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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 1

    Vari-lite is a philips group brand.

  • Page 2

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual ii 01 -ju ly-200 8 0 2 . 9 6 7 6 .0 0 2 0 a vari ❋lite ® is a trademark owned by philips group and is registered in the united states and other countries. Vl1000™, vl2000™, vl2201™, vl2202™, vl2400™ (and the individual product designations), vl...

  • Page 3

    F oreword 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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...

  • Page 4: Compliance Notice

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual iv 01 -ju ly-200 8 0 2 . 9 6 7 6 .0 0 2 0 a 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 prot...

  • Page 5

    F oreword 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 v general information pertaining to protection against elec- trical shock, fire, exposure to excessive uv radiation, and injury to persons can be found below. Warning: instructions for continued protection against fire 1. Vari ❋lite® luminaires ha...

  • Page 6

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual v i 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 lam...

  • Page 7: Sicherheitshinweise

    F oreword 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 b...

  • Page 8

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual v i i i 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 2. Es ist gefährlich, leuchten ohne linsen oder blenden zu bedienen. Blenden, linsen oder ultraviolettschirme müssen ausgetauscht werden, sofern deren schutzwirkung durch sichtbare beschädigung...

  • Page 9: Notes De Sécurité

    F oreword 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 ...

  • Page 10

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual x 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 so...

  • Page 11: Aviso Sobre Seguridad

    F oreword 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 tod...

  • Page 12

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual x i i 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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....

  • Page 13

    S afety n otice (j apanese ) 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 xiii uv : 1. Vari ❋lite® philips osram hid msr400 msr575hr 4. Vari ❋lite® : 1. Vari ❋lite® 2. Vari ❋lite®.

  • Page 14

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual x i v 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a : uv 1. Vari ❋lite® uv hid : : rf 1. Class a 1. Lamp power-up state l on/ l off.

  • Page 15

    T able of c ontents 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 xv table of contents introduction about this manual ...................................................................................................... 1 additional documentation...........................................................

  • Page 16

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual x v i 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a ballast module assembly replacement .............................................................. 35 pan motor assembly replacement..................................................................

  • Page 17

    T able of c ontents 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 xvii pan eot sensor electrical assembly........................................................................ 98 ballast module (arc power supply) assembly......................................................... 99 cables ground strap...

  • Page 18: Notes

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual x v i i i 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a notes.

  • Page 19

    I ntroduction 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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-lit...

  • Page 20

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 y...

  • Page 21: Hapter

    0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 3 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 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 ...

  • Page 23

    D escription : m ajor c omponents 1 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 la...

  • Page 24: Address

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 enclosur...

  • Page 25

    D escription : m ajor c omponents 1 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 7 head components the following illustration shows the major sub-assemblies that are located in the luminaire head assembly. (yoke and enclosure not shown for clarity.) removable cover dual blade cym color/dimmer bulkhead...

  • Page 26

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a yoke components the following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly. (head and enclosure not shown for clarity.) ignitor pcb tilt motor relay mai...

  • Page 27

    D escription : m ajor c omponents 1 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 9 enclosure components the following illustration shows the major sub-assemblies that are located in the luminaire enclosure assembly. (yoke and head assembly not shown for clarity.) enclosure top covers 150w +24v/6.3a in...

  • Page 28

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 d a ta i/o dmx input pcb main control pcb i...

  • Page 29: Hapter

    0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 11 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 1 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 th...

  • Page 31

    M aintenance : t roubleshooting 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 ...

  • Page 32

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 pos...

  • Page 33

    M aintenance : t roubleshooting 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 th...

  • Page 34

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 wat...

  • Page 35

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 clo...

  • Page 36

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a color/gobo/iris bulkhead replacement parts: 21.9676.4120 assy, color/gobo/iris bulkhead procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. At top head cover, graduall...

  • Page 37

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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...

  • Page 38

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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, loosen two captive screws and ...

  • Page 39

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 c...

  • Page 40

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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...

  • Page 41

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 ste...

  • Page 42

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 a...

  • Page 43

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 shaf...

  • Page 44

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 as...

  • Page 45

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 27 lens barrel assembly replacement parts: 21.9676.4306 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 ca...

  • Page 46

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 2 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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-...

  • Page 47

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 mot...

  • Page 48

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 3 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a main control board (mcb) pcb replacement parts: 24.9676.3730 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 yok...

  • Page 49

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 eac...

  • Page 50

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 3 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 st...

  • Page 51

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 n...

  • Page 52

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 3 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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: layi...

  • Page 53

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 35 ballast module assembly replacement parts: 69.9676.0700 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, r...

  • Page 54

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 3 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a step 6. At ballast, disconnect wiring: figure 2-22: ballast module assembly replacement step 7. At bottom of enclosure, remove four 8-32 ×3/8" pfz screws and four 8/32x3/ 8" ppz screws that secure ...

  • Page 55

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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 ...

  • Page 56

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 3 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a pan encoder replacement parts: 24.9678.9729 pan encoder procedure: step 1. Disconnect luminaire ac input cable from power source. Step 2. Carefully lay luminaire on its side to have access to botto...

  • Page 57

    M aintenance : m aintenance p rocedures 2 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 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...

  • Page 58

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 4 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a power supply (lvs) replacement parts: 69.3177.0151 power supply (lvs) assy repair procedure step 1. Disconnect luminaire ac input cable from power source. Step 2. At enclosure, remove top cover at ...

  • Page 59: Hapter

    0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 41 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 4 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a drawing tree vl2500 series spot luminaire continued on the next page vl2500 generic luminaire 21.9676.0010 rev j upper enclosure assembly 21.9676.0800 rev s yoke assembly 21.9676.0600 rev g tilt mo...

  • Page 61

    I llustrated p arts b reakdown : d rawing t ree 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 43 drawing tree (continued) continued from previous page upper enclosure assembly 21.9676.0800 rev s vl2500 spot luminaire (continued) back cap assembly 22.9676.0115 rev e tilt plate ground cable assembly 25...

  • Page 62

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 4 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a top assembly vl2500 included items kit 28.9676.0001 rev f refer to figure 3-1 . No. Item qty. Um. Description 1 02.8001.0001 1 ea product support sheet, vari-lite customer service 2 02.8052.0001 1 ...

  • Page 63

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 45 figure 3-1: included items kit 6 4 2 9 10 8 1 5 3 7.

  • Page 64

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 4 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a vl2500 spot luminaire 20.9676.0001 rev k refer to figure 3-2 . No. Item qty. Um. Description 1 10.9638.0052 1 ea dam, air, vl6 2 10.9676.8632 2 ea cover, yoke thermoform 3 16.9676.0004.01 1 ea labe...

  • Page 65

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 47 figure 3-2: top assembly 11 6 14 19 (x6) 8 7 16 5 18 (x4) 22 13 15 19 (x4) 24 (x4) 12 1 9 4 21 (x2) 10 17 (x8) 2 (x2) 16 20 23 note: loop lamp wires through ferrite. 18 (x2).

  • Page 66

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 4 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a vl2500 generic luminaire 21.9676.0010 rev j refer to figure 3-3 . No. Item qty. Um. Description 1 10.9628.0211 1 ea stablizer, pan/tilt 2 10.9676.8617 1 ea heatshield, yoke crossmember 3 10.9676.00...

  • Page 67

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 49 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 ...

  • Page 68

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 5 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a front assembly 21.9676.4006 rev f refer to figure 3-4 . No. Item qty. Um. Description 1 10.9660.0129 1 ea shaft stop, rotating gobo wheel 2 10.9660.0130 1 ea shaft, rotating gobo wheel 3 10.9660.02...

  • Page 69

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 51 figure 3-4: front assembly 32 55.6506.0009 1 ea spacer, 1/2" rnd .125" lg .375" id shaft 33 55.6589.0003 2 ea standoff, 1/4" rnd 4-40 .606" lg mf 34 55.6663.0007 1 ea standoff, 3/8" rnd, 1.75" lg, ff no. ...

  • Page 70

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 5 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a lens barrel assembly 21.9676.4306 rev d refer to figure 3-5 . No. Item qty. Um. Description 1 10.9676.4254 1 ea shaft, zoom bearing 2 10.9676.4256 1 ea wear strip, edge lenses 3 10.9676.4258 1 ea w...

  • Page 71

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 53 lens barrel assembly (continued) figure 3-5: lens barrel assembly 21 4 3 13 11 14 (x2) 12 1 9 10 5 8 7 6 18 (x2) 2 15 (x4) 17 (x4) 20 14 16 (x2) 22 (x2) 23 (x2) 19 (x2).

  • Page 72

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 5 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a sub-barrel group 2 assembly 21.9676.4229 rev b refer to figure 3-6 . Figure 3-6: sub-barrel group 2 assembly no. Item qty. Um. Description 1 10.9676.4223 1 ea barrel, zoom, lower 2 10.9676.4250 1 e...

  • Page 73

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 55 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 con...

  • Page 74

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 5 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a rotating gobo wheel assembly 21.9660.0105 rev e 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...

  • Page 75

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 57 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) 15 (6) 15 (3) 14 standard gobos.

  • Page 76

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 5 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a sensor rotating gobo pcb assembly 24.9667.1321 rev - refer to figure 3-9 . Replace as a complete assembly. Figure 3-9: sensor rotating gobo pcb assembly 1 3 3.

  • Page 77

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 59 top cover assembly 22.9676.0008 rev h 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...

  • Page 78

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a bottom cover assembly 22.9676.0011 rev d refer to figure 3-11 . Figure 3-11: bottom cover assembly no. Item qty. Um. Description 1 10.9676.8012 1 ea cover, lower 2 53.2008.0008 3 ea nut, #8 push 3 ...

  • Page 79

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 61 reflector assembly 22.9676.0018 rev b 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, disconne...

  • Page 80

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a back cap assembly 22.9676.0115 rev e 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....

  • Page 81

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 63 back cap assembly (continued) figure 3-13: back cap assembly 1 18 10 (x2) 3 24 (13.5") 24 (9.0") 9 14 (x2) 26 (x2) 31 16 (x2) 25 (x2) 29 (x2) 5 12 (x2) 6 17 (x4) 23 (x2) 20 (x2) 22 11 28 30 (x2) 7 2 15 25...

  • Page 82

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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, rea...

  • Page 83

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 65 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 84

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a iris/color/gobo bulkhead assembly 21.9676.4120 rev c refer to figure 3-15 . No. Item qty. Um. Description 1 10.9676.4124 1 ea bulkhead, iris/gobo/color 2 21.9676.0118 1 ea assy, iris/gobo motor 3 2...

  • Page 85

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 67 iris/color/gobo bulkhead assembly (continued) figure 3-15: iris/color/gobo bulkhead assembly 4 14 (x7) 9 (x3) 8 7 10 1 3 6 12 (x3) 5 9 (x3) 2 11 13 (x2).

  • Page 86

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 6 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a crossfade color assembly 21.9676.0201 rev n refer to figure 3-16 . No. Item qty. Um. Description 1 10.9676.0230.01 4 ea spacer, color wheel 2 10.9676.0230.02 1 ea spacer, color motor 3 10.9676.0234...

  • Page 87

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 69 crossfade color assembly (continued) figure 3-16: crossfade color assembly 14 (x2) dimmer magenta cyan yellow 19 (x4) 18 (x6) 27 (x5) 3 29 1 25 (x2) cyan 12 1 1 1 9 10 11 2 25 6 8 13 18 (x2) 26 (x2) 14 (x...

  • Page 88

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 7 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a iris/gobo motor assembly 21.9676.0118 rev d 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....

  • Page 89

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 71 color motor assembly 21.9676.0119 rev d refer to figure 3-18 . Figure 3-18: color motor assembly no. Item qty. Um. Description 1 10.9621.0097 1 ea stabilizer, stepper, gobo wheel 2 10.9676.1120 1 ea color...

  • Page 90

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 7 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a gobo wheel assembly 21.9676.4146 rev a refer to figure 3-19 . Figure 3-19: gobo wheel assembly no. Item qty. Um. Description 1 22.9676.4142 1 ea assy, gobo wheel, 12 position fixed - 12.9676.4140 1...

  • Page 91

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 73 color filter wheel assembly 21.9676.4145 rev a refer to figure 3-20 . Figure 3-20: filter wheel assembly no. Item qty. Um. Description 1 22.9676.4142 1 ea assy, gobo wheel, 12 position fixed - 12.9676.414...

  • Page 92

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 7 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a strobe assembly 22.9676.0016 rev h refer to figure 3-21 . 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 m...

  • Page 93

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 75 strobe assembly (continued) figure 3-21: 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 b...

  • Page 94

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 7 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a uv / ir window assembly 22.9676.0140 rev g refer to figure 3-22 . Figure 3-22: 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 fi...

  • Page 95

    I llustrated p arts b reakdown : t op a ssembly 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 77 vl2500 main control board pcb assembly 24.9676.3730 rev 0 refer to figure 3-23 replace as a complete assembly. Figure 3-23: vl2500 main control board pcb assembly top side bottom side.

  • Page 96

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 7 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a notes.

  • Page 97

    I llustrated p arts b reakdown : y oke 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 79 yoke yoke assembly 21.9676.0600 rev g refer to figure 3-24 . No. Item qty. Um. Description 1 22.9676.8605 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...

  • Page 98

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a yoke assembly (continued) figure 3-24: 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 99

    I llustrated p arts b reakdown : y oke 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 81 ignitor pcb assembly 24.9661.1126 rev c refer to figure 3-25 . Replace as a complete assembly. Figure 3-25: ignitor pcb assembly.

  • Page 100

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a tilt motor assembly 22.9676.0610 rev c refer to figure 3-26 . No. Item qty. Um. Description 1 10.9661.7298 1 ea plate, tension adjust, pan motor 2 22.9661.0608 1 ea assy, drive pulley - - 10.9661.8...

  • Page 101

    I llustrated p arts b reakdown : y oke 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 83 tilt motor assembly (continued) figure 3-26: tilt motor assembly 5 1 9 (x2) 9 (x2) 8 (x2) 4 7 (x4) 6 (x2) 10 (x2) 2 3 10 (x2).

  • Page 102

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a pan/tilt encoder pcb assembly 24.9661.9629 rev b refer to figure 3-27 . Replace as a complete assembly. Figure 3-27: pan/tilt encoder pcb assembly.

  • Page 103

    I llustrated p arts b reakdown : y oke 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 85 yoke fan assembly 22.9676.0609 rev a refer to figure 3-27 . Figure 3-28: 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 32cfm 3...

  • Page 104

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a.

  • Page 105

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 87 enclosure upper enclosure assembly 21.9676.0800 rev t refer to figures 3-29 and 3-30 . No. Item qty. Um. Description 1 04.9640.0374 1 ea label, p.E. Ground 2 04.9673.0040 1 ea label, 2000 series compliance 3 ...

  • Page 106

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 8 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a 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 sh...

  • Page 107

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 89 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 55.6580.0002 2 ea cable tie, .18" w x 8.00" lg 71 55.2261.0001 1 ea sleeve, nyl, insu...

  • Page 108

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 9 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a upper enclosure assembly (continued) figure 3-29: upper enclosure assembly 5 17 60 (x2) 40 61 75 86 53 (x3) 26 6 83 59 76 (x4) 12 50 (x3) 51 (x4) 53 (x3) 48 (x2) 27 70 54 69 71 84 79 85 1 47 56 42 ...

  • Page 109

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 91 upper enclosure assembly (continued) figure 3-30: upper enclosure assembly 19 77 (x4) 63 (x4) 54 (x4) 10 (x2) 11 (x2) 80 (x4) 54 (x4) 53 (x4) 55 (x4) 15 2 3 16 4 72 (x2) 15 16 21.

  • Page 110

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 9 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a connector panel assembly 21.9676.0805 rev a refer to figure 3-31 . Figure 3-31: connector panel assembly no. Item qty. Um. Description 1 10.9678.0852.01 1 ea layout, enclosure overlay 2 10.9678.085...

  • Page 111

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 93 dmx input pcb assembly 24.9663.3895 rev 0 refer to figure 3-32 figure 3-32: dmx input pcb assembly no. Item qty. Um. Description ref. 1 17.9663.3895 1 ea pcb assy sm, dmx input - 2 52.6259.0006 1 ea header, 5...

  • Page 112

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 9 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a ac input pigtail cable assembly 25.9678.0810 rev b refer to figure 3-32 figure 3-33: dmx input pcb assembly no. Item qty. Um. Description 1 52.6274.2313 1 ea strain relief, skintop flextype pg13 bl...

  • Page 113

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 95 pan tube assembly 21.9678.0880 rev c refer to figure 3-34 . Figure 3-34: 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...

  • Page 114

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 9 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a pan motor assembly 21.9678.0864 rev e refer to figure 3-35 . Figure 3-35: 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...

  • Page 115

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 97 upper enclosure fan assembly 23.9678.0686 rev 0 refer to figure 3-35 . Figure 3-36: 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, ...

  • Page 116

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 9 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a pan eot sensor electrical assembly 23.9678.0687 rev a refer to figure 3-37 . Figure 3-37: pan eot sensor electrical assembly no. Item qty. Um. Description 1 52.6524.0006 1 ea conn, housing 6 pos. R...

  • Page 117

    I llustrated p arts b reakdown : e nclosure 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 99 ballast module (arc power supply) assembly 69.9676.0700 rev 0 refer to figure 3-38 . Replace as a complete assembly. Figure 3-38: ballast module (arc power supply) assy.

  • Page 118

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 0 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a notes.

  • Page 119

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 101 cables ground strap cable assembly 25.8007.2212 rev 0 replace as a complete assembly. Refer to figure 3-48 . Figure 3-48: ground strap cable assembly no. Item qty. Um. Description 1 2 ea term, ring # 6 22-16 aw...

  • Page 120

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 0 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a lvs chassis ground cable assembly 25.9661.1514 rev a replace as a complete assembly. Refer to figure 3-49 . Figure 3-49: lvs chassis ground cable assembly no. Item qty. Um. Description 1 1 ea ter...

  • Page 121

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 103 chassis to yoke ground cable assembly 25.9661.1520 rev c replace as a complete assembly. Refer to figure 3-50 . Figure 3-50: chassis to yoke ground cable assembly no. Item qty. Um. Description 1 2 ea term, #8, ...

  • Page 122

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 0 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a yoke to head ground cable assembly 25.9667.0028 rev a replace as a complete assembly. Refer to figure 3-50 . Figure 3-51: chassis to yoke ground cable assembly no. Item qty. Um. Description 1 2 e...

  • Page 123

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 105 ignitor to relay cable assembly 25.9676.0030 rev 0 replace as a complete assembly. Refer to figure 3-52 . Figure 3-52: ignitor to relay cable assembly no. Item qty. Um. Description 1 1 ea term, ring #6 blue 16-...

  • Page 124

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 0 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a tilt plate ground cable assembly 25.9667.0413 rev a replace as a complete assembly. Refer to figure 3-53 . Figure 3-53: tilt plate ground cable assembly no. Item qty. Um. Description 1 1 ea term,...

  • Page 125

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 107 color/gobo t-stat cable assembly 25.9676.0125 rev b replace as a complete assembly. Refer to figure 3-54 . Figure 3-54: color/gobo t-stat cable assembly no. Item qty. Um. Description 1 1 ea conn, housing 2pos. ...

  • Page 126

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 0 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a color/fixed bulkheads cable assembly 25.9676.0715 rev f replace as a complete assembly. Refer to figure 3-55 . No. Item qty. Um. Description 1 1 ea label set, vl2500 color harness 2 1 ea housing,...

  • Page 127

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 109 color/fixed bulkheads cable assembly (cont.) figure 3-55: 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 128

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 1 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a optics/strobe bulkheads cable assembly 25.9676.0716 rev f replace as a complete assembly. Refer to figure 3-56 . No. Item qty. Um. Description 1 1 ea label set, vl2500 color harness 2 1 ea housin...

  • Page 129

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 111 optics/strobe bulkheads cable assy (cont.) figure 3-56: 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 130

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 1 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a strobe 1 cable assembly 25.9676.0717 rev b replace as a complete assembly. Refer to figure 3-57 . Figure 3-57: strobe 1 cable assembly no. Item qty. Um. Description 1 1 ea label, strobe 1 2 1 ea ...

  • Page 131

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 113 fans/disconnect cable assembly 25.9676.0718 rev g replace as a complete assembly. Refer to figure 3-58 . Figure 3-58: fans/disconnect cable assembly no. Item qty. Um. Description 1 1 ea recept, 3 pos mta100 w/ ...

  • Page 132

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 1 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a ot switch to reflector assy. Cable assembly 25.9676.0719 rev a replace as a complete assembly. Refer to figure 3-59 . Figure 3-59: ot switch to reflector assy. Cable assembly no. Item qty. Um. De...

  • Page 133

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 115 pan/tilt control cable assembly 25.9676.0818 rev b replace as a complete assembly. Refer to figure 3-60 . No. Item qty. Um. Description 1 1 ea housing, 20 pos 26-22 awg dbl row unloaded 2 1 ea cover, front 20 p...

  • Page 134

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 1 6 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a pan/tilt control cable assembly (continued) figure 3-60: pan/tilt control cable assembly 1, 2, 3 4, 7 (x5) 6 (x3) ,5 4, 7 (x5) 6 (x3) ,5 8 (x7).

  • Page 135

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 117 emi filter to power switch cable assembly 25.9678.0811 rev c replace as a complete assembly. Refer to figure 3-61 figure 3-61: emi filter to power switch cable assembly no. Item qty. Um. Description 1 2 ea rcpt...

  • Page 136

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 1 8 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a ac input splitter cable assembly 25.9678.0812 rev e replace as a complete assembly. Refer to figure 3-62 no. Item qty. Um. Description 1 1 ea plug housing, mnlok plug 3pos 2 1 ea term, ring #6 bl...

  • Page 137

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 119 ac input splitter cable assembly (continued) figure 3-62: ac input splitter cable assembly 2 (x2) 4 (x2) 12 5, 9 5, 10 13 11, 6 3 1 7 (x3) 8.

  • Page 138

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 2 0 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a data i/o link cable assembly 25.9678.0813 rev a replace as a complete assembly. Refer to figure 3-63 figure 3-63: data i/o link cable assembly no. Item qty. Um. Description 1 1 ea recept, 4 pos m...

  • Page 139

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 121 display cable assembly 25.9678.1825 rev 0 replace as a complete assembly. Refer to figure 3-64 figure 3-64: display cable assembly no. Item qty. Um. Description 1 2 ea recept, 6 pos mta100 w/pol tab wht clsd en...

  • Page 140

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 2 2 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a ballast to controller cable assembly 25.9678.0816 rev a replace as a complete assembly. Refer to figure 3-65 figure 3-65: ballast to controller cable assembly no. Item qty. Um. Description 1 1 ea...

  • Page 141

    I llustrated p arts b reakdown : c ables 3 0 2 . 9 6 7 6 . 0 0 2 0 a 01 -ju ly- 200 8 123 lamp supply to relay cable assembly 25.9678.0829 rev a replace as a complete assembly. Refer to figure 3-66 figure 3-66: lamp supply to relay cable assembly no. Item qty. Um. Description 1 4 ea recp, faston 1/4...

  • Page 142

    Vari ❋lite® - vl2500™ s pot l uminaire s ervice m anual 1 2 4 01 -ju ly- 200 8 0 2 . 9 6 7 6 . 0 0 2 0 a dc output cable assembly 25.9678.0821 rev e replace as a complete assembly. Refer to figure 3-67 figure 3-67: dc output cable assembly no. Item qty. Um. Description 1 1 ea conn, housing, sl-156 2...

  • Page 143

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 125 vl2500™ spot luminaire schematics vl2500 luminaire wiring diagram.

  • Page 144

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 126 vl2500 luminaire wiring diagram (continued).

  • Page 145

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 127 vl2500 luminaire wiring diagram (continued).

  • Page 146

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 128 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 ...

  • Page 147

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 129 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 ...

  • Page 148

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 130 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] ...

  • Page 149

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 131 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_v...

  • Page 150

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 132 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 +2...

  • Page 151

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 133 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...

  • Page 152

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 134 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...

  • Page 153

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 135 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...

  • Page 154

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 136 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 nu...

  • Page 155

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 137 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_out2...

  • Page 156

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 138 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, ...

  • Page 157

    Vari ❋lite ® - vl2500™ s pot l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 7 6 . 0 0 2 0 a 01-july-2 008 139 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 resist...

  • Page 159

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