Pure Reliability PILOT 300 User manual

PILOT 300
PR-2301
This product manual contains important information about the safe installation and
use of this projector. Please read and follow these instructions carefully and keep this
manual in a safe place for future reference.
PEARL RIVER LIGHT & ACOUSTICS INDUSTRIAL LTD.
Yingbin Road, Dashi Panyu, Guangzhou, 511430 China
http://www.pr-lighting.com

INDEX
SECTION PAGE
SAFE USAGE OF THE PROJECTOR 3
INSTALLINGTHEPROJECTOR 4
FITTINGTHELAMP 4
POWER SUPPLY - MAINS 5
CONTROL CONNECTIONS 5
SETUP OPTIONS – PROJECTOR CONFIGURATION 6
PROJECTOR DMX START ADDRESS 6
DMX CONTROL CHANNEL FUNCTIONS 7
STAND-ALONE MODES – MASTER/SLAVE 7
MAINTENANCE 8
CHANGINGTHEGOBOS 8
LUBRIFICATION 8
KEEPING THE PROJECTOR CLEAN 9
TROUBLESHOOTING 9
TECHNICAL DATA 10
ELECTRICALDIAGRAM 11
COMPONENT ORDER CODES 12
Please note that as part of our ongoing commitment to continuous product development, specifications are subject to change
without notice. Whilst every care is taken in the preparation of this manual we reserve the right to change specifications in the
course of product improvement. The publishers cannot be held responsible for the accuracy of the information herein, or any
consequence arising from them.
Every apparatus is tested completely and packed properly by the manufacturer. Please make sure the packing and / or the
apparatus is in good condition before your installation and use. Should there be any damage caused by transportation, consult
your dealer and do not use the apparatus. Any damage caused by improper use will not be assumed by the manufacturer and /
or dealer.
ACCESSORIES
THESE ITEMS ARE PACKED TOGETHER WITH THE PROJECTOR
Mounting Bracket (2 PCS)
M8x25 screw for mounting brackets (4 PCS)
Power-cord (1 PCS)
XLR plug (1 PCS)
XLR socket (1 PCS)
Safety cord (1 PCS)
Spare gobos (4 PCS)
This manual (1 PCS)
INTRODUCTION
Thank you for purchasing the PILOT 300, PR-2301.
This product manual contains important information about the safe installation and use of this projector.
Please read and follow these instructions carefully and keep this manual in a safe place for future
reference.
The PILOT 300 is an innovative projector with an elegant housing, which is made from high intensity
and heat–resistant complex plastic. PILOT 300 complies to CE norms and standards and uses
international protocol DMX 512. PILOT 300 can be used as a stand-alone unit or linked to a controller,
so it is suitable for many different applications.
PILOT 300 features 9 colours, 7 interchangeable rotating gobos, and an independent adjustable
strobe/shutter, prism effect and remote focus. It can be setup easily via the touch-switches and digital
display screen.
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SAFE USAGE OF THE PROJECTOR
When unpacking and before disposing of the carton check there is no transportation damage before
using the projector. Should there be any damage caused by transportation, consult your dealer and do
not use the apparatus.
The projector is for Indoor use only, IP20. Use only in dry locations. Keep this device away from rain
and moisture, excessive heat, humidity and dust. Do not allow contact with water or any other fluids,
or metallic objects.
The projector is only intended for installation, operation and maintenance by qualified personnel.
The projector is not designed or intended to be mounted directly on to inflammable surfaces.
The projector must be installed in a location with adequate ventilation, at least 50cm from
adjacent surfaces. Be sure that no ventilation slots are blocked.
Do not project the beam onto inflammable surfaces, minimum distance is 3m. 3m
Avoid direct exposure to the light from the lamp. The light is harmful to the eye.
Do not attempt to dismantle and/or modify the projector in any way.
Electrical connection must only be carried out by qualified personnel.
Before installation, ensure that the voltage and frequency of power supply match the power
requirements of the projector.
It is essential that each projector is correctly earthed and that electrical installation conforms to all
relevant standards.
Do not connect this device to any dimmer pack.
Make sure that the power-cord is never crimped or damaged by sharp edges. Never let the power-
cord come into contact with other cables. Only handle the power-cord by the plug. Never pull out the
plug by tugging the power-cord.
The projector should always be installed with a secondary safety fixing. A safety cord is supplied for
this, it should be attached as shown.
The lamp used in this projector is an HTI 300W/DX discharge lamp. After being switched off don’t
attempt to restart the projector until the lamp has cooled, this will require approx 15 minutes. Switching
the lamp on and off at short intervals will reduce the life of both the lamp and the projector.
Never run the projector without a lamp.
Keep the lamp clean. Do not touch the lamp glass with bare hands.
There are no user serviceable parts inside the projector, do not open the housing and never operate
the projector with the covers removed.
Always disconnect from the mains, when the device is not in use or before cleaning it or before
attempting any maintenance work.
If you have any questions, don’t hesitate to consult your dealer or manufacturer.
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INSTALLING THE PROJECTOR
BRACKET
BRACKET
BRACKET
Pass safety fixing
through these holes
106mm
280mm
BRACKET
The projector should be mounted via its brackets using 2 M12 bolts. The brackets attach to the
underside of the projector with 4 M8x25 bolts provided. Always ensure that the projector is firmly
anchored to avoid vibration and slipping whilst functioning. Always ensure that the structure to which
you are attaching the projector is secure and is able to support a weight of 18Kg for each PILOT 300.
For safety the projector should have a secondary fixing with a safety chain through the holes on the
underside of the unit.
WARNING: The projector should NEVER be lifted or carried by the yoke.
FITTING THE LAMP
LAMP ACCESS HATCH
LAMP
BUBBLE
LAMP ACCESS HATCH
ACCESS SCREW
ACCESS SCREW
ACCESS SCREW
LAMP ADJUSTMENT
LAMP ADJUSTMENT
LAMP ADJUSTMENT
A
B
C
Adjust lamp
position by
turning screws
A, B, and C
ONLY USE REPLACEMENT
LAMP TYPE: HTI 300W/DX
Loosen the 3 access screws at the rear of the projector and pull the lamp access hatch straight out
from the rear of the projector. Insert an HTI 300W/DX lamp in the lamp holder.
Close the lamp access hatch, then tighten the 3 access screws.
NOTE: When fitting the lamp position it with the little bubble vertically (either upwards or downwards)
as shown in the diagram above. Do not position it horizontally. Close the access hatch carefully and
re-tighten the 3 screws. To optimize light output it will be necessary to adjust the lamp alignment to
obtain an even distribution of light within the beam. The three screws (marked A, B, and C) may be
gently turned to center the lamp within the reflector. The projector should be switched on with the
shutter open and the beam focused to do this, it is also advisable to allow the lamp 5 minutes to come
up to full brightness before starting to align it. Note: the three screws will only need a small adjustment
to centre the lamp, do not try to unscrew them completely. Read the rest of this manual and then come
back to this section to align the lamp.
The HTI series are high pressure lamps with external igniters ( ). Care should always be taken when
handling these lamps. Always read the manufacturers "Instructions for use" enclosed with the lamp.
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POWER SUPPLY - MAINS
FUSE F6.3A/250V
FUSE HOLDER
LEN
L = BROWN
E = GREEN/YELLOW
N = BLUE
Use the plug provided to connect the mains power to the projector paying attention to the voltage and
frequency marked on the panel of the projector. It is recommended that each projector is supplied
separately so that they may be individually switched on and off.
IMPORTANT
It is essential that each projector is correctly earthed and that electrical installation conforms to all
relevant standards. Power consumption of the PILOT 300 is 480W.
CONTROL CONNECTIONS
DMX IN
12
3
1
2
3
DMX OUT DMX 512
PIN FUNCTION
1
2
3
GND
DATA -
DATA +
Connection between controller and projector and between one projector and another must be made
with 2 core screened cable, with each core having at least a 0.5mm diameter. Connection to and from
the projector is via cannon 3 pin XLR plugs and sockets which are included with the projector. The
XLR's are connected as shown in the table above. Note, care should be taken to ensure that none of
the connections touch the body of the plug or each other. The body of the plug is not connected in any
way. The PILOT 300 accepts digital control signals in standard DMX512 (1990) format.
DMX IN FROM
CONTROLLER TERMINATOR
DMX IN DMX IN DMX INDMX OUT DMX OUT DMX OUT
No. 1 No. 2 No. n
PILOT 300 uses 3-pin XLR plug / socket. If your controller uses 5-pin XLR plug / socket, you should
use a conversion cable from 5-pin to 3-pin as shown bellow.
5 PIN PLUG
Pin 1: GND (Screen)
Pin 2: Signal (data -)
Pin 3: Signal (data +)
Pin 4: N/C
Pin 5: N/C
3 PIN SOCKET
Pin 1: GND (Screen)
Pin 2: Signal (data -)
Pin 3: Signal (data +)
5 PIN SOCKET
Pin 1: GND (Screen)
Pin 2: Signal (data -)
Pin 3: Signal (data +)
Pin 4: N/C
Pin 5: N/C
3 PIN PLUG
Pin 1: GND (Screen)
Pin 2: Signal (data -)
Pin 3: Signal (data +)
When a DMX 512 signal is received the LED located near the digital display will illuminate green.
When not receiving a DMX signal the green and red LEDs will be off, and if the green LED flashes, it
means that the DMX signal is not correct.
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DMX TERMINATOR
At the last fixture in the chain, the DMX output has to be connected with a DMX terminator. This prevents
electrical noise from disturbing and corrupting the DMX control signals.
The DMX terminator is simply an XLR connector with a 120Ω(ohm) resistor connected across pins 2 and 3,
which is then plugged into the output socket on the last projector in the chain. The connections are illustrated
below.
PIN 3
PIN 2
DMX TERMINATOR CONNECTION
Connect a 120Ω(OHM) resistor across
pins 2 and 3 in an XLR plug and insert
into the DMX OUT socket on the last
unit in the chain.
SETUP OPTIONS – PROJECTOR CONFIGURATION
To browse through the various Setup Options, press the FUNC button consecutively. There are 7
Option codes (1~7), and each code has a specific function. The functions provided are listed in the
following table.
SETUP OPTIONS
CODE CHOICE FUNCTION
Y Reverse Tilt enable - Tilt is reversed
1 N Reverse Tilt disable - Tilt is normal
Y Reverse Pan enable - Pan is reversed
2 N Reverse Pan disable - Pan is normal
3 Microphone activation of Auto Programmes 1 & 2
N Automatic programme 1 enable
4 Y Automatic programme 2 enable
N Automatic programmes 1 or 2
5 Y Master / Slave operation of programmes 1 or 2
Y 16bit Pan/Tilt movement resolution enable
6 N 16bit Pan/Tilt movement resolution disable
Y Reduced movement of Pan and Tilt for Auto mode
7 N Normal (full) movement of Pan and Tilt for Auto mode
Once you have selected the desired operation code, press the key UP or DOWN to select either “n”
(means OFF) or “y “ (means ON). n = NO, y = YES.
Press the key ENTER 2 times to save the selected function and configuration. If the display is
showing “y”, then the setting has been enabled. In the same way, if it was showing “n” when you
pressed ENTER the option has been disabled.
The Red LED will flash during this operation.
PROJECTOR DMX START ADDRESS
GREEN LED RED LED
FUNC DOWN UP ENTER
Each PILOT 300 must be given a DMX start address so that the correct projector responds to the
correct control signals. This DMX start address is the channel number from which the projector starts
to “listen” to the digital control information being sent out from the controller. The PILOT 300 has 10
channels, so set the No. 1 projector’s address 001, No. 2 projector’s address 011, No. 3 projector’s
address 021, No. 4 projector’s address 031, and so on.
The display shows the DMX start address after the projector is switched on (if you have already set
the DMX start address and saved it, the screen will display the last setting).
TO SET THE DMX START ADDRESS
Press the UP or DOWN buttons and the display will show the DMX start address.
Confirm your choice by pressing the ENTER button 2 times, this will save and set the DMX start
address. The display will show the latest setting each time the projector is powered up.
To control the projector with a DMX controller the DMX start address must be set.
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Ensure that none of the Stand-Alone options are set or they will interfere with correct DMX operation.

The PILOT 300 uses 10 DMX channels. They are listed in the following table.
DMX CONTROL CHANNEL FUNCTIONS
CHANNEL DMX VALUE DESCRIPTION
0-33 Open / Clear (5-7 for 5 secs.) Soft reset – See Note
34-66 (GLASS) GOBO 1
67-99 (METAL) GOBO 2 (Stars)
100-132 (GLASS) GOBO 3
133-165 (METAL) GOBO 4 (Tri-ring)
166-199 (GLASS) GOBO 5
200-232 (METAL) GOBO 6 (Multi-circle)
1
Gobo
233-255 (GLASS) GOBO 7
0-8 Stop
9-163 Orientation from 0°to 360°
164-205 Rotate from slow to fast
206-213 Stop
2
Gobo rotation
214-255 Rotate in opposite direction from slow to fast
0-27 Open
28-55 Red
56-83 Yellow
84-111 Orange
112-139 Blue
140-167 Light green
168-195 Cyan
196-223 Ultraviolet color
224-251 Pink
3
Colour
252-255 Green
0-13 Black-out
14-195 Open gradually from black to full open (dimming)
196-251 Strobe adjust from slow to fast
4
Strobe/Shutter
252-255 Open
5 Pan 0-255 Pan movement from 0°to 370°
6 Tilt 0-255 Tilt movement from 0°to 265°
7 Focus 0-255 Stepless focus
0-31 Clear
32-48 Prism static
49-127 Prism Orientation
128-189 Prism rotate from slow to fast
190-193 Prism Static
8
Prism
194-255 Prism rotate from slow to fast in opposite direction
9 Pan 16bit 0-255 16 Bit Pan resolution
10 Tilt 16bit 0-255 16 Bit Tilt resolution
NOTE
Soft Reset – If the DMX value sent on this channel (1) stays in the range from 5 to 7 for more than 5
seconds, the projector will start a reset sequence (Remote Requested Reset). The electronics are re-started
and all motors moved to their home positions exactly as they do when the power is first switched on but the
lamp is not switched off in this sequence, although the beam will be blacked out.
The channels 9 and 10 are only available when the Setup Option 6 is “ON”.
For the exact setting refer to “Setup Options” section.
The projectors can operate without a controller. They can do this in one of 3 different ways. Stand-Alone
Mode means automatic operation independent of other projectors and can either be automatic or triggered
by music depending on the combination of Setup Options 4 and 5 that are selected.
STAND-ALONE MODES
–
MASTER / SLAVE
The projectors can also operate synchronously with each other in Master/Slave mode. To do this they must
be connected together as described above in the Control Connections section with the terminator inserted
in the output of the last slave projector in the chain but, of course, without the controller. The same type of
DMX cables must be used to connect the Master with the Slaves. The appropriate Setup Options must also
be set. See the section on “Setup Options – Projector Configuration” for full details of the available
combinations.
Select one projector as the Master, setting the DMX start address at random. Regard the other projectors
as the slaves setting all DMX start addresses to “001”.
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Never have more than ONE (1) projector configured as Master or the system will not work.

MAINTENANCE
If the projector’s lens becomes damaged or broken it should be replaced. If the lamp becomes
damaged or deformed in any way it must be replaced. If the light from the lamp appears dim this
would normally indicate that it is reaching the end of its life and it should be changed at once, old
lamps run to the extremity of their life can explode. If the projector does not function, check the fuses
on the power socket of the projector, they should only be replaced by fuses of the same specified
value 6.3A/250V (fast blow, 5mmx20mm). On the main PCB inside the projector there is also a fuse
rated 4A/250V (fast blow, 5mmx20mm). Should these be damaged call a qualified technician before
replacement. The projector has 2 thermal protection devices that will switch off the projector in case of
overheating, should either of these operate, check that the fans are not blocked, and if they are dirty
clean them before switching on the projector again. Check that the fans are operational, if not call a
qualified technician.
Any maintenance work should only be carried out by qualified technicians.
CHANGING THE GOBOS
LAMP ACCESS HATCH
(THE TEXT IS UPSIDE DOWN)
GOBO
RETAINING SPRING
Carefully lift off the plastic cover by undoing the 4 M4 screws. (NOTE: The projector has two covers
with the same shape. The cover removed must be right one, so you can change the gobos easily. How
to remove the correct cover, the easy way is to position the projector with the text of the lamp access
hatch upside down as shown above, and then remove the upper cover.)
Using a small screwdriver remove the gobo retaining spring.
Insert the new gobo into position, and then insert the retaining spring.
Mount the cover again and retighten the 4 M4 screws.
NOTE: It is recommended to add a little adhesive, such as high temperature silicon sealant, to hold
securely the retaining spring inside the gear.
LUBRIFICATION
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To ensure the continued smooth rotation of the rotating gobos it is recommended that the wheel is
lubricated periodically, preferably every two months. Use only high working temperature low viscosity
oil, a syringe with a fine needle is the easiest way to introduce the oil to the bearings around each
gobo. Do not over lubricate as this will cause spillage when the wheel rotates.

KEEPING THE PROJECTOR CLEAN
To ensure the reliability of the projector it should be kept clean. It is recommended that the fans should
be cleaned every 15 days. The lens and dichroic colour filters should also be regularly cleaned to
maintain an optimum light output. Do NOT use any type of solvent on dichroic colour filters.
Cleaning frequency depends on the environment in which the fixture operates: damp, smoke or
particularly dirty surroundings can cause greater accumulation of dirt on the unit’s optics. A soft cloth
and typical glass cleaning products should be used in cleaning. It is recommended to clean the
external optics at least once every 20 days and clean the internal optics at least once every 30 / 60
days.
Do not use any organic solvent, e.g. alcohol, to clean the reflector mirror, dichroic color filters
or housing of the apparatus.
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE ACTION
The projector doesn’t switch
on
-The power supply is not
present
-The lamp is not working
Check the fuse on the power socket.
Replace the lamp.
The lamp comes on but the
projector doesn’t respond to
the controller
-Wrong DMX configuration
and/or start address
- Defective DMX cable
Make sure that the projector is
correctly configured.
Replace or repair the DMX cable.
The projector only functions
intermittently
-The fan has failed Make sure the fan is working and not
dirty.
Defective projection -The lens is broken
-Dust or grease on lenses
Check the lenses are not broken.
Remove dust or grease from the
lenses.
The projected image
appears to have a halo
-Installation of the lamp is not
correct
-Dust or grease contamination
on the optics.
Make sure the lamp is installed
correctly.
Carefully clean the optical group
lenses and the projector
components.
The beam appears dim -Dust or grease contamination
on the optics.
-The lamp is at the end of its
life
Check the optics are clean.
Replace with a new lamp of the
specified type and rating.
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TECHNICAL DATA
VOLTAGES: 100/120/200/220/230/240V AC, 50Hz or 60Hz To Order.
POWER CONSUMPTION:
480W @ 220V
LAMP: Type : HTI 300W/DX discharge lamp.
Colour Temperature: 6500ºK
Socket:SFc10-4
Manufacturers Rated Lamp Life: 750 Hours
COLOURS:
9 Dichroic colours plus white
GOBOS:
7 interchangeable, rotating gobos,
with 4 extra supplied as standard.
Gobo diameter: 27.9mm
Gobo image diameter: 22mm
PRISM:
1 x 3 Facet, Bi-directionally rotating prism.
FOCUS:
DMX controlled focus.
SHUTTER/STROBE:
Shutter for blackout, dimming and strobe 1 – 7 F.P.S.
HEAD MOVEMENT:
Pan 370º Tilt 265º
BEAM ANGLE:
12º
CONTROL:
DMX512: 8 Channels plus 2 for Hi Res. Pan and Tilt
Stand-Alone Automatic mode and Master/Slave operation
MOTORS:
10 Stepper motors
HOUSING:
Metal and composite plastic (IP20)
DIMENSIONS:
See drawings below.
WEIGHT:
18Kg.
PACKED DIMENSIONS:
450mm LONG x 450mm WIDE x 610mm HIGH
PACKED WEIGHT:
20Kg.
366
458
516
304
381
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LIGHT OUTPUT
DISTANCE 0m 5m 10m 15m 20m 25m
Ø 0m Ø 1.5m Ø 2.1m Ø 3.15m Ø 4.2m Ø 5.25mDIAMETER
6m
6m
5m
5m
4m
4m 3m
3m
2m
2m
1m
1m
0m 12º
3500 lux 870 lux 380 lux 190 lux 100 lux
ELECTRICAL DIAGRAM
PRISM
ROTATION PRISM FOCUS
GOBO
WHEEL
GOBO
ROTATION COLOUR
SHUTTER 1 SHUTTER 2
MOTORMOTOR MOTOR MOTOR MOTOR
MOTOR MOTOR
MOTOR
MOTOR MOTOR
TILT PAN
123456
78
910
9DC 24V
BASE
FAN
HEAD
HEAD
FAN 1
FAN 2
- BLACK
+ RED
A1
MAIN PCB
A2 A3 A4 A5 A6
B1 B2 B3 B4 B5 B6 B7 B8 B9
B
11 12 1310
BBB
A7 A8
A9
A10
C1
D1
16 CORE
FLAT
CABLE
DMX
C2 C3
AC
FUSE
4A/250V
TRANSFORMER
20V
50W BALLAST THERMOSTAT
THERMOSTAT
FUSE
F6.3A
250V
CAP
60µF
1
234567
8
IGNITOR
D
N
L
DMX IN DMX OUT
HTI 300W/DX
LAMP
2
1
3
21
3
LED1 LED2
DISPLAY PCB
16 CORE
FLAT
CABLE
L
N
E
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COMPONENT ORDER CODES – PILOT 300 PR-2301
NO. NAME PART NO. REMARK
040010044 240V, 50/60Hz
040010036 230V, 50/60Hz
040010039 220V, 50/60Hz
1 TRANSFORMER
040010041 200V/60Hz
2 THERMOSTAT 190010065 75℃/10A
3 CAPACITOR 140010018 60µF/370V
040070024 230V/50Hz
040070025 220V/60Hz
4 BALLAST
040070029 200V/60Hz
5 THERMOSTAT 190010054 95℃/10A
040090020 240V/50-60Hz
040090016 230/220V/50-60Hz
6 IGNITOR
040090009 200V/60Hz
7 LAMP 100050023 HTI 300W/DX
8 TOUCH SWITCH 191010028
9 FAN 030069006 DC24V
MOTOR 1 (PRISM ROTATION) MOTOR 030040047 17HS0002-38
MOTOR 2 (PRISM) MOTOR 030040023 42BYGH023-16
MOTOR 3 (FOCUS) MOTOR 030040023 17HS0002-38
MOTOR 4 (GOBO) MOTOR 030040024 17HS0002-03
MOTOR 5 (GOBO ROTATION) MOTOR 030040023 17HS0002-38
MOTOR 6 (COLOR) MOTOR 030040024 17HS0002-03
MOTOR 7 (SHUTTER1) MOTOR 030040023 17HS0002-03
MOTOR 8 (SHUTTER 2) MOTOR 030040024 17HS0002-38
MOTOR 9 (TILT) MOTOR 030040052 23HS0015
MOTOR 10 (PAN) MOTOR 030040053 23HS2029
A1~A7 IC 170050010 DRIVER CHIPS
A8 IC 170110004 DRIVER CHIP
A9 IC 170050001
ARITHMETIC
AMPLIFIER CHIP
A10 170110004 DRIVER CHIP
B1 IC 170040014 TTL LOGICAL CHIP
B2~B7 IC 170170037 D/A REVERSION CHIP
B8 IC 170040014 TTL LOGICAL CHIP
B9~B11 IC 170170037 D/A REVERSION CHIP
B12-B13 IC 170040014 TTL LOGICAL CHIP
C1 IC 170170039
STABLE-VOLTAGE
CHIP
C2 IC 170170012
BUS CHIP FOR
RECEIVING/TRANSMIT
TING
C3 IC 170040033 EEPROM
D1 IC 230040120 MICROPROCESSOR
NOT SHOWN PAN DRIVE BELT 290151217 309-3M-103Z 103 TEETH
NOT SHOWN TILT DRIVE BELT 290151218 HTD420-3M-140Z 140 TEETH
NOTE: You may order all parts of the PILOT 300 besides the table listed above. When ordering please
state the exact name and part no.. Repairs must be carried out by a qualified technician.
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PEARL RIVER LIGHT & ACOUSTICS INDUSTRIAL LTD.
Yingbin Road, Dashi, Panyu, Guangzhou ,China
Post-Code: 511430
TEL: [phone]
FAX: [phone]
P/N: 321010041
Last Revision: 12:11:2002
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