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VARI*LITE VL500 Wash Luminaires Service Manual Rev. A

1. BE km UV 645 1 VARI LITE RE 2
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3. 6 7 RF 1 Class A 1 Lamp Power Up State 2 21 May 2009 02 9685 0010 A TABLE OF CONTENTS Table of Contents Introduction Disclosure enn nere Me re L lt 1 About This Manual z
4. 3 4 VARIKLITE 1 _ _ 2 VARI LITE 3 02 9685 0010 A 21 May 2009 xiii VARFKLITE VL500 LUMINAIRE SERVICE MANUAL UV 1 VARI LITE UV HID 2
5. No Item Qty UM Description 1 52 6400 0020 1 EA PLUG 17 14 REV SEX CPC 600V KEY A 2 52 6400 0120 1 EA PLUG 17 9 REV SEX CPC 600V KEY 3 52 6431 0002 2 EA BACKSHELL CPC17 NYLON 0 300 0 525 CBL RNG 4 52 8201 0005 4 EA GOLD 24 20 AWG TYPE 3 REEL 0 04 0 08 INS DIA 5 52 8201 0007 4 EA SOCKET GOLD 24 20 AWG TYPE 3 REEL 0 04 0 08 INS DIA 6 52 8341 0001 3 PIN GOLD 18 14 AWG TYPE 3 REEL 0 11 0 15 INS DIA 7 52 8342 0001 3 EA SOCKET GOLD 18 14 AWG TYPE 3 REEL 0 11 0 15 INS DIA 8 52 8344 0006 2 EA PIN CPC POWER 14 AWG 23A LOOSE 9 52 8344 0008 2 EA SOCKET CPC POWER 14 AWG 234 LOOSE 10 73 7087 0013 5 00 CABLE COMPOSITE V500 ARC POWER INPUT 168 21 May 2009 02 9685 0010A VL500 Arc Ballast Interconnect Cable Assem bly Continued III ml Pinout Pin Wire Description 1 OPEN N A 2 OPEN N A 3 GRN 16 AWG GROUND 4 BLK 16 AWG POWER HOT 5 DRAIN 22 AWG DRAIN WIRE 6 OPEN N A 7 WHT 16 AWG NEUTRAL 8 WHT 22 AWG DATA 9 BLK 22 AWG DATA 10 RED 22 AWG DATA 11 OPEN N A 12 ORN 14 AWG LAMP POWER 13 OPEN N A 14 VIOL14 AWG LAMP POWER ILLUSTRATED PARTS BREAKDOWN 3 10 Pinout Pin Wire Description 1 VIOL14 AWG LAMP POWER 2 GRN 16 AWG GROUND 3 ORN 14 AWG LAMP POWER 4 BLK 16 AWG POWER HOT 5 DRAIN 22 AWG DRAIN WIRE 6 WHT 16 AWG NEUTRAL gt WHT 22 AWG NEUTRAL 8 BL
6. No Item Qty UM Description 28 54 2065 0001 1 EA BELT TIMING S2M 252 GROOVE 29 55 2203 0001 4 EA SCREW 4 40X1 4 PPZ 30 55 3301 0008 8 EA WASHER 8 FLAT SS 31 55 3301 0010 1 EA WASHER 10 FLAT 32 55 6543 0001 24 IN GROMMET STRIP SERRATED 0 062 33 55 6568 0056 1 EA SPRING CPRSN 0 600 OD 0 080 WIRE 34 55 6568 0058 1 EA SPRING CPRSN 0 600 OD 0 085 WIRE 625 LG 35 55 6669 0005 6 EA STANDOFF 6 32 X 0 500 LG 1 4 HEX 36 69 3178 0121 1 EA POWER SUPPLY 120V 24V 3X5 132 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 80V Yoke Assembly continued Figure 3 40 VL500 80V Yoke Assembly 02 9685 0010 A 21 May 2009 133 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Yoke Assembly continued 20 x4 30 x4 D Figure 3 41 VL500 80V Yoke Assembly 134 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Extra Hardware Kit 28 9685 0999 Rev 0 Note This kit contains addtional US standard hardware that may be difficult to find outside North America It is packaged into the foot of the fixture underneath the pan tube cover Refer to Figure 3 43 No Item Qty UM Description 1 07 5044 0002 1 EA BAG 4 MIL X 2 X 3 ZIP PRESS POLYETHYLENE 2 53 6608 0001 4 EA SCREW 6 32X3 8 PFB 3 53 6523 0013 4 EA SCREW 6 32X3 8 PTB 4 53 6558 0001 4 EA SCREW 6 32X3 8 PPZ 5 53 6558 0009 4 EA SCREW 6 32X3 8 PPZ SEMS 6 5
7. No Item Qty UM Description 1 10 9634 0103 3 EA PAD REFLECTOR MOUNT 2 10 9685 0343 3 EA CLIP REFLECTOR 3 10 9685 0345 2 EA CLIP SOCKET VL500A AND VL500 80V ONLY 4 10 9685 0360 1 EA FOAM HEATSINK LIGHT LEAK 5 12 9685 0335 1 EA HEATSINK MACHINED CASTING 6 12 9685 0337 1 EA BACKCAP INCANDESCENT MACHINED CASTING VL500 ONLY 7 12 9685 0339 1 EA BACKCAP ARC MACHINED CASTING VL500A AND VLS00 80V ONLY 8 12 9685 0346 1 EA BACKCAP EXTENSION HEATSINK MODIFIED VL500A AND 500 80V ONLY 9 22 9685 0215 1 EA LIGHT BAFFLE REFLECTOR 10 23 9685 0780 1 EA ASSY VLS00 LAMP SOCKET HIGH TEMP VL500 ONLY 25 9685 0766 1 EA 700W ARC LAMP WIRES IGNITOR TO SOCKET VL500A ONLY NOT SHOWN 25 9685 0793 1 EA 80V LAMP WIRE HARNESS VL500 80V ONLY NOT SHOWN 25 9685 0777 1 EA CABLE ASSY BACKCAP GROUND NOT SHOWN 11 42 9685 7190 1 EA REFLECTOR PARABOLIC 12 53 6515 1000 3 EA SCREW 10 32X1 LG SCB VLS00 80V ONLY 13 53 6543 0002 3 EA SCREW 6 32X1 8 LG PPB 14 53 6558 0007 2 EA SCREW 6 32X1 4 LG PPZ SEM VL500 ONLY 15 53 6575 0010 4 EA SCREW 8 32X1 2 LG PPZ SEM 16 53 6682 0022 2 EA SCREW 8 32X3 8 LG PPZ SEM VL500A AND VL500 80V ONLY 17 53 6594 0001 3 EA SCREW 10 32X1 1 2 LG PPB VL500A ONLY 18 54 1226 0001 1 EA ASSY LATCH 19 55 2203 0002 2 EA SCREW 4 40X 1 4 LG PPB 20 55 2132 0013 3 EA STANDOFF 1 4 HEX X 0 218 LG 6 32 MF 21 55 6568 0022 3 EA SPRING CPRSN 0 300 OD 1 25 LG
8. No Item Qty UM Description 1 52 8329 0001 1 TERM RING 6 RED 22 16 AWG NON INSUL 2 52 8329 0003 1 EA TERM RING 8 RED 22 16 AWG NON INSUL 3 73 7130 0002 1 17 FT WIRE 7 64 TUBULAR BRAID SILVER PLATED 3 Figure 3 77 VL500 Backcap Ground Cable Assembly 02 9685 0010 A 21 May 2009 177 VAREELITE VL500 LUMINAIRE SERVICE MANUAL LVS Fan Cable Assembly VL500 VL500D VL500A 25 9685 0778 RevA Refer to Figure 3 78 178 No Item Qty UM Description 1 52 6234 0001 2 EA CONN HOUSING 4 PIN MTA CLOSED END BLUE 2 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 3 73 2326 0123 2 67 FT WIRE 26 AWG 4 COND 300V 200 DEGC TEF lt BLK BRN RED ORN gt UL1180 1 x2 Figure 3 78 LVS Fan Cable Assembly VL500 VL500D VL500A 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 MCB Yoke Ground Cable Assembly 25 9685 0782 Rev 0 Refer to Figure 3 79 No Item Qty UM Description 1 52 8231 0005 2 EA TERM RING 6 16 14 AWG REEL PIDG 2 73 6014 0011 2 5 FT WIRE 14 AWG 600V 200 DEGC FEP GRN STRAND 168 36 0 104 DIA 1 2 Figure 3 79 VL500 MCB Yoke Ground Cable Assembly 02 9685 0010 A 21 May 2009 179 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Arc Yoke Lamp Cable Assembly VL500A 25 9685 0783 Rev B Refer to Figure 3 80 No Item Qty UM Description 1 52 8244 0001 2 EA REC
9. est n dise adas solamente para lugares secos La exposici n a la lluvia o humedad pueden da iar la luminaria 2 Desconecte la energ a antes de dar servicio a cualquier equipo de 3 El servicio debe ser realizado solamente por personal calificado ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA LA EXPOSICION EXCESIVA DE RADIACION ULTRA VIOLETA 1 Muchas luminarias usan un tipo de l mpara HID que produce radiaci n UV NO mire directamente a la l mpara 02 9685 0010 A 21 May 2009 xi VAREELITE VL500 LUMINAIRE SERVICE MANUAL 2 Es peligroso operar luminarias sin lentes o protectores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido dafadas y que su efectividad pudiera estar deteriorada Por ejemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTRA LESIONES DE PERSONAS 1 Las superficies exteriores de las luminarias est n calientes durante su operaci n Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando haga ajustes en el equipo y componentes que estan 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 enfrie antes de reemplazarla 3 Las l mparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e infla
10. NOTE Some components not shown for clarity 8 32x7 16 PPZ Tilt Motor Assembly Tilt Motor Slide Plate Spring 8 32x7 16 PPZ Figure 29 Tilt Motor Assembly Replacement Step 8 Press motor towards spring to loosen belt tension Step 9 Remove belt from both drive pulley and driven pulley Step 10 Remove four 8 32x7 16 PPZ screws that mount Tilt Motor Slide Plate to yoke and remove ENTIRE assembly Step 11 Remove four 8 32x7 16 PPZ screws that mount Pan Tilt Motor Assembly to Tilt Motor Slide Plate and remove Pan Tilt Motor Assembly be careful of spring Step 12 Replace by performing Steps 2 through 10 in reverse order Note When tightening four 8 32x7 16 PPZ screws that mount Pan Tilt Motor Assembly to Tilt Motor Slide Plate you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring 02 9685 0010 A 21 May 2009 59 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Pan Motor Assembly Replacement Parts 21 9685 0540 1 EA ASSY PAN TILT MOTOR Tools 2 Phillips Screwdriver WARNING Remove power from luminaire before performing maintenance To remove and replace pan motor assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke cover opposite of display by removing four 6 32x3 8 LG PTB screws Step 3 Remove 4 x 6 32 x 3 8 PFB screws two each side of yoke that hold Top Cover Louve
11. No Item Qty UM Description 1 52 8271 0005 4 EA RECPT FASTON 1 4 16 14 AWG INSULATED REEL 2 55 2186 0001 1 CABLE TIE 0 10 4 SMALL 3 73 6014 0012 0 29 FT WIRE 14 AWG 600V 200DEGC FEP BLACK STRAND 168 36 0 104 DIA 4 73 6014 0013 0 42 FT WIRE 14 AWG 600V 200DEGC FEP WHITE STRAND 168 36 0 104 DIA 2 4 5 00 Figure 3 62 Relay to Ignitor Cable Assembly 02 9685 0010 A 21 May 2009 161 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 AC Input Cable Assembly 25 9685 0756 Rev B Refer to Figure 3 63 No Item Qty UM Description 1 52 6541 0003 1 EA CONN CHASSIS POWER 3 POLE LOCKING 2 52 8231 0005 1 EA TERM RING 6 16 14 AWG REEL PIDG 3 52 8331 0003 3 EA FASTON RECPT 16 14 AWG PIDG BLU 0 170 ID 4 55 2186 0001 1 EA CABLE TIE 0 10 X4 SMALL 5 73 6014 0005 0 58 FT WIRE 14 AWG 600V 105DEGC PVC GRN UL1015 6 73 6014 0009 0 33 FT WIRE 14 AWG 600V 105DEGC PVC WHT UL1015 7 73 6014 0010 0 33 FT WIRE 14 AWG 600V 105DEGC PVC BLK UL1015 Figure 3 63 VL500 AC Input Cable Assembly 162 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Arc Ballast Input Cable Assembly 25 9685 0757 Rev C Refer to Figure 3 64 No Item Qty UM Description 1 52 6400 0027 1 EA RECPT 17 14 SQ FLANGE REV SEX THRD CPC 2 52 6420 0002 7 EA SOCKET GOLD 18 14 AWG TYPE 3 LOOSE 0 08 0 100 INS
12. 500 180 Shielded Display DMX Communication Cable Assembly VLS00A 181 VLS00 80V Display Cable Assembly ss 182 VL500 80V Yoke DMX Communication Cable Assembly 183 VL500 80V LVS Fan Cable Assembly eese 184 80V Shielded Display DMX Communication Cable Assembly VL500 80V 185 80V Dimmer Communication Cable Assembly VL500 80V 186 VLS00 Main Harness Cable Assembly pp 187 VLS00 Arc Main Harness Cable Assembly pp 189 VLS00 80V Main Harness Cable Assembly ppp 191 VL500 80V Lamp Wire esee nennen rennen nennen 193 Arc Ballast Assembly VL500 Arc Ballast Assembly 195 Ballast U O Cable Assembly e ee a eges 197 Appendix A Technical Bulletins and Notices VL500 M Wash Luminaire Technical Bulletins and Notices 199 xviii 21 May 2009 02 9685 0010 A INTRODUCTION Introduction Disclosure This technical manual is confidential property of Vari Lite All 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 WARNING It is important to read ALL accompanying safety instructions to avoid damage to the product and potential injury to yourself or others About This Manual This manual provides descriptions repair procedur
13. WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized Service Center 02 9685 0010 A 21 May 2009 17 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Testing 18 Running Parameter Tests The luminaire is capable of running self tests by using the TEST menu functions For complete details and values for each test refer to Diagnostic Tests on page 20 When running tests on multiple luminaires a DMX termination connector is required at the last luminaire in the chain Refer to user s manual for more information regarding the construction of this connector Note There is a known issue with all versions of code for the VL500 wash luminaires concerning the Test menu options Issues arose when running a test from one VLS00TM wash luminaire to multiple VL500TM wash luminaires of a different type across the VL500TM wash platform To alleviate this when testing in groups only test same Lamp Type luminaires for example VLSOOA wash 700W arc with other VL500ATM wash 700W arc lights VL5007M wash 120V 1200W tungsten wash with other VL500 wash 120V 1200W tungsten lights etc The issue described above does not pose any problems when operating VLS00TM wash luminaires during normal operation under DMX control Master Luminaire running test Slave Luminaire Slave Luminaire 9 A CR fA A
14. Cleaning Optical Lenses and Filters WARNING Remove power from luminaire before performing maintenance WARNING Acetone is a harsh cleaning agent and solvent Acetone is very flammable Please handle acetone according to manufacturer s safety instructions and precautions The front lens optics color filters and reflector may require cleaning after extended use e FRONT LENS Use Isopropyl Alcohol along with a soft lint free cloth to clean the front lens e OPTICS COLOR FILTERS Use Acetone or Isopropyl Alcohol along with a soft lint free cloth to clean the optics color filters REFLECTOR Use Acetone or Isopropyl Alcohol along with a soft lint free cloth to clean the reflector CAUTION Do not continuously rub color filters or reflector it may damage or remove the optical coating Never use ammonia based cleaners at anytime 21 May 2009 02 9685 0010A CHAPTER 3 Illustrated Parts Breakdown Note The following abbreviations are used to identify parts specific to certain models This chapter contains illustrated parts breakdowns for all VL500TM wash luminaire assemblies including the arc ballast unit Drawing Trees Top Assembly Head Assembly Yoke Assembly Cables Arc Ballast Assembly VL500 Model Parts Identifiers ABBREVIATION MODEL INCLUDES STANDARD AND PASTEL COLOR SYSTEMS VL500 VL500 Incandescent Luminaire 120V or 240V VL500D VL500 D Incandescent Lumina
15. Manual wash Luminaires 0296850010 Service NL 4 PHILIPS VARILITE VAREELITE VL500 LUMINAIRE SERVICE MANUAL VARI LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries VL500 and the individual product designations VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 VL3500 Series 500 Series 1000 Series 2000 Series 30007 DICHRO TUNE VAREKIMAGE VARI BRITE the Vari Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC products are protected by one or more of the following patents and other pending patent applications worldwide U S Patents No 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 5 432 601 5 367 444 5 329 431 5 307 295 5 282 121 5 278 742 5 209 560 5 186 536 5 073 847 5 010 459 4 980 806 4 972 306 4 800 474 4 779 176 4 701 833 4 602 321 U S Design Patents No 439 356 420 332 417 300 415 301 413 995 377 338 366 712 359 574 350 408 347 113 Australia Patents No 693 691 683 695 667 109 649 264 646 588 586 095 576 400 546 433 Australia Design Patents No 128 796 128 795 Canada Patents No 2 070 670 2 050 375 1 270 675
16. 1 259 058 1 181 795 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 0 140 994 0 060 068 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 7277 1 37 51 804 6 37 50 201 8 35 87 270 5 32 79 888 1 32 74 291 6 Germany Design Patents No M 98 01 745 4 M 96 04 515 9 M 96 04 514 0 M 94 07 689 8 M 94 02 951 2 M 499 03 583 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 Hong Kong Patents No 965 1990 285 1987 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 1 723 825 1 683 007 1 533 011 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 Singapore Patents No 663 90 134 87 Taiwan Patents No 78 726 66 975 65 380 28 275 United Kingdom Design Registrations No 2082526 2072562 2056387 2056386 2042174 2038212 2033108 2029499 Neutrik amp
17. 6 32X3 8 LG PTB 14 53 6558 0009 8 EA SCREW 6 32X3 8 LG PPZ SEMS 15 53 6558 0010 4 EA SCREW 6 32X1 4 PPB SEMS 16 53 6608 0001 8 EA SCREW 6 32X3 8 PFB 02 9685 0010 A 21 May 2009 85 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 120V or 240V Luminaire continued Figure 3 9 VL500 120V or 240V Luminaire 86 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500D with 120V IGBT Dimmer Luminaire 20 9685 0002 Rev F Standard DICRO TUNE Colors 20 9685 0012 Rev B Pastel DICRO TUNE Colors Refer to Figure 3 10 No Item Qty UM Description 1 04 9685 0573 1 LABEL MCB YOKE COVER 2 04 9685 0574 1 EA LABEL MCB YOKE COVER 3 04 9685 0576 1 EA LABEL YOKE COVER DIMMER 4 04 9685 0577 1 LABEL YOKE COVER DIMMER 5 10 9685 0525 2 EA LOUVER PLATE TOP COVER 6 10 9685 0565 2 EA MOUNT DIMMER 7 10 9685 0580 1 EA YOKE ARM COVER DISPLAY SIDE 8 10 9685 0582 1 EA YOKE ARM COVER DIMMER SIDE 9 21 9685 0011 1 EA ASSY GENERIC VLS00 INCANDESCENT WI DIMMER 10 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0002 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0012 ONLY 11 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 12 22 9685 0086 1 EA HEAD COVER 13 22 9685 0087 1 EA HEAD COVER BOTTOM 9 25 9685 0753 1 CABLE ASSY
18. Disconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 21 Step 4 Open heatsink by releasing latch Top Cover Magenta Blue Bulkhead Assembly RLY B NOTE Heatsink Assembly Heatsink Latch Some components not shown for clarity Figure 21 Accessing the Lamp Socket in VL500A and VL500 80V Fixtures Step 5 Attop cover remove two or four depending on production date 6 32x1 4 PPB SEMS screws Step 6 Remove top cover Step 7 Remove Magenta Blue Bulkhead Assembly as described in Magenta Blue DICHRO TUNE Rear Bulkhead Replacement on page 33 Remove Magenta Blue bulkhead 02 9685 0010 A 21 May 2009 47 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Step 8 Using soft cloth to protect lamp remove lamp from socket Step 9 As indicated in Figure 22 at light baffle remove three 6 32x1 8 PPB screws 10 32x1 1 2 PPB Screws VL500A Only 10 32x1 SCB Screws VL500 80V Only Spring x3 VL500A Only Backcap Extension Backcap Lamp Socket Reflector Light Baffle 8 32x3 8 PPZ Screws x2 1 4 Hex Standoff 3 8 32x1 2 PPZ SEM Screws x4 ins Reflector Clips x3 6 32x1 8 PPB Screws x3 Figure 22 Heatsink Assembly Lamp Socket Removal VL500A and VL500 80V Only Step 10 Remove light baffle Step 11 Loosen but do not r
19. NOTE Some components not shown for clarity 6 32 3 8 PTB Screws x4 4 Yoke Arm Cover Dimmer Side 6 32x3 8 PPZ Screws x4 IGBT Dimmer Figure 33 IGBT Dimmer Replacement VL500D Only Step 7 Replace IGBT Dimmer by performing Steps 2 through 6 in reverse 64 21 May 2009 02 9685 0010A MAINTENANCE 2 80V Dimmer Replacement VL500 80V Only Parts 21 9685 2750 1EA ASSY 80V DIMMER Tools 2 Phillips Screwdriver AN WARNING Remove power from luminaire before performing maintenance To remove and replace 80V dimmer Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke cover on dimmer side by removing four 6 32x3 8 LG PTB screws Step 3 As shown in Figure 34 at dimmer loosen but do not remove four 6 32x3 8 PPZ screws Step 4 Carefully remove 80V dimmer Note that there will be wires connected to dimmer on the back side A CAUTION All AC wiring is same color It is a good idea to mark the connector attached to both the AC Line Input and Load Output terminals on the IGBT dimmer with a black marker before removing so the phasing can be maintained Step 5 At dimmer carefully note and label before removing and disconnect following wiring a 4 position Dimmer Communication from MCB b Four Faston Quick Connects AC Input lamp Power Output c Ground Wires Step 6 Remove four 6 32x3 8 PPZ screws from Step 3 Install these screws in r
20. Rev U 21 9685 0171 Rev G Top Bulkhead Assembly Arc Yoke Lamp Cable Assembly 21 9685 0151 Rev C VL500A 25 9685 0790 Rev J VL500 and Drive Ring Assembly VL500 Extra Hardware Kit 28 9685 0999 Rev 0 MCB Fan Assembly 23 9685 0782 Rev 0 Yoke Crossmember Assembly VL500 VL500D VL500A Lower Crossmember Assembly 21 9685 0512 Rev K Upper Crossmember Assembly 21 9685 0513 Rev H Pan Tube Assembly VL500 VL500D VL500A 21 9685 0535 Rev D VL500 VL500D VL500A VL500 AC Input Cable Assembly 25 9685 0756 Rev B VL500 Display Remote Cable Assembly 25 9685 0770 Rev B VL500 Yoke Lamp Jumper Cable Assembly 25 9685 0776 Rev A Incandescent Power Input Cable Assembly 25 9663 2030 Rev A VL500 Only Figure 3 2 VL500 and VL500D Incandescent Luminaires Drawing Tree Part 2 02 9685 0010 A 21 May 2009 75 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V Incandescent Luminaires VL500 80V with 80V Dimmer Luminaire 20 9685 0004 Rev L Standard DICRO TUNE Colors or 20 9685 0014 Rev G Pastel DICRO TUNE Colors Generic VL500 Luminaire Assembly VL500 Motor Cable VL500 Magenta Blue Color 21 9685 0012 Rev S Incandescent with Assembly Assembly Internal 80V Dimmer 25 9685 0753 RevB 21 9685 0170 Rev H Standard DICRO TUNE Colors VL500 Generic Head Assembly VL500 Head Grounding 21 9685 0312 VL500 80V Rev K Cable Assembly 25 9685 0760 Rev C VL500 Magenta Blue Heatsink Assembly Pastel Color Assembly 21
21. Top Bulkhead Assembly continued 2 x2 7 x10 8 x4 Figure 3 34 Top Bulkhead Assembly 02 9685 0010 A 21 May 2009 123 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Drive Ring Assembly 21 9685 0251 Rev D Refer to Figure 3 36 No Item Qty UM Description 1 10 9634 0105 1 EA LINK SWIVEL 2 10 9685 7240 8 EA ROLLER DRIVE RING 3 22 9685 0238 1 EA RING DRIVE WITH PINS 4 53 5554 0875 1 EA SCREW 4 40X7 8 SET SS FLAT POINT 5 53 6659 0013 2 EA SCREW 2 56X 1 8 PPB 6 55 6603 0001 1 EA SPRING SS 4 6 IN EXTENSION 7 55 6612 0004 8 EA PIN 1 16 OD X 1 2 LG TYPE C 303 S S 7 x8 Insure screws are flush with inside drive ring surface no protrusion Spring 2 56 Screw x2 Figure 3 35 Drive Ring Assembly 124 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Magenta Blue Color Motor Assembly 21 9685 0280 RevA Refer to Figure 3 36 No Item Qty UM Description 1 10 9634 0061 1 EA ACTUATOR MOUNT VLS00 2 10 9634 0075 1 EA HEAT SHIELD MAGENTA BLUE 3 44 9685 0230 2 EA MOTOR LINEAR 0 002 STEP 4 53 6520 0001 3 EA SCREW 4 40X3 8 PPZ 5 53 6682 0002 4 EA SCREW 4 40X1 4 PPZ SEMS 6 54 1217 0004 2 EA LINK VL500 ACTUATOR DRIVE RING 4 x3 e Actuator Screw 5 x4 3 x2 Note Versilube Silicon Grease G321 is used to lubricate the actuator screw Figure 3 36 Magenta Blue
22. 20 53 6607 0002 4 EA SCREW 6 32X1 4 PFB 21 53 6614 0001 16 EA SCREW 6 32X5 8 LG PPB 22 69 9685 0701 1 EA BALLAST 700W SCHEIDERWERKS 02 9685 0010 A 21 May 2009 195 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Arc Ballast Assembly continued 16 x4 22 3 Figure 3 91 VL500 Arc Ballast Assembly 196 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Ballast 1 0 Cable Assembly 25 9685 0807 RevA Refer to Figure 3 92 No Item Qty UM Description 1 52 6231 0001 1 EA PLUG HOUSING MNLOK PLUG 3 POS 2 52 6396 2904 1 EA RECEPT 4 POS MTA100 W POL RED 3 52 6400 0111 1 EA RECEPT 17 9 STD SEX CPC 600V FLANGE 4 52 8201 0005 3 EA PIN GOLD 24 20AWG TYPE3 REEL 040 080 INS DIA 5 52 8202 0001 5 EA PIN GOLD 18 16AWG TYPE 3 REEL 080 100 INS DIA 6 52 8202 0011 1 EA PIN GND GOLD 18 16AWG TYPE 3 REEL 080 100 INS DIA 7 52 8231 0005 3 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 8 52 8257 0002 2 EA PIN PHOS BRZ 20 14AWG REEL MNLOK 060 130 INS DIA 9 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 10 52 8314 0001 1 EA PIN GND 20 14AWG REEL MNLOK 060 130 INS DIA 11 55 2186 0001 5 EA CABLE TIE 10 WD 4 00 LG SMALL 12 73 3522 0002 1 25 FT WIRE 22AWG 300V 105C PVC RED UL1569 13 73 3522 0009 1 25 FT WIRE 22AWG 300V 105C PVC WHT UL1569 14 73 3522 0010 1 25 FT WIRE 22AWG
23. 3 MCB Fan Assembly 23 9685 0782 Rev 0 Refer to Figure 3 43 I 40 7113 0007 FAN 12VDC 30X10 MM 3 3CFM 2 52 6450 0002 1 EA CONNECTOR MTA 100 IDC 2 POS 28 AWG 2 Pin 2 Black 2 Pin 1 Red 6 inch leads Bw Figure 3 45 MCB Fan Assembly 02 9685 0010 A 21 May 2009 139 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Yoke Crossmember Assembly VL500 VL500D VL500A 21 9685 0515 Rev E Refer to Figure 3 46 No Item Qty UM Description 1 10 9685 0547 1 EA BUSHING WIRE PROTECTION 0 95 OD 2 10 9685 7590 1 EA TOGGLE STOP PAN 3 10 9685 7591 1 EA TOGGLE PAN 4 21 9685 0512 1 EA ASSY LOWER CROSSMEMBER 5 21 9685 0513 1 EA ASSY UPPER CROSSMEMBER 6 21 9685 0535 1 EA ASSY PAN TUBE 7 53 6552 0002 8 EA SCREW 8 32X1 2 PFB 8 53 6667 0005 2 EA SCREW 10 32X3 8 SET CUP POINT 9 54 1206 0014 3 EA RING RETAINING 1 375 SHAFT 140 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Yoke Crossmember Assembly VL500 VL500D VL500A continued 7 X4 B T 7 x4 Figure 3 46 Yoke Crossmember Assembly VL500 VL500D VL500A 02 9685 0010 A 21 May 2009 141 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Yoke Crossmember Assembly VL500 80V 21 9685 0516 Rev 0 Refer to Figure 3 47 No Item Qty UM Description 1 10 9685 0547 1 EA B
24. 300V 105C PVC BLK UL1569 15 73 6016 0003 1 33 FT WIRE 16AWG 600V 105C PVC UL1015 16 73 6016 0007 1 33 FT WIRE 16AWG 600V 105C PVC VIO UL1015 17 73 6016 0009 1 33 FT WIRE 16AWG 600V 105C PVC WHT UL1015 18 73 6016 0010 1 33 FT WIRE 16AWG 600V 105C PVC BLK UL1015 19 73 6016 0504 3 0 FT WIRE 16AWG 600V 105C PVC GRN YEL UL1015 02 9685 0010 A 21 May 2009 197 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Ballast 1 0 Cable Assembly continued 7 x3 1 6 e Ba 12 13 14 Figure 3 92 Ballast I O Cable Assembly 198 21 May 2009 02 9685 0010A APPENDIX A Technical Bulletins and Notices VL500 Wash Luminaire Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the VL500 wash luminaire If applicable these improvements have been incorporated into this manual Technical Bulletin Description or Notice S5K 001 Series 500 Yoke Leg Cross Member Screw Torquing Procedure S5K 002 This technical bulletin was rescinded S5K 003 Series 500 Counterweight Replacement Procedure S5K 004 Series 500 80V Step Washer Replacement Procedure S5K 005 Series 500 80V Pan Motor Compression Spring Replacement S5K 006 Series 500 VL500D Dimmer Module Modification Procedure TN 248 Specified and Approved Lamps for use in VARI LITE Luminaires TN 231 Recommended Spare
25. 5 73 2326 0123 0 25 FT WIRE 26 AWG 4 COND 300V 200DEGC BLK BRN RED ORN UL1180 Part of 4 5 3 2 x4 4 Part of 4 Figure 3 71 VL500 Display Remote Cable Assembly 02 9685 0010 A 21 May 2009 171 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Yoke Lamp Cable Assembly VL500 VL500D 25 9685 0771 Rev C Refer to Figure 3 72 No Item Qty UM Description 1 52 8244 0001 2 EA RECEPT FASTON FLAG 0 250 16 14 AWG REEL 2 73 6014 0012 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP BLK STRAND 168 36 0 104 3 73 6014 0013 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP WHT STRAND 168 36 0 104 1 x2 2 28 3 28 Figure 3 72 Yoke Lamp Cable Assembly VL500 VL500D 172 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Yoke Ground Cable Assembly 25 9685 0772 Rev C Refer to Figure 3 73 No Item Qty UM Description 1 52 8231 0005 2 EA TERM RING 6 16 14 AWG REEL PIDG 2 73 6014 0011 2 0 FT WIRE 14 AWG 600V 200 DEGC FEP GRN STRAND 168 36 0 104 DIA 1 2 Figure 3 73 Yoke Ground Cable Assembly 02 9685 0010 A 21 May 2009 173 VAREELITE VL500 LUMINAIRE SERVICE MANUAL LVS AC Cable Assembly VL500 VL500D VL500A 25 9685 0773 Rev C Refer to Figure 3 74 No Item Qty UM Description 1 52 6264 0004 1 EA CONN HOUSING 3 POS SL156 W RAMP NO TABS 2 52 8317 0002 2 EA CONTACT SL156 24 18 AWG 3 73 7
26. 65 VL500 pan Tilt Cable Assembly 164 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Pan Tilt Cable Assembly continued Figure 3 66 VL500 Pan Tilt Cable Assembly Pin Outs 02 9685 0010 A 21 May 2009 165 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Head Grounding Cable Assembly 25 9685 0760 Rev C Refer to Figure 3 67 No Item Qty UM Description TERM RING 6 RED 22 16 AWG INSUL REEL WIRE 14 AWG 600V 200DEGC FEP GRN STRND 168 36 0 104 DIA 1 52 8231 0000 2 EA 2 73 6014 0011 1 33 FT Figure 3 67 VL500 Head Earthing Cable Assembly 166 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Ignitor to Socket Cable Assembly 25 9685 0766 Rev C Refer to Figure 3 68 No Item Qty UM Description 1 25 9685 0777 1 EA CABLE ASSY BACK CAP GROUND VL500 2 52 8244 0001 2 EA FASTON RECEPT FLAG 0 250 16 14 AWG INSULATED REEL 3 55 2186 0001 2 EA CABLE TIE 0 10 X4 SMALL 4 55 2260 0133 2 33 FT SLEEVING FIBERGLASS 0 133 ID 5 55 6699 0010 1 33 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 6 73 3517 0001 4 00 FT WIRE 14 AWG 5KV 200DEGC SILICON 7X24 36 STRAND Figure 3 68 VL500 Iginitor to Socket Cable Assembly 02 9685 0010 A 21 May 2009 167 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Arc Ballast Interconnect Cable Assembly 25 9685 0767 Rev B Refer to Figure 3 69
27. Color Motor Assembly 02 9685 0010 A 21 May 2009 125 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Amber Diffuser Color Motor Assembly 21 9685 0281 RevA Refer to Figure 3 36 No Item Qty UM Description 1 10 9634 0061 1 EA ACTUATOR MOUNT VLS00 2 10 9634 0074 1 EA HEAT SHIELD AMBER DIFFUSER 3 44 9685 0230 2 EA MOTOR LINEAR 0 002 STEP 4 53 6520 0001 3 EA SCREW 4 40X3 8 PPZ 5 53 6682 0002 4 EA SCREW 4 40X 1 4 PPZ SEMS 6 54 1217 0004 2 EA LINK VL500 ACTUATOR DRIVE RING 4 x3 5 x4 6 x2 Actuator Screw Note Versilube Silicon Grease G321 is used to lubricate the actuator screw Figure 3 37 Amber Diffuser Color Motor Assembly 126 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Yoke Assembly VL500 Yoke Assembly 21 9685 0520 VL500 Rev U 21 9685 0521 VL500D Rev U 21 9685 0522 VL500A Rev U Refer to Figure 3 38 and Figure 3 39 No Item Qty UM Description 1 10 9685 0534 1 EA COVER PAN TUBE 2 10 9685 0537 1 EA PLATE MOUNTING LAMP POWER PIGTAIL VL500 ONLY 3 10 9685 0538 1 EA BEZEL LAMP POWER PIGTAIL VL500 ONLY 4 10 9685 1560 1 EA YOKE LEG TILT SIDE 5 10 9685 1561 1 EA YOKE LEG DIMMER SIDE 6 10 9685 0562 1 EA PLATE TILT MOTOR SLIDE 7 10 9685 0596 1 EA MOUNT FAN LVS 8 21 9685 0515 1 EA ASSY YOKE CROSSMEMBER 9 21 9685 0540 2 EA ASSY PAN TI
28. DIA 3 52 8201 0007 3 EA SOCKET GOLD 24 20 AWG TYPE 3 REEL 0 04 0 08 INS DIA 4 52 8321 0005 2 EA TERM RING 6 16 14 AWG REEL PIDG 5 53 7015 0005 1 EA CONN HOUSING 5CIR MTA100 BLU 6 73 2326 0029 2 79 FT WIRE 26 AWG 3COND 300V 200DEGC TEF BLK WHT RED UL1180 7 73 6014 0002 0 46 FT WIRE 14 AWG 600V 105DEGC PVC RED UL1015 8 73 6014 0003 0 46 FT WIRE 14 AWG 600V 105DEGC PVC ORG UL1015 9 73 6014 0005 0 88 FT WIRE 14 AWG 600V 105DEGC PVC GRN UL1015 10 73 6014 0009 0 75 FT WIRE 14 AWG 600V 105DEGC PVC WHT UL1015 11 73 6014 0010 0 75 FT WIRE 14 AWG 600V 105DEGC PVC BLK UL1015 2 x7 2 y Z 3 x3 Figure 3 64 VL500 Arc Ballast Input Cable Assembly 02 9685 0010 A 21 May 2009 163 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Pan Tilt Cable Assembly 25 9685 0758 RevA Refer to Figure 3 65 and Figure 3 66 No Item Qty UM Description 1 52 6224 0020 1 EA HOUSING 20 POS 26 22 AWG PRELOADED MT RECEPT DBL ROW 2 52 6224 1020 1 EA COVER LATCH MT RECEPT 20 PIN 3 52 6224 2020 1 EA COVER BACK MT 20 PIN 4 52 6524 0004 2 EA CONN HOUSING 4 POS RECEPT 5 52 6588 0007 2 EA HOUSING 7POS XH 250V3A 2 5MM PITCH 6 52 7007 0001 8 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT SXH 7 55 2186 0001 4 EA CABLE TIE 0 10 X 4 SMALL 8 73 2326 0123 9 20 FT WIRE 4 COND 300V 200 DEGC TEF lt BLK BRN RED ORN gt 4 5 6 4 4 8 7 x4 8 15 4 5 6 Figure 3
29. MANUAL 26 Lamp Replacement Incandescent continued WARNING 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 soft lint free cloth to thoroughly clean glass portion of lamp Step Step Step Step Step Remove lamp by pulling straight out of socket Carefully clean reflector with soft lint free cloth to remove dust and other debris Install lamp by pressing firmly into socket Ensure lamp is fully seated in socket with base of lamp against socket base 8 Close and re latch back of luminaire Disengage service tilt lock to allow luminaire head to move freely Note For an updated list of approved lamps for all versions of the VL500 luminaire please refer to Vari Lite Technical Notice TN 248 current version on the Vari Lite web site at www vari lite com 21 May 2009 02 9685 0010A MAINTENANCE 2 Lamp Replacement Arc Parts 71 9685 0702 1 EA MSR700 2 700 WATT MSR ARC LAMP Tools Cotton gloves or finger cots A WARNING Remove power from luminaire before performing maintenance To remove and replace arc lamp Step 1 Remove power from luminaire WARNING Lamps will be extremely HOT after operation Allow lamp to cool before N replacing Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire h
30. MOD4 CRIMP SNAP IN 4 52 6696 0001 1 EA RECEPT WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 5 52 6694 0001 4 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2MM 28 24 AWG 6 73 5126 0130 0 42 FT WIRE 26 AWG 4 COND 300V 200 DEGC lt BLK WHT RED WHT RED gt 7 73 2326 0123 3 25 FT WIRE 4 COND 300V 200 DEGC TEF lt BLK BRN RED ORN gt 2 3 See Detail A Detail A Connector Layout viewed from wire side 6 1 v TE Figure 3 82 VL500 80V Display Cable Assembly 182 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 80V Yoke DMX Communication Cable Assembly 25 9685 0786 RevA Refer to Figure 3 83 No Item Qty UM Description 1 52 6234 0001 1 EA CONN HOUSING 4 PIN MTA CLOSED END BLUE 2 52 6270 0002 1 EA CONN HOUSING 5 PIN MTA CLOSED END BLUE 3 52 8311 0001 1 EA TERM RING 6 26 22 AWG NON INS TAPE 4 73 2326 0123 3 17 FT WIRE 26 AWG 4 COND 300V 200DEGC BLK BRN RED ORN UL1180 5 73 3526 0005 0 67 FT WIRE 26 AWG 300V 105 DEGC PVC GRN UL1569 3 4 8 1 DMX 5 38 2 Figure 3 83 VL500 80 Yoke DMX Communication Cable Assembly 02 9685 0010 A 21 May 2009 183 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V LVS Fan Cable Assembly 25 9685 0787 Rev 0 Refer to Figure 3 84 No Item Qty UM Description 1 52 6234 0001 2 EA CONN HOUSING 4 PIN MTA CLOSED END BLUE 2 55 2186 0001 2 EA CABLE TIE 0 10
31. 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 other 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 1 877 827 4548 or customerservice genlytecontrols com 02 9685 0010 A 21 May 2009 199 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Notes 200 21 May 2009 02 9685 0010A Vari Lite 10911 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 21 May 2009 Manual Part Number 02 9685 0010 A 2003 2009 Vari Lite a Philips group company All rights reserved Printed in the U S A
32. SIDE 9 21 9685 0011 1 EA ASSY GENERIC VLS00 INCANDESCENT WI DIMMER 10 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0003 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0013 ONLY 11 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 12 22 9685 0086 1 EA HEAD COVER 13 22 9685 0087 1 EA HEAD COVER BOTTOM 9 25 9685 0753 1 CABLE ASSY VL500 MOTOR NOT SHOWN 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDING NOT SHOWN 28 9685 0003 1 EA INCLUDED ITEMS KIT VL500 INCANDESCENT NOT SHOWN 14 42 9685 0207 1 EA LENS PAR 64 NSP STIPPLE 15 53 6523 0013 8 EA SCREW 6 32X3 8 LG PTB 16 53 6558 0001 8 EA SCREW 6 32X3 8 LG PPZ 17 53 6558 0009 8 EA SCREW 6 32X3 8 LG PPZ SEMS 18 53 6558 0010 4 EA SCREW 6 32X1 4 PPB SEMS 19 53 6608 0001 8 EA SCREW 6 32X3 8 PFB 20 69 3173 0240 1 EA DIMMER 1200W 240V REV PHASE CONT 02 9685 0010 A 21 May 2009 89 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500D with 240V IGBT Dimmer Luminaire continued Figure 3 11 VL500D with 240V IGBT Dimmer Luminaire 90 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 80V with 80V Dimmer Luminaire 20 9685 0004 Rev L Standard DICRO TUNE Colors 20 9685 0014 Rev G Pastel DICRO TUNE Colors Refer to Figure 3 12 No Item Qty
33. Step Step Step Step Step Step Step Step Step 10 11 Remove light baffle Loosen but do not remove three 1 4 hex standoffs and turn reflector clips out of way and remove reflector Remove yoke arm cover opposite display side by removing four 6 32x3 8 LG PTB screws If applicable remove dimmer See IGBT Dimmer Replacement VL500D Only on page 63 for IGBT dimmer removal At inside of side rail remove two 4 40x1 8 LG PPB screws and remove Lamp Wire Cover At support rib closest to tilt tube remove one 6 32x1 4 LG PPG screw and remove ground strap Remove tilt tube plug and pass lamp wires through tilt tube Inside heatsink remove four 8 32x1 2 LG PPZ SEM screws and remove back cap Remove heatsink light leak foam and pass lamp wire through heatsink At socket remove two 6 32x1 4 LG PPZ SEM screws and remove socket Replace by performing Steps 3 through 19 in reverse order 21 May 2009 02 9685 0010A MAINTENANCE 2 Arc Lamp Socket Assembly VL500A and VL500 80V Only Replacement Parts 23 9685 0780 1 EA ASSY LAMP SOCKET VL500 AND VL500D ONLY Tools 2 Phillips Screwdriver 1 4 Hex Nutdriver 5 64 Allen Wrench To remove and replace lamp socket assembly Step 1 CLOSE ALL GLASS IN BULKHEADS Power up unit and allow all DICHRO TUNE glass to calibrate Once they close power down unit A WARNING Remove power from luminaire before performing maintenance Step 2
34. VL500 MOTOR NOT SHOWN 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDING NOT SHOWN 28 9685 0002 1 EA INCLUDED ITEMS KIT VL500 INCANDESCENT NOT SHOWN 14 42 9685 0207 1 EA LENS PAR 64 NSP STIPPLE 15 53 6523 0013 8 EA SCREW 6 32X3 8 LG PTB 16 53 6558 0001 8 EA SCREW 6 32X3 8 LG PPZ 17 53 6558 0009 8 EA SCREW 6 32X3 8 LG PPZ SEMS 18 53 6558 0010 4 EA SCREW 6 32X1 4 PPB SEMS 19 53 6608 0001 8 EA SCREW 6 32X3 8 PFB 20 69 3173 0115 1 EA DIMMER 1200W 115V REV PHASE CONT 02 9685 0010 A 21 May 2009 87 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500D with 120V IGBT Dimmer Luminaire continued Figure 3 10 VL500D with 120V IGBT Dimmer Luminaire 88 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500D with 240V IGBT Dimmer Luminaire 20 9685 0003 Rev F Standard DICRO TUNE Colors 20 9685 0013 Rev B Pastel DICRO TUNE Colors Refer to Figure 3 11 No Item Qty UM Description 1 04 9685 0573 1 LABEL MCB YOKE COVER 2 04 9685 0574 1 EA LABEL MCB YOKE COVER 3 04 9685 0576 1 EA LABEL YOKE COVER DIMMER 4 04 9685 0577 1 LABEL YOKE COVER DIMMER 5 10 9685 0525 2 EA LOUVER PLATE TOP COVER 6 10 9685 0565 2 EA MOUNT DIMMER 7 10 9685 0580 1 EA YOKE ARM COVER DISPLAY SIDE 8 10 9685 0582 1 EA YOKE ARM COVER DIMMER
35. VL500A ONLY 22 55 6635 0010 3 EA WASHER 10 SPHERICAL VL500A AND VL500 80V ONLY 23 71 2560 0001 1 EA SOCKET LAMP ARC VL500A AND VL500 80V ONLY 02 9685 0010 A 21 May 2009 105 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Heatsink Assembly continued Figure 3 20 VL500 Heatsink Assembly VL500 VL500D 106 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Heatsink Assembly continued Figure 3 21 VL500 Heatsink Assembly VL500A 02 9685 0010 A 21 May 2009 107 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Heatsink Assembly continued 13 x3 20 x3 Figure 3 22 VL500 Heatsink Assembly VL500 80V 108 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Magenta Blue Color Assembly 21 9685 0170 Rev H Standard DICRO TUNE Colors Refer to Figure 3 23 No Item Qty UM Description 1 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 2 21 9685 0160 1 EA ASSY MAGENTA BLUE STANDARD DICRO TUNE 3 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 4 53 6592 0250 8 EA SCREW 4 40 1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 4 x4 Figure 3 23 VL500 Magenta Blue Color Assembly 02 9685 0010 A 21 May 2009 10
36. Yoke Arm Cover Arm Cover Pan Mechanism Ignitor PCB Ignites lamp in arc models 10 21 May 2009 02 9685 0010A DESCRIPTION 1 Arc Ballast Unit An external ballast unit is included with VL500A arc models In this case the lamp power input cable is already connectorized for use with this unit The following illustration shows the external arc ballast components Truss Hook Mount Used to attach a truss hook Safety Cable Tab Used to attach safety cable clip Ballast Unit s es Provides power for arc lamp source Lamp Connector underside Lamp Power Input Cable CPC type connector for connecting Supplied cable and connector used Lamp Power Input cable from luminaire to connect luminaire to ballast unit 40 inches 1m Note The Lamp Power Input Cable has conductors for lamp power and ballast control It is NOT compatible with Series 300 lamp runs Dimmer Models An on board dimmer is included with VL500D and ne dd lamp power VLS00 80V incandescent dimmer configured for either 120V or dirmimer models Thedimmer 240V operation depending on model heatsink is visible on the power side yoke leg as shown in this illustration VL500 80V Models Internal lamp power dimmer configured specifically for 80V lamps 02 9685 0010 A 21 May 2009 11 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Principles of Operation VL500 Incandescent Lumina
37. a Power up luminaire b At Menu Display press Menu Press Up Down arrows until CFG Configuration appears Press Enter d Press Up Down arrows until LAMP appears Press Enter e Press Up Down arrows to access RHrs Press Enter to reset lamp hour and strike counters Note For an updated list of approved lamps for all versions of the VL500 luminaire please refer to Vari Lite Technical Notice TN 248 current version on the Vari Lite web site at www vari lite com 21 May 2009 02 9685 0010A MAINTENANCE 2 Align Lamp For Maximum Beam Irradiance After a new lamp is installed in a VL500A luminaire it will be necessary to align the lamp to optimize the beam Tools 1 Phillips Screwdriver 1 4 Nutdriver Cotton Gloves or Finger Cots e Clean Lint free Soft Cloth WARNING Remove power from luminaire before performing maintenance To align lamp for maximum bean irradiance Step 1 Remove power from luminaire WARNING Lamps will be extremely HOT after operation Allow lamp to cool before N replacing Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 4 As shown in Figure 5 at heatsink assembly open latch and swing open back of luminaire Heatsink Assembly Backcap Assembly Latch Arc Lamp Figure 5 Accessing the Reflector in VL500
38. around with no large blotches of color at any one point b Maximize spot intensity by making hot spot as small and tightly focused as possible Hot spot should be centered in halo and in larger brownish circle sur rounding it Beam Adjustment Screws Figure 6 Lamp Alignment Screws Step 15 Close and latch front lens ring 30 21 May 2009 02 9685 0010A MAINTENANCE Front Glass Replacement Parts As needed 42 9685 0201 1 EA GLASS FRONT CLEAR 42 9685 0207 1 EA GLASS FRONT STIPPLE 42 9685 0203 1 EA GLASS FRONT MED FLOOD 8 ROW LENT 42 9685 0206 1 EA GLASS FRONT MED FLOOD 10 ROW LENT 42 9685 0204 1 EA GLASS FRONT MED FLOOD 12 ROW LENT 42 9685 0205 1EA GLASS FRONT VERY WIDE FLOOD BUXOM Tools Cotton Gloves or Finger Cots e Clean Lint free Soft Cloth To remove and replace front glass WARNING Remove power from luminaire before performing maintenance Note It is often easier to replace the lenses when the fixture is warm However use caution when handling a warm fixture as damage to glass components can occur lamp reflector etc gt Step 1 Remove power from luminaire Step 2 At front ring assembly open latch and swing open Refer to Figure 7 Front Ring Assembly Head Assembly Front Lens Hinge Latch Figure 7 Replacing Front Glass 02 9685 0010 A 21 May 2009 31 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 32 F
39. as the beginning of the warranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form included at the end of this manual and place in shipping container along with a copy of your invoice if available Write the RMA number legibly on or near the shipping address label and return the unit freight prepaid to Vari Lite Attention Warranty Service RMAZ 10911 Petal Street Dallas Texas 75238 USA As stated in the warranty it is required that the shipment be insured and FOB our service center Manual Revision History VERSION DATE Rev 0 Initial 17 July 2006 Rev A 21 May 2009 02 9685 0010 A 21 May 2009 iii VAREELITE VL500 LUMINAIRE SERVICE MANUAL FCC C Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with Vari Lite system service and safety guidelines may cause harmful interference to radio communica tions Operation of this equipment in a residential area is likely to cause harmful inter ference in which case the user will be required to correct the i
40. horizontal position with top cover one with bubble facing up as shown in Figure 10 Step 4 As indicated in Figure 10 open front ring by releasing latch Magenta Blue Assembly Top Cover Amber Diffuser Assembly Incandescent Models See separate procedure for removing and replacing this assembly or Amber Dimmer Assembly Arc Models Front Ring NOTE Some components not shown for clarity Figure 10 Amber Diffuser or Dimmer Bulkhead Step 5 At top cover remove two or four depending on production date 6 32x1 4 PPB SEMS screws Step 6 Remove top cover 02 9685 0010 A 21 May 2009 35 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Replacement continued Step 7 Disconnect wiring at two linear actuators on Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Step 8 As shown in Figure 11 at side rails from top remove four 6 32x3 8 LG PPZ SEMS screws Amber Diffuser or Dimmer Assembly 6 32x3 8 PPZ SEMS x4 Side Rail NOTE Some components not shown for clarity Figure 11 Amber Diffuser or Dimmer Bulkhead Step 9 Carefully lift Amber Diffuser or Dimmer bulkhead out of luminaire head Step 10 Replace by performing steps 2 through 9 in reverse order 36 21 May 2009 02 9685 0010A MAINTENANCE 2 Color Filter and Diffuser Panel Replacement Parts 22 9685 0122 16 EA ASSY FILTER MAGENTA D
41. panels for dimming operation and amber dichroic glass for color mixing Backcap Assembly Provides access to lamp for replacement Front Ring Provides frame for mounting lenses stipple standard with fixture Optional lenses clear 8 row 10 row 12 row or buxom 8 21 May 2009 02 9685 0010A DESCRIPTION 1 Luminaire Yoke Components The following illustration shows the major sub assemblies that are located in the luminaire yoke assembly Note Head assembly not shown for clarity Tilt Mechanism Yoke Arm Cover Power Supply Side Power Supply Side VL500 Models 120V or 240V Yoke Arm Cover Display Side Display LCD Luminaire technical status info Pan Mechanism 120W Power Supply Supplies power to electronic and motor components Except models with 80V dimmers See next page for other individual model variations 02 9685 0010 A 21 May 2009 9 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Luminaire Yoke Components continued The following illustrations show additional model variations for the power supply side of the luminaire yoke assembly VL500D Models 120V or 240V Pan Mechanism IGBT Dimmer Yoke Arm Cover 120W Power Supply Supplies power to electronic and motor components VL500 80V Models 120V or 240V IGBT Dimmer Module Pan Mechanism VL500A Models 80V Dimmer i Module 80V Dimmer Yoke Standard
42. shipping package for this VARI LITE product Additional Documentation A support web page for VL500 series luminaires is available at www vari lite com follow the Support link 21 May 2009 1 VAREELITE VL500 LUMINAIRE SERVICE MANUAL A user s manual is available for installation and operation of the VL500 wash luminaire This manual is available in electronic PDF format m VLS500 Luminaire User s Manual 02 9685 0001 Technical bulletins concerning the latest changes to VARI LITE equipment also available at the web site Technical Support Center These are documentation supplements that contain procedures for equipment upgrades retrofits and additional repairs Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on hand to provide support How to Reach Us For assistance in your area call the dealer from which your product s were purchased Or Contact an Authorized Service Center Or Contact the Vari Lite Customer Service Department 9am 6p
43. silicone pad Step 12 Reassemble luminaire 38 21 May 2009 02 9685 0010A MAINTENANCE 2 Arc Dimmer Panel Replacement Parts 10 9685 0210 16 EA DIMMER BLADE PANEL VL500 Tools 1 Phillips screwdriver Tweaker Screwdriver Cotton Gloves or Finger Cots e Clean lint free soft cloth To remove and replace dimmer panels Step 1 Ensure all glass filters and dimmer panels are in closed position WARNING Remove power from luminaire before performing maintenance Step 2 Remove power from luminaire Step 3 Set the luminaire head horizontally Step 4 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 5 Unlatch and swing open front ring Step 6 Remove Amber Diffuser bulkhead by following procedure Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Replacement on page 35 Step 7 Disconnect actuator screw from swivel coupler using tweaker screwdriver by carefully prying apart from Drive Ring Link Step 8 Open dimmer panels slightly Step 9 Remove one 4 40 x 1 8 PPB screw that attaches dimmer panel to Dimmer Carrier 4 40x1 8 PPB Screw Dimmer Panel Bearing I Arm Link Figure 13 Dimmer Panel Step 10 Remove dimmer panel from center hub 02 9685 0010 A 21 May 2009 39 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Dimmer Panel Replacement Continued rrier Dimmer Panel Carrie Y Inser
44. sobre seguridad que se indica en este manual asi 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 simbolos de seguridad usados en este manual son los siguientes CUIDADO indica posibles da os al producto Q 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 PROTECCION CONTINUA CONTRA INCENDIO 1 Las luminarias han sido dise adas para ser usadas solamente con algunas l mparas HID Philips y Osram Tome nota del tipo de l mpara MSR400 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 Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las luminarias ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA CHOQUE ELECTRICO 1 Las luminarias
45. x4 1 l 5 6 x4 ai A Riel 1 x4 Figure 3 28 VL500 Magenta Blue Arc Color Assembly 114 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Magenta Blue Color Assembly 21 9685 0160 Rev E Standard DICRO TUNE Colors Refer to Figure 3 29 No Item Qty UM Description 1 10 9634 0034 32 EA SPRING DRIVE ARM FILTER 2 10 9634 0035 32 EA LINK DRIVE ARM 3 10 9634 0166 32 EA CARRIER FILTER METAL INJ MOLD 4 21 9685 0150 1 EA ASSY BOTTOM BULKHEAD 5 22 9685 0122 16 EA ASSY FILTER MAGENTA DICRO TUNE 6 22 9685 0123 16 EA ASSY FILTER BLUE DICRO TUNE 3 x16 6 x16 Eee es 1 18 2 x16 3 x16 2 x16 1 x16 5 x16 Figure 3 29 Magenta Blue Color Assembly 02 9685 0010 A 21 May 2009 115 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Magenta Blue Pastel Color Assembly 21 9685 0164 Rev 0 Pastel DICRO TUNE Colors Refer to Figure 3 30 No Item Qty UM Description 1 10 9634 0034 32 EA SPRING DRIVE ARM FILTER 10 9634 0035 32 EA LINK DRIVE ARM 3 10 9634 0166 32 EA CARRIER FILTER METAL INJ MOLD 4 21 9685 0150 1 EA ASSY BOTTOM BULKHEAD 5 22 9685 0120 16 EA ASSY FILTER MAGENTA PASTEL DICRO TUNE 6 22 9685 0121 16 EA ASSY FILTER BLUE PASTEL DICRO TUNE 3 x16 6 x16 1018 2 x16 5 x16 Figure 3 30 Magenta Blue Pastel Color Asse
46. 0 32X1 2 PFB 32 53 6596 0001 1 EA SCREW 4 40X5 16 PPZ 33 54 2065 0001 1 EA BELT TIMING S2M 252 GROOVE 34 55 2166 0250 1 EA STANDOFF 1 4 HEX 6 32 0 250 LG MF SS 35 55 2288 0001 3 EA STANDOFF 1 4 HEX 6 32 X 13 16 LG 36 55 3301 0008 8 EA WASHER 8 FLAT SS 37 55 3301 0010 1 EA WASHER 10 FLAT 38 55 6543 0001 24 IN GROMMET STRIP SERRATED 0 062 39 55 6568 0056 2 EA SPRING CPRSN 0 600 OD 0 080 WIR 40 55 6662 0010 1 EA HOLE PLUG 1 093 DIA BLK NYLON VL500D ONLY 41 55 6669 0005 6 EA STANDOFF 6 32 X 0 500 LG 1 4 HEX 42 55 6669 0012 1 EA STANDOFF 6 32 X 1 00 LG 1 4 HEX MF CSTL ZINC 128 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Yoke Assembly continued 27 x6 25 x2 18 x2 21 x4 15 VL500A 40 VL500D 28 x2 Figure 3 38 VL500 Yoke Assembly VL500 VL500D VL500A 02 9685 0010 A 21 May 2009 129 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Yoke Assembly continued 26 x6 44 x4 e 27 x12 FAR Pd pu 41 x6 d 5 Figure 3 39 VL500 Yoke Assembly VL500 VL500D VL500A 130 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 80V Yoke Assembly 21 9685 0523 VL500 80V Rev Q Refer to Figure 3 40 Figure 3 41 No Item Qty UM Description 1 10 9685 0542 1 EA SHIELD WIRE 2 10 9685 0543
47. 00 80V Rev Q VL500 80V Main Harness Cable Assembly 25 9685 2792 Rev A VL500 80V VL500 Extra Hardware Kit 28 9685 0999 Rev 0 MCB Fan Assembly 23 9685 0782 Rev 0 Yoke Crossmember Assembly VL500 80V 21 9685 0516 Rev 0 Lower Crossmember Assembly 21 9685 0512 Rev K Upper Crossmember Assembly 21 9685 0513 Rev H Pan Tube Assembly VL500 80V 21 9685 0536 Rev A VL500 80V VL500 AC Input Cable Assembly 25 9685 0756 Rev B VL500 Display Remote Cable Assembly 25 9685 0770 Rev B Incandescent Power Input Cable Assembly 25 9685 0742 Rev 0 P4V Power Cable Assembly VL500 80V 25 9685 0746 Rev 0 Figure 3 4 VL500 80V Incandescent Luminaires Drawing Tree Part 2 02 9685 0010 A 21 May 2009 77 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500A Arc Luminaires VL500A 700W Arc Luminaire 20 9685 0006 Rev H Standard DICRO TUNE Colors or 20 9685 0016 Rev B Pastel DICRO TUNE Colors VL500 Magenta Blue Arc Color Assembly 21 9685 0173 Rev A Standard DICRO TUNE Colors Generic VL500 Luminaire Assembly VL500 Motor Cable 21 9685 0013 Rev S Arc Assembly 25 9685 0753 Rev B VL500 Generic Head Assembly VL500 Head Grounding 21 9685 0311 VL500A Rev K Cable Assembly 25 9685 0760 Rev C VL500 Magenta Blue Arc Heatsink Assembly Pastel Color Assembly 21 9685 0321 VL500A Rev H 21 9685 0174 Rev A Pastel Included Items Kit DICRO TUNE Colors 28 9685 0006 Rev G 700W VL500 Backcap Ground Ca
48. 0010 A 21 May 2009 83 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Label Locations continued 6 Non Arc Models Only 5 Non Arc Models Only Figure 3 8 Label Locations 84 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 120V or 240V Luminaire 20 9685 0001 Rev G Standard DICRO TUNE Colors 20 9685 0011 Rev B Pastel DICRO TUNE Colors Refer to Figure 3 9 No Item Qty UM Description 1 04 9685 0573 1 LABEL MCB YOKE COVER 2 04 9685 0574 1 EA LABEL MCB YOKE COVER 3 04 9685 0588 1 EA LABEL YOKE COVER PLAIN VL500 4 10 9685 0525 2 LOUVER PLATE TOP COVER 5 10 9685 0580 1 EA YOKE ARM COVER DISPLAY SIDE 6 10 9685 0584 1 EA YOKE ARM COVER POWER SUPPLY SIDE 7 21 9685 0010 1 EA ASSY GENERIC VL500 INCANDESCENT 8 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0001 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0011 ONLY 9 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 10 22 9685 0086 1 EA HEAD COVER 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 CABLE ASSY VL500 MOTOR NOT SHOWN x 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDING NOT SHOWN 28 9685 0001 1 EA INCLUDED ITEMS KIT VL500 INCANDESCENT NOT SHOWN 12 42 9685 0207 1 EA LENS PAR 64 NSP STIPPLE 13 53 6523 0013 8 EA SCREW
49. 0D 120V MODELS ONLY 04 9685 0922 00 2 EA LABEL AC INPUT RATING CLR VL500D 120V MODELS ONLY 04 9685 0923 2 EA LABEL AC INPUT RATING VL500D 120V PASTEL MODELS ONLY 04 9685 0923 00 2 EA LABEL AC INPUT RATING CLR VL500D 120V PASTEL MODELS ONLY 04 9685 0924 2 EA LABEL AC INPUT RATING VL500D 240V MODELS ONLY 04 9685 0924 00 2 EA LABEL AC INPUT RATING CLR VL500D 240V MODELS ONLY 04 9685 0925 2 EA LABEL AC INPUT RATING VL500D 240V PASTEL MODELS ONLY 04 9685 0925 00 2 EA LABEL AC INPUT RATING CLR VL500D 240V PASTEL MODELS ONLY 04 9685 0926 2 EA LABEL AC INPUT RATING VL500 80 MODELS ONLY 04 9685 0926 00 2 EA LABEL AC INPUT RATING CLR VL500 80 MODELS ONLY 04 9685 0927 2 EA LABEL AC INPUT RATING VL500 80V PASTEL MODELS ONLY 04 9685 0927 00 2 EA LABEL AC INPUT RATING CLR VL500 80 PASTEL MODELS ONLY 04 9685 0930 1 EA LABEL AC INPUT RATING VL500 700W MODELS ONLY 04 9685 0930 00 1 EA LABEL AC INPUT RATING CLR VL500 700W MODELS ONLY 04 9685 0931 1 EA LABEL AC INPUT RATING VL500 700W PASTEL MODELS ONLY 04 9685 0931 00 1 EA LABEL AC INPUT RATING CLR VL500 700W PASTEL MODELS ONLY I 04 9685 0941 1 EA LABEL PRODUCT 700W ARC BALLAST NOT SHOWN 04 9685 0941 00 1 EA LABEL PRODUCT 700W ARC BALLAST CLR NOT SHOWN 04 9685 0942 1 EA LABEL COMPLIANCE ARC BALLAST NOT SHOWN 04 9685 0942 00 1 EA LABEL COMPLIANCE ARC BALLAST CLR NOT SHOWN 02 9685
50. 1 EA SHIELD SENSOR BOARD 3 10 9685 1554 1 EA COVER PAN TUBE 80V 4 10 9685 0557 1 EA COVER VENT LVS 5 10 9685 0558 1 EA FAN MOUNT LVS 6 10 9685 1560 1 EA YOKE LEG TILT SIDE 7 10 9685 1561 1 EA YOKE LEG DIMMER SIDE 8 10 9685 0562 1 EA PLATE TILT MOTOR SLIDE 9 21 9685 0516 1 EA ASSY YOKE CROSSMEMBER 80V 10 21 9685 0540 2 EA ASSY PAN TILT MOTOR 11 23 9685 0782 1 EA ASSY FAN MCB 12 24 9663 3895 1 EA PCB ASSY DMX INPUT 13 24 9685 3740 1 EA TEMPERATURE BOARD LVS 25 9685 0742 1 EA 80V LVS AC VL500 NOT SHOWN 25 9685 0746 1 EA 80V SURGE PROTECTOR VL500 NOT SHOWN 14 25 9685 0756 1 EA CABLE ASSY AC INPUT 15 25 9685 0770 1 EA DISPLAY CABLE RECEPTACLE BLACK 25 9685 2792 1 EA CABLE ASSY MAIN HARNESS 80V VL500 NOT SHOWN 28 9685 0999 1 EA KIT EXTRA US HARDWARE NOT SHOWN 16 51 0541 4 EA SCREW 4X3 8 H L PN BLK ZN 17 52 8295 0002 1 TERMINAL BLOCK 300V 12 AWG 20A 2 POS 18 53 2001 0003 1 EA NUT 10 32 NYLOCK 19 53 2200 0004 4 EA NUT 4 40 KEPS SS 20 53 6521 0001 4 EA SCREW 8 32X1 2 PPB 21 53 6546 0003 8 EA SCREW 8 32X7 16 PPZ 22 53 6552 0002 18 EA SCREW 8 32X1 2 PFB 23 53 6558 0001 1 EA SCREW 6 32X3 8 PPZ 24 53 6559 0002 8 EA SCREW 4 40X1 4 PFB 25 53 6606 0001 2 EA SCREW 4 40X1 2 PFB 26 53 6616 0001 1 EA SCREW 6 32 3 4 PPZ F 27 53 6624 0001 1 EA SCREW 10 32X1 2 PFB 02 9685 0010 A 21 May 2009 131 VAREELITE VL500 LUMINAIRE SERVICE MANUAL
51. 137 0011 2 42 FT WIRE 20 AWG 600V 200 DEGC FEP BLK STRAND 105 40 0 06 DIA 4 73 7137 0012 2 42 FT WIRE 20 AWG 600V 200 DEGC FEP RED STRAND 105 40 0 06 DIA 1 3 174 4 29 Figure 3 74 LVS AC Cable Assembly VL500 VL500D VL500A 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Yoke DMX Communication Cable Assembly 25 9685 0774 Rev E Refer to Figure 3 75 No Item Qty UM Description 1 52 6234 0001 1 EA CONN HOUSING 4 PIN MTA CLOSED END BLUE 2 52 6270 0002 1 EA CONN HOUSING 5 PIN MTA CLOSED END BLUE 3 52 8311 0001 1 EA TERM RING 6 26 22 AWG NON INS TAPE 4 73 2326 0123 3 0 FT WIRE 26 AWG 4 COND 300V 200DEGC BLK BRN RED ORN UL1180 5 73 3526 0005 0 5 FT WIRE 26 AWG 300V 105 DEGC PVC GRN UL1569 3 4 6 1 DMX 5 36 2 Figure 3 75 VL500 Yoke DMX Communication Cable Assembly 02 9685 0010 A 21 May 2009 175 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Yoke Lamp J umper Cable Assembly 25 9685 0776 RevA Refer to Figure 3 76 No Item Qty UM Description 1 52 8348 0001 2 TAB ULTRA FAST 1 4 16 14 AWG INSULATED LOOSE 2 0 13 FT WIRE 14 AWG 200DEGC STRAND TEF WHT Figure 3 76 VL500 Yoke Lamp Jumper Cable Assembly 176 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Backcap Ground Cable Assembly 25 9685 0777 RevA Refer to Figure 3 77
52. 15 1 2 x2 4 Figure 3 55 80V LVS AC Cable Assembly 02 9685 0010 A 21 May 2009 153 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 24V Power Cable Assembly VL500 80V 25 9685 0744 Rev 0 Refer to Figure 3 56 No Item Qty UM Description 1 52 6442 2003 1 EA RECEPT 3 POS MTA156 W TAB 20 AWG 52 6442 2004 1 EA RECEPT 4 POS MTA156 W TAB 20 AWG 3 52 6442 2006 1 EA RECEPT 6 POS MTA156 W TAB YEL 20 AWG 4 73 7137 0011 4 42 FT WIRE 20 AWG 600V 200 DEG C FEP BLK STRAND 105 40 0 06 DIA 5 73 7137 0012 4 42 FT WIRE 20 AWG 600V 200 DEG C FEP RED STRAND 105 40 0 06 DIA 5 8 L 2 4 8 4 45 Figure 3 56 24V Power Cable Assembly VL500 80V 154 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 Yoke Lamp Cable Assembly VL500 80V 25 9685 0745 RevA Refer to Figure 3 57 No Item Qty UM Description 1 52 8244 0001 2 EA RECEPT FASTON FLAG 0 250 16 14 AWG REEL 2 52 8329 0001 2 EA TERM RING 6 22 16 AWG NON INS 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 73 3520 0005 0 63 FT WIRE 20 AWG 300V 105 DEGC PVC GRN UL1015 5 73 6014 0012 1 9 FT WIRE 14 AWG 600V 200 DEGC FEP BLK STRAND 168 36 0 104 DIA 6 73 6014 0013 1 8 FT WIRE 14 AWG 600V 200 DEGC FEP WHT STRAND 168 36 0 104 DIA 7 73 7130 0006 1 25 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER Figure 3 57 Yoke Lamp Cable Assem
53. 25 9685 0745 1 EA CABLE ASSY 80V YOKE LAMP WIRES 4 25 9685 0758 1 EA CABLE ASSY PAN TILT 5 25 9685 0772 1 EA CABLE ASSY YOKE GROUND 6 25 9685 0788 1 EA CABLE ASSY SHIELDED DISPLAY DMX COMM VL500 80V 7 25 9685 0782 1 EA CABLE ASSY MCB YOKE GROUND 8 55 2186 0001 8 CABLETIE 0 10 4 SMALL 9 55 6699 0010 2 10 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 02 9685 0010 A 21 May 2009 191 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V Main Harness Cable Assembly con tinued Figure 3 89 VL500 80V Main Harness Cable Assembly VL500 80V 192 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 80V Lamp Wire Harness 25 9685 0793 Rev B Refer to Figure 3 90 No Item Qty UM Description 1 25 9685 0777 1 EA CABLE ASSY BACK CAP GROUND VL500 2 52 8244 0001 2 EA FASTON RECEPT FLAG 0 250 16 14 AWG INSULATED REEL 3 52 8298 1140 2 EA FERRULE WIRE 1 X 14AWG NON INSUL 4 55 2186 0002 2 EA CABLE TIE 3 3 4 LG 0 9WD TEFZEL 5 55 2199 1000 0 38 FT HEATSHRINK 1 BLACK 6 55 2260 0133 2 42 FT SLEEVING FIBERGLASS 0 133 ID 7 55 6699 0010 1 25 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 8 68 4541 0001 1 EA FERRITE 15 X 5 9 X 35MM CYLINDRICAL CORE 9 68 4541 0002 1 EA FERRITE 18 67 X 10 16 X 28 58MM CYLINDRICAL CORE 10 73 3517 0001 5 04 FT WIRE 14 AWG 5KV 200DEGC SILICON 7X24 36 STRA
54. 3 6558 0010 4 EA SCREW 6 32X1 4 PPZ SEMS 4 x4 5 4 Figure 3 42 VL500 US Extra Hardware Kit 02 9685 0010 A 21 May 2009 135 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Pan Tilt Motor Assembly 21 9685 0540 Rev C Refer to Figure 3 43 No Item Qty UM Description 1 10 9685 0541 1 EA PLATE TENSION ADJUSTMENT PAN TILT 2 21 9685 0545 1 EA ASSY DRIVE PULLEY VL500 2a 10 9685 0524 1 EA PULLEY DRIVE PAN TILT 2MM GT 18 TOOTH 2b 10 9678 8720 1 EA CODEWHEEL 120 COUNT 3 24 9685 7735 1 EA BOARD ASSY PAN TILT ENCODER VL500 4 44 9678 0680 EA MOTOR 3 PHASE SZ 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6558 0001 2 EA SCREW 6 32X3 8 PPZ 7 53 6575 0004 4 EA SCREW 8 32X5 8 PPZ 8 55 6627 0001 2 EA WASHER 6 SPLIT LOCK 9 84 0100 0 5 IN TAPE KAPTON 0 035 WIDE P221 136 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Pan Tilt Motor Assembly continued Detail A 2 See Detail A 7 x4 Drive Pulley Detail amp Installation 2 Step 1 Apply one drop of Loctite 603 to motor shaft Tape goes under this Step 2 Install drive pulley on motor shaft using twisting motion board between standoffs to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Note location o
55. 31 Rev 0 VL500 Extra Hardware Kit 28 9685 0999 Rev 0 VL500 AC Input Cable Assembly 25 9685 0756 Rev B VL500 Arc Ballast Interconnect Cable Assembly 25 9685 0767 Rev B Relay to Ignitor Cable Assembly 25 9685 0755 Rev B VL500 Arc Ballast Assembly 21 9685 0802 Rev H VL500 Arc Ballast Input Cable Assembly 25 9685 0757 Rev C Ballast I O Cable Assembly 25 9685 0807 Rev A VL500 Display Remote Cable Assembly 25 9685 0770 Rev B VL500 Arc Main Harness Cable Assembly 25 9685 0791 Rev C VL500A Yoke Crossmember Assembly VL500 VL500D VL500A 21 9685 0515 Rev E Lower Crossmember Assembly 21 9685 0512 Rev K Upper Crossmember Assembly 21 9685 0513 Rev H Pan Tube Assembly VL500 VL500D VL500A 21 9685 0535 Rev D VL500 VL500D VL500A Figure 3 6 VL500A Arc Luminaires Drawing Tree Part 2 02 9685 0010 A 21 May 2009 79 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Top Assembly Included Items Kit 28 9685 0001 Rev G 120V or 240V Standard Colors No Dimmer 28 9685 0002 Rev G Standard Colors 120V IGBT On Board Dimmer 28 9685 0003 Rev G Standard Colors 240V IGBT On Board Dimmer 28 9685 0004 Rev G Standard Colors 80V On Board Dimmer 28 9685 0006 Rev G 700W Arc Standard Colors Arc Ballast Refer to Figure 3 7 No Item Qty UM Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVIC
56. 5 3301 0010 2 WASHER 10 FLAT 14 55 6549 0001 1 EA WASHER 1 4 SPLIT LOCK 15 55 6677 0035 2 WASHER 0 750 OD 0 187 ID 144 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Lower Crossmember Assembly continued 7 x2 11 Figure 3 48 Lower Crossmember Assembly 02 9685 0010 A 21 May 2009 145 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Upper Crossmember Assembly 21 9685 0513 Rev H Refer to Figure 3 48 146 Figure 3 49 Upper Crossmember Assembly No Item Qty UM Description 1 10 9685 1510 1 EA UPPER CROSSMEMBER 2 10 9685 0527 2 EA WASHER CENTERING STEP 3 53 2020 0001 2 NUT 1 4X20 HEX STL ZINC PLTD 4 54 1255 0001 1 EA ASSY BEARING HOUSING 5 55 6549 0001 2 EA WASHER 1 4 SPLIT LOCK 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Pan Tube Assembly VL500 VVL500D VL500A 21 9685 0535 Rev D VL500 VL500D VL500A Refer to Figure 3 50 No Item Qty UM Description 1 10 9685 0521 1 EA PULLEY DRIVEN PAN TILT 2 10 9685 0531 1 EA PAN TUBE 3 10 9685 0532 1 EA PANPULLEY SPACER 4 53 2200 0006 4 EA NUT 6 32 KEPS SS 5 53 6608 0750 2 EA SCREW 6 32X3 4 PFB X 5 x2 4 x4 Figure 3 50 Pan Tube Assembly VL500 VL500D VL500A 02 9685 0010 A 21 May 2009 147 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Pan Tube Assembly
57. 52 8271 0005 1 EA RECEPT FASTON 1 4 16 14 AWG INSULATED REEL 5 73 7137 0011 3 79 FT WIRE 20 AWG 600V 200 DEG C FEP BLK STRAND 105 40 0 06 DIA 6 73 7137 0012 4 54 FT WIRE 20 AWG 600V 200 DEG C FEP RED STRAND 105 40 0 06 DIA 6 8 1 5 37 5 6 37 5 Figure 3 60 24V Power Cable Assembly VL500 VL500D 158 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Motor Cable Assembly 25 9685 0753 Rev B Refer to Figure 3 61 No Item Qty UM Description 1 52 6224 1034 1 EA COVER FRONT 34 POS MT LATCHING 2 52 6224 2034 1 EA COVER BACK 34 POS MT 3 52 6610 0034 1 EA CONN HOUSING 34 POS DBL ROW UNLOADED 4 52 6694 0001 16 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2MM 28 24 AWG 5 52 6696 0001 4 EA RECEPT WIRE TO WIRE 4 POS 2MM PITCH 28 24 AWG 6 52 8351 0004 34 EA CONTACT 26 22 AWG RECP MTE REEL 7 55 2186 0001 2 EA CABLE TIE 0 10 X4 SMALL 8 55 6699 0010 1 FT SLEEVING 5 16 NOM DIA WOV POLY ROUNDIT 2000 9 73 2326 0123 5 35 FT WIRE 26 AWG 4 COND 300V 200DEGC TEF BLK BRN RED ORG 02 9685 0010 A 21 May 2009 159 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Motor Cable Assembly continued 1 2 3 6 Figure 3 61 VL500 Motor Cable Assembly 160 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Relay to Ignitor Cable Assembly 25 9685 0755 Rev B Refer to Figure 3 62
58. 8 J3 J2 Magenta Motor Ferrite i p Thermal Core Blue DMX Display Switch Motor PCB Remote 1 LVS Conn Amber Motor Far Far v Diffuser Terminal 80V Motor Block gt Dimmer an T Luminaire Power In 14 21 May 2009 02 9685 0010 A DESCRIPTION 1 VL500A Luminaire VL500A Arc Block Diagram With External Arc Ballast Backcap Interlock Motor Block Pan Tilt 1 Motor Motor i ARC Ballast Relay 4 gt Pan Tilt Encoder Encoder v J4 J5 VL500 Main Control Board MCB J7 J6 J8 J3 Tee A A Magenta Motor Thermal Blue DMX lt Display amp P_ Switch Motor PCB Remote LVS Conn Amber Maec re Thru In x Far Far Terminal A Luminaire Power In 02 9685 0010 A 21 May 2009 15 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Notes 16 21 May 2009 02 9685 0010A CHAPTER 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Equipment Handling e Maintenance Procedures A WARNING All maintenance procedures are to be performed with power removed from the luminaire Never remove cover or backcap while lamp is in operation
59. 85 0010A MAINTENANCE 2 Step 4 Disconnect the following wiring connections on PCB a 2 position connector LVS Fan b 4 position connector LVS Fan from MCB Step 5 As shown in Figure 28 remove one 6 32x3 8 PPZ securing LVS Temperature PCB to LVS fan mount Step 6 Remove LVS Temperature PCB Step 7 Replace by performing steps 2 through 6 in reverse order 02 9685 0010 A 21 May 2009 57 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 58 Tilt Motor Assembly Replacement Parts 21 9685 0540 1 EA ASSY PAN TILT MOTOR Tools 2 Phillips Screwdriver Diagonal Cutters WARNING Remove power from luminaire before performing maintenance To remove and replace tilt motor assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove display side yoke cover by removing four 6 32x3 8 LG PTB screws Step 3 Remove Display PCB and Main Control PCB by following procedures Display PCB Replacement on page 49 and Main Control PCB Fan Assembly Replacement on page 50 Step 4 Remove 4 x 6 32 x 3 8 PFB screws two each side of yoke that hold Top Cover Louver Plate and remove plate Step 5 Disconnect wiring from motor and encoder PCB Step 6 Cut wire tie connecting wiring to yoke arm 21 May 2009 02 9685 0010A MAINTENANCE 2 Step 7 Loosen do NOT remove four 8 32x7 16 PPZ screws that mount Pan Tilt motor assembly to Tilt Motor Slide Plate Tilt Motor imus Assembly s
60. 87 1 EA HEAD COVER BOTTOM 25 9685 0753 1 EA CABLE ASSY VL500 MOTOR 5 25 9685 0755 1 EA CABLE ASSY RELAY HARNESS NOT SHOWN 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDING NOT SHOWN s 25 9685 0767 1 EA CABLE ASSY BALLAST INTERCONNECT 700W NOT SHOWN S 28 9685 0006 1 EA INCLUDED ITEMS KIT VL500 ARC NOT SHOWN 12 42 9685 0207 1 EA LENS PAR 64 NSP STIPPLE 13 53 6523 0013 8 EA SCREW 6 32X3 8 LG PTB 14 53 6558 0009 8 EA SCREW 6 32X3 8 LG PPZ SEMS 15 53 6558 0010 4 EA SCREW 6 32X1 4 PPB SEMS 16 53 6608 0001 8 EA SCREW 6 32X3 8 02 9685 0010 A 21 May 2009 93 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500A 700W Arc Luminaire continued Figure 3 13 VLS00A Luminaire 700W Arc 94 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Generic VL500 Luminaire Assembly 21 9685 0010 Re 21 9685 0011 Re 21 9685 0012 Re 21 9685 0013 Re S 5 5 5 lt lt lt lt Incandescent without Internal Dimmer Incandescent with Internal IGBT Dimmer Incandescent with Internal 80V Dimmer Arc Refer to Figure 3 14 Figure 3 15 and Figure 3 16 No Item Qty UM Description 1 10 9685 0521 1 EA PULLEY DRIVEN PAN TILT 2 10 9685 0542 1 EA SHIELD WIRE LVS 3 10 9685 0555 1 EA LENS DISPLAY VL500 4 10 9685 0556 1 EA
61. 9 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Magenta Blue Pastel Color Assembly 21 9685 0174 Rev A Pastel DICRO TUNE Colors Refer to Figure 3 24 No Item Qty UM Description 1 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 2 21 9685 0164 1 EA ASSY MAGENTA BLUE PASTEL DICRO TUNE 3 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 4 53 6592 0250 8 EA SCREW 4 40 1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 4 x4 Figure 3 24 VL500 Magenta Blue Pastel Color Assembly 110 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Amber Diffuser Color Assembly 21 9685 0171 Rev G Refer to Figure 3 25 No Item Qty UM Description 1 10 9685 0245 2 EA LIGHT BAFFLE TOP 2 21 9685 0161 1 EA ASSY AMBER DIFFUSER DICRO TUNE 3 21 9685 0281 1 EA MOTOR ASSY AMBER DIFFUSER 4 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 1 4 x4 2 3 4 x4 Figure 3 25 VL500 Amber Diffuser Color Assembly 02 9685 0010 A 21 May 2009 111 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Amber Dimmer Color Assembly 21 9685 0172 Rev F Refer to Figure 3 26 No Item Qty UM Description 1 10 9685 0245 2 LIGHT BAFFLE TOP 2 21 9685 0162 1 ASSY AMBER DIMMER DICRO TUNE 3 21 9685 0281 1 MOTOR ASSY AMB
62. 9685 0322 VL500 80V Rev H Included Items Kit 21 9685 0174 Rev A Pastel 28 9685 0004 Rev G DICRO TUNE Colors Standard Colors 80V On Board Dimmer or Magenta Blue Color Motor 28 9685 0006 Rev G 700W Assembly Arc Standard Colors Arc 21 9685 0280 Rev A VL500 Backcap Ground Cable Assembly 25 9685 0777 Rev A Ballast VL500 80V Lamp Wire Harness 25 9685 0793 Rev B Magenta Blue Pastel VL500 Amber Diffuser Color Color Assembly Assembly 21 9685 0164 Rev 0 Pastel 21 9685 0171 RevG DICRO TUNE Colors VL500 80V Yoke Assembly 21 9685 0523 VL500 80V Rev Q Amber Diffuser Color Motor Bottom Bulkhead Assembly Assembly 21 9685 0150 Rev C VL500 Pan Tilt Motor 21 9685 0281 Rev A Assembly 21 9685 0540 Rev C Drive Ring Assembly 21 9685 0280 Rev A Amber Diffuser Color VL500 MCB FAN Assembly Assembly M 21 9685 0280 Rev A Top Bulkhead Assembly OD MCB Fan Assembly 21 9685 0151 Rev C Magenta Blue Color Drive Ring Assembly Assembly DMX Input PCB Assembly 21 9685 0280 RevA 21 9685 0160 Rev E Standard DICRO TUNE Colors 24 9663 3895 Rev 0 Bottom Bulkhead Assembly 21 9685 0150 Rev continued next page Drive Ring Assembly 21 9685 0280 Rev A Figure 3 3 VL500 80V Incandescent Luminaires Drawing Tree Part 1 76 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 80V Incandescent Luminaires contin ue continued from previous page VL500 80V Yoke Assembly 21 9685 0523 VL5
63. A Fixtures 02 9685 0010 A 21 May 2009 29 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Step 5 Ensure the following Step Step Step Step Step Step Step Step Step Do not remove or use to access lamp a Reflector is mounted in center of rear casting and secure enough to prevent it from moving If not at three reflector mounting clips using 1 Phillips screw driver remove three 6 32x1 8 PPSS screws remove light baffle ring and loosen three 1 4 hex standoffs b Center reflector and retighten reflector clips by tightening standoffs Make sure clips are square so the light baffle ring will fit perfectly over the clips c Reinstall light baffle ring d Lamp is properly and completely seated in the lamp socket in the centered in opening of reflector Adjust as necessary Using soft lint free dry cloth wipe lamp and reflector clean of any dust or finger prints Close and latch heatsink assembly Disengage service tilt lock to allow luminaire head to move freely Supply power to luminaire Disable pan tilt if necessary Set color to WHITE and intensity to 100 Unlatch and swing open front lens ring this will make hot spot and halo easier to see Shine lamp on flat surface 10 20 feet away Using lamp adjustment screws shown in Figure 6 adjust lamp a Minimize size of halo around hot spot It will not completely disappear but should be even and symmetrical all the way
64. 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 VorsichtsmaDnahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet VORSICHT weist auf m glichen Produktschaden hin WARNUNG weist auf m gliche K rperverletzung und Leb ensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHER HEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUER BERH HTE UV STRAHLUNG UND KORPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VARIX LITE Scheinwerfer sind ausschlie lich f r den Einsatz mit bestimmten Philips und Osram HID Lampen geeignet Achten Sie auf den Lampentyp MSR400 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 VAREKLITEG Scheinwerfer von brennbarem Material oder beleuchteten Objekten WARNUNG HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK 1 VARI LITE Scheinwerfer eignen
65. ATED 7 68 4541 0003 2 EA FERRITE 25 91 X 12 83 X 28 58 MM CYLINDRICAL CONE 8 71 0632 0 75 IN WIRE 18 AWG GRN UL1007 STRANDED 9 73 7140 0003 1 EA CABLE 3 COND BRAID SHIELD 26 AWG TFE INS 200 DEGC 6 2 7 7 5 1 2 3 8 4 5 52 6396 2803 Pin Out Wire Red Black White 52 6396 2804 Pin Out Wire Open Red Black White Figure 3 86 80V Dimmer Communication Cable Assembly VL500 80V 186 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Main Harness Cable Assembly 25 9685 0790 Rev J VL500 and VL500D Refer to Figure 3 87 No Item Qty UM Description 1 25 9685 0750 1 EA CABLE ASSY DIMMER COMM 2 25 9685 0752 1 EA CABLE ASSY 24V POWER 3 25 9685 0758 1 EA CABLE ASSY PAN TILT 4 25 9685 0769 1 EA CABLE ASSY DISPLAY CABLE 5 25 9685 0771 1 EA CABLE ASSY YOKE LAMP WIRES 6 25 9685 0772 1 EA CABLE ASSY YOKE GROUND 7 25 9685 0773 1 EA CABLE ASSY LVS AC 8 25 9685 0774 1 EA CABLE ASSY YOKE DMX COMM 9 25 9685 0778 1 EA CABLE ASSY LVS FAN 10 25 9685 0782 1 EA CABLE ASSY MCB YOKE GROUND 11 55 2186 0001 8 CABLE TIE 0 10 4 SMALL 12 55 6699 0003 1 19 FT SLEEVING 1 2 NOM DIA WOVEN POLY 13 55 6699 0010 0 92 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 02 9685 0010 A 21 May 2009 187 VAREELITE VL500 LUMINAIRE SERVICE MANUAL de Main H
66. B Heatsink Assembly Provides access to lamp for replacement 02 9685 0010 A Lamp Power Input Cable 8 ILE Menu Display Used to input manual commands program test Set defaults and access internal status information 21 May 2009 Input Panel Connections Mini XLR for Remote Data Thru 3 Pole Neutrik Data In Locking Connector for AC Input Input Panel Provides DMX In and Thru and AC Power connections AC Power Input Cable Yoke Leg Power Contains power supply and dimmer dimmer models Head Assembly Houses color dimmer arc models or difusser tungsten models mechanisms Menu Display Controls _ LCD Display Softkeys The menu has four softkey buttons that change to accommodate menu selection VAREELITE VL500 LUMINAIRE SERVICE MANUAL Luminaire Internal Head Components The following illustration shows the major sub assemblies that are located in the luminaire head assembly Note Yoke assembly not shown for clarity Amber Diffuser Assembly Tungsten Models DICHRO TUNE color bulkhead 16 radially Magenta Blue Assembly All Models mounted diffuser panels for beam control and amber dichroic glass for color mixing DICHRO TUNE color bulkhead 16 radially mounted magenta and blue dichroic glass for color mixing Amber Dimming Assembly Arc Models DICHRO TUNE color bulkhead 16 radially mounted blackout
67. E 2 02 8001 0002 1 EA QA CERTIFICATE VARI LITE 3 02 8052 0001 1 EA CARD LIMITED WARRANTY 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION VL500 5 02 9685 0002 1 EA UNPACK QUICK START SHEET VL500 6 07 9685 1005 1 EA SHIPPING BOX CARDBOARD VL500 7 08 0500 0001 1 EA CD ROM VL500 PRODUCT DOCUMENTATION 8 52 6541 0001 1 EA CONN BLUE CABLE PWR INLET 3 POLE LOCKING POWERCON 9 53 6505 0027 1 EA BOLT 1 2 X 13 X 1 LG HX HD ZINC VL500A MODELS ONLY 10 55 6539 0001 1 EA WASHER 1 2 SPLIT LOCK VL500A MODELS ONLY 11 71 2526 0230 1 EA 230V 1000W TUNGSTEN HALOGEN LAMP VL500D 240V ONLY 71 2529 0120 1 EA 120V 1200W TUNGSTEN HALOGEN LAMP VL500D 120V ONLY 71 9685 0082 1 EA 80V 1200W TUNGSTEN HALOGEN LAMP VLS00 80V ONLY 71 9685 0702 1 EA 700W MSR ARC LAMP VL500A ONLY 80 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Included Items Kit continued 10 Arc Models Only Figure 3 7 Included Items Kit 02 9685 0010 A 21 May 2009 81 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Label Locations 16 9685 00YY Rev D Refer to Figure 3 8 Note CLR Clear labels for use with non black fixtures No Item Qty UM Description 1 04 9661 0034 1 EA LABEL RELAMPING 2000 SERIES 2 04 9663 1837 1 EA LABEL PATENT 3 04 9685 0911 1 EA LABEL WARNING VL500 04 9685 0911 00 1 EA LABEL WARNING VL
68. EPT FASTON FLAG 0 250 16 14 AWG REEL 2 52 8329 0001 2 EA TERM RING 6 22 16 AWG NON INS 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 73 3520 0005 0 75 FT WIRE 20 AWG 300V 105 DEGC PVC GRN UL1015 5 73 6014 0012 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP BLK STRAND 168 36 0 104 DIA 6 73 6014 0013 2 33 FT WIRE 14 AWG 600V 200 DEGC FEP WHT STRAND 168 36 0 104 DIA 7 73 7130 0006 2 17 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER 2 x2 4 7 4 2 1 x2 Figure 3 80 Arc Yoke Lamp Cable Assembly VL500A 180 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Shielded Display DMX Communication Cable Assembly VL500A 25 9685 0784 Rev C Refer to Figure 3 81 No Item Qty UM Description 1 25 9685 0769 1 EA CABLE ASSY DISPLAY 2 25 9685 0774 1 EA CABLE ASSY YOKE DMX 3 52 8311 0004 2 EA TERM RING 6 16 14 AWG NON INS BOX 4 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 5 73 7130 0006 8 33 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER Figure 3 81 Shielded Display DMX Communication Cable Assembly VL500A 02 9685 0010 A 21 May 2009 181 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V Display Cable Assembly 25 9685 0785 Rev 0 Refer to Figure 3 82 No Item Qty UM Description 1 52 6363 0001 1 EA CONN HOUSING 6 PIN MTA CLOSED END BLUE 52 6264 0005 1 EA CONN HOUSING MOD4 CRIMP SNAP IN 0 1 X 0 1 3 52 6240 0003 9 EA CONTACT FEMALE
69. ER DIFFUSER 4 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 5 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 1 4 x4 Figure 3 26 VL500 Amber Dimmer Color Assembly 112 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Magenta Blue Arc Color Assembly 21 9685 0173 Rev A Standard DICRO TUNE Colors Refer to Figure 3 27 No Item Qty UM Description 1 10 9685 0246 4 EA CLIP UV GLASS 2 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 3 21 9685 0160 1 EA ASSY MAGENTA BLUE STANDARD DICRO TUNE 4 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 5 42 9685 0130 1 EA GLASS UV 6 53 6592 0250 8 EA SCREW 4 40 1 4 PPB SEMS 7 55 6704 0015 1 EA STANDOFF 5 16 HEX 6 32X0 593 LG 6 x4 2 x2 6 x4 1 x4 Figure 3 27 VL500 Magenta Blue Arc Color Assembly 02 9685 0010 A 21 May 2009 113 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Magenta Blue Arc Pastel Color Assembly 21 9685 0175 Rev A Pastel DICRO TUNE Colors Refer to Figure 3 28 No Item Qty UM Description 1 10 9685 0246 4 EA CLIP UV GLASS 2 10 9685 0257 2 EA LIGHT BAFFLE REAR BULKHEAD 3 21 9685 0164 1 EA ASSY MAGENTA BLUE PASTEL DICRO TUNE 4 21 9685 0280 1 EA MOTOR ASSY MAG BLUE 5 42 9685 0130 1 EA GLASS UV 6 53 6592 0250 8 EA SCREW 4 40X1 4 PPB SEMS 7 55 6704 0015 1 STANDOFF 5 16 HEX 6 32X0 593 LG 4 6
70. EW 6 32X3 8 PFB 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL NOT SHOWN 23 67 4006 0007 1 EA CLAMP CABLE EMI SUP FERRITE 0 193 ID 02 9685 0010 A 21 May 2009 91 VARE LITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V with 80V Dimmer Luminaire con tinued 19 x8 12 VL500 80V with 80V Dimmer Luminaire Figure 3 12 02 9685 0010 A 21 May 2009 92 ILLUSTRATED PARTS BREAKDOWN 3 VL500A 700W Arc Luminaire 20 9685 0006 Rev H Standard DICRO TUNE Colors 20 9685 0016 Rev B Pastel DICRO TUNE Colors Refer to Figure 3 13 No Item Qty UM Description 1 04 9685 0573 1 LABEL MCB YOKE COVER 2 04 9685 0574 1 EA LABEL MCB YOKE COVER 3 04 9685 0588 1 EA LABEL YOKE COVER PLAIN VL500 4 10 9685 0525 2 LOUVER PLATE TOP COVER 5 10 9685 0580 1 EA YOKE ARM COVER DISPLAY SIDE 6 10 9685 0584 1 EA YOKE ARM COVER IGNITOR SIDE 7 21 9685 0013 1 EA ASSY GENERIC VL500 ARC 8 21 9685 0172 1 EA ASSY COLOR AMBER DIMMER 9 21 9685 0173 1 EA ASSY COLOR MAGENTA BLUE ARC STANDARD 20 9685 0006 ONLY 21 9685 0175 1 EA ASSY COLOR MAGENTA BLUE ARC PASTEL 20 9685 0016 ONLY S 21 9685 0802 1 EA ASSY BALLAST 700 EXTERNAL NOT SHOWN 10 22 9685 0086 1 EA HEAD COVER 11 22 9685 00
71. ICHRO TUNE STD 22 9685 0123 16 EA ASSY FILTER BLUE DICHRO TUNE STD 22 9685 0120 16 EA ASS FILTER MAGENTA DICHRO TUNE PASTEL 22 9685 0121 16 EA ASSY FILTER BLUE DICHRO TUNE PASTEL 22 9685 0124 16 EA ASSY FILTER AMBER DICHRO TUNE 22 9685 0126 16 EA ASSY FILTER DIFFUSER PANEL Tools 1 Phillips screwdriver Tweaker Screwdriver Cotton Gloves or Finger Cots Clean lint free soft cloth To remove and replace color filters or diffuser panels Step 1 Ensure glass filter or diffuser panels are in closed position WARNING Remove power from luminaire before performing maintenance Step 2 Remove power from luminaire Step 3 Set the luminaire head horizontally Step 4 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 5 Remove desired bulkhead assembly as follows a For Magenta Blue bulkhead removal refer to Magenta Blue DICHRO TUNE Rear Bulkhead Replacement on page 33 Remove Magenta Blue bulkhead b For Amber Diffuser bulkhead removal refer to Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Replacement on page 35 Remove Amber Diffuser bulkhead WARNING Wear cotton gloves or other covering while handling filters or diffuser panels If required use isopropyl alcohol and soft lint free cloth to thoroughly clean glass portion of lamp CAUTION Work carefully when removing filter and panels Filters and pan
72. K 22 AWG DATA 9 RED 22 AWG DATA Figure 3 69 VL500 Arc Ballast Interconnect Cable Assembly 02 9685 0010 A 21 May 2009 169 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Display Cable Assembly 25 9685 0769 Rev C Refer to Figure 3 70 No Item Qty UM Description 1 52 6363 0001 1 EA CONN HOUSING 6 PIN MTA CLOSED END BLUE 52 6264 0005 1 EA CONN HOUSING MOD4 CRIMP SNAP IN 0 1 X 0 1 3 52 6240 0003 9 EA CONTACT FEMALE MOD4 CRIMP SNAP IN 4 52 6696 0001 1 EA RECEPT WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 5 52 6694 0001 4 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2MM 28 24 AWG 6 73 5126 0130 0 42 FT WIRE 26 AWG 4 COND 300V 200 DEGC TEF lt BLK WHT RED WHT RED gt 7 73 2326 0123 3 08 FT WIRE 4 COND 300V 200 DEGC TEF lt BLK BRN RED ORN gt 2 3 See Detail A Detail A Connector Layout viewed from wire side 170 6 1 re Figure 3 70 VL500 Display Cable Assembly 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Display Remote Cable Assembly 25 9685 0770 Rev B Refer to Figure 3 71 No Item Qty UM Description 1 10 9685 0536 01 1 EA ADAPTER PLATE MINI XLR BLACK 10 9685 0536 02 1 EA ADAPTER PLATE MINI XLR WHITE 2 52 6694 0002 4 EA CRIMP TERM WIRE TO WIRE MALE 3 52 6696 0003 1 EA PLUG WIRE TO WIRE 4 POS 4 53 6501 0002 1 EA CONN MINI XLR 4 PIN PANEL MOUNT
73. LT MOTOR 10 23 9685 0782 1 EA ASSY FAN MCB 11 24 9663 3895 1 EA PCB ASSY DMX INPUT 12 24 9685 3740 1 EA TEMPERATURE BOARD LVS 13 25 9663 2030 1 EA CABLE ASSY INCANDESCENT POWER VL500 ONLY 14 25 9685 0756 1 EA CABLE ASSY AC INPUT 15 25 9685 0757 1 EA CABLE ASSY ARC BALLAST INPUT VLS00A ONLY 16 25 9685 0770 1 EA DISPLAY CABLE RECEPTACLE BLACK 25 9685 0790 1 EA CABLE ASSY MAIN HARNESS INCANDESCENT VL500 AND VL500D ONLY NOT SHOWN 25 9685 0791 1 EA CABLE ASSY MAIN HARNESS VLS00A ONLY NOT SHOWN 28 9685 0999 1 EA KIT EXTRA US HARDWARE NOT SHOWN 17 51 0541 4 EA SCREW 4X3 8 H L PN BLK ZN 18 52 8295 0002 2 EA TERMINAL BLOCK 300V 12 AWG 20A 2 POS 19 53 2001 0003 1 EA NUT 10 32 NYLOCK 20 53 2200 0004 2 EA NUT 4 40 KEPS SS 21 53 2200 0006 4 EA NUT 6 32 KEPS SS VL500D AND VL500A ONLY 22 53 2202 0004 4 EA NUT 4 40 HEX SS NYLON INSERT 02 9685 0010 A 21 May 2009 127 VAREELITE VL500 LUMINAIRE SERVICE MANUAL No Item Qty UM Description 23 53 6519 0001 3 EA SCREW 4 40X5 8 PPZ 24 53 6521 0001 4 EA SCREW 8 32X1 2 PPB 25 53 6526 0002 2 EA SCREW 6 32X5 8 PPZ TYPE F 26 53 6546 0003 8 EA SCREW 8 32X7 16 PPZ 27 53 6552 0002 18 EA SCREW 8 32X1 2 PFB 28 53 6559 0002 2 EA SCREW 4 40X1 4 PFB 29 53 6606 0001 2 EA SCREW 4 40X1 2 PFB 30 53 6608 0750 4 EA SCREW 6 32X3 8 PFB 31 53 6624 0001 1 EA SCREW 1
74. ND 11 73 7130 0006 0 83 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER 12 55 2183 0001 0 17 FT HEATSHRINK 1 2 BLACK 3 6 58 11 12 5 EC e Figure 3 90 VL500 80V Iginitor to Socket Cable Assembly 02 9685 0010 A 21 May 2009 193 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Notes 194 21 May 2009 02 9685 0010A Arc Ballast Assembly ILLUSTRATED PARTS BREAKDOWN 3 VL500 Arc Ballast Assembly 21 9685 0802 Rev H Refer to Figure 3 91 No Item Qty UM Description 1 04 9685 0941 1 EA LABEL PRODUCT VL500APS 700W 2 04 9685 0942 1 EA LABEL PRODUCT VL500APS COMPLIANCE BLK 3 04 9685 0946 1 EA LABEL BALLAST WATTAGE 700W 4 10 9669 0034 1 EA PLATE NUT 5 10 9685 0822 1 EA MOUNT PLATE BALLAST 6 10 9685 0823 1 EA BOTTOM PLATE BALLAST BLK 7 10 9685 0824 1 EA TOP PLATE BALLAST BLK 8 10 9685 0825 1 EA COVER BALLAST BLK 9 10 9685 0826 1 EA PANEL FILLER BALLAST BLK 10 12 9685 0821 2 EA HEATSINK BALLAST MACHINED BLK 11 23 9685 0827 1 EA FAN ASSY ARC BALLAST 700W 12 25 9685 0807 1 EA CABLE ASSY BALLAST IO 13 53 2002 0001 EA NUT 6 32 KEPS ZINC 14 53 2003 0001 EA NUT 4 40 KEP ZINC PLATED 15 53 6520 0001 EA SCREW 4 40X3 8 PPZ 4 4 5 16 53 6545 0001 4 EA SCREW 8 32X3 8 PPZ 4 4 17 53 6551 0001 EA SCREW 4 40X3 8 PPB 18 53 6571 0002 EA SCREW 6 32X1 1 4 LG PPB 19 53 6575 0021 12 EA SCREW 8 32X5 8 PPB TYPE F
75. NUAL Magenta Blue DICHRO TUNE Rear Bulkhead Replacement continued Step 5 At top cover remove two or four depending on production date 6 32x1 4 PPB SEMS screws Step 6 Remove top cover Step 7 Disconnect wiring at two linear actuators on Magenta Blue DICHRO TUNE Bulkhead Step 8 As shown in Figure 9 at side rails from top remove four 6 32x3 8 LG PPZ SEMS screws Magenta Blue Assembly 6 32x3 8 PPZ SEMS x4 Side Rail NOTE Some components not shown for clarity Figure 9 Magenta Blue Color Bulkhead Step 9 Carefully lift Magenta Blue bulkhead out of luminaire head Step 10 Replace by performing steps 2 through 9 in reverse order Note This is also the procedure to convert a standard color bulkhead to pastel color bulkhead or vice versa 34 21 May 2009 02 9685 0010A MAINTENANCE 2 Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Replacement Parts 21 9685 0171 1 EA ASSY AMBER DIFFUSER INCANDESCENT MODELS 21 9685 0172 1 EA ASSY AMBER DIMMER ARC MODELS Tools 2 Phillips Screwdriver To remove and replace Amber Diffuser or Dimmer bulkhead assembly Step 1 CLOSE ALL GLASS IN BULKHEADS Power up unit and allow all DICHRO TUNE glass to calibrate Once they close power down unit A WARNING Remove power from luminaire before performing maintenance Step 2 Disconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in
76. OVERLAY DISPLAY VL500 5 10 9685 0564 1 EA PANEL TILT CLOSEOUT 6 10 9685 0566 1 EA PLATE TILT LOCK 7 10 9685 0567 1 EA HEAT SHIELD TILT SIDE 8 10 9685 0568 1 EA HEAT SHIELD DIMMER POWER SUPPLY SIDE 9 10 9685 1569 1 EA HEAT SHIELD CROSSMEMBER 10 10 9685 0570 1 EA SPACER TILT TUBE 11 10 9685 0571 2 EA PLUG TILT TUBE 12 10 9685 0572 1 EA CONTERWEIGHT VL500 VLS00 80V ONLY 10 9685 0575 1 EA CONTERWEIGHT VL500 VL500D ONLY 13 21 9685 0310 1 EA ASSY GENERIC VL500 INCANDESCENT VL500 AND VLS00D ONLY 14 21 9685 0311 1 EA ASSY GENERIC VL500 ARC 1 500 ONLY 15 21 9685 0312 1 EA ASSY GENERIC VL500 INCANDESCENT 80V VL500 80 ONLY 16 21 9685 0520 1 EA ASSY YOKE BASE INCANDESCENT VL500 ONLY 17 21 9685 0521 1 EA ASSY YOKE BASE INTERNAL IGBT DIMMER VL500D ONLY 18 21 9685 0522 1 EA ASSY YOKE BASE EXTERNAL BALLAST VLS00A ONLY 19 21 9685 0523 1 EA ASSY YOKE BASE INTERNAL 80V DIMMER VL500 80V ONLY 20 21 9685 0731 1 EA ASSY MCB FAN 21 23 9650 3327 1 EA RELAY ELECTRICAL ASSY VL500A ONLY 22 24 9685 4826 1 EA ASSY VL500 DISPLAY BOARD 23 24 9685 1000 1 EA IGNITOR ARC VL500A ONLY 5 25 9685 0776 2 EA YOKE LAMP JUMPER WIRES VL500 ONLY NOT SHOWN 24 53 2001 0003 8 EA NUT 10 32 HEX NYLON INSERT 25 53 2019 0004 8 EA NUT 3 8 16X7 32 THK HEX JAM G 26 53 6539 0001 2 WASHER 3 8 SPLIT LOCK 02 9685 0010 A 21 May 2009 VAREELITE VL500 LUMINAIRE SER
77. PowerCon and EtherCon are registered trademarks of Neutrik Inc All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or organizations VL500 Luminaires Service Manual 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 21 May 2009 Part number 02 9685 0010 A VL500 Luminaires Service Manual 2003 2009 Vari Lite a Philips group company All Rights Reserved ii 21 May 2009 02 9685 0010 A How TO OBTAIN WARRANTY SERVICE How To Obtain Warranty Service A copy of the Vari Lite Limited Warranty was included in the shipping package for this VARI LITE 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 will 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
78. Rev G 120V or 240V Standard Colors No Dimmer or 28 9685 0002 Rev G Standard Colors 120V IGBT On Board Dimmer or 28 9685 0002 Rev G Standard Colors 120V IGBT On Board Dimmer or 28 9685 0003 Rev G Standard Colors 240V IGBT On Board Dimmer Amber Diffuser Color Motor Assembly 21 9685 0281 Rev A Amber Diffuser Color Assembly 21 9685 0161 Rev F VL500 Magenta Blue Color Assembly 21 9685 0170 Rev H Standard DICRO TUNE Colors VL500 Magenta Blue Pastel Color Assembly 21 9685 0174 Rev A Pastel DICRO TUNE Colors Magenta Blue Color Motor Assembly 21 9685 0280 Rev Magenta Blue Pastel Color Assembly 21 9685 0164 Rev 0 Pastel DICRO TUNE Colors Bottom Bulkhead Assembly 21 9685 0150 Rev C Drive Ring Assembly 21 9685 0280 Rev A Magenta Blue Color Motor Assembly 21 9685 0280 Rev A Magenta Blue Color Assembly 21 9685 0160 Rev E Standard DICRO TUNE Colors VL500 Amber Diffuser Bottom Bulkhead Assembly 21 9685 0150 Rev C Color Assembly Drive Ring Assembly 21 9685 0280 Rev 21 9685 0171 Rev G continued next page Figure 3 1 VL500 and VL500D Incandescent Luminaires Drawing Tree Part 1 74 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 and VL500D Incandescent Luminaires continued continued from previous page continued from previous page VL500 Yoke Assembly VL500 Amber Diffuser Color 21 9685 0520 VL500 Rev U or Assembly 21 9685 0521 VL500D
79. S00 CLR 4 04 9685 0912 1 EA LABEL COMPLIANCE VL500 04 9685 0912 00 1 EA LABEL COMPLIANCE VLS00 CLR 5 04 9685 0913 1 EA LABEL LAMP TYPE 120V OR 240V INCANDESCENT VL500 MODELS ONLY 04 9685 0913 00 1 EA LABEL LAMP TYPE 120V OR 240V INCANDESCENT CLR VL500 MODELS ONLY 04 9685 0914 1 EA LABEL LAMP TYPE 120V INCANDESCENT VL500D 120V MODELS ONLY 04 9685 0914 00 1 EA LABEL LAMP TYPE 120V INCANDESCENT CLR VL500D 120V MODELS ONLY 04 9685 0915 1 EA LABEL LAMP TYPE 240V INCANDESCENT VL500D 240V MODELS ONLY 04 9685 0915 00 1 EA LABEL LAMP TYPE 240V INCANDESCENT CLR VL500D 240V MODELS ONLY 04 9685 0917 1 EA LABEL LAMP TYPE 700W ARC VL500A MODELS ONLY 04 9685 0917 00 1 EA LABEL LAMP TYPE 700W ARC CLR VL500A MODELS ONLY 04 9685 0918 1 EA LABEL LAMP TYPE 80V INCANDESCENT VL500 80 MODELS ONLY 04 9685 0918 00 1 EA LABEL LAMP TYPE 80 INCANDESCENT CLR 1 500 80V MODELS ONLY 82 21 May 2009 02 9685 0010 ILLUSTRATED PARTS BREAKDOWN 3 No Item Qty UM Description 6 04 9685 0920 2 EA LABEL AC INPUT RATING VL500 MODELS ONLY 04 9685 0920 00 2 EA LABEL AC INPUT RATING CLR VL500 MODELS ONLY 04 9685 0921 2 EA LABEL AC INPUT RATING VL500 PASTEL MODELS ONLY 04 9685 0921 00 2 EA LABEL AC INPUT RATING CLR VL500 PASTEL MODELS ONLY 04 9685 0922 2 EA LABEL AC INPUT RATING VL50
80. Simuna nulla tin nt 1 Additional Documentation pp 1 Customer Service des 2 Chapter 1 Description Features Product Peatures p en Peto e Me ERE D 4 Model Specific Features EE 5 Component Descriptions External Luminaire Components ss 7 Luminaire Internal Head Componetnts ss 8 Luminaire Yoke 2 nine 9 Arc Ballast Unit oer EE EE IE 11 Dimmer Models ee teet ee dete hr EEN de EE eret 11 Principles of Operation VLS00 Incandescent Luminaires Ne 12 VL500 Incandescent Block Diagram Without On Board IGBT Dimmer 120V or CR E 12 VL500D Incandescent Luminaires 13 VLS00D Incandescent Block Diagram With On Board IGBT Dimmer 120V or 2 0 aa S a eee dote 13 VLS00 80V Incandescent Luminaires a 14 VLS00 80V Incandescent Block Diagram With On Board 80V Dimmer 14 VESOOA Luminaire 15 VLS00A Arc Block Diagram With External Arc Ballast 15 Chapter 2 Maintenance Testing Running Parameter Tests Ga 18 Diagnostic SS EE 20 Fest D
81. TOP FLEX TYPE PG13 BLK 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 4 55 2268 0187 1 FT HEATSHRINK 3 16 CLEAR KYNAR VDE UL 600V 150DEG C 5 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR VDE UL 600V 150DEG C 6 73 9636 0153 4 FT CORDAGE 1 5 3 750V 60C EURO BLK HD 22 11MMOD 3 6 1 GRN YEL GND 2 Figure 3 53 Incandescent Power Input Cable Assembly VL500 Only 02 9685 0010 A 21 May 2009 151 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Disconnect Cable Assembly 25 9685 0350 Rev B Refer to Figure 3 54 No Item Qty UM Description 1 10 9685 0351 1 EA MOUNT DISCONNECT 2 10 9685 0352 1 EA CONTACT DISCONNECT 3 52 8230 0003 1 RECPT 1 4 FASTON 22 18 AWG TAPE 4 53 6534 0006 2 EA RIVET SOLID 0 094 DIA X 3 16 AL 100 DEG CSK 5 73 1624 0005 45 IN WIRE 24 AWG 300V TYPE MIL W 16878 5 2 Bag N 4 Figure 3 54 Disconnect Cable Assembly 152 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 80V LVS AC Cable Assembly 25 9685 0742 Rev 0 Refer to Figure 3 55 No Item Qty UM Description 1 52 6264 0004 1 CONN HOUSING 3 POS SL156 W RAMP NO TABS 2 52 8317 0002 2 CONTACT SL156 24 18AWG 3 73 6018 0002 0 71 FT WIRE 18 AWG 600V 105DEGC PVC RED UL1015 4 73 6018 0010 0 63 FT WIRE 18 AWG 600V 105DEGC PVC BLACK UL10
82. TSINK 80V INCANDESCENT VL500 80V ONLY 11 25 9685 0350 1 EA CABLE ASSY DISCONNECT VL500A ONLY 12 53 6556 0004 6 EA SCREW 4 40X 1 8 LG PPB 13 53 6598 0187 4 EA SCREW 4 40X0 187 LG PFB UNDERCUT HD 14 53 6607 0001 4 EA SCREW 6 32X1 4 LG PPB 15 54 1226 0001 1 EA LATCH ASSEMBLY 16 54 1226 0002 1 EA STRIKE LATCH 17 55 2203 0001 2 EA SCREW 4 40X 1 4 LG PPZ VLS00A ONLY 18 55 3500 0002 1 EA WASHER 10 FIBRE FLAT 0 196 ID 19 55 3500 0003 1 EA WASHER 3 8 FIBRE FLAT 0 385 ID 20 55 6612 0005 1 EA PIN FRONT CASTING PIVOT 21 55 6612 0009 1 EA PIN REAR CASTING PIVOT 02 9685 0010 A 21 May 2009 101 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Generic Head Assembly continued 14 x4 Figure 3 17 VL500 Generic Head Assembly VL500 and VL500D 102 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Generic Head Assembly continued Figure 3 18 VLS00 Generic Head Assembly VL500A 02 9685 0010 A 21 May 2009 103 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Generic Head Assembly continued 14 x4 Figure 3 19 VL500 Generic Head Assembly VL500 80V 104 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN Heatsink Assembly 21 9685 0320 VL500 and VL500D Rev H 21 9685 0321 VL500A Rev H 21 9685 0322 VL500 80V Rev H Refer to Figure 3 20 Figure 3 21 and Figure 3 22
83. Top Assembly Inctuded Items Kit 2 kau a k ha haga EN lt 80 Label Locations zs auae 82 VLS00 120V or 240V Luminaire 85 Xvi 21 May 2009 02 9685 0010A TABLE OF CONTENTS VLS00D with 120V IGBT Dimmer Luminaire pp 87 VLS00D with 240V IGBT Dimmer Luminaire pp 89 1500 80V with 80V Dimmer Luminaire pp 91 VL500A 700W Arc Luminaire eene nnne nennen 93 Generic VL500 Luminaire Assembly esee 95 Head Assembly VLS00 Generic Head Assembly 2 101 Heatsink Assembly 105 VLS00 Magenta Blue Color Assembly 2 109 VLS00 Magenta Blue Pastel Color Assembly pp 110 VLS00 Amber Diffuser Color Assembly 111 VLS00 Amber Dimmer Color Assembly 112 VLS00 Magenta Blue Arc Color Assembly 2 113 VLS00 Magenta Blue Arc Pastel Color Assembly ieee 114 Magenta Blue Color Assembly 115 Magenta Blue Pastel Color Assembly pp 116 Amber Diffuser Color Assembly ts 117 Amber Dimmer Color Assembly ss 118 Bottom Bulkhead Assembly a 120 Bulkhead Assembly Et 122 Drive Ring Assembly uuu eei t
84. UM Description 1 04 9685 0573 1 LABEL MCB YOKE COVER 2 04 9685 0574 1 EA LABEL MCB YOKE COVER 3 04 9685 0578 1 EA LABEL YOKE COVER 80V DIMMER 4 04 9685 0579 1 EA LABEL YOKE COVER 80V DIMMER 5 10 9685 0525 2 LOUVER PLATE TOP COVER 6 10 9685 0580 1 EA YOKE ARM COVER DISPLAY SIDE 7 10 9685 0586 1 EA YOKE ARM COVER 80V DIMMER SIDE 8 10 9685 0870 1 EA BRACKET MOUNTING LEFT 80V DIMMER 9 10 9685 0871 1 EA BRACKET MOUNTING RIGHT 80V DIMMER 16 9686 0004 1 LABEL INSTALLATION KIT NOT SHOWN 10 21 9685 0012 1 EA ASSY GENERIC VLS00 80V INCANDESCENT W DIMMER 11 21 9685 0170 1 EA ASSY COLOR MAGENTA BLUE STANDARD 20 9685 0004 ONLY 21 9685 0174 1 EA ASSY COLOR MAGENTA BLUE PASTEL 20 9685 0014 ONLY 12 21 9685 0171 1 EA ASSY COLOR AMBER DIFFUSION 13 21 9685 2750 1 EA ASSY DIMMER 80V 14 22 9685 0086 1 EA HEAD COVER 15 22 9685 0087 1 EA HEAD COVER BOTTOM 25 9685 0753 1 CABLE ASSY VL500 MOTOR NOT SHOWN s 25 9685 0760 1 EA CABLE ASSY HEAD GROUNDING NOT SHOWN 28 9685 0004 1 EA INCLUDED ITEMS KIT VL500 80V INCANDESCENT NOT SHOWN 16 42 9685 0207 1 EA LENS PAR 64 NSP STIPPLE 17 53 6523 0013 8 EA SCREW 6 32X3 8 LG PTB 18 53 6882 0022 4 EA SCREW 8 32X3 8 LG PPZ SEMS 19 53 6558 0009 8 EA SCREW 6 32X3 8 LG PPZ SEMS 20 53 6558 0010 4 EA SCREW 6 32X1 4 PPB SEMS 21 53 6558 0001 4 EA SCREW 6 32 X 3 8 LG PPZ 22 53 6608 0001 8 EA SCR
85. USHING WIRE PROTECTION 0 95 OD 10 9685 7590 1 EA TOGGLE STOP PAN 3 10 9685 7591 1 EA TOGGLE PAN 4 21 9685 0512 1 EA ASSY LOWER CROSSMEMBER 5 21 9685 0513 1 EA ASSY UPPER CROSSMEMBER 6 21 9685 0536 1 EA ASSY PAN TUBE VL500 80V 7 53 6552 0002 8 EA SCREW 8 32X1 2 PFB 8 53 6667 0005 2 EA SCREW 10 32X3 8 SET CUP POINT 9 54 1206 0014 3 EA RING RETAINING 1 375 SHAFT 142 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Yoke Crossmember Assembly VL500 80V continued 9 Pd lon eme Del 7 3 0 4 ro da 7 6 Figure 3 47 Yoke Crossmember Assembly VL500 80V 02 9685 0010 A 21 May 2009 143 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Lower Crossmember Assembly 21 9685 0512 Rev K Refer to Figure 3 48 No Item Qty UM Description 1 10 9685 1509 1 EA LOWER CROSSMEMBER 4 10 9685 0522 1 EA PLATE PAN LOCK 3 10 9685 0527 2 EA WASHER CENTERING STEP 4 10 9685 0533 1 EA LANYARD SAFETY 5 53 2001 0003 2 EA NUT 10 32 NYLON INSERT 6 53 2019 0004 1 EA NUT 3 8 16 HEX 7 53 2020 0001 2 EA NUT 1 4X20 HEX STL ZINC PLTD 8 53 6539 0001 1 EA WASHER 3 8 SPLIT LOCK 9 53 6634 0875 1 EA SCREW 3 8 16X7 8 SCSS 10 53 6648 0001 2 EA SCREW 10 32X3 4 PPZ 11 54 1255 0001 1 EA ASSY BEARING HOUSING 12 54 1261 0001 2 EA BUSHING LOW DAMP THRMOPLS 189 13 5
86. V LVS AC Cable Assembly sise 153 24V Power Cable Assembly VL500 80V VU 154 Yoke Lamp Cable Assembly VL500 80 sese 155 80V Surge Protector Cable Assembly sse 156 02 9685 0010 A 21 May 2009 xvii VAREELITE VL500 LUMINAIRE SERVICE MANUAL Dimmer Communication Cable Assembly VL500 VL500D 157 24V Power Cable Assembly VL500 VL500D 158 VL500 Motor Cable Assembly Ls a ia Ea 159 Relay to Ignitor Cable Assembly ss 161 VL500 AC Input Cable Assembly ss 162 VLS00 Arc Ballast Input Cable Assembly pp 163 VLS00 Pan Tilt Cable Assembly 164 VLS00 Head Grounding Cable Assembly A 166 VLS00 Ignitor to Socket Cable Assembly Nt 167 VLS00 Arc Ballast Interconnect Cable Assembly RN 168 VLS00 Display Cable Assembly ss 170 VL500 Display Remote Cable Assembly a 171 Yoke Lamp Cable Assembly VL500 VL500D 2 172 VL500 Yoke Ground Cable Assembly ss 173 LVS AC Cable Assembly VL500 VLSOOD VLSOOA 174 VLS00 Yoke DMX Communication Cable Assembly 175 VLS00 Yoke Lamp Jumper Cable Assembly pp 176 VLS00 Backcap Ground Cable Assembly 177 LVS Fan Cable Assembly VL500 VLSOOD VLSO0A 178 VLS00 MCB Yoke Ground Cable Assembly 179 Arc Yoke Lamp Cable Assembly
87. VICE MANUAL No Item Qty UM Description 27 53 6558 0009 11 EA SCREW 6 32X3 8 PPZ SEMS VL500 ONLY 53 6558 0009 10 EA SCREW 6 32X3 8 PPZ SEMS VL500D AND VL500 80V ONLY 53 6558 0009 14 EA SCREW 6 32X3 8 PPZ SEMS VL500A ONLY 28 53 6558 0010 4 EA SCREW 6 32X1 4 PPB SEMS 29 53 6596 0002 2 EA SCREW 4 40X5 16 LG PPZ SEMS VL500A ONLY 30 53 6608 0001 4 EA SCREW 6 32X3 8 PFB 31 53 6634 0003 4 EA SCREW 3 8 16X1 2 SOC HD CAP 32 53 6634 1000 2 EA SCREW 3 8 16X1 00 SOC HD CAP 33 54 1206 0021 1 EA RING RETAINING 1 562 SHAFT 34 54 1255 0002 2 EA ASSY BEARING HOUSING 35 54 1261 0001 2 EA BUSHING LOW DAMP THRMOPLS 189 36 54 2066 0001 1 EA BELT TIMING S2M 396 GRV 9MM WIDE gt 55 2178 0001 1 EA CABLE SADDLE 6 MOUNTING HOLE VL500 ONLY NOT SHOWN 37 55 2287 0001 4 EA STANDOFF MF 6 32X9 32 LG 1 4 HEX 38 55 2288 0001 4 EA STANDOFF MF 6 32X13 16 LG 1 4 HEX VL500 VL500D VL500 80V ONLY 55 2288 0001 12 EA STANDOFF MF 6 32X13 16 LG 1 4 HEX VL500A ONLY 39 55 3301 0010 2 EA WASHER 10 FLAT 40 55 6517 0001 2 EA WASHER 0 375 OD 0 150 ID 0 031 THK VL500A ONLY 41 55 6677 0041 2 EA WASHER 0 750 OD 0 203 ID 0 04 THK 42 69 3178 0121 1 EA POWER SUPPLY 120W 24V 3X5 VL500 VL500D VL500A ONLY 96 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 a VL500 L
88. VL500 80V 21 9685 0536 Rev A VL500 80V Refer to Figure 3 51 No Item Qty UM Description 1 10 9685 0521 1 EA PULLEY DRIVEN PAN TILT 10 9685 0532 1 EA PAN PULLEY SPACER 3 12 9685 1553 1 EA PAN TUBE 80V 4 53 2200 0006 4 EA NUT 6 32 KEPS SS 5 53 6608 0750 2 EA SCREW 6 32X3 4 PFB 78 E um 5 2 4 4 Figure 3 51 Pan Tube Assembly VL500 80V 148 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 DMX Input PCB Assembly 24 9663 3895 Rev 0 Refer to Figure 3 52 No Item Qty UM Description Ref 1 17 9663 3895 1 EA PCB DMX INPUT a 2 52 6259 0006 1 EA HEADER 5POS MTA FRCT LOK STRT J3 3 52 6625 0006 1 EA CONN RECEPT XLR 5PIN FEMALE 1 4 52 6626 0006 1 EA CONN RECEPT XLR 5PIN MALE 2 5 62 3039 0102 1 EA CAP 1000PF 250V RAD CER DISC 20 X Y CI Figure 3 52 DMX Input PCB Assembly 02 9685 0010 A 21 May 2009 149 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Notes 150 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Cables Note Cables are only available as complete assemblies The information contained in this section is for reference only Incandescent Power Input Cable Assembly 25 9663 2030 Rev A VL500 Only Refer to Figure 3 53 No Item Qty UM Description 1 52 6274 2313 1 EA STRAIN RELIEF SKIN
89. X 4 SMALL 3 73 2326 0123 3 67 FT WIRE 26 AWG 4 COND 300V 200 DEGC lt BLK BRN RED ORN gt UL1180 1 x2 44 Figure 3 84 VL500 80 LVS Fan Cable Assembly 184 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 80V Shielded Display DMX Communication Cable Assembly VL500 80V 25 9685 0788 RevA Refer to Figure 3 85 No Item Qty UM Description 1 25 9685 0785 1 EA CABLE ASSY DISPLAY 80V VL500 2 25 9685 0786 1 EA CABLE ASSY YOKE DMX COMM 80V VL500 3 25 9685 0787 1 EA CABLE ASSY LVS FAN 80V VL500 4 52 8311 0004 2 EA TERM RING 6 16 14 AWG NON INS BOX 5 55 2186 0001 2 EA CABLE TIE 0 10 X 4 SMALL 6 73 7130 0006 8 33 FT WIRE 5 64 TUBULAR BRAID TINNED COPPER Figure 3 85 80V Shielded Display DMX Communication Cable Assembly VL500 80V 02 9685 0010 A 21 May 2009 185 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 80V Dimmer Communication Cable Assembly VL500 80V 25 9685 1794 Rev 0 Refer to Figure 3 86 No Item Qty UM Description 1 28 2432 0 2 1 SPLIT CORE FERRITE 160 OHMS 100MHZ 8 2 MM ID 2 52 0274 18 5 IN HEATSHRINK TUBE 1 4 BLACK 3 52 6396 2603 1 EA RECEPT 3 POS MTA 100 W POL TAB BLUE CLOSED END 4 52 6396 2604 1 EA RECEPT 4 POS MTA 100 W POL TAB BLUE CLOSED END 5 52 8271 0004 2 EA RECEPT FASTON 0 250 22 18 AWG 6 52 8329 0001 1 EA TERM RING 6 22 16 AWG NON INSUL
90. X communications CAUTION This connector is similar to the connector for the LVS Fan Temperature Switch connector used on the Display PCB It is imperative that you do not confuse the two f 3 position connector 24V DC g 5 position connector Ballast communications VL500A models only Step 5 Remove two 6 32x3 8 PPZ screws one has a ground wire terminal attached Step 6 Remove four 1 4 hex 13 16 long standoffs as indicated in Figure 24 50 21 May 2009 02 9685 0010A MAINTENANCE 2 Main Control PCB Fan Assembly Replacement continued Menu Display 6 32x1 4 PPB x4 1 4 Hex 9 32 Long p Standoff x4 JF SN Display PCB S E D 1 4 Hex 13 16 Long Standoff x4 Main Control PCB Main Control PCB NOTE Some components not shown for clarity Figure 24 Main Control PCB Fan Replacement Step 7 Remove Main Control PCB Fan Assembly Step 8 Replace Main Control PCB Fan Assembly by following Steps 2 through 7 in reverse order Step 9 Configure Main Control PCB using menus as needed 02 9685 0010 A 21 May 2009 51 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 52 gt gt Low Voltage Supply LVS Replacement VL500 VL500D VL500A Only Parts 69 3178 0121 1EA POWER SUPPLY 120W 24VDC Tools 2 Phillips Screwdriver WARNING Remove power from luminaire before performing maintenance WARNING With power applied LIVE AC is present at heats
91. Yellow Color System Yellow 1 Yellow 2 Yellow 3 Magenta Magenta Color System Magenta 1 Magenta 2 Magenta 3 Encoder Encoder Allows hand Pan Value Displays encoder movement to check values value Tilt Value Displays encoder Fans Fans Test Value 1 slow to 7 fastest Temp Temperature LVS Temp Low Voltage Supply temperature Value Displays temperature in C MCB Temp Main Control Board temperature Refer to Diagnostic Tests on page 20 for more information 02 9685 0010 A 21 May 2009 Value Displays temperature in C 21 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Series 500 Menu Display Lamp Hours Progress Bar Arc Models Only For arc models there is a Lamp Hours Progress Bar representing lamp hours used on the lamp It is tied directly to the lamp hours within the MCB The bar when fully extended across the full width of the menu display represents 750 lamp hours as indicated in Figure 2 Resetting lamp hours will reset the progress bar This bar is only for a quick graphical representation of the lamp hours used For actual lamp hours used please read the following note Note 750 hours is the default setting for the Lamp Hours Progress Bar However the scale of the progress bar is user definable by adjusting Warning Hours in Config When the lamp hours exceed the allotted or defined hours the display will reverse contrast with a warning of Exceed
92. arness Cable Assembly contin ue Figure 3 87 VL500 Main Harness Cable Assembly VL500 and VL500D 188 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 Arc Main Harness Cable Assembly 25 9685 0791 Rev C VL500A Refer to Figure 3 88 No Item Qty UM Description 1 25 9685 0752 1 EA CABLE ASSY 24V POWER 2 25 9685 0758 1 EA CABLE ASSY PAN TILT 3 25 9685 0772 1 EA CABLE ASSY YOKE GROUND 4 25 9685 0773 1 EA CABLE ASSY LVS AC 5 25 9685 0778 1 EA CABLE ASSY LVS FAN 6 25 9685 0782 1 EA CABLE ASSY MCB YOKE GROUND 7 25 9685 0783 1 EA CABLE ASSY ARC YOKE LAMP WIRES 8 25 9685 0784 1 EA CABLE ASSY SHIELDED DISPLAY DMX COMM 9 55 2186 0001 8 EA CABLE TIE 0 10 4 SMALL 10 55 6699 0003 1 19 FT SLEEVING 1 2 NOM DIA WOVEN POLY 11 55 6699 0010 0 92 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 2000 02 9685 0010 A 21 May 2009 189 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Arc Main Harness Cable Assembly con tinued Figure 3 88 VL500 Arc Main Harness Cable Assembly VL500A 190 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 VL500 80V Main Harness Cable Assembly 25 9685 2792 Rev A VL500 80V Refer to Figure 3 89 No Item Qty UM Description 1 25 9685 1794 1 EA CABLE ASSY 80V DIMMER COMM VL500 80V 2 25 9685 0744 1 EA CABLE ASSY 24V POWER VL500 80V 3
93. ble Arc Standard Colors Arc Assembly Ballast or Figure 3 7 25 9685 0777 Rev A Magenta Blue Color Motor Assembly 21 9685 0280 Rev A VL500 Ignitor to Socket Cable Assembly 25 9685 0766 Rev C Magenta Blue Pastel Color Assembly 21 9685 0164 Rev 0 Pastel DICRO TUNE Colors VL500 Yoke Assembly 21 9685 0522 VL500A Rev U VL500 Amber Dimmer Color Assembly Bottom Bulkhead Assembly VL500 Pan Tilt Motor 2 Assembly 21 9685 0540 Rev Amber Diffuser Color Motor Drive Ring Assembly Assembly 21 9685 0280 Rev A VL500 MCB FAN Assembly 21 9685 0281 Rev A 21 9685 0731 Rev 0 Magenta Blue Color Motor Amber Diffuser Color 4 2 ev MCB Fan Assembly Assembly 23 9685 0782 Rev 0 21 9685 0162 Rev E Top Bulkhead Assembly Assembly My 21 9685 0151 Rev C 21 9685 0160 Rev E Standard SUMMUS were DICRO TUNE Colors Drive Ring Assembly 21 9685 0280 Rev A Bottom Bulkhead Assembly 21 9685 0150 Rev C Drive Ring Assembly EE NEN PEDE 21 9685 0280 Rev A Figure 3 5 VL500A Arc Luminaires Drawing Tree Part 1 Magenta Blue Color continued next page 78 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN 3 VL500A Arc Luminaires continued continued from previous page continued from previous page VL500 Yoke Assembly VL500A 700W Arc Luminaire 21 9685 0522 VL500A Rev U 28 9685 0006 Rev G 700W Arc Standard Colors Arc Ballast or Figure 5 7 MCB Fan Assembly 21 9685 07
94. bly VL500 80V 02 9685 0010 A 21 May 2009 155 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 80V Surge Protector Cable Assembly 25 9685 0746 Rev 0 Refer to Figure 3 58 No Item Qty UM Description 1 33 0441 2 EA 430V 6500A 20MM ZNR 2 52 8231 0005 1 EA TERMRING 6 BLUE 16 14 AWG REEL PIDG 3 55 2198 0001 0 08 FT HEATSRINK 1 8 BLACK 4 55 2199 0001 0 13 FT HEATSRINK 1 16 BLACK 5 55 2200 0001 0 08 FT HEATSRINK 3 16 BLACK 6 73 6016 0504 0 75 FT WIRE 16 AWG 600V 105DEGC GREEN YELLOW UL1015 2 3 6 1 x2 5 4 x4 Figure 3 58 80V Surge Protector Cable Assembly 156 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Dimmer Communication Cable Assembly VL500 VL500D 25 9685 0750 Rev B Refer to Figure 3 59 es 52 6396 2603 RECEPT 3 POS MTA100 W POL TAB BLUE CLOSED END 73 2326 0029 2 83 WIRE 26 AWG 3 COND 300V 200 DEGC TEF lt BLK RED WHT gt UL1180 Figure 3 59 Dimmer Communication Cable Assembly VL500 VL500D 02 9685 0010 A 21 May 2009 157 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 24V Power Cable Assembly VL500 VL500D 25 9685 0752 Rev C Refer to Figure 3 60 No Item Qty UM Description 1 52 6442 2003 1 EA RECEPT 3 POS MTA156 W TAB YEL 20 AWG 2 52 6442 2004 EA RECEPT 4 POS MTA156 W TAB YEL 20 AWG 3 52 6442 2006 1 EA RECEPT 6 POS MTA156 W TAB YEL 20 AWG 4
95. 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 bloBen H nden ber hrt wird reinigen Sie sie mit isopropyl 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 Spannungsgefalle wieder aufzuleuchten In einigen Fallen wird die Lampe nach Abk hlung automatisch wieder aufleuchten je nach der Systemkonfigurationseinstellung des Lampeneinschaltungsstatus L ON LOFF Die Brennposition ist Universal 21 May 2009 02 9685 0010A NOTES DE SECURITE Notes de s curit Avant de proc der l installation des produits d crits dans ce guide et de les mettre en marche il est extr mement important de lire TOUS les renseignements et TOUTES les directives de s curit contenues dans ce guide ainsi que toute documentation joi
96. cement Step 4 Remove display overlay Step 5 As indicated in Figure 23 remove four 1 4 hex 9 32 long standoffs Step 6 At display PCB disconnect the following wiring connections a 4 position MTA connector 24V DC b 2 position connector MCB Fan c 4 position connector LVS Fan Temperature Switch d 6 position connector Display Communication Step 7 Remove Display PCB Step 8 Replace by performing Steps 2 through 7 in reverse order Note Orientation of display overlay the overlay should be black paper side out to allow proper and free button travel 02 9685 0010 A 21 May 2009 49 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Main Control PCB Fan Assembly Replacement Parts 21 9685 0731 1EA ASSY VL500 MAIN CONTROL PCB FAN Tools 1 4 Hex Nutdriver 2 Phillips Screwdriver A WARNING Remove power from luminaire before performing maintenance To remove and replace main control PCB fan assembly Step 1 Remove power from luminaire Step 2 Remove display side yoke arm cover by removing four 6 32x3 8 PTB screws Step 3 Remove Display PCB as described in Display PCB Replacement on page 49 Step 4 At Main Control PCB Fan Assembly disconnect the following wiring connections Pan Tilt wiring harness b Head motor wiring harness c 3 position connector Dimmer communications VL500D VL500 80V models only d 10 position AMP connector Display Communications e 4 position connector DM
97. cement Amber Dif fuser or Dimmer Bulkhead Parts 44 9685 0230 2EA MOTOR LINEAR 0 002 STEP Tools 1 Phillips Screwdriver 2 Phillips Screwdriver 2 Slotted Screwdriver WARNING Remove power from luminaire before performing maintenance To remove and replace linear actuator motor assembly Step 1 Remove power from luminaire Step 2 Set the luminaire head horizontally Step 3 Engage tilt service lock to secure luminaire head in horizontal position to access heatsink latch Magenta Blue Assembly Top Cover See separate procedure for linear motor replacement for these assemblies Linear Actuator Motor Assembly Amber Diffuser Assembly Ds jj Incandescent Models or Heatsink Assembly Amber Dimmer Assembly Arc Models NOTE Some components not shown for clarity Figure 17 Amber Diffuser or Dimmer Bulkhead Linear Actuator Motors Step 4 Remove top head cover Note Linear actuator motors should be seen with cover removed If not flip head over 02 9685 0010 A 21 May 2009 43 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Step 5 Step 6 Step 7 4 40x1 4 PPZ Screw 2 for each motor Motor Mount At linear actuator motor to be replaced on Amber Diffuser or Dimmer assembly disconnect wiring at both motors Remove linear actuator motor assembly as follows a At linear actuator motor assembly using 1 Phillips screwdriver remove thr
98. diagnostic tests are available in the test menu Test Descriptions All Seq Tests all functions in sequential order Pan Tilt Tests different pan and tilt movements Tests different pan movements Tests different tilt movements Dimmer Tests different dimmer moves operation Diffuser Tests diffuser movement Cyan Tests Cyan color wheel movements Yellow Tests Yellow color wheel movements Magenta Tests Magenta color wheel movements Encoder Disables pan and tilt and displays encoder value Tests fan level speed 1 to 7 7 is fastest Temperature Displays LVS or MCB temperatures in C 21 May 2009 02 9685 0010A Test Menu System Chart The following table shows all the tests that can be performed by accessing the tests via the luminaire s on board tech display MAINTENANCE 2 Table 2 1 VL500 Test Menu System Chart value 1st Level 2nd Level 3rd Level 4th Level 5thLevel Test ALL SEQ Sequence Through All RunTest Press Menu to stop tests System Test Tests Pan Tilt Pan Tilt RunTest Pan Pan Pan 1 Pan 2 Tilt Tilt Tilt 1 Tilt 2 Dimmer Dimmer Dimmer 1 Dimmer 2 Dimmer 3 Diffuser Diffuser Diffuser 1 Diffuser 2 Diffuser 3 Cyan Cyan Color System Cyan 1 Cyan 2 Cyan 3 Yellow
99. ead in horizontal position to access heatsink latch Step 4 As shown in Figure 4 at heatsink assembly open latch and swing open back of luminaire CAUTION Kk Ensure lamp is seated straight in socket before re installing backcap Heatsink Assembly Back Cap Assembly Arc Lamp Latch x Figure 4 Installing Arc Lamp in VL500A Models 02 9685 0010 A 21 May 2009 27 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 28 Lamp Replacement Arc continued WARNING 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 soft lint free cloth to thoroughly clean glass portion of lamp Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Remove lamp by pulling straight out of socket Carefully clean reflector and facing UV glass lens with soft lint free cloth to remove dust and other debris Install lamp by pressing firmly into socket Ensure lamp is fully seated in socket with base of lamp against socket base Close and re latch back of luminaire Disengage service tilt lock to allow luminaire head to move freely Align lamp Refer to Align Lamp For Maximum Beam Irradiance on page 29 If required and only on arc models reset lamp hour counter as follows Refer to Menu Systems Functions in the VL500 User s Manual for more information
100. ed Lamp Hours Arc Lamp Hours Progress Bar a EN 575W ARC NORMAL lt 750 Hours gt MENU ENTER Y Menu Display Softkeys The menu has four softkey buttons that change to accommodate menu selection 22 Figure 2 VL500A Luminaire Menu Display Note To identify the exact number of hours used users should still refer to the Config Lamp Lamp Hours setting within the menu system 21 May 2009 02 9685 0010 A MAINTENANCE 2 Equipment Handling Below are some basic tips and information on handling VL500 luminaires and their associated components Locations Use luminaires are designed for dry locations only Exposure to rain or moisture including but not limited to fog machines misters etc may damage luminaires Lamps Servicing When handling a lamp hold it by the ceramic base while wearing cotton gloves or finger cots Do not touch the glass envelope bulb If you touch the glass with bare fingers immediately wipe off any fingerprints with isopropyl alcohol Use care when opening and closing the rear castings or covers of luminaires and cleaning reflectors Any jarring can undo the optical alignment of the lamp Heat On Forced Air Cooled Units When lamps are lit the interiors of the luminaires become very hot To aid in the airflow circulation within the luminaires after dousing the lamps wait t
101. ee 4 40x1 4 PPZ screws and three 4 lock washers securing motor mount to luminaire head b At linear actuator motor assemblies using 2 slotted screwdriver disconnect actuator drive ring links from swivel links on drive rings At linear actuator motor using 1 Phillips screwdriver remove two 4 40x1 4 PPZ screws securing linear actuator motor to actuator mount and remove motor See Figure 18 Note Versilube Silicon Grease G321 is used to lubricate the actuator screw Actuator Screw Linear Actuator Motor Drive Ring Link Figure 18 Amber Diffuser or Dimmer Linear Actuator Motor Replacement Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Place linear actuator motor in place on actuator mount Re install two 4 40x1 4 PPZ screws and two 4 lock washers and using 1 Phillips screwdriver tighten to secure linear actuator motor and heatsink to actuator mount Secure actuator drive ring link to drive ring swivel link Attach wiring Re install top head cover Release tilt service lock 1 Note If mechanism is too noisy loosen the two 4 40 x 1 4 PPZ screws and align actuator motor to motor mount to lessen noise 44 21 May 2009 02 9685 0010A MAINTENANCE 2 Incandescent Lamp Socket Assembly VL500 and VL500D Only Replacement Parts 23 9685 0780 1 EA ASSY LAMP SOCKET VL500 AND VL500D ONLY Tools 2 Phillips Screwdriver 1 4 Hex Nutdriver To remove and replace lamp soc
102. ei eerie en E T 124 Magenta Blue Color Motor Assembly pp 125 Amber Diffuser Color Motor Assembly 126 Yoke Assembly VE500 Yoke Assembly 2 e nieder 127 XE500 80V Yoke Assembly 131 VES00 Extra Hardware Kit 7 aaa eei 135 VLS00 Pan Tilt Motor Assembly 136 VLS00 MCB FAN Assembly eese 138 _ V 139 Yoke Crossmember Assembly VL500 VLS00D VLSOOA 140 Yoke Crossmember Assembly VL500 80V ss 142 Lower Crossmember Assembly ss 144 Upper Crossmember Assembly 2 rennen 146 Pan Tube Assembly VL500 VL500D VL500A 147 Pan Tube Assembly VL500 80V 148 DMX Input PCB Assembly nent nina 149 Cables Note Cables are only available as complete assemblies The information contained in this section is for reference only Incandescent Power Input Cable Assembly seen 151 Disconnect Cable Assemb uuu rere e t eve aer 152 80
103. els are secured A to silicone pad with UV cured RTV and pad can become separated If they become separated a new filter or panel must be installed since RTV must be UV cured 02 9685 0010 A 21 May 2009 37 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Filter and Diffuser Panel Removal contin ue Step 6 Disconnect actuator screw from Swivel Coupler using tweaker screwdriver by carefully prying apart from Drive Ring Link Color Filter Pad Lip Diffuser Panel SN Silicone Pad Insert Filter Carrier Pin Center Hub K Carrier Arch Filter Carrier Bulkhead Figure 12 Color Filter and Diffuser Panel Removal Step 7 Open glass filter or diffuser panels Step 8 Remove filter or panel as follows shown in Figure 12 a At filter or panel gently push assembly with silicon pad in towards center hub away from carrier and work end of tweaker screwdriver between silicon pad and carrier b Gently work side of silicone pad not under carrier arch free c After side of silicone pad is free from carrier remove silicone pad from under carrier arch and remove filter or panel Step 9 Insert filter carrier pin of replacement filter or panel into center hub as shown in Figure 12 Step 10 Place side of silicone pad with lip into arch on installed carrier Step 11 Using tweaker screwdriver gently run screwdriver tip over silicone pad driving silicone pad into carrier and fully seating
104. emove three 1 4 hex standoffs and turn reflector clips out of way and remove reflector Step 12 Inside heatsink remove four 8 32x1 2 LG PPZ SEM screws and remove back cap Step 13 Remove lamp alignment screws as follows a For VL500A models at backcap remove three 10 32x1 1 2 LG PPB screws and springs b For VL500 80V models at backcap remove three 10 32x1 LG SCB screws Step 14 Remove backcap extension Step 15 At socket remove two 8 32x3 8 LG PPZ SEM screws and two socket clips Step 16 Remove socket from backcap Step 17 Using 5 64 Allen wrench loosen two set screws and remove lamp wires from socket Step 18 Replace lamp socket by performing Steps 3 through 17 in reverse order 48 21 May 2009 02 9685 0010A D MAINTENANCE 2 Display PCB Replacement Parts 24 9685 0826 1EA ASSY VL500 DISPLAY PCB Tools 1 4 Hex Nutdriver 2 Phillips Screwdriver WARNING Remove power from luminaire before performing maintenance To remove and replace display PCB assembly Step 1 Remove power from luminaire Step 2 Remove display side yoke arm cover by removing four 6 32x3 8 PTB screws Step 3 At display overlay as indicated in Figure 23 remove four 6 32x1 4 PPB screws 6 32x1 4 PPB x4 1 4 Hex 9 32 Long Standoff x4 Menu Display Display Lens il 2 Display Overlay Display PCB NOTE Some components not shown for clarity Figure 23 Display PCB Repla
105. en minutes before removing power to the luminaires This will provide enough time for the equipment fan to cool off the unit On Natural Convection Cooled Units When lamps are lit the interior and exterior heatsink of the luminaires becomes very hot Naturally convection cooled units require longer to fully cool before being handled Users should wait until the unit is cool to the touch before servicing or handling Lamp Life When operating arc lamps allow luminaires to operate for at least 3 minutes It takes about 3 minutes for the fill components mercury and halogen metal compounds in the lamp tubes to vaporize completely If the lamps are switched off earlier than 3 minutes the fill components are partially vaporized The inadequately vaporized fill components and the electrode material tungsten are deposited in the areas of the lamp tubes that have remained cool As a result the lamp tubes blacken prematurely and reduce the service life of the lamps If system will be unattended for more than two hours luminaire lamps should be doused Standby mode should not be used for more than two hours 02 9685 0010 A 21 May 2009 23 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 24 When the lamp is struck the luminaire should be maintained in a horizontal position when not in use For arc lamp luminaires heads should be tilted horizontal before starting lamps Lamps generate light by an electrical discharge arc w
106. eplacement 45 Arc Lamp Socket Assembly VL500A VL500 80V Only Replacement 47 Display PCB Replacement u k u n u 49 Main Control PCB Fan Assembly Replacement pp 50 Low Voltage Supply LVS Replacement VL500 VL500D VL5004A Only 52 Low Voltage Supply LVS Temperature PCB Replacement VL500 VL500D VL500A 085 53 Low Voltage Supply LVS Replacement VL500 80V Only 54 Low Voltage Supply LVS Temperature PCB Replacement VL500 80V Only 56 Tilt Motor Assembly Replacement nas 58 Pan Motor Assembly Replacement 4 60 Pan Tilt Encoder PCB Replacement enne ener 61 Arc Ignitor PCB Replacement VLS00A 3 1 ss 62 IGBT Dimmer Replacement VL500D Only 63 80V Dimmer Replacement VL500 80V Only ss 65 Arc Ballast Replacement VLS00A Only ss 67 Safety Relay Replacement VL5004A Only 68 AC Input PowerCon Connector Replacement sese 69 Mini XLR Display Remote Programming Connector Replacement 70 DMX PCB Assembly Replacement eee uae 71 Cleaning Optical Lenses and Filters ss 72 Chapter 3 Illustrated Parts Breakdown Drawing Trees VLS00 VL500D Incandescent Luminalres 74 VLS00 80V Incandescent Luminaires 76 WEO00A Arc LEON rore Ek 78
107. eplacement 80V dimmer WARNING Be careful with ferrite cores on lamp wires Make sure they do not come in contact with dimmer they may damage components on dimmer 02 9685 0010 A 21 May 2009 65 VAREELITE VL500 LUMINAIRE SERVICE MANUAL NOTE Some components not shown for clarity 6 32x3 8 PTB Screws x4 Yoke Arm Cover Dimmer Side 6 32x3 8 PPZ Screws x4 80V Dimmer Figure 34 80V Dimmer Replacement VL500 80V only Step 7 Replace 80V Dimmer by performing Steps 2 through 6 in reverse 66 21 May 2009 02 9685 0010A MAINTENANCE 2 Arc Ballast Replacement VL500A Only Parts 21 9685 0802 1 EA ASSY BALLAST 700W Tools None AN WARNING Remove power from luminaire before performing maintenance To remove and replace arc ballast dimmer Step 1 Disconnect luminaire AC input cable from power source Note The Arc Ballast Unit is separate from the luminaire Step 2 Disconnect Ballast Interconnect Cable Assembly from ballast and luminaire Step 3 Connect Ballast Interconnect Cable Assembly to replacement ballast and luminaire Figure 35 Arc Ballast Assembly 02 9685 0010 A 21 May 2009 67 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 68 Safety Relay Replacement VL500A Only Parts 23 9650 3327 1 EA RELAY ELECTRICAL ASSY VL500A ONLY Tools 2 Phillips Screwdriver WARNING Remove power from luminaire before performing main
108. es and illustrated parts breakdowns for all configurations of the VL500 Luminaire The manual is intended for use by Vari Lite personnel and by Authorized Vari Lite Dealers and Service Centers only This manual covers the following models Model Part Number Source Comments VL500 Luminaire 20 9685 0001 Tungsten 120V or 230V Standard Color System VL500 Luminaire 20 9685 0011 Tungsten 120V or 230V Pastel Color System VL500D Wash Luminaire 20 9685 0002 Tungsten 120V Integral IGBT Dimmer Standard Color System VL500D Wash Luminaire 20 9685 0012 Tungsten 120V Integral IGBT Dimmer Pastel Color System VL500D Wash Luminaire 20 9685 0003 Tungsten 240V Integral IGBT Dimmer Standard Color System VL500D Wash Luminaire 20 9685 0013 Tungsten 240V Integral IGBT Dimmer Pastel Color System VL500 80V Wash Luminaire 20 9685 0004 Tungsten 80V Dimmer 100 240V Input Standard Color System VL500 80V Wash Luminaire 20 9685 0014 Tungsten 80V Dimmer 100 240V Input Pastel Color System VL500A Wash Luminaire 20 9685 0006 Arc 700W Ballast Standard Color System VL500A Wash Luminaire 20 9685 0016 Arc 700W Ballast Pastel Color System Note Lamp Type is specified by customer at time of ordering A 02 9685 0010 A Note Performing maintenance procedures contained in this manual may void the product warranty Refer to the Vari Lite Limited Warranty card included in the
109. escrptOnS EE 20 Test Menu System ha 21 Lamp Hours Progress Bar Arc Models Only 22 Equipment Handling Locations U8e i oe ea 23 tee Me 23 23 FAG aU 23 02 9685 0010 21 May 2009 XV VAREELITE VL500 LUMINAIRE SERVICE MANUAL Lampes annees 23 SolidiState Blectronies a 24 Electrostatic Discharge ESD ss 24 Printed Circuit Boards 5 24 Maintenance Procedures Lamp Replacement Incandescent eese nee 25 Lamp Replacement err nete reete tr et 27 Align Lamp For Maximum Beam Irradiance pp 29 Front Glass Replacement nee reme ien de 31 Magenta Blue DICHRO TUNE Rear Bulkhead Replacement 33 Amber Diffuser or Dimmer DICHRO TUNE Front Bulkhead Replacement 35 Color Filter and Diffuser Panel Replacement pp 37 Arc Dimmer Panel Replacement pp 39 Linear Actuator Motor Replacement Magenta Blue Bulkhead 41 Linear Actuator Motor Replacement Amber Diffuser or Dimmer Bulkhead 43 Incandescent Lamp Socket Assembly VL500 and VLS00D Only R
110. f Set pulley height as shown codewheel with above respect to sensor Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft 0 090 from Pulley to Motor Drive Pulley Installation Pan amp Tilt Motor Cross Section Note Vari Lite recommends that this assembly be replaced as a 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 43 VL500 Pan Tilt Motor Assembly 02 9685 0010 A 21 May 2009 137 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 MCB FAN Assembly 21 9685 0731 Rev 0 Refer to Figure 3 44 No Item Qty UM Description 1 10 9676 0735 2 EA HEATSINK PAN TILT DRIVERS 10 9676 0885 2 EA PAD THERMAL TRANSFER PAN TILT 3 10 9685 0594 1 EA BRACKET FAN MCB 4 10 9685 0595 1 EA SEAL AIR 5 23 9685 0782 1 EA ASSY FAN MCB 6 24 9685 3730 1 EA MCB VL500 7 53 2200 0004 5 EA NUT 4 40 KEPS SS 8 53 6556 0001 2 EA SCREW 4 40X3 4 PPZ 9 53 6592 0001 3 EA SCREW 4 40X 1 2 PPB 10 55 6537 0001 2 EA WASHER 4 LOCK INTERNAL TOOTH 138 9 x3 Figure 3 44 VL500 MCB Fan Assembly 21 May 2009 02 9685 0010 A ILLUSTRATED PARTS BREAKDOWN
111. h Luminaire 20 9685 0003 e 240 1000W Tungsten Halogen lamp source Standard color dichroic glass DICHRO K TUNE color system 240V on board IGBT dimmer VL500D Wash Luminaire 20 9685 0013 240 1000W Tungsten Halogen lamp source Pastel color dichroic glass DICHRO KTUNE color system 240V on board IGBT dimmer VL500 80V Wash Luminaire 20 9685 0004 80V 1200W Tungsten Halogen lamp source Standard color dichroic glass DICHRO K TUNE color system 80V on board dimmer 02 9685 0010 A 21 May 2009 5 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V Wash Luminaire 20 9685 0014 80V 1200W Tungsten Halogen lamp source Pastel color dichroic glass DICHRO KTUNE color system SOV on board dimmer VL500A Wash Luminaire 20 9685 0006 700W arc lamp source with external ballast unit Standard color dichroic glass DICHRO K TUNE color system VL500A Wash Luminaire 20 9685 0016 700W arc lamp source with external ballast unit Pastel color dichroic glass DICHRO KTUNE color system 6 21 May 2009 02 9685 0010A Component Descriptions DESCRIPTION 1 External Luminaire Components The following illustration shows the external luminaire components and controls Base Provides hook mounting holes and safety cable connection Lamp Power 5 Input Cable Yoke Leg Control Contains main control PCB and display PC
112. harness from assembly Step 4 As shown in Figure 31 remove two 6 32x3 8 PPZ screws and remove assembly 6 32x3 8 PPZ Pan Tilt Motor Encoder PCB rr Encoder Disk 11 Figure 31 Pan Tilt Motor Encoder PCB Replacement Step 5 Replace by performing Steps 2 through 4 in reverse order A Note Ensure that encoder disk passes freely through the optical sensor on PCB 02 9685 0010 A 21 May 2009 61 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Arc Ignitor PCB Replacement VL500A Only Parts 24 9685 1000 1EA IGNITOR ARC VL500A ONLY Tools 2 Phillips Screwdriver A WARNING Remove power from luminaire before performing maintenance To remove and replace ignitor PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke cover opposite of display by removing four 6 32x3 8 LG PTB screws Step 3 AtIgnitor PCB disconnect Input and Output lamp wires Step 4 As shown in Figure 32 remove four 6 32x3 8 PPZ SEMS screws from PCB NOTE Some components not shown for clarity Ignitor PCB 6 32x3 8 PPZ SEMS x4 i Ignitor PCB Yoke Arm Cover Figure 32 Ignitor PCB Replacement Step 5 Remove Ignitor PCB Note Make sure and install ignitor with proper orientation Wires from Relay attached to posts labeled From Relay Wires going to lamp attach to posts labeled To Bulb Step 6 Replace Ignitor PCB by performing Steps 2 through 6 i
113. hereby the electrons from two electrodes excite the fill components to give off light Because of the alternating current position the electrons are alternately given off by the two electrodes When a lamp is set in a vertical position the halogen metal compounds which determine the color temperature of the lamp collect at the top end of the glass envelope When the lamp is started color deviations occur since the concentration of halogen compounds is greater around the top electrode than the bottom electrode In addition the fill components that are difficult to vaporize congeal around the bottom electrode thereby reducing lamp life Solid State Electronics Electrostatic Discharge ESD Electrostatic discharge ESD presents a significant danger to solid state electronic components semiconductor devices and PC board assemblies Static electricity can build on a variety of common objects including people simply by handling or moving ESD rarely results in immediate failure of a component but shows up later as an intermittent problem or severely reduces the life of the component All equipment uses solid state electronics and appropriate precautions to protect them should be observed when servicing Printed Circuit Boards PCBs All PC boards should be shipped in electrostatic shielding bags When handling PC boards or components devices such as conductive mats and conductive wrist straps should be used wheneve
114. i XLR Display Remote Programming Connector Replacement Step 5 Disconnect wiring from Mini XLR Step 6 Remove two 4 40x1 4 PFB screws at front of Mini XLR connector Step 7 Replace Mini XLR by performing Steps 3 through 6 in reverse 70 21 May 2009 02 9685 0010A MAINTENANCE 2 DMX PCB Assembly Replacement Parts 24 9663 3895 1 EA ASSY DMX INPUT PCB Tools 2 Phillips Screwdriver AN WARNING Remove power from luminaire before performing maintenance To remove and replace DMX PCB assembly Step 1 Remove power from luminaire Step 2 Position light to access top of pan tube assembly 1 2 Step 3 As shown in Figure 38 at pan tube cover remove six 8 32x1 2 PFB screws 4 Step 4 Remove pan tube cover Note tether will still hold cover E 8 32x1 2 PFB Screws x6 hw m Do not remove this screw Tube Cover NOTE Pe ub Some components not d shown for clarity This procedure is applicable for all models Pan Tube Assembly Cover Tether VL500 80V gt Pan Tube Assembly DMX PCB c Assembly 4x3 8 HLN PN BLK ZN Screws x4 Figure 38 DMX PCB Assembly Replacement Step 5 Disconnect wiring from DMX PCB Assembly Step 6 Remove four 4x3 8 H L PN BLK ZN screws at front of DMX PCB Assembly Step 7 Replace DMX PCB Assembly by performing Steps 3 through 6 in reverse 02 9685 0010 A 21 May 2009 71 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 72 gt
115. ily interchangeable front lenses provide a variety of beam size and shape options In the VL500 VL500D and VL500 80V models an internal variable diffuser mechanism provides additional beam control With stipple lens standard on all models in place and adjustment of diffusion beam angle is capable of variance from 8 24 LCD Display All VL500 wash luminaires come with a on board backlit LCD display for luminaire status address set up etc Pan and 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 resolution 4 21 May 2009 02 9685 0010A DESCRIPTION 1 Model Specific Features Each individual configuration has the following specific features VL500 Wash Luminaire 20 9685 0001 120V or 240V 1200W or 1000W Tungsten Halogen lamp source Standard color dichroic glass DICHRO K TUNE color system VL500 Wash Luminaire 20 9685 0011 120V or 240V 1200W or 1000W Tungsten Halogen lamp source Pastel color dichroic glass DICHRO KTUNE color system VL500D Wash Luminaire 20 9685 0002 e 120V 1200W Tungsten Halogen lamp source Standard color dichroic glass DICHRO K TUNE color system 120V on board IGBT dimmer VL500D Wash Luminaire 20 9685 0012 e 120V 1200W Tungsten Halogen lamp source Pastel color dichroic glass DICHRO TUNE color system 120 on board IGBT dimmer VL500D Was
116. ing Low Voltage Supply LVS Temperature PCB Replacement VL500 80V Only on page 56 Step 6 Disconnect the following wiring connections a 3 position connector AC Input 6 position MTA connector DC Output Step 7 As shown in Figure 27 remove four 4 40x1 4 PPZ screws Step 8 Remove LVS Note fish paper Wire Shield under LVS save and reuse with replacement LVS Step 9 Replace by performing steps 3 through 7 in reverse order 02 9685 0010 A 21 May 2009 55 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Low Voltage Supply LVS Temperature PCB Replacement VL500 80V Only Parts 24 9685 0740 1 EA TEMPERATURE BOARD LVS Tools 2 Phillips Screwdriver WARNING Remove power from luminaire before performing maintenance gt P WARNING With power applied LIVE AC is present at heatsink Do not touch when unit is powered To remove and replace LVS temperature PCB Step 1 Remove power from luminaire Step 2 As shown in Figure 27 at pan tube cover remove six 8 32x1 2 PFB screws and remove pan tube cover Note cover tether will still hold cover Step 3 Remove two 4 40 x 1 4 PFB screws and remove LVS fan mount ___ LVS Power Supply LVS Temperature PCB 6 32x3 8 PPZ Screws 4 40x1 4 PFB Screws Pan Tube __ LVS Fan Mount NOTE Some components not shown for clarity Figure 28 LVS Temperature PCB Replacement VL500 VL500D VL500A Only 56 21 May 2009 02 96
117. ink Do not touch when unit is powered To remove and replace LVS Step 1 Remove power from luminaire Step 2 Remove yoke arm cover opposite display side by removing four 6 32x3 8 PTB screws 2 Wire Shield fish paper LVS Power Supply 6 32x3 8 PPZ x4 NOTE Some components not shown for clarity Figure 25 LVS Replacement VL500 VL500D VL500A Only Step 3 Disconnect the following wiring connections a 3 position connector AC Input 6 position MTA connector DC Output Step 4 As shown in Figure 25 remove four 6 32x3 8 PPZ SEMS screws Step 5 Remove LVS Note fish paper Wire Shield behind LVS save and reuse with replacement LVS Step 6 Replace by performing steps 2 through 5 in reverse order 21 May 2009 02 9685 0010A gt P MAINTENANCE 2 Low Voltage Supply LVS Temperature PCB 0 Replacement VL500 VL500D VL500A Only Parts 24 9685 0740 1EA TEMPERATURE BOARD LVS Tools 2 Phillips Screwdriver WARNING Remove power from luminaire before performing maintenance WARNING With power applied LIVE AC is present at heatsink Do not touch when unit is powered To remove and replace LVS temperature PCB Step 1 Remove power from luminaire Step 2 Remove LVS by following procedure Low Voltage Supply LVS Replacement VL500 VL500D VL500A Only on page 52 2 Yoke Arm LVS Temperature PCB 1 4 Hex Standoff Some compone
118. ire with IGBT On Board Dimmer 120V or 240V VL500 80V VL500 80V Incandescent Luminaire with 80V On Board Dimmer VL500A VL500 A Arc Luminaire with External Ballast 02 9685 0010 A 21 May 2009 AN 73 VAREKLITEG VL500 LUMINAIRE SERVICE MANUAL Drawing Trees VL500 and VL500D Incandescent Luminaires VL500 120V or 240V Luminaire Incandescent Versions 20 9685 0001 Rev G Standard DICRO TUNE Colors or 20 9685 0011 Rev B Pastel DICRO TUNE Colors or 20 9685 0002 Rev F Standard DICRO TUNE Colors or 20 9685 0012 Rev B Pastel DICRO TUNE Colors or 20 9685 0003 Rev F Standard DICRO TUNE Colors or 20 9685 0013 Rev B Pastel DICRO TUNE Colors Generic VL500 Luminaire Assembly 21 9685 0010 Rev S Incandescent without Internal Dimmer or 21 9685 0011 Rev S Incandescent with Internal IGBT Dimmer VL500 Generic Head Assembly 21 9685 0310 VL500 and VL500D Rev K Heatsink Assembly 21 9685 0320 VL500 and VL500D Rev H VL500 Backcap Ground Cable Assembly 25 9685 0777 Rev VL500 Yoke Assembly 21 9685 0520 VL500 Rev U or 21 9685 0521 VL500D Rev U VL500 Pan Tilt Motor Assembly 21 9685 0540 Rev C VL500 MCB FAN Assembly 21 9685 0731 Rev 0 MCB Fan Assembly 23 9685 0782 Rev 0 DMX Input PCB Assembly 24 9663 3895 Rev 0 continued next page VL500 Motor Cable Assembly 25 9685 0753 Rev B VL500 Head Grounding Cable Assembly 25 9685 0760 Rev C Included Items Kit 28 9685 0001
119. ires VL500 Incandescent Block Diagram Without On Board IGBT Dimmer 120V or 240V Pan Motor T Pan Tilt Encoder Encoder v J4 VL500 Main Control Board MCB J7 J6 J8 J3 Magenta Motor i Thermal Blue DMX Display 4 p Switch Motor PCB Remote i 8 Conn Amber Motor Thru In 1 Far Far Diffuser Terminal Motor Block Luminaire Power In Lamp Power In 12 21 May 2009 02 9685 0010A DESCRIPTION 1 VL500D Incandescent Luminaires VL500D Incandescent Block Diagram With On Board IGBT Dimmer 120V or 240V Pan Motor Pan Tilt Encoder lt Encoder T VL500 Main Control Board MCB ji Y Diffuser Terminal IGBT gt Dimmer Motor Block J7 J6 J8 J3 J2 A Magenta Motor i 4 Thermal Blue DMX Display Switch Motor PCB Remote i LVS Conn Amber n 9 6 Luminaire Power In des 02 9685 0010 A 21 May 2009 13 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 80V Incandescent Luminaires VL500 80V Incandescent Block Diagram With On Board 80V Dimmer Pan Motor Pan Tilt Encoder lt Encoder 7 VL500 Main Control Board MCB J6 J
120. ket assembly Step 1 CLOSE ALL GLASS IN BULKHEADS Power up unit and allow all DICHRO TUNE glass to calibrate Once they close power down unit A WARNING Remove power from luminaire before performing maintenance Step 2 Disconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 19 Step 4 Open heatsink by releasing latch Top Cover Magenta Blue Bulkhead Assembly Heatsink Assembly NOTE Some components not shown for clarity Heatsink Latch Figure 19 Accessing the Lamp Socket in VL500 and VL500D Fixtures Step 5 At top cover remove four 6 32x1 4 PPB SEMS screws Step 6 Remove top cover Step 7 Remove Magenta Blue Bulkhead Assembly as described in Magenta Blue DICHRO TUNE Rear Bulkhead Replacement on page 33 Remove Magenta Blue bulkhead Step 8 Using soft cloth to protect lamp remove lamp from socket 02 9685 0010 A 21 May 2009 45 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 46 Step 9 As indicated in Figure 20 at light baffle remove three 6 32x1 8 PPB screws Light Baffle Backcap Light Leak Foam Reflector Lamp Socket 6 32x1 4 PPZ Screws x2 8 32x1 2 PPZ SEM Screws x4 Reflector Clips x3 1 4 Hex Standoff x3 6 32x1 8 PPB Screws x3 Figure 20 Heatsink Assembly Lamp Socket Removal VL500 and VL500D Only Step Step
121. m CST Monday through Friday at the following phone 1 877 VARI LITE 1 877 827 4548 or 1 214 647 7880 fax 1 214 647 8038 E mail customerservice genlytecontrols com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link 2 21 May 2009 02 9685 0010 A CHAPTER 1 Description This chapter provides an overview of luminaire features components and operations Features Component Descriptions Principles of Operation 02 9685 0010 A 21 May 2009 5 1 35 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Features Product Features VL500 Wash Luminaire have the following features Color Enhanced DICHRO TUNET radial color changing mechanism featuring independent magenta blue and amber color control capable of smooth timed color crossfades or changes Pastel Dichroic Glass Option As an option all versions of the VLS00TW wash luminaire are available with pastel or lighter colored magenta and blue color filters VL500TM wash luminaires fitted with pastel colored dichroic glass maintain the electrical specifications of the standard version of the VL500TM wash Intensity Control Tungsten models offer an optional integral dimmer or may be dimmed with a customer supplied external dimmer Arc models contain an internal mechanical douser Beam Control In all models a selection of six eas
122. maci 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 dafiadas 6 Sitoca la l mpara con las manos limpie la l mpara con alcohol isopropyl 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 A En el ambiente de la casa este producto puede ocasionar radiointerferencia en cuyo caso el usuario debe tomar las medidas adecuadas CONSIDERACIONES SOBRE LAS CARACTER STICAS DE LA L MPARA DE ARCO 1 xii 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 L ON L OFF L encendida L apagada La posici n de encendido es universal 21 May 2009 02 9685 0010 A SAFETY NOTICE J APANESE
123. mbly 116 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Amber Diffuser Color Assembly 21 9685 0161 Rev F Refer to Figure 3 31 No Item Qty UM Description 1 10 9634 0034 32 EA SPRING DRIVE ARM FILTER 2 10 9634 0035 32 EA LINK DRIVE ARM 3 10 9634 0166 32 EA CARRIER FILTER METAL INJ MOLD 4 21 9685 0151 1 EA ASSY BULKHEAD TOP 5 22 9685 0124 16 EA ASSY FILTER AMBER DICRO TUNE 6 22 9685 0126 16 EA ASSY DIFFUSER PANEL 3 x16 x16 ds 5 x16 Figure 3 31 Amber Diffuser Color Assembly 02 9685 0010 A 21 May 2009 117 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Amber Dimmer Color Assembly 21 9685 0162 Rev E Refer to Figure 3 32 No Item Qty UM Description 1 10 9634 0034 32 EA SPRING DRIVE ARM FILTER 10 9634 0035 32 EA LINK DRIVE ARM 3 10 9634 0166 16 EA CARRIER FILTER METAL INJ MOLD 4 10 9647 0121 1 EA BAFFLE INNER LIGHT 5 10 9661 0307 16 EA CARRIER DIMMER 6 10 9661 0312 16 EA BEARING DIMMER 7 10 9661 0313 1 EA BAFFLE OUTER LIGHT DIMMER 8 10 9685 0210 16 EA DIMMER BLADE VL500 9 21 9685 0151 1 EA ASSY BULKHEAD TOP 10 22 9685 0124 16 EA ASSY FILTER AMBER DICRO TUNE 11 53 6556 0004 16 EA SCREW 4 40X1 8 PPB 118 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Amber Dimmer Color Assembly continued 10 x16 We Figure 3 32 Amber Dimme
124. n reverse 62 21 May 2009 02 9685 0010A MAINTENANCE 2 IGBT Dimmer Replacement VL500D Only Parts 69 3173 0115 1 EA DIMMER IGBT 1200W 120V REV PHASE CONT VLS00D 115V MODELS ONLY 69 3173 0240 1EA DIMMER IGBT 1200W 240V REV PHASE CONT VL500D 240V MODELS ONLY Tools 2 Phillips Screwdriver AN WARNING Remove power from luminaire before performing maintenance To remove and replace IGBT dimmer Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke cover on dimmer side by removing four 6 32x3 8 LG PTB screws Step 3 As shown in Figure 33 at dimmer loosen but do not remove four 6 32x3 8 PPZ screws Step 4 Carefully remove IGBT dimmer Note that there will be wires connected to dimmer on the back side A CAUTION All AC wiring is same color It is a good idea to mark the connector attached to both the AC Line Input and Load Output terminals on the IGBT dimmer with a black marker before removing so the phasing can be maintained Step 5 At dimmer carefully note and label before removing and disconnect following wiring a 3 position Dimmer Communication from MCB b Four Faston Quick Connects AC Input lamp Power Output Step 6 Remove four 6 32x3 8 PPZ screws from Step 3 Install these screws in replacement IGBT dimmer 02 9685 0010 A 21 May 2009 63 VAREELITE VL500 LUMINAIRE SERVICE MANUAL IGBT Dimmer Replacement VL500D Only con tinued e
125. niquement Une exposition la pluie et l humidit risque d endommager le luminaire D brancher l appareil avant de proc der la r vision de tout mat riel VARI LITE 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9685 0010 A 21 May 2009 ix VAREELITE VL500 LUMINAIRE SERVICE MANUAL AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1 Plusieurs luminaires VARI LITE utilisent une lampe de type HID qui produit des rayons UV NE PAS fixer son regard sur la lampe 2 L utilisation des luminaires sans lentille ou blindage pose des risques Tous blindages lentilles ou crans ultraviolet visiblement endommag s au point que leur efficacit en est affect e doivent tre remplac s par exemple s il y a des fissures ou de profondes rayures AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES ACCIDENTS POUVANT ENTRAINER DES BLESSURES 1 Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour manceuvrer ou ajuster des appareils br lants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 La lampe du luminaire est br lante lorqu il est en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons ultraviolets pouvant causer de graves br lures sur la peau et une inflammation des yeu
126. nte Tenir compte de tous les avertissements et suivre toutes les pr cautions pendant l installation et l utilisation de cet appareil Les symboles de s curit utilis s dans ce guide sont les suivants ATTENTION Ce symbole annonce que l appareil risque d tre endommag 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 VAREKLITEQ ont t con us pour tre utilis s uniquement avec certaines lampes Philips et Osram HID V rifier le type de lampe MSR400 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 VARI LITE AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les luminaires sont con us pour une utilisation au sec u
127. nterference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents Safety EN 60598 1 200 A11 2000 A12 2002 Luminaire Safety Standard General Requirements EN 60598 2 17 1989 A2 1991 Specification for Luminaires for Stage and Studio Lighting EMC EN 61000 6 4 2001 Emission Standard for industrial environments EN 61000 6 2 2001 Immunity for industrial environments We certify that the product conforms to the protection requirements of council directives 73 23 EEC LVD and 89 336 EEC EMC 21 May 2009 02 9685 0010 A Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein Heed all cautions and warnings during installation and use of this product Safety symbols used throughout this manual are as follows A CAUTION advising of potential damage to product AN 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 VARI LITE luminaires have been designed for use only with certain Philips and Osram HID lamps No
128. nts not shown for clarity Figure 26 LVS Temperature PCB Replacement VL500 VL500D VL500A Only Step 3 Disconnect the following wiring connections on PCB a 2 position connector LVS Fan b 4 position connector LVS Fan from MCB Step 4 As shown in Figure 26 remove one 1 4 hex standoff Step 5 Remove LVS Temperature PCB Step 6 Replace by performing steps 2 through 5 in reverse order 02 9685 0010 A 21 May 2009 53 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Low Voltage Supply LVS Replacement VL500 80V Only Parts 69 3178 0121 1EA POWER SUPPLY 120W 24VDC Tools 2 Phillips Screwdriver WARNING Remove power from luminaire before performing maintenance gt gt WARNING With power applied LIVE AC is present at heatsink Do not touch when unit is powered To remove and replace LVS Step 1 Remove power from luminaire Step 2 Position light to access top of pan tube assembly Step 3 At pan tube cover remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note cover tether will still hold cover Do not remove this screw Pan Tube Cover 8 32x1 2 Screws x6 4 40x1 4 PPZ Screws x4 LVS Power Supply d Shield fish paper Cover Tether Pan Tube NOTE Some components not shown for clarity e Figure 27 LVS Replacement VL500 80V Only 54 21 May 2009 02 9685 0010 A MAINTENANCE 2 Step 5 Remove LVS Temperature Sensor PCB by follow
129. of c A of 1 PEN _ AC In AC In AC In Data Thru Data Thru Termination Figure 1 Test Setup 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 Refer to VL500 Test Menu System Chart on page 21 for a complete list of test parameters which can be chosen Step 4 Press Enter to run test Step 5 Press Menu to stop test at any time Note Connected luminaires may not respond on the first action may delay of the master luminaire 21 May 2009 02 9685 0010 A MAINTENANCE 2 Movement Disable The Movement option allows pan and tilt to be disabled so that the luminaire can be placed in any position for testing without movement occurring In order to regain full control of the luminaire Movement will need to be enabled after testing Note When using the Movement option pan and tilt will be disabled for all the luminaires that are linked To set movement option Step 1 Press Menu Step 2 Press Up Down arrows until Config appears Press Enter Step 3 Press Up Down arrows until Pan Tilt appears Press Enter Step 4 Movement will be displayed Press Enter 5 Step 5 Use Up Down arrows to select Enable or Disable Press Enter to select 02 9685 0010 A 21 May 2009 19 VAREELITE VL500 LUMINAIRE SERVICE MANUAL 20 Diagnostic Tests The following
130. onnect wiring at both motors Remove linear actuator motor assembly as follows a At linear actuator motor assembly using 1 Phillips screwdriver remove three 4 40x1 4 PPZ screws and three 4 lock washers securing motor mount to luminaire head b At linear actuator motor assemblies using 2 slotted screwdriver disconnect actuator drive ring links from swivel links on drive rings At linear actuator motor using 1 Phillips screwdriver remove two 4 40x1 4 PPZ screws securing linear actuator motor to actuator mount and remove motor See Figure 16 Note Versilube Silicon Grease G321 is used to lubricate the actuator screw 4 40x1 4 PPZ Screw 2 for each motor Motor Mount Step Step 9 Step 10 Step 11 Step 12 Step 13 Actuator Screw Linear Actuator Motor Drive Ring Link Figure 16 Magenta Blue Linear Actuator Motor Replacement 8 Place linear actuator motor in place on actuator mount Re install two 4 40x1 4 PPZ screws and two 4 lock washers and using 1 Phillips screwdriver tighten to secure linear actuator motor and heatsink to actuator mount Secure actuator drive ring link to drive ring swivel link Attach wiring Re install top head cover Release tilt service lock Note If mechanism is too noisy loosen the two 4 40 x 1 4 PPZ screws and align actuator motor to motor mount to lessen noise 42 21 May 2009 02 9685 0010A MAINTENANCE 2 Linear Actuator Motor Repla
131. r Color Assembly 02 9685 0010 A 21 May 2009 119 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Bottom Bulkhead Assembly 21 9685 0150 Rev C Refer to Figure 3 33 No Item Qty UM Description 1 10 9661 0315 4 SUPPORT BULKHEAD 21 9685 0251 2 ASSY DRIVE RING 3 22 9634 0119 1 ASSY CENTER HUB 4 22 9685 0201 1 EA ASSY GENERIC BULKHEAD 5 53 6682 0002 12 EA SCREW 4 40X1 4 PPZ SEMS 6 55 6612 0008 10 EA PIN 1 8 OD X 3 8 LG AL DRIV LOX 7 55 6669 0009 4 EA STANDOFF 1 4 HEX 40 40X0 625 MF 120 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 Bottom Bulkhead Assembly continued 6 x10 7 x4 Figure 3 33 Bottom Bulkhead Assembly 02 9685 0010 A 21 May 2009 121 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Top Bulkhead Assembly 21 9685 0151 Rev C Refer to Figure 3 34 No Item Qty UM Description 1 10 9661 0315 4 EA SUPPORT BULKHEAD 10 9685 0219 2 EA AUX RING COLOR BULKHEAD 3 21 9685 0251 2 EA ASSY DRIVE RING 4 22 9634 0120 l EA ASSY LIGHT BAFFLE 5 22 9685 0201 1 EA ASSY GENERIC BULKHEAD 6 53 6682 0002 12 EA SCREW 4 40X 1 4 PPZ SEMS 7 55 6612 0008 10 EA PIN 1 8 OD X 3 8 LG AL DRIV LOX 8 55 6669 0009 4 EA STANDOFF 1 4 HEX 40 40X0 625 MF 9 55 6858 0002 4 EA STANDOFF 1 4 HEX 40 40X0 343 MF 122 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3
132. r Plate and remove plate Step 4 Disconnect wiring from motor and encoder PCB Step 5 Asshown in Figure 30 loosen but do not remove four 8 32x1 2 PPB screws Step 6 Press motor towards driven pulley and remove belt from drive pulley Step 7 Remove four 8 32x1 2 PPB screws from Step 5 Step 8 Remove Pan Tilt Motor Assembly Spring NOTE 8 32 1 2 4 Some components not shown for clarity Pan Belt a Pan Motor Assembly Pan Motor Assembly lt Yoke Arm Figure 30 Pan Motor Assembly Replacement Step 9 Replace pan motor assembly by performing Steps 2 through 8 in reverse Note When tightening four 8 32x1 2 PPB screws you must tighten CLOCKWISE pattern starting with screw in lower left hand side from spring 60 21 May 2009 02 9685 0010A MAINTENANCE 2 Pan Tilt Encoder PCB Replacement Parts 24 9685 7735 1 EA BOARD ASSY PAN TILT ENCODER Tools 2 Phillips Screwdriver AN WARNING Remove power from luminaire before performing maintenance To remove and replace pan tilt encoder PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 To access pan tilt encoder PCB a For Tilt Motor Encoder PCB removal remove display side yoke cover by removing four 6 32x3 8 LG PTB screws b For Pan Motor Encoder PCB removal access pan motor assembly see Pan Motor Assembly Replacement on page 60 Step 3 At encoder PCB disconnect wiring
133. r possible If these precautionary devices are not available handling of PC boards and components should be avoided CAUTION Black foam used to package solid state electronics should never be used for packing batteries or put in contact with PC boards which contain batteries 21 May 2009 02 9685 0010 A MAINTENANCE 2 Maintenance Procedures Lamp Replacement Incandescent Parts 71 2529 0120 1BA 1200 WATT TUNGSTEN HALOGEN LAMP 120 VAC VL500 AND VL500D MODELS 71 2526 0230 1 EA 1000 WATT TUNGSTEN HALOGEN LAMP 230 VAC VL500 AND VL500D MODELS 71 9685 0082 1 EA 1200 WATT TUNGSTEN HALOGEN LAMP 80 VAC VL500 80V MODELS Tools Cotton gloves or finger cots WARNING Remove power from luminaire before performing maintenance To remove and replace incandescent lamp Step 1 Remove power from luminaire WARNING Lamps will be extremely HOT after operation Allow lamp to cool before N replacing Step 2 Set the luminaire head horizontally Step 3 Engage service tilt lock to secure luminaire head in horizontal position to access heatsink latch Step 4 As shown in Figure 3 at heatsink assembly open latch and swing open back of luminaire CAUTION Ensure lamp is seated straight in socket before re installing backcap Heatsink Assembly Latch d Incandescent Lamp Figure 3 Lamp Replacement Incandescent 02 9685 0010 A 21 May 2009 25 VAREELITE VL500 LUMINAIRE SERVICE
134. ront Glass Replacement continued CAUTION Wear thick protective gloves or other protective covering while handling front lens The lens is extremely fragile and can break if too much force is applied If dirty clean with isopropyl alcohol and a soft lint free cloth Step 3 At front ring assembly carefully press front side of lens inward with thumbs while holding ring with fingers until glass is free of holder Remove lens WARNING When installing a new or replacement lens a VL500A ARC Wash all lens types must be installed curve out convex In tungsten fixtures VL500 VL500D and VL500 80V Wash Clear and Stipple lenses may be installed curve in concave and all Lenticular 8 Row 10 Row and 12 Row and Buxom lenses must be installed curve out convex Step 4 Position new glass in front ring assembly Be sure glass is fully and properly seated into rubber ring See Table 2 2 Lens Mounting Orientation for each model Incandescent Models VL500 VL500D and VL500 80V Clear Lens Concave or Convex Stipple Lens Concave or Convex 8 Row Lens Convex Only 10 Row Lens Convex Only 12 Row Lens Convex Only Buxom Lens Convex Only Arc Models VL500A Clear Lens Convex Only Stipple Lens Convex Only 8 Row Lens Convex Only 10 Row Lens Convex Only 12 Row Lens Convex Only Buxom Lens Convex Only Note Concave Bubble In Convex Bubble Out Table 2 2 Len
135. s Mounting Orientation Step 5 Close and latch front ring assembly 21 May 2009 02 9685 0010 A MAINTENANCE 2 Magenta Blue DICHRO TUNE Rear Bulkhead Replacement Parts 21 9685 0170 1 EA ASSY MAGENTA BLUE STANDARD DICHRO TUNE COLORS INCANDESCENT 21 9685 0174 1 EA ASSY MAGENTA BLUE PASTEL DICHRO TUNE COLORS INCANDESCENT 21 9685 0173 1 EA ASSY MAGENTA BLUE STANDARD DICHRO TUNE COLORS ARC 21 9685 0175 1 EA ASSY MAGENTA BLUE PASTEL DICHRO TUNE COLORS ARC Tools 2 Phillips Screwdriver To remove and replace Magenta Blue bulkhead assembly Step 1 CLOSE ALL GLASS IN BULKHEADS Power up unit and allow all DICHRO TUNE glass to calibrate Once they close power down unit A WARNING Remove power from luminaire before performing maintenance Step 2 Disconnect luminaire AC input cable from power source Step 3 Engage tilt lock so luminaire head is in horizontal position with top cover one with bubble facing up as shown in Figure 8 Step 4 As indicated in Figure 8 open heatsink by releasing latch Magenta Blue Assembly Top Cover Amber Diffuser Assembly Incandescent Models or Amber Dimmer Assembly Arc Models Heatsink Assembl d See separate procedure for removing and replacing these assemblies NOTE Some components not shown for clarity Figure 8 Magenta Blue Color Bulkhead 02 9685 0010 A 21 May 2009 33 VAREELITE VL500 LUMINAIRE SERVICE MA
136. 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 VARISKLITE Geriten beginnen 3 Die Gerate sollten nur von qualifiziertem Personal gewartet werden WARNUNG HINWEISE ZUM SCHUTZ GEGEN UBERHOHTE UV STRAHLUNG 1 Viele VAREKLITEG Scheinwerfer verwenden einen HID Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 02 9685 0010 A 21 May 2009 vii VAREELITE VL500 LUMINAIRE SERVICE MANUAL 2 Es ist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen oder Ultraviolettschirme miissen ausgetauscht werden sofern deren Schutzwirkung durch sichtbare Besch digung z Spr nge oder Schrammen eingeschr nkt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN KORPERVERLETZUNGEN 1 Bei Betrieb sind die AuBenfl 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 die Lampe zerbrechen besteht die Gefahr von K rperverletzung
137. t Panel Bearing Here ES Center Hub K Figure 14 Dimmer Panel Replacement Step 11 Replace by performing steps 3 through 10 in reverse order 40 21 May 2009 02 9685 0010A MAINTENANCE 2 Linear Actuator Motor Replacement Magenta Blue Bulkhead Parts 44 9685 0230 2EA MOTOR LINEAR 0 002 STEP Tools 1 Phillips Screwdriver 2 Phillips Screwdriver 2 Slotted Screwdriver WARNING Remove power from luminaire before performing maintenance To remove and replace linear actuator motor assembly Step 1 Remove power from luminaire Step 2 Set the luminaire head horizontally Step 3 Engage tilt service lock to secure luminaire head in horizontal position to access heatsink latch Magenta Blue Assembly 7 Amber Diffuser Assembly Incandescent Models Linear Actuator Motor Assembly or Amber Dimmer Assembly Arc Models Heatsink Assembl d See separate procedure for linear motor replacement for these assemblies NOTE Some components not shown for clarity Figure 15 Magenta Blue Color Bulkhead Linear Actuator Motors Step 4 Remove top head cover Note Linear actuator motors should be seen with cover removed If not flip head position 02 9685 0010 A 21 May 2009 41 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Step 5 Step 6 Step 7 At linear actuator motor to be replaced on Magenta Blue assembly disc
138. te lamp type MSR400 MSR700HR etc before replacing lamps Installing another type of lamp may be hazardous 2 Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detailed in this manual 3 Replace fuses with same type and rating only Note distance requirement from combustible materials or illuminated objects for VARIKLITE luminaires WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1 luminaires are designed for dry locations only Exposure to rain or moisture may damage luminaire Disconnect power before servicing equipment 3 Servicing to be performed by qualified personnel only 02 9685 0010 A 21 May 2009 V VAREELITE VL500 LUMINAIRE SERVICE MANUAL WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1 Many VARI LITE luminaires use an HID type lamp that produces UV radiation 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 operation Use appropriate safety equipment gloves eye protec
139. tenance To remove and replace safety relay assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke cover opposite of display by removing four 6 32x3 8 LG PTB screws Step 3 At Relay disconnect following wiring a Bundled AC from Ballast b White AC to Ignitor c Red 24V DC from MCB d Green 24V DC from Backcap Interlock Kill Switch Step 4 At Relay loosen but do not remove two 4 40x5 16 PPZ SEMS screws NOTE E Some components not shown for clarity 1 Relay 4 40x5 16 PPZ SEMS x2 Relay Yoke Arm Cover Step 5 Carefully slide Relay out of yoke arm Note When replacing Relay do not overtighten screws securing Relay as described in Step 4 Doing so may crack plastic tabs on Relay Step 6 Replace Relay by performing Steps 2 through 5 in reverse 21 May 2009 02 9685 0010 A MAINTENANCE 2 AC Input PowerCon Connector Replacement Parts 25 9685 0756 1 EA CONNECTOR AC INPUT POWERCON Tools 2 Phillips Screwdriver AN WARNING Remove power from luminaire before performing maintenance To remove and replace AC input PowerCon connector Step 1 Remove power from luminaire Step 2 Position light to access top of pan tube assembly Step 3 As shown in Figure 36 at pan tube cover remove six 8 32x1 2 PFB screws 4 Step 4 Remove pan tube cover Note tether will still hold cover Do not remove this screw Screws
140. tion 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 If lamp is touched with bare hands clean lamp with isopropyl 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 L ON LOFF system configuration setting 2 Burning position is universal vi 21 May 2009 02 9685 0010 A SICHERHEITSHINWEISE Sicherheitshinweise Es ist u erst wichtig
141. uminaire Assembly contin ue 4 12 VL500D Only 16 VL500 Only 17 VL500D Only Figure 3 14 Generic VL500 Luminaire Assembly VL500 and VL500D 02 9685 0010 A 21 May 2009 97 VAREELITE VL500 LUMINAIRE SERVICE MANUAL VL500 Luminaire Assembly contin ue 19 Figure 3 15 Generic VL500 Luminaire Assembly VL500 80V 98 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN 3 a VL500 Luminaire Assembly contin ue Figure 3 16 Generic VL500 Luminaire Assembly VL500A 02 9685 0010 A 21 May 2009 99 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Notes 100 21 May 2009 02 9685 0010A ILLUSTRATED PARTS BREAKDOWN Head Assembly VL500 Generic Head Assembly 21 9685 0310 VL500 and VL500D Rev K 21 9685 0311 VL500A Rev K 21 9685 0312 VL500 80V Rev K Refer to Figure 3 17 Figure 3 18 and Figure 3 19 No Item Qty UM Description 1 10 9634 0162 2 125 FT GASKET LENS FRONT CASTING 2 10 9685 0340 2 EA SUPPORT RIB 3 10 9685 0344 1 EA COVER LAMP WIRE 4 12 9685 1331 1 EA SIDE RAIL HINGE MACHINED CASTING 5 12 9685 0333 1 EA SIDE RAIL LATCH MACHINED CASTING 6 12 9685 0388 1 EA FRONT RING VL500 7 21 9685 0315 1 EA ASSY COUNTERWEIGHT SUPPORT 8 21 9685 0320 1 EA ASSY HEATSINK INCANDESCENT VL500 VL500D ONLY 9 21 9685 0321 1 EA ASSY HEATSINK ARC VL500A ONLY 10 21 9685 0322 1 EA ASSY HEA
142. x 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 Si la lampe a t touch e avec des mains nues la nettoyer avec de l alcool isopropyl et l essuyer avec un chiffon non pelucheux avant d installer ou de brancher le luminaire 7 Si la lampe a t endommag e ou a re u une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERFERENCE RF 1 Cet appareil est de Classe A Dans un environnement domestique cet appareil peut causer des interf rences radio et si c est le cas l utilisateur peut avoir prendre des mesures ad quates CONSID RATIONS DES CARACT RISTIQUES DE LAMPES ARC 1 Apr s une interruption de courant ou une baisse importante de voltage les lampes arc mettent du temps avant de se rallumer Dans certains cas la lampe se rallumera automatiquemet apr s s tre refroidie Cela d pend de la mani re dont le syst me est r gl pour le statut de mise en marche de la lampe L ON LOFF 2 La position Br ler est Universelle x 21 May 2009 02 9685 0010 A AVISO SOBRE SEGURIDAD Aviso sobre Seguridad Es muy importante leer TODA la informacion e instrucciones
143. x6 S Pan Tube Cover NOTE Die Some components not e shown for clarity This procedure is applicable for all models Pan Tube Assembly Cover Tether VL500 80V Pan Tube Assembly 4 40x1 2 PFB Screws x2 AC Input PowerCon Connector Figure 36 AC Input PowerCon Connector Replacement Step 5 Remove two 4 40x1 2 PFB screws at front of PowerCon Step 6 Disconnect wiring from PowerCon Step 7 Replace PowerCon by performing Steps 3 through 6 in reverse 02 9685 0010 A 21 May 2009 69 VAREELITE VL500 LUMINAIRE SERVICE MANUAL Mini XLR Display Remote Programming Con nector Replacement Parts 25 9685 0770 1EA CONNECTOR MINI XLR DISPLAY REMOTE PROGRAMMING Tools 2 Phillips Screwdriver A WARNING Remove power from luminaire before performing maintenance To remove and replace Mini XLR connector Step 1 Remove power from luminaire Step 2 Position light to access top of pan tube assembly Step 3 As shown in Figure 37 at pan tube cover remove six 8 32x1 2 PFB screws Step 4 Remove pan tube cover Note tether will still hold cover 8 32x1 2 PFB Screws x6 Do not remove this screw 3 Pan Tube Cover NOTE Some components not d shown for clarity This procedure is applicable for all models Pan Tube Assembly Cover Tether VL500 80V Pan Tube Assembly Mini XLR Connector 4 40x1 4 PFB Screws x2 Figure 37 Min

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