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Vari Lite VL500 Service Manual

Vl500 wash luminaire
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Summary of Contents for Vari Lite VL500

  • Page 2 ERVICE ANUAL ® VARI❋LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries. VL500™ (and the individual product designations), VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the ™ ™ ™ ™...
  • Page 3 BTAIN ARRANTY ERVICE 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® - VL500™ L 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: Safety Notice

    AFETY OTICE Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product.
  • Page 6 VARI❋LITE® - VL500™ L 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 ICHERHEITSHINWEISE 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® - VL500™ L 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 OTES DE SÉCURITÉ Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 10 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 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.
  • Page 11 VISO SOBRE EGURIDAD 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® - VL500™ L UMINAIRE ERVICE ANUAL 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.
  • Page 13 AFETY OTICE APANESE 02.96 85.001 0 0 17-July-2006 xiii...
  • Page 14 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 17-July-2006 02 .9 685.00 10 0...
  • Page 15 HAPTER Description This chapter provides an overview of luminaire features, components and operations. • Features • Component Descriptions • Principles of Operation 02.96 85.001 0 0 17-July-2006...

  • Page 16: Features

    Pastel (Dichroic Glass) Option: As an option, all versions of the VL500 wash luminaire are available with “pastel” or lighter colored magenta and blue color filters. VL500 wash luminaires fitted with pastel-colored dichroic glass maintain the electrical specifications of the standard version of the VL500 wash.

  • Page 17: Model Specific Features

    230V, 1000W Tungsten Halogen lamp source. • Pastel color dichroic glass DICHRO❋TUNE color system. • 230V on-board IGBT dimmer. VL500 80V Wash Luminaire (20.9685.0004) • 80V, 1200W Tungsten Halogen lamp source. • Standard color dichroic glass DICHRO❋TUNE color system. •...
  • Page 18 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V Wash Luminaire (20.9685.0014) • 80V, 1200W Tungsten Halogen lamp source. • Pastel color dichroic glass DICHRO❋TUNE color system. • 80V on-board dimmer. VL500A Wash Luminaire (20.9685.0005) • 575W arc lamp source with external ballast unit.

  • Page 19: Component Descriptions

    ESCRIPTION Component Descriptions External Luminaire Components The following illustration shows the external luminaire components and controls. Input Panel Connections Mini XLR for Remote Lamp Power Data Thru 3-Pole Neutrik Input Cable Data In Locking Connector for AC Input Input Panel Base Provides DMX In and Provides hook mounting...

  • Page 20: Luminaire Internal Head Components

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Luminaire Internal Head Components The following illustration shows the major sub-assemblies which are located in the luminaire head assembly. Note: Yoke assembly not shown for clarity. Amber/Diffuser Assembly (Tungsten Models) ™ DICHRO❋TUNE color bulkhead - 16-radially mounted diffuser panels for beam control and amber dichroic glass for color mixing.

  • Page 21: Luminaire Yoke Components

    Yoke Arm Cover (Power Supply Side) Main Controller PCB Luminaire control circuit board. Power Supply Side Yoke Arm Cover (Display Side) VL500 Models (120V or 230V) Pan Mechanism Display LCD Luminaire technical status/info. 120W Power Supply Supplies power to electronic and motor components.
  • Page 22 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Luminaire Yoke Components (continued) The following illustrations show additional model variations for the power supply side of the luminaire yoke assembly. VL500D Models (120V or 230V) Pan Mechanism IGBT Dimmer Yoke Arm Cover...

  • Page 23: Arc Ballast Unit

    120V or 230V operation depending on model. dimmer models. The dimmer VL500 80V Models - Internal lamp power heatsink is visible on the power- dimmer configured specifically for 80V side yoke leg as shown in this lamps.

  • Page 24: Principles Of Operation

    Terminal Motor Block Luminaire Lamp Lamp Power In Power In Note: For detailed information on wiring, connections, signals, etc., please refer to “VL500 Wiring Diagram - Sheet 1 of 1” on page 163. xxiv 17-July-2006 02 .9 685.00 10 0...

  • Page 25: Vl500D Incandescent Luminaires

    Thru In Motor IGBT Diffuser Terminal Dimmer Motor Block Luminaire Power In Lamp Note: For detailed information on wiring, connections, signals, etc., please refer to “VL500 Wiring Diagram - Sheet 1 of 1” on page 163. 02.96 85.001 0 0 17-July-2006...

  • Page 26: Vl500 80V Incandescent Luminaires

    Diffuser Terminal Dimmer Motor Block Luminaire Power In Lamp Note: For detailed information on wiring, connections, signals, etc., please refer to “VL500 Wiring Diagram - Sheet 1 of 1” on page 163. xxv i 17-July-2006 02 .9 685.00 10 0...

  • Page 27: Vl500A Luminaire

    Amber Thru In Motor Dimmer Terminal Motor Block Luminaire Power In Note: For detailed information on wiring, connections, signals, etc., please refer to “VL500 Wiring Diagram - Sheet 1 of 1” on page 163. 02.96 85.001 0 0 17-July-2006 xxvii...
  • Page 28 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes xxv iii 17-July-2006 02 .9 685.00 10 0...

  • Page 29: Table Of Contents

    Dimmer Models ...................... xxiii Principles of Operation VL500 Incandescent Luminaires ................xxiv VL500 Incandescent Block Diagram - Without On-Board IGBT Dimmer ..xxiv VL500D Incandescent Luminaires ................xxv VL500D Incandescent Block Diagram - With On-Board IGBT Dimmer ..xxv VL500 80V Incandescent Luminaires ..............xxvi VL500 80V Incandescent Block Diagram - With On-Board 80V Dimmer..
  • Page 30 Linear Actuator Motor Replacement (Amber/Diffuser [or Dimmer] Bulkhead) ..29 Incandescent Lamp Socket Assembly (VL500 and VL500D Only) Replacement ..31 Arc lamp Socket Assembly (VL500A and VL500 80V Only) Replacement .... 33 Display PCB Replacement ..................35 Main Control PCB/Fan Assembly Replacement............36 Low Voltage Supply (LVS) Replacement (VL500/VL500D/VL500A Only)....
  • Page 31 ABLE OF ONTENTS VL500 80V (with 80V Dimmer) Luminaire .............. 75 VL500A Luminaire (575W Arc) ................77 VL500A Luminaire (700W Arc) ................79 Generic VL500 Luminaire Assembly ................ 81 Head Assembly VL500 Generic Head Assembly ................87 Heatsink Assembly ....................91 VL500 Magenta/Blue Color Assembly ..............

  • Page 32: July-2006 02 .9 685.00 10

    VL500 Wiring Diagram - Sheet 1 of 1 ..............163 DMX Input PCB (24.9663.1895) Schematic ............164 VL500 Controller PCB (24.9685.0730) Schematic - Sheet 1 of 6......165 VL500 Controller PCB (24.9685.0730) Schematic - Sheet 2 of 6......166 VL500 Controller PCB (24.9685.0730) Schematic - Sheet 3 of 6......167 VL500 Controller PCB (24.9685.0730) Schematic - Sheet 4 of 6......

  • Page 33: Introduction

    About This Manual This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL500™ Luminaire. The manual is intended for use by Vari-Lite personnel and by Authorized Vari-Lite Dealers and Service Centers only. This manual covers the following models:...

  • Page 34: Additional Documentation

    A support web page for VL500 series luminaires is available at www.vari-lite.com (follow the Support link). A user’s manual is available for installation and operation of the VL500 luminaire. This manual is available in both printed and electronic (PDF) formats. VL500™ Luminaire User’s Manual (02.9685.0001).

  • Page 35: Chapter 1. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Equipment Handling • Maintenance Procedures WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation. WARNING: Maintenance, repairs, and adjustments should only be performed by a quali- ❋...

  • Page 36: Testing

    Note: There is a known issue with all versions of code for the VL500™ wash luminaires concerning the “Test” menu options. Issues arose when running a test from one VL500™ wash luminaire to multiple VL500™ wash luminaires (of a different type) across the VL500™...
  • Page 37 AINTENANCE Movement Disable The Movement option allows pan and tilt to be disabled so that the luminaire can be placed in any position for testing without movement occurring. In order to regain full control of the luminaire, Movement will need to be enabled after testing. Note: When using the Movement option, pan and tilt will be disabled for all the luminaires that are linked.

  • Page 38: Diagnostic Tests

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Diagnostic Tests The following diagnostic tests are available in the test menu. Test Descriptions All Seq....Tests all functions in sequential order. Pan/Tilt ....Tests different pan and tilt movements. Pan...... Tests different pan movements.

  • Page 39: Test Menu System Chart

    AINTENANCE Test Menu System Chart The following shows all the tests that can be performed by accessing the tests via the luminaire’s on-board tech display. Table 2-1: VL500 Test Menu System Chart 1st Level 2nd Level 3rd Level 4th Level...

  • Page 40: Lamp Hours Progress Bar (Arc Models Only)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lamp Hours Progress Bar (Arc Models Only) For arc models, there is a Lamp Hours Progress Bar representing lamp hours used on the lamp. It is tied directly to the lamp hours within the MCB. The bar, when fully extended across the...

  • Page 41: Equipment Handling

    AINTENANCE Equipment Handling Below are some basic tips and information on handling luminaires and their associated components. Locations/Use ❋ VARI LITE luminaires are designed for dry locations only. Exposure to rain or moisture (including, but not limited to, fog machines, misters, etc.,) may damage luminaire. Lamps Servicing •...

  • Page 42: Solid State Electronics

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL • When the lamp is struck, the luminaire should be maintained in a horizontal position when not in use. • For arc lamp luminaires, heads should be tilted horizontal before starting lamps. Lamps generate light by an electrical discharge arc, whereby the electrons from two electrodes excite the fill components to give off light.

  • Page 43: Maintenance Procedures

    AINTENANCE Maintenance Procedures Lamp Replacement - Incandescent Parts: 71.2529.0120 1200 WATT TUNGSTEN HALOGEN LAMP, 120 VAC (VL500 AND VL500D MODELS) 71.2526.0230 1 EA 1000 WATT TUNGSTEN HALOGEN LAMP, 230 VAC (VL500 AND VL500D MODELS) 71.9685.0080 1 EA 1200 WATT TUNGSTEN HALOGEN LAMP, 80 VAC...
  • Page 44 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL WARNING: Wear cotton gloves or other covering while servicing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If required, use alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp.

  • Page 45: Lamp Replacement (Arc Model)

    AINTENANCE Lamp Replacement (Arc Model) Parts: 71.2528.0575 1 EA MSR575, 575 WATT ARC LAMP (VL500A 575W MODELS) 71.9685.0702 1 EA MSR700/2, 700 WATT MSR ARC LAMP (VL500A 700W MODELS) Tools: • Cotton gloves or finger cots. WARNING: Remove power from luminaire before performing maintenance. To remove and replace arc lamp: Step 1.
  • Page 46 15 Step 11. If required, and only on arc models, reset lamp hour counter as follows. (Refer to "Menu Systems Functions" in the VL500 User’s Manual for more information.) a. Power up luminaire. b. At Menu Display, press [Menu].

  • Page 47: Align Lamp For Maximum Beam Irradiance

    AINTENANCE Align Lamp For Maximum Beam Irradiance After a new lamp is installed in a VL500A luminaire, it will be necessary to align the lamp to optimize the beam. Tools: • #1 Phillips Screwdriver • 1/4" Nutdriver • Cotton Gloves or Finger Cots •...
  • Page 48 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Step 5. Ensure the following: a. Reflector is mounted in center of rear casting and secure enough to prevent it from moving. If not, at three reflector mounting clips, using #1 Phillips screw- driver, remove three 6-32x1/8"...

  • Page 49: Front Glass Replacement

    AINTENANCE Front Glass Replacement Parts: As needed: 42.9685.0201 1 EA GLASS, FRONT, CLEAR 42.9685.0207 1 EA GLASS, FRONT, STIPPLE 42.9685.0203 1 EA GLASS, FRONT, MED. FLOOD 8-ROW LENT. 42.9685.0206 1 EA GLASS, FRONT, MED. FLOOD 10-ROW LENT. 42.9685.0204 1 EA GLASS, FRONT, MED.
  • Page 50 WARNING: When installing a new or replacement lens in a VL500A (ARC) Wash, all lens types must be installed curve out (convex). In tungsten fixtures (VL500 , VL500D and VL500 80V Wash), Clear and Stipple lenses may be installed curve in (concave) and all Lenticular (8-Row, 10-Row, and 12-Row) and Buxom lenses must be installed curve out (convex).

  • Page 51: Magenta/Blue Dichro*Tune Rear Bulkhead Replacement

    AINTENANCE Magenta/Blue DICHRO*TUNE Rear Bulkhead Replacement Parts: 21.9685.0170 1 EA ASSY, MAGENTA/BLUE (STANDARD DICHRO*TUNE COLORS - INCANDESCENT) 21.9685.0174 1 EA ASSY, MAGENTA/BLUE (PASTEL DICHRO*TUNE COLORS - INCANDESCENT) 21.9685.0173 1 EA ASSY, MAGENTA/BLUE (STANDARD DICHRO*TUNE COLORS - ARC) 21.9685.0175 1 EA ASSY, MAGENTA/BLUE (PASTEL DICHRO*TUNE COLORS - ARC) Tools:...
  • Page 52 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Step 5. At top cover, remove four 6-32x1/4" PPB SEMS screws. Step 6. Remove top cover. Step 7. Disconnect wiring at two linear actuators on Magenta/Blue DICHRO*TUNE Bulkhead. Figure 9 Step 8. As shown in , at side rails from top, remove four 6-32x3/8"...

  • Page 53: Amber/Diffuser (Or Dimmer) Dichro*Tune Front Bulkhead Replacement

    AINTENANCE Amber/Diffuser (or Dimmer) DICHRO*TUNE Front Bulkhead Replacement Parts: 21.9685.0171 1 EA ASSY, AMBER/DIFFUSER (INCANDESCENT MODELS) 21.9685.0172 1 EA ASSY, AMBER/DIMMER (ARC MODELS) Tools: • #2 Phillips Screwdriver To remove and replace Amber/Diffuser (or Dimmer) bulkhead assembly: Step 1. CLOSE ALL GLASS IN BULKHEADS - Power up unit and allow all DICHRO*TUNE glass to calibrate.
  • Page 54 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Figure 11 Step 8. As shown in , at side rails from top, remove four 6-32x3/8" LG PPZ SEMS screws. NOTE: Some components not shown for clarity. 6-32x3/8" PPZ SEMS (x4) Amber/Diffuser (or Dimmer) Assembly...

  • Page 55: Color Filter And Diffuser Panel Replacement

    AINTENANCE Color Filter and Diffuser Panel Replacement Parts: 22.9685.0122 16 EA ASSY, FILTER, MAGENTA, DICHRO*TUNE (STD) 22.9685.0123 16 EA ASSY, FILTER, BLUE, DICHRO*TUNE (STD) 22.9685.0120 16 EA ASSY, FILTER, MAGENTA, DICHRO*TUNE (PASTEL) 22.9685.0121 16 EA ASSY, FILTER, BLUE, DICHRO*TUNE (PASTEL) 22.9685.0124 16 EA ASSY, FILTER, AMBER, DICHRO*TUNE...
  • Page 56 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL WARNING: Wear cotton gloves or other covering while handling filters or diffuser panels. If required, use isopropyl alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp. CAUTION: Work carefully when removing filter and panels. Filters and panels are secured to silicone pad with UV-cured RTV and pad can become separated.

  • Page 57: Arc Dimmer Panel Replacement

    AINTENANCE Arc Dimmer Panel Replacement Parts: 10.9685.0210 16 EA DIMMER BLADE (PANEL), VL500 Tools: • #1 Phillips screwdriver • Tweaker Screwdriver • Cotton Gloves or Finger Cots • Clean, lint-free (soft) cloth To remove and replace dimmer panels: Step 1. Ensure all glass filters and dimmer panels are in closed position.
  • Page 58 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Step 10. Remove dimmer panel from center hub. Dimmer Panel Carrier Insert Panel Bearing Here Center Hub Bulkhead Figure 14: Dimmer Panel Replacement Step 11. Replace by performing steps 3 through 10 in reverse order.

  • Page 59: Linear Actuator Motor Replacement (Magenta/Blue Bulkhead)

    AINTENANCE Linear Actuator Motor Replacement (Magenta/ Blue Bulkhead) Parts: 44.9685.0230 2 EA MOTOR, LINEAR, 0.002"/STEP Tools: • #1 Phillips Screwdriver • #2 Phillips Screwdriver • #2 Slotted Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace linear actuator motor assembly: Step 1.
  • Page 60 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Step 5. At linear actuator motor to be replaced on Magenta/Blue assembly, disconnect wiring at both motors. Step 6. Remove linear actuator motor assembly as follows: a. At linear actuator motor assembly, using #1 Phillips screwdriver, remove three 4-40x1/4"...

  • Page 61: Linear Actuator Motor Replacement (Amber/Diffuser [Or Dimmer] Bulkhead)

    AINTENANCE Linear Actuator Motor Replacement (Amber/Dif- fuser [or Dimmer] Bulkhead) Parts: 44.9685.0230 2 EA MOTOR, LINEAR, 0.002"/STEP Tools: • #1 Phillips Screwdriver • #2 Phillips Screwdriver • #2 Slotted Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace linear actuator motor assembly: Step 1.
  • Page 62 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Step 5. At linear actuator motor to be replaced on Amber/Diffuser (or Dimmer) assembly, disconnect wiring at both motors. Step 6. Remove linear actuator motor assembly as follows: a. At linear actuator motor assembly, using #1 Phillips screwdriver, remove three 4-40x1/4"...

  • Page 63: Incandescent Lamp Socket Assembly (Vl500 And Vl500D Only) Replacement

    Heatsink Latch Some components not shown for clarity. Lamp Figure 19: Accessing the Lamp Socket in VL500 and VL500D Fixtures Step 5. At top cover, remove four 6-32x1/4" PPB SEMS screws. Step 6. Remove top cover. Step 7. Remove Magenta/Blue Bulkhead Assembly as described in “Magenta/Blue...
  • Page 64 1/4" Hex Standoff (x3) 6-32x1/8" PPB Screws (x3) Figure 20: Heatsink Assembly - Lamp Socket Removal (VL500 and VL500D Only) Step 10. Remove light baffle. Step 11. Loosen, but do not remove, three 1/4" hex standoffs and turn reflector clips out of way and remove reflector.

  • Page 65: Arc Lamp Socket Assembly (Vl500A And Vl500 80V Only) Replacement

    Heatsink Latch Some components not shown for clarity. Lamp Figure 21: Accessing the Lamp Socket in VL500A and VL500 80V Fixtures Step 5. At top cover, remove four 6-32x1/4" PPB SEMS screws. Step 6. Remove top cover. Step 7. Remove Magenta/Blue Bulkhead Assembly as described in “Magenta/Blue...
  • Page 66 Reflector Clips (x3) 6-32x1/8" PPB Screws (x3) Figure 22: Heatsink Assembly - Lamp Socket Removal (VL500A and VL500 80V Only) Step 10. Remove light baffle. Step 11. Loosen, but do not remove, three 1/4" hex standoffs and turn reflector clips out of way and remove reflector.

  • Page 67: Display Pcb Replacement

    AINTENANCE Display PCB Replacement Parts: 24.9685.0826 1 EA ASSY, VL500 DISPLAY PCB Tools: • 1/4" Hex Nutdriver • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace display PCB assembly: Step 1. Remove power from luminaire.

  • Page 68: Main Control Pcb/Fan Assembly Replacement

    Step 4. At Main Control PCB/Fan Assembly, disconnect the following wiring connections: a. Pan/Tilt wiring harness b. Head motor wiring harness c. 3-position connector (Dimmer communications - VL500D and VL500 80V models only) d. 10-position AMP connector (Display Communications) e. 4-position connector (DMX communications)*...
  • Page 69 AINTENANCE Figure 24 Step 6. Remove four 1/4" hex (13/16" long) standoffs as indicated in 1/4" Hex (9/32" Long) 6-32x1/4" PPB (x4) Standoff (x4) Menu Display Yoke Arm Cover Display PCB 1/4" Hex (13/16" Long) Standoff (x4) Main Control PCB NOTE: Some components not shown for clarity.

  • Page 70: Low Voltage Supply (Lvs) Replacement (Vl500/Vl500D/Vl500A Only)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Low Voltage Supply (LVS) Replacement (VL500/ VL500D/VL500A Only) Parts: 69.3178.0120 1 EA POWER SUPPLY, 120W, 24VDC Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. WARNING: With power applied, LIVE AC is present at heatsink. Do not touch when unit is powered.

  • Page 71: Low Voltage Supply (Lvs) Temperature Pcb Replacement (Vl500/Vl500D/Vl500A Only)

    LVS Temperature PCB 1/4" Hex Standoff NOTE: Some components not shown for clarity. Figure 26: LVS Temperature PCB Replacement (VL500/VL500D/VL500A Only) Step 3. Disconnect the following wiring connections on PCB: a. 2-position connector (LVS Fan) b. 4-position connector (LVS Fan from MCB) Figure 26 Step 4.

  • Page 72: Low Voltage Supply (Lvs) Replacement (Vl500 80V Only)

    Wire Shield (fish paper) Pan Tube NOTE: Some components not shown for clarity. Figure 27: LVS Replacement (VL500 80V Only) Step 5. Disconnect the following wiring connections: a. 3-position connector (AC Input) b. 6-position MTA connector (DC Output) Figure 27 Step 6.

  • Page 73: Low Voltage Supply (Lvs) Temperature Pcb Replacement (Vl500 80V Only)

    Pan Tube NOTE: Some components not shown for clarity. Figure 28: LVS Temperature PCB Replacement (VL500/VL500D/VL500A Only) Step 3. Disconnect the following wiring connections on PCB: a. 2-position connector (LVS Fan) b. 4-position connector (LVS Fan from MCB) Figure 26 Step 4.

  • Page 74: Tilt Motor Assembly Replacement

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Tilt Motor Assembly Replacement Parts: 21.9685.0540 1 EA ASSY, PAN/TILT MOTOR Tools: • #2 Phillips Screwdriver • Diagonal Cutters WARNING: Remove power from luminaire before performing maintenance. To remove and replace tilt motor assembly: Step 1.
  • Page 75 AINTENANCE Step 7. Loosen (do NOT remove) four 8-32x7/16" PPZ screws that mount Pan/Tilt motor assembly to Tilt Motor Slide Plate. Tilt Motor Assembly NOTE: Some components not shown for clarity. 8-32x7/16" PPZ Tilt Motor Assembly Tilt Motor Slide Plate Yoke Arm Cover 8-32x7/16"...

  • Page 76: Pan Motor Assembly Replacement

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Pan Motor Assembly Replacement Parts: 21.9685.0540 1 EA ASSY, PAN/TILT MOTOR Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace pan motor assembly: Step 1. Disconnect luminaire AC input cable from power source.

  • Page 77: Pan/Tilt Encoder Pcb Replacement

    AINTENANCE Pan/Tilt Encoder PCB Replacement Parts: 24.9685.7735 1 EA BOARD ASSY, PAN/TILT ENCODER Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace pan/tilt encoder PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 78: Arc Ignitor Pcb Replacement (Vl500A Only)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Arc Ignitor PCB Replacement (VL500A Only) Parts: 24.9685.1000 1 EA IGNITOR, ARC (VL500A ONLY) Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace ignitor PCB: Step 1.

  • Page 79: Igbt Dimmer Replacement (Vl500D Only)

    AINTENANCE IGBT Dimmer Replacement (VL500D Only) Parts: 69.3173.0115 1 EA DIMMER, IGBT, 1200W 115V REV PHASE CONT (VL500D 115V MODELS ONLY) 69.3173.0230 1 EA DIMMER, IGBT, 1000W 230V REV PHASE CONT (VL500D 230V MODELS ONLY) Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance.
  • Page 80 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL NOTE: Some components not shown for clarity. 6-32x3/8" PTB Screws (x4) Yoke Arm Cover (Dimmer Side) 6-32x3/8" PPZ Screws (x4) IGBT Dimmer Figure 33: IGBT Dimmer Replacement (VL500D Only) Step 7. Replace IGBT Dimmer by performing Steps 2 through 6 in reverse.

  • Page 81: Dimmer Replacement (Vl500 80V Only)

    AINTENANCE 80V Dimmer Replacement (VL500 80V Only) Parts: 21.9685.0750 1 EA ASSY, 80V DIMMER Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace 80V dimmer: Step 1. Disconnect luminaire AC input cable from power source.
  • Page 82 6-32x3/8" PTB Screws (x4) Yoke Arm Cover (Dimmer Side) 6-32x3/8" PPZ Screws (x4) 80V Dimmer Figure 34: 80V Dimmer Replacement (VL500 80V only) Step 7. Replace 80V Dimmer by performing Steps 2 through 6 in reverse. 17-July-2006 02 .9 685.00 10 0...

  • Page 83: Arc Ballast Replacement (Vl500A Only)

    AINTENANCE Arc Ballast Replacement (VL500A Only) Parts: 21.9685.0800 1 EA ASSY, BALLAST, 625W (575W MODELS ONLY) 21.9685.0802 1 EA ASSY, BALLAST, 700W (700W MODELS ONLY) Tools: • None WARNING: Remove power from luminaire before performing maintenance. To remove and replace arc ballast dimmer: Step 1.

  • Page 84: Safety Relay Replacement (Vl500A Only)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Safety Relay Replacement (VL500A Only) Parts: 23.9650.3327 1 EA RELAY, ELECTRICAL ASSY (VL500A ONLY) Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace safety relay assembly: Step 1.

  • Page 85: Ac Input (Powercon) Connector Replacement

    Some components not shown for clarity. This procedure is applicable for all models. Pan Tube Assembly Cover Tether VL500 80V Pan Tube Assembly 4-40x1/2" PFB Screws (x2) AC Input (PowerCon) Connector Figure 36: AC Input (PowerCon) Connector Replacement Step 5. Remove two 4-40x1/2" PFB screws at front of PowerCon.

  • Page 86: Mini-Xlr (Display/Remote Programming) Connector Replacement

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Mini-XLR (Display/Remote Programming) Con- nector Replacement Parts: 25.9685.0770 1 EA CONNECTOR, MINI-XLR (DISPLAY / REMOTE PROGRAMMING) Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace Mini-XLR connector: Step 1.

  • Page 87: Dmx Pcb Assembly Replacement

    NOTE: Some components not shown for clarity. This procedure is applicable for all models. Pan Tube Assembly Cover Tether VL500 80V Pan Tube Assembly DMX PCB Assembly #4x3/8" HLN PN BLK ZN Screws (x4) Figure 38: DMX PCB Assembly Replacement Step 5.

  • Page 88: Cleaning Optical Lenses And Filters

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Cleaning Optical Lenses and Filters WARNING: Remove power from luminaire before performing maintenance. WARNING: Acetone is a harsh cleaning agent and solvent. Acetone is very flammable. Please handle acetone according to manufacturer’s safety instructions and precautions.

  • Page 89: Chapter 2. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL500 wash luminaire assemblies including the arc ballast unit. • Drawing Trees • Top Assembly • Head Assembly • Yoke Assembly • Cables • Arc Ballast Assembly Note: The following abbreviations are used to identify parts specific to certain models.

  • Page 90: Drawing Trees

    24.9663.1895 Rev A 21.9685.0150 Rev C Color Assembly 21.9685.0171 Rev G Drive Ring Assembly continued next page 21.9685.0280 Rev A continued next page Figure 3-1: VL500 and VL500D Incandescent Luminaires Drawing Tree (Part 1) 17-July-2006 02 .9 685.00 10 0...
  • Page 91 VL500 Display (Remote) Cable Assembly 25.9685.0770 Rev B VL500 Yoke Lamp Jumper Cable Assembly 25.9685.0776 Rev A Incandescent Power Input Cable Assembly 25.9663.2030 Rev A (VL500 Only) Figure 3-2: VL500 and VL500D Incandescent Luminaires Drawing Tree (Part 2) 02.96 85.001 0 0 17-July-2006...

  • Page 92: Vl500 80V Incandescent Luminaires

    23.9685.0782 Rev 0 Bottom Bulkhead Assembly DMX Input PCB Assembly 21.9685.0150 Rev C 24.9663.1895 Rev A Drive Ring Assembly 21.9685.0280 Rev A continued next page Figure 3-3: VL500 80V Incandescent Luminaires Drawing Tree (Part 1) 17-July-2006 02 .9 685.00 10 0...
  • Page 93 25.9685.0756 Rev B VL500 Display (Remote) Cable Assembly 25.9685.0770 Rev B Incandescent Power Input Cable Assembly 25.9685.0742 Rev 0 80V Surge Protector Cable Assembly 25.9685.0746 Rev 0 Figure 3-4: VL500 80V Incandescent Luminaires Drawing Tree (Part 2) 02.96 85.001 0 0 17-July-2006...

  • Page 94: Vl500A (575W/700W) Arc Luminaires

    G (575W Arc, Pastel Colors, Assembly 25.9685.0777 Rev A Arc Ballast) 28.9685.0006 21.9685.0280 Rev A Rev G (700W Arc, Standard VL500 Ignitor to Socket Cable Colors, Arc Ballast) 28.9685.0016 Rev G (700W Assembly Magenta/Blue (Pastel) Arc, Pastel Colors, Arc 25.9685.0766 Rev C...
  • Page 95 28.9685.0006 Rev G (700W Arc, Standard Colors, Arc Ballast) MCB Fan Assembly 28.9685.0016 Rev G (700W Arc, Pastel Colors, Arc Ballast) 21.9685.0731 Rev 0 VL500 Arc Ballast Interconnect Cable Assembly VL500 Extra Hardware Kit 25.9685.0767 Rev B 28.9685.0999 Rev 0...

  • Page 96: Top Assembly

    230V/1000W TUNGSTEN HALOGEN LAMP, (VL500D, 230V ONLY) 71.2528.0575 575W MSR ARC LAMP, (VL500A, 575W ONLY) 71.2529.0120 120V/1200W TUNGSTEN HALOGEN LAMP, (VL500D, 120V ONLY) 71.9685.0080 80V/1200W TUNGSTEN HALOGEN LAMP, (VL500 80V ONLY) 71.9685.0702 700W MSR ARC LAMP, (VL500A, 700W ONLY) 17-July-2006 02 .9 685.00 10 0...
  • Page 97 LLUSTRATED ARTS REAKDOWN Included Items Kit (continued) (Arc Models Only) (Arc Models Only) Figure 3-7: Included Items Kit 02.96 85.001 0 0 17-July-2006...

  • Page 98: Label Locations

    04.9685.0912.00 LABEL, COMPLIANCE VL500 (CLR) 04.9685.0913 LABEL, LAMP TYPE 120V OR 230V INCANDESCENT (VL500 MODELS ONLY) 04.9685.0913.00 LABEL, LAMP TYPE 120V OR 230V INCANDESCENT (CLR) (VL500 MODELS ONLY) 04.9685.0914 LABEL, LAMP TYPE 120V INCANDESCENT (VL500D 120V MODELS ONLY) 04.9685.0914.00 LABEL, LAMP TYPE 120V INCANDESCENT (CLR) (VL500D 120V MODELS ONLY) 04.9685.0915...
  • Page 99 LABEL, AC INPUT RATING (CLR) (VL500 MODELS ONLY) 04.9685.0921 LABEL, AC INPUT RATING (VL500 PASTEL MODELS ONLY) 04.9685.0921.00 LABEL, AC INPUT RATING (CLR) (VL500 PASTEL MODELS ONLY) 04.9685.0922 LABEL, AC INPUT RATING (VL500D 120V MODELS ONLY) 04.9685.0922.00 LABEL, AC INPUT RATING (CLR) (VL500D 120V MODELS ONLY) 04.9685.0923...
  • Page 100 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Label Locations (continued) (VL500 Models Only) (Non-Arc Models Only) (Non-Arc Models Only) 10911 PETAL STREET LI ST DALLAS, TX. 75238 U.S.A. − 1.877.VARILITE NOT FOR RESIDENTIAL USE Vari-Lite, Inc. IMPROPERE A L’USAGE DOMESTIQUE WWW.VARI−LITE.COM...

  • Page 101: Vl500 Luminaire (120V Or 230V)

    HEAD COVER, BOTTOM 25.9685.0753 CABLE ASSY, VL500 MOTOR (NOT SHOWN) 25.9685.0760 CABLE ASSY, HEAD GROUNDING (NOT SHOWN) 28.9685.0001 INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN) 42.9685.0207 LENS, PAR 64 NSP (STIPPLE) 53.6523.0013 SCREW, 6-32X3/8" LG PTB 53.6558.0009 SCREW, 6-32X3/8" LG PPZ SEMS 53.6558.0010...
  • Page 102 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL (x2) (x8) (x8) (x8) (x8) Figure 3-9: VL500 Luminaire (120V or 230V) 17-July-2006 02 .9 685.00 10 0...

  • Page 103: Vl500D (With 120V Igbt Dimmer) Luminaire

    HEAD COVER, BOTTOM 25.9685.0753 CABLE ASSY, VL500 MOTOR (NOT SHOWN) 25.9685.0760 CABLE ASSY, HEAD GROUNDING (NOT SHOWN) 28.9685.0002 INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN) 42.9685.0207 LENS, PAR 64 NSP (STIPPLE) 53.6523.0013 SCREW, 6-32X3/8" LG PTB 53.6558.0001 SCREW, 6-32X3/8" LG PPZ 53.6558.0009...
  • Page 104 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL (x2) (x8) (x8) (x8) (x8) (x2) (x8) Figure 3-10: VL500D (with 120V IGBT Dimmer) Luminaire 17-July-2006 02 .9 685.00 10 0...

  • Page 105: Vl500D (With 230V Igbt Dimmer) Luminaire

    HEAD COVER, BOTTOM 25.9685.0753 CABLE ASSY, VL500 MOTOR (NOT SHOWN) 25.9685.0760 CABLE ASSY, HEAD GROUNDING (NOT SHOWN) 28.9685.0003 INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN) 42.9685.0207 LENS, PAR 64 NSP (STIPPLE) 53.6523.0013 SCREW, 6-32X3/8" LG PTB 53.6558.0001 SCREW, 6-32X3/8" LG PPZ 53.6558.0009...
  • Page 106 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL (x2) (x8) (x8) (x8) (x8) (x2) (x8) Figure 3-11: VL500D (with 230V IGBT Dimmer) Luminaire 17-July-2006 02 .9 685.00 10 0...

  • Page 107: Vl500 80V (With 80V Dimmer) Luminaire

    HEAD COVER, BOTTOM 25.9685.0753 CABLE ASSY, VL500 MOTOR (NOT SHOWN) 25.9685.0760 CABLE ASSY, HEAD GROUNDING (NOT SHOWN) 28.9685.0004 INCLUDED ITEMS KIT, VL500 80V INCANDESCENT (NOT SHOWN) 42.9685.0207 LENS, PAR 64 NSP (STIPPLE) 53.6523.0013 SCREW, 6-32X3/8" LG PTB 53.6882.0022 SCREW, 8-32X3/8" LG PPZ SEMS 53.6558.0009...
  • Page 108 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL (x2) (x8) (x8) (x8) (x8) (x8) Figure 3-12: VL500 80V (with 80V Dimmer) Luminaire 17-July-2006 02 .9 685.00 10 0...

  • Page 109: Vl500A Luminaire (575W Arc)

    CABLE ASSY, RELAY HARNESS (NOT SHOWN) 25.9685.0760 CABLE ASSY, HEAD GROUNDING (NOT SHOWN) 25.9685.0767 CABLE ASSY, BALLAST INTERCONNECT, 575/700W (NOT SHOWN) 28.9685.0005 INCLUDED ITEMS KIT, VL500 ARC (NOT SHOWN) 42.9685.0207 LENS, PAR 64 NSP (STIPPLE) 53.6523.0013 SCREW, 6-32X3/8" LG PTB 53.6558.0009 SCREW, 6-32X3/8"...
  • Page 110 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL (x2) (x8) (x8) (x8) (x8) Figure 3-13: VL500A Luminaire (575W Arc) 17-July-2006 02 .9 685.00 10 0...

  • Page 111: Vl500A Luminaire (700W Arc)

    CABLE ASSY, RELAY HARNESS (NOT SHOWN) 25.9685.0760 CABLE ASSY, HEAD GROUNDING (NOT SHOWN) 25.9685.0767 CABLE ASSY, BALLAST INTERCONNECT, 575/700W (NOT SHOWN) 28.9685.0006 INCLUDED ITEMS KIT, VL500 ARC (NOT SHOWN) 42.9685.0207 LENS, PAR 64 NSP (STIPPLE) 53.6523.0013 SCREW, 6-32X3/8" LG PTB 53.6558.0009 SCREW, 6-32X3/8"...
  • Page 112 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL (x2) (x8) (x8) (x8) (x8) Figure 3-14: VL500A Luminaire (700W Arc) 17-July-2006 02 .9 685.00 10 0...

  • Page 113: Generic Vl500 Luminaire Assembly

    ASSY, YOKE, BASE, INCANDESCENT (VL500 ONLY) 21.9685.0521 ASSY, YOKE, BASE, INTERNAL IGBT DIMMER (VL500D ONLY) 21.9685.0522 ASSY, YOKE, BASE, EXTERNAL BALLAST (VL500A ONLY) 21.9685.0523 ASSY, YOKE, BASE, INTERNAL 80V DIMMER (VL500 80V ONLY) 21.9685.0731 ASSY, MCB / FAN 23.9650.3327 RELAY, ELECTRICAL ASSY (VL500A ONLY) 24.9685.0826 ASSY, VL500 DISPLAY BOARD 24.9685.1000...
  • Page 114 Item Qty. Description 53.6558.0009 SCREW, 6-32X3/8", PPZ, SEMS (VL500 ONLY) 53.6558.0009 SCREW, 6-32X3/8", PPZ, SEMS (VL500D AND VL500 80V ONLY) 53.6558.0009 SCREW, 6-32X3/8", PPZ, SEMS (VL500A ONLY) 53.6558.0010 SCREW, 6-32X1/4", PPB, SEMS 53.6596.0002 SCREW, 4-40X5/16" LG PPZ SEMS (VL500A ONLY) 53.6608.0001...
  • Page 115 LLUSTRATED ARTS REAKDOWN Generic VL500 Luminaire Assembly (continued) (VL500D Only) (VL500 Only) (VL500D Only) (x4) Figure 3-15: Generic VL500 Luminaire Assembly (VL500 and VL500D) 02.96 85.001 0 0 17-July-2006...
  • Page 116 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Generic VL500 Luminaire Assembly (continued) (x4) Figure 3-16: Generic VL500 Luminaire Assembly (VL500 80V) 17-July-2006 02 .9 685.00 10 0...
  • Page 117 LLUSTRATED ARTS REAKDOWN Generic VL500 Luminaire Assembly (continued) (x4) 29, 41 (x4) Figure 3-17: Generic VL500 Luminaire Assembly (VL500A) 02.96 85.001 0 0 17-July-2006...
  • Page 118 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 17-July-2006 02 .9 685.00 10 0...

  • Page 119: Head Assembly

    ASSY, COUNTERWEIGHT SUPPORT 21.9685.0320 ASSY, HEATSINK, INCANDESCENT (VL500/VL500D ONLY) 21.9685.0321 ASSY, HEATSINK, ARC (VL500A ONLY) 21.9685.0322 ASSY, HEATSINK, 80V INCANDESCENT (VL500 80V ONLY) 25.9685.0350 CABLE ASSY, DISCONNECT (VL500A ONLY) 53.6556.0004 SCREW, 4-40X1/8" LG PPB 53.6598.0187 SCREW, 4-40X0.187" LG PFB UNDERCUT HD 53.6607.0001...
  • Page 120 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Generic Head Assembly (continued) (x2) (x4) (x2) (x2) (x4) Figure 3-18: VL500 Generic Head Assembly (VL500 and VL500D) 17-July-2006 02 .9 685.00 10 0...
  • Page 121 LLUSTRATED ARTS REAKDOWN VL500 Generic Head Assembly (continued) (x2) (x2) (x4) (x2) (x2) (x4) Figure 3-19: VL500 Generic Head Assembly (VL500A) 02.96 85.001 0 0 17-July-2006...
  • Page 122 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Generic Head Assembly (continued) (x2) (x4) (x2) (x2) (x4) Figure 3-20: VL500 Generic Head Assembly (VL500 80V) 17-July-2006 02 .9 685.00 10 0...

  • Page 123: Heatsink Assembly

    SCREW, 6-32X1/8" LG PPB 53.6558.0007 SCREW, 6-32X1/4" LG PPZ SEM (VL500 ONLY) 53.6575.0010 SCREW, 8-32X1/2" LG PPZ SEM 53.6682.0022 SCREW, 8-32X3/8" LG PPZ SEM (VL500A AND VL500 80V ONLY) 53.6594.0001 SCREW, 10-32X1-1/2" LG PPB (VL500A ONLY) 54.1226.0001 ASSY, LATCH 55.2203.0002 SCREW, 4-40X1/4"...
  • Page 124 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Heatsink Assembly (continued) (x3) (x2) (x2) (x4) (x3) (x3) (x3) Figure 3-21: VL500 Heatsink Assembly (VL500 and VL500D) 17-July-2006 02 .9 685.00 10 0...
  • Page 125 LLUSTRATED ARTS REAKDOWN VL500 Heatsink Assembly (continued) (x3) (x3) (x3) (x3) (x2) (x2) (x2) (x4) (x3) (x3) (x3) Figure 3-22: VL500 Heatsink Assembly (VL500A) 02.96 85.001 0 0 17-July-2006...
  • Page 126 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Heatsink Assembly (continued) (x3) (x3) (x3) (x2) (x2) (x2) (x4) (x3) (x3) (x3) Figure 3-23: VL500 Heatsink Assembly (VL500 80V) 17-July-2006 02 .9 685.00 10 0...

  • Page 127: Vl500 Magenta/Blue Color Assembly

    Qty. Description 10.9685.0257 LIGHT BAFFLE, REAR BULKHEAD 21.9685.0160 ASSY, MAGENTA/BLUE, STANDARD, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x4) Figure 3-24: VL500 Magenta/Blue Color Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 128: Vl500 Magenta/Blue (Pastel) Color Assembly

    10.9685.0257 LIGHT BAFFLE, REAR BULKHEAD 21.9685.0164 ASSY, MAGENTA/BLUE, PASTEL, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x4) Figure 3-25: VL500 Magenta/Blue (Pastel) Color Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 129: Vl500 Amber/Diffuser Color Assembly

    3-26. Item Qty. Description 10.9685.0245 LIGHT BAFFLE, TOP 21.9685.0161 ASSY, AMBER/DIFFUSER, DICRO❋TUNE 21.9685.0281 MOTOR ASSY, AMBER/DIFFUSER 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x4) Figure 3-26: VL500 Amber/Diffuser Color Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 130: Vl500 Amber/Dimmer Color Assembly

    Item Qty. Description 10.9685.0245 LIGHT BAFFLE, TOP 21.9685.0162 ASSY, AMBER/DIMMER, DICRO❋TUNE 21.9685.0281 MOTOR ASSY, AMBER/DIFFUSER 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x4) Figure 3-27: VL500 Amber/Dimmer Color Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 131: Vl500 Magenta/Blue (Arc) Color Assembly

    LIGHT BAFFLE, REAR BULKHEAD 21.9685.0160 ASSY, MAGENTA/BLUE, STANDARD, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 42.9685.0130 GLASS, UV 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x2) (x4) (x4) Figure 3-28: VL500 Magenta/Blue (Arc) Color Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 132: Vl500 Magenta/Blue (Arc Pastel) Color Assembly

    21.9685.0164 ASSY, MAGENTA/BLUE, PASTEL, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 42.9685.0130 GLASS, UV 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x2) (x4) (x4) Figure 3-29: VL500 Magenta/Blue (Arc) Color Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 133: Magenta/Blue Color Assembly

    LLUSTRATED ARTS REAKDOWN Magenta/Blue Color Assembly 21.9685.0160 Rev E (Standard DICRO*TUNE Colors) Refer to Figure 3-30. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 21.9685.0150 ASSY, BOTTOM BULKHEAD 22.9685.0122 ASSY, FILTER, MAGENTA, DICRO❋TUNE 22.9685.0123 ASSY, FILTER, BLUE, DICRO❋TUNE (x16)

  • Page 134: Magenta/Blue (Pastel) Color Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Magenta/Blue (Pastel) Color Assembly 21.9685.0164 Rev 0 (Pastel DICRO*TUNE Colors) Refer to Figure 3-31. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 21.9685.0150 ASSY, BOTTOM BULKHEAD 22.9685.0120...

  • Page 135: Amber/Diffuser Color Assembly

    LLUSTRATED ARTS REAKDOWN Amber/Diffuser Color Assembly 21.9685.0161 Rev F Refer to Figure 3-32. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 21.9685.0151 ASSY, BULKHEAD, TOP 22.9685.0124 ASSY, FILTER, AMBER, DICRO❋TUNE 22.9685.0126 ASSY, DIFFUSER PANEL (x16)

  • Page 136: Amber/Dimmer Color Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Amber/Dimmer Color Assembly 21.9685.0162 Rev E Refer to Figure 3-33. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 10.9647.0121 BAFFLE, INNER LIGHT 10.9661.0307 CARRIER, DIMMER 10.9661.0312...
  • Page 137 LLUSTRATED ARTS REAKDOWN (x16) (x16) (x16) (x16) (x16) (x16) (x16) (x16) (x16) (x16) Figure 3-33: Amber/Dimmer Color Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 138: Bottom Bulkhead Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Bottom Bulkhead Assembly 21.9685.0150 Rev C Refer to Figure 3-34. Item Qty. Description 10.9661.0315 SUPPORT, BULKHEAD 21.9685.0251 ASSY, DRIVE RING 22.9634.0119 ASSY, CENTER HUB 22.9685.0201 ASSY, GENERIC BULKHEAD 53.6682.0002 SCREW, 4-40X1/4" PPZ SEMS 55.6612.0008...
  • Page 139 LLUSTRATED ARTS REAKDOWN Bottom Bulkhead Assembly (continued) (x4) (x10) (x4) (x8) (x4) Figure 3-34: Bottom Bulkhead Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 140: Top Bulkhead Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Top Bulkhead Assembly 21.9685.0151 Rev C Refer to Figure 3-35. Item Qty. Description 10.9661.0315 SUPPORT, BULKHEAD 10.9685.0219 AUX RING, COLOR BULKHEAD 21.9685.0251 ASSY, DRIVE RING 22.9634.0120 ASSY, LIGHT BAFFLE 22.9685.0201 ASSY, GENERIC BULKHEAD 53.6682.0002...
  • Page 141 LLUSTRATED ARTS REAKDOWN Top Bulkhead Assembly (continued) (x4) (x2) (x4) (x8) (x10) (x4) (x4) Figure 3-35: Top Bulkhead Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 142: Drive Ring Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Drive Ring Assembly 21.9685.0251 Rev B Refer to Figure 3-37. Item Qty. Description 10.9634.0105 LINK, SWIVEL 10.9685.7240 ROLLER, DRIVE RING 22.9685.0238 RING, DRIVE 53.5554.0875 SCREW, 4-40X7/8" SET SS FLAT POINT 53.6659.0013 SCREW, 2-56X1/8" PPB 55.6603.0001...

  • Page 143: Magenta/Blue Color Motor Assembly

    10.9634.0075 HEAT SHIELD, MAGENTA/BLUE 44.9685.0230 MOTOR, LINEAR, 0.002"/STEP 53.6520.0001 SCREW, 4-40X3/8" PPZ 53.6682.0002 SCREW, 4-40X1/4" PPZ SEMS 54.1217.0004 LINK, VL500 ACTUATOR-DRIVE RING (x3) Actuator Screw (x4) (x2) (x2) Note: Versilube Silicon Grease (G321) is used to lubricate the actuator screw.

  • Page 144: Amber/Diffuser Color Motor Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Amber/Diffuser Color Motor Assembly 21.9685.0281 Rev A Refer to Figure 3-37. Item Qty. Description 10.9634.0061 ACTUATOR MOUNT, VL500 10.9634.0074 HEAT SHIELD, AMBER/DIFFUSER 44.9685.0230 MOTOR, LINEAR, 0.002"/STEP 53.6520.0001 SCREW, 4-40X3/8" PPZ 53.6682.0002 SCREW, 4-40X1/4" PPZ SEMS 54.1217.0004...

  • Page 145: Yoke Assembly

    3-39, Figure 3-40. Item Qty. Description 10.9685.0534 COVER, PAN TUBE 10.9685.0537 PLATE, MOUNTING, LAMP POWER PIGTAIL (VL500 ONLY) 10.9685.0538 BEZEL, LAMP POWER PIGTAIL (VL500 ONLY) 10.9685.0560 YOKE LEG, TILT SIDE 10.9685.0561 YOKE LEG, DIMMER SIDE 10.9685.0562 PLATE, TILT MOTOR, SLIDE 10.9685.0596...
  • Page 146 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Item Qty. Description 53.6519.0001 SCREW, 4-40X5/8" PPZ 53.6521.0001 SCREW, 8-32X1/2" PPB 53.6526.0002 SCREW, 6-32X5/8" PPZ TYPE F 53.6546.0003 SCREW, 8-32X7/16" PPZ 53.6552.0002 SCREW, 8-32X1/2" PFB 53.6559.0002 SCREW, 4-40X1/4" PFB 53.6606.0001 SCREW, 4-40X1/2" PFB 53.6608.0750...
  • Page 147 LLUSTRATED ARTS REAKDOWN VL500 Yoke Assembly (continued) (x6) (x2) (x2) (x4) (VL500A) (VL500D) (x4) (x4) (x2) (x2) (x4) (x2) Figure 3-39: VL500 Yoke Assembly (VL500/VL500D/VL500A) 02.96 85.001 0 0 17-July-2006...
  • Page 148 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Yoke Assembly (continued) (x4) (x4) (x4) (x4) (x6) (x3) (x3) (x4) (x12) (x6) Figure 3-40: VL500 Yoke Assembly (VL500/VL500D/VL500A) 17-July-2006 02 .9 685.00 10 0...

  • Page 149: Vl500 80V Yoke Assembly

    80V SURGE PROTECTOR, VL500 (NOT SHOWN) 25.9685.0756 CABLE ASSY, AC INPUT 25.9685.0770 DISPLAY CABLE RECEPTACLE, BLACK 25.9685.0792 CABLE ASSY, MAIN HARNESS, 80V, VL500 (NOT SHOWN) 28.9685.0999 KIT, EXTRA US HARDWARE (NOT SHOWN) 51-0541 SCREW, #4X3/8" H/L PN BLK ZN 52.8295.0002 TERMINAL BLOCK, 300V 12 AWG 20A 2-POS 53.2001.0003...
  • Page 150 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Item Qty. Description 54.2065.0001 BELT, TIMING, S2M 252 GROOVE 55.2203.0001 SCREW, 4-40X1/4" PPZ 55.3301.0008 WASHER, #8 FLAT SS 55.3301.0010 WASHER, #10 FLAT 55.6543.0001 GROMMET STRIP, SERRATED, 0.062 55.6568.0056 SPRING, CPRSN, 0.600 OD, 0.080 WIR 55.6669.0005...
  • Page 151 LLUSTRATED ARTS REAKDOWN VL500 80V Yoke Assembly (continued) (x6) (x4) (x2) (x4) (x4) (x2) (x2) (x2) (x2) Figure 3-41: VL500 80V Yoke Assembly 02.96 85.001 0 0 17-July-2006...
  • Page 152 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Yoke Assembly (continued) (x4) (x4) (x4) (x6) (x12) (x6) Figure 3-42: VL500 80V Yoke Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 153: Vl500 Extra Hardware Kit

    BAG, 4-MIL X 2" X 3", ZIP PRESS POLYETHYLENE 53.6008.0001 SCREW, 6-32X3/8" PFB 53.6523.0013 SCREW, 6-32X3/8" PTB 53.6558.0001 SCREW, 6-32X3/8" PPZ 53.6558.0009 SCREW, 6-32X3/8" PPZ SEMS 53.6558.0010 SCREW, 6-32X1/4" PPZ SEMS (x4) (x4) (x4) (x4) (x4) Figure 3-43: VL500 US Extra Hardware Kit 02.96 85.001 0 0 17-July-2006...

  • Page 154: Vl500 Pan/Tilt Motor Assembly

    MOTOR, 3-PHASE SZ 23 HIGH TORQUE 53.2200.0008 NUT, 8-32 KEPS SS 53.6558.0001 SCREW, 6-32X3/8" PPZ 53.6575.0004 SCREW, 8-32X5/8" PPZ 55.6627.0001 WASHER, #6 SPLIT LOCK (x2) (x2) (x4) (x4) Figure 3-44: VL500 Pan/Tilt Motor Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 155: Vl500 Mcb/Fan Assembly

    SEAL, AIR 23.9685.0782 ASSY, FAN, MCB 24.9685.0730 MCB, VL500 53.2200.0004 NUT, 4-40 KEPS SS 53.6556.0001 SCREW, 4-40X3/4" PPZ 53.6592.0001 SCREW, 4-40X1/2" PPB 55.6537.0001 WASHER, #4 LOCK INTERNAL TOOTH (x3) (x2) (x2) Figure 3-45: VL500 MCB/Fan Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 156: Mcb Fan Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL MCB Fan Assembly 23.9685.0782 Rev 0 Refer to Figure 3-44. Item Qty. Description 40.7113.0007 FAN, 12VDC, 30X10 MM, 3.3CFM 52.6450.0002 CONNECTOR, MTA 100 IDC 2-POS, 28 AWG Pin 2 (Black) Pin 1 (Red)

  • Page 157: Yoke Crossmember Assembly

    ASSY, LOWER CROSSMEMBER 21.9685.0513 ASSY, UPPER CROSSMEMBER 21.9685.0535 ASSY, PAN TUBE 53.6552.0002 SCREW, 8-32X1/2" PFB 53.6667.0005 SCREW, 10-32X3/8" SET CUP POINT 54.1206.0014 RING, RETAINING 1.375" SHAFT (x4) (x4) (x2) Figure 3-47: Yoke Crossmember Assembly (VL500/VL500D/VL500A) 02.96 85.001 0 0 17-July-2006...

  • Page 158: Yoke Crossmember Assembly (Vl500 80V)

    ASSY, UPPER CROSSMEMBER 21.9685.0536 ASSY, PAN TUBE, VL500 80V 53.6552.0002 SCREW, 8-32X1/2" PFB 53.6667.0005 SCREW, 10-32X3/8" SET CUP POINT 54.1206.0014 RING, RETAINING 1.375" SHAFT (x4) (x4) (x2) Figure 3-48: Yoke Crossmember Assembly (VL500 80V) 17-July-2006 02 .9 685.00 10 0...

  • Page 159: Lower Crossmember Assembly

    LLUSTRATED ARTS REAKDOWN Lower Crossmember Assembly 21.9685.0512 Rev J Refer to Figure 3-49. Item Qty. Description 10.9685.0509 LOWER CROSSMEMBER 10.9685.0522 PLATE, PAN LOCK 10.9685.0527 WASHER, CENTERING, STEP 10.9685.0533 LANYARD, SAFETY 53.2001.0003 NUT, 10-32 NYLON INSERT 53.2019.0004 NUT, 3/8-16 HEX 53.2020.0001 NUT, 1/4X20 HEX STL ZINC PLTD 53.6539.0001 WASHER, 3/8"...
  • Page 160 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lower Crossmember Assembly (continued) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) Figure 3-49: Lower Crossmember Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 161: Upper Crossmember Assembly

    LLUSTRATED ARTS REAKDOWN Upper Crossmember Assembly 21.9685.0513 Rev G Refer to Figure 3-49. Item Qty. Description 10.9685.0510 UPPER CROSSMEMBER 10.9685.0527 WASHER, CENTERING, STEP 53.2020.0001 NUT, 1/4X20 HEX STL ZINC PLTD 54.1255.0001 ASSY, BEARING/HOUSING 55.6549.0001 WASHER, 1/4" SPLIT LOCK (x2) (x2) (x2) Figure 3-50: Upper Crossmember Assembly 02.96 85.001 0 0...

  • Page 162: Pan Tube Assembly

    Refer to Figure 3-51. Item Qty. Description 10.9685.0521 PULLEY, DRIVEN, PAN/TILT 10.9685.0531 PAN TUBE 10.9685.0532 PAN PULLEY SPACER 53.2200.0006 NUT, 6-32 KEPS SS 53.6608.0750 SCREW, 6-32X3/4" PFB (x2) (x4) Figure 3-51: Pan Tube Assembly (VL500/VL500D/VL500A) 17-July-2006 02 .9 685.00 10 0...

  • Page 163: Pan Tube Assembly

    3-52. Item Qty. Description 10.9685.0521 PULLEY, DRIVEN, PAN/TILT 10.9685.0532 PAN PULLEY SPACER 12.9685.0553 PAN TUBE, 80V 53.2200.0006 NUT, 6-32 KEPS SS 53.6608.0750 SCREW, 6-32X3/4" PFB (x2) (x4) Figure 3-52: 80V Pan Tube Assembly (VL500 80V) 02.96 85.001 0 0 17-July-2006...

  • Page 164: Dmx Input Pcb Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL DMX Input PCB Assembly 24.9663.1895 Rev A Refer to Figure 3-53. Item Qty. Description 11.9663.1895 PCB, DMX INPUT 35-0053 DIODE, ZENER, 6.2V 1W SM (NOT SHOWN) D1, D2 52.6259.0001 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0005...

  • Page 165: Vl500 Main Control Board Pcb Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Main Control Board PCB Assembly 24.9685.0730 Rev B Refer to Figure 3-54 Item Description Ref. 10-0207 RESISTOR, 47K, 1/10W, 5% SM 0805 R167, R168 10-0211 RESISTOR, 100K, 1/10W, 5% SM 0805 R144 10-0269 RESISTOR, 100, 1/10W, 5% SM 0805...
  • Page 166 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Item Description Ref. 60.1161.7503 RES, 1/16W 1% 7.50 K CHIP THK FLM SMT0402 R89, R90, R95, R96, R110, R111, R114, R115, R123, R124, R126, R127, R134, R135, R137, R138 60.1165.1002 RES, 1/16W 5% 100 OHM CHIP THK FLM SMT0402...
  • Page 167 LLUSTRATED ARTS REAKDOWN Item Description Ref. 62.4240.0103 CAP, .01UF 25V 10% CER CHIP SUR MT X7R EIA0603 C13-17, C24-25, C29, C62, C66, C78, C82, C101, C103, C110, C112 62.4240.0104 CAP, .1UF 25V 10% CER CHIP SUR MT X7R EIA0603 C18-23, C26, 27, C30-42, C131 62.4240.0223 CAP, .022UF 25V 10% CER CHIP SUR MT X7R EIA0603...
  • Page 168 IC, CYCLONE EP1C3T144 TQFP-144 88.8145.0001 LED, REVERSE MOUNT RED SMT 88.8145.0002 LED, REVERSE MOUNT GREEN SMT D3-4 88.8145.0003 LED, REVERSE MOUNT YELLOW SMT Top Side Bottom Side Figure 3-54: VL500 Main Control Board PCB Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 169: Incandescent Power Input Cable Assembly

    HEATSHRINK, 3/16" CLEAR KYNAR VDE UL 600V 150DEG C 55.2268.0500 0.13 HEATSHRINK, 1/2" CLEAR KYNAR VDE UL 600V 150DEG C 73.9636.0153 CORDAGE, 1.5/3 750V 60C EURO BLK HD-22 11MMOD GRN/YEL Figure 3-55: Incandescent Power Input Cable Assembly (VL500 Only) 02.96 85.001 0 0 17-July-2006...

  • Page 170: 80V Lvs Ac Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 80V LVS AC Cable Assembly 25.9685.0742 Rev 0 Refer to Figure 3-56. Item Qty. Description 52.6264.0004 CONN HOUSING, 3-POS SL156 W/ RAMP NO TABS 52.8317.0002 CONTACT, SL156 24-18AWG 73.6018.0002 0.71 WIRE, 18 AWG 600V 105DEGC PVC RED UL1015 73.6018.0010...

  • Page 171: 80V Surge Protector Cable Assembly

    LLUSTRATED ARTS REAKDOWN 80V Surge Protector Cable Assembly 25.9685.0746 Rev 0 Refer to Figure 3-57. Item Qty. Description 33-0441 MOV, 430V 6500A 20MM ZNR 52.8231.0005 TERM RING, #6 BLUE 16-14 AWG REEL PIDG 55.2198.0001 0.08 HEATSRINK, 1/8" BLACK 55.2199.0001 0.13 HEATSRINK, 1/16"...

  • Page 172: Vl500 Motor Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Motor Cable Assembly 25.9685.0753 Rev B Refer to Figure 3-58. Item Qty. Description 52.6224.1034 COVER, FRONT 34-POS MT LATCHING 52.6224.2034 COVER, BACK 34-POS MT 52.6610.0034 CONN, HOUSING 34-POS DBL ROW UNLOADED 52.6694.0001 CRIMP, TERMINAL WIRE TO WIRE FEMALE 2MM 28-24 AWG 52.6696.0001...
  • Page 173 LLUSTRATED ARTS REAKDOWN VL500 Motor Cable Assembly (continued) 4 (x4), 5 1, 2, 3, 6 4 (x4), 5 4 (x4), 5 (x2) 4 (x4), 5 Figure 3-58: VL500 Motor Cable Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 174: Relay To Ignitor Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Relay to Ignitor Cable Assembly 25.9685.0755 Rev B Refer to Figure 3-59. Item Qty. Description 52.8271.0005 RECPT, FASTON 1/4" 16-14 AWG INSULATED (REEL) 55.2186.0001 CABLE TIE, 0.10"X4" SMALL 73.6014.0012 0.29 WIRE, 14 AWG 600V 200DEGC FEP BLACK STRAND 168/36 0.104 DIA 73.6014.0013...

  • Page 175: Vl500 Ac Input Cable Assembly

    WIRE, 14 AWG 600V 105DEGC PVC GRN UL1015 73.6014.0009 0.33 WIRE, 14 AWG 600V 105DEGC PVC WHT UL1015 73.6014.0010 0.33 WIRE, 14 AWG 600V 105DEGC PVC BLK UL1015 (x3) Figure 3-60: VL500 AC Input Cable Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 176: Vl500 Arc Ballast Input Cable Assembly

    WIRE, 14 AWG 600V 105DEGC PVC GRN UL1015 73.6014.0009 0.75 WIRE, 14 AWG 600V 105DEGC PVC WHT UL1015 73.6014.0010 0.75 WIRE, 14 AWG 600V 105DEGC PVC BLK UL1015 (x7) 11 9 (x3) Figure 3-61: VL500 Arc Ballast Input Cable Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 177: Vl500 Head Grounding Cable Assembly

    Figure 3-62. Item Qty. Description 52.8231.0000 TERM, RING #6 RED 22-16 AWG INSUL REEL 73.6014.0011 1.33 WIRE, 14 AWG 600V 200DEGC FEP GRN STRND 168/36 0.104 DIA (x2) Figure 3-62: VL500 Head Earthing Cable Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 178: Vl500 Ignitor To Socket Cable Assembly

    SLEEVING, FIBERGLASS 0.133" ID 55.6699.0010 1.33 SLEEVING, 5/16" NOM. DIA. WOVEN POLY, ROUNDIT 2000 73.3517.0001 4.00 WIRE, 14 AWG 5KV 200DEGC SILICON 7X24/36 STRAND (x2) (2 pl) Figure 3-63: VL500 Iginitor to Socket Cable Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 179: Vl500 Arc Ballast Interconnect Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Arc Ballast Interconnect Cable Assembly 25.9685.0767 Rev B Refer to Figure 3-64. Item Qty. Description 52.6400.0020 PLUG, 17-14 REV SEX CPC 600V KEY A 52.6400.0120 PLUG, 17-9 REV SEX CPC 600V KEY A 52.6431.0002 BACKSHELL, CPC17 NYLON 0.300-0.525 CBL RNG 52.8201.0005...
  • Page 180 NEUTRAL BLK/22 AWG DATA WHT/22 AWG DATA RED/22 AWG DATA BLK/22 AWG DATA RED/22 AWG DATA OPEN ORN/14 AWG LAMP POWER OPEN VIOL14 AWG LAMP POWER Figure 3-64: VL500 Arc Ballast Interconnect Cable Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 181: Vl500 Display (Remote) Cable Assembly

    CRIMP TERM, WIRE TO WIRE, MALE 52.6696.0003 PLUG, WIRE TO WIRE, 4-POS 53.6501.0002 CONN, MINI XLR, 4-PIN, PANEL MOUNT 73.2326.0123 0.25 WIRE, 26 AWG 4-COND 300V 200DEGC (BLK-BRN-RED-ORN) UL1180 (x4) Figure 3-65: VL500 Display (Remote) Cable Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 182: Vl500 Yoke Lamp Jumper Cable Assembly

    25.9685.0776 Rev A Refer to Figure 3-66. Item Qty. Description 52.8348.0001 TAB, ULTRA-FAST 1/4" 16-14 AWG INSULATED (LOOSE) 0.13 WIRE, 14 AWG 200DEGC STRAND TEF WHT (x2) Figure 3-66: VL500 Yoke Lamp Jumper Cable Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 183: Vl500 Backcap Ground Cable Assembly

    3-62. Item Qty. Description 52.8329.0001 TERM, RING #6 RED 22-16 AWG NON-INSUL 52.8329.0003 TERM, RING #8 RED 22-16 AWG NON-INSUL 73.7130.0002 1.17 WIRE, 7/64" TUBULAR BRAID SILVER PLATED Figure 3-67: VL500 Backcap Ground Cable Assembly 02.96 85.001 0 0 17-July-2006...

  • Page 184: Vl500 Main Harness Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Main Harness Cable Assembly 25.9685.0790 Rev J (VL500 and VL500D) Refer to Figure 3-68. Item Qty. Description 25.9685.0750 CABLE ASSY, DIMMER COMM 25.9685.0752 CABLE ASSY, 24V POWER 25.9685.0758 CABLE ASSY, PAN/TILT 25.9685.0769 CABLE ASSY, DISPLAY CABLE 25.9685.0771...
  • Page 185 LLUSTRATED ARTS REAKDOWN VL500 Main Harness Cable Assembly (contin- ued) (x8) Figure 3-68: VL500 Main Harness Cable Assembly (VL500 and VL500D) 02.96 85.001 0 0 17-July-2006...

  • Page 186: Vl500 Arc Main Harness Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Arc Main Harness Cable Assembly 25.9685.0791 Rev C (VL500A) Refer to Figure 3-68. Item Qty. Description 25.9685.0752 CABLE ASSY, 24V POWER 25.9685.0758 CABLE ASSY, PAN/TILT 25.9685.0772 CABLE ASSY, YOKE GROUND 25.9685.0773 CABLE ASSY, LVS AC 25.9685.0778...
  • Page 187 LLUSTRATED ARTS REAKDOWN VL500 Arc Main Harness Cable Assembly (con- tinued) (x8) Figure 3-69: VL500 Arc Main Harness Cable Assembly (VL500A) 02.96 85.001 0 0 17-July-2006...

  • Page 188: Vl500 80V Main Harness Cable Assembly

    25.9685.0792 Rev C (VL500 80V) Refer to Figure 3-68. Item Qty. Description 25.9678.0743 CABLE ASSY, 80V DIMMER COMM, VL500 80V 25.9685.0744 CABLE ASSY, 24V POWER, VL500 80V 25.9685.0745 CABLE ASSY, 80V YOKE LAMP WIRES 25.9685.0758 CABLE ASSY, PAN/TILT 25.9685.0772 CABLE ASSY, YOKE GROUND 25.9685.0788...
  • Page 189 LLUSTRATED ARTS REAKDOWN VL500 80V Main Harness Cable Assembly (con- tinued) (x8) Figure 3-70: VL500 80V Main Harness Cable Assembly (VL500 80V) 02.96 85.001 0 0 17-July-2006...
  • Page 190 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 17-July-2006 02 .9 685.00 10 0...

  • Page 191: Arc Ballast Assembly

    LLUSTRATED ARTS REAKDOWN Arc Ballast Assembly VL500 Arc Ballast Assembly 21.9685.0800 Rev G (625W - VL500A 575W Arc) 21.9685.0802 Rev G (700W - VL500A 700W Arc) Refer to Figure 3-71. Item Qty. Description 04.9685.0940 LABEL, PRODUCT, VL500APS-575W (575W ARC ONLY) 04.9685.0941...
  • Page 192 VL500 Arc Ballast Assembly (continued) (575W Only) (x4) (700W Only) (x4) (x4) (x5) (x16) (x4) (575W Only) (700W Only) (x4) (x4) (x2) (x12) (575W Only) (700W Only) (575W Only) (700W Only) Figure 3-71: VL500 Arc Ballast Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 193: Ballast I/O Cable Assembly

    LLUSTRATED ARTS REAKDOWN Ballast I/O Cable Assembly 25.9685.0807 Rev A Refer to Figure 3-72. Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3-POS 52.6396.2904 RECEPT, 4-POS MTA100 W/POL RED 52.6400.0111 RECEPT, 17-9 STD SEX CPC 600V FLANGE 52.8201.0005 PIN, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA 52.8202.0001 PIN, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA 52.8202.0011...
  • Page 194 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Ballast I/O Cable Assembly (continued) (x3) (x5) 12, 13, 14 (x2) (x3) (x5) Figure 3-72: Ballast I/O Cable Assembly 17-July-2006 02 .9 685.00 10 0...

  • Page 195: Vl500 Wiring And Schematic Diagrams

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Wiring and Schematic Diagrams VL500 Wiring Diagram - Sheet 1 of 1 17-July-2006 02.96 85.001 0 0...

  • Page 196: Dmx Input Pcb (24.9663.1895) Schematic

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE DMX Input PCB (24.9663.1895) Schematic ECO # ECO # ECO # DESCRIPTION DESCRIPTION DESCRIPTION APPROVED APPROVED APPROVED REV. NO REV. NO REV. NO DATE DATE DATE S05-945 RELEASE 12/14/05 SHIELD DMX/VL_IN-...

  • Page 197: Vl500 Controller Pcb (24.9685.0730) Schematic - Sheet 1 Of 6

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Controller PCB (24.9685.0730) Schematic - Sheet 1 of 6 REV. NO REV. NO REV. NO ECO # ECO # ECO # DESCRIPTION DESCRIPTION DESCRIPTION DATE DATE DATE APPROVED APPROVED APPROVED...

  • Page 198: Vl500 Controller Pcb (24.9685.0730) Schematic - Sheet 2 Of 6

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Controller PCB (24.9685.0730) Schematic - Sheet 2 of 6 D[0..31] 3/D1, 3/B1, 3/C3 +3.3V +1.8V +3.3V +3.3V +3.3V +3.3V +3.3V A[0..24] CS_MTR- 3/D3, 3/D1, 3/C1 2/B3, 3/B3 +3.3V CS_UART- 2/B3, 3/C1 +3.3V...

  • Page 199: Vl500 Controller Pcb (24.9685.0730) Schematic - Sheet 3 Of 6

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Controller PCB (24.9685.0730) Schematic - Sheet 3 of 6 +3.3V +3.3V +3.3V +1.5V +1.5V +1.5V +24V +3.3V +1.5V R144 R144 2/C3 A[0..24] 2/D1 R145 R145 INIT_DONE 2/B5, 2/D4, 2/C3 PWM_PH_8...

  • Page 200: Vl500 Controller Pcb (24.9685.0730) Schematic - Sheet 4 Of 6

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Controller PCB (24.9685.0730) Schematic - Sheet 4 of 6 18V BATT ISO_VCC ISO_VCC ISO_VCC 18V BATT TX_EN_C- 3/C1 U17C U17C ISO_VCC +3.3V +3.3V +3.3V +24V ISO_VCC ISO_VCC +24V TXDB 2/B4...

  • Page 201: Vl500 Controller Pcb (24.9685.0730) Schematic - Sheet 5 Of 6

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Controller PCB (24.9685.0730) Schematic - Sheet 5 of 6 +24V +24V C117 C117 C118 C118 SPARE MAGENTA (DO NOT STUFF) PWM_PH_7 MAGENTA_OUT1A SPARE_PWM_PH_11 SPARE_OUT1A 3/C1 6/D5, 6/A3 3/B1 6/A3, 6/D5...

  • Page 202: Vl500 Controller Pcb (24.9685.0730) Schematic - Sheet 6 Of 6

    ® VARI❋LITE - VL500™ L UMINAIRE ERVICE ANUAL EFERENCE VL500 Controller PCB (24.9685.0730) Schematic - Sheet 6 of 6 +24V +24V C100 C100 C120 C120 AMBER R122 R122 MAGENTA_OUT1A 6/A3, 5/D4 MAGENTA_OUT1B 6/A4, 5/D4 AMBER_OUT1A PWM_PH_1 3/A1 6/A3, 6/C5 R123...

  • Page 203: Appendix A. Technical Bulletins

    PPENDIX Technical Bulletins VL500 Wash Luminaire Technical Bulletins The following table identifies the current technical bulletins associated with the VL500 wash luminaire. If applicable, these improvements have been incorporated into this manual. Technical Bulletin Description S5K-001 Series 500™ Yoke Leg/Cross Member Screw Torquing Procedure Technical Bulletins, Technical Notices, Software Updates, and support, and other information is available online at http://www.vari-lite.com/Support/.
  • Page 204 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 17-July-2006 02 .9 685.00 10 0...
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