1. DL manuals
  2. Vari Lite
  3. Lantern
  4. VL500 Wash Luminaires
  5. Service Manual

Vari Lite VL500 Wash Luminaires Service Manual

Other manuals for VL500 Wash Luminaires: Service Manual, User Manual
Manual is about: VL500 Wash Luminaires

Summary of VL500 Wash Luminaires

  • Page 2

    Vari ❋lite® - vl500™ l uminaire s ervice m anual ii 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vari ❋lite ® is a trademark owned by genlyte thomas group llc and is registered in the united states and other countries. Vl500™ (and the individual product designations), vl1000™, vl2000™, vl2201™, vl2202™, vl24...

  • Page 3: Manual Revision History

    H ow t o o btain w arranty s ervice 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 iii how to obtain warranty service a copy of the vari-lite limited warranty was included in the shipping package for this vari ❋lite® product. To obtain warranty service, please contact customer service at 1-877-vari-lite (1-8...

  • Page 4: Compliance Notice

    Vari ❋lite® - vl500™ l uminaire s ervice m anual iv 21-may-2009 0 2 .9 6 8 5 .0 0 1 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 protection again...

  • Page 5: Safety Notice

    S afety n otice 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 v safety notice it is extremely important to read all safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings dur...

  • Page 6

    Vari ❋lite® - vl500™ l uminaire s ervice m anual v i 21-may-2009 0 2 .9 6 8 5 .0 0 1 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 lamp. 2. It is ha...

  • Page 7: Sicherheitshinweise

    S icherheitshinweise 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 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...

  • Page 8

    Vari ❋lite® - vl500™ l uminaire s ervice m anual v i ii 21-may-2009 0 2 .9 6 8 5 .0 0 1 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 (z. B. Sprünge...

  • Page 9: Notes De Sécurité

    N otes de sÉcuritÉ 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 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 ai...

  • Page 10

    Vari ❋lite® - vl500™ l uminaire s ervice m anual x 21-may-2009 0 2 .9 6 8 5 .0 0 1 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 son regard sur l...

  • Page 11: Aviso Sobre Seguridad

    A viso sobre s eguridad 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 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 atenc...

  • Page 12

    Vari ❋lite® - vl500™ l uminaire s ervice m anual x i i 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada. Po...

  • Page 13

    S afety n otice (j apanese ) 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 xiii.

  • Page 14

    Vari ❋lite® - vl500™ l uminaire s ervice m anual x i v 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a.

  • Page 15

    T able of c ontents 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 xv table of contents introduction disclosure .................................................................................................................... 1 about this manual ...............................................................

  • Page 16

    Vari ❋lite® - vl500™ l uminaire s ervice m anual x v i 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lamp life............................................................................................................. 23 solid state electronics...................................................................

  • Page 17

    T able of c ontents 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 xvii vl500d (with 120v igbt dimmer) luminaire ...................................................... 87 vl500d (with 240v igbt dimmer) luminaire ...................................................... 89 vl500 80v (with 80v dimmer) luminaire ....

  • Page 18

    Vari ❋lite® - vl500™ l uminaire s ervice m anual x v i i i 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a dimmer communication cable assembly (vl500/vl500d) ................................157 24v power cable assembly (vl500/vl500d) ......................................................158 vl500 motor cable as...

  • Page 19

    I ntroduction : 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 1 introduction disclosure this technical manual is confidential property of vari-lite. All information contained herein is the sole and exclusive property of vari-lite and may not be used, disclosed, or reproduced in any manner without the prior ...

  • Page 20

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a a user’s manual is available for installation and operation of the vl500™ wash luminaire. This manual is available in electronic (pdf) format. ■ vl500™ luminaire user’s manual (02.9685.0001). Technical bulletins c...

  • Page 21: Hapter

    0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 3 c hapter 1. Description this chapter provides an overview of luminaire features, components and operations. • features • component descriptions • principles of operation.

  • Page 22

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a features product features vl500™ wash luminaire have the following features: color enhanced dichro ❋tune tm radial color changing mechanism featuring independent magenta, blue, and amber color control capable of s...

  • Page 23

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 5 model specific features each individual configuration has the following specific features: vl500 wash luminaire (20.9685.0001) • 120v (or 240v), 1200w (or 1000w) tungsten halogen lamp source. • standard color dichroic glass dichro ❋tune tm col...

  • Page 24

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v wash luminaire (20.9685.0014) • 80v, 1200w tungsten halogen lamp source. • pastel color dichroic glass dichro ❋tune tm color system. • 80v on-board dimmer. Vl500a wash luminaire (20.9685.0006) • 700w arc...

  • Page 25

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 7 component descriptions external luminaire components the following illustration shows the external luminaire components and controls. Head assembly lamp power data in data thru input panel menu display input panel connections provides dmx in a...

  • Page 26

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a luminaire internal head components the following illustration shows the major sub-assemblies that are located in the luminaire head assembly. Note: yoke assembly not shown for clarity. Backcap assembly provides ac...

  • Page 27

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 9 luminaire yoke components the following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly. Note: head assembly not shown for clarity. Main controller pcb luminaire control circuit board. Tilt mechanism...

  • Page 28

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a luminaire yoke components (continued) the following illustrations show additional model variations for the power supply side of the luminaire yoke assembly. 80v dimmer 120w power supply supplies power to electro...

  • Page 29

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 11 arc ballast unit an external ballast unit is included with vl500a arc models. In this case, the lamp power input cable is already connectorized for use with this unit. The following illustration shows the external arc ballast components. Note...

  • Page 30

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a principles of operation vl500 incandescent luminaires vl500 incandescent block diagram - without on-board igbt dimmer (120v or 240v) j3 j8 j6 magenta j4 motor blue motor amber motor diffuser motor j7 dmx pcb j6 ...

  • Page 31

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 13 vl500d incandescent luminaires vl500d incandescent block diagram - with on-board igbt dimmer (120v or 240v) j3 j8 j6 magenta j4 motor blue motor amber motor diffuser motor j7 dmx pcb j6 thru in lvs luminaire power in igbt dimmer fan fan displ...

  • Page 32

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v incandescent luminaires vl500 80v incandescent block diagram - with on-board 80v dimmer j3 j8 j6 magenta j4 motor blue motor amber motor diffuser motor j7 dmx pcb j6 thru in lvs luminaire power in 80v ...

  • Page 33

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 15 vl500a luminaire vl500a arc block diagram - with external arc ballast j3 j8 j6 magenta j4 motor blue motor amber motor dimmer motor j7 dmx pcb j6 thru in lvs luminaire power in arc ballast fan fan remote conn. Thermal lamp tilt motor pan moto...

  • Page 34

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a notes.

  • Page 35: Hapter

    0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 17 c hapter 2. Maintenance this chapter contains test, service, and standard maintenance procedures. • testing • equipment handling • maintenance procedures warning: all maintenance procedures are to be performed with power removed from the luminaire. Never remo...

  • Page 36

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a testing running parameter tests the luminaire is capable of running self tests by using the testmenu functions. For complete details and values for each test refer to “diagnostic tests” on page 20 . When running...

  • Page 37

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 19 movement disable the movement option allows pan and tilt to be disabled so that the luminaire can be placed in any position for testing without movement occurring. In order to regain full control of the luminaire, movement will need to be ena...

  • Page 38

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a diagnostic tests the following diagnostic tests are available in the test menu. Test descriptions all seq ................. Tests all functions in sequential order. Pan/tilt ................ Tests different pan ...

  • Page 39

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 21 test menu system chart the following table shows all the tests that can be performed by accessing the tests via the luminaire’s on-board tech display. Table 2-1: vl500 test menu system chart 1st level 2nd level 3rd level 4th level 5thlevel te...

  • Page 40

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lamp hours progress bar (arc models only) for arc models, there is a lamp hours progress bar representing lamp hours used on the lamp. It is tied directly to the lamp hours within the mcb. The bar, when fully ex...

  • Page 41

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 23 equipment handling below are some basic tips and information on handling vl500 luminaires and their associated components. Locations/use vari ❋ lite luminaires are designed for dry locations only. Exposure to rain or moisture (including, but ...

  • Page 42

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a • when the lamp is struck, the luminaire should be maintained in a horizontal position when not in use. • for arc lamp luminaires, heads should be tilted horizontal before starting lamps. Lamps generate light by...

  • Page 43

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 25 maintenance procedures lamp replacement - incandescent parts: 71.2529.0120 1ea 1200 watt tungsten halogen lamp, 120 vac (vl500 and vl500d models) 71.2526.0230 1 ea 1000 watt tungsten halogen lamp, 230 vac (vl500 and vl500d models) 71.9685.008...

  • Page 44

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lamp replacement - incandescent (continued) warning: 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 la...

  • Page 45

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 27 lamp replacement - arc parts: 71.9685.0702 1 ea msr700/2, 700 watt msr arc lamp tools: • cotton gloves or finger cots. Warning: remove power from luminaire before performing maintenance. To remove and replace arc lamp: step 1. Remove power fr...

  • Page 46

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lamp replacement - arc (continued) warning: 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. ...

  • Page 47

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 29 align lamp for maximum beam irradiance after a new lamp is installed in a vl500a luminaire, it will be necessary to align the lamp to optimize the beam. Tools: • #1 phillips screwdriver • 1/4" nutdriver • cotton gloves or finger cots • clean,...

  • Page 48

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 3 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a step 5. Ensure the following: a. Reflector is mounted in center of rear casting and secure enough to prevent it from moving. If not, at three reflector mounting clips, using #1 phillips screw- driver, remove thr...

  • Page 49

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 31 front glass replacement parts: as needed: 42.9685.0201 1 ea glass, front, clear 42.9685.0207 1 ea glass, front, stipple 42.9685.0203 1 ea glass, front, med. Flood 8-row lent. 42.9685.0206 1 ea glass, front, med. Flood 10-row lent. 42.9685.020...

  • Page 50

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 3 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a front glass replacement (continued) caution: wear thick, protective gloves or other protective covering while handling front lens. The lens is extremely fragile and can break if too much force is applied. If dir...

  • Page 51

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 33 magenta/blue dichro*tune rear bulkhead replacement parts: 21.9685.0170 1 ea assy, magenta/blue (standard dichro*tune colors - incandescent) 21.9685.0174 1 ea assy, magenta/blue (pastel dichro*tune colors - incandescent) 21.9685.0173 1 ea assy...

  • Page 52

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 3 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a magenta/blue dichro*tune rear bulkhead replacement (continued) step 5. At top cover, remove two (or four, depending on production date) 6-32x1/4" ppb sems screws. Step 6. Remove top cover. Step 7. Disconnect wir...

  • Page 53

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 35 amber/diffuser (or dimmer) dichro*tune front bulkhead replacement parts: 21.9685.0171 1 ea assy, amber/diffuser (incandescent models) 21.9685.0172 1 ea assy, amber/dimmer (arc models) tools: • #2 phillips screwdriver to remove and replace amb...

  • Page 54

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 3 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a amber/diffuser (or dimmer) dichro*tune front bulkhead replacement (continued) step 7. Disconnect wiring at two linear actuators on amber/diffuser (or dimmer) dichro*tune front bulkhead. Step 8. As shown in figur...

  • Page 55

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 37 color filter and diffuser panel replacement parts: 22.9685.0122 16 ea assy, filter, magenta, dichro*tune (std) 22.9685.0123 16 ea assy, filter, blue, dichro*tune (std) 22.9685.0120 16 ea assy, filter, magenta, dichro*tune (pastel) 22.9685.012...

  • Page 56

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 3 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a color filter and diffuser panel removal (contin- ued) step 6. Disconnect actuator screw from swivel coupler using tweaker screwdriver by carefully prying apart from drive ring link. Figure 12: color filter and d...

  • Page 57

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 39 arc dimmer panel replacement parts: 10.9685.0210 16 ea dimmer blade (panel), vl500 tools: • #1 phillips screwdriver • tweaker screwdriver • cotton gloves or finger cots • clean, lint-free (soft) cloth to remove and replace dimmer panels: step...

  • Page 58

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 4 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a dimmer panel replacement (continued). Figure 14: dimmer panel replacement step 11. Replace by performing steps 3 through 10 in reverse order. Dimmer panel bulkhead center hub insert panel bearing here carrier.

  • Page 59

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 41 linear actuator motor replacement (magenta/ blue bulkhead) parts: 44.9685.0230 2 ea motor, linear, 0.002"/step tools: • #1 phillips screwdriver • #2 phillips screwdriver • #2 slotted screwdriver warning: remove power from luminaire before per...

  • Page 60

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 4 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a step 5. At linear actuator motor to be replaced on magenta/blue assembly, disconnect wiring at both motors. Step 6. Remove linear actuator motor assembly as follows: a. At linear actuator motor assembly, using #...

  • Page 61

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 43 linear actuator motor replacement (amber/dif- fuser [or dimmer] bulkhead) parts: 44.9685.0230 2 ea motor, linear, 0.002"/step tools: • #1 phillips screwdriver • #2 phillips screwdriver • #2 slotted screwdriver warning: remove power from lumin...

  • Page 62

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 4 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a step 5. At linear actuator motor to be replaced on amber/diffuser (or dimmer) assembly, disconnect wiring at both motors. Step 6. Remove linear actuator motor assembly as follows: a. At linear actuator motor ass...

  • Page 63

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 45 incandescent lamp socket assembly (vl500 and vl500d only) replacement parts: 23.9685.0780 1 ea assy, lamp socket (vl500 and vl500d only) tools: • #2 phillips screwdriver • 1/4" hex nutdriver to remove and replace lamp socket assembly: step 1....

  • Page 64

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 4 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a step 9. As indicated in figure 20 , at light baffle, remove three 6-32x1/8" ppb screws. Figure 20: heatsink assembly - lamp socket removal (vl500 and vl500d only) step 10. Remove light baffle. Step 11. Loosen, b...

  • Page 65

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 47 arc lamp socket assembly (vl500a and vl500 80v only) replacement parts: 23.9685.0780 1 ea assy, lamp socket (vl500 and vl500d only) tools: • #2 phillips screwdriver • 1/4" hex nutdriver • 5/64" allen wrench to remove and replace lamp socket a...

  • Page 66

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 4 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a step 8. Using soft cloth to protect lamp, remove lamp from socket. Step 9. As indicated in figure 22 , at light baffle, remove three 6-32x1/8" ppb screws. Figure 22: heatsink assembly - lamp socket removal (vl50...

  • Page 67

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 49 display pcb replacement parts: 24.9685.0826 1 ea assy, vl500 display pcb tools: • 1/4" hex nutdriver • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and replace display pcb assembly: ste...

  • Page 68

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 5 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a main control pcb/fan assembly replacement parts: 21.9685.0731 1 ea assy, vl500 main control pcb/fan tools: • 1/4" hex nutdriver • #2 phillips screwdriver warning: remove power from luminaire before performing ma...

  • Page 69

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 51 main control pcb/fan assembly replacement (continued) figure 24: main control pcb/fan replacement step 7. Remove main control pcb/fan assembly. Step 8. Replace main control pcb/fan assembly by following steps 2 through 7 in reverse order. Ste...

  • Page 70

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 5 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a low voltage supply (lvs) replacement (vl500/ vl500d/vl500a only) parts: 69.3178.0121 1 ea power supply, 120w, 24vdc tools: • #2 phillips screwdriver warning: remove power from luminaire before performing mainten...

  • Page 71

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 53 low voltage supply (lvs) temperature pcb replacement (vl500/vl500d/vl500a only) parts: 24.9685.0740 1 ea temperature board, lvs tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. Warning: with...

  • Page 72

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 5 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a low voltage supply (lvs) replacement (vl500 80v only) parts: 69.3178.0121 1 ea power supply, 120w, 24vdc tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. Warni...

  • Page 73

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 55 step 5. Remove lvs temperature sensor pcb by following “low voltage supply (lvs) temperature pcb replacement (vl500 80v only)” on page 56 . Step 6. Disconnect the following wiring connections: a. 3-position connector (ac input) b. 6-position ...

  • Page 74

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 5 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a low voltage supply (lvs) temperature pcb replacement (vl500 80v only) parts: 24.9685.0740 1 ea temperature board, lvs tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maint...

  • Page 75

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 57 step 4. Disconnect the following wiring connections on pcb: a. 2-position connector (lvs fan) b. 4-position connector (lvs fan from mcb) step 5. As shown in figure 28 , remove one 6-32x3/8" ppz securing lvs temperature pcb to lvs fan mount. S...

  • Page 76

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 5 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a tilt motor assembly replacement parts: 21.9685.0540 1 ea assy, pan/tilt motor tools: • #2 phillips screwdriver • diagonal cutters warning: remove power from luminaire before performing maintenance. To remove and...

  • Page 77

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 59 step 7. Loosen (do not remove) four 8-32x7/16" ppz screws that mount pan/tilt motor assembly to tilt motor slide plate. Figure 29: tilt motor assembly replacement step 8. Press motor towards spring to loosen belt tension. Step 9. Remove belt ...

  • Page 78

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 6 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a pan motor assembly replacement parts: 21.9685.0540 1 ea assy, pan/tilt motor tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and replace pan motor a...

  • Page 79

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 61 pan/tilt encoder pcb replacement parts: 24.9685.7735 1 ea board assy, pan/tilt encoder tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and replace pan/tilt encoder pcb: step 1. Di...

  • Page 80

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 6 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a arc ignitor pcb replacement (vl500a only) parts: 24.9685.1000 1 ea ignitor, arc (vl500a only) tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and re...

  • Page 81

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 63 igbt dimmer replacement - vl500d only parts: 69.3173.0115 1 ea dimmer, igbt, 1200w 120v rev phase cont (vl500d 115v models only) 69.3173.0240 1 ea dimmer, igbt, 1200w 240v rev phase cont (vl500d 240v models only) tools: • #2 phillips screwdri...

  • Page 82

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 6 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a igbt dimmer replacement - vl500d only (con- tinued) figure 33: igbt dimmer replacement (vl500d only) step 7. Replace igbt dimmer by performing steps 2 through 6 in reverse. 6-32x3/8" ptb screws (x4) some compone...

  • Page 83

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 65 80v dimmer replacement - vl500 80v only parts: 21.9685.2750 1 ea assy, 80v dimmer tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and replace 80v dimmer: step 1. Disconnect lumina...

  • Page 84

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 6 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a figure 34: 80v dimmer replacement (vl500 80v only) step 7. Replace 80v dimmer by performing steps 2 through 6 in reverse. 6-32x3/8" ptb screws (x4) some components not shown for clarity. Note: 80v dimmer yoke ar...

  • Page 85

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 67 arc ballast replacement (vl500a only) parts: 21.9685.0802 1 ea assy, ballast, 700w tools: • none warning: remove power from luminaire before performing maintenance. To remove and replace arc ballast dimmer: step 1. Disconnect luminaire ac inp...

  • Page 86

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 6 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a safety relay replacement (vl500a only) parts: 23.9650.3327 1 ea relay, electrical assy (vl500a only) tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove...

  • Page 87

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 69 ac input (powercon) connector replacement parts: 25.9685.0756 1 ea connector, ac input (powercon) tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and replace ac input (powercon) c...

  • Page 88

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 7 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a mini-xlr (display/remote programming) con- nector replacement parts: 25.9685.0770 1 ea connector, mini-xlr (display / remote programming) tools: • #2 phillips screwdriver warning: remove power from luminaire bef...

  • Page 89

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 71 dmx pcb assembly replacement parts: 24.9663.3895 1 ea assy, dmx input pcb tools: • #2 phillips screwdriver warning: remove power from luminaire before performing maintenance. To remove and replace dmx pcb assembly: step 1. Remove power from l...

  • Page 90

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 7 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a cleaning optical lenses and filters warning: remove power from luminaire before performing maintenance. Warning: acetone is a harsh cleaning agent and solvent. Acetone is very flammable. Please handle acetone ac...

  • Page 91: Hapter

    0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 73 c hapter 3. Illustrated parts breakdown this chapter contains illustrated parts breakdowns for all vl500™ wash luminaire assemblies including the arc ballast unit. • drawing trees • top assembly • head assembly • yoke assembly • cables • arc ballast assembly ...

  • Page 92

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 7 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a drawing trees vl500 and vl500d incandescent luminaires figure 3-1: vl500 and vl500d incandescent luminaires drawing tree (part 1) continued next page vl500 (120v or 240v) luminaire incandescent versions 20.9685....

  • Page 93

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 75 vl500 and vl500d incandescent luminaires (continued) figure 3-2: vl500 and vl500d incandescent luminaires drawing tree (part 2) vl500 yoke assembly 21.9685.0520 (vl500) rev u or 21.9685.0521 (vl500d) rev u arc yoke lamp cabl...

  • Page 94

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 7 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v incandescent luminaires figure 3-3: vl500 80v incandescent luminaires drawing tree (part 1) continued next page vl500 80v (with 80v dimmer) luminaire 20.9685.0004 rev l (standard dicro*tune colors) or ...

  • Page 95

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 77 vl500 80v incandescent luminaires (contin- ued) figure 3-4: vl500 80v incandescent luminaires drawing tree (part 2) vl500 80v yoke assembly 21.9685.0523 (vl500 80v) rev q vl500 80v main harness cable assembly 25.9685.2792 re...

  • Page 96

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 7 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500a arc luminaires figure 3-5: vl500a arc luminaires drawing tree (part 1) continued next page vl500a (700w arc) luminaire 20.9685.0006 rev h (standard dicro*tune colors) or 20.9685.0016 rev b (pastel dicro*t...

  • Page 97

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 79 vl500a arc luminaires (continued) figure 3-6: vl500a arc luminaires drawing tree (part 2) vl500 yoke assembly 21.9685.0522 (vl500a) rev u vl500 arc main harness cable assembly 25.9685.0791 rev c (vl500a) vl500 extra hardware...

  • Page 98

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 8 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a top assembly included items kit 28.9685.0001 rev g (120v or 240v, standard colors, no dimmer) 28.9685.0002 rev g (standard colors, 120v igbt on-board dimmer) 28.9685.0003 rev g (standard colors, 240v igbt on-boa...

  • Page 99

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 81 included items kit (continued) figure 3-7: included items kit 5 8 4 1 2 3 7 9 (arc models only) 10 (arc models only) 11 6.

  • Page 100

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 8 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a label locations 16.9685.00yy rev d refer to figure 3-8 . Note: (clr) = clear labels - for use with non-black fixtures. No. Item qty. Um. Description 1 04.9661.0034 1 ea label, relamping - 2000 series 2 04.9663.1...

  • Page 101

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 83 6 04.9685.0920 2 ea label, ac input rating (vl500 models only) 04.9685.0920.00 2 ea label, ac input rating (clr) (vl500 models only) 04.9685.0921 2 ea label, ac input rating (vl500 pastel models only) 04.9685.0921.00 2 ea la...

  • Page 102

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 8 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a label locations (continued) figure 3-8: label locations c r li st ed us − 1.877.Varilite dallas, tx. 75238 u.S.A. Www.Vari−lite.Com 10911 petal street not for residential use impropere a l’usage domestique suita...

  • Page 103

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 85 vl500 (120v or 240v) luminaire 20.9685.0001 rev g (standard dicro*tune colors) 20.9685.0011 rev b (pastel dicro*tune colors) refer to figure 3-9 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke cover 2 04.96...

  • Page 104

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 8 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 (120v or 240v) luminaire (continued) figure 3-9: vl500 (120v or 240v) luminaire 9 12 7 4 (x2) 5 6 8 14 (x8) 13 (x8) 11 10 15 (x4) 16 (x8) 3 1 2.

  • Page 105

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 87 vl500d (with 120v igbt dimmer) luminaire 20.9685.0002 rev f (standard dicro*tune colors) 20.9685.0012 rev b (pastel dicro*tune colors) refer to figure 3-10 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke co...

  • Page 106

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 8 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500d (with 120v igbt dimmer) luminaire (continued) figure 3-10: vl500d (with 120v igbt dimmer) luminaire 11 14 9 7 8 10 17 (x8) 15 (x8) 12 13 18 (x4) 5 (x2) 19 (x8) 6 (x2) 20 16 (x8) 3 4 1 2.

  • Page 107

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 89 vl500d (with 240v igbt dimmer) luminaire 20.9685.0003 rev f (standard dicro*tune colors) 20.9685.0013 rev b (pastel dicro*tune colors) refer to figure 3-11 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke co...

  • Page 108

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 9 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500d (with 240v igbt dimmer) luminaire (continued) figure 3-11: vl500d (with 240v igbt dimmer) luminaire 11 14 9 7 8 10 17 (x8) 15 (x8) 12 13 18 (x4) 5 (x2) 19 (x8) 6 (x2) 20 16 (x8) 3 4 1 2.

  • Page 109

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 91 vl500 80v (with 80v dimmer) luminaire 20.9685.0004 rev l (standard dicro*tune colors) 20.9685.0014 rev g (pastel dicro*tune colors) refer to figure 3-12 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke cover...

  • Page 110

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 9 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v (with 80v dimmer) luminaire (con- tinued) figure 3-12: vl500 80v (with 80v dimmer) luminaire 11 16 10 6 7 19 (x8) 14 15 17 (x8) 5 (x2) 22 (x8) 8 18 (x4) 3 4 1 2 20 (x4) 13 9 12 23 21 (x4).

  • Page 111

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 93 vl500a (700w arc) luminaire 20.9685.0006 rev h (standard dicro*tune colors) 20.9685.0016 rev b (pastel dicro*tune colors) refer to figure 3-13 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke cover 2 04.9685...

  • Page 112

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 9 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500a (700w arc) luminaire (continued) figure 3-13: vl500a luminaire (700w arc) 8 12 7 4 (x2) 5 6 9 14 (x8) 13 (x8) 11 10 15 (x4) 16 (x8) 3 1 2.

  • Page 113

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 95 generic vl500 luminaire assembly 21.9685.0010 rev s (incandescent - without internal dimmer) 21.9685.0011 rev s (incandescent - with internal igbt dimmer) 21.9685.0012 rev s (incandescent - with internal 80v dimmer) 21.9685....

  • Page 114

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 9 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 27 53.6558.0009 11 ea screw, 6-32x3/8", ppz, sems (vl500 only) 53.6558.0009 10 ea screw, 6-32x3/8", ppz, sems (vl500d and vl500 80v only) 53.6558.0009 14 ea screw, 6-32x3/8", ppz, sems (vl500a only) 28 53.6558.0...

  • Page 115

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 97 generic vl500 luminaire assembly (contin- ued) figure 3-14: generic vl500 luminaire assembly (vl500 and vl500d) 28 16 (vl500 only) 4 3 37 22 20 38 36 36 12 (vl500d only) 27 25 11 1 31 26 25 32 5 34 10 13 9 7 8 2 42 27 41 35 ...

  • Page 116

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 9 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a generic vl500 luminaire assembly (contin- ued) figure 3-15: generic vl500 luminaire assembly (vl500 80v) 28 19 4 3 37 22 20 38 36 12 27 25 11 1 31 26 25 32 5 34 10 15 9 30 (x4) 7 8 27 25 33 34 31 11 6 41 35 39 2...

  • Page 117

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 99 generic vl500 luminaire assembly (contin- ued) figure 3-16: generic vl500 luminaire assembly (vl500a) 28 18 4 3 37 22 20 38 36 36 25 11 1 31 26 25 32 5 34 10 14 9 7 8 2 42 41 35 39 24 6 27 25 33 34 31 27 11 27 39 (x4) 23 29,...

  • Page 118

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 0 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a notes.

  • Page 119

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 101 head assembly vl500 generic head assembly 21.9685.0310 (vl500 and vl500d) rev k 21.9685.0311 (vl500a) rev k 21.9685.0312 (vl500 80v) rev k refer to figure 3-17 , figure 3-18 , and figure 3-19 . No. Item qty. Um. Description...

  • Page 120

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 0 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 generic head assembly (continued) figure 3-17: vl500 generic head assembly (vl500 and vl500d) 5 14 (x4) 12 (x2) 8 16 15 12 (x2) 1 6 13 (x4) 18 20 2 7 19 21 4 3 12 (x2).

  • Page 121

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 103 vl500 generic head assembly (continued) figure 3-18: vl500 generic head assembly (vl500a) 5 14 (x4) 12 (x2) 9 16 15 12 (x2) 1 6 13 (x4) 18 20 2 7 19 21 4 3 12 (x2) 11 17 (x2).

  • Page 122

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 0 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 generic head assembly (continued) figure 3-19: vl500 generic head assembly (vl500 80v) 5 14 (x4) 12 (x2) 10 16 15 12 (x2) 1 6 13 (x4) 18 20 2 7 19 21 4 3 12 (x2).

  • Page 123

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 105 heatsink assembly 21.9685.0320 (vl500 and vl500d) rev h 21.9685.0321 (vl500a) rev h 21.9685.0322 (vl500 80v) rev h refer to figure 3-20 , figure 3-21 , and figure 3-22 . No. Item qty. Um. Description 1 10.9634.0103 3 ea pad...

  • Page 124

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 0 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 heatsink assembly (continued) figure 3-20: vl500 heatsink assembly (vl500 and vl500d) 14 (x2) 6 10 4 19 (x2) 15 (x4) 13 (x3) 20 (x3) 2 (x3) 5 1 (x3) 11 9 18.

  • Page 125

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 107 vl500 heatsink assembly (continued) figure 3-21: vl500 heatsink assembly (vl500a) 19 (x2) 7 16 (x2) 18 15 (x4) 13 (x3) 20 (x3) 2 (x3) 23 1 (x3) 11 17 (x3) 22 (x3) 21 (x3) 3 (x2) 8 9 5 4.

  • Page 126

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 0 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 heatsink assembly (continued) figure 3-22: vl500 heatsink assembly (vl500 80v) 19 (x2) 7 16 (x2) 18 15 (x4) 13 (x3) 20 (x3) 2 (x3) 23 1 (x3) 11 12 (x3) 22 (x3) 3 (x2) 8 9 5 4.

  • Page 127

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 109 vl500 magenta/blue color assembly 21.9685.0170 rev h (standard dicro*tune colors) refer to figure 3-23 . Figure 3-23: vl500 magenta/blue color assembly no. Item qty. Um. Description 1 10.9685.0257 2 ea light baffle, rear bu...

  • Page 128

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 1 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 magenta/blue (pastel) color assembly 21.9685.0174 rev a (pastel dicro*tune colors) refer to figure 3-24 . Figure 3-24: vl500 magenta/blue (pastel) color assembly no. Item qty. Um. Description 1 10.9685.0...

  • Page 129

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 111 vl500 amber/diffuser color assembly 21.9685.0171 rev g refer to figure 3-25 . Figure 3-25: vl500 amber/diffuser color assembly no. Item qty. Um. Description 1 10.9685.0245 2 ea light baffle, top 2 21.9685.0161 1 ea assy, am...

  • Page 130

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 1 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 amber/dimmer color assembly 21.9685.0172 rev f refer to figure 3-26 . Figure 3-26: vl500 amber/dimmer color assembly no. Item qty. Um. Description 1 10.9685.0245 2 ea light baffle, top 2 21.9685.0162 1 e...

  • Page 131

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 113 vl500 magenta/blue (arc) color assembly 21.9685.0173 rev a (standard dicro*tune colors) refer to figure 3-27 . Figure 3-27: vl500 magenta/blue (arc) color assembly no. Item qty. Um. Description 1 10.9685.0246 4 ea clip, uv ...

  • Page 132

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 1 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 magenta/blue (arc pastel) color assembly 21.9685.0175 rev a (pastel dicro*tune colors) refer to figure 3-28 . Figure 3-28: vl500 magenta/blue (arc) color assembly no. Item qty. Um. Description 1 10.9685....

  • Page 133

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 115 magenta/blue color assembly 21.9685.0160 rev e (standard dicro*tune colors) refer to figure 3-29 . Figure 3-29: magenta/blue color assembly no. Item qty. Um. Description 1 10.9634.0034 32 ea spring, drive arm, filter 2 10.9...

  • Page 134

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 1 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a magenta/blue (pastel) color assembly 21.9685.0164 rev 0 (pastel dicro*tune colors) refer to figure 3-30 . Figure 3-30: magenta/blue (pastel) color assembly no. Item qty. Um. Description 1 10.9634.0034 32 ea sp...

  • Page 135

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 117 amber/diffuser color assembly 21.9685.0161 rev f refer to figure 3-31 . Figure 3-31: amber/diffuser color assembly no. Item qty. Um. Description 1 10.9634.0034 32 ea spring, drive arm, filter 2 10.9634.0035 32 ea link, driv...

  • Page 136

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 1 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a amber/dimmer color assembly 21.9685.0162 rev e refer to figure 3-32 . No. Item qty. Um. Description 1 10.9634.0034 32 ea spring, drive arm, filter 2 10.9634.0035 32 ea link, drive arm 3 10.9634.0166 16 ea carr...

  • Page 137

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 119 amber/dimmer color assembly (continued) figure 3-32: amber/dimmer color assembly 4 8 (x16) 2 (x16) 6 (x16) 5 (x16) 1 (x16) 11 (x16) 7 9 2 (x16) 3 (x16) 10 (x16) 1 (x16).

  • Page 138

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 2 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a bottom bulkhead assembly 21.9685.0150 rev c refer to figure 3-33 . No. Item qty. Um. Description 1 10.9661.0315 4 ea support, bulkhead 2 21.9685.0251 2 ea assy, drive ring 3 22.9634.0119 1 ea assy, center hub ...

  • Page 139

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 121 bottom bulkhead assembly (continued) figure 3-33: bottom bulkhead assembly 3 4 7 (x4) 1 (x4) 2 5 (x4) 5 (x8) 2 6 (x10).

  • Page 140

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 2 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a top bulkhead assembly 21.9685.0151 rev c refer to figure 3-34 . No. Item qty. Um. Description 1 10.9661.0315 4 ea support, bulkhead 2 10.9685.0219 2 ea aux ring, color bulkhead 3 21.9685.0251 2 ea assy, drive ...

  • Page 141

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 123 top bulkhead assembly (continued) figure 3-34: top bulkhead assembly 4 3 5 2 (x2) 7 (x10) 1 (x4) 3 6 (x4) 6 (x8) 9 (x4) 8 (x4).

  • Page 142

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 2 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a drive ring assembly 21.9685.0251 rev d refer to figure 3-36 . Figure 3-35: drive ring assembly no. Item qty. Um. Description 1 10.9634.0105 1 ea link, swivel 2 10.9685.7240 8 ea roller, drive ring 3 22.9685.02...

  • Page 143

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 125 magenta/blue color motor assembly 21.9685.0280 rev a refer to figure 3-36 . Figure 3-36: magenta/blue color motor assembly no. Item qty. Um. Description 1 10.9634.0061 1 ea actuator mount, vl500 2 10.9634.0075 1 ea heat shi...

  • Page 144

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 2 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a amber/diffuser color motor assembly 21.9685.0281 rev a refer to figure 3-36 . Figure 3-37: amber/diffuser color motor assembly no. Item qty. Um. Description 1 10.9634.0061 1 ea actuator mount, vl500 2 10.9634....

  • Page 145

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 127 yoke assembly vl500 yoke assembly 21.9685.0520 (vl500) rev u 21.9685.0521 (vl500d) rev u 21.9685.0522 (vl500a) rev u refer to figure 3-38 and figure 3-39 . No. Item qty. Um. Description 1 10.9685.0534 1 ea cover, pan tube 2...

  • Page 146

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 2 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 23 53.6519.0001 3 ea screw, 4-40x5/8" ppz 24 53.6521.0001 4 ea screw, 8-32x1/2" ppb 25 53.6526.0002 2 ea screw, 6-32x5/8" ppz type f 26 53.6546.0003 8 ea screw, 8-32x7/16" ppz 27 53.6552.0002 18 ea screw, 8-32...

  • Page 147

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 129 vl500 yoke assembly (continued) figure 3-38: vl500 yoke assembly (vl500/vl500d/vl500a) 25 (x2) 27 (x6) 31 37 1 19 18 (x2) 21 (x4) 11 15 (vl500a) 40 (vl500d) 30 (x4) 17 (x4) 8 29 (x2) 14 20 (x2) 28 (x2) 16 2 30 (x4) 3 13.

  • Page 148

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 3 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 yoke assembly (continued) figure 3-39: vl500 yoke assembly (vl500/vl500d/vl500a) 24 (x4) 33 41 (x6) 39 36 (x4) 9 7 22 (x4) 10 32 23 (x3) 35 (x3) 12 42 34 5 44 (x4) 27 (x12) 26 9 6 36 (x4) 26 (x6) 4 38 39.

  • Page 149

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 131 vl500 80v yoke assembly 21.9685.0523 (vl500 80v) rev q refer to figure 3-40 , figure 3-41 . No. Item qty. Um. Description 1 10.9685.0542 1 ea shield, wire 2 10.9685.0543 1 ea shield, sensor board 3 10.9685.1554 1 ea cover, ...

  • Page 150

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 3 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 28 54.2065.0001 1 ea belt, timing, s2m 252 groove 29 55.2203.0001 4 ea screw, 4-40x1/4" ppz 30 55.3301.0008 8 ea washer, #8 flat ss 31 55.3301.0010 1 ea washer, #10 flat 32 55.6543.0001 2.4 in grommet strip, s...

  • Page 151

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 133 vl500 80v yoke assembly (continued) figure 3-40: vl500 80v yoke assembly 29 (x4) 22 (x6) 27 3 31 18 1 36 5 4 24 (x4) 24 (x2) 11 19 (x2) 13 23 9 19 (x2) 25 (x2) 14 24 (x2) 15 16 (x4) 12 17 26 2.

  • Page 152

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 3 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 yoke assembly (continued) figure 3-41: vl500 80v yoke assembly 20 (x4) 34 35 (x6) 28 30 (x4) 10 7 22 (x12) 21 10 8 30 (x4) 21 (x6) 6 32 33.

  • Page 153

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 135 vl500 extra hardware kit 28.9685.0999 rev 0 note: this kit contains addtional us-standard hardware (that may be difficult to find outside north america). It is packaged into the foot of the fixture (underneath the pan tube ...

  • Page 154

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 3 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 pan/tilt motor assembly 21.9685.0540 rev c refer to figure 3-43 . No. Item qty. Um. Description 1 10.9685.0541 1 ea plate, tension adjustment, pan/tilt 2 21.9685.0545 1 ea assy, drive pulley, vl500 2a 10...

  • Page 155

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 137 vl500 pan/tilt motor assembly (continued) figure 3-43: vl500 pan/tilt motor assembly 6 (x2) note: vari-lite recommends that this assembly be replaced as a complete assembly. Although you can replace only the motor, the pull...

  • Page 156

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 3 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 mcb/fan assembly 21.9685.0731 rev 0 refer to figure 3-44 . Figure 3-44: vl500 mcb/fan assembly no. Item qty. Um. Description 1 10.9676.0735 2 ea heatsink, pan/tilt drivers 2 10.9676.0885 2 ea pad, therma...

  • Page 157

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 139 mcb-fan assembly 23.9685.0782 rev 0 refer to figure 3-43 . Figure 3-45: mcb-fan assembly no. Item qty. Um. Description 1 40.7113.0007 1 ea fan, 12vdc, 30x10 mm, 3.3cfm 2 52.6450.0002 1 ea connector, mta 100 idc 2-pos, 28 aw...

  • Page 158

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 4 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a yoke crossmember assembly (vl500/vl500d/ vl500a) 21.9685.0515 rev e refer to figure 3-46 . No. Item qty. Um. Description 1 10.9685.0547 1 ea bushing, wire protection, 0.95" od 2 10.9685.7590 1 ea toggle stop, ...

  • Page 159

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 141 yoke crossmember assembly (vl500/vl500d/ vl500a) (continued) figure 3-46: yoke crossmember assembly (vl500/vl500d/vl500a) 5 7 (x4) 9 9 9 7 (x4) 8 (x2) 4 6 2 3 1.

  • Page 160

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 4 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a yoke crossmember assembly (vl500 80v) 21.9685.0516 rev 0 refer to figure 3-47 . No. Item qty. Um. Description 1 10.9685.0547 1 ea bushing, wire protection, 0.95" od 2 10.9685.7590 1 ea toggle stop, pan 3 10.96...

  • Page 161

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 143 yoke crossmember assembly (vl500 80v) (continued) figure 3-47: yoke crossmember assembly (vl500 80v) 5 7 (x4) 9 9 9 7 (x4) 8 (x2) 4 6 2 3 1.

  • Page 162

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 4 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lower crossmember assembly 21.9685.0512 rev k refer to figure 3-48 . No. Item qty. Um. Description 1 10.9685.1509 1 ea lower crossmember 2 10.9685.0522 1 ea plate, pan lock 3 10.9685.0527 2 ea washer, centerin...

  • Page 163

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 145 lower crossmember assembly (continued) figure 3-48: lower crossmember assembly 7 (x2) 11 14 (x2) 3 (x2) 4 1 5 (x2) 13 (x2) 12 (x2) 9 8 2 10 (x2), 15 (x2) 6.

  • Page 164

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 4 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a upper crossmember assembly 21.9685.0513 rev h refer to figure 3-48 . Figure 3-49: upper crossmember assembly no. Item qty. Um. Description 1 10.9685.1510 1 ea upper crossmember 2 10.9685.0527 2 ea washer, cent...

  • Page 165

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 147 pan tube assembly (vl500/vl500d/vl500a) 21.9685.0535 rev d (vl500/vl500d/vl500a) refer to figure 3-50 . Figure 3-50: pan tube assembly (vl500/vl500d/vl500a) no. Item qty. Um. Description 1 10.9685.0521 1 ea pulley, driven, ...

  • Page 166

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 4 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a pan tube assembly (vl500 80v) 21.9685.0536 rev a (vl500 80v) refer to figure 3-51 . Figure 3-51: pan tube assembly (vl500 80v) no. Item qty. Um. Description 1 10.9685.0521 1 ea pulley, driven, pan/tilt 2 10.96...

  • Page 167

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 149 dmx input pcb assembly 24.9663.3895 rev 0 refer to figure 3-52 . Figure 3-52: dmx input pcb assembly no. Item qty. Um. Description ref 1 17.9663.3895 1 ea pcb, dmx input - 2 52.6259.0006 1 ea header, 5pos mta frct lok strt ...

  • Page 168

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 5 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a notes.

  • Page 169

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 151 cables note: cables are only available as complete assemblies. The information contained in this section is for reference only. Incandescent power input cable assembly 25.9663.2030 rev a (vl500 only) refer to figure 3-53 . ...

  • Page 170

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 5 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a disconnect cable assembly 25.9685.0350 rev b refer to figure 3-54 . Figure 3-54: disconnect cable assembly no. Item qty. Um. Description 1 10.9685.0351 1 ea mount, disconnect 2 10.9685.0352 1 ea contact, disco...

  • Page 171

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 153 80v lvs ac cable assembly 25.9685.0742 rev 0 refer to figure 3-55 . Figure 3-55: 80v lvs ac cable assembly no. Item qty. Um. Description 1 52.6264.0004 1 ea conn housing, 3-pos sl156 w/ ramp no tabs 2 52.8317.0002 2 ea cont...

  • Page 172

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 5 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 24v power cable assembly (vl500 80v) 25.9685.0744 rev 0 refer to figure 3-56 . Figure 3-56: 24v power cable assembly (vl500 80v) no. Item qty. Um. Description 1 52.6442.2003 1 ea recept, 3 pos mta156 w/tab yel...

  • Page 173

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 155 yoke lamp cable assembly (vl500 80v) 25.9685.0745 rev a refer to figure 3-57 . Figure 3-57: yoke lamp cable assembly (vl500 80v) no. Item qty. Um. Description 1 52.8244.0001 2 ea recept, faston flag, 0.250" 16-14 awg (reel)...

  • Page 174

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 5 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 80v surge protector cable assembly 25.9685.0746 rev 0 refer to figure 3-58 . Figure 3-58: 80v surge protector cable assembly no. Item qty. Um. Description 1 33-0441 2 ea mov, 430v 6500a 20mm znr 2 52.8231.0005...

  • Page 175

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 157 dimmer communication cable assembly (vl500/vl500d) 25.9685.0750 rev b refer to figure 3-59 . Figure 3-59: dimmer communication cable assembly (vl500 / vl500d) no. Item qty. Um. Description 1 52.6396.2603 2 ea recept, 3 pos ...

  • Page 176

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 5 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 24v power cable assembly (vl500/vl500d) 25.9685.0752 rev c refer to figure 3-60 . Figure 3-60: 24v power cable assembly (vl500 / vl500d) no. Item qty. Um. Description 1 52.6442.2003 1 ea recept, 3 pos mta156 w...

  • Page 177

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 159 vl500 motor cable assembly 25.9685.0753 rev b refer to figure 3-61 . No. Item qty. Um. Description 1 52.6224.1034 1 ea cover, front 34-pos mt latching 2 52.6224.2034 1 ea cover, back 34-pos mt 3 52.6610.0034 1 ea conn, hous...

  • Page 178

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 6 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 motor cable assembly (continued) figure 3-61: vl500 motor cable assembly 7 (x2) 1, 2, 3, 6 8 4 (x4) , 5 4 (x4) , 5 4 (x4) , 5 4 (x4) , 5 9 9.

  • Page 179

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 161 relay to ignitor cable assembly 25.9685.0755 rev b refer to figure 3-62 . Figure 3-62: relay to ignitor cable assembly no. Item qty. Um. Description 1 52.8271.0005 4 ea recpt, faston 1/4" 16-14 awg insulated (reel) 2 55.218...

  • Page 180

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 6 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 ac input cable assembly 25.9685.0756 rev b refer to figure 3-63 . Figure 3-63: vl500 ac input cable assembly no. Item qty. Um. Description 1 52.6541.0003 1 ea conn, chassis power 3-pole locking 2 52.8231...

  • Page 181

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 163 vl500 arc ballast input cable assembly 25.9685.0757 rev c refer to figure 3-64 . Figure 3-64: vl500 arc ballast input cable assembly no. Item qty. Um. Description 1 52.6400.0027 1 ea recpt, 17-14 sq flange rev sex thrd cpc ...

  • Page 182

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 6 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 pan / tilt cable assembly 25.9685.0758 rev a refer to figure 3-65 and figure 3-66 . Figure 3-65: vl500 pan / tilt cable assembly no. Item qty. Um. Description 1 52.6224.0020 1 ea housing, 20 pos 26-22 aw...

  • Page 183

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 165 vl500 pan / tilt cable assembly (continued) figure 3-66: vl500 pan / tilt cable assembly (pin outs).

  • Page 184

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 6 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 head grounding cable assembly 25.9685.0760 rev c refer to figure 3-67 . Figure 3-67: vl500 head earthing cable assembly no. Item qty. Um. Description 1 52.8231.0000 2 ea term, ring #6 red 22-16 awg insul...

  • Page 185

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 167 vl500 ignitor to socket cable assembly 25.9685.0766 rev c refer to figure 3-68 . Figure 3-68: vl500 iginitor to socket cable assembly no. Item qty. Um. Description 1 25.9685.0777 1 ea cable assy, back cap ground, vl500 2 52...

  • Page 186

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 6 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 arc ballast interconnect cable assembly 25.9685.0767 rev b refer to figure 3-69 . No. Item qty. Um. Description 1 52.6400.0020 1 ea plug, 17-14 rev sex cpc 600v key a 2 52.6400.0120 1 ea plug, 17-9 rev s...

  • Page 187

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 169 vl500 arc ballast interconnect cable assem- bly (continued) figure 3-69: vl500 arc ballast interconnect cable assembly 1 pinout pin wire description 1 open n/a 2 open n/a 3 grn/16 awg ground 4 blk/16 awg power (hot) 5 drain...

  • Page 188

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 7 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 display cable assembly 25.9685.0769 rev c refer to figure 3-70 . Figure 3-70: vl500 display cable assembly no. Item qty. Um. Description 1 52.6363.0001 1 ea conn housing, 6 pin mta closed end blue 2 52.6...

  • Page 189

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 171 vl500 display (remote) cable assembly 25.9685.0770 rev b refer to figure 3-71 . Figure 3-71: vl500 display (remote) cable assembly no. Item qty. Um. Description 1 10.9685.0536.01 1 ea adapter plate, mini xlr, black 10.9685....

  • Page 190

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 7 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a yoke lamp cable assembly (vl500/vl500d) 25.9685.0771 rev c refer to figure 3-72 . Figure 3-72: yoke lamp cable assembly (vl500/vl500d) no. Item qty. Um. Description 1 52.8244.0001 2 ea recept, faston flag, 0.2...

  • Page 191

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 173 vl500 yoke ground cable assembly 25.9685.0772 rev c refer to figure 3-73 . Figure 3-73: yoke ground cable assembly no. Item qty. Um. Description 1 52.8231.0005 2 ea term, ring #6 16-14 awg reel pidg 2 73.6014.0011 2.0 ft wi...

  • Page 192

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 7 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lvs ac cable assembly (vl500/vl500d/ vl500a) 25.9685.0773 rev c refer to figure 3-74 . Figure 3-74: lvs ac cable assembly (vl500/vl500d/vl500a) no. Item qty. Um. Description 1 52.6264.0004 1 ea conn housing, 3...

  • Page 193

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 175 vl500 yoke dmx communication cable assembly 25.9685.0774 rev e refer to figure 3-75 . Figure 3-75: vl500 yoke dmx communication cable assembly no. Item qty. Um. Description 1 52.6234.0001 1 ea conn housing, 4 pin mta closed...

  • Page 194

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 7 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 yoke lamp jumper cable assembly 25.9685.0776 rev a refer to figure 3-76 . Figure 3-76: vl500 yoke lamp jumper cable assembly no. Item qty. Um. Description 1 52.8348.0001 2 ea tab, ultra-fast 1/4" 16-14 a...

  • Page 195

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 177 vl500 backcap ground cable assembly 25.9685.0777 rev a refer to figure 3-77 . Figure 3-77: vl500 backcap ground cable assembly no. Item qty. Um. Description 1 52.8329.0001 1 ea term, ring #6 red 22-16 awg non-insul 2 52.832...

  • Page 196

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 7 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a lvs fan cable assembly (vl500/vl500d/ vl500a) 25.9685.0778 rev a refer to figure 3-78 . Figure 3-78: lvs fan cable assembly (vl500/vl500d/vl500a) no. Item qty. Um. Description 1 52.6234.0001 2 ea conn housing,...

  • Page 197

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 179 vl500 mcb yoke ground cable assembly 25.9685.0782 rev 0 refer to figure 3-79 . Figure 3-79: vl500 mcb yoke ground cable assembly no. Item qty. Um. Description 1 52.8231.0005 2 ea term, ring #6 16-14 awg reel pidg 2 73.6014....

  • Page 198

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 8 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a arc yoke lamp cable assembly (vl500a) 25.9685.0783 rev b refer to figure 3-80 . Figure 3-80: arc yoke lamp cable assembly (vl500a) no. Item qty. Um. Description 1 52.8244.0001 2 ea recept, faston flag, 0.250" ...

  • Page 199

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 181 shielded display/dmx communication cable assembly (vl500a) 25.9685.0784 rev c refer to figure 3-81 . Figure 3-81: shielded display/dmx communication cable assembly (vl500a) no. Item qty. Um. Description 1 25.9685.0769 1 ea ...

  • Page 200

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 8 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v display cable assembly 25.9685.0785 rev 0 refer to figure 3-82 . Figure 3-82: vl500 80v display cable assembly no. Item qty. Um. Description 1 52.6363.0001 1 ea conn housing, 6 pin mta closed end blu...

  • Page 201

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 183 vl500 80v yoke dmx communication cable assembly 25.9685.0786 rev a refer to figure 3-83 . Figure 3-83: vl500 80v yoke dmx communication cable assembly no. Item qty. Um. Description 1 52.6234.0001 1 ea conn housing, 4 pin mt...

  • Page 202

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 8 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v lvs fan cable assembly 25.9685.0787 rev 0 refer to figure 3-84 . Figure 3-84: vl500 80v lvs fan cable assembly no. Item qty. Um. Description 1 52.6234.0001 2 ea conn housing, 4 pin mta closed end blu...

  • Page 203

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 185 80v shielded display/dmx communication cable assembly (vl500 80v) 25.9685.0788 rev a refer to figure 3-85 . Figure 3-85: 80v shielded display/dmx communication cable assembly (vl500 80v) no. Item qty. Um. Description 1 25.9...

  • Page 204

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 8 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a 80v dimmer communication cable assembly (vl500 80v) 25.9685.1794 rev 0 refer to figure 3-86 . Figure 3-86: 80v dimmer communication cable assembly (vl500 80v) no. Item qty. Um. Description 1 28a2432-0a2 1 ea s...

  • Page 205

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 187 vl500 main harness cable assembly 25.9685.0790 rev j (vl500 and vl500d) refer to figure 3-87 . No. Item qty. Um. Description 1 25.9685.0750 1 ea cable assy, dimmer comm 2 25.9685.0752 1 ea cable assy, 24v power 3 25.9685.07...

  • Page 206

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 8 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 main harness cable assembly (contin- ued) figure 3-87: vl500 main harness cable assembly (vl500 and vl500d) 2 2 1 3 3 9 7 6 10 5 12 3 3 8 12 4 3 10 1 9 2 13 11 (x8) 5 6 8 4 7.

  • Page 207

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 189 vl500 arc main harness cable assembly 25.9685.0791 rev c (vl500a) refer to figure 3-88 . No. Item qty. Um. Description 1 25.9685.0752 1 ea cable assy, 24v power 2 25.9685.0758 1 ea cable assy, pan/tilt 3 25.9685.0772 1 ea c...

  • Page 208

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 9 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 arc main harness cable assembly (con- tinued) figure 3-88: vl500 arc main harness cable assembly (vl500a) 2 2 1 4 6 5 10 2 2 5 10 8 2 6 8 1 11 9 (x8) 7 3 8 8 4 7 3 1.

  • Page 209

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 191 vl500 80v main harness cable assembly 25.9685.2792 rev a (vl500 80v) refer to figure 3-89 . No. Item qty. Um. Description 1 25.9685.1794 1 ea cable assy, 80v dimmer comm, vl500 80v 2 25.9685.0744 1 ea cable assy, 24v power,...

  • Page 210

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 9 2 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 80v main harness cable assembly (con- tinued) figure 3-89: vl500 80v main harness cable assembly (vl500 80v) 4 1 7 9 4 4 9 4 7 8 2 9 8 (x8) 3 5 6 6 2 3 5 6 3 4 8 8 8 8 1.

  • Page 211

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 193 vl500 80v lamp wire harness 25.9685.0793 rev b refer to figure 3-90 . Figure 3-90: vl500 80v iginitor to socket cable assembly no. Item qty. Um. Description 1 25.9685.0777 1 ea cable assy, back cap ground, vl500 2 52.8244.0...

  • Page 212

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 9 4 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a notes.

  • Page 213

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 195 arc ballast assembly vl500 arc ballast assembly 21.9685.0802 rev h refer to figure 3-91 . No. Item qty. Um. Description 1 04.9685.0941 1 ea label, product, vl500aps-700w 2 04.9685.0942 1 ea label, product, vl500aps complian...

  • Page 214

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 9 6 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a vl500 arc ballast assembly (continued) figure 3-91: vl500 arc ballast assembly 7 20 (x4) 2 23 (x2) 13 (x4) 11 5 9 18 (x4) 17 (x4) 19 (x12) 12 21 (x16) 10 14 (x4) 15 (x5) 16 (x4) 8 22 4 1 3 6.

  • Page 215

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 197 ballast i/o cable assembly 25.9685.0807 rev a refer to figure 3-92 . No. Item qty. Um. Description 1 52.6231.0001 1 ea plug housing, mnlok plug 3-pos 2 52.6396.2904 1 ea recept, 4-pos mta100 w/pol red 3 52.6400.0111 1 ea re...

  • Page 216

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 1 9 8 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a ballast i/o cable assembly (continued) figure 3-92: ballast i/o cable assembly 2 11 (x5) 7 (x3) 9 4 (x3) 5 (x5) 6 3 8 (x2) 10 1 12, 13, 14 17 18 19 19 15 16 9.

  • Page 217: Ppendix

    0 2 . 9 6 8 5 . 0 0 1 0 a 21-may-2009 199 a ppendix a. Technical bulletins and notices vl500™ wash luminaire technical bulletins and notices the following table identifies the current technical bulletins and notices associated with the vl500™ wash luminaire. If applicable, these improvements have be...

  • Page 218

    Vari ❋lite® - vl500™ l uminaire s ervice m anual 2 0 0 21-may-2009 0 2 .9 6 8 5 .0 0 1 0 a notes.

  • Page 220

    Vari-lite 10911 petal street dallas, texas 75238 usa 1.877.Vari-lite ❋ fax 1.214.647.8038 www.Vari-lite.Com date: 21-may-2009 / manual part number: 02.9685.0010 a ©2003-2009 vari-lite, a philips group company. All rights reserved. Printed in the u.S.A..