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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 i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 ™,...

  • 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 0 17 -ju ly- 200 6 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-lit...

  • Page 4: Compliance Notice

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual i v 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 compliance notice this equipment has been tested and found to comply with the limits for a class a digital device pursuant to part 15 of fcc rules. These limits are designed to provide reasonable protect...

  • Page 5: Safety Notice

    S afety n otice 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 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 warning...

  • Page 6

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual v i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 warning: instructions for continued protection against excessive exposure to uv radiation 1. Many vari ❋ lite® luminaires use an hid type lamp that produces uv radiation. Do not look directly at lamp. 2....

  • Page 7: Sicherheitshinweise

    S icherheitshinweise 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 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. H...

  • Page 8

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual v i i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 2. Es ist gefährlich, leuchten ohne linsen oder blenden zu bedienen. Blenden, linsen oder ultraviolettschirme müssen ausgetauscht werden, sofern deren schutzwirkung durch sichtbare beschädigung (z. B...

  • Page 9: Notes De Sécurité

    N otes de sÉcuritÉ 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 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 gui...

  • Page 10

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual x 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 avertissement: directives pour se protÉger contre une exposition excessive aux rayons uv 1. Plusieurs luminaires vari ❋ lite® utilisent une lampe de type hid qui produit des rayons uv. Ne pas fixer son reg...

  • Page 11: Aviso Sobre Seguridad

    A viso sobre s eguridad 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 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 ...

  • Page 12

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual x i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 deterio...

  • Page 13

    S afety n otice (j apanese ) 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xiii.

  • Page 14

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual x i v 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0

  • Page 15: Hapter

    0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xv c hapter 1. Description this chapter provides an overview of luminaire features, components and operations. • features • component descriptions • principles of operation.

  • Page 16

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x v i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 features product features vl500 wash luminaires have the following features: color enhanced dichro ❋ tune tm radial color changing mechanism featuring independent magenta, blue, and amber color contro...

  • Page 17

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xvii model specific features each individual configuration has the following specific features: vl500 wash luminaire (20.9685.0001) • 120v (or 230v), 1200w (or 1000w) tungsten halogen lamp source. • standard color dichroic glass dichro ❋ tu...

  • Page 18

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x v i i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 (20.968...

  • Page 19

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xix 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 d...

  • Page 20

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x x 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 luminaire internal head components the following illustration shows the major sub-assemblies which are located in the luminaire head assembly. Note: yoke assembly not shown for clarity. Provides frame f...

  • Page 21

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xxi luminaire yoke components the following illustration shows the major sub-assemblies which are located in the luminaire yoke assembly. Note: head assembly not shown for clarity. Main controller pcb luminaire control circuit board. Tilt m...

  • Page 22

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x x i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 pow...

  • Page 23

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xxiii 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 componen...

  • Page 24

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x x i v 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 principles of operation vl500 incandescent luminaires vl500 incandescent block diagram - without on-board igbt dimmer note: for detailed information on wiring, connections, signals, etc., please ref...

  • Page 25

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xxv vl500d incandescent luminaires vl500d incandescent block diagram - with on-board igbt dimmer note: for detailed information on wiring, connections, signals, etc., please refer to “vl500 wiring diagram - sheet 1 of 1” on page 163 . J3 j8...

  • Page 26

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x x v i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 80v incandescent luminaires vl500 80v incandescent block diagram - with on-board 80v dimmer note: for detailed information on wiring, connections, signals, etc., please refer to “vl500 wiring ...

  • Page 27

    D escription : 1 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xxvii vl500a luminaire vl500a arc block diagram - with external arc ballast note: for detailed information on wiring, connections, signals, etc., please refer to “vl500 wiring diagram - sheet 1 of 1” on page 163 . J3 j8 j6 magenta j4 motor ...

  • Page 28

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual x x v i i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 notes.

  • Page 29

    T able of c ontents 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xxix table of contents chapter 1. Description features product features........................................................................................................ Xvi model specific features ....................................

  • Page 30

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual x x x 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 electrostatic discharge (esd) ............................................................................. 10 printed circuit boards (pcbs)................................................................

  • Page 31

    T able of c ontents 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 xxxi vl500 80v (with 80v dimmer) luminaire .............................................................. 75 vl500a luminaire (575w arc) ............................................................................... 77 vl500a luminaire ...

  • Page 32

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual x x x i i 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 display (remote) cable assembly ..............................................................149 vl500 yoke lamp jumper cable assembly ..........................................................

  • Page 33

    I ntroduction : 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 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 p...

  • Page 34

    Vari ❋ lite® - vl500™ l uminaire s ervice m anual 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 additional documentation a support web page for vl500 series luminaires is available at www.Vari-lite.Com (follow the support link). A user’s manual is available for installation and operation of the vl500...

  • Page 35: Hapter

    0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 3 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 ...

  • Page 36

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 testing running parameter tests the luminaire is capable of running self tests by using the test menu functions. For complete details and values for each test refer to “diagnostic tests” on page 6 . When ...

  • Page 37

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 5 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...

  • Page 38

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 differe...

  • Page 39

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 7 test menu system chart the following 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 test...

  • Page 40

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 f...

  • Page 41

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 9 equipment handling below are some basic tips and information on handling luminaires and their associated components. Locations/use vari ❋ lite luminaires are designed for dry locations only. Exposure to rain or moisture (including, but no...

  • Page 42

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 • 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...

  • Page 43

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 11 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) 71.968...

  • Page 44

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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. If required, use alcohol a...

  • Page 45

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 13 lamp replacement (arc model) parts: 71.2528.0575 1 ea msr575, 575 watt arc lamp (vl500a 575w models) 71.9685.0702 1 ea msr700/2, 700 watt msr arc lamp (vl500a 700w models) tools: • cotton gloves or finger cots. Warning: remove power from...

  • Page 46

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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. If required, use alcohol a...

  • Page 47

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 15 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 • c...

  • Page 48

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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, r...

  • Page 49

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 17 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. 42.96...

  • Page 50

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 dirty, clean with common glass...

  • Page 51

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 19 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...

  • Page 52

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 2 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 step 5. At top cover, remove four 6-32x1/4" ppb sems screws. Step 6. Remove top cover. Step 7. Disconnect wiring at two linear actuators on magenta/blue dichro*tune bulkhead. Step 8. As shown in figure ...

  • Page 53

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 21 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 replac...

  • Page 54

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 2 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 step 8. As shown in figure 11 , at side rails from top, remove four 6-32x3/8" lg ppz sems screws. Figure 11: amber/diffuser (or dimmer) bulkhead step 9. Carefully lift amber/diffuser (or dimmer) bulkhea...

  • Page 55

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 23 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) 22.968...

  • Page 56

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 2 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 warning: wear cotton gloves or other covering while handling filters or diffuser panels. If required, use isopropyl alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp. Caution: ...

  • Page 57

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 25 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:...

  • Page 58

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 2 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 step 10. Remove dimmer panel from center hub. Figure 14: dimmer panel replacement step 11. Replace by performing steps 3 through 10 in reverse order. Dimmer panel bulkhead center hub insert panel bearin...

  • Page 59

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 27 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 befor...

  • Page 60

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 2 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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...

  • Page 61

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 29 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 ...

  • Page 62

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 3 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 ...

  • Page 63

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 31 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: st...

  • Page 64

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 3 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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. ...

  • Page 65

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 33 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 soc...

  • Page 66

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 3 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 remo...

  • Page 67

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 35 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...

  • Page 68

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 3 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 perf...

  • Page 69

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 37 step 6. Remove four 1/4" hex (13/16" long) standoffs as indicated in figure 24 . 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...

  • Page 70

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 3 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 low voltage supply (lvs) replacement (vl500/ vl500d/vl500a only) parts: 69.3178.0120 1 ea power supply, 120w, 24vdc tools: • #2 phillips screwdriver warning: remove power from luminaire before performin...

  • Page 71

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 39 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:...

  • Page 72

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 4 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 maintenan...

  • Page 73

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 41 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 maintenance. Warning: with powe...

  • Page 74

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 4 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 r...

  • Page 75

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 43 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 ...

  • Page 76

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 4 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 pa...

  • Page 77

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 45 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 ...

  • Page 78

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 4 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 remo...

  • Page 79

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 47 igbt dimmer replacement (vl500d only) parts: 69.3173.0115 1 ea dimmer, igbt, 1200w 115v rev phase cont (vl500d 115v models only) 69.3173.0230 1 ea dimmer, igbt, 1000w 230v rev phase cont (vl500d 230v models only) tools: • #2 phillips scr...

  • Page 80

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 4 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 components not shown for clarity. Note: igbt dimme...

  • Page 81

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 49 80v dimmer replacement (vl500 80v only) parts: 21.9685.0750 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 l...

  • Page 82

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 5 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 dimme...

  • Page 83

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 51 arc ballast replacement (vl500a only) parts: 21.9685.0800 1 ea assy, ballast, 625w (575w models only) 21.9685.0802 1 ea assy, ballast, 700w (700w models only) tools: • none warning: remove power from luminaire before performing maintenan...

  • Page 84

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 5 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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. ...

  • Page 85

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 53 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 (powerc...

  • Page 86

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 5 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 lumi...

  • Page 87

    M aintenance : 2 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 55 dmx pcb assembly replacement parts: 24.9663.1895 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 f...

  • Page 88

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 5 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 a...

  • Page 89: Hapter

    0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 57 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 assem...

  • Page 90

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 58 17-july-2006 02.9685.0010 0 drawing trees vl500 and vl500d incandescent luminaires figure 3-1: vl500 and vl500d incandescent luminaires drawing tree (part 1) continued next page vl500 luminaire (120v or 230v) incandescent versions 20.9685.0001 re...

  • Page 91

    I llustrated p arts b reakdown : 3 02.9685.0010 0 17-july-2006 59 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 s or 21.9685.0521 (vl500d) rev s vl500 main harness cable ass...

  • Page 92

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 60 17-july-2006 02.9685.0010 0 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 j (standard dicro*tune colors) or 20.9685...

  • Page 93

    I llustrated p arts b reakdown : 3 02.9685.0010 0 17-july-2006 61 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 g vl500 80v main harness cable assembly 25.9685.0792 rev c (vl500...

  • Page 94

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 62 17-july-2006 02.9685.0010 0 vl500a (575w/700w) arc luminaires figure 3-5: vl500a (575w/700w) arc luminaires drawing tree (part 1) continued next page vl500a luminaire (575w arc) or vl500a luminaire (700w arc) 20.9685.0005 rev h (standard dicro*tu...

  • Page 95

    I llustrated p arts b reakdown : 3 02.9685.0010 0 17-july-2006 63 vl500a (575w/700w) arc luminaires (contin- ued) figure 3-6: vl500a (575w/700w) arc luminaires drawing tree (part 2) vl500 yoke assembly 21.9685.0522 (vl500a) rev s vl500 arc main harness cable assembly 25.9685.0791 rev c (vl500a) vl50...

  • Page 96

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 6 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 top assembly included items kit 28.9685.0001 rev g (120v or 230v, standard colors, no dimmer) 28.9685.0011 rev g (120v or 230v, pastel colors, no dimmer) 28.9685.0002 rev g (standard colors, 120v igbt o...

  • Page 97

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 65 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 98

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 6 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 ...

  • Page 99

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 67 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 ...

  • Page 100

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 6 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 domesti...

  • Page 101

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 69 vl500 luminaire (120v or 230v) 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 ...

  • Page 102

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 7 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 figure 3-9: vl500 luminaire (120v or 230v) 9 12 7 4 (x2) 5 6 8 14 (x8) 13 (x8) 11 10 15 (x8) 16 (x8) 3 1 2.

  • Page 103

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 71 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 yo...

  • Page 104

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 7 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 figure 3-10: vl500d (with 120v igbt dimmer) luminaire 11 14 9 7 8 10 17 (x8) 15 (x8) 12 13 18 (x8) 5 (x2) 19 (x8) 6 (x2) 20 16 (x8) 3 4 1 2.

  • Page 105

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 73 vl500d (with 230v 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 yo...

  • Page 106

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 7 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 figure 3-11: vl500d (with 230v igbt dimmer) luminaire 11 14 9 7 8 10 17 (x8) 15 (x8) 12 13 18 (x8) 5 (x2) 19 (x8) 6 (x2) 20 16 (x8) 3 4 1 2.

  • Page 107

    I llustrated p arts b reakdown : 3 02.9685.0010 0 17-july-2006 75 vl500 80v (with 80v dimmer) luminaire 20.9685.0004 rev j (standard dicro*tune colors) 20.9685.0014 rev d (pastel dicro*tune colors) refer to figure 3-12 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke cover 2 04.9685...

  • Page 108

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 76 17-july-2006 02.9685.0010 0 figure 3-12: vl500 80v (with 80v dimmer) luminaire 11 16 10 6 7 19 (x8) 14 15 17 (x8) 5 (x2) 21 (x8) 8 18 (x8) 3 4 1 2 20 (x8) 13 9 12 22.

  • Page 109

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 77 vl500a luminaire (575w arc) 20.9685.0005 rev h (standard dicro*tune colors) 20.9685.0015 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...

  • Page 110

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 7 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 figure 3-13: vl500a luminaire (575w arc) 8 12 7 4 (x2) 5 6 9 14 (x8) 13 (x8) 11 10 15 (x8) 16 (x8) 3 1 2.

  • Page 111

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 79 vl500a luminaire (700w arc) 20.9685.0006 rev h (standard dicro*tune colors) 20.9685.0016 rev b (pastel dicro*tune colors) refer to figure 3-14 no. Item qty. Um. Description 1 04.9685.0573 1 ea label, mcb yoke cover 2 04...

  • Page 112

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 8 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 figure 3-14: vl500a luminaire (700w arc) 8 12 7 4 (x2) 5 6 9 14 (x8) 13 (x8) 11 10 15 (x8) 16 (x8) 3 1 2.

  • Page 113

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 81 generic vl500 luminaire assembly 21.9685.0010 rev p (incandescent - without internal dimmer) 21.9685.0011 rev p (incandescent - with internal igbt dimmer) 21.9685.0012 rev p (incandescent - with internal 80v dimmer) 21....

  • Page 114

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 8 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 ...

  • Page 115

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 83 generic vl500 luminaire assembly (continued) figure 3-15: generic vl500 luminaire assembly (vl500 and vl500d) 28 16 (vl500 only) 4 3 38 22 20 39 36 36 12 (vl500d only) 27 25 11 1 31 26 25 32 5 34 10 13 9 7 8 2 43 27 42 ...

  • Page 116

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 8 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 generic vl500 luminaire assembly (continued) figure 3-16: generic vl500 luminaire assembly (vl500 80v) 28 19 4 3 38 22 20 39 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 42 ...

  • Page 117

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 85 generic vl500 luminaire assembly (continued) figure 3-17: generic vl500 luminaire assembly (vl500a) 28 18 4 3 38 22 20 39 36 36 25 11 1 31 26 25 32 5 34 10 14 9 7 8 2 43 42 35 40 24 6 27 25 33 34 31 27 11 27 39 (x4) 23 ...

  • Page 118

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 8 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 notes.

  • Page 119

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 87 head assembly vl500 generic head assembly 21.9685.0310 (vl500 and vl500d) rev h 21.9685.0311 (vl500a) rev h 21.9685.0312 (vl500 80v) rev h refer to figure 3-18 , figure 3-19 , figure 3-20 . No. Item qty. Um. Description...

  • Page 120

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 8 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 generic head assembly (continued) figure 3-18: vl500 generic head assembly (vl500 and vl500d) 5 14 (x4) 12 (x2) 8 16 15 12 (x2) 1 6 13 (x4) 18 20 2 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 0 17 -ju ly- 200 6 89 vl500 generic head assembly (continued) figure 3-19: vl500 generic head assembly (vl500a) 5 14 (x4) 12 (x2) 9 16 15 12 (x2) 1 6 13 (x4) 18 20 2 2 7 19 21 4 3 12 (x2) 11 17 (x2).

  • Page 122

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 9 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 generic head assembly (continued) figure 3-20: vl500 generic head assembly (vl500 80v) 5 14 (x4) 12 (x2) 10 16 15 12 (x2) 1 6 13 (x4) 18 20 2 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 0 17 -ju ly- 200 6 91 heatsink assembly 21.9685.0320 (vl500 and vl500d) rev g 21.9685.0321 (vl500a) rev g 21.9685.0322 (vl500 80v) rev g refer to figure 3-21 , figure 3-22 , figure 3-23 . No. Item qty. Um. Description 1 10.9634.0103 3 ea pad...

  • Page 124

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 9 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 heatsink assembly (continued) figure 3-21: vl500 heatsink assembly (vl500 and vl500d) 14 (x2) 6 10 4 19 (x2) 18 15 (x4) 13 (x3) 20 (x3) 2 (x3) 5 1 (x3) 11 9.

  • Page 125

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 93 vl500 heatsink assembly (continued) figure 3-22: 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 9 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 heatsink assembly (continued) figure 3-23: 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 0 17 -ju ly- 200 6 95 vl500 magenta/blue color assembly 21.9685.0170 rev h (standard dicro*tune colors) refer to figure 3-24 . Figure 3-24: vl500 magenta/blue color assembly no. Item qty. Um. Description 1 10.9685.0257 2 ea light baffle, rea...

  • Page 128

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 9 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 magenta/blue (pastel) color assembly 21.9685.0174 rev a (pastel dicro*tune colors) refer to figure 3-25 . Figure 3-25: vl500 magenta/blue (pastel) color assembly no. Item qty. Um. Description 1 10...

  • Page 129

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 97 vl500 amber/diffuser color assembly 21.9685.0171 rev g refer to figure 3-26 . Figure 3-26: 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...

  • Page 130

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 9 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 amber/dimmer color assembly 21.9685.0172 rev f refer to figure 3-27 . Figure 3-27: vl500 amber/dimmer color assembly no. Item qty. Um. Description 1 10.9685.0245 2 ea light baffle, top 2 21.9685.0...

  • Page 131

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 99 vl500 magenta/blue (arc) color assembly 21.9685.0173 rev a (standard dicro*tune colors) refer to figure 3-28 . Figure 3-28: vl500 magenta/blue (arc) color assembly no. Item qty. Um. Description 1 10.9685.0246 4 ea clip,...

  • Page 132

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 0 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 magenta/blue (arc pastel) color assembly 21.9685.0175 rev a (pastel dicro*tune colors) refer to figure 3-29 . Figure 3-29: vl500 magenta/blue (arc) color assembly no. Item qty. Um. Description 1...

  • Page 133

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 101 magenta/blue color assembly 21.9685.0160 rev e (standard dicro*tune colors) refer to figure 3-30 . Figure 3-30: magenta/blue color assembly no. Item qty. Um. Description 1 10.9634.0034 32 ea spring, drive arm, filter 2...

  • Page 134

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 0 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 magenta/blue (pastel) color assembly 21.9685.0164 rev 0 (pastel dicro*tune colors) refer to figure 3-31 . Figure 3-31: magenta/blue (pastel) color assembly no. Item qty. Um. Description 1 10.9634.0034...

  • Page 135

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 103 amber/diffuser color assembly 21.9685.0161 rev f refer to figure 3-32 . Figure 3-32: 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,...

  • Page 136

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 0 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 amber/dimmer color assembly 21.9685.0162 rev e refer to figure 3-33 . 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 1...

  • Page 137

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 105 figure 3-33: 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 0 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 bottom bulkhead assembly 21.9685.0150 rev c refer to figure 3-34 . 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, ce...

  • Page 139

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 107 bottom bulkhead assembly (continued) figure 3-34: 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 0 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 top bulkhead assembly 21.9685.0151 rev c refer to figure 3-35 . 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 ass...

  • Page 141

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 109 top bulkhead assembly (continued) figure 3-35: 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 1 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 drive ring assembly 21.9685.0251 rev b refer to figure 3-37 . Figure 3-36: 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 2...

  • Page 143

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 111 magenta/blue color motor assembly 21.9685.0280 rev a refer to figure 3-37 . Figure 3-37: 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 hea...

  • Page 144

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 1 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 amber/diffuser color motor assembly 21.9685.0281 rev a refer to figure 3-37 . Figure 3-38: amber/diffuser color motor assembly no. Item qty. Um. Description 1 10.9634.0061 1 ea actuator mount, vl500 2...

  • Page 145

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 113 yoke assembly vl500 yoke assembly 21.9685.0520 (vl500) rev s 21.9685.0521 (vl500d) rev s 21.9685.0522 (vl500a) rev s refer to figure 3-39 , figure 3-40 . No. Item qty. Um. Description 1 10.9685.0534 1 ea cover, pan tub...

  • Page 146

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 1 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 sc...

  • Page 147

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 115 vl500 yoke assembly (continued) figure 3-39: 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 1...

  • Page 148

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 1 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 yoke assembly (continued) figure 3-40: 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...

  • Page 149

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 117 vl500 80v yoke assembly 21.9685.0523 (vl500 80v) rev g refer to figure 3-41 , figure 3-42 . No. Item qty. Um. Description 1 10.9685.0542 1 ea shield, wire 2 10.9685.0543 1 ea shield, sensor board 3 10.9685.0554 1 ea co...

  • Page 150

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 1 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 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 ft grommet...

  • Page 151

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 119 vl500 80v yoke assembly (continued) figure 3-41: vl500 80v yoke assembly 29 (x4) 22 (x6) 27 3 31 18 1 35 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 2 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 yoke assembly (continued) figure 3-42: vl500 80v yoke assembly 20 (x4) 33 34 (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 0 17 -ju ly- 200 6 121 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 ...

  • Page 154

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 2 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 pan/tilt motor assembly 21.9685.0540 rev b refer to figure 3-44 . Figure 3-44: vl500 pan/tilt motor assembly no. Item qty. Um. Description 1 10.9685.0541 1 ea plate, tension adjustment, pan/tilt...

  • Page 155

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 123 vl500 mcb/fan assembly 21.9685.0731 rev 0 refer to figure 3-45 . Figure 3-45: 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, thermal transfe...

  • Page 156

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 2 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 mcb fan assembly 23.9685.0782 rev 0 refer to figure 3-44 . Figure 3-46: 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, m...

  • Page 157

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 125 yoke crossmember assembly 21.9685.0515 rev e refer to figure 3-47 . Figure 3-47: yoke crossmember assembly (vl500/vl500d/vl500a) no. Item qty. Um. Description 1 10.9685.0547 1 ea bushing, wire protection, 0.95" od 2 10...

  • Page 158

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 2 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 yoke crossmember assembly (vl500 80v) 21.9685.0516 rev 0 refer to figure 3-48 . Figure 3-48: yoke crossmember assembly (vl500 80v) no. Item qty. Um. Description 1 10.9685.0547 1 ea bushing, wire prote...

  • Page 159

    I llustrated p arts b reakdown : 3 02.9685.0010 0 17-july-2006 127 lower crossmember assembly 21.9685.0512 rev j refer to figure 3-49 . No. Item qty. Um. Description 1 10.9685.0509 1 ea lower crossmember 2 10.9685.0522 1 ea plate, pan lock 3 10.9685.0527 2 ea washer, centering, step 4 10.9685.0533 1...

  • Page 160

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 128 17-july-2006 02.9685.0010 0 lower crossmember assembly (continued) figure 3-49: 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 161

    I llustrated p arts b reakdown : 3 02.9685.0010 0 17-july-2006 129 upper crossmember assembly 21.9685.0513 rev g refer to figure 3-49 . Figure 3-50: upper crossmember assembly no. Item qty. Um. Description 1 10.9685.0510 1 ea upper crossmember 2 10.9685.0527 2 ea washer, centering, step 3 53.2020.00...

  • Page 162

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 3 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 pan tube assembly 21.9685.0535 rev d (vl500/vl500d/vl500a) refer to figure 3-51 . Figure 3-51: pan tube assembly (vl500/vl500d/vl500a) no. Item qty. Um. Description 1 10.9685.0521 1 ea pulley, driven,...

  • Page 163

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 131 80v pan tube assembly 21.9685.0536 rev 0 (vl500 80v) refer to figure 3-52 . Figure 3-52: 80v pan tube assembly (vl500 80v) no. Item qty. Um. Description 1 10.9685.0521 1 ea pulley, driven, pan/tilt 2 10.9685.0532 1 ea ...

  • Page 164

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 3 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 dmx input pcb assembly 24.9663.1895 rev a refer to figure 3-53 . Figure 3-53: dmx input pcb assembly no. Item qty. Um. Description ref 1 11.9663.1895 1 ea pcb, dmx input - - 35-0053 2 ea diode, zener,...

  • Page 165

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 133 vl500 main control board pcb assembly 24.9685.0730 rev b refer to figure 3-54 item um. Description ref. 10-0207 2 ea resistor, 47k, 1/10w, 5% sm 0805 r167, r168 10-0211 1 ea resistor, 100k, 1/10w, 5% sm 0805 r144 10-02...

  • Page 166

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 3 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 60.1161.7503 16 ea res, 1/16w 1% 7.50 k chip thk flm smt0402 r89, r90, r95, r96, r110, r111, r114, r115, r123, r124, r126, r127, r134, r135, r137, r138 60.1165.1002 9 ea res, 1/16w 5% 100 ohm chip thk...

  • Page 167

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 135 62.4240.0103 16 ea cap, .01uf 25v 10% cer chip sur mt x7r eia0603 c13-17, c24-25, c29, c62, c66, c78, c82, c101, c103, c110, c112 62.4240.0104 39 ea cap, .1uf 25v 10% cer chip sur mt x7r eia0603 c18-23, c26, 27, c30-42...

  • Page 168

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 3 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 figure 3-54: vl500 main control board pcb assembly 85.5134.0001 1 ea ic, sn75lbc180d low-power diff line drvr & rcvr pairs u20 85.5164.0002 2 ea ic, l6234pd so-20 85.5168.0001 1 ea ic, ds1834as dual r...

  • Page 169

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 137 cables incandescent power input cable assembly 25.9663.2030 rev a (vl500 only) refer to figure 3-55 . Figure 3-55: incandescent power input cable assembly (vl500 only) no. Item qty. Um. Description 1 52.6274.2313 1 ea ...

  • Page 170

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 3 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 80v lvs ac cable assembly 25.9685.0742 rev 0 refer to figure 3-56 . Figure 3-56: 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...

  • Page 171

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 139 80v surge protector cable assembly 25.9685.0746 rev 0 refer to figure 3-57 . Figure 3-57: 80v surge protector cable assembly no. Item qty. Um. Description 1 33-0441 2 ea mov, 430v 6500a 20mm znr 2 52.8231.0005 1 ea ter...

  • Page 172

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 4 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 motor cable assembly 25.9685.0753 rev b refer to figure 3-58 . 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 52.66...

  • Page 173

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 141 vl500 motor cable assembly (continued) figure 3-58: 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 174

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 4 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 relay to ignitor cable assembly 25.9685.0755 rev b refer to figure 3-59 . Figure 3-59: relay to ignitor cable assembly no. Item qty. Um. Description 1 52.8271.0005 4 ea recpt, faston 1/4" 16-14 awg in...

  • Page 175

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 143 vl500 ac input cable assembly 25.9685.0756 rev b refer to figure 3-60 . Figure 3-60: vl500 ac input cable assembly no. Item qty. Um. Description 1 52.6541.0003 1 ea conn, chassis power 3-pole locking 2 52.8231.0005 1 e...

  • Page 176

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 4 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 arc ballast input cable assembly 25.9685.0757 rev c refer to figure 3-60 . Figure 3-61: vl500 arc ballast input cable assembly no. Item qty. Um. Description 1 52.6400.0027 1 ea recpt, 17-14 sq f...

  • Page 177

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 145 vl500 head grounding cable assembly 25.9685.0760 rev c refer to figure 3-62 . Figure 3-62: vl500 head earthing cable assembly no. Item qty. Um. Description 1 52.8231.0000 2 ea term, ring #6 red 22-16 awg insul reel 2 7...

  • Page 178

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 4 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 ignitor to socket cable assembly 25.9685.0766 rev c refer to figure 3-63 . Figure 3-63: vl500 iginitor to socket cable assembly no. Item qty. Um. Description 1 25.9685.0777 1 ea cable assy, back...

  • Page 179

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 147 vl500 arc ballast interconnect cable assembly 25.9685.0767 rev b refer to figure 3-64 . 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 sex cpc 60...

  • Page 180

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 4 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 arc ballast interconnect cable assem- bly (continued) figure 3-64: 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 ...

  • Page 181

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 149 vl500 display (remote) cable assembly 25.9685.0770 rev b refer to figure 3-63 . Figure 3-65: vl500 display (remote) cable assembly no. Item qty. Um. Description 1 10.9685.0536.01 1 ea adapter plate, mini xlr, black 2 5...

  • Page 182

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 5 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 yoke lamp jumper cable assembly 25.9685.0776 rev a refer to figure 3-66 . Figure 3-66: vl500 yoke lamp jumper cable assembly no. Item qty. Um. Description 1 52.8348.0001 2 ea tab, ultra-fast 1/4...

  • Page 183

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 151 vl500 backcap ground cable assembly 25.9685.0777 rev a refer to figure 3-62 . Figure 3-67: 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 5...

  • Page 184

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 5 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 main harness cable assembly 25.9685.0790 rev j (vl500 and vl500d) refer to figure 3-68 . No. Item qty. Um. Description 1 25.9685.0750 1 ea cable assy, dimmer comm 2 25.9685.0752 1 ea cable assy,...

  • Page 185

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 153 vl500 main harness cable assembly (contin- ued) figure 3-68: 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 186

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 5 4 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 arc main harness cable assembly 25.9685.0791 rev c (vl500a) refer to figure 3-68 . No. Item qty. Um. Description 1 25.9685.0752 1 ea cable assy, 24v power 2 25.9685.0758 1 ea cable assy, pan/til...

  • Page 187

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 155 vl500 arc main harness cable assembly (con- tinued) figure 3-69: 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 188

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 5 6 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 80v main harness cable assembly 25.9685.0792 rev c (vl500 80v) refer to figure 3-68 . No. Item qty. Um. Description 1 25.9678.0743 1 ea cable assy, 80v dimmer comm, vl500 80v 2 25.9685.0744 1 ea...

  • Page 189

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 157 vl500 80v main harness cable assembly (con- tinued) figure 3-70: vl500 80v main harness cable assembly (vl500 80v) 4 1 7 9 4 4 9 4 7 8 2 10 8 (x8) 3 5 6 6 2 3 5 6 3 4 8 8 8 8 1.

  • Page 190

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 5 8 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 notes.

  • Page 191

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 159 arc ballast assembly vl500 arc ballast assembly 21.9685.0800 rev g (625w - vl500a 575w arc) 21.9685.0802 rev g (700w - vl500a 700w arc) refer to figure 3-71 . No. Item qty. Um. Description 1 04.9685.0940 1 ea label, pr...

  • Page 192

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 6 0 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 vl500 arc ballast assembly (continued) figure 3-71: vl500 arc ballast assembly 9 23 (x4) 4 (575w only) 5 (700w only) 1 (575w only) 2 (700w only) 3 23 (x2) 16 (x4) 14 7 11 21 (x4) 20 (x4) 22 (x12) 15 1...

  • Page 193

    I llustrated p arts b reakdown : 3 0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 161 ballast i/o cable assembly 25.9685.0807 rev a refer to figure 3-72 . 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 ...

  • Page 194

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 6 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 ballast i/o cable assembly (continued) figure 3-72: 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.

  • Page 195

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 163 vl500 wiring and schematic diagrams vl500 wiring diagram - sheet 1 of 1.

  • Page 196

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 164 dmx input pcb (24.9663.1895) schematic 5 5 4 4 3 3 2 2 1 1 d d c c b b a a shield shield shield dmx/vl_in- dmx/vl_in- dmx/vl_in- dmx/vl_in+ dmx/vl_in+ dmx/vl_in+ vl_out- vl_out- vl_o...

  • Page 197

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 165 vl500 controller pcb (24.9685.0730) schematic - sheet 1 of 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a +3.3v +3.3v +1.8v +24v vcc +3.3v +1.5v +1.5v vcc +24v +3.3v +1.8v 18v batt 18v batt +...

  • Page 198

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 166 vl500 controller pcb (24.9685.0730) schematic - sheet 2 of 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a d30 d31 a20 a14 a21 a15 a11 a13 a17 a12 a9 a10 a18 a21 a19 a22 a20 a23 a24 clk0 a19 s...

  • Page 199

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 167 vl500 controller pcb (24.9685.0730) schematic - sheet 3 of 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a d25 a7 d26 a8 d27 a6 d28 d[0..31] a9 a[0..24] d18 d20 d21 d22 d23 a4 d24 a5 a2 d30 d3...

  • Page 200

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 168 vl500 controller pcb (24.9685.0730) schematic - sheet 4 of 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a ci+ ci- 1 1 1 1 iso_vcc vcc 1 vcc vcc vcc vcc vcc vcc +3.3v iso_vcc iso_vcc vcc +3.3v...

  • Page 201

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 169 vl500 controller pcb (24.9685.0730) schematic - sheet 5 of 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc vcc vcc vcc +24v vcc +24v +24v +24v +24v vcc vcc +24v +24v +24v +24v vcc +24v vcc...

  • Page 202

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual r eference f old -o uts 0 2 . 9 6 8 5 . 0 0 1 0 0 17-july-2006 170 vl500 controller pcb (24.9685.0730) schematic - sheet 6 of 6 5 5 4 4 3 3 2 2 1 1 d d c c b b a a vcc +24v vcc vcc +24v vcc +24v vcc vcc vcc +24v vcc vcc +1.5v vcc +24v +3.3v +1.8v 18...

  • Page 203: Ppendix

    0 2 . 9 6 8 5 . 0 0 1 0 0 17 -ju ly- 200 6 171 a ppendix a. Technical bulletins vl500 wash luminaire technical bulletins the following table identifies the current technical bulletins associated with the vl500 wash luminaire. If applicable, these improvements have been incorporated into this manual....

  • Page 204

    Vari ❋ lite ® - vl500™ l uminaire s ervice m anual 1 7 2 17 -ju ly- 200 6 0 2 . 9 6 8 5 . 0 0 1 0 0 notes.

  • Page 206

    Vari-lite 10911 petal street dallas, texas 75238 usa 1.877.Vari-lite o 1.214.647.7880 o fax 1.214.647.8038 www.Vari-lite.Com © 2006 genlyte group llc. All rights reserved. Printed in usa.