VariLite VL1000 Service manual

02.9663.0010

VL1000™ ERS

Luminaire

Service Manual

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VARI❋LITE

®

, Artisan®, VL2®, and VLD® are trademarks owned by Vari-Lite, Inc., 201 Rega l Row, Dallas TX 75247 USA.

and are registered in the United States and other countries.

VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, Virtuoso™,
Virtuoso™ DX, VARI❋LITE Visionary

™

VL6B

, VL6C™, VL7™, VL7B™, VLM™, APS6™, C3™, ArtisanVLQ™, SPC-36™, UDM™, AutoTruss™, SmartDMX™,
Smart Repeater
DICHRO❋TUNE

™

, Series 100™, Series 200™, Series 300™, Series 2000™, Series 3000™, DICHRO❋WHEEL™,

™

, VACU❋DEP™, VARI❋IMAGE™, VARI❋BEAM™, and the Vari-Lite Asterisk are also trademarks

™

, VL1™, VL2B™, VL2C™, VL3™, VL4™, VL5™, VL5Arc™, VL5B™, VL6™,

owned by Vari-Lite, Inc.
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; 6,1 13,252; 6,046,861; 6,031,749; 6,011,640; 5,969,868; 5,959,768; 5,934,794; 5,882,107; 5,829,868;

5,825,548; 5,798,619; 5,7 74, 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; 5,2 82, 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; 4,6 02, 321;

U. S. Design Patents No. 439,356; 420,3 32; 417, 300; 415,301; 413,995; 377,338; 366,712; 359,574; 350 ,4 08; 347,113 ;
Australia Patents No. 693,691; 683, 695; 667,109; 649,264; 646,588; 586,095; 576,400 ; 546 ,4 33;
Australia Design Patents No. 128,796; 128 ,7 95;
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 ,2 33; 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; 0 379 970; 0 253 082;

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 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 951.2; M 499 03 583.6; M

498 11 203.9; G 93 12 884.3;
Spain Patents No. 2 090 191; 2 084 289; 2 020 96 0; 0 548 328;
Spain Utility Model Patent No. 2.031. 74 8;
Spain Design Patents No. 0.137.502; 0.1 37.501; 0.133.573;
Greece Patent No. 910.400.544;
Hong Kong Patents No. 965/1990; 28 5/ 1987;
Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889 ,4 81; 1,7 92, 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; 28 3, 770; 181,180;
Korea Design Patents No. 209,896; 209,895;
Mexico Patent No. 180,148;
Singapore Patents No. 663/90; 134/8 7;
Taiwan Patents No. 78,726; 66,975; 65,380; 28,275;
United Kingdom Design Regi stra ti ons N o. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.
Apple®, Macintosh®, and FireWire® are registered trademarks of Apple Computer, Inc.

Neutrik®, Pow erCon®, and EtherCon® are registered trademarks of Neutrik, Inc.
All other brand or product na m es wh i ch ma y 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. Vari-Lite, Inc.

assumes no responsibility or liabili ty for any errors or inaccuracies that may appear in this manual. All information and graphic
representations are property of Vari-Lite, Inc. 201 Regal Row, Dallas, Texas 75247 USA.

Version as of: 23- O ct-02
Part number: 02.9663.001 0 D

VL1000™ ERS Luminaire Service Manual
©2002 Vari-Lite, Inc. All Rights Reserved.

ii 23-Oct-02 02.9663.0010 D

HOW TO OBTAIN WARRANTY SERVICE

How To Obtain Warranty Service

A copy of the Vari-Lite, Inc. 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 [e-mail] and request a Return Material
Authorization (RMA) for warranty service. You 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 product in its original packing material along with
a copy of your invoice (if available) and write the RMA number legibly on or near the
shipping address label. Return the unit, freight prepaid to:

Vari-Lite, Inc.
201 Regal Row
Dallas, TX 75247
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 D

1-191 D

VERSION DATE

Basic 14-Mar-02
Revision A 25-Apr-02
Revision B 02-May-02
Revision C 18-Jun-02
Revision D 23-Oct-02

02.9663.0010 D 23-Oct-02 iii

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:

Safety

EN 60598-1:1997 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989 Specification for Luminaires for Stage and Studio Li ghting

EMC

EN 55022A:1994 Radiated and Conducted Emissions
EN 50082-1:1997 Generic Immunity Standard

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

iv 23-Oct-02 02.9663.0010 D

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 h ave been d esigned f or use onl y with ce rtain Phi lips 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 inst ructions 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.

02.9663.0010 D 23-Oct-02 v

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 the y have become vis ibly damaged to such an extent that their
effectiveness is impaired. For example, by cracks or de ep 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 adjust ing 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 pers onal 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
interferen ce, in which case, the user may be required to take adequate meas ures.

ARC LAMP CHARACTERISTIC CONSIDERATIONS

1. Arc lamps require a pe ri od of time to relight after a power in te rr upt ion 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.

vi 23-Oct-02 02.9663.0010 D

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. 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 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 gewart et werden.

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG

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

abgibt. SCHAUEN SIE NICHT direkt in die Lam pe.

02.9663.0010 D 23-Oct-02 vii

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

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

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN

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

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

3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sol lte 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 Siche rheitsausr üstung (Han dschuhe, Augenschu tz) sollte beim Umgang mi t
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
ausgetaus cht 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 Universa l.

viii 23-Oct-02 02.9663.0010 D

NOTES DE SÉCURITÉ

Notes de sécurité

A vant 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 cert ai nes

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 m êmes 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.

02.9663.0010 D 23-Oct-02 ix

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

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 blinda ges,
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 com posants, 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 grave s br ûl ures 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 Cla sse A. Dans u n env ironneme nt domesti que, cet appare il peut cause r
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’êt re r efroi die. Cela dé pen d de l a mani ère do nt le s ystème est rég lé
pour le statut de mise en marche de la lampe (L ON/ LOFF).

2. La position Brûler est Universelle.

x 23-Oct-02 02.9663.0010 D

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 PROTECCIÓ N CONTINUA CONTRA INCENDIO

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

lámparas HID Philips y Osra m. 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 PROTEC CIÓ N 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.

02.9663.0010 D 23-Oct-02 xi

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

ADVERTENCIA:
INSTRUCCIONES PARA PROTECC IÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN 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 PROTECCIÓ N 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 equi po y componentes que están calientes.

2. Cuando las luminarias están en operación la lámpara estará muy cali ente. 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 lámpar a con l as manos , limpie la l ámpara c on alc ohol de snatur aliz ado y co n tel a
sin pelusas antes de instalar o volver a conectar la luminaria.

7. Cambie la lámpara si está dañada o deformada term icamente.

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 interrupció n de ene rgía o de una severa caída de vo lt aj e. En al gunos casos, la lámpara
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2. La posición de encendido es universal.

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Table of Contents

Introduction

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

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

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

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

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

Chapter 1. Description

Features

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

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

Component Descriptions

External Luminaire Components................................................................................. 5

Luminaire Internal Head Components......................................................................... 6

Luminaire Internal Yoke Components......................................................................... 7

Arc Ballast Unit........................................................................................................... 8

Principle s of Operation

VL1000 Incandescent Source Luminaire..................................................................... 9

VL1000 Incandescent Block Diagram.................................................................. 9

VL1000 Incandescent Cable Routing.................................................................. 10

VL1000 575W Arc Source Luminaire....................................................................... 11

VL1000 Arc Block Diagram............................................................................... 11

VL1000 Arc Cable Routing ................................................................................ 12

VL1000 Arc Ballast Unit........................................................................................... 13

Ballast Block Diagram........................................................................................ 13

TABLE OF CONTENTS

Chapter 2. Maintenance

Testing

Running Parameter Tests ........................................................................................... 16

Maintenance Procedures

Lamp Replacement (Incandescent Mode l)................................................................ 18

Lamp Replacement (Arc Model)............................................................................... 20

Align Lamp For Maximum Beam Irradiance............................................................ 22

Frame or Top Hat Replacement................................................................................. 23

Front Cover Removal................................................................................................. 24

Rear Head Assembly Removal.................................................................................. 25

Rotating Gobo Replacement...................................................................................... 26

Gobo Index Timing Belt Alignment .......................................................................... 28

Gobo Wheel Bulkhead Replacement......................................................................... 30

Gobo Gear Planet Alignment..................................................................................... 32

02.9663.0010 D 23-Oct-02 xv

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Shutter Assembly Replacement.................................................................................. 34

Shutter Blade or Rack Replacement........................................................................... 36

Edge/Zoom/Color Bulkhead Replacement................................................................. 38

Fan/Temp Switch Assembly Replacement................................................................. 39

Beam-Size Iris Assembly Replacement........................................ ............................. 40

Ignitor PCB Replacement........................................................................................... 41

Power Supply Replacement........................................................................................ 42

Controller PCB Replacement..................................................................................... 44

Tilt Encoder PCB Replacement.................................................................................. 46

Tilt Motor Assembly Replacement............................................................................. 47

Pan Motor Assembly Replacement............................................................................ 49

DMX Input PCB Replacement................................................................................... 51

Cleaning Optical Lenses and Filters........................................................................... 52

Chapter 3. Illustrated Parts Breakdown

Drawing Trees

VL1000 Incandescent Luminaires.............................................................................. 54

VL1000 Arc Luminaires............................................................................................. 56

Top Assembly

Included Items Kit...................................................................................................... 58

Label Locations.......................................................................................................... 59

VL1000 Luminaire .....................................................................................................60

Front Cover Assembly ................................................................................................62

Gel Frame Holder Assembly ......................................................................................63

COT Flag Assembly ...................................................................................................64

Controller PCB Assembly ..........................................................................................65

Head Assembly

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

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

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

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

Color Changer Drive Motor .......................................................................................79

Cover Plate Assembly .................................................................. ......... ......... ............80

Barrel Assembly .................................................................................... ......... ......... ...81

Lens #6 Assembly ......................................................................................................83

Lens #7 Assembly ......................................................................................................84

Lens #8 Assembly ......................................................................................................85

Fan Assembly .............................................................................................................86

Pulley Side Rail Assembly .........................................................................................87

Sensor Side Rail Assembly ........................................................................................88

Incandescent Gobo Wheel Assembly .........................................................................89

Temperature Sensor Electrical Assembly ..................................................................92

Arc Gobo/Dimmer Bulkhead Assembly ....................................................................93

Gobo Wheel Assembly ...............................................................................................96

Gobo Bulkhead FAB Assembly .................................................................................97

Gobo/Dimmer Bulkhead FAB Assembly ...................................................................98

xvi 23-Oct-02 02.9663.0010 D

TABLE OF CONTENTS

Dimmer Wheel Assembly ..........................................................................................99

Wheel Sensor PCB ................................................................................................... 100

Index Sensor PCB .................................................................................................... 101

Shutter Assembly ..................................................................................................... 102

Shutter 6 Rollers Assembly ..................................................................................... 105

Beam-Size Iris Assembly ................................................................ ......... ......... .......108

Rear Head Assembly ................................................................................................ 109

Bulkhead Assembly ................................................................................................. 111

Back Cap Assembly ................................................................................................. 112

Yoke Assembly

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

Tilt Motor Assembly ................................................................................................ 117

Ignitor PCB .............................................................................................................. 118

Pan/Tilt Encoder PCB Assembly ............................................................................. 119

Crossmember Assembly .......................................................................................... 120

Inner Crossmember Assembly ................................................................................. 122

Outer Crossmember Assembly ................................................................................ 123

Pan Motor Assembly ................................................................................................ 124

Pan Tube Assembly ................................................................................................. 125

DMX Input PCB Assembly ............................................................ ......... ......... .......127

Cables

Arc Power Input (Pigtail) Cable Assembly ............................................................. 129

Pan EOT Cable Assembly ....................................................................................... 131

Tilt COT Cable Assembly ....................................................................................... 132

AC Line Input Cable Assembly ...............................................................................133

Incandescent LVS AC Input Cable Assembly .........................................................134

Arc LVS AC Input Cable Assembly ........................................................................ 135

LVS Chassis Ground Cable Assembly .................................................................... 136

Head to Backcap Ground Cable Assembly .............................................................. 137

Yoke to Head Ground Cable Assembly ................................................................... 138

Pan/Tilt Control Cable Asembly .............................................................................. 1 39

Ballast Control Link Cable Assembly .....................................................................1 41

Data I/O Link Cable Assembly ................................................................................ 142

LVS DC Output Cable Assembly ............................................................................ 143

Incandescent Power Input Cable Assembly ............................................................. 144

Incandescent Lamp Power Cable Assembly ............................................................ 145

Arc Power to Ignitor Cable Asembly ....................................................................... 146

Ignitor to Lamp Socket Cable Assembly ................................................................. 147

Shutter Harness Cable Assembly ............................................................................. 148

Color/Gobo/Lens Harness Cable Assembly ............................................................ 150

Arc Ballast Assembly

Arc Ballast Assembly .............................................................................................. 153

625W Ballast PCB ............................................................................................ .......156

625W Ballast Rider PCB ......................................................................................... 160

575W Ballast I/O Cable Assembly .......................................................................... 164

02.9663.0010 D 23-Oct-02 xvii

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Appendix A. Technical Bulletins

VL1000 ERS Luminaire Technical Bulletins........................................................... 167

Appendix B. Wiring and Schematic Diagrams

VL1000 Incandescent Wiring Diagram - Sheet 1 of 2............................................. 169

VL1000 Incandescent Wiring Diagram - Sheet 2 of 2............................................. 170

VL1000 Arc Wiring Diagram - Sheet 1 of 2............................................................ 171

VL1000 Arc Wiring Diagram - Sheet 2 of 2............................................................ 172

VL1000 Ballast Wiring Diagram ............................................................................. 173

Gobo Wheel Sensor (24.9663.1230 B) Schematic................................................... 174

Gobo Index Sensor (24.9663.1231 A) Schematic.................................................... 175

DMX Input PCB (24.9663.1830 A) Schematic........................................................ 176

625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 1 of 3.............................. 177

625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 2 of 3.............................. 178

625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 3 of 3.............................. 179

625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 1 of 2.................... 180

625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 2 of 2.................... 181

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 1 of 10.................................. 182

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 2 of 10.................................. 183

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 3 of 10.................................. 184

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 4 of 10.................................. 185

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 5 of 10.................................. 186

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 6 of 10.................................. 187

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 7 of 10.................................. 188

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 8 of 10.................................. 189

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 9 of 10.................................. 190

Controller PCB (24.9663.1930 F) Schemat ic - Sheet 10 of 10................................ 191

xviii 23-Oct-02 02.9663.0010 D

Introduction

Disclosure

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

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 customers/clients.

INTRODUCTION : DISCLOSURE

This manual covers the following models:

M

ODEL

VL1000 T 20.9663.0001.01 Incandescent

VL1000 TS 20.9663.0001.02 Incandescent X

VL1000 TI 20.9663.0001.03 Incandescent X

VL1000 A 20.9663.0001.11 Arc

VL1000 AS 20.9663.0001.12 Arc X

VL1000 AI 20.9663.0001.13 Arc X

P

ART NUMBER

S

OURCE

S

HUTTER

I

RIS

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

Additional Documentation

A support webpage for VL1000 series luminaires is available at www.vari-lite.com
(follow the Support link).

A user’s manual is available for installation and operation of the VL1000 ERS
luminaire. This manual is available in both printed and electronic (PDF) formats.

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

■

02.9663.0010 D 23-Oct-02 1

VARI❋LITE® - VL1000™ ERS 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 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.

or

Contact an Authorized Service Center.

or

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

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

fax: [phone]

email: [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, Texas USA office. They are documentation supplements that
contain procedures for equipment 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 S1K-001 (VL1000 series luminaires
Technical Bulletin number 1).

Technical notices are also issued from the Dallas, Texas USA office. They are non­procedural 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 TN­138 (Tech Notice number 138).

2 23-Oct-02 02.9663.0010 D

CHAPTER 1.

Description

Description

DescriptionDescription

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

• Features

• Component Descriptions

• Principles of Operation

02.9663.0010 D 23-Oct-02 3

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 T Luminaire (20.9663.0001.01)

• 1000W Tungsten Halogen lamp source.

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 A (20.9663.0001.11)

• 575W arc lamp source with external ballast unit.

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 23-Oct-0 2 02.9663.0010 D

DESCRIPTION : COMPONENT DESCRIPTIONS

Component Descriptions

External Luminaire Components

The following illustration shows the external luminaire components and controls.

Base

Input Panel

Provides DMX In and
Thru, and AC Power
connections.

Provides hook mounting
holes and safety cable
connection.

1

Lamp Power
Input Cable

Yoke Assembly

Houses Control PCB
and power supply.

Accessory Frame Holder

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

See detail...

Menu Display Controls

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 *

Gel, Silk
or Frost

* Do not remove or use to access lamp.

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

02.9663.0010 D 23-Oct-02 5

3-Pole Neutrik

Locking Connector

for AC Input

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

Luminaire Internal Head Components

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

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

Shutter Assembly (optional)

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

Beam-Size Iris Assembly (optional)

Provides beam sizing capabilities.

Aperture Assembly

Installed when neither
the shutter or beam-size
is used.

Rear Head Assembly

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

A

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

B

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.

6 23-Oct-0 2 02.9663.0010 D

DESCRIPTION : COMPONENT DESCRIPTIONS

1

Luminaire Internal Yoke Components

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

Note: Head assembly not shown for clarity.

Yoke Arm Cover

Tilt Mechanism

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.

02.9663.0010 D 23-Oct-02 7

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

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 Connec t o r

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.

8 23-Oct-0 2 02.9663.0010 D

Principles of Operation

VL1000 Incandescent Source Luminaire

VL1000 Incandescent Block Diagram

DESCRIPTION : PRINCIPLES OF OPERATION

1

VL1000

INCANDESCENT

BLOCK DIAGRAM

VL 1000 INC wire9.vsd

10-23-01 JHC

NEUTRIK

I/O

I/O

XLR-M

DMX INPUT

J2

NEUTRIK

XLR-F

DMX THRU

J1

DMX PCB

24-9663-1830

NEUTRIK

POWERCON

AC LINE IN

2015

USER

PROVIDED

CONNECTOR

FOR LAMP

PWR INPUT

FROM

DIMMER

2030

DIMMER GND

PIGTAIL

DATA

DATA

AC LINE
POWER

LAMP

POWER

J3

AC LINE

16/2
2015

AC GND

16/1
2015

1.5/1
2030

LAMP

POWER

1.5/2
2030

ALL MOTORS

44-9663-XXXX

ALL CABLES

25-9663-XXXX

DATA

22/5

2022

FAN
24/2

2040

(SHUTTERS)

2042

(WITHOUT)

FAN

1

2

J8

J1

AC GND

22x4
2016

CHASSIS

GND STUD

CHASSIS

GND STUD

1766

ZOOM

MOTOR

1202

EDGE

MOTOR

M1

24/4

M2

24/4

J4

SENSOR 1

26/4

GOBO WHEEL

SENSOR

23-9663-2004

TERM

BLOCK

TERM

BLOCK

1202

GOBO

INDEX

1202 1520

GOBO

WHEEL

1

M3

24/4

AC LINE

AC GND

M4

24/4

SENSOR 2

26/4

GOBO INDEX

SENSOR

23-9663-2005

22x4/2

2016

16/1
2017

YOKE

GND STUDS

M5

24/4

AC

IN

2

1520

BLUE

MOTOR

1520

AMBER

MOTOR

M7

24/4

M6

24/4

+24V

18/4

2024

+24V

LOW

VOLTAGE

SUPPLY

69-3128-0150

YOKE TO

HEAD GND

LAMP

POWER

22x4/2

2031

1520 1766
MAG

MOTOR

DIFF

MOTOR

M9

24/4

M8

24/4

DOWNUPMENU ENTER

J7J6J4

22x4
2019

M13
26/4

1301

1A

SHUTTER

FRAME

1301

1B

SHUTTER

FRAME

M14
26/4

M15
26/4

DIMMER

ARC

( )

ONLY

1202/1326

B.S.IRIS/

SHUTTER

ROTATE

M12
24/4

J1

MAIN CONTROL

PCB ASSY

24-9663-1920

J5

SENSOR 3,4,5

24/5

M10
24/4

2020

PAN

MOTOR

GND STUDS

SERIES 30

J1 J1

PAN ENCODER

PCB ASSY

24-9661-0629

J2 J2

PAN EOT

26/4

PAN EOT

SENSOR

23-9663-2001

HEAD

21

AMP

SHUTTER

SHUTTER

20202050

POWER

16/2HT

1301

2A

FRAME

1301

2B

FRAME

M16
26/4

LAMP

2032

M17
26/4

20402050

DISPLAY8

M11
24/4

2020

TILT

MOTOR

18501850

HEAD TO

BACK CAP

BRAID

2018

1301

3A

SHUTTER

FRAME

1301

3B

SHUTTER

FRAME

M19

26/4
M18
26/4

SENSOR 6,7,8

24/5

TILT ENCODER

PCB ASSY

24-9661-0629

TILT COT

26/4

TILT COT
SENSOR

23-9663-2002

1200W

INCAND

LAMP

1301

4A

SHUTTER

FRAME

1301

4B

SHUTTER

FRAME

M20
26/4

BACK CAP
GND STUD

02.9663.0010 D 23-Oct-02 9

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Incandescent Cable Routing

USER

PROVIDED

CONNECTOR

FOR LAMP PWR

INPUT FROM

DIMMER

LAMP PWR

2030

DIMMER GND

PIGTAIL &

STRAIN RELIEF

TILT
COT
2002

PAN

MOTOR

& ENC

PCB

LAMP

PWR

2031

PAN - 2020

GND STUD

TILT COT

SENSOR

PAN EOT

2001

TILT COT - 2002

LAMP PWR - 2031

LVS

.

GND
2017

LVS

ASSY

69-

3128-

0150

YOKE/HEAD GND - 2019

GND STUD GND STUD

VL 1000

INCANDESCENT

CABLE ROUTING

NEUTRIK

POWERCON

AC LINE IN

2015

GND

.

STUD

1

PAN EOT
SENSOR

AC GND - 2016

LAMP PWR - 2031

TILT

TUBE

LINE
2015

GND

STUD

BLOCK

2

AC LINE - 2016

SERIES

AC

TERM

LAMP

PWR
2031

LAMP

PWR
2032

AMP

30

CHASSIS

TERM

BLOCK

AC
GND
2016

+24VDC - 2024

LAMP

SOCKET

INC

LAMP

10

CONTROL

MOTORS

2
GOBO
SENSE

8

SHUTTER

MOTORS

(OPT)

HEAD

AC

DMX

LINE

DATA

2016

2022

BACK CAP

GND STUD

BACK CAP/
HEAD GND

GND STUD

FAN

XLR-M

DMX

INPUT

DMX PCB

5

24-9663-1830

XLR-F

DMX

THRU

PAN

TUBE

YOKE

PAN - 2020

DMX DATA - 2022

5 54

MCB
PCB

2018

10 MOTORS/ 2 SENSORS - 2050

FAN - 2040 or 2042

8 MOTORS - 2040

TILT

TUBE

9663-

Note: All Cable Assys are

VL 1000 INC route5.vsd

TILT COT

2002

PAN
2020

20

40

24-

50

1920

25-9663-XXXX

10-24-01 JHC

TILT

MOTOR

& ENC

PCB

TILT
2020

10 23-Oct-02 02.9663.0010 D

DESCRIPTION : PRINCIPLES OF OPERATION

VL1000 575W Arc Source Luminaire

VL1000 Arc Block Diagram

1

VL1000

575W ARC

BLOCK DIAGRAM

VL 1000 ARC wire9.vsd

10-23-01 JHC

NEUTRIK

I/O

I/O

XLR-M

DMX INPUT

J2

NEUTRIK

XLR-F

DMX THRU

J1

DMX PCB

24-9663-1830

NEUTRIK

POWERCON

AC LINE IN

2015

AMP CPC

17-9 PLUG

LAMP PWR

INPUT &
AC LINE
OUTPUT

TO BALLAST

1921

HIGH

CURRENT

CONTACTS

BALLAST GND

DATA

DATA

AC LINE
POWER

AC LINE
POWER

BALLAST

CONTROL

LAMP

POWER

J3

2040

2042

AC LINE

16/2

AC GND

16/1
2015

CHASSIS

GND STUD
AC LINE

16/2

16/1
1921

LAMP POWER

14/2
1921

PIGTAIL

ALL MOTORS
44-9663-XXXX

ALL CABLES

25-9663-XXXX

DATA

22/5

2022

FAN
24/2

(SHUTTERS)

(WITHOUT)

FAN

1

CHASSIS

2

GND STUD

J8

J1

GOBO WHEEL

23-9663-2004

AC GND

22x4
2016

1766

ZOOM

MOTOR

1202

EDGE

MOTOR

M1

24/4

J4

SENSOR 1

26/4

SENSOR

TERM

BLOCK

TERM

BLOCK

M2

24/4

1202

GOBO
INDEX

1202 1520

GOBO

WHEEL

M3

24/4

1

AC LINE

AC GND

BALLAST

CONTROL

M4

24/4

SENSOR 2

26/4

GOBO INDEX

SENSOR

23-9663-2005

22x4/2

2016

16/1

2017

YOKE

GND STUDS

22/4

1921

M5

24/4

AC
IN

2

LAMP POWER

22x4/2

1520

BLUE

MOTOR

1520

AMBER
MOTOR

M7

24/4

M6

24/4

+24V

18/4
2024

+24V

LOW

VOLTAGE

SUPPLY

69-3128-0150

YOKE TO

HEAD GND

2035

1520 1766
MAG

MOTOR

DIFF

MOTOR

M9

24/4

M8

24/4

DOWNUPMENU ENTER

J7J6J4

BALLAST

CONTROL

22/4

1921

22x4
2019

IN

M13
26/4

1301

1A

SHUTTER

FRAME

1301

1B

SHUTTER

FRAME

M14
26/4

DIMMER

ARC

( )

ONLY

1202/1326

B.S.IRIS/

SHUTTER

ROTATE

M12
24/4

J1

MAIN CONTROL

PCB ASSY

24-9663-1920

J5

SENSOR 3,4,5

24/5

M10
24/4

2020

PAN

MOTOR

GND STUDS

IGNITOR

PCB ASSY

24-9661-1125

J1 J1

PAN ENCODER

PCB ASSY

24-9661-0629

J2 J2

PAN EOT

26/4

PAN EOT

SENSOR

23-9663-2001

HEAD

21

M15
26/4

O
U
T

20202050

1301

2A

SHUTTER

FRAME

1301

2B

SHUTTER

FRAME

M16
26/4

LAMP HV

M17
26/4

20402050

DISPLAY8

M11
24/4
2020

TILT

MOTOR

18501850

HEAD TO

BACK CAP

BRAID

2018

16/2HV

2036

1301

3A

SHUTTER

FRAME

1301

3B

SHUTTER

FRAME

M19

26/4
M18
26/4

SENSOR 6,7,8

24/5

TILT ENCODER

PCB ASSY

24-9661-0629

TILT COT

26/4

TILT COT
SENSOR

23-9663-2002

575W

ARC

LAMP

1301

4A

SHUTTER

FRAME

1301

4B

SHUTTER

FRAME

M20
26/4

BACK CAP

GND STUD

02.9663.0010 D 23-Oct-02 11

VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL

VL1000 Arc Cable Routing

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

VL 1000

575W ARC

CABLE ROUTING

NEUTRIK

POWERCON

AC LINE IN

2015

GND

STUD 1

AC LINE

BAL CONT

LAMP PWR

BALLAST GND

PAN EOT

2001

TILT COT - 2002

LVS
GND
2017

PAN EOT

SENSOR

LAMP PWR - 2035

AC GND - 2016

LVS

ASSY

69-

3128-

0150

LAMP PWR - 2035

YOKE/HEAD GND - 2019

GND STUD GND STUD

AC

.

GND
2016

GND

STUD

2

AC LINE - 2016

TERM

BLOCK

LAMP

PWR
2035

LAMP

2036

IGN

PCB

9661-

1125

TILT

TUBE

AC
LINE
2015

HV

24-

TERM

BLOCK

AC

AC

LINE

GND

2016

2016

+24VDC - 2024

LAMP

SOCKET

ARC

LAMP

10

CONTROL

MOTORS

2

GOBO

SENSE

8

SHUTTER

MOTORS

(OPT)

HEAD

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

5

24-9663-1830

XLR-F

DMX

THRU

PAN

TUBE

YOKE

TILT COT

2002

PAN - 2020

DMX DATA - 2022

BAL CONT - 1921

5 54

MCB
PCB

24-

9663-

1920

10 MOTORS/ 2 SENSORS - 2050

FAN - 2040 or 2042

8 MOTORS - 2040

TILT

TUBE

Note: All Cable Assys are

25-9663-XXXX

VL 1000 ARC route5.vsd

10-24-01 JHC

TILT

MOTOR

& ENC

PCB

TILT

2020

PAN

2020

20

40

50

12 23-Oct-02 02.9663.0010 D