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Vari-Lite is a Philips group brand

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7. ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Color Motor Assembly 21 9676 0119 Rev D Refer to Figure 3 18 No Item Qty UM Description 1 10 9621 0097 1 EA STABILIZER STEPPER GOBO WHEEL 2 10 9676 1120 1 EA COLOR MOTOR BULKHEAD 3 24 9676 1114 1 EA PCB ASSY SENSOR COLOR GOBO 4 44 9676 0116 1 MOTOR GOBO COLOR WHEEL 5 55 2203 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 3 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 Note orientation of 2 9 802 motor connection Figure 3 18 Color Motor Assembly 02 9676 0020 A 01 July 2008 71 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Gobo Wheel Assembly 21 9676 4146 Rev A Refer to Figure 3 19 No Item Qty UM Description 1 22 9676 4142 1 EA ASSY 6080 WHEEL 12 POSITION FIXED 8 12 9676 41
8. 3 02 9676 0020 A 01 July 2008 XIII VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL FE UV
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10. No Item Qty UM Description 1 10 9676 0068 1 EA AIR DUCT FRONT FAN 2 22 9676 0091 1 EA ASSY FAN BULKHEAD 3 22 9676 0095 1 EA AIR DUCT REAR FAN 4 25 8007 2212 1 EA CABLE ASSY GROUND STRAP 6 RING 3 LG 5 40 7113 0002 1 EA FAN 24 VOLT 80 X 80 X 25MM 39 6 40 7146 0002 1 EA DC FAN 3 15 SQ X 1 0 BB LOW FLOW 7 52 6523 0005 1 EA CONN HOUSING 5 POS PLUG SHROUD 8 52 8347 0001 5 EA CONTACT 24 30 AWG CRIMP MALE 9 52 8371 0001 1 EA RECEPT FASTON 20 24 AWG UNINSULATED 10 53 2200 0006 1 EA NUT KEPS 46 32 SS 11 53 5604 0375 8 EA SCREW 4 40 X 3 8 PPSS B 12 53 6558 0010 1 EA SCREW 6 32 X 1 4 LG PPZ BLK 13 53 6596 0001 2 EA SCREW 4 40 X 5 16 PPZ 14 55 2186 0001 1 EA CABLETIE 10 X 4 SMALL 15 55 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 16 55 6616 0008 3 EA STANDOFF 3 8 HEX 8 32 THRD 0 5 LG 17 73 1624 0008 1 FT WIRE 24 AWG 300V 200 DEG TEFLON GRY 64 01 July 2008 02 9676 0020 ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Fan Assembly continued 7 8 5 14 Figure 3 14 Fan Assembly 02 9676 0020 A 01 July 2008 65 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Iris Color Gobo Bulkhead Assembly 21 9676 4120 Rev C Refer to Figure 3 15
11. 124 Figure 3 67 DC Output Cable Assembly 01 July 2008 02 9676 0020 A VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL VL2500 Spot Luminaire Schematics VL2500 Luminaire Wiring Diagram 02 9676 0020 A VOLTAGE TERMINAL BLOCK 68 9678 0827 POWER CABLE 25 9678 0810 GRN YEL 25 9661 1520 SUPPLY A2 700W ARC BALLAST 24 9661 1130 VLFS BALLAST RIDER BOARD BOARD TO BOARD 24 9661 1111 REV G WT TO RELAY PIN 4 SHEET 2 8X TO RELAY PIN 6 SHEET 2 TO YOKE GND STUD SHEET 2 CONNECTOR DISPLAY BOARD 24 9678 0825 ENCODER SENSOR 8 24 9678 0729 01 July 2008 REFERENCE FOLD OUTS REV ECO DESCRIPTION DATE TO AO NONE PROTO aa CONTROLLER 5 Eoc zzd hance ner Mes 6 7 06 CC SHEET 2 45 BLK TO CONTROLLER J3 SHEET 2 TO CONTROLLER J8 SHEET 2 TO six CONTROLLER J2 SHEET 2 LAS ser eu s w nee VARBRLTE in PETAL ST DALLAS TX 75238 WRING DIAGRAM kr rT VL2500 CONTROLLER ta REVISION DRAWING NUMBER CL BO 14 9676 14 9676 0008 We some ALL DIMENSIONS ARE IN INCHES UNLESS NOTED DATE 7 20 04 ACAD UTE 125 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS VL2
12. No Item Qty UM Description 1 10 9676 4124 1 EA BULKHEAD IRIS GOBO COLOR 2 21 9676 0118 1 EA ASSY IRIS GOBO MOTOR 3 21 9676 0119 1 EA ASSY COLOR MOTOR 4 22 9676 4146 1 EA ASSY 6080 WHEEL 5 22 9676 4145 1 EA ASSY COLOR FILTER WHEEL 6 22 9676 1145 1 EA IRIS 53MM CUSTOM 7 25 9676 0125 1 EA CABLE ASSY T STAT COLOR GOBO 8 53 2200 0004 1 EA NUT 4 40 KEPS SS 9 53 6558 0007 6 EA SCREW 4 40 X 1 4 PPZ SEMS 10 53 6559 0001 1 EA SCREW 4 40 X 1 4 PFZ 11 53 6605 0004 1 EA STUD 2 56 X 1 0 FULL THD SST 12 53 6659 0014 3 SCREW 2 56 13 54 1217 0005 2 EA QUICK LINK 2 56 SPRING STEEL 14 55 6538 0005 7 EA WASHER 0 25 OD 0 65 ID 0 15 TEFLON 15 55 6543 0001 1 EA GROMMET STRIP SERRATED 062 NOT SHOWN 66 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ASSEMBLY 3 Iris Color Gobo Bulkhead Assembly continued Figure 3 15 Iris Color Gobo Bulkhead Assembly 02 9676 0020 A 01 July 2008 67 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Crossfade Color Assembly 21 9676 0201 Rev Refer to Figure 3 16 No Item Qty UM Description 1 10 9676 0230 01 4 EA SPACER COLOR WHEEL 2 10 9676 0230 02 1 EA SPACER COLOR MOTOR 3 10 9676 0234 1 EA AFT BULKHEAD CROSSFADE COLOR SYSTEM 4 10 9676 0238 1 EA BULKHEAD SPA
13. D T I 7 3 z I 02 9676 0020 A 01 July 2008 136 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Control Board MCB Schematic continued z 7 z 8 z z m vec A 24V DIA 166 DIA 166 DIA 166 DIA 166 DIA 166 DIA 166 1 pa Soto MNTGI MNTG2 MNTG4 MNTG5 MG7 5 01 10 03 2 x pe aus son our a en mal 0 Kap tuo BAS ovr DISPLAY CONTROL A C 5 C1 10 C5 2 8 44 AMB_OUTIB A K 8D5 10A5 5 4 lt 5 C1 10 C5 peo 1 AMB 015 QUT tC d 51 1063 curis Diz RGOBO_OUTIA A lt 8 D5 10 A3 A 6 D5 10 03 us 2 OA aha 8 85 10 Di8 naomo cunt lt T 4 C 6 D5 10 C5 054 LAMP CNTL OUT CYAN OUTIB 406 2 RGOBO_OUT2A 4 C
14. 7 Z 3 Figure 3 32 DMX Input PCB Assembly 02 9676 0020 A 01 July 2008 93 94 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Refer to Figure 3 32 No Item Qty UM Description 1 52 6274 2313 1 EA STRAIN RELIEF SKINTOP FLEXTYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG MARKED 20A 250V TWIST LOCK 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 5 55 2268 0187 0 92 FT HEATSHRINK 3 16 CLEAR KYNAR 150 DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR 150 DEG C 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60 DEG EURO HD22 Figure 3 33 DMX Input PCB Assembly 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan Tube Assembly 21 9678 0880 Rev C Refer to Figure 3 34 No Item Qty UM Description 1 10 9678 0809 1 EA PAN TOGGLE STOP 2 10 9678 0847 1 EA WASHER SILICONE FOAM 3 10 9678 0848 2 EA WASHER PAN TEFLON 4 12 9678 0891 1 EA TUBE MACHINED 5 54 1206 0021 1 EA RING RETAINING 1 562 SHAFT 1 468 GRV DIA 6 54 1255 0002 1 EA BEARING ASSY FLUSH MOUNT HOUSING LARGE 5 C 6 1 L 3 a N 2 4 Figure 3 3
15. Lamp Power Up State L ON L OFF z 2 01 July 2008 02 9676 0020 A TABLE OF CONTENTS Table of Contents Introduction About This Manual 1 Additional Documentation iii rises testes een 1 Customer Services xu necem idea 2 Technical Bulletins Technical Notices 2 Chapter 1 Description Features 4 ESA ee Du e ADD ee 4 Major Components External 2 2 EE 5 Menu Display item e ER 6 Menu Controls en ar tup Qul eee tees eee tee tee etes 6 Head Components ntn pete te Et e tre red reed EE 7 Yoke Components J ddr rad ec EE 8 Enclos te Components irc ri pend 9 Principles of Operation Power and Data Flow Diagram gt 10 Chapter 2 Maintenance Testing Testing CMT 12 Troubleshooting Error Messages os teet diee tidie me un E en Ne Neh deeds 13 Troubleshooting Guide 1 ede e tpe 14 Maintenance Procedures Head Assembly en ee isla 16 Lamp Replacement ea e 16 Color Gobo Iris Bulkhead Replacement eene 18 Standard Gobo C
16. Motor Zoom Optics Assembly Rotating Gobo Wheel Assembly Sensor Rotating Gobo PCB Assembly Top Cover Assembly esee Bottom Cover Assembly Reflector Assembly 4 Back Cap Assembly sushi Fan Assembly sans m En lie Iris Color Gobo Bulkhead Assembly Crossfade Color Assembly Iris Gobo Motor Assembly Color Motor Assembly Gobo Wheel Assembly Color Filter Wheel Assembly eee Strobe Assembly UV IR Window Assembly VL2500 Main Control Board PCB Assembly Yoke Ignitor PCB Assembly Tilt Motor Assembly issues Pan Tilt Encoder PCB Assembly Yoke Fan Assembly teet egenis Enclosure Upper Enclosure Assembly Connector Panel Assembly DMX Input PCB Assembly AC Input Pigtail Cable Assembly Pan Tube Assembly ua asa ER itti ist uis Pan Motor Assembly i B ya ass Upper Enclosure Fan Assembly eee xvi 01 July 2008 02 9676 0020 A TABLE OF CONTENTS Pan EOT Sensor Electrical Assembly 98 Ballast Module Arc Power Supply Assembly 99 Cables Gr
17. SHOWN 02 9676 0020 A 01 July 2008 115 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Pan Tilt Control Cable Assembly continued 4 7 5 _ Figure 3 60 Pan Tilt Control Cable Assembly 116 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN CABLES 3 EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Replace as a complete assembly Refer to Figure 3 61 No Item Qty UM Description 1 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 2 2 RECP FASTON 187 X0 32 16 14 AWG FLAG DBL 3 1 EA CABLE TIE 10 WD 4 00 LG SMALL 4 0 83 FT WIRE 16AWG 600V 105C PVC WHT 911015 5 0 83 FT WIRE 16AWG 600V 105C PVC UL1015 2 x2 1 x2 4 White 3 White Black Black L L 5 Figure 3 61 EMI Filter to Power Switch Cable Assembly 02 9676 0020 A 01 July 2008 117 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25 9678 0812 Rev E Replace as a complete assembly Refer to Figure 3 62 No Item Qty UM Description 1 1 EA PLUG HOUSING MNLOK PLUG 3POS 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 2 EA TERM SPADE 6 RED 22 16AWG INSERT 4 2 EA RECP FASTON 187 X0 32 16 14 AWG FLAG DBL 5 2 EA CONTACT PIN 20 14AWG MNLOK
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19. No Item Qty UM Description 1 1 EA LABEL SET VL2500 COLOR HARNESS 2 1 EA HOUSING 34 POS 26 22 AWG DBL ROW UNLOADED 3 1 EA COVER FRONT 34 POS MT LATCHING 4 1 EA COVER BACK 34 POS MT 5 1 EA CONN FEMALE 4 POS 30 24 AWG CRIMP PHR 6 2 EA CONN FEMALE 6 POS 30 24 AWG CRIMP PHR 7 12 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 8 2 EA CONN HOUSING 4 POS RECEPT 9 1 EA CONN HOUSING 5 POS RECEPT 10 1 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 11 12 EA CONTACT 24 30 AWG FEMALE CRIMP 12 4 EA CONTACT 26 28 AWG FEMALE CRIMP 1 25 PITCH REEL 13 0 13 HEATSHRINK 1 2 BLACK 14 4 EA CABLE TIE 10 X 4 LG SMALL 15 0 92 FT SLEEVING 3 4 NOM DIA WOVEN POLY ROUNDIT 2000 16 11 71 FT WIRE 26 AWG 4 COND 300V 200 DEG C TEF lt BLK BRN RED ORN gt UL1180 17 2 04 FT WIRE 26 AWG 4 COND 300V 200 DEG C lt BLK RED WHT WHT RED gt UL1180 34 EA CONTACT 26 22 AWG RECP MTE REEL NOT SHOWN 110 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Optics Strobe Bulkheads Cable Assy cont 16 6 7 16 10 12 2 3 4 TROBE BE 16 8 117 16 9 11 ELLIPSE INDICATES TWISTED WI Figure 3 56 Optics Strobe Bulkheads Cable Assembly 02 9676 0020 A 01 July 2008 111 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Strobe 1 Cable Assembly 25 9676 0717 R
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21. K 10 2 a LP P 46 5 y EE 2 wc i a Sis a RI 2 72 24 23 ism E Y x d d d 3 3V Y Kom PI var a PHASE A 1 PHASE 181000 9 DAO Kare PHASE B 1 a La ELA gt P COT IN lon Ki PHASE A 2 CE VCC oo pet pl CYAN MAG ose 4 vec 8260 R257 R207 PP PANA PANB 6 Tp C240 C241 9105 Rioe R76 Y RIS 205 PHASE A ENCODER Ai CYAN SENS 1 87 lt 10 33 33V 8253 PHASE_A2 ENCODER 2 AMBER AMB SENS um lt lt P72 R256 PHASE Bi ENCODER 81 MAGENTA MAG SENS T COT IN y amp o 8 uns PHASE_B_2 8 PHASE 82 8206 16 om X QE 99 amen DIMMER_SENS lon m RGOBO OUT IN RGOBO OUT 2 8 s Cm PAN COT SENS Poe nos ses y a LLLA z Pr om ou Um TT SENS y PE pocsens gioja 4 2 12 m pem Ll IX OUT IN our lt afos pms CM 86080 OUT RGOBO OUT SENS _ SPARE TP1 a R101 ep SENS EG T RM SPARE POG 0 PDC DM 3 3V VCC C238 C239 Slow 8 pao OPT IN opt gt MAG_IN MAGENTA A 5 lt lt 14 one Da2 6 Km 2 2 s CYAN N cran s
22. VL2500 SPOT LUMINAIRE SERVICE MANUAL 86 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Enclosure Upper Enclosure Assembly 21 9676 0800 Rev T Refer to Figures 3 29 and 3 30 No Item Qty UM Description 1 04 9640 0374 1 EA LABEL PE GROUND 2 04 9673 0040 1 EA LABEL 2000 SERIES COMPLIANCE 3 04 9661 1218 01 1 EA LABEL PATENT VL2201 amp VL2400 SERIES LUMINAIRES 4 10 9661 1258 1 EA BRACKET APS SIDE 5 10 9661 1358 1 AIR SEAL DUCT 6 06 6032 0009 1 EA CABLE MARKER TIE 19 X 7 7 10 9678 1874 1 EA PLENUM AIR DISTRIBUTION 700W BALLAST 8 55 6658 0009 1 EA STANDOFF 1 4 HEX 6 32 X 3 4 9 10 9678 0820 1 EA LANYARD PAN 10 10 9678 0839 2 EA COVER TOP 11 10 9686 0846 2 EA HANDLE CAST 12 10 9678 0869 1 EA BRACKET LVS 13 10 9678 0886 1 EA SPACER PAN BEARING 0 235 THK 14 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN TUBE 15 12 9686 1236 2 EA MACHINED COVER SIDE 16 12 9686 1238 2 EA MACHINED COVER SIDE 17 12 9678 0842 1 EA DUCT UPPER ENCLOSURE AIR 18 55 6538 0001 1 EA WASHER INTERNAL TOOTH 6 19 21 9678 1254 1 EA ASSY COVER VENTILATION 20 21 9678 0767 1 EA ASSY STABLIZER 21 21 9676 0805 1 EA ASSY CONNECTOR PANEL 22 21 9678 0807 1 EA ASSY PAN PULLEY 23 21 9678 0864 1 EA ASSY PAN MOTOR 24 21 9678 0880 1 EA ASSY PAN TUBE 25 22 9678
23. aH 8851006 4 lt 7 82 10 85 AMB OUT2A AMB OUT28 8D5 10D6 5 6 soma 8061006 Da7 EDGE OUT28 8 05 10 06 7 8 81051006 AMBER H 4 7 82 10 83 25V MAG OUT2A MAG OUT2B H 8 D2 10 C6 gt 249 100 lt 8 D2 10 C6 MAG OUTIB MAG 8 D2 10 06 y nono lt 8 D2 10 C6 MAGENTA DIM QUTZA DIM 2 L 25v 8 B2 10 06 gt gt ls 14 H4 lt 8 B2 10 D6 OUTIB DIM_OUTIA 8 82 10 C6 y is je lt 8 B2 10 D6 DIMMER FXDG OUTZA FXDG OUT2B 2 UM our lt 7041008 1 8V 7 D4 10 C8 y 12 19 20 20 7 D4 10 08 FXD GOBO FXDC OUT2B 7 84 10 88 gt gt PTE 2 oura lt 7841088 7B410B8 2213 2424 lt 7 84 10 88 FIXED COLOR L av IRIS OUTZA IRIS 00128 5 C2 10 D8 2525 26 26 K 5 C2 10 D8 IRIS OUTIB IRIS QUTIA 5 02 10 D8 y 2 lt 5 02 10 D8 IRIS FXDC SENS 2929 30 lt 4B1 2 FXDG SENS 48 gt las sf A AMB SENS CYAN SENS 481 35155 26 lt 4 B1 MAG SENS DIMMER SENS 481 lo 4 81 Y 39 DRAWN BY lt gt FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT PROJECT ENGR SCHEMATIC VL2500 CONTROLLER DOG CONTROL sss Document Number Rev D 14 9676 0730 80
24. id MSELO us 82 1060 MSELI MSELt ve 88 1061 STATUS m STATUS 2 190 1062 CONFIG 2 20 1069 CONFIG DONE 2 102 1064 A INIT_DONE pone ke 108 1065 104 066 lt CYAN N pi 1 1067 Toia lt DIMMER IN lt 4 33V AMB IN a 1069 gt TMSA FXDG IN Tus 8 as AM 1070 TRST eus ws LI 16 1072 PWMS EN 1 ns 114 1073 QUT 2 1074 DET 121 ors cs una m FXDC IN ROVIBUSY 2 1016 m CLKUSR RSTO E oan 2 TOKA H 0 TA DEV CLR p 2 og He GND GND20 81 HL HL 4 onos nps 4 2 enor anois 141 abis 15 4 351 annis Hal 3 3V DO NOT STUFF u15 DATA DATA VCC2 veci STATUS OE CASC CONF DONE cs SOCKET IS XU15 o Mm ys MB Ds am 05 Um AB pip pip ADD 5
25. vou He amp sise 1 TA c15 2 L P 8 4 L I eo 3 3V s Y 815 VR4 1 8V VIN PL 1 Ce 9 sr Se NONE DRAWNEY FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHEGKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT SCHEMATIC VL2500 CONTROLLER 506 CONTROL Size Document Number ev D 14 9676 0730 80 COPYRIGHT 2004 Tuesday July 20 2004 SHEET 1 OF 10 x I 5 I 02 9676 0020 01 July 2008 128 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Main Control Board 02 9676 0020 A MCB Schematic continued REFERENCE FOLD OUTS
26. Figure 2 19 Removing Top and Bottom Enclosure Covers 02 9676 0020 A 01 July 2008 33 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL A CAUTION Be careful not 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 20 Figure 2 20 Laying Luminaire on Its Side Step 5 At bottom of enclosure remove four 1 4 20 x 1 2 socket screws and 1 4 split lock washers and remove ventilation cover Step 6 Return luminaire to upright position 34 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 Ballast Module Assembly Replacement Parts 69 9676 0700 ASSY BALLAST MODULE 700W ARC To remove the ballast module assembly Step I 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 33 Step 3 Remove both handles by removing two 10 32 X 5 8 PPB screws at each Step 4 At enclosure remove eight 6 32x3 8 PPZ screws and both side covers Figure 2 21 Step 5 Atenclosure remove APS side bracket and front cover from ballast side N Note Please note different size screws and their respective locations Front Cover Arc Ballast Figure 2 21 Accessing Ballast Module 02 9676 0020 A 01 July 2008 35 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Step 6 At ballast disconnect
27. Manual VL2500 Spot Luminaire 02 9676 0020 Service C AN VARBKLITE ss yourself PHILIPS VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL is a trademark owned by Philips Group and is registered in the United States and other countries VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 VL3500 Series 1000 Series 200077 Series 30007 DICHROXTUNE VARI IMAGE VARI BRITE and the Vari Lite Asterisk are also trademarks owned by Philips Group products are protected by one or more of the following patents and other pending patent applications worldwide U S Patents No 6 809 869 6 796 682 6 769 792 6 578 987 6 550 939 6 282 027 6 123 436 6 113 252 6 046 861 6 031 749 6 011 640 5 969 868 5 959 768 5 934 794 5 882 107 5 829 868 5 825 548 5 798 619 5 774 273 5 769 527 5 758 956 5 728 994 5 640 061 5 590 954 5 454 477 5 432 691 5 367 444 5 329 431 5 307 295 5 282 121 5 278 742 5 209 560 5 186 536 5 073 847 5 010 459 4 980 806 4 972 306 4 800 474 4 779 176 4 701 833 4 602 321 U S Design Patents No 524 245 457 678 452 339 451 890 442 944 439 356 420 332 417 300 415 301 414 888 413 995 377 338 366 712 359 574 350 408 347 113 Australia Patents No 693 691 683 695 667 109 649 264 646 588 586 095 576 400 Australia Design Patents No 128 796 128 795 Ca
28. 1 PS0 epa GL 41 46 028 182 PS Kor 33V GN GNDQ3 cuko vec cukour R297 1 4 PST2 541 ans GNDO4 030 ER Has 982 43 2102 1 8V 180 4r psrooaras 18829187 RM Limr cueq2 cue 282 178 er lt 5 C2 6 C8 7 C8 8 C8 Lim ay gt PSTDDATAS 288 3 3V GND PsrppArAs 188 2819287 us gt cls 195 PTS Reo 5 PS Korps 3 3V ie 022 PsToDATA Has PST 28 1 ues gt 18 8 vcc nc di 8 10102204 OUT spar spo 5 DRAWNBY 5 amp POM CE per MA FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT v PROJECT ENGR Lr 7 SCHEMATIC VL2500 CONTROLLER DOG CONTROL Document Number Rev D 14 9676 0730 80 COPYRIGHT 2004 I Date Tuesday July 20 2004 SHEET 2 or 10 z gt z z z I 01 July 2008 129 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Control Board MCB Schematic continued saav Desv eav sav 33 sav on 062 C57 C29 Desv sav sav 33 Desv 2 5V 25V 2 5V 25V szsv
29. Accessing Edge Motor Assembly Attaching Hardware 24 01 July 2008 02 9676 0020 A MAINTENANCE MAINTENANCE PROCEDURES 2 A CAUTION Ensure you place pliers on standoff on edge motor shaft Do not hold edge motor shaft with pliers or shaft may be damaged Step 5 Atlens barrel assembly use pliers to hold standoff on edge motor shaft and using 1 4 open ended wrench remove 4 40 SS KEPS nut from end of motor shaft Figure 2 10 4 40 SS KEPS Nut Standoff on Edge Motor Shaft Lens Barrel Assembly TL Figure 2 10 Removing Nut From Edge Motor Assembly Shaft Step 6 Atside rail disconnect edge motor wire connector from junction connector Figure 2 11 Junction Connector Figure 2 11 Disconnecting Edge Motor Wiring 02 9676 0020 A 01 July 2008 25 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Step 7 Remove two 4 40x3 8 PPZ screws and nuts which secure motor to bulkhead and remove motor assembly Figure 2 12 Edge Motor Assembly 4 40x3 8 PPZ Screw 2 1 4 Nut Figure 2 12 Edge Motor Assembly Replacement Step 8 Install replacement assembly by performing Steps 2 7 in reverse order 26 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 Lens Barrel Assembly Replacement Parts 21 9676 4306 ASSY LENS BARREL To remove and replace lens barrel assembly Step I Disconnect luminaire AC input cable from power source Step 2 At head cover turn two captive screws
30. SPOT LUMINAIRE SERVICE MANUAL Tilt Plate Ground Cable Assembly 25 9667 0413 Rev A Replace as a complete assembly Refer to Figure 3 53 om ee o TERM RING 6 BLUE 14 16 AWG NON INS 2 0 21 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED ibo Figure 3 53 Tilt Plate Ground Cable Assembly 106 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Color Gobo T Stat Cable Assembly 25 9676 0125 Rev B Replace as a complete assembly Refer to Figure 3 54 No Item Qty UM Description 1 1 EA CONN HOUSING 2009 PLUG SHROUD 2 2 EA CONTACT 24 30 AWG MALE CRIMP 3 1 00 IN HEATSHRINK 1 8 CLEAR KYNAR 4 1 EA THERMOSTAT 105 DEG C PCB MOUNT 5 0 50 FT WIRE 24 AWG 300V 105 DEG C PVC GRAY 5 3 long each x 4 1 2 x2 02 9676 0020 3 1 2 long each Figure 3 54 Color Gobo T Stat Cable Assembly 01 July 2008 107 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Color Fixed Bulkheads Cable Assembly 25 9676 0715 Rev F Replace as a complete assembly Refer to Figure 3 55 No Item Qty UM Description 1 1 EA LABEL SET VL2500 COLOR HARNESS 2 1 EA HOUSING 40 POS DBL ROW UNLOADED 3 1 EA COVER FRONT 40 POS MT LATCHING 4 1 EA COVER BACK 40 POS MT 5 2 EA RECEPT 3 POS 100 W PO
31. 0851 1 EA ASSY UPPER ENCLOSURE 26 69 9676 0700 1 EA ASSY BALLAST MODULE 700W ARC SHIELDED 27 23 9678 0686 1 EA FAN ASSY UPPER ENCLOSURE 28 23 9678 0687 1 EA ELEC ASSY PAN EOT SENSOR 29 25 9661 1514 1 EA CABLE ASSY CHASSIS GROUND not shown 02 9676 0020 A 01 July 2008 87 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL No Item Qty UM Description 30 25 9661 1520 1 EA CABLE ASSY CHASSIS TO YOKE GROUND not shown 31 25 9676 0818 1 EA CABLE ASSY PAN TILT CONTROL not shown 32 25 9678 0811 1 EA CABLE ASSY EMI FILTER POWER SWITCH not shown 33 25 9678 0812 1 EA CABLE ASSY AC INPUT SPLITTER not shown 34 25 9678 0813 1 EA CABLE ASSY DATA I O LINK not shown 35 25 9678 1825 1 EA CABLE ASSY DISPLAY not shown 36 25 9678 0816 1 EA CABLE ASSY BALLAST TO CONTROLLER not shown 37 25 9678 0829 1 EA CABLE ASSY LAMP SUPPLY TO RELAY not shown 38 25 9678 0821 1 EA CABLE ASSY DC OUTPUT not shown 39 52 8295 0002 1 EA TERMINAL STRIP 300V 12 AWG 20A 2 POS 40 53 2001 0003 1 EA 10 32 NYLON INSERT 41 53 2019 0004 4 EA 3 8 16 X 7 32 HEX JAM GRDS ZINC PLT 42 53 2200 0006 4 EA 6 32 KEPS SS 43 53 6505 0022 3 EA BOLT 3 8 16 X 3 4 LG CARRIAGE GRDS ZINC PLT 44 53 6513 0044 3 EA SCREW M5 X 10 MM STL CUP PT 45 53 6515 0001 4 EA SCREW 10
32. 1 ZOOM LENSES 3 10 9676 4251 1 SPACER 2 ZOOM LENSES 4 12 9676 4224 1 EA BARREL ZOOM UPPER 5 21 9676 4258 1 EA ASSY ZOOM BUSHING 6 42 9660 0023 1 EA LENS 6 ZOOM OPTICS 7 42 9660 0024 1 LENS 7 OPTICS 8 42 9660 0025 1 EA LENS 8 ZOOM OPTICS 9 53 2200 0006 4 EA NUT 6 32 KEPS SS 10 53 6543 0001 4 EA SCREW 6 32 X 3 8 PPB 11 54 1206 0055 1 EA RETAINING RING EXTERNAL 1 2 PRESS ON 12 54 1206 0056 1 EA RETAINING RING EXTERNAL 1 2 13 55 6568 0091 1 EA SPRING PLUNGER BALL NOSE PUSH FIT 1 4 DIA 5 27 Z 12 Figure 3 6 Sub Barrel Group 2 Assembly 54 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Motor Zoom Optics Assembly 21 9667 0311 Rev Refer to Figure 3 7 No Item Qty UM Description 1 44 9660 0262 1 EA MOTOR 1 LINEAR ZOOM 2 52 6579 0005 1 EA CONN 5 PNL SGL ROW W MTG EARS 3 52 8347 0001 4 EA CONTACT 24 30AWG MALE CRIMP 02 9676 0020 A Figure 3 7 Motor Zoom Optics Assembly 01 July 2008 55 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Rotating Gobo Wheel Assembly 21 9660 0105 RevE Refer to Figure 3 8 No Item Qty UM Description 1 10 9660 0110 4 EA CARRIER SPINNING WHEEL 2 10 9660 0112 1 EA SUN GEAR SPINNING WHEEL 3 10 9660 0144 1 EA SPRING RETAINER SPINN
33. 12 53 6587 0001 6 EA SCREW 4 40 X 1 8 PPZ 13 53 6610 0003 2 EA SCREW 6 32 X 7 16 PPZ 14 53 5559 0250 4 EA SCREW 6 32 X 1 4 SET CONE POINT 15 53 6682 0002 8 EA SCREW 4 40 X 1 4 PPZ SEMS 16 55 6568 0054 2 EA SPRING EXTSN 1 2 FL X 1 8 HOOK OPEN 74 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Strobe Assembly continued Note connector orientation on motors _ Figure 3 21 Strobe Assembly 02 9676 0020 A 01 July 2008 75 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL UV IR Window Assembly 22 9676 0140 Rev G Refer to Figure 3 22 No Item Qty UM Description I 10 9676 0058 1 EA FRAME 2 41 9678 0608 1 EA UV IR FILTER 3 00 X 3 00 3 53 5504 0187 2 EA SCREW 4 40 X 3 16 PPSS 4 55 6569 0001 3 EA WASHER 2 LOCK 5 74 1034 0001 1 EA THERMAL SWITCH 15 AMP 315 OPEN 6 10 9676 0141 1 EA INSULATOR THERMAL SWITCH NOT SHOWN 2 76 Figure 3 22 UV IR Window Assembly 01 July 2008 02 9676 0020A Top Side 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 VL2500 Main Control Board PCB Assembly 24 9676 3730 Rev 0 Refer to Figure 3 23 Replace as a complete assembly
34. 2 4 Standard Gobo Color Filter Replacement 02 9676 0020 A 01 July 2008 19 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Strobe Bulkhead Replacement Parts 22 9676 0016 ASSY STROBE BULKHEAD Procedure Step Step Step Step Step Step Step Step Step 20 1 2 Disconnect luminaire AC input cable from power source At head cover loosen two captive screws and remove cover The cover is attached by tether Figure 2 5 3 Remove CYM crossfade color assembly ND Remove color gobo bulkhead assembly Optional Remove spot optic assembly to gain direct access to four mounting screws if right angle screw driver is not available At strobe bulkhead remove screws Disconnect motor wire connectors from motors Slide bulkhead out of head assembly Install replacement assembly by performing Steps 2 8 in reverse order Captive Screws Removable Cover Strobe Bulkhead Assembly Figure 2 5 Dimmer Bulkhead Replacement 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 Front Assembly Removal This procedure may be necessary to gain access to other components To remove and re install front assembly Step I Disconnect luminaire AC input cable from power source Step 2 At head cover turn two captive screws one quarter turn and remove cover It will remain attached by tether Figure 2 6 Step 3 Remove front nose cover by removing two 10 3
35. 20 VARBELTE Bottom Side LI LI 02 oo Bopp opo eee 0 HH I voc an g y D lt 00 nro 1 ros 1 ok LL 0 0 Cd ML I 1 Im L IL II 11 0000000000 III HU ao gt ea eglgg 56 we 0 0 Poul 8 3 HEATSINK HARDWARE DO NOT REMOVE MI INK HARE n L EE LI 77 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Notes 78 01 July 2008 02 9676 0020A Yoke Yoke Assembly 21 9676 0600 Rev G Refer to Figure 3 24 ILLUSTRATED PARTS BREAKDOWN YOKE 3 No Item Qty UM Description 1 22 9676 8605 1 EA ASSY YOKE STRUCTURE 2 22 9676 0609 1 EA ASSY FAN 3 22 9676 0610 1 EA ASSY TILT MOTOR 4 23 9650 3327 1 EA ASSY ELEC RELAY 5 24 9661 1126 1 EA PCB ASSY SOLID STATE IGNITOR 6 25 9676 0030 2 EA CABLE ASSY IGNITOR TO RELAY not shown 43 0298 5 EA TOROID CORE ZW 42206 TC not shown 7 53 6525 0001 8 EA SCREW 6 32 X 5 16 PPZ 8 53 6558 0001 3 EA SCREW 6 32 X 3 8 PPZ 9 55 2143 0001 4 EA STANDOFF 1 4 HEX 6 32 1 313 10 55 2150 0002 1 EA STANDOFF 1 4 HEX 6 32 1 187 MF 11 55 2201 0001 4 EA SCREW 4 40 X 5 16 12 55 3301 0006 2 EA WASHER 6 FLAT SS 13 55 6538 0001 6 EA WASHER 6 LOCK INTERNAL TOOTH 14 55 6541 0002 2 EA GROMMET 1 ID 1 3 4 OD 1 3 8 DIA RUBBER 15 55 6583 0001 2 EA STANDO
36. 25v prey ee pa Jee qe ss Te 2 5V 25V 25 25V 25V es de Le 33V Ree STATUS arcs 3 02 3 8 CONFIG R27 CONF DONE Rea TMSA us us MSELO P45 MSELI P49 K 3 82 TOKA Kama 33V 2 5V 2 0 24 E 8 8 5 Si y t SE Ber x 125 10 EE E e P E BE 5 5882528858855555 8 jg eium Om S G 3 9295888595855 g oH 1079 L IDX OUT IN 1080 6 88 QUT 1 U16 1081 T COT IN 106 1082 132 PHASE B2 ays 108 1084 H i TX EN C RGOBO_OUT IN ims 12 109 1085 H35 TX EN A PWM3_OUT 3 X 1010 1086 UART QUT A PWM3 OUT 6 91 1087 H2 s UART IN PWM3_OUT 4 85 4 05 1088 s LED TX PWM3 OUT 5 A 1089 LED RX PWMa_EN 2 4 06 22 1090 42 LED STATUS PH 3 r 1091 4 0 5 LAMP ON 4 1016 1092 42 LAMP CNTL PHASE A 1 wer M 1017 1083 Kaya OUT 2 PHASE B 1 AAA or 1094 us OUT 23 P COT IN sos os 1095 49 a OUT 3 PHASE A 2 5 31 1020 1096 Ki OUT 13 P
37. 3 8 PPZ 20 53 6558 0007 1 EA SCREW 4 40 X 1 4 PPZ SEMS 21 53 6559 0001 3 EA SCREW 4 40 X 1 4 PFZ 22 53 6558 0001 2 EA SCREW 6 32 X 3 8 LG PPZ 23 53 6608 0003 8 EA SCREW 6 32 X 3 16 LG PPZ 24 53 6613 0001 6 EA SCREW 6 32 X 1 2 PPZ 25 53 6682 0022 1 EA SCREW 8 32 X 3 8 PPZ SEMS 26 54 2029 0001 1 EA BELT TIMING MXL 080 PITCH 70 3 16 WD KEVLAR 27 54 2032 0001 1 EA BELT TIMING MXL 080 PITCH 87 3 16 POLY WD 28 55 2118 0004 1 EA WASHER 735 OD 395 ID 011 CURVD SPRNG 29 55 2118 0005 1 EA WASHER 735 OD 395 ID 016 THK CURVD SPRNG 30 55 3301 0006 4 EA WASHER 6 FLAT SS 31 55 3301 0010 2 EA WASHER 10 FLAT 50 01 July 2008 02 9676 0020 ILLUSTRATED PARTS BREAKDOWN ASSEMBLY 3 No Item Qty UM Description 32 55 6506 0009 1 EA SPACER 1 2 RND 125 LG 375 ID SHAFT 33 55 6589 0003 2 EA STANDOFF 1 4 RND 4 40 606 LG MF 34 55 6663 0007 1 EA STANDOFF 3 8 1 75 LG FF 02 9676 0020 A Figure 3 4 Front Assembly 01 July 2008 51 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Lens Barrel Assembly 21 9676 4306 Rev D Refer to Figure 3 5 No Item Qty UM Description 1 10 9676 4254 1 EA SHAFT ZOOM BEARING 2 10 9676 4256 1 EA WEAR STRIP EDGE LENSES 3 10 9676 4258 1 EA WEAR STRIP EDGE BARREL 4 10 9676 42
38. 3 TILT PHC OUT 303 14 ours Pl lt 10 03 925 13 Eng 010 EN 1 4 3 A6 4 SENSE 2 4 P 090 092 VCC Lis VREF lt gt VCC PENIS i 1 vgoor H be 19 vssa 8 20 vsse HA vec al Ter vec C236 T AV ESS SS ce VCC 909 du _L B IRIS P95 57 Y 8 5 3 24V E IRIS OUTIA PH S x aos 0 phaser way hi SOTA amp 1007 10 A4 R92 2A36 C87 C88C8 GUN 21 pisi QUT 5 IRIS OUTIB vat mos pa 10107 10 4 ces 891 1 PH 6 IRIS_OUT2A ace lt 25 pases TE 10 07 10 84 133 als IRIS_OUT28 22 vno lt 10 07 10 4 R100 R98 RC GND10 PWM OUT 6 le 365 GND2 GeNpo9 Lo Le je s ERES anos 18 D 12 auos anos LL lt Y Y d d i 4 EV 894 896 bu 1 IV 8 ceo _ 24V za 24V PAN D 085 086 D84 E ust QUT 4 PHA OUT 3 035 La int 6 1003 OUT 5 PAN PHB OUT 3 A6 4 m2 lt 1003 H al eve H QUT 6 PAN QUT 303 14 ing ours pl 10003 126 12 ens 012 EN 2 gt 4 316 LENS 4 sense2 119 X 09 VCC veer pl C74 vec sl ms lanpa 18 4 bit C86 4 0 vssa H2 20
39. 7 21 9676 4120 1 EA BULKHEAD ASSY IRIS COLOR GOBO 8 21 9676 0201 1 EA ASSY CROSSFADE COLOR 9 22 9676 0008 1 EA ASSY TOP COVER 10 22 9676 0011 1 EA ASSY BOTTOM COVER 11 22 9676 0016 1 EA ASSY STROBE 12 22 9676 0018 1 EA ASSY REFLECTOR 13 22 9676 0090 1 EA ASSY FAN 14 22 9676 0115 1 EA ASSY BACK CAP 15 22 9676 0140 1 EA ASSY UV IR WINDOW 25 9676 0715 1 EA CABLE ASSY COLOR FIXED not shown 25 9676 0716 1 EA CABLE ASSY OPTICS STROBE not shown 25 9676 0717 1 EA CABLE ASSY STROBE 1 not shown 25 9676 0718 1 EA CABLE ASSY FAN DISCONNECT not shown 25 9676 0719 1 EA CABLEASSY OT SWITCH TO REFLECTOR ASSY not shown 28 9676 0001 1 EA INCLUDED ITEMS VL2500 LUMINAIRE not shown 16 53 2200 0006 1 EA KEPS 6 32 5 17 53 6523 0013 8 EA SCREW 6 32 X 3 8 18 53 6558 0009 6 EA SCREW 6 32 X 3 8 PPZ SEMS 19 53 6558 0010 10 EA SCREW 6 32 X 1 4 PPB SEMS 20 53 6607 0001 2 EA SCREW 6 32 X 1 4 PPB 21 53 6625 0001 2 EA SCREW 10 32 X 1 2 PPB 22 67 4018 0001 1 EA FERRITE 26 X 28 5 X 13MM CYL 23 55 2178 0001 1 EA ANCHOR CABLE MOUNT 8 SCREW 24 55 6669 0017 4 EA STANDOFF 1 4 HEX 6 32 1 062 46 01 July 2008 02 9676 0020A 3 TOP ASSEMBLY ILLUSTRATED PARTS BREAKDOWN x2 8 1 24 4 15 16 19 4 Note Loop lamp wires through ferrite 22 23 Top Assembly 3 2 Figure 47 01 July 200
40. 8 B5 10 A5 PAL PHG OUT BALLAST CONTROL x 3 K 6D5 10105 PAN PHA QUT LAMP ON IN 4 056 CYAN QUT2A 5 5 lt 5 D4 PAN 4C6 414 pt9 14 C 8 B5 10 A5 OUT LAMP_STBY RGOBO OUT2B 5 C4 2C4 5 14 C 6 D5 10 C3 PHA OUT lt GU 9 10 584 8 B5 10 A3 TILT PHB QUT px oura x ul h OU SR A 685 10 3 ENCODER At OUT 057 DIM_OUTIA 485 39 w lt 5 B4 D2 A lt 8 B2 10 A3 gt ENCODER Bt gt IDX_OUTIB 485 AX lt 6 B5 10 05 ENCODER A2 TILT COT SENS D58 DIM OUTIB 4 85 1 1 C 483 3 E 4 8 82 10 85 ENCODER 82 SENS 5 x ROUTER 485 2 nm 4183 uM Deo DIM_OUT2A 41 _ EP ne A 8 B2 10 A5 IDX_OUT2B aa 6 B5 10 03 DMX IN X a Dos 4 8 B2 10 A3 STROBE1_OUTIA A 6 D2 10 03 pe1 x MATA v ODDS STROSELLOUTIB or A 6 D2 10 05 062 MAG QUTIB rs STROBELLOUTEA ants SM 5202 8 D2 10 A5 D27 smone oures E 4 61D2 10103 MOQUE 1 5 1 029 STROBE2_OUTIA E lt 61B2 10103 2 POWER IN le 3 3 030 STROBE2_OUTIB VCC AX 6 82 10 05 T ee UA 1 STROBE OUT2B gt 6 02 102 10 Deo STROBE2_OUT2A STROBE1_OUT1B STROBE1_OUTIA STROBE 1 4 6B2 10 C5 6 D2 10 C8 gt 313 aH lt 6 D2 10 C8 682 10 08 oy S TR08E2 OUT2A STROBE2 OUT2B uie eee 5 6 101 Dat STROBE2_OUT2B STROBE2_OU
41. A REFERENCE FOLD OUTS 8 6 3 2 1 REVISIONS NOTES UNLESS OTHERWISE SPECIFIED REV DESCRIRTION DATE APPD 1 ENGINEERING PROTOTYPE 7 16 02 B C 1 ALL CAPACITOR VALUES ARE IN MICROFARADS 2 ENG RELEASE PER 09082 9 16 02 B C 2 ALL RESISTOR VALUES ARE IN OHMS A REL TO PROD PER EO 09089 D REFERENCE DESIGNATORS LAST USED NOT USED 5 n C10 C3 C7 C9 4 J4 L1 C3 R19 R2 R5 R12 R13 R16 a V1 4 E e 1 84255 8 4 ST gt i wa wa NEXT 24 9661 1126 DRAWN BY R LITE 201 REGAL ROW ASSY B CURBO N AN LL DALLAS TEXAS 75247 PCBNO 11 9661 1126 6 27 02 2 THE SOLE AND EXCLUSIVE PROPERT SIZE REVISION DRAWING NUMBER USED DISCLOSED OR REPRODUCED 14 9661 1126 Filename SSIGNITOR IN ANY MANNER WITHOUT THE ADVANC Date Time 11 14 2002 14 21 WRITTEN CONSENT OF VARI LITE INC eProduct Designer 2 0 SHEET 1 OF 1 8 6 3 2 1 01 July 2008 139 VAREKLITE Express you
42. D D c 5 0 E 8 7 25 N 9 Le 5 3 7 4 5 7 2 0 Loopback 5 2 8 19 0 4 x2 Figure 3 58 Fans Disconnect Cable Assembly 02 9676 0020 A 01 July 2008 113 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL OT Switch to Reflector Assy Cable Assembly 25 9676 0719 Rev A Replace as a complete assembly Refer to Figure 3 59 114 Figure 3 59 No Item Qty UM Description 1 1 EA RECEPT FASTON 24 22 AWG NON INSUL 0 016 TAB 110SERIES 1 EA RECEPT FASTON 24 20 AWG UNINSUL TIN PLT BRS 250 X 0 32 3 0 67 FT WIRE 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E 2 OT Switch to Reflector Assy Cable Assembly 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Pan Tilt Control Cable Assembly 25 9676 0818 Rev B Replace as a complete assembly Refer to Figure 3 60 No Item Qty UM Description 1 1 EA HOUSING 20 POS 26 22 AWG DBL ROW UNLOADED 2 1 EA COVER FRONT 20 POS MT LATCHING 3 1 EA COVER BACK 20 POS MT 4 2 EA CONN HOUSING 5 POS RECEPT 5 2 EA HOUSING 7 POS 250V 3A 2 5 PITCH 6 6 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT 7 10 EA CONTACT 24 30 AWG FEMALE CRIMP 8 8 EA CABLE TIE 10 X 4 SMALL 9 7 08 FT WIRE 24 AWG 3 COND TW 600V 200 DEG C lt RED YEL BLU gt 10 7 17 FT WIRE 24 AWG 5 COND 300V 80 DEG lt BLK BRN RED GRY WHT gt 16 EA CONTACT 26 22 AWG RECP
43. EOT Sensor Replacement 02 9676 0020 A 01 July 2008 39 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Power Supply LVS Replacement Parts 69 3177 0151 POWER SUPPLY LVS ASSY Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 At enclosure remove top cover at power supply side Step 3 At LVS remove wiring 4 Remove screw closest to pan tube Loosen two screws at opposite end of wiring Remove LVS Step Step Step 6 Install in reverse order Make sure that no wires get pinched or caught in fan assembly Remove this Top Cover Fan Assembly j SLY 2S x Standoff Bottom Cover Power Supply LVS NOTE Head not shown for clarity Figure 2 26 Power Supply LVS Replacement 40 01 July 2008 02 9676 0020A CHAPTER 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500 Spot Luminaire Drawing Tree Top Assembly Yoke Enclosure Cables 02 9676 0020 A 01 July 2008 HD1IAUYISK VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Drawing Tree VL2500 Series Spot Luminaire VL2500 Spot Luminaire 20 9676 0001 Rev K Front Assembly VL2500 Generic Luminaire 21 9676 4006 Rev E 21 9676 0010 Rev J Rotating Gobo Wheel Assembly Upper Enclosure Assembly 21 9660 0105 Rev E 21 9676 0800 Rev S Lens Barrel Assembly 21 9676
44. Knob for lamp access does not adjust beam Vertical i ii Horizontal Focus Figure 2 2 Lamp Alignment 02 9676 0020 A 01 July 2008 17 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Color Gobo lris Bulkhead Replacement Parts 21 9676 4120 ASSY COLOR GOBO IRIS BULKHEAD Procedure Step Step Step Step Step Step Step l 2 Crossfade Color Disconnect luminaire AC input cable from power source At top head cover gradually loosen two 8 32x3 8 captive screws and remove cover Cover remains attached by tether Figure 2 3 AtCYM crossfade color bulkhead disconnect wiring remove two 6 32x1 4 PPB SEMS screws and remove assembly At color gobo iris bulkhead remove two 6 32x3 8 PPZ SEMS screws to release bulkhead At color gobo iris bulkhead disconnect wiring harness connectors from color wheel motor iris motor and color sensor Note Remaining motor and sensor connections will have to be disconnected in Step 6 Slide bulkhead partially out of head assembly and disconnect gobo wheel motor gobo Sensor and temperature sensor connectors Remove bulkhead from head assembly Captive Screws Removable Dimmer Bulkhead Cover Color Gobo lris Bulkhead Figure 2 3 Color Gobo Iris Bulkhead Replacement N CAUTION Make sure wiring placement does not interfere with moving parts Step 8 Inst
45. REEL 6 1 EA GND 20 14AWG MNLOK 060 130 INS DIA 7 3 EA CABLE TIE 10 WD 4 00 LG SMALL 8 1 50 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 9 1 83 FT WIRE 16AWG 600V 105C PVC WHT UL1015 10 1 83 FT WIRE 16AWG 600V 105C PVC BLK UL1015 11 2 08 FT WIRE 16AWG 600V 105C GRN YEL UL1015 12 1 00 FT WIRE 18AWG 600V 105C WHT 01 1015 13 1 00 FT WIRE 18AWG 600V 105C PVC BLK UL1015 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 AC Input Splitter Cable Assembly continued x2 sss N I II I 13 5 10 1 HANS N 7 x3 8 11 8 Figure 3 62 AC Input Splitter Cable Assembly 02 9676 0020 A 01 July 2008 119 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Data 1 0 Link Cable Assembly 25 9678 0813 RevA Replace as a complete assembly Refer to Figure 3 63 No Item Qty UM Description 1 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END 1 EA RECEPT 5 POS MTA100 W POL TAB RED CLSD END 3 2 17 CBL 22AWG STRND 4COND INSUL e 1 3 Figure 3 63 Data I O Link Cable Assembly 120 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOW
46. SCREW 4 40 X 5 8 PPZ VL 1 15 53 6525 0001 I EA SCREW 6 32 X 5 16 PPZ 16 53 6526 0001 2 EA SCREW 6 32 X 5 8 PPZ 17 53 6534 0001 4 EA RIVET 3 32 OD POP 3 32 GRIP RNG ALUM 18 53 6539 0011 1 EA SCREW 10 32 X 2 1 4 PFBSS UNF 2A 19 53 6539 0012 2 EA SCREW 10 32 X 2 PFBSS UNF 2A 20 53 6546 0002 2 EA SCREW 8 32 X 5 16 PPZ 21 53 6515 0001 1 EA SCREW 10 32 X 3 4 CAP 22 10 9676 0071 1 EA SWIVEL PLATE LAMP ADJUST 23 55 2134 0003 2 EA PLATE FLOATING NUT 10 32 24 55 2260 0208 1 92 SLEEVING 208ID SILICONE RUBBER COATED FIBERGLASS 25 55 3301 0006 3 EA WASHER 6 FLAT SS 26 55 3303 0004 2 EA WASHER 4 LOCK INT TOOTH SS 27 55 6540 0001 2 EA WASHER 10 FLAT BRASS 28 55 6568 0017 1 EA SPRING CPRSN 480 1 500 LG 55 29 55 6568 0036 2 EA SPRING CPRSN 360 OD 690 LG 032 WIRE DIA SS 30 55 6568 0048 2 EA SPRING CPRSN 480 OD 1 000 LG SS 31 71 2502 0003 1 EA SOCKET FASSUNG 9 5 W 905 MM LEADS 32 53 6682 0034 1 EA SCREW 10 32 X 1 2 PPB SEMS 62 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN ASSEMBLY 3 Back Cap Assembly continued Figure 3 13 Back Cap Assembly 02 9676 0020 A 01 July 2008 63 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Fan Assembly 22 9676 0090 Rev D Refer to Figure 3 14
47. SSeavsAwaunas 2 ZOOM AUN ERC AS ROTATING GOBO SENSOR GND IND 0UT 24 9667 0321 DIMMER MOTOR 14 COLOR SENSOR WIRING DIAGRAM 24 9676 0299 VL2500 SIZE REVISION DRAWING NUMBER CI 8676 008 DATE 7 20 04 SHEET 3 3 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Control Board MCB Schematic z 2 i I s gt I mvwo DESCRIPTION DATE APPROVED AO NONE ENG RELEASE 4 16 04 NOTES UNLESS OTHERWISE SPECIFIED al VALUES on vmi AND vra 4 27 04 A2 NONE CHANGED VALUES ON RES SHT 2 5 11 04 1 ALL CAPACITOR VALUES IN MICROFARADS 80 06 5 NOW ISO 2 ALL RESISTOR VALUES ARE IN OHMS 3 PAGE 9 OF 10 HAS NO PARTS MAY USE AT A LATER TIME VR2 VCC 17 vin FB IX pn vi E onon gt en m le ls vcc Luce FEN VRI LI 1 vin FB H 1 3 3V 24V 5 oo i 52 Lo a l T 43 3 L 2 5V 3 3V L Ri4 VR3
48. 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 by Council Directive 73 23 EEC EN60598 1 2000 EN60598 2 17 1989 A2 1991 EMC by Council Directive 89 336 EEC EN61000 6 4 2001 We certify that products conform to the requirements of European council directives as stated above 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 AN CAUTION advising of potential damage to product A WARNING advising of potential injury or death to persons 01 July 2008 02 9676 0020 A FOREWORD GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELEC TRICAL SHOCK FIRE EXPOSURE TO EXCESSIVE UV RADIATION AND INJURY TO PERSONS C
49. en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons ultraviolets pouvant causer de graves br lures sur la peau et une inflammation des yeux De plus les lampes arc fonctionnent sous haute tension de tr s hautes temp ratures Si la lampe se casse les particules de la lampe cass e peuvent causer blessures et ou incendie en s parpillant 4 Se prot ger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropri s gants protection des yeux pour manier des lampes endommag es 6 Silalampe a t touch e avec des mains nues la nettoyer avec de l alcool d natur et l essuyer avec un chiffon non pelucheux avant d installer ou de brancher le luminaire 7 Si la lampe a t endommag e ou a re u une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERFERENCE RF 1 Cet appareil 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 CONSID RATIONS DES CARACT RISTIQUES DE LAMPES ARC 1 Apr s une interruption de courant ou une baisse importante de voltage les lampes arc mettent du temps avant de se rallumer Dans certains cas la lampe se rallumera automatiquemet apr s s tre refroidie Cela d pend de la mani re dont le syst me est r gl pour le statut de mis
50. of commands used to configure address operate and test the luminaire The menu system is controlled at the Menu Display available at the enclosure input panel Menu Display VARBRUTE AGN DATA IN DATA THRU Q MENUENTER The menu system has seven main functions which are referred to as Ist level Within these main functions there can be up to four additional sub functions levels 2 thru 5 making five total levels Menu Controls The menu system is controlled by four buttons These buttons function as follows Menu button Displays the menu or if at first level the current address Enter button Selects the current menu option or stores current data value Up arrow Scrolls menu options upward or increases current data value Y Down arrow Scrolls menu options downward or decreases current data value Multi Segment Display Selects the current menu option or stores current data value Displays the menu A V or if at first level the i current address MENU ENTER Down Decrease Up Increase 6 01 July 2008 02 9676 0020 A DESCRIPTION MAJOR COMPONENTS 1 Head Components The following illustration shows the major sub assemblies that are located in the luminaire head assembly Yoke and enclosure not shown for clarity R
51. provides removal and replacement procedures for components found in the luminaire yoke assembly Tilt Motor Assembly Replacement Parts 22 9676 0610 ASSY TILT MOTOR To replace tilt motor assembly Step I Disconnect luminaire AC input cable from power source Step 2 At tilt side leg remove yoke leg cover by removing four two on each side 6 32x5 16 PPB screws Figure 2 15 To find tilt side leg refer to page 8 Tilt Motor Assembly Screws Yoke Leg Cover pe Standoff Figure 2 15 Tilt Motor Assembly Replacement Step 3 At pan tilt encoder mounted behind tilt motor mounting plate discon nect two cable connectors gt Step 4 At tilt motor disconnect motor wire connector Step 5 Using 1 4 nutdriver remove 1 4 hex standoff ON Step 6 Remove three remaining 6 32x5 16 PPZ screws securing tilt motor assembly to yoke leg and remove assembly while freeing pulley from belt I Step 7 Install replacement assembly by performing Steps 2 6 in reverse order 02 9676 0020 A 01 July 2008 29 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Main Control Board MCB PCB Replacement Parts 24 9676 3730 MCB PCB ASSY To replace an MCB PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 At board side leg remove yoke leg cover by removing four 6 32x5 16 PPB screws To find board side leg refer to page 8 A CAUTION Always use anti
52. vss 2 4 5 C237 Y DRAWN BY FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT PROJECT ENGR SCHEMATIC VL2500 CONTROLLER DOC CONTROL s Document Number Rev D 14 9676 0730 80 COPYRIGHT 2004 Date Tuesday July 20 2004 sueer 5 10 z I 7 z 5 z z 02 9676 0020 01 July 2008 132 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUA Main Control Board 02 9676 0020 A MCB Schematic continued REFERENCE FOLD OUTS I gt 5 VCC V0C 24V 24V 24V 24V vec vec 1 L C119 1 C85 8114 Y Y 136 7 7 8 STROBE 1 d 8 8 8 5 RGOBO_OUTIA PH H STROBE O
53. wiring Note Some components not shown for clarity Ballast Module E 8 32x3 8 E PFZ Screw 4 8 32x3 8 PPZ Screws 4 Figure 2 22 Ballast Module Assembly Replacement Step 7 At bottom of enclosure remove four 8 32x3 8 PFZ screws and four 8 32x3 8 PPZ screws that secure ballast module to enclosure Step 8 Remove ballast module Step 9 Install replacement assembly by performing Steps 2 8 in reverse order 36 01 July 2008 02 9676 0020 A MAINTENANCE MAINTENANCE PROCEDURES 2 Pan Motor Assembly Replacement Parts 21 9678 0864 PAN MOTOR ASSY Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Carefully lay luminaire on its side to have access to bottom of enclosure Step 3 At enclosure assembly remove bottom cover Step 4 Remove two connectors to pan encoder board Step 5 Remove four screws securing pan motor to chassis Step 6 Carefully lift motor upwards and remove tensioning springs Step 7 Slide belt from around gears Step 8 Unplug motor connector and remove motor Step 9 Install in reverse order Make sure bottom cover standoffs are seated fully against chassis 2 Encoder Pan Motor Assembly 0 A 2 Standoff gt 4 _ 8 Bottom Cover Enclosure Bottom View NOTE Head not shown for clarity Figure 2 23 Pan Motor Assembly Replacement 02 9676 0020 A
54. 0 IDX OUT2A 14 STROBE2 OUT2A aga GP PASES m lt 1057 1065 366 lt HABE mo 10 07 10 08 24 piso 247 piso us 1007 1008 STROBEE 10071008 R130 R129 RC HA Ris2 151 RC GNp10 28 OUT 10 PWM QUT 14 GT AAA anna CM009 7 4 ace lt A GND2 annog 2 C112 R128 dnp 16 Ci30 2 R150 4 os GNpoe 18 9 34 ons GeNpo7 HS S GNDo7 12 sa u GND5 GND6 coe Nps GNpe 5 8 8 Vv 5 8 8 x R124 R126 R146 R148 3 C107 R86 C111 87 _ C125 Res _ C129 R97 Y Y DRAWN BY FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT PROJEGTENGR re T SCHEMATIC VL2500 CONTROLLER DOC CONTROL Size Document Number Rev D 14 9676 0730 80 COPYRIGHT 2004 Tuesday July 20 2004 SHEET 6 or 10 z 7 I z 5 z 01 July 2008 133 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUA Main Control Board MCB Schematic continued REFERENCE FOLD OUTS
55. 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Upper Enclosure Assembly continued 63 x4 Figure 3 30 Upper Enclosure Assembly 02 9676 0020 A 01 July 2008 91 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Connector Panel Assembly 21 9676 0805 Rev Refer to Figure 3 31 No Item Qty UM Description 1 10 9678 0852 01 I EA LAYOUT ENCLOSURE OVERLAY 2 10 9678 0859 1 EA BRACKET INPUT 3 24 9663 3895 1 EA PCB ASSY DMX INPUT 4 24 9678 3825 1 EA PCB ASSY DISPLAY 5 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 6 51 0541 4 EA SCREW 4 3 8 H L ZINC PLT 7 53 6558 0009 2 EA SCREW 6 32 X 3 8 PPZ SEMS EXT ZINC PLT 8 55 2284 0001 1 EA CARD GUIDE SNAP IN 3 LONG NYLON NATURAL 9 74 2000 0002 1 EA SWITCH ROCKER 16A 125VAC HORIZ NON ILLUM 10 10 9678 0872 1 EA STIFFNER DISPLAY BOARD NOT SHOWN Figure 3 31 Connector Panel Assembly 92 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 DMX Input PCB Assembly 24 9663 3895 Rev 0 Refer to Figure 3 32 No Item Qty UM Description Ref 1 17 9663 3895 1 EA PCB ASSY SM DMX INPUT 6 52 6259 0006 1 EA HEADER 5005 MTA FRCT LOK STRT 1 3 52 6625 0006 1 EA CONN RECEPT XLR 5 FEMALE II 4 52 6626 0006 1 EA CONN RECEPT XLR 5PIN MALE 12 5 62 3039 0102 1 EA 1000PF 250V 20 CD X Y
56. 01 July 2008 37 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Pan Encoder Replacement Parts 24 9678 9729 PAN ENCODER Procedure Step Step Step Step Step 1 Disconnect luminaire AC input cable from power source Carefully lay luminaire on its side to have access to bottom of enclosure At enclosure assembly remove bottom cover 2 3 4 5 Remove pan encoder board Install in reverse order Make sure bottom cover standoffs are seated fully against chassis Encoder Pan Motor Assembly jj gt gt 4 4 Bi a 4 gt N PS fi XL Standoff SSS Bottom Cover gt Bf Enclosure Bottom View NOTE Head not shown for clarity 38 Figure 2 24 Pan Encoder Replacement 01 July 2008 02 9676 0020 A MAINTENANCE MAINTENANCE PROCEDURES 2 Pan EOT Sensor Replacement Parts 86 7002 0003 PAN EOT SENSOR ASSY Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Carefully lay luminaire on its side Step 3 At enclosure assembly remove bottom cover Step 4 Remove pan sensor 5 Install in reverse order Make sure bottom cover standoffs are seated fully against chassis Step 2 Sensor Pan Motor Assembly Standoff ES Sy 8 Bottom Cover D Enclosure Bottom View NOTE Head not shown for clarity Figure 2 25 Pan
57. 134 _ 0156 R138 33V Lan 2 5V 2As 5Ca6C88 C8 TEEN L lt sv 1 8V VCC V0C T we I v 24V vec vec FXD COLOR MOTOR e EDGE te LUS 8166 lt gt 57 R179 Y Y PH 17 gt FXDC_OUTIA EAT EDGE_OUTIA Y 383 E 20 Mat M 309 A PHASE MA OGA 8192 8164 11 usa R201 R177 1 US6 PWM_OUT 7 FxOC_OUTIB jpg yy OUT 3 EDGE ouria 366 lt AAAS 18 vay Ls lt 10A4 306 lt ANA 18 Va Le lt 10141081 Ct42 CI4 R163 1 enor DE C160 C159 8176 1 PH_18 x PH 4 x 303 lt PHASE lt 104 306 PHASE2 maz 1004081 FXDC_OUT2B ee EDGE_OUT2B vea 10A4 vaz KI PORT R194 R193 22 envio 28 R204 R182 22 envio 26 PWM_OUT_18 OUT 4 366 lt GND2 annos 2 386 lt GND2 GND09 2 4 L 8168 3 anna envos 46 4 C167 L cis Rigi 3 anos GNbos Le tH GNpo7 5 GNpo7 HE 4 C145 ___ 3 auos anos C162 13 anos 14 4 5 8 3 gt 5 8 gt R165 R167 R178 R180 Ha dr R123 _L C147 R127 C161 R145 R149 DRAWN BY FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT PROJECT enan SCHEMATI
58. 2 1 EA FASTON RECEPT 16 14 AWG REEL 3 3 5 IN WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 2 Figure 3 49 LVS Chassis Ground Cable Assembly 102 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Replace as a complete assembly Refer to Figure 3 50 ee 700000 TERM 8 RING 10AWG 2 15 17 FT WIRE 22AWG 300V 200C GRN YEL UL1180 Figure 3 50 Chassis To Yoke Ground Cable Assembly 02 9676 0020 A 01 July 2008 103 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Yoke To Head Ground Cable Assembly 25 9667 0028 Rev A Replace as a complete assembly Refer to Figure 3 50 Te TERM 8 RING 10AWG 2 15 17 FT WIRE 22AWG 19X34 MIL 16878 4 TYPE E Figure 3 51 Chassis To Yoke Ground Cable Assembly 104 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Ignitor To Relay Cable Assembly 25 9676 0030 Rev 0 Replace as a complete assembly Refer to Figure 3 52 No Item Qty UM Description 1 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 1 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 1 17 FT WIRE 14AWG 15KV 150C SILICONE 41 30 STRANDING 2 3 1 Figure 3 52 Ignitor To Relay Cable Assembly 02 9676 0020 A 01 July 2008 VAREELITE VL2500
59. 28 use LS lt 10 06 10 45 25 unser LE lt 10 06 10 5 oia vs mee PEDIA 10 D6 10 A3 EN Pa 2 MAG QUTHB 10 06 10 3 R219 R218 22 envio La R252 Rast 22 ac 28 OUT 20 OUT 24 366 A GND2 GNbos 2 SB6 AAA _ om R217 Leslie La _L 8250 sl HE 4 1 4 onos Hi 4 tH onos 182 4 Sn 1 4 onos anos 4 3 cus H onos anos H 7 vec 5 ua 8 8 gt gt s 808 gt El d i El yl El 4 4 vec R213 R215 8246 8248 n pw Ein 332 L ries R189 L cie R202 co R208 3 3V 2 A3 5 C2 6 08 7 C8 P 2 5V lel CMV VCC vec 24V 24V Tele vec vec de crea L ce RES VZ Y Y pua d PH 21 5 OUTIA PWM_PH_25 5 5 DIM OUTIA 2 GP 2 pase lt 10 D6 10 A3 303 c 0 pages lt 10 D6 10 A3 E R220 8222 use R231 R233 4 21 ber us lt a h in 2 YAN ipsas LESE a m 006105 L com Lor i L ow L os 2 Ra HM L PH 22 7 PH 26 DIM OUTZA spa PW PH ls lt 1906105 303 NE lt 1006105 per CYAN mid DIM w maz lt lt 10 D6 10 A3 H 1006 10 43 R230 R229 Goo 2 res R240 8 OUT 22 QUT 26 383 A 0 4
60. 2x1 2 PPB screws one on each side Step 4 At front assembly disconnect wire connectors from rotating gobo index motor and rotating gobo wheel motor Captive Screws 2 Removable Cover Front Nose Cover Wire Connector Junction Connector X gt Route wiring harness here bond Screw 2 Figure 2 6 Front Assembly Removal Step 5 At junction connector disconnect edge motor and zoom motor wires Step 6 Face head nose upward At front of bulkhead using 2 Phillips long handle screwdriver remove four 6 32 X 3 8 PPB screws and pull front assembly partially out of head assembly Step 7 At rear of bulkhead disconnect wires from rotating gobo sensor PCB Figure 2 7 02 9676 0020 A 01 July 2008 21 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Step 8 Re install front assembly by performing Steps 2 6 in reverse order While re installing first connect wiring harness connection to rotating gobo wheel sensor and route wires through corner between head assembly and bulkhead ensuring no wires are pinched Rotating Gobo Sensor PCB Replacement Parts 24 9667 1321 PCB ASSY SENSOR ROTATING GOBO To remove and replace rotating gobo sensor PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front assembly Refer to Front Assembly Removal on page 21 Step 3 At rotating gobo wheel remove two 4 40x3 8 PFZ screws do not remove middle screw and remov
61. 3 PHASE SZ 23 HIGH TORQUE 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 82 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN YOKE 3 Tilt Motor Assembly continued D A 2 6 x2 gm 10 2 gt 8 2 Cont 3 i gt es Fnnn 4 I 10 X2 lt lt gt 5 gt r 1 I L pum L LJ LI 5 EL 7 x4 Figure 3 26 Tilt Motor Assembly 02 9676 0020 A 01 July 2008 83 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Pan Tilt Encoder PCB Assembly 24 9661 9629 Rev B Refer to Figure 3 27 Replace as a complete assembly 11 9661 9629 Figure 3 27 Pan Tilt Encoder Assembly 84 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN YOKE 3 Yoke Fan Assembly 22 9676 0609 Rev A Refer to Figure 3 27 No Item Qty UM Description 1 10 9676 0646 1 FAN TRAY ARM 2 40 7113 0001 1 EA FAN 24V 80 X 80 X 25 MM 32CFM 3 52 6396 2202 1 EA RECPT 2005 MTA100 W POL TAB RED CLSD END 4 53 2200 0006 4 EA NUT 6 32 KEPS SS Direction of Air Flow Figure 3 28 Yoke Fan Assembly 02 9676 0020 A 01 July 2008 85 VAREELITE
62. 32 X 3 4 SCB CAP 46 53 6522 0004 2 EA SCREW 6 32 X 1 4 SOC HD CAP BLK 47 53 6525 0188 2 EA SCREW 6 32 X 3 16 LG PPZ SEMS 48 53 6530 0023 2 EA RIVET 1 8 OD POP 376 500 GRP DOME HD STL MND 49 53 6539 0001 4 EA WASHER 3 8 SPLIT LOCK 50 53 6545 0003 3 EA SCREW 8 32 X 3 8 PFZ 51 53 6545 0004 4 EA SCREW 8 32 X 3 8 PPZ 52 53 6556 0002 1 EA SCREW 4 40 X 3 4 LG PPB 53 53 6558 0009 13 EA SCREW 6 32 X 3 8 PPZ SEMS EXT W 54 53 6558 0010 11 EA SCREW 6 32 X 1 4 LG PPZ BLK SEMS EXT W SHR 55 53 6558 0015 4 EA SCREW 6 32 X 3 8 PPB SEMS 56 53 6571 0003 1 EA SCREW 6 32 X 1 5 PPB 57 53 6591 0001 2 EA SCREW 6 32 X 1 4 PFZ 58 55 6677 0039 8 EA WASHER 438 OD 0219 ID 04 59 53 6522 0001 1 EA SCREW 6 32 X 1 4 PPZ 60 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ 61 53 6626 0001 1 EA SCREW 10 32 X 1 2 PPZ 62 53 6634 1000 1 EA SCREW 3 8 16 X 1 00 LG SOC HD CAP ALLY STL 63 53 6653 0502 4 EA SCREW 1 4 20 X 1 2 LG SOC HD CAP ZINC 64 54 1206 0014 2 EA RING RETAINING 1 375 SHAFT 1 291 DIA GRV X 056 WD 65 54 1255 0001 1 EA BEARING ASSY BLACK FLUSH MOUNT HOUSING 66 54 2055 0001 1 EA BELT TIMING S2M 210 GRV 9 MM WIDE URTH KVLR 67 55 2150 0003 2 EA STANDOFF 1 4 HEX 6 32 X 1 125 LG STL 88 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 No Item Qty UM Description
63. 363 lt GNp2 HL 9 Cle4 As 210 4 L 194 Lis hz 2 218 4 4 euo onns ans Hi 5 8 gt 5 8 8 gt R224 R226 8235 8237 pw he 6196 L cis R198 DRAWN FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT PROJECT ENGR Lyre SCHEMATIC VL2500 CONTROLLER DOC CONTROL Sus Document Number Rev D 14 9676 0730 BO COPYRIGHT 2004 Date Tuesday July 20 2004 sheet 8 10 02 9676 0020 A 01 July 2008 135 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS Main Control Board MCB Schematic continued T I a gt Y 7 VCC Laa os ALL PARTS REMOVED DRAWNEY FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 CHECKED BY INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT PROJECT ENGR Tile SCHEMATIC LV2500 CONTROLLER Sze Document Number sv D 14 9676 0730 80 Date Monday July 12 2004 SHEET 9 or 10 DOG CONTROL COPYRIGHT 2004
64. 4 Pan Tube Assembly 02 9676 0020 A 01 July 2008 95 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21 9678 0864 Rev E Refer to Figure 3 35 No Item Qty UM Description 1 10 9678 0865 1 EA PLATE PAN MOTOR MOUNT 2 21 9678 0828 1 EA ASSY DRIVE PULLY PAN 3 24 9678 9729 1 EA PCB ASSY VL2203 PAN TILT ENCODER 4 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 7 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 8 55 2132 0014 2 EA STANDOFF 1 4 HEX 4 40 1 062 LG CS Note orientation of connector Figure 3 35 Pan Motor Assembly 96 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Upper Enclosure Fan Assembly 23 9678 0686 Rev 0 Refer to Figure 3 35 No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52 8231 0007 2 EA TERM SPADE 6 26 24 AWG INS YELLOW 2 2 Figure 3 36 02 9676 0020 A Upper Enclosure Fan Assembly 01 July 2008 97 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 37 No Item Qty UM Description 1 52
65. 40 1 EA HUB 6080 WHEEL MACHINED CASTING E 10 9676 4141 1 EA SPRINGCLIP PLATE 10 9676 4143 1 EA CLAMP 6080 WHEEL 10 9676 4144 1 EA SPACER CLAMP WHEEL 53 5704 0250 2 EA SCREW 4 40 X 1 4 LG SCSS 2 41 6006 4202 1 EA ASSY VL6 GOBO VERTICAL BARS ST 3 41 6006 5009 1 EA ASSY VL6 GOBO LIQUID TEXTURE 4 41 6006 5011 1 EA ASSY VL6 6080 SKY ST 5 41 6006 5501 1 EA ASSY VL6 6080 LEAVES ST 6 41 6006 5523 1 EA ASSY VL6 TRIBAL BREAKUP P O 7 41 6006 6001 1 EA ASSY VL6 MEDIUM CIRCLE ST 8 41 6006 7002 1 EA ASSY VL6 6080 PEBBLES ST 9 41 6006 7008 1 EA ASSY VL6 6080 WAVE ST 10 41 6006 7015 1 EA ASSY VL6 6080 BLOCK BREAKUP ST 11 41 6006 7025 1 EA ASSY VL6 6080 DUST BREAKUP CA 12 41 6006 7029 1 EA ASSY VL6 ALPHA RAYS 11 4 8 A 5 I e 12 L 3 Figure 3 19 Gobo Wheel Assembly 72 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Color Filter Wheel Assembly 21 9676 4145 Rev Refer to Figure 3 20 No Item Qty UM Description 1 22 9676 4142 1 EA ASSY GOBO WHEEL 12 POSITION FIXED A 12 9676 4140 1 EA HUB 6080 WHEEL MACHINED CASTING 10 9676 4141 1 EA SPRING PLATE gt 10 9676 4143 1 EA CLAMP GOBO WHEEL 10 9676 4144 1 EA SPACER CLAMP WHEEL 53 5704 02
66. 4306 Rev D Continued on the next page Iris Color Gobo Bulkhead Assembly Yoke Assembly 21 9676 0600 Rev G Iris Gobo Motor Assembly 21 9676 0118 Rev B Ignitor PCB Assembly 24 9661 1126 Rev C Color Motor Assembly 21 9676 0119 Rev Tilt Motor Assembly Gobo Wheel Assembly 2230780619 Hay by 21 9676 4146 Rev A Pan Tilt Encoder PCB Color Filter Wheel Assembly Assembly 21 9676 4145 Rev A 24 9661 9629 Rev B Color Gobo T Stat Cable Assembly Ignitor To Relay Cable 25 9676 0125 Rev B Assembly Crossfade Color Assembly TET M 21 9676 0201 Rev N VL2500 Main Control Board PCB Assembly Top Cover Assembly 24 9676 3730 Rev 0 22 9676 0008 Rev H Bottom Cover Assembly 22 9676 0011 Rev D Strobe Assembly 22 9676 0016 Rev H Continued on the next page 42 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN DRAWING TREE 3 Drawing Tree continued Continued from previous page VL2500 Spot Luminaire continued Upper Enclosure Assembly 21 9676 0800 Rev S Reflector Assembl 4 Connector Panel Assembly Connector Panel Assembly 22 9676 0018 Rev B 21 9678 0805 Rev L 21 9678 0805 Rev L Fan Assembly Fas Tuba DMX Input PCB an Tube Assembly 22 9676 0090 Rev D Assembly 21 9678 0880 Rev C 24 9663 3895 Rev 0 Ground Strap Cable Assembly 25 8007 2212 Rev 0 AC Input Pigtail Cable 2 ev UV IR Window Assembly 22 9676 0140 Rev D 25 9678 0810 Rev B Pan EOT Sensor Electrical Upper Enclos
67. 5 ID 032 48 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 VL2500 Generic Luminaire continued 24 x4 16 Figure 3 3 VI 2500 Generic Luminaire Assembly 02 9676 0020 A 01 July 2008 49 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Front Assembly 21 9676 4006 Rev F Refer to Figure 3 4 No Item Qty UM Description 1 10 9660 0129 1 EA SHAFT STOP ROTATING GOBO WHEEL 2 10 9660 0130 1 EA SHAFT ROTATING GOBO WHEEL 3 10 9660 0219 1 EA SHAFT 1 FOCUS BEARING 4 10 9676 4255 2 EA SUPPORT LENS 5 10 9660 0263 1 EA SUPPORT LENS 6 10 9667 0313 1 EA SUPPORT LENS CABLE MOUNT 7 10 9676 4349 1 EA SUPPORT RING OPTICAL 8 10 9676 4355 1 EA BRACKET COVER MOUNTING 9 21 9660 0105 1 EA ASSY ROTATING WHEEL 10 21 9676 4306 1 EA ASSY LENS BARREL 11 21 9667 0310 1 EA ASSY MOTOR EDGE 12 22 9676 0316 1 EA BULKHEAD LENS MOUNTING 13 22 9676 0152 1 EA ASSY TENSION BRACKET MOTOR INDEX 14 22 9676 0153 1 EA ASSY TENSION BRACKET MOTOR WHEEL 15 24 9667 3321 1 EA PCB ASSY SENSOR ROTATING 6080 16 53 2200 0004 1 EA NUT 4 40 KEPS SS 17 53 6515 0001 2 EA SCREW 10 32 X 3 4 SCB CAP 18 53 6520 0001 3 EA SCREW 4 40 X 3 8 PPZ 19 53 6545 0004 3 EA SCREW 8 32 X
68. 50 2 EA SCREW 4 40 X 1 4 LG SCSS 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 FILTER 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 20 Filter Wheel Assembly 02 9676 0020 A 01 July 2008 73 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Strobe Assembly 22 9676 0016 Rev H Refer to Figure 3 21 No Item Qty UM Description 1 10 9676 0043 1 EA BULKHEAD STROBE MOUNTING 2 10 9676 0019 2 EA STROBE BLADE DIMPLED 3 10 9676 0060 2 EA MOUNTING COLLAR STROBE BLADE 4 10 9676 8061 2 EA STABLIZER STROBE MOTOR 5 10 9676 0069 2 EA MOUNTING PLATE STROBE MOTOR 6 10 9678 0491 4 EA BUMPER STOP STROBE 7 44 9678 0455 2 EA MOTOR COLOR 8 53 2200 0006 2 EA NUT 6 32 KEPS SS 9 53 5536 0500 4 EA SCREW 6 32 X 1 2 PFSS B 10 53 6525 0001 2 EA SCREW 6 32 X 5 16 PPZ 11 53 6528 0001 2 WASHER 6 FLAT ZINC
69. 500 Luminaire Wiring Diagram continued FROM FROM CHASSIS FROM BALLAST FROM BALLAST FROM FROM FROM FROM FROM PAN MOTOR PAN SENSOR DMX INPUT J3 LV5 DISPLAY BD J1 BALLAST J112 amp J402 FAN CONN GND STUD J202 J203 SHEET 1 SHEET 1 SHEET 1 ET 1 SHEET 1 SHEET 3 SHEET 1 SHEET 1 SHEET 1 5888 gs 8 vos OPEN ENCODER SENSOR wc wc 24 9661 0629 KER TILT_TRAVEL GRN SOR WT 23 9661 1253 nn IGNITOR BOARD VL2500 CONTROLLER 24 9661 1126 zz 7338 SHEET 3 TO MAG MOTOR SHEET 3 TO DIM MOTOR SHEET 3 TO FXD GOBO MOTOR SHEET 3 TO FIXED WHEEL IRIS BULKHEAD SHEET 3 WIRING DIAGRAM VL2500 CONTROLLER SZE ansion DRANG NUMBER Bo 14 0676 0008 DATE 7 20 04 ACAD SHEET 2 OF 3 02 9676 0020 A 01 July 2008 126 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL VL2500 Luminaire Wiring Diagram continued STROBE FANS SHEET 2 02 9676 0020 A FIXED WHEEL IRIS BULKHEAD SHEET 2 FXD COLOR HH SENSOR SENSOR CR 24 9638 0113 GND FXD GOBO SENSOR VC 24 9638 0113 REAR HEAD FAN 2 Seavoeusuna zzoanourun MAGENTA MOTOR 3 9 CROSS FADER BULKHEAD SHEET 2 01 July 2008 REFERENCE FOLD OUTS OPTICS BULKHEAD SHEET 2
70. 59 1 EA WEAR STRIP ZOOM BALL PLUNGER 5 10 9676 4260 1 EA WEAR STRIP BUMPER EDGE LENSES 6 12 9676 4248 1 EA EDGE BARREL BOTTOM 7 12 9676 4247 1 EA EDGE BARREL 8 21 9660 0225 1 EA ASSY SUB BARREL GROUP 1 9 21 9660 0227 1 EA ASSY GROUP 3 SUB BARREL 10 21 9667 0311 1 EA ASSY MOTOR ZOOM OPTICS 11 21 9676 4257 1 EA ASSY EDGE BUSHING 12 21 9676 4229 1 EA ASSY ZOOM BARREL 13 42 9660 0026 1 EA LENS 9 ZOOM OPTICS 14 53 2200 0004 3 EA NUT 4 40 KEPS SS 15 53 2200 0006 4 EA NUT 6 32 KEPS SS 16 53 6551 0001 2 EA SCREW 4 40 X 3 8 PPB 17 53 6558 0015 4 EA SCREW 6 32 X 3 8 PPB 18 53 6559 0002 2 EA SCREW 4 40 X 1 4 19 53 6592 0250 2 EA SCREW 4 40 X 1 4 SEMS 20 54 1206 0055 1 EA RETAINING RING EXTERNAL 1 2 SHAFT PRESS 21 54 1206 0056 1 EA RETAINING RING EXTERNAL 1 2 SHAFT 22 55 3301 0004 2 EA WASHER 4 FLAT SS 23 55 6512 0001 2 EA WASHER 1 4 SPLIT LOCK 52 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN ASSEMBLY 3 Lens Barrel Assembly continued eG AO Figure 3 5 Lens Barrel Assembly 02 9676 0020 A 01 July 2008 53 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Sub Barrel Group 2 Assembly 21 9676 4229 Rev Refer to Figure 3 6 No Item Qty UM Description 1 10 9676 4223 1 EA BARREL ZOOM LOWER 2 10 9676 4250 1 EA SPACER
71. 6 28 pl E NL 2 04 285 267 2 88 ix GNDos LAMP STBY 10 C2 w st R33 24d ga Troppo r 541 anos nas EDGESEL 25 40 5M gt s 285 id sc R32 moppe 4 R299 BD 02 208 v 15 R34 apps 202 ENABLE oo aa 21984 TipyPP7 RW K 2IC4 21C6 3IA amp MM 20C4 2 C6 3 A6 266 S 92g as P39 gt sizo Ha 2 87 2 06 3 06 o ra D4 R box HI m R35 ps 2106 2897 _ ps CS FLASH 206264 D E 284 e 2066 284 256353 ANT nosa a gt 050 f 2 84 2 66 2 063 03 GNT 71d moss pS As 2 016 2 CA 2 85 2 87 2 C6 81 8 081 206284 AN 2 AD poo 5 080 206 lt more 05 gt 2 4 017 0517 254 07 AT Dat E bs x m pie qu SRE I 2 os 2M PST 2M DREGOUPPS css pa pt 2A4 2200 pngcaupps css ps 55M 2 6 3 A6 au 2 020 PSTCLK 27 2 A4 UAE Dos T 2M cs pin CS VART lt 20D6 3A6 ml Das Ho 2106 e 80 rio E 204 25 6 006 222 Di rovro 2l x xs Li 023 m ps 2 D6 du pi A18 33 pas 4 024 28 69 gt 4 025 57 7 a Das 100 gt R64 A20 BES 026 A D pe 405 OUTS u 22 845 0 2B2 2C2
72. 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 2 52 8346 0001 4 EA CONTACT 24 30 AWG FEMALE CRIMP 3 86 7002 0003 1 EA SWITCH SLOTTED OPTICAL E 3 i E L 1 2 x4 IRE HART SEN ESCRI NO N NNECTI LAGI IRED ATHODE I IRE ANODE EMITTER OILLECTOR Figure 3 37 Pan EOT Sensor Electrical Assembly 98 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Ballast Module Arc Power Supply Assembly 69 9676 0700 Rev 0 Refer to Figure 3 38 Replace as a complete assembly Figure 3 38 Ballast Module Arc Power Supply Assy 02 9676 0020 A 01 July 2008 99 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Notes 100 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Cables Ground Strap Cable Assembly 25 8007 2212 Rev 0 Replace as a complete assembly Refer to Figure 3 48 TERM RING 6 22 16 AWG NON INS 2 0 33 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED Figure 3 48 Ground Strap Cable Assembly 02 9676 0020 A 01 July 2008 101 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Replace as a complete assembly Refer to Figure 3 49 No Item Qty UM Description 1 1 EA TERM RING 6 BLUE 16 14 AWG REEL
73. 68 55 2178 0001 2 EA CABLE ANCHOR MOUNT 8 SCREW MOUNTING 69 55 2179 0001 3 EA CABLE ANCHOR MOUNT 6 SCREW MOUNTING 70 55 6580 0002 2 EA CABLE TIE 18 W X 8 00 LG 7i 55 2261 0001 1 EA SLEEVE NYL INSUL 6 SCREW 1 0 LG 015 WALL 72 55 2267 0001 2 EA RUBBER STRIP SPONGE CLSD CELL 3 8 W 3 16 TALL 73 55 2178 0001 2 EA CABLE ANCHOR MOUNT 8 SCREW MOUNTING 74 55 6532 0004 2 EA BRACKET 6 32 THREADED HOLES 4334 75 55 6543 0001 0 146 GROMMET STRIP SERRATED 76 55 6543 0002 1 08 FT GROMMET STRIP SERRATED 1 8 OPENING 77 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK 78 55 6568 0074 2 EA SPRING CPRSN 420 OD 75 LG 055 DIA WIRE 79 55 6677 0044 1 EA WASHER 877 OD 170 ID 093 FLAT NYL 80 55 6575 0001 4 EA SCREW 10 32 X 3 4 PPB 81 55 6577 0005 2 EA STANDOFF 1 2 HEX 6 32 1 625 LG NYLON 82 55 6775 0009 1 EA BUSHING SNAP 750 ID 1 MT HL NYLON 83 67 4018 0001 1 EA FERRITE 26 X 28 5 X 13MM CYL 84 67 4021 0002 1 EA FILTER EMI CCI 85 68 9678 0827 1 EA CHOKE COMMON MODE 86 69 3177 0151 1 EA POWER SUPPLY 150W 24V 6 3A W MNT PLT 87 55 6799 0001 A R EA SHIM 1 375 ID 1 875 OD 010 THK 88 55 6799 0002 SHIM 1 375 ID 1 875 005 02 9676 0020 01 July 2008 89 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly continued Figure 3 29 Upper Enclosure Assembly 90
74. 8 02 9676 0020 A VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL VL2500 Generic Luminaire 21 9676 0010 Refer to Figure 3 3 No Item Qty UM Description 1 10 9628 0211 1 EA STABLIZER PAN TILT 2 10 9676 8617 1 EA HEATSHIELD YOKE CROSSMEMBER 3 10 9676 0083 1 EA BAFFLE REAR CASTING 4 10 9676 0163 1 EA HARNESS GUARD RIGHT 5 10 9676 0161 1 EA HARNESS GUARD LEFT 6 21 9676 0139 1 EA ASSY REAR HEAD 7 21 9676 0600 1 EA ASSY YOKE 25 9667 0028 1 EA CABLEASSY YOKE TO HEAD GROUND NOT SHOWN 8 21 9676 0800 1 EA UPPER ENCLOSURE 9 24 9676 3730 1 EA ASSY VL2500 MAIN CONTROL BOARD MCB 10 53 6505 0020 5 EA BOLT 1 4 28 X 3 4 HX HD GRD 8 11 53 6517 0001 8 EA SCREW 10 32 X 3 8 PPZ 12 53 6526 0001 1 EA SCREW 6 32 X 5 8 PPZ 13 53 6530 0006 2 EA RIVET 1 8 OD X 188 250 14 53 6539 0008 5 WASHER 1 4 FLAT 15 53 6553 0008 4 EA SCREW 10 32 X 9 16 16 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 17 53 6558 0010 8 EA SCREW 6 32 X 1 4 PPB SEMS 18 53 6682 0025 1 EA SCREW 8 32 X 5 8 PPZ SEMS 19 54 2039 0001 1 EA BELT GT TIMING 2 MM PITCH 182 GRV 20 55 2114 0001 8 EA WASHER 10 LOCK INT TOOTH 21 55 6549 0001 5 EA WASHER 1 4 SPLIT LOCK 22 55 6603 0001 1 EA SPRING EXTENSION 23 55 6663 0007 1 EA STANDOFF 3 8 RND 1 75 LG FF 24 55 6677 0033 4 EA WASHER 281 12
75. AN FOUND BELOW WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1 luminaires have been designed for use only with certain Philips and Osram HID lamps Note lamp type MSR400 575 etc before replacing lamps Installing another type of lamp may be hazardous Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detailed in this manual Replace fuses with same type and rating only Note distance requirement from combustible materials or illuminated objects for VARI LITE luminaires WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1 02 9676 0020 A luminaires are designed for dry locations only Exposure to rain or moisture may damage luminaire Disconnect power before servicing any VAREKLITEG equipment Servicing to be performed by qualified personnel only 01 July 2008 v VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1 Many VARI LITE luminaires use an HID type lamp that produces UV radiation NOT look directly at lamp 2 Itis hazardous to operate luminaires without lens or shield Shields lenses or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired For example by cracks or deep sc
76. ARI LITE QUALITY ASSURANCE CERTIFICATE not shown 3 02 8406 0001 1 EA TAG LAMP NOTICE 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 2000 SERIES 09 09 02 5 02 9676 0002 1 EA UNPACK QUICK START SHEET VL2500 04 9676 0001 2 EA SHIPPING BOX LABELS VL2500 SPOT not shown 04 4037 0001 5 EA LABELS 2 5 X 5 not shown 6 07 9661 0018 1 EA SHIPPING BOX CARDBOARD VL2500 07 5044 0001 1 EA BAG DESICCANT SHIPPING BOX not shown 7 06 6073 0001 1 EA FOAM 8 08 2500 0001 1 EA CD ROM VL2500 LUMINAIRE PRODUCT DOCUMENTATION 9 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 10 71 2528 0700 1 EA 700 WATT SHORT ARC PHILIPS MSR575HR LAMP 04 9678 1000 1 LABEL WHITE ROHS COMPLIANCE s 04 9678 1001 2 EA LABEL GREEN ROHS COMPLIANCE 44 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Figure 3 1 Included Items Kit 02 9676 0020 A 01 July 2008 45 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL VL2500 Spot Luminaire 20 9676 0001 Rev K Refer to Figure 3 2 No Item Qty UM Description 1 10 9638 0052 1 EA DAM AIR VL6 2 10 9676 8632 2 EA COVER YOKE THERMOFORM 3 16 9676 0004 01 1 EA LABEL LOCATION VL2500 LUMINAIRE not shown 4 21 9676 0023 1 EA ASSY FRONT COVER 5 21 9676 4006 1 EA ASSY FRONT 6 21 9676 0010 1 EA GENERIC LUMINAIRE VL2500
77. Assembly 58 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Top Cover Assembly 22 9676 0008 RevH Refer to Figure 3 10 No Item Qty UM Description 1 06 6018 0011 0 041 FT VELCRO DOUBLE HOOK 2 BLACK ADH BACKED 2 07 5049 0001 1 EA LANYARD NYLON COATED 8 LONG 3 10 9676 8009 1 EA COVER TOP VL2500 4 10 9676 0010 1 EA FILTER TOP HEAD COVER 5 12 9676 0076 1 EA BAFFLE RIGHT TOP COVER 6 12 9676 0077 1 EA BAFFLE LEFT TOP COVER 7 53 2008 0008 2 EA PUSH NUT 8 8 53 5655 0250 1 EA SCREW 6 X 1 4 PPZ PLASTIC 9 53 6545 0001 2 EA SCREW 8 32 X 3 8 PPB 10 53 6687 0250 4 EA SCREW 4 40 X 1 4 PEZ THREAD FORMING 11 55 3301 0006 1 EA WASHER 6 FLAT SS 12 55 6599 0001 2 EA WASHER FLAT 10 FLAT BLACK 13 55 6621 0001 1 EA WASHER 4 FLAT ZINC Figure 3 10 Top Cover Assembly 02 9676 0020 A 01 July 2008 59 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Bottom Cover Assembly 22 9676 0011 Rev D Refer to Figure 3 11 No Item Qty UM Description 1 10 9676 8012 1 EA COVER LOWER 2 53 2008 0008 3 EA NUT 8 PUSH 3 53 6545 0001 3 EA SCREW 8 32 X 3 8 PPB 4 53 6599 0001 3 EA WASHER 10 FLAT BLACK Figure 3 11 Bottom Cover Assembly 60 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Reflector Assembly 22 9676 0018 Rev B Refe
78. C VL2500 CONTROLLER DOC CONTROL Size Document Number D 14 9676 0730 COPYRIGHT 2004 Date Tuesday July 20 2004 SHEET 7 or 7 7 T z T 02 9676 0020 A 01 July 2008 134 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUA REFERENCE FOLD OUTS Main Control Board MCB Schematic continued vec vec El T alias 24V vec vec 7 cies 8214 Mi R247 jog P PH 19 5 AMB OUTIA PH 23 5 MAG OUTIA ig 306 c k pases ui lt 10 D6 10 A3 386 C o ease lt 10 06 10 A8 R209 R211 ae us R242 R244 OUT 19 OUTIB OUT 23 MAG OUTIB gg OUT AAA 38 mos LE lt 10 06 10 45 GA OUT BA 138 vs LEE 10 C6 10 A5 0 R210 i ai C196 CI95 R243 aui Las PH 20 Y PH 24 x 383
79. CER 2 COLOR SYSTEM 5 10 9676 0235 5 EA SPACER BULKHEAD COLOR SYSTEM 6 10 9676 0284 1 EA SHAFT COLOR SYSTEM 7 10 9678 0485 4 EA PULLEY COLOR MOTOR 8 21 9676 0289 1 EA ASSY FRONT BULKHEAD DIFFUSER 9 21 9676 0290 1 EA ASSY MAGENTA COLOR WHEEL 10 21 9676 0291 1 EA ASSY CYAN COLOR WHEEL 11 21 9676 0292 1 EA ASSY YELLOW COLOR WHEEL 12 21 9676 0293 1 EA ASSY DIMMER WHEEL 13 21 9676 0298 1 EA ASSY SENSOR PCB BRACKET 14 44 9676 0236 4 EA MOTOR COLOR 15 53 2200 0006 4 EA NUT 6 32 KEPS SS 16 53 2200 0008 1 EA 8 32 5 17 53 5559 0250 4 SCREW 6 32 1 4 SET CONE POINT 18 53 6520 0188 2 EA SCREW 4 40 X 3 16 PFZ UNDERCUT 19 53 6525 0001 4 EA SCREW 6 32 X 5 16 PPZ 20 53 6545 0001 5 EA SCREW 8 32 X 3 8 21 53 6545 0007 1 EA SCREW 8 32 X 3 8 PFB 22 53 6596 0001 4 EA SCREW 4 40 X 5 16 PPZ 23 54 2049 0135 2 EA BELT TIMING MXL 0 08 PITCH 135 GRV 24 54 2059 0001 2 EA BELT TIMING MXL 0 08 PITCH 150 GRV 25 55 2110 0002 3 EA WASHER 400 260 ID 010 26 55 2179 0008 2 EA SADDLE LOCKING TOP 0 067 27 55 6503 0001 5 EA WASHER 8 LOCK INT TOOTH 28 55 6818 0002 1 EA KURLY LOK STANDOFF 45 DEG NYLON 6 6 NOT SHOWN 29 55 9676 0255 1 EA BELLEVILLE SPRING WASHER SPEC B0500 018 S 68 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN ASSEMBLY 3 Crossfade Color Assembly continued 22 x4 14 x2
80. COPYRIGHT 2004 Date Tuesday July 20 2004 SHEET 10 10 z 7 z 5 z z 02 9676 0020 01 July 2008 137 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL REFERENCE FOLD OUTS DMX Input Schematic REVISIONS REV DESCRIPTION DATE APPD A Released per EO 09110 9 27 01 91 NC5FBV D HIELD 3 D DMX VL IN DMX VL VL QUT VL OUT CHASSIS 5 92 NC5MBV C EET C e HIELD e DMX VL IN e DMX VL_IN e VL QUT e VL OUT e CHASST 93 640456 5 HIELD B e DMX VL IM z B DMX VL IN VL_OUT VL_OUT C1 1000PF 20 250 DRAWN BY 1 9 201 REGAL ROW ASSY MARC DYBLE VAR leas L DALLAS TEXAS 75247 A PCB NO 11 9663 1830 MTD 09 01 CONFIDENTIAL VL1000 DMX INPUT BOARD A CHK ALL INFORMATION CONTAINED HEREIN SIZE G NUMBER IS THE SOLE AND EXCLUSIVE PROPERTY roc OF VARI LITE INC AND MAY NOT BE A USED DISCLOSED OR REPRODUCED B 14 9663 1830 Filename ANY MANNER WITHOUT THE ADVANC Date Time WRITTEN CONSENT OF VARI LITE INC ViewDraw for Windows 7 5 SHEET 1 OF 1 8 7 6 5 4 3 2 1 02 9676 0020 A 01 July 2008 138 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Solid State Ignitor Schematic 02 9676 0020
81. FF 1 4 HEX 6 32 500 LG ALUM 02 9676 0020 A 01 July 2008 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Yoke Assembly continued IN Figure 3 24 Yoke Assembly 80 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN 3 Ignitor PCB Assembly 24 9661 1126 Rev C Refer to Figure 3 25 Replace as a complete assembly 1126 RE e 4 Hou ENIRO m e e S LI In vmm Oz 2 IEWED FROM COM NENT SIDE Figure 3 25 Ignitor PCB Assembly 02 9676 0020 A 01 July 2008 81 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Tilt Motor Assembly 22 9676 0610 Rev C Refer to Figure 3 26 No Item Qty UM Description 1 10 9661 7298 1 EA PLATE TENSION ADJUST PAN MOTOR 2 22 9661 0608 1 EA ASSY DRIVE PULLEY 10 9661 8640 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 SET CONE POINT 3 23 9661 1253 1 EA ELEC ASSY PAN EOT SENSOR 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 52 8346 0001 4 EA CONTACT 24 30 AWG FEMALE CRIMP 86 7002 0003 1 EA SWITCH SLOTTED OPTICAL 4 24 9661 9629 1 EA ASSY PAN TILT ENCODER 5 44 9678 0680 1 EA MOTOR
82. H 18 amp o 1097 PWM OUT 5 PWM OUT 10 1098 s PH 5 OUT 11 1099 L PAM PH 25 1 004 10100 188 s PH 6 PH 1 1025 10101 PH 14 II 3 1026 10102 lt 6 0 PWM_OUT 6 PWM_PH_12 1027 10103 PWM OUT 14 1028 10104 22 PH 9 m 53 029 10105 24 PWM OUT 9 PWM_PH 2 ss 10106 OUT 18 26 lt 10107 ars OUT 21 PWM OUT 26 ios 10108 PWM OUT 17 OUT 12 se A 1099 10109 OUT 20 RXINT area AA 1004 10110 OUT 16 v 7 1035 ont PWM OUT 8 6127 AL 10112 PWM PH 16 97 318 1097 PH 8 1008 014 PH 19 1 0 04 1009 10115 PH 15 a AL 10116 PH 7 AAA A 10117 PWM OUT 19 so 6 10118 QUT 7 6 08 2 1049 OUT 15 amp 1044 10120 SPARE 1 S oss 0121 SPARE 2 1046 10122 257 1047 10123 57 1048 10124 8 1049 PWM PH 20 LOCKIO125 s HEY 1050 DATA7IO126 AL 1051 OUT 25 DATA61O127 BL oss PWM OUT 22 PWM OUT 24 DATASIOT28 s scs 8 10859 PH 22 PH 24 DATAANO129 A os m PWM PH 10 PWM PH 23 DATA31O130 soa 2 1055 PH 21 PWM QUT 4 2 0131 vss 1066 PH 17 PH 4 DATA1NO132 1087 gt s 1058 DATA i DATA 2 2 88
83. ING WHEEL 4 10 9660 0153 1 EA MAGNET HALL EFFECT SENSOR 07ID 5 10 9667 0333 1 EA MOUNTING PLATE FRONT ROTATING 6080 WHEEL 6 10 9667 0334 1 EA MOUNTING PLATE AFT ROTATING GOBO WHEEL 7 10 9667 0335 1 EA LIGHT SHIELD SPINNING WHEEL 8 21 9660 0102 1 EA ASSY SENSOR PLANET GEAR 9 21 9660 0147 1 EA ASSY DRIVE HUB PULLEY FLANGE SPINNING GOBO WHEEL 10 9660 0111 1 EA DRIVE HUB SPINNING 6080 WHEEL VL6B 2 10 9660 0148 1 EA PULLEY FLANGE DRIVE HUB SPINNING GOBO WHEEL 10 41 6016 4305 1 EA ASSY 6080 PINWHEEL 11 41 6016 4316 1 EA ASSY VL68 SPINNING 6080 HYPNOSPIRAL 12 41 6016 6011 1 EA ASSY VL68 SPINNING 6080 CIRCLE OF OVALS 13 41 6016 6990 1 EA ASSY VL68 SPINNING GOBO SPIRAL STONES 14 41 6016 8004 1 EA 4 FACET PRISM 15 53 6597 0001 9 EA SCREW 4 40 X 3 16 PPZ 16 53 6633 0002 2 EA SCREW 4 X 3 8 PFZ SHT METAL 56 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Rotating Gobo Wheel Assembly continued SA DD Standard Gobos Figure 3 8 Rotating Gobo Wheel Assembly 02 9676 0020 A 01 July 2008 57 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Sensor Rotating Gobo PCB Assembly 24 9667 1321 Rev Refer to Figure 3 9 Replace as a complete assembly 3 IN LI I Figure 3 9 Sensor Rotating Gobo PCB
84. L TAB BLUE CLOSED END 6 2 EA COVER 3 POS CLOSED END STRAIN RELIEF MTA100 7 4 EA CONN FEMALE 6 POS 30 24 AWG CRIMP PHR 8 18 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 9 4 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 10 16 EA CONTACT 26 28 AWG FEMALE CRIMP 1 25 MM PITCH REEL 11 7 EA CABLE TIE 10 X 4 LG SMALL 12 0 67 FT SLEEVING 3 4 NOM DIA WOVEN POLY ROUNDIT 2000 13 2 EA GROMMET 9 32 ID 9 16 OD 1 4TH SILICONE 14 11 71 FT WIRE 26 AWG 4 COND 300V 200 DEG C TEF BLK BRN RED ORN gt UL1180 15 1 25 FT WIRE 26 AWG 3 COND 300V 200 DEG C TEF lt BLK RED WHT BLK gt UL1180 16 1 92 FT WIRE 26 AWG 3 COND 300V 200 DEG C TEF lt BLK RED WHT GRN gt UL1180 17 1 50 FT WIRE 28 AWG 6 COND 300V 200 DEG C TEF lt BLK WHT BLU WHT YEL WHT BLK WHT PUR RED gt UL1180 40 EA CONTACT 26 22 AWG RECP MTE NOT SHOWN 108 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Color Fixed Bulkheads Cable Assembly cont 14 7 8 14 9 10 x4 each 16 5 6 N 11 X7 2 3 4 ELLIPSE INDICATES TWISTED WIRES Figure 3 55 Color Fixed Bulkheads Cable Assembly 02 9676 0020 A 01 July 2008 109 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Optics Strobe Bulkheads Cable Assembly 25 9676 0716 Rev F Replace as a complete assembly Refer to Figure 3 56
85. Manual This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VL2500 Spot 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 Source VL2000 Spot Luminaire 20 9676 0001 700W Arc 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 VAREKLITE product Additional Documentation A support webpage for VL2500 series luminaires is available at www vari lite com follow the Support link For installation and operation of the VL2000 spot luminaire you can download the following user s manual in electronic PDF format m VL2500 Spot Luminaire Users Manual 02 9676 0019 02 9676 0020 A 01 July 2008 1 VAREELITE VL2500 SPOT 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 troubles
86. N CABLES 3 Display Cable Assembly 25 9678 1825 Rev 0 Replace as a complete assembly Refer to Figure 3 64 No Item Qty UM Description 1 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD END 2 4 EA CABLE TIE 0 10 WD 4 LG SMALL 3 1 EA SLEEVE NYLON THIN WALL 6 SCR 1 0 LG 4 0 208 FT SLEEVING 3 8 NOM DIA POLY EXP 5 1 02 FT WIRE 24AWG 4COND TW lt BLK BRN RED ORN gt 6 0 208 FT WIRE 24 AWG 600V 200 DEG C TFE GRN 7 0 958 FT WIRE TUBULAR BRAID 1 8 X 22 LG LK Figure 3 64 Display Cable Assembly 02 9676 0020 A 01 July 2008 121 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Ballast to Controller Cable Assembly 25 9678 0816 Rev Replace as a complete assembly Refer to Figure 3 65 No Item Qty UM Description 1 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END 2 1 EA RECEPT 5 POS MTA100 W POL TAB WHT CLSD END 3 1 EA RECEPT 8 POS MTA100 W POL TAB WHT CLSD END 4 3 67 FT WIRE 24AWG 5COND lt BLK BRN RED GRN WHT gt 2 3 E HT BERN C 3 ML Y pe 4 1 LK Figure 3 65 Ballast to Controller Cable Assembly 122 01 July 2008 02 9676 0020 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Lamp Supply to Relay Cable Assembly 25 9678 0829 Re
87. TIB STROBE2_OUTIA STROBE 2 A 6 B2 10 C3 6 B2 10 C8 gt 717 aH 6 82 10 08 MONETE T m 700M 0 2 7102 101 w 102 083 FXDG OUTIA ZOOM OUTIB ZOOM 1 ZOOM 4 7 D5 10 C3 7 D2 10 B8 gt gt 12 H2 lt 7 02 10 88 ESTO gt EDGE OUT2B dou T 5 7 82 10 88 ooo EDGE OUTTA i EDGE 1D5 10 05 7 82 10 88 ELE RGOBO OUT2A RGOBO OUT2B ams 6061008 De neopo oura GOBO ROTATE 7 D5 10 C5 6 D6 10 C7 gt gt 1919 20 20 6 85 10 D8 ere 10107 OUT ail OUT2B T le 055 pxpe_oue OUTIB E ue TDX OUTTA GOBO INDEX FANS RELAY 4 7 D5 10 C3 6 86 10 C7 5 23 23 24 24 lt 6 D2 10 D8 037 FXDC OUTIA AGOBO OUT SENS mom IDX OUT SENS A 7 85 10 83 gt 27127 lt 6 B2 10 07 SPARE 1 SPARE 2 1 Dos 3 86 2929 Hi lt 3 86 FXDC_OUTIB SPARE TP1 2 lt 7 B5 10 B5 als 481 3 lg slm x Dio FXOC_OUTEA 10 85 14 7185 101 vec D39 FXDC_OUT2B T 4 7 B5 10 B3 lt Dat Z00M_OUTIA L E 7102 10 83 D42 ZOOM_OUTIB A A lt 7 D2 10 85 24V ZOOM QUT2A A lt 7 D2 10 85 D43 ZOOM OUT2B L A lt 7 D2 10 83 VCC VCC 045 EDGE OUTIA A 7 82 10 83 33V D46 EDGE OUTIB m 4 7 82 10 85 as tope y cran ee a 2 8 B5 10 D6 aav CYAN 0 8 CYAN OUTIA Das EDGE OUT2A 8 85 10 D6
88. Testing Testing Software Testing software is available in all Series 2000 luminaires through the luminaire s menu system TEST function For information on specific tests and test parameters see the VL2500 Spot Luminaire User s Manual VL Part no 02 9676 0019 Note After 10 seconds of inactivity the menu display will change to the default state showing the address Lamp The Lamp option is available in the test menu This option sets the lamp intensity to 10096 and will adjust 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 five wire DMX cable 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 arrows to select a parameter to test Step 4 Press Enter to run test 5 Step 5 Press Menu to stop test at any time 12 01 July 2008 02 9676 0020 A MAINTENANCE TROUBLESHOOTING 2 Troubleshooting Error Messages If a problem occurs during luminaire calibration at the end of the calibration sequence the Menu Display will cycle through any applicable error message s one at a time until the end of the list is reached To review the error messages again it will be necessary to access them using the Status funct
89. UTIA PH 7 Y LPH x 3C6 AL phases T3 MAT lt 10 07 10 03 3C3 lt O mass MI 1007 10 03 R109 R R133 uso OUT 7 86080 oUTIB OUT I STROBE OUT B ml lt 10 D7 10 C3 303 lt va ii lt 107 108 L o Ce R110 Lla cns Cha R132 i an 8 RGOBO OUT2A 12 STROBE1_OUT2A ji sce PHASE2 lt 10071003 363 lt PHASE2 1901098 24 pis 241 pls2 s 9080 10071008 P aM STROBEL_OVR B__ amp 19 67 10 03 8119 8118 m R141 R140 a GNpio 2a PWM QUT 8 PWM OUT 12 306 lt GND2 0 4 393 lt GND2 8117 uns cNDos 128 0122 ciar Rigo 1 Ad anos axe ET GNDO7 HE 4 H anos GNpo7 pa La 4 e cos ans nr nos GND6 vec 5 8 8 5 8 8 Y R113 R115 R135 R137 In 24V P84 C102 85 c116 C120 R89 3 3V A3 5 C2 6 C8 7 C8 8IC8 2 5V L vec T es es 24V 24V 1 8V GOBO INDEX en STROBE 2 R125 8 3 8 Es IDX_OUTIA PH_13 ii E E STROBE2_OUTIA PWM PH 9 1 gt x y 366 Eisai um 10 D7 10 03 366 lt 20 mu 19 7 ano R120 8122 2 2 pis 029 R142 R144 _ 21 piss use gt IDXOUTIB 106710165 men a ae STROREE OUT 10103 CI06 10105 R121 1 CI24 0123 R143 Y PWM PH 1
90. X AB nD ADD Din ADD AB Aem 252 2 2 03095 75 VCC vs 24V av v sv Las 8V DRAWNEY FAE CHECKED BY PROJECT ENGR GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT DOC CONTROL COPYRIGHT 2004 Tie SCHEMATIC VL2500 CONTROLLER Size Document Number ev D 14 9676 0730 80 Date Tuesday July 20 2004 SHEET 3 or 10 02 9676 0020 A 01 July 2008 130 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUA REFERENCE FOLD OUTS Main Control Board MCB Schematic continued
91. Yellow Figure 3 16 Crossfade Color Assembly 02 9676 0020 A 01 July 2008 69 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Iris Gobo Motor Assembly 21 9676 0118 Rev D Refer to Figure 3 17 No Item Qty UM Description 1 10 9621 0097 I EA STABILIZER STEPPER GOBO WHEEL 2 10 9667 1111 I EA MOTOR BULKHEAD IRIS GOBO 3 10 9667 0126 1 IRIS CRANK 4 24 9676 1114 I EA PCB ASSY SENSOR VL68 5 44 9676 0116 I EA MOTOR GOBO COLOR WHEEL 6 44 9676 0118 I EA MOTOR IRIS 7 53 6578 0001 1 SCREW 4 40 X 1 8 SET 8 53 6596 0001 3 SCREW 4 40 X 5 16 PPZ 9 53 6597 0001 2 SCREW 4 40 X 3 16 PPZ 10 53 6599 0001 1 EA SCREW 4 40 X 3 8 PFZ 11 55 2203 0001 3 SCREW 4 40 X 1 4 PPZ 12 55 3301 0004 1 EA WASHER 4 FLAT SS 13 55 6512 0001 2 EA WASHER 4 SPLIT LOCK 14 55 6568 0016 1 EA SPRING EXTSN 125 OD 500 LG 018 WIRE DIA SS 15 55 6579 0005 4 EA GROMMET 3 8 HOLE 3 16 ID 16 55 6589 0002 1 EA STANDOFF 1 4 RND 4 40 328 FF ALUM 17 55 6595 0004 3 EA SPACER 3 160D X 171L X 4HOLE ALUM 18 55 6621 0001 3 EA WASHER 4 FLAT ZINC 7 6 E 14 ff 4 1 EU 10 12 1 5 Figure 3 17 Iris Gobo Motor Assembly 70 01 July 2008 02 9676 0020 A
92. able is connected to power source Pan Encoder Fail Luminaire will not pan Pan Encoder Failure MCB pan tilt connector disconnected connect MCB pan tilt connector 48 Pan motor disconnected connect pan motor power Encoder faulty replace pan end of travel encoder sensor assembly 14 01 July 2008 02 9676 0020A MAINTENANCE TROUBLESHOOTING 2 Table 2 2 Troubleshooting Guide Continued Message Symptom Description Possible Cause and Remedy Pan No Luminaire will not pan or Pan Sensor Not Found EOT flag attached to large pulley is not engaging the Sens hits against stop EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth sufficient to engage the sensor beam Pan belt disconnected extremely loose or not installed properly properly install belt between pan motor and large pulley Tilt Luminaire will not tilt Tilt Encoder Failure MCB pan tilt connector disconnected Encoder connect MCB pan tilt connector J8 Fail Tilt motor disconnected connect tilt motor power Encoder faulty replace tilt end of travel encoder sensor assembly Tilt No Luminaire will not tilt or Tilt Sensor Not Found EOT flag attached to large pulley is not engaging the Sens hits against stop EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth
93. all replacement assembly by performing Steps 2 7 in reverse order 18 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 Standard Gobo Color Filter Replacement use of metal gobos in any product may damage the luminaire and could void the N WARNING Users of luminaires should not install or use metal gobos The luminaire s warranty Parts Standard Gobo or Color Filter as required To remove and replace a standard gobo or color filter Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover loosen two captive screws and remove cover It will remain attached by tether Figure 2 3 Note In some cases it is easier to slide bulkhead partially out of head assembly to access gobos filters To do this use 2 Phillips screwdriver to two 6 32 PPZ screws and slide bulkhead upward Figure 2 4 Step 3 Remove CYM crossfade color assembly Step 4 Rotate wheel until required gobo filter is accessible CAUTION Do not touch filters with bare fingers Wear cotton gloves or other covering while replacing Step 5 Using fingers pull gobo filter out of wheel Figure 2 4 Step 6 Noting proper orientation of carrier slot insert new gobo filter into position and push fully into place Step 7 Re install bulkhead if applicable and re install head cover Gobo Color Filter 4 Carrier Slot r Gobo Color Filter Wheel Figure
94. ci n la l mpara estar muy caliente Desconecte la energ a y deje que la l mpara se enfr e antes de reemplazarla 3 Las l mparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e inflamaci n a los ojos Adem s las l mparas de arco operan a alta presi n y muy alta temperatura Si la l mpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las part culas de la l mpara rota que se caen 4 Use protecci n para los ojos cuando vuelve a colocar una l mpara nueva 5 Useun equipo de seguridad apropiado guantes protecci n para los ojos etc cuando trabaje con l mparas da adas 6 Sitoca la l mpara con las manos limpie la l mpara con alcohol desnaturalizado y con tela sin pelusas antes de instalar o volver a conectar la luminaria 7 Cambie la l mpara si est da ada o deformada termicamente ADVERTENCIA INTERFERENCIA RF 1 Este 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 CONSIDERACIONES SOBRE LAS CARACTER STICAS DE LA L MPARA DE ARCO 1 Las l mparas de arco requieren un per odo de tiempo para volver a iluminarse despu s de una interrupci n de energ a o de una severa ca da de voltaje En algunos casos la l mpara se volver a iluminar en forma autom tica despu s que se ha enfriado dependiendo de la configurac
95. dans ce guide et de les mettre en marche 11 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 N 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 D CHARGES LECTRIQUES LES INCENDIES L EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRA NER DES BLESSURES AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE LES INCENDIES 1 Les luminaires VARI LITE ont t con us pour tre utilis s uniquement avec certaines lampes Philips et Osram HID V rifier le type de lampe MSR400 MSR575HR etc avant de remplacer les lampes L installation d un autre type de lampe peut poser un danger 2 Les luminaires peuvent tre fix s sur tout type de surface tant que les directives de montage sont respect es Voir les explications d taill es dans ce guide 3 Neremplacer les fusibles qu avec ceux du m me type ayant les m mes caract ristiques V rifier la distance respecter entre les mat riaux combustibles ou les objets i
96. e en marche la lampe L ON 2 La position Br ler est Universelle x 01 July 2008 02 9676 0020 A FOREWORD 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 A CUIDADO indica posibles da os al producto IN ADVERTENCIA indica posibles lesiones o muerte a las personas LA INFORMACI N GENERAL RELACIONADA A LA PROTECCI N CON TRAGOLPES DE CORRIENTE EL CTRICA INCENDIO EXPOSICI N EXCESIVA A RADIACI N ULTRA VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA INCENDIO 1 Las luminarias han sido dise adas para ser usadas solamente con algunas l mparas HID Philips y Osram Tome nota del tipo de l mpara MSR400 MSR575HR etc antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalaci n Vea las instrucciones detalladas en este manual 3 Reemplaze los fusibles solamente con los del mismo tipo y especificaci n 4 Tome nota de los requ
97. e wheel Figure 2 7 Rotating Gobo Wheel Me 4 40x3 8 OY PFZ Screws CenterScrew lt Do Not Remove Rotating Gobo Sensor PCB Figure 2 7 Rotating Gobo Wheel Removal 22 01 July 2008 02 9676 0020 A MAINTENANCE MAINTENANCE PROCEDURES 2 1 CAUTION Always use anti static precautions when working with PCBs Step 4 Remove rotating gobo sensor PCB by removing two 4 40 1 4 PEZ screws Figure 2 8 4 40x1 4 PFZ Screws Rotating Gobo Sensor PCB Figure 2 8 Rotating Gobo Sensor PCB Replacement Step 5 Install replacement assembly by performing Steps 2 4 in reverse order 02 9676 0020 A 01 July 2008 23 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Edge Motor Assembly Replacement Parts 21 9667 0310 ASSY MOTOR EDGE To remove and replace edge motor assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front assembly Refer to Front Assembly Removal on page 21 Step 3 Cut cable ties which secure edge motor wires to front assembly Edge motor 1s larger of two linear actuator motors Step 4 The rotating gobo wheel obscures one of the screws securing the edge motor assembly to the front assembly At rotating gobo wheel turn gobo wheel until the open frame is over head of obscured screw Figure 2 9 Rotating Gobo Wheel exploded ICI clarity Open Frame of Gobo Wheel Obscured NN Screw COBDWHRE Figure 2 9
98. eitsabstandes der VARIXLITEO Scheinwerfer von brennbarem Material oder beleuchteten Objekten WARNUNG HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK 1 VARIXLITEO Scheinwerfer eignen sich ausschlie lich f r trockene Standorte Regen oder Feuchtigkeit k nnen die Scheinwerfer besch digen 2 Unterbrechen Sie die Stromzufuhr bevor Sie mit der Arbeit an VARIXLITEO Ger ten beginnen 3 Die Ger te sollten nur von qualifiziertem Personal gewartet werden WARNUNG HINWEISE ZUM SCHUTZ GEGEN UV STRAHLUNG 1 Viele VARI LITE Scheinwerfer verwenden einen HID Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 02 9676 0020 A 01 July 2008 vii VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL 2 Esist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen oder Ultraviolettschirme m ssen ausgetauscht werden sofern deren Schutzwirkung durch sichtbare Besch digung 7 B Spr nge oder Schrammen eingeschr nkt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN KORPERVERLETZUNGEN 1 Bei Betrieb sind die Au enfl chen der Scheinwerfer hei Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausr stung Handschuhe Augenschutz etc Bei Betrieb der Scheinwerfer ist die Lampe hei Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abk hlen wenn Sie diese austauschen Bogenlampen senden ultraviolette Strahlen aus die Hautverbrennu
99. emovable Cover Dual Blade d Strobe Assembly Back Cap Lamp Assembly CYM Color Dimmer Bulkhea Fixed Color Fixed Gobo Iris Bulkhead Fan Assembly Removable Cover Front Assembly Contains Lens Barrel and Rotating Gobo Wheel Nose Cover Note This illustration shows current VL2500 components For information on older models please refer to the preceding revision of this manual 02 9678 0020 0 Revision zero 02 9676 0020 A 01 July 2008 7 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Yoke Components The following illustration shows the major sub assemblies that are located the luminaire yoke assembly Head and enclosure not shown for clarity Yoke Arm Cover Fan Assembly Relay Ignitor PCB Yoke Structure e Yoke Arm Cover Tilt side leg Tilt Motor Tilt Side Rotate yoke fully Yoke Leg counter clockwise Board Side Yoke Leg To determine which yoke leg is which without having to remove the covers rotate yoke counterclockwise until it stops then look at the luminaire while facing the input panel The tilt side leg is the leg to the left the board side leg is the leg to the right 01 July 2008 02 9676 0020A DESCRIPTION MAJOR COMPONENTS 1 Enclosure Components The following illustration shows the major sub assemblies that are located in the luminaire enclosure assembly Yoke and head assembly not shown fo
100. erimientos de distancia de materiales combustibles objetos iluminados para las luminarias VARI LITE ADVERTENCIA INSTRUCCIONES PROTECCION CONTINUA CONTRA CHOQUE ELECTRICO 1 Las luminarias est n dise adas solamente para lugares secos La exposici n a la lluvia o humedad pueden da iar la luminaria Desconecte la energ a antes de dar servicio a cualquier equipo de 3 El servicio debe ser realizado solamente por personal calificado 02 9676 0020 A 01 July 2008 xi VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL ADVERTENCIA INSTRUCCIONES CONTINUA CONTRA LA EXPOSICION EXCESIVA DE RADIACION ULTRA VIOLETA 1 Muchas luminarias VARIXLITEO usan un tipo de l mpara HID que produce radiaci n UV NO mire directamente a la l mpara 2 Es peligroso operar luminarias sin lentes o protectores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido da adas y que su efectividad pudiera estar deteriorada Por ejemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTRA LESIONES DE PERSONAS l Las superficies exteriores de las luminarias est n calientes durante su operaci n Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando haga ajustes en el equipo y componentes que est n calientes 2 Cuando las luminarias est n en opera
101. ev Replace as a complete assembly Refer to Figure 3 57 No Item Qty UM Description 1 1 EA LABEL STROBE 1 2 1 EA CONN HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE 3 1 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 4 4 EA CONTACT 24 30 AWG MALE CRIMP 5 4 CONTACT 26 28 AWG FEMALE CRIMP 1 25 MM PITCH REEL 6 1 EA GROMMET 9 32 ID 9 16 OD 1 4TH SILICONE 7 0 92 FT WIRE 26 AWG 4 COND 300V 200 DEG C TEF BLK BRN RED ORN UL1180 E LI X N X F N E E 1 7 3 5 6 112 2 4 Figure 3 57 Strobe 1 Cable Assembly 01 July 2008 02 9676 0020A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Fans Disconnect Cable Assembly 25 9676 0718 Rev G Replace as a complete assembly Refer to Figure 3 58 No Item Qty UM Description 1 1 EA RECEPT 3 POS 100 W POL TAB 24 AWG 2 1 EA CONN HOUSING 2 POS RECEPT 3 1 EA CONN HOUSING 5 POS RECEPT 4 2 EA RECEPT 1 4 FASTON 22 18 AWG 5 7 CONTACT 24 30 AWG FEMALE CRIMP 6 1 EA CABLE TIE 10 X 4 SMALL 7 2 46 FT WIRE 26 AWG 300V 200 DEG C TEFLON RED 8 2 19 FT WIRE 26 AWG 300V 200 DEG C TEFLON GRY 9 2 08 FT WIRE 26 AWG 300V 200 DEG C TEFLON BLK 92 SLEEVING 5 16 NOM DIA WOVEN POLY NOT SHOWN 1 7 9 23 0 each 6 9 2 0 Loopback ED LI gt D n RE 0 1
102. fs to yoke leg Step 7 Disconnect ignitor PCB wires by removing four screws which secure wire ring terminals to PCB and remove ignitor PCB 02 9676 0020 A 01 July 2008 31 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Step 8 Remove two 1 4 standoffs from ignitor by removing one 6 32 5 16 PPZ screw and 6 lock washer Install in same place on new ignitor PCB Figure 2 18 6 32x5 16 PPZ Screw 6 Lock Washer 1 4 6 32 500 LG Standoff 2 Figure 2 18 Ignitor PCB Standoff Removal Step 9 Install replacement assembly by performing Steps 2 17 8 in reverse order 32 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 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 To remove and replace enclosure covers Step 1 Using console or internal menus run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source Step 3 At each top enclosure cover remove two 6 32x1 4 PPB screws and remove cover Figure 2 19 Ballast Side Cover 6 32x1 4 PPB Screw Power Supply 1 Ventilation Cover 1 4 Split Lock Washer 1 4 20x1 2 Socket Screw
103. hooting 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 CST Monday through Friday at the following phone 1 877 VARI LITE 1 877 827 4548 or 1 214 647 7880 fax 1 214 647 8038 email customerservice genlytecontrols com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link Technical Bulletins Technical Notices Technical Bulletins concerning the latest changes to equipment are issued from Vari Lite They are documentation supplements that contain procedures for equipment upgrades retrofits and repairs not found in the existing manuals Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Technical Notices are non procedural documents that contain information regarding product support issues software updates and documentation corrections technical notices begin with the prefix TN and are numbered sequentially Technical Bulletins Software Updates support and other information is available online at http www vari lite com under the Support Section To request access
104. i n del sistema de energ a de la l mpara L ON L OFF L encendida L apagada 2 La posici n de encendido es universal xii 01 July 2008 02 9676 0020 A SAFETY NOTICE J APANESE AN UV HE 1 VARI LITE Phiips Osram HID MSR400 MSRS7SHR
105. ion Refer to Troubleshooting Guide on page 14 for a list of possible causes and remedies associated with the error messages To access error messages Step 1 Press Menu Step 2 Press Up Down arrows until Fixture appears Press Enter Step 3 Press Up Down arrows to access Status Press Enter Display will now scroll through any error messages or display OK if no errors Table 2 1 Error Messages Display Message OK No Errors Found Pan No Sens Pan sensor not found Pan Encoder Fail Pan encoder failure Tilt No Sens Tilt sensor not found Tilt Encoder Fail Tilt encoder failure Index No Sens Gobo Index sensor not found Gobo No Sens Rotating Gobo sensor not found Fixed Gobo No Sens Fixed Gobo sensor not found Dimmer No Sens Dimmer sensor not found Blue No Sens Blue sensor not found Amber No Sens Amber sensor not found Magenta No Sens Magenta sensor not found ColWheel No Sens Color wheel sensor not found Zoom No Sens Zoom sensor not found Edge No Sens Edge sensor not found WARNING As with any repairs or maintenance to luminaires service should only be performed by a trained and qualified service technician or at an Authorized Vari Lite Service facility 02 9676 0020 A 01 July 2008 13 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Troubleshooting Guide If a problem is suspected try recalibrating the luminaire t
106. llumin s et les luminaires AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les luminaires sont con us pour une utilisation au sec uniquement Une exposition la pluie et l humidit risque d endommager le luminaire D brancher l appareil avant de proc der la r vision de tout mat riel 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9676 0020 A 01 July 2008 ix VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL AVERTISSEMENT gt DIRECTIVES POUR SE PROTEGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1 Plusieurs luminaires VARI LITE utilisent une lampe de type HID qui produit des rayons UV NE PAS fixer son regard sur la lampe 2 L utilisation des luminaires sans lentille ou blindage pose des risques Tous blindages lentilles ou crans ultraviolet visiblement endommag s au point que leur efficacit en est affect e doivent tre remplac s par exemple s il y a des fissures ou de profondes rayures AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES ACCIDENTS POUVANT ENTRAINER DES BLESSURES 1 Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour manceuvrer ou ajuster des appareils br lants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 La lampe du luminaire est br lante lorqu il est
107. nada Patents No 2 070 670 2 050 375 1 270 675 1 259 058 Canada Design Patents No 81 234 81 233 76 046 European UK Patents No 0 652 400 0 586 049 0 565 218 0 547 732 0 534 710 0 495 305 0 474 202 0 379 970 0 253 082 0 253 081 0 248 974 0 192 882 Germany Patents No 694 25 943 8 693 14 122 0 692 08 615 3 692 07 692 1 691 31 478 0 691 21 029 2 690 33 385 4 37 89 166 9 37 68 727 1 37 51 804 6 37 50 201 8 35 87 270 5 Germany Design Patents No M 98 01 745 4 M 96 04 515 9 M 96 04 514 0 M 94 07 689 8 94 02 951 2 M 499 03 583 6 498 11 203 9 G 93 12 884 3 Spain Patents No 2 090 191 2 084 289 2 020 960 0 548 328 Spain Utility Model Patent No 2 031 748 Spain Design Patents No 0 137 502 0 137 501 0 133 573 Greece Patent No 910 400 544 Japan Patents No 2 843 696 2 059 669 2 055 324 2 002 168 1 966 525 1 889 481 1 792 721 1 770 241 Japan Design Patents No 985 985 1 985 985 947 552 945 436 1 945 436 1 106 089 1 077 598 1 072 598 1 060 414 1 002 123 Korea Patents No 76 310 42 639 283 770 181 180 Korea Design Patents No 209 896 209 895 Mexico Patent No 180 148 Taiwan Patents No 78 726 66 975 65 380 28 275 United Kingdom Design Registrations No 2082526 2072562 2056387 2056386 2042174 2038212 2033108 2029499 other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companie
108. ngen und Augenentz ndungen verursachen k nnen Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen Temperaturen Sollte die Lampe zerbrechen besteht die Gefahr von K rperverletzung bzw von Feuer das von Lampenteilen ausgel st werden kann Tragen Sie beim Austausch der Lampen einen Augenschutz Die geeignete Sicherheitsausr stung Handschuhe Augenschutz sollte beim Umgang mit besch digten Lampen verwendet werden Wenn die Lampe mit blo en H nden ber hrt wird reinigen Sie sie mit denaturiertem Alkohol und einem flusenfreien Tuch bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen Wenn die Lampe besch digt oder durch Hitzeeinwirkung deformiert ist muB diese ausgetauscht werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse In einer Wohnumgebung kann das Produkt Hochfrequenzst rungen verursachen In diesem Fall m ssen eventuell geeignete Ma nahmen getroffen werden BESONDERHEITEN VON BOGENLAMPEN 1 2 VIII Bogenlampen ben tigen eine gewisse Zeitdauer um nach einem Stromausfall oder einem Spannungsgef lle wieder aufzuleuchten In einigen F llen wird die Lampe nach Abk hlung automatisch wieder aufleuchten je nach der Systemkonfigurationseinstellung des Lampeneinschaltungsstatus L ON LOFF Die Brennposition ist Universal 01 July 2008 02 9676 0020 A FOREWORD Notes de s curit Avant de proc der l installation des produits d crits
109. o prompt an error message Refer to Troubleshooting on page 13 for more information The chart below provides possible causes and remedies for each message Table 2 2 Troubleshooting Guide Message Symptom Description Possible Cause and Remedy n a No response to DMX data DMX Failure MCB connector disconnected check MCB DATA IN connection n a Lamp douses frequently Lamp will not strike Lamp Douse Lamp Strike Failure Fan failure check fans for proper connection and operation Lamp cutout switch disengaged check lamp cutout switches at lamp box and fan ducts Bad lamp replace lamp Low input voltage check input power must be 200 to 264 VAC n a Luminaire behaves oddly Profile Not Matched Profile not set correctly check Setup menu for correct type spot or wash check start DMX address No Sens No control continuous recalibration and or mechanism at wrong position Mechanism failed to find sensor reported for Cyan Yellow Magenta ColWheel Gobo Index Gobo Zoom Dimmer and Edge Motor power not connected connect motor power Sensor not connected connect sensor Movement restricted or impeded remove obstruction check cable routing and or check voltage at MCB test point Luminaire does not power up No power Switch not turned on verify switch is turned on Not plugged in ensure A C c
110. olor Filter Replacement eere 19 Strobe Bulkhead Replacement ss 20 Front Assembly Removal ss 21 Rotating Gobo Sensor Replacement esee 22 Edge Motor Assembly 24 Lens Barrel Assembly Replacement eene 27 XokeAssembIy n aaa hei 29 Tilt Motor Assembly Replacement ss 29 Main Control Board MCB Replacement 30 Ignitor PCB 31 Enclosure Assembly oet 33 Removing Enclosure Covers ss 33 02 9676 0020 A 01 July 2008 XV VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Ballast Module Assembly Replacement Pan Motor Assembly Replacement Pan Encoder Replacement Pan BOT Sensor Replacement Power Supply LVS Replacement Chapter 3 Illustrated Parts Breakdown Drawing Tree VL2500 Series Spot Luminalre Top Assembly VL2500 Included Items Kit VL2500 Spot Luminaire VL2500 Generic Luminaire esee Front Assembly u ua Lens Barrel Assembly as n EE EES Sub Barrel Group 2 Assembly
111. one quarter turn and remove cover It will remain attached by tether Figure 2 6 Step 3 Remove front nose cover by removing two 10 32x1 2 PPB screws one on each side Figure 2 6 Step 4 Cut cable ties which secure zoom optics motor wires to front assembly Zoom optics motor is smaller of two linear actuator motors Step 5 At lens barrel assembly use pliers to hold standoff on edge motor shaft and using 1 4 open ended wrench remove 4 40 SS KEPS nut from end of motor shaft Figure 2 10 Step 6 Disconnect zoom optics motor wire connector from junction connector Figure 2 13 TES Junction Connector HEADMT Figure 2 13 Disconnecting Zoom Optics Motor Wiring 02 9676 0020 A 01 July 2008 27 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Step 7 At front of optical support ring remove three 8 32x3 8 PPZ screws Figure 2 14 Guide Rod 6 Flat Washer 6 32x1 2 PPZ Screw Lens Barrel Assembly Optical Support Ring 8 32x3 8 PPZ Screw Figure 2 14 Lens Barrel Assembly Replacement Step 8 At each side of optical support ring remove two 6 32x1 2 PPZ screws and 6 flat washers Remove optical support ring Step 9 Remove lens barrel assembly by pulling straight out from front assembly along guide rods Step 10 Install replacement assembly by performing Steps 2 9 in reverse order 28 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 Yoke Assembly This section
112. ound Strap Cable Assembly 101 LVS Chassis Ground Cable Assembly 102 Chassis To Yoke Ground Cable 103 Yoke To Head Ground Cable 104 Ignitor To Relay Cable Assembly 105 Tilt Plate Ground Cable Assembly ss 106 Color Gobo T Stat Cable Assembly 107 Color Fixed Bulkheads Cable Assembly 108 Optics Strobe Bulkheads Cable Assembly eee 110 Strobe T1 Cable Assembly tiet t litis 112 Fans Disconnect Cable Assembly enne 113 OT Switch to Reflector Assy Cable Assembly 114 Pan Tilt Control Cable Assembly ss 115 EMI Filter to Power Switch Cable Assembly 117 AC Input Splitter Cable 118 Data I O Link Cable Assembly 120 Display Cable Assembly aa 121 Ballast to Controller Cable Assembly ss 122 Lamp Supply to Relay Cable Assembly 123 DC Output Cable Assembly 124 VL2000 Spot Luminaire Schematics VL2500 Luminaire Wiring Diagram 125 Main Control Board MCB Schematic 128 DMX Input Schematic eterne ente reci eoi e ri eec 138 Solid State Ignitor Schematic eene enne nennen 139 02 9676 0020 A 01 July 2008 xvii VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Notes XVIII 01 July 2008 02 9676 0020 A INTRODUCTION Introduction About This
113. r Up State Lamp ON Lamp OFF system configuration setting 2 Burning position is Universal vi 01 July 2008 02 9676 0020 A FOREWORD Sicherheitshinweise Es ist uBerst 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 Vorsichtsma nahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet A VORSICHT weist auf m glichen Produktschaden hin WARNUNG weist auf m gliche K rperverletzung und Lebensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHER HEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUER BERH HTE UV STRAHLUNG UND KORPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VARIXLITEO Scheinwerfer sind ausschlie lich f r den Einsatz mit bestimmten Philips und Osram HID Lampen geeignet Achten Sie auf den Lampentyp MSR400 MSR575HR etc bevor Sie die jeweiligen Lampen ersetzen Die Installation eines anderen Lampentyps kann gef hrlich sein 2 Scheinwerfer k nnen auf jeder beliebigen Oberfl che montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher St rke Beachten Sie die Einhaltung des erforderlichen Sicherh
114. r clarity E Enclosure Top Covers 700W Arc Ballast Module Fan Assembly Input Panel Assembly containing DMX Input PCB and Menu Display 2 150W 24V 6 3A Power Supply AC Input Cable Requires standard AC power distribution from 100 264 VAC 50 60 Hz 7 to 12 A depending on the supply voltage Enclosure Bottom Ventilation Cover Wire Connection Green Yellow AC Ground Blue AC Neutral Brown AC Line International Harmonized Standard 02 9676 0020 A 01 July 2008 VAREKLITEG VL2500 SPOT LUMINAIRE SERVICE MANUAL Principles of Operation Power and Data Flow Diagram The following diagram shows how data and power are distributed in the luminaire Fix Gobo UV IR Back Cap OT Sw OT Sw Switch Ignitor Bulb 700W Arc Ballast Pan Tilt Travel Travel Sensor Sensor Power o Switch Pan Tilt Encoder Encoder 8 Tilt 6 Low Voltage Supply Display Pan POR PCB Motor J8 J5 J4 J3 Main Control PCB 412 J11 J1 Yoke Fan Head Fan 1 Head Fan 2 Color Sensor 10 01 July 2008 02 9676 0020 A 2 02 9676 0020 Maintenance This chapter contains test service and standard maintenance procedures Testing Troubleshooting Maintenance Procedures 01 July 2008 32ILA IAIS gt VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL
115. r to Figure 3 12 No Item Qty UM Description 1 10 9678 0647 4 EA CLAMP MOUNTING REFLECTOR 2 22 9660 0338 1 EA ASSY DISCONNECT LAMP 3 22 9676 0130 1 EA ASSY REFLECTOR MOUNT 4 41 9660 7021 1 EA ELLIPSOIDAL REFLECTOR LUNED 5 53 6599 0001 2 EA SCREW 4 40 X 3 8 PFZ 6 55 6669 0016 4 EA STANDOFF 1 4 HEX 6 32 M F SS L 0 875 3 1 x4 Figure 3 12 Reflector Assembly 02 9676 0020 A 01 July 2008 61 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Back Cap Assembly 22 9676 0115 Rev E Refer to Figure 3 13 No Item Qty UM 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 5 10 9667 0411 1 EA LAMP CARRIAGE 6 10 9667 0412 1 EA LAMP TILT PLATE 7 12 9676 8112 1 EA BACKCAP MACHINED VL2500 8 22 9638 0129 1 EA TETHER VL6 BACKCAP 9 25 9667 0413 1 EA CABLE ASSY GROUND TILT PLATE 10 52 8231 0005 2 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 11 53 2200 0010 1 EA NUT 10 32 KEPS SS 12 53 2201 0010 2 EA NUT 10 32 HEX SS 13 53 5638 1250 1 EA SCREW 1 4 28 X 1 1 4 CAPTIVE 14 53 6519 0001 2 EA
116. ratches WARNING INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1 Exterior surfaces of the luminaire will be hot during operation Use appropriate safety equipment gloves eye protection etc when handling and adjusting hot equipment and components 2 Luminaires will have a hot lamp when operating Disconnect power and allow lamp to cool before replacing 3 Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at very high temperatures Should the lamp break there can exist a danger of personal injury and or fire from broken lamp particles being discharged Wear eye protection when relamping 5 Appropriate safety equipment gloves eye protection should be used when handling damaged lamps 6 Iflamp is touched with bare hands clean lamp with denatured alcohol and wipe with lint free cloth before installing or powering up the luminaire 7 The lamp shall be changed if it has become damaged or thermally deformed WARNING RF INTERFERENCE 1 This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures ARC LAMP CHARACTERISTIC CONSIDERATIONS l Arclamps require a period of time to relight after a power interruption or a severe voltage dip In some cases lamp will automatically relight after it has cooled depending on Lamp Powe
117. rn captive knob until loose Backcap Assembly Head Assembly Captive Knob N Guide Rod Lamp Figure 2 1 Replacing Lamp Step 3 Slide backcap away from head assembly it will remain attached by tether and lamp wires 16 01 July 2008 02 9676 0020 A MAINTENANCE MAINTENANCE PROCEDURES 2 Note Wear cotton gloves or other covering while servicing lamp Touching lamp glass with bare fingers will leave and may cause the lamp to explode or reduce lamp life If required use alcohol and cotton cloth to thoroughly clean glass portion of lamp Step 4 Remove lamp by pulling straight out of socket Step 5 Install new lamp by pressing into socket Ensure lamp 15 fully seated in socket and parallel to guide rods Lamp can be damaged when inserted through reflector if not parallel to guide rods Step 6 Align guide rods in guide holes and slide backcap into head assembly Re tighten captive knob Step 7 If required reset lamp hour counter as follows Refer to Menu System in VL2500 Spot User s Manual for more information Power up luminaire b At Menu Display press Menu c Press Up Down arrows until Config Configuration appears Press Enter d Press Up Down arrows until Lamp appears Press Enter e Press Up Down arrows to access ResetHrs Press Enter to reset lamp hour f Align lamp Refer to Align for a Flat Field in VL2500 Spot User s Manual Captive
118. rself Vari Lite 10911 Street Dallas Texas 75238 Toll Free 1 877 VARI LITE Tel 214 647 7880 Fax 214 647 8038 www vari lite com 2008 Philips Group All rights reserved Certain products listed in this document may be protected by applicable patents and patents pending Philips will aggres sively defend all of its intellectual property We reserve the right to change details of design materials and finishes
119. s ilom gun DIMMER IN DIMMER H us AMBER DRAWNBY 2 12 FAE GENLYTE CONTROLS 10911 PETAL ST DALLAS TEXAS 75238 am KEN Epes INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED TE pis OR DISCLOSED WITHOUT WRITTEN CONSENT S e PROJECT ENGR is SCHEMATIC VL2500 CONTROLLER DOG CONTROL Su Document Number Rev 14 9676 0730 80 COPYRIGHT 2004 Date Tuesday July 20 2004 sheet 4 or 10 z 7 z 5 z z T 02 9676 0020 A 01 July 2008 131 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUA REFERENCE FOLD OUTS Main Control Board MCB Schematic continued z I 7 z 5 z z szav 24V 24V L 087 091 un PWM3_OUT 1 TILT PHA OUT ans I 4 1003 8 ent QUT 2 PHB OUT 3 M6 4 m2 K 1003 ene PWM3_OUT
120. s or organizations Vari Lite Philips Lighting Controls Division Vari Lite is a Philips group brand 10911 Petal Street Dallas Texas 75238 1 877 VARILITE www vari lite com customerservice genlytecontrols com This manual is for informational use only and is subject to change without notice Philips Group assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual Version as of 01 July 2008 Part number 02 9676 0020 A VL2500 Spot Luminaire Service Manual 2008 Philips Group All Rights Reserved Certain products listed in this document may be protected by applicable patents and patents pending Philips will aggressively defend all of its intellectual property We reserve the right to change details of design materials and finishes 01 July 2008 02 9676 0020 A 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 genlytecontrols com and request a Return Material Authorization 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 da
121. static precautions when working with PCBs Screws Yoke Leg Cover 6 I WY Figure 2 16 MCB PCB Replacement Step 3 Disconnect wiring harness connectors J8 J9 and J11 Step 4 Remove four 4 6 32 screws securing MCB PCB Step 5 Disconnect upper enclosure connectors at back of MCB Step 6 Install replacement assembly by performing Steps 2 5 in reverse order 30 01 July 2008 02 9676 0020A MAINTENANCE MAINTENANCE PROCEDURES 2 Ignitor Replacement Parts 24 9661 1126 PCB ASSY SOLID STATE IGNITOR To replace ignitor PCB Step 1 Disconnect luminaire AC input cable from power source Ignitor PCB E Screws Yoke Leg Cover Yoke cross HI member M Figure 2 17 Ignitor PCB Replacement Step 2 At each yoke leg remove yoke leg cover by removing four 6 32x5 16 PPB screws Figure 2 17 Step 3 Remove MCB PCB See Main Control Board MCB PCB Replacement on page 30 Step 4 At yoke cross member remove four 6 32x3 16 LG PPZ screws and associ ated washers which secure cross member cover to yoke and remove cover These screws are accessible from inside yoke legs A CAUTION Always use anti static precautions when working with PCBs Step 5 At Ignitor PCB remove two accessible screws which secure PCB to yoke leg Step 6 At yoke cross member remove two 6 32x5 16 PPZ screws and washers which secure ignitor PCB standof
122. sufficient to engage the sensor beam Tilt belt disconnected extremely loose or not installed properly properly install belt between tilt motor and large pulley n a Color dimmer or strobe Color Dimmer or Strobe MCB connector disconnected mechanisms will not Failure check MCB connector at J9 and or J11 move n a Zoom Edge mechanism Zoom Edge Failure MCB connector disconnected will not move check MCB connector at J9 and or J11 n a Gobo or iris mecha Gobos or lris Failure MCB connector disconnected nisms will not move check MCB connector at J9 and or J11 n a Self tests will not run or DMX Data Input Detecting DMX data software download does disconnect DMX input cable not work n a Erratic control of lumi DMX Termination No DMX termination or termination not correct naire check DMX terminator 02 9676 0020 A 01 July 2008 15 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly Lamp Replacement Parts 71 2528 0700 LAMP 700 WATT SHORT ARC A WARNING Remove power from luminaire before performing maintenance To replace lamp Step 1 Remove power from luminaire WARNING Lamps will extremely HOT after operation Allow lamp to cool before replacing Step 2 At backcap using slotted screwdriver or fingers tu
123. te of sale as the beginning of the warranty period Once you obtain the RMA pack the product in its original packing material along with copy of your invoice if available and write the number legibly on or near the shipping address label Return the unit freight prepaid to Vari Lite 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 Vari Lite a Philips group brand AII information contained herein is the sole and exclusive property of Philips Group and may not be used disclosed or reproduced in any manner without the prior written consent of Philips Group The information furnished in this manual is for informa tional use only and is subject to change without notice Philips Group and Vari Lite assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual 02 9676 0020 A 01 July 2008 iii VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Compliance Notice CC This equipment has been tested and found to comply with the limits for a Class A 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
124. to the password protected support areas please contact Vari Lite Customer Service at 1 877 827 4548 1 214 647 7880 or customerservice genlytecontrols com 2 01 July 2008 02 9676 0020 A 1 Description This chapter provides an overview of luminaire features components and operations Features Major Components Principles of Operation 02 9676 0020 A 01 July 2008 ADIANIAS VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Features Overview The VL2500 Spot luminaire comes complete with all of the qualities and options designers love from the original Series 2000 fixtures It is still small lightweight and fast with a 700 watt shortarc lamp impressive lumen output and a zoom range from 18 5 to 42 KG 4 Features Color Mixing System three filter cross fading mechanism A fixed color wheel with 11 interchangeable color filters and one open space capable of continuous rotation for additional effects Gobo Wheels One Six position rotating gobo wheel with five rotatable indexable gobo positions and one open position One 12 position wheel providing 11 easily loaded positions and 1 open for user selectable gobo choices Wheel is capable of continuous rotation for additional effects Zoom Optics Zoom angle of 2 3 to one Continuously variable field angle from 18 5 to 42 Programmable over a timed range of 2 seconds to 20 min
125. ure Fan Assembly Back Cap Assembly Assembly 23 9678 0687 Rev 22 9676 0115 Rev E 23 9678 0686 Rev 0 Ballast Module Arc Power LVS Chassis Ground Cable Supply Assembly Assembly 69 9676 0700 Rev 0 Tilt Plate Ground Cable Assembly 25 9667 0413 Rev A 25 9661 1514 Rev A 25 9661 1520 Rev C Color Fixed Bulkheads Cable Assembly Chassis To Yoke Ground 25 9676 0715 Rev F Cable Assembly Optics Strobe Bulkheads Cable Assembly 25 9676 0716 Rev F Pan Tilt Control Cable Assembly 25 9676 0818 Rev B AC Input Splitter Cable Assembly Strobe 1 Cable Assembly 25 9676 0717 Rev B EMI Filter to Power Switch 25 9678 0812 Rev E Cable Assembly Fans Di t Cable Assembl ido E y 25 9678 0811 Rev C Data Link Cable Assembly 25 9678 0813 Rev Ballast to Controller Cable Assembly Display Cable Assembly 25 9678 1825 Rev 0 VL2500 Included Items Kit mds gt DC Output Cable Assembly 28 9676 0001 Rev F 25 9678 0821 Rev E 02 9676 0020 A 01 July 2008 43 OT Switch to Reflector Assy Cable Assembly 25 9676 0719 Rev A VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Top Assembly VL2500 Included Items Kit 28 9676 0001 Rev F Refer to Figure 3 1 No Item Qty UM Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8052 0001 1 EA CARD LIMITED WARRANTY 02 80001 0002 1 EA V
126. utes Edge and Pattern Focus Variable beam focus to soften edges of gobos or spots Beam Size A mechanical iris provides continuous beam size control for both rapid changes and smooth timed beam angle changes in addition to the zoom optics Strobe A high performance dual blade strobe system capable of ultra fast operation Pan Tilt Smooth time controlled continuous motion by way of a three phase stepper motor system e Range Pan 540 Tilt 270 Pan Tilt Accuracy 0 3 resolution Weight 59 2 lbs 26 9 kg 4 01 July 2008 02 9676 0020A DESCRIPTION MAJOR COMPONENTS 1 Major Components External Components The following illustration shows major luminaire components and controls Truss Hook Bracket Assembly Removable Lamp Assembly to access lamp for replacement Upper Enclosure Assembly Head Assembly Yoke Assembly Vertical 5 __ Captive Knob Horizontal gt Cp for lamp access does not adjust Focus beam Beam Adjustment Controls Product Label ID Menu Display and Main Power Switch Controls ACPWR AC IN AC Input Cable Data Thru Data In Input Panel Components 02 9676 0020 A 01 July 2008 5 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL Menu Display The menu system is programmable set
127. v A Replace as a complete assembly Refer to Figure 3 66 No Item Qty UM Description 1 4 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 2 3 EA CABLE TIE 10 WD 4 00 LG SMALL 3 3 19 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 4 3441 FT WIRE 22AWG 300V TEFLON STRANDED 5 34 41 FT WIRE 22AWG WHT 300V TEFLON STRANDED 6 58 FT WIRE 16AWG 300V 105C PVC GRN YEL UL1569 7 1 EA TERM RING 10 16 14 AWG REEL PIDG 8 2 08 FT WIRE TUBULAR BRAID 7 16 9 33 FT HEATSHRINK 1 2 BLACK To Relay 2 x3 From Lamp Supply 4 x7 Figure 3 66 Lamp Supply to Relay Cable Assembly 02 9676 0020 A 01 July 2008 123 VAREELITE VL2500 SPOT LUMINAIRE SERVICE MANUAL DC Output Cable Assembly 25 9678 0821 Rev E Replace as a complete assembly Refer to Figure 3 67 No Item Qty Description 1 1 EA CONN HOUSING SL 156 2 POS 2 1 EA CONN HOUSING SL 156 3 POS 3 2 TERM RING 6 BLUE 12 10 AWG INSRT 4 4 EA CONTACT CRIMP 18 22 AWG SL 156 5 2 EA CONN BUTT SPLICE 16 14 BLUE 150 OD MAX 6 4 EA CABLE TIE 01 x 4 00 SMALL 7 2 08 FT SLEEVING 1 2 NOM DIA POLY EXP BRAID 8 1 58 FT WIRE 18 AWG 300V 105C PVC RED 9 1 58 FT WIRE 18 AWG 300V 105C PVC 10 2 08 FT WIRE 18 AWG HI VOLT RED YOKE LMP 11 2 08 FT WIRE 18 AWG HI VOLT YOKE LMP

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