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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VARILITE 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
individual product designations), VL3000, VL3500, Series 500, Series 1000, Series 2000, Series 3000,
DICHROTUNE, VARIIMAGE, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC.
VARILITE products are protected by one or more of the following patents, and other pending patent applications worldwide:
U. S. Patents No. 6,123,436; 6,113,252; 6,046,861; 6,031,749; 6,011,640; 5,969,868; 5,959,768; 5,934,794; 5,882,107;
5,829,868; 5,825,548; 5,798,619; 5,774,273; 5,769,527; 5,758,956; 5,728,994; 5,640,061; 5,590,954; 5,454,477; 5,432,691;
5,367,444; 5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806; 4,972,306;
4,800,474; 4,779,176; 4,701,833; 4,602,321;
U. S. Design Patents No. 439,356; 420,332; 417,300; 415,301; 413,995; 377,338; 366,712; 359,574; 350,408; 347,113;
Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646,588; 586,095; 576,400; 546,433;
Australia Design Patents No. 128,796; 128,795;
Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058; 1,181,795;
Canada Design Patents No. 81,234; 81,233; 76,046;
European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710; 0 495 305; 0 474 202; 0 379 970; 0 253 082;
0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068;
Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89
166.9; 37 68 727.1; 37 51 804.6; 37 50 201.8; 35 87 270.5; 32 79 888.1; 32 74 291.6;
Germany Design Patents No. M 98 01 745.4; M 96 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 951.2; M 499 03 583.6; M
498 11 203.9; G 93 12 884.3;
Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328;
Spain Utility Model Patent No. 2.031.748;
Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573;
Greece Patent No. 910.400.544;
Hong Kong Patents No. 965/1990; 285/1987;
Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241; 1,723,825;
1,683,007; 1,533,011;
Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1,072,598; 1,060,414;
1,002,123;
Korea Patents No. 76,310; 42,639; 283,770; 181,180;
Korea Design Patents No. 209,896; 209,895;
Mexico Patent No. 180,148;
Singapore Patents No. 663/90; 134/87;
Taiwan Patents No. 78,726; 66,975; 65,380; 28,275;
United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.
Neutrik, PowerCon, and EtherCon are registered trademarks of Neutrik, Inc.
All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their
respective companies or organizations.
VL500 Luminaire Service Manual
The information furnished in this manual is for informational use only and is subject to change without notice. Please check
www.vari-lite.com for latest version. Vari-Lite assumes no responsibility or liability for any errors or inaccuracies that may
appear in this manual. All information and graphics are property of Genlyte Thomas Group LLC, 10911 Petal Street, Dallas,
Texas 75238.
Version as of: 17-July-2006
Part number: 02.9685.0010 0

VL500 Luminaire Service Manual


2006 Genlyte Thomas Group LLC. All Rights Reserved.

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HOW TO OBTAIN WARRANTY SERVICE

How To Obtain Warranty Service


A copy of the Vari-Lite Limited Warranty was included in the shipping package for
this VARILITE 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. You will need to provide the
model and serial number of the item being returned, a description of the problem or
failure and the name of the registered user or organization. If available, you should
have your sales invoice to establish the date of sale as the beginning of the warranty
period.
Once you obtain the RMA, pack the unit in a secure shipping container or in its
original packing box. Fill out the RMA form included at the end of this manual and
place in shipping container along with a copy of your invoice (if available). Write the
RMA number legibly on or near the shipping address label and return the unit, freight
prepaid to:
Vari-Lite
Attention: Warranty Service (RMA# ________)
10911 Petal Street
Dallas, Texas 75238 USA
As stated in the warranty, it is required that the shipment be insured and FOB our
service center.

Manual Revision History

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VERSION

DATE

Rev. 0 (Initial)

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Compliance Notice
FCC

This equipment has been tested and found to comply with the limits for a Class A
digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when this equipment is operated in
a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with Vari-Lite system,
service, and safety guidelines, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her
own expense.
Declaration of Conformity
We declare, under our sole responsibility, that this product complies with the relevant
clauses of the following standards and harmonized documents:
Safety
EN 60598-1:200/A11:2000 + A12:2002 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989/A2:1991 Specification for Luminaires for Stage and Studio Lighting
EMC
EN 61000-6-4:2001 Emission Standard for industrial environments
EN 61000-6-2:2001 Immunity for industrial environments
We certify that the product conforms to the protection requirements of council directives:
73/23/EEC (LVD) and 89/336/EEC (EMC)

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SAFETY NOTICE

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.
Safety symbols used throughout this manual are as follows:

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND
INJURY TO PERSONS CAN BE FOUND BELOW.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE
1. VARILITE luminaires have been designed for use only with certain Philips and
Osram HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps.
Installing another type of lamp may be hazardous.
2. Luminaires may be mounted on any type of surface as long as mounting instructions are
followed. See instructions detailed in this manual.
3. Replace fuses with same type and rating only.
4. Note distance requirement from combustible materials or illuminated objects for
VARILITE luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARILITE luminaires are designed for dry locations only. Exposure to rain or
moisture may damage luminaire.
2. Disconnect power before servicing any VARILITE equipment.
3. Servicing to be performed by qualified personnel only.

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WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE
EXPOSURE TO UV RADIATION
1. Many VARILITE luminaires use an HID type lamp that produces UV radiation. DO
NOT look directly at lamp.
2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet
screens shall be changed if they have become visibly damaged to such an extent that their
effectiveness is impaired. For example, by cracks or deep scratches.
WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS
1. Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety
equipment (gloves, eye protection, etc.) when handling and adjusting hot equipment and
components.
2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to
cool before replacing.
3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye
inflammation. Additionally, arc lamps operate under high pressure at very high
temperatures. Should the lamp break, there can exist a danger of personal injury and/or
fire from broken lamp particles being discharged.
4. Wear eye protection when relamping.
5. Appropriate safety equipment (gloves, eye protection) should be used when handling
damaged lamps.
6. If lamp is touched with bare hands, clean lamp with isopropyl alcohol and wipe with
lint-free cloth before installing or powering up the luminaire.
7. The lamp shall be changed if it has become damaged or thermally deformed.
WARNING:
RF INTERFERENCE
1. This is a Class A product. In a domestic environment this product may cause radio
interference, in which case, the user may be required to take adequate measures.
ARC LAMP CHARACTERISTIC CONSIDERATIONS
1. Arc lamps require a period of time to relight after a power interruption or a severe voltage
dip. In some cases, lamp will automatically relight after it has cooled depending on Lamp
Power-Up State (L ON/ LOFF) system configuration setting.
2. Burning position is universal.

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SICHERHEITSHINWEISE

Sicherheitshinweise
Es ist uerst 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 Vorsichtsmanahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
VORSICHT - weist auf mglichen Produktschaden hin.

WARNUNG - weist auf mgliche Krperverletzung und Lebensbedrohung hin.

NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, BERHHTE
UV-STRAHLUNG UND KRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARILITE-Scheinwerfer sind ausschlielich fr den Einsatz mit bestimmten Philips
und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp (MSR400,
MSR575HR etc.), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines
anderen Lampentyps kann gefhrlich sein.
2. Scheinwerfer knnen auf jeder beliebigen Oberflche montiert werden, solange Sie die
Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.
3. Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Strke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARILITE-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARILITE-Scheinwerfer eignen sich ausschlielich fr trockene Standorte. Regen
oder Feuchtigkeit knnen die Scheinwerfer beschdigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARILITE-Gerten
beginnen.
3. Die Gerte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN BERHHTE UV-STRAHLUNG
1. Viele VARILITE-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.

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2. Es ist gefhrlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
Ultraviolettschirme mssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschdigung (z. B. Sprnge oder Schrammen) eingeschrnkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KRPERVERLETZUNGEN
1. Bei Betrieb sind die Auenflchen der Scheinwerfer hei. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe hei. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkhlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzndungen verursachen knnen. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Krperverletzung bzw. von Feuer, das von Lampenteilen ausgelst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschdigten Lampen verwendet werden.
6. Wenn die Lampe mit bloen Hnden berhrt wird, reinigen Sie sie mit isopropyl Alkohol
und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb
nehmen.
7. Wenn die Lampe beschdigt oder durch Hitzeeinwirkung deformiert ist, mu diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstrungen verursachen. In diesem Fall mssen eventuell geeignete
Manahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen bentigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgeflle wieder aufzuleuchten. In einigen Fllen wird die Lampe nach
Abkhlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.

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NOTES DE SCURIT

Notes de scurit
Avant de procder linstallation des produits dcrits dans ce guide et de les mettre en
marche, il est extrmement important de lire TOUS les renseignements et TOUTES
les directives de scurit contenues dans ce guide ainsi que toute documentation jointe.
Tenir compte de tous les avertissements et suivre toutes les prcautions pendant
linstallation et lutilisation de cet appareil.
Les symboles de scurit utiliss dans ce guide sont les suivants :
ATTENTION Ce symbole annonce que lappareil risque
dtre endommag.
AVERTISSEMENT Ce symbole annonce quil y a risque
daccident grave ou mme fatal.

CETTE SECTION CONTIENT DES INFORMATIONS GNRALES POUR SE


PROTGER CONTRE LES DCHARGES LECTRIQUES , LES INCENDIES,
LEXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRANER DES BLESSURES.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE LES INCENDIES
1. Les luminaires VARILITE ont t conus pour tre utiliss uniquement avec certaines
lampes Philips et Osram HID. Vrifier le type de lampe (MSR400, MSR575HR etc.)
avant de remplacer les lampes. Linstallation dun autre type de lampe peut poser un
danger.
2. Les luminaires peuvent tre fixs sur tout type de surface tant que les directives de
montage sont respectes. Voir les explications dtailles dans ce guide.
3. Ne remplacer les fusibles quavec ceux du mme type, ayant les mmes caractristiques.
4. Vrifier la distance respecter entre les matriaux combustibles ou les objets illumins et
les luminaires VARILITE.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE LES DCHARGES LECTRIQUES
1. Les luminaires VARILITE sont conus pour une utilisation au sec uniquement. Une
exposition la pluie et lhumidit risque dendommager le luminaire.
2. Dbrancher lappareil avant de procder la rvision de tout matriel VARILITE.
3. Les rvisions doivent tre effectues uniquement par des personnes qualifies.

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AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE UNE EXPOSITION EXCESSIVE
AUX RAYONS UV
1. Plusieurs luminaires VARILITE utilisent une lampe de type HID qui produit des
rayons UV. NE PAS fixer son regard sur la lampe.
2. Lutilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages,
lentilles ou crans ultraviolet visiblement endommags au point que leur efficacit en est
affecte doivent tre remplacs, par exemple sil y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE LES ACCIDENTS POUVANT
ENTRANER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brlantes quand lappareil est en marche.
Pour manuvrer ou ajuster des appareils brlants et leurs composants, se protger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brlante lorquil est en marche. Dbrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes arc mettent des rayons ultraviolets pouvant causer de graves brlures sur la
peau et une inflammation des yeux. De plus, les lampes arc fonctionnent sous haute
tension de trs hautes tempratures. Si la lampe se casse, les particules de la lampe
casse peuvent causer blessures et/ou incendie en sparpillant.
4. Se protger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropris (gants, protection des yeux) pour manier
des lampes endommages.
6. Si la lampe a t touche avec des mains nues, la nettoyer avec de lalcool isopropyl et
lessuyer avec un chiffon non-pelucheux avant dinstaller ou de brancher le luminaire.
7. Si la lampe a t endommage ou a reu une dformation thermique, elle doit tre
remplace.
AVERTISSEMENT:
INTERFRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interfrences radio, et si cest le cas, lutilisateur peut avoir prendre des mesures
adquates.
CONSIDRATIONS DES CARACTRISTIQUES DE LAMPES ARC
1. Aprs une interruption de courant ou une baisse importante de voltage, les lampes arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet aprs stre refroidie. Cela dpend de la manire dont le systme est rgl
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brler est Universelle.

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AVISO SOBRE SEGURIDAD

Aviso sobre Seguridad


Es muy importante leer TODA la informacin e instrucciones sobre seguridad que se
indica en este manual as como en los documentos adjuntos antes de instalar y operar
los productos descritos. Se debe prestar atencin a todos los avisos y advertencias
durante la instalacin y uso de este producto.
Los smbolos de seguridad usados en este manual son los siguientes:
CUIDADO, indica posibles daos al producto.

ADVERTENCIA, indica posibles lesiones o muerte a las


personas.

LA INFORMACIN GENERAL RELACIONADA A LA PROTECCIN CONTRAGOLPES DE CORRIENTE ELCTRICA, INCENDIO, EXPOSICIN


EXCESIVA A RADIACIN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTINUA CONTRA INCENDIO
1. Las luminarias VARILITE han sido diseadas para ser usadas solamente con algunas
lmparas HID Philips y Osram. Tome nota del tipo de lmpara (MSR400, MSR575HR
etc.) antes de reemplazarla. Instalacin de otro tipo de lmpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalacin. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificacin.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARILITE.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTINUA CONTRA CHOQUE
ELCTRICO
1. Las luminarias VARILITE estn diseadas solamente para lugares secos. La
exposicin a la lluvia o humedad pueden daar la luminaria.
2. Desconecte la energa antes de dar servicio a cualquier equipo de VARILITE.
3. El servicio debe ser realizado solamente por personal calificado.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTINUA CONTRA LA EXPOSICIN
EXCESIVA DE RADIACIN ULTRA VIOLETA
1. Muchas luminarias VARILITE usan un tipo de lmpara HID que produce radiacin
UV. NO mire directamente a la lmpara.

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2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores,
lentes o pantallas ultravioletas si se aprecia que han sido daadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias estn calientes durante su operacin. Use un
equipo de seguridad apropiado (guantes, proteccin para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que estn calientes.
2. Cuando las luminarias estn en operacin la lmpara estar muy caliente. Desconecte la
energa y deje que la lmpara se enfre antes de reemplazarla.
3. Las lmparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamacin a los ojos. Adems, las lmparas de arco operan a alta
presin y muy alta temperatura. Si la lmpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partculas de la lmpara rota que se
caen.
4. Use proteccin para los ojos cuando vuelve a colocar una lmpara nueva.
5. Use un equipo de seguridad apropiado (guantes, proteccin para los ojos, etc.) cuando
trabaje con lmparas daadas.
6. Si toca la lmpara con las manos, limpie la lmpara con alcohol isopropyl y con tela sin
pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lmpara si est daada o deformada termicamente.
ADVERTENCIA:
INTERFERENCIA RF
1. Este es un producto de Clase A. En el ambiente de la casa este producto puede ocasionar
radiointerferencia, en cuyo caso, el usuario debe tomar las medidas adecuadas.
CONSIDERACIONES SOBRE LAS CARACTERSTICAS DE LA LMPARA DE
ARCO
1. Las lmparas de arco requieren un perodo de tiempo para volver a iluminarse despus de
una interrupcin de energa o de una severa cada de voltaje. En algunos casos, la lmpara
se volver a iluminar en forma automtica despus que se ha enfriado dependiendo de la
configuracin del sistema de energa de la lmpara (L ON / L OFF) (L encendida / L
apagada).
2. La posicin de encendido es universal.

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SAFETY NOTICE (JAPANESE)

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CHAPTER 1.
Description
This chapter provides an overview of luminaire features, components and operations.

Features
Component Descriptions
Principles of Operation

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Features
Product Features
VL500 wash luminaires have the following features:
Color
Enhanced DICHROTUNETM radial color changing mechanism
featuring independent magenta, blue, and amber color control
capable of smooth, timed color crossfades or changes.
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.
Intensity Control
Tungsten models offer an optional integral dimmer or may be dimmed with a
customer supplied external dimmer. Arc models contain an internal mechanical
douser.
Beam Control
In all models, a selection of six, easily interchangeable front lenses provide a variety
of beam size and shape options. In the VL500, VL500D, and VL500 80V models an
internal, variable diffuser mechanism provides additional beam control. With stipple
lens (standard on all models) in place and adjustment of diffusion, beam angle is
capable of variance from 8-24.
LCD Display
All VL500 wash luminaires come with a on-board, backlit LCD display for luminaire
status, address, set-up, etc.
Pan and Tilt
Smooth, time-controlled continuous motion by way of a three-phase stepper motor
system. Range: Pan - 540, Tilt - 270. Pan/Tilt Accuracy: 0.3 resolution.

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DESCRIPTION :

Model Specific Features


Each individual configuration has the following specific features:
VL500 Wash Luminaire (20.9685.0001)

120V (or 230V), 1200W (or 1000W) Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

VL500 Wash Luminaire (20.9685.0011)

120V (or 230V), 1200W (or 1000W) Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

VL500D Wash Luminaire (20.9685.0002)

120V, 1200W Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

120V on-board IGBT dimmer.

VL500D Wash Luminaire (20.9685.0012)

120V, 1200W Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

120V on-board IGBT dimmer.

VL500D Wash Luminaire (20.9685.0003)

230V, 1000W Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

230V on-board IGBT dimmer.

VL500D Wash Luminaire (20.9685.0013)

230V, 1000W Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

230V on-board IGBT dimmer.

VL500 80V Wash Luminaire (20.9685.0004)

80V, 1200W Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

80V on-board dimmer.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 80V Wash Luminaire (20.9685.0014)

80V, 1200W Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

80V on-board dimmer.

VL500A Wash Luminaire (20.9685.0005)

575W arc lamp source with external ballast unit.

Standard color dichroic glass DICHROTUNETM color system.

VL500A Wash Luminaire (20.9685.0015)

575W arc lamp source with external ballast unit.

Pastel color dichroic glass DICHROTUNETM color system.

VL500A Wash Luminaire (20.9685.0006)

700W arc lamp source with external ballast unit.

Standard color dichroic glass DICHROTUNETM color system.

VL500A Wash Luminaire (20.9685.0016)

xviii

700W arc lamp source with external ballast unit.

Pastel color dichroic glass DICHROTUNETM color system.

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DESCRIPTION :

Component Descriptions
External Luminaire Components
The following illustration shows the external luminaire components and controls.
Input Panel Connections

Lamp Power
Input Cable

Mini XLR for Remote


Data Thru
Data In

3-Pole Neutrik
Locking Connector
for AC Input

Input Panel
Provides DMX In and
Thru, and AC Power
connections.

Base
Provides hook mounting
holes and safety cable
connection.

AC Power
Input Cable

Lamp Power
Input Cable

Yoke Leg (Power)


Contains power supply,
and dimmer (dimmer models).

Yoke Leg (Control)


Contains main control
PCB and display PCB.

Head Assembly
Houses color, dimmer (arc models) or
difusser (tungsten models) mechanisms.

Heatsink Assembly
Provides access to lamp
for replacement.
Menu Display
Used to input manual
commands, program, test,
set defaults and access
internal status information.

Menu Display Controls

LCD
Display

Softkeys - The menu has four


softkey buttons that change to
accommodate menu selection.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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)


DICHROTUNE color bulkhead - 16-radially
mounted diffuser panels for beam control and
amber dichroic glass for color mixing.
Magenta/Blue Assembly (All Models)
DICHROTUNE color bulkhead - 16-radially
mounted magenta and blue dichroic glass for color
mixing.

Amber/Dimming Assembly (Arc Models)


DICHROTUNE color bulkhead - 16-radially
mounted blackout panels for dimming operation
and amber dichroic glass for color mixing.

Backcap Assembly
Provides access to lamp
for replacement

Backend / Heatsink Assembly


Contains reflector and heatsink.

Front Ring
Provides frame for mounting lenses - stipple (standard with fixture).
Optional lenses: clear, 8-row, 10-row, 12-row, or buxom.

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DESCRIPTION :

Luminaire Yoke Components


The following illustration shows the major sub-assemblies which are located in the
luminaire yoke assembly.
Note: Head assembly not shown for clarity.

Tilt Mechanism

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)

Display LCD
Luminaire technical status/info.

Pan Mechanism

120W Power Supply


Supplies power to
electronic and motor
components. (Except
models with 80V dimmers).

See next page for other individual model variations

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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

120W Power Supply


Supplies power to
electronic and motor
components.
VL500 80V Models
120V or 230V IGBT
Dimmer Module

Pan Mechanism

VL500A Models (575W or 700W)


Pan Mechanism
Standard Yoke
Arm Cover

80V Dimmer
Module
80V Dimmer Yoke
Arm Cover

Ignitor PCB
Ignites lamp in arc models

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DESCRIPTION :

Arc Ballast Unit


An external ballast unit is included with VL500A arc models. In this case, the lamp
power input cable is already connectorized for use with this unit.
The following illustration shows the external arc ballast components.
Safety Cable Tab
Used to attach
safety cable clip.

Truss Hook Mount


Used to attach a truss hook.

Ballast Unit
Provides power for
arc lamp source.

Lamp Power Input Cable


Supplied cable and connector used
to connect luminaire to ballast unit.
40 inches (1m)

Lamp Connector (underside)


CPC-type connector for connecting
Lamp Power Input cable from luminaire.

Note: The Lamp Power Input Cable has conductors for lamp power and ballast
control. It is NOT compatible with VARILITE Series 300 lamp runs.

Dimmer Models
An on-board dimmer is
included with VL500D and
VL500 80V incandescent
dimmer models. The dimmer
heatsink is visible on the powerside yoke leg as shown in this
illustration.

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On-Board Dimmer
VL500D Models - Internal lamp power
dimmer configured for either 120V or
230V operation depending on model.
VL500 80V Models - Internal lamp power
dimmer configured specifically for 80V
lamps.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Principles of Operation
VL500 Incandescent Luminaires
VL500 Incandescent Block Diagram - Without On-Board
IGBT Dimmer

Pan
Motor

Tilt
Motor

Pan
Encoder

Tilt
Encoder

J4

VL500 Main Control Board (MCB)

J7

J6

J8

J3

Magenta
Motor

Blue
Motor

Display

DMX
PCB

Thermal
Switch
Remote
Conn.

LVS
Amber
Motor

Diffuser
Motor

Thru In

Fan

Fan

Terminal
Block

Luminaire
Power In

Lamp
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.

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DESCRIPTION :

VL500D Incandescent Luminaires


VL500D Incandescent Block Diagram - With On-Board
IGBT Dimmer

Pan
Motor

Tilt
Motor

Pan
Encoder

Tilt
Encoder

J4

VL500 Main Control Board (MCB)

J7

J6

J8

J3

J2

Magenta
Motor

Blue
Motor

Display

DMX
PCB

Thermal
Switch
Remote
Conn.

LVS
Amber
Motor

Diffuser
Motor

Thru In

Fan

Terminal
Block

Luminaire
Power In

Fan

IGBT
Dimmer

Lamp

Note: For detailed information on wiring, connections, signals, etc., please refer to
VL500 Wiring Diagram - Sheet 1 of 1 on page 163.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 80V Incandescent Luminaires


VL500 80V Incandescent Block Diagram - With On-Board
80V Dimmer

Pan
Motor

Tilt
Motor

Pan
Encoder

Tilt
Encoder

J4

VL500 Main Control Board (MCB)

J7

J6

J8

J3

J2

Magenta
Motor

Blue
Motor

Display

DMX
PCB

Remote
Conn.

LVS
Amber
Motor

Diffuser
Motor

Thru In

Fan

Terminal
Block

Luminaire
Power In

Ferrite
Core

Thermal
Switch

Fan

80V
Dimmer

Fan

Lamp

Note: For detailed information on wiring, connections, signals, etc., please refer to
VL500 Wiring Diagram - Sheet 1 of 1 on page 163.

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DESCRIPTION :

VL500A Luminaire
VL500A Arc Block Diagram - With External Arc Ballast

Lamp

Backcap
Interlock

Fan 700W Ballast Only

Tilt
Motor

Pan
Motor

Ignitor
PCB
Pan
Encoder

Relay

ARC Ballast
(575W or 700W)

Tilt
Encoder

J4

J5

VL500 Main Control Board (MCB)

J7

J6

J8

J3

Magenta
Motor

Blue
Motor

Display

DMX
PCB

Thermal
Switch
Remote
Conn.

LVS
Amber
Motor

Dimmer
Motor

Thru In

Fan

Fan

Terminal
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.

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Notes

xxv iii

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TABLE OF CONTENTS

Table of Contents
Chapter 1. Description
Features
Product Features........................................................................................................ xvi
Model Specific Features .......................................................................................... xvii
Component Descriptions
External Luminaire Components .............................................................................. xix
Luminaire Internal Head Components....................................................................... xx
Luminaire Yoke Components ................................................................................... xxi
Arc Ballast Unit ...................................................................................................... xxiii
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..... xxvi
VL500A Luminaire................................................................................................ xxvii
VL500A Arc Block Diagram - With External Arc Ballast ............................. xxvii

Introduction
Disclosure ....................................................................................................................
About This Manual ......................................................................................................
Additional Documentation...........................................................................................
Customer Service .........................................................................................................

1
1
2
2

Chapter 1. Maintenance
Testing
Running Parameter Tests ............................................................................................. 4
Diagnostic Tests ........................................................................................................... 6
Test Descriptions................................................................................................... 6
Test Menu System Chart ....................................................................................... 7
Lamp Hours Progress Bar (Arc Models Only) ............................................................ 8
Equipment Handling
Locations/Use .............................................................................................................. 9
Lamps........................................................................................................................... 9
Servicing................................................................................................................ 9
Heat ....................................................................................................................... 9
Lamp Life .............................................................................................................. 9
Solid State Electronics ............................................................................................... 10

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Electrostatic Discharge (ESD) ............................................................................. 10


Printed Circuit Boards (PCBs)............................................................................. 10
Maintenance Procedures
Lamp Replacement - Incandescent............................................................................. 11
Lamp Replacement (Arc Model)................................................................................ 13
Align Lamp For Maximum Beam Irradiance............................................................. 15
Front Glass Replacement............................................................................................ 17
Magenta/Blue DICHRO*TUNE Rear Bulkhead Replacement.................................. 19
Amber/Diffuser (or Dimmer) DICHRO*TUNE Front Bulkhead Replacement ........ 21
Color Filter and Diffuser Panel Replacement ............................................................ 23
Arc Dimmer Panel Replacement ................................................................................ 25
Linear Actuator Motor Replacement (Magenta/Blue Bulkhead) ............................... 27
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)............ 38
Low Voltage Supply (LVS) Temperature PCB Replacement (VL500/VL500D/VL500A
Only)........................................................................................................................... 39
Low Voltage Supply (LVS) Replacement (VL500 80V Only)................................... 40
Low Voltage Supply (LVS) Temperature PCB Replacement (VL500 80V Only) ..... 41
Tilt Motor Assembly Replacement............................................................................. 42
Pan Motor Assembly Replacement ............................................................................ 44
Pan/Tilt Encoder PCB Replacement........................................................................... 45
Arc Ignitor PCB Replacement (VL500A Only)......................................................... 46
IGBT Dimmer Replacement (VL500D Only)............................................................ 47
80V Dimmer Replacement (VL500 80V Only) ......................................................... 49
Arc Ballast Replacement (VL500A Only) ................................................................. 51
Safety Relay Replacement (VL500A Only)............................................................... 52
AC Input (PowerCon) Connector Replacement ......................................................... 53
Mini-XLR (Display/Remote Programming) Connector Replacement....................... 54
DMX PCB Assembly Replacement ........................................................................... 55
Cleaning Optical Lenses and Filters........................................................................... 56

Chapter 2. Illustrated Parts Breakdown


Drawing Trees
VL500 and VL500D Incandescent Luminaires.......................................................... 58
VL500 80V Incandescent Luminaires........................................................................ 60
VL500A (575W/700W) Arc Luminaires ................................................................... 62
Top Assembly
Included Items Kit ......................................................................................................64
Label Locations .......................................................................................................... 66
VL500 Luminaire (120V or 230V) ............................................................................69
VL500D (with 120V IGBT Dimmer) Luminaire .......................................................71
VL500D (with 230V IGBT Dimmer) Luminaire .......................................................73

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TABLE OF CONTENTS

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 ..................................................................... 95
VL500 Magenta/Blue (Pastel) Color Assembly ........................................................ 96
VL500 Amber/Diffuser Color Assembly ................................................................... 97
VL500 Amber/Dimmer Color Assembly ................................................................... 98
VL500 Magenta/Blue (Arc) Color Assembly ............................................................ 99
VL500 Magenta/Blue (Arc Pastel) Color Assembly ............................................... 100
Magenta/Blue Color Assembly ................................................................................ 101
Magenta/Blue (Pastel) Color Assembly ................................................................... 102
Amber/Diffuser Color Assembly ............................................................................. 103
Amber/Dimmer Color Assembly ............................................................................. 104
Bottom Bulkhead Assembly .................................................................................... 106
Top Bulkhead Assembly .......................................................................................... 108
Drive Ring Assembly ............................................................................................... 110
Magenta/Blue Color Motor Assembly ..................................................................... 111
Amber/Diffuser Color Motor Assembly .................................................................. 112
Yoke Assembly
VL500 Yoke Assembly ............................................................................................ 113
VL500 80V Yoke Assembly .................................................................................... 117
VL500 Extra Hardware Kit ...................................................................................... 121
VL500 Pan/Tilt Motor Assembly ............................................................................ 122
VL500 MCB/FAN Assembly .................................................................................. 123
MCB Fan Assembly ................................................................................................. 124
Yoke Crossmember Assembly ................................................................................. 125
Yoke Crossmember Assembly (VL500 80V) .......................................................... 126
Lower Crossmember Assembly ............................................................................... 127
Upper Crossmember Assembly ............................................................................... 129
Pan Tube Assembly ................................................................................................. 130
80V Pan Tube Assembly ......................................................................................... 131
DMX Input PCB Assembly ..................................................................................... 132
VL500 Main Control Board PCB Assembly ........................................................... 133
Cables
Incandescent Power Input Cable Assembly ............................................................. 137
80V LVS AC Cable Assembly ................................................................................ 138
80V Surge Protector Cable Assembly ..................................................................... 139
VL500 Motor Cable Assembly ................................................................................ 140
Relay to Ignitor Cable Assembly ............................................................................. 142
VL500 AC Input Cable Assembly ........................................................................... 143
VL500 Arc Ballast Input Cable Assembly .............................................................. 144
VL500 Head Grounding Cable Assembly ............................................................... 145
VL500 Ignitor to Socket Cable Assembly ............................................................... 146
VL500 Arc Ballast Interconnect Cable Assembly ................................................... 147

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Display (Remote) Cable Assembly ..............................................................149


VL500 Yoke Lamp Jumper Cable Assembly ...........................................................150
VL500 Backcap Ground Cable Assembly ...............................................................151
VL500 Main Harness Cable Assembly ....................................................................152
VL500 Arc Main Harness Cable Assembly .............................................................154
VL500 80V Main Harness Cable Assembly ............................................................156
Arc Ballast Assembly
VL500 Arc Ballast Assembly ...................................................................................159
Ballast I/O Cable Assembly .....................................................................................161
VL500 Wiring and Schematic Diagrams
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........................... 168
VL500 Controller PCB (24.9685.0730) Schematic - Sheet 5 of 6........................... 169
VL500 Controller PCB (24.9685.0730) Schematic - Sheet 6 of 6........................... 170

Appendix A. Technical Bulletins


VL500 Wash Luminaire Technical Bulletins ........................................................... 171

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INTRODUCTION :

Introduction
Disclosure
This technical manual is confidential property of Vari-Lite. All information contained
herein is the sole and exclusive property of Vari-Lite and may not be used, disclosed,
or reproduced in any manner without the prior written consent of Vari-Lite.
WARNING: It is important to read ALL accompanying safety instructions to avoid
damage to the product and potential injury to yourself or others.

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:
Model
VL500 Luminaire

Part Number

Source

Comments

20.9685.0001

Tungsten

120V or 230V*, Standard Color System

VL500 Luminaire

20.9685.0011

Tungsten

120V or 230V*, Pastel Color System

VL500DTM Wash Luminaire

20.9685.0002

Tungsten

120V, Integral IGBT Dimmer, Standard Color System

VL500DTM Wash Luminaire

20.9685.0012

Tungsten

120V, Integral IGBT Dimmer, Pastel Color System

VL500D

TM

Wash Luminaire

20.9685.0003

Tungsten

230V, Integral IGBT Dimmer, Standard Color System

VL500D

TM

Wash Luminaire

20.9685.0013

Tungsten

230V, Integral IGBT Dimmer, Pastel Color System

Wash Luminaire

20.9685.0004

Tungsten

80V, Dimmer (100 - 240V Input), Standard Color System

VL500 80VTM Wash Luminaire

20.9685.0014

Tungsten

80V, Dimmer (100 - 240V Input), Pastel Color System

VL500ATM Wash Luminaire

20.9685.0005

Arc

575W, Ballast, Standard Color System

VL500ATM Wash Luminaire

20.9685.0015

Arc

575W, Ballast, Pastel Color System

VL500 80V

TM

TM

Wash Luminaire

20.9685.0006

Arc

700W, Ballast, Standard Color System

TM

Wash Luminaire

20.9685.0016

Arc

700W, Ballast, Pastel Color System

VL500A
VL500A

N ot e : * = L a m p T yp e i s s p e c i f i e d b y c u s t o me r a t t i m e o f o r d e r i n g .

Note: Performing maintenance procedures contained in this manual may void the
product warranty. Refer to the Vari-Lite Limited Warranty card included in the
shipping package for this VARILITE product.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Additional Documentation
A support web page for VL500 series luminaires is available at www.vari-lite.com
(follow the Support link).
A users manual is available for installation and operation of the VL500 luminaire.
This manual is available in both printed and electronic (PDF) formats.

VL500 Luminaire Users Manual (02.9685.0001).

Technical bulletins concerning the latest changes to VARILITE equipment are also
available at the web site Technical Support Center. These are documentation
supplements that contain procedures for equipment upgrades, retrofits, and additional
repairs. Technical bulletins are integrated into the appropriate equipment manuals as
those manuals are revised.

Customer Service
Our Goal

At Vari-Lite, we are committed to providing you the highest quality in customer


service. Our comprehensive resources are available to help your business succeed and
ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are
telephone troubleshooting assistance, product training or technical service, our fulltime staff of experienced professionals are on-hand to provide support.
How to Reach Us

For assistance in your area, call the dealer from which your product(s) were
purchased.
or
Contact an Authorized Service Center.
or
Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through
Friday, at the following:
phone: 1.877.VARI-LITE (1-877.827.4548) or 1.214.647.7880
fax: 1.214.647.8038
E-mail: customerservice@genlytecontrols.com
Additional Resources

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

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CHAPTER 2.
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 qualified, factory-trained service technician at an Authorized VARILITE Service Center.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Testing
Running Parameter Tests
The luminaire is capable of running self tests by using the TEST menu functions. For
complete details and values for each test refer to Diagnostic Tests on page 6.
When running tests on multiple luminaires, a DMX termination connector is required at the
last luminaire in the link. (Refer to users manual for more information regarding the
construction of this connector.)

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
wash platform. To alleviate this, when testing in groups, only test same Lamp Type luminaires
(for example: VL500A wash [575W arc] with other VL500A wash [575W arc] lights,
VL500 wash [120V/1200W tungsten] wash with other VL500 wash [120V/1200W
tungsten] lights, etc.). The issue, described above, does not pose any problems when operating
VL500 wash luminaires during normal operation under DMX control.

Master Luminaire (running test)

Slave Luminaire

AC In

Slave Luminaire

AC In

AC In

Data Thru

Data Thru

Termination

Figure 1: Test Setup


To run tests:
Step

1. Press [Menu].

Step

2. Press [Up] / [Down] arrows until Test appears. Press [Enter].

Step

3. Use [Up] / [Down] arrows to select a parameter to test. Refer to VL500 Test
Menu System Chart on page 7 for a complete list of test parameters which can
be chosen.

Step

4. Press [Enter] to run test.

Step

5. Press [Menu] to stop test at any time.

Note: Connected luminaires may not respond on the first action (may delay) of the master
luminaire.

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MAINTENANCE :

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.
To set movement option:
Step

1. Press [Menu].

Step

2. Press [Up] / [Down] arrows until Config appears. Press [Enter].

Step

3. Press [Up] / [Down] arrows until Pan/Tilt appears. Press [Enter].

Step

4. Movement will be displayed. Press [Enter].

Step

5. Use [Up] / [Down] arrows to select Enable or Disable. Press [Enter] to select.

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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.
Tilt........................ Tests different tilt movements.
Dimmer................ Tests different dimmer moves/operation.
Diffuser ................ Tests diffuser movement.
Cyan.................... Tests Cyan color wheel movements.
Yellow .................. Tests Yellow color wheel movements.
Magenta .............. Tests Magenta color wheel movements.
Encoder............... Disables pan and tilt and displays encoder value.
Fan ...................... Tests fan level (speed 1 to 7, 7 is fastest).
Temperature ........ Displays LVS or MCB temperatures (in oC).

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MAINTENANCE :

Test Menu System Chart


The following shows all the tests that can be performed by accessing the tests via the
luminaires on-board tech display.
Table 2-1: VL500 Test Menu System Chart
1st Level
Test **
System Test

2nd Level

3rd Level

ALL SEQ Sequence Through All


Tests

RunTest

Pan/Tilt Pan/Tilt

RunTest

Pan Pan

Pan 1

4th Level

5thLevel

Press [Menu] to stop tests

Pan 2
Tilt Tilt

Tilt 1
Tilt 2

Dimmer Dimmer

Dimmer 1
Dimmer 2
Dimmer 3

Diffuser Diffuser

Diffuser 1
Diffuser 2
Diffuser 3

Cyan Cyan Color System

Cyan 1
Cyan 2
Cyan 3

Yellow Yellow Color System

Yellow 1
Yellow 2
Yellow 3

Magenta Magenta Color System

Magenta 1
Magenta 2
Magenta 3

Encoder Encoder (Allows hand


movement to check values)

Pan

Value Displays encoder


value

Tilt

Value Displays encoder


value

Fans Fans Test

Value 1 (slow) to 7 (fastest)

Temp Temperature

LVS Temp Low Voltage


Supply temperature

Value Displays
temperature in oC

MCB Temp Main Control


Board temperature

Value Displays
temperature in oC

** Refer to Diagnostic Tests on page 6 for more information.

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17-July-2006

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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
full width of the menu display, represents 750 lamp hours (as indicated in Figure 2).
Resetting lamp hours will reset progress bar. This bar is only for a quick graphical
representation of the lamp hours used. For actual lamp hours used, please read the note below.

Note: 750 hours is the default setting for the Lamp Hours Progress Bar. However, the scale of
the progress bar is user definable by adjusting "Warning Hours" in [Config].When the lamp
hours exceed the allotted (or defined) hours, the display will reverse contrast with a warning of
"Exceeded Lamp Hours".

Series 500 Menu Display


Arc Lamp Hours Progress Bar

575W ARC NORMAL

750 Hours

MENU

169

ENTER

Menu Display

Softkeys - The menu has four softkey


buttons that change to accommodate
menu selection.

Figure 2: VL500A Luminaire Menu Display

Note: To identify the exact number of hours used, users should still refer to the [Config] [Lamp] - "Lamp Hours" setting within the menu system.

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

Equipment Handling
Below are some basic tips and information on handling luminaires and their associated
components.

Locations/Use
VARILITE 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

When handling a lamp, hold it by the ceramic base while wearing cotton gloves or finger
cots. Do not touch the glass envelope (bulb). If you touch the glass with bare fingers,
immediately wipe off any fingerprints with isopropyl alcohol.

Use care when opening and closing the rear castings (or covers) of luminaires and
cleaning reflectors. Any jarring can undo the optical alignment of the lamp.

Heat
On Forced Air Cooled Units
When lamps are lit, the interior of the luminaires becomes very hot. To aid in the airflow
circulation within the luminaires, after dousing the lamps, wait ten minutes before
removing power to the luminaires. This will provide enough time for the equipment fan to
cool off the unit.
On Natural Convection Cooled Units
When lamps are lit, the interior and exterior heatsink of the luminaires becomes very hot.
Naturally convection cooled units require longer to fully cool before being handled. Users
should wait until the unit is cool to the touch before servicing or handling.

Lamp Life

When operating arc lamps, allow luminaires to operate for at least 3 minutes. It takes
about 3 minutes for the fill components (mercury and halogen-metal compounds) in the
lamp tubes to vaporize completely. If the lamps are switched off earlier than 3 minutes, the
fill components are partially vaporized. The inadequately vaporized fill components and
the electrode material (tungsten) are deposited in the areas of the lamp tubes that have
remained cool. As a result, the lamp tubes blacken prematurely and reduce the service life
of the lamps.

If system will be unattended for more than two hours, luminaire lamps should be doused.
Standby mode should not be used for more than two hours.

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17-July-2006

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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. Because of the alternating current position,
the electrons are alternately given off by the two electrodes. When a lamp is set in a
vertical position, the halogen-metal compounds, which determine the color temperature of
the lamp, collect at the top end of the glass envelope. When the lamp is started, color
deviations occur since the concentration of halogen compounds is greater around the top
electrode than the bottom electrode. In addition, the fill components that are difficult to
vaporize congeal around the bottom electrode, thereby reducing lamp life.

Solid State Electronics


Electrostatic Discharge (ESD)
Electrostatic discharge (ESD) presents a significant danger to solid state electronic
components (semiconductor devices and PC board assemblies). Static electricity can build on
a variety of common objects (including people) simply by handling or moving. ESD rarely
results in immediate failure of a component, but shows up later as an intermittent problem or
severely reduces the life of the component. All VARILITE equipment uses solid state
electronics and appropriate precautions to protect them should be observed when servicing.

Printed Circuit Boards (PCBs)


All PC boards should be shipped in electrostatic shielding bags. When handling PC boards or
components, devices such as conductive mats and conductive wrist straps should be used
whenever possible. If these precautionary devices are not available, handling of PC boards and
components should be avoided.

CAUTION: Black foam (used to package solid state electronics) should never be used for
packing batteries or put in contact with PC boards which contain batteries.

10

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

Maintenance Procedures
Lamp Replacement - Incandescent
Parts:
71.2529.0120

1EA

71.2526.0230

1 EA

71.9685.0080

1 EA

1200 WATT TUNGSTEN HALOGEN LAMP, 120 VAC


(VL500 AND VL500D MODELS)
1000 WATT TUNGSTEN HALOGEN LAMP, 230 VAC
(VL500 AND VL500D MODELS)
1200 WATT TUNGSTEN HALOGEN LAMP, 80 VAC
(VL500 80V MODELS)

Tools:

Cotton gloves or finger cots.

WARNING: Remove power from luminaire before performing maintenance.


To remove and replace incandescent lamp:
Step

1. Remove power from luminaire.

WARNING: Lamps will be extremely HOT after operation. Allow lamp to cool before
replacing.
Step

2. Set the luminaire head horizontally.

Step

3. Engage service tilt lock to secure luminaire head in horizontal position to access
heatsink latch.

Step

4. As shown in Figure 3, at heatsink assembly, open latch and swing open back of
luminaire.

CAUTION:
Ensure lamp is seated
straight in socket before
re-installing backcap.

Heatsink
Assembly

Latch
Incandescent Lamp

Figure 3: Replacing Lamp

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17-July-2006

11

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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.

12

Step

5. Remove lamp by pulling straight out of socket.

Step

6. Carefully clean reflector with soft, lint-free cloth to remove dust and other debris.

Step

7. Install lamp by pressing firmly into socket. Ensure lamp is fully seated in socket
with base of lamp against socket base.

Step

8. Close and re-latch back of luminaire.

Step

9. Disengage service tilt lock to allow luminaire head to move freely.

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

Lamp Replacement (Arc Model)


Parts:
71.2528.0575

1 EA

71.9685.0702

1 EA

MSR575, 575 WATT ARC LAMP


(VL500A 575W MODELS)
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. Remove power from luminaire.

WARNING: Lamps will be extremely HOT after operation. Allow lamp to cool before
replacing.
Step

2. Set the luminaire head horizontally.

Step

3. Engage service tilt lock to secure luminaire head in horizontal position to access
heatsink latch.

Step

4. As shown in Figure 4, at heatsink assembly, open latch and swing open back of
luminaire.
CAUTION:
Ensure lamp is seated
straight in socket before
re-installing backcap.
Heatsink
Assembly
Back Cap
Assembly

Arc Lamp

Menu

Latch

Figure 4: Installing Arc Lamp in VL500A Models

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17-July-2006

13

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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.
Step

5. Remove lamp by pulling straight out of socket.

Step

6. Carefully clean reflector and facing UV glass lens with soft, lint-free cloth to
remove dust and other debris.

Step

7. Install lamp by pressing firmly into socket. Ensure lamp is fully seated in socket
with base of lamp against socket base.

Step

8. Close and re-latch back of luminaire.

Step

9. Disengage service tilt lock to allow luminaire head to move freely.

Step 10. Align lamp. (Refer to Align Lamp For Maximum Beam Irradiance on
page 15.)
Step 11. If required, and only on arc models, reset lamp hour counter as follows. (Refer to
"Menu Systems Functions" in the VL500 Users Manual for more information.)
a. Power up luminaire.
b. At Menu Display, press [Menu].
c. Press [Up] / [Down] arrows until CFG (Configuration) appears. Press [Enter].
d. Press [Up] / [Down] arrows until LAMP appears. Press [Enter].
e. Press [Up] / [Down] arrows to access RHrs . Press [Enter] to reset lamp hour
and strike counters.

14

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

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

Clean, Lint-free (Soft) Cloth

WARNING: Remove power from luminaire before performing maintenance.


To align lamp for maximum bean irradiance:
Step

1. Remove power from luminaire.

WARNING: Lamps will be extremely HOT after operation. Allow lamp to cool before
replacing.
Step

2. Set the luminaire head horizontally.

Step

3. Engage service tilt lock to secure luminaire head in horizontal position to access
heatsink latch.

Step

4. As shown in Figure 5, at heatsink assembly, open latch and swing open back of
luminaire.

Heatsink
Assembly
Backcap
Assembly

Latch
Arc Lamp

Figure 5: Accessing the Reflector in VL500A Fixtures

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17-July-2006

15

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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 screwdriver, remove three 6-32x1/8" PPSS screws. remove light baffle ring and
loosen three 1/4" hex standoffs.
b. Center reflector and retighten reflector clips by tightening standoffs. Make sure
clips are square so the light baffle ring will fit perfectly over the clips.
c. Reinstall light baffle ring.
d. Lamp is properly and completely seated in the lamp socket in the centered in
opening of reflector. Adjust as necessary.

Step

6. Using soft, lint-free dry cloth, wipe lamp and reflector clean of any dust or fingerprints.

Step

7. Close and latch heatsink assembly.

Step

8. Disengage service tilt lock to allow luminaire head to move freely.

Step

9. Supply power to luminaire.

Step 10. Disable pan/tilt (if necessary).


Step 11. Set color to WHITE and intensity to 100%.
Step 12. Unlatch and swing open front lens ring (this will make hot spot and halo easier to
see).
Step 13. Shine lamp on flat surface 10-20 feet away.
Step 14. Using lamp adjustment screws (shown in Figure 6), adjust lamp.
a. Minimize size of halo around hot spot. It will not completely disappear, but
should be even and symmetrical all the way around with no large blotches of
color at any one point.
b. Maximize spot intensity by making hot spot as small and tightly focused as
possible. Hot spot should be centered in halo and in larger brownish circle surrounding it.

Beam Adjustment Screws*


* Do not remove or use to access lamp.

Figure 6: Lamp Alignment Screws


Step 15. Close and latch front lens ring.

16

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02 .9 685.00 10 0

MAINTENANCE :

Front Glass Replacement


Parts:As needed:
42.9685.0201
42.9685.0207
42.9685.0203
42.9685.0206
42.9685.0204
42.9685.0205

1 EA
1 EA
1 EA
1 EA
1 EA
1 EA

GLASS, FRONT, CLEAR


GLASS, FRONT, STIPPLE
GLASS, FRONT, MED. FLOOD 8-ROW LENT.
GLASS, FRONT, MED. FLOOD 10-ROW LENT.
GLASS, FRONT, MED. FLOOD 12-ROW LENT.
GLASS, FRONT, VERY WIDE FLOOD - BUXOM

Tools:

Cotton Gloves or Finger Cots

Clean, Lint-free (Soft) Cloth

To remove and replace front glass:

WARNING: Remove power from luminaire before performing maintenance.

Note: It is often easier to replace the lenses when the fixture is warm. However, use caution
when handling a warm fixture as damage to glass components can occur (lamp, reflector, etc.).
Step

1. Remove power from luminaire.

Step

2. At front ring assembly, open latch and swing open. Refer to Figure 7.

Front Ring
Assembly

Head Assembly

Front Lens
Hinge Latch

Figure 7: Replacing Front Glass

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17-July-2006

17

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

CAUTION: Wear thick, protective gloves or other protective covering while handling front
lens. The lens is extremely fragile and can break if too much force is applied. If dirty, clean
with common glass cleaner and a soft, lint-free cloth.
Step

3. At front ring assembly, carefully press front side of lens inward with thumbs while
holding ring with fingers until glass is free of holder. Remove lens.

WARNING: When installing a new or replacement lens in a VL500ATM (ARC) Wash, all
lens types must be installed curve out (convex). In tungsten fixtures (VL500TM, VL500DTM,
and VL500 80VTM 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).
Step

4. Position new glass in front ring assembly. Be sure glass is fully and properly seated
into rubber ring. See Table 2-2, Lens Mounting Orientation, for each model.
Incandescent Models (VL500, VL500D, and VL500 80V)
Clear Lens

Concave or Convex

Stipple Lens

Concave or Convex

8-Row Lens

Convex Only

10-Row Lens

Convex Only

12-Row Lens

Convex Only

Buxom Lens

Convex Only

Arc Models (VL500A)


Clear Lens

Convex Only

Stipple Lens

Convex Only

8-Row Lens

Convex Only

10-Row Lens

Convex Only

12-Row Lens

Convex Only

Buxom Lens

Convex Only

Note: Concave = Bubble In / Convex = Bubble Out

Table 2-2: Lens Mounting Orientation


Step

18

5. Close and latch front ring assembly.

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

Magenta/Blue DICHRO*TUNE Rear Bulkhead


Replacement
Parts:
21.9685.0170

1 EA

21.9685.0174

1 EA

21.9685.0173

1 EA

21.9685.0175

1 EA

ASSY, MAGENTA/BLUE (STANDARD DICHRO*TUNE


COLORS - INCANDESCENT)
ASSY, MAGENTA/BLUE (PASTEL DICHRO*TUNE
COLORS - INCANDESCENT)
ASSY, MAGENTA/BLUE (STANDARD DICHRO*TUNE
COLORS - ARC)
ASSY, MAGENTA/BLUE (PASTEL DICHRO*TUNE
COLORS - ARC)

Tools:

#2 Phillips Screwdriver

To remove and replace Magenta/Blue bulkhead assembly:


Step

1. CLOSE ALL GLASS IN BULKHEADS - Power up unit and allow all


DICHRO*TUNE glass to calibrate. Once they close, power down unit.

WARNING: Remove power from luminaire before performing maintenance.


Step

2. Disconnect luminaire AC input cable from power source.

Step

3. Engage tilt lock so luminaire head is in horizontal position with top cover (one with
bubble) facing up (as shown in Figure 8).

Step

4. As indicated in Figure 8, open heatsink by releasing latch.


Magenta/Blue Assembly

Top Cover
Amber/Diffuser Assembly*
(Incandescent Models)
or
Amber/Dimmer Assembly*
(Arc Models)

Heatsink Assembly

*See separate procedure for


removing and replacing these
assemblies.

NOTE:

Some components not shown for clarity.

Figure 8: Magenta/Blue Color Bulkhead

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17-July-2006

19

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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.

Step

8. As shown in Figure 9, at side rails from top, remove four 6-32x3/8" LG PPZ
SEMS screws.

Magenta/Blue Assembly

6-32x3/8" PPZ SEMS (x4)

Side Rail
NOTE:

Some components not shown for clarity.

Figure 9: Magenta/Blue Color Bulkhead


Step

9. Carefully lift Magenta/Blue bulkhead out of luminaire head.

Step 10. Replace by performing steps 2 through 10 in reverse order.

Note: This is also the procedure to convert a standard color bulkhead to pastel color bulkhead
or vice versa.

20

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

Amber/Diffuser (or Dimmer) DICHRO*TUNE


Front Bulkhead Replacement
Parts:
21.9685.0171
21.9685.0172

1 EA
1 EA

ASSY, AMBER/DIFFUSER (INCANDESCENT MODELS)


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. Once they close, power down unit.

WARNING: Remove power from luminaire before performing maintenance.


Step

2. Disconnect luminaire AC input cable from power source.

Step

3. Engage tilt lock so luminaire head is in horizontal position with top cover (one with
bubble) facing up (as shown in Figure 10).

Step

4. As indicated in Figure 10, open front ring by releasing latch.


Magenta/Blue Assembly*

Top Cover
Amber/Diffuser Assembly
(Incandescent Models)

*See separate procedure for


removing and replacing this
assembly.

or
Amber/Dimmer Assembly
(Arc Models)

Front Ring

NOTE:

Some components not shown for clarity.

Figure 10: Amber/Diffuser (or Dimmer) Bulkhead


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 Amber/Diffuser (or Dimmer)


DICHRO*TUNE Front Bulkhead.

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17-July-2006

21

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Step

8. As shown in Figure 11, 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

Side Rail

Figure 11: Amber/Diffuser (or Dimmer) Bulkhead


Step

9. Carefully lift Amber/Diffuser (or Dimmer) bulkhead out of luminaire head.

Step 10. Replace by performing steps 2 through 10 in reverse order.

22

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

Color Filter and Diffuser Panel Replacement


Parts:
22.9685.0122
22.9685.0123
22.9685.0120
22.9685.0121
22.9685.0124
22.9685.0126

16 EA
16 EA
16 EA
16 EA
16 EA
16 EA

ASSY, FILTER, MAGENTA, DICHRO*TUNE (STD)


ASSY, FILTER, BLUE, DICHRO*TUNE (STD)
ASSY, FILTER, MAGENTA, DICHRO*TUNE (PASTEL)
ASSY, FILTER, BLUE, DICHRO*TUNE (PASTEL)
ASSY, FILTER, AMBER, DICHRO*TUNE
ASSY, FILTER, DIFFUSER PANEL

Tools:

#1 Phillips screwdriver

Tweaker Screwdriver

Cotton Gloves or Finger Cots

Clean, lint-free (soft) cloth

To remove and replace color filters or diffuser panels:


Step

1. Ensure glass filter or diffuser panels are in closed position.

WARNING: Remove power from luminaire before performing maintenance.


Step

2. Remove power from luminaire.

Step

3. Set the luminaire head horizontally.

Step

4. Engage service tilt lock to secure luminaire head in horizontal position to access
heatsink latch.

Step

5. Remove desired bulkhead assembly as follows:


a. For Magenta/Blue bulkhead removal, refer to, Magenta/Blue DICHRO*TUNE
Rear Bulkhead Replacement on page 19. Remove Magenta/Blue bulkhead.
b. For Amber/Diffuser bulkhead removal, refer to, Amber/Diffuser (or Dimmer)
DICHRO*TUNE Front Bulkhead Replacement on page 21. Remove Amber/
Diffuser bulkhead.

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23

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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. If they become separated,
a new filter or panel must be installed since RTV must be UV-cured.
Step

6. Disconnect actuator screw from Swivel Coupler using tweaker screwdriver by


carefully prying apart from Drive Ring Link.

Color Filter/
Diffuser Panel

Pad Lip
Silicone Pad

Insert Filter
Carrier Pin

Center Hub
Carrier Arch

Filter Carrier

Bulkhead

Figure 12: Color Filter and Diffuser Panel Removal


Step

7. Open glass filter or diffuser panels.

Step

8. Remove filter or panel as follows (shown in Figure 12):


a. At filter or panel, gently push assembly (with silicon pad) in towards center hub
(away from carrier) and work end of tweaker screwdriver between silicon pad
and carrier.
b. Gently work side of silicone pad (not under carrier arch) free.
c. After side of silicone pad is free from carrier, remove silicone pad from under
carrier arch and remove filter or panel.

Step

9. Insert filter carrier pin (of replacement filter or panel) into center hub as shown in
Figure 12.

Step 10. Place side of silicone pad with lip into arch on installed carrier.
Step 11. Using tweaker screwdriver, gently run screwdriver tip over silicone pad, driving
silicone pad into carrier and fully seating silicone pad.
Step 12. Reassemble luminaire.

24

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

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.

WARNING: Remove power from luminaire before performing maintenance.


Step

2. Remove power from luminaire.

Step

3. Set the luminaire head horizontally.

Step

4. Engage service tilt lock to secure luminaire head in horizontal position to access
heatsink latch.

Step

5. Unlatch and swing open front ring.

Step

6. Remove Amber/Diffuser bulkhead by following procedure, Amber/Diffuser (or


Dimmer) DICHRO*TUNE Front Bulkhead Replacement on page 21.

Step

7. Disconnect actuator screw from swivel coupler using tweaker screwdriver by


carefully prying apart from Drive Ring Link.

Step

8. Open dimmer panels slightly.

Step

9. Remove one 4-40 x 1/8" PPB screw that attaches dimmer panel to Dimmer Carrier.
4-40x1/8" PPB Screw
Dimmer Panel

Bearing

Carrier
Spring

Drive Arm Link

Figure 13: Dimmer Panel

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17-July-2006

25

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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.

26

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

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. Remove power from luminaire.

Step

2. Set the luminaire head horizontally.

Step

3. Engage tilt service lock to secure luminaire head in horizontal position to access
heatsink latch.
Magenta/Blue Assembly

Top Cover
Amber/Diffuser Assembly*
(Incandescent Models)
or

Linear Actuator Motor Assembly

Amber/Dimmer Assembly*
(Arc Models)
Heatsink Assembly

*See separate procedure for


linear motor replacement for
these assemblies.

Front Ring

NOTE:

Some components not shown for clarity.

Figure 15: Magenta/Blue Color Bulkhead - Linear Actuator Motors


Step

4. Remove top head cover.

Note: Linear actuator motors should be seen with cover removed. If not, flip head position.

02.96 85.001 0 0

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27

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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" PPZ screws and three #4 lock washers securing motor mount to
luminaire head.
b. At linear actuator motor assemblies, using #2 slotted screwdriver, disconnect
actuator/drive ring links from swivel links on drive rings.

Step

7. At linear actuator motor, using #1 Phillips screwdriver, remove two 4-40x1/4" PPZ
screws securing linear actuator motor to actuator mount, and remove motor. See
Figure 16.

4-40x1/4 PPZ Screw (2 for each motor)


Actuator Screw

Note:

Versilube Silicon Grease (G321) is


used to lubricate the actuator screw.

Motor Mount

Linear Actuator Motor


Drive Ring Link

Figure 16: Magenta/Blue Linear Actuator Motor Replacement


Step

8. Place linear actuator motor in place on actuator mount.

Step

9. Re-install two 4-40x1/4" PPZ screws and two #4 lock washers and, using #1 Phillips
screwdriver, tighten to secure linear actuator motor and heatsink to actuator mount.

Step 10. Secure actuator/drive ring link to drive ring swivel link.
Step 11. Attach wiring.
Step 12. Re-install top head cover.
Step 13. Release tilt service lock.

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MAINTENANCE :

Linear Actuator Motor Replacement (Amber/Diffuser [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. Remove power from luminaire.

Step

2. Set the luminaire head horizontally.

Step

3. Engage tilt service lock to secure luminaire head in horizontal position to access
heatsink latch.
Magenta/Blue Assembly*
*See separate procedure for
linear motor replacement for
these assemblies.

Top Cover

Linear Actuator
Motor Assembly

Amber/Diffuser Assembly
(Incandescent Models)

Heatsink Assembly

or
Amber/Dimmer Assembly
(Arc Models)

Front Ring

NOTE:

Some components not shown for clarity.

Figure 17: Amber/Diffuser (or Dimmer) Bulkhead - Linear Actuator Motors


Step

4. Remove top head cover.

Note: Linear actuator motors should be seen with cover removed. If not, flip head over.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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" PPZ screws and three #4 lock washers securing motor mount to
luminaire head.
b. At linear actuator motor assemblies, using #2 slotted screwdriver, disconnect
actuator/drive ring links from swivel links on drive rings.

Step

7. At linear actuator motor, using #1 Phillips screwdriver, remove two 4-40x1/4" PPZ
screws securing linear actuator motor to actuator mount, and remove motor. See
Figure 18.

4-40x1/4 PPZ Screw (2 for each motor)

Actuator Screw

Note:

Versilube Silicon Grease (G321) is


used to lubricate the actuator screw.

Motor Mount

Linear Actuator Motor


Drive Ring Link

Figure 18: Amber/Diffuser (or Dimmer) Linear Actuator Motor Replacement


Step

8. Place linear actuator motor in place on actuator mount.

Step

9. Re-install two 4-40x1/4" PPZ screws and two #4 lock washers and, using #1 Phillips
screwdriver, tighten to secure linear actuator motor and heatsink to actuator mount.

Step 10. Secure actuator/drive ring link to drive ring swivel link.
Step 11. Attach wiring.
Step 12. Re-install top head cover.
Step 13. Release tilt service lock.

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MAINTENANCE :

Incandescent Lamp Socket Assembly (VL500


and VL500D Only) Replacement
Parts:
23.9685.0780

1 EA

ASSY, LAMP SOCKET (VL500 AND VL500D ONLY)

Tools:

#2 Phillips Screwdriver

1/4" Hex Nutdriver

To remove and replace lamp socket assembly:


Step

1. CLOSE ALL GLASS IN BULKHEADS - Power up unit and allow all


DICHRO*TUNE glass to calibrate. Once they close, power down unit.

WARNING: Remove power from luminaire before performing maintenance.


Step

2. Disconnect luminaire AC input cable from power source.

Step

3. Engage tilt lock so luminaire head is in horizontal position with top cover (one with
bubble) facing up (as shown in Figure 19).

Step

4. Open heatsink by releasing latch.


Top Cover

Magenta/Blue Bulkhead Assembly

Heatsink Assembly
NOTE:

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


DICHRO*TUNE Rear Bulkhead Replacement on page 19. Remove Magenta/Blue
bulkhead.

Step

8. Using soft cloth to protect lamp, remove lamp from socket.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Step

9. As indicated in Figure 20, at light baffle, remove three 6-32x1/8" PPB screws.
Backcap
Light Leak Foam

Lamp Socket

Reflector
Light Baffle

6-32x1/4" PPZ
Screws (x2)

8-32x1/2" PPZ SEM Screws (x4)

Reflector Clips (x3)


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.
Step 12. Remove yoke arm cover opposite display side by removing four 6-32x3/8" LG PTB
screws.
Step 13. If applicable, remove dimmer. See, IGBT Dimmer Replacement (VL500D Only) on
page 47 for IGBT dimmer removal.
Step 14. At inside of side rail, remove two 4-40x1/8" LG PPB screws and remove Lamp
Wire Cover.
Step 15. At support rib closest to tilt tube, remove one 6-32x1/4" LG PPG screw and remove
ground strap.
Step 16. Remove tilt tube plug and pass lamp wires through tilt tube.
Step 17. Inside heatsink, remove four 8-32x1/2" LG PPZ SEM screws and remove back cap
Step 18. Remove heatsink light leak foam and pass lamp wire through heatsink.
Step 19. At socket, remove two 6-32x1/4" LG PPZ SEM screws and remove socket.
Step 20. Replace by performing Steps 3 through 19 in reverse order.

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MAINTENANCE :

Arc lamp Socket Assembly (VL500A and VL500


80V Only) Replacement
Parts:
23.9685.0780

1 EA

ASSY, LAMP SOCKET (VL500 AND VL500D ONLY)

Tools:

#2 Phillips Screwdriver

1/4" Hex Nutdriver

5/64" Allen Wrench

To remove and replace lamp socket assembly:


Step

1. CLOSE ALL GLASS IN BULKHEADS - Power up unit and allow all


DICHRO*TUNE glass to calibrate. Once they close, power down unit.

WARNING: Remove power from luminaire before performing maintenance.


Step

2. Disconnect luminaire AC input cable from power source.

Step

3. Engage tilt lock so luminaire head is in horizontal position with top cover (one with
bubble) facing up (as shown in Figure 21).

Step

4. Open heatsink by releasing latch.


Top Cover

Magenta/Blue Bulkhead Assembly

Heatsink Assembly
NOTE:

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


DICHRO*TUNE Rear Bulkhead Replacement on page 19. Remove Magenta/Blue
bulkhead.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Step

8. Using soft cloth to protect lamp, remove lamp from socket.

Step

9. As indicated in Figure 22, at light baffle, remove three 6-32x1/8" PPB screws.
10-32x1-1/2" PPB Screws VL500A Only
10-32x1" SCB Screws VL500 80V Only
Spring (x3) VL500A Only
Backcap Extension

Backcap
Lamp Socket
Reflector
Light Baffle

8-32x3/8" PPZ
Screws (x2)

1/4" Hex
Standoff (x3)

8-32x1/2" PPZ SEM Screws (x4)


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.
Step 12. Inside heatsink, remove four 8-32x1/2" LG PPZ SEM screws and remove back cap
Step 13. Remove lamp alignment screws as follows:
a. For VL500A models, at backcap, remove three 10-32x1-1/2" LG PPB screws
and springs.
b. For VL500 80V models, at backcap, remove three 10-32x1" LG SCB screws.
Step 14. Remove backcap extension.
Step 15. At socket, remove two 8-32x3/8" LG PPZ SEM screws and two socket clips.
Step 16. Remove socket from backcap.
Step 17. Using 5/64" Allen wrench, loosen two set-screws and remove lamp wires from
socket.
Step 18. Replace lamp socket by performing Steps 3 through 17 in reverse order.

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MAINTENANCE :

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.

Step

2. Remove display-side yoke arm cover by removing four 6-32x3/8" screws.

Step

3. At display overlay, as indicated in Figure 23, remove four 6-32x1/4" PPB screws.
6-32x1/4" PPB (x4)

1/4" Hex (9/32" Long)


Standoff (x4)

Menu
Display
Display Lens
Yoke Arm
Cover

Display Overlay
Display PCB

NOTE:

Some components not shown for clarity.

Figure 23: Display PCB Replacement


Step

4. Remove display overlay.

Step

5. As indicated in Figure 23, remove four 1/4" hex (9/32" long) standoffs.

Step

6. At display PCB, disconnect the following wiring connections:


a. 4-position MTA connector (24V DC)
b. 2-position connector (MCB Fan)
c. 4-position connector (LVS Fan/Temperature Switch)
d. 6-position connector (Display Communication)

Step

7. Remove Display PCB.

Step

8. Replace by performing Steps 2 through 7 in reverse order.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Main Control PCB/Fan Assembly Replacement


Parts:
21.9685.0731

1 EA

ASSY, VL500 MAIN CONTROL PCB/FAN

Tools:

1/4" Hex Nutdriver

#2 Phillips Screwdriver

WARNING: Remove power from luminaire before performing maintenance.


To remove and replace main control PCB/fan assembly:
Step

1. Remove power from luminaire.

Step

2. Remove display-side yoke arm cover by removing four 6-32x3/8" screws.

Step

3. Remove Display PCB as described in, Incandescent Lamp Socket Assembly (VL500
and VL500D Only) Replacement on page 31.

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)*

CAUTION: *This connector is similar to the connector for the LVS Fan/Temperature
Switch connector used on the Display PCB. It is imperative that you do not confuse the two.
f.

3-position connector (24V DC)

g. 5-position connector (Ballast communications - VL500A models only)


Step

36

5. Remove two 6-32x3/8" PPZ screws (one has a ground wire terminal attached).

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MAINTENANCE :

Step

6. Remove four 1/4" hex (13/16" long) standoffs as indicated in Figure 24.
6-32x1/4" PPB (x4)

1/4" Hex (9/32" Long)


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.

Figure 24: Main Control PCB/Fan Replacement


Step

7. Remove Main Control PCB/Fan Assembly.

Step

8. Replace Main Control PCB/Fan Assembly by following Steps 2 through 7 in reverse


order.

Step

9. Configure Main Control PCB using menus as needed.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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.
To remove and replace LVS:
Step

1. Remove power from luminaire.

Step

2. Remove yoke arm cover opposite display side by removing four 6-32x3/8" screws.

Wire Shield (fish paper)


LVS Power Supply

6-32x3/8" PPZ (x4)

NOTE:

Some components not shown for clarity.

Figure 25: LVS Replacement (VL500/VL500D/VL500A Only)


Step

3. Disconnect the following wiring connections:


a. 3-position connector (AC Input)
b. 6-position MTA connector (DC Output)

38

Step

4. As shown in Figure 25, remove four 6-32x3/8" PPZ, SEMS screws.

Step

5. Remove LVS. Note fish paper (Wire Shield) behind LVS, save and reuse with
replacement LVS.

Step

6. Replace by performing steps 2 through 5 in reverse order.

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MAINTENANCE :

Low Voltage Supply (LVS) Temperature PCB


Replacement (VL500/VL500D/VL500A Only)
Parts:
24.9685.0740

1 EA

TEMPERATURE BOARD, LVS

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.
To remove and replace LVS temperature PCB:
Step

1. Remove power from luminaire.

Step

2. Remove LVS by following procedure, Low Voltage Supply (LVS) Replacement


(VL500/VL500D/VL500A Only) on page 38.

Yoke Arm
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)

Step

4. As shown in Figure 26, remove one 1/4" hex standoff.

Step

5. Remove LVS Temperature PCB.

Step

6. Replace by performing steps 2 through 5 in reverse order.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Low Voltage Supply (LVS) Replacement (VL500


80V Only)
Parts:
69.3178.0121

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.
To remove and replace LVS:
Step

1. Remove power from luminaire.

Step

2. Position light to access top of pan tube assembly.

Step

3. At pan tube cover, remove six 8-32x1/2" PFB screws.

Step

4. Remove pan tube cover. (Note, tether will still hold cover).
Do not remove this screw

Pan Tube Cover

8-32x1/2" PFB Screws (x6)


4-40x1/4" PPZ Screws (x4)

Cover Tether

LVS Power Supply


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)

40

Step

6. As shown in Figure 27, remove four 4-40x1/4" PPZ screws.

Step

7. Remove LVS. Note fish paper (Wire Shield) under LVS, save and reuse with
replacement LVS.

Step

8. Replace by performing steps 3 through 7 in reverse order.

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MAINTENANCE :

Low Voltage Supply (LVS) Temperature PCB


Replacement (VL500 80V Only)
Parts:
24.9685.0740

1 EA

TEMPERATURE BOARD, LVS

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.
To remove and replace LVS temperature PCB:
Step

1. Remove power from luminaire.

Step

2. Remove LVS by following procedure, Low Voltage Supply (LVS) Replacement


(VL500 80V Only) on page 40.
LVS Power Supply

LVS Temperature PCB


6-32x3/8" PPZ
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)

Step

4. As shown in Figure 26, remove one 6-32x3/8" PPZ securing LVS Temperature
PCB to fan bracket assembly.

Step

5. Remove LVS Temperature PCB.

Step

6. Replace by performing steps 2 through 5 in reverse order.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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:

42

Step

1. Disconnect luminaire AC input cable from power source.

Step

2. Remove display side yoke cover by removing four 6-32x3/8" LG PTB screws.

Step

3. Remove Display PCB and Main Control PCB by following procedures Display PCB
Replacement on page 35 and Main Control PCB/Fan Assembly Replacement on page
36.

Step

4. Remove 4 x 6-32 x 3/8" PFB screws (two each side of yoke) that hold Top Cover
Louver Plate and remove plate.

Step

5. Disconnect wiring from motor and encoder PCB.

Step

6. Cut wire tie connecting wiring to yoke arm.

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MAINTENANCE :

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" PPZ (x4)

Spring
8-32x7/16" PPZ

Figure 29: Tilt Motor Assembly Replacement


Step

8. Press motor towards spring to loosen belt tension.

Step

9. Remove belt from both drive pulley and driven pulley.

Step 10. Remove four 8-32x7/16" PPZ screws that mount Tilt Motor Slide Plate to yoke and
remove ENTIRE assembly.
Step 11. Remove four 8-32x7/16" PPZ screws that mount Pan/Tilt Motor Assembly to Tilt
Motor Slide Plate and remove Pan/Tilt Motor Assembly (be careful of spring).
Step 12. Replace by performing Steps 2 through 10 in reverse order.

Note: When tightening four 8-32x7/16" PPZ screws that mount Pan/Tilt Motor Assembly to
Tilt Motor Slide Plate, you must tighten in a CLOCKWISE pattern starting with screw in
lower left-hand side from spring.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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.

Step

2. Remove yoke cover opposite of display by removing four 6-32x3/8" LG PTB


screws.

Step

3. Remove 4 x 6-32 x 3/8" PFB screws (two each side of yoke) that hold Top Cover
Louver Plate and remove plate.

Step

4. Disconnect wiring from motor and encoder PCB.

Step

5. As shown in Figure 30, loosen, but do not remove, four 8-32x1/2" PPB screws.

Step

6. Press motor towards driven pulley and remove belt from drive pulley.

Step

7. Remove four 8-32x1/2" PPB screws from Step 5.

Step

8. Remove Pan/Tilt Motor Assembly.


NOTE:

Spring
8-32x1/2" PPB (x4)

Some components not shown for clarity.

Pan Belt
Pan Motor
Assembly
Pan Motor Assembly

Yoke Arm

Figure 30: Pan Motor Assembly Replacement


Step

9. Replace pan motor assembly by performing Steps 2 through 8 in reverse.

Note: When tightening four 8-32x1/2" PPB screws, you must tighten in a CLOCKWISE
pattern starting with screw in lower left-hand side from spring.

44

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MAINTENANCE :

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. To access pan/tilt encoder PCB:


a. For Tilt Motor Encoder PCB removal, remove display side yoke cover by
removing four 6-32x3/8" LG PTB screws.
b. For Pan Motor Encoder PCB removal, access pan motor assembly see, Pan
Motor Assembly Replacement on page 44.

Step

3. At encoder PCB, disconnect wiring harness from assembly.

Step

4. As shown in Figure 31, remove two 6-32x3/8" PPZ screws and remove assembly.
Pan/Tilt Motor Encoder PCB

6-32x3/8" PPZ

Encoder Disk

Figure 31: Pan/Tilt Motor Encoder PCB Replacement


Step

5. Replace by performing Steps 2 through 4 in reverse order.

Note: Ensure that encoder disk passes freely through the optical sensor on PCB.

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45

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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. Disconnect luminaire AC input cable from power source.

Step

2. Remove yoke cover opposite of display by removing four 6-32x3/8" LG PTB


screws.

Step

3. At Ignitor PCB, disconnect Input and Output lamp wires.

Step

4. As shown in Figure 32, remove four 6-32x3/8" PPZ SEMS screws from PCB.
NOTE:

Some components not shown for clarity.

Ignitor PCB
6-32x3/8" PPZ SEMS (x4)

Ignitor PCB
Yoke Arm Cover

Figure 32: Ignitor PCB Replacement


Step

5. Remove Ignitor PCB.

Note: Make sure and install ignitor with proper orientation. Wires from Relay attached to
posts labeled "From Relay". Wires going to lamp attach to posts labeled "To Bulb".
Step

46

6. Replace Ignitor PCB by performing Steps 2 through 6 in reverse.

17-July-2006

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MAINTENANCE :

IGBT Dimmer Replacement (VL500D Only)


Parts:
69.3173.0115

1 EA

69.3173.0230

1 EA

DIMMER, IGBT, 1200W 115V REV PHASE CONT


(VL500D 115V MODELS ONLY)
DIMMER, IGBT, 1000W 230V REV PHASE CONT
(VL500D 230V MODELS ONLY)

Tools:

#2 Phillips Screwdriver

WARNING: Remove power from luminaire before performing maintenance.


To remove and replace IGBT dimmer:
Step

1. Disconnect luminaire AC input cable from power source.

Step

2. Remove yoke cover on dimmer side by removing four 6-32x3/8" LG PTB screws.

Step

3. As shown in Figure 33, at dimmer, loosen, but do not remove, four 6-32x3/8" PPZ
screws.

Step

4. Carefully remove IGBT dimmer. Note that there will be wires connected to dimmer
on the back side.

CAUTION: All AC wiring is same color. It is a good idea to mark the connector attached to
both the AC Line Input and Load (Output) terminals on the IGBT dimmer with a black marker
before removing so the phasing can be maintained.
Step

5. At dimmer, carefully note (and label before removing) and disconnect following
wiring:
a. 3-position (Dimmer Communication from MCB)
b. Four Faston (Quick Connects - AC Input / lamp Power Output)

Step

02.96 85.001 0 0

6. Remove four 6-32x3/8" PPZ screws from Step 3. Install these screws in replacement
IGBT dimmer.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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

48

7. Replace IGBT Dimmer by performing Steps 2 through 6 in reverse.

17-July-2006

02 .9 685.00 10 0

MAINTENANCE :

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.

Step

2. Remove yoke cover on dimmer side by removing four 6-32x3/8" LG PTB screws.

Step

3. As shown in Figure 34, at dimmer, loosen, but do not remove, four 6-32x3/8" PPZ
screws.

Step

4. Carefully remove 80V dimmer. Note that there will be wires connected to dimmer
on the back side.

CAUTION: All AC wiring is same color. It is a good idea to mark the connector attached to
both the AC Line Input and Load (Output) terminals on the IGBT dimmer with a black marker
before removing so the phasing can be maintained.
Step

5. At dimmer, carefully note (and label before removing) and disconnect following
wiring:
a. 4-position (Dimmer Communication from MCB)
b. Four Faston (Quick Connects - AC Input / lamp Power Output)

Step

02.96 85.001 0 0

6. Remove four 6-32x3/8" PPZ screws from Step 3. Install these screws in replacement
80V dimmer.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

NOTE:

Some components not shown for clarity.

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

50

7. Replace 80V Dimmer by performing Steps 2 through 6 in reverse.

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MAINTENANCE :

Arc Ballast Replacement (VL500A Only)


Parts:
21.9685.0800
21.9685.0802

1 EA
1 EA

ASSY, BALLAST, 625W (575W MODELS ONLY)


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. Disconnect luminaire AC input cable from power source.

Note: The Arc Ballast Unit is separate from the luminaire.


Step

2. Disconnect Ballast Interconnect Cable Assembly from ballast and luminaire.

Step

3. Connect Ballast Interconnect Cable Assembly to replacement ballast and luminaire.

Figure 35: Arc Ballast Assembly

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51

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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. Disconnect luminaire AC input cable from power source.

Step

2. Remove yoke cover opposite of display by removing four 6-32x3/8" LG PTB


screws.

Step

3. At Relay, disconnect following wiring:


a. Bundled AC from Ballast
b. White AC to Ignitor
c. Red +24V DC from MCB
d. Green -24V DC from Backcap Interlock (Kill) Switch

Step

4. At Relay, loosen, but do not remove, two 4-40x5/16" PPZ SEMS screws.
NOTE:

Some components not shown for clarity.

Relay
4-40x5/16" PPZ SEMS (x2)

Relay
Yoke Arm Cover

Step

5. Carefully slide Relay out of yoke arm.

Note: When replacing Relay, do not overtighten screws securing Relay (as described in Step
4). Doing so may crack plastic tabs on Relay.
Step

52

6. Replace Relay by performing Steps 2 through 5 in reverse.

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MAINTENANCE :

AC Input (PowerCon) Connector Replacement


Parts:
25.9685.0756

1 EA

CONNECTOR, AC INPUT (POWERCON)

Tools:

#2 Phillips Screwdriver

WARNING: Remove power from luminaire before performing maintenance.


To remove and replace AC input (PowerCon) connector:
Step

1. Remove power from luminaire.

Step

2. Position light to access top of pan tube assembly.

Step

3. As shown in Figure 36, at pan tube cover, remove six 8-32x1/2" PFB screws.

Step

4. Remove pan tube cover. (Note, tether will still hold cover).
8-32x1/2" PFB
Screws (x6)

Do not remove this screw


Pan Tube Cover

NOTE:

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.

Step

6. Disconnect wiring from PowerCon.

Step

7. Replace PowerCon by performing Steps 3 through 6 in reverse.

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Mini-XLR (Display/Remote Programming) Connector 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. Remove power from luminaire.

Step

2. Position light to access top of pan tube assembly.

Step

3. As shown in Figure 37, at pan tube cover, remove six 8-32x1/2" PFB screws.

Step

4. Remove pan tube cover. (Note, tether will still hold cover).
8-32x1/2" PFB
Screws (x6)

Do not remove this screw


Pan Tube Cover

NOTE:

Some components not


shown for clarity. This
procedure is applicable
for all models.

Pan Tube Assembly

Cover Tether

Mini-XLR
Connector

VL500 80V
Pan Tube Assembly

4-40x1/4" PFB
Screws (x2)

Figure 37: Mini-XLR (Display/Remote Programming) Connector Replacement

54

Step

5. Disconnect wiring from Mini-XLR.

Step

6. Remove two 4-40x1/4" PFB screws at front of Mini-XLR connector.

Step

7. Replace Mini-XLR by performing Steps 3 through 6 in reverse.

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MAINTENANCE :

DMX PCB Assembly Replacement


Parts:
24.9663.1895

1 EA

ASSY, DMX INPUT PCB

Tools:

#2 Phillips Screwdriver

WARNING: Remove power from luminaire before performing maintenance.


To remove and replace DMX PCB assembly:
Step

1. Remove power from luminaire.

Step

2. Position light to access top of pan tube assembly.

Step

3. As shown in Figure 38, at pan tube cover, remove six 8-32x1/2" PFB screws.

Step

4. Remove pan tube cover. (Note, tether will still hold cover).
8-32x1/2" PFB
Screws (x6)

Do not remove this screw


Pan Tube Cover

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. Disconnect wiring from DMX PCB Assembly.

Step

6. Remove four #4x3/8" H/L PN BLK ZN screws at front of DMX PCB Assembly.

Step

7. Replace DMX PCB Assembly by performing Steps 3 through 6 in reverse.

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55

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

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 manufacturers safety instructions and precautions.
The front lens, optics/color filters, and reflector may require cleaning after extended use.

FRONT LENS: Use a common glass cleaner along with a soft, lint-free cloth to clean the
front lens.

OPTICS/COLOR FILTERS: Use Acetone or Isopropyl Alcohol along with a soft, lint-free
cloth to clean the optics/color filters.

REFLECTOR: Use Acetone or Isopropyl Alcohol along with a soft, lint-free cloth to clean
the reflector.

CAUTION: Do not continuously rub color filters or reflector - it may damage or remove the
optical coating.

56

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CHAPTER 3.
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.

VL500 Model Parts Identifiers


ABBREVIATION
VL500
VL500D
VL500 80V
VL500A

02.96 85.001 0 0

MODEL (INCLUDES STANDARD AND PASTEL COLOR SYSTEMS)


VL500 Incandescent Luminaire (120V or 230V)
VL500D Incandescent Luminaire with IGBT On-Board Dimmer (120V or 230V)
VL500 80V Incandescent Luminaire with 80V On-Board Dimmer
VL500A Arc Luminaire (575W or 700W) with External Ballast

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Drawing Trees
VL500 and VL500D Incandescent Luminaires
VL500 Luminaire (120V or 230V) Incandescent Versions
20.9685.0001 Rev G (Standard DICRO*TUNE Colors) or 20.9685.0011 Rev B (Pastel DICRO*TUNE Colors) or 20.9685.0002 Rev F (Standard
DICRO*TUNE Colors) or 20.9685.0012 Rev B (Pastel DICRO*TUNE Colors) or 20.9685.0003 Rev F (Standard DICRO*TUNE Colors) or 20.9685.0013
Rev B (Pastel DICRO*TUNE Colors)

Generic VL500 Luminaire Assembly


21.9685.0010 Rev P (Incandescent - without Internal
Dimmer) or 21.9685.0011 Rev P (Incandescent with Internal IGBT Dimmer)

VL500 Generic Head Assembly

VL500 Motor Cable


Assembly

VL500 Magenta/Blue Color


Assembly

25.9685.0753 Rev B

21.9685.0170 Rev H (Standard


DICRO*TUNE Colors)

VL500 Head Grounding


Cable Assembly

or

21.9685.0310 (VL500 and VL500D)


Rev H

25.9685.0760 Rev C

VL500 Magenta/Blue
(Pastel) Color Assembly

Included Items Kit


Heatsink Assembly

28.9685.0001 Rev G
(120V or 230V, Standard
Colors, No Dimmer) or
28.9685.0011 Rev G
(120V or 230V, Pastel
Colors, No Dimmer) or
28.9685.0002 Rev G
(Standard Colors, 120V
IGBT On-Board Dimmer)
or 28.9685.0012 Rev G
(Pastel Colors, 120V IGBT
On-Board Dimmer) or
28.9685.0003 Rev G
(Standard Colors, 230V
IGBT On-Board Dimmer)
or 28.9685.0013 Rev G
(Pastel Colors, 230V IGBT
On-Board Dimmer)

21.9685.0174 Rev A (Pastel


DICRO*TUNE Colors)

21.9685.0320 (VL500 and VL500D)


Rev G

VL500 Backcap Ground Cable


Assembly
25.9685.0777 Rev A

VL500 Yoke Assembly


21.9685.0520 (VL500) Rev S or
21.9685.0521 (VL500D) Rev S

VL500 Pan/Tilt Motor


Assembly
21.9685.0540 Rev B

VL500 MCB/FAN Assembly


21.9685.0731 Rev 0

VL500 Main Control Board


PCB Assembly

Amber/Diffuser Color
Motor Assembly
21.9685.0281 Rev A

Magenta/Blue Color Motor


Assembly
21.9685.0280 Rev A

Magenta/Blue (Pastel)
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)

Bottom Bulkhead Assembly


21.9685.0150 Rev C

Drive Ring Assembly


21.9685.0280 Rev A

Magenta/Blue Color Motor


Assembly
21.9685.0280 Rev A

24.9685.0730 Rev B

MCB Fan Assembly


23.9685.0782 Rev 0

DMX Input PCB Assembly


24.9663.1895 Rev A

Amber/Diffuser Color
Assembly
21.9685.0161 Rev F

VL500 Amber/Diffuser
Color Assembly

Magenta/Blue Color
Assembly
21.9685.0160 Rev E (Standard
DICRO*TUNE Colors)

Bottom Bulkhead Assembly


21.9685.0150 Rev C

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)

58

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ILLUSTRATED PARTS BREAKDOWN :

VL500 and VL500D Incandescent Luminaires


(continued)
continued from previous page

VL500 Yoke Assembly


21.9685.0520 (VL500) Rev S or
21.9685.0521 (VL500D) Rev S

continued from previous page

VL500 Amber/Diffuser Color


Assembly
21.9685.0171 Rev G

Top Bulkhead Assembly


VL500 Main Harness Cable
Assembly

21.9685.0151 Rev C

25.9685.0790 Rev J (VL500 and


VL500D)

Drive Ring Assembly


21.9685.0280 Rev A

VL500 Extra Hardware Kit


28.9685.0999 Rev 0

MCB Fan Assembly


23.9685.0782 Rev 0

Yoke Crossmember Assembly


21.9685.0515 Rev E

Lower Crossmember Assembly


21.9685.0512 Rev H

Upper Crossmember Assembly


21.9685.0513 Rev F

Pan Tube Assembly


21.9685.0535 Rev D (VL500/VL500D/
VL500A)

VL500 AC Input Cable Assembly


25.9685.0756 Rev B

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

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 80V Incandescent Luminaires


VL500 80V (with 80V Dimmer) Luminaire
20.9685.0004 Rev H (Standard DICRO*TUNE Colors) or 20.9685.0014 Rev C (Pastel DICRO*TUNE Colors)

Generic VL500 Luminaire Assembly


21.9685.0012 Rev P (Incandescent - with
Internal 80V Dimmer)

VL500 Generic Head Assembly


21.9685.0312 (VL500 80V) Rev H

VL500 Motor Cable


Assembly

VL500 Magenta/Blue Color


Assembly

25.9685.0753 Rev B

21.9685.0170 Rev H (Standard


DICRO*TUNE Colors)

VL500 Head Grounding


Cable Assembly

or

25.9685.0760 Rev C

VL500 Magenta/Blue
(Pastel) Color Assembly

21.9685.0322 (VL500 80V) Rev G

Included Items Kit

21.9685.0174 Rev A (Pastel


DICRO*TUNE Colors)

VL500 Backcap Ground Cable


Assembly

28.9685.0004 Rev G
(Standard Colors, 80V OnBoard Dimmer) or
28.9685.0014 Rev G (Pastel
Colors, 80V On-Board
Dimmer)

Heatsink Assembly

25.9685.0777 Rev A

VL500 Ignitor to Socket Cable


Assembly
25.9685.0766 Rev C

VL500 Amber/Diffuser Color


Assembly

VL500 80V Yoke Assembly

21.9685.0171 Rev G

Magenta/Blue Color Motor


Assembly
21.9685.0280 Rev A

Magenta/Blue (Pastel)
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)

21.9685.0523 (VL500 80V) Rev G

VL500 Pan/Tilt Motor


Assembly
21.9685.0540 Rev B

Amber/Diffuser Color Motor


Assembly

Drive Ring Assembly

VL500 MCB/FAN Assembly


21.9685.0731 Rev 0

21.9685.0161 Rev F

24.9685.0730 Rev B

MCB Fan Assembly

21.9685.0150 Rev C

21.9685.0281 Rev A

Amber/Diffuser Color
Assembly

VL500 Main Control Board


PCB Assembly

Bottom Bulkhead Assembly

Top Bulkhead Assembly

21.9685.0280 Rev A

Magenta/Blue Color Motor


Assembly
21.9685.0280 Rev A

21.9685.0151 Rev C

Drive Ring Assembly


21.9685.0280 Rev A

23.9685.0782 Rev 0

Magenta/Blue Color
Assembly
21.9685.0160 Rev E (Standard
DICRO*TUNE Colors)

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)

60

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02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 80V Incandescent Luminaires (continued)


continued from previous page

VL500 80V Yoke Assembly


21.9685.0523 (VL500 80V) Rev G

VL500 80V Main Harness Cable


Assembly
25.9685.0792 Rev C (VL500 80V)

VL500 Extra Hardware Kit


28.9685.0999 Rev 0

MCB Fan Assembly


23.9685.0782 Rev 0

Yoke Crossmember Assembly


(VL500 80V)
21.9685.0516 Rev 0

Lower Crossmember Assembly


21.9685.0512 Rev H

Upper Crossmember Assembly


21.9685.0513 Rev F

80V Pan Tube Assembly


21.9685.0536 Rev 0 (VL500 80V)

VL500 AC Input Cable Assembly


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

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500A (575W/700W) Arc Luminaires


VL500A Luminaire (575W Arc) or VL500A Luminaire (700W Arc)
20.9685.0005 Rev H (Standard DICRO*TUNE Colors) or 20.9685.0015 Rev B (Pastel DICRO*TUNE Colors) or 20.9685.0006 Rev
H (Standard DICRO*TUNE Colors) or 20.9685.0016 Rev B (Pastel DICRO*TUNE Colors)

Generic VL500 Luminaire Assembly


21.9685.0013 Rev P (Arc)

VL500 Generic Head Assembly


21.9685.0311 (VL500A) Rev H

VL500 Motor Cable


Assembly

VL500 Magenta/Blue (Arc)


Color Assembly

25.9685.0753 Rev B

21.9685.0173 Rev A (Standard


DICRO*TUNE Colors)

VL500 Head Grounding


Cable Assembly
25.9685.0760 Rev C

VL500 Magenta/Blue (Arc


Pastel) Color Assembly

Included Items Kit

21.9685.0174 Rev A (Pastel


DICRO*TUNE Colors)

Heatsink Assembly
21.9685.0321 (VL500A) Rev G

VL500 Backcap Ground Cable


Assembly
25.9685.0777 Rev A

VL500 Ignitor to Socket Cable


Assembly
25.9685.0766 Rev C

28.9685.0005 Rev G (575W


Arc, Standard Colors, Arc
Ballast) or 28.9685.0015 Rev
G (575W Arc, Pastel Colors,
Arc Ballast) or 28.9685.0006
Rev G (700W Arc, Standard
Colors, Arc Ballast) or
28.9685.0016 Rev G (700W
Arc, Pastel Colors, Arc
Ballast)

VL500 Yoke Assembly


21.9685.0522 (VL500A) Rev S

VL500 Pan/Tilt Motor


Assembly

VL500 Amber/Dimmer
Color Assembly
21.9685.0172 Rev F

21.9685.0540 Rev B

Amber/Diffuser Color Motor


Assembly

VL500 MCB/FAN Assembly

21.9685.0281 Rev A

21.9685.0731 Rev 0

VL500 Main Control Board


PCB Assembly

Amber/Diffuser Color
Assembly

Magenta/Blue Color Motor


Assembly
21.9685.0280 Rev A

Magenta/Blue (Pastel)
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)

Bottom Bulkhead Assembly


21.9685.0150 Rev C

Drive Ring Assembly


21.9685.0280 Rev A

Magenta/Blue Color Motor


Assembly
21.9685.0280 Rev A

21.9685.0162 Rev E

24.9685.0730 Rev B

Top Bulkhead Assembly


MCB Fan Assembly

or

21.9685.0151 Rev C

23.9685.0782 Rev 0

Magenta/Blue Color
Assembly
21.9685.0160 Rev E (Standard
DICRO*TUNE Colors)

Drive Ring Assembly


DMX Input PCB Assembly

21.9685.0280 Rev A

continued next page

Bottom Bulkhead Assembly


21.9685.0150 Rev C

24.9663.1895 Rev A

continued next page

Drive Ring Assembly


21.9685.0280 Rev A

Figure 3-5: VL500A (575W/700W) Arc Luminaires Drawing Tree (Part 1)

62

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ILLUSTRATED PARTS BREAKDOWN :

VL500A (575W/700W) Arc Luminaires (continued)


continued from previous page

continued from previous page

VL500 Yoke Assembly

VL500A Luminaire (575W Arc) or VL500A Luminaire (700W Arc)

21.9685.0522 (VL500A) Rev S

28.9685.0005 Rev G (575W Arc, Standard Colors, Arc Ballast) or


28.9685.0015 Rev G (575W Arc, Pastel Colors, Arc Ballast) or
28.9685.0006 Rev G (700W Arc, Standard Colors, Arc Ballast) or
28.9685.0016 Rev G (700W Arc, Pastel Colors, Arc Ballast)

MCB Fan Assembly


21.9685.0731 Rev 0

VL500 Extra Hardware Kit

VL500 Arc Ballast Interconnect Cable Assembly

28.9685.0999 Rev 0

25.9685.0767 Rev B

VL500 AC Input Cable Assembly

Relay to Ignitor Cable Assembly


25.9685.0755 Rev B

25.9685.0756 Rev B

VL500 Arc Ballast Input Cable


Assembly
25.9685.0757 Rev C

VL500 Arc Ballast Assembly


21.9685.0800 Rev G (625W - VL500A 575W Arc) or
21.9685.0802 Rev G (700W - VL500A 700W Arc)

VL500 Display (Remote) Cable


Assembly

Ballast I/O Cable Assembly


25.9685.0807 Rev A

25.9685.0770 Rev B

VL500 Arc Main Harness Cable


Assembly
25.9685.0791 Rev C (VL500A)

Yoke Crossmember Assembly


21.9685.0515 Rev E

Lower Crossmember Assembly


21.9685.0512 Rev H

Upper Crossmember Assembly


21.9685.0513 Rev F

Pan Tube Assembly


21.9685.0535 Rev D (VL500/VL500D/
VL500A)

Figure 3-6: VL500A (575W/700W) Arc Luminaires Drawing Tree (Part 2)

02.96 85.001 0 0

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63

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Top Assembly
Included Items Kit
28.9685.0001
28.9685.0011
28.9685.0002
28.9685.0012
28.9685.0003
28.9685.0013
28.9685.0004
28.9685.0014
28.9685.0005
28.9685.0015
28.9685.0006
28.9685.0016

Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev

G
G
G
G
G
G
G
G
G
G
G
G

(120V or 230V, Standard Colors, No Dimmer)


(120V or 230V, Pastel Colors, No Dimmer)
(Standard Colors, 120V IGBT On-Board Dimmer)
(Pastel Colors, 120V IGBT On-Board Dimmer)
(Standard Colors, 230V IGBT On-Board Dimmer)
(Pastel Colors, 230V IGBT On-Board Dimmer)
(Standard Colors, 80V On-Board Dimmer)
(Pastel Colors, 80V On-Board Dimmer)
(575W Arc, Standard Colors, Arc Ballast)
(575W Arc, Pastel Colors, Arc Ballast)
(700W Arc, Standard Colors, Arc Ballast)
(700W Arc, Pastel Colors, Arc Ballast)

Refer to Figure 3-7.

No.

Item

Qty.

UM.

02.8001.0001

EA

PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE

02.8001.0002

EA

QA CERTIFICATE, VARI-LITE

02.8052.0001

EA

CARD, LIMITED WARRANTY

02.8700.0001

EA

CARD, PRODUCT REGISTRATION - VL500

02.9685.0002

EA

UNPACK/QUICK START SHEET, VL500

07.9685.1005

EA

SHIPPING BOX, CARDBOARD - VL500

08.0500.0001

EA

CD ROM, VL500 PRODUCT, DOCUMENTATION

52.6541.0001

EA

CONN, BLUE CABLE PWR INLET 3-POLE LOCKING - POWERCON

53.6505.0027

EA

BOLT, 1/2" X 13 X 1" LG HX HD ZINC (VL500A MODELS ONLY)

10

55.6539.0001

EA

WASHER, 1/2" SPLIT LOCK (VL500A MODELS ONLY)

11

71.2526.0230

EA

230V/1000W TUNGSTEN HALOGEN LAMP, (VL500D, 230V ONLY)

71.2528.0575

EA

575W MSR ARC LAMP, (VL500A, 575W ONLY)

71.2529.0120

EA

120V/1200W TUNGSTEN HALOGEN LAMP, (VL500D, 120V ONLY)

71.9685.0080

EA

80V/1200W TUNGSTEN HALOGEN LAMP, (VL500 80V ONLY)

71.9685.0702

EA

700W MSR ARC LAMP, (VL500A, 700W ONLY)

64

Description

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ILLUSTRATED PARTS BREAKDOWN :

Included Items Kit (continued)


1

4
2

7
3

8
11

9 (Arc Models Only)

10 (Arc Models Only)

Figure 3-7: Included Items Kit

02.96 85.001 0 0

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65

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Label Locations
16.9685.00YY Rev D

Refer to Figure 3-8.


Note: (CLR) = Clear labels - for use with non-black fixtures.

No.

Item

Qty.

UM.

04.9661.0034

EA

LABEL, RELAMPING - 2000 SERIES

04.9663.1837

EA

LABEL, PATENT

04.9685.0911

EA

LABEL, WARNING VL500

04.9685.0911.00

EA

LABEL, WARNING VL500 (CLR)

04.9685.0912

EA

LABEL, COMPLIANCE VL500

04.9685.0912.00

EA

LABEL, COMPLIANCE VL500 (CLR)

04.9685.0913

EA

LABEL, LAMP TYPE 120V OR 230V INCANDESCENT (VL500


MODELS ONLY)

04.9685.0913.00

EA

LABEL, LAMP TYPE 120V OR 230V INCANDESCENT (CLR) (VL500


MODELS ONLY)

04.9685.0914

EA

LABEL, LAMP TYPE 120V INCANDESCENT (VL500D 120V MODELS


ONLY)

04.9685.0914.00

EA

LABEL, LAMP TYPE 120V INCANDESCENT (CLR) (VL500D 120V


MODELS ONLY)

04.9685.0915

EA

LABEL, LAMP TYPE 230V INCANDESCENT (VL500D 230V MODELS


ONLY)

04.9685.0915.00

EA

LABEL, LAMP TYPE 230V INCANDESCENT (CLR) (VL500D 230V


MODELS ONLY)

04.9685.0916

EA

LABEL, LAMP TYPE 575W ARC (VL500A 575W MODELS ONLY)

04.9685.0916.00

EA

LABEL, LAMP TYPE 575W ARC (CLR) (VL500A 575W MODELS


ONLY)

04.9685.0917

EA

LABEL, LAMP TYPE 700W ARC (VL500A 700W MODELS ONLY)

04.9685.0917.00

EA

LABEL, LAMP TYPE 700W ARC (CLR) (VL500A 700W MODELS


ONLY)

04.9685.0918

EA

LABEL, LAMP TYPE 80V INCANDESCENT (VL500 80V MODELS


ONLY)

04.9685.0918.00

EA

LABEL, LAMP TYPE 80V INCANDESCENT (CLR) (VL500 80V


MODELS ONLY)

66

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

No.

Item

Qty.

UM.

04.9685.0920

EA

LABEL, AC INPUT RATING (VL500 MODELS ONLY)

04.9685.0920.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 MODELS ONLY)

04.9685.0921

EA

LABEL, AC INPUT RATING (VL500 PASTEL MODELS ONLY)

04.9685.0921.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 PASTEL MODELS ONLY)

04.9685.0922

EA

LABEL, AC INPUT RATING (VL500D 120V MODELS ONLY)

04.9685.0922.00

EA

LABEL, AC INPUT RATING (CLR) (VL500D 120V MODELS ONLY)

04.9685.0923

EA

LABEL, AC INPUT RATING (VL500D 120V PASTEL MODELS ONLY)

04.9685.0923.00

EA

LABEL, AC INPUT RATING (CLR) (VL500D 120V PASTEL MODELS


ONLY)

04.9685.0924

EA

LABEL, AC INPUT RATING (VL500D 230V MODELS ONLY)

04.9685.0924.00

EA

LABEL, AC INPUT RATING (CLR) (VL500D 230V MODELS ONLY)

04.9685.0925

EA

LABEL, AC INPUT RATING (VL500D 230V PASTEL MODELS ONLY)

04.9685.0925.00

EA

LABEL, AC INPUT RATING (CLR) (VL500D 230V PASTEL MODELS


ONLY)

04.9685.0926

EA

LABEL, AC INPUT RATING (VL500 80V MODELS ONLY)

04.9685.0926.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 80V MODELS ONLY)

04.9685.0927

EA

LABEL, AC INPUT RATING (VL500 80V PASTEL MODELS ONLY)

04.9685.0927.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 80V PASTEL MODELS


ONLY)

04.9685.0928

EA

LABEL, AC INPUT RATING (VL500 575W MODELS ONLY)

04.9685.0928.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 575W MODELS ONLY)

04.9685.0929

EA

LABEL, AC INPUT RATING (VL500 575W PASTEL MODELS ONLY)

04.9685.0929.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 575W PASTEL MODELS


ONLY)

04.9685.0930

EA

LABEL, AC INPUT RATING (VL500 700W MODELS ONLY)

04.9685.0930.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 700W MODELS ONLY)

04.9685.0931

EA

LABEL, AC INPUT RATING (VL500 700W PASTEL MODELS ONLY)

04.9685.0931.00

EA

LABEL, AC INPUT RATING (CLR) (VL500 700W PASTEL MODELS


ONLY)

04.9685.0940

EA

LABEL, PRODUCT, 575W ARC BALLAST (NOT SHOWN)

04.9685.0940.00

EA

LABEL, PRODUCT, 575W ARC BALLAST (CLR) (NOT SHOWN)

04.9685.0941

EA

LABEL, PRODUCT, 700W ARC BALLAST (NOT SHOWN)

04.9685.0941.00

EA

LABEL, PRODUCT, 700W ARC BALLAST (CLR) (NOT SHOWN)

04.9685.0942

EA

LABEL, COMPLIANCE, ARC BALLAST (NOT SHOWN)

04.9685.0942.00

EA

LABEL, COMPLIANCE, ARC BALLAST (CLR) (NOT SHOWN)

02.96 85.001 0 0

Description

17-July-2006

67

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Label Locations (continued)

2
6 (VL500 Models Only)
3

6 (Non-Arc Models Only)

5 (Non-Arc Models Only)


R

C LI ST
US
ED
10911 PETAL STREET

DALLAS, TX. 75238 U.S.A.


NOT FOR RESIDENTIAL USE
1.877.VARILITE
WWW.VARILITE.COM IMPROPERE A LUSAGE DOMESTIQUE

SUITABLE FOR DRY LOCATIONS ONLY.


EMPLACEMENT SECS
NO USER SERVICEABLE PARTS INSIDE.

Vari-Lite, Inc.

VL500D-120V-B

120 VAC
11A 50/60Hz

Figure 3-8: Label Locations

68

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Luminaire (120V or 230V)


20.9685.0001 Rev G (Standard DICRO*TUNE Colors)
20.9685.0011 Rev B (Pastel DICRO*TUNE Colors)

Refer to Figure 3-9

No.

Item

Qty.

UM.

04.9685.0573

EA

LABEL, MCB YOKE COVER

04.9685.0574

EA

LABEL, MCB YOKE COVER

04.9685.0588

EA

LABEL, YOKE COVER, PLAIN, VL500

10.9685.0525

EA

LOUVER PLATE, TOP COVER

10.9685.0580

EA

YOKE ARM COVER, DISPLAY SIDE

10.9685.0584

EA

YOKE ARM COVER, POWER SUPPLY SIDE

21.9685.0010

EA

ASSY, GENERIC VL500, INCANDESCENT

21.9685.0170

EA

ASSY, COLOR, MAGENTA / BLUE, STANDARD (20.9685.0001 ONLY)

21.9685.0174

EA

ASSY, COLOR, MAGENTA / BLUE, PASTEL (20.9685.0011 ONLY)

21.9685.0171

EA

ASSY, COLOR, AMBER / DIFFUSION

10

22.9685.0086

EA

HEAD COVER, TOP

11

22.9685.0087

EA

HEAD COVER, BOTTOM

25.9685.0753

EA

CABLE ASSY, VL500 MOTOR (NOT SHOWN)

25.9685.0760

EA

CABLE ASSY, HEAD GROUNDING (NOT SHOWN)

28.9685.0001

EA

INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN)

12

42.9685.0207

EA

LENS, PAR 64 NSP (STIPPLE)

13

53.6523.0013

EA

SCREW, 6-32X3/8" LG PTB

14

53.6558.0009

EA

SCREW, 6-32X3/8" LG PPZ SEMS

15

53.6558.0010

EA

SCREW, 6-32X1/4" PPB SEMS

16

53.6608.0001

EA

SCREW, 6-32X3/8" PFB

02.96 85.001 0 0

Description

17-July-2006

69

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

4 (x2)
16 (x8)

1
7
6
2
10
8
9
15 (x8)

11

13 (x8)
3
14 (x8)
12

Figure 3-9: VL500 Luminaire (120V or 230V)

70

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500D (with 120V IGBT Dimmer) Luminaire


20.9685.0002 Rev F (Standard DICRO*TUNE Colors)
20.9685.0012 Rev B (Pastel DICRO*TUNE Colors)

Refer to Figure 3-10

No.

Item

Qty.

UM.

04.9685.0573

EA

LABEL, MCB YOKE COVER

04.9685.0574

EA

LABEL, MCB YOKE COVER

04.9685.0576

EA

LABEL, YOKE COVER, DIMMER

04.9685.0577

EA

LABEL, YOKE COVER, DIMMER

10.9685.0525

EA

LOUVER PLATE, TOP COVER

10.9685.0565

EA

MOUNT, DIMMER

10.9685.0580

EA

YOKE ARM COVER, DISPLAY SIDE

10.9685.0582

EA

YOKE ARM COVER, DIMMER SIDE

21.9685.0011

EA

ASSY, GENERIC VL500, INCANDESCENT W/ DIMMER

10

21.9685.0170

EA

ASSY, COLOR, MAGENTA / BLUE, STANDARD (20.9685.0002 ONLY)

21.9685.0174

EA

ASSY, COLOR, MAGENTA / BLUE, PASTEL (20.9685.0012 ONLY)

11

21.9685.0171

EA

ASSY, COLOR, AMBER / DIFFUSION

12

22.9685.0086

EA

HEAD COVER, TOP

13

22.9685.0087

EA

HEAD COVER, BOTTOM

25.9685.0753

EA

CABLE ASSY, VL500 MOTOR (NOT SHOWN)

25.9685.0760

EA

CABLE ASSY, HEAD GROUNDING (NOT SHOWN)

28.9685.0002

EA

INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN)

14

42.9685.0207

EA

LENS, PAR 64 NSP (STIPPLE)

15

53.6523.0013

EA

SCREW, 6-32X3/8" LG PTB

16

53.6558.0001

EA

SCREW, 6-32X3/8" LG PPZ

17

53.6558.0009

EA

SCREW, 6-32X3/8" LG PPZ SEMS

18

53.6558.0010

EA

SCREW, 6-32X1/4" PPB SEMS

19

53.6608.0001

EA

SCREW, 6-32X3/8" PFB

20

69.3173.0115

EA

DIMMER, 1200W 115V REV PHASE CONT

02.96 85.001 0 0

Description

17-July-2006

71

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

5 (x2)
19 (x8)
1
9
2
8
12

10
11

3
18 (x8)

13

15 (x8)
16 (x8)
6 (x2)
20

14
17 (x8)

Figure 3-10: VL500D (with 120V IGBT Dimmer) Luminaire

72

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500D (with 230V IGBT Dimmer) Luminaire


20.9685.0003 Rev F (Standard DICRO*TUNE Colors)
20.9685.0013 Rev B (Pastel DICRO*TUNE Colors)

Refer to Figure 3-11

No.

Item

Qty.

UM.

04.9685.0573

EA

LABEL, MCB YOKE COVER

04.9685.0574

EA

LABEL, MCB YOKE COVER

04.9685.0576

EA

LABEL, YOKE COVER, DIMMER

04.9685.0577

EA

LABEL, YOKE COVER, DIMMER

10.9685.0525

EA

LOUVER PLATE, TOP COVER

10.9685.0565

EA

MOUNT, DIMMER

10.9685.0580

EA

YOKE ARM COVER, DISPLAY SIDE

10.9685.0582

EA

YOKE ARM COVER, DIMMER SIDE

21.9685.0011

EA

ASSY, GENERIC VL500, INCANDESCENT W/ DIMMER

10

21.9685.0170

EA

ASSY, COLOR, MAGENTA / BLUE, STANDARD (20.9685.0003 ONLY)

21.9685.0174

EA

ASSY, COLOR, MAGENTA / BLUE, PASTEL (20.9685.0013 ONLY)

11

21.9685.0171

EA

ASSY, COLOR, AMBER / DIFFUSION

12

22.9685.0086

EA

HEAD COVER, TOP

13

22.9685.0087

EA

HEAD COVER, BOTTOM

25.9685.0753

EA

CABLE ASSY, VL500 MOTOR (NOT SHOWN)

25.9685.0760

EA

CABLE ASSY, HEAD GROUNDING (NOT SHOWN)

28.9685.0003

EA

INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN)

14

42.9685.0207

EA

LENS, PAR 64 NSP (STIPPLE)

15

53.6523.0013

EA

SCREW, 6-32X3/8" LG PTB

16

53.6558.0001

EA

SCREW, 6-32X3/8" LG PPZ

17

53.6558.0009

EA

SCREW, 6-32X3/8" LG PPZ SEMS

18

53.6558.0010

EA

SCREW, 6-32X1/4" PPB SEMS

19

53.6608.0001

EA

SCREW, 6-32X3/8" PFB

20

69.3173.0230

EA

DIMMER, 1000W 230V REV PHASE CONT

02.96 85.001 0 0

Description

17-July-2006

73

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

5 (x2)
19 (x8)
1
9
2
8
12

10
11

3
18 (x8)

16 (x8)
6 (x2)
20

13

15 (x8)

14
17 (x8)

Figure 3-11: VL500D (with 230V IGBT Dimmer) Luminaire

74

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 80V (with 80V Dimmer) Luminaire


20.9685.0004 Rev H (Standard DICRO*TUNE Colors)
20.9685.0014 Rev C (Pastel DICRO*TUNE Colors)

Refer to Figure 3-12

No.

Item

Qty.

UM.

04.9685.0573

EA

LABEL, MCB YOKE COVER

04.9685.0574

EA

LABEL, MCB YOKE COVER

04.9685.0578

EA

LABEL, YOKE COVER, 80V DIMMER

04.9685.0579

EA

LABEL, YOKE COVER, 80V DIMMER

10.9685.0525

EA

LOUVER PLATE, TOP COVER

10.9685.0580

EA

YOKE ARM COVER, DISPLAY SIDE

10.9685.0586

EA

YOKE ARM COVER, 80V DIMMER SIDE

10.9685.0870

EA

BRACKET, MOUNTING, LEFT, 80V DIMMER

10.9685.0871

EA

BRACKET, MOUNTING, RIGHT, 80V DIMMER

10

21.9685.0012

EA

ASSY, GENERIC VL500 80V, INCANDESCENT W/ DIMMER

11

21.9685.0170

EA

ASSY, COLOR, MAGENTA / BLUE, STANDARD (20.9685.0004 ONLY)

21.9685.0174

EA

ASSY, COLOR, MAGENTA / BLUE, PASTEL (20.9685.0014 ONLY)

12

21.9685.0171

EA

ASSY, COLOR, AMBER / DIFFUSION

13

21.9685.0750

EA

ASSY, DIMMER, 80V

14

22.9685.0086

EA

HEAD COVER, TOP

15

22.9685.0087

EA

HEAD COVER, BOTTOM

25.9685.0753

EA

CABLE ASSY, VL500 MOTOR (NOT SHOWN)

25.9685.0760

EA

CABLE ASSY, HEAD GROUNDING (NOT SHOWN)

28.9685.0004

EA

INCLUDED ITEMS KIT, VL500 80V INCANDESCENT (NOT SHOWN)

16

42.9685.0207

EA

LENS, PAR 64 NSP (STIPPLE)

17

53.6523.0013

EA

SCREW, 6-32X3/8" LG PTB

18

53.6558.0001

EA

SCREW, 6-32X3/8" LG PPZ

19

53.6558.0009

EA

SCREW, 6-32X3/8" LG PPZ SEMS

20

53.6558.0010

EA

SCREW, 6-32X1/4" PPB SEMS

21

53.6608.0001

EA

SCREW, 6-32X3/8" PFB

22

67.4006.0007

EA

CLAMP, CABLE EMI SUP. FERRITE 0.193" ID

02.96 85.001 0 0

Description

17-July-2006

75

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

5 (x2)
21 (x8)
1
10
22

9
13

7
20 (x8)
14
15
3

19 (x8)
11

12
8

4
18 (x8)

16

17 (x8)

Figure 3-12: VL500 80V (with 80V Dimmer) Luminaire

76

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500A Luminaire (575W Arc)


20.9685.0005 Rev H (Standard DICRO*TUNE Colors)
20.9685.0015 Rev B (Pastel DICRO*TUNE Colors)

Refer to Figure 3-13

No.

Item

Qty.

UM.

04.9685.0573

EA

LABEL, MCB YOKE COVER

04.9685.0574

EA

LABEL, MCB YOKE COVER

04.9685.0588

EA

LABEL, YOKE COVER, PLAIN, VL500

10.9685.0525

EA

LOUVER PLATE, TOP COVER

10.9685.0580

EA

YOKE ARM COVER, DISPLAY SIDE

10.9685.0584

EA

YOKE ARM COVER, IGNITOR SIDE

21.9685.0013

EA

ASSY, GENERIC VL500, ARC

21.9685.0172

EA

ASSY, COLOR, AMBER / DIMMER

21.9685.0173

EA

ASSY, COLOR, MAGENTA / BLUE, ARC, STANDARD (20.9685.0005


ONLY)

21.9685.0175

EA

ASSY, COLOR, MAGENTA / BLUE, ARC, PASTEL (20.9685.0015


ONLY)

21.9685.0800

EA

ASSY, BALLAST, 625W EXTERNAL (NOT SHOWN)

10

22.9685.0086

EA

HEAD COVER, TOP

11

22.9685.0087

EA

HEAD COVER, BOTTOM

25.9685.0753

EA

CABLE ASSY, VL500 MOTOR

25.9685.0755

EA

CABLE ASSY, RELAY HARNESS (NOT SHOWN)

25.9685.0760

EA

CABLE ASSY, HEAD GROUNDING (NOT SHOWN)

25.9685.0767

EA

CABLE ASSY, BALLAST INTERCONNECT, 575/700W (NOT SHOWN)

28.9685.0005

EA

INCLUDED ITEMS KIT, VL500 ARC (NOT SHOWN)

12

42.9685.0207

EA

LENS, PAR 64 NSP (STIPPLE)

13

53.6523.0013

EA

SCREW, 6-32X3/8" LG PTB

14

53.6558.0009

EA

SCREW, 6-32X3/8" LG PPZ SEMS

15

53.6558.0010

EA

SCREW, 6-32X1/4" PPB SEMS

16

53.6608.0001

EA

SCREW, 6-32X3/8" PFB

02.96 85.001 0 0

Description

17-July-2006

77

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

4 (x2)
16 (x8)

1
7
6
2
10

9
8

15 (x8)

11

13 (x8)
14 (x8)

12

Figure 3-13: VL500A Luminaire (575W Arc)

78

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500A Luminaire (700W Arc)


20.9685.0006 Rev H (Standard DICRO*TUNE Colors)
20.9685.0016 Rev B (Pastel DICRO*TUNE Colors)

Refer to Figure 3-14

No.

Item

Qty.

UM.

04.9685.0573

EA

LABEL, MCB YOKE COVER

04.9685.0574

EA

LABEL, MCB YOKE COVER

04.9685.0588

EA

LABEL, YOKE COVER, PLAIN, VL500

10.9685.0525

EA

LOUVER PLATE, TOP COVER

10.9685.0580

EA

YOKE ARM COVER, DISPLAY SIDE

10.9685.0584

EA

YOKE ARM COVER, IGNITOR SIDE

21.9685.0013

EA

ASSY, GENERIC VL500, ARC

21.9685.0172

EA

ASSY, COLOR, AMBER / DIMMER

21.9685.0173

EA

ASSY, COLOR, MAGENTA / BLUE, ARC, STANDARD (20.9685.0006


ONLY)

21.9685.0175

EA

ASSY, COLOR, MAGENTA / BLUE, ARC, PASTEL (20.9685.0016


ONLY)

21.9685.0802

EA

ASSY, BALLAST, 700W EXTERNAL (NOT SHOWN)

10

22.9685.0086

EA

HEAD COVER, TOP

11

22.9685.0087

EA

HEAD COVER, BOTTOM

25.9685.0753

EA

CABLE ASSY, VL500 MOTOR

25.9685.0755

EA

CABLE ASSY, RELAY HARNESS (NOT SHOWN)

25.9685.0760

EA

CABLE ASSY, HEAD GROUNDING (NOT SHOWN)

25.9685.0767

EA

CABLE ASSY, BALLAST INTERCONNECT, 575/700W (NOT SHOWN)

28.9685.0006

EA

INCLUDED ITEMS KIT, VL500 ARC (NOT SHOWN)

12

42.9685.0207

EA

LENS, PAR 64 NSP (STIPPLE)

13

53.6523.0013

EA

SCREW, 6-32X3/8" LG PTB

14

53.6558.0009

EA

SCREW, 6-32X3/8" LG PPZ SEMS

15

53.6558.0010

EA

SCREW, 6-32X1/4" PPB SEMS

16

53.6608.0001

EA

SCREW, 6-32X3/8" PFB

02.96 85.001 0 0

Description

17-July-2006

79

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

4 (x2)
16 (x8)

1
7
6
2
10

9
8

15 (x8)

11

13 (x8)
14 (x8)

12

Figure 3-14: VL500A Luminaire (700W Arc)

80

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Generic VL500 Luminaire Assembly


21.9685.0010
21.9685.0011
21.9685.0012
21.9685.0013

Rev
Rev
Rev
Rev

P
P
P
P

(Incandescent - without Internal Dimmer)


(Incandescent - with Internal IGBT Dimmer)
(Incandescent - with Internal 80V Dimmer)
(Arc)

Refer to Figure 3-15, Figure 3-16, and Figure 3-17


No.

Item

Qty.

UM.

10.9685.0521

EA

PULLEY, DRIVEN, PAN/TILT

10.9685.0542

EA

SHIELD, WIRE, LVS (VL500/VL500D/VL500A ONLY)

10.9685.0555

EA

LENS, DISPLAY, VL500

10.9685.0556

EA

OVERLAY, DISPLAY, VL500

10.9685.0564

EA

PANEL, TILT, CLOSEOUT

10.9685.0566

EA

PLATE, TILT LOCK

10.9685.0567

EA

HEAT SHIELD, TILT SIDE

10.9685.0568

EA

HEAT SHIELD, DIMMER/POWER SUPPLY SIDE

10.9685.0569

EA

HEAT SHIELD, CROSSMEMBER

10

10.9685.0570

EA

SPACER, TILT TUBE

11

10.9685.0571

EA

PLUG, TILT TUBE

12

10.9685.0572

EA

CONTERWEIGHT, VL500 (VL500 80V ONLY)

10.9685.0575

EA

CONTERWEIGHT, VL500 (VL500D ONLY)

13

21.9685.0310

EA

ASSY, GENERIC VL500, INCANDESCENT (VL500 AND VL500D


ONLY)

14

21.9685.0311

EA

ASSY, GENERIC VL500, ARC (VL500A ONLY)

15

21.9685.0312

EA

ASSY, GENERIC VL500, INCANDESCENT, 80V (VL500 80V ONLY)

16

21.9685.0520

EA

ASSY, YOKE, BASE, INCANDESCENT (VL500 ONLY)

17

21.9685.0521

EA

ASSY, YOKE, BASE, INTERNAL IGBT DIMMER (VL500D ONLY)

18

21.9685.0522

EA

ASSY, YOKE, BASE, EXTERNAL BALLAST (VL500A ONLY)

19

21.9685.0523

EA

ASSY, YOKE, BASE, INTERNAL 80V DIMMER (VL500 80V ONLY)

20

21.9685.0731

EA

ASSY, MCB / FAN

21

23.9650.3327

EA

RELAY, ELECTRICAL ASSY (VL500A ONLY)

22

24.9685.0826

EA

ASSY, VL500 DISPLAY BOARD

23

24.9685.1000

EA

IGNITOR, ARC (VL500A ONLY)

25.9685.0776

EA

YOKE LAMP JUMPER WIRES (VL500 ONLY) (NOT SHOWN)

24

53.2001.0003

EA

NUT, 10-32 HEX NYLON INSERT

25

53.2019.0004

EA

NUT, 3/8-16X7/32" THK HEX JAM G

26

53.6539.0001

EA

WASHER, 3/8" SPLIT LOCK

02.96 85.001 0 0

Description

17-July-2006

81

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

No.

Item

Qty.

UM.

27

53.6558.0009

11

EA

SCREW, 6-32X3/8", PPZ, SEMS (VL500 ONLY)

53.6558.0009

10

EA

SCREW, 6-32X3/8", PPZ, SEMS (VL500D AND VL500 80V ONLY)

53.6558.0009

14

EA

SCREW, 6-32X3/8", PPZ, SEMS (VL500A ONLY)

28

53.6558.0010

11

EA

SCREW, 6-32X1/4", PPB, SEMS

29

53.6596.0002

EA

SCREW, 4-40X5/16" LG PPZ SEMS (VL500A ONLY)

30

53.6608.0001

11

EA

SCREW, 6-32X3/8", PFB

31

53.6634.0003

EA

SCREW, 3/8-16X1/2" SOC HD CAP

32

53.6634.1000

EA

SCREW, 3/8-16X1.00" SOC HD CAP

33

54.1206.0021

EA

RING, RETAINING, 1.562" SHAFT

34

54.1255.0002

EA

ASSY, BEARING/HOUSING

35

54.1261.0001

EA

BUSHING, LOW DAMP THRMOPLS.189

36

54.2066.0001

EA

BELT, TIMING, S2M, 396 GRV, 9MM WIDE

37

55.2187.0001

EA

CABLE SADDLE, #6 MOUNTING HOLE (VL500 ONLY)

38

55.2287.0001

EA

STANDOFF, MF 6-32X9/32" LG, 1/4" HEX

39

55.2288.0001

EA

STANDOFF, MF 6-32X13/16" LG, 1/4" HEX (VL500/VL500D/VL500 80V


ONLY)

55.2288.0001

12

EA

STANDOFF, MF 6-32X13/16" LG, 1/4" HEX (VL500A ONLY)

40

55.3301.0010

EA

WASHER, #10 FLAT

41

55.6517.0001

EA

WASHER, 0.375" OD, 0.150 ID, 0.031" THK (VL500A ONLY)

42

55.6677.0041

EA

WASHER, 0.750" OD, 0.203" ID, 0.04" THK

43

69.3178.0120

EA

POWER SUPPLY, 120W +24V 3X5 (VL500/VL500D/VL500A ONLY)

82

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Generic VL500 Luminaire Assembly (continued)


4
28

12 (VL500D Only)
3

38
22

39

16 (VL500 Only)
17 (VL500D Only)

36

30 (x4)
20

2
43
27

27
25

26
25
32
5
11

31

8
7

31

34
25
33
6

1
34
10
42
35
40

24

11
13

Figure 3-15: Generic VL500 Luminaire Assembly (VL500 and VL500D)

02.96 85.001 0 0

17-July-2006

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Generic VL500 Luminaire Assembly (continued)

4 3
28

19

12
38
22

36

30 (x4)
39

27

20
27

26

25

25

32
5

7 31

42
35
40
24

11
1
31
10

34

25

34

33

11

15

Figure 3-16: Generic VL500 Luminaire Assembly (VL500 80V)

84

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Generic VL500 Luminaire Assembly (continued)


4
28

38
22

39

18

36

27

20

30 (x4)
43

27
21
29, 41
39 (x4)
27

26
25
32

25

23
5

11

34
25

8
7

31

33
6

1
34
31

10

42
35
40

24

11
14

Figure 3-17: Generic VL500 Luminaire Assembly (VL500A)

02.96 85.001 0 0

17-July-2006

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Notes

86

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Head Assembly
VL500 Generic Head Assembly
21.9685.0310 (VL500 and VL500D) Rev H
21.9685.0311 (VL500A) Rev H
21.9685.0312 (VL500 80V) Rev H

Refer to Figure 3-18, Figure 3-19, Figure 3-20.

No.

Item

Qty.

UM.

Description

10.9634.0162

EA

GASKET, LENS, FRONT CASTING

10.9685.0340

EA

SUPPORT, RIB

10.9685.0344

EA

COVER, LAMP WIRE

12.9685.0331

EA

SIDE RAIL, HINGE, MACHINED CASTING

12.9685.0333

EA

SIDE RAIL, LATCH, MACHINED CASTING

12.9685.0388

EA

FRONT RING, VL500

21.9685.0315

EA

ASSY, COUNTERWEIGHT SUPPORT

21.9685.0320

EA

ASSY, HEATSINK, INCANDESCENT (VL500/VL500D ONLY)

21.9685.0321

EA

ASSY, HEATSINK, ARC (VL500A ONLY)

10

21.9685.0322

EA

ASSY, HEATSINK, 80V INCANDESCENT (VL500 80V ONLY)

11

25.9685.0350

EA

CABLE ASSY, DISCONNECT (VL500A ONLY)

12

53.6556.0004

EA

SCREW, 4-40X1/8" LG PPB

13

53.6598.0187

EA

SCREW, 4-40X0.187" LG PFB UNDERCUT HD

14

53.6607.0001

EA

SCREW, 6-32X1/4" LG PPB

15

54.1226.0001

EA

LATCH ASSEMBLY

16

54.1226.0002

EA

STRIKE, LATCH

17

55.2203.0001

EA

SCREW, 4-40X1/4" LG PPZ (VL500A ONLY)

18

55.3500.0002

EA

WASHER, #10 FIBRE FLAT 0.196" ID

19

55.3500.0003

EA

WASHER, 3/8" FIBRE FLAT 0.385" ID

20

55.6612.0005

EA

PIN, FRONT CASTING PIVOT

21

55.6612.0009

EA

PIN, REAR CASTING PIVOT

02.96 85.001 0 0

17-July-2006

87

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Generic Head Assembly (continued)

16
12 (x2)
19
14 (x4)
15
12 (x2)

3
12 (x2)

20
21

18
1
2
6
2
7

13 (x4)

Figure 3-18: VL500 Generic Head Assembly (VL500 and VL500D)

88

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Generic Head Assembly (continued)

17 (x2)
11

16
12 (x2)
19
14 (x4)
15
12 (x2)

3
12 (x2)

20
21

18
1
2
6
2
7

13 (x4)

Figure 3-19: VL500 Generic Head Assembly (VL500A)

02.96 85.001 0 0

17-July-2006

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Generic Head Assembly (continued)

10

16
12 (x2)
19
14 (x4)
15
12 (x2)

3
12 (x2)

20
21

18
1
2
6
2
7

13 (x4)

Figure 3-20: VL500 Generic Head Assembly (VL500 80V)

90

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Heatsink Assembly
21.9685.0320 (VL500 and VL500D) Rev G
21.9685.0321 (VL500A) Rev G
21.9685.0322 (VL500 80V) Rev G

Refer to Figure 3-21, Figure 3-22, Figure 3-23.

No.

Item

Qty.

UM.

Description

10.9634.0103

EA

PAD, REFLECTOR MOUNT

10.9685.0343

EA

CLIP, REFLECTOR

10.9685.0345

EA

CLIP, SOCKET (VL500A AND VL500 80V ONLY)

10.9685.0360

EA

FOAM, HEATSINK LIGHT LEAK

12.9685.0335

EA

HEATSINK, MACHINED CASTING

12.9685.0337

EA

BACKCAP, INCANDESCENT, MACHINED CASTING (VL500 ONLY)

12.9685.0339

EA

BACKCAP, ARC, MACHINED CASTING (VL500A AND VL500 80V


ONLY)

12.9685.0346

EA

BACKCAP, EXTENSION, HEATSINK, MODIFIED (VL500A AND


VL500 80V ONLY)

22.9685.0215

EA

LIGHT BAFFLE, REFLECTOR

10

23.9685.0780

EA

ASSY, VL500 LAMP SOCKET, HIGH TEMP (VL500 ONLY)

25.9685.0766

EA

575W/700W/80V LAMP WIRES, IGNITOR TO SOCKET (VL500A AND


VL500 80V ONLY) (NOT SHOWN)

25.9685.0777

EA

CABLE ASSY, BACKCAP GROUND (NOT SHOWN)

11

42.9685.0190

EA

REFLECTOR, PARABOLIC

12

53.6515.1000

EA

SCREW, 10-32X1" LG SCB (VL500 80V ONLY)

13

53.6543.0002

EA

SCREW, 6-32X1/8" LG PPB

14

53.6558.0007

EA

SCREW, 6-32X1/4" LG PPZ SEM (VL500 ONLY)

15

53.6575.0010

EA

SCREW, 8-32X1/2" LG PPZ SEM

16

53.6682.0022

EA

SCREW, 8-32X3/8" LG PPZ SEM (VL500A AND VL500 80V ONLY)

17

53.6594.0001

EA

SCREW, 10-32X1-1/2" LG PPB (VL500A ONLY)

18

54.1226.0001

EA

ASSY, LATCH

19

55.2203.0002

EA

SCREW, 4-40X1/4" LG PPB

20

55.2132.0013

EA

STANDOFF, 1/4 HEX X 0.218" LG 6-32 MF

21

55.6568.0022

EA

SPRING, CPRSN 0.300" OD, 1.25" LG (VL500A ONLY)

22

55.6635.0010

EA

WASHER, #10 SPHERICAL (VL500A AND VL500 80V ONLY)

23

71.2560.0001

EA

SOCKET, LAMP, ARC (VL500A AND VL500 80V ONLY)

02.96 85.001 0 0

17-July-2006

91

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Heatsink Assembly (continued)


6
10
4
5

11

1 (x3)

9
14 (x2)

19 (x2)
18
15 (x4)
2 (x3)
20 (x3)
13 (x3)

Figure 3-21: VL500 Heatsink Assembly (VL500 and VL500D)

92

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Heatsink Assembly (continued)


17 (x3)
22 (x3)
21 (x3)

23
5

4
1 (x3)
11
3 (x2)
16 (x2)

19 (x2)

18
15 (x4)

20 (x3)

2 (x3)

13 (x3)

Figure 3-22: VL500 Heatsink Assembly (VL500A)

02.96 85.001 0 0

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Heatsink Assembly (continued)

12 (x3)
7

23

22 (x3)

1 (x3)
11

3 (x2)
16 (x2)
8

19 (x2)

18

15 (x4)
2 (x3)
13 (x3)
20 (x3)

Figure 3-23: VL500 Heatsink Assembly (VL500 80V)

94

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Magenta/Blue Color Assembly


21.9685.0170 Rev H (Standard DICRO*TUNE Colors)

Refer to Figure 3-24.

No.

Item

Qty.

UM.

Description

10.9685.0257

EA

LIGHT BAFFLE, REAR BULKHEAD

21.9685.0160

EA

ASSY, MAGENTA/BLUE, STANDARD, DICROTUNE

21.9685.0280

EA

MOTOR ASSY, MAG/BLUE

53.6592.0250

EA

SCREW, 4-40X1/4" PPB SEMS

55.6704.0015

EA

STANDOFF, 5/16" HEX, 6-32X0.593" LG

2
3
4 (x4)

4 (x4)

Figure 3-24: VL500 Magenta/Blue Color Assembly

02.96 85.001 0 0

17-July-2006

95

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Magenta/Blue (Pastel) Color Assembly


21.9685.0174 Rev A (Pastel DICRO*TUNE Colors)

Refer to Figure 3-25.

No.

Item

Qty.

UM.

Description

10.9685.0257

EA

LIGHT BAFFLE, REAR BULKHEAD

21.9685.0164

EA

ASSY, MAGENTA/BLUE, PASTEL, DICROTUNE

21.9685.0280

EA

MOTOR ASSY, MAG/BLUE

53.6592.0250

EA

SCREW, 4-40X1/4" PPB SEMS

55.6704.0015

EA

STANDOFF, 5/16" HEX, 6-32X0.593" LG

2
3
4 (x4)

4 (x4)

Figure 3-25: VL500 Magenta/Blue (Pastel) Color Assembly

96

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Amber/Diffuser Color Assembly


21.9685.0171 Rev G

Refer to Figure 3-26.

No.

Item

Qty.

UM.

Description

10.9685.0245

EA

LIGHT BAFFLE, TOP

21.9685.0161

EA

ASSY, AMBER/DIFFUSER, DICROTUNE

21.9685.0281

EA

MOTOR ASSY, AMBER/DIFFUSER

53.6592.0250

EA

SCREW, 4-40X1/4" PPB SEMS

55.6704.0015

EA

STANDOFF, 5/16" HEX, 6-32X0.593" LG

4 (x4)

2
1
3

4 (x4)
5

Figure 3-26: VL500 Amber/Diffuser Color Assembly

02.96 85.001 0 0

17-July-2006

97

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Amber/Dimmer Color Assembly


21.9685.0172 Rev F

Refer to Figure 3-27.

No.

Item

Qty.

UM.

Description

10.9685.0245

EA

LIGHT BAFFLE, TOP

21.9685.0162

EA

ASSY, AMBER/DIMMER, DICROTUNE

21.9685.0281

EA

MOTOR ASSY, AMBER/DIFFUSER

53.6592.0250

EA

SCREW, 4-40X1/4" PPB SEMS

55.6704.0015

EA

STANDOFF, 5/16" HEX, 6-32X0.593" LG

4 (x4)

2
1
3

4 (x4)
5

Figure 3-27: VL500 Amber/Dimmer Color Assembly

98

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Magenta/Blue (Arc) Color Assembly


21.9685.0173 Rev A (Standard DICRO*TUNE Colors)

Refer to Figure 3-28.

No.

Item

Qty.

UM.

Description

10.9685.0246

EA

CLIP, UV GLASS

10.9685.0257

EA

LIGHT BAFFLE, REAR BULKHEAD

21.9685.0160

EA

ASSY, MAGENTA/BLUE, STANDARD, DICROTUNE

21.9685.0280

EA

MOTOR ASSY, MAG/BLUE

42.9685.0130

EA

GLASS, UV

53.6592.0250

EA

SCREW, 4-40X1/4" PPB SEMS

55.6704.0015

EA

STANDOFF, 5/16" HEX, 6-32X0.593" LG

3
4
6 (x4)

2 (x2)
7
5

6 (x4)

1 (x4)

Figure 3-28: VL500 Magenta/Blue (Arc) Color Assembly

02.96 85.001 0 0

17-July-2006

99

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Magenta/Blue (Arc Pastel) Color


Assembly
21.9685.0175 Rev A (Pastel DICRO*TUNE Colors)

Refer to Figure 3-29.

No.

Item

Qty.

UM.

Description

10.9685.0246

EA

CLIP, UV GLASS

10.9685.0257

EA

LIGHT BAFFLE, REAR BULKHEAD

21.9685.0164

EA

ASSY, MAGENTA/BLUE, PASTEL, DICROTUNE

21.9685.0280

EA

MOTOR ASSY, MAG/BLUE

42.9685.0130

EA

GLASS, UV

53.6592.0250

EA

SCREW, 4-40X1/4" PPB SEMS

55.6704.0015

EA

STANDOFF, 5/16" HEX, 6-32X0.593" LG

3
4
6 (x4)

2 (x2)
7
5

6 (x4)

1 (x4)

Figure 3-29: VL500 Magenta/Blue (Arc) Color Assembly

100

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Magenta/Blue Color Assembly


21.9685.0160 Rev E (Standard DICRO*TUNE Colors)

Refer to Figure 3-30.

No.

Item

Qty.

UM.

10.9634.0034

32

EA

SPRING, DRIVE ARM, FILTER

10.9634.0035

32

EA

LINK, DRIVE ARM

10.9634.0166

32

EA

CARRIER, FILTER, METAL INJ MOLD

21.9685.0150

EA

ASSY, BOTTOM BULKHEAD

EA

ASSY, FILTER, MAGENTA, DICROTUNE

EA

ASSY, FILTER, BLUE, DICROTUNE

22.9685.0122

16

22.9685.0123

16

Description

3 (x16)
6 (x16)

1 (x16)
2 (x16)

2 (x16)

5 (x16)
3 (x16)

1 (x16)

Figure 3-30: Magenta/Blue Color Assembly

02.96 85.001 0 0

17-July-2006

101

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Magenta/Blue (Pastel) Color Assembly


21.9685.0164 Rev 0 (Pastel DICRO*TUNE Colors)

Refer to Figure 3-31.

No.

Item

Qty.

UM.

Description

10.9634.0034

32

EA

SPRING, DRIVE ARM, FILTER

10.9634.0035

32

EA

LINK, DRIVE ARM

10.9634.0166

32

EA

CARRIER, FILTER, METAL INJ MOLD

21.9685.0150

EA

ASSY, BOTTOM BULKHEAD

22.9685.0120

16

EA

ASSY, FILTER, MAGENTA, PASTEL, DICROTUNE

22.9685.0121

16

EA

ASSY, FILTER, BLUE, PASTEL, DICROTUNE

3 (x16)
6 (x16)

1 (x16)
2 (x16)

2 (x16)

5 (x16)
3 (x16)

1 (x16)

Figure 3-31: Magenta/Blue (Pastel) Color Assembly

102

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Amber/Diffuser Color Assembly


21.9685.0161 Rev F

Refer to Figure 3-32.

No.

Item

Qty.

UM.

10.9634.0034

32

EA

SPRING, DRIVE ARM, FILTER

10.9634.0035

32

EA

LINK, DRIVE ARM

10.9634.0166

32

EA

CARRIER, FILTER, METAL INJ MOLD

21.9685.0151

EA

ASSY, BULKHEAD, TOP

EA

ASSY, FILTER, AMBER, DICROTUNE

EA

ASSY, DIFFUSER PANEL

22.9685.0124

16

22.9685.0126

16

Description

3 (x16)
1 (x16)

6 (x16)

2 (x16)

5 (x16)
3 (x16)

2 (x16)

1 (x16)

Figure 3-32: Amber/Diffuser Color Assembly

02.96 85.001 0 0

17-July-2006

103

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Amber/Dimmer Color Assembly


21.9685.0162 Rev E

Refer to Figure 3-33.

No.

Item

Qty.

UM.

10.9634.0034

32

EA

SPRING, DRIVE ARM, FILTER

10.9634.0035

32

EA

LINK, DRIVE ARM

10.9634.0166

16

EA

CARRIER, FILTER, METAL INJ MOLD

10.9647.0121

EA

BAFFLE, INNER LIGHT

10.9661.0307

16

EA

CARRIER, DIMMER

10.9661.0312

16

EA

BEARING, DIMMER

10.9661.0313

EA

BAFFLE, OUTER LIGHT, DIMMER

10.9685.0210

16

EA

DIMMER BLADE, VL500

21.9685.0151

EA

ASSY, BULKHEAD, TOP

10

22.9685.0124

16

EA

ASSY, FILTER, AMBER, DICROTUNE

11

53.6556.0004

16

EA

SCREW, 4-40X1/8" PPB

104

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

6 (x16)

8 (x16)

11 (x16)

5 (x16)
1 (x16)

2 (x16)

3 (x16)

2 (x16)
10 (x16)

1 (x16)

Figure 3-33: Amber/Dimmer Color Assembly

02.96 85.001 0 0

17-July-2006

105

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Bottom Bulkhead Assembly


21.9685.0150 Rev C

Refer to Figure 3-34.

No.

Item

Qty.

UM.

10.9661.0315

EA

SUPPORT, BULKHEAD

21.9685.0251

EA

ASSY, DRIVE RING

22.9634.0119

EA

ASSY, CENTER HUB

22.9685.0201

EA

ASSY, GENERIC BULKHEAD

53.6682.0002

12

EA

SCREW, 4-40X1/4" PPZ SEMS

55.6612.0008

10

EA

PIN, 1/8" OD X 3/8" LG AL DRIV-LOX

55.6669.0009

EA

STANDOFF, 1/4" HEX, #40-40X0.625" MF

106

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Bottom Bulkhead Assembly (continued)


2

3
5 (x4)

6 (x10)

7 (x4)
5 (x8)
1 (x4)

4
2

Figure 3-34: Bottom Bulkhead Assembly

02.96 85.001 0 0

17-July-2006

107

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Top Bulkhead Assembly


21.9685.0151 Rev C

Refer to Figure 3-35.

No.

Item

Qty.

UM.

Description

10.9661.0315

EA

SUPPORT, BULKHEAD

10.9685.0219

EA

AUX RING, COLOR BULKHEAD

21.9685.0251

EA

ASSY, DRIVE RING

22.9634.0120

EA

ASSY, LIGHT BAFFLE

22.9685.0201

EA

ASSY, GENERIC BULKHEAD

53.6682.0002

12

EA

SCREW, 4-40X1/4" PPZ SEMS

55.6612.0008

10

EA

PIN, 1/8" OD X 3/8" LG AL DRIV-LOX

55.6669.0009

EA

STANDOFF, 1/4" HEX, #40-40X0.625" MF

55.6858.0002

EA

STANDOFF, 1/4" HEX, #40-40X0.343" MF

108

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Top Bulkhead Assembly (continued)


3

6 (x4)
2 (x2)
9 (x4)

6 (x8)
7 (x10)
1 (x4)

8 (x4)

Figure 3-35: Top Bulkhead Assembly

02.96 85.001 0 0

17-July-2006

109

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Drive Ring Assembly


21.9685.0251 Rev B

Refer to Figure 3-37.

No.

Item

Qty.

UM.

Description

10.9634.0105

EA

LINK, SWIVEL

10.9685.7240

EA

ROLLER, DRIVE RING

22.9685.0238

EA

RING, DRIVE

53.5554.0875

EA

SCREW, 4-40X7/8" SET SS FLAT POINT

53.6659.0013

EA

SCREW, 2-56X1/8" PPB

55.6603.0001

EA

SPRING, SS 4.6#/IN EXTENSION

55.6612.0004

EA

PIN, 1/16" OD X 1/2" LG TYPE C 303 S/S

7 (x8)

Insure screws are flush with inside drive


ring surface (no protrusion).

5 (x2)
1

6
2 (x8)

Spring

2-56 Screw (x2)

Figure 3-36: Drive Ring Assembly

110

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Magenta/Blue Color Motor Assembly


21.9685.0280 Rev A

Refer to Figure 3-37.

No.

Item

Qty.

UM.

Description

10.9634.0061

EA

ACTUATOR MOUNT, VL500

10.9634.0075

EA

HEAT SHIELD, MAGENTA/BLUE

44.9685.0230

EA

MOTOR, LINEAR, 0.002"/STEP

53.6520.0001

EA

SCREW, 4-40X3/8" PPZ

53.6682.0002

EA

SCREW, 4-40X1/4" PPZ SEMS

54.1217.0004

EA

LINK, VL500 ACTUATOR-DRIVE RING

4 (x3)
Actuator Screw

5 (x4)
1

3 (x2)
6 (x2)

Note:

Versilube Silicon Grease (G321) is


used to lubricate the actuator screw.

Figure 3-37: Magenta/Blue Color Motor Assembly

02.96 85.001 0 0

17-July-2006

111

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Amber/Diffuser Color Motor Assembly


21.9685.0281 Rev A

Refer to Figure 3-37.

No.

Item

Qty.

UM.

Description

10.9634.0061

EA

ACTUATOR MOUNT, VL500

10.9634.0074

EA

HEAT SHIELD, AMBER/DIFFUSER

44.9685.0230

EA

MOTOR, LINEAR, 0.002"/STEP

53.6520.0001

EA

SCREW, 4-40X3/8" PPZ

53.6682.0002

EA

SCREW, 4-40X1/4" PPZ SEMS

54.1217.0004

EA

LINK, VL500 ACTUATOR-DRIVE RING

4 (x3)
3 (x2)

1
5 (x4)

Note:

2
6 (x2)

Actuator Screw

Versilube Silicon Grease (G321) is


used to lubricate the actuator screw.

Figure 3-38: Amber/Diffuser Color Motor Assembly

112

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Yoke Assembly
VL500 Yoke Assembly
21.9685.0520 (VL500) Rev S
21.9685.0521 (VL500D) Rev S
21.9685.0522 (VL500A) Rev S

Refer to Figure 3-39, Figure 3-40.

No.

Item

Qty.

UM.

1
2

Description

10.9685.0534

EA

COVER, PAN TUBE

10.9685.0537

EA

PLATE, MOUNTING, LAMP POWER PIGTAIL (VL500 ONLY)

10.9685.0538

EA

BEZEL, LAMP POWER PIGTAIL (VL500 ONLY)

10.9685.0560

EA

YOKE LEG, TILT SIDE

10.9685.0561

EA

YOKE LEG, DIMMER SIDE

10.9685.0562

EA

PLATE, TILT MOTOR, SLIDE

10.9685.0596

EA

MOUNT, FAN, LVS

21.9685.0515

EA

ASSY, YOKE CROSSMEMBER

21.9685.0540

EA

ASSY, PAN/TILT MOTOR

10

23.9685.0782

EA

ASSY, FAN MCB

11

24.9663.1895

EA

PCB ASSY, DMX INPUT

12

24.9685.0740

EA

TEMPERATURE BOARD, LVS

13

25.9663.2030

EA

CABLE ASSY, INCANDESCENT POWER (VL500 ONLY)

14

25.9685.0756

EA

CABLE ASSY, AC INPUT

15

25.9685.0757

EA

CABLE ASSY, ARC BALLAST INPUT (VL500A ONLY)

16

25.9685.0770

EA

DISPLAY CABLE RECEPTACLE, BLACK

25.9685.0790

EA

CABLE ASSY, MAIN HARNESS, INCANDESCENT (VL500 AND


VL500D ONLY) (NOT SHOWN)

25.9685.0791

EA

CABLE ASSY, MAIN HARNESS, ARC (VL500A ONLY) (NOT


SHOWN)

28.9685.0999

EA

KIT, EXTRA US HARDWARE (NOT SHOWN)

17

51-0541

EA

SCREW, #4X3/8" H/L PN BLK ZN

18

52.8295.0002

EA

TERMINAL BLOCK, 300V 12 AWG 20A 2-POS

19

53.2001.0003

EA

NUT, 10-32 NYLOCK

20

53.2200.0004

EA

NUT, 4-40 KEPS SS

21

53.2200.0006

EA

NUT, 6-32 KEPS SS (VL500D AND VL500A ONLY)

22

53.2202.0004

EA

NUT, 4-40 HEX SS NYLON INSERT

02.96 85.001 0 0

17-July-2006

113

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

No.

Item

Qty.

UM.

23

53.6519.0001

EA

SCREW, 4-40X5/8" PPZ

24

53.6521.0001

EA

SCREW, 8-32X1/2" PPB

25

53.6526.0002

EA

SCREW, 6-32X5/8" PPZ TYPE F

26

53.6546.0003

EA

SCREW, 8-32X7/16" PPZ

27

53.6552.0002

18

EA

SCREW, 8-32X1/2" PFB

28

53.6559.0002

EA

SCREW, 4-40X1/4" PFB

29

53.6606.0001

EA

SCREW, 4-40X1/2" PFB

30

53.6608.0750

EA

SCREW, 6-32X3/8" PFB

31

53.6624.0001

EA

SCREW, 10-32X1/2" PFB

32

53.6596.0001

EA

SCREW, 4-40X5/16" PPZ

33

54.2065.0001

EA

BELT, TIMING, S2M 252 GROOVE

34

55.2166.0250

EA

STANDOFF, 1/4" HEX 6-32, 0.250" LG MF SS

35

55.2288.0001

EA

STANDOFF, 1/4" HEX 6-32 X 13/16" LG

36

55.3301.0008

EA

WASHER, #8 FLAT SS

37

55.3301.0010

EA

WASHER, #10 FLAT

38

55.6543.0001

2.4

FT

GROMMET STRIP, SERRATED, 0.062

39

55.6568.0056

EA

SPRING, CPRSN, 0.600 OD, 0.080 WIR

40

55.6662.0010

EA

HOLE PLUG, 1.093" DIA, BLK NYLON (VL500D ONLY)

41

55.6669.0005

EA

STANDOFF, 6-32 X 0.500" LG 1/4" HEX

42

55.6669.0012

EA

STANDOFF, 6-32 X 1.00" LG 1/4" HEX MF CSTL ZINC

114

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Yoke Assembly (continued)

27 (x6)
31
1
25 (x2)
18 (x2)
37
19

21 (x4)
15 (VL500A)
40 (VL500D)

11

30 (x4)
8

17 (x4)
20 (x2)
14
29 (x2)

2
16
30 (x4)

28 (x2)

13

Figure 3-39: VL500 Yoke Assembly (VL500/VL500D/VL500A)

02.96 85.001 0 0

17-July-2006

115

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Yoke Assembly (continued)

24 (x4)
39

36 (x4)

33

26

7
22 (x4)

26 (x6)

32
10

36 (x4)

23 (x3)
6

42
12
34
35 (x3)

38
44 (x4)
39
27 (x12)

5
41 (x6)

Figure 3-40: VL500 Yoke Assembly (VL500/VL500D/VL500A)

116

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 80V Yoke Assembly


21.9685.0523 (VL500 80V) Rev G

Refer to Figure 3-41, Figure 3-42.

No.

Item

Qty.

UM.

Description

10.9685.0542

EA

SHIELD, WIRE

10.9685.0543

EA

SHIELD, SENSOR BOARD

10.9685.0554

EA

COVER, PAN TUBE, 80V

10.9685.0557

EA

COVER, VENT, LVS

10.9685.0558

EA

FAN MOUNT, LVS

10.9685.0560

EA

YOKE LEG, TILT SIDE

10.9685.0561

EA

YOKE LEG, DIMMER SIDE

10.9685.0562

EA

PLATE, TILT MOTOR, SLIDE

21.9685.0516

EA

ASSY, YOKE CROSSMEMBER, 80V

10

21.9685.0540

EA

ASSY, PAN/TILT MOTOR

11

23.9685.0782

EA

ASSY, FAN MCB

12

24.9663.1895

EA

PCB ASSY, DMX INPUT

13

24.9685.0740

EA

TEMPERATURE BOARD, LVS

25.9685.0742

EA

80V LVS AC, VL500 (NOT SHOWN)

25.9685.0746

EA

80V SURGE PROTECTOR, VL500 (NOT SHOWN)

14

25.9685.0756

EA

CABLE ASSY, AC INPUT

15

25.9685.0770

EA

DISPLAY CABLE RECEPTACLE, BLACK

25.9685.0792

EA

CABLE ASSY, MAIN HARNESS, 80V, VL500 (NOT SHOWN)

28.9685.0999

EA

KIT, EXTRA US HARDWARE (NOT SHOWN)

16

51-0541

EA

SCREW, #4X3/8" H/L PN BLK ZN

17

52.8295.0002

EA

TERMINAL BLOCK, 300V 12 AWG 20A 2-POS

18

53.2001.0003

EA

NUT, 10-32 NYLOCK

19

53.2200.0004

EA

NUT, 4-40 KEPS SS

20

53.6521.0001

EA

SCREW, 8-32X1/2" PPB

21

53.6546.0003

EA

SCREW, 8-32X7/16" PPZ

22

53.6552.0002

18

EA

SCREW, 8-32X1/2" PFB

23

53.6558.0001

EA

SCREW, 6-32X3/8" PPZ

24

53.6559.0002

EA

SCREW, 4-40X1/4" PFB

25

53.6606.0001

EA

SCREW, 4-40X1/2" PFB

26

53.6616.0001

EA

SCREW, 6-32X3/4" PPZ TYPE F

27

53.6624.0001

EA

SCREW, 10-32X1/2" PFB

02.96 85.001 0 0

17-July-2006

117

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

No.

Item

Qty.

UM.

28

54.2065.0001

EA

BELT, TIMING, S2M 252 GROOVE

29

55.2203.0001

EA

SCREW, 4-40X1/4" PPZ

30

55.3301.0008

EA

WASHER, #8 FLAT SS

31

55.3301.0010

EA

WASHER, #10 FLAT

32

55.6543.0001

2.4

FT

GROMMET STRIP, SERRATED, 0.062

33

55.6568.0056

EA

SPRING, CPRSN, 0.600 OD, 0.080 WIR

34

55.6669.0005

EA

STANDOFF, 6-32 X 0.500" LG 1/4" HEX

35

69.3178.0121

EA

POWER SUPPLY, 120V +24V 3X5

118

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 80V Yoke Assembly (continued)

22 (x6)

27

31
35

18

29 (x4)

13

2
26
5

17
12

24 (x2)
4
24 (x4)

16 (x4)
11
19 (x2)
24 (x2)

23

15
14

19 (x2)
25 (x2)

Figure 3-41: VL500 80V Yoke Assembly

02.96 85.001 0 0

17-July-2006

119

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Yoke Assembly (continued)

20 (x4)
30 (x4)
28

33

21

21 (x6)

10

30 (x4)
8

10

32

33

22 (x12)

34 (x6)
7

Figure 3-42: VL500 80V Yoke Assembly

120

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Extra Hardware Kit


28.9685.0999 Rev 0

Note: This kit contains addtional US-standard hardware (that may be difficult to find
outside North America). It is packaged into the foot of the fixture (underneath the pan
tube cover).
Refer to Figure 3-44.

No.

Item

Qty.

UM.

Description

07.5044.0002

EA

BAG, 4-MIL X 2" X 3", ZIP PRESS POLYETHYLENE

53.6008.0001

EA

SCREW, 6-32X3/8" PFB

53.6523.0013

EA

SCREW, 6-32X3/8" PTB

53.6558.0001

EA

SCREW, 6-32X3/8" PPZ

53.6558.0009

EA

SCREW, 6-32X3/8" PPZ SEMS

53.6558.0010

EA

SCREW, 6-32X1/4" PPZ SEMS

2 (x4)

6 (x4)

3 (x4)
1
4 (x4)

5 (x4)

Figure 3-43: VL500 US Extra Hardware Kit

02.96 85.001 0 0

17-July-2006

121

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Pan/Tilt Motor Assembly


21.9685.0540 Rev B

Refer to Figure 3-44.

No.

Item

Qty.

UM.

Description

10.9685.0541

EA

PLATE, TENSION ADJUSTMENT, PAN/TILT

21.9685.0545

EA

ASSY, DRIVE PULLEY, VL500

- 10.9685.0720

EA

PULLEY, DRIVE - PAN/TILT, 2MM GT 18 TOOTH

- 10.9678.0720

EA

CODEWHEEL, 120 COUNT, LARGE ID

24.9685.7735

EA

BOARD ASSY, PAN/TILT ENCODER, VL500

44.9678.0680

EA

MOTOR, 3-PHASE SZ 23 HIGH TORQUE

53.2200.0008

EA

NUT, 8-32 KEPS SS

53.6558.0001

EA

SCREW, 6-32X3/8" PPZ

53.6575.0004

EA

SCREW, 8-32X5/8" PPZ

55.6627.0001

EA

WASHER, #6 SPLIT LOCK

6 (x2)
3

8 (x2)
5 (x4)
1

7 (x4)

Figure 3-44: VL500 Pan/Tilt Motor Assembly

122

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 MCB/FAN Assembly


21.9685.0731 Rev 0

Refer to Figure 3-45.

No.

Item

Qty.

UM.

Description

10.9676.0735

EA

HEATSINK, PAN/TILT DRIVERS

10.9676.0885

EA

PAD, THERMAL TRANSFER, PAN/TILT

10.9685.0594

EA

BRACKET, FAN, MCB

10.9685.0595

EA

SEAL, AIR

23.9685.0782

EA

ASSY, FAN, MCB

24.9685.0730

EA

MCB, VL500

53.2200.0004

EA

NUT, 4-40 KEPS SS

53.6556.0001

EA

SCREW, 4-40X3/4" PPZ

53.6592.0001

EA

SCREW, 4-40X1/2" PPB

10

55.6537.0001

EA

WASHER, #4 LOCK INTERNAL TOOTH

9 (x3)

8 (x2)
10 (x2)
3

2
2
1
7

Figure 3-45: VL500 MCB/Fan Assembly

02.96 85.001 0 0

17-July-2006

123

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

MCB Fan Assembly


23.9685.0782 Rev 0

Refer to Figure 3-44.

No.

Item

Qty.

UM.

Description

40.7113.0007

EA

FAN, 12VDC, 30X10 MM, 3.3CFM

52.6450.0002

EA

CONNECTOR, MTA 100 IDC 2-POS, 28 AWG

Pin 2 (Black)

Pin 1 (Red)

6-inch leads

Figure 3-46: MCB Fan Assembly

124

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Yoke Crossmember Assembly


21.9685.0515 Rev E

Refer to Figure 3-47.

No.

Item

Qty.

UM.

10.9685.0547

EA

BUSHING, WIRE PROTECTION, 0.95" OD

10.9685.7590

EA

TOGGLE STOP, PAN

10.9685.7591

EA

TOGGLE, PAN

21.9685.0512

EA

ASSY, LOWER CROSSMEMBER

21.9685.0513

EA

ASSY, UPPER CROSSMEMBER

21.9685.0535

EA

ASSY, PAN TUBE

53.6552.0002

EA

SCREW, 8-32X1/2" PFB

53.6667.0005

EA

SCREW, 10-32X3/8" SET CUP POINT

54.1206.0014

EA

RING, RETAINING 1.375" SHAFT

Description

7 (x4)

7 (x4)
2
3

8 (x2)
9
4

Figure 3-47: Yoke Crossmember Assembly (VL500/VL500D/VL500A)

02.96 85.001 0 0

17-July-2006

125

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Yoke Crossmember Assembly (VL500 80V)


21.9685.0516 Rev 0

Refer to Figure 3-48.

No.

Item

Qty.

UM.

Description

10.9685.0547

EA

BUSHING, WIRE PROTECTION, 0.95" OD

10.9685.7590

EA

TOGGLE STOP, PAN

10.9685.7591

EA

TOGGLE, PAN

21.9685.0512

EA

ASSY, LOWER CROSSMEMBER

21.9685.0513

EA

ASSY, UPPER CROSSMEMBER

21.9685.0536

EA

ASSY, PAN TUBE, VL500 80V

53.6552.0002

EA

SCREW, 8-32X1/2" PFB

53.6667.0005

EA

SCREW, 10-32X3/8" SET CUP POINT

54.1206.0014

EA

RING, RETAINING 1.375" SHAFT

1
7 (x4)
9
5
7 (x4)
9
2

8 (x2)

9
4

Figure 3-48: Yoke Crossmember Assembly (VL500 80V)

126

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Lower Crossmember Assembly


21.9685.0512 Rev H

Refer to Figure 3-49.

No.

Item

Qty.

UM.

Description

10.9685.0509

EA

LOWER CROSSMEMBER

10.9685.0522

EA

PLATE, PAN LOCK

10.9685.0526

EA

WASHER, CENTERING, STEP

10.9685.0533

EA

LANYARD, SAFETY

53.2001.0003

EA

NUT, 10-32 NYLON INSERT

53.2019.0004

EA

NUT, 3/8-16 HEX

53.2020.0001

EA

NUT, 1/4X20 HEX STL ZINC PLTD

53.6539.0001

EA

WASHER, 3/8" SPLIT LOCK

53.6634.0875

EA

SCREW, 3/8-16X7/8" SCSS

10

53.6648.0001

EA

SCREW, 10-32X3/4" PPZ

11

54.1255.0001

EA

ASSY, BEARING/HOUSING

12

54.1261.0001

EA

BUSHING, LOW DAMP THRMOPLS.189

13

55.3301.0010

EA

WASHER, #10 FLAT

14

55.6549.0001

EA

WASHER, 1/4" SPLIT LOCK

15

55.6677.0035

EA

WASHER, 0.750" OD, 0.187" ID

02.96 85.001 0 0

17-July-2006

127

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Lower Crossmember Assembly (continued)

10 (x2)
15 (x2)

7 (x2)
14 (x2)
3 (x2)

11
8
9

12 (x2)
13 (x2)
5 (x2)

Figure 3-49: Lower Crossmember Assembly

128

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Upper Crossmember Assembly


21.9685.0513 Rev F

Refer to Figure 3-49.

No.

Item

Qty.

UM.

Description

10.9685.0510

EA

UPPER CROSSMEMBER

10.9685.0526

EA

WASHER, CENTERING, STEP

53.2020.0001

EA

NUT, 1/4X20 HEX STL ZINC PLTD

54.1255.0001

EA

ASSY, BEARING/HOUSING

55.6549.0001

EA

WASHER, 1/4" SPLIT LOCK

3 (x2)
5 (x2)
2 (x2)

Figure 3-50: Upper Crossmember Assembly

02.96 85.001 0 0

17-July-2006

129

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Pan Tube Assembly


21.9685.0535 Rev D (VL500/VL500D/VL500A)

Refer to Figure 3-51.

No.

Item

Qty.

UM.

Description

10.9685.0521

EA

PULLEY, DRIVEN, PAN/TILT

10.9685.0531

EA

PAN TUBE

10.9685.0532

EA

PAN PULLEY SPACER

53.2200.0006

EA

NUT, 6-32 KEPS SS

53.6608.0750

EA

SCREW, 6-32X3/4" PFB

1
3

5 (x2)

4 (x4)

Figure 3-51: Pan Tube Assembly (VL500/VL500D/VL500A)

130

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

80V Pan Tube Assembly


21.9685.0536 Rev 0 (VL500 80V)

Refer to Figure 3-52.

No.

Item

Qty.

UM.

Description

10.9685.0521

EA

PULLEY, DRIVEN, PAN/TILT

10.9685.0532

EA

PAN PULLEY SPACER

12.9685.0553

EA

PAN TUBE, 80V

53.2200.0006

EA

NUT, 6-32 KEPS SS

53.6608.0750

EA

SCREW, 6-32X3/4" PFB

5 (x2)

4 (x4)

Figure 3-52: 80V Pan Tube Assembly (VL500 80V)

02.96 85.001 0 0

17-July-2006

131

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

DMX Input PCB Assembly


24.9663.1895 Rev A

Refer to Figure 3-53.

No.

Item

Qty.

UM.

Description

Ref

11.9663.1895

EA

PCB, DMX INPUT

35-0053

EA

DIODE, ZENER, 6.2V 1W SM (NOT SHOWN)

D1, D2

52.6259.0001

EA

HEADER, 5POS MTA FRCT LOK STRT POST

J3

52.6625.0005

EA

CONN, RECEPT XLR 5PIN FEMALE PC MT


VERTICAL

J1

52.6626.0005

EA

CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL

J2

62.3017.0102

EA

CAP, 1000PF 250V RAD CER DISC 20% Y-TYPE

C1

1
5
2

Figure 3-53: DMX Input PCB Assembly

132

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Main Control Board PCB Assembly


24.9685.0730 Rev B

Refer to Figure 3-54


Item

UM.

Description

Ref.

10-0207

EA

RESISTOR, 47K, 1/10W, 5% SM 0805

R167, R168

10-0211

EA

RESISTOR, 100K, 1/10W, 5% SM 0805

R144

10-0269

EA

RESISTOR, 100, 1/10W, 5% SM 0805

R169

10-0621

EA

RESISTOR, 0, 1/10W, 5% SM 0805

R37

10.9661.1275

EA

HEATSINK, MAIN CONTROLLER

10.9676.0735

EA

HEATSINK, CONTROLLER, PAN/TILT DRIVERS

10.9678.0885

EA

KIT, THERMAL TRANSFER MAIN CONTROLLER

11.9685.0730

EA

PCB, CONTROLLER BOARD, VL500

13-0071

EA

RESISTOR, 1K, 1/4W, 5% SM 1210

R71

13-0114

EA

RESISTOR, 1K, 1/8W, 1% SM 0805

R146-154

13-0115

EA

RESISTOR, 10K, 1/10W, 1% 805

22-0036

EA

CAP, 470PF, 50V, 5% SM NPO 805

C48

25-0059

EA

CAP, 4.7UF, 35V

C28

25-0100

EA

CAP, 220PF, 50V, 10% NPO CER 0805

33-0043

EA

DIODE, 3A, 1N5404

D45, D46

33-0118

EA

DIODE, ZNR 3.3V 1N4684

D47, D48

40-0867

EA

HEADER, 10-POS SHROUDED

J3

52.6259.0003

EA

HEADER, 3 POS MTA156 STRT FRCT LOK

J8

52.6260.0004

EA

HEADER, 4 POS MTA-100 SHROUDED STRAIGHT

J6

52.6260.0005

EA

HEADER, 5 POS MTA-100 SHROUDED STRAIGHT

J5

52.6260.0006

EA

HEADER, 6 POS MTA-100 SHROUDED STRAIGHT

J4

52.6260.1004

EA

HEADER, 3 POS MTA-100 SHROUDED

J2

52.6599.0029

EA

HEADER, 14 PIN DUAL ROW AMP MODU VERT THRU

J9

52.6599.0040

EA

HEADER, 20 PIN DUAL ROW AMP MODU VERT THRU

J4

52.6599.0068

EA

HEADER, 34 PIN DUAL ROW AMP MODU VERT THRU

J7

52.8412.0026

EA

CONNECTOR, 26-PIN, 0.025" SQ PIN SOCKET

J1

53.6519.0001

EA

SCREW, 4-40 X 5/8" PPZ

55.3303.0004

EA

WASHER, #4 LOCK INT.TOOTH SS

60.1160.0000

EA

RES, 1/16W 0 OHM CHIP THK FLM SMT0402

60.1161.4323

EA

RES, 1/16W 1% 4.32 K CHIP THK FLM SMT0402

02.96 85.001 0 0

17-July-2006

R145, R155-162

R24, R39, R52


R91, R99, R112, R116,
R125, R128, R136, R139

133

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Item
60.1161.7503

UM.
16

EA

Description
RES, 1/16W 1% 7.50 K CHIP THK FLM SMT0402

Ref.
R89, R90, R95, R96,
R110, R111, R114, R115,

R123, R124, R126, R127, R134, R135, R137, R138

134

60.1165.1002

EA

RES, 1/16W 5% 100 OHM CHIP THK FLM SMT0402

R28, R74, R76-78,R81,


R83, R163-164

60.1165.1003

20

EA

RES, 1/16W 5% 1.0K CHIP THK FLM SMT0402

R12-18, R20, R35, R4143, R45-49, R57, R59,


R62

60.1165.1004

12

EA

RES, 1/16W 5% 10 K CHIP THK FLM SMT0402

R53, R56, R75, R79,


R101-102, R117-118,
R129-130, R140, R141
R66, R67

60.1165.1803

EA

RES, 1/16W 5% 1.8 K CHIP THK FLM SMT0402

60.1165.2201

EA

RES, 1/16W 5% 22 OHM CHIP THK FLM SMT0402

60.1165.2404

EA

RES, 1/16W 5% 24.0 K CHIP THK FLM SMT0402

60.1165.2702

EA

RES, 1/16W 5% 270 OHM CHIP THK FLM SMT0402

R73

60.1165.3302

EA

RES, 1/16W 5% 330 OHM CHIP THK FLM SMT0402

R55, R61, R65, R69

60.1165.3604

EA

RES, 1/16W 5% 36.0 K CHIP THK FLM SMT0402

R64, R70, R80, R82

60.1165.4702

EA

RES, 1/16W 5% 470 OHM CHIP THK FLM SMT0402

60.1165.4703

15

EA

RES, 1/16W 5% 4.7 K CHIP THK FLM SMT0402

60.3242.1000

EA

RES, 1W 1% 1.0 OHM WW SUR MT

60.4500.4703

EA

RES, .1W 5% 4.7 K CHIP THK FLM SMT

60.9460.1003

EA

RES, .1W 5% 1.0 K 100V CHIP THICK FILM SMT0805

60.9460.1004

12

EA

RES, .1W 5% 10.0 K 100V CHIP THICK FILM

60.9460.1502

EA

RES, .1W 5% 150.0 OHM 100V CHIP THICK FILM


SMT0805

R84

60.9466.4703

EA

RES, 1/4W 5% 4.7K 200V CHIP THK FLM SMT1210

R60

62.3038.0472

EA

CAP, 4700PF 50V 10% X7R CER 805

62.4003.0104

EA

CAP, 0.1UF 50V 10% CER CHIP SUR MT X7R EIA0805

62.4003.0105

EA

CAP, 220PF 50V 10% X7R SM 0603

C132-133

62.4004.0221

EA

CAP, 220PF 50V 20% CER CHIP S

C122-128

62.4206.0105

EA

CAP, 1UF 16V 10% TANT CHIP

C84, C94

62.4209.0224

EA

CAP, .22UF 50V 10% TANT CHIP SUR MT

C85, C95

62.4225.0107

EA

CAP, 100UF 35V 20% ALUM ELECTRO SUR MT

C1-2, C5-6

62.4227.0107

EA

CAP, 100UF 10V 20% ALUM ELECTRO SUR MT

C3-4, C7-12

62.4228.0106

EA

CAP, 10UF 50V 20% ALUM ELECTRO SUR MT

C58, C76, C86-87, C9697, C99, C108

17-July-2006

R31-34
R87, R109, R122, R133

R54, R58, R63, R68


R3-11, R22, R36, R85-86,
R165-166
R105-106, R119-120,
R131-132, R142-143
R38, R40, R170
R44, R50
R1-2, R19, R21, R23,
R25-27, R29-30, R113,
R121

C52-55
C80-81, C88, C92-93, C98

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Item

UM.

Description

Ref.

62.4240.0103

16

EA

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

39

EA

CAP, .1UF 25V 10% CER CHIP SUR MT X7R EIA0603

C18-23, C26, 27, C30-42,


C131

62.4240.0223

EA

CAP, .022UF 25V 10% CER CHIP SUR MT X7R EIA0603

C63, C67, C79, C83,


C102, C104, C111, C113

62.4245.0272

EA

CAP, 2700 PF 25V 10% CER CHIP SUR MT X7R EIA0402

C70, C89, C105, C114

62.4245.0471

EA

CAP, 470PF 25V 10% CER CHIP SUR MT X7R EIA0402

C72-73, C90-91, C106107, C115-116

64.4029.0001

EA

OSCILLATOR, 40.000 MHZ SM7745HV SUR MT

Y1

67.4012.0001

EA

FILTER, EMI 600 OHM 1MHZ CHIP FERRITE

FB1

68.4581.0001

EA

INDUCTOR, 100UH 2.22A PE-54037S

L1-2

70.3763.0001

EA

FUSE, PTC 500MA 60V SMD050

74.1097.0001

EA

SWITCH, TACT, TIGHT ANGLE, THRU HOLE

82.5326.0002

EA

DIODE, DL4148CT RECTIFIER

82.5329.0001

EA

DIODE, MBRS340T3 40V 3A SCHOTTKY SUR MT

D1-2

82.5350.0001

EA

DIODE, BAT54SLT1 DUAL SCHOTTKY CATHODE TO


ANODE CONNECTED 30V 200MA

D7-8

82.5361.0001

EA

DIODE, ZENER TVS 10V 23A SMT

Z1-6

82.5362.0001

28

EA

DIODE, SCHOTTKY BARRIER RECTIFIER, 40V, 1A,


SMT

83.3174.0001

EA

IC, 2596S VOLTAGE REG 5V TO-26

VR1

83.3174.0004

EA

IC, LM2596S-3.3 VOLTAGE REGULATOR PWR


CONVERTER 150K HZ 3A STEPDOWN 0

VR2

83.3206.0001

EA

IC, LP3965ES-1.8 1.8V SMT

VR4

83.3209.0001

EA

IC, 74LCX244MTC LOW VOLT BUFFER / LINE DRIVER


SMT

83.3215.0001

EA

IC, TPS72515 1.5V REGH DDPAK

VR3

84.4234.0002

EA

IC, RS485 TRANSCEIVER SUR MT SOIC PKG

U14

84.4297.0002

EA

IC, MT48LC4M16A2TG-75 DRAM 1MEGX6X4 SMT

84.4300.0001

EA

IC, CY2305SC-1 PLL CLOCK DRIVER 3.3V SMT

84.4305.0001

EA

IC, NC7SZ04M5 UHS INVERTER -SMT

84.4306.0001

EA

IC, NC7SZ08M5 UHS 2-INPUT AND GATE

U8, U18

84.4350.0001

EA

IC, MCF5407FT162A MICROPROCESSOR

U1

84.7408.0001

EA

IC, 74ACT00SC SOIC-14-N

84.7420.0003

EA

IC, LTC1480 SOIC-8-N

84.7430.0001

EA

IC, MAU202 SIP DC-DC CONVERTER

84.7433.0001

EA

IC, MCP3008ADC10BIT2.7V SOIC-16

85.3773.0001

EA

IC, STEPMOTOR DRIVER

U25, U28, U32-33

17-July-2006

135

02.96 85.001 0 0

FTC1-4

D12, D16, D20, D24

D9-11, D13-15, D17-19,


D21-23, D25-28, D33-44

U23-24

U3, U5

U22, U29, U31, U34

U13

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Item

UM.

Description

Ref.

85.5134.0001

EA

IC, SN75LBC180D LOW-POWER DIFF LINE DRVR &


RCVR PAIRS

U20

85.5164.0002

EA

IC, L6234PD SO-20

85.5168.0001

EA

IC, DS1834AS DUAL RESET MONITOR W/


PUSHBUTTON SMT

86.6105.0001

EA

IC, HCPL-0600 OPTO COUPLER SMD

87.7248.0001

EA

IC, AM29LV400BB-44REI 4MEGBIT FLASH MEMORY

U2

87.7404.0001

EA

IC, M24C02WMN6T EEPROM (BLANK) 2K BIT (256X8)


SERIAL I2C BUS

U6

87.7405.0001

EA

IC, CYCLONE EP1C3T144 TQFP-144

U10

88.8145.0001

EA

LED, REVERSE MOUNT RED SMT

D5

88.8145.0002

EA

LED, REVERSE MOUNT GREEN SMT

88.8145.0003

EA

LED, REVERSE MOUNT YELLOW SMT

U4
U12, U16, U19, U21

D3-4
D6

Top Side

Bottom Side

Figure 3-54: VL500 Main Control Board PCB Assembly

136

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Cables
Incandescent Power Input Cable Assembly
25.9663.2030 Rev A (VL500 Only)

Refer to Figure 3-55.

No.

Item

Qty.

UM.

Description

52.6274.2313

EA

STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK

52.8231.0005

EA

TERM, RING #6 BLUE 16-14 AWG REEL PIDG

52.8298.1160

EA

FERRULE, WIRE 1X16 AWG L2=8MM BLACK

55.2268.0187

FT

HEATSHRINK, 3/16" CLEAR KYNAR VDE UL 600V 150DEG C

55.2268.0500

0.13

FT

HEATSHRINK, 1/2" CLEAR KYNAR VDE UL 600V 150DEG C

73.9636.0153

FT

CORDAGE, 1.5/3 750V 60C EURO BLK HD-22 11MMOD

L
BRN
N
BLU
GRN/YEL

GND

Figure 3-55: Incandescent Power Input Cable Assembly (VL500 Only)

02.96 85.001 0 0

17-July-2006

137

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

80V LVS AC Cable Assembly


25.9685.0742 Rev 0

Refer to Figure 3-56.

No.

Item

Qty.

UM.

Description

52.6264.0004

EA

CONN HOUSING, 3-POS SL156 W/ RAMP NO TABS

52.8317.0002

EA

CONTACT, SL156 24-18AWG

73.6018.0002

0.71

FT

WIRE, 18 AWG 600V 105DEGC PVC RED UL1015

73.6018.0010

0.63

FT

WIRE, 18 AWG 600V 105DEGC PVC BLACK UL1015

1, 2 (x2)

Figure 3-56: 80V LVS AC Cable Assembly

138

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

80V Surge Protector Cable Assembly


25.9685.0746 Rev 0

Refer to Figure 3-57.

No.

Item

Qty.

UM.

Description

33-0441

EA

MOV, 430V 6500A 20MM ZNR

52.8231.0005

EA

TERM RING, #6 BLUE 16-14 AWG REEL PIDG

55.2198.0001

0.08

FT

HEATSRINK, 1/8" BLACK

55.2199.0001

0.13

FT

HEATSRINK, 1/16" BLACK

55.2200.0001

0.08

FT

HEATSRINK, 3/16" BLACK

73.6016.0504

0.75

FT

WIRE, 16 AWG 600V 105DEGC GREEN/YELLOW UL1015

4 (4 pl)

6
1 (x2)

Figure 3-57: 80V Surge Protector Cable Assembly

02.96 85.001 0 0

17-July-2006

139

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Motor Cable Assembly


25.9685.0753 Rev B

Refer to Figure 3-58.

No.

Item

Qty.

UM.

Description

52.6224.1034

EA

COVER, FRONT 34-POS MT LATCHING

52.6224.2034

EA

COVER, BACK 34-POS MT

52.6610.0034

EA

CONN, HOUSING 34-POS DBL ROW UNLOADED

52.6694.0001

16

EA

CRIMP, TERMINAL WIRE TO WIRE FEMALE 2MM 28-24 AWG

52.6696.0001

EA

RECEPT, WIRE TO WIRE 4-POS 2MM PITCH 28-24 AWG

52.8351.0004

34

EA

CONTACT, 26-22 AWG RECP MTE (REEL)

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

55.6699.0010

FT

SLEEVING, 5/16" NOM DIA WOV POLY, ROUNDIT 2000

73.2326.0123

5.35

FT

WIRE, 26 AWG 4-COND 300V 200DEGC TEF (BLK-BRN-RED-ORG)

140

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Motor Cable Assembly (continued)


4 (x4), 5
1, 2, 3, 6
4 (x4), 5
8
4 (x4), 5

7 (x2)

4 (x4), 5

Figure 3-58: VL500 Motor Cable Assembly

02.96 85.001 0 0

17-July-2006

141

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Relay to Ignitor Cable Assembly


25.9685.0755 Rev B

Refer to Figure 3-59.

No.

Item

Qty.

UM.

Description

52.8271.0005

EA

RECPT, FASTON 1/4" 16-14 AWG INSULATED (REEL)

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

73.6014.0012

0.29

FT

WIRE, 14 AWG 600V 200DEGC FEP BLACK STRAND 168/36 0.104 DIA

73.6014.0013

0.42

FT

WIRE, 14 AWG 600V 200DEGC FEP WHITE STRAND 168/36 0.104 DIA

2
1 (x4)

Figure 3-59: Relay to Ignitor Cable Assembly

142

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 AC Input Cable Assembly


25.9685.0756 Rev B

Refer to Figure 3-60.

No.

Item

Qty.

UM.

Description

52.6541.0003

EA

CONN, CHASSIS POWER 3-POLE LOCKING

52.8231.0005

EA

TERM, RING #6 16-14 AWG REEL PIDG

52.8331.0003

EA

FASTON RECPT., 16-14 AWG PIDG BLU 0.170" ID

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

73.6014.0005

0.58

FT

WIRE, 14 AWG 600V 105DEGC PVC GRN UL1015

73.6014.0009

0.33

FT

WIRE, 14 AWG 600V 105DEGC PVC WHT UL1015

73.6014.0010

0.33

FT

WIRE, 14 AWG 600V 105DEGC PVC BLK UL1015

4
3 (x3)

7
2

Figure 3-60: VL500 AC Input Cable Assembly

02.96 85.001 0 0

17-July-2006

143

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Arc Ballast Input Cable Assembly


25.9685.0757 Rev C

Refer to Figure 3-60.

No.

Item

Qty.

UM.

52.6400.0027

EA

Description
RECPT, 17-14 SQ FLANGE REV SEX THRD CPC

52.6420.0002

EA

SOCKET, GOLD 18-14 AWG TYPE 3+ LOOSE 0.08-0.100 INS DIA

52.8201.0007

EA

SOCKET, GOLD 24-20 AWG TYPE 3+ (REEL) 0.04-0.08 INS DIA

52.8321.0005

EA

TERM, RING #6 16-14 AWG REEL PIDG

53.7015.0005

EA

CONN, HOUSING 5CIR MTA100 BLU

73.2326.0029

2.79

FT

WIRE, 26 AWG 3COND 300V 200DEGC TEF (BLK-WHT-RED) UL1180

73.6014.0002

0.46

FT

WIRE, 14 AWG 600V 105DEGC PVC RED UL1015

73.6014.0003

0.46

FT

WIRE, 14 AWG 600V 105DEGC PVC ORG UL1015

73.6014.0005

0.88

FT

WIRE, 14 AWG 600V 105DEGC PVC GRN UL1015

10

73.6014.0009

0.75

FT

WIRE, 14 AWG 600V 105DEGC PVC WHT UL1015

11

73.6014.0010

0.75

FT

WIRE, 14 AWG 600V 105DEGC PVC BLK UL1015

2 (x7)
4

1
7

9 8 11 9

10

6
3 (x3)

Figure 3-61: VL500 Arc Ballast Input Cable Assembly

144

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Head Grounding Cable Assembly


25.9685.0760 Rev C

Refer to Figure 3-62.

No.

Item

Qty.

UM.

52.8231.0000

EA

TERM, RING #6 RED 22-16 AWG INSUL REEL

73.6014.0011

1.33

FT

WIRE, 14 AWG 600V 200DEGC FEP GRN STRND 168/36 0.104 DIA

1 (x2)

Description

Figure 3-62: VL500 Head Earthing Cable Assembly

02.96 85.001 0 0

17-July-2006

145

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Ignitor to Socket Cable Assembly


25.9685.0766 Rev C

Refer to Figure 3-63.

No.

Item

Qty.

UM.

25.9685.0777

EA

Description
CABLE ASSY, BACK CAP GROUND, VL500

52.8244.0001

EA

FASTON RECEPT FLAG, 0.250 16-14 AWG INSULATED (REEL)

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

55.2260.0133

2.33

FT

SLEEVING, FIBERGLASS 0.133" ID

55.6699.0010

1.33

FT

SLEEVING, 5/16" NOM. DIA. WOVEN POLY, ROUNDIT 2000

73.3517.0001

4.00

FT

WIRE, 14 AWG 5KV 200DEGC SILICON 7X24/36 STRAND

2 (x2)
6

3
5

4 (2 pl)

6
1

Figure 3-63: VL500 Iginitor to Socket Cable Assembly

146

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Arc Ballast Interconnect Cable


Assembly
25.9685.0767 Rev B

Refer to Figure 3-64.

No.

Item

Qty.

UM.

Description

52.6400.0020

EA

PLUG, 17-14 REV SEX CPC 600V KEY A

52.6400.0120

EA

PLUG, 17-9 REV SEX CPC 600V KEY A

52.6431.0002

EA

BACKSHELL, CPC17 NYLON 0.300-0.525 CBL RNG

52.8201.0005

EA

PIN, GOLD 24-20 AWG TYPE 3+ REEL 0.04-0.08 INS DIA

52.8201.0007

EA

SOCKET, GOLD 24-20 AWG TYPE 3+ REEL 0.04-0.08 INS DIA

52.8341.0001

EA

PIN, GOLD 18-14 AWG TYPE 3+ REEL 0.11-0.15 INS DIA

52.8342.0001

EA

SOCKET, GOLD 18-14 AWG TYPE 3+ REEL 0.11-0.15 INS DIA

52.8344.0006

EA

PIN, CPC POWER 14 AWG 23A LOOSE

52.8344.0008

EA

SOCKET, CPC POWER 14 AWG 23A LOOSE

10

73.7087.0013

5.00

FT

CABLE, COMPOSITE V500 ARC POWER INPUT

02.96 85.001 0 0

17-July-2006

147

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Arc Ballast Interconnect Cable Assembly (Continued)


1
4 (x4)
6 (x3)
8 (x2)

2
5 (x4)
7 (x3)
9 (x2)

10

Pinout

Pinout
Pin

Wire

Description

Pin

Wire

Description

OPEN

N/A

VIOL14 AWG

LAMP POWER

OPEN

N/A

GRN/16 AWG

GROUND

GRN/16 AWG

GROUND

ORN/14 AWG

LAMP POWER

BLK/16 AWG

POWER (HOT)

BLK/16 AWG

POWER (HOT)

DRAIN/22 AWG

DRAIN WIRE

DRAIN/22 AWG

DRAIN WIRE

OPEN

N/A

WHT/16 AWG

NEUTRAL

WHT/16 AWG

NEUTRAL

WHT/22 AWG

NEUTRAL

WHT/22 AWG

DATA

BLK/22 AWG

DATA

BLK/22 AWG

DATA

RED/22 AWG

DATA

10

RED/22 AWG

DATA

11

OPEN

N/A

12

ORN/14 AWG

LAMP POWER

13

OPEN

N/A

14

VIOL14 AWG

LAMP POWER

Figure 3-64: VL500 Arc Ballast Interconnect Cable Assembly

148

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Display (Remote) Cable Assembly


25.9685.0770 Rev B

Refer to Figure 3-63.

No.

Item

Qty.

UM.

Description

10.9685.0536.01

EA

ADAPTER PLATE, MINI XLR, BLACK

52.6694.0002

EA

CRIMP TERM, WIRE TO WIRE, MALE

52.6696.0003

EA

PLUG, WIRE TO WIRE, 4-POS

53.6501.0002

EA

CONN, MINI XLR, 4-PIN, PANEL MOUNT

73.2326.0123

0.25

FT

WIRE, 26 AWG 4-COND 300V 200DEGC (BLK-BRN-RED-ORN)


UL1180

2 (x4)
3

Figure 3-65: VL500 Display (Remote) Cable Assembly

02.96 85.001 0 0

17-July-2006

149

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Yoke Lamp Jumper Cable Assembly


25.9685.0776 Rev A

Refer to Figure 3-66.

No.

Item

Qty.

UM.

Description

52.8348.0001

EA

TAB, ULTRA-FAST 1/4" 16-14 AWG INSULATED (LOOSE)

TBD

0.13

FT

WIRE, 14 AWG 200DEGC STRAND TEF WHT

1 (x2)

Figure 3-66: VL500 Yoke Lamp Jumper Cable Assembly

150

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Backcap Ground Cable Assembly


25.9685.0777 Rev A

Refer to Figure 3-62.

No.

Item

Qty.

UM.

Description

52.8329.0001

EA

TERM, RING #6 RED 22-16 AWG NON-INSUL

52.8329.0003

EA

TERM, RING #8 RED 22-16 AWG NON-INSUL

73.7130.0002

1.17

FT

WIRE, 7/64" TUBULAR BRAID SILVER PLATED

Figure 3-67: VL500 Backcap Ground Cable Assembly

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17-July-2006

151

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Main Harness Cable Assembly


25.9685.0790 Rev J (VL500 and VL500D)

Refer to Figure 3-68.

No.

Item

Qty.

UM.

25.9685.0750

EA

CABLE ASSY, DIMMER COMM

25.9685.0752

EA

CABLE ASSY, 24V POWER

25.9685.0758

EA

CABLE ASSY, PAN/TILT

25.9685.0769

EA

CABLE ASSY, DISPLAY CABLE

25.9685.0771

EA

CABLE ASSY, YOKE LAMP WIRES

25.9685.0772

EA

CABLE ASSY, YOKE GROUND

25.9685.0773

EA

CABLE ASSY, LVS AC

25.9685.0774

EA

CABLE ASSY, YOKE DMX COMM

25.9685.0778

EA

CABLE ASSY, LVS FAN

10

25.9685.0782

EA

CABLE ASSY, MCB YOKE GROUND

11

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

12

55.6699.0003

1.19

FT

SLEEVING, 1/2" NOM DIA WOVEN POLY

13

55.6699.0010

0.92

FT

SLEEVING, 5/16" NOM DIA WOVEN POLY ROUNDIT 2000

152

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Main Harness Cable Assembly (continued)

7
10

5
3

3
4

12

13

12
11 (x8)
10

3
1
8

Figure 3-68: VL500 Main Harness Cable Assembly (VL500 and VL500D)

02.96 85.001 0 0

17-July-2006

153

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Arc Main Harness Cable Assembly


25.9685.0791 Rev C (VL500A)

Refer to Figure 3-68.

No.

Item

Qty.

UM.

25.9685.0752

EA

CABLE ASSY, 24V POWER

25.9685.0758

EA

CABLE ASSY, PAN/TILT

25.9685.0772

EA

CABLE ASSY, YOKE GROUND

25.9685.0773

EA

CABLE ASSY, LVS AC

25.9685.0778

EA

CABLE ASSY, LVS FAN

25.9685.0782

EA

CABLE ASSY, MCB YOKE GROUND

25.9685.0783

EA

CABLE ASSY, ARC YOKE LAMP WIRES

25.9685.0784

EA

CABLE ASSY, SHIELDED DISPLAY/DMX COMM

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

10

55.6699.0003

1.19

FT

SLEEVING, 1/2" NOM DIA WOVEN POLY

11

55.6699.0010

0.92

FT

SLEEVING, 5/16" NOM DIA WOVEN POLY ROUNDIT 2000

154

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 Arc Main Harness Cable Assembly (continued)

4
6

5
8

5
7
2

10

11

10
9 (x8)
6
2

8
8

Figure 3-69: VL500 Arc Main Harness Cable Assembly (VL500A)

02.96 85.001 0 0

17-July-2006

155

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 80V Main Harness Cable Assembly


25.9685.0792 Rev C (VL500 80V)

Refer to Figure 3-68.

No.

Item

Qty.

UM.

25.9678.0743

EA

CABLE ASSY, 80V DIMMER COMM, VL500 80V

25.9685.0744

EA

CABLE ASSY, 24V POWER, VL500 80V

25.9685.0745

EA

CABLE ASSY, 80V YOKE LAMP WIRES

25.9685.0758

EA

CABLE ASSY, PAN/TILT

25.9685.0772

EA

CABLE ASSY, YOKE GROUND

25.9685.0788

EA

CABLE ASSY, SHIELDED DISPLAY/DMX COMM, VL500 80V

25.9685.0782

EA

CABLE ASSY, MCB YOKE GROUND

55.2186.0001

EA

CABLE TIE, 0.10"X4" SMALL

55.6699.0003

1.19

FT

SLEEVING, 1/2" NOM DIA WOVEN POLY

10

55.6699.0010

0.92

FT

SLEEVING, 5/16" NOM DIA WOVEN POLY ROUNDIT 2000

156

Description

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

VL500 80V Main Harness Cable Assembly (continued)

3
5

8
4

4
8

10
8 (x8)
7
1

6
6

Figure 3-70: VL500 80V Main Harness Cable Assembly (VL500 80V)

02.96 85.001 0 0

17-July-2006

157

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Notes

158

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

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.

No.

Item

Qty.

UM.

04.9685.0940

EA

LABEL, PRODUCT, VL500APS-575W (575W ARC ONLY)

04.9685.0941

EA

LABEL, PRODUCT, VL500APS-700W (700W ARC ONLY)

04.9685.0942

EA

LABEL, PRODUCT, VL500APS COMPLIANCE (BLK)

04.9685.0945

EA

LABEL, BALLAST WATTAGE, 575W (575W ARC ONLY)

04.9685.0946

EA

LABEL, BALLAST WATTAGE, 700W (700W ARC ONLY)

10.9669.0034

EA

PLATE, NUT

10.9685.0822

EA

MOUNT PLATE, BALLAST

10.9685.0823

EA

BOTTOM PLATE, BALLAST (BLK) (700W ARC ONLY)

10.9685.0824

EA

TOP PLATE, BALLAST (BLK)

10

10.9685.0825

EA

COVER, BALLAST (BLK)

11

10.9685.0826

EA

PANEL, FILLER, BALLAST (BLK)

12

10.9685.7823

EA

BOTTOM PLATE, BALLAST (BLK) (575W ARC ONLY)

13

12.9685.0821

EA

HEATSINK, BALLAST, MACHINED (BLK)

14

23.9685.0827

EA

FAN ASSY, ARC BALLAST, 700W (700W ARC ONLY)

15

25.9685.0807

EA

CABLE ASSY, BALLAST I/O

16

53.2002.0001

EA

NUT, 6-32 KEPS, ZINC (700W ARC ONLY)

17

53.2003.0001

EA

NUT, 4-40 KEP ZINC PLATED

18

53.6520.0001

EA

SCREW, 4-40X3/8" PPZ

19

53.6545.0001

EA

SCREW, 8-32X3/8" PPZ

20

53.6551.0001

EA

SCREW, 4-40X3/8" PPB

21

53.6571.0002

EA

SCREW, 6-32X1-1/4" LG PPB (700W ARC ONLY)

22

53.6575.0021

12

EA

SCREW, 8-32X5/8" PPB TYPE-F

23

53.6607.0002

EA

SCREW, 6-32X1/4" PFB

24

53.6614.0001

16

EA

SCREW, 6-32X5/8" LG PPB

25

69.9685.0626

EA

BALLAST, 625W, SCHEIDERWERKS (575W ARC ONLY)

26

69.9685.0701

EA

BALLAST, 700W, SCHEIDERWERKS (700W ARC ONLY)

02.96 85.001 0 0

Description

17-July-2006

159

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Arc Ballast Assembly (continued)


25 (575W Only)
26 (700W Only)

19 (x4)

10
9

23 (x4)

13
17 (x4)

13
18 (x5)
6

15

24 (x16)

16 (x4)

12 (575W Only)
8 (700W Only)

14
7

20 (x4)

21 (x4)

23 (x2)

22 (x12)

11

1 (575W Only)
2 (700W Only)

4 (575W Only)
5 (700W Only)

Figure 3-71: VL500 Arc Ballast Assembly

160

17-July-2006

02 .9 685.00 10 0

ILLUSTRATED PARTS BREAKDOWN :

Ballast I/O Cable Assembly


25.9685.0807 Rev A

Refer to Figure 3-72.

No.

Item

Qty.

UM.

Description

52.6231.0001

EA

PLUG HOUSING, MNLOK PLUG 3-POS

52.6396.2904

EA

RECEPT, 4-POS MTA100 W/POL RED

52.6400.0111

EA

RECEPT, 17-9 STD SEX CPC 600V FLANGE

52.8201.0005

EA

PIN, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA

52.8202.0001

EA

PIN, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA

52.8202.0011

EA

PIN, GND GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA

52.8231.0005

EA

TERM, RING #6 BLUE 16-14 AWG REEL PIDG

52.8257.0002

EA

PIN, PHOS BRZ 20-14AWG (REEL) MNLOK .060"- .130"INS DIA

52.8313.0001

EA

RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL)

10

52.8314.0001

EA

PIN, GND 20-14AWG (REEL) MNLOK .060"- .130"INS DIA

11

55.2186.0001

EA

CABLE TIE, .10"WD 4.00"LG SMALL

12

73.3522.0002

1.25

FT

WIRE, 22AWG 300V 105C PVC RED UL1569

13

73.3522.0009

1.25

FT

WIRE, 22AWG 300V 105C PVC WHT UL1569

14

73.3522.0010

1.25

FT

WIRE, 22AWG 300V 105C PVC BLK UL1569

15

73.6016.0003

1.33

FT

WIRE, 16AWG 600V 105C PVC ORN UL1015

16

73.6016.0007

1.33

FT

WIRE, 16AWG 600V 105C PVC VIO UL1015

17

73.6016.0009

1.33

FT

WIRE, 16AWG 600V 105C PVC WHT UL1015

18

73.6016.0010

1.33

FT

WIRE, 16AWG 600V 105C PVC BLK UL1015

19

73.6016.0504

3.0

FT

WIRE, 16AWG 600V 105C PVC GRN/YEL UL1015

02.96 85.001 0 0

17-July-2006

161

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Ballast I/O Cable Assembly (continued)

7 (x3)
19
9
11 (x5)

16

19

15
17
1
8 (x2)
10

12, 13, 14
18
3
4 (x3)
5 (x5)
6

Figure 3-72: Ballast I/O Cable Assembly

162

17-July-2006

02 .9 685.00 10 0

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Wiring and Schematic Diagrams


VL500 Wiring Diagram - Sheet 1 of 1

02.96 85.001 0 0

17-July-2006

163

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

DMX Input PCB (24.9663.1895) Schematic

A0

ECO #

REV. NO

S05-945

DESCRIPTION

APPROVED

DATE

12/14/05

RELEASE

FAE

J1

D1
2

SHIELD
DMX/VL_INDMX/VL_IN+
VL_OUTVL_OUT+
CHASSIS

1
2
3
4
5
6

D2
2

J2
C

SHIELD
DMX/VL_INDMX/VL_IN+
VL_OUTVL_OUT+
CHASSIS

1
2
3
4
5
6

SHIELD
DMX/VL_IN+
DMX/VL_INVL_OUT+
VL_OUT-

1
2
3
4
5

J3

C1

DRAWN BY :

FAE
A

GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238


INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE

CHECKED BY :

PROJECT ENGR. :

Title
DOC. CONTROL :
Size

B
C 2005 Genlyte Group LLC
Date:
5

02.96 85.001 0 0

17-July-2006

CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED


OR DISCLOSED WITHOUT WRITTEN CONSENT.

SCHMATIC VL1000 DMX INPUT BD.


Document Number

Rev

14-9663-1895

Wednesday, December 14, 2005

SHEET

A0

OF

164

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Controller PCB (24.9685.0730) Schematic - Sheet 1 of 6

ECO #

REV. NO

A0
NOTES: UNLESS OTHERWISE SPECIFIED
1.) ALL CAPACITOR VALUES ARE IN MICROFARADS.

n/a

B0

n/a

C0

S05-701

DESCRIPTION

APPROVED

DATE

PROTO RUN

6/1/05

FAE

MODIFY J3, J9 & U18

7/5/05

FAE

MODIFY DISPLAY COMMUNICATIONS

9/26/05

FAE

2.) ALL RESISTOR VALUES ARE IN OHMS.

+24V

VCC

VR1
D45

18V BATT

C2

Gnd

C1

C3

C4

18V BATT

D1

24V_DET

VCC
1

3/C3

R167

TAB

L1

D47

VCC
18V BATT

+3.3V

VR2
D46

C5

C6

Gnd

TAB

L2

C7

C8

+24V

D2

R168

+24V

+3.3V

3/B3 BATT_DET

D48

+3.3V

+1.5V
+3.3V

+1.5V
R1

VR3

+1.5V
+1.8V

CONNECT SENSE AT LOAD


+

C9

TAB

GND

C10

+1.8V

GND
+3.3V

R2

VR4

+1.8V

CONNECT SENSE AT LOAD

GND
3

C11

C12

TAB

+
+

DRAWN BY :

FAE

GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238


INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE

CHECKED BY :

CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED


OR DISCLOSED WITHOUT WRITTEN CONSENT.

PROJECT ENGR. :

Title

SCHEMATIC VL500 CONTROLLER

DOC. CONTROL :
Size

Document Number

D
C 2005 Genlyte Group LLC
Date:

02.96 85.001 0 0

17-July-2006

Rev

14-9685-0730

Wednesday, October 26, 2005

SHEET

C0
1OF

165

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Controller PCB (24.9685.0730) Schematic - Sheet 2 of 6

D[0..31]

3/D1, 3/B1, 3/C3

+3.3V

+3.3V

R3
CS_MTR-

C15

C16

2/B3, 3/B3

C17
R4
CS_UART-

D0

2/B3, 3/C1

R5
+3.3V

+3.3V

+3.3V

C19

+3.3V

C20

+3.3V

C21

CS_FLASH-

+3.3V

C22

C23

D2

2/B3, 2/C2

TIN0

2/B4
R7

TIN1

2/B4

R8
HIZ-

C25

R9
DSI

2/B5, 2/A3
R10
BKPT-

R11
DSCLK

2/B5, 2/C3, 3/D1

R13
VCC

AS-

2/C4

RSTI2/C4, 2/B5, 2/A3, 2/C2

2/C3, 2/C2, 3/B3

R15
IRQ7-

+3.3V
U4

2/B3

R16

A2

D17

A3

A3

D18

A4

A4

D19

D5

A5

A5

D20

D6

A6

A6

D21

D7

A7

A7

D22

A8
A9

A9

D24

A10

A10

D25

D11

A11

A11

D26

D12

A12

A12

D27

D13

A13

A13

D28

A14

D0

A14

D1

A13

D2

A12

D3

A11

D4

A10

D5

A9

D6

A2

A17

D7

A3

A18

D8

A4

A19

D9

A5

A20

D10

A6

A21

D11

A7

A24

D12

R17
TX_INT-

2/C3, 3/B1

R18
IRQ1-

2/B3
R20
RSTI-

D1
D2
D3

A14

D4
D5
D6

D8

A15

A15

D30

A22

A16

A16

D31

A23

D17

A17

A17

D18

A18

A18

D19

A19

D10
D11

D13

A9

D14

A10

D12
D13

2/B3
2/B3

CS_FLASH-

2/D4, 2/B3

D21

A21

D22

A22

2/C4, 2/C3, 3/B3

D23

A23

2/C5, 2/C4, 2/B5, 2/A3

D24

A24

2/B1, 2/B3

OE-

2/B3

R/W-

RAS0-

A12

CAS3-

A13

D15
D16
A14

CAS2-

D17
A15

DRAMW-

A20

2/B1, 2/B2

SRAS-

A21

2/B2, 2/B1

SCAS-

D18
A16
D19
A17
D20
A18

RSTI-

D21

+3.3V
2/B3, 2/B1

+3.3V

2/A4
DCLK

A11
D14

2/B3, 2/B1
A19

A19

CLK_EN

D22
A20

CLK1

D23
A21

3/A5, 3/C3, 3/C5

D27

DATA

D28

INIT_DONE

D24

D30

STATUS-

D31

CONFIG-

A22

+3.3V

3/A5, 3/C3

CONF_DONE

D9

A8

D29

D16

A20

A1

D7

D15

D29

D0

A0

D23

D10

D26

2/C3, 3/B1

D25
A23
D26

3/D3
A24

3/C5, 3/A5, 3/B1

D27

3/C5, 3/A5, 3/B1

D28

3/C5, 3/C3

D29

2/C5, 2/B5, 2/A3, 2/C2

D30
LAMP_STBY

S1

A8

A15

D25
RX_INT-

C26

D16

A2

U1

D20

R14
R/W-

A1

D15

2/B5, 2/A3

R12
TA-

A1

D4

D14

2/B5, 2/A3

3/D3, 3/D1, 3/C1

U3

D3

D9

+1.8V

C24

U2
A0

D8

2/A4
+1.8V

A[0..24]

+3.3V

D1

R6
C18

7
13
21
29
37
45
52
65
81
89
97
113
121
129
137
145
167
191
205

+3.3V

C14

+1.8V

VCC3.3-1
VCC3.3-2
VCC3.3-3
VCC3.3-4
VCC3.3-5
VCC3.3-6
VCC3.3-7
VCC3.3-8
VCC3.3-9
VCC3.3-10
VCC3.3-11
VCC3.3-12
VCC3.3-13
VCC3.3-14
VCC3.3-15
VCC3.3-16
VCC3.3-17
VCC3.3-18
VCC3.3-19

+3.3V

C13

VCC1.8-1
VCC1.8-2
VCC1.8-3
VCC1.8-4
VCC1.8-5
VCC1.8-6
VCC1.8-7
VCC1.8-8
VCC1.8-9
VCC1.8-10

+3.3V

1
57
73
105
152
157
171
175
185
197

+3.3V

R22

6/D4
PP1

EDGESEL

D31

R19

+3.3V

D0

2/A3

PP2

PLL MULT = 4X

R21

VCC

R24

R/WAS-

2/C4

25-40.5MHz

R23
2/C4, 2/C2, 3/D3

TA-

2/B5, 2/D4, 3/D1

CLK IN =
D1

+3.3V

MTR_ENABLE-

D2

R36

C27

R25
BE = R/W
D3

2/A3
2/C5, 2/C4, 2/A3, 2/C2
2/A3
2/A3
2/A3
2/A3

IRQ7-

2/C4

J1

RSTI-

PST6
PST4
PST2
PST0

BKPTDSCLK

2/A3, 2/D4
2/D4, 2/A3

DSI
DSO
PST7
PST5
PST3
PST1

2/D4, 2/A3
2/A3
2/A3
2/A3
2/A3
2/A3

PSTCLK
TA-

2/A3
2/D4, 2/C3, 3/D1

3/B1, 2/C4

RX_INT-

2/C4, 3/B1

TX_INT-

CS_FLASH-

R26

+3.3V

2/D4, 2/C2

D4

MTR_EN-

PAR PORT

U5

18V BATT

R27
5/C5, 6/C3

IRQ1-

2/C4

U8

R28

TCK

A15

D16

A14

D17

A13

D18

A12

D19

D5
16 BIT BUS

R29

18V BATT

D6
CS_WBCS_MTRCS_UARTOE-

TIN0

2/D4

3/B3

R30
AUTO ACK

A11

D20

2/D4, 3/C1

A10

D21

2/C2

A9

D22

A17

D23

A18

D24

A19

D25

A20

D26

A21

D27

A24

D28

2/D4, 3/B3

TIN1

2/D4

PLACE RESISTORS CLOSE TO MICROPROCESSOR


R31
UART_OUT_B

4/C3

RAS0-

RAS_0-

2/B1, 2/C1

UART_IN

3/C3, 4/C3

TX_EN_B-

4/D3

CAS0CAS1CAS2-

TXDB

4/C5

CAS3RXDB

4/C5

R32
SRAS-

2/C1, 2/B1

SCAS-

2/C1, 2/B1

D31
A23

CAS1-

2/B3

U6

2/B1,2/C1

R34
DRAMW-

DRAMWR-

2/B1, 2/C1

SCL

+3.3V

CAS0-

2/B3

S_CASCLK_EN

+3.3V
RAS0-

2/C1, 2/B3

R33

SDA

+24V

A22

2/D1

S_RAS-

SCL

+24V

D30

2/D1

+3.3V

SDA

VCC

D29

2/B1
2/B1

VCC

D7

2/B3, 2/C1

DRAMW-

2/B3, 2/C1

SRAS-

2/C1, 2/B2

SCAS-

2/C1, 2/B3

CLK_EN

+1.5V
+3.3V

RSTI-

2/C5, 2/C4, 2/C2


+3.3V

RSTO-

+3.3V

EDGESEL

2/C4
Y1

BKPT-

U7

DSO
CLK0
DSI
CLK1

2/C1

CLK2

2/A1

CLK3

3/C3

DSCLK
TCK
HIZ-

2/D4

PSTCLK
PST0
PST1
PST2

+1.8V

PST3
PST4

FB1

PST5

+3.3V

PST6

R38
PST7

C28

C29

R39

2/B5

+3.3V

+1.8V

2/B5, 2/D4
2/B5, 2/D4
2/B5

+1.8V

2/B5
2/B5
2/B5
2/B5

GND

2/B5
2/B5
2/B5

2/B5
2/B5

4
10
17
25
33
41
48
53
61
69
77
85
93
101
104
109
117
125
133
141
148
156
162
169
173
183
188
194
201
208

R40

+1.5V

CLK2

2/A4
2/B5, 2/D4

GND1
GND2
GND3
GND4
GND5
GND6
GND8
GND7
GND9
GND10
GND11
GND12
GND13
GND14
GND15
GND16
GND17
GND18
GND19
GND20
GND21
GND22
GND23
GND24
GND25
GND26
GND27
GND28
GND29
GND30

3/B1

FB2

SCHEMATIC VL500 CONTROLLER

DO NOT
STUFF

Size

Document Number

Date:

Wednesday, October 26, 2005

Rev

C0

14-9685-0730
5

02.96 85.001 0 0

17-July-2006

Sheet

of

166

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Controller PCB (24.9685.0730) Schematic - Sheet 3 of 6

+3.3V

C31

C32

+1.5V
+24V

+1.5V

+3.3V
R144

46

15
VCC15_1

VCC15_2

137

115

VCC33_8

102

VCC33_7

81

VCC33_6

66

VCC33_5

44

VCC33_4

INIT_DONE

VCC33_3

A[0..24]

R145

VCC33_2

2/D1

29

2/C3

VCC33_1

135

C35

117

C34

VCC15_5

+1.5V
C33

64

+1.5V

VCC15_4

C30

+3.3V

VCC15_3

+3.3V

TA-

2/B5, 2/D4, 2/C3

A9
PWM_PH_8

A6

R146

I_SENSE

A0

A8

6/B4
C122

A7

D17

A5

D19

U10

PWM_OUT_13

R147

R41

3/D1

STATUS-

2/C3, 3/B1, 3/A5

PWM_OUT_14

R148

3/A5, 2/C3

R149

THERMAL_1

2/C3, 3/C5

6/B4

D16

PWM_PH_13

DATA

PWM_PH_14

CONFIG-

PWM_OUT_7
TX_EN_A-

R42
CONFIG-

CLK3

C123

R150

2/A4

TX_EN_C-

2/C3, 3/C3
A1
D29

VCC

R43

3/B5

DCLK

SPARE_PWM_OUT_11

MSEL0

2/C3, 3/A5, 3/C3

VCC

R44
CONF_DONE

R152

THERMAL_2

CS_UART-

3/C5

R151
C

CE-

MSEL1

PWM_OUT_8

DCLK

UART_OUT_A

3/B5
+3.3V

R153

2/C3, 3/A5, 3/C5

A3

6/B4

2/C3, 3/B1, 3/A5

R45

C129

PWM_PH_7

C130

TMSA

PWM_OUT_1

3/B1
2/B3, 4/C3

UART_IN

V_SENSE

LED_RX-

6/B4

LED_STATUS

D7

A8

D8

A9

D9

A10

D10

A11

D11

A12

D12

A13

D13
D14
D15

A16

D16

A17

D17

A18

D18

A19

D19

A20

D20

A21

D21

A22

D22

A23

D23

A24

D24

3/B1, 2/D1

5/B3
5/B3
5/B2
5/B2
5/D5

D25

4/C3

D26

4/D3

D27

2/D1
D28

2/D1
D29

5/D3

D30

2/D4, 2/B3

D31

5/D5

4/C3
2/D1

18V BATT

LAMP_ON-

U13

LAMP_CNTL
PWM_OUT_2

D25

6/D3
PWM_OUT_3

D26

6/B3

R157

6/B4
R158

C126

3/C3

VCC

D24

4/B5
3/C3

18V BATT
VCC

D23

4/B5

MSEL0

5/D5
6/D3

D22

4/C4

C125

R156

A/D_SPARE_1

D6

A7

D21

4/C4

3/B1

R47

MSEL1

D5

A6

2/D1

D20

4/C4

R155

R48

D4

A5

D18

LED_TXTDIA

D3

A4

C124

R154

R46

D2

A3

A15

A4

1/C4 24V_DET

D1

A2

A14

VCC

A2

D0

A1

5/D4

D[0..31]

+3.3V

A0

CLK_A/D

D27

DOUT_A/D

D28

+24V

+24V

DIN_A/D
CS_SHDN_A/D
D30
D31

R159

R51

OPT_31

TX_INT-

OPT_41

RX_INT-

BATT_DET

TDIA

4/A3

A/D_SPARE_2

6/B4

DO NOT STUFF

1/C4

D[0..31]

3/D1, 2/D1

2/C4, 2/C3

4/A3
C127

R160

+3.3V

2/C4, 2/C3
SPARE_PWM_OUT_12

DTXE

+3.3V

3/C5
5/D3

SPARE_2

4/B1, 6/A4

R52

+1.5V

PWM_OUT_4

6/B3
PWM_PH_4

PWM_PH_2

6/B2

R161

A/D_SPARE_3

6/D2

OPT_1_IN

+1.5V

4/A3

6/B4

PWM3_EN_1

R49

C128

R162

CE-

TMSA

5/B5
PWM3_OUT_2

3/C3

TCKA

5/B5
OPT_2_IN

STATUS-

4/A3
2/B3

R50

RSTO-

CONF_DONE

R/WTCKA

SPARE_PWM_PH_12

2/C4, 2/C3, 2/C2

3/B1

2/D4, 2/B3

3/B5
+1.8V

2/C3, 3/A5, 3/C5


2/C3, 3/A5, 3/C5
5/D2

+1.8V

CS_MTRCS_WB-

SPARE_PWM_PH_11

2/B3

5/B5

3/C5

PWM_PH_1

PWM3_OUT_1

5/D2
6/D2

DRX

4/A4
4/A4

GND14

6/B2

138

GND13
136

GND11

GND12
118

116

GND10
101

GND8

GND9
80

DISPLAY CONTROL

65

9
DCOMR71

GND7

PWM_PH_3
PWM3_EN_2

63

INT / EXT

C131

PWM3_OUT_5

GND6

5/A5

J3

45

5/A5
R80

DO NOT STUFF

GND5

R72

PHASE_A_1

43

R37

GND

4/A4

DTX
PHASE_B_1

GND4

R35

U9

DO NOT STUFF

PHASE_A_2

PWM3_OUT_4

30

5/A5

PWM3_OUT_3

GNDG_PLL1

5/A5

PHASE_B_2

PWM3_OUT_6

GNDA_PLL1

5/B5

GND3

18V BATT

19

VCC

18

4/A3

VCC

+3.3V

DCOM+

+3.3V
U11
2/C3, 3/C3
A

2/C3, 3/C5, 3/C3


2/C3, 3/C5, 3/B1
2/C3, 3/C5, 3/B1

DATA
DCLK

STATUS-

C132
CONF_DONE

R82
Z5

C133

Z6

SOCKET IS XU15

SCHEMATIC VL500 CONTROLLER


Size

Document Number

Date:

Wednesday, October 26, 2005

Rev

C0

14-9685-0730
5

02.96 85.001 0 0

17-July-2006

Sheet

of

167

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Controller PCB (24.9685.0730) Schematic - Sheet 4 of 6

VCC

18V BATT

VCC

VCC
C36
R53

ISO_VCC

ISO_VCC

18V BATT

ISO_VCC

U12
R54

U14

C38

14

C37
R55

VCC
VCC

TX_EN_C-

3/C1

VCC

ISO_VCC

ISO

U17C

+3.3V

VCC
5

U34

+3.3V

R57

+24V

TXDB

C39

C40

R56

ISO_VCC
C41

C42

R60

+24V

R61

TX_EN_A-

D3

+24V

U15

R58

U17D

14

R59
TX

ISO_VCC

U16

VCC

2/B4
R170

VCC

VCC
+3.3V

3/C1
TX_EN_B-

2/B3

VCC

D4

+3.3V

D5

LED_RX-

+3.3V

R62

3/C3
LED_STATUS

RXDB

VCC

3/C3

U18

2/B4

POWER

LED_TX-

3/C3

J2

+3.3V

RX

R169

C46

VCC

ISO_VCC
ISO_VCC

ISO_VCC

ISO_VCC

U19
C47

14

14

STATUS
C48

UART_OUT_A

D6

R63

+1.5V

R65

3/C1

R64
U20

UART_OUT_B

+1.5V
U17A

FTC1

U17B

COMOUT+

2/B3

6/C4

COMOUT-

6/C4
CI+

FTC2
FTC3

R66

CI-

VCC

+1.8V

COMIN+

ISO_VCC

VCC

+1.8V

6/C4
COMIN-

6/C4
R68

C49

R67
U21

FTC4

R69

Z1

UART_IN

C50

3/C3, 2/B3

1
1

Z3

GND

Z4

VCC
3

VCC

Z2

R70

D7

C51
R163
PANB1

C52

PANA1

TILTA1

3/C3

6/A3

4/A3
R164
OPT_3

U22

SPARE_3

6/A4

4/A3

R73

LAMP_CNTL

LAMP_CNTL_OUT

R74
6/D4

ENCODER_A1

PHASE_A1

4/A4

R165

6/A5

R166

R76

R75

SPARE_4

OPT_4

C53

TILTB1

PHASE_A2

VCC

SPARE1

ENCODER_A2

4/A4

6/A5

D8

R77

SPARE2
ENCODER_B1

PHASE_B1

4/A4

VCC

6/A5
R78

VCC

4/A3

ENCODER_B2

PHASE_B2

6/A5

R81
OPT_2

R79

3/B3, 6/A4

4/A3
C54

C55

R83

R84
LAMP_ON-

SPARE_2

SPARE_1

OPT_1
LAMP_ON_IN-

4/A3

6/D4

3/C3

6/A3

R85

R86

SPARE3
SPARE4

VCC

+3.3V
+3.3V

C56

PHASE_B1

3/A1

OPT_1_IN

4/B4

3/B3

4/B4

3/B3

PHASE_A2

PHASE_A_2

4/B4

3/A1

VCC

20
VCC

PHASE_B_1

U24
PHASE_A1

20

C57

U23
PHASE_A_1

3/A1

OPT_1

4/B2
OPT_2_IN

OPT_2

PHASE_B_2

PHASE_B2

OPT_31

OPT_3

3/A3

4/B2
4/A3, 4/B4

3/B3

4/B2

OPT_4

OPT_41

4/B2

GND
10

10

GND

3/B3

SCHEMATIC VL500 CONTROLLER


Size

Document Number

Date:

Wednesday, October 26, 2005

Rev

C0

14-9685-0730

02.96 85.001 0 0

17-July-2006

Sheet

of

168

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Controller PCB (24.9685.0730) Schematic - Sheet 5 of 6

VCC

VCC
+24V

+24V

VCC

SPARE
(DO NOT STUFF)

MAGENTA

PWM_PH_7

23
R91
MAGENTA_OUT1B

C63

MAGENTA_OUT2A

R92

SPARE_OUT1B

6/A4, 6/D5

R94
3/B1

SPARE_PWM_PH_12

SPARE_OUT2A

6/A4, 6/C5

SPARE_OUT2B

6/D5, 6/A3

R96

R97
3/B1
C67

6/A3, 6/D5

U26

C65

6/D5, 6/A4

PWM_OUT_8

C66

SPARE_OUT1A

SPARE_PWM_OUT_11

C64
PWM_PH_8

MAGENTA_OUT2B

R95

3/C1

6/D5, 6/A4

R93
3/D1

SPARE_PWM_PH_11

U25

R90

PWM_OUT_7

C62

3/C1

3/B1

6/D5, 6/A3

C118

VCC

MAGENTA_OUT1A

C59

R88

4
VMM2

3/C1
R89
3/C1

VMM1

VCC

23

12

R87

C61

C117

VMM2

C58

12

C60

VMM1

VCC

6/A3, 6/C5

R98

SPARE_PWM_OUT_12

18V BATT

R99

C68

C69

R100

18V BATT

R102

C72

R105

VCC

E2

C2

26

E1

C1

R101

10

19

E2
6

26

E1
10

19

C2

C71

C1

C70

R103

C73

R106

VCC

R104

C74

R107

C75

+24V

R108

+24V

+3.3V
6/C3, 2/A2

MTR_EN-

+3.3V

+1.5V
+24V

+24V

+24V

VCC

TILT

+1.5V

+24V

D9

D10

D11

VCC

+24V

C77

C76

C119
+1.8V

TILT_PHB_OUT

DIFFUSER

R109

6/A5
PWM3_OUT_3

3/C1

TILT_PHC_OUT

6/A5

3/A3
U29

D12

R110
3/C1

PWM3_EN_1

D13

3/B3

D14

VMM1

VCC

23

6/A5

PWM_PH_13

+1.8V

TILT_PHA_OUT

PWM3_OUT_2

3/B3

VMM2

PWM3_OUT_1

3/A3

12

U27

DIFFUSER_OUT1A

6/A3, 6/C5

R111

U28

PWM_OUT_13

DIFFUSER_OUT1B

6/A4, 6/C5

D15

C78

C79

GND

R112
3/C1

VCC

DIFFUSER_OUT2A

PWM_PH_14

6/A4, 6/C5

C80
B

VCC

DIFFUSER_OUT2B

6/A3, 6/C5

R113
D16

R114

C81
3/C1

R115

PWM_OUT_14

C82

C85

C86

C83

R116

C87

+24V

E2
6

+24V

19

+24V

PAN

C2

C89

C1

C88

26

E1

C84

10

R117
D17

D18

R118

D19

+24V
U30
PWM3_OUT_4

PAN_PHA_OUT

PWM3_OUT_5

PAN_PHB_OUT

3/A3

3/A3

C90

R119

C91

R120

6/A5

6/A5
PWM3_OUT_6

PAN_PHC_OUT

3/A3

6/A5
U31

D20

PWM3_EN_2

D21

3/A3

D22

D23

VCC
C92

VCC

R121
D24
C93

C94

C95

C98

C96

C97

SCHEMATIC VL500 CONTROLLER


Size

Document Number

Date:

Wednesday, October 26, 2005

Rev

C0

14-9685-0730
5

02.96 85.001 0 0

17-July-2006

Sheet

of

169

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

REFERENCE FOLD-OUTS

VL500 Controller PCB (24.9685.0730) Schematic - Sheet 6 of 6

VCC

+24V

+24V

VCC

AMBER

D27

3/A1
R123

MAGENTA_OUT2A

6/A4, 5/D4
D28

3/C1

PWM_PH_1

R124

C120

4
VMM2

MAGENTA_OUT1B

6/A4, 5/D4
D

12

23
VCC

6/A3, 5/D4
D26

C99

R122

MAGENTA_OUT1A

VMM1

D25

C100

AMBER_OUT1A

6/A3, 6/C5
D

U32
AMBER_OUT1B

PWM_OUT_1

C101

MAGENTA_OUT2B

C102

6/A4, 6/C5

R125

6/A3, 5/D4

3/B1

AMBER_OUT2A

PWM_PH_2

6/A4, 6/B5

AMBER_OUT2B

R126
3/C3

C103

SPARE_OUT1A

6/A3, 5/D2

18V BATT
BALLAST CONTROL
E2

LAMP_STBY

2/C3

VCC

LAMP_ON_IN-

2/B5

C2

6/A4, 5/D2

SPARE_OUT2B

C105

LAMP_CNTL_OUT

2/B5

26

SPARE_OUT2A

D32

18V BATT

J5

DO NOT
STUFF

E1

6/A4, 5/D2

C1

D31

SPARE_OUT1B

6/A3, 6/B5

R128

19

6/A3, 5/D2
D30

C104

10

D29

R127

PWM_OUT_2

R129

R130

VCC

D33

C106

J6

DIFFUSER_OUT1A

6/A3, 5/B2

R131

C107

R132
+24V

COMIN+

4/C1
D34

COMINDIFFUSER_OUT1B

4/C1

6/A4, 5/B2

DMX IN

COMOUT+

+24V

4/C1
COMOUT-

D35

DIFFUSER_OUT2A

D36

4/C1

6/A4, 5/B2

2/A2, 5/C5
DIFFUSER_OUT2B

MTR_EN-

+3.3V

6/A3, 5/B2

+3.3V
VCC

VCC

J8

+24V

+24V

+1.5V
AMBER_OUT1A

VCC

POWER IN

6/D2, 6/A3

6/D2, 6/A4

C121

3/A1

AMBER_OUT2B

VCC

6/D2, 6/A3

R134
3/C3

PWM_PH_3

R135

+1.8V

VMM2

VCC

AMBER_OUT2A

D40

C108

R133

BLUE

12

6/D2, 6/A4
D39

C109

+1.5V

AMBER_OUT1B

VMM1

D38

23

D37

BLUE_OUT1A

BLUE_OUT1B

C110

6/B5, 6/A3

U33

PWM_OUT_3

C111

+1.8V
6/B5, 6/A4

R136

J9

3/B3

I_SENSE

PWM_PH_4

BLUE_OUT2A

6/B5, 6/A4

3/D4
V_SENSE
BLUE_OUT2B

3/C4

D41

BLUE_OUT1A

THERMAL_1

6/B2, 6/A3

3/C4

R137

THERMAL_2

D42

3/C4
BLUE_OUT1B

3/B3

A/D_SPARE_1

6/B2, 6/A4

GND

6/B5, 6/A3

R138

PWM_OUT_4

3/B4

C112

A/D_SPARE_2

C113

R139

3/B4

D43

BLUE_OUT2A

A/D_SPARE_3

6/B2, 6/A4

A/D INPUTS

3/B4

C114

D44

BLUE_OUT2B

E2
6

C2
26

E1
10

19

C1

6/B2, 6/A3

R140

C115

VCC

R141

R142

C116

R143

VCC

J7
VCC

SPARE_OUT2A

SPARE_OUT2B

SPARE_OUT1B

SPARE_OUT1A

DIFFUSER_OUT2A

DIFFUSER_OUT2B

DIFFUSER_OUT1B

DIFFUSER_OUT1A

AMBER_OUT2A

AMBER_OUT2B

AMBER_OUT1B

AMBER_OUT1A

BLUE_OUT2A

BLUE_OUT2B

BLUE_OUT1B

BLUE_OUT1A

6/C5, 5/D2

J4

6/C5, 5/B2
PAN_PHC_OUT

6/C5, 5/B2

5/A4
5/A4

PAN

PAN_PHB_OUT

5/A4
5/B4
5/B4

6/B2, 6/B5
MAGENTA_OUT2A

MNTG1

DIA. .166"
MNTG2

DIA. .166"
MNTG3

BLUE

MAGENTA_OUT2B

6/D5, 5/D4

6/D5, 5/D4
MAGENTA_OUT1B

MAGENTA_OUT1A

6/D5, 5/D4

ENCODER_B1

DIA. .166"

AMBER

6/B2, 6/B5

5/B4

4/B3
A

TILT

DIFFUSER

6/C5, 6/D2

6/B2, 6/B5

TILT_PHB_OUT
TILT_PHC_OUT

6/B5, 6/D2

6/C5, 6/D2
6/B2, 6/B5

TILT_PHA_OUT

SPARE

6/D5, 5/D2
6/C5, 5/B2
6/C5, 5/B2

6/B5, 6/D2

PAN_PHA_OUT

ENCODER_A1

6/C5, 5/D2

6/D5, 5/D2

MAGENTA

6/D5, 5/D4

SPARE_1

4/B3
ENCODER_A2

4/B1

4/B3
ENCODER_B2
SPARE_2

4/B3

3/B3, 4/B1
SPARE_3

4/B1

DIA. .166"

SPARE_4

4/B1

MNTG5

DIA. .166"
MNTG6

DIA. .166"
MNTG4

SCHEMATIC VL500 CONTROLLER


Size

Document Number

Date:

Wednesday, October 26, 2005

Rev

C0

14-9685-0730

02.96 85.001 0 0

17-July-2006

Sheet

of

170

APPENDIX A.
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
S5K-001

Description
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/. To request access
to the password-protected support areas, please contact Vari-Lite Customer Service at
1-877-827-4548 or customerservice@genlytecontrols.com.

02.96 85.001 0 0

17-July-2006

171

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Notes

172

17-July-2006

02 .9 685.00 10 0

Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
1.877.VARI-LITE o 1.214.647.7880 o Fax 1.214.647.8038
www.vari-lite.com
2006 Genlyte Group LLC. All rights reserved. Printed in USA