Philips VARI*LITE VL1100 ERS Luminaire Service Manual
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Philips VARI*LITE VL1100 ERS Luminaire Service Manual

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Summary of Contents for Philips VARI*LITE VL1100 ERS Luminaire

  • Page 2 All information and graphics are property of Vari-Lite, 10911 Petal Street, Dallas, Texas 75238. Version as of: 20 October 2010 Part number: 02.9664.0010 0 VL1100 ERS Luminaire Service Manual ©2002-2010, Vari-Lite, a Philips group company. All Rights Reserved. 20 Octo be r 20 10 02 .9 664.00 10 0...
  • Page 3 BTAIN ARRANTY ERVICE How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548) or 1-214-647-7880 or via e-mail at entertainment.service@phil- ips.com request a Return Material Authorization (RMA) for warranty service.
  • Page 4 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
  • Page 5 WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1. VARI❋LITE luminaires have been designed for use only with certain Philips and Osram HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps. Installing another type of lamp may be hazardous.
  • Page 6 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL 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. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired.
  • Page 7 UV-STRAHLUNG UND KÖRPERVERLETZUNGEN. WARNUNG: HINWEISE ZUM FEUERSCHUTZ 1. VARI❋LITE-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Philips und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp (MSR400, MSR575HR etc.), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines anderen Lampentyps kann gefährlich sein.
  • Page 8 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1.
  • Page 9 1. Les luminaires VARI❋LITE ont été conçus pour être utilisés uniquement avec certaines lampes Philips et Osram HID. Vérifier le type de lampe (MSR400, MSR575HR etc.) avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un danger.
  • Page 10 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE utilisent une lampe de type HID qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2.
  • Page 11 INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO 1. Las luminarias VARI❋LITE han sido diseñadas para ser usadas solamente con algunas lámparas HID Philips y Osram. Tome nota del tipo de lámpara (MSR400, MSR575HR etc.) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.
  • Page 12 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE usan un tipo de lámpara HID que produce radiación UV. NO mire directamente a la lámpara. 2.
  • Page 13 AFETY OTICE APANESE 02.96 64.001 0 0 20 Octo be r 20 10 xiii...
  • Page 14 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 15: Table Of Contents

    ABLE OF ONTENTS Table of Contents Introduction Disclosure ........................1 About This Manual ...................... 1 Additional Documentation................... 2 Customer Service ......................2 Chapter 1. Description Features Standard Features......................4 Model Specific Features ....................4 Component Descriptions External Luminaire Components ................. 6 Luminaire Internal Head Components.................
  • Page 16 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Gobo Index Timing Belt Alignment................33 Gobo Wheel Bulkhead Replacement................35 Gobo Gear Planet Alignment ..................37 Shutter Assembly Replacement.................. 39 Shutter Blade or Rack Replacement................41 Edge/Zoom/Color Bulkhead Replacement..............43 Fan/Temp Switch Assembly Replacement ..............44 Beam-Size Iris Assembly Replacement ..............
  • Page 17 ABLE OF ONTENTS Rear Head Assembly ....................101 Back Cap Assembly ....................103 Yoke Assembly Yoke Legs Assembly ....................105 Tilt Motor Assembly ....................108 Crossmember Assembly ..................110 Inner Crossmember Assembly ................. 112 Outer Crossmember Assembly ................113 Pan Motor Assembly ....................114 Pan Tube Assembly ....................
  • Page 18 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL (This page intentionally blank.) xviii 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 19: Disclosure

    NTRODUCTION Introduction Disclosure This technical manual is confidential property of Vari-Lite All information contained herein is the sole and exclusive property of Vari-Lite and may not be used, disclosed, or reproduced in any manner without the prior written consent of Vari-Lite WARNING: It is important to read ALL accompanying safety instructions to avoid damage to the product and potential injury to yourself or others.

  • Page 20: Additional Documentation

    Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through Friday, at the following: phone: 1-877-VARI-LITE (1-877-827-4548) or 1-214-647-7880 fax: 1-214-647-8038 email: entertainment.service@philips.com Additional Resources For additional resources and documentation, please visit our website at: www.vari-lite.com and follow the Support link.

  • Page 21: Chapter 1. Description

    HAPTER Description This chapter provides an overview of luminaire features, components and operations. • Features • Component Descriptions • Principles of Operation 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 22: Features

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Features Standard Features VL1100 Ellipsoidal Reflector Spotlight (ERS) luminaires have the following standard features: • Automated zoom optics system. • Crossfading CYM color system. • Diffusion system. • Six-position rotating gobo wheel (five rotatable, indexable gobo positions and one open gobo position).
  • Page 23 ESCRIPTION • Mechanical dimmer. VL1100 TSD Luminaire (20.9664.0001.22 - Black / 20.9664.0001.22.02 - White) • 1000W Tungsten Halogen lamp source. • 115V on-board electronic IGBT dimmer. • Four-blade shutter framing system. VL1100 TID Luminaire (20.9664.0001.23 - Black / 20.9664.0001.23.02 - White) •...

  • Page 24: Component Descriptions

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Component Descriptions External Luminaire Components The following illustration shows the external luminaire components and controls. Base Input Panel Provides hook mounting holes and safety cable Provides DMX In and connection. Thru, and AC Power connections.

  • Page 25: Luminaire Internal Head Components

    ESCRIPTION Luminaire Internal Head Components The following illustration shows the major sub-assemblies that are located in the luminaire head assembly. A options - Shutter or Beam-size Iris bulkhead is dependent on model. B options - Rotating Gobo Bulkhead version is dependent on model. Beam-Size Iris Assembly (optional) Provides beam sizing capabilities.

  • Page 26: Luminaire Internal Yoke Components

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Luminaire Internal Yoke Components The following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly. Note: Head assembly not shown for clarity. Tilt Mechanism Yoke Arm Cover (Power Supply Side) Pan Mechanism Yoke Arm Cover (Display Side)

  • Page 27: Arc Ballast Unit

    ESCRIPTION Arc Ballast Unit An external ballast unit is included with VL1100 arc models. In this case, the lamp power input cable is already connectorized for use with this unit. The following illustration shows the external arc ballast components. Lamp Connector CPC-type connector for connecting Lamp Power Input cable from luminaire.

  • Page 28: Principles Of Operation Vl1100 Incandescent Source Luminaire

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Principles of Operation VL1100 Incandescent Source Luminaire VL1100 Incandescent Block Diagram - Without On-Board IGBT Dimmer 1766 1202 1520 1520 1766 1301 1301 1301 1301 DIMMER ZOOM GOBO BLUE SHUTTER SHUTTER SHUTTER SHUTTER MOTOR INDEX...

  • Page 29: Vl1100 Incandescent Cable Routing - Without On-Board Igbt Dimmer

    ESCRIPTION VL1100 Incandescent Cable Routing - Without On-Board IGBT Dimmer CHASSIS NEUTRIK XLR-M TERM POWERCON LINE BLOCK AC LINE IN 2015 INPUT 2015 DMX PCB STUD USER PROVIDED XLR-F LAMP PWR CONNECTOR 2030 FOR LAMP PWR DIMMER GND THRU INPUT FROM TERM STUD DIMMER...

  • Page 30: Vl1100 Incandescent Block Diagram - With On-Board Igbt Dimmer

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL VL1100 Incandescent Block Diagram - With On-Board IGBT Dimmer 1766 1202 1520 1520 1766 1301 1301 1301 1301 DIMMER ZOOM GOBO BLUE SHUTTER SHUTTER SHUTTER SHUTTER MOTOR INDEX MOTOR MOTOR ONLY FRAME FRAME FRAME FRAME...

  • Page 31: Vl1100 Incandescent Cable Routing - With On-Board Igbt Dimmer

    ESCRIPTION VL1100 Incandescent Cable Routing - With On-Board IGBT Dimmer CHASSIS NEUTRIK XLR-M TERM POWERCON LINE BLOCK AC LINE IN 2015 INPUT 2015 DMX PCB STUD XLR-F THRU LINE DATA TUBE 2016 2016 2022 YOKE TILT MOTOR PAN EOT PAN EOT TILT COT MOTOR &...

  • Page 32: Vl1100 Arc Source Luminaire

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL VL1100 Arc Source Luminaire VL1100 Arc Block Diagram 1766 1202 1520 1520 1766 1301 1301 1301 1301 DIMMER ZOOM GOBO BLUE SHUTTER SHUTTER SHUTTER SHUTTER MOTOR INDEX MOTOR MOTOR ONLY FRAME FRAME FRAME FRAME 1202...

  • Page 33: Vl1100 Arc Cable Routing

    ESCRIPTION VL1100 Arc Cable Routing CHASSIS NEUTRIK LINE XLR-M TERM POWERCON 2015 BLOCK AC LINE IN INPUT 2015 DMX PCB STUD 1 2016 AC LINE CPC 17-9 XLR-F BAL CONT LAMP POWER IN & AC LINE OUT LAMP PWR THRU TO BALLAST BALLAST GND 1921...
  • Page 34 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Notes 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 35: Chapter 2. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Maintenance Procedures WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation. 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 36: Testing

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Testing Running Parameter Tests The luminaire is capable of running self tests by using the TEST menu functions. For detailed instructions regarding the luminaire’s self-test function, refer to the VL1100 User’s Manual for your luminaire (02.9664.0001).

  • Page 37: Calibration Sequence

    AINTENANCE Table 2-1: Self Test Function Chart 1st Level 2nd Level 3rd Level 4th Level 5thLevel Test ALL SEQ Test All Motors RUN TEST Run-Test in Progress Press [Menu] to stop System Test tests Pan/Tilt RUN TEST Run-Test in Progress Dimmer (Arc Only) RUN TEST Run-Test in Progress Blue...

  • Page 38: Auto Recalibration

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Auto Recalibration Mechanisms with sensors (Gobo and Index) will check their sensor when at a zero position, if the sensor is not detected within 3 seconds, the mechanism will recalibrate. This applies to all except pan and tilt, pan and tilt are corrected continuously if required by encoders fitted to the motor shaft.
  • Page 39 AINTENANCE • Pan and tilt sensors read high when the tab is in the sensor. The mechanism calibrates to the edge and its tab covers 50% of travel. Pan and tilt encoders are best read with a scope to read the encoder ticks. Notes regarding lamp control: •...

  • Page 40: Maintenance Procedures

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Maintenance Procedures Lamp Replacement (Incandescent Model) Parts: 1000 WATT INCANDESCENT LAMP, 100 VAC (71.2552.0100) - TS/TI 1000 WATT INCANDESCENT LAMP, 100 VAC (71.2554.0100) - TS/TI 1000 WATT INCANDESCENT LAMP, 115 VAC (71.2552.0115) - TS/TI 1000 WATT INCANDESCENT LAMP, 115 VAC (71.2554.0115) - TS/TI 1000 WATT INCANDESCENT LAMP, 230 VAC (71.2552.0230) - TS/TI 1000 WATT INCANDESCENT LAMP, 230 VAC (71.2554.0230) - TS/TI...
  • Page 41 AINTENANCE Do not touch lamp CAUTION: with bare fingers. Rear Head Assembly Backcap Align when re-installing Alignment Stud (2) 10-32x2-3/8 PPSS Holes and studs MUST be Black Screws (captive) CAUTION: aligned when re-installing. - loosen each gradually Alignment Hole (2) Backcap Interior View Figure 2-1: Removing Incandescent Backcap Step 3.
  • Page 42 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Step 7. Close base and bail clamps, locking into place. Do not touch lamp with bare fingers. CAUTION: Flip bail clamps outward. Flip base clamps outward. Install lamp, firmly pressing into place. Bail Clamps Lamp Socket...

  • Page 43: Lamp Replacement (Arc Model)

    AINTENANCE Lamp Replacement (Arc Model) Parts: 575 WATT ARC LAMP, MSR575HR (71.2528.0575) - AS/AI 575 WATT LONG-LIFE ARC LAMP, MSD575HR (71.2554.0575) - AS/AI Tools: #2 Phillips screwdriver, cotton gloves CAUTION: Wear cotton gloves or other covering while installing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life.
  • Page 44 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Step 3. Grip lamp by base and firmly install in socket (Figure 2-4). Do not touch lamp with bare fingers. CAUTION: Socket Lamp Install lamp, firmly pressing into place. Figure 2-4: Installing Arc Lamp in Socket Step 4.

  • Page 45: Align Lamp For Maximum Beam Irradiance

    AINTENANCE Align Lamp For Maximum Beam Irradiance After a new lamp is installed in either the incandescent or arc version of the luminaire, it will be necessary to align the lamp to optimize the beam. Tools: None - See Warning WARNING: Backcap and adjustment knobs will be HOT during lamp operation.

  • Page 46: Frame Or Top Hat Replacement

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Frame or Top Hat Replacement An accessory frame holder is provided for the addition of a top hat or gel frame with silks, frosts or color correction if required. The frame holder is designed to fit a standard 7.5-inch gel frame or top hat.

  • Page 47: Front Cover Removal

    AINTENANCE Front Cover Removal Parts: ASSY, FRONT COVER Tools: #2 Phillips screwdriver To remove and replace front cover: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head assembly, press in front cover latches to release (Figure 2-7).

  • Page 48: Rear Head Assembly Removal

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Rear Head Assembly Removal This procedure is necessary in order to access some components such as the gobo wheel bulkhead and shutter assembly. Refer to as needed. Tools: #2 Phillips long handle screwdriver To remove rear head assembly: Step 1.

  • Page 49: Rotating Gobo Replacement

    AINTENANCE Rotating Gobo Replacement WARNING: Remove power from luminaire before performing maintenance. Gobos may be HOT after operation. Allow to cool before replacing. WARNING: Users of VARI❋LITE luminaires should not install or use metal gobos. The use of metal gobos in any VARI❋LITE product may damage the luminaire and could void the luminaire’s warranty.
  • Page 50 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Rotating Gobo Replacement (continued) Inside Edge - orient toward center of wheel CAUTION: Gobo MUST be oriented with side marked ThisEdgeIn "This Edge In" toward center of wheel and side marked "Lamp Side" toward lamp. If not oriented properly, gobo will break.

  • Page 51: Gobo Index Timing Belt Alignment

    AINTENANCE Gobo Index Timing Belt Alignment The index timing belt (54.9663.1220) must be aligned so that the mechanism "clocks" properly. This belt is installed around the index gear and top gear of the gobo wheel (refer to Figure 2-11). The wheel position belt (54.2045.0002) is installed around the wheel position gear and bottom gear of the gobo wheel, and does not require alignment.
  • Page 52 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Step 2. If applicable, lower gobo wheel into place over rotating shaft, fitting wheel position belt around lower gear and index timing belt around top gear. Install 4-40x1/4 " PPZ screw, split lock washer, flat black washer and flat Teflon washer to secure gobo wheel in place.

  • Page 53: Gobo Wheel Bulkhead Replacement

    AINTENANCE Gobo Wheel Bulkhead Replacement Parts: ASSEMBLY, GOBO BULKHEAD INCANDESCENT - TS/TI ASSEMBLY, GOBO BULKHEAD ARC - AS/AI Tools: #2 Phillips long handle screwdriver To remove and replace gobo wheel bulkhead: Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 54 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Gobo Wheel Bulkhead Replacement (contin- ued) Gobo Bulkhead #10 Split-Lock Washers 10-32x3/8" PPB Screw Side Rail Spacer Front Assembly NOTE: Incandescent model gobo bulkhead not shown. Figure 2-12: Gobo Bulkhead Assembly Replacement 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 55: Gobo Gear Planet Alignment

    AINTENANCE Gobo Gear Planet Alignment Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly. Use the following procedure to re-align the gears in the event the gobo wheel is disassembled. To re-align gobo gears: Step 1.
  • Page 56 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Gobo Gear Planet Alignment (continued) 1) Start with center gear alignment 2) Rotate center gear clockwise until alignment mark facing Position 1 (open). mark is directly across from Position 6. Rotate Position 6 gear until marks align. Alignment Mark open Align both marks...

  • Page 57: Shutter Assembly Replacement

    AINTENANCE Shutter Assembly Replacement Parts: ASSEMBLY, SHUTTER 6 ROLLERS Tools: #2 Phillips long handle screwdriver+ To remove and replace shutter assembly: Step 1. Disconnect luminaire AC input cable from power source. CAUTION: The rear assembly is heavy and will remain attached by lamp wires. Place luminaire on tech bench before removing rear assembly.
  • Page 58 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Step 4. At Controller PCB, disconnect shutter wiring harness at position marked SHUTTERS. Step 5. Noting placement, cut tie-wraps securing harness to other wires. Step 6. Feed shutter harness cable out of yoke arm. Step 7.

  • Page 59: Shutter Blade Or Rack Replacement

    AINTENANCE Shutter Blade or Rack Replacement Parts: as required: BLADE, SHUTTER, COATED SIDE A BLADE, SHUTTER, COATED SIDE B RACK, SHUTTER Tools: #2 Phillips screwdriver To remove and replace a shutter blade or rack: Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 60 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Step 4. Carefully remove plates and components until blade or rack to be replaced is reached. Install new component(s) as required. Step 5. Re-assemble shutter’s four layers. Ensure that components are oriented and aligned as shown in Figure 2-17.

  • Page 61: Edge/Zoom/Color Bulkhead Replacement

    AINTENANCE Edge/Zoom/Color Bulkhead Replacement Parts: ASSEMBLY, EDGE CONTROL, DIMMER AND COLOR Tools: #2 Phillips screwdriver To remove and replace edge/zoom/color bulkhead: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover. (Refer to “Front Cover Removal” on page 29.) Step 3.

  • Page 62: Fan/Temp Switch Assembly Replacement

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Fan/Temp Switch Assembly Replacement Note: Fan does not operate under normal luminaire operating conditions. Parts: CABLE ASSEMBLY, FAN/TEMP SWITCH Tools: #2 Phillips screwdriver To remove and replace fan/temp switch assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 63: Beam-Size Iris Assembly Replacement

    AINTENANCE Beam-Size Iris Assembly Replacement Note: This procedure not applicable to all units. Parts: ASSEMBLY, IRIS Tools: #2 Phillips screwdriver To remove and replace beam-size iris assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove front cover, rear head assembly, and gobo wheel bulkhead. Refer to procedures “Front Cover Removal”...

  • Page 64: Ignitor Pcb Replacement

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Ignitor PCB Replacement Note: This procedure not applicable to all units. Parts: PCB ASSEMBLY, IGNITOR Tools: #2 Phillips screwdriver To remove and replace ignitor PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 65: Power Supply Replacement

    AINTENANCE Power Supply Replacement Parts: POWER SUPPLY, 130W +24V/6.3A Tools: #2 Phillips screwdriver To remove and replace power supply: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side without menu display) by removing four 6- 32x3/8"...
  • Page 66 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Power Supply Replacement (continued) NOTE: Head not shown for clarity. Crossmember Assembly 10-32x1/2" PPB Screw Yoke Leg Cover 6-32x3/8" PTB Screws Power Supply Figure 2-23: Power Supply Replacement 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 67: Controller Pcb Replacement

    AINTENANCE Controller PCB Replacement Parts: PCB ASSEMBLY, CONTROLLER Tools: #2 Phillips screwdriver To remove and replace controller PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing four 6-32x3/ 8"...
  • Page 68 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Controller PCB Replacement (continued) NOTE: Head not shown for clarity. 6-32x3/8" PPB Screw Controller PCB Display Plate* Display Overlay* Yoke Leg Cover 6-32x1/2" PPB Screw *These items remove 6-32x3/8" PTB Screw and install as one. Figure 2-24: Controller PCB Replacement 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 69: Tilt Encoder Pcb Replacement

    AINTENANCE Tilt Encoder PCB Replacement Parts: PCB ASSY, PAN/TILT ENCODER Tools: #1 Phillips screwdriver #2 Phillips screwdriver To remove and replace tilt encoder PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove yoke leg cover (side with menu display) by removing four 6-32x3/ 8"...

  • Page 70: Tilt Motor Assembly Replacement

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Tilt Motor Assembly Replacement Parts: ASSEMBLY, TILT MOTOR Tools: #1 Phillips screwdriver #2 Phillips screwdriver To remove and replace tilt motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 71 AINTENANCE Tilt Motor Assembly Replacement (continued) 6-32x3/8" PTB Screws 6-32x3/8" PPB Screw Controller PCB *These items remove Display Plate* and install as one. Display Overlay* Yoke Leg Cover 6-32x1/2" PPB Screw NOTE: Tilt Motor Assembly Head not shown for clarity. #6 Flat Washer 6-32x1"...

  • Page 72: Pan Motor Assembly Replacement

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Pan Motor Assembly Replacement Parts: ASSEMBLY, PAN MOTOR Tools: #1 Phillips screwdriver #2 Phillips screwdriver To remove and replace pan motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 73 AINTENANCE Pan Motor Replacement (continued) Pan Wire Shield 4-40x3/8" PPZ Screw 6-32x1" PPB Screw Spring #6 Flat Washer Pan Motor Assembly Timing Belt Nut Plate Crossmember Assembly 10-32x1/2" PPB Screw 6-32x3/8" PTB Screws Yoke Leg Cover NOTE: Head not shown for clarity. Figure 2-27: Pan Motor Assembly Replacement 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 74: Dmx Input Pcb Replacement

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL DMX Input PCB Replacement Parts: PCB ASSEMBLY, DMX INPUT Tools: #1 Phillips screwdriver #2 Phillips screwdriver To remove and replace DMX input PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 75: Cleaning Optical Lenses And Filters

    AINTENANCE Cleaning Optical Lenses and Filters WARNING: Remove power from luminaire before performing maintenance. The front lens, color filters, and gobos may require cleaning after extended use. Isopropyl Alcohol should only be used, with a soft, lint-free cloth, to clean these components.
  • Page 76 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Notes 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 77: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL1100 ERS Luminaire assemblies. • Drawing Trees • Top Assembly • Head Assembly • Yoke Assembly • Cables The following abbreviations are used to identify parts specific to certain models: BBREVIATION ODEL...

  • Page 78: Drawing Trees

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Drawing Trees VL1100 Incandescent Luminaires VL1100 Luminaire (Incandescent Versions) 20.9664.0001.02 (TS) Rev C 20.9664.0001.03 (TI) Rev C 20.9664.0001.22 (TSD115) Rev C 20.9664.0001.23 (TID115) Rev C 20.9664.0001.32 (TSD230) Rev C 20.9664.0001.33 Color/Gobo/Lens Harness Cable Head Assembly Front Cover Assembly Assembly...
  • Page 79 LLUSTRATED ARTS REAKDOWN VL1100 Incandescent Luminaires (continued) continued from previous page continued from previous page Yoke Legs Assembly Rear Head Assembly 21.9664.1850.01 (TS/TI) Rev B 21.9664.1002.01 Rev A (TS/TI) 21.9664.1850.21 (TSD/TID - 115V DIM) Rev B 21.9664.1850.31 (TSD/TID - 230V DIM) Rev B Back Cap Assembly Tilt Motor Assembly 21.9664.1127.01 (TS/TI) Rev...

  • Page 80: Vl1100 Arc Luminaires

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL VL1100 Arc Luminaires VL1100 Luminaire (Arc Versions) 20.9664.0001.12 (AS) Rev C 20.9664.0001.13 (AI) Rev C Color/Gobo/Lens Harness Cable Head Assembly Front Cover Assembly Assembly 21.9664.1000.12 (AS) Rev A 22.9664.1038 Rev A 25.9663.2050 Rev K 21.9664.1000.13 (AI) Rev A Gel Frame Holder Front Head Assembly...
  • Page 81 LLUSTRATED ARTS REAKDOWN VL1100 Arc Luminaires (continued) continued from previous page continued from previous page Yoke Legs Assembly Rear Head Assembly 21.9664.1850.11 (AS/AI) Rev B 21.9664.1002.11 Rev A (AS/AI) Tilt Motor Assembly Back Cap Assembly 21.9665.8816 Rev B 21.9664.1127.11 (AS/AI) Rev Tilt COT Cable Assembly Ignitor to Lamp Socket 25.9663.2002 Rev A...

  • Page 82: Top Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Top Assembly Included Items Kit 28.9664.0001.02 Rev A (Incandescent - TS Only) 28.9664.0001.03 Rev A (Incandescent - TI Only) 28.9664.0001.12 Rev A (Arc - AS Only) 28.9664.0001.13 Rev A (Arc - AI Only) 28.9664.0001.22 Rev A (Incandescent - TSD 115V Only) 28.9664.0001.23 Rev A (Incandescent - TID 115V Only) 28.9664.0001.32 Rev A (Incandescent - TSD 230V Only)

  • Page 83: Included Items Kit (Continued)

    LLUSTRATED ARTS REAKDOWN Included Items Kit (continued) VL1100 Luminaire page 66 Lamp per customer order (Arc Models Only) (Arc Models Only) Arc Ballast (Arc Models Only) Figure 3-5: Included Items 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 84: Vl1100 Luminaire

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL VL1100 Luminaire 20.9664.0001.02 (TS) Rev C 20.9664.0001.03 (TI) Rev C 20.9664.0001.12 (AS) Rev C 20.9664.0001.13 (AI) Rev C 20.9664.0001.22 (TSD115) Rev C 20.9664.0001.23 (TID115) Rev C 20.9664.0001.32 (TSD230) Rev C 20.9664.0001.33 (TID230) Rev C Refer to Figure 3-6 Item...
  • Page 85 LLUSTRATED ARTS REAKDOWN Item Qty. Description 25.9663.2040 CABLE ASSY, SHUTTER HARNESS (TS/TSD/AS ONLY - NOT SHOWN) 25.9663.2050 CABLE ASSY, 10 MOTORS / 2 SENSORS 28.9664.0001.02 INCLUDED ITEMS KIT (TS ONLY - NOT SHOWN) 28.9664.0001.03 INCLUDED ITEMS KIT (TI ONLY - NOT SHOWN) 28.9664.0001.12 INCLUDED ITEMS KIT (AS ONLY - NOT SHOWN) 28.9664.0001.13...
  • Page 86 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL VL1100 Luminaire (continued) - AI / AS only (x 4) TSD/TID Models Only TI/TS/AI/AS Models Only (x4) (x3) (x4) (x8) (x2) (x3) (x4) (x12) NOTE: Items 3 and 4 will remove and install together. IGBT Dimmer TSD/TID Models Only...

  • Page 87: Front Cover Assembly

    LLUSTRATED ARTS REAKDOWN Front Cover Assembly 22.9664.1038 Rev A Refer to Figure 3-7. Item Qty. Description 10.9663.2020 COVER, FRONT VL1100 21.9664.1028 ASSY, GEL FRAME HOLDER 53.2004.0002 NUT, 8-32 KEPS, ZINC PLATE 53.6545.0007 SCREW, 8-32 X 3/8" PFB 53.6552.0002 SCREW, 8-32 X 1/2" PFB (x4) (x3) Figure 3-7: Front Cover Assembly...

  • Page 88: Gel Frame Holder Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Gel Frame Holder Assembly 21.9664.1028 Rev A Refer to Figure 3-8. Item Qty. Description 10.9663.1027 HOLDER, GEL FRAME 10.9663.1031 LATCH, GEL FRAME 55.6568.0026 SPRING, CPRSN .180"OD .810"LG .026" WIRE DIA SS 55.6738.0003 TUBING, SILICONE RUBBER 1/8"ID X 1/4"OD TRANSLUCENT Figure 3-8: Gel Frame Holder Assembly 20 Octo be r 20 10...

  • Page 89: Cot (Center Of Travel) Flag Assembly

    LLUSTRATED ARTS REAKDOWN COT (Center of Travel) Flag Assembly 21.9663.1845 Rev 0 Refer to Figure 3-9. Item Qty. Description 10.9663.1824 SPACER, TILT TUBE 10.9663.1826 FLAG, CENTER OF TRAVEL - TILT 53.6602.0001 SCREW, 4-40 X 1/4" PPZ TYPE F Figure 3-9: COT Flag Assembly 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 90: Vl1100 Main Control Board (Mcb) Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL VL1100 Main Control Board (MCB) Assembly 24.9664.1700 Rev C Refer to Figure 3-9. Item Qty. Description 04.9664.1700 LABEL, VL1100 MCB WARNING 10.9664.1840 HEATSINK, MAIN CONTROLLER 10.9664.1736 CLAMP, PAN/TILT DRIVERS 53.2200.0004 NUT, 4-40 KEPS SS 53.2200.0006 NUT, 6-32 KEPS SS 53.6404.0003...

  • Page 91: Head Assembly

    LLUSTRATED ARTS REAKDOWN Head Assembly Head Assembly 21.9664.1000.02 (TS) Rev A 21.9664.1000.03 (TI) Rev A 21.9664.1000.12 (AS) Rev A 21.9664.1000.13 (AI) Rev A Refer to Figure 3-11. Item Qty. Description 10.9663.1032 SPACER, SIDE RAIL (TI/TS ONLY) SPACER, SIDE RAIL (AI/AS ONLY) 21.9664.1001.02 ASSY, FRONT HEAD, INCANDESCENT WITH SHUTTER (TS ONLY) 21.9664.1001.03...

  • Page 92: Front Head Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Front Head Assembly 21.9664.1001.02 (TS) Rev B 21.9664.1001.03 (TI) Rev B 21.9664.1001.12 (AS) Rev B 21.9664.1001.13 (AI) Rev B Refer to Figure 3-12. Item Qty. Description 07.5049.0001 LANYARD, NYLON COATED 8" LG 21.9663.1003 ASSY, EDGE, ZOOM &...
  • Page 93 LLUSTRATED ARTS REAKDOWN Front Head Assembly (continued) (x4) (x4) (x4) (x4) A: Models w/ Shutter B: Models w/ Iris Either A, B, C, or D (x4) (x4) (x4) (x4) C: Incandescent Models (x4) (x3) (x4) (x4) (x4) D: Arc Models Figure 3-12: Front Head Assembly 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 94: Edge Control, Zoom, Dimmer & Color Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Edge Control, Zoom, Dimmer & Color Assembly 21.9663.1003 Rev E Refer to Figure 3-13. Item Qty. Description 10.9663.1039 SUPPORT, AXIAL FAN 10.9663.1755 ROLLER, BARREL 10.9663.1756 ROLLER, LENS 10.9663.1757 CLAMP, BELT BASE 10.9663.1758 BELT CLAMP 10.9663.1767 ZOOM TEFLON SPACER...
  • Page 95 LLUSTRATED ARTS REAKDOWN Edge Control, Dimmer & Color Assembly (con- tinued) (x3) (x3) (x3) (x3) (x6) (x6) (x2) (x2) (x2) (x2) (x2) (x4) (x4) Figure 3-13: Edge Control, Dimmer & Color Assembly 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 96: Color Changer Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Color Changer Assembly 21.9663.1500 Rev U Refer to Figure 3-14. Item Qty. Description 04.9663.1524 LABEL, MAGENTA MOTOR 04.9663.1525 LABEL, BLUE MOTOR 04.9663.1526 LABEL, AMBER MOTOR 04.9663.1527 LABEL, DIFFUSER MOTOR 10.9663.3505 DRIVE RING, COLOR SYSTEM LAYER, PLASTIC 10.9663.1506 DIFFUSER COVER PLATE 10.9663.1507...
  • Page 97 LLUSTRATED ARTS REAKDOWN Item Qty. Description 53.2200.0004 NUT, 4-40 KEPS SS 53.5636.0375 SCREW, 6-32 X 3/8 " PFSS BLACK 53.6556.0001 SCREW, 4-40 X 3/4"LG PPZ 55.6588.0003 SPACER, 1/4"RND #6 THRU 1/8"LG .140"ID ZINC PLT BRS 10.9663.1537 DRIVE RING LOCATOR BEARING 02.96 64.001 0 0 20 Octo be r 20 10...
  • Page 98 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Color Changer Assembly (continued) (x4) (x2) (x8) (x2) (x2) (x4) (x3) (x3) (x2) (x8) (x4) (x4) Figure 3-14: Color Changer Assembly 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 99: Edge Barrel Assembly

    LLUSTRATED ARTS REAKDOWN Edge Barrel Assembly 21.9663.1710 Rev C Refer to Figure 3-15. Item Qty. Description 10.9663.1701 BARREL, HALF OUTER LENS EDGE SYSTEM 10.9663.1708 EDGE GEAR/CAM, 8 ELEMENT SYSTEM 10.9663.1711 BARREL, HALF INNER LENS EDGE SYSTEM 10.9663.1737 EDGE, LIGHT BAFFLE 21.9663.1722 ASSY, EDGE MOTOR 42.9663.1728...
  • Page 100 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Barrel Assembly (continued) (x2) (x4) (x2) (x2) (x4) Figure 3-15: Edge Barrel Assembly 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 101: Lens #8 Assembly

    LLUSTRATED ARTS REAKDOWN Lens #8 Assembly 21.9663.1780 Rev B Refer to Figure 3-16. Item Qty. Description 10.9663.1782 RING, RETAINING FRONT LENS 10.9663.1781 BULKHEAD, FRONT -LENS #8 ASSY 42.9663.1735 LENS #8 53.2202.0004 NUT, 4-40 HEX SS NYLON INSERT 53.6559.0001 SCREW, 4-40 X 1/4" PFZ (x6) (x6) Figure 3-16: Lens #8 Assembly...

  • Page 102: Pulley Side Rail Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Pulley Side Rail Assembly 21.9664.1033 Rev A Refer to Figure 3-17. Item Qty. Description 10.9663.1026 LATCH, SPRING 12.9663.2025 RAIL, SIDE MACHINED LONG TILT TUBE 53.2002.0004 NUT, 6-32 ACORN THREAD LOCKING SS 53.5636.0500 SCREW, 6-32 X 1/2"...

  • Page 103: Sensor Side Rail Assembly

    LLUSTRATED ARTS REAKDOWN Sensor Side Rail Assembly 21.9664.1034 Rev B Refer to Figure 3-18. Item Qty. Description 10.9663.1026 LATCH, SPRING 12.9663.2029 RAIL, SIDE MACHINED SHORT TILT TUBE 53.2002.0004 NUT, 6-32 ACORN THREAD LOCKING SS 53.5636.0625 SCREW, 6-32 X 5/8" PFSS BLACK 53.6530.0009 RIVET, 1/8"OD POP .126-.187GL STL BODY STL MNDRL DOME 55.6623.0004...

  • Page 104: Incandescent Gobo Wheel Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Incandescent Gobo Wheel Assembly 21.9664.1200 (TS/TI/TSD/TID) Rev A Refer to Figure 3-19. Item Qty. Description 10.9663.1212 PULLEY, MOTOR GOBO 10.9663.1217 PULLEY, GOBO DRIVE MOTOR MOUNTED 10.9663.1228 PLATE, GOBO IDLER MOUNT PLATE 10.9663.1229 PLATE, WHEEL IDLER MOUNT 10.9663.1239 MOUNT, SENSOR BOARD...
  • Page 105 LLUSTRATED ARTS REAKDOWN Item Qty. Description 55.3301.0006 WASHER, #6 FLAT, SS 55.6506.0010 SPACER, 0.250" OD X 0.140" ID X 0.375" LG, ALUM 55.6506.0010 WASHER, #6 LOCK INTERNAL TOOTH 55.6568.0061 SPRING, EXTENSION, 0.250" OD, 2.00" LONG 55.6621.0001 WASHER, #4 FLAT ZINC 55.6677.0039 WASHER, FLAT, 0.438"...
  • Page 106 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Incandescent Gobo Wheel Assy (continued) (x2) (x3) (x2) 0.475" 0.125" 23, 31 Set pulleys to dimensions shown. (x4) Detail A (x2) (x2) (x2) (x2) (x2) (x2) See Detail A 33, 22 (x2) (x2) (x2) (x4)

  • Page 107: Temperature Sensor Electrical Assembly

    LLUSTRATED ARTS REAKDOWN Temperature Sensor Electrical Assembly 23.9663.1248.01 (TS) Rev A 23.9663.1248.11 (AS) Rev A Refer to Figure 3-20. Item Qty. Description 23.9663.2008 ASSY, FAN (TI/TS ONLY) - 40.7140.0001 BLOWER, CENTRIFUGAL 24VDC 9CFM 3" X 3" - 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP 52.6523.0004 CONN, HOUSING 4POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001...

  • Page 108: Arc Gobo/Dimmer Bulkhead Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Arc Gobo/Dimmer Bulkhead Assembly 21.9664.1600 (AI/AS) Rev A Refer to Figure 3-21. Item Qty. Description 10.9663.1212 PULLEY, MOTOR GOBO 10.9663.1217 PULLEY, GOBO DRIVE 10.9663.1228 PLATE, GOBO IDLER MOUNT PLATE 10.9663.1229 PLATE, WHEEL IDLER MOUNT 10.9663.1239 MOUNT, SENSOR BOARD 10.9663.1241...
  • Page 109 LLUSTRATED ARTS REAKDOWN Item Qty. Description 53.6537.0001 SCREW, 4-40 X 5/8" PPB 53.6543.0001 SCREW, 6-32 X 3/8" PPB 53.6558.0015 SCREW, 6-32X 3/8" PPB 53.6598.0312 SCREW, 4-40 X 5/16" PFB 53.6600.0001 SCREW, 4-40 X 5/16" PPB 53.6614.0001 SCREW, 6-32 X 5/8" PPB 53.6682.0002 SCREW, 4-40 X 1/4"...
  • Page 110 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Arc Gobo/Dimmer Bulkhead (continued) (x2) (x2) 33, 43 (x2) (x2) (x2) (x8) (x2) (x2) (x2) (x2) (x7) (x18) (x2) (x2) (x6) (x3) 8, 25 (x2) Detail A 32, 47 (x2) (x2) (x2) (x2) (x2) See Detail A...

  • Page 111: Gobo Wheel Assembly

    LLUSTRATED ARTS REAKDOWN Gobo Wheel Assembly 21.9665.1201 Rev A Refer to Figure 3-22. Item Qty. Description 10.9663.1210 CLIP, RETAINING 10.9663.1211 SPACER, TEFLON, GOBO GEAR 10.9663.1240 BEARING, GOBO WHEEL BORE 10.9663.1247 TAB, GOBO WHEEL SENSOR 10.9663.2203 GEAR, PLANET, CAST 10.9663.2204 WHEEL, ROTATING GOBO 21.9665.1222 PULLEY ASSY, GOBO WHEEL 41.6010.0001...
  • Page 112 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Gobo Wheel Assembly (continued) (x5) - See Note Below (x5) (x10) (x2) (x5) (x3) (x3) (x5) Note: Patterns are sold separately and are not included with the fixture. Figure 3-22: Gobo Wheel Assembly 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 113: Gobo Wheel Pulley Assembly

    LLUSTRATED ARTS REAKDOWN Gobo Wheel Pulley Assembly 21.9665.2222 Rev B Refer to Figure 3-20. Item Qty. Description 10.9663.1206 FLANGE, MIDDLE 10.9665.2210 SPACER 1, ROTATING GOBO WHEEL 10.9665.2211 SPACER 2, ROTATING GOBO WHEEL 12.9665.2205 PULLEY, GOBO WHEEL DRIVE 12.9665.2219 SUN GEAR, MOLDED 54.1206.0060 RETAINING RING, INTERNAL, 36.5MM BORE 54.1259.0020...

  • Page 114: Shutter 6 Rollers Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Shutter 6 Rollers Assembly 21.9663.1350 Rev D Refer to Figure 3-24. Item Qty. Description 10.9663.1311 SEPARATOR, SHUTTER 10.9663.1313 COVER, SHUTTER 10.9663.1314 RACK, SHUTTER 10.9663.1320 PAD, MOTOR 10.9663.1321 CLAMP RING, MOTOR 10.9663.1325 ROLLER, NYLON 10.9663.1327 GEAR, SHUTTER ROTATE SECTOR 10.9663.1328...
  • Page 115 LLUSTRATED ARTS REAKDOWN Item Qty. Description 55.6621.0001 WASHER, #4 FLAT ZINC 55.6697.0020 STANDOFF, 3/16" RND, 4-40, .375"LG, ZINC PLATED STEEL 02.96 64.001 0 0 20 Octo be r 20 10...
  • Page 116 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Shutter Assembly (continued) Detail A (x8) Shutter Motors (x4) (x8) Detail A (x8) (x4) (x4) (x8) (x2) (x2) (x2) (x2) (x6) (x6) (x4) (x4) Figure 3-24: Shutter 6 Rollers Assembly 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 117: Beam-Size Iris Assembly

    LLUSTRATED ARTS REAKDOWN Beam-Size Iris Assembly 21.9663.1400 Rev E Refer to Figure 3-25. Item Qty. Description 10.9663.1339.03 DONUT, ANTI-REFLECTION IRIS 10.9663.1411 BULKHEAD, IRIS 21.9663.1409 ASSY, MOTOR ARM - 10.9663.1402 ARM, MOTOR - 10.9663.1406 BOSS, MOTOR ARM - 53.6659.0008 SCREW, 2-56 X 3/16" PFZ 22.9663.1410 IRIS, 67MM OD 44.9663.1326...
  • Page 118 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Beam-Size Iris Assembly (continued) (x3) (x2) Detail A (x2) Detail A 3.263 Figure 3-25: Beam-Size Iris Assembly 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 119: Rear Head Assembly

    LLUSTRATED ARTS REAKDOWN Rear Head Assembly 21.9664.1002.01 Rev A (TS/TI) 21.9664.1002.11 Rev A (AS/AI) Refer to Figure 3-26. Item Qty. Description 10.9634.0100 CLIP, MOUNTING, REFLECTOR 10.9663.1104 REFLECTOR MOUNT 10.9663.1109 COUNTERWEIGHT 12.9663.2023 HEAD REAR CASTING, MACHINED 21.9663.1101.01 ASSY, INCANDESCENT BULKHEAD (TS/TI ONLY) 21.9663.1101.11 ASSY, ARC BULKHEAD (AS/AI ONLY) 21.9664.1127.01...
  • Page 120 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Rear Head Assembly (continued) (x2) (x4) (x3) (x4) (x3) (x4) (x3) Reflector Orientation Alignment Reference Point* Note: * When installing reflector, align dimple in reflector flange (item 7) with reflector mount (item 2) as shown (for all models).

  • Page 121: Back Cap Assembly

    LLUSTRATED ARTS REAKDOWN Back Cap Assembly 21.9664.1127.01 (TS/TI) Rev J 21.9664.1127.11 (AS/AI) Rev J Refer to Figure 3-27. Item Qty. Description 10.9663.1116 CLAMP, LAMP BASE BAIL (TS/TI ONLY) 10.9663.1119 LAMP BASE CLAMP (TS/TI ONLY) 10.9663.2136 PLATE, BACKCAP ADJUST 12.9663.2126 BACKCAP, MACHINED 10.9678.0645 KNOB, LAMP ADJUST, MOLDED 53.2030.0001...
  • Page 122 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Back Cap Assembly (continued) (x2) (TS/TI ONLY) (x2) (x3) (x3) (TS/TI ONLY) (x3) (x3) (x2) (x3) (x2) (TS/TI ONLY) (x2) (TS/TI ONLY) AS/AI ONLY TS/TI ONLY Arc Models Incandescent Models Figure 3-27: Back Cap Assembly 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 123: Yoke Assembly

    LLUSTRATED ARTS REAKDOWN Yoke Assembly Yoke Legs Assembly 21.9664.1850.01 (TS/TI) Rev B 21.9664.1850.11 (AS/AI) Rev B 21.9664.1850.21 (TSD/TID - 115V DIM) Rev B 21.9664.1850.31 (TSD/TID - 230V DIM) Rev B Refer to Figure 3-28. Item Qty. Description 10.9661.1364 INSULATOR, ADHESIVE BACKED - TOP COVER (AS/AI ONLY) 10.9663.1827 NUT PLATE, PAN/TILT MOTOR 10.9663.2842...
  • Page 124 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Item Qty. Description 55.2143.0002 STANDOFF, 1/4"HEX 6-32 1.375"LG FF ALUM 55.2203.0001 SCREW, 4-40 X 1/4 " PPZ 55.2204.0001 WASHER, #4 NYLON (AS/AI ONLY) 55.3301.0006 WASHER, #6 FLAT SS 55.6525.0005 WASHER, #4 SHOULDER NYLON .125 DP (AS/AI ONLY) 55.6568.0056 SPRING, CPRSN .600"OD .625"LG .080"WIRE DIA MUSIC WIRE 55.6597.0003...
  • Page 125 LLUSTRATED ARTS REAKDOWN Yoke Legs Assembly (continued) (x4) (x2) (x4) (x7) (x3) (x3) (x3) (x4) (x2) (x6) (x4) - DIM Only - AS/AI only - DIM Only (x4) (x4) - AS/AI only (x4) - AS/AI only (x2) (x2) (x2) (x2) Figure 3-28: Yoke Legs Assembly 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 126: Tilt Motor Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Tilt Motor Assembly 21.9665.8816 Rev B Refer to Figure 3-29. Item Qty. Description 10.9663.8825 MOUNT, MOTOR TILT 21.9663.1818 ASSY, DRIVE PULLEY - 10.9663.1810 PULLEY, DRIVING - PAN/TILT - 10.9663.8820 CODE WHEEL - 53.5561.0250 SCREW, 6-40 X 1/4"...
  • Page 127 LLUSTRATED ARTS REAKDOWN Tilt Motor Assembly (continued) (x2) (x4) (x4) (x4) (x4) Pulley Height Detail & Installation 0.266" Note: Vari-Lite recommends that this assembly be replaced as a complete assembly. Although you can replace only the motor, the pulley (Item 2) is bonded to the motor shaft during assembly and cannot be removed intact.

  • Page 128: Crossmember Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Crossmember Assembly 21.9664.1811.01 (TS/TI) Rev C 21.9664.1811.11 (AS/AI) Rev C 21.9664.1811.21 (TSD/TID) Rev C Refer to Figure 3-30. Item Qty. Description 10.9663.1808 TOGGLE, PAN 10.9663.1809 ACTUATOR, TOGGLE PAN 10.9663.1827 NUT PLATE, PAN/TILT MOTOR 10.9663.1844 SHIELD, WIRE PAN 10.9663.1846...
  • Page 129 LLUSTRATED ARTS REAKDOWN Item Qty. Description 55.6799.0001 SHIM, 1.375" ID, 1.875" OD, 0.010" THK 55.6799.0002 SHIM, 1.375" ID, 1.875" OD, 0.005" THK (x4) (x3) (x4) (x4) (x2) (x6) (x14) (x2) Figure 3-30: Crossmember Assembly 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 130: Inner Crossmember Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Inner Crossmember Assembly 21.9664.1812 Rev A Refer to Figure 3-31. Item Qty. Description 10.9663.2805 CROSSMEMBER, INNER 10.9678.0886 SPACER, PAN BEARING .235" THK 53.2019.0001 NUT, 3/8-16 HEX 53.6505.0022 BOLT, 3/8-16 X 3/4"LG CARRIAGE GRD5 ZINC PLT 53.6539.0001 WASHER, 3/8"...

  • Page 131: Outer Crossmember Assembly

    LLUSTRATED ARTS REAKDOWN Outer Crossmember Assembly 21.9664.1813 Rev C Refer to Figure 3-32. Item Qty. Description 10.9663.1897 SPACER, PAN BEARING 21.9664.1843 ASSY, CROSSMEMBER OUTER 53.2019.0001 NUT, 3/8-16 HEX 53.6505.0022 BOLT, 3/8-16 X 3/4"LG CARRIAGE GRD5 ZINC PLT 53.6505.0023 BOLT, 3/8-16 X 1-1/4"LG CARRIAGE GRD5 ZINC PLT 53.6539.0001 WASHER, 3/8"...

  • Page 132: Pan Motor Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Pan Motor Assembly 21.9665.9815 Rev A Refer to Figure 3-33. Item Qty. Description 10.9665.8817 MOTOR MOUNT, PAN MOTOR 21.9663.1818 ASSY, DRIVE PULLEY - (2a) 10.9663.1810 PULLEY, DRIVING - PAN/TILT - (2b) 10.9663.8820 CODE WHEEL - (2c) 53.5561.0250 SCREW, 6-40 X 1/4"...
  • Page 133 LLUSTRATED ARTS REAKDOWN Pan Motor Assembly (continued) (x2) (x2) (x4) (x4) (x4) (x4) Pulley Height Detail & Installation 0.248" Step 1. Apply one drop of Loctite 603 to motor shaft. Note: Vari-Lite recommends that this assembly be replaced as Step 2.

  • Page 134: Pan Tube Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Pan Tube Assembly 21.9664.1819.01 (TS/TI) Rev C 21.9664.1819.11 (AS/AI) Rev C 21.9664.1819.21 (TSD/TID) Rev C Refer to Figure 3-34. Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 10.9664.1851 PAN TUBE, TOP 24.9664.4895 PCB ASSY, DMX INPUT 25.9663.1921 CABLE ASSY, ARC POWER INPUT (PIGTAIL) (AS/AI ONLY) 25.9663.2015.01...
  • Page 135 LLUSTRATED ARTS REAKDOWN Pan Tube Assembly (continued) - A/AS only (x4) 7, 15 - AS/AI only - AS/AI only (x2) (x2) (x4) - A/AS only (x2) - T/TS only (On-Board IGBT Dimmer Models Only) Figure 3-34: Pan Tube Assembly 02.96 64.001 0 0 20 Octo be r 20 10...
  • Page 136 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Notes 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 137: Arc Power Input (Pigtail) Cable Assembly

    LLUSTRATED ARTS REAKDOWN Cables Arc Power Input (Pigtail) Cable Assembly 25.9663.1921 Rev M Refer to Figure 3-35. 52.6274.2316 (STRAIN RELIEF, SKINTOP FLEX TY) 4.0" 0.5" FRONTVIEW CPC 17-9 4.0" 4.0" 8.0" GRN/YEL 4.0" 40.0" .25" 0.0" 8.0" 4.0" CABLE JACKET PLUG CPC 17-9 GRN/YEL...

  • Page 138: Pan Eot Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Pan EOT Cable Assembly 25.9663.2001 Rev A Refer to Figure 3-36. 13.0" Figure 3-36: Pan EOT Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 139: Tilt Cot Cable Assembly

    LLUSTRATED ARTS REAKDOWN Tilt COT Cable Assembly 25.9663.2002 Rev A Refer to Figure 3-37. 33.0" Indicates Pin 1 Figure 3-37: Tilt COT Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 140: Ac Line Input Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL AC Line Input Cable Assembly 25.9663.2015.01 Rev C Refer to Figure 3-38. 5.0 IN AC GND (GRN / YEL) Figure 3-38: AC Line Input Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 141: Incandescent Lvs Ac Input Cable Assembly

    LLUSTRATED ARTS REAKDOWN Incandescent LVS AC Input Cable Assembly 25.9663.2816.01 Rev B Refer to Figure 3-39. 37.0" 2.0" 2.0" AC LINE AC LINE AC NEUT AC NEUT AC GND AC GND 2.0" 28.0" Figure 3-39: Incandescent LVS AC Input Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.

  • Page 142: Arc Lvs Ac Input Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Arc LVS AC Input Cable Assembly 25.9663.2816.11 Rev B Refer to Figure 3-40. 37.0" 2.0" 2.0" AC LINE AC LINE AC NEUT AC NEUT AC GND AC GND 2.0" 28.0" Figure 3-40: Arc LVS AC Input Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.

  • Page 143: Lvs Chassis Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN LVS Chassis Ground Cable Assembly 25.9663.2817 Rev B Refer to Figure 3-41 Figure 3-41: LVS Chassis Ground Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 144: Yoke To Head Ground Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Yoke to Head Ground Cable Assembly 25.9663.2019 Rev B Refer to Figure 3-42. 12.0" Figure 3-42: Yoke to Head Ground Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 145: Pan/Tilt Control Cable Assembly

    LLUSTRATED ARTS REAKDOWN Pan/Tilt Control Cable Assembly 25.9664.2020 Rev A Refer to Figure 3-43. Figure 3-43: Pan/Tilt Control Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 146: Ballast Control Link Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Ballast Control Link Cable Assembly 25.9663.2021 Rev A Refer to Figure 3-44. DRAIN PWR LVL PWR LVL DATA GND NOT ON NOT ON TO MAIN CONTROL FROM ARC POWER INPUT PCB J7 PIGTAIL DATA CONNECTOR Figure 3-44: Ballast Control Link Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.

  • Page 147: Data I/O Link Cable Assembly

    LLUSTRATED ARTS REAKDOWN Data I/O Link Cable Assembly 25.9663.2022 Rev B Refer to Figure 3-45. MAIN CONTROLLER INPUT COLOR SIGNAL SIGNAL COM IN+ BDCAST+ BLACK COM IN- BDCAST- WHITE COM OUT+ REPLY+ GREEN COM OUT- REPLY- Figure 3-45: Data I/O Link Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.

  • Page 148: Lvs Dc Output Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL LVS DC Output Cable Assembly 25.9663.2824 Rev A Refer to Figure 3-46 18.0" 2.0" 2.0" +24V +24V +24V (V1) TO VL1100 LVS DC CONTROLLER OUTPUT PCB J2 Figure 3-46: LVS DC Output Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.

  • Page 149: Incandescent Power Input Cable Assembly

    LLUSTRATED ARTS REAKDOWN Incandescent Power Input Cable Assembly 25.9663.2030 Rev A Refer to Figure 3-47. 52.6274.2316 (STRAIN RELIEF, SKINTOP FLEXTYPE PG13 BLK) 4.0" 4.0" GRN/YEL 0.6" 4.0" 1.5" 1.0" 0.0" 0.5" 44.0" 42.5" Figure 3-47: Incandescent Power Input Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only (except as noted above).

  • Page 150: Incandescent Lamp Power Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Incandescent Lamp Power Cable Assembly 25.9663.2033 Rev G Refer to Figure 3-48. 3.50" 1.25" FROM LAMP LAMP POWER SOCKET TERM BLOCK DIMMER LINE LINE DIMMER NEUT NEUT 48.0" (REF) 21.0" 24.0" 72.0" 69.0"...

  • Page 151: Arc Power To Ignitor Cable Asembly

    LLUSTRATED ARTS REAKDOWN Arc Power to Ignitor Cable Asembly 25.9663.2035 Rev C Refer to Figure 3-49. 36.0" 32.0" 2.0" 4X ORN 4X ORN 4X VIO 4X VIO FROM LAMP POWER IGNITOR TERM BLOCK INPUT Figure 3-49: Arc Power to Ignitor Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.

  • Page 152: Ignitor To Lamp Socket Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Ignitor to Lamp Socket Cable Assembly 25.9663.2036 Rev H Refer to Figure 3-50. 34.0" 1.5" 21.0" 29.0" 21.0" Figure 3-50: Ignitor to Lamp Socket Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 153: Shutter Harness Cable Assembly

    LLUSTRATED ARTS REAKDOWN Shutter Harness Cable Assembly 25.9663.2040 Rev F Refer to Figure 3-51 Figure 3-52. Figure 3-51: Shutter Harness Cabe Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 02.96 64.001 0 0 20 Octo be r 20 10...
  • Page 154 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Shutter Harness Cable Assembly (continued) Figure 3-52: Shutter Harness Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 155: Color/Gobo/Lens Harness Cable Assembly

    LLUSTRATED ARTS REAKDOWN Color/Gobo/Lens Harness Cable Assembly 25.9663.2050 Rev K Refer to Figure 3-53 Figure 3-54. PIN 1 TO CONTROLLER PCB J8 LABEL SET (FOR REF. ONLY) LINE 1 TEXT LINE 2 TEXT SNSR SHUT INDX SNSR INDX BLUE AMBR ZOOM EDGE DIMM...
  • Page 156 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Color/Gobo/Lens Cable Assembly (continued) Figure 3-54: Color/Gobo/Lens Harness Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 157: Dimmer To Lvs Cable Assembly

    LLUSTRATED ARTS REAKDOWN Dimmer to LVS Cable Assembly 25.9663.2826 Rev A Refer to Figure 3-55. Figure 3-55: Dimmer to LVS Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 02.96 64.001 0 0 20 Octo be r 20 10...

  • Page 158: Dimmer To Controller Cable Assembly

    VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Dimmer to Controller Cable Assembly 25.9663.2026 Rev 0 Refer to Figure 3-56. Figure 3-56: Dimmer to LVS Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only. Cable assemblies are shown for visual reference only. 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 159: Dimmer To Lamp Socket Cable Assembly

    LLUSTRATED ARTS REAKDOWN Dimmer to Lamp Socket Cable Assembly 25.9663.2037 Rev 0 Refer to Figure 3-57. 3.50" 1.25" DIMMER LINE LINE FROM LAMP SOCKET DIMMER NEUT DIMMER NEUT 0.75" 1.00" 21.0" 20.0" (Ref) 41.0" Figure 3-57: Dimmer to LVS Cable Assembly NOTE: Cable assemblies are sold as complete assemblies only.
  • Page 160 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Notes 20 Octo be r 20 10 02 .9 664.00 10 0...

  • Page 161: Appendix A. Technical Bulletins

    Technical Bulletins, Software Updates, support, and other information is available online at www.vari-lite.com under the "Support" link. To request access to the password-protected support areas, please contact Vari-Lite Customer Service at 1- 877-827-4548 or +1-214-647-7880 or entertainment.service@philips.com. 02.96 64.001 0 0 20 Octo be r 20 10...
  • Page 162 VARI❋LITE - VL1100 ERS L UMINAIRE ERVICE ANUAL Notes 20 Octo be r 20 10 02 .9 664.00 10 0...
  • Page 164 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA 1.877.VARI-LITE ❋ 1.214.647.7880 ❋ Fax 1.214.647.8038 www.vari-lite.com Date: 20 October 2010 / Manual Part Number: 02.9664.0010 0 © 2002-2010 Vari-Lite, A Philips Group Company. All rights reserved. Printed in the U.S.A.

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