Philips VL500 Wash Luminaires, Vari-Lite VL500, Vari-Lite VL500D Wash, Vari-Lite VL500 80V Wash, Vari-Lite VL500A Wash Service Manual
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VARI❋LITE® - 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
DICHRO❋TUNE
Thomas Group LLC.
VARI❋LITE® 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; 5,432,691;
5,367,444; 5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806; 4,972,306;
4,800,474; 4,779,176; 4,701,833; 4,602,321;
U. S. Design Patents No. 439,356; 420,332; 417,300; 415,301; 413,99 5; 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; 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 97 0; 0 25 3 08 2;
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 68 727.1; 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 5 15. 9; M 96 04 5 14.0; M 94 0 7 689. 8; M 94 0 2 95 1.2; M 499 03 5 83.6; 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; 2,0 02,168; 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.
™
, VARI❋IMAGE™, VARI❋BRITE™and the Vari-Lite Asterisk are also trademarks owned by Genlyte
™
, Series 1000™, Series 2000™, Series 3000™,
Neutrik®, 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
©2003 - 2009, Vari-Lite, a Philips group company. All Rights Reserved.
ii 21-May-2009 02.9685.0010 A
VL500™ Luminaires Service Manual
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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 [email protected] 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 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 (RMA# ________)
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
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Compliance Notice
FCC
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 communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her
own expense.
Declaration of Conformity
We declare, under our sole responsibility, that this product complies with the relevant
clauses of the following standards and harmonized documents:
Safety
EN 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)
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SAFETY NOTICE
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:
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.
GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL 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. Note 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.
4. Note distance requirement from combustible materials or illuminated objects for
VARI❋LITE® luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARI❋LITE® luminaires are designed for dry locations only. Exposure to rain or
moisture may damage luminaire.
2. Disconnect power before servicing any VARI❋LITE® equipment.
3. Servicing to be performed by qualified personnel only.
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VARI❋LITE® - 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. It is 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 protection, etc.) when handling and adjusting hot equipment and
components.
2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to
cool before replacing.
3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye
inflammation. Additionally, arc lamps operate under high pressure at very high
temperatures. Should the lamp break, there can exist a danger of personal injury and/or
fire from broken lamp particles being discharged.
4. 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
1. Arc lamps require a period of time to relight after a power i nterruption 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.
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SICHERHEITSHINWEISE
Sicherheitshinweise
Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem
Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin
beschriebenen Produkte installieren bzw . be dienen. Halten Sie bei der Installation und
dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
VORSICHT - weist auf möglichen Produktschaden hin.
WARNUNG - weist auf mögliche Körperverletzung und Leb-
ensbedrohung hin.
NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE
UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARI❋LITE®-Scheinwerfer sind ausschließlich für 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 gefährlich sein.
2. Scheinwerfer können auf jeder beliebigen Oberfläche 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 Stärke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARI❋LITE®-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARI❋LITE®-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen
oder Feuchtigkeit können die Scheinwerfer beschädigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE®-Geräten
beginnen.
3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG
1. Viele VARI❋LITE®-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen ode r
Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN
1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkühlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen T emperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Körperverletzung bzw. von Feuer, das von Lampenteilen ausgelöst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.
6. Wenn die Lampe mit bloßen Händen berührt wird, reinigen Sie sie mit isopropyl Alkohol
und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb
nehmen.
7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstörungen verursachen. In diesem Fall müssen eventuell geeignete
Maßnahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach
Abkühlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.
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NOTES DE SÉCURITÉ
Notes de sécurité
Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en
marche, il est extrêmement important de lire TOUS les renseignements et TOUTES
les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe.
Tenir compte de tous les avertissements et suivre toutes les précautions pendant
l’installation et l’utilisation de cet appareil.
Les symboles de sécurité utilisés dans ce guide sont les suivants :
ATTENTION Ce symbole annonce que l’appareil risque
d’être endommagé.
AVERTISSEMENT Ce symbole annonce qu’il y a risque
d’accident grave ou même fatal.
CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE
PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES , LES INCENDIES,
L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRAÎNER DES BLESSURES.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES
1. Les luminaires VARI❋LITE® ont été conçus pour être utilisés uniquement avec certaines
lampes Philips et Osram HID. Vérifier 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 être fixés sur tout type de surface tant que les directives de
montage sont respectées. Voir les explications détaillées dans ce guide.
3. Ne remplacer les fusibles qu’avec ceux du même type, ayant les mêmes caractéristiques.
4. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et
les luminaires VARI❋LITE®.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES
1. Les luminaires VARI❋LITE® sont conçus pour une utilisation au sec uniquement. Une
exposition à la pluie et à l’humidité risque d’endommager le luminaire.
2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE®.
3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER 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 écrans ultraviolet visiblement endommagés au point que leur efficacité en est
affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT
ENTRAÎNER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche.
Pour manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la
peau et une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute
tension à de très hautes températures. Si la lampe se casse, les particules de la lampe
cassée peuvent causer blessures et/ou incendie en s’éparpillant.
4. Se protéger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier
des lampes endommagées.
6. Si la lampe a été touchée 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 été endommagée ou a reçu une déformation thermique, elle doit être
remplacée.
AVERTISSEMENT:
INTERFÉRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures
adéquates.
CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC
1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet après s’être refroidie. Cela dépend de la manière dont le système est réglé
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brûler est Universelle.
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AVISO SOBRE SEGURIDAD
Aviso sobre Seguridad
Es muy importante leer TODA la información e instrucciones sobre seguridad que se
indica en este manual así como en los documentos adjuntos antes de instalar y operar
los productos descritos. Se debe prestar atención a todos los avisos y advertencias
durante la instalación y uso de este producto.
Los símbolos de seguridad usados en este manual son los siguientes:
CUIDADO, indica posibles daños al producto.
ADVERTENCIA, indica posibles lesiones o muerte a las
personas.
LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CONTRAGOLPES DE CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN
EXCESIVA A RADIACIÓN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO
1. Las luminarias VARI❋LITE® han sido diseñadas para ser usadas solamente con algunas
lámparas HID Philips y Osram. Tome nota del tipo de lámpara (MSR400, MSR700HR
etc.) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalación. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificación.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARI❋LITE®.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE
ELÉCTRICO
1. Las luminarias VARI❋LITE® están diseñadas solamente para lugares secos. La
exposición a la lluvia o humedad pueden dañar la luminaria.
2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE®.
3. El servicio debe ser realizado solamente por personal calificado .
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA
1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación
UV. NO mire directamente a la lámpara.
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VARI❋LITE® - 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 dañadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un
equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que están calientes.
2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la
energía y deje que la lámpara se enfríe antes de reemplazarla.
3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamación a los ojos. Además, las lámparas de arco operan a alta
presión y muy alta temperatura. Si la lámpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se
caen.
4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.
5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando
trabaje con lámparas dañadas.
6. Si toca la lámpara con las manos, limpie la lámpara con alcohol isopropyl y con tela sin
pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lámpara si está dañada 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 CARACTERÍSTICAS DE LA LÁMPARA DE
ARCO
1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de
una interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara
se volverá a iluminar en forma automática después que se ha enfriado dependiendo de la
configuración del sistema de energía de la lámpara (L ON / L OFF) (L encendida / L
apagada).
2. La posición de encendido es universal.
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SAFETY NOTICE (JAPANESE)
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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Table of Contents
Introduction
Disclosure .................................................................................................................... 1
About This Manual...................................................................................................... 1
Additional Documentation........................................................................................... 1
Customer Service......................................................................................................... 2
Chapter 1. Description
Features
Product Features....................................................... ..... .... ........................................... 4
Model Specific Features .............................................................................................. 5
Component Descriptions
External Luminaire Components................................................................................. 7
Luminaire Internal Head Components......................................................................... 8
Luminaire Yoke Components ...................................................................................... 9
Arc Ballast Unit ......................................................................................................... 11
Dimmer Models......................................................................................................... 11
Principles of Operation
VL500 Incandescent Luminaires............................................................................... 12
VL500 Incandescent Block Diagram - Without On-Board IGBT Dimmer (120V or
240V)................................................................................................................... 12
VL500D Incandescent Luminaires............................................................................ 13
VL500D Incandescent Block Diagram - With On-Board IGBT Dimmer (120V or
240V)................................................................................................................... 13
VL500 80V Incandescent Luminaires....................................................................... 14
VL500 80V Incandescent Block Diagram - With On-Board 80V Dimmer........ 14
VL500A Luminaire.................................................................................................... 15
VL500A Arc Block Diagram - With External Arc Ballast................................. 15
TABLE OF CONTENTS
Chapter 2. Maintenance
Testing
Running Parameter Tests ........................................................................................... 18
Diagnostic Tests......................................................................................................... 20
Test Descriptions................................................................................................. 20
Test Menu System Chart..................................................................................... 21
Lamp Hours Progress Bar (Arc Models Only).......................................................... 22
Equipment Handling
Locations/Use ............................................................................................................ 23
Lamps......................................................................................................................... 23
Servicing.............................................................................................................. 23
Heat ..................................................................................................................... 23
02.9685.0 010 A 21-May-2009 xv
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Lamp Life............................................................................................................. 23
Solid State Electronics................................................................................................ 24
Electrostatic Discharge (ESD)............................................................................. 24
Printed Circuit Boards (PCBs)............................................................................. 24
Maintenance Procedures
Lamp Replacement - Incandescent............................................................................. 25
Lamp Replacement - Arc............................................................................................ 27
Align Lamp For Maximum Beam Irradiance............................................................. 29
Front Glass Replacement............................................................................................ 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 ............................................................ 37
Arc Dimmer Panel Replacement................................................................................ 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 VL500D Only) Replacement.... 45
Arc Lamp Socket Assembly (VL500A and VL500 80V Only) Replacement........... 47
Display PCB Replacement......................................................................................... 49
Main Control PCB/Fan Assembly Replacement........................................................ 50
Low Voltage Supply (LVS) Replacement (VL500/VL500D/VL500A Only)............ 52
Low Voltage Supply (LVS) Temperature PCB Replacement (VL500/VL500D/VL500A
Only)........................................................................................................................... 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............................................................................. 58
Pan Motor Assembly Replacement............................................................................ 60
Pan/Tilt Encoder PCB Replacement........................................................................... 61
Arc Ignitor PCB Replacement (VL500A Only)......................................................... 62
IGBT Dimmer Replacement - VL500D Only............................................................ 63
80V Dimmer Replacement - VL500 80V Only ......................................................... 65
Arc Ballast Replacement (VL500A Only)................................................................. 67
Safety Relay Replacement (VL500A Only)............................................................... 68
AC Input (PowerCon) Connector Replacement......................................................... 69
Mini-XLR (Display/Remote Programming) Connector Replacement....................... 70
DMX PCB Assembly Replacement ........................................................................... 71
Cleaning Optical Lenses and Filters........................................................................... 72
Chapter 3. Illustrated Parts Breakdown
Drawing Trees
VL500 and VL500D Incandescent Luminaires.......................................................... 74
VL500 80V Incandescent Luminaires....................................................... ................. 76
VL500A Arc Luminaires............................................................................................ 78
Top Assembly
Included Items Kit ....................................................................... ...............................80
Label Locations.......................................................................................................... 82
VL500 (120V or 240V) Luminaire ............................................. .... ..... .... ..................85
xvi 21-May-2009 02.9685.0010 A
Page 17
TABLE OF CONTENTS
VL500D (with 120V IGBT Dimmer) Luminaire ...................................................... 87
VL500D (with 240V IGBT Dimmer) Luminaire ...................................................... 89
VL500 80V (with 80V Dimmer) Luminaire ..............................................................91
VL500A (700W Arc) Luminaire ...............................................................................93
Generic VL500 Luminaire Assembly ........................................................................ 95
Head Assembly
VL500 Generic Head Assembly .............................................................................. 101
Heatsink Assembly ..................................................................................................105
VL500 Magenta/Blue Color Assembly ................................................................... 109
VL500 Magenta/Blue (Pastel) Color Assembly ...................................................... 110
VL500 Amber/Diffuser Color Assembly ................................................................. 111
VL500 Amber/Dimmer Color Assembly ................................................................. 112
VL500 Magenta/Blue (Arc) Color Assembly .......................................................... 113
VL500 Magenta/Blue (Arc Pastel) Color Assembly ............................................... 114
Magenta/Blue Color Assembly ................................................................................115
Magenta/Blue (Pastel) Color Assembly ................................................................... 116
Amber/Diffuser Color Assembly ............................................................................. 117
Amber/Dimmer Color Assembly .......................................................................... ...118
Bottom Bulkhead Assembly .................................................................................... 120
Top Bulkhead Assembly ..........................................................................................122
Drive Ring Assembly ............................................................................................... 124
Magenta/Blue Color Motor Assembly ..................................................................... 125
Amber/Diffuser Color Motor Assembly ..................................................................126
Yoke Assembly
VL500 Yoke Assembly ............................................................................................ 127
VL500 80V Yoke Assembly ....................................................................................131
VL500 Extra Hardware Kit ......................................................................................135
VL500 Pan/Tilt Motor Assembly ............................................................................ 136
VL500 MCB/FAN Assembly .................................................................................. 138
MCB-Fan Assembly ................................................................................................139
Yoke Crossmember Assembly (VL500/VL500D/VL500A) ................................... 140
Yoke Crossmember Assembly (VL500 80V) ..........................................................142
Lower Crossmember Assembly ............................................................................... 144
Upper Crossmember Assembly ............................................................................... 146
Pan Tube Assembly (VL500/VL500D/VL500A) .................................................... 147
Pan Tube Assembly (VL500 80V) .......................................................................... 148
DMX Input PCB Assembly .....................................................................................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 ............................................................. 151
Disconnect Cable Assembly .................................................................................... 152
80V LVS AC Cable Assembly ................................................................................153
24V Power Cable Assembly (VL500 80V) ............................................................. 154
Yoke Lamp Cable Assembly (VL500 80V) ............................................................ 155
80V Surge Protector Cable Assembly ..................................................................... 156
02.9685.0 010 A 21-May-2009 xvii
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Dimmer Communication Cable Assembly (VL500/VL500D) ................................157
24V Power Cable Assembly (VL500/VL500D) ......................................................158
VL500 Motor Cable Assembly ................................................................................159
Relay to Ignitor Cable Assembly .............................................................................161
VL500 AC Input Cable Assembly ...........................................................................162
VL500 Arc Ballast Input Cable Assembly ...............................................................163
VL500 Pan / Tilt Cable Assembly ............................................................................164
VL500 Head Grounding Cable Assembly ................................................................166
VL500 Ignitor to Socket Cable Assembly ................................................................167
VL500 Arc Ballast Interconnect Cable Assembly ...................................................168
VL500 Display Cable Assembly ..............................................................................170
VL500 Display (Remote) Cable Assembly ..............................................................171
Yoke Lamp Cable Assembly (VL500/VL500D) .....................................................172
VL500 Yoke Ground Cable Assembly .....................................................................173
LVS AC Cable Assembly (VL500/VL500D/VL500A) ........................................... 174
VL500 Yoke DMX Communication Cable Assembly .............................................175
VL500 Yoke Lamp Jumper Cable Assembly ...........................................................176
VL500 Backcap Ground Cable Assembly ...............................................................177
LVS Fan Cable Assembly (VL500/VL500D/VL500A) ...........................................178
VL500 MCB Yoke Ground Cable Assembly ...........................................................179
Arc Yoke Lamp Cable Assembly (VL500A) ...........................................................180
Shielded Display/DMX Communication Cable Assembly (VL500A) ....................181
VL500 80V Display Cable Assembly ......................................................................182
VL500 80V Yoke DMX Communication Cable Assembly .....................................183
VL500 80V LVS Fan Cable Assembly ....................................................................184
80V Shielded Display/DMX Communication Cable Assembly (VL500 80V) .......185
80V Dimmer Communication Cable Assembly (VL500 80V) ................................186
VL500 Main Harness Cable Assembly ....................................................................187
VL500 Arc Main Harness Cable Assembly .............................................................189
VL500 80V Main Harness Cable Assembly ............................................................191
VL500 80V Lamp Wire Harness ..............................................................................193
Arc Ballast Assembly
VL500 Arc Ballast Assembly ...................................................................................195
Ballast I/O Cable Assembly .....................................................................................197
Appendix A. Technical Bulletins and Notices
VL500™ Wash Luminaire Technical Bulletins and Notices ................................... 199
xviii 21-May-2009 02.9685.0010 A
Page 19
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 procedures, 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.
INTRODUCTION :
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
TM
VL500D
VL500D
VL500D
VL500D
VL500 80V
VL500 80V
VL500A
VL500A
Note: * = Lamp Type is specified by customer at time of ordering.
Wash Luminaire
TM
Wash Luminaire
TM
Wash Luminaire
TM
Wash Luminaire
TM
Wash Luminaire
TM
Wash Luminaire
TM
Wash Luminaire
TM
Wash Luminaire
20.9685.0002 Tungsten 120V, Integral IGBT Dimmer, Standard Color System
20.9685.0012 Tungsten 120V, Integral IGBT Dimmer, Pastel Color System
20.9685.0003 Tungsten 240V, Integral IGBT Dimmer, Standard Color System
20.9685.0013 Tungsten 240V, Integral IGBT Dimmer, Pastel Color System
20.9685.0004 Tungsten 80V, Dimmer (100 - 240V Input), Standard Color System
20.9685.0014 Tungsten 80V, Dimmer (100 - 240V Input), Pastel Color System
20.9685.0006 Arc 700W, Ballast, Standard Color System
20.9685.0016 Arc 700W, Ballast, Pastel Color System
Note: Performing maintenance procedures contained in this manual may void the
product warranty. Refer to the Vari-Lite Limited Warranty card included in the
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).
02.9685.0 010 A 21-May-2009 1
Page 20
VARI❋LITE® - 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.
■ VL500™ Luminaire User’s Manual (02.9685.0001).
Technical bulletins concerning the latest changes to VARI❋LITE® equipment are
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 fulltime staff of experienced professionals are on-hand to provide support.
How to Reach Us
For assistance in your area, call the dealer from which your product(s) were
purchased.
or
Contact an Authorized Service Center.
or
Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through
Friday, at the following:
phone: 1.877.VARI-LITE (1-877.827.4548) or 1.214.647.7880
fax: 1.214.647.8038
E-mail: [email protected]
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
Page 21
CHAPTER 1.
Description
This chapter provides an overview of luminaire features, components
and operations.
• Features
• Component Descriptions
• Principles of Operation
02.9685.0 010 A 21-May-2009 3
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Features
Product Features
VL500™ Wash Luminaire have the following features:
Color
Enhanced DICHRO❋TUNETM 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 VL500™ wash luminaire are available with “pastel”
or lighter colored magenta and blue color filters. VL500™ wash luminaires fitted with
pastel-colored dichroic glass maintain the electrical specifications of the standard
version of the VL500™ 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, easily 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 02.9685.0010 A
Page 23
DESCRIPTION :
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❋TUNE
VL500 Wash Luminaire (20.9685.0011)
• 120V (or 240V), 1200W (or 1000W) Tungsten Halogen lamp source.
• Pastel color dichroic glass DICHRO❋TUNE
VL500D Wash Luminaire (20.9685.0002)
• 120V, 1200W Tungsten Halogen lamp source.
• Standard color dichroic glass DICHRO❋TUNE
TM
color system.
TM
color system.
TM
color system.
1
• 120V on-board IGBT dimmer.
VL500D Wash Luminaire (20.9685.0012)
• 120V, 1200W Tungsten Halogen lamp source.
• Pastel color dichroic glass DICHRO❋TUNE
TM
• 120V on-board IGBT dimmer.
VL500D Wash Luminaire (20.9685.0003)
• 240V, 1000W Tungsten Halogen lamp source.
• Standard color dichroic glass DICHRO❋TUNE
• 240V on-board IGBT dimmer.
VL500D Wash Luminaire (20.9685.0013)
• 240V, 1000W Tungsten Halogen lamp source.
• Pastel color dichroic glass DICHRO❋TUNE
TM
• 240V on-board IGBT dimmer.
VL500 80V Wash Luminaire (20.9685.0004)
• 80V, 1200W Tungsten Halogen lamp source.
• Standard color dichroic glass DICHRO❋TUNE
color system.
TM
color system.
color system.
TM
color system.
• 80V on-board dimmer.
02.9685.0 010 A 21-May-2009 5
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
VL500 80V Wash Luminaire (20.9685.0014)
• 80V, 1200W Tungsten Halogen lamp source.
• Pastel color dichroic glass DICHRO❋TUNE
• 80V on-board dimmer.
VL500A Wash Luminaire (20.9685.0006)
• 700W arc lamp source with external ballast unit.
• Standard color dichroic glass DICHRO❋TUNE
VL500A Wash Luminaire (20.9685.0016)
• 700W arc lamp source with external ballast unit.
• Pastel color dichroic glass DICHRO❋TUNE
TM
color system.
TM
color system.
TM
color system.
6 21-May-2009 02.9685.0010 A
Page 25
Component Descriptions
External Luminaire Components
The following illustration shows the external luminaire components and controls.
Input Panel Connections
DESCRIPTION :
1
Base
Provides hook mounting
holes and safety cable
connection.
Yoke Leg (Control)
Contains main control
PCB and display PCB.
Heatsink Assembly
Provides access to lamp
for replacement.
Lamp Power
Input Cable
Lamp Power
Input Cable
Input Panel
Provides DMX In and
Thru, and AC Power
connections.
Menu Display
Used to input manual
commands, program, test,
set defaults and access
internal status information.
Data Thru
Data In
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
Mini XLR for Remote
3-Pole Neutrik
Locking Connector
for AC Input
LCD
Display
02.9685.0 010 A 21-May-2009 7
Softkeys - The menu has four
softkey buttons that change to
accommodate menu selection.
Page 26
VARI❋LITE® - 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.
Magenta/Blue Assembly (All Models)
DICHRO❋TUNE
radially mounted magenta and blue dichroic
glass for color mixing.
Backcap Assembly
Provides access to lamp
for replacement
Backend / Heatsink Assembly
Contains reflector and heatsink.
™
color bulkhead - 16-
Amber/Diffuser Assembly (Tungsten Models)
DICHRO❋TUNE
mounted diffuser panels for beam control and
amber dichroic glass for color mixing.
Amber/Dimming Assembly (Arc Models)
DICHRO❋TUNE
mounted blackout panels for dimming operation
and amber dichroic glass for color mixing.
™
color bulkhead - 16-radially
™
color bulkhead - 16-radially
Head Covers
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 02.9685.0010 A
Page 27
DESCRIPTION :
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)
1
Yoke Arm Cover
(Display Side)
Display LCD
Luminaire technical status/info.
Main Controller PCB
Luminaire control circuit board.
Power Supply Side
VL500 Models (120V or 240V)
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
02.9685.0 010 A 21-May-2009 9
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VARI❋LITE® - 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
VL500 80V Models
120W Power Supply
Supplies power to
electronic and motor
components.
120V or 240V IGBT
Dimmer Module
VL500A Models
Pan Mechanism
Standard Yoke
Arm Cover
Pan Mechanism
80V Dimmer
Module
80V Dimmer Yoke
Arm Cover
10 21-May-2009 02.9685.0010 A
Ignitor PCB
Ignites lamp in arc models
Page 29
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
Safety Cable Tab
Used to attach
safety cable clip.
Used to attach a truss hook.
Ballast Unit
Provides power for
arc lamp source.
Lamp Power Input Cable
Supplied cable and connector used
to connect luminaire to ballast unit.
40 inches (1m)
Lamp Connector (underside)
CPC-type connector for connecting
Lamp Power Input cable from luminaire.
Note: The Lamp Power Input Cable has conductors for lamp power and ballast
control. It is NOT compatible with VARI❋LITE Series 300™ lamp runs.
Dimmer Models
An on-board dimmer is
included with VL500D and
VL500 80V incandescent
dimmer models. The dimmer
heatsink is visible on the powerside yoke leg as shown in this
illustration.
On-Board Dimmer
VL500D Models - Internal lamp power
dimmer configured for either 120V or
240V operation depending on model.
VL500 80V Models - Internal lamp power
dimmer configured specifically for 80V
lamps.
02.9685.0 010 A 21-May-2009 11
Page 30
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Principles of Operation
VL500 Incandescent Luminaires
VL500 Incandescent Block Diagram - Without On-Board
IGBT Dimmer (120V or 240V)
Encoder
Magenta
Motor
Blue
Motor
Amber
Motor
Pan
Motor
Pan
Tilt
Motor
Tilt
Encoder
J4
VL500 Main Control Board (MCB)
J6
J7
J6
DMX
PCB
Thru In
LVS
J3J8
Display
Fan
Thermal
Switch
Fan
Remote
Conn.
Diffuser
Motor
12 21-May-2009 02.9685.0010 A
Terminal
Block
Luminaire
Power In
Lamp
Power In
Lamp
Page 31
DESCRIPTION :
VL500D Incandescent Luminaires
VL500D Incandescent Block Diagram - With On-Board
IGBT Dimmer (120V or 240V)
1
Encoder
Magenta
Motor
Blue
Motor
Amber
Motor
Pan
Motor
Pan
Tilt
Motor
Tilt
Encoder
J4
VL500 Main Control Board (MCB)
J6
J7
J6
DMX
PCB
Thru In
LVS
J3J8
Display
Fan
Thermal
Switch
Fan
J2
Remote
Conn.
Diffuser
Motor
02.9685.0 010 A 21-May-2009 13
Terminal
Block
Luminaire
Power In
IGBT
Dimmer
Lamp
Page 32
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
VL500 80V Incandescent Luminaires
VL500 80V Incandescent Block Diagram - With On-Board
80V Dimmer
Encoder
Magenta
Motor
Blue
Motor
Amber
Motor
Pan
Motor
Pan
Tilt
Motor
Tilt
Encoder
J4
VL500 Main Control Board (MCB)
J6
J7
J6
DMX
PCB
Thru In
LVS
J3J8
Display
Fan
Thermal
Switch
Fan
J2
Remote
Conn.
Ferrite
Core
Diffuser
Motor
14 21-May-2009 02.9685.0010 A
Terminal
Block
Luminaire
Power In
80V
Dimmer
Lamp
Fan
Page 33
DESCRIPTION :
VL500A Luminaire
VL500A Arc Block Diagram - With External Arc Ballast
1
Encoder
Magenta
Motor
Blue
Motor
Amber
Motor
Pan
Motor
Pan
Lamp
Tilt
Motor
Ignitor
PCB
Tilt
Encoder
J4
VL500 Main Control Board (MCB)
J6
J7
J6
DMX
PCB
Thru In
LVS
Backcap
Interlock
Relay
J3J8
Display
Fan
ARC Ballast
Thermal
Switch
Fan
Fan
J5
Remote
Conn.
Dimmer
Motor
02.9685.0 010 A 21-May-2009 15
Terminal
Block
Luminaire
Power In
Page 34
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Notes
16 21-May-2009 02.9685.0010 A
Page 35
CHAPTER 2.
Maintenance
This chapter contains test, service, and standard maintenance
procedures.
• Testing
• Equipment Handling
• Maintenance Procedures
WARNING: All maintenance procedures are to be performed with power
removed from the luminaire. Never remove cover or backcap while lamp is in
operation.
WARNING: Maintenance, repairs, and adjustments should only be
performed by a qualified, factory-trained service technician at an Authorized
VARI❋LITE® Service Center.
02.9685.0 010 A 21-May-2009 17
Page 36
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Testing
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
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 VL500™
wash luminaire to multiple VL500™ wash luminaires (of a different type) across the VL500™
wash platform. T o alleviate this, when testing in groups, only test same Lamp Type luminaires
(for example: VL500A™ wash [700W arc] with other VL500A™ wash [700W arc] lights,
VL500™ 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
VL500™ wash luminaires during normal operation under D MX control.
“Diagnostic Tests” on page 20.
Master Luminaire (running test) Slave Luminaire Slave Luminaire
AC In
Data Thru
AC In
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.
AC In
18 21-May-2009 02.9685.0010 A
Page 37
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].
Step 5. Use [Up] / [Down] arrows to select Enable or Disable. Press [Enter] to select.
02.9685.0 010 A 21-May-2009 19
Page 38
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Diagnostic Tests
The following 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.
Pan......................Tests different pan movements.
Tilt........................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.
Fan......................Tests fan level (speed 1 to 7, 7 is fastest).
Temperature........Displays LVS or MCB temperatures (in
o
C).
20 21-May-2009 02.9685.0010 A
Page 39
MAINTENANCE :
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.
Table 2-1: VL500 Test Menu System Chart
1st Level 2nd Level 3rd Level 4th Level 5thLevel
Test **
System Test
** Refer to “Diagnostic Tests” on page 20 for more information.
ALL SEQ Sequence Through All
Tests
Pan/Tilt Pan/Tilt RunTest
Pan Pan Pan 1
Tilt Tilt Tilt 1
Dimmer Dimmer Dimmer 1
Diffuser Diffuser Diffuser 1
Cyan Cyan Color System Cyan 1
Yellow Yellow Color System Yellow 1
Magenta Magenta Color System Magenta 1
Encoder Encoder (Allows hand
movement to check values)
Fans Fans Test Value 1 (slow) to 7 (fastest)
Temp Temperature LVS Temp Low Voltage
RunTest Press [Menu] to stop tests
Pan 2
Tilt 2
Dimmer 2
Dimmer 3
Diffuser 2
Diffuser 3
Cyan 2
Cyan 3
Yellow 2
Yellow 3
Magenta 2
Magenta 3
Pan Value Displays encoder
Tilt Value Displays encoder
Supply temperature
MCB Temp Main Control
Board temperature
value
value
Value Displays
temperature in
Value Displays
temperature in
o
C
o
C
2
02.9685.0 010 A 21-May-2009 21
Page 40
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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
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
"Exceeded Lamp Hours".
Series 500 Menu Display
Arc Lamp Hours Progress Bar
Figure 2).
575W ARC NORMAL
750 Hours
169
MENU
ENTER
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.
Menu Display
Softkeys - The menu has four softkey
buttons that change to accommodate
menu selection.
22 21-May-2009 02.9685.0010 A
Page 41
Equipment Handling
Below are some basic tips and information on handling VL500 luminaires and their associated
components.
Locations/Use
VARI❋LITE 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.
MAINTENANCE :
2
• 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 ten 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 of f 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.
02.9685.0 010 A 21-May-2009 23
Page 42
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
• 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, whereby 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 VARI
electronics and appropriate precautions to protect them should be observed when servicing.
❋LITE equipment uses solid state
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
whenever 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 ba tteries.
24 21-May-2009 02.9685.0010 A
Page 43
Maintenance Procedures
Lamp Replacement - Incandescent
Parts:
71.2529.0120 1EA 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.
MAINTENANCE :
2
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
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
luminaire.
CAUTION:
Ensure lamp is seated
straight in socket before
re-installing backcap.
Figure 3, at heatsink assembly, open latch and swing open back of
Heatsink
Assembly
02.9685.0 010 A 21-May-2009 25
Latch
Incandescent Lamp
Figure 3: Lamp Replacement - Incandescent
Page 44
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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 5. Remove lamp by pulling straight out of socket.
Step 6. Carefully clean reflector with soft, lint-free cloth to remove dust and other debris.
Step 7. Install lamp by pressing firmly into socket. Ensure lamp is fully seated in socket
with base of lamp against socket base.
Step 8. Close and re-latch back of luminaire.
Step 9. 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 T echnical Notice TN-248 (c urrent version) on the Vari-Lite web site at
www.vari-lite.com.
26 21-May-2009 02.9685.0010 A
Page 45
MAINTENANCE :
2
Lamp Replacement - Arc
Parts:
71.9685.0702 1 EA MSR700/2, 700 WATT MSR ARC LAMP
Tools:
• Cotton gloves or finger cots.
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
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
luminaire.
CAUTION:
Ensure lamp is seated
straight in socket before
re-installing backcap.
Figure 4, at heatsink assembly, open latch and swing open back of
Heatsink
Assembly
Back Cap
Assembly
Arc Lamp
Latch
Menu
02.9685.0 010 A 21-May-2009 27
Figure 4: Installing Arc Lamp in VL500A Models
Page 46
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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. Remove lamp by pulling straight out of socket.
Step 6. Carefully clean reflector and facing UV glass lens with soft, lint-free cloth to
remove dust and other debris.
Step 7. Install lamp by pressing firmly into socket. Ensure lamp is fully seated in socket
with base of lamp against socket base.
Step 8. Close and re-latch back of luminaire.
Step 9. Disengage service tilt lock to allow luminaire head to move freely.
Step 10. Align lamp. (Refer to
“Align Lamp For Maximum Beam Irradiance” on
page 29.)
Step 11. 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.)
a. Power up luminaire.
b. At Menu Display, press [Menu].
c. Press [Up] / [Down] arrows until
d. Press [Up] / [Down] arrows until
e. Press [Up] / [Down] arrows to ac cess
and strike counters.
CFG (Configuration) appears. Press [Enter].
LAMP appears. Press [Enter].
RHrs. Press [Enter] to reset lamp hour
Note: For an updated list of approved lamps for all versions of the VL500™ luminaire,
please refer to Vari-Lite T echnical Notice TN-248 (c urrent version) on the Vari-Lite web site at
www.vari-lite.com.
28 21-May-2009 02.9685.0010 A
Page 47
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
• 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
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
luminaire.
Backcap
Assembly
Figure 5, at heatsink assembly, open latch and swing open back of
Heatsink
Assembly
02.9685.0 010 A 21-May-2009 29
Latch
Figure 5: Accessing the Reflector in VL500A Fixtures
Arc Lamp
Page 48
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Step 5. Ensure the following:
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 screwdriver, 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.
Step 6. Using soft, lint-free dry cloth, wipe lamp and reflector clean of any dust or finger-
prints.
Step 7. Close and latch heatsink assembly.
Step 8. Disengage service tilt lock to allow luminaire head to move freely.
Step 9. Supply power to luminaire.
Step 10. Disable pan/tilt (if necessary).
Step 11. Set color to WHITE and intensity to 100%.
Step 12. Unlatch and swing open front lens ring (this will make hot spot and halo easier to
see).
Step 13. Shine lamp on flat surface 10-20 feet away.
Step 14. 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 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*
* Do not remove or use to access lamp.
Step 15. Close and latch front lens ring.
30 21-May-2009 02.9685.0010 A
Figure 6: Lamp Alignment Screws
Page 49
MAINTENANCE :
Front Glass R eplacement
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 1 EA GLASS, FRONT, VERY WIDE FLOOD - BUXOM
Tools:
• Cotton Gloves or Finger Cots
• Clean, Lint-free (Soft) Cloth
To remove and replace front glass:
WARNING: Remove power from luminaire before performing maintenance.
2
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.).
Step 1. Remove power from luminaire.
Step 2. At front ring assembly, open latch and swing open. Refer to
Head Assembly
Hinge Latch
Front Lens
Figure 7.
Front Ring
Assembly
02.9685.0 010 A 21-May-2009 31
Figure 7: Replacing Front Glass
Page 50
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Front 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 in a VL500A
lens types must be installed curve out (convex). In tungsten fixtures (VL500
and VL500 80V
TM
Wash), Clear and Stipple lenses may be installed curve in (concave) and all
TM
(ARC) Wash, all
TM
, VL500DTM,
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
Step 5. Close and latch front ring assembly.
32 21-May-2009 02.9685.0010 A
Note: Concave = Bubble In / Convex = Bubble Out
Table 2-2: Lens Mounting Orientation
Page 51
MAINTENANCE :
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:
2
Step 1. CLOSE ALL GLASS IN BULKHEADS
- Power up unit and allow all
DICHRO*TUNE glass to calibrate. Once they close, power down unit.
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
Step 4. As indicated in
Magenta/Blue Assembly
Heatsink Assembly
Figure 8, open heatsink by releasing latch.
Figure 8).
Top Cover
Amber/Diffuser Assembly*
(Incandescent Models)
or
Amber/Dimmer Assembly*
(Arc Models)
*See separate procedure for
removing and replacing these
assemblies.
NOTE:
Some components not shown for clarity.
02.9685.0 010 A 21-May-2009 33
Figure 8: Magenta/Blue Color Bulkhead
Page 52
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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
SEMS screws.
Magenta/Blue Assembly
6-32x3/8" PPZ SEMS (x4)
Figure 9, at side rails from top, remove four 6-32x3/8" LG PPZ
Side Rail
NOTE:
Some components not shown for clarity.
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 02.9685.0010 A
Figure 9: Magenta/Blue Color Bulkhead
Page 53
MAINTENANCE :
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:
2
Step 1. CLOSE ALL GLASS IN BULKHEADS
- Power up unit and allow all
DICHRO*TUNE glass to calibrate. Once they close, power down unit.
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
Step 4. As indicated in
Magenta/Blue Assembly*
*See separate procedure for
removing and replacing this
assembly.
Figure 10, open front ring by releasing latch.
Figure 10).
Top Cover
Amber/Diffuser Assembly
(Incandescent Models)
or
Amber/Dimmer Assembly
(Arc Models)
NOTE:
Some components not shown for clarity.
Step 5. At top cover, remove two (or four, depending on production date) 6-32x1/4" PPB
SEMS screws.
Step 6. Remove top cover.
02.9685.0 010 A 21-May-2009 35
Front Ring
Figure 10: Amber/Diffuser (or Dimmer) Bulkhead
Page 54
VARI❋LITE® - 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 02.9685.0010 A
Page 55
MAINTENANCE :
Color Filter and Diffuser Panel Replacement
Parts:
22.9685.0122 16 EA ASSY, FILTER, MAGENTA, DICHRO*TUNE (STD)
22.9685.0123 16 EA ASSY, FILTER, BLUE, DICHRO*TUNE (STD)
22.9685.0120 16 EA ASSY, 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 Screw driver
• Cotton Gloves or Finger Cots
• Clean, lint-free (soft) cloth
To remove and replace color filters or diffuser panels:
2
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,
Rear Bulkhead Replacement” on page 33
b. For Amber/Diffuser bulkhead removal, refer to,
DICHRO*TUNE Front Bulkhead Replacement” on page 35
Diffuser bulkhead.
. Remove Magenta/Blue bulkhead.
“Magenta/Blue DICHRO*TUNE
“Amber/Diffuser (or Dimmer)
. Remove Amber/
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 panels are secured
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.
02.9685.0 010 A 21-May-2009 37
Page 56
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Color Filter and Diffuser Panel Remo val (continued)
Step 6. Disconnect actuator screw from Swivel Coupler using tweaker screwdriver by
carefully prying apart from Drive Ring Link.
Color Filter/
Diffuser Panel
Silicone Pad
Insert Filter
Carrier Pin
Center Hub
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
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.
Pad Lip
Carrier Arch
Figure 12):
Filter 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 silicone pad.
Step 12. Reassemble luminaire.
38 21-May-2009 02.9685.0010 A
Page 57
MAINTENANCE :
Arc Dimmer Panel Replacement
Parts:
10.9685.0210 16 EA DIMMER BLADE (PANEL), VL500
Tools:
• #1 Phillips screwdriver
• Tweaker Screw driver
• Cotton Gloves or Finger Cots
• 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.
2
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,
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
“Amber/Diffuser (or
.
Carrier
Spring
Drive Arm Link
Step 10. Remove dimmer panel from center hub
02.9685.0 010 A 21-May-2009 39
Figure 13: Dimmer Panel
Page 58
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Dimmer Panel Replacement (Continued).
Center Hub
Dimmer Panel
Insert Panel Bearing Here
Carrier
Bulkhead
Step 11. Replace by performing steps 3 through 10 in reverse order.
40 21-May-2009 02.9685.0010 A
Figure 14: Dimmer Panel Replacement
Page 59
MAINTENANCE :
2
Linear Actuator Motor Replacement (Magenta/
Blue Bulkhead)
Parts:
44.9685.0230 2 EA 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
Linear Actuator Motor Assembly
Heatsink Assembly
NOTE:
Some components not shown for clarity.
Top Cover
Amber/Diffuser Assembly*
(Incandescent Models)
or
Amber/Dimmer Assembly*
(Arc Models)
*See separate procedure for
linear motor replacement for
these assemblies.
Front Ring
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.
02.9685.0 010 A 21-May-2009 41
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Step 5. At linear actuator motor to be replaced on Magenta/Blue assembly, disconnect
wiring at both motors.
Step 6. 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.
Step 7. 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.
4-40x1/4 PPZ Screw (2 for each motor)
Note: Versilube Silicon Grease (G321) is
used to lubricate the actuator screw.
Actuator Screw
Motor Mount
Linear Actuator Motor
Drive Ring Link
Figure 16: Magenta/Blue Linear Actuator Motor Replacement
Step 8. Place linear actuator motor in place on actuator mount.
Step 9. 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.
Step 10. Secure actuator/drive ring link to drive ring swivel link.
Step 11. Attach wiring.
Step 12. Re-install top head cover.
Step 13. 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 02.9685.0010 A
Page 61
MAINTENANCE :
2
Linear Actuator Motor Replacement (Amber/Diffuser [or Dimmer] Bulkhead)
Parts:
44.9685.0230 2 EA 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*
*See separate procedure for
linear motor replacement for
these assemblies.
Heatsink Assembly
NOTE:
Some components not shown for clarity.
Top Cover
Linear Actuator
Motor Assembly
Amber/Diffuser Assembly
(Incandescent Models)
or
Amber/Dimmer Assembly
(Arc Models)
Front Ring
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.
02.9685.0 010 A 21-May-2009 43
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Step 5. At linear actuator motor to be replaced on Amber/Diffuser (or Dimmer) assembly,
disconnect wiring at both motors.
Step 6. 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.
Step 7. 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.
4-40x1/4 PPZ Screw (2 for each motor)
Note: Versilube Silicon Grease (G321) is
used to lubricate the actuator screw.
Actuator Screw
Motor Mount
Linear Actuator Motor
Drive Ring Link
Figure 18: Amber/Diffuser (or Dimmer) Linear Actuator Motor Replacement
Step 8. Place linear actuator motor in place on actuator mount.
Step 9. 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.
Step 10. Secure actuator/drive ring link to drive ring swivel link.
Step 11. Attach wiring.
Step 12. Re-install top head cover.
Step 13. 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.
44 21-May-2009 02.9685.0010 A
Page 63
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 socket assembly:
Step 1. CLOSE ALL GLASS IN BULKHEADS
DICHRO*TUNE glass to calibrate. Once they close, power down unit.
- Power up unit and allow all
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
Step 4. Open heatsink by releasing latch.
Magenta/Blue Bulkhead Assembly
Heatsink Assembly
Heatsink Latch
Figure 19).
Top Cover
NOTE:
Some components not shown for clarity.
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
DICHRO*TUNE Rear Bulkhead Replacement” on page 33
bulkhead.
Step 8. Using soft cloth to protect lamp, remove lamp from socket.
02.9685.0 010 A 21-May-2009 45
Lamp
“Magenta/Blue
. Remove Magenta/Blue
Page 64
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Step 9. As indicated in Figure 20, at light baffle, remove three 6-32x1/8" PPB screws.
Light Leak Foam
Backcap
Reflector
Light Baffle
8-32x1/2" PPZ SEM Screws (x4)
Reflector Clips (x3)
1/4" Hex Standoff (x3)
6-32x1/8" PPB Screws (x3)
Lamp Socket
6-32x1/4" PPZ
Screws (x2)
Figure 20: Heatsink Assembly - Lamp Socket Removal (VL500 and VL500D Only)
Step 10. Remove light baffle.
Step 11. Loosen, but do not remove, three 1/4" hex standoffs and turn reflector clips out of
way and remove reflector.
Step 12. Remove yoke arm cover opposite display side by removing four 6-32x3/8" LG PTB
screws.
Step 13. If applicable, remove dimmer. See,
page 63
for IGBT dimmer removal.
Step 14. At inside of side rail, remove two 4-40x1/8" LG PPB screws and remove Lamp
Wire Cover.
Step 15. At support rib closest to tilt tube, remove one 6-32x1/4" LG PPG screw and remove
ground strap.
Step 16. Remove tilt tube plug and pass lamp wires through tilt tube.
Step 17. Inside heatsink, remove four 8-32x1/2" LG PPZ SEM screws and remove back cap
Step 18. Remove heatsink light leak foam and pass lamp wire through heatsink.
Step 19. At socket, remove two 6-32x1/4" LG PPZ SEM screws and remove socket.
Step 20. Replace by performing Steps 3 through 19 in reverse order.
46 21-May-2009 02.9685.0010 A
“IGBT Dimmer Replacement - VL500D Only” on
Page 65
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
DICHRO*TUNE glass to calibrate. Once they close, power down unit.
- Power up unit and allow all
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
Step 4. Open heatsink by releasing latch.
Magenta/Blue Bulkhead Assembly
Heatsink Assembly
Heatsink Latch
Figure 21).
Top Cover
NOTE:
Some components not shown for clarity.
Figure 21: Accessing the Lamp Socket in VL500A and VL500 80V Fixtures
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. Remove Magenta/Blue Bulkhead Assembly as described in
DICHRO*TUNE Rear Bulkhead Replacement” on page 33
bulkhead.
02.9685.0 010 A 21-May-2009 47
Lamp
“Magenta/Blue
. Remove Magenta/Blue
Page 66
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Step 8. Using soft cloth to protect lamp, remove lamp from socket.
Step 9. As indicated in
Reflector
Light Baffle
1/4" Hex
Standoff (x3)
6-32x1/8" PPB Screws (x3)
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
8-32x3/8" PPZ
Screws (x2)
8-32x1/2" PPZ SEM Screws (x4)
Reflector Clips (x3)
Figure 22: Heatsink Assembly - Lamp Socket Removal (VL500A and VL500 80V Only)
Step 10. Remove light baffle.
Step 11. Loosen, but do not remove, 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 02.9685.0010 A
Page 67
MAINTENANCE :
Display PCB Replacement
Parts:
24.9685.0826 1 EA 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.
2
Step 3. At display overlay, as indicated in
6-32x1/4" PPB (x4)
Menu
Display
Display Lens
Yoke Arm
Cover
NOTE:
Some components not shown for clarity.
Display Overlay
Figure 23, remove four 6-32x1/4" PPB screws.
Display PCB
Figure 23: Display PCB Replacement
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)
1/4" Hex (9/32" Long)
Standoff (x4)
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.
02.9685.0 010 A 21-May-2009 49
Page 68
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Main Control PCB/Fan Assembly Replacement
Parts:
21.9685.0731 1 EA ASSY, VL500 MAIN CONTROL PCB/FAN
Tools:
• 1/4" Hex Nutdriver
• #2 Phillips Screwdriver
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,
Step 4. At Main Control PCB/Fan Assembly, disconnect the following wiring connections:
a. Pan/Tilt wiring harness
b. Head motor wiring harness
c. 3-position connector (Dimmer communications - VL500D and VL500 80V
models only)
d. 10-position AMP connector (Display Communications)
e. 4-position connector (DMX communications)*
“Display PCB Replacement” on page 49.
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 02.9685.0010 A
Page 69
MAINTENANCE :
2
Main Control PCB/Fan Assembly Replacement
(continued)
Menu
Display
Yoke Arm
Cover
1/4" Hex (13/16" Long)
Standoff (x4)
Main Control PCB
6-32x1/4" PPB (x4)
1/4" Hex (9/32" Long)
Standoff (x4)
Display PCB
Main Control PCB
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.
02.9685.0 010 A 21-May-2009 51
NOTE:
Some components not shown for clarity.
Figure 24: Main Control PCB/Fan Replacement
Page 70
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Low Voltage Supply (LVS) R eplacement (VL500/
VL500D/VL500A Only)
Parts:
69.3178.0121 1 EA 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 heatsink. 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.
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 followin g wiring connections:
a. 3-position connector (AC Input)
b. 6-position MTA connector (DC Output)
Step 4. As shown in
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.
52 21-May-2009 02.9685.0010 A
Figure 25, remove four 6-32x3/8" PPZ, SEMS screws.
Page 71
MAINTENANCE :
2
Low Voltage Supply (LVS) Temperature PCB
Replacement (VL500/VL500D/VL500A Only)
Parts:
24.9685.0740 1 EA 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,
(VL500/VL500D/VL500A Only)” on page 52
Yoke Arm
Figure 26: LV S 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)
“Low Voltage Supply (LVS) Replacement
.
LVS Temperature PCB
1/4" Hex Standoff
NOTE:
Some components not shown for clarity.
Step 4. As shown in
Step 5. Remove LVS Temperature PCB.
Step 6. Replace by performing steps 2 through 5 in reverse order.
02.9685.0 010 A 21-May-2009 53
Figure 26, remove one 1/4" hex standoff.
Page 72
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Low V oltage Supply (L VS) R eplacement (VL500
80V Only)
Parts:
69.3178.0121 1 EA 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 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
8-32x1/2" PFB Screws (x6)
Cover Tether
Pan Tube
Pan Tube Cover
4-40x1/4" PPZ Screws (x4)
Wire Shield (fish paper)
NOTE:
Some components not
shown for clarity.
LVS Power Supply
54 21-May-2009 02.9685.0010 A
Figure 27: LVS Replacement (VL500 80V Only)
Page 73
MAINTENANCE :
2
Step 5. Remove LVS Temperatu r e Sensor PCB by following “Low Voltage Supply (LVS)
Temperature PCB Replacement (VL500 80V Only)” on page 56
Step 6. Disconnect the followin g wiring connections:
a. 3-position connector (AC Input)
b. 6-position MTA connector (DC Output)
.
Step 7. As shown in
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.
Figure 27, remove four 4-40x1/4" PPZ screws.
02.9685.0 010 A 21-May-2009 55
Page 74
VARI❋LITE® - 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.
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: LV S Temperature PCB Replacement (VL500/VL500D/VL500A Only)
56 21-May-2009 02.9685.0010 A
Page 75
Step 4. Disconnect the following wiring connections on PCB:
a. 2-position connector (LVS Fan)
b. 4-position connector (LVS Fan from MCB)
MAINTENANCE :
2
Step 5. As shown in
PCB to LVS fan mount.
Step 6. Remove LVS Temperature PCB.
Step 7. Replace by performing steps 2 through 6 in reverse order.
Figure 28, remove one 6-32x3/8" PPZ securing LVS Temperature
02.9685.0 010 A 21-May-2009 57
Page 76
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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
Replacement” on page 49
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.
and “Main Control PCB/Fan Assembly Replacement” on page
“Display PCB
58 21-May-2009 02.9685.0010 A
Page 77
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
Assembly
NOTE:
Some components not shown for clarity.
8-32x7/16" PPZ
Tilt Motor Assembly
Yok e Arm Cover
8-32x7/16" PPZ (x4)
8-32x7/16" PPZ
Tilt Motor Slide Plate
Spring
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.
02.9685.0 010 A 21-May-2009 59
Page 78
VARI❋LITE® - 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
Louver Plate and remove plate.
Step 4. Disconnect wiring from motor and encoder PCB.
Step 5. As shown 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
8-32x1/2" PPB (x4)
Pan Belt
Pan Motor Assembly
Yoke Arm
NOTE:
Some components not shown for clarity.
Figure 30: Pan Motor Assembly Replacement
Pan Motor
Assembly
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 in a CLOCKWISE
pattern starting with screw in lower left-hand side from spring.
60 21-May-2009 02.9685.0010 A
Page 79
MAINTENANCE :
Pan/Tilt Encoder PCB Replacement
Parts:
24.9685.7735 1 EA BOARD ASSY, PAN/TILT ENCODER
Tools:
• #2 Phillips Screwdriver
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.
2
b. For Pan Motor Encoder PCB removal, access pan motor assembly see,
Motor Assembly Replacement” on page 60
Step 3. At encoder PCB, disconnect wiring harness from assembly.
Step 4. As shown in
Figure 31, remove two 6-32x3/8" PPZ screws and remove assembly.
Pan/Tilt Motor Encoder PCB
Encoder Disk
.
“Pan
6-32x3/8" PPZ
Step 5. Replace by performing Steps 2 through 4 in reverse order.
Note: Ensure that encoder disk passes freely through the optical sensor on PCB.
02.9685.0 010 A 21-May-2009 61
Figure 31: Pan/Tilt Motor Encoder PCB Replacement
Page 80
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Arc Ignitor PCB Replacement (VL500A Only)
Parts:
24.9685.1000 1 EA IGNITOR, ARC (VL500A ONLY)
Tools:
• #2 Phillips Screwdriver
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. At Ignitor 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)
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 in reverse.
62 21-May-2009 02.9685.0010 A
Page 81
MAINTENANCE :
2
IGBT Dimmer Replacement - VL500D Only
Parts:
69.3173.0115 1 EA DIMMER, IGBT, 1200W 120V REV PHASE CONT
(VL500D 115V MODELS ONLY)
69.3173.0240 1 EA DIMMER, IGBT, 1200W 240V REV PHASE CONT
(VL500D 240V MODELS ONLY)
Tools:
• #2 Phillips Screwdriver
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
screws.
Step 4. Carefully remove IGBT dimmer. Note that there will be wires connected to dimmer
on the back side.
Figure 33, at dimmer, loosen, but do not remove, four 6-32x3/8" PPZ
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.
02.9685.0 010 A 21-May-2009 63
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VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
IGBT Dimmer Replacement - VL500D Only (continued)
NOTE:
Some components not shown for clarity.
6-32x3/8" PPZ Screws (x4)
Figure 33: IGBT Dimmer Replacement (VL500D Only)
6-32x3/8" PTB Screws (x4)
Yoke Arm Cover (Dimmer Side)
IGBT Dimmer
Step 7. Replace IGBT Dimmer by performing Steps 2 through 6 in reverse.
64 21-May-2009 02.9685.0010 A
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MAINTENANCE :
2
80V Dimmer Replacement - VL500 80V Only
Parts:
21.9685.2750 1 EA ASSY, 80V DIMMER
Tools:
• #2 Phillips Screwdriver
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
screws.
Step 4. Carefully remove 80V dimmer. Note that there will be wires connected to dimmer
on the back side.
Figure 34, at dimmer, loosen, but do not remove, four 6-32x3/8" PPZ
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 replacement
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.
02.9685.0 010 A 21-May-2009 65
Page 84
VARI❋LITE® - 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 02.9685.0010 A
Page 85
MAINTENANCE :
Arc Ballast Replacement (VL500A Only)
Parts:
21.9685.0802 1 EA ASSY, BALLAST, 700W
Tools:
•None
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.
2
Step 3. Connect Ballast Interconnect Cable Assembly to replace ment ballast and luminaire.
02.9685.0 010 A 21-May-2009 67
Figure 35: Arc Ballast Assembly
Page 86
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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 maintenance.
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. Bund led 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:
Some components not shown for clarity.
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.
68 21-May-2009 02.9685.0010 A
Page 87
MAINTENANCE :
2
AC Input (PowerCon) Connector Replacement
Parts:
25.9685.0756 1 EA CONNECTOR, AC INPUT (POWERCON)
Tools:
• #2 Phillips Screwdriver
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.
Step 4. Remove pan tube cover. (Note, tether will still hold cover).
8-32x1/2" PFB
Screws (x6)
Pan Tube Assembly
4-40x1/2" PFB
Screws (x2)
AC Input (PowerCon) Connector
Do not remove this screw
Pan Tube Cover
Cover Tether
NOTE:
Some components not
shown for clarity. This
procedure is applicable
for all models.
VL500 80V
Pan Tube Assembly
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.
02.9685.0 010 A 21-May-2009 69
Figure 36: AC Input (PowerCon) Connector Replacement
Page 88
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Mini-XLR (Display/Remote Programming) Connector Replacement
Parts:
25.9685.0770 1 EA CONNECTOR, MINI-XLR (DISPLAY / REMOTE
PROGRAMMING)
Tools:
• #2 Phillips Screwdriver
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)
Pan Tube Assembly
Mini-XLR
Connector
4-40x1/4" PFB
Screws (x2)
Do not remove this screw
Pan Tube Cover
Cover Tether
NOTE:
Some components not
shown for clarity. This
procedure is applicable
for all models.
VL500 80V
Pan Tube Assembly
Figure 37: Mini-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 02.9685.0010 A
Page 89
MAINTENANCE :
DMX PCB Assembly Replacement
Parts:
24.9663.3895 1 EA ASSY, DMX INPUT PCB
Tools:
• #2 Phillips Screwdriver
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.
2
Step 3. As shown in
Figure 38, 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)
Pan Tube Assembly
DMX PCB
Assembly
#4x3/8" HLN PN
BLK ZN Screws (x4)
Do not remove this screw
Pan Tube Cover
Cover Tether
NOTE:
Some components not
shown for clarity. This
procedure is applicable
for all models.
VL500 80V
Pan Tube Assembly
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.
02.9685.0 010 A 21-May-2009 71
Figure 38: DMX PCB Assembly Replacement
Page 90
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
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.
• FRONT LENS: Use Isopropyl Alcohol along with a soft, lint-free cloth to clean the front
lens.
• 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.
72 21-May-2009 02.9685.0010 A
Page 91
CHAPTER 3.
Illustrated Parts Breakdown
This chapter contains illustrated parts breakdowns for all VL500™
wash luminaire assemblies including the arc ballast unit.
• Drawing Trees
• Top Assembly
• Head Assembly
• Yoke Assembly
• Cables
• Arc Ballast Assembly
Note: The following abbreviations are used to identify parts specific to
certain models.
VL500 Model Parts Identifiers
ABBREVIATION MODEL (INCLUDES STANDARD AND PASTEL COLOR SYSTEMS)
VL500 VL500™ Incandescent Luminaire (120V or 240V)
VL500D VL500™D Incandescent Luminaire 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
02.9685.0 010 A 21-May-2009 73
Page 92
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
Drawing Trees
VL500 and VL500D Incandescent Luminaires
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 DI CRO*TUNE Colors) or 20.9685.0003 Rev F (Standard DICRO*TUNE Colors) or 20.9685.0013
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 A
VL500 Yoke Assembly
21.9685.0520 (VL500) Rev U or
21.9685.0521 (VL500D) Rev U
VL500 Pan/Tilt Motor
Rev B (Pastel DICRO*TUNE Colors)
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 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)
VL500 Magenta/Blue Color
Assembly
21.9685.0170 Rev H (Standard
DICRO*TUNE Colors)
or
VL500 Magenta/Blue
(Pastel) Color Assembly
21.9685.0174 Rev A (Pastel
DICRO*TUNE Colors)
Magenta/Blue Color Motor
Assembly
21.9685.0280 Rev A
Magenta/Blue (Pastel)
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)
Bottom Bulkhead Assembly
21.9685.0150 Rev C
Assembly
VL500 (120V or 240V) Luminaire Incandescent Versions
21.9685.0540 Rev C
Drive Ring Assembly
21.9685.0280 Rev A
VL500 MCB/FAN Assembly
21.9685.0731 Rev 0
MCB-Fan Assembly
23.9685.0782 Rev 0
Amber/Diffuser Color
Motor Assembly
21.9685.0281 Rev A
Magenta/Blue Color Motor
Assembly
21.9685.0280 Rev A
DMX Input PCB Assembly
24.9663.3895 Rev 0
continued next page
Figure 3-1: VL500 and VL500D Incandescent Luminaires Drawing Tree (Part 1)
74 21-May-2009 02.9685.0010 A
Amber/Diffuser Color
Assembly
21.9685.0161 Rev F
VL500 Amber/Diffuser
Color Assembly
21.9685.0171 Rev G
continued next page
Magenta/Blue Color
Assembly
21.9685.0160 Rev E (Standard
DICRO*TUNE Colors)
Bottom Bulkhead Assembly
21.9685.0150 Rev C
Drive Ring Assembly
21.9685.0280 Rev A
Page 93
ILLUSTRATED PARTS BREAKDOWN :
3
VL500 and VL500D Incandescent Luminaires
(continued)
continued from previous page
VL500 Yoke Assembly
21.9685.0520 (VL500) Rev U or
21.9685.0521 (VL500D) Rev U
Arc Yoke Lamp Cable Assembly
(VL500A)
25.9685.0790 Rev J (VL500 and
VL500D)
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
continued from previous page
VL500 Amber/Diffuser Color
Assembly
21.9685.0171 Rev G
Top Bulkhead Assembly
21.9685.0151 Rev C
Drive Ring Assembly
21.9685.0280 Rev A
Pan Tube Assembly (VL500/
VL500D/VL500A)
21.9685.0535 Rev D (VL500/VL500D/
VL500 AC Input Cable Assembly
VL500 Display (Remote) Cable
VL500 Yoke Lamp Jumper Cable
Incandescent Power Input Cable
25.9663.2030 Rev A (VL500 Only)
VL500A)
25.9685.0756 Rev B
Assembly
25.9685.0770 Rev B
Assembly
25.9685.0776 Rev A
Assembly
Figure 3-2: VL500 and VL500D Incandescent Luminaires Drawing Tree (Part 2)
02.9685.0 010 A 21-May-2009 75
Page 94
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
VL500 80V Incandescent Luminaires
VL500 80V (with 80V Dimmer) Luminair e
20.9685.0004 Rev L (Standard DICRO*TUNE Colors) or 20.9685.0014 Rev G (Pastel DICRO*TUNE Colors)
Generic VL500 Luminaire Assembly
21.9685.0012 Rev S (Incandescent - with
Internal 80V Dimmer)
VL500 Generic Head Assembly
21.9685.0312 (VL500 80V) Rev K
Heatsink Assembly
21.9685.0322 (VL500 80V) Rev H
VL500 Backcap Ground Cable
Assembly
25.9685.0777 Rev A
VL500 80V Lamp Wire
Harness
25.9685.0793 Rev B
VL500 80V Yoke Assembly
21.9685.0523 (VL500 80V) Rev Q
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
VL500 Motor Cable
Assembly
25.9685.0753 Rev B
VL500 Head Grounding
Cable Assembly
25.9685.0760 Rev C
Included Items Kit
28.9685.0004 Rev G
(Standard Colors, 80V On-
Board Dimmer) or
28.9685.0006 Rev G (700W
Arc, Standard Colors, Arc
Ballast)
VL500 Amber/Diffuser Color
Assembly
21.9685.0171 Rev G
Amber/Diffuser Color Motor
Assembly
21.9685.0281 Rev A
Amber/Diffuser Color
Assembly
21.9685.0161 Rev F
Top Bulkhead Assembly
21.9685.0151 Rev C
Drive Ring Assembly
21.9685.0280 Rev A
VL500 Magenta/Blue Color
Assembly
21.9685.0170 Rev H (Standard
DICRO*TUNE Colors)
or
VL500 Magenta/Blue
(Pastel) Color Assembly
21.9685.0174 Rev A (Pastel
DICRO*TUNE Colors)
Magenta/Blue Color Motor
Assembly
21.9685.0280 Rev A
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)
continued next page
Figure 3-3: VL500 80V Incandescent Luminaires Drawing Tree (Part 1)
76 21-May-2009 02.9685.0010 A
Bottom Bulkhead Assembly
21.9685.0150 Rev C
Drive Ring Assembly
21.9685.0280 Rev A
Page 95
ILLUSTRATED PARTS BREAKDOWN :
VL500 80V Incandescent Luminaires (continued)
continued from previous page
VL500 80V Yoke Assembly
21.9685.0523 (VL500 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
3
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
24V Power Cable Assembly (VL500
80V)
25.9685.0746 Rev 0
Figure 3-4: VL500 80V Incandescent Luminaires Drawing Tree (Part 2)
02.9685.0 010 A 21-May-2009 77
Page 96
VARI❋LITE® - 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)
Generic VL500 Luminaire Assembly
21.9685.0013 Rev S (Arc)
VL500 Generic Head Assembly
21.9685.0311 (VL500A) Rev K
Heatsink Assembly
21.9685.0321 (VL500A) Rev H
VL500 Backcap Ground Cable
Assembly
25.9685.0777 Rev A
VL500 Ignitor to Socket Cable
Assembly
25.9685.0766 Rev C
VL500 Yoke Assembly
21.9685.0522 (VL500A) 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
28.9685.0006 Rev G (700W
Arc, Standard Colors, Arc
Ballast) or Figure 3-7.
VL500 Amber/Dimmer
Color Assembly
21.9685.0172 Rev F
Amber/Diffuser Color Motor
Assembly
21.9685.0281 Rev A
Amber/Diffuser Color
Assembly
21.9685.0162 Rev E
Top Bulkhead Assembly
21.9685.0151 Rev C
Drive Ring Assembly
21.9685.0280 Rev A
VL500 Magenta/Blue (Arc)
Color Assembly
21.9685.0173 Rev A (Standard
DICRO*TUNE Colors)
or
VL500 Magenta/Blue (Arc
Pastel) Color Assembly
21.9685.0174 Rev A (Pastel
DICRO*TUNE Colors)
Magenta/Blue Color Motor
Assembly
21.9685.0280 Rev A
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)
Bottom Bulkhead Assembly
21.9685.0150 Rev C
Figure 3-5: VL500A Arc Luminaires Drawing Tree (Part 1)
78 21-May-2009 02.9685.0010 A
continued next page
Drive Ring Assembly
21.9685.0280 Rev A
Page 97
ILLUSTRATED PARTS BREAKDOWN :
VL500A Arc Luminaires (continued)
3
continued from previous page
VL500 Yoke Assembly
21.9685.0522 (VL500A) Rev U
MCB-Fan Assembly
21.9685.0731 Rev 0
VL500 Extra Hardware Kit
28.9685.0999 Rev 0
VL500 AC Input Cable Assembly
25.9685.0756 Rev B
VL500 Arc Ballast Input Cable
Assembly
25.9685.0757 Rev C
VL500 Display (Remote) Cable
Assembly
25.9685.0770 Rev B
VL500 Arc Main Harness Cable
Assembly
25.9685.0791 Rev C (VL500A)
continued from previous page
VL500A (700W Arc) Luminaire
28.9685.0006 Rev G (700W Arc, Standard Colors, Arc Ballast) or Figure
3-7.
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
Ballast I/O Cable Assembly
25.9685.0807 Rev A
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)
02.9685.0 010 A 21-May-2009 79
Page 98
VARI❋LITE® - 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 SERVICE
2 02.8001.0002 1 EA QA CERTIFICATE, VARI-LITE
3 02.8052.0001 1 EA CARD, LIMITED W A RRANTY
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, (VL500 80V ONLY)
71.9685.0702 1 EA 700W MSR ARC LAMP, (VL500A ONLY )
80 21-May-2009 02.9685.0010 A
Page 99
ILLUSTRATED PARTS BREAKDOWN :
3
Included Items Kit (continued)
1
4
2
7
3
5
8
(Arc Models Only)
9
10 (Arc Models Only)
6
11
Figure 3-7: Included Items Kit
02.9685.0 010 A 21-May-2009 81
Page 100
VARI❋LITE® - 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 VL500 (CLR)
4 04.9685.0912 1 EA LABEL, COMPLIANCE VL500
04.9685.0912.00 1 EA LABEL, COMPLIANCE VL500 (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 80V MODELS
ONLY)
04.9685.0918.00 1 EA LABEL, LAMP TYPE 80V INCANDESCENT (CLR) (VL500 80V
MODELS ONLY)
82 21-May-2009 02.9685.0010 A
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