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2402 Service B.book - Vari-Lite

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5. MSR400 MSR575HR 2 3 4 VARI LITE 44 1 VARI LITE
6. 2 VARI LITE H WHE RBA ABEL 3 HA ROSE 02 9671 0010 C 24 March 2004 3 mde ox Lue 27 VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL FES UV 1 VARI LITE UV 4 EPA HID
7. No Item Qty UM Description 25 9667 1516 01 1 EA CABLE ASSY MAIN TO AUX DATA amp PWR not shown 25 9661 1517 01 1 EA CABLE ASSY PAN TILT CONTROL 2201 not shown 25 9661 1520 1 EA CABLE ASSY CHASSIS TO YOKE GND not shown 25 9661 1532 1 EA CABLE ASSY DATA I O LINK VL2400 not shown 25 9661 1551 01 1 EA CABLE ASSY LAMP SUPPLY HARNESS XPIQ not shown 25 9667 0029 1 EA CABLE ASSY LAMP SUPPLY TO RELAY not shown 25 46 6004 0001 1 EA MOUNTING DISC METAL 90MM DIA 26 53 2002 0003 1 EA NUT 6 32 HEX ZINC NYLON INSERT 27 53 2200 0006 2 EA NUT 6 32 KEPS SS 28 53 6563 0001 1 EA SCREW 10 32 X 2 PPB 29 53 6517 0001 4 EA SCREW 10 32 X 3 8 PPZ 30 53 6543 0001 4 EA SCREW 6 32 X 3 8 PPB 31 53 6545 0003 3 EA SCREW 8 32 X 3 8 PFZ 32 53 6545 0004 2 EA SCREW 8 32 X 3 8 PPZ 33 53 6558 0001 17 EA SCREW 6 32 X 3 8 PPZ 34 53 6558 0010 4 EA SCREW 6 32 X 1 4 LG PPZ BLACK SEMS EXT WSHR 35 53 6594 0003 1 EA SCREW 10 32 X 1 1 2 PPZ 36 53 6607 0001 4 EA SCREW 6 32 X 1 4 PPB 37 53 6608 0003 2 EA SCREW 6 32 X 3 16 LG PPZ 38 53 6609 0001 6 EA SCREW 6 32 X 3 8 PFZ 39 53 6610 0003 4 EA SCREW 6 32 X 7 16 PPZ 40 53 6614 0003 1 EA SCREW 6 32 X 5 8 PFZ 4l 53 6617 0001 1 EA SCREW 6 32 X 1 PPB 42 53 6627 0001 4 EA SCREW 10 32 X 5 8 PPB 43 53 6653 0502 4 EA SCREW 1 4 20 X 1 2 LG SOC HD CAP ZINC 44 54 2039 0001 1 EA BELT GT TIMING 2MM PITCH 182GRV 9MM WD NYL CVRD FBRG
8. 120 VIEWED FROM SIDE Figure 3 40 700W Ballast Board PCB Assembly 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 700W Ballast Rider Board PCB Assembly 24 9661 1131 Rev b Refer to Figure 3 41 No Item Qty UM Description Ref 1 10 9661 1355 2 EA STABILIZING EXTRUSION APS RIDER BD PCB 2 11 9661 1111 1 EA PCB BALLAST RIDER 3 52 6297 0001 1 EA HEADER 2PIN MTA FRCT LOK STRT POST J402 4 52 6576 0012 1 EA CONN 12 CIR 100 PC BOARD 1301 5 52 6576 0015 1 EA CONN 15 100 PC BOARD J401 6 60 0460 1004 1 EA RES 1 8W 5 10 0 FLM CHIP SUR MT R401 EIA 1206 7 60 9462 1003 2 EA RES 1 2W5 1 0K 200V CHIP THK FLM R405 R432 SMT2010 8 60 9463 0000 1 EA RES 1 8W ZERO OHM 200V CHP FLM R433 S MT1206 9 60 9463 1004 1 EA RES 1 8W 1 10 0 200V CHP THK FLM S R306 MT1206 10 60 9463 1005 1 EA RES 1 8W 1 100 0 2007 CHP FLM S R408 MT1206 60 9463 1215 1 EA RES 1 8W 1 121 0 K 200V CHP THK FLM S R407 MT1206 12 60 9463 1474 2 EA RES 1 8W 1 14 7 K 200V CHP FLM R301 R304 SMT1206 13 60 9463 1624 1 EA RES 1 8 1 162 200V CHP THKFLMS R412 MT1206 14 60 9463 2004 1 EA RES I 8W 1 20 0 200V CHP THK FLMS R419 MT1206 15 60 9463 2153 1 EA RES 1 8W 1962 15
9. J3 I 23 9661 1534 RED 24V 1 FAN or_sw 2 BK 1 Hch sPEED L zl Revised per EO 09083 25 9661 1517 01 TWISTED WIRES TWISTED PAIR 25 9661 1516 01 TO AUXILIARY CONTROLLER 1 J4 SHEET 2 SENSE GND VOA VOB ENCODER SENSOR 166 2 vco 24 9661 0629 VCC_R TILT 1 BLK 4 RD TT TRAVEL 5 GN SENSOR 6 23 9661 1253 GND SENSE CONTROLLER DMX E 24 9661 1225 THRU 3 DMX DATA OUT 3 MAIN_TX 4 V VL OUT 4 MAIN 5 VL_COM GND 5 150 DEVELOPMENT CONNECTORS 2 row 5 s 2 para DMX INPUT VOLTAGE 24v x 8E2 DEBUG P 3 Dux 0414 24 9661 1251 SUPPLY en GND 1 860 1 _ N 24 S RE 2 Normal 5 VL_COM N C GND P OPEN 3 t 5 OPEN 6 vcc 35396611512 7 MODA MODB J4 L 6 8 24V 1 EMI CIRCUIT RT GND 2 FILTER BREAKER U J5 GRN YEL aoe AUX_COM AUX_COM CHASSIS stay 92 6401 2321 GND STUD 42 4 ino ee NO 25 9661 1513 lu MM POWER CABLE 7 AUX_COM 24V 25 9861191 25 9661 1514 7 cco CHASSIS GND STUD 1 J106 J107 1112 sh ns 966 1531 ae LP eee tere 25 9661 1520 400 400
10. No Item Qty UM Description Ref 63 80 2623 0003 3 EA TRANSISTOR 2N4403 PNP 40V 600MA TO 92 0103 0204 amp Q211 64 80 2643 0001 2 EA TRANSISTOR MPSW63 1W PNP Q205 amp Q210 DARLINGTON 30V 500MA 1W TO 92 65 82 4308 4937 5 EA DIODE IN4937 FAST 600V 1A D206 D210 66 82 4317 5819 1 EA DIODE IN5819 RECTIFIER 40V 1A D212 67 82 5318 0160 1 EA DIODE MURI60 600V 1A D104 68 82 5322 0001 1 EA DIODE IN4736A D215 69 82 5323 0001 2 EA DIODE MUR460 600V 4AMP ULTRAFAST D202 amp D205 70 82 5349 0001 1 EA DIODE MBR1100 SCHOTTKY 1A 100V AXIAL D103 LEAD RECTIFIER 71 82 5351 0001 1 EA DIODE ZENER 20V IW 5 DO 41 1N4747A D102 72 83 3188 0001 1 EA IC LM317AT 3 TERM ADJUSTABLE VR102 REGULATOR 73 84 7427 0001 1 EA IC WPCO3R24S1SL DC DC CONVERTER 3W 0203 74 85 5120 0001 2 EA IC IR2110 1 2 BRIDGE DRIVER U201 amp U202 75 86 6109 0001 1 EA COUPLER DUAL CHANNEL SPIN U204 DIP U202 Gueeseee BB Lis 98 bt 0207 Q206
11. 1 2 ne lt 11 51 PAD4 vP 55 T 32 5 Tet dor PADS 4 AUX COM 2 02 2 42 L E 3 46 n 7 T PADS EXTAL sp e AUX CON 702 27 17 C16 1 20PF of nas F VCC PINS 2 14 42 79 750K 6 000MHZ amp 111100 Bs 10 11 vce c15 4 2orr C14 mv XU 74AC14 8 1uF UF 0 iur x i or 2 13 12 se o o 111100 Fea 22 14 840288 2 1 51 2 FAN1 111100 644 10K 2 JE 5 244 39 28 8040 ean Mounting Holes 1 3 gt y 47 Fear MTG1 640456 4 ig c 640456 2 ttie e 2 1 18 3 x 39 28 8060 1 4 2 B2 2 A2 g m 2 82 2 A2 2 B B B gt ss MAIN CONTROLLER 2 x REVISION DRAWING NUMBER v D 14 9661 1225 SIZE le SHEET 2 OF 4 Filename Date Time D ViewDraw for Windows 7 5 4 02 9671 0010 C 24 March 2004 158 VARFXLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Controller Schematic cont
12. 4 3 V 4 5 6 7 RE 1 Class
13. No Item Qty UM Description 1 52 6274 2313 1 EA STRAIN RELIEF SKINTOP FLEX TYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG CE MARKED 204 2507 TWIST LOCK MALE LINE 3 WIRE 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP 5 55 2268 0187 0 92 FT HEATSHRINK 3 16 CLEAR KYNAR VDE UL 600V 150 DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR VDE UL 600V 150 DEG C 7 73 9636 0153 4 0 FT CORDAGE 1 5 3 750V 60C EURO BLK HD22 11MM OD 2 Figure 3 44 AC Input Pigtail Euro Cable Assembly 126 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 AC Input Link Cable Assembly 25 9661 1512 Rev B Refer to Figure 3 45 Description 1 52 8312 0001 2 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 2 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP 3 55 2186 0001 1 EA CABLE TIE 10 WD 4 00 LG SMALL 4 73 6016 0009 6 IN WIRE 16AWG 600V 105C PVC WHT UL1015 5 73 6016 0010 6 IN WIRE 16AWG 600V 1056 PVC BLK UL1015 2 2 pl Figure 3 45 AC Input Link Cable Assembly 02 9671 0010 C 24 March 2004 127 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25 9661 1513 Rev C Refer to Figure 3 46 Description 1 52 6231 0001 1 EA PLUG HOUSING MN
14. No Item Qty UM Description 1 52 6524 0005 2 CONN HOUSING 5POS RECEPTACLE 2 52 8346 0001 10 EA 24 30AWG FEMALE CRIMP 3 55 2199 0001 0 10 FT HEATSHRINK 1 16 BLACK 4 55 2200 0001 0 08 FT HEATSHRINK 3 16 BLACK 73 7039 0001 0 33 FT CBL 22AWG STRND 4COND POLYPR INSUL a 4 00 2X 611532A Figure 3 53 Data I O Link Cable Assembly 136 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 DC Output Cable Assembly 25 9661 1543 Rev 0 Refer to Figure 3 54 No Item Qty UM Description 1 52 6464 0002 1 EA CONN HOUSING SL 156 2 POS 2 52 6484 0004 1 EA RECEPT 4 POS DUAL ROW MINI FIT JR 3 52 8298 0002 3 EA TERM WIRE PIN 16 14AWG 4 52 8323 0001 2 EA CONTACT CRIMP 18 22AWG SL 156 5 52 8333 0001 2 EA CONTACT FEMALE 18 20 AWG REEL HCS 6 73 3518 0002 2 3 FT WIRE 18AWG 300V 105C PVC RED UL1569 7 73 3518 0010 2 3 FT WIRE 18AWG 300V 105C PVC BLK UL1569 4 2 pl 1 LAMP POWER 4 17 0 SUPPLY LPS GND 2 17 0 DC INPUT SL 156 2 125 RED 3 0 5 2 pl LOW VOLTAGE J2 2 RED 7 0 25 MAIN CONTROL 7812 BOARD MCB J2 3 BLK oin DC INPUT GND MINI FIT JR 02 9671 0010 C F 4 Figure 3 54 DC Output Cable Assembly 24 March 2004 137 VARFKLI
15. 12 Special Considerations Configuring Controller Board a eere 13 Jumper Config ratiOn neci rre e i eb eee 14 Maintenance Procedures Head Assembly sonne 15 Lamp Replacement lt 15 Alien Lamp for Flat Field cde teet eee teh e caa 17 Color Bulkhead Assembly 18 Color Filter Replacement ene e ete 20 Magenta Color Wheel Glass Assembly 21 Crossfade Color Sensor PCB Assembly Replacement 22 Dimmer Bulkhead Assembly Replacement 23 Front Internal Head Assembly Replacement 24 Blue Amber Color Wheels Assembly Replacement 25 Small Stipple Glass Replacement esses 27 Concave Lens Assembly Replacement 4 28 Convex Lens Assembly 29 100MM Condenser Lens Assembly Replacement 31 Beam Spreader Motor Assembly Replacement 33 Yoke Assembly y pay an sl cie apio euet 35 02 9671 0010 C 24 March 2004 xi VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL xii Tilt Motor Replacement a a u a s sia 35 Au
16. E ci 8 VARPKUTE z MADE IN USA C4 2002 Figure 3 29 Ignitor PCB Assembly 96 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN YOKE 3 Aux Controller PCB Assembly 24 9661 1400 Rev G Refer to Figure 3 30 No Item Qty UM Description Ref 1 11 9661 1400 1 EA CONTROLLER 2 52 6399 0001 1 EA JUMPER PROGRAMMING XJ6 3 52 6499 0007 1 EA CONN 14908 DUAL ROW 2MM SOCKET STRIP FEED THRU 4 52 6578 0006 1 EA HEADER 6 RT DUAL ROW W PEGS J5 TIN PLT 5 52 6590 0003 1 EA HEADER 3PIN SGL ROW 025 SQ PST J6 6 52 6591 0008 1 EA HEADER 8PIN DBL ROW 025 SQ PST 7 52 6611 0010 1 EA HEADER 50POS DBL ROW SHROUDED m 02550 RT 8 60 3242 1000 8 EA RES 1W 1 1 0 OHM WW SUR MT R1 R2 R5 R9 R15 R17 R24 R26 9 60 9460 1003 2 EA RES 1W 5 1 0 K 100V CHIP THICK FILM R29 R48 SMT0805 10 60 9460 1004 7 EA RES 1W 5 10 0 K 100V CHIP THICK FILM R30 R33 R36 R46 R47 60 9460 1802 2 EA RES 1W 5 180 0 OHM 100V CHIP SUR MT R7 R8 12 60 9460 3303 1 EA RES 1W 5 3 3 100V CHIP THICK FILM R45 13 60 9460 7505 1 EA RES 1W 5 750 0 K 100V CHIP THICK FILM R32 14 60 9461 1504 6 EA RES IW 1 15 0 100V CHIP THK FLM R6 R16 22 25 SMT0805 R31 R39 15 60 9461 2433 8 EA RES IW 1 2 43 K 100V CHIP THK FLM R4 R10
17. No Item Qty UM Description Ref 23 60 9461 7323 2 EA RES 1W 1 7 32 K 100V CHIP THK FLM R26 amp R32 SMT0805 24 60 9471 0200 2 EA RES 2W 1 0 2 OHM POWER METAL STRIP R34 amp R42 SUR MT 25 62 2104 3826 1 EA CAP 82UF 35V RAD ALUM 63 15MM 20 C22 LOW ESR 26 62 4000 0105 19 EA CAP 1UF 50V 20 CER CHIP SUR 250 1 14 C17 C20 amp EIA0805 C24 27 62 4000 0200 4 EA 20 50V 5 CER CHIP SUR MT COG C15 C16 C23 amp EIA0805 C27 28 62 4003 0102 2 EA 1000 50V 10 CER CHIP SUR MT X7R C43 amp C44 EIA0805 29 62 4003 0104 6 EA CAP 0 1UF 50V 10 CER CHIP SUR MTX7R C25 C26 C36 amp EIA0805 C39 C41 30 62 4005 0101 2 EA 100PF 50V 10 CER CHIP SURMTCOG C28 amp C29 0805 31 62 4205 0107 1 EA 100UF 10V 20 SUR C21 32 62 4206 0105 2 EA 1UF 16V 10 TANT CHIP SUR MT EIA A C33 amp C37 33 62 4209 0224 2 EA 22UF 50V 10 TANT CHIP SUR MT C34 amp C38 34 62 4210 0103 2 EA CAP O1UF 50V 10 MONO CER CHIP SUR MT C32 amp C35 35 62 4210 0104 1 EA 1UF 50V 10 CER CHIP SUR MT C42 36 62 4225 0107 2 EA 1000 35V 20 ALUM ELECTRO SUR C30 amp C31 37 63 2032 0001 4 EA VARISTOR 250V 145MA RADIAL TR250 PTCI PTC4 38 64 4016 0506 1 EA CRYSTAL 16MHZ SUR MT 39 68 4566 0001 1 EA INDUCTOR 173UH PE 53819S LCI 37 SUR MT Ll 40 70 3738 0001 1 EA FUSE HOLDER F FUSE 7
18. 1 Lamp Power Up State L ON L OFF gt 2 24 March 2004 02 9671 0010C TABLE OF CONTENTS Table of Contents Introduction About This Manual Ee c Ree 1 Additional Documentation 1 CUSTOMER SeEVICG uns uu etta deett d de oec a euet etse 2 Technical Bulletins and Notices 2 Chapter 1 Description Features Standard Features 4 Major Components VE2000 Wash Lumnmnaire cente E e ree iege 5 Ment 0 6 LED Indicators nee ERE I Pe 4 6 Head Components 7 Yoke Components a eee Ree cola tee nine Ee e n Rr pr 8 Enclosure Comporients Deere e uai NE Sa ERA Terres 9 Principles of Operation Power and Data Flow Diagrams 10 Chapter 2 Maintenance Testing Testing Software
19. 4 2 pl Figure 3 9 Blue Motor Assembly 68 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Amber Motor Assembly 21 9671 0184 Rev C Refer to Figure 3 10 Description 1 10 9671 0187 1 EA BRACKET MOTOR ADJUSTABLE 2 44 5031 0001 1 EA MOTOR STEPPER 42MM X 40MM 10 OHM CUSTOM WINDINGS 3 53 6513 0023 4 EA SCREW M3X 8MM PFZ METRIC 4 53 6558 1188 2 EA SCREW 6 40 X 188 SET CUPPED BLK OXIDE 5 54 1246 0001 1 EA BORE REDUCER 1 4 TO 5MM 5 8 LG 6 54 2042 0001 1 EA PULLEY TIMING 080 PITCH 48 TOOTH 1 8 WIDE Figure 3 10 Amber Motor Assembly 02 9671 0010 C 24 March 2004 69 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Front Lens Assembly 21 9671 0492 Rev A Refer to Figure 3 11 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 4 12 9671 0418 1 EA CONCAVE LENS ARRAY SMALL MASKED 5 42 9671 0490 1 EA LENS FRONT STIPPLE 6 53 6611 0001 4 EA SCREW 6 32 X 1 2 PFB Figure 3 11 Concave Lens Assembly 70 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Convex Lens Assembly 22 9671 0414 Rev B Refer to Figure 3 12 Description 1 10 9671 0419 1 EA FRONT CLAMP CONVEX LENS 2 10 9671 0420 1 EA BACK CLAMP CONVEX
20. NEXT 24 9661 1225 DRAWN BY MA SIN IF9 201 REGAL ROW ASSY WALSH R VN DALLAS TEXAS 75247 PCB NO 11 9661 1225 DSN TW 10 7 99 CONFIDENTIAL EHK MAIN CONTROLLER ALL INFORMATION CONTAINED HEREIN S THE SOLE AND EXCLUSIVE PROPERTY SIZE REVISION DRAWING NUMBER OF VARI LITE INC AND MAY NOT BE USED DISCLOSED OR REPRODUCED D 145366151225 Filename VLFS_MAIN_ CONTROL IN ANY MANNER WITHOUT THE ADVANCE Date Time 9 26 2000 13 47 WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 4 8 4 3 2 1 C 24 March 2004 157 VARI KLITE VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Controller Schematic cont O1
21. hh E RH 68 Amber Motor Assembly 69 Front Lens Assembly lt 70 Convex Lens Assembly ucciso ni teer re rU e RR eee eee boe rne 7 Rear Assembly E bose tes no RR 1 72 Tilt Pulley Bearing Assembly 74 Tilt Bearing Housing Assembly 75 Reflector Assembly redet dedu eee ee e ua 76 Back Assembly dti mua re en NE NEAR LIEFER 77 Fan Cover Assembly suisses 79 Dimmer Bulkhead Assembly ss 81 OpticaliSensorASsembl Wu 83 Color Bulkhead Assembly 84 Color W O Color Wheels Bulkhead Assembly 86 Color Motor Assembly 2 tt NE 87 Sensor PCB Assembly 88 Magenta Motor Assembly us 89 Crossfade Color Sensor Assembly 90 Filter Wheel Assembly 91 24 March 2004 02 9671 0010C TABLE OF CONTENTS Chapter 4 Illustrated Parts Breakdown Yoke pem entiende 93 Ignitor PCB Assembly de rete kk 95 Aux Controller PCB Assembly 96 Enclosure Upper Enclosure Assembly n nn R11 99 Connector Panel Assembly 104 Main Controller 3 Phase PCB Assembly 105 DMX Input PCB Assembly 109 Pan Tube Assembly 0 eedem 110 Pan Motor Assembly 112 Pan Tilt Encoder PCB Assembly 114 700W Arc P
22. Description 1 52 8250 0001 2 EA TERM 8 RING 10AWG 2 73 7089 0504 14 FT WIRE 22AWG 300V 2006 TER GRN YEL UL1180 Figure 3 57 Yoke to Head Ground Cable Assembly 02 9671 0010 C 24 March 2004 141 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Lamp Supply To Relay Cable Assembly 25 9667 0029 Rev D Refer to Figure 3 58 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 2 33 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 4 73 7089 0000 19 83 FT WIRE 22AWG BLK 300V TEFLON STRANDED 5 73 7089 0009 19 83 FT WIRE 22AWG WHT TEFLON STRANDED 9D Figure 3 58 Lamp Supply to Relay Cable Assembly 142 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 Ignitor To Relay Cable Assembly 25 9667 0030 Rev A Refer to Figure 3 59 No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG PIDG 2 52 8312 0001 1 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 73 7101 0009 1 FT WIRE 14AWG 15 1506 SILICONE 41 30 STRANDING 2 1 Figure 3 59 Ignitor To Relay Cable Assembly 02 9671 0010 C 24 March 2004 143 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Head OT Switch 2 Cable Assembly 25 9667 0
23. VL2000 WASH LUMINAIRE SERVICE MANUAL Auxiliary Controller Schematic cont 02 9671 0010 C REFERENCE FOLD OUTS 013 7 01 2 48 PHASEL7 O1 2 48 NAGLO 81 2 15 T ziv BE 9 1710 az vcc 818 811 7 5k EA MAGO e 17108 17 4 819 2 12 ui 2 13 PHASES T 10 er 17108 80V 3 4 gt k Riz c5 7 54 4790Pf MAGI 80V 17 108 25 244 7 p in L 10 50Y 1 1 cc EZE wee 4 iH ii ES e 23 az x 2 vc Phasia PHASES 1 3 4 FA PAK 0132 0181 fied MAG iz MB ME EA 17108 17 108 7 B49 PBL37730N 1 ca 1 628 2 43K PHASER Wise Nae 2 3 C4 6 047UF 6 047UF 45 s wama rio 15 1710 0133 iss 5 50V EE Raz ene Naca AA ry EL T gt des ho Je T 10 1710 50V Le lL 125 1 ix ix i id eo
24. ti Apo 8 7 2 33 lt lt PFC X 400W 625W 700W ARC BALLAST CHOKE 24 9661 1130 OT SUA 30 tat OT_SWB Jumper SETTINGS zz J204 8 E 1206 TWSTED 625 700 400 es m Sa mx 2 ec ENCODER SENSOR 08 2 Mr PAN TRAVEL RED 3 E 24 9661 0629 vcc 4 5 SENSOR GRN Or voa 5 5 8 6 203 lt 3 TN 3 549 E 3 23 9661 1253 6 SENSE 2242 6886 TWISTED WRES 56 05 gt 866 3 5 6 tettas Gross or TWISTED WIRES 25 9661 1525 3201 eet cm Q m i o r o o 9 6552980455 VE 555 54 3 coo a m m 5 lt lt VLFS BALLAST RIDER BOARD BOARD TO BOARD 24 9661 1131 WT TO RELAY PIN 4 SHEET 2 WT TO RELAY PIN 6 SHEET 2 GRN YEL TO YOKE GND STUD SHEET 2 24 March 2004 CONFIDENTIAL ALL INFORMATION CONTAINED HEREIN DOC IS THE SOLE AND EXCLUSIVE PROPERTY OF VARISLITE INT AND MAY NOT BE M
25. 10 Eeay PICT vcc us 1 854 2212 1141 16234 LMAR T INA outa 2 82 ENT 322 IN2 LA 10K 17 oe ene mis 74HC94 1 1 2 42 De 010 0L4148 48 VREF 0 01UF ver i jenna veont HE 10 R 10 5 Vd e e ii nac 2 190 24 22 1 AL cnoo DLA14B Y om U 220 10 101 2552 Rad 18V 501 amp R42 For Tout A ces Tout 3A Vout 5V _ 07 42 caa ZSDL4148 10 2W 3006 50V 20 357 Wee cc 5 Ncc 102619 8 Vv XA 2 1 x8 ER 4 3 m ZA 5 18 7 lt re SENSEI SENSE 2 22 m 14 3 42 RIA 15 bases 3 42 exces mic 20 1 cc 21 lt PTCB uzo 1 2 82 MEM 7 2 82 52 xe 2 82 Wk 2 x e enz outa 25 28 ii 2 42 ENa 08 DL4148 26 REF 0 01UF veont HE 10 e E 11 vasa 20 12 1 Da e 1558 014148 mer 10 102 Fibs 18v 50V o 834 For Tout 3A Vout 5V 05 PO 30 24014148 T 6 10 100UF 107 201 50V 3257 DRAWING NUMBER SIZE audes us SHEET OF 4 Date Time D ViewDraw for Windows 7 5 B 6 S 4 3 1 02 9671 0010 C 24 March 2004 160 VARFXLITEG VL2000 WASH LUMINAIRE SERVICE MANU
26. 24 A13 00121 22 012 asa Zi aaz 35 012 19 dios da 41 ta aga t ijui ia Lb ps yam 2 43 37 1 YLCNTR YLOLO 18 pass 214 Ass 15 1 048 014 1 45 4 38 pis 1 A18 0015 4 1 311 18 15 1 046 Et Aaa is 22 _ 38 Du a ma TE de Ya 27 cca 4 Nee Que vece LT T Le T 28 Ncc 25 3 YrLez ce nea k 17 B 28 ae nest Ag 19 nee 2 MET 11 17 Y ziaz FCLK 3 OT E GND 2 41 m iomestr nv aa pis Puces 1 7 e 27 7 1551 vcc v 46 Yssz x 2712 2 2 pi vee sur 2 42 W TRE PTC us cc 150 5 HCPL 9B09 180 5 T8280 145 1 c ec Nea Nm PTCA 1 7 2 1 1 3 ane 2 42 m fxD0 5 TR280 148 1 110 s 1555 71 12 5 PEKE13CA 2 LTC481 MAIN BX 1 103 MAIN 4 14 4 vec MAIN 423 2 816 189 5 I 4 2 42 C20 5 gt B 9 1UF 150 5 5 NORMAL 2 na 17 3 1 74HC04 REB CR c us 5 V 6181 52398 524 E ui amp M PTCA X HCPL 0600 123 csp 2 2 150 8 2 12 7 2 7 1 TR280 148 74HCO4 B21 0 1UF 5 5163 eup 5 NV SHIELD 18250 145 Ncc
27. 250 C304 C402 1210 46 62 4221 0105 1 EA 1UF 50V 20 ALUM ELECTRO SUR C412 47 62 4223 0475 5 EA CAP 4 7UF 50V ALUM ELECTRO SUR MT C308 C405 C406 LOW ESR C420 C424 48 62 4224 0107 1 EA 100UF 35V 20 AL ELEC 8MM DIA 105C C409 S MT 49 63 2049 0001 1 EA 500 OHM CERMET 13 SUR R410 50 82 4327 0001 2 EA DIODE 1 5819 RECTIFIER GLASS D301 D403 51 82 5344 0001 1 EA DIODE GLL4740A ZENER D401 52 82 5345 0001 1 EA DIODE GLL4736A ZENER D402 53 82 5346 0001 6 EA DIODE LL4148 SMALL SIGNAL D404 D409 54 83 3201 0001 1 EA IC LM293D DUAL OP AMP DUAL U402 COMPARATOR 14PIN DIP 55 83 3202 0001 1 EA IC LM258D DUAL DIFFERENTIAL U404 56 85 5157 0001 1 IC UC2854ADW PREREGULATOR 16PIN SOIC 0301 37 85 5160 0001 1 EA IC UCC2305DW HID LAMP CONTROLLER U401 58 86 6120 0001 1 EA IC LTV817S PHOTOCOUPLER SUR M U403 Figure 3 41 700W Ballast Rider Board PCB Assembly 02 9671 0010 C 24 March 2004 123 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Tilt Motor Assembly 22 9661 0610 Rev D Formerly 22 9661 0665 Rev E Refer to Figure 3 42 No Item Qty UM Description 1 10 9661 1298 1 EA PLATE TENSION ADJUST PAN MOTOR 2 22 9661 0608 1 EA ASSY DRIVE PULLEY 10 9661 0640 1 EA CODEWHEEL 90 COUNT 10 9661 0649 1 EA TIMING PULLEY 2MM GT 17 TOOTH
28. AL PIE 201 REGAL ROW ASSY T E WALSH DALLAS TEXAS 75247 PCB NO 11 9661 1400 DSN T W 9 29 99 CONFIDENTIAL RE AUXILIARY CONTROLLER ALL INFORMATION CONTAINED HEREIN m IS THE SOLE AND EXCLUSIVE PROPERTY DRAWINGAN UMBER OF VARI LITE INC AND MAY NOT BE E USED DISCLOSED OR REPRODUCED MFG B 14 8867 7500 Filename VLFS_AUX IN ANY MANNER WITHOUT THE ADVANCE Date Time 10 25 2000 1 WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 3 3 2 0 4 2 1 24 2004 154 VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Auxiliary Controller Schematic cont 4117 61 AL17 01 D 0 15 0 0115 0 u11 D AM28F2008T 55 c
29. Contains Lamp Assembly Fan Assembly Front Internal Assembly Contains lens assemblies and front color assembly AS Nose Cover 02 9671 0010 24 2004 7 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Yoke Components The following illustration shows the major sub assemblies which are located in the luminaire yoke assembly Head and enclosure not shown for clarity Relay Assembly lgnitor PCB Assembly Auxiliary Controller PCB Assembly Se Board side Leg 9 Tilt Motor Assembly Tilt side Leg Tilt side lt gt Yoke Leg 670600B2 Board side Yoke Leg Rotate yoke fully counter clockwise To determine which yoke leg is which without having to remove the covers rotate yoke counterclockwise until it stops then look at the luminaire while facing the input panel assembly The tilt side leg is the leg to the left the board side leg is the leg to the right 2201LV Input Panel Assembly 24 March 2004 02 9671 0010C DESCRIPTION MAJOR COMPONENTS 1 Enclosure Components The following illustration shows the major sub assemblies which are located in the luminaire enclosure assembly Yoke and head assemblies not shown for clarity Input Panel Inside View DMX Input PCB Assembly Enclosure Covers Main Controller PCB Ballast Module Assembly i Main Controller PCB Ass
30. EE 37gw Revised 06442 D 50V C307 D oe oe 3301 8302 6302 rud NOTE 5 NOTE 5 NOTE 5 8414 fd 17 m 1 85 gt M 6313 8403 6303 4 T HI ETE 1000PF 4 nig de 1788 au 5 HU uL a AM 4N5B49M sov Y Tr 20 case 207 1784 3 5 50V 1000PF u301 19 METER R405 1 mnt m e LES ura D R415 E gt cr Et 4 4 3494 224 sense 29 1 0401 178 MULT DUT RSET Bie Sue 611474046 E E 30 va aut E vier e gt 1 TS WARNUFVLPOVER VEUTSENSE as m or 53 4 LOADSENSE WM 1 08 GIEF 82K FT 6 15 1089 e 4 8 UCC2305DW caos 178 e HID 304 4 caNTAOLLER TAM NOTON 50V o ur ls aoutro Nom ui 7 e BAT 24 5 492 1 97 1 08 pypassstopEewAmWureapa rure oe insaieu ZS te 154P L 1744 HEEE 2 J40 6408 6410 1434 640456 2 16001 22149051090 5 222 d ARE 3393433443 BET 49 amp of gt gt ul REMMEEEEEMBEEI Pape ma TABLE 1 NOTE 5 H REF DESIG 1200W 400 625W 700W 8 6301 22PF 22PF 47PF page 1 07 KI gt gt C30
31. SENSE 1 s BLK IHE HI gt Leu m Irma IUBE MN A a vp XN Zr X TE X I BLK RED dd ORN L ne BRN BLK BLK eee RED ORN ORN RED BRN BLK BLK BRN RED ORN BLK RED lorn BRN La WHT WHT LJ OT SWITCH TWSTED WRES JE Es BK 3 vcc 3 at 9 BRN TWSTED WRES m 80 GND COLOR SENSOR BOARD 6 24 9638 0113 BK T COLOR STORN A WIRING DIAGRAM VL2402 700W ARC SIZE REVISION DRAWING NUMBER 14 9671 1550 ACAD LT 2000 SHEET 2 OF 2 DIMMER MOTOR suc eiojmio mem 225 SCALE N A 02 9671 0010 C 24 March 2004 150 VL2000 WASH LUMINAIRE SERVICE MANUAL 400W 625W 700W Ballast Schematic 02 9671 0010 C REFERENCE FOLD OUTS REVISIONS SC Ei DESCRIPTION DATE APPD Unlesss th
32. To remove and replace ignitor PCB assembly CAUTION Always use anti static precautions when working with PCBs WARNING All maintenance procedures are to be performed with power removed from the luminaire gt P Step 1 Disconnect luminaire AC input cable from power source Step 2 At each yoke leg remove yoke leg cover by removing four 6 32 X 5 16 PPB screws Figure 2 20 6 32 X 3 16 PPZ Screw 4 6 Lock Washer 4 Ignitor Assembly Ve 1 4 Hex Standoffs 2 Accessible 6 32 5 16 PPZ screws 2 6 Lock Washer 2 Yoke Leg e x Yoke Cross Member 6 32 X 5 16 PPZ Screw 2 6 Lock Washer 2 6 32 X 5 16 Sat PPB Screw 8 5706008 Figure 2 20 Ignitor Assembly Replacement Step 3 At yoke cross member using 2 Phillips screwdriver remove four 6 32 X 3 16 PPZ screws and four 6 lock washers which secure cross member 02 9671 0010 C 24 March 2004 39 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL cover to yoke and remove cover These screws are accessible from inside yoke legs Step 4 At Ignitor PCB assembly remove two accessible 6 32 X 5 16 screws and two 6 lock washers which secure ignitor PCB assembly to yoke leg Step 5 At yoke cross member remove two 6 32 X 5 16 PPZ screws and two 6 lock washers which secure ignitor PCB assembly 1 4 hex standoffs to yoke leg Step 6 At ignitor PCB assembly disconnect ign
33. ASSY MAIN CONTROLLER 3 PHASE 24 9661 1225 Tools Screwdriver 2 Phillips To remove and replace main controller PCB assembly CAUTION Always use anti static precautions when working with PCBs WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At enclosure remove power supply side and ventilation covers Refer to Removing Enclosure Covers on page 41 Step 3 At main controller PCB disconnect wiring Location J2 Connector 8 Pos Red MTA J3 2 Pos Blue MTA Fan J5 6 Pos White Connector dual row J6 4 Pos White Connector dual row J7 4 Pos Red MTA J9 20 Pos Black Connector dual row 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES 4 Step 4 Attop of PCB remove two 6 32 5 16 PPZ screws and remove Figure 2 28 6 32 X 5 16 PPZ Screw 2 Main Controller PCB Note Some components not shown for clarity Side View PCB fits into card guide on rail 1 Sd MAINPCB Input Pane Figure 2 28 Main Controller PCB Assembly Replacement Step 5 Install replacement main controller PCB assembly by performing Steps 2 4 in reverse order Ensure that bottom of main controller PCB is fitted into card guide on rail 02 9671 0010 C 24 March 2004 49 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE M
34. Wee hec v cc u7 1 1 MTANA25848 111 E 5 7 a7 vec 1 1 189 5 23 2 2 7 2 42 320 DATATN 1133 DATAIN 81733 UK o iur Teas 5 3 5 3 2 42 W CK BIT34 CLKIN ss 5 amp u17 57 3 DATAENA 74HC04 vLEp 2 42 p 12 VY LE lenna Do uic 217 14 NECH OSES i a vec 117 2 74HC04 815 580 Y 4 5 SHIELD ut 74AC14 24 CCo 150 uit HPR490 E o ur VIN 9 EB MAIN CONTROLLER 2 3 REVISION DRAWING NUMBER 3 D 14 9661 1225 SIZE I SHEET 3 OF 4 Filename Dote Time D ViewDraw for Windows 7 5 02 9671 0010 C 24 March 2004 159 VARFXLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Controller Schematic cont cc C40 0 1
35. 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 0003 1 EA SWITCH SLOTTED OPTICAL 4 24 9661 0629 1 EA PCB ASSY PAN TILT ENCODER 44 5034 0001 1 EA MOTOR STEPPER 42 X 40 10 OHM 6 53 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 7 53 5506 0625 4 EA SCREW 6 32 X 5 8 PPSS 8 55 6512 0001 2 EA WASHER 4 SPLIT LOCK 9 53 6520 0001 2 EA SCREW 4 40 X 3 8 PPZ 10 55 6621 0001 4 EA WASHER 4 FLAT ZINC 11 55 6669 0022 2 EA STANDOFF 1 4 HEX 4 40 500 02 9671 0010 C 24 March 2004 113 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly cont Figure 3 37 Pan Motor Assembly 114 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan Tilt Encoder PCB Assembly 24 9661 0629 Rev 0 Refer to Figure 3 38 No Item Qty UM Description Ref 1 11 9661 0629 1 EA PCB ENCODER SENSOR 2 52 6613 0005 1 EA HEADER 5 POS SGL ROW SHROUDED LATCHING 3 52 6613 0006 1 EA HEADER 6 POS SGL ROW SHROUDED m LATCHING 4 60 9460 1802 2 EA RES 1W 5 180 0 OHM 100V CHIP SUR MT RI R2 5 62 3009 0103 1 EA CAP 01UF 50V 10 MONO CER CHIP SUR CI 6 86 7009 0001 1 EA IC GP1A70R PHOTOINTERRUPTER 51 Figure 3 38 Pan Tilt Encoder PCB Assembly 02 9671 0010 C 24 March 2004
36. 5 55 2203 0001 4 EA SCREW 4 40 X 1 4 PPZ Figure 3 25 Magenta Motor Assembly 02 9671 0010 C 24 March 2004 89 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Crossfade Color Sensor PCB Assembly 24 9671 0175 Rev 0 Refer to Figure 3 26 No Item Qty UM Description Ref 1 11 9671 0175 1 EA PCB CROSSFADE COLOR SENSOR 2 52 6229 0001 1 EA HEADER 3 POS MTA FRIC LOK STRT POST J2 3 52 6447 0004 1 EA HEADER SHROUDED 4 POSITION 4 86 7005 0001 3 EA SENSOR HALL EFFECT A3141LLT SUR MT S1 S3 90 Figure 3 26 Crossfade Color Sensor PCB Assembly 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Filter Wheel Assembly 22 9673 0145 Rev A Refer to Figure 3 27 Description 1 22 9673 9143 1 EA ASSY FILTER WHEEL HUB AND CLIP 5 10 9638 0122 1 EA CLIP WHEEL RETAINER 22 9673 9142 1 EA ASSY COLOR WHEEL MARKED 53 6530 0002 1 EA RIVET 1 8 OD POP 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 BASTARD AMBER 1 ST 6 41 6006 0440 1 EA ASSY VL6 FILTER ORANGE ST 7 41 6006 0540 1 EA ASSY VL6 FILTER YELLOW ST 8 41 6006 0660 1 EA ASSY VL6 FILTER GREEN ST 9 41 6006 0820 1 EA ASSY VL6 FI
37. 8 3 4 5 1 24 March 2004 151 VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS 400W 625W 700W Ballast Schematic cont 0205 MUR4E0 1 5 250 1 SKE2804 i 409213 X b 251 skEz50A D 0203 0204 D 4207 E 5 i 6203 es 8214 1 3 2 02 2 03 sy 608 go 2 68 2 86 2782 S 52 esf A L 6 ir nm 21 BUCKBTAS 7F105 THERNALOUT B Le igi ftl nr 5 x 8 22 NOTE 4 1204 120 x POR 0202 4901 501 hd gt As TXFH 32N50 zu is 4 1 E 1 8KE2504 BUCKBIAS lt 4 2 MD Ja von 1 02 0201 TXFH 32N50 1 48 YBULK 5208 L NOTE 5 245 C219 gt NE CAS Lite et at vpp vcc 52 E A218 10 gt 475 ox 203 Rega HIN vas om 174W Taek 3308 E I x 36 Fra ti TAE E 225 8450 182110
38. S6 sa 199 Figure 3 34 Main Controller 3 Phase PCB Assembly 02 9671 0010 C 24 March 2004 109 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL DMX Input PCB Assembly 24 9661 1251 Rev D Refer to Figure 3 35 No Item Qty UM Description Ref 1 11 9661 1251 1 EA PCB DMX INPUT 2 52 6525 0005 1 EA HEADER 5 POS RA SHROUDED 1 CTR 52 6585 0005 1 EA CONN XLR SPIN FEMALE PC MOUNT VERTICAL 4 52 6586 0005 1 EA CONN XLR SPIN MALE PC MOUNT m VERTICAL 5 62 3017 0102 1 EA 1000PF 250V RAD CER DISC 20 Y TYPE 6 73 7046 0001 16 FT WIRE 22 AWG STRND GREEN Figure 3 35 DMX Input PCB Assembly 110 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan Tube Assembly 21 9661 1208 Rev K Refer to Figure 3 36 No Item Qty UM Description 1 10 9661 1247 1 EA TOGGLE STOP 2 10 9661 1290 1 EA PAN TUBE 3 10 9661 1291 1 EA FLANGE PAN TUBE 4 21 9661 1207 1 EA ASSY PAN SUPPORT PLATE gt 10 9661 1297 1 EA PLATE PAN SUPPORT 55 2139 0003 1 EA STANDOFF 1 4 RND 8 32 188 LG FF ALUM 5 21 9661 1212 1 EA ASSY PAN BEARING CUP FLANGE SIDE 10 9661 0611 2 1 EA PAN BEARING HOUSING 54 1244 0001 1 EA BEARING 1 25 BORE 2 2 WD CONRAD 6 22 9661 0601 1 EA ASSY PAN TILT BEARING 10 9661 0611 1 1 EA TILT
39. SCREW 8 32 x 3 8 LG UNDERCUT changed 12 10 03 14 54 2044 0001 2 EA BELT TIMING MXL 080 PITCH 93 TOOTH 1 8 WD 15 55 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 16 55 2234 0001 1 EA E RING 188 SHAFT DIA CAR SPR 511 17 55 6503 0001 2 EA WASHER 8 LOCK INT TOOTH 18 55 6578 0003 2 EA STANDOFF 5 16 HEX 8 32 1 500 LG FF ALUM 19 55 6677 0034 1 EA WASHER 500 OD 187 ID 045 THK FLAT TEFLON 20 55 6706 0001 1 EA GROMMET 9 32 ID 9 16 OD 1 4T SILICONE RED 02 9671 0010 C 24 March 2004 63 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Front Color Assembly cont 17 2 pl 77 8 10 2 14 2 10 3 13 4 18 2 Figure 3 5 Color Assembly 64 24 March 2004 0007E 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Blue Amber Color Wheels Assembly 21 9671 0150 Rev D Refer to Figure 3 6 Description 1 10 9671 0190 1 EA BUSHING BLUE AMBER 2 10 9671 0191 1 EA ASSY BLUE WHEEL 3 10 9671 0194 1 EA PULLEY BLUE COLOR WHEEL 4 10 9671 0198 1 EA GASKET COLOR WHEELS 5 10 9671 0199 1 EA SPRING COLOR WHEELS 6 21 9671 0158 1 EA ASSY AMBER COLOR WHEEL 7 21 9671 0162 1 EA GLASS ASSY BLUE COLOR WHEEL 8 53 5558 0376 2 EA SCREW SET 6 32 X 375 HALF DOG 9 53 6597 0001 4 EA SCREW 4 40 X 3 16 PPZ Figure 3 6 Blue Amber Assembly 02 9671 0010 C 24 March 2004
40. following standard features DICHRO TUNE radial color changer which employs enhanced dichroic color filters to produce smooth full spectrum color crossfades The mechanism allows independent cyan magenta and amber color control An internal mechanical douser which provides intensity control and strobing An upper enclosure that houses the control electronics as well as a power factor corrected arc power supply or an SCR dimmer appropriate to the particular lamp source Control by systems or a wide variety of DMX 512 consoles without the need for additional interface equipment Two easy install truss hook brackets for versatile hanging configurations 700W arc source Zoomable beam spreader 24 March 2004 02 9671 0010C DESCRIPTION MAJOR COMPONENTS 1 Major Components VL2000 Wash Luminaire The following illustration shows the major luminaire components and controls Removable Lamp Assembly to access lamp for replacement r Upper Enclosure Assembly Truss Hook Bracket Assembly AC Input Cable Vertical Horizontal Focus Captive Knob for lamp access does not adjust beam Input Panel Components Product Label ID ___ Power and Data Menu Display Main Power Switch LED Indicators MENU ENTER 2 AC Input Cable
41. 0129 1 EA VL6 BACKCAP 9 22 9638 0265 1 CASTING ASSEMBLY VL6 10 9638 0034 1 EA CASTING BACK VL6 x 55 6612 0005 2 PIN 3 1600 X 2 3 41 TYPE C LOW CARBON STEEL 10 25 9667 0413 1 EA CABLE ASSY GROUND TILT PLATE 52 8311 0003 2 TERM RING 6 14 16AWG NON INS 73 7130 0002 0 21 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED 11 52 8231 0005 2 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 12 53 2200 0010 1 EA 10 32 KEPS SS 13 53 2201 0010 2 NUT 10 32 HEX SS 14 53 5638 1250 1 EA SCREW 1 4 28 X 1 1 4 CAPTIVE 15 53 6519 0001 2 SCREW 4 40 X 5 8 PPZ VL 1 16 53 6525 0001 1 EA SCREW 6 32 5 16 PPZ 17 53 6526 0001 2 SCREW 6 32 X 5 8 PPZ 18 53 6534 0002 4 EA RIVET 3 32 OD POP 3 16 GRIP RNG ALUM 19 53 6539 0008 2 EA WASHER 1 4 FLAT SS 20 53 6539 0011 1 EA SCREW 10 32 X 2 1 4 PFBSS UNF 2A 21 53 6539 0012 2 EA SCREW 10 32 X 2 PFBSS UNF2A 22 53 6546 0002 2 EA SCREW 8 32 X 5 16 PPZ 23 53 6593 0001 1 EA SCREW 10 32 1 PPB 24 54 1209 0002 1 SWIVEL BEARING ASSY 385 STUD LNGTH 25 55 2134 0003 2 PLATE FLOATING NUT 10 32 26 55 2260 0208 1 92 FT SLEEVING FIBERGLASS 0 208 ID 27 55 3301 0006 3 EA WASHER 6 FLAT SS 02 9671 0010 C 24 March 2004 77 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Description 28 55 3303 0004 2 EA WASHER 4 LOCK INT TOOTH SS 29 55 6540 000
42. 1 445 846 47 lt Mes PEs7Mpp4 1 aa ET 10K 10 10k 849 s 5 e 008 22 3 1278 To hee ui vois Lamp Ballast 24 Nen 35 u23 gt 15 INT Nee 840456 8 Peast 55 1 s 4 7 pouse STAY Put csi 83 42 2 T PPE 5 70 2 22 T 2in2 ENSE4 7 72 D 47Az PF47CSD CE 3 45 3 TRE 73 5 ce 4 A2 LE Pus Pra cspo capro asar Linz asce p VEn rg7cspa 7 10 CRI BRA 2 22 2 02 43 78204 20 2 8 Aux cow 848 2 22 2 02 AAA 4 u 75 27 2 42 meei 850 8 00 BXDO RXDO 7 n E ITT TE 51 1 0 58 xps 102 77 3 errn pu Psz WXD1 1 13 VRS VRE 78 toy psavtxoap 158 3 v RS GREEN E ea 5 5V 5 6v 5 6v 62 5 6V7S 5 BY 81 75011341 pss soo 2 300 s n E 103 WEAR s PS amp SCK ENa 104 ss 144 4 82 EN 57 55 58 ERSTES 8921900410802 Lp 1 2 3 4 105 1NA VAL t mia 106 1NAZ vona PTi IDCi EXE se 197 1143 T vss 4 61271062 INA3 mp 4 42 ISA 57 108 1181 pano 51571063 EXE R36 arcem noe 1882 gays u18 110 INB3 76 PAD 15 1065 1883 4 42 751764 so 111
43. 1 25 mET u10 24 ET C34 0 4 OT tur TC5818844A4J AR Jaa nai 01 A3 23 33 22 re 5 aon az naz 1701 Ad 22 35 pa PE n 8 1702 5 21 4 A3 3 3 pz bas A2 1 03 20 40 4 2 10 na nas MCBBHCB812 538 rn FS sas de 15 p4 s2 1705 18 di 49 Ao po us 44 14 pg aa 047 az 14 53 48 is 28 Wee 4 01 ag 42 ray 20s gt 42 5 lia 52 vont 2 ioa 2607 nas 22 m 1 n 34 ns 58 pa 16 E 1 08 3 5 3 EE 04 00 REFIN 28 30 na 411 0011 1 57 25 pg PRESS 43 1 010 mE 4 As ps 5 01 25 31 pig 412 0012 sa 280 pio 5 A10 1 011 12 4i 43 pg 02 mS 24 3i piji Re 413 0013 T pz 11 5 411 1 032 1 fis 2 a is AT p7 gt pa A13 35 pig 0114 28 pe pie 4 412 1 013 1 45 iit 58 gt 04 20 38 18 0 15 4 1 A14 212 104 25 pa pis HAGE 413 1 014 ee Aa 05 vouta 55 3 03 uu 14 S Ta TE 30 pig 014 5 A414 1 018 liec 410 010 1 06 18 38 015 P 31 pii 18 A18 1 018 411 011 07 vouta 23 23 412 012 Die 11 eet I i oee veca PE 28 023 lec Are E Ni EE qa 41 014 cs 38 dis METUS poii 20 5 415 015 238 40 23 2768 Ast PES ce mes 20 mest 7 iT owe
44. 1 EA IC 5485 TRANSCEIVER SUR MT SOICPKG U2 32 84 4263 0001 1 EA IC AD7302BR 8 BIT 2 7 5 5V PARALLEL U9 INPUT DUAL VOLTAGE OUTPUT 33 84 4270 0001 1 EA IC NC7S08M5 SINGLE AND GATE SUR U12 34 84 4285 0001 1 EA 1 NC7S04M5 HS INVERTER U6 35 85 3773 0001 4 EA IC STEPMOTOR DRIVER U1 U3 U4 07 36 87 7247 0001 1 EA IC AM29F200BT FLASH MEMORY 5V Ull 37 87 7302 00XX 1 EA INSTALLER DISK SET BURNER VL2000 LUMINAIRES 38 88 8130 0001 1 EA LED GREEN SUR MT WATER CLEAR LENS D2 REEL 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN YOKE 3 Aux Controller PCB Assembly cont 1 MOTOR 1 31 r OO SI 32 Mm C2 OUI 2 1 643 umm 1 21 rMOTOR 4 10 m rm LUE Figure 3 30 Aux Controller PCB Assembly 02 9671 0010 C 24 March 2004 99 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Enclosure Upper Enclosure Assembly 21 9661 0004 05 Rev DD Refer to Figure 3 31 and Figure 3 32 No Item Qty UM Description 1 04 9640 0374 1 EA LABEL PE GROUND 2 04 9661 1218 01 1 EA LABEL PATENT VL2201 VL2400 SERIES LUMINAIRES 3 04 9673 0040 1 EA LABEL VL2202 VL2402 4 10 9640 0002 2 EA PAD CHOKE 5 10
45. 152 gt gt 22 ze lt ac 10 MOI x suns a 16 1010 922 297 15 2 C4 mp HAs NDS 15 ci te 22 HEEL 57 aa le le 17108 L_4 17 815 ty ty 1 1 AUXILIARY CONTROLLER REVISION DRAWING NUMBER B 14 3661 1400 S SE SHEET 3 OF 3 Filename Date Time D ViewDraw for Windows 7 5 1 24 March 2004 156 VL2000 WASH LUMINAIRE SERVICE MANUAL Main Controller Schematic REFERENCE FOLD OUTS 02 9671 0010 Notes Unlesss Otherwise specifi 1 11 capacitor values 2 11 resistor values 3 qe SOS lt 2 4 Resistors are 1 10W 5 Power and ground symbols Wee tia te pews ed vee Vee 75V Logic power 211 24V C 24V Power sb Gnd Logic ground fie fer ered Des ge toms Last Used Not Used C42 D11 F1 1 11 Lad 467 R43 56 023 41 2 VH 1 WT 74 ed ar re 0 2 crofarads ohms REVISIONS REV DESCRIPTION DATE APPD Released per EO 406405 10 7 98 T W A Revised per EO 06415 1 26 00 B Revised per EO 06420 3 7 00 T W C Revised per EO 406421 9 18 00 T W D Revised per EO 06435
46. 2 1 2 8 Reference Designators Z1 72 8191 e 1 Last Used Not 2 1 5 220 1 5KE220CA 11 C45 3 MU LEE 0 0041UF 4 e B 2 14 e 80 20 LLL Li 3 15KV e J 4 R12 8191 561 4 E 72 J 2 8191 3 1 4 2 3 DUNTING 4 1 M2 Notes M3 NEXT 24 9001 1129 DRAWN BY VARIBKLITE 201 REGAL ROW lind ess E EA M4 amp ASSY K FELDHAUS AN DALLAS TEXAS 75247 1 11 capacitor values microfarads Ni 11 9661 1125 DSN VLFS IGNITOR ya epe d 3 E E E IS THE SOLE AND EXCLUSIVE PROPERTY p p c SIZE REVISION DRAWING NUMBER apacitors are OF VARI LITE INC AND MAY NOT BE 14 9661 1125 USED DISCLOSED OR REPRODUCED MF 6 eere Filename VLFS_IGNITOR IN ANY MANNER WITHOUT THE ADVANCE Date Time 10 20 1999 7 15 WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 1 02 9671 0010 C 24 March 2004 162 VARPKLITE Express yourself Vari Lite 10911 Petal Street Dallas Texas 75238 1 877 VARI LITE Fax 214 647 8038 www vari lite com 2001 2004 Genlyte Thomas Group LLC All rights reserved Printed in the U S A
47. 32 750 LG MF SS 23 55 6736 2500 0 11 FT TUBING TEFLON 053ID STD WALL 500V MIL FOR AWG 16 24 60 9244 0501 1 EA RES 30W 5 05 OHM TO 220 POWER FILM 25 60 9245 0751 1 EA RES 30W 1 075 OHM TO 220 POWER FILM 26 63 2047 0075 1 THERMOSTAT 75DEG MT CLOSE ON RISE 27 63 2047 0105 2 EA THERMOSTAT 105DEG PCB MOUNT CLOSE ON RISE 28 67 4018 0001 1 EA FERRITE 26 X 28 5 X 13MM CYLINDRICAL CORE 29 73 7051 0001 3 FT WIRE 22AWG BUSS 30 80 2628 0001 4 EA TRANSISTOR IXGH39N60BDI IGBT 76A 600V 31 80 2647 0001 1 EA TRANSISTOR IXGH32N60C IGBT 32A 600V 32 80 2648 0001 2 EA TRANSISTOR IXFH32N50 POWER MOSFET 5004 32A TO 247 33 82 4323 0001 1 EA DIODE BRIDGE D25XB60 600V 25A SIP 34 82 5341 0001 2 EA DIODE DSEI30 06A FRED 25 37A T0 247 AD 24 March 2004 02 9671 0010 ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 700W Arc Power Supply Ballast Module cont 18 2 pl 17 2 pl 15 2 pl 71125001 11 4 pl 19 3 Figure 3 39 700W Arc Power Supply Ballast Module Assembly 02 9671 0010 C 24 March 2004 117 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 700W Ballast Board PCB Assembly 24 9661 1130 Rev C Refer to Figure 3 40 No Item Qty UM Description Ref 1 10 9661 1336 1 EA GUIDE APS RIDER 2 11 9661 1120 1 EA P
48. 4 Lens Shaft 4 8 32 X 2 Screw Small Stipple Glass 7ogosors Figure 2 15 Convex Lens Assembly Replacement 02 9671 0010 C 24 March 2004 29 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 30 AN CAUTION Do not touch lens with bare fingers Wear cotton gloves or other covering while replacing Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Remove convex lens assembly from lens shafts In replacement convex lens assembly using 1 4 Allen Wrench adjust 8 32 X 2 screw so that screw head is nearly flush with drive bushing plate to create a 020 gap between concave and convex lens assemblies Slide replacement convex lens assembly and then old concave lens assembly onto lens shafts Hold convex and concave lens assemblies together and using 2 Phillips screwdriver re install four 8 lock washers and four 8 32 X 1 2 PPB screws and tighten to keep lens assemblies aligned Re install four 6 32 X 3 16 PPB screws and four 6 lock washers securing concave lens assembly to lens support arm Using 1 4 nutdriver re install one 4 40 KEPS nut on end of beam spreader motor assembly shaft Re install small stipple glass Refer to Small Stipple Glass Replacement on page 27 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES 100MM Condenser Lens Assembly Replacement Parts 100MM CONDENSER LENS 22 9671 0402 Tools Allen wrench 5 64 Cotton gloves Locti
49. 400W 625W 700W BALLAST REVISION DRAWING NUMBER SIZE H SHEET 2 OF 2 Filename Date Time D ViewDraw for Windows 7 5 02 9671 0010 C 24 March 2004 152 VARFXLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Ballast Rider Schematic 8 7 4 3 2 1 VO REVISIONS e AA A H BAT REV DESCRIPTION DATE APPD Released per EO 04545 9 20 99 BUCKPMN 10K D405 D404 20K T 1765 Revised per EO 406419 2 11 00 B C alle 2 er ore Tum PETRA s 5221 Revised per EO 406455 9 20 00 B C 9 Bebop 8185 ue 00 Tir d ir L 61 406442 1784 1 88 50
50. 65 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Amber Color Wheel Assembly 21 9671 0158 Rev D Refer to Figure 3 7 Description 1 10 9671 0192 1 EA ASSY AMBER COLOR WHEEL 2 10 9671 0196 1 EA SPACER CLAMP 3 10 9671 0198 1 EA GASKET COLOR WHEELS 4 10 9671 0199 1 EA SPRING COLOR WHEELS 5 21 9671 0163 1 EA GLASS ASSY AMBER COLOR WHEEL 6 22 9671 0506 1 EA PULLEY ASSY AMBER COLOR WHEEL 7 53 6536 0001 4 EA SCREW 4 40 X 1 2 PFZ Figure 3 7 Amber Color Wheel Assembly 66 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Amber Color Wheel Pulley Assembly 22 9671 0506 Rev 0 Refer to Figure 3 8 Description 1 10 9671 0193 1 EA PULLEY AMBER COLOR WHEEL 2 54 1251 0001 1 BEARING FLANGED 5 16 ID X 3 8 LG SINTERED BRONZE Figure 3 8 Amber Color Wheel Pulley Assembly 02 9671 0010 C 24 March 2004 67 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Blue Motor Assembly 21 9671 0183 Rev C Refer to Figure 3 9 Description 1 10 9671 0187 1 EA BRACKET MOTOR ADJUSTABLE 2 44 5031 0001 1 EA MOTOR STEPPER 42MM X 40MM 10 OHM CUSTOM WINDINGS 3 53 6513 0023 4 EA SCREW M3X LG PFZ METRIC 4 53 6558 1188 2 EA SCREW 6 40 X 188 SET CUPPED BLK OXIDE 5 54 1246 0001 1 EA BORE REDUCER 1 4 TO SMM 5 8 LG 6 54 2042 0001 1 EA PULLEY TIMING 080 PITCH 48 TOOTH 1 8 WIDE
51. Assembly 24 9661 1130 DMX Input PCB Assembly AC Input Splitter 700W Ballast Rider 24 9661 1251 Cable Board PCB Assembly 25 9661 1513 24 9661 1131 AC Input Pigtail Euro Cable 25 9661 1511 LVS Chassis Data Link Ground Cable Cable 25 9661 1514 25 9661 1532 MAIN TO AUX DATA amp Lamp Supply Harness PWR 2201 Cable Cable 25 9661 1516 01 25 9661 1537 01 Pan Tilt Control Cable Lamp Supply To Relay 25 9661 1517 01 Cable 25 9667 0029 Chassis To Yoke Ground Cable 25 9661 1520 02 9671 0010 C 24 March 2004 55 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Top Assembly Included Items Kit 28 9671 0001 Rev H Refer to Figure 3 1 Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8052 0001 1 EA CARD LIMITED WARRANTY 09 09 02 3 02 8406 0001 1 EA TAG LAMP NOTICE added 09 03 03 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION VL2000 5 02 9671 0002 1 EA UNPACK QUICK START SHEET VL2000 6 07 9667 0035 1 EA SHIPPING BOX CARDBOARD VL2000 7 08 2000 0001 1 EA CD ROM VL2000 LUMINAIRE 8 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 9 71 2528 0700 1 EA 700 WATT SHORT ARC PHILIPS MSR575HR LAMP Figure 3 1 Included Items Kit 56 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Top Assembly VL2000 Wash Luminaire 20 9671 0001 Rev D
52. EA CLAMP CABLE 3 8 SS W WHITE SILICONE CUSHION 15 55 6699 0003 1 17 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 72 24 March 2004 02 9671 0010C HEAD ILLUSTRATED PARTS BREAKDOWN Rear Assembly cont Rear Assembly Figure 3 13 73 24 March 2004 02 9671 0010 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Tilt Pulley Bearing Assembly 22 9667 0036 Rev F Refer to Figure 3 14 No Item Qty UM Description 1 10 9667 0621 1 SPACER FLANGE TILT PULLEY 2 22 9667 0039 1 EA ASSY REAR CASTING amp SIDE RAILS 3 22 9676 0086 3 EA ASSY TILT BEARING HOUSING 4 22 9667 0602 1 EA ASSY TILT PULLEY 150 TOOTH 2MM PITCH gt 10 9667 0618 1 EA TIMING PULLEY 150 TOOTH 2MM PITCH 2 062 ID 5 10 9667 0620 1 EA EOTFLAG TILT VL2201 53 6530 0004 2 EA RIVET 1 8 OD CSK 126 250 CRB STL 55 6612 0023 1 EA PIN GRV 250 OD 500 LG STL ZINC PLTD Figure 3 14 Tilt Pulley Bearing Assembly 74 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Tilt Bearing Housing Assembly 22 9676 0086 Rev 0 Refer to Figure 3 15 No Item Qty UM Description 1 12 9676 0085 1 EA HOUSING TILT BEARING MACHINED 2 53 6506 0001 1 EA BEARING TORQUE TUBE 2 625 OD 3 53 6522 2500 3 EA SCREW 6 32 X 1 4 HEX MACH UNSLOTTED ZINC 4 55 3303 0006 3 EA WASHER 6 LOCK INT TOOT
53. Filter Replacement Step 5 Noting proper orientation of carrier slot insert new color filter into position and push fully into place Step 6 Re install color bulkhead assembly as required and re install head cover 20 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Magenta Color Wheel Glass Assembly Parts GLASS ASSEMBLY MAGENTA COLOR WHEEL 21 9671 0161 Tools Screwdriver 2 Phillips Cotton gloves To remove and replace magenta color wheel glass assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove color bulkhead assembly Refer to Color Bulkhead Assembly Replacement on page 18 CAUTION Do not touch glass with bare fingers Wear cotton gloves or other covering while replacing Step 3 At color bulkhead assembly remove four 4 40 X 3 16 PPZ screws spacer gasket and spring and remove glass assembly from bulkhead Figure 2 7 Color Bulkhead Assembly Spring Spacer 4 40 X 3 16 PPZ Screws 4 Glass Assembly Figure 2 7 Magenta Color Wheel Glass Assembly Replacement Step 4 Install replacement magenta color wheel glass assembly by performing Steps 2 and 3 in reverse order 02 9671 0010 C 24 March 2004 21 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Crossfade Color Sensor PCB Assembly Replacement Parts PCB ASSEMBLY CROSSFADE COL
54. G VL2000 WASH LUMINAIRE SERVICE MANUAL 38 6 32x5 16 PPZ Screw 4 Aux Controller PCB 1 Aux Controller PCB 2 Counter Weight m Assembly va De 6 Lock Washer 12 1 4 Hex 6 32 750 Standoff 8 Connector Board side 6 Figure 2 19 Auxiliary Controller PCB Replacement Step 7 Perform one of the following steps as required a Ifauxiliary controller PCB 2 is being replaced install connector in new auxiliary controller PCB 2 at J1 b Ifauxiliary controller PCB 2 is not being replaced re install connector in auxiliary controller PCB 2 at J1 Step 8 To remove auxiliary controller PCB 2 disconnect yoke cable assembly from auxiliary controller PCB 2 at J2 Step 9 Using 1 4 nutdriver or open ended wrench remove next set of four 1 4 hex standoffs and 6 lock washers and remove auxiliary controller PCB 2 Step 10 Perform the following steps as required a Remove connector from auxiliary controller PCB 2 at 11 b Install connector on new auxiliary controller PCB 2 at J1 Note When installing auxiliary controller PCB 1 ensure pins of connector are seated correctly into connector 11 on back of PCB Step 11 Install replacement assemblies by performing Steps 2 10 in reverse order 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Ignitor Assembly Replacement Parts PCB ASSY IGNITOR 24 9661 1125 Tools Screwdriver 2 Phillips
55. HO Boos M34951 7008 HIGH 475K VOLTAGE 1821 3 4004 244 1 aaa azos Zn SEE osne M m ui 1 48 VOLTAGE m VPFCSNS E 0204 205 sp 4 HFA25FB50 990PF mas DRIVER 800v VM 42 2 1 0194 1010 Lo 1 24 5k 104 Ncap c216 12 Nea GND NC con LIN 1 24 5 gt 5 A B 10x GND X 1000v S 1201 0 08 1685 4 4 4 X He PFCGND LISNS T 20 oo 250v GATER GATES LI 1 C3 2 02 2 03 2 86 2 82 2 07 284401 7 2 2 C4 2 B2 4 2 82 0203 GATEA BUCKBIAS gt 0208 x vi 2 S 18453725 2 1 2 82 2 61 2 82 i 213 1 0 47uF 10 4 1201 2 82 1 5 2782 2 10 3 m 2501 oo H eg f 4E f Jas ts FE 22 e FDDUSE mo g2 JN 1211 B His 1 C3 2 02 2 03 2 CB 2 82 2 D7 HE 10201 722 z 1 85 1 A6 1 46 2 C5 2 1 1 A4 M XS mouse 1 44 mDOUSE 5 2 SE 1 4 1 4 5 Reza iP ias 3 5 aii RUCKPRN gt on 2 7 5 6 3 ES EN 4 5 GATER reie fL 868 0786 4 nggo b gt S 0313 N NS 1 10 s 295835 4 BUCKBT AS I1 63 2 22 2 23 2 C8 2 88 2 07 0215 1 4 m eres 2 83 gt 8 12 s 18473864 H r eins 1 THEBMALOUT wy 3 2 07 14 1 44 XSRIN 1 e 25 I
56. LENS 3 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 LENS ARRAY SMALL 8 53 2202 0006 2 EA NUT 6 32 HEX SS NYLON INSERT 9 53 5808 2000 1 EA SCREW 8 32 X 2 00 LG SCSS 10 53 6542 0001 8 EA SCREW 6 32 X 5 16 PFB 11 53 6608 0750 2 EA SCREW 6 32 X 3 4 LG PFB 12 53 6617 0002 2 EA SCREW 6 32 X 1 PFB 11 2 pl 7 10 6 pl 5 Figure 3 12 Convex Lens Assembly 02 9671 0010 C 24 March 2004 71 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Rear Assembly 21 9671 0009 Rev D Refer to Figure 3 13 Description 1 10 9638 0052 1 EA DAM AIR VL6 2 21 9660 0340 04 1 EA ASSY REFLECTOR VL6 VL6B LUMINAIRE 3 22 9667 0036 1 EA ASSY TILT PULLEY BEARING ASSY PRESS TO CASTING ASSY 4 22 9671 0404 1 EA ASSY BACK CAP 5 25 9667 0028 1 EA CABLE ASSY YOKE TO HEAD GND 6 52 8231 0005 2 EA TERM 6 RING 16 14AWG INS LOOSE 7 53 2002 0001 1 EA NUT 6 32 KEP ZINC PLATED 8 53 6525 0001 5 EA SCREW 6 32 X 5 16 PPZ 9 53 6534 0004 2 EA RIVET 3 32 OD POP 3 16 GRIP L STEEL 10 55 2186 0001 2 EA CABLE TIE 10 WD 4 00 LG SMALL 11 55 2233 0001 1 EA RECEPTACLE 1 4 TURN 12 55 3301 0006 1 EA WASHER 6 FLAT SS 13 55 3303 0006 5 EA WASHER 6 LOCK INT TOOTH SS 14 55 6596 0009 1
57. R14 R18 SMT0805 R23 R27 R38 R40 16 60 9461 7503 12 EA RES IW 1 7 5 K 100V CHIP FLM R3 211 813 R19 SMT0805 R21 RR28 R37 R41 R43 17 61 4817 1004 EA RES 10K 08W 50V 5 SUR R44 18 62 3009 0472 4 EA 4700PF 50V 10 MONO CER CHIP SUR C5 C11 C18 C27 MT 19 62 3009 0473 12 EA 047UF 50V 10 MONO CER CHIP SUR C3 C6 C7 C9 C12 MT C14 C15 C19 C25 C28 C30 20 62 4000 0105 14 EA 1UF 50V 20 CER CHIP SUR 250 C4 C10 C13 C17 EIA0805 C24 C26 C31 C38 21 62 4000 0200 2 EA CAP 20PF 50V 5 CER CHIP SUR MT COG C20 C21 EIA0805 22 62 4201 0106 4 EA CAP 10UF 35V 20 TANT ELECTRO CHIP SUR C1 C2 C8 C16 MT EIA D 02 9671 0010 C 24 March 2004 VL2000 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description Ref 23 62 4205 0107 1 EA 100UF 10V 20 SUR C22 24 62 4225 0107 1 EA 100UF 35V 20 ALUM ELECTRO SUR C23 25 64 4016 0506 1 EA 16MHZ SUR MT 26 68 4566 0001 1 EA INDUCTOR 173UH 538198 LCI 37 SUR MT 11 27 82 5325 0001 1 EA DIODE MBRS130LT3 SCHOTTKY SUR MT 1 28 83 3163 0001 1 EA IC MC34164D 5 SENSING CIRCUIT 05 UNDERVOLTAGE SURFACE MOUNT 29 83 3173 0005 1 EA IC LM2594M 5 150KHZ 0 5 STEP DOWN VRI VOLTAGE REGULATOR 30 84 0068 0812 1 EA IC MC68HC812A4PV8 UNPRGMMD 16BIT U8 MICROCONTROLLER 31 84 4234 0002
58. Refer to Figure 3 2 Description 1 10 9628 0211 1 EA STABILIZER PAN TILT 2 10 9667 0617 1 EA HEAT SHIELD YOKE CROSSMEMBER 3 10 9667 0632 2 EA COVER YOKE THERMOFORM 4 16 9671 0004 1 EA LABEL LOCATION VL2000 WASH LUMINAIRE 5 21 9661 0004 05 1 EA ASSY UPPER ENCLOSURE VL2202 700W 6 21 9671 0005 1 EA HEAD ASSY 7 22 9661 0665 1 EA ASSY TILT MOTOR 8 22 9667 0600 1 EA ASSY YOKE 9 53 2002 0001 1 EA NUT 6 32 KEP ZINC PLATED 10 53 6505 0020 5 EA BOLT 1 4 28 X 3 4 HX GRD 8 ZINC PLT FULL THRD 53 6517 0001 8 SCREW 10 32 X 3 8 PPZ 12 53 6525 0001 1 EA SCREW 6 32 X 5 16 PPZ 13 53 6526 0001 1 EA SCREW 6 32 X 5 8 PPZ 14 53 6539 0008 5 EA WASHER 1 4 FLAT SS 15 53 6543 0001 8 EA SCREW 6 32 X 3 8 PPB 16 53 6608 0003 4 EA SCREW 6 32 X 3 16 LG PPZ VL 1 17 53 6610 0005 3 EA SCREW 6 32 X 7 16 PPB 18 54 2039 0001 1 EA BELT GT TIMING 2MM PITCH 182GRV 9MM WD NYL CVRD FBRGLS NEOP 19 55 2114 0001 8 EA WASHER 10 LOCK INT TOOTH 20 55 2132 0006 1 EA STANDOFF 1 4 HEX 6 32 1 188 LG M F SS 21 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNTING 22 55 2186 0001 1 EA CABLE TIE 10 WD 4 00 LG SMALL 23 55 2191 0001 1 EA CABLE CLAMP 1 2 WIDE 5 8 CABLE 24 55 6538 0001 4 EA WASHER 46 LOCK INTERNAL TOOTH 25 55 6549 0001 5 EA WASHER 1 4 SPLIT LOCK 26 55 6603 0001 1 EA SPRING SS 4 6 IN EXT
59. STABILIZER MOTOR 5 10 9667 0291 1 EA DIMMER BULKHEAD 6 21 9667 0293 1 EA ASSY UV DIMMER HEATSHIELD 10 9673 0292 1 EA DIMMER HEATSHIELD 41 9637 0047 1 EA MIRROR UV BLOCKER 7 23 9667 0216 1 EA ASSY OPTICAL SENSOR 8 44 5029 0001 1 EA MOTOR STEPPER 42MM X 34MM 9 53 2005 0001 1 EA NUT 3 8 32 X 3 321 WHEEL 10 53 6513 0021 3 EA SCREW M3 X 5 X 8MM LG PPSS METRIC 11 53 6513 0029 1 EA SCREW M3 X 5 X 12MM PFZ METRIC 12 53 6600 0001 2 EA SCREW 4 40 X 5 16 PPB 13 53 6608 0003 2 EA SCREW 6 32 X 3 16 LG PPZ 14 53 6613 0001 4 EA SCREW 6 32 X 1 2 PPZ 15 55 2118 0003 2 EA WASHER 750 OD 380 ID 034 THK BELLV SPRN H CARBON 16 55 3301 0004 2 EA WASHER 4 FLAT SS 17 55 3301 0006 3 EA WASHER 6 FLAT SS 18 55 6504 0001 4 EA WASHER 6 LOCK EXT TOOTH 19 55 6579 0005 4 EA GROMMET 3 8 HOLE 3 16 ID 20 55 6595 0004 3 EA SPACER 3 160D X 171L X 4HOLE ALUM 21 55 6603 0001 1 EA SPRING SS 4 6 IN EXTENSION 22 55 6818 0002 1 EA KURLY LOK STANDOFF 45 DEG NYLON 6 6 23 74 1034 0001 1 EA SWITCH THERMAL 315 DEG F OPEN changed 08 21 03 02 9671 0010 C 24 March 2004 81 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Dimmer Bulkhead Assembly cont Note connector orientation gt m 20 3 pl Z Figure 3 19 Dimmer Bulkhead Assembly 82 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Optical Sensor Assembly 23 9667 0216 Rev C Refer
60. TO BOARD 9 24 9661 1400 6 GNO 9 CONNECTOR vec 24 9661 1400 GND 10 V Sa eee M 424v 11 24V 24V 12 24v 24V 13 24V 25 9667 0030 24V 14 24V Ua IGNITOR BOARD amp j89892529522295219z919z98989898989890 9 98885888608588 1767673535235535215325222215656969696969 amp 82806606569686256880 24 9661 1125 ooo TK AMSEMORDMAOHE ANT OOH MAQNARARARRAGASBAHHHOSSEIE LE LIES TT TILT HEAD GND STUD x TMSTED WIRES BULB d 25 9667 0007 SOCKET e 22 9658 0129 BLUE J EH g MOTOR BACK SCREW PART OF DISCONNECT BD 9667 TWSTED WRES FAN2 FAN1 22 9660 0338 RED BK usen Se gt MOTOR J 9 DIMMER TWSTED WRES SENSOR RED 1 Bk 25 9667 0413 Bd OT SWITCH TWISTED WRES 5 TWSTED WRES RED RED B Bk rr C i is dd m TWISTED WIRES TWISTED WIRES J2 m BLUTT eo CROSSFADE COLOR SENSE REp 2 SENSE SENSOR BOARD
61. cont amp 31 3 pl 50 2 pl Y 33 2 pl 32 2 pl Figure 3 32 Upper Enclosure Assembly bottom views 104 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Connector Panel Assembly 21 9661 1205 Rev E Refer to Figure 3 33 No Item Qty UM Description 1 10 9661 1252 1 EA LAYOUT ENCLOSURE OVERLAY 2 10 9661 1259 1 EA BRACKET INPUT 3 24 9661 1225 1 EA ASSY MAIN CONTROLLER 3 PHASE 4 24 9661 1251 1 EA 55 DMX INPUT 5 25 9661 1511 1 EA CABLE ASSY AC INPUT PIGTAIL EURO VL8 6 53 6513 0019 4 EA SCREW M3 X 5MM LG PPB METRIC 7 53 6525 0001 2 EA SCREW 6 32 X 5 16 PPZ 8 55 2253 0001 1 EA CARD GUIDE SNAP IN 6 LONG NYLON NATURAL 9 70 3744 1150 1 EA C BREAKER 15 0A 240V HORIZ 1 0 NON ILLUM Figure 3 33 Connector Panel Assembly 02 9671 0010 C 24 March 2004 105 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Main Controller 3 Phase PCB Assembly 24 9661 1225 Rev R Refer to Figure 3 34 No Item Qty UM Description Ref 1 10 9661 1275 1 EA HEATSINK MAIN CONTROLLER 2 11 9661 1225 1 MAIN CONTROLLER 3 52 6284 0001 1 EA HEADER 4POS MTA FRCT LOK STRT POST J7 4 52 6296 0001 1 EA HEADER 8POS MTA FRCT LOK STRT POST 2 5 52 6297 0001 2 EA HEADER 2PIN MTA FRCT LOK STRT P
62. realizado solamente por personal calificado ADVERTENCIA INTERFERENCIA RF 1 Bste es un producto de Clase A En el ambiente de la casa este producto puede ocasionar radiointerferencia en cuyo caso el usuario debe tomar las medidas adecuadas viii 24 March 2004 02 9671 0010 C SAFETY NOTICE JAPANESE d ss 3 ZW sna UV 1 Phiips Osram HID
63. 0 3738 1001 Fl 41 70 3742 0002 1 EA FUSE POLY 60V MAX 40A MAX IH 40A PTCS IT 80A 20 DEG C 42 73 7051 0001 1 EA WIRE 22AWG BUSS added 04 230 03 R37 43 74 1047 0001 1 EA SWITCH KEY SUR MT S6 44 74 1085 0001 4 EA SWITCH 12MM 5 52 S4 amp S5 45 74 1085 0011 4 CAP SWITCH 8MM SQ GREY TL1100160Q XS1 XS2 XS4 amp 755 46 74 1094 0001 1 EA SWITCH MERCURY TILT METAL TYPE S3 47 75 7105 0805 6 EA TVS 6VOLT 0805 SMT VR2 VR7 48 82 4322 0001 1 EA DIODE TVS ZENER 1 SSMC27AT3 27 40 15 SMT 49 82 5325 0001 1 EA DIODE MBRS130LT3 SCHOTTKY SUR MT D4 50 82 5326 0001 6 EA DIODE DL4148CT RECTIFIER D6 D11 51 82 5331 0001 4 EA DIODE P6KE13CA TVS ZENER 13V Z1 Z4 52 82 5360 0001 2 EA DIODE BAV199LT1 SWITCHING 70 215 D12 amp D13 53 83 3173 0005 1 IC LM2594M 5 150KHZ 0 5A STEP DOWN VRI VOLTAGE REGULATOR 02 9671 0010 C 24 March 2004 107 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description Ref 54 83 3189 0001 1 EA IC OPA2340VA AMP SINGLE SUPPLY RAIL U19 TO RAIL 55 84 0068 0812 1 IC MC68HC812A4PV8 UNPRGMMD 16BIT U14 MICROCONTROLLER 56 84 4234 0002 3 EA 1 5485 TRANSCEIVER SUR MT SOIC PKG U18 U24 amp 025 57 84 4264 0001 1 EA IC TC551664AJ 64K X 16 STATIC RAM U4 58 84 4270 0001 1 EA 1 NC7S08M5 S
64. 001 1 67 FT CBL 22AWG 8COND Figure 3 50 Lamp Supply Control Cable Assembly 02 9671 0010 C 24 March 2004 133 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev A Refer to Figure 3 51 No Item Qty UM Description 1 52 8250 0001 2 EA TERM 8 RING 10AWG 2 73 7089 0504 15 17 FT WIRE 22AWG 300V 200C TEF GRN YEL 01 1180 1 2 pl Figure 3 51 Chassis to Yoke Ground Cable Assembly 134 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 Lamp Supply OT Not On Cable Assembly 25 9661 1531 Rev A Refer to Figure 3 52 No Item Qty UM Description 1 52 6396 2202 1 EA RECEPT 2POS MTA100 W POL TAB RED CLSD END 2 52 6396 2203 1 EA RECEPT 3POS MTA100 W POL TAB RED CLSD END 3 52 6396 2204 1 EA RECEPT 4POS MTA100 W POL TAB RED CLSD END 4 73 3522 0002 1 33 FT WIRE 22AWG 300V 105C PVC RED UL1569 5 73 3522 0005 1 33 FT WIRE 22AWG 300V 105C PVC GRN UL1569 6 73 3522 0009 1 67 FT WIRE 22AWG 300V 105C PVC WHT UL1S69 7 73 3522 0010 1 67 WIRE 22AWG 300V 105C BLK UL1369 Figure 3 S2 Lamp Supply On Cable Assembly 02 9671 0010 C 24 March 2004 135 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Data Link Cable Assembly 25 9661 1532 Rev A Refer to Figure 3 53
65. 0603 Dimmer Bulkhead Assembly 21 9673 0290 Yoke to Head Blue Motor Assembly Amber Motor Assembly 21 9671 0184 Concave Lens Assembly 22 9671 0413 Convex Lens Assembly 22 9671 0414 Ground Cable 25 9667 0028 Optical Sensor Assembly 23 9667 0216 Motor Harness Cable 25 9671 0007 Color Bulkhead Assembly 22 9671 0077 Assembly 24 9661 1125 Aux Controller PCB Assembly 24 9661 1400 Ignitor To Relay Cable 25 9667 0030 Head OT Switch Filter Wheel Assembly 22 9673 0145 2 Cable 25 9667 0146 Color Motor Color W O Color Wheels Bulkhead Assembly 21 9671 0124 Assembly 21 9667 0119 Sensor PCB 24 March 2004 Assembly 24 9638 0113 Magenta Motor Assembly 21 9671 0182 Crossfade Color Sensor PCB Assembly 24 9671 0175 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN DRAWING TREE 3 VL2000 Wash Luminaire 20 9671 0001 cont continued from previous page Upper Enclosure Assembly 21 9661 0004 05 Pan Motor Assembly 22 9661 0664 Connector Panel Pan Tube Assembly Assembly 21 9661 1205 21 9661 1208 700W Arc Power Supply Ballast Module Assembly 23 9671 1250 Pan Tilt Encoder Main Controller 3 Phase PCB AC Input Link PCB Assembly Assembly Cable 700W Ballast Board 24 9661 0629 24 9661 1225 25 9661 1512 PCB
66. 0MM FAN 40 7113 0002 1 FAN 24V 80 X 80 X 25MM 39CFM 52 8347 0001 2 CONTACT 24 30AWG MALE CRIMP 7 25 8007 2212 1 EA GND STRAP ASSY 6 RING 6 RING 3 LG 52 6579 0004 1 EA CONN 4CIR PNL SGL ROW W MTG EARS not shown 8 53 2200 0004 10 EA NUT 4 40 KEPS SS 9 53 5604 0250 2 EA SCREW 4 40 X 1 4 PPSS BLK 10 53 6525 0001 2 EA SCREW 6 32 X 5 16 PPZ 11 53 6537 0001 4 EA SCREW 4 40 X 5 8 PPB 12 53 6556 0002 4 EA SCREW 4 40 X 3 4 PPB 13 53 6613 0001 3 EA SCREW 6 32 X 1 2 PPZ 14 55 3301 0004 8 EA WASHER 4 FLAT SS 15 55 6517 0001 16 EA WASHER 375 OD 150 ID 031 FLAT STEEL 16 55 6538 0001 3 EA WASHER 46 LOCK INTERNAL TOOTH 17 55 6579 0006 8 EA GROMMET 3 8 3 16 ID 1 2 OD 18 55 6595 0004 8 EA SPACER 3 160D X 171L X 4HOLE ALUM 19 55 6659 0001 4 EA SPACER 1 4 RND 4 THRU 3 16 AL 02 9671 0010 C 24 March 2004 79 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Fan Cover Assembly cont Figure 3 18 Fan Cover Assembly 80 24 March 2004 730024C 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Dimmer Bulkhead Assembly 21 9673 0290 Rev D Refer to Figure 3 19 Description 1 10 9621 0069 1 EA NUT LOCK WHEEL SHAFT 2 10 9621 0102 1 EA COLLET LOCK WHEEL SHAFT 3 10 9671 0039 1 EA BLADE DIMMER changed 08 21 03 4 10 9638 0151 1 EA
67. 1 3274291 6 DGM G9312884 DGM 9407689 8 European Patents No 0586049 FR GB 0547732 BE DK FR GB 0534710 BE FR GB 0474202 BE DK FR GB 0253082 BE FR GB 0253081 BE FR GB 0192882 BE FR GB 0140994 BE FR GB 0060068 BE FR GB France Design Reg No 335132 335147 Spain Patents No 2090191 2084289 2082384 2058071 2020960 0548328 Spain Utility Model No 2031748 Spain Design Reg No 129596 Japan Patents No 2 059 669 2 055 324 2 002 168 1 889 481 1 770 241 1 723 825 1 683 007 1 553 011 KR 206051 181180 76310 47673 Japan Design Reg No 947552 945436 1 945436 Korean Design Reg No 175178 Mexico Patents No 180148 179138 Taiwan Patents No 78726 66975 65380 63471 40611 28275 United Kingdom Design Reg No 2042174 2033108 2029499 other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or organizations VL2000 Wash Luminaire Service Manual The information furnished in this manual is for informational use only and is subject to change without notice Vari Lite Inc assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual All information and graphic representations are property of Vari Lite Inc 201 Regal Row Dallas Texas 75247 USA Version as of 24 March 2004 Printed in the USA Part number 02 9671 0010 C VL2000 Wash Lum
68. 1 1251 DSN TW 9 99 CONFIDENTIAL CHK DMX INPUT BOARD ALL INFORMATION CONTAINED HEREIN IS THE SOLE AND EXCLUSIVE PROPERTY p p c SIZE REVISION DRAWING NUMBER OF VARI LITE INC AND MAY NOT BE T _ USED DISCLOSED OR REPRODUCED 14 9661 1251 VLFS_DMX_INPUT IN ANY MANNER WITHOUT THE ADVANCE WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 1 5 4 3 2 1 02 9671 0010 24 March 2004 161 VL2000 WASH LUMINAIRE SERVICE MANUAL lgnitor Schematic REFERENCE FOLD OUTS REVISIONS REV DESCRIPTION DATE C13 612 C 1 C 2 Released Per EO 04546 0 033 033 0 0 033UF 0 033UF 0 033UF 11 10 10 101 101 10 1000 000 1000V 1000 1000V D 812 811 89 R 8 R1 82 R3 R 4 85 85 10M 10M 1 0 10M 10M 10M 10M 10M 10M 10M e 61818 61818 61818 61818 61818 61818 61818 61818 61818 N N N N N N e V V Vi e Vi Vi Vi Vi Ve 012 011 08 01 02 D3 D4 05 DB 610 65 0 033UF 0 0 0 033UF 0 033UF 10 10 10 C7 1000V 1000V 1000V 0 033UF e 10 10007 5
69. 1 2 EA WASHER 10 FLAT BRASS 30 55 6568 0017 1 EA SPRING CPRSN 480 OD 1 500 LG SS 31 55 6568 0036 2 EA SPRING CPRSN 360 OD 690 LG 032 WIRE DIA SS 32 55 6568 0048 1 EA SPRING CPRSN 480 OD 1 000 LG SS 33 71 2502 0003 1 EA SOCKET FASSUNG GY9 5 W 584MM LEADS 1 3 pl 7 13 6 7 31 2 pl 27 2 pl 27 7 17 2 pl 33 28 2 15 2 pl Figure 3 17 Lamp Assembly 78 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Fan Cover Assembly 21 9673 0024 Rev C Refer to Figure 3 18 No Item Qty UM Description 1 12 9671 0192 1 EA BAFFLE COVER MOLDED PLASTIC 2 21 9667 0510 1 EA ASSY FAN DUCT 10 9667 05 11 1 DUCT SMALL FAN 10 9667 0512 1 EA CABLE MOUNT SMALL DUCT 53 6534 0002 2 EA RIVET 3 32 OD POP 3 16 GRIP RNG ALUM 3 21 9671 0058 1 EA DUCT ASSY FAN LARGE 10 9671 0051 1 EA LARGE FAN DUCT 10 9638 0056 1 EA AIR DEFLECTOR LARGE FAN 3 53 6534 0001 4 EA RIVET 3 32 OD POP 3 32 GRIP RANGE ALUM 4 22 9671 0148 1 EA COVER ASSY SLIDING FAN MOUNT 10 9638 0061 1 EA COVER SLIDING 12 9671 0091 1 EA MOUNT FAN 5 23 9667 0025 1 EA ASSY 60MM FAN 40 7110 0006 1 EA FAN 60MM SQ X 25MM 24V HIGH VOLUME 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 6 23 9673 0026 1 EA ASSY 8
70. 115 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 700W Arc Power Supply Ballast Module 23 9671 1250 Rev D Refer to Figure 3 39 No Item Qty UM Description 1 06 6032 0009 1 EA CABLE MARKER TIE WHITE 19 X 74 2 10 9661 1260 1 EA HEAT SINK LEFT 1200 WATT POWER SUPPLY 3 10 9661 1261 1 EA HEAT SINK RIGHT 1200 WATT POWER SUPPLY 4 10 9661 1262 1 EA AIR DUCT 1200 WATT POWER SUPPLY 5 10 9661 1274 3 EA INSULATOR ELECTRICAL TO 247 6 10 9661 1353 1 EA CHANNEL AIR APS 7 24 9661 1130 1 EA PCB ASSY 700W BALLAST BOARD 8 24 9661 1131 1 EA PCB ASSY 700W BALLAST RIDER BOARD 9 51 5006 0004 3 EA INSULATOR TO 220 ALUMINUIM OXIDE 4171 10 51 5029 0001 7 EA INSULATOR TO 247 ALUMINUM OXIDE 53 6520 0002 6 EA SCREW 4 40 X 7 16 PPZ 12 53 6522 0001 5 EA SCREW 6 32 X 1 4 PPZ 13 53 6530 0007 2 EA RIVET 1 8 OD POP 063 125GRP RG 26SLG CSKH AL5052 14 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ 15 53 6616 0001 9 EA SCREW 6 32 X 3 4 PPZ 16 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNTING 17 55 6509 0001 3 WASHER SHOULDER HEATSINK 18 55 6528 0001 9 WASHER 6 FLAT ZINC 19 55 6537 0001 3 EA WASHER 4 LOCK INTERNAL TOOTH 20 55 6538 0001 10 EA WASHER 6 LOCK INTERNAL TOOTH 21 55 6621 0001 3 WASHER 4 FLAT ZINC 22 55 6658 0009 1 EA STANDOFF 1 4 HEX 6
71. 146 Rev A Refer to Figure 3 60 Description 1 52 6523 0002 1 CONN HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 2 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 3 52 8371 0001 2 EA RECEPT FASTON 24 20AWG UNISUL TIN PLT BRS 250 X 032 TAB 4 73 6224 0005 55 FT WIRE 24AWG 600V 200C TFE GRN UL1213 CSA 4 5 1 m 20 3 _ 2 id gt 1 MOLEX SL 2M 670126A Figure 3 60 Head OT Switch 2 Cable Assembly 144 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 DC Output XPiQ Cable Assembly 25 9661 1550 Rev 0 Refer to Figure 3 61 Description 1 52 6434 1806 1 EA CONN 6 POS 18 AWG MTA 156 WO TABS ORG RECPT 2 52 6464 0002 1 EA CONN HOUSING SL 156 2 POS 3 52 6484 0004 1 EA RECEPT 4 POS DUAL ROW MINI FIT JR 4 52 8323 0001 2 EA CONTACT CRIMP 18 22 AWG SL 156 5 52 8333 0001 2 EA CONTACT FEMALE 18 20 AWG REEL HCS 6 73 3518 0002 2 00 FT WIRE 18 AWG 300V 105C PVC RED UL 1569 7 73 3518 0010 2 00 FT WIRE 18 AWG 300V 105C BLK UL 1569 3 5 X2 RED BLK Figure 3 61 DC Output XPiQ Cable Assembly 02 9671 0010 C 24 March 2004 145 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 146 24 March 2004 02 9671 0010C APPENDIX A VL2000 WASH LUMINAIRE TECHNICAL BULLETIN LIST A Technical Bulletins VL2000 Wash Luminaire Technical Bulletin List The following table identifies the c
72. 16 PPZ 8 55 3301 0006 2 EA WASHER 6 FLAT SS 9 55 6538 0001 18 EA WASHER 46 LOCK INTERNAL TOOTH 10 55 6541 0002 2 EA GROMMET I ID 1 3 4 OD 1 3 8 GRV DIA RUBBER 11 55 6583 0001 2 EA STANDOFF 1 4 HEX 6 32 500 LG ALUM 12 55 6658 0009 4 EA STANDOFF 1 4 HEX 6 32 750 LG MF SS 13 55 6669 0014 4 EA STANDOFF 1 4 HEX 6 32 5 8 LG MF SS 02 9671 0010 C 24 March 2004 93 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Yoke Assembly cont 7 4 pl 9 1 1 7 4 pl 2 2 8 2 pl Figure 3 28 Yoke Assembly 24 March 2004 02 9671 0010C 94 ILLUSTRATED PARTS BREAKDOWN YOKE 3 Ignitor PCB Assembly 24 9661 1126 Rev B Formerly 24 9661 1125 Rev D Refer to Figure 3 29 No Item Qty UM Description Ref 1 11 9661 1126 1 EA PCB IGNITOR 2 52 8218 0002 4 EA TERM PC VERT MNT 6 32 SCREW 15A J1 J4 3 60 1230 6493 EA RESISITOR 1 4W 1 6 49K OHM 4 60 1420 5104 1 EA RESISITOR 1 4 5 51 0K OHM RI 5 60 1421 1205 1 EA RESISITOR 1 4 5 120 0K OHM R7 6 60 1422 2001 1 EA RESISITOR 1 4 5 2 0K OHM R15 7 60 1424 1005 1 EA RESISITOR 1 4 5 10 0K OHM R17 8 60 1426 1003 1 EA RESISITOR 1 4 5 100 0K OHM R10 9 60 1431 1007 1 EA RESISITOR 1 4 5 10 0K OHM 10 60 3430 5104 1 EA RES 1W 596 51 0K OHM METAL OXIDE R6 11 60 3430 5600 2 EA RE
73. 2 18 AWG 12 52 8271 0010 1 EA RECEPT FASTON 24 22 AWG NON INSUL FITS 016 TAB 110SERIES 13 52 8346 0001 14 EA CONTACT 24 30 AWG FEMALE CRIMP 14 52 8351 0001 100 EA CONTACT 26 22 AWG RECEPTACLE MTE LOOSE 15 55 2186 0001 15 EA CABLE TIE 10 WD 4 00 LG SMALL 16 55 6699 0003 1 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 17 73 2624 0008 1 83 FT WIRE 24 AWG 600V 2006 TEF GRY TYPE E 18 73 3524 0002 5 92 FT WIRE 24 AWG 300V 105C PVC RED UL1007 19 73 3524 0007 2 30 FT WIRE 24 AWG 300V 105C PVC VIO UL1007 20 73 3524 0009 2 21 FT WIRE 24 AWG 300V 105C PVC WHT UL1007 21 73 3524 0010 7 13 FT WIRE 24 AWG 300V 105C PVC BLK UL1007 22 73 5115 0246 4 83 FT WIRE 24 AWG 3 COND TW 300V 80C lt RED YEL BLU gt UL1061 23 73 5116 0123 17 5 FT WIRE 24 AWG 4 COND TW 300V 80C lt BLK BRN RED ORG gt UL1061 02 9671 0010 C 24 March 2004 139 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Motor Harness Cable Assembly cont 16 2 AUX 3 10 2 6 7 4 pl HEE RS 7 7 or 5 MBA CLRS FIXCLRS Ed MAG WHL BLU WHL LT Pe 6 13 4 Figure 3 56 Motor Harness Cable Assembly 140 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 Yoke to Head Ground Cable Assembly 25 9667 0028 Rev 0 Refer to Figure 3 57
74. 2 2206 2206 4708 Reference Designators 3 4 1430 ETE 444344444 8301 5 2 1 14 7 1 14 7 1 Last Used Not Used 22293432353 Y Y E 3 ud d 3 d ids 84 3712433944 R302 68K 88K 47K C313 C429 a duds 33525 ER CERES A Ka mon AT 525 0301 0409 18 8303 2 0 1 2 1 1 2 15 1 2 B BA J301 J402 En e je 5 79 22 nm d 8304 5 62 1 14 7 1 1 14 7 1 309 R433 R403 CA 3405 8307 20 0 1 20 0 1 27 4 1 U301 U403 zs 198 nur ge 5 1 Eu del 4 410 500 OHM 1K 500 HHM auckaras 3 Notes 4 t rs R411 6 19 1 6 19 1 7 50 1 Unlesss Otherwise specified ET Ho Ups BE ice 8423 47K 47K 36 1 11 capacitor values are 15210 caza 5906 e zs d 1784 4 TUF 178 PUTE Ex 178u COUR 4 TUR 6 1ur 2 11 resistor values are ohms 24 9661 1111 2 BALLASIGND z _ 3 Capacitors ere 50V 20 NExT 24 9661 1121 DRAWN BY MA 201 REGAL ROW 4 Resistors ere 1 10W 54 ASSY 24 9661 1151 B CURBO AR JAN DALLAS TEXAS 75247 5 See Table 1 for component values for gepropriete board assembly PCBNO 11 9661 1111 DSN B CURBO 9 20 99 96 W ider oard ower and ground symbols used 24 3651 1121 400 8625W Rider Board o ucc CONFIDENTIAL BALLAST RID
75. 22 417 LDAC AGND 22 34 R34 aaa PEO XIRR 10k PES IRD 420 PEZ R W m lt Aza E3 LSTRB 34154 PE4 ECLK 1 4 RESET RESET PES MODA 18 e Bi d ts i it ayu 103758 57 103785 4 vec mee MA Epit og 2 1 2 DEBUG E Yss_PLL 3 PHASEO io T NORMAL T BAT 7 1 51 Ncc 10K 7508 2 32 PF3 c53 2 Pr47csD 5 5 PS0 RxD0 F Ps47TXD0 22 CLT10702LDA PS3 TXD1 5 101 e ps47s0 VP1 p be 7 Aux cou 102 Pss spo T VP 2 103 E i pss sck oe vP of EE 104 T TT vp 4 b NER ic B n4 10K lt gt 23 PT47TOC4 160UF i 35 3 84 81571065 IM PT4 10C4 3 84 p PTS I0CS 2 3 84 16 10 uw 3 84 PT7 rnc7 601 3 105 T 8i 18 2 84 833 80v 39 30 0060 RIAL 2 5 20 3 1 18 41 80 F 11811180 205 lt MOUNTING HOLES 20 lt Siu 552 Mz e Wa 3 08 4 Y 7 0 3 07 Y 1817 01 3 07 A AUXILIARY CONTROLLER REVISION DRAWING NUMBER B 14 9661 1400 SIZE 3 SHEET 2 OF 3 Filename Date Time D ViewDraw for Windows 7 5 02 9671 0010 C 24 March 2004 155
76. 45 62 3021 2331 1 EA CAP 330PF 200V RAD CER 20 X7R C203 46 62 3023 0104 12 EA CAP 1UF 50V RAD CER 20 750 C109 C115 C120 C206 C209 C211 C214 C218 C220 C222 C225 amp C226 47 62 3023 0333 1 EA CAP 33UF 50V RAD CER 20 250 6106 48 62 3023 0473 3 EA 47UF 50V RAD CER 20 250 C107 C210 amp C215 49 62 3027 0102 1 EA 1000PF 1600V RAD POLYPROPYLENE C205 600 1096 50 62 3029 0333 1 EA 033UF 1000V RAD POLYPROPYLENE C216 886 10 51 62 4010 0106 1 EA CAP 10UF 50V RAD ALUM4X11MM20 C221 52 62 4010 0475 8 EA CAP 4 7UF 50V RAD ALUM 5 X 11 MM 20 C108 C116 C119 C207 C208 C212 C213 amp C217 53 63 2050 0001 1 EA VARISTOR METAL OXIDE 300V RMS 165J VR101 775V CLAMP 54 63 2055 0001 2 EA THERMISTOR 12A 0 7 OHM NTC INRUSH NTC101 amp NTC102 CURRENT LIMIT 55 68 4536 0002 1 CHOKE COMMON MODE FILTER 1 35 L102 56 68 4577 0001 1 EA INDUCTOR CURRENT SENSE PE 51688 L201 57 68 9661 1112 1 EA TRANSFORMER DRIVE T201 58 68 9661 1115 EA CHOKE EMI DIFFERENTIAL L101 59 70 3727 0002 2 EA FUSE CLIP 1 4 PC BOARD TINNED BRASS XF101 60 70 3762 0020 1 EA FUSE 20A 250VAC VERY FAST ACT 1 4 X1 1 F101 4 CERAMIC 61 73 6016 0006 0 25 FT WIRE 16AWG 600V 105C PVC BLU 1015 62 80 2623 0001 2 EA TRANSISTOR 2N4401 NPN 40V 600MA Q102 amp Q203 02 9671 0010 C 24 March 2004 119 VL2000 WASH LUMINAIRE SERVICE MANUAL
77. 53 5561 0250 lt EA SCREW 6 40 X 1 4 SET 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 0003 1 EA SWITCH SLOTTED OPTICAL 4 24 9661 0629 1 EA PCB ASSY PAN TILT ENCODER 44 5034 0001 1 EA MOTOR STEPPER 42 X 40 10 OHM 6 53 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 7 53 5506 0625 4 EA SCREW 6 32 X 5 8 PPSS 8 55 6512 0001 2 EA WASHER 4 SPLIT LOCK 9 53 6520 0001 9 EA SCREW 4 40 X 3 8 PPZ 10 55 6621 0001 4 EA WASHER 4 FLAT ZINC 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Tilt Motor Assembly cont 6 2 pl D c 10 2 pl Ll pl Figure 3 42 Tilt Motor Assembly 02 9671 0010 C 24 March 2004 125 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 126 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 Cables Ground Strap Cable Assembly 25 8007 2212 Rev 0 Refer to Figure 3 43 Description 1 52 8329 0001 2 EA TERM RING 6 22 16 AWG NON INS 2 73 7130 0002 0 33 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED Figure 3 43 Ground Strap Cable Assembly 02 9671 0010 C 24 March 2004 125 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL AC Input Pigtail Euro Cable Assembly 25 9661 1511 Rev D Refer to Figure 3 44
78. 7 26 60 1421 4700 1 EA RES 1 4W 5 47 OHM R208 27 60 1421 6805 1 EA RES 1 4W 5 680 0 CF R102 28 60 1422 1001 3 EA RES I AW 5 1 0K CF R219 R220 amp R223 29 60 1422 2001 1 EA RES 1 4W5 2 0K CF R119 30 60 1424 1502 1 EA RES 1 4W 5 15 0 CF R104 31 60 1424 2004 1 EA RES 1 4W 5 20 0 K R108 24 March 2004 02 9671 0010 ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 No Item Qty UM Description Ref 32 60 1424 2702 2 EA RES I AW 5 27 0 CF R103 amp R118 33 60 1426 1003 2 EA RES 1 4W 5 100 0 6 CF R226 amp R227 34 60 1431 1007 1 EA RES 1 4W 5 10 0 OHM R217 35 60 3432 2004 2 EA RES 2W 5 20 0 K MET OXIDE R115 amp R116 36 60 7440 1002 1 EA RES 5W 5 100 0 OHM WW R209 37 62 2110 0474 1 EA CAP 47UF 250V RAD METALLIZED POLYEST C219 15MM L S 10 38 62 2112 0337 4 EA 330 UF 250V RAD ALUM 25MM X 30MM C110 C113 39 62 2114 0107 EA CAP 100UF 50V RAD ALUM 10MM X 15MM C114 20 40 62 3007 0474 2 EA 47UF 275VAC RAD SUPPRESSOR 10 C101 amp C102 4l 62 3013 0105 2 EA IUF 630V RAD MET PLYPLN 10 C201 amp C204 42 62 3013 0474 1 EA 47UF 630V RAD MET PLYPLN 10 C105 43 62 3017 0102 4 EA 1000PF 250V RAD CER DISC 20 C117 6118 6103 amp C104 44 62 3017 0472 1 EA 4700PF 250V RAD CER DISC Y CLASS C223
79. 9661 0670 1 EA BRACKET STABILIZER SLOTTED 6 10 9661 0671 1 EA BRACKET STABILIZER NO SLOT 7 10 9661 1258 1 EA BRACKET APS SIDE 8 10 9661 1354 1 EA AIR SEAL UPPER ENCLOSURE 9 10 9661 1358 1 EA AIR SEAL DUCT 10 10 9661 1360 1 EA INSULATOR BUCK CHOKE UPPER ENCLOSURE 11 10 9661 1361 1 EA INSULATOR CHOKE UPPER ENCLOSURE 12 10 9673 1352 1 EA DUCT W HOLE UPPER ENCLOSURE AIR 13 69 3174 0130 1 EA POWER SUPPLY 130W 24V 5 4A 18CFM 14 12 9661 0657 1 EA TILT DAMPER 2400 YOKE STRUCTURE 15 12 9661 1236 2 EA COVER FRONT MACHINED 16 12 9661 1238 2 EA COVER SIDE MACHINED 17 21 9661 1205 1 EA ASSY CONNECTOR PANEL 18 21 9661 1208 1 EA ASSY PAN TUBE 19 21 9661 1254 1 EA ASSY COVER VENTILATION 10 9661 1249 4 EA POST TRUSS HOOK 10 9661 1350 1 EA COVER VENTILATION VL2000 10 9661 1357 2 EA AIR SEAL UPPER ENCLOSURE 54 1206 0015 4 EA RING RETAINING PRESS ON 1 SHAFT 20 21 9661 1365 2 EA ASSY TOP COVER 21 21 9661 1210 1 EA ASSY PAN MOTOR 22 22 9661 1351 1 EA FAB ASSY UPPER ENCLOSURE 23 23 9661 1534 1 EA FAN ASSEMBLY HIGH SPEED 24 23 9671 1250 1 EA ASSY BALLAST MODULE 700W ARC POWER SUPPLY 25 9661 1512 1 EA CABLE ASSY AC INPUT LINK not shown 25 9661 1513 1 EA CABLE ASSY AC INPUT SPLITTER not shown 25 9661 1514 1 EA CABLE ASSY LVS CHASSIS GND not shown 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3
80. AL DMX Input Schematic REFERENCE FOLD OUTS Notes Unlesss Ot 1 11 ca All 3 Capaci 4 Resist Power and VCC VEE Reference herwise specified pacitor values are microfarads sistor values are ohms tors are 50V 20 ors are 1 10W 5 ground symbols used Vcc 5V Logic power Vee 5V Logic power Gnd Logic ground Designators Last Used Not Used C 1 J3 STE 1 NC5FDM3 V 1 DMX VL_IN 2 DMX VL_TN 3 2 5r WE OUT SHTELD DMX Thru J2 NCS5MDM3 V 4 DMX VL_IN 2 DMX VL_TN 3 1 VL OUT DMX VL_TN DMX In J3 705530004 1 DMX VL_TN 2 VL_OUT 3 VL_OUT 4 SHIELD 5 Cu 1000PF 120 250V SOLDER PADS 16 62 Filename Date Time 4 3 2000 11 50 Controller REVISIONS REV DESCRIPTION DATE APPD Released per EO 04542 9 7 99 TW A Revised per EO 06413 1 18 00 B Revised per EO 06415 1 26 00 T W C Revised per EO 06422 3 13 00 TW D Revised per EO 06423 NEXT 24 9661 1251 DRAWN BY MA 201 REGAL ROW ASSY TOM WALSH AR VIN DALLAS TEXAS 75247 PCB NO 11 966
81. ANUAL DMX Input PCB Assembly Replacement Parts PCB ASSY DMX INPUT 24 9661 1251 Tools Screwdriver 2 Phillips To remove and replace DMX Input PCB assembly CAUTION Always use anti static precautions when working with PCBs from the luminaire WARNING All maintenance procedures to be performed with power removed Step 1 Disconnect luminaire AC input cable from power source Step 2 At enclosure remove power supply side and ventilation covers Refer to Removing Enclosure Covers on page 41 Step 3 At DMX input PCB assembly disconnect wiring connector at J3 Step 4 At connector panel remove four M3 X 5MM PPB screws which secure DMX input PCB assembly to connector panel and remove assembly Figure 2 29 Input Panel Inside View DMX Input PCB M3 X 5MM Note Some components N PPB Screws 4 not shown for clarity perd Figure 2 29 DMX Input PCB Assembly Replacement Step 5 Install replacement DMX input PCB assembly by performing Steps 2 4 in reverse order 50 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Cleaning Lens Tools 99 Isopropyl alcohol commercial grade Clean white lint free cloth Cotton gloves To clean lens WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect AC input cable from power source CAUTION Use caution when handling lens Avoid touching or scratc
82. BEARING HOUSING 54 1244 0001 1 EA BEARING 1 25 BORE 2 25 OD 500 WD CONRAD 7 22 9661 0607 1 EA ASSY DRIVEN PULLEY 10 9661 0650 1 EA TIMING PULLEY 150 TOOTH 2MM PITCH 10 9661 0655 1 EA EOT FLAG 53 6530 0006 2 EA RIVET 1 8 OD POP 188 250GL 55 6612 0022 1 EA PIN GRV 250 OD 625 LG STEEL 8 53 6517 0001 4 EA SCREW 10 32 X 3 8 PPZ 9 54 1206 0010 1 EA RING RETAINING 1 118 GRV DIA 056 GRV WD EXTERNAL 10 55 2123 0005 1 EA SPRING WAVE 1 62 OD 1 31 ID CAR STL 11 55 2152 0002 3 SHIM 1 500 OD 1 200 ID 024 THK SS 12 55 3301 0010 4 WASHER 10 FLAT 13 55 6612 0018 1 PIN 250 OD 1 0 LG STL ZINC PLT 14 55 6677 0027 1 EA WASHER 1 75 OD 1 281 ID 015 THK FLAT NYLON 02 9671 0010 C 24 March 2004 111 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Pan Tube Assembly cont pl D 8 4 pl Figure 3 36 Pan Tube Assembly 112 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan Motor Assembly 21 9661 1210 Rev F Formerly 22 9661 0664 Rev E Refer to Figure 3 37 No Item Qty UM Description 1 10 9661 1298 1 EA PLATE TENSION ADJUST PAN MOTOR 2 22 9661 0608 1 EA ASSY DRIVE PULLEY 10 9661 0640 1 EA CODEWHEEL 90 COUNT 10 9661 0649 1 EA TIMING PULLEY 2MM GT 17 TOOTH 53 5561 0250 2 EA SCREW 6 40 X 1 4 POINT
83. BL ROW UNLOADED 6 52 7007 0001 6 EA CONTACT 28 22AWG PHOSPHOR BRONZE TIN PLT SXH 7 52 8346 0001 10 EA CONTACT 24 30AWG FEMALE CRIMP 8 52 8351 0002 16 EA CONTACT 26 22AWG RECEPTACLE MTE REEL 9 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 10 55 6699 0003 3 30 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 11 73 5119 0246 3 83 FT WIRE 24AWG 3COND TW 600V 200C lt RED YEL BLU gt UL1213 12 73 5121 0001 3 92 FT CABLE 24AWG 5COND TW 600V 200C PTFE TEF 02 9671 0010 C 24 March 2004 131 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Pan Tilt Control Cable Assembly cont ES 27 00 2 5 1 2 217 413 4 of 9 2 9 2 GRY 4 M 20 SE 3 S 8 16 pl 2 28 00 10 16 0 Le 23 00 611517 Figure 3 49 Pan Tilt Control Cable Assembly 132 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 Lamp Supply Control Cable Assembly 25 9661 1518 Rev A Refer to Figure 3 50 No Item Qty UM Description 1 52 6396 2208 2 EA RECEPT 8POS MTA100 W POL TAB RED CLSD END 2 55 2197 0001 1 25 IN HEATSHRINK 3 8 BLACK 73 7028 0
84. CB 400 625W BALLAST BOARD 51 5031 0001 1 EA HEATSINK TO 220 CLIP ON ALUM BLACK ANODIZED PC MT 4 52 6229 0001 1 EA HEADER 3POS FRIC LOK STRT POST J113 5 52 6261 0002 1 EA HEADER 2PIN 156 102 6 52 6296 0001 1 EA HEADER 8POS MTA FRCT LOK STRT POST J112 7 52 6370 0003 1 EA HEADER ASSY 3CIR SOCKET MNLOK FMLE 7103 8 52 6574 0012 1 EA HEADER 12CIR VERTICAL KK STYLE J101 9 52 6574 0015 1 EA HEADER 15 VERTICAL KK STYLE 1201 10 52 8252 0001 8 EA TERM 250 TAB PC QUICK FIT BRASS J108 111 amp J202 205 52 8283 5202 1 EA TEST POINT PCB MT 052 HOLE RED GLASS 7106 BEAD 12 52 8283 5210 1 EA TEST POINT MT 052 HOLE BLK GLASS 7107 BEAD 13 60 1230 1004 1 EA RES 1 4W 1 10 0K MF R225 14 60 1230 1214 1 EA RES 1 477 1 12 1 K R203 15 60 1230 4755 4 EA RES 1 4W 1 475 0 MF R112 113 R202 amp R218 16 60 1230 7153 2 EA RES I AW 1 7 15K MF R114 amp R222 17 60 1230 8255 1 EA RES 1 4W 1 825 0 MF R210 18 60 1231 5623 1 EA RES 1 4W1 5 62K MF R211 19 60 1420 2001 2 EA RES 1 4W 5 20 0 OHM CF R117 amp R109 20 60 1420 3002 1 EA RES 1 4W 5 300 0 OHM CF R107 21 60 1420 4302 3 EA RES 1 4W 5 430 0 OHM CF R216 224 amp R221 22 60 1420 5101 4 EA RES 1 4W 5 51 0 OHM CF R212 R215 23 60 1420 5105 2 EA RES I AW 5 510 0 CF R110 amp RIII 24 60 1420 7505 2 EA RES 1 4W 5 750 0 K CF R105 amp R106 25 60 1421 1201 2 EA RES 1 4W 5 12 0 OHM CF R206 amp R20
85. EL 2 10 9667 0120 1 EA COLOR MOTOR BULKHEAD 3 24 9638 0113 1 EA PCB ASSY SENSOR 4 44 9667 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 PFZ 7 55 2203 0001 3 EA SCREW 4 40 X 1 4 PPZ 8 55 3301 0004 1 EA WASHER 4 FLAT SS 9 55 6512 0001 2 EA WASHER 4 SPLIT LOCK 10 55 6568 0016 1 EA SPRING EXTSN 125 OD 500 LG 018 WIRE DIA SS 2 3 9 2 pl Z b 5 2 pl Figure 3 23 Color Motor Assembly 02 9671 0010 C 24 March 2004 87 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Sensor PCB Assembly 24 9638 0113 Rev B Refer to Figure 3 24 11 9638 011 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 60 1429 1503 1 EA RES 1 4W 5 150 0 OHM CF 4 86 7004 0001 1 EA SENSOR OPTICAL GP1S23 3 1 Ur WH 2 lt 4 REV 24 9638 0113 REV Figure 3 24 Sensor PCB Assembly 88 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Magenta Motor Assembly 21 9671 0182 Rev A Refer to Figure 3 25 Description 1 10 9671 0120 1 EA MOTOR PLATE MAGENTA COLOR WHEEL 2 10 9671 0185 1 EA HUB MAGENTA COLOR WHEEL 3 44 9667 0116 1 EA MOTOR GOBO COLOR WHEEL 4 53 5554 0250 2 EA SCREW 4 40 X 1 4 LG SOCKET SET CUP POINT
86. ENSION 02 9671 0010 C 24 March 2004 57 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL VL2000 Wash Luminaire cont A 7 F amp Se Lee NU IN 2 2 if b VL2000 Wash Luminaire Figure 3 2 02 9671 0010C 24 March 2004 58 ILLUSTRATED PARTS BREAKDOWN HEAD 3 Head Head Assembly 21 9671 0005 Rev E Refer to Figure 3 3 Description 1 21 9667 0023 1 EA ASSY FRONT COVER 10 9660 0332 2 EA PANEL VENT COVER 10 9660 0333 2 EA AIR FRONT COVER 12 9667 0020 1 MACHINED FRONT COVER 53 6534 0004 2 EA RIVET 3 32 OD POP 3 16 GRIP L STEEL 53 6633 0002 4 EA SCREW 4 X 3 8 PFZ SHT METAL 55 2233 0001 1 1 4 TURN 2 21 9671 0006 1 EA FRONTINTERNAL HEAD ASSY 3 21 9671 0009 1 EA ASSY REAR 4 21 9673 0024 1 EA ASSY FAN COVER 5 21 9673 0290 1 EA DIMMER BULKHEAD ASSY 6 22 9667 0031 1 EA ASSY TOP COVER REMOVABLE 10 9638 0233 1 EA TETHER REMOVABLE COVER 5 10 9660 0710 1 EA COVER REMOVABLE 55 2233 0003 2 EA RETAINER PUSH ON TYPE 55 2233 0008 1 EA STUD 1 4 TURN 495 L STEEL BLK ZINC 55 2233 0014 1 EA STUD 1 4 TURN 615 L STEEL BLK ZINC 7 22 9671 0077 1 EA BULKHEAD ASSY COLOR 25 9671 0007 1 EA CABLE ASSY MOTOR HARNESS not sho
87. ER BOARD 24 1131 700W Rider Board wee Ru ALL INFORMATION CONTAINED HEREIN 8 SR S OR TA Li S THE SOLE AND EXCLUSIVE PROPERTY SIZE REVISION DRAWING NUMBER tallad 6903 C311 C414 8414 EES x 232 lt OF VARI LITE INC AND MAY NOT BE 14 9661 1111 2 5 S s gt on c em USED DISCLOSED OR REPRODUCED MFG md SpA ilenome N ANY MANNER WITHOUT THE ADVANCE Date Time WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 1 s 8 5 4 3 2 1 02 9671 0010 24 2004 153 VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL Auxiliary Controller Schematic 02 9671 0010 C REFERENCE FOLD OUTS 4 3 2 1 REVISIONS REV DESCRIPTION APPD Released per EO 06402 9 29 99 T W A Revised per EO 06411 1 13 00 TW B Revised per EO 06440 Notes Unlesss therwise specified 1 All capacitor values are micrafarads 2 All resistor values are ohms 3 Capacitors are 50V 20 4 Resistors are 1 10W 5 Power and ground symbols used Vee poweri vee Vee 5V Logic power Gnd Logic graund Reference Designatars Last Used Not Used kis D 2 JB J3 L1 R48 112 1 Y 1 NEXT 24 9661 1400 DRAWN BY
88. FG USED DISCLOSED OR REPRODUCED IN MANNER WITHOUT WRITTEN CONSENT OF VARISLITE INC UT THE WIRING DIAGRAM VL2402 700W ARC ADVANCE 149 VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS VL2000 Wash Luminaire Wire Diagram Sheet 2 4 5 FROM YOKE GND STUD FROM BALLAST J202 FROM BALLAST J203 FROM MAIN CONTROLLER J5 SHEET 1 SHEET 1 SHEET 1 SHEET 1 PAN aus w S ALIN GRN YEL LL TWSIED PAR 25 9661 1516 01 25 9661 1520 25 9661 1525 D gas a E EIL m gt x 1 2 3 4 3 1 gt 1 gt AUx_coM 1 1 AUX_COM 412273 WHT 6 4 WHT 263263 T 2 AUX_COM J4 886644 cj p SONON J4 AUX_COM 2 DEVELOPMENT 88 9 YOKE GND STUD WHT 9 7 WHT 9 DEVELOPMENT 7 AUX_COM 3 3 AUX DEBUG CONNECTORS 5 5 AUX_COM 4 4 AUX COM BKGD 22 lt 2 J J6 5 5 GND GND J3 J6 SPO GND 6 6 GND OPEN CSPO DEBUG 3 OPEN DEBUG GND 7 52 6498 0014 7 GND RST AUXILIARY CONTROLLER 1 NORMAL GND 5 open NORMAL AUXILIARY CONTROLLER 2 25 9667 0028 5 OPEN BOARDS
89. Figure 2 S Color Bulkhead Assembly Replacement Step 3 At color bulkhead assembly turn captive screw one quarter turn to release bulkhead 18 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Step 4 Slide color bulkhead assembly partially out of head assembly and disconnect wiring harness connectors from color motor assembly connector and color motor assembly sensor magenta motor assembly connector and two crossfade color sensor PCB assembly connectors Step 5 Remove color bulkhead assembly from head assembly Step 6 Install replacement assembly by performing Steps 2 5 in reverse order 02 9671 0010 C 24 March 2004 19 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Color Filter Replacement Parts Standard Color Filter as required Tools Screwdriver 2 Phillips Cotton gloves To remove and replace a standard color filter WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover turn two captive screws one quarter turn and remove cover Figure 2 5 Step 3 Rotate wheel until color filter is accessible CAUTION Do not touch filters with bare fingers Wear cotton gloves or other covering while replacing Step 4 Using fingers pull color filter out of filter wheel assembly Figure 2 6 Color Filter Carrier Slot Filter Wheel Figure 2 6 Color
90. H SS 5 55 6677 0006 3 EA WASHER 434 OD 156 ID 062 THK FLAT SS Figure 3 15 Tilt Bearing Housing Assembly 02 9671 0010 C 24 March 2004 75 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Reflector Assembly 21 9660 0340 04 Rev F Refer to Figure 3 16 Description 1 10 9638 0057 4 EA CLIP MOUNTING REFLECTOR 2 12 9660 0073 1 EA ELLIPSOIDAL REFLECTOR W COATING 3 22 9673 0333 1 EA MOUNT ASSY REFLECTOR 4 22 9660 0338 1 EA ASSY DISCONNECT LAMP 10 9660 0335 1 EA CONTACT CONTACT DISCONNECT LAMP 10 9660 0336 1 EA INSULATOR DISCONNECT gt 53 6534 0365 2 EA RIVET 3 32 0D POP 365L 126 250 GRIP AL5052 55 3301 0003 2 EA WASHER FLAT 2 AN ID 099 X OD 250 5 53 6525 0001 4 EA SCREW 6 32 X 5 16 PPZ 6 53 6599 0001 2 EA SCREW 4 40 X 3 8 PFZ 5 4 pl Figure 3 16 Reflector Assembly 76 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Back Cap Assembly 22 9671 0404 Rev D Refer to Figure 3 17 Description 1 10 9638 0117 3 EA KNOB KNURLED VL6 BACK CAP LAMP ASSY 2 10 9638 0128 1 EA BRACKET IGNITOR CABLE 3 10 9638 0130 1 EA SPRING BULB WIRE SHEATH 4 10 9638 0164 1 EA WASHER FELT 2 10 9638 0188 1 EA COUNTERWEIGHT 6 10 9667 0411 1 EA LAMP CARRIAGE 7 10 9667 0412 1 EA LAMP TILT PLATE 8 22 9638
91. HK FLM 5 R421 MT1206 31 60 9464 8204 1 EA RES 1 8W 5 82 0 200V CHP THKFLMS R305 MT1206 32 62 3009 0473 1 EA 047UF 50V 10 MONO CER CHIP SUR C417 MT 33 62 4000 0102 1 EA 1000 50V 5 CER CHIP MONO COG C309 34 62 4000 0105 14 EA CAP 1UF 50V 20 CER CHIP SUR 250 C305 C306 C307 EIA0805 C310 C312 C404 C407 C408 C419 C421 C422 C423 C426 C427 35 62 4000 0331 1 EA 330PF 50V 5 CER CHIP SUR MT COG C413 EIA0805 36 62 4003 0102 3 EA CAP 1000PF 50V 10 CER CHIP SUR MT X7R C416 C418 C425 EIA0805 37 62 4003 0331 1 EA 330PF 50 10 CER CHIP SUR MTX7R C313 0805 38 62 4003 0471 1 EA CAP 470PF 50V 10 CER CHIP SUR MTX7R C302 0805 39 62 4004 0221 1 EA 220PF 50 20 CER CHIP SUR MT X7R C403 EIA0805 40 62 4004 0222 1 EA 2200PF 50 20 CER CHIP SUR MT X7R C415 EIA0805 41 62 4005 0101 3 EA 100 50V 10 CER CHIP SUR MTCOG 410 429 0805 42 62 4005 0330 1 EA CAP 33PF 50V 10 CER CHIP SUR MT COG C428 0805 43 62 4005 0470 1 EA 47PF 50V 10 CER CHIP SUR MT C301 0805 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 No Item Qty UM Description Ref 44 62 4006 0222 1 EA 2200PF 50V 5 CHIP SUR MTX7R C401 0805 45 62 4007 0474 2 EA CAP 47UF 50V 20 CER CHIP SUR
92. INGLE AND GATE SUR MT US 59 84 4288 0001 1 EA IC MAX6314US44D3 T MICROPROCESSOR 15 RESET CIRCUIT 60 84 4291 0001 1 IC STI6C550CQ48 UART RCVR TRSMTTR W 02 16 BYTE FIFO 61 84 4305 0001 1 EA IC NC7SZ04MS UHS INVERTER SMT U22 62 84 4306 0001 1 EA IC NC7SZ08MS UHS 2 INPUT AND GATE U23 63 84 7408 0014 1 IC 74AC14SC HEX INVERTER W SCHMITT Ul TRIGGER INPUT 14PIN SOIC 64 84 7411 0007 l EA IC HPR400 DC DC CONVTR 5V Ull ISOLATED 65 84 7426 0001 1 EA IC SN74HC04D HEX INVERTER U17 66 85 5163 0001 1 IC LS7266R1 S ENCODER TO U6 MICROPROCESSOR INTERFACE CHIP 67 85 5164 0001 2 EA IC L6234PD THREE PHASE MOTOR DRIVER 020 amp U21 68 86 6105 0001 3 EA IC HCPL 0600 COUPLER SMD U9 U10 amp U16 69 87 7247 0001 1 EA IC AM29F200BT FLASH MEMORY 5V U13 87 7302 00XX 1 EA INSTALLER DISK SET BURNER VL2000 LUMINAIRES not shown 70 88 8123 0002 1 EA LED YEL HP 1719 D3 71 88 8123 0003 2 EA LED HP 1790 amp D2 72 88 8139 0002 2 EA DISPLAY INTELLIGNET ALPHA NUMERIC U3 amp 07 0 54 H EFF RED 73 88 8140 0009 3 EA LED MOUNT 140 TALL NATURAL NYLON XDI XD3 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Main Controller 3 Phase PCB Assembly cont R46 mm ma 2 jojo x 7 5 U13 x CT 5 P S N MADE E
93. INT TOOTH SS 13 55 6506 0019 4 EA SPACER 1 2 RND 1 844 LG 257 ID SS BLK 14 55 6520 0001 4 EA WASHER WAVE SPRING 265 ID 367 OD 006 THK 302SS 15 55 6662 0001 2 EA HOLE PLUG 3 4 BRASS W BLK OXIDE 02 9671 0010 C 24 March 2004 61 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Front Internal Head Assembly cont Figure 3 4 Front Internal Head Assembly 62 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Front Color Assembly 21 9671 0007 Rev F Refer to Figure 3 5 Description 1 10 9671 0219 4 EA LENS SHAFT 2 10 9671 0347 1 EA MOUNTING BRACKET HEAD FRONT 3 21 9671 0150 1 EA ASSY BLUE AMBER COLOR WHEELS 4 21 9671 0173 1 EA ASSY BLOCK SHAFT 10 9671 0171 1 EA SHAFT BLUE AMBER COLOR WHEELS gt 10 9671 0172 1 EA BLOCK MOUNTING SHAFT 5 21 9671 0183 1 EA MOTOR ASSY BLUE 6 21 9671 0184 1 EA MOTOR ASSY AMBER 7 22 9667 0337 1 EA ASSY 1 4 TURN MOUNTING BRACKET 8 22 9671 0468 1 EA ASSY MOTOR BEAM SPREADER 44 9671 0467 1 EA MOTOR 1 4 LINEAR 52 6579 0004 1 CONN 4CIR PNL SGL ROW W MTG EARS 52 8347 0001 4 EA CONTACT 24 30AWG MALE CRIMP 9 53 2200 0004 2 EA NUT 4 40 KEPS SS 10 53 6521 0001 5 EA SCREW 8 32 X 1 2 PPB 11 53 6545 0004 4 EA SCREW 8 32 X 3 8 PPZ 12 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 13 53 6687 0375 4 EA
94. K 200V CHP FLM R303 SMT1206 16 60 9463 2744 1 EA RES 1 8 1 27 4 K200VCHP FLM R307 SMT1206 17 60 9463 7503 1 EA RES 1 8W 1 7 50 K 200V CHP FLM R411 SMT1206 18 60 9463 9313 1 EA RES 1 8W 1 9 31 K 200VCHP THK FLM S R420 MT1206 19 60 9463 9315 1 EA RES 1 8 1 931 0 K 200V CHP THK FLM S R427 MT1206 20 60 9464 1003 1 EA RES I 8W 5 1 0K 200V CHP THKFLMS R406 MT1206 21 60 9464 2003 1 EA RES 1 8 5 2 0K 200VCHPTHKFLMS R413 MT1206 02 9671 0010 C 24 March 2004 121 VL2000 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description Ref 22 60 9464 2004 9 EA RES 1 8 5 20 0 2007 CHP THK FLM S R308 R309 R402 MT1206 R417 R418 R424 R425 R426 R428 23 60 9464 2005 1 EA RES 1 8W 5 200 0 2007 CHP FLM S R422 MT1206 24 60 9464 2703 1 EA RES I 8W 5 2 7K 200V CHP THKFLMS R416 MT1206 25 60 9464 3002 2 EA RES 1 8W 5 300 0 OHM 200V CHP FLM R403 R404 S MT1206 26 60 9464 3005 1 EA RES 1 8W 5 300 0 K 2007 CHP FLM S R429 MT1206 27 60 9464 3604 1 EA RES I 8W 5 36 0 K200V CHP THK FLM R423 SMT1206 28 60 9464 4703 2 EA RES I 8W 5 4 7K 2007 CHP THK FLM S R430 R431 MT1206 29 60 9464 4704 1 EA RES 1 8 5 47 0 200V CHP THKFLMS R302 MT1206 30 60 9464 7505 1 EA RES 1 8 5 750 0 2007 CHP T
95. LITE product Additional Documentation A support webpage for VL2000 series luminaires is available at www vari lite com follow the Support link A users manual is available for installation and operation of the VL2000 wash luminaire This manual is available in both printed and electronic PDF formats m VL2000 Wash Luminaire Users Manual 02 9671 0001 02 9671 0010 C 24 March 2004 1 VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL 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 ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on hand to provide support How to Reach Us For assistance in your area call the dealer from which your product s were purchased or Contact an Authorized Service Center or Contact the Vari Lite Customer Service Department 9am 6pm CST Monday through Friday at the following phone 1 877 VARI LITE 1 877 827 4548 fax 214 647 8038 email customerservice vari lite com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link Technical Bulletins and Notices Technical bulletins concern
96. LOK PLUG 3POS 2 52 6464 0003 1 EA CONN HOUSING SL 156 3 POS 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8270 0001 2 EA CONTACT PIN 20 14 AWG MNLOK REEL 5 52 8312 0001 2 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 6 52 8314 0001 1 CONTACT GROUND PIN 20 14 AWG MATENLOK 7 52 8323 0001 2 EA CONTACT CRIMP 18 22 AWG SL 156 8 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 9 55 6699 0003 1 50 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 10 73 6016 0009 1 75 FT WIRE 16AWG 600V 105C PVC WHT UL1015 11 73 6016 0010 1 75 FT WIRE 16AWG 600V 105C PVC BLK UL1015 12 73 6016 0504 0 42 FT WIRE 16AWG 600V 105C PVC GRN YEL 1 1015 13 73 6018 0009 0 42 FT WIRE 18AWG 600V 105C PVC WHT UL1015 14 73 6018 0010 0 42 FT WIRE 18AWG 600V 1056 BLK UL1015 No Figure 3 46 AC Input Splitter Cable Assembly 128 24 March 2004 02 9671 0010 ILLUSTRATED PARTS BREAKDOWN CABLES 3 LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Refer to Figure 3 47 No Item Qty UM Description 1 52 8231 0001 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8271 0001 1 EA FASTON RECEPT 16 14 AWG REEL 3 73 3516 0504 3 5 IN WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 02 9671 0010 C 2 GRN YEI 357 U I Figure 3 47 LVS Chassis Ground Cable Assembly 24 March 2004 129 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Main To Au
97. LS NEOP 45 55 2030 0001 2 EA PCB SUPPORT 3 8 COMBO STACKING SPACER 46 55 2179 0003 1 EA SADDLE CABLE 75 X 75 4WAY ADH BACK WHITE 47 55 2180 0002 0 17 FT SPIRAL WRAP 3 8 OD TEFLON 48 55 2267 0001 2 00 FT RUBBER STRIP SPONGE CLSD CELL 3 8 W 3 16 THK ADHV BACK 49 55 3303 0010 4 EA WASHER 10 438 OD 040 THK SPLIT LOCK SS 50 55 6512 0006 2 EA WASHER 6 SPLIT LOCK SS 51 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK 52 55 6568 0046 1 EA SPRING BLUE EXTSN 120 OD 50 LG 020 WIRE DIA SS 53 55 6627 0001 8 EA WASHER 46 SPLIT LOCK 54 55 6677 0041 1 EA WASHER 10 750 OD 203 ID 040 THK FLAT SS 55 6695 0002 1 FT HEATSHRINK 3 8 ADHESIVE WALL not shown 55 55 6775 0009 1 EA BUSHING SNAP 750 ID 1 MT HOLE NYLON BLACK 56 10 9678 0846 2 EA HANDLE CAST ENCLOSURE changed 06 02 03 02 9671 0010 C 24 March 2004 101 102 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 57 67 4015 0001 1 EA FILTER EMI 16A 250V SINGLE PHASE 58 68 4580 0001 1 EA PFC POTTED 700W APS 59 68 9661 1113 1 EA CHOKE BUCK 3 15MH 4 CORE 12 AWG WIRE 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Upper Enclosure Assembly cont 51 4 pl 43 4 pl Figure 3 31 Upper Enclosure Assembly 02 9671 0010 C 24 March 2004 103 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly
98. LTER LT BLUE GREEN ST 10 41 6006 0850 1 EA ASSY VL6 FILTER BLUE ST 11 41 6006 0960 1 EA ASSY VL6 FILTER LAVENDER ST 12 41 6006 0990 1 EA ASSY VL6 FILTER UV ST Figure 3 27 Filter Wheel Assembly 02 9671 0010 C 24 March 2004 91 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Notes 92 24 March 2004 02 9671 0010C Yoke ILLUSTRATED PARTS BREAKDOWN 3 Yoke Assembly 22 9667 0600 Rev F Refer to Figure 3 28 No Item Qty UM Description 1 21 9667 0659 1 EA ASSY COUNTERWEIGHT VL2201 YOKE 10 9667 0657 l EA PLATE MOUNT VL2201 YOKE COUNTERWEIGHT 10 9667 0658 1 EA COUNTERWEIGHT YOKE 53 2200 0010 2 EA NUT 10 32 KEPS SS 53 6514 0001 2 EA SCREW 10 32 X 1 1 4 PPB 2 22 9667 0605 1 EA FABASSY YOKE STRUCTURE 3 23 9630 3327 1 EA ELEC ASSY RELAY 04 9650 0044 1 EA LABEL RELAY WIRING VL7 52 8271 0005 2 EA RECP FASTON 1 4 16 14 AWG INS REEL 66 4510 0002 1 EA RELAY 204 250VAC DPDT UL CSA VDE 82 4307 4002 1 EA DIODE IN4002 RECTIFIER 4 24 9661 1126 1 EA PCB ASSY SOLID STATE IGNITOR added 04 02 03 5 24 9661 1400 2 EA PCBASSY AUX CONTROLLER 25 9667 0030 1 EA CABLE ASSY IGNITOR TO RELAY not shown 6 52 6498 0014 1 EA CONN 14 POS DUAL ROW 1 11 TH 650 230 7 53 6525 0001 12 EA SCREW 6 32 X 5
99. Manual VL2000 Wash Luminaire 029671000 Service Iz AN VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL Artisan VL2 VLD are trademarks owned by Vari Lite Inc 201 Regal Row Dallas TX 75247 USA and are registered in the United States and other countries VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 Virtuoso Virtuoso DX VARI LITE Visionary VLI VL2B VL2C VL3 VLA VLS VLSArc VLSB VL6 VL6B VL6C VL7 APS6 C3 ArtisanVLQ SPC 36 AutoTruss SmartDMX Smart Repeater Series 100 Series 200 Series 300 Series 2000 Series 30007 DICHRO WHEEL DICHRO TUNE VACU DEP VARIXIMAGE VARI BEAM and the Vari Lite Asterisk are also trademarks owned by Vari Lite Inc VARI LITE products are protected by one or more of the following patents and other pending patent applications worldwide US Patents No 5 959 758 5 728 994 5 590 954 5 367 444 5 329 431 5 209 560 5 186 536 5 073 847 5 010 459 4 980 806 4 602 321 4 392 187 U S Design Patents No 366 712 359 574 Australia Patents No 703868 693691 683695 667109 657152 649264 646588 618559 586095 576400 575271 546433 Australia Design Reg No 126781 German Patents No DBP 69314122 0 69208615 3 69207692 1 69121029 2 3768727 1 3750201 8 3587270 5 3279888
100. OCK INT TOOTH SS 13 55 3303 0006 2 EA WASHER 6 LOCK INT TOOTH SS 14 74 1089 0001 1 EA SWITCH THERMAL 15AMP 295 DEG F OPEN 84 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Color Bulkhead Assembly cont Figure 3 21 Color Bulkhead Assembly 02 9671 0010 C 24 March 2004 85 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Color W O Color Wheels Bulkhead Assembly 21 9671 0124 Rev 0 Refer to Figure 3 22 Description 1 10 9671 0125 1 EA LIGHT SHIELD COLOR BULKHEAD 2 10 9671 0181 1 EA BULKHEAD COLOR 3 10 9671 0195 1 EA BRACKET MOUNTING SENSOR 4 21 9667 0119 1 EA ASSY COLOR MOTOR 5 21 9671 0182 1 EA MOTOR ASSY MAGENTA 6 24 9671 0175 1 EA PCB ASSY CROSSFADE COLOR SENSOR 7 53 2200 0006 2 EA NUT 6 32 KEPS SS 8 53 6522 0001 3 EA SCREW 6 32 X 1 4 PPZ 9 53 6558 0001 3 EA SCREW 6 32 X 3 8 PPZ 10 53 6600 0001 2 EA SCREW 4 40 X 5 16 PPB 11 55 2233 0003 1 EA RETAINER PUSH ON TYPE 12 55 2233 0004 1 EA STUD 1 4 TURN OPR 415L STEEL ZINC 13 55 3303 0006 6 EA WASHER 6 LOCK INT TOOTH SS 12 Figure 3 22 Color W O Color Wheels Bulkhead Assembly 86 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Color Motor Assembly 21 9667 0119 Rev D Refer to Figure 3 23 Description 1 10 9621 0097 1 EA STABILIZER STEPPER GOBO WHE
101. OR SENSOR 24 9671 0175 Tools Screwdriver 1 Phillips To remove and replace crossfade color sensor PCB assembly CAUTION Always use anti static precautions when working with PCBs WARNING All maintenance procedures to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove color bulkhead assembly Refer to Color Bulkhead Assembly Replacement on page 18 Step 3 At color bulkhead assembly remove two 4 40 X 5 16 PPB screws and remove crossfade color sensor PCB assembly from mounting bracket Figure 2 8 Color Bulkhead Assembly Mounting Bracket Crossfade Color Sensor y m m x Assembly b d 4 40 X 5 16 PPB Screw 2 I En Figure 2 8 Crossfade Color Sensor PCB Assembly Replacement Step 4 Install replacement crossfade color sensor PCB assembly by performing Steps 2 and 3 in reverse order 22 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Dimmer Bulkhead Assembly Replacement Parts DIMMER BULKHEAD ASSEMBLY 21 9673 0205 Tools Screwdriver 2 Phillips To remove and replace dimmer bulkhead assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover turn two captive screws one quarter turn and remove cover Figure 2 5 It will
102. OST J3 amp 6 52 6399 0001 1 EA JUMPER PROGRAMMING XJI amp XJ11 7 52 6583 0004 1 EA HEADER 4 CIR DUAL ROW W O PEGS 165 J6 CTRS 8 52 6583 0006 1 EA HEADER 6 CIR DUAL ROW W O PEGS 165 J5 CTRS 9 52 6592 0005 1 EA HEADER 5PIN SGL ROW VERT 1 PITCH J10 SHROUDED 10 52 6593 0004 1 EA HEADER 2PIN DBL ROW VERT MT 2X2 PIN 025 SQ PIN 11 52 6615 0020 1 EA CONN HEADER 20POS DBL ROW SHROUDED J9 STRAIGHT 12 52 6628 0008 1 EA HEADER ASSY 8 POS RT ANG DBL ROW W J8 HOLD DOWN MOD 13 52 6629 0003 1 EA HEADER ASSY 3 POS RT ANGSGLROW W Jl HOLD DOWN MOD 14 52 8390 0001 24 EA CONTACT SOCKET RND PLATED AUGAT HOLTITE 15 53 5504 0187 2 EA SCREW 4 40 X 3 16 PPSS 16 60 4500 4703 2 EA RES 1W 5 4 7 CHIP FLM SMT R38 amp R40 17 60 9460 1001 2 EA RES 1W 5 10 0 OHM 100V CHIP THICK R39 amp R43 FILM 18 60 9460 1003 7 EA RES 1W 5 1 0 K 100V CHIP THICK FILM R16 R17 R23 R29 SMT0805 R31 R33 amp R41 19 60 9460 1004 22 EA RES 1W 5 10 0 K 100V CHIP THICK FILM RI R9 R11 R18 R19 R22 R24 R25 R30 R35 R36 amp R44 R47 20 60 9460 5602 6 EA RES 1W 5 560 0 OHM 100V CHIP THK FILM RIO R12 R15 amp R21 SUR MT 21 60 9460 7505 1 RES 1W 5 750 0 100V CHIP THICK FILM R20 22 60 9461 1003 2 EA RES 1W 1 1 0 K 100V CHIP THK FLM R27 amp R28 SMT0805 106 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3
103. PAN MOTOR 22 9661 0664 Tools Screwdriver 2 Phillips To remove and replace pan motor assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Using console or internal menus run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source CAUTION Be careful not to damage lens during next step Step 3 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Figure 2 23 Step 4 At enclosure remove ventilation cover Refer to Removing Enclosure Covers on page 41 Step 5 At pan motor assembly remove four 6 32 X 3 8 PPZ screws and four 6 lock washers Figure 2 27 Pan Motor Pulley Sensor Figure 2 27 Pan Motor Assembly Replacement 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Step 6 Slip belt off pan motor pulley Step 7 Pull pan motor assembly part way out of enclosure and disconnect sensor and motor wire connectors Step 8 Remove pan motor assembly CAUTION Ensure no wire will be pinched between mounting plates before securing replacement pan motor assembly with screws Step 9 Install replacement pan motor assembly by performing Steps 2 8 in reverse order 02 9671 0010 C 24 March 2004 47 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 48 AN Main Controller Parts Assembly Replacement
104. S IW 5 5 6 OHM METAL OXIDE 12 60 3430 8205 2 EA RES IW 3 820 0K OHM METAL OXIDE R3 R4 13 62 3021 2101 1 EA CAPACITOR 100PF 200V RAD CER 10 Ce 14 62 3021 2330 1 EA CAPACITOR 330PF RAD CER 5 C5 15 62 3023 0104 2 0 1UF 50 20 C8 C10 16 62 3035 0102 1 EA CAPACITOR 1000PF 10 RAD CER CI 17 62 4010 0106 1 EA CAPACITOR 10UF 50V RAD ALUM C2 18 62 4010 0475 1 EA CAPACITOR 4 7UF 50V RAD ALUM C4 19 68 9661 1117 1 EA COIL SOLID STATE IGNITOR LI 20 71 2564 0001 1 EA LIGHT NEON STD BRIGHTNESS 1 21 80 2623 0001 1 EA TRANSISTOR 2N4401 NPN 40V Q2 22 80 2623 0003 1 EA TRANSISTOR 2N4403 PNP 40V Q3 23 80 2657 0001 1 EA TRANSISTOR BIMOSFET IXBH16N17 24 82 4308 4937 1 EA DIODE IN4937 FAST D3 25 82 4332 0001 2 EA DIODE MUR8100E 1000V 8A D4 D5 26 82 5351 0001 1 EA DIODE ZENER 20V 1W 5 DO 41 D2 27 82 5373 0001 1 EA DIODE ZENER 1 5955 180V 3W De 28 83 3212 0001 1 EA IC MC14536B PROGRAMMABLE TIMER Ul 02 9671 0010 C 24 March 2004 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Ignitor PCB Assembly cont SOLID STATE IGNITOR V 24 9661 1126 REM ae 1 e J4 Mu te 5 24 29 J2 20M C1 2 P WM 88 UL ni a ase JLE 5 s J1
105. TE G VL2000 WASH LUMINAIRE SERVICE MANUAL Lamp Supply Harness Cable Assembly 25 9661 1551 01 Rev 0 Formerly 25 9661 1544 01 Refer to Figure 3 55 No Item Qty UM Description 1 25 9661 1518 1 EA CABLE ASSY LAMP SUPPLY CONTROL 2 25 9661 1531 1 EA LAMP SUPPLY OT NOT ON 3 25 9661 1550 1 EA CABLE ASSY DC OUTPUT VLT130 4 55 2186 0001 2 EA CABLE TIE 10 WD 4 00 LG SMALL 5 55 6699 0003 67 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 8 0 Figure 3 55 Lamp Supply Harness Cable Assembly 138 24 March 2004 02 9671 0010C ILLUSTRATED PARTS BREAKDOWN CABLES 3 Motor Harness Cable Assembly 25 9671 0007 Rev D Refer to Figure 3 56 Description 1 04 9671 0041 00 1 EA LABEL SET MOTOR HARNESS 2402 2 52 6211 0017 2 EA COVER BACK SHIELD NON SHIELD F DBL ROW 50 POS 3 52 6212 0017 2 EA COVER FRONT LATCH F DBL ROW 50 POS 4 52 6396 2403 2 EA RECEPT 3 POS MTA100 W POL TAB 24AWG CLSD END 5 52 6467 0004 1 EA CONN FEM PLUG 4 POS 30 24 AWG CRIMP PHR 6 52 6467 0011 5 EA CONN FEM PLUG 11 POS 30 24 AWG CRIMP PHR 7 52 6467 0024 24 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 8 52 6524 0004 2 EA CONN HOUSING 4 POS RECEPTACLE 9 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 10 52 6610 0017 2 EA CONN HOUSING 50 POS DBL ROW UNLOADED 11 52 8230 0002 2 EA TERM 1 4 FASTON 2
106. __ L Data Thru Data In 02 9671 0010 C 24 March 2004 5 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Menu Display The Menu System Display is used to access the menu system which is a programmable set of commands used to address operate and test the luminaire The menu system is controlled by four buttons These buttons function as follows Changes value NY scrolls through menus Multi Segment Display Changes value or scrolls through menus Displays the menu or if at first level current address Selects the current menu option Or enters current data value Note Refer to the VL2000 Wash Luminaire User s Manual for more detailed instructions regarding display operation LED Indicators The LED indicators report the status of power and data to the luminaire Indicates DC power is being supplied via AC Input when lit Indicates data is being transmitted when flashing 3 amp 5 5 ES Indicates data is being received when flashing fast when flashing in 2 sec heartbeat indicates luminaire is idle 6 24 March 2004 02 9671 0010 C DESCRIPTION MAJOR COMPONENTS 1 Head Components The following illustration shows the major sub assemblies which are located in the luminaire head assembly Dimmer Bulkhead Assembly Removable Cover Rear Assembly
107. arrows to select a parameter to test Step 4 Press Enter to run test Step 5 Press Menu to stop test at any time 24 March 2004 02 9671 0010C MAINTENANCE SPECIAL CONSIDERATIONS Special Considerations Configuring Main Controller Board When performing maintenance or troubleshooting procedures on Series 2000 luminaires it may be necessary to configure the Main Controller Board MCB for installation When moving an MCB from one luminaire another different jumper configurations must be set correctly in order for the luminaire to operate The Main Controller Board MCB contains two blue jumpers N CAUTION Always use anti static precautions when working with PCBs Programming Jumper J1 For Vari Lite engineering use The jumper at J1 is necessary and must be in the correct position in order for the luminaire to operate DO NOT change the configuration of jumper J1 Figure 2 1 Jumper at J11 Power Supply Connection at J2 Jumper at J1 Figure 2 1 Jumper Locations on MCB Luminaire Type Jumper J11 The jumper at J11 configures the luminaire type between VL2000 spot VL2000 wash and VL2416 wash For VL2000 spot or VL2416 wash luminaires it is fitted to non active pins This inactive setting is the default or shipping configuration For VL2000 wash luminaires it is fitted to the active pins Power Supply Connection J2 The power supply connection at J2 sets the luminaire type according to the powe
108. ea 2 VEN VOUT FFCBTAS g 1 4 1 6 MTe4 1 EN m TABLE 1 NOTE 5 CEND ciis 1 44 6 1UF ae REF DESIG 400W 625W 700M 1734 NTC101 2 5 OHM 10A 0 7 12 NTC102 2 5 OHM 10A 0 7 12 PFCSND LISNS _ T 8 1 C5 1 48 1 A486 2 C5 2 B2 8101 0 10 OHM 0 075 OHM R109 33 OHM 20 OHM Reference Designators 8114 8 38 1 7 18 1 Last Used Not Used R208 5 1 OHM 4 7 OHM Sht 1 Sht 21Sht 1 Sht 2 1102 T LE 2122 Lvs C120 C226 C202 mi c 1 88 3 C C DCC PrCISNS em ias 0104 0215 Poe ___ 11885 gii cs 1 85 1 48 2 C5 2 82 La pause F101 5 TE wives Husi m eses 5 VANS gaca GFF ID JUMPERS J113 J205 J105 o NIU 3 2 e5 110 L102 L2041 po ibe B e 1 1 oos 24 9661 1120 DRAWN BY s PFCPEM mic NEXT Ee 201 REGAL ROW 0103 02414 ASSY 24 9661 1130 B CURBO L I DALLAS TEXAS 75247 1 i Le R118 R227 R204 R205 a PCB NO 11 9661 1120 DSN B CURBO 9 21 99 1201 CONFIDENTIAL 400W 625W 700W BALLAST 15102 15201 ALL INFORMATION CONTAINED HEREIN le 5 i 0 54 S THE SOLE AND EXCLUSIVE PROPERTY SIZE REVISION DRAWING NUMBER OF VARI LITE INC AND MAY NOT BE D 14 9661 1120 VR102 USED DISCLOSED OR REPRODUCED MF 6 Filename N ANY MANNER WITHOUT THE ADVANCE Date Time WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 2 c
109. embly 0 DMX Input PCB Assembly Input Panel Assembly Enclosure Assembly 02 9671 0010 C 24 March 2004 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Principles of Operation Power and Data Flow Diagrams The following diagram shows how data and power are distributed in the luminaire HEAD HEAD FAN FAN 1 2 AMBER MOTOR o PAN M4 24V 24V M2 M3 M2 M3 TILT DMX MAIN ATA AUX DATA AUX DATA 1 0 INPUT DATA CONTROL CONTROL CONTROL PCB PCB 4V PCB 2 4V PCB 1 TILT ENCODER TILT EOT PAN EOT DIMMER COLOR SENSOR SENSOR HEAD OVERTEMP SWITCH LOW VOLTAGE V EAD SUPPLY BACK E CONTROL SWITCH EMI AC LNE NA FILTER fun AC ON OFF ARC POWER APS SUPPLY 10 24 March 2004 02 9671 0010C CHAPTER 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Special Considerations Maintenance Procedures power removed from the luminaire Never remove cover or backcap WARNING maintenance procedures to be performed with while lamp is in operation 02 9671 0010 C 24 March 2004 i I X z E S VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Testing 12 Testing Software Testing software is available in all Series 2000 luminaires through the luminaire s menu s
110. erwise specif Releosed per FO 804547 9 21 99 B C 11 capacitor values are rafarads Et We A Revised per EO 06419 2 11 00 B C SE B Engineering Prototype 9 20 00 B C Capacitors are 50V 20 C Revised per EO 06434 9 20 00 B C The following components are not installed on the following board assy D Revised per EO 06442 24 9661 1120 0210 202 210 8207 822 5 5 1 1 1108 1108 See Table 1 for component alu 25 B 803 901 1 appropriate board assembl TREET i 50 24 96B1 1120 400M B25M B S af t youu PA 24 8681 1130 700W BALLAST Power and ground symbols use a 112 Gnd Logic ground 2 D2 2 03 2 C8 2 86 2 82 2 07 cm E 5 5 9 1746 1785 Z 3149 E gt iba 3744 6 205 250V 280 rii M C aR iude LINE LE ol e dy Hd ELE NOTE 5 KN a VANS a M 333895 asic 148 En 8108 5 EN oM 811 Age Lg Sie s Sabie 8134 20 20 1 4 CHASSISB 250 50v 174w o Lou ra 11 min dol Bt 4 1107 807 109 0 PFCEND LISNS T8 e 146 1 88 1748 1 48 27 C5 2 82 i T 1 PFCGNO LISNS NOTE 5 Mounting Holes 1 05 M MTG14 CHA35154 g vids MTG2 ECHASSISB g 1 c6 LM317AT MT
111. fy that products conform to the protection requirements of European council directives 73 23 EEC LVD and 89 336 EEC EMC Manual Revision History PAGE NUMBER CHANGE NUMBER Title Page xiv C 1 162 C VERSION DATE BASIC 15 Apr 01 Rev A 05 June 02 Rev B 03 Oct 02 Rev C 24 Mar 2004 24 March 2004 02 9671 0010 C FOREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein Heed all cautions and warnings during installation and use of this product Safety symbols used throughout this manual are as follows N CAUTION advising of potential damage to product A WARNING advising of potential injury or death to persons GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST FIRE AND ELECTRICAL SHOCK WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1 Replace fuses with same type and rating only WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1 VARI LITE control consoles are designed for dry locations only Exposure to rain or moisture may damage the console 2 Disconnect power before servicing any VARI LITE equipment 3 Servicing to be performed by qualified personnel only WARNING RF INTERFERENCE 1 Thisisa Class A product In a domestic environment this produc
112. hen In diesem Fall m ssen eventuell geeignete Mafinahmen getroffen werden vi 24 March 2004 02 9671 0010 C FOREWORD Notes de s curit Avant de proc der l installation des produits d crits dans ce guide et de les mettre en marche il est extr mement important de lire TOUS les renseignements et TOUTES les directives de s curit contenues dans ce guide ainsi que toute documentation jointe Tenir compte de tous les avertissements et suivre toutes les pr cautions pendant l installation et l utilisation de cet appareil Les symboles de s curit utilis s dans ce guide sont les suivants ATTENTION Ce symbole annonce que l appareil risque d tre endommag AN AVERTISSEMENT Ce symbole annonce qu il y a risque d accident grave ou m me fatal CETTE SECTION CONTIENT DES INFORMATIONS G N RALES POUR SE PROT GER CONTRE LES INCENDIES ET LES D CHARGES LECTRIQUES AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES INCENDIES 1 Ne remplacer les fusibles qu avec ceux du m me type ayant les m mes caract ristiques AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES 1 Les consoles de commande VARI LITE sont con ues pour une utilisation au sec uniquement Une exposition la pluie et l humidit risque d endommager la console 2 D brancher l appareil avant de proc der la r vision de tout mat riel 3 Lesr visions doivent tre effectu es uniquement
113. hing optical surfaces Step 2 Apply a small amount of isopropyl alcohol to a clean white lint free cloth Step 3 Clean lens by gently wiping with cloth Step 4 Repeat Step 3 several times using a new clean cloth each time 02 9671 0010 C 24 March 2004 51 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Notes 52 24 March 2004 02 9671 0010C 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL2000 wash luminaire assemblies Drawing Tree Top Assembly Head Yoke Enclosure Cables 02 9671 0010 C 24 March 2004 Drawing Tree VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL VL2000 Wash Luminaire 20 9671 0001 Upper Enclosure Assembly 21 9661 0004 05 continued on next page Front Internal Head Assembly 21 9671 0006 Front Color Assembly 21 9671 0007 Reflector Assembly Blue Amber Color Wheels Assembly 21 9671 0150 VL2000 Wash Luminaire 20 967 1 0001 Head Assembly 21 9671 0005 Rear Assembly 21 9671 0009 21 9660 0340 04 Yoke Assembly Tilt Motor Assembly 22 9667 0600 22 9661 0665 Ignitor Fan Cover Assembly 21 9673 0024 Ground Strap Cable 25 8007 2212 Back Cap Assembly Amber Color Wheel Assembly 21 9671 0158 21 9671 0183 22 9671 0404 Tilt Bearing Stabilizer Side Assembly 22 9667
114. ical Bulletins 147 VL2000 Wash Luminaire Technical Bulletin List 147 VL2000 Wash Luminaire Wire Diagram Sheet 1 149 VL2000 Wash Luminaire Wire Diagram Sheet 2 150 400W 625W 700W Ballast Schematic sss 151 02 9671 0010 C 24 March 2004 xiii VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL Ballast Rider Schematic see Auxiliary Controller Schematic Main Controller Schematic eene DMX Input Schematic Ignitor xiv 24 March 2004 02 9671 0010 C INTRODUCTION Introduction About This Manual This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VL2000 Wash Luminaire The manual is intended for use by Vari Lite personnel and by Vari Lite s customers clients WARNING It is important to read ALL accompanying safety and installation instructions to avoid damage to the product and potential injury to yourself or others This manual covers the following models Model Part Number VL2000 Wash Luminaire 20 9671 0001 Note Performing maintenance procedures contained in this manual may void the product warranty Refer to the Vari Lite Inc Limited Warranty card included in the shipping package for this VARI
115. inaire Service Manual 2000 2004 Genlyte Thomas Group LLC All Rights Reserved ii 24 March 2004 02 9671 0010 C FOREWORD How To Obtain Warranty Service A copy of the Vari Lite Inc Limited Warranty was included in the shipping package for this product To obtain warranty service please contact customer service at 1 877 VARI LITE 1 877 827 4548 or customerservice vari lite com and request a Return Material Authorization RMA for warranty service You need to provide the model and serial number of the item being returned a description of the problem or failure and the name of the registered 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 product in its original 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 Inc 10911 Petal Street Dallas Texas 75238 Attention Warranty Service As stated in the warranty it is required that the shipment be insured and FOB our service center Confidential Property Disclosure This technical manual is confidential property of Genlyte Thomas Group LLC AII information contained herein is the sole and exclusive property of Genlyte Thomas Group LLC and may not be used disclosed or reproduced in any manner without
116. ing the latest changes to VARI LITE equipment are issued from the Dallas Texas USA office They are documentation supplements that contain procedures for equipment upgrades retrofits and repairs not found in the existing manuals Operator technical bulletins are also issued to document changes in control software Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Bulletins are categorized by assembly or subassembly and identified by a number such as V24 001 VL24XX luminaire Technical Bulletin number 1 Technical notices are also issued from the Dallas Texas USA office They are non procedural documents that contain information regarding product support issues current equipment problems software bugs and documentation corrections All technical notices begin with the prefix TN and are numbered sequentially such as TN 138 Tech Notice number 138 2 24 March 2004 02 9671 0010C CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Major Components Principles of Operation 02 9671 0010 C 24 March 2004 HOIIAAS VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Features Standard Features The VL2000 wash luminaire features zoomable beam spreader optics CYM color mixing a separate fixed color wheel and a high performance dimmer strobe mechanism The VL2000 wash luminaire contains the
117. isconnect luminaire AC input cable from power source WARNING Allow lamp to cool before replacing gt Step 2 At backcap using screwdriver or fingers turn captive knob until loose Figure 2 3 Backcap Assembly Captive Knob Head Assembly Guide Figure 2 3 Lamp Replacement 02 9671 0010 C 24 March 2004 15 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 16 AN Step 3 Slide backcap away from head assembly it will remain attached by tether CAUTION Wear cotton gloves or other covering while servicing lamp Touching lamp glass with bare fingers will leave oil and cause the lamp to explode or burn out early If touched use alcohol to thoroughly clean glass Step 4 Remove lamp by pulling straight out of socket Step 5 Install new lamp pressing firmly into socket Step 6 Align guide rods in guide holes and slide backcap into head assembly Re tighten captive knob Step 7 Align lamp Refer to next procedure 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Align Lamp for Flat Field The design of the optical system is based on a flat field A flat field is one where there is no detectable hot spot After a new lamp is installed it will be necessary to align the lamp to optimize the beam Knobs located at the luminaire s backcap will allow adjustment WARNING Backcap and adjustment knobs will be HOT during lamp operation Wear gloves and or use to
118. itor PCB assembly wires by removing four 6 32 X 1 4 PPZ screws and four 6 lock washers which secure wire ring terminals to PCB and remove ignitor PCB assembly Figure 2 21 6 32 X 1 4 PPZ Screw 4 6 Lock Washer 4 6 32x5 16 PPZ Screw 2 AS ZEN 1 4 6 32 500 LG Standoff 2 Ignitor PCB Assembly v CBIGN1 Figure 2 21 Ignitor PCB Assembly Wire Terminals and Standoffs Removal Note Install two standoffs removed from old ignitor PCB assembly in step 7 in same position on replacement ignitor PCB assembly Step 7 Remove two 6 32 X 5 16 PPZ screw and two 6 lock washer one each standoff and remove two 1 4 hex standoffs from ignitor PCB assembly Install hex standoffs in same position on replacement ignitor PCB assembly Step 8 Install replacement ignitor PCB assembly by performing Steps 2 7 in reverse order 40 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Enclosure Assembly This section provides removal and replacement procedures for components found in the luminaire enclosure assembly Removing Enclosure Covers To gain access to enclosure components it will be necessary to remove the top and bottom covers Tools Screwdriver 2 Phillips Allen Wrench 3 16 To remove and replace enclosure covers WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Using console or internal menus run lens a
119. minaire yoke assembly Tilt Motor Replacement Parts ASSY TILT MOTOR 22 9661 0665 Tools Screwdriver 2 Phillips Nutdriver 1 4 To remove and replace tilt motor assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At tilt side leg remove yoke leg cover by removing four 6 32 X 5 16 PPB screws Figure 2 18 To find tilt side leg refer to page 9 Tilt Motor Assembly 6 32 X 5 16 Tilt side PPZ Screw 3 Leg Yoke Leg Cover 1 4 Hex Standoff Cable Anchor 6 32 X 5 16 PPZ Screw 6 32 X 5 16 PPB Screw 4 TMOTOR Figure 2 18 Tilt Motor Assembly Replacement 02 9671 0010 C 24 March 2004 35 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 36 Step 3 At pan tilt encoder mounted behind tilt motor mounting plate Step Step Step Step Step disconnect two cable connectors At tilt motor disconnect motor wire connector At cable anchor standoff remove one 6 32 X 5 16 PPZ screw and remove free cable Cable will still be attached by a cable tie to anchor Using 1 4 nutdriver remove 1 4 hex standoff Remove three remaining 6 32 X 5 16 PPZ screws securing tilt motor assembly to yoke leg and remove tilt motor assembly while freeing pulley from timing belt Install replacement tilt motor assembly by performing Steps 2 8 in
120. ols to prevent burns To align lamp Step 1 Using internal menus select Lamp test to set beam Refer to VL2000 Wash Luminaire User s Manual for more information If using console set intensity to 100 and adjust diffusion to produce a tight beam Step 2 Position beam on a white wall at a distance of 10 to 20 Step 3 At backcap using Vertical and Horizontal knobs adjust hot spot to center of beam Figure 2 4 Step 4 Using Focus knob adjust beam for flattest field Captive Knob for lamp access does not adjust beam Vertical Horizontal Focus Figure 2 4 Aligning Lamp for Flat Field 02 9671 0010 C 24 March 2004 17 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Color Bulkhead Assembly Replacement Parts BULKHEAD ASSEMBLY COLOR 22 9671 0077 Tools Screwdriver 2 Phillips To remove and replace color bulkhead assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover turn two captive screws one quarter turn and remove cover Figure 2 5 It will remain attached by tether Crossfade Color Sensor PCB Assembly Color Bulkhead Assembly Captive Screw Wiring Harness Connector Wiring Harness Connector Color Motor Assembly Magenta Motor Assembly Captive Screws Removable Cover Head Assembly 710005DTL
121. ower Supply Ballast Module 115 700W Ballast Board Assembly 117 700W Ballast Rider Board PCB Assembly 120 Tilt Motor Assembly eie Ie tr etr b reb ee eot t Ure ete 123 Chapter 5 Illustrated Parts Breakdown Cables Ground Strap Cable Assembly 125 AC Input Pigtail Euro Cable Assembly 4 126 AC Input Link Cable Assembly 127 AC Input Splitter Cable Assembly 128 LVS Chassis Ground Cable Assembly 129 Main To Aux Data amp Power Cable Assembly 130 Pan Tilt Control Cable Assembly ene 131 Lamp Supply Control Cable Assembly 133 Chassis To Yoke Ground Cable Assembly 134 Lamp Supply OT Not On Cable Assembly 135 Data I O Link Cable Assembly 136 DC Output Cable Assembly sise 137 Lamp Supply Harness Cable Assembly 138 Motor Harness Cable Assembly 139 Yoke to Head Ground Cable Assembly 141 Lamp Supply To Relay Cable Assembly 142 Ignitor To Relay Cable Assembly 143 Head OT Switch 2 Cable Assembly 0000 enne 144 DC Output XPiO Cable Assembly ss 145 Appendix A Techn
122. par des personnes qualifi es AVERTISSEMENT INTERF RENCE RF 1 Cetappareil est de Classe A Dans un environnement domestique cet appareil peut causer des interf rences radio et si c est le cas l utilisateur peut avoir prendre des mesures ad quates 02 9671 0010 C 24 March 2004 vii VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL Aviso sobre Seguridad Es muy importante leer TODA la informaci n e instrucciones sobre seguridad que se indica en este manual as como en los documentos adjuntos antes de instalar y operar los productos descritos Se debe prestar atenci n a todos los avisos y advertencias durante la instalaci n y uso de este producto Los s mbolos de seguridad usados en este manual son los siguientes ADVERTENCIA indica posibles lesiones o muerte a las personas N CUIDADO indica posibles da os al producto LA INFORMACI N GENERAL RELACIONADA A LA PROTECCI N CONTRA INCENDIO Y GOLPES DE CORRIENTE EL CTRICA ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA INCENDIO 1 Reemplaze los fusibles solamente con los del mismo tipo y especificaci n ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA CHOQUE EL CTRICO 1 Los controles de la consola de VARI LITE est n dise ados solamente para lugares secos La exposici n a la lluvia o humedad pueden la consola 2 Desconecte la energ a antes de dar servicio a cualquier equipo de VARI LITE 3 Elservicio debe ser
123. r Motor Assemblies Front Internal Head Assembly 2 Flat Washer 4 Sh 6 32 X 5 16 PPZ Screw 4 Figure 2 10 Front Internal Head Assembly Replacement Step 4 At head assembly disconnect wire connectors from blue and amber motors Step 5 Face head nose upward At front of bulkhead using 2 Phillips long handle screwdriver remove four 6 32 X 5 16 PPZ screws and four 6 lock washers securing front assembly to rear assembly and remove front assembly Step 6 Install replacement front internal head assembly by performing Steps 2 5 in reverse order 24 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Blue Amber Color Wheels Assembly Replacement Parts ASSEMBLY BLUE AMBER COLOR WHEELS 21 9671 0150 Tools Screwdriver 1 Phillips Screwdriver 2 Phillips Pick and hook tool Cotton gloves To remove and replace blue amber color wheels assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front internal head assembly Refer to Front Internal Head Assembly Replacement on page 24 Step 3 At front of bulkhead loosen four 8 32 X 3 8 PPZ screws to loosen tension on blue and amber motor assembly timing belts Figure 2 11 8 32 X 3 8 PPZ Screw 4 Blue Motor Assembly Front Internal Head Assembly Amber Motor Assembly 10006DTL Figure 2 11 Loo
124. r supply output VL2416 wash luminaire 1200W VL2000 spot luminaire and VL2000 wash luminaire 700W If the power selection setting and the luminaire type setting jumper J11 do not correspond the luminaire will not operate properly 02 9671 0010 C 24 March 2004 13 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Jumper Configuration To configure jumper Determine which type luminaire the MCB is to be installed in and configure jumper according to Figure 2 2 Note If luminaire will not calibrate or operate after MCB replacement check jumper setting and download new software 216 8 PT7 56 MADE IN USA 1999 Main Controller Board Component Side Jumper lt lt VL2000 Wash lt VL2000 Spot and VL2416 Wash 611225DTL2 Figure 2 2 MCB Jumper Configuration 14 24 March 2004 02 9671 0010 C MAINTENANCE MAINTENANCE PROCEDURES Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly Lamp Replacement Parts LAMP 700 WATT ARC PHILLIPS MSR700 71 2528 0700 Tools 2 Phillips Screwdriver Cotton gloves To remove and replace lamp WARNING All maintenance procedures are to be performed with power removed from the luminaire Never remove covers or open front lens or backcap assemblies while lamp is in operation gt Step 1 D
125. r Assembly 4 40 KEPS Nut 2 710006DTL4 Figure 2 17 Beam Spreader Motor Assembly Replacement 02 9671 0010 C 24 March 2004 33 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 34 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Remove two 4 40 X 1 4 PPZ screws and two 4 40 KEPS nuts securing beam spreader motor assembly to bulkhead and remove motor Install replacement beam spreader motor assembly in bulkhead Re install two 4 40 X 1 4 PPZ screws and two 4 40 KEPS nuts securing beam spreader motor assembly to bulkhead but do not tighten Using 1 4 wrench and pliers re install 4 40 KEPS nut on end of motor shaft Reconnect beam spreader motor assembly wire connector to motor harness cable assembly Re install front internal head assembly Refer to Front Internal Head Assembly Replacement on page 24 Re apply ac power CAUTION Before applying power be sure the luminaire is positioned so that the head and yoke can move freely without restriction Step 12 Step 13 Step 14 Seat motor shaft by applying power to luminaire and allowing luminaire to cycle through calibration Tighten two 4 40 X 1 4 PPZ screws and two 4 40 KEPS nuts Re install front cover assembly and head cover Figure 2 10 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Yoke Assembly This section provides removal and replacement procedures for components found in the lu
126. re AC input cable from power source Step 2 Atenclosure remove power supply side and ventilation covers Refer to Removing Enclosure Covers on page 41 Step 3 At power supply disconnect wiring at J1 J2 and GND Step 4 At power supply remove two 6 32 X 3 8 PPZ screws securing power supply PCB to standoffs Figure 2 24 Standoff 2 Power Supply PCB Friction Clasp 2 6 32 X 3 8 Screw 2 Note Some components not shown for clarity f ENCL3E Figure 2 24 Power Supply Replacement Step 5 Free bottom of power supply PCB from two friction clasps and remove power supply Step 6 Install replacement power supply by performing Steps 2 5 in reverse order 02 9671 0010 C 24 March 2004 43 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Ballast Module Assembly Replacement Parts ASSY BALLAST MODULE 700W ARC POWER SUPPLY 23 9671 1250 Tools Screwdriver 2 Phillips To remove and replace ballast module assembly CAUTION Always use anti static precautions when working with PCBs WARNING maintenance procedures to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At enclosure remove ballast side and ventilation covers Refer to Removing Enclosure Covers on page 41 Step 3 Remove both handles by removing two 10 32 X 5 8 PPB screws at each Step 4 Remove eight 6 32 X 3 8 PPZ
127. remain attached by tether Step 3 At dimmer bulkhead assembly remove two 6 32 X 3 8 PPZ screws securing dimmer bulkhead assembly to rear assembly and remove dimmer bulkhead assembly Figure 2 9 6 32 X 3 8 PPZ Screw 2 Dimmer Bulkhead Assembly Rear Assembly Figure 2 9 Dimmer Bulkhead Assembly Replacement MZ Step 4 Disconnect wire connector from stepper motor Step 5 Disconnect wires from thermal switch Step 6 Slide dimmer bulkhead assembly from head assembly Step 7 Install replacement dimmer bulkhead assembly by performing Steps 2 6 in reverse order 02 9671 0010 C 24 March 2004 23 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Front Internal Head Assembly Replacement Parts FRONT INTERNAL HEAD ASSEMBLY 21 9671 0006 Tools Screwdriver 2 Phillips long handle Screwdriver 2 Phillips To remove and replace front internal head assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove color bulkhead assembly Refer to Color Bulkhead Assembly Replacement on page 18 Step 3 At front cover assembly remove two 10 32 X 1 2 PPB screws and remove front cover assembly Figure 2 10 Captive Screws Rear Assembly Head Cover Front Cover Assembly 10 32 X 1 2 PPB Screw 2 N Blue and Ambe
128. reverse order 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Auxiliary Controller PCB Assembly Replacement Parts PCB ASSY AUX CONTROLLER 24 9661 1400 Tools Screwdriver 2 Phillips Nutdriver 1 4 Wrench open ended 1 4 To remove and replace auxiliary controller PCBs CAUTION Always use anti static precautions when working with PCBs WARNING maintenance procedures are to be performed with power removed from the luminaire gt Step 1 Disconnect luminaire AC input cable from power source Step 2 At board side leg remove yoke leg cover by removing four 6 32 X 5 16 PPB screws To find board side leg refer to page 9 Step 3 Remove counter weight assembly by removing four 6 32 X 5 16 PPZ screws and four 6 lock washers Figure 2 19 Step 4 To remove auxiliary controller PCB 1 disconnect yoke cable assembly from first auxiliary controller PCB at J2 and main to aux data and power cable at 15 Step 5 Using 1 4 nutdriver or open ended wrench remove 1 4 hex four standoffs and four 6 lock washers and remove auxiliary controller PCB 1 Note A connector is installed between auxiliary controller PCBs 1 and 2 The connector may remain attached to auxiliary controller PCB 1 when it is removed Step 6 If connector remains attached to auxiliary controller PCB 1 when PCB is removed remove connector from auxiliary controller PCB 1 02 9671 0010 C 24 March 2004 37 VARFKLITE
129. s Assembly 8 Lock Washer 4 8 32 X 1 2 PPB Screw 4 N 9 SAN Lens Support Arm 6 32 X 3 16 PPB Screw 4 6 Lock Washer 4 id Small Stipple Glass 100060711 Figure 2 14 Lens Assembly Replacement CAUTION Do not touch lens with bare fingers Wear cotton gloves or other covering while replacing Step 4 Remove four 8 32 X 1 2 PPB screws and four S lock washers securing concave lens assembly to lens shafts and remove concave lens assembly Step 5 Install replacement concave lens assembly by performing Steps 2 4 in reverse order 28 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Convex Lens Assembly Replacement Parts ASSEMBLY CONVEX LENS 22 9671 0414 Tools Screwdriver 2 Phillips Allen wrench 1 4 Nutdriver 1 4 Cotton gloves To remove and replace convex lens assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove small stipple glass Small Stipple Glass Replacement on page 27 Step 3 Remove concave lens assembly Concave Lens Assembly Replacement on page 28 Step 4 Using 1 4 nutdriver remove one 4 40 KEPS nut on end of beam spreader motor assembly shaft Figure 2 15 Beam Spreader Motor Assembly Convex Lens Assembly Concave Lens Assembly V 8 Lock Washer 4 8 32 X 1 2 PPB Screw
130. s far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source Step 3 Ateach top enclosure cover remove two 6 32 X 1 4 PPB screws and remove cover Figure 2 22 6 32 X 1 4 PPB Screw 4 Sel Two each cover gt Ballast Side Cover Si Power Supply Side Cover Ventilation Cover 1 4 Lock Washer 1 4 20 X 1 2 Socket Screw 8 Figure 2 22 Removing Top and Bottom Enclosure Covers 02 9671 0010 C 24 March 2004 41 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL CAUTION Be careful to damage lens during next step Step 4 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Figure 2 23 Figure 2 23 Laying Luminaire on Its Side Step 5 At bottom of enclosure using 3 16 Allen wrench remove four 1 4 20 X 1 2 socket screws and four 1 4 lock washers and remove ventilation cover Figure 2 22 Step 6 Return luminaire to upright position 42 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Power Supply Replacement Parts POWER SUPPLY 130W 24V 5 4A 12 3126 1103 Tools Screwdriver 2 Phillips stubby To remove and replace power supply CAUTION Always use anti static precautions when working with PCBs WARNING All maintenance procedures are to be performed with power removed from the luminaire gt P Step 1 Disconnect luminai
131. screws and remove both side covers Figure 2 25 10 32x5 8 PPB Screw 2 TUM N Front Cover APS Side Bracket 6 32x3 8 PPZ Screw 8 Figure 2 25 Accessing Ballast Module Assembly Step 5 At ballast side of enclosure remove front cover and APS side bracket 44 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Step 6 At ballast module assembly disconnect wiring Location Connector J102 2 Pos Connector J103 3 Pos Mate N Lok J108 Red 1 Choke J109 Dark Blue 2 Choke J110 Orange 3 Choke J111 Orange 4 Choke J112 8 Pos MTA J113 3 Pos MTA J202 Lamp Wires White J203 Lamp Wires White J204 Red Buck Choke J205 Blue Buck Choke Step 7 Pull wires through ferrite core Figure 2 26 Ferrite Core lt Pull wires through here Ballast Module Note Some components not shown for clarity 8 32 X 3 8 PFZ Screw 3 gt 8 32 X 3 8 PPZ Screw 2 Figure 2 26 Ballast Module Assembly Replacement ENCL3F Step 8 At bottom of enclosure remove three 8 32 X 3 8 PFZ screws and two 8 32 X 3 8 PPZ screws which secure ballast module to enclosure Step 9 Remove ballast module Step 10 Install replacement assembly by performing Steps 2 9 in reverse order 02 9671 0010 C 24 March 2004 45 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL 46 Pan Motor Assembly Replacement Parts ASSY
132. sening Tension on Timing Belts Note When removing timing belts from blue and amber color wheel pulleys ensure belts remain in place on blue and amber motor pulleys Step 4 Remove timing belts from blue and amber color wheel pulleys Figure 2 12 02 9671 0010 C 24 March 2004 25 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Timing Belts EX Flat Washer Block Shaft Assembly Blue Amber Color Wheels Assembly Figure 2 12 Blue Amber Color Wheels Assembly Replacement Step 5 Using pick and hook tool remove c clip securing blue amber color wheels assembly on block shaft assembly CAUTION Do not touch wheels with bare fingers Wear cotton gloves or other covering while replacing Step 6 Remove blue amber color wheels assembly and flat washer from block shaft assembly Step 7 Install replacement blue amber color wheels assembly by performing Steps 2 6 in reverse order 26 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Small Stipple Glass Replacement Parts SMALL STIPPLE GLASS 12 9671 0408 Tools Screwdriver 2 Phillips Cotton gloves To remove and replace small stipple glass WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover turn two captive screws one quarter turn and remove cover Figure 2 10 It
133. t may cause radio interference in which case the user may be required to take adequate measures 02 9671 0010 C 24 March 2004 V VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL Sicherheitshinweise Es ist u erst wichtig ALLE Sicherheitsinformationen und hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen bevor Sie die hierin beschriebenen Produkte installieren bzw bedienen Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmafinahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet N VORSICHT weist auf m glichen Produktschaden hin WARNUNG weist auf m gliche K rperverletzung und Leb ensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHER HEITSVORKEHRUNGEN GEGEN FEUER UND ELEKTROSCHOCK WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Starke WARNUNG HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK 1 VARI LITE Konsole eignen sich ausschlie lich f r trockene Standorte Regen oder Feuchtigkeit k nnen die Konsole besch digen 2 Unterbrechen Sie die Stromzufuhr bevor Sie mit der Arbeit an VARI LITE Ger ten beginnen 3 Die Gerate sollten nur von qualifiziertem Personal gewartet werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse A In einer Wohnumgebung kann das Produkt Hochfrequenzst rungen verursac
134. te 242 To remove and replace 100MM condenser lens assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove small stipple glass Small Stipple Glass Replacement on page 27 Step 3 Remove concave lens assembly Concave Lens Assembly Replacement on page 28 Step 4 Remove convex lens assembly Convex Lens Assembly Replacement on page 29 Note Before removing shaft collets note orientation for use during re installation Step 5 Using 5 64 Allen wrench loosen eight setscrews two each collet and remove four shaft collets and four wave spring washers from lens shafts Figure 2 16 CAUTION Do not touch lens with bare fingers Wear cotton gloves or other covering while replacing Step 6 Remove 100MM condenser lens assembly from lens shafts Step 7 Slide replacement 100MM condenser lens assembly onto lens shafts Step 8 Re install four wave spring washers on lens shafts Step 9 Re install four shaft collets on lens shafts Note Ensure wave spring washers are compressed before tightening shaft collet set Screws Step 10 Slide shaft collet down on lens shaft until wave spring washer is compressed 02 9671 0010 C 24 March 2004 31 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Step 11 Apply Loctite 242 to threads of setscrews and using 5 64 Allen wrench tighten setscre
135. the prior written consent of Genlyte Thomas Group LLC The information furnished in this manual is for informational use only and is subject to change without notice Genlyte Thomas Group LLC assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual 02 9671 0010 C 24 March 2004 iii VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL Compliance Notice FCC 6 This equipment has been tested and found to comply with the limits for Class digital device pursuant to Part 15 of FCC Rules These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with Vari Lite system service and safety guidelines may cause harmful interference to radio communica tions Operation of this equipment in a residential area is likely to cause harmful inter ference in which case the user will be required to correct the interference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents Safety EN 60950 1999 Safety Standard for Information Technology Equipment EMC EN55022A 1998 Radiated and Conducted Emissions EN50082 1 1997 Generic Immunity Standard We certi
136. to Figure 3 20 No Item Qty UM Description 1 52 6523 0006 1 EA CONN HOUSING 6POS PLUG SHROUDED WIRE TO WIRE 2 52 6524 0002 1 EA CONN HOUSING 2POS RECEPTACLE 3 52 8346 0001 2 EA CONTACT 24 30AWG FEMALE CRIMP 4 52 8347 0001 6 EA CONTACT 24 30AWG MALE CRIMP 5 52 8371 0001 2 EA RECEPT FASTON 24 20AWG UNISUL TIN PLT BRS 250 X 032 TAB 6 55 6706 0001 2 EA GROMMET 9 32 ID 9 16 OD 1 4 SILICONE RED 7 73 6224 0005 1 WIRE 24AWG 600V 2006 UL1213 CSA 8 86 7002 0003 1 EA SWITCH SLOTTED OPTICAL Figure 3 20 Optical Sensor Assembly 02 9671 0010 C 24 March 2004 83 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Color Bulkhead Assembly 22 9671 0077 Rev C Refer to Figure 3 21 Description 1 10 9671 0121 1 EA HEAT SHIELD COLOR BULKHEAD 2 10 9671 0196 1 EA SPACER CLAMP 3 10 9671 0198 1 EA GASKET COLOR WHEELS 4 10 9671 0199 1 EA SPRING COLOR WHEELS 5 21 9671 0124 1 EA BULKHEAD ASSY COLOR W O COLOR WHEELS 6 21 9671 0161 1 EA GLASS ASSY MAGENTA COLOR WHEEL 7 22 9673 0145 1 EA ASSY FILTER WHEEL 8 25 9667 0146 1 EA CABLE ASSY HEAD OT SWITCH 2 9 53 6522 0001 EA SCREW 6 32 X 1 4 PPZ S gt 53 6597 0001 SCREW 4 40 X 3 16 PPZ 55 2186 0002 1 EA CABLE TIE 09 WD 3 750 LG TEFZEL En 12 55 3303 0004 2 EA WASHER 4 L
137. urrent technical bulletins associated with the VL2000 wash luminaire These improvements have been incorporated into this manual Technical Bulletin Description V24 008 Thermal switch upgrade S2K 012 Adding washers to sensors S2K 014 Modifying wire harness for installation of new style power supply S2K 015 Main Controller PCB jumper configuration S2K 016 Installation of capacitors for hot restarts S2K 017 Installation of washers for vertical hang positions S2K 018 Adding stabilizer brackets S2K 019 Pan bolt modification S2K 021 Changing two diodes on ignitor board S2K 022 Auxiliary PCB capacitor change S2K 023 Auxiliary card capacitor change to improve reliability Technical Bulletins Software Updates support and other information is available online at http www vari lite com Support To request access to the password protected support areas please contact Vari Lite Customer Service at 1 877 827 4548 or customerservice vari lite com 02 9671 0010 C 24 March 2004 147 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Notes 148 24 March 2004 02 9671 0010C VARFKLITEG VL2000 WASH LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS VL2000 Wash Luminaire Wire Diagram Sheet 1 4 2 REVISIONS SHIELD TWISTED PAIR S EO 8153 Gu 02 9671 0010 C
138. will remain attached by tether Step 3 At front cover assembly remove two 10 32 X 1 2 PPB screws and remove front cover assembly Figure 2 10 CAUTION Do not touch glass with bare fingers Wear cotton gloves or other covering while replacing Step 4 Face head nose upward At front of bulkhead remove four 6 32 X 5 16 PPB screws and 6 lock washers securing diffuser glass retainer and small stipple glass to concave lens assembly and remove retainer and glass Figure 2 13 Concave Lens Assembly Small Stipple Glass Diffuser Glass Retainer 6 Lock Washer 4 6 32 X 5 16 PPB Screw 4 S 710006DTL2 Figure 2 13 Small Stipple Glass Replacement Step 5 Install replacement small stipple glass by performing Steps 2 4 in reverse order 02 9671 0010 C 24 March 2004 27 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Concave Lens Assembly Replacement Parts ASSEMBLY CONCAVE LENS 22 9671 0413 Tools Screwdriver 2 Phillips Cotton gloves To remove and replace concave lens assembly WARNING All maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove small stipple glass Refer to Small Stipple Glass Replacement on page 27 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 14 Lens Shaft 4 Concave Len
139. wn 8 53 5604 0250 1 EA SCREW 4 40 X 1 4 PPSS BLK 9 53 6525 0001 4 EA SCREW 6 32 X 5 16 PPZ 10 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 11 53 6625 0001 2 EA SCREW 10 32 X 1 2 PPB 12 55 3301 0006 2 EA WASHER 46 FLAT SS 13 55 3303 0004 1 EA WASHER 4 LOCK INT TOOTH SS 14 55 3303 0006 6 EA WASHER 6 LOCK INT TOOTH SS 15 55 6596 0009 2 EA CLAMP CABLE 3 8 SS W WHITE SILICONE CUSHION 16 55 6621 0001 1 EA WASHER 4 FLAT ZINC 02 9671 0010 C 24 March 2004 59 VARFKLITE G VL2000 WASH LUMINAIRE SERVICE MANUAL Head Assembly cont 60 es 8 NW 2 pl 10 2 9 4 pl m Figure 3 3 Head Assy 24 March 2004 02 9671 0010 C ILLUSTRATED PARTS BREAKDOWN HEAD 3 Front Internal Head Assembly 21 9671 0006 Rev E Refer to Figure 3 4 Description 1 10 9671 0223 4 EA SHAFT COLLET 2 10 9671 0313 2 EA LENS SUPPORT ARM 3 21 9671 0007 1 EA FRONT COLOR ASSY 4 21 9671 0492 1 EA ASSEMBLY FRONT LENS added 11 08 02 5 22 9671 0402 1 EA 100MM CONDENSER LENS 6 22 9671 0414 1 EA ASSY CONVEX LENS 7 53 2200 0004 1 EA 4 40 KEPS SS 8 53 5558 0188 8 EA SCREW 8 32 188 SET SS BRASS UNC 2A 9 53 6543 0003 4 EA SCREW 6 32 X 3 16 PPB 10 53 6552 0002 4 EA SCREW 8 32 X 1 2 PPB 11 53 6608 0003 8 EA SCREW 6 32 X 3 16 LG PPZ 12 55 3303 0006 12 EA WASHER 6 LOCK
140. ws to secure shaft collet to base of lens shaft Step 12 Repeat steps 10 and 11 for remaining three shaft collets 100MM Condenser Lens Assembly Wave Spring Washer 4 Lens Shaft 4 Shaft Collet 4 Setscrew 8 Convex Lens Assembly Small Stipple Glass Concave Lens Assembly Figure 2 16 100MM Condenser Lens Assembly Replacement Step 13 Re install convex and concave lens assemblies Convex Lens Assembly Replacement on page 29 Step 14 Re install small stipple glass Refer to Small Stipple Glass Replacement on page 27 32 24 March 2004 02 9671 0010C MAINTENANCE MAINTENANCE PROCEDURES Beam Spreader Motor Assembly Replacement Parts ASSEMBLY MOTOR BEAM SPREADER 22 9671 0468 Tools Pliers 3 channel lock Screwdriver 1 Phillips Screwdriver 2 Phillips Wrench open ended 1 3 To remove and replace beam spreader motor assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front internal head assembly Refer to Front Internal Head Assembly Replacement on page 24 Step 3 Disconnect beam spreader motor assembly wire connector from motor harness cable assembly Step 4 At beam spreader motor assembly using 1 4 open ended wrench and pliers remove one 4 40 KEPS nut from end of motor shaft Figure 2 17 4 40 X 1 4 PPZ Screw 2 Beam Spreader Moto
141. x Data amp Power Cable Assembly 25 9667 1516 01 Rev Formerly 25 9661 1516 01 Rev B Refer to Figure 3 48 No Item Qty UM Description 1 52 6484 0006 2 EA RECEPT 6POS DUAL ROW MINI FIT JR 2 52 8333 0001 8 EA CONTACT FEMALE 18 20 AWG REEL HCS PWR 3 52 8333 2228 4 EA CONTACT 22 28AWG FEM REEL GOLD MFJR DATA 4 55 2186 0001 2 EA CABLE TIE 10 WD 4 00 LG SMALL 5 55 6699 0003 2 50 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 6 73 5114 0406 2 67 FT WIRE 24AWG TWISTED PAIR PVC 300V 80C lt YEL BLU gt UL106 7 73 7060 0001 5 33 FT WIRE 18AWG HIGH VOLT RED YOKE LAMP 8 73 7060 0002 5 33 FT WIRE 18AWG HIGH VOLT BLACK YOKE LAMP 2 4 pl MOLEX MINI FIT JR VIEW FROM WIRE SIDE 130 le pl Figure 3 48 Main to Aux Data amp Power Cable Assembly 24 March 2004 02 9671 0010 ILLUSTRATED PARTS BREAKDOWN CABLES 3 Pan Tilt Control Cable Assembly 25 9661 1517 01 Rev E Refer to Figure 3 49 No Item Qty UM Description 1 52 6211 0008 1 EA COVER BACK SHIELD NON SHIELD F DBL ROW 20POS 2 52 6212 0008 1 EA COVER FRONT LATCH F DBL ROW 20POS 3 52 6524 0005 2 EA CONN HOUSING 5POS RECEPTACLE 4 52 6588 0007 2 EA CONN HOUSING 7CIR DISCONNECTABLE CRIMP STYLE XH 5 52 6610 0008 1 EA CONN HOUSING 20POS D
142. xiliary Controller PCB Assembly Replacement 37 Ignitor PCB Assembly Replacement 39 Enclosure Assembly 41 Removing Enclosure Covers 41 Power Supply Replacement 43 Ballast Module Assembly Replacement 44 Pan Motor Assembly 1 21 2 1 10 10000000000000000000000000000004 46 Main Controller PCB Assembly Replacement 48 DMX Input PCB Assembly Replacement 50 Cleaning Lens peer eret n Pe ee ee E rdg ener Eee eade rus 5 Chapter 3 Illustrated Parts Breakdown Drawing Tree VL2000 Wash Luminaire 20 9671 0001 54 Top Assembly Included Kite rdc cte e un 56 Top Assembly VL2000 Wash Luminaire ss 57 Head Head Assembly rte Ret ee tegere 59 Front Internal Head Assembly 61 Front Color Assembly ses 63 Blue Amber Color Wheels Assembly 65 Amber Color Wheel Assembly 1 1 0 20224 2 02 20000000004600000000000000 000000000 66 Amber Color Wheel Pulley Assembly sse enn 67 Blue Motor
143. ystem TEST function For information on specific tests and test parameters see the VL2000 Wash Luminaire User s Manual VL Part no 02 9671 0001 When running tests on multiple luminaires a loopback connector is required at the first luminaire in the link and a male termination connector is required at the last luminaire Note After 10 seconds of inactivity the menu display will change to the default state showing the address Move Disable The Move option is available in the test menu This allows for pan tilt functions to be disabled so that the luminaire can be placed in any position for testing without movement occurring In order to regain full control of the luminaire Move will need to be enabled after testing Note When setting the Move option to disable luminaires linked by a loopback connector will have pan and tilt disabled for all the luminaires that are linked Lamp The Lamp option is also available in the test menu This option sets the lamp intensity to 100 and will adjust the diffusion to produce a tight beam Pan Tilt are disabled while using the Lamp option and pan tilt settings will be restored upon exit of the Lamp feature Note When setting the Lamp option on luminaires linked by a loopback connector pan and tilt will be disabled for all the luminaires that are linked To run tests Step 1 Press Menu Step 2 Press Up Down arrows until TEST appears Press Enter Step 3 Use Up Down

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