Philips VARI*LITE VL1100 ERS Luminaire User manual

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
ii 20 October 2010 02.9664.0010 0
Neutrik®, PowerCon®, and EtherCon® are registered trademarks of Neutrik, Inc.
All other brand or product names which may be mentioned in this manual are trade-
marks or registered trademarks of their respective companies or organizations.
The information furnished in this manual is for informational use only and is subject to
change without notice. Please check www.vari-lite.com for latest version. Vari-Lite
assumes no responsibility or liability for any errors or inaccuracies that may appear in
this manual. All information and graphics are property of Vari-Lite, 10911 Petal
Street, Dallas, Texas 75238.
Version as of: 20 October 2010
Part number: 02.9664.0010 0
VL1100 ERS Luminaire Service Manual
©2002-2010, Vari-Lite, a Philips group company. All Rights Reserved.

HOW TOOBTAIN WARRANTY SERVICE
02.9664.0010 0 20 October 2010 iii
How To Obtain Warranty Service
A copy of the Vari-Lite Limited Warranty was included in the shipping package for
this VARI❋LITE product.
To obtain warranty service, please contact customer service at 1-877-VARI-LITE
(1-877-827-4548) or 1-214-647-7880 or via e-mail at entertainment.service@phil-
ips.com 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 descrip-
tion 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 warranty period.
Once you obtain the RMA, pack the unit in a secure shipping container or in its
original packing box. Fill out the RMA form included at the end of this manual and
place in shipping container along with a copy of your invoice (if available). Write the
RMA number legibly on or near the shipping address label and return the unit, freight
prepaid to:
Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
Attention: Warranty Service / RMA# __________________
As stated in the warranty, it is required that the shipment be insured and FOB our
service center.
Manual Revision History
VERSION DATE
Revision 0 (Inital Version) 20 October 2010

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
iv 20 October 2010 02.9664.0010 0
Compliance Notice
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 communica-
tions. Operation of this equipment in a residential area is likely to cause harmful inter-
ference, 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 (as applicable):
Safety:
(by Low Voltage Directive 2006/95/EC)
EN60598-1: 1997/A1:1998
EN60598-2-17: 1989/A2:1991
EN60922
Electromagnetic Compatibility:
(by Council Directive 89/336/EEC)
EN55022:1998, Class A
EN61000-4-2: 1995, Performance Criteria: B
EN61000-4-3: 1995, Performance Criteria: A
EN61000-4-4: 1995, Performance Criteria: B
EN61000-4-5: 1995, Performance Criteria: B
EN61000-4-6: 1996, Performance Criteria: A
EN61000-4-8: 1996, Performance Criteria: A
EN61000-4-11: 1994, Performance Criteria: B and C
EN61000-3-2: 1995
EN61000-3-3: 1994
We certify that the product conforms to the protection requirements of council direc-
tives: 2006/95/EC (LVD) and 89/336/EEC (EMC)
FCC

SAFETY NOTICE
02.9664.0010 0 20 October 2010 v
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:
GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELEC-
TRICAL 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 only with certain Philips and Osram
HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps.
Installing another type of lamp may be hazardous.
2. Luminaires may be mounted on any type of surface as long as mounting instructions are
followed. See instructions detailed in this manual.
3. Replace fuses with same type and rating only.
4. Note distance requirement from combustible materials or illuminated objects for
VARI❋LITE luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARI❋LITE luminaires are designed for dry locations only. Exposure to rain or moisture
may damage luminaire.
2. Disconnect power before servicing any VARI❋LITE equipment.
3. Servicing to be performed by qualified personnel only.
WARNING: It is not recommended to power any VARI❋LITE luminaire from a
dimmer - even in 'NONDIM' mode. Dimmer and non-dim modules are not suitable
sources of power because their output modifies the AC wave form. This may work for
a short time, but will eventually result in power problems, luminaire mis-operation
and/or failure. See Vari-Lite Technical Notice TN-229A for more information.
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
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WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE
EXPOSURE TO UV RADIATION
1. Many VARI❋LITE luminaires use an HID type lamp that produces UV radiation. DO
NOT look directly at lamp.
2. It is 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. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye
inflammation. Additionally, arc lamps operate under high pressure at very high
temperatures. Should the lamp break, there can exist a danger of personal injury and/or
fire from broken lamp particles being discharged.
4. Wear eye protection when relamping.
5. Appropriate safety equipment (gloves, eye protection) should be used when handling
damaged lamps.
6. If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with
lint-free cloth before installing or powering up the luminaire.
7. The lamp shall be changed if it has become 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.
ARC LAMP CHARACTERISTIC CONSIDERATIONS
1. Arc lamps require a period of time to relight after a power interruption or a severe voltage
dip. In some cases, lamp will automatically relight after it has cooled depending on Lamp
Power-Up State (L ON/ LOFF) system configuration setting.
2. Burning position is Universal.

SICHERHEITSHINWEISE
02.9664.0010 0 20 October 2010 vii
Sicherheitshinweise
Es ist äußerst 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 Vorsichtsmaßnahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHER-
HEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE
UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARI❋LITE-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Philips
und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp (MSR400,
MSR575HR etc.), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines
anderen Lampentyps kann gefährlich sein.
2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die
Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.
3. Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Stärke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARI❋LITE-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARI❋LITE-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen oder
Feuchtigkeit können die Scheinwerfer beschädigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE-Geräten
beginnen.
3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG
1. Viele VARI❋LITE-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.
VORSICHT - weist auf möglichen Produktschaden hin.
WARNUNG - weist auf mögliche Körperverletzung und Leb-
ensbedrohung hin.

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
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2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN
1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkühlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Körperverletzung bzw. von Feuer, das von Lampenteilen ausgelöst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.
6. Wenn die Lampe mit bloßen Händen berührt wird, reinigen Sie sie mit denaturiertem
Alkohol und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in
Betrieb nehmen.
7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstörungen verursachen. In diesem Fall müssen eventuell geeignete
Maßnahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach
Abkühlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.

NOTES DE SÉCURITÉ
02.9664.0010 0 20 October 2010 ix
Notes de sécurité
Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en
marche, il est extrêmement important de lire TOUS les renseignements et TOUTES
les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe.
Tenir compte de tous les avertissements et suivre toutes les précautions pendant
l’installation et l’utilisation de cet appareil.
Les symboles de sécurité utilisés dans ce guide sont les suivants :
CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE
PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES , LES INCENDIES,
L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRAÎNER DES BLESSURES.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES
1. Les luminaires VARI❋LITE ont été conçus pour être utilisés uniquement avec certaines
lampes Philips et Osram HID. Vérifier le type de lampe (MSR400, MSR575HR etc.)
avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un
danger.
2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de
montage sont respectées. Voir les explications détaillées dans ce guide.
3. Ne remplacer les fusibles qu’avec ceux du même type, ayant les mêmes caractéristiques.
4. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et
les luminaires VARI❋LITE.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES
1. Les luminaires VARI❋LITE sont conçus pour une utilisation au sec uniquement. Une
exposition à la pluie et à l’humidité risque d’endommager le luminaire.
2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE.
3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.
ATTENTION Ce symbole annonce que l’appareil risque
d’être endommagé.
AVERTISSEMENT Ce symbole annonce qu’il y a risque
d’accident grave ou même fatal.

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
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AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE
AUX RAYONS UV
1. Plusieurs luminaires VARI❋LITE utilisent une lampe de type HID qui produit des rayons
UV. NE PAS fixer son regard sur la lampe.
2. L’utilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages,
lentilles ou écrans ultraviolet visiblement endommagés au point que leur efficacité en est
affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT
ENTRAÎNER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche.
Pour manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la
peau et une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute
tension à de très hautes températures. Si la lampe se casse, les particules de la lampe
cassée peuvent causer blessures et/ou incendie en s’éparpillant.
4. Se protéger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier
des lampes endommagées.
6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool dénaturé et
l’essuyer avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire.
7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être
remplacée.
AVERTISSEMENT:
INTERFÉRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures
adéquates.
CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC
1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet après s’être refroidie. Cela dépend de la manière dont le système est réglé
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brûler est Universelle.

AVISO SOBRE SEGURIDAD
02.9664.0010 0 20 October 2010 xi
Aviso sobre Seguridad
Es muy importante leer TODA la información e instrucciones sobre seguridad que se
indica en este manual así como en los documentos adjuntos antes de instalar y operar
los productos descritos. Se debe prestar atención a todos los avisos y advertencias
durante la instalación y uso de este producto.
Los símbolos de seguridad usados en este manual son los siguientes:
LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CON-
TRAGOLPES DE CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN
EXCESIVA A RADIACIÓN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO
1. Las luminarias VARI❋LITE han sido diseñadas para ser usadas solamente con algunas
lámparas HID Philips y Osram. Tome nota del tipo de lámpara (MSR400, MSR575HR
etc.) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalación. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificación.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARI❋LITE.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE
ELÉCTRICO
1. Las luminarias VARI❋LITE están diseñadas solamente para lugares secos. La exposición
a la lluvia o humedad pueden dañar la luminaria.
2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE.
3. El servicio debe ser realizado solamente por personal calificado.
CUIDADO,indica posibles daños al producto.
ADVERTENCIA, indica posibles lesiones o muerte a las
personas.

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
xii 20 October 2010 02.9664.0010 0
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA
1. Muchas luminarias VARI❋LITE usan un tipo de lámpara HID que produce radiación UV.
NO mire directamente a la lámpara.
2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores,
lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un
equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que están calientes.
2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la
energía y deje que la lámpara se enfríe antes de reemplazarla.
3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamación a los ojos. Además, las lámparas de arco operan a alta
presión y muy alta temperatura. Si la lámpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se
caen.
4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.
5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando
trabaje con lámparas dañadas.
6. Si toca la lámpara con las manos, limpie la lámpara con alcohol desnaturalizado y con tela
sin pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lámpara si está dañada 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.
CONSIDERACIONES SOBRE LAS CARACTERÍSTICAS DE LA LÁMPARA DE
ARCO
1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de
una interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara
se volverá a iluminar en forma automática después que se ha enfriado dependiendo de la
configuración del sistema de energía de la lámpara (L ON / L OFF) (L encendida / L
apagada).
2. La posición de encendido es universal.

SAFETY NOTICE (JAPANESE)
02.9664.0010 0 20 October 2010 xiii

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
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TABLE OF CONTENTS
02.9664.0010 0 20 October 2010 xv
Table of Contents
Introduction
Disclosure .................................................................................................................... 1
About This Manual...................................................................................................... 1
Additional Documentation........................................................................................... 2
Customer Service......................................................................................................... 2
Chapter 1. Description
Features
Standard Features......................................................................................................... 4
Model Specific Features .............................................................................................. 4
Component Descriptions
External Luminaire Components................................................................................. 6
Luminaire Internal Head Components......................................................................... 7
Luminaire Internal Yoke Components......................................................................... 8
Arc Ballast Unit ........................................................................................................... 9
Dimmer Model............................................................................................................. 9
Principles of Operation
VL1100 Incandescent Source Luminaire................................................................... 10
VL1100 Incandescent Block Diagram - Without On-Board IGBT Dimmer...... 10
VL1100 Incandescent Cable Routing - Without On-Board IGBT Dimmer ....... 11
VL1100 Incandescent Block Diagram - With On-Board IGBT Dimmer........... 12
VL1100 Incandescent Cable Routing - With On-Board IGBT Dimmer............. 13
VL1100 Arc Source Luminaire.................................................................................. 14
VL1100 Arc Block Diagram............................................................................... 14
VL1100 Arc Cable Routing ................................................................................ 15
Chapter 2. Maintenance
Testing
Running Parameter Tests ........................................................................................... 18
Calibration Sequence................................................................................................. 19
Auto Recalibration..................................................................................................... 20
Sensor Testing............................................................................................................ 20
Maintenance Procedures
Lamp Replacement (Incandescent Model) ................................................................ 22
Lamp Replacement (Arc Model)............................................................................... 25
Align Lamp For Maximum Beam Irradiance ............................................................ 27
Frame or Top Hat Replacement................................................................................. 28
Front Cover Removal................................................................................................. 29
Rear Head Assembly Removal.................................................................................. 30
Rotating Gobo Replacement...................................................................................... 31

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
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Gobo Index Timing Belt Alignment........................................................................... 33
Gobo Wheel Bulkhead Replacement.......................................................................... 35
Gobo Gear Planet Alignment ..................................................................................... 37
Shutter Assembly Replacement.................................................................................. 39
Shutter Blade or Rack Replacement........................................................................... 41
Edge/Zoom/Color Bulkhead Replacement................................................................. 43
Fan/Temp Switch Assembly Replacement................................................................. 44
Beam-Size Iris Assembly Replacement ..................................................................... 45
Ignitor PCB Replacement........................................................................................... 46
Power Supply Replacement........................................................................................ 47
Controller PCB Replacement..................................................................................... 49
Tilt Encoder PCB Replacement.................................................................................. 51
Tilt Motor Assembly Replacement............................................................................. 52
.............................................................................................................................. 53
Pan Motor Assembly Replacement............................................................................ 54
DMX Input PCB Replacement................................................................................... 56
Cleaning Optical Lenses and Filters........................................................................... 57
Chapter 3. Illustrated Parts Breakdown
Drawing Trees
VL1100 Incandescent Luminaires.............................................................................. 60
VL1100 Arc Luminaires............................................................................................. 62
Top Assembly
Included Items Kit...................................................................................................... 64
Included Items Kit (continued)................................................................................... 65
VL1100 Luminaire .....................................................................................................66
Front Cover Assembly ................................................................................................69
Gel Frame Holder Assembly ......................................................................................70
COT (Center of Travel) Flag Assembly .....................................................................71
VL1100 Main Control Board (MCB) Assembly ........................................................72
Head Assembly
Head Assembly ...........................................................................................................73
Front Head Assembly .................................................................................................74
Edge Control, Zoom, Dimmer & Color Assembly .....................................................76
Color Changer Assembly ...........................................................................................78
Edge Barrel Assembly ................................................................................................81
Lens #8 Assembly ......................................................................................................83
Pulley Side Rail Assembly .........................................................................................84
Sensor Side Rail Assembly ........................................................................................85
Incandescent Gobo Wheel Assembly .........................................................................86
Temperature Sensor Electrical Assembly ..................................................................89
Arc Gobo/Dimmer Bulkhead Assembly ....................................................................90
Gobo Wheel Assembly ...............................................................................................93
Gobo Wheel Pulley Assembly ....................................................................................95
Shutter 6 Rollers Assembly ........................................................................................96
Beam-Size Iris Assembly ...........................................................................................99

TABLE OF CONTENTS
02.9664.0010 0 20 October 2010 xvii
Rear Head Assembly ................................................................................................ 101
Back Cap Assembly ................................................................................................. 103
Yoke Assembly
Yoke Legs Assembly ............................................................................................... 105
Tilt Motor Assembly ................................................................................................ 108
Crossmember Assembly .......................................................................................... 110
Inner Crossmember Assembly ................................................................................. 112
Outer Crossmember Assembly ................................................................................ 113
Pan Motor Assembly ................................................................................................ 114
Pan Tube Assembly ................................................................................................. 116
Cables
Arc Power Input (Pigtail) Cable Assembly ............................................................. 119
Pan EOT Cable Assembly ....................................................................................... 120
Tilt COT Cable Assembly ....................................................................................... 121
AC Line Input Cable Assembly ............................................................................... 122
Incandescent LVS AC Input Cable Assembly ......................................................... 123
Arc LVS AC Input Cable Assembly ........................................................................ 124
LVS Chassis Ground Cable Assembly .................................................................... 125
Yoke to Head Ground Cable Assembly ................................................................... 126
Pan/Tilt Control Cable Assembly ............................................................................ 127
Ballast Control Link Cable Assembly ..................................................................... 128
Data I/O Link Cable Assembly ................................................................................ 129
LVS DC Output Cable Assembly ............................................................................ 130
Incandescent Power Input Cable Assembly ............................................................. 131
Incandescent Lamp Power Cable Assembly ............................................................ 132
Arc Power to Ignitor Cable Asembly ....................................................................... 133
Ignitor to Lamp Socket Cable Assembly ................................................................. 134
Shutter Harness Cable Assembly ............................................................................. 135
Color/Gobo/Lens Harness Cable Assembly ............................................................ 137
Dimmer to LVS Cable Assembly ............................................................................ 139
Dimmer to Controller Cable Assembly ................................................................... 140
Dimmer to Lamp Socket Cable Assembly ............................................................... 141
Appendix A. Technical Bulletins
VL1100 ERS Luminaire Technical Bulletins .......................................................... 143

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
xviii 20 October 2010 02.9664.0010 0
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INTRODUCTION :
02.9664.0010 0 20 October 2010 1
Introduction
Disclosure
This technical manual is confidential property of Vari-Lite All information contained
herein is the sole and exclusive property of Vari-Lite and may not be used, disclosed,
or reproduced in any manner without the prior written consent of Vari-Lite
WARNING: It is important to read ALL accompanying safety instructions to avoid
damage to the product and potential injury to yourself or others.
About This Manual
This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL1100 ERS Luminaire. The manual is intended for use
by Vari-Lite personnel and by Vari-Lite’s Authorized Dealers and Service Centers.
This manual covers the following models:
Note: Performing maintenance procedures contained in this manual may void the
product warranty. Refer to the Vari-Lite Limited Warranty card included in the
shipping package for this VARI❋LITE product.
WARNING: It is not recommended to power any VARI❋LITE luminaire from a
dimmer - even in 'NONDIM' mode. Dimmer and non-dim modules are not suitable
sources of power because their output modifies the AC wave form. See Vari-Lite
Technical Notice TN-229A for more information.
Model Part Number Source Integral Dimmer Shutter Iris
VL1100 TS 20.9664.0001.02 Incandescent No Yes No
VL1100 TI 20.9664.0001.03 Incandescent No No Yes
VL1100 AS 20.9664.0001.12 Arc Mechanical Yes No
VL1100 AI 20.9664.0001.13 Arc Mechanical No Yes
VL1100 TSD 20.9664.0001.22 Incandescent Electronic 115V Yes No
VL1100 TID115 20.9664.0001.23 Incandescent Electronic 115V No Yes
VL1100 TSD230 20.9664.0001.32 Incandescent Electronic 230V Yes No
VL1100 TID230 20.9664.0001.33 Incandescent Electronic 230V No Yes

VARI❋LITE - VL1100 ERS LUMINAIRE SERVICE MANUAL
2 20 October 2010 02.9664.0010 0
Additional Documentation
A support web page for Series 1000 luminaires (For all VL1000 and VL1100 ERS
models) is available at www.vari-lite.com (follow the Support link).
A user’s manual is available for installation and operation of all versions of the
VL1100 ERS Luminaire. This manual is only available in electronic (PDF) format.
■VL1100 ERS Luminaire User’s Manual (02.9664.0001).
Technical bulletins concerning the latest changes to VARI❋LITE equipment are also
available at the website Technical Support Center. These are documentation
supplements that contain procedures for equipment upgrades, retrofits, and additional
repairs. Technical bulletins are integrated into the appropriate equipment manuals as
those manuals are revised.
Customer Service
Our Goal
At Vari-Lite, we are committed to providing you the highest quality in customer
service. Our comprehensive resources are available to help your business succeed and
ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are
telephone troubleshooting assistance, product training or technical service, our full-
time staff of 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) were
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) or 1-214-647-7880
fax: [phone]
email: [email protected]
Additional Resources
For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.