Vari Lite VL500 Wash Luminaires Service Manual Download Page 145

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LLUSTRATED

ARTS

REAKDOWN

0 2 . 9 6 8 5 . 0 0 1 0 0

17 -Ju ly- 200 6

113

Yoke Assembly

VL500 Yoke Assembly

21.9685.0520 (VL500) Rev S
21.9685.0521 (VL500D) Rev S
21.9685.0522 (VL500A) Rev S

Refer to

Figure 3-39

Figure 3-40

No.

Item

Qty.

UM.

Description

10.9685.0534

COVER, PAN TUBE

10.9685.0537

PLATE, MOUNTING, LAMP POWER PIGTAIL

(VL500 ONLY)

10.9685.0538

BEZEL, LAMP POWER PIGTAIL

(VL500 ONLY)

10.9685.0560

YOKE LEG, TILT SIDE

10.9685.0561

YOKE LEG, DIMMER SIDE

10.9685.0562

PLATE, TILT MOTOR, SLIDE

10.9685.0596

MOUNT, FAN, LVS

21.9685.0515

ASSY, YOKE CROSSMEMBER

21.9685.0540

ASSY, PAN/TILT MOTOR

23.9685.0782

ASSY, FAN MCB

24.9663.1895

PCB ASSY, DMX INPUT

24.9685.0740

TEMPERATURE BOARD, LVS

25.9663.2030

CABLE ASSY, INCANDESCENT POWER

(VL500 ONLY)

25.9685.0756

CABLE ASSY, AC INPUT

25.9685.0757

CABLE ASSY, ARC BALLAST INPUT

(VL500A ONLY)

25.9685.0770

DISPLAY CABLE RECEPTACLE, BLACK

25.9685.0790

CABLE ASSY, MAIN HARNESS, INCANDESCENT

(VL500 AND

VL500D ONLY) (NOT SHOWN)

25.9685.0791

CABLE ASSY, MAIN HARNESS, ARC

(VL500A ONLY) (NOT

SHOWN)

28.9685.0999

KIT, EXTRA US HARDWARE

(NOT SHOWN)

51-0541

SCREW, #4X3/8" H/L PN BLK ZN

52.8295.0002

TERMINAL BLOCK, 300V 12 AWG 20A 2-POS

53.2001.0003

NUT, 10-32 NYLOCK

53.2200.0004

NUT, 4-40 KEPS SS

53.2200.0006

NUT, 6-32 KEPS SS

(VL500D AND VL500A ONLY)

53.2202.0004

NUT, 4-40 HEX SS NYLON INSERT

Summary of Contents for VL500 Wash Luminaires

Page 1: ......

Page 2: ...0 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...

Page 3: ...gistered 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 sh...

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...

Page 5: ...se only with certain Philips and Osram HID lamps Note lamp type MSR400 MSR575HR etc before replacing lamps Installing another type of lamp may be hazardous 2 Luminaires may be mounted on any type of s...

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 a...

Page 7: ...pentyps 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 Ers...

Page 8: ...steht 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: ...nes 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 fi...

Page 10: ...es 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 peuvent c...

Page 11: ...n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalaci n Vea las instrucciones detallada...

Page 12: ...a l mpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las part culas de la l mpara rota que se caen 4 Use protecci n para los ojos cuando vuelve a colocar un...

Page 13: ...SAFETY NOTICE JAPANESE 02 9685 0010 0 17 July 2006 xiii...

Page 14: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL xiv 17 July 2006 02 9685 0010 0...

Page 15: ...02 9685 0010 0 17 July 2006 xv CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Component Descriptions Principles of Operation...

Page 16: ...wash 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...

Page 17: ...Standard 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...

Page 18: ...ernal ballast unit Standard color dichroic glass DICHRO TUNETM color system VL500A Wash Luminaire 20 9685 0015 575W arc lamp source with external ballast unit Pastel color dichroic glass DICHRO TUNETM...

Page 19: ...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 Disp...

Page 20: ...nt Ring Backcap Assembly Provides access to lamp for replacement Amber Diffuser Assembly Tungsten Models DICHRO TUNE color bulkhead 16 radially mounted diffuser panels for beam control and amber dichr...

Page 21: ...t 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 m...

Page 22: ...pply side of the luminaire yoke assembly 80V Dimmer 120W Power Supply Supplies power to electronic and motor components 120V or 230V IGBT Dimmer Module IGBT Dimmer Yoke Arm Cover Module 80V Dimmer Yok...

Page 23: ...and 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 t...

Page 24: ...r Note For detailed information on wiring connections signals etc please refer to VL500 Wiring Diagram Sheet 1 of 1 on page 163 J3 J8 J6 Magenta J4 Motor Blue Motor Amber Motor Diffuser Motor J7 DMX P...

Page 25: ...tion on wiring connections signals etc please refer to VL500 Wiring Diagram Sheet 1 of 1 on page 163 J3 J8 J6 Magenta J4 Motor Blue Motor Amber Motor Diffuser Motor J7 DMX PCB J6 Thru In LVS Luminaire...

Page 26: ...information on wiring connections signals etc please refer to VL500 Wiring Diagram Sheet 1 of 1 on page 163 J3 J8 J6 Magenta J4 Motor Blue Motor Amber Motor Diffuser Motor J7 DMX PCB J6 Thru In LVS L...

Page 27: ...refer to VL500 Wiring Diagram Sheet 1 of 1 on page 163 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 Therm...

Page 28: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL xxviii 17 July 2006 02 9685 0010 0 Notes...

Page 29: ...v VL500D Incandescent Luminaires xxv VL500D Incandescent Block Diagram With On Board IGBT Dimmer xxv VL500 80V Incandescent Luminaires xxvi VL500 80V Incandescent Block Diagram With On Board 80V Dimme...

Page 30: ...acement VL500 VL500D VL500A Only 38 Low Voltage Supply LVS Temperature PCB Replacement VL500 VL500D VL500A Only 39 Low Voltage Supply LVS Replacement VL500 80V Only 40 Low Voltage Supply LVS Temperatu...

Page 31: ...y 110 Magenta Blue Color Motor Assembly 111 Amber Diffuser Color Motor Assembly 112 Yoke Assembly VL500 Yoke Assembly 113 VL500 80V Yoke Assembly 117 VL500 Extra Hardware Kit 121 VL500 Pan Tilt Motor...

Page 32: ...I O Cable Assembly 161 VL500 Wiring and Schematic Diagrams VL500 Wiring Diagram Sheet 1 of 1 163 DMX Input PCB 24 9663 1895 Schematic 164 VL500 Controller PCB 24 9685 0730 Schematic Sheet 1 of 6 165 V...

Page 33: ...e for this VARI LITE product 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...

Page 34: ...revised Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business succeed and en...

Page 35: ...andling 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...

Page 36: ...form To alleviate this when testing in groups only test same Lamp Type luminaires for example VL500A wash 575W arc with other VL500A wash 575W arc lights VL500 wash 120V 1200W tungsten wash with other...

Page 37: ...uminaire 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 Men...

Page 38: ...nd 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 movem...

Page 39: ...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 Ma...

Page 40: ...tual lamp hours used please read the note below 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...

Page 41: ...mps 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...

Page 42: ...om electrode thereby reducing lamp life Solid State Electronics Electrostatic Discharge ESD Electrostatic discharge ESD presents a significant danger to solid state electronic components semiconductor...

Page 43: ...r from 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...

Page 44: ...lcohol and soft lint free cloth to thoroughly clean glass portion of lamp Step 5 Remove lamp by pulling straight out of socket Step 6 Carefully clean reflector with soft lint free cloth to remove dust...

Page 45: ...ep 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 s...

Page 46: ...p 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 lum...

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 S...

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 ne...

Page 49: ...E 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...

Page 50: ...M 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 gla...

Page 51: ...LKHEADS 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 inpu...

Page 52: ...own 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...

Page 53: ...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 indi...

Page 54: ...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 throug...

Page 55: ...To remove and replace color filters or diffuser panels Step 1 Ensure glass filter or diffuser panels are in closed position WARNING Remove power from luminaire before performing maintenance Step 2 Re...

Page 56: ...or diffuser panels Step 8 Remove filter or panel as follows shown in Figure 12 a At filter or panel gently push assembly with silicon pad in towards center hub away from carrier and work end of tweake...

Page 57: ...he luminaire head horizontally 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 Dif...

Page 58: ...6 17 July 2006 02 9685 0010 0 Step 10 Remove dimmer panel from center hub Figure 14 Dimmer Panel Replacement Step 11 Replace by performing steps 3 through 10 in reverse order Dimmer Panel Bulkhead Cen...

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 Re...

Page 60: ...r using 1 Phillips screwdriver remove two 4 40x1 4 PPZ screws securing linear actuator motor to actuator mount and remove motor See Figure 16 Figure 16 Magenta Blue Linear Actuator Motor Replacement S...

Page 61: ...e 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 Motor...

Page 62: ...r using 1 Phillips screwdriver remove two 4 40x1 4 PPZ screws securing linear actuator motor to actuator mount and remove motor See Figure 18 Figure 18 Amber Diffuser or Dimmer Linear Actuator Motor R...

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 la...

Page 64: ...GBT 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 g...

Page 65: ...tenance 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 21...

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 extens...

Page 67: ...ve four 6 32x1 4 PPB screws Figure 23 Display PCB Replacement 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 th...

Page 68: ...ket Assembly VL500 and VL500D Only Replacement on page 31 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...

Page 69: ...7 Remove Main Control 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 Contro...

Page 70: ...move power from luminaire Step 2 Remove yoke arm cover opposite display side by removing four 6 32x3 8 screws Figure 25 LVS Replacement VL500 VL500D VL500A Only Step 3 Disconnect the following wiring...

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 38 Figure 26 LVS Temperature PCB Replacement VL500...

Page 72: ...At pan tube cover remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note tether will still hold cover Figure 27 LVS Replacement VL500 80V Only Step 5 Disconnect the following wiring connect...

Page 73: ...uminaire Step 2 Remove LVS by following procedure Low Voltage Supply LVS Replacement VL500 80V Only on page 40 Figure 28 LVS Temperature PCB Replacement VL500 VL500D VL500A Only Step 3 Disconnect the...

Page 74: ...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 procedur...

Page 75: ...TIRE 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 performin...

Page 76: ...r 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 pul...

Page 77: ...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 44 S...

Page 78: ...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 Ign...

Page 79: ...crews 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 CA...

Page 80: ...2 9685 0010 0 Figure 33 IGBT Dimmer Replacement VL500D Only Step 7 Replace IGBT Dimmer by performing Steps 2 through 6 in reverse 6 32x3 8 PTB Screws x4 Some components not shown for clarity NOTE IGBT...

Page 81: ...t remove four 6 32x3 8 PPZ screws Step 4 Carefully remove 80V 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 th...

Page 82: ...2 9685 0010 0 Figure 34 80V Dimmer Replacement VL500 80V only Step 7 Replace 80V Dimmer by performing Steps 2 through 6 in reverse 6 32x3 8 PTB Screws x4 Some components not shown for clarity NOTE 80V...

Page 83: ...move power from luminaire before performing 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...

Page 84: ...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...

Page 85: ...gure 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...

Page 86: ...p 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 Replac...

Page 87: ...r 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...

Page 88: ...nd precautions The front lens optics color filters and reflector may require cleaning after extended use FRONT LENS Use a common glass cleaner along with a soft lint free cloth to clean the front lens...

Page 89: ...rc 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 V...

Page 90: ...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...

Page 91: ...ev J Upper Crossmember Assembly 21 9685 0513 Rev G Pan Tube Assembly 21 9685 0535 Rev D VL500 VL500D VL500A continued from previous page Yoke Crossmember Assembly 21 9685 0515 Rev E VL500 AC Input Cab...

Page 92: ...r 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...

Page 93: ...ware Kit 28 9685 0999 Rev 0 Lower Crossmember Assembly 21 9685 0512 Rev J Upper Crossmember Assembly 21 9685 0513 Rev G 80V Pan Tube Assembly 21 9685 0536 Rev 0 VL500 80V continued from previous page...

Page 94: ...5 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 S VL500 Pan Tilt Motor Assembly 21 9685 0540 Rev B VL5...

Page 95: ...e 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 Ass...

Page 96: ...W Arc Pastel Colors Arc Ballast Refer to Figure 3 7 No Item Qty UM Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8001 0002 1 EA QA CERTIFICATE VARI LITE 3 02 80...

Page 97: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 65 Included Items Kit continued Figure 3 7 Included Items Kit 5 8 4 1 2 3 7 9 Arc Models Only 10 Arc Models Only 11 6...

Page 98: ...30V 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...

Page 99: ...926 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 MODELS...

Page 100: ...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 SERVICEABL...

Page 101: ...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 0...

Page 102: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 70 17 July 2006 02 9685 0010 0 Figure 3 9 VL500 Luminaire 120V or 230V 9 12 7 4 x2 5 6 8 14 x8 13 x8 11 10 15 x8 16 x8 3 1 2...

Page 103: ...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...

Page 104: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 72 17 July 2006 02 9685 0010 0 Figure 3 10 VL500D with 120V IGBT Dimmer Luminaire 11 14 9 7 8 10 17 x8 15 x8 12 13 18 x8 5 x2 19 x8 6 x2 20 16 x8 3 4 1 2...

Page 105: ...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...

Page 106: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 74 17 July 2006 02 9685 0010 0 Figure 3 11 VL500D with 230V IGBT Dimmer Luminaire 11 14 9 7 8 10 17 x8 15 x8 12 13 18 x8 5 x2 19 x8 6 x2 20 16 x8 3 4 1 2...

Page 107: ...21 9685 0012 1 EA ASSY 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 ON...

Page 108: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 76 17 July 2006 02 9685 0010 0 Figure 3 12 VL500 80V with 80V Dimmer Luminaire 11 16 10 6 7 19 x8 14 15 17 x8 5 x2 21 x8 8 18 x8 3 4 1 2 20 x8 13 9 12 22...

Page 109: ...IMMER 9 21 9685 0173 1 EA ASSY COLOR MAGENTA BLUE ARC STANDARD 20 9685 0005 ONLY 21 9685 0175 1 EA ASSY COLOR MAGENTA BLUE ARC PASTEL 20 9685 0015 ONLY 21 9685 0800 1 EA ASSY BALLAST 625W EXTERNAL NOT...

Page 110: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 78 17 July 2006 02 9685 0010 0 Figure 3 13 VL500A Luminaire 575W Arc 8 12 7 4 x2 5 6 9 14 x8 13 x8 11 10 15 x8 16 x8 3 1 2...

Page 111: ...IMMER 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...

Page 112: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 80 17 July 2006 02 9685 0010 0 Figure 3 14 VL500A Luminaire 700W Arc 8 12 7 4 x2 5 6 9 14 x8 13 x8 11 10 15 x8 16 x8 3 1 2...

Page 113: ...T TUBE 11 10 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...

Page 114: ...06 0021 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 37 55 2187 00...

Page 115: ...Generic VL500 Luminaire Assembly continued Figure 3 15 Generic VL500 Luminaire Assembly VL500 and VL500D 28 16 VL500 Only 4 3 38 22 20 39 36 36 12 VL500D Only 27 25 11 1 31 26 25 32 5 34 10 13 9 7 8...

Page 116: ...AL 84 17 July 2006 02 9685 0010 0 Generic VL500 Luminaire Assembly continued Figure 3 16 Generic VL500 Luminaire Assembly VL500 80V 28 19 4 3 38 22 20 39 36 12 27 25 11 1 31 26 25 32 5 34 10 15 9 30 x...

Page 117: ...17 July 2006 85 Generic VL500 Luminaire Assembly continued Figure 3 17 Generic VL500 Luminaire Assembly VL500A 28 18 4 3 38 22 20 39 36 36 25 11 1 31 26 25 32 5 34 10 14 9 7 8 2 43 42 35 40 24 6 27 2...

Page 118: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 86 17 July 2006 02 9685 0010 0 Notes...

Page 119: ...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 INCANDESC...

Page 120: ...LUMINAIRE SERVICE MANUAL 88 17 July 2006 02 9685 0010 0 VL500 Generic Head Assembly continued Figure 3 18 VL500 Generic Head Assembly VL500 and VL500D 5 14 x4 12 x2 8 16 15 12 x2 1 6 13 x4 18 20 2 2 7...

Page 121: ...D PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 89 VL500 Generic Head Assembly continued Figure 3 19 VL500 Generic Head Assembly VL500A 5 14 x4 12 x2 9 16 15 12 x2 1 6 13 x4 18 20 2 2 7 19 21 4 3 12 x...

Page 122: ...00 LUMINAIRE SERVICE MANUAL 90 17 July 2006 02 9685 0010 0 VL500 Generic Head Assembly continued Figure 3 20 VL500 Generic Head Assembly VL500 80V 5 14 x4 12 x2 10 16 15 12 x2 1 6 13 x4 18 20 2 2 7 19...

Page 123: ...EFLECTOR 10 23 9685 0780 1 EA ASSY VL500 LAMP SOCKET HIGH TEMP VL500 ONLY 25 9685 0766 1 EA 575W 700W 80V LAMP WIRES IGNITOR TO SOCKET VL500A AND VL500 80V ONLY NOT SHOWN 25 9685 0777 1 EA CABLE ASSY...

Page 124: ...E VL500 LUMINAIRE SERVICE MANUAL 92 17 July 2006 02 9685 0010 0 VL500 Heatsink Assembly continued Figure 3 21 VL500 Heatsink Assembly VL500 and VL500D 14 x2 6 10 4 19 x2 18 15 x4 13 x3 20 x3 2 x3 5 1...

Page 125: ...D PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 93 VL500 Heatsink Assembly continued Figure 3 22 VL500 Heatsink Assembly VL500A 19 x2 7 16 x2 18 15 x4 13 x3 20 x3 2 x3 23 1 x3 11 17 x3 22 x3 21 x3 3 x...

Page 126: ...0 LUMINAIRE SERVICE MANUAL 94 17 July 2006 02 9685 0010 0 VL500 Heatsink Assembly continued Figure 3 23 VL500 Heatsink Assembly VL500 80V 19 x2 7 16 x2 18 15 x4 13 x3 20 x3 2 x3 23 1 x3 11 12 x3 22 x3...

Page 127: ...o Figure 3 24 Figure 3 24 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 21 968...

Page 128: ...efer to Figure 3 25 Figure 3 25 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 TU...

Page 129: ...3 26 Figure 3 26 VL500 Amber Diffuser Color Assembly No Item Qty UM Description 1 10 9685 0245 2 EA LIGHT BAFFLE TOP 2 21 9685 0161 1 EA ASSY AMBER DIFFUSER DICRO TUNE 3 21 9685 0281 1 EA MOTOR ASSY...

Page 130: ...Figure 3 27 Figure 3 27 VL500 Amber Dimmer Color Assembly No Item Qty UM Description 1 10 9685 0245 2 EA LIGHT BAFFLE TOP 2 21 9685 0162 1 EA ASSY AMBER DIMMER DICRO TUNE 3 21 9685 0281 1 EA MOTOR AS...

Page 131: ...enta 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...

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 TUN...

Page 133: ...ta 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 E...

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 015...

Page 135: ...er 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 ASS...

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...

Page 137: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 105 Figure 3 33 Amber Dimmer Color Assembly 4 8 x16 2 x16 6 x16 5 x16 1 x16 11 x16 7 9 2 x16 3 x16 10 x16 1 x16...

Page 138: ...3 34 No Item Qty UM Description 1 10 9661 0315 4 EA SUPPORT BULKHEAD 2 21 9685 0251 2 EA ASSY DRIVE RING 3 22 9634 0119 1 EA ASSY CENTER HUB 4 22 9685 0201 1 EA ASSY GENERIC BULKHEAD 5 53 6682 0002 12...

Page 139: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 107 Bottom Bulkhead Assembly continued Figure 3 34 Bottom Bulkhead Assembly 3 4 7 x4 1 x4 2 5 x4 5 x8 2 6 x10...

Page 140: ...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...

Page 141: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 109 Top Bulkhead Assembly continued Figure 3 35 Top Bulkhead Assembly 4 3 5 2 x2 7 x10 1 x4 3 6 x4 6 x8 9 x4 8 x4...

Page 142: ...4 0105 1 EA LINK SWIVEL 2 10 9685 7240 8 EA ROLLER DRIVE RING 3 22 9685 0238 1 EA RING DRIVE 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...

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...

Page 144: ...em 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 66...

Page 145: ...10 23 9685 0782 1 EA ASSY FAN MCB 11 24 9663 1895 1 EA PCB ASSY DMX INPUT 12 24 9685 0740 1 EA TEMPERATURE BOARD LVS 13 25 9663 2030 1 EA CABLE ASSY INCANDESCENT POWER VL500 ONLY 14 25 9685 0756 1 EA...

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 STAND...

Page 147: ...N 3 02 9685 0010 0 17 July 2006 115 VL500 Yoke Assembly continued Figure 3 39 VL500 Yoke Assembly VL500 VL500D VL500A 25 x2 27 x6 31 37 1 19 18 x2 21 x4 11 15 VL500A 40 VL500D 30 x4 17 x4 8 29 x2 14 2...

Page 148: ...VICE MANUAL 116 17 July 2006 02 9685 0010 0 VL500 Yoke Assembly continued Figure 3 40 VL500 Yoke Assembly VL500 VL500D VL500A 24 x4 33 41 x6 39 36 x4 9 7 22 x4 10 32 23 x3 35 x3 12 42 34 5 44 x4 27 x1...

Page 149: ...685 0740 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 DIS...

Page 150: ...01 4 EA SCREW 4 40X1 4 PPZ 30 55 3301 0008 8 EA WASHER 8 FLAT SS 31 55 3301 0010 1 EA WASHER 10 FLAT 32 55 6543 0001 2 4 FT GROMMET STRIP SERRATED 0 062 33 55 6568 0056 2 EA SPRING CPRSN 0 600 OD 0 08...

Page 151: ...BREAKDOWN 3 02 9685 0010 0 17 July 2006 119 VL500 80V Yoke Assembly continued Figure 3 41 VL500 80V Yoke Assembly 29 x4 22 x6 27 3 31 18 1 35 5 4 24 x4 24 x2 11 19 x2 13 23 9 19 x2 25 x2 14 24 x2 15...

Page 152: ...ARI LITE VL500 LUMINAIRE SERVICE MANUAL 120 17 July 2006 02 9685 0010 0 VL500 Yoke Assembly continued Figure 3 42 VL500 80V Yoke Assembly 20 x4 33 34 x6 28 30 x4 10 7 22 x12 21 10 8 30 x4 21 x6 6 32 3...

Page 153: ...he foot of the fixture underneath the pan tube cover Refer to Figure 3 44 Figure 3 43 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 POLYETHYLEN...

Page 154: ...TMENT PAN TILT 2 21 9685 0545 1 EA ASSY DRIVE PULLEY VL500 10 9685 0720 1 EA PULLEY DRIVE PAN TILT 2MM GT 18 TOOTH 10 9678 0720 1 EA CODEWHEEL 120 COUNT LARGE ID 3 24 9685 7735 1 EA BOARD ASSY PAN TIL...

Page 155: ...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 0730 1 EA MCB V...

Page 156: ...85 0010 0 MCB Fan Assembly 23 9685 0782 Rev 0 Refer to Figure 3 44 Figure 3 46 MCB Fan Assembly No Item Qty UM Description 1 40 7113 0007 1 EA FAN 12VDC 30X10 MM 3 3CFM 2 52 6450 0002 1 EA CONNECTOR M...

Page 157: ...n 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 CROSS...

Page 158: ...on 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 CROS...

Page 159: ...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 087...

Page 160: ...LITE VL500 LUMINAIRE SERVICE MANUAL 128 17 July 2006 02 9685 0010 0 Lower Crossmember Assembly continued Figure 3 49 Lower Crossmember Assembly 7 x2 11 14 x2 3 x2 4 1 5 x2 13 x2 12 x2 9 8 2 10 x2 15...

Page 161: ...to Figure 3 49 Figure 3 50 Upper Crossmember Assembly No Item Qty UM Description 1 10 9685 0510 1 EA UPPER CROSSMEMBER 2 10 9685 0527 2 EA WASHER CENTERING STEP 3 53 2020 0001 2 EA NUT 1 4X20 HEX STL...

Page 162: ...VL500D VL500A Refer to Figure 3 51 Figure 3 51 Pan Tube Assembly VL500 VL500D VL500A No Item Qty UM Description 1 10 9685 0521 1 EA PULLEY DRIVEN PAN TILT 2 10 9685 0531 1 EA PAN TUBE 3 10 9685 0532...

Page 163: ...500 80V Refer to Figure 3 52 Figure 3 52 80V Pan Tube Assembly VL500 80V No Item Qty UM Description 1 10 9685 0521 1 EA PULLEY DRIVEN PAN TILT 2 10 9685 0532 1 EA PAN PULLEY SPACER 3 12 9685 0553 1 EA...

Page 164: ...Item Qty UM Description Ref 1 11 9663 1895 1 EA PCB DMX INPUT 35 0053 2 EA DIODE ZENER 6 2V 1W SM NOT SHOWN D1 D2 2 52 6259 0001 1 EA HEADER 5POS MTA FRCT LOK STRT POST J3 3 52 6625 0005 1 EA CONN REC...

Page 165: ...P 4 7UF 35V C28 25 0100 2 EA CAP 220PF 50V 10 NPO CER 0805 33 0043 2 EA DIODE 3A 1N5404 D45 D46 33 0118 2 EA DIODE ZNR 3 3V 1N4684 D47 D48 40 0867 1 EA HEADER 10 POS SHROUDED J3 52 6259 0003 1 EA HEAD...

Page 166: ...P THK FLM SMT0402 R54 R58 R63 R68 60 1165 4703 15 EA RES 1 16W 5 4 7 K CHIP THK FLM SMT0402 R3 11 R22 R36 R85 86 R165 166 60 3242 1000 8 EA RES 1W 1 1 0 OHM WW SUR MT R105 106 R119 120 R131 132 R142 1...

Page 167: ...EA DIODE BAT54SLT1 DUAL SCHOTTKY CATHODE TO ANODE CONNECTED 30V 200MA D7 8 82 5361 0001 6 EA DIODE ZENER TVS 10V 23A SMT Z1 6 82 5362 0001 28 EA DIODE SCHOTTKY BARRIER RECTIFIER 40V 1A SMT D9 11 D13 1...

Page 168: ...NITOR W PUSHBUTTON SMT U4 86 6105 0001 4 EA IC HCPL 0600 OPTO COUPLER SMD U12 U16 U19 U21 87 7248 0001 1 EA IC AM29LV400BB 44REI 4MEGBIT FLASH MEMORY U2 87 7404 0001 1 EA IC M24C02WMN6T EEPROM BLANK 2...

Page 169: ...ty 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...

Page 170: ...to Figure 3 56 Figure 3 56 80V LVS AC Cable Assembly No Item Qty UM Description 1 52 6264 0004 1 EA CONN HOUSING 3 POS SL156 W RAMP NO TABS 2 52 8317 0002 2 EA CONTACT SL156 24 18AWG 3 73 6018 0002 0...

Page 171: ...ector 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 000...

Page 172: ...BACK 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...

Page 173: ...ILLUSTRATED PARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 141 VL500 Motor Cable Assembly continued Figure 3 58 VL500 Motor Cable Assembly 7 x2 1 2 3 6 8 4 x4 5 4 x4 5 4 x4 5 4 x4 5 9 9...

Page 174: ...ure 3 59 Relay to Ignitor Cable Assembly No Item Qty UM Description 1 52 8271 0005 4 EA RECPT FASTON 1 4 16 14 AWG INSULATED REEL 2 55 2186 0001 1 EA CABLE TIE 0 10 X4 SMALL 3 73 6014 0012 0 29 FT WIR...

Page 175: ...1 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 SMA...

Page 176: ...A SOCKET 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...

Page 177: ...nding Cable Assembly 25 9685 0760 Rev C Refer to Figure 3 62 Figure 3 62 VL500 Head Earthing Cable Assembly No Item Qty UM Description 1 52 8231 0000 2 EA TERM RING 6 RED 22 16 AWG INSUL REEL 2 73 601...

Page 178: ...Item 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 55 226...

Page 179: ...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 0...

Page 180: ...16 AWG 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 PO...

Page 181: ...VL500 Display Remote Cable Assembly No Item Qty UM Description 1 10 9685 0536 01 1 EA ADAPTER PLATE MINI XLR BLACK 2 52 6694 0002 4 EA CRIMP TERM WIRE TO WIRE MALE 3 52 6696 0003 1 EA PLUG WIRE TO WIR...

Page 182: ...L500 Yoke Lamp Jumper Cable Assembly 25 9685 0776 Rev A Refer to Figure 3 66 Figure 3 66 VL500 Yoke Lamp Jumper Cable Assembly No Item Qty UM Description 1 52 8348 0001 2 EA TAB ULTRA FAST 1 4 16 14 A...

Page 183: ...y 25 9685 0777 Rev A Refer to Figure 3 62 Figure 3 67 VL500 Backcap Ground Cable Assembly No Item Qty UM Description 1 52 8329 0001 1 EA TERM RING 6 RED 22 16 AWG NON INSUL 2 52 8329 0003 1 EA TERM RI...

Page 184: ...CABLE 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 96...

Page 185: ...BREAKDOWN 3 02 9685 0010 0 17 July 2006 153 VL500 Main Harness Cable Assembly contin ued Figure 3 68 VL500 Main Harness Cable Assembly VL500 and VL500D 2 2 1 3 3 9 7 6 10 5 12 3 3 8 12 4 3 10 1 9 2 1...

Page 186: ...Y PAN 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 CA...

Page 187: ...ARTS BREAKDOWN 3 02 9685 0010 0 17 July 2006 155 VL500 Arc Main Harness Cable Assembly con tinued Figure 3 69 VL500 Arc Main Harness Cable Assembly VL500A 2 2 1 4 6 5 10 2 2 5 10 8 2 6 8 1 11 9 x8 7 3...

Page 188: ...744 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...

Page 189: ...TS BREAKDOWN 3 02 9685 0010 0 17 July 2006 157 VL500 80V Main Harness Cable Assembly con tinued Figure 3 70 VL500 80V Main Harness Cable Assembly VL500 80V 4 1 7 9 4 4 9 4 7 8 2 10 8 x8 3 5 6 6 2 3 5...

Page 190: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 158 17 July 2006 02 9685 0010 0 Notes...

Page 191: ...0 9685 0824 1 EA TOP PLATE BALLAST BLK 10 10 9685 0825 1 EA COVER BALLAST BLK 11 10 9685 0826 1 EA PANEL FILLER BALLAST BLK 12 10 9685 7823 1 EA BOTTOM PLATE BALLAST BLK 575W ARC ONLY 13 12 9685 0821...

Page 192: ...10 0 VL500 Arc Ballast Assembly continued Figure 3 71 VL500 Arc Ballast Assembly 9 23 x4 4 575W Only 5 700W Only 1 575W Only 2 700W Only 3 23 x2 16 x4 14 7 11 21 x4 20 x4 22 x12 15 12 575W Only 8 700W...

Page 193: ...6 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...

Page 194: ...TE VL500 LUMINAIRE SERVICE MANUAL 162 17 July 2006 02 9685 0010 0 Ballast I O Cable Assembly continued Figure 3 72 Ballast I O Cable Assembly 2 11 x5 7 x3 9 4 x3 5 x5 6 3 8 x2 10 1 12 13 14 17 18 19 1...

Page 195: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 02 9685 0010 0 17 July 2006 163 VL500 Wiring and Schematic Diagrams VL500 Wiring Diagram Sheet 1 of 1...

Page 196: ...1895 A0 SCHMATIC VL1000 DMX INPUT BD Wednesday December 14 2005 Title Size Document Number Rev Date SHEET OF B GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 INFORMATION AND DESIGN DISCLOSED ON T...

Page 197: ...UMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT CHECKED BY PROJECT ENGR DOC CONTROL DRAWN BY FAE C 2005 Genlyte Group LLC 14 9685 0730 C0 SCHEMATIC VL...

Page 198: ...05 Size Document Number Rev Date Sheet of 14 9685 0730 C0 SCHEMATIC VL500 CONTROLLER 2 6 Wednesday October 26 2005 3 C5 3 A5 3 B1 2 B5 2 D4 2 B5 2 B5 2 B5 3 C5 3 C3 2 B5 2 B5 2 B5 2 B5 2 D4 2 C2 6 D4...

Page 199: ...r 26 2005 Size Document Number Rev Date Sheet of 14 9685 0730 C0 SCHEMATIC VL500 CONTROLLER 3 6 Wednesday October 26 2005 Size Document Number Rev Date Sheet of 14 9685 0730 C0 SCHEMATIC VL500 CONTROL...

Page 200: ...nesday October 26 2005 Size Document Number Rev Date Sheet of 14 9685 0730 C0 SCHEMATIC VL500 CONTROLLER 4 6 Wednesday October 26 2005 6 C4 6 C4 6 C4 6 C4 6 A3 6 A4 4 A3 4 A3 3 B3 6 A4 6 A3 6 D4 3 C3...

Page 201: ...dnesday October 26 2005 3 C1 3 C1 3 C1 3 C1 3 C1 3 C1 3 C1 3 D1 6 D5 6 A3 6 D5 6 A4 6 D5 6 A4 6 D5 6 A3 3 A3 3 B3 3 A3 3 B3 6 A5 6 A5 6 A5 MAGENTA 3 A3 3 A3 DIFFUSER SPARE DO NOT STUFF 3 A3 3 A3 6 A5...

Page 202: ...er Rev Date Sheet of 14 9685 0730 C0 SCHEMATIC VL500 CONTROLLER 6 6 Wednesday October 26 2005 PAN TILT 2 B5 2 B5 2 C3 AMBER DIFFUSER SPARE DIA 166 DIA 166 DIA 166 DIA 166 DIA 166 DIA 166 BLUE MAGENTA...

Page 203: ...s have been incorporated into this manual Technical Bulletins Technical Notices Software Updates and support and other information is available online at http www vari lite com Support To request acce...

Page 204: ...VARI LITE VL500 LUMINAIRE SERVICE MANUAL 172 17 July 2006 02 9685 0010 0 Notes...

Page 205: ......

Page 206: ...Vari Lite 10911 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE o 1 214 647 7880 o Fax 1 214 647 8038 www vari lite com 2006 Genlyte Group LLC All rights reserved Printed in USA...

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