Philips VL1000 TS, VL1000 TSD, VL1000 AS, VL1000 AI, VL1000 TI Service Manual

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VARI❋LITE® is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries. VL500™, VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations) , VL3000™, VL3500™, Series 500 VARI❋BRITE VARI❋LITE® products are protected by one or more of the following patents, and other pending patent applications worldwide:

U. S. Patents No. 6,123,436; 6,113,25 2; 6,046,861; 6,031,74 9; 6,01 1,640; 5,96 9,868; 5,959,768; 5, 934,794; 5,882, 107; 5,829,868; 5,825,548; 5,798,619; 5,774,273; 5,769,527; 5,758,956; 5,728,994; 5,640,061; 5,590,954; 5,454,477; 5,432,691; 5,367,444; 5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806; 4,972,306; 4,800,474; 4,779,176; 4,701,833; 4,602,321;

U. S. Design Patents No. 439,356; 420,332; 417,300; 415,301; 413,99 5; 377,338; 366,712; 359,574; 350,408; 347,113; Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646 ,588; 586,095; 576,400; 546,433; Australia Design Patents No. 128,796; 128,795; Canada Patents No. 2,070,670; 2,050,375; 1,270 ,675; 1,259,058; 1,181,795; Canada Design Patents No. 81,234; 81,233; 76,046; European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710; 0 495 305 ; 0 474 202 ; 0 379 97 0; 0 25 3 08 2;

0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068; Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89

166.9; 37 68 727.1; 37 51 804.6; 37 50 201.8; 35 87 270.5; 32 79 888.1; 32 74 291.6; Germany Design Patents No. M 98 01 745.4; M 96 04 5 15. 9; M 96 04 5 14.0; M 94 0 7 689. 8; M 94 0 2 95 1.2; M 499 03 5 83.6; M

498 11 203.9; G 93 12 884.3; Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328; Spain Utility Model Patent No. 2.031.748; Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573; Greece Patent No. 910.400.544; Hong Kong Patents No. 965/1990; 285/1987; Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,0 02,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241; 1,723,825;

1,683,007; 1,533,011; Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1,072,598; 1,060,414;

1,002,123; Korea Patents No. 76,310; 42,639; 283,770; 181,180; Korea Design Patents No. 209,896; 209,895; Mexico Patent No. 180,148; Singapore Patents No. 663/90; 134/87; Taiwan Patents No. 78,726; 66,975; 65,380; 28,275; United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.

™

, series 1000™, Series 2000™, Series 3000™, DICHRO❋TUNE™, VARI ❋IMAGE™,

™

, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC.

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. VL1000™ ERS Luminaire Service Manual 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. 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 Vari-Lite, 10911 Petal Street, Dallas, Texas 75238.

Version as of: 14-May-2009 Part number: 02.9663.0010 F

VL1000™ ERS Luminaire Service Manual

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HOW TO OBTAIN WARRANTY SERVICE

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) 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 included at the end of this manual and place in shipping container along with a copy of your invoice (if available). W r ite 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

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

Manual Revision History

PAGE NUMBER CHANGE NUMBER

Title Page – xviii F

1-205 F

VERSION DATE

Basic 14-March-02 Revision A 25-April-02 Revision B 02-May-02 Revision C 18-June-02 Revision D 23-October-02 Revision E 25-March-04 Revision F 14-May-2009

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Compliance Notice

FCC

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with Vari-Lite system, service, and safety guidelines, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her own expense.

Declaration of Conformity

We declare, under our sole responsibility, that this product complies with the relevant clauses of the following standards and harmonized documents (as applicable):

Safety:

(by Council Directive 73/23/EEC)

EN60598-1: 1997/A1:1998 EN60598-2-17: 1989/A2:1991 EN60922

Electromagnetic Compatibility:

(by Council Directive 89/336/EEC)

EN55022:1998, Class A EN61000-4-2: 1995, Performance Criteria: B EN61000-4-3: 1995, Performance Criteria: A EN61000-4-4: 1995, Performance Criteria: B EN61000-4-5: 1995, Performance Criteria: B EN61000-4-6: 1996, Performance Criteria: A EN61000-4-8: 1996, Performance Criteria: A EN61000-4-11: 1994, Performance Criteria: B and C EN61000-3-2: 1995 EN61000-3-3: 1994

We certify that the product conforms to the protection requirements of council directives: 73/23/EEC (LVD) and 89/336/EEC (EMC)

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SAFETY NOTICE

Safety Notice

It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product.

Safety symbols used throughout this manual are as follows:

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

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 only with certain Philips and Osram HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps. Installing another type of lamp may be hazardous.

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

3. Replace fuses with same type and rating only.

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

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.

WARNING: It is not recommended to power any VARI❋LITE® luminaire from a dimmer - even in 'NONDIM' mode. Dimmer and non-dim modules are not suitable sources of power because their output modifies the AC wave form. This may work for a short time, but will eventually result in power problems, luminaire mis-operation and/or failure. See Vari-Lite Technical Notice TN-229A for more information.

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

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

1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO NOT look directly at lamp.

2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired. For example, by cracks or deep scratches.

WARNING: INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS

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

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

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

4. Wear eye protection when relamping.

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

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

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

WARNING: RF INTERFERENCE

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

ARC LAMP CHARACTERISTIC CONSIDERATIONS

1. Arc lamps require a period of time to relight after a power i nterruption or a severe voltage dip. In some cases, lamp will automatically relight after it has cooled depending on Lamp Power-Up State (L ON/ LOFF) system configuration setting.

2. Burning position is Universal.

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SICHERHEITSHINWEISE

Sicherheitshinweise

Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw . be dienen. 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 Leb-

ensbedrohung hin.

NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.

WARNUNG: HINWEISE ZUM FEUERSCHUTZ

1. VARI❋LITE®-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Philips

und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp (MSR400, MSR575HR etc.), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines anderen Lampentyps kann gefährlich sein.

2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die

Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.

3. Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Stärke.

4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der

VARI ❋LITE®-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.

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.

WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG

1. Viele VARI❋LITE®-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen

abgibt. SCHAUEN SIE NICHT direkt in die Lampe.

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen ode r Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.

WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN

1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz etc.).

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

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

4. Tragen Sie beim Austausch der Lampen einen Augenschutz.

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

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

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

WARNUNG: HF-INTERFERENZ

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

BESONDERHEITEN VON BOGENLAMPEN

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

2. Die Brennposition ist Universal.

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NOTES DE SÉCURITÉ

Notes de sécurité

Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.

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.

AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES

1. Les luminaires VARI❋LITE® ont été conçus pour être utilisés uniquement avec certaines

lampes Philips et Osram HID. Vérifier le type de lampe (MSR400, MSR575HR etc.) avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un danger.

2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de

montage sont respectées. Voir les explications détaillées dans ce guide.

3. Ne remplacer les fusibles qu’avec ceux du même type, ayant les mêmes caractéristiques.

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

1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des rayons UV. NE PAS fixer son regard sur la lampe.

2. L’utilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages, lentilles ou écrans ultraviolet visiblement endommagés au point que leur efficacité en est affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures.

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

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

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

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

4. Se protéger les yeux pour remplacer la lampe.

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

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

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

AVERTISSEMENT: INTERFÉRENCE RF

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

CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC

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

2. La position Brûler est Universelle.

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AVISO SOBRE SEGURIDAD

Aviso sobre Seguridad

Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto.

Los símbolos de seguridad usados en este manual son los siguientes:

CUIDADO, indica posibles daños al producto.

ADVERTENCIA, indica posibles lesiones o muerte a las

personas.

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

ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO

1. Las luminarias VARI❋LITE® han sido diseñadas para ser usadas solamente con algunas

lámparas HID Philips y Osram. Tome nota del tipo de lámpara (MSR400, MSR575HR etc.) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.

2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las

instrucciones de instalación. Vea las instrucciones detalladas en este manual.

3. Reemplaze los fusibles solamente con los del mismo tipo y especificación.

4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos

iluminados para las luminarias VARI❋LITE®.

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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ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIAC IÓN ULTRA VIOLETA

1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación UV. NO mire directamente a la lámpara.

2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.

ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS

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

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

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

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

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

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

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

ADVERTENCIA: INTERFERENCIA RF

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

CONSIDERACIONES SOBRE LAS CARACTERÍSTICAS DE LA LÁMPARA DE ARCO

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

2. La posición de encendido es universal.

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SAFETY NOTICE (JAPANESE)

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Introduction

Disclosure .................................................................................................................... 1

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

Additional Documentation........................................................................................... 2

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

Chapter 1. Description

Features

Standard Features................................................................................................... .... .. 4

Model Specific Features .............................................................................................. 4

Component Descriptions

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

Luminaire Internal Head Components......................................................................... 7

Luminaire Internal Yoke Components......................................................................... 8

Arc Ballast Unit ........................................................................................................... 9

Dimmer Model............................................................................................................. 9

Principles of Operation

VL1000 Incandescent Source Luminaire................................................................... 10

VL1000 Incandescent Block Diagram - Without On-Board IGBT Dimmer...... 10

VL1000 Incandescent Cable Routing - Without On-Board IGBT Dimmer ....... 11

VL1000 Incandescent Block Diagram - With On-Board IGBT Dimmer........... 12

VL1000 Incandescent Cable Routing - With On-Board IGBT Dimmer............. 13

VL1000 Arc Source Luminaire ................................................................................. 14

VL1000 Arc Block Diagram............................................................................... 14

VL1000 Arc Cable Routing ................................................................................ 15

TABLE OF CONTENTS

Chapter 2. Maintenance

Testing

Running Parameter Tests ........................................................................................... 18

Maintenance Procedures

Lamp Replacement (Incandescent Model) ................................................................ 20

Lamp Replacement (Arc Model)............................................................................... 22

Align Lamp For Maximum Beam Irradiance............................................................ 24

Frame or Top Hat Replacement................................................................................. 25

Front Cover Removal................................................................................................. 26

Rear Head Assembly Removal.................................................................................. 27

Rotating Gobo Replacement...................................................................................... 28

Gobo Index Timing Belt Alignment.......................................................................... 30

Gobo Wheel Bulkhead Replacement......................................................................... 32

Gobo Gear Planet Alignment..................................................................................... 34

02.9663.0 010 F 14-May-2009 xv

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Shutter Assembly Replacement.................................................................................. 36

Shutter Blade or Rack Replacement........................................................................... 38

Edge/Zoom/Color Bulkhead Replacement................................................................. 40

Fan/Temp Switch Assembly Replacement................................................................. 41

Beam-Size Iris Assembly Replacement ..................................................................... 42

Ignitor PCB Replacement........................................................................................... 43

Power Supply Replacement........................................................................................ 44

Controller PCB Replacement..................................................................................... 46

Tilt Encoder PCB Replacement.................................................................................. 48

Tilt Motor Assembly Replacement............................................................................. 49

.............................................................................................................................. 50

Pan Motor Assembly Replacement............................................................................ 51

DMX Input PCB Replacement................................................................................... 53

Cleaning Optical Lenses and Filters........................................................................... 54

Chapter 3. Illustrated Parts Breakdown

Drawing Trees

VL1000 Incandescent Luminaires.............................................................................. 56

VL1000 Arc Luminaires............................................................................................. 58

Top Assembly

Included Items Kit...................................................................................................... 60

Included Items Kit (continued)................................................................................... 61

Label Locations.......................................................................................................... 62

VL1000 Luminaire .....................................................................................................64

Front Cover Assembly ....................................................................................... ..... ....67

Gel Frame Holder Assembly ......................................................................................68

COT (Center of Travel) Flag Assembly .....................................................................69

Head Assembly

Head Assembly ...........................................................................................................71

Front Head Assembly .................................................................................................72

Edge Control, Zoom, Dimmer & Color Assembly .....................................................74

Color Changer Assembly ...........................................................................................76

Cover Plate Assembly ................................................................................................79

Edge Barrel Assembly ................................................................................................80

Lens #6 Assembly ......................................................................................................82

Lens #7 Assembly ......................................................................................................83

Lens #8 Assembly ......................................................................................................84

Fan Assembly .............................................................................................................85

Pulley Side Rail Assembly .........................................................................................86

Sensor Side Rail Assembly ........................................................................................87

Incandescent Gobo Wheel Assembly ......................................................................... 88

Temperature Sensor Electrical Assembly ..................................................................91

Arc Gobo/Dimmer Bulkhead Assembly ....................................................................92

Gobo Wheel Assembly ...............................................................................................95

Shutter 6 Rollers Assembly ........................................................................................97

Beam-Size Iris Assembly .........................................................................................100

xvi 14-May-2009 02.9663.0 010 F

Page 17

TABLE OF CONTENTS

Rear Head Assembly ................................................................................................ 102

Back Cap Assembly ................................................................................................. 104

Yoke Assembly

Yoke Legs Assembly ............................................................................................... 107

Tilt Motor Assembly ................................................................................................ 110

Crossmember Assembly ..........................................................................................112

Inner Crossmember Assembly ................................................................................. 114

Outer Crossmember Assembly ................................................................................ 115

Pan Motor Assembly ................................................................. ..... .......................... 116

Pan Tube Assembly ................................................................................................. 118

DMX Input PCB Assembly ..................................................................................... 120

Cables

Arc Power Input (Pigtail) Cable Assembly ............................................................. 121

Pan EOT Cable Assembly ....................................................................................... 123

Tilt COT Cable Assembly ....................................................................................... 124

AC Line Input Cable Assembly ............................................................................... 125

Incandescent LVS AC Input Cable Assembly ......................................................... 126

Arc LVS AC Input Cable Assembly ........................................................................127

LVS Chassis Ground Cable Assembly ....................................................................128

Head to Backcap Ground Cable Assembly .............................................................. 129

Yoke to Head Ground Cable Assembly ................................................................... 130

Pan/Tilt Control Cable Assembly ............................................................................ 131

Ballast Control Link Cable Assembly .....................................................................133

Data I/O Link Cable Assembly ................................................................................134

LVS DC Output Cable Assembly ............................................................................135

Incandescent Power Input Cable Assembly ............................................................. 136

Incandescent Lamp Power Cable Assembly ......................................................... ...137

Arc Power to Ignitor Cable Asembly ....................................................................... 138

Ignitor to Lamp Socket Cable Assembly .................................................................139

Shutter Harness Cable Assembly ............................................................................. 140

Color/Gobo/Lens Harness Cable Assembly ............................................................ 142

Dimmer to LVS Cable Assembly ............................................................................ 145

Dimmer to Controller Cable Assembly ................................................................... 146

Dimmer to Lamp Socket Cable Assembly ............................................................... 147

575W Ballast I/O Cable Assembly .......................................................................... 148

Appendix A. Technical Bulletins

VL1000™ ERS Luminaire Technical Bulletins ...................................................... 151

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Page 18

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

(This page intentionally blank.)

xviii 14-May-2009 02.9663.0 010 F

Page 19

Introduction

Disclosure

This technical manual is confidential property of Vari-Lite All information contained herein is the sole and exclusive property of Vari-Lite and may not be used, disclosed, or reproduced in any manner without the prior written consent of Vari-Lite

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

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL1000™ ERS Luminaire. The manual is intended for use by Vari-Lite personnel and by Vari-Lite’s Authorized Dealers and Service Centers.

INTRODUCTION :

This manual covers the following models:

Model Part Number Source Dimmer Shutter Iris

VL1000 TS 20.9663.0001.02 Incandescent - X VL1000 TI 20.9663.0001.03 Incandescent - X VL1000 AS 20.9663.0001.12 Arc - X VL1000 AI 20.9663.0001.13 Arc - X VL1000 TSD 20.9663.0001.22 Incandescent 115V X VL1000 TID 20.9663.0001.23 Incandescent 115V X VL1000 TSE 20.9663.0001.32 Incandescent 240V X VL1000 TIE 20.9663.0001.33 Incandescent 240V X

Note: Performing maintenance procedures contained in this manual may void the product warranty. Refer to the Vari-Lite Limited Warranty card included in the shipping package for this VARI❋LITE® product.

WARNING: It is not recommended to power any VARI❋LITE® luminaire from a dimmer - even in 'NONDIM' mode. Dimmer and non-dim modules are not suitable sources of power because their output modifies the AC wave form. See Vari-Lite Technical Notice TN-229A for more information.

02.9663.0 010 F 14-May-2009 1

Page 20

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Additional Documentation

A support webpage for Series 1000 luminaires is available at www.vari-lite.com (follow the Support link).

A user’s manual is available for installation and operation of all versions of the VL1000™ ERS Luminaire. This manual is only available in electronic (PDF) format.

■ VL1000™ ERS Luminaire User’s Manual (02.9663.0001).

T echnical bulletins concerning the latest changes to VARI❋LITE® equipment are also available at the website Technical Support Center. These are documentation supplements that contain procedures for equipment upgrades, retrofits, and additional repairs. Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised.

Customer Service

Our Goal

At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone troubleshooting assistance, product training or technical service, our fulltime staff of experienced professionals are on-hand to provide support.

How to Reach Us

For assistance in your area, call the dealer from which your product(s) were purchased.

Contact an Authorized Service Center.

Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through Friday, at the following:

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

fax: 1-214-647-8038

email: [email protected]

Additional Resources

For additional resources and documentation, please visit our website at:

www.vari-lite.com and follow the Support link.

2 14-May-2009 02.9663.0 010 F

Page 21

CHAPTER 1.

Description

This chapter provides an overview of luminaire features, components and operations.

• Features

• Component Descriptions

• Principles of Operation

02.9663.0 010 F 14-May-2009 3

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Features

Standard Features

VL1000 Ellipsoidal Reflector Spotlight (ERS) luminaires have the following standard features:

• Automated zoom optics system.

• Crossfading CYM color system.

• Diffusion system.

• Six-position rotating gobo wheel (five rotatable, indexable gobo positions and one open gobo position).

• Repositional pan/tilt system.

• Control by DMX512 protocol.

Model Specific Features

Each individual configuration has the following specific features:

VL1000 TS (20.9663.0001.02)

• 1000W Tungsten Halogen lamp source.

• Four-blade shutter framing system.

VL1000 TI Luminaire (20.9663.0001.03)

• 1000W Tungsten Halogen lamp source.

• Beam-size iris mechanism.

VL1000 AS (20.9663.0001.12)

• 575W arc lamp source with external ballast unit.

• Four-blade shutter framing system.

VL1000 AI (20.9663.0001.13)

• 575W arc lamp source with external ballast unit.

• Beam-size iris mechanism.

4 14-May-2009 02.9663.0010 F

Page 23

VL1000 TSD Luminaire (20.9663.0001.22)

• 1000W Tungsten Halogen lamp source.

• 115V on-board dimmer.

• Four-blade shutter framing system.

VL1000 TID Luminaire (20.9663.0001.23)

• 1000W Tungsten Halogen lamp source.

• 115V on-board dimmer.

• Beam-size iris mechanism.

VL1000 TSE Luminaire (20.9663.0001.32)

• 1000W Tungsten Halogen lamp source.

• 240V on-board dimmer.

• Four-blade shutter framing system.

DESCRIPTION :

VL1000 TIE Luminaire (20.9663.0001.33)

• 1000W Tungsten Halogen lamp source.

• 240V on-board dimmer.

• Beam-size iris mechanism.

02.9663.0 010 F 14-May-2009 5

Page 24

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Component Descriptions

External Luminaire Components

The following illustration shows the external luminaire components and controls.

Input Panel

Provides DMX In and Thru, and AC Power connections.

Lamp Power Input Cable

Yoke Leg (Power)

Contains power supply, and ignitor board (arc units) or dimmer (dimmer units).

Accessory Frame Holder

Provides frame for optional silks, frosts, color. correction or top hats.

See detail...

Menu Display Controls

Base

Provides hook mounting holes and safety cable connection.

Yoke Leg (Control)

Contains main control PCB and display PCB.

Backcap Assembly

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

Menu Display

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

Head Assembly

Houses color, gobo, dimmer, strobe, and optional shutter or iris mechanisms.

LCD Display

Input Panel Connections

Latch

Accepts frames or top hats

Accessory Frame Holder

Accessory Frame

Beam Adjustment Controls

Beam Adjust Screws *

* Do not remove or use to access lamp.

Gel, Silk or Frost

Address

ENTERMENU

Press to show menu, or if at first level, the current address.

Press to select current menu option or current data value.

Down / Decrease

Up / Increase

Lamp Power

Input Cable

Data In Data Thru

6 14-May-2009 02.9663.0010 F

3-Pole Neutrik

Locking Connector

for AC Input

Page 25

DESCRIPTION :

Luminaire Internal Head Components

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

A options - Shutter or Beam-size Iris bulkhead is dependent on model. B options - Rotating Gobo Bulkhead version is dependent on model.

Beam-Size Iris Assembly (optional)

Provides beam sizing capabilities.

Shutter Assembly (optional)

Four-blade system can frame and crop beam field and gobos.

Rear Head Assembly

Six-position rotating gobo wheel with five rotatable, indexable gobo positions and one open gobo position.

Edge, Zoom, Dimmer Bulkhead

Contains automated zoom optics lenses, crossfading CYM system, and diffusion.

Front Cover

Provides frame for mounting silks, frosts, color correction or top hat. Removed by unlatching two latches.

Arc Gobo Bulkhead

Provides six position rotatable/indexable gobo wheel for projecting images.

See options A

Backcap Assembly

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

See options B

Incandescent Gobo Bulkhead

Provides six position rotatable/indexable gobo wheel for projecting images.

02.9663.0 010 F 14-May-2009 7

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Luminaire Internal Yoke Components

The following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly.

Note: Head assembly not shown for clarity.

Tilt Mechanism

Yoke Arm Cover (Power Supply Side)

Yoke Arm Cover

(Display Side)

Main Controller PCB

Luminaire control circuit board.

Pan Mechanism

150W Power Supply

Supplies power to electronic and motor components.

Ignitor PCB

Ignites lamp in arc models.

Internal Dimmer

Powers lamp in some models.

8 14-May-2009 02.9663.0010 F

Page 27

DESCRIPTION :

Arc Ballast Unit

An external ballast unit is included with VL1000 arc models. In this case, the lamp power input cable is already connectorized for use with this unit.

The following illustration shows the external arc ballast components.

Lamp Connector

CPC-type connector for connecting Lamp Power Input cable from luminaire.

Truss Hook Mount

Used to attach a truss hook.

Safety Cable Tab

Used to attach safety cable clip.

Ballast Unit

Provides power for arc lamp source.

Lamp Power Input Cable

Supplied cable and connector used to connect luminaire to ballast unit. 40 inches (1m)

Note: The Lamp Power Input Cable has conductors for lamp power and ballast control. It is not compatible with VARI❋LITE Series 300™ lamp runs.

Dimmer Model

An on-board IGBT dimmer is included with VL1000 incandescent dimmer models. The dimmer heatsink is visible on the power-side yoke leg as shown in this illustration.

On-Board IGBT Dimmer

Internal lamp power dimmer, configured for either 120V or 240V operation depending on model.

02.9663.0 010 F 14-May-2009 9

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Principles of Operation

VL1000 Incandescent Source Luminaire

VL1000 Incandescent Block Diagram - Without On-Board IGBT Dimmer

DATA

I/O

DATA

I/O

AC LINE POWER

LAMP

POWER

NEUTRIK

XLR-M

DMX INPUT

NEUTRIK

XLR-F

DMX THRU

DMX PCB

NEUTRIK

POWERCON

AC LINE IN

2015

USER

PROVIDED

CONNECTOR

FOR LAMP

PWR INPUT

FROM

DIMMER

2030

2040

2042

AC LINE

16/2 2015

AC GND

16/1 2015

DIMMER GND

1.5/1 2030

LAMP

POWER

1.5/2 2030

PIGTAIL

DATA

22/5

2022

FAN 24/2

(SHUTTERS)

(WITHOUT)

FAN

AC GND

22x4 2016

CHASSIS

GND STUD

CHASSIS

GND STUD

1766

ZOOM

MOTOR

1202

EDGE

MOTOR

24/4

SENSOR 1

26/4

GOBO WHEEL

SENSOR

TERM

BLOCK

TERM

BLOCK

1202

GOBO INDEX

1202 1520

GOBO

WHEEL

24/4

AC LINE

AC GND

24/4

SENSOR 2

26/4

GOBO INDEX

SENSOR

22x4/2

2016

16/1

2017

YOKE

GND STUDS

24/4

1520

BLUE

MOTOR

1520

AMBER MOTOR

24/4

+24V

18/4

2024

+24V

LOW

VOLTAGE

SUPPLY

HEAD GND

LAMP

POWER

22x4/2

2031

1520 1766 MAG

MOTOR

DIFF

MOTOR

24/4

DOWNUPMENU ENTER

J7J6J4

YOKE TO

22x4 2019

24/4

DIMMER

ARC

( )

ONLY

1202/1326

B.S.IRIS/

SHUTTER

ROTATE

M12 24/4

M13 26/4

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M14 26/4

MAIN CONTROL

PCB ASSY

SENSOR 3,4,5

M10

PAN ENCODER

24/4

2020

PAN

MOTOR

PCB ASSY

PAN EOT

PAN EOT SENSOR

HEAD

GND STUDS

AMP

SERIES 30

1301

M15 26/4

SHUTTER

FRAME

1301

SHUTTER

FRAME

M16 26/4

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M17 26/4

M18 26/4

20402050

DISPLAY8

20202050

M11 24/4 2020

2018

SENSOR 6,7,8

TILT ENCODER

24/5

J1 J1

J2 J2

TILT

26/4

MOTOR

18501850

HEAD TO

BACK CAP

LAMP

POWER

16/2HT

2032

BRAID

M19 26/4

24/5

PCB ASSY

TILT COT

26/4

TILT COT SENSOR

1000W

INCAND

LAMP

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M20 26/4

BACK CAP GND STUD

10 14-May-2009 02.9663.0010 F

Page 29

DESCRIPTION :

VL1000 Incandescent Cable Routing - Without On-Board IGBT Dimmer

CHASSIS

USER

PROVIDED

CONNECTOR

FOR LAMP PWR

INPUT FROM

DIMMER

PIGTAIL &

STRAIN RELIEF

GND

STUD

LAMP PWR

2030

DIMMER GND

NEUTRIK

POWERCON

AC LINE IN

2015

GND

STUD

AC LINE 2015

TERM

BLOCK

LAMP

PWR

2031

TERM

BLOCK

AC GND 2016

AC LINE 2016

DMX

DATA

2022

DMX PCB

PAN

TUBE

XLR-M

DMX

INPUT

XLR-F

DMX

THRU

TILT COT 2002

PAN

MOTOR

& ENC

PCB

LAMP

PWR 2031

TILT COT SENSOR

PAN EOT

PAN - 2020

TILT COT - 2002

LVS

GND 2017

GND STUD

2001

PAN EOT SENSOR

LAMP PWR - 2031

AC GND - 2016

LVS

ASSY

LAMP PWR - 2031

YOKE/HEAD GND - 2019

GND STUD GND STUD

TILT

TUBE

AC LINE - 2016

LAMP

PWR

2032

AMP

SERIES

+24VDC - 2024

LAMP

SOCKET

INC

LAMP

CONTROL

MOTORS

GOBO

SENSE

SHUTTER

MOTORS

(OPT)

BACK CAP

GND STUD

BACK CAP/ HEAD GND

2018

GND STUD

10 MOTORS/ 2 SENSORS - 2050

FAN

8 MOTORS - 2040

YOKE

TILT COT

PAN - 2020

DMX DATA - 2022

5 54

MCB

PCB

FAN - 2040 or 2042

TILT

TUBE

2002

TILT

MOTOR

& ENC

PCB

TILT 2020

PAN

2020

HEAD

02.9663.0 010 F 14-May-2009 11

Page 30

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Incandescent Block Diagram - With On-Board IGBT Dimmer

DATA

I/O

DATA

I/O

AC LINE POWER

NEUTRIK

XLR-M

DMX INPUT

NEUTRIK

XLR-F

DMX THRU

DMX PCB

NEUTRIK

POWERCON

AC LINE IN

2015

AC LINE

16/2 2015

AC GND

16/1 2015

2040

2042

DATA

22/5

2022

FAN 24/2

(SHUTTERS)

(WITHOUT)

FAN

AC GND

22x4 2016

CHASSIS

GND STUD

1766

ZOOM

MOTOR

1202

EDGE

MOTOR

24/4

SENSOR 1

26/4

GOBO WHEEL

SENSOR

TERM

BLOCK

1202

GOBO INDEX

1202 1520

GOBO

WHEEL

24/4

AC LINE

AC GND

GND STUDS

24/4

SENSOR 2

26/4

GOBO INDEX

SENSOR

22x4/2

2016

16/1

2017

YOKE

24/4

1520

BLUE

MOTOR

1520

AMBER MOTOR

24/4

+24V

18/4

2024

+24V

LOW

VOLTAGE

SUPPLY

HEAD GND

1520 1766 MAG

MOTOR

DIFF

MOTOR

24/4

DOWNUPMENU ENTER

J7J6J4

YOKE TO

22x4 2019

24/4

DIMMER

ARC

( )

ONLY

1202/1326

B.S.IRIS/

SHUTTER

ROTATE

M12 24/4

M13 26/4

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M14 26/4

MAIN CONTROL

PCB ASSY

SENSOR 3,4,5

M10

PAN ENCODER

24/4

2020

PAN

MOTOR

PCB ASSY

HEAD

GND STUDS

PAN EOT

PAN EOT SENSOR

1301

M15 26/4

SHUTTER

FRAME

1301

SHUTTER

FRAME

M16 26/4

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M17 26/4

M18 26/4

20402050

DISPLAY8

20202050

M11 24/4 2020

2018

SENSOR 6,7,8

TILT ENCODER

24/5

J1 J1

J2 J2

TILT

26/4

MOTOR

18501850

HEAD TO

BACK CAP

BRAID

M19 26/4

24/5

PCB ASSY

TILT COT

26/4

TILT COT SENSOR

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M20 26/4

BACK CAP GND STUD

LAMP

POWER

16/2HT

2032

DIMMER

115V or 240V

LAMP

POWER

22x4/2

2031

1000W

INCAND

LAMP

12 14-May-2009 02.9663.0010 F

Page 31

DESCRIPTION :

VL1000 Incandescent Cable Routing - With On-Board IGBT Dimmer

CHASSIS

NEUTRIK

POWERCON

AC LINE IN

GND

STUD

2015

AC LINE 2015

TERM

BLOCK

AC GND 2016

AC LINE 2016

DMX

DATA

2022

DMX PCB

PAN

TUBE

XLR-M

DMX

INPUT

XLR-F

DMX

THRU

TILT COT 2002

PAN

MOTOR

& ENC

PCB

LAMP

PWR

2031

TILT COT

PAN - 2020

GND STUD

SENSOR

PAN EOT

2001

TILT COT - 2002

LVS

GND 2017

PAN EOT

SENSOR

AC GND - 2016

AC LINE - 2016

LVS

ASSY

69-

3128-

0150

LAMP PWR - 2031

YOKE/HEAD GND - 2019

GND STUD GND STUD

TILT

TUBE

LAMP

PWR 2032

DIMMER

+24VDC - 2024

LAMP

SOCKET

INC

LAMP

CONTROL

MOTORS

GOBO

SENSE

SHUTTER

MOTORS

(OPT)

BACK CAP

GND STUD

BACK CAP/ HEAD GND

2018

GND STUD

10 MOTORS/ 2 SENSORS - 2050

FAN

8 MOTORS - 2040

YOKE

TILT COT

PAN - 2020

DMX DATA - 2022

5 54

MCB PCB

FAN - 2040 or 2042

TILT

TUBE

2002

TILT

MOTOR

& ENC

PCB

TILT

2020

PAN 2020

HEAD

02.9663.0 010 F 14-May-2009 13

Page 32

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Arc Source Luminaire

VL1000 Arc Block Diagram

DATA

I/O

DATA

I/O

AC LINE POWER

BALLAST

CONTROL

LAMP

POWER

NEUTRIK

XLR-M

DMX INPUT

NEUTRIK

XLR-F

DMX THRU

DMX PCB

NEUTRIK

POWERCON

AC LINE IN

2015

AMP CPC 17-9 PLUG LAMP PWR

INPUT & AC LINE OUTPUT

TO BALLAST

1921 HIGH

CURRENT

CONTACTS

2040

2042

AC LINE

16/2

AC GND

16/1 2015

CHASSIS

GND STUD AC LINE

16/2

BALLAST GND

16/1 1921

LAMP POWER

14/2

1921

PIGTAIL

DATA

22/5

2022

FAN 24/2

(SHUTTERS)

(WITHOUT)

FAN

AC GND

22x4 2016

CHASSIS

GND STUD

1766

ZOOM

MOTOR

1202

EDGE

MOTOR

24/4

SENSOR 1

26/4

GOBO WHEEL

SENSOR

TERM

BLOCK

TERM

BLOCK

1202

GOBO INDEX

1202 1520

GOBO

WHEEL

24/4

CONTROL

AC LINE

AC GND

BALLAST

24/4

SENSOR 2

26/4

GOBO INDEX

SENSOR

22x4/2

2016

16/1

2017

YOKE

GND STUDS

22/4

1921

24/4

LAMP POWER

22x4/2

1520

BLUE

MOTOR

1520

AMBER MOTOR

24/4

+24V

18/4

2024

+24V

LOW

VOLTAGE

SUPPLY

YOKE TO

HEAD GND

2035

1520 1766 MAG

MOTOR

DIFF

MOTOR

24/4

DOWNUPMENU ENTER

J7J6J4

BALLAST

CONTROL

22/4 1921

22x4 2019

M13 26/4

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M14 26/4

M15 26/4

DIMMER

ARC

( )

ONLY

1202/1326

B.S.IRIS/

SHUTTER

ROTATE

M12 24/4

MAIN CONTROL

PCB ASSY

SENSOR 3,4,5

24/5

M10 24/4 2020

PAN

MOTOR

GND STUDS

IGNITOR

PCB ASSY

J1 J1

PAN ENCODER

PCB ASSY

J2 J2

PAN EOT

26/4

PAN EOT SENSOR

HEAD

O U T

SHUTTER

20202050

1301

FRAME

1301

FRAME

M17

26/4 M16 26/4

20402050

DISPLAY8

M11 24/4

2020

TILT

MOTOR

18501850

HEAD TO

BACK CAP

BRAID

2018

LAMP HV

16/2HV

2036

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M19

26/4 M18 26/4

SENSOR 6,7,8

24/5

TILT ENCODER

PCB ASSY

TILT COT

26/4

TILT COT

SENSOR

575W

ARC

LAMP

1301

SHUTTER

FRAME

1301

SHUTTER

FRAME

M20 26/4

BACK CAP GND STUD

14 14-May-2009 02.9663.0010 F

Page 33

VL1000 Arc Cable Routing

DESCRIPTION :

AMP

CPC 17-9

LAMP POWER IN

& AC LINE OUT

TO BALLAST

1921

PIGTAIL &

STRAIN RELIEF

PAN

MOTOR

& ENC

PCB

PAN - 2020

GND STUD

TILT COT 2002

LAMP

PWR

2035

TILT COT

SENSOR

NEUTRIK

POWERCON

AC LINE IN

GND

STUD 1

AC LINE

BAL CONT

LAMP PWR

BALLAST GND

PAN EOT

2001

TILT COT - 2002

LAMP PWR - 2035

LVS GND 2017

LVS

ASSY

2015

PAN EOT SENSOR

AC GND - 2016

GND 2016

GND

STUD

AC LINE - 2016

TERM

BLOCK

LAMP

PWR

2035

LAMP

2036

IGN

PCB

LAMP PWR - 2035

YOKE/HEAD GND - 2019

GND STUD GND STUD

TILT

TUBE

AC LINE 2015

TERM

BLOCK

LINE

GND

2016

+24VDC - 2024

LAMP

SOCKET

ARC

LAMP

CONTROL

MOTORS

GOBO

SENSE

8 SHUTTER MOTORS

(OPT)

CHASSIS

DMX

BAL

DATA

CONT

2022

1921

BACK CAP

GND STUD

BACK CAP/ HEAD GND

2018

GND STUD

FAN

XLR-M

DMX

INPUT

DMX PCB

XLR-F

DMX

THRU

PAN

TUBE

YOKE

TILT COT

2002

PAN - 2020

DMX DATA - 2022

BAL CONT - 1921

5 54

MCB

PCB

10 MOTORS/ 2 SENSORS - 2050

FAN - 2040 or 2042

8 MOTORS - 2040

TILT

TUBE

TILT

MOTOR

& ENC

PCB

TILT

2020

PAN 2020

HEAD

02.9663.0 010 F 14-May-2009 15

Page 34

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Notes

16 14-May-2009 02.9663.0010 F

Page 35

CHAPTER 2.

Maintenance

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

• Testing

• Maintenance Procedures

WARNING: All maintenance procedures are to be performed with

power removed from the luminaire. Never remove cover or backcap while lamp is in operation.

02.9663.0 010 F 14-May-2009 17

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Testing

Running Parameter Tests

The luminaire is capable of running self tests by using the TEST menu functions. When running tests on multiple luminaires, a loopback connector is required at the

master luminaire (first in link) and a male termination connector is required at the last luminaire in the link. Refer to the VL1000 ERS User’s Manual for more information regarding these connectors.

Note: After 10 seconds of inactivity , the menu display will change to the default state showing the address.

To connect luminaires for simultaneous testing:

Step 1. At first luminaire in link, install loopback connector into DATA IN XLR

connector.

Step 2. At last luminaire, install male termination connector into DATA THRU XLR

connector.

First luminaire containing software version to download

Data Thru

Loopback Connector

Luminaire 1 requiring update

Luminaire 2 requiring update

Data Thru

Male Termination Connector

Step 3. At master luminaire Menu Display, press [Menu].

Movement Disable

The Movement option has been added to the configuration menu. This allows for pan/tilt functions to be disabled so that the luminaire can be placed in any position for testing without movement occurring. In order to regain full control of the luminaire, Movement will need to be enabled after testing.

Note: When setting the Movement option to disable, luminaires linked by a loopback connector will have pan and tilt disabled for all the luminaires that are linked.

18 14-May-2009 02.9663.0010 F

Page 37

MAINTENANCE :

WARNING: Backcap and adjustment knobs will be HOT during lamp operation. Wear gloves and/or use tools to prevent burns.

To run tests:

Step 1. Press [Menu]. Step 2. Press [Up] / [Down] arrows until Test appears. Press [Enter]. Step 3. Use [Up] / [Down] arrows to select a parameter to test. Refer to table below

for a complete list of test parameters. Step 4. Press [Enter] to run test. Step 5. Press [Menu] to stop test at any time.

Table 2-1: Self Test Function Chart

1st Level 2nd Level 3rd Level 4th Level 5thLevel

Test

System Test

ALL Test All Motors RUN TEST Run-Test in Progress Press [Menu] to stop Pan/Tilt RUN TEST Run-Test in Progress Dimmer (Arc Only) RUN TEST Run-Test in Progress Blue RUN TEST Run-Test in Progress Amber RUN TEST Run-Test in Progress Magenta RUN TEST Run-Test in Progress ColorMix Blue, Amber, Magenta test RUN TEST Run-Test in Progress Diffusn Diffusion Test RUN TEST Run-Test in Progress Rot Gobo Rotating Gobo Test RUN TEST Run-Test in Progress Edge RUN TEST Run-Test in Progress Zoom RUN TEST Run-Test in Progress Beam (If Beam-Size Iris Accessory) RUN TEST Run-Test in Progress Shutter (If Shutter Accessory) RUN TEST Run-Test in Progress Rot Shut (If Shutter Accessory) RUN TEST Run-Test in Progress Lamp Disables Pan/Tilt and executes

Home position.

Encoder Encoders Pan Pan Encoder XXXX Data

Sensor Sensors Pan COT Sensor STST Sensor Test in

RUN TEST Run-Test in Progress

Tilt Tilt Encoder XXXX Data

Tilt COT Sensor

Rot Gobo Gobo Select EOT

Sensor GoboIndx Gobo Index EOT

Sensor

tests

Progress STST Sensor Test in

Progress

PASS/FAIL

02.9663.0 010 F 14-May-2009 19

Page 38

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Maintenance Procedures

Lamp Replacement (Incandescent Model)

Parts:

1000 WATT INCANDESCENT LAMP, 100 VAC (71.2552.0100) - TS/TI 1000 WATT INCANDESCENT LAMP, 115 VAC (71.2552.0115) - TS/TI 1000 WATT INCANDESCENT LAMP, 240 VAC (71.2554.0240) - TS/TI

Tools:

#2 Phillips screwdriver, cotton gloves

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

To install incandescent lamp:

Step 1. Remove power from luminaire. Step 2. At backcap, gradually loosen two 10-32x2-3/8" PPSS black screws

(Figure 2-1) a few turns at a time until backcap is free. (Screws must be alternately loosened to prevent one side from locking up.)

Do not touch lamp

Rear Head Assembly

Align when re-installing

CAUTION:

Alignment Stud (2)

Holes and studs MUST be aligned when re-installing.

CAUTION:

with bare fingers.

Backcap

10-32x2-3/8 PPSS Black Screws (captive)

- loosen each gradually

Backcap Interior View

Alignment Hole (2)

Figure 2-1: Removing Incandescent Backcap

20 14-May-2009 02.9663.0010 F

Page 39

MAINTENANCE :

Step 3. Carefully pull backcap straight out of rear head assembly. (It will still be

attached by lamp wires and tether.) Step 4. At backcap, flip two bail clamps outward (Figure 2-2). Step 5. Flip two base clamps outward away from socket. Step 6. Grip lamp by base and firmly install in socket. Step 7. Close base and bail clamps, locking into place.

Do not touch lamp

CAUTION:

with bare fingers.

Flip bail clamps outward.

Socket

Close base clamps.

Bail Clamps

Flip base clamps outward.

Install lamp, firmly pressing into place.

Lamp

Base Clamps

Close bail clamps.

Figure 2-2: Installing Incandescent Lamp in Socket

Step 8. Re-install backcap, ensuring that alignment studs and holes are aligned

(Figure 2-1). Step 9. Align lamp. (Refer to “Align Lamp For Maximum Beam Irradiance” on

page 24.)

02.9663.0 010 F 14-May-2009 21

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Lamp Replacement (Arc Model)

Parts:

575 WATT ARC LAMP, MSR575HR (71.2528.0575) - AS/AI

Tools:

#2 Phillips screwdriver, cotton gloves

To install arc lamp:

Step 1. Remove power from luminaire. Step 2. At backcap, gradually loosen two 10-32x2-3/8" PPSS black screws

(Figure 2-3) a few turns at a time until backcap is free. (Screws must be alternately loosened to prevent one side from locking up.)

Rear Head Assembly

Backcap Interior View

CAUTION:

Align when re-installing

Alignment Stud (2)

Holes and studs MUST be

CAUTION:

Alignment Hole (2)

aligned when re-installing.

Figure 2-3: Removing Arc Backcap

Do not touch lamp with bare fingers.

Backcap

10-32x2-3/8 PPSS Black Screws (captive)

- loosen each gradually

22 14-May-2009 02.9663.0010 F

Page 41

MAINTENANCE :

Step 3. Grip lamp by base and firmly install in socket (Figure 2-4).

Do not touch lamp

CAUTION:

Socket

Lamp

Install lamp, firmly pressing into place.

with bare fingers.

Figure 2-4: Installing Arc Lamp in Socket

Step 4. Re-install backcap, ensuring that alignment studs and holes are aligned

(Figure 2-3). Step 5. Align lamp. (Refer to “Align Lamp For Maximum Beam Irradiance” on

page 24.)

02.9663.0 010 F 14-May-2009 23

Page 42

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Align Lamp For Maximum Beam Irradiance

After a new lamp is installed in either the incandescent or arc version of the luminaire, it will be necessary to align the lamp to optimize the beam.

Tools:

#2 Phillips screwdriver

WARNING: Backcap and adjustment screws will be HOT during lamp operation. Wear gloves and/or use tools to prevent burns.

To align lamp:

Step 1. Set intensity to 100%. Step 2. Position beam on a white wall at a distance of 10 to 20 feet. Step 3. Using console or internal luminaire menu controls, set zoom to zero and

focus to a hard edge. If installed, be sure that beam-size iris and shutters are open.

Step 4. Using three adjustment screws, adjust hot spot to center of beam

(Figure 2-5).

Step 5. Check color uniformity as follows:

a. Position one of the color stages at 30% of maximum. (Cyan or Magenta

work best.)

b. Verify that beam color is uniform (if lamp is misaligned, color will be

concentrated to one side of beam). If color is not uniform, readjust lamp

until color is uniform across entire beam field.

Beam Adjustment Screws *

* Do not remove or use to access lamp.

Figure 2-5: Lamp Alignment Screws

24 14-May-2009 02.9663.0010 F

Page 43

MAINTENANCE :

Frame or Top Hat Replacement

An accessory frame holder is provided for the addition of a top hat or gel frame with silks, frosts or color correction if required. The frame holder is designed to fit a standard 7.5-inch gel frame or top hat.

To remove and replace frame or top hat:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. At front lens, press upward on accessory frame latch and turn to open. Step 3. Remove frame/top hat, if any (Figure 2-6). Step 4. Install frame/top hat and close latch.

Gel, Silk, or Frost

Latch

Press Up

and Turn

Head Assembly

Accessory Frame

NOTE:

The accessory frame is not a Vari-Lite accessory.

Figure 2-6: Installing a Frame or Top Hat

02.9663.0 010 F 14-May-2009 25

Page 44

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Front Cover Removal

Parts:

ASSY, FRONT COVER (22.9663.1038)

Tools:

#2 Phillips screwdriver

To remove and replace front cover:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head assembly, press in front cover latches to release (Figure 2-7). Step 3. Pull cover straight out until stopped by tether. Step 4. Disconnect tether by removing 8-32x1/2" PFB screw and 8-32 Keps nut as

shown. Step 5. Remove cover. Step 6. Replace front cover by doing steps 2 through 5 in reverse. Ensure latches

lock into place.

Head Assembly

Front Cover

Latch (x2)

NOTE:

Yoke not shown for clarity.

Press in to release cover

Remove this 8-32x1/2" screw (and nut) to disconnect tether

Figure 2-7: Front Cover Removal/Replacement

26 14-May-2009 02.9663.0010 F

Page 45

MAINTENANCE :

Rear Head Assembly Removal

This procedure is necessary in order to access some components such as the gobo wheel bulkhead and shutter assembly. Refer to as needed.

Tools:

#2 Phillips long handle screwdriver

To remove rear head assembly:

Step 1. Disconnect luminaire AC input cable from power source.

CAUTION: The rear head assembly is heavy and will remain attached by lamp wires. Place luminaire on tech bench before removing rear assembly.

Step 2. At side rails, remove four 10-32x5/8" PPB screws and #10 split lock washers

(Figure 2-8). (Side rail spacers will come loose also.)

Step 3. Pull rear head assembly away from front head assembly. Step 4. Re-install by doing steps 2 and 3 in reverse.

Front Head Assembly

NOTE:

Yoke not shown for clarity.

Lamp Wires

Side Rail Spacer

Rear Head Assembly

#10 Split Lock Washer

Figure 2-8: Rear Head Assembly Removal and Replacement

10-32x5/8" PPB Screw

02.9663.0 010 F 14-May-2009 27

Page 46

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Rotating Gobo Replacement

WARNING: Remove power from luminaire before performing maintenance. Gobos may be HOT after operation. Allow to cool before replacing.

WARNING: Users of VARI❋LITE luminaires should not install or use metal gobos. The

use of metal gobos in any VARI luminaire’s warranty.

To replace a rotating gobo:

Step 1. Remove power from luminaire. Step 2. At either side of head assembly, press in front cover latch and pull cover

straight back until stopped by tether (Figure 2-7). Step 3. Rotate gobo wheel until required gobo position is accessible at finger access

cutout (Figure 2-9).

❋LITE product may damage the luminaire and could void the

Step 4. Rotate gobo gear until open end of carrier is upward.

CAUTION: Do not touch gobos with bare fingers. Wear cotton gloves or other covering while replacing. Clean with glass cleaner and soft cloth if required.

CAUTION: Do not pull metal spring clip carrier back too far or it will not close properly.

Step 5. If applicable, carefully pull current gobo up and out of carrier. Gobo can be

easily scratched on sides of carrier if not careful.

Step 6. Carefully install new gobo, orienting side marked "This Edge In" toward

center of gobo wheel and side marked "Lamp Side" (mirror finish) toward

lamp. Gobo can be easily scratched on sides of carrier if not careful. Ensure

gobo is firmly set in carrier grooves. Step 7. Re-install front cover.

28 14-May-2009 02.9663.0010 F

Page 47

Rotating Gobo Replacement (continued)

CAUTION:

Gobo MUST be oriented with side marked "This Edge In" toward center of wheel and side marked "Lamp Side" toward lamp. If not oriented properly, gobo will break.

Be careful not to scratch gobo on side of carrier when installing.

MAINTENANCE :

Inside Edge

- orient toward center of wheel

ThisEdgeIn

Gobo Positions

Sensor

Gobo Wheel Front View

open

LampSide

Lamp Side (mirrored)

- orient toward luminaire lamp

Front Cover

Gobo (black side)

Closed End

Latch

Rotate until open end of carrier is up

Gear

Open End

Rotating Gobo Wheel

Lamp End

CAUTION:

Be careful not to pull metal spring clip carrier back too far or it will not close properly.

Center of Wheel

Figure 2-9: Rotating Gobo Replacement/Cleaning

02.9663.0 010 F 14-May-2009 29

Page 48

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Gobo Index Timing Belt Alignment

The index timing belt (54.9663.1220) must be aligned so that the mechanism "clocks" properly. This belt is installed around the index gear and top gear of the gobo wheel (refer to Figure 2-11). The wheel position belt (54.2045.0002) is installed around the wheel position gear and bottom gear of the gobo wheel, and does not require alignment. Each belt is also routed around one pulley as shown in Figure 2-11.

Note: The alignment procedure is the same for both arc and incandescent versions.

Use the following procedure to re-align the index timing belt in the event it slips or the gobo wheel is removed from the bulkhead. (This procedure assumes that the wheel has been removed from the bulkhead assembly . If you are simply re-aligning the belt, S tep 2 can be skipped.)

To align index timing belt:

Step 1. At large gear, align one of belt’s clock marks with small groove at inside of

gear. The clock mar ks will either be two ridges (newer belts) or one ridge and

one red mark (older belts).

Ridge

Groove

Clock Mark

use red mark (older belts)

ridge (newer belts)

Index Timing Belt

red mark will be one-tooth inside ridge, use as clock mark (instead of ridge) if present

Index Timing Belt

Ridge

Index Gear (Larger Gear)

Arc Gobo Bulkhead

Figure 2-10: Aligning Index Gear Groove and Clock Mark

30 14-May-2009 02.9663.0010 F

Page 49

MAINTENANCE :

Step 2. If applicable, lower gobo wheel into place over rotating shaft, fitting wheel

position belt around lower gear and index timing belt around top gear . Install 4-40x1/4 " PPZ screw, split lock washer, flat black washer and flat Teflon washer to secure gobo wheel in place. (Belt tension is automatically set by springs of pivot mechanism.)

Step 3. Orient gobo wheel so that notch of gobo wheel gear aligns with small ridge

found on index timing belt.

Step 4. Re-check alignment of clock mark with groove of index gear. Adjust as

necessary until marks are perfectly aligned at both gears.

4-40x1/4 " PPZ screw

Split Lock W asher

Flat Black Washer

Teflon Washer

Wheel Position Gear

Wheel Position Belt (no alignment)

Gobo Wheel

Pivot Mechanism (automatically sets belt tension)

Align ridge in belt with notch in gobo wheel gear

Gobo Wheel Gear

Rotating Gobo Bulkhead Crossview

Notch

Figure 2-11: Aligning Second Clock Mark

Index Gear

Index Timing Belt (gray for clarity)

02.9663.0 010 F 14-May-2009 31

Page 50

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Gobo Wheel Bulkhead Replacement

Parts:

ASSEMBLY, GOBO BULKHEAD INCANDESCENT (21.9663.1200) - TS/TI ASSEMBLY, GOBO BULKHEAD ARC (21.9663.1600) - AS/AI

Tools:

#2 Phillips long handle screwdriver

To remove and replace gobo wheel bulkhead:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. Refer to “Front Cover Removal” on page 26.

CAUTION: The rear assembly is heavy and will remain attached by lamp wires. Place luminaire on tech bench before removing rear assembly.

Step 3. At side rails, remove four 10-32x5/8" PPB screws and #10 split lock washers

(Figure 2-12). (Side rail spacers will come loose also.) Pull rear head

assembly away from front head assembly. Step 4. At gobo bulkhead, disconnect all motor and sensor wiring. Step 5. At side rails, remove four 10-32x3/8" PPB screws and #10 split-lock

washers. Step 6. Remove gobo bulkhead. Step 7. Replace by doing steps 2 through 6 in reverse.

32 14-May-2009 02.9663.0010 F

Page 51

MAINTENANCE :

Gobo Wheel Bulkhead Replacement (continued)

Gobo Bulkhead

#10 Split-Lock Washers

10-32x3/8" PPB Screw

Front Assembly

Side Rail Spacer

NOTE:

Incandescent model gobo bulkhead not shown.

Figure 2-12: Gobo Bulkhead Assembly Replacement

02.9663.0 010 F 14-May-2009 33

Page 52

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Gobo Gear Planet Alignment

Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly. Use the following procedure to re-align the gears in the event the gobo wheel is disassembled.

To re-align gobo gears:

Step 1. Place center (sun) gear at starting point so that alignment mark is directly

facing Position 1 (open) as shown in Figure 2-13. Step 2. Set Position 6 planet gear as follows:

a. Rotate center gear clockwise until alignment mark is directly facing

Position 6.

b. Lift edge of center gear slightly (so that it will not turn), while at same

time rotating Position 6 gear until alignment mark is directly across from center gear alignment mark. Lower center gear into place and verify alignment.

Step 3. Set Position 5 planet gear as follows:

a. Rotate center gear clockwise until alignment mark is directly facing

Position 5.

b. Lift edge of center gear slightly (so that it will not turn), while at same

time rotating Position 5 gear until alignment mark is directly across from center gear alignment mark. Lower center gear into place and verify alignment.

Step 4. Set remaining planet gears by following same procedure. When all gears are

aligned, rotate center gear in full rotation to verify alignments. When

rotating, marks should align perfectly at each gear as they pass. Adjust as

necessary and recheck. Step 5. Install flange, pulley and three 4-40x5/16" PFB screws to secure gears in

place.

34 14-May-2009 02.9663.0010 F

Page 53

MAINTENANCE :

Gobo Gear Planet Alignment (continued)

1) S t art with center gear a lignment mark facing Position 1 (open).

Alignment Mark

open

2) Rotate center gear clockwise until alignment

mark is directly across from Position 6. Rotate Position 6 gear until marks align.

Align both marks

3) Align remaining gobo gears

using the same method.

4) Verify alignment of all marks and adjust as necessary.

Figure 2-13: Aligning Gobo Wheel Gears

02.9663.0 010 F 14-May-2009 35

Page 54

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Shutter Assembly Replacement

Parts:

ASSEMBLY, SHUTTER (21.9663.1300) (Old Version) or ASSEMBLY, SHUTTER 6 ROLLERS (21.9663.1350) (New Version)

Tools:

#2 Phillips long handle screwdriver+

To remove and replace shutter assembly:

Step 1. Disconnect luminaire AC input cable from power source.

CAUTION: The rear assembly is heavy and will remain attached by lamp wires. Place luminaire on tech bench before removing rear assembly.

Step 2. Remove front cover, rear head assembly and gobo wheel bulkhead. Refer to

“Gobo Wheel Bulkhead Replacement” on page 32.

Step 3. Remove yoke leg cover (side with menu display) by removing two 6-32x1/2"

PPB screws and two 6-32x3/8" PPB screws (Figure 2-14).

6-32x1/2" PPB Screw

Yoke Leg Cover

Controller PCB

NOTE:

6-32x3/8" PPB Screw

Head not shown for clarity.

Figure 2-14: Removing Yoke Leg Cover to Access Controller PCB

36 14-May-2009 02.9663.0010 F

Page 55

MAINTENANCE :

Step 4. At Controller PCB, disconnect shutter wiring harness at position marked

SHUTTERS. Step 5. Noting placement, cut tie-wraps securing harness to other wires. Step 6. Feed shutter harness cable out of yoke arm. Step 7. At side rails, remove four 10-32x3/8" PPB screws and #10 split-lock washers

and remove shutter assembly (Figure 2-15).

CAUTION: Do not overtighten tie-wraps when re-installing.

Step 8. Replace shutter assembly by doing steps 2 through 7 in reverse.

Gobo Wheel Bulkhead

#10 Split-Lock Washers

10-32x3/8" PPB Screw

Shutter Assembly

NEW *

#10 Split Lock Washer

10-32x5/8" PPB Screw

OLD *

Rear Head Assembly

Side Rail Spacer

Head Assembly

* Depending on when the luminaire was manufactured.

NOTE:

Yoke not shown for clarity.

Figure 2-15: Shutter Assembly Replacement

02.9663.0 010 F 14-May-2009 37

Page 56

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Shutter Blade or Rack Replacement

Parts:

as required:

BLADE, SHUTTER, COATED SIDE A (12.9663.1323) BLADE, SHUTTER, COATED SIDE B (12.9663.1324) RACK, SHUTTER (10.9663.1314)

Tools:

#2 Phillips screwdriver

To remove and replace a shutter blade or rack:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove shutter assembly. Refer to “Shutter Assembly Replacement” on

page 36.

Step 3. Place shutter assembly on work bench, motor side down. Remove four

6-32x1/4" PFS screws and remove cover plate (Figure 2-16).

6-32x1/4" PFS Screw

Cover

Separator

Spacer

Beveled Blade

Separator

Stiff Separator

Spacer

Straight Blade

Layer 4

Separator

Stiff Separator

Spacer

Beveled Blade

CAUTION:

Do not touch shutter blades with bare fingers. Clean with soft cloth if touched.

Layer 3

Separator

Stiff Separator

Spacer

Cover Plate

6-32x1/4" PFS Screw

Layer 2

Rack (x8)

Straight Blade

Separator

Shutter Assembly

Layer 1

Figure 2-16: Shutter Assembly Breakdown

38 14-May-2009 02.9663.0010 F

Page 57

MAINTENANCE :

Step 4. Carefully remove plates and components until blade or rack to be replaced is

reached. Install new component(s) as required. Step 5. Re-assemble shutter’s four layers. Ensure that components are oriented and

aligned as shown in Figure 2-17.

Note: The difference between the two types of shutter blades can be found by examining the main edge. Coated Side A blades (12.9663.1323) are beveled and the Coated Side B blades (12.9663.1324) are not.

Rack

Straight

Blade

Shutter Blade

Layer 1

Rack

Install shutter blades with dark mirror coating facing down. DO NOT touch blades with bare fingers.

Align main edge of blade with small hole in shutter rack

Beveled Blade

Layer 2

Straight

Blade

Beveled

Blade

Layer 3

Layer 4

Figure 2-17: Shutter Assembly Layer Orientation

02.9663.0 010 F 14-May-2009 39

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Edge/Zoom/Color Bulkhead Replacement

Parts:

ASSEMBLY, EDGE CONTROL, DIMMER AND COLOR (21.9663.1003)

Tools:

#2 Phillips screwdriver

To remove and replace edge/zoom/color bulkhead:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. (Refer to “Front Cover Removal” on page 26.) Step 3. At edge/zoom/color assembly, disconnect wiring harness connections. Step 4. At side rail, remove four 8-32x1/2" PFB screws (Figure 2-18). Step 5. At front, remove four 8-32 Keps nuts and remove assembly. Step 6. Replace assembly by doing steps 2 through 5 in reverse.

8-32x1/2" PFB Screw

Edge/Zoom/Color Assembly

8-32 Keps Nut

Figure 2-18: Edge/Zoom/Color Bulkhead Replacement

Side Rail

NOTE:

Yoke not shown for clarity.

40 14-May-2009 02.9663.0010 F

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MAINTENANCE :

Fan/Temp Switch Assembly Replacement

Note: Fan does not operate under normal luminaire operating conditions.

Parts:

CABLE ASSEMBLY, FAN/TEMP SWITCH (23.9663.2009)

Tools:

#2 Phillips screwdriver

To remove and replace fan/temp switch assembly:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove edge/dimmer/color bulkhead. Refer to “Edge/Zoom/Color Bulkhead

Replacement” on page 40.

Step 3. At fan, remove four 6-32 x 3/8 " PPSS black screws and 6-32 nylon insert

hex nuts and remove fan/temp switch assembly (Figure 2-19). Step 4. Replace assembly by doing steps 2 and 3 in reverse.

6-32x3/8" PPSS Screw

6-32 Nylon Insert Hex Nut

Figure 2-19: Fan/Temp Switch Assembly Replacement

02.9663.0 010 F 14-May-2009 41

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Beam-Size Iris Assembly Replacement

Note: This procedure not applicable to all units. Parts:

ASSEMBLY, IRIS (21.9663.1400)

Tools:

#2 Phillips screwdriver

To remove and replace beam-size iris assembly:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. Refer to “Front Cover Removal” on page 26. Step 3. At beam-size iris assembly, disconnect motor connectors (Figure 2-20). Step 4. At side rails, remove four 10-32x3/8" PPB screws and #10 split-lock washers

and remove iris assembly.

Step 5. Replace iris assembly by doing steps 2 through 4 in reverse.

10-32x3/8" PPB Screw

#10 Split-Lock Washers

Beam-Size Iris Assembly

Head Assembly

NOTE:

Yoke not shown for clarity.

Figure 2-20: Beam-Size Iris Assembly Replacement

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MAINTENANCE :

Ignitor PCB Replacement

Note: This procedure not applicable to all units. Parts:

PCB ASSEMBLY, IGNITOR (24.9661.3126)

Tools:

#2 Phillips screwdriver

To remove and replace ignitor PCB:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side without menu display) by removing four 6-

32x3/8" PTB screws as shown in Figure 2-21. Step 3. At ignitor PCB, disconnect lamp connectors. Step 4. Remove four 6-32x3/8" PPB screws and remove ignitor PCB. Step 5. Replace ignitor PCB by doing steps 2 through 4 in reverse.

6-32x1/2" PPB Screw

NOTE:

Head not shown for clarity.

Ignitor PCB

6-32x3/8" PPB Screw

Yoke Leg Cover

6-32x3/8" PPB Screw

Figure 2-21: Ignitor PCB Replacement

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Power Supply Replacement

Parts:

POWER SUPPLY, 130W +24V/6.3A (69.3177.0151)

Tools:

#1 Phillips screwdriver, 5/16 inch nutdriver

To remove and replace power supply:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side without menu display) by removing four 6-

32x3/8" PTB screws as shown in Figure 2-23.

Step 3. At power supply, disconnect all connectors. Step 4. Loosen two 4-40x1/2" PPZ screws and remove one 4-40x1/2" PPZ screw. Remove

power supply.

Step 5. Replace LVS. Reconnect all cables as follows:

To Dimmer Module

LVS

Red Wire (24VDC)

Dimmer to LVS Cable Assembly

(part number 25.9663.2826)

(TD, TID, TSD models Only)

White Wire (AC Neutral or ACN)

Green/Yellow Wire (Ground)

Black Wire (24VDC)

Black Wire (AC Line or ACL)

Stack Connections

as Shown

AC Input Cable Assembly

25.9663.2826 will connect

to ACN and ACL as indicated.

Figure 2-22: VL1000 Low-Voltage Supply (LVS)

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Power Supply Replacement (continued)

Crossmember Assembly

NOTE:

Head not shown for clarity.

10-32x1/2" PPB Screw

MAINTENANCE :

Yoke Leg Cover

6-32x3/8" PPB Screw (can only be accessed by removing crossmember)

4-40x1/2" PPZ Screws

Power Supply

6-32x3/8" PTB Screws

Figure 2-23: Power Supply Replacement

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Controller PCB Replacement

Parts:

PCB ASSEMBLY, CONTROLLER (24.9663.3930)

Tools:

#1 Phillips screwdriver

To remove and replace controller PCB:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing four 6-32x3/

8" PTB screws as shown in Figure 2-24.

Step 3. Remove display overlay and plate, by removing three 6-32x1/2" PPB screws. Step 4. At controller PCB, disconnect wiring at connectors marked:

a. GOBO/COLOR/ZOOM/EDGE/DIMMER/ROTATE b. PAN/TILT c. POWER d. COMM e. SHUTTERS (if applicable)

f. BALLAST (if applicable) Step 5. At controller PCB, remove four 6-32x3/8" PPB screws and remove PCB. Step 6. Replace controller PCB by doing steps 2 through 5 in reverse.

46 14-May-2009 02.9663.0010 F

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MAINTENANCE :

Controller PCB Replacement (continued)

NOTE:

Head not shown for clarity.

Yoke Leg Cover

6-32x3/8" PTB Screw

6-32x3/8" PPB Screw

Controller PCB

Display Plate

Display Overlay

6-32x1/2" PPB Screw

Figure 2-24: Controller PCB Replacement

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Tilt Encoder PCB Replacement

Parts:

PCB ASSY, PAN/TILT ENCODER (24.9661.9629)

Tools:

#2 Phillips screwdriver

To remove and replace tilt encoder PCB:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing four 6-32x3/

8" PTB screws. Step 3. As shown in Figure 2-25, at tilt encoder PCB, remove two 4-32 screws. Step 4. Disconnect connectors at J1 and J2. Step 5. Remove encoder PCB. Step 6. Replace encoder PCB by doing steps 2 through 5 in reverse.

4-32 Screw

Tilt Encoder PCB

Figure 2-25: Tilt Encoder PCB Replacement

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MAINTENANCE :

Tilt Motor Assembly Replacement

Parts:

ASSEMBLY, TILT MOTOR (21.9663.1816)

Tools:

#2 Phillips screwdriver

To remove and replace tilt motor assembly:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing four 6-32x3/

8" PTB screws (Figure 2-26).

Step 3. Remove display overlay and plate, by removing three 6-32x1/2" PPB screws. Step 4. At controller PCB, disconnect wiring at connectors marked:

a. GOBO/COLOR/ZOOM/EDGE/DIMMER/ROTATE b. PAN/TILT c. POWER d. COMM e. SHUTTERS (if applicable)

f. BALLAST (if applicable) Step 5. Remove four 6-32x3/8" PPB screws and remove controller PCB. Step 6. At encoder PCB, remove two 4-32 screws. Step 7. Disconnect connectors at J1 and J2 and remove encoder PCB. Step 8. At tilt motor assembly, loosen four 6-32x1" PPB screws. Slide assembly

forward and remove belt from pulley. Step 9. Remove four 6-32x1" PPB screws and #6 flat washers and remove tilt motor

assembly (spring will come loose also). Step 10. Replace by doing steps 2 through 9 in reverse. (Belt tension is automatically

set by spring.)

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Tilt Motor Assembly Replacement (continued)

6-32x3/8" PTB Screws

6-32x3/8" PPB Screw

Yoke Leg Cover

Controller PCB

Display Plate

Display Overlay

6-32x1/2" PPB Screw

Tilt Motor Assembly

#6 Flat Washer

6-32x1" PPB Screw

Spring

NOTE:

Head not shown for clarity.

Figure 2-26: Tilt Motor Assembly Replacement

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MAINTENANCE :

Pan Motor Assembly Replacement

Parts:

ASSEMBLY, PAN MOTOR (21.9663.1815)

Tools:

#2 Phillips screwdriver

To remove and replace pan motor assembly:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg covers by removing four 6-32x3/8" PTB screws on each

side (Figure 2-27). Step 3. Remove crossmember assembly from yoke by removing sixteen 10-32x1/2"

PPB screws. Step 4. At crossmember assembly, remove pan wire shield by removing four

4-40x3/8" PPZ screws. Step 5. At pan motor assembly, loosen four 6-32x1" PPB screws. Slide assembly

forward and remove belt from pulley. Step 6. Remove four 6-32x1" PPB screws and #6 flat washers and remove pan motor

assembly (nut plate will come loose also). Step 7. Replace pan motor assembly by doing steps 2 through 6 in reverse. (Belt

tension is automatically set by spring.)

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Pan Motor Replacement (continued)

Pan Wire Shield

6-32x1" PPB Screw

#6 Flat Washer

Pan Motor Assembly

Nut Plate

4-40x3/8" PPZ Screw

Spring

Timing Belt

Crossmember Assembly

10-32x1/2" PPB Screw

6-32x3/8" PTB Screws

Yoke Leg Cover

NOTE:

Head not shown for clarity.

Figure 2-27: Pan Motor Assembly Replacement

52 14-May-2009 02.9663.0010 F

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MAINTENANCE :

DMX Input PCB Replacement

Parts:

PCB ASSEMBLY, DMX INPUT (24.9663.3895)

Tools:

#2 Phillips screwdriver

To remove and replace DMX input PCB:

Step 1. Disconnect luminaire AC input cable from power source. Step 2. At pan tube cover, remove four 8-32x3/8" PFZ screws and remove cover

(Figure 2-28). Step 3. Remove four #4x3/8" HiLo screws. Step 4. Disconnect DMX input PCB wiring and remove PCB. Step 5. Replace DMX input PCB by doing steps 2 through 4 in reverse.

Pan Tube Cover

DMX Input PCB

#4x3/8" HiLo Screw

Figure 2-28: DMX Input PCB Replacement

8-32x3/8" PFZ Screw

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Cleaning Optical Lenses and Filters

WARNING: Remove power from luminaire before performing maintenance.

The front lens, color filters, and gobos may require cleaning after extended use. Isopropyl Alcohol should only be used, with a soft, lint-free cloth, to clean these components.

To access gobos, refer to “Rotating Gobo Replacement” on page 28.

54 14-May-2009 02.9663.0010 F

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CHAPTER 3.

Illustrated Parts Breakdown

This chapter contains illustrated parts breakdowns for all VL1000™ ERS Luminaire assemblies.

• Drawing Trees

• Top Assembly

• Head Assembly

• Yoke Assembly

• Cables

• Arc Ballast Assembly

The following abbreviations are used to identify parts specific to certain models:

ABBREVIATION MODEL

TI VL1000 Incandescent Luminaire w/ Beam-Size Iris

TS VL1000 Incandescent Luminaire w/ Shutter System

AI VL1000 Arc Luminaire with Beam-Size Iris

AS VL1000 Arc Luminaire with Shutter System

TSD VL000 Incandescent with 115V Dimmer and Shu tt er System

TID VL000 Incandescent with 115V Dimmer and Beam-Size Iris

TSE VL000 Incandescent with 240V Dimmer and Shutter System

TIE VL000 Incandescent with 240V Dimmer and Beam-Size Iris

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Drawing Trees

VL1000 Incandescent Luminaires

VL1000 Luminaire (Incandescent Versions)

20.9663.0001.02 (TS) Rev M or 20.9663.0001.03 (TI) Rev M or 20.9663.0001.22 (TSD) Rev M or

20.9663.0001.23 (TID) Rev M or 20.9663.0001.32 (TSE) Rev M or 20.9663.0001.33 (TIE) Rev M

Head Assembly

21.9663.1000.02 (TS) Rev B

21.9663.1000.03 (TI) Rev B

Front Head Assembly

21.9663.1001.02 (TS) Rev H

21.9663.1001.03 (TI) Rev H

Shutter 6 Rollers Assembly

21.9663.1350 Rev B (new)

Beam-Size Iris Assembly

21.9663.1400 Rev E

Edge Control, Zoom,

Dimmer & Color Assembly

21.9663.1003 Rev E

Color Changer Assembly

21.9663.1500 Rev N

Lens #6 Assembly

21.9663.1760 Rev 0

Lens #7 Assembly

21.9663.1770 Rev 0

Lens #8 Assembly

21.9663.1780 Rev B

Fan Assembly

23.9663.2009 Rev C

Rear Head Assembly

21.9663.1002.01 Rev P (TS/TI)

Color/Gobo/Lens Harness Cable

Assembly

25.9663.2050 Rev K

Incandescent Gobo Wheel

Assembly

21.9663.1200 (TS/TI/TSD/TID) Rev V

Gobo Wheel Assembly

21.9663.1201 Rev E

Temperature Sensor

Electrical Assembly

23.9663.1248.01 (TS) Rev A

Shutter Harness Cable

Assembly

25.9663.2040 Rev F

Edge Barrel Assembly

21.9663.1710 Rev C

Cover Plate Assembly

21.9663.1534 Rev 0

COT (Center of Travel) Flag

Assembly

21.9663.1845 Rev 0

Yoke Legs Assembly

21.9663.1850.01 (TS/TI) Rev J or

21.9663.1850.21 (TSD/TID - 115V DIM) Rev J or

21.9663.1850.31 (TSE/TIE - 240V

DIM) Rev J

continued next page

Front Cover Assembly

22.9663.1038 Rev B

Gel Frame Holder

Assembly

21.9663.1028 Rev A

Crossmember Assembly

21.9663.1811.01 (TS/TI) Rev J

21.9663.1811.21 (TSD/TID - 115V DIM) Rev J

21.9663.1811.31 (TSE/TIE - 240V DIM) Rev J

Outer Crossmember

Assembly

21.9663.1813 Rev C

Pan Motor Assembly

21.9663.1815 Rev D

Inner Crossmember

Assembly

21.9663.1812 Rev D

Pan EOT Cable Assembly

25.9663.2001 Rev A

Pan Tube Assembly

21.9663.1819.01 (TS/TI) Rev P

continued next page

Yoke to Head Ground

Cable Assembly

25.9663.2019 Rev B

Figure 3-1: VL1000 Incandescent Luminaires Drawing Tree (Part 1)

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ILLUSTRATED PARTS BREAKDOWN :

VL1000 Incandescent Luminaires (continued)

continued from previous page

Rear Head Assembly

21.9663.1002.01 Rev P (TS/TI)

Back Cap Assembly

21.9663.1127.01 (TS/TI) Rev J

Incandescent Lamp Power

Cable Assembly

25.9663.2033 Rev G

continued from previous page

Pan Tube Assembly

21.9663.1819.01 (TS/TI) Rev P

DMX Input PCB Assembly

24.9663.3895 Rev 0

continued from previous page

Yoke Legs Assembly

21.9663.1850.01 (TS/TI) Rev J or

21.9663.1850.21 (TSD/TID - 115V DIM) Rev J or

21.9663.1850.31 (TSE/TIE - 240V DIM) Rev J

Tilt Motor Assembly

21.9663.1816 Rev D

LVS Chassis Ground

Cable Assembly

25.9663.2817 Rev B

Tilt COT Cable Assembly

25.9663.2002 Rev A

L VS DC Output Cable

Assembly

25.9663.2824 Rev A

Pan/Tilt Control Cable

Assembly

25.9663.2020 Rev B

AC Line Input Cable

Assembly

25.9663.2015.01 Rev C

Incandescent LVS AC Input Cable Assembly

25.9663.2816.01 Rev B

Data I/O Link Cable

Assembly

25.9663.2022 Rev B

Incandescent Power Input

Cable Assembly

25.9663.2030 Rev A

Abbreviation Meaning

TI VL1000 TI Incandescent with Beam-Size Iris

TS VL1000 TS Incandescent with Shutter System

Figure 3-2: VL1000 Incandescent Luminaires Drawing Tree (Part 2)

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Arc Luminaires

VL1000 Luminaire (Arc Versions)

20.9663.0001.12 (AS) Rev M or 20.9663.0001.13 (AI) Rev M

Head Assembly

21.9663.1000.12 (AS) Rev B

21.9663.1000.13 (AI) Rev B

Front Head Assembly

21.9663.1001.12 (AS) Rev H

21.9663.1001.13 (AI) Rev H

Shutter 6 Rollers Assembly

21.9663.1350 Rev B (new)

Beam-Size Iris Assembly

21.9663.1400 Rev E

Edge Control, Zoom,

Dimmer & Color Assembly

21.9663.1003 Rev E

Color Changer Assembly

21.9663.1500 Rev N

Lens #6 Assembly

21.9663.1760 Rev 0

Lens #7 Assembly

21.9663.1770 Rev 0

Lens #8 Assembly

21.9663.1780 Rev B

Fan Assembly

23.9663.2009 Rev C

Rear Head Assembly

21.9663.1002.11 Rev P (AS/AI)

Color/Gobo/Lens Harness Cable

Assembly

25.9663.2050 Rev K

Arc Gobo/Dimmer Bulkhead

Assembly

21.9663.1600 (AS) Rev T

Gobo Wheel Assembly

21.9663.1201 Rev E

Temperature Sensor

Electrical Assembly

23.9663.1248.11 (AS) Rev A

Shutter Harness Cable

Assembly

25.9663.2040 Rev F

Edge Barrel Assembly

21.9663.1710 Rev C

Cover Plate Assembly

21.9663.1534 Rev 0

COT (Center of Travel) Flag

Assembly

21.9663.1845 Rev 0

Yoke Legs Assembly

21.9663.1850.11 (AS/AI) Rev J

continued next page

Front Cover Assembly

22.9663.1038 Rev B

Gel Frame Holder

Assembly

21.9663.1028 Rev A

Crossmember Assembly

21.9663.1811.11 (AS/AI) Rev J

Outer Crossmember

Assembly

21.9663.1813 Rev C

Pan Motor Assembly

21.9663.1815 Rev D

Inner Crossmember

Assembly

21.9663.1812 Rev D

Pan EOT Cable Assembly

25.9663.2001 Rev A

Pan Tube Assembly

21.9663.1819.11 (AS/AI) Rev P

continued next page

Yoke to Head Ground

Cable Assembly

25.9663.2019 Rev B

VL1000 Arc Ballast

Assembly

21.9663.1900

575W Ballast I/O Cable

Assembly

25.9663.1907 Rev C

Figure 3-3: VL1000 Arc Luminaires Drawing Tree (Part 1)

58 14-May-2009 02.9663.0010 F

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ILLUSTRATED PARTS BREAKDOWN :

VL1000 Arc Luminaires (continued)

continued from previous page

Rear Head Assembly

21.9663.1002.11 Rev P (AS/AI)

Back Cap Assembly

21.9663.1127.11 (AS/AI) Rev

Ignitor to Lamp Socket

Cable Assembly

25.9663.2036 Rev H

continued from previous page

Pan Tube Assembly

21.9663.1819.11 (AS/AI) Rev P

Ballast Control Link Cable

Assembly

25.9663.2021 Rev A

Arc Power to Ignitor Cable

Asembly

25.9663.2035 Rev C

Arc Power Input (Pigtail)

Cable Assembly

25.9663.2021 Rev A

continued from previous page

Yoke Legs Assembly

21.9663.1850.11 (AS/AI) Rev J

Tilt Motor Assembly

21.9663.1816 Rev D

Tilt COT Cable Assembly

25.9663.2002 Rev A

LVS DC Output Cable

Assembly

25.9663.2824 Rev A

Pan/Tilt Control Cable

Assembly

25.9663.2020 Rev B

DMX Input PCB Assembly

24.9663.3895 Rev 0

AC Line Input Cable

Assembly

25.9663.2015.01 Rev C

Arc LVS AC Input Cable

Assembly

25.9663.2816.11 Rev B

Data I/O Link Cable

Assembly

25.9663.2022 Rev B

Abbreviation Meaning

AI VL1000 AI Arc with Beam-Size Iris

AS VL1000 AS Arc with Shutter System

Figure 3-4: VL1000 Incandescent Luminaires Drawing Tree (Part 2)

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Top Assembly

Included Items Kit

28.9663.0001 Rev J

Refer to Figure 3-5.

No. Item Qty. UM. Description

1 02.8001.0001 1 EA PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 2 02.8052.0001 1 EA CARD, LIMITED WARRANTY 09-09-02 3 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION - VL2000 4 02.9663.0002 1 EA UNPACK/QUICK START SHEET, VL1000 5 07.9663.0032 1 EA SHIPPING BOX, CARDBOARD - VL1000 (changed 03-05-04) 6 08.1000.0001 1 EA CD ROM, VL1000 PRODUCT, DOCUMENTATION 7 52.6541.0001 1 EA CONN, BLUE CABLE PWR INLET 3-POLE LOCKING - POWERCON

8 53.6505.0027 1 EA BOLT, 1/2" X 13 X 1" LG HX HD ZINC (AS/AI ONLY)

9 55.6539.0001 1 EA WASHER, 1/2" SPLIT LOCK (AS/AI ONLY)

10 71.2554.0115 1 EA 1000 WATT INCANDESCENT LAMP, 115 VAC (TS/TI ONLY)

52.6541.0002 1 EA CONN, WHITE CABLE PWR INLET (240V W/ INTG DIMMER ONLY - NOT SHOWN)

53.6523.0013 8 EA SCREW, 6-32 X 3/8" PTB (NOT SHOWN)

71.2554.0240 1 EA 1000 WATT INCANDESCENT LAMP, 240 VAC (TS/TI ONLY)

71.2528.0575 1 EA 575 WATT ARC LAMP (AS/AI ONLY)

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ILLUSTRATED PARTS BREAKDOWN :

Included Items Kit (continued)

8 (Arc Models Only)

VL1000 Luminaire

- page 64

9 (Arc Models Only)

Arc Ballast (Arc Models Only)

Figure 3-5: Included Items

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Label Locations

Rev D

Refer to Figure 3-6.

No. Item Qty. UM. Description

1 04.9661.0033.01 1 EA LABEL, WARNING -2000 SERIES 2 04.9661.0034 1 EA LABEL, RELAMPING -2000 SERIES 3 04.9661.0037 1 EA LABEL, 625W ARC -2400 SERIES (AI/AS ONLY) 4 04.9663.1837 1 EA LABEL, PATENT 5 04.9663.1860 1 EA LABEL, 1000 SERIES COMPLIANCE 6 04.9663.1862 1 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TS

04.9663.1864 1 EA LABEL, AC INPUT RATING LABEL MODEL VL1000AS

04.9663.1873 1 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TI

04.9663.1874 1 EA LABEL, AC INPUT RATING LABEL MODEL VL1000AI

7 04.9663.1881 2 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TXD

04.9663.1882 2 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TSD

04.9663.1883 2 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TID

04.9663.1884 2 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TXD230

04.9663.1885 2 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TSD230

04.9663.1886 2 EA LABEL, AC INPUT RATING LABEL MODEL VL1000TID230

8 04.9663.1865 1 EA LABEL, 1000 SERIES INCANDESCENT (TI/TS ONLY) 9 04.9663.1920 1 EA LABEL, PRODUCT VL1000APS (AI/AS ONLY - NOT SHOWN)

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ILLUSTRATED PARTS BREAKDOWN :

Label Locations (continued)

6, 7

Figure 3-6: Label Locations

3, 8

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Luminaire

20.9663.0001.02 (TS) Rev M

20.9663.0001.03 (TI) Rev M

20.9663.0001.12 (AS) Rev M

20.9663.0001.13 (AI) Rev M

20.9663.0001.22 (TSD) Rev M

20.9663.0001.23 (TID) Rev M

20.9663.0001.32 (TSE) Rev M

20.9663.0001.33 (TIE) Rev M

Refer to Figure 3-7

No. Item Qty. UM. Description

1 10.9663.1823 1 EA PULLEY, TILT 2 10.9663.1824 1 EA SPACER, TILT TUBE 3 10.9663.1831 1 EA PLATE, YOKE ARM DISPLAY 4 10.9663.1832 1 EA OVERLAY, DISPLAY 5 10.9663.1835 1 EA COVER, YOKE ARM DISPLAY SIDE 6 10.9663.1836 1 EA COVER, YOKE ARM NO DISPLAY (TS/TI/AS/AI ONLY) 7 10.9663.1874 1 EA COVER, YOKE ARM DIM SIDE (TSD/TID/TSE/TIE ONLY) 8 21.9663.1000.02 1 EA ASSY, HEAD W/ SHUTTER (TS/TSD/TSE ONLY)

21.9663.1000.03 1 EA ASSY, HEAD W/ IRIS (TI/TID/TIE ONLY)

21.9663.1000.12 1 EA ASSY, HEAD ARC, W/ SHUTTER (AS ONLY)

21.9663.1000.13 1 EA ASSY, HEAD ARC W/ IRIS (AI ONLY)

9 21.9663.1811.01 1 EA ASSY, CROSSMEMBER (TI/TS ONLY)

21.9663.1811.1 1 1 EA ASSY, CROSSMEMBER (AI/AS ONLY)

21.9663.1811.21 1 EA ASSY, CROSSMEMBER, 115V DIMMER (TSD/TID ONLY)

21.9663.1811.31 1 EA ASSY, CROSSMEMBER, 230V DIMMER (TSE/TIE ONLY)

10 21.9663.1845 1EAASSY, COT FLAG 11 21.9663.1850.01 1 EA ASSY, YOKE LEGS (TI/TS ONLY)

21.9663.1850.11 1 EA ASSY, YOKE LEGS (AI/AS ONLY)

21.9663.1850.21 1 EA ASSY, YOKE LEGS W/ 115V DIMMER (TSD/TID ONLY)

21.9663.1850.31 1 EA ASSY, YOKE LEGS W/ 230V DIMMER (TSE/TIE ONLY)

12 22.9663.1038 1 EA ASSY, FRONT COVER 13 24.9663.3930 1 EA PCB ASSY, VL1000 CONTROLLER

14 53.2019.0004 4 EA NUT, 3/8-16 X 7/32"THK HEX JAM GRD5 ZINC PLT

25.9663.2019 1 EA CABLE ASSY, YOKE TO HEAD GROUND - NOT SHOWN

25.9663.2036 1 EA CABLE ASSY, IGNITOR TO LAMP (AI/AS ONLY)- NOT SHOWN

25.9663.2050 1 EA CABLE ASSY, COLOR/GOBO/LENS HARNESS - NOT SHOWN

64 14-May-2009 02.9663.0010 F

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ILLUSTRATED PARTS BREAKDOWN :

No. Item Qty. UM. Description

15 53.6517.0001 3 EA SCREW, 10-32 X 3/8"LG PPZ 16 53.6543.0001 4 EA SCREW, 6-32 X 3/8" PPB 17 53.6614.0001 3 EA SCREW, 6-32 X 5/8" PPB 18 53.6627.0001 12 EA SCREW, 10-32 X 5/8" PPB 19 53.6634.0003 4 EA SCREW, 3/8-16 X 1/2"LG SOC HD CAP ALLY STL 20 53.6642.0001 3 EA SCREW, 10-32 X 5/8" SLF TAP TYPE F PPZ 21 54.1255.0001 2 EA BEARING ASSY, BLACK FLUSH MOUNT HOUSING 22 54.2047.0039 1 EA BELT, TIMING GT 3MM PITCH 350GRV 6MM WD NEOPRENE 23 55.2115.0001 4 EA WASHER, 3/8 X .04 THK HEX JAM 24 53.6523.0013 8 EA SCREW, 6-32 X 3/8" PTB 25 21.9663.1901 1 EA BALLAST ASSEMBLY (AI/AS ONLY)

25.9663.1907 1 EA CABLE ASSY, 575W BALLAST I/O (AI/AS ONLY)- NOT SHOWN

02.9663.0 010 F 14-May-2009 65

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Luminaire (continued)

24 (x4)

17 (x3)

14 (x4), 23 (x4)

24(x4)

19 (x4)

15 (x3)

16 (x4)

25 - AI / AS only

18 (x12)

Dimmer

TSD/TID/ TSE/TIE Only

20 (x3)

Figure 3-7: VL1000 Luminaire

66 14-May-2009 02.9663.0010 F

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Front Cover Assembly

22.9663.1038 Rev B

Refer to Figure 3-8.

No. Item Qty. UM. Description

ILLUSTRATED PARTS BREAKDOWN :

1 10.9663.1020 1 2 21.9663.1028 1 3 53.2004.0002 4 4 53.6545.0007 3 5 53.6552.0002 1

3 (x4)

EA EA EA EA EA

COVER, FRONT VL1000 ASSY, GEL FRAME HOLDER NUT, 8-32 KEPS, ZINC PLATE (changed 09-02-03) SCREW, 8-32 X 3/8" PFB SCREW, 8-32 X 1/2" PFB

4 (x3)

Figure 3-8: Front Cover Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Gel Frame Holder Assembly

21.9663.1028 Rev A

Refer to Figure 3-9.

No. Item Qty. UM. Description

1 10.9663.1027 1 2 10.9663.1031 1 3 55.6568.0026 1 4 55.6738.0003 .06 FT TUBING, SILICONE RUBBER 1/8"ID X 1/4"OD TRANSLUCENT

EA EA EA

HOLDER, GEL FRAME LATCH, GEL FRAME SPRING, CPRSN .180"OD .810"LG .026" WIRE DIA SS

Figure 3-9: Gel Frame Holder Assembly

68 14-May-2009 02.9663.0010 F

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COT (Center of Travel) Flag Assembly

21.9663.1845 Rev 0

Refer to Figure 3-10.

No. Item Qty. UM. Description

ILLUSTRATED PARTS BREAKDOWN :

1 2 3

10.9663.1824

10.9663.1826

53.6602.0001

1 1 3

EA SPACER, TILT TUBE EA FLAG, CENTER OF TRAVEL -TILT EA SCREW, 4-40 X 1/4 " PPZ TYPE F

Figure 3-10: COT Flag Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Notes

70 14-May-2009 02.9663.0010 F

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Head Assembly

21.9663.1000.02 (TS) Rev B

21.9663.1000.03 (TI) Rev B

21.9663.1000.12 (AS) Rev B

21.9663.1000.13 (AI) Rev B

Refer to Figure 3-11.

No. Item Qty. UM. Description

ILLUSTRATED PARTS BREAKDOWN :

2 21.9663.1001.02 1

3 21.9663.1002.01 1

4 53.6627.0001 4 5 55.3303.0010 4

10.9663.1032 2

21.9663.1001.03 1

21.9663.1001.12 1

21.9663.1001.13 1

21.9663.1002.11 1

EA EA EA EA EA EA EA EA EA

SPACER, SIDE RAIL (TS ONLY) SPACER, SIDE RAIL (AS ONLY) ASSY, FRONT HEAD (TS ONLY) ASSY, FRONT HEAD (TI ONLY) ASSY, FRONT HEAD (AS ONLY) ASSY, FRONT HEAD (AI ONLY) ASSY, REAR HEAD (TS ONLY) ASSY, REAR HEAD (AS ONL Y) SCREW, 10-32 X 5/8" PPB WASHER, #10 .438"OD .040"THK SPLIT LOCK SS

4 (x4)

5 (x4)

1 (x2)

Figure 3-11: Head Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Front Head Assembly

21.9663.1001.02 (TS) Rev H

21.9663.1001.03 (TI) Rev H

21.9663.1001.12 (AS) Rev H

21.9663.1001.13 (AI) Rev H

Refer to Figure 3-12.

No. Item Qty. UM. Description

1 2 21.9663.1003 3 21.9663.1033

4 21.9663.1034 5 21.9663.1200

6 7 8

9 10 11 12

07.5049.0001

21.9663.1600 1 EA ASSY, GOBO/DIMMER BULKHEAD, ARC (AS ONLY)

21.9663.1350 1 EA ASSY, SHUTTER 6 ROLLERS (TS/AS ONLY) (NEW VERSION)

21.9663.1400 1 EA ASSY, IRIS (TI/AI ONLY)

53.6552.0002 4 EA SCREW, 8-32 X 1/2" PFB

53.2004.0002 4 EA NUT, 8-32 KEPS ZINC PLATE

53.6627.0001 12 EA SCREW, 10-32 X 5/8" PPB

55.2179.0006 3 EA SADDLE WIRE BLIND HOLE .79" (added 12-09-02)

55.3303.0010 12 EA WASHER, #10 .438"OD .040THK SPLIT LOCK SS

1EA 1EA 1EA 1EA 1EA

LANYARD, NYLON COATED 8" LG ASSY, EDGE, ZOOM & COLOR ASSY, SIDE RAIL, PULLEY ASSY, SIDE RAIL, SENSOR ASSY, GOBO BULKHEAD, INCANDESCENT (TS ONLY)

72 14-May-2009 02.9663.0010 F

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ILLUSTRATED PARTS BREAKDOWN :

Front Head Assembly (continued)

(x4)

A: Models w/ Shutter

9 (x4)

8 (x4)

B: Models w/ Iris

Either A or B

11 (x3)

Either C or D

C: Incandescent Models

(x4)

D: Arc Models

(x4)

Figure 3-12: Front Head Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Edge Control, Zoom, Dimmer & Color Assembly

21.9663.1003 Rev E

Refer to Figure 3-13.

No. Item Qty. UM. Description

1 10.9663.1039 1

2 10.9663.1755 3

3 10.9663.1756 6

4 10.9663.1757 1

5 10.9663.1758 1

6 10.9663.1767 1

7 10.9663.1790 1

8 12.9663.1754 1

9 21.9663.1500 1 10 21.9663.1760 1 11 21.9663.1770 1 12 21.9663.1780 1 13 23.9663.2009 1 14 44.9663.1766 1 15 53.2003.0001 2 16 53.2202.0006 4 17 53.5506.0750 6 18 55.5559.0250 2 19 53.5604.0437 2 20 53.5606.0375 7 21 53.6558.0003 2 22 53.6567.0001 2 23 54.2048.0002 1 24 55.3301.0006 2 25 55.3303.0006 3 26 55.6588.0003 3

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

SUPPORT, AXIAL FAN ROLLER, BARREL ROLLER, LENS CLAMP, BELT BASE BELT CLAMP ZOOM TEFLON SPACER BELT PULLEY, GT 3MM PITCH 16 GROOVES MACHINED EXTRUSION, OUTER BARREL ZOOM ASSY, COLOR CHANGER ASSY, LENS #6 ASSY, LENS #7 ASSY, LENS #8 ASSY, FAN MOTOR, 17 1.24" SHAFT 11.8MH 5.5 OHM NUT, 4-40 KEP ZINC PLATED NUT, 6-32 HEX SS NYLON INSERT SCREW, 6-32 X 3/4 " PPSS SCREW, 6-32 X 1/4" SET CONE (added 08-28-03) SCREW , 4-40 X 7/16"LG PPSS BLACK SCREW, 6-32 X 3/8 " PPSS BLACK SCREW, 6-32 X 3/8" PPZ PLASTIC THREAD ROLLING SCREW, 4-40 X 1/2" PPZ BELT, TIMING HTD 3MMPITCH 195 GROOVE 6MMWIDE WASHER, #6 FLAT SS WASHER, #6 LOCK INT. TOOTH SS SPACER, 1/4"RND #6 THRU 1/8"LG .140"ID ZINC PLT BRS

74 14-May-2009 02.9663.0010 F

Page 93

20 (x3)

25 (x3)

ILLUSTRATED PARTS BREAKDOWN :

Edge Control, Dimmer & Color Assembly (continued)

26 (x3)

2 (x3)

3 (x6)

17 (x6)

22 (x2)

18 (x2)

15 (x2)

24 (x2)

21 (x2)

20 (x4)

16 (x4)

Figure 3-13: Edge Control, Dimmer & Color Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Color Changer Assembly

21.9663.1500 Rev N

Refer to Figure 3-14.

No. Item Qty. UM. Description

1 04.9663.1524 1

2 04.9663.1525 1

3 04.9663.1526 1

4 04.9663.1527 1

5 10.9663.1505 4

6 10.9663.1506 1

7 10.9663.1507 2

8 10.9663.1508 1

9 10.9663.1509 1

10 10.9663.1511 3 11 12.9663.1512 1 12 10.9663.1514 3 13 10.9663.1515 1 14 10.9663.1516 1 15 10.9663.1518 4 16 10.9663.1521 1 17 10.9663.1522 1 18 10.9663.1532 2 19 10.9663.1755 3 20 10.9663.1767 1 21 12.9663.1752 1 22 44.9663.1539 4 23 21.9663.1534 1 24 21.9663.1538.01 2 25 21.9663.1538.02 2 26 21.9663.1538.03 2 27 21.9663.1538.04 2 28 21.9663.1710 1 29 53.2002.0003 4

10.9663.1510 1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

LABEL, MAGENTA MOTOR LABEL, BLUE MOTOR LABEL, AMBER MOTOR LABEL, DIFFUSER MOTOR DRIVE RING DIFFUSER COVER PLATE COLOR SEPERATOR MOTOR MOUNT PLATE COLOR COVER PLATE, LINER SHEET DIFFUSER COVER PLATE LINER SHEET (NOT SHOWN) COLOR SPACER 1 DRIVE RING LOCATOR, MACHINED COLOR SPACER 2 DIFFUSER SPACER 1 DIFFUSER SPACER 2 COLOR MOTOR MOUNT CLIP COLOR COVER PLATE, LINER SHEET DIFFUSER COVER PLATE, LINER SHEET RING SPACER ROLLER, BARREL ZOOM TEFLON SPACER MACHINED EXTRUSION, INNER BARREL ZOOM MOTOR SIZE 14, 10.8MH, 10.1 OHM WITH SPUR GEAR ASSY, COVER PLATE ASSY, MAGENTA COLOR FILTER ASSY, BLUE COLOR FILTER ASSY, AMBER COLOR FILTER ASSY, DIFFUSER GLASS RIGHT ASSY, BARREL NUT, 6-32 HEX ZINC NYLON INSERT

76 14-May-2009 02.9663.0010 F

Page 95

No. Item Qty. UM. Description

ILLUSTRATED PARTS BREAKDOWN :

30 53.2200.0004 8 31 53.5636.0375 3 32 53.6556.0001 8 33 55.6588.0003 3 34 10.9663.1537 1

EA EA EA EA EA

NUT, 4-40 KEPS SS SCREW, 6-32 X 3/8 " PFSS BLACK SCREW, 4-40 X 3/4"LG PPZ SPACER, 1/4"RND #6 THRU 1/8"LG .140"ID ZINC PLT BRS DRIVE RING LOCATOR BEARING

02.9663.0 010 F 14-May-2009 77

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Color Changer Assembly (continued)

33 (x3)

19 (x3)

31 (x4)

29 (x4)

27 (x2)

25 (x2)

24 (x2)

26 (x2)

30 (x8)

32 (x8)

22 (x4)

15 (x4)

Figure 3-14: Color Changer Assembly

78 14-May-2009 02.9663.0010 F

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ILLUSTRATED PARTS BREAKDOWN :

Cover Plate Assembly

21.9663.1534 Rev 0

Refer to Figure 3-15.

No. Item Qty. UM. Description

1 10.9663.1517 1 EA COVER PLATE, COLOR CHANGER 2 3

10.9663.1535 1 EA DISC, .63 DIA ALUM

41.9663.1530 1 EA GLASS, BEAM OCCLUSION

53.6659.0008 4 EA SCREW, 2-56 X 3/16" PFZ

4 (x4)

Figure 3-15: Cover Plate Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Edge Barrel Assembly

21.9663.1710 Rev C

Refer to Figure 3-16.

No. Item Qty. UM. Description

2 10.9663.1708 1

3 10.9663.1711 2

4 10.9663.1737 1

5 21.9663.1722 1

6 42.9663.1728 1

7 42.9663.1731 1

8 42.9663.1732 1

9 42.9663.1736 1 10 53.2202.0006 4 11 53.6558.0001 4 12 53.6558.0003 4 13 55.2123.0012 1 14 55.6636.0003 2

10.9663.1701 2

EA EA EA EA EA EA EA EA EA EA EA EA EA EA

BARREL, HALF OUTER LENS EDGE SYSTEM EDGE GEAR/CAM, 8 ELEMENT SYSTEM BARREL, HALF INNER LENS EDGE SYSTEM EDGE, LIGHT BAFFLE ASSY, EDGE MOTOR LENS #1 LENS #4 LENS #5 ASSY, LENS #2 & #3 NUT, 6-32 HEX SS NYLON INSERT SCREW, 6-32 X 3/8" PPZ SCREW, 6-32 X 3/8" PPZ PLASTIC THREAD ROLLING WASHER, WAVE SPRING .484"OD .397"ID .009"THK CSTL WASHER, .562"OD .156"ID .046"THK #6 FLAT ZINC PLT

80 14-May-2009 02.9663.0010 F

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ILLUSTRATED PARTS BREAKDOWN :

Barrel Assembly (continued)

12 (x2)

11 (x4)

1 (x2)

3 (x2)

10 (x4)

Figure 3-16: Edge Barrel Assembly

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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Lens #6 Assembly

21.9663.1760 Rev 0

Refer to Figure 3-17.

No. Item Qty. UM. Description

1 10.9663.1761 1

2 42.9663.1733 1

EA EA

LENS CARRIER, MOLDED -LENS #6 ASSY LENS #6

Figure 3-17: Lens #6 Assembly

82 14-May-2009 02.9663.0010 F

Philips VL1000 TS, VL1000 TSD, VL1000 AS, VL1000 AI, VL1000 TI Service Manual

Table of Contents

Introduction

Disclosure

About This Manual

Additional Documentation

Customer Service

Description

Features

Standard Features

Model Specific Features

Component Descriptions

External Luminaire Components

Luminaire Internal Head Components

Luminaire Internal Yoke Components

Arc Ballast Unit

Dimmer Model

Principles of Operation

VL1000 Incandescent Source Luminaire

VL1000 Incandescent Block Diagram - Without On-Board IGBT Dimmer

VL1000 Incandescent Cable Routing - Without On-Board IGBT Dimmer

VL1000 Incandescent Block Diagram - With On-Board IGBT Dimmer

VL1000 Incandescent Cable Routing - With On-Board IGBT Dimmer

VL1000 Arc Source Luminaire

VL1000 Arc Block Diagram

VL1000 Arc Cable Routing

Maintenance

Testing

Running Parameter Tests

Maintenance Procedures

Lamp Replacement (Incandescent Model)

Lamp Replacement (Arc Model)

Align Lamp For Maximum Beam Irradiance

Frame or Top Hat Replacement

Front Cover Removal

Rear Head Assembly Removal

Rotating Gobo Replacement

Gobo Index Timing Belt Alignment

Gobo Wheel Bulkhead Replacement

Gobo Gear Planet Alignment

Shutter Assembly Replacement

Shutter Blade or Rack Replacement

Edge/Zoom/Color Bulkhead Replacement

Fan/Temp Switch Assembly Replacement

Beam-Size Iris Assembly Replacement

Ignitor PCB Replacement

Power Supply Replacement

Controller PCB Replacement

Tilt Encoder PCB Replacement

Tilt Motor Assembly Replacement

Pan Motor Assembly Replacement

DMX Input PCB Replacement

Cleaning Optical Lenses and Filters

Illustrated Parts Breakdown

Drawing Trees

VL1000 Incandescent Luminaires

VL1000 Arc Luminaires

Top Assembly

Included Items Kit

Included Items Kit (continued)

Label Locations

VL1000 Luminaire

Front Cover Assembly

Gel Frame Holder Assembly

COT (Center of Travel) Flag Assembly

Head Assembly

Head Assembly

Front Head Assembly

Edge Control, Zoom, Dimmer & Color Assembly

Color Changer Assembly

Cover Plate Assembly

Edge Barrel Assembly

Lens #6 Assembly