Xenotech BRITELIGHT 10000AR User manual

PAGE 1
COPYRIGHT © 1994 Xenotech, Inc.
REV 1.3
®
®
10000AR

PAGE 2
BRITELIGHT 10000AR SPECIFICATIONS
POWER SUPPLY
MAIN POWER INPUT
INPUT VOLTAGE: 230/120 VAC.
INPUT CURRENT: 40 AMPS
PHASE: THREE
FREQUENCY: 60/50 HZ.
CONTROL INPUT
120 VAC 5 AMP SWITCHED CIRCUIT
OUTPUT
OUTPUT VOLTAGE: 50 - 60 VDC.
OUTPUT CURRENT: 190 - 220 ADC.
OUTPUT RIPPLE: LESS THAN 5% P-P
OUTPUT ADJ. RANGE:16 STEPS
LAMP HEAD
LAMP INPUT
LAMP VOLTAGE: 50 - 60 VDC.
LAMP CURRENT: 190 - 200 ADC.
COOLING & IGNITION CIRCUIT INPUT
INPUT VOLTAGE: 120 VAC.
INPUT CURRENT: 5 AMPS PEAK
PHASE: SINGLE
FREQUENCY: 60 HZ.
SYSTEM OPERATION TEMPERATURE RANGE
NOMINAL AMBIENT: 0o- 50oC.
SYSTEM WEIGHT
900 LBS.

PAGE 3
BRITELIGHT 10000AR INSTALLATION INSTRUCTIONS
NOTE
THE BL10000AR SYSTEM SHOULD BE INSTALLED BY AN ELECTRICAL CONTRACTOR FOLLOWING ALL APPLICABLE
ELECTRICAL AND BUILDING CODES FOR THE INSTALLATION SITE.
UNPACKING
BASE UNIT
1. REMOVE THE SYSTEM BASE FROM IT'S SHIPPING PALLET BY REMOVING THE 4 RETAINING BOLTS FROM THE
BASE FOOTINGS AND LIFTING THE SYSTEM FROM THE PALLET.
2. POSITION THE SYSTEM BASE IN THE LOCATION THAT IT WILL BE OPERATING AND CHECK THE SYSTEM FOR
STABILITY. IT IS RECOMMENDED THAT THE SYSTEM BE BOLTED DOWN TO THE MOUNTING SURFACE. IF THE
SURFACE IS UNEVEN IT MAY BE NECESSARY TO SHIM THE FOOTINGS OF THE BASE UNIT TO STABILIZE THE
SYSTEM.
3. WHEN POSITIONING THE SYSTEM BE SURE TO ALLOW ADEQUATE CLEARANCE FOR THE AIR INTAKES AND
EXHAUSTS ON BOTH THE BASE AND HEAD UNITS AND ALSO ADEQUATE CLEARANCE TO THE FRONT AND
BACK OF THE BASE UNIT FOR SERVICE AND FOR A FULL RANGE OF MOTION OF THE LAMP HEAD.
LAMP HEAD
1. UNPACK THE LAMP HEAD BY UNWRAPPING IT AND CUTTING THE BANDING STRAPS.
2. REMOVE TWO ADJACENT LAMP HEAD RETAINING CLAMPS FROM THE TOP OF THE BASE AND LOOSEN THE
TWO REMAINING CLAMPS IN PREPARATION FOR MOUNTING THE LAMP HEAD.
3. LIFT THE LAMP HEAD FROM THE PALLET AND POSITION THE SUPPORT PLATE UNDER THE TWO MOUNTING
CLAMPS ON THE TOP OF THE BASE. POINT THE LAMP HEAD IN THE DESIRED OPERATING DIRECTION AND
INSTALL THE REMAINING CLAMPS.

PAGE 4
CONNECTIONS
LAMP HEAD
1. REMOVE THE FRONT AND REAR BASE COVERS. EXAMINE THE INTERIOR OF THE BASE FOR ANY HIDDEN
DAMAGE, LOOSE CONNECTIONS, MISSING COMPONENTS, OR OTHER DAMAGE AND CHANGES THAT
MAY HAVE OCCURRED DURING SHIPPING.
2. LOCATE THE CORD GRIP ASSEMBLY AT THE END OF THE LAMP HEAD CABLE AND REMOVE THE LOCKNUT
FROM THE CORD GRIP.
3. INSERT THE LAMP HEAD CABLE END THROUGH THE HOLE LOCATED ON THE LOWER RIGHT SIDE OF THE BASE
UNTIL THE CORD GRIP IS FULLY SEATED. REINSTALL THE LOCKNUT ON THE CORD GRIP AND TIGHTEN UNTIL
THE CORD GRIP IS SECURE.
CAUTION
EXTREME CARE MUST BE TAKEN WHEN CONNECTING THE LAMP HEAD TO THE BALLAST OUTPUT
IF THE POLARITY OF THE CONNECTIONS ARE REVERSED THE XENON GLOBE WILL BE IMMEDIATELY DESTROYED
UPON IGNITION.
NOTE
ONLY LOOSEN THE FIRST NUT ON THE LOWER OUTPUT CHOKE TERMINAL WHEN CONNECTING THE LAMP HEAD
4. CONNECT THE LARGE RED WIRE FROM THE LAMP HEAD CABLE TO THE LONG BRASS STUD LOCATED ON
THE LOWER OUTPUT CHOKE.
5. CONNECT THE LARGE BLACK WIRE TO THE LOWER CONNECTING BOLT ON THE OUTPUT SHUNT LOCATED
ABOVE AND TO THE RIGHT OF THE LOWER OUTPUT CHOKE.
6. LOCATE THE MULTI-PIN CONNECTOR IN THE GENERAL LOCATION OF THE LOWER OUTPUT CHOKE AND THE
OUTPUT SHUNT CONNECTIONS. CONNECT THE MATING CONTROL WIRE CONNECTOR FROM THE LAMP
HEAD CABLE TO THIS CONNECTOR. WHEN THE CONNECTORS ARE PROPERLY MATED THEY WILL LOCK
INTO POSITION.
8. CHECK THE ROUTING OF THE LAMP HEAD WIRING AND TIGHTNESS OF THE HIGH CURRENT CONNECTIONS.
THE LAMP HEAD INSTALLATION IS NOW COMPLETE.
POWER AND CONTROL
1. THE BL10000AR SYSTEM REQUIRES TWO ELECTRICAL SERVICES. THE MAIN POWER SERVICE SHOULD BE A
230/120 VOLT 3 PHASE MINIMUM 40 AMP SERVICE THAT IS ALWAYS ENERGIZED. THE REMOTE CONTROL
CIRCUIT SHOULD BE A 5 AMPS 120 VAC CIRCUIT THAT IS CONTROLLED BY A TIMER OR OTHER CONTROL
SYSTEM TO TURN THE SYSTEM ON AND OFF AT THE REQUIRED TIMES.
2. TO ALLOW FLEXIBILITY IN THE INSTALLATION OF THE BL10000AR SYSTEM NO PRE KNOCKED OUT HOLES HAVE
BEEN PROVIDED. INSTEAD APPROPRIATE HOLES CAN BE PUNCHED AT ANY CONVENIENT LOCATION IN THE
LEFT AND RIGHT SIDE PANELS DURING INSTALLATION AS ALLOWED BY LOCAL CODES.
3. THE MAIN POWER INPUT AND REMOTE CONTROL WIRING CONNECTIONS FOR THE BL10000AR ARE VERY
STRAIGHT FORWARD AND ARE SHOWN ON THE INSTALLATION WIRING DRAWING. REMOVE THE FRONT
AND REAR ACCESS PANELS ON THE BASE UNIT TO INSTALL THE POWER SERVICE. CONNECT THE HOT LINES
FROM THE MAIN POWER SERVICE TO THE LINE SIDE (TOP) OF CONTACTOR K1 LOCATED ON THE POWER
SUPPLY. THE NEUTRAL LINE CONNECTS TO TERMINAL BOARD TB7 TERMINAL #3 LOCATED BELOW THE
CONTACTOR. THE REMOTE CONTROL POWER WIRING IS CONNECTED TO TERMINAL BLOCK TB7 #1 & #2.
ALL INPUT GROUNDS ATTACH TO THE GROUND STUD LOCATED AT THE LOWER LEFT OF THE HEATSINK
ASSEMBLY ON THE LOWER POWER SUPPLY.
4. THE MAIN POWER AND CONTROL INSTALLATION IS NOW COMPLETE. PROCEED TO THE GLOBE
INSTALLATION PROCEDURES.

PAGE 5

PAGE 6
BL10000AR CONTROL PANEL & SYSTEM OPERATION
1. MAIN POWER SWITCH
USED TO MANUALLY CONTROL THE SYSTEM OPERATION. WHEN THE NORMAL / SERVICE SELECTOR SWITCH IS
IN THE NORMAL POSITION THE MAIN POWER SWITCH WILL PREVENT THE SYSTEM FROM ENERGIZING WHEN THE
CONTROL POWER CIRCUIT TURNS ON. WHEN THE NORMAL / SERVICE SELECTOR SWITCH IS IN THE SERVICE
POSITION THE MAIN POWER SWITCH ACTS AS A NORMAL POWER SWITCH TURNING THE SYSTEM BOTH ON
AND OFF.
2. NORMAL / SERVICE SELECTOR SWITCH
USED TO SELECT THE MODE OF OPERATION FOR THE SYSTEM. WHEN THIS SWITCH IS IN THE NORMAL POSITION
THE SYSTEM IS ENERGIZED AND DE-ENERGIZED BY THE REMOTE CONTROL CIRCUIT. WHEN THIS SWITCH IS IN
THE SERVICE POSITION THE SYSTEM GENERATES IT'S CONTROL POWER INTERNALLY FROM THE 230 VOLT MAIN
SERVICE SO THE SYSTEM CAN BE OPERATED AS AN INDEPENDENT UNIT WITHOUT THE REMOTE CONTROL
CIRCUIT ENERGIZED.
3. CIRCUIT BREAKER CB2
THIS CIRCUIT BREAKER PROTECTS THE REMOTE CONTROL POWER CIRCUIT OUTPUT AND THE 120VAC
AUXILIARY POWER SOURCE FROM OVERLOADS AND SHORT CIRCUITS.
4. MANUAL STRIKE SWITCH
THIS SWITCH IS NOT NORMALLY USED. IT HAS BEEN INSTALLED AS A TROUBLE SHOOTING AID. THIS SWITCH IS
WIRED IN PARALLEL WITH THE AUTO STRIKE RELAY CIRCUIT. IF A SYSTEM DOES NOT STRIKE AUTOMATICALLY
THIS SWITCH WILL ENERGIZE THE IGNITOR CIRCUIT IN THE LAMP HEAD. IF THE IGNITOR IN THE HEAD FIRES WHEN
THIS SWITCH IS DEPRESSED THE IGNITOR CIRCUIT IN THE HEAD IS IN OPERATING ORDER. IF THE IGNITOR WORKS
AND THE LAMP LIGHTS THEN THE AUTO STRIKE CIRCUIT SHOULD BE CHECKED. IF THE LAMP DOES NOT LIGHT
WHEN THE IGNITOR FIRES THEN THE TROUBLE MAY BE IN THE POWER SUPPLY OR LAMP HEAD.
5. CONTROL READY INDICATOR
MONITORS THE VOLTAGE ON THE CIRCUIT THAT CONTROLS THE OPERATION OF THE SYSTEM. THIS INDICATOR
WILL LIGHT WHENEVER CONTROL POWER IS AVAILABLE AT THE LINE SIDE OF THE MAIN POWER SWITCH. THIS
CONDITION WILL EXIST WHEN THE SYSTEM IS IN THE NORMAL OPERATING MODE AND THE REMOTE CONTROL
SWITCH CIRCUIT IS CLOSED AND WHEN THE SYSTEM IS OPERATING IN THE SERVICE MODE.
6. BOOST READY INDICATOR
MONITORS THE OUTPUT OF THE BALLAST AND LIGHTS WHENEVER THE OUTPUT VOLTAGE IS OVER 100 VDC.
WHEN THIS INDICATOR LIGHTS THE OUTPUT OF THE BALLAST IS AT A VOLTAGE SUFFICIENT TO IGNITE THE LAMP.
UNDER NORMAL OPERATING CONDITIONS THIS INDICATOR WILL LIGHT FOR A MOMENT JUST BEFORE THE
AUTO STRIKE CIRCUIT IGNITES THE LAMP. IF THE SYSTEM DOES NOT AUTO STRIKE AND THIS LAMP IS LIT CHECK
THE AUTO STRIKE AND IGNITOR CIRCUITS. IF THE SYSTEM DOES NOT AUTO STRIKE AND THIS LAMP IS NOT LIT
CHECK THE BALLAST CORE.
7. 120 VAC AUXILIARY POWER INDICATOR
INDICATES THE OPERATION OF THE INTERNAL 120 VOLT POWER CIRCUIT WHEN THIS INDICATOR IS LIT THE
CIRCUIT IS OPERATING.
8. POWER SUPPLY OVER TEMP / MAIN POWER PHASE FAULT INDICATOR.
THIS INDICATOR WILL LIGHT IF THE FOLLOWING CONDITIONS EXIST IN THE BALLAST SECTION OF THE SYSTEM. IF
THE POWER SUPPLY FAULT INDICATOR IS LIT THE BALLAST CORE IS OVER SAFE OPERATING TEMPERATURE OR
THE PHASE LOSS CIRCUIT BREAKER HAS TRIPPED. CHECK THE HEAT SINK AND EXHAUST COOLING FAN
OPERATION. IF THE PHASE LOSS CIRCUIT BREAKER IS TRIPPED CHECK THE INPUT POWER FOR A MISSING PHASE
OR LINE IMBALANCE. WHEN THE PROBLEM IS CORRECTED THIS INDICATOR WILL EXTINGUISH AND THE SYSTEM
WILL GO INTO NORMAL OPERATION.

PAGE 7
9. HEAD SAFETY CIRCUIT FAULT INDICATOR.
THIS INDICATOR LIGHTS INDICATING A TROUBLE CONDITION IN THE LAMP HEAD. UNDER NORMAL OPERATING
CONDITIONS THIS INDICATOR WILL LIGHT FOR A FEW SECONDS WHEN THE SYSTEM IS FIRST ENERGIZED UNTIL
PRESSURE BUILDS UP IN THE LAMP HEAD COOLING SYSTEM. THIS INDICATOR WILL LIGHT IF THE FOLLOWING
FAULT CONDITIONS EXIST IN THE LAMP HEAD SECTION OF THE SYSTEM. OVER TEMPERATURE, COOLING
BLOWER FAILURE, INSUFFICIENT AIRFLOW WITHIN THE COOLING SYSTEM. WHEN THE PROBLEM IS CORRECTED
THIS INDICATOR WILL EXTINGUISH AND THE SYSTEM WILL GO INTO NORMAL OPERATION.
NOTE
IF A FAULT CONDITION EXISTS IN BOTH THE LAMP HEAD AND BALLAST UNITS ( SUCH AS A TRIPPED PHASE LOSS
CIRCUIT BREAKER AND A NON OPERATING LAMP HEAD COOLING SYSTEM ) BOTH INDICATOR WILL LIGHT
DIMLY.
10. BALLAST CURRENT OUTPUT TEST POINTS
USED TO MONITOR THE BALLAST OUTPUT CURRENT DURING THE POWER OUTPUT ADJUSTMENT PROCEDURE.
OUTPUT RANGE 0 - 50 MILLIVOLTS DC = (0 - 300 AMPS DC).
11. BALLAST CURRENT OUTPUT METER
USED TO MONITOR THE BALLAST OUTPUT CURRENT DURING THE POWER OUTPUT ADJUSTMENT PROCEDURE.
12. VOLT METER DISPLAY SWITCH
THIS SWITCH MUST BE PRESSED TO VIEW THE BALLAST OUTPUT VOLTAGE WHILE THE LAMP IS OPERATING.
CAUTION
PRESSING THIS SWITCH WHILE THE BALLAST IS IN PRE IGNITION MODE (BOOST MODE) MAY DAMAGE THE VOLT
METER.
13. BALLAST VOLTAGE OUTPUT TEST POINTS
USED TO MONITOR THE BALLAST OUTPUT VOLTAGE DURING THE POWER OUTPUT ADJUSTMENT PROCEDURE.
OUTPUT RANGE 0 - 140 VDC.
14. BALLAST VOLTAGE METER
USED TO MONITOR THE BALLAST OUTPUT VOLTAGE DURING THE POWER OUTPUT ADJUSTMENT PROCEDURE.
15. BALLAST OUTPUT FINE ADJUSTMENT SWITCH
USED TO ADJUST THE BALLAST OUTPUT DURING THE POWER OUTPUT ADJUSTMENT PROCEDURE.
16. BALLAST OUTPUTCOARSE ADJUSTMENT SWITCH
USED TO ADJUST THE BALLAST OUTPUT DURING THE POWER OUTPUT ADJUSTMENT PROCEDURE.
LAMP HEAD
1. FOCUS SWITCH
LOCATED ON THE REAR OF THE LAMP HEAD THIS SWITCH IS USED TO FOCUS THE SEARCHLIGHTS BEAM
ANGLE. MOVING THE SWITCH TO THE UPPER OR LOWER POSITION STARTS THE MOTOR THAT ADJUSTS THE
LAMP. MOVING THE SWITCH TO THE OPPOSITE POSITION REVERSES THE MOVEMENT.
NOTE
THE TWO PUSH BUTTON SWITCHES TO THE RIGHT OF THE FOCUS SWITCH ARE REMOTE LAMP STRIKE AND OFF
SWITCHES AND ARE NOT USED ON SYSTEMS ARCHITECTURAL SYSTEMS INCORPORATING AUTOMATIC
IGNITION CIRCUITRY. PRESSING THE OFF SWITCH WHILE THE LAMP IS LIT WILL CAUSE THE LIGHT TO
EXTINGUISH MOMENTARILY UNTIL THE AUTO IGNITION RESTARTS THE LAMP. PRESSING THE ON BUTTON WILL
ENERGIZE THE IGNITOR CIRCUIT. THIS FUNCTION IS THE SAME AS THE MANUAL STRIKE SWITCH LOCATED ON
THE BALLAST CONTROL PANEL AND MAY BE USED TO TEST A SYSTEM THAT DOES NOT AUTOSTRIKE.

PAGE 8
FRONT LAMP HOLDER ASEMBLY

PAGE 9
INSTRUCTIONS FOR REMOVING AND INSTALLING A TYPE TH LAMP IN A
SUPER 10 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.
NOTE
THE LAMP HEAD SHOULD BE IN THE HORIZONTAL POSITION DURING THE GLOBING PROCEDURES.
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 LAMP INSTALLED OR WHEN HANDLING THE XENON LAMPS. SERIOUS INJURY
MAY OCCUR IF PROPER SAFETY PRECAUTIONS ARE NOT OBSERVED. READ ALL ENCLOSED INSTRUCTIONS AND
INFORMATION SHEETS BEFORE HANDLING THE LAMP.
WARNING
NEVER OPERATE A FIXTURE WITH AN EXPOSED LAMP! THERE IS AN EXTREME DANGER OF SEVERE BURNS TO
EXPOSED SKIN AND EYES FROM THE ULTRAVIOLET LIGHT EMITTED FROM THE EXPOSED LAMP. DAMAGE CAN
OCCUR IN AS LITTLE AS 30 SECONDS OF EXPOSURE. THERE IS ALSO AN ADDITIONAL DANGER FROM FLYING
GLASS IF AN EXPOSED LAMP EXPLODES!
EQUIPMENT REQUIRED
1. PROTECTIVE SAFETY EQUIPMENT KIT
2. 7/16 WRENCH OR SOCKET
3. ALLEN WRENCH 5/32

PAGE 10
DISASSEMBLY PROCEDURE
IF THERE IS NO LAMP INSTALLED IN THE FIXTURE
1. RELEASE THE 4 FASTENERS LOCATED AT THE SMALL SIDES OF THE COWL BY PRESSING IN ON THE FASTENERS
AND PULLING FORWARD TO 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. 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 11
DISASSEMBLY PROCEDURE
IF THERE IS A LAMP IS INSTALLED IN THE FIXTURE
1. RELEASE THE 4 FASTENERS LOCATED AT THE SMALL SIDES OF THE COWL BY PRESSING IN ON THE FASTENERS
AND PULLING FORWARD TO REMOVE THE COWLING.
CAUTION
DO NOT PLACE ANY EXCESSIVE FORCE ON THE LAMP WHILE REPLACING THE PROTECTIVE WRAPPER!
2. WRAP THE LAMP SECURELY IN THE PROTECTIVE WRAPPER THAT THE LAMP WAS ORIGINALLY SHIPPED WITH.
3. REMOVE THE 2 BRASS BOLTS CONNECTING THE SHORT LEADS TO THE FRONT LAMP HOLDER USING A 7/16
WRENCH.
4. 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 LAMP DOES NOT DROP WHEN THE
MOUNTING SCREW IS REMOVED.
WARNING
DO NOT EXSERT EXCESSIVE FORCE ON THE LAMP WHILE UNSCREWING IT FROM THE REAR LAMP HOLDER! THE
LAMP SHOULD RELEASE FROM THE REAR LAMP HOLDER WITH A VERY LIGHT COUNTER CLOCKWISE ROTATION IF
THIS DOES NOT HAPPEN SEE THE PROCEDURE FOR REMOVING A FROZEN LAMP.
5. REMOVE THE LAMP BY LIGHTLY PUSHING BACK ON THE LAMP TO MOVE THE REAR LAMP HOLDER TO IT’S
REAR MOST POSITION WHILE LIGHTLY TURNING THE LAMP IN A COUNTERCLOCKWISE ROTATION. THE LAMP
WILL RELEASE FROM THE REAR LAMP HOLDER IN APPROXIMATELY 1.5 COMPLETE TURNS.
6. REMOVE THE LAMP WITH THE FRONT LAMP HOLDER ATTACHED FROM THE FIXTURE AND PLACE IT ON A
STABLE WORKING SURFACE FOR THE REMOVAL OF THE FRONT LAMP HOLDER.
7. TO REMOVE THE FRONT LAMP HOLDER FROM THE LAMP 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 LAMP AND PLACE THE LAMP INTO ITS SHIPPING CONTAINER FOR

PAGE 12
SAFE KEEPING. RESECURE THE PROTECTIVE WRAPPER IF NECESSARY.
REMOVING A FROZEN LAMP
1. REPLACE THE FRONT LAMP HOLDER RETAINING BOLT TO SUPPORT THE FRONT OF THE LAMP WHILE FREEING
THE LAMP FROM THE REAR LAMP HOLDER.
WARNING
DO EXERT ANY FORCE ON THE GLASS PORTIONS OF THE LAMP WHILE ATTEMPTING TO FREE IT FROM THE REAR
LAMP HOLDER!
2. REACH THROUGH THE OPENING IN THE REAR OF THE REFLECTOR AND GRASP THE LAMP BY ITS REAR
FERRULE AND WHILE LIGHTLY PUSHING THE LAMP BACK INTO THE RECEIVER BLOCK TURN THE LAMP IN A
COUNTERCLOCKWISE DIRECTION UNTIL THE LAMP BEGINS TO ROTATE FREELY.
3. ONCE THE LAMP IS FREE DO NOT REMOVE IT COMPLETELY FROM THE REAR LAMP HOLDER.
4. RETURN TO STEP 5 OF :
“DISASSEMBLY PROCEDURE

PAGE 13
IF THERE IS A LAMP IS INSTALLED IN THE FIXTURE”
ASSEMBLY PROCEDURE
WARNING
DO NOT REMOVE THE PROTECTIVE COVER FROM THE LAMP UNTIL INSTRUCTED TO DO SO!
WARNING
DO EXERT ANY FORCE ON THE GLASS PORTIONS OF THE LAMP 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 LAMP 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.
WARNING
DO NOT PLACE ANY PRESSURE ON THE LAMP WHILE REASSEMBLING THE FRONT LAMP HOLDER!
3. 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 LAMP 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 LAMP COUNTERCLOCKWISE UNTIL THE LAMP THREADS DROP
INTO THE RECEIVER THREADS.
CAUTION
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 LAMP CLOCKWISE UNTIL RESISTANCE IS FELT.
8. AT THIS POINT THE LAMP SHOULD BE IN CONTACT WITH THE SPRING PLUNGER ASSEMBLIES. GENTLY TURN
THE LAMP 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. CONNECT THE 2 SHORT LEADS FROM THE SPIDER TO THE FRONT LAMP HOLDER USING THE 2 BRASS BOLTS

PAGE 14
AND WASHERS THAT WERE REMOVED DURING DISASSEMBLY.
NOTE
ANY TYPE OF ALCOHOL IS SUITABLE FOR CLEANING THE LAMP EXCEPT FOR ALCOHOL THAT HAS BEEN
DENATURED USING PETROLEUM PRODUCTS SINCE THE DENATURING AGENT WILL LEAVE A RESIDUE ON THE
LAMP.
11. REMOVE THE PROTECTIVE COVER FROM THE LAMP AND CLEAN THE GLASS PORTION OF THE LAMP
COMPLETELY WITH ALCOHOL.
12. THE INSTALLATION IS NOW COMPLETE. REPLACE THE FRONT COWL AND TEST THE LAMP.
13. LOG THE HOUR METER READING AT INSTALLATION.
14. PERFORM THE OUTPUT POWER ADJUSTMENT PROCEDURES.
15. PREFORM THE FOCUS AND X-Y PROCEDURES.

PAGE 15
FOCUS AND X-Y ADJUSTMENT INSTRUCTIONS
FOR SYSTEMS W/ ELECTRIC FOCUS
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.
EQUIPMENT REQUIRED
1. ALLEN WRENCH 5/32
2. # 5 WELDERS GLASSES OR VERY DARK SUNGLASSES
WARNING
THE SUPER 10 SYSTEMS PROJECT A VERY INTENSE BEAM OF FULL SPECTRUM LIGHT. THE USE OF DARK GLASSES
WHILE ADJUSTING THE BEAM PARAMETERS ON A LIGHT COLORED REFLECTIVE SURFACE AT A CLOSE DISTANCE
IS REQUIRED.
WARNING
NEVER LOOK DIRECTLY INTO A LIT FIXTURE'S LIGHT SOURCE.
ADJUSTMENT INSTRUCTIONS
1. LOOSEN THE POSITIONING FASTENERS AND POINT THE LAMP HEAD TOWARD A WALL, CEILING, OR OTHER
FLAT SURFACE AT LEAST 10 FEET AWAY.
2. LOCATE THE FOCUS SWITCH LOCATED ON THE REAR OF THE LAMP HEAD.
3. REMOVE THE FRONT COWL AND LOCATE THE X & Y ADJUSTMENT HOLES LOCATED ON THE LOWER SMALL
SIDES OF THE FIXTURE AT THE ENDS OF THE FRONT SPIDER ARMS.
WARNING
THE SUPER 10 SYSTEMS PROJECT A VERY INTENSE BEAM OF FULL SPECTRUM LIGHT. CAUTION MUST BE TAKEN
WHEN POINTING THE BEAM AT AN OBJECT AT A DISTANCE OF LESS THAN 100 FEET WITH THE FOCUS SET FOR A
CONVERGING BEAM. COMBUSTIBLE OBJECTS AND OBJECTS WITH A DARK COLOR MAY UNEXPECTEDLY
IGNITE IF CARE IS NOT TAKEN IN THE FOCUSING AND POSITIONING OF THE BEAM.
4. ENERGIZE THE FIXTURE AND IGNITE THE LAMP.
5. ADJUST THE FOCUS BY MOVING THE FOCUS SWITCH UP OR DOWN TO PRODUCE A DIVERGING BEAM
PATTERN WITH 2-3 CLEARLY DEFINED RINGS OF LIGHT WITH OR WITHOUT AN OFF CENTER HOT SPOT.
6. ADJUST THE X & Y ADJUSTMENT SCREWS USING A 5/32 ALLEN WRENCH TO MOVE THE INNER RINGS OF
LIGHT TO CREATE CONCENTRIC RINGS WITH THE HOT SPOT AT THE CENTER OF THE LIGHT FIELD. TURNING
THE ADJUSTMENT SCREW CLOCKWISE WILL MOVE THE RINGS TOWARD THAT ADJUSTMENT AXIS AND
TURNING THE SCREW COUNTERCLOCKWISE WILL MOVE THE RINGS AWAY FROM THAT ADJUSTMENT AXIS.
7. READJUST THE FOCUS SCREW TO SET THE DESIRED BEAM SPREAD.
8. REPLACE THE FRONT COWL REPOSITION THE LAMP HEAD AND RESECURE THE POSITION LOCKING
FASTENERS.

PAGE 16
OUTPUT POWER ADJUSTMENT PROCEDURES
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
THIS SYSTEM USES TWO SOURCES OF POWER. DISCONNECT BOTH POWER SOURCES BEFORE SERVICING THIS
EQUIPMENT.
WARNING
THIS SYSTEM MAY BE UNDER THE CONTROL OF AN AUTOMATIC TIMING SYSTEM AND MAY START AT ANY TIME
WHEN THE NORMAL / SERVICE SELECTOR SWITCH IS IN THE NORMAL POSITION.
EQUIPMENT REQUIRED
1. WRENCH 3/8
ADJUSTMENT INSTRUCTIONS
1. REMOVE LOWER ACCESS COVER FROM THE FRONT OF THE BASE ENCLOSURE BY REMOVING THE 6
SCREWS ALONG THE SIDES OF THE PANEL WITH A 3/8 WRENCH.
2. NOTE THE LOCATION AND SETTINGS OF THE POWER SUPPLY POWER ADJUSTMENT SWITCHES.
3. IF THE SYSTEM IS TO BE ADJUSTED WITHOUT THE CONTROL TIMING CIRCUIT ENERGIZED SET THE MAIN
POWER SWITCH TO THE OFF POSITION AND SET THE NORMAL / SERVICE SELECTOR SWITCH TO THE SERVICE
POSITION.
4. SET THE MAIN POWER SWITCH TO THE ON POSITION. THE UNIT COOLING SYSTEM SHOULD START
IMMEDIATELY, AND THE LAMP SHOULD STRIKE AFTER A SEVERAL SECOND DELAY. IF NOTHING HAPPENS
AND THE SELECTOR SWITCH IS SET PER STEP 2 CHECK THE MAIN 3 PHASE POWER SUPPLING THIS SYSTEM IN
ALL LIKELIHOOD THE MAIN POWER HAS BEEN TURNED OFF AT THE SOURCE.
5. USING THE METERS ON THE CONTROL PANEL MEASURE THE OUTPUT VOLTAGE AND CURRENT OF THE
POWER SUPPLY.
6. CALCULATE THE OUTPUT POWER USING THE FORMULA (VOLTS) X (AMPS) = (WATTS). IF THE POWER LEVEL IS
OVER 10500 WATTS IMMEDIATELY TURN OFF THE LIGHT AND GO TO STEP 8.
7. ALLOW THE LIGHT TO RUN AT LEAST 10 MINUTES BEFORE MAKING ANY ADJUSTMENTS.
8. TURN OFF THE LIGHT USING THE MAIN POWER SWITCH ON THE CONTROL PANEL. THE COOLING SYSTEM
WILL CONTINUE TO RUN FOR AT LEAST 30 MINUTES AFTER THE POWER IS TURNED OFF. DO NOT BE
CONCERNED. THE POWER TO THE POWER SUPPLY ADJUSTMENT SWITCHES HAS BEEN DISCONNECTED BY
THE UNIT’S MAIN POWER CONTACTOR.

PAGE 17
WARNING
DO NOT ATTEMPT TO SET THE POWER ADJUSTMENT TAP SWITCHES WITH THE LAMP ON. DOING SO WILL
DAMAGE THE SWITCH.
9. ADJUST THE OUTPUT POWER LEVEL TO 10000 WATTS +\- 5% USING THE POWER TAP SWITCHES LOCATED ON
THE LEFT SIDE OF THE CONTROL PANEL.
10. AFTER RESETTING THE POWER SWITCHES REPEAT STEPS 4 - 9 UNTIL THE POWER LEVEL HAS BEEN
CORRECTLY SET.
11. WHEN FINISHED REPLACE THE ACCESS COVER.

PAGE 18
GLOBE MAINTENANCE
IN ORDER TO INSURE MAXIMUM LAMP LIFE THE FOLLOWING PROCEDURES SHOULD BE FOLLOWED EVERY 75 -
100 HOURS OF OPERATION.
GLOBE ROTATION
IF THE FIXTURE IS USED IN A POSITION OTHER THAN POINTED WITHIN 15 % OF VERTICAL THE GLOBE SHOULD BE
ROTATED 1/3 OF A TURN TO INSURE EVEN DEPOSITION OF THE VAPORIZED TUNGSTEN GENERATED BY THE
ARC INSIDE THE GLOBE.
ADJUSTMENT PROCEDURES
1. REFER TO THE INSTRUCTIONS FOR REMOVAL AND INSTALLATION OF THE GLOBE NOTING ALL WARNINGS.
2. FOLLOW THE DISASSEMBLY PROCEDURE FOR A FIXTURE WITH THE GLOBE INSTALLED STEPS 1 THRU 5.
3. WHEN ROTATING THE GLOBE FOR REMOVAL CONTINUE LIGHTLY PRESSING REARWARD ON THE GLOBE.
THE THREADS OF THE GLOBE WILL RIDE OUT OF THEIR CURRENT LEADS AND DROP INTO THE NEXT SET OF
THREADS IN THE RECEIVER BLOCK. WHEN THIS HAPPENS YOU WILL FEEL THE GLOBE DROP DOWN INTO THE
RECEIVER BLOCK.
4. IMMEDIATELY STOP TURNING THE GLOBE AND REVERSE DIRECTION TO SCREW THE GLOBE IN AT THE NEW
ORIENTATION.
5. COMPLETE REINSTALLING THE GLOBE PER THE GLOBE INSTALLATION PROCEDURE.
POWER LEVEL ADJUSTMENT
CHECK THE OUTPUT POWER LEVEL OF THE SYSTEM AND READJUST AS NECESSARY TO MAINTAIN THE OUTPUT
BELOW 10000 WATTS. (SEE POWER ADJUSTMENT PROCEDURES )

PAGE 19
CIRCUIT DESCRIPTIONS

PAGE 20
Lamp Head Schematic