Vari Lite VL2B User manual

CONFIDENTIAL: This technical manual is confidential property of Vari-Lite, Inc.
VL2B

and VL2C
™
Spot Luminaire
02.9631.0010
15 Jan 1997

The Automated LightingCompany
Service Manual

ii VARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
15 Jan 98
NOTICE
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™, 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. 5,640,061; 5,590,955; 5,590,954; 5,454,477; 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.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 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. 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. 2,059,669; 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 Patents No. 134.458; 134.491;
129.596; 129.595;
Taiwan Patents No. 212,234; 123,393; 61,420; 57,219; 53,673; 52,156; 40,611;
28,275;
United Kingdom Design Reg. No. 2056387; 2056386; 2029499; 2033108; 2042174;
2045352.
© 1995, 1996, 1997, 1998 Vari-Lite, Inc. All Rights Reserved.

VARI*LITE® -VL2BAND VL2CSPOT LUMINAIRE SERVICE MANUAL iii
02.9631.0010 CONFIDENTIAL
15 Jan 98
VL2B
and
VL2C

Spot Luminaire
Service Manual
List of Effective Pages
Page Change
Number Number
Title Page thru xiv 0
1-1 thru 1-20 0
2-1 thru 2-12 0
3-1 thru 3-132 0
4-1 thru 4-96 0
5-1 thru 5-36 0
FO-1 thru FO-5 0
Revision History
BASIC 15 Jan 1998

iv VARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
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VARI*LITE® -VL2BAND VL2CSPOT LUMINAIRE SERVICE MANUAL v
02.9631.0010 CONFIDENTIAL
15 Jan 98
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 Recommended Safety Practices.......................................................... 1-5
1.2 Equipment Description.................................................................... 1-7
1.2.1 VL2B™ luminaire .............................................................................. 1-7
1.2.2 VL2C™ luminaire.............................................................................. 1-8
1.2.3 Dimensions and Weight...................................................................... 1-9
1.2.4 Technical Specifications................................................................... 1-10
1.2.4.1 Description................................................................................. 1-10
1.2.4.2 Programmable Functions............................................................ 1-11
1.3 Location of Major Luminaire Components.................................. 1-12
1.3.1 Head Components............................................................................ 1-12
1.3.2 Electronic Chassis Components........................................................ 1-14
1.4 Photometric Data........................................................................... 1-16
1.5 Principles of Operation.................................................................. 1-17
1.5.1 Operation Overview......................................................................... 1-17
1.5.2 Operation Description...................................................................... 1-17
1.5.2.1 Electronics Components............................................................. 1-17
1.5.2.2 Bulkhead Assemblies.................................................................. 1-19
1.5.3 Data and Power Flow Diagram ........................................................ 1-20
Chapter 2. Installation and Checkout
2.1 Installation....................................................................................... 2-3
2.1.1 Luminaire Hanging............................................................................. 2-3
2.1.1.1 Luminaire-To-Luminaire Distance Requirements.......................... 2-3
2.1.1.2 Clearances.................................................................................... 2-4
2.1.2 Luminaire Packing ............................................................................. 2-5
2.2 Checkout.......................................................................................... 2-7
2.2.1 Power-Up.......................................................................................... 2-7
2.3 Installing VL2B/VL2C Accessories.................................................. 2-9
2.3.1 Installing Sound Baffles...................................................................... 2-9
2.3.1.1 VL2B and VL2C Luminaire Sound Blanket Installation............... 2-10
2.4 Lamp Optical Alignment............................................................... 2-11

vi VARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
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Contents (continued)
Chapter 3. Maintenance Procedures
3.1 Test Procedures................................................................................ 3-3
3.1.1 EPROM Test..................................................................................... 3-3
3.1.1.1 Description................................................................................... 3-3
3.1.1.2 Thumbwheel ................................................................................ 3-3
3.1.1.3 EPROM Test Setup ..................................................................... 3-5
3.1.1.4 EPROM Test Code Description ................................................... 3-6
3.1.2 Download Test ................................................................................ 3-11
3.1.2.1 Description................................................................................. 3-11
3.1.2.2 Test Number.............................................................................. 3-11
3.1.2.3 Downloadable Test Setup........................................................... 3-12
3.1.2.4 Verifying Software Downloaded ................................................ 3-12
3.1.2.5 Perform Test.............................................................................. 3-12
3.1.2.6 Reading Error Codes.................................................................. 3-13
3.1.2.7 Conclude Test............................................................................ 3-14
3.1.2.8 Test Code Description................................................................ 3-15
3.2 Luminaire Fault Isolation.............................................................. 3-29
3.2.1 Luminaire Fault Isolation Chart........................................................ 3-29
3.2.2 Luminaire Fault Isolation Procedures ............................................... 3-33
3.2.2.1 Luminaire Powers Up, But Will Not Calibrate............................ 3-33
3.2.2.2 Luminaire Calibrates, But Will Not Come On-Line..................... 3-35
3.2.2.3 Luminaire Powers Up, but Recalibrates Repeatedly.................... 3-35
3.2.2.4 Luminaire Has No Power........................................................... 3-36
3.2.2.5 Lamp Will Not Strike................................................................. 3-36
3.2.2.6 Intensity Iris Not Working Properly............................................ 3-37
3.2.2.7 Color Filters Not Working Properly ........................................... 3-38
3.2.2.8 Edge Control Not Working Properly.......................................... 3-39
3.2.2.9 Gobo Filters Not Working Properly............................................ 3-40
3.2.2.10 Improper Tilt Response.............................................................. 3-41
3.2.2.11 Improper Pan Response.............................................................. 3-41
3.3 Luminaire Maintenance Procedures............................................. 3-42
3.3.1 Brightness/Filter Bulkhead Maintenance........................................... 3-42
3.3.1.1 Brightness/Filter Bulkhead Removal and Replacement................ 3-42
3.3.1.2 Brightness/Focus Bulkhead Brightness Iris
Removal and Replacement.......................................................... 3-45
3.3.1.3 Brightness/Focus Bulkhead Belt Removal and Replacement ....... 3-49
3.3.1.4 Brightness/Focus Bulkhead Sensor Switch
Removal and Replacement.......................................................... 3-51
3.3.1.5 Brightness/Focus Bulkhead Linear Actuator Motor Removal and
Replacement............................................................................... 3-53

CONTENTS vii
02.9631.0010 CONFIDENTIAL
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Contents (continued)
Chapter 3. Maintenance Procedures
3.3.2 Gobo/Beam Projector Maintenance.................................................. 3-55
3.3.2.1 Gobo/Beam Projector Removal and Replacement....................... 3-55
3.3.2.2 Gobo/Beam Projector Sensor Removal and Replacement ........... 3-57
3.3.2.3 Gobo/Beam Projector Beam Size Iris
Removal and Replacement.......................................................... 3-59
3.3.2.4 Gobo/Beam Projector Gobo Removal and Replacement............. 3-61
3.3.3 Color Filter Bulkhead Maintenance.................................................. 3-62
3.3.3.1 Color Filter Bulkhead Removal and Replacement ....................... 3-62
3.3.3.2 Color Filter Bulkhead Sensor Removal and Replacement............ 3-64
3.3.4 Lamp Assembly Maintenance........................................................... 3-66
3.3.4.1 Lamp Assembly / Lamp Removal and Replacement.................... 3-66
3.3.4.2 Lamp Assembly Socket Removal and Replacement .................... 3-67
3.3.5 Tilt / Pan Mechanism Maintenance................................................... 3-69
3.3.5.1 Tilt Mechanism Removal and Replacement................................. 3-69
3.3.5.2 Tilt Mechanism Belt Removal and Replacement ......................... 3-74
3.3.5.3 Pan Mechanism Removal and Replacement ................................ 3-75
3.3.5.4 Pan Mechanism Belt Removal and Replacement......................... 3-77
3.3.6 Yoke Cable Assembly Removal and Replacement............................. 3-80
3.3.7 Yoke Removal and Replacement...................................................... 3-85
3.3.8 ARC Power Supply Ignitor Maintenance.......................................... 3-87
3.3.8.1 APS Ignitor Assembly Removal and Replacement ...................... 3-87
3.3.8.2 APS Ignitor Assembly Spark Gap
Removal and Replacement.......................................................... 3-91
3.3.9 Yoke Termination Board Removal and Replacement........................ 3-92
3.3.10 Transformer Assembly Removal and Replacement............................ 3-94
3.3.11 Control Interface Board (CIB), Low Voltage Supply (LVS),
Lamp Control Board (LCB) Removal and Replacement ................... 3-96
3.3.12 Motherboard Removal and Replacement.......................................... 3-97
3.3.13 Voltage Selector Board Removal and Replacement.......................... 3-99
3.3.14 Voltage Selector Board Fuses Removal and Replacement ...............3-100
3.3.15 Card Cage Assembly PCB Removal and Replacement.....................3-101
3.3.16 Control Interface Board SN75436NE IC Driver Chip
Removal and Replacement ..............................................................3-102
3.3.17 Arc Power Supply Maintenance ......................................................3-103
3.3.17.1 Arc Power Supply Removal and Replacement.................................3-103
3.3.17.2 APS Switch Board Rectifier and Diode
Removal and Replacement ..............................................................3-105
3.3.17.3 APS MJ10005 and IRF450 Transistor
Removal and Replacement ..............................................................3-107
3.3.17.4 APS Control Board IC, Diode, and Resistor Removal and
Replacement..............................................................................3-109
3.3.18 Input/Output Connector Removal and Replacement........................3-111

viii VARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
15 Jan 98
Contents (continued)
Chapter 3. Maintenance Procedures (continued)
3.3.19 Thumbwheel Switch Assembly Removal and Replacement..............3-113
3.3.20 VL2C Fan Drive Plus PCB Removal and Replacement.....................3-115
3.3.21 VL2C DC-to-DC Converter PCB Removal and Replacement ..........3-117
3.3.22 Stuck Truss Hook Removal and Truss Hook Receptacle
Removal and Replacement ..............................................................3-119
3.3.23 VL2C Reflector/Mirror Assembly Removal and Replacement ..........3-123
3.3.24 Calibration Procedures....................................................................3-125
3.3.24.1 Color and Gobo Wheel Sensor Calibration ................................3-125
3.3.24.2 Control Interface Board Trimpot Calibration.............................3-129
Chapter 4. Illustrated Parts Breakdown
4.1 Drawing Trees.................................................................................. 4-3
4.1.1 VL2B Spot Luminaire (20.5002.0004)................................................ 4-3
4.1.2 VL2C Spot Luminaire (20.9637.0001)................................................ 4-5
4.2 Parts Breakdown ............................................................................. 4-6
4.2.1 Assembly, Hooks and Covers............................................................. 4-6
4.2.2 Assembly, Head................................................................................. 4-8
4.2.3 Assembly, Gobo/Beam Bulkhead Projector...................................... 4-10
4.2.4 Assembly, Gobo Wheel.................................................................... 4-12
4.2.5 Assembly, Beam Size Iris................................................................. 4-13
4.2.6 Assembly, Brightness/Focus Bulkhead ............................................. 4-15
4.2.7 Assembly, Brightness Iris................................................................. 4-19
4.2.8 Assembly, Color Filter Bulkhead...................................................... 4-20
4.2.9 Assembly, Filter Wheel #1................................................................ 4-22
4.2.10 Assembly, Filter Wheel #2................................................................ 4-23
4.2.11 Assembly, Reflector......................................................................... 4-24
4.2.12 Assembly, Lamp............................................................................... 4-26
4.2.13 Assembly, Yoke Rails & Covers....................................................... 4-29
4.2.14 Assembly, Pan/Tilt Mechanism......................................................... 4-32
4.2.15 Cable Assembly, Tilt........................................................................ 4-34
4.2.16 PCB Assembly, Yoke Cable Termination ......................................... 4-35
4.2.17 Assembly, APS Ignitor..................................................................... 4-36
4.2.18 PCB Assembly, APS Ignitor............................................................. 4-37
4.2.19 Cable Assembly, APS Ignitor........................................................... 4-38
4.2.20 Assembly, Electronics Chassis.......................................................... 4-39
4.2.21 Assembly, Chassis Cover.................................................................. 4-42
4.2.22 Cable Assembly, Pan Mech – Mother Bd.......................................... 4-44
4.2.23 Cable Assembly, Yoke..................................................................... 4-45
4.2.24 Assembly, Arc Power Supply........................................................... 4-47
4.2.25 Assembly, Arc Pwr Supply Chassis .................................................. 4-48
4.2.26 Cable Assembly, ACB-LPS Interconnect.......................................... 4-51

CONTENTS ix
02.9631.0010 CONFIDENTIAL
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Contents (continued)
Chapter 4. Illustrated Parts Breakdown (continued)
4.2.27 Assembly, APS Heat Sink................................................................ 4-52
4.2.28 PCB Assembly, APS 400X Switch................................................... 4-54
4.2.29 PCB Assembly, APS 400X Control.................................................. 4-57
4.2.30 Assembly, Electronic Card Cage ...................................................... 4-60
4.2.31 PCB Assembly, Mother Board......................................................... 4-61
4.2.32 Assembly, AC Control ..................................................................... 4-63
4.2.33 PCB Assembly, AC Voltage Selector (VSB).................................... 4-64
4.2.34 Assembly, Transformer .................................................................... 4-66
4.2.35 PCB Assembly, DC-DC Converter................................................... 4-68
4.2.36 Elec Assembly, LCB (VL2B)............................................................ 4-69
4.2.37 Elec Assembly, VL2B Memory Board.............................................. 4-71
4.2.38 PCB Assembly, LCB (VL2B) ........................................................... 4-72
4.2.39 Elec Assembly, LCB Combo w/Upgrade Bd .................................... 4-74
4.2.40 PCB Assembly, Modem................................................................... 4-75
4.2.41 PCB Assembly, LCB Upgrade w\All Parts ....................................... 4-76
4.2.42 PCB Assembly, LCB Modified For Upgrade .................................... 4-78
4.2.43 PCB Assembly, Low Voltage Supply............................................... 4-80
4.2.44 PCB Assembly, CIB (VL2B) ............................................................ 4-82
4.2.45 PCB Assembly, CIB Modified For Upgrade..................................... 4-85
4.2.46 Cable Assembly. AC Power Input .................................................... 4-88
4.2.47 Cable Assembly, APS-Mother Board ............................................... 4-89
4.2.48 Cable Assembly, Thumbwheel Switch .............................................. 4-91
4.2.49 PCB Assembly, Fan Drive Plus ........................................................ 4-92
4.2.50 Cable Assembly, Fandrive Plus, 18” ................................................. 4-94
4.2.51 Cable Assembly, Fan Drive DC Power............................................. 4-95
Chapter 5. Wiring 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 Mate-N-Lok ...................................................................................... 5-4
5.1.4 MT.................................................................................................... 5-4
5.2 Connector Pin Diagrams ................................................................. 5-5
5.2.1 9-Position Chassis Mount Lamp Receptacle....................................... 5-5
5.2.2 Pan Mechanism- Mother Board Cable................................................ 5-6
5.2.3 APS Mother Board Cable .................................................................. 5-8
5.2.4 Yoke Cable Assembly...................................................................... 5-10
5.2.5 ACB-LPS Interconnect Cable Assembly........................................... 5-13
5.2.6 Fandrive Plus, 18” Cable Assembly .................................................. 5-14
5.2.7 Fan Drive DC Power Cable Assembly .............................................. 5-15
5.2.8 Yoke Termination Board Header Connector Pinouts........................ 5-16

xVARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
15 Jan 98
Contents (continued)
Chapter 5.Wiring Diagrams (continued)
5.2.9 Tilt Cable Assembly.........................................................................5-17
5.2.10 AC Power Input Cable Assembly.....................................................5-19
5.2.11 Transformer Assembly.....................................................................5-20
5.2.11.1 Capacitors..................................................................................5-22
5.2.11.2 Bridge Rectifier..........................................................................5-24
5.2.12 Motorized Fan.................................................................................5-25
5.2.13 Thumbwheel Switch Cable Assembly...............................................5-26
5.2.14 Motor Connectors............................................................................5-28
5.2.14.1 Pan/Tilt Motor (10.9620.0107)..................................................5-28
5.2.14.2 Yoke Termination Board Motors...............................................5-29
5.3 Schematics and Wiring Diagrams.................................................5-35
5.3.1 Transformer Schematic....................................................................5-35

CONTENTS xi
02.9631.0010 CONFIDENTIAL
15 Jan 98
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 supersedes all existing VL2B and VL2C luminaire
information and procedures. The following Vari-Lite technical publications
are superseded by this service manual and should be discarded.
02.9631.0002 VL2 Illustrated Parts Breakdown
02.9631.0003 VL2 Maintenance Procedures
These documents may also be contained in the Series 200 System
Notebook.
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: Luminaire intensity

xii VARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
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CONTENTS xiii
02.9631.0010 CONFIDENTIAL
15 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 VL2B and VL2C Wash Luminaire Service Manual (02.9631.0010)
FROM:
DATE:
PAGE 1 OF 1
Copy or tear this page from manual, complete, and fax
(or mail) to Product Support Department
Comments:

xiv VARI*LITE® -VL2BAND VL2C™ SPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
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1-1
02.9631.0010 CONFIDENTIAL
15 Jan 98
Chapter 1. Introduction
This chapter contains the following sections:
1.1 General Information
1.2 Equipment Description
1.3 Photometric Data
1.4 Location of Major Luminaire Components
1.5 Principles of Operation

1-2 VARI*LITE® -VL2BAND VL2CSPOT LUMINAIRE SERVICE MANUAL
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CHAPTER 1. INTRODUCTION 1-3
02.9631.0010 CONFIDENTIAL
15 Jan 98
1.1 General Information
1.1.1 About This Manual
This manual describes specific information regarding description and
installation of the VL2Band VL2Cspot luminaires. It provides test,
fault isolation, and repair procedures for the purpose of general service and
repair of the luminaires. 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
VL2B Spot Luminaire 20.5002.0004
VL2C Spot Luminaire 20.9637.0001
Note: Some VL2B spot luminaires have been upgraded with VL2C Lamp
Control Board (LCB) and Control Interface Board (CIB). These
luminaires are referred to as VL2B+ spot luminaires. This distinction
refers only to the implementation of Tech Bulletin LCB-004 and not to a
separate version of luminaire. Other than the unique VL2B+ Form and
Function Switch setting mentioned in the Test Code Description
paragraph for Test 24 (Form and Function Test) in the Download Test
section of Chapter 3, the 2B+ is not discussed in this manual.
1.1.2 Documentation
1.1.2.1 Technical Manuals
Procedures for operating and maintaining a Series 200or Series 300
system are contained in Series 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-Artisan®2).
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 of Artisan consoles are covered in the Artisan
Control Console Service Manual (02.9622.0101). The mini-Artisan
consoles are covered 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® -VL2BAND VL2CSPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
15 Jan 98
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 concerning VARI*LITE equipment.
Technical bulletins are categorized by assembly or subassembly, and
identified by a number such as BFB-003 (VL2B Luminaire Dimmer Belt
Change).
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 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
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
02.9631.0010 CONFIDENTIAL
15 Jan 98
1.1.4 Recommended Safety Practices
This section describes the various types of safety factors to be considered
while installing and operating VL2 luminaires.
Equipment High Voltage
All components of the Series 200 and 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.
Luminaire Hanging
Safety is the prime consideration when hanging luminaires. Safety far
outweighs any concern about operator convenience, speed of load-in or
load-out, or ease of changing-out luminaires when the truss is in the air.
The first consideration must be whether the truss or pipe can safely support
the weight of the luminaires and repeaters. The second consideration must
be whether the luminaires are securely attached so they cannot possibly
come off the truss or pipe (even if the truss goes 90°from horizontal due
to a failure of the chain motor or fly system). In addition to mounting
hooks, all truss-mounted equipment are provided with a safety cable to
prevent the equipment from falling off the truss. The safety cable is
connected to the equipment's base, looped around the truss, and then
reattached to the equipment base. The cable should be wound tightly,
leaving as little slack as possible.
Lamp Handling
Due to the use of high power lamps (bulbs) in all VL2 luminaires, the heat
of the luminaire head can reach temperatures of around 400°F when the
lamp is lit. To aid in the airflow circulation within the luminaires, after
dousing the lamps, wait ten minutes before removing power to the
luminaires. This will provide enough time for the equipment fan to cool off
the unit, which will increase lamp life.

1-6 VARI*LITE® -VL2BAND VL2CSPOT LUMINAIRE SERVICE MANUAL
CONFIDENTIAL 02.9631.0010
15 Jan 98
• When handling a lamp, use the ceramic base to hold the lamp. Do not
touch the glass part of the lamp. If you touch the glass part with your
fingers, wipe off the fingerprints with alcohol. Oils contained in the
skin, and therefore the fingerprints, deteriorate the glass when the oils
are heated causing hot spots on the glass. Lamps could explode at
these hot spots.
• On occasion, lamps have exploded. Wear protective glasses whenever
the covers are removed from the head of the luminaire and the lamp is
exposed.
• Use care when opening and closing the rear door of the VL2
luminaires. Any jarring of the rear door can undo the optical alignment
of the lamp.
• In the event that a large quantity of luminaires need to be optically
aligned, wear dark glasses during the alignment procedure to prevent
eye strain. In addition, always operate the lamp in the closed housing.
There is a danger of glare due to high luminance. Also, a high portion
(three to five percent) of the consumed electrical power is given off in
the form of ultraviolet radiation.
• When operating arc lamps, allow luminaires to operate for at least three
minutes. It takes about three minutes for the fill components (mercury
and halogen-metal compounds) in the lamp tubes of 250-, 400- and
600-watt lamps to vaporize completely. If the lamps are switched off
earlier than three minutes, the fill components are partially vaporized.
The inadequately vaporized fill components and the electrode material
(tungsten) are deposited in the areas of the lamp tubes that have
remained cool. As a result, the lamp tubes blacken prematurely and
reduce the service lives of the lamps.
• Luminaire heads should be tilted to the horizontal position before
starting lamps. The lamps generate light in an electrical discharge arc,
whereby the electrons from the 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 started, 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
electrode, thereby reducing the service life of the lamp.
• When system will be unattended for more than two hours, luminaire
lamps should be doused. Otherwise, if system will be unattended for
less than two hours, system can remain in standby.