Philips VL500 Wash Luminaires, Vari-Lite VL500, Vari-Lite VL500D Wash, Vari-Lite VL500 80V Wash, Vari-Lite VL500A Wash Service Manual
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
HOW TO OBTAIN WARRANTY SERVICE
How To Obtain Warranty Service
A copy of the Vari-Lite Limited Warranty was included in the shipping package for
this VARI❋LITE® product.
To obtain warranty service, please contact customer service at 1-877-VARI-LITE
(1-877-827-4548) or customerservice@genlytecontrols.com and request a Return
Material Authorization (RMA) for warranty service. You will need to provide the
model and serial number of the item being returned, a description of the problem or
failure and the name of the registered user or organization. If available, you should
have your sales invoice to establish the date of sale 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
02.9685.0 010 A 21-May-2009 iii
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)
iv 21-May-2009 02.9685.0010 A
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.
02.9685.0 010 A 21-May-2009 v
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.
vi 21-May-2009 02.9685.0010 A
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.
02.9685.0 010 A 21-May-2009 vii
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.
viii 21-May-2009 02.9685.0010 A
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.
02.9685.0 010 A 21-May-2009 ix
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.
x 21-May-2009 02.9685.0010 A
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.
02.9685.0 010 A 21-May-2009 xi
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.
xii 21-May-2009 02.9685.0010 A
SAFETY NOTICE (JAPANESE)
02.9685.0 010 A 21-May-2009 xiii
VARI❋LITE® - VL500™ LUMINAIRE SERVICE MANUAL
xiv 21-May-2009 02.9685.0010 A
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
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
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
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
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
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: customerservice@genlytecontrols.com
Additional Resources
For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.
2 21-May-2009 02.9685.0010 A
CHAPTER 1.
Description
This chapter provides an overview of luminaire features, components
and operations.
• Features
• Component Descriptions
• Principles of Operation
02.9685.0 010 A 21-May-2009 3
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
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
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
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.
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
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
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
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
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
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