Download Vari Lite Virtuoso DX Service manual

M a n u a l
VL1000™ ERS
Luminaire
S e r v i c e
02.9663.0010
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
VARI❋LITE®, Artisan®, VL2®, and VLD® are trademarks owned by Vari-Lite, Inc., 201 Regal Row, Dallas TX 75247 USA.
and are registered in the United States and other countries.
VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, Virtuoso™,
Virtuoso™ DX, VARI❋LITE Visionary™, VL1™, VL2B™, VL2C™, VL3™, VL4™, VL5™, VL5Arc™, VL5B™, VL6™,
VL6B™, VL6C™, VL7™, VL7B™, VLM™, APS6™, C3™, ArtisanVLQ™, SPC-36™, UDM™, AutoTruss™, SmartDMX™,
Smart Repeater™, Series 100™, Series 200™, Series 300™, Series 2000™, Series 3000™, DICHRO❋WHEEL™,
DICHRO❋TUNE™, VACU❋DEP™, VARI❋IMAGE™, VARI❋BEAM™, and the Vari-Lite Asterisk are also trademarks
owned by Vari-Lite, Inc.
VARI❋LITE® products are protected by one or more of the following patents, and other pending patent applications worldwide:
U. S. Patents No. 6,123,436; 6,113,252; 6,046,861; 6,031,749; 6,011,640; 5,969,868; 5,959,768; 5,934,794; 5,882,107; 5,829,868;
5,825,548; 5,798,619; 5,774,273; 5,769,527; 5,758,956; 5,728,994; 5,640,061; 5,590,954; 5,454,477; 5,432,691; 5,367,444;
5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806; 4,972,306; 4,800,474;
4,779,176; 4,701,833; 4,602,321;
U. S. Design Patents No. 439,356; 420,332; 417,300; 415,301; 413,995; 377,338; 366,712; 359,574; 350,408; 347,113;
Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646,588; 586,095; 576,400; 546,433;
Australia Design Patents No. 128,796; 128,795;
Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058; 1,181,795;
Canada Design Patents No. 81,234; 81,233; 76,046;
European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710; 0 495 305; 0 474 202; 0 379 970; 0 253 082;
0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068;
Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89
166.9; 37 68 727.1; 37 51 804.6; 37 50 201.8; 35 87 270.5; 32 79 888.1; 32 74 291.6;
Germany Design Patents No. M 98 01 745.4; M 96 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 951.2; M 499 03 583.6; M
498 11 203.9; G 93 12 884.3;
Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328;
Spain Utility Model Patent No. 2.031.748;
Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573;
Greece Patent No. 910.400.544;
Hong Kong Patents No. 965/1990; 285/1987;
Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241; 1,723,825;
1,683,007; 1,533,011;
Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1,072,598; 1,060,414;
1,002,123;
Korea Patents No. 76,310; 42,639; 283,770; 181,180;
Korea Design Patents No. 209,896; 209,895;
Mexico Patent No. 180,148;
Singapore Patents No. 663/90; 134/87;
Taiwan Patents No. 78,726; 66,975; 65,380; 28,275;
United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.
Apple®, Macintosh®, and FireWire® are registered trademarks of Apple Computer, Inc.
Neutrik®, PowerCon®, and EtherCon® are registered trademarks of Neutrik, Inc.
All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their
respective companies or organizations.
VL1000™ ERS Luminaire Service Manual
The information furnished in this manual is for informational use only and is subject to change without notice. Vari-Lite, Inc.
assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual. All information and graphic
representations are property of Vari-Lite, Inc. 201 Regal Row, Dallas, Texas 75247 USA.
Version as of: 23-Oct-02
Part number: 02.9663.0010 D
VL1000™ ERS Luminaire Service Manual
©2002 Vari-Lite, Inc. All Rights Reserved.
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HOW TO OBTAIN WARRANTY SERVICE
How To Obtain Warranty Service
A copy of the Vari-Lite, Inc. Limited Warranty was included in the shipping package
for this VARI❋LITE® product.
To obtain warranty service, please contact customer service at 1-877-VARI-LITE
(1-877-827-4548) or [email protected] and request a Return Material
Authorization (RMA) for warranty service. You need to provide the model and serial
number of the item being returned, a description of the problem or failure and the
name of the registered user or organization. If available, you should have your sales
invoice to establish the date of sale as the beginning of the warranty period.
Once you obtain the RMA, pack the product in its original packing material along with
a copy of your invoice (if available) and write the RMA number legibly on or near the
shipping address label. Return the unit, freight prepaid to:
Vari-Lite, Inc.
201 Regal Row
Dallas, TX 75247
Attention: Warranty Service
As stated in the warranty, it is required that the shipment be insured and FOB our
service center.
Manual Revision History
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PAGE NUMBER
CHANGE NUMBER
Title Page – xviii
D
1-191
D
VERSION
DATE
Basic
14-Mar-02
Revision A
25-Apr-02
Revision B
02-May-02
Revision C
18-Jun-02
Revision D
23-Oct-02
23-Oct-02
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Compliance Notice
FCC
This equipment has been tested and found to comply with the limits for a Class A
digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when this equipment is operated in
a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with Vari-Lite system,
service, and safety guidelines, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her
own expense.
Declaration of Conformity
We declare, under our sole responsibility, that this product complies with the relevant
clauses of the following standards and harmonized documents:
Safety
EN 60598-1:1997 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989 Specification for Luminaires for Stage and Studio Lighting
EMC
EN 55022A:1994 Radiated and Conducted Emissions
EN 50082-1:1997 Generic Immunity Standard
We certify that the product conforms to the protection requirements of council directives: 73/23/EEC (LVD) and 89/336/EEC (EMC)
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SAFETY NOTICE
Safety Notice
It is extremely important to read ALL safety information and instructions provided in
this manual and any accompanying documentation before installing and operating the
products described herein. Heed all cautions and warnings during installation and use
of this product.
Safety symbols used throughout this manual are as follows:
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.
GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND
INJURY TO PERSONS CAN BE FOUND BELOW.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE
1. VARI❋LITE® luminaires have been designed for use only with certain Philips and Osram
HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps.
Installing another type of lamp may be hazardous.
2. Luminaires may be mounted on any type of surface as long as mounting instructions are
followed. See instructions detailed in this manual.
3. Replace fuses with same type and rating only.
4. Note distance requirement from combustible materials or illuminated objects for
VARI❋LITE® luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARI❋LITE® luminaires are designed for dry locations only. Exposure to rain or
moisture may damage luminaire.
2. Disconnect power before servicing any VARI❋LITE® equipment.
3. Servicing to be performed by qualified personnel only.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE
EXPOSURE TO UV RADIATION
1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO
NOT look directly at lamp.
2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet
screens shall be changed if they have become visibly damaged to such an extent that their
effectiveness is impaired. For example, by cracks or deep scratches.
WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS
1. Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety
equipment (gloves, eye protection, etc.) when handling and adjusting hot equipment and
components.
2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to
cool before replacing.
3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye
inflammation. Additionally, arc lamps operate under high pressure at very high
temperatures. Should the lamp break, there can exist a danger of personal injury and/or
fire from broken lamp particles being discharged.
4. Wear eye protection when relamping.
5. Appropriate safety equipment (gloves, eye protection) should be used when handling
damaged lamps.
6. If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with
lint-free cloth before installing or powering up the luminaire.
7. The lamp shall be changed if it has become damaged or thermally deformed.
WARNING:
RF INTERFERENCE
1. This is a Class A product. In a domestic environment this product may cause radio
interference, in which case, the user may be required to take adequate measures.
ARC LAMP CHARACTERISTIC CONSIDERATIONS
1. Arc lamps require a period of time to relight after a power 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.
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SICHERHEITSHINWEISE
Sicherheitshinweise
Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem
Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin
beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und
dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
VORSICHT - weist auf möglichen Produktschaden hin.
WARNUNG - weist auf mögliche Körperverletzung und Lebensbedrohung hin.
NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE
UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARI❋LITE®-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Philips
und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp (MSR400,
MSR575HR etc.), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines
anderen Lampentyps kann gefährlich sein.
2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die
Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.
3. Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Stärke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARI❋LITE®-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARI❋LITE®-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen
oder Feuchtigkeit können die Scheinwerfer beschädigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE®-Geräten
beginnen.
3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG
1. Viele VARI❋LITE®-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN
1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkühlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Körperverletzung bzw. von Feuer, das von Lampenteilen ausgelöst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.
6. Wenn die Lampe mit bloßen Händen berührt wird, reinigen Sie sie mit denaturiertem
Alkohol und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in
Betrieb nehmen.
7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstörungen verursachen. In diesem Fall müssen eventuell geeignete
Maßnahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach
Abkühlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.
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NOTES DE SÉCURITÉ
Notes de sécurité
Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en
marche, il est extrêmement important de lire TOUS les renseignements et TOUTES
les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe.
Tenir compte de tous les avertissements et suivre toutes les précautions pendant
l’installation et l’utilisation de cet appareil.
Les symboles de sécurité utilisés dans ce guide sont les suivants :
ATTENTION Ce symbole annonce que l’appareil risque
d’être endommagé.
AVERTISSEMENT Ce symbole annonce qu’il y a risque
d’accident grave ou même fatal.
CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE
PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES , LES INCENDIES,
L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRAÎNER DES BLESSURES.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES
1. Les luminaires VARI❋LITE® ont été conçus pour être utilisés uniquement avec certaines
lampes Philips et Osram HID. Vérifier le type de lampe (MSR400, MSR575HR etc.)
avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un
danger.
2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de
montage sont respectées. Voir les explications détaillées dans ce guide.
3. Ne remplacer les fusibles qu’avec ceux du même type, ayant les mêmes caractéristiques.
4. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et
les luminaires VARI❋LITE®.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES
1. Les luminaires VARI❋LITE® sont conçus pour une utilisation au sec uniquement. Une
exposition à la pluie et à l’humidité risque d’endommager le luminaire.
2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE®.
3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE
AUX RAYONS UV
1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des
rayons UV. NE PAS fixer son regard sur la lampe.
2. L’utilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages,
lentilles ou écrans ultraviolet visiblement endommagés au point que leur efficacité en est
affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT
ENTRAÎNER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche.
Pour manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la
peau et une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute
tension à de très hautes températures. Si la lampe se casse, les particules de la lampe
cassée peuvent causer blessures et/ou incendie en s’éparpillant.
4. Se protéger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier
des lampes endommagées.
6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool dénaturé et
l’essuyer avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire.
7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être
remplacée.
AVERTISSEMENT:
INTERFÉRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures
adéquates.
CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC
1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet après s’être refroidie. Cela dépend de la manière dont le système est réglé
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brûler est Universelle.
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AVISO SOBRE SEGURIDAD
Aviso sobre Seguridad
Es muy importante leer TODA la información e instrucciones sobre seguridad que se
indica en este manual así como en los documentos adjuntos antes de instalar y operar
los productos descritos. Se debe prestar atención a todos los avisos y advertencias
durante la instalación y uso de este producto.
Los símbolos de seguridad usados en este manual son los siguientes:
CUIDADO, indica posibles daños al producto.
ADVERTENCIA, indica posibles lesiones o muerte a las
personas.
LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CONTRAGOLPES DE CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN
EXCESIVA A RADIACIÓN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO
1. Las luminarias VARI❋LITE® han sido diseñadas para ser usadas solamente con algunas
lámparas HID Philips y Osram. Tome nota del tipo de lámpara (MSR400, MSR575HR
etc.) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalación. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificación.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARI❋LITE®.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE
ELÉCTRICO
1. Las luminarias VARI❋LITE® están diseñadas solamente para lugares secos. La
exposición a la lluvia o humedad pueden dañar la luminaria.
2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE®.
3. El servicio debe ser realizado solamente por personal calificado.
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA
1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación
UV. NO mire directamente a la lámpara.
2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores,
lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un
equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que están calientes.
2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la
energía y deje que la lámpara se enfríe antes de reemplazarla.
3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamación a los ojos. Además, las lámparas de arco operan a alta
presión y muy alta temperatura. Si la lámpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se
caen.
4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.
5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando
trabaje con lámparas dañadas.
6. Si toca la lámpara con las manos, limpie la lámpara con alcohol desnaturalizado y con tela
sin pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lámpara si está dañada o deformada termicamente.
ADVERTENCIA:
INTERFERENCIA RF
1. Este es un producto de Clase A. En el ambiente de la casa este producto puede ocasionar
radiointerferencia, en cuyo caso, el usuario debe tomar las medidas adecuadas.
CONSIDERACIONES SOBRE LAS CARACTERÍSTICAS DE LA LÁMPARA DE
ARCO
1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de
una interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara
se volverá a iluminar en forma automática después que se ha enfriado dependiendo de la
configuración del sistema de energía de la lámpara (L ON / L OFF) (L encendida / L
apagada).
2. La posición de encendido es universal.
xii
23-Oct-02
02. 9663.0 010 D
SAFETY NOTICE (JAPANESE)
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02.9 663.00 10 D
23-Oct-02
xiii
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
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xiv
23-Oct-02
02. 9663.0 010 D
TABLE OF CONTENTS
Table of Contents
Introduction
Disclosure ....................................................................................................................
About This Manual ......................................................................................................
Additional Documentation...........................................................................................
Customer Service .........................................................................................................
Technical Bulletins and Notices...................................................................................
1
1
1
2
2
Chapter 1. Description
Features
Standard Features......................................................................................................... 4
Model Specific Features .............................................................................................. 4
Component Descriptions
External Luminaire Components ................................................................................. 5
Luminaire Internal Head Components......................................................................... 6
Luminaire Internal Yoke Components ......................................................................... 7
Arc Ballast Unit ........................................................................................................... 8
Principles of Operation
VL1000 Incandescent Source Luminaire..................................................................... 9
VL1000 Incandescent Block Diagram .................................................................. 9
VL1000 Incandescent Cable Routing.................................................................. 10
VL1000 575W Arc Source Luminaire....................................................................... 11
VL1000 Arc Block Diagram ............................................................................... 11
VL1000 Arc Cable Routing ................................................................................ 12
VL1000 Arc Ballast Unit ........................................................................................... 13
Ballast Block Diagram ........................................................................................ 13
Chapter 2. Maintenance
Testing
Running Parameter Tests ...........................................................................................
Maintenance Procedures
Lamp Replacement (Incandescent Model) ................................................................
Lamp Replacement (Arc Model) ...............................................................................
Align Lamp For Maximum Beam Irradiance ............................................................
Frame or Top Hat Replacement .................................................................................
Front Cover Removal.................................................................................................
Rear Head Assembly Removal ..................................................................................
Rotating Gobo Replacement ......................................................................................
Gobo Index Timing Belt Alignment ..........................................................................
Gobo Wheel Bulkhead Replacement .........................................................................
Gobo Gear Planet Alignment.....................................................................................
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16
18
20
22
23
24
25
26
28
30
32
xv
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Shutter Assembly Replacement.................................................................................. 34
Shutter Blade or Rack Replacement........................................................................... 36
Edge/Zoom/Color Bulkhead Replacement................................................................. 38
Fan/Temp Switch Assembly Replacement ................................................................. 39
Beam-Size Iris Assembly Replacement ..................................................................... 40
Ignitor PCB Replacement........................................................................................... 41
Power Supply Replacement........................................................................................ 42
Controller PCB Replacement ..................................................................................... 44
Tilt Encoder PCB Replacement.................................................................................. 46
Tilt Motor Assembly Replacement............................................................................. 47
Pan Motor Assembly Replacement ............................................................................ 49
DMX Input PCB Replacement................................................................................... 51
Cleaning Optical Lenses and Filters........................................................................... 52
Chapter 3. Illustrated Parts Breakdown
Drawing Trees
VL1000 Incandescent Luminaires.............................................................................. 54
VL1000 Arc Luminaires............................................................................................. 56
Top Assembly
Included Items Kit ...................................................................................................... 58
Label Locations .......................................................................................................... 59
VL1000 Luminaire .....................................................................................................60
Front Cover Assembly ................................................................................................62
Gel Frame Holder Assembly ......................................................................................63
COT Flag Assembly ...................................................................................................64
Controller PCB Assembly ..........................................................................................65
Head Assembly
Head Assembly ...........................................................................................................71
Front Head Assembly .................................................................................................72
Edge Control, Zoom, Dimmer & Color Assembly .....................................................74
Color Changer Assembly ...........................................................................................76
Color Changer Drive Motor .......................................................................................79
Cover Plate Assembly ................................................................................................80
Barrel Assembly .........................................................................................................81
Lens #6 Assembly ......................................................................................................83
Lens #7 Assembly ......................................................................................................84
Lens #8 Assembly ......................................................................................................85
Fan Assembly .............................................................................................................86
Pulley Side Rail Assembly .........................................................................................87
Sensor Side Rail Assembly ........................................................................................88
Incandescent Gobo Wheel Assembly .........................................................................89
Temperature Sensor Electrical Assembly ..................................................................92
Arc Gobo/Dimmer Bulkhead Assembly ....................................................................93
Gobo Wheel Assembly ...............................................................................................96
Gobo Bulkhead FAB Assembly .................................................................................97
Gobo/Dimmer Bulkhead FAB Assembly ...................................................................98
xvi
23-Oct-02
02. 9663.0 010 D
TABLE OF CONTENTS
Dimmer Wheel Assembly .......................................................................................... 99
Wheel Sensor PCB ................................................................................................... 100
Index Sensor PCB .................................................................................................... 101
Shutter Assembly ..................................................................................................... 102
Shutter 6 Rollers Assembly ..................................................................................... 105
Beam-Size Iris Assembly ......................................................................................... 108
Rear Head Assembly ................................................................................................ 109
Bulkhead Assembly ................................................................................................. 111
Back Cap Assembly ................................................................................................. 112
Yoke Assembly
Yoke Legs Assembly ............................................................................................... 115
Tilt Motor Assembly ................................................................................................ 117
Ignitor PCB .............................................................................................................. 118
Pan/Tilt Encoder PCB Assembly ............................................................................. 119
Crossmember Assembly .......................................................................................... 120
Inner Crossmember Assembly ................................................................................. 122
Outer Crossmember Assembly ................................................................................ 123
Pan Motor Assembly ................................................................................................ 124
Pan Tube Assembly ................................................................................................. 125
DMX Input PCB Assembly ..................................................................................... 127
Cables
Arc Power Input (Pigtail) Cable Assembly ............................................................. 129
Pan EOT Cable Assembly ....................................................................................... 131
Tilt COT Cable Assembly ....................................................................................... 132
AC Line Input Cable Assembly ............................................................................... 133
Incandescent LVS AC Input Cable Assembly ......................................................... 134
Arc LVS AC Input Cable Assembly ........................................................................ 135
LVS Chassis Ground Cable Assembly .................................................................... 136
Head to Backcap Ground Cable Assembly .............................................................. 137
Yoke to Head Ground Cable Assembly ................................................................... 138
Pan/Tilt Control Cable Asembly .............................................................................. 139
Ballast Control Link Cable Assembly ..................................................................... 141
Data I/O Link Cable Assembly ................................................................................ 142
LVS DC Output Cable Assembly ............................................................................ 143
Incandescent Power Input Cable Assembly ............................................................. 144
Incandescent Lamp Power Cable Assembly ............................................................ 145
Arc Power to Ignitor Cable Asembly ....................................................................... 146
Ignitor to Lamp Socket Cable Assembly ................................................................. 147
Shutter Harness Cable Assembly ............................................................................. 148
Color/Gobo/Lens Harness Cable Assembly ............................................................ 150
Arc Ballast Assembly
Arc Ballast Assembly .............................................................................................. 153
625W Ballast PCB ................................................................................................... 156
625W Ballast Rider PCB ......................................................................................... 160
575W Ballast I/O Cable Assembly .......................................................................... 164
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xvii
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Appendix A. Technical Bulletins
VL1000 ERS Luminaire Technical Bulletins........................................................... 167
Appendix B. Wiring and Schematic Diagrams
VL1000 Incandescent Wiring Diagram - Sheet 1 of 2 ............................................. 169
VL1000 Incandescent Wiring Diagram - Sheet 2 of 2 ............................................. 170
VL1000 Arc Wiring Diagram - Sheet 1 of 2 ............................................................ 171
VL1000 Arc Wiring Diagram - Sheet 2 of 2 ............................................................ 172
VL1000 Ballast Wiring Diagram ............................................................................. 173
Gobo Wheel Sensor (24.9663.1230 B) Schematic................................................... 174
Gobo Index Sensor (24.9663.1231 A) Schematic .................................................... 175
DMX Input PCB (24.9663.1830 A) Schematic........................................................ 176
625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 1 of 3.............................. 177
625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 2 of 3.............................. 178
625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 3 of 3.............................. 179
625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 1 of 2 .................... 180
625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 2 of 2 .................... 181
Controller PCB (24.9663.1930 F) Schematic - Sheet 1 of 10 .................................. 182
Controller PCB (24.9663.1930 F) Schematic - Sheet 2 of 10 .................................. 183
Controller PCB (24.9663.1930 F) Schematic - Sheet 3 of 10 .................................. 184
Controller PCB (24.9663.1930 F) Schematic - Sheet 4 of 10 .................................. 185
Controller PCB (24.9663.1930 F) Schematic - Sheet 5 of 10 .................................. 186
Controller PCB (24.9663.1930 F) Schematic - Sheet 6 of 10 .................................. 187
Controller PCB (24.9663.1930 F) Schematic - Sheet 7 of 10 .................................. 188
Controller PCB (24.9663.1930 F) Schematic - Sheet 8 of 10 .................................. 189
Controller PCB (24.9663.1930 F) Schematic - Sheet 9 of 10 .................................. 190
Controller PCB (24.9663.1930 F) Schematic - Sheet 10 of 10 ................................ 191
xvii i
23-Oct-02
02. 9663.0 010 D
INTRODUCTION : DISCLOSURE
Introduction
Disclosure
This technical manual is confidential property of Vari-Lite, Inc. All information
contained herein is the sole and exclusive property of Vari-Lite, Inc. and may not be
used, disclosed, or reproduced in any manner without the prior written consent of
Vari-Lite, Inc.
WARNING: It is important to read ALL accompanying safety instructions to avoid
damage to the product and potential injury to yourself or others.
About This Manual
This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL1000™ ERS Luminaire. The manual is intended for
use by Vari-Lite personnel and by Vari-Lite’s customers/clients.
This manual covers the following models:
MODEL
PART NUMBER
SOURCE
VL1000 T
20.9663.0001.01
Incandescent
VL1000 TS
20.9663.0001.02
Incandescent
VL1000 TI
20.9663.0001.03
Incandescent
VL1000 A
20.9663.0001.11
Arc
VL1000 AS
20.9663.0001.12
Arc
VL1000 AI
20.9663.0001.13
Arc
SHUTTER
IRIS
X
X
X
X
Note: Performing maintenance procedures contained in this manual may void the
product warranty. Refer to the Vari-Lite, Inc. Limited Warranty card included in the
shipping package for this VARI❋LITE® product.
Additional Documentation
A support webpage for VL1000 series luminaires is available at www.vari-lite.com
(follow the Support link).
A user’s manual is available for installation and operation of the VL1000 ERS
luminaire. This manual is available in both printed and electronic (PDF) formats.
■
02.9 663.00 10 D
VL1000™ ERS Luminaire User’s Manual (02.9663.0001).
23-Oct-02
1
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Customer Service
Our Goal
At Vari-Lite, we are committed to providing you the highest quality in customer
service. Our comprehensive resources are available to help your business succeed and
ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are
telephone/troubleshooting assistance, product training or technical service, our fulltime staff of experienced professionals are on-hand to provide support.
How to Reach Us
For assistance in your area, call the dealer from which your product(s) were
purchased.
or
Contact an Authorized Service Center.
or
Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through
Friday, at the following:
phone: 1-877-VARI-LITE (1-877-827-4548)
fax: 214.630.5867
email: [email protected]
Additional Resources
For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.
Technical Bulletins and Notices
Technical bulletins concerning the latest changes to VARI❋LITE equipment are
issued from the Dallas, Texas USA office. They are documentation supplements that
contain procedures for equipment upgrades, retrofits, and repairs not found in the
existing manuals. Operator technical bulletins are also issued to document changes in
control software. Technical bulletins are integrated into the appropriate equipment
manuals as those manuals are revised. Bulletins are categorized by assembly or
subassembly, and identified by a number such as S1K-001 (VL1000 series luminaires
Technical Bulletin number 1).
Technical notices are also issued from the Dallas, Texas USA office. They are nonprocedural documents that contain information regarding product support issues,
current equipment problems, software bugs, and documentation corrections. All
technical notices begin with the prefix TN and are numbered sequentially, such as TN138 (Tech Notice number 138).
2
23-Oct-02
02. 9663.0 010 D
CHAPTER 1.
Description
This chapter provides an overview of luminaire features, components and operations.
• Features
• Component Descriptions
• Principles of Operation
02.9 663.00 10 D
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3
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Features
Standard Features
VL1000 Ellipsoidal Reflector Spotlight (ERS) luminaires
have the following standard features:
•
•
•
•
•
•
Automated zoom optics system.
Crossfading CYM color system.
Diffusion system.
Six-position rotating gobo wheel (five rotatable,
indexable gobo positions and one open gobo position).
Repositional pan/tilt system.
Control by DMX512 protocol.
Model Specific Features
Each individual configuration has the following specific features:
VL1000 T Luminaire (20.9663.0001.01)
•
1000W Tungsten Halogen lamp source.
VL1000 TS (20.9663.0001.02)
•
1000W Tungsten Halogen lamp source.
•
Four-blade shutter framing system.
VL1000 TI Luminaire (20.9663.0001.03)
•
1000W Tungsten Halogen lamp source.
•
Beam-size iris mechanism.
VL1000 A (20.9663.0001.11)
•
575W arc lamp source with external ballast unit.
VL1000 AS (20.9663.0001.12)
•
575W arc lamp source with external ballast unit.
•
Four-blade shutter framing system.
VL1000 AI (20.9663.0001.13)
4
•
575W arc lamp source with external ballast unit.
•
Beam-size iris mechanism.
23-Oct-02
02. 9663.0 010 D
DESCRIPTION : COMPONENT DESCRIPTIONS
1
Component Descriptions
External Luminaire Components
The following illustration shows the external luminaire components and controls.
Base
Provides hook mounting
holes and safety cable
connection.
Input Panel
Provides DMX In and
Thru, and AC Power
connections.
Latch
Lamp Power
Input Cable
Gel, Silk
or Frost
Accepts frames
or top hats
Yoke Assembly
Houses Control PCB
and power supply.
Accessory Frame
Accessory Frame Holder
Backcap Assembly
Provides access to lamp
for replacement and
provides controls for
beam adjustment
Accessory Frame Holder
Provides frame for
optional silks, frosts, color.
correction or top hats.
See detail...
Beam Adjustment Controls
Menu Display
Used to input manual
commands, program, test,
set defaults and access
internal status information.
Head Assembly
Houses color, gobo, dimmer, strobe,
and optional shutter or iris mechanisms.
Beam
Adjust
Screws *
* Do not remove or use to access lamp.
Menu Display Controls
LCD Display
Input Panel Connections
Address
MENU ENTER
Press to
show menu,
or if at first
level, the
current
address.
02.9 663.00 10 D
Down / Decrease
Up / Increase
Lamp Power
Input Cable
Data In
Data Thru
3-Pole Neutrik
Locking Connector
for AC Input
Press to select current menu
option or current data value.
23-Oct-02
5
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Luminaire Internal Head Components
The following illustration shows the major sub-assemblies which are located in the
luminaire head assembly.
A options - Shutter, Beam-size Iris or Aperture bulkhead is dependent on model.
B options - Rotating Gobo Bulkhead version is dependent on model.
Beam-Size Iris Assembly (optional)
Provides beam sizing capabilities.
Shutter Assembly (optional)
Four-blade system can frame
and crop beam field and gobos.
Aperture Assembly
Installed when neither
the shutter or beam-size
is used.
Rear Head Assembly
Six-position rotating gobo
wheel with five rotatable,
indexable gobo positions
and one open gobo position.
A
See options A
Edge, Zoom, Dimmer Bulkhead
Contains automated zoom optics lenses,
crossfading CYM system, and diffusion.
Backcap Assembly
Provides access to lamp
for replacement and
provides controls for
beam adjustment
See options B
B
Front Cover
Provides frame for mounting
silks, frosts, color correction
or top hat. Removed by unlatching
two latches.
Arc Gobo Bulkhead
Provides six position rotatable/indexable
gobo wheel for projecting images.
6
23-Oct-02
Incandescent Gobo Bulkhead
Provides six position rotatable/indexable
gobo wheel for projecting images.
02. 9663.0 010 D
DESCRIPTION : COMPONENT DESCRIPTIONS
1
Luminaire Internal Yoke Components
The following illustration shows the major sub-assemblies which are located in the
luminaire yoke assembly.
Note: Head assembly not shown for clarity.
Yoke Arm Cover
Tilt Mechanism
Pan Mechanism
Yoke Arm Cover
(Display Side)
Main Controller PCB
Luminaire control circuit board.
150W Power Supply
Supplies power to
electronic and motor
components.
Ignitor PCB
Ignites lamp in arc models.
02.9 663.00 10 D
23-Oct-02
7
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Arc Ballast Unit
An external ballast unit is included with VL1000 arc models. In this case, the lamp
power input cable is already connectorized for use with this unit.
The following illustration shows the external arc ballast components.
Lamp Connector
CPC-type connector for connecting
Lamp Power Input cable from luminaire.
Truss Hook Mount
Used to attach a truss hook.
Safety Cable Tab
Used to attach
safety cable clip.
Ballast Unit
Provides power for
arc lamp source.
Lamp Power Input Cable
Supplied cable and connector used
to connect luminaire to ballast unit.
40 inches (1m)
Note: The Lamp Power Input Cable has conductors for lamp power and ballast
control. It is not compatible with VARI❋LITE Series 300™ lamp runs.
8
23-Oct-02
02. 9663.0 010 D
DESCRIPTION : PRINCIPLES OF OPERATION
1
Principles of Operation
VL1000 Incandescent Source Luminaire
VL1000 Incandescent Block Diagram
VL1000
INCANDESCENT
1766
1202
1520
1520
1766
1301
1301
1301
ZOOM
MOTOR
GOBO
INDEX
BLUE
MOTOR
MAG
MOTOR
DIMMER
ARC
ONLY
1A
2A
3A
4A
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
BLOCK DIAGRAM
VL 1000 INC wire9.vsd
10-23-01 JHC
1202
1202
1520
1520
1202/1326
1301
EDGE
MOTOR
GOBO
WHEEL
AMBER
MOTOR
DIFF
MOTOR
B.S.IRIS/
SHUTTER
ROTATE
1B
2B
3B
4B
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
ALL MOTORS
44-9663-XXXX
DATA
I/O
M3
24/4
M5
24/4
M2
24/4
ALL CABLES
25-9663-XXXX
NEUTRIK
XLR-M
DMX INPUT
M4
24/4
DATA
22/5
2022
J3
NEUTRIK
XLR-F
DMX THRU
M7
24/4
M6
24/4
J4
J2
DATA
I/O
M1
24/4
M9
24/4
M8
24/4
ENTER
UP
DOWN
FAN
24/2
2040 (SHUTTERS)
2042 (WITHOUT)
FAN
J4
J6
2050
SENSOR 1
26/4
SENSOR 2
26/4
GOBO WHEEL
SENSOR
23-9663-2004
GOBO INDEX
SENSOR
23-9663-2005
J7
AC
IN
AC GND
22x4
2016
CHASSIS
GND STUD
LAMP
POWER
USER
PROVIDED
CONNECTOR
FOR LAMP
PWR INPUT
FROM
DIMMER
2030
DIMMER GND
1.5/1
2
2030
LAMP
POWER
1.5/2
2030
M19
26/4
M18
26/4
M20
26/4
2040
MAIN CONTROL
PCB ASSY
1
AC GND
16/1
2017
J5
DISPLAY8
2020
SENSOR 3,4,5
24/5
+24V
18/4
2024
+24V
AC LINE
22x4/2
2016
TERM
BLOCK
1
M17
26/4
M16
26/4
1301
24-9663-1920
AC LINE
16/2
2015
AC GND
16/1
2015
1301
M15
26/4
M14
26/4
J1
J1
24-9663-1830
1301
M13
26/4
M12
24/4
J8
J1
NEUTRIK
POWERCON
AC LINE IN
2015
)
2050
MENU
DMX PCB
AC LINE
POWER
(
1301
LOW
VOLTAGE
SUPPLY
J1
M10
24/4
2020
2
YOKE TO
HEAD GND
22x4
2019
PAN ENCODER
PCB ASSY
24-9661-0629
J1
M11
24/4
2020
J2
PAN
MOTOR
1850
69-3128-0150
YOKE
GND STUDS
SENSOR 6,7,8
24/5
1
TILT ENCODER
PCB ASSY
24-9661-0629
J2
PAN EOT
26/4
TILT
MOTOR
TILT COT
26/4
PAN EOT
SENSOR
23-9663-2001
1850
TILT COT
SENSOR
23-9663-2002
HEAD
GND STUDS
2
HEAD TO
BACK CAP
BRAID
2018
BACK CAP
GND STUD
CHASSIS
GND STUD
TERM
BLOCK
LAMP
POWER
22x4/2
2031
AMP
SERIES 30
LAMP
POWER
16/2HT
2032
1200W
INCAND
LAMP
PIGTAIL
02.9 663.00 10 D
23-Oct-02
9
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
VL1000 Incandescent Cable Routing
CHASSIS
NEUTRIK
POWERCON
AC LINE IN
2015
GND
STUD
1
AC
LINE
2015
XLR-M
DMX
INPUT
TERM
BLOCK
.
USER
PROVIDED
CONNECTOR
FOR LAMP PWR
INPUT FROM
DIMMER
LAMP PWR
2030
DIMMER GND
5
GND
STUD
2
PIGTAIL &
STRAIN RELIEF
DMX PCB
24-9663-1830
XLR-F
DMX
THRU
TERM
BLOCK
LAMP
PWR
2031
AC
GND
2016
AC
LINE
2016
DMX
DATA
2022
PAN
TUBE
YOKE
PAN
MOTOR
& ENC
PCB
PAN EOT
2001
PAN EOT
SENSOR
TILT COT
2002
PAN - 2020
TILT
MOTOR
& ENC
PCB
PAN - 2020
TILT COT - 2002
LAMP PWR - 2031
AC GND - 2016
.
TILT
2020
DMX DATA - 2022
AC LINE - 2016
LVS
GND
2017
PAN
2020
+24VDC - 2024
5
4
GND STUD
20
BACK CAP
TILT
COT
2002
LVS
ASSY
LAMP
PWR
2031
LAMP
PWR
2032
LAMP
SOCKET
INC
LAMP
6931280150
AMP
SERIES
30
LAMP PWR - 2031
YOKE/HEAD GND - 2019
GND STUD
GND STUD
TILT
TUBE
BACK CAP/
HEAD GND
2018
CABLE ROUTING
10
10
CONTROL
MOTORS
2
GOBO
SENSE
HEAD
23-Oct-02
2496631920
40
50
GND STUD
8
SHUTTER
MOTORS
(OPT)
VL 1000
INCANDESCENT
MCB
PCB
GND STUD
10 MOTORS/ 2 SENSORS - 2050
FAN
TILT COT
SENSOR
5
FAN - 2040 or 2042
8 MOTORS - 2040
TILT
TUBE
Note: All Cable Assys are
25-9663-XXXX
VL 1000 INC route5.vsd
10-24-01 JHC
02. 9663.0 010 D
DESCRIPTION : PRINCIPLES OF OPERATION
1
VL1000 575W Arc Source Luminaire
VL1000 Arc Block Diagram
VL1000
575W ARC
BLOCK DIAGRAM
VL 1000 ARC wire9.vsd
10-23-01 JHC
ALL MOTORS
44-9663-XXXX
DATA
I/O
1520
1520
1766
1301
1301
1301
BLUE
MOTOR
MAG
MOTOR
DIMMER
ARC
ONLY
1A
2A
3A
4A
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
1301
DATA
22/5
2022
J3
NEUTRIK
XLR-F
DMX THRU
(
1202
1202
1520
1520
1202/1326
1301
1301
1301
GOBO
WHEEL
AMBER
MOTOR
DIFF
MOTOR
B.S.IRIS/
SHUTTER
ROTATE
1B
2B
3B
4B
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
SHUTTER
FRAME
M3
24/4
M5
24/4
M2
24/4
M4
24/4
M7
24/4
M6
24/4
M9
24/4
M13
26/4
M8
24/4
M12
24/4
MENU
ENTER
DMX PCB
FAN
24/2
2040 (SHUTTERS)
2042 (WITHOUT)
FAN
UP
DOWN
AC LINE
POWER
BALLAST
CONTROL
LAMP
POWER
AMP CPC
17-9 PLUG
LAMP PWR
INPUT &
AC LINE
OUTPUT
TO BALLAST
1921
J4
2050
SENSOR 1
26/4
SENSOR 2
26/4
GOBO WHEEL
SENSOR
23-9663-2004
GOBO INDEX
SENSOR
23-9663-2005
HIGH
CURRENT
CONTACTS
AC LINE
22x4/2
2016
TERM
BLOCK
AC GND
16/1
2015
AC
IN
AC GND
22x4
2016
J6
J7
+24V
18/4
2024
BALLAST
CONTROL
22/4
1921
1
AC GND
16/1
2017
LOW
VOLTAGE
SUPPLY
J5
2
2
LAMP POWER
14/2
1921
CHASSIS
GND STUD
TERM
BLOCK
SENSOR 3,4,5
24/5
BALLAST
CONTROL
22/4
1921
LAMP POWER
22x4/2
2035
23-Oct-02
SENSOR 6,7,8
24/5
J1
M10
24/4
2020
J1
PAN ENCODER
PCB ASSY
24-9661-0629
M11
24/4
2020
J2
PAN
MOTOR
1850
YOKE TO
HEAD GND
22x4
2019
PIGTAIL
02.9 663.00 10 D
DISPLAY8
2020
69-3128-0150
YOKE
GND STUDS
AC LINE
16/2
BALLAST GND
16/1
1921
M20
26/4
24-9663-1920
AC LINE
16/2
CHASSIS
1
GND STUD
M19
26/4
M18
26/4
2040
MAIN CONTROL
PCB ASSY
+24V
AC LINE
POWER
M17
26/4
M16
26/4
J1
J1
24-9663-1830
M15
26/4
M14
26/4
2050
J8
J1
NEUTRIK
POWERCON
AC LINE IN
2015
)
1301
EDGE
MOTOR
J4
J2
DATA
I/O
1202
GOBO
INDEX
M1
24/4
ALL CABLES
25-9663-XXXX
NEUTRIK
XLR-M
DMX INPUT
1766
ZOOM
MOTOR
1
IN
TILT ENCODER
PCB ASSY
24-9661-0629
J2
PAN EOT
26/4
TILT
MOTOR
TILT COT
26/4
PAN EOT
SENSOR
23-9663-2001
1850
TILT COT
SENSOR
23-9663-2002
HEAD
GND STUDS
IGNITOR
PCB ASSY
24-9661-1125
HEAD TO
BACK CAP
BRAID
2018
2
O
U
T
LAMP HV
16/2HV
2036
BACK CAP
GND STUD
575W
ARC
LAMP
11
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
VL1000 Arc Cable Routing
CHASSIS
AC
NEUTRIK
LINE
POWERCON
2015
AC LINE IN
2015
AC
GND
GND
STUD 1
2016
AC LINE
XLR-M
DMX
INPUT
TERM
BLOCK
.
AMP
CPC 17-9
LAMP POWER IN
& AC LINE OUT
TO BALLAST
1921
5
XLR-F
DMX
THRU
BAL CONT
LAMP PWR
BALLAST GND
GND
STUD
2
PIGTAIL &
STRAIN RELIEF
DMX PCB
24-9663-1830
TERM
BLOCK
LAMP AC
PWR GND
2035 2016
AC
BAL DMX
LINE CONT DATA
2016 1921 2022
PAN
TUBE
YOKE
PAN
MOTOR
& ENC
PCB
PAN EOT
2001
PAN EOT
SENSOR
TILT COT
2002
PAN - 2020
TILT
MOTOR
& ENC
PCB
PAN - 2020
TILT COT - 2002
LAMP PWR - 2035
AC GND - 2016
.
LVS
GND
2017
BAL CONT - 1921
PAN
2020
+24VDC - 2024
5
4
GND STUD
TILT
COT
2002
LVS
ASSY
LAMP
PWR
2035
6931280150
LAMP
SOCKET
IGN
PCB
ARC
LAMP
LAMP PWR - 2035
BACK CAP/
HEAD GND
2018
10
CONTROL
MOTORS
CABLE ROUTING
12
2496631920
40
50
10 MOTORS/ 2 SENSORS - 2050
FAN
VL 1000
575W ARC
MCB
PCB
GND STUD
GND STUD
YOKE/HEAD GND - 2019
GND STUD
GND STUD
TILT
TUBE
5
20
BACK CAP
LAMP
HV
2036
2496611125
TILT COT
SENSOR
TILT
2020
DMX DATA - 2022
AC LINE - 2016
2
GOBO
SENSE
8
SHUTTER
MOTORS
(OPT)
HEAD
23-Oct-02
FAN - 2040 or 2042
8 MOTORS - 2040
TILT
TUBE
Note: All Cable Assys are
25-9663-XXXX
VL 1000 ARC route5.vsd
10-24-01 JHC
02. 9663.0 010 D
DESCRIPTION : PRINCIPLES OF OPERATION
1
VL1000 Arc Ballast Unit
Ballast Block Diagram
VL1000
575W ARC BALLAST
VL1000
575W ARC BALLAST
RIDER PCB
24-9663-1902
WIRING DIAGRAM
VL1000balwire8.vsd
10-4-01 JHC
1 - 14
1 - 15
J101
J201
SINGLE-ROW HEADERS
AC LINE
POWER
4
AC LINE
16-BLK
3
6
AC NEUT
16-WHT
2
2
AMP CPC
STD SEX
17-9
RECEPT
PWR LVL
& NOT ON
AC GND
16-GRN/YEL
AC GND
16-GRN/YEL
MATE
-NLOK
J102
1
VL1000
CHASSIS
GND STUD
9
NOT ON-22-RED
4
7
PWR LVL-22-WHT
3
8
DATA GND-22-BLK
2
5
DATA DRAIN-22-GRN/YEL
575W ARC BALLAST
MAIN PCB
24-9663-1901
MTA
-100
J601
1
TWISTED
1
LAMP
POWER
HIGH
CURRENT
CONTACTS
A
J206
1/4" FASTON
3
AC IN & LAMP
POWER OUT
to VL1000
02.9 663.00 10 D
LAMP POWER
OUT HI
14-ORN
LAMP POWER
OUT LO
14-VIO
B
J207
INPUT/OUTPUT
CABLE ASSY
25-9663-1907
23-Oct-02
1/4" FASTON
1/4" FASTON
1/4" FASTON
J104
J103
J202
J203
J204
J205
C
D
E
F
G
H
PFC
PFC
CHOKE CHOKE
16-RED 16-BLU
BUCK
BUCK
CHOKE CHOKE
16-RED 16-BLU
BUCK
BUCK
CHOKE CHOKE
16-RED 16-BLU
TWISTED
TWISTED
TWISTED
PFC
CHOKE
68-96631912
BUCK
CHOKE A
68-96631913
BUCK
CHOKE B
68-96631913
13
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
14
23-Oct-02
02. 9663.0 010 D
CHAPTER 2.
Maintenance
This chapter contains test, service, and standard maintenance procedures.
• Testing
• Maintenance Procedures
WARNING: All maintenance procedures are to be performed with power removed
from the luminaire. Never remove cover or backcap while lamp is in operation.
02.9 663.00 10 D
23-Oct-02
15
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Testing
Running Parameter Tests
The luminaire is capable of running self tests by using the TEST menu functions.
When running tests on multiple luminaires, a loopback connector is required at the
master luminaire (first in link) and a male termination connector is required at the last
luminaire in the link. Refer to the VL1000 ERS User’s Manual for more information
regarding these connectors.
Note: After 10 seconds of inactivity, the menu display will change to the default state
showing the address.
To connect luminaires for simultaneous testing:
Step 1. At first luminaire in link, install loopback connector into DATA IN XLR
connector.
Step 2. At last luminaire, install male termination connector into DATA THRU XLR
connector.
First luminaire containing
software version to download
Luminaire 1
requiring update
Data Thru
Luminaire 2
requiring update
Data Thru
Male Termination Connector
Loopback Connector
Step 3. At master luminaire Menu Display, press [Menu].
Movement Disable
The Movement option has been added to the configuration menu. This allows for
pan/tilt functions to be disabled so that the luminaire can be placed in any position for
testing without movement occurring. In order to regain full control of the luminaire,
Movement will need to be enabled after testing.
Note: When setting the Movement option to disable, luminaires linked by a
loopback connector will have pan and tilt disabled for all the luminaires that are
linked.
16
23-Oct-02
02. 9663.0 010 D
MAINTENANCE : TESTING
2
WARNING: Backcap and adjustment knobs will be HOT during lamp operation.
Wear gloves and/or use tools to prevent burns.
To run tests:
Step 1. Press [Menu].
Step 2. Press [Up] / [Down] arrows until Test appears. Press [Enter].
Step 3. Use [Up] / [Down] arrows to select a parameter to test. Refer to table below
for a complete list of test parameters.
Step 4. Press [Enter] to run test.
Step 5. Press [Menu] to stop test at any time.
Table 2-1: Self Test Function Chart
1st Level
Test
System Test
02.9 663.00 10 D
2nd Level
3rd Level
4th Level
Press [Menu] to stop
tests
ALL Test All Motors
RUN TEST Run-Test in Progress
Pan/Tilt
RUN TEST Run-Test in Progress
Dimmer (Arc Only)
RUN TEST Run-Test in Progress
Blue
RUN TEST Run-Test in Progress
Amber
RUN TEST Run-Test in Progress
Magenta
RUN TEST Run-Test in Progress
ColorMix Blue, Amber, Magenta test
RUN TEST Run-Test in Progress
Diffusn Diffusion Test
RUN TEST Run-Test in Progress
Rot Gobo Rotating Gobo Test
RUN TEST Run-Test in Progress
Edge
RUN TEST Run-Test in Progress
5thLevel
Zoom
RUN TEST Run-Test in Progress
Beam (If Beam-Size Iris Accessory)
RUN TEST Run-Test in Progress
Shutter (If Shutter Accessory)
RUN TEST Run-Test in Progress
Rot Shut (If Shutter Accessory)
RUN TEST Run-Test in Progress
Lamp Disables Pan/Tilt and executes
Home position.
RUN TEST Run-Test in Progress
Encoder Encoders
Pan Pan Encoder
XXXX Data
Tilt Tilt Encoder
XXXX Data
Sensor Sensors
Pan COT Sensor
STST Sensor Test in
Progress
PASS/FAIL
Tilt COT Sensor
STST Sensor Test in
Progress
PASS/FAIL
Rot Gobo Gobo Select EOT
Sensor
STST Sensor Test in
Progress
PASS/FAIL
GoboIndx Gobo Index EOT
Sensor
STST Sensor Test in
Progress
PASS/FAIL
23-Oct-02
17
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Maintenance Procedures
Lamp Replacement (Incandescent Model)
Parts:
1000 WATT INCANDESCENT LAMP, 100 VAC (71.2552.0100) - T/TS/TI
1000 WATT INCANDESCENT LAMP, 115 VAC (71.2552.0115) - T/TS/TI
1000 WATT INCANDESCENT LAMP, 230 VAC (71.2552.0230) - T/TS/TI
Tools:
#2 Phillips screwdriver, cotton gloves
CAUTION: Wear cotton gloves or other covering while installing lamp. Touching
lamp glass with bare fingers will leave oil and may cause the lamp to explode or
reduce lamp life. If touched, use alcohol and cotton cloth to thoroughly clean glass
portion of lamp.
To install incandescent lamp:
Step 1. Remove power from luminaire.
Step 2. At backcap, gradually loosen two 10-32x2-3/8" PPSS black screws
(Figure 2-1) a few turns at a time until backcap is free. (Screws must be
alternately loosened to prevent one side from locking up.)
Do not touch lamp
CAUTION: with bare fingers.
Rear Head
Assembly
Backcap
Align when
re-installing
Alignment Stud (2)
Holes and studs MUST be
CAUTION: aligned when re-installing.
Backcap Interior View
10-32x2-3/8 PPSS
Black Screws (captive)
- loosen each gradually
Alignment Hole (2)
Figure 2-1: Removing Incandescent Backcap
18
23-Oct-02
02. 9663.0 010 D
MAINTENANCE : MAINTENANCE PROCEDURES
2
Step 3. Carefully pull backcap straight out of rear head assembly. (It will still be
attached by lamp wires and tether.)
Step 4. At backcap, flip two bail clamps outward (Figure 2-2).
Step 5. Flip two base clamps outward away from socket.
Step 6. Grip lamp by base and firmly install in socket.
Step 7. Close base and bail clamps, locking into place.
Do not touch lamp
CAUTION: with bare fingers.
1
2
Flip bail clamps outward.
Flip base clamps outward.
Install lamp, firmly pressing into place.
Bail Clamps
Lamp
Socket
Base Clamps
3
4
Close base clamps.
Close bail clamps.
Figure 2-2: Installing Incandescent Lamp in Socket
Step 8. Re-install backcap, ensuring that alignment studs and holes are aligned
(Figure 2-1).
Step 9. Align lamp. (Refer to “Align Lamp For Maximum Beam Irradiance” on
page 22.)
02.9 663.00 10 D
23-Oct-02
19
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Lamp Replacement (Arc Model)
Parts:
575 WATT ARC LAMP, MSR575HR (71.2528.0575) - A/AS/AI
Tools:
#2 Phillips screwdriver, cotton gloves
CAUTION: Wear cotton gloves or other covering while installing lamp. Touching
lamp glass with bare fingers will leave oil and may cause the lamp to explode or
reduce lamp life. If touched, use alcohol and cotton cloth to thoroughly clean glass
portion of lamp.
To install arc lamp:
Step 1. Remove power from luminaire.
Step 2. At backcap, gradually loosen two 10-32x2-3/8" PPSS black screws
(Figure 2-3) a few turns at a time until backcap is free. (Screws must be
alternately loosened to prevent one side from locking up.)
Do not touch lamp
CAUTION: with bare fingers.
Rear Head
Assembly
Backcap
Align when
re-installing
Alignment Stud (2)
Holes and studs MUST be
CAUTION: aligned when re-installing.
Backcap Interior View
10-32x2-3/8 PPSS
Black Screws (captive)
- loosen each gradually
Alignment Hole (2)
Figure 2-3: Removing Arc Backcap
20
23-Oct-02
02. 9663.0 010 D
MAINTENANCE : MAINTENANCE PROCEDURES
2
Step 3. Grip lamp by base and firmly install in socket (Figure 2-4).
Do not touch lamp
CAUTION: with bare fingers.
Socket
Lamp
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 22.)
02.9 663.00 10 D
23-Oct-02
21
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Align Lamp For Maximum Beam Irradiance
After a new lamp is installed in either the incandescent or arc version of the luminaire,
it will be necessary to align the lamp to optimize the beam.
Tools:
#2 Phillips screwdriver
WARNING: Backcap and adjustment screws will be HOT during lamp operation.
Wear gloves and/or use tools to prevent burns.
To align lamp:
Step 1. Set intensity to 100%.
Step 2. Position beam on a white wall at a distance of 10 to 20 feet.
Step 3. Using console or internal luminaire menu controls, set zoom to zero and
focus to a hard edge. If installed, be sure that beam-size iris and shutters are
open.
Step 4. Using three adjustment screws, adjust hot spot to center of beam
(Figure 2-5).
Step 5. Check color uniformity as follows:
a. Position one of the color stages at 30% of maximum. (Cyan or Magenta
work best.)
b. Verify that beam color is uniform (if lamp is misaligned, color will be
concentrated to one side of beam). If color is not uniform, readjust lamp
until color is uniform across entire beam field.
Beam Adjustment Screws *
* Do not remove or use to access lamp.
Figure 2-5: Lamp Alignment Screws
22
23-Oct-02
02. 9663.0 010 D
MAINTENANCE : MAINTENANCE PROCEDURES
2
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 8-inch gel frame or top hat.
To remove and replace frame or top hat:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At front lens, press upward on accessory frame latch and turn to open.
Step 3. Remove frame/top hat, if any (Figure 2-6).
Step 4. Install frame/top hat and close latch.
Gel, Silk, or Frost
Press Up
and Turn
Latch
Head Assembly
Accessory Frame
NOTE:
The accessory frame is not a Vari-Lite accessory.
Figure 2-6: Installing a Frame or Top Hat
02.9 663.00 10 D
23-Oct-02
23
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Front Cover Removal
Parts:
ASSY, FRONT COVER (22.9663.1038)
Tools:
#2 Phillips screwdriver
To remove and replace front cover:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At head assembly, press in front cover latches to release (Figure 2-7).
Step 3. Pull cover straight out until stopped by tether.
Step 4. Disconnect tether by removing 8-32x1/2" PFB screw and 8-32 Keps nut as
shown.
Step 5. Remove cover.
Step 6. Replace front cover by doing steps 2 through 5 in reverse. Ensure latches
lock into place.
Head Assembly
Front Cover
Latch (x2)
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
24
23-Oct-02
02. 9663.0 010 D
MAINTENANCE : MAINTENANCE PROCEDURES
2
Rear Head Assembly Removal
This procedure is necessary in order to access some components such as the gobo
wheel bulkhead and shutter assembly. Refer to as needed.
Tools:
#2 Phillips long handle screwdriver
To remove rear head assembly:
Step 1. Disconnect luminaire AC input cable from power source.
CAUTION: The rear head assembly is heavy and will remain attached by lamp wires.
Place luminaire on tech bench before removing rear assembly.
Step 2. At side rails, remove four 10-32x5/8" PPB screws and #10 split lock washers
(Figure 2-8). (Side rail spacers will come loose also.)
Step 3. Pull rear head assembly away from front head assembly.
Step 4. Re-install by doing steps 2 and 3 in reverse.
Front Head Assembly
Lamp Wires
Side Rail Spacer
NOTE:
Yoke not shown for clarity.
Rear Head Assembly
#10 Split
Lock Washer
10-32x5/8"
PPB Screw
Figure 2-8: Rear Head Assembly Removal and Replacement
02.9 663.00 10 D
23-Oct-02
25
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Rotating Gobo Replacement
WARNING: Remove power from luminaire before performing maintenance. Gobos
may be HOT after operation. Allow to cool before replacing.
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 carrier is upward.
CAUTION: Do not touch gobos with bare fingers. Wear cotton gloves or other
covering while replacing. Clean with glass cleaner and soft cloth if required.
CAUTION: Do not pull metal spring clip carrier back too far or it will not close
properly.
Step 5. If applicable, carefully pull current gobo up and out of carrier. Gobo can be
easily scratched on sides of carrier if not careful.
Step 6. Carefully install new gobo, orienting side marked "This Edge In" toward
center of gobo wheel and side marked "Lamp Side" (mirror finish) toward
lamp. Gobo can be easily scratched on sides of carrier if not careful. Ensure
gobo is firmly set in carrier grooves.
26
23-Oct-02
02. 9663.0 010 D
MAINTENANCE : MAINTENANCE PROCEDURES
2
Step 7. Re-install front cover.
Inside Edge
- orient toward center of wheel
CAUTION:
ThisEdgeIn
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
LampSide
Lamp Side (mirrored)
- orient toward luminaire lamp
Closed End
Gear
Open End
Gobo Positions
Sensor
1
open
2
6
3
5
4
Front Cover
Gobo Wheel Front View
Gobo
(black side)
Latch
Lamp End
Rotating
Gobo Wheel
CAUTION:
Be careful not to pull metal spring clip carrier
back too far or it will not close properly.
Center of Wheel
Figure 2-9: Rotating Gobo Replacement/Cleaning
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Gobo Index Timing Belt Alignment
The index timing belt (54.9663.1220) must be aligned so that the mechanism "clocks"
properly. This belt is installed around the index gear and top gear of the gobo wheel
(refer to Figure 2-11). The wheel position belt (54.2045.0001) 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 belt’s clock marks with small groove at inside of
gear. The clock marks will either be two ridges (newer belts) or one ridge and
one red mark (older belts).
Index Timing Belt
red mark will be one-tooth inside ridge,
use as clock mark (instead of ridge) if present
Ridge
Ridge
Index Gear (Larger Gear)
Arc Gobo
Bulkhead
Groove
Clock Mark
use red mark (older belts)
or
ridge (newer belts)
Index Timing Belt
Figure 2-10: Aligning Index Gear Groove and Clock Mark
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2
Step 2. If applicable, lower gobo wheel into place over rotating shaft, fitting wheel
position belt around lower gear and index timing belt around top gear. Install
4-40x1/4 " PPZ screw, split lock washer, flat black washer and flat Teflon
washer to secure gobo wheel in place. (Belt tension is automatically set by
springs of pivot mechanism.)
Step 3. Orient gobo wheel so that notch of gobo wheel gear aligns with small ridge
found on index timing belt.
Step 4. Re-check alignment of clock mark with groove of index gear. Adjust as
necessary until marks are perfectly aligned at both gears.
4-40x1/4 " PPZ screw
Split Lock Washer
Flat Black Washer
Wheel Position Gear
Teflon Washer
Wheel Position Belt
(no alignment)
Index Gear
Gobo Wheel
Index Timing Belt
(gray for clarity)
Pivot Mechanism
(automatically sets
belt tension)
Gobo Wheel Gear
Align ridge in belt with
notch in gobo wheel gear
Notch
Rotating Gobo Bulkhead Crossview
Figure 2-11: Aligning Second Clock Mark
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Gobo Wheel Bulkhead Replacement
Parts:
ASSEMBLY, GOBO BULKHEAD INCANDESCENT (21.9663.1200) - T/TS/TI
ASSEMBLY, GOBO BULKHEAD ARC (21.9663.1600) - A/AS/AI
Tools:
#2 Phillips long handle screwdriver
To remove and replace gobo wheel bulkhead:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove front cover. Refer to “Front Cover Removal” on page 24.
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.
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2
Step 7. Replace by doing steps 2 through 6 in reverse.
Gobo Bulkhead
Side Rail Spacer
Front Assembly
10-32x3/8"
PPB Screw
#10 Split-Lock
Washers
NOTE:
Incandescent model gobo
bulkhead not shown.
Figure 2-12: Gobo Bulkhead Assembly Replacement
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Gobo Gear Planet Alignment
Each gear of the gobo wheel assembly must be aligned so that the gobos will index
correctly. Use the following procedure to re-align the gears in the event the gobo
wheel is disassembled.
To re-align gobo gears:
Step 1. Place center (sun) gear at starting point so that alignment mark is directly
facing Position 1 (open) as shown in Figure 2-13.
Step 2. Set Position 6 planet gear as follows:
a. Rotate center gear clockwise until alignment mark is directly facing
Position 6.
b. Lift edge of center gear slightly (so that it will not turn), while at same
time rotating Position 6 gear until alignment mark is directly across from
center gear alignment mark. Lower center gear into place and verify
alignment.
Step 3. Set Position 5 planet gear as follows:
a. Rotate center gear clockwise until alignment mark is directly facing
Position 5.
b. Lift edge of center gear slightly (so that it will not turn), while at same
time rotating Position 5 gear until alignment mark is directly across from
center gear alignment mark. Lower center gear into place and verify
alignment.
Step 4. Set remaining planet gears by following same procedure. When all gears are
aligned, rotate center gear in full rotation to verify alignments. When
rotating, marks should align perfectly at each gear as they pass. Adjust as
necessary and recheck.
Step 5. Install flange, pulley and three 4-40x5/16" PFB screws to secure gears in
place.
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1) Start with center gear alignment
mark facing Position 1 (open).
2
2) Rotate center gear clockwise until alignment
mark is directly across from Position 6. Rotate
Position 6 gear until marks align.
Alignment Mark
1
open
6
2
6
5
3
4
Align both marks
5
3) Align remaining gobo gears
using the same method.
4) Verify alignment of all marks
and adjust as necessary.
Figure 2-13: Aligning Gobo Wheel Gears
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Shutter Assembly Replacement
Parts:
ASSEMBLY, SHUTTER (21.9663.1300) (Old Version) or
ASSEMBLY, SHUTTER 6 ROLLERS (21.9663.1350) (New Version)
Tools:
#2 Phillips long handle screwdriver+
To remove and replace shutter assembly:
Step 1. Disconnect luminaire AC input cable from power source.
CAUTION: The rear assembly is heavy and will remain attached by lamp wires.
Place luminaire on tech bench before removing rear assembly.
Step 2. Remove front cover, rear head assembly and gobo wheel bulkhead. Refer to
“Gobo Wheel Bulkhead Replacement” on page 30.
Step 3. Remove yoke leg cover (side with menu display) by removing two 6-32x1/2"
PPB screws and two 6-32x3/8" PPB screws (Figure 2-14).
6-32x1/2" PPB Screw
Controller PCB
Yoke Leg Cover
NOTE:
Head not shown for clarity.
6-32x3/8" PPB Screw
Figure 2-14: Removing Yoke Leg Cover to Access Controller PCB
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2
Step 4. At Controller PCB, disconnect shutter wiring harness at position marked
SHUTTERS.
Step 5. Noting placement, cut tie-wraps securing harness to other wires.
Step 6. Feed shutter harness cable out of yoke arm.
Step 7. At side rails, remove four 10-32x3/8" PPB screws and #10 split-lock washers
and remove shutter assembly (Figure 2-15).
CAUTION: Do not overtighten tie-wraps when re-installing.
Step 8. Replace shutter assembly by doing steps 2 through 7 in reverse.
Gobo Wheel Bulkhead
#10 Split-Lock Washers
10-32x3/8" PPB Screw
Shutter Assembly
#10 Split Lock Washer
NEW *
10-32x5/8" PPB Screw
OLD *
OR
Rear Head Assembly
Side Rail Spacer
NOTE:
Head Assembly
Yoke not shown for clarity.
* Depending on when the luminaire was manufactured.
Figure 2-15: Shutter Assembly Replacement
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Shutter Blade or Rack Replacement
Parts:
as required:
BLADE, SHUTTER, COATED SIDE A (12.9663.1323)
BLADE, SHUTTER, COATED SIDE B (12.9663.1324)
RACK, SHUTTER (10.9663.1314)
Tools:
#2 Phillips screwdriver
To remove and replace a shutter blade or rack:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove shutter assembly. Refer to “Shutter Assembly Replacement” on
page 34.
Step 3. Place shutter assembly on work bench, motor side down. Remove four
6-32x1/4" PFS screws and remove cover plate (Figure 2-16).
6-32x1/4"
PFS Screw
Cover Plate
Layer 4
6-32x1/4" PFS Screw
Cover
Separator
Spacer
Layer 3
Beveled Blade
Separator
Stiff Separator
Layer 2
Shutter
Assembly
Spacer
Straight Blade
Separator
Stiff Separator
Spacer
Beveled Blade
Separator
Layer 1
Stiff Separator
Spacer
Rack (x8)
CAUTION:
Straight Blade
Do not touch shutter blades with bare
fingers. Clean with soft cloth if touched.
Separator
Figure 2-16: Shutter Assembly Breakdown
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MAINTENANCE : MAINTENANCE PROCEDURES
2
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
Align main edge of blade with
small hole in shutter rack
Shutter Blade
Rack
Rack
Beveled
Blade
Straight
Blade
Layer 1
Install shutter blades
with dark mirror coating
facing down. DO NOT
touch blades with
bare fingers.
Layer 2
Straight
Blade
Beveled
Blade
Layer 3
Layer 4
Figure 2-17: Shutter Assembly Layer Orientation
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Edge/Zoom/Color Bulkhead Replacement
Parts:
ASSEMBLY, EDGE CONTROL, DIMMER AND COLOR (21.9663.1003)
Tools:
#2 Phillips screwdriver
To remove and replace edge/zoom/color bulkhead:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove front cover. (Refer to “Front Cover Removal” on page 24.)
Step 3. At edge/zoom/color assembly, disconnect wiring harness connections.
Step 4. At side rail, remove four 8-32x1/2" PFB screws (Figure 2-18).
Step 5. At front, remove four 8-32 Keps nuts and remove assembly.
Step 6. Replace assembly by doing steps 2 through 5 in reverse.
Side Rail
8-32x1/2" PFB Screw
Edge/Zoom/Color
Assembly
NOTE:
Yoke not shown for clarity.
8-32 Keps Nut
Figure 2-18: Edge/Zoom/Color Bulkhead Replacement
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2
Fan/Temp Switch Assembly Replacement
Note: Fan does not operate under normal luminaire operating conditions.
Parts:
CABLE ASSEMBLY, FAN/TEMP SWITCH (23.9663.2009)
Tools:
#2 Phillips screwdriver
To remove and replace fan/temp switch assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove edge/dimmer/color bulkhead. Refer to “Edge/Zoom/Color Bulkhead
Replacement” on page 38.
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
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Beam-Size Iris Assembly Replacement
Note: This procedure not applicable to all units.
Parts:
ASSEMBLY, IRIS (21.9663.1400)
Tools:
#2 Phillips screwdriver
To remove and replace beam-size iris assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove front cover. Refer to “Front Cover Removal” on page 24.
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
NOTE:
Yoke not shown for clarity.
Head Assembly
Figure 2-20: Beam-Size Iris Assembly Replacement
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2
Ignitor PCB Replacement
Note: This procedure not applicable to all units.
Parts:
PCB ASSEMBLY, IGNITOR (24.9661.1125)
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 two
6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-21).
Step 3. At ignitor PCB, disconnect lamp connectors.
Step 4. Remove four 6-32x3/8" PPB screws and remove ignitor PCB.
Step 5. Replace ignitor PCB by doing steps 2 through 4 in reverse.
6-32x1/2" PPB Screw
NOTE:
Head not shown for clarity.
Yoke Leg Cover
Ignitor PCB
6-32x3/8" PPB Screw
6-32x3/8" PPB Screw
Figure 2-21: Ignitor PCB Replacement
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Power Supply Replacement
Parts:
POWER SUPPLY, 130W +24V/6.3A (69.3126.0150)
Tools:
#1 Phillips screwdriver, 5/16 inch nutdriver
To remove and replace power supply:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove yoke leg cover (side without menu display) by removing two
6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-22).
Step 3. At power supply, disconnect all connectors. Power input and output wiring is
connected as follows:
V1
ADJ
V1
V1
G
Red
Black
(output) (output)
G
N
V2
Grn/Yel
(input)
White
(input)
L
Black
(input)
Step 4. To access top mounting screw and Keps nut, remove crossmember assembly
from yoke by removing sixteen 10-32x1/2" PPB screws.
Step 5. At interior of yoke assembly, remove one 6-32x3/8" PPB screw (and 6-32
Keps nut) which secures top end of power supply.
Step 6. At outer portion of yoke, remove two additional 6-32 Keps nuts and two
6-32x3/8" PPB screws and remove power supply.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Step 7. Replace power supply by doing steps 2 through 6 in reverse.
Crossmember Assembly
NOTE:
Head not shown for clarity.
10-32x1/2" PPB Screw
6-32x1/2" PPB Screw
Yoke Leg Cover
6-32x3/8" PPB Screw
(can only be accessed by
removing crossmember)
6-32x3/8" PPB Screw
6-32x3/8" PPB Screws
Power Supply
6-32 Keps Nut (3)
Figure 2-22: Power Supply Replacement
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Controller PCB Replacement
Parts:
PCB ASSEMBLY, CONTROLLER (24.9663.1930)
Tools:
#1 Phillips screwdriver
To remove and replace controller PCB:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove yoke leg cover (side with menu display) by removing two
6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-23).
Step 3. Remove display overlay and plate, by removing three 6-32x1/2" PPB screws.
Step 4. At controller PCB, disconnect wiring at connectors marked:
a. GOBO/COLOR/ZOOM/EDGE/DIMMER/ROTATE
b. PAN/TILT
c. POWER
d. COMM
e. SHUTTERS (if applicable)
f. BALLAST (if applicable)
Step 5. At controller PCB, remove four 6-32x3/8" PPB screws and remove PCB.
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2
Step 6. Replace controller PCB by doing steps 2 through 5 in reverse.
NOTE:
Head not shown for clarity.
6-32x1/2" PPB Screw
6-32x3/8"
PPB Screw
Controller PCB
Display Plate
Display Overlay
Yoke Leg Cover
6-32x3/8" PPB Screw
6-32x1/2" PPB Screw
Figure 2-23: Controller PCB Replacement
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Tilt Encoder PCB Replacement
Parts:
PCB ASSY, PAN/TILT ENCODER (24.9661.0629)
Tools:
#2 Phillips screwdriver
To remove and replace tilt encoder PCB:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove yoke leg cover (side with menu display) by removing two
6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-24).
Step 3. At tilt encoder PCB, remove two 4-32 screws.
Step 4. Disconnect connectors at J1 and J2.
Step 5. Remove encoder PCB.
Step 6. Replace encoder PCB by doing steps 2 through 5 in reverse.
Tilt Encoder PCB
4-32 Screw
Figure 2-24: Tilt Encoder PCB Replacement
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Tilt Motor Assembly Replacement
Parts:
ASSEMBLY, TILT MOTOR (21.9663.1816)
Tools:
#2 Phillips screwdriver
To remove and replace tilt motor assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove yoke leg cover (side with menu display) by removing two
6-32x1/2" PPB screws and two 6-32x3/8" PPB screws (Figure 2-25).
Step 3. Remove display overlay and plate, by removing three 6-32x1/2" PPB screws.
Step 4. At controller PCB, disconnect wiring at connectors marked:
a. GOBO/COLOR/ZOOM/EDGE/DIMMER/ROTATE
b. PAN/TILT
c. POWER
d. COMM
e. SHUTTERS (if applicable)
f. BALLAST (if applicable)
Step 5. Remove four 6-32x3/8" PPB screws and remove controller PCB.
Step 6. At encoder PCB, remove two 4-32 screws.
Step 7. Disconnect connectors at J1 and J2 and remove encoder PCB.
Step 8. At tilt motor assembly, loosen four 6-32x1" PPB screws. Slide assembly
forward and remove belt from pulley.
Step 9. Remove four 6-32x1" PPB screws and #6 flat washers and remove tilt motor
assembly (spring will come loose also).
Step 10. Replace by doing steps 2 through 9 in reverse. (Belt tension is automatically
set by spring.)
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
.
6-32x1/2" PPB Screw
Yoke Leg Cover
6-32x3/8"
PPB Screw
Controller PCB
Display Plate
Display Overlay
6-32x1/2" PPB Screw
6-32x3/8" PPB Screw
NOTE:
Head not shown for clarity.
Tilt Motor Assembly
#6 Flat Washer
6-32x1" PPB Screw
Spring
Figure 2-25: Tilt Motor Assembly Replacement
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2
Pan Motor Assembly Replacement
Parts:
ASSEMBLY, PAN MOTOR (21.9663.1815)
Tools:
#2 Phillips screwdriver
To remove and replace pan motor assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove yoke leg covers by removing two 6-32x1/2" PPB screws and two 632x3/8" PPB screws on each side (Figure 2-26).
Step 3. Remove crossmember assembly from yoke by removing sixteen 10-32x1/2"
PPB screws.
Step 4. At crossmember assembly, remove pan wire shield by removing four
4-40x3/8" PPZ screws.
Step 5. At pan motor assembly, loosen four 6-32x1" PPB screws. Slide assembly
forward and remove belt from pulley.
Step 6. Remove four 6-32x1" PPB screws and #6 flat washers and remove pan motor
assembly (nut plate will come loose also).
Step 7. Replace pan motor assembly by doing steps 2 through 6 in reverse. (Belt
tension is automatically set by spring.)
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Pan Wire Shield
4-40x3/8" PPZ Screw
6-32x1"
PPB Screw
Spring
#6 Flat
Washer
Pan Motor
Assembly
Timing Belt
Nut Plate
Crossmember Assembly
10-32x1/2" PPB Screw
Yoke Leg Cover
6-32x1/2"
PPB Screw
6-32x3/8"
PPB Screw
NOTE:
Head not shown for clarity.
Figure 2-26: Pan Motor Assembly Replacement
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2
DMX Input PCB Replacement
Parts:
PCB ASSEMBLY, DMX INPUT (24.9663.1830)
Tools:
#2 Phillips screwdriver
To remove and replace DMX input PCB:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At pan tube cover, remove four 8-32x3/8" PFZ screws and remove cover
(Figure 2-27).
Step 3. Remove four 4-40x3/8" PPZ 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"
PFZ Screw
Pan Tube Cover
DMX Input PCB
4-40x3/8" PPZ Screw
Figure 2-27: DMX Input PCB Replacement
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Cleaning Optical Lenses and Filters
WARNING: Remove power from luminaire before performing maintenance.
The front lens and gobos may require cleaning after extended use. A common glass
cleaner can be used along with a soft, lint-free cloth to clean these components.
To access gobos, refer to “Rotating Gobo Replacement” on page 26.
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CHAPTER 3.
Illustrated Parts Breakdown
This chapter contains illustrated parts breakdowns for all VL1000 assemblies
including the arc ballast unit.
• Drawing Trees
• Top Assembly
• Head Assembly
• Yoke Assembly
• Cables
• Arc Ballast Assembly
The following abbreviations are used in the Illustrated Parts Breakdown to identify
parts specific to certain models:
02.9 663.00 10 D
ABBREVIATION
MEANING
T
VL1000 T Incandescent Luminaire
TI
VL1000 TI Incandescent Luminaire w/ Beam-Size Iris
TS
VL1000 TS Incandescent Luminaire w/ Shutter System
A
VL1000 A Arc Luminaire
AI
VL1000 AI Arc Luminaire w/ Beam-Size Iris
AS
VL1000 AS Arc Luminaire w/ Shutter System
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VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Drawing Trees
VL1000 Incandescent Luminaires
VL1000 Luminaire (Incandescent Versions)
20.9663.0001.01 (T) Rev D or 20.9663.0001.02 (TS) Rev D or 20.9663.0001.03 (TI) Rev D
Yoke to Head Ground
Cable Assembly
Shutter Harness
Cable Assembly
Color/Gobo/Lens Harness
Cable Assembly
Controller PCB
Assembly
25.9663.2019 Rev A
25.9663.2040 Rev C
25.9663.2050 Rev H
24.9663.1930 Rev H
COT Flag Assembly
Front Cover Assembly
21.9663.1845 Rev 0
Head Assembly
21.9663.1000.01 (T) Rev B
21.9663.1000.02 (TS) Rev B
21.9663.1000.03 (TI) Rev B
22.9663.1038 Rev A
21.9663.1028 Rev A
continued next page
Crossmember Assembly
Front Head Assembly
21.9663.1001.01 (T) Rev G
21.9663.1001.02 (TS) Rev G
21.9663.1001.03 (TI) Rev G
Shutter Assembly
21.9663.1300 Rev Q (old)
21.9663.1350 Rev 0 (new)
Beam-Size Iris Assembly
21.9663.1400 Rev D
Edge Control, Zoom, Dimmer
& Color Assembly
21.9663.1003 Rev D
Color Changer Assembly
21.9663.1500 Rev K
Lens #6 Assembly
21.9663.1760 Rev 0
Gel Frame Holder
Assembly
Yoke Legs Assembly
21.9663.1850.01 (T/TS) Rev C
21.9663.1811.01 (T/TS) Rev D
Incandescent Gobo
Wheel Assembly
Outer Crossmember
Assembly
21.9663.1200 (T/TS) Rev P
21.9663.1813 Rev A
Gobo Wheel Assembly
Pan Motor Assembly
21.9663.1201 Rev B
21.9663.1815 Rev B
Gobo Bulkhead FAB Assembly
Pan/Tilt Encoder
PCB Assembly
22.9663.1226 Rev M
Temperature Sensor
Electrical Assembly
24.9661.0629 Rev 0
Inner Crossmember
Assembly
23.9663.1248.01 (T/TS) Rev A
Wheel Sensor PCB
21.9663.1812 Rev B
24.9663.1230 Rev D
Wheel Sensor PCB
24.9663.1230 Rev D
Index Sensor PCB
24.9663.1231 Rev B
Pan EOT Cable Assembly
25.9663.2001 Rev 0
Lens #7 Assembly
21.9663.1770 Rev 0
Lens #8 Assembly
21.9663.1780 Rev B
Fan Assembly
23.9663.2009 Rev C
Rear Head Assembly
21.9663.1002.01 Rev J (T/TS)
Barrel Assembly
Pan Tube Assembly
21.9663.1710 Rev B
21.9663.1819.01 (T/TS) Rev G
Cover Plate Assembly
continued next page
21.9663.1534 Rev 0
Abbreviation
Color Changer Drive Motor
21.9663.1501 Rev C
continued next page
Meaning
T
VL1000 T Incandescent
TI
VL1000 TI Incandescent
w/ Beam-Size Iris
TS
VL1000 TS Incandescent
w/ Shutter System
Figure 3-1: VL1000 Incandscent Luminaires Drawing Tree (Part 1)
54
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : DRAWING TREES
3
VL1000 Incandescent Luminaires (cont.)
continued from previous page
continued from previous page
Rear Head Assembly
Yoke Legs Assembly
21.9663.1002.01 Rev J (T/TS)
21.9663.1850.01 (T/TS) Rev C
Bulkhead Assembly
Tilt Motor Assembly
21.9663.1101.01 (T/TS) Rev G
21.9663.1816 Rev B
Back Cap Assembly
Pan/Tilt Encoder PCB Assembly
21.9663.1127.01 (T/TS) Rev D
24.9661.0629 Rev 0
Incandescent Lamp Power
Cable Assembly
Wheel Sensor PCB
24.9663.1230 Rev D
25.9663.2033 Rev E
LVS Chassis Ground Cable Assembly
25.9663.2017 Rev B
Tilt COT Cable Assembly
25.9663.2002 Rev 0
continued from previous page
Pan/Tilt Control Cable Asembly
25.9663.2020 Rev A
Pan Tube Assembly
LVS DC Output Cable Assembly
21.9663.1819.01 (T/TS) Rev G
25.9663.2024 Rev A
DMX Input PCB Assembly
24.9663.1830 Rev A
AC Line Input Cable Assembly
25.9663.2015 Rev A
Incandescent LVS AC Input Cable Assembly
25.9663.2016.01 Rev 0
Data I/O Link Cable Assembly
25.9663.2022 Rev A
Incandescent Power Input Cable Assembly
25.9663.2030 Rev A
Abbreviation
Meaning
T
VL1000 T Incandescent
TI
VL1000 TI Incandescent
w/ Beam-Size Iris
TS
VL1000 TS Incandescent
w/ Shutter System
Figure 3-2: VL1000 Incandscent Luminaires Drawing Tree (Part 2)
02.9 663.00 10 D
23-Oct-02
55
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
VL1000 Arc Luminaires
VL1000 Luminaire (Arc Versions)
20.9663.0001.11 (A) Rev D or 20.9663.0001.12 (AS) Rev D or 20.9663.0001.13 (AI) Rev D
Yoke to Head Ground
Cable Assembly
Shutter Harness
Cable Assembly
Color/Gobo/Lens Harness
Cable Assembly
Controller PCB
Assembly
25.9663.2019 Rev A
25.9663.2040 Rev C
25.9663.2050 Rev H
24.9663.1930 Rev H
COT Flag Assembly
Front Cover Assembly
21.9663.1845 Rev 0
Head Assembly
21.9663.1000.11 (A) Rev B
21.9663.1000.12 (AS) Rev B
21.9663.1000.13 (AI) Rev B
22.9663.1038 Rev A
21.9663.1028 Rev A
continued next page
Crossmember Assembly
Front Head Assembly
21.9663.1001.11 (A) Rev G
21.9663.1001.12 (AS) Rev G
21.9663.1001.13 (AI) Rev G
Shutter Assembly
21.9663.1300 Rev Q (old)
21.9663.1350 Rev 0 (new)
Beam-Size Iris Assembly
21.9663.1400 Rev D
Edge Control, Zoom, Dimmer
& Color Assembly
21.9663.1003 Rev D
Color Changer Assembly
21.9663.1500 Rev K
Lens #6 Assembly
21.9663.1760 Rev 0
Gel Frame Holder
Assembly
Yoke Legs Assembly
21.9663.1850.11 (A/AS) Rev C
21.9663.1811.11 (A/AS) Rev D
Arc Gobo/Dimmer
Bulkhead Assembly
21.9663.1600 (A/AS) Rev N
Outer Crossmember
Assembly
21.9663.1813 Rev A
Gobo Wheel Assembly
21.9663.1201 Rev B
Pan Motor Assembly
21.9663.1815 Rev B
Dimmer Wheel Assembly
Pan/Tilt Encoder
PCB Assembly
22.9663.1629 Rev D
Temperature Sensor
Electrical Assembly
23.9663.1248.11 (A/AS) Rev A
24.9661.0629 Rev 0
Inner Crossmember
Assembly
Wheel Sensor PCB
21.9663.1812 Rev B
24.9663.1230 Rev D
Wheel Sensor PCB
Index Sensor PCB
24.9663.1231 Rev B
24.9663.1230 Rev D
Pan EOT Cable Assembly
25.9663.2001 Rev 0
Lens #7 Assembly
21.9663.1770 Rev 0
Lens #8 Assembly
21.9663.1780 Rev B
Fan Assembly
23.9663.2009 Rev C
Rear Head Assembly
21.9663.1002.11 Rev J (A/AS)
Barrel Assembly
21.9663.1710 Rev B
Pan Tube Assembly
21.9663.1819.11 (A/AS) Rev G
Cover Plate Assembly
continued next page
21.9663.1534 Rev 0
Abbreviation
Color Changer Drive Motor
21.9663.1501 Rev C
continued next page
Meaning
A
VL1000 A Arc
AI
VL1000 AI Arc w/
Beam-Size Iris
AS
VL1000 AS Arc w/
Shutter System
Figure 3-3: VL1000 Arc Luminaires Drawing Tree (Part 1)
56
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : DRAWING TREES
3
VL1000 Arc Luminaires (cont.)
continued from previous page
continued from previous page
Rear Head Assembly
Yoke Legs Assembly
21.9663.1002.11 Rev J (A/AS)
21.9663.1850.11 (A/AS) Rev C
Bulkhead Assembly
Tilt Motor Assembly
21.9663.1101.11 (A/AS) Rev G
21.9663.1816 Rev B
Back Cap Assembly
Pan/Tilt Encoder PCB Assembly
21.9663.1127.11 (A/AS) Rev D
24.9661.0629 Rev 0
Ignitor to Lamp Socket
Cable Assembly
Wheel Sensor PCB
24.9663.1230 Rev D
25.9663.2036 Rev B
Ignitor PCB
24.9661.1125 Rev D
Tilt COT Cable Assembly
continued from previous page
25.9663.2002 Rev 0
Pan/Tilt Control Cable Asembly
Pan Tube Assembly
25.9663.2020 Rev A
21.9663.1819.11 (A/AS) Rev G
LVS DC Output Cable Assembly
25.9663.2024 Rev A
DMX Input PCB Assembly
24.9663.1830 Rev A
AC Line Input Cable Assembly
Arc Ballast Assembly
25.9663.2015 Rev A
21.9663.1900 Rev E
Arc LVS AC Input Cable Assembly
625W Ballast PCB
25.9663.2016.11 Rev 0
24.9663.1901 Rev B
Data I/O Link Cable Assembly
625W Ballast Rider PCB
25.9663.2022 Rev A
24.9663.1902 Rev A
Arc Power Input (Pigtail) Cable Assembly
575W Ballast I/O Cable Assembly
25.9663.1921 Rev D
25.9663.1907 Rev B
Ballast Control Link Cable Assembly
25.9663.2021 Rev 0
Arc Power to Ignitor Cable Asembly
25.9663.2035 Rev B
Abbreviation
Meaning
A
VL1000 A Arc
AI
VL1000 AI Arc w/
Beam-Size Iris
AS
VL1000 AS Arc w/
Shutter System
Figure 3-4: VL1000 Arc Luminaires Drawing Tree (Part 2)
02.9 663.00 10 D
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57
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Top Assembly
Included Items Kit
28.9663.0001 Rev 0
Refer to Figure 3-5.
No.
Item
Qty.
UM.
1
02.8001.0001
1
EA
PRODUCT SUPPORT SHEET, VARI-LITE INC. CUSTOMER SERVICE
2
02.8051.0001
1
EA
CARD, LIMITED WARRANTY 01-16-01
3
02.8700.0001
1
EA
CARD, PRODUCT REGISTRATION - VL2000
4
02.9663.0001
1
EA
USER’S MANUAL, VL1000 LUMINAIRE
5
02.9663.0002
1
EA
UNPACK/QUICK START SHEET, VL1000
6
07.9663.0030
1
EA
SHIPPING BOX, CARDBOARD - VL1000
7
52.6541.0001
1
EA
CONN, BLUE CABLE PWR INLET 3POLE LOCKING - POWERCON
8
71.2552.0100
1
EA
1000 WATT INCANDESCENT LAMP, 100 VAC (T/TS/TI ONLY)
71.2552.0115
1
EA
1000 WATT INCANDESCENT LAMP, 115 VAC (T/TS/TI ONLY)
71.2552.0230
1
EA
1000 WATT INCANDESCENT LAMP, 230 VAC (T/TS/TI ONLY)
1
3
Description
5
2
4
7
6
8
Arc Ballast (Arc Models Only)
VL1000 Luminaire
- page 153
- page 60
Figure 3-5: Included Items
58
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Label Locations
Rev A
Refer to Figure 3-6.
No.
Item
Qty.
UM.
1
04.9661.0033
1
EA
LABEL, WARNING -2000 SERIES
2
04.9661.0034
1
EA
LABEL, RELAMPING -2000 SERIES
3
04.9661.0037
1
EA
LABEL, 625W ARC -2400 SERIES (A/AI/AS ONLY)
4
04.9663.1837
1
EA
LABEL, PATENT
5
04.9663.1860
1
EA
LABEL, 1000 SERIES COMPLIANCE
6
04.9663.1861
1
EA
LABEL, AC INPUT RATING LABEL MODEL VL1000T
04.9663.1862
1
EA
LABEL, AC INPUT RATING LABEL MODEL VL1000TS
04.9663.1863
1
EA
LABEL, AC INPUT RATING LABEL MODEL VL1000A
04.9663.1864
1
EA
LABEL, AC INPUT RATING LABEL MODEL VL1000AS
04.9663.1873
1
EA
LABEL, AC INPUT RATING LABEL MODEL VL1000TI
04.9663.1874
1
EA
LABEL, AC INPUT RATING LABEL MODEL VL1000AI
04.9663.1865
1
EA
LABEL, 1000 SERIES INCANDESCENT (T/TI/TS ONLY)
7
Description
6
5
3, 7
2
1
2
4
Figure 3-6: Label Locations
02.9 663.00 10 D
23-Oct-02
59
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
VL1000 Luminaire
20.9663.0001.01
20.9663.0001.02
20.9663.0001.03
20.9663.0001.11
20.9663.0001.12
20.9663.0001.13
(T) Rev D
(TS) Rev D
(TI) Rev D
(A) Rev D
(AS) Rev D
(AI) Rev D
Refer to Figure 3-7
No.
Item
Qty.
UM.
Description
1
10.9663.1823
1
EA
PULLEY, TILT
2
10.9663.1824
1
EA
SPACER, TILT TUBE
3
10.9663.1831
1
EA
PLATE, YOKE ARM DISPLAY
4
10.9663.1832
1
EA
OVERLAY, DISPLAY
5
10.9663.1835
1
EA
COVER, YOKE ARM DISPLAY SIDE
6
10.9663.1836
1
EA
COVER, YOKE ARM NO DISPLAY
7
21.9663.1000.01
1
EA
ASSY, HEAD (T ONLY)
21.9663.1000.02
1
EA
ASSY, HEAD W/ SHUTTER (TS ONLY)
21.9663.1000.03
1
EA
ASSY, HEAD W/ IRIS (TI ONLY)
21.9663.1000.11
1
EA
ASSY, HEAD W/ DIMMER (A ONLY)
21.9663.1000.12
1
EA
ASSY, HEAD W/ SHUTTER & DIMMER (AS ONLY)
21.9663.1000.13
1
EA
ASSY, HEAD W/ IRIS (AI ONLY)
21.9663.1811.01
1
EA
ASSY, CROSSMEMBER (T, TI & TS ONLY)
21.9663.1811.11
1
EA
ASSY, CROSSMEMBER (A, AI & AS ONLY)
9
21.9663.1845
1
EA
ASSY, COT FLAG
10
21.9663.1850.01
1
EA
ASSY, YOKE LEGS (T, TI & TS ONLY)
21.9663.1850.11
1
EA
ASSY, YOKE LEGS (A, AI & AS ONLY)
11
22.9663.1038
1
EA
ASSY, FRONT COVER
12
24.9663.1930
1
EA
PCB ASSY, VL1000 CONTROLLER
-
25.9663.2019
1
EA
CABLE ASSY, YOKE TO HEAD GROUND - NOT SHOWN
25.9663.2036
1
EA
CABLE ASSY, IGNITOR TO LAMP (A/AI/AS ONLY)- NOT SHOWN
EA
CABLE ASSY, SHUTTER HARNESS (AS/TS ONLY) - NOT SHOWN
25.9663.2050
1
EA
CABLE ASSY, COLOR/GOBO/LENS HARNESS - NOT SHOWN
13
53.2019.0004
4
EA
NUT, 3/8-16 X 7/32"THK HEX JAM GRD5 ZINC PLT
14
53.6517.0001
3
EA
SCREW, 10-32 X 3/8"LG PPZ
15
53.6543.0001
8
EA
SCREW, 6-32 X 3/8" PPB
8
60
25.9663.2040
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
No.
Item
Qty.
UM.
16
53.6612.0001
7
EA
SCREW, 6-32 X 1/2" PPB
17
53.6627.0001
12
EA
SCREW, 10-32 X 5/8" PPB
18
53.6634.0003
4
EA
SCREW, 3/8-16 X 1/2"LG SOC HD CAP ALLY STL
19
53.6642.0001
3
EA
SCREW, 10-32 X 5/8" SLF TAP TYPE F PPZ
20
54.1255.0001
2
EA
BEARING ASSY, BLACK FLUSH MOUNT HOUSING
21
54.2047.0039
1
EA
BELT, TIMING GT 3MM PITCH 350GRV 6MM WD NEOPRENE
3
Description
6
8
16 (x2)
10
16 (x2)
5
15 (x2)
17 (x12)
12
14 (x3)
18 (x4)
13 (x2)
20
7
15 (x2)
15 (x4)
11
16 (x3)
20
13
(x2)
9
4 3
19 (x3)
21
1
2
Figure 3-7: VL1000 Luminaire
02.9 663.00 10 D
23-Oct-02
61
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Front Cover Assembly
22.9663.1038 Rev A
Refer to Figure 3-8.
No.
Item
Qty.
UM.
Description
1
10.9663.1020
1
EA
COVER, FRONT VL1000
2
21.9663.1028
1
EA
ASSY, GEL FRAME HOLDER
3
53.2004.0001
4
EA
NUT, 8-32 KEP
4
53.6545.0007
3
EA
SCREW, 8-32 X 3/8" PFB
5
53.6552.0002
1
EA
SCREW, 8-32 X 1/2" PFB
1
3 (x4)
2
4 (x3)
5
Figure 3-8: Front Cover Assembly
62
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Gel Frame Holder Assembly
21.9663.1028 Rev A
Refer to Figure 3-9.
No.
Item
Qty.
UM.
Description
1
10.9663.1027
1
EA
HOLDER, GEL FRAME
2
10.9663.1031
1
EA
LATCH, GEL FRAME
3
55.6568.0026
1
EA
SPRING, CPRSN .180"OD .810"LG .026" WIRE DIA SS
4
55.6738.0003
.06
FT
TUBING, SILICONE RUBBER 1/8"ID X 1/4"OD TRANSLUCENT
3
4
2
1
Figure 3-9: Gel Frame Holder Assembly
02.9 663.00 10 D
23-Oct-02
63
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
COT Flag Assembly
21.9663.1845 Rev 0
Refer to Figure 3-10.
No.
Item
Qty.
UM.
1
Description
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
3
Figure 3-10: COT Flag Assembly
64
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Controller PCB Assembly
24.9663.1930 Rev H
Refer to Figure 3-11.
No.
Item
Qty.
UM.
Description
Ref.
1
10.9663.1840
1
EA
HEAT SINK, MAIN CONTROLLER
-
PCB, VL1000 CONTROLLER
-
2
11.9663.1930
1
EA
3
50.2769.0001
20
EA
SOCKET, 28PIN PLCC SMT
XU9-XU28
4
52.6259.0004
1
EA
HEADER, 4POS, MTA-100 SHROUDED RT
ANG
J3
5
52.6445.0005
1
EA
HEADER, 5POS, MTA-100 SHROUDED R/A
J2
6
52.6598.0040
1
EA
HEADER, 20PIN DUAL ROW AMP MODU RT
ANG THRU
J4
7
52.6598.0080
1
EA
HEADER, 40PIN DUAL ROW AMP MODU RT
ANG THRU
J6
8
52.6598.0100
1
EA
HEADER, 50PIN DUAL ROW AMP MODU RT
ANG THRU
J5
9
52.6627.0005
1
EA
HEADER ASSY, 5POS MTA-156 FRCTN LOCK
RT ANG .045" SQ
J1
10
52.6631.0001
1
EA
CONNECTOR, ZEBRA ELASTOMERIC
-
11
52.8412.0026
1
EA
CONN, 26 PIN .025" SQ PIN SOCKET SUR MT
J9
12
53.2200.0004
6
EA
NUT, 4-40 KEPS SS
-
13
53.6519.0001
6
EA
SCREW, 4-40 X 5/8" PPZ VL-1
-
14
53.6659.0003
4
EA
SCREW, 2-56 X 3/8"
-
15
55.6569.0001
4
EA
WASHER, LOCK #2 SPLIT RING ZINC STL
-
16
55.6621.0001
6
EA
WASHER, #4 FLAT ZINC
-
17
55.6821.0002
4
EA
STANDOFF, 5/32" RND 2-56 .125" LG BRASS
SWAGE TYPE, .105"
-
18
60.1160.0000
2
EA
RES, 1/16W 0 OHM CHIP THK FLM SMT0402
R263 & R266
19
60.1161.2673
24
EA
RES, 1/16W 1% 2.67 K CHIP THK FLM
SMT0402
R74, R79, R82, R89,
R93, R100, R104,
Ref. for 19 continued:
20
60.1161.4323
02.9 663.00 10 D
R111, R168, R173, R176, R183, R187, R194, R198, R205, R212, R218, R221, R227, R230, R236,
R239 & R245
16
EA
RES, 1/16W 1% 4.32 K CHIP THK FLM
SMT0402
23-Oct-02
R30, R35, R38, R45,
R49, R56, R60, R67,
R124, R129, R132,
R139, R143, R150,
R154 & R161
65
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
21
60.1161.7503
80
EA
Ref. for 21 continued:
Ref.
RES, 1/16W 1% 7.50 K CHIP THK FLM
SMT0402
R33, R36, R37, R42,
R43, R47, R48, R53,
R54, R58, R59, R64, R65, R69, R70, R72, R77, R80, R81, R86, R87, R91, R92, R97, R98, R102,
R103, R108, R109, R113, R114, R116, R127, R130, R131, R136, R137, R141, R142, R147, R148,
R152, R153, R158, R159, R163, R164, R166, R171, R174, R175, R180, R181, R185, R186, R191,
R192, R196, R197, R202, R203, R207, R208, R210, R215, R216, R219, R220, R224, R225, R228,
R229, R233, R234, R237, R238, R242, R243, R246 & R247
22
60.1165.1002
9
EA
RES, 1/16W 5% 100 OHM CHIP THK FLM
SMT0402
R22-R26, R28, R118,
R120 & R277
23
60.1165.1003
25
EA
RES, 1/16W 5% 1.0K CHIP THK FLM SMT0402
R254, R257-R262,
R264, R265, R267,
R269, R271, R273,
R274, R286-R289,
R297, R298, R301R305
24
60.1165.1004
45
EA
RES, 1/16W 5% 10 K CHIP THK FLM SMT0402
R9, R31, R34, R39,
Ref. for 24 continued:
R44, R50, R55, R61, R66, R75, R78, R83, R88, R94, R99, R105, R110, R125, R128, R133, R138,
R144, R149, R155, R160, R169, R172, R177, R182, R188, R193, R199, R204, R213, R217, R222,
R226, R231, R235, R240, R244, R292, R294, R296 & R306
25
60.1165.1803
3
EA
RES, 1/16W 5% 1.8 K CHIP THK FLM SMT0402
R2, R3 & R300
26
60.1165.2201
8
EA
RES, 1/16W 5% 22 OHM CHIP THK FLM
SMT0402
R249, R250. R251,
R253, R283, R284,
R285 & R291
27
60.1165.2404
20
EA
RES, 1/16W 5% 24.0 K CHIP THK FLM
SMT0402
R32, R40, R51, R62,
R76, R84, R95, R106,
R126, R134, R145,
R156, R170, R178,
R189, R200, R214,
R223, R232 & R241
28
60.1165.2702
3
EA
RES, 1/16W 5% 270 OHM CHIP THK FLM
SMT0402
R13, R122 & R123
29
60.1165.3302
4
EA
RES, 1/16W 5% 330 OHM CHIP THK FLM
SMT0402
R8, R290, R293 &
R295
30
60.1165.3604
2
EA
RES, 1/16W 5% 36.0 K CHIP THK FLM
SMT0402
R1 & R4
31
60.1165.4702
4
EA
RES, 1/16W 5% 470 OHM CHIP THK FLM
SMT0402
R5-R7 & R12
32
60.1165.4703
17
EA
RES, 1/16W 5% 4.7 K CHIP THK FLM SMT0402
R27, R29, R119,
R121, R248, R252,
R255, R256, R268,
R270, R272, R275,
R276, R278-R280 &
R282
33
60.1165.8203
1
EA
RES, 1/16W 5% 8.2K OHM CHIP THK FLM
SMT0402
R299
34
60.3242.1000
40
EA
RES, 1W 1% 1.0 OHM WW SUR MT
R14-R21, R41, R46,
Ref. for 34 continued:
66
Description
R52, R57, R63, R68, R71, R73, R85, R90, R96, R101, R107, R112, R115, R117, R135, R140,
R146, R151, R157, R162, R165, R167, R179, R184, R190, R195, R201, R206, R209 & R211
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
No.
Item
Qty.
UM.
35
60.9460.1502
1
36
60.9466.4703
37
3
Description
Ref.
EA
RES, .1W 5% 150.0 OHM 100V CHIP THICK
FILM SMT0805
R10
1
EA
RES, 1/4W 5% 4.7K 200V CHIP THK FLM
SMT1210
R11
61.4817.1004
1
EA
RES NET,
R281
38
62.4225.0107
8
EA
CAP, 100UF 35V 20% ALUM ELECTRO SUR
MT
C240-C244, C246C248
39
62.4227.0107
2
EA
CAP, 100UF 10V 20% ALUM ELECTRO SUR
MT
C238 & C239
40
62.4228.0106
20
EA
CAP, 10UF 50V 20% ALUM ELECTRO SUR
MT
C5-C7, C9, C16, C25,
C34, C43, C52, C61,
C70, C79, C88, C97,
C106, C115, C124,
C133, C142 & C151
41
62.4240.0103
65
EA
CAP, .01UF 25V 10% CER CHIP SUR MT X7R
EIA0603
C13, C18, C22, C27,
C31, C36, C40, C45,
Ref. for 41 continued:
42
62.4240.0104
Ref. for 42 continued:
43
62.4240.0223
Ref. for 43 continued:
C49, C54, C58, C63, C67, C72, C76, C81, C85, C90, C94, C99, C103, C108, C112, C117, C121,
C126, C130, C135, C139, C144, C148, C153, C157, C158, C162, C166, C170, C174, C178, C182,
C186-C188, C191-C194, C197, C198, C200, C202, C203, C207, C210, C211, C216, C220, C222C228, C232
49
EA
CAP, .1UF 25V 10% CER CHIP SUR MT X7R
EIA0603
C1-C4, C8, C14, C23,
C32, C41, C50, C59,
C68, C77, C86, C95, C104, C113, C122, C131, C140, C149, C159, C167, C175, C183, C189,
C190, C195, C196, C199, C201, C204-C206, C208, C209, C212, C213- C215, C217-C219, C221,
C229-C231, C233 & C245
40
EA
CAP, .022UF 25V 10% CER CHIP SUR MT X7R
EIA0603
C10, C17, C19, C26,
C28, C35, C37, C44,
C46, C53, C55, C62, C64, C71, C73, C80, C82, C89, C91, C98, C100, C107, C109, C116, C118,
C125, C127, C134, C136, C143, C145, C152, C154, C161, C163, C169, C171, C177, C179 &
C185
44
62.4245.0272
20
EA
CAP, 2700 PF 25V 10% CER CHIP SUR MT X7R
EIA0402
C12, C21, C30, C39,
C48, C57, C66, C75,
C84, C93, C102,
C111, C120, C129,
C138, C147, C156,
C165, C173 & C181
45
62.4245.0471
40
EA
CAP, 470PF 25V 10% CER CHIP SUR MT X7R
EIA0402
C11, C15, C20, C24,
C29, C33, C38, C42,
Ref. for 45 continued:
C47, C51, C56, C60, C65, C69, C74, C78, C83, C87, C92, C96, C101, C105, C110, C114, C119,
C123, C128, C132, C137, C141, C146, C150, C155, C160, C164, C168, C172, C176, C180 &
C184
46
64.4029.0001
1
EA
OSCILLATOR, 40.000 MHZ SM7745HV SUR
MT
47
67.4012.0001
2
EA
FILTER, EMI 600 OHM 1MHZ CHIP FERRITE
FB1 & FB2
INDUCTOR, 100UH 2.22A PE-54037S
L1 & L2
FUSE, PTC 500MA 60V SMD050
PTC1-PTC4
48
68.4581.0001
2
EA
49
70.3763.0001
4
EA
02.9 663.00 10 D
23-Oct-02
Y1
67
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
50
72.2129.0001
1
51
74.1085.0001
52
68
Description
Ref.
EA
DISPLAY, LCD 8 CHARACTER X1 LINE
U40
4
EA
SWITCH, 12MM TACT MOM N/O
S2-S5
74.1085.0011
4
EA
CAP, SWITCH 8MM SQ GREY -TL1100160Q
-
53
74.1097.0001
1
EA
SWITCH, TACT, TIGHT ANGLE, THRU HOLE
S1
54
82.5329.0001
2
EA
DIODE, MBRS340T3 40V 3A SCHOTTKY SUR
MT
D12 & D13
55
82.5350.0001
10
EA
DIODE, BAT54SLT1 DUAL SCHOTTKY
CATHODE TO ANODE CONNECTED 30V
200MA
D2-D11
56
82.5361.0001
4
EA
DIODE, ZENER TVS 10V 23A SMT
Z1-Z4
57
82.5362.0001
32
EA
DIODE, SCHOTTKY BARRIER RECTIFIER,
40V, 1A, SMT
D17-D48
58
83.3174.0001
1
EA
IC, 2596S VOLTAGE REG 5V TO-263 SUR MT
VR3
59
83.3174.0004
1
EA
IC, LM2596S-3.3 VOLTAGE REGULATOR
PWR CONVERTER 150K HZ 3A STEPDOWN 0
VR2
60
83.3198.0001
1
EA
IC, LP3965ES-2.5 LINEAR REGULATOR 1.5A
FAST ULTRA LOW DROPOUT
VR1
61
84.4234.0002
1
EA
IC, RS485 TRANSCEIVER SUR MT SOIC PKG
U2
62
84.4297.0002
2
EA
IC, MT48LC4M16A2TG-75 DRAM IMEGX16X4
U31 & U35
63
84.4298.0001
1
EA
IC, MCF5307FT90B INT COLDFIRE
MICROPROCESSOR
U33
64
84.4300.0001
1
EA
IC, CY2305SC-1 PLL CLOCK DRIVER 3.3V
SMT
U36
65
84.4305.0001
1
EA
IC, NC7SZ04M5 UHS INVERTER-SMT
U8
66
84.7408.0000
1
EA
IC, 74ACT00SC NAND GATE QUAD 2-INPUT
ACT LOGIC
U39
67
84.7430.0001
1
EA
IC, MAU202 SIP DC-DC CONVERTER 5VDC
U7
IC, STEPMOTOR DRIVER
U9-28
68
85.3773.0001
20
EA
69
85.5134.0001
1
EA
IC, SN75LBC180D LOW-POWER DIFF LINE
DRVR & RCVR PAIRS
U1
70
85.5168.0001
1
EA
IC, DS1834AS DUAL RESET MONITOR W/
PUSHBUTTON SMT
U37
71
86.6105.0001
4
EA
IC, HCPL-0600 OPTO COUPLER SMD
U3-U6
72
87.7188.0001
1
EA
IC, EPIK50QC208-3 (BLANK) ACEX FPGA
U32
73
87.7248.0001
1
EA
IC, AM29LV400BB-44REI 4MEGBIT FLASH
MEMORY
U29
74
87.7404.0001
1
EA
IC, M24C02WMN6T EEPROM (BLANK) 2K
BIT (256X8) SERIAL I2C BUS
U30
75
88.8145.0001
1
EA
LED, REVERSE MOUNT RED SMT
D1
76
88.8145.0002
2
EA
LED, REVERSE MOUNT GREEN SMT
D15 & D16
77
88.8145.0003
1
EA
LED, REVERSE MOUNT YELLOW SMT
D14
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Controller PCB Assembly (continued)
Figure 3-11: Controller PCB Assembly
02.9 663.00 10 D
23-Oct-02
69
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
70
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Head Assembly
Head Assembly
21.9663.1000.01
21.9663.1000.02
21.9663.1000.03
21.9663.1000.11
21.9663.1000.12
21.9663.1000.13
(T) Rev B
(TS) Rev B
(TI) Rev B
(A) Rev B
(AS) Rev B
(AI) Rev B
Refer to Figure 3-12.
No.
Item
Qty.
UM.
1
10.9663.1032
2
2
Description
EA
SPACER, SIDE RAIL (T/TS ONLY)
4
EA
SPACER, SIDE RAIL (A/AS ONLY)
21.9663.1001.01
1
EA
ASSY, FRONT HEAD (T ONLY)
21.9663.1001.02
1
EA
ASSY, FRONT HEAD (TS ONLY)
21.9663.1001.03
1
EA
ASSY, FRONT HEAD (TI ONLY)
21.9663.1001.11
1
EA
ASSY, FRONT HEAD (A ONLY)
21.9663.1001.12
1
EA
ASSY, FRONT HEAD (AS ONLY)
21.9663.1001.13
1
EA
ASSY, FRONT HEAD (AI ONLY)
21.9663.1002.01
1
EA
ASSY, REAR HEAD (T/TS ONLY)
21.9663.1002.11
1
EA
ASSY, REAR HEAD (A/AS ONLY)
4
53.6627.0001
4
EA
SCREW, 10-32 X 5/8" PPB
5
55.3303.0010
4
EA
WASHER, #10 .438"OD .040"THK SPLIT LOCK SS
3
2
4 (x4)
3
5 (x4)
1 (x2)
Figure 3-12: Head Assembly
02.9 663.00 10 D
23-Oct-02
71
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Front Head Assembly
21.9663.1001.01
21.9663.1001.02
21.9663.1001.03
21.9663.1001.11
21.9663.1001.12
21.9663.1001.13
(T) Rev G
(TS) Rev G
(TI) Rev G
(A) Rev G
(AS) Rev G
(AI) Rev G
Refer to Figure 3-13.
No.
Item
Qty.
UM.
1
07.5049.0001
1
EA
LANYARD, NYLON COATED 8" LG
2
21.9663.1003
1
EA
ASSY, EDGE, ZOOM & COLOR
3
21.9663.1033
1
EA
ASSY, SIDE RAIL, PULLEY
4
21.9663.1034
1
EA
ASSY, SIDE RAIL, SENSOR
5
21.9663.1200
1
EA
ASSY, GOBO BULKHEAD, INCANDESCENT (T/TS ONLY)
21.9663.1600
1
EA
ASSY, GOBO/DIMMER BULKHEAD, ARC (A/AS ONLY)
6
21.9663.1250
1
EA
ASSY, APERTURE (T/A ONLY)
7
21.9663.1300
1
EA
ASSY, SHUTTER (TS/AS ONLY) (OLD VERSION)
21.9663.1350
1
EA
ASSY, SHUTTER 6 ROLLERS (TS/AS ONLY) (NEW VERSION)
8
21.9663.1400
1
EA
ASSY, IRIS (TI/AI ONLY)
72
Description
9
53.6552.0002
4
EA
SCREW, 8-32 X 1/2" PFB
10
53.2004.0002
4
EA
NUT, 8-32 KEPS ZINC PLATE
11
53.6627.0001
12
EA
SCREW, 10-32 X 5/8" PPB
12
55.3303.0010
12
EA
WASHER, #10 .438"OD .040THK SPLIT LOCK SS
23-Oct-02
02. 9663.0 010 D
3
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
Front Head Assembly (continued)
11 (x4)
12 (x4)
11 (x4)
12 (x4)
11 (x4)
12 (x4)
8
7 Note *
6
A: Models w/o Shutter
C: Models w/ Iris
B: Models w/ Shutter
Note *
Can be either (item 7)
21.9663.1300 (Old Version) or
21.9663.1350 ( New Version).
11 (x4)
5
Either A, B or C
12
(x4)
4
D: Incandescent Models
Either D or E
9 (x4)
2
10 (x4)
12 (x4)
5
3
13
(x4)
1
12 (x4)
11 (x4)
E: Arc Models
Figure 3-13: Front Head Assembly
02.9 663.00 10 D
23-Oct-02
73
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Edge Control, Zoom, Dimmer & Color Assembly
21.9663.1003 Rev D
Refer to Figure 3-14.
No.
Item
Qty.
UM.
1
10.9663.1039
1
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, OUTER BARREL ZOOM
74
Description
9
21.9663.1500
1
EA
ASSY, COLOR CHANGER
10
21.9663.1760
1
EA
ASSY, LENS #6
11
21.9663.1770
1
EA
ASSY, LENS #7
12
21.9663.1780
1
EA
ASSY, LENS #8
13
23.9663.2009
1
EA
CABLE ASSY, FAN TEMP SWITCH
14
44.9663.1766
1
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
53.5604.0437
2
EA
SCREW, 4-40 X 7/16"LG PPSS BLACK
19
53.5606.0375
7
EA
SCREW, 6-32 X 3/8 " PPSS BLACK
20
53.6558.0003
2
EA
SCREW, 6-32 X 3/8" PPZ PLASTIC THREAD ROLLING
21
53.6567.0001
2
EA
SCREW, 4-40 X 1/2" PPZ
22
54.2048.0002
1
EA
BELT, TIMING HTD 3MMPITCH 195 GROOVE 6MMWIDE
23
55.3301.0006
2
EA
WASHER, #6 FLAT SS
24
55.3303.0006
3
EA
WASHER, #6 LOCK INT.TOOTH SS
25
55.6588.0003
3
EA
SPACER, 1/4"RND #6 THRU 1/8"LG .140"ID ZINC PLT BRS
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Edge Control, Dimmer & Color Assembly (continued)
19 (x3)
24 (x3)
12
6
5 4
8
18
22
11
10
25 (x3)
2 (x3)
9
21 (x2)
7
3 (x6)
14
17 (x6)
15 (x2)
23 (x2)
20 (x2)
19 (x4)
1
13
16 (x4)
Figure 3-14: Edge Control, Dimmer & Color Assembly
02.9 663.00 10 D
23-Oct-02
75
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Color Changer Assembly
21.9663.1500 Rev K
Refer to Figure 3-15.
No.
Item
Qty.
UM.
1
04.9663.1524
1
EA
LABEL, MAGENTA MOTOR
2
04.9663.1525
1
EA
LABEL, BLUE MOTOR
3
04.9663.1526
1
EA
LABEL, AMBER MOTOR
4
04.9663.1527
1
EA
LABEL, DIFFUSER MOTOR
5
10.9663.1505
4
EA
DRIVE RING
6
10.9663.1506
1
EA
DIFFUSER COVER PLATE
7
10.9663.1507
2
EA
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
10.9663.1512
1
EA
DRIVE RING LOCATOR
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
2
EA
RING SPACER
20
10.9663.1537
1
EA
DRIVE RING LOCATOR BEARING STRIP W/PSA
21
10.9663.1755
3
EA
ROLLER, BARREL
22
10.9663.1767
1
EA
ZOOM TEFLON SPACER
23
12.9663.1752
1
EA
MACHINED EXTRUSION, INNER BARREL ZOOM
24
21.9663.1501
4
EA
ASSY, COLOR CHANGER DRIVE MOTOR
25
21.9663.1534
1
EA
ASSY, COVER PLATE
26
21.9663.1538.01
2
EA
ASSY, MAGENTA COLOR FILTER
- 10.9663.1504
1
EA
FILTER CARRIER
- 41.9663.1502.01
1
EA
FILTER, COLOR MAGENTA
21.9663.1538.02
2
EA
ASSY, BLUE COLOR FILTER
1
EA
FILTER CARRIER
27
- 10.9663.1504
76
Description
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
No.
28
29
Item
Qty.
UM.
- 41.9663.1502.02
1
EA
FILTER, COLOR BLUE
21.9663.1538.03
2
EA
ASSY, AMBER COLOR FILTER
- 10.9663.1504
1
EA
FILTER CARRIER
- 41.9663.1502.03
1
EA
FILTER, COLOR AMBER
21.9663.1538.04
2
EA
ASSY, DIFFUSER GLASS RIGHT
- 10.9663.1504
1
EA
FILTER CARRIER
- 42.9663.1503
1
EA
DIFFUSER GLASS
Description
30
21.9663.1710
1
EA
ASSY, BARREL
31
53.2002.0003
4
EA
NUT, 6-32 HEX ZINC NYLON INSERT
32
53.2200.0004
8
EA
NUT, 4-40 KEPS SS
33
53.5636.0375
3
EA
SCREW, 6-32 X 3/8 " PFSS BLACK
34
53.6556.0001
8
EA
SCREW, 4-40 X 3/4"LG PPZ
35
55.6588.0003
3
EA
SPACER, 1/4"RND #6 THRU 1/8"LG .140"ID ZINC PLT BRS
02.9 663.00 10 D
3
23-Oct-02
77
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Color Changer Assembly (continued)
1
2
24 (x4)
31 (x4)
30
16 (x4)
8
12
14
3
29 (x2)
4
6
19
5
32 (x8)
17
7
27 (x2)
11
5
18
11
11
7
5
15
20
5
9
26 (x2)
33 (x4)
13
35 (x3)
21 (x3)
13
23
28 (x2)
13
19
25
22
34 (x8)
Figure 3-15: Color Changer Assembly
78
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Color Changer Drive Motor
21.9663.1501 Rev C
Refer to Figure 3-16.
No.
Item
Qty.
UM.
Description
1
10.9663.1513
1
EA
GEAR, PINION 8 TOOTH 32 PITCH
2
44.9663.1520
1
EA
MOTOR, 14 .47" SHAFT 10.8MH 10.1 OHM
3
55.6677.0002
1
EA
WASHER, .360"OD .123"ID .025" THK FLAT NYLON
2
3
1
Figure 3-16: Color Changer Drive Motor
02.9 663.00 10 D
23-Oct-02
79
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Cover Plate Assembly
21.9663.1534 Rev 0
Refer to Figure 3-17.
No.
Item
Qty.
UM.
Description
1
10.9663.1517
1
EA
COVER PLATE, COLOR CHANGER
2
10.9663.1535
1
EA
DISC, .63 DIA ALUM
3
41.9663.1530
1
EA
GLASS, BEAM OCCLUSION
4
53.6659.0008
4
EA
SCREW, 2-56 X 3/16" PFZ
1
4 (x4)
2
3
Figure 3-17: Cover Plate Assembly
80
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Barrel Assembly
21.9663.1710 Rev B
Refer to Figure 3-18.
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
- 10.9663.1709
1
EA
PINION, EDGE
- 44.9663.1326
1
EA
MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM
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 & #3
10
53.2202.0006
4
EA
NUT, 6-32 HEX SS NYLON INSERT
11
53.6558.0001
4
EA
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
02.9 663.00 10 D
23-Oct-02
81
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Barrel Assembly (continued)
12 (x2)
12
5
15
2
13
11 (x4)
3 (x2)
6
7
9
1 (x2)
8
10 (x4)
4
14
12
Figure 3-18: Barrel Assembly
82
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Lens #6 Assembly
21.9663.1760 Rev 0
Refer to Figure 3-19.
No.
Item
Qty.
UM.
Description
1
10.9663.1761
1
EA
LENS CARRIER, MOLDED -LENS #6 ASSY
2
42.9663.1733
1
EA
LENS #6
2
1
Figure 3-19: Lens #6 Assembly
02.9 663.00 10 D
23-Oct-02
83
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Lens #7 Assembly
21.9663.1770 Rev 0
Refer to Figure 3-20.
No.
Item
Qty.
UM.
Description
1
10.9663.1771
1
EA
LENS CARRIER, MOLDED -LENS #7
2
42.9663.1734
1
EA
LENS #7
2
1
Figure 3-20: Lens #7 Assembly
84
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Lens #8 Assembly
21.9663.1780 Rev B
Refer to Figure 3-21.
No.
Item
Qty.
UM.
Description
1
10.9663.1781
1
EA
BULKHEAD, FRONT -LENS #8 ASSY
2
10.9663.1782
1
EA
RING, RETAINING FRONT LENS
3
42.9663.1735
1
EA
LENS #8
4
53.2202.0004
6
EA
NUT, 4-40 HEX SS NYLON INSERT
5
53.6559.0001
6
EA
SCREW, 4-40 X 1/4" PFZ
5
1
4
2
3
Figure 3-21: Lens #8 Assembly
02.9 663.00 10 D
23-Oct-02
85
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Fan Assembly
23.9663.2009 Rev C
Refer to Figure 3-22.
No.
Item
Qty.
UM.
Description
1
40.7113.0003
1
EA
FAN, +24V 80X80X25MM 24LFM
2
52.6523.0002
1
EA
CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE
3
52.8347.0001
2
EA
CONTACT, 24-30AWG MALE CRIMP
FAN CONNECTOR
3 (x2)
2
RED 6.0"
BLK 6.0"
RED
PIN 1
PIN 2
1
BLK
MOLEX SL-2F
Figure 3-22: Fan Assembly
86
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Pulley Side Rail Assembly
21.9663.1033 Rev B
Refer to Figure 3-23.
No.
Item
Qty.
UM.
Description
1
10.9663.1026
1
EA
LATCH, SPRING
2
12.9663.1025
1
EA
RAIL, SIDE MACHINED LONG TILT TUBE
3
53.2002.0004
1
EA
NUT, 6-32 ACORN THREADLOCKING 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
55.5178.0002
1
EA
CABLE ANCHOR MOUNT, #10 SCREW MOUNTING
3
6
2
4
1
5 (x2)
Figure 3-23: Pulley Side Rail Assembly
02.9 663.00 10 D
23-Oct-02
87
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Sensor Side Rail Assembly
21.9663.1034 Rev B
Refer to Figure 3-24.
No.
Item
Qty.
UM.
Description
1
10.9663.1026
1
EA
LATCH, SPRING
2
12.9663.1029
1
EA
RAIL, SIDE MACHINED SHORT TILT TUBE
3
53.2002.0004
1
EA
NUT, 6-32 ACORN THREADLOCKING 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 .203ID .625OD .050 THK
3
6
2
4
1
5 (x2)
Figure 3-24: Sensor Side Rail Assembly
88
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Incandescent Gobo Wheel Assembly
21.9663.1200 (T/TS) Rev P
Refer to Figure 3-25.
No.
Item
Qty.
UM.
Description
1
10.9663.1212
1
EA
PULLEY, MOTOR -GOBO
2
10.9663.1214
1
EA
SHAFT, ROTATING GOBO
3
10.9663.1217
1
EA
PULLEY, GOBO DRIVE MOTOR MOUNTED
4
10.9663.1241
2
EA
PULLEY, IDLER TEFLON
5
10.9663.1242
2
EA
SPACER, PIVOT BELT ADJUST
6
10.9663.1228
1
EA
PLATE, GOBO IDLER MOUNT PLATE
7
10.9663.1229
1
EA
PLATE, WHEEL IDLER MOUNT
8
10.9663.1236
2
EA
MOUNT, SENSOR BOARD
9
21.9663.1201
1
EA
ASSY, GOBO WHEEL
10
22.9663.1226
1
EA
ASSY, GOBO BULKHEAD
11
23.9663.1248.01
1
EA
ELEC ASSY, TEMPERATURE SENSOR
12
24.9663.1230
1
EA
PCB ASSY, WHEEL SENSOR
13
24.9663.1231
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
3
EA
NUT, 4-40 KEPS ZINC PLATED
16
53.5560.0187
4
EA
SCREW, 8-32 X .187" SET CONE POINT
17
53.6520.0001
1
EA
SCREW, 4-40 X 3/8" PPZ
18
53.6524.0002
4
EA
SCREW, 6-32 X 5/16" PPB
19
53.6530.0022
2
EA
RIVET, 1/8"OD POP .188-250GRP CSK HD AL W/STL MNDRL
20
53.6530.0023
1
EA
RIVET, 1/8"OD POP .376-.500GRP DOME HD W/STL MNDRL
21
53.6537.0001
1
EA
SCREW, 4-40 X 5/8" PPB (VL 1)
22
53.6543.0001
1
EA
SCREW, 6-32 X 3/8" PPB
23
53.6581.0001
2
EA
SCREW, 4-40 X 1 3/8" PFZ
24
53.6598.0312
4
EA
SCREW, 4-40 X 5/16" PFB
25
53.6600.0001
3
EA
SCREW, 4-40 X 5/16" PPB
26
53.6614.0001
2
EA
SCREW, 6-32 X 5/8" PPB
27
54.2045.0002
1
EA
BELT, TIMING MXL .080" PITCH .187W 250 TEETH SILICONE
28
54.9663.1220
1
EA
BELT, TIMING INDEX
29
55.2123.0003
2
EA
WASHER, WAVE SPRING W0367-006-S
30
55.6506.0010
1
EA
SPACER, 1/4" RND .375" LG .140" ID THRU AL NO FNSH
02.9 663.00 10 D
23-Oct-02
89
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
31
55.6512.0001
1
EA
WASHER, #4 SPLIT LOCK
32
55.6538.0001
1
EA
SCREW, #6 LOCK INTERNAL TOOTH
33
55.6568.0061
2
EA
SPRING, EXTSN .250"OD 2.00"LG .022" WIRE DIA MUSIC WIRE
34
55.6609.0005
2
EA
WASHER, .625"OD .376"ID .020"THK FLAT TEFLON
35
55.6621.0001
1
EA
WASHER, #4 FLAT ZINC
36
55.6677.0035
1
EA
WASHER, .750"OD .187"ID .030"THK FLAT SS
37
55.6677.0036
1
EA
WASHER, .875"OD .406"ID .030"THK FLAT SS
38
55.6677.0039
2
EA
WASHER, .438"OD .219"ID .042"THK #12 FLAT CSTL
39
55.6677.0040
5
EA
WASHER, .624"OD .145"ID .030"THK FLAT BLACK OXIDE
40
55.6677.0042
1
EA
WASHER, .500"OD .145"ID .031"THK FLAT TEFLON
41
55.6706.0001
1
EA
GROMMET, 9/32"ID 9/16"OD 1/4T SILICONE RED
42
55.6818.0002
1
EA
STANDOFF, 45 DEG NYLON 6/6 KURLY-LOK
90
Description
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Incandescent Gobo Wheel Assy (continued)
9
17
40
39
31
This componet blanked in
Exploded View for clarity.
41
42
37
34 (x2)
25
10
35
33
30
22
32
36
6
7
15
12
15 (x2)
2
26 (x2)
39 (x2)
4 (x2)
39 (x2)
38 (x2)
29 (x2)
5 (x2)
11
18 (x4)
14 (x2)
20
8 (x2)
11
21
19 (x2)
16 (x4)
27
28
25 (x2)
1
24 (x4)
3
13
23 (x2)
Figure 3-25: Incandescent Gobo Wheel Assembly
02.9 663.00 10 D
23-Oct-02
91
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Temperature Sensor Electrical Assembly
23.9663.1248.01 (T/TS) Rev A
23.9663.1248.11 (A/AS) Rev A
Refer to Figure 3-26.
No.
Item
Qty.
UM.
1
23.9663.2008
Description
1
EA
ASSY, FAN (T ONLY)
- 40.7140.0001
1
EA
BLOWER, CENTRIFUGAL 24VDC 9CFM 3" X 3"
- 52.8347.0001
2
EA
CONTACT, 24-30AWG MALE CRIMP
2
52.6523.0004
1
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
HEATSHRINK 1/8" BLACK
5
63.2047.0001
1
EA
THERMOSTANT, 100 DEG C PCB MOUNT CLOSE ON RISE
6
73.3524.0002
2.5
FT
WIRE 24AWG 300V 105C PVC RED UL1007
15.0"
Indicates Pin 1
1.0"
RED
RED
RED
BLK
5
4
6
3 (x2)
2
1
Figure 3-26: Temperature Sensor Electrical Assembly
92
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Arc Gobo/Dimmer Bulkhead Assembly
21.9663.1600 (A/AS) Rev N
Refer to Figure 3-27.
No.
Item
Qty.
UM.
1
10.9663.1212
2
EA
PULLEY, MOTOR -GOBO
2
10.9663.1214
1
EA
SHAFT, ROTATING GOBO
3
10.9663.1217
1
EA
PULLEY, GOBO DRIVE MOTOR MOUNTED
4
10.9663.1228
1
EA
PLATE, GOBO IDLER MOUNT PLATE
5
10.9663.1229
1
EA
PLATE, WHEEL IDLER MOUNT
6
10.9663.1236
2
EA
MOUNT, SENSOR BOARD
7
10.9663.1241
2
EA
PULLEY, IDLER TEFLON
8
10.9663.1242
2
EA
SPACER, PIVOT BELT ADJUST
9
10.9663.1621
1
EA
PULLEY, W/FLANGES 26GROOVE .25 WIDE MXL-DIMMER/GOBO
ASSY
10
10.9663.1625
1
EA
SHAFT, DIMMER .250 OD
11
10.9663.1627
1
EA
FLANGED BUSHING, DIMMER
12
10.9663.1630
2
EA
SEAL, COVER LONG
13
10.9663.1631
2
EA
SEAL, COVER SHORT
14
10.9663.1632
2
EA
PLATE, COVER SEAL LONG
15
10.9663.1633
2
EA
PLATE, COVER SEAL SHORT
16
21.9663.1201
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
20
24.9663.1230
1
EA
PCB ASSY, WHEEL SENSOR
21
24.9663.1231
1
EA
PCB ASSY, INDEX SENSOR
22
44.9663.1202
3
EA
MOTOR, 17 2.42" SHAFT 11.8MH 5.5 OHM
23
53.2002.0001
1
EA
NUT, 6-32 KEP ZINC PLATED
24
53.2003.0001
1
EA
NUT, 4-40 KEP ZINC PLATED
25
53.6520.0001
1
EA
SCREW, 4-40 X 3/8" PPZ
26
53.5560.0187
10
EA
SCREW, 8-32 X .187" SET CONE POINT
27
53.6524.0002
6
EA
SCREW, 6-32 X 5/16" PPB
28
53.6530.0022
2
EA
RIVET, 1/8"OD POP .188-250GRP CSK HD AL W/STL MNDRL
29
53.6530.0023
1
EA
RIVET, 1/8"OD POP .376-500GRP DOME HD W/STL MNDRL
30
53.6534.0001
18
EA
RIVET, 3/32"OD POP 3/32GRIP RANGE ALUM
02.9 663.00 10 D
Description
23-Oct-02
93
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
31
53.6537.0001
1
EA
SCREW, 4-40 X 5/8" PPB (VL 1)
32
53.6543.0001
1
EA
SCREW, 6-32 X 3/8" PPB
33
53.6598.0312
7
EA
SCREW, 4-40 X 5/16" PFB
34
53.6600.0001
3
EA
SCREW, 4-40 X 5/16" PPB
35
53.6614.0001
2
EA
SCREW, 6-32 X 5/8" PPB
36
53.6682.0002
2
EA
SCREW, 4-40 X 1/4"LG PPZ SEMS-EXT
37
54.2045.0002
1
EA
BELT, TIMING MXL .080" PITCH .187W 250 TEETH SILICONE
38
54.2050.0001
1
EA
BELT, TIMING MXL .080" PITCH 93 TEETH 1/4" WD SILICONE
39
54.9663.1220
1
EA
BELT, TIMING INDEX
40
55.2123.0003
2
EA
WASHER, WAVE SPRING W0367-006-S
41
55.6506.0010
1
EA
SPACER, 1/4" RND .375"LG .140"ID THRU AL NO FNSH
42
55.6512.0001
3
EA
WASHER, #4 SPLIT LOCK
43
55.6538.0001
1
EA
WASHER, #6 LOCK INTERNAL TOOTH
44
55.6568.0061
2
EA
SPRING, EXTSN .250"OD 2.00"LG .022" WIRE DIA MUSIC WIRE
45
55.6609.0005
2
EA
WASHER, .625"OD .376"ID .020"THK FLAT TEFLON
46
55.6621.0001
3
EA
WASHER, #4 FLAT SINC
47
55.6659.0007
2
EA
STANDOFF, 3/16"HEX 4-40 .250"LG ALUM
48
55.6677.0035
1
EA
WASHER, .750"OD .187"ID .030"THK FLAT SS
49
55.6677.0036
1
EA
WASHER, .875"OD .406"ID .030"THK FLAT SS
50
55.6677.0039
2
EA
WASHER, .438"OD .219"ID .042"THK #12 FLAT CSTL
51
55.6677.0040
5
EA
WASHER, .624"OD .145"ID .030"THK FLAT BLACK OXIDE
52
55.6677.0042
1
EA
WASHER, .500"OD .145"ID .031"THK FLAT TEFLON
53
55.6706.0001
1
EA
GROMMET, 9/32" ID 9/16" OD 1/4T SILICONE RED
54
55.6818.0002
1
EA
STANDOFF, 45 DEG NYLON 6/6 KURLY-LOK
94
Description
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Arc Gobo/Dimmer Bulkhead (continued)
25
42
51
52
16
54
22 (x3)
27 (x6)
34 (x2)
35 (x2)
12 (x2)
21
51 (x2)
1, 26 (x2)
7 (x2)
14 (x2)
50 (x2)
38
11
2
51 (x2)
40 (x2)
8 (x2)
4
13 (x2)
30 (x18)
15 (x2)
6 (x2)
20
34
19
53
31
9, 26 (x2)
24
5
17
32
49
46
41
44 (x2)
29
28 (x2)
39
37
43
48
10
33 (x7)
45 (x2)
36 (x2)
42 (x2)
47 (x2)
18
26 (x2)
3 23
26 (x2)
1
26 (x2)
Figure 3-27: Arc Gobo/Dimmer Bulkhead Assembly
02.9 663.00 10 D
23-Oct-02
95
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Gobo Wheel Assembly
21.9663.1201 Rev B
Refer to Figure 3-28.
No.
Item
Qty.
UM.
Description
1
10.9663.1203
5
EA
GEAR, PLANET CAST
2
10.9663.1204
1
EA
WHEEL, ROTATING GOBO
3
10.9663.1206
1
EA
FLANGE, MIDDLE
4
10.9663.1210
5
EA
CLIP, RETAINING
5
10.9663.1211
10
EA
SPACER, TEFLON GOBO GEAR
6
10.9663.1219
1
EA
SUN GEAR, MOLDED
7
10.9663.1247
1
EA
TAB, GOBO WHEEL SENSOR
8
10.9663.1240
5
EA
BEARING, GOBO WHEEL BORE
9
22.9663.1222
1
EA
PULLEY ASSY, GOBO WHEEL
10
41.9663.1207
5
EA
BLANK, GOBO
11
53.6534.0001
2
EA
RIVET, 3/32" OD, 3/32 GRIP RANGE, ALUM
12
53.6598.0312
3
EA
SCREW, 4-40 X 5/16" PFB
12 (x3)
7
11 (x2)
4 (x5)
6
8
(x5)
3
9
5
(x5)
10 (x5)
2
5 (x5)
1 (x5)
Figure 3-28: Gobo Wheel Assembly
96
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Gobo Bulkhead FAB Assembly
22.9663.1226 Rev M
Refer to Figure 3-29.
No.
Item
Qty.
UM.
Description
1
10.9663.1213
1
EA
BULKHEAD, GOBO MOUNT
2
10.9663.1224
1
EA
PLATE, GOBO MOTOR MOUNT
3
10.9663.1225
1
EA
BRACKET, FAN MOUNT/BRACE
4
10.9663.1238
1
EA
LIGHT CONE
5
53.6540.0003
4
EA
RIVET, 1/8"OD .126" - .187"GL DOME HD CLOSED END AL BODY
6
53.6540.0004
8
EA
RIVET, 1/8"OD .126"- .187"GL CSK HD CLOSED END AL BODY
7
53.6540.0005
3
EA
RIVET, 1/8"OD .063"- .125"GL CSK HD CLOSED END AL BODY
1
7 (x3)
6 (x8)
4
2
3
5 (x4)
Figure 3-29: Gobo Bulkhead FAB Assembly
02.9 663.00 10 D
23-Oct-02
97
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Gobo/Dimmer Bulkhead FAB Assembly
22.9663.1232 Rev L
Refer to Figure 3-30.
No.
Item
Qty.
UM.
Description
1
10.9663.1233
1
EA
BULKHEAD, DIMMER/GOBO MOUNT
2
10.9663.1234
1
EA
PLATE, DIMMER/GOBO MOTOR MOUNT
3
10.9663.1238
1
EA
LIGHT CONE
4
53.6540.0004
10
EA
RIVET, 1/8"OD .126"- .187"GL CSK HD CLOSED END AL BODY
1
4 (x10)
3
2
Figure 3-30: Gobo/Dimmer Bulkhead FAB Assembly
98
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Dimmer Wheel Assembly
22.9663.1629 Rev D
Refer to Figure 3-31.
No.
Item
Qty.
UM.
Description
1
10.9663.1624
1
EA
WHEEL MOUNT, DIMMER
2
10.9663.1626
1
EA
WASHER, SILICONE
3
10.9663.1628
1
EA
SHIM, DIMMER WHEEL BLACKOUT
4
41.9663.1622
1
EA
GLASS, DIMMER WHEEL
5
53.2212.0001
1
EA
NUT, THIN, 5/8" -27 NS THD 3/4 HEX WIDTH 1/8" HIGH
6
55.3309.0001
1
EA
WASHER 1" OD .625" ID .062" THK 18-8 SS
1
Clear area
4
2
6
3
5
Mirror coated side of glass
Figure 3-31: Dimmer Wheel Assembly
02.9 663.00 10 D
23-Oct-02
99
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Wheel Sensor PCB
24.9663.1230 Rev D
Refer to Figure 3-32.
No.
Item
Qty.
UM.
Description
1
11.9663.1230
1
EA
PCB, WHEEL SENSOR
2
52.6507.0003
1
EA
HEADER, 3POS R/A 2MM SHROUDED
3
86.7002.0004
1
EA
SWITCH, SLOTTED OPTICAL OPB610
2
1
3
VARI-LITE
24-9663-1230
REV D
WHEEL
SENSOR
VIEWED FROM SENSOR SIDE
SOLDER SIDE
Figure 3-32: Wheel Sensor PCB
100
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Index Sensor PCB
24.9663.1231 Rev B
Refer to Figure 3-33.
No.
Item
Qty.
UM.
Description
1
11.9663.1231
1
EA
PCB, INDEX SENSOR
2
52.6447.0004
1
EA
HEADER, SHROUDED 4 POSITION
3
86.7002.0004
1
EA
SWITCH, SLOTTED OPTICAL OPB610
2
3
24-96631231
REV B
INDEX
SENSOR
VARI-LITE
1
SOLDER SIDE
VIEWED FROM SENSOR SIDE
Figure 3-33: Index Sensor PCB
02.9 663.00 10 D
23-Oct-02
101
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Shutter Assembly
21.9663.1300 Rev Q
Refer to Figure 3-34.
No.
Item
Qty.
UM.
Description
1
10.9660.0129
1
EA
SHAFT STOP, ROTATING GOBO WHEEL
2
10.9663.1310
1
EA
BASE PLATE, SHUTTER
3
10.9663.1311
5
EA
SEPARATOR, SHUTTER
4
10.9663.1312
4
EA
SPACER, SHUTTER
5
10.9663.1313
1
EA
COVER, SHUTTER
6
10.9663.1314
8
EA
RACK, SHUTTER
7
10.9663.1317
1
EA
BULKHEAD, SHUTTER
8
10.9663.1319
1
EA
SHIM, ROTATION
9
10.9663.1320
8
EA
PAD, MOTOR
10
10.9663.1321
1
EA
CLAMP RING, MOTOR
11
10.9663.1325
3
EA
ROLLER, NYLON
12
10.9663.1331
3
EA
STIFF SEPARATOR, SHUTTER
13
10.9663.1332
1
EA
BRASS PINON, SHUTTER
14
10.9663.1333
1
EA
ROLLER, AUX SHUTTER
15
10.9663.1334
1
EA
STOP, SHUTTER ROTATION
16
10.9663.1339.02
1
EA
DONUT, ANTI-REFLECTION, SHUTTER
17
12.9663.1323
2
EA
BLADE, SHUTTER COATED SIDE A
18
12.9663.1324
2
EA
BLADE, SHUTTER COATED SIDE B
19
21.9663.1302
8
EA
ASSY, SHUTTER MOTOR
- 10.9663.1316
1
EA
PINION, SHUTTER
- 44.9663.1301
1
EA
MOTOR, 10 .32" SHAFT 2.8MH 5.8 OHM
-
25.9663.2040
1
EA
CABLE ASSY, BEAM SHAPER HARNESS - NOT SHOWN
20
44.9663.1326
1
EA
MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM
21
53.2002.0001
1
EA
NUT, 6-32 KEP ZINC PLATED
22
53.2202.0004
1
EA
NUT, 4-40 HEX SS NYLON INSERT
23
53.2202.0006
1
EA
NUT, 6-32 HEX SS NYLON INSERT
24
53.5638.0252
4
EA
SCREW, 6-32 X 1/4"LG PFS UNDERCUT HEAD
25
53.6525.0001
1
EA
SCREW, 6-32 X 5/16" PPZ
26
53.6536.1000
1
EA
SCREW, 4-40 X 1" PFZ
27
53.6613.0001
1
EA
SCREW, 6-32 X 1/2" PPZ
102
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
No.
Item
Qty.
UM.
28
53.6616.0001
7
EA
SCREW, 6-32 X 3/4" PPZ
29
55.2178.0002
1
EA
CABLE ANCHOR MOUNT, #10 SCREW MOUNTING
30
55.3301.0006
3
EA
WASHER, #6 FLAT SS
31
55.3303.0006
4
EA
WASHER, #6 LOCK INT. TOOTH SS
32
55.6655.0006
1
EA
SPACER, 1/4" RND .116" ID THRU 1/4" LG ZINC PLATED BRAS
02.9 663.00 10 D
3
Description
23-Oct-02
103
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Shutter Assembly (continued)
24 (x4)
5
SHUTTER MOTOR (x8)
3
6 (x8)
3B
3
3A
4A
2B
4B
2A
12
18
1A
1B
3
17
12
17
13
3
9 (x8)
19 (x8)
12
26
1
14
32 8
23
3
22
20
21
18
25
29
27
10
7
2
32 (x4)
28 (x4)
11 (x3)
30 (x3)
28 (x3)
16
Figure 3-34: Shutter Assembly
104
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Shutter 6 Rollers Assembly
21.9663.1350 Rev 0
Refer to Figure 3-35.
No.
Item
Qty.
UM.
Description
1
10.9663.1311
5
EA
SEPARATOR, SHUTTER
2
10.9663.1312
4
EA
SPACER, SHUTTER
3
10.9663.1313
1
EA
COVER, SHUTTER
4
10.9663.1314
8
EA
RACK, SHUTTER
5
10.9663.1320
8
EA
PAD, MOTOR
6
10.9663.1321
1
EA
CLAMP RING, MOTOR
7
10.9663.1325
6
EA
ROLLER, NYLON
8
10.9663.1327
1
EA
GEAR, SHUTTER ROTATE SECTOR
9
10.9663.1328
1
EA
BULKHEAD, SHUTTER MACHINED
10
10.9663.1329
1
EA
STOP SLEEVE, SILICONE
11
10.9663.1330
1
EA
PINON, SHUTTER
12
10.9663.1331
3
EA
STIFF SEPARATOR, SHUTTER
13
10.9663.1339.02
1
EA
DONUT, ANTI-REFLECTION, SHUTTER
14
10.9663.1351
1
EA
BASE PLATE, SHUTTER 6 ROLLERS
15
12.9663.1323
2
EA
BLADE, SHUTTER COATED SIDE A
16
12.9663.1324
2
EA
BLADE, SHUTTER COATED SIDE B
17
21.9663.1302
8
EA
ASSY, SHUTTER MOTOR
- 10.9663.1316
1
EA
PINION, SHUTTER
- 44.9663.1301
1
EA
MOTOR, 10 .32" SHAFT 2.8MH 5.8 OHM
-
25.9663.2040
1
EA
CABLE ASSY, BEAM SHAPER HARNESS - NOT SHOWN
18
44.9663.1326
1
EA
MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM
19
53.2200.0006
1
EA
NUT, 6-32 KEPS SS
20
53.2202.0004
4
EA
NUT, 4-40 HEX SS NYLON INSERT
21
53.2202.0006
2
EA
NUT, 6-32 HEX SS NYLON INSERT
22
53.5638.0252
4
EA
SCREW, 6-32 X 1/4"LG PFS UNDERCUT HEAD
23
53.6525.0001
10
EA
SCREW, 6-32 X 5/16" PPZ
24
53.6526.0001
2
EA
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
02.9 663.00 10 D
23-Oct-02
105
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
28
55.3301.0006
6
EA
WASHER, #6 FLAT SS
29
55.3303.0006
4
EA
WASHER, #6 LOCK INT. TOOTH SS
30
55.6621.0001
4
EA
WASHER, #4 FLAT ZINC
31
55.6697.0020
2
EA
STANDOFF, 3/16" RND, 4-40, .375"LG, ZINC PLATED STEEL
106
Description
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Shutter Assembly (continued)
22 (x4)
3
SHUTTER MOTOR (x8)
1
3B
1
3A
4A
2B
4B
2A
12
16
1A
1B
1
15
12
4 (x8)
15
1
5 (x8)
12
17 (x8)
30 (x4)
20 (x4)
11
1
21 (x2)
9
18
16
24 (x2)
10 (x2)
31 (x2)
6
19
25 (x2)
14
27
7 (x6)
28 (x6)
23 (x6)
26
29 (x4)
23 (x4)
Figure 3-35: Shutter 6 Rollers Assembly
02.9 663.00 10 D
23-Oct-02
107
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Beam-Size Iris Assembly
21.9663.1400 Rev D
Refer to Figure 3-36.
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
1
EA
IRIS, 67MM OD
5
44.9663.1326
1
EA
MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM
6
53.5560.0250
1
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
1
EA
STUD, 2-56 X 2.0"LG FULL THREAD STAINLESS STEEL
10
54.1217.0005
2
EA
KWIK LINK, 2-56 SPRING STEEL
11
55.6546.0004
1
EA
WASHER, TEFLON, .201 ID X .438 0D X .040 THK
3.263
2
7 (x3)
10 (x2)
9
6
5
3
8 (x2)
11
4
1
Figure 3-36: Beam-Size Iris Assembly
108
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Rear Head Assembly
21.9663.1002.01 Rev J (T/TS)
21.9663.1002.11 Rev J (A/AS)
Refer to Figure 3-37.
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
12.9663.1023
1
EA
CASTING, REAR MACHINED
5
21.9663.1101.01
1
EA
ASSY, INC BULKHEAD (T/TS ONLY)
21.9663.1101.11
1
EA
ASSY, ARC BULKHEAD (A/AS ONLY)
6
21.9663.1127.01
1
EA
ASSY, BACK CAP (T/TS ONLY)
21.9663.1127.11
1
EA
ASSY, BACK CAP (A/AS ONLY)
-
25.9663.2033
REF
EA
CABLE ASSY, LAMP POWER INCANDESCENT (T/TS ONLY)
NOT SHOWN
-
25.9663.2036
REF
EA
CABLE ASSY, IGNITOR TO LAMP SOCKET (A/AS ONLY)
NOT SHOWN
7
42.9663.0237
1
EA
REFLECTOR, 48 LUNE (T/TS ONLY)
42.9663.1117
1
EA
REFLECTOR, 8, 10, 14 DEGREE LUNES FACETED (A/AS 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
4
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
53.6625.0001
4
EA
SCREW, 10-32 X 1/2" PPB
13
53.6682.0037
1
EA
SCREW, 10-32 X 1/2" LG PPZ SEMS-EXT
14
55.3301.0010
1
EA
WASHER, #10 FLAT
15
55.6636.0004
1
EA
WASHER, #10 FENDER ZINC PLT SS 1.250"OD .219"ID .047"THK
02.9 663.00 10 D
23-Oct-02
109
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Rear Head Assembly (continued)
13
14
15
3 (x2)
12 (x4)
6
9 (x4)
4
8 (x3)
2
10 (x4)
1 (x3)
7
11 (x3)
5
Note *
Note *
Note *
Align dimple in reflector flange (item 7)
with reflector mount (item 2) as shown.
* Item 5 removed for clarity.
Incandescent (Old Version)
Reflector Orientation
Incandescent & Arc (New Version)
Reflector Orientation
Figure 3-37: Rear Head Assembly
110
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Bulkhead Assembly
21.9663.1101.01 (T/TS) Rev G
21.9663.1101.11 (A/AS) Rev G
Refer to Figure 3-38.
No.
Item
Qty.
UM.
1
10.9663.1103
1
EA
THERMAL BULKHEAD
2
10.9663.1128
2
EA
BAFFLE, EXHAUST LIGHT (A/AS ONLY)
3
4
Description
41.9663,1120
2
EA
AR SOLITE (T/TS ONLY) OLD VERSION
41.9663.1133
2
EA
UV/IR FILTER (T/TS & A/AS) NEW VERSION
53.6540.0005
4
EA
RIVET, 1/8"OD .063"-.125"GL, CSK HD CLOSED END AL
(A/AS ONLY)
1
3 (x2)
1
4 (x4)
2 (x2)
3 (x2)
(T/TS ONLY-OLD VERSION)
(T/TS & A/AS-NEW VERSION)
Figure 3-38: Bulkhead Assembly
02.9 663.00 10 D
23-Oct-02
111
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Back Cap Assembly
21.9663.1127.01 (T/TS) Rev D
21.9663.1127.11 (A/AS) Rev D
Refer to Figure 3-39.
No.
Item
Qty.
UM.
Description
1
10.9663.1116
2
EA
CLAMP, LAMP BASE BAIL (T/TS ONLY)
2
10.9663.1118
1
EA
PLATE, BACKCAP ADJUST
3
10.9663.1119
2
EA
LAMP BASE CLAMP (T/TS ONLY)
4
12.9663.1126
1
EA
BACKCAP, MACHINED
5
53.2008.0003
2
EA
NUT, PUSH #10
6
53.2022.0003
3
EA
NUT, 10-32 THUMB 1/2"OD RND KNURLED BRASS
7
53.5510.2375
2
EA
SCREW, 10-32 X 2 3/8" LG PPSS BLACK
8
53.6539.0011
3
EA
SCREW, 10-32 X 2 1/4" PFBSS UNF-2A
9
53.6575.0001
2
EA
SCREW, 8-32 X 1.0" PPZ
10
53.6575.0005
2
EA
SCREW, 8-32 X 1 1/2" PPZ (T/TS ONLY)
11
55.6568.0059
3
EA
SPRING, CPRSN, .360" OD 1.50" LG .045" DIA SS
12
55.6623.0004
3
EA
WASHER, #10 FLAT SS .203 ID .625 OD .050 THK
13
55.6704.0013
1
EA
STANDOFF, 1/4" HEX 8-32 .500" LG (T/TS ONLY)
14
71.2560.0001
1
EA
SOCKET, LAMP G22 SCREW TERMINALS
112
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : HEAD ASSEMBLY
3
Back Cap Assembly (continued)
6 (x3)
12 (x3)
4
10 (x2) (T/TS ONLY)
13 (T/TS ONLY)
9 (x2)
7 (x2)
11 (x3)
14
8 (x3)
1 (x2) (T/TS ONLY)
3 (x2) (T/TS ONLY)
5 (x3)
2
T/TS ONLY
A/AS ONLY
Incandescent Models
Arc Models
Figure 3-39: Back Cap Assembly
02.9 663.00 10 D
23-Oct-02
113
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
114
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
Yoke Assembly
Yoke Legs Assembly
21.9663.1850.01 (T/TS) Rev C
21.9663.1850.11 (A/AS) Rev C
Refer to Figure 3-40.
No.
Item
Qty.
UM.
Description
1
10.9661.1364
1
EA
INSULATOR, ADHESIVE BACKED - TOP COVER
2
10.9663.1827
2
EA
NUT PLATE, PAN/TILT MOTOR
3
10.9663.1842
2
EA
HEATSHIELD, YOKE LEG
4
21.9663.1816
1
EA
ASSY, TILT MOTOR
5
22.9663.1801
1
EA
ASSY, YOKE
6
24.9661.1125
1
EA
PCB ASSY, IGNITOR (A/AS ONLY)
7
24.9663.1230
1
EA
PCB ASSY, WHEEL SENSOR
-
25.9663.2017
1
EA
CABLE ASSY, LVS CHASSIS GROUND - NOT SHOWN (T/TS ONLY)
25.9663.2002
1
EA
CABLE ASSY, TILT COT - NOT SHOWN
25.9663.2020
1
EA
CABLE ASSY, PAN/TILT CONTROL - NOT SHOWN
25.9663.2024
1
EA
CABLE ASSY, LVS DC OUTPUT - NOT SHOWN
8
53.2019.0004
2
EA
NUT, 3/8-16 X 7/32"THK HEX JAM GRD5 ZINC PLT
9
53.6539.0001
2
EA
WASHER, 3/8" SPLIT LOCK
10
53.6543.0001
14
EA
SCREW, 6-32 X 3/8" PPB (A/AS ONLY)
10
EA
SCREW, 6-32 X 3/8" PPB (T/TS ONLY)
11
53.6567.0001
3
EA
SCREW, 4-40 X 1/2" PPZ
12
53.6617.0001
4
EA
SCREW, 6-32 X 1" PPB
13
53.6634.0003
2
EA
SCREW, 3/8-16 X 1/2"LG SOC HD CAP ALLY STL
14
55.2140.0001
4
EA
STANDOFF, 1/4" HEX 6-32 .813"LG (A/AS ONLY)
15
55.2143.0002
7
EA
STANDOFF, 1/4"HEX 6-32 1.375"LG FF ALUM
16
55.2203.0001
2
EA
SCREW, 4-40 X 1/4 " PPZ
17
55.2204.0001
3
EA
WASHER, #4 NYLON
18
55.3301.0006
4
EA
WASHER, #6 FLAT SS
19
55.6525.0005
3
EA
WASHER, #4 SHOULDER NYLON .125 DP
20
55.6568.0056
1
EA
SPRING, CPRSN .600"OD .625"LG .080"WIRE DIA MUSIC WIRE
21
55.6597.0003
4
EA
CLIP, CABLE SELF RETAINING 1/8"THK PANEL
22
69.3128.0150
1
EA
POWER SUPPLY, 150W +24V/6.3A
02.9 663.00 10 D
23-Oct-02
115
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Yoke Legs Assembly (continued)
4
18 (x4)
12 (x4)
2 (x2)
20
15 (x7)
5
17 (x3)
11 (x3)
19 (x3)
10 (x6)
3 (x2)
10 (x4)
21 (x4)
22
10 (x4)
6
- A/AS only
13 (x2)
14 (x4)
- A/AS only
7
16 (x2)
9 (x2)
8 (x2)
Figure 3-40: Yoke Legs Assembly
116
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
Tilt Motor Assembly
21.9663.1816 Rev B
Refer to Figure 3-41.
No.
Item
Qty.
UM.
Description
1
10.9663.1825
1
EA
MOUNT, MOTOR TILT
2
21.9663.1818
1
EA
ASSY, DRIVE PULLEY
- 10.9663.1818
1
EA
PULLEY, DRIVING - PAN/TILT
- 10.9663.1820
1
EA
CODEWHEEL, 120 COUNT
3
24.9661.0629
1
EA
PCB ASSY, PAN/TILT ENCODER
4
44.9663.1850
1
EA
MOTOR, 23 .81" SHAFT 12MH 6 OHM
5
53.2200.0008
4
EA
NUT, 8-32 KEPS SS
6
53.6521.0001
4
EA
SCREW, 8-32 X 1/2" 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
7 (x2)
3
2
6 (x4)
9 (x4)
8 (x4)
1
5 (x4)
4
Figure 3-41: Tilt Motor Assembly
02.9 663.00 10 D
23-Oct-02
117
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Ignitor PCB
24.9661.1125 Rev D
Refer to Figure 3-42.
No.
Item
Qty.
1
11.9661.1125
1
EA
PCB, IGNITOR
2
51.5006.0003
1
EA
INSULATOR, TO-220, 53.77-AC
3
52.8218.0002
4
EA
TERM, PC VERT MNT 6-32 SCREW 15A
53.6522.0001
4
EA
SCREW, 6-32 X 1/4" PPZ
ON J1-J4
5
55.6538.0001
4
EA
WASHER, #6 LOCK INTERNAL TOOTH
ON J1-J4
6
60.1422.1002
12
EA
RES, 1/4W 5% 10.0 MEG CF
62.2032.0001
1
EA
CAP, .01UF, 3000V, RAD, CERAMIC, .375", 20%
62.3000.0033
13
EA
CAP, .033UF 1000V RAD POLYPRO .600" 10%
9
62.3002.0102
1
EA
CAP, .001UF, 15KV, RAD, CERAMIC DISC
C15
10
68.4515.0003
1
EA
INDUCTOR, HIGH VOLT, IGNITOR
L1
75.7102.0001
1
EA
SPARK GAP, 2.5KV
82.4311.0818
12
EA
DIODE, MR818 RECTIFIER 1KV 1A
D1-D12
82.5310.7250
2
EA
DIODE, 1.5KE250CA Z CLIPPER 250V 5W
Z1 & Z2
4
7
8
11
12
13
C1
UM.
Description
C2
Ref
UNDER SG1
J1-J4
R1-R12
VLFS IGNITOR
24-9661-1125 REV
C3
D3
R3
D4
R4
C1-C13
SG1
D6
D2
R2
D1
C14
L1
D5
R5
R1
TO
BULB
R6
C6
J4
C4
J2
C5
C 1999
C7
SG1
Z1
FROM
RELAY
C15
Z2
J1
C8
C14
C9
C10
J3
S/N
R7
D7
R12
R8
D8
R9
D9
R10
D10
TO
BULB
R11
D11
D12
C11
C12
C13
MADE IN USA
611125D
Figure 3-42: Ignitor PCB
118
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
Pan/Tilt Encoder PCB Assembly
24.9661.0629 Rev 0
Refer to Figure 3-43.
No.
Item
Qty.
1
11.9661.0629
1
EA
PCB, ENCODER SENSOR
-
2
52.6613.0005
1
EA
HEADER, 5POS SGL ROW SHROUDED LATCHING
J1
3
52.6613.0006
1
EA
HEADER, 6POS SGL ROW SHROUDED LATCHING
J2
60.9460.1802
2
EA
RES, .1W 5% 180.0 OHM 100V CHIP SUR MT
R1, R2
5
62.3009.0103
1
EA
CAP, .01UF 50V 10% MONO CER CHIP SUR MT
C1
6
86.7009.0001
1
EA
IC, GP1A70R OPIC PHOTOINTERRUPTER
S1
4
UM.
Description
Ref
Figure 3-43: Pan/Tilt Encoder PCB Assembly
02.9 663.00 10 D
23-Oct-02
119
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Crossmember Assembly
21.9663.1811.01 (T/TS) Rev D
21.9663.1811.11 (A/AS) Rev D
Refer to Figure 3-44.
No.
Item
Qty.
UM.
Description
1
10.9663.1808
1
EA
TOGGLE, PAN
2
10.9663.1809
1
EA
ACTUATOR, TOGGLE PAN
3
10.9663.1814
1
EA
PULLEY, PAN
4
10.9663.1821
1
EA
COVER, PAN TUBE
5
10.9663.1827
2
EA
NUT PLATE, PAN/TILT MOTOR
6
10.9663.1844
1
EA
SHIELD, WIRE PAN
7
10.9663.1846
1
EA
TETHER, PAN TUBE SAFETY
8
21.9663.1812
1
EA
ASSY, INNER CROSSMEMBER
9
21.9663.1813
1
EA
ASSY, OUTER CROSSMEMBER
10
21.9663.1815
1
EA
ASSY, PAN MOTOR
11
21.9663.1819.01
1
EA
ASSY, PAN TUBE (T/TS ONLY)
21.9663.1819.11
1
EA
ASSY, PAN TUBE (A/ASONLY)
12
24.9663.1230
1
EA
PCB ASSY, WHEEL SENSOR
-
25.9663.2001
1
EA
CABLE ASSY, PAN EOT - NOT SHOWN
13
53.2020.0001
1
EA
NUT, 1/4-20 HEX STL ZINC PLTD
14
53.5509.1375
1
EA
SCREW, 8-32 X 3/8" PPZ TYPE F
15
53.6505.0009
1
EA
BOLT, 1/4-20 X 2 1/2" HX HD CAP ZINC
16
53.6552.0001
6
EA
SCREW, 8-32 X 1/2" PFZ
17
53.6556.0006
4
EA
SCREW, 4-40 X 3/8" LG PPZ TYPE F
18
53.6575.0020
14
EA
SCREW, 8-32 X 3/8" LG PFZ TYP-F THRD CUTNG
19
53.6617.0001
4
EA
SCREW, 6-32 X 1"
20
54.1206.0014
3
EA
RING, RETAINING 1.375" SHAFT 1.291" GRV DIA .056" GRVWD
EXTERNAL
21
54.2047.0024
1
EA
BELT, TIMING GT 3MM PITCH 150GRV 6MM WD NEOPRENE
22
55.2203.0001
2
EA
SCREW, 4-40 X 1/4 " PPZ
23
55.3301.0006
4
EA
WASHER, #6 FLAT SS
24
55.6563.0001
3
EA
SCREW, 10-32 X 1/4" PPZ
25
55.6568.0055
1
EA
SPRING, CPRSN .240"OD .813"LG .038" WIRE DIA MUSIC WIRE
120
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
Crossmember Assembly (continued)
17 (x4)
13
20
7
6
2
24 (x3)
14
21
19 (x4)
23 (x4)
15
1
25
3
12
22 (x2)
20
10
9
18 (x14)
20
8
11
5 (x2)
4
16
Figure 3-44: Crossmember Assembly
02.9 663.00 10 D
23-Oct-02
121
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Inner Crossmember Assembly
21.9663.1812 Rev B
Refer to Figure 3-45.
No.
Item
Qty.
UM.
Description
1
10.9663.1805
1
EA
CROSSMEMBER, INNER
2
53.2019.0001
2
EA
NUT, 3/8-16 HEX
3
53.6505.0022
2
EA
BOLT, 3/8-16 X 3/4"LG CARRIAGE GRD5 ZINC PLT
4
53.6539.0001
2
EA
WASHER, 3/8" SPLIT LOCK
5
54.1255.0002
1
EA
BEARING ASSY, FLUSH MOUNT HOUSING LARGE
2 (x2)
4 (x2)
1
5
3 (x2)
Figure 3-45: Crossmember Inner Assembly
122
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
Outer Crossmember Assembly
21.9663.1813 Rev A
Refer to Figure 3-46.
No.
Item
Qty.
UM.
Description
1
10.9663.1898
1
EA
SPACER, PAN BEARING
2
21.9663.1843
1
EA
ASSY, CROSSMEMBER OUTER
3
53.2019.0001
2
EA
NUT, 3/8-16 HEX
4
53.6505.0022
1
EA
BOLT, 3/8-16 X 3/4"LG CARRIAGE GRD5 ZINC PLT
5
53.6505.0023
1
EA
BOLT, 3/8-16 X 1 1/4"LG CARRIAGE GRD5 ZINC PLT
6
53.6539.0001
2
EA
WASHER, 3/8" SPLIT LOCK
7
54.1255.0001
1
EA
BEARING ASSY, BLACK FLUSH MOUNT HOUSING
3 (x2)
6 (x2)
2
1
7
4
5
Figure 3-46: Crossmember Outer Assembly
02.9 663.00 10 D
23-Oct-02
123
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Pan Motor Assembly
21.9663.1815 Rev B
Refer to Figure 3-47.
No.
Item
Qty.
UM.
Description
1
10.9663.1817
1
EA
MOUNT, MOTOR PAN
2
21.9663.1818
1
EA
ASSY, DRIVE PULLEY
- 10.9663.1810
1
EA
PULLEY, DRIVING - PAN/TILT
- 10.9663.1820
1
EA
CODEWHEEL, 120 COUNT
3
24.9661.0629
1
EA
PCB ASSY, PAN/TILT ENCODER
4
44.9663.1850
1
EA
MOTOR, 23 .81" SHAFT 12MH 6 OHM
5
53.2200.0008
4
EA
NUT, 8-32 KEPS SS
6
53.6521.0001
4
EA
SCREW, 8-32 X1/2, 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
7 (x2)
3
2
9 (x4)
6 (x4)
8 (x4)
1
4
5 (x4)
Figure 3-47: Pan/Tilt Motor Assembly
124
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
Pan Tube Assembly
21.9663.1819.01 (T/TS) Rev G
21.9663.1819.11 (A/AS) Rev G
Refer to Figure 3-48.
No.
Item
Qty.
UM.
1
04.9640.0374
1
EA
LABEL, P.E. GROUND
2
10.9663.1851
1
EA
PAN TUBE, TOP
3
24.9663.1830
1
EA
PCB ASSY, DMX INPUT
4
25.9663.1921
1
EA
CABLE ASSY, ARC POWER INPUT (PIGTAIL) (A/AS ONLY)
5
25.9663.2015
1
EA
CABLE ASSY, AC LINE INPUT
-
25.9663.2016.01
1
EA
CABLE ASSY, INCANDESCENT LVS AC INPUT (T/TS ONLY)
NOT SHOWN
25.9663.2016.11
1
EA
CABLE ASSY, ARC LVS AC INPUT (A/AS ONLY) - NOT SHOWN
-
25.9663.2021
1
EA
CABLE ASSY, BALLAST CONTROL LINK (A/AS ONLY)
NOT SHOWN
-
25.9663.2022
1
EA
CABLE ASSY, DATA I/O LINK - NOT SHOWN
6
25.9663.2030
1
EA
CABLE ASSY, INCANDESCENT POWER INPUT (PIGTAIL)
(T/TS ONLY)
-
25.9663.2033
1
EA
CABLE ASSY, LAMP POWER INCANDESCENT (T/TS ONLY)
NOT SHOWN
-
25.9663.2035
1
EA
CABLE ASSY, ARC POWER TO IGNITOR (A/AS ONLY)
NOT SHOWN
7
52.8295.0002
2
EA
TERMINAL STRIP, 300V 12AWG 20A 2 POS. (A/AS ONLY)
52.8295.0002
1
EA
TERMINAL STRIP, 300V 12AWG 20A 2 POS. (T/TS ONLY)
8
52.8295.1002
1
EA
SPACER, TERMINAL STRIP, 600V, 2 POS (CUT 12 POS)
9
53.2200.0004
2
EA
NUT, 4-40 KEPS SS
10
53.2200.0006
4
EA
NUT, 6-32 KEPS SS
11
53.6526.0002
1
EA
SCREW, 6-32 X 5/8" PPZ TYPE F
12
53.6536.0001
2
EA
SCREW, 4-40 X 1/2" PFZ
13
53.6556.0006
4
EA
SCREW, 4-40 X 3/8"LG PPZ TYPE F
14
53.6614.0003
2
EA
SCREW, 6-32 X 5/8" PFZ
15
67.4018.0043
1
EA
FERRITE CORE, ROUND CABLE EMI SUPPRESSION
25.9MMX28.6MM (A/AS ONLY)
16
68.4536.0003
1
EA
CHOKE, COMON MODE FILTER 1.35 MH 11A W/LEADS
(A/AS ONLY)
02.9 663.00 10 D
Description
23-Oct-02
125
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Pan Tube Assembly (continued)
11
16
7
8
7 - A/AS only
10 (x4)
3
15
1
9 (x2)
5
13 (x4)
12 (x2)
14 (x2)
4 - A/AS only
or
6 - T/TS only
2
Figure 3-48: Pan Tube Assembly
126
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : YOKE ASSEMBLY
3
DMX Input PCB Assembly
24.9663.1830 Rev A
Refer to Figure 3-49.
No.
Item
Qty.
UM.
Description
Ref
1
11.9663.1830
1
EA
PCB FAB, DMX INPUT
-
2
52.6259.0001
1
EA
HEADER, 5POS MTA FRCT LOK STRT POST
J3
3
52.6625.0005
1
EA
CONN, RECEPT XLR 5PIN FEMALE PC MT
VERTICAL
J1
4
52.6626.0005
1
EA
CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL
J2
5
62.3017.0102
1
EA
CAP, 1000PF 250V RAD CER DISC 20% Y-TYPE
C1
1
5
2
4
3
Figure 3-49: DMX Input PCB Assembly
02.9 663.00 10 D
23-Oct-02
127
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
128
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Cables
Arc Power Input (Pigtail) Cable Assembly
25.9663.1921 Rev D
Refer to Figure 3-50.
No.
Item
Qty.
UM.
Description
1
52.6274.2316
1
EA
STRAIN RELIEF, SKINTOP FLEX TYPE PG16 BLK
2
52.6400.0110
1
EA
PLUG, 17-9 STD SEX CPC 600V KEY A
3
52.6431.0003
1
EA
BACKSHELL, CPC17 NYLON .500-.650 CBL RNG
4
52.6523.0004
1
EA
CONN, HOUSING 4POS PLUG SHROUDED WIRE TO WIRE
5
52.8201.0007
4
EA
SOCKET, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA
6
52.8205.0001
3
EA
SOCKET, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA
7
52.8231.0005
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
8
52.8298.1146
2
EA
FERRULE, WIRE 1X14 AWG L2=8MM BLUE
9
52.8298.1160
2
EA
FERRULE, WIRE 1X16 AWG L2=8MM BLACK
10
52.8344.0008
2
EA
SOCKET, CPC POWER 14AWG 23A LOOSE
11
52.8366.0001
4
EA
CONTACT, 22-24AWG MALE CRIMP
12
55.2199.0002
0.33
FT
HEATSHRINK, 1/16" CLEAR
13
73.7087.0009
4
FT
CABLE, COMPOSITE VL1000 ARC POWER INPUT
02.9 663.00 10 D
23-Oct-02
129
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Arc Power Input Cable Assembly (continued)
11(x4)
4
2
3
6
9
1
5
4
7
8
4.0"
12
8
FRONTVIEW
9 (x2)
CPC 17-9
4.0"
ORN
VIO
4.0"
8.0"
BLK
GRN/YEL
7
4.0"
13
40.0"
1
.25" 0.0"
3
2
5 (x4)
6 (x3)
10 (x2)
8.0"
WHT
4.0"
CABLE JACKET
PLUG
CPC 17-9
LAMP HI
1
AC GND
2
LAMP LO
3
AC LINE
4
DRAIN
5
AC NEUT
6
PWR LVL
7
DATA GND
8
NOT ON
9
GRN/YEL
ORN
ORN
GRN/YEL
VIO
CHASSIS GND
LAMP HI
LAMP LO
VIO
BLK
BLK
SHIELD
WHT
WHT
WHT
AC LINE
AC NEUT
BLK
SHIELD
RED
WHT
BLK
RED
SHIELDED
TWISTED WIRE
1.0"
1
DRAIN
2
PWR LVL
3
DATA GND
4
NOT ON
MOLEX
SL-4M
4.0"
39.0"
8.0"
Figure 3-50: Arc Power Input (Pigtail) Cable Assembly
130
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Pan EOT Cable Assembly
25.9663.2001 Rev 0
Refer to Figure 3-51.
No.
Item
Qty.
UM.
1
52.6467.0003
1
EA
CONN, FEM PLUG 3 POS 30-24 AWG CRIMP PHR
2
52.6467.0024
3
EA
CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST)
3
52.6524.0006
1
EA
CONN, HOUSING 6POS RECEPTACLE
4
52.8346.0001
3
EA
CONTACT, 24-30AWG FEMALE CRIMP
5
73.5126.0029
1.08
FT
WIRE, 26AWG 3COND 300V 80C <BLK-RED-WHT> UL1061, 19
STRND
3, 4
Description
1, 2
5
13.0"
WHT
6
BLK
5
RED
4
3
2
1
BLK
WHT
RED
3
2
1
Figure 3-51: Pan EOT Cable Assembly
02.9 663.00 10 D
23-Oct-02
131
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Tilt COT Cable Assembly
25.9663.2002 Rev 0
Refer to Figure 3-52.
No.
Item
Qty.
UM.
1
52.6467.0003
1
EA
CONN, FEM PLUG 3 POS 30-24 AWG CRIMP PHR
2
52.6467.0024
3
EA
CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST)
3
52.6524.0006
1
EA
CONN, HOUSING 6POS RECEPTACLE
4
52.8346.0001
3
EA
CONTACT, 24-30AWG FEMALE CRIMP
5
73.5126.0029
2.75
FT
WIRE, 26AWG 3COND 300V 80C <BLK-RED-WHT> UL1061, 19
STRND
3, 4
Description
1, 2
5
33.0"
WHT
6
BLK
5
RED
4
3
2
1
BLK
WHT
RED
3
2
1
Figure 3-52: Tilt COT Cable Assembly
132
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
AC Line Input Cable Assembly
25.9663.2015 Rev A
Refer to Figure 3-53.
No.
Item
Qty.
UM.
Description
1
52.6541.0003
1
EA
CONN, CHASSIS PWR INLET 3POLE LOCKING
2
52.8231.0005
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
3
52.8331.0003
3
EA
RECEPT, FASTON .187" 16-14AWG PIDG BLUE (REEL) .170"ID
4
73.3516.0504
0.42
FT
WIRE, 16AWG 300V 105C PVC GRN/YEL UL1569
1
L
N
3
5.0 IN
4
2
Figure 3-53: AC Line Input Cable Assembly
02.9 663.00 10 D
23-Oct-02
133
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Incandescent LVS AC Input Cable Assembly
25.9663.2016.01 Rev 0
Refer to Figure 3-54.
No.
Item
Qty.
UM.
Description
1
52.8231.0005
4
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
52.8331.0003
2
EA
RECEPT, FASTON .187" 16-14AWG PIDG BLU REEL
3
55.2186.0001
2
EA
CABLE TIE, .10"WD 4.00"LG SMALL
4
73.7089.0000
9.33
FT
WIRE, 22AWG BLK 300V TEFLON STRANDED
5
73.7089.0009
9.33
FT
WIRE, 22AWG WHT TEFLON STRANDED
6
73.7089.0504
9.33
FT
WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180
28.0"
1 (x4)
2.0"
4X BLK
4X BLK
4X WHT
4X WHT
2
AC LINE
AC LINE
AC NEUT
AC NEUT
AC GND
AC GND
4X GRN
4X GRN
4
5
6
3 (x2)
Figure 3-54: Incandescent LVS AC Input Cable Assembly
134
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Arc LVS AC Input Cable Assembly
25.9663.2016.11 Rev 0
Refer to Figure 3-55.
No.
Item
Qty.
UM.
Description
1
52.8231.0005
4
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
52.8298.1160
2
EA
WIRE, FERRULE, 1X 16 AWG L2-8MM BLK
3
55.2186.0001
2
EA
CABLE TIE, .10"WD 4.00"LG SMALL
4
73.7089.0000
9.33
FT
WIRE, 22AWG BLK 300V TEFLON STRANDED
5
73.7089.0009
9.33
FT
WIRE, 22AWG WHT TEFLON STRANDED
6
73.7089.0504
9.33
FT
WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180
28.0"
1 (x4)
2.0"
4X BLK
4X BLK
4X WHT
4X WHT
2
AC LINE
AC LINE
AC NEUT
AC NEUT
AC GND
AC GND
4X GRN
4X GRN
4
5
6
3 (x2)
Figure 3-55: Arc LVS AC Input Cable Assembly
02.9 663.00 10 D
23-Oct-02
135
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
LVS Chassis Ground Cable Assembly
25.9663.2017 Rev B
Refer to Figure 3-56.
No.
Item
Qty.
UM.
1
52.8231.0005
2
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
73.3516.0504
0.25
FT
WIRE, 16AWG 300V 105C PVC GRN/YEL UL1569
1
Description
2
Figure 3-56: LVS Chassis Ground Cable Assembly
136
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Head to Backcap Ground Cable Assembly
25.9663.2018 Rev C
Refer to Figure 3-57.
No.
Item
Qty.
UM.
1
55.2036.0001
2
EA
SLEEVE, 1/16" ROPE DIA. ALUM OVAL COMPRESSION
2.17
FT
WIRE ROPE, 1/16" ROPE DIA. 7X7 GALV STEEL
2
73.7188.0002
1
Description
2
HEAD
GND
BACKCAP
GND
1.0"
1.0"
24.0"
Figure 3-57: Head to Backcap Ground Cable Assembly
02.9 663.00 10 D
23-Oct-02
137
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Yoke to Head Ground Cable Assembly
25.9663.2019 Rev A
Refer to Figure 3-58.
No.
Item
Qty.
UM.
Description
1
52.8231.0005
2
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
73.7089.0504
4
FT
WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180
12.0"
1
2
Figure 3-58: Yoke to Head Ground Cable Assembly
138
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Pan/Tilt Control Cable Asembly
25.9663.2020 Rev A
Refer to Figure 3-59.
No.
Item
Qty.
UM.
1
52.6224.0020
1
EA
HOUSING, 20POS 26-22AWG PRELOADED MT RECEPT DBL ROW
2
52.6224.1020
1
EA
COVER, FRONT 20POS MT LATCHING
3
52.6224.2020
1
EA
COVER, BACK 20POS MT
4
52.6524.0005
2
EA
CONN, HOUSING 5POS RECEPTACLE
5
52.6588.0006
2
EA
HOUSING, 6POS XH 250V/3A 2.5MMPITCH -USE SXH CONTACTS
6
52.7007.0001
8
EA
CONTACT, 28-22AWG PHOSPHOR BRONZE TIN-PLT SXH
7
52.8346.0001
10
EA
CONTACT, 24-30AWG FEMALE CRIMP
8
73.5116.0123
2.67
FT
WIRE, 24AWG 4COND TW 300V 80C <BLK-BRN-RED-ORG> UL1061
9
73.5124.1289
2.33
FT
WIRE, 24AWG 5COND 300V 80C (BLK-BRN-RED-GRY-WHT)
02.9 663.00 10 D
Description
23-Oct-02
139
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Pan/Tilt Control Cable Asembly (continued)
2
3
2
1
4
3
6
5
8
7
10
9
12 11
14 13
16 15
18 17
20 19
AMP CONNECTOR
VIEWED FROM WIRE SIDE
22.0"
5
6
5
6
10.0"
8
1
2
3
4
5
6
8
RED
NC
BLK
ORN
TILT MOTOR
JST XHP-6
1
2
3
4
5
6
1
RED
NC
BLK
ORN
ORN
BRN
BLK
RED
ORN
BRN
BLK
RED
RED
RED
WHT
WHT
GRY
GRY
BLK
BLK
BRN
BRN
NC
BRN
NC
BRN
PAN MOTOR
JST XHP-6
9
5 GRY
RED
4
3 BLK
2 WHT
1 BRN
VOA
VCC
GND
VOB
SENSE
PAN ENCODER PCB
24-9661-0629
MOLEX SL-F-5
4
7
GRY
5
RED
4
3 BLK
WHT
2
BRN
1
VOA
VCC
GND
VOB
SENSE
N/C
N/C
TILT ENCODER PCB
24-9661-0629
MOLEX SL-F-5
9
4
7
1
M2OUT4A
M2OUT4B
M2 = TILT MOTOR
M2OUT3B
M2OUT3A
M1OUT2A
M1OUT2B
M1 = PAN MOTOR
M1OUT1B
M1OUT1A
VCC
VCC
ENCODER_B1
ENCODER_B2
EVEN PIN# = TILT PCB
ENCODER_A1
ODD PIN# = PAN PCB
ENCODER_A2
GND
GND
PAN_COT_SENS
TILT_COT_SENS
GND
GND
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
TO VL1000 CONTROLLER PCB J4
24-9663-1930
AMP MT-20F
8.0"
20.0"
Figure 3-59: Pan/Tilt Control Cable Assembly
140
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Ballast Control Link Cable Assembly
25.9663.2021 Rev 0
Refer to Figure 3-60.
No.
Item
Qty.
UM.
Description
1
52.6396.2204
1
EA
RECEPT, 4POS MTA100 W/POL TAB RED CLSD END
2
52.6524.0004
1
EA
CONN, HOUSING 4POS RECEPTACLE
3
52.8367.0001
4
EA
CONTACT, 22-24AWG FEMALE CRIMP
4
55.2186.0001
2
EA
CABLE TIE, .10"WD 4.00"LG SMALL
5
73.5122.0259
2
FT
WIRE, 22AWG 4COND 300V 80C <BLK-RED-GRN-WHT> UL1061, 19
STRAND
1
GND
PWR LVL
GND
NOT ON
2
1
2
3
4
GRN
GRN
WHT
WHT
BLK
BLK
RED
RED
TO MAIN CONTROL
PCB J7
4
5
3
DRAIN
PWR LVL
DATA GND
NOT ON
FROM ARC POWER INPUT
PIGTAIL DATA CONNECTOR
Figure 3-60: Ballast Control Link Cable Assembly
02.9 663.00 10 D
23-Oct-02
141
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Data I/O Link Cable Assembly
25.9663.2022 Rev A
Refer to Figure 3-61.
No.
Item
Qty.
UM.
Description
1
52.6396.2205
2
EA
RECEPT, 5POS MTA100 W/POL TAB RED CLSD END
2
73.5122.0259
2
FT
WIRE, 22AWG 4COND 300V 80C <BLK-RED-GRN-WHT> UL1061, 19
STRAND
1
2
DMX
INPUT
PCB
J3
PIN
1
2
3
4
5
COLOR
N/C
RED
BLACK
WHITE
GREEN
1
2
3
4
5
N/C
RED
BLK
WHT
GRN
N/C
RED
BLK
WHT
GRN
DMX
SIGNAL
COM IN+
COM INCOM OUT+
COM OUT-
1
2
3
4
5
MAIN
CONTROLLER
PCB
J1
SIGNAL
BDCAST+
BDCASTREPLY+
REPLY-
Figure 3-61: Data I/O Link Cable Assembly
142
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
LVS DC Output Cable Assembly
25.9663.2024 Rev A
Refer to Figure 3-62.
No.
Item
Qty.
UM.
Description
1
52.6442.1805
1
EA
RECEPT, MTA156 W/TAB ORN 5POS 18AWG CLOSED END
2
52.8231.0005
2
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
3
55.2186.0001
EA
CABLE TIE, .10"WD 4.00"LG SMALL
4
73.3518.0002
3
FT
WIRE, 18AWG 300V 105C PVC RED UL1569
5
73.3518.0010
3
FT
WIRE, 18AWG 300V 105C PVC BLK UL1569
18.0"
2.0"
2.0"
1
4
+24V
(V1)
GND
(G)
TO
LVS DC
OUTPUT
2
RED
RED
RED
RED
BLK
N/C
BLK
BLK
BLK
5
3
5
+24V
4
3
+24V
2
GND
1
GND
+5V
TO VL1000
CONTROLLER
PCB J2
Figure 3-62: LVS DC Output Cable Assembly
02.9 663.00 10 D
23-Oct-02
143
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Incandescent Power Input Cable Assembly
25.9663.2030 Rev A
Refer to Figure 3-63.
No.
Item
Qty.
UM.
Description
1
52.6274.2313
1
EA
STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK
2
52.8231.0005
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
3
52.8298.1160
2
EA
FERRULE, WIRE 1X16 AWG L2=8MM BLACK
4
55.2268.0187
1
FT
HEATSHRINK, 3/16" CLEAR KYNAR VDE UL 600V 150DEG C
5
55.2268.0500
0.13
FT
HEATSHRINK, 1/2" CLEAR KYNAR VDE UL 600V 150DEG C
6
73.9636.0153
4
FT
CORDAGE, 1.5/3 750V 60C EURO BLK HD-22 11MMOD
3
6
1
5
4
L
4.0" BRN
N
4.0" BLU
GRN/YEL
4.0"
0.6"
1.5"
44.0"
1.0"
42.5"
0.0" 0.5"
GND
2
Figure 3-63: Incandescent Power Input Cable Assembly
144
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Incandescent Lamp Power Cable Assembly
25.9663.2033 Rev E
Refer to Figure 3-64.
No.
Item
Qty.
UM.
Description
1
25.9663.2018
1
EA
CABLE ASSY, HEAD TO BACKCAP GND
2
52.8298.1160
2
EA
FERRULE, WIRE 1X16 AWG L2=8MM BLACK
3
52.8386.0001
2
EA
CONN, BUTT SPLICE 16-22AWG UNISULATED SOLISTRAND
4
55.2186.0002
1
EA
CABLE TIE, .09"WD 3.750"LG TEFZEL
5
55.2200.0003
0.33
FT
HEATSHRINK, 3/16" VITON
6
55.2260.0133
4.42
FT
SLEEVING, FIBERGLASS .133" ID
7
55.2260.0294
2
FT
SLEEVING, FIBERGLASS .294" ID
8
73.6616.0011
4
FT
WIRE, 16AWG 600V 600C MICA TAPE TAN
9
73.7089.0001
16
FT
WIRE, 22AWG BRN 300V TEFLON STRANDED
10
73.7089.0006
16
FT
WIRE, 22AWG VIO TEFLON STRANDED
3.50"
1.25"
FROM
LAMP POWER
TERM BLOCK
9 (x4)
5 (x2)
1
4
7
6 (x2)
10 (x4)
TO
LAMP
SOCKET
BRN
LINE
DIMMER LINE
NEUT
DIMMER NEUT
BLU
2 (x2)
3 (x2)
8 (x2)
48.0" (REF)
24.0"
72.0"
Figure 3-64: Incand Power to Lamp Socket Cable Assembly
02.9 663.00 10 D
23-Oct-02
145
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Arc Power to Ignitor Cable Asembly
25.9663.2035 Rev B
Refer to Figure 3-65.
No.
Item
Qty.
UM.
Description
1
52.8231.0005
2
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
52.8298.2160
2
EA
FERRULE, WIRE 2X16 AWG L2=8MM BLACK
3
55.2186.0001
2
EA
CABLE TIE, .10"WD 4.00"LG SMALL
4
55.6699.0003
2.67
FT
SLEEVING, 1/2"NOM.DIA. POLY EXP BRAIDED
5
73.6222.0003
12
FT
WIRE, 22AWG 600V 200C TFE ORN UL1199
6
73.6222.0007
12
FT
WIRE, 22AWG 600V 200C TFE VIO UL 1199
36.0"
32.0"
2.0"
4X ORN
4X ORN
4X VIO
TO
IGNITOR
INPUT
1
6
2
4X VIO
4
3
5
FROM
LAMP POWER
TERM BLOCK
Figure 3-65: Arc Power to Ignitor Cable Assembly
146
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Ignitor to Lamp Socket Cable Assembly
25.9663.2036 Rev B
Refer to Figure 3-66.
No.
Item
Qty.
UM.
Description
1
25.9663.2018
1
EA
CABLE ASSY, HEAD TO BACKCAP GND
2
52.8231.0005
2
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
3
55.2186.0001
1
EA
CABLE TIE, .10"WD 4.00"LG SMALL
4
55.2260.0294
2
FT
SLEEVING, FIBERGLASS .294"ID
5
73.7100.0001
5
FT
WIRE, 16AWG 20KVDC 41/32 STRD 200C SILICONE
30.0"
24.0"
1.5"
0.5"
5
TO ARC
LAMP
SOCKET
FROM
IGNITOR
OUTPUT
2
1
3
4
Figure 3-66: Ignitor to Lamp Socket Cable Assembly
02.9 663.00 10 D
23-Oct-02
147
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Shutter Harness Cable Assembly
25.9663.2040 Rev C
Refer to Figure 3-67.
No.
Item
Qty.
UM.
Description
04.9663.2040.00
1
EA
LABEL SET, SHUTTER HARNESS
1
52.6224.0040
1
EA
HOUSING, 40POS 26-22AWG PRELOADED MT RECEPT DBL ROW
2
52.6224.1040
1
EA
COVER, FRONT 40POS MT LATCHING
3
52.6224.2040
1
EA
COVER, BACK 40POS MT
4
52.6661.0006
8
EA
CONN, RECEPT 6CIR WIRE TO WIRE 1.25MM PITCH
5
52.8387.0001
32
EA
CONTACT, 26-28AWG FEMALE CRIMP 1.25MM PITCH (REEL)
6
55.2186.0001
15
EA
CABLE TIE, .10"WD 4.00"LG SMALL
7
55.6699.0004
.5
FT
SLEEVING, 3/4"NOM.DIA. POLY EXP BRAIDED
8
73.5126.0123
17.67
FT
WIRE, 26AWG 4COND TW 300V 80C (BLK-BRN-RED-ORG)
148
23-Oct-02
02. 9663.0 010 D
1, 2, 3
02.9 663.00 10 D
TO VL1000
CONTROLLER PCB J10
PIN 1
8"
30.0"
14"
23-Oct-02
25.0"
8
28.0"
23.0"
BR
OR N
BL N
RE K
D
2B
2A
4, 5
2B
2A
N
BR N
OR K
BL
D
RE
3A
1B
BR
OR N
N
BL
K
RE
D
N
BR N
OR K
BL
D
RE
3A
1B
3B
1A
BRN
ORN
BLK
RED
BRN
ORN
BLK
RED
1A
3B
4A
4B
BRN
ORN
BLK
RED
BRN
ORN
BLK
RED
4A
4B
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Shutter Harness Cable Assembly (continued)
7
6
Figure 3-67: Shutter Harness Cable Assembly
149
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Color/Gobo/Lens Harness Cable Assembly
25.9663.2050 Rev H
Refer to Figure 3-68.
No.
Item
Qty.
UM.
Description
1
04.9663.2050.00
1
EA
LABEL SET, COLOR/GOBO/LENS HARNESS
2
52.6224.0050
1
EA
HOUSING, 50POS 26-22AWG PRELOADED MT RECEPT DBL ROW
3
52.6224.1050
1
EA
COVER, FRONT 50POS MT LATCHING
4
52.6224.2050
1
EA
COVER, BACK 50POS MT
5
52.6467.0003
1
EA
CONN, FEM PLUG 3 POS 30-24 AWG CRIMP PHR
6
52.6467.0004
1
EA
CONN, FEM PLUG 4 POS 30-24 AWG CRIMP PHR
7
52.6467.0024
6
EA
CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST)
8
52.6524.0002
1
EA
CONN, HOUSING 2POS RECEPTACLE
9
52.6524.0004
1
EA
CONN, HOUSING 4POS RECEPTACLE
10
52.6661.0006
4
EA
CONN, RECEPT 6CIR WIRE TO WIRE 1.25MM PITCH
11
52.6662.0006
6
EA
HOUSING, 6POS 125V/2A 2.00MMPITCH
12
52.8346.0001
6
EA
CONTACT, 24-30AWG FEMALE CRIMP
13
52.8387.0001
16
EA
CONTACT, 26-28AWG FEMALE CRIMP 1.25MM PITCH (REEL)
14
52.8388.0001
24
EA
CONTACT, 24-30AWG FEMALE CRIMP 2.00MMPITCH (REEL)
15
55.2186.0001
12
EA
CABLE TIE, .10"WD 4.00"LG SMALL
16
55.6699.0004
0.50
FT
SLEEVING, 3/4"NOM.DIA. POLY EXP BRAIDED
17
73.5116.0123
12.75
FT
WIRE, 24AWG 4COND TW 300V 80C <BLK-BRN-RED-ORG> UL1061
18
73.5126.0002
2.42
FT
WIRE, 26AWG 2COND 300V 80C <BLK-RED> UL1061, 19STRND
19
73.5126.0029
5.42
FT
WIRE, 26AWG 3COND 300V 80C <BLK-RED-WHT> UL1061, 19STRND
20
73.5126.0123
10.42
FT
WIRE, 26AWG 4COND TW 300V 80C (BLK-BRN-RED-ORG)
21
73.7094.0001
.17
FT
WIRE, 26AWG, TEFLON, RED, 19 STRAND
150
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : CABLES
3
Color/Gobo/Lens Cable Assembly (continued)
PIN 1
4
3
2
TO VL1000
CONTROLLER
PCB J8
15 (x12)
16
12 (x2)
8
14 (x4)
11
17
FAN
13 (x4)
10
-08
18
-07
-13
13 (x4)
10
20
18 21
13 (x4)
20 10
1
-06
20
-12
-14
-11
FAN
9
12 (x4)
17
17
-02
17
17
-09
10
13 (x4)
-03
11
14 (x4)
11
14 (x4)
11
14 (x4)
-10
17
LABEL SET (FOR REF. ONLY)
7 (x3)
6
11
14 (x4)
-05
-04
19
17
11
14 (x4)
7 (x3)
5
-01
19
P/N
-01
-02
-03
-04
-05
-06
-07
-08
-09
-10
-11
-12
-13
-14
LINE 1 TEXT
WHL
WHL
SHUT
INDX
INDX
BLUE
AMBR
ZOOM
EDGE
DIMM
MAG
DIFF
FAN
TS
LINE 2 TEXT
SNSR
MTR
ROT
SNSR
MTR
MTR
MTR
MTR
MTR
MTR
MTR
MTR
1
FAN2
Figure 3-68: Color/Gobo/Lens Harness Cable Assembly
02.9 663.00 10 D
23-Oct-02
151
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
152
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
3
Arc Ballast Assembly
Arc Ballast Assembly
21.9663.1900 Rev E
Refer to Figure 3-69.
No.
Item
Qty.
UM.
Description
1
04.9640.0374
1
EA
LABEL, P.E. GROUND
2
04.9663.1920
1
EA
LABEL, PRODUCT VL1000 APS
3
06.6032.0009
1
EA
CABLE MARKER TIE, WHITE 19 X 7.4"
4
10.9663.1911
1
EA
ENCLOSURE BALLAST
5
10.9663.1912
1
EA
COVER, ENCLOSURE BALLAST
6
10.9663.1915
3
EA
TOROID, DISK MOUNTING 1 1/2"OD 3/4"ID
7
10.9663.1918
3
EA
PAD CLAMP, TOROID 1 5/8"OD .125"THK
8
10.9663.1919
3
EA
GAP PAD, VO ULTRASOFT 3.0"OD .120"THK
9
10.9669.0034
1
EA
PLATE, NUT
10
12.9663.1913
2
EA
ASSY, BALLAST -HEATSINK
11
24.9663.1901
1
EA
PCB ASSY, BALLAST 625W
12
24.9663.1902
1
EA
PCB ASSY, BALLAST RIDER 625W
13
25.9663.1907
1
EA
ASSY, CABLE 575W BALLAST I/O
14
51.5025.0003
1
EA
PAD, THERMALLY CONDUCTIVE HF105 .75 X .50 IN
15
51.5025.0004
1
EA
PAD, THERMALLY CONDUCTIVE HF105 1.50 X 1.00 IN
16
51.5038.0008
17
EA
CLAMP, HEATSINK MAX CLIP08 TO218/TO247
17
51.9663.1905
1
EA
PAD, THERMALLY CONDUCTIVE HF625AC 10.25" X 1.15"
18
51.9663.1906
1
EA
PAD, THERMALLY CONDUCTIVE HF625AS 6.35" X 1.15"
19
53.2002.0001
7
EA
NUT, 6-32 KEP ZINC PLATED
20
53.2011.0001
17
EA
NUT, #8
21
53.6517.0002
4
EA
SCREW, 10-32 X 3/8"LG PPB BLACK SEMS
22
53.6525.0001
1
EA
SCREW, 6-32 X 5/16" PPZ
23
53.6546.0002
16
EA
SCREW, 8-32 X 5/16" PPZ
24
53.6546.0003
1
EA
SCREW, 8-32 X 7/16" PPZ
25
53.6558.0007
5
EA
SCREW, 6-32 X 1/4" PPZ SEMS-EXT WSHR
26
53.6575.0009
4
EA
SCREW, 8-32 X 3/8"LG PPZ SEMS EXT BLACK ZINC
27
53.6575.0021
8
EA
SCREW, 8-32 X 5/8"LG PPZ BLACK TYPE F
28
53.6593.0001
3
EA
SCREW, 10-32 X 1" PPB
02.9 663.00 10 D
23-Oct-02
153
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
29
53.6607.0002
4
EA
SCREW, 6-32 X 1/4" PFB
30
55.2001.0008
2
EA
PCB SUPPORT, 1" SPACING SNAP-IN NYLON
31
55.2178.0001
1
EA
CABLE ANCHOR MOUNT, #8 SCREW MOUNTING
32
55.2214.0001
1
EA
SPACER, 10 THRU 11/64LX5/16R
33
55.3303.0008
17
EA
WASHER, #8 LOCK INT.TOOTH SS
34
55.6623.0001
4
EA
WASHER, #10 FLAT
35
55.6696.0004
4
EA
BUMPER, RUBBER M/AII SHEET METAL FRAME
36
68.9663.1912
1
EA
PFC CHOKE
37
68.9663.1913
2
EA
IBC CHOKE
154
Description
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
3
Arc Ballast Assembly (continued)
21 (x4)
34 (x4)
35 (x4)
26 (x4)
5
22
3
31
12
11
30 (x2)
23 (x10)
33 (x10)
16 (x10)
25 (x5)
14
19 (x4)
28 (x3)
13
6 (x3)
7 (x3)
17
36
9
37 (x2)
8 (x3)
29 (x4)
1
19 (x3)
20 (x10)
24
27 (x8)
23 (x6)
33 (x7)
16 (x7)
15
10 (x2)
2
18
4
32
20 (x7)
Figure 3-69: Arc Ballast Assembly
02.9 663.00 10 D
23-Oct-02
155
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
625W Ballast PCB
24.9663.1901 Rev B
Refer to Figure 3-70.
No.
Item
Qty.
UM.
Description
Ref.
1
11.9663.1901
1
EA
PCB, BALLAST 625W
-
2
23.9663.1925
1
EA
FAB ASSY, POTTED ZVT MAG-AMP
L103
3
52.6260.0004
1
EA
HEADER, 4POS MTA-100 SHROUDED
STRAIGHT
J601
4
52.6370.0003
1
EA
HEADER ASSY, 3CIR SOCKET MNLOK FMLE
J102
5
52.6663.0014
1
EA
HEADER, 14PIN .025"SQ .665"STACK HT
BOARD STACKING
J101
6
52.6663.0015
1
EA
HEADER, 15PIN .025"SQ .665"STACK HT
BOARD STACKING
J201
7
52.8252.0001
10
EA
TERM, .250"TAB PC QUICK-FIT BRASS
J103-J106 & J202J207
8
60.1230.0000
1
EA
RES, 1/4W ZERO OHM CF
R111
9
60.1230.1004
2
EA
RES, 1/4W 1% 10.0 K MF
R611 & R612
10
60.1230.1054
1
EA
RES, 1/4W 1% 10.5 K MF
R118
11
60.1230.1074
1
EA
RES, 1/4W 1% 10.7 K CF
R603
12
60.1230.1501
2
EA
RES, 1/4W 1% 15.0 OHM MF
R204 & R205
13
60.1230.1744
1
EA
RES, 1/4W 1% 17.4 K MF
R121
14
60.1230.2004
1
EA
RES, 1/4W 1% 20.0 K MF
R613
15
60.1230.4645
2
EA
RES, 1/4W 1% 464.0 K MF
R209 & R210
16
60.1230.4755
2
EA
RES, 1/4W 1% 475.0 K MF
R218 & R219
17
60.1230.5113
1
EA
RES, 1/4W 1% 5.11 K MF
R211
18
60.1230.5115
2
EA
RES, 1/4W 1% 511.O K MF
R119 & R120
19
60.1230.6493
1
EA
RES, 1/4W 1% 6.49 K MF
R220
20
60.1230.7505
2
EA
RES, 1/4W 1% 750.0 K MF
R116 & R117
21
60.1420.1305
1
EA
RES, 1/4W 5% 130.0 K CF
R123
22
60.1420.2001
6
EA
RES, 1/4W 5% 20.0 OHM CF
R212, R215 &
R222-R225
23
60.1420.2204
1
EA
RES, 1/4W 5% 2.2 K CF
R124
24
60.1420.2403
1
EA
RES, 1/4W 5% 2.4 K CF
R607
25
60.1420.3905
4
EA
RES, 1/4W 5% 390.0 K CF
R102, R103, R106
& R107
26
60.1420.4300
1
EA
RES, 1/4W 5% 4.3 OHM CF
R101
156
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
No.
Item
Qty.
UM.
27
60.1420.5105
2
28
60.1420.6800
29
3
Description
Ref.
EA
RES, 1/4W 5% 510.0 K CF
R114 & R115
1
EA
RES, 1/4W 5% 6.8 OHM CF
R601
60.1421.1201
2
EA
RES, 1/4W 5% 12.0 OHM CF
R110 & R112
30
60.1421.1205
1
EA
RES, 1/4W 5% 120.0 K CF
R104
31
60.1421.2003
1
EA
RES, 1/4W 5% 200.0 K CF
R608
32
60.1421.2202
1
EA
RES, 1/4W 5% 220.0 OHM CF
R109
33
60.1421.5100
3
EA
RES, 1/4W 5% 5.1 OHM CF
R113, R214 & R217
34
60.1422.1001
4
EA
RES, 1/4W 5% 1.0 K CF
R213, R216, R604
& R606
35
60.1422.2202
1
EA
RES, 1/4W 5% 22.0 K CF
R105
36
60.1424.2004
1
EA
RES, 1/4W 5% 20.0 K CF
R610
37
60.1424.8205
1
EA
RES, 1/4W 5% 820.0 K CF
R122
38
60.1425.1003
1
EA
RES, 1/4W 5% 100.0 OHMS CF
R602
39
60.1425.5603
1
EA
RES, 1/4W 5% 560.0 OHM CF
R609
40
60.2150.5101
1
EA
RES, 1/2W 5% 51 OHM METAL OXIDE
R108
41
60.3430.1002
1
EA
RES, 1W 5% 100.0 OHM METAL OXIDE
R208
42
60.4450.2402
1
EA
RES, 2W 5% 240.0 OHM MET OXIDE
R605
43
60.9245.0100
1
EA
RES, 30W 1% 0.1 OHM TO-220 POWER FILM
R201
44
62.2110.0474
2
EA
CAP, .47UF 250V RAD METALLIZED POLYEST
15MM L.S. 10%
C214 & C217
45
62.2112.0337
4
EA
CAP, 330 UF 250V RAD ALUM 25MM X 30MM
C114-C117
46
62.2115.4706
1
EA
CAP, 47UF 16V RAD ALUM ELECTRO 105DEG
C 20%
C602
47
62.3007.0105
2
EA
CAP, 1.0 UF 275VAC X2 RFI SUPPRESSOR 10%
C103 & C104
48
62.3013.0105
3
EA
CAP, 1UF 630V RAD MET PLYPLN 10%
C107, C201 & C202
49
62.3017.0102
3
EA
CAP, 1000PF 250V RAD CER DISC 20% Y-TYPE
C101, C102 & C231
50
62.3017.0222
2
EA
CAP, 2200PF 250V RAD CER DISC Y-CLASS
C105 & C106
51
62.3021.2102
1
EA
CAP, 1000PF 200V RAD CER 10% X7R
C112
52
62.3021.2221
1
EA
CAP, 220PF 200V RAD CER 20% X7R
C211
53
62.3021.2331
2
EA
CAP, 330PF 200V RAD CER 20% X7R
C207 & C208
54
62.3022.0103
2
EA
CAP, .01UF 50V RAD CER 10% X7R
C610 & C611
55
62.3023.0104
10
EA
CAP, .1UF 50V RAD CER 20% Z5U
C108, C213, C216,
C221, C224, C226,
C229, C607, C608
& C609
56
62.3023.0473
6
EA
CAP, .47UF 50V RAD CER 20% Z5U
C109, C118, C119,
C218, C225 & C230
57
62.3027.0102
2
EA
CAP, 1000PF 1600V RAD POLYPROPYLENE
.600" 10%
C203 & C601
58
62.3029.0333
1
EA
CAP, .033UF 1000V RAD POLYPROPYLENE
.886" 10%
C204
02.9 663.00 10 D
23-Oct-02
157
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
Description
Ref.
59
62.3033.0331
1
EA
CAP, 330PF 3000VDC 20% CERAMIC DISC
C113
60
62.4009.0107
4
EA
CAP, 100UF 35V RAD ALUM 8 X 11.5 MM 20%
C603-C606
61
62.4010.0106
1
EA
CAP, 10UF 50V RAD ALUM 4 X 11 MM 20%
C232
62
62.4010.0475
6
EA
CAP, 4.7UF 50V RAD ALUM 5 X 11 MM 20%
C212, C215, C222,
C223, C227 & C228
63
63.2047.0085
2
EA
THERMOSTAT, 85DEG C PCB MT CLOSE ON
RISE
TS101 & TS201
64
63.2050.0001
1
EA
VARISTOR, METAL OXIDE 300V RMS 165J
775V CLAMP
VR101
65
63.2055.0001
2
EA
THERMISTOR, 12A 0.7 OHM NTC INRUSH
CURRENT LIMIT
NTC101 & NTC102
66
67.4019.0001
2
EA
FERRITE, BEAD ON LEADS .138"DIA X .206"L
X .65"DIA LEADS
L601 & L602
67
68.4536.0002
1
EA
CHOKE, COMMON MODE FILTER 1.35MH 11A
L103
68
68.4563.0001
3
EA
TRANSFORMER, TOROIDAL CURRENT SENSE
PE-51686
L104, L201 & L202
69
68.9661.1112
2
EA
TRANSFORMER, GATE DRIVE
T201 & T202
70
68.9663.1911
1
EA
RESONANT INDUCTOR
L101
71
68.9663.1923
1
EA
BIAS TRANSFORMER
T601
72
70.3727.0002
4
EA
FUSE CLIP, 1/4" PC BOARD TINNED BRASS
XF101 & XF102
73
70.3762.0020
2
EA
FUSE, 20A 250VAC VERY FAST ACT 1/4"X1 1/
4" CERAMIC
F101 & F102
74
73.6016.0006
0.50
FT
WIRE, 16AWG 600V 105C PVC BLU UL1015
75
80.2623.0001
2
EA
TRANSISTOR, 2N4401 NPN 40V 600MA
Q203 & Q206
76
80.2623.0003
3
EA
TRANSISTOR, 2N4403 PNP 40V 600MA TO-92
Q103, Q204, Q207
77
80.2628.0001
4
EA
TRANSISTOR, IXGH39N60BD1 IGBT 76A 600V
Q209-Q212
78
80.2643.0001
2
EA
TRANSISTOR, MPSW63 1W PNP DARLINGTON
30V 500MA 1W TO-92
Q205 & Q208
79
80.2648.0001
2
EA
TRANSISTOR, IXFH32N50 POWER MOSFET
500V 32A TO-247
Q201 & Q202
80
80.2652.0001
1
EA
TRANSISTOR, IXGH24N60CD1 IGBT 600V 48A
LIGHTSPEED SERIES W/DIODE T0-24 0
Q101
81
80.2653.0001
1
EA
TRANSISTOR, IRFB9N60A MOSFET 600V 9.2A
N-CH ENHANCEMENT TO-220
Q102
82
82.4308.4937
7
EA
DIODE, 1N4937 FAST 600V
D104, D208-D211,
D213 & D214
83
82.4317.5819
3
EA
DIODE, 1N5819 RECTIFIER 40V
D110, D111 & D610
84
82.4323.0001
1
EA
DIODE, BRIDGE D25XB60 600V 25A SIP
BR549
85
82.4330.0001
3
EA
DIODE, RECTIFIER ULTRA FAST 600V 15A
D101, D201, D202
86
82.5302.4148
4
EA
DIODE, 1N4148 ULTRAFAST 75V 300MA
D107, D113, D204
& D205
87
82.5318.0160
3
EA
DIODE, MUR160, 600V, 1A
D602-D604
88
82.5322.0001
1
EA
DIODE, 1N4736A
D606
158
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
No.
Item
Qty.
UM.
89
82.5323.0001
4
90
82.5334.0001
91
3
Description
Ref.
EA
DIODE, MUR460 600V 4AMP ULTRAFAST
D103, D106, D203
& D219
1
EA
DIODE, 1N5245B ZENER VOLTAGE
REGULATOR
D605
82.5340.0001
3
EA
DIODE, ZENER 1.5KE250A TVS 250V 1500W
D215, D216, D601
92
82.5351.0001
4
EA
DIODE, ZENER 20V 1W 5% DO-41 1N4747A
D108, D109, D217
& D218
93
82.5357.0001
1
EA
DIODE, RHRP1560 HYPERFAST RECTIFIER
600V 15A TO-220
D102
94
82.5359.0001
1
EA
DIODE, 1N5240B ZENER REGULATOR 10V
500MW AXIAL
D608
95
83.3117.0001
1
EA
IC, LM393 DUAL COMPARATOR
U604
96
84.7432.0001
1
EA
IC, TOP234P INTEGRATED OFFLINE SMPS
CONTROLLER (CMOS)
U601
97
85.5120.0001
2
EA
IC, IR2110,1/2 BRIDGE DRIVER
U201 & U202
98
86.6110.0001
2
EA
IC, LTV817 SINGLE CHANNEL
OPTOCOUPLER
U602 & U605
99
86.6111.0001
1
EA
IC, HCPL-2201 HI-SPEED OPTOCOUPLER
LOGIC GATE TOTEM POLE OUTPUT
U603
100
88.8122.0001
1
EA
LED, RED, DIFFUSED,5300H1
D607
101
88.8122.0002
1
EA
LED, GRN, DIFFUSED,5300H5
D609
Figure 3-70: 625W Arc Ballast PCB
02.9 663.00 10 D
23-Oct-02
159
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
625W Ballast Rider PCB
24.9663.1902 Rev A
Refer to Figure 3-71.
No.
Item
Qty.
UM.
Description
Ref.
1
11.9663.1902
1
2
52.6662.0014
1
EA
PCB, BALLAST RIDER 625W
-
EA
SOCKET STRIP, 14PIN SGL ROW .100"PITCH
J301
3
52.6662.0015
1
EA
SOCKET STRIP, 15PIN SGL ROW .100"PITCH
J401
4
60.0460.1004
2
EA
RES, 1/8W 5% 10.0 K THK FLM CHIP SUR MT EIA1206
R502, R503
5
60.9462.1003
3
EA
RES, 1/2W 5% 1.0 K 200V CHIP THK FLM
SMT2010
R415, R420,
R508
6
60.9463.0000
1
EA
RES, 1/8W 1% ZERO OHM 200V CHP THK FLM
SMT1206
R402
7
60.9463.1001
1
EA
RES, 1/8W 1% 10.0 OHM 200V CHP THK FLM
SMT1206
R427
8
60.9463.1004
3
EA
RES, 1/8W 1% 10.0 K 200V CHP THK FLM
SMT1206
R406, R424,
R425
9
60.9463.1005
1
EA
RES, 1/8W 1% 100.0 K 200V CHP THK FLM
SMT1206
R314
10
60.9463.1023
1
EA
RES, 1/8W 1% 1.02 K 200V CHP THK FLM
SMT1206
R401
11
60.9463.1214
1
EA
RES, 1/8W 1% 12.1K 200V CHP THK FLM
SMT1206
R308
12
60.9463.1405
1
EA
RES, 1/8W 1% 140.0 K 200V CHP THK FLM
SMT1206
R428
13
60.9463.2004
3
EA
RES, 1/8W 1% 20.0 K 200V CHP THK FLM
SMT1206
R408, R409,
R422
14
60.9463.2214
1
EA
RES, 1/8W 1% 22.1 K 200V CHP THK FLM
SMT1206
R306
15
60.9463.2614
1
EA
RES, 1/8W 1% 26.1 K 200V CHP THK FLM
SMT1206
R315
16
60.9463.3015
1
EA
RES, 1/8W 1% 301.0 K 200V CHP THK FLM
SMT1206
R426
17
60.9463.3834
1
EA
RES, 1/8W 1% 38.3 K 200V CHP THK FLM
SMT1206
R405
18
60.9463.4024
1
EA
RES, 1/8W 1% 40.2 K 200V CHP THK FLM
SMT1206
R403
19
60.9463.4025
1
EA
RES, 1/8W 1% 402.0 K 200V CHP THK FLM
SMT1206
R429
20
60.9463.4324
1
EA
RES, 1/8W 1% 43.2 K 200V CHP THK FLM
SMT1206
R414
160
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
No.
Item
Qty.
UM.
21
60.9463.5113
2
22
60.9463.6653
23
3
Description
Ref.
EA
RES, 1/8W 1% 5.11 K 200V CHP THK FLM
SMT1206
R301, R307
1
EA
RES, 1/8W 1% 6.65 K 200V CHP THK FLM
SMT1206
R404
60.9463.7683
1
EA
RES, 1/8W 1% 7.68 K 200V CHP THK FLM
SMT1206
R423
24
60.9464.1002
1
EA
RES, 1/8W 5% 100 OHM 200V CHP THK FLM
SMT1206
R305
25
60.9464.1003
7
EA
RES, 1/8W 5% 1.0 K 200V CHP THK FLM
SMT1206
R303, R412,
R416, R501,
R506, R507,
R509
26
60.9464.1005
1
EA
RES, 1/8W 5% 100.0 K 200V CHP THK FLM
SMT1206
R417
27
60.9464.1206
2
EA
RES, 1/8W 5% 1.2 MEG 200V CHP THK FLM
SMT1206
R309, R410
28
60.9464.1503
1
EA
RES, 1/8W 5% 1.5 K 200V CHP THK FLM
SMT1206
R505
29
60.9464.1505
1
EA
RES, 1/8W 5% 150.0 K 200V CHP THK FLM
SMT1206
R430
30
60.9464.1605
1
EA
RES, 1/8W 5% 160.0 K 200V CHP THK FLM
SMT1206
R302
31
60.9464.1914
1
EA
RES, 1/8W 5% 19.1 K 200V CHP THK FLM
SMT1206
R431
32
60.9464.2003
1
EA
RES, 1/8W 5% 2.0 K 200V CHP THK FLM
SMT1206
R313
33
60.9464.2004
3
EA
RES, 1/8W 5% 20.0 K 200V CHP THK FLM
SMT1206
R407, R411,
R418
34
60.9464.2005
1
EA
RES, 1/8W 5% 200.0 K 200V CHP THK FLM
SMT1206
R421
35
60.9464.2203
1
EA
RES, 1/8W 5% 2.2 K 200V CHP THK FLM
SMT1206
R312
36
60.9464.5103
1
EA
RES, 1/8W 5% 5.1 K 200V CHP THK FLM
SMT1206
R311
37
60.9464.5603
1
EA
RES, 1/8W 5% 5.6 K 200V CHP THK FLM
SMT1206
R413
38
60.9464.6204
1
EA
RES, 1/8W 5% 62.0 K 200V CHP THK FLM
SMT1206
R419
39
60.9464.6803
1
EA
RES, 1/8W 5% 6.8 K 200V CHP THK FLM
SMT1206
R504
40
62.4000.0102
2
EA
CAP, 1000PF 50V 5% CER CHIP MONO COG
C304, C412
02.9 663.00 10 D
23-Oct-02
161
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
Description
Ref.
41
62.4000.0105
14
EA
CAP, .1UF 50V 20% CER CHIP SUR MT Z5U
EIA0805
C306, C307,
C309, C402,
C405, C406,
C408, C414,
C415, C416,
C424, C504,
C507, C508
42
62.4003.0102
6
EA
CAP, 1000PF 50V 10% CER CHIP SUR MT X7R
EIA0805
C301, C311,
C313, C403,
C404, C503
43
62.4003.0103
1
EA
CAP, .01UF 50V 20% CER CHIP SUR MT Z5U
EIA0805
C422
44
62.4003.0104
1
EA
CAP, 0.1UF 50V 10% CER CHIP SUR MT X7R
EIA0805
C303
45
62.4003.0152
1
EA
CAP, 1500PF 50V 10% CER CHIP SUR MT X7R
EIA0805
C312
46
62.4003.0221
1
EA
CAP, 220PF 50V 10% CER CHIP SUR MT X7R 0805
C314
47
62.4003.0222
1
EA
CAP, 2200PF 50V 10% CER CHIP SUR MT X7R
EIA0805
C420
48
62.4003.0223
1
EA
CAP, .022UF 50V 10% CER CHIP SUR MT X7R
EIA0805
C411
49
62.4003.0331
1
EA
CAP, 330PF 50V 10% CER CHIP SUR MT X7R 0805
C505
50
62.4003.0471
3
EA
CAP, 470PF 50V 10% CER CHIP SUR MT X7R 0805
C305, C409,
C417
51
62.4005.0101
5
EA
CAP, 100PF 50V 10% CER CHIP SUR MT COG 0805
C410, C418,
C419, C423,
C502
52
62.4005.0220
1
EA
CAP, 22PF 50V 10% CER CHIP SUR MT COG 0805
C501
53
62.4007.0474
3
EA
CAP, .47UF 50V 20% CER CHIP SUR MT Z5U 1210
C302, C310,
C315
54
62.4223.0475
6
EA
CAP, 4.7UF 50V ALUM ELECTRO SUR MT LOW
ESR
C308, C401,
C407, C413,
C421, C506
55
80.2650.0001
3
EA
TRANSISTOR, MMBT4401LT1 NPN 40V 600MA
SOT-23
Q301, Q501,
Q503
56
80.2651.0001
2
EA
TRANSISTOR, MMBT4403LT1 PNP 40V 600MA
SOT-23
Q302, Q502
57
82.4327.0001
5
EA
DIODE, 1N5819M RECTIFIER GLASS MELF
D301, D302,
D303, D402,
D403
58
82.5346.0001
6
EA
DIODE, LL4148 SMALL SIGNAL
D401, D404D407, D501
59
82.5355.0001
1
EA
DIODE, ZM4733A ZENER REGULATOR 5.1V 1W
SMT DO-213AB
D504
60
82.5356.0001
3
EA
DIODE, ZMM5240B ZENER REGULATOR 10V .5W
SMT SOD-80C
D305-D307
162
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
No.
Item
Qty.
UM.
Description
Ref.
61
82.5358.0001
1
EA
DIODE, ZM4747A ZENER REGULATOR 20V 1W
SMT DO-213AB
D304
62
83.3201.0001
2
EA
IC, LM293D LOW OFFSET VOLTAGE DUAL
COMPARATORS SO-8
U302, U403
63
83.3202.0001
2
EA
IC, LM258D DUAL DIFFERENTIAL INPUT LOW
POWER OP-AMPS SO-8
U402, U404
64
84.4320.0001
1
EA
IC, MC14040BD 12-BIT BINARY COUNTER SOIC16
U501
65
84.7431.0001
1
EA
IC, MC14013BD DUAL TYPE D FLIP-FLOP SOIC-14
U502
66
85.5169.0001
1
EA
IC, UCC2810DW DUAL CH SYNCH CURRENT
MODE PWM SOIC-16
U401
67
85.5170.0001
1
EA
IC, UC2855BDW POWER FACTOR PREREGULATOR SOIC-20
U301
3
Figure 3-71: 625W Ballast Rider PCB
02.9 663.00 10 D
23-Oct-02
163
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
575W Ballast I/O Cable Assembly
25.9663.1907 Rev B
Refer to Figure 3-72.
No.
Item
Qty.
UM.
Description
1
52.6231.0001
1
EA
PLUG HOUSING, MNLOK PLUG 3POS
2
52.6396.2204
1
EA
RECEPT, 4POS MTA100 W/POL TAB RED CLSD END
3
52.6400.0111
1
EA
RECEPT, 17-9 STD SEX CPC 600V KEY A SQ FLANGE
4
52.8201.0005
3
EA
PIN, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA
5
52.8202.0001
5
EA
PIN, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA
6
52.8202.0011
1
EA
PIN, GND GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA
7
52.8231.0005
3
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
8
52.8257.0002
2
EA
PIN, PHOS BRZ 20-14AWG (REEL) MNLOK .060"- .130"INS DIA
9
52.8313.0001
2
EA
RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL)
10
52.8314.0001
1
EA
PIN, GND 20-14AWG (REEL) MNLOK .060"- .130"INS DIA
11
55.2186.0001
5
EA
CABLE TIE, .10"WD 4.00"LG SMALL
12
55.2199.1500
.19
FT
HEATSHRINK, 1 1/2" BLACK
13
67.4018.0001
1
EA
FERRITE, 26 X 28.5 X 13MM, CYLINDRICAL CORE
14
73.3522.0002
0.25
FT
WIRE, 22AWG 300V 105C PVC RED UL1569
15
73.3522.0009
0.25
FT
WIRE, 22AWG 300V 105C PVC WHT UL1569
16
73.3522.0010
0.25
FT
WIRE, 22AWG 300V 105C PVC BLK UL1569
17
73.6016.0003
2.19
FT
WIRE, 16AWG 600V 105C PVC ORG UL1015
18
73.6016.0007
2.02
FT
WIRE, 16AWG 600V 105C PVC VIO UL1015
19
73.6016.0009
0.50
FT
WIRE, 16AWG 600V 105C PVC WHT UL1015
20
73.6016.0010
0.50
FT
WIRE, 16AWG 600V 105C PVC BLK UL1015
21
73.6016.0504
1.33
FT
WIRE, 16AWG 600V 105C PVC GRN/YEL UL1015
164
23-Oct-02
02. 9663.0 010 D
ILLUSTRATED PARTS BREAKDOWN : ARC BALLAST ASSEMBLY
3
575W Ballast I/O Cable Assembly (continued)
7 (x3)
GRN/
YEL
GRN/
YEL
4.0" MIN
9 (x2)
4.5" MIN
GRN/
YEL
18
VIO
21
ORN
GRN/YEL
1
2
3
WHT
BLK
3
6
9
2
5
8
17
1
4
7
6.5" MIN
13 12
19
1
8 (x2)
10
1
2
3
ORN
20
1
2
3
4
3
4 (x3)
5 (x5)
6
14, 15, 16
2
FERRITE
26.25"
GRN/YEL 4"
VIO
24.25"
FASTON
RING TERM
FASTON
BLK
6"
GRN/YEL 4"
5
WHT 6"
6
WHT 3"
7
BLK
3"
8
RED 3"
9
4
11 (x5)
3
2
1
GRN/YEL
CPC
RECEPT
9POS
WHT
RED
TWISTED WIRE
8"
RING TERM
MATE-N-LOK
3POS
RING TERM
BLK
GRN/YEL
1
2
3
4
MTA-100
4POS
Figure 3-72: 575W Ballast I/O Cable Assembly
02.9 663.00 10 D
23-Oct-02
165
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
166
23-Oct-02
02. 9663.0 010 D
APPENDIX A.
Technical Bulletins
VL1000 ERS Luminaire Technical Bulletins
The following table identifies the current technical bulletins associated with the
VL1000 ERS luminaire. These improvements have been incorporated into this
manual.
02.9 663.00 10 D
Technical Bulletin
Description
S1K-001
VL1000 Tilt Bearing Hardware Check/Modification
S1K-002
VL1000 Lamp Wire Sleeving Modification
S1K-003
VL1000 Arc Luminaire IR Coated Glass Retrofit
23-Oct-02
167
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
Notes
168
23-Oct-02
02. 9663.0 010 D
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Wiring and Schematic Diagrams
VL1000 Incandescent Wiring Diagram - Sheet 1 of 2
02.9 663.00 10 D
23-Oct-02
169
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL1000 Incandescent Wiring Diagram - Sheet 2 of 2
02.9 663.00 10 D
23-Oct-02
170
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL1000 Arc Wiring Diagram - Sheet 1 of 2
02.9 663.00 10 D
23-Oct-02
171
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL1000 Arc Wiring Diagram - Sheet 2 of 2
02.9 663.00 10 D
23-Oct-02
172
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL1000 Ballast Wiring Diagram
02.9 663.00 10 D
23-Oct-02
173
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Gobo Wheel Sensor (24.9663.1230 B) Schematic
02.9 663.00 10 D
23-Oct-02
174
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Gobo Index Sensor (24.9663.1231 A) Schematic
02.9 663.00 10 D
23-Oct-02
175
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
DMX Input PCB (24.9663.1830 A) Schematic
02.9 663.00 10 D
23-Oct-02
176
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 1 of 3
02.9 663.00 10 D
23-Oct-02
177
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 2 of 3
02.9 663.00 10 D
23-Oct-02
178
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
625W Ballast PCB (24.9663.1901 A) Schematic - Sheet 3 of 3
02.9 663.00 10 D
23-Oct-02
179
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 1 of 2
02.9 663.00 10 D
23-Oct-02
180
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
625W Ballast Rider PCB (24.9663.1902 A) Schematic - Sheet 2 of 2
02.9 663.00 10 D
23-Oct-02
181
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 1 of 10
8
7
6
5
4
2
3
1
REVISIONS
REV
APPD
Initial Release per EO #9003
DESCRIPTION
12/01
T.E.W.
B
Revised per EO #09010
01/02
T.E.W.
C
Revised per EO #09013
01/02
T.E.W.
D
Revised per EO #09021
02/02
T.E.W.
Unlesss Otherwise specified.
E
Revised per EO #09025
02/02
T.E.W.
1.
All capacitor values are microfarads.
F
Revised per EO #09028
2.
All resistor values are ohms.
3.
Capacitors are 50V, 20%.
4.
Resistors are 1/10W 5%.
Notes:
D
DATE
A
D
Power and ground symbols used.
VCC
Vcc (+5V Logic power)
VEE
Vee (-5V Logic power)
+24V
VR3
LM2596S-5
5
4
ON/OFF
FB
VCC
L1
1
VIN
2
OUT
GND
Gnd (Logic ground)
C246
100UF
20%
35V
TAB
3
C248
100UF
20%
35V
114UH
6
D13
C242
100UF
20%
35V
MBRS340T3
C243
100UF
20%
35V
Reference Designators
C
Last Used
Not Used
+24V
VR2
LM2596S-3.3
5
C
+3.3V
4
ON/OFF
C248
FB
L2
1
VIN
D48
2
OUT
GND
FB2
C244
100UF
20%
35V
J9
TAB
3
C247
100UF
20%
35V
114UH
6
D12
C240
100UF
20%
35V
C241
100UF
20%
35V
MBRS340T3
L2
PTC4
R306
S5
+3.3V
U40
+2.5V
R292
10K
VR3
VR1
LP3965ES-2.5
2
Y1
4
VIN
1
Z4
VOUT
5
SD-
Connect Sense at Load
SENSE
GND
C238
100UF
10V
20%
TAB
3
C239
100UF
10V
20%
6
B
B
DRAWN BY
NEXT
ASSY
A
PCB NO.
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
24-9663-1930
3-5-2002_7:31
11.9663.1930
CONFIDENTIAL
R
T. WALSH
24.9663.1930
A
DSN
VL1000 CONTROLLER
CHK
ALL INFORMATION CONTAINED HEREIN
IS THE SOLE AND EXCLUSIVE PROPERTY DOC
OF VARI-LITE, INC. AND MAY NOT BE
USED, DISCLOSED, OR REPRODUCED MFG
IN ANY MANNER WITHOUT, THE ADVANCE
WRITTEN CONSENT OF VARI-LITE, INC.
ViewDraw for Windows 7.5
3
201 REGAL ROW
DALLAS, TEXAS 75247
2
SIZE
REVISION
D
F
DRAWING NUMBER
SHEET
14-9663-1930
1
OF
10
1
182
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 2 of 10
8
7
6
5
4
2
3
1
3/B4,3/A4,4/A6
+3.3V
D[0:31]
D[0:31]
D[0:31]
D[0:31]
A[0:24]
A[0:24]
R281
10K
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
1
16
D0
2
15
D1
3
14
D2
4
13
D3
PLL DIV = 1/2
C228
.01UF
10%
25V
D
C188
.01UF
10%
25V
C216
.01UF
10%
25V
C197
.01UF
10%
25V
C211
.01UF
10%
25V
C203
.01UF
10%
25V
2/C3,3/D7,3/A4
U33
MCF5307
CLK IN = 39-45
5
12
D4
6
11
D5
7
10
D6
+3.3V
C205
0.1UF
10%
25V
+3.3V
+3.3V
C215
0.1UF
10%
25V
+3.3V
C189
0.1UF
10%
25V
C212
0.1UF
10%
25V
+3.3V
C196
0.1UF
10%
25V
8
C219
0.1UF
10%
25V
D7
9
R272
4.7K
2/B4,3/B4
R270
4.7K
CS_MTR-
2/B4,3/A7
R268
4.7K
CS_UART+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
CS_FLASHC193
.01UF
10%
25V
C194
.01UF
10%
25V
C232
.01UF
10%
25V
C157
.01UF
10%
25V
C187
.01UF
10%
25V
2/B4,3/A7
R275
4.7K
+3.3V
C198
.01UF
10%
25V
2/C4,2/C4
R256
4.7K
TIN0
2/B5
R255
4.7K
TIN1
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
2/B5
HIZC233
0.1UF
10%
25V
C217
0.1UF
10%
25V
C195
0.1UF
10%
25V
146
D2
144
D3
143
D4
142
D5
140
D6
139
D7
138
D8
136
D9
135
D10
134
D11
132
D12
131
D13
130
D14
128
D15
127
D16
126
D17
124
D18
123
D19
122
D20
120
D21
119
D22
118
C245
0.1UF
10%
25V
C231
0.1UF
10%
25V
2/A5
R279
4.7K
EDGESEL
2/B5
R252
4.7K
SCL
C
2/B5,4/D8
D0/DIVIDE0
A0
D1/DIVIDE1
A1
D2/FREQ0
A2
D3/FREQ1
A3
D4/ADDR_CONF
A5
D6/CS_CONF1
A6
D7/CS_CONF2
A7
D8
A8
D9
A9
115
D25
114
D26
112
D27
111
D28
110
D29
108
D30
107
D31
106
A11
D12
A12
D14
A14
D15
A15
A17
D18
A18
D19
A19
D20
A20
D21
A21
A23
D24
A24/PP8
A25/PP9
D26
A26/PP10
D27
A27/PP11
D28
A28/PP12
D29
A29/PP13
D30
A30/PP14
3.3VIN
8
5VRST
3.3VRST
7
5VTOL
3.3VTOL
6
PBRST
5
4
GND
A11
19
A12
A14
23
A15
A17
27
A18
A19
30
A20
31
A21
32
A22
34
A23
35
A24
2/C4,2/C6
2/B4
2/C4,2/B6,3/A7
BUTTON3
2/B6
AS-
62
2/C6,2/B7,3/B4
TA-
64
3/C8,3/A2,3/A4
DATA
3/A2,3/B4
40
INIT_DONE
3/B4
42
CONF_DONE
3/B8,3/A2,3/B4
43
STATUS-
3/C8,3/A2,3/B4
68
RX_INT-
70
TX_INT-
71
IRQ1-
2/B6
3/C8,3/B4
PP0
2/A8
PP1
2/A8
2/A8
PP3
2/A8
202
BUTTON0
4/C7
5
2/C4,2/C7,2/B5,2/B6
7
RSTI-
8
9
10
IRQ7
CS0
IRQ5/4
CS1
IRQ3/6
CS2
2/B4,2/C6
DSO
2/B4
IRQ1/2
CS3
72
BUTTON2
4/C8
BUTTON1
200
DREQ0/PP6
CS5
DREQ1/PP5
CS6
TIN0
80
TIN0
TIN1
TIN1
R/W-
CS_FLASH-
UART_OUT_B
4/C6
2/D6,3/B4
2/D6,3/A7
2/C5,3/C7
3/D7,4/C6
4/D6
83
TXD1
UART_IN
165
TX_EN_B-
164
RAS0
RAS1
RTS1
CAS0
86
CTS1
CS_UARTOE-
TXDB
4/A8
RXDB
4/A8
2/C4,2/C7,2/B5,2/B8
TXD2
2/A4
2/A4
2/C6,4/D8
SDA
103
DDATA3
2/A4
2/C6,4/D8
SCL
102
2/A4
DDATA2
17
DDATA1
2/A4
SRAS
2/A4
DDATA0
19
20
21
22
23
24
PSTCLK
2/A3
176
25
26
TA-
2/C5,2/C6,3/B4
177
RSTIEDGESEL
2/C6
S_CASCLK_EN
DRAMWR-
RSTI
EDGESEL
DQ11
A21
A12
DQ12
D28
A24
36
A13
DQ13
A22
20
A23
21
39
41
43
DQ14
45
A-1/DQ15
D29
D30
D31
A17
NC5
CE-
VCC
OE-
NC1
RAS0CAS3-
15
16
2/B4
2/B4
CAS2-
39
2/B3,2/B2
DRAMW-
16
2/B3,2/B2
SRAS-
18
2/B3,2/B2
SCAS-
17
WE-
NC2
RESET-
NC3
2/B2,2/B4
CLK_EN
37
37
9
10
A20
A21
13
27
RY/BY-
GND1
BYTE-
GND2
2/B3
BCLK1
DQ4
A5
DQ5
A6
DQ6
A7
DQ7
A8
DQ8
A9
DQ9
A11
DQ11
NC/A12
DQ12
D3
8
D4
10
D5
11
D6
13
D7
42
D8
44
D9
45
D10
47
D11
48
D12
50
D13
51
D14
53
D15
DQ13
DQ14
DQ15
D
CS
DQML
DQMH
40
WE
NC
RAS
+3.3V
CAS
CKE
3
V3.3_Q1
38
CLK
9
V3.3_Q2
46
43
V3.3_Q3
1
V3.3_1
49
V3.3_Q4
6
28
C
12
GND1
GNDQ2
GND2
GNDQ3
GND3
GNDQ4
41
HIZ
46
52
CLKIN
PVDD
PGND
J7
TMM10401SDSM
2/C6,2/B7
2/C6,2/B7
192
PST0
DDATA3
C227
.01UF
10%
25V
FB2
A11
29
A10
30
A9
31
A17
32
A18
33
A19
34
A20
22
A21
35
A24
36
A22
20
15
PST1
2/B7
PST2
2/B8
196
PST3
2/B7
184
PST_CLK
186
DDATA0
2/B8
187
DDATA1
2/B7
189
DDATA2
2/B8
190
DDATA3
2/B7
2
D16
4
D17
5
D18
7
D19
8
D20
DQ0
DQ1
A2
DQ2
A3
DQ3
A4
DQ4
A5
DQ5
A6
DQ6
A7
DQ7
A8
DQ8
A9
DQ9
A10
DQ10
A11
DQ11
NC/A12
DQ12
10
D21
11
D22
13
D23
42
D24
44
D25
45
D26
47
D27
48
D28
50
D29
51
D30
53
D31
DQ13
DQ14
BA1
DQ15
B
CS
DQML
CAS0-
39
2/B3,2/C2
DRAMW-
16
2/B3,2/C2
SRAS-
18
2/B3,2/C2
SCAS-
17
CLK_EN
37
DQMH
40
WE
NC
RAS
+3.3V
CAS
BCLK2
38
CLK
CLK3
7
9
V3.3_Q2
2/C2
43
BCLK2
2/B2
V3.3_Q3
1
V3.3_1
49
V3.3_Q4
V3.3_2
27
V3.3_3
6
GNDQ1
5
GND
3
V3.3_Q1
+3.3V
BCLK1
R284
22
2
CLK2
4
CKE
14
3
CLK1
REF
2/B8
195
SDRAM
4Mx16
A1
BA0
CAS1-
CLKOUT
1
2/B8
193
DDATA2
FB1
600 OHM
8
VCC
DSI
TCK
DDATA1
26
2/B4
R283
22
U36
CY2305
6
DSCLK
DDATA0
178
+3.3V
A12
19
2/B3
+3.3V
3/A7
150
PSTCLK
180
GND
25
A23
2/B4,2/C2
149
PST3
A13
A0
2/B2,2/C2
BCLK
153
PST2
24
RAS0-
2/B2,2/C2
DRAMW-
2/B7
PST1
174
CLK40
23
A14
2/C2,2/B3
2/B4
R251
22
2/C6,2/B7
TCK
A15
21
2/B2,2/C2
SCAS2/B2,2/C2
DSO
PST0
155
2
28
R291
22
CLK4
12
GND1
GNDQ2
GND2
GNDQ3
GND3
GNDQ4
41
BCLK3
3/A7
46
54
52
R285
22
PSTCLK
2/B7
V3.3 PINS: 1,7,13,21,29,37,
57,65,73,81,89,97,105,113,
121,129,137,145,152,157,167,
171,175,185,191,197,205
CPU
GND PINS: 4,10,17,25,33,41,48,
53,61,69,77,85,93,101,104,
109,117,125,133,141,148,156,
162,169,173,183,188,194,201,208
600 OHM
VL1000 CONTROLLER
REVISION
F
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
D2
7
DQ10
BA1
2/B2,2/B3
A19
A4
BA0
14
NC4
DQ3
A10
19
R249
22
BKPT-
DSI/TDI
MTMOD3
2/C6
OUT
3/A4
A11
2/B2,2/C2
SRAS-
RSTO-
DSO/TDO
4
3
2/C2
151
DSCLK/TRST
VCC
8
D27
35
R250
22
154
BKPT/TMS
168
182
6
22
2/B2
172
RSTO
67
+3.3V
7
A20
36
15
RAS0-
S_RAS-
91
SCKE
DRAMW
MTMOD2
5
D26
34
DQ10
SCL
MTMOD1
Y1
40.000MHZ
CAS3-
95
SCAS
SDA
MTMOD0
HIZ-
CAS0-
94
170
2/C4,2/C7,2/B6,2/B8
RAS_0-
2/C2
BCLKO
PP3
12
34
TO MICROPROCESSOR
2/B2
92
CTS2
PST3
PST1
PP2
RSTI-
A19
R253
22
CAS2-
90
159
16
2/C4
11
D25
32
D1
5
U31
MT48LC4M16A2
RXD2
14
2/C4
DQ9
PLACE RESISTORS CLOSE
CAS1-
CAS3
160
12
2/C4
R/W-
A18
2/C4
88
CAS2
161
181
A
28
D24
33
2/D6,3/A7
87
CAS1
2/B5
15
3/A4
A9
17
26
32
84
RXD1
163
13
TEST1
DQ8
A16
OE-
31
A17
D0
4
GNDQ1
CS_MTR-
BE2
166
11
TEST0
A8
A15
CS_FLASH-
A9
D23
30
A[0:24]
CS_LCD-
100
PST0
4
48
A10
D22
44
A3
2/C4,2/C6
99
TOUT1
PST2
2
A17
D21
42
DQ2
2/C4,2/B6,3/A7
BE1
78
2/A4
3
DQ7
DQ1
A2
14
98
82
RTS2
1
DQ6
A7
30
+3.3V
59
OE
158
PP1
1
29
BE0
2/C5,3/C7
RSTI-
PP0
DQ5
A6
A14
A16
A11
40
96
TOUT0
2/C6
IRQ1-
2/C4
A15
2
A5
A10
+3.3V
58
49
79
R258
1K
SW TESTPOINTS
3
D20
38
55
2/A4
18
A14
26
54
60
R254
1K
DSI
4
A12
2
DQ0
A1
51
4/C8
2/C6
TX_INT-
6
A13
D19
35
SDRAM
4Mx16
A0
47
50
199
2/C5
R269
1K
2/B4,2/C6
A12
5
25
46
BE3
2/B4,2/C6
6
24
A13
27
CONFIG-
PP2
63
2/C4,2/C4,3/A7
RX_INT-
DSCLK
A11
DQ4
23
A14
D18
CS4
R271
1K
BKPT-
7
A4
A15
D17
33
56
PTS645VH83
4
A10
DQ3
D16
31
SIZ0
2/C5
IRQ7-
3
A9
8
A3
29
V3.3_3
204
R/W
TA
IRQ7-
R273
1K
TCK
18
DQ2
2/D4,3/D7,3/A4
206
CS7
2/B4
19
A8
DQ1
A2
V3.3_2
203
TM2/PP4
AS
2/B6,3/C7
2/B6
R/W-
B
A7
DQ0
A1
47
DCLK
39
TM1/PP3
TIP/PP7
2/B6,3/C7
2/C5,2/B7,3/B4
R257
1K
2
A6
20
A0
2/B4,2/B7
AS-
1
21
U35
MT48LC4M16A2
SIZ1
R259
1K
J9
SSM113SDVLCPTR
A5
2/C7,2/B5,2/B6,2/B8
38
TM0/PP2
198
4/C8
2/B4,2/B7
TA-
+3.3V
22
A18
28
TT1/PP1
TS
DSCLK
R277
100
A4
A16
26
A31/PP15
BD
R274
1K
S1
23
A13
22
TT0/PP0
75
2/B4,2/B7
R282
4.7K
5VIN
18
44
74
R278
4.7K
BKPT-
3
24
A3
A10
36
D25
BG
+3.3V
2
A9
A22
D23
66
1
A8
A16
D17
76
DSI
U37
DS1834AS
A7
15
24
25
A2
A6
14
A13
A1
A5
12
207
2/B5,4/D8
R280
4.7K
VCC
A4
20
BR
2/C4,2/B5,2/B6,2/B8
A3
8
U29
AM29LV400BB
54
SDA
RSTI-
A2
6
A10
D11
D31
R248
4.7K
A1
5
16
D22
116
3
11
D16
D24
A0
A4
D5/CS_CONF0
D13
D23
2
9
D10
+3.3V
R276
4.7K
C213
0.1UF
10%
25V
D1
AUTO ACK
+3.3V
CS_LCD-
147
PAR PORT
16 BIT BUS
+3.3V
D0
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
A
DRAWING NUMBER
14-9663-1930
SHEET
2
OF 10
ViewDraw for Windows 7.5
1
183
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 3 of 10
8
7
6
5
4
2
3
1
+3.3V
+3.3V
+3.3V
C190
0.1UF
10%
25V
+3.3V
+3.3V
C229
0.1UF
10%
25V
C230
0.1UF
10%
25V
+3.3V
C218
0.1UF
10%
25V
+3.3V
C204
0.1UF
10%
25V
C214
0.1UF
10%
25V
+2.5V
C224
.01UF
10%
25V
+2.5V
+2.5V
+2.5V
C225
.01UF
10%
25V
+2.5V
C220
.01UF
10%
25V
+2.5V
+2.5V
C226
.01UF
10%
25V
+2.5V
+2.5V
C222
.01UF
10%
25V
+2.5V
C200
.01UF
10%
25V
C206
0.1UF
10%
25V
C199
0.1UF
10%
25V
C221
0.1UF
10%
25V
+3.3V
R288
1K
STATUS-
CONFIG-
DCLK
2/C4,3/B4
CONF_DONE
R289
1K
TMSA
3/B4
LCD_RS
26
4/A3
LCD_EN
27
4/A3
LCD_R/W-
28
4/B8
LED_STATUS
29
4/B8
LED_TX-
30
LED_RX-
31
2/C5,2/B6
TX_INT-
36
2/C5,2/B6
RX_INT-
37
LAMP_ON-
38
MSEL0
3/B4
R265
1K
B
MSEL1
41
PWM_PH_14
44
8/D3
45
8/D3
PWM_PH_29
46
8/B5
PWM_OUT_32
47
5/B3
PWM_PH_7
53
5/B3
PWM_PH_8
54
5/B5
PWM_OUT_8
55
5/B5
PWM_OUT_7
56
6/B3
PWM_PH_15
57
6/B3
PWM_PH_16
58
6/B5
PWM_OUT_16
60
6/B5
PWM_OUT_15
61
PWM_PH_40
63
PWM_PH_23
64
7/B3
PWM_EN_23
65
7/B3
PWM_EN_24
67
7/B3
PWM_PH_24
68
7/B5
PWM_OUT_24
69
7/B5
PWM_OUT_23
70
8/B3
PWM_PH_31
71
8/B3
PWM_PH_32
73
PWM_PH_39
74
9/B5
PWM_OUT_39
75
9/C5
PWM_OUT_38
83
PWM_PH_38
85
PWM_PH_37
86
PWM_OUT_37
87
9/B8
PWM_OUT_36
88
9/B6
PWM_PH_36
89
9/B6
PWM_PH_35
90
9/B8
PWM_OUT_35
92
9/C8
PWM_OUT_34
93
9/D6
PWM_PH_34
94
9/D6
PWM_PH_33
95
9/D8
PWM_OUT_33
96
7/C5
PWM_OUT_22
97
7/D3
PWM_PH_22
99
7/D3
PWM_PH_21
100
7/D5
PWM_OUT_21
101
8/C5
PWM_OUT_30
102
6/D3
PWM_PH_13
103
6/D5
PWM_OUT_13
104
5/C5
PWM_OUT_6
111
5/D3
PWM_PH_6
112
5/D3
PWM_PH_5
113
3/B4
R261
1K
CE-
3/B4
R286
1K
TCKA
3/A4
R263
0 OHM
R266
0 OHM
INSTALL ONLY WITH EPC1
39
40
PWM_OUT_29
9/D5
R264
1K
LAMP_CNTL
PWM_OUT_14
PWM_PH_30
9/D3
5/D5
5/B6
5/B6
201
185
152
130
77
VCC_CLK
VCCINT11
VCCINT9
VCCINT8
VCCINT10
91
124
VCCINT7
VCCINT6
72
106
VCCINT5
VCCINT4
VCCINT3
21
48
33
VCCINT1
VCCINT2
VCCIO14
165
194
146
138
178
VCCIO13
VCCIO12
VCCIO11
VCCIO10
98
118
VCCIO9
84
66
42
110
VCCIO8
PWM_PH_12
6/B6
126
PWM_PH_11
6/B6
127
PWM_OUT_12
6/B8
128
PWM_OUT_11
6/B8
7/B6
IO81
131
PWM_EN_20
132
PWM_PH_20
133
PWM_EN_19
134
PWM_PH_19
7/B6
135
PWM_OUT_20
7/B8
136
PWM_OUT_19
139
PWM_OUT_28
140
PWM_PH_28
8/B6
141
PWM_PH_27
8/B6
142
PWM_OUT_27
8/B8
143
PWM_OUT_2
144
PWM_PH_2
147
PWM_EN_2
5/D6
148
PWM_EN_1
5/D6
IO82
U32
7/B6
IO83
EP1K50
IO84
IO9
IO85
IO10
IO86
IO11
IO87
IO12
IO88
IO13
IO89
IO14
IO90
IO15
IO91
IO16
IO92
IO93
IO18
IO94
IO19
IO95
IO20
IO96
IO21
IO97
IO22
IO98
149
IO23
IO99
IO24
IO100
IO25
IO101
IO26
IO102
IO27
IO103
IO28
IO104
IO29
IO105
IO30
IO106
IO31
IO107
IO32
IO108
IO33
IO109
IO34
IO110
IO35
IO111
IO36
IO112
IO37
IO113
IO38
IO114
IO39
IO115
IO40
IO116
IO41
IO117
IO42
IO118
IO43
IO119
IO44
IO120
IO45
IO121
IO46
IO122
IO47
IO123
IO48
IO124
8/B8
5/C8
5/D6
5/D6
150
PWM_OUT_1
5/D8
160
PWM_PH_17
7/D6
163
PWM_OUT_17
7/D8
167
P_COT_IN
4/B6
168
T_COT_IN
4/B6
169
PHASE_A_2
4/B6
170
PHASE_A_1
4/B6
172
GOBO_POS_IN
173
GOBO_IDX_IN
4/B6
174
PHASE_B_2
4/B6
175
PHASE_B_1
4/B6
176
PWM_OUT_31
177
PWM_OUT_25
179
PWM_PH_25
8/D6
187
PWM_PH_26
8/D6
189
PWM_OUT_26
8/C8
190
D31
191
D30
192
D29
193
D28
195
D27
196
D26
197
D25
198
D24
199
D23
200
D22
202
D21
203
D20
205
D18
4/B6
C
8/B5
8/D8
LOCK/IO125
IO51
DATA7/IO126
D[0:31]
IO52
DATA6/IO127
IO53
DATA5/IO128
IO54
DATA4/IO129
62
PWM_OUT_40
9/B5
166
PWM_OUT_18
7/C8
164
PWM_PH_18
7/D6
162
IO55
DATA3/IO130
IO56
DATA2/IO131
IO57
DATA1/IO132
PWM_OUT_10
6/C8
161
PWM_PH_10
159
CS_LCD-
2/D6,2/B4
158
TA-
2/C5,2/C6,2/B7
6/D6
157
PWM_PH_9
156
DATA
108
MSEL0
3/B8
107
MSEL1
3/B8
DATA
IO60
MSEL0
IO61
MSEL1
IO62
STATUS
IO63
CONFIG
IO64
CONF_DONE
IO65
INIT_DONE
IO66
CE
PWM_OUT_5
PWM_EN_4
115
PWM_PH_4
116
PWM_PH_3
120
5/B8
PWM_OUT_4
121
5/B8
PWM_OUT_3
122
2/B4
RSTO-
78
R/W-
80
STATUS-
105
B
6/D6
CONFIG-
19
INIT_DONE
2/C4
CE-
3/B8
TDIA
3/B8
+3.3V
153
TDI
TDO
4
50
IO70
TMS
IO71
TRST
IO72
WS
TMSA
3/B8
206
TEST0
2/A7
204
D19
207
D17
208
D16
51
IO73
RS
IO74
CS
CS
A0
10
A6
182
CS_UART-
184
BCLK3
79
155
DCLK
1
TCKA
DCLK
IN2
TCK
IN3
DEV_CLR
IN4
DEV_OE
D[0:31]
16
RDY/BUSY
IN1
CS_MTR-
2/C4,3/B8,3/A2
CEO
IO68
IO69
IO76
2/B4,2/D6
2/C4,3/C8,3/A2
2/C4,3/C8
CONF_DONE
3
IO75
2/B4,2/D6
2/C4,3/A2
2
154
IO67
114
52
CLKUSR
180
PWM_OUT_9
186
TEST1
2/D6,3/B4,4/A6
+3.3V
A[0:24]
U34
2/D4,2/C3,3/D7
EPC1
2/C4,3/B4
DATA
1
2/C4,3/C8,3/A4
DCLK
2
2/C4,3/C8,3/B4
STATUS-
3
2/C4,3/B8,3/B4
CONF_DONE
4
3/B8
02.9 663.00 10 D
6
5
23-Oct-02
VCC1
OE
CASC
7
6
5
CS
GND
FPGA
GND20
VL1000 CONTROLLER
Filename:
Date/Time:
7
DCLK
6/D8
2/A7
REVISION
DRAWING NUMBER
F
14-9663-1930
SIZE
8
VCC2
SOCKET IS XU34
188
GND19
GND18
181
GND16
GND15
GND17
171
151
145
GND14
137
129
GND13
GND12
GND11
117
109
123
GND10
GND9
82
GND7
GND6
GND8
76
59
49
GND5
43
35
GND4
GND3
32
GND2
GND1
6
20
81
23
GND_CLK
CLK2
8
DATA
2/C4,3/C8,3/A2
CLK1
183
A
7/B8
2/D6,3/A4,4/A6
IO50
IO59
PWM_EN_3
2/A3
7/B6
IO58
5/B6
2/C4,2/C4,2/B6
PWM_PH_1
D
IO49
119
5/B6
IO80
IO17
6/D3
9/D3
IO4
IO8
4/A3
9/B3
TDIA
15
IO79
IO7
UART_IN
3/A4
R262
1K
A1
IO78
IO3
IO6
125
IO77
IO2
IO5
25
7/B3
2/C4,3/A2,3/B4
14
24
2/C4,3/A2,3/A4
R287
1K
13
A2
UART_OUT_A
9/B3
R260
1K
12
A3
4/C6
2/C4,3/A2,3/B4
R267
1K
A4
18
8/D5
C
11
TX_EN_A-
4/B3
C208
0.1UF
10%
25V
A5
IO1
TX_EN_C-
6/C5
C209
0.1UF
10%
25V
9
4/D5
4/B3
C201
0.1UF
10%
25V
8
A7
4/D6
4/B8
+2.5V
7
A8
17
2/B5,4/C6
+2.5V
A9
VCCIO7
2/D4,2/C3,3/A4
C192
.01UF
10%
25V
VCCIO6
C223
.01UF
10%
25V
VCCIO1
D
C210
.01UF
10%
25V
VCCIO5
+3.3V
A[0:24]
C202
.01UF
10%
25V
VCCIO4
+3.3V
5
+3.3V
22
+3.3V
C191
.01UF
10%
25V
VCCIO3
+3.3V
C207
.01UF
10%
25V
VCCIO2
+3.3V
34
+2.5V
4
3
24-9663-1930
3-5-2002_7:31
2
D
SHEET
3
A
OF 10
ViewDraw for Windows 7.5
1
184
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 4 of 10
8
7
6
5
4
2
3
1
ISO_VCC
VCC
R294
10K
ISO_VCC
U3
HCPL-0600
R5
470
1
9
TX_EN_C-
3/D7
VCC
ISO_VCC
2
7
3
6
C2
0.1UF
10%
25V
R293
330
8
D
8
NC1
VCC
U39
SN74ACT00
U2
SN75176
3
DE
+3.3V
5
SDA
2/B5,2/C6
SCL
2/B5,2/C6
D
2
10
U30
M24C02
4
GND
RE
5
NC2
SDA
VCC
8
E0
1
6
SCL
E1
2
E2
3
7
WC-
VSS
4
SHIELD
6
A
4
D
7
B
1
1
VCC
R
R296
10K
ISO_VCC
U4
HCPL-0600
1
8
NC1
VCC
U39
SN74ACT00
12
TX_EN_A-
3/D7
VCC
2
7
3
6
C3
0.1UF
10%
25V
R295
330
11
ISO_VCC
2/B5
+3.3V
13
TX_EN_B-
ISO_VCC
4
GND
5
NC2
SHIELD
2
2/C4
1
BUTTON0
R1
36K
1
S2
R297
1K
ISO_VCC
U5
HCPL-0600
U39
SN74ACT00
2
2/B5
1
BUTTON1
3/D7
UART_OUT_A
1
2/B5
UART_OUT_B
2
3
TL1100
ISO_VCC
U1
1
4
SN75LBC180
8
NC1
VCC
U39
SN74ACT00
S3
R298
1K
R7
470
R6
470
TL1100
VCC
1
2
7
3
6
C4
0.1UF
10%
25V
R290
330
6
GND
5
NC2
C
R
A
CO-
12
CI+
VCC2
COMOUT-
10/C2
COMIN+
10/C2
COMIN-
10/C2
13
C
500MA
R12
470
U6
HCPL-0600
VCC
C1
0.1UF
10%
25V
1
1
VCC
BUTTON3
NC1
UART_IN
2/B5,3/D7
7
C8
0.1UF
10%
25V
S5
TL1100
R2
1.8K
ISO_VCC
8
1
R302
1K
10/C2
PTC2
8
NC2
GND2
COMOUT+
500MA
CI-
B
GND1
7
1
CO+
11
6
VCC
9
10
TL1100
2
2/C5
Z
REB
1
S4
R301
1K
Y
D
3
SHIELD
2
BUTTON2
DE
5
2
4
PTC1
VCC1
4
5
2/B5
14
NC1
2
PTC4
500MA
R8
330
6
3
R3
1.8K
1
5
PTC3
4
GND
NC2
SHIELD
500MA
ISO_VCC
1
1SMA10CAT3
Z2
4
VIN+
VOUT+
VIN-
VOUT-
2
Z3
Z4
R4
36K
U7
MAU202
VCC
1SMA10CAT3
Z1
1SMA10CAT3
1SMA10CAT3
3
VCC
+3.3V
VCC
R305
1K
PAN A
PAN B
TILT A
D6
D7
D2
D3
BAT54
BAT54
BAT54
BAT54
1
R119
4.7K
TILT B
R121
4.7K
R27
4.7K
1
1
1
1
R29
4.7K
1
VCC
R304
1K
D4
TX
D16
BAT54
R25
100
+24V
RX
GREEN
3/C4
PHASE_A_1
3/C4
PHASE_A_2
ENCODER_A1
10/C5
ENCODER_A2
10/C3
ENCODER_B1
10/C5
D15
R24
100
GREEN
B
3/C7
LED_TX-
3/C7
LED_RX-
3/C7
LED_STATUS
R11
4.7K
5%
1/4W
R303
1K
R23
100
3/C4
STATUS
PHASE_B_1
D1
D14
U8
NC7SZ04
3/C7
R22
100
POWER
RED
3/C4
PHASE_B_2
3/C4
P_COT_IN
ENCODER_B2
2
LAMP_CNTL
10/C3
R13
270
4
LAMP_CNTL_OUT
10/D2
B
R306
10K
YELLOW
R28
100
PAN_COT_SENS
10/C5
VCC
VCC
R26
100
3/C4
T_COT_IN
TILT_COT_SENS
D5
10/C3
BAT54
R9
10K
R120
100
3/C4
GOBO_POS_IN
3/C4
GOBO_IDX_IN
GOBO_POS_SENS
10/B3
GOBO_IDX_SENS
10/B5
R118
100
VCC
C235
0.1UF
10%
25V
C234
0.1UF
10%
25V
VCC
16
SP232A
1
C1+
VCC
2
IDX
POS
TCOT
PCOT
V+
3
D9
D8
D11
D10
BAT54
BAT54
BAT54
BAT54
VCC
V-
11
14
T1
10
7
T2
2/B5
RXDB
GOBO_POS_LED
10/B3
GOBO_IDX_LED
TXDB232
1
RXDB232
2
10/B5
3
12
13
R1
9
D[0:31]
8
GND
15
VCC
2/D6,3/B4,3/A4
R2
C237
0.1UF
10%
25V
A
U40
HDM08111H-L
D8
7
D0
D/INST-
4
LCD_RS
3/D7
D9
8
D1
R/W-
5
LCD_R/W-
3/C7
D10
9
D2
E
6
LCD_EN
3/D7
D11
10
D3
LED+
15
D12
11
D4
LED-
16
D13
12
D5
VDD
2
D14
13
D6
VSS
1
D15
14
D7
VLCD
3
R299
8.2K
User I/O
VL1000 CONTROLLER
R300
1.8K
REVISION
F
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
10/D2
R122
270
J8
640456-3
C2-
TXDB
LAMP_ON_IN-
6
C2+
5
2/B5
LAMP_ON-
R123
270
C14
R10
150
3/C7
C236
0.1UF
10%
25V
U38
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
A
DRAWING NUMBER
14-9663-1930
SHEET
4
OF 10
ViewDraw for Windows 7.5
1
185
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 5 of 10
8
7
6
5
4
2
3
1
+24V
VCC
D
PAN
M1
R32
24K
5%
1/16W
R36
7.50K
3/C4
R33
7.50K
PWM_PH_1
20
3/C4
PWM_EN_1
21
23
12
VCC
PHASE1
VMM1
11
C13
.01UF
10%
25V
3/C4
R30
4.32K
1%
1/16W
PWM_PH_2
25
PWM_EN_2
24
R37
7.50K
1/16W
1%
1/16W
1%
5
PHASE2
7
VR2
M1OUT2B
MB2
VR1
GND10
GND9
GND3
GND8
3/B7
PHASE2
VR2
19
10
26
RC
C11
470PF
10%
25V
GND8
15
GND7
14
GND5
C1
1/16W
1%
E1
19
R56
4.32K
1%
1/16W
C35
.022UF
10%
25V
GND6
E2
C2
10
26
6
C30
2700PF
10%
25V
R34
10K
R14
1
1%
1W
16
GND4
C36
.01UF
10%
25V
R31
10K
17
GND9
13
C12
2700PF
10%
25V
R50
10K
R15
1
1%
1W
C15
470PF
10%
25V
10/C6,10/C3
GND10
9
R59
7.50K
1/16W
1%
M3OUT6B
28
22
PWM_OUT_6
6
10/C6,10/C5
7
MB2
GND3
R64
7.50K
3/B7
M3OUT6A
DIS2
27
GND2
GND6
E2
C2
10/C6,10/C5
5
24
R49
4.32K
1%
1/16W
3
14
E1
10/C6,10/C3
M3OUT5B
MA2
2
GND7
GND5
C1
M3OUT5A
8
PBL3773QN
25
PWM_PH_6
15
GND4
11
MB1
GND1
C28
.022UF
10%
25V
16
13
C
1/16W
1%
17
GND2
4
VMM2
MA1
U11
1
C31
.01UF
10%
25V
10/D6,10/D3
28
RC
12
VMM1
DIS1
18
1/16W
1%
10/D5,10/D6
23
VCC
PHASE1
21
PWM_OUT_5
DIS2
9
C17
.022UF
10%
25V
M1OUT2A
MA2
22
PWM_OUT_2
C18
.01UF
10%
25V
10/D5,10/D6
20
PWM_PH_5
R54
7.50K
3/A7
27
R35
4.32K
1%
1/16W
R58
7.50K
PBL3773QN
3
R42
7.50K
M1OUT1B
MB1
2
3/C4
10/D3,10/D6
U9
GND1
3/C4
M1OUT1A
3/B7
1
D
C7
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
8
VR1
C10
.022UF
10%
25V
VCC
M3
DIS1
PWM_OUT_1
1/16W
1%
C32
0.1UF
10%
25V
R51
24K
5%
1/16W
18
1/16W
1%
GOBO INDEX
C5
10UF
50V
20%
+24V
VCC
3/C4
+24V
VCC
C14
0.1UF
10%
25V
VCC
R55
10K
R18
1
1%
1W
C29
470PF
10%
25V
C
R19
1
1%
1W
C33
470PF
10%
25V
+24V
+24V
VCC
VCC
TILT
C23
0.1UF
10%
25V
VCC
M2
R40
24K
5%
1/16W
R47
7.50K
3/A7
R43
7.50K
3/A7
PWM_PH_3
20
3/A7
PWM_EN_3
21
23
12
VCC
PHASE1
VMM1
11
C22
.01UF
10%
25V
MB1
GND1
3/A7
R38
4.32K
1%
1/16W
3/A7
PWM_PH_4
25
PWM_EN_4
24
5
MA2
7
VR2
MB2
22
RC
GND8
E1
19
R45
4.32K
1%
1/16W
PHASE2
R72
7.50K
GND6
E2
C2
10
26
3/C7
VR2
22
C24
470PF
10%
25V
M4OUT8B
10/C6,10/C3
28
RC
GND10
17
GND2
GND9
GND3
GND8
GND4
GND7
15
14
GND5
C1
1/16W
1%
C44
.022UF
10%
25V
R67
4.32K
1%
1/16W
E1
GND6
E2
C2
10
26
6
C39
2700PF
10%
25V
R61
10K
R17
1
1%
1W
B
16
13
PWM_OUT_8
R44
10K
C20
470PF
10%
25V
10/C6,10/C5
7
MB2
19
R16
1
1%
1W
M4OUT8A
DIS2
27
9
C45
.01UF
10%
25V
R39
10K
10/C6,10/C5
5
24
R60
4.32K
1%
1/16W
R70
7.50K
1/16W
1%
6
C21
2700PF
10%
25V
10/C6,10/C3
M4OUT7B
MA2
3
14
M4OUT7A
8
PBL3773QN
25
PWM_PH_8
2
GND7
GND5
C1
C26
.022UF
10%
25V
3/C7
15
GND4
11
MB1
GND1
C37
.022UF
10%
25V
16
13
1/16W
1%
1/16W
1%
17
GND9
GND3
4
VMM2
MA1
U12
1
C40
.01UF
10%
25V
10/C6,10/D3
GND10
GND2
9
PWM_OUT_4
M2OUT4B
12
VMM1
DIS1
VR1
1/16W
1%
10/C6,10/D5
23
VCC
PHASE1
21
18
28
3
C27
.01UF
10%
25V
M2OUT4A
20
PWM_PH_7
R65
7.50K
PWM_OUT_7
DIS2
27
R48
7.50K
1/16W
1%
10/C6,10/D5
PBL3773QN
2
3/A7
M2OUT3B
R69
7.50K
3/C7
PHASE2
B
R53
7.50K
10/D6,10/D3
U10
1
C19
.022UF
10%
25V
M2OUT3A
3/C7
8
VR1
C9
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
DIS1
PWM_OUT_3
1/16W
1%
C41
0.1UF
10%
25V
VCC
M4
R62
24K
5%
1/16W
18
1/16W
1%
GOBO ROTATE
C6
10UF
50V
20%
+24V
VCC
C38
470PF
10%
25V
R66
10K
R20
1
1%
1W
C42
470PF
10%
25V
R21
1
1%
1W
Motor Drivers 1-4
A
VL1000 CONTROLLER
REVISION
F
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
A
DRAWING NUMBER
14-9663-1930
SHEET
5
OF 10
ViewDraw for Windows 7.5
1
186
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 6 of 10
8
7
6
5
4
2
3
+24V
+24V
VCC
D
COLOR BLUE
R76
24K
5%
1/16W
3/B4
R80
7.50K
3/A4
VCC
C50
0.1UF
10%
25V
VCC
M5
20
PWM_PH_9
23
12
VCC
PHASE1
VMM1
11
1/16W
1%
8
GND1
3/B4
3/B7
5
PHASE2
M5OUT10A
MA2
7
VR2
1/16W
1%
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
E1
19
R79
2.67K
1%
1/16W
C2
10
26
3/C7
VR2
10/C3
17
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
16
1/16W
1%
15
14
E1
19
R100
2.67K
1%
1/16W
C71
.022UF
10%
25V
C2
10
26
6
C66
2700PF
10%
25V
R94
10K
R46
1
1%
1W
C51
470PF
10%
25V
M7OUT14B
GND10
GND2
9
R78
10K
R41
1
1%
1W
7
28
RC
13
C72
.01UF
10%
25V
C47
470PF
10%
25V
10/C5
MB2
22
6
R75
10K
M7OUT14A
MA2
27
R103
7.50K
1/16W
1%
10/C5
5
R99
10K
R63
1
1%
1W
C65
470PF
10%
25V
+24V
M6
R84
24K
5%
1/16W
3/D4
R91
7.50K
3/D4
VCC
C59
0.1UF
10%
25V
VCC
20
PWM_PH_11
23
12
VCC
PHASE1
VMM1
11
C58
.01UF
10%
25V
8
MB1
GND1
3/D4
5
PHASE2
MA2
M6OUT12A
10/C5
M6OUT12B
10/C3
3/C7
7
VR2
MB2
22
VR1
1/16W
1%
GND8
C76
.01UF
10%
25V
GND7
GND5
C1
GND6
E2
13
1/16W
1%
E1
C2
10
26
3/C7
PHASE2
VR2
C56
470PF
10%
25V
M8OUT16B
10/C3
28
GND10
17
GND2
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
1/16W
1%
C80
.022UF
10%
25V
R111
2.67K
1%
1/16W
15
14
E1
C2
10
26
6
C75
2700PF
10%
25V
R105
10K
R57
1
1%
1W
B
16
13
PWM_OUT_16
19
C60
470PF
10%
25V
10/C5
7
MB2
RC
R88
10K
R52
1
1%
1W
M8OUT16A
DIS2
22
9
C81
.01UF
10%
25V
R83
10K
10/C5
5
MA2
27
R114
7.50K
1/16W
1%
10/C3
M8OUT15B
24
R104
2.67K
1%
1/16W
6
C57
2700PF
10%
25V
M8OUT15A
8
PBL3773QN
25
PWM_PH_16
3
R116
7.50K
14
19
R89
2.67K
1%
1/16W
3/C7
2
15
11
U16
GND1
C73
.022UF
10%
25V
16
GND4
4
VMM2
MA1
MB1
1
1/16W
1%
17
GND9
GND3
12
VMM1
DIS1
GND10
GND2
23
VCC
PHASE1
21
18
28
RC
PWM_OUT_12
20
PWM_PH_15
PWM_OUT_15
DIS2
27
9
C62
.022UF
10%
25V
10/C5
24
R82
2.67K
1%
1/16W
3
C63
.01UF
10%
25V
M6OUT11B
PBL3773QN
25
PWM_PH_12
R92
7.50K
1/16W
1%
3/C7
R109
7.50K
U14
1
C55
.022UF
10%
25V
2
3/D4
10/C3
DIS1
B
R97
7.50K
M6OUT11A
C43
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
18
1/16W
1%
R106
24K
5%
1/16W
R113
7.50K
VR1
C77
0.1UF
10%
25V
VCC
M8
21
PWM_OUT_11
1/16W
1%
DIFFUSION
C25
10UF
50V
20%
+24V
VCC
R87
7.50K
C
R68
1
1%
1W
C69
470PF
10%
25V
+24V
VCC
COLOR AMBER
10/C3
DIS2
R93
2.67K
1%
1/16W
PWM_OUT_14
C48
2700PF
10%
25V
C
PHASE2
3
R108
7.50K
14
M7OUT13B
24
2
15
M7OUT13A
8
PBL3773QN
25
PWM_PH_14
16
13
C53
.022UF
10%
25V
3/C7
17
9
1/16W
1%
10/C3
11
MB1
GND1
C64
.022UF
10%
25V
C67
.01UF
10%
25V
GND10
GND2
4
VMM2
MA1
U15
1
1/16W
1%
10/C5
28
RC
R81
7.50K
M5OUT10B
MB2
22
12
VMM1
DIS1
VR1
DIS2
27
23
VCC
PHASE1
21
18
24
R74
2.67K
1%
1/16W
C54
.01UF
10%
25V
10/C5
20
PWM_PH_13
PWM_OUT_13
PBL3773QN
25
PWM_PH_10
M5OUT9B
MB1
1
C46
.022UF
10%
25V
PWM_OUT_10
1/16W
1%
3/B7
R98
7.50K
U13
3
R86
7.50K
10/C3
R102
7.50K
2
3/B4
M5OUT9A
D
C34
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
18
C49
.01UF
10%
25V
R95
24K
5%
1/16W
DIS1
VR1
C68
0.1UF
10%
25V
VCC
M7
21
PWM_OUT_9
1/16W
1%
COLOR MAGENTA
C16
10UF
50V
20%
+24V
VCC
R77
7.50K
1
C74
470PF
10%
25V
R110
10K
R71
1
1%
1W
C78
470PF
10%
25V
R73
1
1%
1W
Motor Drivers 5-8
A
VL1000 CONTROLLER
REVISION
DRAWING NUMBER
F
14-9663-1930
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
SHEET
6
A
OF 10
ViewDraw for Windows 7.5
1
187
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 7 of 10
8
7
6
5
4
2
3
1
+24V
+24V
VCC
VCC
D
ZOOM
C86
0.1UF
10%
25V
VCC
M9
3/C4
R130
7.50K
3/C4
+24V
VCC
R126
24K
5%
1/16W
20
PWM_PH_17
23
12
VCC
PHASE1
VMM1
11
8
VR1
GND1
C82
.022UF
10%
25V
3/B4
M9OUT18A
7
M9OUT18B
VR2
MB2
RC
GND10
R129
4.32K
1%
1/16W
27
VR2
10
26
3/B7
22
17
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
16
15
13
1/16W
1%
14
E1
19
C84
2700PF
10%
25V
C108
.01UF
10%
25V
R125
10K
C
R150
4.32K
1%
1/16W
C107
.022UF
10%
25V
C83
470PF
10%
25V
C2
10
26
6
C102
2700PF
10%
25V
R128
10K
R85
1
1%
1W
R144
10K
R90
1
1%
1W
C87
470PF
10%
25V
10/A6,10/B3
GND10
GND2
9
R153
7.50K
1/16W
1%
10/B6,10/B5
M11OUT22B
28
RC
PWM_OUT_22
6
M11OUT22A
7
MB2
3
R158
7.50K
14
GND6
E2
C2
5
MA2
DIS2
15
E1
19
C89
.022UF
10%
25V
PHASE2
2
GND7
GND5
C1
10/B6,10/B5
24
GND8
GND4
10/B6,10/B3
M11OUT21B
PBL3773QN
25
PWM_PH_22
16
GND3
1/16W
1%
3/B7
R143
4.32K
1%
1/16W
17
13
M11OUT21A
8
U19
GND1
C100
.022UF
10%
25V
GND9
9
R131
7.50K
10/B6,10/C3
11
MB1
1
1/16W
1%
C103
.01UF
10%
25V
28
22
4
VMM2
MA1
DIS1
VR1
1/16W
1%
10/B6,10/C5
12
VMM1
18
DIS2
PWM_OUT_18
C90
.01UF
10%
25V
5
MA2
23
VCC
PHASE1
21
PWM_OUT_21
PBL3773QN
PHASE2
27
20
PWM_PH_21
R148
7.50K
24
R124
4.32K
1%
1/16W
GND2
1/16W
1%
10/B6,10/B5
3/B7
25
PWM_PH_18
M9OUT17B
MB1
R152
7.50K
U17
3
R136
7.50K
10/B6,10/B3
3/B7
2
3/B4
M9OUT17A
DIS1
1
D
C70
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
18
1/16W
1%
M11
21
PWM_OUT_17
C85
.01UF
10%
25V
C104
0.1UF
10%
25V
VCC
R145
24K
5%
1/16W
R127
7.50K
1/16W
1%
DIMMER
C52
10UF
50V
20%
R149
10K
R107
1
1%
1W
C101
470PF
10%
25V
C
R112
1
1%
1W
C105
470PF
10%
25V
+24V
+24V
VCC
VCC
BEAM IRIS /
EDGE
C95
0.1UF
10%
25V
VCC
M10
R141
7.50K
3/D4
R137
7.50K
+24V
VCC
R134
24K
5%
1/16W
3/D4
PWM_PH_19
20
3/D4
PWM_EN_19
21
23
12
VCC
PHASE1
VMM1
11
8
MB1
3/D4
PWM_PH_20
25
3/D4
PWM_EN_20
24
5
MA2
7
MB2
22
B
R154
4.32K
1%
1/16W
3/C7
PWM_PH_24
25
10
26
3/C7
3/C7
PWM_EN_24
24
VR2
1/16W
1%
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
C92
470PF
10%
25V
C96
470PF
10%
25V
10/A6,10/B3
B
16
15
14
E1
C2
10
R155
10K
R101
1
1%
1W
M12OUT24B
17
26
6
C111
2700PF
10%
25V
R138
10K
R96
1
1%
1W
7
28
GND9
19
R133
10K
10/A6,10/B5
GND10
GND2
13
R161
4.32K
1%
1/16W
M12OUT24A
MB2
RC
9
C116
.022UF
10%
25V
10/A6,10/B5
5
10/A6,10/B3
DIS2
22
R164
7.50K
C117
.01UF
10%
25V
M12OUT23B
MA2
27
PWM_OUT_24
1/16W
1%
6
C93
2700PF
10%
25V
M12OUT23A
8
U20
3
R166
7.50K
14
11
PBL3773QN
2
GND6
E2
C2
4
VMM2
MA1
MB1
PHASE2
15
19
R139
4.32K
1%
1/16W
C112
.01UF
10%
25V
10/B6,10/C3
GND7
E1
12
VMM1
GND1
C109
.022UF
10%
25V
GND8
GND5
C1
23
VCC
PHASE1
DIS1
16
GND4
C98
.022UF
10%
25V
PWM_EN_23
21
GND9
GND3
1/16W
1%
20
1
1/16W
1%
17
13
C99
.01UF
10%
25V
1/16W
1%
10/B6,10/C5
GND10
9
R142
7.50K
PWM_OUT_20
M10OUT20B
3/C7
PWM_PH_23
VR1
28
RC
GND2
1/16W
1%
M10OUT20A
R159
7.50K
18
DIS2
27
VR2
C79
10UF
50V
20%
+24V
VCC
PWM_OUT_23
PBL3773QN
PHASE2
3
R147
7.50K
10/B6,10/C5
3/B7
2
3/D4
M10OUT19B
R163
7.50K
U18
GND1
R132
4.32K
1%
1/16W
10/B6,10/C3
3/C7
1
C91
.022UF
10%
25V
M10OUT19A
DIS1
VR1
1/16W
1%
M12
4
VMM2
MA1
18
C94
.01UF
10%
25V
C113
0.1UF
10%
25V
VCC
R156
24K
5%
1/16W
PWM_OUT_19
1/16W
1%
SHUTTER ROTATE
C61
10UF
50V
20%
C110
470PF
10%
25V
R160
10K
R115
1
1%
1W
C114
470PF
10%
25V
R117
1
1%
1W
Motor Drivers 9-12
A
VL1000 CONTROLLER
REVISION
DRAWING NUMBER
F
14-9663-1930
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
SHEET
7
A
OF 10
ViewDraw for Windows 7.5
1
188
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 8 of 10
8
7
6
5
4
2
3
1
+24V
+24V
VCC
VCC
D
SHUTTER FRAME 1A
C122
0.1UF
10%
25V
VCC
M13
R170
24K
5%
1/16W
3/C4
R174
7.50K
3/C4
20
PWM_PH_25
23
12
VCC
PHASE1
VMM1
11
8
GND1
3/C4
5
27
7
VR2
C125
.022UF
10%
25V
PHASE2
VR2
26
10
3/B7
6
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
16
9
R197
7.50K
1/16W
1%
C144
.01UF
10%
25V
C
R194
2.67K
1%
1/16W
C143
.022UF
10%
25V
15
14
E1
C119
470PF
10%
25V
C2
10
26
6
C138
2700PF
10%
25V
R172
10K
R135
1
1%
1W
R188
10K
R140
1
1%
1W
C123
470PF
10%
25V
10/B3
17
GND9
19
R169
10K
M15OUT30B
GND10
GND2
13
C120
2700PF
10%
25V
7
28
RC
PWM_OUT_30
1/16W
1%
10/B5
MB2
22
3
R202
7.50K
14
GND6
E2
C2
M15OUT30A
10/B3
DIS2
27
15
E1
10/B5
5
MA2
2
GND7
GND5
C1
M15OUT29B
24
GND8
GND4
M15OUT29A
8
PBL3773QN
25
PWM_PH_30
16
19
C126
.01UF
10%
25V
3/C7
R187
2.67K
1%
1/16W
17
13
11
MB1
GND1
C136
.022UF
10%
25V
GND9
9
R173
2.67K
1%
1/16W
10/B3
GND10
GND3
1/16W
1%
4
VMM2
MA1
U23
1
1/16W
1%
C139
.01UF
10%
25V
28
RC
PWM_OUT_26
M13OUT26B
MB2
22
3
R175
7.50K
VR1
1/16W
1%
10/B5
12
VMM1
DIS1
18
DIS2
GND2
1/16W
1%
M13OUT26A
MA2
23
VCC
PHASE1
21
PWM_OUT_29
PBL3773QN
PHASE2
20
PWM_PH_29
R192
7.50K
24
R168
2.67K
1%
1/16W
R180
7.50K
10/B5
3/C7
25
PWM_PH_26
R196
7.50K
U21
1
C118
.022UF
10%
25V
M13OUT25B
MB1
2
3/C4
10/B3
3/C7
18
C121
.01UF
10%
25V
M13OUT25A
DIS1
VR1
D
C106
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
21
PWM_OUT_25
1/16W
1%
C140
0.1UF
10%
25V
VCC
M15
R189
24K
5%
1/16W
R171
7.50K
1/16W
1%
SHUTTER FRAME 2A
C88
10UF
50V
20%
+24V
VCC
R193
10K
R157
1
1%
1W
C137
470PF
10%
25V
C
R162
1
1%
1W
C141
470PF
10%
25V
+24V
+24V
VCC
VCC
SHUTTER FRAME 1B
C131
0.1UF
10%
25V
VCC
M14
R178
24K
5%
1/16W
3/D4
R185
7.50K
3/D4
+24V
VCC
20
PWM_PH_27
23
12
VCC
PHASE1
VMM1
11
8
MB1
3/D4
5
MA2
R176
2.67K
1%
1/16W
27
7
VR2
MB2
22
GND9
GND3
GND8
GND4
GND7
GND5
C1
E1
19
C134
.022UF
10%
25V
R183
2.67K
1%
1/16W
PHASE2
10
26
3/C7
VR2
RC
GND10
17
GND2
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
1/16W
1%
C152
.022UF
10%
25V
R205
2.67K
1%
1/16W
C132
470PF
10%
25V
15
14
E1
C2
10
26
6
C147
2700PF
10%
25V
R199
10K
R151
1
1%
1W
B
16
13
PWM_OUT_32
R182
10K
C128
470PF
10%
25V
10/B3
28
19
R146
1
1%
1W
M16OUT32B
MB2
22
9
C153
.01UF
10%
25V
R177
10K
10/B5
7
DIS2
27
R208
7.50K
1/16W
1%
6
C129
2700PF
10%
25V
M16OUT32A
24
R198
2.67K
1%
1/16W
3
GND6
E2
C2
10/B5
5
MA2
2
14
10/B3
M16OUT31B
PBL3773QN
25
PWM_PH_32
15
13
1/16W
1%
3/B7
16
R210
7.50K
M16OUT31A
8
U24
GND1
C145
.022UF
10%
25V
17
GND2
9
11
MB1
1
1/16W
1%
C148
.01UF
10%
25V
10/B3
GND10
3
PWM_OUT_28
M14OUT28B
28
RC
4
VMM2
MA1
DIS1
VR1
1/16W
1%
10/B5
12
VMM1
18
DIS2
2
C135
.01UF
10%
25V
M14OUT28A
23
VCC
PHASE1
21
PWM_OUT_31
PBL3773QN
PHASE2
20
PWM_PH_31
R203
7.50K
24
R186
7.50K
1/16W
1%
10/B5
3/C4
25
PWM_PH_28
M14OUT27B
R207
7.50K
U22
GND1
C127
.022UF
10%
25V
B
3/D4
10/B3
3/B7
VR1
R191
7.50K
M14OUT27A
DIS1
1
C115
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
18
1/16W
1%
M16
21
PWM_OUT_27
C130
.01UF
10%
25V
C149
0.1UF
10%
25V
VCC
R200
24K
5%
1/16W
R181
7.50K
1/16W
1%
SHUTTER FRAME 2B
C97
10UF
50V
20%
C146
470PF
10%
25V
R204
10K
R165
1
1%
1W
C150
470PF
10%
25V
R167
1
1%
1W
Motor Drivers 13-16
A
VL1000 CONTROLLER
REVISION
DRAWING NUMBER
F
14-9663-1930
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
SHEET
8
A
OF 10
ViewDraw for Windows 7.5
1
189
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 9 of 10
8
7
6
5
4
2
3
+24V
+24V
VCC
D
SHUTTER FRAME 3A
M17
R214
24K
5%
1/16W
3/B7
R216
7.50K
3/B7
VCC
C159
0.1UF
10%
25V
VCC
20
PWM_PH_33
23
12
VCC
PHASE1
VMM1
11
C158
.01UF
10%
25V
8
MB1
GND1
3/B7
5
PHASE2
10/A5
M17OUT34A
10/A5
M17OUT34B
10/A3
3/B7
MA2
7
VR2
MB2
22
1/16W
1%
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
1/16W
1%
E1
C2
10
26
PHASE2
VR2
M19OUT38B
10/A3
28
GND10
17
GND2
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
16
9
15
13
1/16W
1%
14
E1
19
R236
2.67K
1%
1/16W
C177
.022UF
10%
25V
C2
10
26
6
C173
2700PF
10%
25V
R231
10K
R184
1
1%
1W
C160
470PF
10%
25V
7
MB2
RC
R217
10K
C155
470PF
10%
25V
10/A5
DIS2
22
R238
7.50K
C178
.01UF
10%
25V
R179
1
1%
1W
M19OUT38A
MA2
27
6
R213
10K
10/A5
5
R235
10K
R201
1
1%
1W
C172
470PF
10%
25V
+24V
VCC
3/B7
3/B7
20
PWM_PH_35
23
12
VCC
PHASE1
VMM1
11
1/16W
1%
C166
.01UF
10%
25V
8
MB1
GND1
3/B7
5
PHASE2
MA2
M18OUT36A
10/B5
M18OUT36B
10/B3
3/B7
7
VR2
MB2
22
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
13
VR1
1/16W
1%
1/16W
1%
E1
19
R227
2.67K
1%
1/16W
C2
10
26
M20OUT40A
10/A5
7
M20OUT40B
10/A3
DIS2
VR2
MB2
22
28
RC
3
9
R247
7.50K
GND10
17
GND2
GND9
GND3
GND8
GND4
GND7
GND5
C1
GND6
E2
1/16W
1%
15
14
E1
19
C185
.022UF
10%
25V
R245
2.67K
1%
1/16W
C2
10
26
6
C181
2700PF
10%
25V
R240
10K
R195
1
1%
1W
B
16
13
PWM_OUT_40
6
C168
470PF
10%
25V
10/A5
5
MA2
27
R226
10K
R190
1
1%
1W
10/A3
M20OUT39B
24
2
C165
2700PF
10%
25V
C164
470PF
10%
25V
PHASE2
15
1/16W
1%
M20OUT39A
8
PBL3773QN
25
PWM_PH_40
R239
2.67K
1%
1/16W
C186
.01UF
10%
25V
R222
10K
3/C7
16
R246
7.50K
11
U28
GND1
C179
.022UF
10%
25V
17
3/B4
4
VMM2
MA1
MB1
1
1/16W
1%
C182
.01UF
10%
25V
14
12
VMM1
DIS1
GND10
GND2
23
VCC
PHASE1
21
18
28
RC
PWM_OUT_36
20
PWM_PH_39
PWM_OUT_39
DIS2
27
9
C169
.022UF
10%
25V
10/B5
24
R221
2.67K
1%
1/16W
R229
7.50K
C170
.01UF
10%
25V
M18OUT35B
PBL3773QN
25
PWM_PH_36
3
1/16W
1%
3/B7
R242
7.50K
U26
1
C163
.022UF
10%
25V
2
3/B7
10/B3
DIS1
B
R228
7.50K
M18OUT35A
C151
10UF
50V
20%
+24V
VCC
R241
24K
5%
1/16W
R243
7.50K
VR1
VCC
4
VMM2
MA1
18
PWM_OUT_35
C183
0.1UF
10%
25V
M20
21
R224
7.50K
1/16W
1%
SHUTTER FRAME 4B
C133
10UF
50V
20%
+24V
VCC
R223
24K
5%
1/16W
R225
7.50K
VCC
C167
0.1UF
10%
25V
M18
C
R206
1
1%
1W
C176
470PF
10%
25V
+24V
VCC
SHUTTER FRAME 3B
10/A3
24
R230
2.67K
1%
1/16W
PWM_OUT_38
1/16W
1%
M19OUT37B
PBL3773QN
25
PWM_PH_38
3
R237
7.50K
3/B7
C156
2700PF
10%
25V
C
3/B7
2
14
19
R218
2.67K
1%
1/16W
C161
.022UF
10%
25V
C174
.01UF
10%
25V
15
13
M19OUT37A
8
U27
GND1
C171
.022UF
10%
25V
16
9
11
MB1
1
1/16W
1%
17
GND9
4
VMM2
MA1
DIS1
GND10
GND2
12
VMM1
VR1
28
RC
23
VCC
PHASE1
21
18
DIS2
27
R220
7.50K
20
PWM_PH_37
PWM_OUT_37
24
R212
2.67K
1%
1/16W
C162
.01UF
10%
25V
M17OUT33B
PBL3773QN
25
PWM_PH_34
PWM_OUT_34
1/16W
1%
3/B7
R233
7.50K
U25
1
C154
.022UF
10%
25V
3
R219
7.50K
10/A3
DIS1
2
3/B7
M17OUT33A
D
C142
10UF
50V
20%
+24V
VCC
4
VMM2
MA1
18
1/16W
1%
R232
24K
5%
1/16W
R234
7.50K
VR1
C175
0.1UF
10%
25V
VCC
M19
21
PWM_OUT_33
1/16W
1%
SHUTTER FRAME 4A
C124
10UF
50V
20%
+24V
VCC
R215
7.50K
1
C180
470PF
10%
25V
R244
10K
R209
1
1%
1W
C184
470PF
10%
25V
R211
1
1%
1W
Motor Drivers 17-20
A
VL1000 CONTROLLER
REVISION
DRAWING NUMBER
F
14-9663-1930
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
SHEET
9
A
OF 10
ViewDraw for Windows 7.5
1
190
VARI❋LITE® - VL1000™ ERS LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Controller PCB (24.9663.1930 F) Schematic - Sheet 10 of 10
8
7
6
5
4
2
3
1
D
D
MTG8
MTG HOLE
MTG1
MTG HOLE
1
1
2
2
3
3
4
4
5
5
6
6
+24V
D19
M1OUT1A
5/D5,10/D3
M1OUT1B
5/D5,10/D5
SS14
D18
VCC
SS14
PAN
D17
M1OUT2A
1
2
M2OUT4B
5/B5,10/C6
5/B5,10/C6
M2OUT3B
3
4
M2OUT3A
5/B5,10/D6
5/D5,10/D6
M1OUT2A
5
6
M1OUT2B
5/D5,10/D6
5/D5,10/D6
M1OUT1B
7
8
M1OUT1A
5/D5,10/D6
5/D5,10/D5
D20
M1OUT2B
MTG9
MTG HOLE
5/D5,10/D3
SS14
D22
M2OUT3A
1
1
2
9
10
4/B3
ENCODER_B1
11
12
ENCODER_B2
4/B3
ENCODER_A1
13
14
ENCODER_A2
4/B3
15
16
17
18
TILT_COT_SENS
4/B3
19
20
5/B5,10/D3
SS14
2
J3
644488-4
M2OUT4A
SS14
MTG2
MTG HOLE
VCC
J4
103166-8
5/B5,10/C6
1
TILT
4/B1
LAMP_CNTL_OUT
4/B1
LAMP_ON_IN-
BALLAST CONTROL
3
4
4/B3
D23
3
3
4
M2OUT3B
5/B5,10/D5
5
M2OUT4A
5/B5,10/D5
PAN_COT_SENS
4/B3
SS14
4
J2
644488-5
TILT
D24
5
6
6
1
SS14
D21
M2OUT4B
4/C1
COMIN+
2
4/C1
COMIN-
3
4/C1
COMOUT+
4
4/C1
COMOUT-
5
5/B5,10/D3
SS14
MTG10
MTG HOLE
D26
MTG3
MTG HOLE
1
1
2
2
3
3
4
4
+24V
M3OUT5A
5/D2,10/C3
M3OUT5B
5/D2,10/C5
5/B2,10/C6
5
5
6
6
5/B2,10/C6
SS14
5/D2,10/C6
GOBO INDEX
D28
M3OUT6A
5/D2,10/C6
5/D2,10/C5
6/B5
SS14
6/B5
D25
M3OUT6B
5/D2,10/C3
6/D5
6/D5
SS14
D30
M4OUT7A
MTG11
MTG HOLE
6/B2
5/B2,10/C3
6/B2
MTG4
MTG HOLE
SS14
6/D2
D31
1
1
2
2
3
3
4
4
5
5
6
6
M4OUT7B
5/B2,10/C5
6/D2
SS14
7/B5,10/B6
GOBO ROTATE
D32
M4OUT8A
7/B5,10/B6
5/B2,10/C5
7/D5,10/B6
SS14
7/D5,10/B6
D29
M4OUT8B
5/B2,10/C3
7/B2,10/A6
7/B2,10/A6
SS14
D46
M9OUT17A
1
1
2
2
3
3
4
4
5
5
6
6
D47
M9OUT17B
7/D5,10/B5
SS14
1
3
M3OUT6A
5
M3OUT5B
7
M6OUT12A
9
10
M6OUT11B
M4OUT8B
4
5/B2,10/C6
M4OUT7A
M3OUT6B
8
5/D2,10/C6
M3OUT5A
M6OUT12B
11
12
M6OUT11A
M5OUT10A
13
14
M5OUT10B
15
16
M5OUT9A
M8OUT16A
17
18
M8OUT16B
M8OUT15B
19
20
M8OUT15A
6/B5
COLOR AMBER
1
+24V
2
VCC
COLOR BLUE
3
6/D5
POWER IN
4
6/B2
DIFFUSION
5
6/B2
M7OUT14A
21
22
23
24
M7OUT13A
6/D2
25
26
M10OUT20B
7/B5,10/B6
M10OUT19B
27
28
M10OUT19A
M9OUT18A
29
30
M9OUT18B
M9OUT17B
31
32
M9OUT17A
M12OUT24A
33
34
M12OUT24B
M12OUT23B
35
36
M12OUT23A
6/D2
COLOR MAGENTA
EDGE
7/B5,10/B6
7/D5,10/B6
ZOOM
7/D5,10/B6
7/B2,10/A6
BEAM IRIS/SHUTTER ROTATE
7/B2,10/A6
37
38
M11OUT22B
39
40
M11OUT21A
4/B3
GOBO_IDX_SENS
41
42
GOBO_POS_SENS
4/B3
4/A3
GOBO_IDX_LED
43
44
GOBO_POS_LED
4/A3
45
46
47
48
49
50
ZOOM
J1
640389-5
6/B5
6/D5
M10OUT20A
7/D5,10/C5
C
1
GOBO INDEX
5/D2,10/C6
M7OUT13B
M7OUT14B
GOBO ROTATE
5/B2,10/C6
6
M5OUT9B
D48
M9OUT18A
2
M11OUT22A
SS14
MTG5
MTG HOLE
M4OUT8A
M4OUT7B
M11OUT21B
7/D2,10/B6
7/D5,10/B3
7/D2,10/B6
MTG12
MTG HOLE
DMX IN
J5
2-103166-3
SS14
D27
C
2
PAN
7/D2,10/A6
DIMMER
7/D2,10/B6
MOTOR SUMMARY
M1
PAN
M2
TILT
M3
GOBO INDEX
M4
GOBO ROTATE
M5
COLOR BLUE
M6
COLOR AMBER
M7
COLOR MAGENTA
M8
DIFFUSION
M9
ZOOM
M10
EDGE
M11
DIMMER
M12
BEAM IRIS/SHUTTER ROTATE
M13
SHUTTER FRAME 1A
M14
SHUTTER FRAME 1B
M15
SHUTTER FRAME 2A
M16
SHUTTER FRAME 2B
M17
SHUTTER FRAME 3A
M18
SHUTTER FRAME 3B
M19
SHUTTER FRAME 4A
M20
SHUTTER FRAME 4B
SS14
D45
M9OUT18B
7/D5,10/C3
SS14
D42
B
M10OUT19A
7/B5,10/C3
SS14
B
D43
MTG13
MTG HOLE
M10OUT19B
MTG6
MTG HOLE
1
1
2
2
3
3
7/B5,10/C5
J6
1-103166-8
SS14
EDGE
D44
M10OUT20A
4
5
5
6
6
M14OUT28A
1
8/B5
M14OUT27B
3
8/D5
M13OUT26A
5
8/D5
M13OUT25B
7
8/B2
M16OUT32A
9
10
M16OUT32B
8/B2
M16OUT31B
11
12
M16OUT31A
8/D2
M15OUT30A
13
14
M15OUT30B
8/D2
M15OUT29B
15
16
M15OUT29A
9/B5
M18OUT36A
17
18
M18OUT36B
9/B5
M18OUT35B
19
20
M18OUT35A
9/B5
9/D5
M17OUT34A
21
22
M17OUT34B
9/D5
9/D5
M17OUT33B
23
24
M17OUT33A
9/D5
9/B2
M20OUT40A
25
26
M20OUT40B
9/B2
28
8/B5
7/B5,10/C5
SS14
D41
4
M10OUT20B
7/B5,10/C3
SS14
D38
M11OUT21A
7/D2,10/B3
SS14
D39
M11OUT21B
7/D2,10/B5
SS14
MTG7
MTG HOLE
DIMMER
D40
M11OUT22A
1
7/D2,10/B5
SS14
2
D37
M11OUT22B
3
7/D2,10/B3
SS14
4
D34
5
M12OUT23A
6
+24V
7/B2,10/B3
SS14
2
M14OUT28B
4
M14OUT27A
6
M13OUT26B
8
M13OUT25A
8/B5
SHUTTER FRAME 1B
8/B5
8/D5
SHUTTER FRAME 1A
8/D5
8/B2
SHUTTER FRAME 2B
8/B2
8/D2
SHUTTER FRAME 2A
8/D2
9/B5
9/B2
M20OUT39B
27
M20OUT39A
9/B2
9/D2
M19OUT38A
29
30
M19OUT38B
9/D2
9/D2
M19OUT37B
31
32
M19OUT37A
9/D2
33
34
35
36
37
38
39
40
SHUTTER FRAME 3B
SHUTTER FRAME 3A
SHUTTER FRAME 4B
SHUTTER FRAME 4A
D35
M12OUT23B
7/B2,10/B5
BEAM IRIS
SS14
OR
D36
M12OUT24A
7/B2,10/B5
M12OUT24B
7/B2,10/B3
SHUTTER ROTATE
I/O Connectors
SS14
D33
A
VL1000 CONTROLLER
SS14
REVISION
DRAWING NUMBER
F
14-9663-1930
SIZE
Filename:
Date/Time:
8
02.9 663.00 10 D
7
6
5
23-Oct-02
4
3
24-9663-1930
3-5-2002_7:31
2
D
SHEET 10
A
OF 10
ViewDraw for Windows 7.5
1
191