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VARILITE DMX Power Pack C3 Dimmer Service Manual

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

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Summary of Contents for VARILITE DMX Power Pack C3 Dimmer

  • Page 1 DMX Power Pack 02.9654.0010 23 January 1998 Service Manual ® The Automated Lighting Company CONFIDENTIAL: This technical manual is confidential property of Vari-Lite, Inc.
  • Page 2 ® -DMX P OWER ERVICE ANUAL 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 ™...
  • Page 3 ® -DMX P OWER ERVICE ANUAL DMX Power Pack Service Manual List of Effective Pages Page Change Number Number Title Page thru x 1-1 thru 1-16 2-1 thru 2-14 3-1 thru 3-32 4-1 thru 4-34 5-1 thru 5-10 FO-1 Revision History BASIC 23 January, 1998 02.9654.0010...
  • Page 4 ® -DMX P OWER ERVICE ANUAL (This page intentionally blank) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 5: Table Of Contents

    ® -DMX P OWER ERVICE ANUAL Contents Chapter 1. Introduction 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 Equipment Description ..............1-7 1.2.1 DMX Power Pack ................
  • Page 6 ® -DMX P OWER ERVICE ANUAL Contents (continued) Chapter 3. Maintenance Procedures (continued) 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......
  • Page 7 ONTENTS Contents (continued) 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.
  • Page 8 ® -DMX P viii OWER ERVICE ANUAL 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.
  • Page 9 ONTENTS The Automated Lighting Company TO: Product Support Department Manager 201 Regal Row Dallas, Texas 75247 COMPANY: Vari-Lite International 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: 02.9654.0010...
  • Page 10 ® -DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 11: Chapter 1. Introduction

    Chapter 1. Introduction This chapter contains the following sections: General Information Equipment Description Principles of Operation 02.9654.0010 CONFIDENTIAL 23-Jan-98...
  • Page 12 ® - DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 13: General Information

    1. I HAPTER NTRODUCTION 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.

  • Page 14: Technical Bulletins

    ® - DMX P OWER ERVICE ANUAL 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.

  • Page 15: Safety

    1. I HAPTER NTRODUCTION 1.1.4 Safety All components of the Series 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.
  • Page 16 ® - DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 17: Equipment Description

    1. I HAPTER NTRODUCTION Equipment Description 1.2.1 DMX Power Pack APS6 MODULE 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.

  • Page 18: Front Panel Controls And Indicators

    ® - DMX P OWER ERVICE ANUAL 1.2.1.1 Front Panel Controls and Indicators The following controls and indicators are common for both APS6 module and C3 Dimmer DMX power pack versions. Name Description 12.5A FUSES Two 12.5 amp fuses for lamp power supply protection.

  • Page 19: C3 Dimmer Front Panel Jumpers

    1. I HAPTER NTRODUCTION 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 the C3 dimmer version of the DMX power pack allows you to configure for both 1000W and 1200W bulbs. Name Description *LAMP...

  • Page 20: Aps6 Module Front Panel Jumpers

    1-10 ® - DMX P OWER ERVICE ANUAL 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 module must be in this mode to adjust intensity with a controller.

  • Page 21: Rear Panel

    1-11 1. I HAPTER NTRODUCTION 1.2.1.4 Rear Panel Name Description PSOT Amber LED - Lights if power supply temperature becomes to high. Unit will switch off if temperature is too high. IPRES Green LED - Lights when output current to the lamp is present.

  • Page 22: Internal

    1-12 ® - DMX P OWER ERVICE ANUAL 1.2.1.5 Internal Name Description Toroid Choke Provides stabilized current for lamp power. Low Voltage Provides +24 volts DC for controller operation. Power Supply Controller PCB Provides a junction location for internal wire connections and DMX control for S300 luminaires.

  • Page 23: Technical Specifications

    1-13 1. I HAPTER NTRODUCTION 1.2.1.6 Technical Specifications Functional and Performance Features • Designed specifically to operate VL5, VL5B, VL5Arc, or VL6 luminaires and VLM mirror with DMX control. • Panel indicators for presence of AC power and +24VDC power. •...
  • Page 24 1-14 ® - DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 25: Principles Of Operation

    1-15 1. I HAPTER NTRODUCTION Principles of Operation 1.3.1 System Connections A typical system contains a power cable pigtail with an IEC plug for permanent installation use, DMX power pack (C3 or APS6 unit), a DMX- 512 control console, and a VL5, VL5Arc, VL6 luminaire or VLM mirror. Unit power is supplied from a 110 or 220 volt source (C3 version is 220 volt only).

  • Page 26: Internal Operation

    1-16 ® - DMX P OWER ERVICE ANUAL 1.3.2 Internal Operation AC power is supplied to the DMX power pack at the AC IN IEC connector on the front panel. Power is routed to the line filter and 24V Low Voltage power Supply (LVS). From the line filter, power is supplied to the APS6 or C3 module.

  • Page 27: Chapter 2. Installation And Operation

    Chapter 2. Installation and Operation This chapter contains the following sections: Installation/Checkout Operation Procedures for installing the DMX power pack are included in the installation section. The checkout procedure is included to ensure proper operation of the equipment after installation. Procedures for operation of the equipment under normal conditions are included in the Operating instructions section.
  • Page 28 ® -DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 29: Installation/Checkout

    2. I HAPTER NSTALLATION AND PERATION Installation/Checkout 2.1.1 Hanging Method The DMX power pack is generally hung from pipes or trusses, and suspended near the luminaire. The truss hook fits securely on any pipe with an outer diameter between one and two inches (25.40 to 50.80 mm). (The use of square pipe is not recommended.) The truss hook is clamped to the pipe or truss by turning the wing bolts, installed in two of four threaded holes in the truss hook, clockwise.

  • Page 30: Iec Power Cable

    ® -DMX P OWER ERVICE ANUAL 2.1.2 IEC Power Cables The DMX power pack receives power through a three conductor power cable with a standard U.S. IEC connector on the front panel. The line side of the power cable may be hard-wired to the power source. The following two power cables are available: •...
  • Page 31 2. I HAPTER NSTALLATION AND PERATION 2.1.2.1 Connector Lock The connector lock is used to secure the power cable to the DPP. The lock wraps around the cable connector end and is secured with a pinch screw. The lock is secured to the DPP front panel using the two IEC connector mounting screws.

  • Page 32: Installation

    ® -DMX P OWER ERVICE ANUAL 2.1.3 Installation WARNING: Do not apply power to unit until lamp and data connections are made and unit is properly configured. The DMX power pack does not contain a power circuit breaker. The unit will power up when connected to power source.
  • Page 33 2. I HAPTER NSTALLATION AND PERATION Note: The module must be removed from the chassis to configure the jumpers. Refer to APS6/C3 Module Removal and Replacement section in Chapter 3 of this manual. Step 3. Configure unit jumpers: APS6 Module (VL5Arc & VL6 Luminaires) a.
  • Page 34 ® -DMX P OWER ERVICE ANUAL Step 4. Connect to system: a. At DMX IN, connect five position XLR data cable from controller. b. If needed, at DMX THRU, connect five position XLR data cable to next device. Note: If no data is passing through unit to another DMX device, the DMX parameter dip switch TERM must be on.
  • Page 35 2. I HAPTER NSTALLATION AND PERATION Step 5. Configure DMX control console channels. a. Switch DMX control console on. b. At console, Patch address to console channels. There are four different configuration modes: • 8-Bit with reset, • 16-Bit with reset, •...
  • Page 36 ® -DMX P 2-10 OWER ERVICE ANUAL 8-Bit With Reset DMX-512 VL5/VL5B VL5Arc VLM Moving Channel Luminaire Luminaire Luminaire Mirror External Intensity Intensity Pan Hi Base Dimmer* Address Pan Low Tilt Tilt Tilt Tilt Hi Blue Blue Wheel 1 Tilt Low Amber Amber Wheel 2...
  • Page 37 2-11 2. I HAPTER NSTALLATION AND PERATION 8-Bit With Timing DMX-512 VL5/VL5B VL5Arc VLM Moving Channel Luminaire Luminaire Luminaire Mirror External Intensity Intensity Pan Hi Base Dimmer* Address Pan Low Tilt Tilt Tilt Tilt Hi Blue Blue Wheel 1 Tilt Low Amber Amber Wheel 2...
  • Page 38 ® -DMX P 2-12 OWER ERVICE ANUAL Note: For more information on DMX-512 control, refer to the “DMX Reference Guide” (02.3004.0300). This guide is available from Vari-Lite, Inc. or from our web site at www.vari-lite.com/vl/downloads/downloads.html. WARNING: DO NOT forget to position the voltage selector switch before powering up the unit.
  • Page 39 2-13 2. I HAPTER NSTALLATION AND PERATION Step 8. If in DCV mode, ignite arc lamp . a. Set last DMX channel to 99% (or 252) for three seconds and return to zero. b. To douse lamp, set last DMX channel to 66% (or 168) for three seconds and then return to zero.

  • Page 40: Operation Instructions

    ® -DMX P 2-14 OWER ERVICE ANUAL Operating Instructions The DMX power pack is available in two versions, APS6 and C3 modules. It is important to note a few differences in operating arc or incandescent lamps. 2.2.1 Controlling Arc Lamps ( VL5Arc/VL6 ) PSET Mode •...

  • Page 41: Chapter 3. Maintenance Procedures

    Chapter 3. Maintenance Procedures This chapter contains the following sections: Calibration Procedures Fault Isolation Maintenance Procedures Periodic Maintenance Refer to Series 200™ System Equipment Preparation and Inspection Manual (02.3004.0042) for periodic maintenance procedures for new and used equipment. 02.9654.0010 CONFIDENTIAL 23-Jan-98...
  • Page 42 ® - DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 43: Calibration Procedures

    3. M HAPTER AINTENANCE ROCEDURES Calibration Procedures No calibration procedure is available for the DMX power pack’s 24V power supply. The +24VDC indicator LED on the front panel will signify an operational power supply. Test and calibration procedures for the APS6 and C3 modules are included in the Series 300 Modular Rack Service Manual (02.9640.0010).
  • Page 44 ® - DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 45: Fault Isolation

    3. M HAPTER AINTENANCE ROCEDURES Fault Isolation 3.2.1 Fault Isolation Chart Assuming that all other system components, including lamp run and power cables, are functional and that proper system power has been supplied: Symptom Probable Cause Corrective Action • Loose power cable connector No power to DMX power para.

  • Page 46: Fault Isolation Procedures

    ® - DMX P OWER ERVICE ANUAL 3.2.2 Fault Isolation Procedures Assuming the following: • Lamp run and power cables are good. • Proper system power has been supplied. • Luminaire is fully operational. WARNING: Disconnect power by unplugging the power cable from outlet or front panel when working on internal components of the DMX power pack.

  • Page 47: Control Of Vl5 Luminaires

    3. M HAPTER AINTENANCE ROCEDURES 3.2.2.3 DMX Power Pack Does Not Strike VL6/VL5Arc Luminaire Lamp Step 1. Ensure that APS6 module jumper is configured in the PSET mode (400W or 625W). Refer to the Installation section in Chapter 2 of this manual. Step 2.

  • Page 48: Dmx Power Pack Determined To Be Faulty

    ® - DMX P OWER ERVICE ANUAL Step 9. If problem still persists, replace power pack. 3.2.2.5 DMX Power Pack Determined To Be Faulty Step 1. Remove power, module, and check all PCB connections. Step 2. Replace power pack LVS power supply. Refer to LVS Power Supply Removal and Replacement paragraph.

  • Page 49: Vl6 400W Lamp Very Bright Then Burns Out

    3. M HAPTER AINTENANCE ROCEDURES 3.2.2.9 VL6 400W Lamp Very Bright Then Burns Out Step 1. At APS6 module, at DCV/PSET window, check position of jumper assembly. Jumper should be installed in the 400W DCV or 400W PSET position as required. JUMPER HERE HERE...
  • Page 50 ® - DMX P 3-10 OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 51: Maintenance Procedures

    3-11 3. M HAPTER AINTENANCE ROCEDURES Maintenance Procedures C3 / APS6 Module Removal and Replacement 3.3.1 Parts: 1 EA ASSY, LPS PLATE PP C3 DIMMER (21.9654.0004) 1 EA ASSY, LPS PLATE PP APS6 (21.9654.0006) Tools: Screwdriver, Phillips #2 To remove and replace the C3/APS6 module: Step 1.

  • Page 52: C3/Aps6 Module Jumper Change

    ® - DMX P 3-12 OWER ERVICE ANUAL 3.3.2 C3/APS6 Module Jumper Change Parts: No parts required. Replacement jumper part number is 52.6399.0001. Tools: Screwdriver, Phillips #2 To module jumper location: Step 1. Remove module. Refer to C3/APS6 Module Removal and Replacement paragraph.

  • Page 53: C3/Aps6 Module Pcb/Heatsink Removal And Replacement

    3-13 3. M HAPTER AINTENANCE ROCEDURES 3.3.3 C3/APS6 Module PCB/Heatsink Removal and Replacement Parts: 1 EA ASSY, HEATSINK PP C3 DIMMER (23.9654.0005) 1 EA ASSY, HEATSINK PP APS6 MODULE (23.9654.0007) Tools: Screwdriver, Phillips #2 To remove and replace the C3/APS6 module PCB/Heatsink assembly: Step 1.

  • Page 54: Power Supply Removal And Replacement

    ® - DMX P 3-14 OWER ERVICE ANUAL 3.3.4 Power Supply Removal and Replacement Parts: 1 EA POWER SUPPLY, 110W -140W +24VDC (69.3121.0001) Tools: Screwdriver, Phillips #2 To remove and replace the power supply assembly: Step 1. Remove C3/APS6 module. Refer to C3/APS6 Module Removal and Replacement paragraph.

  • Page 55: Toroid Assembly Removal And Replacement

    3-15 3. M HAPTER AINTENANCE ROCEDURES 3.3.5 Toroid Assembly Removal and Replacement Parts: 1 EA ASSY, TOROID APS/C3 PP (23.9654.0019) Tools: Screwdriver, Phillips #2 Screwdriver, Phillips #3 Nutdriver, 7/16” To remove and replace the toroid assembly: Step 1. Remove C3/APS6 module. Refer to C3/APS6 Module Removal and Replacement paragraph.

  • Page 56: Fan Assembly Removal And Replacement

    ® - DMX P 3-16 OWER ERVICE ANUAL 3.3.6 Fan Assembly Removal and Replacement Parts: 1 EA FAN, +24V 80X80X25MM 32CFM (40.7113-0001) 1 EA RECEPT, MTA100, W/TAB, BLU, 2POS, 26AWG (52.6396.2602) 1 EA COVER, STRAIN RELIEF, 2POS, 26AWG (52.6424.0002) 2 EA CABLE TIE, SMALL, .10 X 4”...
  • Page 57 3-17 3. M HAPTER AINTENANCE ROCEDURES 8-32X9/16"PPSS SCREW GRILL 8-32KEPS NUT REMOVE CABLE TIES FANRMV RED WIRE PIN 1 TWIST WIRE 10 TIMES 11" (280mm) Figure 3-6. Fan Removal and Connector Installation 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 58: Front Panel Removal

    ® - DMX P 3-18 OWER ERVICE ANUAL 3.3.7 Front Panel Removal Parts: No parts necessary. Tools: Screwdriver, Phillips #2 Wire cutters To remove the front panel assembly: Step 1. Remove C3/APS6 module. Refer to C3/APS6 Module Removal and Replacement paragraph. Step 2.
  • Page 59 3-19 3. M HAPTER AINTENANCE ROCEDURES 6-32X7/16"PPZ LINE FILTER SCREWS (2EA.) #6 LOCK WASHERS CONTROL PCB FRONT PANEL ASSEMBLY 8-32X3/8"PFSS SCREWS (2EA.) FNTPRMV 6-32X5/16"PFSS SCREWS (4EA.) 6-32X5/16"PFSS SCREWS (2EA.) Figure 3-7. Front Panel Assembly Removal 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 60: Line Filter Removal And Replacement

    ® - DMX P 3-20 OWER ERVICE ANUAL 3.3.8 Line Filter Removal and Replacement Parts: 1. EA LINE FILTER, 8A 250VAC (67.4010.0001) Tools: Screwdriver, Phillips #2 Wrenches, 3/8”, 7/16” To remove the line filter: Step 1. Remove C3/APS6 module. Refer to C3/APS6 Module Removal and Replacement paragraph.

  • Page 61: Control Pcb Removal And Replacement

    3-21 3. M HAPTER AINTENANCE ROCEDURES 3.3.9 Control PCB Removal and Replacement Parts: 1 EA PCB ASSY, POWER PACK CONTROL (24.9654.0020) 2 EA CABLE TIE, SMALL .10 X 4” (55.2186.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Wrench, 3/8” Wire cutters To remove and replace the control PCB: Step 1.
  • Page 62 ® - DMX P 3-22 OWER ERVICE ANUAL GROUND LUG SCREWS & NUTS 2 EACH REMOVE CABLE TIES CONTROL PCB FRONT PANEL 6-32 X 7/16"PPZ SCREW & LOCK WASHER M3 X 5MM SCREW 4-40 X 1/4"PFZ CNTRLRMV SCREW Figure 3-9. Control PCB Removal CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 63: Lamp Power Supply Cable Assembly Removal And Replacement

    3-23 3. M HAPTER AINTENANCE ROCEDURES 3.3.10 Lamp Power Supply Cable Assembly Removal and Replacement Parts: 1 EA CABLE ASSY, LAMP POWER SUPPLY (25.9654.0028) 3 EA CABLE TIE, SMALL .10 X 4” (55.2186.0001) Tools: Depinning tool Screwdriver, Phillips #2 Wrench, 3/8” Wire cutters To remove and replace the lamp power supply cable assembly: Step 1.
  • Page 64 ® - DMX P 3-24 OWER ERVICE ANUAL TOROID CONNECTOR LOAD LINE REMOVE MTA AT J3 CABLE TIES LAMP POWER SUPPLY REMOVE GROUND CABLE ASSEMBLY LUMINAIRE OUTPUT Figure 3-10. Lamp Power Supply Cable Assembly Removal CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 65: Ac/Data Cable Assembly Removal And Replacement

    3-25 3. M HAPTER AINTENANCE ROCEDURES 3.3.11 AC/Data Out Cable Assembly Removal and Replacement Parts: 1 EA CABLE ASSY, AC/DATA OUT (25.9654.0025) 1 EA CABLE TIE, SMALL .10 X 4” (55.2186.0001) Tools: Depinning tool Screwdriver, Phillips #2 Wrench, 3/8” Wire cutters Pliers To remove and replace the AC/Data out cable assembly: Step 1.
  • Page 66 ® - DMX P 3-26 OWER ERVICE ANUAL Step 7. At front panel LUMINAIRE OUTPUT connector, use screwdriver and 3/8” wrench to remove four 6-32 x 7/16”PFB screws and nylon locking nuts securing connector flange to front panel. Step 8. Using pliers, unscrew 16-pos CPC connector from flange and front panel.
  • Page 67 3-27 3. M HAPTER AINTENANCE ROCEDURES 3.3.12 AC In Cable Assembly Parts: 1 EA CABLE ASSY, AC IN (25.9654.0026) 1 EA CABLE TIE, SMALL .10 X 4” (55.2186.0001) Tools: Screwdriver, Phillips #2 Wire cutters To remove and replace the AC in cable assembly: Step 1.
  • Page 68 ® - DMX P 3-28 OWER ERVICE ANUAL Step 5. Remove two ground terminals. a. At top ground screw closest to IEC, use screwdriver and 3/8” wrench to remove 6-32 x 7/16” PFB screw and nylon lock nut securing ground lug. b.

  • Page 69: Lvs Dc Out Cable Assembly Removal And Replacement

    3-29 3. M HAPTER AINTENANCE ROCEDURES 3.3.13 LVS DC Out Cable Assembly Removal and Replacement Parts: 1 EA CABLE ASSY, LVS DC OUT (25.9654.0027) 1 EA CABLE TIE, SMALL .10 X 4” (55.2186.0001) Tools: Depinning tool Screwdriver, Phillips #2 Wrench, 3/8” Wire cutters To remove and replace the LVS DC out cable assembly: Step 1.
  • Page 70 ® - DMX P 3-30 OWER ERVICE ANUAL Step 5. At control PCB, remove 3-pos MTA connector from header at J2 24V IN. Step 6. At line filter mounting plate, us e screwdriver and 3/8” wrench to remove 6-32 x 5/16” PFB screw and nylon lock nut securing appropriate ground terminal.

  • Page 71: Line Filter Ground Cable Removal And Replacement

    3-31 3. M HAPTER AINTENANCE ROCEDURES 3.3.14 Line Filter Ground Cable Assembly Removal and Replacement Parts: 1 EA CABLE ASSY, LINE FILTER GND (25.9654.0029) 1 EA CABLE TIE, SMALL .10 X 4” (55.2186.0001) Tools: Screwdriver, Phillips #2 Wrench, 3/8” Wire cutters To remove and replace the line filter ground cable assembly: Step 1.
  • Page 72 ® - DMX P 3-32 OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 73: Chapter 4. Illustrated Parts Breakdown

    Chapter 4. Illustrated Parts Breakdown This chapter contains a complete illustrated parts breakdown for the DMX power pack. All parts are identified by their Vari-Lite part number and name for the purpose of identification and ordering. This chapter is divided into the following sections: Drawing Tree: DMX Power Pack Illustrated Parts...
  • Page 74 - DMX P OWER ERVICE ANUAL ® (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...
  • Page 75 4. I HAPTER LLUSTRATED ARTS REAKDOWN Drawing Tree C3 / APS6 DMX Power Pack 4.1.1 (20.9654.001 & 20.9654.002) C3 DIMMER POWER PACK APS6 MODULE POWER PACK 20.9654.0001 20.9654.0002 APS6 MODULE LPS ASSY. C3 DIMMER LPS ASSY. 21.9654.0006 21.9654.0004 C3 DIMMER HEATSINK ASSY. APS6 MODULE HEATSINK ASSY.
  • Page 76 - DMX P OWER ERVICE ANUAL ® (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...
  • Page 77 4. I HAPTER LLUSTRATED ARTS REAKDOWN Parts Breakdown DMX Power Pack, C3 Assembly Version 4.2.1 20.9654.0001 PART NO. DESCRIPTION 21.9654.0003 1 EA ASSY, POWER PACK ENCLOSURE 21.9654.0004 1 EA ASSY, LPS PLATE PP C3 DIMMER 22.9654.0045 1 EA ASSY, HOOK W/WING BOLTS & HRDW 22.9620.0194 1 EA ASSY, LAMP SAFETY CABLE...
  • Page 78 - DMX P OWER ERVICE ANUAL ® 4.2.2 DMX Power Pack, APS6 Assembly Version 20.9654.0002 PART NO. DESCRIPTION 21.9654.0003 1 EA ASSY, POWER PACK ENCLOSURE 21.9654.0006 1 EA ASSY, LPS PLATE PP APS6 22.9654.0045 1 EA ASSY, HOOK W/WING BOLTS & HRDW 22.9620.0194 1 EA ASSY, LAMP SAFETY CABLE...

  • Page 79: Enclosure Assembly

    4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3 Enclosure Assembly 21.9654.0003 PART NO. DESCRIPTION 22.9654.0008 1 EA ASSY, FRONT PANEL - POWER PACK 22.9654.0024 1 EA ASSY, OUTER COVER - POWER PACK 53.5636.0312 11 EA SCREW, 6-32 X 5/16”PFSS BLK 53.5638.0500 6 EA SCREW, 8-32 X 1/2”PFSS BLK 53.6610.0003...

  • Page 80: Front Panel Assembly

    - DMX P OWER ERVICE ANUAL ® 4.2.4 Front Panel Assembly 22.9654.0008 PART NO. DESCRIPTION 04.9640.0374 1 EA LABEL, P.E. GROUND 10.9654.0012 1 EA PLATE, MOUNTING EMI - POWER PACK 10.9654.0015 1 EA PANEL, FRONT - POWER PACK 24.9654.0020 1 EA PCB ASSY, POWER PACK CONTROL 25.9654.0025 1 EA...
  • Page 81 4. I HAPTER LLUSTRATED ARTS REAKDOWN Front Panel Assembly (Continued) 25 15 22,23 (4 PL) (2 PL) (2 PL) (2 PL) (2 PL) (4 PL) FNTPNL (2 PL) TOP VIEW 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 82: Outer Cover Assembly

    4-10 - DMX P OWER ERVICE ANUAL ® 4.2.5 Outer Cover Assembly 22.9654.0024 PART NO. DESCRIPTION 10.9640.0002 2 EA PAD, CHOKE 10.9654.0011 1 EA COVER, OUTER - POWER PACK 23.9654.0019 1 EA ASSY, TOROID APS/C3 PP 40.7113.0001 1 EA FAN, +24V 80X80X25MM 32CFM 46.6004.0001 1 EA MOUNTING DISC, METAL 90MM DIA...

  • Page 83: C3 Dimmer Lps Plate Assembly

    4. I 4-11 HAPTER LLUSTRATED ARTS REAKDOWN 4.2.6 C3 Dimmer LPS Plate Assembly 21.9654.0004 PART NO. DESCRIPTION 04.9654.0035 1 EA LABEL, POWER PACK C3 MODULE 04.9654.0037 1 EA LABEL, POWER PACK C3 DIMMER JUMPER 10.9654.0010 1 EA PANEL, LAMP POWER SUPPLY 23.9654.0005 1 EA ASSEMBLY, HEATSINK PP C3 DIMMER...

  • Page 84: C3 Dimmer Heatsink Assembly

    4-12 - DMX P OWER ERVICE ANUAL ® 4.2.7 C3 Dimmer Heatsink Assembly 23.9654.0005 PART NO. DESCRIPTION 24.9654.0030 1 EA PCB ASSY, POWER PACK C3 DIMMER 51.5006.0002 3 EA INSULATOR, TO-247, 53-020103AC 51.5006.0005 2 EA INSULATOR, TO-220 ALUMINUM OXIDE 10.9654.0018 1 EA HEATSINK, POWER PACK 53.6522.0001...
  • Page 85 4. I 4-13 HAPTER LLUSTRATED ARTS REAKDOWN C3 Dimmer Heatsink Assembly (Continued) 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 86: Aps6 Module Lps Plate Assembly

    4-14 - DMX P OWER ERVICE ANUAL ® 4.2.8 APS6 Module LPS Plate Assembly 21.9654.0006 PART NO. DESCRIPTION 04.9654.0034 1 EA LABEL, P P APS6 MODULE 04.9654.0036 1 EA LABEL, P P JACK APS6 MODULE JUMPER 10.9654.0010 1 EA PANEL, LAMP POWER SUPPLY 23.9654.0007 1 EA ASSY, HEATSINK PP APS6 MODULE...
  • Page 87 4. I 4-15 HAPTER LLUSTRATED ARTS REAKDOWN (This page intentionally blank.) 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 88: Aps6 Module Heatsink Assembly

    4-16 - DMX P OWER ERVICE ANUAL ® 4.2.9 APS6 Module Heatsink Assembly 23.9654.0007 PART NO. DESCRIPTION 24.9654.0040 1 EA PCB ASSY, POWER PACK APS6 51.5006.0002 7 EA INSULATOR, TO-247, 53-020103AC 51.5006.0005 3 EA INSULATOR, TO-220 ALUMINUM OXIDE 10.9654.0018 2 EA HEATSINK, POWER PACK 53.6522.0001 4 EA...
  • Page 89 4. I 4-17 HAPTER LLUSTRATED ARTS REAKDOWN APS6 Module Heatsink Assembly (Continued) 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 90: Control Pcb Assembly

    4-18 - DMX P OWER ERVICE ANUAL ® 4.2.10 Control PCB Assembly 24.9654.0020 PART NO. REF. DES. DESCRIPTION 11.9654.0020 1 EA PCB, POWER PACK CONTROL 28.9654.0020 1 EA COMPONENT KIT, POWER PACK CONTROL 50.2732.0001 2 EA U9,U12 SOCKET, 32PIN DIP 52.6240.0001 1 EA HEADER, MTA FRCT LOK STRT POST 6 PIN...
  • Page 91 4. I 4-19 HAPTER LLUSTRATED ARTS REAKDOWN Control PCB Assembly (Continued) PART NO. REF. DES. DESCRIPTION 82.5329.0001 3 EA D1,D2,D6 DIODE, MBRS340T3 40V 3A SCHOTTKY SUR 82.5330.0001 1 EA DIODE, MURS320T3 200V 3A RECTIFIER SUR 82.5331.0001 8 EA Z1-Z8 DIODE, P6KE13CA TVS ZENER 13V 83.3172.0001 1 EA IC, LM78L15 REGULATOR 15V SUR MT...

  • Page 92: C3 Dimmer Pcb Assembly

    4-20 - DMX P OWER ERVICE ANUAL ® 4.2.11 C3 Dimmer PCB Assembly 24.9654.0030 PART NO. REF. DES. DESCRIPTION 11.9654.0030 1 EA PCB, POWER PACK C3 DIMMER 28.9654.0030 1 EA COMPONENT KIT, POWER PACK C3 DIMMER 51.5021.0001 1 EA HEATSINK, 577002B, TO-220, 1/4"FIN, NO TABS 52.6487.0024 1 EA...
  • Page 93 4. I 4-21 HAPTER LLUSTRATED ARTS REAKDOWN C3 Dimmer PCB Assembly (Continued) PART NO. REF. DES. DESCRIPTION 62.2027.0225 1 EA CAP, 2.2UF 35V RAD TANTATLUM 10% 62.2027.0475 9 EA C4,7,14-19,27 CAP, 4.7UF, 35V,RAD,TANTALUM, .125", 10% 62.2045.0104 7 EA C5,6,20,25,28-30 CAP, .1UF, 63V, RAD, POLYEST 62.2046.0001 1 EA CAP, .001UF, 1000V, RAD, POLYEST, .400", 5%...

  • Page 94: Aps6 Pcb Assembly

    4-22 - DMX P OWER ERVICE ANUAL ® 4.2.12 APS6 PCB Assembly 24.9654.0040 PART NO. REF. DES. DESCRIPTION 11.9654.0040 1 EA PCB, POWER PACK APS6 50.2800.0008 4 EA U3-5,8 SOCKET, 8PIN .3"DIP SCREW MACHINE IC 50.2800.0014 3 EA U6,7,9 SOCKET, 14PIN .3" DIP SCREW MACHINE IC 50.2800.0018 1 EA SOCKET, 18PIN .3"...
  • Page 95 4. I 4-23 HAPTER LLUSTRATED ARTS REAKDOWN APS6 PCB Assembly (Continued) PART NO. REF. DES. DESCRIPTION 62.2046.0001 3 EA C26,33,34 CAP, .001UF, 1000V, RAD, POLYEST, .400", 5% 62.2059.0473 1 EA CAP .47UF, 63V, RAD POLYEST .300 10% METALLIZED 62.2081.0821 4 EA C37-40 CAP, 820UF, 200V, RAD, ALUM 62.2094.0102...
  • Page 96 4-24 - DMX P OWER ERVICE ANUAL ® APS6 PCB Assembly (Continued) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 97: Toroid Assembly, Aps6/C3 Power Pack

    4. I 4-25 HAPTER LLUSTRATED ARTS REAKDOWN 4.2.13 Toroid Assembly, APS6 / C3 Power Pack 23.9654.0019 PART NO. DESCRIPTION 52.6486.0004 1 EA PLUG, 4 POS DUAL ROW FREE HANG 52.8334.0001 4 EA CONTACT, MALE 18-20 AWG REEL HCS 55.2186.0001 2 EA CABLE TIE, SMALL .10 X 4"...

  • Page 98: Ac/Data Out Cable Assembly

    4-26 - DMX P OWER ERVICE ANUAL ® 4.2.14 AC/Data Out Cable Assembly 25.9654.0025 PART NO. DESCRIPTION 52.6396.2204 1 EA RECEPT, MTA100 W/TAB RED 4 POS 52.6400.0003 1 EA PLUG, CPC 17-16 STD SEX 52.6424.0004 1 EA COVER, STRAIN RELIEF 4/POS MTA 52.6427.0012 3 EA PLUG, KEYING, CONNECTOR...

  • Page 99: Ac In Cable Assembly

    4. I 4-27 HAPTER LLUSTRATED ARTS REAKDOWN 4.2.15 AC In Cable Assembly 25.9654.0026 PART NO. DESCRIPTION 52.6434.1805 1 EA CONN, IDC, MTA156, 5POS, 18AWG 52.6436.0005 1 EA COVER, STRAIN RELIEF, 5POS, MTA156 52.6482.0001 1 EA CONN, IEC AC INLET PANEL MOUNT 52.8223.0001 2 EA TERM, RING #6 BLUE 16-14 AWG PIDG...

  • Page 100: Lamp Power Supply Cable Assembly

    4-28 - DMX P OWER ERVICE ANUAL ® 4.2.16 Lamp Power Supply Cable Assembly 25.9654.0028 PART NO. DESCRIPTION 52.6396.2206 1 EA RECEPT, MTA100 W/TAB RED 6 POS 52.6424.0006 1 EA COVER, STRAIN RELIEF/6POS MTA100 52.6484.0004 1 EA RECEPT, 24 POS DUAL ROW 5557 52.6484.0024 1 EA RECEPT, 4 POS DUAL ROW MFJR...
  • Page 101 4. I 4-29 HAPTER LLUSTRATED ARTS REAKDOWN Lamp Power Supply Cable Assembly (Continued) 22,23 14-19 20,21 11,12 02.9654.0010 CONFIDENTIAL 23-Jan-98...

  • Page 102: Dc Out Low Voltage Supply Cable Assembly

    4-30 - DMX P OWER ERVICE ANUAL ® 4.2.17 DC Out Low Voltage Supply Cable Assembly 25.9654.0027 PART NO. DESCRIPTION 52.6434.1803 1 EA CONN, CLOSED WO/TABS 18AWG 3 POS 52.6434.1813 1 EA RECEPT, MTA156 ORG 13 POS W/O TABS 52.6436.0003 1 EA COVER, STRAIN RELIEF 3/POS 52.6436.0013...

  • Page 103: Line Filter Ground Cable Assembly

    4. I 4-31 HAPTER LLUSTRATED ARTS REAKDOWN 4.2.18 Line Filter Ground Cable Assembly 25.9654.0029 PART NO. DESCRIPTION 52.8223.0001 1 EA TERM, RING #6 BLUE 16-14 AWG PIDG 52.8313.0001 1 EA RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP 73.7008.0504 4 IN WIRE, 16AWG 300V 80C GRN/YEL TUV UL1061 02.9654.0010 CONFIDENTIAL...
  • Page 104 4-32 - DMX P OWER ERVICE ANUAL ® 4.2.19 Hook Assy. W/Wing Bolts & HRDW 22.9654.0045 PART NO. DESCRIPTION 10.9654.0039 1 EA TRUSS HOOK, POWER PACK 53.6505.0002 2 EA BOLT, 3/8-16 X 1-1/2 BLK WING 53.6505.0018 4 EA BOLT, 1/4-28 X 3/4” HX HD GRD 5 ZINC PLT FULL THRD 55.6549.0001 4 EA...

  • Page 105: Hook Assy. W/Wing Bolts

    4. I 4-33 HAPTER LLUSTRATED ARTS REAKDOWN 4.2.20 Hook Assy. W/Wing Bolts 22.9654.0044 PART NO. DESCRIPTION 10.9654.0039 1 EA TRUSS HOOK, POWER PACK 53.6505.0002 2 EA BOLT, 3/8-16 X 1-1/2 BLK WING Note: This is a stand-alone assembly designed for hook and wing nut replacement only.
  • Page 106 4-34 - DMX P OWER ERVICE ANUAL ® (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 107: Chapter 5. Diagrams

    Chapter 5. Diagrams This chapter contains electrical diagrams and connector pin codes for the DMX power pack. Sections are as follows: Connector Type Identification Connector Pin Locations Wire Diagram 02-9654-0010 CONFIDENTIAL 23-Jan-98...
  • Page 108 ® - DMX P OWER ERVICE ANUAL (This page intentionally blank.) CONFIDENTIAL 02.9654.0010 23-Jan-98...

  • Page 109: Connector Type Identification

    5. D HAPTER IAGRAMS Connector Type Identification The DMX power pack contains the following connector types: 5.1.1 MTA-100 and MTA-156 MTA-100 and MTA-156 connectors are used to connect wires to PC STRAIN boards. MTA-100 connectors are smaller in size and used smaller RELIEF diameter wire than MTA-156 connectors.

  • Page 110: Molex Mini-Fit, Jr

    ® - DMX P OWER ERVICE ANUAL 5.1.3 Molex Mini-Fit, Jr.™ 5557 Molex Mini-Fit, Jr. Series connectors are used to connect internal wire harnesses. Connector pins are installed on the wires and the wires and connector pins are inserted into the Molex plugs or receptacles. Plugs and receptacles may be free (as shown) or PC board mounted.

  • Page 111: Connector Pin Locations

    5. D HAPTER IAGRAMS Connector Pin Locations 5.2.1 16 Position AC/Data Out Connector (25.9654.0025) WIRE COLOR WIRE SIZE DESCRIPTION VIOLET 18 AWG DIM LINE 1 VIOLET 18 AWG DIM LINE 2 YELLOW 22 AWG BLUE 22 AWG GREEN/YELLOW 16 AWG GROUND 1 18 AWG +24VDC...

  • Page 112: Position Mta Data Out Connector

    ® - DMX P OWER ERVICE ANUAL 5.2.2 4 Position MTA Data Out (part of 25.9654.0025) WIRE COLOR WIRE SIZE DESCRIPTION ORANGE 22 AWG BROWN 22 AWG YELLOW 22 AWG BLUE 22 AWG DETAIL SCHEMATIC 4 POS MTA AT J7 ON PCB BLU 6-1/2"...

  • Page 113: Power Supply Dc Out Mta Connectors

    5. D HAPTER IAGRAMS 5.2.4 Power Supply DC Out MTA Connectors (25.9654.0027) 13 Position MTA WIRE COLOR WIRE SIZE DESCRIPTION 18 AWG +24V 18 AWG +24V BLACK 18 AWG DC GROUND BLACK 18 AWG DC GROUND 3 Position MTA WIRE COLOR WIRE SIZE DESCRIPTION 18 AWG...
  • Page 114 ® - DMX P OWER ERVICE ANUAL 5.2.5 Lamp Power Supply, 24, 4, and 6 Position Connectors (25.9654.0028) 6 Position MTA WIRE COLOR WIRE SIZE DESCRIPTION ORANGE 22 AWG DC CONT. 22 AWG +15V DC BLACK 22 AWG DC GND WHITE 22 AWG -15V DC...
  • Page 115 5. D HAPTER IAGRAMS Lamp Power Supply, 24, 4, and 6 Position Connectors (Continued) 4 Position Molex WIRE COLOR WIRE SIZE DESCRIPTION ORANGE 18 AWG ORANGE 18 AWG YELLOW 18 AWG YELLOW 18 AWG DETAIL SCHEMATIC MODULE PWR & CNTRL. VIOLET 18AWG 10"...

  • Page 116: Ac In Mta And Iec Connectors

    5-10 ® - DMX P OWER ERVICE ANUAL 5.2.6 AC In MTA and IEC Connectors (25.9654.0026) 3 Position IEC WIRE COLOR WIRE SIZE DESCRIPTION BLACK (2 EA) 16, 18 AWG AC HI GREEN/YELLOW 16 AWG AC GROUND WHITE (2 EA) 16, 18 AWG AC LOW 5 Position MTA...
  • Page 117 FO-1 Wire Diagram 02.9654.0010 CONFIDENTIAL 23-Jan-98...

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Dmx power pack aps6 module20.9654.000120.9654.0002

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