PRG VARI LITE VL5 Service Manual Download

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WWW.PRG.COM

VARI

❋

LITE VL5

™

WASH LUMINAIRE

SERVICE MANUAL

Summary of Contents for VARI LITE VL5

Page 1: ...WWW PRG COM VARI LITE VL5 WASH LUMINAIRE SERVICE MANUAL...

Page 2: ...ered trademarks of their respective companies This manual is for informational use only and is subject to change without notice Please check www prg com for the latest version PRG assumes no responsib...

Page 3: ...signed for use only with specific lamps Note lamp type before replacing Installing another type of lamp may be hazardous 2 PRG luminaires may be mounted on any type of surface as long as mounting inst...

Page 4: ...minutes before relamping 3 Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at very high temperatures Sho...

Page 5: ...dures pr cis es dans le manuel du frabricant doit tre fournies AVERTISSEMENT R glage des lampes 1 Chaleur intense D brancher le mat riel et laisser refroidir pendant 15 minutes avant de rallumer 2 Ris...

Page 6: ...sion Release Date Notes C January 28 2004 Miscellaneous updates D February 15 2005 Miscellaneous updates E1 February 7 2008 Miscellaneous updates E2 December 3 2010 Updated book format No change to te...

Page 7: ...Maintenance Procedures Head Assembly 19 VL5 VL5B Lamp Replacement 19 VL5 Arc Lamp Replacement 20 VL5Arc Lamp Adjustment 21 VL5Arc Lens and Bellows Motor Assembly Replacement 23 Separating VL5 VL5B Hea...

Page 8: ...nel Assembly 90 VL5Arc Dimmer Blade Assembly 91 VL5 Blue Amber Motor Assembly 92 VL5 Magenta Diffuser Motor Assembly 93 VL5Arc Lens and Bellows Motor Assembly 94 VL5Arc Motor Bellows Assembly 95 Yoke...

Page 9: ...VL5 WASH LUMINAIRE SERVICE MANUAL VII Appendix A Technical Bulletins List of Technical Bulletins 128 Appendix B Wiring Diagrams VL5 VL5B Wiring Diagram 129 VL5Arc Wiring Diagram 130...

Page 10: ...VIII VL5 WASH LUMINAIRE SERVICE MANUAL Notes...

Page 11: ...allation instructions to avoid damage to the product and potential injury to yourself or others Additional Documentation For additional information regarding the use of VL5 series luminaires in lighti...

Page 12: ...t information for all PRG office locations can be found on our website at www prg com about us locations PRG Dallas International Service 8617 Ambassador Row Suite 120 Dallas Texas 75247 USA Phone 214...

Page 13: ...1 DESCRIPTION FEATURES MAJOR COMPONENTS PRINCIPLES OF OPERATION...

Page 14: ...luminaire systems except the lamp which is powered by a specific external device depending on which VL5 luminaire version is being operated 8 inch glass dichroic cold mirror reflector A truss hook and...

Page 15: ...ICE MANUAL 5 VL5Arc models 575W arc lamp source Internal douser provides intensity control VARI BEAM mechanism provides continuous time beam control or standard VL5Arc lenses may be used Lamps are pow...

Page 16: ...MAJOR COMPONENTS Exterior Components The following illustration shows the major VL5 series wash luminaire components Truss Hook Bracket Assembly Head Assembly Covers Top and Bottom Yoke Assembly Ac I...

Page 17: ...g illustration shows the major sub assemblies located in the VL5 VL5B luminaire head assemblies Hinged Rail Assembly Lamp Reflector Blue Amber Bulkhead Assembly VL5 Magenta Amber Bulkhead Assembly VL5...

Page 18: ...onents The following illustration shows the major sub assemblies located in the VL5Arc luminaire head assembly Hinged Rail Assembly Lamp Reflector Latched Rail Assembly Blue Amber Bulkhead Assembly Ma...

Page 19: ...sub assemblies located in the VL5 series wash luminaire head assemblies Board Side Yoke Leg VL5Arc Tilt Side Yoke Leg VL5Arc Pan Mechanism Assembly Tilt Mechanism Assembly Lamp Control Board PCB Assem...

Page 20: ...he following diagram shows how data and power are distributed in the VL5 VL5B luminaires PAN MOTOR TILT MOTOR 5V LAMP CONTROL PCB PAN ENCODER TILT ENCODER DATA DATA LAMP DATA DATA 24V 24V 24V DATA CPC...

Page 21: ...power are distributed in the VL5Arc luminaire PAN MOTOR TILT MOTOR 5V LAMP CONTROL PCB PAN ENCODER TILT ENCODER DATA DATA LAMP DATA DATA 24V 24V 24V DATA CPC CONNECTO R 5V DATA 24V 24V BLUE MOTOR MOT...

Page 22: ...12 VL5 WASH LUMINAIRE SERVICE MANUAL Notes...

Page 23: ...2 MAINTENANCE EQUIPMENT HANDLING TESTING MAINTENANCE PROCEDURES SERVICING...

Page 24: ...o protect should be observed when servicing All parts in the following PRG part number groups should be considered ESD sensitive 23 Electrical assemblies 24 PCB assemblies 80 Transistor 81 Thyristors...

Page 25: ...testing and which tests to run It takes about three seconds for the unit to respond to thumbwheel changes allowing time to enter the numbers for a test before it attempts to read them Figure 2 1 Smar...

Page 26: ...4 only 451 Port 5 only 551 Port 6 only 651 Only the Timer Test RAM Test Mechanics Tests and Form and Function Test can be performed on all ports simultaneously The Encoder Tests and Data Loopback Test...

Page 27: ...51 and use the test parameter place on the thumbwheels switch the hundreds digit to select the desired ports 0 for all ports 1 through 6 for ports 1 through 6 respectively Figure 2 2 Entering Test Cod...

Page 28: ...Stop Open 001 Pan Test 8 End Stop Clsd 103 No Reset Pan 002 Tilt Test 7 Speed 1 25 203 No Reset Tilt 004 Diffuser Test 6 Speed 2 35 104 No Change Pan 005 Intensity Test VL5Arc Only 5 Speed 3 45 204 No...

Page 29: ...ocedures are to be performed with power removed from the luminaire Never remove covers or open front lens or back cap assemblies while lamp is in operation Step 1 Disconnect luminaire AC input cable f...

Page 30: ...ing open heatsink assembly Figure 2 4 Figure 2 4 VL5Arc Lamp Replacement Step 3 At four reflector mounting clips using 1 Phillips screwdriver loosen but do not remove one 6 32 X 5 16 PPSS screw Step 4...

Page 31: ...r reflector mounting clips using 1 Phillips screwdriver loosen four 6 32 X 3 8 PPSS screws but do not remove Center reflector and retighten screws securely b Lamp is plugged into socket firmly and is...

Page 32: ...MINAIRE SERVICE MANUAL Figure 2 5 VL5Arc Lamp Adjustment Screws Location Step 11 Close and latch front lens ring Lamp Adjustment Screws To start all lamp adjustment screws at an even point drive all t...

Page 33: ...lens ring Figure 2 6 Figure 2 6 VL5Arc Lens and Bellows Motor Assembly Replacement Step 3 Remove bottom head cover Step 4 At bellows mounting plate disconnect bellows motor extension cable assembly co...

Page 34: ...At bellows mounting plate using 2 Phillips screwdriver remove three 6 32 X 5 16 PPB screws three 6 flat washers and three 6 lock washers securing motor bellows assembly to bulkheads Heat light baffle...

Page 35: ...2 6 Step 3 Remove top and bottom head covers Step 4 Remove both yoke leg covers Step 5 Disconnect head assembly cables from yoke assembly a At LCB disconnect four 4 pin MTA connectors at STEP 1 throug...

Page 36: ...bly from yoke assembly a At top yoke cross member using 2 Phillips screwdriver remove four 6 32 X 5 16 PPZ screws and four 6 lock washers securing heatshield to yoke cross member and remove heatshield...

Page 37: ...ke to avoid possible damage e Remove luminaire head from yoke Step 8 Reassemble head and yoke assemblies by performing Steps 4 7 in reverse order Collet and Pulley Acorn Nut Yoke Cover Bracket Heatshi...

Page 38: ...ed from luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Unlatch and swing open heatsink assembly and front lens ring Figure 2 6 Step 3 Remove top and bottom head covers S...

Page 39: ...late Figure 2 13 Figure 2 13 Removing Relay to Access Cables 2 At contact B disconnect green disconnect switch wire 3 Disconnect diode and jumper cable assembly connectors 4 Feed green disconnect swit...

Page 40: ...hout removing c At pulley using 5 16 nutdriver gradually loosen four acorn nuts in cross pattern to prevent pulley from cracking Loosen until collet and pulley can be removed from tilt tube Step 7 At...

Page 41: ...free when pulling head from yoke to avoid possible damage d Remove luminaire head from yoke by pulling up and out of other yoke leg Tilt tube cap will come loose from tilt tube on latched rail Collet...

Page 42: ...ssemblies on page 28 Step 2 For VL5Arc luminaire remove lens bellows assembly Refer to VL5Arc Lens and Bellows Motor Assembly Replacement on page 23 Step 3 Remove hinge rail a At each end of hinged ra...

Page 43: ...sembly are connected by the motor wire spring For the VL5Arc luminaire the bellows motor wire spring is also connected and will come loose Step 5 At middle of head assembly using 1 Phillips screwdrive...

Page 44: ...ter and diffuser dimmer panels are in open position WARNING All maintenance procedures are to be performed with power removed from luminaire Step 2 Disconnect luminaire AC input cable from power sourc...

Page 45: ...ntly 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 panel Figure 2 20 Color Filte...

Page 46: ...e a drive ring pin Step 1 Ensure filter and diffuser douser panels are in open position WARNING All maintenance procedures are to be performed with power removed from luminaire Step 2 Disconnect lumin...

Page 47: ...handling filters Step 8 Remove four filters located on the same carrier holder as the drive ring pins Refer to Color Filter and Diffuser Douser Panel Replacement on page 34 Note Only replace pins tha...

Page 48: ...ree grooves and around base of new pin Step 12 At drive ring using installation tool 10 9624 0109 carefully press prepared pin through drive ring groove into carrier holder until tool is even with dri...

Page 49: ...cloth remove all excess copper paste from pin carrier holder and drive ring Step 16 Repeat Steps 9 through 13 for remaining guide ring pin locations as necessary Step 17 At modified filter panel asse...

Page 50: ...tep 1 Disconnect luminaire AC input cable from power source Step 2 Unlatch and swing open heatsink assembly and front lens ring Figure 2 6 Step 3 Remove top and bottom head covers Step 4 Remove board...

Page 51: ...r motor and heatsink in place on actuator mount Step 13 Re install two 4 40 X 1 4 PPZ screws and two 4 lock washers and using 1 Phillips screwdriver tighten to secure linear actuator motor and heatsin...

Page 52: ...rs remove cable tie securing tilt cable to tilt mechanism b At terminal strip using 1 slotted screwdriver disconnect lamp wires extending from head c Using diagonal cutters remove two cable ties secur...

Page 53: ...Side Yoke Leg LMPWRDSC Ground Stud Pulley Tilt Mechanism Adjustment Screw Acorn Nut Head Ground Cable Lamp Wires From Head Terminal Strip VL5 VL5B or Relay VL5Arc Disconnect lamp wires Lamp Wires Fro...

Page 54: ...cut cable ties securing wires to mechanism Step 8 At tilt mechanism assembly using 1 Phillips screwdriver remove three 6 32 X 5 16 PPZ screws and three flat washers securing mechanism to yoke and rem...

Page 55: ...performed with power removed from luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove both yoke leg covers Step 3 At yoke top cross member using 2 Phillips screwdrive...

Page 56: ...e leg VL5Arc a Using diagonal cutters remove cable tie securing pan cable to pan mechanism b Partially remove relay 1 At relay using 2 Phillips screwdriver remove two 6 32 X 5 8 PPZ screws and two 6 l...

Page 57: ...s back through yoke leg Step 7 Push all input cable wires up into pan tube Step 8 Remove pan mechanism Figure 2 29 a At pan mechanism assembly disconnect 5 pin MTA connector from encoder and 2 pin MTA...

Page 58: ...ghten to secure pan mechanism assembly to yoke Step 16 Re install belt on pulley Step 17 Re install top cross member and pan tube luminaire ensuring pan stop points towards pan mechanism Step 18 Place...

Page 59: ...e 2 31 Figure 2 31 Belt Tension Adjustment Note Bilateral deflection may be observed by loosening the tension adjustment screw and rotating the head assembly As the head is rotated back and forth the...

Page 60: ...Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove board side yoke leg cover CAUTION Always use anti static precautions when working with PCBs Step 3 At LCB disconnect all cabl...

Page 61: ...d four 6 lock washers securing heatshield to cross member and remove heatshield Figure 2 33 Figure 2 33 VL5Arc Ignitor Board Assembly Removal and Replacement CAUTION Always use anti static precautions...

Page 62: ...luminaire AC input cable from power source Step 2 Remove tilt side yoke leg cover Step 3 At tilt mechanism using diagonal cutters remove cable tie securing tilt cable to tilt mechanism Figure 2 13 Ste...

Page 63: ...te to bottom relay adapter plate and remove relay and top adapter plate Retain top relay adapter plate for reuse when installing replacement relay Figure 2 35 Figure 2 35 VL5Arc Relay Replacement Step...

Page 64: ...or several hours to force air out of lens CAUTION Always store a VL5Arc luminaire with full positive pressure to avoid air bubbles Step 7 Unlatch and open front lens ring Step 8 Check for the followin...

Page 65: ...uum cleaner with brush nozzle To clean the outside of the luminaire WARNING All maintenance procedures are to be performed with power removed from luminaire Step 1 Disconnect AC input cable from power...

Page 66: ...56 VL5 WASH LUMINAIRE SERVICE MANUAL Notes...

Page 67: ...3 ILLUSTRATED PARTS BREAKDOWN This chapter contains illustrated parts breakdown for assemblies contained in the VL5 series wash luminaires DRAWING TREES TOP ASSEMBLY COVERS AND HOOKS HEAD YOKE CABLES...

Page 68: ...34 0140 Drive Ring Assy 22 9634 0143 Light Baffle Assy 22 9634 0120 CCF Magenta Filter Assy 22 9647 0074 Diffuser Panel Assy 22 9634 0126 Blu Amb Motor Assy 22 9634 0121 Drive Ring Assy 22 9634 0143 C...

Page 69: ...y 22 9634 0007 Pan Tilt Mechanism Assy 22 9634 0009 Covers and Hook Assy 22 9647 0004 6 Ring 18 14Awg Faston 11 GND Strap Assy 25 8007 2644 Bulb Wires Cable Assy 25 9647 0059 Pan Cable Assy 25 9643 00...

Page 70: ...0140 Drive Ring Assy 22 9634 0143 Light Baffle Assy 22 9634 0120 Diffuser Panel Assy 22 9634 0126 SWP Blue Filter Assy 22 9634 1183 Blu Amb Motor Assy 22 9634 0121 Drive Ring Assy 22 9634 0143 Center...

Page 71: ...VL5A HEAD VL5Arc only 2 22 9660 0164 1 EA ASSY VL5A YOKE VL5Arc only 3 22 9660 0311 1 EA ASSY VL5 HEAD VL5 only 4 22 9634 0003 1 EA ASSY VL5 COVERS AND HOOK VL5 only 5 22 9638 0077 1 EA ASSY VL5 YOKE...

Page 72: ...rc only 11 06 6018 0002 0 58 FT VELCRO HOOK 1 BLK ADHESIVE BACKED 12 10 9634 0134 2 EA COVER VL5 YOKE LEG 13 10 9647 0148 2 EA YOKE ARM RETAINER WASHER VL5Arc only 14 12 9647 0138 1 EA VL5A LIGHT MASK...

Page 73: ...embly No Item Qty UM Description 8 04 9634 0136 1 EA LABEL VARI LITE YOKE LEG COVER 11 06 6018 0002 0 33 IN VELCRO HOOK 1 BLK ADHESIVE BACKED 12 10 9634 0134 1 EA COVER VL5 YOKE LEG 25 53 6668 0001 2...

Page 74: ...64 VL5 WASH LUMINAIRE SERVICE MANUAL Notes...

Page 75: ...22 9634 0203 1 EA ASSY VL5B MAG AMB BULKHEAD VL5B only 5 22 9634 0007 1 EA ASSY VL5 MAG DIF BULKHEAD VL5 only 22 9634 0204 EA ASSY VL5B BLU DIF BULKHEAD VL5B only 6 22 9634 0121 1 EA ASSY VL5 BLU AMB...

Page 76: ...66 VL5 WASH LUMINAIRE SERVICE MANUAL VL5 VL5B Head Assembly cont Figure 3 3 VL5 VL5B Head Assembly 2 7 13 12 6 10 8 PL 8 8 PL 3 1 9 4 PL 9 8 pl 11 4 pl 11 4 pl 4 5...

Page 77: ...7 1 EA ASSY UV GLASS MOUNTING VL5A 13 25 9647 0108 1 EA CABLE ASSY BELLOWS MOTOR EXTENSION 14 52 8244 0005 1 EA FASTON RECEPT INS 250 22 18AWG STRIP 15 53 5506 0312 8 EA SCREW 6 32 X 5 16 PPSS 16 53 5...

Page 78: ...c Head Assembly cont Figure 3 4 VL5Arc Head Assembly 2 22 2 pl 18 2 pl 8 21 4 23 16 28 18 4 pl 3 23 3 pl 17 3 pl 20 3 pl 24 2 pl 19 2 pl 27 1 15 4 pl 23 4 pl 5 6 26 13 25 10 22 4 pl 18 4 pl 25 12 7 18...

Page 79: ...2 EA GND STRAP ASSY 6 RING 18 14AWG FASTON 11 14 25 8007 3344 1 EA GND STRAP ASSY 8 RING 8 RING 11 15 25 9634 0140 1 EA CABLE ASSY VL5 GROUND SAFETY 16 53 2002 0001 2 EA NUT 6 32 KEP ZINC PLATED 17 5...

Page 80: ...VL5B Hinged Rail Assembly cont Figure 3 5 VL5 Hinged Rail Assembly Lamp ref 3 12 25 2 pl 18 2 pl 10 26 2 pl 17 2 pl 23 28 4 pl 19 4 pl 4 4 pl 27 4 pl 21 4 pl 11 6 24 2 pl 26 2 pl 20 22 4 pl 27 4 pl 7...

Page 81: ...EA GND STRAP ASSY 6 RING 18 14WG FASTON 11 18 25 9647 0059 1 EA CABLE ASSY VL5A BULB WIRES 19 53 2002 0001 2 EA NUT 6 32 KEP ZINC PLATED 20 53 5504 0187 2 EA SCREW 4 40 X 3 16 PPSS 21 53 5506 0500 4 E...

Page 82: ...sembly cont Figure 3 6 VL5Arc Hinged Rail Assembly HRISOEXP 27 20 2 pl 31 2 pl 24 3 pl 38 3 pl 11 35 39 33 2 pl 22 2 pl 15 7 13 6 4 pl 32 4 pl 26 4 pl 28 2 pl 31 2 pl 4 21 4 pl 32 4 pl 25 5 1 10 37 2...

Page 83: ...TUBE VL5 3 10 9647 0084 1 EA HEAT INSULATOR MACHINED VL5A 4 53 5504 0187 4 EA SCREW 4 40 X 3 16 PPSS 5 53 6610 0003 4 EA SCREW 6 32 X 7 16 PPZ 6 54 1226 0001 1 EA LATCH ASSY VL5 7 54 1226 0002 1 EA S...

Page 84: ...INSULATING PAD 5 25 9647 0129 1 EA CABLE ASSY VL5A DISCONNECT 6 53 2003 0001 2 EA NUT 4 40 KEP ZINC PLATED 7 53 5504 0187 2 EA SCREW 4 40 X 3 16 PPSS 8 53 5506 0500 4 EA SCREW 6 32 X 1 2 PPSS 9 53 65...

Page 85: ...D 7 22 9634 0024 1 EA ASSY VL5 BULKHEAD 8 22 9634 0119 1 EA ASSY VL5 CENTER HUB 9 22 9634 0123 16 EA ASSY FILTER PANEL VL5 SWP BLUE 10 22 9634 0124 16 EA ASSY FILTER PANEL VL5 LWP AMBER 11 22 9634 014...

Page 86: ...VICE MANUAL VL5 Blu Amb Bulkhead Assembly cont Figure 3 9 VL5 Blu Amb Bulkhead Assembly 11 2 pl 2 32 pl 10 16 pl 6 32 pl 1 32 pl 9 16 pl 18 8 pl 7 12 4 pl 13 4 pl 17 4 pl 14 4 pl 4 2 pl 19 4 pl 15 4 p...

Page 87: ...0166 32 EA CARRIER FILTER METAL INJ MOLDED 7 22 9634 0024 1 EA ASSY VL5 BULKHEAD 8 22 9634 0119 1 EA ASSY VL5 CENTER HUB 9 22 9634 0124 16 EA ASSY FILTER PANEL VL5 LWP AMBER 10 22 9634 0143 2 EA ASSY...

Page 88: ...SERVICE MANUAL VL5B Mag Amb Bulkhead Assembly cont Figure 3 10 VL5B Mag Amb Bulkhead Assembly 10 2 pl 2 32 pl 9 6 32 pl 1 32 pl 11 18 8 pl 3 2 pl 12 4 pl 13 4 pl 17 4 pl 14 4 pl 4 2 pl 19 4 pl 15 4 p...

Page 89: ...5 2 EA LINK SWIVEL 6 22 9634 0024 1 EA ASSY VL5 BULKHEAD 7 22 9634 0120 1 EA ASSY VL5 LIGHT BAFFLE 8 22 9634 0126 16 EA ASSY VL5 DIFFUSER PANEL 9 22 9634 0143 2 EA ASSY VL5 DRIVE RING 10 22 9647 0074...

Page 90: ...IRE SERVICE MANUAL VL5 Mag Dif Bulkhead Assembly cont Figure 3 11 VL5 Mag Dif Bulkhead Assembly 9 2 pl 3 32 pl 7 8 16 pl 1 32 pl 2 32 pl 10 16 pl 12 4 pl 13 4 pl 11 4 pl 14 8 pl 6 15 4 pl 12 4 pl 13 4...

Page 91: ...VL5ARC OUTER LIGHT BAFFLE 9 10 9647 0124 16 EA CARRIER VL5ARC 10 22 9634 0024 1 EA ASSY VL5 BULKHEAD 11 22 9634 0120 1 EA ASSY VL5 LIGHT BAFFLE 12 22 9634 0143 2 EA ASSY VL5 DRIVE RING 13 22 9647 007...

Page 92: ...Arc Magenta Dimmer Bulkhead Assembly Cont Figure 3 12 VL5Arc Magenta Dimmer Bulkhead Assembly 22_0007 19 8 pl 5 2 pl 12 2 pl 3 32 pl 14 16 pl 9 16 pl 2 32 pl 7 11 8 13 16 pl 1 16 pl 10 20 4 pl 18 4 pl...

Page 93: ...32 EA LINK DRIVE ARM 4 10 9634 0102 2 EA BAFFLE FRONT LIGHT 5 10 9634 0105 2 EA LINK SWIVEL 6 22 9634 0024 1 EA ASSY VL5 BULKHEAD 7 22 9634 0120 1 EA ASSY VL5 LIGHT BAFFLE 8 22 9634 0126 16 EA ASSY V...

Page 94: ...84 VL5 WASH LUMINAIRE SERVICE MANUAL VL5B Blu Dif Bulkhead Assembly cont Figure 3 13 VL5B Blu Dif Bulkhead Assembly 9 3 5 7 4 8 10 1 2 12 4 pl 13 4 pl 11 14 6 15 12 4 pl 13 4 pl...

Page 95: ...o Item Qty UM Description 1 10 9634 0028 1 EA HUB CENTER VL5 BULKHEAD 2 10 9634 0029 2 EA SPRING FINGER FILTER SUPPORT 3 10 9634 0133 1 EA PLUG HUB 4 53 5704 0250 4 EA SCREW 4 40 X 1 4 SCSS 5 53 6534...

Page 96: ...2 10 9634 0156 1 EA CARRIER CENTER FILTER BLU AMB DIFF USED ON 22 9634 0123 22 9634 0124 AND 22 9634 1185 10 9634 0157 1 EA CARRIER CENTER FILTER MAGENTA USED ON 22 9634 1183 AND 22 9647 0074 3 41 963...

Page 97: ...Figure 3 16 Figure 3 16 VL5 Drive Ring Assembly No Item Qty UM Description 1 10 9634 0027 1 EA RING DRIVE 2 10 9634 0044 4 EA ROLLER VL5 DRIVE RING SM 3 53 5554 0875 1 EA SCREW SET 4 40 X 7 8 SET SS...

Page 98: ...LIGHT BAFFLE 1 4 10 9634 0079 1 EA RING LIGHT BAFFLE 2 5 10 9634 0080 1 EA RING LIGHT BAFFLE 3 6 10 9634 0081 1 EA RING LIGHT BAFFLE 4 7 10 9634 0082 1 EA RING LIGHT BAFFLE 5 8 10 9634 0083 1 EA RING...

Page 99: ...VL5 WASH LUMINAIRE SERVICE MANUAL 89 VL5 Light Baffle Assembly cont Figure 3 17 VL5 Light Baffle Assembly 1 2 2 pl 3 4 5 6 7 8 9 10 11 4 pl 12 8 pl 13 4 pl...

Page 100: ...bly 22 9634 0126 Refer to Figure 3 18 Figure 3 18 VL5 Diffuser Panel Assembly No Item Qty UM Description 1 10 9634 0067 1 EA PAD FILTER EXTRUSION SILICONE WHITE 2 10 9634 0156 1 EA CARRIER CENTER FILT...

Page 101: ...L 91 VL5Arc Dimmer Blade Assembly 22 9647 0136 Refer to Figure 3 19 Figure 3 19 VL5 Dimmer Blade Assembly No Item Qty UM Description 1 10 9634 0067 1 EA PAD FILTER EXTRUSION SILICONE WHITE 2 10 9647 0...

Page 102: ...ption 1 10 9634 0061 1 EA ACTUATOR MOUNT VL5 2 10 9634 0075 1 EA HEAT SHIELD BLUE AMBER 3 10 9634 0141 2 EA HEAT SINK MODIFIED ACTUATOR 4 44 5026 0001 2 EA MOTOR LINEAR ACTUATOR HI TEMP 5 53 6520 0001...

Page 103: ...tion 1 10 9634 0061 1 EA ACTUATOR MOUNT VL5 2 10 9634 0074 1 EA HEAT SHIELD MAGENTA DIFFUSER 3 10 9634 0141 2 EA HEAT SINK MODIFIED ACTUATOR 4 44 5026 0001 2 EA MOTOR LINEAR ACTUATOR HI TEMP 5 53 6520...

Page 104: ...Assembly 22 9647 0131 Refer to Figure 3 22 Figure 3 22 VL5Arc Lens and Bellows Motor Assembly No Item Qty UM Description 1 22 9647 0083 1 EA ASSY LIQUID LENS NEW MOLD VL5A 2 22 9647 0132 1 EA ASSY VL...

Page 105: ...1 EA SHIELD DEBRIS MOTOR BELLOWS VL5A 7 22 9647 0078 1 EA ASSY BELLOWS VL5A 8 22 9647 0096 1 EA ASSY BELLOWS MTG PLATE INSULATED 9 22 9647 0113 1 EA ASSY LINE ACTUATOR 10 53 2200 0008 1 EA NUT 8 32 KE...

Page 106: ...INAIRE SERVICE MANUAL VL5Arc Motor Bellows Assembly cont Figure 3 23 VL5Arc Motor Bellows Assembly 1 3 4 5 6 7 8 9 10 11 2 pl 12 13 4 pl 14 4 pl 14 2 pl 14 4 pl 15 2 pl 16 2 pl 16 4 pl 16 2 pl 16 2 pl...

Page 107: ...RCAND VL6 VL5Arc only 16 10 9647 0131 1 EA TOP RELAY ADAPTER PLATE VL5ARC AND VL6 VL5Arc only 17 22 9634 0009 2 EA ASSY PAN TILT MECHANISM VL5 18 22 9634 0110 1 EA CROSS MEMBER ASSY YOKE 19 22 9634 01...

Page 108: ...001 1 EA RING RETAINING 1 963 ID 46 54 1206 0001 4 EA RING RETAINING 2 521 ID 47 55 2129 0002 1 EA SHIM STAINLESS STEEL PAN TUBE 48 55 2177 0001 2 EA CABLE ANCHOR MOUNT BLACK 49 55 2178 0001 2 EA CABL...

Page 109: ...3 52 33 2 pl 48 2 pl 22 58 2 31 20 21 26 27 14 41 58 2 8 51 2 pl 5 38 46 47 45 29 4 46 38 6 28 44 16 1 9 53 37 52 29 54 3 pl 40 17 32 4 pl 43 11 12 19 38 46 3 2 pl 60 24 34 6 pl 40 4 pl 4 pl 34 6 pl 5...

Page 110: ...35 2202 1 EA CONN MTA156 RED 2PIN CBL CBL 13 52 6436 0002 1 EA COVER STRAIN RELIEF 2POS MTA156 14 53 2001 0001 1 EA NUT 10 32 KEPS ZINC PLATED 15 53 5506 0312 4 EA SCREW 6 32 X 5 16 PPSS 16 53 5652 01...

Page 111: ...NAIRE SERVICE MANUAL 101 VL5 Pan Tilt Mechanism Assembly cont Figure 3 25 VL5 Pan Tilt Mechanism Assembly 23 25 20 22 12 17 2 1 4 8 21 24 7 5 26 4 pl 11 18 2 pl 6 9 3 10 13 14 15 4 pl 16 17 3 pl 19 3...

Page 112: ...n 1 10 9634 0019 1 EA GEAR WORM 1M6RL17080 2 10 9634 0051 1 EA WASHER D PTA 3 22 9638 0220 1 EA ASSY DRIVE SHAFT PAN AND TILT 4 54 1222 0002 1 EA RING RETAINING METRIC F 9MM SHAFT 5 55 2128 0001 7 EA...

Page 113: ...650 0756 1 EA PCB ASSY IGNITOR VL7 3 25 9647 0048 1 EA CABLE ASSY VL5A IGNITOR 4 53 2016 0002 2 EA NUT 4 40 HEX ZINC 5 53 5506 0500 2 EA SCREW 6 32 X 1 2 PPSS 6 53 6569 0001 2 EA SCREW 4 40 X 5 16 PPZ...

Page 114: ...ABLE TIE 10 WD 4 00 LG SMALL 4 60 1422 1002 12 EA RES 1 4W 5 10 0 MEG CF R1 R12 5 62 2032 0001 1 EA CAP 01UF 3000V RAD CERAMIC 375 20 C14 6 62 3000 0033 13 EA CAP 033UF 1000V RAD POLYPRO 600 10 C1 C13...

Page 115: ...COMPONENT VL5 PCB ASSY VL5 VL5B only 22 9638 0087 1 EA KIT COMPONENTS VL6 PCB ASSY VL5Arc only 3 52 5000 0002 1 EA SOCKET 132 PIN PQFP PGA ADVANCED INTRCON 4 53 5508 0500 1 EA SCREW 8 32 X 1 2 PPSS 5...

Page 116: ...17 52 8284 0001 3 EA HEADER 2 PIN SGL ROW STRGHT GOLD CONT 100CNTR J2 J4 18 52 8402 0002 1 EA JACK MODULAR 8 PIN STRAIGHT J1 19 55 6703 0001 1 EA HANDLE VL5 PCB BLACK 20 60 1420 2703 2 EA RES 1 4W 5 2...

Page 117: ...C LMD18200 H BRIDGE 55V 3A X23 X24 50 84 0068 0332 1 EA IC MC68332 MICROPROCESSOR U16 51 84 4131 0001 1 EA IC 74HC05 HEX INVERTER W OPEN COLLECTOR U20 52 84 4234 0001 2 EA IC LTC485CN8 RS422 RS485 TRA...

Page 118: ...108 VL5 WASH LUMINAIRE SERVICE MANUAL VL5 PCB Assembly Components Kit cont Figure 3 30 VL5 PCB Assembly Components Kit...

Page 119: ...52 6373 0005 4 EA SOCKET STRIP 8 POS SGL ROW LOW PRO U11 U13 16 52 6373 0007 4 EA SOCKET STRIP 8 POS DOUBLE ROW XU14 17 52 6373 0008 2 EA SOCKET STRIP 8 POS SGL ROW TIN XU14 18 52 6374 0007 2 EA SOCK...

Page 120: ...5301 5908 4 EA DIODE ZENER TS 1N5908 5V 5W D3 D6 51 82 5316 6281 1 EA DIODE ZENER 1N6281 27V 1500W 10 D7 52 83 3157 0001 2 EA IC 6N137 OPTOCOUPLER U25 U26 53 83 5000 0001 5 EA IC L293D QUAD HALF BRID...

Page 121: ...VL5 WASH LUMINAIRE SERVICE MANUAL 111 VL6 PCB Assembly Components Kit cont Figure 3 31 VL6 PCB Assembly Components Kit...

Page 122: ...112 VL5 WASH LUMINAIRE SERVICE MANUAL Notes...

Page 123: ...Ring 11 GND Strap Assembly 25 8007 2244 Refer to Figure 3 32 Figure 3 32 6 Ring 6 Ring 11 GND Strap Assembly No Item Qty UM Description 1 52 8329 0001 2 EA TERM RING 6 22 16AWG NON INS 2 73 7130 0002...

Page 124: ...8007 2644 Refer to Figure 3 33 Figure 3 33 6 Ring 18 14AWG Faston 11 GND Strap Assembly No Item Qty UM Description 1 52 8271 0009 1 EA RECEPT FASTON 250 18 14AWG NON INS 2 52 8329 0001 1 EA TERM RING...

Page 125: ...11 GND Strap Assembly 25 8007 3344 Refer to Figure 3 34 Figure 3 34 8 Ring 8 Ring 11 GND Strap Assembly No Item Qty UM Description 1 52 8329 0003 2 EA TERM RING 8 22 16AWG NON INS 2 73 7130 0002 0 92...

Page 126: ...TRAIN RELIEF 3 52 6396 2202 1 EA RECEPT 2 POS MTA100 W POL TAB RED CLSD END 4 52 6424 0005 1 EA COVER 5 POS CLOSED END STRAIN RELIEF MTA 5 52 6434 2202 1 EA RECEPT MTA156 RED 2 POS 6 52 6436 0002 1 EA...

Page 127: ...RAIN RELIEF 3 52 6396 2202 1 EA RECEPT 2 POS MTA100 W POL TAB RED CLSD END 4 52 6424 0005 1 EA COVER 5 POS CLOSED END STRAIN RELIEF MTA 5 52 6434 2202 1 EA RECEPT MTA156 RED 2 POS 6 52 6436 0002 1 EA...

Page 128: ...ety Cable Assembly 25 9634 0140 Refer to Figure 3 37 Figure 3 37 VL5 Ground Safety Cable Assembly No Item Qty UM Description 1 52 8231 0005 2 EA TERM RING 6 BLUE 16 14AWG REEL PIDG 2 73 7089 0504 8 00...

Page 129: ...ED END STRAIN RELIEF MTA 5 52 6424 0004 1 EA COVER 4 POS CLOSED END STRAIN RELIEF MTA 6 52 6431 0002 1 EA BACKSHELL CPC17 NYLON 300 525 CBL RNG 7 52 8201 0001 5 EA CONTACT PIN 22AWG GLD REEL TYPE 3 8...

Page 130: ...638 0222 Refer to Figure 3 39 Figure 3 39 Ignitor Board Output Cable Assembly No Item Qty UM Description 1 52 6264 0003 1 EA CONN HOUSING 30 SERIES W FLNGS 3 POS 2 52 8247 0002 2 EA CRIMP CONTACT S30...

Page 131: ...ound Cable Assembly 25 9638 0243 Refer to Figure 3 40 Figure 3 40 Ground Cable Assembly No Item Qty UM Description 1 52 8231 0005 2 EA TERM RING BLUE 16 14AWG REEL PIDG 2 73 7089 0504 5 30 FT WIRE 22A...

Page 132: ...3 41 Figure 3 41 Ground Cable Assembly No Item Qty UM Description 1 52 8271 0005 2 EA RECPT FASTON 1 4 16 14AWG INS REEL 2 52 8298 0002 2 EA TERM WIRE PIN 16 14 GA 3 73 7089 0000 4 50 FT WIRE 22AWG B...

Page 133: ...y UM Description 1 25 9634 0140 1 EA CABLE ASSY VL5 GROUND SAFETY 2 52 8247 0001 2 EA CRIMP CONTACT S30 TIN REEL 3 55 6601 0002 0 50 FT HEATSHRINK 0 191 ID TFE TEFLON 4 55 6695 0002 0 30 FT HEATSHRINK...

Page 134: ...n 1 52 6469 0001 1 EA CONN PLUG HI TEMP 4 PIN 26AWG 2 52 6470 0010 1 EA CLAMP CABLE RECEPTACLE 3 73 2528 0002 2 25 FT WIRE 28AWG 250V 200C TFE RED STRND MIL W 16878 4 73 2528 0005 2 25 FT WIRE 28AWG 2...

Page 135: ...1 EA COVER 4 POS CLOSED END STRAIN RELIEF MTA 6 52 6431 0002 1 EA BACKSHELL CPC17 NYLON 300 525 CBL RNG 7 52 8277 0001 5 EA CONTACT PIN 22AWG GLD REEL TYPE 3 8 52 8276 0001 7 EA CONTACT PIN TIN 18 16...

Page 136: ...Figure 3 45 VL5Arc Disconnect Cable Assembly No Item Qty UM Description 1 10 9647 0118 1 EA VL5A DISCONNECT CONTACT 2 10 9647 0150 1 EA VL5A DISCONNECT MOUNT 3 53 6534 0006 2 EA RIVET 3 32 OD 3 16 SO...

Page 137: ...A TECHNICAL BULLETINS...

Page 138: ...L5Arc VL5B VL5 030 New VL5 VL5B luminaire input rating label and lamp wire sleeving VL5 VL5B VL5 032 Ferrite bead EMI shield for VL5 VL6 VLM pan and tilt motor wires VL5 VL5 034 Revised pan and tilt b...

Page 139: ...VL5 WASH LUMINAIRE SERVICE MANUAL 129 WIRING DIAGRAMS VL5 VL5B Wiring Diagram...

Page 140: ...VL5 WASH LUMINAIRE SERVICE MANUAL 130 VL5Arc Wiring Diagram CONNECTOR LEGEND DETAIL A SEE DETAIL A...

Page 141: ...VL5 Wash Luminaire Service Manual Version as of October 26 2011 PRG part number 02 9634 0010 F...

Page 142: ...Production Resource Group Dallas Office 8617 Ambassador Row Suite 120 Dallas Texas 75247 www prg com...

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