Philips Vari-Lite VL4000, VL4000 Service Manual

10 September 2014

(Preliminary Release Version)

VL4000 Spot Luminaire

Service Manual

All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or
organizations.

Philips Vari-Lite
A Philips Group Company
10911 Petal Street
Dallas, Texas 75238 USA

This manual is for informational use only and is subject to change without notice. Philips Vari-Lite assumes no responsibility or liability for any claims
resulting from errors or inaccuracies that may appear in this manual.

Version as of: 10 September 2014 (Preliminary Release Version)

Part number: 02.9704.0010 0

©2014, Vari-Lite, a Philips group company. All Rights Reserved.

VL4000 Spot Luminaire Service Manual

How To Obtain Warranty Service

A copy of the Vari-Lite 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),
[phone], or [e-mail] and request a Return Material Authorization
(RMA) for warranty service. You will need to provide the model and serial number of the item being
returned, a description of the problem or failure and the name of the registered user or organization. If
available, you should have your sales invoice to establish the date of sale as the beginning of the
warranty period.

Once you obtain the RMA, pack the unit in a secure shipping container or in its original packing box.
Fill out the RMA form included at the end of this manual and place in shipping container along with a
copy of your invoice (if available). Write the RMA number legibly on or near the shipping address
label and return the unit, freight prepaid to:

Philips Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
Attention: Warranty Service (RMA# _______)

FOREWORD

As stated in the warranty, it is required that the shipment be insured and FOB our service center*.

Note: *When returning products to Philips Vari-Lite for repairs (warranty or out-of-warranty) from a
country other than the USA, “Philips Lighting Controls Division”, must appear in the address block as
the Importer of Record (IOR) on all shipping documentation, Commercial Invoices, etc. This must be
done in order to clear customs in a timely manner and prevent returns.

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VARI❋LITE - VL4000 SPOT 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. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance
with Vari-Lite system, service, and safety guidelines, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at his/her own expense.

Declaration of Conformity

We, Philips Lighting B.V. 10911 Petal Street, Dallas, Texas 75238 USA, declare under our
responsibility for the products:

Product Range Professional Stag e Luminaire

Product Code VL4000 Spot

The designated products are in conformity with the essential requirements of the following European
Directives and harmonized standards:

Low Voltage Directive (LVD), 2006/95/EC

EN 60589-2-17:1984+A1:1987+A2:1990 used in conjunction with 60598-1:2008/A11:2009

Electromagnetic Compatibility Directive (EMC), 2004/108/EC

EN 55022:2010, EN55024:2010

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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:

GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK,
FIRE, EXPOSURE TO EXCESSIVE UV RADIAT ION, AND INJURY TO PERSONS CAN BE
FOUND BELOW.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE

1. VARI❋LITE lumi naires have been designed for use with specific lamp types. VL4000 Spot
Luminaires is supplied with an Osram HTI 1500 D7/60 metal halide lamp or other lamps as
approved by Vari-Lite. Installing another type of lamp not approved by Vari-Lite may be
hazardous.

2. Luminaires may be mounted on any type of surface as long as mounting instructions are followed.
See instructions detailed in this manual.

3. Note distance requirement from combustible materials or illuminated objects for VARI❋LITE
luminaires.

FOREWORD

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK

1. VARI❋LITE luminaires are designed for dry locations only. Exposure to rain or moisture may
damage luminaire.

2. Disconnect power before servicing any VARI❋LITE equipment.

3. Servicing to be performed by qualified personnel only.

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VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE
TO UV RADIATION

1. Many VARI❋LITE lum i naires use a 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.

WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS

1. Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety equipment
(gloves, eye protection, etc.) when handling and adjusting hot equipment and components.

2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to cool before
replacing.

3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation.
Additionally, arc lamps operate under high pressure at very high temperatures. Should the lamp
break, there can exist a danger of personal injury and/or fire from broken lamp particles being
discharged.

4. Wear eye protection when relamping.

5. Appropriate safety equipment (gloves, eye protection) should be used when handling damaged
lamps.

6. If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with lint-free
cloth before installing or powering up the luminaire.

7. The lamp shall be changed if it has become damaged or thermally deformed.

WARNING:
RF INTERFERENCE

1. This is a Class A product. In a domestic environment this product may cause radio interference, in
which case, the user may be required to take adequate measures.

ARC LAMP CHARACTERISTIC CONSIDERATIONS

1. Arc lamps require a period of time to relight after a power interruption or a severe voltage dip. In
some cases, the lamp will automatically relight after it has cooled depending on Lamp Power-Up
State configuration setting.

2. Burning position is universal.

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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.

WARNUNG - weist auf mögliche Körperverletzung und Lebensbedrohung hin.

NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER
SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE UV­STRAHLUNG UND KÖRPERVERLETZUNGEN.

WARNUNG:
HINWEISE ZUM FEUERSCHUTZ

1. VARI❋LITE -Scheinwerfer sind ausschließlich für den Einsatz mit bestimmte n Lampentyps.
Achten Sie auf den Lampentyp (Osram HTI 1500 D7/60 metal halide lamp), bevor Sie die
jeweiligen Lampen ersetzen. Die Installation eines anderen Lampentyps kann gefährlich sein.

2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die
Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.

3. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der VARI❋LITE ­Scheinwerfer von brennbarem Material oder beleuchteten Objekten.

FOREWORD

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK

1. VARI❋LITE -Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen oder
Feuchtigkeit können die Scheinwerfer beschädigen.

2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE -Geräten beginnen.

3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.

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VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG

1. Viele VARI❋LITE -Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt. SCHAUEN
SIE NICHT direkt in die Lampe.

2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linse n 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. Verwenden Sie bei der Bedienung von
aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz
etc.).

2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und lassen Sie
die Lampe abkühlen, wenn Sie diese austauschen.

3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und Augenentzündungen
verursachen können. Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen
Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr von Körperverletzung bzw. von
Feuer, das von Lampenteilen ausgelöst werden kann.

4. Tragen Sie beim Austausch der Lampen einen Augenschutz.

5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.

6. Wenn die Lampe mit bloßen Händen berührt wird , reinigen Sie sie mit denaturi ertem Alkohol und
einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen.

7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese ausgetauscht
werden.

WARNUNG:
HF-INTERFERENZ

1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt Hochfre­quenzstörungen verursachen. In diesem Fall müssen eventuell geeignete Maßnahmen getroffen
werden.

BESONDERHEITEN VON BOGENLAMPEN

1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach Abkühlung
automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung des Lampenein­schaltungsstatus.

2. Die Brennposition ist Universal.

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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.

Les symboles de sécurité utilisés dans ce guide sont les suivants :

ATTENTION Ce symbole annonce que l’appareil risque d’être endommagé.

AVERTISSEMENT Ce symbole annonce qu’il y a risque d’accident grave ou même fatal.

CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE PROTÉGER
CONTRE LES DÉCHARGES ÉLECTRIQUES , LES INCENDIES, L’EXPOSITION EXCESSIVE
AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRAÎNER DES BLESSURES.

FOREWORD

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES

1. Les luminaires VARI❋LITE ont été conçus pour être utilisés uniquement avec certaines type de
lampes. Vérifier le type de lampe (Osram HTI 1500 D7/60 metal halide lamp) avant de remplacer
les lampes. L’installation d’un autre type de lampe peut poser un danger.

2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de montage sont
respectées. Voir les explications détaillées dans ce guide.

3. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et les
luminaires VARI❋LITE .

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES

1. Les luminaires VARI❋LITE sont conçus pour une utilisation au sec uniquement. Une exposition
à la pluie et à l’humidité risque d’endommager le luminaire.

2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE .

3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.

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VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX
RAYONS UV

1. Plusieurs luminaires VARI❋LITE utilisent une lampe 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. Tous blindages, lentilles ou
écrans ultraviolet visiblement endommagés au point que leur efficacité en est affectée doivent être
remplacés, par exemple s’il y a des fissures ou de profondes rayures.

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT ENTRAÎNER
DES BLESSURES

1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche. Pour
manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger suffisamment (gants,
protection pour les yeux, etc.).

2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et attendre que la
lampe ait refroidi avant de la remplacer.

3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la peau et
une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute tension à de très
hautes températures. Si la lampe se casse, les particules de la lampe cassée peuvent causer
blessures et/ou incendie en s’éparpillant.

4. Se protéger les yeux pour remplacer la lampe.

5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier des lampes
endommagées.

6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool dénaturé et l’essuyer
avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire.

7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être remplacée.

AVERTISSEMENT:
INTERFÉRENCE RF

1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer des
interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures adéquates.

CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC

1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc mettent du
temps avant de se rallumer. Dans certains cas, la lampe se rallumera automatiquemet après s’être
refroidie. Cela dépend de la manière dont le système est réglé pour le statut de mise en marche de
la lampe.

2. La position Brûler est Universelle.

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Aviso sobre Seguridad

Es muy importante leer TODA la in formación e instrucciones sobre seguridad que se indica en es te
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.

ADVERTENCIA, indica posibles lesiones o muerte a las personas.

LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CONTRAGOLPES DE
CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN EXCESIVA A RADIACIÓN ULTRA
VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE:

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO

1. Las luminarias VARI❋LITE han sido diseñadas para ser usadas solamente con algunas lámparas.
T ome nota del tipo d e lámpara (Osram HTI 1500 D7/60 metal halide lamp) antes de reemplazarla.
Instalación de otro tipo de lámpara puede ser peligroso.

2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalación. Vea las instrucciones detalladas en este manual.

3. Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados
para las luminarias VARI❋LITE .

FOREWORD

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE ELÉCTRICO

1. Las luminarias VARI❋LITE están diseñadas solamente para lugares secos. La exposición a la
lluvia o humedad pueden dañar la luminaria.

2. Desconecte la energía antes de dar servicio a cualquier equipo de VA RI❋LITE .

3. El servicio debe ser realizado solamente por personal calificado .

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VARI❋LITE - VL4000 SPOT 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 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. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS

1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un equipo de
seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga ajustes en el equipo y
componentes que están calientes.

2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la energía y
deje que la lámpara se enfríe antes de reemplazarla.

3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la
piel e inflamación a los ojos. Además, las lámparas de arco operan a alta presión y muy alta
temperatura. Si la lámpara se rompe, puede existir el peligro de lesiones al personal o un incendio
ocasionado por las partículas de la lámpara rota que se caen.

4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.

5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando trabaje con
lámparas dañadas.

6. Si toca la lámpara con las manos, limpie la lámpara con alcohol desnaturalizado y con tela sin
pelusas antes de instalar o volver a conectar la luminaria.

7. Cambie la lámpara si está dañada o deformada termicamente.

ADVERTENCIA:
INTERFERENCIA RF

1. Este es un producto de Clase A. En el ambiente de la casa este producto puede ocasionar
radiointerferencia, en cuyo caso, el usuario debe tomar las medidas adecuadas.

CONSIDERACIONES SOBRE LAS CARACTERÍSTICAS DE LA LÁMPARA DE ARCO

1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de una
interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara se volverá a
iluminar en forma automática después que se ha enfriado dependiendo de la configuración del
sistema de energía de la lámpara.

2. La posición de encendido es universal.

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FOREWORD

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VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

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Table of Contents

Introduction

About This Manual ...................................................... ............................................................. 1

Additional Documentation........................................................................................................ 1

Customer Service...................................................................................................................... 2

Technical Bulletins and Notices................................................................................................ 2

Chapter 1. Description

Features

Product Features........................................................................................................................ 4

Technical Specifications ........................................................................................................... 5

Components

External Luminaire Components.............................................................................................. 6

Head and Yoke Components..................................................................................................... 7

Enclosure Components ............................................................................................................. 8

TABLE OF CONTENTS

Chapter 2. Rountine Maintenance

Troubleshooting

Error Messages........................................................................................................................ 10

Troubleshooting Guide............................................................................................................ 11

Routine Maintenance Procedures

Lamp Removal and Installation.............................................................................................. 13

Fixed Color Wheel Filter Removal and Installation............................................. .................. 16

Rotating Gobo Removal and Installation................................................................................ 18

Animation Wheels Removal and Installation .............................................. .... ..... .................. 21

Cleaning Optical Lenses and Filters ....................................................................................... 23

Chapter 3. Illustrated Parts Breakdown

Drawing Trees

VL4000 Spot Luminaire (Part 1)............................................................................................ 26

VL4000 Spot Luminaire (Part 2)............................................................................................ 27

VL4000 Spot Luminaire (Part 3)............................................................................................ 28

VL4000 Spot Luminaire (Part 4)............................................................................................ 29

VL4000 Spot Luminaire (Part 5)............................................................................................ 30

VL4000 Spot Luminaire (Part 6)............................................................................................ 31

Principle of Operation

VL4000 Spot Functional Block Diagram ............................................................................... 32

Top Assembly

Included Items Kit, VL4000 Spot........................................................................................... 33

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VL4000 Spot Luminaire ......................................................................................................... 35

VL4000 Generic Luminaire Assembly................................................................................... 37

VL4000 Head Cover Assembly.............................................................................................. 39

VL4000 Yoke Arm Cover Assembly........................................................... ........................... 40

Stabilizer Assembly ................................................................................................................ 41

Head Assembly

Head Frame Assembly............................................................................................................ 43

VL4000 Zoom Spot Assembly ............................................................................................... 45

Prism Motor Assembly ........................................................................................................... 49

Prism Assembly ...................................................................................................................... 51

Frost Motor Assembly ............................................................................................................ 53

Frost Flag Assembly ............................................................................................................... 55

Lens Group 3 Motor Assembly............................................................................................... 56

Slotted Optical Switch ............................................................................................................ 58

Back End Assembly................................................................................................................ 59

Reflector Assembly................................................................................................................. 61

Lamp Cover Assembly............................................................................................................ 62

Shutter/Gobo/Animation Module Assembly ............................................................ ..... ......... 63

Gobo Wheel 1 Assembly ........................................................................................................ 69

Gobo Wheel 2 Assembly ........................................................................................................ 71

Gobo 1 Sensor Index Assembly.............................................................................................. 73

Gobo 2 Sensor Index Assembly.............................................................................................. 74

Edge Motor Assembly ............................................................................................................ 75

Gobo Bulkhead Left Bracket Assembly ................................................................................. 76

Gobo Bulkhead Right Bracket Assembly............................................................................... 77

Animation Wheel 1 Assembly................................................................................................ 78

Animation Wheel 1 Motor Assembly..................................................................................... 80

Animation Wheel 2 Assembly................................................................................................ 81

Animation Wheel 2 Motor Assembly..................................................................................... 83

Shutter Bulkhead with Rotation Assembly............................................................................. 84

Shutter Module Assembly....................................................................................................... 86

Shutter Rotate Motor Assembly.............................................................................................. 90

Shutter Rotate Adjustable Roller Arm Assembly................................................................... 91

Color Module Assembly......................................................................................................... 93

210 Groove Belt Assembly..................................................................................................... 98

240 Groove Belt Assembly..................................................................................................... 99

Fixed Color Wheel Assembly............................................................................................... 100

Fixed Color Wheel 1 Assembly............................................................................................ 102

Fixed Color Wheel 2 Assembly............................................................................................ 104

Fixed Color Motor Assembly ............................................................................................... 106

Cross-Flow Blower Assembly.............................................................................................. 107

Left Strobe Assembly............................................................................................................ 108

Right Strobe Assembly ......................................................................................................... 110

Control Belt Idler Assembly................................................................................................. 112

Color Flags Sensor Board Assembly.................................................................................... 113

Yoke Assembly

Yoke Assembly ..................................................................................................................... 115

Tilt Motor Assembly............................................................................................................

. 117

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TABLE OF CONTENTS

Tilt Motor with Pulley Assembly.......................................................................................... 119

Enclosure Assembly

Upper Enclosure Assembly................................................................................................... 121

Upper Enclosure Assembly - Part 1...................................................................................... 122

Upper Enclosure Assembly - Part 2...................................................................................... 124

Upper Enclosure Assembly - Part 3...................................................................................... 126

Upper Enclosure Assembly - Part 4...................................................................................... 128

Side Mount Fan Assembly.................................................................................................... 130

Front Panel Assembly....................................................... .... ..... .... ....................................... 131

Side Mount Filter Holder Assembly..................................................................................... 133

Pan Bearing / Pulley Assembly............................................................................................. 134

Pan / Fan Driver Board Assembly ........................................................................................ 136

Pan Module Assembly.......................................................................................................... 137

Upper Enclosure Cover Assembly........................................................................................ 139

Note: Cables are only available as complete assemblies. The information contained in this

section is for reference only.

Cable Assemblies

LVS Chassis Ground Cable Assembly.................................................................................. 141

VL4000 Pan / Tilt Cable Assembly...................................................................................... 142

VL4000 Tilt Cable Assembly............................................................................................... 143

VL4000 Color Power Distribution Cable Assembly ............................................................ 144

VL4000 Main from MCB Data Cable Assembly ................................................................. 145

VL4000 Main to Bulkheads Data Cable Assembly.............................................................. 146

VL4000 Lamp Base & Tip Fan Extension Cable Assembly................................................ 147

VL4000 Main Power Distribution Cable Assembly............................................................. 148

VL4000 Lamp Socket Cable Assembly................................................................................ 149

VL4000 Gobo Bulkhead 1 Cable Assembly......................................................................... 150

VL4000 Gobo Bulkhead 2 Cable Assembly......................................................................... 151

VL4000 Gobo Bulkhead 3 Cable Assembly......................................................................... 152

VL4000 Data Network Extension Cable Assembly ............................................................. 153

VL4000 Shutter 1 Cable Assembly ...................................................................................... 154

VL4000 Shutter 2 Cable Assembly ...................................................................................... 155

VL4000 Shutter 3 Cable Assembly ...................................................................................... 156

VL4000 Power Distribution Output-Shutter Cable Assembly ............................................. 157

VL4000 Data Network Cable Assembly .............................................................................. 158

VL4000 Color Bulkhead 1 Cable Assembly......................................................................... 159

VL4000 Color Bulkhead 2 Cable Assembly......................................................................... 160

VL4000 Color Bulkhead 3 Cable Assembly......................................................................... 161

VL4000 Color Bulkhead 4 Cable Assembly......................................................................... 162

VL4000 Color A to Color B Cable Assembly...................................................................... 163

VL4000 Ballast to Ignitor Cable Assembly.......................................................................... 164

VL4000 Pan / Power Distribution Input Cable Assembly.................................................... 165

VL4000 Enclosure PFC Input Cable Assembly ................................................................... 166

VL4000 Enclosure PFC Output Cable Assembly................................................................. 167

VL4000 DMX Cable Assembly............................................................................................ 168

VL4000 Ballast Control Cable Assembly............................................................................. 169

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VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

VL4000 USB Interface Cable Assembly.............................................................................. 170

VL4000 Thermal Control Cable Assembly.......................................................................... 171

VL4000 Chassis to Yoke Cable Assembly........................................................................... 172

VL4000 AC Input Connector Assembly............................................................................... 173

VL4000 Optics-E to Optics-F Data Cable Assembly........................................................... 174

VL4000 Optics Bulkhead 3 Cable Assembly....................................................................... 175

VL4000 Optics Bulkhead 4 Cable Assembly....................................................................... 176

VL4000 Optics Bulkhead 1 Cable Assembly....................................................................... 177

VL4000 Optics Bulkhead 2 Cable Assembly....................................................................... 178

Appendix A. Technical Notices & Bulletins

VL4000 Spot Luminaire ....................................................................................................... 179

Technical Notices............................................................................................................ 179

Technical Bulletins.......................................................................................................... 179

xvi 02.9704.0010 0

Introduction

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns for the
VL4000 Spot Luminaire. The manual is intended for use by Vari-Lite personnel and Authorized
VARI❋LITE Service Centers and technicians only.

WARNING: It is important to read ALL accompanying safety and installation instructions to avoid
damage to the product and potential injury to yourself or others.

This manual covers the following models:

VL4000 Spot Luminaire 20.9704.0001 1200W Short Arc

INTRODUCTION : ABOUT THIS MANUAL

Model Part Number Source

Note: Performing maintenance procedures may void the product warranty. Refer to the Vari-Lite
Limited Warranty card included in the product shipping package for more information.

Additional Documentation

For complete installation and operation instructions, refer to the VL4000 Spot Luminaire User’s
Manual. This manual is only available in electronic (PDF) format:

• VL4000 Spot Luminaire User’s Manual (02.9704.0002)

Note: The user’s manual is available on the Philips Vari-Lite web site at www.vari-lite.com in the
Product Downloads Section.

For more information regarding DMX512 systems, refer to the DMX512/1990 & AMX 192 Standards
publication available from United States Institute for Theatre Technology, Inc. (USITT).

USITT Inc.
315 South Crouse Avenue Suite 200
Syracuse, NY 13210
Tel: [phone] or [phone]
Fax: [phone] or [phone]

www.usitt.org

02.9704.0010 0 1

VARI❋LITE - VL4000 SPOT 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 full-time staff of experienced professionals are on-hand to
provide support.

How to Reach Us

For assistance in your area, call the dealer from which your product(s) was purchased.
or
Contact an Authorized Service Center.
or
Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through Friday, at the

following:

phone: 1-877-VARI-LITE (1-877-827-4548)

e-mail: [e-mail]

Additional Resources

For additional resources and documentation, please visit our website at www.vari-lite.com and follow
the Support link.

Technical Bulletins and Notices

Technical bulletins concerning the latest changes to VARI❋LITE equipment are issued from the
Dallas, T exas USA office. They are documentation supplements that contain procedures for equipmen t
upgrades, retrofits, and repairs not found in the existing manuals. Operator technical bulletins are also
issued to document changes in control software. Technical bulletins are integrated into the appropriate
equipment manuals as those manuals are revised. Bulletins are categorized by assembly or
subassembly, and identified by a number such as S3K-001 (Series 3000 Lumin aires Technical Bulletin
number 1).

Technical notices are also issued from the Dallas, Texas USA office. They are non-procedural
documents that contain information regarding product support issues, current equipment problems,
software bugs, and documentation corrections. All technical notices begin with the prefix TN and are
numbered sequentially, such as TN-138 (Tech Notice number 138).

2 02.9704.0010 0

CHAPTER 1.

Description

This chapter contains descriptions of luminaire features and components.

• Features

• Components

02.9704.0010 0 3

VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

Features

Product Features

All VL4000 Spot Luminaires have the following standard features:

• Color System: A three filter CYM cross fading system capable of extremely smooth movements at
both slow and fast speeds, and a variable CTO color temperature correction system.

• Fixed Color Wheels: T wo opposing fixed color wheels each with five interchangeable color filters
are capable of producing multi-color effects and variable wheel rotations.

• Zoom Optics: A 12-element 5:1 zoom optics system, covering a range from 9° to 47°.

• Beam Size Control: A mechanical iris provides continuous beam size control for rapid and smooth
timed beam angle changes.

• Shutter Control: A four-blade shutter mechanism that allows the blades to be operated
independently or in unison on two planes for a clear and crisp image. The entire mechanism can
rotate 50º in either direction.

• Rotating Gobo Wheels: Two gobo wheels combine to each offer seven rotatable, indexable gobo
positions and one open position.

• Animation Wheels: Two animation wheels each offer unique rotatable, indexable patterns with
variable motion control from horizontal to vertical . Unique Dichro*Fusion pattern is chromatically
tuned to provide endless color effects.

• Rotating Prism: Independent rotating and indexing 3-facet prism with variable deviation control.

• Edge and Pattern Focus: Variable beam focus to soften edges of gobos or spot. Remarkable depth
of field capability allows morphing effects between gobo and animation wheels.

• Variable Frost: Independent variable frost glass with adjustable softness control.

• Intensity Control: Full field dimming designed for smooth timed fades as well as quick dimming
effects.

• Strobe: High-performance dual blade strobe system capable of ultra-fast operation.

• Pan and Tilt: Smooth, time-controlled continuous motion by way of three-phase stepper motor
systems.

• Range: Pan - 540°, Tilt - 270°.

• Accuracy: 0.1° resolution.

• Weights: Unit weighs (luminaire only, without accessories) 83 lbs (37.7 kg).

• Spacing: Unit hangs on 25 inch (635 mm) centers.

• Operational Temperature:

• Standard Mode: -20° to +104° F (-29° to +40° C)

• Studio Mode: -20° to +122° F (-29° to +50° C)

• Control:

• DMX: Completely compatible with a wide variety of DMX512 consoles.

• DMX Channels: 57 (Enhanced 16-bit mode) / 52 (16-bit mode).

4 02.9704.0010 0

FEATURES : TECHNICAL SPECIFICATIONS

1

• RDM Control: Completely compatible with a wide variety of RDM devices.

• Power Requirements: Standard AC power distribution from 200 - 240VAC, 50/60 Hz. The unit
requires up to 11.0A depending on the AC supply voltage.

• Source: 1200W Short Arc Lamp, Philips MSR Gold FastFit.

Technical Specifications

For additional technical specifications and information, please refer to VL4000 Spot Luminaire User’s
Manual (02.9704.0002) and the product specification sheet. These documents can be found in the
product downloads section of the Vari-Lite web site at www.vari-lite.com.

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VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

Components

External Luminaire Components

The following illustration shows the external luminaire components and controls.

Head Assembly

Houses color system,
gobos, animation
wheels, strobe, iris and
zoom lens mechanisms

Backcap Assembly

Provides access to lamp
for replacement and
provides controls for
beam adjustment.

Upper Enclosure Assembly

Houses power supply, PFC,
lamp driver, pan motor
assembly, and display board.

Input Panel

Provides DMX In and Thru,
and AC Power connections.

(see detail below)

Input Panel Components

Yoke Assembly

Houses Master Control
Board (MCB), tilt motor,
ignitor, and cooling fans.

Menu Display

Used to input manual
commands, program, test,
set defaults and access
internal status information.

Data Thru

AC Input

6 02.9704.0010 0

Data In

COMPONENTS : HEAD AND YOKE COMPONENTS

1

Head and Yoke Components

The following illustration shows the major sub-assemblies which are located in the luminaire head and
yoke assemblies.

Head Cover

(attached by tether)

Color Module Assembly

Contains fixed color wheels,
dimmer mechanism, strobe

mechanism, CYM color mixer
and CTO color correction.

Yoke Arm
Cover

Shutter/Gobo/Animation Assembly

Contains two rotating gobo / effects wheels,
four-blade shutter mechanism, two rotating
animation sheels, and iris mechanism

Backend Assembly

Houses lamp, reflector, and
UV/IR assembly.

Y oke Arm Cover

Head Cover

(attached by tether)

Spot Optics Assembly

Houses zoom lenses
and edge mechanisms.

02.9704.0010 0 7

Enclosure Assembly

see page 8

VARI❋LITE - VL4000 SPOT LUMINAIRE SERVICE MANUAL

Enclosure Components

The following illustration shows the major sub-assemblies which are located in the luminaire
enclosure assembly. (Yoke and head assemblies not shown for clarity.)

Enclosure Top Covers

Pan Motor Assembly

Enclosure Handle

Lamp Driver

Pan Tube Assembly

36 VDC / Low-Voltage
Power Supply

Fan Assembly

Enclosure Handle

Input Panel Assembly

Contains DMX Input, PCB
AC Input, and Menu Display

PFC Supply

8 02.9704.0010 0

Bracket Mounting Buttons

CHAPTER 2.

Rountine Maintenance

This chapter contains test, service, and standard maintenance procedures.

• Troubleshooting

• Routine Maintenance Procedures

Note: This manual is a preliminary release version. Additional maintenance

procedures and information will be released in an updated version of the manual.

WARNING: All maintenance procedures are to be performed with power
removed from the luminaire. Never remove cover or backcap while lamp is in oper­ation.

WARNING: Maintenance, repairs, and adjustments should only be performed by
a qualified, factory-trained service technician at an Authorized VARI❋LITE
Service Center.

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VARI❋LITE - VL4000 SPOT LUMINAIRES SERVICE MANUAL

Troubleshooting

Error Messages

If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu
Display will cycle through any applicable error message(s) until the end of the list is reached. To
review the error messages again, it will be necessary to access them using the Status function.

To access error messages:

Step 1. Press [ESC].
Step 2. Press [Up] / [Down] arrows until Fixture appears. Press [OK].
Step 3. Press [Up]/ [Down] arrows to access Status. Press [OK]. (Display will now scroll through

any error messages or display OK if no errors).

Table 2-1: Error Messages

Display Meaning

OK No Errors Found - All Sensors Responded Properly

Pan Sensor Pan Senso r (Encoder) Error

Tilt Sensor Tilt Sensor (Encoder) Error

Dimmer Sensor Dimmer Sensor Error

Cyan Sensor Cyan Color Sensor Error

Yellow Sensor Yellow Color Sensor Error

Magenta Sensor Magenta Color Sensor Error

CTO Sensor CTO Sensor Error
Color Whl1 Sensor Color Wheel 1 Sensor Error
Color Whl2 Sensor Color Wheel 2 Sensor Error

Gobo Whl1 Sensor Rotating Gobo Wheel 1 Sensor Error

Gobo 1 Index Sensor Rotating Gobo Wheel 1 Indexing Sensor Error

Gobo Whl2 Sensor Rotating Gobo Wheel 2 Sensor Error

Gobo 2 Index Sensor Rotating Gobo Wheel 2 Indexing Sensor Error

Animation Whl1 Sensor Animation Wheel 1 Sensor Error

Animation 1 Index Sensor Animation Wheel 1 Indexing Sensor Error

Animation Whl2 Sensor Animation Wheel 2 Sensor Error

Animation 2 Index Sensor Animation Wheel 2 Indexing Sensor Error

Prism Sensor Prism Mechanism Sensor Error

Prism Rotate Sensor Prism Rotating Sensor Error

Prism Diverge Sensor Prism Diverge Sensor Error

Frost Sensor Frost Mechanism Sensor Error

Frost Adjust Sensor Frost Adjustment Sensor Error

Zoom Sensor Zoom Assembly Sensor Error

10 02.9704.0010 0

TROUBLESHOOTING : TROUBLESHOOTING GUIDE

Troubleshooting Guide

If a problem is suspected, try recalibrating the luminaire to prompt an error message. If a problem is
suspected, first try recalibrating the luminaire to prompt an error message (refer to “Error Messages”

on page 10). The chart below provides possible causes and remedies for various error messages and/or

symptoms.

CAUTION: Some troubleshooting is included for reference only. Performing remedies may void
product warranty. Refer to the Vari-Lite Limited Warranty card included with the product.

Table 2-2: Troubleshooting Guide

Message Symptom Description Possible Cause/Remedy

Lamp
Power
Douse

n/a Lamp douses frequently Lamp Douse Fan failure...

n/a Lamp will not strike Lamp Strike Failure Lamp cutout switch disengag ed...

n/a Luminaire behaves

n/a Luminaire does not

n/a Self tests will not run or

n/a No response to DMX

Lamp does not strike
upon start-up

oddly

power up

software download does
not work from luminaire.

data

Lamp Off option is config­ured

DMX Map Not Matched Console library not set correctly...

No power Circuit not energized...

DMX Data Input Detecting DMX data...

DMX Failure DMX connector disconnected...

- Reconfigure lamp startup option in Lamp config
menu.

- check head and enclosure fans for proper
operation.

Ballast overheating...

- operating within the specified ambient
temperature?

- check enclosure vents for debris / dirt.

- check fan settings in menu.

- check enclosure fans for proper operation.

NOTE: Upon initial power up, ballast fans will run for
a few seconds and then operate as needed.
Enclosure vents must be clear of debris and dirt to
allow proper airflow.

- check lamp cutout switches at lamp box and fan
ducts.

Bad lamp...

- replace lamp.

Low input voltage...

- check input power (must be 200 to 240 VAC).

- check console library matches DMX map of
luminaire.

- verify circuit breaker (at source) is turned on.

Not plugged in...

- ensure A/C cable is connected to power source.

- disconnect DMX input cable.

- check DMX DATA IN connection.

2

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VARI❋LITE - VL4000 SPOT LUMINAIRES SERVICE MANUAL

Message Symptom Description Possible Cause/Remedy

n/a Erratic control of

luminaire

DMX Termination No DMX termination or termination not correct...

- check for DMX terminator.

- Luminaire DMX address does not match console
patch.

12 02.9704.0010 0