Vari Lite VL6 Series User manual

CONFIDENTIAL: This technical manual is confidential property of Vari-Lite, Inc.
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The Automated Lighting Company

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02.9638.0010 CONFIDENTIAL
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VARI*LITE®, Artisan®, mini-Artisan®, mini-Artisan®2, Artisan®Plus,
mini-Artisan®Plus, VL2®, and VLD®are trademarks owned by Vari-Lite, Inc., 201
Regal Row, Dallas TX 75247 USA. and are registered in the United States and other
countries.
VL1™, VL2B™, VL2C™, VL3™, VL4™, VL5™, VL5Arc™, VL5B™, VL6™, VL6B™,
VL7™, VLM™, APS6™, C3™, SPC-36™, UDM™, AutoTruss™, SmartDMX™,
Smart Repeater™, Smart Repeater Plus™, Series 100™, Series 200™, Series 300™,
DICHRO*WHEEL™, DICHRO*TUNE™, VACU*DEP™, VARI*IMAGE™,
VARI*BEAM™, VARI*LITE Visionary™, and ArtisanVLQ™are also trademarks
owned by Vari-Lite, Inc.
VARI*LITE®products and services are protected by one or more of the following
patents, and other pending patent applications worldwide:
U.S. Patents No. 5,758,956; 5,728,994; 5,691,886; 5,640,061; 5,590,955; 5,590,954;
5,537,303; 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; 5,031,078; 5,010,459; 4,980,806; 4,972,306; 4,800,474;
4,779,176; 4,709,311; 4,701,833; 4,688,161; 4,602,321; 4,392,187;
U.S. Design Patents No. D 377,338; D 366,712; D 359,574; D 350,408; D 347,133;
Argentina Patent No. 0 251 081; 0 250 627;
Australia Patents No. 683,695; 673,172; 667,109; 657,152; 652,409; 649,264; 637,343;
618,559; 586,095; 582,305; 580,213; 576,400; 575,271; 571,135; 546,433;
Australia Design Reg. No. 128,796; 128,795; 127,644; 126,781;
Canada Patents No. 2,076,171; 2,075,268; 2,070,670; 2,065,774; 2,050,375 2,006,314;
1,293,989; 1,292,379; 1,284,794; 1,276,607; 1,270,675; 1,259,058; 1,181,795;
Canada Design Reg. No. 78,662; 75,750; 73,695; 72,772;
Europe Patents No. 0 586 088; 0 565 218; 0 547 732; 0 534 710; 0 474 202; 0 253 152;
0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068;
France Design Reg. No. 95-1125;
Germany Utility Model Reg. No. G9312884.3; G9314158.5;
German Design Reg. No. M9501553.7; M9407689.8;
Hong Kong Patents No. 965/1990; 285/1987;
Japan Patents No. 2,724,074; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481;
1,792,721; 1,770,241; 1,742,923; 1,723,825; 1,683,007; 1,533,011;
Japan Design Reg. No. 970,593; 956,262; 947,552;
Korea Patents No. 92,269; 76,310; 47,673; 42,641; 42,640; 42,639;
Korea Design Reg. No. 175,178;
Mexico Patent No. 180,766; 180,687; 180,148; 179,138;
Singapore Patents No. 663/90; 134/87;
Spain Patent No. 2.031.748; 548.328;
Design Reg. No. 134.458; 134.491; 129.596; 129.595;
Taiwan Patents No. 129,950; 123,394; 123,393; 121,014; 116,323; 107,424; 91,799;
86,861; 78,726; 66,975; 65,380; 63,471; 61,420; 57,219; 53,673; 52,156; 40,611; 28,275;
United Kingdom Design Reg. No. 2056387; 2056386; 2029499; 2033108; 2042174;
© 1998 Vari-Lite, Inc. All Rights Reserved.

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CONFIDENTIAL 02.9638.0010
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VL6™ Spot Luminaire (Part Number 20.9638.0001)
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.
This product meets UL1573 and CSA C22.2 No. 166-1983 requirements for stage and
studio lighting equipment.
Declaration of Conformity
We declare, under our sole responsibility, that this product complies with the relevant
clauses of the following standards and harmonized documents:
EN 60589-1:1997 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989 Specification for luminaires for stage lighting, etc...
EN 55022:1994 Radiated and Conducted Emissions
EN 50082-1:1997 Generic Emissions Standard
We certify that the product conforms to the protection requirements of council directives:
73/23/EEC (LVD) and 89/336/EEC (EMC)
Place of issuance: Vari-Lite Europe Ltd.
20-22 Fairway Drive, Greenford, Middlesex, UB6 8PW, UK
Competent Body (EMC) Notified Body (LVD)
Integrity Design & Test Services, Inc.
37-7 Ayer Road, Littleton, Massachusetts
01460 USA
Report Reference: 62802.e1 / 62802.c1
Integrity Design & Test Services, Inc.
37-7 Ayer Road, Littleton, Massachusetts
01460 USA
Report Reference: 62800
FCC
CUS
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GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRI-
CAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND INJURY
TO PERSONS CAN BE FOUND BELOW.
ADDITIONAL SAFETY INFORMATION CAN BE FOUND IN THE SAFETY AND
EQUIPMENT HANDLING SECTION OF THIS MANUAL.
IT IS IMPORTANT TO READ ALL SAFETY INFORMATION AND INSTRUCTIONS
BEFORE MOUNTING OR OPERATING ANY VARI*LITE® LUMINAIRES OR
EQUIPMENT.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE
1. Series 200™/300™ luminaires have been designed for use only with certain Phillips
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 lighted objects for Series
300™ luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. Series 200™/300™ 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.
4. Power distribution equipment is designated as Class 1 equipment. Connection to
mains power must be done using a five-wire method; Line 1, Line 2, Line 3, Neutral,
and Ground. All power distribution equipment (ACS Racks, Modular Racks, 200A
disconnects, etc.) must be grounded.
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. Lenses or shields must be
replaced if they are missing or damaged.
WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS
1. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp
to cool before replacing. Lamp compartments may utilize a disconnect switch that
removes power from lamp when backcap is opened.
2. Wear eye protection when relamping.
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.

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Revision History
Page Number Change Number
Title Page thru xii -
1 thru 236 -
Version Date
BASIC 17-Dec-96
REV. A 05-Aug-98
REV. B 20-Aug-99

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Introduction Forward ......................................................................................................... 15
About This Manual........................................................................................ 15
Product Support............................................................................................. 16
Customer Service.................................................................................... 16
Technical Bulletins and Notices............................................................. 16
Maintenance Philosophy......................................................................... 16
Equipment Handling...................................................................................... 18
Lamps...................................................................................................... 18
Solid State Electronics............................................................................ 19
Chapter 1.
Equipment Description
Features............................................................................................................... 23
Standard Features .......................................................................................... 23
Location of Major Components........................................................................ 24
Exterior Components..................................................................................... 24
Internal Head Components............................................................................ 26
Internal Yoke Components............................................................................ 27
Dimensions and Clearances .............................................................................. 28
Dimensions.................................................................................................... 28
Hanging Clearances....................................................................................... 29
Floor Mount Clearances................................................................................ 30
Specifications...................................................................................................... 31
Technical ....................................................................................................... 31
Programmable Functions............................................................................... 32
Principles of Operation...................................................................................... 33
Standard Operation Overview....................................................................... 33
VL6 Lamp Control PCB......................................................................... 33
Internal Block Diagrams ............................................................................... 34
VL6 Power and Data Flow ..................................................................... 34
Series 300 VL Comm System Diagram........................................................ 35
DMX Control Overview................................................................................ 36
DMX Operating System ......................................................................... 36
Termination............................................................................................. 36
Operating System Download.................................................................. 36
Series 300 DMX System Diagram................................................................ 37
Chapter 2.
Installation Installation Hardware ....................................................................................... 41
Truss Hooks................................................................................................... 41
Truss Hook Replacement........................................................................ 41
Floor Stand .................................................................................................... 42
Floor Stand Removal and Replacement.................................................. 42

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Safety Cable .................................................................................................. 45
Alternate Hanging Methods.......................................................................... 45
Hanging Preparation......................................................................................... 47
Luminaire Orientation and Placement........................................................... 47
Truss Pipe Requirements............................................................................... 47
Spacing Requirements................................................................................... 48
Installation Methods...................................................................................... 49
Standard Hang ........................................................................................ 49
Three-Point Hang.................................................................................... 49
Installation/Checkout Procedure...................................................................... 50
Installation .............................................................................................. 50
Checkout................................................................................................. 52
Packing................................................................................................................ 54
Installing Accessories......................................................................................... 56
Optional Lenses............................................................................................. 56
Installing Narrow Field of View Lens.................................................... 57
Installing Medium Field of View Lens................................................... 59
Installing Wide Field of View Lens........................................................ 60
Chapter 3.
Maintenance Testing................................................................................................................. 65
Using Smart Repeater Test Software ............................................................ 65
VL5 Test Codes and Parameters ................................................................... 66
Troubleshooting.................................................................................................. 67
Troubleshooting Chart................................................................................... 67
Troubleshooting Procedures.......................................................................... 68
No Luminaire Calibration....................................................................... 68
Luminaire Will Not Come On-Line ....................................................... 69
Lamp Will Not Start / No Intensity........................................................ 70
No Tilt Response .................................................................................... 71
Jerky or Dragging Tilt Movement.......................................................... 71
No Pan Response.................................................................................... 71
Jerky or Dragging Pan Movement.......................................................... 72
No Color Control.................................................................................... 72
No Gobo Control .................................................................................... 73
No Beam Control.................................................................................... 73
No Dimming Control.............................................................................. 74
Maintenance Procedures................................................................................... 75
Head Assembly ............................................................................................. 75
Dimmer Bulkhead Replacement............................................................. 75
Dimmer Blade Replacement................................................................... 76
Dimmer Optical Switch Replacement.................................................... 78
Dimmer P.T. Sensor Replacement.......................................................... 79
Dimmer Stepper Motor Replacement..................................................... 80
Dimmer Thermal Switch Replacement .................................................. 82
Color Bulkhead Replacement................................................................. 83
Gobo/Filter Wheel Replacement ............................................................ 84

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Wheel 1/Beam Iris Motors Replacement................................................ 87
Wheel 1 or 2 Sensor PCB Replacement ................................................. 88
Wheel 2 Motor Replacement.................................................................. 90
Lamp Replacement................................................................................. 91
Lens Assembly Replacement.................................................................. 92
Lens Motor Replacement........................................................................ 95
Yoke Termination Board Replacement .................................................. 96
Ignitor Board Replacement..................................................................... 98
Repairing Loose PEM Nuts.................................................................. 100
Yoke Assembly............................................................................................ 101
Tilt Mechanism Replacement............................................................... 101
Tilt Cable Replacement ........................................................................ 103
Tilt Driven Pulley Replacement ........................................................... 104
Pan Driven Pulley Replacement........................................................... 107
Pan Mechanism Replacement............................................................... 112
Pan Cable Replacement........................................................................ 113
Lamp Control PCB Replacement ......................................................... 114
LCB 5A Fuse Replacement .................................................................. 115
LCB 1/16A Fuse Replacement............................................................. 116
LCB EPROM Replacement.................................................................. 117
Input Cable Replacement...................................................................... 118
Input Cable Connector Replacement.................................................... 121
Input Cable Connector Pin Replacement.............................................. 122
Yoke Cable Replacement...................................................................... 123
Miscellaneous.............................................................................................. 124
Pan/Tilt Belt Tension Adjustment ........................................................ 124
Color/Gobo Wheel Calibration (Shop Only)........................................ 125
Narrow Lens Dust Prevention............................................................... 128
Where To Use Loctite Products............................................................ 130
Chapter 4.
Illustrated Parts Breakdown
VL6 Drawing Tree ........................................................................................... 133
VL6B Drawing Tree......................................................................................... 135
VL6 Covers and Hooks Assembly.................................................................. 136
VL6B Covers and Hooks Assembly................................................................ 138
VL6 Head Assembly ........................................................................................ 140
VL6B Head Assembly...................................................................................... 142
Color Bulkhead Assembly........................................................................... 144
Gobo Wheel Assembly................................................................................ 145
Beam Size Iris Assembly ............................................................................ 146
Wheel1/Beam Size Iris Motors Assy........................................................... 148
VL6 Sensor PCB Assembly........................................................................ 150
Wheel 1 Sensor Cable Assembly ................................................................ 151
Wheel 2 Motor Assembly............................................................................ 152
Wheel 2 Sensor Cable Assembly ................................................................ 153
Filter Wheel Assembly................................................................................ 154
VL6 Rear Assy............................................................................................ 155

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VL6B Rear Assembly ................................................................................. 156
Lamp Assembly........................................................................................... 158
VL6 Reflector Assembly............................................................................. 160
VL6B Relector Assembly ........................................................................... 161
VL6 Ignitor Board Assembly (IGN6)......................................................... 162
VL6/VL6B Ignitor PCB Assembly............................................................. 163
VL6 Ignitor PCB Assembly (IGN6) ........................................................... 164
Ignitor PCB Assembly (VL6B/VL7) .......................................................... 165
Ignitor Board Output Cable Assembly........................................................ 166
VL6 Ignitor Cable Assembly ...................................................................... 167
VL6B Ignitor PCB Input Cable Assembly.................................................. 168
Ground Cable Assembly ............................................................................. 169
Dimmer Bulkhead Assembly...................................................................... 170
Covers Assembly......................................................................................... 172
VL6 Front Assembly................................................................................... 174
VL6B Front Assembly................................................................................ 176
VL6 Narrow Angle Lens Assembly............................................................ 178
VL6 Medium Angle Lens Assembly .......................................................... 179
VL6 Wide Angle Lens Assembly ............................................................... 180
VL6B Lens Barrel Assembly...................................................................... 182
VL6B Sub-Barrel Group 1 Lens Assembly ................................................ 184
VL6B Sub-Barrel Group 2 Lens Assembly ................................................ 185
VL6B Sub-Barrel Group 3 Lens Assembly ................................................ 186
VL6B Zoom Optics Motor Assembly......................................................... 187
VL6 Yoke Termination PCB Assembly (YTB6)......................................... 188
VL6B Yoke Termination PCB Assembly.................................................... 189
Yoke Cable Assembly ................................................................................. 190
VL6B Sensor PCB Assembly ..................................................................... 191
VL6B Rotating Gobo Assembly................................................................. 192
VL6 Yoke Assembly......................................................................................... 195
VL6B Yoke Assembly ...................................................................................... 199
Pan/Tilt Mechanism Assembly ................................................................... 202
VL5/VL6 Pan/Tilt Clutch Assembly (Repair Part)..................................... 204
IGN6 Cable Assembly #1 ........................................................................... 205
VL6B/VL7 Relay Assembly....................................................................... 206
VL6/VL6B Lamp Control PCB Assembly ................................................. 207
VL6/VL6B LCB Components Kit .............................................................. 208
VL6B Auxillary Controller PCB Assembly................................................ 211
VL5 Input w/Grn-Yel Cable Assembly....................................................... 213
VL5Arc Input Cable Assembly................................................................... 214
VLM/VL6 Tilt Cable Assembly.................................................................. 215
VLM/VL6 Pan Cable Assembly................................................................. 216
VL6B Motor Harness Cable Assembly....................................................... 218
Chapter 5. Diagrams
Connector Type Identification........................................................................ 223
MTA-100 and MTA-156 ............................................................................. 223
CPC ............................................................................................................. 223

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Connector Pin Locations................................................................................. 224
VL5 (VL6) Input Cable (25.9634.0180)..................................................... 224
2-Pos Red MTA100 Receptacle ........................................................... 224
2-Pos Red MTA100 Receptacle
(not used with VL6 luminaire).............................................................. 224
4-Pos Red MTA100 Receptacle ........................................................... 224
16-Pos Red CPC Receptacle (Luminaire Input)................................... 224
VL6 Yoke Cable (25.9638.0073) ................................................................ 226
34 Position Receptacle.......................................................................... 226
MTA Receptacles ........................................................................................ 227
6-Pos Blue MTA100 Receptacle
(Connects to LCB SENSORS) ............................................................. 227
4-Pos Blue MTA100 Receptacle (Lens)
(Connects to LCB STEP 1)................................................................... 228
4-Pos Blue MTA100 Receptacle (Beam)
(Connects to LCB STEP 2)................................................................... 228
4-Pos Blue MTA100 Receptacle (Dim)
(Connects to LCB STEP 3)................................................................... 228
4-Pos Blue MTA100 Receptacle (WH1)
(Connects to LCB STEP 4)................................................................... 228
4-Pos Blue MTA100 Receptacle (WH2)
(Connects to LCB STEP 5)................................................................... 229
2-Pos Red MTA100 Receptacle (Power)
(Connects to LCB POWER)................................................................. 229
VL6 Pan Cable (25.9643.0018)................................................................... 230
2-Pos Red MTA100 Receptacle (To LCB)........................................... 230
5-Pos Red MTA100 Receptacle (To LCB)........................................... 230
2-Pos Red MTA156 Receptacle (To PTM Motor)............................... 230
5-Pos Red MTA100 Receptacle (To Encoder)..................................... 230
VL6 Tilt Cable (25.9643.0017)................................................................... 231
2-Pos Red MTA100 Receptacle (To LCB)........................................... 231
5-Pos Red MTA100 Receptacle (To LCB)........................................... 231
2-Pos Red MTA156 Receptacle (To PTM Motor)............................... 231
5-Pos Red MTA100 Receptacle (To Encoder)..................................... 232
WH1 Sensor Jumper Cable (25.9638.0149)................................................ 232
3-Pos Red MTA100 Receptacle ........................................................... 232
WH2 Sensor Jumper Cable (25.9638.0150)................................................ 233
3-Pos Red MTA100 Receptacle ........................................................... 233
Motor Connectors........................................................................................ 233
Gobo Wheel , Filter Wheel, Dimmer, and Iris Motors......................... 233
Focus Assembly Motor......................................................................... 234
PTM Motor........................................................................................... 234
Photo Sensor......................................................................................... 235
Thermal Switch..................................................................................... 235
Fans....................................................................................................... 236

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CONFIDENTIAL 02.9638.0010
23-Aug-99
TO: Product Support Department Manager 201 Regal Row
Dallas, Texas 75247
COMPANY: Vari-Lite International USA
FAX NO: 214-630-5867
RE: Comments to VL6/VL6B Spot Luminaire Service Manual (02.9638.0010)
FROM:
DATE:
PAGE: 1 OF
Copy or tear this page from manual, complete, and
fax (or mail) to Product Support Department.
Comments:
FAX
The Automated Lighting Company

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02.9638.0010 CONFIDENTIAL
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(This page intentionally blank.)

15
CONFIDENTIAL 02.9638.0010
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This technical manual is confidential property of Vari-Lite, Inc. All
information contained herein is the sole and exclusive property of Vari-
Lite, Inc. and may not be used, disclosed, or reproduced in any manner
without the prior written consent of Vari-Lite, Inc.
Macintosh® is a registered trademark of Apple Computer, Inc.
Loctite® is a registered trademark of Loctite Corporation.
Loctite Super Bonder™ is a trademark of Loctite Corporation.
Kellums® is a registered trademark of Hubbell, Inc.
Blue Shower® is a registered trademark of Tech Spray, Inc.
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This manual describes specific information regarding description and
installation of the VL6™ spot luminaire. It provides test, fault isolation,
and repair procedures for the purpose of general service and repair of the
luminaire. The manual is intended for use by Vari-Lite personnel and by
Vari-Lite’s customers/clients. The following equipment item is covered in
this manual:
Equipment Description Part Number
VL6™ Spot Luminaire 20.9638.0001
VL6B™ Spot Luminaire 20.9660.0001
For complete safety guidelines regarding use of all VARI*LITE products,
refer to VARI*LITE Safety Guidelines document (02.2000.0001).
For more information on products used in conjunction with this luminaire,
refer to the appropriate VARI*LITE service manual.
For general information on system installations, refer to Series 200™/
Series 300™ System Installation and Checkout manual (02.3004.0200).

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02.9638.0010 CONFIDENTIAL
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3URGXFW6XSSRUW
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The Vari-Lite Product Support Department provides customer service to
anyone with a problem or question about VARI*LITE equipment. The
Product Support Department will help troubleshoot any problem and
recommend possible solutions or improvements. Whenever a problem is
encountered that is not readily repairable or if there are questions, technical
or otherwise, call the Product Support Department at the office from which
the equipment originated. If for any reason that office cannot be reached,
contact the Vari-Lite Product Support Department in Dallas, Texas, USA at
[phone].
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Technical bulletins concerning the latest changes to VARI*LITE
equipment are issued from the Dallas, Texas USA office. They are docu-
mentation 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 VL6-005 (VL6 luminaire
Technical Bulletin number 5).
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 documen-
tation corrections. All technical notices begin with the prefix TN and are
numbered sequentially, such as TN-138 (Tech Notice number 138).
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Field Repair
Field repair for VARI*LITE equipment is primarily composed of sub-
assembly or module replacement. While there is some component repair
within sub-assemblies, this type of maintenance is less frequent. For those
assemblies containing parts not available for field repair, or for those
repairs that require tools or test equipment not provided in the test rack,
sub-assemblies must be returned for repair.
It is extremely important to note that while many of the commonly identi-
fied solutions to equipment failure are provided in Vari-Lite service
manuals, they do not cover all possible situations. Contact the appropriate
Vari-Lite Support Department if you have questions or if the procedures
given do not solve the problem.

, 1752'8&7,21 3 52'8&7 6 833257 17
CONFIDENTIAL 02.9638.0010
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Class Definitions
Support for VARI*LITE products is provided by the Product Support
Department and by various technical publications. Authorization for field
repair of the equipment is based upon a user class rating. This protects
both the user and the equipment.
Class 1. Users with no training or resources, but that are covered by
warranty. These would include architectural, DMX clients, clients of
dealers, and some limited leases. No maintenance to VARI*LITE
equipment should be performed by Class 1 users.
Class 2. Users with limited training and resources, and covered by
warranty. These would include dealers, some leases, and Vari-Lite road
staff. Maintenance to VARI*LITE equipment should be limited to replace-
ment of end-item (the equipment itself) sub-assemblies or easily accessible
components (e.g., a fuse) in order to return the equipment to proper opera-
tion.
Class 3. Users with full training, extended resources, but that are not
covered by warranty. These would include Vari-Lite office technicians,
distributors, and sub-distributors. Maintenance is applicable to situations
in which tools and experience of the technician allow for more extensive
procedures such as sub-assembly repair.
Class 4. Users with full technical certification and training, working from a
Vari-Lite repair depot. (Note: Vari-Lite Training Department does not
grant technical certification.)
Fault Isolation
The fault isolation (troubleshooting) section of the manual provides a
logical path of fault isolation and repair designed to return the equipment to
proper operation. The fault isolation procedures for the equipment end
item have been broken into two categories, which lead the technician to
maintenance procedures that he/she can reasonably be expected to perform.
The criteria for separating fault isolation and maintenance procedures into
two categories can be defined by Class 2 and Class 3 repairs. Class 2
repairs only require the technician to replace an end item subassembly or
easily accessible component (e.g., a fuse) in order to return the equipment
to proper operation. Class 2 repairs are applicable to situations in which
tools and/or experience of the technician are limited, or time does not
permit extensive maintenance. Class 3 repairs (identified as Shop Only)
involve in-depth repair to subassemblies that have been identified as faulty.
Class 3 repairs are applicable to situations in which tools and experience of
the technician allow for more extensive procedures. In some cases, even
though a technician may have the ability and resources to perform
extensive repair, he/she may decide to replace the entire subassembly in
order to return the equipment to proper operation more quickly. The subas-
sembly could then be repaired at a more appropriate time.

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Observe the following to ensure proper operation and integrity of the
equipment.
/DPSV
When handling a lamp, hold it by the ceramic base while wearing cotton
gloves or finger cots. Do not touch the glass envelope (bulb). If you touch
the glass with bare fingers, wipe off any fingerprints with alcohol.
Luminaires will have a hot lamp when operating. Disconnect power and
allow lamp to cool before replacing.
When Operating Arc Lamps
Allow arc lamps to operate for at least 3 minutes. It takes about 3 minutes
for the fill components (mercury and halogen-metal compounds) in the
lamp tubes to vaporize completely. If the lamps are doused sooner than 3
minutes, the fill components are partially vaporized. The inadequately
vaporized fill components and the electrode material (tungsten) are
deposited in areas of the envelope that have remained cool. As a result, the
lamp blackens prematurely.
If system will be unattended for more than two hours, lamps should be
doused. Standby mode should not be used for more than two hours.
If an arc luminaire is struck, the luminaire should be maintained in a hori-
zontal position when not in use.
All arc luminaire heads should be tilted horizontal before starting lamps.
Lamps generate light by an electrical discharge arc, whereby the electrons
from two electrodes excite the fill components to give off light. Because of
the alternating current position, the electrons are alternately given off by
the two electrodes. When a lamp is set in a vertical position, the halogen-
metal compounds, which determine the color temperature of the lamp,
collect at the top end of the glass envelope. When the lamp is struck, color
deviations occur since the concentration of halogen compounds is greater
around the top electrode than the bottom electrode. In addition, the fill
components that are difficult to vaporize congeal around the bottom elec-
trode, thereby reducing lamp life.

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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 VARI*LITE equipment
uses solid state electronics and appropriate precautions to protect them
should be observed when servicing.
All parts in the following VARI*LITE part number groups should be con-
sidered ESD sensitive:
23- Electrical assemblies
24- Printed circuit board assemblies
80- Transistors
81- Thyristors
82- Diodes
83- IC’s:linear
84- IC’s:digital
85- IC’s:interface
86- Optoelectronic devices
87- Firmware
88- LED’s, displays
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 precau-
tionary 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 batteries or put in contact with PC boards which
contain batteries.

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21
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• Features
• Location of Major Components
• Dimensions and Clearances
• Specifications
• Principles of Operation

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