Philips VLX3 Service Manual

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

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

Version as of: 14 November 2011

Part number: 02.9703.0010 0

VLX3 LED Wash Luminaire Service Manual

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

How To Obtain Warranty Service

A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE
product.

To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548),
[phone], or [e-mail] and request a Return Material Authorization
(RMA) for warranty service. You will need to provide the model and serial number of the item being
returned, a description of the problem or failure and the name of the registered user or organization. If
available, you should have your sales invoice to establish the date of sale as the beginning of the
warranty period.

Once you obtain the RMA, pack the unit in a secure shipping container or in its original packing box.
Fill out the RMA form (obtained from the Vari-Lite web site www.vari-lite.com or through customer
service) and place in shipping container along with a copy of your invoice (if available). Write the
RMA number legibly on or near the shipping address label and return the unit, freight prepaid to:

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

FOREWORD

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

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VARI❋LITE - VLX3 LED WASH 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:

Safety

EN 60598-1:2000 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989/A2: 1991 Specification for Luminaires for Stage and Studio Lighting

EMC

EN 61000-6-4: 2001 Radiated and Conducted Emissions

W e certify that the product conforms to the protection requirements of Low Voltage Directive 2006/95/
EC and Council Directive 89/336/EEC (EMC)

ii 02.9703.0010 0

Safety Notice

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

Safety symbols used throughout this manual are as follows:

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

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE

1. VARI❋LITE luminaires have been designed for use with specific light sources. The VLX3 LED
Wash Luminaire uses a special type of LED light source. Installing another type of light source
will be hazardous and void the luminaire warranty.

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

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

FOREWORD

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK

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

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

3. Servicing to be performed by qualified personnel only.

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

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

1. Many VARI❋LITE luminaires us e a lamp that produces UV radiation. DO NOT look directly at
lamp.

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

WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS

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

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

3. Wear eye protection when relam ping.

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

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

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

WARNING:
RF INTERFERENCE

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

iv 02.9703.0010 0

Sicherheitshinweise

Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem
beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren
bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und
Vorsichtsmaßnahmen ein.

Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:

VORSICHT - weist auf möglichen Produktschaden hin.

WARNUNG - weist auf mögliche Körperverletzung und Lebensbedrohung hin.

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

WARNUNG:
HINWEISE ZUM FEUERSCHUTZ

1. VARI❋LITE Beleuchtungen sind für Gebrauch mit spezifischen Lichtquellen bestimmt worden.
Die VLX3 LED Wash Luminaire Beleuchtung benutzt eine spezielle Art LED-Lichtquelle. Eine
andere Art Lichtquelle anzubringen ist gefährlich und hebt die Beleuchtunggarantie auf.

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

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

FOREWORD

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK

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

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

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

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG

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

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

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN

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

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

3. Tragen Sie beim Austausch der Lampen einen Augenschutz.

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

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

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

WARNUNG:
HF-INTERFERENZ

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

vi 02.9703.0010 0

Notes de sécurité

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

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

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

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

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

FOREWORD

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES

1. Des appareils d'éclairage de VARI❋LITE ont été conçus pour l'usage avec des sources lumineuses
spécifiques. L'appareil d'éclairage de VLX3 LED Wash Luminaire emploie un type spécial de
source lumineuse de LED. L'installation d'un autre type de source lumineuse sera dangereuse et
videra la garantie d'appareil d'éclairage.

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

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

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES

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

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

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

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

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

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

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

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

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

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

4. Se protéger les yeux pour remplacer la lampe.

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

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

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

AVERTISSEMENT:
INTERFÉRENCE RF

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

viii 02.9703.0010 0

Aviso sobre Seguridad

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

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

CUIDADO, indica posibles daños al producto.

ADVERTENCIA, indica posibles lesiones o muerte a las personas.

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

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO

1. Los alumbrados de VARI❋LITE se han diseñado para el uso con fuentes de luz específicas. El
alumbrado de VLX3 LED Wash Luminaire utiliza un tipo especial de fuente de luz del LED. La
instalación de otro tipo de fuente de luz será peligrosa y anulará la garantía del alumbrado.

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

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

FOREWORD

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE ELÉCTRICO

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

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

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

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

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

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

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

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS

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

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

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

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

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

ADVERTENCIA:
INTERFERENCIA RF

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

x 02.9703.0010 0

FOREWORD

02.9703.0010 0 xi

VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

xii 02.9703.0010 0

Table of Contents

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

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

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

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

Chapter 1. Description

Features

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

Technical Specifications .............................................................................................. 4

Components

VLX3 Wash External Components.............................................................................. 5

VLX3 Wash Luminaire Components........................................................................... 6

VLX3 Wash Luminaire Head Components................................................................. 7

VLX3 Wash Enclosure Components........................................................................... 8

Principles of Operation

VLX3 Wash Luminaire Functional Block Diagram.................................................... 9

TABLE OF CONTENTS

Chapter 2. Maintenance

Testing

Luminaire Self-Tests....................................................................... ........................... 12

Calibration Sequence................................................................................................. 12

Sensor Testing............................................................................................................ 12

Troubleshooting

Error Messages........................................................................................................... 13

Troubleshooting Guide .............................................................................................. 14

Special Care and Handling

Introduction................................................................................................................ 16

Special Cleaning and Care Instructions..................................................................... 16

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

Locations/Use...................................................................................................... 17

Solid State Electronics............................................................................................... 17

Electrostatic Discharge (ESD)............................................................................. 17

Printed Circuit Boards (PCBs)............................................................................ 17

Required Tools for VLX3 Wash Luminaire Service.................................................. 17

Maintenance Procedures

Moving Zoom Assembly Replacement ..................................................................... 18

Main Control Board (MCB) Replacement................................................................. 20

Low Voltage Supply (LVS)/LED Power Supply Replacement.................................. 22

Tilt Motor Assembly Replacement............................................................................ 24

Tilt Encoder Assembly Replacement......................................................................... 25

Tilt Sensor Assembly Replacement........................................................................... 26

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LED Driver Assembly Replacement.......................................................................... 29

Motherboard Assembly Replacement ........................................................................ 32

Light Pipe Replacement ............................................................................................. 34

120W RGBW LED Assembly Replacement.............................................................. 36

LED Cooling Assembly Replacement........................................................................ 38

Zoom Motor Assembly Replacement......................................................................... 40

DMX PCB Assembly Replacement ........................................................................... 42

PowerCon (AC Input) Assembly Replacement.......................................................... 43

Display PCB Assembly Replacement....................................................... ..... ............ 44

Wireless DMX Interconnect PCB Replacement ........................................................ 45

Enclosure Fans Replacement...................................................................................... 46

Pan Motor Assembly Replacement............................................................................ 47

Pan Belt Replacement................................................................................................. 48

VLX3 Wash dropCal (Reinstall Factory LED Calibration)....................................... 50

Chapter 3. Illustrated Parts Breakdown

Drawing Tree

VLX3 Wash Luminaire .............................................................................................. 54

Top Assembly

VLX3 Wash Included Items Kit................................................................................. 56

VLX3 Wash Luminaire .............................................................................................. 58

VLX3 Wash Generic Assembly ................................................................................. 60

VLX3 Wash Head Cover Assembly........................................................................... 62

Head Assembly

VLX3 Wash Head Assembly...................................................................................... 63

Moving Zoom Assembly............................................................................................ 65

Tilt Cradle Assembly.................................................................................................. 67

Right Tilt Tube Assembly .......................................................................................... 69

Left Tilt Tube Assembly............................................................................................. 70

Tilt Motor Mount Assembly....................................................................................... 71

Pulley Pinion Assembly ............................................................................................. 73

Light Engine (3 Source LED) Assembly............................................................ ..... ... 74

LED Engine Cooling Assembly................................................................................. 76

LED Driver Board Assembly..................................................................................... 78

Zoom Intermediate Plate Assembly ........................................................................... 79

Enclosure Assembly

VLX3 Wash Upper Enclosure Assembly................................................................... 81

Pan Motor Assembly.................................................................................................. 86

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

Cable Assemblies

Chassis To Yoke Ground Cable Assembly................................................................. 89

VLX3 Wash AC Input Cable Assembly..................................................................... 90

APS Fan Cable Assembly .......................................................................................... 91

xiv 14 November 2011 02.9703.0010 0

DMX I/O Cable Assembly......................................................................................... 92

VLX3 Wash Display Link Cable Assembly.............................................................. 93

VLX3 Wash 36VDC Supply Cable Assembly .......................................................... 94

- 12V Driver Board #1 Cable Assembly.................................................................... 95

- 12V Driver Board #2 Cable Assembly.................................................................... 96

- 12V Driver Board #3 Cable Assembly.................................................................... 97

LED Driver Grounds Cable Assembly...................................................................... 98

LED Drive Cable Assembly ...................................................................................... 99

Zoom Cable Assembly............................................................................................. 100

VLX3 Wash Tilt Cable Assembly............................................................................ 101

VLX3 Tilt Sensor Cable Assembly ......................................................................... 102

VLX3 Wash Tilt Cable Assembly............................................................................ 103

VLX3 Wash Pan Encoder Cable Assembly............................................................. 104

VLX3 AUX COMM Interface Cable Assembly ..................................................... 105

VLX3 LED Driver Grounds Cable Assembly......................................................... 106

VLX3 Yoke to Head Chassis Ground Cable Assembly........................................... 107

Appendix A. Technical Bulletins and Notices

TABLE OF CONTENTS

VLX3 Wash Technical Bulletins and Notices.......................................................... 109

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xvi 14 November 2011 02.9703.0010 0

Introduction

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all
configurations of the VLX3 LED Wash Luminaire. The manual is intended for use by Vari-Lite
personnel and Authorized VARI❋LITE Service Centers and technicians.

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

This manual covers the following models:

VLX3 Wash Luminaire 20.9703.0001 Three x 120W RGBW LEDs

VLX3 Wash Luminaire, White 20.9703.0001.02 Three x 120W RGBW LEDs

INTRODUCTION : ABOUT THIS MANUAL

Model Part Number Source

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

Additional Documentation

For complete installation and operation instructions, refer to the VLX3 Series Luminaire User’s
Manual. This manual is available in electronic (PDF) format on the Vari-Lite web site at www.vari-

lite.com in the Support (Product Downloads) section.

• VLX3 Series Luminaire User’s Manual (02.9703.0001)

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

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

www.usitt.org

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

Customer Service

Our Goal

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

How to Reach Us

For assistance in your area, call the dealer from which your product(s) was purchased.
or
Contact an Authorized Service Center.
or
Contact the Vari-Lite Customer Service Department, 7am - 6pm CST Monday through Friday, at the

following:

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

e-mail: [e-mail]

Additional Resources

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

Technical Bulletins and Notices

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

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

A list of current technical bulletins and notices associated with VLX Series Luminaires is found in

“VLX3 Wash Technical Bulletins and Notices” on page 109.

2 02.9703.0010 0

CHAPTER 1.

Description

This chapter contains descriptions of luminaire features and components.

• Features

• Components

• Principles of Operation

SERVICE

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

Features

Standard Features

All VLX3 series luminaires have the following standard features:

• Three, 120 Watt custom RGBW Chipsets (each chipset contains
high density red, green, blue, and white LED emitters).

• Optical zoom system with continuously variable field angle from
approximately 15° to 55°.

• Smooth, high resolution intensity and dimming control of red,
green, blue, and white LEDs.

• Color temperature (white) variable between 3000 and 9000K.

• LED manufacturer rated life in excess of 10,000 hours (at full
RGBW).

• Output exceeds 6,000 lumens (white light).

• High speed strobe operation with multiple strobe effects.

• Smooth, time-controlled continuous motion by way of a pair of three-phase stepper motor systems.
Pan range is 540°/ Tilt range is 240° both with a 0.3° resolution.

• Control by DMX512 protocol.

• Variable forced-air cooling.

• Operational Temperature of -20° to 122°F (-29° to 50°C).

• Power Requirements: Standard AC power distribution from 100-240VAC, 50/60Hz. The unit
requires up to 7A depending on the AC supply voltage.

• 23 channels DMX channels (in Map 1 mode).

• May be mounted and operated in any orientation.

• Hangs on 21.50 inch (54.6 cm) centers.

• Weight is 44 lbs. / 20 kg (luminaire only).

Technical Specifications

For detailed technical specifications, refer to VLX3 LED Wash Luminaire User’s Manual
(02.9701.0001) or the Vari-Lite web site at www.vari-lite.com.

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Components

VLX3 Wash External Components

The following illustration shows the external luminaire components and controls.

Upper Enclosure Assembly

Houses power supply, pan motor,
and display board.

Menu LCD Display

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

(see detail below)

Head Assembly

Front lens/optics, LED
driver PCBs, LEDs, and
cooling fans, tilt motor,
and MCB.

COMPONENTS : VLX3 WASH EXTERNAL COMPONENTS

Truss Hook Brackets

Attaches to enclosure base
to allow truss hook installation.

(Truss hooks sold separately)

Input Panel

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

1

Input Panel

AC Input
Cable*

Menu LCD Display Panel

Arrow Keys (Left/Right/Up/Down)

To Menu Navigate Menu Options
and make Data Selections

Data In
Data Thru

Enter Button

To Select or Change a
Setting or Data Value

ENTER

Yoke Assembly

Upper Enclosure Components

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

LCD Display

Displays all Data and
Luminaire Settings

POWER

TX

RX

ERROR

ESC

Escape (ESC)

To Exit or Go to
Previous Menu Item

Status LEDs

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

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

VLX3 Wash Luminaire Components

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

Luminaire Head Covers

Two covers, one on each side
of luminaire head assembly.

Head Assembly

See “VLX3 Wash Luminaire
Head Components” on page 7.

Y oke Arm Covers

Two covers, one on each side
of yoke assembly.

Enclosure Assembly

See “VLX3 Wash Enclosure
Components” on page 8.

Enclosure Covers

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

6 02.9703.0010 0

Power Supply Assembly

Supplies power for luminaire
operation.

COMPONENTS : VLX3 WASH LUMINAIRE HEAD COMPONENTS

VLX3 Wash Luminaire Head Components

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

LEDs/LED Cooling Assembly

Houses three 120W LEDs and
LED cooling assembly.

LED Driver PCBs

One Driver PCB per LED.

1

LED Lightpipes

One lightpipe per LED. Transmits
light from LED to optics.

Zoom Assembly

Connects to motor
assembly for movement.

Zoom Motor Assembly

Connects to zoom
assembly.

Cradle Assembly

Connects head to yoke
and contains tilt motor
assembly.

Main Control Board (MCB)

Luminaire control circuit
board assembly.

Note:

Yoke and Enclosure assemblies not
shown for clarity.

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

VLX3 Wash Enclosure Components

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

LCD Display Assembly

For addressing, accessing

menu options and settings. See

page 5 for details.

Wireless DMX Interconnect

Allows connection of optional
wireless DMX module

Input Panel Assembly

Contains DMX Input
PCB and AC Input*

Fan Assemblies

Pan Motor Assembly

Enclosure Cover Plate

*AC Input

Requires standard AC power distribution
from 100-240 VAC, 50/60 Hz., up to 10A
depending on the AC supply voltage.

Wire** Connection

Note:

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

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Green/Yellow AC Ground

Blue AC Neutral

Brown AC Line

** International (Harmonized) Standard

PRINCIPLES OF OPERATION : VLX3 WASH LUMINAIRE FUNCTIONAL BLOCK DIAGRAM

Principles of Operation

VLX3 Wash Luminaire Functional Block Diagram

1

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

Notes

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CHAPTER 2.

Maintenance

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

• Testing

• Troubleshooting

• Special Care and Handling

• Maintenance Procedures

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

pletely removed from the luminaire. Never remove covers while unit is in oper­ation.

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

SERVICE

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VARI❋LITE - VLX3 LED WASH LUMINAIRE SERVICE MANUAL

Testing

Luminaire Self-Tests

The luminaire is capable of running self tests by using the TEST menu functions. For detailed
instructions regarding the luminaire’s self-test function, refer to the VLX3 LED Wash Luminaire
User’s Manual (02.9703.0001).

Calibration Sequence

The following is an outline of the luminaire’s standard calibration sequence:

Phase 1

• Tilt

• LEDs Off

• LED Upload

Phase 2

•Zoom

Phase 3

•Pan

Sensor Testing

Most mechanisms within the VLX3 luminaire are equipped with either optical or magnetic sensors.
The VLX3 master control board (MCB) has labeled test points for reading DC voltages at each sensor.
Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan/tilt
encoder readings. The values can be used to determine whether a circuit is opening correctly or needs
further troubleshooting.

Guidelines:

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

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

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

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

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

• Optical sensors read high when the sensor is Closed.

• Magnetic sensors read Low when the sensor is Closed.

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

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

Notes regarding specific mechanisms:

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

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