Vari Lite VL2000 Service Manual

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

VA R I ❋LITE®, Artisan®, VL2® and VLD® are trademarks owned by Vari-Lite, Inc., 201 Regal 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, VA R I ❋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

owned by Vari-Lite, Inc.
VA R I ❋LITE® products are protected by one or more of the following patents, and other pending patent applications worldwide:
US Patents No. 5,959,758; 5,728,994; 5,590,954;5,367,444; 5,329,431; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806;

4,602,321; 4,392,187; U.S. Design Patents No. 366,712; 359,574;
Australia Patents No. 703868; 693691; 683695; 667109; 657152; 649264; 646588; 618559; 586095; 576400; 575271; 546433;

Australia Design Reg. No. 126781;
German Patents No. (DBP) 69314122.0; 69208615.3; 69207692.1; 69121029.2; 3768727.1; 3750201.8; 3587270.5; 3279888.1;

3274291.6; DGM G9312884; DGM 9407689.8;
European Patents No. 0586049 (FR, GB); 0547732 (BE, DK, FR, GB); 0534710 (BE, FR, GB); 0474202 (BE, DK, FR, GB);

0253082 (BE, FR, GB); 0253081 (BE, FR, GB); 0192882 (BE, FR, GB); 0140994 (BE, FR, GB); 0060068 (BE, FR, GB);
France Design Reg. No. 335132 - 335147;
Spain Patents No. 2090191; 2084289; 2082384; 2058071; 2020960; 0548328; Spain Utility Model No. 2031748; Spain Design

Reg. No. 129596;
Japan Patents No. 2,059,669; 2,055,324; 2,002,168; 1,889,481; 1,770,241; 1,723,825; 1,683,007; 1,553,011; KR 206051; 181180;

76310; 47673; Japan Design Reg. No. 947552; 945436-1; 945436;
Korean Design Reg. No. 175178;
Mexico Patents No. 180148; 179138;
Taiwan Patents No. 78726; 66975; 65380; 63471; 40611; 28275;
United Kingdom Design Reg. No. 2042174; 2033108; 2029499.

™

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

All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their
respective companies or organizations.

VL2000™ Wash 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 liability 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: 24-March-2004

Printed in the USA.

Part number: 02.9671.0010 C

VL2000™ Wash Luminaire Service Manual

© 2000-2004 Genlyte Thomas Group LLC All Rights Reserved.

ii 24-March-2004 02.9671.0010 C

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.
10911 Petal Street
Dallas, Texas 75238
Attention: Warranty Service

FOREWORD

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

Confidential Property Disclosure

This technical manual is confidential property of Genlyte Thomas Group LLC All
information contained herein is the sole and exclusive property of Genlyte Thomas
Group LLC and may not be used, disclosed, or reproduced in any manner without the
prior written consent of Genlyte Thomas Group LLC The information furnished in
this manual is for informational use only and is subject to change without notice.
Genlyte Thomas Group LLC assumes no responsibility or liability for any errors or
inaccuracies that may appear in this manual.

02.9671.0010 C 24-March-2004 iii

VARI❋LITE® - VL2000™ 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 60950: 1999 Safety Standard for Information Technology Equipment

EMC

EN55022A: 1998 Radiated and Conducted Emissions
EN50082-1: 1997 Generic Immunity Standard

We certify that VARI❋LITE products conform to the protection requirements of
European council directives: 73/23/EEC (LVD) and 89/336/EEC (EMC)

Manual Revision History

iv 24-March-2004 02.9671.0010 C

PAGE NUMBER CHANGE NUMBER

Title Page - xiv C

1 - 162 C

VERSION DATE

BASIC 15-Apr-01

Rev A 05-June-02

Rev B 03-Oct-02

Rev C 24-Mar-2004

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:

FOREWORD

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST FIRE
AND ELECTRICAL SHOCK.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE

1. Replace fuses with same type and rating only.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK

1. VARI❋LITE® control consoles are designed for dry locations only. Exposure to rain or
moisture may damage the console.

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

3. Servicing to be performed by qualified personnel only.

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.

02.9671.0010 C 24-March-2004 v

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

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 FEUER UND ELEKTROSCHOCK.

WARNUNG:
HINWEISE ZUM FEUERSCHUTZ

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

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK

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

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

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

WARNUNG:
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 24-March-2004 02.9671.0010 C

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 :

FOREWORD

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 INCENDIES ET LES DÉCHARGES ÉLECTRIQUES :

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES

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

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES

1. Les consoles de commande VARI❋LITE® sont conçues pour une utilisation au sec

uniquement. Une exposition à la pluie et à l’humidité risque d’endommager la console.

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.

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.

02.9671.0010 C 24-March-2004 vii

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

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 CONTRA
INCENDIO Y GOLPES DE CORRIENTE ELÉCTRICA:

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO

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

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE
ELÉCTRICO

1. Los controles de la consola de VARI❋LITE® están diseñados solamente para lugares
secos. La exposición a la lluvia o humedad pueden dañar la consola.

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

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

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.

viii 24-March-2004 02.9671.0010 C

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Table of Contents

Introduction

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

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

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

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

Chapter 1. Description

Features

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

Major Components

VL2000 Wash Luminaire............................................................................................. 5

Menu Display............................................................................................................... 6

LED Indicators............................................................................................................. 6

Head Components........................................................................................................ 7

Yoke Components ........................................................................................................ 8

Enclosure Components ................................................................................................ 9

Principles of Operation

Power and Data Flow Diagrams ................................................................................ 10

TABLE OF CONTENTS

Chapter 2. Maintenance

Te st in g

Testing Software ........................................................................................................ 12

Special Considerations

Configuring Main Controller Board .......................................................................... 13

Jumper Configuration.......................................................................................... 14

Maintenance Procedures

Head Assembly.......................................................................................................... 15

Lamp Replacement.............................................................................................. 15

Align Lamp for Flat Field ................................................................................... 17

Color Bulkhead Assembly Replacement............................................................. 18

Color Filter Replacement .................................................................................... 20

Magenta Color Wheel Glass Assembly............................................................... 21

Crossfade Color Sensor PCB Assembly Replacement........................................ 22

Dimmer Bulkhead Assembly Replacement ........................................................ 23

Front Internal Head Assembly Replacement....................................................... 24

Blue/Amber Color Wheels Assembly Replacement ........................................... 25

Small Stipple Glass Replacement........................................................................ 27

Concave Lens Assembly Replacement ............................................................... 28

Convex Lens Assembly Replacement................................................................. 29

100MM Condenser Lens Assembly Replacement.............................................. 31

Beam Spreader Motor Assembly Replacement................................................... 33

Yoke Assembly .......................................................................................................... 35

02.9671.0010 C 24-March-2004 xi

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Tilt Motor Replacement....................................................................................... 35

Auxiliary Controller PCB Assembly Replacement’............................................ 37

Ignitor PCB Assembly Replacement................................................................... 39

Enclosure Assembly................................................................................................... 41

Removing Enclosure Covers................................................................................ 41

Power Supply Replacement................................................................................. 43

Ballast Module Assembly Replacement.............................................................. 44

Pan Motor Assembly Replacement...................................................................... 46

Main Controller PCB Assembly Replacement.................................................... 48

DMX Input PCB Assembly Replacement ........................................................... 50

Cleaning Lens............................................................................................................. 51

Chapter 3. Illustrated Parts Breakdown

Drawing Tree

VL2000 Wash Luminaire (20.9671.0001).................................................................. 54

Top Ass emb ly

Included Items Kit...................................................................................................... 56

Top Ass emb ly

VL2000 Wash Luminaire ........................................................................................... 57

Head

Head Assembly........................................................................................................... 59

Front Internal Head Assembly.................................................................................... 61

Front Color Assembly ................................................................................................ 63

Blue/Amber Color Wheels Assembly........................................................................ 65

Amber Color Wheel Assembly .................................................................................. 66

Amber Color Wheel Pulley Assembly ....................................................................... 67

Blue Motor Assembly................................................................................................. 68

Amber Motor Assembly............................................................................................. 69

Front Lens Assembly.................................................................................................. 70

Convex Lens Assembly.............................................................................................. 71

Rear Assembly............................................................................................................ 72

Tilt Pulley/Bearing Assembly .................................................................................... 74

Tilt Bearing Housing Assembly ................................................................................. 75

Reflector Assembly .................................................................................................... 76

Back Cap Assembly ................................................................................................... 77

Fan Cover Assembly .................................................................................................. 79

Dimmer Bulkhead Assembly ..................................................................................... 81

Optical Sensor Assembly ........................................................................................... 83

Color Bulkhead Assembly.......................................................................................... 84

Color W/O Color Wheels Bulkhead Assembly.......................................................... 86

Color Motor Assembly............................................................................................... 87

Sensor PCB Assembly................................................................................................ 88

Magenta Motor Assembly.......................................................................................... 89

Crossfade Color Sensor PCB Assembly..................................................................... 90

Filter Wheel Assembly............................................................................................... 91

xii 24-March-2004 02.9671.0010 C

Chapter 4. Illustrated Parts Breakdown

Yo ke

Yoke Assembly .......................................................................................................... 93

Ignitor PCB Assembly............................................................................................... 95

Aux Controller PCB Assembly.................................................................................. 96

Enclosure

Upper Enclosure Assembly........................................................................................ 99

Connector Panel Assembly...................................................................................... 104

Main Controller 3-Phase PCB Assembly ................................................................ 105

DMX Input PCB Assembly ..................................................................................... 109

Pan Tube Assembly ................................................................................................. 110

Pan Motor Assembly................................................................................................ 112

Pan/Tilt Encoder PCB Assembly............................................................................. 114

700W Arc Power Supply Ballast Module................................................................ 115

700W Ballast Board PCB Assembly ....................................................................... 117

700W Ballast Rider Board PCB Assembly ............................................................. 120

Tilt Motor Assembly................................................................................................ 123

TABLE OF CONTENTS

Chapter 5. Illustrated Parts Breakdown

Cables

Ground Strap Cable Assembly................................................................................. 125

AC Input Pigtail (Euro) Cable Assembly ................................................................ 126

AC Input Link Cable Assembly............................................................................... 127

AC Input Splitter Cable Assembly .......................................................................... 128

LVS Chassis Ground Cable Assembly..................................................................... 129

Main To Aux/Data & Power Cable Assembly......................................................... 130

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

Lamp Supply Control Cable Assembly ................................................................... 133

Chassis To Yoke Ground Cable Assembly .............................................................. 134

Lamp Supply OT/Not On Cable Assembly............................................................. 135

Data I/O Link Cable Assembly................................................................................ 136

DC Output Cable Assembly ..................................................................................... 137

Lamp Supply Harness Cable Assembly................................................................... 138

Motor Harness Cable Assembly .............................................................................. 139

Yoke to Head Ground Cable Assembly ................................................................... 141

Lamp Supply To Relay Cable Assembly ................................................................. 142

Ignitor To Relay Cable Assembly............................................................................ 143

Head OT Switch #2 Cable Assembly ...................................................................... 144

DC Output XPiQ Cable Assembly .......................................................................... 145

Appendix A. Technical Bulletins 147

VL2000 Wash Luminaire Technical Bulletin List ................................................... 147

VL2000 Wash Luminaire Wire Diagram (Sheet 1) ................................................. 149

VL2000 Wash Luminaire Wire Diagram (Sheet 2) ................................................. 150

400W/625W/700W Ballast Schematic .................................................................... 151

02.9671.0010 C 24-March-2004 xiii

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Ballast Rider Schematic ........................................................................................... 153

Auxiliary Controller Schematic................................................................................ 154

Main Controller Schematic....................................................................................... 157

DMX Input Schematic.............................................................................................. 161

Ignitor Schematic...................................................................................................... 162

xiv 24-March-2004 02.9671.0010 C

Introduction

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL2000™ Wash Luminaire. The manual is intended for
use by Vari-Lite personnel and by Vari-Lite’s customers/clients.

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

This manual covers the following models:

INTRODUCTION

Model Part Number

VL2000 Wash Luminaire 20.9671.0001

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 VL2000 series luminaires is available at www.vari-lite.com
(follow the Support link).

A users manual is available for installation and operation of the VL2000 wash
luminaire. This manual is available in both printed and electronic (PDF) formats.

■ VL2000™ Wash Luminaire Users Manual (02.9671.0001).

02.9671.0010 C 24-March-2004 1

VARI❋LITE® - VL2000™ 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 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 V24-001 (VL24XX luminaire 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 24-March-2004 02.9671.0010 C

CHAPTER 1.

Description

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

• Features

• Major Components

• Principles of Operation

SERVICE

02.9671.0010 C 24-March-2004 3

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Features

Standard Features

The VL2000 wash luminaire features zoomable
beam spreader optics, CYM color mixing, a
separate fixed color wheel and a high
performance dimmer/strobe mechanism.

The VL2000 wash luminaire contains the
following standard features:

•DICHRO❋TUNE™ radial color changer
which employs enhanced dichroic color
filters to produce smooth, full spectrum color
crossfades. The mechanism allows
independent cyan, magenta and amber color
control.

• An internal mechanical douser which provides intensity control and strobing.

• An upper enclosure that houses the control electronics as well as a power factor
corrected arc power supply or an SCR dimmer appropriate to the particular lamp
source.

• Control by VARI❋LITE systems or a wide variety of DMX-512 consoles without
the need for additional interface equipment.

• Two easy-install truss hook brackets for versatile hanging configurations.

• 700W arc source.

• Zoomable beam spreader.

4 24-March-2004 02.9671.0010 C

Major Components

VL2000 Wash Luminaire

The following illustration shows the major luminaire components and controls.

DESCRIPTION : MAJOR COMPONENTS

1

Head Assembly

Upper Enclosure Assembly

Yoke Assembly

Removable Lamp Assembly
(to access lamp for replacement)

Truss Hook
Bracket Assembly

AC Input Cable

Beam Adjustment Controls

Vertica l

Input Panel Components

Product Label ID

Main Power Switch

AC Input Cable

Data In

02.9671.0010 C 24-March-2004 5

Power and Data
LED Indicators

Data Thru

Horizontal

Focus

Menu Display

Captive Knob
for lamp access
(does not adjust

beam)

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Menu Display

The Menu System Display is used to access the menu system, which is a
programmable set of commands used to address, operate, and test the luminaire.

The menu system is controlled by four buttons. These buttons function as follows:

Multi-Segment
Display

Displays the menu,
or if at first level, the
current address

Changes a value or
scrolls through menus

Changes a value or
scrolls through menus

Selects the current menu option
or enters current data value

Note: Refer to the VL2000 Wash Luminaire User’s Manual for more detailed
instructions regarding display operation.

LED Indicators

The LED indicators report the status of power and data to the luminaire.

Indicates DC power is being
supplied via AC Input when lit

Indicates data is being
transmitted when flashing

Indicates data is being
received when flashing fast;

when flashing in 2 sec. heartbeat,
indicates luminaire is idle

6 24-March-2004 02.9671.0010 C

DESCRIPTION : MAJOR COMPONENTS

1

Head Components

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

Dim

Dimmer Bulkhead Assembly

Color Bulkhead Assembly

Removable Cover

Rear Assembly
(Contains Lamp

Assembly)

Fan Assembly

Front Internal Assembly
(Contains lens assemblies and

front color assembly.)

02.9671.0010 C 24-March-2004 7

Nose Cover

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Yoke Components

The following illustration shows the major sub-assemblies which are located in the
luminaire yoke assembly. (Head and enclosure not shown for clarity.)

Auxiliary Controller
PCB Assembly

Board-side Leg

Relay Assembly

Tilt-side Leg

Ignitor PCB Assembly

Tilt Motor

Assembly

Tilt-side

Yoke Leg

Rotate yoke fully
counter-clockwise

Input Panel Assembly

8 24-March-2004 02.9671.0010 C

Board-side Yoke Leg

To determine which yoke leg is which without having to remove

the covers, rotate yoke counterclockwise until it stops, then look
at the luminaire while facing the input panel assembly. The tilt­side leg is the leg to the left; the board-side leg is the leg to the
right.

DESCRIPTION : MAJOR COMPONENTS

1

Enclosure Components

The following illustration shows the major sub-assemblies which are located in the
luminaire enclosure assembly. (Yoke and head assemblies not shown for clarity.)

Enclosure Covers

Ballast Module
Assembly

Power Supply

Input Panel Inside View

DMX Input PCB Assembly

Main Controller PCB

Main Controller
PCB Assembly

DMX Input
PCB Assembly

02.9671.0010 C 24-March-2004 9

Input Panel
Assembly

Enclosure Assembly

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Principles of Operation

Power and Data Flow Diagrams

The following diagram shows how data and power are distributed in the luminaire.

DMX

INPUT

PCB

EMI

FILTER

PAN

MOTOR

CONTROL

PAN

ENCODER

PAN EOT

AC

ON/OFF

C.B.

CHASSIS

FAN

MAIN

PCB

TILT

MOTOR

TILT

ENCODER

TILT EOT

LOW

VOLTAGE

SUPPLY

AMBER

BLUE

HEAD

FAN

#1

AUX

CONTROL

PCB #2

BLUE/AMBER

SAFTEY

RELAY

NOT

USED

BEAM

DIMMER

MAGENTA

MAGENTA

HEAD

FAN

AUX

CONTROL

PCB #1

DIMMER

SENSOR

HEAD

OVERTEMP

SWITCH

#2

COLOR

NOT

USED

COLOR

SENSOR

BACK

CAP

SWITCH

10 24-March-2004 02.9671.0010 C

ARC

POWER

SUPPLY

IGNITOR

PCB

ARC

LAMP

CHAPTER 2.

Maintenance

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

• Testing

• Special Considerations

• Maintenance Procedures

WARNING: All maintenance procedures are to be performed with

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

SERVICE

02.9671.0010 C 24-March-2004 11

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Testing

Testing Software

Testing software is available in all Series 2000 luminaires through the luminaire’s
menu system TEST function.

For information on specific tests and test parameters, see the VL2000 Wash Luminaire
User’s Manual (VL Part no. 02.9671.0001).

When running tests on multiple luminaires, a loopback connector is required at the
first luminaire in the link and a male termination connector is required at the last
luminaire.

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

Move Disable

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

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

Lamp

The Lamp option is also available in the test menu. This option sets the lamp
intensity to 100% and will adjust the diffusion to produce a tight beam. Pan/Tilt are
disabled while using the Lamp option, and pan/tilt settings will be restored upon exit
of the Lamp feature.

Note: When setting the Lamp option on luminaires linked by a loopback connector,
pan and tilt will be disabled for all the luminaires that are linked.

To r un tests:

Step 1. Press [Menu].
Step 2. Press [Up] / [Down] arrows until TEST appears. Press [Enter].
Step 3. Use [Up] / [Down] arrows to select a parameter to test.
Step 4. Press [Enter] to run test.
Step 5. Press [Menu] to stop test at any time.

12 24-March-2004 02.9671.0010 C

Special Considerations

Configuring Main Controller Board

When performing maintenance or troubleshooting procedures on Series 2000
luminaires, it may be necessary to configure the Main Controller Board (MCB) for
installation. When moving an MCB from one luminaire another, different jumper
configurations must be set correctly in order for the luminaire to operate.

The Main Controller Board (MCB) contains two blue jumpers.

CAUTION: Always use anti-static precautions when working with PCBs.

Programming Jumper - J1 (For Vari-Lite engineering use.)

The jumper at J1 is necessary and must be in the correct position in order for the
luminaire to operate. DO NOT change the configuration of jumper J1 (Figure 2-1).

Jumper at J11

MAINTENANCE : SPECIAL CONSIDERATIONS

2

Power Supply
Connection
at J2

Jumper at J1

Figure 2-1: Jumper Locations on MCB

Luminaire Type Jumper - J11

The jumper at J11 configures the luminaire type between VL2000 spot, VL2000 wash
and VL2416 wash. For VL2000 spot or VL2416 wash luminaires, it is fitted to non­active pins. (This inactive setting is the default or shipping configuration.) For
VL2000 wash luminaires, it is fitted to the active pins.

Power Supply Connection - J2

The power supply connection at J2 sets the luminaire type according to the power
supply output. (VL2416 wash luminaire - 1200W / VL2000 spot luminaire and
VL2000 wash luminaire - 700W). If the power selection setting and the luminaire type
setting jumper (J11) do not correspond, the luminaire will not operate properly.

02.9671.0010 C 24-March-2004 13

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Jumper Configuration

To configure jumper:

Determine which type luminaire the MCB is to be installed in, and configure jumper
according to Figure 2-2.

Note: If luminaire will not calibrate or operate after MCB replacement, check jumper
setting and download new software.

VL2000 Spot,

and VL2416 Wash

Figure 2-2: MCB Jumper Configuration.

Main Controller Board

Component Side

PH3

J11

PH4

Jumper

VL2000 Wash

PH3

J11

PH4

14 24-March-2004 02.9671.0010 C

MAINTENANCE : MAINTENANCE PROCEDURES

Maintenance Procedures

Head Assembly

This section provides removal and replacement procedures for components found in
the luminaire head assembly.

Lamp Replacement

Parts:

LAMP, 700 WATT ARC - PHILLIPS MSR700 (71.2528.0700)

Tools:

#2 Phillips Screwdriver,
Cotton gloves

To remove and replace lamp:

2

WARNING: All maintenance procedures are to be performed with power removed
from the luminaire. Never remove covers or open front lens or backcap assemblies
while lamp is in operation.

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

WARNING: Allow lamp to cool before replacing.

Step 2. At backcap, using screwdriver or fingers, turn captive knob until loose

(Figure 2-3).

Head Assembly

Backcap Assembly

Lamp

Captive
Knob

02.9671.0010 C 24-March-2004 15

Guide Rod

Figure 2-3: Lamp Replacement

VARI❋LITE® - VL2000™ WASH LUMINAIRE SERVICE MANUAL

Step 3. Slide backcap away from head assembly (it will remain attached by tether).

CAUTION: Wear cotton gloves or other covering while servicing lamp. Touching
lamp glass with bare fingers will leave oil and cause the lamp to explode or burn out
early. If touched, use alcohol to thoroughly clean glass.

Step 4. Remove lamp by pulling straight out of socket.
Step 5. Install new lamp, pressing firmly into socket.
Step 6. Align guide rods in guide holes and slide backcap into head assembly. Re-

tighten captive knob.

Step 7. Align lamp. (Refer to next procedure.)

16 24-March-2004 02.9671.0010 C