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 [email protected] 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: [email protected]

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.

2 02.9687.0010 0

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.

4 02.9687.0010 0

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.

6 02.9687.0010 0

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

02.9687.0010 0 7

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.

8 02.9687.0010 0

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.

10 02.9687.0010 0

*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

12 02.9687.0010 0

CHAPTER 2.

Maintenance

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

• Testing

• Troubleshooting

• Special Care and Handling

• Maintenance Procedures

WARNING: All maintenance procedures are to be performed with power com-

pletely removed from the luminaire. Never remove covers while unit 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.

SERVICE

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

Testing

Luminaire Self-Tests

The luminaire is capable of running self tests by using the TEST menu functions. For detailed
instructions regarding the luminaire’s self-test function, refer to the VL440 / VL770 / VL880 Spot
Luminaires User’s Manual (02.9687.0001).

Calibration Sequence

When the luminaire is powered up for the first time, the default setting is enabled and the lamp will
remain off. When AC power is applied, the luminaire will immediately begin a calibration sequence
that steps it through full pan and tilt movements. The internal color and beam mechanisms will also
move through a full range of motion. After calibration, the luminaire head will either stop at its "home"
position (which positions the pan axis at mid-rotation and the head parallel to the yoke with the lens
pointing away from the luminaire enclosure) or move to its current DMX-defined position if DMX
data is present. All internal mechanisms also move to their "home" or DMX-defined positions.

CAUTION: Before applying power, be sure the luminaire is hung (or positioned), and the service tilt
and pan locks are disengaged, so that the head and yoke can move freely without restriction.

Sensor Testing

Most mechanisms within the VL440 / VL770 / VL880 luminaire are equipped with either optical or
magnetic sensors. The VL440 / VL770 / VL880 master control board (MCB) has labeled test points for
reading DC voltages at each sensor. Testing is best performed with a digital voltmeter for sensor
readings or an Oscilloscope for pan/tilt encoder readings. The values can be used to determine whether
a circuit is opening correctly or needs further troubleshooting.

Guidelines:

• The values will change depending on whether the sensor reading is Open or Closed.

• The values will be different depending on the type of sensor: optical or magnetic.

• As a general rule, if a change occurs from 5v to 0v or visa versa, then it is working.

• An Open reading occurs when the sensor is not aligned - tab not at sensor (typically a non-zero
DMX value).

• A Closed reading occurs when the sensor is aligned -tab in or at sensor (typically a zero DMX
value).

• Optical sensors read high when the sensor is Closed.

• Magnetic sensors read Low when the sensor is Closed.

• High value - 5 volts (typically 4.9 volts).

• Low value - 0 volts, or up to approximately 0.2 volts.

Notes regarding specific mechanisms:

• Tilt sensor reads high when the tab is in the sensor. The mechanism calibrates to the edge and its
tab covers 50% of travel. Pan and tilt encoders are best read with a scope to read the encoder ticks.

14 02.9687.0010 0

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), one at a time 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. (Refer to “Troubleshooting Guide” on page 16 for a list of possible causes and remedies
associated with the error messages.)

To access error messages:

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

through any error messages or display OK if no errors.)

Pan/Encoder/Fail Pan encoder failure.

Tilt/No Sens Tilt sensor not found.

Tilt/Encoder/Fail Tilt encoder failure.

Index/No Sens Gobo Index sensor not found.

RotGobo/No Sens Rotating Gobo wheel sensor not found.

FixGobo/No Sens Fixed Gobo wheel sensor not found.

Dimmer/No Sens Dimmer sensor not found.

Cyan/No Sens Cyan sensor not found.

Yellow/No Sens Yellow sensor not found.

Magenta/No Sens Magenta sensor not found.

ColWheel/No Sens Color wheel sensor not found.

Zoom/No Sens Zoom sensor not found.
Edge/No Sens Edge sensor not found.

TROUBLESHOOTING : ERROR MESSAGES

2

Display Message

OK No Errors Found

WARNING: As with any repairs or maintenance to VARI❋LITE luminaires, service should only be
performed by a trained and qualified service technician or at an Authorized VARI❋LITE
Center.

02.9687.0010 0 15

Service

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

Troubleshooting Guide

If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error

Messages” on page 15 for more information. The chart below provides possible causes and remedies

for various error messages and/or symptoms.

Table 2-1: 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 disengaged...

n/a Luminaire behaves

n/a Luminaire does not

n/a Self tests will not run or

n/a No response to DMX

n/a Erratic control of lumi-

Lamp does not strike
upon start-up

oddly

power up

software download does
not work from luminaire.

data

naire

Lamp Off option is config­ured

Profile Not Matched Profile not set correctly...

No power Circuit not energized...

DMX Data Input Detecting DMX data...

DMX Failure DMX connector disconnected...

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

- 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 100 to 240 VAC).

- check Setup menu for correct type (console patch
/ profile).

- 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.

- check for DMX terminator.

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SPECIAL CARE AND HANDLING : INTRODUCTION

Special Care and Handling

WARNING: As with any repairs or maintenance to VARI❋LITE luminaires, service should only be
performed by a trained and qualified service technician or at an Authorized VARI❋LITE
Center.

Introduction

The VL440 / VL770 / VL880 Spot Luminaires requires very little routine maintenance by the user.
This section covers all the parts or assemblies that can be removed, cleaned, and checked by the user.
Any additional maintenance or service should only be completed by an Authorized VARI❋LITE
Service Center.

Special Cleaning and Care Instructions

The VL440 / VL770 / VL880 Spot Luminaires requires special care when it comes to cleaning front
and internal lens assemblies.

2

Service

The following is a list of cleaning materials required to care for your VL440 / VL770 / VL880 Spot
Luminaires:

• Lint free lens tissue

• Lint free cotton swabs (for hard-to-reach spot cleaning)

• Lint or powder free gloves

• Reagent grade isopropyl alcohol

• A mild soap solution.
Reagent grade isopropyl alcohol is good to use on the VL440 / VL770 / VL880 Spot Luminaires optics

with anti-reflection coatings.
If the lens is still dirty after using isopropyl alcohol, for instance if fingerprints or oil is just

redistributed and not cleaned off the optic, then a mild soap and water solution can be used to gently
wash the lens. Repeat the cleaning with isopropyl alcohol to eliminate streaks and soap residue.

WARNING: Under no circumstances should ammonia-based cleaners or other harsh solvents be used
on or near the VL440 / VL770 / VL880 Spot Luminaires. These types of cleaners or solvents can
permanently damage the optics or housings of the fixture.

If you have any questions regarding the use or care of your VL44 0 / VL770 / VL880 Spot Luminaires,
please contact Vari-Lite technical support at 1.877-VARI-LITE or +1.214.647.7880.

General Care and Equipment Handling

Below are some basic tips and information on handling VARI❋LITE luminaires and their associated
components.

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

Locations/Use

VARI❋LITE luminaires are designed for dry locations only. Exposure to rain or moisture (including,
but not limited to, fog machines, misters, etc.) may damage luminaires and will void the fixture’s
warranty.

Solid State Electronics

Electrostatic Discharge (ESD)

Electrostatic discharge (ESD) presents a significant danger to solid state electronic components
(semiconductor devices and PC board assemblies). Static electricity can build on a variety of common
objects (including people) simply by handling or moving. ESD rarely resu lts in immediate failure of a
component, but shows up later as an intermittent problem or severely reduces the life of the
component. All VARI❋LITE
protect them should be observed when servicing.

Printed Circuit Boards (PCBs)

products use solid state electronics and appropriate precautions to

All PC boards should be shipped in electrostatic shielding bags. When handling PC boards or
components, devices such as conductive mats and conductive wrist straps should be used whenever
possible. If these precautionary devices are not available, handling of PC boards and components
should be avoided.

CAUTION: Black foam (used to package solid state electronics) should never be used for packing
batteries or put in contact with PC boards which contain batteries.

18 02.9687.0010 0

MAINTENANCE PROCEDURES : FRONT COVER ASSEMBLY REMOVAL

Maintenance Procedures

Front Cover Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove front cover assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. As illustrated in Figure 2-1, remove front head cover by loosening two quarter-turn Dzus

fasteners.

Note: The front cover is secured by a safety tether.

2

Remove power and

CAUTION:

Step 3. Unclip safety tether at cover.
Step 4. Reinstall by performing steps in reverse order.

allow fixture to cool.

Front Head Cover

Quart-Turn Dzus
Fasteners (x2)

Figure 2-1: VL440 / VL770 / VL880 Front Head Cover Removal

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

Rear Cover Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove rear cover assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. As illustrated in Figure 2-1, remove rear head cover by loosening two quarter-turn Dzus

fasteners.

Note: The rear cover is secured by a safety tether.

CAUTION:

Remove power and
allow fixture to cool.

Figure 2-2: VL440 / VL770 / VL880 Rear Head Cover Removal

Step 3. Unclip safety tether at cover.
Step 4. Reinstall by performing steps in reverse order.

Rear Head Cover

Quart-Turn Dzus
Fasteners (x2)

20 02.9687.0010 0

MAINTENANCE PROCEDURES : LAMP REMOVAL AND INSTALLATION

2

Lamp Removal and Installation

WARNING: Ensure that power is completely removed from luminaire when removing or installing
lamp.

CAUTION: Wear cotton gloves or other covering while installing lamp. Touching lamp glass with
bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If touched, use
isopropyl alcohol and cotton cloth to thoroughly clean glass portion of lamp.

To remove and install lamp:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Set the luminaire head horizontally.
Step 3. Engage service tilt lock to secure luminaire head in position.
Step 4. At back of luminaire, using #2 Phillips screwdriver, remove lamp socket cover by loosening

the two quarter-turn fasteners. Note: lamp socket cover is connected with a safety tether.

Lamp Socket

Lamp

Lamp Socket
Cover

Quarter-Turn
Fasteners

Figure 2-3: Lamp Socket Cover Removal

Step 5. Remove old lamp from socket by rotating lamp base counter-clockwise until lamp tabs align

with lamp socket slots.

02.9687.0010 0 21

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

Step 6. As shown in Figure 2-4, align lamp tabs with lamp socket.

Align tabs of lamp with
socket when installing

Lamp*

NOTE: * "Bow" of
lamp must be oriented
with "Slot" in reflector.

Bow

Lamp Socket Cover

Figure 2-4: Lamp Installation

Step 7. Install lamp fully into lamp socket, taking care not to touch lamp glass.
Step 8. Turn lamp clockwise to seat lamp into socket. Lamp base should be aligned as illustrated in

Figure 2-5.

Lamp

Note alignment of fully seated lamp

Ensure lamp is completely
seated before reinstalling lamp
socket cover.

Figure 2-5: Installed Lamp

Step 9. Reinstall lamp socket cover . Make sure safety tether is completely encapsulated within lamp

socket cover.
Step 10. Disengage service tilt lock to allow luminaire head to move freely.
Step 11. Align lamp as described in the luminaire’s users manual.

22 02.9687.0010 0

MAINTENANCE PROCEDURES : GOBO MODULE ASSEMBLY REMOVAL

2

Gobo Module Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove gobo module assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. At MCU, disconnect lamp fans harness at J6.
Step 4. At Driver Board, disconnect Gobo Module and CYMD Module harness.
Step 5. For VL770 and VL880 luminaires only - disconnect H1, H5 & H6 fan connectors.

CAUTION: In next step, be extremely careful when removing gobo module assembly so you do not
damage gobos or color filters.

Step 6. As shown in Figure 2-6, loosen two captive fasteners and carefully pull Gobo Module

assembly from luminaire.

Captive Fasteners

Gobo Module Assembly

CYMD Module Assembly

Remove power and

CAUTION:

Figure 2-6: Gobo Module Assembly Removal

Step 7. Reinstall by performing steps in reverse order.

allow fixture to cool.

02.9687.0010 0 23

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

CYMD Module Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove CYMD module assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. At MCU, disconnect lamp fans harness at J6.
Step 4. At Driver Board, disconnect CYMD Harness.

CAUTION: In next step, be extremely careful when removing CYMD module assembly so you do
not color filters or dimmer wheel.

Step 5. As illustrated in Figure 2-7, loosen two captive fasteners and carefully pull assembly from

luminaire.

Remove power and

CYMD Module Assembly

CAUTION:

Captive Fasteners

allow fixture to cool.

Figure 2-7: CYMD Module Assembly Removal

Step 6. Reinstall by performing steps in reverse order.

24 02.9687.0010 0

MAINTENANCE PROCEDURES : ZOOM MODULE ASSEMBLY REMOVAL

2

Zoom Module Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove zoom module assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. Remove Gobo Module Assembly as described in “Gobo Module Assembly Removal” on

page 23.

Step 4. At Driver Board, disconnect Zoom Module Harness. Cut any cable ties and pull harness

free. DO NOT cut any wires.
Step 5. As indicated in Figure 2-8, loosen captive screw and carefully tilt MCU/Driver Board

assembly open.

CAUTION:

Remove power and
allow fixture to cool.

Figure 2-8: MCU Assembly Captive Screw

MCU / Driver Assembly

Captive Screw

02.9687.0010 0 25

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

Step 6. At bottom of fixture, as shown in Figure 2-9, remove four 8-32 x 1/2" PPZ SEMS screws

securing zoom assembly to head frame assembly.

8-32 x 1/2" PPZ
SEMS Screw (x4)

Zoom Assembly

MCU / Driver Assembly

Figure 2-9: Zoom Module Assembly Removal

Step 7. Carefully remove zoom module assembly from fixture.
Step 8. Replace by performing steps in reverse order.

26 02.9687.0010 0

MAINTENANCE PROCEDURES : MAIN CONTROL UNIT (MCU) ASSEMBLY REMOVAL

2

Main Control Unit (MCU) Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove MCU assembly:

CAUTION: When handling printed circuit boards (such as the MCU assembly) make sure to follow
appropriate precautions to protect them ESD damage.

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front cover assembly as described in “Front Cover Assembly Removal” on page 19.
Step 3. At MCU assembly, disconnect the following cable assemblies:

a. 36Vdc - Connector J7

b. DMX - Connector J10

c. Display Com - Connector J11

d. Ballast Com - Connector J8

e. Head Fans (VL770/880 luminaires only) - Connector J5

f. Wireless Accessory - Connector J12

g. Lamp Fans - Connector J6
Step 4. Remove six 4-40 x 1/2" PPZ screws (as indicated in Figure 2-10).

4-40 x 1/2" PPZ Screws

MCU Board Assembly

Driver Board Assembly

Remove power and

CAUTION:

Step 5. Carefully disconnect MCU from Driver Board and remove from luminaire.

allow fixture to cool.

Figure 2-10: MCU Assembly Removal

Step 6. Replace by performing steps in reverse order.

02.9687.0010 0 27

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

Driver Board Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove driver board assembly:

CAUTION: When handling printed circuit boards (such as the MCU assembly) make sure to follow
appropriate precautions to protect them ESD damage.

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front cover assembly as described in “Front Cover Assembly Removal” on page 19.
Step 3. Remove MCU assembly as described in “Main Control Unit (MCU) Assembly Removal” on

page 27.

Step 4. At driver board assembly, disconnect the following cable assemblies:

a. Pan Motor Power (make note of connector orientation) - Connector J9

b. 36Vdc - Connector J6

c. Zoom Harness

d. Gobo Harness

e. Tilt Harness - Connector J3

f. Pan Encoder - Connector J1

g. Edge Harness

h. CYMD Harness
Step 5. At driver board assembly , remove two 4- 40 x 3/8" PPZ SEMS screws as indicated in Figure

2-10 on page 27.

28 02.9687.0010 0

MAINTENANCE PROCEDURES : DRIVER BOARD ASSEMBLY REMOVAL

NOTE:

Components removed for clarity.

4-40 x 3/8" PPZ
SEMS Screws

2

4-40 x 1/2" PPZ Screw (x6)

MCU Board Assembly

Driver Board Assembly

MCU Board Assembly

Driver Board Assembly

Remove power and

CAUTION:

allow fixture to cool.

Figure 2-11: Driver Board Assembly Removal

Step 6. Remove Driver Board Assembly from luminaire.
Step 7. Replace by performing steps in reverse order.

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

Front Lens Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove front lens assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front cover assembly as described in “Front Cover Assembly Removal” on page 19.
Step 3. At front lens, as indicated in Figure 2-12, remove four 6-32 x 1/4" PFB screws and remove

lens from inside.

Front Lens Assembly

6-32 x 1/4"
PFB Screws

Figure 2-12: Front Lens Assembly Removal

Step 4. Reinstall by performing steps in reverse.

30 02.9687.0010 0

MAINTENANCE PROCEDURES : UV / IR FILTER ASSEMBLY REMOVAL

2

UV / IR Filter Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove UV/IR filter assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. Remove Gobo Module Assembly as described in “Gobo Module Assembly Removal” on

page 23.

Step 4. Remove CYMD Module Assembly as described in “CYMD Module Assembly Removal”

on page 24.

Step 5. As shown in Figure 2-13, at UV/IR Filter Assembly, remove four 8-32 x 3/4" PFB screws

and remove UV/IR Filter Assembly. Note air diverter placement.

Air Diverter

UV / IR Filter Assembly

8-32 x 3/4" PFB
Screw (x4)

Figure 2-13: UV / IR Filter Assembly Removal

Step 6. Reinstall by performing steps in reverse.

NOTE:

Components removed for clarity.

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

Edge Motor Assembly Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove edge motor assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. Remove Gobo Module Assembly as described in “Gobo Module Assembly Removal” on

page 23.

Step 4. Remove CYMD Module Assembly as described in “CYMD Module Assembly Removal”

on page 24.

Step 5. Remove Zoom Module Assembly as described in “Zoom Module Assembly Removal” on

page 25.

Step 6. Disconnect H3 fan and power from edge motor assembly.
Step 7. Remove four 4-40 x 1/4" PPB SEMS screws, as shown in F igur e 2-14, securing edge motor

assembly.

4-40 x 1/4" PPB
SEMS Screw (x4)

Edge Motor
Assembly

NOTE:

Components removed for clarity.

Figure 2-14: Edge Motor Assembly Removal

Step 8. Rotate motor shaft from edge carrier and remove motor.

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MAINTENANCE PROCEDURES : EDGE MOTOR ASSEMBLY REMOVAL

2

Step 9. Reinstall by performing steps in reverse.

Note: When reinstalling edge motor assembly , the connector orientation should face in the downward
position as shown in Figure 2-15.

Note position of edge
motor connector.

Figure 2-15: Edge Motor Assembly Connector Orientation

02.9687.0010 0 33

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

Tilt Motor Assembly / Tilt Encoder / Tilt Belt Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove tilt motor assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. Remove Gobo Module Assembly as described in “Gobo Module Assembly Removal” on

page 23.

Step 4. Remove CYMD Module Assembly as described in “CYMD Module Assembly Removal”

on page 24.

Step 5. Remove Zoom Module Assembly as described in “Zoom Module Assembly Removal” on

page 25.

Step 6. Cut cable tie connecting wiring to bottom of motor assembly.
Step 7. Disconnect wiring from motor assembly and tilt encoder PCB.
Step 8. As shown in Figure 2-16, remove three 8-32 x 3/8" PPB SEMS screws.

Tilt Belt

Tilt Encoder PCB

NOTE:

Components removed for clarity.

8-32 x 3/8" PPB
SEMS Screw (x3)

Tilt Motor
Assembly

Figure 2-16: Tilt Motor Assembly Removal

Step 9. Carefully, remove tilt belt from pulley and remove motor assembly. Note, when installing,

loop tilt belt around pulley.
Step 10. Start all three 8-32 x 3/8" PPB SEMS screws but do not tighten at this time.
Step 11. Insert flat blade screwdriver into slot between bottom two screws and pull motor assembly

to tighten belt tension (should be tight). Then tighten three 8-32 x 3/8" PPB SEMS screws.
Step 12. Continue reassembly by following previous steps in reverse order.

34 02.9687.0010 0

MAINTENANCE PROCEDURES : TILT MOTOR ASSEMBLY / TILT ENCODER / TILT BELT REMOVAL

To remove tilt encoder

Step 1. Remove tilt motor assembly following procedure in “Tilt Motor Assembly / Tilt Encoder /

Tilt Belt Removal” on page 34.

Step 2. Remove two 4-40 x 1/4" PPG SEMS screws and associated nylon spacers and remove Tilt

Encoder PCB.

4-40 x 1/4" PPB
SEMS Screw (x2)

Tilt Encoder PCB

Nylon Spacer (x2)

Tilt Motor
Assembly

2

NOTE:

Components removed and exploded for clarity.

Step 3. Reassemble following steps in reverse order.

To remove tilt belt:

Step 1. Remove tilt motor assembly following procedure in “Tilt Motor Assembly / Tilt Encoder /

Tilt Belt Removal” on page 34.

Step 2. Disconnect all wiring coming through tilt belt side tilt tube, from inside head assembly.
Step 3. Cut any cable ties required
Step 4. Carefully, pull wiring through tilt belt.
Step 5. Remove tilt belt.
Step 6. Reassemble following steps in reverse order.

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

Tilt Sensor Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove tilt sensor:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. As shown in Figure 2-17, remove both yoke covers by removing one 8-32 x 3/8" PPB SEMS

screw per side.

Yoke Arm Cover*

8-32 x 3/8" PPB
SEMS Screw*

*One per side

Figure 2-17: Yoke Arm Cover Removal

Step 3. Remove Yoke Filler by removing two 6-32 x 3/16" PPB screws and one 8-32 x 3/8" PPB

SEMS screw mounting tilt stabilizer to yoke filler.

6-32 x 3/16" PPB Screw (x2)

Yoke Filler

NOTE:

Components removed and exploded for clarity.

Figure 2-18: Yoke Filler Removal

36 02.9687.0010 0

MAINTENANCE PROCEDURES : TILT SENSOR REMOVAL

2

Step 4. Tilt head from side to side to access two 6-32 x 3/8" PFZ screws as indicated in Figure 2 -19.

4-40 x 1/4" PPB SEMS Screw (x2)

Right Tilt Bearing Assembly

Tilt Sensor
Bracket

Tilt Sensor
Assembly

6-32 x 3/8" PFZ Screw (x2)

NOTE:

Components removed and exploded for clarity.

Figure 2-19: Tilt Sensor Removal

Step 5. Disconnect wiring at tilt sensor and remove tilt sensor.
Step 6. Reassemble following steps in reverse order.

02.9687.0010 0 37

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

Tilt Stabilizer Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove tilt stabilizer:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. As shown in Figure 2-20, remove both yoke covers by removing one 8-32 x 3/8" PPB SEMS

screw per side.

Yoke Arm Cover*

8-32 x 3/8" PPB
SEMS Screw*

*One per side

Figure 2-20: Yoke Arm Cover Removal

Step 3. Remove Tilt Lock Assembly by removing two 6-32 x 3/16" PPB screws.

Tilt Lock Assembly

6-32 x 3/16" PPB Screw (x2)

NOTE:

Components removed and exploded for clarity.

Figure 2-21: Tilt Lock Assembly Removal

38 02.9687.0010 0

MAINTENANCE PROCEDURES : TILT STABILIZER REMOVAL

Step 4. Remove Yoke Filler by removing two 6-32 x 3/16" PPB screws and one 8-32 x 3/8" PPB

SEMS screw mounting tilt stabilizer to yoke filler.

6-32 x 3/16" PPB Screw (x2)

Yoke Filler

NOTE:

Components removed and exploded for clarity.

Figure 2-22: Yoke Filler Removal

Step 5. Remove four 8-32 x 3/8" PFZ screws securing each tilt bearing to yoke.
Step 6. Cut any cable ties to give enough wiring slack to lift head from yoke
Step 7. At Right Tilt Bearing Assembly, disconnect extension spring from stabilizer and pass

stabilizer around wiring and tilt bearing.

2

NOTE:

Components removed and exploded for clarity.

Figure 2-23: Tilt Stabilizer

Step 8. Reassemble following steps in reverse order.

Tilt Stabilizer

Extension Spring

02.9687.0010 0 39

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

Ignitor Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove tilt sensor:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. As shown in Figure 2-24, remove tilt lock side yoke arm cover by removing one 8-32 x 3/8"

PPB SEMS screw.

Tilt Lock Assembly

Figure 2-24: Tilt Lock Side Yoke Arm Cover Removal

Step 3. Disconnect wiring from ignitor.
Step 4. As shown in Figure 2-25, remove ignitor as follows:

a. Remove one 4-40 x 1-3/8" PPZ screw with #4 flat washer.

b. Remove one 4-40 x 1-3/8" PPZ screw with #4 flat washer AND one #4 KEPS nut.

Yoke Arm Cover

8-32 x 3/8" PPB
SEMS Screw

40 02.9687.0010 0

#4 KEPS Nut (x1)

Ignitor

#4 Flat Washer (x2)

4-40 x 1-3/8" PPZ Screw (x2)

MAINTENANCE PROCEDURES : IGNITOR REMOVAL

2

Figure 2-25: Ignitor Removal

Step 5. Reassemble by performing steps in reverse.

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

Lamp Socket Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove lamp socket assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove front and rear cover assemblies (see “Front Cover Assembly Removal” on page 19

and “Rear Cover Assembly Removal” on page 20).
Step 3. Remove Gobo Module Assembly as described in “Gobo Module Assembly Removal” on

page 23.

Step 4. Remove CYMD Module Assembly as described in “CYMD Module Assembly Removal”

on page 24.

Step 5. As shown in Figure 2-26, remove tilt lock side yoke cover by removing one 8-32 x 3/8" PPB

SEMS screw.

Tilt Lock Assembly

Yoke Arm Cover

8-32 x 3/8" PPB
SEMS Screw

Figure 2-26: Tilt Side Yoke Arm Cover Removal

Step 6. Disconnect lamp wires from output of ignitor and pass through tilt tube grommets to back

lamp house.

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MAINTENANCE PROCEDURES : LAMP SOCKET REMOVAL

Step 7. Loosen two quarter-turn Dzus rapier fasteners from lamp house cover and remove lamp.

Lamp Socket

Lamp

Lamp Socket
Cover

Quarter-Turn
Fasteners

2

Figure 2-27: Lamp Socket Cover Removal

Step 8. Remove one 6-32 x 3/8" PPZ SEMS screw and flat washer and detach lamp cover tether

from fixture.
Step 9. As shown in Figure 2-28 on page 44, at each side:

a. Remove two 8-32 x 5/8" PPZ SEMS screw (1 per side) at counter weight plate, closest

to rear of assembly.

b. Note, the counter weight plates will stay attached by 2 screws closest to inside of fixture.
Step 10. Remove two 6-32 x 3/8" PPZ SEMS screws from rear of assembly, closest to L1 & L2 fans.

02.9687.0010 0 43

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

Step 11. Remove four 8-32 x 3/8" PPB SEMS screws from rear.

NOTE:

Components removed and exploded for clarity.

Remove this screw only

8-32 x 3/8" PPB SEMS Screw (x4)

10-32 x 1-1/2" PPZ Screw (x3)

Counter Weights

10-32 Acorn

Nut (x3)

#10 Flat Washer (x3)

Figure 2-28: Lamp Socket Removal

Step 12. Carefully remove lamp housing, socket and rear plate.

Spring (x3)

Spacer (x3)

8-32 x 7/8" PPZ
SEMS Screw (x2)

Lamp Socket

Remove this screw only

Counter Weights

Step 13. Slide lamp wires through hot box insulation blanket.
Step 14. Remove grommet from lamp housing and carefully slide lamp wire through lamp housing,

then remove grommet from lamp wire.
Step 15. Remove three 10-32 Acorn nuts.
Step 16. Remove three 10-32 x 1-1/2" PPZ Screws and flat washers with spring and spacer.

CAUTION: Note orientation of lamp socket before removing lamp socket from fixture. Replacement
socket must be installed in the same orientation.

Step 17. Remove two 8-32 x 7/8" PPZ SEMS screws mounting socket.
Step 18. Remove lamp socket.
Step 19. Reassemble by following steps in reverse order.

Note: Refer to “Lamp Removal and Installation” on page 21 for lamp installation information.

44 02.9687.0010 0

MAINTENANCE PROCEDURES : REFLECTOR REMOVAL

2

Reflector Removal

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove reflector assembly:

Step 1. Remove power from luminaire and allow unit to completely cool.
Step 2. Remove rear cover assembly as described in “Rear Cover Assembly Removal” on page 20.
Step 3. Loosen two quarter-turn Dzus rapier fasteners from lamp house cover and remove lamp.

Lamp Socket

Lamp

Lamp Socket
Cover

Quarter-Turn
Fasteners

Figure 2-29: Lamp Socket Cover Removal

Step 4. Remove one 6-32 x 3/8" PPZ SEMS screw and flat washer and detach lamp cover tether

from fixture.
Step 5. As shown in Figure 2-28 on page 44, at each side:

a. Remove two 8-32 x 5/8" PPZ SEMS screw (1 per side) at counter weight plate, closest

to rear of assembly.

b. Note, the counter weight plates will stay attached by 2 screws closest to inside of fixture.
Step 6. Remove two 6-32 x 3/8" PPZ SEMS screws from rear of assembly, closest to L1 & L2 fans.

02.9687.0010 0 45

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

Step 7. Remove four 8-32 x 3/8" PPB SEMS screws from rear.

NOTE:

Components removed and exploded for clarity.

Remove this screw only

Counter Weights

Reflector

#8 KEPS Nut (x4)

Reflector Retaining Clip (x2)

8-32 x 3/8" PPB SEMS Screw (x4)

Remove this screw only

Counter Weights

Figure 2-30: Reflector Assembly Removal

Step 8. Carefully remove lamp housing, socket and rear plate.
Step 9. At reflector, remove four #8 KEPS nuts and remove both reflector retainer clips.
Step 10. Remove reflector.
Step 11. Reassemble by following steps in reverse order.

Note: Refer to “Lamp Removal and Installation” on page 21 for lamp installation information.

46 02.9687.0010 0

MAINTENANCE PROCEDURES : CYMD WHEEL REPLACEMENT

2

CYMD Wheel Replacement

This section contains individual procedures to remove and install the dimmer, magenta, cyan, and
yellow wheels.

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove color wheels and dimmer from CYMD assembly:

Step 1. Remove CYMD assembly from luminaire by following procedure described in “CYMD

Module Assembly Removal” on page 24.

Step 2. At yellow wheel, remove two 0-80 x 3/16" PFSS Screws holding yellow wheel to shaft and

remove wheel.
Step 3. At cyan wheel, remove two 0-80 x 3/16" PFSS Screws holding cyan wheel to shaft and

remove wheel.
Step 4. Carefully remove magenta wheel from shaft.
Step 5. Carefully remove dimmer wheel from shaft.

0-80 x 3/16" PFSS
Screw (x2)

Magenta

Yellow

Cyan

0-80 x 3/16" PFSS Screw (x2)

Dimmer

NOTE:

Components removed and exploded for clarity.

Figure 2-31: CYMD Module Assembly Wheel Locations

02.9687.0010 0 47

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

To install dimmer wheel:

Step 1. Carefully slide dimmer wheel assembly onto shaft (opposite side where wiring harness is

attached).
Step 2. Align timing mark on dimmer wheel with timing mark on drive pulley hub on motor shaft as

shown in Figure 2-32.

Drive Pulley Hub
Timing Mark

Dimmer Hub
Timing Mark

Dimmer or
Color Wheel

Figure 2-32: Wheel and Drive Hub Timing Marks

Note: When optical sensor tab on drive pulley is in sensor, the CLOSED portion of the dimmer wheel

should align with gate.

To install magenta wheel:

Step 1. Install dimmer wheel first by following previous procedure in this section.
Step 2. Carefully slide magenta wheel assembly on to shaft (closest to where wiring harness is

attached)
Step 3. Align the timing mark on the magenta wheel with the timing mark on the drive pulley hub

on motor shaft as shown in Figure 2-32.

Note: When optical sensor tab on drive pulley is in sensor, the OPEN portion of the magenta wheel
should align with gate.

To install cyan wheel:

Step 1. Install dimmer and magenta wheels first by following previous procedures in this section.

48 02.9687.0010 0

MAINTENANCE PROCEDURES : CYMD WHEEL REPLACEMENT

2

Step 2. Ensure that sensor tab on drive pulley of motor is in sensor slot.
Step 3. Align wheel to shaft screws, so that open spot of wheel is in gate.

WARNING: It is very important not to over-tighten screws in the next step.

Step 4. Install two 0-80 x 3/16" PFSS screws.

Note: When installing or reinstalling Cyan wheel, you must add a bead of RTV 5083 on top of 0-80 x
3/16" LG PFSS Screws (as illustrated in Figure 2-33). Allow enough time for RTV to cure before
putting the assembly into use.

Step 5. Ensure cyan wheel and dimmer wheel move independent of each other.

To Install Yellow Wheel

Step 1. Install dimmer, magenta and cyan wheels by following previous procedures in this section.
Step 2. Ensure that sensor tab on drive pulley of motor is in sensor slot.
Step 3. Align wheel to shaft screws, so that open spot of wheel is in gate.

WARNING: It is very important not to over-tighten screws in the next step.

Step 4. Install two 0-80 x 3/16" PFSS screws.

Note: When installing or reinstalling Yellow wheel, you must add a bead of RTV 5083 on top of 0-80
x 3/16" LG PFSS Screws (as illustrated in Figure 2-33). Allow enough time for RTV to cure before
putting the assembly into use.

Step 5. Ensure yellow wheel and magenta wheel move independent of each other.

Glass Filter
(Yellow or Cyan)

RTV 5083 Bead

Filter Hub
(Yellow or Cyan)

0-80 x 3/16" PFSS Screws

Figure 2-33: Cyan or Yellow Filter Wheel - RTV 5083 Bead

02.9687.0010 0 49

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

Strobe Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the strobe assembly:

Step 1. Remove CYMD assembly from luminaire by following procedure described in “CYMD

Module Assembly Removal” on page 24.

Step 2. Remove all glass wheels from CYMD assembly as described in “CYMD Wheel

Replacement” on page 47.

Step 3. Remove one 4-40 x 1/4" PPB SEMS screw mounting color mix shaft to bearing. Carefully

remove shaft.
Step 4. Remove one 4-40 x 1/4" PFZ and three 4-40 x 1/4" PPB SEMS screws and remove strobe

assembly from CYMD assembly.

Left Strobe Assembly

B

4-40 x 1/4" PFZ Screw

A

A

B

NOTE:

Components removed and exploded for clarity.

4-40 x 1/4" PPB SEMS Screw

B

Right Strobe Assembly

Figure 2-34: Strobe Assemblies Removal

Step 5. Reassemble following steps in reverse order.

50 02.9687.0010 0

MAINTENANCE PROCEDURES : DIMMER OR MAGENTA MOTOR ASSEMBLY REPLACEMENT

Dimmer or Magenta Motor Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the dimmer or magenta motor assembly:

Step 1. Remove CYMD assembly from luminaire by following procedure described in “CYMD

Module Assembly Removal” on page 24.

Step 2. Remove all glass wheels from CYMD assembly as described in “CYMD Wheel

Replacement” on page 47.

Step 3. Remove appropriate strobe assembly.

Note: Screws, in the next step, have Loctite 242 and may require small amount of heat to loosen.

Step 4. Using 1/16" Allen Driver, loosen cone set screw attaching Dimmer or Magenta Outdrive

from motor shaft.

2

4-40 x 1/4"
PFZ Screws

Magenta
Outdrive

Dimmer
Outdrive

NOTE:

Components removed and exploded for clarity.

Figure 2-35: Dimmer / Magenta Motor Assemblies Removal

Step 5. Remove Outdrive.
Step 6. Remove two 4-40 x 1/4" PFZ screws and remove motor.

Magenta Motor Assembly

Dimmer Motor Assembly

4-40 x 1/4"
PFZ Screws

Step 7. When installing Outdrive, place sensor tab into optical sensor.
Step 8. Apply Loctite 242 onto cone set screw.
Step 9. Tighten cone set screw to flat part of shaft, with the slot centered in the sensor.
Step 10. Continue reassembly following remaining steps in reverse order.

02.9687.0010 0 51

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

Strobe Blade Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the strobe assembly:

Step 1. Remove appropriate strobe assembly as described in “Strobe Assembly Replacement” on

page 50.

Note: Cone Set Screw has Loctite 242 and may require small amount of heat to loosen.

Step 2. Using 1/16" Allen driver, loosen cone set screw attaching strobe assembly to motor shaft.
Step 3. Remove strobe blade assembly.
Step 4. To Install, power motor to hold on whole step.
Step 5. Hold blade against stop in closed position and slide blade onto motor shaft.
Step 6. Set height per tolerance as shown in Figure 2-36.

Left Strobe Motor Assembly

.240

.235

Right Strobe Motor Assembly

Figure 2-36: Strobe Assemblies - Strobe Blade Height Settings

.320

.110

Step 7. Apply Loctite 242 to cone set screw threads.
Step 8. Tighten set screw.
Step 9. Reinstall strobe assembly.

52 02.9687.0010 0

MAINTENANCE PROCEDURES : CYAN OR YELLOW MOTOR REPLACEMENT

Cyan or Yellow Motor Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the cyan or yellow motor assemblies:

Step 1. Remove CYMD module assembly from luminaire as described in “CYM D Mod ule

Assembly Removal” on page 24.

Step 2. Remove all glass wheels from CYMD assembly as described in “CYMD Wheel

Replacement” on page 47.

Step 3. Remove appropriate strobe assembly as described in “Strobe Assembly Replacement” on

page 50. Refer to Figure 2-37 for motor location.

2

Left Strobe Assembly

Yellow Motor
Assembly

NOTE:

Components removed and exploded for clarity.

Figure 2-37: Cyan and Yellow Motor Assemblies.

Note: Cone Set Screw has Loctite 242 and may require small amount of heat to loosen.

Right Strobe Assembly

Cyan Motor
Assembly

Step 4. Using 1/16" Allen driver, loosen cone set screw attaching outdrive to motor shaft.
Step 5. Remove outdrive.
Step 6. At motor to be removed, remove two 4-40 x 1/4" PFB SEMS Screws securing motor.
Step 7. Reassemble following steps in reverse order.

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Fixed Color Wheel Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the fixed color wheel assembly:

Step 1. Remove gobo module assembly from luminaire as described in “Gobo Module Assembly

Removal” on page 23.

Note: Cone Set Screw has Loctite 242 and may require small amount of heat to loosen.

Step 2. Using 1/16" Allen driver, loosen cone set screw attaching fixed color wheel to drive shaft.

Fixed Gobo Wheel

Fixed Color Wheel

See Detail

NOTE:

Components removed and
exploded for clarity.

Fixed Color
Wheel Hub

Hub Cone
Set Screw

Rotating Gobo Wheel

IMPORTANT! When replacing Fixed
Color Motor, ensure the rear homing
plate is installed with the set screw to
the flat part of motor shaft when tab is
in sensor.

Figure 2-38: Fixed Color Wheel Assembly

Step 3. To install, align drive rear motor homing plate so tab is in optical sensor.
Step 4. Apply Loctite 242 on Cone set screw.
Step 5. Center open spot of wheel to gate and tighten set screw to flat motor shaft.

54 02.9687.0010 0

MAINTENANCE PROCEDURES : ROTATING GOBO WHEEL REPLACEMENT

2

Rota ting Gobo Wheel Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the rotating gobo wheel assembly:

Step 1. Remove gobo module assembly from luminaire as described in “Gobo Module Assembly

Removal” on page 23.

Step 2. Remove the fixed color wheel assembly from gobo module assembly as described in “Fixed

Color Wheel Replacement” on page 54.

Note: Cone Set Screw has Loctite 242 and may require small amount of heat to loosen.

Step 3. Using 1/16" Allen driver, loosen cone set screw attaching rotating gobo wheel to drive shaft.

Fixed Color Wheel

NOTE:

Components removed and
exploded for clarity.

Rotating Gobo
Wheel Hub

Hub Cone
Set Screw

Fixed Gobo Wheel

Rotating Gobo Wheel

See Detail

Figure 2-39: Rotating Gobo Wheel

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Step 4. To install, align drive rear motor homing plate so tab is in optical sensor.
Step 5. Apply Loctite 242 on Cone set screw.
Step 6. Center open spot of wheel to gate and tighten set screw to flat motor shaft.

CAUTION: During reassembly, the alignment of the rotating gobo wheel assembly (alignment drive
rear motor homing plate tab in the optical sensor) is very critical for index to calibrate correctly.

IMPORTANT! When replacing Rotating Gobo Motor, ensure the rear homing plate is installed with
the set screw to the flat part of motor shaft when tab is in sensor. When replacing Index Motor, ensure
the Index Outdrive is installed with set screw to flat part of motor shaft.

56 02.9687.0010 0

MAINTENANCE PROCEDURES : FIXED GOBO WHEEL REPLACEMENT

2

Fixed Gobo Wheel Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the fixed gobo wheel assembly:

Step 1. Remove gobo module assembly from luminaire as described in “Gobo Module Assembly

Removal” on page 23.

Step 2. Remove the fixed color wheel assembly from gobo module assembly as described in “Fixed

Color Wheel Replacement” on page 54.

Step 3. Remove the rotating gobo wheel assembly from gobo module assembly as described in

“Rotating Gobo Wheel Replacement” on page 55.

Step 4. Remove Rotate Gobo COAX assembly from shaft. Note that the bearings in the assembly

that may come loose. Keep these bearings.
Step 5. Remove two 6-32 x 3/8" PPZ SEMS screws mounting stabilizer retainer and carefully

remove. Note that there is a spring between retainer and stabilizer that will be removed.

Spring

Stabilizer

Fixed Gobo Wheel

6-32 x 3/8" PPZ SEMS Screws

Retainer

Rotate Gobo Coax Assembly

NOTE:

Components removed and
exploded for clarity.

Figure 2-40: Fixed Gobo Wheel

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Step 6. As shown in Figure 2-41, slide Stabilizer from mount.

Fixed Gobo Wheel

Stabilizer

Bearing

Bearing

NOTE:

Components removed and
exploded for clarity.

Figure 2-41: Fixed Gobo Wheel

Step 7. Carefully lift wheel off shaft. Note bearings may come loose (refer to Figure 2-41 for

bearing locations).
Step 8. When installing, align fixed gobo outdrive so tab is in sensor .
Step 9. Align wheel so open spot is aligned with gate.
Step 10. Slide on to shaft.
Step 11. Continue reassembly by following steps in reverse order.

IMPORTANT! When replacing Fixed Gobo Motor, ensure the Fixed Gobo Outdrive is installed with
set screw to flat part of motor shaft when tab is in optical sensor.

58 02.9687.0010 0

MAINTENANCE PROCEDURES : IRIS ASSEMBLY REPLACEMENT

2

Iris Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work. Wear protection on hands (soft cotton gloves) when handling glass.

To remove the iris assembly:

Step 1. Remove gobo module assembly from luminaire as described in “Gobo Module Assembly

Removal” on page 23.

Step 2. Remove the fixed color wheel assembly from gobo module assembly as described in “Fixed

Color Wheel Replacement” on page 54.

Step 3. Remove the rotating gobo wheel assembly from gobo module assembly as described in

“Rotating Gobo Wheel Replacement” on page 55.

Step 4. Remove the fixed gobo wheel assembly from gobo module assembly as described in “Fixed

Gobo Wheel Replacement” on page 57.

Step 5. Remove three 2-56 x 3/16" PFZ screws and remove iris assembly.

NOTE:

Components removed and
exploded for clarity.

2-56 x 3/16" PFZ Screw (x3)

Iris Linkage

Iris Assembly

Figure 2-42: Iris Assembly

Step 6. Disconnect iris linkage.
Step 7. Reassemble by following steps in reverse order.

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Ballast / LVS Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the ballast / LVS assembly:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. At enclosure, remove display side handle by removing four 10-32 x 5/8" PPB screws.

Display Side Handle

Ballast / LVS Assembly

NOTE:

Components removed and
exploded for clarity.

10-32 x 5/8" PPB Screw (x4)

Figure 2-43: Ballast / LVS Assembly Removal

Step 3. Remove the inlet exhaust screen.
Step 4. Remove two 10-32 x 9/16" PFB screws in supply.
Step 5. Slide Ballast / LVS assembly out of enclosure. Note, wiring is still attached to assembly.
Step 6. Disconnect wiring:

Connection Wire Color (s)

AC Line Input Black, White, Green/Yellow

36 VDC Output Orange/Black

Enclosure Fan Red/Black (x2) Note, it does not matter which wire goes where

Lamp Wire Black, White

Step 7. Reassemble by performing steps in reverse order.

60 02.9687.0010 0

MAINTENANCE PROCEDURES : DMX PCB ASSEMBLY REPLACEMENT

2

DMX PCB Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the DMX PCB assembly:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

NOTE:

Components removed and
exploded for clarity.

Figure 2-44: Enclosure Assembly Bottom Plate Removal

Step 5. At DMX PCB assembly, disconnect wiring.

Enclosure Assembly

Bottom Plate

1/4-20 x 1/2" PFZ Screw (x6)

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Step 6. From front panel, remove four 4-40 x 3/8" PFB screws and remove DMX PCB assembly.

DMX PCB
Assembly

Enclosure Assembly

4-40 x 3/8"
PFB Screw (x4)

Figure 2-45: DMX PCB Assembly Removal

Step 7. Reassemble by performing steps in reverse order.

NOTE:

Components removed and
exploded for clarity.

62 02.9687.0010 0

MAINTENANCE PROCEDURES : POWERCON (AC INPUT) ASSEMBLY REPLACEMENT

2

Po werCon (AC Input) Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the PowerCon (AC input) assembly:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

1/4-20 x 1/2" PFZ Screw (x6)

NOTE:

Components removed and
exploded for clarity.

Figure 2-46: Enclosure Assembly Bottom Plate Removal

Bottom Plate

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Step 5. As indicated in Figure 2-47, remove fan assembly by removing two 6-32 x 1/4" PPZ SEMS

screws.

#4 Nuts (x2)

PowerCon (AC Input) Assembly

4-40 x 3/8" PFB
Screw (x2)

Fan Assembly

6-32 x 1/4" PPZ
SEMS Screw (x2)

NOTE:

Components removed and
exploded for clarity.

Figure 2-47: PowerCon (AC Input) Assembly Removal

Step 6. Disconnect wiring from PowerCon (AC Input ) assembly.
Step 7. At front panel, remove two 4-40 x 3/8" PFB screws and nuts and remove PowerCon (AC

Input) assembly.
Step 8. Reassemble by performing steps in reverse order.

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MAINTENANCE PROCEDURES : DISPLAY PCB ASSEMBLY REPLACEMENT

2

Display PCB Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the display PCB assembly:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

NOTE:

Components removed and
exploded for clarity.

Bottom Plate

1/4-20 x 1/2" PFZ Screw (x6)

Figure 2-48: Enclosure Assembly Bottom Plate Removal

Step 5. At Display PCB assembly, disconnect all wiring.

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Step 6. As shown in Figure 2-49, remove four 6-32 x 3/16" PPZ screws and remove Display PCB

assembly.

6-32 x 3/16"
PPZ Screw (x4)

Display PCB
Assembly

Figure 2-49: Display PCB Assembly Removal

Step 7. Reassemble by performing steps in reverse order.

NOTE:

Components removed and
exploded for clarity.

66 02.9687.0010 0

MAINTENANCE PROCEDURES : WIRELESS DMX INTERFACE PCB ASSEMBLY REPLACEMENT

2

Wireless DMX Interface PCB Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the wireless DMX interface PCB assembly:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

Bottom Plate

1/4-20 x 1/2" PFZ Screw (x6)

NOTE:

Components removed and
exploded for clarity.

Figure 2-50: Enclosure Assembly Bottom Plate Removal

Step 5. At wireless DMX interface PCB assembly, disconnect all wiring.

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Step 6. As shown in Figure 2-49, remove two 6-32 x 3/16" PPZ screws and remove wireless DMX

interface PCB assembly.

Wireless DMX PCB Assembly

6-32 x 3/16" PPZ Screw (x2)

Figure 2-51: Wireless DMX Interface PCB Assembly Removal

Step 7. Reassemble by performing steps in reverse order.

NOTE:

Components removed and
exploded for clarity.

68 02.9687.0010 0

MAINTENANCE PROCEDURES : PAN MOTOR ASSEMBLY REPLACEMENT

2

Pan Motor Assembly Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the pan motor assembly:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

1/4-20 x 1/2" PFZ Screw (x6)

NOTE:

Components removed and
exploded for clarity.

Figure 2-52: Enclosure Assembly Bottom Plate Removal

Bottom Plate

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Step 5. As indicated in Figure 2-53, remove both fan assemblies by removing two 6-32 x 1/4" PPZ

SEMS screws (per fan assembly).

Fan Assembly

Fan Assembly

6-32 x 1/4" PPZ
SEMS Screw (x2)

Pan Motor Assembly

NOTE:

Components removed and
exploded for clarity.

Figure 2-53: Enclosure Fan Assemblies Removal

Step 6. Disconnect wiring from motor and encoder assemblies.
Step 7. Remove four 8-32 x 1/4" PPB SEMS screws and their flat washers.

8-32 x 1/4" PPB
SEMS Screw (x4)

#8 Flat Washer (x4)

6-32 x 1/4" PPZ
SEMS Screw (x2)

Pan Motor Assembly

NOTE:

Components removed and
exploded for clarity.

Figure 2-54: Pan Motor Assembly Removal

Step 8. Remove pan motor assembly
Step 9. Reassemble by performing steps in reverse order.

Note: Ensure proper belt tension when replacing.

70 02.9687.0010 0

MAINTENANCE PROCEDURES : PAN BELT REPLACEMENT

2

Pan Belt Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the pan belt:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

NOTE:

Components removed and
exploded for clarity.

Bottom Plate

1/4-20 x 1/2" PFZ Screw (x6)

Figure 2-55: Enclosure Assembly Bottom Plate Removal

Step 5. Remove pan motor assembly as described in “Pan Motor Assembly Replacement” on

page 69.

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Step 6. At Wire Tray, remove four 8-32 x 1/4" PPZ SEMS screws and remove tray.

Figure 2-56: Wire tray Removal

Step 7. Disconnect all wiring from inside enclosure
Step 8. At pan pulley cover, remove four 8-32 KEPS nuts and remove cover.

Wire Tray

8-32 x 1/4" PPZ
SEMS Screw (x4)

8-32 KEPS Nuts (x4)

Pan Pulley Cover

Pan Belt

Pan Pulley

NOTE:

Components removed and
exploded for clarity.

Figure 2-57: Pan Pulley Cover Removal

Step 9. Slide pan belt over and off pan pulley.
Step 10. Reassemble by performing steps in reverse order.

Note: Ensure proper belt tension when replacing.

72 02.9687.0010 0

MAINTENANCE PROCEDURES : PAN STABILIZER REPLACEMENT

2

Pan Stabilizer Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove the stabilizer:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

NOTE:

Components removed and
exploded for clarity.

Bottom Plate

1/4-20 x 1/2" PFZ Screw (x6)

Figure 2-58: Enclosure Assembly Bottom Plate Removal

Step 5. Remove pan motor assembly as described in “Pan Motor Assembly Replacement” on

page 69.

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Step 6. At Wire Tray, remove four 8-32 x 1/4" PPZ SEMS screws and remove tray.

Wire Tray

8-32 x 1/4" PPZ
SEMS Screw (x4)

Figure 2-59: Wire tray Removal

Step 7. At pan pulley cover, remove four 8-32 KEPS nuts and remove cover.

8-32 KEPS Nuts (x4)

Pan Pulley Cover

8-32 x 1/2" PPZ SEMS Screw

10-32 x 3/8" SCZ-B Screw (x4)

Pan Pulley

Pan Stabilizer

Pan St ab i liz e r Spring

NOTE:

Components removed and
exploded for clarity.

Figure 2-60: Pan Pulley Cover Removal

Step 8. Slide pan belt over and off pan pulley.
Step 9. Using 5/32" Allen driver, remove four 10-32 x 3/8" SCZ-B screws and remove pulley from

pan tube.
Step 10. At Stabilizer mount, remove one 8-32 x 1/2" PPZ SEMS screw.
Step 11. Remove spring from stabilizer, pass stabilizer around wiring harness. IMPORT ANT! When

replacing stabilizer, install new spring.

Step 12. Reassemble by performing steps in reverse order.

Note: Ensure proper belt tension when replacing.

74 02.9687.0010 0

MAINTENANCE PROCEDURES : ENCLOSURE FAN ASSEMBLIES REPLACEMENT

2

Enclosure Fan Assemblies Replacement

WARNING: Ensure that power is completely removed (disconnected) from luminaire before
attempting any work.

To remove one or both enclosure fan assemblies:

Step 1. Ensure power is completely removed from luminaire and luminaire has cooled completely.
Step 2. Remove Ballast / LVS assembly as described in “Ballast / LVS Assembly Replacement” on

page 60.

WARNING: Do not set head on or damage front lens during next step!

Step 3. Carefully, flip luminaire to access bottom of enclosure. Do not set on lens.
Step 4. Remove six 1/4-20 x 1/2" PFZ screws and remove Bottom Plate from enclosure assembly.

Enclosure Assembly

1/4-20 x 1/2" PFZ Screw (x6)

NOTE:

Components removed and
exploded for clarity.

Figure 2-61: Enclosure Assembly Bottom Plate Removal

Bottom Plate

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Step 5. As indicated in Figure 2-47, remove both fan assemblies by removing two 6-32 x 1/4" PPZ

SEMS screws for each assembly.

Fan Assembly

8-32 x 1-1/2" PPZ
Screw (x2 / assembly)

#8 Internal Tooth
Lock Washer (x2 / assembly)

#8 Flat Washer (x2 / assembly)

6-32 x 1/4" PPZ
SEMS Screw (x2)

NOTE:

Components removed and
exploded for clarity.

Fan Assembly

6-32 x 1/4" PPZ
SEMS Screw (x2)

Figure 2-62: Enclosure Fan Assemblies Removal

Step 6. Remove fan from mounting assembly by removing two 6-32 x 1-1/2" PPZ screws, #8

internal tooth lock washers, and #8 flat washers (per assembly).
Step 7. Disconnect wiring and remove fans.
Step 8. Reassemble by performing steps in reverse order.

76 02.9687.0010 0

CHAPTER 3.

Illustrated Parts Breakdown

This chapter contains illustrated parts breakdowns for all VL440 / VL770 / VL880 Spot
Luminaires assemblies.

• VL440 Spot Luminaire Drawing Tree

• VL770 Spot Luminaire Drawing Tree

• VL880 Spot Luminaire Drawing Tree

• Top Assembly

• Head Assembly

• Enclosure Assembly

• Cable Assemblies

SERVICE

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Drawing Trees

VL440 Spot Luminaire Drawing Tree

VL440 Spot Luminaire

20.9687.0002 Rev G

Included Items Kit

28.9687.0440 Rev A (for VL440
Spot only)

Front Head Cover Assembly

21.9687.0620 Rev C

Rear Head Cover Assembly

21.9687.0625 Rev A

Zoom Assembly

21.9687.0160 Rev D

Prism Assembly

21.9687.0151 Rev B

Frost Assembly

21.9687.0152 Rev A

Zoom Linear Slide Assembly

21.9687.0180 Rev A

Gobo Module Assembly

21.9687.0301 Rev J

Wedge Fixed Color Wheel

Assembly

21.9687.0256 Rev C

Rotating Gobo Wheel Assembly

21.9687.0257 Rev C

Fixed Gobo Wheel Assembly

21.9687.0258 Rev B

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Sensor Index Cable Assembly

25.9687.0024 Rev A

Generic Luminaire Assembly

21.9687.0010 Rev D

Ballast Comm Cable Assembly

25.9687.0004 Rev B

Tilt Cable Assembly

25.9687.0008 Rev A

Edge Cable Assembly

25.9687.0009 Rev 0

Zoom Group Cable Assembly

25.9687.0010 Rev A

CYMD Group Cable Assembly

25.9687.001 1 Rev B

Gobo Group Cable Assembly

25.9687.0012 Rev 0

Lamp to Fans Cable Assembly

25.9687.0015 Rev A

Front Carrier Assembly

21.9687.0106 Rev B

Rear Carrier Assembly

21.9687.0111 Rev B

Continued next page

CYMD Color Module Assembly

21.9687.0511 Rev C

VL440 - VL770 Lamp Socket /

Cable Assembly

25.9687.0021.07 Rev A

Continued next page

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Figure 3-1: VL440 Spot Luminaire Subassembly Drawing Tree Part 1

78 02.9687.0010 0

VL440 Spot Luminaire Drawing Tree (continued)

Continued from previous page

DRAWING TREES : VL440 SPOT LUMINAIRE DRAWING TREE

3

Generic Luminaire Assembly

21.9687.0010 Rev D

Upper Enclosure Assembly

21.9687.0850 Rev N

Chassis To Yoke Grou nd Cable

36 Volt Supply Cable Assembly

Ballast to Ignitor Cable Assembly

Pan Encoder Cable Assembly

Assembly

25.9661.1520 Rev D

AC Input Cable Assembly

25.9687.0001 Rev A

DMX / Display Comm Cable

Assembly

25.9687.0003 Rev A

25.9687.0005 Rev A

25.9687.0006 Rev A

Pan Motor Cable Assembly

25.9687.0007.01 Rev C

25.9687.0007.02 Rev C

Head Frame Assembly

21.9687.0650 Rev N

Pan Motor Assembly

21.9687.0860 Rev. B

Pulley Pinion Assembly

21.9687.0655 Rev. A

Continued from

previous page

Left Tilt Bearing Assembly

21.9687.0632 Rev A

Right Tilt Bearing Assembly

21.9687.1633 Rev A

Linear Roller Assembly

21.9687.0634 Rev B

Lamp Housing Assembly

21.9687.0652 Rev J

Tilt Motor Assembly

21.9687.0670 Rev C

Slotted Optical Switch Cable

25.9687.0020 Rev A

CYMD Color Module Assembly

21.9687.0511 Rev C

Pulley Pinion Assembly

21.9687.0655 Rev . A

Assembly

Slotted Optical Switch Cable

Assembly

APS Fan Cable Assembly

25.9703.0002 Rev B

AUX Comm Interface Cable

Assembly

25.9703.0016 Rev A

Left Flag Motor Plate Assembly

21.9687.1435 Rev A

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

25.9687.0020 Rev A

Right Flag Motor Plate Assembly

21.9687.1437 Rev A

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Figure 3-2: VL440 Spot Luminaire Subassembly Drawing Tree Part 2

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

VL770 Spot Luminaire Drawing Tree

VL770 Spot Luminaire

20.9687.0003 Rev H

Included Items Kit

28.9687.0770 Rev A (for VL770
Spot only)

Front Head Cover Assembly

21.9687.0620 Rev C

Rear Head Cover Assembly

21.9687.0625 Rev A

Zoom Assembly

21.9687.0160 Rev D

Prism Assembly

21.9687.0151 Rev B

Frost Assembly

21.9687.0152 Rev A

Zoom Linear Slide Assembly

21.9687.0180 Rev A

Gobo Module Assembly

21.9687.0301 Rev J

Wedge Fixed Color Wheel

Assembly

21.9687.0256 Rev C

Rotating Gobo Wheel Assembly

21.9687.0257 Rev C

Fixed Gobo Wheel Assembly

21.9687.0258 Rev B

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Sensor Index Cable Assembly

25.9687.0024 Rev A

Transfer Fans Assembly

21.9687.0260 Rev A

Ballast Comm Cable Assembly

25.9687.0004 Rev B

Tilt Cable Assembly

25.9687.0008 Rev A

Edge Cable Assembly

25.9687.0009 Rev 0

Zoom Group Cable Assembly

25.9687.0010 Rev A

CYMD Group Cable Assembly

25.9687.001 1 Rev B

Gobo Group Cable Assembly

25.9687.0012 Rev 0

Lamp to Fans Cable Assembly

25.9687.0015 Rev A

Front Carrier Assembly

21.9687.0106 Rev B

Rear Carrier Assembly

21.9687.0111 Rev B

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Dual Gobo Cooling Blower

Assembly

21.9687.1630 Rev A

Generic Luminaire Assembly

21.9687.0010 Rev D

Continued next page

CYMD Color Module Assembly

21.9687.0511 Rev C

VL440 - VL770 Lamp Socket /

Cable Assembly

25.9687.0021.07 Rev A

Continued next page

Figure 3-3: VL770 Spot Luminaire Subassembly Drawing Tree Part 1

80 02.9687.0010 0

VL770 Spot Luminaire Drawing Tree (continued)

Continued from previous page

DRAWING TREES : VL770 SPOT LUMINAIRE DRAWING TREE

3

Generic Luminaire Assembly

21.9687.0010 Rev D

Upper Enclosure Assembly

21.9687.0850 Rev N

Chassis To Yoke Grou nd Cable

36 Volt Supply Cable Assembly

Ballast to Ignitor Cable Assembly

Pan Encoder Cable Assembly

Assembly

25.9661.1520 Rev D

AC Input Cable Assembly

25.9687.0001 Rev A

DMX / Display Comm Cable

Assembly

25.9687.0003 Rev A

25.9687.0005 Rev A

25.9687.0006 Rev A

Pan Motor Cable Assembly

25.9687.0007.01 Rev C

25.9687.0007.02 Rev C

Head Frame Assembly

21.9687.0650 Rev N

Pan Motor Assembly

21.9687.0860 Rev. B

Pulley Pinion Assembly

21.9687.0655 Rev. A

Continued from

previous page

Left Tilt Bearing Assembly

21.9687.0632 Rev A

Right Tilt Bearing Assembly

21.9687.1633 Rev A

Linear Roller Assembly

21.9687.0634 Rev B

Lamp Housing Assembly

21.9687.0652 Rev J

Tilt Motor Assembly

21.9687.0670 Rev C

Slotted Optical Switch Cable

25.9687.0020 Rev A

CYMD Color Module Assembly

21.9687.0511 Rev C

Pulley Pinion Assembly

21.9687.0655 Rev . A

Assembly

Slotted Optical Switch Cable

Assembly

APS Fan Cable Assembly

25.9703.0002 Rev B

AUX Comm Interface Cable

Assembly

25.9703.0016 Rev A

Left Flag Motor Plate Assembly

21.9687.1435 Rev A

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

25.9687.0020 Rev A

Right Flag Motor Plate Assembly

21.9687.1437 Rev A

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Figure 3-4: VL770 Spot Luminaire Subassembly Drawing Tree Part 2

02.9687.0010 0 81

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

VL880 Spot Luminaire Drawing Tree

VL880 Spot Luminaire

20.9687.0004 Rev J

Included Items Kit

28.9687.0880 Rev A (for VL880
Spot only)

Front Head Cover Assembly

21.9687.0620 Rev C

Rear Head Cover Assembly

21.9687.0625 Rev A

Zoom Assembly

21.9687.0160 Rev D

Prism Assembly

21.9687.0151 Rev B

Frost Assembly

21.9687.0152 Rev A

Zoom Linear Slide Assembly

21.9687.0180 Rev A

Gobo Module Assembly

21.9687.0301 Rev J

Wedge Fixed Color Wheel

Assembly

21.9687.0256 Rev C

Rotating Gobo Wheel Assembly

21.9687.0257 Rev C

Fixed Gobo Wheel Assembly

21.9687.0258 Rev B

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Sensor Index Cable Assembly

25.9687.0024 Rev A

Transfer Fans Assembly

21.9687.0260 Rev A

800 Watt Ballast Comm Cable

Zoom Group Cable Assembly

CYMD Group Cable Assembly

Lamp to Fans Cable Assembly

Assembly

25.9687.0023 Rev 0

Tilt Cable Assembly

25.9687.0008 Rev A

Edge Cable Assembly

25.9687.0009 Rev 0

25.9687.0010 Rev A

25.9687.001 1 Rev B

Gobo Group Cable Assembly

25.9687.0012 Rev 0

25.9687.0015 Rev A

Front Carrier Assembly

21.9687.0106 Rev B

Rear Carrier Assembly

21.9687.0111 Rev B

Slotted Optical Switch Cable

Assembly

25.9687.0020 Rev A

Dual Gobo Cooling Blower

Assembly

21.9687.1630 Rev A

Generic Luminaire Assembly

21.9687.0010 Rev D

Continued next page

CYMD Color Module Assembly

21.9687.0511 Rev C

VL880 Lamp Socket / Cable

Assembly

25.9687.0021.08 Rev A

Continued next page

Figure 3-5: VL880 Spot Luminaire Subassembly Drawing Tree Part 1

82 02.9687.0010 0