Xenotech BRITELIGHT 7000 User manual

PAGE 1
COPYRIGHT © 2001 Xenotech-Strong, Inc.
Issue 1.0
208 / 230 V.AC
BL7000 SYSTEM
OPERATING MANUAL
PATTERN PROFILE PROJECTOR
"P3"

PAGE 2
POWER INPUT CONNECTOR WIRING INSTRUCTIONS
THE INPUT POWER REQUIREMENTS FOR A 7 KW POWER SUPPLY (62-80110) ARE AS FOLLOWS:
VOLTAGE NOMINAL 208 / 230 VAC
FREQUENCY RANGE 50 / 60 HZ
INPUT CURRENT 30 AMPS
PHASE 3PH 4 WIRE
MINIMUM INPUT WIRE SIZE 12 AWG
CONNECTIONS
THREE PHASE OPERATION
LINE DESIGNATION WIRE COLOR CONNECTOR PIN
PHASE A BLACK X
PHASE B RED Y
PHASE C ORANGE Z
SAFETY GROUND GREEN GREEN

PAGE 3
BRITELIGHT 7000 SPECIFICATIONS
BALLAST
MAIN POWER INPUT
INPUT VOLTAGE: 208 / 230 VAC.
INPUT CURRENT: 30 AMPS
PHASE: THREE 4 WIRE
FREQUENCY: 50 / 60 HZ.
OUTPUT
OUTPUT VOLTAGE: 40 - 50 V.DC.
OUTPUT CURRENT: 130 -180 A.DC.
OUTPUT RIPPLE: LESS THAN 5% P-P
OUTPUT ADJ. RANGE:16 STEPS
LAMPHEAD
LAMP INPUT
LAMP VOLTAGE: 43 - 49 V.DC.
LAMP CURRENT: 120 - 160 A.DC.
LIGHT OUTPUT: 795 MILLION PBCP.
COOLING FOCUS & IGNITION CIRCUIT INPUTS
INPUT VOLTAGE: 120 V.AC
INPUT CURRENT: 5 AMPS PEAK
PHASE: SINGLE
FREQUENCY: 50 / 60 HZ.
SYSTEM OPERATION TEMPERATURE RANGE
NOMINAL AMBIENT: -18o- 50oC

PAGE 4
OPERATING INSTRUCTIONS FOR 7 kW XENON SYSTEM
CONNECTIONS
1. Connect lamphead cable to the (14) pin OUTPUT MS CONNECTOR located on the top of the xenon
power supply cabinet.
2. Connect the AC power cable to the (4) pin twistlock AC INPUT POWER CONNECTOR located pn the
top of the xenon power supply.
3. Connect the power cable to the power source.
4. When the power is energized the following should occur:
a. The green LED indicator lights on the top of the xenon power supply should light.
b. Cooling fans in the xenon power supply and in the P3 should start.
c. The LED displays on the DMX control boards should light.
NOTE
THERE IS A 3 - 5 SECOND DELAY AFTER THE MAIN POWER IS ENERGIZED
BEFORE THE LAMP HEAD COOLING SYSTEM IS UP TO FULL PRESSURE.
LIGHT OPERATION
Prior to operation, the xenon bulb must be installed, and DC output set to the correct level. These
procedures are to be performed by a trained technician using the proper tools, protective measures, and test
instruments. Bulb installation procedures follow in this manual, and a separate manual detailing operation of
the xenon power supply is furnished with the unit.
This unit is designed to operate from a remote DMX controller. DMX instructions and addresses are included
in a following section of this manual.

PAGE 5
FRONT LAMP HOLDER ASEMBLY

PAGE 6
INSTRUCTIONS FOR REMOVING AND INSTALLING A TYPE TH BULB IN A BL7000
FIXTURE
NOTE
FAMILIARIZE YOURSELF WITH THE LOCATION AND IDENTIFICATION OF THE COMPONENTS OF THIS
SYSTEM AND ALSO THE NORMAL OPERATION OF THE SYSTEM BEFORE ATTEMPTING ANY
ADJUSTMENT OR SERVICE.
NOTE
COMPLETELY READ THROUGH AND HAVE A GOOD UNDERSTANDING OF THE PROCEDURES BEFORE
ATTEMPTING TO SERVICE THIS SYSTEM. FAILURE TO DO SO MAY RESULT IN FATAL INJURY OR
EQUIPMENT DAMAGE.
WARNING
DISCONNECT POWER SOURCE BEFORE SERVICING THIS EQUIPMENT.
WARNING
A PROTECTIVE JACKET, FULL FACE SHIELD, AND PROTECTIVE GLOVES MUST BE WORN AT ALL
TIMES WHEN THE LAMP HEAD IS OPENED WITH A BULB INSTALLED OR WHEN HANDLING THE XENON
BULBS. SERIOUS INJURY MAY OCCUR IF PROPER SAFETY PRECAUTIONS ARE NOT OBSERVED. READ
ALL ENCLOSED INSTRUCTIONS AND INFORMATION SHEETS BEFORE HANDLING THE BULB.
WARNING
NEVER OPERATE A FIXTURE WITH AN EXPOSED BULB! THERE IS AN EXTREME DANGER OF SEVERE
BURNS TO EXPOSED SKIN AND EYES FROM THE ULTRAVIOLET LIGHT EMITTED FROM THE EXPOSED
BULB. DAMAGE CAN OCCUR IN AS LITTLE AS 30 SECONDS OF EXPOSURE. THERE IS ALSO AN
ADDITIONAL DANGER FROM FLYING QUARTZ IF AN EXPOSED BULB EXPLODES!
EQUIPMENT REQUIRED
1. PROTECTIVE SAFETY EQUIPMENT KIT
2. 7/16", 5/16", 3/8" OPEN END WRENCH
3. ALLEN WRENCH 5/32"
4. PHILLIPS SCREWDRIVER #2

PAGE 7
DISASSEMBLY PROCEDURE
IF THERE IS NO XENON BULB INSTALLED IN THE FIXTURE
1. Remove the (8) screws located on the small sides of the front cowling using a #2 phillips screwdriver and
remove the cowling.
2. Remove the (2) brass bolts connecting the short leads to the front lamp holder using a 7/16" wrench..
3. Remove the center mounting screw washer and spring from the spider using a 5/32" allen wrench while
supporting the front lamp holder so that it does not fall when the screw is removed.
4. Remove the lamp holder from the fixture.
5. Disconnect the focus rod swivel joint from the spider arm using the 5/16" and 3/8" open end wrenches. Do not
turn the swivel joint or focus rod.
6. To disassemble the front lamp holder remove the (2) clamp retaining screws located on the side of the lamp
swivel hub using a 5/32" allen wrench and remove the clamp.

PAGE 8
DISASSEMBLY PROCEDURE
IF THERE IS A XENON BULB INSTALLED IN THE FIXTURE
1. Remove the (8) screws located on the small sides of the front cowling using a #2 phillips screwdriver and
remove the cowling.
CAUTION
DO NOT PLACE ANY EXCESSIVE FORCE ON THE XENON BULB WHILE REPLACING THE PROTECTIVE
WRAPPER!
2. Wrap the bulb securely in the protective wrapper that the bulb was originally shipped in.
3. Remove the (2) brass bolts connecting the short leads to the front lamp holder using a 7/16" wrench.
4. Disconnect the focus rod swivel joint from the spider arm using the 5/16" and 3/8" open end wrenches. Do not
turn the swivel joint or focus rod.
5. Remove the center mounting screw washer and spring from the spider using a 5/32" allen wrench while
supporting the front lamp holder so that the globe does not drop when the mounting screw is removed.
WARNING
DO NOT EXERT EXCESSIVE FORCE ON THE BULB WHILE UNSCREWING IT FROM THE REAR LAMP
HOLDER! THE BULB SHOULD RELEASE FROM THE REAR LAMP HOLDER WITH A VERY LIGHT
COUNTERCLOCKWISE ROTATION. IF THIS DOES NOT HAPPEN, SEE THE PROCEDURE FOR
REMOVING A "FROZEN" BULB.
6. Remove the bulb by lightly pushing back on the bulb to move the rear lamp holder to its rearmost position
while lightly turning the bulb in a counterclockwise rotation. The bulb will release from the rear lamp holder in
approximately 1½ complete turns.
7. Remove the bulb from the fixture with the front lamp holder attached and place it on a stable working surface
for the removal of the front lamp holder.
8. To remove the front lamp holder from the bulb, remove the (2) clamp retaining screws located on the side of
the lamp swivel hub using a 5/32" allen wrench and remove the clamp.
9. Remove the lamp holder from the bulb and place the bulb into its shipping container for safekeeping.
Resecure the protective wrapper if necessary.

PAGE 9
ASSEMBLY PROCEDURE
WARNING
DO NOT REMOVE THE PROTECTIVE COVER FROM THE LAMP UNTIL INSTRUCTED TO DO SO!
WARNING
DO EXERT ANY FORCE ON THE QUARTZ PORTIONS OF THE XENON BULB AT ANY TIME!
NOTE
IF THE FRONT LAMP HOLDER HAS NOT BEEN DISASSEMBLED, SEE THE LAST STEPS IN THE
APPROPRIATE DISASSEMBLY INSTRUCTIONS.
1. Untie the cord on the anode (+) end of the protective cover. Do not remove the cover at this time!
2. Fasten front lamp holder to the globe by placing the anode end (large electrode) of the lamp in the lamp
holder and aligning the stud on the end of the lamp ferrule with the channel in the nose of the lamp holder
body. Slide the lamp completely down the channel as far as it will go.
4. Replace the clamp and reinstall the (2) clamp retaining screws located on the side of the lamp swivel hub
using a 5/32" allen wrench.
5. Install the bulb into the fixture by inserting the cathode (-) end of the lamp through the opening in the reflector.
6. Insert the end of the lamp ferrule into the opening in the rear lamp holder receiver block and align the threads
by turning the bulb counterclockwise until the bulb threads drop into the receiver threads.
NOTE
DO NOT OVER TIGHTEN THE LAMP IN THE RECEIVER BLOCK AS THIS MAY CAUSE THE LAMP TO
"FREEZE" IN THE RECEIVER BLOCK MAKING IT DIFFICULT TO REMOVE. TIGHTEN THE LAMP JUST
ENOUGH TO APPLY SPRING PRESSURE TO THE THREADS BUT NOT SO MUCH AS TO BOTTOM OUT
THE LAMP FERRULE COMPLETELY AGAINST THE RECEIVER BLOCK.
7. Gently rotate the bulb clockwise until resistance is felt.
8. At this point, the bulb should be in contact with the spring plunger assemblies. Gently turn the bulb an
additional 1/16-1/8 of a turn to load the threads with the spring plungers.
9. Secure the front lamp holder to the spider with the shoulder bolt, spring, and washer that was removed during
disassembly.
10. Reconnect the focus rod swivel joint to the spider arm using the 5/16" and 3/8" open end wrenches. Do not
turn the swivel joint or focus rod.
11. Reconnect the (2) short leads from the spider to the front lamp holder using the (2) brass bolts and washers
that were removed during disassembly.

PAGE 10
NOTE
ANY TYPE OF ALCOHOL IS SUITABLE FOR CLEANING THE BULB EXCEPT FOR ALCOHOL THAT HAS
BEEN DENATURED USING PETROLEUM PRODUCTS. THE DENATURING AGENT WILL LEAVE A
RESIDUE ON THE BULB.
12. Remove the protective cover from the globe and clean the quartz portion of the bulb completely with alcohol.
13. Reinstall the front cowl using the screws that were removed during disassembly.
14. Log the hour meter reading at installation.
15. Test the lamp operation and preform the output power adjustment procedure.
CAUTION
LAMP COOLING
DO NOT DISCONNECT THE MAIN POWER UNTIL THE BULB HAS COMPLETELY COOLED. THE LAMP
HEAD COOLING SYSTEM WILL RUN WHENEVER THE MAIN INPUT POWER LINES ARE ENERGIZED.
NOTE
LAMP HEAD TEMPERATURE AND COOLING SYSTEM PROTECTION CIRCUIT
THE LAMP HEAD AND POWER SUPPLY ARE THERMALLY PROTECTED. THE LAMP HEAD IS ALSO
PROTECTED BY AN AIR PRESSURE SWITCH . IF THE LAMP HEAD COOLING SYSTEM FAILS OR THE
EQUIPMENT IS USED IN AN EXCESSIVELY HOT ENVIRONMENT ( ABOVE 50 DEG C ) THE LAMP POWER
SYSTEM WILL SHUT OFF TO PREVENT EQUIPMENT DAMAGE AND THE HEAD OVER TEMP / SAFETY
CIRCUIT FAULT INDICATOR (8) WILL LIGHT. WHEN THE EQUIPMENT COOLS TO A SAFE OPERATING
TEMPERATURE OR WHEN THE FAULT IS CLEARED THE INDICATOR WILL GO OUT, THE MAIN POWER
CONTACTOR IN THE POWER SUPPLY WILL REENERGIZE, AND THE LAMP MAY THEN BE RELIT.
NOTE
ARC MAGNETIC STABILIZATION
THE LAMP HEAD INCORPORATES MAGNETIC STABILIZATION OF THE GLOBE ARC. THE LAMP HEAD
MUST BE OPERATED IN AN UPRIGHT POSITION FOR THE STABILIZATION TO WORK PROPERLY. THE
POSITION OF THE LAMP HEAD CAN BE DETERMINED BY THE POSITION OF THE TEXT ON THE SIDES
OF THE LAMP HEAD WHICH SHOULD BE UPRIGHT. OPERATING THE LAMP HEAD UPSIDEDOWN MAY
CAUSE MASSIVE INSTABILITY IN THE GLOBE ARC TO THE POINT OF EXTINGUISHING AND MAY
CAUSE EXCESSIVE LAMP WEAR.
CAUTION
SHOCK HAZARD
THE POWER SUPPLY CONTAINS A CAPACITOR BANK ACROSS THE OUTPUT TERMINALS THE ENERGY
STORED IN THE CAPACITORS MAY BE PRESENT FOR SEVERAL MINUTES AFTER THE POWER SUPPLY
IS DE-ENERGIZED.
CAUTION
SHOCK HAZARD
DISCONNECT THE INPUT POWER CONNECTOR BEFORE SERVICING THIS EQUIPMENT. DANGEROUS
VOLTAGES ARE PRESENT IN THIS EQUIPMENT.

PAGE 11
REMOVING A "FROZEN" XENON BULB
1. Replace the front lamp holder retaining bolt to support the front of the bulb while freeing the bulb from the rear
lamp holder.
2. Remove the fixture rear cover by removing the (10) screws around the perimeter of the sides using a #2
phillips screwdriver and pulling the cover straight back using the rear handle.
3. Disconnect the rear panel wiring connectors from the head wiring harness then set the cover aside.
4. Remove the plenum access cover by removing the (10) screws from around the cover using a #2 phillips
screwdriver and remove the cover.
WARNING
DO EXERT ANY FORCE ON THE QUARTZ PORTIONS OF THE BULB WHILE ATTEMPTING TO FREE IT
FROM THE REAR LAMP HOLDER!
5. Reach around the rear lamp holder assembly and grasp the bulb by its rear ferrule and while lightly pulling the
bulb back into the receiver block; turn the bulb in a clockwise direction until the bulb begins to rotate freely.
6. Once the bulb is free, do not remove it completely from the rear lamp holder.
7. Replace the plenum cover, rear panel wiring, and fixture rear cover.
8. Return to step 5 of : “DISASSEMBLY PROCEDURE
IF THERE IS A XENON BULB INSTALLED IN THE FIXTURE”

PAGE 12
OUTPUT POWER ADJUSTMENT PROCEDURES
EQUIPMENT REQUIRED
1. Phillips screwdriver #2 3. Clamp-On DC Ammeter
2. Flat-blade screwdriver, large 4. Volt/Ohm Meter
ADJUSTMENT INSTRUCTIONS
1. Remove the top cover of the P3 by loosening the (12) slot head screws and lifting the cover off.
2. Locate the heavy DC leads (red & black) connected to the MS receptacle at the bottom of the
lamp head rear panel. Clamp (1) of the leads with the DC ammeter.
3. Turn on the power supply and ignite the lamp. Exercise all due caution taking readings in a "Power
ON" condition!
4. Using the ammeter, measure the output current of the power supply.
5. If the power level is over 160 amperes, immediately turn off the light and decrease DC output (see
Xenon Power Supply Manual)
6. If the power level is less than 140 amperes, allow the light to run at least 5 minutes before making
any adjustments.
7. If the power level is at or near 150 amperes and the output current is less than 155 amperes, no
adjustment is necessary.
8. Measure the DC voltage while the bulb is operating. A 7000 watt bulbs should display an arc
voltage of 43-49 volts DC. A voltage reading below this level, particulary in the presence of a high
current reading, may indicate a leaking bulb.
9. It is not unusual for the quartz envelope of the xenon bulb to darken after prolonged operation. To
compensate for the loss of light, the DC output may be increased as the xenon bulb ages. DO NOT
exceed the bulb manufacturer's maximum rated current level (usually 160 amperes). See the test
documents packaged with the xenon bulb.

PAGE 13
PARTS LIST
Ref.
Desig. Part No. Description
B1 31-03039 Blower, Squirrelcage; 220 V.AC, 50/60 Hz.
B2,3 71220000 Blower, Muffin; 110 V.AC, 50/60 Hz.
B4,5 44191000 Blower, Squirrelcage; 110 V.AC, 50/60 Hz.
NOTE: B5 Optional
C1 39110000 Capacitor, 24 pf, 20k VDC
C2 31-08177 Capacitor, Motor Start; 4 µf
DS1 31-30243 Xenon Bulb, 7 kW; LTIX-7000W-XT
E1 31-61018 Spark Gap
S1 91-61005 Switch, ON-OFF
S2 31-61007 Thermal Switch
S3 31-61078 Switch, Air Pressure
S4 40913000 Auto Strike PC Board Assembly
T1 32-50231 High Voltage Transformer
T2 32-50053 RF Coil
TB1 31-62011 Terminal, (10 req'd.)
- 31-62012 End Block, Terminal Strip
TB2 31-62025 Terminal Board, (2) Position

PAGE 14
Yoke Assembly
32-40738
(see Fig. 10)
Base Assembly
32-50522
(see Figure 10)
Handle
49342000
Top Cover
32-40623
Front Cowl Assembly
32-50359
Handle
31-28039
Access Cover
32-40735
Base Pan
32-40734
FIGURE 1
NOTE: After transporting the P3 unit to its desired
position, lower all (4) leveling feet to shift all weight
fromCasters. Casterbrakesalonemaybeinadequate
to prevent unintended movement.

PAGE 15
FIGURE 2
Slide Bracket
32-40621
Locking Knob
32-20145
Stud Plate
32-40622
(concealed by
Slide Bracket)
Friction Disc
31-98574
(not shown)
Lamphead Assembly
(see Figure 3)
Gobo Rotator Assembly
32-50523 (optional)
see Page 27
Lens Mechanism
32-50521
(see Figure 6)
Glass
31-98274*
Glass Retainer Clip (4 req'd.)
32-40285*
* included with 32-50359 (Fig. 1)

PAGE 16
FIGURE 3
PARTS LIST
Item Part No. Description
1 32-40601 Frame, Welded Assembly
2 32-20236 Reflector Mount
3 31-98983 Reflector
- Mounting Screw
4 32-50538 Back Panel Assembly (see Figure 4)
5 32-50540 Bulkhead Assembly (see Figure 5)
6 31-98679 Clip (2 req'd.)
7 32-50401 Front Bulb Support Spyder
- Spyder Mounting Screw
- 31-61007 Thermal Switch (S2), not shown
- Switch Mounting Screw
8 32-50052 Front Lamp Holder Assembly
- 31-30243 Xenon Bulb, 7 kW (not shown)
9 32-50252 Bulb Focus Rod
Lamphead Assembly

PAGE 17
FIGURE 4
Rear Panel Assembly

PAGE 18
PARTS LIST
Figure 4
Item Part No. Description
1 32-50538 Back Panel Assembly (items 2-11)
2 32-70350 Potentiometer Assembly
3 91-61005 Switch (S1)
4 31-98889 Overlay
5 32-70123 XLR Assembly
6 32-70124 XLR Assembly
7 11-28021 Knob
8 32-40049 Air Baffle Plate
9 91-61008 DMX Switch
10 32-70357 DMX Relay Assembly
11 32-70356 MS Connector & Cable Assembly
32-70357 DMX ASSEMBLY
Item Part No. Description
1 23-40365 DMX Mount
2 32-70348 DMX Board
3 31-98745 Stand-Off, 4-40 x 1/4" (4 req'd.)

PAGE 19
FIGURE 5
Bulkhead Assembly

PAGE 20
PARTS LIST
Figure 5
Item Part No. Description
1 32-40740 Bulkhead Plate
2 31-22010 Blower Gasket
3 31-02039 Squirrelcage Blower (B1), 230 V.AC, 50/60 Hz.
- Mounting Screw
4 31-62025 Terminal Board (TB2)
- Mounting Screw
5 32-50053 RF Coil (T2)
- Mounting Screw
6 32-50231 High Voltage Transformer (T1)
- Mounting Screw
7 39110000 Ignition Capacitor (C1); 24 pf, 20k VDC
8 31-62011 Terminal (10 req'd.) for TB1
- 31-62012 Terminal Strip End Block
- Mounting Screw
9 31-08077 Motor Start Capacitor (C2), 4µf
10 32-70347 Gobo Rotator Control PC Board (optional)
11 32-70346 Transformer (optional; with Item 10)
12 40913000 Auto Strike PC Board Assembly (S4)
13 32-50050 Bulb Receiver, Threaded
13a 31-98076 Receiver Support Bracket (2 req'd.)
- 32-50346 Bulb Receiver Assembly (Items 13 & 13a)
14 31-61018 Spark Gap (E1)
15 31-98182 Shock Mount Bushing (4 req'd.)
16 32-40294 Insulated Cover Plate (2 req'd.)
16a 32-40438 Plenum
17 31-61078 Pressure Switch (S3)
- 41-51915 Switch Mounting Screw, 8-32 x 3/8" Pan Head
17a 32-40285 Air Pressure Hose
17b 31-20001 Hose Barb (2 req'd.)
- 32-50344 Air Plenum Assembly (Items 16, 16a,17)