Vari Lite DMX Power Pack C3 Dimmer User manual

CONFIDENTIAL: This technical manual is confidential property of Vari-Lite, Inc.
DMX Power Pack
02.9654.0010
23 January 1998

The Automated Lighting Company
Service Manual

ii VARI*LITE-DMX POWER PACK SERVICE MANUAL
CONFIDENTIAL 02.9640.0011
23-Jan-98
NOTICE
VARI*LITE®, Artisan®, mini-Artisan®, mini-Artisan®2, Artisan®Plus,
mini-Artisan®Plus, VL2®, and VLD®are registered trademarks owned by
Vari-Lite, Inc., 201 Regal Row, Dallas TX 75247 USA.
VL1™, VL2B™, VL2C™, VL3™, VL4™, VL5™, VL5Arc™, VL5B™,
VL6™, VL6B™, VLM™, Series 100™, Series 200™, Series 300™,
Smart Repeater™, SmartDMX™, AutoTruss™, Dichro*Wheel™,
Dichro*Tune™, Vacu*Dep™, Vari*Image™, Vari*Beam™, Visionary™,
Artisan VLQ™, APS6™, C3™, SPC-36™, and UDM™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. 5,590,955; 5,590,954; 5,537,303; 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; 4,095,139;
U.S. Design Patents No. D 366,712; D 359,574; D 350,408; D 347,133;
Australia Patents No. 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 Patent Reg. No. 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 Patents Reg. No. 75,750; 72,772;
Europe Patents No. 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. 2,059,669; 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;
Korea Patents No. 92,269; 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 Patents No. 134.458; 134.491;
129.596; 129.595;
Taiwan Patents No. 61,420; 57,219; 53,673; 52,156; 40,611; 28,275;
United Kingdom Design Reg. No. 2056387; 2056386; 2029499; 2033108; 2042174;
2045352.
© 1997 Vari-Lite, Inc. All Rights Reserved.

VARI*LITE-DMX POWER PACK SERVICE MANUAL iii
02.9654.0010 CONFIDENTIAL
23-Jan-98
DMX Power Pack
Service Manual
List of Effective Pages
Page Change
Number Number
Title Page thru x 0
1-1 thru 1-16 0
2-1 thru 2-14 0
3-1 thru 3-32 0
4-1 thru 4-34 0
5-1 thru 5-10 0
FO-1 0
Revision History
BASIC 23 January, 1998

iv VARI*LITE-DMX POWER PACK SERVICE MANUAL
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VARI*LITE-DMX POWER PACK SERVICE MANUAL v
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Contents
Chapter 1. Introduction
1.1 General Information........................................................................1-3
1.1.1 About This Manual.............................................................................1-3
1.1.2 Documentation...................................................................................1-3
1.1.2.1 Technical Manuals........................................................................1-3
1.1.2.2 Technical Bulletins.......................................................................1-4
1.1.3 Maintenance Philosophy.....................................................................1-4
1.1.4 Safety.................................................................................................1-5
1.2 Equipment Description....................................................................1-7
1.2.1 DMX Power Pack..............................................................................1-7
1.2.1.1 Front Panel Controls and Indicators..............................................1-8
1.2.1.2 C3 Dimmer Front Panel Jumpers..................................................1-9
1.2.1.3 APS6 Module Front Panel Jumpers.............................................1-10
1.2.1.4 Rear Panel..................................................................................1-11
1.2.1.5 Internal.......................................................................................1-12
1.2.1.6 Technical Specifications..............................................................1-13
1.3 Principles of Operation..................................................................1-15
1.3.1 System Connections.........................................................................1-15
1.3.2 Internal Operation............................................................................1-16
Chapter 2. Installation and Operation
2.1 Installation/Checkout.......................................................................2-3
2.1.1 Hanging Method................................................................................2-3
2.1.2 IEC Power Cable ...............................................................................2-4
2.1.3 Installation.........................................................................................2-6
2.2 Operation Instructions...................................................................2-14
2.2.1 Controlling Arc Lamps (VL5Arc/VL6)..............................................2-14
2.2.2 Controlling Incandescent Lamps(VL5/VL5B)...................................2-14
Chapter 3. Maintenance Procedures
3.1 Calibration Procedures....................................................................3-3
3.2 Fault Isolation..................................................................................3-5
3.2.1 Fault Isolation Chart...........................................................................3-5
3.2.2 Fault Isolation Procedures..................................................................3-6
3.2.2.1 No Power to DMX power pack ....................................................3-6
3.2.2.2 Intermittent Power to DMX power pack.......................................3-6
3.2.2.3 DMX Power Pack Doesn’t Strike VL6/VL5Arc Lamp...................3-7
3.2.2.4 DMX Power Pack Doesn’t Allow Manual Intensity
Control of VL5 Luminaires...........................................................3-7
3.2.2.5 DMX Power Pack Determined To Be Faulty................................3-8

vi VARI*LITE-DMX POWER PACK SERVICE MANUAL
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Contents (continued)
Chapter 3. Maintenance Procedures (continued)
3.2 Fault Isolation (continued)
3.2.2.6 VL5 1000W Lamp Very Bright Then Burns Out...........................3-8
3.2.2.7 VL5 1200W Lamp Operating Very Dim........................................3-8
3.2.2.8 VL5Arc 575W Lamp Operating Very Dim....................................3-8
3.2.2.9 VL6 400W Lamp Very Bright Then Burns Out.............................3-9
3.2.2.10 DMX Power Pack Shuts Down Unexpectantly.............................3-9
3.3 Maintenance Procedures................................................................3-11
3.3.1 C3/APS6 Module Removal and Replacement....................................3-11
3.3.2 C3/APS6 Module Jumper Change....................................................3-12
3.3.3 C3/APS6 Module PCB/Heatsink Removal and Replacement.............3-13
3.3.4 Power Supply Removal and Replacement.........................................3-14
3.3.5 Toroid Assembly Removal and Replacement....................................3-15
3.3.6 Fan Assembly Removal and Replacement.........................................3-16
3.3.7 Front Panel Removal........................................................................3-18
3.3.8 Line Filter Removal and Replacement...............................................3-20
3.3.9 Control PCB Removal and Replacement...........................................3-21
3.3.10 Lamp Power Supply Cable Assembly Removal and Replacement......3-23
3.3.11 AC/Data Cable Assembly Removal and Replacement........................3-25
3.3.12 AC In Cable Assembly Removal and Replacement............................3-27
3.3.13 LVS DC Out Cable Assembly Removal and Replacement.................3-29
3.3.14 Line Filter Ground Cable Removal and Replacement........................3-31
Chapter 4. Illustrated Parts Breakdown
4.1 Drawing Tree: C3/APS6 DMX Power Pack...................................4-3
4.2 Illustrated Parts................................................................................4-5
4.2.1 DMX Power Pack, C3 Dimmer Version.............................................4-5
4.2.2 DMX Power Pack, APS6 Module Version..........................................4-6
4.2.3 Enclosure Assembly...........................................................................4-7
4.2.4 Front Panel Assembly.........................................................................4-8
4.2.5 Outer Cover Assembly.....................................................................4-10
4.2.6 C3 DimmerLPS Plate Assembly.......................................................4-11
4.2.7 C3 DimmerHeatsink Assembly........................................................4-12
4.2.8 APS6 Module LPS Plate Assembly...................................................4-14
4.2.9 APS6 Module Heatsink Assembly..................................................... 4-16
4.2.10 Control PCB Assembly.....................................................................4-18
4.2.11 C3 Dimmer PCB Assembly...............................................................4-20
4.2.12 APS6 PCB Assembly........................................................................4-22
4.2.13 Toroid Assembly, APS6/C3 Power Pack..........................................4-25
4.2.14 AC/Data Out Cable Assembly..........................................................4-26
4.2.15 AC In Cable Assembly......................................................................4-27

CONTENTS vii
02.9654.0010 CONFIDENTIAL
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Contents (continued)
4.2 Illustrated Parts (continued)
4.2.16 Lamp Power Supply Cable Assembly................................................4-28
4.2.17 DC Out Low Voltage Supply Cable Assembly..................................4-30
4.2.18 Line Filter Ground Cable Assembly..................................................4-31
4.2.19 Hook Assy., w/Wing Bolts & Hardware...........................................4-32
4.2.20 Hook Assy., w/Wing Bolts...............................................................4-33
Chapter 5. Diagrams
5.1 Connector Type Identification.........................................................5-3
5.1.1 MTA-100 and MTA-156....................................................................5-3
5.1.2 CPC...................................................................................................5-3
5.1.3 Molex Mini-Fit, Jr..............................................................................5-4
5.2 Connector Pin Locations..................................................................5-5
5.2.1 16 Position AC/Data In Connector.....................................................5-5
5.2.2 4 Position MTA Data Out Connector .................................................5-6
5.2.3 2 Position Fan Connector ...................................................................5-6
5.2.4 Power Supply DC Out MTA Connectors............................................5-7
5.2.5 Lamp Power Supply, 24, 4, & 6 Pos. Connectors ...............................5-8
5.2.6 AC In MTA and IEC Connectors.....................................................5-10
5.3 Wire Diagrams..............................................................................FO-1

viii VARI*LITE-DMX POWER PACK SERVICE MANUAL
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Foreword
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.
This manual incorporates distinct type styles to differentiate between
certain types of text. These styles are defined as follows:
Boldface Trademarked or registered
product. Example: Artisancontrol console
Italics Words with specialized meanings
such as luminaire attributes. Example: Luminaireintensity
Bold Italics
Highlighting trademarked
products within titles. Example:
Artisan Control Console
Ariel Font Macintosh computer screen
commands. Example: Click onSAVE.
ALL CAPS Board Control menu option. Example: Select RESET.
[brackets] Console button name. Example: Press [STRT] button.
#-pos. Indicates the number of position
or pins in a connector. Example: 4-pos MTA connector
Macintoshis a registered trademark of Apple Computer, Inc.
Loctiteis a registered trademark of Loctite Corporation.
Hubbellis a registered trademark of Hubbell, Inc.
Epicis a registered trademark of Contact Electronics, Inc.
Blue Showeris a trademark of Tech Spray, Inc.

CONTENTS ix
02.9654.0010 CONFIDENTIAL
23-Jan-98
FAX The Automated Lighting Company
TO: Product Support Department Manager 201 Regal Row
Dallas, Texas 75247
COMPANY: Vari-Lite International USA
FAX NUMBER: 214-630-5867
RE: Comments to DMX Power Pack Service Manual (02.9654.0010)
FROM:
DATE:
PAGE 1 OF 1
Copy or tear this page from manual, complete, and fax
(or mail) to Product Support Department
Comments:

xVARI*LITE-DMX POWER PACK SERVICE MANUAL
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1-1
02.9654.0010 CONFIDENTIAL
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Chapter 1. Introduction
This chapter contains the following sections:
1.1 General Information
1.2 Equipment Description
1.3 Principles of Operation

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CHAPTER 1. INTRODUCTION 1-3
02.9654.0010 CONFIDENTIAL
23-Jan-98
1.1 General Information
1.1.1 About This Manual
This manual describes specific information regarding description and
installation of the DMX power pack and related equipment. It provides
test, fault isolation, and repair procedures for the purpose of general
service and repair of the DMX power pack. The manual is intended for use
by Vari-Lite personnel and by Vari-Lite’s customers/clients. The following
equipment items are covered in this manual:
Equipment Description Part Number
DMX Power Pack, C3 Dimmer 20.9654.0001
DMX Power Pack, APS6 Module 20.9654.0002
1.1.2 Documentation
1.1.2.1 Technical Manuals
Procedures for operating and maintaining aSeries 200or Series 300
system are contained inSeries 200 System Manual (02.3004.0200) and
various equipment manuals. Programming procedures are contained in the
Operator Programming Manuals, which are kept with the console. There
are currently two programming manuals: 02.3004.0010 (Artisan®and
mini-Artisan®control consoles) and 02.3004.0210 (Artisan Plus®, mini-
Artisan Plus®, and mini-Artisan2®consoles).
All of the ACS equipment are contained in the ACS Equipment Service
Manual (02.9623.0200). Each luminaire and console has its own service
manual. Both types ofArtisan consoles are covered in the Artisan
Control Console Service Manual (02.9622.00101). The three mini-
Artisan consoles are contained in separate service manuals.
Procedures for inspecting and preparing equipment for shipment are found
in the Series 200 System Equipment Preparation and Inspection
Procedures (02.3004.0042).

1-4 VARI*LITE® - DMX POWER PACK SERVICE MANUAL
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1.1.2.2 Technical Bulletins
Technical bulletins are issued from the Dallas, Texas USA office. They are
updates to documentation that discuss changes to the equipment, software,
and the latest available information concerningVARI*LITE®equipment.
Technical bulletins are categorized by assembly or subassembly, and
identified by a number such as ART-075 (Artisan Technical Bulletin
number 75).
1.1.3 Maintenance Philosophy
The fault isolation and maintenance sections of this manual provide a
logical path of fault isolation and repair designed to return the equipment
to proper operation in most cases. The fault isolation procedures for the
equipment end item have been broken into two sections, 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 sections 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 asShop 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
subassembly could then be repaired at a more appropriate time.
It is extremely important to note that while many of the commonly
identified solutions to equipment failure are provided in this manual, it does
not cover all possible situations. Contact the appropriate Vari-Lite
Support Group if you have questions or if the procedures given do not
solve the problem.

CHAPTER 1. INTRODUCTION 1-5
02.9654.0010 CONFIDENTIAL
23-Jan-98
1.1.4 Safety
All components of theSeries 200 and Series 300 systems use high voltage
to operate. These voltages can produce death on contact. When working
around or within powered components and cables, extreme caution must be
used. When conditions permit, maintenance should be performed with
power off.
WARNING: The modular rack is a power distribution system and
requires extra caution when installing and servicing!

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CHAPTER 1. INTRODUCTION 1-7
02.9654.0010 CONFIDENTIAL
23-Jan-98
1.2 Equipment Description
1.2.1 DMX Power Pack
APS6MODULE VERSION
C3 MODULE VERSION
The DMX Power Pack (DPP) is a portable electronics chassis that provides
lamp power and control to Series 300™ luminaires. The unit interprets
DMX-512 data and sends the appropriate VL Comm protocol to the
luminaire. Two versions of the DPP are available: one for arc lamps
(VL6™ & VL5Arc™ luminaires) and one for incandescent lamps (VL5™
& VL5B™ luminaires). The two versions are indicated with either an
APS6™ or C3™ module marking on the unit’s front panel. Either unit
may be used with theVLM™ moving mirror.
The DPP is used in conjunction with a DMX-512 control console to fully
operate/test Series 300 luminaires. This product’s primary function is
operating Series 300 luminaires with DMX control at permanent
installations. The DPP may also be used as a shop tool or demonstration
device for Series 300 luminaires.

1-8 VARI*LITE® - DMX POWER PACK SERVICE MANUAL
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1.2.1.1 Front Panel Controls and Indicators
The following controls and indicators are common for bothAPS6 module
and C3 Dimmer DMX power pack versions.
No. Name Description
112.5A FUSES Two 12.5 amp fuses for lamp power supply
protection.
2AC ON Neon indicator. Lit when AC power is
applied to unit and the fuses are good.
3AC IN Standard IEC inlet for AC power cord.
4110/220V
MODE Toggle switch for 110V or 220V AC mode.
5DMX
CHANNEL Three knobs for DMX address channel control (1, 10, 100 positions).
6LUMINAIRE
OUTPUT 16-pos. CPC connector provides power and data connection to luminaire.
7DMX
Parameter Dip
switch
Four position dip switch for particular DMX
parameters. Positions are as follows:
TERM - Terminator,
8/16 - 8 or 16 bit DMX,
TIME - DMX timing support,
SW4 - Open (no function).
8DMX THRU Five position XLR connector provides DMX
through to other equipment.
9DMX IN Five position XLR connector provides DMX
data input from controller.
10 DATA
VALID Flashing green LED indicates valid data received to unit.
11 24 VDC Yellow LED indicates 24VDC is supplied to
unit.
32
1
4
5
6
7
8
9
10
11
or

CHAPTER 1. INTRODUCTION 1-9
02.9654.0010 CONFIDENTIAL
23-Jan-98
1.2.1.2 C3 Dimmer Front Panel Jumpers
The VL5 luminaire may use either a 1000W or *1200W bulb. A jumper
behind the front panel of theC3 dimmer version of the DMX power pack
allows you to configure for both 1000W and 1200W bulbs.
No. Name Description
1*LAMP
CURRENT
SELECT 1200W
Jumper window. Used to view position of
jumper which configuresVL5 luminaire
operation in 10.0A (1200W) mode.
2LAMP
CURRENT
SELECT 1000W
Jumper window. Used to view position of
jumper which configuresVL5 luminaire
operation in 8.33A (1000W) mode.
* 1200W lamp only available at 120V and must be used withC3 module
operating in 220VAC mode only.
Notes:
• To achieve full rated power, a DPP with aC3 Dimmer module must be
powered by a 208-260VAC line voltage.
• C3 dimmer module must be removed from unit to change jumper
position. Refer to the “Maintenance” chapter in this manual.
1
2

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1.2.1.3 APS6 Module Front Panel Jumpers
The DCV mode allows DMX input signal to control remote start/douse of
arc lamps (400W or 625W). The modulemust be in this mode to adjust
intensity with a controller.
The PSET or Preset mode operates the module at one of two fixed level
wattage’s (400W or 625W). This mode is the normal mode of operation
for the module.
Note:APS6 module must be removed from unit to change jumper
position. Refer to the Maintenance chapter in this manual.
No. Name Description
1DCV 400W Jumper window. Used to view position of a
jumper which configures operation of aVL6
luminaire using DMX signal to control remote
start/douse of arc lamps.
2DCV 625W Jumper window. Used to view position of a
jumper which configures operation of aVL5Arc
luminaire DMX signal to control remote
start/douse of arc lamps.
3PSET 400W Jumper window. Used to view position of a
jumper which configures DPP to strikeVL6 lamp
when power is applied to unit.
4PSET 625W Jumper window. Used to view position of a
jumper which configures DPP to strikeVL5Arc
lamp when power is applied to unit.
1
2
3
4