Kino Flo Flathead 80 User manual

Operation Manual
Part No. 3100076 Rev A 10-21-2015
Flathead 80 DMX
Flathead 80

2
Flathead 80 System
Each Flathead 80 System consists of:
1 Fixture
1 Mounting Plate
2 Extension Cable
2 4Bank or 4Bank DMX Ballast
CFX-4808
Flathead 80 Fixture
MTP-K81
Kino 81 Mount w/ Junior Pin (28mm)
X16-25
4Bank Extension, 25ft (x2)
BAL-427-120U
4Bank Ballast, Univ 120U (x2)
BAL-427-230U
4Bank Ballast, Univ 230U (x2)
BAL-457-120U
4Bank DMX Ballast, Univ 120U (x2)
BAL-457-230U
4Bank DMX Ballast, Univ 230U (x2)

3
True Match Lamps
Flathead 80 Kits
488-K32-S 4ft Kino KF32 Safety-Coated
488-K55-S 4ft Kino KF55 Safety-Coated
®
KIT-F80-120U
Flathead 80 Kit, Univ 120U
KIT-F80-230U
Flathead 80 Kit, Univ 230U
Kit Contents:
1 Flathead 80 Fixture
1 Mount w/ Junior Pin (28mm)
2 4Bank Ballast
2 Extension, 25ft
1 Ship Case
Dimensions:
Weight:
57 x 10.5 x 29” 83 lb
(145 x 27 x 74cm) (38kg)
KIT-F80-X120U
Flathead 80 DMX Kit, Univ 120U
KIT-F80-X230U
Flathead 80 DMX Kit, Univ 230U
Kit Contents:
1 Flathead 80 Fixture
1 Mount w/ Junior Pin (28mm)
2 4Bank DMX Ballast
2 Extension, 25ft
1 Ship Case
Dimensions:
Weight:
57 x 10.5 x 29” 85 lb
(145 x 27 x 74cm) (39kg)
Flathead 80 Kit
Flathead 80 DMX Kit

4
Inserting Lamps
Inserting Gel Frame
Inserting Louver
Applying Gel to Frame
Insert lamps into both lamp holders. Twist ¼ turn to make electrical contact.
Option 1 – The Gel Frame comes with gel clips. Cut the gel to size
and use the clips to fasten the gel to the frame.
Note: It is recommended to attach one clip on each side and one
clip near all four corners.
Option 2 – Another method is to apply transfer tape directly to the
gel frame. The clips are not necessary when taping the gel.
The gel frame is secured to the xture by 4 spring-loaded pins. Align the pins of the
gel frame with the oval receptacle holes on the edge of the xture. Pull back the pins
and release into the receptacles to properly secure the gel frame.
Place the long edge of the Louver (LVR-I80-S) into the lower channel containing a set
of leaf springs. Press down on the Louver and slip the upper edge of the louver into
the upper channel of the xture. To remove, reverse the procedure.

5
Mounting the Fixture
The Flathead 80 is designed to operate on a Junior stand, hang from a Junior pipe
hanger or mount directly to a set wall.
Mount Plate Operation
Align the center pin of the Mounting Plate (MTP-K81)
to the center hole on the mating plate. Rotate plate
clockwise until the four shoulder rivets drop into the
receptacle. A locking pin will snap into place when the
plate is properly seated.
To remove the plate, pull up on the locking pin and
reverse the mounting procedure.
To loosen or tighten the lollipop, turn lock lever.
With a 180 degree turn, the lever can be adjusted to
provide the necessary clamping strength. Reorienting
the lever allows for further tightening or loosening of the
clamp.
To reorient the lock lever, pull lever away from mount.
This disengages the lever from the screw mechanism
and allows it to be reoriented.
Note: You can also use a screwdriver to adjust the
travel. Pull back on lever and adjust the screw in the
center of the lever.
Mounted on a Junior Stand

Extension Cable
6
Mounting to a Set Wall
Cardholders MTP-IB1 (x2), MTP-IB2 (x2)
The Flathead 80 has screw points within the xture to allow it to be
fastened at against a surface.
The Flathead 80 is equipped with unique cardholder corner brackets
that allow foam core panels to be clipped in place.
To insert the cable, position the logo up to
align the key ways on the extension cable
with the circular receptacle on the ballasts.
Rotate the locking ring until it clicks into the
lock position.
Fixture can operate as far as 75 feet from
the ballast (3 x 25ft extensions).

7
Ballast Operation
WARNING!
1) ALWAYS TURN OFF THE BALLAST BEFORE connecting or
disconnecting Lamps, Harnesses or Extension Cables.
2) Use only with Sine wave inverters. Do not operate on SCR dimmers.
3) If powering the ballasts through a Dimmer Pack, set the Dimmer
to Non-Dim mode.
The Ballast requires 100-240VAC 50/60 Hertz on an earth grounded circuit;
The electronic Ballast operates at a high frequency of 25kHz. It is dead-
quiet, instant-on and lightweight.
The Ballasts operate remote from the xture. Connect the extension cables
to the ballasts and the Flathead 80 xture. After the lamps are properly
installed, the ballasts can be turned on.
Cold Temperature Operation
The Ballast is designed to operate at temperatures from 14°F to 122°F
(-10°C to +50°C). In cold temperatures, the Ballast may not strike the
lamp(s) instantly. Switch the Ballast to OFF, wait seven seconds and try
again. If the Ballast does not strike after two or three attempts, turn off
the Ballast, check that the Extension and Harness connections are secure
and re-strike. Once operating for a few minutes, the lamps should re-strike
instantly.

8
4Bank DMX Control Panel
A) Circular Output Connector: Provides electrical power to the lamp head
with the use of a 4Bank extension cable.
B) DMX-In & DMX-Out: DMX-In receives DMX signals from Dimmer Board.
DMX-Out relays DMX signals through other Fixtures or Instruments.
Note: Each BAL-457 ballast has an “AUTO TERMINATE”
feature. The last ballast that does not have an XLR cable attached
to the DMX “Out” port will automatically terminate.
C) DMX Address: Sets DMX Address of Fixture.
(Channels 1~4 = Lamps; Channel 5 = 4ft/2ft)
D) DMX OK: Lights if valid DMX signal is present and conforms to
DMX512/1990 protocol.
E) Manual Switches: Turns lamps on and off manually.
F) Lamp Select Switch: Set to 4ft for 4ft lamps and 2ft for 2ft lamps.
G) Fuse: Provides circuit protection. Note: If Fuse is “blown” or “open”,
replace with same type of fuse rating as marked.
A B C D E F G

9
Manual Operation
Lamp Select Feature
The 4Bank and 4Bank DMX Ballasts have a 4ft/2ft switch. Set the selector switch to
4ft for 4ft lamps.
When operating 4ft lamps in high ambient temperature or where the units are rigged
into place with restricted airow, the 2ft setting can be used to lower the color
temperature and remove any green spike. The light drops about a ½ f-stop in
exposure when dropping from 4ft to 2ft setting.
Note: The manual 2ft/4ft switch is disabled as soon as the DMX cable is applied.
To manually control the 2ft/4ft switch with DMX cables plugged in:
1) Unplug the DMX cable or
2) Leave cables plugged in and set DMX address to “000”.
There is a 5 second delay when switching between DMX and Manual Control.
Lamp Switching
The Flathead 80 operates remotely on two 4Bank or 4Bank
DMX Ballasts. Each ballast includes four lamp switches for
individual lamp control. The multi-pin connectors on the side of
the Flathead 80 xture are numbered 1 and 2.
Ballast 1 operates the four inner lamps; Ballast 2 operates
the four outside lamps as illustrated below.

10
DMX Operation
DMX Addressing
Push the tabs above or below the number window to
set the address. (Valid addresses range from 001 to
512.) The yellow light above the address block will
illuminate if a DMX signal is present.
Each 4Bank DMX ballast operates on 5
addresses. This is useful in achieving light effects
like ickering, chasing or creating light patterns.
BAL-457 operates on 5 addresses:
Lamps = 1-4
4ft/2ft = 5
The 5th address controls the 4ft/2ft setting.
Dimmer level from 0%~50% operates all the lamps
at the 4ft setting. Dimmer level from 50%~100%
operates the lamps in the 2ft setting and the overall
light output drops by ½ f-stop.
Note: If the 5th address is not addressed, the ballast
will default in the 4ft setting. The 4ft/2ft select setting
controls all 4 lamps equally. Individual settings per
lamp are not possible.
IMPORTANT!
The dimmer board/light console should have its channel set to LINEAR light
output response. (LINEAR response is the default setting on most dimmer
boards.)
Note: If a Fixture or Ballast loses its DMX signal, it will hold its last
DMX command. For this reason, it is important to turn a Fixture or Ballast
off using the DMX commands. For example, if you try to turn off the lights by
turning off the dimmer board, the lights will remember their last DMX com-
mand and stay on. The Fixtures or Ballasts require a DMX “Off” or “Black-
out” command in order to turn off.

11
To chase one lamp through multiple xtures:
1) Set each ballast with its own address: 001, 006, 011, 016 and so on.
2) Program address 005, 010, 015, etc. for 2ft operation.
3) Program lamp sequence to chase from 001 through 004, 006-009,
011-014 and so on.
To chase same lamp position simultaneously through multiple xtures:
1) For each Flathead 80 xture, set Ballast 1 address to 001
(or a common address) and set Ballast 2 address to 006
(or a common address).
2) Program address 005, 010, 015, etc. for 2ft operation.
3) Program lamps to chase from address 001-004 and 006-009.
For example: If the 4Bank DMX base address is set at 001 for Ballast 1, and Ballast 2
is set at 006, the conguration below will provide 8 lamps individually addressable
through DMX 512.
DMX Lamp Sequence
DMX Address = 001, 006
Lamp # DMX Address
Lamp 1.1 1
Lamp 1.2 2
Lamp 1.3 3
Lamp 1.4 4
4ft/2ft 5
Lamp 2.1 6
Lamp 2.2 7
Lamp 2.3 8
Lamp 2.4 9
4ft/2ft 10
DMX Lamp Sequence

12
DMX Cables
The ballast uses 5-pin XLR male and female
connectors to receive DMX signals from the
Dimmer Board and jumper the Ballasts in a series.
DMX pin-out wiring follows the USITT DMX 512
standard:
Pin 1: Shield
Pin 2: Data –
Pin 3: Data +
Pin 4: Spare –
Pin 5: Spare +
Note: Pin four and ve in the ballast are
connected internally as Pin four to four and
Pin ve to ve. Connecting Pin four and ve as
the pass-through allows secondary data to be
passed through for other equipment.
Do Not use Microphone Cables and other general purpose, two-core cables
designed for audio or signaling use. They are not suitable for DMX 512. Problems
due to incorrect cabling may not be immediately apparent. Microphone Cables may
appear to work ne, but systems built with such cables may fail or be prone to random
errors. Cable must comply with EIA-485 (RS485).
Auto Terminate Feature
4Bank DMX ballasts (457 Series) have an
“AUTO TERMINATE” feature. The last ballast that
does not have an XLR cable attached to the DMX
“Out” port will automatically terminate.
Any theatrical lighting board with DMX 512
protocol can be used to individually turn on/off
lamps in a xture.
4Bank DMX ballasts can be jumpered using the
IN and OUT ports. As many as 100 ballasts can
be jumpered on one chain as long as the DMX
cable run remains under 1000 feet or 40 x 25ft
DMX cables.
Note: When operating ballasts at great distances from the dimmer board, it is
recommended to use Opto-Isolators to provide DMX signal amplication.

13
Accessories and Parts
GFR-I80 Image 87/Flathead 80 Gel Frame
LVR-I80-B Image 87/Flathead 80 Louver (Black)
LVR-I80-S Image 87/Flathead 80 Louver (Silver)
MTP-IB Image/Flathead 80 Cardholder
REF-I80 Image 87/Flathead 80 Reector
X16-25 4Bank Extension Cable, 25ft
X16-12 4Bank Extension Cable, 12ft
XLR-525 DMX Cable 5-Pin XLR, 25ft
XLR-515 DMX Cable 5-Pin XLR, 15ft

14
Fixture Specications
CFX-4808 Flathead 80 Fixture
Lamps: 8
Weight w/ Lamps: 27lbs / 12kg
Dimensions: 51 x 24 x 4”
(129 x 61 x 10cm)
Lamp Type: F75/T12
True Match Lamps
488-K32-S 4ft Kino KF32 Safety-Coated
488-K55-S 4ft Kino KF55 Safety-Coated
488-K10-S 4ft Kino 420 Blue Safety-Coated
488-K5-S 4ft Kino 525 Green Safety-Coated
®

Ballast Specications
15
4Bank DMX
BAL-457-120U 4Bank DMX Ballast, Univ 120U
Input Voltage: 100~240VAC 50/60Hz
Output Frequency: 25kHz
Amperage: 2 x 2.6A = 5.2A
Lamp Switching: 1~4
Output Switching: 4ft / 2ft
Ballast Size: 12 x 11 x 3”
(30.5 x 28 x 7.6cm)
Weight: 5.3 lb (2.4kg)
BAL-457-230U 4Bank DMX Ballast, Univ 230U
Input Voltage: 240~100VAC 50/60Hz
Output Frequency: 25kHz
Amperage: 2 x 1.4A = 2.8A
Lamp Switching: 1~4
Output Switching: 4ft / 2ft
Ballast Size: 12 x 11 x 3”
(30.5 x 28 x 7.6cm)
Weight: 5.3 lb (2.4kg)
4Bank
BAL-427-120U 4Bank Ballast, Univ 120U
Input Voltage: 100~240VAC 50/60Hz
Output Frequency: 25kHz
Amperage: 2 x 2.6A = 5.2A
Lamp Switching: 1~4
Output Switching: 4ft / 2ft
Ballast Size: 13 x 9.5 x 3”
(33 x 24 x 7.6cm)
Weight: 4.9lb (2.2kg)
BAL-427-230U 4Bank Ballast, Univ 230U
Input Voltage: 240~100VAC 50/60Hz
Output Frequency: 25kHz
Amperage: 2 x 1.4A = 2.8A
Lamp Switching: 1~4
Output Switching: 4ft / 2ft
Ballast Size: 13 x 9.5 x 3”
(33 x 24 x 7.6cm)
Weight: 4.9lb (2.2kg)

16
For latest Warranty information and Certications,
see Kino Flo website at www.kinoo.com.
Environmental: Disposal of Old Electrical & Electronic Equipment.
This symbol on the product or on its packaging indicates that this
product shall not be treated as household waste. This product is made
of recyclable materials and should be disposed of in accordance with
local and state regulations.
Kino Flo, Inc. 2840 N. Hollywood Way, Burbank, CA 91505, USA
Tel: [phone] website: www.kinoo.com