SETTING UP A SHOW. Sample Flow chart. SX3K DMX Can daisy chain through each ballast. SS7K. SX7K ST7K Ballast

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1 SETTING UP A SHOW This diagram shows using SS7K, ST7K, SX7K and SX3K with cable and signal distribution. The Syncrolite system is like all other moving and automated lights and is easy to integrate into any plot. Sample Flow chart Power DMX Control Console SX3K DMX Can daisy chain through each ballast. SX3K Ballast 3K Distro PD for 7Ks P D SS7K SX7K ST7K Ballast SX7K ST7K Hoffman Splitter Box DMX Can daisy chain through each ballast. CABLE KEY DMX 208 3ø Unit cable Syncrolite 8/5 Syncrolite Head cable Combo

2 SETTING UP THE SYSTEM Connective Cables The figure on the next page shows the required components and how they connect for proper system operation. The components shown include: 1. All Syncrolite products are DMX. We recommend maximum cable of 2000 in this mode, but the system will operate up to 1 mile from the DMX source unbuffered with quality cable and DMX splitter. 2. Any standard DMX splitter is acceptable, preferably Fleenor or other optoisolated devices. 3. Syncrolite provides a 6-way and 10-way DMX Splitter/Combiner for use with our Xenon products requiring standard 5-pin DMX. Syncrolite DMX distros with splitter/combiner circuits are required where Syncrolite status monitors are used. 4. DC lamp head cables are built into SS7K units. All other luminaires (ST7K,SX7K,SX3K) employ a ballast to lamp head cable which is a triped bundle with DC lamp and a custom 8-wire multicable with 4 strands of #16 gauge wire for AC to fans and electronics and 2 #20 gauge twisted pairs for DMX I/O. The ST7K uses a 4 cable bundle with 2 DC cables for lamp and 1 cable for color changer/douser harness and 1 cable for focus drive plus fans wiring harness. See Reference Section for all appropriate cable diagrams and pin-outs for each unit.

3 Power DMX Input 3K or 7K 9 way distro Syncrolite DMX Distro 10 X DMX Utility Breaker 6 way or 8 way Distro 3X30a 3ø Cam Inputs DMX in Power supply 6X DMX out Hoffman Box DMX Distro for SS7Ks

4 Mounting 1. The SS7K lamp head is the most weatherproof outdoor package. It requires level floor mounting and is not designed for flying. It has steel channels and reinforced base for crane picks and helicopter lifts. See reference section for details. 2. The ST7K, SX7K and SX3K are flyable for truss type grids or ground mount using certified connectors and proper ESTA safety procedures. The SX3K& SX7K may be flown in any orientation such as parallel to the ground with the use of special counterweights. TURNING ON THE POWER PROPER INITIALIZATION IS CRITICAL TO SUCCESSFUL OPERATIONS OF THE SYNCROLITE PRODUCT SO WE ADVISE THE OPERATOR TO CAREFULLY AND SYSTEMATICALLY FOLLOW THE RECOMMENDED START-UP ROUTINE. IF THERE IS A PROBLEM, IT USUALLY BEGINS HERE. 1. Once your system is properly connected, we recommend the following steps: 2. Check each unit s ID switch and make a note of its channel number, its physical position or location in the lighting system and its corresponding AC distro channel. If necessary, make a written chart or console map of this for each show to eliminate confusion between the AC distro channel and the control channel number. The unit ID can be any number from as the operator requires for programming. The SX3K and SX7K have digital switches built into the outer cover or this can be accomplished with the use of the lap top. The SS7K and ST7K Rotary ID switches are on the electronics box. These ID's if need to be set by laptop, must be set at 00. Once ID position and distro channel are set, it is time to power up. All units will initialize upon power up.the units will not strike until strike command is given from DMX, laptop, or onboard menu. 3. Turn on your DMX controller (check to make sure proper DMX profile has been loaded into the controller. The Whole Hog and Animator console profiles are currently available from Syncrolite.

5 4. You may turn on each individual unit at the distro and watch it go through its initialization routine. The Syncrolite units have specific calibration routines. The calibration routine will take each of the five motors to its sensor marks and to the home position after calibration. The calibration routine usually takes 30 seconds. If a particular parameter does not calibrate properly, issue a reset command. Maximum time out for a function is 2.0 minutes. After this if a parameter is still not calibrating refer to the Trouble Shooting Section. 5. At this point, each unit should have fans running and be in the home position, 50% tilt and 50% pan, with all motors active and douser closed after initialization. If the unit is still trying to initialize after 30 seconds, reset. If the unit does not properly initialize after several attempts you may have a problem. Go to the unit and check for mechanical problems, fuses or power problems and refer to Trouble-shooting section. 6. WATCH AND/OR LISTEN CAREFULLY AS YOU STRIKE EACH UNIT YOU SHOULD HEAR THE LAMP TRY TO STRIKE. a. If any unit does not properly initialize, reset. If the unit still does not properly initialize refer to the Trouble-shooting procedures. b. If the unit will not strike or kill, switch off the power at the unit and inspect. Check the read switch in the ballast and inspect the connections at the lamp. c. Due to the high voltage surge required to energize the arc in a Xenon lamp, our micro-processor shuts down momentarily during lamp strike and thereafter re-initializes the system to counteract any loss of function in the processor caused by the RF generated. Once the lamp is struck, the operating voltage drops to normal levels and the 7K unit draws approximately amps per phase at 120V, whereas the 3K draws amps per phase at 120V 7. When all lamps are struck, each unit will calibrate in the home position. At this time the lamp will go to what ever DMX is being sent to it. At this time you can select channels and test the individual motor functions (color, beam size, douse, pan and tilt) at the console for each unit to ascertain if all units are receiving and responding to commands. Refer to using the laptop for fine tuning variations in pan and tilt and other calibrations.

6 8. If all units are responding, you are ready to program. If any unit fails to respond, refer to your Trouble-Shooting procedures, correct the problem and proceed. DMX Connection If you are operating Syncrolite Xenon units with the Compulite Animator, Spark or Sabre or Hole Hog or ETC Expression, you will plug the 5-pin DMX output of the console into the Syncrolite DMX distro or any opto-isolated DMX splitter. If you are using the pass through in the ballast of each light you will not need to use a Opto-isolater to distribute the DMX. Gel Life In all Syncrolite Xenon systems, especially the 7K system it is very important to conserve gel life by observing certain rules: a. Do not stay on dark colors for long periods, i.e seconds maximum before changing, consider scanning for these cues. b. Avoid dark colors for skylight cues they do not read and can cause problems by warping gel strings. c. Keep douser closed during show and programming sessions when lamp is not in a cue or needed. d. Use machine made gel strings from any commercial manufacturer such as Wybron. The stock gel string and gel specs are listed in the Reference section. e. Check Rosco heat shield at base of color changer and change when discoloration or breakage occurs. f. Use only Rosco or Lee high temp gel or SFX super gel. g. Use double color frames and scan for long cues on darker colors, keeping beam size large will also help. A tight beam will burn most any color in less than two seconds. h. Consider using super gel or special FX for dark colors with double frames for long application. The cost is approximately $40/frame. i. If gel is severely burnt it does not travel smoothly. Inspect sensor unit and gel guide periodically. Replace damaged gel. Sometimes individual frames can be replaced to save money. j. SX3K gel strings will last indefinitely when cared for. Fans may be disable for certain applications where gel flutter is a problem. k. Frost, silks and diffusion are very useful in smoothing out the field, when the Syncrolite instruments are used in a long throw or film/tv application. Refer to the Photometric and Design section for further information. These may be taped to the point of the front of the lamp or custom made.

7 Mechanical Calibration Pan and Tilt Motor/Encoders - keys on each motor and set screws on the outboard encoder make it impossible to improperly mount these units. Periodically check encoder belt tension and surface of encoder wheel for impurities. Impurities or dings on the encoder wheel will cause the pan or tilt function to shutter or move erratically. Sometimes this is mistaken for missing or broken gear teeth in the motor. Belt tension must be maintained to drive encoder wheel. All units now employ calibration sensors to establish limits of pan/tilt. Familiarize yourself with these components and where the encoder calibrates. Douser - is a Venetian blind type with 11 blades attached to levers connected by a common shaft turned by a 9412 servo motor with built in encoder. All blades should open and close together. Check adjustment of each blade periodically. Closure can be adjusted by removing drive shafts and adjusting the end couplers. Focus Plate - the unit adjusts focus from collimated to flood by moving the lamp up and down in relation to the fixed reflector. The anode end of the Xenon lamp requires a factory extender shaped like a bullet to facilitate movement through a guide hole in the center of the spider lamp mount assembly at the top of the inner lamp head. The base plate moves forward and backward using a Pittman 9412 servo motor with encoder driving 3 pinion gears connected to the plate. These are set at the factory. Avoid obstructions by insulated lamphead cables that can interfere with belt movements.

8 Focus initializes by driving the plate to the limit switch and then going to a collimated position. This limit switch should be in the same place on all units to provide uniform calibration. Improper calibration or loose limit switch can cause plate to close or jam and in some cases overheat and damage lamp. Check the limit switch periodically to insure it is firmly in place. All units have diagnostic adjustments for tweaking beam size. This is built in to the onboard menus of the SX3K and SX7K. It requires a laptop for the SS7K and ST7K. See "Using the Laptop" In the reference section. Lamp Alignment. FNOTE: The spider mount at the top of the inner lamp head has three adjustable brackets at its extremities which attach to the inner lamp head cover. In the center is the linear bearing which receives the bullet tip of the Xenon lamp. The lamp must be properly centered within the spider mount to allow proper focus movement of the Xenon lamp and avoid lateral torque which might cause damage to the bulb. These can be adjusted to center the beam.

9 Color Changer - Syncrolite scroller type mechanism uses opaque gel tags traveling through an emitter sensor to read beginning and end of strings at calibration. Once length of gel is known, DMX channel value from 0-100% or can be set to correspond to each color panel or split panel and loaded into libraries. Check emitter sensor for impurities in the guide hole and make sure your gel is in the track at all times. Observe all safety procedures for gel preservation to effect longer gel life. Damaged or overheated gel will not track properly. If you are experiencing problems, check the gel string. With proper handling they will last longer. Some consoles have scan features, this is desirable for dark colors. Douser- the venetian blind douser is an effective fader for our xenon product. This is achieved through a linear belt drive assembly. The SS7K and ST7K use a direct linking system that calibrates to a mechanical stop. This is the first step in the calibration routine and does not recalibrate after the lamp is struck. This is to avoid reviling the light source to the audience. The SX3K employees a similar linkage, but with rotary douser cam drive wheel traveling in one direction. The SX3K can effectively strobe the douser using the following values. Fade = Strobe= a. From DMX is normal dousing ( 0-85%, blackout to full open) b. From DMX the SX3K strobes at increasing speeds (86%-100%). Some consoles have special libraries for this feature, Color changer / Douser

10 Installing Gel Scrolls SS7K/ST7K/SX7K using machine made gel scrolls per recommended Syncrolite specifications, proceed with the following steps: 1. Do not install gel string with power on check to make sure unit and scroller are unplugged before changing scrolls. 2. Take leading edge of gel and tape full lengths of end evenly and straight to the right scroller drum roller (roller opposite driver motor and sensor). 3. Use belt to feed scroll onto roller. 4. Make sure end and beginning sensor tags pass through the sensor. 5. Once all framed are evenly rolled onto the right scroller drum, take the spring-loaded left scroller drum and rotate three times (turning it to the right scroller drum) to create tension on the gel frame. 6. Holding correct scroller drum tension, tape end of scroll evenly to the drum surface. 7. Manually advance scroll past end tag checking for placement in sensor and proper travel. 8. Power the unit to view proper calibration. If all is well, proceed to replacing the front cover. 9. Load up to 12-color frame libraries into console by centering individual frames and recording DMX values into color pallates. Please observe gel conservation procedures especially during programming.

11 Lamp All Syncrolite units use the Ushio or ORC (Hanovia style) Xenon lamps. Installation requires the addition of the focus bullet on the end of the stock lamp to allow the lamp an up and down motion in the reflector for variable beam size. Bullet Retaining set screw (2) Lamp

12 Changing or Installing Xenon Lamps The Syncrolite Xenon product line utilizes high powered Xenon lamps which are under up to 16 atmospheres of pressure. Handling of lamps should be with extreme care utilizing face, shield, gloves, helmet and apron by professional personnel only. Lamps occasionally explode and can inflict severe bodily damage. HANDLE WITH CARE. The 3000W and 7000W Xenon lamps are high voltage devices and all maintenance or disassembly for repair should be effected with power off. Before you begin, kill all power and remove 3 phase power input plug and DC lamp cables. 1. Disconnect fan, lamp and motor power on back of rear plate of SS7K, or power cables from ST7K, SX3K, SX7K. 2. Remove inner lamp head - set on a level surface. (SS7K only) Inner lamphead Outer Lamphead 2 Harnesses in Fan/Focus and Color/Douser 4 bolts to remove inner lamphead Lamp/focus drive Access cover Lamp power

13 3. Remove one or both side panels. (SS7K only) 4. For ST7K, SX7K and SX3K lamp removal is simplified After disconnecting power, open cover/ door at base of lamp and remove access panel on front of lamp head. 7/16" bolt Braided Lamp Cable 5. Disconnect braided lamp cable from spider at the anode end of the lamp and insulated lamp case from the donut connector at the base of bulb keeping the focus plate insulator attached to the lamp. 6. Remove insulator screws and extract the lamp with insulator and focus drive bullet still attached. 3 screws Insulated Lamp cable Insulator plate Donut Beam sensor Belt drive for Beam

14 7. Carefully remove the donut connector and spring clips from the lamp and wrap the lamp in plastic handling sheet and place in safety container. Take care not to lose the spring clip between the lamp insulator base and donut. Remove and keep the bullet from the other end of the lamp. 8. Take new lamp and attach appropriate Syncrolite focus bullet to anode (-) of lamp. Tighten braided lamp cable and focus set screws with appropriate torque. Bullet Lamp Retaining set screw (2) Braided lamp cable connector must be tightened before lamp installed.

15 9. Put spring clip over cathode (+) end ferrel. 10 Attach insulating base plate. place second spring clip on (+) ferrel. 11. Tighten donut connector, using hex key while holding insulator plate and spring clips tight to lamp end. Lamp should be snug, spring clips act as shock absorbers. 12. Install lamp bullet and tighten both set screws. Next place (-) end with bullet into the spider inside lamp housing. 13. First tighten connections of lamp insulator to focus drive plate at lamp base (+) then attach conductors at lamp ends (+ and -). Check all connections for cleanliness and make sure they are securely in place. 14. DO NOT TOUCH LAMP QUARTZ - any fingerprints will cause the lamp to fail. If touched clean quartz with alcohol. 15. Replace side panels in SS7K or both lamp access covers in the ST7K, SX7K or SX3K. 16 Install and re-connect inner lamp head, fan, lamp, and motor cables. 17. Strike the lamp and run for 15 minutes and observe. Note: All terminals and connectors must be clean and tight. Loose connectors at any point create resistance and cause overheating. Overheating compromises the lamp seals and reduces lamp life. Terminal should be checked before every use and cleaned and retightened periodically. Always clean inside of donut and end ferrel. Burnt terminals must be replaced. Refer to maintenance/pre-show check list.

16 SX3K/SX7K ON BOARD MENUS The five buttons on the side of the lamp are multi function a. To access the menu with the power on ( with or without DMX), press buttons 1 and 5 simultaneously. This will access the menus. Reverse and forward (1 and 2) will take you through the options. 3 will enter a menu function such as pan, tilt, beam, dowser, color, strike, kill etc. Buttons 4 and 5 (+/-) will advance or retard the main item. b. Unit ID# is set by entering the menu and using buttons 4 and 5 to set the unit #. c. The on-board diagnostics are useful in tweaking the values for pan and tilt, beam focus, etc. where there are perceived differences in them due to mechanical variations. Because usual Xenon applications are long throw, small variances in pan and tilt and collimated beam can be noticeable, therefor it is helpful to be able to easily tweak these values at any time. d. When DMX is being received, the on-board diagnostics will show DMX values in real time for each function. e. For diagnostics purposes you can see the actual encoder count range I real time. f. The lamp can be struck or killed without DMX per the appropriate menu function. g. If you are under show control, you must push buttons 1 and 5 simultaneously to disable DMX temporarily. If you forget to return the unit to DMX control, it times out automatically in a couple of minutes and returns to console control. h. We suggest that new technicians play with the menus before striking to get familiarized with its functions.

17 1. Before you leave your shop: Check List a. Check each unit for proper operation. b. Be sure you include basic tools, fuses and lamps. c. Check your controller, disks, set-up charts, plots, etc. d. Be aware of lamp life. e. Take a DMXter, MicroTech, and if available, a laptop with Syncrolite diagnostics. 2. After any long airfreight flight or trucking of your system, check individual units thoroughly for any loose wiring harnesses, mechanical parts or loose connections of any kind in both the top box and lamp housing. 3. Power up, initialize and strike each unit before units are used in show. 4. Balance your pan, tilt and beam (focus) collimation with laptop or onboard menu. 5. Never pull out and reinsert a unit Skid (internal electronic circuit board) or CPU or motor driver card in a powered up unit. Turn off the unit power at the distro before any electronics are removed 6. If it is necessary to re-initialize a lost or non-responsive unit, use the reset command. Or, if at unit, switch breaker on/off or pull power supply card and reinsert. 7. All Syncrolite units can be diagnosed with a lap top PC or with software built into the unit