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Philips Vari-Lite VL500 Service Manual Download Page 17

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21-May-2009

xvii

VL500D (with 120V IGBT Dimmer) Luminaire ...................................................... 87
VL500D (with 240V IGBT Dimmer) Luminaire ...................................................... 89
VL500 80V (with 80V Dimmer) Luminaire .............................................................. 91
VL500A (700W Arc) Luminaire  ............................................................................... 93
Generic VL500 Luminaire Assembly ........................................................................ 95

Head Assembly

VL500 Generic Head Assembly  .............................................................................. 101
Heatsink Assembly  .................................................................................................. 105
VL500 Magenta/Blue Color Assembly  ................................................................... 109
VL500 Magenta/Blue (Pastel) Color Assembly ...................................................... 110
VL500 Amber/Diffuser Color Assembly ................................................................. 111
VL500 Amber/Dimmer Color Assembly ................................................................. 112
VL500 Magenta/Blue (Arc) Color Assembly .......................................................... 113
VL500 Magenta/Blue (Arc Pastel) Color Assembly  ............................................... 114
Magenta/Blue Color Assembly ................................................................................ 115
Magenta/Blue (Pastel) Color Assembly ................................................................... 116
Amber/Diffuser Color Assembly ............................................................................. 117
Amber/Dimmer Color Assembly  ............................................................................. 118
Bottom Bulkhead Assembly  .................................................................................... 120
Top Bulkhead Assembly .......................................................................................... 122
Drive Ring Assembly ............................................................................................... 124
Magenta/Blue Color Motor Assembly ..................................................................... 125
Amber/Diffuser Color Motor Assembly .................................................................. 126

Yoke Assembly

VL500 Yoke Assembly ............................................................................................ 127
VL500 80V Yoke Assembly .................................................................................... 131
VL500 Extra Hardware Kit ...................................................................................... 135
VL500 Pan/Tilt Motor Assembly  ............................................................................ 136
VL500 MCB/FAN Assembly  .................................................................................. 138
MCB-Fan Assembly  ................................................................................................ 139
Yoke Crossmember Assembly (VL500/VL500D/VL500A)  ................................... 140
Yoke Crossmember Assembly (VL500 80V) .......................................................... 142
Lower Crossmember Assembly ............................................................................... 144
Upper Crossmember Assembly  ............................................................................... 146
Pan Tube Assembly (VL500/VL500D/VL500A) .................................................... 147
Pan Tube Assembly (VL500 80V)  .......................................................................... 148
DMX Input PCB Assembly  ..................................................................................... 149

Cables

Note:  Cables are only available as complete assemblies. The information contained in this 
section is for reference only.

Incandescent Power Input Cable Assembly ............................................................. 151
Disconnect Cable Assembly  .................................................................................... 152
80V LVS AC Cable Assembly  ................................................................................ 153
24V Power Cable Assembly (VL500 80V) ............................................................. 154
Yoke Lamp Cable Assembly (VL500 80V) ............................................................ 155
80V Surge Protector Cable Assembly  ..................................................................... 156

Summary of Contents for Vari-Lite VL500

Page 1: ......

Page 2: ...9 2 690 33 385 4 37 89 166 9 37 68 727 1 37 51 804 6 37 50 201 8 35 87 270 5 32 79 888 1 32 74 291 6 Germany Design Patents No M 98 01 745 4 M 96 04 515 9 M 96 04 514 0 M 94 07 689 8 M 94 02 951 2 M 499 03 583 6 M 498 11 203 9 G 93 12 884 3 Spain Patents No 2 090 191 2 084 289 2 020 960 0 548 328 Spain Utility Model Patent No 2 031 748 Spain Design Patents No 0 137 502 0 137 501 0 133 573 Greece P...

Page 3: ...user or organization If available you should have your sales invoice to establish the date of sale as the beginning of the warranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form included at the end of this manual and place in shipping container along with a copy of your invoice if available Write the RMA number legi...

Page 4: ...tions Operation of this equipment in a residential area is likely to cause harmful inter ference in which case the user will be required to correct the interference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents Safety EN 60598 1 200 A11 2000 A12 2002 ...

Page 5: ...se only with certain Philips and Osram HID lamps Note lamp type MSR400 MSR700HR etc before replacing lamps Installing another type of lamp may be hazardous 2 Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detailed in this manual 3 Replace fuses with same type and rating only 4 Note distance requirement from combustible materials or i...

Page 6: ... which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at very high temperatures Should the lamp break there can exist a danger of personal injury and or fire from broken lamp particles being discharged 4 Wear eye protection when relamping 5 Appropriate safety equipment gloves eye protection should be used when handling damaged lamps 6 If lamp is...

Page 7: ...ampentyps kann gefährlich sein 2 Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Stärke 4 Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der VARI LITE Scheinwerfer von brennbarem Materia...

Page 8: ...esteht die Gefahr von Körperverletzung bzw von Feuer das von Lampenteilen ausgelöst werden kann 4 Tragen Sie beim Austausch der Lampen einen Augenschutz 5 Die geeignete Sicherheitsausrüstung Handschuhe Augenschutz sollte beim Umgang mit beschädigten Lampen verwendet werden 6 Wenn die Lampe mit bloßen Händen berührt wird reinigen Sie sie mit isopropyl Alkohol und einem flusenfreien Tuch bevor Sie d...

Page 9: ...s lampes Philips et Osram HID Vérifier le type de lampe MSR400 MSR700HR etc avant de remplacer les lampes L installation d un autre type de lampe peut poser un danger 2 Les luminaires peuvent être fixés sur tout type de surface tant que les directives de montage sont respectées Voir les explications détaillées dans ce guide 3 Ne remplacer les fusibles qu avec ceux du même type ayant les mêmes cara...

Page 10: ...ûlures sur la peau et une inflammation des yeux De plus les lampes à arc fonctionnent sous haute tension à de très hautes températures Si la lampe se casse les particules de la lampe cassée peuvent causer blessures et ou incendie en s éparpillant 4 Se protéger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropriés gants protection des yeux pour manier des lampes endomma...

Page 11: ...ión de otro tipo de lámpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalación Vea las instrucciones detalladas en este manual 3 Reemplaze los fusibles solamente con los del mismo tipo y especificación 4 Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las lum...

Page 12: ...a lámpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se caen 4 Use protección para los ojos cuando vuelve a colocar una lámpara nueva 5 Use un equipo de seguridad apropiado guantes protección para los ojos etc cuando trabaje con lámparas dañadas 6 Si toca la lámpara con las manos limpie la lámpara con alcohol isoprop...

Page 13: ...SAFETY NOTICE JAPANESE 02 9685 0010 A 21 May 2009 xiii ...

Page 14: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL xiv 21 May 2009 02 9685 0010 A ...

Page 15: ...Incandescent Luminaires 12 VL500 Incandescent Block Diagram Without On Board IGBT Dimmer 120V or 240V 12 VL500D Incandescent Luminaires 13 VL500D Incandescent Block Diagram With On Board IGBT Dimmer 120V or 240V 13 VL500 80V Incandescent Luminaires 14 VL500 80V Incandescent Block Diagram With On Board 80V Dimmer 14 VL500A Luminaire 15 VL500A Arc Block Diagram With External Arc Ballast 15 Chapter 2...

Page 16: ...trol PCB Fan Assembly Replacement 50 Low Voltage Supply LVS Replacement VL500 VL500D VL500A Only 52 Low Voltage Supply LVS Temperature PCB Replacement VL500 VL500D VL500A Only 53 Low Voltage Supply LVS Replacement VL500 80V Only 54 Low Voltage Supply LVS Temperature PCB Replacement VL500 80V Only 56 Tilt Motor Assembly Replacement 58 Pan Motor Assembly Replacement 60 Pan Tilt Encoder PCB Replaceme...

Page 17: ...sembly 120 Top Bulkhead Assembly 122 Drive Ring Assembly 124 Magenta Blue Color Motor Assembly 125 Amber Diffuser Color Motor Assembly 126 Yoke Assembly VL500 Yoke Assembly 127 VL500 80V Yoke Assembly 131 VL500 Extra Hardware Kit 135 VL500 Pan Tilt Motor Assembly 136 VL500 MCB FAN Assembly 138 MCB Fan Assembly 139 Yoke Crossmember Assembly VL500 VL500D VL500A 140 Yoke Crossmember Assembly VL500 80...

Page 18: ...MX Communication Cable Assembly 175 VL500 Yoke Lamp Jumper Cable Assembly 176 VL500 Backcap Ground Cable Assembly 177 LVS Fan Cable Assembly VL500 VL500D VL500A 178 VL500 MCB Yoke Ground Cable Assembly 179 Arc Yoke Lamp Cable Assembly VL500A 180 Shielded Display DMX Communication Cable Assembly VL500A 181 VL500 80V Display Cable Assembly 182 VL500 80V Yoke DMX Communication Cable Assembly 183 VL50...

Page 19: ...ing package for this VARI LITE product Additional Documentation A support web page for VL500 series luminaires is available at www vari lite com follow the Support link Model Part Number Source Comments VL500 Luminaire 20 9685 0001 Tungsten 120V or 230V Standard Color System VL500 Luminaire 20 9685 0011 Tungsten 120V or 230V Pastel Color System VL500DTM Wash Luminaire 20 9685 0002 Tungsten 120V In...

Page 20: ...viding you the highest quality in customer service Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on hand to provide support How to Reach Us For assistance in...

Page 21: ...02 9685 0010 A 21 May 2009 3 CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Component Descriptions Principles of Operation ...

Page 22: ...ash Intensity Control Tungsten models offer an optional integral dimmer or may be dimmed with a customer supplied external dimmer Arc models contain an internal mechanical douser Beam Control In all models a selection of six easily interchangeable front lenses provide a variety of beam size and shape options In the VL500 VL500D and VL500 80V models an internal variable diffuser mechanism provides ...

Page 23: ...tandard color dichroic glass DICHRO TUNETM color system 120V on board IGBT dimmer VL500D Wash Luminaire 20 9685 0012 120V 1200W Tungsten Halogen lamp source Pastel color dichroic glass DICHRO TUNETM color system 120V on board IGBT dimmer VL500D Wash Luminaire 20 9685 0003 240V 1000W Tungsten Halogen lamp source Standard color dichroic glass DICHRO TUNETM color system 240V on board IGBT dimmer VL50...

Page 24: ...stel color dichroic glass DICHRO TUNETM color system 80V on board dimmer VL500A Wash Luminaire 20 9685 0006 700W arc lamp source with external ballast unit Standard color dichroic glass DICHRO TUNETM color system VL500A Wash Luminaire 20 9685 0016 700W arc lamp source with external ballast unit Pastel color dichroic glass DICHRO TUNETM color system ...

Page 25: ... power supply and dimmer dimmer models Houses color dimmer arc models or difusser tungsten models mechanisms AC Power Yoke Leg Power Heatsink Assembly Provides access to lamp for replacement Menu Display Controls internal status information Input Cable connections Input Cable 3 Pole Neutrik Locking Connector for AC Input Base Provides hook mounting holes and safety cable connection Contains main c...

Page 26: ... radially mounted diffuser panels for beam control and amber dichroic glass for color mixing Amber Dimming Assembly Arc Models DICHRO TUNE color bulkhead 16 radially mounted blackout panels for dimming operation and amber dichroic glass for color mixing Magenta Blue Assembly All Models DICHRO TUNE color bulkhead 16 radially mounted magenta and blue dichroic glass for color mixing Contains reflecto...

Page 27: ... shown for clarity Main Controller PCB Luminaire control circuit board Tilt Mechanism Yoke Arm Cover Display Side Yoke Arm Cover Power Supply Side 120W Power Supply Supplies power to electronic and motor components Except Pan Mechanism See next page for other individual model variations Display LCD Luminaire technical status info Power Supply Side models with 80V dimmers VL500 Models 120V or 240V ...

Page 28: ...wer supply side of the luminaire yoke assembly 80V Dimmer 120W Power Supply Supplies power to electronic and motor components 120V or 240V IGBT Dimmer Module IGBT Dimmer Yoke Arm Cover Module 80V Dimmer Yoke Arm Cover VL500D Models 120V or 240V VL500 80V Models Ignitor PCB Ignites lamp in arc models Standard Yoke Arm Cover VL500A Models Pan Mechanism Pan Mechanism Pan Mechanism ...

Page 29: ...nd VL500 80V incandescent dimmer models The dimmer heatsink is visible on the power side yoke leg as shown in this illustration Ballast Unit Provides power for arc lamp source Truss Hook Mount Used to attach a truss hook Safety Cable Tab Used to attach safety cable clip Lamp Power Input Cable Supplied cable and connector used to connect luminaire to ballast unit 40 inches 1m Lamp Connector undersi...

Page 30: ...0 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 Thru In LVS Lamp Power In Fan Fan Display Remote Conn Lamp Tilt Motor Pan Motor Pan Encoder Tilt Encoder VL500 Main Control Board MCB Luminaire Power In Terminal Block Thermal Switch ...

Page 31: ...gram 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 Display Remote Conn Lamp Tilt Motor Pan Motor Pan Encoder Tilt Encoder VL500 Main Control Board MCB J2 Terminal Block Thermal Switch ...

Page 32: ...escent 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 Dimmer Fan Fan Display Remote Conn Lamp Tilt Motor Pan Motor Pan Encoder Tilt Encoder VL500 Main Control Board MCB J2 Terminal Block Ferrite Core Fan Thermal Switch ...

Page 33: ...allast 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 Motor Pan Encoder Tilt Encoder VL500 Main Control Board MCB Terminal Block Fan Display Relay Backcap Interlock Ignitor PCB J5 Switch ...

Page 34: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 16 21 May 2009 02 9685 0010 A Notes ...

Page 35: ...Handling Maintenance Procedures WARNING All maintenance procedures are to be performed with power removed from the luminaire Never remove cover or backcap while lamp is in operation WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized VARI LITE Service Center ...

Page 36: ...atform To alleviate this when testing in groups only test same Lamp Type luminaires for example VL500A wash 700W arc with other VL500A wash 700W arc lights VL500 wash 120V 1200W tungsten wash with other VL500 wash 120V 1200W tungsten lights etc The issue described above does not pose any problems when operating VL500 wash luminaires during normal operation under DMX control Figure 1 Test Setup To ...

Page 37: ...luminaire Movement will need to be enabled after testing Note When using the Movement option pan and tilt will be disabled for all the luminaires that are linked To set movement option Step 1 Press Menu Step 2 Press Up Down arrows until Config appears Press Enter Step 3 Press Up Down arrows until Pan Tilt appears Press Enter Step 4 Movement will be displayed Press Enter Step 5 Use Up Down arrows t...

Page 38: ...and tilt movements Pan Tests different pan movements Tilt Tests different tilt movements Dimmer Tests different dimmer moves operation Diffuser Tests diffuser movement Cyan Tests Cyan color wheel movements Yellow Tests Yellow color wheel movements Magenta Tests Magenta color wheel movements Encoder Disables pan and tilt and displays encoder value Fan Tests fan level speed 1 to 7 7 is fastest Tempe...

Page 39: ...t 2 Dimmer Dimmer Dimmer 1 Dimmer 2 Dimmer 3 Diffuser Diffuser Diffuser 1 Diffuser 2 Diffuser 3 Cyan Cyan Color System Cyan 1 Cyan 2 Cyan 3 Yellow Yellow Color System Yellow 1 Yellow 2 Yellow 3 Magenta Magenta Color System Magenta 1 Magenta 2 Magenta 3 Encoder Encoder Allows hand movement to check values Pan Value Displays encoder value Tilt Value Displays encoder value Fans Fans Test Value 1 slow...

Page 40: ...ctual lamp hours used please read the following note Note 750 hours is the default setting for the Lamp Hours Progress Bar However the scale of the progress bar is user definable by adjusting Warning Hours in Config When the lamp hours exceed the allotted or defined hours the display will reverse contrast with a warning of Exceeded Lamp Hours Figure 2 VL500A Luminaire Menu Display Note To identify...

Page 41: ...he lamps wait ten minutes before removing power to the luminaires This will provide enough time for the equipment fan to cool off the unit On Natural Convection Cooled Units When lamps are lit the interior and exterior heatsink of the luminaires becomes very hot Naturally convection cooled units require longer to fully cool before being handled Users should wait until the unit is cool to the touch...

Page 42: ...tom electrode thereby reducing lamp life Solid State Electronics Electrostatic Discharge ESD Electrostatic discharge ESD presents a significant danger to solid state electronic components semiconductor devices and PC board assemblies Static electricity can build on a variety of common objects including people simply by handling or moving ESD rarely results in immediate failure of a component but s...

Page 43: ...luminaire before performing maintenance To remove and replace incandescent lamp Step 1 Remove power from luminaire WARNING Lamps will be extremely HOT after operation Allow lamp to cool before replacing Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 4 As shown in Figure 3 at heatsink assembly ...

Page 44: ... 5 Remove lamp by pulling straight out of socket Step 6 Carefully clean reflector with soft lint free cloth to remove dust and other debris Step 7 Install lamp by pressing firmly into socket Ensure lamp is fully seated in socket with base of lamp against socket base Step 8 Close and re latch back of luminaire Step 9 Disengage service tilt lock to allow luminaire head to move freely Note For an upd...

Page 45: ...mps will be extremely HOT after operation Allow lamp to cool before replacing Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 4 As shown in Figure 4 at heatsink assembly open latch and swing open back of luminaire Figure 4 Installing Arc Lamp in VL500A Models Heatsink Latch Arc Lamp CAUTION Ens...

Page 46: ...f lamp against socket base Step 8 Close and re latch back of luminaire Step 9 Disengage service tilt lock to allow luminaire head to move freely Step 10 Align lamp Refer to Align Lamp For Maximum Beam Irradiance on page 29 Step 11 If required and only on arc models reset lamp hour counter as follows Refer to Menu Systems Functions in the VL500 User s Manual for more information a Power up luminair...

Page 47: ...ore performing maintenance To align lamp for maximum bean irradiance Step 1 Remove power from luminaire WARNING Lamps will be extremely HOT after operation Allow lamp to cool before replacing Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 4 As shown in Figure 5 at heatsink assembly open latch ...

Page 48: ... dust or finger prints Step 7 Close and latch heatsink assembly Step 8 Disengage service tilt lock to allow luminaire head to move freely Step 9 Supply power to luminaire Step 10 Disable pan tilt if necessary Step 11 Set color to WHITE and intensity to 100 Step 12 Unlatch and swing open front lens ring this will make hot spot and halo easier to see Step 13 Shine lamp on flat surface 10 20 feet awa...

Page 49: ...DE FLOOD BUXOM Tools Cotton Gloves or Finger Cots Clean Lint free Soft Cloth To remove and replace front glass WARNING Remove power from luminaire before performing maintenance Note It is often easier to replace the lenses when the fixture is warm However use caution when handling a warm fixture as damage to glass components can occur lamp reflector etc Step 1 Remove power from luminaire Step 2 At...

Page 50: ... VL500TM VL500DTM and VL500 80VTM Wash Clear and Stipple lenses may be installed curve in concave and all Lenticular 8 Row 10 Row and 12 Row and Buxom lenses must be installed curve out convex Step 4 Position new glass in front ring assembly Be sure glass is fully and properly seated into rubber ring See Table 2 2 Lens Mounting Orientation for each model Table 2 2 Lens Mounting Orientation Step 5 ...

Page 51: ...ULKHEADS Power up unit and allow all DICHRO TUNE glass to calibrate Once they close power down unit WARNING Remove power from luminaire before performing maintenance Step 2 Disconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 8 Step 4 As indicated in Figure 8 open heatsi...

Page 52: ...on Magenta Blue DICHRO TUNE Bulkhead Step 8 As shown in Figure 9 at side rails from top remove four 6 32x3 8 LG PPZ SEMS screws Figure 9 Magenta Blue Color Bulkhead Step 9 Carefully lift Magenta Blue bulkhead out of luminaire head Step 10 Replace by performing steps 2 through 9 in reverse order Note This is also the procedure to convert a standard color bulkhead to pastel color bulkhead or vice ve...

Page 53: ...efore performing maintenance Step 2 Disconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 10 Step 4 As indicated in Figure 10 open front ring by releasing latch Figure 10 Amber Diffuser or Dimmer Bulkhead Step 5 At top cover remove two or four depending on production date...

Page 54: ...mmer DICHRO TUNE Front Bulkhead 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 bulkhead out of luminaire head Step 10 Replace by performing steps 2 through 9 in reverse order Amber Diffuser or Dimmer Assembly Some components not shown for clarity NOTE 6 32x3 8 PPZ...

Page 55: ...m luminaire Step 3 Set the luminaire head horizontally Step 4 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 5 Remove desired bulkhead assembly as follows a For Magenta Blue bulkhead removal refer to Magenta Blue DICHRO TUNE Rear Bulkhead Replacement on page 33 Remove Magenta Blue bulkhead b For Amber Diffuser bulkhead removal refer to Amber ...

Page 56: ...d of tweaker screwdriver between silicon pad and carrier b Gently work side of silicone pad not under carrier arch free c After side of silicone pad is free from carrier remove silicone pad from under carrier arch and remove filter or panel Step 9 Insert filter carrier pin of replacement filter or panel into center hub as shown in Figure 12 Step 10 Place side of silicone pad with lip into arch on ...

Page 57: ...izontally Step 4 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 5 Unlatch and swing open front ring Step 6 Remove Amber Diffuser bulkhead by following procedure Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Replacement on page 35 Step 7 Disconnect actuator screw from swivel coupler using tweaker screwdriver by carefully prying apart fro...

Page 58: ...NUAL 40 21 May 2009 02 9685 0010 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: ...inaire head horizontally Step 3 Engage tilt service lock to secure luminaire head in horizontal position to access heatsink latch Figure 15 Magenta Blue Color Bulkhead Linear Actuator Motors Step 4 Remove top head cover Note Linear actuator motors should be seen with cover removed If not flip head position Magenta Blue Assembly Amber Diffuser Assembly Incandescent Models Amber Dimmer Assembly Arc ...

Page 60: ...securing linear actuator motor to actuator mount and remove motor See Figure 16 Figure 16 Magenta Blue Linear Actuator Motor Replacement Step 8 Place linear actuator motor in place on actuator mount Step 9 Re install two 4 40x1 4 PPZ screws and two 4 lock washers and using 1 Phillips screwdriver tighten to secure linear actuator motor and heatsink to actuator mount Step 10 Secure actuator drive ri...

Page 61: ...he luminaire head horizontally Step 3 Engage tilt service lock to secure luminaire head in horizontal position to access heatsink latch Figure 17 Amber Diffuser or Dimmer Bulkhead Linear Actuator Motors Step 4 Remove top head cover Note Linear actuator motors should be seen with cover removed If not flip head over Magenta Blue Assembly Amber Diffuser Assembly Incandescent Models Amber Dimmer Assem...

Page 62: ...securing linear actuator motor to actuator mount and remove motor See Figure 18 Figure 18 Amber Diffuser or Dimmer Linear Actuator Motor Replacement Step 8 Place linear actuator motor in place on actuator mount Step 9 Re install two 4 40x1 4 PPZ screws and two 4 lock washers and using 1 Phillips screwdriver tighten to secure linear actuator motor and heatsink to actuator mount Step 10 Secure actua...

Page 63: ...AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 19 Step 4 Open heatsink by releasing latch Figure 19 Accessing the Lamp Socket in VL500 and VL500D Fixtures Step 5 At top cover remove four 6 32x1 4 PPB SEMS screws Step 6 Remove top cover Step 7 Remove Magenta Blue Bulkhead Assembly as de...

Page 64: ...IGBT dimmer removal Step 14 At inside of side rail remove two 4 40x1 8 LG PPB screws and remove Lamp Wire Cover Step 15 At support rib closest to tilt tube remove one 6 32x1 4 LG PPG screw and remove ground strap Step 16 Remove tilt tube plug and pass lamp wires through tilt tube Step 17 Inside heatsink remove four 8 32x1 2 LG PPZ SEM screws and remove back cap Step 18 Remove heatsink light leak f...

Page 65: ...sconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 21 Step 4 Open heatsink by releasing latch Figure 21 Accessing the Lamp Socket in VL500A and VL500 80V Fixtures Step 5 At top cover remove two or four depending on production date 6 32x1 4 PPB SEMS screws Step 6 Remove t...

Page 66: ...t screws as follows a For VL500A models at backcap remove three 10 32x1 1 2 LG PPB screws and springs b For VL500 80V models at backcap remove three 10 32x1 LG SCB screws Step 14 Remove backcap extension Step 15 At socket remove two 8 32x3 8 LG PPZ SEM screws and two socket clips Step 16 Remove socket from backcap Step 17 Using 5 64 Allen wrench loosen two set screws and remove lamp wires from soc...

Page 67: ...ment Step 4 Remove display overlay Step 5 As indicated in Figure 23 remove four 1 4 hex 9 32 long standoffs Step 6 At display PCB disconnect the following wiring connections a 4 position MTA connector 24V DC b 2 position connector MCB Fan c 4 position connector LVS Fan Temperature Switch d 6 position connector Display Communication Step 7 Remove Display PCB Step 8 Replace by performing Steps 2 thr...

Page 68: ... Step 4 At Main Control PCB Fan Assembly disconnect the following wiring connections a Pan Tilt wiring harness b Head motor wiring harness c 3 position connector Dimmer communications VL500D and VL500 80V models only d 10 position AMP connector Display Communications e 4 position connector DMX communications CAUTION This connector is similar to the connector for the LVS Fan Temperature Switch conn...

Page 69: ...rol PCB Fan Assembly Step 8 Replace Main Control PCB Fan Assembly by following Steps 2 through 7 in reverse order Step 9 Configure Main Control PCB using menus as needed Main Control PCB Display PCB 6 32x1 4 PPB x4 Some components not shown for clarity NOTE Menu Display 1 4 Hex 9 32 Long Standoff x4 1 4 Hex 13 16 Long Standoff x4 Yoke Arm Cover Main Control PCB ...

Page 70: ...ve power from luminaire Step 2 Remove yoke arm cover opposite display side by removing four 6 32x3 8 PTB screws Figure 25 LVS Replacement VL500 VL500D VL500A Only Step 3 Disconnect the following wiring connections a 3 position connector AC Input b 6 position MTA connector DC Output Step 4 As shown in Figure 25 remove four 6 32x3 8 PPZ SEMS screws Step 5 Remove LVS Note fish paper Wire Shield behin...

Page 71: ... PCB Step 1 Remove power from luminaire Step 2 Remove LVS by following procedure Low Voltage Supply LVS Replacement VL500 VL500D VL500A Only on page 52 Figure 26 LVS Temperature PCB Replacement VL500 VL500D VL500A Only Step 3 Disconnect the following wiring connections on PCB a 2 position connector LVS Fan b 4 position connector LVS Fan from MCB Step 4 As shown in Figure 26 remove one 1 4 hex stan...

Page 72: ...eatsink Do not touch when unit is powered To remove and replace LVS Step 1 Remove power from luminaire Step 2 Position light to access top of pan tube assembly Step 3 At pan tube cover remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note cover tether will still hold cover Figure 27 LVS Replacement VL500 80V Only LVS Power Supply Some components not NOTE Wire Shield fish paper Pan Tube ...

Page 73: ...80V Only on page 56 Step 6 Disconnect the following wiring connections a 3 position connector AC Input b 6 position MTA connector DC Output Step 7 As shown in Figure 27 remove four 4 40x1 4 PPZ screws Step 8 Remove LVS Note fish paper Wire Shield under LVS save and reuse with replacement LVS Step 9 Replace by performing steps 3 through 7 in reverse order ...

Page 74: ...ink Do not touch when unit is powered To remove and replace LVS temperature PCB Step 1 Remove power from luminaire Step 2 As shown in Figure 27 at pan tube cover remove six 8 32x1 2 PFB screws and remove pan tube cover Note cover tether will still hold cover Step 3 Remove two 4 40 x 1 4 PFB screws and remove LVS fan mount Figure 28 LVS Temperature PCB Replacement VL500 VL500D VL500A Only LVS Power...

Page 75: ...onnections 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 Step 6 Remove LVS Temperature PCB Step 7 Replace by performing steps 2 through 6 in reverse order ...

Page 76: ... Disconnect luminaire AC input cable from power source Step 2 Remove display side yoke cover by removing four 6 32x3 8 LG PTB screws Step 3 Remove Display PCB and Main Control PCB by following procedures Display PCB Replacement on page 49 and Main Control PCB Fan Assembly Replacement on page 50 Step 4 Remove 4 x 6 32 x 3 8 PFB screws two each side of yoke that hold Top Cover Louver Plate and remov...

Page 77: ...NTIRE assembly Step 11 Remove four 8 32x7 16 PPZ screws that mount Pan Tilt Motor Assembly to Tilt Motor Slide Plate and remove Pan Tilt Motor Assembly be careful of spring Step 12 Replace by performing Steps 2 through 10 in reverse order Note When tightening four 8 32x7 16 PPZ screws that mount Pan Tilt Motor Assembly to Tilt Motor Slide Plate you must tighten in a CLOCKWISE pattern starting with...

Page 78: ...er Louver Plate and remove plate Step 4 Disconnect wiring from motor and encoder PCB Step 5 As shown in Figure 30 loosen but do not remove four 8 32x1 2 PPB screws Step 6 Press motor towards driven pulley and remove belt from drive pulley Step 7 Remove four 8 32x1 2 PPB screws from Step 5 Step 8 Remove Pan Tilt Motor Assembly Figure 30 Pan Motor Assembly Replacement Step 9 Replace pan motor assemb...

Page 79: ...Encoder PCB removal remove display side yoke cover by removing four 6 32x3 8 LG PTB screws b For Pan Motor Encoder PCB removal access pan motor assembly see Pan Motor Assembly Replacement on page 60 Step 3 At encoder PCB disconnect wiring harness from assembly Step 4 As shown in Figure 31 remove two 6 32x3 8 PPZ screws and remove assembly Figure 31 Pan Tilt Motor Encoder PCB Replacement Step 5 Rep...

Page 80: ...of display by removing four 6 32x3 8 LG PTB screws Step 3 At Ignitor PCB disconnect Input and Output lamp wires Step 4 As shown in Figure 32 remove four 6 32x3 8 PPZ SEMS screws from PCB Figure 32 Ignitor PCB Replacement Step 5 Remove Ignitor PCB Note Make sure and install ignitor with proper orientation Wires from Relay attached to posts labeled From Relay Wires going to lamp attach to posts labe...

Page 81: ...screws Step 3 As shown in Figure 33 at dimmer loosen but do not remove four 6 32x3 8 PPZ screws Step 4 Carefully remove IGBT dimmer Note that there will be wires connected to dimmer on the back side CAUTION All AC wiring is same color It is a good idea to mark the connector attached to both the AC Line Input and Load Output terminals on the IGBT dimmer with a black marker before removing so the ph...

Page 82: ...er 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 components not shown for clarity NOTE IGBT Dimmer Yoke Arm Cover Dimmer Side 6 32x3 8 PPZ Screws x4 ...

Page 83: ...t there will be wires connected to dimmer on the back side CAUTION All AC wiring is same color It is a good idea to mark the connector attached to both the AC Line Input and Load Output terminals on the IGBT dimmer with a black marker before removing so the phasing can be maintained Step 5 At dimmer carefully note and label before removing and disconnect following wiring a 4 position Dimmer Commun...

Page 84: ...02 9685 0010 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 Arm Cover Dimmer Side 6 32x3 8 PPZ Screws x4 ...

Page 85: ...rforming maintenance To remove and replace arc ballast dimmer Step 1 Disconnect luminaire AC input cable from power source Note The Arc Ballast Unit is separate from the luminaire Step 2 Disconnect Ballast Interconnect Cable Assembly from ballast and luminaire Step 3 Connect Ballast Interconnect Cable Assembly to replacement ballast and luminaire Figure 35 Arc Ballast Assembly ...

Page 86: ...ay by removing four 6 32x3 8 LG PTB screws Step 3 At Relay disconnect following wiring a Bundled AC from Ballast b White AC to Ignitor c Red 24V DC from MCB d Green 24V DC from Backcap Interlock Kill Switch Step 4 At Relay loosen but do not remove two 4 40x5 16 PPZ SEMS screws Step 5 Carefully slide Relay out of yoke arm Note When replacing Relay do not overtighten screws securing Relay as describ...

Page 87: ...igure 36 at pan tube cover remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note tether will still hold cover Figure 36 AC Input PowerCon Connector Replacement Step 5 Remove two 4 40x1 2 PFB screws at front of PowerCon Step 6 Disconnect wiring from PowerCon Step 7 Replace PowerCon by performing Steps 3 through 6 in reverse AC Input PowerCon Connector Some components not NOTE Pan Tube Co...

Page 88: ...ep 3 As shown in Figure 37 at pan tube cover remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note tether will still hold cover Figure 37 Mini XLR Display Remote Programming Connector Replacement Step 5 Disconnect wiring from Mini XLR Step 6 Remove two 4 40x1 4 PFB screws at front of Mini XLR connector Step 7 Replace Mini XLR by performing Steps 3 through 6 in reverse Mini XLR Some comp...

Page 89: ...er remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note tether will still hold cover Figure 38 DMX PCB Assembly Replacement Step 5 Disconnect wiring from DMX PCB Assembly Step 6 Remove four 4x3 8 H L PN BLK ZN screws at front of DMX PCB Assembly Step 7 Replace DMX PCB Assembly by performing Steps 3 through 6 in reverse DMX PCB Some components not NOTE Pan Tube Cover 8 32x1 2 PFB Cover ...

Page 90: ...front lens optics color filters and reflector may require cleaning after extended use FRONT LENS Use Isopropyl Alcohol along with a soft lint free cloth to clean the front lens OPTICS COLOR FILTERS Use Acetone or Isopropyl Alcohol along with a soft lint free cloth to clean the optics color filters REFLECTOR Use Acetone or Isopropyl Alcohol along with a soft lint free cloth to clean the reflector C...

Page 91: ...bles Arc Ballast Assembly Note The following abbreviations are used to identify parts specific to certain models VL500 Model Parts Identifiers ABBREVIATION MODEL INCLUDES STANDARD AND PASTEL COLOR SYSTEMS VL500 VL500 Incandescent Luminaire 120V or 240V VL500D VL500 D Incandescent Luminaire with IGBT On Board Dimmer 120V or 240V VL500 80V VL500 80V Incandescent Luminaire with 80V On Board Dimmer VL...

Page 92: ...nternal Dimmer or 21 9685 0011 Rev S Incandescent with Internal IGBT Dimmer VL500 Amber Diffuser Color Assembly 21 9685 0171 Rev G Amber Diffuser Color Assembly 21 9685 0161 Rev F VL500 Magenta Blue Pastel Color Assembly 21 9685 0174 Rev A Pastel DICRO TUNE Colors VL500 Yoke Assembly 21 9685 0520 VL500 Rev U or 21 9685 0521 VL500D Rev U VL500 Pan Tilt Motor Assembly 21 9685 0540 Rev C VL500 MCB FA...

Page 93: ...r Crossmember Assembly 21 9685 0513 Rev H Pan Tube Assembly VL500 VL500D VL500A 21 9685 0535 Rev D VL500 VL500D VL500A continued from previous page Yoke Crossmember Assembly VL500 VL500D VL500A VL500 AC Input Cable Assembly 25 9685 0756 Rev B VL500 Display Remote Cable Assembly 25 9685 0770 Rev B VL500 Yoke Lamp Jumper Cable Assembly 25 9685 0776 Rev A MCB Fan Assembly 23 9685 0782 Rev 0 continued...

Page 94: ...9685 0171 Rev G Magenta Blue Color Motor Assembly 21 9685 0280 Rev A Drive Ring Assembly 21 9685 0280 Rev A Top Bulkhead Assembly 21 9685 0151 Rev C VL500 Magenta Blue Pastel Color Assembly 21 9685 0174 Rev A Pastel DICRO TUNE Colors VL500 80V Yoke Assembly 21 9685 0523 VL500 80V Rev Q VL500 Pan Tilt Motor Assembly 21 9685 0540 Rev C VL500 MCB FAN Assembly 21 9685 0731 Rev 0 DMX Input PCB Assembly...

Page 95: ...e Kit 28 9685 0999 Rev 0 Lower Crossmember Assembly 21 9685 0512 Rev K Upper Crossmember Assembly 21 9685 0513 Rev H Pan Tube Assembly VL500 80V 21 9685 0536 Rev A VL500 80V continued from previous page Yoke Crossmember Assembly VL500 80V 21 9685 0516 Rev 0 VL500 AC Input Cable Assembly 25 9685 0756 Rev B VL500 Display Remote Cable Assembly 25 9685 0770 Rev B MCB Fan Assembly 23 9685 0782 Rev 0 24...

Page 96: ...0 Rev A Top Bulkhead Assembly 21 9685 0151 Rev C VL500 Magenta Blue Arc Pastel Color Assembly 21 9685 0174 Rev A Pastel DICRO TUNE Colors VL500 Yoke Assembly 21 9685 0522 VL500A Rev U VL500 Pan Tilt Motor Assembly 21 9685 0540 Rev C VL500 MCB FAN Assembly 21 9685 0731 Rev 0 DMX Input PCB Assembly 24 9663 3895 Rev 0 Heatsink Assembly 21 9685 0321 VL500A Rev H VL500 Backcap Ground Cable Assembly 25 ...

Page 97: ... D VL500 VL500D VL500A continued from previous page Yoke Crossmember Assembly VL500 VL500D VL500A 21 9685 0515 Rev E VL500 AC Input Cable Assembly 25 9685 0756 Rev B VL500 Display Remote Cable Assembly 25 9685 0770 Rev B MCB Fan Assembly 21 9685 0731 Rev 0 VL500 Arc Ballast Input Cable Assembly 25 9685 0757 Rev C VL500 Arc Ballast Assembly 21 9685 0802 Rev H continued from previous page VL500A 700...

Page 98: ...A QA CERTIFICATE VARI LITE 3 02 8052 0001 1 EA CARD LIMITED WARRANTY 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION VL500 5 02 9685 0002 1 EA UNPACK QUICK START SHEET VL500 6 07 9685 1005 1 EA SHIPPING BOX CARDBOARD VL500 7 08 0500 0001 1 EA CD ROM VL500 PRODUCT DOCUMENTATION 8 52 6541 0001 1 EA CONN BLUE CABLE PWR INLET 3 POLE LOCKING POWERCON 9 53 6505 0027 1 EA BOLT 1 2 X 13 X 1 LG HX HD ZINC VL...

Page 99: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ...NCANDESCENT VL500 MODELS ONLY 04 9685 0913 00 1 EA LABEL LAMP TYPE 120V OR 240V INCANDESCENT CLR VL500 MODELS ONLY 04 9685 0914 1 EA LABEL LAMP TYPE 120V INCANDESCENT VL500D 120V MODELS ONLY 04 9685 0914 00 1 EA LABEL LAMP TYPE 120V INCANDESCENT CLR VL500D 120V MODELS ONLY 04 9685 0915 1 EA LABEL LAMP TYPE 240V INCANDESCENT VL500D 240V MODELS ONLY 04 9685 0915 00 1 EA LABEL LAMP TYPE 240V INCANDES...

Page 101: ... LABEL AC INPUT RATING VL500D 240V PASTEL MODELS ONLY 04 9685 0925 00 2 EA LABEL AC INPUT RATING CLR VL500D 240V PASTEL MODELS ONLY 04 9685 0926 2 EA LABEL AC INPUT RATING VL500 80V MODELS ONLY 04 9685 0926 00 2 EA LABEL AC INPUT RATING CLR VL500 80V MODELS ONLY 04 9685 0927 2 EA LABEL AC INPUT RATING VL500 80V PASTEL MODELS ONLY 04 9685 0927 00 2 EA LABEL AC INPUT RATING CLR VL500 80V PASTEL MODE...

Page 102: ...D 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 SUITABLE FOR DRY LOCATIONS ONLY EMPLACEMENT SECS NO USER SERVICEABLE PARTS INSIDE Vari Lite Inc VL500D 120V B 120 VAC 11A 50 60Hz 6 VL500 Models Only 6 2 5 Non Arc Models Only 1 6 Non Arc Models Only 4 3 ...

Page 103: ...7 21 9685 0010 1 EA ASSY GENERIC VL500 INCANDESCENT 8 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0001 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0011 ONLY 9 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 10 22 9685 0086 1 EA HEAD COVER TOP 11 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 EA CABLE ASSY VL500 MOTOR NOT SHOWN 25 9685 0760 1 EA CABLE ASSY HEAD GRO...

Page 104: ...ARI LITE VL500 LUMINAIRE SERVICE MANUAL 86 21 May 2009 02 9685 0010 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: ... EA ASSY GENERIC VL500 INCANDESCENT W DIMMER 10 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0002 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0012 ONLY 11 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 12 22 9685 0086 1 EA HEAD COVER TOP 13 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 EA CABLE ASSY VL500 MOTOR NOT SHOWN 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDIN...

Page 106: ...NAIRE SERVICE MANUAL 88 21 May 2009 02 9685 0010 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: ... EA ASSY GENERIC VL500 INCANDESCENT W DIMMER 10 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0003 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0013 ONLY 11 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 12 22 9685 0086 1 EA HEAD COVER TOP 13 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 EA CABLE ASSY VL500 MOTOR NOT SHOWN 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDIN...

Page 108: ...NAIRE SERVICE MANUAL 90 21 May 2009 02 9685 0010 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: ...Y GENERIC VL500 80V INCANDESCENT W DIMMER 11 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0004 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0014 ONLY 12 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 13 21 9685 2750 1 EA ASSY DIMMER 80V 14 22 9685 0086 1 EA HEAD COVER TOP 15 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 EA CABLE ASSY VL500 MOTOR NOT SHOWN 25 9685 ...

Page 110: ...IRE SERVICE MANUAL 92 21 May 2009 02 9685 0010 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: ... DIMMER 9 21 9685 0173 1 EA ASSY COLOR MAGENTA BLUE ARC STANDARD 20 9685 0006 ONLY 21 9685 0175 1 EA ASSY COLOR MAGENTA BLUE ARC PASTEL 20 9685 0016 ONLY 21 9685 0802 1 EA ASSY BALLAST 700W EXTERNAL NOT SHOWN 10 22 9685 0086 1 EA HEAD COVER TOP 11 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 EA CABLE ASSY VL500 MOTOR 25 9685 0755 1 EA CABLE ASSY RELAY HARNESS NOT SHOWN 25 9685 0760 1 EA CABL...

Page 112: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 94 21 May 2009 02 9685 0010 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: ... 9685 0571 2 EA PLUG TILT TUBE 12 10 9685 0572 1 EA CONTERWEIGHT VL500 VL500 80V ONLY 10 9685 0575 1 EA CONTERWEIGHT VL500 VL500D ONLY 13 21 9685 0310 1 EA ASSY GENERIC VL500 INCANDESCENT VL500 AND VL500D ONLY 14 21 9685 0311 1 EA ASSY GENERIC VL500 ARC VL500A ONLY 15 21 9685 0312 1 EA ASSY GENERIC VL500 INCANDESCENT 80V VL500 80V ONLY 16 21 9685 0520 1 EA ASSY YOKE BASE INCANDESCENT VL500 ONLY 17...

Page 114: ...021 1 EA RING RETAINING 1 562 SHAFT 34 54 1255 0002 2 EA ASSY BEARING HOUSING 35 54 1261 0001 2 EA BUSHING LOW DAMP THRMOPLS 189 36 54 2066 0001 1 EA BELT TIMING S2M 396 GRV 9MM WIDE 55 2178 0001 1 EA CABLE SADDLE 6 MOUNTING HOLE VL500 ONLY NOT SHOWN 37 55 2287 0001 4 EA STANDOFF MF 6 32X9 32 LG 1 4 HEX 38 55 2288 0001 4 EA STANDOFF MF 6 32X13 16 LG 1 4 HEX VL500 VL500D VL500 80V ONLY 55 2288 0001...

Page 115: ... 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 39 24 6 27 25 33 34 31 17 VL500D Only 11 30 x4 ...

Page 116: ...UAL 98 21 May 2009 02 9685 0010 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 24 ...

Page 117: ...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 40 21 30 x4 ...

Page 118: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 100 21 May 2009 02 9685 0010 A Notes ...

Page 119: ...9685 0315 1 EA ASSY COUNTERWEIGHT SUPPORT 8 21 9685 0320 1 EA ASSY HEATSINK INCANDESCENT VL500 VL500D ONLY 9 21 9685 0321 1 EA ASSY HEATSINK ARC VL500A ONLY 10 21 9685 0322 1 EA ASSY HEATSINK 80V INCANDESCENT VL500 80V ONLY 11 25 9685 0350 1 EA CABLE ASSY DISCONNECT VL500A ONLY 12 53 6556 0004 6 EA SCREW 4 40X1 8 LG PPB 13 53 6598 0187 4 EA SCREW 4 40X0 187 LG PFB UNDERCUT HD 14 53 6607 0001 4 EA ...

Page 120: ...0 LUMINAIRE SERVICE MANUAL 102 21 May 2009 02 9685 0010 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: ...TED PARTS BREAKDOWN 3 02 9685 0010 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: ...L500 LUMINAIRE SERVICE MANUAL 104 21 May 2009 02 9685 0010 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: ...0780 1 EA ASSY VL500 LAMP SOCKET HIGH TEMP VL500 ONLY 25 9685 0766 1 EA 700W ARC LAMP WIRES IGNITOR TO SOCKET VL500A ONLY NOT SHOWN 25 9685 0793 1 EA 80V LAMP WIRE HARNESS VL500 80V ONLY NOT SHOWN 25 9685 0777 1 EA CABLE ASSY BACKCAP GROUND NOT SHOWN 11 42 9685 7190 1 EA REFLECTOR PARABOLIC 12 53 6515 1000 3 EA SCREW 10 32X1 LG SCB VL500 80V ONLY 13 53 6543 0002 3 EA SCREW 6 32X1 8 LG PPB 14 53 65...

Page 124: ...TE VL500 LUMINAIRE SERVICE MANUAL 106 21 May 2009 02 9685 0010 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: ...ED PARTS BREAKDOWN 3 02 9685 0010 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: ...00 LUMINAIRE SERVICE MANUAL 108 21 May 2009 02 9685 0010 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: ...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 BULKHEAD 2 21 9685 0160 1 EA ASSY MAGENTA BLUE STANDARD DICRO TUNE 3 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 4 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 1 3 5 4 x4 2 4 x4 1 ...

Page 128: ...Refer to Figure 3 24 Figure 3 24 VL500 Magenta Blue Pastel Color Assembly No Item Qty UM Description 1 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 2 21 9685 0164 1 EA ASSY MAGENTA BLUE PASTEL DICRO TUNE 3 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 4 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 1 3 5 4 x4 2 4 x4 1 ...

Page 129: ...e 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 AMBER DIFFUSER DICRO TUNE 3 21 9685 0281 1 EA MOTOR ASSY AMBER DIFFUSER 4 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 1 3 5 4 x4 2 4 x4 1 ...

Page 130: ...o 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 EA ASSY AMBER DIMMER DICRO TUNE 3 21 9685 0281 1 EA MOTOR ASSY AMBER DIFFUSER 4 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 1 3 5 4 x4 2 4 x4 1 ...

Page 131: ...genta Blue Arc Color Assembly No Item Qty UM Description 1 10 9685 0246 4 EA CLIP UV GLASS 2 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 3 21 9685 0160 1 EA ASSY MAGENTA BLUE STANDARD DICRO TUNE 4 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 5 42 9685 0130 1 EA GLASS UV 6 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 7 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 2 x2 4 7 6 x4 3 6 x4 1 x4 5 ...

Page 132: ... VL500 Magenta Blue Arc Color Assembly No Item Qty UM Description 1 10 9685 0246 4 EA CLIP UV GLASS 2 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 3 21 9685 0164 1 EA ASSY MAGENTA BLUE PASTEL DICRO TUNE 4 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 5 42 9685 0130 1 EA GLASS UV 6 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 7 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 2 x2 4 7 6 x4 3 6 x4 1 x4 5 ...

Page 133: ...nta Blue Color Assembly 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 32 EA CARRIER FILTER METAL INJ MOLD 4 21 9685 0150 1 EA ASSY BOTTOM BULKHEAD 5 22 9685 0122 16 EA ASSY FILTER MAGENTA DICRO TUNE 6 22 9685 0123 16 EA ASSY FILTER BLUE DICRO TUNE 4 1 x16 5 x16 3 x16 2 x16 6 x16 2 x16 3 x16 1 x16 ...

Page 134: ... Blue Pastel Color Assembly 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 32 EA CARRIER FILTER METAL INJ MOLD 4 21 9685 0150 1 EA ASSY BOTTOM BULKHEAD 5 22 9685 0120 16 EA ASSY FILTER MAGENTA PASTEL DICRO TUNE 6 22 9685 0121 16 EA ASSY FILTER BLUE PASTEL DICRO TUNE 4 1 x16 5 x16 3 x16 2 x16 6 x16 2 x16 3 x16 1 x16 ...

Page 135: ...ser Color Assembly 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 32 EA CARRIER FILTER METAL INJ MOLD 4 21 9685 0151 1 EA ASSY BULKHEAD TOP 5 22 9685 0124 16 EA ASSY FILTER AMBER DICRO TUNE 6 22 9685 0126 16 EA ASSY DIFFUSER PANEL 4 1 x16 5 x16 3 x16 2 x16 6 x16 2 x16 3 x16 1 x16 ...

Page 136: ...2 10 9634 0035 32 EA LINK DRIVE ARM 3 10 9634 0166 16 EA CARRIER FILTER METAL INJ MOLD 4 10 9647 0121 1 EA BAFFLE INNER LIGHT 5 10 9661 0307 16 EA CARRIER DIMMER 6 10 9661 0312 16 EA BEARING DIMMER 7 10 9661 0313 1 EA BAFFLE OUTER LIGHT DIMMER 8 10 9685 0210 16 EA DIMMER BLADE VL500 9 21 9685 0151 1 EA ASSY BULKHEAD TOP 10 22 9685 0124 16 EA ASSY FILTER AMBER DICRO TUNE 11 53 6556 0004 16 EA SCREW...

Page 137: ...LUSTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ... 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 4 22 9685 0201 1 EA ASSY GENERIC BULKHEAD 5 53 6682 0002 12 EA SCREW 4 40X1 4 PPZ SEMS 6 55 6612 0008 10 EA PIN 1 8 OD X 3 8 LG AL DRIV LOX 7 55 6669 0009 4 EA STANDOFF 1 4 HEX 40 40X0 625 MF ...

Page 139: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ...A SUPPORT BULKHEAD 2 10 9685 0219 2 EA AUX RING COLOR BULKHEAD 3 21 9685 0251 2 EA ASSY DRIVE RING 4 22 9634 0120 1 EA ASSY LIGHT BAFFLE 5 22 9685 0201 1 EA ASSY GENERIC BULKHEAD 6 53 6682 0002 12 EA SCREW 4 40X1 4 PPZ SEMS 7 55 6612 0008 10 EA PIN 1 8 OD X 3 8 LG AL DRIV LOX 8 55 6669 0009 4 EA STANDOFF 1 4 HEX 40 40X0 625 MF 9 55 6858 0002 4 EA STANDOFF 1 4 HEX 40 40X0 343 MF ...

Page 141: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ...5 1 EA LINK SWIVEL 2 10 9685 7240 8 EA ROLLER DRIVE RING 3 22 9685 0238 1 EA RING DRIVE WITH PINS 4 53 5554 0875 1 EA SCREW 4 40X7 8 SET SS FLAT POINT 5 53 6659 0013 2 EA SCREW 2 56X1 8 PPB 6 55 6603 0001 1 EA SPRING SS 4 6 IN EXTENSION 7 55 6612 0004 8 EA PIN 1 16 OD X 1 2 LG TYPE C 303 S S 2 x8 4 7 x8 3 1 5 x2 6 Insure screws are flush with inside drive ring surface no protrusion Spring 2 56 Scr...

Page 143: ... UM Description 1 10 9634 0061 1 EA ACTUATOR MOUNT VL500 2 10 9634 0075 1 EA HEAT SHIELD MAGENTA BLUE 3 44 9685 0230 2 EA MOTOR LINEAR 0 002 STEP 4 53 6520 0001 3 EA SCREW 4 40X3 8 PPZ 5 53 6682 0002 4 EA SCREW 4 40X1 4 PPZ SEMS 6 54 1217 0004 2 EA LINK VL500 ACTUATOR DRIVE RING 2 4 x3 3 x2 1 5 x4 6 x2 Actuator Screw Note Versilube Silicon Grease G321 is used to lubricate the actuator screw ...

Page 144: ...tem Qty UM Description 1 10 9634 0061 1 EA ACTUATOR MOUNT VL500 2 10 9634 0074 1 EA HEAT SHIELD AMBER DIFFUSER 3 44 9685 0230 2 EA MOTOR LINEAR 0 002 STEP 4 53 6520 0001 3 EA SCREW 4 40X3 8 PPZ 5 53 6682 0002 4 EA SCREW 4 40X1 4 PPZ SEMS 6 54 1217 0004 2 EA LINK VL500 ACTUATOR DRIVE RING 2 4 x3 3 x2 1 5 x4 6 x2 Actuator Screw Note Versilube Silicon Grease G321 is used to lubricate the actuator scr...

Page 145: ...TOR 10 23 9685 0782 1 EA ASSY FAN MCB 11 24 9663 3895 1 EA PCB ASSY DMX INPUT 12 24 9685 3740 1 EA TEMPERATURE BOARD LVS 13 25 9663 2030 1 EA CABLE ASSY INCANDESCENT POWER VL500 ONLY 14 25 9685 0756 1 EA CABLE ASSY AC INPUT 15 25 9685 0757 1 EA CABLE ASSY ARC BALLAST INPUT VL500A ONLY 16 25 9685 0770 1 EA DISPLAY CABLE RECEPTACLE BLACK 25 9685 0790 1 EA CABLE ASSY MAIN HARNESS INCANDESCENT VL500 A...

Page 146: ...1 1 EA SCREW 10 32X1 2 PFB 32 53 6596 0001 1 EA SCREW 4 40X5 16 PPZ 33 54 2065 0001 1 EA BELT TIMING S2M 252 GROOVE 34 55 2166 0250 1 EA STANDOFF 1 4 HEX 6 32 0 250 LG MF SS 35 55 2288 0001 3 EA STANDOFF 1 4 HEX 6 32 X 13 16 LG 36 55 3301 0008 8 EA WASHER 8 FLAT SS 37 55 3301 0010 1 EA WASHER 10 FLAT 38 55 6543 0001 2 4 IN GROMMET STRIP SERRATED 0 062 39 55 6568 0056 2 EA SPRING CPRSN 0 600 OD 0 0...

Page 147: ...WN 3 02 9685 0010 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: ...ERVICE MANUAL 130 21 May 2009 02 9685 0010 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: ...9685 3740 1 EA TEMPERATURE BOARD LVS 25 9685 0742 1 EA 80V LVS AC VL500 NOT SHOWN 25 9685 0746 1 EA 80V SURGE PROTECTOR VL500 NOT SHOWN 14 25 9685 0756 1 EA CABLE ASSY AC INPUT 15 25 9685 0770 1 EA DISPLAY CABLE RECEPTACLE BLACK 25 9685 2792 1 EA CABLE ASSY MAIN HARNESS 80V VL500 NOT SHOWN 28 9685 0999 1 EA KIT EXTRA US HARDWARE NOT SHOWN 16 51 0541 4 EA SCREW 4X3 8 H L PN BLK ZN 17 52 8295 0002 1...

Page 150: ...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 SERRATED 0 062 33 55 6568 0056 1 EA SPRING CPRSN 0 600 OD 0 080 WIRE 34 55 6568 0058 1 EA SPRING CPRSN 0 600 OD 0 085 WIRE 625 LG 35 55 6669 0005 6 EA STANDOFF 6 32 X 0 500 LG 1 4 HEX 36 69 3178 0121 1 EA POWER SUPPLY 120V 24V 3X5 No Item Qty UM Description ...

Page 151: ...TS BREAKDOWN 3 02 9685 0010 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 LUMINAIRE SERVICE MANUAL 134 21 May 2009 02 9685 0010 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: ...he foot of the fixture underneath the pan tube cover Refer to Figure 3 43 Figure 3 42 VL500 US Extra Hardware Kit No Item Qty UM Description 1 07 5044 0002 1 EA BAG 4 MIL X 2 X 3 ZIP PRESS POLYETHYLENE 2 53 6608 0001 4 EA SCREW 6 32X3 8 PFB 3 53 6523 0013 4 EA SCREW 6 32X3 8 PTB 4 53 6558 0001 4 EA SCREW 6 32X3 8 PPZ 5 53 6558 0009 4 EA SCREW 6 32X3 8 PPZ SEMS 6 53 6558 0010 4 EA SCREW 6 32X1 4 PP...

Page 154: ...45 1 EA ASSY DRIVE PULLEY VL500 2a 10 9685 0524 1 EA PULLEY DRIVE PAN TILT 2MM GT 18 TOOTH 2b 10 9678 8720 1 EA CODEWHEEL 120 COUNT 3 24 9685 7735 1 EA BOARD ASSY PAN TILT ENCODER VL500 4 44 9678 0680 1 EA MOTOR 3 PHASE SZ 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6558 0001 2 EA SCREW 6 32X3 8 PPZ 7 53 6575 0004 4 EA SCREW 8 32X5 8 PPZ 8 55 6627 0001 2 EA WASHER 6 SPLIT LOCK 9 84 01...

Page 155: ... installation information 2 Drive Pulley Installation Step 1 Apply one drop of Loctite 603 to motor shaft Step 2 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 3 Do not allow Loctite to drip into motor bearing Step 4 Set pulley height as shown above Step 5 Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on ...

Page 156: ...5 2 EA HEATSINK PAN TILT DRIVERS 2 10 9676 0885 2 EA PAD THERMAL TRANSFER PAN TILT 3 10 9685 0594 1 EA BRACKET FAN MCB 4 10 9685 0595 1 EA SEAL AIR 5 23 9685 0782 1 EA ASSY FAN MCB 6 24 9685 3730 1 EA MCB VL500 7 53 2200 0004 5 EA NUT 4 40 KEPS SS 8 53 6556 0001 2 EA SCREW 4 40X3 4 PPZ 9 53 6592 0001 3 EA SCREW 4 40X1 2 PPB 10 55 6537 0001 2 EA WASHER 4 LOCK INTERNAL TOOTH 6 4 7 1 7 9 x3 8 x2 10 x...

Page 157: ... 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 AWG 1 2 6 inch leads Pin 1 Red Pin 2 Black ...

Page 158: ...ption 1 10 9685 0547 1 EA BUSHING WIRE PROTECTION 0 95 OD 2 10 9685 7590 1 EA TOGGLE STOP PAN 3 10 9685 7591 1 EA TOGGLE PAN 4 21 9685 0512 1 EA ASSY LOWER CROSSMEMBER 5 21 9685 0513 1 EA ASSY UPPER CROSSMEMBER 6 21 9685 0535 1 EA ASSY PAN TUBE 7 53 6552 0002 8 EA SCREW 8 32X1 2 PFB 8 53 6667 0005 2 EA SCREW 10 32X3 8 SET CUP POINT 9 54 1206 0014 3 EA RING RETAINING 1 375 SHAFT ...

Page 159: ...USTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ... 9685 0547 1 EA BUSHING WIRE PROTECTION 0 95 OD 2 10 9685 7590 1 EA TOGGLE STOP PAN 3 10 9685 7591 1 EA TOGGLE PAN 4 21 9685 0512 1 EA ASSY LOWER CROSSMEMBER 5 21 9685 0513 1 EA ASSY UPPER CROSSMEMBER 6 21 9685 0536 1 EA ASSY PAN TUBE VL500 80V 7 53 6552 0002 8 EA SCREW 8 32X1 2 PFB 8 53 6667 0005 2 EA SCREW 10 32X3 8 SET CUP POINT 9 54 1206 0014 3 EA RING RETAINING 1 375 SHAFT ...

Page 161: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ...533 1 EA LANYARD SAFETY 5 53 2001 0003 2 EA NUT 10 32 NYLON INSERT 6 53 2019 0004 1 EA NUT 3 8 16 HEX 7 53 2020 0001 2 EA NUT 1 4X20 HEX STL ZINC PLTD 8 53 6539 0001 1 EA WASHER 3 8 SPLIT LOCK 9 53 6634 0875 1 EA SCREW 3 8 16X7 8 SCSS 10 53 6648 0001 2 EA SCREW 10 32X3 4 PPZ 11 54 1255 0001 1 EA ASSY BEARING HOUSING 12 54 1261 0001 2 EA BUSHING LOW DAMP THRMOPLS 189 13 55 3301 0010 2 EA WASHER 10 ...

Page 163: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 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: ... 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 CENTERING STEP 3 53 2020 0001 2 EA NUT 1 4X20 HEX STL ZINC PLTD 4 54 1255 0001 1 EA ASSY BEARING HOUSING 5 55 6549 0001 2 EA WASHER 1 4 SPLIT LOCK 1 3 x2 5 x2 4 2 x2 ...

Page 165: ...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 PAN TILT 2 10 9685 0531 1 EA PAN TUBE 3 10 9685 0532 1 EA PAN PULLEY SPACER 4 53 2200 0006 4 EA NUT 6 32 KEPS SS 5 53 6608 0750 2 EA SCREW 6 32X3 4 PFB 2 4 x4 1 3 5 x2 ...

Page 166: ...36 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 9685 0532 1 EA PAN PULLEY SPACER 3 12 9685 1553 1 EA PAN TUBE 80V 4 53 2200 0006 4 EA NUT 6 32 KEPS SS 5 53 6608 0750 2 EA SCREW 6 32X3 4 PFB 2 4 x4 1 3 5 x2 ...

Page 167: ...2 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 J3 3 52 6625 0006 1 EA CONN RECEPT XLR 5PIN FEMALE J1 4 52 6626 0006 1 EA CONN RECEPT XLR 5PIN MALE J2 5 62 3039 0102 1 EA CAP 1000PF 250V RAD CER DISC 20 X Y C1 1 2 3 4 5 ...

Page 168: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 150 21 May 2009 02 9685 0010 A Notes ...

Page 169: ...Incandescent Power Input Cable Assembly VL500 Only No Item Qty UM Description 1 52 6274 2313 1 EA STRAIN RELIEF SKINTOP FLEX TYPE PG13 BLK 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 4 55 2268 0187 1 FT HEATSHRINK 3 16 CLEAR KYNAR VDE UL 600V 150DEG C 5 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR VDE UL 600V 150DEG C 6 73 9636...

Page 170: ... 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 DISCONNECT 3 52 8230 0003 1 EA RECPT 1 4 FASTON 22 18 AWG TAPE 4 53 6534 0006 2 EA RIVET SOLID 0 094 DIA X 3 16 AL 100 DEG CSK 5 73 1624 0005 45 IN WIRE 24 AWG 300V TYPE EE MIL W 16878 5 GRN 2 1 5 44 0 3 4 x2 ...

Page 171: ...igure 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 CONTACT SL156 24 18AWG 3 73 6018 0002 0 71 FT WIRE 18 AWG 600V 105DEGC PVC RED UL1015 4 73 6018 0010 0 63 FT WIRE 18 AWG 600V 105DEGC PVC BLACK UL1015 1 2 x2 4 3 ...

Page 172: ...0 80V No Item Qty UM Description 1 52 6442 2003 1 EA RECEPT 3 POS MTA156 W TAB YEL 20 AWG 2 52 6442 2004 1 EA RECEPT 4 POS MTA156 W TAB YEL 20 AWG 3 52 6442 2006 1 EA RECEPT 6 POS MTA156 W TAB YEL 20 AWG 4 73 7137 0011 4 42 FT WIRE 20 AWG 600V 200 DEG C FEP BLK STRAND 105 40 0 06 DIA 5 73 7137 0012 4 42 FT WIRE 20 AWG 600V 200 DEG C FEP RED STRAND 105 40 0 06 DIA 2 3 1 5 8 5 45 4 45 4 8 ...

Page 173: ...FASTON FLAG 0 250 16 14 AWG REEL 2 52 8329 0001 2 EA TERM RING 6 22 16 AWG NON INS 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 73 3520 0005 0 63 FT WIRE 20 AWG 300V 105 DEGC PVC GRN UL1015 5 73 6014 0012 1 9 FT WIRE 14 AWG 600V 200 DEGC FEP BLK STRAND 168 36 0 104 DIA 6 73 6014 0013 1 8 FT WIRE 14 AWG 600V 200 DEGC FEP WHT STRAND 168 36 0 104 DIA 7 73 7130 0006 1 25 FT WIRE 5 64 TUBULAR BRAID TI...

Page 174: ...ge Protector Cable Assembly No Item Qty UM Description 1 33 0441 2 EA MOV 430V 6500A 20MM ZNR 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 55 2198 0001 0 08 FT HEATSRINK 1 8 BLACK 4 55 2199 0001 0 13 FT HEATSRINK 1 16 BLACK 5 55 2200 0001 0 08 FT HEATSRINK 3 16 BLACK 6 73 6016 0504 0 75 FT WIRE 16 AWG 600V 105DEGC GREEN YELLOW UL1015 2 6 5 1 x2 4 x4 3 ...

Page 175: ...mbly 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 MTA100 W POL TAB BLUE CLOSED END 2 73 2326 0029 2 83 FT WIRE 26 AWG 3 COND 300V 200 DEGC TEF BLK RED WHT UL1180 1 2 ...

Page 176: ...1 52 6442 2003 1 EA RECEPT 3 POS MTA156 W TAB YEL 20 AWG 2 52 6442 2004 1 EA RECEPT 4 POS MTA156 W TAB YEL 20 AWG 3 52 6442 2006 1 EA RECEPT 6 POS MTA156 W TAB YEL 20 AWG 4 52 8271 0005 1 EA RECEPT FASTON 1 4 16 14 AWG INSULATED REEL 5 73 7137 0011 3 79 FT WIRE 20 AWG 600V 200 DEG C FEP BLK STRAND 105 40 0 06 DIA 6 73 7137 0012 4 54 FT WIRE 20 AWG 600V 200 DEG C FEP RED STRAND 105 40 0 06 DIA 2 3 ...

Page 177: ...34 POS MT 3 52 6610 0034 1 EA CONN HOUSING 34 POS DBL ROW UNLOADED 4 52 6694 0001 16 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2MM 28 24 AWG 5 52 6696 0001 4 EA RECEPT WIRE TO WIRE 4 POS 2MM PITCH 28 24 AWG 6 52 8351 0004 34 EA CONTACT 26 22 AWG RECP MTE REEL 7 55 2186 0001 2 EA CABLE TIE 0 10 X4 SMALL 8 55 6699 0010 1 FT SLEEVING 5 16 NOM DIA WOV POLY ROUNDIT 2000 9 73 2326 0123 5 35 FT WIRE 26 AWG 4...

Page 178: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 160 21 May 2009 02 9685 0010 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: ...elay 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 2186 0001 1 EA CABLE TIE 0 10 X4 SMALL 3 73 6014 0012 0 29 FT WIRE 14 AWG 600V 200DEGC FEP BLACK STRAND 168 36 0 104 DIA 4 73 6014 0013 0 42 FT WIRE 14 AWG 600V 200DEGC FEP WHITE STRAND 168 36 0 104 DIA 1 x4 4 5 00 3 6 00 2 ...

Page 180: ...52 6541 0003 1 EA CONN CHASSIS POWER 3 POLE LOCKING 2 52 8231 0005 1 EA TERM RING 6 16 14 AWG REEL PIDG 3 52 8331 0003 3 EA FASTON RECPT 16 14 AWG PIDG BLU 0 170 ID 4 55 2186 0001 1 EA CABLE TIE 0 10 X4 SMALL 5 73 6014 0005 0 58 FT WIRE 14 AWG 600V 105DEGC PVC GRN UL1015 6 73 6014 0009 0 33 FT WIRE 14 AWG 600V 105DEGC PVC WHT UL1015 7 73 6014 0010 0 33 FT WIRE 14 AWG 600V 105DEGC PVC BLK UL1015 2 ...

Page 181: ...KET GOLD 24 20 AWG TYPE 3 REEL 0 04 0 08 INS DIA 4 52 8321 0005 2 EA TERM RING 6 16 14 AWG REEL PIDG 5 53 7015 0005 1 EA CONN HOUSING 5CIR MTA100 BLU 6 73 2326 0029 2 79 FT WIRE 26 AWG 3COND 300V 200DEGC TEF BLK WHT RED UL1180 7 73 6014 0002 0 46 FT WIRE 14 AWG 600V 105DEGC PVC RED UL1015 8 73 6014 0003 0 46 FT WIRE 14 AWG 600V 105DEGC PVC ORG UL1015 9 73 6014 0005 0 88 FT WIRE 14 AWG 600V 105DEGC...

Page 182: ...OUSING 20 POS 26 22 AWG PRELOADED MT RECEPT DBL ROW 2 52 6224 1020 1 EA COVER LATCH MT RECEPT 20 PIN 3 52 6224 2020 1 EA COVER BACK MT 20 PIN 4 52 6524 0004 2 EA CONN HOUSING 4 POS RECEPT 5 52 6588 0007 2 EA HOUSING 7 POS XH 250V3A 2 5MM PITCH 6 52 7007 0001 8 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT SXH 7 55 2186 0001 4 EA CABLE TIE 0 10 X 4 SMALL 8 73 2326 0123 9 20 FT WIRE 4 COND 300V 200 D...

Page 183: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 A 21 May 2009 165 VL500 Pan Tilt Cable Assembly continued Figure 3 66 VL500 Pan Tilt Cable Assembly Pin Outs ...

Page 184: ...d 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 REEL 2 73 6014 0011 1 33 FT WIRE 14 AWG 600V 200DEGC FEP GRN STRND 168 36 0 104 DIA 1 x2 2 ...

Page 185: ...Qty UM Description 1 25 9685 0777 1 EA CABLE ASSY BACK CAP GROUND VL500 2 52 8244 0001 2 EA FASTON RECEPT FLAG 0 250 16 14 AWG INSULATED REEL 3 55 2186 0001 2 EA CABLE TIE 0 10 X4 SMALL 4 55 2260 0133 2 33 FT SLEEVING FIBERGLASS 0 133 ID 5 55 6699 0010 1 33 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 6 73 3517 0001 4 00 FT WIRE 14 AWG 5KV 200DEGC SILICON 7X24 36 STRAND 2 x2 6 6 1 5 3 x2 5 4 x...

Page 186: ...1 0002 2 EA BACKSHELL CPC17 NYLON 0 300 0 525 CBL RNG 4 52 8201 0005 4 EA PIN GOLD 24 20 AWG TYPE 3 REEL 0 04 0 08 INS DIA 5 52 8201 0007 4 EA SOCKET GOLD 24 20 AWG TYPE 3 REEL 0 04 0 08 INS DIA 6 52 8341 0001 3 EA PIN GOLD 18 14 AWG TYPE 3 REEL 0 11 0 15 INS DIA 7 52 8342 0001 3 EA SOCKET GOLD 18 14 AWG TYPE 3 REEL 0 11 0 15 INS DIA 8 52 8344 0006 2 EA PIN CPC POWER 14 AWG 23A LOOSE 9 52 8344 000...

Page 187: ...G POWER HOT 5 DRAIN 22 AWG DRAIN WIRE 6 OPEN N A 7 WHT 16 AWG NEUTRAL 8 WHT 22 AWG DATA 9 BLK 22 AWG DATA 10 RED 22 AWG DATA 11 OPEN N A 12 ORN 14 AWG LAMP POWER 13 OPEN N A 14 VIOL14 AWG LAMP POWER Pinout Pin Wire Description 1 VIOL14 AWG LAMP POWER 2 GRN 16 AWG GROUND 3 ORN 14 AWG LAMP POWER 4 BLK 16 AWG POWER HOT 5 DRAIN 22 AWG DRAIN WIRE 6 WHT 16 AWG NEUTRAL 7 WHT 22 AWG NEUTRAL 8 BLK 22 AWG D...

Page 188: ... 6264 0005 1 EA CONN HOUSING MOD4 CRIMP SNAP IN 0 1 X 0 1 3 52 6240 0003 9 EA CONTACT FEMALE MOD4 CRIMP SNAP IN 4 52 6696 0001 1 EA RECEPT WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 5 52 6694 0001 4 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2MM 28 24 AWG 6 73 5126 0130 0 42 FT WIRE 26 AWG 4 COND 300V 200 DEGC TEF BLK WHT RED WHT RED 7 73 2326 0123 3 08 FT WIRE 4 COND 300V 200 DEGC TEF BLK BRN RED ORN 2 3...

Page 189: ... No Item Qty UM Description 1 10 9685 0536 01 1 EA ADAPTER PLATE MINI XLR BLACK 10 9685 0536 02 1 EA ADAPTER PLATE MINI XLR WHITE 2 52 6694 0002 4 EA CRIMP TERM WIRE TO WIRE MALE 3 52 6696 0003 1 EA PLUG WIRE TO WIRE 4 POS 4 53 6501 0002 1 EA CONN MINI XLR 4 PIN PANEL MOUNT 5 73 2326 0123 0 25 FT WIRE 26 AWG 4 COND 300V 200DEGC BLK BRN RED ORN UL1180 3 2 x4 5 1 Part of 4 4 Part of 4 ...

Page 190: ...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 0 250 16 14 AWG REEL 2 73 6014 0012 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP BLK STRAND 168 36 0 104 3 73 6014 0013 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP WHT STRAND 168 36 0 104 1 x2 2 28 3 28 ...

Page 191: ...oke 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 WIRE 14 AWG 600V 200 DEGC FEP GRN STRAND 168 36 0 104 DIA 1 1 2 ...

Page 192: ...igure 3 74 LVS AC Cable Assembly VL500 VL500D VL500A 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 CONTACT SL156 24 18 AWG 3 73 7137 0011 2 42 FT WIRE 20 AWG 600V 200 DEGC FEP BLK STRAND 105 40 0 06 DIA 4 73 7137 0012 2 42 FT WIRE 20 AWG 600V 200 DEGC FEP RED STRAND 105 40 0 06 DIA 1 2 4 29 3 29 ...

Page 193: ...nication Cable Assembly No Item Qty UM Description 1 52 6234 0001 1 EA CONN HOUSING 4 PIN MTA CLOSED END BLUE 2 52 6270 0002 1 EA CONN HOUSING 5 PIN MTA CLOSED END BLUE 3 52 8311 0001 1 EA TERM RING 6 26 22 AWG NON INS TAPE 4 73 2326 0123 3 0 FT WIRE 26 AWG 4 COND 300V 200DEGC BLK BRN RED ORN UL1180 5 73 3526 0005 0 5 FT WIRE 26 AWG 300V 105 DEGC PVC GRN UL1569 1 4 6 5 36 2 3 ...

Page 194: ... 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 AWG INSULATED LOOSE 2 0 13 FT WIRE 14 AWG 200DEGC STRAND TEF WHT 1 x2 2 ...

Page 195: ...ly 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 8329 0003 1 EA TERM RING 8 RED 22 16 AWG NON INSUL 3 73 7130 0002 1 17 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED 1 2 3 ...

Page 196: ...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 4 PIN MTA CLOSED END BLUE 2 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 3 73 2326 0123 2 67 FT WIRE 26 AWG 4 COND 300V 200 DEGC TEF BLK BRN RED ORN UL1180 1 x2 2 x2 3 32 ...

Page 197: ... 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 0011 2 5 FT WIRE 14 AWG 600V 200 DEGC FEP GRN STRAND 168 36 0 104 DIA 1 1 2 ...

Page 198: ...ASTON FLAG 0 250 16 14 AWG REEL 2 52 8329 0001 2 EA TERM RING 6 22 16 AWG NON INS 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 73 3520 0005 0 75 FT WIRE 20 AWG 300V 105 DEGC PVC GRN UL1015 5 73 6014 0012 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP BLK STRAND 168 36 0 104 DIA 6 73 6014 0013 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP WHT STRAND 168 36 0 104 DIA 7 73 7130 0006 2 17 FT WIRE 5 64 TUBULAR BRAID T...

Page 199: ...Figure 3 81 Shielded Display DMX Communication Cable Assembly VL500A No Item Qty UM Description 1 25 9685 0769 1 EA CABLE ASSY DISPLAY 2 25 9685 0774 1 EA CABLE ASSY YOKE DMX 3 52 8311 0004 2 EA TERM RING 6 16 14 AWG NON INS BOX 4 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 5 73 7130 0006 8 33 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER 4 x2 3 1 1 2 2 5 5 5 5 3 ...

Page 200: ...2 52 6264 0005 1 EA CONN HOUSING MOD4 CRIMP SNAP IN 0 1 X 0 1 3 52 6240 0003 9 EA CONTACT FEMALE MOD4 CRIMP SNAP IN 4 52 6696 0001 1 EA RECEPT WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 5 52 6694 0001 4 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2MM 28 24 AWG 6 73 5126 0130 0 42 FT WIRE 26 AWG 4 COND 300V 200 DEGC TEF BLK WHT RED WHT RED 7 73 2326 0123 3 25 FT WIRE 4 COND 300V 200 DEGC TEF BLK BRN RED ORN...

Page 201: ...mmunication Cable Assembly No Item Qty UM Description 1 52 6234 0001 1 EA CONN HOUSING 4 PIN MTA CLOSED END BLUE 2 52 6270 0002 1 EA CONN HOUSING 5 PIN MTA CLOSED END BLUE 3 52 8311 0001 1 EA TERM RING 6 26 22 AWG NON INS TAPE 4 73 2326 0123 3 17 FT WIRE 26 AWG 4 COND 300V 200DEGC BLK BRN RED ORN UL1180 5 73 3526 0005 0 67 FT WIRE 26 AWG 300V 105 DEGC PVC GRN UL1569 1 4 8 5 38 2 3 ...

Page 202: ...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 BLUE 2 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 3 73 2326 0123 3 67 FT WIRE 26 AWG 4 COND 300V 200 DEGC TEF BLK BRN RED ORN UL1180 1 x2 2 x2 3 44 ...

Page 203: ...Communication Cable Assembly VL500 80V No Item Qty UM Description 1 25 9685 0785 1 EA CABLE ASSY DISPLAY 80V VL500 2 25 9685 0786 1 EA CABLE ASSY YOKE DMX COMM 80V VL500 3 25 9685 0787 1 EA CABLE ASSY LVS FAN 80V VL500 4 52 8311 0004 2 EA TERM RING 6 16 14 AWG NON INS BOX 5 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 6 73 7130 0006 8 33 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER 5 x2 4 x2 1 1 2 2 6 6...

Page 204: ...52 6396 2603 1 EA RECEPT 3 POS MTA 100 W POL TAB BLUE CLOSED END 4 52 6396 2604 1 EA RECEPT 4 POS MTA 100 W POL TAB BLUE CLOSED END 5 52 8271 0004 2 EA RECEPT FASTON 0 250 22 18 AWG 6 52 8329 0001 1 EA TERM RING 6 22 16 AWG NON INSULATED 7 68 4541 0003 2 EA FERRITE 25 91 X 12 83 X 28 58 MM CYLINDRICAL CONE 8 71 0632 0 75 IN WIRE 18 AWG GRN UL1007 STRANDED 9 73 7140 0003 1 EA CABLE 3 COND BRAID SHI...

Page 205: ... ASSY PAN TILT 4 25 9685 0769 1 EA CABLE ASSY DISPLAY CABLE 5 25 9685 0771 1 EA CABLE ASSY YOKE LAMP WIRES 6 25 9685 0772 1 EA CABLE ASSY YOKE GROUND 7 25 9685 0773 1 EA CABLE ASSY LVS AC 8 25 9685 0774 1 EA CABLE ASSY YOKE DMX COMM 9 25 9685 0778 1 EA CABLE ASSY LVS FAN 10 25 9685 0782 1 EA CABLE ASSY MCB YOKE GROUND 11 55 2186 0001 8 EA CABLE TIE 0 10 X4 SMALL 12 55 6699 0003 1 19 FT SLEEVING 1 ...

Page 206: ...AIRE SERVICE MANUAL 188 21 May 2009 02 9685 0010 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: ... TILT 3 25 9685 0772 1 EA CABLE ASSY YOKE GROUND 4 25 9685 0773 1 EA CABLE ASSY LVS AC 5 25 9685 0778 1 EA CABLE ASSY LVS FAN 6 25 9685 0782 1 EA CABLE ASSY MCB YOKE GROUND 7 25 9685 0783 1 EA CABLE ASSY ARC YOKE LAMP WIRES 8 25 9685 0784 1 EA CABLE ASSY SHIELDED DISPLAY DMX COMM 9 55 2186 0001 8 EA CABLE TIE 0 10 X4 SMALL 10 55 6699 0003 1 19 FT SLEEVING 1 2 NOM DIA WOVEN POLY 11 55 6699 0010 0 9...

Page 208: ...UMINAIRE SERVICE MANUAL 190 21 May 2009 02 9685 0010 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: ...M VL500 80V 2 25 9685 0744 1 EA CABLE ASSY 24V POWER VL500 80V 3 25 9685 0745 1 EA CABLE ASSY 80V YOKE LAMP WIRES 4 25 9685 0758 1 EA CABLE ASSY PAN TILT 5 25 9685 0772 1 EA CABLE ASSY YOKE GROUND 6 25 9685 0788 1 EA CABLE ASSY SHIELDED DISPLAY DMX COMM VL500 80V 7 25 9685 0782 1 EA CABLE ASSY MCB YOKE GROUND 8 55 2186 0001 8 EA CABLE TIE 0 10 X4 SMALL 9 55 6699 0010 2 10 FT SLEEVING 5 16 NOM DIA ...

Page 210: ...INAIRE SERVICE MANUAL 192 21 May 2009 02 9685 0010 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: ...14AWG NON INSUL 4 55 2186 0002 2 EA CABLE TIE 3 3 4 LG 0 9WD TEFZEL 5 55 2199 1000 0 38 FT HEATSHRINK 1 BLACK 6 55 2260 0133 2 42 FT SLEEVING FIBERGLASS 0 133 ID 7 55 6699 0010 1 25 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 8 68 4541 0001 1 EA FERRITE 15 X 5 9 X 35MM CYLINDRICAL CORE 9 68 4541 0002 1 EA FERRITE 18 67 X 10 16 X 28 58MM CYLINDRICAL CORE 10 73 3517 0001 5 04 FT WIRE 14 AWG 5KV...

Page 212: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 194 21 May 2009 02 9685 0010 A Notes ...

Page 213: ...ATE BALLAST BLK 8 10 9685 0825 1 EA COVER BALLAST BLK 9 10 9685 0826 1 EA PANEL FILLER BALLAST BLK 10 12 9685 0821 2 EA HEATSINK BALLAST MACHINED BLK 11 23 9685 0827 1 EA FAN ASSY ARC BALLAST 700W 12 25 9685 0807 1 EA CABLE ASSY BALLAST I O 13 53 2002 0001 4 EA NUT 6 32 KEPS ZINC 14 53 2003 0001 4 EA NUT 4 40 KEP ZINC PLATED 15 53 6520 0001 5 EA SCREW 4 40X3 8 PPZ 16 53 6545 0001 4 EA SCREW 8 32X3...

Page 214: ...INAIRE SERVICE MANUAL 196 21 May 2009 02 9685 0010 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: ...16 14 AWG REEL PIDG 8 52 8257 0002 2 EA PIN PHOS BRZ 20 14AWG REEL MNLOK 060 130 INS DIA 9 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 10 52 8314 0001 1 EA PIN GND 20 14AWG REEL MNLOK 060 130 INS DIA 11 55 2186 0001 5 EA CABLE TIE 10 WD 4 00 LG SMALL 12 73 3522 0002 1 25 FT WIRE 22AWG 300V 105C PVC RED UL1569 13 73 3522 0009 1 25 FT WIRE 22AWG 300V 105C PVC WHT UL1569 14 73 3522 ...

Page 216: ...TE VL500 LUMINAIRE SERVICE MANUAL 198 21 May 2009 02 9685 0010 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: ...rotected support areas please contact Vari Lite Customer Service at 1 877 827 4548 or customerservice genlytecontrols com Technical Bulletin or Notice Description S5K 001 Series 500 Yoke Leg Cross Member Screw Torquing Procedure S5K 002 This technical bulletin was rescinded S5K 003 Series 500 Counterweight Replacement Procedure S5K 004 Series 500 80V Step Washer Replacement Procedure S5K 005 Serie...

Page 218: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 200 21 May 2009 02 9685 0010 A Notes ...

Page 219: ......

Page 220: ...al 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 ...

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