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VARILITE VL4, Manual

The VARILITE VL4 is a cutting-edge lighting fixture that brings brilliance to any event. To ensure you make the most of this powerful tool, a user manual is available for download, completely free, on our website. Unlock its full potential by accessing the manual at manualshive.com.

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CONFIDENTIAL:  This technical manual is confidential property of Vari-Lite, Inc.

VL4

Wash Luminaire

02.9628.0010

7 Oct 1997

The Automated Lighting

 

Company

Service Manual

Summary of Contents for VL4

Page 1: ...CONFIDENTIAL This technical manual is confidential property of Vari Lite Inc VL4 Wash Luminaire 02 9628 0010 7 Oct 1997 The Automated LightingCompany Service Manual ...

Page 2: ... 673 172 667 109 657 152 652 409 649 264 637 343 618 559 586 095 582 305 580 213 576 400 575 271 571 135 546 433 Australia Design Patent Reg No 127 644 126 781 Canada Patents No 2 076 171 2 075 268 2 070 670 2 065 774 2 050 375 2 006 314 1 293 989 1 292 379 1 284 794 1 276 607 1 270 675 1 259 058 1 181 795 Canada Design Patents Reg No 78 662 75 750 73 695 72 772 Europe Patents No 0 565 218 0 547 7...

Page 3: ... CONFIDENTIAL 7 Oct 97 VL4 Wash Luminaire Service Manual List of Effective Pages Page Change Number Number Title Page thru xiv 0 1 1 thru 1 20 0 2 1 thru 2 12 0 3 1 thru 3 108 0 4 1 thru 4 60 0 5 1 thru 5 24 0 FO 1 thru FO 7 0 Revision History BASIC 07 Oct 1997 ...

Page 4: ...iv VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 This page intentionally blank ...

Page 5: ...tions 1 9 1 3 Photometric Data 1 11 1 4 Location of Major Luminaire Components 1 13 1 4 1 Head Components 1 13 1 4 2 Electronic Chassis Components 1 15 1 5 Principles of Operation 1 17 1 5 1 Operation Overview 1 17 1 5 2 Operation Description 1 17 1 5 2 1 Electronics Components 1 17 1 5 2 2 Bulkhead Assemblies 1 18 1 5 3 Data and Power Flow Diagram 1 19 Chapter 2 Installation and Checkout 2 1 Inst...

Page 6: ...25 3 7 3 1 5 Program Modes Tests 30 Through 39 3 7 3 1 6 Error History Tests 40 and 41 3 7 3 1 7 Thumbwheel Test Program Bug 3 8 3 1 8 Test Setup 3 9 3 1 9 Test Results Charts 3 10 3 2 Luminaire Fault Isolation 3 21 3 2 1 Luminaire Fault Isolation Chart 3 21 3 2 2 Luminaire Fault Isolation Procedures 3 23 3 2 2 1 Luminaire Powers Up But Will Not Calibrate 3 23 3 2 2 2 Luminaire Calibrates But Will...

Page 7: ...3 3 2 Magenta Stepper Motor Removal and Replacement 3 48 3 3 3 3 Filter Sensor Removal and Replacement 3 50 3 3 3 4 Magenta Motor Worm Wheel and Spur Gear Removal and Replacement 3 52 3 3 3 5 Dimmer Belt Removal and Replacement 3 54 3 3 3 6 Dimmer Sub Micro Switch Removal and Replacement 3 55 3 3 3 7 Dimmer Leaves Removal and Replacement 3 56 3 3 3 8 Dimmer Filter Douser Solenoid Assembly Removal ...

Page 8: ...oval and Replacement Shop Only 3 95 3 3 5 11 Input Connector Removal and Replacement 3 97 3 3 5 12 Stuck Truss Hook and Fastener Removal and Replacement 3 100 3 3 6 Yoke Cables Maintenance 3 103 3 3 6 1 Yoke Cables and Lamp Wire Removal and Replacement 3 103 Chapter 4 Illustrated Parts Breakdown 4 1 Drawing Tree 4 3 4 1 1 VL4 Wash Luminaire 4 3 4 2 Parts Breakdown 4 5 4 2 1 Hooks and Covers 4 5 4 ...

Page 9: ... 13 Lamp Control UCB IFB Electrical Assy 4 46 4 2 3 14 Universal Control UCB PCB Assy 4 47 4 2 3 15 Interface IFB PCB Assy 4 50 4 2 3 16 Arc Power Supply 400Watt APS Assy 4 52 4 2 3 17 APS Chassis Assy 4 53 4 2 3 18 APS Heatsink Assy 4 55 4 2 3 19 APS Control Current Sense Assy 4 56 4 2 3 20 APS Control PCB Assy 4 57 4 2 3 21 APS Current Sense PCB Assy 4 60 Chapter 5 Wiring Diagrams 5 1 Connector ...

Page 10: ...h Cable 5 15 5 2 7 Yoke A 38 Inch Cable continued 5 16 5 2 8 Yoke B 41 Inch Cable 5 17 5 2 9 Yoke B 41 Inch Cable continued 5 18 5 2 10 Lamp Wire A B Assembly 5 19 5 2 11 Connectorized Fan 5 19 5 2 12 Pan Motor Connections 5 20 5 3 Schematics and Wiring Diagrams 5 21 5 3 1 LVS Transformer Schematic 5 21 5 3 2 INA117 Emulator Board Schematic 5 22 5 3 3 Ignitor Board Schematic 5 23 5 3 4 Yoke Termin...

Page 11: ...te technical publications are superseded by this service manual and should be discarded 02 3004 0024 VL4 Maintenance Procedures Manual 02 9628 0002 VL4 Illustrated Parts Breakdown 02 9628 0003 VL4 Maintenance Procedures This manual incorporates distinct type styles to differentiate between certain types of text These styles are defined as follows Boldface Trademarked or registered product Example ...

Page 12: ...xii VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 This page intentionally blank ...

Page 13: ...port Department Manager 201 Regal Row Dallas Texas 75247 COMPANY Vari Lite International USA FAX NUMBER 214 630 5867 RE Comments to VL4 Wash Luminaire Service Manual 02 9628 0010 FROM DATE PAGE 1 OF 1 Copy or tear this page from manual complete and fax or mail to Product Support Department Comments ...

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Page 15: ...ENTIAL 7 Oct 97 Chapter 1 Introduction This chapter contains the following sections 1 1 General Information 1 2 Equipment Description 1 3 Photometric Data 1 4 Location of Major Luminaire Components 1 5 Principles of Operation ...

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Page 17: ...pt with the console There are currently two programming manuals 02 3004 0010 Artisan and mini Artisan control consoles and 02 3004 0210 Artisan Plus mini Artisan Plus and mini Artisan 2 All of the ACS equipment are contained in the ACS Equipment Service Manual 02 9623 0200 Each luminaire and console has its own service manual Both types of Artisan consoles are covered in the Artisan Control Consol...

Page 18: ...ation Class 2 repairs are applicable to situations in which tools and or experience of the technician are limited or time does not permit extensive maintenance Class 3 repairs identified as Shop Only involve in depth repair to subassemblies that have been identified as faulty Class 3 repairs are applicable to situations in which tools and experience of the technician allow for more extensive proce...

Page 19: ...fely support the weight of the luminaires and repeaters The second consideration must be whether the luminaires are securely attached so they cannot possibly come off the truss or pipe even if the truss goes 90 from horizontal due to a failure of the chain motor or fly system In addition to mounting hooks all truss mounted equipment are provided with a safety cable to prevent the equipment from fa...

Page 20: ...mponents mercury and halogen metal compounds in the lamp tubes of 250 400 and 600 watt lamps to vaporize completely If the lamps are switched off earlier than three minutes the fill components are partially vaporized The inadequately vaporized fill components and the electrode material tungsten are deposited in the areas of the lamp tubes that have remained cool As a result the lamp tubes blacken ...

Page 21: ...l dimmer provides smooth full field control at all light levels and a shutter douser provides fast blackouts bumps and strobe like effects The position of the lamp in respect to the reflector may be varied to change the beam angle from spot to flood providing further beam output versatility A glass diffuser containing textured glass provides diffusion capabilities The rear housing provides access ...

Page 22: ...and Weight The VL4 luminaire weight is 38 pounds 17 24 kg Note Refer to Figure 2 1 in Chapter 2 for luminaire clearance and truss hook hanging dimensions 14 0 in 4 5 in 4 5 in 9 0 in 4 75 in 28 85 in 24 1 in 356 mm 114 mm 114 mm 229 mm 121 mm 612 mm 733 mm TOP VIEW FRONT VIEW SIDE VIEW 17 26 in 438 mm ...

Page 23: ...Control Processor Two Motorola 68000 processors operating at 12 MHz with 256k RAM and 256k ROM Operating Temperature 0 to 120 F 18 to 49 C 1 2 2 2 Programmable Functions Color Dichro Tune crossfading dichroic color changer with independent control of cyan magenta and amber color panels Color change speed 0 3 second Color Correction 3200 K preset selectable from console Intensity Control Mechanical...

Page 24: ...nd minimum Accuracy 0 3 degree resolution Pan 360 degrees in 3 0 seconds Tilt 270 degrees in 2 7 seconds Beam Diffuser Beam size variable by movable lamp mount from spot to flood Beam edge variable by travelling textured glass diffuser panels from sharp to soft in 0 5 second Beam Size Control Position of lamp in reflector may be remotely varied via the console to change the beam angle from spot to...

Page 25: ...ON CANDELA cd BEAM ANGLE degrees BEAM DIAMETER TN FIELD ANGLE degrees FIELD DIAMETER TN HTI 400 W SE Narrow Beam Spot Flood 876 000 126 400 4 11 07 19 11 24 19 42 HTI 400 W SE Wide Beam Spot Flood 235 200 81 200 9 14 16 24 20 29 35 52 HTI 404 W SE Narrow Beam Spot Flood 1 012 000 146 400 4 11 07 19 10 24 17 42 HTI 404 W SE Wide Beam Spot Flood 576 000 107 200 5 13 09 23 15 28 26 5 Multiply distanc...

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Page 27: ...hrough color filters dimming iris and douser mechanism 4 Ignitor Board Assembly Develops high voltage pulse for arc lamp 5 Lamp Cable Assembly Contains high voltage lamp cables and ground cable 6 Yoke Cable Assemblies Provide power to yoke termination board via two 26 pin connectors 7 Yoke Termination Board Provides motor and sensor wiring connections to head assemblies 8 Lamp OSRAM model HTI SE 4...

Page 28: ...1 14 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 Head Components continued 1 2 3 5 4 6 7 8 9 ...

Page 29: ...ormer primaries in series 220 mode or parallel 110 mode 4 Capacitor Assembly Part of Item 1 5 Arc Power Supply Provides regulated AC power to lamp 6 Lamp Control Electrical Assembly Consists of universal control board and lamp control board Controls stepper motors system timing pan tilt and incandescent dimming shaft encoder interface and sensor inputs Controls various luminaire functions communic...

Page 30: ...1 16 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 Electronic Chassis Components continued 1 2 3 4 5 6 7 ...

Page 31: ...ssembly Rear bulkhead and bulb mounting assembly Pan mechanism and tilt mechanism 1 5 2 Operation Description 1 5 2 1 Electronics Components Voltage Selector Board VSB The voltage selector board senses the amplitude of the AC input power and switches the transformer primaries in series for 220 mode or parallel for 110 mode When in 110 mode the voltage selector board accepts an incoming voltage of ...

Page 32: ...tage required by the arc lamp 1 5 2 2 Bulkhead Assemblies Rear Bulkhead and Bulb Mounting Assembly The rear bulkhead and bulb mounting assembly contains the lamp and the lamp alignment controls The knurled knob alignment controls aid in the redirection of the lamp in the X and Y planes Blue Amber Bulkhead BAB This assembly contains two sets of glass dichroic filters and the reflector Two motors co...

Page 33: ...buted to the APS power supply which supplies operating voltage for the lamp and the low voltage supply which supplies DC voltage to the control boards Control boards receive power and data distributing to the main mechanical assemblies located in the luminaire head assembly FAN DATA IN VAC IN UNIVERSAL CONTROL BOARD INTERFACE BOARD MOTHERBOARD MOTOR DRIVERS LOW VOLTAGE SUPPLY XFMR ELECTRONICS CHAS...

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Page 35: ... 02 9628 0010 CONFIDENTIAL 7 Oct 97 Chapter 2 Installation and Checkout This chapter contains the following sections 2 1 Installation 2 2 Checkout 2 3 Installing VL4 Accessories 2 4 Lamp Optical Alignment ...

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Page 37: ... VLM VL2B VL2C 21 50 in 546 mm 19 50 in 495 mm 19 75 in 502 mm 19 00 in 483 mm 19 50 in 495 mm VL4 19 50 in 495 mm 17 50 in 445 mm 17 75 in 451 mm 17 00 in 432 mm 17 50 in 445 mm VL5 VL5Arc VL5B 19 75 in 502 mm 17 75 in 451 mm 18 00 in 457 mm 17 25 in 438 mm 17 75 in 451 mm VL6 19 00 in 483 mm 17 00 in 432 mm 17 25 in 438 mm 16 50 in 419 mm 17 00 in 432 mm VLM 19 50 in 495 mm 17 50 in 445 mm 17 75...

Page 38: ...e The VL4 luminaire requires 3 1 2 inches 8 89 cm clearance between the chassis assemblies of adjacent luminaires 14 0 in 4 5 in 4 5 in 9 0 in 4 75 in 28 85 in 24 1 in 356 mm 114 mm 114 mm 229 mm 121 mm 612 mm 733 mm TOP VIEW FRONT VIEW SIDE VIEW 17 26 in 438 mm Figure 2 1 VL4 Luminaire Hanging Clearances ...

Page 39: ...prevents bending the chassis top cover In order to ensure that luminaires are not damaged during shipment it is important to properly pack in the case CAUTION Ensure yoke is not resting against pan stop when packing To pack VL4 luminaire Step 1 At console run pack up cue to place luminaire in proper orientation for transport Pan should be 180 from stops and tilt halfway between stops Step 2 Discon...

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Page 41: ...upply system power to luminaire Step 3 Watch for luminaire calibration If luminaire does not calibrate check lamp cable connection Refer to Test and Fault Isolation sections in Chapter 3 as needed Step 4 Verify that luminaire responds to control console commands Instructions for exercising luminaire functions should be referenced from the console operator s manual If luminaire does not respond pro...

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Page 43: ...ured to the luminaire with safety cables For ground installations safety cables are not required For all uses of the sound baffles the baffle fits over the fan opening and air filter It is necessary to remove the air filter from VL4 luminaires before installation 4ECA009 To install sound baffle Step 1 Route safety cable through eyelet in sound baffle Step 2 Align sound baffle with air intakes Step...

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Page 45: ...at surface such as floor or wall onto which to direct light beam This makes light beam hotspot visible Step 4 Focus beam on flat surface with no color and no diffusion Step 5 At console turn BEAM control knob counterclockwise one half turn Dark spot at center of beam should almost disappear CAUTION To avoid breaking lamp if there is difficulty in turning horizontal and vertical adjustment knobs an...

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Page 47: ...contains the following sections 3 1 Test Procedures 3 2 Luminaire Fault Isolation 3 3 Luminaire Maintenance Procedures Periodic Maintenance Refer to Series 200 System Equipment Preparation and Inspection Manual 02 3004 0042 for periodic maintenance procedures for new and used equipment ...

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Page 49: ...re activated by setting the thumbwheel address to a corresponding self test 3 1 1 2 Thumbwheel The two least significant digits of the thumbwheel are defined as the test number This number is used to select the required test The most significant digit is defined as the parameter for the selected test Not all tests have selectable parameters but on those that do it will alter an aspect of the test ...

Page 50: ... are an absolute value arising from that test displayed in hexadecimal Remember Characters are always separated by a decimal dot Lists of error codes are always separated by three scrolling bars before the start of the list is rescrolled Tests above number 15 only produce results unique to those tests Scroll speeds of all displays are set by the scroll speed selectable with test 40 the error histo...

Page 51: ...s Sensor hits too early Backlash too small Backlash too large result backlash value Sensor hit too late sensor not hit within an additional 40 steps driven motion Error stuck low Note Two errors must be detected in a bulkhead before test halts 3 1 3 3 Simultaneous Tests Tests 12 and 13 Test 12 runs all mechanics tests in phase with each other synchronized and Test 13 allows them to free run indepe...

Page 52: ...isplayed 3 1 4 Manual Tests The manual tests do not generate error codes The tests do not generate movement but allow analysis by software from a manual stimulus of the respective assembly These tests may not be used in program mode 3 1 4 1 PSU Control Test Test 20 The PSU control test duplicates PSU control just as Test 15 The difference is that Test 20 is not intelligent and does not douse the p...

Page 53: ...ndication or selection is twofold the test can be visibly seen to start and the test number is indicated on the display Deselection is indicated by the test stopping and the test number on the display flashing Only tests 1 thru 11 are valid in this mode An illegal test number is indicated by P reappearing on the display The program mode is exited by selecting a program save channel numbers 31 thru...

Page 54: ... procedure instructs you to set thumbwheel to 000 If you set any two digits to 0 and punch the third digit you may exit the thumbwheel test either on first punch or on second punch The most likely explanation for this problem is that the processor sees that third digit when the thumbwheel is between digits so that as you punch the third digit the processor sees 000 and exits the test ...

Page 55: ...T EPROMS Step 3 Install test EPROMs a At universal control board using IC extractor tool remove system EPROMs b Install HI and LO self test EPROMs 1 HI EPROM 87 7137 0001 2 LO EPROM 87 7137 0002 Step 4 Re install lamp control assembly Close chassis lid Step 5 Set thumbwheel address to 000 Note Power is immediately sent to luminaire when cheater cable is connected Do not connect cheater cable to lu...

Page 56: ...an None 101 No data activity error 102 Data activity error 103 No reset error Tilt None 201 No data error activity 202 Data activity error 203 No reset error Table 3 2 Mechanics Tests Test Parameter Error Codes Results 1 Pan 9 End stop 104 Count does not change Display count last seen 8 End stop 105 Bit count is not sequential Display received and expected count 7 Speed 1 6 Speed 2 5 Speed 3 4 Spe...

Page 57: ...peed 1 413 Backlash too large Indicate backlash value half steps in hexadecimal 6 Speed 2 414 Sensor not hit motion impeded sensor permanently high 5 Speed 3 415 Sensor permanently low 4 Speed 4 3 Speed 5 2 Speed 6 1 Speed 7 0 Speed 8 5 Intensity 9 End stop 511 Sensor hit too early motion impeded 8 End stop 512 Backlash too small 0 7 Speed 1 513 Backlash too large Indicate backlash value half step...

Page 58: ...614 Sensor not hit motion impeded sensor permanently high 5 Speed 3 615 Sensor permanently low 4 Speed 4 3 Speed 5 2 Speed 6 1 Speed 7 0 Speed 8 7 Color 2 9 End stop 711 Sensor hit too early motion impeded 8 End stop 712 Backlash too small 0 7 Speed 1 713 Backlash too large Indicate backlash value half steps in hexadecimal 6 Speed 2 714 Sensor not hit motion impeded sensor permanently high 5 Speed...

Page 59: ... Sensor not hit motion impeded sensor permanently high 5 Speed 3 815 Sensor permanently low 4 Speed 4 3 Speed 5 2 Speed 6 1 Speed 7 0 Speed 8 9 Gobo 1 Null 10 Gobo 2 Null 11 Douser 9 End stop 8 End stop 7 Speed 1 6 Speed 2 5 Speed 3 4 Speed 4 3 Speed 5 2 Speed 6 1 Speed 7 0 Speed 8 12 All mechanics synchro nized 9 End stop Error codes as for all other tests 8 End stop 7 Speed 1 6 Speed 2 5 Speed 3...

Page 60: ...iescent 7 Lamp on and start and intensity at 90 percent F91 IPRES with lamp on signal only 6 Lamp on and start and intensity at 80 percent F92 PSOT with lamp on signal only 5 Lamp on and start and intensity at 70 percent F93 HOT with lamp on signal only 4 Lamp on and start and intensity at 65 percent F94 SHORT with lamp on signal only 3 Lamp on and start and intensity at 60 percent FA2 PSOT while ...

Page 61: ...at 50 percent 0 Douse latching 21 EOT sensors 8 Read color 3 sensor Display character for closure flashing character for open 7 Read color 2 sensor Display character for closure flashing character for open 6 Read color 1 sensor Display character for closure flashing character for open 5 Select intensity iris sensor Display character for closure flashing character for open 4 Select edge sensor Disp...

Page 62: ...last changed on thumbwheel Table 3 5 Program Mode Selection Test Parameter Results 30 Enter program mode None Indication of test number for selection flashing number for deselection or P if invalid test number 31 Program mode exit save and run program 9 Synchronized mode Error code displays during that session 8 Unsynchronized mode 32 to 39 Same as above Same as above Same as above Table 3 6 Error...

Page 63: ...2 3 Beam 3 4 Edge 4 5 Intensity 5 6 Color 1 6 7 Color 2 7 8 Color 3 8 9 Null 9 10 Null A 11 Douser b 12 All mechanics synchronized C 13 All mechanics unsynchronized d 15 PSU test 20 PSU control 21 EOT sensors 22 Pan encoder 23 Tilt encoder 24 Form and function 25 Data loop back 88 Thumbwheel 30 Enter program mode 31 to 39 Program mode exit save and run program 40 Error history display 41 Clear err...

Page 64: ...lect NSD Internal loop back relay closed 7 Speed 1 Intensity at 90 percent Lamp on and start on and intensity at 100 percent Select color 2 sensor Select LSD 6 Speed 2 Intensity at 80 percent Intensity at 90 percent Select color 1 sensor 5 Speed 3 Intensity at 70 percent Intensity at 90 percent Select Intensity iris sensor 4 Speed 4 Intensity at 65 percent Intensity at 80 percent Select edge senso...

Page 65: ... Mechanics Error Codes After Error Code 01 IPRES No data activity error 02 PSOT Data activity error 03 HOT No reset error 04 SHORT Count does not change Display count last seen 05 NOT IPRES Bit count is not sequential Display received and expected count 11 Sensor hit too early motion impeded 12 Backlash too small 0 13 Backlash too large Indicate backlash value half steps in hexadecimal 14 Sensor n...

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Page 67: ...ector pins pushed in Blown VSB 3A fuse Bad VSB para 3 2 2 3 Luminaire powers up but recalibrates repeatedly Loose YTB MBD connection Bad pan or tilt mechanism Bad LVS Bad UCB para 3 2 2 4 Lamp will not start Bad lamp Bad APS Bad UCB Bad ignitor board or lamp wires para 3 2 2 5 Douser not working properly Loose connection at YTB Bad UCB Dashpots out of adjustment Loose or missing douser spring Dama...

Page 68: ...ke termination board para 3 2 2 9 Amber filters not working properly Loose connection at YTB Bad UCB Bad worm or spur gear Bad motor Broken glass Bad sensor Gears carriers not free floating in bushings Bad yoke termination board para 3 2 2 10 Blue filters not working properly Loose connection at YTB Bad UCB Bad worm or spur gear Bad motor Broken glass Broken drive shaft Bad yoke termination board ...

Page 69: ...imal point is flashing in display If not flashing or if character 8 is appears then replace UCB and retest Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph Wait at least 60 seconds for luminaire calibration b If symptom persists replace LVS and retest Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph Step 4 Check transfor...

Page 70: ... 0 48 ohms 0 46 0 48 ohms e Replace bridge rectifiers as needed 3 2 2 2 Luminaire Calibrates But Will Not Come On Line Assuming the following Console is powered up and working properly Repeater unit is properly connected and working Lamp cable is good Step 1 At VL4 lamp input connector check for pushed in data pins gold pins 2 thru 6 Repair as needed Ensure that CPC connector is properly connected...

Page 71: ...val and Replacement paragraph b Replace VSB Refer to Voltage Selector PCB Removal and Replacement paragraph 3 2 2 4 Luminaire Powers Up But Recalibrates Repeatedly Step 1 At yoke termination board check connections Ensure all connectors are properly and securely connected Step 2 At motherboard ensure all connectors are properly and securely connected Step 3 Replace tilt mechanism Refer to Tilt Mec...

Page 72: ...ded Refer to Yoke Cables and Lamp Wire Removal and Replacement paragraph 3 2 2 6 Douser Not Working Properly Step 1 At yoke termination board check connections Ensure all connectors are properly and securely connected Step 2 Replace UCB Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph Step 3 Remove Dimmer Filter Douser assembly Refer to Dimmer Filter Douser A...

Page 73: ...p 3 Remove Dimmer Filter Douser assembly Refer to Dimmer Filter Douser Assembly Removal and Replacement paragraph CAUTION Wear white cotton gloves when working with douser leaves Oils and dirt from hands will damage douser leaves a Inspect dimmer leaves Ensure that leaves are not bent and that leaf pins are not smashed or otherwise damaged Replace as needed Refer to Dimmer Leaves Removal and Repla...

Page 74: ...l and Replacement paragraph Step 6 Replace UCB Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph 3 2 2 9 Magenta Filters Not Working Properly Step 1 At yoke termination board check connections Ensure all connectors are properly and securely connected a One 4 pin connector at header marked YTB P11 b One 8 pin connector at header marked YTB P10 c Two 26 pin blac...

Page 75: ...perly and securely connected a One 4 pin connector at header marked YTB P9 b One 8 pin connector at header marked YTB P8 c Two 26 pin black yoke cable connectors at 26 pin headers Step 2 At yoke termination board swap amber connectors with another color and see if symptom occurs with other filters Step 3 Replace UCB Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement para...

Page 76: ...CB Removal and Replacement paragraph Step 4 Remove Blue Amber bulkhead Refer to Blue Amber Bulkhead Removal and Replacement paragraph a Inspect worm wheel Ensure that wheel is not damaged and that it is securely attached to motor shaft Replace worm wheel as needed Refer to Blue Amber Bulkhead Worm Wheel Removal and Replacement paragraph b Inspect spur gear Ensure that teeth are not stripped or oth...

Page 77: ...val and Replacement paragraph Step 5 Replace yoke cables Refer to Yoke Cables and Lamp Wire Removal and Replacement paragraph 3 2 2 13 Improper Pan Response Step 1 At motherboard check MTA connection Step 2 Replace UCB Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph Step 3 Replace LVS Refer to Low Voltage Supply and Universal Control PCB Removal and Replacem...

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Page 79: ... Step 2 Remove 12 6 32x5 16 PPB screws that secure head covers to rails and remove both head covers Figure 3 1 6 32 KEPS NUT LAMP ASSEMBLY BLUE AMBER BULKHEAD LAMP ASSEMBLY MUST BE REMOVED BEFORE REMOVING BLUE AMBER BULKHEAD NOTE 6 32x5 16 PPB SCREW Figure 3 1 Blue Amber Bulkhead Removal and Replacement Step 3 At yoke termination board disconnect blue amber bulkhead connectors a 4 pin connector fr...

Page 80: ...nd slide out lamp assembly CAUTION When removing bulkhead make sure that connectors do not get caught on yoke termination board Step 5 Remove blue amber bulkhead a At blue amber bulkhead using 5 16 inch nutdriver remove two 6 32 KEPS nuts that secure bulkhead to male studs on rail covers b Slide bulkhead out of luminaire head Step 6 Replace blue amber bulkhead by doing Steps 2 thru 5 in reverse ...

Page 81: ...the motor mounting bracket outside of a shop a repair assembly has been created with two new motors and a modified mounting bracket The required MTA connectors and strain reliefs are part of the repair assembly Step 1 Remove power to luminaire Step 2 Remove 12 6 32x5 16 PPB screws that secure head covers to rails and remove both head covers Figure 3 1 Step 3 At yoke termination board disconnect mo...

Page 82: ...ll replacement motor assembly and re install blue amber bulkhead by doing Steps 2 thru 4 in reverse a Apply small amount of Versilube to both motor worm gears and make sure that worm wheels are aligned properly on drive shaft so that they engage worm gears in center b If during replacement motor mount bushing or bearing comes loose place bead of Superbonder 498 glue around bushing flange and fully...

Page 83: ...river Phillips 2 Pliers needle nosed Nutdriver 1 4 inch Diagonal cutters MTA Crimper Fine point permanent ink marker To remove and replace blue amber bulkhead sensor Step 1 Remove power to luminaire Step 2 Remove blue amber bulkhead Figure 3 1 Step 3 Remove faulty sensor a At bulkhead corners remove two cable ties securing sensor wires to cable anchors Figure 3 3 b Remove two cable ties placed on ...

Page 84: ...b Trim sensor assembly wires to 15 inches CAUTION To avoid poor connections do not reuse MTA connector from removed sensor on replacement sensor c Using MTA crimper crimp wires into new 4 pin MTA connector using the following pinouts Pin Wire 4 Blue 3 Blue 2 N C 1 N C d Install strain relief cover on 4 pin connector Using permanent ink marker mark strain relief either BLUE or AMB as necessary CAUT...

Page 85: ...Remove power to luminaire Step 2 Remove 12 6 32x5 16 PPB screws that secure head covers to rails and remove both head covers Figure 3 1 Step 3 Remove motor worm wheel a At motor mount remove four 4 40 KEPS nuts that secure mount to bulkhead and remove mount Figure 3 4 b At damaged worm wheel using 1 16 inch Allen wrench loosen setscrew in damaged worm wheel and remove worm wheel from shaft 4 40 KE...

Page 86: ... in reverse b Make sure that worm wheel is aligned properly on drive shaft so that it engages worm gear in center c Apply small amount of Versilube to drive shaft d If during replacement motor mount bushing or bearing comes loose place bead of Superbonder 498 glue around bushing flange and fully reseat bushing in motor mount Allow 15 minutes for glue to dry before re installing motor mount ...

Page 87: ...marked YTB P15 b 8 pin connector from header marked YTB P14 Step 4 Remove diffuser mechanism a At front aperture rails remove four 6 32x5 16 PPB screws that secure front aperture to rails Figure 3 5 b Remove cable ties as necessary Close diffuser c Slide out front aperture plate with diffuser mechanism 6 32X5 16 PPB SCREW DIFFREMV DIFFUSER MOTOR ON SAME SIDE AS YOKE TERMINATION BOARD Figure 3 5 Di...

Page 88: ...r fine Diagonal cutters MTA Crimper Fine point permanent ink marker To remove and replace diffuser assembly sensor Step 1 Remove power to luminaire Step 2 Remove diffuser mechanism Figure 3 5 Step 3 Remove diffuser sensor a Fully close diffuser b At stepper motor mounting plate using diagonal cutters remove cable tie securing motor and sensor wires Figure 3 6 LONG BELT 4 40 KEPS NUT 6 32 KEPS NUT ...

Page 89: ...d sensor lead to 45 angle b Trim sensor assembly wires to 21 inches CAUTION To avoid poor connections do not reuse MTA connector from removed sensor on replacement sensor c Using MTA crimper crimp wires into new 4 pin MTA connector using the following pinouts Pin Wire 4 Blue 3 Blue 2 N C 1 N C d Install strain relief cover on 4 pin connector Using permanent ink marker mark strain relief DIFF Note ...

Page 90: ... motor Step 1 Remove power to luminaire Step 2 Remove diffuser mechanism Figure 3 5 Step 3 At stepper motor mounting plate using diagonal cutters remove cable tie securing motor and sensor wires Figure 3 6 Step 4 Using screwdriver remove two 4 40x1 4 PPZ screws and 4 40 KEPS nuts that secure motor assembly to mounting plate Step 5 Remove belt from motor pulley and remove motor assembly Step 6 Inst...

Page 91: ...or 1 2 inch needle to Loctite Superbonder 498 bottle To verify glue flows smoothly allow few drops of glue to flow thru needle Step 4 At diffuser position diffuser panels so that diffuser carriers on first clear diffuser panels of both sets are accessible thru aperture in front plate Step 5 Tilt luminaire head slightly down Apply 1 16 inch fillet bead of glue along edge of lower carrier of first c...

Page 92: ...nation board disconnect dimmer douser connectors a 4 pin connector from header marked YTB P15 b 8 pin connector from header marked YTB P14 c 4 pin magenta connector from header marked YTB P11 d 8 pin magenta connector from header marked YTB P10 e 4 pin dimmer connector from header marked YTB P12 f 8 pin dimmer connector from header marked YTB P13 g 4 pin douser connector from header marked YTB P5 ...

Page 93: ...TENANCE PROCEDURES 3 47 02 9628 0010 CONFIDENTIAL 7 Oct 97 6 32 KEPS NUT 6 32x5 16 PPB SCREW Figure 3 7 Dimmer Filter Douser Assembly Removal and Replacement Step 5 Install bulkhead by doing Steps 2 thru 4 in reverse ...

Page 94: ...art of the repair assembly Step 1 Remove power to luminaire Step 2 Remove dimmer filter douser assembly from luminaire head Figure 3 7 Note If bulkhead is fitted with black Kevlar dimmer belt replace black belt with new blue belt 10 9628 0221 Step 3 Remove dimmer motor with mount and pulley and magenta motor with mount a At magenta motor remove two 4 40x3 8 PFZ screws and two 4 40x3 8 PPZ screws a...

Page 95: ...ement motor a Apply thick bead of Versilube onto magenta stepper motor worm wheel b Verify that motor mount drive shaft bearing is installed in place c Install drive shaft in place on motor mount assembly Note Drive shaft will not be secured in place until shaft is installed in bulkhead bushing d Install and fully tighten two 4 40x3 8 PFZ screws and two 4 40x3 8 PPZ screws and 4 internal tooth loc...

Page 96: ...eedle nosed Diagonal cutters MTA Crimper Fine point permanent ink marker To remove and replace magenta filter sensor Step 1 Remove power to luminaire Step 2 Remove dimmer filter douser assembly from luminaire head Figure 3 7 Step 3 Remove filter sensor a At bulkhead cable anchors remove cable tie securing wires to cable anchors Figure 3 9 b At sensor using 1 4 inch nutdriver remove two 3 56 nylon ...

Page 97: ... on replacement sensor c Using MTA crimper crimp wires into new 4 pin MTA connector using the following pinouts Pin Wire 4 Blue 3 Blue 2 N C 1 N C d Install strain relief cover on 4 pin connector Using permanent ink marker mark strain relief as MAG CAUTION Do not overtighten nuts when installing replacement sensor e Install replacement sensor and re assemble dimmer filter douser assembly by doing ...

Page 98: ...ead is fitted with black Kevlar dimmer belt replace black belt with new blue belt 10 9628 0221 Step 3 Remove dimmer motor with mount and pulley and magenta motor with mount Figure 3 10 a At magenta motor remove two 4 40x3 8 PFZ screws and two 4 40x3 8 PPZ screws and 4 internal tooth lock washers that secure motor mount to bulkhead b Remove motor mount DFDVW2 2 56X1 4 PPZ SCREW DIMMER MOTOR PULLEY ...

Page 99: ...l d Verify that motor mount drive shaft bearings is installed in place Step 6 Install motor mount and drive shaft in bulkhead a Install drive shaft in place on motor mount Note Drive shaft will not be secured in place until shaft is installed in bulkhead bearing b Center worm wheel with worm gear and fully tighten worm wheel setscrew c Verify that magenta filters are in fully opened position d Ori...

Page 100: ... dimmer motor belt remove 2 56x1 4 PPZ screw that secures belt clamp to dimmer actuator tab and remove clamp and screw Figure 3 11 b Slip belt over end of one pulley and remove DIMMER ACTUATOR BELT CLAMP BELT RINGVW 2 56X1 4 PPZ SCREW SECURE REPLACEMENT BELT IN UPWARD MOST POSTION Figure 3 11 Dimmer Filter Douser Assembly Dimmer Belt Removal and Replacement Note If bulkhead is fitted with black Ke...

Page 101: ... Step 1 Remove power to luminaire Step 2 Remove dimmer filter douser assembly from luminaire head Figure 3 7 Step 3 Remove sub micro switch a Remove two 0 80x5 16 PPZ screws and KEPS nuts if used that secure switch to bulkhead and remove switch Figure 3 12 Step 4 Replace switch by doing Steps 2 and 3 in reverse Note When installing switch verify that switch is oriented so that switch leads point t...

Page 102: ...e power to luminaire Step 2 Remove dimmer filter douser assembly from luminaire head Figure 3 7 Step 3 Remove belt clamp At dimmer motor belt remove 2 56x1 4 PPZ screw that secures belt clamp to dimmer actuator tab and remove clamp and screw Figure 3 11 CAUTION Do not touch iris leaves with bare fingers Oils and dirt will damage iris leaves CAUTION Open dimmer before removing cover plate Step 4 Re...

Page 103: ...SITION BEFORE DISASSEMBLY Figure 3 13 Dimmer Cover Plate and Honeycomb Removal and Replacement Step 5 Remove left hand iris leaves a Remove two small thin nylon washers from standoff 7 b Remove large thin nylon washer from standoffs 5 6 and 8 c Remove left hand iris leaves from standoffs 5 6 7 and 8 DISASSEMBLY STAGE 1 LARGE THIN WASHER SMALL THIN WASHER 5 6 7 8 10 9628 0105 10 9628 0106 LEFT HAND...

Page 104: ...emove dimmer actuator ring DISASSEMBLY STAGE 2 SMALL THICK WASHER SMALL THIN WASHER 10 9628 0109 10 9628 0106 ACTUATOR RING 1 2 3 4 5 6 8 Step 7 Remove right hand iris leaves a Remove nylon roller from standoffs 1 2 3 and 4 b Remove small thin nylon washer from standoffs 1 2 3 and 4 c Remove right hand iris leaves from standoffs 1 2 3 and 4 DISASSEMBLY STAGE 3 ROLLER SMALL THIN WASHER 10 9628 0101...

Page 105: ...damaged leaves and washers can be reused during replacement Note Install a new belt or re install the belt clamp in the same position on old belt Clamp ruins some of the belt s teeth and will cause problems if clamp is not re installed in the same position Step 10 Re assemble iris assembly by doing Steps 2 thru 7 in reverse a Right hand iris leaves are installed on standoffs 1 2 3 and 4 nub side u...

Page 106: ...mbly from luminaire head Figure 3 7 Step 3 Remove douser tab plate a At bulkhead cable anchors remove cable tie securing wires to cable anchors Figure 3 14 4 40X1 4 PPZ SCREWS DOUSER RING TAB SPRINGS ROUTE SOLENOID ASSEMBLY WIRES IN SPACE 4 LOCK WASHER 4 40X3 8 PPZ SCREW DASHPOT EYELOT DOUSER TAB PLATE SLOT FOR SOLENOID PIN DASHPOT CONNECTING LINK SOLREMV Figure 3 14 Dimmer Filter Douser Solenoid ...

Page 107: ...clamp loosen four 4 40x1 4 PPZ screws that secure clamp to solenoid mounting plate and bulkhead and slide solenoid out from under clamp It is not necessary to remove screws that secure clamp Step 5 Replace solenoid by doing Steps 2 thru 4 in reverse Step 6 Calibrate dashpots Refer to Douser Dashpot Calibration paragraph ...

Page 108: ...te a At douser ring tab using needle nosed pliers remove loop of each spring from holes in ring tab Figure 3 14 b At douser tab plate remove three 4 40x3 8 PPZ screws and 4 internal tooth lockwashers that secure plate to douser ring tab c At dashpots remove eyelets from standoffs on douser tab plate and remove tab plate Step 4 Remove douser leaves a At douser ring remove eight 4 40x3 16 PTHZ screw...

Page 109: ...2 thru 7 lay partly on top preceding leaf Leaf on standoff number 8 rests on top of leaves on standoffs 1 and 7 c Complete bulkhead assembly and installation by doing Steps 2 thru 9 in reverse Refer to Figure 3 16 for placement of douser leaf attachment hardware Be careful to not clamp down on 0 35 dia X 0 010 thick washer LEAF NUB ROLLER DOUSER LEAF DOUSER RING TRUSS HEAD SCREW 0 5 DIA X 0 010 TH...

Page 110: ... Nutdriver 5 16 inch To remove and replace douser spring Step 1 Remove power to luminaire Step 2 Remove dimmer filter douser assembly from luminaire head Figure 3 7 Step 3 At damaged douser spring using needle nosed pliers remove spring Figure 3 17 DOUSER RING TAB SPRINGS SOLREMV Figure 3 17 Douser Spring Removal and Replacement Step 4 Replace douser spring by doing Steps 2 and 3 in reverse order ...

Page 111: ...and shut If adjustment is too loose the douser mechanism slams open or shut If adjustment is too tight the douser mechanism will not fully open and shut Hint In a properly adjusted dashpot the piston goes to end of travel and stops with no clicking sound and no slowing down To calibrate douser dashpots Step 1 Connect luminaire to console Step 2 Using console cycle douser During cycling process adj...

Page 112: ... lamp with bare fingers Oils on fingers will deteriorate glass when heated and may cause glass to explode Step 2 At lamp assembly turn 1 4 turn fasteners on rear of lamp assembly and carefully slide out lamp assembly from luminaire head Figure 3 19 REAR COVER LAMP MOUNTING ASSEMBLY LAMP WIRE 4 40X5 16 PFB SCREW TETHER ATTACHMENT SCREW LAMPREMV Figure 3 19 Lamp Assembly Removal and Replacement Step...

Page 113: ...ke termination board disconnect 8 pin IDC connector from header marked FOCUS CAUTION Do not touch glass envelope of lamp with bare fingers Oils on fingers will deteriorate glass when heated and may cause glass to explode Step 4 Remove lamp assembly a At lamp assembly turn 1 4 turn fasteners on rear of lamp assembly and carefully slide out lamp assembly from luminaire head Figure 3 19 b At lamp ass...

Page 114: ... wires and remove socket a At 30 series connector while using 1 4 inch open end wrench to hold 4 40 KEPS nuts remove two 4 40x5 16 PPZ screws and 4 40 KEPS nuts that secure series 30 connector to lamp wire connector bracket b Using 1 slotted screwdriver push pins 1 and 3 out of series 30 connector c At lamp retainer remove two 4 40x1 PPZ screws and 4 flat washers that secure retainer to lamp socke...

Page 115: ...d remove both head covers Figure 3 1 Step 3 At yoke termination board disconnect 8 pin IDC connector from header marked FOCUS Step 4 Remove lamp assembly a At lamp assembly turn 1 4 turn fasteners on rear of lamp assembly and carefully slide out lamp assembly from luminaire head Figure 3 19 b At lamp assembly opening remove one 4 40x5 16 PFB screw and 4 40 KEPS nut that secures lamp assembly safet...

Page 116: ...CTOR 4 40X3 8 PPB SCREW 8 32X3 8 PPB SCREW 8 32 KEPS NUT SWIVEL BEARING ASSEMBLY 4 1 2 INCH RUBBER COATED FIBERGLASS SLEEVING 3 1 2 INCH RUBBER COATED FIBERGLASS SLEEVING LAMP RETAINER Figure 3 21 Lamp Mounting Assembly Actuator Motor Removal and Replacement Step 7 Remove linear actuator motor a At rear of lamp access plate fully unscrew two knurled knobs and remove knobs and compression springs f...

Page 117: ...de 4 1 2 inch piece of rubber coated fiberglass sleeving over motor wires d Insert safety tether in 4 1 2 inch piece of rubber coated fiberglass sleeving along with motor wires e Using two cable ties secure ends of 4 1 2 inch piece of rubber coated fiberglass sleeving Verify that ends of safety tether extend past cable ties f Slide 3 1 2 inch piece of rubber coated fiberglass sleeving over remaini...

Page 118: ...r marked YTB P6 e 4 pin connector from MAG header marked YTB P11 f 8 pin connector from MAG header marked YTB P10 g 4 pin connector from DOUSER header marked YTB P5 h 5 pin connector from TILT header marked YTB P3 j 4 pin connector from TILT header marked YTB P4 k 4 pin connector from DIM header marked YTB P13 m 8 pin connector from DIM header marked YTB P12 n 4 pin connector from DIFF header mark...

Page 119: ...1 6 32X5 16 PPB SCREW Figure 3 22 Yoke Termination Board Removal and Replacement Step 5 Replace yoke termination board by doing Steps 2 thru 4 in reverse Note 26 pin connector with blue heat shrink is connected to header marked YOKE B Blue and 26 pin connector with yellow heat shrink is connected to header marked YOKE A Amber ...

Page 120: ...refully slide lamp assembly out of luminaire head Figure 3 19 Step 4 Remove ignitor board a At ignitor board remove four 6 32x5 16 PPZ screws and 6 internal tooth lock washers that secure ignitor board to side rails and pull out board Figure 3 23 White nylon 0 5 inch spacers may fall off rear of board when board is removed b At right side disconnect two pin red series 30 connector from board and r...

Page 121: ...lips 2 Soldering iron and solder To remove and replace ignitor board 2 5KV spark gap Step 1 Remove power to luminaires Step 2 Remove 12 6 32x5 16 PPB screws that secure head covers to rails and remove both head covers Figure 3 1 Step 3 Remove ignitor board assembly Figure 3 23 Step 4 Unsolder spark gap from ignitor board Step 5 Install replacement spark gap and re install ignitor board by doing St...

Page 122: ... from BLUE header marked YTB P6 e 4 pin connector from MAG header marked YTB P11 f 8 pin connector from MAG header marked YTB P10 g 4 pin connector from DOUSER header marked YTB P5 h 5 pin connector from TILT header marked YTB P3 j 4 pin connector from TILT header marked YTB P4 k 4 pin connector from DIM header marked YTB P13 m 8 pin connector from DIM header marked YTB P12 n 4 pin connector from ...

Page 123: ...mechanism cover remove three 6 32x5 16 PPB screws that secure tilt mechanism cover to side rail and remove cover PULLEY SIDE RAIL COVER TILT MECHANSIM COVER 8 BLACK FLAT WASHER RCOVREMV 8 32X5 16 PPB SCREW 6 32X5 16 PPB SCREW 8 32X1 PPB TILT ADJUSTMENT SCREW MECHANISM Figure 3 24 Pulley Side Rail and Tilt Mechanism Cover Removal and Replacement Step 11 Remove tilt mechanism a At rear cover remove ...

Page 124: ...mechanism a At replacement tilt mechanism using syringe apply small amount of Versilube to worm gear Put on only enough Versilube to gently coat meshing surfaces b At replacement tilt mechanism place timing belt over tilt pulley c At tilt mechanism bottom plate secure tilt mechanism to pulley side rail using three 6 32x3 8 PFB screws 6 flat washers and 6 32 nylon stop lock nuts CAUTION To ensure p...

Page 125: ...E OF BELT PULLEY DRIVE PULLEY BELT MUST BE TAUT NO DEFLECTIONS PULLEY SIDE RAIL REAR COVER BEARING HOLE DRIVEVW GOOD GAP EXISTS BETWEEN BEARING AND HOLE TOO TIGHT BEARING IS FLUSH AGAINST HOLE TOO LOOSE BEARING IS FLUSH AGAINST HOLE Figure 3 26 Tilt Mechanism Adjustment Screw Setting b Turn head so that pulleys rotate back and forth At same time slowly tighten adjustment screw until both tension a...

Page 126: ...ile pressing down on filter pop out top of filter from chassis and fully remove filter Step 3 Remove power supply a At bottom of chassis in countersink remove 6 32x5 16 PPB screw and shoulder bushing washer securing power supply Figure 3 27 b Remove power supply by sliding out CAUTION Ensure that shoulder bushing is in place failure to re install will cause comm problems Step 4 Replace power suppl...

Page 127: ...p 2 Remove left air filter and left chassis cover a At left electronics chassis air filter while pressing down on filter pop out top of filter from chassis and fully remove filter b Remove four 6 32x5 16 PPB screws that secure left top cover to chassis and remove cover Figure 3 28 Step 3 Remove arc power supply APSTB1 AIR FILTER ARC POWER SUPPLY CHASSIS COVER COUNTERSINK 6 32X5 16 PPB SCREW 6 32X5...

Page 128: ...onnectors from top of voltage selector PCB Figure 3 30 1 3 pin MATE N LOK connector from P2 2 4 pin MATE N LOK connector from P3 3 3 pin MATE N LOK connector from P1 4 12 pin MTA connector from P4 c At bottom of VSB disconnect red 2 pin connector and remove PCB 3A FUSES 3 PIN MATE N LOK CONNECTOR P2 4 PIN MATE N LOK CONNECTOR P3 10A FUSES 10 PIN MTA100 CONNECTOR P4 3 PIN MATE N LOK CONNECTOR P1 2 ...

Page 129: ...0001 1 EA FUSE 3A 250V 5X20MM GLASS 70 3723 0003 Tools Screwdriver Phillips 1 Screwdriver Phillips 2 To remove and replace voltage selector PCB fuses Step 1 Remove power to luminaire Step 2 Remove voltage selector PCB Figure 3 29 Step 3 Remove blown 3A or 10A fuses Figure 3 30 Step 4 Replace fuses and re install voltage selector PCB by doing Steps 2 and 3 in reverse ...

Page 130: ...control PCB Step 1 Remove power to luminaire Step 2 At right electronics chassis air filter while pressing down on filter pop out top of filter from chassis and fully remove filter Step 3 Remove faulty PCB Figure 3 31 a At card retainer press down on spring release and open retainer b Pull out faulty PCB Step 4 Replace faulty PCB by doing Steps 2 thru 3 in reverse UNIVERSAL CONTROL BOARD LOW VOLTA...

Page 131: ...At card retainer press down on spring release and open retainer b Pull out low voltage power supply PCB and universal control PCB Step 4 Remove power supply a At bottom of chassis in countersink remove 6 32x5 16 PPB screw securing power supply Figure 3 27 b Pull out power supply Step 5 Remove voltage selector PCB Figure 3 29 Step 6 Remove yoke bearing frame a At yoke bearing frame remove four 6 32...

Page 132: ...of motherboard disconnect 5 pin MTA connector from header marked DATA MB P9 b At upper left of motherboard disconnect 12 pin MTA connector from header marked LVPS VIA VSB MB P6 c At bottom right of motherboard disconnect 4 pin MATE N LOK connector from header marked UNREG DC MB P8 d At motherboard corners remove three 6 32x5 16 PPZ screws and 6 internal tooth lockwashers Figure 3 32 e At P1 P2 and...

Page 133: ...Figure 3 31 a At card retainer press down on spring release and open retainer b Pull out low voltage power supply PCB and universal control PCB Step 4 Remove power supply a At bottom of chassis in countersink remove 6 32x5 16 PPB screw securing power supply Figure 3 27 b Pull out power supply Step 5 Remove voltage selector PCB Figure 3 29 Step 6 Remove yoke bearing frame a At yoke bearing frame re...

Page 134: ...mmet from grommet slot Figure 3 33 PAN CABLE AND GROMMET YOKE BEARING FRAME PAN MECHANISM 10 32X1 1 2 PPB SCREW FAN MOUNTING BRACKET 8 32X1 PPB PAN ADJUSTMENT SCREW 10 32 NYLON INSERT STOP LOCK NUT 0 76 OD X 0 192 ID FLAT WASHER Figure 3 33 Pan Mechanism Removal and Replacement Note Belt is not removed with pan drive assembly b At side of yoke bearing frame remove 8 32x1 PPB pan assembly belt adju...

Page 135: ...tor PCB Figure 3 29 Step 3 Disconnect bridge rectifier transformer wire spade connectors a At transformer orange and yellow wires using diagonal cutters remove cable ties securing wires together b At bridge rectifier transformer wires disconnect two red two yellow and one red yellow wire spade connectors Figure 3 34 XFRMRVW 10 32X2 PPB SCREW 10 FLAT WASHER 10 NYLON INSERT STOP LOCK NUT TRANSFORMER...

Page 136: ... 3 8 inch nutdriver remove 10 32 nylon insert stop lock nut and 10 32x2 PPB screw securing transformer to chassis bottom b Remove 10 flat washer from top of rubber pad rubber pad and second 10 flat washer from top of transformer c Remove transformer assembly from chassis Step 5 Replace transformer capacitor assembly by doing Steps 2 thru 4 in reverse ...

Page 137: ...Bs Figure 3 31 a At card retainer press down on spring release and open retainer b Pull out low voltage power supply PCB and universal control PCB Step 4 Remove power supply a At bottom of chassis in countersink remove 6 32x5 16 PPB screw securing power supply Figure 3 27 b Pull out power supply Step 5 Remove voltage selector PCB Figure 3 29 Step 6 Remove yoke bearing frame a At yoke bearing frame...

Page 138: ...diagonal cutters remove cable ties securing capacitor assembly to five cable anchors Figure 3 35 b At bottom right corner of motherboard disconnect 4 pin MATE N LOK connector from header marked UNREG DC MB P8 c At bridge rectifiers disconnect red green blue and yellow mounted capacitor assembly spade connectors d At capacitor bracket remove two 6 32x5 16 PPB screws and 6 lock washers that secure b...

Page 139: ...ct 97 Note Capacitors are secured to chassis side with RTV e Using slotted screwdriver or other flat sharp instrument carefully pry capacitor assembly from chassis side and remove from chassis Step 8 Replace mounted capacitor assembly by doing Steps 2 thru 7 in reverse ...

Page 140: ...PCB diodes or resistors Step 1 Remove power to luminaire Step 2 Remove power supply Figure 3 27 Step 3 Separate heatshrink from power supply chassis a At power supply control PCB remove four 6 32x3 4 PPZ screws that secure heatsink assembly to power supply chassis b Gently pry apart sides of power supply chassis and remove heatsink Step 4 Replace faulty resistor or diode a Locate resistor or diode...

Page 141: ...FETs are manufactured by Motorola GE or RCA FETs manufactured by International Rectifiers IR should not be used and returned to the shop To remove and replace APS heatsink assembly MJ10005 transistor or IRF450 FET Step 1 Remove power to luminaire Step 2 Remove power supply Figure 3 27 Step 3 Separate heatshrink from power supply chassis a At power supply control PCB remove four 6 32x3 4 PPZ screws...

Page 142: ...IFIER HSVW TO 3 INSULATOR 6 32X9 16 PPZ SCREW MJ10005 TRANSISTORS IRF450 Figure 3 37 APS Plus MJ10005 and IRF450 FET Removal and Replacement Step 5 Replace transistor or FET a At rear of replacement transistor or FET apply new TO 3 insulator b Replace transistor or FET by doing Steps 2 thru 4 in reverse ...

Page 143: ...s Figure 3 31 a At card retainer press down on spring release and open retainer b Pull out low voltage power supply PCB and universal control PCB Step 4 Remove power supply a At bottom of chassis in countersink remove 6 32x5 16 PPB screw securing power supply Figure 3 27 b Pull out power supply Step 5 Remove voltage selector PCB Figure 3 29 Step 6 Remove yoke bearing frame a At yoke bearing frame ...

Page 144: ... motherboard disconnect 5 pin MTA connector from header DATA MB P9 Figure 3 38 CONNTB CONNECTOR KEYING 4 40 KEPS NUT FIVE PIN MTA100 CONNECTOR DATA MB P9 FIVE PIN MTA100 CONNECTOR PAN MB P7 INPUT CONNECTOR 6 32 KEPS NUT MOTHERBOARD GROUNDING WIRES RING LUG 4 40X5 16 PPB SCREW Figure 3 38 Input Connector Removal and Replacement b At input connector at outside of chassis remove four 4 40x5 16 PPB sc...

Page 145: ...eceptacle insert five 22 AWG wires and three 18 AWG wires using the following pinouts Pin Wire Wire Size Description 1 N C 2 RED 22 AWG BRDCST 3 GRN 22 AWG DATA GND 4 BLK 22 AWG BRDCST 5 GRY 22 AWG REPLY 6 WHT 22 AWG REPLY 7 WHT 18 AWG NEUTRAL 8 GRN 18 AWG GROUND 9 BLK 18 AWG AC b Complete receptacle replacement by doing Steps 2 thru 7 in reverse ...

Page 146: ...ls Screwdriver Phillips 1 and 2 Rivet gun Drill hand with 30 0 1285 inch drill bit Center punch Glue Note This procedure only works with new Fastex truss hook fasteners To remove stuck truss hook from luminaire and to remove and replace truss hook fastener Step 1 Remove power to luminaire Step 2 Turn truss hook so that slot in pin head points toward edge of dimple in corresponding hook slot Figure...

Page 147: ...nd remove covers 3 At card retainer press down on spring release and open retainer 4 Pull out low voltage power supply PCB and universal control PCB 5 At bottom of chassis in countersink remove 6 32x5 16 PPB screw securing power supply 6 Pull out power supply 7 Remove voltage selector PCB Figure 3 29 8 At yoke bearing frame remove four 6 32x5 16 PPB screws that secure frame to flanges on top of ch...

Page 148: ...ssis Figure 3 40 At other end of screw install second flat washer on screw and firmly tighten nut onto screw Screw will hold fastener assembly securely to chassis when installing pop rivets POP RIVET TRUSS HOOK FASTENER ASSEMBLY 5 16 INCH FLAT WASHER 5 16 INCH FLAT WASHER 5 16 18X1 HCSZ SCREW 5 16 INCH HEX NUT Figure 3 40 Truss Hook Fastener Removal and Replacement Step 12 From exterior of chassis...

Page 149: ... head covers Figure 3 1 Step 3 At yoke termination PCB disconnect all connectors a 4 pin connector from AMBER header marked YTB P9 b 8 pin connector from AMBER header marked YTB P8 c 4 pin connector from BLUE header marked YTB P7 d 8 pin connector from BLUE header marked YTB P6 e 4 pin connector from MAG header marked YTB P11 f 8 pin connector from MAG header marked YTB P10 g 4 pin connector from ...

Page 150: ...ble side rail cover to side rail and remove cover b Using diagonal cutters remove cable tie that secures three cables to cable side rail Step 11 For removal of lamp wire only at green grounding wires next to tilt tube using 5 16 inch nutdriver remove 6 32 KEPS nut and ring lug Step 12 Remove both air filters and chassis covers a At each electronics chassis air filter while pressing down on filter ...

Page 151: ...aring frame closest to transformer away from transformer and disconnect 8 pin MTA connector from motherboard header marked MB P7 d While holding up luminaire head with one hand reach under yoke bearing and disconnect black 26 pin connector from motherboard marked YOKE A MB P4 Connector is located next to connector marked YOKE B e At rear of chassis behind power supply disconnect 26 pin black conne...

Page 152: ...res to fan mount b At yoke bearing frame remove faulty yoke cable or lamp wire with grommet from grommet slot Figure 3 42 FAN MOUNTING BRACKET CONNECTORIZED FAN CABLE GROMMETS YOKE BEARING FRAME PAN DRIVE YBFVW Figure 3 42 Yoke Bearing Frame Base c At yoke cable connector in luminaire head turn connector sideways and insert in tilt tube Figure 3 43 d From bottom of yoke bearing frame pull faulty y...

Page 153: ... wire tape one connector to very long cable tie Tape connector to cable tie so that connector s short side faces forward Figure 3 44 INSERT END INTO PAN TUBE AND UP INTO TILT TUBE PULL TIE WRAP THROUGH TAPE 26 PIN CONNECTOR TO END OF VERY LONG TIE WRAP Figure 3 44 Yoke Cables and Lamp Wire Replacement b Insert untaped end of cable tie into pan tube from yoke bearing frame side Push cable tie thru ...

Page 154: ...ct 97 d Untape connector from cable tie e Maneuver yoke cable or lamp wires so that spring on cable extends equally from pan tube and tilt tube Note Cables should only come out of side rail approximately 1 to 1 1 2 Step 19 Re assemble luminaire by doing Steps 2 thru 17 in reverse ...

Page 155: ... part number and name for the purpose of identification and ordering This chapter is divided into the following sections 4 1 Drawing Tree 4 2 Parts Breakdown Note All parts for each sub assembly are listed in part number order Parts are identified on the corresponding illustration by item numbers If a part is used multiple times in different places the quantity is noted next to the illustration it...

Page 156: ...4 2 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 This page intentionally blank ...

Page 157: ... LAMP WIRE 25 9628 0149 ASSY A B PCB ASSY VL4 LOW VOLTAGE SUPPLY 24 9628 0045 CABLE ASSY 25 9628 0152 MB VSB LK 1 PCB ASSY VL4 VOLTAGE SELECTOR 24 9628 0026 ELEC ASSY VL4 23 9628 0232 LAMP CTRL UCB IFB PCB ASSY 24 9628 0053 VL4 MOTHER ASSY VL4 22 4000 0056 UPPER ENCLOSURE ASSY CARD RETAINER 22 9628 0171 CABLE ASSY 25 9628 0150 INPUT CONN WIRE ASSY TRANSFORMER 23 9628 0005 CAPACITOR ASSY CONNECTORI...

Page 158: ...4 4 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 This page intentionally blank ...

Page 159: ... EA LAMP ID TAG VL4 2 04 9628 0246 1 EA LABEL INPUT RATING VL4 3 10 9628 0128 2 EA COVER TOP CHASSIS 4 22 9620 0194 1 EA ASSY LAMP SAFETY CABLE 5 22 9620 0217 2 EA ASSY TRUSS HOOK 200S 12 9620 0093 1 EA ASSY TRUSS HOOK 52 8207 0001 1 EA PIN CROSS FOR 7 Q F 53 6505 0002 1 EA BOLT 3 8 16X1 1 2 BLK WING 55 6632 0001 1 EA WASHER TRUSS HK BRASS 016X 997ODX 364ID 6 52 6524 0002 8 EA SCREW 6 32X5 16 PPB ...

Page 160: ... VL4 2 22 4003 0001 1 EA ASSY DIFFUSER MECHANISM VL4 3 22 4005 0001 1 EA ASSY DIMMER FILTER DOUSER VL4 4 22 4006 0001 1 EA ASSY BLUE AMBER BULKHEAD VL4 5 22 4007 0001 1 EA ASSY REAR BULKHD BULB MTG VL4 6 22 9628 0125 2 EA ASSY VL4 HEAD COVERS 7 53 2200 0006 4 EA NUT 6 32 KEPS SS 8 53 6524 0002 16 EA SCREW 6 32X5 16 PPB 9 71 2524 0002 1 EA LAMP HTI 404 WATT W SE 6 3 2 4 1 9 5 8 6 PL 8 4 PL 8 6 PL 7...

Page 161: ...6 10 9628 0108 1 EA PLATE MOUNTING MOTOR DIMMER 17 10 9628 0109 8 EA WASHER SPECIAL 025THK X 350 DIA 18 10 9628 0113 1 EA CLAMP BELT DIMMER 19 10 9628 0140 1 EA FRAME FILTER ULTRA VIOLET 20 10 9628 0162 1 EA PAD MOTOR DIMMER 21 10 9628 0167 1 EA HONEYCOMB VL4 22 10 9628 0178 1 EA PLATE MOUNTING SOLENOID 23 10 9628 0179 1 EA CLAMP SOLENOID 24 10 9628 0180 1 EA MOUNT DASHPOT 25 10 9628 0182 1 EA PLA...

Page 162: ...25 0001 1 EA SCREW 6 32 X 5 16 PPZ 51 53 6559 0001 2 EA SCREW 4 40 X 1 4 PFZ 52 53 6596 0001 1 EA SCREW 4 40 X 5 16 PPZ 53 53 6599 0001 2 EA SCREW 4 40 X 3 8 PFZ 54 53 6601 0002 8 EA SCREW 4 40 X 3 16 PTH Z 55 53 6659 0002 1 EA SCREW 2 56 X 1 4 PPZ 56 53 6659 0004 2 EA SCREW 2 56 X 1 4 PPZ 57 53 6659 006 2 EA SCREW 2 56 X 3 16 PPZ 58 53 6659 0008 1 EA SCREW 2 56 X 3 16 PFZ 59 53 6660 0001 1 EA SCR...

Page 163: ... 3 8 ID 74 55 9628 0192 4 EA SPACER DMR COVER 250 OD X 175 ID 146T 75 73 7021 0006 2 EA WIRE 24AWG BLUE TWISTED PR 76 74 1023 0001 1 EA SWITCH GOLD CROSSPOINT CONTACT 21 27 18 55 59 8 64 11 26 63 70 20 16 37 41 39 29 13 6 19 10 4 44 66 52 35 22 45 30 34 23 73 25 24 58 71 42 72 43 76 67 40 38 75 31 28 50 66 62 68 2 PL 68 2 PL 68 2 PL 61 48 53 9 46 51 32 3 5 36 1 65 2 60 54 14 7 15 68 4 PL 69 4 PL 5...

Page 164: ...28 0107 1 EA SHAFT EXTENSION FILTER GEAR 12 41 9628 0136 2 EA FILTER LWP 4 1 8 X 1 11 16 VL4 13 41 9628 0137 1 EA FILTER LWP 4 1 8 X 2 14 41 9628 0138 2 EA FILTER SWP 4 1 8 X 1 11 16 VL4 15 41 9628 0139 1 EA FILTER SWP 4 1 8 X 2 VL4 16 52 6300 0001 2 EA CONN HOUSNG MTA CLOSED END NATRL 4PIN 17 52 6383 0001 2 EA CONN HOUSING MTA CLOSED END BLU 8PIN 18 52 6424 0004 2 EA COVER STRAIN RELIEF 4POS MTA ...

Page 165: ...3 2 EA PIN 3 64 X 1 2 SPRIAL STAINLESS STEEL 35 55 6689 0001 4 EA INSULATOR MOLDED NYL SCREW 6 x 1 4 L 36 55 6689 0003 4 EA WASHER MOLDED NYL 8 X 1 8 T X 3 8 D 37 55 6689 0004 4 EA WASHER MOLDED NYL SHOULDER 8 38 73 7021 0006 44 IN WIRE 24AWG BLUE TWISTED PR 39 74 1023 0001 2 EA SWITCH GOLD CROSSPOINT CONTACT 3 5 7 8 24 6 1 28 2 25 35 37 36 20 13 12 10 11 14 1 PL 34 38 39 30 22 33 32 2 PL 26 2 PL ...

Page 166: ... RELIEF 8POS MTA 14 52 8247 0002 2 EA CRIMP CONTACT S30 TIN LOOSE 15 53 2002 0001 2 EA NUT 6 32 KEP ZINC PLATED 16 53 2003 0001 5 EA NUT 4 40 KEP ZINC PLATED 17 53 2004 0001 2 EA NUT 8 32 KEP 18 53 2009 0001 1 EA NUT 2 56 19 53 6404 0003 2 EA SCREW 4 40X1 PPZ 20 53 6545 0001 2 EA SCREW 8 32X3 8 PPB 21 53 6551 0001 7 EA SCREW 4 40X3 8 PPB 22 53 6565 0003 2 EA KNOB KNURLED 10 32 23 53 6594 0001 2 EA...

Page 167: ... 0010 CONFIDENTIAL 7 Oct 97 Assy Rear Bulkhead Bulb continued 22 4007 0001 2 10 3 12 7 11 13 4 9 5 30 15 26 1 5 IN 26 4 5 IN 26 4 IN 24 21 2 PL 20 33 23 22 21 2 PL 27 28 16 1 PL 16 1 PL 16 2 PL 21 2 PL 21 1 PL 1 14 32 8 19 18 31 6 25 17 29 2 PL 29 2 PL ...

Page 168: ...INED MOSS PATTERN 17 22 9628 0092 1 EA ASSY VL4 DIFFUSER FRNT APERTURE PLATE 18 44 5001 0000 1 EA MOTOR STEPPER 7 5DEG 25 OHM COIL 19 52 6300 0001 1 EA CONN HOUSING MTA CLOSED END Natrl 4PIN 20 52 6383 0001 1 EA CONN HOUSING MTA CLOSED END BLU 8PIN 21 52 6424 0004 1 EA COVER STRAIN RELIEF 4POS MTA 22 52 6424 0008 1 EA COVER STRAIN RELIEF 8POS MTA 23 53 2002 0001 2 EA NUT 6 32 KEP ZINC PLATED 24 53...

Page 169: ...ION 38 55 6621 0001 2 EA WASHER FLAT 4 ID 120 028THK 39 55 6677 0002 3 EA WASHER 360OD X 123ID X 025THK NYLON 40 73 7021 0006 23 IN WIRE 24AWG BLUE TWISTED PR 41 74 1023 0001 1 EA SWITCH GOLD CROSSPOINT CONTACT 1 30 31 9 39 32 18 6 15 14 2 30 31 14 11 8 17 21 19 7 34 35 20 22 36 40 41 26 24 37 38 4 5 27 13 29 23 25 10 33 3 12 16 1 PL 28 16 1 PL 15 4 3 ...

Page 170: ...RING RETAINING 2 521 ID 15 22 9628 0040 1 EA ASSY VL4 CABLE SIDE RAIL 10 9628 0040 1 EA RAIL SIDE CABLE 53 6506 0001 1 EA BEARING TORQUE TUBE 2 6250OD X 2 0620ID 54 1206 0001 1 EA RING RETAINING 2 521 ID 16 22 9628 0057 1 EA ASSY VL4 YOKE BEARING FRAME 17 22 9628 0118 1 EA COVER VL4 PULLEY SIDE 18 22 9628 0177 1 EA ASSY CONNECTORIZED FAN 19 24 9628 0049 1 EA PCB ASSY VL4 YOKE CABLE TERM YTB 20 24 ...

Page 171: ...1 EA SPRING CURVE HIGH CARBON 43 55 2129 0002 2 EA SHIM STAINLESS STEEL PAN TUBE 44 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNTING 45 55 2201 0001 1 EA SCREW 4 40 X 5 16 PFB 46 55 6517 0001 1 EA WASHER FLAT STEEL 375ODx 150IDx 031THK 47 55 6522 0001 3 EA WASHER FLAT 750 OD 192 ID 48 55 6528 0001 3 EA WASHER FLAT 6 ZINC 49 55 6568 0015 3 EA SPRING COMP 1 25FL X 455 OD S S 50 55 6568 0016 1 E...

Page 172: ...ers VL4 continued 22 4002 0001 30 4 PL 19 36 26 1 PL 15 45 25 44 51 50 7 9 2 PL 2 30 3 PL 54 3 31 30 4 PL 30 4 PL 32 1 37 52 1 PL 10 28 30 4 PL 24 1 PL 20 56 30 3 PL 12 35 48 14 27 40 17 26 1 PL 46 13 33 52 1 PL 34 16 30 3 PL 4 5 42 18 26 1 PL 24 4 PL 43 38 6 8 41 29 53 49 55 39 30 4 PL 25 47 11 22 21 23 ...

Page 173: ...2003 0001 2 EA NUT 4 40 KEP ZINC PLATED 6 53 2016 0002 2 EA NUT 4 40 HEX ZINC 7 53 6567 0001 2 EA NUT 4 40 X 1 2 PPZ 8 55 2203 0001 2 EA SCREW 4 40X1 4 PPZ 9 55 7003 0001 2 EA SPACER 5 16 RND X 3 16 L NYLON 10 68 4515 0003 1 EA INDUCTOR HIGH VOLT IGNITOR 60 1422 1002 14 EA R1 R14 RES 1 4W 5 10MEG CF 62 2032 0001 1 EA C14 CAP 01UF 3000V RAD CERAMIC 375 20 62 3000 0033 13 EA C1 C13 CAP 033UF 1000V R...

Page 174: ...4 20 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 PCB Assy VL4 Ignitor IGN4 continued 24 9628 0096 2 1 10 7 8 4 2 PL 9 5 6 4 2 PL 3 ...

Page 175: ... 0177 NO PART NO QTY DESCRIPTION 1 10 9628 0127 1 EA MOUNT FAN 2 40 7108 0001 1 EA FAN SNGLE INLET BLOWER AC 110V VL4 3 52 6231 0001 1 EA PLUG HOUSING MNLOK PLUG 3POS 4 52 8258 0001 3 EA CONTACT PIN 20 14AWG MNLOK LOOSE 5 53 2001 0001 4 EA NUT 10 32 KEPS ZINC PLATED 6 53 6549 0001 4 EA SCREW 10 32X3 8 PPB 2 3 1 4 6 5 ...

Page 176: ...52 6300 0001 1 EA CONN HOUSING MTA CLOSED END Natrl 4PIN 16 52 6424 0004 1 EA COVER STRAIN RELIEF 4POS MTA 17 52 6424 0005 1 EA COVER STRAIN RELIEF 5POS MTA 18 53 2001 0001 1 EA NUT 10 32 KEPS ZINC PLATED 19 53 6513 0001 3 EA SCREW 2 5MM X 4MM 20 53 6515 0001 1 EA SCREW 10 32X3 4 SCB CAP 21 53 6522 0001 3 EA SCREW 6 32X1 4 PPZ 22 53 6591 0001 5 EA SCREW 6 32X1 4 PFZ 23 53 6592 0002 3 EA SCREW 4 40...

Page 177: ...2 9628 0010 CONFIDENTIAL 7 Oct 97 Assy Tilt Mechanism VL4 continued 22 4004 0001 7 1 PL 22 1 PL 6 20 18 4 8 10 22 4 PL 24 1 PL 11 2 19 7 2 PL 27 26 12 35 1 9 29 34 25 28 24 1 PL 5 33 3 PL 21 3 13 23 ENCODER MOTOR 15 16 14 17 31 32 30 1 EA 30 1 EA ...

Page 178: ... 9628 0114 1 EA ASSY VL4 PAN BOTTOM PLATE 10 9628 0114 1 EA PLATE BOTTOM PAN 55 2134 0003 1 EA PLATE FLOATING NUT 12 45 5101 0001 1 EA ENCODER 256 COUNT 13 52 6424 0008 1 EA COVER STRAIN RELIEF 8POS MTA 14 52 6434 2208 1 EA CONN CLOSED W O TABS 22AWG 8 POS 15 53 2001 0001 1 EA NUT 10 32 KEPS ZINC PLATED 16 53 2005 0001 2 EA NUT WHEEL 3 8 32X3 32T 17 53 6513 0001 3 EA SCREW 2 5MM X 4MM 18 53 6515 0...

Page 179: ...AT SHRINK 3 8 BLACK 33 55 6592 0001 1 EA CABLE TIE MEDIUM 10 X 8 34 55 6602 0001 1 EA GROMMET 1 4 0 THRU 3 8 HOLE 1 8 PLATE 35 55 6618 0001 1 EA WASHER LOCK INT TTH 1 2 OD X 3 8 ID 19 20 2 PL 26 2 PL 16 1 PL 35 21 18 15 2 7 29 10 9 24 20 2 PL 26 3 PL 23 12 20 2 PL 6 3 33 25 1 PL 27 30 16 1 PL 28 1 8 25 1 PL 4 17 11 5 26 1 PL 22 31 1 PL 31 1 PL 34 32 13 14 ENCODER MOTOR ...

Page 180: ...ADER MTA FRCT LOK STRT POST 4PIN 4 52 6296 0001 6 EA HEADER MTA FRCT LOK STRT POST 8PIN 5 52 6420 0026 2 EA PIN HEADER ASSY WO LATCH 26POS 6 52 6421 0027 4 EA LATCH w o PUSH TABS for Pin Header Assy 7 53 2003 0001 1 EA NUT 4 40 KEP ZINC PLATED 8 53 6591 0001 1 EA SCREW 6 32X1 4 PFZ 9 53 6633 0001 4 EA SCREW 4 1 4 PPZ SHT METAL 10 60 1431 1803 6 EA RES 1 4W 5 180 CF 11 74 1006 0004 1 EA SWITCH THER...

Page 181: ...057 NO PART NO QTY DESCRIPTION 1 10 9628 0057 1 EA FRAME BEARING YOKE 2 10 9628 0094 1 EA GUIDE CARD INSIDE 3 10 9628 0168 2 EA GUIDE CARD MODIFIED PCG 3 LVS 4 53 6506 0001 2 EA BEARING TORQUE TUBE 2 6250OD X 2 0620ID 5 54 1206 0001 2 EA RING RETAINING 2 521 ID 6 55 6662 0001 1 EA HOLE PLUG 3 4 BRASS W BLK OXIDE 6 2 1 4 5 3 ...

Page 182: ...6 0002 2 EA COVER EJECT STYLE MT 26POS 26 22AWG 3 52 6228 0001 2 EA CONN HOUSING MT RECEPT 26POS 4 55 2182 0001 1 EA GROMMET 5 55 2197 0001 4 IN HEAT SHRINK 3 8 BLACK 6 55 2197 0002 3 IN HEAT SHRINK 3 8 YELLOW 7 55 6699 0003 5 IN SLEEVING POLY EXP BRAIDED 1 2 NOM DIA 8 55 9628 0175 1 EA SPRING YOKE CABLE 24 VL4 9 73 7083 0001 38 IN CBL 24AWG 26COND NO JCKT VL4 YOKE 2 3 1 6 7 4 5 8 5 6 1 3 2 SIDE A...

Page 183: ...0002 2 EA COVER EJECT STYLE MT 26POS 26 22AWG 3 52 6228 0001 2 EA CONN HOUSING MT RECEPT 26POS 4 55 2182 0001 1 EA GROMMET 5 55 2197 0001 4 IN HEAT SHRINK 3 8 BLACK 6 55 2197 0003 3 IN HEAT SHRINK 3 8 BLUE 7 55 6699 0003 7 IN SLEEVING POLY EXP BRAIDED 1 2 nom dia 8 55 9628 0175 1 EA SPRING YOKE CABLE 24 VL4 9 73 7083 0001 41 IN CBL 24AWG 26COND NO JCKT VL4 YOKE 2 3 1 6 7 4 5 8 5 6 1 3 2 SIDE A PIN...

Page 184: ...AWG VL 1 LOOSE 3 52 8247 0002 4 EA CRIMP CONTACT S30 TIN LOOSE 4 55 2200 0002 7 IN SLEEVING SIL RUB COATED FBRGLAS 162ID 5 55 6695 0003 4 IN HEAT SHRINK ADHESIVE 1 4 BLACK 6 55 6698 0001 1 EA GROMMET 3 16 IDx3 4 ODx3 8 THKx1 8 GRV 7 55 9628 0174 1 EA SPRING LAMP WIRE 24 VL4 8 73 7046 0002 80 IN WIRE 24AWG STRND GREEN 9 73 7084 0000 40 IN WIRE 24AWG BLK 5COND W BINDER 10 73 7084 0002 40 IN WIRE 24A...

Page 185: ...CB IFB 4 24 9628 0026 1 EA PCB ASSY VL4 VOLTAGE SELECTOR VSB 5 24 9628 0045 1 EA PCB ASSY VL4 LOW VOLTAGE SUPPLY LVS 6 24 9628 0053 1 EA PCB ASSY VL4 MOTHER MBD 7 25 9628 0152 1 EA CABLE ASSY MB VSB LK 1 VL4 8 53 6520 0001 6 EA SCREW 4 40 X 3 8 PPZ 9 53 6524 0002 1 EA SCREW 6 32X5 16 PPB 10 53 6596 0001 3 EA SCREW 4 40X5 16 PPZ 11 53 6600 0001 1 EA SCREW 4 40X 5 16 PPB 12 55 6525 0001 1 EA BUSHING...

Page 186: ...ARD RETAINER 5 23 9628 0005 1 EA ASSY TRANSFORMER CAPACITOR VL4 6 25 9628 0150 1 EA CABLE ASSY INPUT CONN WIRE VL4 7 40 7101 0001 2 EA FILTER AIR 200S 8 53 2001 0001 1 EA NUT 10 32 KEPS ZINC PLATED 9 53 2002 0001 5 EA NUT 6 32 KEP ZINC PLATED 10 53 2003 0001 4 EA NUT 4 40 KEP ZINC PLATED 11 53 2004 0001 2 EA NUT 8 32 KEP 12 53 6524 0002 6 EA SCREW 6 32X5 16 PPB 13 53 6546 0001 2 EA SCREW 8 32 X 5 ...

Page 187: ...R 4 ILLUSTRATED PARTS BREAKDOWN 4 33 02 9628 0010 CONFIDENTIAL 7 Oct 97 Assy VL4 Upper Enclosure continued 22 4000 0056 14 13 7 21 11 8 20 23 5 20 22 2 1 4 3 18 19 17 15 6 16 10 12 4 PL 12 2 PL 9 1 PL 9 4 PL ...

Page 188: ... 10 9628 0170 1 EA PLUNGER CARD RETAINER 2 10 9628 0184 1 EA PAD CARD RETAINER 3 22 9628 0169 1 EA CARD RETAINER 4 53 2001 0003 1 EA NUT 10 32 NYLON INSERT 5 53 6514 0001 1 EA SCREW 10 32X1 1 4 PPB 6 55 2234 0002 2 EA E RING 187 SHAFT DIA 7 55 6568 0014 1 EA SPRING 240ODX2 00LG W 022DIA SS WIRE 8 55 6584 0001 1 EA SPACER 3 8 X5 8 BLACK 1 3 7 6 5 8 2 4 ...

Page 189: ...OOSE TYPE 3 6 52 8276 0001 3 EA CONTACT PIN TIN 18 16AWG LOOSE TYPE 3 7 52 8256 0001 3 EA CONTACT SCKT 20AWG TIN MNLOK LOOSE 8 52 8232 0001 1 EA TERM RING 10 16 14AWG LOOSE 9 73 7006 0001 7 IN WIRE 16AWG STRND BLK STRND UL1061 10 73 7007 0001 7 IN WIRE 16AWG STRND WHT STRND UL1061 11 73 7008 0001 11 IN WIRE 16AWG STRND GRN STRND UL1061 12 73 7018 0001 6 IN WIRE 22AWG STRND RED 13 73 7030 0001 6 IN...

Page 190: ...4 2 3 5 Assy Transformer Capacitor VL4 23 9628 0005 NO PART NO QTY DESCRIPTION 1 23 9628 0159 1 EA ASSY CONNECTORIZED TRANSFORMER VL4 2 23 9628 0234 1 EA ASSY MOUNTED CAPACITOR VL4 3 52 8217 0001 1 EA TERM DUPLEX 250 NON INS 4 82 4303 2506 2 EA BRIDGE RECTIFIER MDA2506 600V 25A 4 3 1 2 ...

Page 191: ...sy Connectorized Transformer VL4 23 9628 0159 NO PART NO QTY DESCRIPTION 1 52 6319 0001 1 EA PLUG HOUSING MNLOK 4POS 2 52 8244 0002 5 EA FASTON RECEPT FLAG 250 16 14AWG LOOSE 3 52 8258 0001 4 EA CONTACT PIN 20 14AWG MNLOK LOOSE 4 68 4518 0004 1 EA TRANSFORMER VL4 110 220V LAMP UNIT 2 4 1 3 ...

Page 192: ... NO QTY DESCRIPTION 1 10 9628 0122 1 EA BRACKET MOUNTING CAPACITOR 2 25 9628 0156 1 EA CABLE ASSY XFRMR CAPACITOR VL4 3 55 2114 0001 6 EA WASHER LCK INT TTH 10 4 55 6564 0001 6 EA SCREW 10 32X5 16 PPZ 5 62 2096 1900 2 EA CAP 19000UF 40V RAD ALUMNUM 500 REF 6 62 2097 5300 1 EA CAP 53000UF 15V RAD ALUMNUM 500 REF 4 3 1 5 6 2 YEL BLU ORG GRN ...

Page 193: ...001 4 EA CONTACT SCKT 20AWG TIN MNLOK LOOSE 3 52 8244 0002 4 EA FASTON RECEPT FLAG 250 16 14AWG LOOSE 4 52 8232 0001 4 EA TERM RING 10 16 14AWG LOOSE 55 2186 0001 8 EA CABLE TIE SMALL 10X4 Not Shown 5 73 7008 0001 47 IN WIRE 16AWG STRND GREEN UL1061 6 73 7011 0001 48 IN WIRE 16AWG STRND ORANGE UL1061 7 73 7013 0001 49 IN WIRE 16AWG STRND BLUE UL1061 8 73 7042 0001 50 IN WIRE 16AWG STRND YELLOW UL1...

Page 194: ...V WHT 50 2708 0001 1 EA XU1 SOCKET 8PIN DIP 51 5001 0001 1 EA AP REG1 HEATSINK TO 220 1 W PINS 51 5006 0001 1 EA AP REG1 INSULATOR TO 220 51 5011 0001 1 EA AP REG2 MOUNTING PAD TO 5 52 6230 0001 1 EA P1 PIN HEADER ASSY MNLOK MALE 3CIR 52 6357 0001 1 EA P4 HEADER MTA FRCT LOK STRT POST 10PIN 52 6370 0003 1 EA P2 SOCKET HEADER ASSY MNLOK FMLE 3CIR 52 6370 0004 1 EA P3 SOCKET HEADER ASSY MNLOK FMLE 4...

Page 195: ... 3725 0001 8 EA AP F1 F4 FUSEHOLDER PC MT 2 REQ D 80 2513 0055 1 EA Q1 TRANSISTOR MPSA55 PNP 60V 500MA TO92 82 4302 0004 2 EA BR1 2 BRIDGE RECTIFIER W06G 600V 1 5A 82 4306 4001 1 EA D3 DIODE RECTIFIER 1N4001 50V 1A 82 5302 4148 2 EA D1 2 DIODE ULTRAFAST 1N4148 100V 10MA 83 3103 0001 1 EA REG1 IC LM317T ADJ POS VOLT REGULATOR 83 3117 0001 1 EA U1 IC LM393 DUAL COMPARATOR 83 3130 0002 1 EA REG2 IC L...

Page 196: ...6 55 2188 0001 1 EA CABLE TIE BLACK 18 X 12 17 55 6509 0001 5 EA AP REG1 5 WASHER SHOULDER HEATSINK 18 80 1612 5759 1 EA Q3 TRANSISTOR 2N5759 NPN 120V 6A TO3 19 80 1613 6227 2 EA Q1 2 TRANSISTOR MJ15016 PNP 120V 15A TO3 20 83 3107 0001 1 EA REG6 IC MPC100 5V 5A VOLT REGULATOR 60 1221 1301 2 EA R7 13 RES 1 4W 1 1 30K CF 60 1223 1787 2 EA R5 11 RES 1 4W 1 1 78K CF 60 1225 1186 4 EA R4 6 10 12 RES 1 ...

Page 197: ...02 8 EA D5 12 DIODE RECTIFIER 1N4002 100V 1A 82 4309 5401 4 EA D1 4 DIODE RECTIFIER 1N5401 100V 3A 83 3103 0001 2 EA REG1 2 IC LM317T ADJ POS VOLT REGULATOR 83 3104 0001 2 EA REG3 4 IC LM337T ADJ NEG VOLT REGULATOR 83 3111 0001 1 EA U1 IC 1458 DUAL BIPOLAR OP AMP 83 3120 0001 1 EA REG5 IC 79M05CT VOLT REG 5V 500MA 14 10 8 4 7 17 11 19 6 19 18 13 20 9 4 PL 1 15 3 16 5 12 2 9 5 PL ...

Page 198: ...4 52 6259 0001 1 EA HEADER MTA FRCT LOK STRT POST 5PIN 5 52 6296 0001 1 EA HEADER MTA FRCT LOK STRT POST 8PIN 6 52 6357 0001 1 EA HEADER MTA FRCT LOK STRT POST 10PIN 7 52 6399 0001 8 EA JUMPER PROGRAMMING 8 52 6420 0026 2 EA PIN HEADER ASSY WO LATCH 26POS 9 52 6421 0027 4 EA PIN HEADER ASSY LATCH WO PUSH TABS 10 52 6425 0004 1 EA PIN HEADER ASSY MNLOK INLINE 4CIR 11 52 8283 0005 7 EA TERM SWAGE TU...

Page 199: ...0010 CONFIDENTIAL 7 Oct 97 4 2 3 12 Cable Assy MB VSB LK 1 VL4 25 9628 0152 NO PART NO QTY DESCRIPTION 1 52 6372 0012 2 EA CONN HOUSING MTA CLOSED END RED 12POS 2 52 8291 0001 4 EA KEYING PLUG MTA 3 73 7080 0001 8 IN CBL 22AWG 10COND TWSTD UNJCKT 1 2 3 ...

Page 200: ...OL UCB 3 24 9628 0082 1 EA PCB ASSY VL4 INTERFACE IFB 4 53 2004 0001 1 EA NUT 8 32 KEP 5 53 6545 0004 1 EA SCREW 8 32X3 8 PPZ 6 53 6659 0003 4 EA SCREW 2 56X3 8 PPZ 7 53 6659 0004 4 EA SCREW 2 56X1 2 PPZ 8 55 2188 0000 1 EA CLAMP CABLE BLK 75DIA X 50WIDE 9 55 6677 0002 2 EA WASHER 360OD X 123ID X 025THK NYLON 10 55 6694 0001 2 EA STANDOFF 5 32 RND 2 56X7 16 11 55 6694 0002 2 EA STANDOFF 5 32 HEX 2...

Page 201: ... 32POS ELEVATED 52 8284 0001 7 EA J1 7 TERM STRIP 2 PIN STRAIGHT GOLD CONTACT 52 8284 0002 2 EA J8 9 TERM STRIP DBL ROW RT ANGLE 52 8285 0001 5 EA J1 3 6 7 9 CONTACT GOLD MICROSHUNT 260 HEIGHT 53 6659 0003 4 EA SCREW 2 56X3 8 PPZ 60 1421 2701 1 EA R12 RES 1 4W 5 2 7M CF 60 1421 4701 1 EA R13 RES 1 4W 5 4 7K CF 60 1422 1001 2 EA R10 14 RES 1 4W 5 1K CF 60 1423 1004 1 EA R11 RES 1 4W 5 1MEG CF 60 14...

Page 202: ... EA U54 IC 74HC138 3 TO 8 DECODER 84 4134 0001 2 EA U8 11 IC 74HC14 HEX INV SCHMIDT TRIGGER 84 4137 0001 1 EA U50 IC 74HC164 8 BIT SHIFT REG SER IN P OUT 84 4139 0001 2 EA U45 61 IC 74HC191 UP DOWN COUNTER 84 4140 0001 6 EA U9 34 55 57 58 71 IC 74HC244 OCTAL TRISTATE BUFFER 84 4141 0001 1 EA U72 IC 74HC273 OCTAL D FLIP FLOP 84 4143 0001 1 EA U7 IC 74HC4040 12 STAGE BINARY COUNTER 84 4145 0001 2 EA...

Page 203: ... U12 IC R68561AP MULTI PROTOCOL COMM CTRLR 87 7129 0002 1 EA U39 IC LOGIC PGM VL4UCB B U39 87 7129 0003 1 EA U40 IC LOGIC PGM VL4UCB B U40 87 7129 0004 1 EA U49 IC LOGIC PGM VL4UCB B U49 87 7129 0005 1 EA U51 IC LOGIC PGM VL4UCB B U51 87 7129 0006 1 EA U56 IC LOGIC PGM VL4UCB B U56 87 7129 0007 1 EA U63 IC LOGIC PGM VL4UCB B U63 87 7129 0008 1 EA U64 IC LOGIC PGM VL4UCB B U64 87 7129 0009 1 EA U66...

Page 204: ... 4 99K 60 1421 4701 5 EA R9 16 19 RES 1 4W5 4 7K CF 60 1429 3305 2 EA R3 4 RES 1 4W5 330K CF 61 4306 0102 1 EA RP1 RES SIP 1026PIN BUSSED LW PRFLE 61 4308 0272 1 EA RP2 RES SIP 272 8PIN BUSSED LW PRFLE 61 4310 0102 1 EA RP3 RES SIP 102 10PIN BUSSED LW PRFLE 62 2013 0104 35 EA C2 5 7 8 11 32 34 40 CAP 1UF 50V AXL CERAMIC 100 20 62 2015 0474 2 EA C1 6 CAP 47UF 50V SIP CERAMIC 100 20 62 2099 0103 2 E...

Page 205: ... U20 IC 74HC4040 12 STAGE BINARY COUNTER 84 4199 0001 2 EA U22 35 IC 74HC245 OCTAL BUS XCVR W 3 ST OUTPUT 84 4227 0767 2 EA U3 4 IC AD767 ANALOG TO DIG CONVERTER 84 7407 0010 1 EA U18 IC 74HC10 TRIPLE3 IN NAND GATE 84 7407 4017 1 EA U19 IC 74HC4017 DECADE COUNTER DIVIDER 84 7407 4078 1 EA U14 IC 74HC4078 8 IN NOR CMOS 85 5104 0001 2 EA U9 10 IC HCTL 2000 QUADRATURE DECDR COUNTER 85 5107 0001 6 EA ...

Page 206: ...AL CONFIDENTIAL 02 9628 0010 7 Oct 97 4 2 3 16 Assy Arc Power Supply 400Watt APS 21 9628 0020 NO PART NO QTY DESCRIPTION 1 23 9628 0029 1 EA ASSY APS CHASSIS VL4 2 23 9628 0031 1 EA ASSY APS HEATSINK VL4 3 53 6616 0001 4 EA SCREW 6 32X3 4 PPZ 1 2 3 ...

Page 207: ...EP ZINC PLATED 11 53 6558 0001 1 EA SCREW 6 32X3 8 PPZ 12 53 6569 0003 2 EA RIVET ALUM COUNTERSINK 3 16 X1 2 13 55 2114 0001 4 EA WASHER LCK INT TTH 10 14 55 2186 0001 8 EA CABLE TIE SMALL 10X4 Not Shown 15 55 2197 0001 1 IN HEAT SHRINK 3 8 BLACK Not Shown 16 55 6564 0001 4 EA SCREW 10 32X5 16 PPZ 17 60 4430 4702 2 EA RES 2W 5 47K MF 18 62 2028 0471 2 EA CAP 470UF 200V RAD ALUMNUM 500 REF 19 67 40...

Page 208: ...LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 Assy APS Chassis VL4 continued 23 9628 0029 4 2 8 26 22 10 23 18 5 17 16 17 13 3 11 6 1 20 15 1 9 7 21 12 19 22 23 24 25 24 3 12 4 7 4 7 4 ...

Page 209: ...0001 11 EA SCREW 6 32X1 2 PPZ 6 55 2188 0001 1 EA CABLE TIE BLACK 18 X 12 Not Shown 7 55 6525 0001 1 EA BUSHING NYLON SHOULDER 6X 170DX 125L 8 55 6689 0001 4 EA INSULATOR MOLDED NYL SCREW 6 X 1 4 L 9 55 6689 0002 4 EA SPACER MOLDED NYL SCREW 8X5 16OD X 3 8L 10 73 7051 0003 1 IN WIRE 18AWG BUSS 11 80 1610 0450 1 EA TRANSISTOR IRF450 NCH 500V 13A TO3 12 80 1612 1005 4 EA TRANSISTOR MJ10005 NPN 400V ...

Page 210: ...AIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 4 2 3 19 Assy APS Control Current Sense 21 9628 0197 NO PART NO QTY DESCRIPTION 1 24 9628 0023 1 EA PCB ASSY APS CONTROL VL4 2 24 9628 0197 1 EA PCB ASSY APS CURRENT SENSE 1 2 ...

Page 211: ... NYLON 375OD 256ID 032TH 19 55 6690 0001 1 EA AP U2 PAD MNTG IC DISCRETE COMPON 10PIN 20 55 9628 0001 1 EA GROMMET 3 8 ID X7 8 ODX7 16 THICK 21 68 4507 0001 2 EA P O T1 CORE DRIVE 22 68 4521 0001 1 EA T2 TRANSFORMER 400HZ 1PRI 4SEC 23 68 9628 0023 1 EA T1 TRANSFORMER APS VL4 24 73 7006 0001 6 IN WIRE 16AWG STRND BLACK 25 73 7007 0001 6 IN WIRE 16AWG STRND WHITE 26 73 7008 0001 6 IN WIRE 16AWG STRN...

Page 212: ...1 EA CDS CAP 0022UF 1000V AXL CERAMIC 295 5 62 2049 0105 1 EA C12 CAP 1UF 400V AXL POLYPRO 1 500 10 62 2083 0108 1 EA C10 CAP 1000UF 35V AXL ALUMNUM 1 240 20 62 2087 0220 1 EA C5 CAP 22UF 100V RAD POLYEST 400 10 62 3000 0033 2 EA C14 16 CAP 033UF 1000V RAD POLYPRO 400 10 63 2012 0001 1 EA TR1 POT 10K LIN 1TRN HORIZ MNT 10 80 1512 0112 1 EA Q10 TRANSISTOR TIP112 NPN 100V 2A TO220 80 1513 0117 2 EA ...

Page 213: ...USTRATED PARTS BREAKDOWN 4 59 02 9628 0010 CONFIDENTIAL 7 Oct 97 PCB Assy APS Control VL4 continued 24 9628 0023 12 11 8 24 25 26 17 21 9 13 15 17 21 23 5 3 18 19 2 4 7 14 16 6 7 33 1 22 6 14 16 27 28 29 30 31 32 10 ...

Page 214: ... 9628 0198 1 EA PCB APS CURRENT SENSE 3 73 7088 0001 9 IN WIRE 26AWG TW PR BLU WHT SOLID TINNED 52 6373 0003 1 EA SOCKET STRIP SNGL ROW 8PIN 52 8241 0001 4 EA AP R52A 52B PIN CONTACT 16AWG GOLD 55 2199 0001 1 IN HEATSHRINK 1 16 BLACK 60 1230 2003 4 EA R54 57 RES 1 4W 1 200K MF 60 7242 0501 2 EA R52A 52B RES 5W 1 05 WW 62 2063 0180 1 EA C30 CAP 18PF 500V RAD DIPMICA 234 5 63 2012 0002 2 EA TR2 3 PO...

Page 215: ...apter 5 Wiring Diagrams This chapter contains electrical diagrams connector pin codes and schematics for the VL4 luminaire Sections are as follows 5 1 Connector Type Identification 5 2 Connector Pin Diagrams 5 3 Schematics and Wiring Diagrams ...

Page 216: ...5 2 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 This page intentionally blank ...

Page 217: ... positions and come in red yellow and black colors A strain relief is usually used in conjunction with the connector to protect the wire connection This illustration shows a typical five position MTA style connector and strain relief 5 1 2 CPC CONTACT PIN RECEPTACLE PLUG CPC connectors are used to connect luminaire wiring to external cables The VL4 luminaire input panel uses one nine position CPC ...

Page 218: ...erted into the Mate N Lok plugs or receptacles Plugs and receptacles may be free as shown or PC board mounted Although a three position connector is shown the VL4 luminaire uses three and four position connectors 5 1 4 MT SIDE A PIN 1 SIDE B PIN 1 MT connectors are used to connect wire cables to PC boards The black MT connector has 26 positions divided into an A and B side Wires are installed from...

Page 219: ...C 3 GRN 22 AWG 20V 4 RED 22 AWG 20V 5 BRN 22 AWG MO1A 6 BLK 22 AWG MO1B 7 YEL 22 AWG MO1C 8 ORG 22 AWG MO1D 8 Pos MTA Amber Stepper Motor Pos Wire Wire Size Description 1 N C 2 N C 3 GRN 22 AWG 20V 4 RED 22 AWG 20V 5 BRN 22 AWG MO2A 6 BLK 22 AWG MO2B 7 YEL 22 AWG MO2C 8 ORG 22 AWG MO2D BRAIDED WIRE 8 PIN MTA CONN GRN RED BRN BLK YEL ORG 8 7 6 5 4 3 15 STEPPER MOTOR CAN STACK 0 2 1 OPEN OPEN AMBER ...

Page 220: ... BLU 22 AWG SENS2 4 POS MTA CONN CONTACT SWITCH BLU BLU 4 3 TWISTED PR HEAT SHRINK N C NC NO C 2 1 OPEN OPEN AMBER TO P9 ON YTB BLUE TO P7 ON YTB 5 2 1 2 Dimmer Magenta Douser Bulkhead 8 Pos MTA Magenta Stepper Motor Pos Wire Wire Size Description 1 N C 2 N C 3 GRN 22 AWG 20V 4 RED 22 AWG 20V 5 BRN 22 AWG MO3A 6 BLK 22 AWG MO3B 7 YEL 22 AWG MO3C 8 ORG 22 AWG MO3D BRAIDED WIRE 8 PIN MTA CONN GRN RE...

Page 221: ...G 8 7 6 5 4 3 9 0 STEPPER MOTOR 48 OHM 8 POS MTA CONN 2 1 OPEN OPEN 4 Pos MTA Magenta Contact Switch Pos Wire Wire Size Description 1 N C 2 N C 3 BLU 22 AWG 15V 4 BLU 22 AWG SENS1 4 POS MTA CONN CONTACT SWITCH BLU BLU 4 3 TWISTED PR HEAT SHRINK N C NC NO C 2 1 OPEN OPEN 4 Pos MTA Dimmer Sub Micro Switch Pos Wire Wire Size Description 1 N C 2 N C 3 BLU 22 AWG 15V 4 BLU 22 AWG SENS2 VIO VIO 4 3 4 PO...

Page 222: ...2 AWG DOUSER A 4 YEL 22 AWG DOUSER B YEL WHT WHT YEL 1 2 3 4 4 POS MTA CONN SOLENOID ASSY 5 2 1 3 Diffuser Assembly 8 Pos MTA Diffuser Stepper Motor Pos Wire Wire Size Description 1 N C 2 N C 3 GRN 22 AWG 20V 4 RED 22 AWG 20V 5 BRN 22 AWG MO5A 6 BLK 22 AWG MO5B 7 YEL 22 AWG MO5C 8 ORG 22 AWG MO5D GRN RED ORG BRN BLK YEL 8 7 6 5 4 3 7 5 0 STEPPER MOTOR 8 POS MTA CONN 2 1 OPEN OPEN ...

Page 223: ...e linear actuator motor used in this assembly is manufactured by two different manufacturers Use the applicable pin wire code 8 Pos MTA Focus Linear Actuator Pos Wire Version 1 Wire Version 2 Wire Size Description 1 N C N C 2 N C N C 3 WHT from blue red group GRN 22 AWG 20V 4 WHT RED 22 AWG 20V 5 BLK BRN 22 AWG MO6A 6 RED BLK 22 AWG MO6B 7 GRN YEL 22 AWG MO6C 8 BLU ORG 22 AWG MO6D GRN RED ORG BRN ...

Page 224: ...os Wire Wire Size Description 1 YEL 22 AWG TILT ENC B 2 BLK 22 AWG TILT ENC A 3 WHT 22 AWG GND 4 RED 22 AWG 5V 5 N C 1 WHT 22 AWG TILT TACH 2 BLU 22 AWG TILT V 3 RED 22 AWG GND 4 BLK 22 AWG GND 1 2 3 4 YEL 22AWG BLK 22AWG WHT22AWG RED 22AWG ENCODER 1 2 3 4 WHT 22AWG BLU 22AWG RED 22AWG BLK 22AWG MOTOR 5 OPEN TO P3 ON YTB TO P4 ON YTB ...

Page 225: ...5 Pos MTA Plug Pos Wire Wire Size Description 1 GRN 22 AWG SIGNAL GND 2 WHT 22 AWG REPLY 3 GRY 22 AWG REPLY 4 RED 22 AWG BROADCAST 5 BLK 22 AWG BROADCAST 3 Pos MATE N LOK Socket Plug Pos Wire Wire Size Description 1 GRN 16 AWG EARTH GND 2 WHT 16 AWG AC LO 3 BLK 16 AWG AC HI OPEN RED 22AWG 6 GRN 22AWG 6 BLK 22AWG 6 GRY 22AWG 6 WHT 22AWG 6 WHT 16AWG 7 GRN 16AWG 2 BLK 16AWG 7 GRN 16AWG 9 1 2 3 1 2 3 ...

Page 226: ... 16 AWG GND Ring Terminals Term Wire Wire Size Description 1 ORG 16 AWG 10V 2 BLU 16 AWG 30V 3 YEL 16 AWG 30V 4 GRN 16 AWG GND 4 Pos MATE N LOK Plug Pos Wire Wire Size Description 1 ORG 16 AWG 10V 2 BLU 16 AWG 30V 3 YEL 16 AWG 30V 4 GRN 16 AWG GND ORG 16AWG 27 GRN 16AWG 27 BLU 16AWG 26 5 YEL 16AWG 26 5 GRN 16AWG 19 5 YEL 16AWG 23 BLU 16AWG 21 5 ORG 16AWG 19 5 1 2 3 4 4 POS MATE N LOK PLUG RING TER...

Page 227: ...WG Y1 30V 2 RED YEL 16 AWG Y1 30V 3 RED N A 16 AWG C T GND 4 YEL N A 16 AWG Y1 30V 5 YEL N A 16 AWG Y1 30V 4 Pos MATE N LOK Plug Pos Wire Jacket Wire Size Description 1 WHT BLK 16 AWG X2 2 BLK WHT 16 AWG X3 3 WHT WHT 16 AWG X4 LO 4 BLK BLK 16 AWG X1 HI TRANSFORMER 1 2 3 4 RED YEL RED RED 6 5 5 4 0 YEL YEL BLK WHT WHT BLK WHT WHT BLK BLK 1 2 3 4 5 6 5 4 POS MATE N LOK 1 4 FASTON FLAG TO P3 ON VSB ...

Page 228: ...ARTH GND 3 ORG 22 AWG I PRESENT 4 WHT 22 AWG 15V 5 GRY 22 AWG SHORT 6 BLU 22 AWG 15V 7 BRN 22 AWG LPS OVER TMP 8 RED 22 AWG 20V 9 BLK 22 AWG LAMP ON 10 PRP 22 AWG INTENSITY RED 10 POS MTA CONN YEL 22 AWG 8 GRN 22 AWG 8 ORG 22 AWG 8 WHT 22 AWG 8 GRY 22 AWG 8 BLU 22 AWG 8 BRN 22 AWG 8 RED 22 AWG 8 BLK 22 AWG 8 PRP 22 AWG 8 1 2 3 4 5 6 7 8 9 10 10 9 8 7 6 5 4 3 2 1 RED 10 POS MTA CONN TO P4 ON VSB TO...

Page 229: ...U 24 AWG MO 1A 8 VIO 24 AWG MO 1B 9 GRY 24 AWG SENS1 10 WHT 24 AWG MO2A 11 BLK WHT 24 AWG MO2B 12 BRN WHT 24 AWG 20V 13 RED WHT 24 AWG 15V 26 Pos MT Connector Side B Pos Wire Wire Size Description 1 ORG WHT 24 AWG 5 2 YEL WHT 24 AWG TILT ENC B 3 GRN WHT 24 AWG TILT TSCH 4 BLU WHT 24 AWG N C 5 VIO WHT 24 AWG N C 6 GRY WHT 24 AWG DOWSER B 7 RED BLK 24 AWG MO 1C 8 ORG BLK 24 AWG MO 1D 9 YEL BLK 24 AW...

Page 230: ... BLU 24 AWG VIO 24 AWG GRY 24 AWG WHT 24 AWG BLK WHT 24 AWG BRN WHT 24 AWG RED WHT 24 AWG 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 ORG WHT 24 AWG YEL HWT 24 AWG GRN WHT 24 AWG BLU WHT 24 AWG VIO WHT 24 AWG GRY WHT 24 AWG RED WHT 24 AWG ORG BLK 24 AWG YEL BLK 24 AWG GRN BLK 24 AWG BLU BLK 24 AWG VIO BLK 24 AWG GRY BLK 24 AWG 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 1...

Page 231: ...B 8 VIO 24 AWG MO 5A 9 GRY 24 AWG MO 5B 10 WHT 24 AWG SENS5 11 BLK WHT 24 AWG MO 6A 12 BRN WHT 24 AWG MO 6B 13 RED WHT 24 AWG H O T 26 Pos Connector Side B Pos Wire Wire Size Description 1 ORG WHT 24 AWG 20V 2 YEL WHT 24 AWG 20V 3 GRN WHT 24 AWG MO 3C 4 BLU WHT 24 AWG MO 3D 5 VIO WHT 24 AWG SENS4 6 GRY WHT 24 AWG MO 4C 7 RED BLK 24 AWG MO 4D 8 ORG BLK 24 AWG MO 5C 9 YEL BLK 24 AWG MO 5D 10 GRN BLK...

Page 232: ... BLU 24 AWG VIO 24 AWG GRY 24 AWG WHT 24 AWG BLK WHT 24 AWG BRN WHT 24 AWG RED WHT 24 AWG 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 ORG WHT 24 AWG YEL HWT 24 AWG GRN WHT 24 AWG BLU WHT 24 AWG VIO WHT 24 AWG GRY WHT 24 AWG RED WHT 24 AWG ORG BLK 24 AWG YEL BLK 24 AWG GRN BLK 24 AWG BLU BLK 24 AWG VIO BLK 24 AWG GRY BLK 24 AWG 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 1...

Page 233: ...AWG 5COND 2 BLK 24 AWG 5COND R T GRN 24 AWG EARTH GND RED 24 AWG 40 BLK 24 AWG 40 GRN 24 AWG 40 RING TERMINAL RED 2 POS S30 CONN RING TERMINAL 1 2 2 1 RED 2 POS S30 CONN 5 2 11 VL4 Connectorized Fan 22 9628 0177 3 Pos Mate N Lok Pos Wire Wire Size Description 1 BRN 16 AWG CAP 2 BLK 16 AWG HI 3 BLU 16 AWG FAN BLK 16AWG BRN 16AWG BLU 16AWG 1 2 3 3 POS MATE N LOK FAN TO P2 ON VSB ...

Page 234: ...A 100 Pos Wire Wire Size Description 1 BLK 22 AWG PAN ENC A 2 YEL 22 AWG PAN ENC B 3 WHT 22 AWG GND 4 RED 22 AWG 5V 5 WHT 22 AWG PAN TACH 6 BLU 22 AWG PAN TACH 7 RED 22 AWG PAN V 8 BLK 22 AWG GND 1 2 3 4 5 6 7 8 BLK 22AWG YEL 22AWG WHT 22AWG RED 22AWG WHT 22AWG BLU 22AWG RED 22AWG BLK 22AWG ENCODER MOTOR TO P7 ON MB 8 POS MTA100 CONN ...

Page 235: ...CHAPTER 5 WIRING DIAGRAMS 5 21 02 9628 0010 CONFIDENTIAL 7 Oct 97 5 3 Schematics and Wiring Diagrams 5 3 1 LVS Transformer Schematic ...

Page 236: ...5 22 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 5 3 2 INA117 Emulator Board Schematic ...

Page 237: ...CHAPTER 5 WIRING DIAGRAMS 5 23 02 9628 0010 CONFIDENTIAL 7 Oct 97 5 3 3 Ignitor Board Schematic ...

Page 238: ...5 24 VARI LITE VL4 WASH LUMINAIRE SERVICE MANUAL CONFIDENTIAL 02 9628 0010 7 Oct 97 5 3 4 Yoke Termination Board Schematic ...

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