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PRG VARI LITE VL5 Service Manual

Wash luminaire
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VARI❋LITE VL5
WASH LUMINAIRE
SERVICE MANUAL

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  • Page 1 WWW.PRG.COM ™ VARI❋LITE VL5 WASH LUMINAIRE SERVICE MANUAL...
  • Page 2 All other brand names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies. This manual is for informational use only and is subject to change without notice. Please check www.prg.com for the latest version.
  • Page 3 1) PRG luminaires have been designed for use only with specific lamps. Note lamp type before replacing. Installing another type of lamp may be hazardous. 2) PRG luminaires may be mounted on any type of surface as long as mounting instructions are followed. See instructions detailed in this manual.
  • Page 4 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. Service and maintenance should be performed only by qualified personnel as determined by the high pressure lighting fixture manufacturer. 2) Arc lamps generate intense heat.
  • Page 5 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.
  • Page 6 Revision History This manual has been revised as follows: Version Release Date Notes January 28, 2004 Miscellaneous updates. February 15, 2005 Miscellaneous updates. February 7, 2008 Miscellaneous updates. December 3, 2010 Updated book format. (No change to technical information.) October 26, 2011 Added Yoke Leg Cover Assembly to IPB “Covers and Hooks Assy.”...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction About This Manual..................................1 Additional Documentation ................................1 Special Note ....................................1 Customer Service ..................................2 Chapter 1. Description Features Overview....................................... 4 Standard Features................................. 4 Specific Features................................... 4 Major Components Exterior Components..................................6 Head Components ..................................7 VL5/VL5B Luminaire Head Components ..........................
  • Page 8 Chapter 3. Illustrated Parts Breakdown Drawing Trees VL5 Drawing Tree..................................58 VL5Arc Drawing Tree .................................. 59 VL5B Drawing Tree ..................................60 Top Assembly VL5 Series Wash Luminaire ................................ 61 Covers and Hooks Covers and Hook Assembly ............................... 62 Head VL5/VL5B Head Assembly................................65 VL5Arc Head Assembly ................................
  • Page 9 Appendix A. Technical Bulletins List of Technical Bulletins ................................. 128 Appendix B. Wiring Diagrams VL5/VL5B Wiring Diagram ................................ 129 VL5Arc Wiring Diagram ................................130 VL5 ™ WASH LUMINAIRE SERVICE MANUAL...
  • Page 10 Notes VIII VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 11: Introduction

    Special Note Customer support for this product is provided by Production Resource Group (not Vari-Lite). Refer to "Customer Service" on page 2. Technical updates regarding this product are issued by the PRG Dallas office. VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 12: Customer Service

    Customer Service For technical assistance, contact the PRG International Service Center or contact your nearest PRG office. Contact information for all PRG office locations can be found on our website at: www.prg.com/about-us/locations/ PRG Dallas (International Service) 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 USA Phone: 214.630.1963...

  • Page 13: Chapter 1. Description

    DESCRIPTION FEATURES MAJOR COMPONENTS PRINCIPLES OF OPERATION...

  • Page 14: Features

    Enhanced DICHRO❋TUNE cross-fadable dichroic colors feature independent cyan, magenta and amber color control. Smooth, timed color crossfades can occur in as little as 0.7 second. Control by PRG consoles or a wide variety of DMX512 consoles. Smooth, time controlled continuous 360° pan and 270° tilt movement.
  • Page 15 VL5Arc models 575W arc lamp source. Internal douser provides intensity control. VARI❋BEAM mechanism provides continuous time beam control or standard VL5Arc lenses may be used. Lamps are powered by the APS6 module. VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 16: Major Components

    MAJOR COMPONENTS Exterior Components The following illustration shows the major VL5 series wash luminaire components: Truss Hook Bracket Assembly Yoke Assembly Ac Input Cable Covers Head Assembly (Top and Bottom) NOTE: VL5 luminaire shown. VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 17: Head Components

    Head Components VL5/VL5B Luminaire Head Components The following illustration shows the major sub-assemblies located in the VL5/VL5B luminaire head assemblies: Hinged Rail Assembly Magenta/Diffuser Bulkhead Assembly (VL5) Blue/Diffuser Bulkhead Assembly (VL5B) Lamp Reflector Latched Rail Assembly Blue/Amber Bulkhead Assembly (VL5) Magenta/Amber Bulkhead Assembly (VL5B) VL5 ™...

  • Page 18: Vl5Arc Luminaire Head Components

    VL5Arc Luminaire Head Components The following illustration shows the major sub-assemblies located in the VL5Arc luminaire head assembly: Lens and Bellows/Motor Assembly Hinged Rail Assembly Lamp Magenta/Dimmer Bulkhead Assembly Reflector Blue/Amber Bulkhead Assembly Latched Rail Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 19: Yoke Components

    Yoke Components The following illustration shows the major sub-assemblies located in the VL5 series wash luminaire head assemblies: Ignitor Board Assembly Pan Mechanism Assembly (VL5Arc only) Terminal Strip (VL5/VL5B Only) Relay Assembly (VL5Arc Only) Tilt Mechanism Assembly Board-Side Yoke Tilt-Side Yoke Leg (VL5Arc) Leg (VL5Arc) Lamp Control Board...

  • Page 20: Principles Of Operation

    PRINCIPLES OF OPERATION Power and Data Flow Diagrams VL5/VL5B Luminaire The following diagram shows how data and power are distributed in the VL5/VL5B luminaires: TILT AMBER BLUE MOTOR MOTOR MOTOR MOTOR DATA DATA DATA +24V LAMP CONTROL PCB +24V DATA +24V TERMINAL DATA...

  • Page 21: Vl5Arc Luminaire

    VL5Arc Luminaire The following diagram shows how data and power are distributed in the VL5Arc luminaire: AMBER BELLOWS TILT BLUE MOTOR MOTOR MOTOR MOTOR MOTOR DATA DATA DATA DATA +24V LAMP CONTROL PCB +24V DATA +24V DATA DATA DATA +24V DATA RELAY DATA...
  • Page 22 Notes VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 23: Chapter 2. Maintenance

    MAINTENANCE EQUIPMENT HANDLING TESTING MAINTENANCE PROCEDURES SERVICING...

  • Page 24: Equipment Handling

    All VARI❋LITE equipment uses solid state electronics, and appropriate precautions to protect should be observed when servicing. All parts in the following PRG part number groups should be considered ESD sensitive: 23 - Electrical assemblies...

  • Page 25: Testing

    TESTING Smart Repeater Test Mode Operation The Smart Repeater / Smart Repeater Plus unit provides test software stored in its EPROMs for testing all VARI❋LITE Series 300 luminaires, including the VL5. The following section provides a brief explanation of Smart Repeater operations.
  • Page 26 To control the display scroll rate (slow it down or speed it up), set the thumbwheel switch to 040. After waiting a few seconds, set the thumbwheel to 940 for the slowest scroll rate. The normal scroll rate is about 540. Scroll rate 040 is too fast to read.
  • Page 27 Step 6. To select other ports for testing, set the thumbwheel switch to 051 and use the test parameter place on the thumbwheels switch (the hundreds digit) to select the desired ports: 0 for all ports, 1 through 6 for ports 1 through 6 respectively.

  • Page 28: Smart Repeater Test Codes

    Smart Repeater Test Codes The following tables provide test numbers, parameters, error codes, and comments for running luminaire tests. Test numbers which are not listed are not valid. CAUTION: Tests should not be run for more than 30 seconds, as this can further damage the luminaire. Any tests run at FULL SPEED should not be run for more than 15 seconds.

  • Page 29: Maintenance Procedures

    MAINTENANCE PROCEDURES The following maintenance procedures apply to all VL5 luminaire models unless otherwise noted. Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly. VL5/VL5B Lamp Replacement Parts: 71.2526.0100 1 EA LAMP,VL5 1000W 100V (Asia,) or 71.2526.0120 1 EA LAMP, VL5 1000W 120V (U.S.), or...

  • Page 30: Vl5 Arc Lamp Replacement

    VL5 Arc Lamp Replacement Parts: 71.2528.0575 1 EA LAMP, 575 WATT ARC - PHILLIPS MSR575HR Tools: Screwdriver, #1 Phillips Cotton gloves or finger cots To remove and replace lamp: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove covers or open front lens or back cap assemblies while lamp is in operation.

  • Page 31: Vl5Arc Lamp Adjustment

    VL5Arc Lamp Adjustment Note: The VL5Arc luminaire lamp requires adjustment to maximize beam intensity. Tools: Screwdriver, #1 Phillips Cotton gloves or finger cots Clean, soft, lint-free cloth Glass cleaner (commercial grade) To adjust Lamp: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove covers or open front lens or back cap assemblies while lamp is in operation.
  • Page 32 Note: To start all lamp adjustment screws at an even point, drive all the way in. Lamp Adjustment Screws Figure 2-5: VL5Arc Lamp Adjustment Screws Location Step 11. Close and latch front lens ring. VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 33: Vl5Arc Lens And Bellows/Motor Assembly Replacement

    VL5Arc Lens and Bellows/Motor Assembly Replacement Parts: 22.9647.0131 1 EA ASSY, VL5A LENS AND BELLOWS/MOTOR Tools: Screwdriver, #2 Phillips To remove and replace VL5Arc lens and bellows/motor assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1.
  • Page 34 Bellows Mounting Plate Motor-Bellows Assembly Motor Connector Clamp Bellows Motor Extension Cable Assembly Connector Figure 2-7: Disconnecting Bellows Motor Extension Cable Step 5. At front light baffle, using #2 Phillips screwdriver, remove two 4-40 X 1/4" PPZ screws and two #4 lock washers and remove baffle.

  • Page 35: Separating Vl5/Vl5B Head And Yoke Assemblies

    Separating VL5/VL5B Head and Yoke Assemblies This procedure is required during some repairs and is referenced elsewhere in this chapter. Tools: Screwdriver, #2 Phillips Screwdriver, #1 slotted Allen wrench, 5/32" Nutdriver, 5/16" Diagonal cutters To separate VL5/VL5B head and yoke assemblies: WARNING: All maintenance procedures are to be performed with power removed from luminaire.
  • Page 36 6-32 X 5/16" PPZ Screw (3) Lamp Wires Ground Cables (3) 6-32 KEPS Nut (3) Flat Washer (3) (From Head) Cable Tie (2) Collet and Pulley Acorn Nut LMPWRDSC Terminal Strip Tilt Tube Adjustment Screw Tilt Mechanism Figure 2-9: Disconnecting Wires at VL5/VL5B Tilt-Side Yoke Leg Step 6.
  • Page 37 Collet and Pulley Acorn Nut Tilt-Side Yoke Leg Yoke Cover Bracket Pivot leg away from head. 8-32 X 3/8" PPSS Screw (6) Pivot Screws Loosen, but do not remove. 8-32 X 3/8" PPSS Screw (2) 6-32 X 5/16" PPZ Screw (4) Heatshield #6 Flat Washer (4) Figure 2-10: Separating VL5/VL5B Head and Yoke Assemblies...

  • Page 38: Separating Vl5Arc Head And Yoke Assemblies

    Separating VL5Arc Head and Yoke Assemblies This procedure is required during some repairs and is referenced elsewhere in this chapter. Tools: Screwdriver, #2 Phillips Nutdriver, 5/16" Allen wrench 5/32" Diagonal cutters To separate VL5Arc head and yoke assemblies: WARNING: All maintenance procedures are to be performed with power removed from luminaire. Step 1.
  • Page 39 b. At tilt-side yoke leg, using diagonal cutters, remove cable tie securing tilt cable to tilt mechanism. Figure 2-12. 6-32 KEPS Nut (3) Tilt Cable Cable Tie (2) Cable Tie Collet and Pulley Ground Cables (2) Relay Tilt Tube Acorn Nut Adjustment Screw 6-32 X 5/16"...
  • Page 40 d. Using diagonal cutters, remove cable ties securing lamp/ground wires to two yoke leg cable anchors. Figure 2-12. e. Disconnect lamp cable 3-position connector from ignitor board. At ground stud, using 5/16" nutdriver, remove three 6-32 KEPS nuts securing ring terminals of two ground wires.
  • Page 41 Acorn Nut Yoke Cover Bracket Collet and Pulley 8-32 X 3/8" PPSS Screw (2) 8-32 X 3/8" PPSS Screw (6) #6 Flat Washer (4) 6-32 X 5/16" PPZ Screw (4) Heatshield Figure 2-15: Separating VL5Arc Head and Yoke Assemblies CAUTION: Ensure MTA connectors of motor wires are free when pulling head from yoke to avoid possible damage.

  • Page 42: Separating Front And Rear Bulkheads

    Separating Front and Rear Bulkheads This procedure is required during some repairs and is referenced elsewhere in this chapter. Front Bulkhead Rear Bulkhead Figure 2-16: Head Assembly Tools: Screwdriver, #1 Phillips Screwdriver, #2 Phillips Screwdriver, #2 Phillips, long Screwdriver, #2 slotted Nutdriver, 5/16"...
  • Page 43 #6 Internal Tooth 6-32 X 5/16" Lock Washer (4) PPZ Screw (4) Front Bulkhead Assembly Swivel Link Actuator/Drive Latched Rail Assembly Ring Link Rear Bulkhead Assembly #4 Internal Tooth Lock Washer (8) Motor Wire Spring 4-40 x 1/4" 4-40 X 1/4" PPZ Screw (4) PPZ Screw (8) Heatshield Figure 2-18: Linear Actuator Motor and Latched Rail Assemblies Replacement...

  • Page 44: Color Filter And Diffuser/Douser Panel Replacement

    Color Filter and Diffuser/Douser Panel Replacement Parts: 22.9634.0123 1 EA ASSY, VL5 SWP FILTER (BLUE) * 22.9634.0124 1 EA ASSY, VL5 LWP FILTER (AMBER) ** 22.9634.0126 1 EA ASSY, VL5 DIFFUSER PANEL 22.9634.1183 1 EA ASSY, VL5B FILTER SWP (BLUE) 22.9634.1185 1 EA ASSY, VL5B FILTER CCF (MAGENTA)
  • Page 45 CAUTION: Wear cotton gloves or finger cots when handling filters. CAUTION: Work carefully when removing filter and panels. Filters and panels are secured to silicone pad with UV-cured RTV and pad can become separated. If they become separated, a new filter or panel must be installed since RTV must be UV-cured.

  • Page 46: Drive Ring Pin Replacement

    Drive Ring Pin Replacement Parts: 55.6612.0008 1 EA PIN, 1/8 OD X 3/8L TYPE-H, AL606-T6 DRIV-LOK 06.6041.0001 1 EA COPPER POWDER Tools: Screwdriver, #2 Phillips Screwdriver, #2 slotted Screwdriver, tweaker Needle-nose pliers Rubber gloves Cotton gloves or finger cots Clean, lint-free cloth Water, room temperature Salt, granular VL5 guide pin installation tool (10.9624.0109)
  • Page 47 Step 6. At appropriate linear actuator motors, using #2 slotted screwdriver, disconnect actuator/drive ring links from swivel links on drive ring. Figure 2-21. Drive Ring Link #4 Internal Tooth Lock Washer (4) 4-40 X 1/4"PPZ Screw (4) Drive Ring Linear Actuator Motor Heatshield...
  • Page 48 Step 10. Prepare copper powder paste. a. Take room temperature water and mix in more salt than can be dissolved (i.e., there will be salt at bottom of container). b. Place some copper powder into another container and add enough salt water to form paste. If too much salt water is added, pour or blot it off.
  • Page 49 Note: The pin will quickly become locked and very difficult to remove. Step 14. Quickly check pin alignment. If pin is misaligned, use pliers to remove pin, discard pin, and repeat steps 11- 13 to install a new pin. Important! Thoroughly remove all excess copper paste from pin, carrier holder and drive ring. Step 15.

  • Page 50: Linear Actuator Motor Replacement

    Linear Actuator Motor Replacement Parts: as needed: 22.9634.0121 1 EA ASSY, VL5 BLU/AMB MOTOR 22.9634.0122 1 EA ASSY, VL5 MAG/DIF MOTOR 44.5026.0001 1 EA MOTOR, LINEAR ACTUATOR BLUE 44.9634.0128 1 EA MOTOR, LINEAR ACTUATOR 52.6396.2804 1 EA RECEPT. MTA100 W/TAB GRN 4-POS 52.6424.0004 1 EA COVER, STRAIN RELIEF/4-POS MTA...
  • Page 51 Step 7. Remove linear actuator motor assemblies. a. At linear actuator motor assemblies, using #2 slotted screwdriver, disconnect actuator/drive ring links from swivel links on drive rings. b. At each linear actuator motor assembly heatshield, using #1 Phillips screwdriver, remove four 4-40 X 1/ 4"...

  • Page 52: Yoke Assembly

    Yoke Assembly This section provides removal and replacement procedures for components found in the luminaire yoke assembly. Tilt Mechanism Assembly Replacement Parts: 22.9634.0009 1 EA ASSY, PAN/TILT MECHANISM, VL5 55.2186.0001 2 EA CABLE TIE, .10" WD 4.00" LG SMALL Tools: Screwdriver, #2 Phillips Screwdriver, #1 slotted Nutdriver, 5/16"...
  • Page 53 Lamp Wires (From Head) Remove cable ties. Head Ground Cable Lamp Wires (From Head) LMPWRDSC Belt Adjustment Screw Acorn Nut Tilt Mechanism Pulley Ground Stud Terminal Strip (VL5/VL5B) VL5/VL5B Version or Relay (VL5Arc) Shown Disconnect lamp wires. Figure 2-25: Tilt-Side Yoke Leg VL5 ™...
  • Page 54 Step 4. At top of yoke, using 5/32" Allen wrench, insert wrench through hole in top of yoke cross member and into head of 10-32 X 1" SCSS belt tension and adjustment screw, and remove screw and #10 flat washer. Figure 2-26.

  • Page 55: Pan Mechanism Assembly Replacement

    Pan Mechanism Assembly Replacement Parts:: 22.9634.0009 1 EA ASSY, PAN/TILT MECHANISM, VL5 55.2186.0001 2 EA CABLE TIE, .10" WD 4.00" LG SMALL Tools: Screwdriver, #2 Phillips Screwdriver, #1 slotted Nutdriver, 5/16" Diagonal cutters T-wrench, long handled To remove and replace pan mechanism assembly: WARNING: All maintenance procedures are to be performed with power removed from luminaire.
  • Page 56 VL5/VL5B: a. At tilt-side yoke leg, at terminal strip, disconnect lamp power bundles (from input cable side). Slide wires back through yoke leg. b. At ground stud, using 5/16" nutdriver, remove three 6-32 Keps nuts securing ground cable ring terminals and remove ring terminals. c.
  • Page 57 2) At contact "B", disconnect green disconnect switch wire. 3) Disconnect diode and jumper cable assembly connectors. 4) Feed green disconnect switch wire back through yoke leg cutout and pull through to opposite yoke leg. c. Using diagonal cutters, remove two cable ties securing lamp and ground wires to yoke leg. Figure 2-25. d.
  • Page 58 Step 9. At cross member, using #2 Phillips screwdriver, remove twelve 8-32 X 3/8" PFSS screws securing top cross member to bottom cross member. Figure 2-30. Cross-Section Detail Pan Tube Cross Member Top Cross Member Stabilizer Pan Tube Pulley Pan Stop Ring Bearing Retaining Ring 8-32 X 3/8”...

  • Page 59: Pan/Tilt Belt Tension Adjustment

    Pan/Tilt Belt Tension Adjustment Tools: Wrench, Allen, 5/32", long handled T-wrench, long handled Loose pan/tilt drive belts can create calibration problems. When the luminaire reaches the end of travel, excess belt slack can produce a vibration causing the encoder to continue producing a movement output signal to the processor (even though the luminaire is at its stop).

  • Page 60: Lcb Pcb Assembly Replacement

    LCB PCB Assembly Replacement Parts: 24.9634.0070 1 EA PCB ASSY, VL5 24.9634.0070.01 1 EA PCB ASSY, VL5B LCB 24.9638.0009.02 1 EA PCB ASSY, VL5A LAMP CONTROL BD W/EPROM Tools: None To remove and replace LCB PCB assembly: WARNING: All maintenance procedures are to be performed with power removed from luminaire. Step 1.

  • Page 61: Vl5Arc Luminaire Ignitor Board Assembly Replacement

    VL5Arc Luminaire Ignitor Board Assembly Replacement Parts: 23.9647.0047 1 EA ASSY, VL5A IGNITOR BOARD Tools: Screwdriver, #2 Phillips Wrench, 7/16" open-ended To remove and replace VL5Arc luminaire ignitor board assembly: WARNING: All maintenance procedures are to be performed with power removed from luminaire. Step 1.

  • Page 62: Vl5Arc Luminaire Relay Replacement

    VL5Arc Luminaire Relay Replacement Parts: 66.4510.0002 RELAY, 20A 250VAC DPDT UL/CSA/VDE Tools: Screwdriver, #2 Phillips Diagonal cutters To remove and replace VL5Arc luminaire relay: WARNING: All maintenance procedures are to be performed with power removed from luminaire. Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 63 Step 5. At relay, using #2 Phillips screwdriver, remove two 6-32 X 5/8" PPZ screws and two #6 lock washers securing relay and top relay adapter plate to bottom relay adapter plate, and remove relay and top adapter plate. Retain top relay adapter plate for reuse when installing replacement relay. Figure 2-35. Top Relay Adapter Plate (May come loose.) Relay...

  • Page 64: Servicing

    SERVICING Cleaning VL5Arc Lens Cleaning and Fluid Level Check Tools: Glass cleaner (commercial grade) Clean, soft, lint-free cloth To clean lens or check fluid: WARNING: All maintenance procedures are to be performed with power removed from luminaire. Step 1. Disconnect AC input cable from power source. Step 2.

  • Page 65: Cleaning The Luminaire

    Cleaning the Luminaire Tools: Window cleaner (commercial grade) Clean, white, lint-free cloth Vacuum cleaner with brush nozzle To clean the outside of the luminaire: WARNING: All maintenance procedures are to be performed with power removed from luminaire. Step 1. Disconnect AC input cable from power source. Step 2.
  • Page 66 Notes VL5 ™ WASH LUMINAIRE SERVICE MANUAL...
  • Page 67 ILLUSTRATED PARTS BREAKDOWN This chapter contains illustrated parts breakdown for assemblies contained in the VL5 series wash luminaires. DRAWING TREES TOP ASSEMBLY COVERS AND HOOKS HEAD YOKE CABLES...

  • Page 68: Drawing Trees

    DRAWING TREES VL5 Drawing Tree Wash Luminaire 20.9634.0001 Covers and Head Assy Yoke Assy Hook Assy 22.9634.0002 VL5 22.9634.0010 22.9634.0003 Input W/Grn-Yel Cable Assy Blu/Amb Bulkhead Mag/Dif Bulkhead Latched Rail Assy Hinged Rail Assy 25.9634.0180 Assy Assy 22.9634.0005 22.9634.0004 22.9634.0006 22.9634.0007 Tilt Cable Assy Ground Safety...

  • Page 69: Vl5Arc Drawing Tree

    VL5Arc Drawing Tree Wash Luminaire 20.9647.0001 VL5Arc Covers and Hook Head Assy Yoke Assy Assy 21.9647.0002 21.9647.0003 22.9647.0004 Input Cable Assy Grn-Yel 25.9647.0128 Blu/Amb Magenta/Dimmer Latched Rail Assy Hinged Rail Assy Bulkhead Assy Bulkhead Assy 22.9647.0014 22.9647.0005 22.9634.0006 22.9634.0007 Tilt Cable Assy 25.9643.0017 #6 Ring 11"...

  • Page 70: Vl5B Drawing Tree

    VL5B Drawing Tree Wash Luminaire 20.9634.0201 VL5B Covers and Head Assy Yoke Assy Hook Assy 22.9634.0202 22.9634.0122 22.9634.0205 Input W/Grn-Yel Cable Assy Hinged Rail Assy Mag/Amb Blu/Dif Bulkhead Latched Rail Assy 25.9634.0180 22.9634.0004 Bulkhead Assy Assy 22.9634.0005 22.9634.0203 22.9634.0204 Tilt Cable Assy Drive Ring Assy Ground Safety 25.9643.0017...

  • Page 71: Top Assembly

    TOP ASSEMBLY VL5 Series Wash Luminaire 20.9634.0001 VL5 20.9647.0001 VL5Arc 20.9634.0201 VL5B Refer to Figure 3-1. Item Qty. Description VL5Arc only 21.9647.0002 ASSY, VL5A HEAD ( VL5Arc only 22.9660.0164 ASSY, VL5A YOKE ( VL5 only 22.9660.0311 ASSY, VL5 HEAD ( VL5 only 22.9634.0003 ASSY, VL5 COVERS AND HOOK (...

  • Page 72: Covers And Hooks

    COVERS AND HOOKS Covers and Hook Assembly 22.9634.0003 VL5 22.9634.0205 VL5B 22.9647.0004 VL5Arc Refer to Figure 3-2. Item Qty. Description VL5/VL5B only 04.3001.0005 LABEL, VL5 ID TAG (PATENT & TRADEMARK) ( VL5Arc only 04.9647.0070 LABEL, VL5A ID TAG ( VL5/VL5B only 04.3001.0006 LABEL, VL5 INPUT RATING ( VL5Arc only...
  • Page 73 Covers and Hooks Assembly (cont) Order the following items as a complete assembly: 22.9634.0163 ASSY, VL5 YOKE LEG COVER (2 per luminaire) Item Qty. Description 04.9634.0136 LABEL, VARI*LITE, YOKE LEG COVER 06.6018.0002 0.33 VELCRO HOOK, 1" BLK ADHESIVE BACKED 10.9634.0134 COVER, VL5 YOKE LEG 53.6668.0001 FASTENER, U-TYPE SPRG.
  • Page 74 Notes VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 75: Head

    HEAD VL5/VL5B Head Assembly 22.9634.0002 VL5 22.9634.0202 VL5B Refer to Figure 3-3. Item Qty. Description 10.9634.0077 0.50 PAD, EXTRUDED, SILICONE, BULKHEAD 22.9634.0004 ASSY, VL5 HINGED RAIL 22.9634.0005 ASSY, VL5 LATCHED RAIL VL5 only 22.9634.0006 ASSY, VL5 BLU/AMB BULKHEAD ( VL5B only 22.9634.0203 ASSY, VL5B MAG/AMB BULKHEAD ( VL5 only...
  • Page 76 VL5/VL5B Head Assembly (cont.) 11 (4 pl) 8 (8 PL) 11 (4 pl) 10 (8 PL) 9 (8 pl) 9 (4 PL) Figure 3-3: VL5/VL5B Head Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 77: Vl5Arc Head Assembly

    VL5Arc Head Assembly 21.9647.0002 Refer to Figure 3-4. Item Qty. Description 10.9634.0077 PAD, EXTRUDED SILICONE, BULKHEAD 10.9647.0044 BAFFLE, VL5A FRONT LIGHT 10.9647.0092 BAFFLE, HEAT/LIGHT, VL5A 10.9647.0097 TUBE RETAINER, VL5A 22.9634.0006 ASSY, VL5 BLU/AMB BULKHEAD 22.9634.0121 ASSY, VL5 BLU/AMB MOTOR 22.9634.0122 ASSY, VL5 MAG/DIF MOTOR 22.9647.0005 ASSY, VL5A HINGED RAIL...
  • Page 78 VL5Arc Head Assembly (cont.) 11 (ref) 22 (2 pl) 15 (4 pl) 18 (2 pl) 23 (4 pl) 22 (4 pl) 18 (4 pl) 18 (4 pl) 18 (4 pl) 22 (4 pl) 23 (3 pl) 17 (3 pl) 20 (3 pl) 24 (2 pl) 19 (2 pl) 15 (4 pl)

  • Page 79: Vl5/Vl5B Hinged Rail Assembly

    VL5/VL5B Hinged Rail Assembly 22.9634.0004 Refer to Figure 3-5. Item Qty. Description 10.9634.0088 FRONT RING, VL5 10.9634.0090 SIDE RAIL, VL5 HINGED 10.9634.0092 CAP, HEATSINK 10.9634.0100 CLIP, MOUNTING REFLECTOR 10.9634.0103 PAD, MOUNTING, REFLECTOR 10.9634.0135 PLATE, LAMP WIRE, VL5 10.9634.0162 2.17 PAD, VL5 FRONT RING 10.9634.0226 MACHINED TILT TUBE -VL5 10.9647.0084...
  • Page 80 VL5/VL5B Hinged Rail Assembly (cont.) 17 (2 pl) Lamp (ref) 26 (2 pl) 28 (4 pl) 19 (4 pl) 4 (4 pl) 25 (2 pl) 27 (4 pl) 18 (2 pl) 21 (4 pl) 24 (2 pl) 26 (2 pl) 22 (4 pl) 27 (4 pl) 5 (3 pl)

  • Page 81: Vl5Arc Hinged Rail Assembly

    VL5Arc Hinged Rail Assembly 22.9647.0005 Refer to Figure 3-6. Item Qty. Description 10.9634.0088 FRONT RING, VL5 10.9634.0090 SIDE RAIL, VL5 HINGED 10.9634.0103 PAD, MOUNTING, REFLECTOR 10.9634.0135 PLATE, LAMP WIRE, VL5 10.9634.0162 2.17 PAD, VL5 FRONT RING 10.9647.0039 CLIP, VL5A REFLECTOR MOUNTING 10.9647.0068 PLATE, REFLECTOR MOUNTING, VL5A 10.9647.0082...
  • Page 82 VL5Arc Hinged Rail Assembly (cont.) 38 (3 pl) 24 (3 pl) 23 (2 pl) 30 (2 pl) 20 (2 pl) 31 (2 pl) 33 (2 pl) 22 (2 pl) 6 (4 pl) 32 (4 pl) 26 (4 pl) 28 (2 pl) 31 (2 pl) 3 (3 pl) 21 (4 pl)

  • Page 83: Vl5 Latched Rail Assembly

    VL5 Latched Rail Assembly 22.9634.0005 Refer to Figure 3-7. Item Qty. Description 10.9634.0089 SIDE RAIL, VL5 LATCHED 10.9634.0226 MACHINED TILT TUBE - VL5 10.9647.0084 HEAT INSULATOR, MACHINED - VL5A 53.5504.0187 SCREW, 4-40 X 3/16" PPSS 53.6610.0003 SCREW, 6-32 X 7/16" PPZ 54.1226.0001 LATCH, ASSY, VL5 54.1226.0002...

  • Page 84: Vl5Arc Latched Rail Assembly

    VL5Arc Latched Rail Assembly 22.9647.0014 Refer to Figure 3-8. Item Qty. Description 10.9634.0089 SIDE RAIL, VL5 LATCHED 10.9647.0082 TILT TUBE, ALUMINUM MACHINED - VL5A 10.9647.0084 HEAT INSULATOR, HEAT, MACHINED - VL5A 10.9647.0117 DISCONNECT INSULATING PAD 25.9647.0129 CABLE ASSY, VL5A DISCONNECT 53.2003.0001 NUT, 4-40 KEP ZINC PLATED 53.5504.0187...

  • Page 85: Vl5 Blu/Amb Bulkhead Assembly

    VL5 Blu/Amb Bulkhead Assembly 22.9634.0006 Refer to Figure 3-9. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0098 DEFLECTOR, HEAT 10.9634.0101 BAFFLE, REAR LIGHT 10.9634.0105 LINK, SWIVEL 10.9634.0166 CARRIER, FILTER, METAL INJ. MOLDED 22.9634.0024 ASSY, VL5 BULKHEAD 22.9634.0119 ASSY, VL5 CENTER HUB 22.9634.0123...

  • Page 86: Vl5 Blu/Amb Bulkhead Assembly (Cont.)

    VL5 Blu/Amb Bulkhead Assembly (cont.) 11 (2 pl) 5 (2 pl) 2 (32 pl) 10 (16 pl) 6 (32 pl) 1 (32 pl) 16 (4 pl) 9 (16 pl) 15 (4 pl) 18 (8 pl) 19 (4 pl) 3 (2 pl) 12 (4 pl) 4 (2 pl) 13 (4 pl)

  • Page 87: Vl5B Mag/Amb Bulkhead Assembly

    VL5B Mag/Amb Bulkhead Assembly 22.9634.0203 Refer to Figure 3-10. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0098 DEFLECTOR, HEAT 10.9634.0101 BAFFLE, REAR LIGHT 10.9634.0105 LINK, SWIVEL 10.9634.0166 CARRIER, FILTER, METAL INJ. MOLDED 22.9634.0024 ASSY, VL5 BULKHEAD 22.9634.0119 ASSY, VL5 CENTER HUB 22.9634.0124...
  • Page 88 VL5B Mag/Amb Bulkhead Assembly (cont.) 10 (2 pl) 2 (32 pl) 5 (2 pl) 6 (32 pl) 1 (32 pl) 16 (4 pl) 15 (4 pl) 18 (8 pl) 3 (2 pl) 19 (4 pl) 12 (4 pl) 14 (4 pl) 4 (2 pl) 13 (4 pl) 17 (4 pl)

  • Page 89: Vl5 Mag/Dif Bulkhead Assembly

    VL5 Mag/Dif Bulkhead Assembly 22.9634.0007 Refer to Figure 3-11. Item Qty. Description 10.9634.0026 CARRIER, FILTER 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0102 BAFFLE, FRONT LIGHT 10.9634.0105 LINK, SWIVEL 22.9634.0024 ASSY, VL5 BULKHEAD 22.9634.0120 ASSY, VL5 LIGHT BAFFLE 22.9634.0126 ASSY, VL5 DIFFUSER PANEL 22.9634.0143...
  • Page 90 VL5 Mag/Dif Bulkhead Assembly (cont.) 9 (2 pl) 3 (32 pl) 5 (2 pl) 8 (16 pl) 10 (16 pl) 1 (32 pl) 2 (32 pl) 4 (2 pl) 12 (4 pl) 13 (4 pl) 13 (4 pl) 11 (4 pl) 12 (4 pl) 14 (8 pl) 15 (4 pl)

  • Page 91: Vl5Arc Magenta/Dimmer Bulkhead Assembly

    VL5Arc Magenta/Dimmer Bulkhead Assembly 22.9647.0007 Refer to Figure 3-12. Item Qty. Description 10.9634.0026 CARRIER, FILTER 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0077 0.17 PAD, EXTRUDED SILICONE, BULKHEAD 10.9634.0105 LINK, SWIVEL 10.9647.0044 BAFFLE, VL5A FRONT LIGHT 10.9647.0121 VL5ARC INNER LIGHT BAFFLE 10.9647.0122 VL5ARC OUTER LIGHT BAFFLE 10.9647.0124...
  • Page 92 VL5Arc Magenta/Dimmer Bulkhead Assembly (Cont.) 12 (2 pl) 19 (8 pl) 3 (32 pl) 14 (16 pl) 5 (2 pl) 9 (16 pl) 2 (32 pl) 17 (2 pl) 21 (2 pl) 13 (16 pl) 18 (2 pl) 1 (16 pl) 16 (2 pl) 18 (4 pl) 16 (4 pl)

  • Page 93: Vl5B Blu/Dif Bulkhead Assembly

    VL5B Blu/Dif Bulkhead Assembly 22.9634.0204 Refer to Figure 3-13. Item Qty. Description 10.9634.0026 CARRIER, FILTER 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0102 BAFFLE, FRONT LIGHT 10.9634.0105 LINK, SWIVEL 22.9634.0024 ASSY, VL5 BULKHEAD 22.9634.0120 ASSY, VL5 LIGHT BAFFLE 22.9634.0126 ASSY, VL5 DIFFUSER PANEL 22.9634.0143...
  • Page 94 VL5B Blu/Dif Bulkhead Assembly (cont.) 13 (4 pl) 12 (4 pl) 13 (4 pl) 12 (4 pl) Figure 3-13: VL5B Blu/Dif Bulkhead Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 95: Vl5 Center Hub Assembly

    VL5 Center Hub Assembly 22.9634.0119 Refer to Figure 3-14. Item Qty. Description 10.9634.0028 HUB, CENTER, VL5 BULKHEAD 10.9634.0029 SPRING, FINGER, FILTER SUPPORT 10.9634.0133 PLUG, HUB 53.5704.0250 SCREW, 4-40 X 1/4" SCSS 53.6534.0003 RIVET, 3/32" OD POP X 3/32GRIP STEEL 55.6669.0008 STANDOFF, 5/32"...

  • Page 96: Filter Panel Assemblies

    Filter Panel Assemblies 22.9634.0123 VL5 22.9634.0124 VL5 22.9634.1183 VL5B 22.9634.1185 VL5B 22.9647.0074 VL5Arc Refer to Figure 3-15. Item Qty. Description 10.9634.0067 PAD, FILTER, EXTRUSION, SILICONE, WHITE CARRIER, CENTER FILTER, BLU/AMB/DIFF 10.9634.0156 (USED ON 22.9634.0123, 22.9634.0124 AND 22.9634.1185) CARRIER, CENTER FILTER, MAGENTA 10.9634.0157 (USED ON 22.9634.1183 AND 22.9647.0074) 41.9634.0040...

  • Page 97: Vl5 Drive Ring Assembly

    VL5 Drive Ring Assembly 22.9634.0143 Refer to Figure 3-16. Item Qty. Description 10.9634.0027 RING, DRIVE 10.9634.0044 ROLLER, VL5 DRIVE RING, SM 53.5554.0875 SCREW, SET, 4-40 X 7/8" SET SS FLAT POINT 55.6612.0004 PIN, 1/16 OD X 1/2L, TYPE C 303 SS 4 (4 pl) 2 (4 pl) Figure 3-16: VL5 Drive Ring Assembly...

  • Page 98: Vl5 Light Baffle Assembly

    VL5 Light Baffle Assembly 22.9634.0120 Refer to Figure 3-17. Item Qty. Description 10.9634.0028 HUB, CENTER, VL5 BULKHEAD 10.9634.0029 SPRING, FINGER, FILTER SUPPORT 10.9634.0078 RING, LIGHT BAFFLE, #1 10.9634.0079 RING, LIGHT BAFFLE, #2 10.9634.0080 RING, LIGHT BAFFLE, #3 10.9634.0081 RING, LIGHT BAFFLE, #4 10.9634.0082 RING, LIGHT BAFFLE, #5 10.9634.0083...
  • Page 99 VL5 Light Baffle Assembly (cont.) 11 (4 pl) 2 (2 pl) 12 (8 pl) 13 (4 pl) Figure 3-17: VL5 Light Baffle Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 100: Vl5 Diffuser Panel Assembly

    VL5 Diffuser Panel Assembly 22.9634.0126 Refer to Figure 3-18. Item Qty. Description 10.9634.0067 PAD, FILTER, EXTRUSION, SILICONE, WHITE 10.9634.0156 CARRIER, CENTER FILTER BLU/AMB/DIFF -VL5 42.9634.0063 PANEL, DIFFUSER Figure 3-18: VL5 Diffuser Panel Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 101: Vl5Arc Dimmer Blade Assembly

    VL5Arc Dimmer Blade Assembly 22.9647.0136 Refer to Figure 3-19. Item Qty. Description 10.9634.0067 PAD, FILTER, EXTRUSION, SILICONE, WHITE 10.9647.0125 DIMMER BLADE, VL5ARC Figure 3-19: VL5 Dimmer Blade Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 102: Vl5 Blue/Amber Motor Assembly

    VL5 Blue/Amber Motor Assembly 22.9634.0121 Refer to Figure 3-20. Item Qty. Description 10.9634.0061 ACTUATOR MOUNT, VL5 10.9634.0075 HEAT SHIELD, BLUE/AMBER 10.9634.0141 HEAT SINK, MODIFIED ACTUATOR 44.5026.0001 * MOTOR, LINEAR ACTUATOR HI TEMP 53.6520.0001 SCREW, 4-40 X 3/8" PPZ 54.1217.0004 * LINK, VL5 ACTUATOR/DRIVE RING (5441-P) 55.2203.0001 SCREW, 4-40 X 1/4"...

  • Page 103: Vl5 Magenta/Diffuser Motor Assembly

    VL5 Magenta/Diffuser Motor Assembly 22.9634.0122 Refer to Figure 3-21. Item Qty. Description 10.9634.0061 ACTUATOR MOUNT, VL5 10.9634.0074 HEAT SHIELD, MAGENTA/DIFFUSER 10.9634.0141 HEAT SINK, MODIFIED ACTUATOR 44.5026.0001 * MOTOR, LINEAR ACTUATOR HI TEMP 53.6520.0001 SCREW, 4-40 X 3/8" PPZ 54.1217.0004 * LINK, VL5 ACTUATOR/DRIVE RING (5441-P) 55.2203.0001 SCREW, 4-40 X 1/4"...

  • Page 104: Vl5Arc Lens And Bellows/Motor Assembly

    VL5Arc Lens and Bellows/Motor Assembly 22.9647.0131 Refer to Figure 3-22. Item Qty. Description 22.9647.0083 ASSY, LIQUID LENS - NEW MOLD (VL5A) 22.9647.0132 ASSY, VL5A MOTOR-BELLOWS 55.6596.0006 CLAMP, 5/16"-7/16" HOSE SS Figure 3-22: VL5Arc Lens and Bellows/Motor Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 105: Vl5Arc Motor-Bellows Assembly

    VL5Arc Motor-Bellows Assembly 22.9647.0132 Refer to Figure 3-23. Item Qty. Description 10.9647.0062 BELLOWS BRACKET - VL5A 10.9647.0064 BELLOWS, ENCLOSURE-EXTRUDED/ANODIZED - VL5A 10.9647.0076 BELLOWS MOTOR BRACKET - VL5A 10.9647.0080 TEFLON EXTRUSION INSERT - VL5A 10.9647.0081 MOTOR HEAT SINK - VL5A 10.9647.0093 SHIELD, DEBRIS, MOTOR/BELLOWS, VL5A 22.9647.0078 ASSY, BELLOWS - VL5A...
  • Page 106 VL5Arc Motor-Bellows Assembly (cont.) 16 (2 pl) 11 (2 pl) 14 (4 pl) 14 (2 pl) 16 (4 pl) 16 (2 pl) 16 (4 pl) 14 (4 pl) 15 (2 pl) 13 (4 pl) 16 (2 pl) Figure 3-23: VL5Arc Motor-Bellows Assembly VL5 ™...

  • Page 107: Yoke

    YOKE Yoke Assembly 22.9634.0010 VL5 22.9634.0222 VL5B 21.9647.0003 VL5Arc Refer to Figure 3-24. Item Qty. Description VL5/VL5B only 06.6018.0001 0.42 VELCRO LOOP, 5/8" BLK ADHESIVE BACKED ( VL5Arc only 06.6018.0001 0.58 VELCRO LOOP, 5/8" BLK ADHESIVE BACKED ( 10.9628.0211 STABILIZER, PAN/TILT 10.9634.0095 HEAT SHIELD, YOKE LEG 10.9634.0096...
  • Page 108 Item Qty. Description VL5Arc only 53.2002.0001 NUT, 6-32 KEP ZINC PLATED ( 53.2002.0003 NUT, 6-32 HEX ZINC NYLON INSERT 53.2002.0004 NUT, 6-32, ACORN THREADLOCKING, SS 53.2003.0001 NUT, 4-40 KEP ZINC PLATED 53.5508.0375 SCREW, 8-32 X 3/8" PPSS 53.5536.0375 SCREW, 6-32 X 3/8" PFSS 53.5638.0375 SCREW, 8-32 X 3/8"...
  • Page 109 Yoke Assembly (cont.) 40 (3 pl) 54 (3 pl) (4 pl) 36 (12 pl) 34 (6 pl) 33 (2 pl) 48 (2 pl) 40 (4 pl) 50 (2 pl) (8 pl) (4 pl) (6 pl) (2 pl) 51(2 pl) (2 pl) 34 (4 pl) (8 pl) (2 pl)

  • Page 110: Vl5 Pan/Tilt Mechanism Assembly

    VL5 Pan/Tilt Mechanism Assembly 22.9634.0009 Refer to Figure 3-25. Item Qty. Description 10.9620.0293 PAD, ANTI-BACKLASH, PTA 10.9628.0117 SPACER, ADJUSTMENT, BACKLASH, TILT 10.9628.0143 STANDOFF, SPECIAL RND, 6-32 X 5/16 X .187 10.9628.0144 STANDOFF, SPECIAL, SQR, TILT MECHANISM 10.9634.0053 PLATE, TOP, PTA 10.9634.0054 MOUNT, MOTOR, PTA 10.9634.0055...
  • Page 111 VL5 Pan/Tilt Mechanism Assembly (cont.) 18 (2 pl) 15 (4 pl) 26 (4 pl) (3 pl) 27 (3 pl) 19 (3 pl) Figure 3-25: VL5 Pan/Tilt Mechanism Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 112: Vl4 Tilt Clutch Assembly

    VL4 Tilt Clutch Assembly 22.9634.0237 Refer to Figure 3-26. Item Qty. Description 10.9634.0019 GEAR, WORM, 1M6RL17080 10.9634.0051 WASHER, "D", PTA 22.9638.0220 ASSY, DRIVE SHAFT - PAN AND TILT 54.1222.0002 RING, RETAINING METRIC F/ 9MM SHAFT 55.2128.0001 SPRING, DISC CLUTCH - VL5 55.6677.0007 WASHER, ,.750"...

  • Page 113: Vl5Arc Ignitor Board Assembly

    VL5Arc Ignitor Board Assembly 23.9647.0047 Refer to Figure 3-27. Item Qty. Description 10.9638.0064 BRACKET, MOUNTING, IGN6 PCB 24.9650.0756 PCB ASSY, IGNITOR - VL7 25.9647.0048 CABLE ASSY, VL5A IGNITOR 53.2016.0002 NUT, 4-40 HEX ZINC 53.5506.0500 SCREW, 6-32 X 1/2" PPSS 53.6569.0001 SCREW, 4-40 X 5/16"...

  • Page 114: Vl7 Ignitor Pcb Assembly

    VL7 Ignitor PCB Assembly 24.9650.0756 Refer to Figure 3-28. Item Qty. Description 11.9650.0756 PCB, IGNITOR -VL7 25.9638.0222 CABLE ASSY, IGNITOR BOARD OUTPUT 55.2186.0001 CABLE TIE, .10" WD 4.00" LG SMALL 60.1422.1002 RES, 1/4W 5% 10.0 MEG CF R1-R12 CAP, .01UF, 3000V, RAD, CERAMIC, .375", 62.2032.0001 CAP, .033UF, 1000V, RAD, POLYPRO, .600"...

  • Page 115: Lamp Control Pcb Assembly

    Lamp Control PCB Assembly 24.9634.0070 VL5 24.9634.0070.01 VL5B 24.9638.0009.02 VL5A Refer to Figure 3-29. Item Qty. Description VL5/VL5B only 11.9634.0071 PCB, VL5 ( VL5Arc only 11.9638.0010 PCB, VL6 CONTROL ( VL5/VL5B only 22.9634.0104 KIT, COMPONENT, VL5 PCB ASSY ( 22.9638.0087 VL5Arc only KIT, COMPONENTS, VL6 PCB ASSY ( 52.5000.0002...

  • Page 116: Vl5 Pcb Assembly Components Kit

    VL5 PCB Assembly Components Kit 22.9634.0104 Refer to Figure 3-30. Item Qty. Description 50.2708.0001 SOCKET, 8-PIN DIP XF1, XU21, XU26-XU29 50.2714.0001 SOCKET, 14-PIN DIP XU9, XU20 50.2732.0001 SOCKET, 32-PIN DIP XU11-XU13 51.5017.0001 HEATSINK, 7128D, TO-220 51.5018.0001 HEATSINK, 7148D, TO-220 U23, U24 52.5000.0001 TERM STRIP, 4-PIN, DBL-ROW TSW 52.5000.0003...
  • Page 117 Item Qty. Description 70.3729.0001 FUSE, 1/16A, 125V, PICO II 70.3731.0001 FUSE, 5AMP, 19374K, TR5-T TIME LAG 70.3732.0001 FUSEHOLDER, TR5, 19560 82.4309.5401 DIODE, 1N5401 RECTIFIER 100V 3A 82.4316.5822 DIODE, 1N5822 SCHOTTKY 40V 3A 82.5301.5908 DIODE, ZENER TS 1N5908 5V 5W D3-D6 82.5316.6281 DIODE, ZENER, 1N6281 27V 1500W 10% 83.3157.0001...
  • Page 118 VL5 PCB Assembly Components Kit (cont.) Figure 3-30: VL5 PCB Assembly Components Kit VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 119: Vl6 Pcb Assembly Components Kit

    VL6 PCB Assembly Components Kit 22.9638.0087 Refer to Figure 3-31. Item Qty. Description XF1, XU23, XU25, XU26, 50.2708.0001 SOCKET, 8-PIN DIP XU30 50.2714.0001 SOCKET, 14-PIN DIP XU22 51.5017.0001 HEATSINK, 7128D, TO-220 51.5018.0001 HEATSINK, 7148D, TO-220 U27, U28 52.5000.0001 TERM STRIP, 4-PIN, DBL-ROW TSW 52.5000.0003 COVER, SOCKET 132-POS PQFP #821942-1 XU18...
  • Page 120 Item Qty. Description C1-C7, C16-C19, C20-C25, C28, C29, C30, C31, C35- 62.2013.0104 CAP, .1UF, 50V, AXL, CERAMIC, .100", 20% C39, C40-C44, C46, C52, C59, C60, C61 62.2034.0206 CAP, 20PF, 50V, SIP, CERAMIC, .100", 5% C27, C28 62.2094.0106 CAP, 10UF, 35V, TANTALUM AXIAL 20% C8 -C12, C48, C51 62.2099.0104 CAP, .1UF, 50V, SIP, CERAMIC, .100", 10%...
  • Page 121 VL6 PCB Assembly Components Kit (cont.) Figure 3-31: VL6 PCB Assembly Components Kit VL5 ™ WASH LUMINAIRE SERVICE MANUAL...
  • Page 122 Notes VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 123: Cables

    CABLES #6 Ring/#6 Ring 11" GND Strap Assembly 25.8007.2244 Refer to Figure 3-32. Item Qty. Description 52.8329.0001 TERM, RING #6 22-16AWG NON-INS 73.7130.0002 0.92 WIRE, 7/64" TUBULAR BRAID SILVER-PLATED 1 (2 pl) Figure 3-32: #6 Ring/#6 Ring 11" GND Strap Assembly VL5 ™...

  • Page 124: Ring/18-14Awg Faston 11" Gnd Strap Assembly

    #6 Ring/18-14AWG Faston 11" GND Strap Assembly 25.8007.2644 Refer to Figure 3-33. Item Qty. Description 52.8271.0009 RECEPT, FASTON .250" 18-14AWG NON INS 52.8329.0001 TERM, RING #6 22-16AWG NON-INS 73.7130.0002 0.92 WIRE, 7/64" TUBULAR BRAID SILVER-PLATED Figure 3-33: #6 Ring/18-14AWG Faston 11" GND Strap Assembly VL5 ™...

  • Page 125: Ring/#8 Ring 11" Gnd Strap Assembly

    #8 Ring/#8 Ring 11" GND Strap Assembly 25.8007.3344 Refer to Figure 3-34. Item Qty. Description 52.8329.0003 TERM, RING #8 22-16AWG NON-INS 73.7130.0002 0.92 WIRE, 7/64" TUBULAR BRAID SILVER-PLATED 1 (2 pl) Figure 3-34: #8 Ring/#8 Ring 11" GND Strap Assembly VL5 ™...

  • Page 126: Tilt Cable Assembly

    Tilt Cable Assembly 25.9643.0017 Refer to Figure 3-35. Item Description 52.6270.0001 CONN HOUSING, 5-PIN MTA CLOSED END RED 52.6396.0003 COVER, 7-POS MTA100 STRAIN RELIEF 52.6396.2202 RECEPT, 2-POS MTA100 W/POL TAB RED CLSD END 52.6424.0005 COVER, 5-POS CLOSED END STRAIN RELIEF - MTA 52.6434.2202 RECEPT, MTA156 RED 2-POS.

  • Page 127: Pan Cable Assembly

    Pan Cable Assembly 25.9643.0018 Refer to Figure 3-36. Item Description 52.6270.0001 CONN HOUSING, 5-PIN MTA CLOSED END RED 52.6396.0003 COVER, 7-POS MTA100 STRAIN RELIEF 52.6396.2202 RECEPT, 2-POS MTA100 W/POL TAB RED CLSD END 52.6424.0005 COVER, 5-POS CLOSED END STRAIN RELIEF - MTA 52.6434.2202 RECEPT, MTA156 RED 2-POS.

  • Page 128: Vl5 Ground Safety Cable Assembly

    VL5 Ground Safety Cable Assembly 25.9634.0140 Refer to Figure 3-37. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14AWG REEL PIDG 73.7089.0504 8.00 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 1 (2 pl) Figure 3-37: VL5 Ground Safety Cable Assembly VL5 ™...

  • Page 129: Vl5 Input W/Grn-Yel Cable Assembly

    VL5 Input W/Grn-Yel Cable Assembly 25.9634.0180 Refer to Figure 3-38. Item Qty. Description 52.6396.2202 RECEPT, 2-POS MTA100 W/POL TAB RED CLSD END 52.6396.2204 RECEPT, 4-POS MTA100 W/POL TAB RED 4 CLSD END 52.6400.0015 RECEPT, 17-16, FREE HANG CPC 52.6424.0002 COVER, 2-POS CLOSED END STRAIN RELIEF - MTA 52.6424.0004 COVER, 4-POS CLOSED END STRAIN RELIEF - MTA 52.6431.0002...

  • Page 130: Ignitor Board Output Cable Assembly

    Ignitor Board Output Cable Assembly 25.9638.0222 Refer to Figure 3-39. Item Qty. Description 52.6264.0003 CONN HOUSING, 30 SERIES W/FLNGS 3-POS 52.8247.0002 CRIMP CONTACT, S30 TIN (REEL) 73.7027.0001 .033 WIRE, 16AWG 30KV CHAMPLAIN ONLY 3239B 2 (2 pl) Figure 3-39: Ignitor Board Output Cable Assembly VL5 ™...

  • Page 131: Ground Cable Assembly

    Ground Cable Assembly 25.9638.0243 Refer to Figure 3-40. Item Qty. Description 52.8231.0005 TERM, RING BLUE 16-14AWG REEL PIDG 73.7089.0504 5.30 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 1 (2 pl) Figure 3-40: Ground Cable Assembly VL5 ™ WASH LUMINAIRE SERVICE MANUAL...

  • Page 132: Vl5Arc Ignitor Cable Assembly

    VL5Arc Ignitor Cable Assembly 25.9647.0048 Refer to Figure 3-41. Item Qty. Description 52.8271.0005 RECPT. FASTON 1/4" 16-14AWG INS. (REEL) 52.8298.0002 TERM, WIRE PIN 16-14 GA. 73.7089.0000 4.50 WIRE, 22AWG BLK 300V TEFLON STRANDED 73.7089.0009 4.50 WIRE, 22AWG WHT TEFLON STRANDED 2 (2 pl) 1 (2 pl) Figure 3-41: Ground Cable Assembly...

  • Page 133: Vl5Arc Bulb Wires Cable Assembly

    VL5Arc Bulb Wires Cable Assembly 25.9647.0059 Refer to Figure 3-42. Item Qty. Description 25.9634.0140 CABLE ASSY, VL5 GROUND SAFETY 52.8247.0001 CRIMP CONTACT, S30 TIN (REEL) 55.6601.0002 0.50 HEATSHRINK, 0.191" ID TFE TEFLON 55.6695.0002 0.30 HEATSHRINK, 3/8" ADHESIVE WALL 73.6616.0011 1.58 WIRE, 16AWG 600V 600C MICA TAPE TAN 73.7100.0001 4.08...

  • Page 134: Bellows Motor Extension Cable Assembly

    Bellows Motor Extension Cable Assembly 25.9647.0108 Refer to Figure 3-43. Item Qty. Description 52.6469.0001 CONN, PLUG HI-TEMP 4-PIN 26AWG 52.6470.0010 CLAMP, CABLE RECEPTACLE 73.2528.0002 2.25 WIRE, 28AWG 250V 200C TFE RED STRND MIL-W-16878 73.2528.0005 2.25 WIRE, 28AWG 250V 200C TFE GRN STRND MIL-W-16878 73.2528.0006 2.25 WIRE, 28AWG 250V 200C TFE BLU STRND MIL-W-16878...

  • Page 135: Vl5A Input Cable Assembly Grn-Yel

    VL5A Input Cable Assembly Grn-Yel 25.9647.0128 Refer to Figure 3-44. Item Qty. Description 52.6396.2202 RECEPT, 2-POS MTA100 W/POL TAB RED CLSD END 52.6396.2204 RECEPT, 4-POS MTA100 W/POL TAB RED CLSD END 52.6400.0015 RECEPT, 17-16, FREE HANG CPC 52.6424.0002 COVER, 2-POS CLOSED END STRAIN RELIEF - MTA 52.6424.0004 COVER, 4-POS CLOSED END STRAIN RELIEF - MTA 52.6431.0002...

  • Page 136: Vl5Arc Disconnect Cable Assembly

    VL5Arc Disconnect Cable Assembly 25.9647.0129 Refer to Figure 3-45. Item Qty. Description 10.9647.0118 VL5A DISCONNECT CONTACT 10.9647.0150 VL5A DISCONNECT MOUNT 53.6534.0006 RIVET, 3/32" OD 3/16 SOLID 2117-T4A1 100DEG CSK HD 73.1522.0005 3.00 WIRE, 22AWG 150V 200C TFE GRN UL1213/CSA 3 (2 pl) Figure 3-45: VL5Arc Disconnect Cable Assembly VL5 ™...
  • Page 137 TECHNICAL BULLETINS...
  • Page 138 List of Technical Bulletins The following table identifies the current technical bulletins associated with the VL5 series wash luminaires. Associated Technical Bulletin Description Luminaire Install new VL5 and VL6 luminaire and VLM moving mirror pan and tilt assembly VL5-021A driven pulleys and stops and lamp wire tie-wrap mounting block location VL5-022 Install new VL5 and VL6 luminaire pan and tilt assembly driven pulleys and stops VL5-023...
  • Page 139 WIRING DIAGRAMS VL5/VL5B Wiring Diagram VL5 ™ WASH LUMINAIRE SERVICE MANUAL...
  • Page 140 VL5Arc Wiring Diagram CONNECTOR LEGEND DETAIL SEE DETAIL VL5 ™ WASH LUMINAIRE SERVICE MANUAL...
  • Page 141 VL5™ Wash Luminaire Service Manual Version as of: October 26, 2011 PRG part number: 02.9634.0010 F...
  • Page 142 Production Resource Group Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.com...

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