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VARILITE VL4 Manual

Wash luminaire
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VL4 ™
Wash Luminaire
02.9628.0010
7 Oct 1997
Service Manual
®
The Automated Lighting Company
CONFIDENTIAL: This technical manual is confidential property of Vari-Lite, Inc.

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  • Page 1 VL4 ™ Wash Luminaire 02.9628.0010 7 Oct 1997 Service Manual ® The Automated Lighting Company CONFIDENTIAL: This technical manual is confidential property of Vari-Lite, Inc.
  • Page 2 201 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 ™...
  • Page 3 - VL4™ W UMINAIRE ERVICE ANUAL ITE® VL4 ™ Wash Luminaire Service Manual List of Effective Pages Page Change Number Number Title Page thru xiv 1-1 thru 1-20 2-1 thru 2-12 3-1 thru 3-108 4-1 thru 4-60 5-1 thru 5-24...
  • Page 4 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 5: Table Of Contents

    Luminaire Hanging................2-3 2.1.1.1 Distance-To-Distance Requirements ..........2-3 2.1.1.2 Clearances ..................2-4 2.1.2 Luminaire Packing................2-5 Checkout................... 2-7 2.2.1 Power-Up ..................2-7 Installing VL4 Accessories ............... 2-9 2.3.1 Installing Sound Baffles..............2-9 Lamp Optical Alignment ............... 2-11 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 6 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Contents (continued) Chapter 3. Maintenance Procedures Test Procedures ................3-3 3.1.1 Test EPROMs ..................3-3 3.1.1.1 Description................... 3-3 3.1.1.2 Thumbwheel................. 3-3 3.1.1.3 Seven-Segment Display ..............3-4 3.1.2 Reset Tests..................3-4 3.1.3 Mechanics Tests (Tests 1 Through 15) ..........3-5 3.1.3.1...
  • Page 7 ONTENTS Contents (continued) Chapter 3. Maintenance Procedures (continued) Luminaire Maintenance Procedures ..........3-33 3.3.1 Blue/Amber Bulkhead Maintenance..........3-33 3.3.1.1 Blue/Amber Bulkhead Removal and Replacement....... 3-33 3.3.1.2 Blue/Amber Bulkhead Stepper Motor Removal and Replacement............3-35 3.3.1.3 Blue/Amber Bulkhead Sensor Removal and Replacement ... 3-37 3.3.1.4 Blue/Amber Bulkhead Worm Wheel Removal and Replacement............
  • Page 8 Yoke Cables Maintenance .............. 3-103 3.3.6.1 Yoke Cables and Lamp Wire Removal and Replacement... 3-103 Chapter 4. Illustrated Parts Breakdown Drawing Tree..................4-3 4.1.1 VL4 Wash Luminaire................4-3 Parts Breakdown................4-5 4.2.1 Hooks and Covers................4-5 4.2.1.1 Hooks and Covers Assy..............4-5 4.2.2...
  • Page 9 ONTENTS Contents (continued) Chapter 4. Illustrated Parts Breakdown (continued) Parts Breakdown (continued) 4.2.3 Chassis Assembly ................4-31 4.2.3.1 Chassis Assy................4-31 4.2.3.2 Upper Enclosure................. 4-32 4.2.3.3 Card Retainer ................4-34 4.2.3.4 Input Conn. Wire Cable Assy............4-35 4.2.3.5 Transformer/Capacitor Assy ............4-36 4.2.3.6 Connectorized Transformer Assy..........
  • Page 10 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Contents (continued) Chapter 5. Wiring Diagrams (continued) 5.2.4 Connectorized Transformer Connections.......... 5-13 5.2.5 LK1 Cable..................5-14 5.2.6 Yoke “A” 38 Inch Cable..............5-15 5.2.7 Yoke “A” 38 Inch Cable (continued) ..........5-16 5.2.8 Yoke “B”...

  • Page 11: Contents (Continued)

    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 VL4 luminaire information and procedures. The following Vari-Lite technical publications are superseded by this service manual and should be discarded.
  • Page 12 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...
  • Page 13 TO: Product Support Department Manager 201 Regal Row Dallas, Texas 75247 COMPANY: Vari-Lite International FAX NUMBER: 214-630-5867 RE: Comments to VL4 Wash Luminaire Service Manual (02.9628.0010) FROM: DATE: PAGE 1 OF 1 Copy or tear this page from manual, complete, and fax...
  • Page 14 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 15: Chapter 1. Introduction

    Chapter 1. Introduction This chapter contains the following sections: General Information Equipment Description Photometric Data Location of Major Luminaire Components Principles of Operation 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 16 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 17: General Information

    About This Manual This manual describes specific information regarding description and installation of the VL4™ wash luminaire. 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.

  • Page 18: Maintenance Philosophy

    - VL4™ W UMINAIRE ERVICE ANUAL ITE® 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...

  • Page 19: Recommended Safety Practices

    Lamp Handling Due to the use of high power lamps (bulbs) in all VL4 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.
  • Page 20 • Use care when opening and closing the rear door of the VL4 luminaires. Any jarring of the rear door can undo the optical alignment of the lamp.

  • Page 21: Equipment Description

    The rear housing provides access to the lamp, through which the beam shape may be adjusted. The VL4 head and yoke assembly is mounted on an electronics chassis, which houses components for lamp power and luminaire control. The chassis contains an arc power supply (APS), voltage selector board, pan mechanism, cooling fan, and two processors for luminaire control.

  • Page 22: Dimensions And Weight

    UMINAIRE ERVICE ANUAL ITE® 1.2.1 Dimensions and Weight The VL4 luminaire weight is 38 pounds (17.24 kg). Note: Refer to Figure 2-1 in Chapter 2 for luminaire clearance and truss hook hanging dimensions. 14.0 in 356 mm 4.5 in 4.5 in...

  • Page 23: Technical Specifications

    1. I HAPTER NTRODUCTION 1.2.2 Technical Specifications 1.2.2.1 Description Light Source OSRAM HTI SE 400W metal halide arc lamp, 5000°K. Power Requirements 85 to 265 VAC, 50/60 Hz, 3 to 8A depending on the line voltage. Reflector Chemically brightened aluminum parabola. Cooling Forced air.
  • Page 24 1-10 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Focus (Pan/Tilt) Digital servo system with 320:1 speed range. • Velocity 240 degrees per second (maximum) 0.75 degrees per second (minimum) • Accuracy 0.3 degree resolution • Pan 360 degrees in 3.0 seconds •...

  • Page 25: Photometric Data

    1-11 1. I HAPTER NTRODUCTION Photometric Data The chart below represents beam specifications for the VL4 luminaire. Specifications are given for spot diffusion and flood diffusion. VL4 Wash Luminaire with 400W Metal Hallide Lamp LENS and DIFFUSION CANDELA BEAM BEAM...
  • Page 26 1-12 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 27: Location Of Major Luminaire Components

    1-13 1. I HAPTER NTRODUCTION Location of Major Luminaire Components 1.4.1 Head Components Ref. Name Description Dimmer/Filter Contains dimming iris for limiting apparent /Douser light beam brightness, magenta dichroic filters, Assembly and douser mechanism for fully obscuring light beam. Diffuser Contains two sets of five diffuser panels to Assembly obscure light beam to vary apparent focus.
  • Page 28 1-14 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Head Components (continued) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 29: Electronic Chassis Components

    1-15 1. I HAPTER NTRODUCTION 1.4.2 Electronic Chassis Components Ref. Name Description Transformer/ Provides unregulated DC power from AC input Capacitor for use by lamp power supply assembly and low Assembly voltage supply PCB assembly. Consists of connectorized transformer assembly and connectorized capacitor assembly.
  • Page 30 1-16 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Electronic Chassis Components (continued) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 31: Principles Of Operation

    1-17 1. I HAPTER NTRODUCTION Principles of Operation 1.5.1 Operation Overview Operation of the luminaire is provided by software within the luminaire. The processing functions are carried out on the universal control board (composed of the lamp control board and the interface board). The voltage selector board senses the incoming voltage and automatically configures the power supplies for either 110 or 220 VAC.

  • Page 32: Bulkhead Assemblies

    1-18 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Universal Control Board (UCB) The universal control board is a dual-processor control board. One processor is the main controller. It communicates with the console via the communications link, executes commands it receives, operates the pan and tilt servos, and issues stepper motor commands to the second processor, whose sole purpose is to control the stepper motors.

  • Page 33: Data And Power Flow Diagram

    1-19 1. I HAPTER NTRODUCTION 1.5.3 Data and Power Flow Diagram Input data and power is supplied to the luminaire via the Series 200 connector on the electronics chassis. Power is directed to the voltage select board (VSB). The VSB switches the transformer primaries for the appropriate mode.
  • Page 34 1-20 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 35: Chapter 2. Installation And Checkout

    Chapter 2. Installation and Checkout This chapter contains the following sections: Installation Checkout Installing VL4 Accessories Lamp Optical Alignment 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 36 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 37: Installation

    Installation 2.1.1 Luminaire Hanging VL4 luminaires can be hung from a truss or similar structure by one of several methods. All methods utilize hanging clamps called truss hooks. VL4 luminaires have four receptacles for hook connection. For an in-depth explanation of hanging methods, refer to Series 200 Installation and Checkout Manual (02.9622.0010).

  • Page 38: Clearances

    - VL4™ W UMINAIRE ERVICE ANUAL ITE® 2.1.1.2 Clearances Note: The VL4 luminaire requires 3-1/2 inches (8.89 cm) clearance between the chassis assemblies of adjacent luminaires. 14.0 in 356 mm 4.5 in 4.5 in 114 mm 114 mm TOP VIEW 4.75 in...

  • Page 39: Luminaire Packing

    In order to ensure that luminaires are not damaged during shipment, it is important to properly pack in the case. When packing VL4 luminaires into road cases, it is important to load them so that the air screens are in the case lengthwise. This orientation prevents the screens from being pulled loose when the luminaires are unpacked.
  • Page 40 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 41: Checkout

    2. I & C HAPTER NSTALLATION HECKOUT Checkout Use this procedure to verify proper equipment operation. 2.2.1 Power-Up Step 1. Connect luminaire to a VARI*LITE Series 200 console through an ACS rack or truss repeater. Step 2. Supply system power to luminaire. Step 3.
  • Page 42 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 43: Installing Vl4 Accessories

    For ground installations, safety cables are not required. For all uses of the sound baffles, the baffle fits over the fan opening and air filter. It is necessary to remove the air filter from VL4 luminaires before installation.
  • Page 44 2-10 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 45: Lamp Optical Alignment

    2-11 2. I & C HAPTER NSTALLATION HECKOUT Lamp Optical Alignment The proper focus of the luminaire occurs when the source of illumination (lamp) is on the optical axis of the parabolic reflector. The optical alignment can be achieved by moving the hotspot to the center of the beam using the horizontal and vertical adjustment knobs on the lamp access plate of the luminaire.
  • Page 46 2-12 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 47: Chapter 3. Maintenance Procedures

    Chapter 3. Maintenance Procedures This chapter contains the following sections: Test Procedures Luminaire Fault Isolation Luminaire 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. 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 48 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 49: Test Procedures

    Test EPROMs 3.1.1.1 Description The VL4 luminaire has the ability to use diagnostic EPROMs to aid in troubleshooting. After installation of the EPROMs on the lamp control assembly’s universal control board (refer to Test Setup paragraph), the luminaire can perform self-tests to help determine a faulty assembly. The self-tests are activated by setting the thumbwheel address to a corresponding self-test.

  • Page 50: Seven-Segment Display

    - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.1.1.3 Seven-Segment Display The seven-segment display is initially used to display the test number (in hexadecimal) for tests 1 thru 15. Error codes and results from these tests are then displayed whenever they occur. Mechanics tests, multiple function tests, and PSU test settings (tests 1 thru 15) all display their results as error codes that could be multiple during each test.

  • Page 51: Mechanics Tests (Tests 1 Through 15)

    3. M HAPTER AINTENANCE ROCEDURES 3.1.3 Mechanics Tests (Tests 1 Through 15) The mechanics tests are composed of tests for the pan and tilt mechanisms and all bulkheads in the luminaire head. The mechanics oscillate at a speed selectable by the test parameter. While the oscillations are running, software checks the operation of position encoders (pan/tilt) or sensors where they exist.

  • Page 52: Manual Tests

    3.1.4.4 Form and Function Test (Test 24) The form and function test setting displays switch status in real time hexadecimal, which for a VL4 luminaire, at present, is 9 (hex). CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 53: Data Loop-Back Test (Test 25)

    3. M HAPTER AINTENANCE ROCEDURES 3.1.4.5 Data Loop-Back Test (Test 25) The data line test requires an external link between broadcast and reply lines if the parameter setting is set to 9. On parameter setting 8, the test will loop back via board relay. A valid loop is indicated by a chasing single segment circle.

  • Page 54: Thumbwheel Test Program Bug

    - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.1.7 Thumbwheel Test Program Bug A bug exists in thumbwheel test 88. To exit thumbwheel test, the test procedure instructs you to set thumbwheel to "000." If you set any two digits to "0" and punch the third digit, you may exit the thumbwheel test, either on first punch or on second punch.

  • Page 55: Test Setup

    3. M HAPTER AINTENANCE ROCEDURES 3.1.8 Test Setup To install test EPROMs and test luminaire: Step 1. Remove luminaire from system installation. Step 2. Remove lamp control assembly. a. At right chassis air filter, while pressing down on filter, pop out top of filter from chassis and fully remove filter.

  • Page 56: Test Results Charts

    3-10 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.1.9 Test Results Charts Tables 3-2 through 3-9 contain a symptom/probable cause/corrective action troubleshooting table that isolates faults to the major subassemblies. Table 3-1 isolates a general luminaire fault to a subassembly. After using Table 3-1, use Table 3-2 to isolate further.
  • Page 57 3-11 3. M HAPTER AINTENANCE ROCEDURES Table 3-2. Mechanics Tests (continued) Test Parameter Error Codes Results Beam End stop End stop Speed 1 Speed 2 Speed 3 Speed 4 Speed 5 Speed 6 Speed 7 Speed 8 Edge End stop Sensor hit too early, motion impeded.
  • Page 58 3-12 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Table 3-2. Mechanics Tests (continued) Test Parameter Error Codes Results Intensity Speed 7 Speed 8 Color 1 End stop Sensor hit too early, motion impeded. End stop Backlash too small (0). Speed 1 Backlash too large.
  • Page 59 3-13 3. M HAPTER AINTENANCE ROCEDURES Table 3-2. Mechanics Tests (continued) Test Parameter Error Codes Results Color 3 Speed 1 Backlash too large. Indicate backlash value (half steps in hexadecimal). Speed 2 Sensor not hit, motion impeded, sensor permanently high Speed 3 Sensor permanently low.
  • Page 60 3-14 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Table 3-2. Mechanics Tests (continued) Test Parameter Error Codes Results End stop Error codes as for all mechanics other tests. unsynchro -nized End stop Speed 1 Speed 2 Speed 3 Speed 4...
  • Page 61 3-15 3. M HAPTER AINTENANCE ROCEDURES Table 3-4. Manual Tests Test Parameter Results PSU control Lamp on (latching). Scroll status of IPRES, PSOT,. HOT, and SHORT. Start (latching). Lamp on and start and intensity at 100 percent (latching). Lamp on and start and intensity at 100 percent.
  • Page 62 3-16 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Table 3-4. Manual Tests (continued) Test Parameter Results Form and Display form and function switch in function two characters of hexadecimal. Data loop- External loop-back (relay Loop-back successful = 0 (chasing) back open and link required).
  • Page 63 3-17 3. M HAPTER AINTENANCE ROCEDURES Table 3-7. General Test Brief Summary Numbers Test Display Character Selection for Error Codes Number Title Commencement Tilt Beam Edge Intensity Color 1 Color 2 Color 3 Null Null Douser All mechanics synchronized All mechanics unsynchronized PSU test PSU control EOT sensors...
  • Page 64 3-18 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Table 3-8. General Parameter Summary Pan/Tilt Encoder Para- Mechanics PSU Test Sensors Tests Loop-Back meter (1 to 11) (15) Control Test (21) (22, 23) Test End stop Lamp on Lamp on Select MSD...
  • Page 65 3-19 3. M HAPTER AINTENANCE ROCEDURES Table 3-9 General Error Codes Error for PSU Test (15) Error for Mechanics Results Associated With MSC = F Tests (1 to 11) Mechanics Error Codes Error NSC = Parameter MSC = Test Number (After Error Code) Number LDC = Error Number...
  • Page 66 3-20 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 67: Luminaire Fault Isolation

    3-21 3. M HAPTER AINTENANCE ROCEDURES Luminaire Fault Isolation 3.2.1 Luminaire Fault Isolation Chart Assuming that all other system components are working properly and that proper system power has been supplied to the luminaire: Symptom Probable Cause Corrective Action Luminaire powers up, but will not Bad UCB para.
  • Page 68 3-22 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Luminaire Fault Isolation Chart (continued) Assuming that all other system components are working properly and that proper system power has been supplied to the luminaire: Symptom Probable Cause Corrective Action Magenta filters not working Loose connection at YTB para.

  • Page 69: Luminaire Fault Isolation Procedures

    • Repeater unit is properly connected and working. • Lamp cable is good. Step 1. At VL4 lamp input connector, check for pushed in pins. Repair as needed. Ensure that CPC connector is properly connected. Step 2. Hard reset luminaire by removing and then resupplying power to unit.

  • Page 70: Luminaire Calibrates, But Will Not Come On-Line

    • Repeater unit is properly connected and working. • Lamp cable is good. Step 1. At VL4 lamp input connector, check for pushed in data pins (gold pins 2 thru 6). Repair as needed. Ensure that CPC connector is properly connected.

  • Page 71: Luminaire Has No Power

    Assuming the following: • Repeater unit is properly connected and working. • Lamp cable is good. Step 1. Inspect VL4 lamp input connector. a. Check connection to lamp run cable. Ensure good connection. b. Check condition of input connector. Replace connector or pins as needed.

  • Page 72: Lamp Will Not Start

    3-26 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.2.2.5 Lamp Will Not Start CAUTION: Do not touch glass envelope of lamp with bare fingers. Oils on fingers will deteriorate glass when heated and may cause glass to explode. Step 1.

  • Page 73: Dimmer Iris Not Working Properly

    3-27 3. M HAPTER AINTENANCE ROCEDURES d. Inspect ring washers. Ensure that plastic washers and rollers are correctly installed. Refer to Douser Leaves Removal and Replacement paragraph. e. Inspect ring. Ensure that ring is not bent, dented, or otherwise damaged. Replace as needed. Refer to Douser Leaves Removal and Replacement paragraph.

  • Page 74: Diffuser Not Working Properly

    3-28 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.2.2.8 Diffuser Not Working Properly Step 1. At yoke termination board, check connections. Ensure all connectors are properly and securely connected. Step 2. Replace UCB. Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph.

  • Page 75: 3.2.2.10 Amber Filters Not Working Properly

    3-29 3. M HAPTER AINTENANCE ROCEDURES b. Inspect spur gear. Ensure that teeth are not stripped or otherwise damaged. Replace as needed. Refer to Magenta Motor Worm Wheel and Spur Gear Removal and Replacement paragraph. c. Inspect washer/spacer stacking. Ensure that washers/spacers are in correct order.

  • Page 76: 3.2.2.11 Blue Filters Not Working Properly

    3-30 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 5. Replace motor. Refer to Blue/Amber Bulkhead Stepper Motor Removal and Replacement paragraph. Step 6. Replace sensor. Refer to Blue/Amber Bulkhead Sensor Removal and Replacement paragraph. Step 7. Replace yoke termination board. Refer to Yoke Termination Board Removal and Replacement paragraph.

  • Page 77: 3.2.2.12 Improper Tilt Response

    3-31 3. M HAPTER AINTENANCE ROCEDURES 3.2.2.12 Improper Tilt Response Step 1. At yoke termination board, ensure proper connection. a. 5-pin connector from TILT header marked YTB-P3. b. 4-pin connector from TILT header marked YTB-P4. Step 2. Replace UCB. Refer to Low Voltage Supply and Universal Control PCB Removal and Replacement paragraph.
  • Page 78 3-32 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 79: Luminaire Maintenance Procedures

    Luminaire Maintenance Procedures 3.3.1 Blue/Amber Bulkhead Maintenance 3.3.1.1 Blue/Amber Bulkhead Removal and Replacement Parts: 1 EA ASSY, BLUE/AMBER BULKHEAD (VL4) (22.4006.0001) Tools: Screwdriver, Phillips #2 Nutdriver, 5/16 inch To remove and replace blue/amber bulkhead: Step 1. Remove power to luminaire.
  • Page 80 3-34 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 4. Remove lamp assembly from head. a. At lamp access plate, turn 1/4-turn fasteners to open lamp access plate and slide out lamp assembly. CAUTION: When removing bulkhead, make sure that connectors do not get caught on yoke termination board.

  • Page 81: Blue/Amber Bulkhead Stepper Motor Removal And Replacement

    3-35 3. M HAPTER AINTENANCE ROCEDURES 3.3.1.2 Blue/Amber Bulkhead Stepper Motor Removal and Replacement Parts: 1 EA ASSY, MOTOR & MOUNT, BAB (22.9628.0240) 2 EA CABLE TIE, SMALL .10X4" (55.2186.0001) Tools: Screwdriver, #1 Phillips Screwdriver, #2 Phillips Nutdriver, 5/16 inch Versilube Superbonder 498, as needed (06.6007.0498) To remove and replace Blue/Amber Bulkhead Stepper Motor:...
  • Page 82 3-36 - VL4™ W UMINAIRE ERVICE ANUAL ITE® APPLY SUPERBONDER 498 STEPPER MOTORS AROUND BEARINGS IF LOOSE MOTOR MOUNT 1 INCH CONTINUOUS GROMMET (REFLECTOR SIDE) 4-40 KEPS NUT Figure 3-2. Blue/Amber Bulkhead Stepper Motor Removal and Replacement Step 5. Install replacement motor assembly and re-install blue/amber bulkhead by doing Steps 2 thru 4 in reverse.

  • Page 83: Blue/Amber Bulkhead Sensor Removal And Replacement

    3-37 3. M HAPTER AINTENANCE ROCEDURES 3.3.1.3 Blue/Amber Bulkhead Sensor Removal and Replacement Parts: 1 EA ASSY, MICROSWITCH WITH 24 AWG WIRES (22.1023.0003) 1 EA CONN HOUSING, MTA CLOSED END NATURAL 4PIN (52.6300.0001) 1 EA COVER, STRAIN RELIEF/4 POS MTA (52.6424.0004) 2 EA CABLE TIE, SMALL .10X4"...
  • Page 84 3-38 - VL4™ W UMINAIRE ERVICE ANUAL ITE® SENSOR 2-56 NYLON INSERT STOP LOCK NUT CABLE ANCHOR REFLECTOR BATOP Figure 3-3. Blue/Amber Bulkhead Assembly Sensor Removal and Replacement Step 4. Prepare replacement sensor. a. At replacement sensor assembly, using needle-nosed pliers, bend unused sensor lead to 45 degree angle.

  • Page 85: Blue/Amber Bulkhead Worm Wheel Removal And Replacement

    3-39 3. M HAPTER AINTENANCE ROCEDURES 3.3.1.4 Blue/Amber Bulkhead Worm Wheel Removal and Replacement Parts: 1 EA WORM WHEEL, MOLDED 48P 40T 3/16F 1/4"BOR (55.6570.0001) - Brown Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Nutdriver, 5/16 inch Diagonal cutters Wrench, Allen 1/16 inch Superbonder 498 (06.6007.0498) Versilube To remove and replace blue/amber bulkhead worm wheel:...
  • Page 86 3-40 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 4. Install replacement worm wheel and re-assemble luminaire. a. Replace worm wheel by doing Steps 2 and 3 in reverse. b. Make sure that worm wheel is aligned properly on drive shaft so that it engages worm gear in center.

  • Page 87: Diffuser Mechanism Maintenance

    AINTENANCE ROCEDURES 3.3.2 Diffuser Mechanism Maintenance 3.3.2.1 Diffuser Mechanism Removal and Replacement Parts: 1 EA ASSY, DIFFUSER MECHANISM (VL4) (22.4003.0001) Tools: Screwdriver, Phillips #2 Cutters, diagonal To remove and replace diffuser mechanism: Step 1. Remove power to luminaire. Step 2.

  • Page 88: Diffuser Sensor Removal And Replacement

    3-42 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.2.2 Diffuser Sensor Removal and Replacement Parts: 1 EA ASSY, MICROSWITCH WITH 24 AWG WIRES (22.1023.0003) 1 EA CONN HOUSING, MTA CLOSED END NATURAL 4PIN (52.6300.0001) 1 EA COVER, STRAIN RELIEF /4POS MTA (52.6424.0004)
  • Page 89 3-43 3. M HAPTER AINTENANCE ROCEDURES CAUTION: Space for nutdriver is very limited, be careful not to break diffuser panel during procedure. c. Using 1/4 inch nutdriver, remove two 3-56 nylon insert stop lock nuts that secure sensor to threaded standoffs and remove sensor.

  • Page 90: Diffuser Motor Removal And Replacement

    3-44 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.2.3 Diffuser Motor Removal and Replacement Parts: 1 EA ASSY, MOTOR W/PULLEY (DIF4) (22.5001.0000) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Cutters, diagonal To remove and replace diffuser mechanism motor: Step 1.

  • Page 91: Loose Diffuser Panel Emergency Fix

    Loctite, Superbonder 498 Protective glasses Note: This procedure is provided for use during an emergency situation. During transportation, all VL4 luminaires should be placed in pack-up cues to prevent damage to diffuser panels. To repair loose diffuser panels in an emergency situation: Step 1.

  • Page 92: Dimmer/Filter/Douser Assembly Maintenance

    ITE® 3.3.3 Dimmer/Filter/Douser Assembly Maintenance 3.3.3.1 Dimmer/Filter/Douser Assembly Removal and Replacement Parts: 1 EA ASSY, DIMMER/FILTER/DOUSER (VL4) (22.4005.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Nutdriver, 5/16 inch To remove and replace dimmer/filter/douser assembly: Step 1. Remove power to luminaire.
  • Page 93 3-47 3. M HAPTER AINTENANCE ROCEDURES 6-32x5/16"PPB SCREW 6-32 KEPS NUT Figure 3-7. Dimmer/Filter/Douser Assembly Removal and Replacement Step 5. Install bulkhead by doing Steps 2 thru 4 in reverse. 02.9628.0010 CONFIDENTIAL 7-Oct-97...

  • Page 94: Magenta Stepper Motor Removal And Replacement

    3-48 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.3.2 Magenta Stepper Motor Removal and Replacement Parts: 1 EA ASSY, MOTOR & MOUNT, DFD (22.9628.0239) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Nutdriver, 5/16 inch Versilube Note: The stepper motors currently manufactured have a larger bearing that older versions.
  • Page 95 3-49 3. M HAPTER AINTENANCE ROCEDURES Note: Magenta motor drive shaft has two bearings that secure shaft in place, one in bulkhead and one in motor mount. Bearings are not glued in place and may fall out when motor or drive shaft is removed. Step 4.

  • Page 96: Filter Sensor Removal And Replacement

    3-50 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.3.3 Filter Sensor Removal and Replacement Parts: 1 EA ASSY, MICROSWITCH WITH 24 AWG WIRES (22.1023.0003) 1 EA CONN HOUSING, MTA CLOSED END NATURAL 4 PIN (52.6300.0001) 1 EA COVER, STRAIN RELIEF, 4 POS MTA (52.6424.0004)
  • Page 97 3-51 3. M HAPTER AINTENANCE ROCEDURES Step 4. Prepare and install replacement sensor. a. At replacement sensor assembly, using needle-nosed pliers, bend unused sensor lead to 45° angle. b. Trim sensor assembly wires to 17 inches. CAUTION: To avoid poor connections, do not reuse MTA connector from removed sensor on replacement sensor.

  • Page 98: Magenta Motor Worm Wheel And Spur Gear Removal And Replacement

    3-52 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.3.4 Magenta Motor Worm Wheel and Spur Gear Removal and Replacement Parts: 1 EA WORM WHEEL, MOLDED 48P 40T 3/16F 1/4" (55.6570.0002) - White 1 EA GEAR, SPUR (10.9628.0021) Tools: Screwdrivers, Phillips #1 and #2...
  • Page 99 3-53 3. M HAPTER AINTENANCE ROCEDURES Note: Magenta motor drive shaft has two bearings that secure shaft in place, one in bulkhead and one in motor mount. Bearings are not glued in place and may fall out when motor or drive shaft is removed. Step 4.

  • Page 100: Dimmer Belt Removal And Replacement

    ERVICE ANUAL ITE® 3.3.3.5 Dimmer Belt Removal and Replacement Parts: 1 EA BELT, DFD, VL4, .0826P, 98T, .250W (10.9628.0221) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Screwdriver, slotted #2 Nutdriver, 5/16 inch To remove and replace dimmer/filter/douser assembly dimmer belt: Step 1.

  • Page 101: Dimmer Sub-Micro Switch Removal And Replacement

    3. M HAPTER AINTENANCE ROCEDURES 3.3.3.6 Dimmer Sub-Micro Switch Removal and Replacement Parts: 1 EA ASSY, SWITCH, SUB-MICRO W/WIRES (VL4 DIM) (22.1026.0002) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Nutdriver, 5/16 inch To remove and replace dimmer/filter/douser assembly sub-micro switch: Step 1.

  • Page 102: Dimmer Leaves Removal And Replacement

    ANUAL ITE® 3.3.3.7 Dimmer Leaves Removal and Replacement Parts: 1 EA ASSY, VL4 DIMMER LEAF, LFT.HAND (22.9628.0187) 1 EA ASSY, VL4 DIMMER LEAF, RT.HAND (22.9628.0188) as needed: ROLLER, DOUSER/DIMMER (10.9628.0101) WASHER, SPECIAL .010 THK X 0500 DIA (10.9628.0105) WASHER, SPECIAL .010 THK X .350 DIA (10.9628.0106) WASHER, SPECIAL, .025 THK X .350 DIA (10.9628.0109)
  • Page 103 3-57 3. M HAPTER AINTENANCE ROCEDURES 4-40X1/4" PPZ SCREW & #4 LOCK WASHER DIMMER COVER PLATE HONEYCOMB DIMMER ACTUATOR RING MOVE TAB TO THIS POSITION BEFORE DISASSEMBLY DFDVW4 Figure 3-13. Dimmer Cover Plate and Honeycomb Removal and Replacement Step 5. Remove left-hand iris leaves.
  • Page 104 3-58 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 6. Remove dimmer actuator ring. a. Remove small thin nylon washer from standoffs 5, 6, and 8. b. Remove small thick nylon washer from standoffs 1, 2, 3, and 4. c. Remove dimmer actuator ring.
  • Page 105 3-59 3. M HAPTER AINTENANCE ROCEDURES Step 8. Ensure remaining rollers and washers are still in place. Stage 4 should be as follows: DISASSEMBLY STAGE 4 = ROLLER (10.9628.0101) = SMALL THIN WASHER (10.9628.0106) = SMALL THICK WASHER (10.9628.0109) = LARGE THIN WASHER (10.9628.0105) Step 9.

  • Page 106: Dimmer/Filter/Douser Solenoid Assembly Removal And Replacement

    ERVICE ANUAL ITE® 3.3.3.8 Dimmer/Filter/Douser Solenoid Assembly Removal and Replacement Parts: 1 EA ASSY, VL4 SOLENOID (22.9628.0231) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Diagonal cutters Nutdriver, 5/16 inch Permanent ink marker To remove and replace dimmer/filter/douser solenoid assembly: Step 1.
  • Page 107 3-61 3. M HAPTER AINTENANCE ROCEDURES Step 4. Remove solenoid assembly. a. At solenoid clamp, loosen four 4-40x1/4"PPZ screws that secure clamp to solenoid mounting plate and bulkhead and slide solenoid out from under clamp. It is not necessary to remove screws that secure clamp.

  • Page 108: Douser Leaves Removal And Replacement

    3-62 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.3.9 Douser Leaves Removal and Replacement Parts: 1 EA LEAF, DOUSER (10.9628.0066) as needed: ROLLER, DOUSER/DIMMER (10.9628.0101) WASHER, SPECIAL .010 THK X .500 DIA (10.9628.0105) WASHER, SPECIAL .010 THK X .350 DIA (10.9628.0106)
  • Page 109 3-63 3. M HAPTER AINTENANCE ROCEDURES STANDOFF DOUSER RING DOUSER LEAVES LEAF NUB SLOT DFDVW5 Figure 3-15. Douser Leaves Removal and Replacement Step 5. Replace douser leaves. a. Undamaged leaves and washers may be reused. b. Starting at standoff number 1, moving counterclockwise, install douser leaves.

  • Page 110: 3.3.3.10 Douser Spring Removal And Replacement

    3-64 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.3.10 Douser Spring Removal and Replacement Parts: 1 EA SPRING, SS 4.6#/IN. EXTENSION (55.6603.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Diagonal cutters Needle-nosed pliers Nutdriver, 5/16 inch To remove and replace douser spring: Step 1.

  • Page 111: 3.3.3.11 Douser Dashpot Calibration

    3-65 3. M HAPTER AINTENANCE ROCEDURES 3.3.3.11 Douser Dashpot Calibration Tools: Screwdriver, Phillips #1 Artisan console The dashpot is a piston traveling in a glass cylinder. The adjustment screw controls the air pressure that builds up in the cylinder as the piston approaches the end of the cylinder.

  • Page 112: Miscellaneous Head Assembly Maintenance

    3-66 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.4 Miscellaneous Head Assembly Maintenance 3.3.4.1 Lamp Removal and Replacement Parts: 1 EA ASSY, VL2X LAMP SOCKET W/SERIES 30 PINS (22.2521.0001) Tools: none To remove and replace lamp: Step 1. Remove power to luminaire.

  • Page 113: Lamp Assembly Socket Removal And Replacement

    3-67 3. M HAPTER AINTENANCE ROCEDURES 3.3.4.2 Lamp Assembly Socket Removal and Replacement Parts: 1 EA ASSY, VL2X LAMP SOCKET W/SERIES 30 PINS (22.2521.0001) Tools: Screwdriver, Phillips #1 Screwdriver, slotted #1 Wrench, 1/4 inch, open end To remove and replace lamp assembly lamp socket: Step 1.
  • Page 114 3-68 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4-40X1"PPZ SCREW #4 FLAT WASHER LAMP RETAINER CLIP 4-40X5/16"PPZ SCREW LAMP WIRES CONNECTOR MOUNTNG BRACKET SERIES 30 CONNECTOR 4-40 KEPS NUT Figure 3-20. Lamp Socket Removal and Replacement Step 6. Disconnect socket wires and remove socket.

  • Page 115: Lamp Mounting Assembly Actuator Motor Removal And Replacement (Shop Only)

    3-69 3. M HAPTER AINTENANCE ROCEDURES 3.3.4.3 Lamp Mounting Assembly Actuator Motor Removal and Replacement ( Shop Only ) Parts: 1 EA MOTOR, LINEAR ACTUATOR 12V (44.5013.0001) 1 EA CONN HOUSING, MTA CLOSED END BLUE 8PIN (52.6383.0001) 1 EA COVER, STRAIN RELIEF /8POS MTA (52.6424.0008) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2...
  • Page 116 3-70 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 6. Remove actuator motor wire sleeving and safety tether (Figure 3-21). a. Using diagonal cutters, remove cable ties from ends of middle piece of rubber-coated fiberglass sleeving. b. Using diagonal cutters, remove 8-pin MTA100 connector.
  • Page 117 3-71 3. M HAPTER AINTENANCE ROCEDURES d. At linear actuator motor, remove two 6-32x1/2"PPZ screws and 6-32 KEPS nuts that secure motor to mounting plate and remove motor. Step 8. Install replacement actuator motor. a. Secure replacement linear actuator motor to mounting plate with two 6-32x1/2"PPZ screws and 6-32 KEPS nuts.

  • Page 118: Yoke Termination Board Removal And Replacement

    ERVICE ANUAL ITE® 3.3.4.4 Yoke Termination Board Removal and Replacement Parts: 1 EA PCB ASSY, VL4 YOKE CABLE TERM (YTB) (24.9628.0049) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace yoke termination board: Step 1. Remove power to luminaires.
  • Page 119 3-73 3. M HAPTER AINTENANCE ROCEDURES 6-32X5/16"PPB SCREW 26-PIN BLACK CONNECTORS LOCATED ON REAR OF PCB YTBVW1 Figure 3-22. Yoke Termination Board Removal and Replacement Step 5. Replace yoke termination board by doing Steps 2 thru 4 in reverse. Note: 26-pin connector with blue heat shrink is connected to header marked YOKE B (Blue) and 26-pin connector with yellow heat shrink is connected to header marked YOKE A (Amber).

  • Page 120: Ignitor Pcb Removal And Replacement

    ERVICE ANUAL ITE® 3.3.4.5 Ignitor PCB Removal and Replacement Parts: 1 EA PCB ASSY, VL4 IGNITOR (IGN4) (24.9628.0096) Tools: Screwdrivers, Phillips #1 and #2 To remove and replace ignitor board: Step 1. Remove power to luminaires. Step 2. Remove 12, 6-32x5/16"PPB screws that secure head covers to rails and remove both head covers (Figure 3-1).

  • Page 121: Ignitor Pcb Spark Gap Removal And Replacement (Shop Only)

    3-75 3. M HAPTER AINTENANCE ROCEDURES 3.3.4.6 Ignitor PCB Spark Gap Removal and Replacement ( Shop Only ) Parts: 1 EA SPARK GAP, 2.5KV (75.7102.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Soldering iron and solder To remove and replace ignitor board 2.5KV spark gap: Step 1.

  • Page 122: Tilt Mechanism Removal And Replacement

    UMINAIRE ERVICE ANUAL ITE® 3.3.4.7 Tilt Mechanism Removal and Replacement Parts: 1 EA ASSY, TILT MECHANISM (VL4) (22.4004.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Nutdriver, 5/16 inch Versilube To remove and replace tilt mechanism: Step 1. Remove power to luminaire.
  • Page 123 3-77 3. M HAPTER AINTENANCE ROCEDURES Step 8. Remove dimmer/filter/douser assembly from luminaire head (Figure 3-7). Step 9. Remove ignitor board (Figure 3-23). Step 10. Remove pulley side rail cover and tilt mechanism cover. a. At pulley side rail cover, remove three 6-32x5/16"PPB screws that secure pulley side rail cover to side rail and remove cover (Figure 3-24).
  • Page 124 3-78 - VL4™ W UMINAIRE ERVICE ANUAL ITE® CAUTION: Do NOT remove tilt flange (bushing). c. Remove timing belt from tilt pulley, pull tilt mechanism bushing from pulley side rail, and remove tilt mechanism (Figure 3-25). 6-32 NYLON STOP LOCK NUT...
  • Page 125 3-79 3. M HAPTER AINTENANCE ROCEDURES CAUTION: It is essential that tilt mechanism belt be adjusted correctly. Overtightening belt can cause high failure rate. Step 13. Adjust belt tension. a. Tighten belt adjustment screw and then check tension of belt (Figure 3-26). PULLEY FEED SIDE OF BELT DRIVE PULLEY...

  • Page 126: Electronics Chassis Maintenance

    ITE® 3.3.5 Electronics Chassis Maintenance 3.3.5.1 Arc Power Supply Removal and Replacement Parts: 1 EA ASSY, ARC PWR SUPPLY+ 400WATT (VL4) (21.9628.0020) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace arc power supply plus: Step 1. Remove power to luminaire.

  • Page 127: Voltage Selector Pcb Removal And Replacement

    HAPTER AINTENANCE ROCEDURES 3.3.5.2 Voltage Selector PCB Removal and Replacement Parts: 1 EA PCB ASSY, VL4 VOLTAGE SELECTOR (VSB) (24.9628.0026) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace voltage selector PCB: Step 1. Remove power to luminaire.
  • Page 128 3-82 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 4. Remove voltage selector PCB. a. At VSB, from outside of chassis, remove 4-40x5/16"PPB screw that secures PCB to chassis (Figure 3-29). 4-40X5/16"PPB SCREW VOLTAGE SELECTOR BOARD Figure 3-29. Voltage Selector PCB Removal and Replacement b.

  • Page 129: Voltage Selector Pcb Fuses Removal And Replacement

    3-83 3. M HAPTER AINTENANCE ROCEDURES 3.3.5.3 Voltage Selector PCB Fuses Removal and Replacement Parts: 1 EA FUSE, 10AMP, 250V (70.3723.0001) 1 EA FUSE, 3A, 250V, 5X20MM, GLASS (70.3723.0003) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace voltage selector PCB fuses: Step 1.

  • Page 130: Low Voltage Supply And Universal Control Pcb

    ANUAL ITE® 3.3.5.4 Low Voltage Supply and Universal Control PCB Removal and Replacement Parts: 1 EA PCB ASSEMBLY, VL4 LOW VOLTAGE SUPPLY (LVS) (24.9628.0045) 1 EA ELEC. ASSY, VL4 LAMP CTRL (UCB/IFB) (23.9628.0232) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace low voltage supply or universal control PCB: Step 1.

  • Page 131: Motherboard Removal And Replacement

    3. M HAPTER AINTENANCE ROCEDURES 3.3.5.5 Motherboard Removal and Replacement Parts: 1 EA PCB ASSY, VL4 MOTHER (MBD) (24.9628.0053) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace motherboard: Step 1. Remove power to luminaire. Step 2. Remove both air filters and chassis covers.
  • Page 132 3-86 - VL4™ W UMINAIRE ERVICE ANUAL ITE® d. While holding up luminaire head with one hand, reach under yoke bearing and disconnect black, 26-pin connector from motherboard marked YOKE A MB-P4. Connector is located next to connector marked YOKE B.

  • Page 133: Pan Drive Assembly Removal And Replacement

    HAPTER AINTENANCE ROCEDURES 3.3.5.6 Pan Drive Assembly Removal and Replacement Parts: 1 EA ASSY, PAN DRIVE (VL4) (22.4001.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Nutdriver, 3/8 inch To remove and replace pan drive assembly: Step 1. Remove power to luminaire.
  • Page 134 3-88 - VL4™ W UMINAIRE ERVICE ANUAL ITE® d. While holding up luminaire head with one hand, reach under yoke bearing and disconnect black, 26-pin connector from motherboard marked YOKE A MB-P4. Connector is located next to connector marked YOKE B.

  • Page 135: Transformer Assembly Removal And Replacement

    3. M HAPTER AINTENANCE ROCEDURES 3.3.5.7 Transformer Assembly Removal and Replacement Parts: 1 EA ASSY, CONNECTORIZED TRANSFORMER (VL4) (23.9628.0159) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 To remove and replace transformer assembly: Step 1. Remove power to luminaire. Step 2.
  • Page 136 3-90 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 4. Remove transformer assembly. a. At transformer assembly, using 3/8 inch nutdriver, remove 10-32 nylon insert stop lock nut and 10-32x2"PPB screw securing transformer to chassis bottom. b. Remove #10 flat washer from top of rubber pad, rubber pad, and second #10 flat washer from top of transformer.

  • Page 137: Mounted Capacitor Removal And Replacement

    HAPTER AINTENANCE ROCEDURES 3.3.5.8 Mounted Capacitor Removal and Replacement Parts: 1 EA ASSY, MOUNTED CAPACITOR (VL4) (23.9628.0234) Tools: Screwdriver, Phillips #1 and #2 Screwdriver, slotted #2 Cutters, diagonal To remove and replace mounted capacitor assembly: Step 1. Remove power to luminaire.
  • Page 138 3-92 - VL4™ W UMINAIRE ERVICE ANUAL ITE® d. While holding up luminaire head with one hand, reach under yoke bearing and disconnect black, 26-pin connector from motherboard marked YOKE A MB-P4. (Connector is located next to connector marked YOKE B.) e.
  • Page 139 3-93 3. M HAPTER AINTENANCE ROCEDURES Note: Capacitors are secured to chassis side with RTV. e. Using slotted screwdriver or other flat sharp instrument, carefully pry capacitor assembly from chassis side and remove from chassis. Step 8. Replace mounted capacitor assembly by doing Steps 2 thru 7 in reverse.

  • Page 140: Aps Control Pcb Resistor/Diode Removal And Replacement (Shop Only)

    3-94 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 3.3.5.9 APS Control PCB Resistor/Diode Removal and Replacement ( Shop Only ) Parts: 1 EA DIODE, FAST, MR856, 600V 3A (82.4304.0856) 1 EA DIODE, ZENER TS, 1.5KE200 200V, 5W (82.5301.0303) 1 EA DIODE, ZENER, 1N4742 12V 1W (82.5304.4742)

  • Page 141: Aps Mj10005 And Irf450 Transistor Removal And Replacement (Shop Only)

    3-95 3. M HAPTER AINTENANCE ROCEDURES 3.3.5.10 APS MJ10005 and IRF450 Transistor Removal and Replacement ( Shop Only ) Parts: 1 EA TRANSISTOR, MJ10005 NPN 400V 20A TO3 (80.1612.1005) 1 EA TRANSISTOR, IRF450 NCH500V 10A TO3 (80.1610.0450) 1 EA INSULATOR, TO-3 (51.5005.0001) Tools: Screwdriver, Phillips #2 Notes:...
  • Page 142 3-96 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 6-32X9/16"PPZ SCREW TO-3 INSULATOR IRF450 MJ10005 TRANSISTORS MUR 1550/1560 RECTIFIER HSVW Figure 3-37. APS Plus MJ10005 and IRF450 FET Removal and Replacement Step 5. Replace transistor or FET. a. At rear of replacement transistor or FET, apply new TO-3 insulator.

  • Page 143: 3.3.5.11 Input Connector Removal And Replacement

    3-97 3. M HAPTER AINTENANCE ROCEDURES 3.3.5.11 Input Connector Removal and Replacement Parts: 1 EA RECEPT, 9POS, CHASSIS MNT LAMP (52.6251.0001) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Extractor tool, pin To remove and replace input connector: Step 1. Remove power to luminaire. Step 2.
  • Page 144 3-98 - VL4™ W UMINAIRE ERVICE ANUAL ITE® d. While holding up luminaire head with one hand, reach under yoke bearing and disconnect black, 26-pin connector from motherboard marked YOKE A MB-P4. Connector is located next to connector marked YOKE B.
  • Page 145 3-99 3. M HAPTER AINTENANCE ROCEDURES Step 8. Prepare and install replacement input connector. a. At replacement receptacle, insert five 22 AWG wires and three 18 AWG wires using the following pinouts: Wire Wire Size Description 22 AWG BRDCST + 22 AWG DATA GND 22 AWG...

  • Page 146: Stuck Truss Hook And Fastener Removal And Replacement

    (Figure 3-39). This ensures that cross pins in truss hook are aligned with slots that are supposed to be in fastener. HOOK SLOT TRUSS HOOK FASTENER Figure 3-39. Proper Orientation of VL4 Truss Hook Fastener Slots CONFIDENTIAL 02.9628.0010 7-Oct-97...
  • Page 147 3-101 3. M HAPTER AINTENANCE ROCEDURES Step 3. Rock truss hook back and forth in direction parallel to corner of chassis. This allows cross pins in truss hook to bend tabs in fastener back to allow removal of hook. Push hard on truss hook to make this happen.
  • Page 148 3-102 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 7. Using center punch, punch center of two rivets that secure damaged fastener and stop to chassis. Step 8. Using #30 drill bit and drill, drill out rivets. Step 9. Remove damaged fastener and stop.

  • Page 149: Yoke Cables Maintenance

    1 EA CABLE ASSY, YOKE "A", 38" (VL4) (25.9628.0145) 1 EA CABLE ASSY, YOKE "B", 41" (VL4) (25.9628.0147) 1 EA LAMP WIRE ASSY, A & B (VL4) (25.9628.0149) Tools: Screwdriver, Phillips #1 Screwdriver, Phillips #2 Tape Cable tie, long length...
  • Page 150 3-104 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 4. Remove yoke termination PCB (Figure 3-22). Step 5. Remove lamp assembly. a. At lamp assembly, turn 1/4-turn fasteners on rear of lamp assembly and carefully slide out lamp assembly from luminaire head (Figure 3-19).
  • Page 151 3-105 3. M HAPTER AINTENANCE ROCEDURES Step 15. Remove voltage selector PCB (Figure 3-29). Step 16. Remove yoke bearing frame (Figure 3-41). a. At yoke bearing frame, remove four 6-32x5/16"PPB screws that secure frame to flanges on top of chassis. b.
  • Page 152 3-106 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Step 17. Remove yoke cable or lamp wire. a. For lamp wire replacement only, at fan mount, using 5/16 inch nutdriver, remove 6-32 KEPS nut and ring lug securing green grounding wires to fan mount.
  • Page 153 3-107 3. M HAPTER AINTENANCE ROCEDURES TURN 26-PIN CONNECTOR AND INSERT IN TILT TUBE SMALL END FIRST SPRING TILT FLANGE CABLE SIDE RAIL YOKE CABLES AND LAMP WIRE CABLVW CABLE ANCHOR Figure 3-43. Yoke Cables and Lamp Wire Removal Step 18. Install replacement yoke cable or lamp wire.
  • Page 154 3-108 - VL4™ W UMINAIRE ERVICE ANUAL ITE® d. Untape connector from cable tie. e. Maneuver yoke cable or lamp wires so that spring on cable extends equally from pan tube and tilt tube. Note: Cables should only come out of side rail approximately 1 to 1-1/2".

  • Page 155: Chapter 4. Illustrated Parts Breakdown

    Chapter 4. Illustrated Parts Breakdown This chapter contains a complete illustrated parts breakdown for the VL4 wash luminaire All parts are identified by their Vari-Lite part number and name for the purpose of identification and ordering. This chapter is divided...
  • Page 156 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 157: Drawing Tree

    20.9628.0001 ASSY, VL4 HOOKS HEAD ASSY ASSY, VL4 CHASSIS AND COVER 21.9628.0002 21.9628.0001 22.9628.0242 ASSY, REAR BULKHD ASSY, DIMMER/ PCB ASSY, VL4 LOW PCB ASSY, VL4 PCB ASSY, & BULB MTG FILTER/DOUSER VOLTAGE SUPPLY VOLTAGE SELECTOR VL4 MOTHER 22.4007.0001 22.4005.0001 24.9628.0045...
  • Page 158 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 159: Parts Breakdown

    4. I HAPTER LLUSTRATED ARTS REAKDOWN Parts Breakdown 4.2.1 Hooks and Covers Assy, VL4 Hooks and Covers 4.2.1.1 22.9628.0242 PART NO. DESCRIPTION 04.3001.0004 1 EA LAMP ID TAG, VL4 04.9628.0246 1 EA LABEL, INPUT RATING -VL4 10.9628.0128 2 EA COVER, TOP, CHASSIS 22.9620.0194...

  • Page 160: Head Assembly

    22.4005.0001 1 EA ASSY, DIMMER/FILTER/DOUSER (VL4) 22.4006.0001 1 EA ASSY, BLUE/AMBER BULKHEAD (VL4) 22.4007.0001 1 EA ASSY, REAR BULKHD & BULB MTG. (VL4) 22.9628.0125 2 EA ASSY, VL4 HEAD COVERS 53.2200.0006 4 EA NUT, 6-32 KEPS SS 53.6524.0002 16 EA SCREW, 6-32X5/16"PPB 71.2524.0002...
  • Page 161 ASSY, VL4 DIMMER LEAF, LFT-HAND 22.9628.0188 4 EA ASSY, VL4 DIMMER LEAF, RT-HAND 22.9628.0231 1 EA ASSY, VL4 SOLENOID 41.9628.0034 1 EA FILTER, CCF, 4 1/8” X 2” (VL4) 41.9628.0035 2 EA FILTER, CCF, 4 1/8” X 1 11/16” (VL4) 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 162 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Assy, Dimmer/Filter/Douser VL4 (continued) 22.4005.0001 PART NO. DESCRIPTION 44.6000.0001 1 EA MOTOR, STEPPER .9DEG 48 OHM 52.6300.0001 1 EA CONN HOUSING, MTA CLOSE END NATRL 4 PIN 52.6383.0001 1 EA CONN, HOUSING, MTA CLOSED END BLU 8 PIN 52.6424.0004...
  • Page 163 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Dimmer/Filter/Douser VL4 (continued) 22.4005.0001 PART NO. DESCRIPTION 55.6612.0003 1 EA PIN, 3/64” X 1/2” SPIRAL STAINLESS STEEL 55.6618.0001 1 EA WASHER, LOCK INT TTH 1/2”OD X 3/8” ID 55.9628.0192 4 EA SPACER, DMR COVER, .250 OD X .175 ID , .146T 73.7021.0006...
  • Page 164 GEAR, FILTER 10.9628.0107 1 EA SHAFT, EXTENSION, FILTER GEAR 41.9628.0136 2 EA FILTER, LWP, 4 1/8" X 1 11/16" (VL4) 41.9628.0137 1 EA FILTER, LWP, 4 1/8" X 2" 41.9628.0138 2 EA FILTER, SWP, 4 1/8" X 1 11/16" (VL4) 41.9628.0139...
  • Page 165 4-11 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Blue/Amber Bulkhead ( VL4 ) (continued) 22.4006.0001 PART NO. DESCRIPTION 55.6537.0001 4 EA WASHER, LOCK #4 INTERNAL TOOTH 55.6570.0001 2 EA WORM WHEEL, ULTEM 100Q 55.6612.0003 2 EA PIN, 3/64” X 1/2” SPRIAL STAINLESS STEEL 55.6689.0001...
  • Page 166 4-12 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.4 Assy, Rear Bulkhead & Bulb MTG. ( VL4 ) 22.4007.0001 PART NO. DESCRIPTION 10.9620.0240 1 EA CARRIAGE, UNIVERSAL, LAMP 10.9628.0043 1 EA PLATE, ACCESS, LAMP 10.9628.0111 1 EA BRACKET, CONNECTOR, LAMP WIRE 10.9628.0193...
  • Page 167 4-13 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Rear Bulkhead & Bulb (continued) 22.4007.0001 (2 PL) (1 PL) (2 PL) (2 PL) (1 PL) (1.5 IN) (1 PL) (4.5 IN) (4 IN) (2 PL) (2 PL) (2 PL) 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 168 4-14 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.5 Assy, Diffuser Mechanism ( VL4 ) 22.4003.0001 PART NO. DESCRIPTION 10.9628.0063 1 EA TRACK, DIFFUSER, TOP 10.9628.0064 1 EA TRACK, DIFFUSER, BOTTOM 10.9628.0075 2 EA PULLEY, IDLER 10.9628.0076 2 EA PULLEY, REDUCTION 10.9628.0099...
  • Page 169 4-15 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Diffuser Mechanism ( VL4 ) (continued) 22.4003.0001 PART NO. DESCRIPTION 55.6621.0001 2 EA WASHER, FLAT #4 ID .120 .028THK 55.6677.0002 3 EA WASHER, .360OD X .123ID X .025THK,NYLON 73.7021.0006 23 IN WIRE, 24AWG BLUE TWISTED PR.
  • Page 170 4-16 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.6 Assy, Yoke Rails & Covers ( VL4 ) 22.4002.0001 PART NO. DESCRIPTION 10.9628.0042 1 EA COVER, REAR 10.9628.0119 1 EA COVER, SIDE, CABLE 10.9628.0120 1 EA COVER, TILT MECHANISM 10.9628.0123 1 EA PLATE, STOP, PAN 10.9628.0124...
  • Page 171 4-17 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Yoke Rails & Covers ( VL4 ) (continued) 22.4002.0001 PART NO. DESCRIPTION 53.6594.0001 3 EA SCREW, 10-32X1-1/2"PPB 53.6608.0001 3 EA SCREW, 6-32X3/8"PFB 53.6612.0001 1 EA SCREW, 6-32X1/2"PPB 53.6621.0001 1 EA SCREW, 8-32X1"PPB 54.1205.0001...
  • Page 172 4-18 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Assy, Yoke Rails & Covers ( VL4 ) (continued) 22.4002.0001 (4 PL) 32 1 37 (1 PL) 10 28 (1 PL) (4 PL) (4 PL) (3 PL) 3 31 (3 PL) (2 PL)
  • Page 173 4-19 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.2.7 PCB Assy, VL4 Ignitor (IGN4) 24.9628.0096 PART NO. REF DES DESCRIPTION 11.9628.0097 1 EA PCB, VL4 IGNITOR 52.6264.0001 1 EA CONN HOUSING, 30 SERIES W/FLNGS 2POS 52.6264.0003 1 EA CONN HOUSING, 30 SERIES W/FLNGS 3POS 52.8209.0001...
  • Page 174 4-20 - VL4™ W UMINAIRE ERVICE ANUAL ITE® PCB Assy, VL4 Ignitor (IGN4) (continued) 24.9628.0096 (2 PL) (2 PL) CONFIDENTIAL 02.9628.0010 7-Oct-97...
  • Page 175 Assy, Connectorized Fan 22.9628.0177 PART NO. DESCRIPTION 10.9628.0127 1 EA MOUNT, FAN 40.7108.0001 1 EA FAN, SNGLE INLET BLOWER AC 110V (VL4) 52.6231.0001 1 EA PLUG HOUSING, MNLOK PLUG 3POS 52.8258.0001 3 EA CONTACT PIN, 20-14AWG MNLOK (LOOSE) 53.2001.0001 4 EA NUT, 10-32, KEPS ZINC PLATED 53.6549.0001...
  • Page 176 4-22 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.9 Assy, Tilt Mechanism ( VL4 ) 22.4004.0001 PART NO. DESCRIPTION 10.9620.0005 1 EA WHEEL, WORM, REDUCTION, PAN/TILT 10.9620.0107 1 EA MOUNT, MOTOR, PAN/TILT 10.9620.0270 1 EA SEAL, ENCODER 10.9620.0293 1 EA PAD, ANTI-BACKLASH, PTA 10.9628.0116...
  • Page 177 4-23 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Tilt Mechanism ( VL4 ) (continued) 22.4004.0001 33 (3 PL) (1 PL) 24 (1 PL) (1 PL) 7 (2 PL) 24 (1 PL) 22 (4 PL) 30 (1 EA) 30 (1 EA)
  • Page 178 4-24 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.10 Assy, Pan Drive ( VL4 ) 22.4001.0001 PART NO. DESCRIPTION 10.9620.0005 1 EA WHEEL, WORM, REDUCTION, PAN/TILT 10.9620.0101 1 EA SPACER, ADJUSTMENT, BACKLASH 10.9620.0105 1 EA PLATE/MOUNT, BEARING/Encoder, PAN & TILT 10.9620.0107...
  • Page 179 4-25 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, Pan Drive ( VL4 ) (continued) 22.4001.0001 PART NO. DESCRIPTION 55.2197.0001 2 IN HEAT SHRINK 3/8” BLACK 55.6592.0001 1 EA CABLE TIE, MEDIUM 10 X 8” 55.6602.0001 1 EA GROMMET, 1/4"0 THRU/3/8"HOLE 1/8"PLATE 55.6618.0001...
  • Page 180 4-26 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.11 PCB Assy, VL4 Yoke Cable Term (YTB) 24.9628.0049 PART NO. DESCRIPTION 11.9628.0050 1 EA PCB, VL4 YOKE CABLE TERMINATION 52.6259.0001 1 EA HEADER, MTA FRCT LOK STRT POST 5PIN 52.6284.0001 8 EA HEADER, MTA FRCT LOK STRT POST 4PIN 52.6296.0001...

  • Page 181: Parts Breakdown (Continued)

    4-27 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.2.12 Assy, VL4 Yoke Bearing Frame 22.9628.0057 PART NO. DESCRIPTION 10.9628.0057 1 EA FRAME, BEARING, YOKE 10.9628.0094 1 EA GUIDE, CARD, INSIDE 10.9628.0168 2 EA GUIDE, CARD, MODIFIED PCG-3, LVS 53.6506.0001 2 EA BEARING, TORQUE TUBE,2.6250OD X 2.0620ID...
  • Page 182 4-28 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.2.13 Cable Assy, Yoke “A” 38 Inch ( VL4 ) 25.9628.0145 PART NO. DESCRIPTION 52.6226.0001 2 EA COVER, BACK MT 26POS 30-26AWG 52.6226.0002 2 EA COVER, EJECT STYLE MT 26POS 26-22AWG 52.6228.0001...
  • Page 183 4-29 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.2.14 Cable Assy, Yoke “B” 41 Inch ( VL4 ) 25.9628.0147 PART NO. DESCRIPTION 52.6226.0001 2 EA COVER, BACK MT 26POS 30-26AWG 52.6226.0002 2 EA COVER, EJECT STYLE MT 26POS 26-22AWG 52.6228.0001 2 EA CONN HOUSING, MT RECEPT 26POS 55.2182.0001...
  • Page 184 HEAT SHRINK, ADHESIVE 1/4" BLACK 55.6698.0001 1 EA GROMMET, 3/16"IDx3/4"ODx3/8"THKx1/8"GRV 55.9628.0174 1 EA SPRING, LAMP WIRE, 24" (VL4) 73.7046.0002 80 IN WIRE, 24AWG STRND GREEN 73.7084.0000 40 IN WIRE, 24AWG BLK 5COND W/BINDER 73.7084.0002 40 IN WIRE, 24AWG RED 5COND W/BINDER CONFIDENTIAL 02.9628.0010...

  • Page 185: Chassis Assembly

    ELEC.ASSY, VL4 LAMP CTRL (UCB/IFB) 24.9628.0026 1 EA PCB ASSY, VL4 VOLTAGE SELECTOR (VSB) 24.9628.0045 1 EA PCB ASSY, VL4 LOW VOLTAGE SUPPLY (LVS) 24.9628.0053 1 EA PCB ASSY, VL4 MOTHER (MBD) 25.9628.0152 1 EA CABLE ASSY, MB-VSB (LK 1) VL4 53.6520.0001...

  • Page 186: Card Retainer

    HANDLE. SPRING LOADED, 180*SWING AL. 22.9628.0171 1 EA ASSY, CARD RETAINER 23.9628.0005 1 EA ASSY, TRANSFORMER/CAPACITOR (VL4) 25.9628.0150 1 EA CABLE ASSY, INPUT CONN. WIRE (VL4) 40.7101.0001 2 EA FILTER, AIR (200S) 53.2001.0001 1 EA NUT, 10-32, KEPS ZINC PLATED 53.2002.0001 5 EA NUT, 6-32 KEP ZINC PLATED 53.2003.0001...
  • Page 187 4-33 4. I HAPTER LLUSTRATED ARTS REAKDOWN Assy, VL4 Upper Enclosure (continued) 22.4000.0056 (2 PL) (4 PL) (1 PL) (4 PL) 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 188 4-34 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.3 Assy, Card Retainer 22.9628.0171 PART NO. DESCRIPTION 10.9628.0170 1 EA PLUNGER, CARD RETAINER 10.9628.0184 1 EA PAD, CARD RETAINER 22.9628.0169 1 EA CARD RETAINER 53.2001.0003 1 EA NUT, 10-32 NYLON INSERT 53.6514.0001...
  • Page 189 4-35 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.4 Cable Assy, Input Conn. Wire ( VL4 ) 25.9628.0150 PART NO. DESCRIPTION 52.6231.0001 1 EA PLUG HOUSING, MNLOK PLUG 3POS 52.6251.0001 1 EA RECEPT, 9POS CHASSIS MNT LAMP 52.6270.0001 1 EA CONN HOUSING, MTA CLOSED END RED 5PIN 52.6424.0005...
  • Page 190 4-36 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.5 Assy, Transformer/Capacitor ( VL4 ) 23.9628.0005 PART NO. DESCRIPTION 23.9628.0159 1 EA ASSY, CONNECTORIZED TRANSFORMER (VL4) 23.9628.0234 1 EA ASSY, MOUNTED CAPACITOR (VL4) 52.8217.0001 1 EA TERM, DUPLEX .250 NON. INS 82.4303.2506...
  • Page 191 4-37 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.6 Assy, Connectorized Transformer ( VL4 ) 23.9628.0159 PART NO. DESCRIPTION 52.6319.0001 1 EA PLUG HOUSING, MNLOK 4POS 52.8244.0002 5 EA FASTON RECEPT FLAG,.250 16-14AWG (LOOSE) 52.8258.0001 4 EA CONTACT PIN, 20-14AWG MNLOK (LOOSE) 68.4518.0004...
  • Page 192 4-38 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.7 Assy, Mounted Capacitor ( VL4 ) 23.9628.0234 PART NO. DESCRIPTION 10.9628.0122 1 EA BRACKET, MOUNTING, CAPACITOR 25.9628.0156 1 EA CABLE ASSY, XFRMR & CAPACITOR (VL4) 55.2114.0001 6 EA WASHER, LCK INT TTH #10 55.6564.0001...
  • Page 193 4-39 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.8 Cable Assy, Transformer & Capacitor ( VL4 ) 25.9628.0156 PART NO. DESCRIPTION 52.6319.0001 1 EA PLUG HOUSING, MNLOK 4POS 52.8256.0001 4 EA CONTACT SCKT, 20AWG TIN MNLOK (LOOSE) 52.8244.0002 4 EA FASTON RECEPT FLAG,.250 16-14AWG (LOOSE) 52.8232.0001...
  • Page 194 4-40 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.9 PCB Assy, VL4 Voltage Selector (VSB) 24.9628.0026 PART NO. REF DES DESCRIPTION 11.9628.0027 1 EA PCB, VL4 VOLTAGE SELECTOR 52.6362.0001 2 EA CONN HOUSING, 30 SERIES RED 52.8247.0002 2 EA CRIMP CONTACT, S30 TIN (LOOSE) 53.2003.0001...
  • Page 195 4-41 4. I HAPTER LLUSTRATED ARTS REAKDOWN PCB Assy, VL4 Voltage Selector (VSB) (continued) 24.9628.0026 PART NO. REF DES DESCRIPTION 62.2098.0337 1 EA CAP, 330UF, 63V,RAD,ALUMNUM, .300", 20% 63.2001.0001 2 EA VR1, 2 VARIS, MET. OX,250V, 100A, RAD 70.3725.0001 8 EA...
  • Page 196 4-42 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.10 PCB Assy, VL4 Low Voltage Supply (LVS) 24.9628.0045 PART NO. REF DES DESCRIPTION 10.9628.0074 1 EA HEATSINK, LOW VOLT SUPPLY 11.9628.0046 1 EA PCB, VL4 LOW VOLTAGE SUPPLY 50.2708.0001 1 EA SOCKET, 8PIN DIP 51.5001.0001...
  • Page 197 4-43 4. I HAPTER LLUSTRATED ARTS REAKDOWN PCB Assy, VL4 Low Voltage Supply (LVS) (continued) 24.9628.0045 PART NO. REF DES DESCRIPTION 82.4307.4002 8 EA D5.12 DIODE, RECTIFIER, 1N4002 100V 1A 82.4309.5401 4 EA D1.4 DIODE, RECTIFIER, 1N5401 100V 3A 83.3103.0001...
  • Page 198 4.2.3.11 PCB Assy, Mother (MBD) 24.9628.0053 PART NO. DESCRIPTION 10.9628.0164 1 EA COVER, FOOT, CHASSIS 11.9628.0054 1 EA PCB, VL4 MOTHER BOARD 52.6247.0001 3 EA CONN, EURO 64POS SCKT TYPE C 52.6259.0001 1 EA HEADER, MTA FRCT LOK STRT POST 5PIN 52.6296.0001 1 EA HEADER, MTA FRCT LOK STRT POST 8PIN 52.6357.0001...
  • Page 199 4-45 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.12 Cable Assy, MB-VSB (LK 1) VL4 25.9628.0152 PART NO. DESCRIPTION 52.6372.0012 2 EA CONN HOUSING, MTA CLOSED END RED 12POS 52.8291.0001 4 EA KEYING PLUG, MTA 73.7080.0001 8 IN CBL, 22AWG 10COND TWSTD/UNJCKT 02.9628.0010...
  • Page 200 4-46 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.13 Elec. Assy, VL4 Lamp Control (UCB/IFB) 23.9628.0232 PART NO. DESCRIPTION 10.9628.0190 1 EA BRACKET, HANDLE, UCB 24.9628.0073 1 EA PCB ASSY, VL4 UNIVERSAL CONTROL (UCB) 24.9628.0082 1 EA PCB ASSY, VL4 INTERFACE (IFB) 53.2004.0001...
  • Page 201 4-47 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.14 PCB Assy, VL4 Universal Control (UCB) 24.9628.0073 PART NO. REF DES DESCRIPTION 11.9628.0070 1 EA PCB, UNIVERSAL CONTROL BOARD (UCB) 50.2714.0003 1 EA XLD1 SOCKET, 14PIN RT ANGLE 90DEG 52.6246.0002 1 EA CONN, 64PIN TYPE C RT W/MFBL PIN 52.6422.0096 1 EA...
  • Page 202 4-48 - VL4™ W UMINAIRE ERVICE ANUAL ITE® PCB Assy, VL4 Universal Control (UCB) (continued) 24.9628.0073 PART NO. REF DES DESCRIPTION 80.2513.0005 1 EA TRANSISTOR, MPSA05 NPN 60V 500MA TO92 82.4306.4001 1 EA DIODE, RECTIFIER, 1N4001 50V 1A 82.4310.5817 1 EA DIODE, RECTIFIER, 1N5817 20V 1A 82.4312.0105...
  • Page 203 4-49 4. I HAPTER LLUSTRATED ARTS REAKDOWN PCB Assy, VL4 Universal Control (UCB) (continued) 24.9628.0073 PART NO. REF DES DESCRIPTION 87.7101.0002 2 EA U25, 26 IC, 27C256.2 32KX8 U/V EPROM 87.7111.0001 1 EA IC, R68561AP MULTI.PROTOCOL COMM.CTRLR 87.7129.0002 1 EA IC, LOGIC, PGM:VL4UCB/B U39 87.7129.0003...
  • Page 204 4-50 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.15 PCB Assy, VL4 Interface (IFB) 24.9628.0082 PART NO. REF DES DESCRIPTION 11.9628.0083 1 EA PCB, VL4 INTERFACE 52.6246.0002 1 EA CONN,64PIN TYPE C RT W/MFBL PIN 52.6423.0096 1 EA CONN, EURO 96POS TYPE R 50.2708.0001...
  • Page 205 4-51 4. I HAPTER LLUSTRATED ARTS REAKDOWN PCB Assy, VL4 Interface (IFB) (continued) 24.9628.0082 PART NO. REF DES DESCRIPTION 84.4140.0001 1 EA IC, 74HC244 OCTAL TRISTATE BUFFER 84.4141.0001 5 EA U1, 30.33 IC, 74HC273 OCTAL D FLIP FLOP 84.4143.0001 1 EA IC, 74HC4040 12.STAGE BINARY COUNTER...
  • Page 206 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.16 Assy, Arc Power Supply +400Watt (APS+) 21.9628.0020 PART NO. DESCRIPTION 23.9628.0029 1 EA ASSY, APS+ CHASSIS (VL4) 23.9628.0031 1 EA ASSY, APS+ HEATSINK (VL4) 53.6616.0001 4 EA SCREW, 6-32X3/4"PPZ CONFIDENTIAL 02.9628.0010 7-Oct-97...
  • Page 207 4-53 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.17 Assy, APS+ Chassis ( VL4 ) 23.9628.0029 PART NO. DESCRIPTION 10.9620.0157 2 EA PAD, CHOKE, APS 10.9628.0030 1 EA CHASSIS, APS+ 10.9628.0206 1 EA PAD, INSULATOR, APS+ 10.9628.0229 2 EA INSULATOR, CHASSIS SIDE, APS+ 11.9620.0163...
  • Page 208 4-54 - VL4™ W UMINAIRE ERVICE ANUAL ITE® Assy, APS+ Chassis ( VL4 ) (continued) 23.9628.0029 16 17 13 (4") (7") (7") (4") (4") (3") CONFIDENTIAL 02.9628.0010 7-Oct-97...
  • Page 209 4-55 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.18 Assy, APS+ Heatsink ( VL4 ) 23.9628.0031 PART NO. DESCRIPTION 10.9628.0032 1 EA HEATSINK, APS 21.9628.0197 1 EA ASSY, APS+ CNTRL/CURRENT SENSE 51.5005.0001 5 EA INSULATOR, TO-3 51.5006.0001 1 EA INSULATOR, TO-220 53.6613.0001...
  • Page 210 4-56 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.19 Assy, APS+ Control/Current Sense 21.9628.0197 PART NO. DESCRIPTION 24.9628.0023 1 EA PCB ASSY, APS+ CONTROL (VL4) 24.9628.0197 1 EA PCB ASSY, APS+ CURRENT SENSE CONFIDENTIAL 02.9628.0010 7-Oct-97...
  • Page 211 4-57 4. I HAPTER LLUSTRATED ARTS REAKDOWN 4.2.3.20 PCB Assy, APS+ Control ( VL4 ) 24.9628.0023 PART NO. REF DES DESCRIPTION 11.9628.0024 1 EA PCB, APS + CONTROL BOARD 50.2108.0001 3 EA XU3, 4, 5 SOCKET, IC PRECI.DIP 8 PIN 50.2110.0002...
  • Page 212 4-58 - VL4™ W UMINAIRE ERVICE ANUAL ITE® PCB Assy, APS+ Control ( VL4 ) (continued) 24.9628.0023 PART NO. REF DES DESCRIPTION 60.1425.1003 1 EA RES, 1/4W 5% 100 OHMS CF 60.1425.5603 2 EA R13, 37 RES, 1/4W 5% 560 OHM CF 60.1426.1003...
  • Page 213 4-59 4. I HAPTER LLUSTRATED ARTS REAKDOWN PCB Assy, APS+ Control ( VL4 ) (continued) 24.9628.0023 24,25,26 27, 28, 29, 30, 31, 32 14, 16 3,18,19 14, 16 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 214 4-60 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4.2.3.21 PCB Assy, APS+ Current Sense 24.9628.0197 PART NO. REF DES DESCRIPTION 10.9628.0241 1 EA HEAT SINK, CURRENT SENSING RESISTOR 11.9628.0198 1 EA PCB, APS+ CURRENT SENSE 73.7088.0001 9 IN WIRE, 26AWG TW.PR BLU/WHT SOLID,TINNED 52.6373.0003...

  • Page 215: Chapter 5. Wiring Diagrams

    Chapter 5. Wiring Diagrams This chapter contains electrical diagrams, connector pin codes, and schematics for the VL4 luminaire. Sections are as follows: Connector Type Identification Connector Pin Diagrams Schematics and Wiring Diagrams 02.9628.0010 CONFIDENTIAL 7-Oct-97...
  • Page 216 - VL4™ W UMINAIRE ERVICE ANUAL ITE® (This page intentionally blank.) CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 217: Connector Type Identification

    CON_MTA 5.1.2 CPC connectors are used to connect luminaire wiring to external cables. The VL4 luminaire input panel uses one, nine position CPC connector (receptacle type). Contact pins are installed on the wires CONTACT and the wires and contact pins are inserted into the CPC connector.

  • Page 218: Mate-N-Lok

    Connector pins are installed on the wires and the wires and connector pins are inserted into the Mate-N-Lok plugs or receptacles. Plugs and receptacles may be free (as shown) or PC board mounted. Although a three position connector is shown, the VL4 luminaire uses three and POS. 1 POS. 1 four position connectors.

  • Page 219: Connector Pin Diagrams

    5. W HAPTER IRING IAGRAMS Connector Pin Diagrams 5.2.1 Yoke Termination PCB Connections 5.2.1.1 Blue/Amber Bulkhead 8-Pos MTA Blue Stepper Motor Pos. Wire Wire Size Description 22 AWG +20V 22 AWG +20V 22 AWG MO1A 22 AWG MO1B 22 AWG MO1C 22 AWG MO1D...

  • Page 220: Dimmer/Magenta/Douser Bulkhead

    - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4-Pos MTA Blue Contact Switch Pos. Wire Wire Size Description 22 AWG +15V 22 AWG SENS1 4-Pos MTA Amber Contact Switch Pos. Wire Wire Size Description 22 AWG +15V 22 AWG SENS2 4-POS MTA CONN.
  • Page 221 5. W HAPTER IRING IAGRAMS 8-Pos MTA Dimmer Stepper Motor Pos. Wire Wire Size Description 22 AWG +20V 22 AWG +20V 22 AWG MO4A 22 AWG MO4B 22 AWG MO4C 22 AWG MO4D STEPPER MOTOR 8-POS MTA CONN. 48 OHM OPEN- OPEN- 4-Pos MTA Magenta Contact Switch...

  • Page 222: Diffuser Assembly

    - VL4™ W UMINAIRE ERVICE ANUAL ITE® 4-Pos MTA Douser Soleniod Pos. Wire Wire Size Description 22 AWG 22 AWG 22 AWG DOUSER A 22 AWG DOUSER B 4-POS MTA CONN. SOLENOID ASSY 5.2.1.3 Diffuser Assembly 8-Pos MTA Diffuser Stepper Motor Pos.

  • Page 223: Rear Bulkhead And Bulb

    5. W HAPTER IRING IAGRAMS 4-Pos MTA Diffuser Contact Switch Pos. Wire Wire Size Description 22 AWG +15V 22 AWG SENS5 4-POS MTA CONN. CONTACT SWITCH HEAT SHRINK OPEN- OPEN- TWISTED PR 5.2.1.4 Rear Bulkhead and Bulb Note: The linear actuator motor used in this assembly is manufactured by two different manufacturers.

  • Page 224: Tilt Motor Connections

    5-10 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 5.2.1.5 Tilt Motor Connections 5 & 4-Pos MTA-100’s Pos. Wire Wire Size Description 22 AWG TILT ENC-B 22 AWG TILT ENC-A 22 AWG 22 AWG 22 AWG TILT TACH- 22 AWG TILT V+...

  • Page 225: Input Connector Wire Cable

    5-11 5. W HAPTER IRING IAGRAMS VL4 Input Connector Wire Cable 5.2.2 (25.9628.0150) 9-Pos CPC Receptacle Pos. Wire Wire Size Description 22 AWG BROADCAST + 22 AWG SIGNAL GND. 22 AWG BROADCAST - 22 AWG REPLY - 22 AWG REPLY +...

  • Page 226: Transformer/Capacitor Lk3 Cable

    5-12 - VL4™ W UMINAIRE ERVICE ANUAL ITE® VL4 Transformer/Capacitor LK3 Cable 5.2.3 (25.9628.0156) 1/4 Inch Faston Term. Wire Wire Size Description 16 AWG +10V 16 AWG +30V 16 AWG -30V 16 AWG Ring Terminals Term. Wire Wire Size Description...

  • Page 227: Connectorized Transformer Connections

    5-13 5. W HAPTER IRING IAGRAMS VL4 Connectorized Transformer Connections 5.2.4 (23.9628.0159) 1/4 Inch Faston Term. Wire Jacket Wire Size Description 16 AWG Y1 (+/-30V) 16 AWG Y1 (+/-30V) 16 AWG C.T. GND 16 AWG Y1 (+/-30V) 16 AWG Y1 (+/-30V) 4-Pos MATE-N-LOK Plug Pos.
  • Page 228 5-14 - VL4™ W UMINAIRE ERVICE ANUAL ITE® VL4 LK1 Cable (25.9628.0152) 5.2.5 Two 10-Pos MTA Connectors Pos. Wire Wire Size Description 22 AWG START 22 AWG EARTH GND. 22 AWG I PRESENT 22 AWG -15V 22 AWG SHORT 22 AWG...

  • Page 229: Yoke "A" 38 Inch Cable

    5-15 5. W HAPTER IRING IAGRAMS 5.2.6 Yoke “A” 38 Inch Cable (25.9628.0145) 26-Pos MT Connector (Side A) Pos. Wire Wire Size Description 24 AWG EARTH GND 24 AWG TILT ENC-A 24 AWG TILT TACH + 24 AWG TILT V+ 24 AWG EARTH GND 24 AWG...

  • Page 230: Yoke "A" 38 Inch Cable (Continued)

    5-16 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 5.2.7 Yoke “A” 38 Inch Cable (continued) (25.9628.0145) 26-POS MT CONNECTOR (SIDE A) BLK 24 AWG TO P1 ON YTB BRN 24 AWG RED 24 AWG ORG 24 AWG YEL 24 AWG...

  • Page 231: Yoke "B" 41 Inch Cable

    5-17 5. W HAPTER IRING IAGRAMS 5.2.8 Yoke “B” 41 Inch Cable (25.9628.0147) 26-Pos Connector (Side A) Pos. Wire Wire Size Description 24 AWG +20V 24 AWG +20V 24 AWG MO 3A 24 AWG MO 3B 24 AWG SENS3 24 AWG MO 4A 24 AWG MO 4B...

  • Page 232: Yoke "B" 41 Inch Cable (Continued)

    5-18 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 5.2.9 Yoke “B” 41 Inch Cable (continued) (25.9628.0147) 26-POS MT CONNECTOR (SIDE A) BLK 24 AWG TO P2 ON YTB BRN 24 AWG RED 24 AWG ORG 24 AWG YEL 24 AWG...

  • Page 233: Lamp Wire A & B Assembly

    5-19 5. W HAPTER IRING IAGRAMS VL4 Lamp Wire A & B Assembly 5.2.10 (25.9628.0149) 26-Pos Connector (Side A) Pos. Wire Wire Size Description 24 AWG 5COND 24 AWG 5COND R.T. 24 AWG EARTH GND RED 2-POS S30 CONN. RED 2-POS S30 CONN.

  • Page 234: Pan Motor Connections

    5-20 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 5.2.12 Pan Motor Connections (22.4001.0001) 8-Pos MTA-100 Pos. Wire Wire Size Description 22 AWG PAN ENC-A 22 AWG PAN ENC-B 22 AWG 22 AWG 22 AWG PAN TACH+ 22 AWG PAN TACH-...

  • Page 235: Schematics And Wiring Diagrams

    5-21 5. W HAPTER IRING IAGRAMS Schematics and Wiring Diagrams 5.3.1 LVS Transformer Schematic 02.9628.0010 CONFIDENTIAL 7-Oct-97...

  • Page 236: Ina117 Emulator Board Schematic

    5-22 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 5.3.2 INA117 Emulator Board Schematic CONFIDENTIAL 02.9628.0010 7-Oct-97...

  • Page 237: Ignitor Board Schematic

    5-23 5. W HAPTER IRING IAGRAMS 5.3.3 Ignitor Board Schematic 02.9628.0010 CONFIDENTIAL 7-Oct-97...

  • Page 238: Yoke Termination Board Schematic

    5-24 - VL4™ W UMINAIRE ERVICE ANUAL ITE® 5.3.4 Yoke Termination Board Schematic CONFIDENTIAL 02.9628.0010 7-Oct-97...

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