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Vari Lite VL6 Series User manual

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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.
III
CONFIDENTIAL 02.9638.0010
23-Aug-99
&RPSOLDQFH
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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02.9638.0010 CONFIDENTIAL
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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.
V
CONFIDENTIAL 02.9638.0010
23-Aug-99
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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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CONFIDENTIAL 02.9638.0010
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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