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Challenger Servicing

By Sylvia Marshall,2015-01-12 02:52
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Challenger ServicingChal

    A guide to Challenger maintenance

    Faulting the Challenger 250

Fault Cause Cure

Led not lit , No lamp, No fan No power to the unit or Fuse blown Check fuses & power to the unit

    No lamp , led flashing, Head Lamp blown Replace lamp and check lamp moving driver triac.

    Led flashing fast , no lamp Unit has overheated Check fan & ventilation,

    Disconnect & restore power to

    reset.

    Head movement not smooth Stepper(s) lost a phase Check wiring to steppers on the

    head. Change Stepper driver ICs

Head will not reset to the Steppers shifted on shafts Reset starting positions of steppers

    same position

    Serial will not pass through Serial cabling fault Check cabling . Check wiring to unit. but unit will work in XLR's on bottom of unit

    standalone.

Unit will not respond to serial Processor not receiving data Replace serial opto-isolator

    but serial passes through unit.

    unit works in standalone.

Unit resets but no lamp or Unit in self test Check DIP switch 1&2 settings

    movement afterwards

    Lamp life poor Lamp holder worn or no ventilation Check ventilation , Change lamp

    Wrong lamp used holder. We recommend 24V 250W

    GE ELC lamps

    Unit loses position Stepper wiring faulty or dirt build-up Check stepper wiring , check for

    dirt between stepper & angle

    bracket

Cleaning

    Tools Required:-

    10mm box spanner

    4mm allen key

    Cotton buds

    Compressed Air duster

    We recommend that from time to time the unit is cleaned to prevent a build up of dust in the fan grill and the lamp grill. To clean the ventilation slots use a soft brush and an air duster (compressed air can).The mirror and the objective lens can be cleaned with a soft cloth. Do not use any abrasive cleaners or abrasive cloths since this will remove the surface of the externally silvered mirror.

     To clean the optics inside the unit, the unit must be taken apart. First ensure that the power to the unit has been disconnected. Open the unit by removing either of the black extrusions on the front of the unit (nearest the lamp holder) and removing the two freed side plates.

     It is now possible to clean the filters and the flat side of the condenser lens with a cotton bud or similar. Do not take the optic assembly apart and be very careful not to bend the gobo disk. The curved side of the objective lens can be cleaned with a soft cloth. To clean the inside of the objective lens remove the three allen bolts around this lens. The lens will now be free and can be cleaned.

     To reassemble the unit replace the three allen bolts and then replace the extrusion.

Software Upgrade

    Tools required:-

    Small Screwdriver +

    Small Screwdriver -

1. Ensure that there is no power on the unit

    2. Remove the two screws holding the fan in place & remove the fan

    3. Using a small screwdriver prise the EPROM from its socket (The EPROM is the rectangular IC with

    28 pins that is socketed and labelled.)

    4. Insert the new EPROM ensuring that the semicircular indentation is towards the top of the unit. Also

    ensure that all of the EPROM’s pins are correctly seated in the holder.

    5. Replace the fan.

To Reset the starting positions of the colour, gobo pan & tilt.

    Tools required:-

    2mm Allen key (80mm long)

    10mm Spanner

1. Ensure there is no power on the unit

    2. Set the dip switches 1&2 to on, 3-8 off

    3 Open the unit by removing the black extrusion nearest to the XLR connectors and removing the two

    freed sides.

    4 Check the free movement of the colour & gobo wheels.

    5 Power up the unit & wait for the movement to stop.

    6 Check that the colour & gobo wheels are sitting approximately 0.5mm away from the stops. Adjust if

    necessary by slackening the grub screws holding the wheels to the stepper motor shaft and re-tightien

    grub screw.

    7 Check the pan & tilt positions are also 0.5mm away from the stops. Adjust if necessary by slackening

    the grub screw holding the pan/tilt head to the stepper motor shaft and re-tightening the grub screw. 8 Disconnect the power.

    9 Ensure that all movement is still free after adjustment.

    10 Repeat steps 5 to 9 to ensure the unit regains this position every time.

11 Reassemble the unit.

    Mirror Replacement

    Screwdriver +

    5mm box driver

1. Remove the Rubber stop on the back of the mirror

    2. Then remove the 10mm stand-off.

    3. Remove the two screws holding the mirror bracket

    4. Replace the mirror

    5. Replace the two screws

    6. Replace the stand-off and the rubber stop.

Tilt Stepper Motor Replacement

    Screwdriver +

    5mm box driver

    5.5mm box driver

    2mm allen key

1 Remove mirror (see Mirror replacement)

    2 If stepper leads do not have a plug ,Remove nuts and washers holding stepper PCB to the head of the

    unit.

    3 Loosen 2mm grub screw holding the angle bracket to the stepper motor shaft 4 Remove stepper .

    5 Remove other rubber stop.

    6 Unplug or unsolder stepper motor leads noting their colour order. 7 Plug in or solder new stepper leads.

    8 Replace stepper PCB if previously removed.

    9 Replace stepper onto angle bracket nip up grub screw (do not tighten) 10 Replace mirror (see Mirror replacement)

    11 Reset starting position of tilt motor (see resetting starting positions).

Pan Stepper Motor Replacement

    Screwdriver +

    5mm box driver

    5.5mm box driver

    2mm allen key

    3mm allen key

1 If stepper leads do not have a plug ,Remove nuts and washers holding stepper PCB to the head of the

    unit.

    2 Loosen 2mm grub screw holding the angle bracket to the stepper motor shaft. 3 Remove the two 3mm allen bolts holding the pan stepper to the head of the unit. 4 Unplug or unsolder stepper motor leads noting their colour order. 5 Remove stepper.

    6 Remove rubber stop & 10mm stand-off .

    7 Replace rubber stop onto new stepper ensure the stand-off is on the correct screw. The screws in the

    new stepper may have to be rearranged.

    8 Plug in or solder new stepper leads.

    9 Replace the stepper onto head with the two 3mm allen bolts. 10 Reset starting position of tilt motor (see resetting starting positions).

    Ryger Ltd 1995 (Manual Date)

    (Ryger UK Ltd 2008 do not give any technical support on this obsolete product)

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