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Summary of Contents for VL2500 Spot Luminaire

Page 1: ......

Page 2: ...ny Patents No 694 25 943 8 693 14 122 0 692 08 615 3 692 07 692 1 691 31 478 0 691 21 029 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 Des...

Page 3: ...ginal packing material along with a copy of your invoice if available and write the RMA number legibly on or near the shipping address label Return the unit freight prepaid to Vari Lite 10911 Petal St...

Page 4: ...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 co...

Page 5: ...eplacing 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 manua...

Page 6: ...n 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...

Page 7: ...typs kann gef hrlich sein 2 Scheinwerfer k nnen auf jeder beliebigen Oberfl che montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Ersetz...

Page 8: ...teht die Gefahr von K rperverletzung bzw von Feuer das von Lampenteilen ausgel st werden kann 4 Tragen Sie beim Austausch der Lampen einen Augenschutz 5 Die geeignete Sicherheitsausr stung Handschuhe...

Page 9: ...s lampes Philips et Osram HID V rifier le type de lampe MSR400 MSR575HR etc avant de remplacer les lampes L installation d un autre type de lampe peut poser un danger 2 Les luminaires peuvent tre fix...

Page 10: ...raves br lures sur la peau et une inflammation des yeux De plus les lampes arc fonctionnent sous haute tension de tr s hautes temp ratures Si la lampe se casse les particules de la lampe cass e peuven...

Page 11: ...mparas HID Philips y Osram Tome nota del tipo de l mpara MSR400 MSR575HR etc antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cualqu...

Page 12: ...a la piel e inflamaci n a los ojos Adem s las l mparas de arco operan a alta presi n y muy alta temperatura Si la l mpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasio...

Page 13: ...iii _KH 2 0 2 Q X Q X _KH P s 0 P T Q X _KQo 4 UV q P N 6 4 Z Ef 1 VARI LITE zU Philips Osram HID fJ 3 fJ d fJ MSR400 MSR575HR z fJ zU Q X 0 2 2 J Y f Q X EXo d EXo 4 VARI LITE zU 0 6 6 Z Ef 1 VARI LI...

Page 14: ...2 9676 0022 0 6 UV Ef 1 VARI LITE zU UV HID 2 J fJ fJ _f o zU P _f o Y 2 6 G 2 Z Ef zU P zU fPo f U zU P fJ fJ d zU fJ 2 fJ c 64 fJ o v o 6 o _ _ q P 4 0 cP fJ U fJ 0 o fJ zU I fJ fJ 6 RF 1 Class A 8c...

Page 15: ...sting Testing Software 12 Troubleshooting Error Messages 13 Troubleshooting Guide 14 Maintenance Procedures Head Assembly 16 Lamp Replacement 16 Align Lamp for Flat Field 18 Fixed Color Bulkhead Repla...

Page 16: ...ector Assembly 55 Back Cap Assembly 56 Wash Fan Assembly 58 Wash Fixed Color Assembly 60 Crossfade Color Assembly 62 Sensor PCB Assembly 64 Color Motor Assembly 65 Filter Wheel Assembly 66 Strobe Asse...

Page 17: ...y 117 Fans Disconnect Cable Assembly 118 OT Switch to Reflector Assy Cable Assembly 119 Pan Tilt Control Cable Assembly 120 EMI Filter to Power Switch Cable Assembly 122 AC Input Splitter Cable Assemb...

Page 18: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL xviii 09 December 2004 02 9676 0022 0 Notes...

Page 19: ...hers This manual covers the following models Note Performing maintenance procedures contained in this manual may void the product warranty Refer to the Vari Lite Inc Limited Warranty card included in...

Page 20: ...yte com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link Technical Bulletins Technical Notices Technical Bullet...

Page 21: ...02 9676 0022 0 09 December 2004 3 SERVICE CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Major Components Principles of Operation...

Page 22: ...erchangeable color filters and one open space capable of continuous rotation for additional effects Zoom Optics Continuously variable field angle from 14 to 55 5 Intensity Control A coated glass dimme...

Page 23: ...r Enclosure Truss Hook Bracket Assembly Assembly AC Input Cable Yoke Assembly Removable Lamp Assembly to access lamp for replacement Beam Adjustment Controls Vertical Horizontal Focus Captive Knob for...

Page 24: ...at first level the current address Enter button Selects the current menu option or stores current data value Up arrow Scrolls menu options upward or increases current data value Down arrow Scrolls men...

Page 25: ...ows the major sub assemblies which are located in the luminaire head assembly Yoke and enclosure not shown for clarity Removable Cover Dual Blade CYM Color Dimmer Bulkhead Fan Assembly Front Assembly...

Page 26: ...ilt Motor Relay Main Control Board MCB Tilt side leg leg To determine which yoke leg is which without having to remove the covers rotate yoke counterclockwise until it stops then look at the luminaire...

Page 27: ...own for clarity Enclosure Top Covers 150W 24V 6 3A Input Panel Assembly 700W Arc Ballast Module Enclosure Bottom Ventilation Cover Power Supply Fan Assembly containing DMX Input PCB and Menu Display W...

Page 28: ...in Control PCB Input Power Head Fan 1 Beam Dimmer Strobe Pan Encoder Pan EOT Tilt Encoder Tilt EOT Display PCB Color Sensor Color Sensor J9 EMI Filter Low Voltage Supply VLFS Ballast Back Cap Switch P...

Page 29: ...service and standard maintenance procedures Testing Troubleshooting Maintenance Procedures WARNING All maintenance procedures are to be performed with power removed from the luminaire and by a traine...

Page 30: ...ire can be placed in any position for testing without movement occurring In order to regain full control of the luminaire Move will need to be enabled after testing Note When setting the Move option t...

Page 31: ...Down arrows until Fixture appears Press Enter Step 3 Press Up Down arrows to access Status Press Enter Display will now scroll through any error messages or display OK if no errors WARNING As with an...

Page 32: ...Douse Lamp does not strike upon start up Lamp Off option is config ured Reconfigure lamp startup option in Lamp config menu n a Luminaire behaves oddly Profile Not Matched Profile not set correctly c...

Page 33: ...inst stop Tilt Sensor Not Found EOT flag attached to large pulley is not engaging the EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth suffi...

Page 34: ...SHORT ARC WARNING Remove power from luminaire before performing maintenance To replace lamp Step 1 Remove power from luminaire WARNING Lamps will be extremely HOT after operation Allow lamp to cool be...

Page 35: ...inserted through reflector if not parallel to guide rods Step 6 Align guide rods in guide holes and slide backcap into head assembly Re tighten captive knob Step 7 If required reset lamp hour counter...

Page 36: ...ing lamp operation Wear protective gloves and or use tools to prevent burns To align lamp Step 1 Using internal menus select Lamp test to set beam Refer to VL2500 Wash Luminaire User s Manual for more...

Page 37: ...CYM crossfade color bulkhead disconnect wiring screws and remove assembly Step 4 At fixed color bulkhead turn captive screw one quarter turn to release bulkhead Step 5 At fixed color bulkhead disconne...

Page 38: ...s color filters To do this use 2 Phillips screwdriver to turn captive screw one quarter turn and slide bulkhead upward Step 3 Remove CYM crossfade color assembly Step 4 Rotate wheel until required fil...

Page 39: ...ep 3 Remove CYM crossfade color assembly Step 4 Remove fixed color bulkhead assembly Step 5 Optional Remove front assembly to gain direct access to four mounting screws if right angle screw driver is...

Page 40: ...emove front nose cover by removing two 10 32 1 2 PPB screws one on each side Figure 2 7 Front Assembly Removal Step 4 At junction connector disconnect edge motor wiring Step 5 Face head nose upward At...

Page 41: ...assembly Refer to Front Assembly Removal on page 22 Step 3 Disconnect beam spreader motor assembly wire connector from motor harness cable assembly Step 4 Remove two 4 40 KEPS nuts securing motor asse...

Page 42: ...Removal on page 22 Step 3 Remove four 6 32 X 3 16 PPB screws and four 6 lock washers securing concave lens assembly to lens support arm Figure 2 9 Figure 2 9 Concave Lens Assembly Replacement CAUTION...

Page 43: ...wer source Step 2 Remove concave lens assembly Refer to Concave Lens Assembly Replacement on page 24 Step 3 Using 1 4 nutdriver remove one 4 40 KEPS nut on end of beam spreader motor assembly shaft Fi...

Page 44: ...e replacement convex lens assembly and then old concave lens assembly onto lens shafts Step 7 Hold convex and concave lens assemblies together and using 2 Phillips screwdriver re install four 8 lock w...

Page 45: ...ng re installation Step 5 Using 5 64 Allen wrench loosen eight setscrews two each collect and remove four shaft collets and four wave spring washers from lens shafts Figure 2 11 CAUTION Do not touch l...

Page 46: ...mber 2004 02 9676 0022 0 Figure 2 11 100MM Condenser Lens Assembly Replacement Step 13 Re install convex and concave lens assemblies Concave Diffuser Lens Assembly Convex Lens Assembly Shaft Collet 4...

Page 47: ...5 16 PPB screws Figure 2 12 To find tilt side leg refer to page 8 Figure 2 12 Tilt Motor Assembly Replacement Step 3 At pan tilt encoder PCB mounted behind tilt motor mounting plate discon nect two ca...

Page 48: ...e leg cover by removing four 6 32 5 16 PPB screws To find board side leg refer to page 8 CAUTION Always use anti static precautions when working with PCBs Figure 2 13 MCB PCB Replacement Step 3 Discon...

Page 49: ...tep 4 At yoke cross member remove four 6 32 3 16 LG PPZ screws and associ ated washers which secure cross member cover to yoke and remove cover These screws are accessible from inside yoke legs CAUTIO...

Page 50: ...ffs from ignitor PCB by removing the 6 32 5 16 PPZ screws and 6 lock washers Install in same place on new ignitor PCB Figure 2 15 Figure 2 15 Ignitor PCB Standoff Removal Step 10 Install replacement a...

Page 51: ...to remove the top and bottom covers To remove and replace enclosure covers Step 1 Using console or internal menus run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable fr...

Page 52: ...step Step 4 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Figure 2 17 Figure 2 17 Laying Luminaire on Its Side Step 5 At bottom of enclosure remov...

Page 53: ...remove ballast side and ventilation covers Refer to Removing Enclosure Covers on page 33 Step 3 Remove both handles by removing two 10 32 X 5 8 PPB screws at each Step 4 At enclosure remove eight 6 32...

Page 54: ...ssembly Replacement Step 8 At bottom of enclosure remove three 8 32 3 8 PFZ screws and two 8 32x3 8 PPZ screws which secure ballast module to enclosure Step 9 Remove ballast module Step 10 Install rep...

Page 55: ...move bottom cover Step 4 Remove two connectors to pan encoder board Step 5 Remove four screws securing pan motor to chassis Step 6 Carefully lift motor upwards and remove tensioning springs Step 7 Sli...

Page 56: ...urce Step 2 Carefully lay luminaire on its side to have access to bottom of enclosure Step 3 At enclosure assembly remove bottom cover Step 4 Remove pan encoder board Step 5 Install in reverse order M...

Page 57: ...put cable from power source Step 2 Carefully lay luminaire on its side Step 3 At enclosure assembly remove bottom cover Step 4 Remove pan sensor Step 5 Install in reverse order Make sure bottom cover...

Page 58: ...er source Step 2 At enclosure remove top cover at power supply side Step 3 At LVS remove wiring Step 4 Remove screw closest to pan tube Loosen two screws at opposite end of wiring Step 5 Remove LVS St...

Page 59: ...0 09 December 2004 41 SERVICE CHAPTER 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500 Wash Luminaire Drawing Tree Top Assembly Yoke Enclo...

Page 60: ...24 9661 1126 Rev B Pan Tilt Encoder PCB Assembly 24 9661 0629 Rev 0 Ignitor To Relay Cable Assembly 25 9667 0030 Rev A VL2500 Main Control Board PCB Assembly 24 9676 0730 Rev B Front Wash Assembly 21...

Page 61: ...Rev 0 LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev B Pan Tilt Control Cable Assembly 25 9676 0818 Rev A EMI Filter to Power Switch Cable...

Page 62: ...ERVICE 2 02 8052 0001 1 EA CARD LIMITED WARRANTY 3 02 8406 0001 1 EA TAG LAMP NOTICE 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 2000 SERIES 09 09 02 5 02 9676 0002 1 EA UNPACK QUICK START SHEET VL2...

Page 63: ...22 9676 0140 1 EA ASSY UV IR WINDOW 14 22 9676 1018 1 EA ASSY REFLECTOR 15 22 9676 1090 1 EA ASSY FAN WASH 25 9676 0717 1 EA CABLE ASSY STROBE 1 not shown 25 9676 0718 1 EA CABLE ASSY FAN DISCONNECT...

Page 64: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 46 09 December 2004 02 9676 0022 0 Figure 3 2 Top Assembly 11 5 14 19 x6 8 7 21 23 6 18 x4 15 13 19 x4 12 1 9 4 20 x2 10 17 x8 2 x2 24 x4 19 16 22...

Page 65: ...NTROL BOARD MCB 10 53 6505 0020 5 EA BOLT 1 4 28 X 3 4 HX HD GRD 8 11 53 6517 0001 8 EA SCREW 10 32 X 3 8 PPZ 12 53 6526 0001 1 EA SCREW 6 32 X 5 8 PPZ 13 53 6530 0006 2 EA RIVET POP 1 8 OD X 188 250...

Page 66: ...ERVICE MANUAL 48 09 December 2004 02 9676 0022 0 VL2500 Generic Luminaire continued Figure 3 3 VL2500 Generic Luminaire Assembly 18 23 13 x2 3 6 19 11 x8 20 x8 5 17 x2 4 17 x2 7 10 x5 21 x5 14 x5 15 x...

Page 67: ...0402 1 EA 100 MM CONDENSER LENS ASSY 8 22 9671 0414 1 EA ASSY CONVEX LENS 9 22 9671 0468 1 EA ASSY MOTOR BEAM SPREADER 10 53 2200 0004 3 EA NUT 4 40 KEPS SS 11 53 5558 0188 8 EA SCREW 8 32 X 188 LG SE...

Page 68: ...WASH LUMINAIRE SERVICE MANUAL 50 09 December 2004 02 9676 0022 0 Front Wash Assembly continued Figure 3 4 Front Wash Assembly 10 x2 7 8 12 x4 5 2 x4 11 x8 19 x4 1 x4 3 x2 14 x12 18 x2 9 4 17 x4 6 13 x...

Page 69: ...3 5 Figure 3 5 Concave Diffuser Front Lens Assembly No Item Qty UM Description 1 10 9671 0409 1 EA BACK CLAMP CONCAVE LENS 2 10 9671 0421 2 EA LENS GASKET 3 10 9671 0491 1 EA FRONT CLAMP CONCAVE LENS...

Page 70: ...10 9671 0421 2 EA LENS GASKET 4 10 9671 0463 1 EA BUSHING CONVEX LENS SLOTTED 5 10 9671 0464 1 EA BUSHING CONVEX LENS DRIVE 6 10 9671 0465 1 EA PLATE DRIVE BUSHING 7 12 9671 0416 1 EA MASKED CONVEX LE...

Page 71: ...3 10 9676 0009 1 EA COVER TOP VL2500 4 10 9676 0010 1 EA FILTER TOP HEAD COVER 5 12 9676 0076 1 EA BAFFLE RIGHT TOP COVER 6 12 9676 0077 1 EA BAFFLE LEFT TOP COVER 7 53 2008 0008 2 EA PUSH NUT 8 8 53...

Page 72: ...om Cover Assembly 22 9676 0011 Rev C Refer to Figure 3 8 Figure 3 8 Bottom Cover Assembly No Item Qty UM Description 1 10 9676 0012 1 EA COVER BOTTOM VL2500 2 53 2008 0008 3 EA NUT 8 PUSH 3 53 6545 00...

Page 73: ...Reflector Assembly No Item Qty UM Description 1 10 9678 0647 4 EA CLAMP MOUNTING REFLECTOR 2 12 9660 0073 1 EA ELLIPSOIDAL REFLECTOR SMOOTH COATED 3 22 9660 0338 1 EA ASSY DISCONNECT LAMP 4 22 9676 01...

Page 74: ...2 EA SCREW 4 40 X 5 8 PPZ VL 1 15 53 6525 0001 1 EA SCREW 6 32 X 5 16 PPZ 16 53 6526 0001 2 EA SCREW 6 32 X 5 8 PPZ 17 53 6534 0002 4 EA RIVET 3 32 OD POP 3 16 GRIP RNG ALUM 18 53 6539 0008 2 EA WASH...

Page 75: ...EMBLY 3 02 9676 0022 0 09 December 2004 57 Back Cap Assembly continued Figure 3 10 Back Cap Assembly 1 19 10 x2 3 25 13 5 25 9 0 9 14 x2 27 x2 32 16 x2 26 x2 30 x2 5 12 x2 6 17 x4 24 x2 18 x2 21 x2 23...

Page 76: ...2 6524 0002 1 EA CONN HOUSING 2 POS RECEPTACLE 9 52 8346 0001 2 EA CONTACT 24 30 AWG FEMALE CRIMP 10 52 8347 0001 5 EA CONTACT 24 30 AWG CRIMP MALE 11 52 8371 0001 1 EA RECEPT FASTON 20 24 AWG UNINSUL...

Page 77: ...ARTS BREAKDOWN TOP ASSEMBLY 3 02 9676 0022 0 09 December 2004 59 Wash Fan Assembly continued Figure 3 11 Wash Fan Assembly 1 3 2 5 13 x8 18 x3 15 x2 17 x2 12 4 14 6 11 19 7 10 x5 16 20 21 8 9 Directio...

Page 78: ...10 9676 1181 1 EA BULKHEAD COLOR 3 21 9676 0119 1 EA ASSY COLOR MOTOR 4 22 9673 0145 1 EA ASSY FILTER WHEEL 5 25 9676 0125 1 EA CABLE ASSY T STAT COLOR GOBO not shown 6 53 2200 0004 1 EA NUT 4 40 KEP...

Page 79: ...ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 02 9676 0022 0 09 December 2004 61 Wash Fixed Color Assembly continued Figure 3 12 Wash Fixed Color Assembly 7 x3 1 10 9 11 x3 5 6 8 3 2 4...

Page 80: ...SY YELLOW COLOR WHEEL 11 21 9676 0293 1 EA ASSY DIMMER WHEEL 12 21 9676 0298 1 EA ASSY SENSOR PCB BRACKET 13 21 9676 1236 1 EA ASSY FAN WASH 14 21 9676 1289 1 EA ASSY FRONT BULKHEAD DIFFUSER 15 44 967...

Page 81: ...ember 2004 63 Crossfade Color Assembly continued Figure 3 13 Crossfade Color Assembly 15 x2 Dimmer Magenta Cyan Yellow 19 x2 20 x6 25 x6 3 27 6 26 Cyan 11 1 1 1 8 9 10 6 2 5 14 12 18 x2 24 x2 15 x2 19...

Page 82: ...Assembly 24 9638 0113 Rev B Refer to Figure 3 14 Figure 3 14 Sensor PCB Assembly No Item Qty UM Description 1 11 9638 0114 1 EA PCB SENSOR VL6 2 52 6229 0001 1 EA HEADER 3POS MTA FRIC LOK STRT POST 3...

Page 83: ...0 9667 0120 1 EA COLOR MOTOR BULKHEAD 3 24 9638 0113 1 EA PCB ASSY SENSOR VL6 4 44 9676 0116 1 EA MOTOR GOBO COLOR WHEEL 5 53 6597 0001 2 EA SCREW 4 40 X 3 16 PPZ 6 53 6599 0001 1 EA SCREW 4 40 X 3 8...

Page 84: ...OP 63 125 GR LENGTH 2 41 6006 0020 1 EA ASSY VL6 FILTER MAGENTA ST 3 41 6006 0150 1 EA ASSY VL6 FILTER PINK ST 4 41 6006 0240 1 EA ASSY VL6 FILTER LIGHT RED ST 5 41 6006 0320 1 EA ASSY VL6 FILTER BAST...

Page 85: ...OBE MOTOR 5 10 9676 0069 2 EA MOUNTING PLATE STROBE MOTOR 6 10 9678 0491 4 EA BUMPER STOP STROBE 7 44 9678 0455 2 EA MOTOR COLOR 8 53 2200 0006 2 EA NUT 6 32 KEPS SS 9 53 5536 0500 4 EA SCREW 6 32 X 1...

Page 86: ...SERVICE MANUAL 68 09 December 2004 02 9676 0022 0 Strobe Assembly continued Figure 3 17 Strobe Assembly 10 x2 13 x2 7 x2 5 x2 11 x2 1 6 x4 9 x4 16 x2 4 x2 8 x2 15 x8 4 12 x6 3 x2 14 x4 Note connector...

Page 87: ...0 Rev B Refer to Figure 3 18 Figure 3 18 UV IR Window Assembly No Item Qty UM Description 1 10 9676 0058 1 EA UV IR FRAME 2 41 9678 0608 1 EA UV IR FILTER 3 00 X 3 00 3 53 5504 0187 2 EA SCREW 4 40 X...

Page 88: ...HRU J8 52 6559 0052 1 EA CONN HDR SMD 26POS 1LS VERT J13 52 6599 0068 1 EA HEADER 34 PIN DUAL ROW AMP MODU VERT THRU J9 52 6599 0080 1 EA HEADER 40 PIN DUAL ROW AMP MODU VERT THRU J11 52 8412 0026 1 E...

Page 89: ...500 4703 2 EA RES 1W 5 4 7 K CHIP THK FLM SMT R68 R69 60 9460 1003 2 EA RES 1W 5 1 0 K 100V CHIP THICK FILM SMT0805 R27 R28 60 9460 1004 14 EA RES 1W 5 10 0 K 100V CHIP THICK FILM R14 R15 R30 R32 R34...

Page 90: ...4 EA DIODE DL4148CT RECTIFIER D9 D12 82 5329 0001 2 EA DIODE MBRS340T3 40V 3A SCHOTTKY SUR MT D1 D2 82 5350 0001 2 EA DIODE BAT54SLT1 DUAL SCHOTTKY CATHODE TO ANODE CONNECTED 30V 200MA D4 D5 82 5361...

Page 91: ...1 EA IC DS1834AS DUAL RESET MONITOR W PUSHBUTTON SMT U9 86 6105 0001 4 EA IC HCPL 0600 OPTO COUPLER SMD U2 U3 U5 U7 87 7188 0001 1 EA IC EPIK50FC208 3 BLANK FPGA U16 87 7248 0001 1 EA IC AM29LV400BB 4...

Page 92: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 74 09 December 2004 02 9676 0022 0 VL2500 Main Control Board PCB Assy cont Figure 3 19 VL2500 Main Control Board PCB Assembly Top Side Bottom Side...

Page 93: ...B ASSY SOLID STATE IGNITOR 6 25 9667 0030 2 EA CABLE ASSY IGNITOR TO RELAY not shown 7 53 6525 0001 12 EA SCREW 6 32 X 5 16 PPZ 8 53 6558 0001 3 EA SCREW 6 32 X 3 8 PPZ 9 55 2143 0001 4 EA STANDOFF 1...

Page 94: ...I LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 76 09 December 2004 02 9676 0022 0 Yoke Assembly continued Figure 3 20 Yoke Assembly 1 12 x2 4 7 x2 2 14 x2 9 x4 11 x4 10 3 8 x3 7 x2 13 x2 7 x4 13 x4 15 x2...

Page 95: ...TAL OXIDE 12 60 3430 8205 2 EA RES 1W 5 820 0K OHM METAL OXIDE R3 R4 13 62 3021 2101 1 EA CAPACITOR 100PF 200V RAD CER 10 C6 14 62 3021 2330 1 EA CAPACITOR 330PF RAD CER 5 C5 15 62 3023 0104 2 EA CAPA...

Page 96: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 78 09 December 2004 02 9676 0022 0 Ignitor PCB Assembly continued Figure 3 21 Ignitor PCB Assembly...

Page 97: ...5561 0250 2 EA SCREW 6 40 X 1 4 SET CONE POINT 3 23 9661 1253 1 EA ELEC ASSY PAN EOT SENSOR 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 52 8346 0001 4 EA CONTACT 24 30 AWG FEMALE CRIMP 86 7002 00...

Page 98: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 80 09 December 2004 02 9676 0022 0 Tilt Motor Assembly continued Figure 3 22 Tilt Motor Assembly 5 1 9 x2 9 x2 8 x2 4 7 x4 6 x2 10 x2 2 3 10 x2...

Page 99: ...embly No Item Qty UM Description Ref 1 11 9661 0629 1 EA PCB ENCODER SENSOR 2 52 6613 0005 1 EA HEADER 5POS SGL ROW SHROUDED LATCHING J1 3 52 6613 0006 1 EA HEADER 6POS SGL ROW SHROUDED LATCHING J2 4...

Page 100: ...6 0609 Rev A Refer to Figure 3 23 Figure 3 24 Yoke Fan Assembly No Item Qty UM Description 1 10 9676 0646 1 EA FAN TRAY YOKE ARM 2 40 7113 0001 1 EA FAN 24V 80 X 80 X 25 MM 32CFM 3 52 6396 2202 1 EA R...

Page 101: ...A COVER TOP 11 10 9678 0846 2 EA HANDLE CAST 12 10 9678 0869 1 EA BRACKET LVS 13 10 9678 0886 1 EA SPACER PAN BEARING 0 235 THK 14 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN TUBE 15 12 9661 1236 2...

Page 102: ...B CAP 46 53 6522 0004 2 EA SCREW 6 32 X 1 4 SOC HD CAP BLK 47 53 6525 0188 2 EA SCREW 6 32 X 3 16 LG PPZ SEMS 48 53 6530 0023 2 EA RIVET 1 8 OD POP 376 500 GRP DOME HD STL MND 49 53 6539 0001 4 EA WAS...

Page 103: ...43 0001 0 146 FT GROMMET STRIP SERRATED 77 55 6543 0001 1 08 FT GROMMET STRIP SERRATED 1 8 OPENING 78 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK 79 55 6568 0074 2 EA SPRING CPRSN 420 OD 75 LG 055 DIA WIR...

Page 104: ...Upper Enclosure Assembly 18 5 17 58 73 80 8 60 x2 40 61 75 76 89 53 26 87 6 85 59 77 x2 12 50 x3 51 x2 53 x3 48 x2 27 70 54 69 71 56 81 88 1 47 86 42 39 52 83 x2 9 14 44 x3 22 45 x4 79 x2 66 64 65 41...

Page 105: ...02 9676 0022 0 09 December 2004 87 Upper Enclosure Assembly continued Figure 3 26 Upper Enclosure Assembly Unpainted surface of APS Cover only 19 78 x4 63 x4 54 x4 10 x2 7 11 x2 82 x2 54 53 53 53 55 x...

Page 106: ...EA LAYOUT ENCLOSURE OVERLAY 2 10 9678 0859 1 EA BRACKET INPUT 3 24 9663 1830 1 EA PCB ASSY DMX INPUT 4 24 9678 0825 1 EA PCB ASSY DISPLAY 5 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 6 53 6551 0001...

Page 107: ...MX Input PCB Assembly No Item Qty UM Description Ref 1 11 9663 1830 1 EA PCB FAB DMX INPUT 2 52 6259 0001 1 EA HEADER 5POS MTA FRCT LOK STRT POST J3 3 52 6625 0005 1 EA CONN RECEPT XLR 5PIN FEMALE PC...

Page 108: ...13 1 EA STRAIN RELIEF SKINTOP FLEXTYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG CE MARKED 20A 250V TWIST LOCK 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8298 1160 2 EA FERRULE WIRE 1X...

Page 109: ...e 3 30 Pan Tube Assembly No Item Qty UM Description 1 10 9678 0809 1 EA PAN TOGGLE STOP 2 10 9678 0847 1 EA WASHER SILICONE FOAM 3 10 9678 0848 2 EA WASHER PAN TEFLON 4 12 9678 0891 1 EA PAN TUBE MACH...

Page 110: ...EA PLATE PAN MOTOR MOUNT 2 21 9678 0828 1 EA ASSY DRIVE PULLY PAN 3 24 9678 0729 1 EA PCB ASSY VL2203 PAN TILT ENCODER 4 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 3...

Page 111: ...09 December 2004 93 Upper Enclosure Fan Assembly 23 9678 0686 Rev 0 Refer to Figure 3 31 Figure 3 32 Upper Enclosure Fan Assembly No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52...

Page 112: ...nsor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 33 Figure 3 33 Pan EOT Sensor Electrical Assembly No Item Qty UM Description 1 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 2 52 8346 0...

Page 113: ...007 2 EA RIVET 1 8 OD POP 063 125GRP RG 265LG CSKH AL5052 14 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ 15 53 6616 0001 8 EA SCREW 6 32 X 3 4 PPZ 16 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNTING 1...

Page 114: ...96 09 December 2004 02 9676 0022 0 32 80 2648 0001 1 EA TRANSISTOR IXFH32N50 POWER MOSFET 500V 32A TO 247 33 82 4323 0001 1 EA DIODE BRIDGE D25XB60 600V 25A SIP 34 82 5341 0001 2 EA DIODE DSEI30 06A F...

Page 115: ...ENCLOSURE 3 02 9676 0022 0 09 December 2004 97 Ballast Module Assembly continued Figure 3 34 Ballast Module Arc Power Supply Assy 6 2 3 23 4 13 x2 14 x4 7 23 12 x4 29 8 16 22 28 1 20 12 21 x2 19 x3 15...

Page 116: ...98 09 December 2004 02 9676 0022 0 Ballast Module Assy continued Figure 3 35 Ballast Module Arc Power Supply Assy 26 9 2 pl 27 31 10 34 25 33 24 11 10 4 pl 15 4 pl 18 4 pl 20 4 pl 30 4 pl 9 27 11 32...

Page 117: ...111 J202 205 11 52 8283 5202 1 EA TEST POINT PCB MT 052 HOLE RED GLASS BEAD J106 12 52 8283 5210 1 EA TEST POINT PCB MT 052 HOLE BLK GLASS BEAD J107 13 60 1230 1004 1 EA RES 1 4W 1 10 0 K MF R225 14...

Page 118: ...VAC RAD SUPPRESSOR 10 C101 C102 41 62 3013 0105 2 EA CAP 1UF 630V RAD MET PLYPLN 10 C201 C204 42 62 3013 0474 1 EA CAP 47UF 630V RAD MET PLYPLN 10 C105 43 62 3017 0102 4 EA CAP 1000PF 250V RAD CER DIS...

Page 119: ...80 2623 0003 3 EA TRANSISTOR 2N4403 PNP 40V 600MA TO 92 Q103 Q204 Q211 64 80 2643 0001 2 EA TRANSISTOR MPSW63 1W PNP DARLINGTON 30V 500MA 1W TO 92 Q205 Q210 65 82 4308 4937 5 EA DIODE 1N4937 FAST 600V...

Page 120: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 102 09 December 2004 02 9676 0022 0 700W Ballast Board PCB Assembly cont Figure 3 36 700W Ballast Board PCB Assembly...

Page 121: ...6 R433 9 60 9463 1004 1 EA RES 1 8W 1 10 O K 200V CHP THK FLM S MT1206 R306 10 60 9463 1005 1 EA RES 1 8W 1 100 0 K 200V CHP THK FLM S MT1206 R408 11 60 9463 1215 1 EA RES 1 8W 1 121 0 K 200V CHP THK...

Page 122: ...A RES 1 8W 5 47 0 K 200V CHP THK FLM S MT1206 R302 30 60 9464 7505 1 EA RES 1 8W 5 750 0 K 200V CHP THK FLM S MT1206 R421 31 60 9464 8204 1 EA RES 1 8W 5 82 0 K 200V CHP THK FLM S MT1206 R305 32 62 30...

Page 123: ...5 EA CAP 4 7UF 50V ALUM ELECTRO SUR MT LOW ESR C308 C405 C406 C420 C424 48 62 4224 0107 1 EA CAP 100UF 35V 20 AL ELEC 8MM DIA 105C S MT C409 49 63 2049 0001 1 EA POT 500 OHM CERMET 13 TRN SUR MT R410...

Page 124: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 106 09 December 2004 02 9676 0022 0 Notes...

Page 125: ...04 107 Cables Ground Strap Cable Assembly 25 8007 2212 Rev 0 Refer to Figure 3 48 Figure 3 48 Ground Strap Cable Assembly No Item Qty UM Description 1 52 8329 0001 2 EA TERM RING 6 22 16 AWG NON INS 2...

Page 126: ...Cable Assembly 25 9661 1514 Rev A Refer to Figure 3 49 Figure 3 49 LVS Chassis Ground Cable Assembly No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8271 0001...

Page 127: ...109 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev B Refer to Figure 3 50 Figure 3 50 Chassis To Yoke Ground Cable Assembly No Item Qty UM Description 1 52 8250 0001 2 EA TERM 8 RING 10AWG 2...

Page 128: ...ssembly 25 9667 0030 Rev A Refer to Figure 3 51 Figure 3 51 Ignitor To Relay Cable Assembly No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8312 0001 1 EA RECP...

Page 129: ...11 Tilt Plate Ground Cable Assembly 25 9667 0413 Rev A Refer to Figure 3 52 Figure 3 52 Tilt Plate Ground Cable Assembly No Item Qty UM Description 1 52 8311 0003 1 EA TERM RING 6 BLUE 14 16 AWG NON I...

Page 130: ...3 53 Color Gobo T Stat Cable Assembly No Item Qty UM Description 1 52 6523 0002 1 EA CONN HOUSING 2POS PLUG SHROUD 2 52 8347 0001 2 EA CONTACT 24 30 AWG MALE CRIMP 3 55 2268 0125 1 00 IN HEATSHRINK 1...

Page 131: ...TA100 7 52 6467 0006 2 EA CONN FEMALE 6 POS 30 24 AWG CRIMP PHR 8 52 6467 0024 10 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 9 52 6661 0006 4 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 10 52 83...

Page 132: ...LUMINAIRE SERVICE MANUAL 114 09 December 2004 02 9676 0022 0 Color Fixed Bulkheads Cable Assembly cont Figure 3 54 Color Fixed Bulkheads Cable Assembly 16 7 8 14 9 10 11 x6 13 x2 12 14 7 8 2 3 4 15 5...

Page 133: ...2034 1 EA COVER BACK 34 POS MT 5 52 6524 0004 2 EA CONN HOUSING 4 POS RECEPT 6 52 6524 0005 1 EA CONN HOUSING 5 POS RECEPT 7 52 6661 0006 1 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 8 52 8346 000...

Page 134: ...ANUAL 116 09 December 2004 02 9676 0022 0 Optics Strobe Bulkheads Cable Assy cont Figure 3 55 Optics Strobe Bulkheads Cable Assembly 12 2 3 4 1 1 13 5 8 13 7 9 13 5 8 11 1 Note OPEN positions will hav...

Page 135: ...LABEL STROBE 1 2 52 6523 0004 1 EA CONN HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE 3 52 6661 0006 1 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 4 52 8347 0001 4 EA CONTACT 24 30 AWG MALE CRIMP 5 52...

Page 136: ...4 0002 1 EA CONN HOUSING 2 POS RECEPT 3 52 6524 0005 1 EA CONN HOUSING 5 POS RECEPT 4 52 8230 0003 2 EA RECEPT 1 4 FASTON 22 18 AWG 5 52 8346 0001 7 EA CONTACT 24 30 AWG FEMALE CRIMP 6 55 2186 0001 1...

Page 137: ...v 0 Refer to Figure 3 58 Figure 3 58 OT Switch to Reflector Assy Cable Assembly No Item Qty UM Description 1 52 8271 0010 1 EA RECEPT FASTON 24 22 AWG NON INSUL 0 016 TAB 110SERIES 2 52 8371 0001 1 EA...

Page 138: ...VER FRONT 20 POS MT LATCHING 3 52 6224 2020 1 EA COVER BACK 20 POS MT 4 52 6524 0005 2 EA CONN HOUSING 5 POS RECEPT 5 52 6588 0007 2 EA HOUSING 7 POS 250V 3A 2 5 MM PITCH 6 52 7007 0001 6 EA CONTACT 2...

Page 139: ...ILLUSTRATED PARTS BREAKDOWN CABLES 3 02 9676 0022 0 09 December 2004 121 Pan Tilt Control Cable Assembly continued Figure 3 59 Pan Tilt Control Cable Assembly 1 2 3 4 7 x5 6 x3 5 4 7 x5 6 x3 5 8 x7...

Page 140: ...Power Switch Cable Assembly No Item Qty UM Description 1 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 2 52 8392 0001 2 EA RECP FASTON 187 X0 32 16 14 AWG FLAG DBL CRP 3 55 2186 0001 1...

Page 141: ...ON 187 X0 32 16 14 AWG FLAG DBL CRP 5 52 8270 0001 2 EA CONTACT PIN 20 14AWG MNLOK REEL 6 52 8314 0001 1 EA PIN GND 20 14AWG MNLOK 060 130 INS DIA 7 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 8 5...

Page 142: ...ITE VL2500 WASH LUMINAIRE SERVICE MANUAL 124 09 December 2004 02 9676 0022 0 AC Input Splitter Cable Assembly continued Figure 3 61 AC Input Splitter Cable Assembly 2 x2 4 x2 12 5 9 5 10 13 11 6 3 1 7...

Page 143: ...bly 25 9678 0813 Rev 0 Refer to Figure 3 62 Figure 3 62 Data I O Link Cable Assembly No Item Qty UM Description 1 52 6396 2204 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END 2 52 6396 2205 1 EA RECEP...

Page 144: ...02 9676 0022 0 Display Cable Assembly 25 9678 0815 Rev 0 Refer to Figure 3 63 Figure 3 63 Display Cable Assembly No Item Qty UM Description 1 52 6396 2406 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD E...

Page 145: ...ure 3 64 Figure 3 64 Ballast to Controller Cable Assembly No Item Qty UM Description 1 52 6396 2402 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END 2 52 6396 2405 1 EA RECEPT 5 POS MTA100 W POL TAB WH...

Page 146: ...lay Cable Assembly No Item Qty UM Description 1 52 8312 0001 4 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 2 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 3 55 6699 0003 3 75 FT SLEEVING 1 2 NOM DIA P...

Page 147: ...A TERM RING 6 BLUE 12 10 AWG INSRT 4 52 8323 0001 4 EA CONTACT CRIMP 18 22 AWG SL 156 5 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 BLUE 150 OD MAX 6 55 2186 0001 4 EA CABLE TIE 01 x 4 00 SMALL 7 55 6699...

Page 148: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL 130 09 December 2004 02 9676 0022 0 Notes...

Page 149: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9676 0022 0 09 December 2004 131 VL2500 Wash Luminaire Schematics 700W Ballast Schematic...

Page 150: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9676 0022 0 09 December 2004 132 700W Ballast Schematic continued...

Page 151: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9676 0022 0 09 December 2004 133 Ballast Rider Schematic...

Page 152: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9676 0022 0 09 December 2004 134 VL2500 Luminaire Schematic...

Page 153: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9676 0022 0 09 December 2004 135 VL2500 Luminaire Schematic continued...

Page 154: ...VARI LITE VL2500 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9676 0022 0 09 December 2004 136 VL2500 Luminaire Schematic continued...

Page 155: ...N BY FAE COP YRIGHT 2004 14 9676 0730 B0 SCHEMATIC VL2500 CONTROLLER Tuesday July 20 2004 DESCRIPTION DATE APPROVED REV NO ECO A0 CONNECT SENSE AT LOAD CONNECT SENSE AT LOAD NOTES UNLESS OTHERWISE SPE...

Page 156: ...5MHz BE R W PAR PORT 16 BIT BUS AUTO ACK 2 B2 2 B3 2 B4 2 B4 2 B2 2 B3 2 B2 2 B3 2 B2 2 B3 2 B2 2 B4 2 A6 2 B2 2 B3 2 B4 2 B4 2 B2 2 B3 2 B2 2 B3 2 B2 2 B3 2 B2 2 B4 2 A6 3 B3 3 A3 2 C3 3 D6 3 A3 2 C...

Page 157: ...C5 4 A8 8 C5 8 D4 8 D4 7 B5 7 B3 2 B4 2 D6 2 D6 2 B4 2 A6 4 A8 5 C8 5 C8 4 A8 4 A8 2 B4 2 C4 2 C4 2 C6 4 A8 4 A8 4 A8 4 B8 4 B8 5 D8 4 B8 4 B8 5 B8 5 B8 5 C8 5 B8 5 B8 7 B3 4 B8 4 B8 4 B8 4 B8 7 B7 6...

Page 158: ...POWER 10 C2 10 C2 10 C2 10 C2 4 A3 4 B2 4 A3 4 B2 4 B3 4 B2 4 A3 3 A6 3 A6 3 A6 3 B6 3 B6 3 B6 3 B6 3 D3 3 D3 3 D3 3 D4 4 B6 4 B5 4 B6 4 A6 4 B6 4 B6 4 B6 4 B5 3 C3 3 C3 3 C3 3 C3 10 B5 10 B3 10 C3 10...

Page 159: ...NTROL DRAWN BY FAE COP YRIGHT 2004 14 9676 0730 B0 SCHEMATIC VL2500 CONTROLLER Tuesday July 20 2004 3 D3 3 A6 3 D3 3 A6 10 D3 10 D3 10 D3 3 D3 3 A6 3 D3 3 A6 10 D3 10 D3 10 D3 PAN TILT 3 C6 2 A3 6 C8...

Page 160: ...10 C5 10 C7 10 C5 10 C7 10 C3 3 C3 3 C3 3 C3 3 C3 10 C7 10 C3 10 C7 10 C3 10 C7 10 C3 10 C7 10 C3 3 C6 3 C6 10 C7 10 C3 10 C7 10 C3 10 C7 10 C3 10 C7 10 C3 3 C6 3 C6 3 C6 3 C6 10 6 C125 R135 R140 R97...

Page 161: ...C4 10 B1 10 C4 10 B1 10 C4 10 B1 10 C4 10 B1 EDGE ZOOM 3 C6 3 B3 3 C3 3 C3 10 B7 10 C4 10 B7 10 C4 10 B7 10 C4 10 B7 10 C4 10 7 C161 C154 C118 R191 C156 C139 R149 C158 R173 R194 C149 R145 R181 C150 R1...

Page 162: ...8 3 C6 3 B3 3 B3 3 B3 10 D6 10 A3 10 D6 10 A5 10 D6 10 A5 10 D6 10 A3 3 B3 3 C3 3 C3 3 C3 10 D6 10 A3 10 D6 10 A5 10 D6 10 A5 10 D6 10 A3 10 8 R237 C176 C174 C182 C163 C183 R214 C152 R202 C185 R235 R2...

Page 163: ...1 8V Title Size Document Number Rev Date SHEET OF D GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 INFORMATIONANDDESIGNDISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRO...

Page 164: ...5 6 D5 10 C5 6 D5 10 C3 6 B5 10 C3 6 B5 10 C5 6 B5 10 C5 6 B5 10 C3 6 D2 10 C3 6 D2 10 C5 6 D2 10 C5 6 D2 10 C3 6 B2 10 C3 6 B2 10 C5 6 B2 10 C5 6 B2 10 C3 7 D5 10 C3 7 D5 10 C5 7 D5 10 C5 7 D5 10 C3...

Page 165: ...D MAY NOT BE IS THE SOLE AND EXCLUSIVE PROPERTY ALL INFORMATION CONTAINED HEREIN CONFIDENTIAL DRAWN BY MFG DOC CHK DSN DRAWING NUMBER REVISION SIZE OF SHEET 8 201 REGAL ROW DALLAS TEXAS 75247 B A B C...

Page 166: ...NO Filename REVISIONS eProduct Designer 2 0 SIZE D REVISION DRAWING NUMBER REV SHEET OF APPD DSN CHK DOC MFG MOUNTING HOLES C3 C7 C9 R2 R5 R12 R13 R16 9 16 02 B C ENG RELEASE PER EO 09082 2 A REL TO...

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