ColorSource Fresnel V (Max) Complete Repair Guide

Steps to repair

The steps below detail how to strip down a ColorSouce Fresnel V or V Max to the casing. It is recommended to read through the whole document before starting, so as not to unnecessarily dismantle a part that can stay intact.

For any questions or concerns, please contact your local ETC tech service department.

Disconnect mains power before servicing, and wait at least 1 hour before starting work so that capacitors can discharge. Only proceed if you feel comfortable doing so

Look out for the following symbols in the repair guide

⚠️Warnings - these give advice on avoiding damage to (other) components
ℹ️Information - these give helpful tips to save you work or get into tricky places
🛠️Reassembly notes - tips when following the instructions in reverse to reassembly the device

Opening the casing

1.Lay the fixture flat on an antistatic mat, top side up, yoke at the back (the yoke can stay on for most repairs)
2. Unscrew the antenna from its mount and place to one side Remove the 4 screws holding the top casing to the bottom casing
3. Carefully lift the top casing vertically upwards to remove The top case remains attached to the electronics by an earth bond. For most repairs, it's easier to remove this by removing the T20 screw

Removing the electronics assembly

4. To work on any part of the electronics, you will need to lift out the entire electronics assembly, shown here in the red box. This will give you access to the PSU, control card, array, UI PCB, NFC PCB and antenna mount assembly Move the zoom lens to the front before continuing
5. Using a long-shaft driver, remove the two T20 screws either side of the beam tube, which hold the electronics assembly to the bottom casing
6. Gently remove the connectors from the motor, and the zoom sensor PCB
7. Using a long-shaft driver, remove only this screw which holds the electronics assembly to the base (just behind the motor). Other similar screws can stay in place (T10)
8. Lift the entire assembly vertically upwards. Some wiggling may be required, but it is no longer attached to the bottom casing at this point. Do not pull too far, because the fan wires are still attached
9. For most repairs, it will be easier to disconnect the fan wires. Using the Wago 2059 tool or paperclip, gently remove each wire from the connector by poking into the hole in the connector 🛠 Tool not required for re-insertion, just push the wire in

Replacing the PSU

10. While the PSU is now exposed, replacing it requires removal of the 4 screws on the other side of the metalwork. To access these, you need to detach the metal plate the PSU is sitting on.  First, remove the black plastic blocker plate and set aside
11. Remove the screws from the power input connector ⚠️ This is not strictly necessary, but helps access one of the screws in the next step
12. Remove the 4 screws holding the plate in place. One is under the rear lugs of the line filter, and it may be easier to remove the line filter first
13. The metalwork with the PSU can now flip out as shown. Remove the PSU by removing the 4 screws circled here

Accessing the control card and UI

Note: you do not need to do steps 10-13 to access the control card

14. Remove the 2 nuts holding the control card tray to the rear cover, and the screw holding the control card tray to the heatsink/array assembly
15. Unplug the LED harnesses from the control card Lift the array/heatsink assembly away and place to one side
16. If replacing the control card, remove the DC power wires from the input connector, by pressing down gently on each tab with a small screwdriver ⚠️ This connector is fragile, apply only the amount of force necessary to remove the wire 🛠️ Apply very gentle pressure to the tabs when re-inserting the wires. Observe correct polarity (red/+ is marked with a small triangle)
17. Remove the 4 screws holding the DMX ports to the rear plate, and pull off the zoom knob cap
18. Remove the 2 screws holding the UI PCB to the rear plate. If replacing the control card, gently disconnect the NFC ribbon cable from the control card - release the ribbon cable by moving the plastic bar in the direction of the orange arrows, moving both sides at the same time
19. Gently separate the control card from the rear plate, paying attention to the zoom knob and the push tab on the female XLR If replacing the UI PCB, pull this vertically out of its socket and push the new one in. Begin reassembly from this step backwards
20. If replacing the NFC PCB, very gently pry this up with a spudger ⚠️ The PCB is held directly to the rear sticker using the sticker's own glue. Do not puncture the sticker with the spudger! Some delicate leverage may be required to release the PCB 🛠️ Reassembly note: Push the new PCB down into the glue. Pay attention to the ribbon cable orientation as pictured (note blue sides)
21. If replacing the control card, remove the 6 screws and disconnect the two zoom harnesses. Gently lift up the antenna connector from the PCB 🛠️ Remember to move the UI PCB to the new control card, if not replacing. You will reconnect 2x LED harnesses, 2x zoom harnesses, DC power, antenna, and NFC ribbon cable at various stages of the reassembly process

Accessing the array PCB and optics elements

 

22. Remove the 2 central screws holding the large plastic lens holder to the beam tube ℹ️ You can access the screw on the PSU side without removing the PSU, using a long-shafted screwdriver Loosen, but do not fully remove, the 2 screws holding the 2 halves of the lens holder together One side shown in picture, the opposite side is the same
23. Gently pull the lens holder apart so you can lift it, and the glass lens, off the beam tube, being careful to bring the glass lens with you and not let it drop
24. Remove the 2 screws holding the beam tube to the PCB/heatsink. Lift off the beam tube and set aside Remove the 4 screws holding the array PCB to the heatsink. Gently lift up the array and remove the thermal pad 🛠️ Use the new thermal pad that came with your control card & array kit. Make sure it's perfectly flat and free of wrinkles before screwing down the new array PCB

 Replacing the fan

Note: steps 10 - 24 are not required for this

25. Remove the 4 nuts holding the fan down. Replace the fan, respecting the orientation as shown. See step 9 for the correct fan pinout on the control card

Replacing the zoom sensor PCB and zoom motor and belt

Note: steps 10 - 25 are not required for this

26. To replace the zoom sensor PCB, remove the single T20 screw
27. To remove the zoom belt, compress the tension spring and remove the belt from the wheel
28. With the belt removed, to replace the zoom motor, remove the 2 screws from the bracket. Swap the new motor onto the bracket by removing the 3 black screws