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Philips VL1000 AI Service Manual Download Page 106

VARI

❋

LITE

®

 - VL1000™ ERS L

UMINAIRE

 S

ERVICE

 M

ANUAL

8 8

14-May-2009

0 2 . 9 6 6 3 . 0 0 1 0  F

Incandescent Gobo Wheel Assembly

21.9663.1200 (TS/TI/TSD/TID) Rev V

Refer to 

Figure 3-23

.

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

10.9663.1239

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

24.9663.3230

1

EA

PCB ASSY, WHEEL SENSOR

13

24.9663.3231

1

EA

PCB ASSY, INDEX SENSOR

14

44.9663.1202

2

EA

MOTOR,  17 2.42" SHAFT 11.8MH 5.5 OHM

15

53.2003.0001

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

55.6520.0001

2

EA

WASHER, WAVE SPRING, .265 ID X .367 OD

30

55.6506.0010

1

EA

SPACER, 1/4" RND .375" LG .140" ID THRU AL NO FNSH

Summary of Contents for VL1000 AI

Page 1: ......

Page 2: ... 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 H...

Page 3: ...ablish the date of sale as the beginning of the warranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form included at the end of this manual and place in shipping container along with a copy of your invoice if available Write the RMA number legibly on or near the shipping address label and return the unit freight prepa...

Page 4: ...case the user will be required to correct the interference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents as applicable Safety by Council Directive 73 23 EEC EN60598 1 1997 A1 1998 EN60598 2 17 1989 A2 1991 EN60922 Electromagnetic Compatibility by Coun...

Page 5: ... 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...

Page 6: ...ion 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...

Page 7: ...ampentyps 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 Materia...

Page 8: ...esteht 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 S...

Page 9: ...s 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 cara...

Page 10: ... 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 endo...

Page 11: ...nas 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 especific...

Page 12: ...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 ...

Page 13: ...SAFETY NOTICE JAPANESE 02 9663 0010 F 14 May 2009 xiii ...

Page 14: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL xiv 14 May 2009 02 9663 0010 F ...

Page 15: ...n Board IGBT Dimmer 10 VL1000 Incandescent Cable Routing Without On Board IGBT Dimmer 11 VL1000 Incandescent Block Diagram With On Board IGBT Dimmer 12 VL1000 Incandescent Cable Routing With On Board IGBT Dimmer 13 VL1000 Arc Source Luminaire 14 VL1000 Arc Block Diagram 14 VL1000 Arc Cable Routing 15 Chapter 2 Maintenance Testing Running Parameter Tests 18 Maintenance Procedures Lamp Replacement I...

Page 16: ...wing Trees VL1000 Incandescent Luminaires 56 VL1000 Arc Luminaires 58 Top Assembly Included Items Kit 60 Included Items Kit continued 61 Label Locations 62 VL1000 Luminaire 64 Front Cover Assembly 67 Gel Frame Holder Assembly 68 COT Center of Travel Flag Assembly 69 Head Assembly Head Assembly 71 Front Head Assembly 72 Edge Control Zoom Dimmer Color Assembly 74 Color Changer Assembly 76 Cover Plat...

Page 17: ...7 LVS Chassis Ground Cable Assembly 128 Head to Backcap Ground Cable Assembly 129 Yoke to Head Ground Cable Assembly 130 Pan Tilt Control Cable Assembly 131 Ballast Control Link Cable Assembly 133 Data I O Link Cable Assembly 134 LVS DC Output Cable Assembly 135 Incandescent Power Input Cable Assembly 136 Incandescent Lamp Power Cable Assembly 137 Arc Power to Ignitor Cable Asembly 138 Ignitor to ...

Page 18: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL xviii 14 May 2009 02 9663 0010 F This page intentionally blank ...

Page 19: ...and Service Centers This manual covers the following models Note Performing maintenance procedures contained in this manual may void the product warranty Refer to the Vari Lite Limited Warranty card included in the shipping package for this VARI LITE product WARNING It is not recommended to power any VARI LITE luminaire from a dimmer even in NONDIM mode Dimmer and non dim modules are not suitable ...

Page 20: ... those manuals are revised Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of e...

Page 21: ...02 9663 0010 F 14 May 2009 3 CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Component Descriptions Principles of Operation ...

Page 22: ...obo position Repositional pan tilt system Control by DMX512 protocol Model Specific Features Each individual configuration has the following specific features 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 AS 20 9663 0001 12 575W arc lamp source wit...

Page 23: ...stem VL1000 TID Luminaire 20 9663 0001 23 1000W Tungsten Halogen lamp source 115V on board dimmer Beam size iris mechanism VL1000 TSE Luminaire 20 9663 0001 32 1000W Tungsten Halogen lamp source 240V on board dimmer Four blade shutter framing system VL1000 TIE Luminaire 20 9663 0001 33 1000W Tungsten Halogen lamp source 240V on board dimmer Beam size iris mechanism ...

Page 24: ...nisms Provides frame for optional silks frosts color Lamp Power Yoke Leg Power Accessory Frame Holder Backcap Assembly Provides access to lamp for replacement and provides controls for Beam Adjust Screws Menu Display Controls Accessory Frame Holder Accessory Frame Gel Silk Latch correction or top hats internal status information beam adjustment Up Increase Down Decrease LCD Display Press to select...

Page 25: ...es crossfading CYM system and diffusion Edge Zoom Dimmer Bulkhead Provides beam sizing capabilities Beam Size Iris Assembly optional Backcap Assembly Provides access to lamp for replacement and provides controls for beam adjustment Arc Gobo Bulkhead Provides six position rotatable indexable gobo wheel for projecting images Rear Head Assembly Six position rotating gobo wheel with five rotatable Fou...

Page 26: ...e located in the luminaire yoke assembly Note Head assembly not shown for clarity Main Controller PCB Luminaire control circuit board Tilt Mechanism Yoke Arm Cover Display Side Yoke Arm Cover Power Supply Side 150W Power Supply Supplies power to electronic and motor Ignitor PCB Ignites lamp in arc models components Pan Mechanism Internal Dimmer Powers lamp in some models or ...

Page 27: ...mer Model An on board IGBT dimmer is included with VL1000 incandescent dimmer models The dimmer heatsink is visible on the power side yoke leg as shown in this illustration Lamp Connector CPC type connector for connecting Lamp Power Input cable from luminaire Ballast Unit Provides power for arc lamp source Truss Hook Mount Used to attach a truss hook Safety Cable Tab Used to attach safety cable cl...

Page 28: ...26 4 PAN EOT SENSOR TILT COT SENSOR CHASSIS GND STUD FAN FAN 24 2 2040 SHUTTERS 2042 WITHOUT 1850 1850 NEUTRIK POWERCON AC LINE IN 2015 TERM BLOCK AC GND 16 1 2015 YOKE GND STUDS AC GND 22x4 2016 AC GND 16 1 2017 2040 2050 2020 2050 24V DMX PCB J7 J6 J4 J4 J8 J1 J5 J1 J3 AC IN J1 J1 J2 J2 YOKE TO HEAD GND 22x4 2019 1 2 J1 J2 HEAD GND STUDS HEAD TO BACK CAP BRAID 2018 2 1 BACK CAP GND STUD 1000W IN...

Page 29: ...ENSORS 2050 8 MOTORS 2040 FAN 2 GOBO SENSE FAN 2040 or 2042 PAN 2020 USER PROVIDED CONNECTOR FOR LAMP PWR INPUT FROM DIMMER TERM BLOCK PIGTAIL STRAIN RELIEF PAN EOT SENSOR PAN EOT 2001 TILT COT SENSOR TILT COT 2002 TILT COT 2002 TILT COT 2002 DIMMER GND AC GND 2016 YOKE HEAD GND 2019 LAMP SOCKET AMP SERIES 30 5 5 4 GND STUD GND STUD GND STUD LAMP PWR 2031 NEUTRIK POWERCON AC LINE IN 2015 XLR M DMX...

Page 30: ...LAY8 DATA 22 5 2022 PAN EOT 26 4 TILT COT 26 4 PAN EOT SENSOR TILT COT SENSOR CHASSIS GND STUD FAN FAN 24 2 2040 SHUTTERS 2042 WITHOUT 1850 1850 NEUTRIK POWERCON AC LINE IN 2015 TERM BLOCK AC GND 16 1 2015 YOKE GND STUDS AC GND 22x4 2016 AC GND 16 1 2017 2040 2050 2020 2050 24V DMX PCB J7 J6 J4 J4 J8 J1 J5 J1 J3 AC IN J1 J1 J2 J2 YOKE TO HEAD GND 22x4 2019 1 2 J1 J2 HEAD GND STUDS HEAD TO BACK CAP...

Page 31: ...20 TILT 2020 20 40 50 10 MOTORS 2 SENSORS 2050 8 MOTORS 2040 FAN 2 GOBO SENSE FAN 2040 or 2042 PAN 2020 PAN EOT SENSOR PAN EOT 2001 TILT COT SENSOR TILT COT 2002 TILT COT 2002 TILT COT 2002 AC GND 2016 YOKE HEAD GND 2019 LAMP SOCKET DIMMER 5 5 4 GND STUD GND STUD GND STUD LAMP PWR 2031 NEUTRIK POWERCON AC LINE IN 2015 XLR M DMX INPUT XLR F DMX THRU 5 DMX PCB TERM BLOCK GND STUD 1 LAMP PWR 2032 AC ...

Page 32: ...EEL GOBO INDEX DIFF MOTOR M12 24 4 M14 26 4 1A SHUTTER FRAME 1B SHUTTER FRAME 2A SHUTTER FRAME 2B SHUTTER FRAME 3A SHUTTER FRAME 3B SHUTTER FRAME 4A SHUTTER FRAME 4B SHUTTER FRAME M5 24 4 M13 26 4 M15 26 4 DOWN UP MENU ENTER DISPLAY8 IGNITOR PCB ASSY LAMP HV 16 2HV 2036 DATA 22 5 2022 HIGH CURRENT CONTACTS PAN EOT 26 4 TILT COT 26 4 PAN EOT SENSOR TILT COT SENSOR CHASSIS GND STUD FAN FAN 24 2 2040...

Page 33: ... or 2042 PAN 2020 TERM BLOCK PIGTAIL STRAIN RELIEF PAN EOT SENSOR PAN EOT 2001 TILT COT SENSOR TILT COT 2002 TILT COT 2002 TILT COT 2002 AC GND 2016 YOKE HEAD GND 2019 LAMP SOCKET IGN PCB 5 5 4 GND STUD GND STUD GND STUD LAMP PWR 2035 NEUTRIK POWERCON AC LINE IN 2015 XLR M DMX INPUT XLR F DMX THRU 5 DMX PCB TERM BLOCK GND STUD 1 GND STUD 2 LAMP HV 2036 AC GND 2016 GND STUD LVS GND 2017 GND STUD BA...

Page 34: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 16 14 May 2009 02 9663 0010 F Notes ...

Page 35: ... 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 ...

Page 36: ...k install loopback connector into DATA IN XLR connector Step 2 At last luminaire install male termination connector into DATA THRU XLR 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 move...

Page 37: ...in Progress Amber RUN TEST Run Test in Progress Magenta RUN TEST Run Test in Progress ColorMix Blue Amber Magenta test RUN TEST Run Test in Progress Diffusn Diffusion Test RUN TEST Run Test in Progress Rot Gobo Rotating Gobo Test RUN TEST Run Test in Progress Edge RUN TEST Run Test in Progress Zoom RUN TEST Run Test in Progress Beam If Beam Size Iris Accessory RUN TEST Run Test in Progress Shutter...

Page 38: ...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 Figure 2 1 Removing In...

Page 39: ...mly install in socket Step 7 Close base and bail clamps locking into place 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 24 Lamp Bail Clamps Base Clamps Socket Flip bail clamps outward Flip base clamps outward Install lamp firmly pre...

Page 40: ...on 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 Figure 2 3 Removing Arc Backcap 10 32x2 3 8 PPSS Black Screws captive Backcap Rear Head CAUTION Do...

Page 41: ...2 4 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 24 Lamp Socket Install lamp firmly pressing into place CAUTION Do not touch lamp with bare fingers ...

Page 42: ...te 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 bes...

Page 43: ...nch 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 Figure 2 6 Installing a Frame or Top Hat Accessory Frame Head Assembly Latch Press Up and Turn The accessory...

Page 44: ...n 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 Figure 2 7 Front Cover Removal Replacement Front Cover Head Assembly Press in to Latch x2 Yoke not sho...

Page 45: ...ead 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 Figure 2 8 Rear Head Assembly Remova...

Page 46: ...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 Ste...

Page 47: ...is 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 Inside Edge ThisEdgeIn LampSide Lamp Side mirrored orient toward luminaire lamp black side Center of Wheel Gobo Positions Gobo Wheel Front View orient toward center of wheel Be careful not to pull metal spring clip carrie...

Page 48: ...sions 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 ...

Page 49: ...o 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 Figure 2 11 Aligning Second Clock Mark Index Timing Belt gray for clarity 4 40x1 4 PPZ screw Flat Black Washer Teflon Washer Wheel Position Gear Index Gear Wheel Position Bel...

Page 50: ...r Refer to Front Cover Removal on page 26 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 ...

Page 51: ...y 2009 33 Gobo Wheel Bulkhead Replacement contin ued Figure 2 12 Gobo Bulkhead Assembly Replacement Gobo Bulkhead Front Assembly 10 32x3 8 PPB Screw 10 Split Lock Washers Incandescent model gobo NOTE bulkhead not shown Side Rail Spacer ...

Page 52: ...ame 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 alignm...

Page 53: ...6 Alignment Mark 1 Start with center gear alignment mark facing Position 1 open 2 Rotate center gear clockwise until alignment mark is directly across from Position 6 Rotate Position 6 gear until marks align Align both marks 6 5 3 Align remaining gobo gears using the same method 4 Verify alignment of all marks and adjust as necessary ...

Page 54: ...rce 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 32 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 Figure 2 14 R...

Page 55: ...crews 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 Figure 2 15 Shutter Assembly Replacement Head Assembly Shutter Assembly 10 32x3 8 PPB Screw 10 Split Lock Washers Yoke not shown for clarity NOTE Gobo Wheel Bulkhead Side Rail Spacer 10 32x5 8 PPB Screw...

Page 56: ...ly Refer to Shutter Assembly Replacement on page 36 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 Figure 2 16 Shutter Assembly Breakdown 6 32x1 4 PFS Screw Shutter Layer 1 Layer 2 Layer 3 Layer 4 Separator Spacer Cover Rack x8 6 32x1 4 PFS Screw Spacer Spacer Spacer Separator Stiff Separator Separator Stiff Separator ...

Page 57: ... 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 Figure 2 17 Shutter Assembly Layer Orientation Shutter Blade Rack Rack Layer 1 Layer 2 Layer 3 Layer 4 Align main edge of blade with small hole in shutter rack Install shutter blades with dark mirror coating facing down DO ...

Page 58: ...rom power source Step 2 Remove front cover Refer to Front Cover Removal on page 26 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 Figure 2 18 Edge Zoom Color Bulkhead Replacement 8 32x1...

Page 59: ... 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 40 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 Figure 2 19 Fan Temp Switch Asse...

Page 60: ...input cable from power source Step 2 Remove front cover Refer to Front Cover Removal on page 26 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 Figure 2 20 Beam Size Iris Assembly Replacement Head Assem...

Page 61: ... from power source Step 2 Remove yoke leg cover side without menu display by removing four 6 32x3 8 PTB screws as shown in Figure 2 21 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 Figure 2 21 Ignitor PCB Replacement 6 32x1 2 PPB Screw 6 32x3 8 PPB Screw Ignitor PCB 6 3...

Page 62: ...screws as shown in Figure 2 23 Step 3 At power supply disconnect all connectors Step 4 Loosen two 4 40x1 2 PPZ screws and remove one 4 40x1 2 PPZ screw Remove power supply Step 5 Replace LVS Reconnect all cables as follows Figure 2 22 VL1000 Low Voltage Supply LVS LVS 25 9663 2826 will connect to ACN and ACL as indicated Black Wire AC Line or ACL Green Yellow Wire Ground To Dimmer Module Red Wire ...

Page 63: ...placement continued Figure 2 23 Power Supply Replacement 4 40x1 2 PPZ Screws 6 32x3 8 PTB Screws Yoke Leg Cover Head not shown for clarity NOTE 10 32x1 2 PPB Screw Crossmember Assembly 6 32x3 8 PPB Screw can only be accessed by removing crossmember Power Supply ...

Page 64: ...ke leg cover side with menu display by removing four 6 32x3 8 PTB screws as shown in Figure 2 24 Step 3 Remove display overlay and plate by removing three 6 32x1 2 PPB screws Step 4 At controller PCB disconnect wiring at connectors marked a 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...

Page 65: ...ay 2009 47 Controller PCB Replacement continued Figure 2 24 Controller PCB Replacement Yoke Leg Cover 6 32x1 2 PPB Screw Display Plate Display Overlay Controller PCB 6 32x3 8 PPB Screw Head not shown for clarity NOTE 6 32x3 8 PTB Screw ...

Page 66: ...p 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke leg cover side with menu display by removing four 6 32x3 8 PTB screws Step 3 As shown in Figure 2 25 at tilt encoder PCB remove two 4 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 Figure 2 25 Tilt Encoder PCB Replacement 4 32 ...

Page 67: ...B 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 assemb...

Page 68: ...or Assembly Replacement continued Figure 2 26 Tilt Motor Assembly Replacement Yoke Leg Cover 6 32x1 2 PPB Screw Controller PCB 6 32x3 8 PPB Screw 6 Flat Washer Tilt Motor Assembly Spring 6 32x1 PPB Screw Display Overlay Display Plate 6 32x3 8 PTB Screws Head not shown for clarity NOTE ...

Page 69: ...ure 2 27 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 com...

Page 70: ... Replacement continued Figure 2 27 Pan Motor Assembly Replacement 6 32x3 8 Yoke Leg Cover PTB Screws Pan Motor Assembly Timing Belt Crossmember Assembly Pan Wire Shield 6 32x1 6 Flat Nut Plate 4 40x3 8 PPZ Screw Washer PPB Screw Spring 10 32x1 2 PPB Screw Head not shown for clarity NOTE ...

Page 71: ...ect luminaire AC input cable from power source Step 2 At pan tube cover remove four 8 32x3 8 PFZ screws and remove cover Figure 2 28 Step 3 Remove four 4x3 8 HiLo screws Step 4 Disconnect DMX input PCB wiring and remove PCB Step 5 Replace DMX input PCB by doing steps 2 through 4 in reverse Figure 2 28 DMX Input PCB Replacement 4x3 8 HiLo Screw 8 32x3 8 PFZ Screw Pan Tube Cover DMX Input PCB ...

Page 72: ...Filters WARNING Remove power from luminaire before performing maintenance The front lens color filters and gobos may require cleaning after extended use Isopropyl Alcohol should only be used with a soft lint free cloth to clean these components To access gobos refer to Rotating Gobo Replacement on page 28 ...

Page 73: ...identify parts specific to certain models ABBREVIATION MODEL TI VL1000 Incandescent Luminaire w Beam Size Iris TS VL1000 Incandescent Luminaire w Shutter System AI VL1000 Arc Luminaire with Beam Size Iris AS VL1000 Arc Luminaire with Shutter System TSD VL000 Incandescent with 115V Dimmer and Shutter System TID VL000 Incandescent with 115V Dimmer and Beam Size Iris TSE VL000 Incandescent with 240V ...

Page 74: ...ter 6 Rollers Assembly 21 9663 1350 Rev B new Beam Size Iris Assembly 21 9663 1400 Rev E Fan Assembly 23 9663 2009 Rev C Inner Crossmember Assembly 21 9663 1812 Rev D Pan Motor Assembly 21 9663 1815 Rev D Pan Tube Assembly 21 9663 1819 01 TS TI Rev P Pan EOT Cable Assembly 25 9663 2001 Rev A Lens 7 Assembly 21 9663 1770 Rev 0 Rear Head Assembly 21 9663 1002 01 Rev P TS TI continued next page Edge ...

Page 75: ...1 9663 1819 01 TS TI Rev P continued from previous page DMX Input PCB Assembly 24 9663 3895 Rev 0 Tilt Motor Assembly 21 9663 1816 Rev D LVS Chassis Ground Cable Assembly 25 9663 2817 Rev B Tilt COT Cable Assembly 25 9663 2002 Rev A LVS DC Output Cable Assembly 25 9663 2824 Rev A Pan Tilt Control Cable Assembly 25 9663 2020 Rev B continued from previous page AC Line Input Cable Assembly 25 9663 20...

Page 76: ...Crossmember Assembly 21 9663 1812 Rev D Pan Motor Assembly 21 9663 1815 Rev D Pan Tube Assembly 21 9663 1819 11 AS AI Rev P Pan EOT Cable Assembly 25 9663 2001 Rev A Yoke to Head Ground Cable Assembly 25 9663 2019 Rev B Lens 7 Assembly 21 9663 1770 Rev 0 Rear Head Assembly 21 9663 1002 11 Rev P AS AI continued next page Edge Barrel Assembly 21 9663 1710 Rev C Cover Plate Assembly 21 9663 1534 Rev ...

Page 77: ... Assembly 21 9663 1816 Rev D Tilt COT Cable Assembly 25 9663 2002 Rev A LVS DC Output Cable Assembly 25 9663 2824 Rev A Pan Tilt Control Cable Assembly 25 9663 2020 Rev B continued from previous page AC Line Input Cable Assembly 25 9663 2015 01 Rev C Arc LVS AC Input Cable Assembly 25 9663 2816 11 Rev B Data I O Link Cable Assembly 25 9663 2022 Rev B Arc Power Input Pigtail Cable Assembly 25 9663 ...

Page 78: ...3 0032 1 EA SHIPPING BOX CARDBOARD VL1000 changed 03 05 04 6 08 1000 0001 1 EA CD ROM VL1000 PRODUCT DOCUMENTATION 7 52 6541 0001 1 EA CONN BLUE CABLE PWR INLET 3 POLE LOCKING POWERCON 52 6541 0002 1 EA CONN WHITE CABLE PWR INLET 240V W INTG DIMMER ONLY NOT SHOWN 8 53 6505 0027 1 EA BOLT 1 2 X 13 X 1 LG HX HD ZINC AS AI ONLY 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB NOT SHOWN 9 55 6539 0001 1 EA WASH...

Page 79: ...ED PARTS BREAKDOWN 3 02 9663 0010 F 14 May 2009 61 Included Items Kit continued Figure 3 5 Included Items 6 5 4 1 2 3 7 8 Arc Models Only Arc Ballast Arc Models Only VL1000 Luminaire page 64 9 Arc Models Only 10 ...

Page 80: ... 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 7 04 9663 1881 2 EA LABEL AC INPUT RATING LABEL MODEL VL1000TXD 04 9663 1882 2 EA LABEL AC INPUT RATING LABEL MODEL VL1000TSD 04 9663 1883 2 EA LABEL AC INPUT RATING LABEL MODEL VL1000TID 04 9663 1884 2 EA LABEL AC INPUT RATING LABEL MODEL ...

Page 81: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9663 0010 F 14 May 2009 63 Label Locations continued Figure 3 6 Label Locations 6 7 5 2 4 3 8 1 7 ...

Page 82: ... HEAD W IRIS TI TID TIE ONLY 21 9663 1000 12 1 EA ASSY HEAD ARC W SHUTTER AS ONLY 21 9663 1000 13 1 EA ASSY HEAD ARC W IRIS AI ONLY 9 21 9663 1811 01 1 EA ASSY CROSSMEMBER TI TS ONLY 21 9663 1811 11 1 EA ASSY CROSSMEMBER AI AS ONLY 21 9663 1811 21 1 EA ASSY CROSSMEMBER 115V DIMMER TSD TID ONLY 21 9663 1811 31 1 EA ASSY CROSSMEMBER 230V DIMMER TSE TIE ONLY 10 21 9663 1845 1 EA ASSY COT FLAG 11 21 9...

Page 83: ...EW 3 8 16 X 1 2 LG SOC HD CAP ALLY STL 20 53 6642 0001 3 EA SCREW 10 32 X 5 8 SLF TAP TYPE F PPZ 21 54 1255 0001 2 EA BEARING ASSY BLACK FLUSH MOUNT HOUSING 22 54 2047 0039 1 EA BELT TIMING GT 3MM PITCH 350GRV 6MM WD NEOPRENE 23 55 2115 0001 4 EA WASHER 3 8 X 04 THK HEX JAM 24 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB 25 21 9663 1901 1 EA BALLAST ASSEMBLY AI AS ONLY 25 9663 1907 1 EA CABLE ASSY 575W ...

Page 84: ...ICE MANUAL 66 14 May 2009 02 9663 0010 F VL1000 Luminaire continued Figure 3 7 VL1000 Luminaire 1 2 3 4 5 6 8 9 10 11 12 13 14 x4 23 x4 15 x3 24 x4 18 x12 19 x4 22 17 x3 24 x4 21 21 20 x3 16 x4 7 Dimmer TSD TID TSE TIE Only 25 AI AS only ...

Page 85: ...Figure 3 8 Figure 3 8 Front Cover Assembly 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 0002 4 EA NUT 8 32 KEPS ZINC PLATE changed 09 02 03 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 2 4 x3 3 x4 5 ...

Page 86: ... 1028 Rev A Refer to Figure 3 9 Figure 3 9 Gel Frame Holder Assembly 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 2 4 3 1 ...

Page 87: ...Center of Travel Flag Assembly 21 9663 1845 Rev 0 Refer to Figure 3 10 Figure 3 10 COT Flag Assembly No Item Qty UM Description 1 10 9663 1824 1 EA SPACER TILT TUBE 2 10 9663 1826 1 EA FLAG CENTER OF TRAVEL TILT 3 53 6602 0001 3 EA SCREW 4 40 X 1 4 PPZ TYPE F 1 2 3 ...

Page 88: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 70 14 May 2009 02 9663 0010 F Notes ...

Page 89: ... 10 9663 1032 2 EA SPACER SIDE RAIL TS ONLY 4 EA SPACER SIDE RAIL AS ONLY 2 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 12 1 EA ASSY FRONT HEAD AS ONLY 21 9663 1001 13 1 EA ASSY FRONT HEAD AI ONLY 3 21 9663 1002 01 1 EA ASSY REAR HEAD TS ONLY 21 9663 1002 11 1 EA ASSY REAR HEAD AS ONLY 4 53 6627 0001 4 EA SCREW 10 32 X 5 8 PPB 5 55 3303 00...

Page 90: ...3 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 TS ONLY 21 9663 1600 1 EA ASSY GOBO DIMMER BULKHEAD ARC AS ONLY 6 21 9663 1350 1 EA ASSY SHUTTER 6 ROLLERS TS AS ONLY NEW VERSION 7 21 9663 1400 1 EA ASSY IRIS TI AI ONLY 8 53 6552 0002 4 EA SCREW 8 32 X 1 2 PFB 9 53 2004 0002 4 EA NUT 8 32 KEPS ZINC PLATE 10 53 6627 0001 12 E...

Page 91: ...9 73 Front Head Assembly continued Figure 3 12 Front Head Assembly 4 Either C or D 6 2 3 5 5 12 x4 12 x4 10 x4 12 x4 10 x4 10 x4 Either A or B 9 x4 8 x4 1 10 x4 12 x4 A Models w Shutter B Models w Iris 10 x4 12 x4 7 C Incandescent Models D Arc Models 11 x3 ...

Page 92: ...1 21 9663 1770 1 EA ASSY LENS 7 12 21 9663 1780 1 EA ASSY LENS 8 13 23 9663 2009 1 EA ASSY FAN 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 55 5559 0250 2 EA SCREW 6 32 X 1 4 SET CONE added 08 28 03 19 53 5604 0437 2 EA SCREW 4 40 X 7 16 LG PPSS B...

Page 93: ...2 9663 0010 F 14 May 2009 75 Edge Control Dimmer Color Assembly con tinued Figure 3 13 Edge Control Dimmer Color Assembly 1 2 x3 3 x6 4 5 6 7 8 9 10 11 12 13 14 15 x2 16 x4 17 x6 19 20 x3 21 x2 22 x2 23 24 x2 25 x3 26 x3 20 x4 18 x2 ...

Page 94: ...RIVE RING LOCATOR MACHINED 12 10 9663 1514 3 EA COLOR SPACER 2 13 10 9663 1515 1 EA DIFFUSER SPACER 1 14 10 9663 1516 1 EA DIFFUSER SPACER 2 15 10 9663 1518 4 EA COLOR MOTOR MOUNT CLIP 16 10 9663 1521 1 EA COLOR COVER PLATE LINER SHEET 17 10 9663 1522 1 EA DIFFUSER COVER PLATE LINER SHEET 18 10 9663 1532 2 EA RING SPACER 19 10 9663 1755 3 EA ROLLER BARREL 20 10 9663 1767 1 EA ZOOM TEFLON SPACER 21...

Page 95: ...200 0004 8 EA NUT 4 40 KEPS SS 31 53 5636 0375 3 EA SCREW 6 32 X 3 8 PFSS BLACK 32 53 6556 0001 8 EA SCREW 4 40 X 3 4 LG PPZ 33 55 6588 0003 3 EA SPACER 1 4 RND 6 THRU 1 8 LG 140 ID ZINC PLT BRS 34 10 9663 1537 1 EA DRIVE RING LOCATOR BEARING No Item Qty UM Description ...

Page 96: ...8 14 May 2009 02 9663 0010 F Color Changer Assembly continued Figure 3 14 Color Changer Assembly 24 x2 5 9 7 11 13 14 23 16 17 19 x3 20 21 28 27 x2 25 x2 7 10 12 30 x8 32 x8 33 x3 15 x4 22 x4 31 x4 10 10 5 6 8 5 12 5 12 26 x2 29 x4 4 1 2 3 18 18 34 ...

Page 97: ...ly 21 9663 1534 Rev 0 Refer to Figure 3 15 Figure 3 15 Cover Plate Assembly 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 3 2 1 4 x4 ...

Page 98: ... INNER LENS EDGE SYSTEM 4 10 9663 1737 1 EA EDGE LIGHT BAFFLE 5 21 9663 1722 1 EA ASSY EDGE MOTOR 6 42 9663 1728 1 EA LENS 1 7 42 9663 1731 1 EA LENS 4 8 42 9663 1732 1 EA LENS 5 9 42 9663 1736 1 EA ASSY LENS 2 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 WA...

Page 99: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9663 0010 F 14 May 2009 81 Barrel Assembly continued Figure 3 16 Edge Barrel Assembly 1 x2 2 4 5 6 8 7 9 10 x4 12 x2 13 15 3 x2 11 x4 14 12 12 ...

Page 100: ...VICE MANUAL 82 14 May 2009 02 9663 0010 F Lens 6 Assembly 21 9663 1760 Rev 0 Refer to Figure 3 17 Figure 3 17 Lens 6 Assembly 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 1 2 ...

Page 101: ...DOWN 3 02 9663 0010 F 14 May 2009 83 Lens 7 Assembly 21 9663 1770 Rev 0 Refer to Figure 3 18 Figure 3 18 Lens 7 Assembly No Item Qty UM Description 1 10 9663 1771 1 EA LENS CARRIER MOLDED LENS 7 2 42 9663 1734 1 EA LENS 7 1 2 ...

Page 102: ...Rev B Refer to Figure 3 19 Figure 3 19 Lens 8 Assembly No Item Qty UM Description 1 10 9663 1782 1 EA RING RETAINING FRONT LENS 2 10 9663 1781 1 EA BULKHEAD FRONT LENS 8 ASSY 3 42 9663 1735 1 EA LENS 8 4 53 2202 0004 6 EA NUT 4 40 HEX SS NYLON INSERT 5 53 6559 0001 6 EA SCREW 4 40 X 1 4 PFZ 1 2 3 4 x6 5 x6 ...

Page 103: ...r to Figure 3 20 Figure 3 20 Fan Assembly 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 BLK MOLEX SL 2F PIN 2 PIN 1 RED RED 6 0 BLK 6 0 FAN CONNECTOR 1 2 3 x2 ...

Page 104: ...il Assembly 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 THREAD LOCKING SS 4 53 5636 0500 1 EA SCREW 6 32 X 1 2 PFSS BLACK 5 53 6530 0009 2 EA RIVET 1 8 OD POP 126 187GL STL BODY STL MNDRL DOME 6 55 2178 0002 1 EA CABLE ANCHOR MOUNT 10 SCREW MOUNTING 5 x2 1 6 3 4 2 ...

Page 105: ...e 3 22 Sensor Side Rail Assembly 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 THREAD LOCKING SS 4 53 5636 0625 1 EA SCREW 6 32 X 5 8 PFSS BLACK 5 53 6530 0009 2 EA RIVET 1 8 OD POP 126 187GL STL BODY STL MNDRL DOME 5 x2 1 3 4 2 ...

Page 106: ...24 9663 3231 1 EA PCB ASSY INDEX SENSOR 14 44 9663 1202 2 EA MOTOR 17 2 42 SHAFT 11 8MH 5 5 OHM 15 53 2003 0001 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...

Page 107: ...1 EA WASHER 4 3 8 OD FLAT ZINC changed 07 18 03 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...

Page 108: ...eel Assy continued Figure 3 23 Incandescent Gobo Wheel Assembly 37 34 x2 2 36 26 x2 39 x2 4 x2 38 x2 18 x4 14 x2 15 x2 11 17 39 40 9 10 24 x4 25 x2 23 x2 1 25 15 12 19 x2 27 7 6 This componet blanked in Exploded View for clarity 21 5 x2 29 x2 30 35 13 8 x2 11 20 28 33 42 3 31 32 22 39 x2 16 x4 41 ...

Page 109: ... 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 25 9663 0390 1 EA WIRE ASSEMBLY JUMPER THERMOSTAT NOT SHOWN RED BLK RED RED 15 0 1 0 1 ...

Page 110: ... EA BEARING RADIAL 251 ID X 625 OD NOT SHOWN 55 6506 0029 1 EA SPACER 9 32 RND X 250 LG X 253 ID THRU AL NOT SHOWN 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 W...

Page 111: ... 265 ID X 367 OD 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 0003 1 EA WASHER 4 3 8 OD FLAT ZINC changed 07 18 03 47 55 6659 0007 2 EA STANDO...

Page 112: ...d Figure 3 25 Arc Gobo Dimmer Bulkhead Assembly 12 x2 14 x2 15 x2 30 x18 13 x2 34 x2 21 24 52 51 25 27 x6 22 x3 35 x2 51 x2 7 x2 50 x2 10 18 33 x7 39 37 2 5 17 11 9 26 x2 38 1 26 x2 1 23 3 16 36 x2 47 x2 42 x2 34 20 19 31 6 x2 29 28 x2 51 x2 40 x2 46 41 44 x2 42 26 x2 8 x2 26 x2 26 x2 4 32 43 49 45 x2 48 53 54 ...

Page 113: ... 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 53 6534 0001 2 EA RIVET 3 32 OD 3 32 GRIP RANGE ALUM 11 53 6598 0312 3 EA SCREW 4 40 X 5 16 PFB 12 55 6504 0004 3 EA WA...

Page 114: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 96 14 May 2009 02 9663 0010 F Gobo Wheel Assembly continued Figure 3 26 Gobo Wheel Assembly 2 3 6 7 9 5 x5 5 x5 4 x5 10 x2 8 x5 1 x5 12 x3 11 x3 ...

Page 115: ...SHUTTER 6 ROLLERS 14 12 9663 1323 2 EA BLADE SHUTTER COATED SIDE A 15 12 9663 1324 2 EA BLADE SHUTTER COATED SIDE B 25 9663 2040 1 EA CABLE ASSY BEAM SHAPER HARNESS NOT SHOWN 16 44 9663 1326 1 EA MOTOR 17 53 SHAFT 11 8MH 5 5 OHM 17 44 9663 1351 8 EA ASSY SHUTTER MOTOR changed 05 22 03 18 53 2200 0006 1 EA NUT 6 32 KEPS SS 19 53 2202 0004 4 EA NUT 4 40 HEX SS NYLON INSERT 20 53 2202 0006 2 EA NUT 6...

Page 116: ...LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 98 14 May 2009 02 9663 0010 F 29 55 6621 0001 4 EA WASHER 4 FLAT ZINC 30 55 6697 0020 2 EA STANDOFF 3 16 RND 4 40 375 LG ZINC PLATED STEEL No Item Qty UM Description ...

Page 117: ...r Assembly continued Figure 3 27 Shutter 6 Rollers Assembly 13 2 24 x2 1 16 1 15 14 14 15 22 x6 6 x6 23 x4 17 x8 4 x8 11 11 11 20 x2 8 29 x4 19 x4 9 17 x8 4B 1A 1B 2A 2B 3A 3B 4A 21 x4 5 26 27 30 x2 25 x2 18 3 x8 Shutter Motors 10 10 Detail A Detail A 10 10 7 12 28 x4 ...

Page 118: ... 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 SPRIN...

Page 119: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9663 0010 F 14 May 2009 101 Beam Size Iris Assembly continued Figure 3 28 Beam Size Iris Assembly 1 2 3 4 5 7 x3 8 x2 9 10 x2 11 6 3 263 Detail A Detail A ...

Page 120: ...ACK CAP TS TI ONLY 21 9663 1127 11 1 EA ASSY BACK CAP AS AI ONLY 25 9663 2033 REF EA CABLE ASSY LAMP POWER INCANDESCENT TS TI ONLY NOT SHOWN 25 9663 2036 REF EA CABLE ASSY IGNITOR TO LAMP SOCKET AS AI ONLY NOT SHOWN 7 42 9663 7237 1 EA REFLECTOR 48 LUNE TS TI ONLY 42 9663 7118 1 EA REFLECTOR 8 10 14 DEGREE LUNES FACETED AS AI ONLY 8 53 2002 0001 3 EA NUT 6 32 KEP ZINC PLATED 9 53 6522 0005 4 EA SC...

Page 121: ... 3 29 Rear Head Assembly 1 x3 2 3 x2 4 5 7 8 x3 12 9 x4 11 x3 14 10 x4 13 6 Alignment Reference Point 10 x4 Reflector Orientation Note When installing reflector align dimple in reflector flange item 7 with reflector mount item 2 as shown for all models Bulkhead assembly item 5 removed for clarity ...

Page 122: ... EA KNOB LAMP ADJUST MODLED added 11 19 03 6 53 2030 0001 3 EA NUT ACORN 10 32 THD 3 8 W BLK ZINC added 11 19 03 7 53 5711 2500 2 EA SCREW 10 32 X 2 1 2 Phillips Truss Head SS Black changed 10 31 02 8 53 6539 0011 3 EA SCREW 10 32 X 2 1 4 PFBSS UNF 2A 9 55 6546 0004 3 EA WASHER TEFLON 201 ID 438 OD X 04 THK added 11 19 03 10 53 6575 0001 2 EA SCREW 8 32 X 1 0 PPZ 11 53 6575 0005 2 EA SCREW 8 32 X ...

Page 123: ...0010 F 14 May 2009 105 Back Cap Assembly continued Figure 3 30 Back Cap Assembly 1 x2 TS TI ONLY 2 3 x2 TS TI ONLY 4 11 x2 TS TI ONLY 7 x2 8 x3 10 x2 13 TS TI ONLY 6 x3 9 x3 14 5 x3 TS TI ONLY Incandescent Models AS AI ONLY Arc Models 12 x3 ...

Page 124: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 106 14 May 2009 02 9663 0010 F Notes ...

Page 125: ...OWN 25 9663 2020 1 EA CABLE ASSY PAN TILT CONTROL NOT SHOWN 25 9663 2026 1 EA CABLE ASSY DIMMER TO CNTRLR NOT SHOWN DIM ONLY 25 9663 2037 1 EA CABLE ASSY DIMMER TO LAMP SCKT NOT SHOWN DIM ONLY 25 9663 2817 1 EA CABLE ASSY LVS CHASSIS GROUND NOT SHOWN TS TI ONLY 25 9663 2824 1 EA CABLE ASSY LVS DC OUTPUT NOT SHOWN 25 9663 2826 1 EA CABLE ASSY DIMMER TO LVS NOT SHOWN DIM ONLY 9 53 2019 0004 2 EA NUT...

Page 126: ...RE DIA MUSIC WIRE 23 55 6597 0003 4 EA CLIP CABLE SELF RETAINING 1 8 THK PANEL 24 67 4006 0006 1 EA CLAMP CABLE EMI SUP FERRITE 0 52 0 61 LG 25 69 3173 0115 1 EA DIMMER 1200W 115V REV PHASE CNTRL TSD TID ONLY 69 3173 0240 1 EA DIMMER 1200W 240V REV PHASE CNTRL TSE TIE ONLY 26 69 3177 0151 1 EA POWER SUPPLY 150W 24V 6 3A changed 08 28 03 No Item Qty UM Description VL1000 TS TI Units VL1000 AS AI Un...

Page 127: ...ay 2009 109 Yoke Legs Assembly continued Figure 3 31 Yoke Legs Assembly 2 x2 3 x2 5 6 7 8 9 x2 13 x3 10 x2 11 x4 14 x4 17 x7 18 x2 20 x4 23 x4 22 26 11 x4 11 x6 15 x2 AS AI only 16 x4 AS AI only 21 x3 19 x3 24 AS AI only 12 x4 DIM Only 25 DIM Only 4 1 ...

Page 128: ...3 1810 1 EA PULLEY DRIVING PAN TILT 10 9663 8820 1 EA CODEWHEEL 53 5561 0250 2 EA SCREW 6 40 X 1 4 SET CONE POINT 3 24 9661 9629 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...

Page 129: ...rip into motor bearing Step 4 Set pulley height as shown above Step 5 Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Pulley Height Detail Installation Note Vari Lite recommends that this assembly be replaced as a complete assembly Although you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly a...

Page 130: ...11 1 EA ASSY PAN TUBE AS AI ONLY 21 9663 1819 21 1 EA ASSY PAN TUBE 115V DIMMER added 08 25 03 21 9663 1819 31 1 EA ASSY PAN TUBE 240V DIMMER added 08 25 03 12 24 9663 3230 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 ZIN...

Page 131: ...gure 3 33 Crossmember Assembly 26 55 6799 0001 1 EA SHIM 1 375 ID 1 875 OD 0 010 THK 27 55 6799 0002 1 EA SHIM 1 375 ID 1 875 OD 0 005 THK No Item Qty UM Description 20 14 15 2 1 13 17 x4 19 x4 5 21 23 x4 25 7 10 9 8 4 x2 18 x14 11 12 22 x2 24 x3 20 20 3 16 6 27 26 ...

Page 132: ...rossmember Inner Assembly No Item Qty UM Description 1 10 9663 1805 1 EA CROSSMEMBER INNER 2 10 9678 0886 1 EA SPACER PAN BEARING 235 THK 3 53 2019 0001 2 EA NUT 3 8 16 HEX 4 53 6505 0022 2 EA BOLT 3 8 16 X 3 4 LG CARRIAGE GRD5 ZINC PLT 5 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 6 54 1255 0002 1 EA BEARING ASSY FLUSH MOUNT HOUSING LARGE 1 3 x2 4 x2 5 x2 6 2 ...

Page 133: ...M Description 1 10 9663 1897 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 2 4 5 1 3 x2 6 x2 7 ...

Page 134: ...3 1810 1 EA PULLEY DRIVING PAN TILT 10 9663 8820 1 EA CODEWHEEL 53 5561 0250 2 EA SCREW 6 40 X 1 4 SET CONE POINT 3 24 9661 9629 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...

Page 135: ...d intact If you order a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information 0 226 2 1 3 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...

Page 136: ... ASSY DATA I O LINK NOT SHOWN 6 25 9663 2030 1 EA CABLE ASSY STRAIN RELIEF TS TI ONLY 25 9663 2033 1 EA CABLE ASSY LAMP PWR INC TS TI ONLY NOT SHOWN 25 9663 2035 1 EA CABLE ASSY ARC PWR TO IGNITOR AS AI ONLY NOT SHOWN 7 52 8295 0002 2 EA TERMINAL STRIP 300V 12AWG 20A 2 POS AS AI ONLY 52 8295 0002 1 EA TERMINAL STRIP 300V 12AWG 20A 2 POS TS TI ONLY 8 52 8295 1002 1 EA SPACER TERMINAL STRIP 600V 2 P...

Page 137: ...9663 0010 F 14 May 2009 119 Pan Tube Assembly continued Figure 3 37 Pan Tube Assembly 2 4 A AS only 13 11 x2 8 14 x2 16 On Board IGBT Dimmer Models Only 10 x4 5 3 12 x4 7 18 A AS only 17 AS AI only 7 15 AS AI only 1 or 6 T TS only 9 x2 ...

Page 138: ...re 3 38 Figure 3 38 DMX Input PCB Assembly No Item Qty UM Description Ref 1 11 9663 1830 1 EA PCB FAB DMX INPUT 2 52 6259 0006 1 EA HEADER 5POS MTA FRCT LOK STRT J3 3 52 6625 0006 1 EA CONN RECEPT XLR 5PIN FEMALE J1 4 52 6626 0006 1 EA CONN RECEPT XLR 5PIN MALE J2 5 62 3039 0102 1 EA CAP 1000PF 250V RAD CER DISC 20 X Y C1 1 2 3 4 5 ...

Page 139: ...ING 4POS PLUG SHROUDED WIRE TO WIRE 5 52 8210 0002 4 EA SOCKET GOLD 24 20AWG TYPE3 0 080 0 100 INS DIA 6 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 7 52 8298 1146 2 EA FERRULE WIRE 1X14 AWG L2 8MM BLUE 8 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 9 52 8342 0001 3 EA SOCKET GOLD 18 14AWG TYPE 3 REEL 0 11 0 15 INS DIA 10 52 8344 0003 2 EA SOCKET CPC POWER 14AWG 13A LOOSE 11 52 ...

Page 140: ...4 0 4 0 ORN VIO 4 0 4 0 BLK 8 0 WHT 8 0 0 5 1 2 3 4 11 x4 6 7 13 14 8 5 x4 9 x3 10 x2 12 CPC 17 9 PLUG SHIELDED TWISTED WIRE CABLE JACKET MOLEX SL 4M 4 0 AC GND LAMP HI LAMP LO AC LINE DRAIN AC NEUT PWR LVL DATA GND NOT ON ORN GRN YEL VIO 6 8 9 7 5 3 4 1 2 RED BLK WHT WHT SHIELD BLK SHIELD WHT RED BLK GRN YEL VIO ORN DRAIN PWR LVL DATA GND NOT ON BLK WHT CHASSIS GND LAMP HI LAMP LO AC LINE AC NEUT...

Page 141: ...y UM Description 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 2 1 WHT BLK 6 4 5 RED 1 BLK WHT RED 2 3 13 0 1 2 3 4 5 ...

Page 142: ...ty UM Description 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 33 0 1 2 3 4 5 3 BLK RED WHT 2 1 5 BLK 2 1 RED 4 3 WHT 6 Indicates Pin 1 ...

Page 143: ...e Input Cable Assembly No Item Qty UM Description 1 52 6541 0003 1 EA CONN CHASSIS PWR INLET 3POLE LOCKING 115V 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 52 8331 0003 1 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 5 0 IN N L 1 2 3 4 Housing Blue 115V AC GND GRN YEL ...

Page 144: ...UM Description 1 52 8331 0003 2 EA RECEPT FASTON 187 16 14AWG PIDG BLU 170 ID 2 52 8362 0001 4 EA TERM RING 6 16 14 AWG INS SMALL DIAMETER 3 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 4 73 7089 0000 12 33 FT WIRE 22AWG BLK 300V TEFLON STRANDED 5 73 7089 0009 12 33 FT WIRE 22AWG WHT TEFLON STRANDED 6 73 7089 0504 9 33 FT WIRE 22AWG 300V 200C TEF GRN YEL UL1180 2 0 37 0 2 0 2 0 28 0 2 6 3 x3 4 ...

Page 145: ...iption 1 52 8298 1160 2 EA WIRE FERRULE 1X 16 AWG L2 8MM BLK 2 52 8362 0001 4 EA TERM RING 6 16 14 AWG INS SMALL DIAMETER 3 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 4 73 7089 0000 12 33 FT WIRE 22AWG BLK 300V TEFLON STRANDED 5 73 7089 0009 12 33 FT WIRE 22AWG WHT TEFLON STRANDED 6 73 7089 0504 9 33 FT WIRE 22AWG 300V 200C TEF GRN YEL UL1180 2 0 2 0 37 0 28 0 1 2 3 x3 4 5 6 2 2 AC LINE AC NE...

Page 146: ...ble Assembly 25 9663 2817 Rev B Formaly 25 9663 2017 Rev B Refer to Figure 3 45 Figure 3 45 LVS Chassis Ground Cable Assembly No Item Qty UM Description 1 52 8362 0001 2 EA TERM RING 6 BLUE 16 14 AWG SMALL DIAMETER 2 73 3516 0504 1 0 FT WIRE 16AWG 300V 105C PVC GRN YEL UL1569 changed 09 11 03 1 2 1 ...

Page 147: ... 9663 2018 Rev G Refer to Figure 3 46 Figure 3 46 Head to Backcap Ground Cable Assembly No Item Qty UM Description 1 55 2036 0001 2 EA SLEEVE 1 16 ROPE DIA ALUM OVAL COMPRESSION 2 73 7188 0002 1 92 FT WIRE ROPE 1 16 ROPE DIA 7X7 GALV STEEL changed 11 19 03 1 0 1 0 21 0 1 2 1 Head Ground Backcap Ground ...

Page 148: ... Yoke to Head Ground Cable Assembly 25 9663 2019 Rev B Refer to Figure 3 47 Figure 3 47 Yoke to Head Ground Cable Assembly 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 1 ...

Page 149: ...OT SHOWN 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 ...

Page 150: ... ENCODER_B1 ENCODER_A1 ENCODER_B2 ENCODER_A2 GND GND GND TILT_COT_SENS PAN_COT_SENS GND VCC 10 N C N C BRN BRN 20 19 17 18 BLK BLK GRY GRY WHT WHT 15 16 14 11 13 12 4 RED RED BLK RED ORN BRN 7 8 9 6 5 RED BLK ORN BRN 1 2 3 M1 PAN MOTOR M2 TILT MOTOR 9 10 12 14 16 20 0 8 0 GND VCC VOA SENSE VOB MOLEX SL F 5 PAN ENCODER PCB 24 9661 0629 WHT BRN 1 2 RED BLK GRY 4 3 5 RED ORN BLK BRN NC 2 PAN MOTOR JS...

Page 151: ... 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 DATA GND PIGTAIL DATA CONNECTOR GRN WHT BLK RED FROM ARC POWER INPUT NOT ON DRAIN PWR LVL TO MAIN CONTROL PCB J7 NOT ON GND PWR LVL GND ...

Page 152: ... Item Qty UM Description 1 53 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 WHT GRN RED BLK N C CONTROLLER J1 PCB 4 5 MAIN 2 3 1 N C GRN BLK WHT RED J3 PCB DMX INPUT 5 4 3 2 1 1 2 GREEN WHITE 5 4 COM OUT COM OUT BLACK COLOR 3 2 1 PIN RED N C COM IN COM IN SIGNAL DMX REPLY REPLY BDCAST BDCAST SIGNAL 1 ...

Page 153: ...ECEPT MTA156 W TAB ORN 5POS 18AWG CLOSED END 2 52 8362 0001 2 EA TERM RING 6 BLUE 16 14 AWG SMALL DIAMETER 3 55 2186 0001 2 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 RED G LVS DC OUTPUT TO GND 24V V1 BLK BLK RED 24V RED CONTROLLER TO VL1000 PCB J2 5 4 3 2 1 N C BLK BLK RED GND 24V 5V GND 18 0 2 0...

Page 154: ... 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 42 5 44 0 0 6 1 5 0 0 1 0 4 0 4...

Page 155: ...ICE 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 0 FT SLEEVING FIBERGLASS 133 ID 7 55 2260 0294 1 75 FT SLEEVING FIBERGLASS 294 ID 8 73 6616 0011 3 5 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 BL...

Page 156: ...2 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 4X VIO 4X ORN 4X VIO 4X ORN 36 0 32 0 2 0 FROM LAMP POWER TERM BL...

Page 157: ...KCAP GND 2 52 8231 0005 2 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG changed 12 13 02 3 55 2260 0166 5 50 FT SLEEVING FIBERGLASS 166 ID changed 12 13 02 4 55 2260 0294 1 75 FT SLEEVING FIBERGLASS 294 ID changed 12 13 02 5 73 7100 0001 2 17 FT WIRE 16AWG 20KVDC 41 32 STRD 200C SILICONE 6 73 7190 0001 3 5 FT WIRE 250 DEG C 7 52 8274 1614 2 EA CONNECTOR BUTT SPLICE 16 14 PIDG 8 55 2200 0003 33 FT HEAT S...

Page 158: ...40POS 26 22AWG UNLOADED MT RECEPT DBL ROW 52 8351 0004 32 EA CONTACT 26 22 AWG RECP MTE 3 52 6224 1040 1 EA COVER FRONT 40POS MT LATCHING 4 52 6224 2040 1 EA COVER BACK 40POS MT 5 52 6661 0006 8 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25MM PITCH 6 52 8387 0001 32 EA CONTACT 26 28AWG FEMALE CRIMP 1 25MM PITCH REEL 7 55 2186 0001 15 EA CABLE TIE 10 WD 4 00 LG SMALL 8 55 6699 0004 0 5 FT SLEEVING 3 4 NOM ...

Page 159: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9663 0010 F 14 May 2009 141 Shutter Harness Cable Assembly continued Figure 3 57 Shutter Harness Cable Assembly ...

Page 160: ...02 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 ...

Page 161: ...IFF FAN MTR MTR MTR MTR MTR MTR ROT MTR LABEL SET FOR REF ONLY LINE 2 TEXT SNSR SNSR MTR LINE 1 TEXT WHL SHUT WHL P N 03 02 01 INDX INDX AMBR ZOOM BLUE 04 05 08 07 06 DIMM EDGE MAG 09 10 12 11 PIN 1 TO VL1000 CONTROLLER PCB J8 14 FAN2 11 2 3 4 14 x4 10 13 x4 10 13 x4 10 13 x4 1 8 12 x2 17 20 20 18 10 13 x4 17 17 11 14 x4 11 14 x4 9 12 x4 11 14 x4 11 14 x4 11 14 x4 17 19 19 6 7 x3 5 7 x3 15 x12 16 ...

Page 162: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 144 14 May 2009 02 9663 0010 F Color Gobo Lens Cable Assembly continued Figure 3 59 Color Gobo Lens Harness Cable Assembly ...

Page 163: ... to LVS Cable Assembly No Item Qty UM Description 1 52 8313 0001 2 EA RECEPT FASTON 1 4 18 14 AWG FLAG DBL CRIP 2 52 8362 0001 2 EA TERM RING 6 BLUE 16 14 AWG INS SMALL DIAM 3 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 4 73 6016 0009 1 5 FT WIRE 16 AWG 600V 105C PVC WHT UL1015 5 73 6016 0010 1 5 FT WIRE 16 AWG 600V 105C PVC BLK UL1015 3 4 5 1 x2 2 x2 ...

Page 164: ...010 F Dimmer to Controller Cable Assembly 25 9663 2026 Rev 0 Refer to Figure 3 61 Figure 3 61 Dimmer to LVS Cable Assembly No Item Qty UM Description 1 52 6396 2403 2 EA RECEPT 3POS MTA100 W POL TAB 24AWG 2 73 5119 0246 3 50 FT WIRE 24AWG 3COND TW RED YEL BLU UL1213 1 x2 2 ...

Page 165: ... BUTT SPLICE 16 22AWG UNINSULATED 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 0 FT SLEEVING FIBERGLASS 0 133 ID 7 55 2260 0294 1 75 FT SLEEVING FIBERGLASS 0 294 ID 8 73 6616 0011 3 50 FT WIRE 16 AWG 600V 600C MICA TAPE TAN 9 73 7089 0001 6 67 FT WIRE 22 AWG BRN TEFLON STRANDED 10 73 7089 0006 6 67 FT WIRE 22 AWG BLU TEFLON STRAN...

Page 166: ... 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 UL15...

Page 167: ...9 8 5 2 1 4 7 VIO ORN 4 0 MIN 4 5 MIN GRN YEL GRN YEL GRN YEL 3 2 1 4 2 11 x5 14 15 16 17 12 19 20 21 7 x3 9 x2 13 3 4 x3 5 x5 6 1 8 x2 10 18 9POS RECEPT CPC 3 3 3 6 6 24 25 26 25 4 4 TWISTED WIRE 4POS MTA 100 RING TERM RING TERM FERRITE MATE N LOK 3POS FASTON FASTON 8 RING TERM ORN GRN YEL VIO BLK GRN YEL WHT WHT BLK RED GRN YEL RED WHT BLK 1 2 3 4 1 2 3 GRN YEL 9 8 7 6 5 4 3 2 1 ...

Page 168: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 150 14 May 2009 02 9663 0010 F Notes ...

Page 169: ...877 827 4548 or 1 214 647 7880 or customerservice genlytecontrols com Technical Bulletin Description S1K 001 VL1000 Tilt Bearing Hardware Check Modification S1K 002 VL1000 Lamp Wire Sleeving Modification S1K 003A VL1000 Arc Luminaire IR Coated Glass Retrofit S1K 004A VL1000 Incandescent Luminaire IR Coated Glass Retrofit S1K 005 VL1000 Shutter Upgrade S1K 006 VL1000 LVS Upgrade S1K 007 VL1000 Ther...

Page 170: ...VARI LITE VL1000 ERS LUMINAIRE SERVICE MANUAL 152 14 May 2009 02 9663 0010 F Notes ...

Page 171: ......

Page 172: ...1 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 14 May 2009 Manual Part Number 02 9663 0010 F 2003 2009 A Philips Group Company All rights reserved Printed in the U S A ...

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