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Vari Lite VL2500 Spot Luminaire Service Manual - page 156
VARI
❋LITE
®
- VL2500™ W
ASH
L
UMINAIRE
S
ERVICE
M
ANUAL
R
EFERENCE
F
OLD
-O
UTS
02.9676.0022 0
09-December-2004
138
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
D22
D26
D28
D 3
D 6
D12
D 1
R AS_0-
S _RAS-
D RAMWR-
S _CAS-
S DA
S DA
SCL
SCL
C LK0
D16
D17
D16
D19
D18
D17
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D 1
D 2
D 3
D 4
D 5
D 6
D 7
D 0
D 0
D16
D19
D18
D17
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D[0..3 1]
D10
D 9
D 1
D 2
D15
D 8
D 7
D12
D14
D 6
D 5
D 0
D11
D13
D 3
D 4
A 18
A 23
A 10
A9
A 14
A 21
A 13
A 20
A7
A0
A 17
A 19
A6
A 18
A3
A5
A 14
A 17
A 18
A5
A 23
A 19
A4
A3
A 15
A 24
A 21
A2
A 10
A6
A[0 ..24]
A 20
A 12
A9
A7
A 13
A 10
A8
A 11
A 15
A 14
A 21
A 13
A 13
A 10
A 19
A 21
A1
A 22
A 11
A 11
A 12
A9
A 23
A 16
A 22
A 12
A9
A 24
A 17
A 20
A 12
A 15
A8
A 20
A 14
A 16
A 18
A 11
A2
A 19
A4
A 22
A 15
A 24
A1
A 17
+1.8V
+1.8V
+1.8V
+1.8V
+1.8V
+1.8V
+1.8V
+1.8V
+1.8V
+1.8V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
VCC
+3.3V
+3.3V
+3.3V
+3.3V
VCC
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
VCC
+24V
+3.3V
+2.5V
+1.8V
+3.3V
+1.8V
+3.3V
RSTI-
TCK
RSTI-
PST6
PST4
PST2
PST0
BKPT-
DSCLK
DSI
DSO
PST7
PST5
PST3
PST1
PSTCLK
TA-
DCLK
DATA
INIT_DONE
CONF_DONE
STATUS-
CONFIG-
LAMP_STBY
MTR_ENABLE-
R/W-
CS_FLASH-
CS_MTR-
CS_UART-
OE-
RAS0-
CAS0-
CAS1-
CAS2-
CAS3-
SRAS-
DRAMW-
SCAS-
CLK_EN
RSTO-
BKPT-
DSO
DSI
DSCLK
TCK
PSTCLK
PST0
PST1
PST2
PST3
PST4
PST5
PST6
PST7
RX_INT-
IRQ7-
IRQ1-
TX_INT-
TIN0
TIN1
UART_OUT_B
UART_IN
TX_EN_B-
TXDB
RXDB
RSTI-
EDGESEL
HIZ-
SCL_OUT
SDA_OUT
CLK1
CLK2
CLK3
OE-
CS_FLASH-
RSTI-
R/W-
CAS3-
RAS0-
DRAMW-
CAS2-
SCAS-
SRAS-
CLK1
CLK_EN
CAS1-
RAS0-
DRAMW-
CAS0-
SCAS-
SRAS-
CLK2
CLK_EN
A1
A0
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D1
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D0
D2
D3
D4
AS-
TA-
D25
D26
D27
D28
D29
D30
D31
VCC
+24V
+3.3V
+2.5V
GND
+1.8V
MTR_EN-
MTR_ENABLE-
CS_MTR-
CS_UART-
CS_FLASH-
TIN0
TIN1
HIZ-
EDGESEL
DSI
BKPT-
DSCLK
TA-
AS-
R/W-
IRQ7-
RX_INT-
TX_INT-
IRQ1-
RSTI-
Title
Size
Document Number
R e v
D ate:
SHEET OF
D
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
DRAWN BY :
FAE
C O P Y R I G H T 2 0 0 4
14-9676-0730
B0
SCHEMATIC VL2500 CONTROLLER
Tuesday, July 20, 2004
2/C4, 2/B5, 2/B8, 2/C6
2/B4
2/C4, 2/B5, 2/B7, 2/C6
2/A4
2/A4
2/A4
2/A4
2/D6, 2/B4
2/B4, 2/C6
2/D6,2/B4
2/B4
2/A4
2/A4
2/A4
2/A4
2/A4
2/A4
3/C7,3/A2,3/A3
3/A2,3/B3
3/B3
3/A2,3/B7,3/B3
3/A2,3/C7,3/B3
3/C7,3/B3
10/C2
2/A4
2/C4,2/C6,3/A6
2/D6,2/C4
2/D6,3/A6
2/D6,3/A6
2/C4
2/B2,2/C2
2/B2
2/B2
2/C2
2/C2
2/B2,2/C2
2/B2,2/C2
2/B2,2/C2
2/B2,2/C2
3/A6
2/D6,2/B7
2/B7
2/D6,2/B7
2/B7,2/C6
2/B8
2/B7
2/B8
2/B7
2/B8
2/B7
2/B8
2/B7
2/B8
2/B7
2/B7,2/C6,3/D6
2/C6
2/C6
2/C6,3/C3
2/C6,3/C3
2/C6
2/D6
2/D6
4/C5
3/D6,4/C5
4/D5
4/D8
4/D8
2/C4,2/C7,2/B8,2/C6
2/D6
2/D6
10/D2
10/D2
2/C2
2/B2
3/A6
V1.8 PINS: 1,57,73,105,152,
157,171,175,185,197
V3.3 PINS: 7,13,21,29,37,45,
52,65,81,89,97,113,121,129,
137,145,167,191,205
GND PINS: 4,10,17,25,33,41,48,
53,61,69,77,85,93,101,104,
109,117,125,133,141,148,156,
162,169,173,183,188,194,201,208
PLACE RESISTORS CLOSE TO MICROPROCESSOR
2/D6,2/C4
2/B4
2/C6
2/C4,2/C6,3/A6
PLL MULT = 4X
CLK IN =
25-40.5MHz
BE = R/W
PAR PORT
16 BIT BUS
AUTO ACK
2/B2,2/B3
2/B4
2/B4
2/B2,2/B3
2/B2,2/B3
2/B2,2/B3
2/B2,2/B4
2/A6
2/B2,2/B3
2/B4
2/B4
2/B2,2/B3
2/B2,2/B3
2/B2,2/B3
2/B2,2/B4
2/A6
3/B3,3/A3
2/C3,3/D6,3/A3
2/C4
5/C2,6/C8,7/C8,8/C8
10
2
DO NOT
STUFF
2/C5
2/C5,2/B7,3/D6
2/C4,2/C4
2/B5
2/B4,3/A6
2/B4,3/A6
2/C5,3/C3
2/B5
2/C4,2/C4,3/A6
2/B5
2/C5
2/C5,3/C3
2/C4,2/B5,2/C7,2/B8
2/B4,2/B7
2/B5
2/A5
2/B4,2/B7
2/B4,2/B7
S1
C21
U24
A0
25
A1
24
A2
23
A3
22
A4
21
A5
20
A6
19
A7
18
A8
8
A9
7
A10
6
A11
5
A12
4
A13
3
A14
2
A15
1
A16
48
A17
17
CE-
26
OE-
28
WE-
11
RESET-
12
RY/BY-
15
BYTE-
47
DQ0
29
DQ1
31
DQ2
33
DQ3
35
DQ4
38
DQ5
40
DQ6
42
DQ7
44
DQ8
30
DQ9
32
DQ10
34
DQ11
36
DQ12
39
DQ13
41
DQ14
43
A-1/DQ15
45
NC4
14
NC5
16
VCC
37
NC1
9
NC2
10
NC3
13
GND1
27
GND2
46
R58
C25
C67
R57
R34
R30
R69
C26
R60
C53
R63
R67
R54
C45
R51
U22
VCC
8
E0
1
E1
2
E2
3
VSS
4
SDA
5
SCL
6
WC-
7
C54
R41
R298
R37
C44
C47
R52
R31
R68
C27
U18
A0
23
A1
24
A2
25
A3
26
A4
29
A5
30
A6
31
A7
32
A8
33
A9
34
A10
22
A11
35
NC/A12
36
BA0
20
BA1
21
CS
19
DQML
15
DQMH
39
WE
16
RAS
18
CAS
17
CKE
37
CLK
38
V3.3_1
1
V3.3_2
14
V3.3_3
27
GND1
28
GND2
41
GND3
54
DQ0
2
DQ1
4
DQ2
5
DQ3
7
DQ4
8
DQ5
10
DQ6
11
DQ7
13
DQ8
42
DQ9
44
DQ10
45
DQ11
47
DQ12
48
DQ13
50
DQ14
51
DQ15
53
NC
40
V3.3_Q1
3
V3.3_Q2
9
V3.3_Q3
43
GNDQ1
6
GNDQ2
12
GNDQ3
46
GNDQ4
52
V3.3_Q4
49
U9
5VIN
1
5VRST
2
5VTOL
3
GND
4
3.3VIN
8
3.3VRST
7
3.3VTOL
6
PBRST
5
R71
C52
R297
J6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
R29
FB2
C48
C66
R59
C46
R42
C51
R39
R36
C18
R61
C43
R55
PP2
1
C19
C68
R65
R299
U14
A0
23
A1
24
A2
25
A3
26
A4
29
A5
30
A6
31
A7
32
A8
33
A9
34
A10
22
A11
35
NC/A12
36
BA0
20
BA1
21
CS
19
DQML
15
DQMH
39
WE
16
RAS
18
CAS
17
CKE
37
CLK
38
V3.3_1
1
V3.3_2
14
V3.3_3
27
GND1
28
GND2
41
GND3
54
DQ0
2
DQ1
4
DQ2
5
DQ3
7
DQ4
8
DQ5
10
DQ6
11
DQ7
13
DQ8
42
DQ9
44
DQ10
45
DQ11
47
DQ12
48
DQ13
50
DQ14
51
DQ15
53
NC
40
V3.3_Q1
3
V3.3_Q2
9
V3.3_Q3
43
GNDQ1
6
GNDQ2
12
GNDQ3
46
GNDQ4
52
V3.3_Q4
49
C77
R62
R56
C69
Y1
1
2
3
4
R35
R53
R32
C55
R40
U23
VCC
8
SDA1
6
SCL1
7
GND
4
NC
1
SDA0
3
SCL0
2
EN
5
R70
R38
C50
U12
REF
1
VCC
6
GND
4
CLKOUT
8
CLK1
3
CLK2
2
CLK3
5
CLK4
7
PP1
1
R64
C49
U17
D0
147
D1
146
D2
144
D3
143
D4
142
D5
140
D6
139
D7
138
D8
136
D9
135
D10
134
D11
132
D12
131
D13
130
D14
128
D15
127
D16
126
D17
124
D18
123
D19
122
D20
120
D21
119
D22
118
D23
116
D24
115
D25
114
D26
112
D27
111
D28
110
D29
108
D30
107
D31
106
BR
74
BG
76
BD
75
TS
66
TIP/PP7
198
AS
62
TA
64
IRQ7
68
IRQ5/4
70
IRQ3/6
71
IRQ1/2
72
DREGQ0/PP6
199
DREGQ1/PP5
200
TIN0
80
TOUT0
79
TIN1
82
TOUT1
78
TXD1
166
RXD1
165
RTS1
164
CTS1
163
TXD2
161
RXD2
160
RTS2
159
CTS2
158
SDA
103
SCL
102
RSTI
67
EDGESEL
168
MTMOD0
176
MTMOD1
177
MTMOD2
181
MTMOD3
182
HIZ
155
CLKIN
174
PVDD
180
PGND
178
A0
2
A1
3
A2
5
A3
6
A4
8
A5
9
A6
11
A7
12
A8
14
A9
15
A10
16
A11
18
A12
19
A13
20
A14
22
A15
23
A16
24
A17
26
A18
27
A19
28
A20
30
A21
31
A22
32
A23
34
A24/PP8
35
A25/PP9
36
A26/PP10
38
A27/PP11
39
A28/PP12
40
A29/PP13
42
A30/PP14
43
A31/PP15
44
TT0/PP0
207
TT1/PP1
206
TM0/PP2
204
TM1/PP3
203
TM2/PP4
202
R/W
63
SIZ0
46
SIZ1
47
CS0
50
CS1
51
CS2
54
CS3
55
CS4
56
CS5
58
CS6
59
CS7
60
OE
49
BE0
96
BE1
98
BE2
99
BE3
100
RAS0
83
RAS1
84
CAS0
86
CAS1
87
CAS2
88
CAS3
90
SRAS
92
SCAS
94
SCKE
95
DRAMW
91
BCLKO
170
RSTO
172
BKP/TMS
154
DS0/TD0
151
DS1/TD1
153
DSCLK/TRST
149
TCK
150
PST/CLK
184
PSTDDATA0
186
PSTDDATA1
187
PSTDDATA2
189
PSTDDATA3
190
PSTDDATA4
192
PSTDDATA5
193
PSTDDATA6
195
PSTDDATA7
196
R66
C28
+ C242
U45
1
2
4
R33
FB1
Summary of VL2500 Spot Luminaire
Page 2
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual ii 09-december-2004 02.9676.0022 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 an...
Page 3
F oreword 02.9676.0022 0 09-december-2004 iii how to obtain warranty service a copy of the vari-lite limited warranty was included in the shipping package for this vari ❋lite® product. To obtain warranty service, please contact customer service at 1-877-vari-lite (1-877-827-4548) or customerservice@...
Page 4: Compliance Notice
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual iv 09-december-2004 02.9676.0022 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 ag...
Page 5
F oreword 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual vi 09-december-2004 02.9676.0022 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 ...
Page 7: Sicherheitshinweise
F oreword 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual viii 09-december-2004 02.9676.0022 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. Sprüng...
Page 9: Notes De Sécurité
F oreword 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual x 09-december-2004 02.9676.0022 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 su...
Page 11: Aviso Sobre Seguridad
F oreword 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual xii 09-december-2004 02.9676.0022 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 dire...
Page 15
T able of c ontents 02.9676.0022 0 09-december-2004 xv table of contents about this manual ...................................................................................................... 1 additional documentation...................................................................................
Page 16
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual xvi 09-december-2004 02.9676.0022 0 ballast module assembly replacement .............................................................. 35 pan motor assembly replacement...................................................................... 37 pa...
Page 17
T able of c ontents 02.9676.0022 0 09-december-2004 xvii cables ground strap cable assembly................................................................................. 107 lvs chassis ground cable assembly..................................................................... 108 chassis to yoke ...
Page 18
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual xviii 09-december-2004 02.9676.0022 0 notes.
Page 19
I ntroduction 02.9676.0022 0 09-december-2004 1 introduction about this manual this manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the vl2500™ wash luminaire. The manual is intended for use by vari-lite personnel and by vari-lite’s custome...
Page 20
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 2 09-december-2004 02.9676.0022 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 ...
Page 21: Hapter
02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 4 09-december-2004 02.9676.0022 0 features overview the vl2500 wash 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...
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D escription : m ajor c omponents 1 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 6 09-december-2004 02.9676.0022 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 pan...
Page 25
D escription : m ajor c omponents 1 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 8 09-december-2004 02.9676.0022 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 ...
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D escription : m ajor c omponents 1 02.9676.0022 0 09-december-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 ...
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Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 10 09-december-2004 02.9676.0022 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 he...
Page 29: Hapter
02.9676.0022 0 09-december-2004 11 ser v ice c hapter 2. Maintenance this chapter contains test, service, and standard maintenance procedures. • testing • troubleshooting • maintenance procedures warning: all maintenance procedures are to be performed with power removed from the luminaire and by a t...
Page 30
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 12 09-december-2004 02.9676.0022 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 was...
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M aintenance : t roubleshooting 2 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 14 09-december-2004 02.9676.0022 0 troubleshooting guide if a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to the troubleshooting guide table (below) for more information. This table provides possible ...
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M aintenance : t roubleshooting 2 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 16 09-december-2004 02.9676.0022 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 ...
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M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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...
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Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 18 09-december-2004 02.9676.0022 0 align lamp for flat field the design of the optical system is based on a flat field. A flat field is one where there is no detectable hot spot. After a new lamp is installed, it will be necessary to align the ...
Page 37
M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-2004 19 fixed color bulkhead replacement parts: 21.9676.1120 assy, fixed color bulkhead procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. At head cover, turn captive screws and remove cover. (it will...
Page 38
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 20 09-december-2004 02.9676.0022 0 standard color filter replacement parts: color filter as required to remove and replace a standard color filter: step 1. Disconnect luminaire ac input cable from power source. Step 2. At head cover, turn two c...
Page 39
M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-2004 21 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. (it will remai...
Page 40
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 22 09-december-2004 02.9676.0022 0 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 hea...
Page 41
M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-2004 23 beam spreader motor assembly replacement parts: 22.9671.0468 assy, beam spreader motor assy to remove and replace beam spreader motor assembly: warning: all maintenance procedures are to be performed with power removed from...
Page 42
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 24 09-december-2004 02.9676.0022 0 concave lens assembly replacement parts: 22.9671.0413 assy, concave lens to remove and replace concave lens assembly: warning: all maintenance procedures are to be performed with power removed from the luminai...
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M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-2004 25 convex lens assembly replacement parts: 22.9671.0414 assy, convex lens to remove and replace convex lens assembly: warning: all maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disco...
Page 44
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 26 09-december-2004 02.9676.0022 0 step 5. In replacement convex lens assembly, using 1/4" allen wrench, adjust 8-32 x 2" screw so that screw head is nearly flush with drive bushing plate to create a .020" gap between concave and convex lens as...
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M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-2004 27 100mm condenser lens assembly replacement parts: 22.9671.0402 100mm condenser lens assembly to remove and replace 100mm condenser lens assembly: warning: all maintenance procedures are to be performed with power removed fro...
Page 46
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 28 09-december-2004 02.9676.0022 0 figure 2-11: 100mm condenser lens assembly replacement step 13. Re-install convex and concave lens assemblies. Concave/diffuser lens assembly convex lens assembly shaft collet (4) lens shaft (4) 100mm condense...
Page 47
M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 30 09-december-2004 02.9676.0022 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 ...
Page 49
M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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 2-14: ignitor pcb replacement step 2. At each yoke leg,...
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Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 32 09-december-2004 02.9676.0022 0 step 9. Remove two 1/4" hex standoffs from ignitor pcb by removing the 6-32 ×5/ 16" ppz screws and #6 lock washers. Install in same place on new ignitor pcb. Figure 2-15 . Figure 2-15: ignitor pcb standoff rem...
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M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 34 09-december-2004 02.9676.0022 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 2-17 . Figure 2-17: laying luminaire...
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M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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...
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Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 36 09-december-2004 02.9676.0022 0 step 6. At ballast, disconnect wiring: step 7. Pull lamp wires through ferrite core. Figure 2-19 . Figure 2-19: ballast module assembly replacement step 8. At bottom of enclosure, remove three 8-32 ×3/8" pfz s...
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M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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. ...
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Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 38 09-december-2004 02.9676.0022 0 pan encoder replacement parts: 24.9678.0729 pan encoder 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 en...
Page 57
M aintenance : m aintenance p rocedures 2 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 40 09-december-2004 02.9676.0022 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
02.9676.0022 0 09-december-2004 41 ser v ice c hapter 3. Illustrated parts breakdown this chapter contains illustrated parts breakdowns for assemblies in the vl2500 wash luminaire. • drawing tree • top assembly • yoke • enclosure • cables.
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Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 42 09-december-2004 02.9676.0022 0 drawing tree vl2500 wash luminaire convex lens assembly 22.9671.0414 rev b concave/diffuser front lens assembly 21.9671.0492 rev a continued on the next page vl2500 generic luminaire 21.9676.0010 rev d upper e...
Page 61
I llustrated p arts b reakdown : d rawing t ree 3 02.9676.0022 0 09-december-2004 43 drawing tree (continued) continued from previous page upper enclosure assembly 21.9676.0800 rev e vl2500 wash luminaire (continued) back cap assembly 22.9676.0115 rev 0 tilt plate ground cable assembly 25.9667.0413 ...
Page 62
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 44 09-december-2004 02.9676.0022 0 top assembly vl2500 wash included items kit 28.9676.0002 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 s...
Page 63
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 45 vl2500 wash luminaire 20.9676.0002 rev h 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 16.9676.0004.02 2 ea label location, vl2500...
Page 64
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 46 09-december-2004 02.9676.0022 0 figure 3-2: top assembly 11 5 14 19 (x6) 8 7 21 23 6 18 (x4) 15 13 19 (x4) 12 1 9 4 20 (x2) 10 17 (x8) 2 (x2) 24 (x4) 19 16 22.
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I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-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™ w ash l uminaire s ervice m anual 48 09-december-2004 02.9676.0022 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 ...
Page 67
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 49 front wash assembly 21.9676.1006 rev a refer to figure 3-4 . No. Item qty. Um. Description 1 10.9671.0219 4 ea lens shaft 2 10.9671.0223 4 ea shaft collet 3 10.9671.0313 2 ea lens support arm 4 10.9676.1347 1 ea was...
Page 68
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 50 09-december-2004 02.9676.0022 0 front wash assembly (continued) figure 3-4: front wash assembly 10 (x2) 7 8 12 (x4) 5 2 (x4) 11 (x8) 19 (x4) 1 (x4) 3 (x2) 14 (x12) 18 (x2) 9 4 17 (x4) 6 13 (x2) 15 (x4) 16 (x2) 10
Page 69
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 51 concave/diffuser front lens assembly 21.9671.0492 rev a refer to figure 3-5 . Figure 3-5: concave/diffuser front lens assembly no. Item qty. Um. Description 1 10.9671.0409 1 ea back clamp, concave lens 2 10.9671.042...
Page 70
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 52 09-december-2004 02.9676.0022 0 convex lens assembly 22.9671.0414 rev b refer to figure 3-6 . Figure 3-6: convex lens assembly no. Item qty. Um. Description 1 10.9671.0419 1 ea front clamp, convex lens 2 10.9671.0420 1 ea back clamp, convex ...
Page 71
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 53 top cover assembly 22.9676.0008 rev g refer to figure 3-7 . Figure 3-7: 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 lanyard, ...
Page 72
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 54 09-december-2004 02.9676.0022 0 bottom cover assembly 22.9676.0011 rev c refer to figure 3-8 . Figure 3-8: 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 53.654...
Page 73
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 55 reflector assembly 22.9676.1018 rev a refer to figure 3-9 . Figure 3-9: reflector assembly no. Item qty. Um. Description 1 10.9678.0647 4 ea clamp, mounting, reflector 2 12..9660.0073 1 ea ellipsoidal reflector, smo...
Page 74
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 56 09-december-2004 02.9676.0022 0 back cap assembly 22.9676.0115 rev 0 refer to figure 3-10 . 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 ...
Page 75
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 57 back cap assembly (continued) figure 3-10: 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 13 4...
Page 76
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 58 09-december-2004 02.9676.0022 0 wash fan assembly 22.9676.1090 rev c refer to figure 3-11 . No. Item qty. Um. Description 1 10.9676.1068 1 ea air duct, front fan, wash 2 22.9676.0091 1 ea assy, fan bulkhead 3 22.9676.0095 1 ea air duct, rear...
Page 77
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 59 wash fan assembly (continued) figure 3-11: wash fan assembly 1 3 2 5 13 (x8) 18 (x3) 15 (x2) 17 (x2) 12 4 14 6 11 19 7, 10 (x5) 16 20, 21, 8, 9 direction of air flow.
Page 78
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 60 09-december-2004 02.9676.0022 0 wash fixed color assembly 21.9676.1120 rev b refer to figure 3-12 no. Item qty. Um. Description 1 10.9671.0125 1 ea bulkhead, light shield, color 2 10.9676.1181 1 ea bulkhead, color 3 21.9676.0119 1 ea assy, c...
Page 79
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 61 wash fixed color assembly (continued) figure 3-12: wash fixed color assembly 7 (x3) 1 10 9 11 (x3) 5 6 8 3 2 4.
Page 80
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 62 09-december-2004 02.9676.0022 0 crossfade color assembly 21.9676.1201 rev b refer to figure 3-13 . 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 bu...
Page 81
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 63 crossfade color assembly (continued) figure 3-13: crossfade color assembly 15 (x2) dimmer magenta cyan yellow 19 (x2) 20 (x6) 25 (x6) 3 27 6 26 cyan 11 1 1 1 8 9 10 6 2 5 14 12 18 (x2) 24 (x2) 15 (x2) 19 (x4) 4 (x6)...
Page 82
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 64 09-december-2004 02.9676.0022 0 sensor pcb assembly 24.9638.0113 rev b refer to figure 3-14 . Figure 3-14: 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 s...
Page 83
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 65 color motor assembly 21.9676.0119 rev 0 refer to figure 3-15 . Figure 3-15: 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 84
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 66 09-december-2004 02.9676.0022 0 filter wheel assembly 22.9673.0145 rev a refer to figure 3-16 . Figure 3-16: 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, wh...
Page 85
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 67 strobe assembly 22.9676.0016 rev e refer to figure 3-17 . 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 collar, st...
Page 86
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 68 09-december-2004 02.9676.0022 0 strobe assembly (continued) figure 3-17: 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 ...
Page 87
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 69 uv / ir window assembly 22.9676.0140 rev b refer to figure 3-18 . Figure 3-18: 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 3.00...
Page 88
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 70 09-december-2004 02.9676.0022 0 vl2500 main control board pcb assembly 24.9676.0730 rev b refer to figure 3-19 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 ...
Page 89
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 71 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, r235, r...
Page 90
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 72 09-december-2004 02.9676.0022 0 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, c10...
Page 91
I llustrated p arts b reakdown : t op a ssembly 3 02.9676.0022 0 09-december-2004 73 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 ea i...
Page 92
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 74 09-december-2004 02.9676.0022 0 vl2500 main control board pcb assy (cont.) figure 3-19: vl2500 main control board pcb assembly top side bottom side.
Page 93
I llustrated p arts b reakdown : y oke 3 02.9676.0022 0 09-december-2004 75 yoke yoke assembly 21.9676.0600 rev c refer to figure 3-20 . 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 94
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 76 09-december-2004 02.9676.0022 0 yoke assembly (continued) figure 3-20: 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 95
I llustrated p arts b reakdown : y oke 3 02.9676.0022 0 09-december-2004 77 ignitor pcb assembly 24.9661.1126 rev b refer to figure 3-21 . 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 96
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 78 09-december-2004 02.9676.0022 0 ignitor pcb assembly (continued) figure 3-21: ignitor pcb assembly.
Page 97
I llustrated p arts b reakdown : y oke 3 02.9676.0022 0 09-december-2004 79 tilt motor assembly 22.9676.0610 rev 0 refer to figure 3-22 . 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 98
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 80 09-december-2004 02.9676.0022 0 tilt motor assembly (continued) figure 3-22: tilt motor assembly 5 1 9 (x2) 9 (x2) 8 (x2) 4 7 (x4) 6 (x2) 10 (x2) 2 3 10 (x2).
Page 99
I llustrated p arts b reakdown : y oke 3 02.9676.0022 0 09-december-2004 81 pan/tilt encoder pcb assembly 24.9661.0629 rev 0 refer to figure 3-23 . Figure 3-23: 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 100
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 82 09-december-2004 02.9676.0022 0 yoke fan assembly 22.9676.0609 rev a refer to figure 3-23 . Figure 3-24: 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 32c...
Page 101
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 83 enclosure upper enclosure assembly 21.9676.0800 rev e refer to figures 3-25 and 3-26 . 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 102
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 84 09-december-2004 02.9676.0022 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 25.9...
Page 103
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 85 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 104
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 86 09-december-2004 02.9676.0022 0 upper enclosure assembly (continued) figure 3-25: 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 ...
Page 105
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 87 upper enclosure assembly (continued) figure 3-26: 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 106
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 88 09-december-2004 02.9676.0022 0 connector panel assembly 21.9678.0805 rev d refer to figure 3-27 . Figure 3-27: connector panel assembly no. Item qty. Um. Description 1 10.9678.0852.01 1 ea layout, enclosure overlay 2 10.9678.0859 1 ea brack...
Page 107
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 89 dmx input pcb assembly 24.9663.1830 rev a refer to figure 3-28 figure 3-28: 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 108
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 90 09-december-2004 02.9676.0022 0 ac input pigtail cable assembly 25.9678.0810 rev a refer to figure 3-28 figure 3-29: dmx input pcb assembly no. Item qty. Um. Description 1 52.6274.2313 1 ea strain relief, skintop flextype pg13 blk 2 52.6401....
Page 109
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 91 pan tube assembly 21.9678.0880 rev c refer to figure 3-30 . Figure 3-30: 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 110
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 92 09-december-2004 02.9676.0022 0 pan motor assembly 21.9678.0864 rev b refer to figure 3-31 . Figure 3-31: 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 111
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 93 upper enclosure fan assembly 23.9678.0686 rev 0 refer to figure 3-31 . Figure 3-32: 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 26...
Page 112
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 94 09-december-2004 02.9676.0022 0 pan eot sensor electrical assembly 23.9678.0687 rev a refer to figure 3-33 . Figure 3-33: pan eot sensor electrical assembly no. Item qty. Um. Description 1 52.6524.0006 1 ea conn, housing 6 pos. Receptacle 2 ...
Page 113
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 95 ballast module (arc power supply) assembly 23.9671.1250 rev f refer to figures 3-34 and 3-35 . 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 1200...
Page 114
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 96 09-december-2004 02.9676.0022 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. De...
Page 115
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 97 ballast module assembly (continued) figure 3-34: 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 116
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 98 09-december-2004 02.9676.0022 0 ballast module assy (continued) figure 3-35: 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 (4...
Page 117
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 99 700w ballast board pcb assembly 24.9661.1130 rev d refer to figure 3-36 . 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 h...
Page 118
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 100 09-december-2004 02.9676.0022 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 3...
Page 119
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 101 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 120
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 102 09-december-2004 02.9676.0022 0 700w ballast board pcb assembly (cont.) figure 3-36: 700w ballast board pcb assembly.
Page 121
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 103 700w ballast rider board pcb assembly 24.9661.1131 rev c refer to figure 3-37 . 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 122
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 104 09-december-2004 02.9676.0022 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 123
I llustrated p arts b reakdown : e nclosure 3 02.9676.0022 0 09-december-2004 105 figure 3-37: 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 124
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 106 09-december-2004 02.9676.0022 0 notes.
Page 125
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 107 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 126
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 108 09-december-2004 02.9676.0022 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 p...
Page 127
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 109 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 128
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 110 09-december-2004 02.9676.0022 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 ...
Page 129
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 111 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 130
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 112 09-december-2004 02.9676.0022 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....
Page 131
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 113 color/fixed bulkheads cable assembly 25.9676.1715 rev 0 refer to figure 3-54 . No. Item qty. Um. Description 1 04.9676.1715.00 1 ea label set, vl2500 color harness 2 52.6224.0040 1 ea housing, 40 pos 26-22 awg preloaded m...
Page 132
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 114 09-december-2004 02.9676.0022 0 color/fixed bulkheads cable assembly (cont.) figure 3-54: color/fixed bulkheads cable assembly 16, 7, 8 14, 9, 10 11 (x6) 13 (x2) 12 14, 7, 8 2, 3, 4 15, 5, 6 1 1 1 1 1 1 14, 9, 10
Page 133
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 115 optics/strobe bulkheads cable assembly 25.9676.1716 rev a refer to figure 3-55 . No. Item qty. Um. Description 1 04.9676.1716.00 1 ea label set, vl2500 color harness 2 52.6224.0034 1 ea housing, 34 pos 26-22 awg preloaded...
Page 134
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 116 09-december-2004 02.9676.0022 0 optics/strobe bulkheads cable assy (cont.) figure 3-55: optics/strobe bulkheads cable assembly 12 2, 3, 4 1 1 13, 5, 8 13, 7, 9 13, 5, 8 11 1 note: open positions will have pins loaded for a better mechanical...
Page 135
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 117 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 136
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 118 09-december-2004 02.9676.0022 0 fans/disconnect cable assembly 25.9676.0718 rev e 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 ...
Page 137
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 119 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 138
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 120 09-december-2004 02.9676.0022 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, fro...
Page 139
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 121 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 140
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 122 09-december-2004 02.9676.0022 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-...
Page 141
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 123 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 142
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 124 09-december-2004 02.9676.0022 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 143
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 125 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 144
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 126 09-december-2004 02.9676.0022 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 ...
Page 145
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 127 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 146
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 128 09-december-2004 02.9676.0022 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 insul...
Page 147
I llustrated p arts b reakdown : c ables 3 02.9676.0022 0 09-december-2004 129 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 148
Vari ❋lite® - vl2500™ w ash l uminaire s ervice m anual 130 09-december-2004 02.9676.0022 0 notes.
Page 149
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 131 vl2500 wash luminaire schematics 700w ballast schematic.
Page 150
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 132 700w ballast schematic (continued).
Page 151
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 133 ballast rider schematic.
Page 152
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 134 vl2500 luminaire schematic.
Page 153
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 135 vl2500 luminaire schematic (continued).
Page 154
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 136 vl2500 luminaire schematic (continued).
Page 155
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 137 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 +1.8...
Page 156
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 138 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 ...
Page 157
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 139 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 a...
Page 158
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 140 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 i...
Page 159
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 141 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 160
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 142 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 +...
Page 161
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 143 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 f...
Page 162
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 144 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 a...
Page 163
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 145 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 164
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-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 +24v +24v vcc vcc vcc vcc +24v vcc +24v vcc +24v +3.3v +2.5v +1.8v vcc edge_out2b edge_o...
Page 165
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 147 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 ...
Page 166
Vari ❋lite ® - vl2500™ w ash l uminaire s ervice m anual r eference f old -o uts 02.9676.0022 0 09-december-2004 148 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 value...
Page 168
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..