Philips Vari-Lite VL770 Service Manual Download

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VARI

❋

LITE - VL440 / VL770 / VL880 S

POT

UMINAIRES

ERVICE

ANUAL

2 0

0 2 . 9 6 8 7 . 0 0 1 0 0

Rear Cover Assembly Removal

WARNING:

Ensure that power is completely removed (disconnected) from luminaire before

attempting any work.

To remove rear cover assembly:

Step

1. Remove power from luminaire and allow unit to completely cool.

Step

2. As illustrated in

Figure 2-1

, remove rear head cover by loosening two quarter-turn Dzus

fasteners.

Note:

The rear cover is secured by a safety tether.

Figure 2-2: VL440 / VL770 / VL880 Rear Head Cover Removal

Step

3. Unclip safety tether at cover.

Step

4. Reinstall by performing steps in reverse order.

CAUTION:

Remove power and
allow fixture to cool.

Quart-Turn Dzus
Fasteners (x2)

Rear Head Cover

Summary of Contents for Vari-Lite VL770

Page 1: ......

Page 2: ...nal use only and is subject to change without notice Please check www vari lite com for latest version Philips Vari Lite assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual All information and graphics are property of Philips Vari Lite 10911 Petal Street Dallas Texas 75238 Version as of 19 December 2011 Part number 02 9687 0010 0 VL440 VL770 VL880 S...

Page 3: ...stered user or organization If available you should have your sales invoice to establish the date of sale as the beginning of the warranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form obtained from the Vari Lite web site www vari lite com or through customer service and place in shipping container along with a copy...

Page 4: ...unications 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 2008 Luminaire Saf...

Page 5: ...with specific light sources The VL440 VL770 VL880 Spot Luminaires uses a special type of light source Installing another type of light source will be hazardous and void the luminaire warranty 2 Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detail in this manual 3 Note distance requirement from combustible materials or illuminated ob...

Page 6: ...luminaire will be hot during operation Use appropriate safety equipment gloves eye protection etc when handling and adjusting hot equipment and components 2 Luminaires will have a hot lamp when operating Disconnect power and allow lamp to cool before replacing 3 Wear eye protection when relamping 4 Appropriate safety equipment gloves eye protection should be used when handling damaged lamps 5 If l...

Page 7: ...minaires Beleuchtung benutzt eine spezielle Art Lichtquelle Eine andere Art Lichtquelle anzubringen ist gefährlich und hebt die Beleuchtunggarantie auf 2 Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der VARI LIT...

Page 8: ...ignete Sicherheitsausrüstung Handschuhe Augenschutz etc 2 Bei Betrieb der Scheinwerfer ist die Lampe heiß Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abkühlen wenn Sie diese austauschen 3 Tragen Sie beim Austausch der Lampen einen Augenschutz 4 Die geeignete Sicherheitsausrüstung Handschuhe Augenschutz sollte beim Umgang mit beschädigten Lampen verwendet werden 5 Wenn die Lampe mit b...

Page 9: ...ineuses spécifiques L appareil d éclairage de VL440 VL770 VL880 Spot Luminaires emploie un type spécial de source lumineuse de L installation d un autre type de source lumineuse sera dangereuse et videra la garantie d appareil d éclairage 2 Les luminaires peuvent être fixés sur tout type de surface tant que les directives de montage sont respectées Voir les explications détaillées dans ce guide 3 ...

Page 10: ...e 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 cau...

Page 11: ... específicas El alumbrado de VL440 VL770 VL880 Spot Luminaires utiliza un tipo especial de fuente de luz del La instalación de otro tipo de fuente de luz será peligrosa y anulará la garantía del alumbrado 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalación Vea las instrucciones detalladas en este manual 3 Tome nota de los requer...

Page 12: ...s luminarias están calientes durante su operación Use un equipo de seguridad apropiado guantes protección para los ojos etc cuando haga ajustes en el equipo y componentes que están calientes 2 Cuando las luminarias están en operación la lámpara estará muy caliente Desconecte la energía y deje que la lámpara se enfríe antes de reemplazarla 3 Use un equipo de seguridad apropiado guantes protección p...

Page 13: ...FOREWORD 02 9687 0010 0 xi ...

Page 14: ...VARI LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL xii 02 9687 0010 0 ...

Page 15: ...losure Components 10 Principles of Operation VL440 VL770 VL880 Spot Luminaires Functional Block Diagram 11 Chapter 2 Maintenance Testing Luminaire Self Tests 14 Calibration Sequence 14 Sensor Testing 14 Troubleshooting Error Messages 15 Troubleshooting Guide 16 Special Care and Handling Introduction 17 Special Cleaning and Care Instructions 17 General Care and Equipment Handling 17 Locations Use 1...

Page 16: ... Replacement 54 Rotating Gobo Wheel Replacement 55 Fixed Gobo Wheel Replacement 57 Iris Assembly Replacement 59 Ballast LVS Assembly Replacement 60 DMX PCB Assembly Replacement 61 PowerCon AC Input Assembly Replacement 63 Display PCB Assembly Replacement 65 Wireless DMX Interface PCB Assembly Replacement 67 Pan Motor Assembly Replacement 69 Pan Belt Replacement 71 Pan Stabilizer Replacement 73 Enc...

Page 17: ...136 Rear Carrier Assembly 137 Enclosure Assembly Upper Enclosure Assembly 139 Pan Motor Assembly 144 Note Cables are only available as complete assemblies The information contained in this section is for reference only Cable Assemblies Chassis To Yoke Ground Cable Assembly 147 AC Input Cable Assembly 148 DMX Display Comm Cable Assembly 149 Ballast Comm Cable Assembly 150 36 Volt Supply Cable Assem...

Page 18: ...er 2011 02 9687 0010 0 800 Watt Ballast Comm Cable Assembly 165 Sensor Index Cable Assembly 166 APS Fan Cable Assembly 167 AUX Comm Interface Cable Assembly 168 Appendix A Technical Bulletins and Notices VL440 VL770 VL880 Spot Luminaires Technical Bulletins and Notices 169 ...

Page 19: ...mplete installation and operation instructions refer to the VL440 VL770 VL880 Spot Luminaires User s Manual This manual is available in electronic PDF format on the Vari Lite web site at www vari lite com in the Support Product Downloads section VL440 VL770 VL880 Spot Luminaires User s Manual 02 9687 0001 For more information regarding DMX512 systems refer to the DMX512 1990 AMX 192 Standards publ...

Page 20: ...d 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 approp...

Page 21: ...02 9687 0010 0 3 SERVICE CHAPTER 1 Description This chapter contains descriptions of luminaire features and components Features Components Principles of Operation ...

Page 22: ...erns and one open position capable of continuous rotation for additional effects 17 total gobos positions VL440 Spot accepts both metal and glass gobos VL770 VL880 Spot accept glass gobos ONLY Frost and Prism Capability Independent drop in armature with frost glass Second independent drop in armature with rotating and indexable four facet prism Both the frost and prism pieces are interchangeable P...

Page 23: ...ibution from 100 240VAC 50 60 Hz The unit requires up to 6 6A at 100V depending on the AC supply voltage VL770 Spot Standard AC power distribution from 100 240VAC 50 60 Hz The unit requires up to 10 2A at 100V depending on the AC supply voltage VL880 Spot Standard AC power distribution from 100 240VAC 50 60 Hz The unit requires up to 12 0A at 100V depending on the AC supply voltage Note For a brea...

Page 24: ...Channels 30 channels Mounting Position The luminaire can be mounted and operated in any orientation Technical Specifications For additional technical specifications refer to VL440 VL770 VL880 Spot Luminaires User s Manual 02 9687 0001 or the Vari Lite web site at www vari lite com ...

Page 25: ...obo assembly lamp and cooling fans tilt motor and Menu LCD Display Used to input manual commands program test set defaults and access internal status information see detail below AC Input Data In Data Thru Upper Enclosure Components Input Panel Menu LCD Display Panel ENTER ESC POWER RX TX ERROR Enter Button To Select or Change a Setting or Data Value Arrow Keys Left Right Up Down To Menu Navigate ...

Page 26: ...rs One on each end of enclosure Luminaire Rear Head Cover assembly two with handles Enclosure Assembly See VL440 VL770 VL880 Spot Luminaires Enclosure Components on page 10 Head Assembly See VL440 VL770 VL880 Spot Luminaires Head Components on page 9 Yoke Arm Covers Two covers one on each side of yoke assembly Luminaire Front Head Cover Ballast and Low Voltage Supply Assembly Supplies power for la...

Page 27: ...M color mixing wheels glass dimmer and strobe assembly CYM Color System Dimmer Zoom optics for beam control and focus Optics Main control unit and driver PCBs Main Control Board Fixed Gobo Fixed Color Rotating Gobo Assembly 10 fixed gobo positions 7 rotating gobo positions and 8 fixed color positions Note Enclosure assembly not shown for clarity Provides more air circulation and cooling capacity H...

Page 28: ...andard LCD Display Assembly For addressing accessing menu options and settings See page 7 for details Enclosure Cover Plate AC Input Requires standard AC power distribution from 100 240 VAC 50 60 Hz current depends on the AC supply voltage See user s manual for more information on current draw Note Other assemblies not shown for clarity Power supply not shown is part of the generic luminaire assem...

Page 29: ...ply Assembly AC Input Enclosure Fans Dual gobo blower assembly is in VL770 and VL880 Spot fixtures only Dual Gobo Blower Head Transfer Fans Lamp Ignitor Lamp Socket Prism Rotate Lamp Housing Fans 36V Ballast COM Edge Motor Sensor Iris Motor Rotating Gobo Sensor Fixed Gobo Sensor Gobo Index Rotating Sensor Fixed Color Rotating Sensor Right Strobe Prism Assembly Sensor Zoom Motor Sensor Frost Assemb...

Page 30: ...VARI LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 12 02 9687 0010 0 Notes ...

Page 31: ...are and Handling Maintenance Procedures WARNING All maintenance procedures are to be performed with power com pletely removed from the luminaire Never remove covers while unit is in oper ation WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized VARI LITE Service Center ...

Page 32: ...ke can move freely without restriction Sensor Testing Most mechanisms within the VL440 VL770 VL880 luminaire are equipped with either optical or magnetic sensors The VL440 VL770 VL880 master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan tilt encoder readings The valu...

Page 33: ... Status Press Enter Display will now scroll through any error messages or display OK if no errors WARNING As with any repairs or maintenance to VARI LITE luminaires service should only be performed by a trained and qualified service technician or at an Authorized VARI LITE Service Center Display Message OK No Errors Found Pan Encoder Fail Pan encoder failure Tilt No Sens Tilt sensor not found Tilt...

Page 34: ...n NOTE Upon initial power up ballast fans will run for a few seconds and then operate as needed Enclosure vents must be clear of debris and dirt to allow proper airflow n a Lamp will not strike Lamp Strike Failure Lamp cutout switch disengaged check lamp cutout switches at lamp box and fan ducts Bad lamp replace lamp Low input voltage check input power must be 100 to 240 VAC n a Luminaire behaves ...

Page 35: ...abs for hard to reach spot cleaning Lint or powder free gloves Reagent grade isopropyl alcohol A mild soap solution Reagent grade isopropyl alcohol is good to use on the VL440 VL770 VL880 Spot Luminaires optics with anti reflection coatings If the lens is still dirty after using isopropyl alcohol for instance if fingerprints or oil is just redistributed and not cleaned off the optic then a mild so...

Page 36: ...ling or moving ESD rarely results in immediate failure of a component but shows up later as an intermittent problem or severely reduces the life of the component All VARI LITE products use solid state electronics and appropriate precautions to protect them should be observed when servicing Printed Circuit Boards PCBs All PC boards should be shipped in electrostatic shielding bags When handling PC ...

Page 37: ...tep 1 Remove power from luminaire and allow unit to completely cool Step 2 As illustrated in Figure 2 1 remove front head cover by loosening two quarter turn Dzus fasteners Note The front cover is secured by a safety tether Figure 2 1 VL440 VL770 VL880 Front Head Cover Removal Step 3 Unclip safety tether at cover Step 4 Reinstall by performing steps in reverse order CAUTION Remove power and allow ...

Page 38: ...move power from luminaire and allow unit to completely cool Step 2 As illustrated in Figure 2 1 remove rear head cover by loosening two quarter turn Dzus fasteners Note The rear cover is secured by a safety tether Figure 2 2 VL440 VL770 VL880 Rear Head Cover Removal Step 3 Unclip safety tether at cover Step 4 Reinstall by performing steps in reverse order CAUTION Remove power and allow fixture to ...

Page 39: ...ss portion of lamp To remove and install lamp Step 1 Ensure power is completely removed from luminaire and luminaire has cooled completely Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire head in position Step 4 At back of luminaire using 2 Phillips screwdriver remove lamp socket cover by loosening the two quarter turn fasteners Note lamp socket cover ...

Page 40: ...rated in Figure 2 5 Figure 2 5 Installed Lamp Step 9 Reinstall lamp socket cover Make sure safety tether is completely encapsulated within lamp socket cover Step 10 Disengage service tilt lock to allow luminaire head to move freely Step 11 Align lamp as described in the luminaire s users manual Lamp Socket Cover Lamp Align tabs of lamp with socket when installing NOTE Bow of lamp must be oriented ...

Page 41: ...20 Step 3 At MCU disconnect lamp fans harness at J6 Step 4 At Driver Board disconnect Gobo Module and CYMD Module harness Step 5 For VL770 and VL880 luminaires only disconnect H1 H5 H6 fan connectors CAUTION In next step be extremely careful when removing gobo module assembly so you do not damage gobos or color filters Step 6 As shown in Figure 2 6 loosen two captive fasteners and carefully pull G...

Page 42: ...ssembly Removal on page 19 and Rear Cover Assembly Removal on page 20 Step 3 At MCU disconnect lamp fans harness at J6 Step 4 At Driver Board disconnect CYMD Harness CAUTION In next step be extremely careful when removing CYMD module assembly so you do not color filters or dimmer wheel Step 5 As illustrated in Figure 2 7 loosen two captive fasteners and carefully pull assembly from luminaire Figur...

Page 43: ...cover assemblies see Front Cover Assembly Removal on page 19 and Rear Cover Assembly Removal on page 20 Step 3 Remove Gobo Module Assembly as described in Gobo Module Assembly Removal on page 23 Step 4 At Driver Board disconnect Zoom Module Harness Cut any cable ties and pull harness free DO NOT cut any wires Step 5 As indicated in Figure 2 8 loosen captive screw and carefully tilt MCU Driver Boar...

Page 44: ...n in Figure 2 9 remove four 8 32 x 1 2 PPZ SEMS screws securing zoom assembly to head frame assembly Figure 2 9 Zoom Module Assembly Removal Step 7 Carefully remove zoom module assembly from fixture Step 8 Replace by performing steps in reverse order 8 32 x 1 2 PPZ MCU Driver Assembly Zoom Assembly SEMS Screw x4 ...

Page 45: ...over assembly as described in Front Cover Assembly Removal on page 19 Step 3 At MCU assembly disconnect the following cable assemblies a 36Vdc Connector J7 b DMX Connector J10 c Display Com Connector J11 d Ballast Com Connector J8 e Head Fans VL770 880 luminaires only Connector J5 f Wireless Accessory Connector J12 g Lamp Fans Connector J6 Step 4 Remove six 4 40 x 1 2 PPZ screws as indicated in Fi...

Page 46: ...uminaire and allow unit to completely cool Step 2 Remove front cover assembly as described in Front Cover Assembly Removal on page 19 Step 3 Remove MCU assembly as described in Main Control Unit MCU Assembly Removal on page 27 Step 4 At driver board assembly disconnect the following cable assemblies a Pan Motor Power make note of connector orientation Connector J9 b 36Vdc Connector J6 c Zoom Harne...

Page 47: ...tep 6 Remove Driver Board Assembly from luminaire Step 7 Replace by performing steps in reverse order CAUTION Remove power and allow fixture to cool Driver Board Assembly MCU Board Assembly MCU Board Assembly Driver Board Assembly 4 40 x 1 2 PPZ Screw x6 4 40 x 3 8 PPZ SEMS Screws NOTE Components removed for clarity ...

Page 48: ...s when handling glass To remove front lens assembly Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Remove front cover assembly as described in Front Cover Assembly Removal on page 19 Step 3 At front lens as indicated in Figure 2 12 remove four 6 32 x 1 4 PFB screws and remove lens from inside Figure 2 12 Front Lens Assembly Removal Step 4 Reinstall by performing steps ...

Page 49: ...mblies see Front Cover Assembly Removal on page 19 and Rear Cover Assembly Removal on page 20 Step 3 Remove Gobo Module Assembly as described in Gobo Module Assembly Removal on page 23 Step 4 Remove CYMD Module Assembly as described in CYMD Module Assembly Removal on page 24 Step 5 As shown in Figure 2 13 at UV IR Filter Assembly remove four 8 32 x 3 4 PFB screws and remove UV IR Filter Assembly N...

Page 50: ... and Rear Cover Assembly Removal on page 20 Step 3 Remove Gobo Module Assembly as described in Gobo Module Assembly Removal on page 23 Step 4 Remove CYMD Module Assembly as described in CYMD Module Assembly Removal on page 24 Step 5 Remove Zoom Module Assembly as described in Zoom Module Assembly Removal on page 25 Step 6 Disconnect H3 fan and power from edge motor assembly Step 7 Remove four 4 40...

Page 51: ...2 Step 9 Reinstall by performing steps in reverse Note When reinstalling edge motor assembly the connector orientation should face in the downward position as shown in Figure 2 15 Figure 2 15 Edge Motor Assembly Connector Orientation Note position of edge motor connector ...

Page 52: ... Step 5 Remove Zoom Module Assembly as described in Zoom Module Assembly Removal on page 25 Step 6 Cut cable tie connecting wiring to bottom of motor assembly Step 7 Disconnect wiring from motor assembly and tilt encoder PCB Step 8 As shown in Figure 2 16 remove three 8 32 x 3 8 PPB SEMS screws Figure 2 16 Tilt Motor Assembly Removal Step 9 Carefully remove tilt belt from pulley and remove motor a...

Page 53: ...e following steps in reverse order To remove tilt belt Step 1 Remove tilt motor assembly following procedure in Tilt Motor Assembly Tilt Encoder Tilt Belt Removal on page 34 Step 2 Disconnect all wiring coming through tilt belt side tilt tube from inside head assembly Step 3 Cut any cable ties required Step 4 Carefully pull wiring through tilt belt Step 5 Remove tilt belt Step 6 Reassemble followi...

Page 54: ...wer from luminaire and allow unit to completely cool Step 2 As shown in Figure 2 17 remove both yoke covers by removing one 8 32 x 3 8 PPB SEMS screw per side Figure 2 17 Yoke Arm Cover Removal Step 3 Remove Yoke Filler by removing two 6 32 x 3 16 PPB screws and one 8 32 x 3 8 PPB SEMS screw mounting tilt stabilizer to yoke filler Figure 2 18 Yoke Filler Removal Yoke Arm Cover 8 32 x 3 8 PPB SEMS ...

Page 55: ...ndicated in Figure 2 19 Figure 2 19 Tilt Sensor Removal Step 5 Disconnect wiring at tilt sensor and remove tilt sensor Step 6 Reassemble following steps in reverse order NOTE Components removed and exploded for clarity 6 32 x 3 8 PFZ Screw x2 Right Tilt Bearing Assembly Tilt Sensor Assembly Tilt Sensor Bracket 4 40 x 1 4 PPB SEMS Screw x2 ...

Page 56: ...lt stabilizer Step 1 Remove power from luminaire and allow unit to completely cool Step 2 As shown in Figure 2 20 remove both yoke covers by removing one 8 32 x 3 8 PPB SEMS screw per side Figure 2 20 Yoke Arm Cover Removal Step 3 Remove Tilt Lock Assembly by removing two 6 32 x 3 16 PPB screws Figure 2 21 Tilt Lock Assembly Removal Yoke Arm Cover 8 32 x 3 8 PPB SEMS Screw One per side 6 32 x 3 16...

Page 57: ...ing each tilt bearing to yoke Step 6 Cut any cable ties to give enough wiring slack to lift head from yoke Step 7 At Right Tilt Bearing Assembly disconnect extension spring from stabilizer and pass stabilizer around wiring and tilt bearing Figure 2 23 Tilt Stabilizer Step 8 Reassemble following steps in reverse order 6 32 x 3 16 PPB Screw x2 Yoke Filler NOTE Components removed and exploded for cla...

Page 58: ...nit to completely cool Step 2 As shown in Figure 2 24 remove tilt lock side yoke arm cover by removing one 8 32 x 3 8 PPB SEMS screw Figure 2 24 Tilt Lock Side Yoke Arm Cover Removal Step 3 Disconnect wiring from ignitor Step 4 As shown in Figure 2 25 remove ignitor as follows a Remove one 4 40 x 1 3 8 PPZ screw with 4 flat washer b Remove one 4 40 x 1 3 8 PPZ screw with 4 flat washer AND one 4 KE...

Page 59: ...MAINTENANCE PROCEDURES IGNITOR REMOVAL 02 9687 0010 0 41 2 Figure 2 25 Ignitor Removal Step 5 Reassemble by performing steps in reverse 4 40 x 1 3 8 PPZ Screw x2 4 Flat Washer x2 Ignitor 4 KEPS Nut x1 ...

Page 60: ...r assemblies see Front Cover Assembly Removal on page 19 and Rear Cover Assembly Removal on page 20 Step 3 Remove Gobo Module Assembly as described in Gobo Module Assembly Removal on page 23 Step 4 Remove CYMD Module Assembly as described in CYMD Module Assembly Removal on page 24 Step 5 As shown in Figure 2 26 remove tilt lock side yoke cover by removing one 8 32 x 3 8 PPB SEMS screw Figure 2 26 ...

Page 61: ...washer and detach lamp cover tether from fixture Step 9 As shown in Figure 2 28 on page 44 at each side a Remove two 8 32 x 5 8 PPZ SEMS screw 1 per side at counter weight plate closest to rear of assembly b Note the counter weight plates will stay attached by 2 screws closest to inside of fixture Step 10 Remove two 6 32 x 3 8 PPZ SEMS screws from rear of assembly closest to L1 L2 fans Lamp Socket...

Page 62: ...s and flat washers with spring and spacer CAUTION Note orientation of lamp socket before removing lamp socket from fixture Replacement socket must be installed in the same orientation Step 17 Remove two 8 32 x 7 8 PPZ SEMS screws mounting socket Step 18 Remove lamp socket Step 19 Reassemble by following steps in reverse order Note Refer to Lamp Removal and Installation on page 21 for lamp installa...

Page 63: ... 20 Step 3 Loosen two quarter turn Dzus rapier fasteners from lamp house cover and remove lamp Figure 2 29 Lamp Socket Cover Removal Step 4 Remove one 6 32 x 3 8 PPZ SEMS screw and flat washer and detach lamp cover tether from fixture Step 5 As shown in Figure 2 28 on page 44 at each side a Remove two 8 32 x 5 8 PPZ SEMS screw 1 per side at counter weight plate closest to rear of assembly b Note t...

Page 64: ...ector remove four 8 KEPS nuts and remove both reflector retainer clips Step 10 Remove reflector Step 11 Reassemble by following steps in reverse order Note Refer to Lamp Removal and Installation on page 21 for lamp installation information 8 32 x 3 8 PPB SEMS Screw x4 NOTE Components removed and exploded for clarity Counter Weights Remove this screw only Counter Weights Remove this screw only Refl...

Page 65: ... assembly Step 1 Remove CYMD assembly from luminaire by following procedure described in CYMD Module Assembly Removal on page 24 Step 2 At yellow wheel remove two 0 80 x 3 16 PFSS Screws holding yellow wheel to shaft and remove wheel Step 3 At cyan wheel remove two 0 80 x 3 16 PFSS Screws holding cyan wheel to shaft and remove wheel Step 4 Carefully remove magenta wheel from shaft Step 5 Carefully...

Page 66: ... align with gate To install magenta wheel Step 1 Install dimmer wheel first by following previous procedure in this section Step 2 Carefully slide magenta wheel assembly on to shaft closest to where wiring harness is attached Step 3 Align the timing mark on the magenta wheel with the timing mark on the drive pulley hub on motor shaft as shown in Figure 2 32 Note When optical sensor tab on drive pu...

Page 67: ...o Install Yellow Wheel Step 1 Install dimmer magenta and cyan wheels by following previous procedures in this section Step 2 Ensure that sensor tab on drive pulley of motor is in sensor slot Step 3 Align wheel to shaft screws so that open spot of wheel is in gate WARNING It is very important not to over tighten screws in the next step Step 4 Install two 0 80 x 3 16 PFSS screws Note When installing...

Page 68: ...dule Assembly Removal on page 24 Step 2 Remove all glass wheels from CYMD assembly as described in CYMD Wheel Replacement on page 47 Step 3 Remove one 4 40 x 1 4 PPB SEMS screw mounting color mix shaft to bearing Carefully remove shaft Step 4 Remove one 4 40 x 1 4 PFZ and three 4 40 x 1 4 PPB SEMS screws and remove strobe assembly from CYMD assembly Figure 2 34 Strobe Assemblies Removal Step 5 Rea...

Page 69: ... strobe assembly Note Screws in the next step have Loctite 242 and may require small amount of heat to loosen Step 4 Using 1 16 Allen Driver loosen cone set screw attaching Dimmer or Magenta Outdrive from motor shaft Figure 2 35 Dimmer Magenta Motor Assemblies Removal Step 5 Remove Outdrive Step 6 Remove two 4 40 x 1 4 PFZ screws and remove motor Step 7 When installing Outdrive place sensor tab in...

Page 70: ...s Loctite 242 and may require small amount of heat to loosen Step 2 Using 1 16 Allen driver loosen cone set screw attaching strobe assembly to motor shaft Step 3 Remove strobe blade assembly Step 4 To Install power motor to hold on whole step Step 5 Hold blade against stop in closed position and slide blade onto motor shaft Step 6 Set height per tolerance as shown in Figure 2 36 Figure 2 36 Strobe...

Page 71: ...cribed in CYMD Wheel Replacement on page 47 Step 3 Remove appropriate strobe assembly as described in Strobe Assembly Replacement on page 50 Refer to Figure 2 37 for motor location Figure 2 37 Cyan and Yellow Motor Assemblies Note Cone Set Screw has Loctite 242 and may require small amount of heat to loosen Step 4 Using 1 16 Allen driver loosen cone set screw attaching outdrive to motor shaft Step...

Page 72: ...amount of heat to loosen Step 2 Using 1 16 Allen driver loosen cone set screw attaching fixed color wheel to drive shaft Figure 2 38 Fixed Color Wheel Assembly Step 3 To install align drive rear motor homing plate so tab is in optical sensor Step 4 Apply Loctite 242 on Cone set screw Step 5 Center open spot of wheel to gate and tighten set screw to flat motor shaft Rotating Gobo Wheel Fixed Color ...

Page 73: ...inaire as described in Gobo Module Assembly Removal on page 23 Step 2 Remove the fixed color wheel assembly from gobo module assembly as described in Fixed Color Wheel Replacement on page 54 Note Cone Set Screw has Loctite 242 and may require small amount of heat to loosen Step 3 Using 1 16 Allen driver loosen cone set screw attaching rotating gobo wheel to drive shaft Figure 2 39 Rotating Gobo Wh...

Page 74: ... motor shaft CAUTION During reassembly the alignment of the rotating gobo wheel assembly alignment drive rear motor homing plate tab in the optical sensor is very critical for index to calibrate correctly IMPORTANT When replacing Rotating Gobo Motor ensure the rear homing plate is installed with the set screw to the flat part of motor shaft when tab is in sensor When replacing Index Motor ensure t...

Page 75: ...assembly as described in Fixed Color Wheel Replacement on page 54 Step 3 Remove the rotating gobo wheel assembly from gobo module assembly as described in Rotating Gobo Wheel Replacement on page 55 Step 4 Remove Rotate Gobo COAX assembly from shaft Note that the bearings in the assembly that may come loose Keep these bearings Step 5 Remove two 6 32 x 3 8 PPZ SEMS screws mounting stabilizer retaine...

Page 76: ...ations Step 8 When installing align fixed gobo outdrive so tab is in sensor Step 9 Align wheel so open spot is aligned with gate Step 10 Slide on to shaft Step 11 Continue reassembly by following steps in reverse order IMPORTANT When replacing Fixed Gobo Motor ensure the Fixed Gobo Outdrive is installed with set screw to flat part of motor shaft when tab is in optical sensor Fixed Gobo Wheel NOTE ...

Page 77: ...l assembly from gobo module assembly as described in Fixed Color Wheel Replacement on page 54 Step 3 Remove the rotating gobo wheel assembly from gobo module assembly as described in Rotating Gobo Wheel Replacement on page 55 Step 4 Remove the fixed gobo wheel assembly from gobo module assembly as described in Fixed Gobo Wheel Replacement on page 57 Step 5 Remove three 2 56 x 3 16 PFZ screws and r...

Page 78: ...8 PPB screws Figure 2 43 Ballast LVS Assembly Removal Step 3 Remove the inlet exhaust screen Step 4 Remove two 10 32 x 9 16 PFB screws in supply Step 5 Slide Ballast LVS assembly out of enclosure Note wiring is still attached to assembly Step 6 Disconnect wiring Step 7 Reassemble by performing steps in reverse order Connection Wire Color s AC Line Input Black White Green Yellow 36 VDC Output Orang...

Page 79: ...ep 2 Remove Ballast LVS assembly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 44 Enclosure Assembly Bottom Plate Removal Step 5 At DMX PCB a...

Page 80: ... 6 From front panel remove four 4 40 x 3 8 PFB screws and remove DMX PCB assembly Figure 2 45 DMX PCB Assembly Removal Step 7 Reassemble by performing steps in reverse order NOTE Components removed and exploded for clarity Enclosure Assembly 4 40 x 3 8 DMX PCB PFB Screw x4 Assembly ...

Page 81: ...nd luminaire has cooled completely Step 2 Remove Ballast LVS assembly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 46 Enclosure Assembly Bot...

Page 82: ...on AC Input Assembly Removal Step 6 Disconnect wiring from PowerCon AC Input assembly Step 7 At front panel remove two 4 40 x 3 8 PFB screws and nuts and remove PowerCon AC Input assembly Step 8 Reassemble by performing steps in reverse order NOTE Components removed and exploded for clarity Fan Assembly 6 32 x 1 4 PPZ SEMS Screw x2 4 40 x 3 8 PFB Screw x2 4 Nuts x2 PowerCon AC Input Assembly ...

Page 83: ...Step 2 Remove Ballast LVS assembly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 48 Enclosure Assembly Bottom Plate Removal Step 5 At Display...

Page 84: ...6 As shown in Figure 2 49 remove four 6 32 x 3 16 PPZ screws and remove Display PCB assembly Figure 2 49 Display PCB Assembly Removal Step 7 Reassemble by performing steps in reverse order NOTE Components removed and exploded for clarity Display PCB Assembly 6 32 x 3 16 PPZ Screw x4 ...

Page 85: ...led completely Step 2 Remove Ballast LVS assembly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 50 Enclosure Assembly Bottom Plate Removal St...

Page 86: ...ure 2 49 remove two 6 32 x 3 16 PPZ screws and remove wireless DMX interface PCB assembly Figure 2 51 Wireless DMX Interface PCB Assembly Removal Step 7 Reassemble by performing steps in reverse order NOTE Components removed and exploded for clarity Wireless DMX PCB Assembly 6 32 x 3 16 PPZ Screw x2 ...

Page 87: ... has cooled completely Step 2 Remove Ballast LVS assembly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 52 Enclosure Assembly Bottom Plate Re...

Page 88: ...ep 7 Remove four 8 32 x 1 4 PPB SEMS screws and their flat washers Figure 2 54 Pan Motor Assembly Removal Step 8 Remove pan motor assembly Step 9 Reassemble by performing steps in reverse order Note Ensure proper belt tension when replacing NOTE Components removed and exploded for clarity Fan Assembly 6 32 x 1 4 PPZ SEMS Screw x2 Fan Assembly 6 32 x 1 4 PPZ SEMS Screw x2 Pan Motor Assembly 8 32 x ...

Page 89: ... described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 55 Enclosure Assembly Bottom Plate Removal Step 5 Remove pan motor assembly as described in Pan M...

Page 90: ... inside enclosure Step 8 At pan pulley cover remove four 8 32 KEPS nuts and remove cover Figure 2 57 Pan Pulley Cover Removal Step 9 Slide pan belt over and off pan pulley Step 10 Reassemble by performing steps in reverse order Note Ensure proper belt tension when replacing 8 32 x 1 4 PPZ SEMS Screw x4 Wire Tray 8 32 KEPS Nuts x4 Pan Pulley Cover NOTE Components removed and exploded for clarity Pa...

Page 91: ...mbly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 58 Enclosure Assembly Bottom Plate Removal Step 5 Remove pan motor assembly as described i...

Page 92: ... 10 32 x 3 8 SCZ B screws and remove pulley from pan tube Step 10 At Stabilizer mount remove one 8 32 x 1 2 PPZ SEMS screw Step 11 Remove spring from stabilizer pass stabilizer around wiring harness IMPORTANT When replacing stabilizer install new spring Step 12 Reassemble by performing steps in reverse order Note Ensure proper belt tension when replacing 8 32 x 1 4 PPZ SEMS Screw x4 Wire Tray 8 32...

Page 93: ...and luminaire has cooled completely Step 2 Remove Ballast LVS assembly as described in Ballast LVS Assembly Replacement on page 60 WARNING Do not set head on or damage front lens during next step Step 3 Carefully flip luminaire to access bottom of enclosure Do not set on lens Step 4 Remove six 1 4 20 x 1 2 PFZ screws and remove Bottom Plate from enclosure assembly Figure 2 61 Enclosure Assembly Bo...

Page 94: ... fan from mounting assembly by removing two 6 32 x 1 1 2 PPZ screws 8 internal tooth lock washers and 8 flat washers per assembly Step 7 Disconnect wiring and remove fans Step 8 Reassemble by performing steps in reverse order NOTE Components removed and exploded for clarity Fan Assembly 6 32 x 1 4 PPZ SEMS Screw x2 Fan Assembly 6 32 x 1 4 PPZ SEMS Screw x2 8 32 x 1 1 2 PPZ Screw x2 assembly 8 Inte...

Page 95: ...his chapter contains illustrated parts breakdowns for all VL440 VL770 VL880 Spot Luminaires assemblies VL440 Spot Luminaire Drawing Tree VL770 Spot Luminaire Drawing Tree VL880 Spot Luminaire Drawing Tree Top Assembly Head Assembly Enclosure Assembly Cable Assemblies ...

Page 96: ... 25 9687 0010 Rev A CYMD Group Cable Assembly 25 9687 0011 Rev B Gobo Group Cable Assembly 25 9687 0012 Rev 0 Lamp to Fans Cable Assembly 25 9687 0015 Rev A VL440 VL770 Lamp Socket Cable Assembly 25 9687 0021 07 Rev A Prism Assembly 21 9687 0151 Rev B Frost Assembly 21 9687 0152 Rev A Zoom Linear Slide Assembly 21 9687 0180 Rev A Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A Gobo Module...

Page 97: ...near Roller Assembly 21 9687 0634 Rev B Lamp Housing Assembly 21 9687 0652 Rev J Tilt Motor Assembly 21 9687 0670 Rev C Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A AC Input Cable Assembly 25 9687 0001 Rev A DMX Display Comm Cable Assembly 25 9687 0003 Rev A 36 Volt Supply Cable Assembly 25 9687 0005 Rev A Ballast to Ignitor Cable Assembly 25 9687 0006 Rev A Pan Motor Cable Assembly 25...

Page 98: ...0011 Rev B Gobo Group Cable Assembly 25 9687 0012 Rev 0 Lamp to Fans Cable Assembly 25 9687 0015 Rev A VL440 VL770 Lamp Socket Cable Assembly 25 9687 0021 07 Rev A Prism Assembly 21 9687 0151 Rev B Frost Assembly 21 9687 0152 Rev A Zoom Linear Slide Assembly 21 9687 0180 Rev A Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A Gobo Module Assembly 21 9687 0301 Rev J Wedge Fixed Color Wheel A...

Page 99: ...near Roller Assembly 21 9687 0634 Rev B Lamp Housing Assembly 21 9687 0652 Rev J Tilt Motor Assembly 21 9687 0670 Rev C Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A AC Input Cable Assembly 25 9687 0001 Rev A DMX Display Comm Cable Assembly 25 9687 0003 Rev A 36 Volt Supply Cable Assembly 25 9687 0005 Rev A Ballast to Ignitor Cable Assembly 25 9687 0006 Rev A Pan Motor Cable Assembly 25...

Page 100: ...5 9687 0011 Rev B Gobo Group Cable Assembly 25 9687 0012 Rev 0 Lamp to Fans Cable Assembly 25 9687 0015 Rev A VL880 Lamp Socket Cable Assembly 25 9687 0021 08 Rev A Prism Assembly 21 9687 0151 Rev B Frost Assembly 21 9687 0152 Rev A Zoom Linear Slide Assembly 21 9687 0180 Rev A Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A Gobo Module Assembly 21 9687 0301 Rev J Wedge Fixed Color Wheel ...

Page 101: ...near Roller Assembly 21 9687 0634 Rev B Lamp Housing Assembly 21 9687 0652 Rev J Tilt Motor Assembly 21 9687 0670 Rev C Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A AC Input Cable Assembly 25 9687 0001 Rev A DMX Display Comm Cable Assembly 25 9687 0003 Rev A 36 Volt Supply Cable Assembly 25 9687 0005 Rev A Ballast to Ignitor Cable Assembly 25 9687 0006 Rev A Pan Motor Cable Assembly 25...

Page 102: ...2 1 EA UNPACK QUICK START SHEET VL440 VL770 VL880 SPOT 04 4037 0001 5 EA LABEL 2 5 X 5 BARCODE not shown 04 9678 1001 2 EA LABEL GREEN ROHS COMPLIANT not shown 06 9687 0001 1 EA SHIPPING FOAM not shown 07 5044 0001 1 EA BAG DESICCANT SHIPPING BOX not shown 07 9687 0001 1 EA CARDBOARD SHIPPING BOX VL440 VL770 VL880 not shown 6 08 9687 0001 1 EA CD ROM VL440 VL770 VL880 PRODUCT DOCUMENTATION USER 7 ...

Page 103: ...luded Items Kit 6 5 7 x2 1 3 2 4 3 Pole Neutrik PowerCon Locking Connector for AC Input Power Power input cable must be constructed by user 8 400W MSR Gold MiniFastFit Lamp VL440 only 700W MSR Gold MiniFastFit Lamp VL770 only 800W MSR Platinum 35 Lamp VL880 only Note truss hooks sold separately 9 ...

Page 104: ... 21 9687 0620 1 EA ASSY HEAD COVER FRONT 14 21 9687 0625 1 EA ASSY HEAD COVER REAR 15 21 9687 0630 1 EA ASSY LAMP COVER 25 9687 0004 1 EA CABLE ASSY BALLAST COMM not shown 25 9687 0008 1 EA CABLE ASSY TILT not shown 25 9687 0009 1 EA CABLE ASSY EDGE not shown 25 9687 0010 1 EA CABLE ASSY ZOOM GROUP not shown 25 9687 0011 1 EA CABLE ASSY CMYD GROUP not shown 25 9687 0012 1 EA CABLE ASSY GOBO GROUP ...

Page 105: ...00W 27 69 9687 0400 1 EA ASSY BALLAST 400W 150W LVS 28 10 9687 1614 1 EA BLOCKING PLATE FAN LAMP COOLING 29 10 9687 1615 1 EA AIR DIVERTER SINGLE BLOWER LAMP COOLING 30 40 9687 0001 1 EA BLOWER 75 X 30 85C HI FLOW 31 53 6581 0002 2 EA SCREW 4 40 X 1 1 2 PPZ 32 53 6597 0001 2 EA SCREW 4 40 X 3 16 PPZ 33 55 6546 0004 8 EA WASHER TEFLON 0 201 ID X 0 433 OD 34 55 6568 0115 2 EA SPRING CPRSN 0 300 OD 1...

Page 106: ...VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 88 02 9687 0010 0 VL440 Spot Luminaire continued Figure 3 9 VL440 Spot Luminaire 18 x2 3 6 8 12 17 x2 7 11 24 x2 16 26 25 x2 22 x2 32 x2 28 31 x2 34 x2 30 33 x8 29 ...

Page 107: ...TOP ASSEMBLY VL440 SPOT LUMINAIRE 02 9687 0010 0 89 3 VL440 Spot Luminaire continued Figure 3 10 VL440 Spot Luminaire 2 23 x8 2 13 14 5 x2 20 x4 4 x2 1 20 x2 27 19 x2 15 ...

Page 108: ... 21 9687 0620 1 EA ASSY HEAD COVER FRONT 14 21 9687 0625 1 EA ASSY HEAD COVER REAR 15 21 9687 0630 1 EA ASSY LAMP COVER 16 21 9687 1630 1 EA BLOWER ASSY DUAL GOBO COOLING 25 9687 0004 1 EA CABLE ASSY BALLAST COMM not shown 25 9687 0008 1 EA CABLE ASSY TILT not shown 25 9687 0009 1 EA CABLE ASSY EDGE not shown 25 9687 0010 1 EA CABLE ASSY ZOOM GROUP not shown 25 9687 0011 1 EA CABLE ASSY CMYD GROUP...

Page 109: ...178 0001 2 EA CABLE ANCHOR MOUNT 8 SCREW 29 55 2233 2001 2 EA DZUS RAPIER MINI CLIP ON RETAINER 30 55 3301 0004 2 EA WASHER 4 FLAT SS 31 68 9687 0001 1 EA IGNITOR 700W 800W 32 69 9687 0700 1 EA ASSY BALLAST 700W 150W LVS 33 10 9687 0610 1 EA AIR DEFLECTOR DUAL BLOWER 34 40 9687 0001 2 EA BLOWER 75 X 30 85C HI FLOW 35 53 6581 0002 4 EA SCREW 4 40 X 1 1 2 PPZ 36 55 6546 0004 8 EA WASHER TEFLON 0 201...

Page 110: ...0 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 92 02 9687 0010 0 VL770 Spot Luminaire continued Figure 3 12 VL770 Spot Luminaire 7 17 12 6 20 x2 29 x2 18 31 30 x2 25 x2 11 19 x2 22 x2 10 26 x2 1 35 x4 37 x4 34 x2 36 x8 ...

Page 111: ...TOP ASSEMBLY VL770 SPOT LUMINAIRE 02 9687 0010 0 93 3 VL770 Spot Luminaire continued Figure 3 13 VL770 Spot Luminaire 2 27 x8 2 13 14 4 x2 23 x4 3 x2 23 x2 32 21 x2 15 16 28 x2 24 x2 ...

Page 112: ... 21 9687 0620 1 EA ASSY HEAD COVER FRONT 14 21 9687 0625 1 EA ASSY HEAD COVER REAR 15 21 9687 0630 1 EA ASSY LAMP COVER 16 21 9687 1630 1 EA BLOWER ASSY DUAL GOBO COOLING 25 9687 0008 1 EA CABLE ASSY TILT not shown 25 9687 0009 1 EA CABLE ASSY EDGE not shown 25 9687 0010 1 EA CABLE ASSY ZOOM GROUP not shown 25 9687 0011 1 EA CABLE ASSY CMYD GROUP not shown 25 9687 0012 1 EA CABLE ASSY GOBO GROUP n...

Page 113: ...178 0001 2 EA CABLE ANCHOR MOUNT 8 SCREW 29 55 2233 2001 2 EA DZUS RAPIER MINI CLIP ON RETAINER 30 55 3301 0004 2 EA WASHER 4 FLAT SS 31 68 9687 0001 1 EA IGNITOR 700W 800W 32 69 9687 0800 1 EA ASSY BALLAST 800W 200W LVS 33 10 9687 0610 1 EA AIR DEFLECTOR DUAL BLOWER 34 40 9687 0001 2 EA BLOWER 75 X 30 85C HI FLOW 35 53 6581 0002 4 EA SCREW 4 40 X 1 1 2 PPZ 36 55 6546 0004 8 EA WASHER TEFLON 0 201...

Page 114: ...0 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 96 02 9687 0010 0 VL880 Spot Luminaire continued Figure 3 15 VL880 Spot Luminaire 7 17 12 6 20 x2 29 x2 18 31 30 x2 25 x2 11 19 x2 22 x2 10 26 x2 1 35 x4 37 x4 34 x2 36 x8 ...

Page 115: ...TOP ASSEMBLY VL880 SPOT LUMINAIRE 02 9687 0010 0 97 3 VL880 Spot Luminaire continued Figure 3 16 VL880 Spot Luminaire 2 27 x8 2 13 14 4 x2 23 x4 3 x2 23 x2 32 21 x2 15 16 28 x2 24 x2 ...

Page 116: ...5049 0001 1 EA LANYARD NYLON 8 INCH LONG 2 10 9687 0615 1 EA FILTER FOAM HEAD COVER FRONT 3 10 9687 0620 1 EA HEAD COVER FRONT 4 10 9687 2653 1 EA RETAINER FILTER FOAM HEAD COVER 5 53 5655 0250 3 EA SCREW 6 X 1 4 PPZ PLASTIC 6 55 2011 0003 1 EA SNAP SPRING 3 16 EYE DIA 7 55 2233 2003 2 EA DZUS RAPIER 1 4 TURN STUD RETAINER 5 MM 8 55 2233 2005 2 EA DZUS RAPIER 1 4 TURN STUD 5 MM 12 MM LG 1 8 x2 6 7...

Page 117: ...er Assembly No Item Qty UM Description 1 07 5049 0001 1 EA LANYARD NYLON 8 INCH LONG 2 10 9687 0625 1 EA HEAD COVER REAR 3 53 5655 0250 1 EA SCREW 6 X 1 4 PPZ PLASTIC 4 55 2011 0003 1 EA SNAP SPRING 3 16 EYE DIA 5 55 2233 2003 2 EA DZUS RAPIER 1 4 TURN STUD RETAINER 5 MM 6 55 2233 2005 2 EA DZUS RAPIER 1 4 TURN STUD 5 MM 12 MM LG 1 6 x2 3 2 4 5 x2 ...

Page 118: ...9 Figure 3 19 Lamp Cover Assembly No Item Qty UM Description 1 10 9638 0233 1 EA TETHER REMOVABLE COVER 2 10 9687 0630 1 EA HEAD COVER LAMP ACCESS 3 53 5655 0250 1 EA SCREW 6 X 1 4 LG PLASTIC THREADING 4 55 2233 2003 2 EA DZUS RAPIER 1 4 TURN STUD RETAINER 5 MM 5 55 2233 2005 2 EA DZUS RAPIER 1 4 TURN STUD 5 MM 12 MM LG 1 4 x2 3 2 5 x2 ...

Page 119: ...mbly No Item Qty UM Description 1 10 9687 0250 1 EA BRACKET FAN TRANSFER 2 10 9687 0251 1 EA BRACKET HINGE TRANSFER FAN 3 40 9687 0003 2 EA FAN AXIAL 50 MM X 15 MM 4 53 2200 0008 4 EA NUT 8 32 KEPS SS 5 53 6613 0001 2 EA SCREW 6 32 X 1 2 PPZ 6 53 6575 0003 4 EA SCREW 6 32 X 7 8 PPZ 7 55 6538 0002 4 EA WASHER 6 NYLON NATURAL 3 4 x4 6 x4 2 1 5 x2 7 x4 ...

Page 120: ...oling Blower Assembly 21 9687 1630 Rev A Refer to Figure 3 21 Figure 3 21 Dual Gobo Cooling Blower Assembly No Item Qty UM Description 1 10 9687 1632 1 EA BRACKET DUAL BLOWER GOBO COOLING 2 23 9687 0040 2 EA BLOWER ASSY 50 MM 3 53 6604 0004 4 EA SCREW 10 16 X 3 8 PPSS THD FORMING 3 x4 2 x2 1 ...

Page 121: ... 9687 0650 1 EA ASSY HEAD FRAME 2 21 9687 0751 1 EA ASSY TILT LOCK 3 21 9687 0850 1 EA ASSY UPPER ENCLOSURE 4 22 9687 0701 1 EA ASSY YOKE 5 22 9687 0705 1 EA ASSY FILLER YOKE SLOTTED 6 53 6543 0003 4 EA SCREW 6 32 X 3 16 PPB 7 53 6575 0009 7 EA SCREW 8 32 X 3 8 PPB SEMS 8 53 6608 0001 4 EA SCREW 6 32 X 3 8 PFB 9 53 6682 0037 6 EA SCREW 10 32 X 1 2 LG PPZ SEMS ...

Page 122: ...VARI LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 104 02 9687 0010 0 Generic Luminaire Assembly continued Figure 3 22 Generic Luminaire Assembly 2 5 6 x2 6 x2 7 x7 4 3 9 x6 8 x4 1 ...

Page 123: ...0686 1 EA BRACKET CONTROL BOARD 11 10 9687 0688 1 EA BRACKET DRIVE NUT FOCUS 12 10 9687 1617 1 EA BRACKET CABLE MANAGEMENT 13 10 9687 1661 2 EA STANDOFF POSITION GOBO MODULE 14 10 9687 1691 1 EA AIR DUCT LAMP BASE PINCH 15 10 9687 2616 1 EA BRACKET CABLE MANAGEMENT 16 21 9687 0632 1 EA ASSY TILT BEARING LEFT 17 21 9687 1633 1 EA ASSY TILT BEARING RIGHT 18 21 9687 0634 2 EA ASSY ROLLER LINEAR 19 21...

Page 124: ... 8 PPZ 32 53 6545 0003 18 EA SCREW 8 32 X 3 8 PFZ 33 53 6567 0001 6 EA SCREW 4 40 X 1 2 PPZ 34 53 6575 0008 2 EA SCREW 8 32 X 1 4 PPZ SEMS 35 53 6575 0009 15 EA SCREW 8 32 X 3 8 PPB SEMS 36 53 6592 0250 4 EA SCREW 4 40 X 1 4 PPB SEMS 37 53 6596 0002 2 EA SCREW 6 32 X 1 4 PPB SEMS 38 53 6607 0002 4 EA SCREW 6 32 X 1 4 PFB 39 53 6609 0500 2 EA SCREW 6 32 X 1 2 PFZ 40 53 9690 0051 4 EA SCREW 8 32 X 3...

Page 125: ...34 x2 32 x4 3 8 29 x3 11 27 for reference only supplied with item 26 only 35 x2 25 6 36 x4 32 x4 26 13 x2 16 39 x2 43 x2 44 35 x6 5 x4 19 35 x4 2 14 20 40 x4 4 33 x6 23 24 10 32 x4 17 21 41 18 x2 15 30 x2 35 x3 Note position of motor connector item 26 1 see note 28 x2 Shown for reference positioning only Item 1 is used in VL770 VL880 fixtures only 31 x2 ...

Page 126: ...gure 3 24 Left Tilt Bearing Assembly No Item Qty UM Description 1 10 9687 0656 1 EA PLATE BEARING MOUNT RIGHT 2 10 9687 0659 1 EA RETAINER TILT BEARING 3 10 9687 0660 1 EA TILT STOP 4 10 9687 0662 1 EA TILT TUBE 5 53 6545 0003 4 EA SCREW 8 32 X 3 8 PFZ 6 53 6609 0500 3 EA SCREW 6 32 X 1 2 PFZ 7 54 9687 0250 1 EA BEARING 68072RS 5 x4 7 3 6 x3 1 4 2 ...

Page 127: ...ING TILT 5 10 9687 0660 1 EA TILT STOP 6 10 9687 0662 1 EA TILT TUBE 7 10 9687 1659 1 EA RETAINER TILT BEARING SMOOTH 8 25 9687 0019 1 EA SENSOR SWITCH SLOTTED OPTICAL 9 53 6527 0001 3 EA SCREW 6 32 X 1 2 SCSS LOW PROFILE 10 53 6545 0003 4 EA SCREW 8 32 X 3 8 PFZ 11 53 6559 0001 3 EA SCREW 4 40 X 1 4 PFZ 12 53 6592 0250 2 EA SCREW 4 40 X 1 4 PPB SEMS 13 53 6609 0001 2 EA SCREW 6 32 X 3 8 PFZ 14 54...

Page 128: ... LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 110 02 9687 0010 0 Right Tilt Bearing Assembly continued Figure 3 25 Right Tilt Bearing Assembly 6 13 x2 16 1 7 14 3 10 x4 5 11 x3 4 15 9 x3 12 x2 8 2 ...

Page 129: ...y 21 9687 0634 Rev B Refer to Figure 3 26 Figure 3 26 Linear Roller Assembly No Item Qty UM Description 1 10 9687 0670 4 EA SHAFT FOCUS BEARING 2 10 9687 1665 1 EA BLOCK LINEAR ROLLER 3 53 65200375 4 EA SCREW 4 40 X 3 8 PPZ SEMS 4 54 9687 0253 4 EA BEARING MR105ZZ 1 x4 3 x4 2 4 x4 ...

Page 130: ...Y SHOWN FOR REFERENCE ONLY 13 22 9687 0610 1 EA ASSY REFLECTOR SHIELD 14 42 9687 0200 1 EA REFLECTOR FACETED SVL 15 53 2004 0002 4 EA NUT 8 32 KEPS ZINC PLATED 16 53 2030 0001 3 EA NUT ACORN 10 32 THD 3 8 WIDE 17 53 6525 0188 2 EA SCREW 6 32 X 3 16 LG PPZ 18 53 6558 0009 6 EA SCREW 6 32 X 3 8 LG PPZ SEMS 19 53 6575 0007 2 EA SCREW 8 32 X 7 8 LG PPZ SEMS 20 53 6575 0009 2 EA SCREW 8 32 X 3 8 LG PPB...

Page 131: ...sembly reference only These items are part of the top level luminaire assembly and are specific to their respective fixture See Top Assembly on page 84 for more information 30 25 9687 0021 XX 1 EA LAMP SOCKET ASSEMBLY NOTE PART OF TOP ASSEMBLY SHOWN FOR REFERENCE ONLY No Item Qty UM Description ...

Page 132: ...es 20 x4 21 x3 25 x3 24 x2 23 x2 29 x3 9 x3 30 see notes 19 x2 7 16 x3 18 x6 22 x4 13 6 x6 28 10 11 3 26 x2 15 x4 5 x2 4 x2 8 x2 14 1 27 2 Notes Items 12 and 34 are shown for assembly reference only These items are part of the top level luminaire assembly and are specific to their respective fixture See Top Assembly on page 84 for more information 17 x2 ...

Page 133: ...0 9687 0655 1 EA BRACKET MOTOR MOUNT TILT 2 21 9687 0655 1 EA PULLEY PINION INCLUDES ENCODER WHEEL AND SET SCREWS 3 24 9661 5000 1 EA BRD ASSY PAN TILT ENCODER 4 44 9678 1680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 6575 0010 3 EA SCREW 8 32 X 1 2 LG PPZ SEMS 6 53 6592 0250 2 EA SCREW 4 40 X 1 4 LG PPB SEMS 7 55 2204 0001 2 EA WASHER 4 NYLON ...

Page 134: ...If you order a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information 6 x2 Step 1 Apply one drop of Loctite 603 to motor shaft Step 2 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 3 Do not allow Loctite to drip into motor bearing Step 4 Set pulley height as shown above Step 5 Ap...

Page 135: ...fer to Figure 3 29 Figure 3 29 Pulley Pinion Assembly No Item Qty UM Description 1 10 9663 8820 1 EA CODE WHEEL 120 COUNT 2 10 9687 1655 1 EA TIMING PULLEY 18 GROVE GT2 6 MM BELT 3 53 5559 0250 2 EA SCREW SET 6 40 X 0 25 CONE POINT 1 3 x2 2 NOTE On item 1 remove backing over adhesive and stick to item 2 ...

Page 136: ...IXED GOBO 13 22 9687 0202 1 EA ASSY OUTDRIVE GOBO ROTATE 14 22 9687 0203 1 EA ASSY CONTROL ARM IRIS 15 22 9687 0204 2 EA ASSY PLATE HOMING MOTOR REAR 16 22 9687 0222 1 EA ASSY COAX GOBO ROTATE 17 22 9687 0230 1 EA ASSY IRIS 25MM FIXED APERTURE 18 24 9678 3240 1 EA PCB ASSY WHEEL POSITION SENSOR 19 25 9687 0020 3 EA SWITCH SLOTTED OPTICAL 20 25 9687 0024 3 EA CABLE ASSY INDEX SENSOR 21 44 9687 1204...

Page 137: ...e Fixed Gobo Outdrive is installed with set screw to flat part of motor shaft when tab is in optical sensor When replacing Index Motor ensure the Index Outdrive is installed with set screw to flat part of motor shaft 32 55 1000 0009 1 EA SPRING COMPRESS SS 316 33 55 2123 0013 8 EA WAVE SPRING 0 265 ID X 0 367 OD X 0 006 THK 34 55 2179 0001 2 EA CABLE ANCHOR MOUNT 6 SCREW 35 55 3301 0010 2 EA 10 0 ...

Page 138: ...SPOT LUMINAIRES SERVICE MANUAL 120 02 9687 0010 0 Gobo Module Assembly continued Figure 3 30 Gobo Module Assembly 22 x2 15 x2 21 x2 1 2 x4 26 x4 3 x2 36 x2 33 x8 23 27 x2 7 35 x2 24 x4 28 x8 30 x3 17 7 25 x3 8 18 29 x2 19 x3 27 x6 ...

Page 139: ...HEAD ASSEMBLY GOBO MODULE ASSEMBLY 02 9687 0010 0 121 3 Gobo Module Assembly continued Figure 3 31 Gobo Module Assembly 6 34 x2 5 32 12 4 x2 13 14 16 31 x4 11 10 9 20 25 x3 ...

Page 140: ...07 1 EA FILTER ASSY CTO 2 21 9687 0431 1 EA FILTER ASSY RED 3 21 9687 0433 1 EA FILTER ASSY MAGENTA 4 21 9687 0434 1 EA FILTER ASSY KELLY GREEN 5 21 9687 0435 1 EA FILTER ASSY CONGO BLUE 6 21 9687 0436 1 EA FILTER ASSY BLUE 7 21 9687 0439 1 EA FILTER ASSY DARK ORANGE 8 21 9687 0441 1 EA FILTER ASSY FLESH PINK 9 22 9687 0225 1 EA ASSY WEDGE WHEEL 2 9 Red Blue Kelly Green 6 Magenta 4 3 CTO 1 Flesh P...

Page 141: ...21 6004 4011 1 EA ASSY ROTATING GOBO VERTICAL SLOT 3 21 6004 4322 1 EA ASSY ROTATING GOBO PINWHEEL 2 4 21 6004 6008 1 EA ASSY ROTATING GOBO TRI CONE W MAGNET 5 21 6004 7018 1 EA ASSY ROTATING GOBO SHOCK BREAKUP 6 21 6004 7029 1 EA ASSY ROTATING GOBO ALPHA RAYS 7 21 9687 8002 1 EA ASSY GAG ROTATOR GLACIER 8 22 9687 0220 1 EA ASSY ROTATING GOBO WHEEL 2 6 4 3 1 OPEN 8 7 5 Note Gobo and gag artwork no...

Page 142: ...1 EA GOBO FIXED HORIZONTAL BARS SVL 4 41 6004 5011 1 EA GOBO FIXED NIGHT SKY SVL 5 41 6004 5501 1 EA GOBO FIXED LEAVES SVL 6 41 6004 5523 1 EA GOBO FIXED TRIBAL BREAK UP SVL 7 41 6004 6001 1 EA GOBO FIXED MEDIUM CIRCLE SVL 8 41 6004 7002 1 EA GOBO FIXED PEBBLES SVL 9 41 6004 7008 1 EA GOBO FIXED WAVE SVL 10 41 6004 7015 1 EA GOBO FIXED BLOCK BREAK UP SVL 11 41 6004 7025 1 EA GOBO FIXED DUST BREAK ...

Page 143: ...FT COLOR MIX 2 5 21 9687 1415 1 EA ASSY DIMMER WHEEL 6 21 9687 1416 1 EA ASSY MAGENTA COLOR WHEEL 7 21 9687 1417 1 EA ASSY CYAN COLOR WHEEL 8 21 9687 1418 1 EA ASSY YELLOW COLOR WHEEL 9 21 9687 1435 1 EA ASSY FLAG MOTOR PLATE LEFT 10 21 9687 1437 1 EA ASSY FLAG MOTOR PLATE RIGHT 11 22 9687 0460 1 EA ASSY OUTDRIVE DIMMER 12 22 9687 0462 1 EA ASSY OUTDRIVE MAGENTA 13 25 9687 0020 2 EA SWITCH SLOTTED...

Page 144: ...ly 8 Yellow Cyan Magenta Dimmer 7 6 5 18 x4 19 x4 11 3 12 16 x8 17 x11 13 x2 15 x2 14 x2 9 10 1 17 x2 20 x4 4 2 15 x2 Yellow Cyan Magenta Dimmer See Note Note When installing or reinstalling Yellow or Cyan wheels you must add a bead of RTV 5083 on top of 0 80 x 3 16 LG PFSS Screws Allow enough time for RTV to cure before putting the assembly into use ...

Page 145: ...n 1 10 9687 1437 1 EA PLATE MOTOR STROBE 2 22 9687 0453 1 EA ASSY FLAG DIM STROBE 3 22 9687 1455 1 EA ASSY OUTDRIVE OFFSET TAB 0 155 4 25 9687 0020 1 EA SWITCH SLOTTED OPTICAL 5 44 9687 1213 2 EA MOTOR SIZE 14 SHAFT 0 50 LG 6 55 2202 0004 2 EA NUT 4 40 HEX SS NYLON INSERT 7 53 6601 0001 4 EA SCREW 4 40 X 3 16 PFZ 8 55 6738 0005 2 EA TUBING SILICONE 4 MM ID 8MM SOFT RED 2 1 7 x4 6 x2 5 x2 4 8 x2 3 ...

Page 146: ...E MOTOR DIMMER STROBE 2 22 9687 0453 1 EA ASSY FLAG DIM STROBE 3 22 9687 1456 1 EA ASSY OUTDRIVE CYAN 4 25 9687 0020 1 EA SWITCH SLOTTED OPTICAL 5 44 9687 1213 2 EA MOTOR SIZE 14 SHAFT 0 50 LG 6 55 2202 0004 2 EA NUT 4 40 HEX SS NYLON INSERT 7 53 6601 0001 4 EA SCREW 4 40 X 3 16 PFZ 8 55 6738 0005 2 EA TUBING SILICONE 4 MM ID 8MM SOFT RED 9 55 9687 0203 2 EA WASHER SPACER 0 120 ID X 0 250 OD X 0 0...

Page 147: ...OR MIX SHAFT 13 21 9687 0151 1 EA ASSY PRISM 14 21 9687 0152 1 EA ASSY FROST 15 21 9687 0180 1 EA ASSY LINEAR SLIDE ZOOM 16 22 9687 0101 1 EA ASSY POSITIONING CAM 17 22 9687 0106 1 EA ASSY DRIVE GEAR ZOOM 18 22 9687 0120 1 EA ASSY GROUP ONE LENS 19 22 9687 0121 1 EA ASSY GROUP TWO LENS 20 22 9687 0122 1 EA ASSY GROUP THREE LENS 21 25 9687 0020 3 EA SWITCH SLOTTED OPTICAL 22 44 9687 1209 2 EA MOTOR...

Page 148: ...CREW 4 40 X 3 8 PFZ 34 53 6659 0002 2 EA SCREW 2 56 X 1 4 PPZ 35 53 6608 0001 5 EA SCREW 6 32 X 3 8 PFB 36 53 6682 0026 2 EA SCREW 8 32 X 3 4 PPZ SEMS 37 54 9687 0104 2 EA BEARING DUAL SHIELDED MR83 38 54 9687 0253 2 EA BEARING MR105ZZ 39 55 3301 0004 1 EA WASHER 4 FLAT SS 40 55 6520 0001 1 EA WASHER WAVE SPRING 0 265 ID No Item Qty UM Description ...

Page 149: ...02 9687 0010 0 131 3 Zoom Assembly continued Figure 3 38 Zoom Assembly 36 x2 9 20 22 x2 4 31 x2 6 30 x2 25 x3 14 8 x3 13 28 x2 10 19 24 x6 27 x4 17 7 23 18 2 1 35 x5 11 21 x3 16 15 5 29 x5 32 x9 39 40 12 38 x2 37 x2 3 34 x2 33 x4 ...

Page 150: ...NG PRISM ROTATE 4 22 9687 0116 1 EA ASSY PRISM FLAG 5 42 9687 0130 1 EA PRISM 5 FACETS 6 44 9687 1218 1 EA MOTOR SIZE 14 LO PRFL 0 9 DEG 7 53 3301 0003 3 EA WASHER FLAT 2 AN ID 0 099 X 0 8 53 6578 0002 2 EA SCREW 6 32 X 3 16 SET CUP POINT 9 53 6592 0250 2 EA SCREW 4 40 X 1 4 PPB SEMS 10 53 6601 0001 2 EA SCREW 4 40 X 3 16 PFZ 11 53 6659 0005 3 EA SCREW 2 56 X 1 4 PFZ 12 54 9687 0104 3 EA BEARING D...

Page 151: ...HEAD ASSEMBLY PRISM ASSEMBLY 02 9687 0010 0 133 3 Prism Assembly continued Figure 3 39 Prism Assembly 2 11 x3 6 8 x2 10 x2 4 5 1 13 7 x3 12 x3 3 x3 9 x2 ...

Page 152: ...st Assembly No Item Qty UM Description 1 10 9687 0177 1 EA RETAINER FROST GLASS 2 22 9687 0115 1 EA ASSY FROST FLAG 3 42 9687 0151 1 EA GLASS FROST SVL 4 53 2009 0001 3 EA NUT HEX 2 56 5 53 3303 0002 3 EA WASHER FLAT 2 LOCK INT TOOTH SS 6 53 6578 0002 1 EA SCREW 6 32 X 3 16 SET CUP POINT 7 53 6659 0002 1 EA SCREW 2 56 X 1 4 PPZ 7 4 x3 5 x3 6 3 2 1 ...

Page 153: ...de Assembly No Item Qty UM Description 1 10 9687 0111 2 EA SHAFT CAM FOLLOWER 2 10 9687 0140 1 EA RAIL LINEAR SLIDE 3 21 9687 0106 1 EA ASSY CARRIER FRONT 4 21 9687 0111 1 EA ASSY CARRIER REAR 5 53 6659 0016 2 EA SCREW 2 56 X 5 8 PPZ SEMS 6 54 9687 0104 2 EA BEARING DUAL SHIELDED MR83 7 55 3303 0002 2 EA WASHER 2 LOCK INT TOOTH SS 4 1 x2 2 6 x2 5 x2 7 x2 3 ...

Page 154: ...06 Rev B Refer to Figure 3 42 Figure 3 42 Front Carrier Assembly No Item Qty UM Description 1 10 9687 0145 1 EA CARRIAGE FRONT 2 10 9687 1670 4 EA SHAFT FOCUS BEARING 3 53 6558 1188 2 EA SCREW SET 6 40 X 0 188 4 53 6596 0002 4 EA SCREW 6 32 X 1 4 PPB SEMS 5 54 9687 0253 4 EA BEARING MR105ZZ 3 x2 1 4 x4 5 x4 2 x4 ...

Page 155: ...ure 3 43 Rear Carrier Assembly No Item Qty UM Description 1 10 9687 0146 1 EA CARRIAGE REAR 2 10 9687 1670 4 EA SHAFT FOCUS BEARING 3 53 6558 1188 2 EA SCREW SET 6 40 X 0 188 4 53 6599 0001 2 EA SCREW 4 40 X 3 8 PFZ 5 53 6682 0002 2 EA SCREW 4 40 X 1 4 PPZ SEMS 6 54 9687 0253 4 EA BEARING MR105ZZ 3 x2 1 4 x2 6 x4 2 x4 5 x2 ...

Page 156: ...VARI LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 138 02 9687 0010 0 Notes ...

Page 157: ... 1 EA COVER PAN PULLEY 11 10 9687 0829 1 EA WIRE TRAY 12 10 9687 0836 4 EA STANDOFF BLOWER ASSY 13 10 9687 0840 4 EA MOUNTING BUTTON 14 10 9687 0841 1 EA PAN LATCH 15 10 9687 0860 4 EA TEFLON SPACER PAN LOCK 16 10 9687 0861 2 EA LATCH SPRING PAN LOCK 17 10 9687 1811 1 EA STABILIZER 50 MM DIA 18 10 9687 1825 1 EA CAP BEARING PAN INSIDE 19 21 9687 0860 1 EA ASSY PAN MOTOR 20 22 9687 0807 1 EA ASSY P...

Page 158: ...0001 4 EA SCREW 10 32 X 3 4 SCB 32 53 6515 0375 4 EA SCREW 10 32 X 3 8 SCZ B 33 53 6515 0875 4 EA SCREW 10 32 X 7 8 SKT CAP 34 53 6525 0188 6 EA SCREW 6 32 X 3 16 LG PPZ 35 53 6558 0007 4 EA SCREW 6 32 X 1 4 PPZ SEMS 36 53 6575 0005 4 EA SCREW 8 32 X 1 1 2 PPZ 37 53 6575 0008 4 EA SCREW 8 32 X 1 4 PPZ SEMS 38 53 6575 0009 4 EA SCREW 8 32 X 1 4 PPB SEMS 39 53 6575 0010 1 EA SCREW 8 32 X 1 2 PPZ SEM...

Page 159: ... UPPER ENCLOSURE ASSEMBLY 02 9687 0010 0 141 3 Upper Enclosure Assembly continued Figure 3 44 Upper Enclosure Assembly Part 1 6 x6 7 x4 44 47 31 x4 8 20 43 38 x4 45 x4 19 29 x4 10 Part of item 19 33 x4 9 32 x4 5 39 17 18 ...

Page 160: ... VL880 SPOT LUMINAIRES SERVICE MANUAL 142 02 9687 0010 0 Upper Enclosure Assembly continued Figure 3 45 Upper Enclosure Assembly Part 2 21 28 x2 26 24 34 x4 25 29 x10 40 x6 22 12 x4 46 x4 36 x4 27 x2 23 48 34 x2 35 x4 45 x4 ...

Page 161: ...BLY 02 9687 0010 0 143 3 Upper Enclosure Assembly continued Figure 3 46 Upper Enclosure Assembly Part 3 2 3 14 41 x6 30 x4 16 x2 15 x4 1 11 37 x4 4 13 x4 42 x6 32 x4 Note When installing these items use thread locker Loctite 271 or equivalent ...

Page 162: ...n 1 10 9687 0822 1 EA PLATE PAN MOTOR MOUNT 2 21 9687 0655 1 EA PULLEY PINION INCLUDES ENCODER WHEEL AND SET SCREWS 3 24 9661 5000 1 EA BRD ASSY PAN TILT ENCODER 4 44 9687 1680 1 EA MOTOR 3 PHASE SZ 23 HI TRQ MOONS 5 53 6575 0010 4 EA SCREW 8 32 X 1 2 PPZ SEMS 6 53 6682 0002 2 EA SCREW 4 40 X 1 4 PPZ SEMS 7 54 9687 0805 1 EA BELT PAN 185 TOOTH GT 2 MM 6 MM WIDE ...

Page 163: ...replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information 1 2 5 x4 3 6 x2 Step 1 Apply one drop of Loctite 603 to motor shaft Step 2 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 3 Do not allow Loctite to drip into motor bearing Step 4 Set pulley height as shown above Step 5 Apply ...

Page 164: ...VARI LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 146 02 9687 0010 0 Notes ...

Page 165: ...0 147 3 Cable Assemblies Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev D Refer to Figure 3 48 Figure 3 48 Chassis To Yoke Ground Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 166: ...L 148 02 9687 0010 0 AC Input Cable Assembly 25 9687 0001 Rev A Refer to Figure 3 49 Figure 3 49 AC Input Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only Line Neutral Ground ...

Page 167: ... 9687 0010 0 149 3 DMX Display Comm Cable Assembly 25 9687 0003 Rev A Refer to Figure 3 50 Figure 3 50 DMX Display Comm Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 168: ... MANUAL 150 02 9687 0010 0 Ballast Comm Cable Assembly 25 9687 0004 Rev B Refer to Figure 3 51 Figure 3 51 Ballast Comm Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 169: ...2 9687 0010 0 151 3 36 Volt Supply Cable Assembly 25 9687 0005 Rev A Refer to Figure 3 52 Figure 3 52 36 Volt Supply Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 170: ...L 152 02 9687 0010 0 Ballast to Ignitor Cable Assembly 25 9687 0006 Rev A Refer to Figure 3 53 Figure 3 53 Ballast to Ignitor Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 171: ...02 9687 0010 0 153 3 Pan Motor Cable Assembly 25 9687 0007 01 Rev C Refer to Figure 3 54 Figure 3 54 Pan Motor Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 172: ... MANUAL 154 02 9687 0010 0 Pan Encoder Cable Assembly 25 9687 0007 02 Rev C Refer to Figure 3 55 Figure 3 55 Pan Encoder Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 173: ...BLY 02 9687 0010 0 155 3 Tilt Cable Assembly 25 9687 0008 Rev A Refer to Figure 3 56 Figure 3 56 Tilt Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 174: ... SERVICE MANUAL 156 02 9687 0010 0 Edge Cable Assembly 25 9687 0009 Rev 0 Refer to Figure 3 57 Figure 3 57 Edge Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 175: ... 02 9687 0010 0 157 3 Zoom Group Cable Assembly 25 9687 0010 Rev A Refer to Figure 3 58 Figure 3 58 Zoom Group Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 176: ...CE MANUAL 158 02 9687 0010 0 CYMD Group Cable Assembly 25 9687 0011 Rev B Refer to Figure 3 59 Figure 3 59 CYMD Group Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 177: ... 02 9687 0010 0 159 3 Gobo Group Cable Assembly 25 9687 0012 Rev 0 Refer to Figure 3 60 Figure 3 60 Gobo Group Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 178: ... MANUAL 160 02 9687 0010 0 Lamp to Fans Cable Assembly 25 9687 0015 Rev A Refer to Figure 3 61 Figure 3 61 Lamp to Fans Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 179: ...687 0010 0 161 3 Tilt Sensor Cable Assembly 25 9687 0019 Rev 0 Refer to Figure 3 62 Figure 3 62 Tilt Sensor Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only 8 inches ...

Page 180: ... 02 9687 0010 0 Slotted Optical Switch Cable Assembly 25 9687 0020 Rev A Refer to Figure 3 63 Figure 3 63 Sensor Switch Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only 1 5 inches ...

Page 181: ... 0010 0 163 3 VL440 VL770 Lamp Socket Cable Assembly 25 9687 0021 07 Rev A Refer to Figure 3 64 Figure 3 64 VL440 VL770 Lamp Socket Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 182: ...L 164 02 9687 0010 0 VL880 Lamp Socket Cable Assembly 25 9687 0021 08 Rev A Refer to Figure 3 65 Figure 3 65 VL880 Lamp Socket Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 183: ...687 0010 0 165 3 800 Watt Ballast Comm Cable Assembly 25 9687 0023 Rev 0 Refer to Figure 3 66 Figure 3 66 800 Watt Ballast Comm Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 184: ... MANUAL 166 02 9687 0010 0 Sensor Index Cable Assembly 25 9687 0024 Rev A Refer to Figure 3 67 Figure 3 67 Sensor Index Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 185: ...LY 02 9687 0010 0 167 3 APS Fan Cable Assembly 25 9703 0002 Rev B Refer to Figure 3 68 Figure 3 68 APS Fan Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 186: ...L 168 02 9687 0010 0 AUX Comm Interface Cable Assembly 25 9703 0016 Rev A Refer to Figure 3 69 Figure 3 69 AUX Comm Interface Cable Assembly Note Cables are only available as complete assemblies The information contained in this section is for reference only ...

Page 187: ...manual where applicable and are available on the Vari Lite web site at www vari lite com Please note that not all bulletins or notices are applicable to all versions of the fixtures included in this manual Refer to each bulletin and notice for specific information and application Technical Bulletins Technical Notices For the latest technical bulletins and notices please visit the Support section o...

Page 188: ...VARI LITE VL440 VL770 VL880 SPOT LUMINAIRES SERVICE MANUAL 170 02 9687 0010 0 Notes ...

Page 189: ......

Page 190: ...al Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 19 December 2011 Manual Part Number 02 9687 0010 0 2011 Vari Lite A Philips Group Company All rights reserved Printed in the U S A ...

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