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Vari Lite VL2500 Service Manual

Wash luminaire
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  • Page 2 All information and graphics are property of Vari-Lite, 10911 Petal Street, Dallas, Texas 75238. Version as of: 04-June-2009 Part number: 02.9676.0022 A VL2500™ Wash Luminaire Service Manual ©2003 - 2009 Vari-Lite, a Philips group company. All Rights Reserved. 04-June-2009...
  • Page 3 OREWORD 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.
  • Page 4 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
  • Page 5 OREWORD 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 ELEC- TRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND INJURY TO PERSONS CAN BE FOUND BELOW.
  • Page 6 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 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.
  • Page 7 OREWORD 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.
  • Page 8 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 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.
  • Page 9 OREWORD 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.
  • Page 10 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 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.
  • Page 11 OREWORD 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.
  • Page 12 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 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.
  • Page 13 AFETY OTICE APANESE Ô ç æ Ð á¿  Á 'ê”ùÕ Q>X^Åî éQ>X^é_ æ Ô±Žã[ ÔôáÅ\úÊÛп•ù Ú”sÙæ  ÌÚö ÔÙæê”Ôôáé çP Å î TæÐçÒáÞ ÒáÊÛп• Q>X^âꔏé_ Qo" ö Òá¿ùÔ• æ à ¾ ǽùÔ• qŠPæßåÇ ¾ ǽùÔ• õ” 4” |¿æ»Ô é:´”ÅîqŠP ËÚüé 屎æß¿áꔏé[ Å\úÊÛп• ËÚü...
  • Page 14 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL æÐ Ðå¿Úü Ef; Êê” Õ 2J \fJ ª 1. VARI❋LITE® Òá¿ùÔ•\fJ ÔÎãê ÌáÊÛп• _f-ùÚê*o^< Õæ P.Ôã âÔ•_f-” *o^<” ¹ ê”íî ÿ ¿ ÞÆÈ åäæ”Ø 2 Ç å ÁæåÞÚ  ÃÁæÒùÔ• 2 ËÚü Ef; ÇP.Òá¿ãÈê”Ø ¥Ç²ÊåùÔ•²ÊåÞÚ...

  • Page 15: Table Of Contents

    ABLE OF ONTENTS Table of Contents Chapter 1. Introduction About This Manual ...................... 1 Additional Documentation................... 1 Customer Service ......................2 Technical Bulletins / Technical Notices............... 2 Chapter 2. Description Features Overview........................4 Features ......................... 4 Major Components External Components....................5 Menu Display ......................
  • Page 16 Chapter 4. Illustrated Parts Breakdown Drawing Tree VL2500™ Wash Luminaire ..................46 Top Assembly VL2500 Wash Included Items Kit ................48 VL2500 Wash Luminaire ................... 49 VL2500 Generic Luminaire ..................51 Front Wash Assembly....................53 Concave/Diffuser Front Lens Assembly ..............55 Convex Lens Assembly....................
  • Page 17 Ballast to Controller Cable Assembly..............113 Lamp Supply to Relay Cable Assembly ..............114 DC Output Cable Assembly..................115 Appendix A. Technical Bulletins and Notices 117 VL2500™ Wash Luminaire Technical Bulletins and Notices......... 117 02.96 76.002 2 A 04-June-2009 xvii...
  • Page 18 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL (This page intentionally blank.) xviii 04-June-2009 02 .9 676 .00 22 A...

  • Page 19: Chapter 1. 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.

  • Page 20: Customer Service

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Customer Service Our Goal At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone/troubleshooting assistance, product training or technical service, our full- time staff of experienced professionals are on-hand to provide support.

  • Page 21: Chapter 2. Description

    HAPTER Description This chapter provides an overview of luminaire features, components and operations. • Features • Major Components • Principles of Operation 02.96 76.002 2 A 04-June-2009...

  • Page 22: Features Overview

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

  • Page 23: Major Components

    ESCRIPTION AJOR OMPONENTS Major Components External Components The following illustration shows major luminaire components and controls. Truss Hook Bracket Assembly Removable Lamp Assembly (to access lamp for replacement) Upper Enclosure Assembly AC Input Cable Head Assembly Yoke Assembly Vertical Captive Knob Horizontal for lamp access (does not adjust...

  • Page 24: Menu Display

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 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.

  • Page 25: Head Components

    Fixed Color Bulkhead Fan Assembly Removable Cover Front Assembly - includes beam spreader Nose Cover Note: This illustration shows current VL2500 components. For information on older models, please refer to the previous versions of this manual. 02.96 76.002 2 A 04-June-2009...

  • Page 26: Yoke Components

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Yoke Components The following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly. (Head and enclosure not shown for clarity.) Yoke Arm Cover Fan Assembly Relay Ignitor PCB Yoke Structure...

  • Page 27: Enclosure Components

    ESCRIPTION AJOR OMPONENTS Enclosure Components The following illustration shows the major sub-assemblies that are located in the luminaire enclosure assembly. (Yoke and head assembly not shown for clarity.) Enclosure Top Covers 700W Arc Ballast Module 150W +24V/6.3A Power Supply Fan Assembly Input Panel Assembly containing DMX Input PCB and Menu Display...

  • Page 28: Principles Of Operation

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Principles of Operation Power and Data Flow Diagram The following diagram shows how data and power are distributed in the luminaire. Fix Color UV / IR Back Cap OT Sw OT Sw Switch...

  • Page 29: Chapter 3. Maintenance

    HAPTER 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. Never remove cover or backcap while lamp is in operation.

  • Page 30: Testing

    Testing software is available in all Series 2000 luminaires through the luminaire’s menu system TEST function. For information on specific tests and test parameters, see the VL2500™ Wash Luminaire User’s Manual (VL Part no. 02.9676.0021). Note: After 10 seconds of inactivity, the menu display will change to the default state showing the address.

  • Page 31: Troubleshooting

    AINTENANCE ROUBLESHOOTING Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s), one at a time until the end of the list is reached. To review the error messages again, it will be necessary to access them using the Status function.

  • Page 32: Troubleshooting Guide

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to the Troubleshooting Guide table (below) for more information. This table provides possible causes and remedies for each message.
  • Page 33 AINTENANCE ROUBLESHOOTING Table 2-2: Troubleshooting Guide (Continued) Message Symptom Description Possible Cause and Remedy Pan No Luminaire will not pan or Pan Sensor Not Found EOT flag attached to large pulley is not engaging the Sens hits against stop EOT sensor... - ensure flag is attached to the large pulley.

  • Page 34: Maintenance Procedures

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly. Lamp Replacement Parts: 71.2528.0700 WARNING: Remove power from luminaire before performing any maintenance. To remove and replace lamp: Step 1.
  • Page 35 Step 6. Align guide rods in guide holes and slide backcap into head assembly. Re- tighten captive knob. Step 7. If required, reset lamp hour counter as follows. (Refer to "Menu System" in VL2500™ Wash Luminaire User’s Manual for more information.) a. Power up luminaire. b. At Menu Display, press [Menu].

  • Page 36: Align Lamp For Flat Field

    Wear protective gloves and/or use tools to prevent burns. To align lamp: Step 1. Using internal menus select Lamp test to set beam. Refer to VL2500™ Wash Luminaire User’s Manual for more information. (If using console, set intensity to 100% and adjust diffusion to produce a tight beam.) Step 2.

  • Page 37: Fixed Color Bulkhead Replacement

    AINTENANCE AINTENANCE ROCEDURES Fixed Color Bulkhead Replacement Parts: 21.9676.1120 To remove and replace fixed color bulkhead assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head cover, gradually loosen two 8-32 x 1/2" PPB captive screws and remove cover (it will remain attached by tether) as shown in Figure 2-4.

  • Page 38: Standard Color Filter Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Standard Color Filter Replacement Parts: Color Filter as required To remove and replace a standard color filter: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head cover, gradually loosen two 8-32 x 1/2" PPB captive screws and...

  • Page 39: Strobe Bulkhead Replacement

    AINTENANCE AINTENANCE ROCEDURES Strobe Bulkhead Replacement Parts: 22.9676.0016 To remove and replace strobe bulkhead assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At luminaire, remove top and bottom head covers as follows: a. At top head cover, gradually loosen two 8-32 x 1/2" PPB captive screws and remove cover (it will remain attached by tether) as shown in Figure on page 19.
  • Page 40 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Strobe Bulkhead Replacement (continued) Step 9. Install replacement assembly by performing Steps 2 through 8 in reverse order. Captive Screws Removable Top Head Cover Strobe Bulkhead Assembly Removable Bottom Head Cover Figure 2-6: Strobe Bulkhead Replacement 04-June-2009 02 .9 676 .00 22 A...

  • Page 41: Front Assembly Removal

    AINTENANCE AINTENANCE ROCEDURES Front Assembly Removal Parts: 21.9676.1006 Note: This procedure may be necessary to gain access to other components. To remove and re-install front assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At luminaire, remove top and bottom head covers as follows: a.
  • Page 42 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Front Assembly Removal (continued) Step 4. At junction connector, disconnect edge motor wiring. Step 5. Face head nose upward. At front of bulkhead, using #2 Phillips long handle screwdriver, remove four 6-32 X 3/8" PPB screws, and pull front assembly out of head assembly.

  • Page 43: Beam Spreader Motor Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Beam Spreader Motor Assembly Replacement Parts: 22.9671.0468 To remove and replace beam spreader motor assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 44: Concave Lens Assembly Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Concave Lens Assembly Replacement Parts: 21.9671.0492 To remove and replace concave lens assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source.

  • Page 45: Convex Lens Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Convex Lens Assembly Replacement Parts: 22.9671.0414 To remove and replace convex lens assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 46 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Convex Lens Assembly Replacement (continued) CAUTION: Do not touch lens with bare fingers. Wear cotton gloves or other covering while replacing. Step 4. Remove convex lens assembly from lens shafts. Step 5. In replacement convex lens assembly, using 1/4" Allen Wrench, adjust 8-32 x 2"...

  • Page 47: 100Mm Condenser Lens Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES 100MM Condenser Lens Assembly Replacement Parts: 22.9671.0402 To remove and replace 100MM condenser lens assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 48 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 100MM Condenser Lens Assembly Replacement (continued) 100MM Condenser Lens Assembly Lens Shaft (4) Wave Spring (4) Shaft Collet (4) Convex Lens Assembly Concave/Diffuser Lens Assembly Figure 2-11: 100MM Condenser Lens Assembly Replacement Step 13. Re-install convex and concave lens assemblies.

  • Page 49: Yoke Assembly

    AINTENANCE AINTENANCE ROCEDURES Yoke Assembly This section provides removal and replacement procedures for components found in the luminaire yoke assembly. Tilt Motor Assembly Replacement Parts: 22.9676.0610 To remove and replace tilt motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 50: Main Control Board (Mcb) Pcb Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Main Control Board (MCB) PCB Replacement Parts: 24.9676.3730 To remove and replace an MCB PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At board-side leg, remove yoke leg cover by removing four 6-32×5/16" PTB...

  • Page 51: Ignitor Pcb Replacement

    AINTENANCE AINTENANCE ROCEDURES Ignitor PCB Replacement Parts: 24.9661.3126 To remove and replace ignitor PCB: Step 1. Disconnect luminaire AC input cable from power source. Ignitor PCB Screws Yoke Leg Cover Yoke cross member Figure 2-14: Ignitor PCB Replacement Step 2. At each yoke leg, remove yoke leg cover by removing four -32×5/16"...
  • Page 52 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Ignitor PCB Replacement (continued) Step 8. Remove two 1/4" hex standoffs from ignitor PCB by removing one 6-32×5/ 16" PPZ screw and #6 lock washer. Install in same place on new ignitor PCB.

  • Page 53: Enclosure Assembly

    AINTENANCE AINTENANCE ROCEDURES Enclosure Assembly This section provides removal and replacement procedures for components found in the luminaire enclosure assembly. Removing Enclosure Covers To gain access to enclosure components, it will be necessary to remove the top and bottom covers. To remove and replace enclosure covers: Step 1.
  • Page 54 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Removing Enclosure Covers (continued) CAUTION: Be careful not to damage lens during next step. Step 4. Carefully lay luminaire on its side as shown in Figure 2-17. Make sure that lens does not come into contact with any surface..

  • Page 55: Ballast Module Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Ballast Module Assembly Replacement Parts: 69.9676.0700 To remove and replace ballast module assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove ballast-side and ventilation covers. Refer to “Removing Enclosure Covers” on page Note: Throughout this procedure, please note different size screws and their respec- tive locations Step 3.
  • Page 56 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Ballast Module Assembly Replacement (continued) Step 6. At ballast, disconnect the following cable assemblies: a. Lamp wires b. AC input a. Control wiring Step 7. Pull lamp wires through ferrite core. Step 8. At bottom of enclosure, remove three 8-32x3/8" PFZ screws and four 8/ 32x3/8"...

  • Page 57: Pan Motor / Pan Belt Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Pan Motor / Pan Belt Assembly Replacement Parts: 21.9678.0864 - Pan Motor Assembly 54.2055.0001 - Pan Motor Belt To remove and replace pan motor assembly: Step 1. Using console or internal menus, run lens as far to the rear as possible. Step 2.
  • Page 58 SCB Cap screws that mount Pan Motor Assembly, you must tighten in a CLOCKWISE pattern starting with screw in lower left-hand side from spring. Enclosure Bottom View Pan Belt Pan Motor Assembly Bottom Cover NOTE: Head not shown for clarity. Figure 2-20: VL2500 Pan Motor Assembly Replacement 04-June-2009 02 .9 676 .00 22 A...

  • Page 59: Pan Encoder Replacement

    AINTENANCE AINTENANCE ROCEDURES Pan Encoder Replacement Parts: 24.9678.9729 To remove and replace pan encoder: Step 1. Using console or internal menus, run lens as far to the rear as possible. Step 2. Disconnect luminaire AC input cable from power source. CAUTION: Be careful not to damage lens during next step.

  • Page 60: Pan Eot (End Of Travel) Sensor Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan EOT (End of Travel) Sensor Replacement Parts: 86.7002.0003 To remove and replace pan EOT sensor: Step 1. Using console or internal menus, run lens as far to the rear as possible. Step 2. Disconnect luminaire AC input cable from power source.

  • Page 61: Lvs (Low-Voltage Supply) Power Supply Replacement

    AINTENANCE AINTENANCE ROCEDURES LVS (Low-Voltage Supply) Power Supply Replacement Parts: 69.3177.0151 To remove and replace LVS power supply: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove two 6-32 x 1/4" LG PPZ screws from display side cover and remove cover.
  • Page 62 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 04-June-2009 02 .9 676 .00 22 A...

  • Page 63: Chapter 4. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500™ Wash Luminaire. • Drawing Tree • Top Assembly • Yoke • Enclosure • Cables WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation.

  • Page 64: Drawing Tree

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Drawing Tree VL2500™ Wash Luminaire VL2500 Wash Luminaire 20.9676.0002 Rev L Front Wash Assembly VL2500 Generic Luminaire 21.9676.1006 Rev A 21.9676.0010 Rev J Concave/Diffuser Front Lens Connector Panel Assembly Assembly 21.9676.0800 Rev T 21.9671.0492 Rev D...
  • Page 65 Ballast to Controller Cable OT Switch to Reflector Assy. Cable Assembly Assembly 25.9678.0816 Rev A 25.9676.0719 Rev A Lamp Supply to Relay Cable VL2500 Wash Included Items Kit Assembly 28.9676.0002 Rev E 25.9678.0829 Rev A 02.96 76.002 2 A 04-June-2009...

  • Page 66: Top Assembly

    TAG, LAMP NOTICE 02.8700.0001 CARD, PRODUCT REGISTRATION - 2000 SERIES (09-09-02) 02.9676.0002 UNPACK/QUICK START SHEET, VL2500 04.9676.0002 SHIPPING BOX LABELS, VL2500 WASH (not shown) 07.9676.0035 SHIPPING BOX, CARDBOARD - VL2500 08.2500.0001 CD-ROM, VL2500 LUMINAIRE 22.9661.1636 FAB ASSY, BRACKET TRUSS HOOK 71.2528.0700...

  • Page 67: Vl2500 Wash Luminaire

    CABLE ASSY, OT SWITCH TO REFLECTOR ASSY (not shown) 25.9676.1715 CABLE ASSY, COLOR / FIXED (not shown) 25.9676.1716 CABLE ASSY, OPTICS / STROBE (not shown) 28.9676.0002 INCLUDED ITEMS KIT, VL2500 LUMINAIRE (not shown) 53.2200.0006 NUT, KEPS #6-32 SS 53.6523.0013 SCREW, 6-32 X 3/8" PTB 53.6558.0009 SCREW, 6-32 X 3/8"...
  • Page 68 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL VL2500 Wash Luminaire (continued) (x6) (x4) (x4) (x4) (x2) (x8) (x2) Figure 3-2: VL2500 Wash Luminaire Top Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 69: Vl2500 Generic Luminaire

    HARNESS, GUARD, LEFT 21.9676.0139 ASSY, REAR HEAD 21.9676.0600 ASSY, YOKE 21.9676.0800 UPPER ENCLOSURE 24.9676.3730 ASSY, VL2500 MAIN CONTROL BOARD (MCB) 53.6505.0020 BOLT, 1/4-28 X 3/4" HX HD GRD 8 53.6517.0001 SCREW, 10-32 X 3/8" PPZ 53.6526.0001 SCREW, 6-32 X 5/8" PPZ 53.6530.0006 RIVET, POP, 1/8"...
  • Page 70 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL VL2500 Generic Luminaire (continued) (x8) (x8) (x2) (x2) (x2) (x5) (x5) (x5) (x4) (x4) (x4) (x4) Figure 3-3: VL2500 Generic Luminaire Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 71: Front Wash Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Front Wash Assembly 21.9676.1006 Rev A Refer to Figure 3-4. Item Qty. Description 10.9671.0219 LENS SHAFT 10.9671.0223 SHAFT COLLET 10.9671.0313 LENS SUPPORT ARM 10.9676.1347 WASH LENS BULKHEAD, FRONT 21.9671.0492 ASSY, CONCAVE / DIFF FRONT LENS 22.9667.0337 ASSY, 1/4 TURN MOUNTING BRACKET 22.9671.0402 100 MM CONDENSER LENS ASSY...
  • Page 72 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Front Wash Assembly (continued) (x2) (x4) (x2) (x4) (x2) (x12) (x8) (x4) (x4) (x2) (x2) (x8) (x4) (x4) Figure 3-4: Front Wash Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 73: Concave/Diffuser Front Lens Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Concave/Diffuser Front Lens Assembly 21.9671.0492 Rev D Refer to Figure 3-5. Item Qty. Description 10.9676.1409 BACK CLAMP, CONCAVE LENS 10.9671.0421 LENS GASKET 10.9676.0491 FRONT CLAMP, CONCAVE LENS 12.9676.0418 LENS, CONCAVE ARRAY, MASKED, 107MM DIA. 42.9671.0490 LENS, FRONT STIPPLE 53.6611.0001 SCREW, 6-32 X 1/2"...

  • Page 74: Convex Lens Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Convex Lens Assembly 22.9671.0414 Rev E Refer to Figure 3-6. Item Qty. Description 10.9676.1419 FRONT CLAMP, CONVEX LENS 10.9676.0420 BACK CLAMP, CONVEX LENS 10.9671.0421 LENS GASKET 10.9671.0463 BUSHING, CONVEX LENS SLOTTED 10.9671.0464 BUSHING, CONVEX LENS DRIVE 10.9671.0465...

  • Page 75: Top Cover Assembly

    Qty. UM. Description 06.6018.0011 0.041 VELCRO, DOUBLE HOOK, 2" BLACK ADH BACKED 07.5049.0001 LANYARD, NYLON COATED, 8" LONG 10.9676.8009 COVER, TOP VL2500 10.9676.0010 FILTER, TOP HEAD COVER 12.9676.0076 BAFFLE, RIGHT, TOP COVER 12.9676.0077 BAFFLE, LEFT, TOP COVER 53.2008.0008 PUSH NUT, #8 53.5655.0250...

  • Page 76: Bottom Cover Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Bottom Cover Assembly 22.9676.0011 Rev E Refer to Figure 3-8. Item Qty. UM. Description 10.9676.8012 COVER, BOTTOM VL2500 53.2008.0008 NUT, #8 PUSH 53.6521.0001 SCREW, 8-32 X 1/2" PPB 53.6599.0001 WASHER, #10 FLAT BLACK...

  • Page 77: Reflector Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Reflector Assembly 22.9676.1018 Rev B Refer to Figure 3-9. Item Qty. UM. Description 10.9678.0647 CLAMP, MOUNTING, REFLECTOR 12.9660.7073 ELLIPSOIDAL REFLECTOR, SMOOTH, COATED 22.9660.0338 ASSY, DISCONNECT LAMP 22.9676.0130 ASSY, REFLECTOR MOUNT 53.6599.0001 SCREW, 4-40 X 3/8" PFZ 55.6669.0016 STANDOFF, 1/4"...

  • Page 78: Back Cap Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Back Cap Assembly 22.9676.0115 Rev E Refer to Figure 3-10. Item Qty. Description 10.9638.0117 KNOB, KNURLED, VL6 BACK CAP/LAMP ASSY. 10.9638.0128 BRACKET, IGNITOR CABLE 10.9638.0130 SPRING, BULB WIRE SHEATH 10.9638.0164 WASHER, FELT 10.9667.0411 LAMP CARRIAGE 10.9667.0412...
  • Page 79 LLUSTRATED ARTS REAKDOWN SSEMBLY Back Cap Assembly (continued) (x3) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x4) (x2) (13.5") (x2) (x2) (9.0") Figure 3-10: Back Cap Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 80: Wash Fan Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Wash Fan Assembly 22.9676.1090 Rev C Refer to Figure 3-11. Item Qty. Description 10.9676.1068 AIR DUCT, FRONT FAN, WASH 22.9676.0091 ASSY, FAN BULKHEAD 22.9676.0095 AIR DUCT, REAR FAN 25.8007.2212 CABLE ASSY, GROUND STRAP, #6 RING 3" LG 40.7113.0002...
  • Page 81 LLUSTRATED ARTS REAKDOWN SSEMBLY Wash Fan Assembly (continued) Direction of Air Flow (x8) (x2) (x2) (x3) 20, 21, 8, 9 7, 10 (x5) Figure 3-11: Wash Fan Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 82: Wash Fixed Color Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Wash Fixed Color Assembly 21.9676.1120 Rev C Refer to Figure 3-12 Item Qty. Description 10.9671.0125 BULKHEAD, LIGHT SHIELD, COLOR 10.9676.1181 BULKHEAD, COLOR 21.9676.0119 ASSY, COLOR MOTOR 21.9676.4145 ASSY, FILTER WHEEL 25.9676.0125 CABLE ASSY, T-STAT, COLOR/GOBO (not shown) 53.2200.0004...
  • Page 83 LLUSTRATED ARTS REAKDOWN SSEMBLY Wash Fixed Color Assembly (continued) (x3) (x3) Figure 3-12: Wash Fixed Color Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 84: Crossfade Color Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Crossfade Color Assembly 21.9676.1201 Rev F Refer to Figure 3-13. Item Qty. Description 10.9676.0230.01 SPACER, COLOR WHEEL 10.9676.0230.02 SPACER, COLOR MOTOR 10.9676.0234 AFT BULKHEAD, CROSSFADE COLOR SYSTEM 10.9676.0235 SPACER, BULKHEAD, COLOR SYSTEM 10.9676.0284 SHAFT, COLOR SYSTEM 10.9678.0238...
  • Page 85 LLUSTRATED ARTS REAKDOWN SSEMBLY Item Qty. Description 55.2110.0002 WASHER, .400" OD X .260" ID X .010 THK 55.6545.0007 SCREW, 8-32 X 3/8" PFB (x2) (x2) (x2) (x4) (x2) (x5) (x4) (x2) Amber (x2) Cyan Cyan (x2) Detail A Magenta Dimmer 2 29 (x2) (x2)

  • Page 86: Color Motor Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Color Motor Assembly 21.9676.0119 Rev D Refer to Figure 3-14. Item Qty. Description 10.9621.0097 STABILIZER, STEPPER, GOBO WHEEL 10.9676.1120 COLOR MOTOR BULKHEAD 24.9676.1114 PCB ASSY, SENSOR, COLOR/GOBO 44.9676.0116 MOTOR, GOBO/COLOR WHEEL 53.6597.0001 SCREW, 4-40 X 3/16" PPZ 53.6599.0001...

  • Page 87: Color Filter Wheel Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Color Filter Wheel Assembly 21.9676.4145 Rev A Refer to Figure 3-15. Item Qty. Description 22.9676.4142 ASSY, GOBO WHEEL, 12 POSITION FIXED 41.6006.0020 ASSY, VL6 FILTER, MAGENTA (ST) 41.6006.0150 ASSY, VL6 FILTER, PINK (ST) 41.6006.0240 ASSY, VL6 FILTER, LIGHT RED (ST) 41.6006.0320 ASSY, VL6 FILTER, BASTARD AMBER #1 (ST) 41.6006.0440...

  • Page 88: Strobe Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Strobe Assembly 22.9676.0016 Rev H Refer to Figure 3-16. Item Qty. Description 10.9676.0043 BULKHEAD, STROBE MOUNTING 10.9676.0019 STROBE BLADE, DIMPLED 10.9676.0060 MOUNTING COLLAR, STROBE BLADE 10.9676.8061 STABLIZER, STROBE MOTOR 10.9676.0069 MOUNTING PLATE, STROBE MOTOR 10.9678.0491...
  • Page 89 LLUSTRATED ARTS REAKDOWN SSEMBLY Strobe Assembly (continued) (x2) (x2) (x4) (x4) (x2) (x2) (x6) (x2) (x2) (x4) (x2) (x2) (x2) (x8) Black Side Note connector orientation on motors Figure 3-16: Strobe Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 90: Uv / Ir Window Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL UV / IR Window Assembly 22.9676.0140 Rev G Refer to Figure 3-17. Item Qty. Description 10.9676.0058 UV / IR FRAME 10.9676.0141 INSULATOR, THERMAL SWITCH 41.9678.0608 UV / IR FILTER, 3.00" X 3.00" 53.5504.0187 SCREW, 4-40 X 3/16"...

  • Page 91: Yoke

    LLUSTRATED ARTS REAKDOWN Yoke Yoke Assembly 21.9676.0600 Rev G Refer to Figure 3-18. 22.9676.8605 ASSY, YOKE STRUCTURE 22.9676.0609 ASSY, FAN 22.9676.0610 ASSY, TILT MOTOR 23.9650.3327 ASSY, ELEC., RELAY 24.9661.3126 PCB ASSY, SOLID STATE IGNITOR CABLE ASSY, IGNITOR TO RELAY (not shown) 25.9676.0030 TOROID CORE ZW-42206-TC (not shown) 43.0298...
  • Page 92 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Yoke Assembly (continued) (x2) (x2) (x2) (x4) (x4) (x2) (x4) (x2) (x3) (x2) (x2) Figure 3-18: Yoke Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 93: Tilt Motor Assembly

    LLUSTRATED ARTS REAKDOWN Tilt Motor Assembly 22.9676.0610 Rev C Refer to Figure 3-19. Item Qty. Description PLATE, TENSION ADJUST, PAN MOTOR 10.9676.7298 ASSY, DRIVE PULLEY 22.9661.0608 CODEWHEEL, 90 COUNT - 10.9661.8640 TIMING PULLEY, 2MM GT, 17 TOOTH - 10.9661.0649 - 53.5561.0250 SCREW, 6-40 X 1/4"...
  • Page 94 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Tilt Motor Assembly (continued) Detail A Detail A (x2) (x2) (x2) (x2) (x2) (x2) Pulley Height Detail & Installation 0.080" (x4) Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2.

  • Page 95: Yoke Fan Assembly

    LLUSTRATED ARTS REAKDOWN Yoke Fan Assembly 22.9676.0609 Rev A Refer to Figure 3-20. Item Qty. Description 10-9676.0646 FAN TRAY, YOKE ARM 40.7113.0001 FAN, +24V 80 X 80 X 25 MM 32CFM RECPT, 2POS MTA100 W/ POL TAB RED CLSD END 52.6396.2202 NUT, 6-32 KEPS SS 53.2200.0006...
  • Page 96 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 04-June-2009 02 .9 676 .00 22 A...

  • Page 97: Enclosure

    LLUSTRATED ARTS REAKDOWN NCLOSURE Enclosure Upper Enclosure Assembly 21.9676.0800 Rev T Refer to Figure 3-21 Figure 3-22. Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 04.9673.0040 LABEL, 2000 SERIES COMPLIANCE 04.9661.1218.01 LABEL, PATENT, VL2201 & VL2400 SERIES LUMINAIRES 10.9661.1258 BRACKET, APS SIDE 10.9661.1358 AIR SEAL, DUCT 06.6032.0009...
  • Page 98 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Item Qty. Description 69.9676.0700 ASSY, BALLAST MODULE, 700W ARC, SHIELDED 23.9678.0686 FAN ASSY, UPPER ENCLOSURE 23.9678.0687 ELEC ASSY, PAN EOT SENSOR 25.9661.1514 CABLE ASSY, CHASSIS GROUND (not shown) 25.9661.1520 CABLE ASSY, CHASSIS TO YOKE GROUND (not shown) 25.9676.0818...
  • Page 99 LLUSTRATED ARTS REAKDOWN NCLOSURE Item Qty. Description 54.1206.0014 RING, RETAINING, 1.375" SHAFT 1.291" DIA GRV X .056" WD 54.1255.0001 BEARING ASSY, BLACK FLUSH MOUNT HOUSING 54.2055.0001 BELT, TIMING S2M 210 GRV 9 MM WIDE URTH/KVLR 55.2150.0003 STANDOFF, 1/4" HEX 6-32 X 1.125" LG FF STL 55.2178.0001 CABLE ANCHOR, MOUNT, #8 SCREW MOUNTING 55.2179.0001...
  • Page 100 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x2) (x4) 83 59, 18 (x3) (x8) (x2) (x3) (x2) (x2) (x2) (x4) 39, 52 (x2) (as required) (x2) Part exploded (as required) for clarity. (x2) (x2) (x2) (x2)
  • Page 101 LLUSTRATED ARTS REAKDOWN NCLOSURE Upper Enclosure Assembly (continued) (x2) (x4) (x2) (x4) (x2) (x4) (x4) (x2) (x4) (x4) Figure 3-22: Upper Enclosure Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 102: Connector Panel Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Connector Panel Assembly 21.9676.0805 Rev B Refer to Figure 3-23. Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY 10.9678.0859 BRACKET, INPUT 10.9678.0872 STIFFNER, DISPLAY BOARD 10.9686.0820 FILLER, PANEL, DMX CONNECTOR 24.9663.3895 PCB ASSY, DMX INPUT 24.9678.3825...

  • Page 103: Dmx Input Pcb Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE DMX Input PCB Assembly 24.9663.3895 Rev 0 Refer to Figure 3-24 Item Qty. Description Ref. 17.9663.3895 PCB FAB, DMX INPUT 52.6259.0006 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0006 CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL 52.6626.0006 CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL 62.3039.0102...

  • Page 104: Ac Input Pigtail Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev B Refer to Figure 3-25 Item Qty. Description 52.6274.2313 STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 52.6401.2321 CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3- WIRE 52.8231.0005...

  • Page 105: Pan Tube Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE Pan Tube Assembly 21.9678.0880 Rev C Refer to Figure 3-26. Item Qty. Description 10.9678.0809 PAN TOGGLE STOP 10.9678.0847 WASHER, SILICONE FOAM 10.9678.0848 WASHER, PAN TEFLON 12.9678.0891 PAN TUBE, MACHINED 54.1206.0021 RING, RETAINING 1.562" SHAFT 1.468" GRV DIA 54.1255.0002 BEARING ASSY, FLUSH MOUNT HOUSING LARGE Figure 3-26: Pan Tube Assembly...

  • Page 106: Pan Motor Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan Motor Assembly 21.9678.0864 Rev E Figure 3-27 Refer to Item Qty. Description 10.9678.0865 PLATE, PAN MOTOR MOUNT 21.9678.0828 ASSY, DRIVE PULLEY, PAN - 10.9686.8720 CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250...
  • Page 107 LLUSTRATED ARTS REAKDOWN NCLOSURE Pan Motor Assembly (continued) Detail A Pressure-Sensitive Adhesive See Detail A (x2) (x2) (x2) (x4) Drive Pulley Detail & Installation (x4) 0.875" Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2. Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite.

  • Page 108: Upper Enclosure Fan Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Fan Assembly 23.9678.0686 Rev 0 Refer to Figure 3-28. Item Qty. Description FAN, 24V FAL6F24LH 40.7125.0001 TERM, SPADE #6 26-24 AWG INS YELLOW 52.8231.0007 (x2) Figure 3-28: Upper Enclosure Fan Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 109: Pan Eot Sensor Electrical Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-29. Item Qty. Description CONN, HOUSING 6 POS. RECEPTACLE 52.6524.0006 CONTACT, 24-30 AWG FEMALE CRIMP 52.8346.0001 SWITCH, SLOTTED OPTICAL 86.7002.0003 1, 2 (x4) Figure 3-29: Pan EOT Sensor Electrical Assembly 02.96 76.002 2 A 04-June-2009...
  • Page 110 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 04-June-2009 02 .9 676 .00 22 A...

  • Page 111: Ground Strap Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Cables Note: Cables are only available as complete assemblies. The information contained in this section is for reference only. Ground Strap Cable Assembly 25.8007.2212 Rev 0 Refer to Figure 3-48. Item Qty. Description 52.8329.0001 TERM, RING # 6 22-16 AWG NON-INS 73.7130.0002 0.33 WIRE, 7/64"...

  • Page 112: Lvs Chassis Ground Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-49. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8271.0001 FASTON RECEPT, 16-14 AWG (REEL) 73.3516.0504 WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569...

  • Page 113: Chassis To Yoke Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-50. Item Qty. Description 52.8250.0006 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (7 x 26.0" LG) (x2) Figure 3-50: Chassis To Yoke Ground Cable Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 114: Ignitor To Relay Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Ignitor To Relay Cable Assembly 25.9676.0030 Rev 0 Refer to Figure 3-51. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009 1.17...

  • Page 115: Tilt Plate Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Tilt Plate Ground Cable Assembly 25.9667.0413 Rev A Refer to Figure 3-52. Item Qty. Description 52.8311.0003 TERM, RING #6 BLUE 14-16 AWG NON-INS. 73.7130.0002 0.21 WIRE, 7/64" TUBULAR BRAID SILVER PLATED (x2) Figure 3-52: Tilt Plate Ground Cable Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 116: Color/Gobo T-Stat Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Color/Gobo T-Stat Cable Assembly 25.9676.0125 Rev B Refer to Figure 3-53. Item Qty. Description 52.6523.0002 CONN, HOUSING 2POS. PLUG SHROUD 52.8347.0001 CONTACT, 24-30 AWG MALE CRIMP 55.2268.0125 1.00 HEATSHRINK, 1/8" CLEAR KYNAR 63.2047.1105 THERMOSTAT, 105 DEG C, PCB MOUNT 73.3524.1008...

  • Page 117: Color/Fixed Bulkheads Cable Assembly

    25.9676.1715 Rev A Refer to Figure 3-54. Item Qty. Description 04.9676.1715.00 LABEL SET, VL2500 COLOR HARNESS 52.6610.0040 HOUSING, 40 POS 26-22 AWG PRELOADED MT RECPT DBL ROW 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.2040 COVER, BACK 40 POS MT 52.6396.2603 RECEPT, 3 POS MTA100 W/POL TAB BLUE CLOSED END 52.6424.0003...
  • Page 118 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Color/Fixed Bulkheads Cable Assembly (contin- ued) 2, 3, 4, 17 14, 9, 10 (x6) 16, 7, 8 14, 7, 8 (x2) 14, 9, 10 15, 5, 6 Figure 3-54: Color/Fixed Bulkheads Cable Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 119: Optics/Strobe Bulkheads Cable Assembly

    Replace as a complete assembly. Refer to Figure 3-55. Item Qty. Description 04.9676.1716.00 LABEL SET, VL2500 COLOR HARNESS 52.6610.0034 HOUSING, 34 POS 26-22 AWG PRELOADED MT RECPT DBL ROW 52.6224.1034 COVER, FRONT 34 POS MT LATCHING 52.6224.2034 COVER, BACK 34 POS MT 52.6524.0004 CONN, HOUSING 4 POS RECEPT 52.6524.0005...
  • Page 120 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Optics/Strobe Bulkheads Cable Assy (contin- ued) 2, 3, 4, 13 12, 7, 9 12, 5, 8 12, 5, 8 Note: OPEN positions will have pins loaded for a better mechanical fit. Figure 3-55: Optics/Strobe Bulkheads Cable Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 121: Strobe 1 Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Strobe 1 Cable Assembly 25.9676.0717 Rev B Refer to Figure 3-56. Item Qty. Description 04.9676.0716.01 LABEL, STROBE 1 52.6523.0004 CONN, HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE 52.6661.0006 CONN, RECEPT 6CIR WIRE TO WIRE 1.25 MM PITCH 52.8347.0001 CONTACT, 24-30 AWG MALE CRIMP 52.8387.0001...

  • Page 122: Fans/Disconnect Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Fans/Disconnect Cable Assembly 25.9676.0718 Rev G Refer to Figure 3-57. Item Qty. Description 52.6396.2403 RECEPT, 3 POS MTA100 W/ POL TAB 24 AWG 52.6524.0002 CONN, HOUSING 2 POS RECEPT 52.6524.0005 CONN, HOUSING 5 POS RECEPT 52.8230.0003...

  • Page 123: Ot Switch To Reflector Assy. Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES OT Switch to Reflector Assy. Cable Assembly 25.9676.0719 Rev A Refer to Figure 3-58. Item Qty. Description 52.8271.0010 RECEPT, FASTON 24-22 AWG NON-INSUL 0.016" TAB 110SERIES 52.8371.0001 RECEPT, FASTON 24-20 AWG UNINSUL TIN PLT BRS .250 X 0.32 73.2624.0008 0.67 WIRE, 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E...

  • Page 124: Pan/Tilt Control Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan/Tilt Control Cable Assembly 25.9676.0818 Rev B Refer to Figure 3-59. Item Qty. Description 52.6610.0008 HOUSING, 20 POS 26-22 AWG DBL ROW UNLOADED 52.6224.1020 COVER, FRONT 20 POS MT LATCHING 52.6224.2020 COVER, BACK 20 POS MT 52.6524.0005...
  • Page 125 LLUSTRATED ARTS REAKDOWN ABLES Pan/Tilt Control Cable Assembly (continued) 4, 7 (x5) 1, 2, 3, 11 (x7) 6 (x3),5 6 (x3),5 4, 7 (x5) Figure 3-59: Pan/Tilt Control Cable Assembly 02.96 76.002 2 A 04-June-2009...

  • Page 126: Emi Filter To Power Switch Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-60 Item Qty. Description 52.8313.0001 RECEPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL) 52.8392.0001 RECEPT, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP 55.2186.0001...

  • Page 127: Ac Input Splitter Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-61 Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3 POS 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8231.0008 TERM, SPADE #6 RED 22-16 AWG INSERT 52.8392.0001 RECP, FASTON .187"...
  • Page 128 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 Note: Heatshrink not shown for clarity. (x3) Figure 3-61: AC Input Splitter Cable Assembly 04-June-2009 02 .9 676 .00 22 A...

  • Page 129: Data I/O Link Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-62 Item Qty. Description 52.6396.2904 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 52.6396.2905 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 73.5122.0259 2.17 CBL, 22AWG STRND 4COND PVC INSUL Figure 3-62: Data I/O Link Cable Assembly...

  • Page 130: Display Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Display Cable Assembly 25.9678.1825 Rev 0 Refer to Figure 3-63 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 73.5116.0123 1.02 WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN> 55.2186.0001 CABLE TIE, .10" WD 4" LG SMALL 73.7130.0004...

  • Page 131: Ballast To Controller Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-64 Item Qty. Description 52.6396.3002 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 52.6396.3005 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 52.6396.3008 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 73.5124.1289 3.67...

  • Page 132: Lamp Supply To Relay Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-65 Item Qty. Description 52.8245.0001 TERM, RING #10 16 - 14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 55.2183.0001...

  • Page 133: Dc Output Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-66 Item Qty. Description 52.6464.0002 CONN, HOUSING, SL-156 2 POS 52.6464.0003 CONN, HOUSING, SL-156 3 POS 52.8231.0004 TERM, RING #6 BLUE 12-10 AWG INSRT 52.8323.0002 CONTACT, CRIMP, 18-22 AWG SL-156 52.8274.1614 CONN BUTT SPLICE 16-14 BLUE .150"...
  • Page 134 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 04-June-2009 02 .9 676 .00 22 A...

  • Page 135: Appendix A. Technical Bulletins And Notices

    Technical Bulletins and Notices VL2500™ Wash Luminaire Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the VL2500™ Wash Luminaire. If applicable, these improvements have been incorporated into this manual. Technical Bulletin Description...
  • Page 136 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 04-June-2009 02 .9 676 .00 22 A...
  • Page 138 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA ❋ 1.877.VARI-LITE Fax 1.214.647.8038 www.vari-lite.com Date: 04-June-2009 / Manual Part Number: 02.9676.0022 A ©2003-2009 Vari-Lite, a Philips group company. All rights reserved. Printed in the U.S.A.

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