Philips Vari-Lite VL440, Vari-Lite VL880, Vari-Lite VL770 Service Manual

Neutrik, PowerCon, and EtherCon are registered trademarks of Neutrik, Inc. All other brand or product names
which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or
organizations.

The information furnished in this manual is for informational use only and is subject to change without notice.
Please check www.vari-lite.com for latest version. Philips Vari-Lite assumes no responsibility or liability for any
errors or inaccuracies that may appear in this manual. All information and graphics are property of Philips Vari­Lite, 10911 Petal Street, Dallas, Texas 75238.

Version as of: 19 December 2011

Part number: 02.9687.0010 0

VL440 / VL770 / VL880 Spot Luminaires Service Manual

©2011, Vari-Lite, a Philips group company. All Rights Reserved.

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 (obtained from the Vari-Lite web site www.vari-lite.com or through customer
service) 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:

Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
Attention: Warranty Service / RMA Number

FOREWORD

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

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES 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 instal and used in accordance with
Vari-Lite system, service, and safety guidelines, may cause harmful interferenc e 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 declare, under our sole responsibility, that this product complies with the relevant clauses of the
following standards and harmonized documents:

Safety

EN 60598-1:2008 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989/A2: 1991 Specification for Luminaires for Stage and Studio Lighting

EMC

EN 61000-6-2: 2005 Immunity Standard for industrial environment
EN 61000-6-4: 2007 Radiated and Conducted Emissions

W e certify that the product conforms to the protection requirements of Low Voltage Directive 2006/95/
EC and Council Directive 2004/108/EC.

ii 02.9687.0010 0

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 RADIATION, AND INJURY TO PERSONS CAN BE
FOUND BELOW.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE

1. VARI❋LITE luminaires have been designed for use with specific light sources. The VL440 /
VL770 / VL880 Spot Luminaires uses a special type of light source. Installing another type of light
source will be hazardous and void the luminaire warranty.

2. Luminaires may be mounted on any type of surface as long as mounting instructions are followed.
See instructions detail 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.

02.9687.0010 0 iii

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

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

1. Many VARI❋LITE luminaires us e 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. Wear eye protection when relam ping.

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

5. 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.

6. 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.

iv 02.9687.0010 0

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 Beleuchtungen sind für Gebrauch mit spezifischen Lichtquellen bestimmt worden.
Die VL440 / VL770 / VL880 Spot Luminaires Beleuchtung benutzt eine spezielle Art ­Lichtquelle. Eine andere Art Lichtquelle anzubringen ist gefährlich und hebt die
Beleuchtunggarantie auf.

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 - VL440 / VL770 / VL880 SPOT LUMINAIRES 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. Tragen Sie beim Austausch der Lampen einen Augenschutz.

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

5. Wenn die Lampe mit bloßen Händen b erührt wird, reinigen Sie sie mit denaturiertem Alkohol und
einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen.

6. 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.

vi 02.9687.0010 0

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. Des appareils d'éclairage de VARI❋LITE ont été conçus pour l'usage avec des sources lumineuses
spécifiques. L'appareil d'éclairage de VL440 / VL770 / VL880 Spot Luminaires emploie un type
spécial de source lumineuse de . L'installation d'un autre type de source lumineuse sera dangereuse
et videra la garantie d'appareil d'éclairage.

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 - VL440 / VL770 / VL880 SPOT LUMINAIRES 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.

viii 02.9687.0010 0

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. Los alumbrados de VARI❋LITE se han diseñado para el uso con fuentes de luz específicas. El
alumbrado de VL440 / VL770 / VL880 Spot Luminaires utiliza un tipo especial de fuente de luz
del . La instalación de otro tipo de fuente de luz será peligrosa y anulará la garantía del alumbrado.

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 VARI❋LITE .

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

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES 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. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando trabaje con
lámparas dañadas.

4. 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.

5. 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.

x 02.9687.0010 0

FOREWORD

02.9687.0010 0 xi

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

xii 02.9687.0010 0

Table of Contents

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

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

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

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

Chapter 1. Description

Features

Mechanical................................................................................................................... 4

Optical.......................................................................................................................... 5

Operational................................................................................................................... 5

Technical Specifications .............................................................................................. 6

Components

VL440 / VL770 / VL880 Spot Luminaires External Components.............................. 7

VL440 / VL770 / VL880 Spot Luminaires Components............................. ..... ..... ...... 8

VL440 / VL770 / VL880 Spot Luminaires Head Components................................... 9

VL440 / VL770 / VL880 Spot Luminaires Enclosure Components.......................... 10

Principles of Operation

VL440 / VL770 / VL880 Spot Luminaires Functional Block Diagram.................... 11

TABLE OF CONTENTS

Chapter 2. Maintenance

Testing

Luminaire Self-Tests....................................................................... ........................... 14

Calibration Sequence................................................................................................. 14

Sensor Testing............................................................................................................ 14

Troubleshooting

Error Messages........................................................................................................... 15

Troubleshooting Guide .............................................................................................. 16

Special Care and Handling

Introduction................................................................................................................ 17

Special Cleaning and Care Instructions..................................................................... 17

General Care and Equipment Handling..................................................................... 17

Locations/Use...................................................................................................... 18

Solid State Electronics............................................................................................... 18

Electrostatic Discharge (ESD)............................................................................. 18

Printed Circuit Boards (PCBs)............................................................................ 18

Maintenance Procedures

Front Cover Assembly Removal................................................................................ 19

Rear Cover Assembly Removal................................................................................. 20

Lamp Removal and Installation................................................................................. 21

Gobo Module Assembly Removal............................................................................. 23

CYMD Module Assembly Removal.......................................................................... 24

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

Zoom Module Assembly Removal............................................................................. 25

Main Control Unit (MCU) Assembly Removal......................................................... 27

Driver Board Assembly Removal .............................................................................. 28

Front Lens Assembly Removal........................................................ .......................... 30

UV / IR Filter Assembly Removal............................................................................. 31

Edge Motor Assembly Removal ................................................................................ 32

Tilt Motor Assembly / Tilt Encoder / Tilt Belt Removal ........................................... 34

Tilt Sensor Removal................................................................................................... 36

Tilt Stabilizer Removal............................................................................................... 38

Ignitor Removal.......................................................................................................... 40

Lamp Socket Removal ............................................................................................... 42

Reflector Removal...................................................................................................... 45

CYMD Wheel Replacement....................................................................................... 47

Strobe Assembly Replacement................................................................................... 50

Dimmer or Magenta Motor Assembly Replacement.................................................. 51

Strobe Blade Replacement ......................................................................................... 52

Cyan or Yellow Motor Replacement .......................................................................... 53

Fixed Color Wheel Replacement................................................................................ 54

Rotating Gobo Wheel Replacement........................................................................... 55

Fixed Gobo Wheel Replacement................................................................................ 57

Iris Assembly Replacement........................................................................................ 59

Ballast / LVS Assembly Replacement........................................................................ 60

DMX PCB Assembly Replacement ........................................................................... 61

PowerCon (AC Input) Assembly Replacement.......................................................... 63

Display PCB Assembly Replacement....................................................... ..... ............ 65

Wireless DMX Interface PCB Assembly Replacement ............................................. 67

Pan Motor Assembly Replacement............................................................................ 69

Pan Belt Replacement................................................................................................. 71

Pan Stabilizer Replacement........................................................................................ 73

Enclosure Fan Assemblies Replacement.................................................................... 75

Chapter 3. Illustrated Parts Breakdown

Drawing Trees

VL440 Spot Luminaire Drawing Tree........................................................................ 78

VL770 Spot Luminaire Drawing Tree........................................................................ 80

VL880 Spot Luminaire Drawing Tree........................................................................ 82

Top Assembly

Included Items Kit...................................................................................................... 84

VL440 Spot Luminaire............................................................................................... 86

VL770 Spot Luminaire............................................................................................... 90

VL880 Spot Luminaire............................................................................................... 94

Front Head Cover Assembly...................................................................................... 98

Rear Head Cover Assembly ............................................................................... ..... ... 99

Lamp Cover Assembly............................................................................................. 100

Transfer Fans Assembly........................................................................................... 101

Dual Gobo Cooling Blower Assembly..................................................................... 102

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TABLE OF CONTENTS

Generic Luminaire Assembly.................................................................................. 103

Head Assembly

Head Frame Assembly............................................................................................. 105

Left Tilt Bearing Assembly...................................................................................... 108

Right Tilt Bearing Assembly................................................................................... 109

Linear Roller Assembly........................................................................................... 111

Lamp Housing Assembly......................................................................................... 112

Tilt Motor Assembly................................................................................................ 115

Pulley Pinion Assembly........................................................................................... 117

Gobo Module Assembly.......................................................................................... 118

Wedge Fixed Color Wheel Assembly.......................................................... ..... ....... 122

Rotating Gobo Wheel Assembly ............................................................................. 123

Fixed Gobo Wheel Assembly.................................................................................. 124

CYMD Color Module Assembly............................................................................. 125

Left Flag Motor Plate Assembly.............................................................................. 127

Right Flag Motor Plate Assembly............................................................................ 128

Zoom Assembly....................................................................................................... 129

Prism Assembly....................................................................................................... 132

Frost Assembly ........................................................................................................ 134

Zoom Linear Slide Assembly .................................................................................. 135

Front Carrier Assembly.......................................................... .................................. 136

Rear Carrier Assembly...................................................................................... ..... .. 137

Enclosure Assembly

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

Pan Motor Assembly......................................................... ....................................... 144

Note: Cables are only available as complete assemblies. The information contained in
this section is for reference only.

Cable Assemblies

Chassis To Yoke Ground Cable Assembly .............................................................. 147

AC Input Cable Assembly......................................................... ..... ......................... 148

DMX / Display Comm Cable Assembly ................................................................. 149

Ballast Comm Cable Assembly............................................................................... 150

36 Volt Supply Cable Assembly .............................................................................. 151

Ballast to Ignitor Cable Assembly........................................................................... 152

Pan Motor Cable Assembly..................................................................................... 153

Pan Encoder Cable Assembly.................................................................................. 154

Tilt Cable Assembly................................................................................................. 155

Edge Cable Assembly.............................................................................................. 156

Zoom Group Cable Assembly ................................................................................. 157

CYMD Group Cable Assembly............................................................................... 158

Gobo Group Cable Assembly.................................................................................. 159

Lamp to Fans Cable Assembly................................................................................ 160

Tilt Sensor Cable Assembly..................................................................................... 161

Slotted Optical Switch Cable Assembly.................................................................. 162

VL440 - VL770 Lamp Socket / Cable Assembly.................................................... 163

VL880 Lamp Socket / Cable Assembly................................................................... 164

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

800 Watt Ballast Comm Cable Assembly................................................................ 165

Sensor Index Cable Assembly.................................................................................. 166

APS Fan Cable Assembly ........................................................................................ 167

AUX Comm Interface Cable Assembly................................................................... 168

Appendix A. Technical Bulletins and Notices

VL440 / VL770 / VL880 Spot Luminaires Technical Bulletins and Notices .......... 169

xvi 19 December 2011 02.9687.0010 0

Introduction

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all
configurations of the VL440 / VL770 / VL880 Spot Luminaires. The manual is intended for use by
Vari-Lite personnel and Authorized VARI❋LITE Service Centers and technicians.

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:

INTRODUCTION : ABOUT THIS MANUAL

Model Part Number Lamp Type

VL440 Spot 20.9687.0002

VL770 Spot 20.9687.0003

VL880 Spot 20.9687.0004

400W MSR Gold 400

MiniFastFit Lamp

700W MSR Gold 700

MiniFastFit Lamp

800W MSR Platinum

35 Lamp

Color Mixing

System

CYM /

8 Filters

CYM /

8 Filters

CYM /

8 Filters

Dimmer

Glass Dimmer

Wheel

Glass Dimmer

Wheel

Glass Dimmer

Wheel

Gobo

Positions

7 Rotating /

(1)

10 Fixed
7 Rotating /

(2)

10 Fixed
7 Rotating /

(2)

10 Fixed

Luminaire

Body Color

Black

Black

Black

Notes:

• (1) = Luminaire accepts metal and glass gobos.

• (2) = Luminaire accepts glass gobos only.

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 VL440 / VL770 / VL880 Spot
Luminaires User’s Manual. This manual is available in electronic (PDF) format on the Vari-Lite web
site at www.vari-lite.com in the Support (Product Downloads) section.

• VL440 / VL770 / VL880 Spot Luminaires User’s Manual (02.9687.0001)

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
315 South Crouse Avenue, Suite 200
Syracuse, NY 13210-1844
Phone: [phone] or 315-463-6463

www.usitt.org

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES 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, 7am - 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 SVL-001 (VL440 / VL770 / VL880 Luminaires
Technical Bulletin number 1) or LSW-001 (Software release technical bulletin).

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).

A list of current technical bulletins and notices associated with VL440 / VL770 / VL880 Spot
Luminaires are found in “VL440 / VL770 / VL880 Spot Luminaires Technical Bulletins and Notices”

on page 169.

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CHAPTER 1.

Description

This chapter contains descriptions of luminaire features and components.

• Features

• Components

• Principles of Operation

SERVICE

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

Features

Mechanical

Color Mixing System

All models feature a three filter CYM cross-fading
mechanism plus a fixed color wheel with 8
interchangeable color filters and 1 open space. Fixed
wheel is capable of continuous rotation for additional
effects.

Gobo Wheels

• All models feature one rotating gobo wheel with seven
rotatable, indexable gobo positions and one open
position. One fixed gobo wheel with 10 easily loaded
patterns and one open position capable of continuous
rotation for additional effects. 17 total gobos positions.

• VL440 Spot accepts both metal and glass gobos.

• VL770 & VL880 Spot accept glass gobos ONLY!.

Frost and Prism Capability

Independent, drop-in armature with frost glass. Second, independent, drop-in armature with
rotating and indexable four facet prism. Both the frost and prism pieces are interchangeable.

Pan/Tilt

Smooth, time-controlled continuous motion by way of a high-power, three-phase stepper
motor system.

• Range: Pan - 540° , Tilt - 260°.

• Pan/Tilt Accuracy: 0.3° resolution.

Weights:

• VL440 Spot: 56 lbs. (25.5 kg)

• VL770 Spot: 56 lbs. (25.5 kg)

• VL880 Spot: 56 lbs. (25.5 kg)

Spacing:

All models hang on 23 inch (58.5 cm) centers.

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FEATURES : OPTICAL

Optical

Source

Model Lamp Color Temperature Output

VL440 Spot 400W MSR Gold 400 MiniFastFit Lamp 6000K 9,000 Lumens
VL770 Spot 700W MSR Gold 700 MiniFastFit Lamp 6000K 15,000 Lumens
VL880 Spot 800W MSR Platinum 35 Lamp 6000K 19,000 Lumens

Reflector

Precision facetted, elliptical glass reflector system with dichroic cold mirror coating.

Zoom Optics / Control

• All models feature a high-speed, precision zoom optical system with continuously variable field
angle from approximately 15° to 36°; programmable over a timed range of 1.5 seconds to 20
minutes.

• Variable beam focus to soften edges of gobos or spots.

1

Intensity Control

All models contain a coated glass dimmer wheel provides full-field dimming designed for
smooth timed fades. These models also feature a high-performance dual blade strobe
system capable of ultra-fast operation.

Operational

Power Requirements

• VL440 Spot: S t andard AC power d istribution from 10 0 - 240VAC, 50/60 Hz. The unit requires up to

6.6A (at 100V) depending on the AC supply voltage.*

• VL770 Spot: S t andard AC power d istribution from 10 0 - 240VAC, 50/60 Hz. The unit requires up to

10.2A (at 100V) depending on the AC supply voltage.*

• VL880 Spot: S t andard AC power d istribution from 10 0 - 240VAC, 50/60 Hz. The unit requires up to

12.0A (at 100V) depending on the AC supply voltage.*

Note: *For a breakdown of total luminaire current draw at dif ferent voltages for all models covered in
this manual, see product user’s manual.

Operational Temperature

-20° to 122°F (-29° to 50°C)

Cooling

Forced-air cooling.

Control

Control by DMX512 protocol. Compatible with a wide variety of DMX512 consoles.

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

DMX Channels

30 channels.

Mounting Position

• The luminaire can be mounted and operated in any orientation.

Technical Specifications

For additional technical specifications, refer to VL440 / VL770 / VL880 Spot Luminaires User’s
Manual (02.9687.0001) or the Vari-Lite web site at www.vari-lite.com.

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COMPONENTS : VL440 / VL770 / VL880 SPOT LUMINAIRES EXTERNAL COMPONENTS

Components

VL440 / VL770 / VL880 Spot Luminaires External Components

The following illustration shows the external luminaire components and controls.

Head Assembly

Optics, color system, gobo
gobo assembly, lamp, and
cooling fans, tilt motor, and
MCB.

Truss Hook Brackets

Attaches to upper enclosure
to allow truss hook installation.

(Truss hooks sold separately)

1

Upper Enclosure Assembly

Houses power supply, pan motor,
and display board.

Menu LCD Display

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

(see detail below)

Input Panel

AC Input
Cable*

Menu LCD Display Panel

Arrow Keys (Left/Right/Up/Down)

To Menu Navigate Menu Options
and make Data Selections

Data In
Data Thru

ENTER

Yoke Assembly

Input Panel

Provides DMX In and Thru,
and AC Power connections.
(see detail below)

Upper Enclosure Components

*3-Pole Neutrik PowerCon Locking
Connector for AC Input Power (supplied).
User must construct power input cable.

LCD Display

Displays all Data and
Luminaire Settings

POWER

TX

RX

ERROR

ESC

Status LEDs

Power State, Data T ransmit, Data
Receive, Data Error

Enter Button

To Select or Change a
Setting or Data Value

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Escape (ESC)

To Exit or Go to
Previous Menu Item

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

VL440 / VL770 / VL880 Spot Luminaires Components

The following illustration shows the major sub-assemblies and components of the luminaire.

Luminaire Rear Head Cover

Head Assembly

See “VL440 / VL770 / VL880 Spot Luminaires
Head Components” on page 9.

Yoke Arm Covers

Two covers, one on each side
of yoke assembly.

Luminaire Front Head Cover

Enclosure Covers

One on each end of enclosure
assembly, two with handles.

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Ballast and Low Voltage Supply Assembly

Supplies power for lamp and luminaire operation.

Enclosure Assembly

See “VL440 / VL770 / VL880 Spot Luminaires
Enclosure Components” on page 10.

COMPONENTS : VL440 / VL770 / VL880 SPOT LUMINAIRES HEAD COMPONENTS

VL440 / VL770 / VL880 Spot Luminaires Head Components

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

Head Transfer Fans

Provides more air circulation
and cooling capacity.

Main Control Board

Main control unit and
driver PCBs

Fixed Gobo / Fixed Color /
Rotating Gobo Assembly

10 fixed gobo positions, 7
rotating gobo positions, and
8 fixed color positions.

CYM Color System & Dimmer

CYM color mixing wheels, glass
dimmer, and strobe assembly.

1

Optics

Zoom optics for beam
control and focus.

Cradle Assembly

Connects head to yoke
and contains tilt motor
assembly.

Solid-State Ignitor

For striking lamp.

Lamp Housing

Contains lamp, lamp
socket, and cooling fans.

Pan Lock

For locking yoke pan
for service or transport.

Tilt Lock

For locking head tilt
for service or transport.

Note:

Enclosure assembly not shown for clarity.

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

VL440 / VL770 / VL880 Spot Luminaires Enclosure Components

The following illustration shows the major sub-assemblies which are located in the luminaire
enclosure assembly.

LCD Display Assembly

For addressing, accessing

menu options and settings. See

page 7 for details.

Wireless DMX Interconnect

Allows connection of optional
wireless DMX module

Input Panel Assembly

Contains DMX Input
PCB and AC Input*

Fan Assemblies

Pan Motor Assembly

Enclosure Cover Plate

Note:

Other assemblies not shown for clarity.
Power supply (not shown) is part of the
generic luminaire assembly but is housed
in the enclosure assembly.

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*AC Input

Requires standard AC power
distribution from 100-240 VAC, 50/
60 Hz., current depends on the AC
supply voltage. See user’s manual
for more information on current
draw

Wire** Connection

Green/Yellow AC Ground

Blue AC Neutral

Brown AC Line

** International (Harmonized) Standard

PRINCIPLES OF OPERATION : VL440 / VL770 / VL880 SPOT LUMINAIRES FUNCTIONAL BLOCK DIA-

GRAM

Principles of Operation

VL440 / VL770 / VL880 Spot Luminaires Functional Block Diagram

1

ENTER

ESC

Lamp

Socket

Lamp

Ignitor

Ballast / Low-Voltage Supply

Assembly

Sensor

Sensor

Rotating

Sensor

Rotating

Sensor

LCD Display

DMX
Input

Ballast COM

Enclosure

Fans

Fixed

Rotating

Fixed

36V

Gobo

Gobo

Gobo
Index

Color

COT

Sensor

Iris

Motor

Frost

Assembly

Zoom
Motor

Prism

Assembly

Prism

Rotate

Main Control Unit PCB

Main Control Board

(MCB) Assembly

Driver PCB

Tilt

Motor

Sensor

Sensor

Sensor

Pan

Motor

Sensor

Sensor

Sensor

Sensor

Edge

Motor

Lamp

Housing

Fans

Dual Gobo

Blower*

Cyan

Wheel

Yellow
Wheel

Magenta

Wheel

Dimmer

Wheel

Right

Strobe

Left

Strobe

Sensor

Head

Transfer

Fans

AC

Input

Tilt

Encoder

Pan

Encoder

*Dual gobo blower assembly is in
VL770 and VL880 Spot fixtures only

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VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL

Notes

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