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Vari Lite VL2500 Spot Luminaire Service Manual - 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]
D17
A1
A7
A9
A8
A0
A[0 ..24]
A6
A2
A4
A3
A5
A[0 ..24]
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+2.5V
+3.3V
+2.5V
+3.3V
+3.3V
+3.3V
VCC
+24V
+3.3V
+2.5V
+1.8V
TDIA
CE-
DCLK
STATUS-
MSEL1
TMSA
TCKA
CONF_DONE
CONFIG-
MSEL0
TX_EN_C-
PWM_OUT_23
PWM_OUT_3
PWM_OUT_13
PWM_OUT_5
PWM_PH_5
PWM_PH_13
PWM_PH_6
PWM_PH_14
PWM_OUT_6
TX_EN_A-
PWM_OUT_14
UART_OUT_A
PWM_PH_9
PWM_PH_19
PWM_PH_15
PWM_PH_7
PWM_OUT_19
PWM_OUT_7
PWM_OUT_15
SPARE_1
SPARE_2
PWM_OUT_9
UART_IN
PWM_OUT_18
PWM_OUT_21
PWM_OUT_17
PWM_OUT_20
PWM_OUT_16
PWM_OUT_8
PWM_PH_16
PWM_PH_8
LED_TX-
LED_RX-
LED_STATUS
LAMP_ON-
CYAN_IN
LAMP_CNTL
DIMMER_IN
PWM_OUT_2
PWM_OUT_24
PWM_PH_24
PWM_PH_23
PWM_OUT_4
PWM_PH_4
AMB_IN
CS_MTR-
CS_UART-
CLK3
FXDG_IN
OPT_IN
PWM3_EN_1
PWM3_OUT_2
MAG_IN
FXDC_IN
RSTO-
R/W-
IDX_OUT_IN
PHASE_B_2
PWM3_OUT_1
T_COT_IN
RGOBO_OUT_IN
PWM3_OUT_6
PWM3_OUT_4
PWM3_OUT_3
PWM3_OUT_5
PWM3_EN_2
PWM_PH_3
PHASE_A_1
PHASE_B_1
P_COT_IN
PHASE_A_2
PWM_PH_18
PWM_OUT_10
PWM_OUT_11
PWM_PH_25
PWM_PH_1
PWM_PH_11
PWM_PH_12
PWM_PH_2
PWM_PH_26
PWM_OUT_26
PWM_OUT_12
RX_INT-
TX_INT-
PWM_PH_20
PWM_OUT_1
PWM_OUT_25
PWM_OUT_22
PWM_PH_22
PWM_PH_10
PWM_PH_21
PWM_PH_17
DATA
MSEL0
MSEL1
STATUS-
CONFIG-
CONF_DONE
INIT_DONE
CE-
TDIA
TMSA
DCLK
TCKA
TA-
DCLK
STATUS-
CONF_DONE
DATA
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
D25
D26
D27
D28
D29
D30
D31
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A1
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A0
A2
A3
A4
VCC
+24V
+3.3V
+2.5V
GND
+1.8V
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
INSTALL ONLY WITH EPC1
3/B3
3/B3
3/A3
3/B3
2/C4,3/A2,3/A3
2/C4,3/A2,3/B3
2/C4,3/B3
2/C4,3/A2,3/B3
3/B3
3/B3
2/D4,2/C3,3/A3
4/D5
8/D5
7/B5
6/B5
5/C4
5/C2
6/B3
5/C2
6/B3
4/D5
5/B4
6/B5
4/C5
6/B7
8/D7
7/D7
6/D7
8/D8
6/D8
7/D8
10/B4
10/B4
6/B8
2/B5,4/C5
7/B8
8/B8
7/B8
8/C8
7/D7
6/D7
7/D7
6/D7
4/D6
4/D6
4/D6
4/C7
4/C7
7/C5
4/A8
8/C5
8/D4
8/D4
7/B5
7/B3
2/B4,2/D6
2/D6,2/B4
2/A6
4/A8
5/C8
5/C8
4/A8
4/A8
2/B4
2/C4,2/C4,2/C6
4/A8
4/A8
4/A8
4/B8
4/B8
5/D8
4/B8
4/B8
5/B8
5/B8
5/C8
5/B8
5/B8
7/B3
4/B8
4/B8
4/B8
4/B8
7/B7
6/B8
6/D3
8/B4
7/D3
6/D3
6/D3
7/D3
8/B4
8/B5
6/C5
2/C5,2/C6
2/C5,2/C6
2/D1,3/A3
8/D7
7/D5
8/B5
8/B8
8/B7
6/B7
8/B7
7/B7
2/C4,3/A2
3/B7
3/B7
2/C4,3/A2,3/C7
2/C4,3/C7
2/C4,3/A2,3/B7
2/C4
3/B7
3/B7
3/B7
2/C4,3/C7,3/A2
3/B7
2/C5,2/B7,2/C6
2/D1,3/B3
2/D4,2/C3,3/D6
SOCKET IS XU15
2/C4,3/C7,3/A3
2/C4,3/C7,3/B3
2/C4,3/C7,3/B3
2/C4,3/B3
10
3
DO NOT STUFF
C37
R46
C36
R27
R43
C39
R23
C57
C63
C38
C32
U15
DATA
1
DCLK
2
OE
3
CS
4
VCC2
8
VCC1
7
CASC
6
GND
5
R45
C61
R47
C35
C41
C56
C65
C34
R49
C58
C31
R48
C30
C60
R44
R50
C64
C40
C62
C42
R22
R28
C29
C59
U16
IO1
7
IO2
8
IO3
9
IO4
11
IO5
12
IO6
13
IO7
14
IO8
15
IO9
17
IO10
18
IO11
24
IO12
25
IO13
26
IO14
27
IO15
28
IO16
29
IO17
30
IO18
31
IO19
36
IO20
37
IO21
38
IO22
39
IO23
40
IO24
41
IO25
44
IO26
45
IO27
46
IO28
47
IO29
53
IO30
54
IO31
55
IO32
56
IO33
57
IO34
58
IO35
60
IO36
61
IO37
63
IO38
64
IO39
65
IO40
67
IO41
68
IO42
69
IO43
70
IO44
71
IO45
73
IO46
74
IO47
75
IO48
83
IO49
85
IO50
86
IO51
87
IO52
88
IO53
89
IO54
90
IO55
92
IO56
93
IO57
94
IO58
95
IO59
96
IO60
97
IO61
99
IO62
100
IO63
101
IO64
102
IO65
103
IO66
104
IO67
111
IO68
112
IO69
113
IO70
114
IO71
115
IO72
116
IO73
119
IO74
120
IO75
121
IO76
122
IN1
78
IN2
80
IN3
182
IN4
184
CLK1
79
CLK2
183
GND_CLK
81
GND1
6
GND2
20
GND3
23
GND4
32
GND5
35
GND6
43
GND7
49
GND8
59
GND9
76
GND10
82
GND11
109
GND12
117
GND13
123
GND14
129
GND15
137
GND16
145
GND17
151
GND18
171
GND19
181
GND20
188
VCIO1
5
VCIO2
22
VCIO3
34
VCIO4
42
VCIO5
66
VCIO6
84
VCIO7
98
VCIO8
110
VCIO9
118
VCIO10
138
VCIO11
146
VCIO12
165
VCIO13
178
VCIO14
194
VCINT1
21
VCINT2
33
VCINT3
48
VCINT4
72
VCINT5
91
VCINT6
106
VCINT7
124
VCINT8
130
VCINT9
152
VCINT10
185
VCINT11
201
VCC_CLK
77
IO77
125
IO78
126
IO79
127
IO80
128
IO81
131
IO82
132
IO83
133
IO84
134
IO85
135
IO86
136
IO87
139
IO88
140
IO89
141
IO90
142
IO91
143
IO92
144
IO93
147
IO94
148
IO95
149
IO96
150
IO97
160
IO98
163
IO99
167
IO100
168
IO101
169
IO102
170
IO103
172
IO104
173
IO105
174
IO106
175
IO107
176
IO108
177
IO109
179
IO110
187
IO111
189
IO112
190
IO113
191
IO114
192
IO115
193
IO116
195
IO117
196
IO118
197
IO119
198
IO120
199
IO121
200
IO122
202
IO123
203
IO124
205
LOCK/IO125
62
DATA7/IO126
166
DATA6/IO127
164
DATA5/IO128
162
DATA4/IO129
161
DATA3/IO130
159
DATA2/IO131
158
DATA1/IO132
157
DATA
156
MSEL0
108
MSEL1
107
STATUS
52
CONFIG
105
CONFIG_DONE
2
INIT_DONE
19
CE
154
CE0
3
TDI
153
TD0
4
TMS
50
TRST
51
WS
206
RS
204
CS
207
CS-
208
RDY/BUSY
16
CLKUSR
10
DCLK
155
TCLK
1
DEV_CLR
180
DEV_OE
186
C33
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.
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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.
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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...
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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...
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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).
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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).
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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.
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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...
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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.
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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).
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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...
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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...
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