Philips Vari-Lite VL440 User manual

Neutrik, PowerCon, and EtherCon are registered trademarks of Neutrik, Inc. All other brand or product names
which may be mentioned in this manual are trademarks 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. Philips 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 Philips Vari-
Lite, 10911 Petal Street, Dallas, Texas 75238.
Version as of: 19 December 2011
Part number: 02.9687.0010 0
VL440 / VL770 / VL880 Spot Luminaires Service Manual
©2011, Vari-Lite, a Philips group company. All Rights Reserved.

FOREWORD
02.9687.0010 0 i
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),
[phone], or [email protected] 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
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 (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). 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 Number
As stated in the warranty, it is required that the shipment be insured and FOB our service center.

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
ii 02.9687.0010 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 instal 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 60598-1:2008 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989/A2: 1991 Specification for Luminaires for Stage and Studio Lighting
EMC
EN 61000-6-2: 2005 Immunity Standard for industrial environment
EN 61000-6-4: 2007 Radiated and Conducted Emissions
We certify that the product conforms to the protection requirements of Low Voltage Directive 2006/95/
EC and Council Directive 2004/108/EC.
FCC

FOREWORD
02.9687.0010 0 iii
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 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 VL440 /
VL770 / VL880 Spot Luminaires uses a special type of 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 detail in this manual.
3. 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.
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
iv 02.9687.0010 0
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE
TO UV RADIATION
1. Many VARI❋LITE luminaires use a 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. 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 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.

FOREWORD
02.9687.0010 0 v
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
SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE UV-
STRAHLUNG UND KÖRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARI❋LITE Beleuchtungen sind für Gebrauch mit spezifischen Lichtquellen bestimmt worden.
Die VL440 / VL770 / VL880 Spot Luminaires Beleuchtung benutzt eine spezielle Art -
Lichtquelle. Eine andere Art Lichtquelle anzubringen ist gefährlich und hebt die
Beleuchtunggarantie auf.
2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die
Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.
3. 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.
VORSICHT - weist auf möglichen Produktschaden hin.
WARNUNG - weist auf mögliche Körperverletzung und Lebensbedrohung hin.

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
vi 02.9687.0010 0
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG
1. Viele VARI❋LITE -Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt. SCHAUEN
SIE NICHT direkt in die Lampe.
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. Tragen Sie beim Austausch der Lampen einen Augenschutz.
4. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.
5. 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.
6. 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 Hochfre-
quenzstörungen verursachen. In diesem Fall müssen eventuell geeignete Maßnahmen getroffen
werden.

FOREWORD
02.9687.0010 0 vii
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. Des appareils d'éclairage de VARI❋LITE ont été conçus pour l'usage avec des sources lumineuses
spécifiques. L'appareil d'éclairage de VL440 / VL770 / VL880 Spot Luminaires emploie un type
spécial de source lumineuse de . L'installation d'un autre type de source lumineuse sera dangereuse
et videra la garantie d'appareil d'éclairage.
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. 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 - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
viii 02.9687.0010 0
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX
RAYONS UV
1. Plusieurs luminaires VARI❋LITE utilisent une lampe 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.

FOREWORD
02.9687.0010 0 ix
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 CONTRAGOLPES 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. Los alumbrados de VARI❋LITE se han diseñado para el uso con fuentes de luz específicas. El
alumbrado de VL440 / VL770 / VL880 Spot Luminaires utiliza un tipo especial de fuente de luz
del . La instalación de otro tipo de fuente de luz será peligrosa y anulará la garantía del alumbrado.
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. 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 - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
x02.9687.0010 0
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA
1. Muchas luminarias VARI❋LITE usan un tipo de lámpara 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. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando trabaje con
lámparas dañadas.
4. 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.
5. 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.

FOREWORD
02.9687.0010 0 xi

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
xii 02.9687.0010 0

TABLE OF CONTENTS
02.9687.0010 0 19 December 2011 xiii
Table of Contents
About This Manual...................................................................................................... 1
Additional Documentation........................................................................................... 1
Customer Service......................................................................................................... 2
Technical Bulletins and Notices................................................................................... 2
Chapter 1. Description
Features
Mechanical................................................................................................................... 4
Optical.......................................................................................................................... 5
Operational................................................................................................................... 5
Technical Specifications .............................................................................................. 6
Components
VL440 / VL770 / VL880 Spot Luminaires External Components.............................. 7
VL440 / VL770 / VL880 Spot Luminaires Components............................................. 8
VL440 / VL770 / VL880 Spot Luminaires Head Components................................... 9
VL440 / VL770 / VL880 Spot Luminaires Enclosure Components.......................... 10
Principles of Operation
VL440 / VL770 / VL880 Spot Luminaires Functional Block Diagram.................... 11
Chapter 2. Maintenance
Testing
Luminaire Self-Tests.................................................................................................. 14
Calibration Sequence................................................................................................. 14
Sensor Testing............................................................................................................ 14
Troubleshooting
Error Messages........................................................................................................... 15
Troubleshooting Guide .............................................................................................. 16
Special Care and Handling
Introduction................................................................................................................ 17
Special Cleaning and Care Instructions..................................................................... 17
General Care and Equipment Handling..................................................................... 17
Locations/Use...................................................................................................... 18
Solid State Electronics............................................................................................... 18
Electrostatic Discharge (ESD)............................................................................. 18
Printed Circuit Boards (PCBs)............................................................................ 18
Maintenance Procedures
Front Cover Assembly Removal................................................................................ 19
Rear Cover Assembly Removal................................................................................. 20
Lamp Removal and Installation................................................................................. 21
Gobo Module Assembly Removal............................................................................. 23
CYMD Module Assembly Removal.......................................................................... 24

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
xiv 19 December 2011 02.9687.0010 0
Zoom Module Assembly Removal............................................................................. 25
Main Control Unit (MCU) Assembly Removal......................................................... 27
Driver Board Assembly Removal .............................................................................. 28
Front Lens Assembly Removal.................................................................................. 30
UV / IR Filter Assembly Removal............................................................................. 31
Edge Motor Assembly Removal ................................................................................ 32
Tilt Motor Assembly / Tilt Encoder / Tilt Belt Removal ........................................... 34
Tilt Sensor Removal................................................................................................... 36
Tilt Stabilizer Removal............................................................................................... 38
Ignitor Removal.......................................................................................................... 40
Lamp Socket Removal ............................................................................................... 42
Reflector Removal...................................................................................................... 45
CYMD Wheel Replacement....................................................................................... 47
Strobe Assembly Replacement................................................................................... 50
Dimmer or Magenta Motor Assembly Replacement.................................................. 51
Strobe Blade Replacement ......................................................................................... 52
Cyan or Yellow Motor Replacement.......................................................................... 53
Fixed Color Wheel Replacement................................................................................ 54
Rotating Gobo Wheel Replacement........................................................................... 55
Fixed Gobo Wheel Replacement................................................................................ 57
Iris Assembly Replacement........................................................................................ 59
Ballast / LVS Assembly Replacement........................................................................ 60
DMX PCB Assembly Replacement ........................................................................... 61
PowerCon (AC Input) Assembly Replacement.......................................................... 63
Display PCB Assembly Replacement........................................................................ 65
Wireless DMX Interface PCB Assembly Replacement ............................................. 67
Pan Motor Assembly Replacement............................................................................ 69
Pan Belt Replacement................................................................................................. 71
Pan Stabilizer Replacement........................................................................................ 73
Enclosure Fan Assemblies Replacement.................................................................... 75
Chapter 3. Illustrated Parts Breakdown
Drawing Trees
VL440 Spot Luminaire Drawing Tree........................................................................ 78
VL770 Spot Luminaire Drawing Tree........................................................................ 80
VL880 Spot Luminaire Drawing Tree........................................................................ 82
Top Assembly
Included Items Kit...................................................................................................... 84
VL440 Spot Luminaire............................................................................................... 86
VL770 Spot Luminaire............................................................................................... 90
VL880 Spot Luminaire............................................................................................... 94
Front Head Cover Assembly...................................................................................... 98
Rear Head Cover Assembly ....................................................................................... 99
Lamp Cover Assembly............................................................................................. 100
Transfer Fans Assembly........................................................................................... 101
Dual Gobo Cooling Blower Assembly..................................................................... 102

TABLE OF CONTENTS
02.9687.0010 0 19 December 2011 xv
Generic Luminaire Assembly.................................................................................. 103
Head Assembly
Head Frame Assembly............................................................................................. 105
Left Tilt Bearing Assembly...................................................................................... 108
Right Tilt Bearing Assembly ................................................................................... 109
Linear Roller Assembly........................................................................................... 111
Lamp Housing Assembly......................................................................................... 112
Tilt Motor Assembly................................................................................................ 115
Pulley Pinion Assembly........................................................................................... 117
Gobo Module Assembly.......................................................................................... 118
Wedge Fixed Color Wheel Assembly...................................................................... 122
Rotating Gobo Wheel Assembly ............................................................................. 123
Fixed Gobo Wheel Assembly.................................................................................. 124
CYMD Color Module Assembly............................................................................. 125
Left Flag Motor Plate Assembly.............................................................................. 127
Right Flag Motor Plate Assembly............................................................................ 128
Zoom Assembly....................................................................................................... 129
Prism Assembly....................................................................................................... 132
Frost Assembly ........................................................................................................ 134
Zoom Linear Slide Assembly .................................................................................. 135
Front Carrier Assembly............................................................................................ 136
Rear Carrier Assembly............................................................................................. 137
Enclosure Assembly
Upper Enclosure Assembly...................................................................................... 139
Pan Motor Assembly................................................................................................ 144
Note: Cables are only available as complete assemblies. The information contained in
this section is for reference only.
Cable Assemblies
Chassis To Yoke Ground Cable Assembly .............................................................. 147
AC Input Cable Assembly....................................................................................... 148
DMX / Display Comm Cable Assembly ................................................................. 149
Ballast Comm Cable Assembly............................................................................... 150
36 Volt Supply Cable Assembly .............................................................................. 151
Ballast to Ignitor Cable Assembly........................................................................... 152
Pan Motor Cable Assembly..................................................................................... 153
Pan Encoder Cable Assembly.................................................................................. 154
Tilt Cable Assembly................................................................................................. 155
Edge Cable Assembly.............................................................................................. 156
Zoom Group Cable Assembly ................................................................................. 157
CYMD Group Cable Assembly............................................................................... 158
Gobo Group Cable Assembly.................................................................................. 159
Lamp to Fans Cable Assembly................................................................................ 160
Tilt Sensor Cable Assembly..................................................................................... 161
Slotted Optical Switch Cable Assembly.................................................................. 162
VL440 - VL770 Lamp Socket / Cable Assembly.................................................... 163
VL880 Lamp Socket / Cable Assembly................................................................... 164

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
xvi 19 December 2011 02.9687.0010 0
800 Watt Ballast Comm Cable Assembly ................................................................ 165
Sensor Index Cable Assembly.................................................................................. 166
APS Fan Cable Assembly ........................................................................................ 167
AUX Comm Interface Cable Assembly................................................................... 168
Appendix A. Technical Bulletins and Notices
VL440 / VL770 / VL880 Spot Luminaires Technical Bulletins and Notices .......... 169

INTRODUCTION : ABOUT THIS MANUAL
02.9687.0010 0 1
Introduction
About This Manual
This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all
configurations of the VL440 / VL770 / VL880 Spot Luminaires. The manual is intended for use by
Vari-Lite personnel and Authorized VARI❋LITE Service Centers and technicians.
WARNING: It 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:
Notes:
• (1) = Luminaire accepts metal and glass gobos.
• (2) = Luminaire accepts glass gobos only.
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 VL440 / VL770 / VL880 Spot
Luminaires User’s Manual. This manual is available in electronic (PDF) format on the Vari-Lite web
site at www.vari-lite.com in the Support (Product Downloads) section.
• VL440 / VL770 / VL880 Spot Luminaires User’s Manual (02.9687.0001)
For more information regarding DMX512 systems, refer to the DMX512/1990 & AMX 192 Standards
publication available from United States Institute for Theatre Technology, Inc. (USITT).
USITT
315 South Crouse Avenue, Suite 200
Syracuse, NY 13210-1844
Phone: [phone] or 315-463-6463
www.usitt.org
Model Part Number Lamp Type Color Mixing
System Dimmer Gobo Positions Luminaire Body Color
VL440 Spot 20.9687.0002 400W MSR Gold 400
MiniFastFit Lamp
CYM /
8 Filters Glass Dimmer Wheel 7 Rotating /
10 Fixed (1) Black
VL770 Spot 20.9687.0003 700W MSR Gold 700
MiniFastFit Lamp
CYM /
8 Filters Glass Dimmer Wheel 7 Rotating /
10 Fixed (2) Black
VL880 Spot 20.9687.0004 800W MSR Platinum
35 Lamp
CYM /
8 Filters Glass Dimmer Wheel 7 Rotating /
10 Fixed (2) Black

VARI❋LITE - VL440 / VL770 / VL880 SPOT LUMINAIRES SERVICE MANUAL
202.9687.0010 0
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, 7am - 6pm CST Monday through Friday, at the
following:
phone: 1-877-VARI-LITE (1-877-827-4548)
e-mail: [email protected]
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 to VARI❋LITE 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 SVL-001 (VL440 / VL770 / VL880 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 VL440 / VL770 / VL880 Spot
Luminaires are found in “VL440 / VL770 / VL880 Spot Luminaires Technical Bulletins and Notices”
on page 169.