006 Clip, reflector retainer 4
3 7060A4010 Bushing, gate 4
4 7060A3016 Plate, clutch 1
5 7060A3019 Spring, reflector support 1
6 7060A4015 Reflector, molded glass, coated 1
7 7060A3058 Bracket, yoke, painted 1
8 HW8144 Handle, yoke knob, 5/16 - 18 1
9 HW753 Rivet, machine, 3/16 x .720, flat head, black zinc 2
10 HW5126 Washer, flat, 5/16, black zinc 3
11 HW5193 Bolt, hex, 5/16-18 x 3/4, black zinc 2
12 HW5125 Bolt, carriage, 5/16-18 x .75, black zinc 1
13 HW752 Rivet machine, 3/16 x 5/16, black zinc 4
1
10
(3 required)
11
(2 required)
9
(2 required)
4
8
5
3
(4 required)
12
7
6
2 (4 required)
13 (4 required)
Figure 13

Source Four Zoom Assembly Guide 11
To remove a reflector
Tools required: Two spare reflector retainer clips (2).
1. Wedge one arm of a spare retainer clip between the lip of one of
the installed clips and the rim of the reflector, then slide the arm
down between the installed clip and the reflector as shown in
figure 14.
2. Insert the other arm of the spare clip between the other arm of
the installed clip and the reflector, as shown in figure 15.
Warning: Do not slide the spare clip all the way in or it will be
very difficult to remove…leave at least a quarter inch exposed.
3. Now slide the entire clip between the reflector and the installed
clip as shown in figure 16. Remember, do not slide it all the way
in.
4. Repeat this procedure with the second spare clip, inserting it
between an adjacent installed clip and the reflector.
5. Turn the reflector housing casting over, so that the rear of the
reflector is in view. Gently push on the reflector, toward the side
of the housing where the extra clips were placed. The reflector
will slip off to the side at an angle.
6. Turn the reflector housing casting back over and gently slide the
reflector out from under the retaining clips.
To install a reflector
Note: The following assumes all four reflector retainer clips (2) have
already been riveted to the reflector housing casting (1) and the gate
bushings (3) installed on the retainer clips.
1. Place the reflector housing casting (1) on a flat work surface
with the large opening facing up.
2. Install the reflector support spring (5) in the circular opening at
the base of the casting.
3. Insert the reflector (6) at an angle, under any three legs of the
reflector's clips.
4. Gently press down on the reflector until it snaps into place under
the clips.
Note: If the reflector does not snap in, turn the casting over.
Gently pull on the side of the reflector that has not snapped in
until the rest of the reflector slides into place.
To clean the reflector
Remove dust with a blast of oil-free air or wipe with a clean, lint-free
cloth using alcohol or distilled water (alcohol is recommended).
Warning: Do not use glass and window cleaners on the reflector.
Chemicals in these cleaners will stain the reflector.
Figure 15
Figure 14
Figure 16

12 Electronic Theatre Controls, Inc.
Gate Housing assembly
Reference Part Description Quantity
Number Number Required
1 7060A3112 Gate barrel, top casting, painted 1
2 7060A3113 Gate barrel, bottom casting, painted 1
3 7060A2025 Shutter blade assembly, 22 gauge 4
4 7060A3001-01 Plate, divider with dimples (bottom) 1
5 7060A3003 Plate, gate (middle) 1
6 7060A3001-02 Plate, divider (top) 1
7 HW754 Shutter spring 4
8 HW391 Screw, PHMS 8-32 x 3/4, black zinc 2
9 7060A3045 Cover, iris slot 1
10 HW2177 Thumb screw, 8-32 x 1/4, black zinc 2
Note: The bottom divider plate (4)
has four dimples punched into the
surface; the top plate (6) has none.
The middle divider plates (5) are
noticeably thinner-gauge metal
than the other two.
(See detail to
the right)
4
1
3
5
6
2
3
4
5
6
8
10
9
7
Figure 17
Figure 18

Source Four Zoom Assembly Guide 13
Gate Housing assembly
Tools required: Phillips head screwdriver.
1. Stand the top and bottom gate barrel castings (1 and 2) upright
with the shutter openings down.
Note: The top gate barrel casting contains the iris slot.
2. Slide in the bottom divider plate (4). The dimples on the divider
plate must point down.
Note: The notches on the divider plates must fit snugly against
the flanges in the casting so the plates do not move.
Warning: Divider plate edges are sharp. Handle with caution!
3. With the bottom barrel to your left, place one shutter blade (3)
on top of dimple plate (4), handle facing outward, up and down.
Note: Install shutter blades with the rounded side facing up
toward the front of the casting.
4. Place a divider plate (5) on top of the shutter blade.
5. Place another shutter blade on top of the divider plate. Then
place another divider plate on top.
6. Place the two shutter blades on top of the divider. Pull the blade
and plate assembly slightly forward to allow the handle to slip
through the slot in the bottom casting.
7. Place the top divider plate (6) on top of the two shutter blades.
Note: Make sure no shutter assembly components are under
the pattern holder guides.
8. With both gate barrel castings still standing upright, join the two
halves, sliding the handle of the top shutter blade through the
slot in the top gate barrel casting (1).
9. Connect the halves of the gate assembly together using the two
PHMS screws (8).
Note: The tops of the two gate barrel castings must be even.
Adjust as necessary before completely tightening the nuts and
screws. Failure to do this could interfere with the barrel rotation.
10. Turn the gate barrel assembly over so that the narrower end is
on your work surface.
11. Install the four shutter springs (7) between the four dimples in
the shutter plate and the tabs in the lip of the casting.
Note: Install the springs at the joints in the castings on either of
the tabs at the joint.
Caution: During assembly, the shutter springs can pop out of
place. Always wear protective eyewear during this procedure.
12. Place iris slot cover (9) over the iris slot. Use two screws (10) to
secure the cover.

14 Electronic Theatre Controls, Inc.
29
2026
25
24
23
22 21
31
30
28
27
Gel frame endcap assembly
Front lens assembly Rear lens assembly
38 32 33
34
35
37
36
1
8
6
7
5
4
3
2
13
12
10
9
17
16
15
14
18
19
15°-30° lens tube assembly
11
Figure 19
Figure 20
Figure 21 Figure 22
20
21
10A

Source Four Zoom Assembly Guide 15
15°-30° lens tube assembly
Reference Part Description Quantity
Number Number Required
1 7060A2030 15°-30° lens tube 1
2 7060A3091-01 Extrusion door 1
3 See below Front lens assembly 1
4 See below Rear lens assembly 1
5 HW5218 Nut 1/4-20 metal lock Lowpro 1
6 7060A4056 Dial adjustment 1
7 7060A4066 Button, push, CAM lever 1
8 HW776 Spring, push-button 1
9 7060A4057 Lever, CAM 1
10 7060A4082 Zoom field angle label 1
10A 7060A4081 S4 Zoom rangle label, 15-30 1
11 7060A4054 Light baffle 1
12 7060A4058 Gear, spur 1
13 HW777 Wash spring 1
14 HW9200 Spacer, 1/4-20 x 0.875, round, aluminum 1
15 HW5224 Screw, 1/4-20 x 1-1/4, PHMS 1
16 HW8227 Retainer, 1/4 turn stud 1
17 7060A3114 Latch bracket 1
18 HW8225 Fasterner, bail style 1
19 See below Gel frame endcap 1
20 HW5217 Screw, 1/4-14 x 1, OHSL 4
21 See page12 Gate housing assembly 1
Reference Part Description Quantity
Number Number Required
27 7060A4046 Front lens holder 1
28 7060A4050 Front gear rack 1
29 HW3118 Washer, flat #8, black 1
30 HW3114 Screw, 8-32 x 2, PHST, plastic 1
31 7060A4067 Front lens glass 1
Front lens assembly
Reference Part Description Quantity
Number Number Required
32 HW4117 Washer, flat, Teflon 2
33 HW4112 Screw, #10-14 x 5/8, plastic 2
34 HW3118 Washer, flat #8, zinc 1
35 HW3114 Screw, 8-32 x 2, PHST plastic 1
36 7060A4051 Rear gear rack 1
37 7060A4068 Rear lens glass 1
38 7060A4048 Rear lens holder 1
Rear lens assembly
Reference Part Description Quantity
Number Number Required
20 HW5217 Screw, 1/4-14 x 1, OHSL 4
21 7060A3111 Endcap, gal frame, black 1
22 7060A3100 Gel clip 1
23 HW750 Spring retainer 1
24 HW8226 Receptable, 1/4 turn stud 1
25 7060A3097 Plate, gel clip retainer 1
26 HW369 Screw, 8-32 x 5/8, PHMS 1
Gel frame endcap assembly

16 Electronic Theatre Controls, Inc.
2026
25
24
23
22
21
1
2
4
3
11
10
9
8
7
6
5
12 13 14 15
16
17
18
19
31
32
30
29
28
27
33
37
40
35
34
36
38
39
25°-50° lens tube assembly
Gel frame endcap assembly
Front lens assembly Rear lens assembly
Figure 23
Figure 24
Figure 25 Figure 26
20
21
10A

Source Four Zoom Assembly Guide 17
25°-50° lens tube assembly
Reference Part Description Quantity
Number Number Required
1 7060A3090-02 25°-50° lens tube 1
2 7060A3091-02 Extrusion door 1
3 See below Front lens assembly 1
4 See below Rear lens assembly 1
5 HW5218 Nut 1/4-20 metal lock Lowpro 1
6 7060A4056 Dial adjustment 1
7 7060A4066 Button, puch, CAM lever 1
8 HW776 Spring, push-button 1
9 7060A4057 Lever, CAM 1
10 7060A4084 Zoom field angle label 1
10A 7060A4080 S4 Zoom range angle, 25-50 1
11 7060A4055 Light baffle 1
12 7060A4058 Gear, spur 1
13 HW777 Wash spring 1
14 HW9200 Spacer, 1/4-20 x 0.875, round, aluminum 1
15 HW5224 Screw, 1/4-20 x 1-1/4, PHMS 1
16 HW8227 Retainer, 1/4 turn stud 1
17 7060A3114 Latch bracket 1
18 HW8225 Fasterner, bail style 1
19 See below Gel frame endcap 1
20 HW5217 Screw, 1/4-14 x 1, OHSL 4
21 See page12 Gate housing assembly 1
Reference Part Description Quantity
Number Number Required
20 HW5217 Screw, 1/4-14 x 1, OHSL 4
21 7060A3111 Endcap, gal frame, black 1
22 7060A3100 Gel clip 1
23 HW750 Spring retainer 1
24 HW8226 Receptable, 1/4 turn stud 1
25 7060A3097 Plate, gel clip retainer 1
26 HW369 Screw, 8-32 x 5/8, PHMS 1
Gel frame endcap assembly
Reference Part Description Quantity
Number Number Required
27 7060A4047 Front lens holder 1
28 7060A4052 Front gear rack 1
29 7060A4069 Front lens glass 1
30 HW4112 Screw, #10 - 10x5/8, plastic 1
31 HW4117 Washer, flat, Teflon 1
32 HW3118 Washer, flat #8, zinc 1
33 HW3114 Screw, 8-32 x 2, PHST, plastic 1
Front lens assembly
Reference Part Description Quantity
Number Number Required
34 7060A4048 Rear lens holder 1
35 7060A4070 Rear lens glass 1
36 7060A4053 Rear gear rack 1
37 HW4117 Washer, flat, Teflon 2
38 HW4112 Screw, #10 - 10x5/8, plastic 2
39 HW3116 Screw, 8-10x1-1/2 1
40 HW3118 Washer, flat #8, zinc 1
Rear lens assembly

18 Electronic Theatre Controls, Inc.
1. Slide the front lens holder (3) into the left-hand top raceway as
shown in figure 27.
2. Slide the rear lens holder (4) into the left-hand bottom raceway
as shown in figure 27.
3. Position the lens assembly gear teeth as shown in figure 27.
4. From inside the unit, place the gear spur (12) between the lens
assemblies. make sure the vertical hash marks on the gear spur
line up with the hash marks on both the front and rear gear
teeth. See figure 26.
5. Slide the spacer (14) onto the screw (15).
6. From inside the unit, pass the screw (15) and spacer (14)
through the washer (13) and insert into the hole on the gear spur
(12).
7. On the outside of the unit, place the adjustment dial (6) over the
screw end (15) and secure with the metal nut (5).
8. Slide the light baffle (11) into the opening of the lens tube.
9. Place the gate assembly (21) onto the rear of the lens tube and
secure with four screws (22).
10. With the extrusion door open, place the gel cap (19) on the front
of the unit and secure with four screws (20).
11. Once the gel cap is in place, close the extrusion door and turn
the fastener (18) one-quarter turn clockwise to secure the baffle
in place.
Assembling the lens tube; 15°-30° and 25°-50°
1
8
6
7
5
4
3
2
13
12
10
9
17
16
15
18
19
11
14
20
21
22
alligned hash marks
front lens
rear lens
gear teeth
Figure 27
Figure 28

Source Four Zoom Assembly Guide 19
Cleaning 15°-30° and 25°-50° glass lenses
1. Dampen a clean, lint-free cloth with vinegar or household
ammonia. You may use water, but it leave spots. You can
remove by polishing the lens gently with a clean, dry cloth.
Warning: Never use glass and window cleaner or any abrasive
material to clean lenses. Glass and window cleaners will stain
the lens surface. Abrasive materials (such as steel wool) will
damage the surface of the lens.
2. Starting from the center, gently wipe the lens.
Note: Refer to the Source Four Zoom User Guide instruction
booklet, included with your fixture, for information regarding lens
tube orientation and lens position when cleaning.

This document is the confidental property of ETC and is loaned subject to return upon demand. Title to this document is never sold or transferred for any reason. This document is to be used only pursuant to written
license or written instructions of ETC. All rights to designs and inventions are reserved by ETC. Possession of this document is subject to the foregoing.
Electronic Theatre Controls
North America 3030 Laura Lane • Middleton, Wisconsin 53562 • USA • Tel: [phone] • Fax: [phone]
Europe 5 Victoria Industrial Estate • Victoria Road • London W3 6UU • Tel: [phone] • Fax: [phone]
Asia Room 605-606 • Tower III, Enterprise Square • 9 Sheung Yuet Road • Kowloon Bay • Hong Kong • Tel: [phone] • Fax: [phone]
World Wide Web http://www.etcconnect.com • Email [email protected]
Source Four™ is protected by US patent numbers 5,268,613; 5,345,371; 5,446,637; 5,544,029. Japan patent number 2,501,772. US and International patents pending.
Copyright 2000. Specifications subject to change.
Revised 2/00. Part number 7060M1010