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VL2500W Serv A.book - Vari-Lite

1. Lamp Power Up State LON L OFF Y 2
2. 3 4 VARI LITE X 7C 13406 O YEYE BR B 72 U B 1 VARI LITB 2 VARI LITE 3 HR ROSE
3. 02 9676 0022 A 04 June 2009 xiii VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL UV 1 VARI LITE UV HID 2 2 1 1 2
4. xiv 04 June 2009 02 9676 0022 A TABLE CONTENTS Table of Contents Chapter 1 Introduction About This Manual ere I doses 1 Additional 1 Customer Service an EE AE A lt lt 2 Technical Bulletins Technical Notices 2 Chapter 2 Description Features cau EE 4 Features saisie er NE 4 Major Components External Components it Getae RS 5 __ 6 Menu Control 6 Head Components 2 nnt et Rte en EE EE 7 Yoke Components a men niet kG 8 Enclosure Components eee e eee PRU Heer 9 Principles of Operation Power and Data Flow 118918 ener nennen 10 Chapter 3 Maintenance Testing Testing SOftWatre enn dantem uota ted ihre ibi ced ade 12 Troubleshooting Error Messages nn nier nen kaa dE d S 525 23252 13 Troubleshooting Guide a anne lt 14 Maintenance Procedures Head ASSemblys cn ec ehren 16 Lamp Replacement cette ernennen eet tas 16 Align Lamp for Flat Field tee EE 18 Fixed Color Bulkhead 19 Standard Color Filter 20 Strobe Bulkhead Replacement ss 21 Front Assembly Removal seen themit 23 Beam Spreader Motor Assembly Replacement
5. 25 Concave Lens Assembly Replacement essent 26 Convex Lens Assembly Replacement nono nonaccnna ns 27 100MM Condenser Lens Assembly 29 Yoke Assembly SRE 31 Tilt Motor Assembly Replacement ss 31 Main Control Board MCB PCB Replacement 32 Ienitor PCB Replacement rte tetto ee Cep 33 02 9676 0022 A 04 June 2009 XV VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL Enclosure Assembly EE EE 35 Removing Enclosure Covers 35 Ballast Module Assembly Replacement oooconnconincnocononoconnnocananonononononnncnnncnn conan 37 Pan Motor Pan Belt Assembly 39 Pan Encoder Replacement ette eerie teer 41 Pan EOT End of Travel Sensor 42 LVS Low Voltage Supply Power Supply Replacement 43 Chapter 4 Illustrated Parts Breakdown Drawing Tree VL2500TM Wash Luminaire tenentes 46 Assembly VL2500 Wash Included Items Kit 48 VE2300 Wash LUminaire turcas lalola a 49 VE2500 Generic Luminaire ES ie osito eee beret 51 Front Wash Assembly sz ae nue made Veget eter tert ete puce ode ste de 53 Concave Diffuser Front Lens Assembly 55 Convex Lens Assembly Sk
6. Lens Assembly Replacement on page 26 Step 4 Remove convex lens assembly Refer to Lens Assembly Replacement on page 27 Note Before removing shaft collets note orientation for use during re installation Step 5 Using 5 64 Allen wrench loosen eight setscrews two each collect and remove four shaft collets and four wave spring washers from lens shafts Figure 2 11 CAUTION Do not touch lens with bare fingers Wear cotton gloves or other covering while replacing Step 6 Remove 100MM condenser lens assembly from lens shafts Step 7 Slide replacement 100MM condenser lens assembly onto lens shafts Step 8 Re install four wave spring washers on lens shafts Step 9 Re install four shaft collets on lens shafts Note Ensure wave spring washers are compressed before tightening shaft collet set Screws Step 10 Slide shaft collet down on lens shaft until wave spring washer is compressed Step 11 Apply Loctite 4242 to threads of setscrews and using 5 64 Allen wrench tighten setscrews to secure shaft collet to base of lens shaft Step 12 Repeat steps 10 and 11 for remaining three shaft collets 02 9676 0022 A 04 June 2009 29 VL2500 WASH LUMINAIRE SERVICE MANUAL 100MM Condenser Lens Assembly Replacement continued 100MM Condenser Lens Assembly Lens Shaft 4 Wave Spring 4 Shaft Collet 4 Convex Lens Assembly Concave Diffuser Lens Assembl
7. No Item Qty UM Description 1 52 6396 2904 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END 2 52 6396 2905 1 EA RECEPT 5 POS MTA100 W POL TAB RED CLSD END 3 73 5122 0259 2 17 FT CBL 22AWG STRND 4COND PVC INSUL 2 1 Figure 3 62 Data I O Link Cable Assembly 02 9676 0022 A 04 June 2009 111 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Display Cable Assembly 25 9678 1825 Rev 0 Refer to Figure 3 63 No Item Qty UM Description 1 52 6396 2406 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD END 2 73 5116 0123 1 02 FT WIRE 24AWG 4COND TW lt BLK BRN RED ORN gt 3 55 2186 0001 4 EA CABLE TIE 10 WD 4 LG SMALL 4 73 7130 0004 0 958 FT WIRE TUBULAR BRAID 1 8 X 23 LG 5 73 6224 0005 0 208 FT WIRE 24AWG 600V 200 GRN 2 5 LG 6 55 6699 0009 2 08 FT SLEEVING 3 8 NOM DIA POLY EXP 7 55 6621 0001 1 EA SLEEVE NYLON THIN WALL 6 SCR 1 0 LG 1 6 3 63 112 Figure 3 63 Display Cable Assembly 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Ballast to Controller Cable Assembly 25 9678 0816 Rev A Refer to Figure 3 64 No Item Qty UM Description 1 52 6396 3002 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END 2 52 6396 3005 1 EA RECEPT 5 POS MTA100 W POL TAB WHT CLSD END 3 52 6396 3008 1 EA RECEPT 8 POS MTA100 W POL TAB WHT CLSD END 4 73 5124 1289 3 67 F
8. Encoder Encoder E Pan EOT Tilt EOT Low Voltage EMI Filter DMX 2 5 5 Main Control J11 Color Sensor Fixed Color Yoke Fan Head Fan 1 2 Magenta Color Sensor 10 04 June 2009 02 9676 0022 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Troubleshooting Maintenance Procedures A WARNING maintenance procedures are to be performed with power removed from the luminaire Never remove cover or backcap while lamp is in operation WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized VARI KLITE Service Center 02 9676 0022 A 04 June 2009 42 AN 11 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Testing 12 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 Wash Luminaire User s Manual VL Part no 02 9676 0021 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 usi
9. 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 and strike counters f Align lamp See Align Lamp for Flat Field on page 18 Captive Knob for lamp access does not adjust beam Vertical Horizontal gt Focus Figure 2 2 Lamp Alignment 02 9676 0022 A 04 June 2009 17 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Align Lamp for Flat Field The design of the optical system is based on a flat field A flat field is one where there is no detectable hot spot After a new lamp is installed it will be necessary to align the lamp to optimize the beam Knobs located at the luminaire s backcap will allow adjustment WARNING Backcap and adjustment knobs will be HOT during lamp operation Wear protective gloves and or use tools to prevent burns To align lamp Step 1 Using internal menus select Lamp test to set beam Refer to VL2500 Wash Luminaire User s Manual for more information If using console set intensity to 100 and adjust diffusion to produce a tight beam Step 2 Position beam on a white wall at a distance of 10 to 20 Step 3 At backcap using Vertical and Horizontal knobs adjust hot spot to center of beam Figure 2 3 Step 4 Using
10. Continued on the next page 46 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN DRAWING TREE 3 Drawing Tree continued Continued from previous page VL2500 Wash Luminaire continued Reflector Assembly 22 9676 1018 Rev B Wash Fan Assembly 22 9676 1090 Rev C Ground Strap Cable Assembly 25 8007 2212 Rev 0 UV IR Window Assembly 22 9676 0140 Rev G Back Cap Assembly 22 9676 0115 Rev E Tilt Plate Ground Cable Assembly 25 9667 0413 Rev A Color Fixed Bulkheads Cable Assembly 25 9676 1715 Rev A Optics Strobe Bulkheads Cable Assembly 25 9676 1716 Rev B Strobe 1 Cable Assembly 25 9676 0717 Rev B Fans Disconnect Cable Assembly 25 9676 0718 Rev G OT Switch to Reflector Assy Cable Assembly 25 9676 0719 Rev A VL2500 Wash Included Items Kit 28 9676 0002 Rev E 02 9676 0022 A Connector Panel Assembly 21 9676 0800 Rev T Connector Panel Assembly Pan Tube Assembly 21 9676 0805 Rev B 21 9678 0880 Rev C DMX Input PCB Pan Motor Assembly Assembly 21 9678 0864 Rev E 24 9663 3895 Rev 0 Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Upper Enclosure Fan AC Input Splitter Cable Assembly Assembly 23 9678 0686 Rev 0 25 9678 0812 Rev E LVS Chassis Ground Cable Data I O Link Cable Assembly Pase 25 9678 0813 Rev A 25 9661 1514 Rev A Display Cable Assembly Chassis To Yoke Ground 25 9678 1825 Rev 0 Cable Assembly 25 9661 1520 Rev
11. EA LABEL SET VL2500 COLOR HARNESS 2 52 6610 0040 1 EA HOUSING 40 POS 26 22 AWG PRELOADED MT RECPT DBL ROW 3 52 6224 1040 1 EA COVER FRONT 40 POS MT LATCHING 4 52 6224 2040 1 EA COVER BACK 40 POS MT 5 52 6396 2603 1 EA RECEPT 3 POS MTA100 W POL TAB BLUE CLOSED END 6 52 6424 0003 1 EA COVER 3 POS CLOSED END STRAIN RELIEF MTA100 7 52 6467 0001 2 EA CONN FEMALE 6 POS 30 24 AWG CRIMP 8 52 6467 0024 10 EA CONTACT SOCKET 30 24 AWG CRIMP REEL PH JST 9 52 6661 0006 4 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 10 52 8387 0001 16 EA CONTACT 26 28 AWG FEMALE CRIMP 1 25 MM PITCH REEL 11 55 2186 0001 6 EA CABLE TIE 0 10 X 4 LG SMALL 12 55 6699 0011 0 67 FT SLEEVING 3 4 NOM DIA WOVEN POLY ROUNDIT 2000 13 55 6706 0001 2 EA GROMMET 9 32 ID 9 16 OD 1 4 SILICONE 14 73 2326 0123 7 88 FT WIRE 26 AWG 4 COND 300 200 DEG C lt BLK BRN RED ORN gt 111180 15 73 2326 3001 1 25 FT WIRE 26 AWG 3 COND 300V 200 DEG C TEF BLK RED WHT BLK UL1180 16 73 2328 6000 1 50 FT WIRE 28 AWG 6 COND 300V 200 DEG C lt BLK WHT BLU WHT YEL WHT BLK WHT PUR RED gt 1 1180 17 52 8351 0004 40 EA CONTACT 26 22 AWG RECPT MTE REEL 02 9676 0022 A 04 June 2009 99 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Color Fixed Bulkheads Cable Assembly contin ued 14 9 10 12 2 8 4 17 16 7 8 S 1 A 14 9 10 lt i Figure 3 5
12. N 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 standoffs 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 0022 A 04 June 2009 33 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Ignitor PCB Replacement continued Step 8 Remove two 1 4 hex standoffs from ignitor PCB by removing one 6 32x5 16 screw and 6 lock washer Install in same place on new ignitor Figure 2 15 6 32 5 16 PPZ Screw 6 Lock Washer 1 4 Hex 6 32 500 LG Standoff 2 Figure 2 15 Ignitor PCB Standoff Removal Step 9 Install replacement assembly by performing Steps 2 through 8 in reverse order 34 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Enclosure Assembly This section provides removal and replacement procedures for components found in the luminaire enclosure assembly Removing Enclosure Covers To gain access to enclosure components it will be necessary to remove the top and bottom covers 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 Ste
13. Tit Side N Rotate yoke fully Yoke Leg N counter clockwise q Board Side 6 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 8 04 June 2009 02 9676 0022 A 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 for clarity Enclosure Top Covers 700W Arc Ballast Module Input Panel Assembly containing DMX Input PCB and Menu Display AC Input Cable Requires standard AC power distribution from 100 264 VAC 50 60 Hz 7 to 12A Enclosure Bottom 4 d i depending on the AC supply voltage Ventilation Cover Wire Connection Green Yellow AC Ground Blue AC Neutral Brown AC Line International Harmonized Standard 02 9676 0022 A 04 June 2009 9 VARFELITES VL2500 WASH 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 Color UV IR Back Cap OT Sw Sw Switch Ignitor Bulb 700W Arc Ballast Pan Tilt Travel Travel Sensor Sensor Power Switch Pan Tilt
14. AC Input Splitter Cable Assembly 25 9678 0812 Rev E Refer to Figure 3 61 No Item Qty UM Description 1 52 6231 0001 1 EA PLUG HOUSING MNLOK PLUG 3 POS 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 52 8231 0008 2 EA TERM SPADE 6 RED 22 16 AWG INSERT 4 52 8392 0001 2 EA RECP FASTON 187 X 0 32 16 14 AWG FLAG DBL 5 52 8270 0001 2 EA CONTACT PIN 20 14 AWG MNLOK REEL 6 52 8314 0001 1 EA PIN GND 20 14 AWG MNLOK 060 130 INS DIA 7 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 8 55 6699 0003 1 50 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 9 73 6016 0009 1 83 FT WIRE 16 AWG 600V 105C PVC WHT UL1015 10 73 6016 0010 1 83 FT WIRE 16 AWG 600V 105C PVC BLK UL1015 11 73 6016 0504 2 08 FT WIRE 16 AWG 600V 105C PVC GRN YEL UL1015 12 73 6018 0009 1 00 FT WIRE 18 AWG 600V 105C PVC WHT UL1015 13 73 6018 0010 1 00 FT WIRE 18 AWG 600V 105C PVC BLK UL1015 02 9676 0022 A 04 June 2009 109 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly continued 4 x2 62 NN 5 10 3 pos 2 1 Note Heatshrink not shown for clarity Figure 3 61 AC Input Splitter Cable Assembly 110 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Data 1 0 Link Cable Assembly 25 9678 0813 Rev A Refer to Figure 3 62
15. TEFLON GRY 20 73 5127 0003 0 83 FT WIRE 26 AWG 300V 200 DEG C TEFLON RED 21 73 5127 0010 0 83 FT WIRE 26 AWG 300V 200 DEG C TEFLON BLK 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Wash Fan Assembly continued Direction of Air Flow SY SAT f 18 gt 74502 j D 18 63 Figure 3 11 Wash Fan Assembly 02 9676 0022 A 04 June 2009 63 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Wash Fixed Color Assembly 21 9676 1120 Rev C Refer to Figure 3 12 No Item Qty UM Description 1 10 9671 0125 1 EA BULKHEAD LIGHT SHIELD COLOR 2 10 9676 1181 1 EA BULKHEAD COLOR 3 21 9676 0119 1 EA ASSY COLOR MOTOR 4 21 9676 4145 1 EA ASSY FILTER WHEEL 5 25 9676 0125 1 EA CABLE ASSY T STAT COLOR GOBO not shown 6 53 2200 0004 1 EA NUT 4 40 KEPS SS 7 53 6522 0001 3 EA SCREW 6 32 X 1 4 PFZ 8 53 6559 0001 1 EA SCREW 4 40 X 1 4 PFZ 9 55 2233 0003 1 EA RETAINER PUSH ON TYPE 10 55 2233 0004 1 EA STUD 1 4 TURN OPR 415L STL Z 11 55 6504 0001 3 EA WASHER 6 LOCK EXT TOOTH 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Wash Fixed Color Assembly continued Z EN A 13 N 2 Z 4 ES 763 E 11 3 1 Figure 3 12 Wash Fixed Color Assembly 02 9676 0022 A 04 June 2009 65 VARFELITES VL2500 WASH LUMINAIRE SERV
16. 6 32 X 1 4 PPZ SEMS 15 53 6687 0375 4 EA SCREW 8 32 X 3 8 PFZ UNDERCUT 16 55 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 17 55 6506 0019 4 EA SPACER 1 2 OD 1 844 LG 0 257 ID RND SS BLK 18 55 6662 0001 2 EA HOLE PLUG 3 4 BRASS W BLK OXID 19 55 6520 0001 4 EA WASHER WAVE SPRING 0 265 ID 0 367 OD 02 9676 0022 A 04 June 2009 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Front Wash Assembly continued Figure 3 4 Front Wash Assembly 54 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Concave Diffuser Front Lens Assembly 21 9671 0492 Rev D Refer to Figure 3 5 No Item Qty UM Description 1 10 9676 1409 1 EA BACK CLAMP CONCAVE LENS 2 10 9671 0421 2 EA LENS GASKET 3 10 9676 0491 1 EA FRONT CLAMP CONCAVE LENS 4 12 9676 0418 1 EA LENS CONCAVE ARRAY MASKED 107MM DIA 5 42 9671 0490 EA LENS FRONT STIPPLE 6 53 6611 0001 4 EA SCREW 6 32 X 1 2 PFB 10 9676 7200 AR EA SPACER LENS ARRAY 4 2 OD 4 0 ID X 039 NOT SHOWN Figure 3 5 Concave Diffuser Front Lens Assembly 02 9676 0022 A 04 June 2009 55 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Convex Lens Assembly 22 9671 0414 Rev E Refer to Figure 3 6 No Item Qty UM Description 10 9676 1419 EA FRONT CLAMP CONVEX LENS 2 10 9676 0420 1 EA BACK CLAMP CONVEX LENS 3 10 9671 0421 2 E
17. 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 TUBE 10 10 9686 0839 3 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 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 20a 10 9678 0757 1 EA STABILIZER 1 377DIA 20b 10 9678 0762 1 EA BRACKET STABLIZER 20c 53 6610 0003 1 EA SCREW 6 32 X 7 16 PPZ 20d 55 6568 0075 1 EA SPRING EXTSN 0 375 OD 1 00 LG 0 041 WIRE DIA 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 0851 1 EA ASSY UPPER ENCLOSURE 02 9676 0022 A 04 June 2009 79 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 26 69 9676 0700 1 EA ASSY BALLAST MODULE 700W ARC SHIELDED 27 23 9678 0686 1 FAN ASSY UPPER ENCLOSURE 28 23
18. PLATE TENSION ADJUST PAN MOTOR 2 22 9661 0608 1 EA ASSY DRIVE PULLEY 2a 10 9661 8640 1 EA CODEWHEEL 90 COUNT 2b 10 9661 0649 TIMING PULLEY 2 GT 17 TOOTH 2c 53 5561 0250 2 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 PCB ASSY PAN TILT ENCODER 5 44 9678 0680 1 MOTOR 3 PHASE SZ 23 HIGH TORQUE 6 53 2203 0001 2 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 44 SPLIT LOCK 9 53 6520 0001 2 SCREW 4 40 X 3 8 PPZ 10 55 6621 0001 4 EA WASHER 4 FLAT ZINC 02 9676 0022 A 04 June 2009 75 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Tilt Motor Assembly continued Detail A Detail 808 7 9 3 10 x2 ios 4 10 x2 Pulley Height Detail amp Installation x4 Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Note Vari Lite recommends that this assembly be replaced as a complete assembly Alth
19. _ 3 2 4 5 6 T RF 1 Class A 1
20. run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source A CAUTION Be careful not to damage lens during next step Step 3 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Step 4 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 5 At encoder PCB remove two 4 40 x 1 4 screws Step 6 Disconnect wiring from encoder board Step 7 Replace by performing Steps 3 through 6 in reverse order Note Make sure the encoder disk passes freely through the optical sensor NOTE Head not shown for clarity Enclosure Bottom View Encoder Disk Encoder Pan Motor Assembly Bottom Cover Figure 2 21 Pan Encoder Replacement 02 9676 0022 A 04 June 2009 41 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL 42 Bottom Cover Pan EOT End of Travel Sensor Replacement Parts 86 7002 0003 To remove and replace pan EOT sensor Step 1 Using console or internal menus run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source CAUTION Be careful not to damage lens during next step Step Step Step Step Step Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface At bottom of enclosure remove four 1 4 20 x 1 2 soc
21. AN Convex Lens Assembly Replacement continued CAUTION Do not touch lens with bare fingers Wear cotton gloves or other covering while replacing Step 4 Remove convex lens assembly from lens shafts Step 5 In replacement convex lens assembly using 1 4 Allen Wrench adjust 8 32 x 2 screw so that screw head is nearly flush with drive bushing plate to create a 0 020 gap between concave and convex lens assemblies Step 6 Slide replacement convex lens assembly and then old concave lens assembly onto lens shafts Step 7 Hold convex and concave lens assemblies together and using 2 Phillips screwdriver re install four 8 lock washers and four 8 32 x 1 2 PPB screws and tighten to keep lens assemblies aligned Step 8 Re install four 6 32 x 3 16 PPB screws and four 6 lock washers securing concave lens assembly to lens support arm Step 9 Using 1 4 nutdriver re install one 4 40 KEPS nut on end of beam spreader motor assembly shaft 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES 100MM Condenser Lens Assembly Replacement Parts 22 9671 0402 To remove and replace 100MM condenser lens assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front internal head assembly Refer to Front Assembly Removal on page 23 Step 3 Remove concave lens assembly Refer to
22. C DC Output Cable Assembly Pan Tilt Control Cable Assembly 25 9676 0818 Rev B EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Ballast to Controller Cable Assembly 25 9678 0816 Rev A Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A 04 June 2009 47 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Top Assembly VL2500 Wash Included Items Kit 28 9676 0002 Rev E 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 8001 0002 EA VARI LITE QUALITY ASSURANCE CERTIFICATE NOT SHOWN 3 02 8052 0001 1 EA CARD LIMITED WARRANTY 4 02 8406 0001 1 EA TAG LAMP NOTICE 5 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 2000 SERIES 09 09 02 6 02 9676 0002 EA UNPACK QUICK START SHEET VL2500 04 9676 0002 2 EA SHIPPING BOX LABELS VL2500 WASH not shown 7 07 9676 0035 1 EA SHIPPING BOX CARDBOARD VL2500 8 08 2500 0001 1 EA CD ROM VL2500 LUMINAIRE 9 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 10 71 2528 0700 1 EA 700 WATT SHORT ARC PHILIPS MSR575HR LAMP Figure 3 1 Included Items Kit 48 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 VL2500 Wash Luminaire 20 9676 0002 Rev Refer to Figure 3 2
23. ELEKTROSCHOCK 1 VARI LITE 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 BERH HTE UV STRAHLUNG 1 Viele VAREKLITEG Scheinwerfer verwenden einen HID Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 02 9676 0022 A 04 June 2009 vii VARFELITEO VL2500 WASH 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 2 B Spr nge oder Schrammen eingeschr nkt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN K RPERVERLETZUNGEN 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 Hautverbrennungen und Augenentz ndungen verursachen k nnen Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen Temperaturen Sollte d
24. Focus knob adjust beam for flattest field Captive Knob for lamp access does not adjust beam Vertical Focus Figure 2 3 Aligning Lamp for Flat Field 18 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Fixed Color Bulkhead Replacement Parts 21 9676 1120 To remove and replace fixed color bulkhead assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover gradually loosen two 8 32 x 1 2 PPB captive screws and remove cover it will remain attached by tether as shown in Figure 2 4 Step 3 At CYM crossfade color bulkhead remove assembly as follows a Disconnect wiring b Remove two 6 32x1 4 PPB screws c Remove assembly Step 4 At fixed color bulkhead turn captive screw one quarter turn to release bulkhead Step 5 At fixed color bulkhead disconnect wiring harness connectors from color wheel motor and color sensor Step 6 Slide bulkhead out of head assembly and then disconnect wiring for thermal switch Captive Screws CYM Crossfade Color Removable Dimmer Bulkhead Cover Fixed Color Bulkhead Figure 2 4 Fixed Color Bulkhead Replacement Step 7 Install replacement assembly by performing Steps 2 through 6 in reverse order 02 9676 0022 A 04 June 2009 19 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Standard Color Filter Replacement Parts Color Filter as required To remove and replace a standard color fi
25. 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 02 2 EA LABEL LOCATION VL2500 LUMINAIRE not shown 4 21 9676 0023 1 EA ASSY FRONT COVER 5 21 9676 0010 1 EA GENERIC LUMINAIRE VL2500 6 21 9676 1006 1 EA ASSY FRONT WASH 7 21 9676 1120 1 EA ASSY FIXED COLOR WASH 8 21 9676 1201 1 EA ASSY CROSSFADE COLOR WASH 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 0115 1 EA ASSY BACK CAP 13 22 9676 0140 1 EA ASSY UV IR WINDOW 14 22 9676 1018 EA ASSY REFLECTOR 15 22 9676 1090 1 EA ASSY FAN WASH 25 9676 0717 EA CABLE ASSY STROBE 1 shown 25 9676 0718 1 EA CABLE ASSY FAN DISCONNECT not shown I 25 9676 0719 EA CABLE ASSY OT SWITCH TO REFLECTOR ASSY not shown 25 9676 1715 EA CABLE ASSY COLOR FIXED not shown A 25 9676 1716 1 EA CABLE ASSY OPTICS STROBE not shown 28 9676 0002 EA INCLUDED ITEMS KIT VL2500 LUMINAIRE not shown 16 53 2200 0006 1 EA NUT KEPS 6 32 SS 17 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB 18 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 19 53 6558 0010 12 EA SCREW 6 32 X 1 4 PPB SEMS 20 53 6625 0001 2 EA SCREW 10 32 X 1 2 PPB 21 53 6682 0022 EA SCREW 8 32 X 3 8 PPZ SEMS 22 55 2178 0001 1 EA ANCHOR CABLE MOUNT 8 SCREW 23 55 6663 0007 1 EA STANDOFF 3 8 RND 1 7
26. PPZ screws and both side covers Figure 2 18 Arc Ballast Front Cover Screws Handle Side Cover 2 d Screws Figure 2 18 Accessing Ballast Module Step 5 Atenclosure bottom remove two 6 32x3 8 PPB screws APS side bracket and front cover from ballast side 02 9676 0022 A 04 June 2009 37 VL2500 WASH LUMINAIRE SERVICE MANUAL Ballast Module Assembly Replacement continued Step 6 At ballast disconnect the following cable assemblies a Lamp wires b ACinput a Control wiring Step 7 Pull lamp wires through ferrite core Step 8 At bottom of enclosure remove three 8 32x3 8 PFZ screws and four 8 32x3 8 PPZ screws which secure ballast module to enclosure Step 9 Remove ballast module Step 10 Install replacement assembly by performing Steps 2 through 9 in reverse order NOTE Some components not shown for clarity Route Lamp to Supply Cable as shown same as original cable assembly Back of Display AC Lamp Supply to Relay 700 Watt Ballast Cable Assembly Assembly Cable must be routed through Ferrite Figure 2 19 Ballast Module Assembly Replacement 38 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Pan Motor Pan Belt Assembly Replacement Parts 21 9678 0864 Pan Motor Assembly 54 2055 0001 Pan Motor Belt To remove and replace pan motor assembly Step 1 Using console or internal menus run lens as far to t
27. WASH LUMINAIRE SERVICE MANUAL Connector Panel Assembly 21 9676 0805 Rev B Refer to Figure 3 23 No Item Qty UM Description 1 10 9678 0852 01 1 EA LAYOUT ENCLOSURE OVERLAY 2 10 9678 0859 1 EA BRACKET INPUT 3 10 9678 0872 1 EA STIFENER DISPLAY BOARD 4 10 9686 0820 1 EA FILLER PANEL DMX CONNECTOR 5 24 9663 3895 1 EA PCB ASSY DMX INPUT 6 24 9678 3825 1 EA PCB ASSY DISPLAY 7 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 8 51 0541 4 EA SCREW 4 X 3 8 H L BLK ZINC PLT 9 53 6558 0009 2 EA SCREW 6 32 X 3 8 PPZ SEMS EXT ZINC PLT a 55 2284 0001 CARD GUIDE SNAP IN 3 LONG NYLON NATURAL he 74 2000 0002 SWITCH ROCKER HIGH CURRENT BLACK 84 4 8 x4 Part of AC Input Cable Assembly Figure 3 23 Connector Panel Assembly 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 DMX Input PCB Assembly 24 9663 3895 Rev 0 Refer to Figure 3 24 No Item Qty UM Description Ref 1 17 9663 3895 1 EA PCBFAB DMX INPUT 2 52 6259 0006 1 EA HEADER 5POS MTA FRCT LOK STRT POST 13 3 52 6625 0006 1 EA CONN RECEPT XLR SPIN FEMALE MT VERTICAL n 4 52 6626 0006 1 EA CONN RECEPT XLR SPIN MALE PC MT VERTICAL 12 5 62 3039 0102 1 1000 250 20 1 1 2 4 02 9676 0022 Figure 3 24 DMX Input Assembly 04 June
28. replace pan motor belt Step 1 Using console or internal menus run lens as far to the rear as possible 02 9676 0022 A 04 June 2009 39 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Step 2 Disconnect luminaire AC input cable from power source Step 3 Ateach top enclosure cover remove two 6 32 x 1 4 PPB screws and remove cover Step 4 Disconnect the following cable assemblies a b C d Disconnect lamp wire from 1202 and 1203 Disconnect DC wire from LVS Disconnect DMX wire from DMX PCB Disconnect Display wire from Display Remove ground wire from chassis Step 5 Remove pan motor assembly See remove and replace motor assem bly on page 39 Step 6 Pass wire through routing hole in chassis Step 7 Remove belt Step 8 Replace by performing steps 2 through 7 in reverse Note Make sure wiring is not pinched during installation When tightening four 10 32x3 4 SCB Cap screws that mount Pan Motor Assembly you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring Bottom Cover NOTE Head not shown for clarity 40 Enclosure Bottom View Pan Belt Pan Motor Assembly Figure 2 20 VL2500 Pan Motor Assembly Replacement 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Pan Encoder Replacement Parts 24 9678 9729 To remove and replace pan encoder Step 1 Using console or internal menus
29. 0 WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21 9678 0864 Rev E Refer to Figure 3 27 No Item Qty UM Description 1 10 9678 0865 1 PLATE PAN MOTOR MOUNT 2 21 9678 0828 1 EA ASSY DRIVE PULLEY PAN 10 9686 8720 1 EA CODEWHEEL 120 COUNT LARGE ID 10 9678 0749 1 EA TIMING PULLEY 2MM GT 17 TOOTH 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET FLAT POINT 3 24 9678 9729 1 EA PCB ASSY VL3000 PAN ENCODER changed 06 27 07 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 4 40 1 062 LG CS changed 05 18 06 88 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan Motor Assembly continued Detail A Pressure Sensitive Adhesive lt 1 3 4 Pas Drive Pulley Detail Installation Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Connector oriented on this side Note Vari Lite recommends that this assembly be replaced as a
30. 00 DEG C TEFLON RED 8 73 5127 0007 2 19 FT WIRE 26 AWG 300V 200 DEG C TEFLON GRY 9 73 5127 0010 2 08 FT WIRE 26 AWG 300V 200 DEG C TEFLON BLK 55 6699 0010 0 92 FT SLEEVING 5 16 NOM DIA WOVEN POLY NOT SHOWN 9 2 0 Loopback 1 6 N 7 9 23 0 each x 5 9 er 8 7 25 7 25 N 7 4 5 N 7 2 0 Loopback N 5 2 pback 8 19 0 4 62 Figure 3 57 Fans Disconnect Cable Assembly 104 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 OT Switch to Reflector Assy Cable Assembly 25 9676 0719 Rev A Refer to Figure 3 58 No Item Qty UM Description 1 52 8271 0010 1 EA FASTON 24 22 AWG NON INSUL 0 016 TAB 110SERIES 3 52 8371 0001 1 EA RECEPT FASTON 24 20 AWG UNINSUL TIN PLT BRS 250 X 0 32 3 73 2624 0008 0 67 FT WIRE 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E 02 9676 0022 A Figure 3 58 OT Switch to Reflector Assy Cable Assembly 04 June 2009 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Pan Tilt Control Cable Assembly 25 9676 0818 Rev B Refer to Figure 3 59 No Item Qty UM Description 1 52 6610 0008 1 EA HOUSING 20 POS 26 22 AWG DBL ROW UNLOADED 2 52 6224 1020 1 EA COVER FRONT 20 POS MT LATCHING 3 52 6224 2020 1 EA COVER BACK 20 POS MT 4 52 6524 0005 2 EA CONN HOUSING 5 POS RECEPT 5 52 6588 0007 2 EA HOUSING 7 POS 250V 3A 2 5 MM PITCH 6 52 70
31. 0164 1 EA WASHER FELT 5 10 9667 0411 1 EA LAMP CARRIAGE 6 10 9667 0412 EA LAMP TILT PLATE 7 12 9676 8112 1 EA MACHINED VL2500 8 22 9638 0129 1 EA VL6 9 25 9667 0413 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 SCREW 4 40 X 5 8 PPZ VL 1 15 53 6525 0001 1 EA SCREW 6 32 X 5 16 PPZ 16 53 6526 0001 2 EA SCREW 6 32 X 5 8 PPZ 17 53 6534 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 SCB 23 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 FT SLEEVING 0 208 ID SILICONE RUBBER COATED FIBERGLASS 25 55 3301 0006 3 EA WASHER 46 FLAT 26 55 3303 0004 2 EA WASHER 4 LOCK INTTOOTH SS 27 55 6540 0001 2 EA WASHER 10 FLAT BRASS 28 55 6568 0017 1 EA SPRING CPRSN 0 480 OD 1 500 LG SS 29 55 6568 0036 2 EA SPRING CPRSN 0 360 OD 690 LG 032 WIRE DIA SS 30 55 6568 0048 2 EA SPRING CPRSN 0 480 OD 1 000 LG SS 31 71 2502 0003 1 EA SOCKET FASSUNG GY9 5 W 905 MM LEADS 32 53 6625 000
32. 07 0001 6 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT 7 52 8346 0001 10 EA CONTACT 24 30 AWG FEMALE CRIMP 8 55 2186 0001 8 EA CABLE TIE 10 X 4 SMALL 9 73 5119 0246 7 08 FT WIRE 24 AWG 3 COND TW 600V 200 DEG C lt RED YEL BLU gt 10 73 5124 1289 7 17 FT WIRE 24 AWG 5 COND 300V 80 DEG C lt BLK BRN RED GRY WHT gt 11 52 8351 0003 16 EA CONTACT 26 22 AWG RECP MTE NOT SHOWN 106 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Pan Tilt Control Cable Assembly continued 4 7 x6 E ao gt 6 x3 5 4 7 5 6 x3 5 Figure 3 59 Pan Tilt Control Cable Assembly 107 04 June 2009 02 9676 0022 A VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Refer to Figure 3 60 No Item Qty UM Description 1 52 8313 0001 2 EA RECEPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 52 8392 0001 2 EA RECEPT FASTON 187 X0 32 16 14 AWG FLAG DBL CRP 3 55 2186 0001 1 EA CABLE TIE 0 10 WD 4 00 LG SMALL 4 73 6016 0009 0 83 FT WIRE 16AWG 600V 105C PVC WHT 1015 5 73 6016 0010 0 83 FT WIRE 16AWG 600V 105C PVC BLK UL1015 2 x2 1 2 4 White 3 White Black Black B Figure 3 60 EMI Filter to Power Switch Cable Assembly 108 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3
33. 1 1 EA SCREW 10 32 X 1 2 PPB 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Back Cap Assembly continued 2302 gt oy 17 x4 Figure 3 10 Back Cap Assembly 02 9676 0022 A 04 June 2009 61 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Wash Fan Assembly 22 9676 1090 Rev C Refer to Figure 3 11 No Item Qty UM Description 1 10 9676 1068 1 EA AIR DUCT FRONT FAN WASH 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 39CFM 6 40 7146 0002 EA DC FAN 3 15 SQ X 1 0 LOW FLOW 7 52 6523 0005 1 EA CONN HOUSING 5 POS PLUG SHROUD 8 52 6524 0002 1 EA CONN HOUSING 2 POS RECEPTACLE 9 52 8346 0001 2 EA CONTACT 24 30 AWG FEMALE CRIMP 10 52 8347 0001 5 EA CONTACT 24 30 AWG CRIMP MALE 11 52 8371 0001 1 EA RECEPT FASTON 20 24 AWG UNINSULATED 12 53 2200 0006 1 EA NUT KEPS 46 32 SS 13 53 5604 0375 8 EA SCREW 4 40 X 3 8 PPSS B 14 53 6558 0010 1 EA SCREW 6 32 X 1 4 LG PPZ BLK 15 53 6596 0001 2 EA SCREW 4 40 X 5 16 PPZ 16 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 17 55 2203 0001 2 EA SCREW 4 40 X 1 4 PPZ 18 55 6616 0008 3 EA STANDOFR 3 8 HEX 8 32 THRD 0 5 LG 19 73 1624 0008 1 FT WIRE 24 AWG 300 200 DEG
34. 2 A SAFETY NOTICE JAPANESE BDV 27 VOR Al T N KR UV 1 VARI LITE Philps Osram HID MSR700HR 2
35. 2009 85 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Refer to Figure 3 25 No Item Qty UM Description 1 52 6274 2313 EA STRAIN RELIEF SKINTOP FLEX TYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG CE MARKED 20A 250 TWIST LOCK MALE LINE 3 WIRE 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 UL 600V 150DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR UL 600V 150DEG C 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60C EURO BLK HD 22 11MM OD 4 x2 2 7 6 HA 3 Figure 3 25 AC Input Pigtail Cable Assembly 86 04 June 2009 02 9676 0022 ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan Tube Assembly 21 9678 0880 Rev C Refer to Figure 3 26 No Item Qty UM Description 1 10 9678 0809 1 EA PAN TOGGLE STOP 2 10 9678 0847 EA WASHER SILICONE 3 10 9678 0848 2 EA WASHER PAN TEFLON 4 12 9678 0891 1 EA PAN 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 6 NIS YY 52 7 L 2 1 2 7 3 2 02 9676 0022 Figure 3 26 Pan Tube Assembly 04 June 2009 87 VARFELITES VL250
36. 312 0001 1 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 73 7101 0009 1 17 FT WIRE 14AWG 15KV 150C SILICONE 41 30 STRANDING 1 Figure 3 51 Ignitor To Relay Cable Assembly 96 04 June 2009 02 9676 0022 ILLUSTRATED PARTS BREAKDOWN CABLES 3 Tilt Plate Ground Cable Assembly 25 9667 0413 Rev A Refer to Figure 3 52 No Item Qty UM Description 1 52 8311 0003 1 EA TERM RING 6 BLUE 14 16 AWG NON INS 2 73 7130 0002 0 21 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED 1 x2 2 Figure 3 52 Tilt Plate Ground Cable Assembly 02 9676 0022 A 04 June 2009 97 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Color Gobo T Stat Cable Assembly 25 9676 0125 Rev B Refer to Figure 3 53 No Item Qty UM Description 1 52 6523 0002 1 EA CONN HOUSING 2POS PLUG SHROUD 2 52 8347 0001 3 EA CONTACT 24 30 AWG MALE CRIMP 3 55 2268 0125 1 00 IN HEATSHRINK 1 8 CLEAR KYNAR 4 63 2047 1105 1 EA THERMOSTAT 105 DEG MOUNT 5 73 3524 1008 0 50 FT WIRE 24 AWG 300V 105 DEG C PVC GRAY 5 8 long each 4 1 2 x2 3 0 5 long each Figure 3 53 Color Gobo T Stat Cable Assembly 98 04 June 2009 02 9676 0022A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Color Fixed Bulkheads Cable Assembly 25 9676 1715 Rev A Refer to Figure 3 54 No Item Qty UM Description 1 04 9676 1715 00
37. 4 Color Fixed Bulkheads Cable Assembly 100 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Optics Strobe Bulkheads Cable Assembly 25 9676 1716 Rev B Replace as a complete assembly Refer to Figure 3 55 No Item Qty UM Description 1 04 9676 1716 00 1 EA LABEL SET VL2500 COLOR HARNESS 2 52 6610 0034 1 EA HOUSING 34 POS 26 22 AWG PRELOADED MT RECPT DBL ROW 3 52 6224 1034 1 EA COVER FRONT 34 POS MT LATCHING 4 52 6224 2034 1 EA COVER BACK 34 POS MT 5 52 6524 0004 2 EA HOUSING 4 POS RECEPT 6 52 6524 0005 1 EA CONN HOUSING 5 POS RECEPT 7 52 6661 0006 1 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 8 52 8346 0001 12 EA CONTACT 24 30 AWG FEMALE CRIMP 9 52 8387 0001 4 EA CONTACT 26 28 AWG FEMALE CRIMP 1 25 MM PITCH REEL 55 2186 0001 4 EA 0 10 4 LG SMALL shown 10 55 2198 0001 0 13 FT HEATSHRINK 1 8 BLACK 11 55 6699 0010 0 92 SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 12 73 2326 0123 5 17 FT WIRE 26 AWG 4 COND 300V 200 DEG C lt BLK BRN RED ORN gt 111180 13 52 8351 0004 34 EA CONTACT 26 22 AWG RECPT MTE REEL 02 9676 0022 A 04 June 2009 101 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Optics Strobe Bulkheads Cable Assy contin ued 1 2 3 4 13 sa gt 11 12 5 8 hte 12 5 8 lt 10 y
38. 5 LG FF 24 55 6669 0017 4 EA STANDOFF 1 4 HEX 6 32 1 062 02 9676 0022 A 04 June 2009 49 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL VL2500 Wash Luminaire continued gt Figure 3 2 VI 2500 Wash Luminaire Top Assembly 50 04 June 2009 02 9676 0022A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 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 CROSSMEMBER HEATSHIELD VL2000 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 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 1 428 X 3 4 HX HD GRD 8 11 53 6517 0001 8 EA SCREW 10 32 X 3 8 PPZ 12 53 6526 0001 1 EA SCREW 6 32 X 5 8 PPZ 13 53 6530 0006 2 EA RIVET POP 1 8 OD X 188 250 G 14 53 6539 0008 5 EA WASHER 1 4 FLAT 15 53 6553 0008 4 EA SCREW 10 32 X 9 16 PFB 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 M
39. 56 5 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 BLUE 150 OD MAX 6 55 2186 0001 4 EA CABLE TIE 01 x 4 00 SMALL 7 55 6699 0003 2 08 FT SLEEVING 1 2 NOM DIA POLY EXP BRAID 8 73 3518 0002 1 58 FT WIRE 18 AWG 300V 105C PVC RED 9 73 3518 0010 1 58 FT WIRE 18 AWG 300V 105C PVC BLK 10 73 7060 0001 2 08 FT WIRE 18 AWG HI VOLT RED YOKE LMP 11 73 7060 0002 2 08 FT WIRE 18 AWG HI VOLT BLK YOKE LMP 1 4 Figure 3 66 DC Output Cable Assembly 02 9676 0022 A 04 June 2009 115 VL2500 WASH LUMINAIRE SERVICE MANUAL Notes 116 04 June 2009 02 9676 0022 A APPENDIX A Technical Bulletins and Notices VL2500 Wash Luminaire Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the VL2500 Wash Luminaire If applicable these improvements have been incorporated into this manual Technical Bulletin Description or Notice S2K 030 Series 2000 and 2500 Lamp Tilt Plate Assembly Replacement Pro cedure S2K 029 VL2500 Spot Wash Strobe Stabilizer Replacement Procedure S2K 027 Series 25007 New Style Ballast Conversion Procedure TN 248 Specified and Approved Lamps for use in VARI LITE Luminaires TN 231 Recommended Spare Parts Kits for VARI LITE Luminaires TN 229 Powering VARI LITE Luminaires From Dimmer Circuits NOT RECOMMENDED Technical Bulletins Technical Notices Software Updates and support and ot
40. 56 Top Cover Assembly ett Re nette eerte ten ertet 57 Bottom Cover Assembly 6 58 ReflectoriAssembly Ju nn ts esae teri tiere dere 59 Back Cap Assembly eee Re e denne ties Pee ds 60 Wash EFan Assembly u uu u endete Eae e eei ni 62 Wash Fixed Color Assembly cna tan 64 Crossfade Color Assembly eter meet 66 Color Motor Assembly EE 68 Color Filter Wheel Assembly ss 69 Strobe Assembly eidem nio 70 UV IR Window Assembly 72 Yoke Yoke Assembly ic savanna Barren an 73 Tilt Motor Assembly u usa net e e ete 75 YokeFan neces 77 Enclosure Upper Enclosure Assembly 79 Connector Panel Assembly 22 2 ni Ire Her La ene 84 DMX Input PCB Assembly u a ar ee alten and 85 AC Input Pigtail Cable Assembly 86 Pan Tube Assist eee secs dus Era RI ER oe ua Pee EE 87 Pan Motor Assembly s e ten nen beads 88 Upper Enclosure Fan Assembly os Sus vdieo ead 90 Pan EOT Sensor Electrical Assembly eese nne 91 xvi 04 June 2009 02 9676 0022 A Note Cables are only available as complete assemblies this section is for reference only TABLE OF CONTENTS The information contained in Cables Ground Str
41. 676 3730 To remove and 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 PTB screws as shown in Figure 2 13 To find board side leg refer to page 8 E CAUTION Always use anti static precautions when working with PCBs Screws Yoke Leg Cover MCB PCB Figure 2 13 MCB PCB Replacement Step 3 Disconnect wiring harness connectors J8 J9 and Step 4 Remove four 4 6 32 x 3 8 PPZ SEMS screws securing MCB PCB Step 5 Disconnect upper enclosure connectors at back of MCB Step 6 Install replacement assembly by performing Steps 2 through 5 in reverse order 32 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Ignitor PCB Replacement Parts 24 9661 3126 To remove and replace ignitor PCB Step 1 Disconnect luminaire AC input cable from power source Ignitor e Screws Yoke Leg Cover Yoke cross member gt Hill Figure 2 14 Ignitor Replacement Step 2 At each yoke leg remove yoke leg cover by removing four 6 32x5 16 PTB screws Figure 2 14 Step 3 Remove MCB See Main Control Board MCB Replacement on page 32 Step 4 At yoke cross member remove four 6 32x3 16 LG PPZ screws and associated washers which secure cross member cover to yoke and remove cover These screws are accessible from inside yoke legs
42. 9678 0687 1 EA ELEC ASSY PAN EOT SENSOR 29 25 9661 1514 1 EA CABLE ASSY CHASSIS GROUND not shown 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 TO 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 EA TERMINAL STRIP 300V 12 AWG 20A 2 POS 40 53 2001 0003 1 EA NUT 10 32 NYLON INSERT 41 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX JAM GRDS ZINC PLT 42 53 2200 0006 4 EA NUT 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 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 4 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 SCREW 4 40 X 3 4 LG PPB 53 53 6558 0009 13 E
43. A LENS GASKET 4 10 9671 0463 1 EA BUSHING CONVEX LENS SLOTTED 5 10 9671 0464 1 EA BUSHING CONVEX LENS DRIVE 6 10 9671 0465 1 EA PLATE DRIVE BUSHING 7 12 9676 0416 1 EA LENS CONVEX ARRAY MASKED 107 DIA 8 53 2202 0006 2 EA NUT 6 32 HEX SS NYLON INSERT 9 53 5808 2000 1 EA SCREW 8 32 X 2 00 LG SCSS CAP 10 53 6542 0001 8 EA SCREW 6 32 X 5 16 PFB 11 53 6608 0750 2 EA SCREW 6 32 X 3 4 LG 12 53 6617 0002 2 EA SCREW 6 32 X 1 PFB 12 x2 6 gt Figure 3 6 Convex Lens Assembly 56 04 June 2009 02 9676 0022A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Top Cover Assembly 22 9676 0008 Rev I Refer to Figure 3 7 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 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 6521 0001 2 EA SCREW 8 32 X 1 2 PPB 10 53 6687 0250 4 EA SCREW 4 40 X 1 4 PFZ THREAD FORMING 1 55 3301 0006 1 EA WASHER 6 FLAT 12 55 6599 0001 2 EA WASHER 10 FLAT BLACK 12 x2 9 x2 Figure 3 7 Top Cover Assembly 02 9676 0022 A 04 J
44. A SCREW 6 32 X 3 8 PPZ SEMS EXT W SHR 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 THK 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 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 No Item Qty UM Description 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 FF STL 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 71 55 2261 0001 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 T
45. Assembly 68 04 June 2009 02 9676 0022A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Color Filter Wheel Assembly 21 9676 4145 Rev A Refer to Figure 3 15 No Item Qty UM Description 1 22 9676 4142 1 EA ASSY WHEEL 12 POSITION FIXED 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 02 9676 0022 A 7 n 4 f FAN 4 gt 6 5 Figure 3 15 Filter Wheel Assembly 04 June 2009 69 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Strobe Assembly 22 9676 0016 Rev H Refer to Figure 3 16 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 MOUN
46. Assembly L 72 04 June 2009 02 9676 0022 Yoke ILLUSTRATED PARTS BREAKDOWN YOKE 3 Yoke Assembly 21 9676 0600 Rev G Refer to Figure 3 18 1 22 9676 8605 1 ASSY YOKE STRUCTURE 2 22 9676 0609 1 55 3 22 9676 0610 1 55 4 23 9650 3327 1 ASSY ELEC RELAY 5 24 9661 3126 1 55 SOLID STATE IGNITOR 25 9676 0030 2 CABLE ASSY IGNITOR TO RELAY not shown 43 0298 2 TOROID CORE ZW 42206 TC not shown 6 53 6525 0001 8 EA SCREW 6 32 X 5 16 PPZ 7 53 6558 0001 3 EA SCREW 6 32 X 3 8 PPZ 8 55 2143 0001 4 EA STANDOFF 1 4 HEX 6 32 1 313 9 55 2150 0002 1 STANDOFF 1 4 HEX 6 32 1 187 10 55 2201 0001 4 EA SCREW 4 40 X 5 16 PFB 11 55 3301 0006 2 EA WASHER 6 FLAT SS 12 55 6538 0001 6 EA WASHER 6 LOCK INTERNAL TOOTH 13 55 6541 0002 2 EA GROMMET 1 ID 1 3 4 OD 1 3 8 GRV DIA RUBBER 14 55 6583 0001 2 STANDOFF 1 4 HEX 6 32 500 LG ALUM 02 9676 0022 A 04 June 2009 73 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Yoke Assembly continued 10 X2 8 X4 Figure 3 18 Yoke Assembly 74 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN 3 Tilt Motor Assembly 22 9676 0610 Rev C Refer to Figure 3 19 No Item Qty UM Description 1 10 9676 7298 1
47. CCION 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 Hlservicio debe ser realizado solamente por personal calificado 02 9676 0022 A 04 June 2009 xi VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL ADVERTENCIA s INSTRUCCIONES PARA PROTECCION 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 dafiadas 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 0jos etc cuando haga ajustes en el equipo y componentes que est n calientes 2 Cuando las luminarias est n en operaci 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 ul
48. HREADED HOLES 4334 75 55 6543 0001 0 146 FT 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 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 EA BUSHING SNAP 750 ID 1 MT HL NYLON BLK 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 AR EA SHIM 1 375 ID 1 875 OD 010 THK 88 55 6799 0002 EA SHIM 1 375 ID 1 875 OD 005 As Required 02 9676 0022 A 04 June 2009 81 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly continued 75 VLA M 5362 4902 28 67 x2 88 as required Part exploded 65 for clarity 2 87 as required Ml Figure 3 21 Upper Enclosure Assembly 82 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Upper Enclosure Assembly continued 80 x2 m X 19 63 4 Figure 3 22 Upper Enclosure Assembly 02 9676 0022 A 04 June 2009 83 VARFELITES 25007
49. ICE MANUAL Crossfade Color Assembly 21 9676 1201 Rev F Refer to Figure 3 13 No Item Qty UM Description 1 10 9676 0230 01 4 EA SPACER COLOR WHEEL 2 10 9676 0230 02 EA SPACER COLOR MOTOR 3 10 9676 0234 1 EA AFT BULKHEAD CROSSFADE COLOR SYSTEM 4 10 9676 0235 5 EA SPACER BULKHEAD COLOR SYSTEM 5 10 9676 0284 1 EA SHAFT COLOR SYSTEM 6 10 9678 0238 EA SPACER 2 BULKHEAD COLOR SYSTEM 7 10 9678 0485 4 EA PULLEY COLOR MOTOR 8 21 9676 0290 EA ASSY MAGENTA COLOR WHEEL 9 21 9676 0291 EA ASSY CYAN COLOR WHEEL 10 21 9676 0292 EA ASSY AMBER COLOR WHEEL 11 21 9676 0293 1 EA ASSY DIMMER WHEEL 12 21 9676 0298 EA ASSY SENSOR PCB BRACKET 12a 10 9676 0272 1 EA SENSOR BRACKET COLOR SYSTEM 125 24 9676 0299 1 EA SENSOR BOARD COLOR 12c 53 6682 0002 3 EA SCREW 4 40 X 1 4 PPZ SEMS 13 21 9676 1236 EA ASSY FAN WASH 14 21 9676 1289 EA ASSY FRONT BULKHEAD DIFFUSER 15 44 9676 0236 4 EA MOTOR COLOR 16 53 2200 0006 4 EA NUT 6 32 KEPS SS 17 53 2200 0008 1 EA NUT 8 32 KEPS SS 18 53 6520 0188 2 EA SCREW 4 40 X 3 16 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 PPB 21 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 22 54 2049 0135 2 EA BELT TIMING MXL 0 08 PITCH 135 GRV 23 54 2059 0001 2 EA BELT TIMING 0 08 PI
50. M PITCH 182 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 WASHER 281 OD 125 ID 032 THK 25 9667 0028 1 EA CABLE ASSY YOKE TO HEAD GROUND NOT SHOWN 02 9676 0022 A 04 June 2009 51 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL VL2500 Generic Luminaire continued 11 x8 24 x4 16 4 Figure 3 3 VL2500 Generic Luminaire Assembly 52 04 June 2009 15 x4 02 9676 0022 ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY Front Wash Assembly 21 9676 1006 Rev A Refer to Figure 3 4 3 No Item Qty UM Description 1 10 9671 0219 4 EA LENS SHAFT 2 10 9671 0223 4 EA SHAFT COLLET 3 10 9671 0313 2 EA LENS SUPPORT ARM 4 10 9676 1347 1 EA WASH LENS BULKHEAD FRONT 5 21 9671 0492 1 EA ASSY CONCAVE DIFF FRONT LENS 6 22 9667 0337 1 EA ASSY 1 4 TURN MOUNTING BRACKET 7 22 9671 0402 EA 100MM CONDENSER LENS ASSY 8 22 9671 0414 1 EA ASSY CONVEX LENS 9 22 9671 0468 1 EA ASSY MOTOR BEAM SPREADER 10 53 2200 0004 3 EA NUT 4 40 KEPS SS 11 53 5558 0188 8 EA SCREW 8 32 X 188 LG SET BRASS UNC 2A 12 53 6521 0001 4 EA SCREW 8 32 X 1 2 PPB 13 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 14 53 6558 0007 12 EA SCREW
51. Manual AN 02 9676 0022 Service PHILIPS VARISLITE VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries VL500 VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 VL3500 Series 500 Series 1000 Series 20007 Series 30007 DICHROXTUNE VARIXBRITE and the Vari Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC VARI LITE products are protected by one or more of the following patents and other pending patent applications worldwide 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 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 Canada
52. Note OPEN positions will have pins loaded for a better mechanical fit Figure 3 55 Optics Strobe Bulkheads Cable Assembly 102 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Strobe 1 Cable Assembly 25 9676 0717 Rev B Refer to Figure 3 56 No Item Qty UM Description 1 04 9676 0716 01 1 EA LABEL STROBE 1 2 52 6523 0004 1 EA CONN HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE 3 52 6661 0006 1 EA CONN RECEPT 6CIR WIRE TO WIRE 1 25 MM PITCH 4 52 8347 0001 4 EA CONTACT 24 30 AWG MALE CRIMP 5 52 8387 0001 4 EA CONTACT 26 28 AWG FEMALE CRIMP 1 25 MM PITCH REEL 6 55 6706 0001 1 EA GROMMET 9 32 ID 9 16 OD 1 4 SILICONE 7 73 2326 0123 0 92 FT WIRE 26 AWG 4 COND 300V 200 DEG C BLK BRN RED ORN gt 111180 3 5 6 7 Figure 3 56 Strobe 1 Cable Assembly 02 9676 0022 A 04 June 2009 103 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Fans Disconnect Cable Assembly 25 9676 0718 Rev Refer to Figure 3 57 No Item Qty UM Description 1 52 6396 2403 1 EA RECEPT 3 POS MTA100 W POL TAB 24 AWG 2 52 6524 0002 1 EA CONN HOUSING 2 POS RECEPT 3 52 6524 0005 1 EA CONN HOUSING 5 POS RECEPT 4 52 8230 0003 2 EA RECEPT 1 4 FASTON 22 18 AWG 5 52 8346 0001 7 EA CONTACT 24 30 AWG FEMALE CRIMP 6 55 2186 0001 1 EA CABLE TIE 0 10 X 4 SMALL 7 73 5127 0003 2 46 FT WIRE 26 AWG 300V 2
53. ORD Sicherheitshinweise Es ist u erst wichtig ALLE Sicherheitsinformationen und hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen bevor Sie die hierin beschriebenen Produkte installieren bzw bedienen Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und 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 K RPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VARI LITE Scheinwerfer sind ausschlie lich f r den Einsatz mit bestimmten Philips und Osram HID Lampen geeignet Achten Sie auf den Lampentyp MSR700HR 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 Sicherheitsabstandes der Scheinwerfer von brennbarem Material oder beleuchteten Objekten WARNUNG HINWEISE ZUM SCHUTZ GEGEN
54. 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 M 94 02 951 2 M 499 03 583 6 M 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 companies or or
55. T WIRE 24AWG 5COND lt BLK BRN RED GRN WHT gt 2 3 4 Figure 3 64 Ballast to Controller Cable Assembly 02 9676 0022 A 04 June 2009 113 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Refer to Figure 3 65 No Item Qty UM Description 52 8245 0001 EA TERM RING 10 16 14 AWG REEL PIDG 2 52 8312 0001 4 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 55 2186 0001 3 EA CABLE TIE 0 10 WD 4 00 LG SMALL 5 55 6699 0003 3 19 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 6 73 3516 0504 0 58 FT WIRE 16 AWG 300V 105 DEG C PVC GRN YEL UL 1569 7 73 7089 0000 34 41 FT WIRE 22 AWG BLK 300V UL1180 TEFLON 19 34 STRANDED 8 73 7089 0009 34 41 FT WIRE 22 AWG WHT 300V 1180 TEFLON 19 34 STRANDED 9 73 7130 0005 2 08 FT WIRE TUBULAR BRAID 7 16 4 2 x2 To Relay From Lamp Supply Figure 3 65 Lamp Supply to Relay Cable Assembly 114 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 DC Output Cable Assembly 25 9678 0821 Rev E Refer to Figure 3 66 No Item Qty UM Description 1 52 6464 0002 1 EA CONN HOUSING SL 156 2 POS 2 52 6464 0003 1 EA CONN HOUSING SL 156 3 POS 3 52 8231 0004 2 EA TERM RING 6 BLUE 12 10 AWG INSRT 4 52 8323 0002 4 EA CONTACT CRIMP 18 22 AWG SL 1
56. TCH 150 GRV 24 55 2179 0008 2 EA SADDLE LOCKING 0 067 HOLE 25 55 6503 0001 5 EA WASHER 8 LOCK INT TOOTH 26 53 6596 0001 4 EA SCREW 4 40 X 5 16 PPZ 27 55 9676 0255 1 EA BELLEVILLE SPRING WASHER SPEC 80500 018 28 55 5559 0250 4 EA SCREW SET CONE POINT 6 32 X 1 4 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 No Item Qty UM Description 29 55 2110 0002 3 EA WASHER 400 OD X 260 ID X 010 THK 30 55 6545 0007 1 EA SCREW 8 32 X 3 8 PFB Detail A Dimmer Magenta Figure 3 13 Crossfade Color Assembly 02 9676 0022 A 04 June 2009 67 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Color Motor Assembly 21 9676 0119 Rev D Refer to Figure 3 14 No Item Qty UM Description 1 10 9621 0097 1 STABILIZER STEPPER WHEEL 2 10 9676 1120 1 COLOR MOTOR BULKHEAD 3 24 9676 1114 1 ASSY SENSOR COLOR GOBO 4 44 9676 0116 1 MOTOR GOBO COLOR WHEEL 2 53 6597 0001 2 SCREW 4 40 X 3 16 PPZ 6 53 6599 0001 1 SCREW 4 40 X 3 8 PFZ 7 55 2203 0001 3 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 SPRING EXTSN 125 OD 500 LG 018 WIRE DIA 9 x2 Note orientation of 2 3 8 x2 motor connection 5 x2 Figure 3 14 Color Motor
57. TING 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 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 EA WASHER 46 FLAT ZINC 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 70 04 June 2009 02 9676 0022 ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Strobe Assembly continued Black Side Note connector orientation on motors 2 Figure 3 16 Strobe Assembly 02 9676 0022 A 04 June 2009 71 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL UV IR Window Assembly 22 9676 0140 Rev G Refer to Figure 3 17 No Item Qty UM Description 1 10 9676 0058 1 EA UV IR FRAME 2 10 9676 0141 1 EA INSULATOR THERMAL SWITCH 3 41 9678 0608 1 EA UV IR FILTER 3 00 X 3 00 4 53 5504 0187 2 EA SCREW 4 40 X 3 16 PPSS 5 55 6569 0001 2 EA WASHER 2 LOCK 6 74 1034 0001 1 EA THERMAL SWITCH 15 315 DEG F OPEN Note Only available in a complete assembly except item 6 Note that tabs must be at a 90 degree angle from assembly when installed E 4 Figure 3 17 UV IR Window
58. aires sont con us pour une utilisation au sec uniquement Une exposition la pluie et l humidit risque d endommager le luminaire 2 D brancher l appareil avant de proc der la r vision de tout mat riel VARI LITE 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1 Plusieurs luminaires utilisent une lampe de type qui produit des rayons UV NE PAS fixer son regard sur la lampe 02 9676 0022 A 04 June 2009 ix VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL 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 PROT GER CONTRE LES ACCIDENTS POUVANT ENTRA NER DES BLESSURES 1 Les surfaces externes du luminaire deviennent br lantes quand l appareil est marche Pour manceuvrer ou ajuster des appareils br lants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 Lalampe du luminaire est br lante lorqu il est en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons u
59. and to provide support How to Reach Us For assistance in your area call the dealer from which your product s were purchased Or Contact an Authorized Service Center Or Contact the Vari Lite Customer Service Department 9am 6pm CST Monday through Friday at the following phone 1 877 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 VARIXLITEO 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 to the password protected support areas please contact Vari Lite Customer Service at 1 877 827 4548 1 214 647 7880 or
60. ap Cable near a eee ut 93 LVS Chassis Ground Cable Assembly 94 Chassis Yoke Ground Cable Assembly 95 Ignitor To Relay Cable Assembly 96 Tilt Plate Ground Cable Assembly rennen 97 Color Gobo T Stat Cable Assembly 98 Color Fixed Bulkheads Cable Assembly 99 Optics Strobe Bulkheads Cable Assembly 101 Strobe 1 Cable Assembl ynni 103 Fans Disconnect Cable Assembly 104 OT Switch to Reflector Assy Cable Assembly 105 Pan Tilt Control Cable Assembly ss 106 EMI Filter to Power Switch Cable Assembly 108 AC Input Splitter Cable Assembly oooococcnonccanccocacinnconaconanononanonan cnn norononncnncnnnncnn noo 109 Data I O Link Cable Assembly 111 Display Cable Assembly tidie kann 112 Ballast to Controller Cable Assembly 113 Lamp Supply to Relay Cable Assembly 114 DE Output Cable Assembly een 115 Appendix A Technical Bulletins and Notices 117 VL2500 Wash Luminaire Technical Bulletins and Notices 117 02 9676 0022 A 04 June 2009 xvii VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL This page intentionally blank xviii 04 June 2009 02 9676 0022 A INTRODUCTION Introduction About This Manual This manual provides descriptions repair procedures and illustrated parts break
61. ay be necessary to gain access to other components To remove and re install front assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 At luminaire remove top and bottom head covers as follows a Attop head cover gradually loosen two 8 32 x 1 2 PPB captive screws and remove cover it will remain attached by tether as shown in Figure 2 4 on page 19 b At bottom head cover gradually loosen three 8 32 x 1 2 PPB captive screws and remove cover Step 3 Remove front nose cover by removing two 10 32x1 2 PPB screws one on each side Remove one screw and disconnect tether for top head cover Captive Screws Removable Cover Front Assembly Front Nose Cover pz screw 2 Figure 2 7 Front Assembly Removal 02 9676 0022 A 04 June 2009 23 VL2500 WASH LUMINAIRE SERVICE MANUAL Front Assembly Removal continued Step 4 At junction connector disconnect edge motor wiring Step 5 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 out of head assembly Step 6 Re install front assembly by performing Step 2 through 5 in reverse order Note While re installing connect wiring harness connection and route wires ensuring no wires are pinched 24 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Beam Spreader Motor Assembly Rep
62. complete assembly Although you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly and cannot be removed intact If you order a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information Figure 3 27 Pan Motor Assembly 02 9676 0022 A 04 June 2009 89 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Upper Enclosure Fan Assembly 23 9678 0686 Rev 0 Refer to Figure 3 28 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 1 2 62 90 Figure 3 28 Upper Enclosure Fan Assembly 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 29 No Item Qty UM Description 52 6524 0006 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 gt Figure 3 29 Pan EOT Sensor Electrical Assembly 02 9676 0022 A 04 June 2009 91 VL2500 WASH LUMINAIRE SERVICE MANUAL Notes 92 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Cables Note Cables are only available as complete assemblies The information contained in this section is for ref
63. 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 V 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 N or if at first level the i current address MENU ENTER Down Decrease Up Increase 6 04 June 2009 02 9676 0022 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 Removable Cover Fan Assembly Removable Cover Front Assembly includes beam spreader Nose Cover Note This illustration shows current VL2500 components For information on older models please refer to the previous versions of this manual 02 9676 0022 A 04 June 2009 7 VL2500 WASH LUMINAIRE SERVICE MANUAL Yoke Components The following illustration shows the major sub assemblies that are located in the luminaire yoke assembly Head and enclosure not shown for clarity Yoke Arm Cover RS Fan Assembly Relay i Relay Yoke Structure Ignitor PCB Tilt Motor
64. customerservice genlytecontrols com 2 04 June 2009 02 9676 0022 A 1 Description This chapter provides an overview of luminaire features components and operations Features Major Components Principles of Operation JO1AY3IS 02 9676 0022 A 04 June 2009 3 VL2500 WASH LUMINAIRE SERVICE MANUAL Features Overview The VL2500 Wash 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 short arc lamp impressive lumen output and a variable field angle from 14 to 55 52 Features Color Mixing System A three filter CYM cross fading mechanism A fixed color wheel with 11 interchangeable color filters and one open space capable of continuous rotation for additional effects Zoom Optics Continuously variable field angle from 14 to 55 52 Intensity Control A coated glass dimmer wheel provides full field dimming designed for smooth timed fades Beam Size A zoomable beam spreader mechanism provides continuous beam size control for both rapid changes and smooth timed beam angle adjustments 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 Range Pan 540 Tilt 270 Pan Tilt Accuracy 0 3 resol
65. downs for all configurations of the VL2500TM Wash Luminaire The manual is intended for use by Vari Lite personnel and by Vari Lite s customers clients WARNING 115 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 VL2500 M Wash Luminaire 20 9676 0002 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 web page for VL2500 series luminaires is available at www vari lite com follow the Support link A separate users manual is available for installation and operation of the VL2500 wash luminaire m VL2500 Wash Luminaire Users Manual 02 9676 0021 02 9676 0022 A 04 June 2009 1 VL2500 WASH LUMINAIRE SERVICE MANUAL Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on h
66. er gradually loosen two 8 32 x 1 2 PPB captive screws and remove cover it will remain attached by tether as shown in Figure 2 4 on page 19 b At bottom head cover gradually loosen three 8 32 x 1 2 PPB captive screws and remove cover Step 3 At CYM crossfade color bulkhead remove assembly as follows a Disconnect wiring b Remove two 6 32x1 4 PPB screws c Remove assembly Step 4 Remove the fixed color bulkhead assembly See Fixed Color Bulkhead Replacement on page 19 for procedure Step 5 Optional to gain direct access to four mounting screws if right angle screw driver is not available Remove front assembly See Front Assembly Removal on page 23 for procedure Step 6 Atstrobe assembly remove six 6 32 x 1 4 PPB SEMS screws Step 7 Disconnect motor wire connectors from motors Step 8 Slide strobe bulkhead assemblyout of head assembly as illustrated in Figure 2 6 on page 22 02 9676 0022 A 04 June 2009 21 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Strobe Bulkhead Replacement continued Step 9 Install replacement assembly by performing Steps 2 through 8 in reverse order Captive Screws Removable P d Top Head Cover Strobe Bulkhead Assembly Removable Bottom Head Cover Figure 2 6 Strobe Bulkhead Replacement 22 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Front Assembly Removal Parts 21 9676 1006 N Note This procedure m
67. erence only Ground Strap Cable Assembly 25 8007 2212 Rev 0 Refer to Figure 3 48 No em pasa n 52 8329 0001 a TERM RING 6 22 16 AWG NON INS 73 7130 0002 0 33 WIRE 7 64 TUBULAR BRAID SILVER PLATED Figure 3 48 Ground Strap Cable Assembly 02 9676 0022 A 04 June 2009 93 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Refer to Figure 3 49 No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL 2 52 8271 0001 1 EA FASTON RECEPT 16 14 AWG REEL 3 73 3516 0504 3 5 IN WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 Figure 3 49 LVS Chassis Ground Cable Assembly 94 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN CABLES 3 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Refer to Figure 3 50 Qty UM Description 1 52 8250 0006 2 TERM 8 RING 10AWG 2 73 7089 0504 15 17 FT WIRE 22AWG 300V 200C TEF GRN YEL UL1180 1 x2 2 7 x 26 0 LG Figure 3 50 Chassis To Yoke Ground Cable Assembly 02 9676 0022 A 04 June 2009 95 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Ignitor To Relay Cable Assembly 25 9676 0030 Rev 0 Refer to Figure 3 51 No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL 2 52 8
68. ganizations Vari Lite 10911 Petal Street Dallas Texas 75238 1 877 VARILITE The information furnished in this manual is for informational use only and is subject to change without notice Please check www vari lite com for latest version Vari Lite assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual All information and graphics are property of Vari Lite 10911 Petal Street Dallas Texas 75238 Version as of 04 June 2009 Part number 02 9676 0022 A VL2500 Wash Luminaire Service Manual 2003 2009 Vari Lite a Philips group company Rights Reserved ii 04 June 2009 02 9676 0022 A FOREWORD How To Obtain Warranty Service A copy of the Vari Lite 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 RMA for warranty service You need to provide the model and serial number of the item being returned a description of the problem or failure and the name of the registered user or organization If available you should have your sales invoice to establish the date of sale as the beginning of the warranty period Once you obtain the RMA pack the product in its original packing material along with a copy of your invoice if available and write the RMA number leg
69. he rear as possible Step 2 Disconnect luminaire AC input cable from power source Step 3 Ateach top enclosure cover remove two 6 32 x 1 4 PPB screws and remove cover Step 4 In each corner from top remove four 6 32 x 3 8 screws CAUTION Be careful not to damage lens during next step Step 5 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Step 6 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 7 Remove pan motor side handle by removing two 10 32x5 8 PPB screws Step 8 Atenclosure bottom remove two 6 32 x 1 4 PPB screws and pan motor side cover Step 9 At side of enclosure remove two 6 32 x 3 8 PFZ screws and two 6 32 KEPS nuts that hold two cable saddles Pull wiring out of way of pan motor Step 10 Loosen but do not remove four 10 32 x 3 4 SCB Cap screws Step 11 Move pan motor assembly toward pan pulley and remove belt Step 12 Remove four 10 32x3 4 SCB Cap screws Step 13 Pull assembly out be mindful of tension springs Step 14 Disconnect wiring Step 15 Replace by performing Steps 3 through 14 in reverse order A Note Make sure wiring is not pinched during installation When tightening four 10 32x3 4 SCB Cap screws that mount Pan Motor Assembly you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring To remove and
70. her information is available online at http www vari lite com and click on the Support tab To request access to the password protected support areas please contact Vari Lite Customer Service at 1 214 647 7880 or 1 877 827 4548 or customerservice genlytecontrols com 02 9676 0022 A 04 June 2009 117 VL2500 WASH LUMINAIRE SERVICE MANUAL Notes 118 04 June 2009 02 9676 0022 A VARISELITE Express yourself Vari Lite 10911 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 04 June 2009 Manual Part Number 02 9676 0022 A 2003 2009 Vari Lite a Philips group company All rights reserved Printed in the U S A
71. ial 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 VARI LITE products conform to the requirements of European council directives as stated above Manual Revision History VERSION DATE First Edition 09 December 2004 Revision A 04 June 2009 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 04 June 2009 02 9676 0022 A FOREWORD Safety symbols used throughout this manual are as follows A CAUTION advising of potential damage to product A WARNING advising of potential injury or death to persons GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELEC TRICAL SHOCK FIRE EXPOSURE TO EXCESSIVE UV RADIATION AND INJURY TO PERSONS CAN BE FOUND BELOW WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1 VARIXLITEO luminaires have been de
72. ibly 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 company information contained herein is the sole and exclusive property of Vari Lite and may not be used disclosed or reproduced in any manner without the prior written consent of Vari Lite The information furnished in this manual is for informational use only and is subject to change without notice Vari Lite assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual 02 9676 0022 A 04 June 2009 iii VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL Compliance Notice FCC C This equipment has been tested and found to comply with the limits for a Class digital device pursuant to Part 15 of FCC Rules These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with Vari Lite system service and safety guidelines may cause harmful interference to radio communica tions Operation of this equipment in a resident
73. ie 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 mu diese ausgetauscht werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse A 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 Lamp ON Lamp OFF Die Brennposition ist Universal 04 June 2009 02 9676 0022 A FOREWORD Notes de s curit Avant de proc der l installation des produits d crits dans ce guide et de les mettre en marche il est extr mement important de lire TOUS les renseignements et TOUTES les directives de
74. ket screws and 1 4 split lock washers and remove ventilation cover At pan sensor remove two 6 32 x 3 8 PPZ screws Disconnect wiring from encoder PCB and remove sensor Replace sensor by performing Steps 3 through 6 in reverse order NOTE Head not shown for clarity Enclosure Bottom View Pan Motor Assembly 4 Figure 2 22 Pan EOT Sensor Replacement 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES LVS Low Voltage Supply Power Supply Replacement Parts 69 3177 0151 To remove and replace LVS power supply Step 1 Disconnect luminaire AC input cable from power source Step 2 At enclosure remove two 6 32 x 1 4 LG PPZ screws from display side cover and remove cover Step 3 At power supply disconnect wiring Location Connector N White AC Wires L Black AC Wires V Red DC Wires V Red DC Wires V Black DC Wires V Black DC Wires Step 4 Remove one 6 32 x 3 8 LG PPZ screw Step 5 Loosen two 6 32 x 3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 Replace by performing Steps 2 through 5 in reverse order Top Cover Power Supply LVS Bottom Cover NOTE Head not shown for clarity Figure 2 23 Power Supply LVS Replacement 02 9676 0022 A 04 June 2009 43 VL2500 WASH LUMINAIRE SERVICE MANUAL Notes 44 04 June 2009 02 9676 0022 A 3 I
75. lacement Parts 22 9671 0468 To remove and replace beam spreader motor assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front internal head assembly Refer to Front Assembly Removal on page 23 Step 3 Disconnect beam spreader motor assembly wire connector from motor harness cable assembly Step 4 Remove two 4 40 KEPS nuts securing motor assembly to bulkhead Step 5 At beam spreader motor assembly using 1 4 open ended wrench and pliers remove one 4 40 KEPS nut from end of motor shaft as shown in Figure 2 8 Step 6 Slide motor forward to clear bulkhead and remove Step 7 Install new motor assembly following Steps 2 through 6 in reverse order 4 40 KEPS Nut 2 Beam Spreader Motor Assembly 4 40 KEPS Nut Figure 2 8 Beam Spreader Motor Assembly Replacement 02 9676 0022 A 04 June 2009 25 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Concave Lens Assembly Replacement Parts 21 9671 0492 remove and replace concave lens assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove front internal head assembly Refer to Front Assembly Removal on page 23 Step 3 Remove four 6 32 x 3 16 PPB screws and four 6 lock
76. llustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500 Wash Luminaire Drawing Tree Top Assembly Yoke Enclosure Cables AN WARNING All maintenance procedures are to be performed with power removed from the luminaire Never remove cover or backcap while lamp is in operation WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized VARI LITE Service Center 02 9676 0022 A 04 June 2009 42 AN 45 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Drawing Tree VL2500 Wash Luminaire VL2500 Wash Luminaire 20 9676 0002 Rev L Front Wash Assembly VL2500 Generic Luminaire 21 9676 1006 Rev A 21 9676 0010 Rev J Concave Diffuser Front Lens Assembly Connector Panel Assembly 21 9671 0492 Rev D 21 9676 0800 Rev T Convex Lens Assembly Continued on the next page 22 9671 0414 Rev E Yoke Assembly Wash Fixed Color Assembly 21 9676 0600 Rev G 21 9676 1120 Rev C Color Motor Assembly Tit Motor Assembly 21 9676 0119 Rev D 22076 DEMO RNS Color Filter Wheel Assembly Ignitor To Relay Cable 21 9676 4145 Rev A Assembly 25 9676 0030 Rev 0 Color Gobo T Stat Cable Assembly 25 9676 0125 Rev B Crossfade Color Assembly 21 9676 1201 Rev F Top Cover Assembly 22 9676 0008 Rev Bottom Cover Assembly 22 9676 0011 Rev E Strobe Assembly 22 9676 0016 Rev H
77. lt 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 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 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 DMX Termination No DMX termination or termination not correct luminaire check DMX terminator 02 9676 0022 A 04 June 2009 15 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly Lamp Re
78. lter Step 1 Disconnect luminaire AC input cable from power source Step 2 At head cover gradually loosen two 8 32 x 1 2 PPB captive screws and remove cover it will remain attached by tether as shown in Figure 2 4 on page 19 Note In some cases it is easier to slide bulkhead partially out of head assembly to access color filters To do this use 2 Phillips screwdriver to turn captive screw one quarter turn and slide bulkhead upward Step 3 At CYM crossfade color bulkhead remove assembly as follows a Disconnect wiring b Remove two 6 32x1 4 PPB screws c Remove assembly Step 4 Rotate wheel until required filter is accessible CAUTION Do not touch filters with bare fingers Wear cotton gloves or other covering while replacing Step 5 Using fingers pull filter out of wheel as illustrated in Figure 2 5 Step 6 Noting proper orientation of carrier slot insert new color filter into position and push fully into place Step 7 Re install CYM crossfade color assembly and re install head cover Color Filter Carrier Slot Color Filter Wheel Figure 2 5 Standard Color Filter Replacement 20 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Strobe Bulkhead Replacement Parts 22 9676 0016 To remove and replace strobe bulkhead assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 At luminaire remove top and bottom head covers as follows a Attop head cov
79. ltraviolets 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 Silalampe a t endommag e ou a une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERFERENCE RF 1 Cetappareil est de Classe A Dans un environnement domestique cet appareil peut causer des interf rences radio et si c est le cas l utilisateur peut avoir prendre des mesures ad quates 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 systeme est r gl pour le statut de mise en marche de la lampe Lamp ON Lamp OFF La position Br ler est Universelle 04 June 2009 02 9676 0022 A FOREWORD Aviso sob
80. ng the Lamp option and pan tilt settings will be restored upon exit of the Lamp feature 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 04 June 2009 02 9676 0022 A MAINTENANCE TROUBLESHOOTING 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 function 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 Dimmer No Sens Dimmer sensor not found Blue No Sens Blue sens
81. or not found Amber No Sens Amber sensor not found Magenta No Sens Magenta sensor not found ColWheel No Sens Color wheel sensor not found WARNING Maintenance repairs and adjustments should only be performed by a quali fied factory trained service technician at an Authorized Service Center 02 9676 0022 A 04 June 2009 13 VL2500 WASH LUMINAIRE SERVICE MANUAL Troubleshooting Guide If a problem is suspected try recalibrating the luminaire to prompt an error message Refer to the Troubleshooting Guide table below for more information This table 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 Douse Fan failure check fans for proper connection and operation Lamp will not strike Lamp Strike Failure 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 100 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 recalibra
82. ough you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly and cannot be removed intact If you order a replacement motor Item 5 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information Figure 3 19 Tilt Motor Assembly 76 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN 3 Yoke Fan Assembly 22 9676 0609 Rev A Refer to Figure 3 20 No Item Qty UM Description 1 10 9676 0646 1 EA FAN TRAY YOKE 2 40 7113 0001 1 EA FAN 24V 80 X 80 X 25 MM 32CFM 3 52 6396 2202 1 EA RECPT 2POS 100 W POL TAB RED CLSD END 4 53 2200 0006 4 EA NUT 6 32 KEPS SS Direction of Air Flow Figure 3 20 Yoke Fan Assembly 02 9676 0022 A 04 June 2009 77 VL2500 WASH LUMINAIRE SERVICE MANUAL Notes 78 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN ENCLOSURE 3 Enclosure Upper Enclosure Assembly 21 9676 0800 Rev T Refer to Figure 3 21 and Figure 3 22 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 6 VL2400 SERIES LUMINAIRES 4 10 9661 1258 1 EA BRACKET APS SIDE 5 10 9661 1358 1 EA AIR SEAL DUCT 6 06 6032 0009 1 EA CABLE MARKER TIE 19 X 7
83. p 3 Ateach top enclosure cover remove two 6 32x1 4 PPB screws and remove cover as shown in Figure 2 16 Ballast Side Cover 6 32x1 4 PPB Screw Power Supply Side Cover Ventilation Cover 1 4 Split Lock Washer 1 4 20x1 2 Socket Screw Figure 2 16 Removing Top and Bottom Enclosure Covers 02 9676 0022 A 04 June 2009 35 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Removing Enclosure Covers continued N CAUTION Be careful not to damage lens during next step Step 4 Carefully lay luminaire on its side as shown in Figure 2 17 Make sure that lens does not come into contact with any surface Figure 2 17 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 36 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Ballast Module Assembly Replacement Parts 69 9676 0700 To remove and replace ballast module assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 At enclosure remove ballast side and ventilation covers Refer to Removing Enclosure Covers on page 35 N Note Throughout this procedure please note different size screws and their respec tive locations Step 3 Remove both handles by removing two 10 32 x 5 8 PPB screws at each Step 4 At enclosure remove eight 6 32 x 3 8
84. placement Parts 71 2528 0700 N WARNING Remove power from luminaire before performing any maintenance To remove and replace lamp Step 1 Remove power from luminaire N WARNING Lamps will be extremely HOT after operation Allow enough time for the lamp to cool before replacing Step 2 At backcap using slotted screwdriver or fingers turn captive knob until loose Backcap Assembly Qe Head Assembly Captive Knob lt Guide Rod Lamp FN J Figure 2 1 Replacing Lamp Step 3 Slide backcap away from head assembly it will remain attached by tether and lamp wires 16 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Note Wear cotton gloves or other covering while servicing lamp Touching lamp glass with bare fingers will leave oil 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 is 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 Wash Luminaire User s Manual for more information
85. re 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 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 MSR700HR 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 requerimientos de distancia de materiales combustibles objetos iluminados para las luminarias VARI LITE ADVERTENCIA INSTRUCCIONES PARA PROTE
86. 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 A 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 ENTRAINER 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 MSR700HR 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 illumin s et les luminaires AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les lumin
87. signed for use only with certain Philips and Osram HID lamps Note lamp type MSR700HR 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 0022 A luminaires are designed for dry locations only Exposure to rain or moisture may damage luminaire Disconnect power before servicing any equipment Servicing to be performed by qualified personnel only 04 June 2009 v VARFELITEO VL2500 WASH LUMINAIRE SERVICE MANUAL WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1 Many VARI LITE luminaires use HID type lamp that produces UV radiation DO 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 scratches WARNING INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1 Exterior surfaces of the luminaire will be hot during opera
88. tion 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 Power Up State Lamp ON Lamp OFF system configuration setting 2 Burning position is Universal vi 04 June 2009 02 9676 0022 A FOREW
89. tion and or mechanism at wrong position Mechanism failed to find sensor reported for Cyan Yellow Magenta ColWheel 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 cable 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 J8 Pan motor disconnected connect pan motor power Encoder faulty replace pan end of travel encoder sensor assembly 04 June 2009 02 9676 0022A MAINTENANCE TROUBLESHOOTING 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 Ti
90. travioletas 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 dafadas 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 dafiada o deformada termicamente ADVERTENCIA INTERFERENCIA RF 1 Este es un producto de Clase 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 configuraci n del sistema de energ a de la l mpara Lamp ON Lamp OFF L encendida L apagada 2 La posici n de encendido es universal xii 04 June 2009 02 9676 002
91. une 2009 57 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Bottom Cover Assembly 22 9676 0011 Rev E Refer to Figure 3 8 No Item Qty UM Description 1 10 9676 8012 1 EA COVER BOTTOM VL2500 2 53 2008 0008 3 EA NUT 8 PUSH 3 53 6521 0001 3 EA SCREW 8 32 X 1 2 PPB 4 53 6599 0001 3 EA WASHER 10 FLAT BLACK NN 4 63 Figure 3 8 Bottom Cover Assembly 58 04 June 2009 02 9676 0022 A ILLUSTRATED PARTS BREAKDOWN TOP ASSEMBLY 3 Reflector Assembly 22 9676 1018 Rev B Refer to Figure 3 9 No Item Qty UM Description 1 10 9678 0647 4 EA CLAMP MOUNTING REFLECTOR 2 12 9660 7073 1 EA ELLIPSOIDAL REFLECTOR SMOOTH COATED 3 22 9660 0338 1 EA ASSY DISCONNECT LAMP 4 22 9676 0130 1 EA ASSY REFLECTOR MOUNT 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 4 1 x4 6 x4 Figure 3 9 Reflector Assembly 02 9676 0022 A 04 June 2009 59 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL Back Cap Assembly 22 9676 0115 Rev E Refer to Figure 3 10 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
92. ution Weight 57 3 lbs 26 1 kg 04 June 2009 02 9676 0022 A 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 ROS Upper Enclosure Assembly Head Assembly Yoke Assembly _ Vertical for lamp access does not adjust beam Horizontal fs Captive Knob Focus Beam Adjustment Controls Product Label ID Menu Display and Main Power Switch Controls DATA IN DATA THRU N Qe SEN MENUENTER AC Input Cable Data Thru Data In Input Panel Components 02 9676 0022 A 04 June 2009 5 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Menu Display The menu system is a programmable set 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 AC PWR ACN DATA IN DATA THRU CGA AFA MENUENTER H 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
93. washers securing concave lens assembly to lens support arm as indicated in Figure 2 9 Convex Lens I Aa an o ope Concave Diffuser Lens Support Arm Lens Assembly Lens Shaft 4 100MM Condenser Lens Assembly Figure 2 9 Concave Lens Assembly Replacement CAUTION Do not touch lens with bare fingers Wear cotton gloves or other covering while replacing Step 4 Remove four 8 32 x 1 2 PPB screws securing concave lens assembly to lens shafts and remove concave lens assembly Step 5 Install replacement concave lens assembly by performing Steps 2 through 4 in reverse order 26 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Convex Lens Assembly Replacement Parts 22 9671 0414 To remove and replace convex lens assembly WARNING maintenance procedures are to be performed with power removed from the luminaire Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove concave lens assembly Refer to Concave Lens Assembly Replacement on page 26 Step 3 Using 1 4 nutdriver remove one 4 40 KEPS nut on end of beam spreader motor assembly shaft see Figure 2 10 Beam Spreader Motor Assembly Lens Shaft 4 100MM Condenser Lens Assembly Convex Lens Assembly Concave Diffuser Lens Assembly Figure 2 10 Convex Lens Assembly Replacement 02 9676 0022 A 04 June 2009 27 VARFELITES VL2500 WASH LUMINAIRE SERVICE MANUAL 28
94. y Figure 2 11 100MM Condenser Lens Assembly Replacement Step 13 Re install convex and concave lens assemblies 30 04 June 2009 02 9676 0022 A MAINTENANCE MAINTENANCE PROCEDURES Yoke Assembly This section provides removal and replacement procedures for components found in the luminaire yoke assembly Tilt Motor Assembly Replacement Parts 22 9676 0610 To remove and replace tilt motor assembly Step 1 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 PTB screws Figure 2 12 To find tilt side leg refer to page 8 Tilt Motor Assembly Screws Leg Cover X L Wf y Standoff y Figure 2 12 Tilt Motor Assembly Replacement Step 3 At pan tilt encoder mounted behind tilt motor mounting plate disconnect two cable connectors gt Step 4 At tilt motor disconnect motor wire connector AN Step 5 Remove 6 32 screw securing cable saddle and then using 1 4 nutdriver remove 1 4 hex standoff 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 Step 7 Install replacement assembly by performing Steps 2 through 6 in reverse order 02 9676 0022 A 04 June 2009 31 VARFELITES 25007 WASH LUMINAIRE SERVICE MANUAL Main Control Board MCB PCB Replacement Parts 24 9

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