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VL1100 Service 0.book - Vari-Lite

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3. No Item Qty UM Description 1 10 9663 1339 03 1 EA DONUT ANTI REFLECTION IRIS 2 10 9663 1411 1 EA BULKHEAD IRIS 3 21 9663 1409 1 EA ASSY MOTOR ARM 10 9663 1402 1 EA ARM MOTOR 10 9663 1406 1 EA BOSS MOTOR ARM 53 6659 0008 3 EA SCREW 2 56 X 3 16 PFZ 4 22 9663 1410 l EA IRIS 67MM OD 5 44 9663 1326 l EA MOTOR 17 53 SHAFT 11 8MH 5 5 OHM 6 53 5560 0250 l EA SCREW 8 32 X 1 4 SET CONE POINT 7 53 6513 0042 3 EA SCREW M2 X 4 X 4MM LG PFB METRIC 8 53 6543 0003 2 EA SCREW 6 32 X 3 16 PPB 9 53 6605 0200 l EA STUD 2 56 X 2 0 LG FULL THREAD STAINLESS STEEL 10 54 1217 0005 2 EA KWIK LINK 2 56 SPRING STEEL 55 6538 0005 4 EA WASHER TEFLON 25 OD 065 ID 015 THK NOT SHOWN 11 55 6546 0004 1 EA WASHER TEFLON 201 ID X 438 0D X 040 THK 02 9664 0010 0 20 October 2010 99 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Beam Size Iris Assembly continued 2 N Detail A 3263 Figure 3 25 Beam Size Iris Assembly 100 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Rear Head Assembly 21 9664 1002 01 Rev A TS TI 21 9664 1002 11 Rev A AS Al Refer to Figure 3 26 No Item Qty UM Description 1 10 9634 0100 3 EA CLIP MOUNTING REFLECTOR 2 10 9663 1104 1 EA REFLECTOR MOUNT 3 10 9663 1109 2 EA COUNTERWEIGHT 4 12 9663 2023 1
4. No Item Qty UM Description 1 10 9663 1026 1 EA LATCH SPRING 2 12 9663 2029 1 EA RAIL SIDE MACHINED SHORT TILT TUBE 3 53 2002 0004 1 EA NUT 6 32 ACORN THREAD LOCKING SS 4 53 5636 0625 1 EA SCREW 6 32 X 5 8 PFSS BLACK 5 53 6530 0009 2 EA RIVET 1 8 OD POP 126 187GL STL BODY STL MNDRL DOME 6 55 6623 0004 1 EA WASHER 10 FLAT SS 0 203ID 0 625OD 0 050THK 2 3 5 x2 Figure 3 18 Sensor Side Rail Assembly 02 9664 0010 0 20 October 2010 85 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Incandescent Gobo Wheel Assembly 21 9664 1200 TS TI TSD TID Rev A Refer to Figure 3 19 No Item Qty UM Description 1 10 9663 1212 1 EA PULLEY MOTOR GOBO 2 10 9663 1217 1 EA PULLEY GOBO DRIVE MOTOR MOUNTED 3 10 9663 1228 1 EA PLATE GOBO IDLER MOUNT PLATE 4 10 9663 1229 1 EA PLATE WHEEL IDLER MOUNT 5 10 9663 1239 2 EA MOUNT SENSOR BOARD 6 10 9663 1241 2 EA PULLEY IDLER TEFLON 7 10 9663 1242 2 EA SPACER PIVOT BELT ADJUST 8 10 9663 2214 l EA SHAFT ROTATING GOBO 9 21 9665 1201 1 EA ASSY GOBO WHEEL 10 22 9663 1226 1 EA ASSY GOBO BULKHEAD ll 23 9663 1248 01 1 EA ELEC ASSY TEMPERATURE SENSOR INCANDESCENT MODELS 12 24 9663 3230 1 EA PCB ASSY WHEEL SENSOR 13 24 9663 3231 1 EA PCB ASSY INDEX SENSOR 14 44 9663 1202 2 EA MOTOR 17 2 42 SHAFT 11 8MH 5 5 OHM 15 53 2003 0001 2 EA NUT 4 40 KEP ZIN
5. No Item Qty UM Description 1 10 9665 8817 1 EA MOTOR MOUNT PAN MOTOR 2 21 9663 1818 1 EA ASSY DRIVE PULLEY 2a 10 9663 1810 1 EA PULLEY DRIVING PAN TILT 2b 10 9663 8820 1 EA CODE WHEEL 2 53 5561 0250 2 EA SCREW 6 40 X 1 4 SET CONE POINT 3 24 9661 7629 1 EA PCB ASSY PAN TILT ENCODER 4 44 9663 0680 1 EA MOTOR 3 PHASE SZ 23 HIGH TORQUE 5 53 2001 0001 4 EA NUT 8 32 KEPS SS 6 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 7 55 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 8 55 6579 0015 4 EA GROMMET 3 8 HOLE 0 250 ID VERSA 9 55 6655 0005 4 EA SPACER 1 4 RND 0 359 LG 0 141 THR 114 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Pan Motor Assembly continued 6 x4 Pulley Height Detail amp Installation Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting Note Vari Lite recommends that this assembly be replaced as complete assembly Although you can replace only the motion to insure coverage of shaftwith loetite motor the pulley Item 2 is bonded to the motor shaft during not allow Loctite to drip into motor bearing assembly and cannot be removed intact If you order a Set pulley height as shown above replacement motor Item 4 also order the pulley Item 2 Apply Loctite 242 to pulley set screws Insure Contact Vari Lite Customer Service for installation information set screws are aligned an
6. RF 1 Class A 1 Lamp Power Up State 2 20 October 2010 02 9664 0010 0 TABLE OF CONTENTS Table of Contents Introduction 222 3 2233 ___3 3 3 4 3 33 1 About This Manual z Si uu cuu usai mui 1 Additional 2 EUSTOMEL SEIVIER ar 2 Chapter 1 Description Features Standard Features erri eet Ee HERI EO eeu eee e ceo He PL etg 4 Model Specific Features cuina indiana 4 Component Descriptions External Luminaire Components ss 6 Luminaire Internal Head Components enne 7 Luminaire Internal Yoke Components
7. ss 8 Arc Ballast UE 9 DimmerMedel u ER EE 9 Principles of Operation VL1100 Incandescent Source Luminaire 10 VL1100 Incandescent Block Diagram Without On Board IGBT Dimmer 10 VL1100 Incandescent Cable Routing Without On Board IGBT Dimmer 11 VL1100 Incandescent Block Diagram With On Board IGBT Dimmer 12 VL1100 Incandescent Cable Routing With On Board IGBT Dimmer 13 VL1100 Arc Source Luminaire 14 VL1100 Arc Block Diagram ss 14 Arc Cable Routing a n een sta 15 Chapter 2 Maintenance Testing Running Parameter Tests r a aa a eee irte Ben 18 Calibration Sequence i u nu iia dad 19 a er Me eae nal 20 Sensor Lestmpg e cde RE PU n EU n e om ert u ku 20 Maintenance Procedures Lamp Replacement Incandescent Model eene 22 Lamp Replacement Arc Model 25 Align Lamp For Maximum Beam Irradiance 27 Frame or Top Hat Replacement ss 28 Front Cover Removal aaa eene Enten Bel 29 Rear Head Assembly Removal eee M M 30 Rotating Gobo Replacement eene non rennen 31 02 9664 0010 0 20 October 2010 xv VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Gobo Index Timing Belt Alignment nana 33 Gobo Wheel Bulkhead Replacemetnt aa 35 Gobo Gear Pla
8. 12 x2 12 2 15 2 13 1 1 x4 4 f N 1 x2 3 x2 Z SN BN 6 8 9 7 3 10 x4 4 14 12 Figure 3 15 Edge Barrel Assembly 82 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Lens 8 Assembly 21 9663 1780 Rev B Refer to Figure 3 16 No Item Qty UM Description 1 10 9663 1782 1 EA RING RETAINING FRONT LENS 2 10 9663 1781 1 EA BULKHEAD FRONT LENS 8 ASSY 3 42 9663 1735 1 EA LENS 8 4 53 2202 0004 6 NUT 4 40 HEX SS NYLON INSERT 5 53 6559 0001 6 EA SCREW 4 40X 1 4 PFZ 5 x6 f 3 2 4 x6 Figure 3 16 Lens 8 Assembly 02 9664 0010 0 20 October 2010 83 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Pulley Side Rail Assembly 21 9664 1033 Rev A Refer to Figure 3 17 No Item Qty UM Description 1 10 9663 1026 1 EA LATCH SPRING 2 12 9663 2025 1 EA RAIL SIDE MACHINED LONG TILT TUBE 3 53 2002 0004 1 EA NUT 6 32 ACORN THREAD LOCKING SS 4 53 5636 0500 1 EA SCREW 6 32 X 1 2 PFSS BLACK 5 53 6530 0009 2 EA RIVET 1 8 OD POP 126 187GL STL BODY STL MNDRL DOME 6 55 2178 0002 1 EA CABLE ANCHOR MOUNT 10 SCREW MOUNTING 2 Figure 3 17 Pulley Side Rail Assembly 84 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Sensor Side Rail Assembly 21 9664 1034 Rev B Refer to Figure 3 18
9. Refer to Figure 3 28 TS TI Rev B AS AI Rev B TSD TID 115V DIM Rev B TSD TID 230V DIM Rev B No Item Qty UM Description 1 10 9661 1364 1 EA INSULATOR ADHESIVE BACKED TOP COVER AS AI ONLY 2 10 9663 1827 2 EA NUT PLATE PAN TILT MOTOR 3 10 9663 2842 2 EA HEATSHIELD YOKE LEG 4 10 9663 1852 1 EA COUNTERWEIGHT DIMMER TSD TID ONLY 5 21 9665 8816 1 EA ASSY TILT MOTOR 6 22 9663 2801 1 EA ASSY YOKE 7 24 9661 1126 1 EA PCB ASSY SOLID STATE IGNITOR AS AI ONLY 8 24 9663 3230 1 EA PCB ASSY WHEEL SENSOR 25 9663 2002 1 EA CABLE ASSY TILT COT NOT SHOWN 25 9663 2026 1 EA CABLE ASSY DIMMER TO CNTRLR NOT SHOWN TSD TID ONLY 25 9663 2037 1 EA CABLE ASSY DIMMER TO LAMP SCKT NOT SHOWN TSD TID ONLY 25 9663 2817 1 EA CABLE ASSY LVS CHASSIS GROUND NOT SHOWN TS TI ONLY 25 9663 2824 1 EA CABLE ASSY LVS DC 24VDC OUTPUT NOT SHOWN 25 9663 2826 1 EA CABLE ASSY DIMMER TO LVS NOT SHOWN TSD TID ONLY 25 9664 2020 1 EA CABLE ASSY PAN MOTOR NOT SHOWN 9 53 2019 0004 2 EA NUT 3 8 16 X 7 32 HEX JAM GRDS ZINC PLT 10 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 11 53 6543 0001 14 SCREW 6 32 X 3 8 PPB AS AI ONLY 10 EA SCREW 6 32 X 3 8 PPB TS TI TSD TID ONLY 12 53 6545 0007 4 EA SCREW 8 32 X 3 8 PFB TSD TID ONLY 13 53 6567 0001 3 EA SCREW 4 40 X 1 2 PPZ 14 53 6617 0001 4 EA SCREW 6 32 X 1 PPB
10. WIRE AC LINE WIRE PIN AC NEUT 1 DRAIN 2 PWRLVL 3 DATA GND 4 NOTON SHIELDED MOLEX TWISTED WIRE SL 4M Figure 3 35 Arc Power Input Pigtail Cable Assembly NOTE Cable assemblies are sold as complete assemblies only except as noted above Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 119 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Pan EOT Cable Assembly 25 9663 2001 Rev A Refer to Figure 3 36 _ 13 0 _ Figure 3 36 Pan EOT Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 120 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Tilt COT Cable Assembly 25 9663 2002 Rev A Refer to Figure 3 37 33 0 Indicates Pin 7 Figure 3 37 Tilt COT Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 121 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL AC Line Input Cable Assembly 25 9663 2015 01 Rev C Refer to Figure 3 38 AC GND GRN YEL Figure 3 38 AC Line Input Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for v
11. Ballast Unit Lamp Power Input Cable Provides power for Supplied cable and connector used arc lamp source 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 Series 300 lamp runs Dimmer Model An on board IGBT dimmer is we included with VL1100 ECL incandescent dimmer models The dimmer heatsink is visible on the power side yoke leg as shown in this illustration On Board IGBT Dimmer Internal lamp power dimmer configured for either 115V or 230V operation depending on model 02 9664 0010 0 20 October 2010 9 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Principles of Operation VO DATA MC POWER LAMP POWER 10 VL1100 Incandescent Source Luminaire VL1100 Incandescent Block Diagram Without On Board IG BT Dimmer NEUTRIK XLR M DMX INPUT J2 DATA TUT J3 22 5 J8 EEE 2022 MAIN CONTROL XLR F MENU ENTER UP DOWN PCB ASSY DISPLAY8 DMX THRU J1 J1 DMX PCB FAN q J4 2050 JG J7 5 2020 24 2 2040 SHUTTERS 4 SR 2042 WITHOUT SENSOR 1 SENSOR 2 SENSOR 3 4 5 SENSOR 6 7 8 26 4 26 4 VAN
12. Temperature Sensor Electrical Assembly Beam Size Iris Assembly 23 9663 1248 01 TS Rev A 21 9663 1400 Rev E Outer Crossmember Shutter Harness Cable Assembly Assembly 21 9664 1813 Rev C 25 9663 2040 Rev F Edge Control Zoom Dimmer amp Color Assembly 21 9663 1003 Rev E Rear Head Assembly 21 9664 1002 01 Rev A TS TI Yoke Legs Assembly 21 9664 1850 01 TS TI Rev B or Pan Motor Assembly 21 9665 9815 Rev A Color Changer Assembly Edge Barrel Assembly Inner Crossmember 21 9663 1500 Rev U 21 9663 1710 Rev C Assembly 21 9664 1812 Rev A Lens 8 Assembly 21 9663 1780 Rev B COT Center of Travel Flag Assembly Pan EOT Cable Assembly 21 9663 1845 Rev 0 25 9663 2001 Rev A Pan Tube Assembly 21 9664 1819 01 TS TI Rev 21 9664 1850 21 TSD TID 115V C DIM Rev B or continued next page continued next page 21 9664 1850 31 TSD TID 230V pag DIM Rev B Yoke to Head Ground continued next page Cable Assembly 25 9663 2019 Rev B Figure 3 1 VL1100 Incandescent Luminaires Drawing Tree Part 1 60 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 VL1100 Incandescent Luminaires continued continued from previous page Rear Head Assembly 21 9664 1002 01 Rev A TS TI Back Cap Assembly 21 9664 1127 01 TS TI Rev J Incandescent Lamp Power Cable Assembly 25 9663 2033 Rev G continued from previous page Pan Tube Assembly 21 9664 1819 01 TS TI Rev C AC Line Inpu
13. 20 53 6634 0003 4 EA SCREW 3 8 16 X 1 2 SOC HD CAP 21 53 6642 0001 3 EA SCREW 10 32 X 5 8 SLE TAP TYPE F 22 54 1255 0001 2 EA ASSY BEARING HOUSING 23 54 2047 0039 1 EA BELT TIMING GT 3MM 350 GRV 24 55 2115 0001 4 EA WASHER 3 8 0 04 THK INT TOOTH 02 9664 0010 0 20 October 2010 67 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL VL1100 Luminaire continued 8 Al AS only TSD TID Models Only E TI TS AVAS IE Models Only h i 14 x4 l 21 x3 IGBT Dimmer TSD TID Models Only Figure 3 6 VL1100 Luminaire 68 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Front Cover Assembly 22 9664 1038 Rev A Refer to Figure 3 7 No Item Qty UM Description 1 10 9663 2020 1 EA COVER FRONT VL1100 2 21 9664 1028 1 EA ASSY GEL FRAME HOLDER 3 53 2004 0002 4 EA NUT 8 32 KEPS ZINC PLATE 4 53 6545 0007 3 EA SCREW 8 32 X 3 8 PFB 5 53 6552 0002 l EA SCREW 8 32 X 1 2 PFB Figure 3 7 Front Cover Assembly 02 9664 0010 0 20 October 2010 69 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Gel Frame Holder Assembly 21 9664 1028 Rev A Refer to Figure 3 8 No Item Qty UM Description 1 10 9663 1027 l EA HOLDER GEL FRAME 2 10 9663 1031 l EA LATCH GEL FRAME 3 55 6568 0026 1 EA SPRING CPRSN 180 OD 810 LG 026 WIR
14. CAUTION The rear head assembly is heavy and will remain attached by lamp wires Place luminaire on tech bench before removing rear assembly Step 2 At side rails remove four 10 32x5 8 PPB screws and 10 split lock washers Figure 2 8 Side rail spacers will come loose also Step 3 Pull rear head assembly away from front head assembly Step 4 Re install by doing steps 2 and 3 in reverse Front Head Assembly Lamp Wires Rear Head Assembly N A P _ P 0 E 2 10 Split NOTE Side Rail Spacer Lock Washer Yoke not shown for clarity 10 32x5 8 PPB Screw Figure 2 8 Rear Head Assembly Removal and Replacement 30 20 October 2010 02 9664 0010 0 MAINTENANCE Rotating Gobo Replacement WARNING Remove power from luminaire before performing maintenance Gobos may be HOT after operation Allow to cool before replacing WARNING Users of luminaires should not install or use metal gobos The use of metal gobos in any product may damage the luminaire and could void the luminaire s warranty gt P To replace a rotating gobo Step 1 Remove power from luminaire Step 2 At either side of head assembly press in front cover latch and pull cover straight back until stopped by tether Figure 2 7 Step 3 Rotate gobo wheel until required gobo position is accessible at finger access cutout Figure 2 9 Step 4 Rotate gobo gear until open end of ca
15. Wear gloves and or use tools to prevent burns To align lamp Step 1 Step 2 Step 3 Step Step 02 9664 0010 0 Set Intensity to 100 Position beam on a white wall at a distance of 10 to 20 feet Using console or internal luminaire menu controls set zoom to zero and focus to a hard edge If installed be sure that beam size iris and shutters are open Using three adjustment knobs adjust hot spot to center of beam Figure 2 5 Check color uniformity as follows a Position one of the color stages at 30 of maximum Cyan or Magenta work best b Verify that beam color is uniform if lamp is misaligned color will be concentrated to one side of beam If color is not uniform readjust lamp until color is uniform across entire beam field Beam Adjustment Knobs Do not remove or use to access lamp Figure 2 5 Lamp Alignment Screws 20 October 2010 27 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Frame or Top Hat Replacement An accessory frame holder is provided for the addition of a top hat or gel frame with silks frosts or color correction if required The frame holder is designed to fit a standard 7 5 inch gel frame or top hat To remove and replace frame or top hat Step 1 Disconnect luminaire AC input cable from power source Step 2 At front lens press upward on accessory frame latch and turn to open Step 3 Remove frame top hat if any Figure 2 6 Step 4 Install frame t
16. 54 Pan Motor Assembly Replacement Parts ASSEMBLY PAN MOTOR Tools 1 Phillips screwdriver 2 Phillips screwdriver To remove and replace pan motor assembly Step Step Step Step Step Step Step 1 2 Disconnect luminaire AC input cable from power source Remove yoke leg covers by removing four 6 32x3 8 PTB screws on each side Figure 2 27 Remove crossmember assembly from yoke by removing twelve 10 32x1 2 PPB screws At crossmember assembly remove pan wire shield by removing four 4 40x3 8 PPZ screws At pan motor assembly loosen four 6 32x1 PPB screws Slide assembly forward and remove belt from pulley Remove four 6 32x1 PPB screws and 6 flat washers and remove pan motor assembly nut plate will come loose also Replace pan motor assembly by doing steps 2 through 6 in reverse Belt tension is automatically set by spring 20 October 2010 02 9664 00100 MAINTENANCE Pan Motor Replacement continued Pan Wire Shield 4 40x3 8 PPZ Screw 6 32x1 PPB Screw Spring 6 Flat Washer Pan Motor SA m gt q Assembly A Timing Belt OR Nut Plate gt x Crossmember Assembly gt CL od 10 32 1 2 PPB Screw T 6 32x3 8 PTB Screws Yoke Leg Cover NOTE Head not shown for clarity Figure 2 27 Pan Motor Assembly Replacement 02 9664 0010 0 20 October 2010 55 VARFXLITE V
17. Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 135 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Shutter Harness Cable Assembly continued Figure 3 52 Shutter Harness Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 136 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Color Gobo Lens Harness Cable Assembly 25 9663 2050 Rev K Refer to Figure 3 53 and Figure 3 54 PIN 1 TO CONTROLLER PCB J8 LABEL SET FOR REF ONLY P N LINE 1 TEXT LINE 2 TEXT 01 WHL SNSR 02 WHL MTR 03 SHUT ROT 04 INDX SNSR 05 INDX MTR 06 BLUE MTR 07 AMBR MTR 08 ZOOM MTR 09 EDGE MTR 10 DIMM MTR 11 MTR 12 DIFF MTR 18 FAN 1 14 TS FAN2 Figure 3 53 Color Gobo Lens Harness Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 137 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Color Gobo Lens Cable Assembly continued of S S DS n S S Sx amp S Figure 3 54 Color Gobo Lens Harness Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference
18. Rev B Rear Head Assembly 21 9664 1002 11 Rev A AS AI Tilt Motor Assembly Back Cap Assembly 21 9665 8816 Rev B 21 9664 1127 11 AS Al Rev J Tilt COT Cable Assembly Ignitor to Lamp Socket 25 9663 2002 Rev A Cable Assembly 25 9663 2036 Rev H LVS DC Output Cable Assembly 25 9663 2824 Rev A continued from previous page Pan Tilt Control Cable Assembly 25 9664 2020 Rev A Pan Tube Assembly 21 9664 1819 11 AS AI Rev C AC Line Input Cable Assembly Ballast Control Link Cable 25 9663 2015 01 Rev C Assembly 25 9663 2021 Rev A Arc LVS AC Input Cable Assembly Arc Power to Ignitor Cable 25 9663 2816 11 Rev B Asembly 25 9663 2035 Rev C Data I O Link Cable Assembly Arc Power Input Pigtail 25 9663 2022 Rev B Cable Assembly 25 9663 2021 Rev A Abbreviation Meaning AI VL1100 AI Arc with Beam Size lris AS VL1100 AS Arc with Shutter System Figure 3 4 VL1100 Incandescent Luminaires Drawing Tree Part 2 02 9664 0010 0 20 October 2010 63 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Top Assembly Included Items Kit 28 9664 0001 02 Rev A Incandescent TS Only 28 9664 0001 03 Rev A Incandescent TI Only 28 9664 0001 12 Rev A Arc AS Only 28 9664 0001 13 Rev A Arc AI Only 28 9664 0001 22 Rev A Incandescent TSD 115V Only 28 9664 0001 23 Rev A Incandescent TID 115V Only 28 9664 0001 32 Rev A Incandescent TSD 230V Only 28 9664 0001 33 Rev A Incandescent TID 230
19. Step 3 Atignitor PCB disconnect lamp connectors Step 4 Remove four 6 32x3 8 PPB screws and remove ignitor PCB Note Make sure and orient ignitor properly as shown in Figure 2 21 Step 5 Replace ignitor PCB by doing steps 2 through 4 in reverse NOTE Head not shown for clarity 6 32x3 8 PTB Screws Yoke Leg Cover From Relay Connections To Bulb Lamp Connections Ignitor PCB 6 32x3 8 PPB Screw Figure 2 21 Ignitor PCB Replacement 20 October 2010 02 9664 00100 MAINTENANCE Power Supply Replacement Parts POWER SUPPLY 130W 24V 6 3A Tools 2 Phillips screwdriver To remove and replace power supply Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke leg cover side without menu display by removing four 6 32x3 8 PTB screws as shown in Figure 2 23 Step 3 At power supply disconnect all connectors Step 4 Loosen two 4 40x1 2 PPZ screws and remove one 4 40x1 2 PPZ screw Remove power supply Step 5 Replace LVS Reconnect all cables as follows Dimmer to LVS Cable Assembly To Dimmer Module part number 25 9663 2826 TD TID TSD models Only white Wire AC Neutral or ACN W S Black Wire AC Line or ACL lt Stack Connections LVS as Shown EM M AC Input Cable Assembly Green Yellow Wire Ground Red Wire 24VDC Black Wire 24VDC OX 25 9663 2826 will connect d to ACN and ACL as
20. rungen verursachen In diesem Fall m ssen eventuell geeignete Ma nahmen getroffen werden BESONDERHEITEN VON BOGENLAMPEN 1 2 viii Bogenlampen ben tigen eine gewisse Zeitdauer um nach einem Stromausfall oder einem Spannungsgefalle wieder aufzuleuchten In einigen Fallen wird die Lampe nach Abk hlung automatisch wieder aufleuchten je nach der Systemkonfigurationseinstellung des Lampeneinschaltungsstatus L ON LOFF Die Brennposition ist Universal 20 October 2010 02 9664 0010 0 NOTES DE S CURIT Notes de s curit Avant de proc der l installation des produits d crits dans ce guide et de les mettre en marche il est extr mement important de lire TOUS les renseignements et TOUTES les directives de s curit contenues dans ce guide ainsi que toute documentation jointe Tenir compte de tous les avertissements et suivre toutes les pr cautions pendant l installation et l utilisation de cet appareil Les symboles de s curit utilis s dans ce guide sont les suivants ATTENTION Ce symbole annonce que l appareil risque d tre endommag AVERTISSEMENT Ce symbole annonce qu il y a risque d accident grave ou m me fatal CETTE SECTION CONTIENT DES INFORMATIONS G N RALES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES LES INCENDIES L EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRAINER DES BLESSURES AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES INCENDIES 1 Le
21. 15 53 6634 0003 2 EA SCREW 3 8 16 X 1 2 LG SOC HD CAP ALLY STL 16 55 2140 0001 4 EA STANDOFF 1 4 HEX 6 32 813 LG AS AI ONLY 02 9664 0010 0 20 October 2010 105 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL No Item Qty UM Description 17 55 2143 0002 7 EA STANDOFF 1 4 HEX 6 32 1 375 LG FF ALUM 18 55 2203 0001 2 EA SCREW 4 40 1 4 PPZ 19 55 2204 0001 3 EA WASHER 4 NYLON AS AI ONLY 4 3 20 55 3301 0006 EA WASHER 6 FLAT SS 21 55 6525 0005 EA WASHER 4 SHOULDER NYLON 125 DP AS AI ONLY 22 55 6568 0056 1 EA SPRING CPRSN 600 OD 625 LG 080 WIRE DIA MUSIC WIRE 23 55 6597 0003 4 EA CLIP CABLE SELF RETAINING 1 8 THK PANEL 24 67 4006 0006 1 EA CLAMP CABLE EMI SUP FERRITE 0 52 0 61 LG 25 69 3173 0115 1 EA DIMMER 1200W 115V REV PHASE CNTRL TSD TID 115V ONLY 69 3173 0240 1 EA DIMMER 1200W 240V REV PHASE CNTRL TSD TID 230V ONLY 26 69 3177 0151 1 EA POWER SUPPLY 150W 24V 6 3A Yoke Mount Configurations A 00 Ar 6e 00 lab Z o 09 LR E e 1 95 VL1100 TS TI Units VL1100 AS AI Units VL1100 TSD TID Units With Integral 115V or 230V Dimmer 106 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Yoke Legs Assembly continued El 5 6 7 20 x4 x a e Er 14 x4 0 00 NS TR B TS 22 90 N
22. 1850 31 1 EA ASSY YOKE LEGS 230V IGBT DIMMER TSD230 TID230 ONLY 12 22 9664 1038 1 EA ASSY FRONT COVER GEL FRAME HOLDER 13 24 9664 1700 1 EA BOARD ASSY VLI100 MCB 5 25 9663 2019 1 CABLE ASSY YOKE HEAD GROUND NOT SHOWN 25 9663 2036 1 EA CABLE ASSY LAMP HIGH VOLTAGE AS AI ONLY NOT SHOWN 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 25 9663 2040 1 EA CABLE ASSY SHUTTER HARNESS TS TSD AS ONLY NOT SHOWN 25 9663 2050 1 EA CABLE ASSY 10 MOTORS 2 SENSORS 28 9664 0001 02 1 EA INCLUDED ITEMS KIT TS ONLY NOT SHOWN 28 9664 0001 03 1 EA INCLUDED ITEMS KIT TI ONLY NOT SHOWN 28 9664 0001 12 1 EA INCLUDED ITEMS KIT AS ONLY NOT SHOWN 28 9664 0001 13 1 EA INCLUDED ITEMS KIT AI ONLY NOT SHOWN 28 9664 0001 22 1 EA INCLUDED ITEMS TSD115 ONLY NOT SHOWN 28 9664 0001 23 1 EA INCLUDED ITEMS KIT TID115 ONLY NOT SHOWN 28 9664 0001 32 1 EA INCLUDED ITEMS KIT TSD230 ONLY NOT SHOWN 28 9664 0001 33 1 EA INCLUDED ITEMS KIT TID230 ONLY NOT SHOWN 14 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX JAM 15 53 6517 0001 3 EA SCREW 10 32 X 3 8 PPB TYPE F 16 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB 17 53 6543 0001 4 EA SCREW 6 32 X 3 8 PPB 18 53 6614 0001 3 EA SCREW 6 32 X 5 8 PPB 19 53 6627 0001 12 EA SCREW 10 32 X 5 8 PPB
23. 9 Controller PCB Display Plate Display Overlay Yoke Leg Cover 6 32x1 2 PPB Screw These items remove 6 32x3 8 PTB Screw and install as one Figure 2 24 Controller PCB Replacement 50 20 October 2010 02 9664 00100 MAINTENANCE Tilt Encoder PCB Replacement Parts PCB ASSY PAN TILT ENCODER Tools 1 Phillips screwdriver 2 Phillips screwdriver To remove and replace tilt encoder PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke leg cover side with menu display by removing four 6 32x3 8 PTB screws Step 3 As shown in Figure 2 25 at tilt encoder PCB remove two 4 40x1 4 PPZ screws Step 4 Disconnect connectors at J1 and J2 Step 5 Remove encoder PCB Step 6 Replace encoder PCB by doing steps 2 through 5 in reverse Tilt Encoder PCB 4 40 Screws N Figure 2 25 Tilt Encoder PCB Replacement 02 9664 0010 0 20 October 2010 51 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL 52 A Tilt Motor Assembly Replacement Parts ASSEMBLY TILT MOTOR Tools 1 Phillips screwdriver 2 Phillips screwdriver To remove and replace tilt motor assembly Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Disconnect luminaire AC input cable from power source Remove yoke leg cover side with menu display by removing four 6 32x3 8 PTB screws Figure 2 26 Remove display overlay an
24. 9664 0001 3 TSD115 Rev C TID115 Rev C TSD230 Rev C TID230 Rev C WNWNWNWN Refer to Figure 3 6 No Item Qty UM Description 04 9678 1000 2 EA LABEL GREEN ROHS COMPLIANT NOT SHOWN 04 9678 1001 2 EA LABEL WHITE ROHS COMPLIANT NOT SHOWN l 10 9663 1823 1 EA PULLEY TILT 2 10 9663 1824 1 EA SPACER TILT TUBE 3 10 9663 1831 1 EA PLATE DISPLAY 4 10 9663 1832 1 EA OVERLAY DISPLAY 5 10 9664 2835 1 EA COVER YOKE ARM DISPLAY SIDE 6 10 9664 2836 1 EA COVER YOKE ARM NO DISPLAY TUTS AVAS ONLY 10 9664 2874 1 EA COVER YOKE ARM DIMMER SIDE TID TSD ONLY 7 21 9663 1845 1 EA ASSY COT FLAG 8 21 9663 1901 1 EA ASSY ARC BALLAST AI AS ONLY 9 21 9664 1000 02 1 EA HEAD ASSEMBLY INCANDESCENT SHUTTER TS TSD ONLY 21 9664 1000 03 1 EA HEAD ASSEMBLY INCANDESCENT IRIS TUTID ONLY 21 9664 1000 12 1 EA HEAD ASSEMBLY ARC SHUTTER AS ONLY 21 9664 1000 13 1 EA HEAD ASSEMBLY ARC IRIS AI ONLY 10 21 9664 1811 01 1 EA ASSY CROSSMEMBER INCANDESCENT TI TS ONLY 21 9664 1811 11 1 EA ASSY CROSSMEMBER ARC AAS ONLY 21 9664 1811 21 1 EA ASSY CROSSMEMBER IGBT DIMMER TSD TID ONLY 11 21 9664 1850 01 1 EA ASSY YOKE LEGS INCANDESCENT TITS ONLY 21 9664 1850 11 1 EA ASSY YOKE LEGS ARC AI AS ONLY 21 9664 1850 21 1 EA ASSY YOKE LEGS 115V IGBT DIMMER TSD115 TID115 ONLY 21 9664
25. EA LABEL BLUE MOTOR 3 04 9663 1526 1 EA LABEL AMBER MOTOR 4 04 9663 1527 1 EA LABEL DIFFUSER MOTOR 5 10 9663 3505 4 EA DRIVE RING COLOR SYSTEM LAYER PLASTIC 6 10 9663 1506 1 EA DIFFUSER COVER PLATE 7 10 9663 1507 2 COLOR SEPERATOR 8 10 9663 1508 1 EA MOTOR MOUNT PLATE 9 10 9663 1509 1 EA COLOR COVER PLATE LINER SHEET 10 10 9663 1510 1 EA DIFFUSER COVER PLATE LINER SHEET 11 10 9663 1511 3 EA COLOR SPACER 1 12 12 9663 1512 1 EA DRIVE RING LOCATOR MACHINED 13 10 9663 1514 3 EA COLOR SPACER 2 14 10 9663 1515 1 EA DIFFUSER SPACER 1 15 10 9663 1516 1 EA DIFFUSER SPACER 2 16 10 9663 1518 4 EA COLOR MOTOR MOUNT CLIP 17 10 9663 1521 1 EA COLOR COVER PLATE LINER SHEET 18 10 9663 1522 1 EA DIFFUSER COVER PLATE LINER SHEET 19 10 9663 1532 3 EA RING SPACER 20 10 9663 1755 3 EA ROLLER BARREL 21 10 9663 1767 1 EA ZOOM TEFLON SPACER 22 12 9663 1752 1 EA MACHINED EXTRUSION INNER BARREL ZOOM 23 44 9663 1539 4 EA MOTOR SIZE 14 10 8MH 10 1 OHM WITH SPUR GEAR 24 21 9663 1534 1 EA ASSY COVER PLATE 25 21 9663 1538 01 2 ASSY MAGENTA COLOR FILTER 26 21 9663 1538 02 2 EA ASSY BLUE COLOR FILTER 27 21 9663 1538 03 P EA ASSY AMBER COLOR FILTER 28 21 9663 1538 04 2 ASSY DIFFUSER GLASS RIGHT 29 21 9663 1710 1 EA ASSY BARREL 30 53 2002 0003 4 EA NUT 6 32 HEX ZINC NYLON INSERT 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 31 53 2200 00
26. Gobo Dimmer Bulkhead Assembly 92 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Gobo Wheel Assembly 21 9665 1201 Rev A Refer to Figure 3 22 No Item Qty UM Description 1 10 9663 1210 5 EA CLIP RETAINING 2 10 9663 1211 10 EA SPACER TEFLON GOBO GEAR 3 10 9663 1240 5 EA BEARING GOBO WHEEL BORE 4 10 9663 1247 1 EA TAB GOBO WHEEL SENSOR 5 10 9663 2203 5 EA GEAR PLANET CAST 6 10 9663 2204 1 EA WHEEL ROTATING GOBO 7 21 9665 1222 1 EA PULLEY ASSY GOBO WHEEL 8 41 6010 0001 5 EA GOBO ASSY E SIZE NOTE PATTERNS ARE SOLD SEPARATELY AND ARE NOT INCLUDED WITH THE FIXTURE 9 53 6534 0001 2 EA RIVET 3 32 OD 3 32 GRIP RANGE ALUM 10 53 6598 0312 3 EA SCREW 4 40 X 5 16 PFB 11 55 6504 0004 3 EA WASHER 4 LOCK CSK EXT TOOTH 02 9664 0010 0 20 October 2010 93 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Gobo Wheel Assembly continued 8 x5 See Note Below 1 x5 Note Patterns are sold separately and are not included with the fixture Figure 3 22 Gobo Wheel Assembly 94 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Gobo Wheel Pulley Assembly 21 9665 2222 Rev B Refer to Figure 3 20 No Item Qty UM Description 1 10 9663 1206 1 EA FLANGE MIDDLE 2 10 9665 2210 1 SPACER 1 ROTATING WHEEL 3 10 9665 2211 1 EA SPACER 2 ROTATING GOBO WHEEL 4 12 9665 2205 1 EA
27. Input Pigtail Cable Assembly 119 Pan EOT Cable Assembly eiii em Rt ei 120 Tilt COT Cable Assembly oo rennen 121 AC Line Input Cable Assembly ss 122 Incandescent LVS AC Input Cable Assembly eee 123 Arc LVS AC Input Cable Assembly eese 124 LVS Chassis Ground Cable Assembly eee 125 Yoke to Head Ground Cable 2 126 Pan Tilt Control Cable Assembly a aasan aaa nennen 127 Ballast Control Link Cable Assembly eene 128 Data I O Link Cable Assembly seen 129 LVS DC Output Cable 130 Incandescent Power Input Cable Assembly eene 131 Incandescent Lamp Power Cable Assembly see 132 Arc Power to Ignitor Cable Asembly ss 133 Ignitor to Lamp Socket Cable Assembly ennen renee 134 Shutter Harness Cable Assembly eese eene 135 Color Gobo Lens Harness Cable Assembly eene 137 Dimmer to LVS Cable Assembly eene nennen 139 Dimmer to Controller Cable Assembly 2 140 Dimmer to Lamp Socket Cable Assembly eene 141 Appendix A Technical Bulletins VL1100 ERS Luminaire Technical 143 02 9664 0010 0 20 October 2010 xvii VARFXLITE VL1100 ERS LUM
28. LITE 3 02 9664 0010 0 20 October 2010 xiii VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL UV 1 VARI LITE UV HID 2 EE 1 2
29. TS TI Rev J 21 9664 1127 11 AS AI Rev J Refer to Figure 3 27 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 1 10 9663 1116 2 EA CLAMP LAMP BASE BAIL TS TI ONLY 2 10 9663 1119 2 EA LAMP BASE CLAMP TS TI ONLY 3 10 9663 2136 1 EA PLATE BACKCAP ADJUST 4 12 9663 2126 1 EA BACKCAP MACHINED 5 10 9678 0645 3 EA KNOB LAMP ADJUST MOLDED 6 53 2030 0001 3 EA NUT ACORN 10 32 THD 3 8 W BLK ZINC 7 53 5711 2500 2 EA SCREW 10 32 X 2 1 2 PTZ BLACK 8 53 6539 0011 3 EA SCREW 10 32 X 2 1 4 PFBSS UNF 2A 9 55 6546 0004 3 EA WASHER TEFLON 201 ID 438 OD X 04 THK 10 53 6575 0001 2 EA SCREW 8 32 X 1 0 PPZ 11 53 6575 0005 2 EA SCREW 8 32 X 1 1 2 PPZ TS TI ONLY 12 55 6568 0059 3 EA SPRING CPRSN 360 OD 1 50 LG 045 DIA SS 13 55 6704 0013 1 EA STANDOFF 1 4 HEX 8 32 500 LG TS TI ONLY 14 71 2560 0001 1 EA SOCKET LAMP G22 SCREW TERMINALS 02 9664 0010 0 20 October 2010 103 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Back Cap Assembly continued 11 x2 TS TI ONLY 10 x2 13 TS TI ONLY 1 x2 TS TI ONLY 2 x2 TS TI ONLY ONLY 2 Incandescent Models Arc Models Figure 3 27 Back Cap Assembly 104 20 October 2010 02 9664 0010 0 Yoke Assembly ILLUSTRATED PARTS BREAKDOWN 3 Yoke Legs Assembly 21 9664 1850 01 21 9664 1850 11 21 9664 1850 21 21 9664 1850 31
30. WARNING It is not recommended to power any VAREKLITE luminaire from 02 9664 0010 0 20 October 2010 v VARFXLITE VL1100 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 Itis hazardous to operate luminaires without lens or shield Shields lenses or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired For example by cracks or deep scratches WARNING INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1 Exterior surfaces of the luminaire will be hot during operation Use appropriate safety equipment gloves eye protection etc when handling and adjusting hot equipment and components 2 Luminaires will have a hot lamp when operating Disconnect power and allow lamp to cool before replacing 3 Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at very high temperatures Should the lamp break there can exist a danger of personal injury and or fire from broken lamp particles being discharged 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 l
31. all marks using the same method and adjust as necessary Figure 2 13 Aligning Gobo Wheel Gears 38 20 October 2010 02 9664 00100 MAINTENANCE Shutter Assembly Replacement Parts ASSEMBLY SHUTTER 6 ROLLERS Tools 2 Phillips long handle screwdriver To remove and replace shutter assembly Step 1 Disconnect luminaire AC input cable from power source CAUTION The rear assembly is heavy and will remain attached by lamp wires Place luminaire on tech bench before removing rear assembly Step 2 Remove front cover rear head assembly and gobo wheel bulkhead Refer to Gobo Wheel Bulkhead Replacement on page 35 Step 3 Remove yoke leg cover side with menu display by removing four 6 32x3 8 PTB screws Figure 2 14 Controller PCB Yoke Leg Cover NOTE 6 32x3 8 PTB Screws Head not shown for clarity Figure 2 14 Removing Yoke Leg Cover to Access Controller PCB 02 9664 0010 0 20 October 2010 39 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL 40 Step 4 At Controller PCB disconnect shutter wiring harness at position marked SHUTTERS Step 5 Noting placement cut tie wraps securing harness to other wires Step 6 Feed shutter harness cable out of yoke arm Step 7 At side rails remove four 10 32x3 8 PPB screws and 10 split lock washers and remove shutter assembly Figure 2 15 CAUTION Do not overtighten tie wraps when re installing Step 8 Replace shut
32. risques Tous blindages lentilles ou crans ultraviolet visiblement endommag s au point que leur efficacit en est affect e doivent tre remplac s par exemple s il y a des fissures ou de profondes rayures AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES ACCIDENTS POUVANT ENTRAINER DES BLESSURES 1 Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour manceuvrer ou ajuster des appareils br lants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 La lampe du luminaire est br lante lorqu il est en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons ultraviolets pouvant causer de graves br lures sur la peau et une inflammation des yeux De plus les lampes arc fonctionnent sous haute tension de tr s hautes temp ratures Si la lampe se casse les particules de la lampe cass e peuvent causer blessures et ou incendie en s parpillant 4 Se prot ger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropri s gants protection des yeux pour manier des lampes endommag es 6 Silalampe a t touch e avec des mains nues la nettoyer avec de l alcool d natur et l essuyer avec un chiffon non pelucheux avant d installer ou de brancher le luminaire 7 Silalampe a t endommag e ou a une d formation thermique elle doit t
33. succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on hand to provide support How to Reach Us For assistance in your area call the dealer from which your product s 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 or 1 214 647 7880 fax 1 214 647 8038 email entertainment service philips com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link 2 20 October 2010 02 9664 0010 0 CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Component Descriptions Principles of Operation 3J2IAM3AS 02 9664 0010 0 20 October 2010 3 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Features Standard Features VL1100 Ellipsoidal Reflector Spotlight ERS luminaires have the following standard features Automated zoom optics system Crossfading CYM color system Diffusion system rotating gobo wheel five rotatable indexable gobo positions and one open gobo position Repositional pan ti
34. this equipment in a residential area is likely to cause harmful inter ference in which case the user will be required to correct the interference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents as applicable Safety by Low Voltage Directive 2006 95 EC EN60598 1 1997 A1 1998 EN60598 2 17 1989 A2 1991 EN60922 Electromagnetic Compatibility by Council Directive 89 336 EEC EN55022 1998 Class A EN61000 4 2 1995 Performance Criteria EN61000 4 3 1995 Performance Criteria EN61000 4 4 1995 Performance Criteria EN61000 4 5 1995 Performance Criteria EN61000 4 6 1996 Performance Criteria EN61000 4 8 1996 Performance Criteria EN61000 4 11 1994 Performance Criteria B and C EN61000 3 2 1995 EN61000 3 3 1994 gt gt gt We certify that the product conforms to the protection requirements of council direc tives 2006 95 EC LVD and 89 336 EEC EMC 20 October 2010 02 9664 0010 0 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 A CAUTI
35. this manual may void the product warranty Refer to the Vari Lite Limited Warranty card included in the shipping package for this VARI LITE product gt WARNING It is not recommended to power any VARI LITE luminaire from a dimmer even in NONDIM mode Dimmer and non dim modules are not suitable sources of power because their output modifies the AC wave form See Vari Lite Technical Notice TN 229A for more information gt 02 9664 0010 0 20 October 2010 1 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Additional Documentation A support web page for Series 1000 luminaires For all VL1000 and VL1100 ERS models is available at www vari lite com follow the Support link A user s manual is available for installation and operation of all versions of the VL1100 ERS Luminaire This manual is only available in electronic PDF format m VLI1100 ERS Luminaire User s Manual 02 9664 0001 Technical bulletins concerning the latest changes to equipment are also available at the website Technical Support Center These are documentation supplements that contain procedures for equipment upgrades retrofits and additional repairs Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business
36. 010 0 20 October 2010 131 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Incandescent Lamp Power Cable Assembly 25 9663 2033 Rev Refer to Figure 3 48 1 25 FROM TO LAMP POWER LAMP TERM BLOCK SOCKET BRN DIMMER LINE I LINE DIMMER NEUT 2 NEUT BLU 48 0 REF 21 0 69 0 gt Figure 3 48 Incandescent Power to Lamp Socket Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 132 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Arc Power t to Ignitor Cable Asembly 25 9663 2035 Rev C Refer to Figure 3 49 15 XXX xxx X X X X RL X lt o d FROM IGNITOR LAMP POWER INPUT TERM BLOCK Figure 3 49 Arc Power to Ignitor Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 133 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Ignitorto Lamp Socket Cable Assembly 25 9663 2036 Rev H Refer to Figure 3 50 15 210 Figure 3 50 Ignitor to Lamp Socket Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 134 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Shutter Harness Cable Assembly 25 9663 2040 Rev F Refer to Figure 3 51 and Figure 3 52 Figure 3 51 Shutter Harness Cabe Assembly NOTE
37. 02 9664 00100 MAINTENANCE Beam Size Iris Assembly Replacement Note This procedure not applicable to all units Parts ASSEMBLY IRIS Tools 2 Phillips screwdriver To remove and replace beam size iris assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front cover rear head assembly and gobo wheel bulkhead Refer to procedures Front Cover Removal on page 29 Rear Head Assembly Removal on page 30 and Gobo Wheel Bulkhead Replacement on page 35 Step 3 At beam size iris assembly disconnect motor connectors Figure 2 20 Step 4 At side rails remove four 10 32x3 8 PPB screws and 10 split lock washers and remove iris assembly Step 5 Replace iris assembly by doing steps 2 through 4 in reverse 10 32x3 8 PPB Screw 10 Split Lock Washers Beam Size Iris Assembly x s NOTE s Yoke not shown for clarity Head Assembly Y mi N 51427 0 Figure 2 20 Beam Size Iris Assembly Replacement 02 9664 0010 0 20 October 2010 45 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL 46 Ignitor PCB Replacement Note This procedure not applicable to all units Parts PCB ASSEMBLY IGNITOR Tools 2 Phillips screwdriver To remove and replace ignitor PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke leg cover side without menu display by removing four 6 32x3 8 PTB screws as shown in Figure 2 21
38. 04 8 EA NUT 4 40 KEPS SS 32 53 5636 0375 3 EA SCREW 6 32 X 3 8 PFSS BLACK 33 53 6556 0001 8 EA SCREW 4 40 X 3 4 LG PPZ 34 55 6588 0003 3 EA SPACER 1 4 RND 6 THRU 1 8 LG 140 ID ZINC PLT BRS 35 10 9663 1537 1 EA DRIVE RING LOCATOR BEARING 02 9664 0010 0 20 October 2010 79 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Color Changer Assembly continued Figure 3 14 Color Changer Assembly 80 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Edge Barrel Assembly 21 9663 1710 Rev C Refer to Figure 3 15 No Item Qty UM Description 1 10 9663 1701 2 EA BARREL HALF OUTER LENS EDGE SYSTEM 2 10 9663 1708 1 EA EDGE GEAR CAM 8 ELEMENT SYSTEM 3 10 9663 1711 2 EA BARREL HALF INNER LENS EDGE SYSTEM 4 10 9663 1737 1 EA EDGE LIGHT BAFFLE 5 21 9663 1722 1 EA ASSY EDGE MOTOR 6 42 9663 1728 1 EA LENS 1 7 42 9663 1731 1 EA LENS 4 8 42 9663 1732 1 EA LENS 5 9 42 9663 1736 1 EA ASSY LENS 2 amp 3 10 53 2202 0006 4 EA NUT 6 32 HEX SS NYLON INSERT 11 53 6558 0001 4 SCREW 6 32 X 3 8 PPZ 12 53 6558 0003 4 EA SCREW 6 32 X 3 8 PPZ PLASTIC THREAD ROLLING 13 55 2123 0012 1 EA WASHER WAVE SPRING 484 OD 397 ID 009 THK CSTL 14 55 6636 0003 2 EA WASHER 562 OD 156 ID 046 THK 6 FLAT ZINC PLT 02 9664 0010 0 20 October 2010 81 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Barrel Assembly continued
39. 17 x7 E 9 x3 off 1 f 0 x3 4 9 n y 00 3 X3 87100 0 j It w 11 x6 pes 12 x4 26 gt DIM Only 7 AS AI only TT 25 DIM Only br x4 41 Na 16 x4 AS AI only a MT x x2 Figure 3 28 Yoke Legs Assembly 1 15 x2 02 9664 0010 0 20 October 2010 107 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Tilt Motor Assembly 21 9665 8816 Rev B Refer to Figure 3 29 No Item Qty UM Description 1 10 9663 8825 1 EA MOUNT MOTOR TILT 2 21 9663 1818 1 EA ASSY DRIVE PULLEY 10 9663 1810 1 EA PULLEY DRIVING PAN TILT 10 9663 8820 1 EA CODE WHEEL 53 5561 0250 2 EA SCREW 6 40 X 1 4 SET CONE POINT 3 24 9661 7629 l EA PCB ASSY PAN TILT ENCODER 4 44 9678 0680 l EA MOTOR 3 PHASE SZ 23 HIGH TORQUE 5 53 2001 0001 4 EA NUT 8 32 KEPS SS 6 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 7 55 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 8 55 6579 0015 4 EA GROMMET 3 8 HOLE 226 ID 125 THK VERSA DAMP 9 55 6655 0005 4 EA SPACER 1 4 RND 359 LG 141 THRU ALUM 108 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Tilt Motor Assembly continued 7 x2 3 2 5 x4 i A 8 x4 9 x4 4 6 x4 Pulley Height Detail amp Installation 2 3 Note Vari Lite recommends that this assembly be replaced as a complete assembly Although
40. 2 9664 0010 0 20 October 2010 33 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Step 2 If applicable lower gobo wheel into place over rotating shaft fitting wheel position belt around lower gear and index timing belt around top gear Install 4 A0x1 4 PPZ screw split lock washer flat black washer and flat Teflon washer to secure gobo wheel in place Belt tension is automatically set by springs of pivot mechanism Step 3 Orient gobo wheel so that notch of gobo wheel gear aligns with small ridge found on index timing belt Step 4 Re check alignment of clock mark with groove of index gear Adjust as necessary until marks are perfectly aligned at both gears 4 40x1 4 PPZ screw Split Lock Washer Flat Black Washer 2 Wheel Position Gear Teflon Washer 2 Wheel Position Belt no alignment Index G Gobo Wheel re Index Timing Belt gray for clarity Pivot Mechanism automatically sets belt tension III II Align ridge in belt with notch in gobo wheel gear Rotating Gobo Bulkhead Crossview Figure 2 11 Aligning Second Clock Mark 34 20 October 2010 02 9664 00100 MAINTENANCE Gobo Wheel Bulkhead Replacement Parts ASSEMBLY GOBO BULKHEAD INCANDESCENT TS TI ASSEMBLY BULKHEAD ARC AS AI Tools 2 Phillips long handle screwdriver To remove and replace gobo wheel bulkhead Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove fr
41. 24 5 24 5 Y Y 18 4 Y Y GOBO WHEEL GOBO INDEX 2024 J J1 SENSOR SENSOR M10 Mi 244 PAN ENCODER 244 TILT ENCODER 2020 PCB ASSY 2020 PCB ASSY 24 AC LINE AC LINE 16 2 gt TERM 22x4 2 gt J2 J2 NEUTRIK 2015 BLOCK 2016 LOW POWERCON ac VOLTAGE PAN PAN EOT TILT CO AC LINE IN IN SUPPLY MOTOR 26 4 26 4 2015 AC GND AC GND AC GND 16 1 22x4 e 161 gt PAN EOT TILT CO 2015 1 2016 1 2017 1850 SENSOR 1850 SENSOR CHASSIS 77 GND STUD 7 STUBS HEAD TO HEAD GND HEAD o BACK CAP BACK CAP USER DIMMER GND 2 22x4 GND STUDS BRAID GND STUD 2019 2018 PROVIDED 1 5 1 CONNECTOR 2030 2 CHASSIS T7 FOR LAMP 77 GND STUD PWR INPUT FROM LAMP LAMP LAMP DIMMER POWER gt TERM POWER gt AMP POWER 2030 1 5 2 BLOCK 22x4 2 SERIES 30 16 2HT 2030 2031 2032 PIGTAIL 20 October 2010 02 9664 00100 DESCRIPTION 7 VL1100 Incandescent Cable Routing Without On Board IGBT Dimmer NEUTRIK POWERCON AC LINE IN 2015 CHASSIS USER PROVIDED CONNECTOR mae FOR LAMP PWR ND INPUT FROM DIMMER GND an SERH DIMMER BLOCK PE LAMP AC DMX PAN STRAIN RELIEF PWR GND LINE DATA TUBE 2031 2016 2016 2022 PAN EOT PAN EOT TILT COT 2001 SENSOR 2002 PAN 2020 PAN 2020 TILT COT 2002 LAMP PWR 2031 TILT A
42. 9664 1001 12 AS Rev B Assembly Assembly 21 9664 1001 13 Al Rev B 21 9664 1600 AI AS Rev A 21 9664 1028 Rev A Crossmember Assembly Gobo Wheel Assembly 21 9664 1811 11 AS AI Rev 21 9665 1201 Rev A Shutter 6 Rollers Assembly 21 9663 1350 Rev D Temperature Sensor Outer Crossmember Electrical Assembly Assembly Beam Size Iris Assembly 23 9663 1248 11 AS Rev A 21 9664 1813 Rev C 21 9663 1400 Rev E Shutter Harness Cable Pan Motor Assembly Assembly 21 9665 9815 Rev A Edge Control Zoom 25 9663 2040 Rev F Dimmer amp Color Assembly Inner Crossmember Assembly 21 9664 1812 Rev A Color Changer Assembly Edge Barrel Assembly 21 9663 1710 Rev C ES 900691800 8001 Pan EOT Cable Assembly 21 9663 1003 Rev E 25 9663 2001 Rev A Lens 8 Assembly COT Center of Travel Flag 21 9663 1780 Rev B Assembly 21 9663 1845 Rev 0 Pan Tube Assembly 21 9664 1819 11 AS Al Rev C Yoke Legs Assembly continued next page 21 9664 1850 11 AS Al Rev B Yoke to Head Ground Cable Assembly continued next page 25 9663 2019 Rev B VL1100 Arc Ballast Assembly Rear Head Assembly continued next page 21 9663 1900 21 9664 1002 11 Rev A AS Al Figure 3 3 VL1100 Arc Luminaires Drawing Tree Part 1 62 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 VL1100 Arc Luminaires continued continued from previous page continued from previous page Yoke Legs Assembly 21 9664 1850 11 AS Al
43. BAL CONT 1921 77 GND STUD TILT COT LVS 2002 ASSY LAMP PWR 2035 BACK CAP LAMP PWR 2035 TILT COT SENSOR YOKE HEAD GND 2019 5 GND STUD 02 9664 0010 0 TILT TUBE 8 GND 7 BACK CAP HEAD GND 2018 GND STUD r 8 MOTORS 2040 SHUTTER MOTORS OPT 20 October 2010 STUD 7 10 MOTORS 2 SENSORS 2050 2040 2042 15 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Notes 16 20 October 2010 02 9664 00100 CHAPTER 2 Maintenance This chapter contains test service and standard maintenance procedures Testing e Maintenance Procedures power removed from the luminaire Never remove cover or backcap while lamp is in operation 2 WARNING All maintenance procedures are to be performed with 02 9664 0010 0 20 October 2010 17 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Testing 18 Running Parameter Tests The luminaire is capable of running self tests by using the TEST menu functions For detailed instructions regarding the luminaire s self test function refer to the VL1100 User s Manual for your luminaire 02 9664 0001 Note After 10 seconds of inactivity the menu display will change to the default state showing the address To conn
44. C GND 2016 DMX DATA 2022 2020 58 AC LINE 2016 PAN GND 24VDC 2024 2020 2017 i GND STUD y BACK CAP TILT LAMP COT LVS SOCKET GND STUD 2002 ASSY WEE BACK CAP HEAD GND 2031 2018 TILT COT SENSOR 02 9664 0010 0 LAMP PWR 2031 YOKE HEAD GND 2019 GND STUD GND STUD TILT TUBE 20 October 2010 SHUTTER MOTORS OPT GND STUD T 10 MOTORS 2 SENSORS 2050 FAN 2040 or 2042 8 MOTORS 2040 11 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL VO DATA 12 VL1100 Incandescent Block Diagram With On Board IGBT immer 1202 1326 1301 B S IRIS 1B SHUTTER ROTATE NEUTRIK XLR M DMX INPUT J2 DATA el gt J3 22 5 gt J8 NEUK 2022 MAIN CONTROL XLRF MENU ENTER UP DOWN PCB ASSY DISPLAY8 DMX THRU J1 J1 DMX PCB Qu 2050 J6 J7 m J5 2020 24 2 2040 SHUTTERS mE 2042 WITHOUT SENSOR 1 SENSOR2 SENSOR 3 4 5 SENSOR 6 7 8 26 4 26 4 24 5 24 5 Y Y 18 4 Y Y GOBO WHEEL GOBO INDEX 2024 nme J1 SENSOR SENSOR M10 un 24 4 PAN ENCODER 24 4 TILT ENCODE
45. C PLATED 16 53 2200 0004 1 EA NUT 4 40 KEPS SS 17 53 5560 0250 4 EA SCREW SET 8 32 X 1 4 L 18 53 6524 0002 4 EA SCREW 6 32 X 5 16 PPB 19 53 6530 0022 2 RIVET 1 8 CSK 0 25 20 53 6530 0023 1 RIVET 1 8 IN OD POP 0 376 0 500 DOME HD AL 21 53 6537 0001 1 EA SCREW 4 40 X 5 8 PPB 22 53 6543 0001 1 EA SCREW 6 32 X 3 8 PPB 23 53 6558 0015 l EA SCREW 6 32 X 3 8 PPB SEMS EXTW 24 53 6581 0002 2 EA SCREW 4 40 X 1 3 8 PFZ 25 53 6598 0312 4 EA SCREW 4 40 X 5 16 PFB 26 53 6600 0001 3 EA SCREW 4 40 X 5 16 PPB 27 53 6614 0001 2 SCREW 6 32 X 5 8 PPB 28 54 2045 0002 1 EA BELT TIMING 29 54 9663 1220 l EA BELT GOBO DRIVE 30 55 2123 0003 2 EA WASHER WAVE SPRING 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 31 55 3301 0006 1 EA WASHER 6 FLAT SS 32 55 6506 0010 1 EA SPACER 0 250 OD X 0 140 ID X 0 375 LG ALUM 33 55 6506 0010 1 EA WASHER 6 LOCK INTERNAL TOOTH 34 55 6568 0061 2 EA SPRING EXTENSION 0 250 OD 2 00 LONG 35 55 6621 0001 1 EA WASHER 4 FLAT ZINC 36 55 6677 0039 2 EA WASHER FLAT 0 438 OD 0 219 ID 0 04 THK 37 55 6677 0040 4 EA WASHER FLAT 0 624 OD 0 145 ID 0 03 THK 38 55 6706 0001 1 EA GROMMET 9 32 ID 9 16 OD 1 4T SI 39 55 6818 0002 1 EA STANDOFF 45 DEGREE NYLOCK KURLY LOK 02 9664 0010 0 20 October 2010 87 VARFXLITE VL1100 ERS L
46. CREW 4 40 X 1 2 PFZ 12 51 0541 4 EA SCREW 4 X 3 8 LG H L PPZ 13 53 6558 0014 1 EA SCREW 6 32 X 3 4 PPZ TYPE F THD CUTTING AS AI TS TI ONLY 14 53 6582 0001 2 EA SCREW 6 32 X 3 4 PFZ 15 55 2199 1000 0 17 FT HEAT SHRINK 1 BLACK AS AI ONLY 16 55 6662 0009 1 EA HOLE PLUG 7 8 HOLE DIA BLACK TSD TID ONLY 17 67 4018 0043 1 EA FERRITE CORE ROUND CABLE EMI 25 9MMX28 6MM AS AI ONLY 18 68 4536 0003 1 EA CHOKE ASSY COMMON MODE AS AI ONLY 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Pan Tube Assembly continued 3 18 A AS only 13 gt 7 53 N 10 x4 NL 7 15 AS AI only 17 AS AI only 4 NAS only or 14 x2 6 T TS only J On Board IGBT Dimmer Models Only Figure 3 34 Pan Tube Assembly 02 9664 0010 0 20 October 2010 117 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Notes 118 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Cables Arc Power Input Pigtail Cable Assembly 25 9663 1921 Rev M Refer to Figure 3 35 52 6274 2316 STRAIN RELIEF SKINTOP FLEX TY FRONTVIEW CPC 17 9 GRN YEL 40 0 25 0 0 WHT CABLE JACKET PLUG CPC 17 9 RNYEL RING TERM CHASSIS GND ORN ORN LAMP HI 1 Vio WIRE PIN LAMP HI AC GND 2 GRNYEL WIRE PIN LAMP LO LAMP LO MO BLK BLK AC LINE SHIELD DRAIN Wi AC NEUT WHT WHT PWR LVL BLK DATA GND RED SHIELD NOT ON WHT BLK RED
47. E SHUTTER COATED SIDE B 25 9663 2040 l EA CABLE ASSY BEAM SHAPER HARNESS NOT SHOWN 16 44 9663 1326 l EA MOTOR 17 53 SHAFT 11 8MH 5 5 OHM 17 44 9663 1351 8 EA ASSY SHUTTER MOTOR changed 05 22 03 18 53 2200 0006 1 EA NUT 6 32 KEPS SS 19 53 2202 0004 4 EA NUT 4 40 HEX SS NYLON INSERT 20 53 2202 0006 2 EA NUT 6 32 HEX SS NYLON INSERT 21 53 5638 0252 4 EA SCREW 6 32 X 1 4 LG PFS UNDERCUT HEAD 22 53 6523 0013 6 EA SCREW 6X32 3 8 LG PTB TRUSS HD BLK ZINC 23 53 6525 0001 4 EA SCREW 6 32 X 5 16 PPZ 24 53 6526 0001 2 SCREW 6 32 X 5 8 PPZ 25 53 6536 0001 2 EA SCREW 4 40 X 1 2 PFZ 26 53 6613 0001 1 EA SCREW 6 32 X 1 2 PPZ 27 55 2178 0002 1 EA CABLE ANCHOR MOUNT 10 SCREW MOUNTING 55 2180 0002 0 25 FT SPIRAL WRAP 3 8 OD TEFLON NOT SHOWN 28 55 3303 0006 4 EA WASHER 6 LOCK INT TOOTH SS 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 29 55 6621 0001 4 EA WASHER 4 FLAT ZINC 30 55 6697 0020 2 EA STANDOFF 3 16 RND 4 40 375 LG ZINC PLATED STEEL 02 9664 0010 0 20 October 2010 97 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Shutter Assembly continued Detail A 17 x8 Detail A 17 x8 22 x6 28 x4 23 x4 Figure 3 24 Shutter 6 Rollers Assembly 98 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Beam Size Iris Assembly 21 9663 1400 Rev E Refer to Figure 3 25
48. E DIA SS 4 55 6738 0003 06 TUBING SILICONE RUBBER 1 8 ID X 1 4 OD TRANSLUCENT 3 4 2 Figure 3 8 Gel Frame Holder Assembly 70 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 COT Center of Travel Flag Assembly 21 9663 1845 Rev 0 Refer to Figure 3 9 No Item Qty UM Description 1 10 9663 1824 1 EA SPACER TILT TUBE 2 10 9663 1826 1 EA FLAG CENTER OF TRAVEL TILT 3 53 6602 0001 3 EA SCREW 4 40 X 1 4 PPZ TYPE F 1 2 02 9664 0010 0 Figure 3 9 COT Flag Assembly 20 October 2010 71 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL VL1100 Main Control Board MCB Assembly 24 9664 1700 Rev C Refer to Figure 3 9 No Item Qty UM Description 1 04 9664 1700 1 EA LABEL VL1100 MCB WARNING 2 10 9664 1840 1 EA HEATSINK MAIN CONTROLLER 3 10 9664 1736 1 EA CLAMP PAN TILT DRIVERS 4 53 2200 0004 2 EA NUT 4 40 KEPS SS 5 53 2200 0006 9 EA NUT 6 32 KEPS SS 6 53 6404 0003 2 EA SCREW 4 40 X 1 00 PPZ 7 53 6616 0001 9 EA SCREW 6 32 X 3 4 PPZ 8 55 3301 0006 9 EA WASHER 6 FLAT SS Label Detail 1 see Label Detail Heatsink Detail 2 BT SS Apply thin coat see Heatsink Detail of heatsink 4 x2 compound on all indicated surfaces of 5 x9 heatsink NOTE MCB Assembly shown sold as a complete assem
49. E N POWERCON 16 2 BLOCK 2016 LOW 7 x AC GND L POWER AC me 161 VOLTAGE PAN PAN EO TILT COT SS AC GND AC GND BURREL STOR a X cHassis 9 224 16 1 PAN EO TILT COT GND STUD 2016 1 2017 1850 SENSOR 1850 SENSOR ACUNE AMP CPG 77 POWER 17 9 PLUG AC LINE Setups YOKE TO HEAD TO LAMPPWR 6277 16 2 4 HEAD GND HEAD BACK CAP BACK CAP INPUT amp BALLAST GND 5 22x4 17 GNDSTUDS BRAID GND STUD BALLAST V ACLINE 16 1 CHASSIS 177 2019 2018 177 CONTROL _ OUTPUT 1921 77 GND STUD BALLAST TO BALLAST CONTROL A AA AAA 22 4 s HIGH LAMP POWER TERM 1921 LAMP POWER IGNITOR LAMP HV 575W CURRENT 142 22x42 gt PCB ASSY 16 2HV ARC POWER CONTACTS 1921 BLOCK 2035 2036 LAMP PIGTAIL 14 20 October 2010 02 9664 0010 0 VL1100 Arc Cable Routing AMP POWERCON AC LINE IN NEUTRIK 2015 CPC 17 9 APUNE LAMP POWER IN 4 BAL CONT amp AC LINE OUT LAMP PWR TO BALLAST 1921 PIGTAIL amp STRAIN RELIEF BALLAST GND CHASSIS DESCRIPTION 7 LAMP AC AG PWR GND LINE CONT DA 2035 2016 2016 1921 BAL DMX TA 2022 TUBE YOKE LAMP PWR 2035 PAN EOT PAN EOT TILT COT 2001 SENSOR 2002 PAN 2020 PAN 2020 TILT COT 2002 AC GND 2016 24VDC 2024 LINE 2016 DMX DATA 2022
50. EA HEAD REAR CASTING MACHINED 5 21 9663 1101 01 1 EA ASSY INCANDESCENT BULKHEAD TS TI ONLY 21 9663 1101 11 1 EA ASSY ARC BULKHEAD AS AI ONLY 6 21 9664 1127 01 1 EA ASSY BACK CAP TS TI ONLY 21 9664 1127 11 1 EA ASSY BACK CAP AS AI ONLY 25 9663 2033 REF EA CABLE ASSY LAMP POWER INCANDESCENT TS TI ONLY NOT SHOWN 25 9663 2036 REF EA CABLE ASSY IGNITOR TO LAMP SOCKET AS AI ONLY NOT SHOWN 7 42 9663 7237 1 EA REFLECTOR 48 LUNE TS TI ONLY 42 9663 7118 1 EA REFLECTOR 8 10 14 DEGREE LUNES FACETED AS AI ONLY 8 53 2002 0001 3 EA NUT 6 32 KEP ZINC PLATED 9 53 6522 0005 4 EA SCREW 6 32 X 3 8 LG PFZ TYPE F 10 53 6553 0004 8 EA SCREW 10 32 X 3 8 LG PPB TYPE F 11 53 6607 0001 3 EA SCREW 6 32 X 1 4 PPB 12 53 6682 0037 1 EA SCREW 10 32 X 1 2 LG PPZ SEMS EXT 13 55 3301 0010 1 EA WASHER 10 FLAT 14 55 6636 0004 1 EA WASHER 10 FENDER ZINC PLT SS 1 250 OD 219 TD 047 THK 02 9664 0010 0 20 October 2010 101 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Rear Head Assembly continued 12 13 14 10 x4 3 x2 9 x4 Reflector Orientation Alignment Reference Point Note When installing reflector align dimple in reflector flange item 7 with reflector mount item 2 as shown for all models Bulkhead assembly item 5 removed for clarity Figure 3 26 Rear Head Assembly 102 20 October 2010 02 9664 0010 0 Back Cap Assembly 21 9664 1127 01
51. ER MOUNT PLATE 4 10 9663 1229 1 EA PLATE WHEEL IDLER MOUNT 5 10 9663 1239 2 EA MOUNT SENSOR BOARD 6 10 9663 1241 2 EA PULLEY IDLER TEFLON 7 10 9663 1242 2 EA SPACER PIVOT BELT ADJUST 8 10 9663 1621 1 EA PULLEY W FLANGES 26 GROOVE 9 10 9663 1625 1 EA SHAFT DIMMER 0 250 OD 10 10 9663 1630 2 EA SEAL COVER LONG 11 10 9663 1631 2 EA SEAL COVER SHORT 12 10 9663 1632 2 EA PLATE COVER SEAL LONG 13 10 9663 1633 2 PLATE COVER SEAL SHORT 14 10 9663 1635 l EA SHAFT SUPPORT DIMMER 15 10 9663 2214 1 EA SHAFT ROTATING GOBO 16 21 9665 1201 1 EA ASSY GOBO WHEEL 17 22 9663 1232 1 EA FAB ASSY DIMMER GOBO BULKHEAD 18 22 9663 1629 1 EA GLASS DIMMER WHEEL 19 23 9663 1248 11 1 EA ELEC ASSY TEMPERATURE SENSOR ARC MODELS 20 24 9663 3230 1 EA PCB ASSY WHEEL SENSOR 21 24 9663 3231 1 EA PCB ASSY INDEX SENSOR 22 44 9663 1202 3 EA MOTOR 17 2 42 SHAFT 11 8 MH 23 53 2002 0001 1 EA NUT 6 32 KEP ZINC PLATED 24 53 2200 0004 1 EA NUT 4 40 KEPS SS 25 53 5558 0125 2 EA SCREW 8 32 X 0 125 SET SS 26 53 5560 0250 8 EA SCREW SET 8 32 X 1 4 L 27 53 6524 0002 6 EA SCREW 6 32 X 5 16 PPB 28 53 6530 0022 2 EA RIVET 1 8 CSK 0 250 GRP 29 53 6530 0023 l EA RIVET 1 8 OD POP 376 500 GRP DOME HD AL 30 53 6534 0001 18 EA RIVET 3 32 OD POP 3 32 GRIP 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Descripti
52. G 2 21 9663 1003 1 EA ASSY EDGE ZOOM amp COLOR 3 21 9664 1033 1 EA ASSY SIDE RAIL PULLEY 4 21 9664 1034 1 EA ASSY SIDE RAIL SENSOR 5 21 9664 1200 1 EA ASSY GOBO BULKHEAD INCANDESCENT TI TS ONLY 21 9664 1600 1 EA ASSY GOBO DIMMER BULKHEAD ARC AI AI ONLY 6 21 9663 1350 1 EA ASSY SHUTTER 6 ROLLERS TS AS ONLY 7 21 9663 1400 1 EA ASSY IRIS TAI ONLY 8 53 6552 0002 4 EA SCREW 8 32 X 1 2 PFB 9 53 2004 0002 4 EA NUT 8 32 KEPS ZINC PLATE 10 53 6627 0001 12 EA SCREW 10 32 X 5 8 PPB 11 55 2179 0006 3 EA SADDLE WIRE BLIND HOLE 0 79 12 55 3303 0010 12 EA WASHER 10 0 438 OD 0 040 THK SPLIT LOCK SS 74 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Front Head Assembly continued A Models w Shutter Either A B C or D D Arc Models Figure 3 12 Front Head Assembly 02 9664 0010 0 20 October 2010 75 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Edge Control Zoom Dimmer amp Color Assembly 21 9663 1003 Rev E Refer to Figure 3 13 No Item Qty UM Description 1 10 9663 1039 l EA SUPPORT AXIAL FAN 2 10 9663 1755 3 EA ROLLER BARREL 3 10 9663 1756 6 EA ROLLER LENS 4 10 9663 1757 1 EA CLAMP BELT BASE 5 10 9663 1758 1 EA BELT CLAMP 6 10 9663 1767 1 EA ZOOM TEFLON SPACER 7 10 9663 1790 1 EA BELT PULLEY GT 3MM PITCH 16 GROOVES 8 12 9663 1754 1 EA MACHINED EXTRUSION O
53. INAIRE SERVICE MANUAL This page intentionally blank xviii 20 October 2010 02 9664 0010 0 INTRODUCTION Introduction Disclosure This technical manual is confidential property of Vari Lite All information contained herein is the sole and exclusive property of Vari Lite and may not be used disclosed or reproduced in any manner without the prior written consent of Vari Lite WARNING It is important to read ALL accompanying safety instructions to avoid damage to the product and potential injury to yourself or others A About This Manual This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VL1100 ERS Luminaire The manual is intended for use by Vari Lite personnel and by Vari Lite s Authorized Dealers and Service Centers This manual covers the following models Model Part Number Source Integral Dimmer Shutter Iris VL1100 TS 20 9664 0001 02 Incandescent No Yes No VL1100 TI 20 9664 0001 03 Incandescent No No Yes VL1100 AS 20 9664 0001 12 Arc Mechanical Yes No VL1100 Al 20 9664 0001 13 Arc Mechanical No Yes VL1100 TSD 20 9664 0001 22 Incandescent Electronic 115V Yes No VL1100 TID115 20 9664 0001 23 Incandescent Electronic 115V No Yes VL1100 TSD230 20 9664 0001 32 Incandescent Electronic 230V Yes No VL1100 TID230 20 9664 0001 33 Incandescent Electronic 230V No Yes Note Performing maintenance procedures contained in
54. L1100 ERS LUMINAIRE SERVICE MANUAL DMX Input PCB Replacement Parts PCB ASSEMBLY DMX INPUT Tools 1 Phillips screwdriver 2 Phillips screwdriver To remove and replace DMX input PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 At pan tube cover remove four 8 32x3 8 PFZ screws and remove cover Figure 2 28 Step 3 Remove four 4x3 8 HiLo screws Step 4 Disconnect DMX input PCB wiring and remove PCB Step 5 Replace DMX input PCB by doing steps 2 through 4 in reverse 8 32x3 8 Pan Tube Cover PEZ Screw DMX Input PCB 4x3 8 HiLo Screw Figure 2 28 DMX Input PCB Replacement 56 20 October 2010 02 9664 0010 0 MAINTENANCE Cleaning Optical Lenses and Filters AN WARNING Remove power from luminaire before performing maintenance The front lens color filters and gobos may require cleaning after extended use Isopropyl Alcohol should only be used with a soft lint free cloth to clean these components To access gobos refer to Rotating Gobo Replacement on page 31 02 9664 0010 0 20 October 2010 57 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Notes 58 20 October 2010 02 9664 00100 CHAPTER 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL1100 ERS Luminaire assemblies Drawing Trees Top Assembly Head Assembly Yoke Assembly Cables The following abbreviatio
55. MANUAL Inner Crossmember Assembly 21 9664 1812 Rev A Refer to Figure 3 31 No Item Qty UM Description 1 10 9663 2805 1 EA CROSSMEMBER INNER 2 10 9678 0886 1 EA SPACER PAN BEARING 235 THK 3 53 2019 0001 2 EA NUT 3 8 16 HEX 4 53 6505 0022 2 EA BOLT 3 8 16 X 3 4 LG CARRIAGE GRDS ZINC PLT 5 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 6 54 1255 0002 1 EA BEARING ASSY FLUSH MOUNT HOUSING LARGE 3 x2 g 5 x2 1 2 6 9 gt 4 x2 l Figure 3 31 Crossmember Inner Assembly 112 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Outer Crossmember Assembly 21 9664 1813 Rev C Refer to Figure 3 32 No Item Qty UM Description 1 10 9663 1897 1 EA SPACER PAN BEARING 2 21 9664 1843 l EA ASSY CROSSMEMBER OUTER 3 53 2019 0001 2 EA NUT 3 8 16 HEX 4 53 6505 0022 l EA BOLT 3 8 16 X 3 4 LG CARRIAGE GRDS ZINC PLT 5 53 6505 0023 l EA BOLT 3 8 16 X 1 1 4 LG CARRIAGE GRDS ZINC PLT 6 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 7 53 6569 0016 2 EA RIVET 5 32 OD LATCH 0 31 GRIP 8 54 1255 0001 1 EA BEARING ASSY BLACK FLUSH MOUNT HOUSING 3 x2 6 x2 Figure 3 32 Crossmember Outer Assembly 02 9664 0010 0 20 October 2010 113 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21 9665 9815 Rev A Refer to Figure 3 33
56. MBER 10 21 9664 1813 1 EA ASSY OUTER CROSSMEMBER 11 21 9664 1819 01 1 ASSY PAN TUBE TS TI ONLY 21 9664 1819 11 l EA ASSY PAN TUBE AS AI ONLY 21 9664 1819 21 l EA ASSY PAN TUBE TSD TID ONLY 12 21 9665 9815 1 EA ASSY PAN MOTOR 13 24 9663 1230 l EA PCB ASSY WHEEL SENSOR 25 9663 2001 1 EA CABLE ASSY PAN EOT NOT SHOWN 14 53 2020 0001 1 EA NUT 1 4 20 HEX STL ZINC PLTD 15 53 5509 1375 l EA SCREW 8 32 X 3 8 PPZ TYPE F 16 53 6505 0009 1 EA BOLT 1 4 20 X 2 1 2 HX HD CAP ZINC 17 53 6552 0002 6 EA SCREW 8 32 UNC X 1 2 PFB 18 53 6556 0006 4 EA SCREW 4 40 X 3 8 LG PPZ TYPE F 19 53 6575 0020 14 EA SCREW 8 32 X 3 8 LG PFZ TYPE F THRD CUTTING 20 53 6617 0001 4 EA SCREW 6 32 X 1 PPB 21 54 1206 0014 3 EA RING RETAINING 1 375 SHAFT 1 291 GRV DIA 056 GRVWD EXTERNAL 22 54 2047 0024 1 EA BELT TIMING GT 3MM PITCH 150GRV 6MM WD NEOPRENE 23 55 2203 0001 2 SCREW 4 40 X 1 4 PPZ 24 55 3301 0006 4 EA WASHER 6 FLAT SS 25 55 6563 0001 3 EA SCREW 10 32 X 1 4 PPZ 26 55 6568 0055 1 EA SPRING CPRSN 240 OD 813 LG 038 WIRE DIA MUSIC WIRE 110 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 27 55 6799 0001 l EA SHIM 1 375 ID 1 875 OD 0 010 THK 28 55 6799 0002 1 EA SHIM 1 375 ID 1 875 OD 0 005 THK 02 9664 0010 0 Figure 3 30 Crossmember Assembly 20 October 2010 111 VARFXLITE VL1100 ERS LUMINAIRE SERVICE
57. MINAIRE SERVICE MANUAL Yoke to Head Ground Cable Assembly 25 9663 2019 Rev B Refer to Figure 3 42 12 0 Figure 3 42 Yoke to Head Ground Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 126 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Pan Tilt Control Cable Assembly 25 9664 2020 Rev A Refer to Figure 3 43 Figure 3 43 Pan Tilt Control Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 127 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Ballast Control Link Cable Assembly 25 9663 2021 Rev A Refer to Figure 3 44 GRN GRN GNDH PWR LV gt WATS 22 WHT i BLK gt gt gt lt SSS BLK GND 807 Na DATA GND NOT ON 4 NOT ON TO MAIN CONTROL FROM ARC POWER INPUT PCB J7 PIGTAIL DATA CONNECTOR Figure 3 44 Ballast Control Link Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 128 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Data 1 0 Link Cable Assembly 25 9663 2022 Rev B Refer to Figure 3 45 1 RED RED lt 1 MAIN INPUT 2 BLK l
58. NCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA INCENDIO 1 Lasluminarias VARI LITE han sido dise adas para ser usadas solamente con algunas l mparas HID Philips y Osram Tome nota del tipo de l mpara MSR400 MSR575HR etc antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalaci n Vea las instrucciones detalladas en este manual 3 Reemplaze los fusibles solamente con los del mismo tipo y especificaci n 4 Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las luminarias ADVERTENCIA I INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA CHOQUE ELECTRICO 1 Las luminarias est n dise adas solamente para lugares secos La exposici n a la lluvia o humedad pueden da ar la luminaria Desconecte la energ a antes de dar servicio a cualquier equipo de VARI XLITE 3 El servicio debe ser realizado solamente por personal calificado 02 9664 0010 0 20 October 2010 xi VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL ADVERTENCIA s INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA LA EXPOSICION EXCESIVA DE RADIACION ULTRA VIOLETA 1 Muchas luminarias VARIXLITE usan un tipo de l mpara HID que produce radiaci n UV NO mire directamente a la l mpara 2 Es peligroso operar luminarias sin lentes o prote
59. ND 2019 FAN 2040 or 2042 02 9664 0010 0 8 MOTORS 2040 GND STUD SHUTTER MOTORS OPT 20 October 2010 13 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL VL1100 Arc Source Luminaire VL1100 Arc Block Diagram 1766 1301 1A SHUTTER FRAME 1202 1326 1B SHUTTER FRAME B S IRIS SHUTTER ROTATE 1301 2A SHUTTER FRAME 2B SHUTTER FRAME 1301 1301 3A SHUTTER FRAME 4A SHUTTER FRAME 3B SHUTTER FRAME 4B SHUTTER FRAME M7 M13 M15 M17 M19 244 26 4 26 4 26 4 26 4 M6 M8 M12 M14 M16 M18 M20 NEUTRIK 24 4 24 4 24 4 26 4 26 4 26 4 26 4 DATA XLR M MO DMX INPUT 2040 J2 DATA ac J3 22 5 J8 VENE 2022 MAIN CONTROL DATA XLR F MENU ENTER UP DOWN PCB ASSY DISPLAY8 VO DMX THRU Jt J1 FAN J4 2050 DMX PCB 24 9 2040 SHUTTERS 2042 WITHOUT SENSOR 1 SENSOR 2 SENSOR 3 4 5 SENSOR 6 7 8 26 4 26 4 424N 24 5 24 5 y y 18 4 CONTROL 4 GOBO WHEEL GOBO INDEX 2024 22 4 31 Ji FAN SENSOR SENSOR 19 1 M11 ENCODER 24 4 TILT ENCODER 2020 PCB ASSY 2020 PCB ASSY AC LINE NEUTRIK AC LINE TERM 242 J2 J2 RCUN
60. NWEISE ZUM FEUERSCHUTZ 1 VARI LITE Scheinwerfer sind ausschlie lich f r 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 gefahrlich sein 2 Scheinwerfer k nnen auf jeder beliebigen Oberfl che 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 St rke 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 ausschlie lich f r trockene Standorte Regen oder Feuchtigkeit k nnen die Scheinwerfer beschadigen 2 Unterbrechen Sie die Stromzufuhr bevor Sie mit der Arbeit an VARI LITE Geraten beginnen 3 Die Gerate sollten nur von qualifiziertem Personal gewartet werden WARNUNG HINWEISE ZUM SCHUTZ GEGEN UBERHOHTE UV STRAHLUNG 1 Viele VARI LITE Scheinwerfer verwenden einen HID Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 02 9664 0010 0 20 October 2010 vii VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL 2 Esist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen oder Ultraviolettschirme m sse
61. ON advising of potential damage to product AN WARNING advising of potential injury or death to persons GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELEC TRICAL SHOCK FIRE EXPOSURE TO EXCESSIVE UV RADIATION AND INJURY TO PERSONS CAN BE FOUND BELOW WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1 VARI LITE luminaires have been designed for use only with certain Philips and Osram HID lamps Note lamp type MSR400 MSR575HR etc before replacing lamps Installing another type of lamp may be hazardous 2 Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detailed in this manual 3 Replace fuses with same type and rating only 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 Disconnect power before servicing any VARIXLITE equipment 3 Servicing to be performed by qualified personnel only dimmer even in NONDIM mode Dimmer and non dim modules are not suitable sources of power because their output modifies the AC wave form This may work for a short time but will eventually result in power problems luminaire mis operation and or failure See Vari Lite Technical Notice TN 229A for more information 4
62. PULLEY GOBO WHEEL DRIVE 5 12 9665 2219 1 EA SUN GEAR MOLDED 6 54 1206 0060 1 EA RETAINING RING INTERNAL 36 5MM BORE 7 54 1259 0020 1 EA BEARING 25MM ID 37MM OD 7MM WD 8 54 1259 0021 1 EA BRG FLANGED 0 250 BORE 0 500 OD 9 54 1259 0022 1 EA BRG FLANGED 0 375 BORE 0 875 OD 9 ex NN Incorrect Correct Retaining Ring Tab Note Retaining Ring Item 6 must be completely captured underneath the tabs in Sun Gear Item 5 The opening in Retaining Clip should not straddle a tab as shown Figure 3 23 Gobo Wheel Pulley Assembly 02 9664 0010 0 20 October 2010 95 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Shutter 6 Rollers Assembly 21 9663 1350 Rev D Refer to Figure 3 24 No Item Qty UM Description 1 10 9663 1311 2 EA SEPARATOR SHUTTER 2 10 9663 1313 l EA COVER SHUTTER 3 10 9663 1314 8 EA RACK SHUTTER 4 10 9663 1320 8 EA PAD MOTOR 5 10 9663 1321 1 EA CLAMP RING MOTOR 6 10 9663 1325 6 EA ROLLER NYLON 7 10 9663 1327 1 EA GEAR SHUTTER ROTATE SECTOR 8 10 9663 1328 l EA BULKHEAD SHUTTER MACHINED 9 10 9663 1330 1 EA PINON SHUTTER 10 10 9663 1380 4 EA SPACER SHUTTER 11 10 9663 1381 3 SEPARATOR SHUTTER 12 10 9663 1339 02 1 EA DONUT ANTI REFLECTION SHUTTER 13 10 9663 1351 1 EA BASE PLATE SHUTTER 6 ROLLERS 14 12 9663 1323 2 EA BLADE SHUTTER COATED SIDE A 15 12 9663 1324 2 EA BLAD
63. R 2020 PCB ASSY 2020 PCB ASSY Fr 24V AC LINE AC LINE 16 2 gt JERM 22x4 2 gt 2 J2 NEUTRIK 2015 BLOCK 2016 LOW POWERCON VOLTAGE PAN PAN EO TILT CO AC LINE IN IN SUPPLY MOTOR 26 4 26 4 2015 AC GND AC GND AC GND 16 1 22x4 161 gt PAN EOT TILT CO 2015 1 2016 1 2017 1850 SENSOR 1850 SENSOR CHASSIS GND STUD 77 HEAD HEAD GND HEAD BACK CAP BACK CAP YOKE 21 22x4 17 GNDSTUDS BRAID GND STUD GND STUDS 2019 2018 77 LAMP LAMP 1000W POWER DIMMER POWER INCAND 16 2HT 115V or 240V 22x4 2 2032 2031 LAMP 20 October 2010 02 9664 00100 DESCRIPTION 7 VL1100 Incandescent Cable Routing With On Board IGBT Dimmer PAN PAN EOT PAN EOT TILT COT 2001 SENSOR 2002 TILT COT 2002 CHASSIS AC TERM XLR M LINE gt BLOCK 2015 NEUTRIK POWERCON AC LINE IN 2015 YOKE 2020 PAN 2020 TILT 2020 AC GND 2016 DMX DATA 2022 Lvs AC LINE 2016 PAN GND 24VDC 2024 2020 TILT COT SENSOR GND STUD y BACK CAP LAMP LAMP SOCKET GND STUD PWR 2032 BACK CAP HEAD GND 2018 DIMMER GND STUD T 10 MOTORS 2 SENSORS 2050 LAMP PWR 2081 YOKE HEAD G
64. UMINAIRE SERVICE MANUAL Incandescent Gobo Wheel Assy continued Set pulleys to dimensions shown 28 See Detail A 3 33 22 19 x2 38 17 x4 2 25 x4 Figure 3 19 Incandescent Gobo Wheel Assembly 88 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Temperature Sensor Electrical Assembly 23 9663 1248 01 TS Rev A 23 9663 1248 11 AS Rev A Refer to Figure 3 20 No Item Qty UM Description 1 23 9663 2008 1 EA ASSY FAN TI TS ONLY 40 7140 0001 1 EA BLOWER CENTRIFUGAL 24VDC 9CEM 3 X 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 2 52 6523 0004 l EA CONN HOUSING 4POS PLUG SHROUDED WIRE TO WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 4 55 2198 0001 17 FT HEAT SHRINK 1 8 BLACK 5 63 2047 0001 l EA THERMOSTAT 100 DEG C PCB MOUNT CLOSE ON RISE 6 73 3524 0002 2 5 WIRE24AWG 300V 105C PVC RED UL1007 1 0 1 TI TS Models Only 02 9664 0010 0 15 0 Indicates Pin 1 Figure 3 20 Temperature Sensor Electrical Assembly 20 October 2010 89 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Arc Gobo Dimmer Bulkhead Assembly 21 9664 1600 AI AS RevA Refer to Figure 3 21 No Item Qty UM Description 1 10 9663 1212 2 EA PULLEY MOTOR GOBO 2 10 9663 1217 1 EA PULLEY GOBO DRIVE 3 10 9663 1228 1 EA PLATE GOBO IDL
65. UTER BARREL ZOOM 9 21 9663 1500 1 EA ASSY COLOR CHANGER 10 21 9663 1760 1 EA ASSY LENS 6 11 21 9663 1770 1 ASSY LENS 7 12 21 9663 1780 1 EA ASSY LENS 8 13 23 9663 2009 1 EA ASSY FAN 14 44 9663 1766 l EA MOTOR 17 1 24 SHAFT 11 8MH 5 5 OHM 15 53 2003 0001 2 EA NUT 4 40 KEP ZINC PLATED 16 53 2202 0006 4 EA NUT 6 32 HEX SS NYLON INSERT 17 53 5506 0750 6 EA SCREW 6 32 X 3 4 PPSS 18 55 5559 0250 2 EA SCREW 6 32 X 1 4 SET CONE added 08 28 03 19 53 5604 0437 2 SCREW 4 40 X 7 16 LG PPSS BLACK 20 53 5606 0375 7 EA SCREW 6 32X 3 8 PPSS BLACK 21 53 6558 0003 2 EA SCREW 6 32 X 3 8 PPZ PLASTIC THREAD ROLLING 22 53 6567 0001 2 EA SCREW 4 40 X 1 2 PPZ 23 54 2048 0002 1 EA BELT TIMING HTD 3MMPITCH 195 GROOVE 6MMWIDE 24 55 3301 0006 2 EA WASHER 6 FLAT SS 25 55 3303 0006 3 EA WASHER 6 LOCK INT TOOTH SS 26 55 6588 0003 3 EA SPACER 1 4 RND 6 THRU 1 8 LG 140 ID ZINC PLT BRS 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Edge Control Dimmer amp Color Assembly con tinued Figure 3 13 Edge Control Dimmer amp Color Assembly 02 9664 0010 0 20 October 2010 77 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Color Changer Assembly 21 9663 1500 Rev U Refer to Figure 3 14 No Item Qty UM Description 1 04 9663 1524 1 EA LABEL MAGENTA MOTOR 2 04 9663 1525 l
66. V Only Refer to Figure 3 5 No Item Qty UM Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8001 0002 1 EA VARI LITE QUALITY ASSURANCE CERTIFICATE 3 02 8052 0001 l EA CARD LIMITED WARRANTY 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 5 02 9664 0002 1 EA UNPACK QUICK START SHEET VL1100 6 06 6073 0001 l EA FOAM SHIPPING 7 07 9663 0032 1 EA SHIPPING BOX CARDBOARD 8 08 1100 0001 1 EA CD ROM VL1100 PRODUCT DOCUMENTATION 9 52 6541 0001 1 EA CONN BLUE CABLE PWR INLET 3 POLE LOCKING POWERCON 10 53 6505 0027 1 EA BOLT 1 2 X 13 X 1 LG HX HD ZINC AS AI ONLY 1 55 6539 0001 1 EA WASHER 1 2 SPLIT LOCK AS AI ONLY Note Lamps supplied per customer order depending on model See User s Manual Product Specifications or contact Vari Lite Customer Service for available lamp types for each model 64 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Included Items Kit continued VL1100 Luminaire page 66 Lamp per customer order 11 Arc Models Only Arc Ballast Arc Models Only Figure 3 5 Included Items 02 9664 0010 0 20 October 2010 65 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL VL1100 Luminaire 20 9664 0001 02 TS Rev C 20 9664 0001 03 TI Rev C 20 9664 0001 12 AS Rev C 20 9664 0001 13 Al Rev C 20 9664 0001 2 20 9664 0001 2 20 9664 0001 3 20
67. VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Maintenance Procedures Lamp Replacement Incandescent Model Parts 1000 WATT INCANDESCENT LAMP 100 VAC 71 2552 0100 TS TI 1000 WATT INCANDESCENT LAMP 100 VAC 71 2554 0100 TS TI 1000 WATT INCANDESCENT LAMP 115 VAC 71 2552 0115 TS TI 1000 WATT INCANDESCENT LAMP 115 VAC 71 2554 0115 TS TI 1000 WATT INCANDESCENT LAMP 230 VAC 71 2552 0230 TS TI 1000 WATT INCANDESCENT LAMP 230 VAC 71 2554 0230 TS TI 1000 WATT INCANDESCENT LAMP 240 VAC 71 2554 0240 TS TI Tools 2 Phillips screwdriver cotton gloves lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life If touched use alcohol and cotton cloth to thoroughly clean glass portion of lamp CAUTION Wear cotton gloves or other covering while installing lamp Touching To install incandescent lamp Step 1 Remove power from luminaire Step 2 Atbackcap gradually loosen two 10 32x2 3 8 PPSS black screws Figure 2 1 a few turns at a time until backcap is free Screws must be alternately loosened to prevent one side from locking up 22 20 October 2010 02 9664 00100 MAINTENANCE Do not touch lamp Rear Head CAUTION with bare fingers Assembly Backcap Align when re installing Alignment Stud 2 A 10 32x2 3 8 PPSS Holes and studs MUST be CAUTION aligned when re installing 2 Interi
68. VL1100 ERS Luminaire _ 02 9664 0010 PHILIPS VARI2 LITE VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Neutrik PowerCon and EtherCon are registered trademarks of Neutrik Inc All other brand or product names which may be mentioned in this manual are trade marks or registered trademarks of their respective companies or organizations The information furnished in this manual is for informational use only and is subject to change without notice Please check www vari lite com for latest version Vari Lite assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual All information and graphics are property of Vari Lite 10911 Petal Street Dallas Texas 75238 Version as of 20 October 2010 Part number 02 9664 0010 0 VL1100 ERS Luminaire Service Manual 2002 2010 Vari Lite a Philips group company All Rights Reserved 20 October 2010 02 9664 0010 0 How To OBTAIN WARRANTY SERVICE How To Obtain Warranty Service A copy of the Vari Lite Limited Warranty was included in the shipping package for this product To obtain warranty service please contact customer service at 1 877 VARI LITE 1 877 827 4548 or 1 214 647 7880 or via e mail at entertainment service phil ips com request a Return Material Authorization RMA for warranty service You will need to provide the model and serial number of the item being returned a descrip tion of th
69. amp with denatured alcohol and wipe with lint free cloth before installing or powering up the luminaire 7 The lamp shall be changed if it has become damaged or thermally deformed WARNING RF INTERFERENCE 1 This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures ARC LAMP CHARACTERISTIC CONSIDERATIONS 1 Arc lamps require a period of time to relight after a power interruption 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 20 October 2010 02 9664 0010 0 SICHERHEITSHINWEISE Sicherheitshinweise Es ist u erst 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 Vorsichtsma nahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet A VORSICHT weist auf m glichen Produktschaden hin WARNUNG weist auf m gliche K rperverletzung und Leb ensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE UBER SICHER HEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUER UBERHOHTE UV STRAHLUNG UND KORPERVERLETZUNGEN WARNUNG HI
70. bly Hardware may be purchased separately Figure 3 10 VL1100 MCB Assembly 72 20 October 2010 02 9664 00100 Head Assembly ILLUSTRATED PARTS BREAKDOWN 3 Head Assembly 21 9664 1000 02 TS Rev A 21 9664 1000 03 TI Rev A 21 9664 1000 12 AS Rev A 21 9664 1000 13 Al Rev A Refer to Figure 3 11 No Item Qty UM Description 1 10 9663 1032 2 EA SPACER SIDE RAIL TI TS ONLY 4 EA SPACER SIDE RAIL AVAS ONLY 2 21 9664 1001 02 1 EA ASSY FRONT HEAD INCANDESCENT WITH SHUTTER TS ONLY 21 9664 1001 03 l EA ASSY FRONT HEAD INCANDESCENT WITH IRIS TI ONLY 21 9664 1001 12 1 EA ASSY FRONT HEAD ARC WITH SHUTTER AS ONLY 21 9664 1001 13 1 EA ASSY FRONT HEAD ARC WITH IRIS AI ONLY 3 21 9664 1002 01 1 EA ASSY REAR HEAD INCANDESCENT TUTS ONLY 21 9664 1002 11 1 EA ASSY REAR HEAD ARC AVAS ONLY 4 53 6627 0001 4 EA SCREW 10 32 X 5 8 PPB 5 55 3303 0010 4 EA WASHER 10 0 438 OD 040 THK SPLIT LOCK SS 02 9664 0010 0 x2 TITS MODELS x4 AVAS MODELS 1 1 Figure 3 11 Head Assembly 20 October 2010 73 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Front Head Assembly 21 9664 1001 02 TS Rev B 21 9664 1001 03 TI Rev B 21 9664 1001 12 AS Rev B 21 9664 1001 13 Al Rev B Refer to Figure 3 12 No Item Qty UM Description 1 07 5049 0001 1 EA LANYARD NYLON COATED 8 L
71. camente 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 CARACTER STICAS DE LA L MPARA DE ARCO 1 Las l mparas de arco requieren un per odo de tiempo para volver a iluminarse despu s de una interrupci n de energ a o de una severa ca da de voltaje En algunos casos la l mpara se volver a iluminar en forma autom tica despu s que se ha enfriado dependiendo de la configuraci n del sistema de energ a de la l mpara L ON L OFF L encendida L apagada 2 La posici n de encendido es universal xii 20 October 2010 02 9664 0010 0 SAFETY NOTICE JAPANESE gt
72. chnical Rule Description TN 229A Powering Luminaires From Dimmer Circuits NOT RECOMMENDED TN 230 Dousing Lamps Before Shutting Off Power TN 232 Use of Third Party Accessories TN 300A All VL1000 VL1100 Series Luminaires Color System Drive Ring Part Number Change TN 308 Series 500 1000 2000 3000 VLX Luminaires Pan amp Tilt Encoder PCB Motor Assemblies Change Notice Technical Bulletins Software Updates support and other information is available online at www vari lite com under the Support link To request access to the password protected support areas please contact Vari Lite Customer Service at 1 877 827 4548 or 1 214 647 7880 or entertainment service philips com 02 9664 0010 0 20 October 2010 143 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Notes 144 20 October 2010 02 9664 00100 VARI2 LITE Express yourself Vari Lite 10911 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE 1 214 647 7880 Fax 1 214 647 8038 www vari lite com Date 20 October 2010 Manual Part Number 02 9664 0010 0 2002 2010 Vari Lite A Philips Group Company All rights reserved Printed in the U S A
73. ctores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido dafadas y que su efectividad pudiera estar deteriorada Por ejemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTRA LESIONES DE PERSONAS 1 Las superficies exteriores de las luminarias est n calientes durante su operaci n Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando haga ajustes en el equipo y componentes que est n calientes 2 Cuando las luminarias est n en operaci n la l mpara estar muy caliente Desconecte la energ a y deje que la l mpara se enfr e antes de reemplazarla 3 Las l mparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e inflamaci n a los ojos Adem s las l mparas de arco operan a alta presi n y muy alta temperatura Si la l mpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las part culas de la l mpara rota que se caen 4 Use protecci n para los ojos cuando vuelve a colocar una l mpara nueva 5 Useun equipo de seguridad apropiado guantes protecci n para los ojos etc cuando trabaje con l mparas dafadas 6 Si la l mpara con las manos limpie la l mpara con alcohol desnaturalizado y con tela sin pelusas antes de instalar o volver a conectar la luminaria 7 Cambie la l mpara si est da ada o deformada termi
74. d plate by removing three 6 32x1 2 PPB screws At controller PCB disconnect wiring at connectors marked GOBO COLOR ZOOM EDGE DIMMER ROTATE PAN TILT POWER COMM e SHUTTERS if applicable f BALLAST if applicable g DIMMER if applicable 0 Remove four 6 32x3 8 PPB screws remove controller PCB At encoder PCB remove two 4 40x1 4 PPZ screws Disconnect connectors at J1 and J2 and remove encoder PCB At tilt motor assembly loosen four 6 32x1 PPB screws Slide assembly forward and remove belt from pulley Remove four 6 32x1 PPB screws and 6 flat washers and remove tilt motor assembly spring and nut plates x2 will come loose also Replace by doing steps 2 through 9 in reverse Belt tension is automatically set by spring Note When tightening start at lower left from spring if spring is at top and continue in clock wise direction 20 October 2010 02 9664 00100 MAINTENANCE Tilt Motor Assembly Replacement continued 6 32x3 8 PTB Screws 6 32x3 8 PPB Screw Controller PCB Display Plate Display Overlay 6 32x1 2 PPB Screw These items remove and install as one Yoke Leg Cover NOTE Head not shown for clarity Tilt Motor Assembly 6 Flat Washer Ly 6 32x1 PPB Screw Nut Plate x2 Figure 2 26 Tilt Motor Assembly Replacement 02 9664 0010 0 20 October 2010 53 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL
75. d tightened on flat sides of motor shaft Figure 3 33 Pan Motor Assembly 02 9664 0010 0 20 October 2010 115 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Pan Tube Assembly 21 9664 1819 01 TS TI Rev 21 9664 1819 11 AS AI Rev 21 9664 1819 21 TSD TID Rev C Refer to Figure 3 34 No Item Qty UM Description 1 04 9640 0374 1 EA LABEL P E GROUND 2 10 9664 1851 1 EA PAN TUBE TOP 3 24 9664 4895 1 EA PCB ASSY DMX INPUT 4 25 9663 1921 1 EA CABLE ASSY ARC POWER INPUT PIGTAIL AS AI ONLY 5 25 9663 2015 01 1 EA CABLE ASSY NEUTRIK CONNECTOR 25 9663 2816 01 1 EA CABLE ASSY INC LVS AC INPUT TS TI TSD TID ONLY NOT SHOWN 25 9663 2816 11 1 EA CABLE ASSY ARC LVS AC INPUT AS AI ONLY NOT SHOWN 25 9663 2021 1 EA CABLE ASSY BALLAST CNTRL LINK AS AI ONLY NOT SHOWN 25 9663 2022 1 EA CABLE ASSY DATA I O LINK NOT SHOWN 6 25 9663 2030 1 EA CABLE ASSY STRAIN RELIEF TS TI ONLY 25 9663 2033 1 EA CABLE ASSY LAMP PWR INC TS TI ONLY NOT SHOWN 25 9663 2035 1 EA CABLE ASSY ARC PWR TO IGNITOR AS AI ONLY NOT SHOWN 7 52 8295 0002 2 EA TERMINAL STRIP 300V 12AWG 20A 2 POS AS AI ONLY 52 8295 0002 1 EA TERMINAL STRIP 300V 12AWG 20A 2 POS TS TI ONLY 8 52 8295 1002 1 EA SPACER TERMINAL STRIP 600V 2 POS AS AI TS TI ONLY 9 53 2200 0004 2 EA NUT 4 40 KEPS SS 10 53 2200 0006 4 EA NUT 6 32 KEPS SS 11 53 6536 0001 2 S
76. e problem or failure and the name of the registered user or organization If available you should have your sales invoice to establish the date of sale as the beginning of the warranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form included at the end of this manual and place in shipping container along with a copy of your invoice if available Write the RMA number legibly on or near the shipping address label and return the unit freight prepaid to Vari Lite 10911 Petal Street Dallas Texas 75238 USA Attention Warranty Service RMA As stated in the warranty it is required that the shipment be insured and FOB our service center Manual Revision History VERSION DATE Revision 0 Inital Version 20 October 2010 02 9664 0010 0 20 October 2010 iii VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL FCC C Compliance Notice 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 communica tions Operation of
77. ead Assembly Baar optional silks frosts color Houses color gobo dimmer strobe Adiust correction or top hats and optional shutter or iris mechanisms ae See detail Menu Display Controls Do not remove or use to access lamp LCD Display Input Panel Connections Address MENU ENTER A Y 3 Pole Neutrik Lamp Power Locking Connector Input Cable Data Thru for AC Input Press to show menu or if at first level the current address Down Decrease Up Increase Press to select current menu option or current data value 6 20 October 2010 02 9664 0010 0 DESCRIPTION 7 Luminaire Internal Head Components The following illustration shows the major sub assemblies that are located in the luminaire head assembly A options Shutter or Beam size Iris bulkhead is dependent on model B options Rotating Gobo Bulkhead version is dependent on model Beam Size Iris Assembly optional Provides beam sizing capabilities Shutter Assembly optional Four blade system can frame and crop beam field and gobos Rear Head Assembly Six position rotating gobo wheel with five rotatable indexable gobo positions and one open gobo position See options A FLY 4 Edge Zoom Dimmer Bulkhead A Contains automated zoom optics lenses S Backcap Assembly crossfading CYM system and diffusion L Ne 2 Provides access to lamp 4 for replacement and provides controls for bea
78. ect luminaires for simultaneous testing Step 1 Connect first luminaire containing software version to download to other luminaires as desired First luminaire containing Luminaire 1 Luminaire 2 software version to download requiring update requiring update s Data Thru En m Data Thru EN Step 2 At master luminaire Menu Display press Menu Movement Disable The Movement option has been added to the configuration menu This allows for pan tilt functions to be disabled so that the luminaire can be placed in any position for testing without movement occurring In order to regain full control of the luminaire Movement will need to be enabled after testing WARNING Backcap and adjustment knobs will be HOT during lamp operation Wear gloves and or use tools to prevent burns To run tests Step 1 Press Menu Step 2 Press Up Down arrows until Test appears Press Enter Step 3 Use Up Down arrows to select a parameter to test Refer to Table 2 1 on page 19 for a complete list of test parameters Step 4 Press Enter to run test Step 5 Press Menu to stop test at any time 20 October 2010 02 9664 00100 Table 2 1 Self Test Function Chart MAINTENANCE 1st Level 2nd Level 3rd Level 4th Level 5thLevel Test ALL SEQ Test All Motors RUN TEST Run Test in Progress Press Menu to stop Syst
79. em Test Pan Tilt RUN TEST Run Test in Progress tests Dimmer Arc Only RUN TEST Run Test in Progress Blue RUN TEST Run Test in Progress Amber RUN TEST Run Test in Progress Magenta RUN TEST Run Test in Progress ColorMix Blue Amber Magenta test RUN TEST Run Test in Progress Diffusn Diffusion Test RUN TEST Run Test in Progress Rot Gobo Rotating Gobo Test RUN TEST Run Test in Progress Edge RUN TEST Run Test in Progress Zoom RUN TEST Run Test in Progress Beam If Beam Size Iris Accessory RUN TEST Run Test in Progress Shutter If Shutter Accessory RUN TEST Run Test in Progress Rot Shut If Shutter Accessory RUN TEST Run Test in Progress Lamp 1 or Lamp 2 Disables Pan Tilt RUN TEST Run Test in Progress and executes Home position Encoder Encoders Pan Pan Encoder XXXX Data Tilt Tilt Encoder XXXX Data Sensor Sensors Pan COT Sensor STST Sensor Test in PASS FAIL Progress Tilt COT Sensor STST Sensor Test in PASS FAIL Progress Rot Gobo Gobo Select EOT STST Sensor Test in PASS FAIL Sensor Progress Gobolndx Gobo Index EOT STST Sensor Test in PASS FAIL Sensor Progress Calibration Sequence The following is an outline of the luminaire s standard calibration sequence Phase 1 Dimmer Colors e Tilt Zoom Edge Phase 2 Gobos Pan Phase 3 e Shutters Iris 02 9664 0010 0 20 October 2010 19 VAREKLITE VL1100 ERS LUMINAIRE SERVICE MANUAL 20 Auto Recalibration Mechanisms with sensors Gobo and Index will check
80. en Halogen lamp source 230V on board electronic IGBT dimmer Four blade shutter framing system VL1100 TID230 Luminaire 20 9664 0001 33 Black 20 9664 0001 33 02 White 1000W Tungsten Halogen lamp source 230V on board electronic IGBT dimmer Beam size iris mechanism Note For complete information on all model specific features please visit the product Section on the Vari Lite web site at www vari lite com 02 9664 0010 0 20 October 2010 5 VAREKLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Component Descriptions External Luminaire Components The following illustration shows the external luminaire components and controls Base Input Panel Provides hook mounting Provides DMX In and holes and safety cable Z Thru and AC Power connection 7 connections gt 4 4 s Yoke Leg Control T Contains main control 2 I 1 Lamp Power display Input Cable 7 N Gel Silk or Frost Yoke Leg Power Contains power supply and ignitor board arc units or dimmer dimmer units Accepts frames or top hats Accessory Frame Accessory Frame Holder Y Backcap Assembly Provides access to lamp for replacement and provides controls for beam adjustment Beam Adjustment Controls Menu Display Used to input manual commands program test set defaults and access internal status information Accessory Frame Holder Provides frame for H
81. indicated Figure 2 22 Low Voltage Supply LVS 02 9664 0010 0 20 October 2010 47 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Power Supply Replacement continued NOTE Head not shown for clarity Crossmember Assembly 10 32x1 2 PPB Screw Yoke Leg Cover 6 32x3 8 PTB Screws Power Supply Figure 2 23 Power Supply Replacement 48 20 October 2010 02 9664 00100 MAINTENANCE Controller PCB Replacement Parts PCB ASSEMBLY CONTROLLER Tools 2 Phillips screwdriver To remove and replace controller PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke leg cover side with menu display by removing four 6 32x3 8 PTB screws as shown in Figure 2 24 Step 3 Remove display overlay and plate by removing three 6 32x1 2 PPB screws Step 4 At controller PCB disconnect wiring at connectors marked a b e f g GOBO COLOR ZOOM EDGE DIMMER ROTATE PAN TILT POWER COMM SHUTTERS if applicable BALLAST if applicable DIMMER if applicable Step 5 At controller PCB remove four 6 32x3 8 PPB screws and remove PCB Step 6 Replace controller PCB by doing steps 2 through 5 in reverse 02 9664 0010 0 20 October 2010 49 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Controller PCB Replacement continued NOTE Head not shown for clarity 6 32x3 8 PPB Screw L Fu i 2 2 gt
82. isual reference only 122 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Incandescent LVS AC Input Cable Assembly 25 9663 2816 01 Rev B Refer to Figure 3 39 E 370 20 2 0 AC LINE AC LINE AcNEUT JS gt AC NEUT ACGND C y il C3 AC GND Figure 3 39 Incandescent LVS AC Input Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 123 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Arc LVS AC Input Cable Assembly 25 9663 2816 11 Rev B Refer to Figure 3 40 370 2 0 L 20 __ AC LINE AC LINE AC NEUT AC NEUT AC GND AC GND 2 0 gt 28 0 Figure 3 40 Arc LVS Input Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 124 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 LVS Chassis Ground Cable Assembly 25 9663 2817 Rev B Refer to Figure 3 41 Figure 3 41 LVS Chassis Ground Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 125 VARFXLITE VL1100 ERS LU
83. lows a Rotate center gear clockwise until alignment mark is directly facing Position 6 b Lift edge of center gear slightly so that it will not turn while at same time rotating Position 6 gear until alignment mark is directly across from center gear alignment mark Lower center gear into place and verify alignment Step 3 Set Position 5 planet gear as follows a Rotate center gear clockwise until alignment mark is directly facing Position 5 b Lift edge of center gear slightly so that it will not turn while at same time rotating Position 5 gear until alignment mark is directly across from center gear alignment mark Lower center gear into place and verify alignment Step 4 Set remaining planet gears by following same procedure When all gears are aligned rotate center gear in full rotation to verify alignments When rotating marks should align perfectly at each gear as they pass Adjust as necessary and recheck Step 5 Install flange pulley and three 4 40x5 16 PFB screws to secure gears in place 02 9664 0010 0 20 October 2010 37 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Gobo Gear Planet Alignment continued 1 Start with center gear alignment 2 Rotate center gear clockwise until alignment mark facing Position 1 open mark is directly across from Position 6 Rotate Position 6 gear until marks align Alignment Mark Align both marks 3 Align remaining gobo gears 4 Verify alignment of
84. lt system via 3 phase stepper motors High frequency drivers to reduce stationary noise when luminaire is in parked position Control by DMX512 protocol Model Specific Features Each individual configuration has the following specific features VL1100 TS Luminaire 20 9664 0001 02 Black 20 9664 0001 02 02 White 1000W Tungsten Halogen lamp source Four blade shutter framing system VL1100 TI Luminaire 20 9664 0001 03 Black 20 9664 0001 03 02 White e 1000W Tungsten Halogen lamp source Beam size iris mechanism VL1100 AS Luminaire 20 9664 0001 12 Black 20 9664 0001 12 02 White e 575W arc lamp source with external ballast unit Four blade shutter framing system Mechanical dimmer VL1100 AI Luminaire 20 9664 0001 13 Black 20 9664 0001 13 02 White e 575W arc lamp source with external ballast unit Beam size iris mechanism 4 20 October 2010 02 9664 0010 0 DESCRIPTION 7 Mechanical dimmer VL1100 TSD Luminaire 20 9664 0001 22 Black 20 9664 0001 22 02 White 1000W Tungsten Halogen lamp source 115V on board electronic IGBT dimmer Four blade shutter framing system VL1100 TID Luminaire 20 9664 0001 23 Black 20 0664 0001 23 02 White 1000W Tungsten Halogen lamp source 115V on board electronic IGBT dimmer Beam size iris mechanism VL1100 TSD230 Luminaire 20 9664 0001 32 Black 20 9664 0001 32 02 White 1000W Tungst
85. ly 72 Head Assembly Head Assembly RS LI F lt 73 Front Head Assembly u EE 74 Edge Control Zoom Dimmer amp Color Assembly eee 76 Color Changer Assembly een ee 78 Edge Barrel Assembly endet EE 81 Lens 5 Asseinbly unte e e ie e e Pat ee eerte 83 Pulley Side Rail Assembly aie Epp ege erg eee ued 84 Sensor Side Rail Assembly Aa nee een 85 Incandescent Gobo Wheel Assembly eese 86 Temperature Sensor Electrical Assembly 2 89 Arc Gobo Dimmer Bulkhead Assembly eee 90 Gobo Wheel Assembly ure cede ona eis ini 93 Gobo Wheel Pulley Assembly 3 95 Shutter 6 Rollers Assembly SS E EE 96 Beam Size Iris Assembly ns ass T Gat 99 xvi 20 October 2010 02 9664 0010 0 TABLE OF CONTENTS Rear Head Assembly stats nan eres eR Pe 101 Back Cap Assembly aida NE od anu E e Ann e 103 Yoke Assembly Yoke Legs Assembly usu u a RR tee e Re OR cd ente 105 Tilt Motor Assembly eee pent Erna nee 108 Crossmember Assembly ie ee e decere ede Bann 110 Inner Crossmember Assembly etei ss 112 Outer Crossmember Assembly enr ennrnnenn 113 Pan Motor Assembly i tne end 114 Pan Tube Assembly sau n Sum HE HER S uuu anu ac 116 Cables Arc Power
86. m adjustment Front Cover Provides frame for mounting silks frosts color correction or top hat Removed by unlatching two latches Arc Gobo Bulkhead Incandescent Gobo Bulkhead Provides six position rotatable indexable Provides six position rotatable indexable gobo wheel for projecting images gobo wheel for projecting images 02 9664 0010 0 20 October 2010 7 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Luminaire Internal Yoke Components The following illustration shows the major sub assemblies that are located in the luminaire yoke assembly Note Head assembly not shown for clarity Tilt Mechanism ARISA Pan Mechanism Yoke Arm Cover Display Side Main Controller PCB RTT Luminaire control circuit board 150W Power Supply Supplies power to electronic and motor components J Ignitor PCB Ignites lamp in arc models Internal Dimmer Powers lamp in some models 8 20 October 2010 02 9664 0010 0 DESCRIPTION 7 Arc Ballast Unit An external ballast unit is included with VL1100 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 r Lamp Connector CPO 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 A safety cable clip
87. n ausgetauscht werden sofern deren Schutzwirkung durch sichtbare Besch digung z B Spr nge oder Schrammen eingeschr nkt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN KORPERVERLETZUNGEN 1 Bei Betrieb sind die Au enfl chen der Scheinwerfer hei Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausr stung Handschuhe Augenschutz etc Bei Betrieb der Scheinwerfer ist die Lampe hei Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abk hlen wenn Sie diese austauschen Bogenlampen senden ultraviolette Strahlen aus die Hautverbrennungen und Augenentz ndungen verursachen k nnen Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen Temperaturen Sollte die Lampe zerbrechen besteht die Gefahr von K rperverletzung bzw von Feuer das von Lampenteilen ausgel st werden kann Tragen Sie beim Austausch der Lampen einen Augenschutz Die geeignete Sicherheitsausr stung Handschuhe Augenschutz sollte beim Umgang mit besch digten Lampen verwendet werden Wenn die Lampe mit blo en H nden ber hrt wird reinigen Sie sie mit denaturiertem Alkohol und einem flusenfreien Tuch bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen Wenn die Lampe besch digt oder durch Hitzeeinwirkung deformiert ist muB diese ausgetauscht werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse A In einer Wohnumgebung kann das Produkt Hochfrequenzst
88. net 37 Shutter Assembly Replacemetnt ss 39 Shutter Blade or Rack Replacement ss 41 Edge Zoom Color Bulkhead Replacement ss 43 Fan Temp Switch Assembly 44 Beam Size Iris Assembly Replacement 45 Ignitor PCB Replacement n eer deste es reet pee HS asss 46 Power Supply Replacement ss 47 Controller PCB Replacement ss 49 Tilt Encoder PCB Replacement 51 Tilt Motor Assembly Replacement nana 52 iba stat EE EE 53 Pan Motor Assembly Replacement eene rennen 54 DMX Input PCB 56 Cleaning Optical Lenses 57 Chapter 3 Illustrated Parts Breakdown Drawing Trees VL1100 Incandescent Luminaires 60 VEL1100 Arc Luminaire curtido tiara EG en dedi ios INS 62 Top Assembly Ineluded Items Kit SS 64 Included Items Kit ss 65 VET100 L minarre nuria tirent lt rt de E D ete i rid 66 Front Cover Assembly aa 69 Gel Frame Holder Assembly eo oasis 70 COT Center of Travel Flag Assembly ss 71 VL1100 Main Control Board MCB Assemb
89. ns are used to identify parts specific to certain models ABBREVIATION MopEL TI VL1100 Incandescent Luminaire w Beam Size Iris TS VL1100 Incandescent Luminaire w Shutter System Al VL1100 Arc Luminaire with Beam Size Iris AS VL1100 Arc Luminaire with Shutter System TSD115 VL1100 Incandescent with 115V Dimmer and Shutter System TID115 VL1100 Incandescent with 115V Dimmer and Beam Size Iris TSD230 VL1100 Incandescent with 230V Dimmer and Shutter System TID230 VL1100 Incandescent with 230V Dimmer and Beam Size Iris 02 9664 0010 0 20 October 2010 59 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Drawing Trees VL1100 Incandescent Luminaires VL1100 Luminaire Incandescent Versions 20 9664 0001 02 TS Rev C or 20 9664 0001 03 TI Rev C or 20 9664 0001 22 TSD115 Rev C or 20 9664 0001 23 TID115 Rev C or 20 9664 0001 32 TSD230 Rev C or 20 9664 0001 33 Head Assembly olor Gobo Lens Harness Cable Front Cover Assembly 21 9664 1000 02 TS Rev A Assembly 22 9664 1038 Rev A 21 9664 1000 03 TI Rev A 25 9663 2050 Rev K Front Head Assembly Incandescent Gobo Wheel Gel Frame Holder 21 9664 1001 02 TS Rev B Assembly Assembly 21 9664 1001 03 TI Rev B 21 9664 1200 TS TI TSD TID Rev A 21 9664 1028 Rev A Gobo Wheel Assembly Crossmember Assembly 21 9665 1201 Rev A 21 9664 1811 01 TS TI Rev C 21 9664 1811 11 AS AI Rev C 21 9664 1811 21 TSD TID Rev C Shutter 6 Rollers Assembly 21 9663 1350 Rev D
90. on 31 53 6537 0001 1 EA SCREW 4 40 X 5 8 PPB 32 53 6543 0001 1 EA SCREW 6 32 X 3 8 PPB 33 53 6558 0015 l EA SCREW 6 32X 3 8 PPB 34 53 6598 0312 7 EA SCREW 4 40 X 5 16 PFB 35 53 6600 0001 3 EA SCREW 4 40 X 5 16 PPB 36 53 6614 0001 2 EA SCREW 6 32 X 5 8 PPB 37 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 38 54 1259 0002 2 EA FLANGE BEARING 1 4 SHAFT 39 54 2045 0002 1 EA BELT TIMING 40 54 2050 0001 1 EA BELT TIMING MXL 080 PITCH 93 TEETH 1 4 WD SILICONE 41 54 9663 1220 1 EA BELT GOBO DRIVE 42 55 2123 0003 2 EA WASHER WAVE SPRING 43 55 3301 0006 1 EA WASHER 6 FLAT SS 44 55 6506 0010 1 EA SPACER 0 250 OD X 0 140 ID X 0 375 LG ALUM 45 55 6506 0029 l EA SPACER 9 32 RND 0 312 LG 0 253 THRU AL 46 55 6512 0001 2 EA WASHER 4 SPLIT LOCK 47 55 6538 0001 1 EA WASHER 6 LOCK INTERNAL TOOTH 48 55 6568 0061 2 EA SPRING EXTENSION 0 250 OD X 2 00 LONG 49 55 6621 0001 1 EA WASHER 4 FLAT ZINC 50 55 6659 0007 2 EA STANDOFF 1 4 HEX 6 32 0 250 LG MF ALUM 51 55 6677 0039 2 EA WASHER FLAT 0 438 OD 0 219 ID 0 04 THK 52 55 6677 0040 4 EA WASHER FLAT 0 624 OD 0 145 ID 0 03 THK 53 55 6706 0001 1 EA GROMMET 9 32 ID 9 16 OD 1 4T SI 54 55 6818 0002 1 EA STANDOFF 45 DEGREE NYLOCK KURLY LOK 02 9664 0010 0 20 October 2010 91 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Arc Gobo Dimmer Bulkhead continued 21 35 28 or Lae 35 x2 2 5 2 Figure 3 21 Arc
91. only 138 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Dimmer to LVS Cable Assembly 25 9663 2826 Rev A Refer to Figure 3 55 Figure 3 55 Dimmer to LVS Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 139 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Dimmer to Controller Cable Assembly 25 9663 2026 Rev 0 Refer to Figure 3 56 Figure 3 56 Dimmer to LVS Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 140 20 October 2010 02 9664 0010 0 ILLUSTRATED PARTS BREAKDOWN 3 Dimmer to Lamp Socket Cable Assembly 25 9663 2037 Rev 0 Refer to Figure 3 57 3 50 DIMMER LINE FROM LINE TO DIMMER NEUT LAMP SOCKET DIMMER NEUT 0 75 1 00 20 0 Ref Figure 3 57 Dimmer to LVS Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 141 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Notes 142 20 October 2010 02 9664 00100 APPENDIX A Technical Bulletins VL1100 ERS Luminaire Technical Bulletins The following table identifies the current technical bulletins associated with the VL1100 ERS luminaire These improvements have been incorporated into this manual Te
92. ont cover Refer to Front Cover Removal on page 29 CAUTION The rear assembly is heavy and will remain attached by lamp wires Place luminaire on tech bench before removing rear assembly Step 3 At side rails remove four 10 32x5 8 PPB screws and 10 split lock washers Figure 2 12 Side rail spacers will come loose also Pull rear head assembly away from front head assembly Step 4 At gobo bulkhead disconnect all motor and sensor wiring Step 5 At side rails remove four 10 32x3 8 PPB screws and 10 split lock washers Step 6 Remove gobo bulkhead Step 7 Replace by doing steps 2 through 6 in reverse 02 9664 0010 0 20 October 2010 35 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL RG Wheel Bulkhead Replacement contin ue Gobo Bulkhead 10 Split Lock Washers 10 32x3 8 PPB Screw Side Rail Spacer Front Assembly NOTE Incandescent model gobo bulkhead not shown Figure 2 12 Gobo Bulkhead Assembly Replacement 36 20 October 2010 02 9664 0010 0 MAINTENANCE Gobo Gear Planet Alignment Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly Use the following procedure to re align the gears in the event the gobo wheel is disassembled To re align gobo gears Step 1 Place center sun gear at starting point so that alignment mark is directly facing Position 1 open as shown in Figure 2 13 Step 2 Set Position 6 planet gear as fol
93. op hat and close latch Gel Silk or Frost lt 5 Press Up and Turn Z Latch Head Assembly Accessory Frame NOTE The accessory frame is not a Vari Lite accessory Figure 2 6 Installing a Frame or Top Hat 28 20 October 2010 02 9664 0010 0 MAINTENANCE Front Cover Removal Parts ASSY FRONT COVER Tools 2 Phillips screwdriver To remove and replace front cover Step 1 Disconnect luminaire AC input cable from power source Step 2 At head assembly press in front cover latches to release Figure 2 7 Step 3 Pull cover straight out until stopped by tether Step 4 Disconnect tether by removing 8 32x1 2 PFB screw and 8 32 Keps nut as shown Step 5 Remove cover Step 6 Replace front cover by doing steps 2 through 5 in reverse Ensure latches lock into place Head Assembly Front Cover Latch x2 Press in to release cover NOTE Yoke not shown for clarity Remove this 8 32x1 2 screw and nut to disconnect tether Figure 2 7 Front Cover Removal Replacement 02 9664 0010 0 20 October 2010 29 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Rear Head Assembly Removal This procedure is necessary in order to access some components such as the gobo wheel bulkhead and shutter assembly Refer to as needed Tools 2 Phillips long handle screwdriver To remove rear head assembly Step 1 Disconnect luminaire AC input cable from power source
94. or View Alignment Hole 2 Figure 2 1 Removing Incandescent Backcap Step 3 Carefully pull backcap straight out of rear head assembly It will still be attached by lamp wires and tether Step 4 At backcap flip two bail clamps outward Figure 2 2 Step 5 Flip two base clamps outward away from socket Step 6 Grip lamp by base and firmly install in socket 02 9664 0010 0 20 October 2010 23 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Step 7 Close base and bail clamps locking into place Do not touch lamp CAUTION with bare fingers 1 Flip bail clamps outward Flip base clamps outward Install lamp firmly pressing into place Bail Clamps Figure 2 2 Installing Incandescent Lamp in Socket Step 8 Re install backcap ensuring that alignment studs and holes are aligned Figure 2 1 Step 9 Align lamp Refer to Align Lamp For Maximum Beam Irradiance on page 27 24 20 October 2010 02 9664 00100 MAINTENANCE Lamp Replacement Arc Model Parts 575 WATT ARC LAMP MSR575HR 71 2528 0575 AS AI 575 WATT LONG LIFE ARC LAMP MSD575HR 71 2554 0575 AS AI Tools 2 Phillips screwdriver cotton gloves lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life If touched use alcohol and cotton cloth to thoroughly clean glass portion of lamp CAUTION Wear cotton gloves or other covering while installing lamp Touching To install arc lamp Ste
95. ot to pull metal spring clip carrier back too far or it will not close properly Center of Wheel Figure 2 9 Rotating Gobo Replacement Cleaning 20 October 2010 02 9664 00100 MAINTENANCE Gobo Index Timing Belt Alignment The index timing belt 54 9663 1220 must be aligned so that the mechanism clocks properly This belt is installed around the index gear and top gear of the gobo wheel refer to Figure 2 11 The wheel position belt 54 2045 0002 is installed around the wheel position gear and bottom gear of the gobo wheel and does not require alignment Each belt is also routed around one pulley as shown in Figure 2 11 Note The alignment procedure is the same for both arc and incandescent versions Use the following procedure to re align the index timing belt in the event it slips or the gobo wheel is removed from the bulkhead This procedure assumes that the wheel has been removed from the bulkhead assembly If you are simply re aligning the belt Step 2 can be skipped To align index timing belt Step 1 At large gear align one of Index Timing Belt s clock marks with small groove at inside of Index Gear The Index Timing Belt contains two clock marks two ridges as seen in Figure 2 10 Index Timing Belt Index Gear Larger Gear Arc Gobo Bulkhead Gear Clock Mark Groove Belt Clock Mark Ridge Index Timing Belt Figure 2 10 Aligning Index Gear Groove and Clock Mark 0
96. p 1 Remove power from luminaire Step 2 At backcap gradually loosen two 10 32x2 3 8 PPSS black screws Figure 2 3 a few turns at a time until backcap is free Screws must be alternately loosened to prevent one side from locking up Do not touch lamp Rear Head CAUTION with bare fingers Assembly Backcap Align when re installing Alignment Stud x2 10 32x2 3 8 PPSS Holes and studs MUST be Black CAUTION aligned when re installing loosen each gradually Backcap Interior View Alignment Hole x2 Figure 2 3 Removing Arc Backcap 02 9664 0010 0 20 October 2010 25 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Step 3 Grip lamp by base and firmly install in socket Figure 2 4 Do not touch lamp CAUTION with bare fingers Socket Lamp LY Install lamp firmly pressing into place Figure 2 4 Installing Arc Lamp in Socket Step 4 Re install backcap ensuring that alignment studs and holes are aligned Figure 2 3 Step 5 Align lamp Refer to Align Lamp For Maximum Beam Irradiance on page 27 26 20 October 2010 02 9664 00100 MAINTENANCE Align Lamp For Maximum Beam Irradiance After a new lamp is installed in either the incandescent or arc version of the luminaire it will be necessary to align the lamp to optimize the beam Tools None See Warning A WARNING Backcap and adjustment knobs will be HOT during lamp operation
97. re remplac e AVERTISSEMENT INTERFERENCE RF 1 Cetappareil est de Classe A Dans un environnement domestique cet appareil peut causer des interf rences radio et si c est le cas l utilisateur peut avoir prendre des mesures ad quates CONSID RATIONS DES CARACT RISTIQUES DE LAMPES ARC 1 Apr s une interruption de courant ou une baisse importante de voltage les lampes arc mettent du temps avant de se rallumer Dans certains cas la lampe se rallumera automatiquemet apr s s tre refroidie Cela d pend de la mani re dont le syst me est r gl pour le statut de mise en marche de la lampe L ON LOFF 2 La position Br ler est Universelle x 20 October 2010 02 9664 0010 0 AVISO SOBRE SEGURIDAD Aviso sobre Seguridad Es muy importante leer TODA la informaci n e instrucciones sobre seguridad que se indica en este manual as como en los documentos adjuntos antes de instalar y operar los productos descritos Se debe prestar atenci n a todos los avisos y advertencias durante la instalaci n y uso de este producto Los s mbolos de seguridad usados en este manual son los siguientes A CUIDADO indica posibles da os al producto A ADVERTENCIA indica posibles lesiones o muerte a las personas LA INFORMACI N GENERAL RELACIONADA A LA PROTECCI N CON TRAGOLPES DE CORRIENTE EL CTRICA INCENDIO EXPOSICI N EXCESIVA A RADIACI N ULTRA VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE ADVERTE
98. remove four 8 32x1 2 PFB screws four 10 32X5 8 PPB screws and four 10 lock washers as indicated in Figure 2 18 Step Step 5 At front remove four 8 32 Keps nuts and remove assembly Note location of attached tether Step 6 Replace assembly by doing steps 2 through 5 in reverse Side Rail 8 32x1 2 PFB Screws Edge Zoom Color LY Assembly NOTE Yoke not shown for clarity Note where tether is attached and reinstall in same place after replacement repair 8 32 Keps Nut 10 Lock Washers 10 32x5 8 PPB Screw Figure 2 18 Edge Zoom Color Bulkhead Replacement 02 9664 0010 0 20 October 2010 43 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Fan Temp Switch Assembly Replacement Note Fan does not operate under normal luminaire operating conditions Parts CABLE ASSEMBLY FAN TEMP SWITCH Tools 2 Phillips screwdriver To remove and replace fan temp switch assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove edge dimmer color bulkhead Refer to Edge Zoom Color Bulkhead Replacement on page 43 Step 3 At fan remove four 6 32 x 3 8 PPSS black screws and 6 32 nylon insert hex nuts and remove fan temp switch assembly Figure 2 19 Step 4 Replace assembly by doing steps 2 and 3 in reverse 6 32x3 8 PPSS Screw 6 32 Nylon Insert Hex Nut Figure 2 19 Fan Temp Switch Assembly Replacement 44 20 October 2010
99. rrier is upward CAUTION Do not touch gobos with bare fingers Wear cotton gloves or other covering while replacing Clean with glass cleaner and soft cloth if required CAUTION Do not pull metal spring clip carrier back too far or it will not close properly gt gt Step 5 If applicable carefully pull current gobo up and out of carrier Gobo can be easily scratched on sides of carrier if not careful Step 6 Carefully install new gobo orienting side marked This Edge In toward center of gobo wheel and side marked Lamp Side mirror finish toward lamp Gobo can be easily scratched on sides of carrier if not careful Ensure gobo is firmly set in carrier grooves Step 7 Re install front cover 02 9664 0010 0 20 October 2010 31 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Rotating Gobo Replacement continued Inside Edge orient toward center of whee CAUTION Gobo MUST be oriented with side marked This Edge In toward center of wheel and side marked Lamp Side toward lamp If not oriented properly gobo will break Be careful not to scratch gobo on side of carrier when installing Rotate until open end of carrier is up Gobo Positions Lamp Side mirrored Closed End Sensor orient toward luminaire lamp Gear Open End Gobo Wheel Front View Front Cover Gobo black side Lamp End Rotating Gobo Wheel AN CAUTION Be careful n
100. s luminaires VARI LITE ont t con us pour tre utilis s uniquement avec certaines lampes Philips et Osram HID V rifier 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 tre fix s sur tout type de surface tant que les directives de montage sont respect es Voir les explications d taill es dans ce guide 3 Neremplacer les fusibles qu avec ceux du m me type ayant les m mes caract ristiques V rifier la distance respecter entre les mat riaux combustibles ou les objets illumin s et les luminaires AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les luminaires sont con us pour une utilisation au sec uniquement Une exposition la pluie et l humidit risque d endommager le luminaire D brancher l appareil avant de proc der la r vision de tout mat riel 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9664 0010 0 20 October 2010 ix VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL AVERTISSEMENT gt DIRECTIVES POUR SE PROTEGER 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
101. s when the sensor is not aligned tab not at sensor typically a non zero DMX value e A Closed reading occurs when the sensor is aligned tab in or at sensor typically a zero DMX value Optical sensors read high when the sensor is Closed High value 5 volts typically 4 9 volts Low value 0 volts or up to approximately 0 2 volts Notes regarding specific mechanisms The gobo wheel reads high when the tab is in the sensor The gobo index rotation reads low when the slot is in the sensor 20 October 2010 02 9664 0010 0 MAINTENANCE Pan and tilt sensors read high when the tab is in the sensor The mechanism calibrates to the edge and its tab covers 50 of travel Pan and tilt encoders are best read with a scope to read the encoder ticks Notes regarding lamp control The douse command applies 5v to the out line When the start command is given this drops to Ov This can be measured at the MCB at the ballast connection The Out pin of the 5 pin connector should read Ov when the lamp is striking or On Con fig gt Lamp gt Power gt On When the douse command is given Config gt Lamp gt Power gt Off the reading should changed to 5v Likewise the standby circuit goes to standby when 5v is received on the standby line Equally if 5v is applied to the standby line the lamp will go into standby mode and if SV is applied to the Out line the lamp will douse 02 9664 0010 0 20 October 2010 21
102. t 2 CONTROLLER PCB 3 WHT wi N WHT 5 PCB J3 5 GRN ip J1 DMX VARI LITE PIN COLOR SIGNAL SIGNAL 1 N C 2 RED COM IN BDCAST 3 BLACK COM IN BDCAST 4 WHITE COM OUT REPLY 5 GREEN COM OUT REPLY Figure 3 45 Data I O Link Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 02 9664 0010 0 20 October 2010 129 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL LVS DC Output Cable Assembly 25 9663 2824 Rev A Refer to Figure 3 46 18 0 2 0 24V RED 5 24V 1 V RED 4 24V 3 5V GND 2 GND O BLK Eie TO TO VL1100 LVS DC CONTROLLER OUTPUT PCB J2 Figure 3 46 LVS DC Output Cable Assembly NOTE Cable assemblies are sold as complete assemblies only Cable assemblies are shown for visual reference only 130 20 October 2010 02 9664 00100 ILLUSTRATED PARTS BREAKDOWN 3 Incandescent Power Input Cable Assembly 25 9663 2030 Rev A Refer to Figure 3 47 52 6274 2316 STRAIN RELIEF SKINTOP FLEXTYPE PG13 BLK L 40 BRN a 4 0 BLU 06 M GRN YEL 4 0 1 5 44 0 42 5 i dics GND Figure 3 47 Incandescent Power Input Cable Assembly NOTE Cable assemblies are sold as complete assemblies only except as noted above Cable assemblies are shown for visual reference only 02 9664 0
103. t Cable Assembly 25 9663 2015 01 Rev C Incandescent LVS AC Input Cable Assembly 25 9663 2816 01 Rev B Data I O Link Cable Assembly 25 9663 2022 Rev B Incandescent Power Input Cable Assembly 25 9663 2030 Rev A continued from previous page Yoke Legs Assembly 21 9664 1850 01 TS TI Rev B or 21 9664 1850 21 TSD TID 115V DIM Rev B or 21 9664 1850 31 TSD TID 230V DIM Rev B Tilt Motor Assembly 21 9665 8816 Rev B Cable Assembly 25 9663 2817 Rev B Tilt COT Cable Assembly 25 9663 2002 Rev A LVS DC Output Cable Assembly 25 9663 2824 Rev A Pan Tilt Control Cable Assembly 25 9664 2020 Rev A Abbreviation Meaning TI VL1100 TI Incandescent with Beam Size Iris TS VL1100 TS Incandescent with Shutter System TID VL1100 TI Incandescent with Beam Size Iris and On Board IGBT Dimmer 115 or 230V TSD VL1100 TS Incandescent with Shutter System and On Board IGBT Dimmer 115 or 230V Figure 3 2 VL1100 Incandescent Luminaires Drawing Tree Part 2 02 9664 0010 0 20 October 2010 61 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL VL1100 Arc Luminaires VL1100 Luminaire Arc Versions 20 9664 0001 12 AS Rev C or 20 9664 0001 13 Al Rev Head Assembly olor Gobo Lens Harness Cable Front Cover Assembly 21 9664 1000 12 AS Rev A Assembly 22 9664 1038 Rev A 21 9664 1000 13 Al Rev A 25 9663 2050 Rev K Front Head Assembly Arc Gobo Dimmer Bulkhead Gel Frame Holder 21
104. ter assembly by doing steps 2 through 7 in reverse Gobo Wheel Bulkhead 10 32x3 8 PPB Screws 10 Lock Washers 10 Lock Washers 10 32x5 8 PPB Screws Shutter Assembly Rear Head Assembly Side Rail Spacers NOTE Head Assembly Yoke not shown for clarity Figure 2 15 Shutter Assembly Replacement 20 October 2010 02 9664 00100 MAINTENANCE Shutter Blade or Rack Replacement Parts as required BLADE SHUTTER COATED SIDE A BLADE SHUTTER COATED SIDE B RACK SHUTTER Tools 2 Phillips screwdriver To remove and replace a shutter blade or rack Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove shutter assembly Refer to Shutter Assembly Replacement on page 39 Step 3 Place shutter assembly on work bench motor side down Remove four 02 9664 0010 0 6 32x1 4 PFS screws and remove cover plate Figure 2 16 6 32x1 4 Cover Plate PFS Screw Layer 4 bt 6 32 1 4 PFS Screw N _ Cover X Separator N gt Spacer LENZ Beveled Blade Separator Shutter Stiff Separator Assembly Spacer Straight Blade Separator Stiff Separator Layer 1 Spacer Beveled Blade 1 60 gt eparator Lal WE Stiff Separator Uf Spacer qi OA Rack 8 CAUTION Straight Blade 4A Do not touch shutter blades with bare NR fingers Clean with soft cloth if touched Separator Figure 2 16 Shutter Assembl
105. their sensor when at a zero position if the sensor is not detected within 3 seconds the mechanism will recalibrate This applies to all except pan and tilt pan and tilt are corrected continuously if required by encoders fitted to the motor shaft It is possible to recalibrate sections of the luminaire from a console This allows greater flexibility and speed by only forcing a recalibration on specific mechanisms Partial recalibration values e Hold DMX value 102 for 3 seconds then 0 recalls color CYM Frost and Dimmer Hold DMX value 114 for 3 seconds then 0 recalls gobos Gobo Wheels Index and Dimmer Hold DMX value 128 for 3 seconds then 0 recalls lenses Edge Zoom or Dimmer Hold DMX value 140 for 3 seconds then recalls Dimmer and Shutter or Iris as equipped Sensor Testing Mechanisms within the VL1100 luminaire that are equipped with a sensor have an optical sensor The VL1100 master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an oscilloscope for pan tilt encoder readings The values can be used to determine whether a circuit is opening correctly or for further troubleshooting Guidelines The values will change depending on whether the sensor reading is Open or Closed s a general rule if a change occurs from 5 volts to 0 volts or visa versa then it is working An Open reading occur
106. y Breakdown 20 October 2010 41 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL 42 Step 4 Carefully remove plates and components until blade or rack to be replaced is reached Install new component s as required Step 5 Re assemble shutter s four layers Ensure that components are oriented and aligned as shown in Figure 2 17 Note The difference between the two types of shutter blades can be found by examining the main edge Coated Side A blades 12 9663 1323 are beveled and the Coated Side B blades 12 9663 1324 are not Shutter Blade 1 Align main edge of blade with small hole in shutter rack gt Shutter Blade Rack a Ne 2 Straight Beveled Blade _ Blade Install shutter blades with dark mirror coating facing down DO NOT Layer 2 Layer 1 touch blades with 4 bare fingers Straight 8 Blade E i i f Beveled Blade Layer 3 Layer 4 Figure 2 17 Shutter Assembly Layer Orientation 20 October 2010 02 9664 0010 0 MAINTENANCE Edge Zoom Color Bulkhead Replacement Parts ASSEMBLY EDGE CONTROL DIMMER AND COLOR Tools 2 Phillips screwdriver To remove and replace edge zoom color bulkhead Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front cover Refer to Front Cover Removal on page 29 Step 3 At edge zoom color assembly disconnect wiring harness connections 4 At side rail
107. you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly and cannot be removed intact If you order a CN NN replacement motor Item 4 also order the pulley Item 2 f Apply one drop of Loctite 603 to motor shaft Contact Vari Lite Customer Service for installation information Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above The dimension is from bottom of code wheel to the top of the motor mount Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Figure 3 29 Tilt Motor Assembly 02 9664 0010 0 20 October 2010 109 VARFXLITE VL1100 ERS LUMINAIRE SERVICE MANUAL Crossmember Assembly 21 9664 1811 01 TS TI 21 9664 1811 11 AS AI Rev C Rev C 21 9664 1811 21 TSD TID Rev C Refer to Figure 3 30 No Item Qty UM Description 1 10 9663 1808 l EA TOGGLE PAN 2 10 9663 1809 1 EA ACTUATOR TOGGLE PAN 3 10 9663 1827 2 EA NUT PLATE PAN TILT MOTOR 4 10 9663 1844 1 EA SHIELD WIRE PAN 5 10 9663 1846 1 EA TETHER PAN TUBE SAFETY 6 10 9663 1881 1 EA FOAM BLOCK SAFETY TETHER 7 10 9663 1890 1 EA PULLEY PAN 8 10 9685 0534 1 EA PLATE PAN TUBE COVER 9 21 9664 1812 1 EA ASSY INNER CROSSME

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