Vari Lite VL2500 Service Manual
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Vari Lite VL2500 Service Manual

Wash luminaire
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Summary of Contents for Vari Lite VL2500

  • Page 2 Plus, mini-Artisan Plus, VL2 , and VLD trademarks owned by Genlyte Thomas Group LLC. and are registered in the United States and other countries. VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL2500™, VL3000™, ™ ™ ™ ™...
  • Page 3 OREWORD How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548) or customerservice@genlyte.com and request a Return Material Authorization (RMA) for warranty service.

  • Page 4: Safety Notice

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
  • Page 5 OREWORD products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product. WARNING advising of potential injury or death to persons. GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELEC- TRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND INJURY TO PERSONS CAN BE FOUND BELOW.
  • Page 6 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired.
  • Page 7 OREWORD Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin.
  • Page 8 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1.
  • Page 9 OREWORD Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 10 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 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 OREWORD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto.
  • Page 12 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación UV. NO mire directamente a la lámpara.
  • Page 13 AFETY OTICE APANESE Ô ç æ Ð á¿  Á 'ê”ùÕ Q>X^Åî éQ>X^é_ æ Ô±Žã[ ÔôáÅ\úÊÛп•ù Ú”sÙæ  ÌÚö ÔÙæê”Ôôáé çP Å î TæÐçÒáÞ ÒáÊÛп• Q>X^âꔏé_ Qo" ö Òá¿ùÔ• æ à ¾ ǽùÔ• qŠPæßåÇ ¾ ǽùÔ• õ” 4” |¿æ»Ô é:´”ÅîqŠP ËÚüé 屎æß¿áꔏé[ Å\úÊÛп• ËÚü...
  • Page 14 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL æÐ Ðå¿Úü Ef; Êê” Õ 2J \fJ ª 1. VARI❋LITE® Òá¿ùÔ•\fJ ÔÎãê ÌáÊÛп• _f-ùÚê*o^< Õæ P.Ôã âÔ•_f-” *o^<” ¹ ê”íî ÿ ¿ ÞÆÈ åäæ”Ø 2 Ç å ÁæåÞÚ  ÃÁæÒùÔ• 2 ËÚü Ef; ÇP.Òá¿ãÈê”Ø ¥Ç²ÊåùÔ•²ÊåÞÚ...

  • Page 15: Table Of Contents

    ABLE OF ONTENTS Table of Contents About This Manual ...................... 1 Additional Documentation................... 1 Customer Service ......................2 Technical Bulletins / Technical Notices............... 2 Chapter 1. Description Features Overview........................4 Features ......................... 4 Major Components External Components....................5 Menu Display ......................6 Menu Controls.......................
  • Page 16 Chapter 3. Illustrated Parts Breakdown Drawing Tree VL2500 Wash Luminaire ................... 42 Top Assembly VL2500 Wash Included Items Kit ................44 VL2500 Wash Luminaire ................... 45 VL2500 Generic Luminaire ..................47 Front Wash Assembly....................49 Concave/Diffuser Front Lens Assembly ..............51 Convex Lens Assembly....................
  • Page 17 Display Cable Assembly..................126 Ballast to Controller Cable Assembly..............127 Lamp Supply to Relay Cable Assembly ..............128 DC Output Cable Assembly..................129 VL2500 Wash Luminaire Schematics 700W Ballast Schematic ..................131 Ballast Rider Schematic................... 133 VL2500 Luminaire Schematic................. 134 Main Control Board (MCB) Schematic..............
  • Page 18 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes xvii i 09-December-2004 0 2.9676 .0022 0...

  • Page 19: About This Manual

    A support web page for VL2500 series luminaires is available at www.vari-lite.com (follow the Support link). A separate users manual is available for installation and operation of the VL2500 wash luminaire. This manual is available in both printed and electronic (PDF) formats. VL2500™ Wash Luminaire Users Manual (02.9676.0021).

  • Page 20: Customer Service

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

  • Page 21: Chapter 1. Description

    HAPTER Description This chapter provides an overview of luminaire features, components and operations. • Features • Major Components • Principles of Operation 02.9 676.00 22 0 09-December-2004...

  • Page 22: Features Overview

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

  • Page 23: Major Components

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

  • Page 24: Menu Display

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Menu Display The menu system is a programmable set of commands used to configure, address, operate, and test the luminaire. The menu system is controlled at the Menu Display available at the enclosure input panel.

  • Page 25: Head Components

    ESCRIPTION AJOR OMPONENTS Head Components The following illustration shows the major sub-assemblies which are located in the luminaire head assembly. (Yoke and enclosure not shown for clarity.) Removable Cover Dual Blade Strobe Assembly Back Cap / CYM Color/Dimmer Bulkhead Lamp Assembly Fixed Color Bulkhead Fan Assembly Removable Cover...

  • Page 26: Yoke Components

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

  • Page 27: Enclosure Components

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

  • Page 28: Principles Of Operation

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

  • Page 29: Chapter 2. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Troubleshooting • Maintenance Procedures WARNING: All maintenance procedures are to be performed with power removed from the luminaire and by a trained and qualified service technician. Never remove cover or backcap while lamp is in operation. 02.9 676.00 22 0 09-December-2004...

  • Page 30: Testing

    Testing software is available in all Series 2000 luminaires through the luminaire’s menu system TEST function. For information on specific tests and test parameters, see the VL2500 Wash Luminaire User’s Manual (VL Part no. 02.9676.0021). When running tests on multiple luminaires, a loopback connector is required at the first luminaire in the link and a male termination connector is required at the last luminaire.

  • Page 31: Troubleshooting

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

  • Page 32: Troubleshooting Guide

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

  • Page 34: Maintenance Procedures

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly. Lamp Replacement Parts: 71.2528.0700 LAMP, 700 WATT SHORT ARC WARNING: Remove power from luminaire before performing maintenance.
  • Page 35 Step 6. Align guide rods in guide holes and slide backcap into head assembly. Re- tighten captive knob. Step 7. If required, reset lamp hour counter as follows. (Refer to "Menu System" in VL2500 Wash Luminaire User’s Manual for more information.) a. Power up luminaire. b. At Menu Display, press [Menu].

  • Page 36: Align Lamp For Flat Field

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

  • Page 37: Fixed Color Bulkhead Replacement

    AINTENANCE AINTENANCE ROCEDURES Fixed Color Bulkhead Replacement Parts: 21.9676.1120 ASSY, FIXED COLOR BULKHEAD Procedure: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head cover, turn captive screws and remove cover. (It will remain attached by tether.) Figure 2-4.

  • Page 38: Standard Color Filter Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Standard Color Filter Replacement Parts: Color Filter as required To remove and replace a standard color filter: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head cover, turn two captive screws and remove cover. (It will remain attached by tether.)

  • Page 39: Strobe Bulkhead Replacement

    AINTENANCE AINTENANCE ROCEDURES Strobe Bulkhead Replacement Parts: 22.9676.0016 ASSY, STROBE BULKHEAD Procedure: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head cover, turn two captive screws and remove cover. (It will remain attached by tether.) Figure 2-6.

  • Page 40: Front Assembly Removal

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Front Assembly Removal This procedure may be necessary to gain access to other components. To remove and re-install front assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At head cover, turn two captive screws one-quarter turn and remove cover. (It will remain attached by tether.)

  • Page 41: Beam Spreader Motor Assembly Replacement

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

  • Page 42: Concave Lens Assembly Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Concave Lens Assembly Replacement Parts: 22.9671.0413 ASSY, CONCAVE LENS To remove and replace concave lens assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source.

  • Page 43: Convex Lens Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Convex Lens Assembly Replacement Parts: 22.9671.0414 ASSY, CONVEX LENS To remove and replace convex lens assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 44 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Step 5. In replacement convex lens assembly, using 1/4" Allen Wrench, adjust 8-32 X 2" screw so that screw head is nearly flush with drive bushing plate to create a .020" gap between concave and convex lens assemblies.

  • Page 45: 100Mm Condenser Lens Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES 100MM Condenser Lens Assembly Replacement Parts: 22.9671.0402 100MM CONDENSER LENS ASSEMBLY To remove and replace 100MM condenser lens assembly: WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 46 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 100MM Condenser Lens Assembly Lens Shaft (4) Wave Spring (4) Shaft Collet (4) Convex Lens Assembly Concave/Diffuser Lens Assembly Figure 2-11: 100MM Condenser Lens Assembly Replacement Step 13. Re-install convex and concave lens assemblies.

  • Page 47: Yoke Assembly

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

  • Page 48: Main Control Board (Mcb) Pcb Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Main Control Board (MCB) PCB Replacement Parts: 24.9676.0730 MCB PCB ASSY To replace an MCB PCB: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At board-side leg, remove yoke leg cover by removing four 6-32×5/16" PPB screws.

  • Page 49: Ignitor Pcb Replacement

    AINTENANCE AINTENANCE ROCEDURES Ignitor PCB Replacement Parts: 24.9661.1126 PCB ASSY, SOLID STATE IGNITOR To replace ignitor PCB: Step 1. Disconnect luminaire AC input cable from power source. Ignitor PCB Screws Yoke Leg Cover Yoke cross member Figure 2-14: Ignitor PCB Replacement Step 2.
  • Page 50 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Step 9. Remove two 1/4" hex standoffs from ignitor PCB by removing the 6-32×5/ 16" PPZ screws and #6 lock washers. Install in same place on new ignitor PCB. Figure 2-15. 6-32×5/16" #6 Lock Washer PPZ Screw 1/4"...

  • Page 51: Enclosure Assembly

    AINTENANCE AINTENANCE ROCEDURES Enclosure Assembly This section provides removal and replacement procedures for components found in the luminaire enclosure assembly. Removing Enclosure Covers To gain access to enclosure components, it will be necessary to remove the top and bottom covers. To remove and replace enclosure covers: Step 1.

  • Page 52: Vari❋Lite® - Vl2500™ Wash Luminaire Service Manual

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL CAUTION: Be careful not to damage lens during next step. Step 4. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any surface. Figure 2-17. Figure 2-17: Laying Luminaire on Its Side Step 5.

  • Page 53: Ballast Module Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Ballast Module Assembly Replacement Parts: 23.9671.1250 ASSY, BALLAST MODULE, 700W ARC To remove the ballast module assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove ballast-side and ventilation covers. Refer to “Removing Enclosure Covers”...
  • Page 54 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Step 6. At ballast, disconnect wiring: Step 7. Pull lamp wires through ferrite core. Figure 2-19. Note: Ferrite core Some components Pull lamp wires through here. not shown for clarity. Ballast Module 8-32×3/8”...

  • Page 55: Pan Motor Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Pan Motor Assembly Replacement Parts: 21.9678.0864 PAN MOTOR ASSY Procedure: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Carefully lay luminaire on its side to have access to bottom of enclosure. Step 3. At enclosure assembly, remove bottom cover. Step 4.

  • Page 56: Pan Encoder Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan Encoder Replacement Parts: 24.9678.0729 PAN ENCODER ASSY Procedure: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Carefully lay luminaire on its side to have access to bottom of enclosure.

  • Page 57: Pan Eot Sensor Replacement

    AINTENANCE AINTENANCE ROCEDURES Pan EOT Sensor Replacement Parts: 86.7002.0003 PAN EOT SENSOR ASSY Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Carefully lay luminaire on its side. Step 3. At enclosure assembly, remove bottom cover. Step 4.

  • Page 58: Power Supply (Lvs) Replacement

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Power Supply (LVS) Replacement Parts: 69.3176.0200 POWER SUPPLY (LVS) ASSY Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove top cover at power supply side.

  • Page 59: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500 Wash Luminaire. • Drawing Tree • Top Assembly • Yoke • Enclosure • Cables 02.9 676.00 22 0 09-December-2004...

  • Page 60: Drawing Tree

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Drawing Tree VL2500 Wash Luminaire VL2500 Wash Luminaire 20.9676.0002 Rev H Front Wash Assembly VL2500 Generic Luminaire 21.9676.1006 Rev A 21.9676.0010 Rev D Concave/Diffuser Front Lens Upper Enclosure Assembly Assembly 21.9676.0800 Rev E 21.9671.0492 Rev A...
  • Page 61 OT Switch to Reflector Assy. Cable Assembly DC Output Cable Assembly Assembly 25.9678.0816 Rev 0 25.9678.0821 Rev D 25.9676.0719 Rev 0 Lamp Supply to Relay Cable VL2500 Wash Included Items Kit Assembly 28.9676.0002 Rev A 25.9678.0819 Rev A 02.9 676.00 22 0 09-December-2004...

  • Page 62: Top Assembly

    TAG, LAMP NOTICE 02.8700.0001 CARD, PRODUCT REGISTRATION - 2000 SERIES (09-09-02) 02.9676.0002 UNPACK/QUICK START SHEET, VL2500 04.9676.0002 SHIPPING BOX LABELS, VL2500 WASH (not shown) 07.9676.0036 SHIPPING BOX, CARDBOARD - VL2500 08.2500.0001 CD-ROM, VL2500 LUMINAIRE 22.9661.1636 FAB ASSY, BRACKET TRUSS HOOK 71.2528.0700...

  • Page 63: Vl2500 Wash Luminaire

    CABLE ASSY, OT SWITCH TO REFLECTOR ASSY (not shown) 25.9676.1715 CABLE ASSY, COLOR / FIXED (not shown) 25.9676.1716 CABLE ASSY, OPTICS / STROBE (not shown) 28.9676.0002 INCLUDED ITEMS KIT, VL2500 LUMINAIRE (not shown) 53.2200.0006 NUT, KEPS #6-32 SS 53.6543.0001 SCREW, 6-32 X 3/8" PPB 53.6558.0009 SCREW, 6-32 X 3/8"...
  • Page 64 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL (x6) (x4) (x4) (x4) (x2) (x2) (x8) Figure 3-2: Top Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 65: Vl2500 Generic Luminaire

    HARNESS, GUARD, LEFT 21.9676.0139 ASSY, REAR HEAD 21.9676.0600 ASSY, YOKE 21.9676.0800 UPPER ENCLOSURE 24.9676.0730 ASSY, VL2500 MAIN CONTROL BOARD (MCB) 53.6505.0020 BOLT, 1/4-28 X 3/4" HX HD GRD 8 53.6517.0001 SCREW, 10-32 X 3/8" PPZ 53.6526.0001 SCREW, 6-32 X 5/8" PPZ 53.6530.0006 RIVET, POP, 1/8"...
  • Page 66 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL VL2500 Generic Luminaire (continued) (x8) (x8) (x2) (x2) (x2) (x5) (x5) (x5) (x4) (x4) (x4) (x4) Figure 3-3: VL2500 Generic Luminaire Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 67: Front Wash Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Front Wash Assembly 21.9676.1006 Rev A Refer to Figure 3-4. Item Qty. Description 10.9671.0219 LENS SHAFT 10.9671.0223 SHAFT COLLET 10.9671.0313 LENS SUPPORT ARM 10.9676.1347 WASH LENS BULKHEAD, FRONT 21.9671.0492 ASSY, CONCAVE / DIFF FRONT LENS 22.9667.0337 ASSY, 1/4 TURN MOUNTING BRACKET 22.9671.0402 100 MM CONDENSER LENS ASSY...
  • Page 68 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Front Wash Assembly (continued) (x2) (x4) (x2) (x4) (x2) (x12) (x4) (x4) (x2) (x2) (x8) (x4) (x4) Figure 3-4: Front Wash Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 69: Concave/Diffuser Front Lens Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Concave/Diffuser Front Lens Assembly 21.9671.0492 Rev A Refer to Figure 3-5. Item Qty. Description 10.9671.0409 BACK CLAMP, CONCAVE LENS 10.9671.0421 LENS GASKET 10.9671.0491 FRONT CLAMP, CONCAVE LENS 12.9671.0418 CONCAVE LENS, ARRAY SMALL MASKED 42.9671.0490 LENS, FRONT STIPPLE 53.6611.0001 SCREW, 6-32 X 1/2"...

  • Page 70: Convex Lens Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Convex Lens Assembly 22.9671.0414 Rev B Refer to Figure 3-6. Item Qty. Description 10.9671.0419 FRONT CLAMP, CONVEX LENS 10.9671.0420 BACK CLAMP, CONVEX LENS 10.9671.0421 LENS GASKET 10.9671.0463 BUSHING, CONVEX LENS SLOTTED 10.9671.0464 BUSHING, CONVEX LENS DRIVE 10.9671.0465...

  • Page 71: Top Cover Assembly

    Qty. UM. Description 06.6018.0011 0.041 VELCRO, DOUBLE HOOK, 2" BLACK ADH BACKED 07.5049.0001 LANYARD, NYLON COATED, 8" LONG 10.9676.0009 COVER, TOP VL2500 10.9676.0010 FILTER, TOP HEAD COVER 12.9676.0076 BAFFLE, RIGHT, TOP COVER 12.9676.0077 BAFFLE, LEFT, TOP COVER 53.2008.0008 PUSH NUT, #8 53.5655.0250...

  • Page 72: Bottom Cover Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Bottom Cover Assembly 22.9676.0011 Rev C Refer to Figure 3-8. Item Qty. UM. Description 10.9676.0012 COVER, BOTTOM VL2500 53.2008.0008 NUT, #8 PUSH 53.6545.0001 SCREW, 8-32 X 3/8" PPB 53.6599.0001 WASHER, #10 FLAT BLACK...

  • Page 73: Reflector Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Reflector Assembly 22.9676.1018 Rev A Refer to Figure 3-9. Item Qty. UM. Description 10.9678.0647 CLAMP, MOUNTING, REFLECTOR 12..9660.0073 ELLIPSOIDAL REFLECTOR, SMOOTH, COATED 22.9660.0338 ASSY, DISCONNECT LAMP 22.9676.0130 ASSY, REFLECTOR MOUNT 53.6599.0001 SCREW, 4-40 X 3/8" PFZ 55.6669.0016 STANDOFF, 1/4"...

  • Page 74: Back Cap Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Back Cap Assembly 22.9676.0115 Rev 0 Refer to Figure 3-10. Item Qty. Description 10.9638.0117 KNOB, KNURLED, VL6 BACK CAP/LAMP ASSY. 10.9638.0128 BRACKET, IGNITOR CABLE 10.9638.0130 SPRING, BULB WIRE SHEATH 10.9638.0164 WASHER, FELT 10.9667.0411 LAMP CARRIAGE 10.9667.0412...
  • Page 75 LLUSTRATED ARTS REAKDOWN SSEMBLY Back Cap Assembly (continued) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x4) (x2) (x2) (13.5") (x2) (9.0") Figure 3-10: Back Cap Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 76: Wash Fan Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Wash Fan Assembly 22.9676.1090 Rev C Refer to Figure 3-11. Item Qty. Description 10.9676.1068 AIR DUCT, FRONT FAN, WASH 22.9676.0091 ASSY, FAN BULKHEAD 22.9676.0095 AIR DUCT, REAR FAN 25.8007.2212 CABLE ASSY, GROUND STRAP, #6 RING 3" LG 40.7113.0002...
  • Page 77 LLUSTRATED ARTS REAKDOWN SSEMBLY Wash Fan Assembly (continued) Direction of Air Flow (x8) (x2) (x2) (x3) 20, 21, 8, 9 7, 10 (x5) Figure 3-11: Wash Fan Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 78: Wash Fixed Color Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Wash Fixed Color Assembly 21.9676.1120 Rev B Refer to Figure 3-12 Item Qty. Description 10.9671.0125 BULKHEAD, LIGHT SHIELD, COLOR 10.9676.1181 BULKHEAD, COLOR 21.9676.0119 ASSY, COLOR MOTOR 22.9673.0145 ASSY, FILTER WHEEL 25.9676.0125 CABLE ASSY, T-STAT, COLOR/GOBO (not shown) 53.2200.0004...
  • Page 79 LLUSTRATED ARTS REAKDOWN SSEMBLY Wash Fixed Color Assembly (continued) (x3) (x3) Figure 3-12: Wash Fixed Color Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 80: Crossfade Color Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Crossfade Color Assembly 21.9676.1201 Rev B Refer to Figure 3-13. Item Qty. Description 10.9676.0230.01 SPACER, COLOR WHEEL 10.9676.0230.02 SPACER, COLOR MOTOR 10.9676.0233 AFT BULKHEAD, CROSSFADE COLOR SYSTEM 10.9676.0239 SPACER, BULKHEAD, COLOR SYSTEM 10.9676.0284 SHAFT, COLOR SYSTEM 10.9678.0457.04...
  • Page 81 LLUSTRATED ARTS REAKDOWN SSEMBLY Crossfade Color Assembly (continued) (x4) (x2) (x2) (x4) (x6) (x4) (x2) Yellow (x2) Cyan Cyan Magenta Dimmer (x2) (x6) (x6) Dimmer Yellow Cyan Magenta Figure 3-13: Crossfade Color Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 82: Sensor Pcb Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Sensor PCB Assembly 24.9638.0113 Rev B Refer to Figure 3-14. Item Qty. Description 11.9638.0114 PCB, SENSOR, VL6 52.6229.0001 HEADER, 3POS MTA FRIC LOK STRT POST 60.1429.1503 RES, 1/4W 5% 150.0 OHM CF 86.7004.0001...

  • Page 83: Color Motor Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Color Motor Assembly 21.9676.0119 Rev 0 Refer to Figure 3-15. Item Qty. Description 10.9621.0097 STABILIZER, STEPPER, GOBO WHEEL 10.9667.0120 COLOR MOTOR BULKHEAD 24.9638.0113 PCB ASSY, SENSOR, VL6 44.9676.0116 MOTOR, GOBO/COLOR WHEEL 53.6597.0001 SCREW, 4-40 X 3/16" PPZ 53.6599.0001 SCREW, 4-40 X 3/8"...

  • Page 84: Filter Wheel Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Filter Wheel Assembly 22.9673.0145 Rev A Refer to Figure 3-16. Item Qty. Description 22.9673.9143 ASSY, FILTER WHEEL HUB AND CLIP 10.9638.0122 CLIP, WHEEL RETAINER 22.9673.9142 ASSY, COLOR WHEEL MARKED 53.6530.0002 RIVET, 1/8" OD POP .-63-.125 GR. LENGTH 41.6006.0020...

  • Page 85: Strobe Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Strobe Assembly 22.9676.0016 Rev E Refer to Figure 3-17. Item Qty. Description 10.9676.0043 BULKHEAD, STROBE MOUNTING 10.9676.0019 STROBE BLADE, DIMPLED 10.9676.0060 MOUNTING COLLAR, STROBE BLADE 10.9676.0061 STABLIZER, STROBE MOTOR 10.9676.0069 MOUNTING PLATE, STROBE MOTOR 10.9678.0491 BUMPER STOP, STROBE 44.9678.0455 MOTOR, COLOR 53.2200.0006...
  • Page 86 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Strobe Assembly (continued) (x2) (x2) (x4) (x4) (x2) (x2) (x6) (x2) (x2) (x4) (x2) (x2) (x2) (x8) Black Side Note connector orientation on motors Figure 3-17: Strobe Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 87: Uv / Ir Window Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY UV / IR Window Assembly 22.9676.0140 Rev B Refer to Figure 3-18. Item Qty. Description 10.9676.0058 UV / IR FRAME 41.9678.0608 UV / IR FILTER, 3.00" X 3.00" 53.5504.0187 SCREW, 4-40 X 3/16" PPSS 55.6569.0001 WASHER, #2 LOCK 74.1089.0001 THERMAL SWITCH, 15 AMP 295 DEG C OPEN Figure 3-18: UV / IR Window Assembly...

  • Page 88: Vl2500 Main Control Board Pcb Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL VL2500 Main Control Board PCB Assembly 24.9676.0730 Rev B Refer to Figure 3-19 Item Description Ref. 10-0255 RES, 0 OHM, 1/10W, SMT0805 R298 10.9661.1275 HEATSINK, MAIN CONTROLLER 10.9676.0735 HEATSINK, CONTROLLER, PAN/TILT DRIVERS 10.9678.0885 KIT, THERMAL TRANSFER MAIN CONTROLLER 11.9676.0730...
  • Page 89 LLUSTRATED ARTS REAKDOWN SSEMBLY Item Description Ref. 60.1165.1004 RES, 1/16W 5% 10 K CHIP THK FLM SMT0402 R16, R19, R24, R25, R94 R96, R113, R115, R124, R126, R135, R137, R146, R148, R159, R161, R165, R167, R172, R174, R178, R180, R213, R215, R224, R226, R235, R237, R246 60.1165.1803 RES, 1/16W 5% 1.8 K CHIP THK FLM SMT0402 R4, R6...
  • Page 90 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Item Description Ref. C39, C42, C47-C50, C52, C56, C58, C60, C63-C68, C92, C101, C110, C119, C128, C136, C146, C155, C164, C173, C182, C191, C200 62.4240.0223 CAP, .022UF 25V 10% CER CHIP SUR MT X7R EIA0603...
  • Page 91 LLUSTRATED ARTS REAKDOWN SSEMBLY Item Description Ref. 85.3773.0001 IC, STEPMOTOR DRIVER U27-U30, U32-U40 85.5134.0001 IC, SN75LBC180D LOW-POWER DIFF LINE DRVR & RCVR PAIRS 85.5164.0001 IC, L6234PD THREE PHASE MOTOR DRIVER U11, U31 85.5168.0001 IC, DS1834AS DUAL RESET MONITOR W/ PUSHBUTTON SMT 86.6105.0001 IC, HCPL-0600 OPTO COUPLER SMD U2, U3, U5, U7...
  • Page 92 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL VL2500 Main Control Board PCB Assy (cont.) Bottom Side Top Side Figure 3-19: VL2500 Main Control Board PCB Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 93: Yoke

    LLUSTRATED ARTS REAKDOWN Yoke Yoke Assembly 21.9676.0600 Rev C Refer to Figure 3-20. Item Qty. Description 22.9676.0605 ASSY, YOKE STRUCTURE ASSY, FAN 22.9676.0609 ASSY, TILT MOTOR 22.9676.0610 ASSY, ELEC., RELAY 23.9650.3327 24.9661.1126 PCB ASSY, SOLID STATE IGNITOR 25.9667.0030 CABLE ASSY, IGNITOR TO RELAY (not shown) SCREW, 6-32 X 5/16"...
  • Page 94 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Yoke Assembly (continued) (x4) (x4) (x2) (x2) (x2) (x4) (x2) (x2) (x2) (x4) (x3) Figure 3-20: Yoke Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 95: Ignitor Pcb Assembly

    LLUSTRATED ARTS REAKDOWN Ignitor PCB Assembly 24.9661.1126 Rev B Refer to Figure 3-21. Item Qty. Description 11.9661.1126 PCB, IGNITOR 52.8218.0002 TERM, PC VERT MNT 6-32 SCREW 15A J1-J4 60.1230.6493 RESISITOR, 1/4W 1% 6.49K OHM 60.1420.5104 RESISITOR, 1/4W 5% 51.0K OHM 60.1421.1205 RESISITOR, 1/4W 5% 120.0K OHM 60.1422.2001...
  • Page 96 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Ignitor PCB Assembly (continued) Figure 3-21: Ignitor PCB Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 97: Tilt Motor Assembly

    LLUSTRATED ARTS REAKDOWN Tilt Motor Assembly 22.9676.0610 Rev 0 Refer to Figure 3-22. Item Qty. Description 10.9661.1298 PLATE, TENSION ADJUST, PAN MOTOR 22.9661.0608 ASSY, DRIVE PULLEY - 10.9661.0640 CODEWHEEL, 90 COUNT - 10.9661.0649 TIMING PULLEY, 2MM GT, 17 TOOTH - 53.5561.0250 SCREW, 6-40 X 1/4"...
  • Page 98 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Tilt Motor Assembly (continued) (x2) (x2) (x2) (x2) (x2) (x2) (x4) Figure 3-22: Tilt Motor Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 99: Pan/Tilt Encoder Pcb Assembly

    LLUSTRATED ARTS REAKDOWN Pan/Tilt Encoder PCB Assembly 24.9661.0629 Rev 0 Refer to Figure 3-23. Item Qty. Description Ref. 11.9661.0629 PCB, ENCODER SENSOR 52.6613.0005 HEADER, 5POS SGL ROW SHROUDED LATCHING 52.6613.0006 HEADER, 6POS SGL ROW SHROUDED LATCHING 60.9460.1802 RES, .1W 5% 180.0 OHM 100V CHIP SUR MT R1, R2 62.3009.0103 CAP, .01UF 50V 10% MONO CER CHIP SUR MT...

  • Page 100: Yoke Fan Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Yoke Fan Assembly 22.9676.0609 Rev A Refer to Figure 3-23. Item Qty. Description 10-9676.0646 FAN TRAY, YOKE ARM 40.7113.0001 FAN, +24V 80 X 80 X 25 MM 32CFM RECPT, 2POS MTA100 W/ POL TAB RED CLSD END 52.6396.2202...

  • Page 101: Enclosure

    LLUSTRATED ARTS REAKDOWN NCLOSURE Enclosure Upper Enclosure Assembly 21.9676.0800 Rev E Refer to Figures 3-25 and 3-26. Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 04.9661.0040 LABEL, 2000 SERIES COMPLIANCE 04.9661.1218.01 LABEL, PATENT, VL2201 & VL2400 SERIES LUMINAIRES 10.9661.1258 BRACKET, APS SIDE 10.9661.1358 AIR SEAL, DUCT 10.9661.1361...
  • Page 102 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Item Qty. Description 25.9661.1520 CABLE ASSY, CHASSIS TO YOKE GROUND (not shown) 25.9676.0818 CABLE ASSY, PAN/TILT CONTROL (not shown) 25.9678.0811 CABLE ASSY, EMI FILTER TO POWER SWITCH (not shown) 25.9678.0812 CABLE ASSY, AC INPUT SPLITTER (not shown) 25.9678.0813...
  • Page 103 LLUSTRATED ARTS REAKDOWN NCLOSURE Item Qty. Description 55.2178.0001 CABLE ANCHOR, MOUNT, #8 SCREW MOUNTING 55.2179.0001 CABLE ANCHOR, MOUNT, #6 SCREW MOUNTING 55.2186.0001 CABLE TIE, .10" W X 4.00" LG SMALL 55.2261.0001 SLEEVE, NYL, INSUL, #6 SCREW 1.0" LG .015 WALL 55.2267.0001 RUBBER STRIP, SPONGE CLSD CELL 3/8"...
  • Page 104 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x4) (x3) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) 70, 68 (x3) 69, 70 (x3) (x2) (x2) (x2) (x2) (x2) (x2) Figure 3-25: Upper Enclosure Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 105: X4)

    LLUSTRATED ARTS REAKDOWN NCLOSURE Upper Enclosure Assembly (continued) (x2) (x2) (x4) (x2) Unpainted surface of APS Cover only (x2) (x4) (x4) (x4) Figure 3-26: Upper Enclosure Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 106: Connector Panel Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Connector Panel Assembly 21.9678.0805 Rev D Refer to Figure 3-27. Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY 10.9678.0859 BRACKET, INPUT 24.9663.1830 PCB ASSY, DMX INPUT 24.9678.0825 PCB ASSY, DISPLAY 25.9678.0810 CABLE ASSY, AC INPUT PIGTAIL 53.6551.0001...

  • Page 107: Dmx Input Pcb Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE DMX Input PCB Assembly 24.9663.1830 Rev A Refer to Figure 3-28 Item Qty. Description Ref. 11.9663.1830 PCB FAB, DMX INPUT 52.6259.0001 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0005 CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL 52.6626.0005 CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL 62.3017.0102...

  • Page 108: Ac Input Pigtail Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev A Refer to Figure 3-28 Item Qty. Description 52.6274.2313 STRAIN RELIEF, SKINTOP FLEXTYPE PG13 BLK 52.6401.2321 CONN, PLUG "CE MARKED" 20A 250V TWIST LOCK 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8298.1160...

  • Page 109: Pan Tube Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE Pan Tube Assembly 21.9678.0880 Rev C Refer to Figure 3-30. Item Qty. Description 10.9678.0809 PAN TOGGLE STOP 10.9678.0847 WASHER, SILICONE FOAM 10.9678.0848 WASHER, PAN TEFLON 12.9678.0891 PAN TUBE, MACHINED 54.1206.0021 RING, RETAINING 1.562" SHAFT 1.468" GRV DIA 54.1255.0002 BEARING ASSY, FLUSH MOUNT HOUSING LARGE Figure 3-30: Pan Tube Assembly...

  • Page 110: Pan Motor Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan Motor Assembly 21.9678.0864 Rev B Refer to Figure 3-31. Item Qty. Description PLATE, PAN MOTOR MOUNT 10.9678.0865 ASSY, DRIVE PULLY, PAN 21.9678.0828 PCB ASSY, VL2203 PAN/TILT ENCODER 24.9678.0729 MOTOR, 3-PHASE SIZE 23 HIGH TORQUE 44.9678.0680...

  • Page 111: Upper Enclosure Fan Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE Upper Enclosure Fan Assembly 23.9678.0686 Rev 0 Refer to Figure 3-31. Item Qty. Description FAN, 24V FAL6F24LH 40.7125.0001 TERM, SPADE #6 26-24 AWG INS YELLOW 52.8231.0007 (x2) Figure 3-32: Upper Enclosure Fan Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 112: Pan Eot Sensor Electrical Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-33. Item Qty. Description CONN, HOUSING 6 POS. RECEPTACLE 52.6524.0006 CONTACT, 24-30 AWG FEMALE CRIMP 52.8346.0001 SWITCH, SLOTTED OPTICAL 86.7002.0003 1, 2...

  • Page 113: Ballast Module (Arc Power Supply) Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE Ballast Module (Arc Power Supply) Assembly 23.9671.1250 Rev F Refer to Figures 3-34 and 3-35. Item Qty. Description 06.6032.0009 CABLE MARKER TIE, WHITE 19 X 7.4" 10.9661.1260 HEAT SINK, LEFT 1200 WATT POWER SUPPLY 10.9661.1261 HEAT SINK, RIGHT 1200 WATT POWER SUPPLY 10.9661.1262 TOP, AIR DUCT 1200 WATT POWER SUPPLY 10.9661.1274...
  • Page 114 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Item Qty. Description 80.2648.0001 TRANSISTOR, IXFH32N50 POWER MOSFET 500V 32A TO-247 82.4323.0001 DIODE, BRIDGE D25XB60 600V 25A SIP 82.5341.0001 DIODE, DSEI30-06A FRED 25-37A T0-247 AD 09-December-2004 0 2.9676 .0022 0...
  • Page 115 LLUSTRATED ARTS REAKDOWN NCLOSURE Ballast Module Assembly (continued) (x4) (x4) (x2) (x2) (x2) (x2) (x2) (x4) (x2) (x3) Figure 3-34: Ballast Module (Arc Power Supply) Assy 02.9 676.00 22 0 09-December-2004...
  • Page 116 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Ballast Module Assy (continued) (2 pl) 10 (4 pl) 15 (4 pl) 30 (4 pl) 15 (4 pl) 18 (4 pl) 18 (4 pl) 20 (4 pl) 20 (4 pl) Figure 3-35: Ballast Module (Arc Power Supply) Assy 09-December-2004 0 2.9676 .0022 0...

  • Page 117: 700W Ballast Board Pcb Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE 700W Ballast Board PCB Assembly 24.9661.1130 Rev D Refer to Figure 3-36. Item Qty. Description Ref. 10.9661.1356 GUIDE, APS RIDER PCB 11.9661.1120 PCB, 400/625W BALLAST BOARD 51.5031.0001 HEATSINK, TO-220 CLIP-ON ALUM BLACK ANODIZED PC MT 52.6229.0001 HEADER, 3POS MTA FRIC LOK STRT POST J113 52.6261.0002...
  • Page 118 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Item Qty. Description Ref. 60.1422.1001 RES, 1/4W 5% 1.0 K CF R219, R220 & R223 60.1422.2001 RES, 1/4W 5% 2.0 K CF R119 60.1424.1502 RES, 1/4W 5% 15.0 K CF R104 60.1424.2004 RES, 1/4W 5% 20.0 K CF R108 60.1424.2702...
  • Page 119 LLUSTRATED ARTS REAKDOWN NCLOSURE Item Qty. Description Ref. 63.2055.0001 THERMISTOR, 12A 0.7 OHM NTC INRUSH NTC101 & CURRENT LIMIT NTC102 68.4536.0002 CHOKE, COMMON MODE FILTER 1.35MH 11A L102 68.4577.0001 INDUCTOR, CURRENT SENSE PE-51688 L201 68.9661.1112 TRANSFORMER, GATE DRIVE T201 68.9661.1115 CHOKE, EMI DIFFERENTIAL L101 70.3727.0002...
  • Page 120 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL 700W Ballast Board PCB Assembly (cont.) Figure 3-36: 700W Ballast Board PCB Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 121: 700W Ballast Rider Board Pcb Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE 700W Ballast Rider Board PCB Assembly 24.9661.1131 Rev C Refer to Figure 3-37. Item Qty. Description Ref. 10.9661.1355 STABILIZING EXTRUSION, APS RIDER BD PCB 11.9661.1111 PCB, BALLAST RIDER 52.6297.0001 HEADER, 2PIN MTA FRCT LOK STRT POST J402 52.6576.0012 CONN, 12 CIR .100"...
  • Page 122 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Item Qty. Description Ref. 60.9464.2003 RES, 1/8W 5% 2.0 K 200V CHP THK FLM S- R413 MT1206 60.9464.2004 RES, 1/8W 5% 20.0 K 200V CHP THK FLM S- R308, R309, MT1206 R402, R417,...
  • Page 123 LLUSTRATED ARTS REAKDOWN NCLOSURE Item Qty. Description Ref. 62.4005.0101 CAP, 100PF 50V 10% CER CHIP SUR MT COG 0805 C410, C411, C429 62.4005.0330 CAP, 33PF 50V 10% CER CHIP SUR MT COG 0805 C428 62.4005.0470 CAP, 47PF 50V 10% CER CHIP SUR MT COG 0805 C301 62.4006.0222 CAP, 2200PF 50V 5% CER CHIP SUR MT X7R 0805...
  • Page 124 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 09-December-2004 0 2.9676 .0022 0...

  • Page 125: Ground Strap Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Cables Ground Strap Cable Assembly 25.8007.2212 Rev 0 Refer to Figure 3-48. Item Qty. Description 52.8329.0001 TERM, RING # 6 22-16 AWG NON-INS 73.7130.0002 0.33 WIRE, 7/64" TUBULAR BRAID SILVER-PLATED Figure 3-48: Ground Strap Cable Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 126: Lvs Chassis Ground Cable Assembly

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

  • Page 127: Chassis To Yoke Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev B Refer to Figure 3-50. Item Qty. Description 52.8250.0001 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (x2) Figure 3-50: Chassis To Yoke Ground Cable Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 128: Ignitor To Relay Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Ignitor To Relay Cable Assembly 25.9667.0030 Rev A Refer to Figure 3-51. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009...

  • Page 129: Tilt Plate Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Tilt Plate Ground Cable Assembly 25.9667.0413 Rev A Refer to Figure 3-52. Item Qty. Description 52.8311.0003 TERM, RING #6 BLUE 14-16 AWG NON-INS. 73.7130.0002 0.21 WIRE, 7/64" TUBULAR BRAID SILVER PLATED (x2) Figure 3-52: Tilt Plate Ground Cable Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 130: Color/Gobo T-Stat Cable Assembly

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

  • Page 131: Color/Fixed Bulkheads Cable Assembly

    25.9676.1715 Rev 0 Refer to Figure 3-54. Item Qty. Description 04.9676.1715.00 LABEL SET, VL2500 COLOR HARNESS 52.6224.0040 HOUSING, 40 POS 26-22 AWG PRELOADED MT RECPT DBL 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.2040 COVER, BACK 40 POS MT 52.6396.2603 RECEPT, 3 POS MTA100 W/POL TAB BLUE CLOSED END 52.6424.0003...
  • Page 132 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Color/Fixed Bulkheads Cable Assembly (cont.) 2, 3, 4 14, 9, 10 (x6) 16, 7, 8 14, 7, 8 (x2) 14, 9, 10 15, 5, 6 Figure 3-54: Color/Fixed Bulkheads Cable Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 133: Optics/Strobe Bulkheads Cable Assembly

    25.9676.1716 Rev A Refer to Figure 3-55. Item Qty. Description 04.9676.1716.00 LABEL SET, VL2500 COLOR HARNESS 52.6224.0034 HOUSING, 34 POS 26-22 AWG PRELOADED MT RECPT DBL 52.6224.1034 COVER, FRONT 34 POS MT LATCHING 52.6224.2034 COVER, BACK 34 POS MT 52.6524.0004 CONN, HOUSING 4 POS RECEPT 52.6524.0005...
  • Page 134 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Optics/Strobe Bulkheads Cable Assy (cont.) 2, 3, 4 13, 7, 9 13, 5, 8 13, 5, 8 Note: OPEN positions will have pins loaded for a better mechanical fit Figure 3-55: Optics/Strobe Bulkheads Cable Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 135: Strobe 1 Cable Assembly

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

  • Page 136: Fans/Disconnect Cable Assembly

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

  • Page 137: Ot Switch To Reflector Assy. Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES OT Switch to Reflector Assy. Cable Assembly 25.9676.0719 Rev 0 Refer to Figure 3-58. Item Qty. Description 52.8271.0010 RECEPT, FASTON 24-22 AWG NON-INSUL 0.016" TAB 110SERIES 52.8371.0001 RECEPT, FASTON 24-20 AWG UNINSUL TIN PLT BRS .250 X 0.32 73.2624.0008 0.67 WIRE, 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E...

  • Page 138: Pan/Tilt Control Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Pan/Tilt Control Cable Assembly 25.9676.0818 Rev A Refer to Figure 3-59. Item Qty. Description 52.6224.0020 HOUSING, 20 POS 26-22 AWG PRELOADED MT RECEPT DBL ROW 52.6224.1020 COVER, FRONT 20 POS MT LATCHING 52.6224.2020 COVER, BACK 20 POS MT 52.6524.0005...
  • Page 139 LLUSTRATED ARTS REAKDOWN ABLES Pan/Tilt Control Cable Assembly (continued) 4, 7 (x5) (x7) 1, 2, 3 6 (x3),5 6 (x3),5 4, 7 (x5) Figure 3-59: Pan/Tilt Control Cable Assembly 02.9 676.00 22 0 09-December-2004...

  • Page 140: Emi Filter To Power Switch Cable Assembly

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

  • Page 141: Ac Input Splitter Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES AC Input Splitter Cable Assembly 25.9678.0812 Rev D Refer to Figure 3-61 Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3POS 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8231.0008 TERM, SPADE #6 RED 22-16AWG INSERT 52.8392.0001 RECP, FASTON .187"X0.32"...
  • Page 142 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 (x3) Figure 3-61: AC Input Splitter Cable Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 143: Data I/O Link Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Data I/O Link Cable Assembly 25.9678.0813 Rev 0 Refer to Figure 3-62 Item Qty. Description 52.6396.2204 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 52.6396.2205 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 73.5122.0259 2.17 CBL, 22AWG STRND 4COND PVC INSUL Figure 3-62: Data I/O Link Cable Assembly...

  • Page 144: Display Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Display Cable Assembly 25.9678.0815 Rev 0 Refer to Figure 3-63 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 73.5116.0123 WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN> (x2) Figure 3-63: Display Cable Assembly 09-December-2004 0 2.9676 .0022 0...

  • Page 145: Ballast To Controller Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Ballast to Controller Cable Assembly 25.9678.0816 Rev 0 Refer to Figure 3-64 Item Qty. Description 52.6396.2402 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 52.6396.2405 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 52.6396.2408 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 73.5124.1289 3.67...

  • Page 146: Lamp Supply To Relay Cable Assembly

    VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Lamp Supply to Relay Cable Assembly 25.9678.0819 Rev A Refer to Figure 3-65 Item Qty. Description 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL 55.6699.0003 3.75 SLEEVING, 1/2" NOM. DIA POLY EXP BRAIDED 73.7089.0000...

  • Page 147: Dc Output Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES DC Output Cable Assembly 25.9678.0821 Rev D Refer to Figure 3-66 Item Qty. Description 52.6464.0002 CONN, HOUSING, SL-156 2 POS 52.6464.0003 CONN, HOUSING, SL-156 3 POS 52.8231.0004 TERM, RING #6 BLUE 12-10 AWG INSRT 52.8323.0001 CONTACT, CRIMP, 18-22 AWG SL-156 52.8274.1614 CONN BUTT SPLICE 16-14 BLUE .150"...
  • Page 148 VARI❋LITE® - VL2500™ W UMINAIRE ERVICE ANUAL Notes 09-December-2004 0 2.9676 .0022 0...

  • Page 149: Vl2500 Wash Luminaire Schematics

    ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE VL2500 Wash Luminaire Schematics 700W Ballast Schematic 02.9 676.00 22 0 09-D ecember-2004...
  • Page 150 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE 700W Ballast Schematic (continued) 02.9 676.00 22 0 09-D ecember-2004...

  • Page 151: Ballast Rider Schematic

    ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Ballast Rider Schematic 02.9 676.00 22 0 09-D ecember-2004...

  • Page 152: Vl2500 Luminaire Schematic

    ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE VL2500 Luminaire Schematic 02.9 676.00 22 0 09-D ecember-2004...
  • Page 153 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE VL2500 Luminaire Schematic (continued) 02.9 676.00 22 0 09-D ecember-2004...
  • Page 154 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE VL2500 Luminaire Schematic (continued) 02.9 676.00 22 0 09-D ecember-2004...

  • Page 155: Main Control Board (Mcb) Schematic

    ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic REV. NO ECO # DESCRIPTION DATE APPROVED NONE ENG RELEASE 4/16/04 NOTES: UNLESS OTHERWISE SPECIFIED NONE CHANGED VALUES ON VR1 AND VR4 4/27/04 NONE CHANGED VALUES ON RES- SHT 2 5/11/04 1.) ALL CAPACITOR VALUES ARE IN MICROFARADS.
  • Page 156 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +3.3V D[0..3 1] 3/B3,3/A3 +1.8V +1.8V +1.8V +1.8V +1.8V A[0 ..24] 2/C3,3/D6,3/A3 CS_MTR- 2/B4,3/A6 CS_UART- 2/B4,3/A6 A 15 +1.8V +1.8V +1.8V +1.8V +1.8V A 14...
  • Page 157 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V +2.5V 2/D4,2/C3,3/A3 A[0 ..24] IO77 +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V IO78 IO79 IDX_OUT_IN IO80 4/B8 PWM3_OUT_1 IO81...
  • Page 158 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) DO NOT STUFF ON ASSY. +3.3V +24V ISO_VCC ISO_VCC ISO_VCC U10C TX_EN_C- BIAS ISO_VCC POWER VIN+ VOUT+ TXDB LED_TX- 2/B5 TXD1 VIN- VOUT- LED_RX- TXD2...
  • Page 159 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +24V +24V +24V TILT +24V PWM3_OUT_1 TILT_PHA_OUT 3/D3 OUT1 10/D3 PWM3_OUT_2 TILT_PHB_OUT 3/A6 OUT2 10/D3 PWM3_OUT_3 TILT_PHC_OUT 3/D3 OUT3 10/D3 SENSE1 PWM3_EN_1 3/A6 SENSE2 VREF...
  • Page 160 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +24V +24V +24V +24V C101 C119 R114 R136 STROBE 1 GOBO ROTATE RGOBO_OUT1A STROBE1_OUT1A PWM_PH_7 PWM_PH_11 3/C6 10/D7,10/C3 3/C3 10/C7,10/C3 PHASE1 PHASE1 R109 R111 R131...
  • Page 161 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +24V +24V +24V +24V C136 C100 C155 C118 FXD GOBO MOTOR ZOOM R160 R173 FXDG_OUT1A ZOOM_OUT1A 3/C6 PWM_PH_15 10/A4 3/C3 PWM_PH_1 10/B7,10/C4 PHASE1 PHASE1 R187...
  • Page 162 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +24V +24V +24V +24V C173 C137 C200 C163 R247 R214 MAGENTA AMBER PWM_PH_19 AMB_OUT1A PWM_PH_23 MAG_OUT1A 3/C6 10/D6,10/A3 3/B6 10/C6,10/A3 PHASE1 PHASE1 R211 R209 R242...
  • Page 163 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +24V +24V +3.3V +3.3V +2.5V - This page is intentionally left blank - +2.5V +1.8V +1.8V ALL PARTS WERE REMOVED DRAWN BY : GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238...
  • Page 164 ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Main Control Board (MCB) Schematic (continued) +24V DIA. .166" DIA. .166" DIA. .166" DIA. .166" DIA. .166" DIA. .166" DIA. .166" +24V MNTG1 MNTG2 MNTG3 MNTG4 MNTG5 MNTG6 MNTG7 IRIS_OUT1A 5/C1,10/C3...

  • Page 165: Dmx Input Schematic

    ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE DMX Input Schematic REVISIONS DESCRIPTION DATE APPD Released per EO #09110 9/27/01 NC5FBV SHIELD DMX/VL_IN- DMX/VL_IN+ VL_OUT- VL_OUT+ CHASSIS NC5MBV SHIELD DMX/VL_IN- DMX/VL_IN+ VL_OUT- VL_OUT+ CHASSIS 640456-5 SHIELD DMX/VL_IN+ DMX/VL_IN- VL_OUT+...

  • Page 166: Solid State Ignitor Schematic

    ® VARI❋LITE - VL2500™ W UMINAIRE ERVICE ANUAL EFERENCE Solid State Ignitor Schematic REVISIONS DESCRIPTION DATE APPD NOTES: UNLESS OTHERWISE SPECIFIED ENGINEERING PROTOTYPE 7/16/02 B.C. 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. ENG RELEASE PER EO #09082 9/16/02 B.C. 2. ALL RESISTOR VALUES ARE IN OHMS.
  • Page 168 Vari-Lite 10911 Petal Street Dallas, Texas 75238 Toll Free 1-877-VARI-LITE Tel 214.647.7880 Fax 214.647.8038 www.vari-lite.com ©2004 Genlyte Thomas Group LLC. All rights reserved. Printed in the U.S.A.

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