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2 - Vari-Lite

1. 1 VARI LITE RE 2 3 4 VARI LITE dE RIL n EAE 3 7 VED SED D BEZA PRB TE 1 VARI LITE 2 VARI LITE
2. 3 4 5 LTS 6 RF 1 Class
3. 1 Lamp Power Up State 2 02 9690 00100 TABLE OF CONTENTS Table of Contents About This Manual ya 28 A nne ioe BAB tibi eee 1 Additional Documentation keke keke ke ke ke ke kek ke ke ke KE KAK KK KAK KK 1 Customer Service yy Kani esla l a annen lea DB A rn V Rek Mek Dea ERE b d 2 Technical Bulletins and Notices 2 Chapter 1 Description Features Standard Features 4 Technical Specifications eee eife Susu e na ic HO 4 Components VLX Wash External Components 5 VLX Wash Luminaire Head Components pp 6 VLX Wash Luminaire Yoke Components a 7 VLX Wash Enclosure Components pp 8 Principles of Operation VLX Wash Luminaire Functional Block Diagram eee 9 Chapter 2 Maintenance Testing Luminaire Self Test ix an ee e eere er
4. 3 02 9690 0010 0 Xi VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL UV 1 VARI LITE UV HID 2 1 2
5. LCD Display Assembly LCD Display PCB Assembly u ek Fuse Replacement Power Distribution Assembly Power Distribution Assembly Power Supply 1 Assembly Power Supply 2 Assembly Pan Motor Assembly Pan Motor echo Re ete ete Pan Encoder PCB a a a dieses VLX Wash dropCal Reinstall Factory LED Calibration Chapter 3 Illustrated Parts Breakdown Drawing Tree VLX Wash Luminaire sus Top Assembly VLX Wash Included Items Kit VLX Wash Luminaire uu a VLX Wash No Covers Assembly eee Yoke Arm Cover Assembly Tilt Motor Side Yoke Arm Cover Assembly MCB Side Yoke Center Cover Assembly Head Assembly Head Structure Assembly u Zoom Array Assembly Ne Motherboard Support Assembly Rear Head Cover Assembly pp Front Head Cover Assembly pp Yoke Assembly VLX Wash Yoke Assembly Tilt Motor Assembly anses KA Enclosure Assembly VLX Wash Upper Enclosure Assembiy VLX Wash Base Sub Assembly u eke VLX Wash Display Assembly VLX Wash Connector Assembly Pan Motor Assembly xiv 10 September 2009 02 9690 00100 TABLE OF CONTENTS VEX W
6. 11 10 9690 0341 7 EA SEAL LIGHT PIPE TOP 12 10 9690 0353 7 EA LIGHT PIPE SUPPORT TOP 13 10 9690 0620 1 EA GRILL AIR EXHAUST HEX 14 10 9690 0621 4 EA STANDOFF EXHAUST GRILL 15 10 9690 0628 4 EA STANDOFF TILT TUBE 16 21 9690 0105 1 EA ASSY ZOOM ARRAY 17 21 9690 0334 1 EA ASSY MOTHERBOARD SUPPORT 18 21 9690 0615 1 EA ASSY HEAD COVER REAR 19 22 9690 0310 1 EA ASSY COOLING SYSTEM VLX 19a 22 9690 0311 6 EA FAN ASSEMBLY LED COOLING VLX WASH 20 22 9690 0140 7 EA ASSY CPC OPTIC 21 22 9690 0652 2 EA ASSY TILT TUBE 22 23 9690 0690 1 EA AIR SENSOR AMBIENT 23 24 9690 0570 7 BOARD ASSY VLX DRIVER 24 42 9690 0128 7 EA LIGHT PIPE HEX GLASS 25 51 5039 0005 7 EA THERMAL INTERFACE LED DIE CUT 26 53 2202 0004 14 EA NUT NYLOC 4 SST 27 53 5655 0250 8 EA SCREW 6 X 1 4 PPZ PLASTIC THREADING 02 9690 0010 0 105 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 28 53 5804 0438 14 EA SCREW 4 40 X 0 438 LG SH CAP ZINC 29 53 6575 0009 4 EA SCREW 8 32 X 3 8 LG PPB SEMS 30 53 6607 0002 3 EA SCREW 6 32 X 1 4 PFB 31 53 6609 0001 3 EA SCREW 6 32 X 3 8 PFZ 32 53 6682 0002 14 EA SCREW 4 40 X 1 4 LG PPZ SEMS 33 53 6682 0022 6 EA SCREW 8 32 X 3 8 LG PPZ SEMS 34 53 6682 0026 4 EA SCREW 8 32 X 3 4 LG PPZ SEMS 35 54 1206 0057 3 EA RING RETAINING EXT E CLIP 0 375 SHAFT Z
7. LCD Display Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace LCD Display assembly Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure and LCD Display Assembly side is up Be sure to rotate head as shown in Figure 2 47 A Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up LCD Display Assembly tl ss 6 Figure 2 47 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 48 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Remove 8 32 x 1 2 PFB screw in enclosure top cover securing LCD Display assembly 02 9690 0010 0 65 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 1 4 20 x 2 CAP 1 4 20 x 1 5 CAP SOC Screws x4 SOC Screws x2 Connector Assembly Upper Enclosure Bottom Cover LCD Display Note Some components not shown for clarity Figure 2 48 VLX Wash Upper Enclosure LCD Dis
8. No Item Qty UM Description 1 10 9690 0801 1 EA DISPLAY MOUNTING PLATE 2 10 9690 0817 1 EA OVERLAY DISPLAY VLX WASH 3 24 9690 0580 1 EA ASSY DISPLAY VLX WASH 4 53 6558 0010 4 EA SCREW 6 32 X 1 4 PPB SEMS 5 55 6627 0001 4 EA WASHER 6 SPLIT LOCK Note Item 5 mounts between Items 1 and 3 Figure 3 12 VLX Wash Display Assembly 122 02 9690 00100 ENCLOSURE ASSEMBLY VLX WASH CONNECTOR ASSEMBLY 3 VLX Wash Connector Assembly 21 9690 0804 Rev C Refer to Figure 3 13 No Item Qty UM Description 1 10 9690 1802 1 EA CONNECTOR PLATE 2 24 9663 3895 1 EA PCB ASSY DMX INPUT 3 25 9690 2551 1 EA CABLE ASSY INPUT VLX WASH 4 53 2003 0001 6 EA NUT 4 40 KEP ZINC PLATED 5 53 6598 0001 6 EA SCREW 4 40 X 3 8 4 x6 1 2 5 x6 3 Figure 3 13 VLX Wash Connector Assembly 02 9690 0010 0 123 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21 9690 0540 Rev 0 Refer to Figure 3 14 No Item Qty UM Description 1 10 9690 0805 1 EA PAN MOTOR MOUNT 2 21 9685 0545 1 EA ASSY DRIVE PULLEY 10 9678 8720 1 EA CODEWHEEL 10 9685 0524 1 EA 18 TOOTH 2 MM TIMING PULLEY WITH SET SCREWS 3 24 9685 7735 1 EA BOARD ASSY PAN TILT ENCODER 4 44 9678 0680 1 EA MOTOR 3 PHASE SZ 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6558 0001
9. 55 5 Figure 3 31 Negative Wire Driver Board 7 Cable Assembly 02 9690 0010 0 143 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Positive Wire Driver Board Tilt Motor Side Cable Assembly 25 9690 1509 Rev B Refer to Figure 3 32 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 48 HOLE SIZE 2 1 LOCKING FORK 16 14 AWG 6 STUD 3 98 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE GREEN 49 0 Figure 3 32 Positive Wire Driver Board Tilt Motor Side Cable Assembly 144 02 9690 00100 CABLE ASSEMBLIES POSITIVE WIRE DRIVER BOARD MCB SIDE CABLE ASSEMBLY 3 Positive Wire Driver Board MCB Side Cable Assembly 25 9690 1510 Rev B Refer to Figure 3 33 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 92 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE GREEN 46 0 Figure 3 33 Positive Wire Driver Board MCB Side Cable Assembly 02 9690 0010 0 145 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash A C Input Cable Assembly 25 9690 2551 RevA Refer to Figure 3 34 No Item Qty UM Description 1 52 6541 0003 1 EA CONN CHASSIS PWR 3 POLE LOCKING 2 52 8331 0003 1 EA FASTON RECPT 16 14 AWG PIDG BLU 0 170 ID 3 1 EA TERM RING 8 16 14 AWG PIDG 4 73 6014 0005 7 IN WIRE
10. Head Structure Assembly 21 9690 0600 Rev K Motherboard Support Assembly 21 9690 0334 RevA Rear Head Cover Assembly 21 9690 0615 Rev A Zoom Array Assembly 21 9690 0105 Rev B VLX Wash Upper Enclosure Assembly 21 9690 0800 Rev VLX Wash Base Sub Assembly 21 9690 0803 Rev B VLX Wash Display Assembly 21 9690 0802 Rev C VLX Wash Connector Assembly 21 9690 0804 Rev C VLX Wash A C Input Cable Assembly 25 9690 2551 RevA Pan Motor Assembly 21 9690 0540 Rev 0 VLX Wash Pan Tube Assembly 22 9690 0800 Rev B continued next page Figure 3 1 VLX Wash Luminaire Subassembly Drawing Tree Part 1 90 02 9690 00100 DRAWING TREE VLX WASH LUMINAIRE 3 VLX Wash Luminaire continued continued from previous page VLX Wash Upper Enclosure Assembly 21 9690 0800 Rev VLX Wash 12V Output 1 Cable Assembly 25 9690 0511 Rev B SE VLX Wash 12V Output 2 Cable Assembly 25 9690 0512 Rev B VLX Wash Display Link MCB to Display Cable Assembly 25 9690 1553 Rev A VLX Wash Data I O Link Cable Assembly 25 9690 1550 Rev A VLX Wash Pan Tilt Cable Assembl 25 9690 1556 Rev D VLX Wash Display Link Ballast to Display Cable Assembly 25 9690 0572 Rev A Negative Wire Driver Board 1 i Cable Assembly 25 9690 1501 Rev B Negative Wire Driver Board 2 Cable Assembly 25 9690 1502 Rev B Negative Wire Driver Board 3 Cable Assembly 25 9690 1503 Rev C Negative Wire Driver Board 4 Cable A
11. 2003 2009 A Philips Group Company All rights reserved Printed in the U S A
12. 14 AWG 600V 105 DEG C PVC GRN UL1015 Neutral Ground Figure 3 34 VLX Wash A C Input Cable Assembly 146 02 9690 00100 CABLE ASSEMBLIES VLX WASH A C SUPPLY CABLE ASSEMBLY 3 VLX Wash A C Supply Cable Assembly 25 9690 3552 RevA Refer to Figure 3 35 No Item Qty UM Description 1 1 EA LOCKING FORK SCOTCHLOK 8 STUD 16 14 AWG 2 52 8313 0001 2 EA RECPT FASTON 1 4 18 14 AWG FLAG DBL CRP 3 52 8231 0005 1 EA TERM RING 6 16 14 AWG REEL PIDG 4 73 6014 0010 36 IN WIRE 14 AWG 600V 105 DEG C PVC BLK UL1015 5 73 6014 0009 36 IN WIRE 14 AWG 600V 105 DEG C PVC WHT UL1015 6 73 6014 0005 26 IN WIRE 14 AWG 600V 105 DEG C PVC GRN UL1015 7 55 2186 0001 2 EA CABLETIE 0 10 WD X 4 00 LG SMALL 8 5 EA LOCKING FORK SCOTCHLOK 8 STUD 12 10 AWG 9 a 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 10 52 8331 0003 2 EA RECEPT FASTON 0 187 16 14 AWG 11 67 4018 0001 1 EA FERRITE 26 X 28 5 X 13 MM CYL 12 52 6264 0004 1 EA CONN HOUSING 3 POS SL156 W RAMP NO TABS 13 2 EA CONTACT SL156 24 18 AWG 14 43 IN WIRE 20 AWG 600V 200 DEG C FEP WHT STRAND 105 40 15 43 IN WIRE 20 AWG 600V 200 DEG C FEP BLK STRAND 105 40 02 9690 0010 0 147 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash A C Supply Cable Assembly continued 12 8 x2 15 Wrap each wire BlK twice through ferrite Figure 3
13. 32 02 9690 00100 MAINTENANCE PROCEDURES TILT MOTOR ASSEMBLY REPLACEMENT 2 Step 12 As shown in Figure 2 17 tighten motor in order shown in an 8 10 2 4 o clock pattern with the spring being 12 noon Note Some components not shown for clarity GO Tightening Order Tilt Motor Spring Q 8 KEPS Nuts x4 Tilt Motor Assembly Note some parts removed for clarity Figure 2 17 Tilt Motor Assembly Installation Step 13 Be sure encoder wiring does not catch on cover mounts Step 14 Reconnect Encoder PCB wiring Step 15 Reinstall yoke center and arm covers Step 16 Power luminaire and test 02 9690 0010 0 33 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Tilt Encoder PCB Replacement Tools 2 Phillips screwdriver Z N WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace Tilt Encoder PCB Step 1 Remove power from luminaire Step 2 At yoke arm cover without tilt lock assembly remove yoke arm cover by loosening four 1 4 turn Dzus fasteners Refer to Figure 2 18 for details A Remove power before CAUTION servicing Luminaire Head Yoke Arm Cover without tilt lock Figure 2 18 VLX Wash Luminaire Step 3 Disconnect wiring from tilt encoder PCB Note routing of wiring 34 02 9690 00100 MAINTENANCE PROCEDURES TILT ENCODER PCB REPLACEMENT 2 Step 4 As shown in Figure 2 1
14. 36 55 3301 0008 3 EA WASHER FLAT 8 0 032 THK 0 375 OD 37 55 6568 0060 3 EA SPRING CPRSN 0 438 OD 2 00 LG 0 024 WD SS 38 55 6568 0113 14 EA SPRING CPRSN 0 188 OD 0 375 LG 0 02 WD SST 39 55 7005 0014 7 EA O RING 9 16 ID 3 4 OD 3 32 THK BUNA N 40 88 8200 0001 7 EA LED RGBW 32 MM X 32 MM 02 9690 00100 HEAD ASSEMBLY HEAD STRUCTURE ASSEMBLY 3 Head Assembly continued 40 x7 25 x7 See Detail A amp B 24 x7 28 x14 7 x7 14 x4 29 x4 7 EUR See Detail D 11 x7 AS 22 32 x14 20 x7 2 x3 18 16 See Detail C 15 x4 i 34 x4 21 x2 3 30 x3 1 x3 31 x3 38 x14 Figure 3 1 Head Structure Assembly Part 1 02 9690 0010 0 107 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Head Assembly continued Detail B Detail A 28 See Torque Note 40 25 Torque Note Torque screws 28 to 80 in oz in 14 places Detail D Detail C ES Head Ass Head Assembly Rear Install array lens assembly 16 with grid running up down left right as shown Install rear grill 13 in orientation shown Figure 3 2 Head Structure Assembly Part 2 108 02 9690 00100 HEAD ASSEMBLY ZOOM ARRAY ASSEMBLY 3 Zoom Array Assembly 21 9690 0105 Rev B Refer to Figure 3 3 No Item Qty UM Description 1 42 9690 0110 1 EA LENS ARRAY CONVEX 2 42 9690 0111 1 EA LE
15. 4 40 x 1 4 PPB screws Note Some components not shown for clarity Wire Harness Guide 4 40 x 1 4 PPB Screws x2 Tilt COT Sensor Tilt Encoder PCB Figure 2 21 VLX Wash Tilt Sensor Replacement Step 6 Remove tilt COT sensor note wire harness guide will come loose Step 7 Replace tilt COT sensor by performing Steps 2 through 6 in reverse order Step 8 Power luminaire and test 02 9690 0010 0 37 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL LED Driver PCB Tools e 2 Phillips screwdriver 90 degree 2 Phillips head screwdriver Z N WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace LED Driver PCBs Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 22 and engage tilt lock Luminaire Head Remove power and CAUTION allow fixture to cool Front Head Cover a Front Cover Latch one on each side of cover Upper Enclosure Figure 2 22 VLX Wash Luminaire Step 3 Remove front head cover by unlatching both head cover latches Please note that one side of front cover is secured by a safety tether Locate clip attached to luminaire and unclip tether Step 4 Gently slide front head cover over optic assembly and set aside 38 02 9690
16. For addressing accessing menu options and settings See page 5 for details Input Panel Assembly Contains DMX Input PCB and AC Input Pan Tube Assembly NS PG Enclosure Air Dam Enclosure Top Cover Power Supply 2 Each 12 Volts DC 600W AC Input ji Requires standard AC power distribution from 100 240 VAC 50 60 Hz up to 10A depending on the AC supply voltage Wire Connection Green Yellow AC Ground Blue AC Neutral Note RV Brown AC Line Head and Yoke assemblies not shown AA A for clarity International Harmonized Standard 8 02 9690 00100 1 VLX WASH LUMINAIRE FUNCTIONAL BLOCK DIAGRAM PRINCIPLES OF OPERATION Principles of Operation iagram Block D lona Funct inaire VLX Wash Lum uonesado ayioeds 10 Bumeip Ajqu esse alqeo ol Jejed amod pue uloq ueo sejqeo eioN s L po JeAud 031 lt 7 ME USEM XTA A a i 9 ded 9 pieog 19M0091 Le m usem XTA S p eog JEAUG Q314ol ue ON 010M S peo JeAUd 091 USEM XTA an pieog 19MI0 031 USEM XTA ses T ar pieog JeAud 031 USEM XTA al 4 2 pieog J8Auq 031 USEM
17. LED WASH LUMINAIRE SERVICE MANUAL c At other EMI shield side with ambient temperature sensor remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield d Carefully work shield over ambient temperature sensor taking care not to snag or pull sensor Once shield is clear of sensor set shield aside Note Some components not shown for clarity Front Head Cover Front Cover Latch N one on each side of cover Front Head Cover 4 Safety Tether 4 40 X 1 4 PPZ SEMS Screws X3 EMI Protective Shield side with ambient temperature sensor EMI Protective Shield side with front cover tether connects to head 6 32 x 1 4 PPZ SEMS Screws x5 Per shield Figure 2 29 Front Head Cover and EMI Shields Removal Step 6 Disengage tilt lock and rotate luminaire head 90 degrees Step 7 At inside of rear head cover remove eight 6 x 1 4 PPZ Plastic Threading Screws Note At reinstalling rear head cover be careful not to over tighten plastic threading screws plastic mounting holes may crack 46 02 9690 0010 0 MAINTENANCE PROCEDURES HEAD FAN COOLING SYSTEM ASSEMBLY 2 Step 8 Atrear of head assembly as shown in Figure 2 30 remove four 8 32 x 3 8 PPB SEMS screws securing grill assembly Noting orientation before removal remove rear grill Note Some components not shown for clarity
18. on temperature to the LED s respective driver PCB Check the thermistor temperatures of each LED through the fixture s LCD display If one LED is much hotter than the others Check to see that the LED s fan is running connected to the Driver PCB Note LED Driver PCB number 5 does not have a fan OR If thermistor is not reading replace Driver PCB OR If still no reading replace the LED n a Colors light output not matching from luminaire to luminaire Color output not match ing other VLX wash fix tures operating at same control settings Calibration turned On or Off Check fixture calibration setting Make sure calibration is set to same setting On or Off as other fixtures Check dimming curve setting Make sure dimming curve selection Linear or Curve is same for all fixtures 16 02 9690 00100 SPECIAL CARE AND HANDLING INTRODUCTION Special Care and Handling A WARNING As with any repairs or maintenance to VARI LITE luminaires service should only be performed by a trained and qualified service technician or at an Authorized VARI LITE Service Center Introduction Being a solid state fixture and unlike most automated arc or tungsten fixtures the VLX LED Wash Luminaire requires very little routine maintenance by the user This section covers all the parts or assemblies that can be removed cleaned and checked by the user Any additional m
19. 00100 MAINTENANCE PROCEDURES LED DRIVER PCB 2 Step 5 Remove protective EMI shields from around optics assembly as shown in Figure 2 23 as follows WARNING On one EMI shield it is imperative to identify the ambient temperature sensor that protrudes through the EMI protective shield it is on the opposite side where the front cover safety tether connects When this shield is removed great care has to employed not to damage the sensor a At EMI shield side where front cover safety tether connects remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield b Remove shield and set aside c At other EMI shield side with ambient temperature sensor remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield d Carefully work shield over ambient temperature sensor taking care not to snag or pull sensor Once shield is clear of sensor set shield aside Note Some components not shown for clarity Front Head Cover Front Cover Latch one on each side of cover Front Head Cover Safety Tether 4 40 X 1 4 PPZ SEMS Screws X3 EMI Protective Shield side with ambient EMI Protective Shield temperature sensor side with front cover tether connects to head 6 32 x 1 4 PPZ SEMS Screws x5 SS Per shield Figure 2 23 Front Head Cover and EMI Shields Removal Step 6 A
20. 2 EA SCREW 6 32 X 3 8 PPZ 7 53 6575 0004 4 EA SCREW 8 32 X 5 8 PPZ 8 55 6627 0001 2 EA WASHER 6 SPLIT LOCK 124 02 9690 00100 ENCLOSURE ASSEMBLY PAN MOTOR ASSEMBLY 3 Pan Motor Assembly continued Detail A 3 etai 6 x2 x2 d See Detail A 2 5 x4 Pressure Sensitive Adhesive Drive Pulley Detail amp Installation Connector oriented on this side Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Note Vari Lite recommends that this assembly be replaced as a complete assembly Although you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly and cannot be removed intact If you order a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information Figure 3 14 Pan Motor Assembly 02 9690 0010 0 125 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Pan Tube Assembly 22 9690 0800 Rev B Refer to Figure 3 15 No Item Qty UM Description 1 10 9687 0601 1 EA PAN TUBE OUTER 2 10 9687 0602 1 EA PAN TUBE STOP SCREW 3 10 9687 0603 1 EA PAN TUBE INTER S
21. 35 VLX Wash A C Supply Cable Assembly 148 02 9690 0010 0 APPENDIX A VLX WASH TECHNICAL BULLETINS AND NOTICES A APPENDIX A Technical Bulletins and Notices VLX Wash Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the Series VLX Wash Luminaires These improvements have been incorporated into this manual where applicable and are available on the Vari Lite web site at www vari lite com Please note that not all bulletins or notices are applicable to all versions of the fixtures included in this manual Refer to each bulletin and notice for specific information and application Technical Bulletins Technical Bulletin Description Model s LSW 048 VLX Wash Luminaire Initial Software Release 08 02 09 All VLX Wash LSW 049 VLX Wash Luminaire Software Release 08 21 09 All VLX Wash This bulletin or notice was superseded and removed from the Vari Lite web site Technical Notices None For the latest technical bulletins and notices please visit the Support section on the Vari Lite web site at www vari lite com 02 9690 0010 0 149 VARFKLITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Notes 150 02 9690 00100 VARISLITE Express yourself Vari Lite 10911 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 10 September 2009 Manual Part Number 02 9690 0010 0
22. 647 7880 02 9690 0010 0 17 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL General Care and Equipment Handling Below are some basic tips and information on handling VARI LITEO luminaires and their associated components Locations Use VARIXLITEO luminaires are designed for dry locations only Exposure to rain or moisture including but not limited to fog machines misters etc may damage luminaires Solid State Electronics Electrostatic Discharge ESD Electrostatic discharge ESD presents a significant danger to solid state electronic components semiconductor devices and PC board assemblies Static electricity can build on a variety of common objects including people simply by handling or moving ESD rarely results in immediate failure of a component but shows up later as an intermittent problem or severely reduces the life of the component All VARIXLITEO products use solid state electronics and appropriate precautions to protect them should be observed when servicing Printed Circuit Boards PCBs All PC boards should be shipped in electrostatic shielding bags When handling PC boards or components devices such as conductive mats and conductive wrist straps should be used whenever possible If these precautionary devices are not available handling of PC boards and components should be avoided CAUTION Black foam used to package solid state electronics should never be used for packing batteri
23. 8 32 x 3 8 PPB SEMS Screws x4 Grill Assembly Rear Cover Assembly LED Cooling Assembly Figure 2 30 VLX Wash Grill Assembly Step 9 As shown in Figure 2 31 perform the following a Remove four 8 32 x 3 8 PPZ SEMS screws securing rear of cooling system closeout plate to luminaire head assembly b Remove six 6 32 x 10mm PPB screws securing closeout plate to cooling assembly c Remove closeout plate d Disconnect fan from LED driver noting routing of fan wiring harness e Slide Fan assembly from LED cooling assembly radiator Remove four T3 X 18mm screws mounting fan to tray 02 9690 0010 0 47 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL g Remove fan from tray noting fan orientation Fan Assembly x6 Note Some components not shown for clarity 6 32 x 10mm PPB SEMS Screws x6 LED Cooling Assembly Cooling Assembly Close Out Plate Cooling System Fan Assembly T3 x 18mm screws x4 Fan Tray Figure 2 31 LED Cooling System Fan Assembly Removal Step 10 Reassemble luminaire by following Steps 3 through 9 in reverse order Step 11 Power luminaire and test 48 02 9690 00100 MAINTENANCE PROCEDURES CPC LENS ASSEMBLY CPC Lens Assembly Tools 2 Phillips screwdriver Slotted Screwdriver AN WARNING Ensure that power is completely removed from luminaire before attempting any work Always wear eye protection and proper gloves when p
24. EA SCREW 8 32 X 3 4 PFB 27 54 2069 0100 1 EA BELT 200 GROOVE GT 2 MM 28 55 6568 0056 1 EA SPRING CPRSN 0 600 OD 0 080 WIR 29 69 3180 0600 2 EA POWER SUPPLY 12VDC 600W 30 10 9690 0632 2 EA SCREEN SMALL VLX 02 9690 00100 ENCLOSURE ASSEMBLY VLX WASH UPPER ENCLOSURE ASSEMBLY 3 VLX Wash Upper Enclosure Assembly continued d 20 x8 Enclosure Cover Screws Reference 19 53 6552 0002 SCREW 8 32 X 1 2 PFB 25 53 9690 0050 SCREW M4 X 12MM PFB 26 53 9690 0051 SCREW 8 32 X 3 4 PFB Figure 3 9 VLX Wash Upper Enclosure Assembly Part 1 02 9690 0010 0 119 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Upper Enclosure Assembly continued 15 17 x4 18 Figure 3 10 VLX Wash Upper Enclosure Assembly Part 2 120 02 9690 00100 ENCLOSURE ASSEMBLY VLX WASH BASE SUB ASSEMBLY 3 VLX Wash Base Sub Assembly 21 9690 0803 Rev B Refer to Figure 3 11 No Item Qty UM Description 1 10 9690 0803 4 EA MOUNTING BUTTON 2 12 9690 0019 1 EA VLX CASTING MACHINING 3 53 7017 0750 4 EA BOLT 0 25 20 X 0 75 ALLEN HEAD 4 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK Figure 3 11 Ventilation Cover Assembly Standard 02 9690 0010 0 121 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Display Assembly 21 9690 0802 Rev C Refer to Figure 3 12
25. F 02 9690 00100 ToP ASSEMBLY VLX WASH No COVERS ASSEMBLY 3 No Item Qty UM Description 29 53 6558 0009 12 EA SCREW 6 32 X 3 8 PPZ SEMS 30 53 6575 0001 5 EA SCREW 10 32 X 3 4 PPB 31 53 6575 0009 8 EA SCREW 8 32 X 3 8 PPZ SEMS BLK 32 53 6592 0250 4 EA SCREW 4 40 X 1 4 PPB SEMS 33 53 6624 0001 4 EA SCREW 10 32 X 1 2 34 53 6682 0023 9 EA SCREW 8 32 X 3 16 LG PPZ SEM 35 54 2069 0001 1 EA BELT GT 2MM 372 GROOVE NEO W FIBERGLASS 36 55 2179 0003 2 EA SADDLE CABLE 0 75 X 0 75 4 WAY 37 55 2191 0001 3 EA CABLE CLAMP 1 2 WIDE 5 8 38 55 2233 2001 4 EA DZUS RAPIER MINI CLIP ON RETAINER 39 55 3303 0010 5 EA WASHER 10 SPLIT LOCK 40 55 6704 0016 6 EA STANDOFF 1 4 HEX 8 32 F F X 0 875 LG SS 41 55 6543 0001 14 IN GROMMET SERRATED STRIP 0 063 42 55 3301 0010 3 EA WASHER 10 FLAT 55 6699 0011 12 IN ROUNDIT 2000 3 4 BLACK not shown 02 9690 0010 0 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash No Covers Assembly continued Figure 3 5 VLX Wash No Covers Assembly Part 1 98 02 9690 00100 ToP ASSEMBLY VLX WASH No COVERS ASSEMBLY 3 VLX Wash No Covers Assembly continued Note Some components removed for clarity Figure 3 6 VLX Wash No Covers Assembly Part 2 02 9690 0010 0 99 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE M
26. F Figure 3 9 Yoke Arm Cover Assembly MCB Side 102 02 9690 0010 0 TOP ASSEMBLY YOKE CENTER COVER ASSEMBLY 3 Yoke Center Cover Assembly 21 9690 0779 Rev B Refer to Figure 3 10 No Item Qty UM Description 1 10 9690 1770 1 EA COVER CENTER YOKE 2 53 2200 0004 2 EA NUT 4 40 KEPS SS 3 53 6598 0001 2 EA SCREW 4 40 X 3 8 PFB 4 53 9690 0511 1 EA COVER HINGED NEUTRIK D CHASSIS 5 53 9690 0512 1 EA USB GENDER CHANGER BLACK D CHASSIS 4 See Detail A Detail A Hinge Side Figure 3 10 Yoke Center Cover Assembly 02 9690 0010 0 103 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Notes 104 02 9690 00100 HEAD ASSEMBLY HEAD STRUCTURE ASSEMBLY 3 Head Assembly Head Structure Assembly 21 9690 0600 Rev K Refer to Figure 3 1 and Figure 3 2 No Item Qty UM Description 1 10 9690 0231 3 EA STANDOFF ZOOM SUPPORT 2 10 9690 0232 3 EA STANDOFF ZOOM SLIDE 3 10 9690 0240 1 EA CLOSEOUT RING ZOOM 4 10 9690 0241 1 EA CLOSEOUT PLATE NON ZOOM 5 10 9690 0331 7 EA SEAL Z AXIS STOP 6 10 9690 0332 7 EA TUBE SHIELD LIGHT PIPE 7 10 9690 0333 7 EA Z AXIS STOP HEX 8 10 9690 0337 3 EA SUPPORT SHAFT INTERMEDIATE PLATE 9 10 9690 0338 3 EA SUPPORT SHAFT INTERMEDIATE MOTHERBOARD 10 10 9690 0339 1 EA PLATE INTERMEDIATE LIGHT PIPE SUPPORT
27. MANUAL Testing 12 Luminaire Self Tests The luminaire is capable of running self tests by using the TEST menu functions For detailed instructions regarding the luminaire s self test function refer to the VLX LED Wash Luminaire User s Manual 02 9690 0001 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence Phase 1 e Tilt LEDs Off LED Upload Phase 2 Zoom Phase 3 Pan Sensor Testing Most mechanisms within the VLX luminaire are equipped with either optical or magnetic sensors The VLX master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan tilt encoder readings The values can be used to determine whether a circuit is opening correctly or needs further troubleshooting Guidelines The values will change depending on whether the sensor reading is Open or Closed The values will be different depending on the type of sensor optical or magnetic Asa general rule if a change occurs from 5v to Ov or visa versa then it is working An Open reading occurs when the sensor is not aligned tab not at sensor typically a non zero DMX value A Closed reading occurs when the sensor is aligned tab in or at sensor typically a zero DMX value Optical sensors read high when the sensor is Closed Magneti
28. No 128 796 128 795 Canada Patents No 2 070 670 2 050 375 1 270 675 1 259 058 Canada Design Patents No 81 234 81 233 76 046 European UK Patents No 0 652 400 0 586 049 0 565 218 0 547 732 0 534 710 0 495 305 0 474 202 0 379 970 0 253 082 0 253 081 0 248 974 0 192 882 Germany Patents No 694 25 943 8 693 14 122 0 692 08 615 3 692 07 692 1 691 31 478 0 691 21 029 2 690 33 385 4 37 89 166 9 37 68 727 1 37 51 804 6 37 50 201 8 35 87 270 5 Germany Design Patents No M 98 01 745 4 M 96 04 515 9 M 96 04 514 0 M 94 07 689 8 M 94 02 951 2 M 499 03 583 6 M 498 11 203 9 G 93 12 884 3 Spain Patents No 2 090 191 2 084 289 2 020 960 0 548 328 Spain Utility Model Patent No 2 031 748 Spain Design Patents No 0 137 502 0 137 501 0 133 573 Greece Patent No 910 400 544 Japan Patents No 2 843 696 2 059 669 2 055 324 2 002 168 1 966 525 1 889 481 1 792 721 1 770 241 Japan Design Patents No 985 985 1 985 985 947 552 945 436 1 945 436 1 106 089 1 077 598 1 072 598 1 060 414 1 002 123 Korea Patents No 76 310 42 639 283 770 181 180 Korea Design Patents No 209 896 209 895 Mexico Patent No 180 148 Taiwan Patents No 78 726 66 975 65 380 28 275 United Kingdom Design Registrations No 2082526 2072562 2056387 2056386 2042174 2038212 2033108 2029499 All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their res
29. PRODUCT DOCUMENTATION USER 7 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 8 52 6541 0001 1 EA CONN BLUE CABLE POWER INLET POWERCON 02 9690 00100 Top ASSEMBLY VLX WASH INCLUDED ITEMS KIT 3 VLX Wash Included Items Kit continued 3 Pole Neutrik PowerCon Locking Connector for AC Input Power Power input cable must be constructed by user Figure 3 3 VLX Wash Included Items Kit 02 9690 0010 0 93 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Luminaire 20 9690 0001 Rev B Refer to Figure 3 4 No Item Qty UM Description 1 21 9690 0010 1 EA ASSY VLX NO COVERS 2 21 9690 0612 1 EA ASSY HEAD COVER FRONT 3 21 9690 0776 1 EA ASSY YOKE COVER TILT MOTOR SIDE 4 21 9690 0777 EA ASSY YOKE COVER MAIN CONTROL BOARD SIDE 5 21 9690 0779 1 EA ASSY CENTER COVER 28 9690 0001 1 EA INCLUDED ITEMS KIT VLX WASH not shown 6 53 6608 0001 6 EA SCREW 6 32 X 3 8 PFB 5 73 7190 0005 1 EA CABLE USB A B 0 31M LG not shown 94 02 9690 0010 0 ToP ASSEMBLY VLX WASH LUMINAIRE 3 VLX Wash Luminaire continued Figure 3 4 VLX Wash Luminaire 02 9690 0010 0 95 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash No Covers Assembly 21 9690 0010 Rev L Refer to Figure 3 5 Figure 3 6 and Figure 3 7
30. Power to the driver board for that LED The driver board has 2 green LEDs on it Each LED signifies a different power supply The outer green LED closest to the edge of the board signifies that the driver board is getting power from the 12V supplies in the base through the blue wire The inner green LED signifies that it is getting 5V power from the round motherboard through the header pin connector LED Driver PCB not Properly Connected Check communication to the driver board for that LED The Driver PCB has 2 red LEDs on it If the LEDs are State 1 Always on but alternating brightness board is communicating properly State 2 Alternating on and off very quickly board is downloading software from Main Control Board This state should be replaced by State 1 after programming Check Motherboard for short to ground 02 9690 0010 0 15 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Table 2 2 Troubleshooting Guide Continued Message Symptom Description Possible Cause and Remedy n a LED light is getting dimmer Fixture appears not to be operating at full bright ness Luminaire has detected an over temperature condi tion The luminaire will reduce power to all 7 LEDs if it senses that one LED is operating over the specified temperature LED temperature is read and recorded through a thermistor imbedded in each LED chip The two yellow wires carry the information
31. Radiated and Conducted Emissions We certify that the product conforms to the protection requirements of Low Voltage Directive 2006 95 EC and Council Directive 89 336 EEC EMC 02 9690 0010 0 FOREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein Heed all cautions and warnings during installation and use of this product Safety symbols used throughout this manual are as follows CAUTION advising of potential damage to product Z N WARNING advising of potential injury or death to persons GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK FIRE EXPOSURE TO EXCESSIVE UV RADIATION AND INJURY TO PERSONS CAN BE FOUND BELOW WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1 VARI LITE luminaires have been designed for use with specific light sources The VLXTM LED Wash Luminaire uses a special type of LED light source Installing another type of light source will be hazardous and void the luminaire warranty 2 Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detailed in this manual 3 Note distance requirement from combustible materials or illuminated objects for VARIXLITEO luminaires WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1 V
32. XTA pueoqueyjoyy G37 USEM XIA USEM XIA preog 031 USEM XTA an 1osu s dual jueiquiy ov ae AddnS JEMOd I uonnqusig lt JEMOd L_J HAddns E mE LI BEN 1epoou3 III I I ued Lpa ad l d MIR i LI I I J0 ON ued 1 al i i i lndul xna i l aon IOJ1UOO USEM XIA AlddnS obeyon MOT A H a AL Ke dsiq a97 nt m E SJOJON uooz 02 9690 0010 0 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Notes 02 9690 00100 CHAPTER 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Troubleshooting Special Care and Handling Maintenance Procedures Z N WARNING All maintenance procedures are to be performed with power com pletely removed from the luminaire Never remove covers while unit is in opera tion WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized VAREKLITEG Service Center 02 9690 0010 0 11 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE
33. be necessary to turn enclosure to access screws 02 9690 0010 0 77 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 1 4 20 x 1 5 CAP 50C Screws x2 1 4 20 x 2 CAP SOC Screws x4 Upper Enclosure Bottom Cover Power Supply 2 Display Side Note Some components not shown for clarity M4 x 12mm PFB Screws Figure 2 58 VLX Wash Power Supply 2 Assembly Step 5 Disconnect wiring from power supply 2 assembly 78 02 9690 00100 MAINTENANCE PROCEDURES POWER SUPPLY 2 ASSEMBLY a AC In Black line White neutral Green earth Loosen terminal screws b DC Out Red 12V 2 wires Black Negative VDC 2 wires Remove terminal screws c COM Power Supply Com from CN1 Note There is an extra set of wires on AC Input These wires Supply power to 24V Low Voltage Supply LVS in yoke assembly Black is LINE and Black Silver is NEUTRAL Step Remove power supply 2 assembly Step 6 Step 7 Replace by performing Steps 3 through 6 in reverse order 8 Position luminaire on upper enclosure so head and yoke move freely 9 Step Power luminaire and test 02 9690 0010 0 79 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 80 Pan Motor Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace pan motor assembly Step 1 Remove power
34. for the USB Programming Cable Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Launch dropCal exe application on PC Drag txt file for specific luminaire in PC window example for VLX 67 67 being the last digits of the serial number drag file 67 txt dropCal window will read Completed LCD display on luminaire will read Cal Complete Press ENTER on menu The luminaire will run its calibration routine and unit shall be ready for use 02 9690 00100 CHAPTER 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VLX LED Wash Luminaire assemblies Drawing Tree Top Assembly Head Assembly Yoke Assembly Enclosure Assembly Cable Assemblies 02 9690 0010 0 89 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Drawing Tree VLX Wash Luminaire VLX Wash Luminaire 20 9690 0001 Rev B VLX Wash No Covers Assembly VLX Wash Included Items Kit 21 9690 0010 Rev L 28 9690 0001 Rev B VLX Wash 24V Supply Cable Yoke Arm Cover Assembly Tilt Assembly Motor Side 25 9690 0554 Rev C 21 9690 0776 Rev D VLX Wash Zoom Motors Cable A Yoke Arm Cover Assembly MCB 25 oo L C Side 21 9690 0777 Rev D VLX Wash LED Drive Cable Assembly Yoke Center Cover Assembly 21 9690 0779 Rev 8 VLX Wash Yoke Assembly 21 9690 0700 Rev F Front Head Cover Assembly 21 9690 0612 Rev A Tilt Motor Assembly 21 9690 0715 Rev C
35. from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure Rotate head as shown in Figure 2 59 Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up fen 9 Figure 2 59 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 60 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Orient upper enclosure so pan motor assembly is down Step 5 Disconnect pan motor wiring harness from motor 02 9690 00100 MAINTENANCE PROCEDURES PAN MOTOR ASSEMBLY 2 Step 6 As shown in Figure 2 60 remove four 8 32 x 1 2 PPB screws that mount motor assembly Note wiring routing 1 4 20 x 1 5 CAP a SOC Screws x2 Upper Enclosure Bottom Cover Pan Motor Assembly 8 32 x 1 2 PPB Screws x4 Pan Motor Assembly Spring Step Step Step Step Step Step Step Step Step 02 9690 0010 0 1 4 20 x 2 CAP SOC Screws x4 Note Some components not shown for clarity Figure 2 60 VLX Wash Pan Motor Assembly Pull top spring side of motor assembly out whi
36. in the Support Product Downloads section e VLX Series Luminaire User s Manual 02 9690 0001 For more information regarding DMX512 systems refer to the DMX512 1990 amp AMX 192 Standards publication available from United States Institute for Theatre Technology Inc USITT USITT 6443 Ridings Road Syracuse NY 13206 1111 USA 1 800 93USITT www usitt org 02 9690 0010 0 1 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on hand to provide support How to Reach Us For assistance in your area call the dealer from which your product s was purchased or Contact an Authorized Service Center or Contact the Vari Lite Customer Service Department 9am 6pm CST Monday through Friday at the following phone 1 877 VARI LITE 1 877 827 4548 e mail entertainment service O philips com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link Technical Bulletins and Notices Technical bulletins concerning the latest changes
37. one side of front cover is secured by a safety tether Locate clip attached to luminaire and unclip tether Step 4 Gently slide front head cover over optic assembly and set aside 02 9690 0010 0 19 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Step 5 Remove protective EMI shields from around optics assembly as shown in Figure 2 2 as follows WARNING On one EMI shield it is imperative to identify the ambient temperature sensor that protrudes through the EMI protective shield it is on the opposite side where the front cover safety tether connects When this shield is removed great care has to employed not to damage the sensor a At EMI shield side where front cover safety tether connects remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield b Remove shield and set aside c At other EMI shield side with ambient temperature sensor remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield d Carefully work shield over ambient temperature sensor taking care not to snag or pull sensor Once shield is clear of sensor set shield aside Note Some components not shown for clarity Front Head Cover Front Cover Latch one on each side of cover Front Head Cover Safety Tether 4 40 X 1 4 PPZ SEMS Screws X3 EMI Protective Shield side with ambient EMI Protective Sh
38. optics assembly posts b Turn optics ring 60 so its mounting holes are in line with optics assembly posts but does not slide over optics CPC lenses Using three standoffs secure Optics Ring Plate to assembly d Be sure to reinstall front ring in proper orientation Secure front ring with three 6 32 x 1 4 PPB screws Step 8 Reinstall EMI protective shields Use care when installing EMI shield on side of ambient temperature sensor as not to damage sensor Step 9 Once luminaire is reassembled power and test Note Carefully store front lens in a soft lint free non abrasive covering for future use Be sure to keep all parts removed with front lens with front lens in a separate container as not to damage lens 02 9690 00100 MAINTENANCE PROCEDURES MAIN CONTROL BOARD MCB REPLACEMENT 2 Main Control Board MCB Replacement Tools 2 Phillips screwdriver Z N WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace MCB Step 1 Remove power from luminaire Step 2 At tilt lock side yoke arm cover remove yoke arm cover by loosening four 1 4 turn Dzus fasteners Refer to Figure 2 9 for details Tilt Lock Remove power before A CAUTION servicing Luminaire Head Yoke Arm Cover with tilt lock LAR Figure 2 9 VLX Wash Luminaire 02 9690 0010 0 27 VARF amp LITEG VLX LED WASH LUMINAIRE SERVIC
39. ou a regu une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERF RENCE RF 1 Cetappareil est de Classe A Dans un environnement domestique cet appareil peut causer des interf rences radio et si c est le cas l utilisateur peut avoir prendre des mesures ad quates 02 9690 00100 FOREWORD Aviso sobre Seguridad Es muy importante leer TODA la informacion e instrucciones sobre seguridad que se indica en este manual asf como en los documentos adjuntos antes de instalar y operar los productos descritos Se debe prestar atenci n a todos los avisos y advertencias durante la instalaci n y uso de este producto Los s mbolos de seguridad usados en este manual son los siguientes CUIDADO indica posibles da os al producto Z N ADVERTENCIA indica posibles lesiones o muerte a las personas LA INFORMACION GENERAL RELACIONADA A LA PROTECCION CONTRAGOLPES DE CORRIENTE ELECTRICA INCENDIO EXPOSICION EXCESIVA ARADIACION ULTRA VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA INCENDIO 1 Los alumbrados de VARI LITE O se han dise ado para el uso con fuentes de luz espec ficas El alumbrado de VLX utiliza un tipo especial de fuente de luz del LED La instalaci n de otro tipo de fuente de luz ser peligrosa y anular la garant a del alumbrado 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se si
40. reverse order Note When installing replacement LED Driver PCB it is important not to bend the pins on LED Driver PCB that go into motherboard assembly header Carefully work LED Driver PCB into a suitable position to slide directly into header Step 14 Disengage tilt lock Step 15 Power luminaire and test 02 9690 0010 0 41 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Motherboard Assembly Tools 2 Phillips screwdriver Slotted screwdriver AN WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace motherboard assembly Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 25 and engage tilt lock Remove power and CAUTION allow fixture to cool Luminaire Head Ah Front Head Cover DA Front Cover Latch LL one on each side of cover A Se nn Upper Enclosure Figure 2 25 VLX Wash Luminaire A WARNING Note that CPC lens assembly light pipe and LEDs must be handled with extreme care or not be damaged All fingerprints grease smudges etc must be removed Any damage to any of these components will require replacement with new Step 3 Remove head cover EMI shields and zoom lens array assembly as described in procedure for Front Lens Removal and Cleaning on page 19 Step 4 R
41. screwdriver 3 16 Hex wrench WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace pan encoder PCB Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure Rotate head as shown in Figure 2 62 Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up Cs 6 pos FINN Figure 2 63 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 64 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Remove pan motor assembly according procedure outlined in Pan Motor Assembly on page 80 02 9690 0010 0 MAINTENANCE PROCEDURES PAN ENCODER PCB 1 4 20 x 1 5 CAP e SOC Screws x2 mu Upper Enclosure 1 4 20 x 2 CAP SOC Screws x4 Bottom Cover Pan Motor Assembly T Ee a 8 32 x 1 2 PPB Screws x4 Pan Motor A 4 Assembly Spring lt Pan Motor Belt Note Some components not shown for clarity Pan
42. 0 1553 Rev A Refer to Figure 3 22 No Item Qty UM Description 1 1 EA CONN FEMALE 8 POS 30 24 AWG PHR JST 2 6 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 3 45 50 IN CABLE 24 AWG STRND 2 COND PVC INSUL BLU YEL TWISTED 4 E 45 50 IN CABLE 24 AWG STRND 2 COND PVC INSUL WHT ORN TWISTED 5 1 EA CONN HSG MOD IV 0 100 X 0 100 CL 8 POS 6 6 EA CONTACT FEMALE MOD IV CRIMP SNAP IN 7 E 45 50 IN CABLE 24 AWG STRND PVC INSUL RED 8 45 50 IN CABLE 24 AWG STRND PVC INSUL BLACK 9 55 2186 0001 4 EA CABLE TIE 0 10 WD X 4 00 LG SMALL 9 x4 12 8 3 5 6 Figure 3 22 VLX Wash Display Link MCB to Display Cable Assembly 02 9690 0010 0 133 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Pan Tilt Cable Assembly 25 9690 1556 Rev D Refer to Figure 3 23 No Item Qty UM Description 1 52 6610 0008 1 EA CONN HOUSING 20 POS DBL ROW UNLOADED 2 52 6224 1020 1 EA COVER FRONT 20 POS MT LATCHING 3 52 6224 2020 1 EA COVER BACK 20 POS MT 4 52 6524 0005 1 EA CONN HOUSING 5 POS RECEPTACLE 5 52 6588 0007 2 EA CONN HOUSING 7 POS 250V 3A 2 5 MM PITCH 6 52 7007 0001 6 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT 7 52 8346 0001 10 EA CONTACT 24 30 AWG FEMALE CRIMP 8 55 2186 0001 4 EA CABLE TIE 0 10 WD X 4 00 LG SMALL 9 73 5119 0246 6
43. 00V 105 DEG C BLACK 5 55 2186 0001 3 EA CABLE TIE 0 10 WD X 4 00 LG SMALL 1 x4 5 x3 4 2 x4 3 Figure 3 19 VLX Wash 12V Output 1 Cable Assembly 130 02 9690 00100 CABLE ASSEMBLIES VLX WASH 12V OUTPUT 2 CABLE ASSEMBLY 3 VLX Wash 12V Output 2 Cable Assembly 25 9690 0512 Rev B Refer to Figure 3 20 No Item Qty UM Description 1 4 EA RING TERMINAL 12 10 AWG 10 HOLE SIZE INSUL PV12 10HDR L 2 4 EA FORK TERMINAL 12 10 AWG 6 STUD SIZE INSUL PV10 6F L 3 23 IN WIRE 10 AWG TEFLON COATED 600V 105 DEG C RED 4 16 IN WIRE 10 AWG TEFLON COATED 600V 105 DEG C BLACK 5 55 2186 0001 3 EA CABLE TIE 0 10 WD X 4 00 LG SMALL 1 x4 5 x3 3 2 x4 4 Figure 3 20 VLX Wash 12V Output 2 Cable Assembly 02 9690 0010 0 131 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Data 1 0 Link Cable Assembly 25 9690 1550 RevA Refer to Figure 3 21 No Item Qty UM Description 1 52 6396 2904 1 EA RECEPT 4POS MTA 100 W POL TABS CLSD END 2 52 6396 2905 1 EA RECEPT 5POS MTA 100 W POL TABS CLSD END 3 73 5122 0259 38 IN CABLE 22 AWG STRND 4 COND PVC INSUL TWISTED 3 2 1 Figure 3 21 VLX Wash Data I O Link Cable Assembly 132 02 9690 00100 CABLE ASSEMBLIES VLX WASH DISPLAY LINK MCB TO DISPLAY CABLE ASSEMBLY 3 VLX Wash Display Link MCB to Display Cable Assembly 25 969
44. 200 DEG C TEF BLK BRN RED ORG 1 2 To Controller PCB Figure 3 17 VLX Wash Zoom Motors Cable Assembly 128 02 9690 00100 CABLE ASSEMBLIES VLX WASH LED DRIVE CABLE ASSEMBLY 3 VLX Wash LED Drive Cable Assembly 25 9690 1557 Rev A Refer to Figure 3 18 No Item Qty UM Description 1 1 EA CONN FEMALE 6 POS 30 24 AWG PHR JST 2 8 6 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 3 a 26 IN CABLE 24 AWG STRND 2 COND PVC INSUL BLU YEL TWISTED 4 26 IN CABLE 24 AWG STRND 2 COND INSUL WHT ORN TWISTED 5 1 EA CONN HSG MOD IV 0 100 X 0 100 CL 8 POS 6 6 EA CONTACT FEMALE MOD IV CRIMP SNAP IN 7 26 IN CABLE 24 AWG STRND INSUL BLACK 8 26 IN CABLE 24 AWG STRND PVC INSUL RED 9 55 2186 0001 3 EA CABLE TIE 0 10 WD X 4 00 LG SMALL 9 3 3 Figure 3 18 VLX Wash LED Drive Cable Assembly 02 9690 0010 0 129 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash 12V Output 1 Cable Assembly 25 9690 0511 Rev B Refer to Figure 3 19 No Item Qty UM Description 1 4 EA RING TERMINAL 12 10 AWG 10 HOLE SIZE INSUL PV12 10HDR L 2 4 EA FORK TERMINAL 12 10 AWG 6 STUD SIZE INSUL PV10 6F L 3 44 IN WIRE 10 AWG TEFLON COATED 600V 105 DEG C RED 4 48 IN WIRE 10 AWG TEFLON COATED 6
45. 3 Blue 12 VDC to LED Driver PCB3 OP4 OP4 Blue 12 VDC to LED Driver PCB4 OP6 OP6 Blue 12 VDC to LED Driver PCB5 OP7 OP7 Blue 12 VDC to LED Driver PCB6 OP8 OP8 Blue 12 VDC to LED Driver PCB7 OP1 No Label Green VDC to Buss Bar in head OP2 No Label Green VDC to Buss Bar in head OP3 No Label Green VDC to Buss Bar in head OP4 No Label Green VDC to Buss Bar in head OP6 No Label Green VDC to Buss Bar in head OP7 No Label Green VDC to Buss Bar in head OP8 No Label Green VDC to Buss Bar in head PS1 PS1 2 wires Black VDC from Power Supply 1 PS2 PS2 2 wires Black VDC from Power Supply 2 PS1 PS1 2 wires Red 12 VDC from Power Supply 1 PS2 PS2 2 wires Red 12 VDC from Power Supply 2 Step 10 Replace bottom enclosure cover Make sure no wires are pinched in installation of bottom cover Step 11 Position luminaire on upper enclosure so head and yoke move freely Step 12 Power luminaire and test 02 9690 0010 0 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Power Supply 1 Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace power supply 1 assembly Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on
46. 375 FT WIRE 24 AWG 3 COND TW 600V 200 DEG C RED YEL BLU 10 73 5124 1289 6 50 FT WIRE 24 AWG 5 COND TW 300V 80 DEG C BLK BRN RED GRY WHT 11 52 8351 0004 16 EA CONTACT 26 22 AWG RECEPT MTE REEL 12 52 6524 0004 1 EA CONN HOUSING 4 POS RECEPTACLE 02 9690 00100 CABLE ASSEMBLIES VLX WASH PAN TILT CABLE ASSEMBLY 3 VLX Wash Pan Tilt Cable Assembly continued 1 2 5 11 To Pan Encoder To Tilt Motor To Tilt Encoder To Controller PCB To Pan Motor Figure 3 23 VLX Wash Pan Tilt Cable Assembly 02 9690 0010 0 135 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Display Link Ballast to Display Cable Assembly 25 9690 0572 RevA Refer to Figure 3 24 No Item Qty UM Description 1 1 EA CONN HOUSING JST PHD SERIES 10 CIRCUIT 2 3 8 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 3 2 EA CONN HOUSING JST PHD SERIES 10 CIRCUIT DOUBLE ROW 4 8 EA CONTACT SOCKET 28 24 AWG CRIMP PHD JST 5 26 IN WIRE 4 COND 300V 200 DEG C TEF BLK BRN RED ORN 1 2 5 3 4 3 4 Figure 3 24 VLX Wash Display Link Ballast to Display Cable Assembly 136 02 9690 00100 CABLE ASSEMBLIES NEGATIVE WIRE DRIVER BOARD 1 CABLE ASSEMBLY 3 Negative Wire Driver Board 1 Cable Assembly 25 9690 1501 Rev B Refer to Figure 3 25 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LO
47. 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Remove pan motor assembly according procedure outlined in Pan Motor Assembly on page 80 02 9690 0010 0 MAINTENANCE PROCEDURES PAN MOTOR BELT 2 1 4 20 x 1 5 CAP SOC Screws x2 1 4 20 x 2 CAP SOC Screws x4 Upper Enclosure Bottom Cover Pan Motor Assembly 8 32 x 1 2 PPB Screws x4 Pan Motor Assembly Spring Pan Motor Belt Note Some components not shown for clarity Figure 2 62 VLX Wash Pan Motor Belt Step 5 In upper enclosure disconnect wiring a At Power Distribution Board Assembly All Blue amp Green wiring b At Power Supply 2 Assembly Black and Black Silver wiring c AtDMX PCB Assembly DMX COM and Display COM wiring Note Be sure to note placement of all cables ties that have to put and replaced in this procedure Step 6 Pull pan belt through pan motor assembly pulley Step 7 Reassemble by following Steps 3 through 6 in reverse order Be sure to follow pan motor assembly installation procedure in Pan Motor Assembly on page 80 Step 8 Position luminaire on upper enclosure so head and yoke move freely Step 9 Power luminaire and test 02 9690 0010 0 83 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 84 Pan Encoder PCB Tools 2 Phillips
48. 9 remove two 4 40 x 3 8 PPZ SEMS screws 4 40 x 3 8 PPZ SEMS Screws x2 Tilt Encoder PCB Tilt Motor Assembly Note Some components not shown for clarity Figure 2 19 VLX Wash Tilt Encoder PCB Step 5 Replace tilt encoder PCB performing Steps 2 through 4 in reverse Note Be sure encoder wiring does not catch on cover mounts Also make sure code wheel passes freely and through center of sensor Step 6 Power luminaire and test 02 9690 0010 0 35 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Tilt COT Sensor Replacement Tools 2 Phillips screwdriver e Diagonal wire cutter Z N WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace Tilt COT Sensor Step 1 Remove power from luminaire Step 2 At yoke arm cover without tilt lock assembly remove yoke arm cover by loosening four 1 4 turn Dzus fasteners Refer to Figure 2 20 for details A Remove power before CAUTION servicing Luminaire Head Yoke Arm Cover without tilt lock Figure 2 20 VLX Wash Luminaire 36 02 9690 00100 MAINTENANCE PROCEDURES TILT COT SENSOR REPLACEMENT 2 Step 3 Noting placements and using diagonal wire cutter cut three cable ties securing wiring to yoke assembly Step 4 Disconnect tilt COT sensor from tilt encoder PCB Step 5 As shown in Figure 2 21 passing screwdriver through holes in harness guide remove two
49. ANUAL VLX Wash No Covers Assembly continued 22 x3 30 x5 39 x5 41 Both Yoke Legs Note Some components removed for clarity Figure 3 7 VLX Wash No Covers Assembly Part 3 100 02 9690 00100 TOP ASSEMBLY YOKE ARM COVER ASSEMBLY TILT MOTOR SIDE 3 Yoke Arm Cover Assembly Tilt Motor Side 21 9690 0776 Rev D Refer to Figure 3 8 No Item Qty UM Description 1 10 9690 0778 1 EA BRACKET FOAM YOKE COVER 2 10 9690 0779 1 EA FOAM AIR FILTER YOKE COVER 3 10 9690 2775 1 EA YOKE COVER TILT MOTOR SIDE 4 53 5655 0250 3 EA SCREW 6 X 1 4 PPZ PLASTIC 5 55 2233 2002 4 EA DZUS RAPIER 1 4 TURN STUD 5 MM 10 MM LG 6 55 2233 2003 4 EA DZUS RAPIER 1 4 TURN STUD RETAINER 5 MM ES PA ey 4 x4 Figure 3 8 Yoke Arm Cover Assembly Tilt Motor Side 02 9690 0010 0 101 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Yoke Arm Cover Assembly MCB Side 21 9690 0777 Rev D Refer to Figure 3 9 No Item Qty UM Description 1 10 9690 0778 1 EA BRACKET FOAM YOKE COVER 2 10 9690 0779 1 EA FOAM AIR FILTER YOKE COVER 3 10 9690 2774 1 EA YOKE COVER MCB SIDE 4 53 5655 0250 3 EA SCREW 6 X 1 4 PPZ PLASTIC 5 55 2233 2002 4 EA DZUS RAPIER 1 4 TURN STUD 5 MM 10 MM LG 6 55 2233 2003 4 EA DZUS RAPIER 1 4 TURN STUD RETAINER 5 MM 5 x4 a sg N E 7
50. ARI LITEO luminaires are designed for dry locations only Exposure to rain or moisture may damage luminaire 2 Disconnect power before servicing any VARIXLITEO equipment 3 Servicing to be performed by qualified personnel only 02 9690 0010 0 iii VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL WA INS TO 1 RNING TRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE UV RADIATION Many VARIXLITEO luminaires use a lamp that produces UV radiation DO NOT look directly at lamp 2 Itis hazardous to operate luminaires without lens or shield Shields lenses or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired For example by cracks or deep scratches WARNING INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1 Exterior surfaces of the luminaire will be hot during operation Use appropriate safety equipment gloves eye protection etc when handling and adjusting hot equipment and components 2 Luminaires will have a hot lamp when operating Disconnect power and allow lamp to cool before replacing 3 Wear eye protection when relamping 4 Appropriate safety equipment gloves eye protection should be used when handling damaged lamps 5 If lamp is touched with bare hands clean lamp with denatured alcohol and wipe with lint free cloth before installing or powering up the luminaire 6 The lamp shall be changed if it has be
51. CKING FORK 16 14 AWG 6 STUD 3 117 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE 58 5 Figure 3 25 Negative Wire Driver Board 1 Cable Assembly 02 9690 0010 0 137 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Negative Wire Driver Board 2 Cable Assembly 25 9690 1502 Rev B Refer to Figure 3 26 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 106 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE 138 Figure 3 26 Negative Wire Driver Board 2 Cable Assembly 53 0 02 9690 00100 CABLE ASSEMBLIES NEGATIVE WIRE DRIVER BOARD 3 CABLE ASSEMBLY 3 Negative Wire Driver Board 3 Cable Assembly 25 9690 1503 Rev C Refer to Figure 3 27 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 113 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE 56 5 Figure 3 27 Negative Wire Driver Board 3 Cable Assembly 02 9690 0010 0 139 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Negative Wire Driver Board 4 Cable Assembly 25 9690 1504 Rev B Refer to Figure 3 28 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 118 IN WIRE TWISTED
52. E MANUAL Step 3 At MCB disconnect wiring note all wire routing MCB Connector Cable Assembly J16 Pan Tilt Wiring Harness J15 Zoom Optic Wiring Harness J14 LCD Display Comm J13 LED Driver Comm J8 24V DC Input J11 DMX Comm J9 USB Step 4 As shown in Figure 2 10 remove six 6 32 x 3 8 PPZ SEMS screws MCB Edge Grommet VLX Wash MCB 6 32 x 3 8 PPZ SEMS Screws x6 Note Some components not shown for clarity Figure 2 10 VLX Wash Main Control Board MCB Step 5 Remove edge grommet from MCB and install on replacement MCB Step 6 Install replacement MCB by performing Step 2 through 5 in reverse order Step 7 Power luminaire and test 28 02 9690 0010 0 MAINTENANCE PROCEDURES LOW VOLTAGE SUPPLY LVS REPLACEMENT 2 Low Voltage Supply LVS Replacement Tools 2 Phillips screwdriver 90 degree 2 Phillips head screwdriver Z N WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace LVS Step 1 Remove power from luminaire Step 2 At tilt lock side yoke arm cover remove yoke arm cover by loosening four 1 4 turn Dzus fasteners Refer to Figure 2 11 for details Tilt Lock A Remove power before z A CAUTION servicing Luminaire Head Yoke Arm Cover with tilt lock Yoke Center Cover Figure 2 11 VLX Wash Luminaire Step 3 Remove MCB as described in M
53. EA CABLE ASSY PAN TILT VLX WASH not shown 25 9690 0572 1 CABLE ASSY VLX DISPLAY LINK not shown 25 9690 1501 1 EA NEG WIRE DRIVE BRD 1 not shown 25 9690 1502 1 EA NEG WIRE DRIVE BRD 2 not shown gt 25 9690 1503 1 EA NEG WIRE DRIVE BRD 3 not shown 25 9690 1504 1 EA NEG WIRE DRIVE BRD 4 not shown 25 9690 1505 1 EA NEG WIRE DRIVE BRD 5 not shown 25 9690 1506 1 EA NEG WIRE DRIVE BRD 6 not shown 25 9690 1507 1 EA NEG WIRE DRIVE BRD 7 not shown 25 9690 1509 4 EA POSITIVE WIRES DRIVE BRD TILT MOTOR SIDE not shown 02 9690 0010 0 117 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 25 9690 1510 3 EA POSITIVE WIRES DRIVE BRD MCB SIDE not shown j 25 9690 3552 1 EA CABLE ASSY A C SUPPLY 1 VLX WASH not shown 15 53 2200 0008 1 EA NUT 8 32 KEPS SS 16 53 6517 0001 5 EA SCREW 10 32 X 3 8 PPZ 17 53 6521 0001 4 EA SCREW 8 32 X 1 2 PPB 18 53 6552 0001 2 EA SCREW 8 32 X 1 2 PFZ 19 53 6552 0002 8 EA SCREW 8 32 X 1 2 PFB 20 53 6626 0001 8 EA SCREW 10 32 X 1 2 PPZ 21 53 6627 0001 5 EA SCREW 10 32 X 5 8 PPB 22 53 6682 0022 12 EA SCREW 8 32 X 3 8 PPZ SEMS 23 53 7017 1500 2 EA BOLT 0 25 20 X 1 50 ALLEN HEAD 24 53 7017 2000 4 EA BOLT 0 25 20 X 2 00 ALLEN HEAD 25 53 9690 0050 8 EA SCREW M4 X 12MM PFB 26 53 9690 0051 1
54. Figure 3 6 No Item Qty UM Description 1 10 9690 0610 1 EA HEAD COVER FRONT MOLDED 2 10 9690 0614 1 EA TETHER COVER 3 10 9690 0616 4 EA FRAME FOAM HEAD COVER 4 10 9690 0617 4 EA FOAM AIR FILTER HEAD COVER 5 10 9690 0618 1 EA CLIP COVER LANYARD 6 53 2202 0004 4 EA NUT 4 40 HEX SS NYLON INSERT 7 53 5655 0250 8 EA SCREW 6 X 1 4 PPZ PLASTIC THREADING 8 53 6551 0001 4 EA SCREW 4 40 X 3 8 PPB 9 54 1226 0001 2 EA LATCH ASSY VLS 10 55 2011 0003 2 EA SNAP SPRING 3 16 EYE DIA 10 x2 8 x2 Figure 3 6 Front Head Cover Assembly 112 02 9690 00100 YOKE ASSEMBLY VLX WASH YOKE ASSEMBLY 3 Yoke Assembly VLX Wash Yoke Assembly 21 9690 0700 Rev F Refer to Figure 3 7 No Item Qty UM Description 1 10 9687 0600 1 EA YOKE PAN TUBE MOUNT 2 10 9690 0723 1 EA CHANNEL PAN MOUNT 3 21 9690 0715 1 EA ASSY TILT MOTOR 4 22 9690 0710 1 EA ASSY YOKE STRUCTURE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6552 0002 10 EA SCREW 8 32 X 1 2 PFB 7 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 8 53 6593 0001 3 EA SCREW 10 32 X 1 00 PPB 9 53 6626 0001 2 EA SCREW 10 32 X 1 2 PPZ 10 55 2233 2001 4 EA DZUS RAPIER MINI CLIP ON RETAINER 11 55 3301 0008 4 EA WASHER 8 FLAT SS 12 55 6568 0056 1 EA SPRING CPRSN 0 600 OD 0 080 WIR 13 69 3178 0121 1 EA POWER SUPPLY 120
55. HAFT 4 53 9690 0001 2 EA SCREW 10 32 SOCKET HEAD CAP 0 250 5 54 1259 0011 2 EA PAN BEARING 6 55 2023 0003 1 EA 0 25 DIA S2 TOOL STEEL 4 x2 Figure 3 15 VLX Wash Pan Tube Assembly 126 02 9690 0010 0 CABLE ASSEMBLIES VLX WASH 24V SUPPLY CABLE ASSEMBLY 3 Cable Assemblies Note Cables are only available as complete assemblies The information contained in this section is for reference only VLX Wash 24V Supply Cable Assembly 25 9690 0554 Rev C Refer to Figure 3 16 No Item Qty UM Description 1 52 6442 2003 1 EA RECEPT 3POS MTA 156 W TAB YEL 20AWG 2 52 6442 2006 1 EA RECEPT 6POS MTA 156 W TAB YEL 20AWG 3 73 7137 0011 3 IN WIRE 20AWG 600V 200 DEG C FEP RED STRAND 105 40 0 06 DIA 4 73 7137 0012 3 IN WIRE 20AWG 600V 200 DEG C FEP BLK STRAND 105 40 0 06 DIA 3 0 Figure 3 16 VLX Wash 24V Supply Cable Assembly 02 9690 0010 0 127 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Zoom Motors Cable Assembly 25 9690 0558 Rev C Refer to Figure 3 17 No Item Qty UM Description 1 1 EA CONN HOUSING PH SERIES JST 4 POS 2MM WHITE 2 4 EA CONTACT TERMINAL 28 24 AWG TIN JST 3 52 6224 1034 1 EA COVER FRONT 34 POS MT LATCHING 4 52 6224 2034 1 EA COVER BACK 34 POS MT 5 52 6610 0034 1 EA CONN HOUSING 34 POS DBL ROW UNLOADED 6 73 2326 0123 28 IN WIRE 26 AWG 4 COND 300V
56. Manual AN 02 9690 0010 Service PHILIPS VARISLITE VARI LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries VL500 VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 VL3500 VLXTM Series 500 Series 1000 Series 2000 Series 3000 Series VLX DICHRO TUNE VARIXIMAGE VARIXBRITE and the Vari Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC VARI LITEO products are protected by one or more of the following patents and other pending patent applications worldwide U S Patents No 6 809 869 6 796 682 6 769 792 6 578 987 6 550 939 6 282 027 6 123 436 6 113 252 6 046 861 6 031 749 6 011 640 5 969 868 5 959 768 5 934 794 5 882 107 5 829 868 5 825 548 5 798 619 5 774 273 5 769 527 5 758 956 5 728 994 5 640 061 5 590 954 5 454 477 5 432 691 5 367 444 5 329 431 5 307 295 5 282 121 5 278 742 5 209 560 5 186 536 5 073 847 5 010 459 4 980 806 4 972 306 4 800 474 4 779 176 4 701 833 4 602 321 6 459 919 6 788 011 6 806 659 6 975 079 7 014 336 7 274 160 7 140 752 U S Design Patents No 524 245 457 678 452 339 451 890 442 944 439 356 420 332 417 300 415 301 414 888 413 995 377 338 366 712 359 574 350 408 347 113 Australia Patents No 693 691 683 695 667 109 649 264 646 588 586 095 576 400 Australia Design Patents
57. Motor Assembly Encoder PCB 6 32 x 3 8 PPZ Screws x2 A j Z Pan Code Wheel Pan Encoder PCB lt 6 Split Lock Washers x2 Figure 2 64 VLX Wash Pan Encoder PCB Step 5 As shown in Figure 2 64 remove two 6 32 x 3 8 PPZ screws and remove PCB Note there are two 6 split lock washers between PCB and pan motor assembly 02 9690 0010 0 85 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 86 Step 6 Reassemble by following Steps 3 through 5 in reverse order Be sure to follow pan motor assembly installation procedure in Pan Motor Assembly on page 80 Note Be sure pan code wheel passes freely through encoder PCB sensor during installation Step 7 Position luminaire on upper enclosure so head and yoke move freely Step 8 Power luminaire and test 02 9690 00100 MAINTENANCE PROCEDURES VLX WASH DROPCAL REINSTALL FACTORY LED CALIBRATION 2 VLX Wash dropCal Reinstall Factory LED Calibration Tools Personal Computer PC Running Windows with an available USB port user supplied The dropCal software allows installation of luminaire s LED factory calibration Note this software is only available from Vari Lite technical support e Calibration txt file dropCal which is specific to the serial number of the fixture Note this file is only available from Vari Lite technical support Vari Lite USB Programming Cable Vari Lite Part Number 28 8500 0054 WA
58. NS ARRAY CONCAVE 3 44 9690 0130 3 EA MOTOR LINEAR ACT JST CONN VLX ZOOM 4 53 2009 0006 3 EA NUT 2 56 HEX SS NYLON INSERT 5 53 6602 0002 6 EA SCREW 4 40 X 3 16 LG PPZ TYPE F 6 55 3301 0003 6 EA WASHER 2 FLAT Figure 3 3 Zoom Array Assembly 02 9690 0010 0 109 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Motherboard Support Assembly 21 9690 0334 RevA Refer to Figure 3 4 No Item Qty UM Description 1 10 9690 0336 1 EA HEAD COVER REAR MOLDED 2 24 9690 0575 1 EA BOARD ASSY VLX MOTHERBOARD 3 53 6544 0002 3 EA SCREW 8 32 X 3 4 PPZ 4 55 6524 0001 3 EA WASHER 0 312 OD 0 171 ID 0 063 THK 8 NYLON 3 x3 4 x3 Figure 3 4 Motherboard Support Assembly 110 02 9690 00100 HEAD ASSEMBLY REAR HEAD COVER ASSEMBLY 3 Rear Head Cover Assembly 21 9690 0615 Rev A Refer to Figure 3 5 No Item Qty UM Description 1 10 9690 0613 1 EA HEAD COVER REAR MOLDED 2 10 9690 0631 2 EA SCREEN REAR COVER INLET TOP 3 10 9690 0632 2 EA SCREEN REAR COVER INLET SIDE 4 53 2202 0004 4 EA NUT 4 40 HEX SS NYLON INSERT 5 53 6551 0001 4 EA SCREW 4 40 X 3 8 PPB 6 54 1226 0002 2 EA STRIKE LATCH CATCH Figure 3 5 Rear Head Cover Assembly 02 9690 0010 0 111 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Front Head Cover Assembly 21 9690 0612 RevA Refer to
59. No Item Qty UM Description 1 10 9690 0618 1 EA CLIP COVER LANYARD 2 10 9690 0637 2 EA SHIELD FRONT HALF 3 10 9690 0639 2 EA GROUND STRAP COMMON SHORT 4 10 9690 0726 2 EA MOUNTING PLATE 1 4 TURN 5 10 9690 0738 1 EA SPACER MOUNT TILT LOCK 6 10 9690 0743 1 EA PULLEY DRIVEN TILT 7 10 9690 0744 1 EA COT FLAG TILT 8 10 9690 0745 1 EA TILT STOP 9 10 9690 0746 1 EA CABLE GUARD TILT LOCK SIDE 10 10 9690 0747 1 EA CABLE GUARD TILT PULLEY SIDE 11 10 9690 0756 2 EA TILT CLOSEOUT PANEL 12 10 9690 0771 2 EA YOKE LEG ANGLE CLOSEOUT 13 10 9690 1739 1 EA LOCK CYLINDER TILT LOCK 14 10 9690 1757 2 EA TILT BEARING CLAMP 15 21 9690 0600 1 EA ASSY HEAD 16 21 9690 0700 1 EA ASSY YOKE 17 21 9690 0800 1 EA ASSY BASE UPPER ENCLOSURE 18 22 9690 0729 1 EA ASSY TILT LOCK 19 22 9690 0801 1 EA ASSY PAN LOCK 20 23 9690 0790 1 EA CABLE ASSY COT SENSOR 21 24 9690 1700 1 EA BOARD ASSY VLX WASH CONTROL BOARD 25 9690 0554 1 EA CABLE ASSY VLX 24V SUPPLY not shown 25 9690 0558 1 EA CABLE ASSY VLX ZOOM MOTORS not shown 25 9690 1557 1 EA CABLE ASSY VLX DRIVE not shown 22 53 2001 0001 3 EA NUT 10 32 KEPS ZINC PLATED 23 53 2200 0008 4 EA NUT 8 32 KEPS SS 24 53 6513 0047 4 EA SCREW M4 X 8 MM PPZ 25 53 6525 0001 8 EA SCREW 6 32 X 5 16 PPZ 26 53 6537 0001 3 EA SCREW 4 40 X 5 8 PPB1 27 53 6544 0002 2 EA SCREW 8 32 X 3 4 PPZ 28 53 6553 0004 6 EA SCREW 10 32 X 3 8 PPB TYPE
60. PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE 140 Figure 3 28 Negative Wire Driver Board 4 Cable Assembly 59 0 02 9690 00100 CABLE ASSEMBLIES NEGATIVE WIRE DRIVER BOARD 5 CABLE ASSEMBLY 3 Negative Wire Driver Board 5 Cable Assembly 25 9690 1505 Rev B Refer to Figure 3 29 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 106 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE 53 0 Figure 3 29 Negative Wire Driver Board 5 Cable Assembly 02 9690 0010 0 141 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Negative Wire Driver Board 6 Cable Assembly 25 9690 1506 Rev C Refer to Figure 3 30 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 104 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE 142 Figure 3 30 Negative Wire Driver Board 6 Cable Assembly 52 0 02 9690 00100 CABLE ASSEMBLIES NEGATIVE WIRE DRIVER BOARD 7 CABLE ASSEMBLY 3 Negative Wire Driver Board 7 Cable Assembly 25 9690 1507 Rev C Refer to Figure 3 31 No Item Qty UM Description 1 1 EA RING TERMINAL 14 16 AWG 8 HOLE SIZE 2 1 EA LOCKING FORK 16 14 AWG 6 STUD 3 111 IN WIRE TWISTED PAIR 18 AWG FEP 168 7 40 EACH WIRE BLUE
61. PCB assembly Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure and connector assembly side is up Be sure to rotate head as shown in Figure 2 43 Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up Connector Assembly fe Ill a 6 LC Figure 2 43 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 44 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Remove 8 32 x 1 2 PFB screw in enclosure top cover securing connector assembly 60 02 9690 00100 MAINTENANCE PROCEDURES DMX PCB ASSEMBLY 2 1 4 20 x 2 CAP 1 4 20 x 1 5 CAP SOC Screws x4 SOC Screws x2 Connector Assembly Upper Enclosure Bottom Cover 8 32 x 1 2 PFB Screw Note Some components not shown for clarity Connector Assembly DMX PCB Assembly j A ETA 4 40 x 3 8 PFB Screws x4 rh Figure 2 44 VLX Wash Upper Enclosure DMX PCB Assembly Step 5 Note wiring will be attached to DMX PCB and Input PowerCon Detach wiring and re
62. RNING The dropCal file is a unique calibration file and is specific to the fixture s serial number Using a dropCal file from another fixture will load a different calibration scheme and will cause the fixture to be out of calibration To reinstall the calibration file in a VLX Wash Luminaire Step 1 Power luminaire and allow calibration routine to run Step 2 Access luminaire LED calibration menu by pressing and holding all four arrow buttons on luminaire Menu simultaneously until LED CAL Mode is shown on LCD display Refer to Figure 2 65 Arrow Buttons VLX Wash Menu LCD Display POWER LED Cal Mode TX RX PHILIPS Esc VARBKLITE Figure 2 65 VLX Wash Menu LCD Display Step 3 Press ENTER on menu Step 4 Display now reads Cal Yes 02 9690 0010 0 87 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 88 Step Step Step Step Step 9 RADA Press ENTER on menu Display now reads Set LED Cal Press ENTER on menu Display now reads Wait for Cal Upper Enclosure Luminaire DMX AC Input Panel Figure 2 66 VLX Wash DMX AC Input Panel At PC attach USB Programming Cable to available USB port and at luminaire using other end of US Programming USB Cable connect to DMX IN at DMX AC Input Panel as indicated in Figure 2 66 Note It is best to use the PC normally used to upload VARI LITE luminaire software since it will already have the necessary drivers installed
63. Step 3 Remove front head cover by unlatching both head cover latches Please note that one side of front cover is secured by a safety tether Locate clip attached to luminaire and unclip tether Step 4 Gently slide front head cover over optic assembly and set aside 02 9690 0010 0 23 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Step 5 Remove protective EMI shields from around optics assembly as shown in Figure 2 6 as follows WARNING On one EMI shield it is imperative to identify the ambient temperature sensor that protrudes through the EMI protective shield it is on the opposite side where the front cover safety tether connects When this shield is removed great care has to employed not to damage the sensor a At EMI shield side where front cover safety tether connects remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield b Remove shield and set aside c Atother EMI shield side with ambient temperature sensor remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield d Carefully work shield over ambient temperature sensor taking care not to snag or pull sensor Once shield is clear of sensor set shield aside Note Some components not shown for clarity Front Head Cover Front Cover Latch one on each side of cover Front Head Cover Safety Tether 4 40 X 1 4 PPZ SEMS Screw
64. UT AUTRE ACCIDENT POUVANT ENTRA NER DES BLESSURES AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES INCENDIES 1 Des appareils d clairage de VARIXLITE ont t con us pour l usage avec des sources lumineuses sp cifiques L appareil d clairage de VLX emploie un type sp cial de source lumineuse de LED L installation d un autre type de source lumineuse sera dangereuse et videra la garantie d appareil d clairage 2 Les luminaires peuvent tre fix s sur tout type de surface tant que les directives de montage sont respect es Voir les explications d taill es dans ce guide 3 Verifier la distance respecter entre les mat riaux combustibles ou les objets illumin s et les luminaires VARIXLITEO AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES 1 Les luminaires VARI LITE sont con us pour une utilisation au sec uniquement Une exposition la pluie et I humidit risque d endommager le luminaire 2 D brancher l appareil avant de proc der la r vision de tout mat riel VARIXLITE 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9690 0010 0 vii VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL viii AVERTISSEMENT 3 DIRECTIVES POUR SE PROTEGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1 Plusieurs luminaires VARI LITE O utilisent une lampe qui produit des rayons UV NE PAS fixer son regard sur la lampe 2 L uti
65. VARI LITE luminaires service should only be performed by a trained and qualified service technician or at an Authorized VARI LITE Service Center 02 9690 00100 TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 Troubleshooting Guide If a problem is suspected try recalibrating the luminaire to prompt an error message Refer to Error Messages on page 14 for more information The chart below provides possible causes and remedies for each message Table 2 2 Troubleshooting Guide Single LED not operat ing seven is not producing light or responding to con trol Message Symptom Description Possible Cause and Remedy n a No power Luminaire does not power Circuit not energized up verify circuit breaker is turned on Not plugged in ensure A C cable is connected to power source Power cable wired incorrectly verify power cable and connector are wired correctly n a DMX Data Input Self tests will not run or Detecting DMX data software download does disconnect DMX input cable not work n a DMX Failure No response to DMX MCB connector disconnected data check MCB DATA IN connection DMX data cable not wired correctly or has a broken conductor check DMX data cable for proper wiring n a DMX Termination Erratic control of No DMX termination or termination not correct luminaire check for DMX terminator n a One LED out of the LED Driver PCB not Powered Check
66. W 24V 3X5 02 9690 0010 0 113 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Yoke Assembly continued 10 x2 Figure 3 7 VLX Wash Yoke Assembly 02 9690 00100 YOKE ASSEMBLY TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21 9690 0715 Rev C Refer to Figure 3 8 No Item Qty UM Description 1 10 9678 8720 1 EA CODEWHEEL 120 COUNT LARGE ID 2 10 9690 0740 1 EA TILT MOTOR MOUNT 3 10 9690 0741 1 EA TILT PULLEY DRIVING 4 10 9690 0742 1 EA ENCODER COLLET 5 24 9678 9729 1 EA PCB ASSY PAN TILT ENCODER 6 44 9678 0680 1 EA MOTOR 3 PHASE SZ 23 HIGH TORQUE 7 53 2200 0008 4 EA NUT 8 32 KEPS SS 8 53 6520 0375 2 EA SCREW 4 40 X 3 8 PPZ SEMS 9 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 02 9690 0010 0 115 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Tilt Motor Assembly continued Pulley Height Detail amp Installation 3 m A Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set Screws are properly aligned and tightened on flat sides of motor shaft Note Vari Lite recommends that this assembly be replaced as a complete assembly Although yo
67. aches to enclosure base to allow truss hook installation Truss hooks sold separately Upper Enclosure Assembly eT Houses power supply ballast mg and display board j SA Input Panel N Provides DMX In and Thru 1 Menu LCD Display TI lb and AC Power connections Used to input manual commands program test set defaults and 2 see detail below access internal status information see detail below Head Assembly 1 EVE Yoke Assembly Front lens optics LED N J i Houses Master Control driver PCBs LEDs and E gt Board MCB and tilt motor cooling fans Upper Enclosure Components Input Panel 3 Pole Neutrik PowerCon Locking Connector for AC Input Power supplied User must construct power input cable AC Input Cable Data Thru Menu LCD Display Panel LCD Display Displays all Data and Luminaire Settings POWER er Status LEDs Arrow Keys Left Right Up Down B DERT ED To Menu Navigate Menu Options O ERROR ower slale 3019 8050 pata PHILIPS Receive Data Error and make Data Selections ESC VARI LITE Enter Button Escape ESC To Select or Change a To Exit or Go to Setting or Data Value Previous Menu Item 02 9690 0010 0 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Luminaire Head Components The following illustration shows the major sub assemblies which are located in
68. aged it must be replaced with new Note 4 40x 438 LG SH CAP Screw Some components not shown for clarity x2 per LED See Torque Note IMPORTANT Torque Note Torque each 4 40 x 0 438 LG SH Cap screw to 80 in OZ Z Axis Stop Z Axis Stop Seal LED Assembly VLX Wash LED Cooling Assembly Thermal Transfer Material ation Note When replacing torque 4 40 x 0 438 cap screws to 80 in oz using a precision torque wrench Step 10 Reassemble luminaire Note After replacing a LED chip recalibration of the fixture is required Please contact Vari Lite technical support at VL Technician philips com or 1 214 647 7880 for details Step 11 Disengage tilt lock Step 12 Power luminaire and test 02 9690 0010 0 57 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Connector Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace connector assembly Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure and connector assembly side is up Be sure to rotate head as shown in Figure 2 41 Remove power and CAUTION allow fixture to cool Luminaire Head Up
69. ain Control Board MCB Replacement on page 27 02 9690 0010 0 29 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Step 4 As shown in Figure 2 12 remove Yoke Center Cover by removing six 6 32 x 3 8 PFB screws Note Some components not shown for clarity Yoke Arm Cover Tilt Lock Side Yoke Center Cover 6 32 x 3 8 PFB Screws x6 Figure 2 12 VLX Wash Yoke Center Cover Step 5 Disconnect wiring from LVS Step 6 As shown in Figure 2 13 remove four 6 32 x 3 8 PPZ SEMS screws securing LVS Note Some components not shown for clarity o 6 32 x 3 8 PPZ SEMS Screws x4 Low Voltage Supply LVS Figure 2 13 VLX Wash LVS Removal Step 7 Carefully slide LVS from yoke assembly note LVS orientation Step 8 Install replacement LVS by performing steps 2 through 7 in reverse order Step 9 Power luminaire and test 30 02 9690 00100 MAINTENANCE PROCEDURES TILT MOTOR ASSEMBLY REPLACEMENT 2 Tilt Motor Assembly Replacement Tools 2 Phillips screwdriver 11 32 Nutdriver 90 degree 2 Phillips head screwdriver AN WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace Tilt Motor Assembly Step 1 Remove power from luminaire Step 2 At yoke arm cover without tilt lock assembly remove yoke arm cover by loosening four 1 4 turn Dzus fasteners Refer to Figure 2 14 for details CAUTION ser
70. aintenance or service should only be completed by an Authorized VAREKLITEG Service Center Special Cleaning and Care Instructions The VLX LED Wash Luminaire requires special care when it comes to cleaning front lens assembly Note Additional care needs to be taken with the plastic components because they are much easier to scratch or damage than glass The following is a list of cleaning materials required to care for your VLX LED Wash Luminaire e Lint free lens tissue e Lint free cotton swabs for hard to reach spot cleaning e Lint or powder free gloves Reagent grade isopropyl alcohol A mild soap solution Reagent grade isopropyl alcohol is good to use on the VLX LED Wash Luminaire plastic optics with anti reflection coatings If the lens is still dirty after using isopropyl alcohol for instance if fingerprints or oil is just redistributed and not cleaned off the optic then a mild soap and water solution can be used to gently wash the lens Repeat the cleaning with isopropyl alcohol to eliminate streaks and soap residue WARNING Under no circumstances should ammonia based cleaners acetone or other harsh solvents be used on or near the VLX LED Wash Luminaire These types of cleaners or solvents can permanently damage the optics or housings of the fixture If you have any questions regarding the use or care of your VLX LED Wash Luminaire please contact Vari Lite technical support at 1 877 VARI LITE or 1 214
71. ash Pan Tube Assembly u nre ak den k 126 Note Cables are only available as complete assemblies The information contained in this section is for reference only Cable Assemblies VLX Wash 24V Supply Cable Assembly pp 127 VLX Wash Zoom Motors Cable Assembly 128 VLX Wash LED Drive Cable Assembly u erkeke eke 129 VLX Wash 12V Output 1 Cable Assembly erkeke eker 130 VLX Wash 12V Output 2 Cable Assembly keke 131 VLX Wash Data I O Link Cable Assembly pp 132 VLX Wash Display Link MCB to Display Cable Assembly 133 VLX Wash Pan Tilt Cable Assembly eese 134 VLX Wash Display Link Ballast to Display Cable Assembly 136 Negative Wire Driver Board 1 Cable Assembly eee 137 Negative Wire Driver Board 2 Cable Assembly esee 138 Negative Wire Driver Board 3 Cable Assembly keke 139 Negative Wire Driver Board 4 Cable Assembly eee 140 Negative Wire Driver Board 5 Cable Assembly Ne 141 Negative Wire Driver Board 6 Cable Assembly ppp 142 Negative Wire Driver Board 7 Cable Assembly ppp 143 Positive Wire Driver Board Tilt Motor Side Cable Assembly 144 Positive Wire Driver Board MCB Side Cable Assembly 145 VLX Wash A C Input Cable A
72. ature sensor remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield d Carefully work shield over ambient temperature sensor taking care not to snag or pull sensor Once shield is clear of sensor set shield aside Note Some components not shown for clarity Front Cover Latch Front Head Cover one on each side of cover di Front Head Cover Safety Tether 4 40 x 1 4 PPZ EMI Protective Shield SEMS Screws x3 side with ambient temperature sensor EMI Protective Shield _ side with front cover II tether connects to head IN 6 32 x 1 4 PPZ SEMS Screws x5 Per shield Figure 2 33 Front Head Cover and EMI Shields Removal Step 6 Athead assembly as shown in Figure 2 34 remove front lens assembly as follows 50 02 9690 00100 MAINTENANCE PROCEDURES CPC LENS ASSEMBLY 2 6 32 x 1 4 PPB Screws x3 Front Lens Ring Eu p P N e Zoom Slide Standoffs x3 Front Lens Optics Ring Plate y MK 7 7 Optics CPC Lenses Figure 2 34 Front Lens Removal Note Before proceeding please note orientation of both front lens ring and front lens assembly They must be mounted in their original orientation position for the front head cover to reinstall properly Remove three screws securing front lens and lens ring Set components aside b Note zoom motor wirin
73. c sensors read Low when the sensor is Closed High value 5 volts typically 4 9 volts Low value 0 volts or up to approximately 0 2 volts 02 9690 00100 TESTING SENSOR TESTING Notes regarding specific mechanisms e Tilt sensor reads high when the tab is in the sensor The mechanism calibrates to the edge and its tab covers 50 of travel Pan and tilt encoders are best read with a scope to read the encoder ticks 02 9690 0010 0 13 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Troubleshooting 14 Error Messages If a problem occurs during luminaire calibration at the end of the calibration sequence the Menu Display will cycle through any applicable error message s one at a time until the end of the list is reached To review the error messages again it will be necessary to access them using the Status function Refer to Troubleshooting Guide on page 15 for a list of possible causes and remedies associated with the error messages To access error messages Step 1 Press ESC to access the main menu screen Step 2 Press Up Down arrows until Fixture appears Press Enter Step 3 Press Up Down arrows to access Status Press Enter Display will now scroll through any error messages or display OK if no errors Table 2 1 Error Messages Display Message OK No Errors Found Tilt Sensor Tilt sensor not found WARNING As with any repairs or maintenance to
74. come damaged or thermally deformed WARNING RF INTERFERENCE 1 This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures 02 9690 00100 FOREWORD Sicherheitshinweise Es ist u erst wichtig ALLE Sicherheitsinformationen und hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen bevor Sie die hierin beschriebenen Produkte installieren bzw bedienen Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und VorsichtsmaBnahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet VORSICHT weist auf m glichen Produktschaden hin A WARNUNG weist auf m gliche K rperverletzung und Lebensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUER UBERHOHTE UV STRAHLUNG UND KORPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VARIXLITEO Beleuchtungen sind f r Gebrauch mit spezifischen Lichtquellen bestimmt worden Die VLX Beleuchtung benutzt eine spezielle Art LED Lichtquelle Eine andere Art Lichtquelle anzubringen ist gef hrlich und hebt die Beleuchtunggarantie auf 2 Scheinwerfer k nnen auf jeder beliebigen Oberfl che montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Beachten Sie die Einhaltung des erforderlichen Sich
75. ction and proper gloves when performing this procedure To remove and replace fan in LED cooling assembly Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 28 and engage tilt lock A Remove power and Luminaire Head CAUTION allow fixture to cool J N Front Head Cover Front Cover Latch one on each side of cover I J l IV Rear Head Cover Upper Enclosure Figure 2 28 VLX Wash Luminaire Step 3 Remove front head cover by unlatching both head cover latches Please note that one side of front cover is secured by a safety tether Locate clip attached to luminaire and unclip tether Step 4 Gently slide front head cover over optic assembly and set aside Step 5 Remove protective EMI shields from around optics assembly as shown in Figure 2 29 as follows WARNING On one EMI shield it is imperative to identify the ambient temperature sensor that protrudes through the EMI protective shield it is on the opposite side where the front cover safety tether connects When this shield is removed great care has to employed not to damage the sensor a At EMI shield side where front cover safety tether connects remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield b Remove shield and set aside 02 9690 0010 0 45 VARF amp LITEG VLX
76. e est n calientes 2 Cuando las luminarias est n en operaci n la l mpara estar muy caliente Desconecte la energ a y deje que la l mpara se enfr e antes de reemplazarla 3 Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando trabaje con l mparas da adas 4 Sitoca la l mpara con las manos limpie la l mpara con alcohol desnaturalizado y con tela sin pelusas antes de instalar o volver a conectar la luminaria 5 Cambie la l mpara si est da ada o deformada termicamente ADVERTENCIA INTERFERENCIA RF 1 Este es un producto de Clase A En el ambiente de la casa este producto puede ocasionar radiointerferencia en cuyo caso el usuario debe tomar las medidas adecuadas 02 9690 00100 FOREWORD ur UV
77. e fuses Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure Be sure to rotate head as shown in Figure 2 51 Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up Figure 2 51 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 52 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 As shown in Figure 2 52 locate blown fuse and replace 02 9690 0010 0 69 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 1 4 20 x 1 5 CAP SOC Screws x2 Upper Enclosure Bottom Cover 1 4 20 x 2 CAP SOC Screws x4 Power Distribution Assembly Note Some components not shown for clarity Power Distribution Assembly Fuses All fuses are rated 30A An extra spare fuse is located in space F9 Note there are no connections for fuses in spaces F5 and F10 Pan Motor Assembly Power Distribution Assembly 30A 30A 30A Space F1 Jumper Bridge SO WARNING All fuses must be ji replaced with sam
78. e k cy ease etalon TANE ERAS 12 Calibration Sequence aun uu E rb e tates 12 Sensor Testing avsa 12 Troubleshooting Error Messages iaa 14 Troubleshooting Guide u Eee RF Re lemen 15 Special Care and Handling Introd cti nz io AA 17 Special Cleaning and Care Instructions pp 17 General Care and Equipment Handling eene 18 O Ie R N een 18 Solid State EleectronicS uod Sa a eme hone 18 Electrostatic Discharge ESD 18 Printed Circuit Boards PCBS ss 18 Required Tools for VLX Wash Luminaire Service 18 Maintenance Procedures Front Lens Removal and Cleaning pe 19 Beam Spreader Removal for Fixed Beam Applications pp 23 Main Control Board MCB Replacement ss 27 Low Voltage Supply LVS Replacement eker 29 Tilt Motor Assembly Replacement nasa 31 Tilt Encoder PCB Replacement 34 02 9690 0010 0 10 September 2009 xiii VARFELITEO VLX LED WASH LUMINAIRE SERVICE MANUAL Tilt COT Sensor Replacement eee CED Driver PEB ees Motherboard Assembly eke keke Head Fan Cooling System Assembly CPC Lens Asseimbly tee P ie feret le LED Chip Assembly n ng Connector Assembly us DMX PCB Assembly ii u a RR as ern PowerCon AC Input Connector Assembly
79. e type and value L N Using anything other than same type or value fuse may result in equipment damage or fire Jumper Bridge 30A gt Spare Fuse Space F10 Figure 2 52 VLX Wash Upper Enclosure Fuse Replacement Step 5 Reinstall upper enclosure bottom cover Step 6 Position luminaire on upper enclosure so head and yoke move freely Step 7 Power luminaire and test 70 02 9690 00100 MAINTENANCE PROCEDURES POWER DISTRIBUTION ASSEMBLY Power Distribution Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench AN WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace power distribution board Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure Be sure to rotate head as shown in Figure 2 53 Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up Figure 2 53 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 54 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as
80. emove CPC lens assemblies as described in procedure for CPC Lens Assembly on page 49 Step 5 Disconnect LED Com connection JST 6 from motherboard assembly Step 6 Disconnect Zoom Com connection JST 4 from motherboard assembly 42 02 9690 00100 Note Some components not shown for clarity MAINTENANCE PROCEDURES MOTHERBOARD ASSEMBLY 2 MI Optics CPC Lenses x7 Motherboard Assembly Note Some components not shown for clarity 6 32 x 3 8 PFZ Screws x3 Zoom Support Standoffs x3 Motherboard Assembly Figure 2 27 Motherboard Assembly Removal Step 8 Noting orientation carefully lift mother board assembly from fixture Step 9 Remove three Zoom Support Standoffs from top of Motherboard Assembly noting their orientation Set standoffs aside Step 10 From motherboard PCB side remove three 8 32x3 4 PPZ screws with nylon washers Set screws and washers aside 02 9690 0010 0 43 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Step 11 Install motherboard assembly by performing Steps 3 through 10 in reverse Step 12 Disengage tilt lock Step 13 Power luminaire and test 44 02 9690 00100 MAINTENANCE PROCEDURES HEAD FAN COOLING SYSTEM ASSEMBLY Head Fan Cooling System Assembly Tools 2 Phillips screwdriver AN WARNING Ensure that power is completely removed from luminaire before attempting any work Always wear eye prote
81. erforming this procedure To remove and replace CPC lens assembly Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 32 and engage tilt lock Remove power and Luminaire Head CAUTION allow fixture to cool N Front Head Cover Front Cover Latch one on each side of cover Upper Enclosure Figure 2 32 VLX Wash Luminaire Step 3 Remove front head cover by unlatching both head cover latches Please note that one side of front cover is secured by a safety tether Locate clip attached to luminaire and unclip tether Step 4 Gently slide front head cover over optic assembly and set aside Step 5 Remove protective EMI shields from around optics assembly as shown in Figure 2 33 as follows WARNING On one EMI shield it is imperative to identify the ambient temperature sensor that protrudes through the EMI protective shield it is on the opposite side where the front cover safety tether connects When this shield is removed great care has to employed not to damage the sensor a At EMI shield side where front cover safety tether connects remove all screws securing cover Be sure to note locations of removed screws in relation to EMI shield 02 9690 0010 0 49 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL b Remove shield and set aside c At other EMI shield side with ambient temper
82. erheitsabstandes der VARI amp LITE Scheinwerfer von brennbarem Material oder beleuchteten Objekten WARNUNG HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK 1 VARI LITE Scheinwerfer eignen sich ausschlie lich f r trockene Standorte Regen oder Feuchtigkeit k nnen die Scheinwerfer besch digen 2 Unterbrechen Sie die Stromzufuhr bevor Sie mit der Arbeit an VARIXLITE Ger ten beginnen 3 Die Ger te sollten nur von qualifiziertem Personal gewartet werden 02 9690 0010 0 M VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL vi WARNUNG HINWEISE ZUM SCHUTZ GEGEN UBERHOHTE UV STRAHLUNG 1 Viele VARI LITE Scheinwerfer verwenden die Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 2 Es ist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen oder Ultraviolettschirme miissen ausgetauscht werden sofern deren Schutzwirkung durch sichtbare Besch digung z B Spriinge oder Schrammen eingeschrankt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN KORPERVERLETZUNGEN 1 Bei Betrieb sind die Au enfl chen der Scheinwerfer hei Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausriistung Handschuhe Augenschutz etc 2 Bei Betrieb der Scheinwerfer ist die Lampe hei Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abkiihlen wenn Sie diese austauschen 3 Tragen Sie beim Austausch der Lampen einen Augenschutz 4 Die geeignete Sich
83. erheitsausriistung Handschuhe Augenschutz sollte beim Umgang mit besch digten Lampen verwendet werden 5 Wenn die Lampe mit blofen H nden beriihrt wird reinigen Sie sie mit denaturiertem Alkohol und einem flusenfreien Tuch bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen 6 Wenn die Lampe besch digt oder durch Hitzeeinwirkung deformiert ist mu diese ausgetauscht werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse A In einer Wohnumgebung kann das Produkt Hochfre quenzst rungen verursachen In diesem Fall m ssen eventuell geeignete MaBnahmen getroffen werden 02 9690 0010 0 FOREWORD Notes de s curit Avant de proc der a l installation des produits d crits dans ce guide et de les mettre en marche il est extr mement important de lire TOUS les renseignements et TOUTES les directives de s curit contenues dans ce guide ainsi que toute documentation jointe Tenir compte de tous les avertissements et suivre toutes les pr cautions pendant l installation et l utilisation de cet appareil Les symboles de s curit utilis s dans ce guide sont les suivants ATTENTION Ce symbole annonce que l appareil risque d tre endommag A AVERTISSEMENT Ce symbole annonce qu il y a risque d accident grave ou m me fatal CETTE SECTION CONTIENT DES INFORMATIONS G N RALES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES LES INCENDIES L EXPOSITION EXCESSIVE AUX RAYONS UV ET TO
84. es or put in contact with PC boards which contain batteries Required Tools for VLX Wash Luminaire Service To properly maintain and service VLXTM LED Wash Luminaires Vari Lite recommends that the following tools in addition to the tools recommended during Vari Lite s technical training classes be available to technicians 90 degree Phillips head screwdriver 2 Precision torque wrench capable of 80 in oz Long 3 32 hex driver 18 02 9690 00100 MAINTENANCE PROCEDURES FRONT LENS REMOVAL AND CLEANING Maintenance Procedures Front Lens Removal and Cleaning Tools 2 Phillips screwdriver Slotted Screwdriver Refer to the list of cleaning materials in Special Cleaning and Care Instructions on page 17 WARNING Ensure that power is completely removed from luminaire before attempting any work Always wear eye protection and proper gloves when performing this procedure To clean from lens assembly and optics Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 1 and engage tilt lock Luminaire Head Remove power and CAUTION allow fixture to cool Front Head Cover Front Cover Latch on each side of cover Upper Enclosure Figure 2 1 VLX Wash Luminaire Step 3 Remove front head cover by unlatching both head cover latches Please note that
85. flat steady surface to have access to bottom cover of upper enclosure Be sure display side of upper enclosure is up and rotate head as shown in Figure 2 55 A Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure IM Position Lens Up Figure 2 55 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 56 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Atupper enclosure top cover as shown in Figure 2 56 remove four M4 x 12mm PFB screws It may be necessary to turn enclosure to access screws 74 02 9690 00100 MAINTENANCE PROCEDURES POWER SUPPLY 1 ASSEMBLY 2 1 4 20 x 1 5 CAP 50C Screws x2 1 4 20 x 2 CAP SOC Screws x4 Upper Enclosure Bottom Cover Power Supply 1 Display Side Note Some components not shown for clarity M4 x 12mm PFB Screws Figure 2 56 VLX Wash Power Supply 1 Assembly Step 5 Disconnect wiring from power supply 1 assembly 02 9690 0010 0 75 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 76 Step Step Step Step OO a In Black line White neutral Green earth Loosen terminal screws b DC Out Red 12V 2 wires Black Negative VDC 2 wires Rem
86. forming Steps 6 through 2 in reverse order Be sure to orient front lens as shown in Figure 2 4 WARNING Front Lens Assembly must be mounted in orientation show If installed incorrectly luminaire performance will be affected Luminaire Head Front Lens Ring Mounting Screw Front Lens Ring Mounting Screw Correct Front Lens Assembly Orientation Yoke Arm Yoke Arm Front Lens Front Lens Ring Mounting Screw Incorrect Front Lens Assembly M gt Orientation Figure 2 4 Front Lens Orientation Step 9 Once luminaire is reassembled power and test 02 9690 00100 MAINTENANCE PROCEDURES BEAM SPREADER REMOVAL FOR FIXED BEAM APPLICATIONS 2 Beam Spreader Removal for Fixed Beam Applications Tools 2 Phillips screwdriver Slotted screwdriver Z N WARNING Ensure that power is completely removed from luminaire before attempting any work Always wear eye protection and proper gloves when performing this procedure To remove beam spreader assembly for fixed beam applications Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 5 and engage tilt lock Luminaire Head Remove power and CAUTION allow fixture to cool Front Head Cover gt Front Cover Latch one on each side of cover Upper Enclosure Figure 2 5 VLX Wash Luminaire
87. g and routing Disconnect wiring from zoom motors to motherboard c At front lens loosen and remove and remove three stand offs Remove lens and place lens on a clean lint free cloth as not to damage or scratch lens d Remove three compression springs and optic ring plate Set components aside 02 9690 0010 0 51 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Note To remove and replace center CPC lens assembly it will be necessary to remove outer lenses to gain proper access Step 7 As shown in Figure 2 35 remove two 4 40 x 1 4 LG PPZ SEMS screws 4 40 x 1 4 PPZ Screws x2 CPC Lens Assembly Note Some components not shown for clarity Figure 2 35 CPC Lens Assembly Removal WARNING Use extreme care when handling as not to scratch the fresnel lens Step 8 Carefully remove CPC Lens Assembly Step 9 Replace CPC lens assembly by performing Steps 3 through 8 in reverse order Note when installing insure CPC lens sets down into top light pipe support Step 10 Disengage tilt lock Step 11 Power luminaire and test 52 02 9690 00100 MAINTENANCE PROCEDURES LIGHT PIPE ASSEMBLY 2 Light Pipe Assembly Tools 2 Phillips screwdriver Slotted Screwdriver 1 4 Nutdriver AN WARNING Ensure that power is completely removed from luminaire before attempting any work Always wear eye protection and proper gloves when performing this procedure To remove and replace light pi
88. gan las instrucciones de instalaci n Vea las instrucciones detalladas en este manual 3 Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las luminarias VARIXLITEO ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA CHOQUE ELECTRICO 1 Las luminarias VARI LITE est n dise adas solamente para lugares secos La exposici n a la lluvia o humedad pueden da ar la luminaria 2 Desconecte la energ a antes de dar servicio a cualquier equipo de VARI LITE 3 El servicio debe ser realizado solamente por personal calificado 02 9690 0010 0 ix VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA EXPOSICION EXCESIVA DE RADIACION ULTRA VIOLETA 1 Muchas luminarias VARI LITE usan un tipo de l mpara que produce radiaci n UV NO mire directamente a la l mpara 2 Es peligroso operar luminarias sin lentes o protectores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido da adas y que su efectividad pudiera estar deteriorada Por ejemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTRA LESIONES DE PERSONAS 1 Las superficies exteriores de las luminarias est n calientes durante su operaci n Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando haga ajustes en el equipo y componentes qu
89. ield temperature sensor side with front cover tether connects to head 6 32 x 1 4 PPZ SEMS Screws x5 SE p A Per shield Figure 2 2 Front Head Cover and EMI Shields Removal Step 6 At head assembly as shown in Figure 2 3 remove front lens assembly as follows 20 02 9690 00100 MAINTENANCE PROCEDURES FRONT LENS REMOVAL AND CLEANING 6 32 x 1 4 PPB Screws x3 Front Lens Ring Eu n y 0 Zoom Slide Standoffs x3 Front Lens Optics Ring Plate MK 7 7 Optics CPC Lenses Figure 2 3 Front Lens Removal Note Before proceeding please note orientation of both front lens ring and front lens assembly They must be mounted in their original orientation position for the front head cover to reinstall properly Remove three screws securing front lens and lens ring Set components aside b Note zoom motor wiring and routing Disconnect wiring from zoom motors to motherboard c At front lens loosen and remove and remove three stand offs Remove lens and place lens on a clean lint free cloth as not to damage or scratch lens d Remove three compression springs and optic ring plate Set components aside Step 7 Clean front lens and optics according to the guidelines set forth in Special Cleaning and Care Instructions on page 17 02 9690 0010 0 21 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 22 Step 8 Once cleaning is complete reassemble by per
90. ing standard features Seven 120 Watt custom RGBW Chipsets each chipset contains PE high density red green blue and white LED emitters LA p e Patented optical zoom system with continuously variable field angle from approximately 22 to 60 Zoom module is easily removable for fixed field angle of 21 L Smooth high resolution intensity and dimming control of red green blue and white LEDs Color temperature white variable between 3000 and 9000K LED manufacturer rated life in excess of 10 000 hours at full RGBW Output exceeds 14 000 lumens white light M High speed strobe operation with multiple strobe effects Smooth time controlled continuous motion by way of a pair of three phase stepper motor systems Pan range is 540 Tilt range is 270 both with a 0 3 resolution Control by DMX512 protocol Fan cooled Operational Temperature of 20 to 122 F 29 to 50 C Power Requirements Standard AC power distribution from 100 240VAC 50 60Hz The unit requires up to 10A depending on the AC supply voltage Technical Specifications For detailed technical specifications refer to VLX LED Wash Luminaire User s Manual 02 9690 0001 4 02 9690 0010 0 COMPONENTS VLX WASH EXTERNAL COMPONENTS Components VLX Wash External Components The following illustration shows the external luminaire components and controls Truss Hook Brackets Att
91. it was removed Step 4 Note all wiring connected to Power Distribution Assembly as shown in Figure 2 54 02 9690 0010 0 71 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 1 4 20 x 1 5 CAP SOC Screws x2 Upper Enclosure Bottom Cover 1 4 20 x 2 CAP SOC Screws x4 8 32 x 3 8 PPZ SEMS Screws x4 Power Distribution Assembly Dielectric Insulator Note Some components not shown for clarity Power Distribution Assembly Pan Motor Assembly x Power Distribution Board GREEN Wiring _ D BLUE Wiring RED Wiring G Ca BLACK Wiring GREEN Wiring _ 4 amp BLUE Wiring Jumpers Bridges Figure 2 54 VLX Wash Upper Enclosure Power Distribution Assembly 72 02 9690 00100 MAINTENANCE PROCEDURES POWER DISTRIBUTION ASSEMBLY Step 5 Disconnect wiring from power distribution assembly Step 6 Remove four 8 32 x 3 8 PPZ SEMS screws and remove power distribution board Step 7 There is a dielectric insulator underneath the power distribution board If this insulator is damaged it must be replaced Step 8 Install replacement power distribution board to assembly Make sure dielectric insulator is properly positioned underneath board Step 9 Reconnect all wiring Board Connection Wire Label Wire Color Notes OP1 OP1 Blue 12 VDC to LED Driver PCB1 OP2 OP2 Blue 12 VDC to LED Driver PCB2 OP3 OP
92. ite the RMA number legibly on or near the shipping address label and return the unit freight prepaid to Vari Lite 10911 Petal Street Dallas Texas 75238 USA Attention Warranty Service RMA Number As stated in the warranty it is required that the shipment be insured and FOB our service center 02 9690 0010 0 i VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Compliance Notice FCC C This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with Vari Lite system service and safety guidelines may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents Safety EN 60598 1 2000 Luminaire Safety Standard General Requirements EN 60598 2 17 1989 A2 1991 Specification for Luminaires for Stage and Studio Lighting EMC EN 61000 6 4 2001
93. le holding spring Remove pan motor assembly from fixture by lifting out and away from enclosure Disconnect encoder PCB To reinstall connect wiring to encoder PCB make sure not to pinch wiring Angle bottom of motor assembly into enclosure catch pan motor belt in pulley With spring in 12 o clock position install 8 32 x 1 2 PPB screws starting to the immediate to left of spring 10 o clock then tighten in clockwise fashion Reassemble luminaire Position luminaire on upper enclosure so head and yoke move freely Power luminaire and test 81 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 82 Pan Motor Belt Tools 2 Phillips screwdriver 3 16 Hex wrench WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace pan motor belt Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure Rotate head as shown in Figure 2 61 Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up Cs 6 pos FINN Figure 2 61 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 62 remove four 1 4 20 x 2 CAP SOC screws and two 1
94. lisation des luminaires sans lentille ou blindage pose des risques Tous blindages lentilles ou crans ultraviolet visiblement endommag s au point que leur efficacit en est affect e doivent tre remplac s par exemple s il y a des fissures ou de profondes rayures AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES ACCIDENTS POUVANT ENTRA NER DES BLESSURES l Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour manceuvrer ou ajuster des appareils br lants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 La lampe du luminaire est br lante lorqu il est en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons ultraviolets pouvant causer de graves br lures sur la peau et une inflammation des yeux De plus les lampes arc fonctionnent sous haute tension de tr s hautes temp ratures Sila lampe se casse les particules de la lampe cass e peuvent causer blessures et ou incendie en s parpillant 4 Se prot ger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropri s gants protection des yeux pour manier des lampes endommag es 6 Silalampe a t touch e avec des mains nues la nettoyer avec de l alcool d natur et l essuyer avec un chiffon non pelucheux avant d installer ou de brancher le luminaire 7 Silalampe a t endommag e
95. move connector assembly Step 6 Atconnector assembly remove four 4 40 x 3 8 PFB screws and nuts securing DMX PCB assembly Remove DMX PCB assembly Step 7 Reinstall by performing Steps 3 through 6 in reverse order Step 8 Position luminaire on upper enclosure so head and yoke move freely Step 9 Power luminaire and test 02 9690 0010 0 61 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL PowerCon AC Input Connector Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace PowerCon connector assembly 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure and connector assembly side is up Be sure to rotate head as shown in Figure 2 45 Remove power and CAUTION allow fixture to cool Step Luminaire Head Upper Enclosure I Position Lens Up o nd PEA a Connector Assembly we SL 6 6 Figure 2 45 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 46 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It
96. must be reinstalled the same way as it was removed Step 4 Remove 8 32 x 1 2 PFB screw in enclosure top cover securing connector assembly 62 02 9690 00100 MAINTENANCE PROCEDURES POWERCON AC INPUT CONNECTOR ASSEMBLY 2 1 4 20 x 2 CAP 1 4 20 x 1 5 CAP SOC Screws x4 SOC Screws x2 Connector Assembly Upper Enclosure Bottom Cover 8 32 x 1 2 PFB Screw Note Some components not shown for clarity Connector Assembly PowerCon AC Input P x 3 8 PFB Screws x2 Connector Assembly PowerCon Connections Wire Color Connection White Neutral Black Line Green Earth Ground Figure 2 46 VLX Wash Upper Enclosure PowerCon Connector Assembly Step 5 Note wiring will be attached to DMX PCB and Input PowerCon Detach wiring and remove connector assembly Step 6 Atconnector assembly remove two 4 40 x 3 8 PFB screws and nuts securing PowerCon connector assembly Remove PowerCon connector assembly 02 9690 0010 0 63 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 64 Step 7 Step 8 Step 9 Step 10 At PowerCon connector disconnect three Faston connectors a White wire neutral b Black wire line c Green wire earth ground Reinstall by performing Steps 3 through 7 in reverse order Position luminaire on upper enclosure so head and yoke move freely Power luminaire and test 02 9690 00100 MAINTENANCE PROCEDURES LCD DISPLAY ASSEMBLY
97. o support Step 10 Tighten nylock nuts so that top of threads are flush with nylock nut Step 11 Reassemble luminaire Step 12 Disengage tilt lock Step 13 Power luminaire and test 02 9690 00100 MAINTENANCE PROCEDURES LED CHIP ASSEMBLY LED Chip Assembly Tools 2 Phillips screwdriver Slotted Screwdriver e 1 4 Nutdriver Flat tweaker screwdriver 3 32 long hex driver Precision torque wrench capable of 80 in oz WARNING Ensure that power is completely removed from luminaire before attempting any work Note After replacing a LED chip recalibration of the fixture is required Please contact Vari Lite technical support at VL Technician philips com or 1 214 647 7880 for details gt gt To remove and replace LED chip assembly Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 38 and engage tilt lock Luminaire Head Remove power and CAUTION allow fixture to cool Front Head Cover Front Cover Latch one on each side of cover Upper Enclosure Figure 2 38 VLX Wash Luminaire WARNING Note that CPC lens assembly light pipe and LEDs must be handled with extreme care or not be damaged All fingerprints grease smudges etc must be removed Any damage to any of these components will require replacement with new Step 3 Remo
98. ove terminal screws c COM Power Supply Com from CN1 Remove power supply 1 assembly Replace by performing Steps 3 through 6 in reverse order Position luminaire on upper enclosure so head and yoke move freely Power luminaire and test 02 9690 0010 0 MAINTENANCE PROCEDURES POWER SUPPLY 2 ASSEMBLY Power Supply 2 Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace power supply 2 assembly Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure Be sure connector side of upper enclosure is up and rotate head as shown in Figure 2 57 A Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up Y Figure 2 57 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 58 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 At upper enclosure top cover as shown in Figure 2 58 remove four M4 x 12mm screws It may
99. pe assembly Step 1 Remove power from luminaire and allow unit to completely cool Step 2 Carefully set luminaire on upper enclosure rotate head as shown in Figure 2 36 and engage tilt lock A Remove power and Luminaire Head CAUTION allow fixture to cool Step Step Step Step 02 9690 0010 0 Front Head Cover Front Cover Latch one on each side of cover Upper Enclosure Figure 2 36 VLX Wash Luminaire 3 Remove corresponding CPC lens assembly as described in procedure for CPC Lens Assembly on page 49 4 As indicated in Figure 2 37 using 1 4 nutdriver remove two 4 nylock nuts from top light pipe support 5 Remove springs under nylock nuts 6 Remove top light pipe support 53 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 54 A WARNING Note that light pipe must be handled with extreme care or not be damaged All fingerprints grease smudges etc must be removed Any damage to light pipe and it should be replaced with new LED x7 Z Axis Stop x7 Light Pipe Assembly x7 Top Light Pipe Support x7 Springs x2 per light pipe Not 4 Nylock Nut x2 per light pipe ote Some components not shown for clarity Figure 2 37 Light Pipe Assembly Removal Step 8 When replacing ensure that light pipe is fully seated into Z Axis Stop at LED Step 9 When installing top light pipe support ensure that hex light pipe is seated correctly int
100. pective companies or organizations Vari Lite A Philips Group Company 10911 Petal Street Dallas Texas 75238 USA This manual is for informational use only and is subject to change without notice Vari Lite assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual Version as of 10 September 2009 Part number 02 9690 0010 0 VLX LED Wash Luminaire Service Manual 2009 Vari Lite a Philips group company All Rights Reserved FOREWORD How To Obtain Warranty Service A copy of the Vari Lite Limited Warranty was included in the shipping package for this VARIXLITEO product To obtain warranty service please contact customer service at 1 877 VARI LITE 1 877 827 4548 1 214 647 7880 or entertainment service O philips com and request a Return Material Authorization RMA for warranty service You will need to provide the model and serial number of the item being returned a description of the problem or failure and the name of the registered user or organization If available you should have your sales invoice to establish the date of sale as the beginning of the watranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form obtained from the Vari Lite web site www vari lite com or through customer service and place in shipping container along with a copy of your invoice if available Wr
101. per Enclosure Position Lens Up Connector Assembly fe Ill a 6 LC Figure 2 41 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 42 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed 58 02 9690 00100 MAINTENANCE PROCEDURES CONNECTOR ASSEMBLY 2 Step 4 Remove 8 32 x 1 2 PFB screw in enclosure top cover securing connector assembly 1 4 20 x 2 CAP Note SOC Screws x4 Some components not shown for clarity 1 4 20 x 1 5 CAP SOC Screws x2 Connector Assembly Upper Enclosure Bottom Cover 8 32 x 1 2 PFB Screw 8 32 x 1 2 PFB Screw Figure 2 42 VLX Wash Upper Enclosure Connector Assembly Step 5 Note wiring will be attached to DMX PCB and Input PowerCon Detach wiring and remove connector assembly Step 6 Reinstall by performing Steps 3 through 5 in reverse order Step 7 Position luminaire on upper enclosure so head and yoke move freely Step 8 Power luminaire and test 02 9690 0010 0 59 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL DMX PCB Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace DMX
102. play Assembly Step 5 Note wiring will be attached to LCD Display assembly Detach wiring and remove assembly Step 6 Reinstall by performing Steps 3 through 5 in reverse order Step 7 Position luminaire on upper enclosure so head and yoke move freely Step 8 Power luminaire and test 66 02 9690 00100 MAINTENANCE PROCEDURES LCD DISPLAY PCB ASSEMBLY 2 LCD Display PCB Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replace LCD Display PCB assembly Step 1 Remove power from luminaire by disconnecting power cable disconnect all DMX cables and allow unit to completely cool Step 2 Carefully lay luminaire on flat steady surface to have access to bottom cover of upper enclosure and LCD Display Assembly side is up Be sure to rotate head as shown in Figure 2 49 A Remove power and CAUTION allow fixture to cool Luminaire Head Upper Enclosure Position Lens Up LCD Display Assembly tl ss 6 Figure 2 49 VLX Wash Luminaire Step 3 Using 3 16 hex wrench and as indicated in Figure 2 50 remove four 1 4 20 x 2 CAP SOC screws and two 1 4 20 x 1 5 CAP SOC screws and remove base cover Note Make note of orientation of bottom cover in relation to upper enclosure It must be reinstalled the same way as it was removed Step 4 Remove 8 32 x 1 2 PFB screw in enclo
103. s X3 EMI Protective Shield side with ambient EMI Protective Shield temperature sensor side with front cover tether connects to head 6 32 x 1 4 PPZ SEMS Screws x5 JG p EZ Per shield Figure 2 6 Front Head Cover and EMI Shields Removal 24 02 9690 00100 MAINTENANCE PROCEDURES BEAM SPREADER REMOVAL FOR FIXED BEAM APPLICATIONS 2 Step 6 At head assembly as shown in Figure 2 7 remove front lens assembly as follows n 6 32 x 1 4 PPB Screws x3 Front Lens Ring N Zoom Slide Standoffs x3 Optics Ring Plate 5 7 Figure 2 7 Front Lens Removal a Remove three screws securing front lens and lens ring Set components aside b Note zoom motor wiring and routing Disconnect wiring from zoom motors to motherboard c At front lens loosen and remove and remove three stand offs Remove lens and place lens on a clean lint free cloth as not to damage or scratch lens d Remove three compression springs and optic ring plate Set components aside Step 7 Reassemble luminaire for fixed beam applications as follows 02 9690 0010 0 25 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 26 6 32 x 1 4 PPB Screws x3 Optics Ring Plate Compression Springs x3 Optics CPC Lenses x7 rp Optics Assembly Posts x3 Figure 2 8 Fixed Beam Application Assembly a As shown in Figure 2 8 slide compression springs over
104. ssembly eene 146 VLX Wash A C Supply Cable Assembly pp 147 Appendix A Technical Bulletins and Notices VLX Wash Technical Bulletins and Notices 149 02 9690 0010 0 10 September 2009 xv VARFELITEO VLX LED WASH LUMINAIRE SERVICE MANUAL This page intentionally blank xvi 10 September 2009 02 9690 00100 INTRODUCTION ABOUT THIS MANUAL Introduction About This Manual This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VLX LED Wash Luminaire The manual is intended for use by Vari Lite personnel and Authorized VARI LITE O Service Centers and technicians WARNING 1t is important to read ALL accompanying safety and installation instructions to avoid damage to the product and potential injury to yourself or others This manual covers the following models Model Part Number Source VLX Wash Luminaire 20 9690 0001 Seven x 120W RGBW LEDs VLX Wash Luminaire White 20 9690 0001 02 Seven x 120W RGBW LEDs Note Performing maintenance procedures may void the product warranty Refer to the Vari Lite Limited Warranty card included in the product shipping package for more information Additional Documentation For complete installation and operation instructions refer to the VLX Series Luminaire User s Manual This manual is available in electronic PDF format on the Vari Lite web site at www vari lite com
105. ssembly 25 9690 1504 Rev B Negative Wire Driver Board 5 i Cable Assembly 25 9690 1505 Rev B Negative Wire Driver Board 6 Cable Assembly 25 9690 1506 Rev C Negative Wire Driver Board 7 id Cable Assembly 25 9690 1507 Rev C Positive Wire Driver Board Tilt Motor Side Cable Assembly 25 61 Positive Wire Driver Board MC8 Side Cable Assembly 25 9690 1510 Rev B VLX Wash A C Supply Cable Assembly 25 9690 3552 Rev A Figure 3 2 VLX Wash Luminaire Subassembly Drawing Tree Part 2 02 9690 0010 0 91 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Top Assembly VLX Wash Included Items Kit 28 9690 0001 Rev B Refer to Figure 3 3 No Item Qty UM Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8001 0002 1 EA VARI LITE QUALITY ASSURANCE SHEET 3 02 8052 0001 1 EA CARD LIMITED WARRANTY 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 5 02 9690 0002 1 EA UNPACK QUICK START SHEET VLX WASH 04 4037 0001 5 EA LABEL 2 5 X 5 BARCODE not shown 04 9678 1001 2 EA LABEL GREEN ROHS COMPLIANT not shown 04 9690 0001 2 EA LABEL SHIPPING BOX VLX WASH not shown j 06 6073 0001 1 EA SHIPPING FOAM not shown 07 5044 0001 1 EA BAG DESICCANT SHIPPING BOX not shown 07 9690 0001 1 EA CARDBOARD SHIPPING BOX VLX WASH not shown 6 08 9690 0001 1 EA CD ROM VLX WASH
106. sure top cover securing LCD Display assembly 02 9690 0010 0 67 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 1 4 20 x 2 CAP 1 4 20 x 1 5 CAP SOC Screws x4 SOC Screws x2 Upper Enclosure Bottom Cover LCD Display Note Some components not shown for clarity LCD Display Assembly LCD Display 6 32 x 1 4 PPB SEMS Screws x4 6 Split Washers x4 LCD Display Panel Note washers must install between LCD and panel Figure 2 50 VLX Wash Upper Enclosure LCD Display Assembly Step 5 Note wiring will be attached to LCD Display assembly Detach wiring and remove assembly Step 6 At LCD Display assembly disconnect Display Com connector J4 and Power Supply Com connector J3 from assembly Step 7 Remove four 6 32 x 1 4 PPB SEMS screws securing LCD Display to assembly Note location of four 6 split washers They must be reinstalled in same position as noted in Figure 2 50 Step 8 Reinstall be performing Steps 3 through 7 in reverse order Step 9 Position luminaire on upper enclosure so head and yoke move freely Step 10 Power luminaire and test 68 02 9690 00100 MAINTENANCE PROCEDURES FUSE REPLACEMENT POWER DISTRIBUTION ASSEMBLY Fuse Replacement Power Distribution Assembly Tools 2 Phillips screwdriver 3 16 Hex wrench A WARNING Ensure that power is completely removed from luminaire before attempting any work To remove and replac
107. t head assembly as shown in Figure 2 24 locate LED driver PCB to be replaced 02 9690 0010 0 39 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Note It is important to note wire harness routing for LED driver PCB being replaced Wiring must be routed exactly as originally installed Head Assembly LED Driver PCBs x7 Figure 2 24 LED Driver PCB Removal Step 7 On LED driver PCB Disconnect 12V DC at connection J4 by removing terminal screw Note The exact screw type must be used in installation of replacement LED driver PCB Step 8 Disconnect fan at connection J3 MTA4 Note LED Driver PCB 5 does not have a fan connected to it Step 9 Disconnect 12V from terminals at connections J5 and J6 Note LED Driver PCBs 3 and 6 have abuss bar that will be removed as part of Step 9 Step 10 Carefully slide the LED driver PCB down and out of motherboard There is a set of pins on the driver that goes into a header on the motherboard assembly There are also two tabs on LED driver PCB that lock into slots on motherboard Step 11 Note the routing of wiring to LED it will be necessary on the replacement LED to bend with wiring to match the original 40 02 9690 0010 0 MAINTENANCE PROCEDURES LED DRIVER PCB 2 Step 12 Disconnect wiring from LED Note that it might be required to remove a neighboring LED driver Step 13 Install replacement LED driver PCB by performing Step 3 through 12 in
108. the luminaire head assembly LEDs LED Cooling Assembly Houses seven 120W LEDs and LED cooling assembly LED Driver PCBs One Driver PCB per LED Rear Head Cover LED Lightpipes One lightpipe per LED Transmits light from LED to optics Optics Assembly Houses lenses and zoom beam spread motors Motherboard Support Assembly LED Driver PCBs Motherboard PCB assembly CPC Optics One CPC optic per LED Connects to lightpipe Front Head Cover attached by tether Note Yoke and Enclosure assemblies not shown for clarity 6 02 9690 00100 COMPONENTS VLX WASH LUMINAIRE YOKE COMPONENTS VLX Wash Luminaire Yoke Components The following illustration shows the major sub assemblies which are located in the luminaire yoke assembly Head Tilt Lock Assembly Yoke Arm Cover Yoke Center Cover Main Controller Board MCB Luminaire control circuit board Low Voltage Power Supply 24V 120W Yoke Structure Assembly Tilt Motor Assembly Yoke Arm Cover Note Head and Enclosure assemblies not shown for clarity 02 9690 0010 0 1 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL VLX Wash Enclosure Components The following illustration shows the major sub assemblies which are located in the luminaire enclosure assembly Enclosure Bottom Cover Power Distro Assembly DC Power Connection Block Pan Motor Assembly LCD Display Assembly
109. to VARI XLITEO equipment are issued from the Dallas Texas USA office They are documentation supplements that contain procedures for equipment upgrades retrofits and repairs not found in the existing manuals Operator technical bulletins are also issued to document changes in control software Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Bulletins are categorized by assembly or subassembly and identified by a number such as SVX 001 VLX Series Luminaires Technical Bulletin number 1 or LSW 001 Software release technical bulletin Technical notices are also issued from the Dallas Texas USA office They are non procedural documents that contain information regarding product support issues current equipment problems software bugs and documentation corrections All technical notices begin with the prefix TN and are numbered sequentially such as TN 138 Tech Notice number 138 A list of current technical bulletins and notices associated with VLX Series Luminaires is found in VLX Wash Technical Bulletins and Notices on page 149 2 02 9690 00100 CHAPTER 1 Description This chapter contains descriptions of luminaire features and components Features Components Principles of Operation JDIAUIS 02 9690 0010 0 3 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Features Standard Features All VLX series luminaires have the follow
110. u can replace only the motor the pulley Item 3 is bonded to the motor shaft during assembly and cannot be removed intact If you order a replacement motor Item 6 also order the pulley Item 3 Contact Vari Lite Customer Service for installation information Figure 3 8 Tilt Motor Assembly 02 9690 00100 ENCLOSURE ASSEMBLY VLX WASH UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly VLX Wash Upper Enclosure Assembly 21 9690 0800 Rev Refer to Figure 3 9 and Figure 3 10 No Item Qty UM Description 1 10 9687 0604 1 EA TIMING PULLEY 150 TOOTH 2 10 9690 0800 6 EA HEX STANDOFF 3 10 9690 0804 1 EA MOTOR ADJ PLATE 4 10 9690 0806 1 EA BEARING LOCK HOLDER 5 10 9690 0814 1 EA DC DISTRO MOUNT 6 10 9690 0818 1 EA DC DISTRO INSULATOR 7 10 9690 1822 1 EA VLX AIR DAM 8 12 9690 0018 1 EA VLX CASTING MACHINING 9 21 9690 0540 1 EA ASSY PAN MOTOR 10 21 9690 0802 1 EA ASSY DISPLAY VLX WASH 11 21 9690 0803 1 EA VLX BASE SUB ASSY 12 21 9690 0804 1 EA ASSY CONNECTOR VLX WASH 13 22 9690 0800 1 EA ASSY PAN TUBE VLX WASH 14 24 9690 0860 1 EA ASSY DC DISTRO gt 25 9690 0511 1 EA CABLE ASSY 12V OUTPUT 1 not shown j 25 9690 0512 1 EA CABLE ASSY 12V OUTPUT 2 not shown 25 9690 1550 1 EA CABLE ASSY VLX DATA I O LINK not shown 25 9690 1553 1 EA VLX DISPLAY LINK not shown 25 9690 1556 1
111. ve head cover EMI shields and zoom lens array assembly as described in procedure for Front Lens Removal and Cleaning on page 19 02 9690 0010 0 55 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL 56 Step 4 Remove corresponding CPC lens assembly as described in procedure for CPC Lens Assembly on page 49 and corresponding light pipe assembly as described in procedure for Light Pipe Assembly on page 53 Note LED number 5 center LED will require complete removal of CPC lens and light pipe assemblies in order to remove and replace it Step 5 Note As shown in Figure 2 39 at light pipe tube of LED to be replaced gently roll black O ring down out of lip at top of tube using a small flat tweaker screwdriver n IN LED x7 Z Axis Stop x7 Light Pipe Assembiy x7 Light Pipe O Ring x7 Top Light Pipe Support x7 Springs x2 per light pipe 4 Nylock Nut x2 per light pipe Some components not shown for clarity Step 6 Step 7 Step 8 Figure 2 39 LED Assembly Removal Lift tube through support while rolling O ring off bottom of tube As indicated in Figure 2 40 using long 3 32 hex driver remove two 4 40 x 0 438 LG SH CAP screws from LED die The Z Axis stop and seal will also be removed 02 9690 0010 0 MAINTENANCE PROCEDURES LED CHIP ASSEMBLY 2 Step 9 Under the LED is a thermal transfer material If material is torn or dam
112. vicing Luminaire Head A Remove power before Yoke Arm Cover without tilt lock Yoke Center Cover Figure 2 14 VLX Wash Luminaire Step 3 As shown in Figure 2 15 remove Yoke Center Cover by removing six 6 32 x 3 8 PFB screws Note Some components not shown for clarity Yoke Center Cover 6 32 x 3 8 PFB Screws x6 Figure 2 15 VLX Wash Yoke Center Cover 02 9690 0010 0 31 VARF amp LITEG VLX LED WASH LUMINAIRE SERVICE MANUAL Step 4 Disconnect wiring from tilt encoder PCB Note routing of wiring Step 5 Using 11 32 nutdriver loosen but do not remove four 8 KEPS nuts until tilt motor assembly will slide up towards spring if tilt belt is squeezed together Refer to Figure 2 16 for details Note Some components not shown for clarity Tilt Belt Tilt Encoder PCB Tilt Motor Spring Tilt Motor Pulley Tilt Motor Assembly 8 KEPS Nut x4 Figure 2 16 VLX Wash Tilt Motor Assembly Step 6 Carefully remove tilt belt from tilt driven pulley Step 6 Step 7 At tilt motor assembly remove four 8 KEPS nuts loosened in Step 5 8 Disconnect tilt motor power harness 9 Step 9 Press motor straight in from yoke side until spring can be removed Step 10 Angle drive pulley down and remove from yoke Step 11 Replace assembly by performing Steps 5 through 10 in reverse making sure 8 KEPS nuts are loose enough for motor to slide against spring

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