VariLite VL2500 Service manual

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

VA R I ❋LITE®, Artisan®, mini-Artisan®, mini-Artisan®2, Artisan®Plus, mini-Artisan®Plus, VL2®, and VLD® are
trademarks owned by Genlyte Thomas Group LLC. and are registered in the United States and other countries.

VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL2500™, VL3000™,
VL3500™, Virtuoso™, Virtuoso™ DX, VARI❋LITE Visionary

™

VL5Arc
AutoTruss
DICHRO❋WHEEL

, VL5B™, VL6™, VL6B™, VL6C™, VL7™, VL7B™, VLM™, APS6™, C3™, ArtisanVLQ™, SPC-36™, UDM™,

™

, SmartDMX™, Smart Repeater™, Series 100™, Series 200™, Series 300™, Series 2000™, Series 3000™,

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Asterisk are also trademarks owned by Genlyte Thomas Group LLC.
VA R I ❋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; 413,995; 377,338; 366,712; 359,574; 350,408; 347,113;
Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646,588; 586,095; 576,400; 546,433;
Australia Design Patents No. 128,796; 128,795;
Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058; 1,181,795;
Canada Design Patents No. 81,234; 81,233; 76,046;
European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710; 0 495 305; 0 474 202; 0 379 970; 0 253 082;

0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068;
Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89

166.9; 37 68 727.1; 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 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 951.2; M 499 03 583.6; M

498 11 203.9; G 93 12 884.3;
Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328;
Spain Utility Model Patent No. 2.031.748;
Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573;
Greece Patent No. 910.400.544;
Hong Kong Patents No. 965/1990; 285/1987;
Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241; 1,723,825;

1,683,007; 1,533,011;
Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1,072,598; 1,060,414;

1,002,123;
Korea Patents No. 76,310; 42,639; 283,770; 181,180;
Korea Design Patents No. 209,896; 209,895;
Mexico Patent No. 180,148;
Singapore Patents No. 663/90; 134/87;
Taiwan Patents No. 78,726; 66,975; 65,380; 28,275;
United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.
Apple®, Macintosh®, and FireWire® are registered trademarks of Apple Computer, Inc.

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All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their

respective companies or organizations.
VL2500™ Wash Luminaire Service Manual
The information furnished in this manual is for informational use only and is subject to change without notice. Vari-Lite, A

Genlyte Group Company, assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual. All
information and graphic representations are property of Vari-Lite, A Genlyte Group Company. 10911 Petal Street, Dallas, Texas
75238 USA.

Version as of: 09-December-2004
Part number: 02.9676.0022 0

VL2500™ Wash Luminaire Service Manual

©2001-2004 Genlyte Group LLC. All Rights Reserved.

™

, VL1™, VL2B™, VL2C™, VL3™, VL4™, VL5™,

ii 09-December-2004 02.9676.0022 0

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 [e-mail] and request a Return Material
Authorization (RMA) for warranty service. You need to provide the model and serial
number of the item being returned, a description of the problem or failure and the
name of the registered user or organization. If available, you should have your sales
invoice to establish the date of sale as the beginning of the warranty period.

Once you obtain the RMA, pack the product in its original packing material along with
a copy of your invoice (if available) and write the RMA number legibly on or near the
shipping address label. Return the unit, freight prepaid to:

Vari-Lite
10911 Petal Street
Dallas, Texas 75238
Attention: Warranty Service

FOREWORD

As stated in the warranty, it is required that the shipment be insured and FOB our
service center.

Confidential Property Disclosure

This technical manual is confidential property of Vari-Lite, A Genlyte Group
Company. All information contained herein is the sole and exclusive property of
Genlyte Group LLC. and may not be used, disclosed, or reproduced in any manner
without the prior written consent of Genlyte Group LLC. The information furnished
in this manual is for informational use only and is subject to change without notice.
Genlyte Group LLC and Vari-Lite assumes no responsibility or liability for any errors
or inaccuracies that may appear in this manual.

02.9676.0022 0 09-December-2004 iii

VARI❋LITE® - VL2500™ WASH 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 (by Council Directive 73/23/EEC)

EN60598-1: 2000
EN60598-2-17: 1989/A2:1991

EMC (by Council Directive 89/336/EEC)

EN61000-6-4: 2001

We certify that VARI❋LITE products conform to the requirements of European
council directives as stated above.

Manual Revision History

PAGE NUMBER CHANGE NUMBER

Title Page - xviii 0 (initial release)

1 - 148 0 (initial release)

VERSION DATE

First Edition 09-December-2004

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

iv 09-December-2004 02.9676.0022 0

FOREWORD

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, MSR575HR 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
VA R I ❋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® - VL2500™ WASH 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 denatured alcohol and wipe with
lint-free cloth before installing or powering up the luminaire.

7. The lamp shall be changed if it has become damaged or thermally deformed.

WARNING:
RF INTERFERENCE

1. This is a Class A product. In a domestic environment this product may cause radio
interference, in which case, the user may be required to take adequate measures.

ARC LAMP CHARACTERISTIC CONSIDERATIONS

1. Arc lamps require a period of time to relight after a power interruption or a severe voltage
dip. In some cases, lamp will automatically relight after it has cooled depending on Lamp
Power-Up State (Lamp ON/ Lamp OFF) system configuration setting.

2. Burning position is Universal.

vi 09-December-2004 02.9676.0022 0

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. bedienen. 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

Lebensbedrohung hin.

NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHER­HEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE
UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.

FOREWORD

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,
MSR575HR 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

VA R I ❋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.

02.9676.0022 0 09-December-2004 vii

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
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 Temperaturen. 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 denaturiertem
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 (Lamp ON/ Lamp OFF).

2. Die Brennposition ist Universal.

viii 09-December-2004 02.9676.0022 0

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 :

FOREWORD

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, MSR575HR 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.

02.9676.0022 0 09-December-2004 ix

VARI❋LITE® - VL2500™ WASH 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 dénaturé 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 (Lamp ON/ Lamp OFF).

2. La position Brûler est Universelle.

x 09-December-2004 02.9676.0022 0

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.

FOREWORD

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, MSR575HR
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.

02.9676.0022 0 09-December-2004 xi

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

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.

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 desnaturalizado 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 (Lamp ON / Lamp OFF) (L encendida
/ L apagada).

2. La posición de encendido es universal.

xii 09-December-2004 02.9676.0022 0

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xiv 09-December-2004 02.9676.0022 0

Table of Contents

About This Manual ...................................................................................................... 1

Additional Documentation........................................................................................... 1

Customer Service......................................................................................................... 2

Technical Bulletins / Technical Notices....................................................................... 2

Chapter 1. Description

Features

Overview...................................................................................................................... 4

Features ................................................................................................................. 4

Major Components

External Components................................................................................................... 5

Menu Display ........................................................................................................ 6

Menu Controls....................................................................................................... 6

Head Components........................................................................................................ 7

Yoke Components ........................................................................................................ 8

Enclosure Components ................................................................................................ 9

Principles of Operation

Power and Data Flow Diagram.................................................................................. 10

TABLE OF CONTENTS

Chapter 2. Maintenance

Te st in g

Testing Software ........................................................................................................ 12

Troubleshooting

Error Messages........................................................................................................... 13

Troubleshooting Guide .............................................................................................. 14

Maintenance Procedures

Head Assembly.......................................................................................................... 16

Lamp Replacement.............................................................................................. 16

Align Lamp for Flat Field ................................................................................... 18

Fixed Color Bulkhead Replacement.................................................................... 19

Standard Color Filter Replacement ..................................................................... 20

Strobe Bulkhead Replacement ............................................................................ 21

Front Assembly Removal.................................................................................... 22

Beam Spreader Motor Assembly Replacement................................................... 23

Concave Lens Assembly Replacement ............................................................... 24

Convex Lens Assembly Replacement................................................................. 25

100MM Condenser Lens Assembly Replacement.............................................. 27

Yoke Assembly .......................................................................................................... 29

Tilt Motor Assembly Replacement ..................................................................... 29

Main Control Board (MCB) PCB Replacement.................................................. 30

Ignitor PCB Replacement.................................................................................... 31

Enclosure Assembly................................................................................................... 33

Removing Enclosure Covers............................................................................... 33

02.9676.0022 0 09-December-2004 xv

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Ballast Module Assembly Replacement.............................................................. 35

Pan Motor Assembly Replacement...................................................................... 37

Pan Encoder Replacement ................................................................................... 38

Pan EOT Sensor Replacement............................................................................. 39

Power Supply (LVS) Replacement...................................................................... 40

Chapter 3. Illustrated Parts Breakdown

Drawing Tree

VL2500 Wash Luminaire ........................................................................................... 42

Top Ass em bly

VL2500 Wash Included Items Kit.............................................................................. 44

VL2500 Wash Luminaire ........................................................................................... 45

VL2500 Generic Luminaire ....................................................................................... 47

Front Wash Assembly................................................................................................. 49

Concave/Diffuser Front Lens Assembly .................................................................... 51

Convex Lens Assembly.............................................................................................. 52

Top Cover Assembly .................................................................................................. 53

Bottom Cover Assembly ............................................................................................ 54

Reflector Assembly .................................................................................................... 55

Back Cap Assembly ................................................................................................... 56

Wash Fan Assembly ................................................................................................... 58

Wash Fixed Color Assembly ...................................................................................... 60

Crossfade Color Assembly......................................................................................... 62

Sensor PCB Assembly................................................................................................ 64

Color Motor Assembly............................................................................................... 65

Filter Wheel Assembly............................................................................................... 66

Strobe Assembly......................................................................................................... 67

UV / IR Window Assembly........................................................................................ 69

VL2500 Main Control Board PCB Assembly............................................................ 70

Yo ke

Yoke Assembly........................................................................................................... 75

Ignitor PCB Assembly................................................................................................ 77

Tilt Motor Assembly .................................................................................................. 79

Pan/Tilt Encoder PCB Assembly ............................................................................... 81

Yoke Fan Assembly.................................................................................................... 82

Enclosure

Upper Enclosure Assembly........................................................................................ 83

Connector Panel Assembly......................................................................................... 88

DMX Input PCB Assembly........................................................................................ 89

AC Input Pigtail Cable Assembly .............................................................................. 90

Pan Tube Assembly.................................................................................................... 91

Pan Motor Assembly.................................................................................................. 92

Upper Enclosure Fan Assembly................................................................................. 93

Pan EOT Sensor Electrical Assembly ........................................................................ 94

Ballast Module (Arc Power Supply) Assembly ......................................................... 95

700W Ballast Board PCB Assembly.......................................................................... 99

700W Ballast Rider Board PCB Assembly.............................................................. 103

xvi 09-December-2004 02.9676.0022 0

TABLE OF CONTENTS

Cables

Ground Strap Cable Assembly................................................................................. 107

LVS Chassis Ground Cable Assembly..................................................................... 108

Chassis To Yoke Ground Cable Assembly .............................................................. 109

Ignitor To Relay Cable Assembly............................................................................ 110

Tilt Plate Ground Cable Assembly .......................................................................... 111

Color/Gobo T-Stat Cable Assembly......................................................................... 112

Color/Fixed Bulkheads Cable Assembly................................................................. 113

Optics/Strobe Bulkheads Cable Assembly .............................................................. 115

Strobe 1 Cable Assembly......................................................................................... 117

Fans/Disconnect Cable Assembly............................................................................ 118

OT Switch to Reflector Assy. Cable Assembly ....................................................... 119

Pan/Tilt Control Cable Assembly ............................................................................ 120

EMI Filter to Power Switch Cable Assembly.......................................................... 122

AC Input Splitter Cable Assembly .......................................................................... 123

Data I/O Link Cable Assembly................................................................................ 125

Display Cable Assembly.......................................................................................... 126

Ballast to Controller Cable Assembly...................................................................... 127

Lamp Supply to Relay Cable Assembly.................................................................. 128

DC Output Cable Assembly..................................................................................... 129

VL2500 Wash Luminaire Schematics

700W Ballast Schematic.......................................................................................... 131

Ballast Rider Schematic........................................................................................... 133

VL2500 Luminaire Schematic................................................................................. 134

Main Control Board (MCB) Schematic................................................................... 137

DMX Input Schematic............................................................................................. 147

Solid State Ignitor Schematic................................................................................... 148

02.9676.0022 0 09-December-2004 xvii

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Notes

xviii 09-December-2004 02.9676.0022 0

Introduction

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL2500™ Wash Luminaire. The manual is intended for
use by Vari-Lite personnel and by Vari-Lite’s customers/clients.

WARNING: It is important to read ALL accompanying safety and installation
instructions to avoid damage to the product and potential injury to yourself or others.

This manual covers the following models:

VL2500 Wash Luminaire 20.9676.0002 700W Arc

INTRODUCTION

Model Part Number Source

Note: Performing maintenance procedures contained in this manual may void the

product warranty. Refer to the Vari-Lite, Inc. Limited Warranty card included in the
shipping package for this VARI❋LITE® product.

Additional Documentation

A support web page for VL2500 series luminaires is available at www.vari-lite.com
(follow the Support link).

A separate users manual is available for installation and operation of the VL2500 wash
luminaire. This manual is available in both printed and electronic (PDF) formats.

■ VL2500™ Wash Luminaire Users Manual (02.9676.0021).

02.9676.0022 0 09-December-2004 1

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Customer Service

Our Goal

At Vari-Lite, we are committed to providing you the highest quality in customer
service. Our comprehensive resources are available to help your business succeed and
ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are
telephone/troubleshooting assistance, product training or technical service, our 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 [phone]

fax: [phone]

email: [e-mail]

Additional Resources

For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.

Technical Bulletins / Technical Notices

Technical Bulletins concerning the latest changes to VARI❋LITE equipment are
issued from Vari-Lite. They are documentation supplements that contain procedures
for equipment upgrades, retrofits, and repairs not found in the existing manuals.
Technical bulletins are integrated into the appropriate equipment manuals as those
manuals are revised.

Technical Notices are non-procedural documents that contain information regarding
product support issues, software updates, and documentation corrections. All technical
notices begin with the prefix TN and are numbered sequentially.

Technical Bulletins, Software Updates, support, and other information is available
online at http://www.vari-lite.com/ under the Support Section.

To request access to the password-protected support areas, please contact Vari-Lite
Customer Service at 1-877-827-4548 ([phone]) or

[e-mail].

2 09-December-2004 02.9676.0022 0

CHAPTER 1.

Description

This chapter provides an overview of luminaire features, components
and operations.

• Features

• Major Components

• Principles of Operation

SERVICE

02.9676.0022 0 09-December-2004 3

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Features

Overview

The VL2500 Wash Luminaire comes complete
with all of the qualities and options designers
love from the original Series 2000™ fixtures. It
is still small, lightweight, and fast with a 700­watt short arc lamp, impressive lumen output,
and a variable field angle from 14° to 55.5°.

Features

• Color Mixing System: A three-filter CYM
cross-fading mechanism. A fixed color wheel with 11 interchangeable color filters
and one open space capable of continuous rotation for additional effects.

• Zoom Optics: Continuously variable field angle from 14° to 55.5°.

• Intensity Control: A coated glass dimmer wheel provides full field dimming
designed for smooth timed fades.

• Beam Size: A zoomable beam spreader mechanism provides continuous beam size
control for both rapid changes and smooth timed beam angle adjustments.

• Strobe: A high-performance dual blade strobe system capable of ultra-fast
operation.

• Pan/Tilt: Smooth, time-controlled continuous motion by way of a three-phase
stepper motor system.

• Range: Pan - 540° , Tilt - 270°.

• Pan/Tilt Accuracy: 0.3° resolution.

• Weight: 57.3 lbs (26.1 kg)

4 09-December-2004 02.9676.0022 0

Major Components

External Components

The following illustration shows major luminaire components and controls.

DESCRIPTION : MAJOR COMPONENTS

1

Truss Hook Bracket Assembly

Head Assembly

Yoke Assembly

Removable Lamp Assembly
(to access lamp for replacement)

Upper Enclosure
Assembly

AC Input Cable

Vertical

Horizontal

Focus

Captive Knob
for lamp access
(does not adjust
beam)

Beam Adjustment Controls

Product Label ID

Main Power Switch

AC Input Cable

AC IN

AC PWR

DATA IN~

Data In

DATA THRU

ENTERMENU

Data Thru

Menu Display and
Controls

Input Panel Components

02.9676.0022 0 09-December-2004 5

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

U

Menu Display

The menu system is a programmable set of commands used to configure, address,
operate, and test the luminaire. The menu system is controlled at the Menu Display
available at the enclosure input panel.

AC PWR

DATA THRU

DATA IN~

AC IN

The menu system has seven main functions which are referred to as “1st level.” Within
these main functions, there can be up to four additional sub-functions (levels 2 thru 5),
making five total levels.

Menu Display

ENTERMENU

Menu Controls

The menu system is controlled by four buttons. These buttons function as follows:

[Menu] button. Displays the menu, or if at first level, the current address.
[Enter] button. Selects the current menu option or stores current data value.
[Up] arrow. Scrolls menu options upward or increases current data value.*
[Down] arrow. Scrolls menu options downward or decreases current data value.*

Multi-Segment
Display

Address

Selects the current menu option
or stores current data value

Displays the menu,
or if at first level, the
current address

* The arrows will have opposite functions if the luminaire is hung upside down in a hanging orientation due to the
automatic orientation feature. In other words, the arrow pointing downward always functions as down/decrease and
the arrow pointing upward always functions as up/increase regardless of the luminaire orientation.

ENTERMEN

Up / Increase *

Down / Decrease *

6 09-December-2004 02.9676.0022 0

DESCRIPTION : MAJOR COMPONENTS

1

Head Components

The following illustration shows the major sub-assemblies which are located in the
luminaire head assembly. (Yoke and enclosure not shown for clarity.)

Removable Cover

Dual Blade
Strobe Assembly

CYM Color/Dimmer Bulkhead

Fixed Color Bulkhead

Back Cap /
Lamp Assembly

Fan Assembly

Removable Cover

Front Assembly - includes beam spreader

Nose Cover

02.9676.0022 0 09-December-2004 7

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Yoke Components

The following illustration shows the major sub-assemblies which are located in the
luminaire yoke assembly. (Head and enclosure not shown for clarity.)

Yoke Arm Cover

Fan Assembly

Main Control Board (MCB)

Relay

Yoke Structure

Tilt-side leg

Ignitor PCB

Yoke Arm Cover

Tilt Motor

leg

Tilt-Side
Yoke Leg

Rotate yoke fully
counter-clockwise

Board-Side
Yoke Leg

To determine which yoke leg is which without having to remove the

covers, rotate yoke counterclockwise until it stops, then look at the
luminaire while facing the input panel. The tilt-side leg is the leg to
the left; the board-side leg is the leg to the right.

Input
Panel

8 09-December-2004 02.9676.0022 0

Enclosure Components

The following illustration shows the major sub-assemblies which are located in the
luminaire enclosure assembly. (Yoke and head assembly not shown for clarity.)

700W Arc Ballast Module

DESCRIPTION : MAJOR COMPONENTS

1

Enclosure Top Covers

Enclosure Bottom
Ventilation Cover

150W +24V/6.3A
Power Supply

Fan Assembly

Input Panel Assembly
containing DMX Input PCB
and Menu Display

AC Input Cable
Requires standard AC power distribution
from 200-264 VAC, 50/60 Hz., 7 to 12 A

depending on the AC supply voltage.

Wire* Connection

Green/Yellow AC Ground

Blue AC Neutral

Brown AC Line

* International (Harmonized) Standard

02.9676.0022 0 09-December-2004 9

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Principles of Operation

Power and Data Flow Diagram

The following diagram shows how data and power are distributed in the luminaire.

Pan

Travel

Sensor

Pan

Encoder

Pan EOT

Pan

Motor

PCB

VLFS
Ballast

Rider

PCB

UV / IR

OT Sw

Input

Power

J1

Bulb
Socket

Back Cap

Switch

J12

Fix Color

OT Sw

Ignitor

J2

1200W Arc Ballast

Low

Supply

J3

Buck

Choke

Power

Switch

EMI

Filter

Upper

Enclosure

Fan

Relay

PFC

Choke

Tilt

Travel

Sensor

Tilt
Encoder
Tilt EOT

Tilt

Motor

J8

DMX
Input
PCB

J5

Data I/O

Display

PCB

J4

Volt age

Main Control PCB

J9

J11

Color

Strobe

Strobe

Beam

Fixed

Color

Cyan

Dimmer

Color

Sensor

Sensor

Yellow

Magenta

Yok e

Fan

Head

Fan

#1

Head

Fan

#2

10 09-December-2004 02.9676.0022 0

CHAPTER 2.

Maintenance

This chapter contains test, service, and standard
maintenance procedures.

• Testing

• Troubleshooting

• Maintenance Procedures

WARNING: All maintenance procedures are to be performed with

power removed from the luminaire and by a trained and qualified service
technician. Never remove cover or backcap while lamp is in operation.

SERVICE

02.9676.0022 0 09-December-2004 11

VARI❋LITE® - VL2500™ WASH LUMINAIRE SERVICE MANUAL

Testing

Testing Software

Testing software is available in all Series 2000 luminaires through the luminaire’s
menu system TEST function.

For information on specific tests and test parameters, see the VL2500 Wash Luminaire
User’s Manual (VL Part no. 02.9676.0021).

When running tests on multiple luminaires, a loopback connector is required at the
first luminaire in the link and a male termination connector is required at the last
luminaire.

Note: After 10 seconds of inactivity, the menu display will change to the default state
showing the address.

Move Disable

The Move option is available in the test menu. This allows for pan/tilt functions 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, Move will need
to be enabled after testing.

Note: When setting the Move option to disable, luminaires linked by a loopback
connector will have pan and tilt disabled for all the luminaires that are linked.

Lamp

The Lamp option is also available in the test menu. This option sets the lamp
intensity to 100% and will adjust to produce a tight beam. Pan/Tilt are disabled while
using the Lamp option, and pan/tilt settings will be restored upon exit of the Lamp
feature.

Note: When setting the Lamp option on luminaires linked by a loopback connector,
pan and tilt will be disabled for all the luminaires that are linked.

To r un test s:

Step 1. Press [Menu].
Step 2. Press [Up] / [Down] arrows until TEST appears. Press [Enter].
Step 3. Use [Up] / [Down] arrows to select a parameter to test.
Step 4. Press [Enter] to run test.
Step 5. Press [Menu] to stop test at any time.

12 09-December-2004 02.9676.0022 0