Vari Lite VL4 Bedienungsanleitung

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

ii VARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL

CONFIDENTIAL 02.9628.0010

7-Oct-97

Notice

VARI*LITE®, Artisan®, mini-Artisan®, mini-Artisan®2, Artisan®Plus,

mini-Artisan®Plus, VL2®, and VLD®are trademarks owned by Vari-Lite, Inc.,

201 Regal Row, Dallas TX 75247 USA. and are registered in the United States

and other countries.

VL1™, VL2B™, VL2C™, VL3™, VL4™, VL5™, VL5Arc™, VL5B™,

VL6™, VL6B™, VLM™, Series 100™, Series 200™, Series 300™,

Smart Repeater™, SmartDMX™, AutoTruss™, Dichro*Wheel™,

Dichro*Tune™, Vacu*Dep™, Vari*Image™, Vari*Beam™, Visionary™,

Artisan VLQ™, APS6™, C3™, SPC-36™, and UDM™are also trademarks

owned by Vari-Lite, Inc.

VARI*LITE®products and services are protected by one or more of the

following patents, and other pending patent applications worldwide:

U.S. Patents No. 5,640,061; 5,590,955; 5,590,954; 5,454,477; 5,537,303;

5,432,691; 5,367,444; 5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560;

5,186,536; 5,073,847; 5,031,078; 5,010,459; 4,980,806; 4,972,306; 4,800,474;

4,779,176; 4,709,311; 4,701,833; 4,688,161; 4,602,321; 4,392,187; 4,095,139;

U.S. Design Patents No. D 366,712; D 359,574; D 350,408; D 347,133;

Australia Patents No.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; 0 547 732; 0 534 710; 0 474 202; 0 253 152;

0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068;

France Design Reg. No. 95-1125;

Germany Utility Model Reg. No. G9312884.3; G9314158.5;

German Design Reg. No. M9501553.7; M9407689.8;

Hong Kong Patents No. 965/1990; 285/1987;

Japan Patents No. 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481;

1,792,721; 1,770,241; 1,742,923; 1,723,825; 1,683,007; 1,533,011;

Japan Design Reg. No. 970,593; 956,262; 947,552;

Korea Patents No. 92,269; 76,310; 47,673; 42,641; 42,640; 42,639;

Korea Design Reg. No. 175,178;

Mexico Patent No. 180,766; 180,687; 180,148; 179,138;

Singapore Patents No. 663/90; 134/87;

Spain Patent No. 2.031.748; 548.328; Design Patents No. 134.458; 134.491;

129.596; 129.595;

Taiwan Patents No. 212,234; 61,420; 57,219; 53,673; 52,156; 40,611; 28,275;

United Kingdom Design Reg. No. 2056387; 2056386; 2029499; 2033108; 2042174;

2045352.

VARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL iii

02.9628.0010 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

iv VARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL

CONFIDENTIAL 02.9628.0010

7-Oct-97

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VARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL v

02.9628.0010 CONFIDENTIAL

7-Oct-97

Contents

Chapter 1. Introduction

1.1 General Information ........................................................................1-3

1.1.1 About This Manual.............................................................................1-3

1.1.2 Documentation...................................................................................1-3

1.1.2.1 Technical Manuals........................................................................1-3

1.1.2.2 Technical Bulletins .......................................................................1-3

1.1.3 Maintenance Philosophy.....................................................................1-4

1.1.4 Recommended Safety Practices..........................................................1-5

1.2 Equipment Description....................................................................1-7

1.2.1 Dimensions and Weight......................................................................1-8

1.2.2 Technical Specifications .....................................................................1-9

1.2.2.1 Description...................................................................................1-9

1.2.2.2 Programmable Functions ..............................................................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 Installation........................................................................................2-3

2.1.1 Luminaire Hanging.............................................................................2-3

2.1.1.1 Distance-To-Distance Requirements.............................................2-3

2.1.1.2 Clearances....................................................................................2-4

2.1.2 Luminaire Packing..............................................................................2-5

2.2 Checkout...........................................................................................2-7

2.2.1 Power-Up ..........................................................................................2-7

2.3 Installing VL4 Accessories ...............................................................2-9

2.3.1 Installing Sound Baffles......................................................................2-9

2.4 Lamp Optical Alignment...............................................................2-11

vi VARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL

CONFIDENTIAL 02.9628.0010

7-Oct-97

Contents (continued)

Chapter 3. Maintenance Procedures

3.1 Test Procedures................................................................................3-3

3.1.1 Test EPROMs....................................................................................3-3

3.1.1.1 Description...................................................................................3-3

3.1.1.2 Thumbwheel.................................................................................3-3

3.1.1.3 Seven-Segment Display................................................................3-4

3.1.2 Reset Tests.........................................................................................3-4

3.1.3 Mechanics Tests (Tests 1 Through 15)...............................................3-5

3.1.3.1 Pan/Tilt Tests (Tests 1 and 2).......................................................3-5

3.1.3.2 Bulkhead Tests (Tests 3 Through 11)...........................................3-5

3.1.3.3 Simultaneous Tests (Tests 12 and 13)...........................................3-5

3.1.3.4 PSU Test (Test 15).......................................................................3-5

3.1.4 Manual Tests......................................................................................3-6

3.1.4.1 PSU Control Test (Test 20)..........................................................3-6

3.1.4.2 Sensor Test (Test 21)...................................................................3-6

3.1.4.3 Encoder Test (Tests 22 and 23)....................................................3-6

3.1.4.4 Form and Function Test (Test 24).................................................3-6

3.1.4.5 Data Loop-Back Test (Test 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 Not Come On-Line .....................3-24

3.2.2.3 Luminaire Has No Power ...........................................................3-25

3.2.2.4 Luminaire Powers Up, But Recalibrates Repeatedly....................3-25

3.2.2.5 Lamp Will Not Start...................................................................3-26

3.2.2.6 Douser Not Working Properly....................................................3-26

3.2.2.7 Dimmer Iris Not Working Properly.............................................3-27

3.2.2.8 Diffuser Not Working Properly...................................................3-28

3.2.2.9 Magenta Filters Not Working Properly.......................................3-28

3.2.2.10 Amber Filters Not Working Properly..........................................3-29

3.2.2.11 Blue Filters Not Working Properly .............................................3-30

3.2.2.12 Improper Tilt Response..............................................................3-31

3.2.2.13 Improper Pan Response..............................................................3-31

CONTENTS vii

02.9628.0010 CONFIDENTIAL

7-Oct-97

Contents (continued)

Chapter 3. Maintenance Procedures (continued)

3.3 Luminaire Maintenance Procedures .............................................3-33

3.3.1 Blue/Amber Bulkhead Maintenance..................................................3-33

3.3.1.1 Blue/Amber Bulkhead Removal and Replacement.......................3-33

3.3.1.2 Blue/Amber Bulkhead Stepper Motor

Removal and Replacement..........................................................3-35

3.3.1.3 Blue/Amber Bulkhead Sensor Removal and Replacement ...........3-37

3.3.1.4 Blue/Amber Bulkhead Worm Wheel

Removal and Replacement..........................................................3-39

3.3.2 Diffuser Mechanism Maintenance.....................................................3-41

3.3.2.1 Diffuser Mechanism Removal and Replacement..........................3-41

3.3.2.2 Diffuser Sensor Removal and Replacement.................................3-42

3.3.2.3 Diffuser Motor Removal and Replacement..................................3-44

3.3.2.4 Loose Diffuser Panel Emergency Fix ..........................................3-45

3.3.3 Dimmer/Filter/Douser Assembly Maintenance ..................................3-46

3.3.3.1 Dimmer/Filter/Douser Assembly Removal and Replacement .......3-46

3.3.3.2 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 and Replacement..........................................................3-60

3.3.3.9 Douser Leaves Removal and Replacement..................................3-62

3.3.3.10 Douser Spring Removal and Replacement...................................3-64

3.3.3.11 Douser Dashpot Calibration........................................................3-65

3.3.4 Miscellaneous Head Assembly Maintenance .....................................3-66

3.3.4.1 Lamp Removal and Replacement................................................3-66

3.3.4.2 Lamp Assembly Socket Removal and Replacement.....................3-67

3.3.4.3 Lamp Mounting Assembly Actuator Motor

Removal and Replacement (Shop Only)......................................3-69

3.3.4.4 Yoke Termination Board Removal and Replacement ..................3-72

3.3.4.5 Ignitor PCB Removal and Replacement......................................3-74

3.3.4.6 Ignitor PCB Spark Gap

Removal and Replacement (Shop Only)......................................3-75

3.3.4.7 Tilt Mechanism Removal and Replacement.................................3-76

viii VARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL

CONFIDENTIAL 02.9628.0010

7-Oct-97

Contents (continued)

Chapter 3. Maintenance Procedures (continued)

3.3.5 Electronics Chassis Maintenance ......................................................3-80

3.3.5.1 Arc Power Supply Removal and Replacement.............................3-80

3.3.5.2 Voltage Selector PCB Removal and Replacement.......................3-81

3.3.5.3 Voltage Selector PCB Fuses Removal and Replacement .............3-83

3.3.5.4 Low Voltage Supply and Universal Control PCB

Removal and Replacement..........................................................3-84

3.3.5.5 Motherboard Removal and Replacement.....................................3-85

3.3.5.6 Pan Drive Assembly Removal and Replacement..........................3-87

3.3.5.7 Transformer Assembly Removal and Replacement......................3-89

3.3.5.8 Mounted Capacitor Removal and Replacement...........................3-91

3.3.5.9 APS Control PCB Resistor/Diode

Removal and Replacement (Shop Only)......................................3-94

3.3.5.10 APS MJ10005 and IRF450 Transistor

Removal 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

4.2.1.1 Hooks and Covers Assy................................................................4-5

4.2.2 Head Assembly...................................................................................4-6

4.2.2.1 Head Assy....................................................................................4-6

4.2.2.2 Dimmer/Filter/Douser Assy ..........................................................4-7

4.2.2.3 Blue/Amber Bulkhead Assy........................................................4-10

4.2.2.4 Rear Bulkhead & Bulb Assy .......................................................4-12

4.2.2.5 Diffuser Mechanism Assy ...........................................................4-14

4.2.2.6 Yoke Rails & Covers Assy .........................................................4-16

4.2.2.7 Ignitor (IGN4) PCB Assy...........................................................4-19

4.2.2.8 Connectorized Fan Assy .............................................................4-21

4.2.2.9 Tilt Mechanism Assy ..................................................................4-22

4.2.2.10 Pan Drive Assy...........................................................................4-24

4.2.2.11 Yoke Cable Term (YTB) PCB Assy ...........................................4-26

4.2.2.12 Yoke Bearing Frame Assy ..........................................................4-27

4.2.2.13 Yoke “A” 38 Inch Cable Assy.....................................................4-28

4.2.2.14 Yoke “B” 41 Inch Cable Assy.....................................................4-29

4.2.2.15 A & B Lamp Wire Assy..............................................................4-30

CONTENTS ix

02.9628.0010 CONFIDENTIAL

7-Oct-97

Contents (continued)

Chapter 4. Illustrated Parts Breakdown (continued)

4.2 Parts Breakdown (continued)

4.2.3 Chassis Assembly .............................................................................4-31

4.2.3.1 Chassis Assy...............................................................................4-31

4.2.3.2 Upper Enclosure.........................................................................4-32

4.2.3.3 Card Retainer .............................................................................4-34

4.2.3.4 Input Conn. Wire Cable Assy......................................................4-35

4.2.3.5 Transformer/Capacitor Assy.......................................................4-36

4.2.3.6 Connectorized Transformer Assy................................................4-37

4.2.3.7 Mounted Capacitor Assy ............................................................4-38

4.2.3.8 Transformer & Capacitor Cable Assy..........................................4-39

4.2.3.9 Voltage Selector (VSB) PCB Assy.............................................4-40

4.2.3.10 Low Voltage Supply (LVS) PCB Assy.......................................4-42

4.2.3.11 Motherboard (MBD) PCB Assy .................................................4-44

4.2.3.12 MB-VSB (LK 1) Cable Assy ......................................................4-45

4.2.3.13 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 Type Identification.........................................................5-3

5.1.1 MTA-100 and MTA-156....................................................................5-3

5.1.2 CPC...................................................................................................5-3

5.1.3 Mate-N-Lok.......................................................................................5-4

5.1.4 MT.....................................................................................................5-4

5.2 Connector Pin Diagrams..................................................................5-5

5.2.1 Yoke Termination PCB Connections..................................................5-5

5.2.1.1 Blue/Amber Bulkhead...................................................................5-5

5.2.1.2 Dimmer/Magenta/Douser Bulkhead..............................................5-6

5.2.1.3 Diffuser Assembly ........................................................................5-8

5.2.1.4 Rear Bulkhead and Bulb...............................................................5-9

5.2.1.5 Tilt Motor Connections ..............................................................5-10

5.2.2 Input Connector Wire Cable.............................................................5-11

5.2.3 Transformer/Capacitor LK3 Cable....................................................5-12

xVARI*LITE® -VL4WASH LUMINAIRE SERVICE MANUAL

CONFIDENTIAL 02.9628.0010

7-Oct-97

Contents (continued)

Chapter 5.Wiring Diagrams (continued)

5.2.4 Connectorized Transformer Connections..........................................5-13

5.2.5 LK1 Cable........................................................................................5-14

5.2.6 Yoke “A” 38 Inch 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 Termination Board Schematic.................................................5-24

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