1. DL manuals
  2. Vari Lite
  3. Lighting Equipment
  4. VL2500 Spot Luminaire
  5. Service Manual

Vari Lite VL2500 Spot Luminaire Service Manual

Other manuals for VL2500 Spot Luminaire: Service Manual, Service Manual, Service Manual, Service Manual
Manual is about: Spot Luminaire

Summary of VL2500 Spot Luminaire

  • Page 2

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual ii 18-november-2004 02.9676.0020 0 vari❋lite ® , artisan ® , mini-artisan ® , mini-artisan ® 2, artisan ® plus, mini-artisan ® plus, vl2 ® , and vld ® are trademarks owned by genlyte thomas group llc. And are registered in the united states and ...

  • Page 3

    F oreword 02.9676.0020 0 18-november-2004 iii how to obtain warranty service a copy of the vari-lite, inc. Limited warranty was included in the shipping package for this vari❋lite® product. To obtain warranty service, please contact customer service at 1-877-vari-lite (1-877-827-4548) or customerser...

  • Page 4: Compliance Notice

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual iv 18-november-2004 02.9676.0020 0 compliance notice this equipment has been tested and found to comply with the limits for a class a digital device pursuant to part 15 of fcc rules. These limits are designed to provide reasonable protection aga...

  • Page 5

    F oreword 02.9676.0020 0 18-november-2004 v products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: general information pertaining to protection against elec- trical shock, fire, exposure to exc...

  • Page 6

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual vi 18-november-2004 02.9676.0020 0 warning: instructions for continued protection against excessive exposure to uv radiation 1. Many vari❋lite® luminaires use an hid type lamp that produces uv radiation. Do not look directly at lamp. 2. It is ha...

  • Page 7: Sicherheitshinweise

    F oreword 02.9676.0020 0 18-november-2004 vii sicherheitshinweise es ist äußerst wichtig, alle sicherheitsinformationen und -hinweise in diesem handbuch und dem beiliegenden informationsmaterial zu lesen, bevor sie die hierin beschriebenen produkte installieren bzw. Bedienen. Halten sie bei der inst...

  • Page 8

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual viii 18-november-2004 02.9676.0020 0 2. Es ist gefährlich, leuchten ohne linsen oder blenden zu bedienen. Blenden, linsen oder ultraviolettschirme müssen ausgetauscht werden, sofern deren schutzwirkung durch sichtbare beschädigung (z. B. Sprünge...

  • Page 9: Notes De Sécurité

    F oreword 02.9676.0020 0 18-november-2004 ix notes de sécurité avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire tous les renseignements et toutes les directives de sécurité contenues dans ce guide ainsi que toute d...

  • Page 10

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual x 18-november-2004 02.9676.0020 0 avertissement: directives pour se protÉger contre une exposition excessive aux rayons uv 1. Plusieurs luminaires vari❋lite® utilisent une lampe de type hid qui produit des rayons uv. Ne pas fixer son regard sur ...

  • Page 11: Aviso Sobre Seguridad

    F oreword 02.9676.0020 0 18-november-2004 xi aviso sobre seguridad es muy importante leer toda la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avis...

  • Page 12

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual xii 18-november-2004 02.9676.0020 0 advertencia: instrucciones para protecciÓn continua contra la exposiciÓn excesiva de radiaciÓn ultra violeta 1. Muchas luminarias vari❋lite® usan un tipo de lámpara hid que produce radiación uv. No mire direct...

  • Page 15

    T able of c ontents 02.9676.0020 0 18-november-2004 xv table of contents about this manual ...................................................................................................... 1 additional documentation...................................................................................

  • Page 16

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual xvi 18-november-2004 02.9676.0020 0 pan encoder replacement ................................................................................... 38 pan eot sensor replacement ..........................................................................

  • Page 17

    T able of c ontents 02.9676.0020 0 18-november-2004 xvii ballast module (arc power supply) assembly....................................................... 103 700w ballast board pcb assembly ....................................................................... 107 700w ballast rider board pcb asse...

  • Page 18

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual xviii 18-november-2004 02.9676.0020 0 notes.

  • Page 19

    I ntroduction 02.9676.0020 0 18-november-2004 1 introduction about this manual this manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the vl2500™ spot luminaire. The manual is intended for use by vari-lite personnel and by vari-lite’s custome...

  • Page 20

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 18-november-2004 02.9676.0020 0 customer service our goal at vari-lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the f...

  • Page 21: Hapter

    02.9676.0020 0 18-november-2004 3 ser v ice c hapter 1. Description this chapter provides an overview of luminaire features, components and operations. • features • major components • principles of operation.

  • Page 22

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 4 18-november-2004 02.9676.0020 0 features overview the vl2500 spot luminaire comes complete with all of the qualities and options designers love from the original series 2000™ fixtures. It is still small, lightweight, and fast with a 700- watt ...

  • Page 23

    D escription : m ajor c omponents 1 02.9676.0020 0 18-november-2004 5 major components external components the following illustration shows major luminaire components and controls. Head assembly upper enclosure truss hook bracket assembly assembly ac input cable yoke assembly removable lamp assembly...

  • Page 24: Address

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 18-november-2004 02.9676.0020 0 menu display the menu system is a programmable set of commands used to configure, address, operate, and test the luminaire. The menu system is controlled at the menu display available at the enclosure input pane...

  • Page 25

    D escription : m ajor c omponents 1 02.9676.0020 0 18-november-2004 7 head components the following illustration shows the major sub-assemblies which are located in the luminaire head assembly. (yoke and enclosure not shown for clarity.) removable cover dual blade cym color/dimmer bulkhead fan assem...

  • Page 26

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 18-november-2004 02.9676.0020 0 yoke components the following illustration shows the major sub-assemblies which are located in the luminaire yoke assembly. (head and enclosure not shown for clarity.) ignitor pcb tilt motor relay main control b...

  • Page 27

    D escription : m ajor c omponents 1 02.9676.0020 0 18-november-2004 9 enclosure components the following illustration shows the major sub-assemblies which are located in the luminaire enclosure assembly. (yoke and head assembly not shown for clarity.) enclosure top covers 150w +24v/6.3a input panel ...

  • Page 28

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 10 18-november-2004 02.9676.0020 0 principles of operation power and data flow diagram the following diagram shows how data and power are distributed in the luminaire. Pan motor tilt motor dat a i/o dmx input pcb main control pcb input power gob...

  • Page 29: Hapter

    02.9676.0020 0 18-november-2004 11 ser v ice c hapter 2. Maintenance this chapter contains test, service, and standard maintenance procedures. • testing • troubleshooting • maintenance procedures.

  • Page 30

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 12 18-november-2004 02.9676.0020 0 testing testing software testing software is available in all series 2000 luminaires through the luminaire’s menu system test function. For information on specific tests and test parameters, see the vl2500 spot...

  • Page 31

    M aintenance : t roubleshooting 2 02.9676.0020 0 18-november-2004 13 troubleshooting error messages if a problem occurs during luminaire calibration, at the end of the calibration sequence the menu display will cycle through any applicable error message(s), one at a time until the end of the list is...

  • Page 32

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 14 18-november-2004 02.9676.0020 0 troubleshooting guide if a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “troubleshooting” on page 13 for more information. The chart below provides possible causes ...

  • Page 33

    M aintenance : t roubleshooting 2 02.9676.0020 0 18-november-2004 15 pan no sens luminaire will not pan or hits against stop pan sensor not found eot flag attached to large pulley is not engaging the eot sensor... - ensure flag is attached to the large pulley. - ensure that flag passes through the s...

  • Page 34

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 16 18-november-2004 02.9676.0020 0 maintenance procedures head assembly this section provides removal and replacement procedures for components found in the luminaire head assembly. Lamp replacement parts: 71.2528.0700 lamp, 700 watt short arc w...

  • Page 35

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 17 note: wear cotton gloves or other covering while servicing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If required, use alcohol and cotton cloth to thoro...

  • Page 36

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 18 18-november-2004 02.9676.0020 0 color/gobo/iris bulkhead replacement parts: 21.9676.0120 assy, color/gobo/iris bulkhead procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. At head cover, turn captive screws and r...

  • Page 37

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 19 standard gobo/color filter replacement warning: users of vari ❋ lite luminaires should not install or use metal gobos. The use of metal gobos in any vari ❋ lite product may damage the luminaire and could void the luminaire’...

  • Page 38

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 20 18-november-2004 02.9676.0020 0 strobe bulkhead replacement parts: 22.9676.0016 assy, strobe bulkhead procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. At head cover, turn two captive screws and remove cover. (...

  • Page 39

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 21 front assembly removal this procedure may be necessary to gain access to other components. To remove and re-install front assembly: step 1. Disconnect luminaire ac input cable from power source. Step 2. At head cover, turn ...

  • Page 40

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 22 18-november-2004 02.9676.0020 0 step 8. Re-install front assembly by performing steps 2–6 in reverse order. While re-installing, first connect wiring harness connection to rotating gobo wheel sensor and route wires through corner between head...

  • Page 41

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 23 caution: always use anti-static precautions when working with pcbs. Step 4. Remove rotating gobo sensor pcb by removing two 4-40 × 1/4” pfz screws. Figure 2-8 . Figure 2-8: rotating gobo sensor pcb replacement step 5. Insta...

  • Page 42

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 24 18-november-2004 02.9676.0020 0 edge motor assembly replacement parts: 21.9667.0310 assy, motor edge to remove and replace edge motor assembly: step 1. Disconnect luminaire ac input cable from power source. Step 2. Remove front assembly. Refe...

  • Page 43

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 25 caution: ensure you place pliers on standoff on edge motor shaft. Do not hold edge motor shaft with pliers, or shaft may be damaged. Step 5. At lens barrel assembly, use pliers to hold standoff on edge motor shaft, and usin...

  • Page 44

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 26 18-november-2004 02.9676.0020 0 step 7. Remove two 4-40 × 3/8" ppz screws and nuts which secure motor to bulkhead and remove motor assembly. Figure 2-12 . Figure 2-12: edge motor assembly replacement step 8. Install replacement assembly by pe...

  • Page 45

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 27 lens barrel assembly replacement parts: 21.9673.0306 assy, lens barrel to remove and replace lens barrel assembly: step 1. Disconnect luminaire ac input cable from power source. Step 2. At head cover, turn two captive screw...

  • Page 46

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 28 18-november-2004 02.9676.0020 0 step 7. At front of optical support ring, remove three 8-32 × 3/8" ppz screws. Figure 2-14 . Figure 2-14: lens barrel assembly replacement step 8. At each side of optical support ring, remove two 6-32 × 1/2" pp...

  • Page 47

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 29 yoke assembly this section provides removal and replacement procedures for components found in the luminaire yoke assembly. Tilt motor assembly replacement parts: 22.9676.0610 assy, tilt motor to replace tilt motor assembly...

  • Page 48

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 30 18-november-2004 02.9676.0020 0 main control board (mcb) pcb replacement parts: 24.9676.0730 mcb pcb assy to replace an mcb pcb: step 1. Disconnect luminaire ac input cable from power source. Step 2. At board-side leg, remove yoke leg cover b...

  • Page 49

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 31 ignitor pcb replacement parts: 24.9661.1126 pcb assy, solid state ignitor to replace ignitor pcb: step 1. Disconnect luminaire ac input cable from power source. Figure 2-17: ignitor pcb replacement step 2. At each yoke leg,...

  • Page 50

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 32 18-november-2004 02.9676.0020 0 step 8. Remove two 1/4" hex standoffs from ignitor pcb by removing one 6-32 × 5/ 16" ppz screw and #6 lock washer. Install in same place on new ignitor pcb. Figure 2-18 . Figure 2-18: ignitor pcb standoff remov...

  • Page 51

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 33 enclosure assembly this section provides removal and replacement procedures for components found in the luminaire enclosure assembly. Removing enclosure covers to gain access to enclosure components, it will be necessary to...

  • Page 52

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 34 18-november-2004 02.9676.0020 0 caution: be careful not to damage lens during next step. Step 4. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any surface. Figure 2-20 . Figure 2-20: laying luminaire ...

  • Page 53

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 35 ballast module assembly replacement parts: 23.9671.1250 assy, ballast module, 700w arc to remove the ballast module assembly: step 1. Disconnect luminaire ac input cable from power source. Step 2. At enclosure, remove balla...

  • Page 54

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 36 18-november-2004 02.9676.0020 0 step 6. At ballast, disconnect wiring: step 7. Pull wires through ferrite core. Figure 2-22 . Figure 2-22: ballast module assembly replacement step 8. At bottom of enclosure, remove three 8-32 × 3/8" pfz screws...

  • Page 55

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 37 pan motor assembly replacement parts: 21.9678.0864 pan motor assy procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. Carefully lay luminaire on its side to have access to bottom of enclosure. ...

  • Page 56

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 38 18-november-2004 02.9676.0020 0 pan encoder replacement parts: 24.9678.0729 pan motor assy procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. Carefully lay luminaire on its side to have access to bottom of enclo...

  • Page 57

    M aintenance : m aintenance p rocedures 2 02.9676.0020 0 18-november-2004 39 pan eot sensor replacement parts: 86.7002.0003 pan eot sensor assy repair procedure step 1. Disconnect luminaire ac input cable from power source. Step 2. Carefully lay luminaire on its side. Step 3. At enclosure assembly, ...

  • Page 58

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 40 18-november-2004 02.9676.0020 0 power supply (lvs) replacement parts: 69.3176.0200 power supply (lvs) assy repair procedure step 1. Disconnect luminaire ac input cable from power source. Step 2. At enclosure, remove top cover at power supply ...

  • Page 59: Hapter

    02.9676.0020 0 18-november-2004 41 ser v ice c hapter 3. Illustrated parts breakdown this chapter contains illustrated parts breakdowns for assemblies in the vl2500 spot luminaire. • drawing tree • top assembly • yoke • enclosure • cables.

  • Page 60

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 42 18-november-2004 02.9676.0020 0 drawing tree vl2500 series spot luminaire continued on the next page vl2500 generic luminaire 21.9676.0010 rev d upper enclosure assembly 21.9676.0800 rev e yoke assembly 21.9676.0600 rev c tilt motor assembly ...

  • Page 61

    I llustrated p arts b reakdown : d rawing t ree 3 02.9676.0020 0 18-november-2004 43 drawing tree (continued) continued from previous page upper enclosure assembly 21.9676.0800 rev e vl2500 spot luminaire (continued) back cap assembly 22.9676.0115 rev 0 tilt plate ground cable assembly 25.9667.0413 ...

  • Page 62

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 44 18-november-2004 02.9676.0020 0 top assembly vl2500 included items kit 28.9676.0001 rev a refer to figure 3-1 . Figure 3-1: included items kit no. Item qty. Um. Description 1 02.8001.0001 1 ea product support sheet, vari-lite customer service...

  • Page 63

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 45 vl2500 spot luminaire 20.9676.0001 rev e refer to figure 3-2 . No. Item qty. Um. Description 1 10.9638.0052 1 ea dam, air, vl6 2 10.9676.0632 2 ea cover, yoke thermoform 3 16.9676.0004.01 2 ea label location, vl2500...

  • Page 64

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 46 18-november-2004 02.9676.0020 0 figure 3-2: top assembly 11 6 14 19 (x6) 8 7 24 22 5 18 (x4) 22 (x2) 13 15 19 (x4) 25 (x4) 12 1 9 4 21 (x2) 10 17 (x8) 2 (x2) 16 20 23.

  • Page 65

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 47 vl2500 generic luminaire 21.9676.0010 rev d refer to figure 3-3 . No. Item qty. Um. Description 1 10.9628.0211 1 ea stablizer, pan/tilt 2 10.9667.0617 1 ea heatshield, vl2000 3 10.9676.0083 1 ea baffle, rear casting...

  • Page 66

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 48 18-november-2004 02.9676.0020 0 vl2500 generic luminaire (continued) figure 3-3: vl2500 generic luminaire assembly 18 23 13 (x2) 3 6 19 11 (x8) 20 (x8) 5 17 (x2) 4 17 (x2) 7 10 (x5) 21 (x5) 14 (x5) 15 (x4) 8 17 (x4) 16 (x4) 24 (x4) 9 2 12 1 2...

  • Page 67

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 49 front assembly 21.9676.0006 rev b refer to figure 3-4 . No. Item qty. Um. Description 1 10.9638.0151 1 ea stabilizer, motor 2 10.9660.0129 1 ea shaft stop, rotating gobo wheel 3 10.9660.0130 1 ea shaft, rotating gob...

  • Page 68

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 50 18-november-2004 02.9676.0020 0 figure 3-4: front assembly 32 55.3301.0006 4 ea washer, #6 flat ss 33 55.3301.0010 2 ea washer, #10 flat 34 55.6506.0009 1 ea spacer, 1/2" rnd .125" lg .375" id shaft 35 55.6603.0001 1 ea spring, ss 4.6#/in. Ex...

  • Page 69

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 51 lens barrel assembly 21.9673.0306 rev a refer to figure 3-5 . No. Item qty. Um. Description 1 10.9673.0232 1 ea molding, barrel main right 2 10.9660.0237 1 ea shaft, zoom 3 10.9660.0267 1 ea bronze sleeve bearing, f...

  • Page 70

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 52 18-november-2004 02.9676.0020 0 lens barrel assembly (continued) figure 3-5: lens barrel assembly 4 16 3 16 12 18 14 (2 pl) 18 12 2 9 11 5 8 7 6 10 (2 pl) 19 1 10 (4 pl) 17 (4 pl) 13 (4 pl) 21.

  • Page 71

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 53 sub-barrel group 2 assembly 21.9673.0229 rev a refer to figure 3-6 . Figure 3-6: sub-barrel group 2 assembly no. Item qty. Um. Description 1 10.9673.0223 1 ea molding barrel, right zoom 2 10.9660.0246 1 ea spacer, g...

  • Page 72

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 54 18-november-2004 02.9676.0020 0 motor zoom optics assembly 21.9667.0311 rev a refer to figure 3-7 . Figure 3-7: motor zoom optics assembly no. Item qty. Um. Description 1 44.9660.0262 1 ea motor, 1" linear - zoom 2 52.6579.0005 1 ea conn, 5ci...

  • Page 73

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 55 rotating gobo wheel assembly 21.9660.0105 rev c refer to figure 3-8 . No. Item qty. Um. Description 1 10.9660.0110 4 ea gobo carrier, spinning gobo wheel 2 10.9660.0112 1 ea sun gear, spinning gobo wheel 3 10.9660.0...

  • Page 74

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 56 18-november-2004 02.9676.0020 0 rotating gobo wheel assembly (continued) figure 3-8: rotating gobo wheel assembly 12 10 13 11 1 7 2 3 4 5 6 8 9 10 11 12 13 14 16 (2 pl) 15 (6 pl) 15 (3 pl) 14 standard gobos 17 (4 pl - used with 10,11,12, & 13...

  • Page 75

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 57 sensor rotating gobo pcb assembly 24.9667.0321 rev a refer to figure 3-9 . Figure 3-9: sensor rotating gobo pcb assembly no. Item qty. Um. Description 1 11.9667.0321 1 ea pcb, sensor rotating gobo 2 52.6447.0004 1 e...

  • Page 76

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 58 18-november-2004 02.9676.0020 0 top cover assembly 22.9676.0008 rev g refer to figure 3-10 . Figure 3-10: top cover assembly no. Item qty. Um. Description 1 06.6018.0011 0.041 ft velcro, double hook, 2" black adh backed 2 07.5049.0001 1 ea la...

  • Page 77

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 59 bottom cover assembly 22.9676.0011 rev c refer to figure 3-11 . Figure 3-11: bottom cover assembly no. Item qty. Um. Description 1 10.9676.0012 1 ea cover, bottom vl2500 2 53.2008.0008 3 ea nut, #8 push 3 53.6545.00...

  • Page 78

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 60 18-november-2004 02.9676.0020 0 reflector assembly 22.9676.0018 rev a refer to figure 3-12 . Figure 3-12: reflector assembly no. Item qty. Um. Description 1 10.9678.0647 4 ea clamp, mounting, reflector 2 22.9660.0338 1 ea assy, disconnect lam...

  • Page 79

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 61 back cap assembly 22.9676.0115 rev 0 refer to figure 3-13 . No. Item qty. Um. Description 1 10.9638.0117 3 ea knob, knurled, vl6 back cap/lamp assy. 2 10.9638.0128 1 ea bracket, ignitor cable 3 10.9638.0130 1 ea spr...

  • Page 80

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 62 18-november-2004 02.9676.0020 0 back cap assembly (continued) figure 3-13: back cap assembly 1 19 10 (x2) 3 25 (13.5") 25 (9.0") 9 14 (x2) 27 (x2) 32 16 (x2) 26 (x2) 30 (x2) 5 12 (x2) 6 17 (x4) 24 (x2) 18 (x2) 21 (x2) 23 11 29 31 7 2 15 26 22...

  • Page 81

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 63 fan assembly 22.9676.0090 rev d refer to figure 3-14 . No. Item qty. Um. Description 1 10.9676.0068 1 ea air duct, front fan 2 22.9676.0091 1 ea assy, fan bulkhead 3 22.9676.0095 1 ea air duct, rear fan 4 25.8007.22...

  • Page 82

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 64 18-november-2004 02.9676.0020 0 fan assembly (continued) figure 3-14: fan assembly 1 3 2 5 11 16 (x3) 13 (x2) 15 (x2) 10 4 12 6 9 17 7, 8 (x5) 14.

  • Page 83

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 65 iris/color/gobo bulkhead assembly 21.9676.0120 rev b refer to figure 3-15 . No. Item qty. Um. Description 1 10.9667.0124 1 ea bulkhead, iris link/gobo/color 2 21.9676.0118 1 ea assy, iris/gobo motor 3 21.9676.0119 1...

  • Page 84

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 66 18-november-2004 02.9676.0020 0 iris/color/gobo bulkhead assembly (continued) figure 3-15: iris/color/gobo bulkhead assembly 4 16 (x3) 9 (x3) 8 7 10 1 14 15 6 12 (x3) 5 16 (x3) 9 (x3) 2 11 13 (x2) 17 (x4).

  • Page 85

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 67 crossfade color assembly 21.9676.0201 rev g refer to figure 3-16 . No. Item qty. Um. Description 1 10.9676.0230.01 3 ea spacer, color wheel 2 10.9676.0230.02 1 ea spacer, color motor 3 10.9676.0233 1 ea aft bulkhead...

  • Page 86

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 68 18-november-2004 02.9676.0020 0 crossfade color assembly (continued) figure 3-16: crossfade color assembly 14 (x2) dimmer magenta cyan yellow 19 (x2) 18 (x6) 23 (x6) 3 25 6 24 cyan 12 1 1 1 9 10 11 6 2 5 8 13 17 (x2) 22 (x2) 14 (x2) 19 (x4) 4...

  • Page 87

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 69 iris/gobo motor assembly 21.9676.0118 rev b refer to figure 3-17 . Figure 3-17: iris/gobo motor assembly no. Item qty. Um. Description 1 10.9621.0097 1 ea stabilizer, stepper, gobo wheel 2 10.9667.0111 1 ea motor bu...

  • Page 88

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 70 18-november-2004 02.9676.0020 0 sensor pcb assembly 24.9638.0113 rev b refer to figure 3-18 . Figure 3-18: sensor pcb assembly no. Item qty. Um. Description 1 11.9638.0114 1 ea pcb, sensor, vl6 2 52.6229.0001 1 ea header, 3pos mta fric lok st...

  • Page 89

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 71 color motor assembly 21.9676.0119 rev 0 refer to figure 3-19 . Figure 3-19: color motor assembly no. Item qty. Um. Description 1 10.9621.0097 1 ea stabilizer, stepper, gobo wheel 2 10.9667.0120 1 ea color motor bulk...

  • Page 90

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 72 18-november-2004 02.9676.0020 0 gobo wheel assembly 22.9673.0144 rev a refer to figure 3-20 . Figure 3-20: gobo wheel assembly no. Item qty. Um. Description 1 22.9673.9143 1 ea assy, filter wheel hub and clip - 10.9638.0122 1 ea clip, wheel r...

  • Page 91

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 73 filter wheel assembly 22.9673.0145 rev a refer to figure 3-21 . Figure 3-21: filter wheel assembly no. Item qty. Um. Description 1 22.9673.9143 1 ea assy, filter wheel hub and clip - 10.9638.0122 1 ea clip, wheel re...

  • Page 92

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 74 18-november-2004 02.9676.0020 0 strobe assembly 22.9676.0016 rev e refer to figure 3-22 . No. Item qty. Um. Description 1 10.9676.0043 1 ea bulkhead, strobe mounting 2 10.9676.0019 2 ea strobe blade, dimpled 3 10.9676.0060 2 ea mounting colla...

  • Page 93

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 75 strobe assembly (continued) figure 3-22: strobe assembly 10 (x2) 13 (x2) 7 (x2) 5 (x2) 11 (x2) 1 6 (x4) 9 (x4) 16 (x2) 4 (x2) 8 (x2) 15 (x8) 4 12 (x6) 3 (x2) 14 (x4) note connector orientation on motors black side.

  • Page 94

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 76 18-november-2004 02.9676.0020 0 uv / ir window assembly 22.9676.0140 rev b refer to figure 3-23 . Figure 3-23: uv / ir window assembly no. Item qty. Um. Description 1 10.9676.0058 1 ea uv / ir frame 2 41.9678.0608 1 ea uv / ir filter, 3.00" x...

  • Page 95

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 77 vl2500 main control board pcb assembly 24.9676.0730 rev b refer to figure 3-24 item um. Description ref. 10-0255 1 ea res, 0 ohm, 1/10w, smt0805 r298 10.9661.1275 1 ea heatsink, main controller 10.9676.0735 1 ea hea...

  • Page 96

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 78 18-november-2004 02.9676.0020 0 60.1165.1004 30 ea res, 1/16w 5% 10 k chip thk flm smt0402 r16, r19, r24, r25, r94 r96, r113, r115, r124, r126, r135, r137, r146, r148, r159, r161, r165, r167, r172, r174, r178, r180, r213, r215, r224, r226, r2...

  • Page 97

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 79 c39, c42, c47-c50, c52, c56, c58, c60, c63-c68, c92, c101, c110, c119, c128, c136, c146, c155, c164, c173, c182, c191, c200 62.4240.0223 26 ea cap, .022uf 25v 10% cer chip sur mt x7r eia0603 c87, c95, c96, c103, c10...

  • Page 98

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 80 18-november-2004 02.9676.0020 0 85.3773.0001 13 ea ic, stepmotor driver u27-u30, u32-u40 85.5134.0001 1 ea ic, sn75lbc180d low-power diff line drvr & rcvr pairs u4 85.5164.0001 2 ea ic, l6234pd three phase motor driver u11, u31 85.5168.0001 1...

  • Page 99

    I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0020 0 18-november-2004 81 vl2500 main control board pcb assy (cont.) figure 3-24: vl2500 main control board pcb assembly top side bottom side.

  • Page 100

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 82 18-november-2004 02.9676.0020 0 notes.

  • Page 101

    I llustrated p arts b reakdown : y oke 3 02.9676.0020 0 18-november-2004 83 yoke yoke assembly 21.9676.0600 rev c refer to figure 3-25 . No. Item qty. Um. Description 1 22.9676.0605 1 ea assy, yoke structure 2 22.9676.0609 1 ea assy, fan 3 22.9676.0610 1 ea assy, tilt motor 4 23.9650.3327 1 ea assy,...

  • Page 102

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 84 18-november-2004 02.9676.0020 0 yoke assembly (continued) figure 3-25: yoke assembly 1 12 (x2) 4 7 (x2) 2 14 (x2) 9 (x4) 11 (x4) 10 3 8 (x3) 7 (x2) 13 (x2) 7 (x4) 13 (x4) 15 (x2) 5.

  • Page 103

    I llustrated p arts b reakdown : y oke 3 02.9676.0020 0 18-november-2004 85 ignitor pcb assembly 24.9661.1126 rev b refer to figure 3-26 . No. Item qty. Um. Description ref 1 11.9661.1126 1 ea pcb, ignitor 2 52.8218.0002 4 ea term, pc vert mnt 6-32 screw 15a j1-j4 3 60.1230.6493 1 ea resisitor, 1/4w...

  • Page 104

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 86 18-november-2004 02.9676.0020 0 ignitor pcb assembly (continued) figure 3-26: ignitor pcb assembly.

  • Page 105

    I llustrated p arts b reakdown : y oke 3 02.9676.0020 0 18-november-2004 87 tilt motor assembly 22.9676.0610 rev 0 refer to figure 3-27 . No. Item qty. Um. Description 1 10.9661.1298 1 ea plate, tension adjust, pan motor 2 22.9661.0608 1 ea assy, drive pulley - - 10.9661.0640 1 ea codewheel, 90 coun...

  • Page 106

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 88 18-november-2004 02.9676.0020 0 tilt motor assembly (continued) figure 3-27: tilt motor assembly 5 1 9 (x2) 9 (x2) 8 (x2) 4 7 (x4) 6 (x2) 10 (x2) 2 3 10 (x2).

  • Page 107

    I llustrated p arts b reakdown : y oke 3 02.9676.0020 0 18-november-2004 89 pan/tilt encoder pcb assembly 24.9661.0629 rev 0 refer to figure 3-28 . Figure 3-28: pan/tilt encoder pcb assembly no. Item qty. Um. Description ref. 1 11.9661.0629 1 ea pcb, encoder sensor 2 52.6613.0005 1 ea header, 5pos s...

  • Page 108

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 90 18-november-2004 02.9676.0020 0 yoke fan assembly 22.9676.0609 rev a refer to figure 3-28 . Figure 3-29: yoke fan assembly no. Item qty. Um. Description 1 10-9676.0646 1 ea fan tray, yoke arm 2 40.7113.0001 1 ea fan, +24v 80 x 80 x 25 mm 32cf...

  • Page 109

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 91 enclosure upper enclosure assembly 21.9676.0800 rev e refer to figures 3-30 and 3-31 . No. Item qty. Um. Description 1 04.9640.0374 1 ea label, p.E. Ground 2 04.9661.0040 1 ea label, 2000 series compliance 3 04.9661.121...

  • Page 110

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 92 18-november-2004 02.9676.0020 0 30 25.9661.1520 1 ea cable assy, chassis to yoke ground (not shown) 31 25.9676.0818 1 ea cable assy, pan/tilt control (not shown) 32 25.9678.0811 1 ea cable assy, emi filter to power switch (not shown) 33 25.96...

  • Page 111

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 93 68 55.2178.0001 2 ea cable anchor, mount, #8 screw mounting 69 55.2179.0001 3 ea cable anchor, mount, #6 screw mounting 70 55.2186.0001 5 ea cable tie, .10" w x 4.00" lg small 71 55.2261.0001 1 ea sleeve, nyl, insul, #6...

  • Page 112

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 94 18-november-2004 02.9676.0020 0 upper enclosure assembly (continued) figure 3-30: upper enclosure assembly 18 5 17 58 73 80 8 60 (x2) 40 61 75 76 89 53 26 87 6 85 59 77 (x2) 12 50 (x3) 51 (x2) 53 (x3) 48 (x2) 27 70 54 69 71 56 81 88 1 47 86 4...

  • Page 113

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 95 upper enclosure assembly (continued) figure 3-31: upper enclosure assembly unpainted surface of aps cover only 19 78 (x4) 63 (x4) 54 (x4) 10 (x2) 7 11 (x2) 82 (x2) 54 53 53 53 55 (x4) 54 15 2 3 16 4 72 (x2) 54 53 15 16 ...

  • Page 114

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 96 18-november-2004 02.9676.0020 0 connector panel assembly 21.9678.0805 rev d refer to figure 3-32 . Figure 3-32: connector panel assembly no. Item qty. Um. Description 1 10.9678.0852.01 1 ea layout, enclosure overlay 2 10.9678.0859 1 ea bracke...

  • Page 115

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 97 dmx input pcb assembly 24.9663.1830 rev a refer to figure 3-33 figure 3-33: dmx input pcb assembly no. Item qty. Um. Description ref. 1 11.9663.1830 1 ea pcb fab, dmx input - 2 52.6259.0001 1 ea header, 5pos mta frct lo...

  • Page 116

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 98 18-november-2004 02.9676.0020 0 ac input pigtail cable assembly 25.9678.0810 rev a refer to figure 3-33 figure 3-34: dmx input pcb assembly no. Item qty. Um. Description 1 52.6274.2313 1 ea strain relief, skintop flextype pg13 blk 2 52.6401.2...

  • Page 117

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 99 pan tube assembly 21.9678.0880 rev c refer to figure 3-35 . Figure 3-35: pan tube assembly no. Item qty. Um. Description 1 10.9678.0809 1 ea pan toggle stop 2 10.9678.0847 1 ea washer, silicone foam 3 10.9678.0848 2 ea ...

  • Page 118

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 100 18-november-2004 02.9676.0020 0 pan motor assembly 21.9678.0864 rev b refer to figure 3-36 . Figure 3-36: pan motor assembly no. Item qty. Um. Description 1 10.9678.0865 1 ea plate, pan motor mount 2 21.9678.0828 1 ea assy, drive pully, pan ...

  • Page 119

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 101 upper enclosure fan assembly 23.9678.0686 rev 0 refer to figure 3-36 . Figure 3-37: upper enclosure fan assembly no. Item qty. Um. Description 1 40.7125.0001 1 ea fan, 24v fal6f24lh 2 52.8231.0007 2 ea term, spade #6 2...

  • Page 120

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 102 18-november-2004 02.9676.0020 0 pan eot sensor electrical assembly 23.9678.0687 rev a refer to figure 3-38 . Figure 3-38: pan eot sensor electrical assembly no. Item qty. Um. Description 1 52.6524.0006 1 ea conn, housing 6 pos. Receptacle 2 ...

  • Page 121

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 103 ballast module (arc power supply) assembly 23.9671.1250 rev f refer to figures 3-39 and 3-40 . No. Item qty. Um. Description 1 06.6032.0009 1 ea cable marker tie, white 19 x 7.4" 2 10.9661.1260 1 ea heat sink, left 120...

  • Page 122

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 104 18-november-2004 02.9676.0020 0 32 80.2648.0001 1 ea transistor, ixfh32n50 power mosfet 500v 32a to-247 33 82.4323.0001 1 ea diode, bridge d25xb60 600v 25a sip 34 82.5341.0001 2 ea diode, dsei30-06a fred 25-37a t0-247 ad no. Item qty. Um. D...

  • Page 123

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 105 ballast module assembly (continued) figure 3-39: ballast module (arc power supply) assy 6 2 3 23 4 13 (x2) 14 (x4) 7 23 12 (x4) 29 8 16 22 28 1 20 12 21 (x2) 19 (x3) 15 (x2) 18 (x2) 20 (x2) 17 (x2) 11 (x4).

  • Page 124

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 106 18-november-2004 02.9676.0020 0 ballast module assy (continued) figure 3-40: ballast module (arc power supply) assy 26 9 (2 pl) 27 31 10 34 25 33 24 11 10 (4 pl) 15 (4 pl) 18 (4 pl) 20 (4 pl) 30 (4 pl) 9 27 11 32 10 15 (4 pl) 18 (4 pl) 20 (...

  • Page 125

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 107 700w ballast board pcb assembly 24.9661.1130 rev d refer to figure 3-41 . No. Item qty. Um. Description ref. 1 10.9661.1356 1 ea guide, aps rider pcb 2 11.9661.1120 1 ea pcb, 400/625w ballast board 3 51.5031.0001 1 ea ...

  • Page 126

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 108 18-november-2004 02.9676.0020 0 28 60.1422.1001 3 ea res, 1/4w 5% 1.0 k cf r219, r220 & r223 29 60.1422.2001 1 ea res, 1/4w 5% 2.0 k cf r119 30 60.1424.1502 1 ea res, 1/4w 5% 15.0 k cf r104 31 60.1424.2004 1 ea res, 1/4w 5% 20.0 k cf r108 32...

  • Page 127

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 109 54 63.2055.0001 2 ea thermistor, 12a 0.7 ohm ntc inrush current limit ntc101 & ntc102 55 68.4536.0002 1 ea choke, common mode filter 1.35mh 11a l102 56 68.4577.0001 1 ea inductor, current sense pe-51688 l201 57 68.9661...

  • Page 128

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 110 18-november-2004 02.9676.0020 0 700w ballast board pcb assembly (cont.) figure 3-41: 700w ballast board pcb assembly.

  • Page 129

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 111 700w ballast rider board pcb assembly 24.9661.1131 rev c refer to figure 3-42 . No. Item qty. Um. Description ref. 1 10.9661.1355 2 ea stabilizing extrusion, aps rider bd pcb 2 11.9661.1111 1 ea pcb, ballast rider 3 52...

  • Page 130

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 112 18-november-2004 02.9676.0020 0 21 60.9464.2003 1 ea res, 1/8w 5% 2.0 k 200v chp thk flm s- mt1206 r413 22 60.9464.2004 9 ea res, 1/8w 5% 20.0 k 200v chp thk flm s- mt1206 r308, r309, r402, r417, r418, r424, r425, r426, r428 23 60.9464.2005 ...

  • Page 131

    I llustrated p arts b reakdown : e nclosure 3 02.9676.0020 0 18-november-2004 113 figure 3-42: 700w ballast rider board pcb assembly 41 62.4005.0101 3 ea cap, 100pf 50v 10% cer chip sur mt cog 0805 c410, c411, c429 42 62.4005.0330 1 ea cap, 33pf 50v 10% cer chip sur mt cog 0805 c428 43 62.4005.0470 ...

  • Page 132

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 114 18-november-2004 02.9676.0020 0 notes.

  • Page 133

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 115 cables ground strap cable assembly 25.8007.2212 rev 0 refer to figure 3-48 . Figure 3-48: ground strap cable assembly no. Item qty. Um. Description 1 52.8329.0001 2 ea term, ring # 6 22-16 awg non-ins 2 73.7130.0002 0.33 ...

  • Page 134

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 116 18-november-2004 02.9676.0020 0 lvs chassis ground cable assembly 25.9661.1514 rev a refer to figure 3-49 . Figure 3-49: lvs chassis ground cable assembly no. Item qty. Um. Description 1 52.8231.0005 1 ea term, ring #6 blue 16-14 awg reel pi...

  • Page 135

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 117 chassis to yoke ground cable assembly 25.9661.1520 rev b refer to figure 3-50 . Figure 3-50: chassis to yoke ground cable assembly no. Item qty. Um. Description 1 52.8250.0001 2 ea term, #8, ring, 10awg 2 73.7089.0504 15....

  • Page 136

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 118 18-november-2004 02.9676.0020 0 ignitor to relay cable assembly 25.9667.0030 rev a refer to figure 3-51 . Figure 3-51: ignitor to relay cable assembly no. Item qty. Um. Description 1 52.8231.0005 1 ea term, ring #6 blue 16-14 awg reel pidg 2...

  • Page 137

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 119 tilt plate ground cable assembly 25.9667.0413 rev a refer to figure 3-52 . Figure 3-52: tilt plate ground cable assembly no. Item qty. Um. Description 1 52.8311.0003 1 ea term, ring #6 blue 14-16 awg non-ins. 2 73.7130.00...

  • Page 138

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 120 18-november-2004 02.9676.0020 0 color/gobo t-stat cable assembly 25.9676.0125 rev a refer to figure 3-53 . Figure 3-53: color/gobo t-stat cable assembly no. Item qty. Um. Description 1 52.6523.0002 1 ea conn, housing 2pos. Plug shroud 2 52.8...

  • Page 139

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 121 color/fixed bulkheads cable assembly 25.9676.0715 rev e refer to figure 3-54 . No. Item qty. Um. Description 1 04.9676.0715.00 1 ea label set, vl2500 color harness 2 52.6224.0040 1 ea housing, 40 pos 26-22 awg preloaded m...

  • Page 140

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 122 18-november-2004 02.9676.0020 0 color/fixed bulkheads cable assembly (cont.) figure 3-54: color/fixed bulkheads cable assembly 14, 7, 8 16, 5, 6 14, 7, 8 17, 7, 8 14, 9, 10 (x4 each) 11 (x7) 13 (x2) 12 14, 7, 8 2, 3, 4 15, 5, 6 1 1 1 1 1 1 1...

  • Page 141

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 123 optics/strobe bulkheads cable assembly 25.9676.0716 rev d refer to figure 3-55 . No. Item qty. Um. Description 1 04.9676.0716.00 1 ea label set, vl2500 color harness 2 52.6224.0034 1 ea housing, 34 pos 26-22 awg preloaded...

  • Page 142

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 124 18-november-2004 02.9676.0020 0 optics/strobe bulkheads cable assy (cont.) figure 3-55: optics/strobe bulkheads cable assembly 16, 6, 7 15 2, 3, 4 1 13 1 1 17, 5, 7 16, 6, 7 16, 9, 11 16, 8, 11 16, 10, 12 14 (x4).

  • Page 143

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 125 strobe 1 cable assembly 25.9676.0717 rev a refer to figure 3-56 . Figure 3-56: strobe 1 cable assembly no. Item qty. Um. Description 1 04.9676.0716.01 1 ea label, strobe 1 2 52.6523.0004 1 ea conn, housing 4 pos plug shro...

  • Page 144

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 126 18-november-2004 02.9676.0020 0 fans/disconnect cable assembly 25.9676.0718 rev d refer to figure 3-57 . Figure 3-57: fans/disconnect cable assembly no. Item qty. Um. Description 1 52.6396.2403 1 ea recept, 3 pos mta100 w/ pol tab 24 awg 2 5...

  • Page 145

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 127 ot switch to reflector assy. Cable assembly 25.9676.0719 rev 0 refer to figure 3-58 . Figure 3-58: ot switch to reflector assy. Cable assembly no. Item qty. Um. Description 1 52.8271.0010 1 ea recept, faston 24-22 awg non...

  • Page 146

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 128 18-november-2004 02.9676.0020 0 pan/tilt control cable assembly 25.9676.0818 rev a refer to figure 3-59 . No. Item qty. Um. Description 1 52.6224.0020 1 ea housing, 20 pos 26-22 awg preloaded mt recept dbl row 2 52.6224.1020 1 ea cover, fron...

  • Page 147

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 129 pan/tilt control cable assembly (continued) figure 3-59: pan/tilt control cable assembly 1, 2, 3 4, 7 (x5) 6 (x3) ,5 4, 7 (x5) 6 (x3) ,5 8 (x7).

  • Page 148

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 130 18-november-2004 02.9676.0020 0 emi filter to power switch cable assembly 25.9678.0811 rev a refer to figure 3-60 figure 3-60: emi filter to power switch cable assembly no. Item qty. Um. Description 1 52.8313.0001 2 ea rcpt, faston 1/4" 18-1...

  • Page 149

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 131 ac input splitter cable assembly 25.9678.0812 rev d refer to figure 3-61 no. Item qty. Um. Description 1 52.6231.0001 1 ea plug housing, mnlok plug 3pos 2 52.8231.0005 1 ea term, ring #6 blue 16-14 awg reel pidg 3 52.8231...

  • Page 150

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 132 18-november-2004 02.9676.0020 0 ac input splitter cable assembly (continued) figure 3-61: ac input splitter cable assembly 2 (x2) 4 (x2) 12 5, 9 5, 10 13 11, 6 3 1 7 (x3) 8.

  • Page 151

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 133 data i/o link cable assembly 25.9678.0813 rev 0 refer to figure 3-62 figure 3-62: data i/o link cable assembly no. Item qty. Um. Description 1 52.6396.2204 1 ea recept, 4 pos mta100 w/pol tab red clsd end 2 52.6396.2205 1...

  • Page 152

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 134 18-november-2004 02.9676.0020 0 display cable assembly 25.9678.0815 rev 0 refer to figure 3-63 figure 3-63: display cable assembly no. Item qty. Um. Description 1 52.6396.2406 2 ea recept, 6 pos mta100 w/pol tab wht clsd end 2 73.5116.0123 2...

  • Page 153

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 135 ballast to controller cable assembly 25.9678.0816 rev 0 refer to figure 3-64 figure 3-64: ballast to controller cable assembly no. Item qty. Um. Description 1 52.6396.2402 1 ea recept, 2 pos mta100 w/pol tab wht clsd end ...

  • Page 154

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 136 18-november-2004 02.9676.0020 0 lamp supply to relay cable assembly 25.9678.0819 rev a refer to figure 3-65 figure 3-65: lamp supply to relay cable assembly no. Item qty. Um. Description 1 52.8312.0001 4 ea recp, faston 1/4" 18-14 awg insula...

  • Page 155

    I llustrated p arts b reakdown : c ables 3 02.9676.0020 0 18-november-2004 137 dc output cable assembly 25.9678.0821 rev d refer to figure 3-66 figure 3-66: dc output cable assembly no. Item qty. Um. Description 1 52.6464.0002 1 ea conn, housing, sl-156 2 pos 2 52.6464.0003 1 ea conn, housing, sl-15...

  • Page 156

    Vari❋lite® - vl2500™ s pot l uminaire s ervice m anual 138 18-november-2004 02.9676.0020 0 notes.

  • Page 157

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 139 vl2500 spot luminaire schematics 700w ballast schematic.

  • Page 158

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 140 700w ballast schematic (continued).

  • Page 159

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 141 ballast rider schematic.

  • Page 160

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 142 vl2500 luminaire schematic.

  • Page 161

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 143 vl2500 luminaire schematic (continued).

  • Page 162

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 144 vl2500 luminaire schematic (continued).

  • Page 163

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 145 main control board (mcb) schematic 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a +24v vcc +24v +3.3v +3.3v +2.5v +3.3v vcc +24v +3.3v +2.5v +1.8v +1.8v vcc +24v +3.3v +2.5v gnd +1.8v...

  • Page 164

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 146 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a d 7 d25 d23 d19 d29 d 9 d18 d30 d15 d27 d20 d 4 d 2 d13 d21 d24 d 8 d10 d14 d 5 d31 d11 d...

  • Page 165

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 147 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a d31 d30 d29 d28 d27 d26 d25 d24 d23 d22 d21 d20 d18 d[0..3 1] d19 d16 d[0..3 1] d17 a1 a7...

  • Page 166

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 148 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a ci+ ci- +3.3v +24v vcc iso_vcc iso_vcc iso_vcc iso_vcc iso_vcc vcc iso_vcc iso_vcc vcc is...

  • Page 167

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 149 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc vcc vcc +24v +24v +24v +24v vcc vcc +24v +24v +24v +24v vcc +24v +24v vcc +24v +3.3v ...

  • Page 168

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 150 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc vcc vcc vcc vcc +24v +24v vcc +24v +24v vcc +24v +24v vcc +24v +24v vcc +24v +3.3v +2...

  • Page 169

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 151 main control board (mcb) schematic (continued) 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc vcc vcc vcc vcc +24v +24v vcc +24v +24v vcc +24v +24v vcc +24v +24v vcc +24v +3.3v +2.5v +1.8v fx...

  • Page 170

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 152 main control board (mcb) schematic (continued) 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc vcc vcc vcc vcc +24v +24v vcc +24v +24v vcc +24v +24v vcc +24v +24v vcc +24v +3.3v +2.5v +1.8v am...

  • Page 171

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 153 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc +24v +3.3v +2.5v +1.8v vcc +24v +3.3v +2.5v gnd +1.8v title size document number r e ...

  • Page 172

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 154 main control board (mcb) schematic (continued) 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a +24v +24v vcc vcc vcc vcc +24v vcc +24v vcc +24v +3.3v +2.5v +1.8v vcc edge_out2b edge_ou...

  • Page 173

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 155 dmx input schematic 1000pf 250v 20% nc5fbv nc5mbv 640456-5 1 viewdraw for windows 7.5 filename: date/time: appd date description rev revisions r written consent of vari-lite, inc. In a...

  • Page 174

    Vari❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 02.9676.0020 0 18-november-2004 156 solid state ignitor schematic gnd vcc 8-bypass a b c d reset osc_inh mono-in set clock_inh in1 out2 out1 decode_out 1 1. All capacitor values are in microfarads. 2. All resistor values...

  • Page 176

    Vari-lite 10911 petal street dallas, texas 75238 toll free 1-877-vari-lite tel 214.647.7880 fax 214.647.8038 www.Vari-lite.Com ©2004 genlyte thomas group llc. All rights reserved. Printed in the u.S.A..