Service manual

ManualsBrandsVari Lite ManualsFitness ElectronicsVirtuoso DX

02.9663.0010

VL1000

™

ERS

Luminaire

Service Manual

Summary of content (209 pages)

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M a n u a l VL1000™ ERS Luminaire S e r v i c e 02.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL VARI❋LITE®, Artisan®, VL2®, and VLD® are trademarks owned by Vari-Lite, Inc., 201 Regal Row, Dallas TX 75247 USA. and are registered in the United States and other countries.
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HOW TO OBTAIN WARRANTY SERVICE How To Obtain Warranty Service A copy of the Vari-Lite, Inc. Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548) or customerservice@vlint.com and request a Return Material Authorization (RMA) for warranty service.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Compliance Notice FCC This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
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SAFETY NOTICE Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product. WARNING advising of potential injury or death to persons.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired. For example, by cracks or deep scratches.
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SICHERHEITSHINWEISE Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß.
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NOTES DE SÉCURITÉ Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2. L’utilisation des luminaires sans lentille ou blindage pose des risques.
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AVISO SOBRE SEGURIDAD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto. Los símbolos de seguridad usados en este manual son los siguientes: CUIDADO, indica posibles daños al producto.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación UV. NO mire directamente a la lámpara. 2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada.
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SAFETY NOTICE (JAPANESE) _KHæPÔ HçPÄ ÎÎæ%¿Ð á¿ ~ ÒÁ'êùÕÄQ>X ^Å î ûéQ>X ^é_KHæPÔ ±ãÿ ÔôáÅúÊÛÐ¿ù ÚsÙæÄ~ ÌÚ öªÔ ÙæêÔôáéHçPÄÅ î TæÐçÒáÞ:ÒáÊÛÐ¿ ÄQ>X ^âê é_KQo" öªÒá¿ùÔ Hç ~ æÊÍ Ã Â¾HÇ½ ùÔ T qPæßåÇ Â¾HÇ½ ùÔ õ +4UV |¿æ»Ô 2é:´Å îqP ËÚüé ûxå±æß¿áê éÿ ÅúÊÛÐ¿ T: +4é¢ ËÚüéEf; 1.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL T: 2é UV |¿æÐ Ð å¿ÚüéEf; 1. VARI❋LITE® ÿzUé ÊêUV |¿ ¢Õ HID 2 Jé\fJ öª Òá¿ùÔ\fJ åÞÔ Îãê±ÌáÊÛÐ¿ _f-ùÚê*o^< ö ÕæÿzU P.Ô ãÂ¾âÔ_f- *o^<¡ "¹Yêíî ÿÓ¿ÞÆÈÍåäæ Øé2 ÇÊå ÁæåÞÚ §Ã ÁæÒùÔ T: qP ËÚüéEf; ÿzUÇP.Òá¿ ãÈêØé ¥Ç²Êå ùÔ²ÊåÞÚzU ÿ&fPo@f; ÒÁÙæê¡¾åUÔ»<ÿ; ª ÜÕ ö ªÒáÊÛÐ¿ ÿzUÇP.Òá¿ ãÈêØé\fJÇ²Êå ùÔ\fJ dµ Ô 'êÿzUé . ¾ \fJé÷2Ç Ç ùâÙÞáÊÛ Ð¿\fJécñÚ ½Ì ã¤¿, 64ÇÛ¿á\fJé .Ç ¾ 'Ç½ ùÔ o".
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TABLE OF CONTENTS Table of Contents Introduction Disclosure .................................................................................................................... About This Manual ...................................................................................................... Additional Documentation........................................................................................... Customer Service ................................................................................
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Shutter Assembly Replacement.................................................................................. 34 Shutter Blade or Rack Replacement........................................................................... 36 Edge/Zoom/Color Bulkhead Replacement................................................................. 38 Fan/Temp Switch Assembly Replacement .................................................................
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TABLE OF CONTENTS Dimmer Wheel Assembly .......................................................................................... 99 Wheel Sensor PCB ................................................................................................... 100 Index Sensor PCB .................................................................................................... 101 Shutter Assembly .....................................................................................................
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Appendix A. Technical Bulletins VL1000 ERS Luminaire Technical Bulletins........................................................... 167 Appendix B. Wiring and Schematic Diagrams VL1000 Incandescent Wiring Diagram - Sheet 1 of 2 ............................................. 169 VL1000 Incandescent Wiring Diagram - Sheet 2 of 2 ............................................. 170 VL1000 Arc Wiring Diagram - Sheet 1 of 2 .........................................
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INTRODUCTION : DISCLOSURE Introduction Disclosure This technical manual is confidential property of Vari-Lite, Inc. All information contained herein is the sole and exclusive property of Vari-Lite, Inc. and may not be used, disclosed, or reproduced in any manner without the prior written consent of Vari-Lite, Inc. WARNING: It is important to read ALL accompanying safety instructions to avoid damage to the product and potential injury to yourself or others.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Customer Service Our Goal At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone/troubleshooting assistance, product training or technical service, our fulltime staff of experienced professionals are on-hand to provide support.
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CHAPTER 1. Description This chapter provides an overview of luminaire features, components and operations. • Features • Component Descriptions • Principles of Operation 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Features Standard Features VL1000 Ellipsoidal Reflector Spotlight (ERS) luminaires have the following standard features: • • • • • • Automated zoom optics system. Crossfading CYM color system. Diffusion system. Six-position rotating gobo wheel (five rotatable, indexable gobo positions and one open gobo position). Repositional pan/tilt system. Control by DMX512 protocol.
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DESCRIPTION : COMPONENT DESCRIPTIONS 1 Component Descriptions External Luminaire Components The following illustration shows the external luminaire components and controls. Base Provides hook mounting holes and safety cable connection. Input Panel Provides DMX In and Thru, and AC Power connections. Latch Lamp Power Input Cable Gel, Silk or Frost Accepts frames or top hats Yoke Assembly Houses Control PCB and power supply.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Luminaire Internal Head Components The following illustration shows the major sub-assemblies which are located in the luminaire head assembly. A options - Shutter, Beam-size Iris or Aperture bulkhead is dependent on model. B options - Rotating Gobo Bulkhead version is dependent on model. Beam-Size Iris Assembly (optional) Provides beam sizing capabilities. Shutter Assembly (optional) Four-blade system can frame and crop beam field and gobos.
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DESCRIPTION : COMPONENT DESCRIPTIONS 1 Luminaire Internal Yoke Components The following illustration shows the major sub-assemblies which are located in the luminaire yoke assembly. Note: Head assembly not shown for clarity. Yoke Arm Cover Tilt Mechanism Pan Mechanism Yoke Arm Cover (Display Side) Main Controller PCB Luminaire control circuit board. 150W Power Supply Supplies power to electronic and motor components. Ignitor PCB Ignites lamp in arc models. 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Arc Ballast Unit An external ballast unit is included with VL1000 arc models. In this case, the lamp power input cable is already connectorized for use with this unit. The following illustration shows the external arc ballast components. Lamp Connector CPC-type connector for connecting Lamp Power Input cable from luminaire. Truss Hook Mount Used to attach a truss hook. Safety Cable Tab Used to attach safety cable clip.
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DESCRIPTION : PRINCIPLES OF OPERATION 1 Principles of Operation VL1000 Incandescent Source Luminaire VL1000 Incandescent Block Diagram VL1000 INCANDESCENT 1766 1202 1520 1520 1766 1301 1301 1301 ZOOM MOTOR GOBO INDEX BLUE MOTOR MAG MOTOR DIMMER ARC ONLY 1A 2A 3A 4A SHUTTER FRAME SHUTTER FRAME SHUTTER FRAME SHUTTER FRAME BLOCK DIAGRAM VL 1000 INC wire9.vsd 10-23-01 JHC 1202 1202 1520 1520 1202/1326 1301 EDGE MOTOR GOBO WHEEL AMBER MOTOR DIFF MOTOR B.S.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL VL1000 Incandescent Cable Routing CHASSIS NEUTRIK POWERCON AC LINE IN 2015 GND STUD 1 AC LINE 2015 XLR-M DMX INPUT TERM BLOCK .
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DESCRIPTION : PRINCIPLES OF OPERATION 1 VL1000 575W Arc Source Luminaire VL1000 Arc Block Diagram VL1000 575W ARC BLOCK DIAGRAM VL 1000 ARC wire9.vsd 10-23-01 JHC ALL MOTORS 44-9663-XXXX DATA I/O 1520 1520 1766 1301 1301 1301 BLUE MOTOR MAG MOTOR DIMMER ARC ONLY 1A 2A 3A 4A SHUTTER FRAME SHUTTER FRAME SHUTTER FRAME SHUTTER FRAME 1301 DATA 22/5 2022 J3 NEUTRIK XLR-F DMX THRU ( 1202 1202 1520 1520 1202/1326 1301 1301 1301 GOBO WHEEL AMBER MOTOR DIFF MOTOR B.S.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL VL1000 Arc Cable Routing CHASSIS AC NEUTRIK LINE POWERCON 2015 AC LINE IN 2015 AC GND GND STUD 1 2016 AC LINE XLR-M DMX INPUT TERM BLOCK .
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DESCRIPTION : PRINCIPLES OF OPERATION 1 VL1000 Arc Ballast Unit Ballast Block Diagram VL1000 575W ARC BALLAST VL1000 575W ARC BALLAST RIDER PCB 24-9663-1902 WIRING DIAGRAM VL1000balwire8.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 14 23-Oct-02 02. 9663.
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CHAPTER 2. Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Maintenance Procedures WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation. 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Testing Running Parameter Tests The luminaire is capable of running self tests by using the TEST menu functions. When running tests on multiple luminaires, a loopback connector is required at the master luminaire (first in link) and a male termination connector is required at the last luminaire in the link. Refer to the VL1000 ERS User’s Manual for more information regarding these connectors.
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MAINTENANCE : TESTING 2 WARNING: Backcap and adjustment knobs will be HOT during lamp operation. Wear gloves and/or use tools to prevent burns. To run tests: Step 1. Press [Menu]. Step 2. Press [Up] / [Down] arrows until Test appears. Press [Enter]. Step 3. Use [Up] / [Down] arrows to select a parameter to test. Refer to table below for a complete list of test parameters. Step 4. Press [Enter] to run test. Step 5. Press [Menu] to stop test at any time.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Maintenance Procedures Lamp Replacement (Incandescent Model) Parts: 1000 WATT INCANDESCENT LAMP, 100 VAC (71.2552.0100) - T/TS/TI 1000 WATT INCANDESCENT LAMP, 115 VAC (71.2552.0115) - T/TS/TI 1000 WATT INCANDESCENT LAMP, 230 VAC (71.2552.0230) - T/TS/TI Tools: #2 Phillips screwdriver, cotton gloves CAUTION: Wear cotton gloves or other covering while installing lamp.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 3. Carefully pull backcap straight out of rear head assembly. (It will still be attached by lamp wires and tether.) Step 4. At backcap, flip two bail clamps outward (Figure 2-2). Step 5. Flip two base clamps outward away from socket. Step 6. Grip lamp by base and firmly install in socket. Step 7. Close base and bail clamps, locking into place. Do not touch lamp CAUTION: with bare fingers. 1 2 Flip bail clamps outward. Flip base clamps outward.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Lamp Replacement (Arc Model) Parts: 575 WATT ARC LAMP, MSR575HR (71.2528.0575) - A/AS/AI Tools: #2 Phillips screwdriver, cotton gloves CAUTION: Wear cotton gloves or other covering while installing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If touched, use alcohol and cotton cloth to thoroughly clean glass portion of lamp. To install arc lamp: Step 1. Remove power from luminaire. Step 2.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 3. Grip lamp by base and firmly install in socket (Figure 2-4). Do not touch lamp CAUTION: with bare fingers. Socket Lamp Install lamp, firmly pressing into place. Figure 2-4: Installing Arc Lamp in Socket Step 4. Re-install backcap, ensuring that alignment studs and holes are aligned (Figure 2-3). Step 5. Align lamp. (Refer to “Align Lamp For Maximum Beam Irradiance” on page 22.) 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Align Lamp For Maximum Beam Irradiance After a new lamp is installed in either the incandescent or arc version of the luminaire, it will be necessary to align the lamp to optimize the beam. Tools: #2 Phillips screwdriver WARNING: Backcap and adjustment screws will be HOT during lamp operation. Wear gloves and/or use tools to prevent burns. To align lamp: Step 1. Set intensity to 100%. Step 2. Position beam on a white wall at a distance of 10 to 20 feet.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Frame or Top Hat Replacement An accessory frame holder is provided for the addition of a top hat or gel frame with silks, frosts or color correction if required. The frame holder is designed to fit a standard 8-inch gel frame or top hat. To remove and replace frame or top hat: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At front lens, press upward on accessory frame latch and turn to open. Step 3. Remove frame/top hat, if any (Figure 2-6).
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Front Cover Removal Parts: ASSY, FRONT COVER (22.9663.1038) Tools: #2 Phillips screwdriver To remove and replace front cover: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head assembly, press in front cover latches to release (Figure 2-7). Step 3. Pull cover straight out until stopped by tether. Step 4. Disconnect tether by removing 8-32x1/2" PFB screw and 8-32 Keps nut as shown. Step 5. Remove cover. Step 6.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Rear Head Assembly Removal This procedure is necessary in order to access some components such as the gobo wheel bulkhead and shutter assembly. Refer to as needed. Tools: #2 Phillips long handle screwdriver To remove rear head assembly: Step 1. Disconnect luminaire AC input cable from power source. CAUTION: The rear head assembly is heavy and will remain attached by lamp wires. Place luminaire on tech bench before removing rear assembly. Step 2.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Rotating Gobo Replacement WARNING: Remove power from luminaire before performing maintenance. Gobos may be HOT after operation. Allow to cool before replacing. To replace a rotating gobo: Step 1. Remove power from luminaire. Step 2. At either side of head assembly, press in front cover latch and pull cover straight back until stopped by tether (Figure 2-7). Step 3.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 7. Re-install front cover. Inside Edge - orient toward center of wheel CAUTION: ThisEdgeIn Gobo MUST be oriented with side marked "This Edge In" toward center of wheel and side marked "Lamp Side" toward lamp. If not oriented properly, gobo will break. Be careful not to scratch gobo on side of carrier when installing.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Gobo Index Timing Belt Alignment The index timing belt (54.9663.1220) must be aligned so that the mechanism "clocks" properly. This belt is installed around the index gear and top gear of the gobo wheel (refer to Figure 2-11). The wheel position belt (54.2045.0001) is installed around the wheel position gear and bottom gear of the gobo wheel, and does not require alignment. Each belt is also routed around one pulley as shown in Figure 2-11.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 2. If applicable, lower gobo wheel into place over rotating shaft, fitting wheel position belt around lower gear and index timing belt around top gear. Install 4-40x1/4 " PPZ screw, split lock washer, flat black washer and flat Teflon washer to secure gobo wheel in place. (Belt tension is automatically set by springs of pivot mechanism.) Step 3. Orient gobo wheel so that notch of gobo wheel gear aligns with small ridge found on index timing belt. Step 4.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Gobo Wheel Bulkhead Replacement Parts: ASSEMBLY, GOBO BULKHEAD INCANDESCENT (21.9663.1200) - T/TS/TI ASSEMBLY, GOBO BULKHEAD ARC (21.9663.1600) - A/AS/AI Tools: #2 Phillips long handle screwdriver To remove and replace gobo wheel bulkhead: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. Refer to “Front Cover Removal” on page 24. CAUTION: The rear assembly is heavy and will remain attached by lamp wires.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 7. Replace by doing steps 2 through 6 in reverse. Gobo Bulkhead Side Rail Spacer Front Assembly 10-32x3/8" PPB Screw #10 Split-Lock Washers NOTE: Incandescent model gobo bulkhead not shown. Figure 2-12: Gobo Bulkhead Assembly Replacement 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Gobo Gear Planet Alignment Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly. Use the following procedure to re-align the gears in the event the gobo wheel is disassembled. To re-align gobo gears: Step 1. Place center (sun) gear at starting point so that alignment mark is directly facing Position 1 (open) as shown in Figure 2-13. Step 2. Set Position 6 planet gear as follows: a.
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MAINTENANCE : MAINTENANCE PROCEDURES 1) Start with center gear alignment mark facing Position 1 (open). 2 2) Rotate center gear clockwise until alignment mark is directly across from Position 6. Rotate Position 6 gear until marks align. Alignment Mark 1 open 6 2 6 5 3 4 Align both marks 5 3) Align remaining gobo gears using the same method. 4) Verify alignment of all marks and adjust as necessary. Figure 2-13: Aligning Gobo Wheel Gears 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Shutter Assembly Replacement Parts: ASSEMBLY, SHUTTER (21.9663.1300) (Old Version) or ASSEMBLY, SHUTTER 6 ROLLERS (21.9663.1350) (New Version) Tools: #2 Phillips long handle screwdriver+ To remove and replace shutter assembly: Step 1. Disconnect luminaire AC input cable from power source. CAUTION: The rear assembly is heavy and will remain attached by lamp wires. Place luminaire on tech bench before removing rear assembly. Step 2.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 4. At Controller PCB, disconnect shutter wiring harness at position marked SHUTTERS. Step 5. Noting placement, cut tie-wraps securing harness to other wires. Step 6. Feed shutter harness cable out of yoke arm. Step 7. At side rails, remove four 10-32x3/8" PPB screws and #10 split-lock washers and remove shutter assembly (Figure 2-15). CAUTION: Do not overtighten tie-wraps when re-installing. Step 8. Replace shutter assembly by doing steps 2 through 7 in reverse.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Shutter Blade or Rack Replacement Parts: as required: BLADE, SHUTTER, COATED SIDE A (12.9663.1323) BLADE, SHUTTER, COATED SIDE B (12.9663.1324) RACK, SHUTTER (10.9663.1314) Tools: #2 Phillips screwdriver To remove and replace a shutter blade or rack: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove shutter assembly. Refer to “Shutter Assembly Replacement” on page 34. Step 3. Place shutter assembly on work bench, motor side down.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 4. Carefully remove plates and components until blade or rack to be replaced is reached. Install new component(s) as required. Step 5. Re-assemble shutter’s four layers. Ensure that components are oriented and aligned as shown in Figure 2-17. Note: The difference between the two types of shutter blades can be found by examining the main edge. Coated Side A blades (12.9663.1323) are beveled and the Coated Side B blades (12.9663.1324) are not.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Edge/Zoom/Color Bulkhead Replacement Parts: ASSEMBLY, EDGE CONTROL, DIMMER AND COLOR (21.9663.1003) Tools: #2 Phillips screwdriver To remove and replace edge/zoom/color bulkhead: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. (Refer to “Front Cover Removal” on page 24.) Step 3. At edge/zoom/color assembly, disconnect wiring harness connections. Step 4. At side rail, remove four 8-32x1/2" PFB screws (Figure 2-18).
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Fan/Temp Switch Assembly Replacement Note: Fan does not operate under normal luminaire operating conditions. Parts: CABLE ASSEMBLY, FAN/TEMP SWITCH (23.9663.2009) Tools: #2 Phillips screwdriver To remove and replace fan/temp switch assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove edge/dimmer/color bulkhead. Refer to “Edge/Zoom/Color Bulkhead Replacement” on page 38. Step 3.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Beam-Size Iris Assembly Replacement Note: This procedure not applicable to all units. Parts: ASSEMBLY, IRIS (21.9663.1400) Tools: #2 Phillips screwdriver To remove and replace beam-size iris assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. Refer to “Front Cover Removal” on page 24. Step 3. At beam-size iris assembly, disconnect motor connectors (Figure 2-20). Step 4.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Ignitor PCB Replacement Note: This procedure not applicable to all units. Parts: PCB ASSEMBLY, IGNITOR (24.9661.1125) Tools: #2 Phillips screwdriver To remove and replace ignitor PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side without menu display) by removing two 6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-21). Step 3. At ignitor PCB, disconnect lamp connectors. Step 4.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Power Supply Replacement Parts: POWER SUPPLY, 130W +24V/6.3A (69.3126.0150) Tools: #1 Phillips screwdriver, 5/16 inch nutdriver To remove and replace power supply: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side without menu display) by removing two 6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-22). Step 3. At power supply, disconnect all connectors.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 7. Replace power supply by doing steps 2 through 6 in reverse. Crossmember Assembly NOTE: Head not shown for clarity. 10-32x1/2" PPB Screw 6-32x1/2" PPB Screw Yoke Leg Cover 6-32x3/8" PPB Screw (can only be accessed by removing crossmember) 6-32x3/8" PPB Screw 6-32x3/8" PPB Screws Power Supply 6-32 Keps Nut (3) Figure 2-22: Power Supply Replacement 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Controller PCB Replacement Parts: PCB ASSEMBLY, CONTROLLER (24.9663.1930) Tools: #1 Phillips screwdriver To remove and replace controller PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing two 6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-23). Step 3. Remove display overlay and plate, by removing three 6-32x1/2" PPB screws. Step 4.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Step 6. Replace controller PCB by doing steps 2 through 5 in reverse. NOTE: Head not shown for clarity. 6-32x1/2" PPB Screw 6-32x3/8" PPB Screw Controller PCB Display Plate Display Overlay Yoke Leg Cover 6-32x3/8" PPB Screw 6-32x1/2" PPB Screw Figure 2-23: Controller PCB Replacement 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Tilt Encoder PCB Replacement Parts: PCB ASSY, PAN/TILT ENCODER (24.9661.0629) Tools: #2 Phillips screwdriver To remove and replace tilt encoder PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing two 6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-24). Step 3. At tilt encoder PCB, remove two 4-32 screws. Step 4. Disconnect connectors at J1 and J2. Step 5.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Tilt Motor Assembly Replacement Parts: ASSEMBLY, TILT MOTOR (21.9663.1816) Tools: #2 Phillips screwdriver To remove and replace tilt motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing two 6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-25). Step 3. Remove display overlay and plate, by removing three 6-32x1/2" PPB screws. Step 4.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL . 6-32x1/2" PPB Screw Yoke Leg Cover 6-32x3/8" PPB Screw Controller PCB Display Plate Display Overlay 6-32x1/2" PPB Screw 6-32x3/8" PPB Screw NOTE: Head not shown for clarity. Tilt Motor Assembly #6 Flat Washer 6-32x1" PPB Screw Spring Figure 2-25: Tilt Motor Assembly Replacement 48 23-Oct-02 02. 9663.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Pan Motor Assembly Replacement Parts: ASSEMBLY, PAN MOTOR (21.9663.1815) Tools: #2 Phillips screwdriver To remove and replace pan motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg covers by removing two 6-32x1/2" PPB screws and two 632x3/8" PPB screws on each side (Figure 2-26). Step 3. Remove crossmember assembly from yoke by removing sixteen 10-32x1/2" PPB screws. Step 4.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Pan Wire Shield 4-40x3/8" PPZ Screw 6-32x1" PPB Screw Spring #6 Flat Washer Pan Motor Assembly Timing Belt Nut Plate Crossmember Assembly 10-32x1/2" PPB Screw Yoke Leg Cover 6-32x1/2" PPB Screw 6-32x3/8" PPB Screw NOTE: Head not shown for clarity. Figure 2-26: Pan Motor Assembly Replacement 50 23-Oct-02 02. 9663.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 DMX Input PCB Replacement Parts: PCB ASSEMBLY, DMX INPUT (24.9663.1830) Tools: #2 Phillips screwdriver To remove and replace DMX input PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At pan tube cover, remove four 8-32x3/8" PFZ screws and remove cover (Figure 2-27). Step 3. Remove four 4-40x3/8" PPZ screws. Step 4. Disconnect DMX input PCB wiring and remove PCB. Step 5. Replace DMX input PCB by doing steps 2 through 4 in reverse.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Cleaning Optical Lenses and Filters WARNING: Remove power from luminaire before performing maintenance. The front lens and gobos may require cleaning after extended use. A common glass cleaner can be used along with a soft, lint-free cloth to clean these components. To access gobos, refer to “Rotating Gobo Replacement” on page 26. 52 23-Oct-02 02. 9663.
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CHAPTER 3. Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL1000 assemblies including the arc ballast unit. • Drawing Trees • Top Assembly • Head Assembly • Yoke Assembly • Cables • Arc Ballast Assembly The following abbreviations are used in the Illustrated Parts Breakdown to identify parts specific to certain models: 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Drawing Trees VL1000 Incandescent Luminaires VL1000 Luminaire (Incandescent Versions) 20.9663.0001.01 (T) Rev D or 20.9663.0001.02 (TS) Rev D or 20.9663.0001.03 (TI) Rev D Yoke to Head Ground Cable Assembly Shutter Harness Cable Assembly Color/Gobo/Lens Harness Cable Assembly Controller PCB Assembly 25.9663.2019 Rev A 25.9663.2040 Rev C 25.9663.2050 Rev H 24.9663.1930 Rev H COT Flag Assembly Front Cover Assembly 21.9663.
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ILLUSTRATED PARTS BREAKDOWN : DRAWING TREES 3 VL1000 Incandescent Luminaires (cont.) continued from previous page continued from previous page Rear Head Assembly Yoke Legs Assembly 21.9663.1002.01 Rev J (T/TS) 21.9663.1850.01 (T/TS) Rev C Bulkhead Assembly Tilt Motor Assembly 21.9663.1101.01 (T/TS) Rev G 21.9663.1816 Rev B Back Cap Assembly Pan/Tilt Encoder PCB Assembly 21.9663.1127.01 (T/TS) Rev D 24.9661.0629 Rev 0 Incandescent Lamp Power Cable Assembly Wheel Sensor PCB 24.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL VL1000 Arc Luminaires VL1000 Luminaire (Arc Versions) 20.9663.0001.11 (A) Rev D or 20.9663.0001.12 (AS) Rev D or 20.9663.0001.13 (AI) Rev D Yoke to Head Ground Cable Assembly Shutter Harness Cable Assembly Color/Gobo/Lens Harness Cable Assembly Controller PCB Assembly 25.9663.2019 Rev A 25.9663.2040 Rev C 25.9663.2050 Rev H 24.9663.1930 Rev H COT Flag Assembly Front Cover Assembly 21.9663.1845 Rev 0 Head Assembly 21.9663.1000.11 (A) Rev B 21.
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ILLUSTRATED PARTS BREAKDOWN : DRAWING TREES 3 VL1000 Arc Luminaires (cont.) continued from previous page continued from previous page Rear Head Assembly Yoke Legs Assembly 21.9663.1002.11 Rev J (A/AS) 21.9663.1850.11 (A/AS) Rev C Bulkhead Assembly Tilt Motor Assembly 21.9663.1101.11 (A/AS) Rev G 21.9663.1816 Rev B Back Cap Assembly Pan/Tilt Encoder PCB Assembly 21.9663.1127.11 (A/AS) Rev D 24.9661.0629 Rev 0 Ignitor to Lamp Socket Cable Assembly Wheel Sensor PCB 24.9663.1230 Rev D 25.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Top Assembly Included Items Kit 28.9663.0001 Rev 0 Refer to Figure 3-5. No. Item Qty. UM. 1 02.8001.0001 1 EA PRODUCT SUPPORT SHEET, VARI-LITE INC. CUSTOMER SERVICE 2 02.8051.0001 1 EA CARD, LIMITED WARRANTY 01-16-01 3 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION - VL2000 4 02.9663.0001 1 EA USER’S MANUAL, VL1000 LUMINAIRE 5 02.9663.0002 1 EA UNPACK/QUICK START SHEET, VL1000 6 07.9663.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Label Locations Rev A Refer to Figure 3-6. No. Item Qty. UM. 1 04.9661.0033 1 EA LABEL, WARNING -2000 SERIES 2 04.9661.0034 1 EA LABEL, RELAMPING -2000 SERIES 3 04.9661.0037 1 EA LABEL, 625W ARC -2400 SERIES (A/AI/AS ONLY) 4 04.9663.1837 1 EA LABEL, PATENT 5 04.9663.1860 1 EA LABEL, 1000 SERIES COMPLIANCE 6 04.9663.1861 1 EA LABEL, AC INPUT RATING LABEL MODEL VL1000T 04.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL VL1000 Luminaire 20.9663.0001.01 20.9663.0001.02 20.9663.0001.03 20.9663.0001.11 20.9663.0001.12 20.9663.0001.13 (T) Rev D (TS) Rev D (TI) Rev D (A) Rev D (AS) Rev D (AI) Rev D Refer to Figure 3-7 No. Item Qty. UM. Description 1 10.9663.1823 1 EA PULLEY, TILT 2 10.9663.1824 1 EA SPACER, TILT TUBE 3 10.9663.1831 1 EA PLATE, YOKE ARM DISPLAY 4 10.9663.1832 1 EA OVERLAY, DISPLAY 5 10.9663.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY No. Item Qty. UM. 16 53.6612.0001 7 EA SCREW, 6-32 X 1/2" PPB 17 53.6627.0001 12 EA SCREW, 10-32 X 5/8" PPB 18 53.6634.0003 4 EA SCREW, 3/8-16 X 1/2"LG SOC HD CAP ALLY STL 19 53.6642.0001 3 EA SCREW, 10-32 X 5/8" SLF TAP TYPE F PPZ 20 54.1255.0001 2 EA BEARING ASSY, BLACK FLUSH MOUNT HOUSING 21 54.2047.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Front Cover Assembly 22.9663.1038 Rev A Refer to Figure 3-8. No. Item Qty. UM. Description 1 10.9663.1020 1 EA COVER, FRONT VL1000 2 21.9663.1028 1 EA ASSY, GEL FRAME HOLDER 3 53.2004.0001 4 EA NUT, 8-32 KEP 4 53.6545.0007 3 EA SCREW, 8-32 X 3/8" PFB 5 53.6552.0002 1 EA SCREW, 8-32 X 1/2" PFB 1 3 (x4) 2 4 (x3) 5 Figure 3-8: Front Cover Assembly 62 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Gel Frame Holder Assembly 21.9663.1028 Rev A Refer to Figure 3-9. No. Item Qty. UM. Description 1 10.9663.1027 1 EA HOLDER, GEL FRAME 2 10.9663.1031 1 EA LATCH, GEL FRAME 3 55.6568.0026 1 EA SPRING, CPRSN .180"OD .810"LG .026" WIRE DIA SS 4 55.6738.0003 .06 FT TUBING, SILICONE RUBBER 1/8"ID X 1/4"OD TRANSLUCENT 3 4 2 1 Figure 3-9: Gel Frame Holder Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL COT Flag Assembly 21.9663.1845 Rev 0 Refer to Figure 3-10. No. Item Qty. UM. 1 Description 10.9663.1824 1 EA SPACER, TILT TUBE 2 10.9663.1826 1 EA FLAG, CENTER OF TRAVEL -TILT 3 53.6602.0001 3 EA SCREW, 4-40 X 1/4 " PPZ TYPE F 1 2 3 Figure 3-10: COT Flag Assembly 64 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Controller PCB Assembly 24.9663.1930 Rev H Refer to Figure 3-11. No. Item Qty. UM. Description Ref. 1 10.9663.1840 1 EA HEAT SINK, MAIN CONTROLLER - PCB, VL1000 CONTROLLER - 2 11.9663.1930 1 EA 3 50.2769.0001 20 EA SOCKET, 28PIN PLCC SMT XU9-XU28 4 52.6259.0004 1 EA HEADER, 4POS, MTA-100 SHROUDED RT ANG J3 5 52.6445.0005 1 EA HEADER, 5POS, MTA-100 SHROUDED R/A J2 6 52.6598.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 21 60.1161.7503 80 EA Ref. for 21 continued: Ref. RES, 1/16W 1% 7.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY No. Item Qty. UM. 35 60.9460.1502 1 36 60.9466.4703 37 3 Description Ref. EA RES, .1W 5% 150.0 OHM 100V CHIP THICK FILM SMT0805 R10 1 EA RES, 1/4W 5% 4.7K 200V CHIP THK FLM SMT1210 R11 61.4817.1004 1 EA RES NET, R281 38 62.4225.0107 8 EA CAP, 100UF 35V 20% ALUM ELECTRO SUR MT C240-C244, C246C248 39 62.4227.0107 2 EA CAP, 100UF 10V 20% ALUM ELECTRO SUR MT C238 & C239 40 62.4228.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 50 72.2129.0001 1 51 74.1085.0001 52 68 Description Ref. EA DISPLAY, LCD 8 CHARACTER X1 LINE U40 4 EA SWITCH, 12MM TACT MOM N/O S2-S5 74.1085.0011 4 EA CAP, SWITCH 8MM SQ GREY -TL1100160Q - 53 74.1097.0001 1 EA SWITCH, TACT, TIGHT ANGLE, THRU HOLE S1 54 82.5329.0001 2 EA DIODE, MBRS340T3 40V 3A SCHOTTKY SUR MT D12 & D13 55 82.5350.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Controller PCB Assembly (continued) Figure 3-11: Controller PCB Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 70 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Head Assembly Head Assembly 21.9663.1000.01 21.9663.1000.02 21.9663.1000.03 21.9663.1000.11 21.9663.1000.12 21.9663.1000.13 (T) Rev B (TS) Rev B (TI) Rev B (A) Rev B (AS) Rev B (AI) Rev B Refer to Figure 3-12. No. Item Qty. UM. 1 10.9663.1032 2 2 Description EA SPACER, SIDE RAIL (T/TS ONLY) 4 EA SPACER, SIDE RAIL (A/AS ONLY) 21.9663.1001.01 1 EA ASSY, FRONT HEAD (T ONLY) 21.9663.1001.02 1 EA ASSY, FRONT HEAD (TS ONLY) 21.9663.1001.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Front Head Assembly 21.9663.1001.01 21.9663.1001.02 21.9663.1001.03 21.9663.1001.11 21.9663.1001.12 21.9663.1001.13 (T) Rev G (TS) Rev G (TI) Rev G (A) Rev G (AS) Rev G (AI) Rev G Refer to Figure 3-13. No. Item Qty. UM. 1 07.5049.0001 1 EA LANYARD, NYLON COATED 8" LG 2 21.9663.1003 1 EA ASSY, EDGE, ZOOM & COLOR 3 21.9663.1033 1 EA ASSY, SIDE RAIL, PULLEY 4 21.9663.1034 1 EA ASSY, SIDE RAIL, SENSOR 5 21.9663.
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3 ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY Front Head Assembly (continued) 11 (x4) 12 (x4) 11 (x4) 12 (x4) 11 (x4) 12 (x4) 8 7 Note * 6 A: Models w/o Shutter C: Models w/ Iris B: Models w/ Shutter Note * Can be either (item 7) 21.9663.1300 (Old Version) or 21.9663.1350 ( New Version). 11 (x4) 5 Either A, B or C 12 (x4) 4 D: Incandescent Models Either D or E 9 (x4) 2 10 (x4) 12 (x4) 5 3 13 (x4) 1 12 (x4) 11 (x4) E: Arc Models Figure 3-13: Front Head Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Edge Control, Zoom, Dimmer & Color Assembly 21.9663.1003 Rev D Refer to Figure 3-14. No. Item Qty. UM. 1 10.9663.1039 1 EA SUPPORT, AXIAL FAN 2 10.9663.1755 3 EA ROLLER, BARREL 3 10.9663.1756 6 EA ROLLER, LENS 4 10.9663.1757 1 EA CLAMP, BELT BASE 5 10.9663.1758 1 EA BELT CLAMP 6 10.9663.1767 1 EA ZOOM TEFLON SPACER 7 10.9663.1790 1 EA BELT PULLEY, GT 3MM PITCH 16 GROOVES 8 12.9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Edge Control, Dimmer & Color Assembly (continued) 19 (x3) 24 (x3) 12 6 5 4 8 18 22 11 10 25 (x3) 2 (x3) 9 21 (x2) 7 3 (x6) 14 17 (x6) 15 (x2) 23 (x2) 20 (x2) 19 (x4) 1 13 16 (x4) Figure 3-14: Edge Control, Dimmer & Color Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Color Changer Assembly 21.9663.1500 Rev K Refer to Figure 3-15. No. Item Qty. UM. 1 04.9663.1524 1 EA LABEL, MAGENTA MOTOR 2 04.9663.1525 1 EA LABEL, BLUE MOTOR 3 04.9663.1526 1 EA LABEL, AMBER MOTOR 4 04.9663.1527 1 EA LABEL, DIFFUSER MOTOR 5 10.9663.1505 4 EA DRIVE RING 6 10.9663.1506 1 EA DIFFUSER COVER PLATE 7 10.9663.1507 2 EA COLOR SEPERATOR 8 10.9663.1508 1 EA MOTOR MOUNT PLATE 9 10.9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY No. 28 29 Item Qty. UM. - 41.9663.1502.02 1 EA FILTER, COLOR BLUE 21.9663.1538.03 2 EA ASSY, AMBER COLOR FILTER - 10.9663.1504 1 EA FILTER CARRIER - 41.9663.1502.03 1 EA FILTER, COLOR AMBER 21.9663.1538.04 2 EA ASSY, DIFFUSER GLASS RIGHT - 10.9663.1504 1 EA FILTER CARRIER - 42.9663.1503 1 EA DIFFUSER GLASS Description 30 21.9663.1710 1 EA ASSY, BARREL 31 53.2002.0003 4 EA NUT, 6-32 HEX ZINC NYLON INSERT 32 53.2200.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Color Changer Assembly (continued) 1 2 24 (x4) 31 (x4) 30 16 (x4) 8 12 14 3 29 (x2) 4 6 19 5 32 (x8) 17 7 27 (x2) 11 5 18 11 11 7 5 15 20 5 9 26 (x2) 33 (x4) 13 35 (x3) 21 (x3) 13 23 28 (x2) 13 19 25 22 34 (x8) Figure 3-15: Color Changer Assembly 78 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Color Changer Drive Motor 21.9663.1501 Rev C Refer to Figure 3-16. No. Item Qty. UM. Description 1 10.9663.1513 1 EA GEAR, PINION 8 TOOTH 32 PITCH 2 44.9663.1520 1 EA MOTOR, 14 .47" SHAFT 10.8MH 10.1 OHM 3 55.6677.0002 1 EA WASHER, .360"OD .123"ID .025" THK FLAT NYLON 2 3 1 Figure 3-16: Color Changer Drive Motor 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Cover Plate Assembly 21.9663.1534 Rev 0 Refer to Figure 3-17. No. Item Qty. UM. Description 1 10.9663.1517 1 EA COVER PLATE, COLOR CHANGER 2 10.9663.1535 1 EA DISC, .63 DIA ALUM 3 41.9663.1530 1 EA GLASS, BEAM OCCLUSION 4 53.6659.0008 4 EA SCREW, 2-56 X 3/16" PFZ 1 4 (x4) 2 3 Figure 3-17: Cover Plate Assembly 80 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Barrel Assembly 21.9663.1710 Rev B Refer to Figure 3-18. No. Item Qty. UM. Description 1 10.9663.1701 2 EA BARREL, HALF OUTER LENS EDGE SYSTEM 2 10.9663.1708 1 EA EDGE GEAR/CAM, 8 ELEMENT SYSTEM 3 10.9663.1711 2 EA BARREL, HALF INNER LENS EDGE SYSTEM 4 10.9663.1737 1 EA EDGE, LIGHT BAFFLE 5 21.9663.1722 1 EA ASSY, EDGE MOTOR - 10.9663.1709 1 EA PINION, EDGE - 44.9663.1326 1 EA MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM 6 42.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Barrel Assembly (continued) 12 (x2) 12 5 15 2 13 11 (x4) 3 (x2) 6 7 9 1 (x2) 8 10 (x4) 4 14 12 Figure 3-18: Barrel Assembly 82 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Lens #6 Assembly 21.9663.1760 Rev 0 Refer to Figure 3-19. No. Item Qty. UM. Description 1 10.9663.1761 1 EA LENS CARRIER, MOLDED -LENS #6 ASSY 2 42.9663.1733 1 EA LENS #6 2 1 Figure 3-19: Lens #6 Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Lens #7 Assembly 21.9663.1770 Rev 0 Refer to Figure 3-20. No. Item Qty. UM. Description 1 10.9663.1771 1 EA LENS CARRIER, MOLDED -LENS #7 2 42.9663.1734 1 EA LENS #7 2 1 Figure 3-20: Lens #7 Assembly 84 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Lens #8 Assembly 21.9663.1780 Rev B Refer to Figure 3-21. No. Item Qty. UM. Description 1 10.9663.1781 1 EA BULKHEAD, FRONT -LENS #8 ASSY 2 10.9663.1782 1 EA RING, RETAINING FRONT LENS 3 42.9663.1735 1 EA LENS #8 4 53.2202.0004 6 EA NUT, 4-40 HEX SS NYLON INSERT 5 53.6559.0001 6 EA SCREW, 4-40 X 1/4" PFZ 5 1 4 2 3 Figure 3-21: Lens #8 Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Fan Assembly 23.9663.2009 Rev C Refer to Figure 3-22. No. Item Qty. UM. Description 1 40.7113.0003 1 EA FAN, +24V 80X80X25MM 24LFM 2 52.6523.0002 1 EA CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52.8347.0001 2 EA CONTACT, 24-30AWG MALE CRIMP FAN CONNECTOR 3 (x2) 2 RED 6.0" BLK 6.0" RED PIN 1 PIN 2 1 BLK MOLEX SL-2F Figure 3-22: Fan Assembly 86 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Pulley Side Rail Assembly 21.9663.1033 Rev B Refer to Figure 3-23. No. Item Qty. UM. Description 1 10.9663.1026 1 EA LATCH, SPRING 2 12.9663.1025 1 EA RAIL, SIDE MACHINED LONG TILT TUBE 3 53.2002.0004 1 EA NUT, 6-32 ACORN THREADLOCKING SS 4 53.5636.0500 1 EA SCREW, 6-32 X 1/2" PFSS BLACK 5 53.6530.0009 2 EA RIVET, 1/8"OD POP .126-.187GL STL BODY STL MNDRL DOME 6 55.5178.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Sensor Side Rail Assembly 21.9663.1034 Rev B Refer to Figure 3-24. No. Item Qty. UM. Description 1 10.9663.1026 1 EA LATCH, SPRING 2 12.9663.1029 1 EA RAIL, SIDE MACHINED SHORT TILT TUBE 3 53.2002.0004 1 EA NUT, 6-32 ACORN THREADLOCKING SS 4 53.5636.0625 1 EA SCREW, 6-32 X 5/8" PFSS BLACK 5 53.6530.0009 2 EA RIVET, 1/8"OD POP .126-.187GL STL BODY STL MNDRL DOME 6 55.6623.0004 1 EA WASHER, #10 FLAT SS .203ID .625OD .
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Incandescent Gobo Wheel Assembly 21.9663.1200 (T/TS) Rev P Refer to Figure 3-25. No. Item Qty. UM. Description 1 10.9663.1212 1 EA PULLEY, MOTOR -GOBO 2 10.9663.1214 1 EA SHAFT, ROTATING GOBO 3 10.9663.1217 1 EA PULLEY, GOBO DRIVE MOTOR MOUNTED 4 10.9663.1241 2 EA PULLEY, IDLER TEFLON 5 10.9663.1242 2 EA SPACER, PIVOT BELT ADJUST 6 10.9663.1228 1 EA PLATE, GOBO IDLER MOUNT PLATE 7 10.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 31 55.6512.0001 1 EA WASHER, #4 SPLIT LOCK 32 55.6538.0001 1 EA SCREW, #6 LOCK INTERNAL TOOTH 33 55.6568.0061 2 EA SPRING, EXTSN .250"OD 2.00"LG .022" WIRE DIA MUSIC WIRE 34 55.6609.0005 2 EA WASHER, .625"OD .376"ID .020"THK FLAT TEFLON 35 55.6621.0001 1 EA WASHER, #4 FLAT ZINC 36 55.6677.0035 1 EA WASHER, .750"OD .187"ID .030"THK FLAT SS 37 55.6677.0036 1 EA WASHER, .875"OD .406"ID .
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Incandescent Gobo Wheel Assy (continued) 9 17 40 39 31 This componet blanked in Exploded View for clarity. 41 42 37 34 (x2) 25 10 35 33 30 22 32 36 6 7 15 12 15 (x2) 2 26 (x2) 39 (x2) 4 (x2) 39 (x2) 38 (x2) 29 (x2) 5 (x2) 11 18 (x4) 14 (x2) 20 8 (x2) 11 21 19 (x2) 16 (x4) 27 28 25 (x2) 1 24 (x4) 3 13 23 (x2) Figure 3-25: Incandescent Gobo Wheel Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Temperature Sensor Electrical Assembly 23.9663.1248.01 (T/TS) Rev A 23.9663.1248.11 (A/AS) Rev A Refer to Figure 3-26. No. Item Qty. UM. 1 23.9663.2008 Description 1 EA ASSY, FAN (T ONLY) - 40.7140.0001 1 EA BLOWER, CENTRIFUGAL 24VDC 9CFM 3" X 3" - 52.8347.0001 2 EA CONTACT, 24-30AWG MALE CRIMP 2 52.6523.0004 1 EA CONN, HOUSING 4POS PLUG SHROUDED WIRE TO WIRE 3 52.8347.0001 2 EA CONTACT, 24-30AWG MALE CRIMP 4 55.2198.0001 .
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ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Arc Gobo/Dimmer Bulkhead Assembly 21.9663.1600 (A/AS) Rev N Refer to Figure 3-27. No. Item Qty. UM. 1 10.9663.1212 2 EA PULLEY, MOTOR -GOBO 2 10.9663.1214 1 EA SHAFT, ROTATING GOBO 3 10.9663.1217 1 EA PULLEY, GOBO DRIVE MOTOR MOUNTED 4 10.9663.1228 1 EA PLATE, GOBO IDLER MOUNT PLATE 5 10.9663.1229 1 EA PLATE, WHEEL IDLER MOUNT 6 10.9663.1236 2 EA MOUNT, SENSOR BOARD 7 10.9663.1241 2 EA PULLEY, IDLER TEFLON 8 10.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 31 53.6537.0001 1 EA SCREW, 4-40 X 5/8" PPB (VL 1) 32 53.6543.0001 1 EA SCREW, 6-32 X 3/8" PPB 33 53.6598.0312 7 EA SCREW, 4-40 X 5/16" PFB 34 53.6600.0001 3 EA SCREW, 4-40 X 5/16" PPB 35 53.6614.0001 2 EA SCREW, 6-32 X 5/8" PPB 36 53.6682.0002 2 EA SCREW, 4-40 X 1/4"LG PPZ SEMS-EXT 37 54.2045.0002 1 EA BELT, TIMING MXL .080" PITCH .187W 250 TEETH SILICONE 38 54.2050.0001 1 EA BELT, TIMING MXL .
PAGE 113
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Arc Gobo/Dimmer Bulkhead (continued) 25 42 51 52 16 54 22 (x3) 27 (x6) 34 (x2) 35 (x2) 12 (x2) 21 51 (x2) 1, 26 (x2) 7 (x2) 14 (x2) 50 (x2) 38 11 2 51 (x2) 40 (x2) 8 (x2) 4 13 (x2) 30 (x18) 15 (x2) 6 (x2) 20 34 19 53 31 9, 26 (x2) 24 5 17 32 49 46 41 44 (x2) 29 28 (x2) 39 37 43 48 10 33 (x7) 45 (x2) 36 (x2) 42 (x2) 47 (x2) 18 26 (x2) 3 23 26 (x2) 1 26 (x2) Figure 3-27: Arc Gobo/Dimmer Bulkhead Assembly 02.9 663.
PAGE 114
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Gobo Wheel Assembly 21.9663.1201 Rev B Refer to Figure 3-28. No. Item Qty. UM. Description 1 10.9663.1203 5 EA GEAR, PLANET CAST 2 10.9663.1204 1 EA WHEEL, ROTATING GOBO 3 10.9663.1206 1 EA FLANGE, MIDDLE 4 10.9663.1210 5 EA CLIP, RETAINING 5 10.9663.1211 10 EA SPACER, TEFLON GOBO GEAR 6 10.9663.1219 1 EA SUN GEAR, MOLDED 7 10.9663.1247 1 EA TAB, GOBO WHEEL SENSOR 8 10.9663.
PAGE 115
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Gobo Bulkhead FAB Assembly 22.9663.1226 Rev M Refer to Figure 3-29. No. Item Qty. UM. Description 1 10.9663.1213 1 EA BULKHEAD, GOBO MOUNT 2 10.9663.1224 1 EA PLATE, GOBO MOTOR MOUNT 3 10.9663.1225 1 EA BRACKET, FAN MOUNT/BRACE 4 10.9663.1238 1 EA LIGHT CONE 5 53.6540.0003 4 EA RIVET, 1/8"OD .126" - .187"GL DOME HD CLOSED END AL BODY 6 53.6540.0004 8 EA RIVET, 1/8"OD .126"- .187"GL CSK HD CLOSED END AL BODY 7 53.6540.
PAGE 116
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Gobo/Dimmer Bulkhead FAB Assembly 22.9663.1232 Rev L Refer to Figure 3-30. No. Item Qty. UM. Description 1 10.9663.1233 1 EA BULKHEAD, DIMMER/GOBO MOUNT 2 10.9663.1234 1 EA PLATE, DIMMER/GOBO MOTOR MOUNT 3 10.9663.1238 1 EA LIGHT CONE 4 53.6540.0004 10 EA RIVET, 1/8"OD .126"- .187"GL CSK HD CLOSED END AL BODY 1 4 (x10) 3 2 Figure 3-30: Gobo/Dimmer Bulkhead FAB Assembly 98 23-Oct-02 02. 9663.
PAGE 117
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Dimmer Wheel Assembly 22.9663.1629 Rev D Refer to Figure 3-31. No. Item Qty. UM. Description 1 10.9663.1624 1 EA WHEEL MOUNT, DIMMER 2 10.9663.1626 1 EA WASHER, SILICONE 3 10.9663.1628 1 EA SHIM, DIMMER WHEEL BLACKOUT 4 41.9663.1622 1 EA GLASS, DIMMER WHEEL 5 53.2212.0001 1 EA NUT, THIN, 5/8" -27 NS THD 3/4 HEX WIDTH 1/8" HIGH 6 55.3309.0001 1 EA WASHER 1" OD .625" ID .
PAGE 118
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Wheel Sensor PCB 24.9663.1230 Rev D Refer to Figure 3-32. No. Item Qty. UM. Description 1 11.9663.1230 1 EA PCB, WHEEL SENSOR 2 52.6507.0003 1 EA HEADER, 3POS R/A 2MM SHROUDED 3 86.7002.0004 1 EA SWITCH, SLOTTED OPTICAL OPB610 2 1 3 VARI-LITE 24-9663-1230 REV D WHEEL SENSOR VIEWED FROM SENSOR SIDE SOLDER SIDE Figure 3-32: Wheel Sensor PCB 100 23-Oct-02 02. 9663.
PAGE 119
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Index Sensor PCB 24.9663.1231 Rev B Refer to Figure 3-33. No. Item Qty. UM. Description 1 11.9663.1231 1 EA PCB, INDEX SENSOR 2 52.6447.0004 1 EA HEADER, SHROUDED 4 POSITION 3 86.7002.0004 1 EA SWITCH, SLOTTED OPTICAL OPB610 2 3 24-96631231 REV B INDEX SENSOR VARI-LITE 1 SOLDER SIDE VIEWED FROM SENSOR SIDE Figure 3-33: Index Sensor PCB 02.9 663.
PAGE 120
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Shutter Assembly 21.9663.1300 Rev Q Refer to Figure 3-34. No. Item Qty. UM. Description 1 10.9660.0129 1 EA SHAFT STOP, ROTATING GOBO WHEEL 2 10.9663.1310 1 EA BASE PLATE, SHUTTER 3 10.9663.1311 5 EA SEPARATOR, SHUTTER 4 10.9663.1312 4 EA SPACER, SHUTTER 5 10.9663.1313 1 EA COVER, SHUTTER 6 10.9663.1314 8 EA RACK, SHUTTER 7 10.9663.1317 1 EA BULKHEAD, SHUTTER 8 10.9663.1319 1 EA SHIM, ROTATION 9 10.9663.
PAGE 121
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY No. Item Qty. UM. 28 53.6616.0001 7 EA SCREW, 6-32 X 3/4" PPZ 29 55.2178.0002 1 EA CABLE ANCHOR MOUNT, #10 SCREW MOUNTING 30 55.3301.0006 3 EA WASHER, #6 FLAT SS 31 55.3303.0006 4 EA WASHER, #6 LOCK INT. TOOTH SS 32 55.6655.0006 1 EA SPACER, 1/4" RND .116" ID THRU 1/4" LG ZINC PLATED BRAS 02.9 663.
PAGE 122
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Shutter Assembly (continued) 24 (x4) 5 SHUTTER MOTOR (x8) 3 6 (x8) 3B 3 3A 4A 2B 4B 2A 12 18 1A 1B 3 17 12 17 13 3 9 (x8) 19 (x8) 12 26 1 14 32 8 23 3 22 20 21 18 25 29 27 10 7 2 32 (x4) 28 (x4) 11 (x3) 30 (x3) 28 (x3) 16 Figure 3-34: Shutter Assembly 104 23-Oct-02 02. 9663.
PAGE 123
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Shutter 6 Rollers Assembly 21.9663.1350 Rev 0 Refer to Figure 3-35. No. Item Qty. UM. Description 1 10.9663.1311 5 EA SEPARATOR, SHUTTER 2 10.9663.1312 4 EA SPACER, SHUTTER 3 10.9663.1313 1 EA COVER, SHUTTER 4 10.9663.1314 8 EA RACK, SHUTTER 5 10.9663.1320 8 EA PAD, MOTOR 6 10.9663.1321 1 EA CLAMP RING, MOTOR 7 10.9663.1325 6 EA ROLLER, NYLON 8 10.9663.1327 1 EA GEAR, SHUTTER ROTATE SECTOR 9 10.9663.
PAGE 124
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 28 55.3301.0006 6 EA WASHER, #6 FLAT SS 29 55.3303.0006 4 EA WASHER, #6 LOCK INT. TOOTH SS 30 55.6621.0001 4 EA WASHER, #4 FLAT ZINC 31 55.6697.0020 2 EA STANDOFF, 3/16" RND, 4-40, .375"LG, ZINC PLATED STEEL 106 Description 23-Oct-02 02. 9663.
PAGE 125
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Shutter Assembly (continued) 22 (x4) 3 SHUTTER MOTOR (x8) 1 3B 1 3A 4A 2B 4B 2A 12 16 1A 1B 1 15 12 4 (x8) 15 1 5 (x8) 12 17 (x8) 30 (x4) 20 (x4) 11 1 21 (x2) 9 18 16 24 (x2) 10 (x2) 31 (x2) 6 19 25 (x2) 14 27 7 (x6) 28 (x6) 23 (x6) 26 29 (x4) 23 (x4) Figure 3-35: Shutter 6 Rollers Assembly 02.9 663.
PAGE 126
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Beam-Size Iris Assembly 21.9663.1400 Rev D Refer to Figure 3-36. No. Item Qty. UM. Description 1 10.9663.1339.03 1 EA DONUT, ANTI-REFLECTION IRIS 2 10.9663.1411 1 EA BULKHEAD, IRIS 3 21.9663.1409 1 EA ASSY, MOTOR ARM - 10.9663.1402 1 EA ARM, MOTOR - 10.9663.1406 1 EA BOSS, MOTOR ARM - 53.6659.0008 3 EA SCREW, 2-56 X 3/16" PFZ 4 22.9663.1410 1 EA IRIS, 67MM OD 5 44.9663.1326 1 EA MOTOR, 17 .53" SHAFT 11.8MH 5.
PAGE 127
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Rear Head Assembly 21.9663.1002.01 Rev J (T/TS) 21.9663.1002.11 Rev J (A/AS) Refer to Figure 3-37. No. Item Qty. UM. Description 1 10.9634.0100 3 EA CLIP,MOUNTING,REFLECTOR 2 10.9663.1104 1 EA REFLECTOR MOUNT 3 10.9663.1109 2 EA COUNTERWEIGHT 4 12.9663.1023 1 EA CASTING, REAR MACHINED 5 21.9663.1101.01 1 EA ASSY, INC BULKHEAD (T/TS ONLY) 21.9663.1101.11 1 EA ASSY, ARC BULKHEAD (A/AS ONLY) 6 21.9663.1127.
PAGE 128
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Rear Head Assembly (continued) 13 14 15 3 (x2) 12 (x4) 6 9 (x4) 4 8 (x3) 2 10 (x4) 1 (x3) 7 11 (x3) 5 Note * Note * Note * Align dimple in reflector flange (item 7) with reflector mount (item 2) as shown. * Item 5 removed for clarity. Incandescent (Old Version) Reflector Orientation Incandescent & Arc (New Version) Reflector Orientation Figure 3-37: Rear Head Assembly 110 23-Oct-02 02. 9663.
PAGE 129
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Bulkhead Assembly 21.9663.1101.01 (T/TS) Rev G 21.9663.1101.11 (A/AS) Rev G Refer to Figure 3-38. No. Item Qty. UM. 1 10.9663.1103 1 EA THERMAL BULKHEAD 2 10.9663.1128 2 EA BAFFLE, EXHAUST LIGHT (A/AS ONLY) 3 4 Description 41.9663,1120 2 EA AR SOLITE (T/TS ONLY) OLD VERSION 41.9663.1133 2 EA UV/IR FILTER (T/TS & A/AS) NEW VERSION 53.6540.0005 4 EA RIVET, 1/8"OD .063"-.
PAGE 130
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Back Cap Assembly 21.9663.1127.01 (T/TS) Rev D 21.9663.1127.11 (A/AS) Rev D Refer to Figure 3-39. No. Item Qty. UM. Description 1 10.9663.1116 2 EA CLAMP, LAMP BASE BAIL (T/TS ONLY) 2 10.9663.1118 1 EA PLATE, BACKCAP ADJUST 3 10.9663.1119 2 EA LAMP BASE CLAMP (T/TS ONLY) 4 12.9663.1126 1 EA BACKCAP, MACHINED 5 53.2008.0003 2 EA NUT, PUSH #10 6 53.2022.0003 3 EA NUT, 10-32 THUMB 1/2"OD RND KNURLED BRASS 7 53.5510.
PAGE 131
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY 3 Back Cap Assembly (continued) 6 (x3) 12 (x3) 4 10 (x2) (T/TS ONLY) 13 (T/TS ONLY) 9 (x2) 7 (x2) 11 (x3) 14 8 (x3) 1 (x2) (T/TS ONLY) 3 (x2) (T/TS ONLY) 5 (x3) 2 T/TS ONLY A/AS ONLY Incandescent Models Arc Models Figure 3-39: Back Cap Assembly 02.9 663.
PAGE 132
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 114 23-Oct-02 02. 9663.
PAGE 133
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 Yoke Assembly Yoke Legs Assembly 21.9663.1850.01 (T/TS) Rev C 21.9663.1850.11 (A/AS) Rev C Refer to Figure 3-40. No. Item Qty. UM. Description 1 10.9661.1364 1 EA INSULATOR, ADHESIVE BACKED - TOP COVER 2 10.9663.1827 2 EA NUT PLATE, PAN/TILT MOTOR 3 10.9663.1842 2 EA HEATSHIELD, YOKE LEG 4 21.9663.1816 1 EA ASSY, TILT MOTOR 5 22.9663.1801 1 EA ASSY, YOKE 6 24.9661.1125 1 EA PCB ASSY, IGNITOR (A/AS ONLY) 7 24.9663.
PAGE 134
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Yoke Legs Assembly (continued) 4 18 (x4) 12 (x4) 2 (x2) 20 15 (x7) 5 17 (x3) 11 (x3) 19 (x3) 10 (x6) 3 (x2) 10 (x4) 21 (x4) 22 10 (x4) 6 - A/AS only 13 (x2) 14 (x4) - A/AS only 7 16 (x2) 9 (x2) 8 (x2) Figure 3-40: Yoke Legs Assembly 116 23-Oct-02 02. 9663.
PAGE 135
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 Tilt Motor Assembly 21.9663.1816 Rev B Refer to Figure 3-41. No. Item Qty. UM. Description 1 10.9663.1825 1 EA MOUNT, MOTOR TILT 2 21.9663.1818 1 EA ASSY, DRIVE PULLEY - 10.9663.1818 1 EA PULLEY, DRIVING - PAN/TILT - 10.9663.1820 1 EA CODEWHEEL, 120 COUNT 3 24.9661.0629 1 EA PCB ASSY, PAN/TILT ENCODER 4 44.9663.1850 1 EA MOTOR, 23 .81" SHAFT 12MH 6 OHM 5 53.2200.0008 4 EA NUT, 8-32 KEPS SS 6 53.6521.
PAGE 136
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Ignitor PCB 24.9661.1125 Rev D Refer to Figure 3-42. No. Item Qty. 1 11.9661.1125 1 EA PCB, IGNITOR 2 51.5006.0003 1 EA INSULATOR, TO-220, 53.77-AC 3 52.8218.0002 4 EA TERM, PC VERT MNT 6-32 SCREW 15A 53.6522.0001 4 EA SCREW, 6-32 X 1/4" PPZ ON J1-J4 5 55.6538.0001 4 EA WASHER, #6 LOCK INTERNAL TOOTH ON J1-J4 6 60.1422.1002 12 EA RES, 1/4W 5% 10.0 MEG CF 62.2032.0001 1 EA CAP, .01UF, 3000V, RAD, CERAMIC, .
PAGE 137
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 Pan/Tilt Encoder PCB Assembly 24.9661.0629 Rev 0 Refer to Figure 3-43. No. Item Qty. 1 11.9661.0629 1 EA PCB, ENCODER SENSOR - 2 52.6613.0005 1 EA HEADER, 5POS SGL ROW SHROUDED LATCHING J1 3 52.6613.0006 1 EA HEADER, 6POS SGL ROW SHROUDED LATCHING J2 60.9460.1802 2 EA RES, .1W 5% 180.0 OHM 100V CHIP SUR MT R1, R2 5 62.3009.0103 1 EA CAP, .01UF 50V 10% MONO CER CHIP SUR MT C1 6 86.7009.
PAGE 138
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Crossmember Assembly 21.9663.1811.01 (T/TS) Rev D 21.9663.1811.11 (A/AS) Rev D Refer to Figure 3-44. No. Item Qty. UM. Description 1 10.9663.1808 1 EA TOGGLE, PAN 2 10.9663.1809 1 EA ACTUATOR, TOGGLE PAN 3 10.9663.1814 1 EA PULLEY, PAN 4 10.9663.1821 1 EA COVER, PAN TUBE 5 10.9663.1827 2 EA NUT PLATE, PAN/TILT MOTOR 6 10.9663.1844 1 EA SHIELD, WIRE PAN 7 10.9663.1846 1 EA TETHER, PAN TUBE SAFETY 8 21.9663.
PAGE 139
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 Crossmember Assembly (continued) 17 (x4) 13 20 7 6 2 24 (x3) 14 21 19 (x4) 23 (x4) 15 1 25 3 12 22 (x2) 20 10 9 18 (x14) 20 8 11 5 (x2) 4 16 Figure 3-44: Crossmember Assembly 02.9 663.
PAGE 140
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Inner Crossmember Assembly 21.9663.1812 Rev B Refer to Figure 3-45. No. Item Qty. UM. Description 1 10.9663.1805 1 EA CROSSMEMBER, INNER 2 53.2019.0001 2 EA NUT, 3/8-16 HEX 3 53.6505.0022 2 EA BOLT, 3/8-16 X 3/4"LG CARRIAGE GRD5 ZINC PLT 4 53.6539.0001 2 EA WASHER, 3/8" SPLIT LOCK 5 54.1255.
PAGE 141
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 Outer Crossmember Assembly 21.9663.1813 Rev A Refer to Figure 3-46. No. Item Qty. UM. Description 1 10.9663.1898 1 EA SPACER, PAN BEARING 2 21.9663.1843 1 EA ASSY, CROSSMEMBER OUTER 3 53.2019.0001 2 EA NUT, 3/8-16 HEX 4 53.6505.0022 1 EA BOLT, 3/8-16 X 3/4"LG CARRIAGE GRD5 ZINC PLT 5 53.6505.0023 1 EA BOLT, 3/8-16 X 1 1/4"LG CARRIAGE GRD5 ZINC PLT 6 53.6539.0001 2 EA WASHER, 3/8" SPLIT LOCK 7 54.1255.
PAGE 142
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21.9663.1815 Rev B Refer to Figure 3-47. No. Item Qty. UM. Description 1 10.9663.1817 1 EA MOUNT, MOTOR PAN 2 21.9663.1818 1 EA ASSY, DRIVE PULLEY - 10.9663.1810 1 EA PULLEY, DRIVING - PAN/TILT - 10.9663.1820 1 EA CODEWHEEL, 120 COUNT 3 24.9661.0629 1 EA PCB ASSY, PAN/TILT ENCODER 4 44.9663.1850 1 EA MOTOR, 23 .81" SHAFT 12MH 6 OHM 5 53.2200.0008 4 EA NUT, 8-32 KEPS SS 6 53.6521.
PAGE 143
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 Pan Tube Assembly 21.9663.1819.01 (T/TS) Rev G 21.9663.1819.11 (A/AS) Rev G Refer to Figure 3-48. No. Item Qty. UM. 1 04.9640.0374 1 EA LABEL, P.E. GROUND 2 10.9663.1851 1 EA PAN TUBE, TOP 3 24.9663.1830 1 EA PCB ASSY, DMX INPUT 4 25.9663.1921 1 EA CABLE ASSY, ARC POWER INPUT (PIGTAIL) (A/AS ONLY) 5 25.9663.2015 1 EA CABLE ASSY, AC LINE INPUT - 25.9663.2016.
PAGE 144
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Pan Tube Assembly (continued) 11 16 7 8 7 - A/AS only 10 (x4) 3 15 1 9 (x2) 5 13 (x4) 12 (x2) 14 (x2) 4 - A/AS only or 6 - T/TS only 2 Figure 3-48: Pan Tube Assembly 126 23-Oct-02 02. 9663.
PAGE 145
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY 3 DMX Input PCB Assembly 24.9663.1830 Rev A Refer to Figure 3-49. No. Item Qty. UM. Description Ref 1 11.9663.1830 1 EA PCB FAB, DMX INPUT - 2 52.6259.0001 1 EA HEADER, 5POS MTA FRCT LOK STRT POST J3 3 52.6625.0005 1 EA CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL J1 4 52.6626.0005 1 EA CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL J2 5 62.3017.
PAGE 146
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 128 23-Oct-02 02. 9663.
PAGE 147
ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Cables Arc Power Input (Pigtail) Cable Assembly 25.9663.1921 Rev D Refer to Figure 3-50. No. Item Qty. UM. Description 1 52.6274.2316 1 EA STRAIN RELIEF, SKINTOP FLEX TYPE PG16 BLK 2 52.6400.0110 1 EA PLUG, 17-9 STD SEX CPC 600V KEY A 3 52.6431.0003 1 EA BACKSHELL, CPC17 NYLON .500-.650 CBL RNG 4 52.6523.0004 1 EA CONN, HOUSING 4POS PLUG SHROUDED WIRE TO WIRE 5 52.8201.0007 4 EA SOCKET, GOLD 24-20AWG TYPE3+ REEL .040-.
PAGE 148
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Arc Power Input Cable Assembly (continued) 11(x4) 4 2 3 6 9 1 5 4 7 8 4.0" 12 8 FRONTVIEW 9 (x2) CPC 17-9 4.0" ORN VIO 4.0" 8.0" BLK GRN/YEL 7 4.0" 13 40.0" 1 .25" 0.0" 3 2 5 (x4) 6 (x3) 10 (x2) 8.0" WHT 4.
PAGE 149
ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Pan EOT Cable Assembly 25.9663.2001 Rev 0 Refer to Figure 3-51. No. Item Qty. UM. 1 52.6467.0003 1 EA CONN, FEM PLUG 3 POS 30-24 AWG CRIMP PHR 2 52.6467.0024 3 EA CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST) 3 52.6524.0006 1 EA CONN, HOUSING 6POS RECEPTACLE 4 52.8346.0001 3 EA CONTACT, 24-30AWG FEMALE CRIMP 5 73.5126.0029 1.08 FT WIRE, 26AWG 3COND 300V 80C UL1061, 19 STRND 3, 4 Description 1, 2 5 13.
PAGE 150
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Tilt COT Cable Assembly 25.9663.2002 Rev 0 Refer to Figure 3-52. No. Item Qty. UM. 1 52.6467.0003 1 EA CONN, FEM PLUG 3 POS 30-24 AWG CRIMP PHR 2 52.6467.0024 3 EA CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST) 3 52.6524.0006 1 EA CONN, HOUSING 6POS RECEPTACLE 4 52.8346.0001 3 EA CONTACT, 24-30AWG FEMALE CRIMP 5 73.5126.0029 2.75 FT WIRE, 26AWG 3COND 300V 80C UL1061, 19 STRND 3, 4 Description 1, 2 5 33.
PAGE 151
ILLUSTRATED PARTS BREAKDOWN : CABLES 3 AC Line Input Cable Assembly 25.9663.2015 Rev A Refer to Figure 3-53. No. Item Qty. UM. Description 1 52.6541.0003 1 EA CONN, CHASSIS PWR INLET 3POLE LOCKING 2 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 52.8331.0003 3 EA RECEPT, FASTON .187" 16-14AWG PIDG BLUE (REEL) .170"ID 4 73.3516.0504 0.42 FT WIRE, 16AWG 300V 105C PVC GRN/YEL UL1569 1 L N 3 5.0 IN 4 2 Figure 3-53: AC Line Input Cable Assembly 02.9 663.
PAGE 152
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Incandescent LVS AC Input Cable Assembly 25.9663.2016.01 Rev 0 Refer to Figure 3-54. No. Item Qty. UM. Description 1 52.8231.0005 4 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8331.0003 2 EA RECEPT, FASTON .187" 16-14AWG PIDG BLU REEL 3 55.2186.0001 2 EA CABLE TIE, .10"WD 4.00"LG SMALL 4 73.7089.0000 9.33 FT WIRE, 22AWG BLK 300V TEFLON STRANDED 5 73.7089.0009 9.33 FT WIRE, 22AWG WHT TEFLON STRANDED 6 73.7089.0504 9.
PAGE 153
ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Arc LVS AC Input Cable Assembly 25.9663.2016.11 Rev 0 Refer to Figure 3-55. No. Item Qty. UM. Description 1 52.8231.0005 4 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8298.1160 2 EA WIRE, FERRULE, 1X 16 AWG L2-8MM BLK 3 55.2186.0001 2 EA CABLE TIE, .10"WD 4.00"LG SMALL 4 73.7089.0000 9.33 FT WIRE, 22AWG BLK 300V TEFLON STRANDED 5 73.7089.0009 9.33 FT WIRE, 22AWG WHT TEFLON STRANDED 6 73.7089.0504 9.
PAGE 154
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9663.2017 Rev B Refer to Figure 3-56. No. Item Qty. UM. 1 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 73.3516.0504 0.25 FT WIRE, 16AWG 300V 105C PVC GRN/YEL UL1569 1 Description 2 Figure 3-56: LVS Chassis Ground Cable Assembly 136 23-Oct-02 02. 9663.
PAGE 155
ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Head to Backcap Ground Cable Assembly 25.9663.2018 Rev C Refer to Figure 3-57. No. Item Qty. UM. 1 55.2036.0001 2 EA SLEEVE, 1/16" ROPE DIA. ALUM OVAL COMPRESSION 2.17 FT WIRE ROPE, 1/16" ROPE DIA. 7X7 GALV STEEL 2 73.7188.0002 1 Description 2 HEAD GND BACKCAP GND 1.0" 1.0" 24.0" Figure 3-57: Head to Backcap Ground Cable Assembly 02.9 663.
PAGE 156
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Yoke to Head Ground Cable Assembly 25.9663.2019 Rev A Refer to Figure 3-58. No. Item Qty. UM. Description 1 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 73.7089.0504 4 FT WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 12.0" 1 2 Figure 3-58: Yoke to Head Ground Cable Assembly 138 23-Oct-02 02. 9663.
PAGE 157
ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Pan/Tilt Control Cable Asembly 25.9663.2020 Rev A Refer to Figure 3-59. No. Item Qty. UM. 1 52.6224.0020 1 EA HOUSING, 20POS 26-22AWG PRELOADED MT RECEPT DBL ROW 2 52.6224.1020 1 EA COVER, FRONT 20POS MT LATCHING 3 52.6224.2020 1 EA COVER, BACK 20POS MT 4 52.6524.0005 2 EA CONN, HOUSING 5POS RECEPTACLE 5 52.6588.0006 2 EA HOUSING, 6POS XH 250V/3A 2.5MMPITCH -USE SXH CONTACTS 6 52.7007.
PAGE 158
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Pan/Tilt Control Cable Asembly (continued) 2 3 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 AMP CONNECTOR VIEWED FROM WIRE SIDE 22.0" 5 6 5 6 10.
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ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Ballast Control Link Cable Assembly 25.9663.2021 Rev 0 Refer to Figure 3-60. No. Item Qty. UM. Description 1 52.6396.2204 1 EA RECEPT, 4POS MTA100 W/POL TAB RED CLSD END 2 52.6524.0004 1 EA CONN, HOUSING 4POS RECEPTACLE 3 52.8367.0001 4 EA CONTACT, 22-24AWG FEMALE CRIMP 4 55.2186.0001 2 EA CABLE TIE, .10"WD 4.00"LG SMALL 5 73.5122.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Data I/O Link Cable Assembly 25.9663.2022 Rev A Refer to Figure 3-61. No. Item Qty. UM. Description 1 52.6396.2205 2 EA RECEPT, 5POS MTA100 W/POL TAB RED CLSD END 2 73.5122.
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ILLUSTRATED PARTS BREAKDOWN : CABLES 3 LVS DC Output Cable Assembly 25.9663.2024 Rev A Refer to Figure 3-62. No. Item Qty. UM. Description 1 52.6442.1805 1 EA RECEPT, MTA156 W/TAB ORN 5POS 18AWG CLOSED END 2 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 55.2186.0001 EA CABLE TIE, .10"WD 4.00"LG SMALL 4 73.3518.0002 3 FT WIRE, 18AWG 300V 105C PVC RED UL1569 5 73.3518.0010 3 FT WIRE, 18AWG 300V 105C PVC BLK UL1569 18.0" 2.0" 2.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Incandescent Power Input Cable Assembly 25.9663.2030 Rev A Refer to Figure 3-63. No. Item Qty. UM. Description 1 52.6274.2313 1 EA STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 2 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 52.8298.1160 2 EA FERRULE, WIRE 1X16 AWG L2=8MM BLACK 4 55.2268.0187 1 FT HEATSHRINK, 3/16" CLEAR KYNAR VDE UL 600V 150DEG C 5 55.2268.0500 0.
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ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Incandescent Lamp Power Cable Assembly 25.9663.2033 Rev E Refer to Figure 3-64. No. Item Qty. UM. Description 1 25.9663.2018 1 EA CABLE ASSY, HEAD TO BACKCAP GND 2 52.8298.1160 2 EA FERRULE, WIRE 1X16 AWG L2=8MM BLACK 3 52.8386.0001 2 EA CONN, BUTT SPLICE 16-22AWG UNISULATED SOLISTRAND 4 55.2186.0002 1 EA CABLE TIE, .09"WD 3.750"LG TEFZEL 5 55.2200.0003 0.33 FT HEATSHRINK, 3/16" VITON 6 55.2260.0133 4.42 FT SLEEVING, FIBERGLASS .
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Arc Power to Ignitor Cable Asembly 25.9663.2035 Rev B Refer to Figure 3-65. No. Item Qty. UM. Description 1 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8298.2160 2 EA FERRULE, WIRE 2X16 AWG L2=8MM BLACK 3 55.2186.0001 2 EA CABLE TIE, .10"WD 4.00"LG SMALL 4 55.6699.0003 2.67 FT SLEEVING, 1/2"NOM.DIA. POLY EXP BRAIDED 5 73.6222.0003 12 FT WIRE, 22AWG 600V 200C TFE ORN UL1199 6 73.6222.
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ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Ignitor to Lamp Socket Cable Assembly 25.9663.2036 Rev B Refer to Figure 3-66. No. Item Qty. UM. Description 1 25.9663.2018 1 EA CABLE ASSY, HEAD TO BACKCAP GND 2 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 55.2186.0001 1 EA CABLE TIE, .10"WD 4.00"LG SMALL 4 55.2260.0294 2 FT SLEEVING, FIBERGLASS .294"ID 5 73.7100.0001 5 FT WIRE, 16AWG 20KVDC 41/32 STRD 200C SILICONE 30.0" 24.0" 1.5" 0.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Shutter Harness Cable Assembly 25.9663.2040 Rev C Refer to Figure 3-67. No. Item Qty. UM. Description 04.9663.2040.00 1 EA LABEL SET, SHUTTER HARNESS 1 52.6224.0040 1 EA HOUSING, 40POS 26-22AWG PRELOADED MT RECEPT DBL ROW 2 52.6224.1040 1 EA COVER, FRONT 40POS MT LATCHING 3 52.6224.2040 1 EA COVER, BACK 40POS MT 4 52.6661.0006 8 EA CONN, RECEPT 6CIR WIRE TO WIRE 1.25MM PITCH 5 52.8387.
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1, 2, 3 02.9 663.00 10 D TO VL1000 CONTROLLER PCB J10 PIN 1 8" 30.0" 14" 23-Oct-02 25.0" 8 28.0" 23.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Color/Gobo/Lens Harness Cable Assembly 25.9663.2050 Rev H Refer to Figure 3-68. No. Item Qty. UM. Description 1 04.9663.2050.00 1 EA LABEL SET, COLOR/GOBO/LENS HARNESS 2 52.6224.0050 1 EA HOUSING, 50POS 26-22AWG PRELOADED MT RECEPT DBL ROW 3 52.6224.1050 1 EA COVER, FRONT 50POS MT LATCHING 4 52.6224.2050 1 EA COVER, BACK 50POS MT 5 52.6467.0003 1 EA CONN, FEM PLUG 3 POS 30-24 AWG CRIMP PHR 6 52.6467.
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ILLUSTRATED PARTS BREAKDOWN : CABLES 3 Color/Gobo/Lens Cable Assembly (continued) PIN 1 4 3 2 TO VL1000 CONTROLLER PCB J8 15 (x12) 16 12 (x2) 8 14 (x4) 11 17 FAN 13 (x4) 10 -08 18 -07 -13 13 (x4) 10 20 18 21 13 (x4) 20 10 1 -06 20 -12 -14 -11 FAN 9 12 (x4) 17 17 -02 17 17 -09 10 13 (x4) -03 11 14 (x4) 11 14 (x4) 11 14 (x4) -10 17 LABEL SET (FOR REF.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 152 23-Oct-02 02. 9663.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY 3 Arc Ballast Assembly Arc Ballast Assembly 21.9663.1900 Rev E Refer to Figure 3-69. No. Item Qty. UM. Description 1 04.9640.0374 1 EA LABEL, P.E. GROUND 2 04.9663.1920 1 EA LABEL, PRODUCT VL1000 APS 3 06.6032.0009 1 EA CABLE MARKER TIE, WHITE 19 X 7.4" 4 10.9663.1911 1 EA ENCLOSURE BALLAST 5 10.9663.1912 1 EA COVER, ENCLOSURE BALLAST 6 10.9663.1915 3 EA TOROID, DISK MOUNTING 1 1/2"OD 3/4"ID 7 10.9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 29 53.6607.0002 4 EA SCREW, 6-32 X 1/4" PFB 30 55.2001.0008 2 EA PCB SUPPORT, 1" SPACING SNAP-IN NYLON 31 55.2178.0001 1 EA CABLE ANCHOR MOUNT, #8 SCREW MOUNTING 32 55.2214.0001 1 EA SPACER, 10 THRU 11/64LX5/16R 33 55.3303.0008 17 EA WASHER, #8 LOCK INT.TOOTH SS 34 55.6623.0001 4 EA WASHER, #10 FLAT 35 55.6696.0004 4 EA BUMPER, RUBBER M/AII SHEET METAL FRAME 36 68.9663.1912 1 EA PFC CHOKE 37 68.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY 3 Arc Ballast Assembly (continued) 21 (x4) 34 (x4) 35 (x4) 26 (x4) 5 22 3 31 12 11 30 (x2) 23 (x10) 33 (x10) 16 (x10) 25 (x5) 14 19 (x4) 28 (x3) 13 6 (x3) 7 (x3) 17 36 9 37 (x2) 8 (x3) 29 (x4) 1 19 (x3) 20 (x10) 24 27 (x8) 23 (x6) 33 (x7) 16 (x7) 15 10 (x2) 2 18 4 32 20 (x7) Figure 3-69: Arc Ballast Assembly 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL 625W Ballast PCB 24.9663.1901 Rev B Refer to Figure 3-70. No. Item Qty. UM. Description Ref. 1 11.9663.1901 1 EA PCB, BALLAST 625W - 2 23.9663.1925 1 EA FAB ASSY, POTTED ZVT MAG-AMP L103 3 52.6260.0004 1 EA HEADER, 4POS MTA-100 SHROUDED STRAIGHT J601 4 52.6370.0003 1 EA HEADER ASSY, 3CIR SOCKET MNLOK FMLE J102 5 52.6663.0014 1 EA HEADER, 14PIN .025"SQ .665"STACK HT BOARD STACKING J101 6 52.6663.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY No. Item Qty. UM. 27 60.1420.5105 2 28 60.1420.6800 29 3 Description Ref. EA RES, 1/4W 5% 510.0 K CF R114 & R115 1 EA RES, 1/4W 5% 6.8 OHM CF R601 60.1421.1201 2 EA RES, 1/4W 5% 12.0 OHM CF R110 & R112 30 60.1421.1205 1 EA RES, 1/4W 5% 120.0 K CF R104 31 60.1421.2003 1 EA RES, 1/4W 5% 200.0 K CF R608 32 60.1421.2202 1 EA RES, 1/4W 5% 220.0 OHM CF R109 33 60.1421.5100 3 EA RES, 1/4W 5% 5.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. Description Ref. 59 62.3033.0331 1 EA CAP, 330PF 3000VDC 20% CERAMIC DISC C113 60 62.4009.0107 4 EA CAP, 100UF 35V RAD ALUM 8 X 11.5 MM 20% C603-C606 61 62.4010.0106 1 EA CAP, 10UF 50V RAD ALUM 4 X 11 MM 20% C232 62 62.4010.0475 6 EA CAP, 4.7UF 50V RAD ALUM 5 X 11 MM 20% C212, C215, C222, C223, C227 & C228 63 63.2047.0085 2 EA THERMOSTAT, 85DEG C PCB MT CLOSE ON RISE TS101 & TS201 64 63.2050.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY No. Item Qty. UM. 89 82.5323.0001 4 90 82.5334.0001 91 3 Description Ref. EA DIODE, MUR460 600V 4AMP ULTRAFAST D103, D106, D203 & D219 1 EA DIODE, 1N5245B ZENER VOLTAGE REGULATOR D605 82.5340.0001 3 EA DIODE, ZENER 1.5KE250A TVS 250V 1500W D215, D216, D601 92 82.5351.0001 4 EA DIODE, ZENER 20V 1W 5% DO-41 1N4747A D108, D109, D217 & D218 93 82.5357.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL 625W Ballast Rider PCB 24.9663.1902 Rev A Refer to Figure 3-71. No. Item Qty. UM. Description Ref. 1 11.9663.1902 1 2 52.6662.0014 1 EA PCB, BALLAST RIDER 625W - EA SOCKET STRIP, 14PIN SGL ROW .100"PITCH J301 3 52.6662.0015 1 EA SOCKET STRIP, 15PIN SGL ROW .100"PITCH J401 4 60.0460.1004 2 EA RES, 1/8W 5% 10.0 K THK FLM CHIP SUR MT EIA1206 R502, R503 5 60.9462.1003 3 EA RES, 1/2W 5% 1.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY No. Item Qty. UM. 21 60.9463.5113 2 22 60.9463.6653 23 3 Description Ref. EA RES, 1/8W 1% 5.11 K 200V CHP THK FLM SMT1206 R301, R307 1 EA RES, 1/8W 1% 6.65 K 200V CHP THK FLM SMT1206 R404 60.9463.7683 1 EA RES, 1/8W 1% 7.68 K 200V CHP THK FLM SMT1206 R423 24 60.9464.1002 1 EA RES, 1/8W 5% 100 OHM 200V CHP THK FLM SMT1206 R305 25 60.9464.1003 7 EA RES, 1/8W 5% 1.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL No. Item Qty. UM. Description Ref. 41 62.4000.0105 14 EA CAP, .1UF 50V 20% CER CHIP SUR MT Z5U EIA0805 C306, C307, C309, C402, C405, C406, C408, C414, C415, C416, C424, C504, C507, C508 42 62.4003.0102 6 EA CAP, 1000PF 50V 10% CER CHIP SUR MT X7R EIA0805 C301, C311, C313, C403, C404, C503 43 62.4003.0103 1 EA CAP, .01UF 50V 20% CER CHIP SUR MT Z5U EIA0805 C422 44 62.4003.0104 1 EA CAP, 0.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY No. Item Qty. UM. Description Ref. 61 82.5358.0001 1 EA DIODE, ZM4747A ZENER REGULATOR 20V 1W SMT DO-213AB D304 62 83.3201.0001 2 EA IC, LM293D LOW OFFSET VOLTAGE DUAL COMPARATORS SO-8 U302, U403 63 83.3202.0001 2 EA IC, LM258D DUAL DIFFERENTIAL INPUT LOW POWER OP-AMPS SO-8 U402, U404 64 84.4320.0001 1 EA IC, MC14040BD 12-BIT BINARY COUNTER SOIC16 U501 65 84.7431.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL 575W Ballast I/O Cable Assembly 25.9663.1907 Rev B Refer to Figure 3-72. No. Item Qty. UM. Description 1 52.6231.0001 1 EA PLUG HOUSING, MNLOK PLUG 3POS 2 52.6396.2204 1 EA RECEPT, 4POS MTA100 W/POL TAB RED CLSD END 3 52.6400.0111 1 EA RECEPT, 17-9 STD SEX CPC 600V KEY A SQ FLANGE 4 52.8201.0005 3 EA PIN, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA 5 52.8202.0001 5 EA PIN, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA 6 52.
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ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY 3 575W Ballast I/O Cable Assembly (continued) 7 (x3) GRN/ YEL GRN/ YEL 4.0" MIN 9 (x2) 4.5" MIN GRN/ YEL 18 VIO 21 ORN GRN/YEL 1 2 3 WHT BLK 3 6 9 2 5 8 17 1 4 7 6.5" MIN 13 12 19 1 8 (x2) 10 1 2 3 ORN 20 1 2 3 4 3 4 (x3) 5 (x5) 6 14, 15, 16 2 FERRITE 26.25" GRN/YEL 4" VIO 24.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 166 23-Oct-02 02. 9663.
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APPENDIX A. Technical Bulletins VL1000 ERS Luminaire Technical Bulletins The following table identifies the current technical bulletins associated with the VL1000 ERS luminaire. These improvements have been incorporated into this manual. 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL Notes 168 23-Oct-02 02. 9663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Wiring and Schematic Diagrams VL1000 Incandescent Wiring Diagram - Sheet 1 of 2 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS VL1000 Incandescent Wiring Diagram - Sheet 2 of 2 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS VL1000 Arc Wiring Diagram - Sheet 1 of 2 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS VL1000 Arc Wiring Diagram - Sheet 2 of 2 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS VL1000 Ballast Wiring Diagram 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Gobo Wheel Sensor (24.9663.1230 B) Schematic 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Gobo Index Sensor (24.9663.1231 A) Schematic 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS DMX Input PCB (24.9663.1830 A) Schematic 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS 625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 1 of 3 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS 625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 2 of 3 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS 625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 3 of 3 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS 625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 1 of 2 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS 625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 2 of 2 02.9 663.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 1 of 10 8 7 6 5 4 2 3 1 REVISIONS REV APPD Initial Release per EO #9003 DESCRIPTION 12/01 T.E.W. B Revised per EO #09010 01/02 T.E.W. C Revised per EO #09013 01/02 T.E.W. D Revised per EO #09021 02/02 T.E.W. Unlesss Otherwise specified. E Revised per EO #09025 02/02 T.E.W. 1. All capacitor values are microfarads. F Revised per EO #09028 2.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 2 of 10 8 7 6 5 4 2 3 1 3/B4,3/A4,4/A6 +3.3V D[0:31] D[0:31] D[0:31] D[0:31] A[0:24] A[0:24] R281 10K +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V 1 16 D0 2 15 D1 3 14 D2 4 13 D3 PLL DIV = 1/2 C228 .01UF 10% 25V D C188 .01UF 10% 25V C216 .01UF 10% 25V C197 .01UF 10% 25V C211 .01UF 10% 25V C203 .
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 3 of 10 8 7 6 5 4 2 3 1 +3.3V +3.3V +3.3V C190 0.1UF 10% 25V +3.3V +3.3V C229 0.1UF 10% 25V C230 0.1UF 10% 25V +3.3V C218 0.1UF 10% 25V +3.3V C204 0.1UF 10% 25V C214 0.1UF 10% 25V +2.5V C224 .01UF 10% 25V +2.5V +2.5V +2.5V C225 .01UF 10% 25V +2.5V C220 .01UF 10% 25V +2.5V +2.5V C226 .01UF 10% 25V +2.5V +2.5V C222 .01UF 10% 25V +2.5V C200 .
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 4 of 10 8 7 6 5 4 2 3 1 ISO_VCC VCC R294 10K ISO_VCC U3 HCPL-0600 R5 470 1 9 TX_EN_C- 3/D7 VCC ISO_VCC 2 7 3 6 C2 0.1UF 10% 25V R293 330 8 D 8 NC1 VCC U39 SN74ACT00 U2 SN75176 3 DE +3.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 5 of 10 8 7 6 5 4 2 3 1 +24V VCC D PAN M1 R32 24K 5% 1/16W R36 7.50K 3/C4 R33 7.50K PWM_PH_1 20 3/C4 PWM_EN_1 21 23 12 VCC PHASE1 VMM1 11 C13 .01UF 10% 25V 3/C4 R30 4.32K 1% 1/16W PWM_PH_2 25 PWM_EN_2 24 R37 7.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 6 of 10 8 7 6 5 4 2 3 +24V +24V VCC D COLOR BLUE R76 24K 5% 1/16W 3/B4 R80 7.50K 3/A4 VCC C50 0.1UF 10% 25V VCC M5 20 PWM_PH_9 23 12 VCC PHASE1 VMM1 11 1/16W 1% 8 GND1 3/B4 3/B7 5 PHASE2 M5OUT10A MA2 7 VR2 1/16W 1% GND9 GND3 GND8 GND4 GND7 GND5 C1 GND6 E2 E1 19 R79 2.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 7 of 10 8 7 6 5 4 2 3 1 +24V +24V VCC VCC D ZOOM C86 0.1UF 10% 25V VCC M9 3/C4 R130 7.50K 3/C4 +24V VCC R126 24K 5% 1/16W 20 PWM_PH_17 23 12 VCC PHASE1 VMM1 11 8 VR1 GND1 C82 .022UF 10% 25V 3/B4 M9OUT18A 7 M9OUT18B VR2 MB2 RC GND10 R129 4.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 8 of 10 8 7 6 5 4 2 3 1 +24V +24V VCC VCC D SHUTTER FRAME 1A C122 0.1UF 10% 25V VCC M13 R170 24K 5% 1/16W 3/C4 R174 7.50K 3/C4 20 PWM_PH_25 23 12 VCC PHASE1 VMM1 11 8 GND1 3/C4 5 27 7 VR2 C125 .022UF 10% 25V PHASE2 VR2 26 10 3/B7 6 GND3 GND8 GND4 GND7 GND5 C1 GND6 E2 16 9 R197 7.50K 1/16W 1% C144 .01UF 10% 25V C R194 2.67K 1% 1/16W C143 .
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.1930 F) Schematic - Sheet 9 of 10 8 7 6 5 4 2 3 +24V +24V VCC D SHUTTER FRAME 3A M17 R214 24K 5% 1/16W 3/B7 R216 7.50K 3/B7 VCC C159 0.1UF 10% 25V VCC 20 PWM_PH_33 23 12 VCC PHASE1 VMM1 11 C158 .
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL REFERENCE FOLD-OUTS Controller PCB (24.9663.