Download Vari-Lite is a Philips group brand

Vari-Lite is a Philips group brand
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
VARI❋LITE® is a trademark owned by Philips Group and is registered in the United States and other countries.
VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, VL3500™,
Series 1000™, Series 2000™,
Series 3000™, DICHRO❋TUNE™, VARI❋IMAGE™, VARI❋BRITE™, and the Vari-Lite Asterisk are also trademarks
owned by Philips Group.
VARI❋LITE® products are protected by one or more of the following patents, and other pending patent applications worldwide:
U. S. Patents No. 6,809,869; 6,796,682; 6,769,792; 6,578,987; 6,550,939; 6,282,027; 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. 524,245; 457,678; 452,339; 451,890; 442,944; 439,356; 420,332; 417,300; 415,301; 414,888; 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;
Australia Design Patents No. 128,796; 128,795;
Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058;
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;
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;
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;
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;
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;
Taiwan Patents No. 78,726; 66,975; 65,380; 28,275;
United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.
All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their
respective companies or organizations.
Vari-Lite
Philips Lighting Controls Division
Vari-Lite is a Philips group brand
10911 Petal Street Dallas, Texas 75238
1.877.VARILITE
www.vari-lite.com
[email protected]
This manual is for informational use only and is subject to change without notice. Philips Group assumes no responsibility or
liability for any claims resulting from errors or inaccuracies that may appear in this manual.
Version as of: 01-July-2008
Part number: 02.9676.0020 A
VL2500™ Spot Luminaire Service Manual
©2008 Philips Group. All Rights Reserved. Certain products listed in this document may be protected by applicable patents and
patents pending. Philips will aggressively defend all of its intellectual property. We reserve the right to change details of design,
materials and finishes.
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FOREWORD
How To Obtain Warranty Service
A copy of the Vari-Lite, Inc. Limited Warranty was included in the shipping package
for this VARI❋LITE® product.
To obtain warranty service, please contact customer service at 1-877-VARI-LITE
(1-877-827-4548) or [email protected] and request a Return
Material Authorization (RMA) for warranty service. You 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 product in its original packing material along with
a copy of your invoice (if available) and write the RMA number legibly on or near the
shipping address label. Return the unit, freight prepaid to:
Vari-Lite
10911 Petal Street
Dallas, Texas 75238
Attention: Warranty Service
As stated in the warranty, it is required that the shipment be insured and FOB our
service center.
Confidential Property Disclosure
This technical manual is confidential property of Vari-Lite, a Philips group brand. All
information contained herein is the sole and exclusive property of Philips Group and
may not be used, disclosed, or reproduced in any manner without the prior written
consent of Philips Group. The information furnished in this manual is for informational use only and is subject to change without notice. Philips Group and Vari-Lite
assumes no responsibility or liability for any errors or inaccuracies that may appear in
this manual.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
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 (by Council Directive 73/23/EEC)
EN60598-1: 2000
EN60598-2-17: 1989/A2:1991
EMC (by Council Directive 89/336/EEC)
EN61000-6-4: 2001
We certify that VARI❋LITE products conform to the requirements of European
council directives as stated above.
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.
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FOREWORD
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. VARI❋LITE® 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
VARI❋LITE® luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARI❋LITE® luminaires are designed for dry locations only. Exposure to rain or
moisture may damage luminaire.
2. Disconnect power before servicing any VARI❋LITE® equipment.
3. Servicing to be performed by qualified personnel only.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE
EXPOSURE TO UV RADIATION
1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO
NOT look directly at lamp.
2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet
screens shall be changed if they have become visibly damaged to such an extent that their
effectiveness is impaired. 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 denatured 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 (Lamp ON/ Lamp OFF) system configuration setting.
2. Burning position is Universal.
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FOREWORD
Sicherheitshinweise
Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem
Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin
beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und
dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
VORSICHT - weist auf möglichen Produktschaden hin.
WARNUNG - weist auf mögliche Körperverletzung und
Lebensbedrohung hin.
NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE
UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARI❋LITE®-Scheinwerfer sind ausschließlich für 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 gefährlich sein.
2. Scheinwerfer können auf jeder beliebigen Oberfläche 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 Stärke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARI❋LITE®-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARI❋LITE®-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen
oder Feuchtigkeit können die Scheinwerfer beschädigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE®-Geräten
beginnen.
3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG
1. Viele VARI❋LITE®-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN
1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkühlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Körperverletzung bzw. von Feuer, das von Lampenteilen ausgelöst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.
6. Wenn die Lampe mit bloßen Händen berührt wird, reinigen Sie sie mit denaturiertem
Alkohol und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in
Betrieb nehmen.
7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstörungen verursachen. In diesem Fall müssen eventuell geeignete
Maßnahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach
Abkühlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.
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FOREWORD
Notes de sécurité
Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en
marche, il est extrêmement important de lire TOUS les renseignements et TOUTES
les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe.
Tenir compte de tous les avertissements et suivre toutes les précautions pendant
l’installation et l’utilisation de cet appareil.
Les symboles de sécurité utilisés dans ce guide sont les suivants :
ATTENTION Ce symbole annonce que l’appareil risque
d’être endommagé.
AVERTISSEMENT Ce symbole annonce qu’il y a risque
d’accident grave ou même fatal.
CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE
PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES , LES INCENDIES,
L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRAÎNER DES BLESSURES.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES
1. Les luminaires VARI❋LITE® ont été conçus pour être utilisés uniquement avec certaines
lampes Philips et Osram HID. Vérifier le type de lampe (MSR400, MSR575HR etc.)
avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un
danger.
2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de
montage sont respectées. Voir les explications détaillées dans ce guide.
3. Ne remplacer les fusibles qu’avec ceux du même type, ayant les mêmes caractéristiques.
4. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et
les luminaires VARI❋LITE®.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES
1. Les luminaires VARI❋LITE® sont conçus pour une utilisation au sec uniquement. Une
exposition à la pluie et à l’humidité risque d’endommager le luminaire.
2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE®.
3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE
AUX RAYONS UV
1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des
rayons UV. NE PAS fixer son regard sur la lampe.
2. L’utilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages,
lentilles ou écrans ultraviolet visiblement endommagés au point que leur efficacité en est
affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT
ENTRAÎNER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche.
Pour manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la
peau et une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute
tension à de très hautes températures. Si la lampe se casse, les particules de la lampe
cassée peuvent causer blessures et/ou incendie en s’éparpillant.
4. Se protéger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier
des lampes endommagées.
6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool dénaturé et
l’essuyer avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire.
7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être
remplacée.
AVERTISSEMENT:
INTERFÉRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures
adéquates.
CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC
1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet après s’être refroidie. Cela dépend de la manière dont le système est réglé
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brûler est Universelle.
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FOREWORD
Aviso sobre Seguridad
Es muy importante leer TODA la información e instrucciones sobre seguridad que se
indica en este manual así como en los documentos adjuntos antes de instalar y operar
los productos descritos. Se debe prestar atención a todos los avisos y advertencias
durante la instalación y uso de este producto.
Los símbolos de seguridad usados en este manual son los siguientes:
CUIDADO, indica posibles daños al producto.
ADVERTENCIA, indica posibles lesiones o muerte a las
personas.
LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CONTRAGOLPES DE CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN
EXCESIVA A RADIACIÓN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO
1. Las luminarias VARI❋LITE® han sido diseñadas para ser usadas solamente con algunas
lámparas HID Philips y Osram. Tome nota del tipo de lámpara (MSR400, MSR575HR
etc.) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalación. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificación.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARI❋LITE®.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE
ELÉCTRICO
1. Las luminarias VARI❋LITE® están diseñadas solamente para lugares secos. La
exposición a la lluvia o humedad pueden dañar la luminaria.
2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE®.
3. El servicio debe ser realizado solamente por personal calificado.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA
1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación
UV. NO mire directamente a la lámpara.
2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores,
lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un
equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que están calientes.
2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la
energía y deje que la lámpara se enfríe antes de reemplazarla.
3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamación a los ojos. Además, las lámparas de arco operan a alta
presión y muy alta temperatura. Si la lámpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se
caen.
4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.
5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando
trabaje con lámparas dañadas.
6. Si toca la lámpara con las manos, limpie la lámpara con alcohol desnaturalizado y con tela
sin pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lámpara si está dañada 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 CARACTERÍSTICAS DE LA LÁMPARA DE
ARCO
1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de
una interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara
se volverá a iluminar en forma automática después que se ha enfriado dependiendo de la
configuración del sistema de energía de la lámpara (L ON / L OFF) (L encendida / L
apagada).
2. La posición de encendido es universal.
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SAFETY NOTICE (JAPANESE)
UV
:
1. VARI❋LITE®
Philips
Osram
HID
MSR400
MSR575HR
4. VARI❋LITE®
:
1. VARI❋LITE®
2. VARI❋LITE®
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
:
UV
1. VARI❋LITE®
UV
HID
:
:
RF
1.
Class A
1.
Lamp Power-Up State
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L ON/ L OFF
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TABLE OF CONTENTS
Table of Contents
Introduction
About This Manual ......................................................................................................
Additional Documentation...........................................................................................
Customer Service .........................................................................................................
Technical Bulletins / Technical Notices.......................................................................
1
1
2
2
Chapter 1. Description
Features
Overview...................................................................................................................... 4
Features ................................................................................................................. 4
Major Components
External Components................................................................................................... 5
Menu Display ........................................................................................................ 6
Menu Controls....................................................................................................... 6
Head Components........................................................................................................ 7
Yoke Components ........................................................................................................ 8
Enclosure Components ................................................................................................ 9
Principles of Operation
Power and Data Flow Diagram.................................................................................. 10
Chapter 2. Maintenance
Testing
Testing Software ........................................................................................................
Troubleshooting
Error Messages...........................................................................................................
Troubleshooting Guide ..............................................................................................
Maintenance Procedures
Head Assembly ..........................................................................................................
Lamp Replacement..............................................................................................
Color/Gobo/Iris Bulkhead Replacement .............................................................
Standard Gobo/Color Filter Replacement ...........................................................
Strobe Bulkhead Replacement ............................................................................
Front Assembly Removal....................................................................................
Rotating Gobo Sensor PCB Replacement ...........................................................
Edge Motor Assembly Replacement...................................................................
Lens Barrel Assembly Replacement ...................................................................
Yoke Assembly ..........................................................................................................
Tilt Motor Assembly Replacement .....................................................................
Main Control Board (MCB) PCB Replacement..................................................
Ignitor PCB Replacement....................................................................................
Enclosure Assembly...................................................................................................
Removing Enclosure Covers ...............................................................................
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13
14
16
16
18
19
20
21
22
24
27
29
29
30
31
33
33
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Ballast Module Assembly Replacement .............................................................. 35
Pan Motor Assembly Replacement...................................................................... 37
Pan Encoder Replacement ................................................................................... 38
Pan EOT Sensor Replacement ............................................................................. 39
Power Supply (LVS) Replacement...................................................................... 40
Chapter 3. Illustrated Parts Breakdown
Drawing Tree
VL2500 Series Spot Luminaire .................................................................................. 42
Top Assembly
VL2500 Included Items Kit........................................................................................ 44
VL2500 Spot Luminaire............................................................................................. 46
VL2500 Generic Luminaire ....................................................................................... 48
Front Assembly .......................................................................................................... 50
Lens Barrel Assembly ................................................................................................ 52
Sub-Barrel Group 2 Assembly ................................................................................... 54
Motor Zoom Optics Assembly ................................................................................... 55
Rotating Gobo Wheel Assembly ................................................................................ 56
Sensor Rotating Gobo PCB Assembly ....................................................................... 58
Top Cover Assembly .................................................................................................. 59
Bottom Cover Assembly ............................................................................................ 60
Reflector Assembly .................................................................................................... 61
Back Cap Assembly ................................................................................................... 62
Fan Assembly ............................................................................................................. 64
Iris/Color/Gobo Bulkhead Assembly ......................................................................... 66
Crossfade Color Assembly ......................................................................................... 68
Iris/Gobo Motor Assembly......................................................................................... 70
Color Motor Assembly ............................................................................................... 71
Gobo Wheel Assembly............................................................................................... 72
Color Filter Wheel Assembly..................................................................................... 73
Strobe Assembly......................................................................................................... 74
UV / IR Window Assembly........................................................................................ 76
VL2500 Main Control Board PCB Assembly............................................................ 77
Yoke
Yoke Assembly........................................................................................................... 79
Ignitor PCB Assembly................................................................................................ 81
Tilt Motor Assembly .................................................................................................. 83
Pan/Tilt Encoder PCB Assembly ............................................................................... 85
Yoke Fan Assembly.................................................................................................... 86
Enclosure
Upper Enclosure Assembly ........................................................................................ 87
Connector Panel Assembly......................................................................................... 92
DMX Input PCB Assembly........................................................................................ 93
AC Input Pigtail Cable Assembly .............................................................................. 94
Pan Tube Assembly .................................................................................................... 95
Pan Motor Assembly .................................................................................................. 96
Upper Enclosure Fan Assembly ................................................................................. 97
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TABLE OF CONTENTS
Pan EOT Sensor Electrical Assembly........................................................................ 98
Ballast Module (Arc Power Supply) Assembly......................................................... 99
Cables
Ground Strap Cable Assembly................................................................................. 101
LVS Chassis Ground Cable Assembly..................................................................... 102
Chassis To Yoke Ground Cable Assembly .............................................................. 103
Yoke To Head Ground Cable Assembly .................................................................. 104
Ignitor To Relay Cable Assembly............................................................................ 105
Tilt Plate Ground Cable Assembly .......................................................................... 106
Color/Gobo T-Stat Cable Assembly......................................................................... 107
Color/Fixed Bulkheads Cable Assembly ................................................................. 108
Optics/Strobe Bulkheads Cable Assembly .............................................................. 110
Strobe 1 Cable Assembly......................................................................................... 112
Fans/Disconnect Cable Assembly............................................................................ 113
OT Switch to Reflector Assy. Cable Assembly ....................................................... 114
Pan/Tilt Control Cable Assembly ............................................................................ 115
EMI Filter to Power Switch Cable Assembly.......................................................... 117
AC Input Splitter Cable Assembly .......................................................................... 118
Data I/O Link Cable Assembly................................................................................ 120
Display Cable Assembly.......................................................................................... 121
Ballast to Controller Cable Assembly...................................................................... 122
Lamp Supply to Relay Cable Assembly .................................................................. 123
DC Output Cable Assembly..................................................................................... 124
VL2000 Spot Luminaire Schematics
VL2500 Luminaire Wiring Diagram ....................................................................... 125
Main Control Board (MCB) Schematic................................................................... 128
DMX Input Schematic ............................................................................................. 138
Solid State Ignitor Schematic................................................................................... 139
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Notes
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INTRODUCTION
Introduction
About This Manual
This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL2500™ Spot Luminaire. The manual is intended for
use by Vari-Lite personnel and by Vari-Lite’s customers/clients.
WARNING: It is important to read ALL accompanying safety and installation
instructions to avoid damage to the product and potential injury to yourself or others.
This manual covers the following models:
Model
Part Number
Source
VL2000 Spot Luminaire
20.9676.0001
700W Arc
Note: Performing maintenance procedures contained in this manual may void the
product warranty. Refer to the Vari-Lite, Inc. Limited Warranty card included in the
shipping package for this VARI❋LITE® product.
Additional Documentation
A support webpage for VL2500 series luminaires is available at www.vari-lite.com
(follow the “Support” link).
For installation and operation of the VL2000 spot luminaire, you can download the
following user’s manual in electronic (PDF) format:
■
02.96 76.002 0 A
VL2500™ Spot Luminaire Users Manual (02.9676.0019).
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
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
email: [email protected]
Additional Resources
For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.
Technical Bulletins / Technical Notices
Technical Bulletins concerning the latest changes to VARI❋LITE equipment are
issued from Vari-Lite. They are documentation supplements that contain procedures
for equipment upgrades, retrofits, and repairs not found in the existing manuals.
Technical bulletins are integrated into the appropriate equipment manuals as those
manuals are revised.
Technical Notices are non-procedural documents that contain information regarding
product support issues, software updates, and documentation corrections. All technical
notices begin with the prefix TN and are numbered sequentially.
Technical Bulletins, Software Updates, support, and other information is available
online at http://www.vari-lite.com/ under the Support Section.
To request access to the password-protected support areas, please contact Vari-Lite
Customer Service at 1-877-827-4548 (+1-214-647-7880) or
[email protected].
2
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CHAPTER 1.
Description
This chapter provides an overview of luminaire features, components
and operations.
• Features
• Major Components
• Principles of Operation
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Features
Overview
The VL2500 Spot luminaire comes complete
with all of the qualities and options designers
love from the original Series 2000™ fixtures. It
is still small, lightweight, and fast with a 700watt shortarc lamp, impressive lumen output,
and a zoom range from 18.5° to 42°.
Features
4
•
Color Mixing System: A three-filter CYM
cross-fading mechanism. A fixed color wheel with 11 interchangeable color filters
and one open space capable of continuous rotation for additional effects.
•
Gobo Wheels: One, Six-position rotating gobo wheel with five rotatable,
indexable gobo positions and one open position. One, 12-position wheel providing
11 easily loaded positions (and 1 open) for user-selectable gobo choices. Wheel is
capable of continuous rotation for additional effects.
•
Zoom Optics: Zoom angle of 2.3 to one. Continuously variable field angle from
18.5° to 42°. Programmable over a timed range of 2 seconds to 20 minutes.
•
Edge and Pattern Focus: Variable beam focus to soften edges of gobos or spots.
•
Beam Size: A mechanical iris provides continuous beam size control for both rapid
changes and smooth timed beam angle changes in addition to the zoom optics.
•
Strobe: A high-performance dual blade strobe system capable of ultra-fast
operation.
•
Pan/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.
•
Weight: 59.2 lbs (26.9 kg)
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DESCRIPTION : MAJOR COMPONENTS
1
Major Components
External Components
The following illustration shows major luminaire components and controls.
Truss Hook Bracket Assembly
Removable Lamp Assembly
(to access lamp for replacement)
Upper Enclosure
Assembly
AC Input Cable
Head Assembly
Yoke Assembly
Vertical
Captive Knob
for lamp access
(does not adjust
beam)
Horizontal
Focus
Beam Adjustment Controls
Product Label ID
Main Power Switch
Menu Display and
Controls
AC PWR
~
AC IN
DATA IN DATA THRU
MENUENTER
AC Input Cable
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Data In
Data Thru
Input Panel Components
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Menu Display
The menu system is a programmable set of commands used to configure, address,
operate, and test the luminaire. The menu system is controlled at the Menu Display
available at the enclosure input panel.
Menu Display
AC PWR
~
AC IN
DATA IN DATA THRU
MENUENTER
The menu system has seven main functions which are referred to as “1st level.” Within
these main functions, there can be up to four additional sub-functions (levels 2 thru 5),
making five total levels.
Menu Controls
The menu system is controlled by four buttons. These buttons function as follows:
[Menu] button. Displays the menu, or if at first level, the current address.
[Enter] button. Selects the current menu option or stores current data value.
[Up] arrow. Scrolls menu options upward or increases current data value.
[Down] arrow. Scrolls menu options downward or decreases current data value.
Multi-Segment
Display
Address
Selects the current menu option
or stores current data value
Displays the menu,
or if at first level, the
current address
6
Up / Increase
MENU ENTER
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Down / Decrease
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DESCRIPTION : MAJOR COMPONENTS
1
Head Components
The following illustration shows the major sub-assemblies that are located in the
luminaire head assembly. (Yoke and enclosure not shown for clarity.)
Removable Cover
Dual Blade
Strobe Assembly
Back Cap /
Lamp Assembly
CYM Color/Dimmer Bulkhead
Fixed Color / Fixed Gobo /
Iris Bulkhead
Fan Assembly
Removable Cover
Front Assembly Contains Lens Barrel
and Rotating Gobo Wheel
Nose Cover
Note: This illustration shows current VL2500 components. For information on older models, please
refer to the preceding revision of this manual, 02.9678.0020 0 (Revision zero).
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Yoke Components
The following illustration shows the major sub-assemblies that are located in the
luminaire yoke assembly. (Head and enclosure not shown for clarity.)
Yoke Arm Cover
Fan Assembly
Relay
Ignitor PCB
Yoke Structure
Yoke Arm Cover
Tilt-side leg
Main Control Board (MCB)
Tilt Motor
Tilt-Side
Yoke Leg
leg
Rotate yoke fully
counter-clockwise
Board-Side
Yoke Leg
To determine which yoke leg is which without having to remove the
covers, rotate yoke counterclockwise until it stops, then look at the
luminaire while facing the input panel. The tilt-side leg is the leg to
the left; the board-side leg is the leg to the right.
Input
Panel
8
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DESCRIPTION : MAJOR COMPONENTS
1
Enclosure Components
The following illustration shows the major sub-assemblies that are located in the
luminaire enclosure assembly. (Yoke and head assembly not shown for clarity.)
Enclosure Top Covers
700W Arc Ballast Module
Fan Assembly
150W +24V/6.3A
Power Supply
Input Panel Assembly
containing DMX Input PCB
and Menu Display
AC Input Cable
Requires standard AC power distribution
from 100-264 VAC, 50/60 Hz., 7 to 12 A
depending on the AC supply voltage.
Enclosure Bottom
Ventilation Cover
Wire*
Connection
Green/Yellow
AC Ground
Blue
AC Neutral
Brown
AC Line
* International (Harmonized) Standard
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Principles of Operation
Power and Data Flow Diagram
The following diagram shows how data and power are distributed in the luminaire.
Fix Gobo
OT Sw
UV / IR
OT Sw
Bulb
Socket
Ignitor
PCB
Relay
Back Cap
Switch
700W Arc Ballast
Tilt
Travel
Sensor
Pan
Encoder
Pan EOT
Tilt
Encoder
Tilt EOT
Pan
Motor
Tilt
Motor
Power
Switch
Data I/O
Pan
Travel
Sensor
Low
Voltage
Supply
DMX
Input
PCB
Display
PCB
J5
J4
J8
EMI
Filter
Input
Power
Upper
Enclosure
Fan
J3
J2
Main Control PCB
J11
J9
Strobe
J12
Strobe
J1
Color
Sensor
Fixed
Color
Gobo
Sensor
Zoom
Gobo
Index
Index
Sensor
Yoke
Fan
Head
Fan
#1
Edge
Fixed
Gobo
Iris
Motor
Cyan
Yellow
Gobo
Rotate
Head
Fan
#2
Rot.
Sensor
Magenta
Dimmer
Color
Sensor
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CHAPTER 2.
Maintenance
This chapter contains test, service, and standard maintenance
procedures.
• Testing
• Troubleshooting
• Maintenance Procedures
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Testing
Testing Software
Testing software is available in all Series 2000 luminaires through the luminaire’s
menu system TEST function.
For information on specific tests and test parameters, see the VL2500™ Spot
Luminaire User’s Manual (VL Part no. 02.9676.0019).
Note: After 10 seconds of inactivity, the menu display will change to the default state
showing the address.
Lamp
The Lamp option is available in the test menu. This option sets the lamp intensity to
100% and will adjust to produce a tight beam. Pan/Tilt are disabled while using the
Lamp option, and pan/tilt settings will be restored upon exit of the Lamp feature.
Note: When setting the Lamp option on luminaires linked by a five-wire DMX
cable, pan and tilt will be disabled for all the luminaires that are linked.
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.
Step 4. Press [Enter] to run test.
Step 5. Press [Menu] to stop test at any time.
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MAINTENANCE : TROUBLESHOOTING
2
Troubleshooting
Error Messages
If a problem occurs during luminaire calibration, at the end of the calibration sequence the
Menu Display will cycle through any applicable error message(s), one at a time until the end
of the list is reached. To review the error messages again, it will be necessary to access them
using the Status function. (Refer to “Troubleshooting Guide” on page 14 for a list of
possible causes and remedies associated with the error messages.)
To access error messages:
Step
1. Press [Menu].
Step
2. Press [Up] / [Down] arrows until Fixture appears. Press [Enter].
Step
3. Press [Up]/ [Down] arrows to access Status. Press [Enter]. (Display will now
scroll through any error messages or display OK if no errors.)
Table 2-1: Error Messages
Display
Message...
OK
No Errors Found
Pan/No Sens
Pan sensor not found.
Pan/Encoder/Fail
Pan encoder failure.
Tilt/No Sens
Tilt sensor not found.
Tilt/Encoder/Fail
Tilt encoder failure.
Index/No Sens
Gobo Index sensor not found.
Gobo/No Sens
Rotating Gobo sensor not found.
Fixed Gobo/No Sens
Fixed Gobo sensor not found.
Dimmer/No Sens
Dimmer sensor not found.
Blue/No Sens
Blue sensor not found.
Amber/No Sens
Amber sensor not found.
Magenta/No Sens
Magenta sensor not found.
ColWheel/No Sens
Color wheel sensor not found.
Zoom/No Sens
Zoom sensor not found.
Edge/No Sens
Edge sensor not found.
WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should
only be performed by a trained and qualified service technician or at an Authorized Vari-Lite
Service facility.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Troubleshooting Guide
If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to
“Troubleshooting” on page 13 for more information. The chart below provides possible
causes and remedies for each message.
Table 2-2: Troubleshooting Guide
Message
n/a
n/a
Symptom
Description
No response to DMX
data
DMX Failure
Lamp douses frequently
Lamp Douse
Possible Cause and Remedy
MCB connector disconnected...
- check MCB DATA IN connection.
Fan failure...
- check fans for proper connection and
operation.
n/a
Lamp will not strike
Lamp Strike Failure
Lamp cutout switch disengaged...
- check lamp cutout switches at lamp box
and fan ducts.
Bad lamp...
- replace lamp.
Low input voltage...
- check input power (must be 200 to 264 VAC)
n/a
No Sens
n/a
Luminaire behaves
oddly
Profile Not Matched
No control, continuous
recalibration, and/or
mechanism at wrong
position
Mechanism failed to find
sensor (reported for
Cyan, Yellow, Magenta,
ColWheel, Gobo, Index,
Gobo, Zoom, Dimmer and
Edge)
Luminaire does not
power-up
Profile not set correctly...
- check Setup menu for correct type (spot or
wash).
- check start DMX address
No power
Motor power not connected...
- connect motor power.
Sensor not connected...
- connect sensor.
Movement restricted or impeded...
- remove obstruction, check cable routing,
and/or check voltage at MCB test point.
Switch not turned on...
- verify switch is turned on.
Not plugged in...
- ensure A/C cable is connected to power
source.
Pan/
Encoder/
Fail
Luminaire will not pan
Pan Encoder Failure
MCB pan/tilt connector disconnected...
- connect MCB pan/tilt connector (J8).
Pan motor disconnected
- connect pan motor power.
Encoder faulty...
- replace pan end-of-travel/encoder sensor
assembly.
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MAINTENANCE : TROUBLESHOOTING
2
Table 2-2: Troubleshooting Guide (Continued)
Message
Pan No
Sens
Symptom
Luminaire will not pan or
hits against stop
Description
Pan Sensor Not Found
Possible Cause and Remedy
EOT flag attached to large pulley is not engaging the
EOT sensor...
- ensure flag is attached to the large pulley.
- ensure that flag passes through the sensor
at a depth sufficient to engage the sensor
beam.
Pan belt disconnected, extremely loose or not
installed properly...
- properly install belt between pan motor
and large pulley.
Tilt/
Encoder/
Fail
Luminaire will not tilt
Tilt Encoder Failure
MCB pan/tilt connector disconnected...
- connect MCB pan/tilt connector (J8).
Tilt motor disconnected
- connect tilt motor power.
Encoder faulty...
- replace tilt end-of-travel/encoder sensor
assembly.
Tilt No
Sens
Luminaire will not tilt or
hits against stop
Tilt Sensor Not Found
EOT flag attached to large pulley is not engaging the
EOT sensor...
- ensure flag is attached to the large pulley.
- ensure that flag passes through the sensor
at a depth sufficient to engage the sensor
beam.
Tilt belt disconnected, extremely loose or not
installed properly...
- properly install belt between tilt motor and
large pulley.
n/a
n/a
n/a
n/a
n/a
Color, dimmer or strobe
mechanisms will not
move
Color, Dimmer, or Strobe
Failure
MCB connector disconnected...
Zoom/Edge mechanism
will not move
Zoom/Edge Failure
MCB connector disconnected...
Gobo or iris mechanisms will not move
Gobos or Iris Failure
Self tests will not run or
software download does
not work.
DMX Data Input
Erratic control of luminaire
DMX Termination
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- check MCB connector at J9 and/or J11.
- check MCB connector at J9 and/or J11.
MCB connector disconnected...
- check MCB connector at J9 and/or J11.
Detecting DMX data...
- disconnect DMX input cable.
No DMX termination or termination not correct...
- check DMX terminator.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Maintenance Procedures
Head Assembly
This section provides removal and replacement procedures for components found in
the luminaire head assembly.
Lamp Replacement
Parts:
71.2528.0700
LAMP, 700 WATT SHORT ARC
WARNING: Remove power from luminaire before performing maintenance.
To replace lamp:
Step 1. Remove power from luminaire.
WARNING: Lamps will be extremely HOT after operation. Allow lamp to cool
before replacing.
Step 2. At backcap, using slotted screwdriver (or fingers) turn captive knob until
loose.
Backcap Assembly
Head Assembly
Captive Knob
Guide Rod
Lamp
Figure 2-1: Replacing Lamp
Step 3. Slide backcap away from head assembly (it will remain attached by tether
and lamp wires).
16
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Note: 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 cotton cloth to thoroughly clean glass portion of
lamp.
Step 4. Remove lamp by pulling straight out of socket.
Step 5. Install new lamp by pressing into socket. Ensure lamp is fully seated in
socket and parallel to guide rods. (Lamp can be damaged when inserted
through reflector if not parallel to guide rods.)
Step 6. Align guide rods in guide holes and slide backcap into head assembly. Retighten captive knob.
Step 7. If required, reset lamp hour counter as follows. (Refer to "Menu System" in
VL2500 Spot User’s Manual for more information.)
a. Power up luminaire.
b. At Menu Display, press [Menu].
c. Press [Up] / [Down] arrows until Config (Configuration) appears. Press
[Enter].
d. Press [Up] / [Down] arrows until Lamp appears. Press [Enter].
e. Press [Up] / [Down] arrows to access ResetHrs. Press [Enter] to reset
lamp hour.
f. Align lamp. Refer to "Align for a Flat Field" in VL2500 Spot User’s
Manual.
Captive Knob for lamp access
(does not adjust beam)
Vertical
Horizontal
Focus
Figure 2-2: Lamp Alignment
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Color/Gobo/Iris Bulkhead Replacement
Parts:
21.9676.4120
ASSY, COLOR/GOBO/IRIS BULKHEAD
Procedure:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At top head cover, gradually loosen two 8-32x3/8" captive screws and
remove cover. (Cover remains attached by tether.) Figure 2-3.
Step 3. At CYM crossfade color bulkhead, disconnect wiring, remove two 6-32x1/4"
PPB SEMS screws, and remove assembly.
Step 4. At color/gobo/iris bulkhead, remove two 6-32x3/8" PPZ SEMS screws to
release bulkhead.
Step 5. At color/gobo/iris bulkhead, disconnect wiring harness connectors from
color wheel motor, iris motor, and color sensor. (Note: Remaining motor and
sensor connections will have to be disconnected in Step 6.)
Step 6. Slide bulkhead partially out of head assembly and disconnect gobo wheel
motor, gobo sensor, and temperature sensor connectors.
Step 7. Remove bulkhead from head assembly.
Captive Screws
CYM Crossfade Color
/Dimmer Bulkhead
Removable
Cover
Color/Gobo/Iris
Bulkhead
Figure 2-3: Color/Gobo/Iris Bulkhead Replacement
CAUTION: Make sure wiring placement does not interfere with moving parts.
Step 8. Install replacement assembly by performing Steps 2–7 in reverse order.
18
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Standard Gobo/Color Filter Replacement
WARNING: Users of VARI❋LITE luminaires should not install or use metal gobos. The
use of metal gobos in any VARI❋LITE product may damage the luminaire and could void the
luminaire’s warranty.
Parts:
Standard Gobo or Color Filter as required
To remove and replace a standard gobo or color filter:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At head cover, loosen two captive screws and remove cover. (It will remain
attached by tether.) Figure 2-3.
Note: In some cases it is easier to slide bulkhead partially out of head assembly to
access gobos/filters. To do this, use #2 Phillips screwdriver to two 6-32 PPZ screws
and slide bulkhead upward. Figure 2-4.
Step 3. Remove CYM crossfade color assembly.
Step 4. Rotate wheel until required gobo/filter is accessible.
CAUTION: Do not touch filters with bare fingers. Wear cotton gloves or other
covering while replacing.
Step 5. Using fingers, pull gobo/filter out of wheel. Figure 2-4.
Step 6. Noting proper orientation of carrier slot, insert new gobo/filter into position
and push fully into place.
Step 7. Re-install bulkhead (if applicable) and re-install head cover.
Gobo/Color Filter
Carrier Slot
Gobo/Color
Filter Wheel
Figure 2-4: Standard Gobo/Color Filter Replacement
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Strobe Bulkhead Replacement
Parts:
22.9676.0016
ASSY, STROBE BULKHEAD
Procedure:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At head cover, loosen two captive screws and remove cover. (The cover is
attached by tether.) Figure 2-5.
Step 3. Remove CYM crossfade color assembly.
Step 4. Remove color/gobo bulkhead assembly.
Step 5. (Optional) Remove spot optic assembly (to gain direct access to four
mounting screws if right-angle screw driver is not available).
Step 6. At strobe bulkhead, remove screws.
Step 7. Disconnect motor wire connectors from motors.
Step 8. Slide bulkhead out of head assembly.
Step 9. Install replacement assembly by performing Steps 2–8 in reverse order.
Captive Screws
Removable
Cover
Strobe
Bulkhead
Assembly
Figure 2-5: Dimmer Bulkhead Replacement
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Front Assembly Removal
This procedure may be necessary to gain access to other components.
To remove and re-install front assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At head cover, turn two captive screws one-quarter turn and remove cover.
(It will remain attached by tether.) Figure 2-6.
Step 3. Remove front nose cover by removing two 10-32×1/2" PPB screws (one on
each side).
Step 4. At front assembly, disconnect wire connectors from rotating gobo index
motor and rotating gobo wheel motor.
Captive Screws
Removable Cover
Front Nose Cover
Wire Connector
Junction Connector
Route wiring harness here
Screw (2)
Figure 2-6: Front Assembly Removal
Step 5. At junction connector, disconnect edge motor and zoom motor wires.
Step 6. Face head nose upward. At front of bulkhead, using #2 Phillips long handle
screwdriver, remove four 6-32 X 3/8" PPB screws, and pull front assembly
partially out of head assembly.
Step 7. At rear of bulkhead, disconnect wires from rotating gobo sensor PCB.
Figure 2-7.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Step 8. Re-install front assembly by performing Steps 2–6 in reverse order. While
re-installing, first connect wiring harness connection to rotating gobo wheel
sensor and route wires through corner between head assembly and bulkhead
(ensuring no wires are pinched).
Rotating Gobo Sensor PCB Replacement
Parts:
24.9667.1321
PCB ASSY, SENSOR ROTATING GOBO
To remove and replace rotating gobo sensor PCB:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove front assembly. Refer to “Front Assembly Removal” on page 21.
Step 3. At rotating gobo wheel, remove two 4-40×3/8" PFZ screws (do not remove
middle screw) and remove wheel. Figure 2-7.
Rotating Gobo Wheel
4-40×3/8”
PFZ Screws
Center Screw
Do Not Remove
Rotating Gobo Sensor PCB
Figure 2-7: Rotating Gobo Wheel Removal
22
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MAINTENANCE : MAINTENANCE PROCEDURES
2
CAUTION: Always use anti-static precautions when working with PCBs.
Step 4. Remove rotating gobo sensor PCB by removing two 4-40×1/4” PFZ screws.
Figure 2-8.
4-40×1/4”
PFZ Screws
Rotating Gobo
Sensor PCB
Figure 2-8: Rotating Gobo Sensor PCB Replacement
Step 5. Install replacement assembly by performing Steps 2–4 in reverse order.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Edge Motor Assembly Replacement
Parts:
21.9667.0310
ASSY, MOTOR EDGE
To remove and replace edge motor assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Remove front assembly. Refer to “Front Assembly Removal” on page 21.
Step 3. Cut cable ties which secure edge motor wires to front assembly. (Edge motor
is larger of two linear actuator motors.)
Step 4. The rotating gobo wheel obscures one of the screws securing the edge motor
assembly to the front assembly. At rotating gobo wheel, turn gobo wheel
until the open frame is over head of obscured screw. Figure 2-9.
Front Assembly
Rotating Gobo Wheel
(Shown exploded for clarity.)
Open Frame
of Gobo Wheel
Obscured
Screw
Figure 2-9: Accessing Edge Motor Assembly Attaching Hardware
24
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MAINTENANCE : MAINTENANCE PROCEDURES
2
CAUTION: Ensure you place pliers on standoff on edge motor shaft. Do not hold
edge motor shaft with pliers, or shaft may be damaged.
Step 5. At lens barrel assembly, use pliers to hold standoff on edge motor shaft, and
using 1/4" open-ended wrench, remove 4-40 SS KEPS nut from end of motor
shaft. Figure 2-10.
4-40 SS KEPS Nut
Standoff on Edge Motor Shaft
Lens Barrel
Assembly
Figure 2-10: Removing Nut From Edge Motor Assembly Shaft
Step 6. At side rail, disconnect edge motor wire connector from junction connector.
Figure 2-11.
Junction Connector
Figure 2-11: Disconnecting Edge Motor Wiring
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Step 7. Remove two 4-40×3/8" PPZ screws and nuts which secure motor to bulkhead
and remove motor assembly. Figure 2-12.
Edge Motor
Assembly
4-40×3/8"
PPZ Screw (2)
1/4" Nut
Figure 2-12: Edge Motor Assembly Replacement
Step 8. Install replacement assembly by performing Steps 2–7 in reverse order.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Lens Barrel Assembly Replacement
Parts:
21.9676.4306
ASSY, LENS BARREL
To remove and replace lens barrel assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At head cover, turn two captive screws one-quarter turn and remove cover.
(It will remain attached by tether.) Figure 2-6.
Step 3. Remove front nose cover by removing two 10-32×1/2" PPB screws (one on
each side). Figure 2-6.
Step 4. Cut cable ties which secure zoom optics motor wires to front assembly.
(Zoom optics motor is smaller of two linear actuator motors.)
Step 5. At lens barrel assembly, use pliers to hold standoff on edge motor shaft, and
using 1/4" open-ended wrench, remove 4-40 SS KEPS nut from end of motor
shaft. Figure 2-10.
Step 6. Disconnect zoom optics motor wire connector from junction connector.
Figure 2-13.
Junction Connector
Figure 2-13: Disconnecting Zoom Optics Motor Wiring
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Step 7. At front of optical support ring, remove three 8-32×3/8" PPZ screws. Figure
2-14.
Guide Rod
#6 Flat Washer
6-32×1/2" PPZ Screw
Lens Barrel Assembly
Optical Support Ring
8-32×3/8" PPZ Screw
Figure 2-14: Lens Barrel Assembly Replacement
Step 8. At each side of optical support ring, remove two 6-32×1/2" PPZ screws and
#6 flat washers. Remove optical support ring.
Step 9. Remove lens barrel assembly by pulling straight out from front assembly
along guide rods.
Step 10. Install replacement assembly by performing Steps 2–9 in reverse order.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Yoke Assembly
This section provides removal and replacement procedures for components found in
the luminaire yoke assembly.
Tilt Motor Assembly Replacement
Parts:
22.9676.0610
ASSY, TILT MOTOR
To replace tilt motor assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At tilt-side leg, remove yoke leg cover by removing four (two on each side)
6-32×5/16" PPB screws. Figure 2-15. To find tilt-side leg, refer to page 8.
Tilt Motor Assembly
Screws
Yoke Leg Cover
Standoff
Figure 2-15: Tilt Motor Assembly Replacement
Step 3. At pan/tilt encoder PCB (mounted behind tilt motor mounting plate), disconnect two cable connectors.
Step 4. At tilt motor, disconnect motor wire connector.
Step 5. Using 1/4" nutdriver, remove 1/4" hex standoff.
Step 6. Remove three remaining 6-32×5/16" PPZ screws securing tilt motor
assembly to yoke leg and remove assembly while freeing pulley from belt.
Step 7. Install replacement assembly by performing Steps 2–6 in reverse order.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Main Control Board (MCB) PCB Replacement
Parts:
24.9676.3730
MCB PCB ASSY
To replace an MCB PCB:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At board-side leg, remove yoke leg cover by removing four 6-32×5/16" PPB
screws. To find board-side leg, refer to page 8.
CAUTION: Always use anti-static precautions when working with PCBs.
Screws
Yoke Leg Cover
MCB PCB
Figure 2-16: MCB PCB Replacement
Step 3. Disconnect wiring harness connectors J8, J9, and J11.
Step 4. Remove four (4) 6-32 screws securing MCB PCB
Step 5. Disconnect upper enclosure connectors at back of MCB.
Step 6. Install replacement assembly by performing Steps 2–5 in reverse order.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Ignitor PCB Replacement
Parts:
24.9661.1126
PCB ASSY, SOLID STATE IGNITOR
To replace ignitor PCB:
Step 1. Disconnect luminaire AC input cable from power source.
Ignitor PCB
Screws
Yoke Leg Cover
Yoke cross
member
Figure 2-17: Ignitor PCB Replacement
Step 2. At each yoke leg, remove yoke leg cover by removing four 6-32×5/16" PPB
screws. Figure 2-17.
Step 3. Remove MCB PCB (See “Main Control Board (MCB) PCB Replacement”
on page 30.).
Step 4. At yoke cross member, remove four 6-32×3/16" LG PPZ screws and associated washers which secure cross member cover to yoke and remove cover.
(These screws are accessible from inside yoke legs.)
CAUTION: Always use anti-static precautions when working with PCBs.
Step 5. At Ignitor PCB, remove two accessible screws which secure PCB to yoke
leg.
Step 6. At yoke cross member, remove two 6-32×5/16" PPZ screws and washers
which secure ignitor PCB standoffs to yoke leg.
Step 7. Disconnect ignitor PCB wires by removing four screws which secure wire
ring terminals to PCB and remove ignitor PCB.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Step 8. Remove two 1/4" hex standoffs from ignitor PCB by removing one 6-32×5/
16" PPZ screw and #6 lock washer. Install in same place on new ignitor
PCB. Figure 2-18.
6-32×5/16"
PPZ Screw
#6 Lock Washer
1/4" Hex 6-32
.500" LG
Standoff (2)
Figure 2-18: Ignitor PCB Standoff Removal
Step 9. Install replacement assembly by performing Steps 2-17–8 in reverse order.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Enclosure Assembly
This section provides removal and replacement procedures for components found in
the luminaire enclosure assembly.
Removing Enclosure Covers
To gain access to enclosure components, it will be necessary to remove the top and
bottom covers.
To remove and replace enclosure covers:
Step 1. Using console or internal menus, run lens as far to the rear as possible.
Step 2. Disconnect luminaire AC input cable from power source.
Step 3. At each top enclosure cover, remove two 6-32×1/4" PPB screws and remove
cover. Figure 2-19.
Ballast-Side Cover
6-32×1/4" PPB Screw
Power Supply
Side Cover
Ventilation
Cover
1/4" Split Lock Washer
1/4-20×1/2" Socket Screw
Figure 2-19: Removing Top and Bottom Enclosure Covers
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
CAUTION: Be careful not to damage lens during next step.
Step 4. Carefully lay luminaire on its side, ensuring that lens does not come into
contact with any surface. Figure 2-20.
Figure 2-20: Laying Luminaire on Its Side
Step 5. At bottom of enclosure, remove four 1/4-20 × 1/2" socket screws and 1/4"
split lock washers and remove ventilation cover.
Step 6. Return luminaire to upright position.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Ballast Module Assembly Replacement
Parts:
69.9676.0700
ASSY, BALLAST MODULE, 700W ARC
To remove the ballast module assembly:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At enclosure, remove ballast-side and ventilation covers. Refer to
“Removing Enclosure Covers” on page 33.
Step 3. Remove both handles by removing two 10-32 X 5/8" PPB screws at each.
Step 4. At enclosure, remove eight 6-32×3/8" PPZ screws and both side covers.
Figure 2-21.
Step 5. At enclosure, remove APS side bracket and front cover from ballast side.
Note: Please note different size screws and their respective locations.
Front Cover
Screw
Arc Ballast
Handle
Side Cover (2)
Figure 2-21: Accessing Ballast Module
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Step 6. At ballast, disconnect wiring:
Note:
Some components
not shown for clarity.
Ballast
Module
8-32×3/8”
PFZ Screw (4)
8-32x3/8"
PPZ Screws (4)
Figure 2-22: Ballast Module Assembly Replacement
Step 7. At bottom of enclosure, remove four 8-32×3/8" PFZ screws and four 8/32x3/
8" PPZ screws that secure ballast module to enclosure.
Step 8. Remove ballast module.
Step 9. Install replacement assembly by performing Steps 2–8 in reverse order.
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Pan Motor Assembly Replacement
Parts:
21.9678.0864
PAN MOTOR ASSY
Procedure:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Carefully lay luminaire on its side to have access to bottom of enclosure.
Step 3. At enclosure assembly, remove bottom cover.
Step 4. Remove two connectors to pan encoder board.
Step 5. Remove four screws securing pan motor to chassis
Step 6. Carefully lift motor upwards and remove tensioning springs.
Step 7. Slide belt from around gears.
Step 8. Unplug motor connector and remove motor.
Step 9. Install in reverse order. Make sure bottom cover standoffs are seated fully
against chassis.
1)
2)
Encoder
Pan Motor
Assembly
Standoff
Bottom Cover
Enclosure Bottom View
NOTE:
Head not shown for clarity.
Figure 2-23: Pan Motor Assembly Replacement
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Pan Encoder Replacement
Parts:
24.9678.9729
PAN ENCODER
Procedure:
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. Carefully lay luminaire on its side to have access to bottom of enclosure.
Step 3. At enclosure assembly, remove bottom cover.
Step 4. Remove pan encoder board.
Step 5. Install in reverse order. Make sure bottom cover standoffs are seated fully
against chassis.
1)
2)
Encoder
Pan Motor
Assembly
Standoff
Bottom Cover
Enclosure Bottom View
NOTE:
Head not shown for clarity.
Figure 2-24: Pan Encoder Replacement
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MAINTENANCE : MAINTENANCE PROCEDURES
2
Pan EOT Sensor Replacement
Parts:
86.7002.0003
PAN EOT SENSOR ASSY
Repair Procedure
Step 1. Disconnect luminaire AC input cable from power source.
Step
2. Carefully lay luminaire on its side.
Step
3. At enclosure assembly, remove bottom cover.
Step
4. Remove pan sensor.
Step
5. Install in reverse order. Make sure bottom cover standoffs are seated fully against
chassis.
1)
2)
Sensor
Pan Motor
Assembly
Standoff
Bottom Cover
Enclosure Bottom View
NOTE:
Head not shown for clarity.
Figure 2-25: Pan EOT Sensor Replacement
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Power Supply (LVS) Replacement
Parts:
69.3177.0151
POWER SUPPLY (LVS) ASSY
Repair Procedure
Step 1. Disconnect luminaire AC input cable from power source.
Step 2. At enclosure, remove top cover at power supply side.
Step 3. At LVS, remove wiring.
Step 4. Remove screw closest to pan tube. Loosen two screws at opposite end of
wiring.
Step 5. Remove LVS.
Step 6. Install in reverse order. Make sure that no wires get pinched or caught in fan
assembly.
1)
Remove this Top Cover
2)
Fan Assembly
Standoff
Bottom Cover
Power Supply (LVS)
NOTE:
Head not shown for clarity.
Figure 2-26: Power Supply (LVS) Replacement
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CHAPTER 3.
Illustrated Parts Breakdown
This chapter contains illustrated parts breakdowns for assemblies in
the VL2500™ Spot Luminaire.
• Drawing Tree
• Top Assembly
• Yoke
• Enclosure
• Cables
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Drawing Tree
VL2500 Series Spot Luminaire
VL2500 Spot Luminaire
20.9676.0001 Rev K
Front Assembly
VL2500 Generic Luminaire
21.9676.4006 Rev E
21.9676.0010 Rev J
Rotating Gobo Wheel Assembly
Upper Enclosure Assembly
21.9660.0105 Rev E
21.9676.0800 Rev S
Lens Barrel Assembly
21.9676.4306 Rev D
Iris/Color/Gobo Bulkhead Assembly
21.9676.4120 Rev B
Continued on the next page
Yoke Assembly
21.9676.0600 Rev G
Iris/Gobo Motor Assembly
21.9676.0118 Rev B
Ignitor PCB Assembly
24.9661.1126 Rev C
Color Motor Assembly
21.9676.0119 Rev C
Gobo Wheel Assembly
21.9676.4146 Rev A
Tilt Motor Assembly
22.9676.0610 Rev C
Color Filter Wheel Assembly
Pan/Tilt Encoder PCB
Assembly
21.9676.4145 Rev A
24.9661.9629 Rev B
Color/Gobo T-Stat Cable Assembly
Ignitor To Relay Cable
Assembly
25.9676.0125 Rev B
Crossfade Color Assembly
21.9676.0201 Rev N
Top Cover Assembly
25.9676.0030 Rev 0
VL2500 Main Control Board
PCB Assembly
24.9676.3730 Rev 0
22.9676.0008 Rev H
Bottom Cover Assembly
22.9676.0011 Rev D
Strobe Assembly
22.9676.0016 Rev H
Continued on the next page
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ILLUSTRATED PARTS BREAKDOWN : DRAWING TREE
3
Drawing Tree (continued)
Continued from previous page
VL2500 Spot Luminaire (continued)
Upper Enclosure Assembly
21.9676.0800 Rev S
Reflector Assembly
22.9676.0018 Rev B
Connector Panel Assembly
Connector Panel Assembly
21.9678.0805 Rev L
21.9678.0805 Rev L
Fan Assembly
22.9676.0090 Rev D
Ground Strap Cable Assembly
25.8007.2212 Rev 0
UV / IR Window Assembly
22.9676.0140 Rev D
DMX Input PCB
Assembly
AC Input Pigtail Cable
Assembly
Pan Motor Assembly
21.9678.0864 Rev E
25.9678.0810 Rev B
Back Cap Assembly
22.9676.0115 Rev E
23.9678.0686 Rev 0
Tilt Plate Ground Cable
Assembly
LVS Chassis Ground Cable
Assembly
25.9667.0413 Rev A
25.9661.1514 Rev A
25.9676.0715 Rev F
21.9678.0880 Rev C
24.9663.3895 Rev 0
Upper Enclosure Fan
Assembly
Color/Fixed Bulkheads Cable Assembly
Pan Tube Assembly
Pan EOT Sensor Electrical
Assembly
23.9678.0687 Rev A
Ballast Module (Arc Power
Supply) Assembly
69.9676.0700 Rev 0
Chassis To Yoke Ground
Cable Assembly
25.9661.1520 Rev C
Optics/Strobe Bulkheads Cable Assembly
25.9676.0716 Rev F
Pan/Tilt Control Cable
Assembly
Strobe 1 Cable Assembly
25.9676.0818 Rev B
AC Input Splitter Cable
Assembly
EMI Filter to Power Switch
Cable Assembly
25.9678.0812 Rev E
25.9678.0811 Rev C
Data I/O Link Cable Assembly
25.9676.0717 Rev B
Fans/Disconnect Cable Assembly
25.9676.0718 Rev G
25.9678.0813 Rev A
Ballast to Controller Cable
Assembly
Display Cable Assembly
25.9678.0816 Rev A
25.9678.1825 Rev 0
VL2500 Included Items Kit
Lamp Supply to Relay Cable
Assembly
DC Output Cable Assembly
28.9676.0001 Rev F
25.9678.0829 Rev A
OT Switch to Reflector Assy. Cable
Assembly
25.9676.0719 Rev A
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01-July-2008
25.9678.0821 Rev E
43
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Top Assembly
VL2500 Included Items Kit
28.9676.0001 Rev F
Refer to Figure 3-1.
No.
Item
Qty.
UM.
1
02.8001.0001
1
EA
PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE
2
02.8052.0001
1
EA
CARD, LIMITED WARRANTY
-
02.80001.0002
1
EA
VARI-LITE QUALITY ASSURANCE CERTIFICATE (not shown)
3
02.8406.0001
1
EA
TAG, LAMP NOTICE
4
02.8700.0001
1
EA
CARD, PRODUCT REGISTRATION - 2000 SERIES (09-09-02)
5
02.9676.0002
1
EA
UNPACK/QUICK START SHEET, VL2500
-
04.9676.0001
2
EA
SHIPPING BOX LABELS, VL2500 SPOT (not shown)
04.4037.0001
5
EA
LABELS, 2.5 X .5 (not shown)
6
07.9661.0018
1
EA
SHIPPING BOX, CARDBOARD - VL2500
07.5044.0001
1
EA
BAG, DESICCANT, SHIPPING BOX (not shown)
7
06.6073.0001
1
EA
FOAM
8
08.2500.0001
1
EA
CD-ROM, VL2500 LUMINAIRE PRODUCT DOCUMENTATION
9
22.9661.1636
2
EA
FAB ASSY, BRACKET TRUSS HOOK
10
71.2528.0700
1
EA
700 WATT SHORT ARC-PHILIPS MSR575HR LAMP
-
04.9678.1000
1
EA
LABEL, WHITE, ROHS COMPLIANCE
04.9678.1001
2
EA
LABEL, GREEN, ROHS COMPLIANCE
44
Description
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
1
3
3
7
2
8
4
5
6
9
10
Figure 3-1: Included Items Kit
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
VL2500 Spot Luminaire
20.9676.0001 Rev K
Refer to Figure 3-2.
No.
Item
Qty.
UM.
Description
1
10.9638.0052
1
EA
DAM, AIR, VL6
2
10.9676.8632
2
EA
COVER, YOKE THERMOFORM
3
16.9676.0004.01
1
EA
LABEL LOCATION, VL2500 LUMINAIRE (not shown)
4
21.9676.0023
1
EA
ASSY, FRONT COVER
5
21.9676.4006
1
EA
ASSY, FRONT
6
21.9676.0010
1
EA
GENERIC LUMINAIRE, VL2500
7
21.9676.4120
1
EA
BULKHEAD ASSY, IRIS/COLOR/GOBO
8
21.9676.0201
1
EA
ASSY, CROSSFADE COLOR
9
22.9676.0008
1
EA
ASSY, TOP COVER
10
22.9676.0011
1
EA
ASSY, BOTTOM COVER
11
22.9676.0016
1
EA
ASSY, STROBE
12
22.9676.0018
1
EA
ASSY, REFLECTOR
13
22.9676.0090
1
EA
ASSY, FAN
14
22.9676.0115
1
EA
ASSY, BACK CAP
15
22.9676.0140
1
EA
ASSY, UV / IR WINDOW
-
25.9676.0715
1
EA
CABLE ASSY, COLOR / FIXED (not shown)
25.9676.0716
1
EA
CABLE ASSY, OPTICS / STROBE (not shown)
25.9676.0717
1
EA
CABLE ASSY, STROBE 1 (not shown)
25.9676.0718
1
EA
CABLE ASSY, FAN / DISCONNECT (not shown)
25.9676.0719
1
EA
CABLE ASSY, OT SWITCH TO REFLECTOR ASSY (not shown)
28.9676.0001
1
EA
INCLUDED ITEMS KIT, VL2500 LUMINAIRE (not shown)
16
53.2200.0006
1
EA
NUT, KEPS #6-32 SS
17
53.6523.0013
8
EA
SCREW, 6-32 X 3/8" PTB
18
53.6558.0009
6
EA
SCREW, 6-32 X 3/8" PPZ, SEMS
19
53.6558.0010
10
EA
SCREW, 6-32 X 1/4" PPB, SEMS
20
53.6607.0001
2
EA
SCREW, 6-32 X 1/4" PPB
21
53.6625.0001
2
EA
SCREW, 10-32 X 1/2" PPB
22
67.4018.0001
1
EA
FERRITE, 26 X 28.5 X 13MM, CYL
23
55.2178.0001
1
EA
ANCHOR, CABLE MOUNT, #8 SCREW
24
55.6669.0017
4
EA
STANDOFF, 1/4" HEX, 6-32, 1.062"
46
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
19 (x6)
3
11
14
8
1
18 (x2)
12
7
24 (x4)
16
15
16
19 (x4)
22
Note: Loop lamp wires
through ferrite.
23
20
5
6
18 (x4)
9
13
4
21 (x2)
17 (x8)
10
2 (x2)
Figure 3-2: Top Assembly
02.96 76.002 0 A
01-July-2008
47
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
VL2500 Generic Luminaire
21.9676.0010 Rev J
Refer to Figure 3-3.
No.
Item
Qty.
UM.
1
10.9628.0211
1
EA
STABLIZER, PAN/TILT
2
10.9676.8617
1
EA
HEATSHIELD, YOKE CROSSMEMBER
3
10.9676.0083
1
EA
BAFFLE, REAR CASTING
4
10.9676.0163
1
EA
HARNESS, GUARD, RIGHT
5
10.9676.0161
1
EA
HARNESS, GUARD, LEFT
6
21.9676.0139
1
EA
ASSY, REAR HEAD
7
21.9676.0600
1
EA
ASSY, YOKE
-
25.9667.0028
1
EA
CABLE ASSY, YOKE TO HEAD GROUND (NOT SHOWN)
8
21.9676.0800
1
EA
UPPER ENCLOSURE
9
24.9676.3730
1
EA
ASSY, VL2500 MAIN CONTROL BOARD (MCB)
10
53.6505.0020
5
EA
BOLT, 1/4-28 X 3/4" HX HD GRD 8
11
53.6517.0001
8
EA
SCREW, 10-32 X 3/8" PPZ
12
53.6526.0001
1
EA
SCREW, 6-32 X 5/8" PPZ
13
53.6530.0006
2
EA
RIVET, POP, 1/8" OD X .188-.250" G
14
53.6539.0008
5
EA
WASHER, 1/4" FLAT
15
53.6553.0008
4
EA
SCREW, 10-32 X 9/16" PFB
16
53.6558.0009
4
EA
SCREW, 6-32 X 3/8" PPZ SEMS
17
53.6558.0010
8
EA
SCREW, 6-32 X 1/4" PPB SEMS
18
53.6682.0025
1
EA
SCREW, 8-32 X 5/8" PPZ SEMS
19
54.2039.0001
1
EA
BELT, GT TIMING 2 MM PITCH 182 GRV
20
55.2114.0001
8
EA
WASHER, #10 LOCK INT. TOOTH
21
55.6549.0001
5
EA
WASHER, 1/4" SPLIT LOCK
22
55.6603.0001
1
EA
SPRING, EXTENSION
23
55.6663.0007
1
EA
STANDOFF, 3/8" RND., 1.75" LG FF
24
55.6677.0033
4
EA
WASHER, .281" OD, .125 ID, .032 THK
48
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
VL2500 Generic Luminaire (continued)
11 (x8)
23
20 (x8)
13 (x2)
18
19
6
3
22
17 (x2)
4
1
5
17 (x2)
12
2
7
10 (x5)
21 (x5)
14 (x5)
9
8
24 (x4)
16 (x4)
15 (x4)
17 (x4)
Figure 3-3: VL2500 Generic Luminaire Assembly
02.96 76.002 0 A
01-July-2008
49
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Front Assembly
21.9676.4006 Rev F
Refer to Figure 3-4.
No.
Item
Qty.
UM.
1
10.9660.0129
1
EA
SHAFT STOP, ROTATING GOBO WHEEL
2
10.9660.0130
1
EA
SHAFT, ROTATING GOBO WHEEL
3
10.9660.0219
1
EA
SHAFT 1, FOCUS BEARING
4
10.9676.4255
2
EA
SHAFT, SUPPORT, LENS
5
10.9660.0263
1
EA
SUPPORT, LENS
6
10.9667.0313
1
EA
SUPPORT, LENS, CABLE MOUNT
7
10.9676.4349
1
EA
SUPPORT RING, OPTICAL
8
10.9676.4355
1
EA
BRACKET, COVER MOUNTING
9
21.9660.0105
1
EA
ASSY, ROTATING GOBO WHEEL
10
21.9676.4306
1
EA
ASSY, LENS BARREL
11
21.9667.0310
1
EA
ASSY, MOTOR EDGE
12
22.9676.0316
1
EA
BULKHEAD, LENS MOUNTING
13
22.9676.0152
1
EA
ASSY, TENSION BRACKET MOTOR INDEX
14
22.9676.0153
1
EA
ASSY, TENSION BRACKET MOTOR WHEEL
15
24.9667.3321
1
EA
PCB ASSY, SENSOR ROTATING GOBO
16
53.2200.0004
1
EA
NUT, 4-40 KEPS SS
17
53.6515.0001
2
EA
SCREW, 10-32 X 3/4" SCB CAP
18
53.6520.0001
3
EA
SCREW, 4-40 X 3/8" PPZ
19
53.6545.0004
3
EA
SCREW, 8-32 X 3/8" PPZ
20
53.6558.0007
1
EA
SCREW, 4-40 X 1/4" PPZ, SEMS
21
53.6559.0001
3
EA
SCREW, 4-40 X 1/4" PFZ
22
53.6558.0001
2
EA
SCREW, 6-32 X 3/8" LG PPZ
23
53.6608.0003
8
EA
SCREW, 6-32 X 3/16" LG PPZ
24
53.6613.0001
6
EA
SCREW, 6-32 X 1/2" PPZ
25
53.6682.0022
1
EA
SCREW, 8-32 X 3/8" PPZ, SEMS
26
54.2029.0001
1
EA
BELT, TIMING MXL .080" PITCH 70 GRV 3/16" WD KEVLAR
27
54.2032.0001
1
EA
BELT, TIMING MXL .080" PITCH 87 GRV 3/16" POLY CORD WD
28
55.2118.0004
1
EA
WASHER, .735" OD .395" ID .011" THK CURVD SPRNG
29
55.2118.0005
1
EA
WASHER, .735" OD .395" ID .016" THK CURVD SPRNG
30
55.3301.0006
4
EA
WASHER, #6 FLAT SS
31
55.3301.0010
2
EA
WASHER, #10 FLAT
50
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
No.
Item
Qty.
UM.
32
55.6506.0009
1
EA
SPACER, 1/2" RND .125" LG .375" ID SHAFT
33
55.6589.0003
2
EA
STANDOFF, 1/4" RND 4-40 .606" LG MF
34
55.6663.0007
1
EA
STANDOFF, 3/8" RND, 1.75" LG, FF
Description
22 (x2)
34
18 (x2)
8
12
31 (x2)
17 (x2)
3
21
25
1
9
23 (x4)
11
26
5
2
28
32
29
24 (x2)
30 (x2)
21 (x2)
18
33 (x2)
3
27
15
23 (x4)
10
16
14
6
20
24 (x2)
4 (x2)
13
30 (x2)
24 (x2)
19 (x3)
7
Figure 3-4: Front Assembly
02.96 76.002 0 A
01-July-2008
51
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Lens Barrel Assembly
21.9676.4306 Rev D
Refer to Figure 3-5.
No.
Item
Qty.
UM.
1
10.9676.4254
1
EA
SHAFT, ZOOM BEARING
2
10.9676.4256
1
EA
WEAR STRIP, EDGE LENSES
3
10.9676.4258
1
EA
WEAR STRIP, EDGE BARREL
4
10.9676.4259
1
EA
WEAR STRIP, ZOOM BALL PLUNGER
5
10.9676.4260
1
EA
WEAR STRIP BUMPER, EDGE LENSES
6
12.9676.4248
1
EA
EDGE BARREL, BOTTOM
7
12.9676.4247
1
EA
EDGE BARREL, TOP
8
21.9660.0225
1
EA
ASSY, SUB-BARREL GROUP 1
9
21.9660.0227
1
EA
ASSY, GROUP 3 SUB BARREL
10
21.9667.0311
1
EA
ASSY, MOTOR, ZOOM OPTICS
11
21.9676.4257
1
EA
ASSY, EDGE BUSHING
12
21.9676.4229
1
EA
ASSY, ZOOM BARREL
13
42.9660.0026
1
EA
LENS 9, ZOOM OPTICS
14
53.2200.0004
3
EA
NUT, 4-40 KEPS SS
15
53.2200.0006
4
EA
NUT, 6-32 KEPS SS
16
53.6551.0001
2
EA
SCREW, 4-40 X 3/8" PPB
17
53.6558.0015
4
EA
SCREW, 6-32 X 3/8" PPB
18
53.6559.0002
2
EA
SCREW, 4-40 X 1/4" PFB
19
53.6592.0250
2
EA
SCREW, 4-40 X 1/4" PFB, SEMS
20
54.1206.0055
1
EA
RETAINING RING, EXTERNAL 1/2" SHAFT, PRESS ON
21
54.1206.0056
1
EA
RETAINING RING, EXTERNAL 1/2" SHAFT
22
55.3301.0004
2
EA
WASHER, #4 FLAT SS
23
55.6512.0001
2
EA
WASHER, 1/4" SPLIT LOCK
52
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Lens Barrel Assembly (continued)
17 (x4)
4
11
20
14 (x2)
7
22 (x2)
1
18 (x2)
21
16 (x2)
10
23 (x2)
3
12
14
9
8
13
6
15 (x4)
2
5
19 (x2)
Figure 3-5: Lens Barrel Assembly
02.96 76.002 0 A
01-July-2008
53
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Sub-Barrel Group 2 Assembly
21.9676.4229 Rev B
Refer to Figure 3-6.
No.
Item
Qty.
UM.
Description
1
10.9676.4223
1
EA
BARREL, ZOOM, LOWER
2
10.9676.4250
1
EA
SPACER 1, ZOOM LENSES
3
10.9676.4251
1
EA
SPACER 2, ZOOM LENSES
4
12.9676.4224
1
EA
BARREL, ZOOM, UPPER
5
21.9676.4258
1
EA
ASSY, ZOOM BUSHING
6
42.9660.0023
1
EA
LENS 6, ZOOM OPTICS
7
42.9660.0024
1
EA
LENS 7, ZOOM OPTICS
8
42.9660.0025
1
EA
LENS 8, ZOOM OPTICS
9
53.2200.0006
4
EA
NUT, 6-32 KEPS SS
10
53.6543.0001
4
EA
SCREW, 6-32 X 3/8" PPB
11
54.1206.0055
1
EA
RETAINING RING, EXTERNAL, 1/2" PRESS ON
12
54.1206.0056
1
EA
RETAINING RING, EXTERNAL, 1/2"
13
55.6568.0091
1
EA
SPRING PLUNGER, BALL NOSE, PUSH FIT, 1/4" DIA
5
12
11
4
13
6
2
7
3
8
1
10 (4)
9 (4)
Figure 3-6: Sub-Barrel Group 2 Assembly
54
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Motor Zoom Optics Assembly
21.9667.0311 Rev A
Refer to Figure 3-7.
No.
Item
Qty.
UM.
1
44.9660.0262
1
EA
MOTOR, 1" LINEAR - ZOOM
2
52.6579.0005
1
EA
CONN, 5CIR PNL MT SGL ROW W/MTG EARS
3
52.8347.0001
4
EA
CONTACT, 24-30AWG MALE CRIMP
Description
3
2
1
Figure 3-7: Motor Zoom Optics Assembly
02.96 76.002 0 A
01-July-2008
55
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Rotating Gobo Wheel Assembly
21.9660.0105 Rev E
Refer to Figure 3-8.
No.
Item
Qty.
UM.
1
10.9660.0110
4
EA
GOBO CARRIER, SPINNING GOBO WHEEL
2
10.9660.0112
1
EA
SUN GEAR, SPINNING GOBO WHEEL
3
10.9660.0144
1
EA
SPRING GOBO RETAINER, SPINNING GOBO WHEEL
4
10.9660.0153
1
EA
MAGNET, HALL EFFECT SENSOR .07ID
5
10.9667.0333
1
EA
MOUNTING PLATE, FRONT (ROTATING GOBO WHEEL)
6
10.9667.0334
1
EA
MOUNTING PLATE, AFT (ROTATING GOBO WHEEL)
7
10.9667.0335
1
EA
LIGHT SHIELD, SPINNING GOBO WHEEL
8
21.9660.0102
1
EA
ASSY, SENSOR PLANET GEAR
9
21.9660.0147
1
EA
ASSY., DRIVE HUB/PULLEY FLANGE, SPINNING GOBO WHEEL
10.9660.0111
1
EA
DRIVE HUB, SPINNING GOBO WHEEL - VL6B
10.9660.0148
1
EA
PULLEY FLANGE, DRIVE HUB SPINNING GOBO WHEEL
-
56
Description
10
41.6016.4305
1
EA
ASSY, GOBO PINWHEEL
11
41.6016.4316
1
EA
ASSY, VL6B SPINNING GOBO HYPNOSPIRAL
12
41.6016.6011
1
EA
ASSY, VL6B SPINNING GOBO CIRCLE OF OVALS
13
41.6016.6990
1
EA
ASSY, VL6B SPINNING GOBO SPIRAL STONES
14
41.6016.8004
1
EA
4 FACET PRISM
15
53.6597.0001
9
EA
SCREW, 4-40 X 3/16" PPZ
16
53.6633.0002
2
EA
SCREW, #4 X 3/8" PFZ SHT METAL
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Rotating Gobo Wheel Assembly (continued)
7
16 (2)
5
1
14
12
3
2
15 (3)
6
15 (6)
8
11
13
10
9
4
14
10
12
13
11
Standard Gobos
Figure 3-8: Rotating Gobo Wheel Assembly
02.96 76.002 0 A
01-July-2008
57
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Sensor Rotating Gobo PCB Assembly
24.9667.1321 Rev -
Refer to Figure 3-9.
Replace as a complete assembly.
3
3
1
Figure 3-9: Sensor Rotating Gobo PCB Assembly
58
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Top Cover Assembly
22.9676.0008 Rev H
Refer to Figure 3-10.
No.
Item
Qty.
UM. Description
1
06.6018.0011
0.041
FT
VELCRO, DOUBLE HOOK, 2" BLACK ADH BACKED
2
07.5049.0001
1
EA
LANYARD, NYLON COATED, 8" LONG
3
10.9676.8009
1
EA
COVER, TOP VL2500
4
10.9676.0010
1
EA
FILTER, TOP HEAD COVER
5
12.9676.0076
1
EA
BAFFLE, RIGHT, TOP COVER
6
12.9676.0077
1
EA
BAFFLE, LEFT, TOP COVER
7
53.2008.0008
2
EA
PUSH NUT, #8
8
53.5655.0250
1
EA
SCREW, 6 X 1/4" PPZ PLASTIC
9
53.6545.0001
2
EA
SCREW, 8-32 X 3/8" PPB
10
53.6687.0250
4
EA
SCREW, 4-40 X 1/4" PFZ THREAD FORMING
11
55.3301.0006
1
EA
WASHER, #6 FLAT, SS
12
55.6599.0001
2
EA
WASHER, FLAT, #10 FLAT BLACK
13
55.6621.0001
1
EA
WASHER, #4 FLAT ZINC
8
11
1
4
6
10 (x4)
3
2
5
7 (x2)
12 (x2)
9 (x2)
Figure 3-10: Top Cover Assembly
02.96 76.002 0 A
01-July-2008
59
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Bottom Cover Assembly
22.9676.0011 Rev D
Refer to Figure 3-11.
No.
Item
Qty.
UM. Description
1
10.9676.8012
1
EA
COVER, LOWER
2
53.2008.0008
3
EA
NUT, #8 PUSH
3
53.6545.0001
3
EA
SCREW, 8-32 X 3/8" PPB
4
53.6599.0001
3
EA
WASHER, #10 FLAT BLACK
1
2 (x3)
3 (x3)
4 (x3)
Figure 3-11: Bottom Cover Assembly
60
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Reflector Assembly
22.9676.0018 Rev B
Refer to Figure 3-12.
No.
Item
Qty.
UM. Description
1
10.9678.0647
4
EA
CLAMP, MOUNTING, REFLECTOR
2
22.9660.0338
1
EA
ASSY, DISCONNECT LAMP
3
22.9676.0130
1
EA
ASSY, REFLECTOR MOUNT
4
41.9660.7021
1
EA
ELLIPSOIDAL REFLECTOR, LUNED
5
53.6599.0001
2
EA
SCREW, 4-40 X 3/8" PFZ
6
55.6669.0016
4
EA
STANDOFF, 1/4" HEX, 6-32 M/F, SS, L = 0.875"
3
1 (x4)
6 (x4)
4
2
5 (x2)
Figure 3-12: Reflector Assembly
02.96 76.002 0 A
01-July-2008
61
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Back Cap Assembly
22.9676.0115 Rev E
Refer to Figure 3-13.
No.
Item
Qty.
UM.
1
10.9638.0117
3
EA
KNOB, KNURLED, VL6 BACK CAP/LAMP ASSY.
2
10.9638.0128
1
EA
BRACKET, IGNITOR CABLE
3
10.9638.0130
1
EA
SPRING, BULB WIRE SHEATH
4
10.9638.0164
1
EA
WASHER, FELT
5
10.9667.0411
1
EA
LAMP CARRIAGE
6
10.9667.0412
1
EA
LAMP TILT PLATE
7
12.9676.8112
1
EA
BACKCAP, MACHINED, VL2500
8
22.9638.0129
1
EA
TETHER, VL6 BACKCAP
9
25.9667.0413
1
EA
CABLE ASSY, GROUND -TILT PLATE
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
62
Description
10
52.8231.0005
2
EA
11
53.2200.0010
1
EA
NUT, 10-32 KEPS SS
12
53.2201.0010
2
EA
NUT, 10-32 HEX SS
13
53.5638.1250
1
EA
SCREW, 1/4-28 X 1 1/4" CAPTIVE
14
53.6519.0001
2
EA
SCREW, 4-40 X 5/8" PPZ VL-1
15
53.6525.0001
1
EA
SCREW, 6-32 X 5/16" PPZ
16
53.6526.0001
2
EA
SCREW, 6-32 X 5/8" PPZ
17
53.6534.0001
4
EA
RIVET, 3/32" OD POP 3/32" GRIP RNG ALUM
18
53.6539.0011
1
EA
SCREW, 10-32 X 2 1/4" PFBSS UNF-2A
19
53.6539.0012
2
EA
SCREW, 10-32 X 2" PFBSS UNF-2A
20
53.6546.0002
2
EA
SCREW, 8-32 X 5/16" PPZ
21
53.6515.0001
1
EA
SCREW, 10-32 X 3/4" SCB CAP
22
10.9676.0071
1
EA
SWIVEL PLATE, LAMP ADJUST
23
55.2134.0003
2
EA
PLATE, FLOATING NUT 10-32
SLEEVING, .208ID SILICONE RUBBER COATED FIBERGLASS
24
55.2260.0208
1.92
FT
25
55.3301.0006
3
EA
WASHER, #6 FLAT SS
26
55.3303.0004
2
EA
WASHER, #4 LOCK INT.TOOTH SS
27
55.6540.0001
2
EA
WASHER, #10 FLAT BRASS
28
55.6568.0017
1
EA
SPRING, CPRSN .480" OD 1.500" LG SS
29
55.6568.0036
2
EA
SPRING, CPRSN .360" OD .690" LG .032" WIRE DIA SS
30
55.6568.0048
2
EA
SPRING, CPRSN .480" OD 1.000" LG SS
31
71.2502.0003
1
EA
SOCKET, FASSUNG GY9.5 W/ 905 MM LEADS
32
53.6682.0034
1
EA
SCREW, 10-32 X 1/2" PPB SEMS
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Back Cap Assembly (continued)
18 4
1
13
32
25
15
7
2
11
19
28
21
27
22
20 (x2)
6
30(x2)
12 (x2)
5
29 (x2)
25 (x2)
16 (x2)
23 (x2)
31
17 (x4)
26 (x2)
14 (x2)
24 (13.5")
10 (x2)
9
3
24 (9.0")
Figure 3-13: Back Cap Assembly
02.96 76.002 0 A
01-July-2008
63
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Fan Assembly
22.9676.0090 Rev D
Refer to Figure 3-14.
No.
Item
Qty.
UM.
1
10.9676.0068
1
EA
AIR DUCT, FRONT FAN
2
22.9676.0091
1
EA
ASSY, FAN BULKHEAD
3
22.9676.0095
1
EA
AIR DUCT, REAR FAN
4
25.8007.2212
1
EA
CABLE ASSY, GROUND STRAP, #6 RING 3" LG
5
40.7113.0002
1
EA
FAN, +24 VOLT, 80 X 80 X 25MM, 39CFM
6
40.7146.0002
1
EA
DC FAN, 3.15" SQ X 1.0" BB LOW FLOW
7
52.6523.0005
1
EA
CONN, HOUSING, 5 POS. PLUG SHROUD
8
52.8347.0001
5
EA
CONTACT, 24-30 AWG, CRIMP MALE
9
52.8371.0001
1
EA
RECEPT., FASTON, 20-24 AWG, UNINSULATED
10
53.2200.0006
1
EA
NUT, KEPS #6-32 SS
11
53.5604.0375
8
EA
SCREW, 4-40 X 3/8", PPSS-B
12
53.6558.0010
1
EA
SCREW, 6-32 X 1/4" LG PPZ BLK
13
53.6596.0001
2
EA
SCREW, 4-40 X 5/16" PPZ
14
55.2186.0001
1
EA
CABLE TIE, .10" X 4" SMALL
15
55.2203.0001
2
EA
SCREW, 4-40 X 1/4" PPZ
16
55.6616.0008
3
EA
STANDOFF, 3/8" HEX 8-32 THRD 0.5" LG
17
73.1624.0008
1
FT
WIRE, 24 AWG 300V 200 DEG C TEFLON GRY
64
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Fan Assembly (continued)
1
3
6
2
10
4
5
11
12
13 (x2)
16 (x3)
15 (x2)
17
7, 8 (x5)
9
14
Figure 3-14: Fan Assembly
02.96 76.002 0 A
01-July-2008
65
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Iris/Color/Gobo Bulkhead Assembly
21.9676.4120 Rev C
Refer to Figure 3-15.
No.
Item
Qty.
UM.
1
1
EA
BULKHEAD, IRIS/GOBO/COLOR
2
10.9676.4124
21.9676.0118
1
EA
ASSY, IRIS/GOBO MOTOR
3
21.9676.0119
1
EA
ASSY, COLOR MOTOR
4
22.9676.4146
1
EA
ASSY, GOBO WHEEL
5
22.9676.4145
1
EA
ASSY, COLOR FILTER WHEEL
6
22.9676.1145
1
EA
IRIS, 53MM OD, CUSTOM
7
25.9676.0125
1
EA
CABLE ASSY, T-STAT, COLOR/GOBO
8
53.2200.0004
1
EA
NUT, 4-40 KEPS SS
9
53.6558.0007
6
EA
SCREW, 4-40 X 1/4" PPZ SEMS
10
53.6559.0001
1
EA
SCREW, 4-40 X 1/4" PFZ
11
53.6605.0004
1
EA
STUD, 2-56 X 1.0 FULL THD SST
12
53.6659.0014
3
EA
SCREW, 2-56
13
54.1217.0005
2
EA
QUICK LINK, 2-56, SPRING STEEL
14
55.6538.0005
7
EA
WASHER, 0.25" OD, 0.65" ID, 0.15" THK TEFLON
15
55.6543.0001
1
EA
GROMMET STRIP, SERRATED .062" (NOT SHOWN)
66
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Iris/Color/Gobo Bulkhead Assembly (continued)
9 (x3)
5
12 (x3)
6
7
2
9 (x3)
8
10
11
1
13 (x2)
14 (x7)
3
4
Figure 3-15: Iris/Color/Gobo Bulkhead Assembly
02.96 76.002 0 A
01-July-2008
67
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Crossfade Color Assembly
21.9676.0201 Rev N
Refer to Figure 3-16.
No.
Item
Qty.
UM.
1
10.9676.0230.01
4
EA
SPACER, COLOR WHEEL
2
10.9676.0230.02
1
EA
SPACER, COLOR MOTOR
3
10.9676.0234
1
EA
AFT BULKHEAD, CROSSFADE COLOR SYSTEM
4
10.9676.0238
1
EA
BULKHEAD SPACER 2, COLOR SYSTEM
5
10.9676.0235
5
EA
SPACER, BULKHEAD, COLOR SYSTEM
6
10.9676.0284
1
EA
SHAFT, COLOR SYSTEM
7
10.9678.0485
4
EA
PULLEY, COLOR MOTOR
8
21.9676.0289
1
EA
ASSY, FRONT BULKHEAD/DIFFUSER
9
21.9676.0290
1
EA
ASSY, MAGENTA COLOR WHEEL
10
21.9676.0291
1
EA
ASSY, CYAN COLOR WHEEL
11
21.9676.0292
1
EA
ASSY, YELLOW COLOR WHEEL
12
21.9676.0293
1
EA
ASSY, DIMMER WHEEL
13
21.9676.0298
1
EA
ASSY, SENSOR PCB/BRACKET
14
44.9676.0236
4
EA
MOTOR, COLOR
15
53.2200.0006
4
EA
NUT, 6-32 KEPS SS
16
53.2200.0008
1
EA
NUT, 8-32 KEPS SS
17
53.5559.0250
4
EA
SCREW, 6-32 X 1/4" SET CONE POINT
18
53.6520.0188
2
EA
SCREW, 4-40 X 3/16" PFZ UNDERCUT
19
53.6525.0001
4
EA
SCREW, 6-32 X 5/16" PPZ
20
53.6545.0001
5
EA
SCREW, 8-32 X 3/8" PPB
21
53.6545.0007
1
EA
SCREW, 8-32 X 3/8" PFB
22
53.6596.0001
4
EA
SCREW, 4-40 X 5/16" PPZ
23
54.2049.0135
2
EA
BELT, TIMING MXL 0.08 PITCH 135 GRV
24
54.2059.0001
2
EA
BELT, TIMING MXL 0.08 PITCH 150 GRV
25
55.2110.0002
3
EA
WASHER, .400" OD, .260" ID, .010" THK
26
55.2179.0008
2
EA
SADDLE, LOCKING TOP, 0.067 HOLE
27
55.6503.0001
5
EA
WASHER, #8 LOCK INT. TOOTH
28
55.6818.0002
1
EA
KURLY LOK, STANDOFF, 45 DEG, NYLON 6/6 (NOT SHOWN)
29
55.9676.0255
1
EA
BELLEVILLE SPRING WASHER, SPEC B0500-018-S
68
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Crossfade Color Assembly (continued)
22 (x4)
14 (x2)
26 (x2)
15 (x4)
28
4
5 (x5)
24
17 (x4)
23
7 (x4)
21
18 (x2)
24
Yellow
23
13
Cyan
14 (x2)
8
Magenta
Dimmer
11
25
10
1
9
19 (x4)
12
6
2
1
1
16
25 (x2)
18 (x6)
27 (x5)
3
1
29
Yellow
Dimmer
Cyan
Magenta
Figure 3-16: Crossfade Color Assembly
02.96 76.002 0 A
01-July-2008
69
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Iris/Gobo Motor Assembly
21.9676.0118 Rev D
Refer to Figure 3-17.
No.
Item
Qty.
UM.
1
10.9621.0097
1
EA
STABILIZER, STEPPER, GOBO WHEEL
2
10.9667.1111
1
EA
MOTOR BULKHEAD, IRIS/GOBO
3
10.9667.0126
1
EA
IRIS CRANK
4
24.9676.1114
1
EA
PCB ASSY, SENSOR, VL6B
5
44.9676.0116
1
EA
MOTOR, GOBO/COLOR WHEEL
6
44.9676.0118
1
EA
MOTOR, IRIS
7
53.6578.0001
1
EA
SCREW, 4-40 X 1/8" SET
8
53.6596.0001
3
EA
SCREW, 4-40 X 5/16" PPZ
9
53.6597.0001
2
EA
SCREW, 4-40 X 3/16" PPZ
10
53.6599.0001
1
EA
SCREW, 4-40 X 3/8" PFZ
11
55.2203.0001
3
EA
SCREW, 4-40 X 1/4" PPZ
12
55.3301.0004
1
EA
WASHER, #4 FLAT SS
13
55.6512.0001
2
EA
WASHER, #4 SPLIT LOCK
14
55.6568.0016
1
EA
SPRING, EXTSN .125" OD .500" LG .018" WIRE DIA SS
15
55.6579.0005
4
EA
GROMMET, 3/8" HOLE 3/16" ID
16
55.6589.0002
1
EA
STANDOFF, 1/4" RND 4-40 .328" FF ALUM
17
55.6595.0004
3
EA
SPACER, 3/16OD X .171L X #4HOLE ALUM.
18
55.6621.0001
3
EA
WASHER, #4 FLAT ZINC
3, 7
15 (x4)
Description
17 (x3)
18 (x3)
8 (x3)
6
16
11 (x3)
Note orientation of
motor connections
2
4
14
1
10, 12
9 (x2)
13 (x2)
5
Figure 3-17: Iris/Gobo Motor Assembly
70
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Color Motor Assembly
21.9676.0119 Rev D
Refer to Figure 3-18.
No.
Item
Qty.
UM.
Description
1
10.9621.0097
1
EA
STABILIZER, STEPPER, GOBO WHEEL
2
10.9676.1120
1
EA
COLOR MOTOR BULKHEAD
3
24.9676.1114
1
EA
PCB ASSY, SENSOR, COLOR/GOBO
4
44.9676.0116
1
EA
MOTOR, GOBO/COLOR WHEEL
5
55.2203.0001
2
EA
SCREW, 4-40 X 3/16" PPZ
6
53.6599.0001
1
EA
SCREW, 4-40 X 3/8" PFZ
7
55.2203.0001
3
EA
SCREW, 4-40 X 1/4" PPZ
8
55.3301.0004
3
EA
WASHER, #4 FLAT SS
9
55.6512.0001
2
EA
WASHER, #4 SPLIT LOCK
10
55.6568.0016
1
EA
SPRING, EXTSN .125" OD.500" LG .018" WIRE DIA SS
2
3
5 (x2)
9, 8 (x2)
Note orientation of
motor connection
4
10
1
7 (x3)
6, 8
Figure 3-18: Color Motor Assembly
02.96 76.002 0 A
01-July-2008
71
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Gobo Wheel Assembly
21.9676.4146 Rev A
Refer to Figure 3-19.
No.
Item
Qty.
UM.
1
22.9676.4142
1
EA
ASSY, GOBO WHEEL, 12 POSITION FIXED
12.9676.4140
1
EA
HUB, CAVITY, GOBO WHEEL MACHINED CASTING
10.9676.4141
1
EA
SPRING CLIP PLATE
10.9676.4143
1
EA
CLAMP, GOBO WHEEL
10.9676.4144
1
EA
SPACER CLAMP, GOBO WHEEL
53.5704.0250
2
EA
SCREW, 4-40 X 1/4" LG SCSS
-
Description
2
41.6006.4202
1
EA
ASSY, VL6 GOBO, VERTICAL BARS (ST)
3
41.6006.5009
1
EA
ASSY, VL6 GOBO LIQUID TEXTURE (P.O.)
4
41.6006.5011
1
EA
ASSY, VL6 GOBO, NIGHT SKY (ST)
5
41.6006.5501
1
EA
ASSY, VL6 GOBO, LEAVES (ST)
6
41.6006.5523
1
EA
ASSY, VL6 GOBO, TRIBAL BREAKUP (P.O.)
7
41.6006.6001
1
EA
ASSY, VL6 GOBO, MEDIUM CIRCLE (ST)
8
41.6006.7002
1
EA
ASSY, VL6 GOBO, PEBBLES (ST)
9
41.6006.7008
1
EA
ASSY, VL6 GOBO, WAVE (ST)
10
41.6006.7015
1
EA
ASSY, VL6 GOBO, BLOCK BREAKUP (ST)
11
41.6006.7025
1
EA
ASSY, VL6 GOBO, DUST BREAKUP (CA)
12
41.6006.7029
1
EA
ASSY, VL6 GOBO ALPHA RAYS (P.O.)
11
1
7
4
5
8
2
9
12
3
6
10
Figure 3-19: Gobo Wheel Assembly
72
01-July-2008
02 .9 676 .00 20 A
3
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
Color Filter Wheel Assembly
21.9676.4145 Rev A
Refer to Figure 3-20.
No.
Item
Qty.
UM.
1
22.9676.4142
1
EA
ASSY, GOBO WHEEL, 12 POSITION FIXED
12.9676.4140
1
EA
HUB, CAVITY, GOBO WHEEL MACHINED CASTING
10.9676.4141
1
EA
SPRING CLIP PLATE
10.9676.4143
1
EA
CLAMP, GOBO WHEEL
10.9676.4144
1
EA
SPACER CLAMP, GOBO WHEEL
53.5704.0250
2
EA
SCREW, 4-40 X 1/4" LG SCSS
-
Description
2
41.6006.0020
1
EA
ASSY, VL6 FILTER, MAGENTA (ST)
3
41.6006.0150
1
EA
ASSY, VL6 FILTER, PINK (ST)
4
41.6006.0240
1
EA
ASSY, VL6 FILTER, LIGHT RED (ST)
5
41.6006.0320
1
EA
ASSY, VL6 FILTER, BASTARD AMBER #1 (ST)
6
41.6006.0440
1
EA
ASSY, VL6 FILTER, ORANGE (ST)
7
41.6006.0540
1
EA
ASSY, VL6 FILTER, YELLOW (ST)
8
41.6006.0660
1
EA
ASSY, VL6 FILTER, GREEN (ST)
9
41.6006.0820
1
EA
ASSY, VL6 FILTER, LT.BLUE-GREEN (ST)
10
41.6006.0850
1
EA
ASSY, VL6 FILTER, BLUE (ST)
11
41.6006.0960
1
EA
ASSY, VL6 FILTER, LAVENDER (ST)
12
41.6006.0990
1
EA
ASSY, VL6 FILTER, UV (ST)
10
7
9
1
3
4
8
2
12
6
5
11
Figure 3-20: Filter Wheel Assembly
02.96 76.002 0 A
01-July-2008
73
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Strobe Assembly
22.9676.0016 Rev H
Refer to Figure 3-21.
No.
Item
Qty.
UM.
1
10.9676.0043
1
EA
BULKHEAD, STROBE MOUNTING
2
10.9676.0019
2
EA
STROBE BLADE, DIMPLED
3
10.9676.0060
2
EA
MOUNTING COLLAR, STROBE BLADE
4
10.9676.8061
2
EA
STABLIZER, STROBE MOTOR
5
10.9676.0069
2
EA
MOUNTING PLATE, STROBE MOTOR
6
10.9678.0491
4
EA
BUMPER STOP, STROBE
7
44.9678.0455
2
EA
MOTOR, COLOR
8
53.2200.0006
2
EA
NUT, 6-32 KEPS SS
9
53.5536.0500
4
EA
SCREW, 6-32 X 1/2" PFSS-B
10
53.6525.0001
2
EA
SCREW, 6-32 X 5/16" PPZ
11
53.6528.0001
2
EA
WASHER, #6 FLAT ZINC
12
53.6587.0001
6
EA
SCREW, 4-40 X 1/8" PPZ
13
53.6610.0003
2
EA
SCREW, 6-32 X 7/16" PPZ
14
53.5559.0250
4
EA
SCREW, 6-32 X 1/4" SET CONE POINT
15
53.6682.0002
8
EA
SCREW, 4-40 X 1/4" PPZ SEMS
16
55.6568.0054
2
EA
SPRING, EXTSN 1/2" FL X 1/8" HOOK OPEN
74
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
Strobe Assembly (continued)
10 (x2)
7 (x2)
6 (x4)
9 (x4)
1
13 (x2)
5 (x2)
12 (x6)
16 (x2)
3 (x2)
14 (x4)
11 (x2)
4 (x2)
8 (x2)
15 (x8)
4
Black Side
Note connector
orientation on motors
Figure 3-21: Strobe Assembly
02.96 76.002 0 A
01-July-2008
75
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
UV / IR Window Assembly
22.9676.0140 Rev G
Refer to Figure 3-22.
No.
Item
Qty.
UM.
Description
1
10.9676.0058
1
EA
UV / IR FRAME
2
41.9678.0608
1
EA
UV / IR FILTER, 3.00" X 3.00"
3
53.5504.0187
2
EA
SCREW, 4-40 X 3/16" PPSS
4
55.6569.0001
2
EA
WASHER, #2 LOCK
5
74.1034.0001
1
EA
THERMAL SWITCH, 15 AMP 315 DEG F OPEN
6
10.9676.0141
1
EA
INSULATOR, THERMAL SWITCH (NOT SHOWN)
2
1
5
4
3
Figure 3-22: UV / IR Window Assembly
76
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY
3
VL2500 Main Control Board PCB Assembly
24.9676.3730 Rev 0
Refer to Figure 3-23
Replace as a complete assembly.
Bottom Side
Top Side
Figure 3-23: VL2500 Main Control Board PCB Assembly
02.96 76.002 0 A
01-July-2008
77
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Notes
78
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: YOKE
3
Yoke
Yoke Assembly
21.9676.0600 Rev G
Refer to Figure 3-24.
No.
Item
Qty.
UM.
Description
1
22.9676.8605
1
EA
ASSY, YOKE STRUCTURE
2
22.9676.0609
1
EA
ASSY, FAN
3
22.9676.0610
1
EA
ASSY, TILT MOTOR
4
23.9650.3327
1
EA
ASSY, ELEC., RELAY
5
24.9661.1126
1
EA
PCB ASSY, SOLID STATE IGNITOR
6
25.9676.0030
2
EA
CABLE ASSY, IGNITOR TO RELAY (not shown)
43.0298
2
EA
TOROID CORE ZW-42206-TC (not shown)
7
53.6525.0001
8
EA
SCREW, 6-32 X 5/16" PPZ
8
53.6558.0001
3
EA
SCREW, 6-32 X 3/8" PPZ
9
55.2143.0001
4
EA
STANDOFF, 1/4" HEX 6-32 1.313"
10
55.2150.0002
1
EA
STANDOFF, 1/4" HEX 6-32 1.187" MF
11
55.2201.0001
4
EA
SCREW, 4-40 X 5/16" PFB
12
55.3301.0006
2
EA
WASHER, #6 FLAT SS
13
55.6538.0001
6
EA
WASHER, #6 LOCK INTERNAL TOOTH
14
55.6541.0002
2
EA
GROMMET, 1" ID 1-3/4" OD 1-3/8" GRV DIA RUBBER
15
55.6583.0001
2
EA
STANDOFF, 1/4" HEX 6-32 .500" LG ALUM
02.96 76.002 0 A
01-July-2008
79
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Yoke Assembly (continued)
7 (x4)
13 (x4)
4
7 (x2)
1
15 (x2)
12 (x2)
5
11 (x4)
2
14 (x2)
13 (x2)
9 (x4)
10
7 (x2)
3
8 (x3)
Figure 3-24: Yoke Assembly
80
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: YOKE
3
Ignitor PCB Assembly
24.9661.1126 Rev C
Refer to Figure 3-25.
Replace as a complete assembly.
Figure 3-25: Ignitor PCB Assembly
02.96 76.002 0 A
01-July-2008
81
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Tilt Motor Assembly
22.9676.0610 Rev C
Refer to Figure 3-26.
No.
Item
Qty.
UM.
1
10.9661.7298
1
EA
PLATE, TENSION ADJUST, PAN MOTOR
2
22.9661.0608
1
EA
ASSY, DRIVE PULLEY
- 10.9661.8640
1
EA
CODEWHEEL, 90 COUNT
- 10.9661.0649
1
2
EA
TIMING PULLEY, 2MM GT, 17 TOOTH
EA
SCREW, 6-40 X 1/4" SET CONE POINT
1
EA
ELEC ASSY, PAN EOT SENSOR
- 52.6524.0006
1
EA
CONN, HOUSING 6-POS RECEPTACLE
- 52.8346.0001
4
EA
CONTACT, 24-30 AWG FEMALE CRIMP
- 86.7002.0003
3
-
82
- 53.5561.0250
23.9661.1253
Description
1
EA
SWITCH, SLOTTED OPTICAL
4
24.9661.9629
1
EA
PCB ASSY, PAN/TILT ENCODER
5
44.9678.0680
1
EA
MOTOR, 3-PHASE SZ 23 HIGH TORQUE
6
53.2203.0001
2
EA
SCREW, 4-40 X 1/4" PPZ
7
53.5506.0625
4
EA
SCREW, 6-32 X 5/8 " PPSS
8
55.6512.0001
2
EA
WASHER, #4 SPLIT LOCK
9
53.6520.0001
2
EA
SCREW, 4-40 X 3/8" PPZ
10
55.6621.0001
4
EA
WASHER, #4 FLAT ZINC
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: YOKE
3
Tilt Motor Assembly (continued)
2
6 (x2)
10 (x2)
9 (x2)
3
4
8 (x2)
10 (x2)
1
5
7 (x4)
Figure 3-26: Tilt Motor Assembly
02.96 76.002 0 A
01-July-2008
83
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Pan/Tilt Encoder PCB Assembly
24.9661.9629 Rev B
Refer to Figure 3-27.
Replace as a complete assembly.
Figure 3-27: Pan/Tilt Encoder PCB Assembly
84
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: YOKE
3
Yoke Fan Assembly
22.9676.0609 Rev A
Refer to Figure 3-27.
No.
Item
Qty.
UM.
Description
1
10-9676.0646
1
EA
FAN TRAY, YOKE ARM
2
40.7113.0001
1
EA
FAN, +24V 80 X 80 X 25 MM 32CFM
3
52.6396.2202
1
EA
RECPT, 2POS MTA100 W/ POL TAB RED CLSD END
4
53.2200.0006
4
EA
NUT, 6-32 KEPS SS
Direction of Air Flow
3
2
4
1
Figure 3-28: Yoke Fan Assembly
02.96 76.002 0 A
01-July-2008
85
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
86
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
3
Enclosure
Upper Enclosure Assembly
21.9676.0800 Rev T
Refer to Figures 3-29 and 3-30.
No.
Item
Qty.
UM.
1
04.9640.0374
1
EA
LABEL, P.E. GROUND
2
04.9673.0040
1
EA
LABEL, 2000 SERIES COMPLIANCE
3
04.9661.1218.01
1
EA
LABEL, PATENT, VL2201 & VL2400 SERIES LUMINAIRES
4
10.9661.1258
1
EA
BRACKET, APS SIDE
5
10.9661.1358
1
EA
AIR SEAL, DUCT
6
06.6032.0009
1
EA
CABLE MARKER TIE, 19 X .7
7
10.9678.1874
1
EA
PLENUM, AIR DISTRIBUTION, 700W BALLAST
8
55.6658.0009
1
EA
STANDOFF, 1/4" HEX 6-32 X 3/4"
9
10.9678.0820
1
EA
LANYARD, PAN TUBE
10
10.9678.0839
2
EA
COVER, TOP
11
10.9686.0846
2
EA
HANDLE, CAST
12
10.9678.0869
1
EA
BRACKET, LVS
13
10.9678.0886
1
EA
SPACER, PAN BEARING 0.235" THK
14
10.9678.0892
1
EA
BUSHING, WIRE PROTECTION, PAN TUBE
15
12.9686.1236
2
EA
MACHINED, COVER SIDE
16
12.9686.1238
2
EA
MACHINED, COVER SIDE
17
12.9678.0842
1
EA
DUCT, UPPER ENCLOSURE AIR
18
55.6538.0001
1
EA
WASHER, INTERNAL TOOTH, # 6
19
21.9678.1254
1
EA
ASSY, COVER - VENTILATION
20
21.9678.0767
1
EA
ASSY, STABLIZER
21
21.9676.0805
1
EA
ASSY, CONNECTOR PANEL
22
21.9678.0807
1
EA
ASSY, PAN PULLEY
23
21.9678.0864
1
EA
ASSY, PAN MOTOR
24
21.9678.0880
1
EA
ASSY, PAN TUBE
25
22.9678.0851
1
EA
ASSY, UPPER ENCLOSURE
26
69.9676.0700
1
EA
ASSY, BALLAST MODULE, 700W ARC, SHIELDED
27
23.9678.0686
1
EA
FAN ASSY, UPPER ENCLOSURE
28
23.9678.0687
1
EA
ELEC ASSY, PAN EOT SENSOR
29
25.9661.1514
1
EA
CABLE ASSY, CHASSIS GROUND (not shown)
02.96 76.002 0 A
Description
01-July-2008
87
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
No.
Item
Qty.
UM.
30
25.9661.1520
1
EA
CABLE ASSY, CHASSIS TO YOKE GROUND (not shown)
31
25.9676.0818
1
EA
CABLE ASSY, PAN/TILT CONTROL (not shown)
32
25.9678.0811
1
EA
CABLE ASSY, EMI FILTER TO POWER SWITCH (not shown)
33
25.9678.0812
1
EA
CABLE ASSY, AC INPUT SPLITTER (not shown)
34
25.9678.0813
1
EA
CABLE ASSY, DATA I/O LINK (not shown)
35
25.9678.1825
1
EA
CABLE ASSY, DISPLAY (not shown)
36
25.9678.0816
1
EA
CABLE ASSY, BALLAST TO CONTROLLER (not shown)
37
25.9678.0829
1
EA
CABLE ASSY, LAMP SUPPLY TO RELAY (not shown)
38
25.9678.0821
1
EA
CABLE ASSY, DC OUTPUT (not shown)
39
52.8295.0002
1
EA
TERMINAL STRIP, 300V 12 AWG 20A 2 POS.
40
53.2001.0003
1
EA
NUT, 10-32 NYLON INSERT
41
53.2019.0004
4
EA
NUT, 3/8-16 X 7/32 THK HEX JAM GRDS ZINC PLT
42
53.2200.0006
4
EA
NUT, 6-32 KEPS SS
43
53.6505.0022
3
EA
BOLT, 3/8-16 X 3/4" LG, CARRIAGE GRDS ZINC PLT
44
53.6513.0044
3
EA
SCREW, M5 X 10 MM STL CUP PT
45
53.6515.0001
4
EA
SCREW, 10-32 X 3/4" SCB CAP
46
53.6522.0004
2
EA
SCREW, 6-32 X 1/4" SOC HD CAP BLK
47
53.6525.0188
2
EA
SCREW, 6-32 X 3/16" LG PPZ SEMS
48
53.6530.0023
2
EA
RIVET, 1/8" OD POP .376-.500 GRP DOME HD STL MND
49
53.6539.0001
4
EA
WASHER, 3/8" SPLIT LOCK
50
53.6545.0003
3
EA
SCREW, 8-32 X 3/8" PFZ
51
53.6545.0004
4
EA
SCREW, 8-32 X 3/8" PPZ
52
53.6556.0002
1
EA
SCREW, 4-40 X 3/4" LG PPB
53
53.6558.0009
13
EA
SCREW, 6-32 X 3/8" PPZ SEMS-EXT W/ SHR
54
53.6558.0010
11
EA
SCREW, 6-32 X 1/4" LG PPZ BLK SEMS-EXT W/ SHR
55
53.6558.0015
4
EA
SCREW, 6-32 X 3/8" PPB SEMS
56
53.6571.0003
1
EA
SCREW, 6-32 X 1.5" PPB
57
53.6591.0001
2
EA
SCREW, 6-32 X 1/4" PFZ
58
55.6677.0039
8
EA
WASHER, .438" OD .0219" ID .04 THK
59
53.6522.0001
1
EA
SCREW, 6-32 X 1/4" PPZ
60
53.6609.0001
4
EA
SCREW, 6-32 X 3/8" PFZ
61
53.6626.0001
1
EA
SCREW, 10-32 X 1/2" PPZ
62
53.6634.1000
1
EA
SCREW, 3/8-16 X 1.00" LG SOC HD CAP ALLY STL
63
53.6653.0502
4
EA
SCREW, 1/4-20 X 1/2" LG SOC HD CAP ZINC
64
54.1206.0014
2
EA
RING, RETAINING, 1.375" SHAFT 1.291" DIA GRV X .056" WD
65
54.1255.0001
1
EA
BEARING ASSY, BLACK FLUSH MOUNT HOUSING
66
54.2055.0001
1
EA
BELT, TIMING S2M 210 GRV 9 MM WIDE URTH/KVLR
67
55.2150.0003
2
EA
STANDOFF, 1/4" HEX 6-32 X 1.125" LG FF STL
88
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
No.
Item
Qty.
UM.
68
55.2178.0001
2
EA
CABLE ANCHOR, MOUNT, #8 SCREW MOUNTING
69
55.2179.0001
3
EA
CABLE ANCHOR, MOUNT, #6 SCREW MOUNTING
70
55.6580.0002
2
EA
CABLE TIE, .18" W X 8.00" LG
71
55.2261.0001
1
EA
SLEEVE, NYL, INSUL, #6 SCREW 1.0" LG .015 WALL
72
55.2267.0001
2
EA
RUBBER STRIP, SPONGE CLSD CELL 3/8" W 3/16" TALL
73
55.2178.0001
2
EA
CABLE ANCHOR MOUNT, # 8 SCREW MOUNTING
74
55.6532.0004
2
EA
BRACKET, 6-32 THREADED HOLES (#4334)
75
55.6543.0001
0.146
FT
GROMMET STRIP, SERRATED
76
55.6543.0002
1.08
FT
GROMMET STRIP, SERRATED, 1/8" OPENING
77
55.6549.0001
4
EA
WASHER, 1/4" SPLIT LOCK
78
55.6568.0074
2
EA
SPRING, CPRSN .420" OD .75" LG .055 DIA WIRE
79
55.6677.0044
1
EA
WASHER, .877" OD .170" ID .093" THK FLAT NYL
80
55.6575.0001
4
EA
SCREW, 10-32 X 3/4" PPB
81
55.6577.0005
2
EA
STANDOFF, 1/2" HEX 6-32 1.625" LG NYLON
82
55.6775.0009
1
EA
BUSHING, SNAP .750" ID 1" MT HL NYLON BLK
83
67.4018.0001
1
EA
FERRITE, 26 X 28.5 X 13MM CYL
84
67.4021.0002
1
EA
FILTER, EMI CCI
85
68.9678.0827
1
EA
CHOKE, COMMON MODE
86
69.3177.0151
1
EA
POWER SUPPLY, 150W +24V/6.3A W/ MNT PLT
87
55.6799.0001
A. R.
EA
SHIM, 1.375" ID 1.875" OD .010 THK
88
55.6799.0002
A. R.
EA
SHIM, 1.375" ID 1.875" OD .005 THK
02.96 76.002 0 A
3
Description
01-July-2008
89
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Upper Enclosure Assembly (continued)
9
26
14
45 (x4)
58 (x4)
23
53 (x2)
28
86
44 (x3)
22
78 (x2)
66
41 (x2)
53 (x3)
6
64, 94
65
53
64, 93
49 (x2)
67 (x2)
76
20
82
41 (x2)
49
70, 68
54
83
47
81 (x2)
43 (x2)
42 (x2)
60 (x2)
59
75
7
39
52
85
71
42 (x2)
18
73
8
76 (x4)
12
1
56
79 54 84
70 53 (x3)
48 (x2)
69
54
69
70
69, 70
25
74 (x2)
46 (x2)
50 (x3)
51 (x4)
17
57 (x2)
27
5
13
24
49
62
43
40
61
60 (x2)
Figure 3-29: Upper Enclosure Assembly
90
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
3
Upper Enclosure Assembly (continued)
3
4
72 (x2) 53 (x4)
2
16
15
21
15
16
11 (x2)
55 (x4)
80 (x4)
54 (x4)
10 (x2)
54 (x4)
19
77 (x4)
63 (x4)
Figure 3-30: Upper Enclosure Assembly
02.96 76.002 0 A
01-July-2008
91
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Connector Panel Assembly
21.9676.0805 Rev A
Refer to Figure 3-31.
No.
Item
Qty.
UM.
1
10.9678.0852.01
1
EA
LAYOUT, ENCLOSURE OVERLAY
2
10.9678.0859
1
EA
BRACKET, INPUT
3
24.9663.3895
1
EA
PCB ASSY, DMX INPUT
4
24.9678.3825
1
EA
PCB ASSY, DISPLAY
5
25.9678.0810
1
EA
CABLE ASSY, AC INPUT PIGTAIL
6
51-0541
4
EA
SCREW, 4-X 3/8" H/L BLK ZINC PLT
7
53.6558.0009
2
EA
SCREW, 6-32 X 3/8" PPZ SEMS EXT ZINC PLT
8
55.2284.0001
1
EA
CARD GUIDE, SNAP-IN 3" LONG NYLON NATURAL
9
74.2000.0002
1
EA
SWITCH, ROCKER, 16A 125VAC HORIZ NON-ILLUM
10
10.9678.0872
1
EA
STIFFNER, DISPLAY BOARD (NOT SHOWN)
8
2
Description
1
9
5
7 (x2)
4
3
6 (x4)
Figure 3-31: Connector Panel Assembly
92
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
3
DMX Input PCB Assembly
24.9663.3895 Rev 0
Refer to Figure 3-32
No.
Item
Qty.
UM.
Description
Ref.
1
17.9663.3895
1
EA
PCB ASSY SM, DMX INPUT
-
2
52.6259.0006
1
EA
HEADER, 5POS MTA FRCT LOK STRT
J3
3
52.6625.0006
1
EA
CONN, RECEPT XLR 5PIN FEMALE
J1
4
52.6626.0006
1
EA
CONN, RECEPT XLR 5PIN MALE
J2
5
62.3039.0102
1
EA
CAP, 1000PF 250V 20% CD X-Y
C1
1
5
2
4
3
Figure 3-32: DMX Input PCB Assembly
02.96 76.002 0 A
01-July-2008
93
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
AC Input Pigtail Cable Assembly
25.9678.0810 Rev B
Refer to Figure 3-32
No.
Item
Qty.
UM.
Description
1
52.6274.2313
1
EA
STRAIN RELIEF, SKINTOP FLEXTYPE PG13 BLK
2
52.6401.2321
1
EA
CONN, PLUG "CE MARKED" 20A 250V TWIST LOCK
3
52.8231.0005
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
4
52.8298.1160
2
EA
FERRULE, WIRE 1X16 AWG L2=8MM BLACK
5
55.2268.0187
0.92
FT
HEATSHRINK, 3/16" CLEAR KYNAR 150 DEG C
6
55.2268.0500
0.13
FT
HEATSHRINK, 1/2" CLEAR KYNAR 150 DEG C
7
73.9636.0153
4.00
FT
CORDAGE, 1.5/3 750V 60 DEG C EURO BLK HD22
4
5
2
7
1
6
L
N
GND
3
Figure 3-33: DMX Input PCB Assembly
94
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
3
Pan Tube Assembly
21.9678.0880 Rev C
Refer to Figure 3-34.
No.
Item
Qty.
UM.
Description
1
10.9678.0809
1
EA
PAN TOGGLE STOP
2
10.9678.0847
1
EA
WASHER, SILICONE FOAM
3
10.9678.0848
2
EA
WASHER, PAN TEFLON
4
12.9678.0891
1
EA
PAN TUBE, MACHINED
5
54.1206.0021
1
EA
RING, RETAINING 1.562" SHAFT 1.468" GRV DIA
6
54.1255.0002
1
EA
BEARING ASSY, FLUSH MOUNT HOUSING LARGE
5
6
3
1
3
2
4
Figure 3-34: Pan Tube Assembly
02.96 76.002 0 A
01-July-2008
95
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Pan Motor Assembly
21.9678.0864 Rev E
Refer to Figure 3-35.
No.
Item
Qty.
1
10.9678.0865
1
EA
PLATE, PAN MOTOR MOUNT
2
21.9678.0828
1
EA
ASSY, DRIVE PULLY, PAN
3
24.9678.9729
1
EA
PCB ASSY, VL2203 PAN/TILT ENCODER
4
44.9678.0680
1
EA
MOTOR, 3-PHASE SIZE 23 HIGH TORQUE
5
53.2200.0008
4
EA
NUT, 8-32 KEPS SS
6
53.6546.0001
4
EA
SCREW, 8-32 X 5/8" PPB
7
53.6682.0002
2
EA
SCREW, 4-40 X 1/4" LG PPZ SEMS-EXT
55.2132.0014
2
EA
STANDOFF, 1/4" HEX 4-40 1.062" LG CS
8
UM.
Description
Note orientation of connector
2
7 (x2)
3
8 (x2)
5 (x4)
1
2
6 (x4)
Figure 3-35: Pan Motor Assembly
96
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
3
Upper Enclosure Fan Assembly
23.9678.0686 Rev 0
Refer to Figure 3-35.
No.
Item
Qty.
UM.
1
40.7125.0001
1
EA
FAN, 24V FAL6F24LH
52.8231.0007
2
EA
TERM, SPADE #6 26-24 AWG INS YELLOW
2
Description
1
2 (x2)
Figure 3-36: Upper Enclosure Fan Assembly
02.96 76.002 0 A
01-July-2008
97
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Pan EOT Sensor Electrical Assembly
23.9678.0687 Rev A
Refer to Figure 3-37.
No.
Item
Qty.
UM.
Description
1
52.6524.0006
1
EA
CONN, HOUSING 6 POS. RECEPTACLE
2
52.8346.0001
4
EA
CONTACT, 24-30 AWG FEMALE CRIMP
3
86.7002.0003
1
EA
SWITCH, SLOTTED OPTICAL
3
1, 2 (x4)
Figure 3-37: Pan EOT Sensor Electrical Assembly
98
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE
3
Ballast Module (Arc Power Supply) Assembly
69.9676.0700 Rev 0
Refer to Figure 3-38.
Replace as a complete assembly.
Figure 3-38: Ballast Module (Arc Power Supply) Assy
02.96 76.002 0 A
01-July-2008
99
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Notes
100
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Cables
Ground Strap Cable Assembly
25.8007.2212 Rev 0
Replace as a complete assembly.
Refer to Figure 3-48.
No.
Item
Qty.
UM.
Description
1
2
EA
TERM, RING # 6 22-16 AWG NON-INS
2
0.33
FT
WIRE, 7/64" TUBULAR BRAID SILVER-PLATED
1
1
2
Figure 3-48: Ground Strap Cable Assembly
02.96 76.002 0 A
01-July-2008
101
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
LVS Chassis Ground Cable Assembly
25.9661.1514 Rev A
Replace as a complete assembly.
Refer to Figure 3-49.
No.
Qty.
UM.
1
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
1
EA
FASTON RECEPT, 16-14 AWG (REEL)
3.5
IN
WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569
3
Item
Description
1
3
2
Figure 3-49: LVS Chassis Ground Cable Assembly
102
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Chassis To Yoke Ground Cable Assembly
25.9661.1520 Rev C
Replace as a complete assembly.
Refer to Figure 3-50.
No.
Item
Qty.
UM.
Description
1
2
EA
TERM, #8, RING, 10AWG
2
15.17
FT
WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180
1 (2 pl)
2
Figure 3-50: Chassis To Yoke Ground Cable Assembly
02.96 76.002 0 A
01-July-2008
103
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Yoke To Head Ground Cable Assembly
25.9667.0028 Rev A
Replace as a complete assembly.
Refer to Figure 3-50.
No.
Item
Qty.
UM.
Description
1
2
EA
TERM, #8, RING, 10AWG
2
15.17
FT
WIRE, 22AWG 19X34 MIL-16878/4 TYPE E
1 (2 pl)
2
Figure 3-51: Chassis To Yoke Ground Cable Assembly
104
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Ignitor To Relay Cable Assembly
25.9676.0030 Rev 0
Replace as a complete assembly.
Refer to Figure 3-52.
No.
Item
Qty.
UM.
1
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
2
1
EA
RECP, FASTON 1/4" 18-14 AWG INSULATED VO
1.17
FT
WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING
3
2
Description
1
3
Figure 3-52: Ignitor To Relay Cable Assembly
02.96 76.002 0 A
01-July-2008
105
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Tilt Plate Ground Cable Assembly
25.9667.0413 Rev A
Replace as a complete assembly.
Refer to Figure 3-53.
No.
Item
Qty.
UM.
1
1
EA
TERM, RING #6 BLUE 14-16 AWG NON-INS.
2
0.21
FT
WIRE, 7/64" TUBULAR BRAID SILVER PLATED
1 (x2)
Description
2
Figure 3-53: Tilt Plate Ground Cable Assembly
106
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Color/Gobo T-Stat Cable Assembly
25.9676.0125 Rev B
Replace as a complete assembly.
Refer to Figure 3-54.
No.
Item
Qty.
UM.
Description
1
1
EA
CONN, HOUSING 2POS. PLUG SHROUD
2
2
EA
CONTACT, 24-30 AWG MALE CRIMP
3
1.00
IN
HEATSHRINK, 1/8" CLEAR KYNAR
4
1
EA
THERMOSTAT, 105 DEG C, PCB MOUNT
5
0.50
FT
WIRE, 24 AWG 300V 105 DEG C PVC GRAY
5 (3" long each)
4
1, 2 (x2)
3 (1/2" long each)
Figure 3-54: Color/Gobo T-Stat Cable Assembly
02.96 76.002 0 A
01-July-2008
107
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Color/Fixed Bulkheads Cable Assembly
25.9676.0715 Rev F
Replace as a complete assembly.
Refer to Figure 3-55.
No.
Qty.
UM.
1
1
EA
LABEL SET, VL2500 COLOR HARNESS
2
1
EA
HOUSING, 40 POS DBL ROW UNLOADED
3
1
EA
COVER, FRONT 40 POS MT LATCHING
4
1
EA
COVER, BACK 40 POS MT
5
2
EA
RECEPT, 3 POS MTA100 W/POL TAB BLUE CLOSED END
6
2
EA
COVER, 3 POS CLOSED END STRAIN RELIEF MTA100
7
4
EA
CONN, FEMALE 6 POS 30-24 AWG CRIMP PHR
8
18
EA
CONTACT, SOCKET 30-24 AWG CRIMP (REEL) PH (JST)
4
EA
CONN, RECEPT 6CIR WIRE TO WIRE 1.25 MM PITCH
10
16
EA
CONTACT, 26-28 AWG FEMALE, CRIMP 1.25 MM PITCH (REEL)
11
7
EA
CABLE TIE, .10" X 4" LG SMALL
0.67
FT
SLEEVING, 3/4" NOM. DIA. WOVEN POLY, ROUNDIT 2000
13
2
EA
GROMMET, 9/32" ID, 9/16" OD, 1/4TH SILICONE
14
11.71
FT
WIRE, 26 AWG 4 COND 300V 200 DEG C TEF <BLK-BRN-REDORN> UL1180
15
1.25
FT
WIRE, 26 AWG 3 COND 300V 200 DEG C TEF <BLK-RED-WHT/
BLK> UL1180
16
1.92
FT
WIRE, 26 AWG 3 COND 300V 200 DEG C TEF <BLK-RED-WHT/
GRN> UL1180
17
1.50
FT
WIRE, 28 AWG 6 COND 300V 200 DEG C TEF <BLK-WHT/BLUWHT/YEL-WHT/BLK-WHT/PUR-RED> UL1180
-
40
EA
CONTACT, 26-22 AWG RECP MTE (NOT SHOWN)
9
12
108
Item
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Color/Fixed Bulkheads Cable Assembly (cont.)
14, 7, 8
14, 9, 10 (x4 each)
2, 3, 4
11 (x7)
16, 5, 6
12
1
1
1
1
1
1
1
14, 7, 8
13 (x2)
17, 7, 8
1
15, 5, 6
14, 7, 8
Figure 3-55: Color/Fixed Bulkheads Cable Assembly
02.96 76.002 0 A
01-July-2008
109
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Optics/Strobe Bulkheads Cable Assembly
25.9676.0716 Rev F
Replace as a complete assembly.
Refer to Figure 3-56.
No.
Qty.
UM.
1
1
EA
LABEL SET, VL2500 COLOR HARNESS
2
1
EA
HOUSING, 34 POS 26-22 AWG DBL ROW UNLOADED
3
1
EA
COVER, FRONT 34 POS MT LATCHING
4
1
EA
COVER, BACK 34 POS MT
5
1
EA
CONN, FEMALE 4 POS 30-24 AWG CRIMP PHR
6
2
EA
CONN, FEMALE 6 POS 30-24 AWG CRIMP PHR
7
12
EA
CONTACT, SOCKET 30-24 AWG CRIMP (REEL) PH (JST)
8
2
EA
CONN, HOUSING 4 POS RECEPT
1
EA
CONN, HOUSING 5 POS RECEPT
10
1
EA
CONN, RECEPT 6CIR WIRE TO WIRE 1.25 MM PITCH
11
12
EA
CONTACT, 24-30 AWG FEMALE CRIMP
4
EA
CONTACT, 26-28 AWG FEMALE, CRIMP 1.25 MM PITCH (REEL)
13
0.13
FT
HEATSHRINK, 1/2" BLACK
14
4
EA
CABLE TIE, .10" X 4" LG SMALL
0.92
FT
SLEEVING, 3/4" NOM. DIA. WOVEN POLY, ROUNDIT 2000
16
11.71
FT
WIRE, 26 AWG 4 COND 300V 200 DEG C TEF <BLK-BRN-REDORN> UL1180
17
2.04
FT
WIRE, 26 AWG 4 COND 300V 200 DEG C TEF <BLK-RED-WHTWHT/RED> UL1180
-
34
EA
CONTACT, 26-22 AWG RECP MTE (REEL) (NOT SHOWN)
9
12
15
110
Item
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Optics/Strobe Bulkheads Cable Assy (cont.)
16, 6, 7
16, 10, 12
17, 5, 7
2, 3, 4
1
15
1
1
16, 8, 11
16, 6, 7
14 (x4)
13
16, 9, 11
Figure 3-56: Optics/Strobe Bulkheads Cable Assembly
02.96 76.002 0 A
01-July-2008
111
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Strobe 1 Cable Assembly
25.9676.0717 Rev B
Replace as a complete assembly.
Refer to Figure 3-57.
No.
Item
Qty.
UM.
1
1
EA
LABEL, STROBE 1
2
1
EA
CONN, HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE
3
1
EA
CONN, RECEPT 6CIR WIRE TO WIRE 1.25 MM PITCH
4
4
EA
CONTACT, 24-30 AWG MALE CRIMP
5
4
EA
CONTACT, 26-28 AWG FEMALE, CRIMP 1.25 MM PITCH (REEL)
1
EA
GROMMET, 9/32" ID, 9/16" OD, 1/4TH SILICONE
0.92
FT
WIRE, 26 AWG 4 COND 300V 200 DEG C TEF <BLK-BRN-REDORN> UL1180
6
7
1
3, 5
Description
7
6
2, 4
Figure 3-57: Strobe 1 Cable Assembly
112
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Fans/Disconnect Cable Assembly
25.9676.0718 Rev G
Replace as a complete assembly.
Refer to Figure 3-58.
No.
Item
Qty.
UM.
1
1
EA
RECEPT, 3 POS MTA100 W/ POL TAB 24 AWG
2
1
EA
CONN, HOUSING 2 POS RECEPT
3
1
EA
CONN, HOUSING 5 POS RECEPT
4
2
EA
RECEPT, 1/4" FASTON 22-18 AWG
5
7
EA
CONTACT, 24-30 AWG FEMALE CRIMP
6
1
EA
CABLE TIE, .10" X 4" SMALL
7
2.46
FT
WIRE, 26 AWG 300V 200 DEG C TEFLON RED
8
2.19
FT
WIRE, 26 AWG 300V 200 DEG C TEFLON GRY
9
2.08
FT
WIRE, 26 AWG 300V 200 DEG C TEFLON BLK
-
.92
FT
SLEEVING, 5/16" NOM DIA WOVEN POLY (NOT SHOWN)
1
Description
7, 9 (23.0" each)
6
9 (2.0" Loopback)
8 (7.25")
5, 3
7 (4.5")
7 (2.0" Loopback)
5, 2
8 (19.0")
4 (x2)
Figure 3-58: Fans/Disconnect Cable Assembly
02.96 76.002 0 A
01-July-2008
113
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
OT Switch to Reflector Assy. Cable Assembly
25.9676.0719 Rev A
Replace as a complete assembly.
Refer to Figure 3-59.
No.
Item
Qty.
UM.
1
EA
RECEPT, FASTON 24-22 AWG NON-INSUL 0.016" TAB
110SERIES
2
1
EA
RECEPT, FASTON 24-20 AWG UNINSUL TIN PLT BRS .250 X 0.32
3
0.67
FT
WIRE, 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E
1
Description
2
1
3
Figure 3-59: OT Switch to Reflector Assy. Cable Assembly
114
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Pan/Tilt Control Cable Assembly
25.9676.0818 Rev B
Replace as a complete assembly.
Refer to Figure 3-60.
No.
Item
Qty.
UM.
1
1
EA
HOUSING, 20 POS 26-22 AWG DBL ROW UNLOADED
2
1
EA
COVER, FRONT 20 POS MT LATCHING
3
1
EA
COVER, BACK 20 POS MT
4
2
EA
CONN, HOUSING 5 POS RECEPT
5
2
EA
HOUSING, 7 POS 250V/3A 2.5 MM PITCH
6
6
EA
CONTACT, 28-22 AWG PHOSPHOR BRONZE TIN-PLT
7
10
EA
CONTACT, 24-30 AWG FEMALE CRIMP
8
8
EA
CABLE TIE, .10" X 4" SMALL
9
7.08
FT
WIRE, 24 AWG 3 COND TW 600V 200 DEG C <RED-YEL-BLU>
10
7.17
FT
WIRE, 24 AWG 5 COND 300V 80 DEG C <BLK-BRN-RED-GRY-WHT>
-
16
EA
CONTACT, 26-22 AWG RECP MTE (NOT SHOWN)
02.96 76.002 0 A
Description
01-July-2008
115
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Pan/Tilt Control Cable Assembly (continued)
4, 7 (x5)
1, 2, 3
8 (x7)
6 (x3),5
6 (x3),5
4, 7 (x5)
Figure 3-60: Pan/Tilt Control Cable Assembly
116
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
EMI Filter to Power Switch Cable Assembly
25.9678.0811 Rev C
Replace as a complete assembly.
Refer to Figure 3-61
No.
Item
Qty.
UM.
Description
1
2
EA
RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL)
2
2
EA
RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP
3
1
EA
CABLE TIE, .10"WD 4.00"LG SMALL
4
0.83
FT
WIRE, 16AWG 600V 105C PVC WHT UL1015
5
0.83
FT
WIRE, 16AWG 600V 105C PVC BLK UL1015
2 (x2)
1 (x2)
4
3
White
White
Black
Black
5
Figure 3-61: EMI Filter to Power Switch Cable Assembly
02.96 76.002 0 A
01-July-2008
117
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
AC Input Splitter Cable Assembly
25.9678.0812 Rev E
Replace as a complete assembly.
Refer to Figure 3-62
No.
Qty.
UM.
1
1
EA
PLUG HOUSING, MNLOK PLUG 3POS
2
1
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
3
2
EA
TERM, SPADE #6 RED 22-16AWG INSERT
4
2
EA
RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP
5
2
EA
CONTACT PIN, 20-14AWG MNLOK (REEL)
6
1
EA
PIN, GND 20-14AWG MNLOK .060"- .130"INS DIA
7
3
EA
CABLE TIE, .10"WD 4.00"LG SMALL
8
1.50
FT
SLEEVING, 1/2"NOM.DIA. POLY EXP BRAIDED
9
1.83
FT
WIRE, 16AWG 600V 105C PVC WHT UL1015
10
1.83
FT
WIRE, 16AWG 600V 105C PVC BLK UL1015
11
2.08
FT
WIRE, 16AWG 600V 105C PVC GRN/YEL UL1015
12
1.00
FT
WIRE, 18AWG 600V 105C PVC WHT UL1015
13
1.00
FT
WIRE, 18AWG 600V 105C PVC BLK UL1015
118
Item
Description
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
AC Input Splitter Cable Assembly (continued)
4 (x2)
2 (x2)
12
3
5, 9
13
5, 10
11, 6
1
7 (x3)
8
Figure 3-62: AC Input Splitter Cable Assembly
02.96 76.002 0 A
01-July-2008
119
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Data I/O Link Cable Assembly
25.9678.0813 Rev A
Replace as a complete assembly.
Refer to Figure 3-63
No.
Item
Qty.
UM.
Description
1
1
EA
RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END
2
1
EA
RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END
3
2.17
FT
CBL, 22AWG STRND 4COND PVC INSUL
2
1
3
Figure 3-63: Data I/O Link Cable Assembly
120
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Display Cable Assembly
25.9678.1825 Rev 0
Replace as a complete assembly.
Refer to Figure 3-64
No.
Item
Qty.
UM.
Description
1
2
EA
RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END
2
4
EA
CABLE TIE, 0.10" WD 4" LG SMALL
3
1
EA
SLEEVE, NYLON THIN WALL #6 SCR 1.0" LG
4
0.208
FT
SLEEVING, 3/8" NOM DIA POLY EXP
5
1.02
FT
WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN>
6
0.208
FT
WIRE, 24 AWG 600V 200 DEG C TFE GRN
7
0.958
FT
WIRE, TUBULAR BRAID, 1/8" X 23" LG
1 (x2)
2
3
2
4
7
2
5
6
Figure 3-64: Display Cable Assembly
02.96 76.002 0 A
01-July-2008
121
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
Ballast to Controller Cable Assembly
25.9678.0816 Rev A
Replace as a complete assembly.
Refer to Figure 3-65
No.
Item
Qty.
UM.
Description
1
1
EA
RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END
2
1
EA
RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END
3
1
EA
RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END
4
3.67
FT
WIRE, 24AWG 5COND <BLK-BRN-RED-GRN-WHT>
2
3
4
1
Figure 3-65: Ballast to Controller Cable Assembly
122
01-July-2008
02 .9 676 .00 20 A
ILLUSTRATED PARTS BREAKDOWN: CABLES
3
Lamp Supply to Relay Cable Assembly
25.9678.0829 Rev A
Replace as a complete assembly.
Refer to Figure 3-66
No.
Item
Qty.
UM.
Description
1
4
EA
RECP, FASTON 1/4" 18-14 AWG INSULATED VO
2
3
EA
CABLE TIE, .10"WD 4.00"LG SMALL
3
3.19
FT
SLEEVING, 1/2" NOM. DIA POLY EXP BRAIDED
4
34.41
FT
WIRE, 22AWG BLK 300V TEFLON STRANDED
5
34.41
FT
WIRE, 22AWG WHT 300V TEFLON STRANDED
6
.58
FT
WIRE, 16AWG 300V 105C PVC GRN/YEL UL1569
7
1
EA
TERM, RING #10 16-14 AWG REEL PIDG
8
2.08
FT
WIRE, TUBULAR BRAID, 7/16"
9
.33
FT
HEATSHRINK, 1/2" BLACK
7
5 (x7)
1 (x2)
6
8
1 (x2)
9
To Relay
From Lamp Supply
3
2 (x3)
4 (x7)
Figure 3-66: Lamp Supply to Relay Cable Assembly
02.96 76.002 0 A
01-July-2008
123
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
DC Output Cable Assembly
25.9678.0821 Rev E
Replace as a complete assembly.
Refer to Figure 3-67
No.
Item
Qty.
UM.
Description
1
1
EA
CONN, HOUSING, SL-156 2 POS
2
1
EA
CONN, HOUSING, SL-156 3 POS
3
2
EA
TERM, RING #6 BLUE 12-10 AWG INSRT
4
4
EA
CONTACT, CRIMP, 18-22 AWG SL-156
5
2
EA
CONN BUTT SPLICE 16-14 BLUE .150" OD MAX
6
4
EA
CABLE TIE, .01" x 4.00" SMALL
7
2.08
FT
SLEEVING, 1/2" NOM DIA POLY EXP BRAID
8
1.58
FT
WIRE, 18 AWG 300V 105C PVC RED
9
1.58
FT
WIRE, 18 AWG 300V 105C PVC BLK
10
2.08
FT
WIRE, 18 AWG HI VOLT RED YOKE LMP
11
2.08
FT
WIRE, 18 AWG HI VOLT BLK YOKE LMP
6
6
8
3
4 (x2), 1
6
11
9
4 (x2), 2
8
9
6
5
10
7
Figure 3-67: DC Output Cable Assembly
124
01-July-2008
02 .9 676 .00 20 A
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL2500™ Spot Luminaire Schematics
VL2500 Luminaire Wiring Diagram
02.96 76.002 0 A
01-July-2008
125
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL2500 Luminaire Wiring Diagram (continued)
02.96 76.002 0 A
01-July-2008
126
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
VL2500 Luminaire Wiring Diagram (continued)
02.96 76.002 0 A
01-July-2008
127
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic
8
7
6
5
4
3
2
1
REV. NO
NOTES: UNLESS OTHERWISE SPECIFIED
ECO #
DESCRIPTION
APPROVED
DATE
A0
NONE
ENG RELEASE
4/16/04
A1
NONE
CHANGED VALUES ON VR1 AND VR4
4/27/04
A2
NONE
CHANGED VALUES ON RES- SHT 2
5/11/04
1.) ALL CAPACITOR VALUES ARE IN MICROFARADS.
B0
S04-
2.) ALL RESISTOR VALUES ARE IN OHMS.
CHANGED NETS & TEST PTS NAMES
U6-5 NOW ISO GND/U21-9 NOW NC
3.) PAGE 9 OF 10 HAS NO PARTS - MAY USE AT A LATER TIME.
D
D
VR2
+24V
FB
4
Out
2
Gnd
VCC
L2
TAB
On/Off
C3
3
+
Vin
5
+
D2
C6
+
C5
6
C4
+
1
VCC
VCC
C
C
VR1
+24V
Vin
5
On/Off
FB
4
Out
2
+3.3V
TAB
1
C2
+
C8
+
+24V
C7
D1
+24V
6
+
Gnd
C1
3
+
L1
+3.3V
+3.3V
+2.5V
+3.3V
+2.5V
R14
+2.5V
Vout
4
1
SD
Sense
5
CONNECT SENSE AT LOAD
+1.8V
C15
TAB
+
+1.8V
6
C14
GND
VIN
3
+
VR3
2
B
B
GND
+3.3V
R15
VR4
SD
+1.8V
Vout
4
Sense
5
CONNECT SENSE AT LOAD
+
C17
TAB
C16
3
+
VIN
6
1
GND
2
A
A
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
3
2
SCHEMATIC VL2500 CONTROLLER
Rev
Document Number
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
1
OF
10
1
128
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
7
6
5
4
3
2
1
+3.3V
+1.8V
+1.8V
+1.8V
+1.8V
D[0..3 1]
R52
C69
C51
C44
C45
A[0 ..24]
CS_MTR-
C46
2/B4,3/A6
CS_UART-
+1.8V
+1.8V
+1.8V
CS_FLASH-
C68
C67
C48
C49
2/B4,3/A6
R51
+1.8V
C47
2/C4,2/C4
TIN1
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
+3.3V
C27
+3.3V
C26
C55
C54
+3.3V
C18
C77
+3.3V
C25
+3.3V
C52
C53
+3.3V
C50
2/A5
R29
+3.3V
DSI
C66
2/B4,2/B7
R38
BKPT-
2/B4,2/B7
R37
DSCLK
2/B4,2/B7
R56
TA-
2/C5,2/B7,3/D6
R54
AS-
2/C5
R55
R/W-
RSTI2/C4, 2/B5, 2/B8, 2/C6
VCC
1
5VIN
2
5VRST
3
5VTOL
4
GND
2/C4,2/C4,3/A6
R58
IRQ7-
+3.3V
U9
2/C5
R59
3.3VIN
8
3.3VRST
7
3.3VTOL
6
PBRST
5
RX_INT-
2/C5,3/C3
R60
TX_INT-
2/C5,3/C3
R61
IRQ1-
2/B5
C
R57
RSTI-
S1
A0
2
A0
D1
A1
3
A1
A1
25
A0
DQ0
29
D16
144
D2
A2
5
A2
A2
24
A1
DQ1
31
D17
D3
A3
6
A2
DQ2
33
143
142
140
139
D7
HIZ-
C43
C21
D0
146
D6
2/B5
R36
C28
147
D2
D5
R63
D
138
2/C6
J6
TCK
1
3
5
7
9
11
13
15
17
19
21
23
25
RSTI-
PST6
PST4
PST2
PST0
2
4
6
8
10
12
14
16
18
20
22
24
26
BKPTDSCLK
2/D6, 2/B4
2/B4, 2/C6
DSI
DSO
PST7
PST5
PST3
PST1
2/D6,2/B4
2/B4
2/A4
2/A4
2/A4
2/A4
A8
18
A7
A9
8
A8
A 10
7
A9
A10
A8
14
A9
15
A9
D10
A10
16
A 10
D11
A11
18
A 11
A 11
6
D12
A12
19
A 12
A 12
5
132
131
DQ0
2
D0
A1
DQ1
4
D1
25
A2
DQ2
5
D2
A 12
26
A3
DQ3
7
D3
A 11
29
A4
DQ4
8
D4
A 10
30
A5
DQ5
10
D5
A9
31
A6
DQ6
11
D6
A 17
32
A7
DQ7
13
D7
A 18
33
A8
DQ8
42
A 19
34
A9
DQ9
44
D9
A 20
22
A10
DQ10
45
D10
A 21
35
A11
DQ11
47
D11
A 24
36
NC/A12
DQ12
48
D12
DQ13
50
D13
DQ14
51
D14
BA0
DQ15
53
D15
D18
D19
D20
D21
A5
DQ5
40
A6
DQ6
42
D22
DQ7
44
D23
DQ8
30
D24
DQ9
32
D25
DQ10
34
D26
A11
DQ11
36
D27
130
D13
A13
20
A 13
A 13
4
A12
DQ12
39
D28
128
D14
A14
22
A 14
A 14
3
A13
DQ13
41
D29
D15
127
D15
A15
23
A 15
A 15
2
A14
DQ14
43
D30
A 22
20
D16
126
D16
A16
24
A 16
A 16
1
A15
A-1/DQ15
45
D31
A 23
21
BA1
D17
124
D17
A17
26
A 17
A 17
48
A16
NC4
14
D18
123
D18
A18
27
A 18
A 18
17
A17
NC5
16
D19
122
D19
A19
28
A 19
D20
120
D20
A20
30
A 20
D21
119
D21
A21
31
A 21
D22
118
D22
A22
32
A 22
D23
116
D23
A23
34
A 23
D24
115
D24
A24/PP8
35
A 24
D25
114
D25
A25/PP9
36
D26
112
D26
A26/PP10
38
DCLK
D27
111
D27
A27/PP11
39
DATA
2/D6,2/C4
2/B4
2/C6
2/C4,2/C6,3/A6
INIT_DONE
110
D28
A28/PP12
40
D29
108
D29
A29/PP13
42
D30
107
D30
A30/PP14
43
D31
106
D31
A31/PP15
44
CONFIG-
TT0/PP0
207
LAMP_STBY
CONF_DONE
STATUS-
74
BR
76
BG
75
BD
66
TS
CE-
VCC
37
2/B2,2/B3
DRAMW-
16
WE
28
OE-
NC1
9
A 20
2/B2,2/B3
SRAS-
18
RAS
11
WE-
NC2
10
A 21
2/B2,2/B3
SCAS-
17
CAS
12
RESET-
15
RY/BY-
2/B2,2/B4
CLK_EN
37
CKE
CLK1
38
RSTI-
BYTE-
NC3
13
GND1
27
GND2
46
+3.3V
203
46
47
IRQ7
CS0
50
TA
PSTCLK
TA-
IRQ7-
68
CS1
51
IRQ3/6
CS2
54
IRQ1/2
CS3
55
2/A4
2/A4
TIN0
2/A6
NC
CLK
1
V3.3_1
14
V3.3_2
27
V3.3_3
R30
+24V
40
V3.3_Q1
3
V3.3_Q2
9
V3.3_Q3
43
V3.3_Q4
49
GNDQ1
6
28
GND1
GNDQ2
12
PLL MULT = 4X
41
GND2
GNDQ3
46
CLK IN =
54
GND3
GNDQ4
52
D0
+3.3V
+2.5V
+2.5V
C
+1.8V
25-40.5MHz
R32
D2
+1.8V
R34
2/A4
BE = R/W
D3
2/C4,2/C6,3/A6
R39
D4
TIN1
PAR PORT
GND
CS4
CS5
58
200
DREGQ1/PP5
CS6
59
CS_MTR-
CS7
60
CS_UART-
OE
49
OE-
79
TOUT0
BE0
96
82
TIN1
BE1
98
BE2
99
BE3
100
166
TXD1
RAS0
83
UART_IN
165
RXD1
RAS1
84
TX_EN_B-
164
RTS1
CAS0
86
CAS0-
163
CTS1
CAS1
87
CAS1CAS2-
161
CAS2
88
TXDB
TXD2
CAS3-
160
CAS3
90
RXDB
RXD2
103
SCL
6
2/D6
RSTI-
67
EDGESEL
168
176
E2
WC-
7
177
181
182
VCC
DQ0
2
D16
A1
DQ1
4
D17
A 13
25
A2
DQ2
5
D18
A 12
26
A3
DQ3
7
D19
2/D6,3/A6
A 11
29
A4
DQ4
8
D20
2/D6,3/A6
A 10
30
A5
DQ5
10
D21
A9
31
A6
DQ6
11
D22
2/C4
SCAS
94
S _CAS-
SCKE
95
CLK_EN
DRAMW
91
SDA
32
A7
DQ7
13
D23
A8
DQ8
42
D24
D25
A 18
33
A 19
34
A9
DQ9
44
R64
A 20
22
A10
DQ10
45
D26
A 21
35
A11
DQ11
47
D27
A 24
36
NC/A12
DQ12
48
D28
DQ13
50
D29
DQ14
51
D30
DQ15
53
D31
RAS0-
2/B2,2/C2
2/B2
2/B2
R66
A 22
SRAS-
2/C2
2/B2,2/C2
SCAS-
2/B2,2/C2
2/B2,2/C2
R65
DRAMW-
D RAMWR-
2/B2,2/C2
SCL
2/D6
+3.3V
HIZ-
155
R70
4
3
1
VCC
REF
2
4
+3.3V
A
CLKOUT
8
C LK0
174
CLK1
3
CLK1
180
2/C2
CLK2
2
CLK2
2/B2
CLK3
5
CLK3
3/A6
CLK4
7
GND
+1.8V
178
FB1
+ C242
8
VCC
NC
1
SDA_OUT
6
SDA1
SDA0
3
SCL_OUT
7
SCL1
SCL0
2
EN
5
RSTO-
154
BKPT-
DS0/TD0
151
DSO
DS1/TD1
153
DSI
DSCLK/TRST
149
DSCLK
TCK
150
TCK
PST/CLK
184
PSTCLK
PSTDDATA0
186
PST0
PSTDDATA1
187
PST1
PSTDDATA2
189
PST2
PSTDDATA3
190
PST3
PSTDDATA4
192
PST4
PSTDDATA5
193
PST5
PSTDDATA6
195
PST6
PSTDDATA7
196
PST7
MTMOD2
MTMOD3
HIZ
CLKIN
PVDD
PGND
D1
D2
D3
D4
D5
D6
A1
D8
A2
D9
A4
D11
A5
BA0
BA1
D13
19
CS
D14
CAS1-
15
DQML
D15
CAS0-
39
DQMH
D16
2/B2,2/B3
DRAMW-
16
WE
2/B2,2/B3
SRAS-
18
RAS
D18
2/B2,2/B3
SCAS-
17
CAS
D19
RAS0-
2/B4
2/B4
2/B2,2/B4
3/A6
2/A6
2/D6,2/B7
2/B7
CLK_EN
37
CKE
CLK2
38
CLK
D12
A6
2/C4
2/B7,2/C6
1
MTR_ENABLE-
A9
A10
NC
40
D17
A11
A12
A13
D20
2/B8
2/B7
V3.3_2
27
V3.3_3
28
2/B8
+3.3V
2/B7
R297
2/B8
1
4
2/B7
GND1
A14
D21
A15
V3.3_Q1
3
D22
V3.3_Q2
9
D23
V3.3_Q3
43
D24
V3.3_Q4
49
D25
GNDQ1
6
D27
GNDQ2
12
D28
D29
D30
V3.3_1
14
A7
A8
+3.3V
2/D6,2/B7
B
A3
D10
21
2/B2,2/B3
A0
D7
+3.3V
BKP/TMS
MTMOD1
C19
U23
172
MTMOD0
R69
+3.3V
RSTO
EDGESEL
U12
6
1
170
RSTI
+3.3V
Y1
BCLKO
D0
20
A 23
2/C2
S _RAS-
92
A 17
PLACE RESISTORS CLOSE TO MICROPROCESSOR
R AS_0-
SRAS
CTS2
R71
GND
A0
24
S DA
5
2/C4,2/C7,2/B8,2/C6
SCL
102
23
A 14
R67
RTS2
U14
A 15
AUTO ACK
D7
DREGQ0/PP6
TOUT1
R41
D6
199
TIN0
16 BIT BUS
2/D6,2/C4
R42
UART_OUT_B
SCL
SDA
CS_FLASH-
56
80
S DA
U22
A16
A17
A18
A19
D26
A20
A21
A22
41
GND2
GNDQ3
46
54
GND3
GNDQ4
52
A23
A24
D31
MTR_EN-
5/C2,6/C8,7/C8,8/C8
2
2/B8
U45
2/B7
A
2/B8
2/B7
V1.8 PINS: 1,57,73,105,152,
157,171,175,185,197
R298
R68
V3.3 PINS: 7,13,21,29,37,45,
52,65,81,89,97,113,121,129,
137,145,167,191,205
DRAWN BY :
FAE
FB2
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
GND PINS: 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
PROJECT ENGR. :
DO NOT
STUFF
DOC. CONTROL :
Title
Size
SCHEMATIC VL2500 CONTROLLER
Document Number
D
COP YRIGHT 2004
D ate:
02.96 76.002 0 A
VCC
R40
IRQ5/4
+3.3V
8
VCC
+3.3V
D1
TM2/PP4
D8
+3.3V
R31
TM1/PP3
D
+24V
+3.3V
3/C7,3/B3
PP2
SIZ1
64
DQMH
26
10/C2
PP1
SIZ0
AS
TA-
39
OE-
3/A2,3/C7,3/B3
1
R/W-
CAS2-
3/A2,3/B7,3/B3
1
MTR_ENABLE-
DQML
2/B4
3/B3
204
63
CS
15
3/A2,3/B3
206
202
19
CAS3-
3/C7,3/A2,3/A3
TT1/PP1
R/W
62
RAS0-
2/B4
R/W-
+3.3V
TM0/PP2
TIP/PP7
AS-
2/B2,2/B3
A 19
CS_FLASH-
47
D28
158
4
A0
24
A 13
D14
159
10/D2
23
A 14
D13
72
4/D8
10/D2
19
D9
71
4/D8
VSS
A7
A8
70
4/D5
4
A7
D8
D12
38
12
134
D11
DQ4
A7
RX_INT-
4/C5
3
20
A4
D7
IRQ1-
3/D6,4/C5
E1
A6
35
11
TX_INT-
2/C6
B
E0
A6
21
135
78
2
A5
DQ3
A6
2/C6,3/C3
2/D6
1
A5
A3
D6
2/C6,3/C3
2/D6
VCC
9
22
A 15
D5
+3.3V
8
A5
A4
136
2/B5
2/C6
2/A4
2/A4
2/A4
2/A4
D5
A4
2/C4,2/B5,2/C7,2/B8
2/B7,2/C6,3/D6
2/B4
8
23
D9
198
2/C4, 2/B5, 2/B7, 2/C6
A4
A3
D10
R299
R35
D4
A3
D8
R33
EDGESEL
U18
D1
D4
2/B5
U24
D0
D3
R62
TIN0
2/C3,3/D6,3/A3
U17
R53
+1.8V
3/B3,3/A3
+1.8V
7
6
5
01-July-2008
4
3
2
Rev
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
2
OF
10
1
129
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
+3.3V
A4
12
A3
13
D
+2.5V
+2.5V
+2.5V
2/B5,4/C5
+2.5V
UART_IN
LED_TX-
4/D6
C36
C56
C42
C63
C60
LED_RX-
C35
4/D6
LED_STATUS
4/D6
LAMP_ON4/C7
LAMP_CNTL
4/C7
PWM_OUT_2
7/C5
PWM_OUT_23
8/D5
+3.3V
PWM_OUT_3
7/B5
PWM_OUT_13
6/B5
R22
PWM_OUT_5
STATUS-
5/C4
PWM_PH_5
2/C4,3/A2,3/B3
5/C2
PWM_PH_13
6/B3
PWM_PH_6
R43
5/C2
CONFIG-
PWM_PH_14
2/C4,3/B3
6/B3
PWM_OUT_6
5/B4
PWM_OUT_14
6/B5
R50
PWM_PH_9
DCLK
6/B7
2/C4,3/A2,3/A3
PWM_OUT_9
6/B8
PWM_OUT_18
7/B8
C
PWM_OUT_21
R27
8/B8
CONF_DONE
PWM_OUT_17
7/B8
2/C4,3/A2,3/B3
PWM_OUT_20
8/C8
PWM_OUT_16
7/D7
R23
PWM_OUT_8
TMSA
6/D7
3/B3
PWM_PH_16
7/D7
PWM_PH_8
6/D7
PWM_PH_19
R48
8/D7
TDIA
PWM_PH_15
3/B3
7/D7
PWM_PH_7
6/D7
PWM_OUT_19
8/D8
R46
PWM_OUT_7
MSEL0
6/D8
PWM_OUT_15
3/B3
7/D8
SPARE_1
10/B4
SPARE_2
R45
10/B4
MSEL1
3/B3
CE3/B3
PWM_OUT_24
R28
8/C5
TCKA
PWM_PH_24
8/D4
3/A3
PWM_PH_23
8/D4
PWM_OUT_4
7/B5
R47
PWM_PH_4
7/B3
INSTALL ONLY WITH EPC1
R44
CYAN_IN
4/A8
4/A8
DIMMER_IN
AMB_IN
4/A8
FXDG_IN
4/A8
OPT_IN
4/A8
PWM3_EN_1
5/C8
PWM3_OUT_2
5/C8
MAG_IN
4/A8
FXDC_IN
4/A8
RSTO2/B4
2/C4,2/C4,2/C6
2/B4,2/D6
2/D6,2/B4
R/WCS_MTRCS_UARTCLK3
A
201
130
185
124
106
91
72
48
33
21
152
VCINT9
VCINT8
VCINT7
VCINT6
VCINT5
VCINT4
VCINT3
VCINT1
VCINT2
194
165
146
138
118
110
98
84
178
VCIO14
VCIO13
VCIO12
VCIO11
VCIO10
VCIO9
VCIO8
VCIO7
66
42
77
IO82
132
133
134
17
IO9
IO85
135
18
IO10
IO86
136
24
IO11
IO87
139
25
IO12
IO88
140
26
IO13
IO89
141
27
IO14
IO90
142
IO91
143
28
29
30
31
36
IO15
IO16
IO17
IO18
IO19
IO92
144
IO93
147
IO94
148
IO95
149
37
IO20
IO96
150
38
IO21
IO97
160
39
IO22
IO98
163
40
IO23
IO99
167
41
IO24
IO100
168
44
IO25
IO101
169
45
IO26
IO102
170
46
IO27
IO103
172
47
IO28
IO104
173
53
IO29
IO105
174
IO106
175
54
55
56
IO30
IO31
IO32
IO107
176
IO108
177
PWM3_OUT_1
PHASE_B_2
RGOBO_OUT_IN
PWM3_OUT_5
PWM_PH_3
PHASE_A_1
PHASE_A_2
PWM_OUT_10
PWM_PH_25
D29
D30
7/D3
PWM_OUT_12
6/C5
RX_INT2/C5,2/C6
2/C5,2/C6
D29
193
D28
195
D27
68
IO41
IO117
196
D26
69
IO42
IO118
197
D25
D24
70
IO43
IO119
198
71
IO44
IO120
199
D23
73
IO45
IO121
200
D22
74
IO46
IO122
202
D21
75
IO47
IO123
203
83
IO48
IO124
205
85
IO49
86
IO50
87
IO51
88
IO52
89
IO53
IO59
IO60
IO61
108
MSEL1
107
IO62
101
IO63
102
IO64
CONFIG
CONFIG_DONE
INIT_DONE
103
IO65
104
IO66
CE
CE0
111
IO67
112
IO68
113
IO69
TDI
IO71
116
IO72
119
IO73
120
IO74
121
IO75
122
IO76
52
105
2
19
154
153
TD0
4
50
TRST
51
2/D1,3/A3
+3.3V
8/D7
PWM_OUT_1
7/D5
PWM_OUT_25
8/B5
+2.5V
PWM_OUT_22
8/B8
PWM_PH_22
8/B7
PWM_PH_10
+2.5V
6/B7
PWM_PH_21
8/B7
PWM_PH_17
B
7/B7
DATA
2/C4,3/A2
MSEL0
3/B7
MSEL1
+1.8V
3/B7
2/C4,3/A2,3/C7
CONFIG2/C4,3/C7
CONF_DONE
2/C4,3/A2,3/B7
INIT_DONE
+3.3V
2/C4
CE-
DATA
3/B7
2/C4,3/B3
DCLK
2/C4,3/C7,3/A3
TDIA
STATUS3/B7
D17
208
D16
16
CLKUSR
10
IN2
TCLK
IN3
DEV_CLR
155
180
IN4
DEV_OE
186
1
CONF_DONE
2/C4,3/C7,3/B3
DATA
VCC2
8
2
DCLK
VCC1
7
3
OE
CASC
6
4
CS
GND
5
3/B7
D19
RDY/BUSY
2/C4,3/C7,3/B3
+3.3V
GND
U15
1
TMSA
207
DCLK
DO NOT STUFF
STATUS-
204
IN1
CLK2
D[0..3 1]
206
80
183
D18
CS
78
CLK1
+3.3V
D20
RS
CS-
79
+24V
PWM_PH_20
WS
182
184
+24V
3
TMS
IO70
115
VCC
+1.8V
STATUS
100
114
MSEL0
VCC
TX_INT-
192
99
C
8/B5
IO116
97
D31
8/B4
PWM_OUT_26
IO40
96
D27
PWM_PH_26
67
156
D26
D28
191
DATA
D[0..3 1]
SOCKET IS XU15
2/D1,3/B3
A[0 ..24]
A0
2/D4,2/C3,3/D6
A6
DCLK
2/C4,3/C7,3/A2
TCKA
3/B7
TA2/C5,2/B7,2/C6
A
DRAWN BY :
188
181
171
151
145
137
129
123
117
109
82
76
59
49
43
35
32
23
20
6
81
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
D24
PWM_PH_2
IO115
IO58
D23
A24
D25
IO114
IO57
D22
A23
6/D3
IO113
95
D21
A22
6/D3
IO39
94
D20
A21
PWM_PH_12
IO38
157
D19
A20
PWM_PH_11
IO37
158
D18
A19
7/D3
65
DATA1/IO132
D17
A18
8/B4
64
DATA2/IO131
D16
A17
PWM_PH_1
63
DATA3/IO130
D15
A16
6/D3
D30
IO56
D14
A15
6/B8
PWM_OUT_11
D31
IO55
D13
A14
7/B7
190
93
D12
A13
4/B8
PWM_PH_18
189
92
D11
A12
4/B8
187
159
D10
A11
4/B8
P_COT_IN
IO112
IO54
A10
D
4/B8
PHASE_B_1
IO111
161
D9
7/B3
IO110
162
D8
A9
5/B8
IO36
164
D7
A8
5/B8
PWM3_EN_2
IO35
DATA4/IO129
D6
A7
5/B8
IO34
DATA5/IO128
D5
A6
5/B8
PWM3_OUT_4
61
DATA6/IO127
D4
A5
5/C8
PWM3_OUT_6
60
90
D3
A4
4/B8
PWM3_OUT_3
58
62
D2
A3
4/B8
179
166
D1
A2
4/B8
IO109
LOCK/IO125
D0
A1
5/D8
T_COT_IN
IO33
DATA7/IO126
A0
4/B8
57
GND_CLK
2/A6
131
IO84
R49
B
1
IDX_OUT_IN
GND20
+2.5V
IO81
IO83
GND19
+2.5V
IO80
128
IO8
GND18
UART_OUT_A
4/C5
127
IO7
GND17
TX_EN_A4/D5
IO79
15
GND16
4/D5
IO78
126
14
GND15
C59
125
A1
GND14
C30
TX_EN_C-
IO77
A2
GND13
C32
+2.5V
GND12
C40
+2.5V
IO6
GND11
C34
+2.5V
U16
GND10
C37
+2.5V
IO5
GND9
+2.5V
IO4
GND8
+2.5V
IO3
VCC_CLK
11
VCINT11
9
A5
IO2
VCINT10
A7
IO1
VCIO6
8
GND7
C39
7
A8
GND6
C33
A9
GND5
C58
+3.3V
GND4
C38
+3.3V
GND3
C64
+3.3V
GND2
C65
+3.3V
2
+2.5V
+3.3V
VCIO5
+3.3V
3
A[0 ..24]
VCIO1
+3.3V
4
C61
GND1
C29
34
+3.3V
C31
22
+3.3V
C57
5
C62
VCIO4
+3.3V
2/D4,2/C3,3/A3
C41
5
VCIO3
+3.3V
6
VCIO2
+3.3V
7
5
01-July-2008
4
3
2
SCHEMATIC VL2500 CONTROLLER
Rev
Document Number
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
3
OF
10
1
130
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
7
6
5
4
3
2
1
DO NOT STUFF ON ASSY.
VCC
VCC
+24V
C24
C2TX1
RXD1
9
RXD2
1
NC1
VCC
8
2
AN1
BIAS
7
R17
TX_EN_C-
9
8
3
K1
OUT
6
4
NC2
GND
5
10
J7
7
TXD2
RX1
13
RX2
8
D7
POWER
LED_TX-
1
2
3
14
TXD1
ISO_VCC
ISO_VCC
R8
U6
D
8
U10C
RX
TX2
12
ISO_VCC
C12
R9
2
3
RE
DE
4
D
VCC
6
LED_RX-
D3
B
A
7
6
R
1
VCC
ISO_VCC
U1
R13
1
VCC
LED_STATUS
1
VIN+
VOUT+
4
2
VIN-
VOUT-
3
C20
1
R19
STATUS
15
2/B5
V-
VCC
U5
D6
ISO
C2+
5
11
10
RXDB
2
5
TXDB
V+
C1-
4
R16
R12
TX
GND
3
C1+
VCC
U13
1
16
C23
D
2/B5
+3.3V
R11
VCC
C22
VCC
ISO_VCC
U3
D8
U10D
VCC
3
TX_EN_A-
D4
R18
NC1
VCC
8
2
AN1
BIAS
7
3
K1
OUT
6
4
NC2
GND
5
12
11
TX_EN_B-
C11
1
13
2
VCC
1
ISO_VCC
VCC
R3
+24V
1
1
+24V
U8
LAMP_CNTL
3/C6
2
R10
VCC
LAMP_CNTL_OUT
4
ISO_VCC
+3.3V
U7
U10A
UART_OUT_A
VCC
3
ISO_VCC
10/D2
R24
UART_OUT_B
D5
C13
U10B
R20
1
3
1
NC1
VCC
8
2
AN1
BIAS
7
3
K1
OUT
6
4
NC2
GND
5
4
2
6
5
R5
R2
U4
2
1
VCC
NC1
4
DE
Y
9
5
D
Z
10
2
R
A
12
CI+
3
REB
11
CI-
6
GND1
NC2
7
GND2
VCC2
VCC1
VCC
R25
ISO_VCC
VCC
R26
LAMP_ON-
LAMP_ON_IN-
10/D2
R21
3/C6
B
14
COMOUT+
10/C2
VCC
NC1
7
BIAS
AN1
2
6
OUT
K1
3
5
GND
NC2
4
10/C2
PHASE_B_1
3/C3
P_COT_IN
3/C3
1
R1
Z1
C9
PHASE_A_2
Z4
+1.8V
Z3
1
1
1
1
GND
OA0
DA0
2
16
OA1
DA1
4
14
OA2
DA2
6
12
OA3
DA3
8
3
OB0
DB0
17
5
OB1
DB1
15
7
OB2
9
OB3
DB2
PHASE_A1
4/B6
PHASE_B1
4/B6
P_COT
4/B6
PHASE_A2
4/B5
VCC
AMB
CYAN
MAG
13
DB3
11
2OE
19
1OE
1
VCC
PANA
R260
PANB
TILTA
10
GND
3/C3
Z2
R7
1
1
18
VCC
3/C3
+1.8V
FTC2
20
U21
10/C2
COMIN-
13
1
8
+2.5V
COMIN+
+3.3V
PHASE_A_1
C
FTC4
FTC1
R4
8
R6
U2
+2.5V
10/C2
COMOUT-
C10
UART_IN
+3.3V
FTC3
1
1
C
ISO_VCC
ISO_VCC
C240
TILTB
R105
R106
R76
R257
R207
C241
R83
B
B
R75
4/B7
R205
ENCODER_A1
PHASE_A1
RGOBO_OUT_IN
3/D3
IDX_OUT_IN
20
OA0
16
OA1
14
12
DA0
2
DA1
4
OA2
DA2
6
OA3
DA3
8
OB0
DB0
17
5
OB1
DB1
15
DB2
13
7
OB2
9
OB3
4/B7
T_COT
R253
AMB_SENS
AMBER
10/A5
R256
ENCODER_B1
PHASE_B1
4/B6
10/D5
4/A7
10/C5
4/A7
10/C3
4/A7
10/C3
4/A7
10/B3
4/A7
MAG_SENS
MAGENTA
10/A5
R82
PHASE_B2
4/B5
R206
ENCODER_B2
PHASE_B2
4/B7
DIMMER_SENS
DIMMER
10/A3
R81
RGOBO_OUT
4/B6
4/B7
3
GND
3/D4
18
VCC
PHASE_B_2
4/A7
10/A3
R72
U20
3/D3
10/C5
ENCODER_A2
PHASE_A2
4/B7
3/D3
4/A7
R73
+3.3V
T_COT_IN
CYAN_SENS
CYAN
10/D5
R254
PAN_COT_SENS
P_COT
FXDG_SENS
FXDG
10/A3
R74
DB3
11
2OE
19
1OE
1
R255
TILT_COT_SENS
T_COT
4/B7
FXDC_SENS
FXDC
R102
IDX_OUT
4/A6
10/A3
R183
RGOBO_OUT_SENS
RGOBO_OUT
4/B7
SPARE_TP1
OPT
10/B3
R101
IDX_OUT_SENS
IDX_OUT
4/B7
R185
R258
R208
10
10/B5
R259
SPARE1
FXDG
FXDC
IDX
MAG_IN
A
3/A6
FXDC_IN
3/A6
CYAN_IN
3/B6
DIMMER_IN
3/B6
AMB_IN
3/B6
FXDG_IN
OA1
14
12
RGOBO
DA0
2
DA1
4
OA2
DA2
6
OA3
DA3
8
VCC
OA0
16
3
OB0
DB0
17
5
OB1
DB1
15
7
OB2
DB2
13
9
OB3
DB3
11
2OE
19
1OE
1
C239
PCOT
OPT
4/A3
MAGENTA
A
4/B2
FXDC
4/A3
CYAN
4/B2
DIMMER
4/B3
DRAWN BY :
AMBER
4/B2
FAE
FXDG
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
4/A3
PROJECT ENGR. :
DOC. CONTROL :
10
GND
3/B6
18
C238
TCOT
20
U19
OPT_IN
3/A6
DIM
VCC
+3.3V
Title
Size
SCHEMATIC VL2500 CONTROLLER
Document Number
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
3
2
Rev
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
4
OF
10
1
131
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
7
6
5
4
3
2
1
D
D
+24V
+24V
+24V
TILT
D87
D89
D91
+24V
U11
PWM3_OUT_1
3/D3
PWM3_OUT_2
3/A6
PWM3_OUT_3
3/D3
U25
PWM3_EN_1
2
3/A6
7
IN1
8
EN1
4
IN2
3
EN2
14
IN3
13
EN3
4
OUT1
6
OUT2
5
OUT3
15
SENSE1
2
SENSE2
19
VREF
16
VCC
VCC
R77
C82
VCP
17
VBOOT
18
1
GNDA
10
GNDB
11
GNDC
VSSA
9
20
GNDD
VSSB
12
TILT_PHA_OUT
10/D3
TILT_PHB_OUT
10/D3
TILT_PHC_OUT
10/D3
D10
D88
D90
D92
C71
D9
VCC
+
C70
+
C72
+
C79
C80
+
+24V
C236
VCC
C
VCC
+24V
C92
+
C76
VCC
IRIS
C
3/C6
R90
3/C6
R92
PWM_OUT_5
C88
C87
R91
PWM_PH_6
R98
PWM_OUT_6
3/C6
C94
C95
PHASE1
21
DIS1
18
VR1
1
3/C6
R100
20
R99
4
VMM2
PWM_PH_5
MTR_EN-
2/A3,6/C8,7/C8,8/C8
VMM1
VCC
23
12
R95
+24V
MA1
11
MB1
8
MA2
5
MB2
7
10/D7,10/A4
+24V
IRIS_OUT1B
10/D7,10/A4
GND1
25
PHASE2
24
DIS2
27
VR2
22
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
13
GND5
GND6
14
C90
IRIS_OUT1A
U27
IRIS_OUT2A
IRIS_OUT2B
10/D7,10/A4
+3.3V
10/D7,10/A4
+3.3V
16
+2.5V
E2
+1.8V
6
C2
26
E1
10
19
C1
+2.5V
R94
R96
+1.8V
C89
B
R79
C93
R80
B
GND
+24V
+24V
+24V
PAN
D85
D86
D84
+24V
U31
PWM3_OUT_4
3/D3
PWM3_OUT_5
3/A6
PWM3_OUT_6
3/D3
U26
PWM3_EN_2
2
3/A6
7
IN1
8
EN1
4
IN2
3
EN2
14
IN3
13
EN3
4
OUT1
6
OUT2
5
OUT3
15
SENSE1
2
SENSE2
19
VREF
16
VCC
VCC
R78
C86
VCP
17
VBOOT
18
1
GNDA
10
GNDB
11
GNDC
VSSA
9
20
GNDD
VSSB
12
PAN_PHA_OUT
10/D3
PAN_PHB_OUT
10/D3
PAN_PHC_OUT
10/D3
D12
D81
D82
D83
C74
D11
+
C73
+
C75
+
C83
C84
+
C237
A
A
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
SCHEMATIC VL2500 CONTROLLER
Document Number
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
3
2
Rev
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
5
OF
10
1
132
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
7
6
5
4
3
VCC
1
VCC
+24V
VCC
2
+24V
+24V
C101
VCC
C78
+
+24V
C119
C85
+
D
D
R119
R118
C104
C103
24
DIS2
27
VR2
22
7
10/D7,10/C3
3/C3
3/C3
RGOBO_OUT2A
RGOBO_OUT2B
20
PHASE1
21
DIS1
18
C114
R132
10/D7,10/C3
PWM_PH_12
10/D7,10/C3
R141
R140
PHASE2
24
DIS2
27
VR2
22
RC
GND10
28
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
GND6
14
13
13
GND5
E1
C1
C99
PWM_OUT_12
3/C3
C122
16
C121
R139
4
11
MB1
8
MA2
5
MB2
7
STROBE1_OUT1A
STROBE1_OUT1B
10/C7,10/C3
10/C7,10/C3
GND1
25
2
MA1
U30
VR1
1
3/C3
VMM1
PWM_PH_11
R133
PWM_OUT_11
VMM2
23
VCC
4
MB2
10/D7,10/C3
C115
PHASE2
R117
5
RGOBO_OUT1B
GND1
25
PWM_OUT_8
MA2
RGOBO_OUT1A
STROBE1_OUT2A
STROBE1_OUT2B
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
GND6
14
GND5
C117
10/C7,10/C3
10/C7,10/C3
16
VCC
E2
3/C6
MB1
8
R131
VR1
1
PWM_PH_8
11
C1
R110
MA1
E2
C96
U28
C2
DIS1
E1
PHASE1
21
18
C97
3/C6
20
C2
PWM_PH_7
R111
PWM_OUT_7
VMM2
23
3/C6
R109
3/C6
VMM1
VCC
GOBO ROTATE
STROBE 1
12
R136
12
R114
R115
6
26
10
19
6
26
10
19
VCC
R113
R135
R137
+24V
C98
C
R84
C102
R85
C116
R88
C120
R89
+24V
C
+3.3V
2/A3,5/C2,6/C8,7/C8,8/C8
+3.3V
MTR_EN-
+2.5V
+2.5V
VCC
VCC
+24V
+24V
+24V
+24V
+1.8V
VCC
GOBO INDEX
C110
+
VCC
C81
C128
+
C91
STROBE 2
+1.8V
R143
RC
GND10
28
GND2
GND09
17
7
PWM_PH_14
VMM1
4
MA2
5
MB2
7
PHASE2
24
DIS2
27
VR2
22
GND10
28
GND09
17
GND3
GND08
15
9
GND4
GND07
15
14
13
GND5
GND6
14
GND07
13
GND5
GND6
PWM_OUT_14
C131
C130
R150
C126
R126
C111
R146
R87
C125
STROBE2_OUT1B
10/C7,10/C3
GND
10/C7,10/C3
STROBE2_OUT2A
STROBE2_OUT2B
10/C7,10/C3
B
10/C7,10/C3
16
E2
GND08
GND4
3/C6
STROBE2_OUT1A
GND1
25
GND2
GND3
R124
8
RC
9
C1
R151
11
MB1
3
16
19
10/C7,10/C3
MA1
U32
2
3
R86
VR1
1
3/C6
R152
DIS1
18
6
MB2
IDX_OUT2B
PHASE1
21
VMM2
23
VCC
4
VMM1
22
C107
C123
10/C7,10/C5
DIS2
VR2
C108
IDX_OUT2A
20
C1
R128
C124
PHASE2
PWM_PH_13
R144
PWM_OUT_13
GND1
27
2
C112
3/C6
3/C6
19
R129
C113
5
10/C7,10/C5
E2
R130
PWM_OUT_10
3/C3
MA2
10/D7,10/C3
R142
IDX_OUT1B
C2
24
IDX_OUT1A
26
25
8
6
PWM_PH_10
11
MB1
E1
1
3/B3
B
MA1
U29
10
VR1
C2
R121
DIS1
18
26
C105
PHASE1
21
E1
C106
20
VMM2
23
VCC
PWM_PH_9
R122
10
3/C6
R120
PWM_OUT_9
3/C6
12
R147
12
R125
R148
R93
C129
R97
A
A
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
3
2
SCHEMATIC VL2500 CONTROLLER
Rev
Document Number
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
6
OF
10
1
133
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
5
4
3
2
VCC
D
VCC
+24V
VCC
1
+24V
+24V
C136
VCC
C100
+
D
+24V
C155
C118
+
FXD GOBO MOTOR
ZOOM
R190
C140
C139
MA2
5
MB2
7
3/C3
10/A4
R169
FXDG_OUT1B
10/A4
3/B3
24
DIS2
27
VR2
22
FXDG_OUT2A
FXDG_OUT2B
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
16
9
GND4
GND07
15
13
GND5
GND6
14
E1
C1
C135
C151
PWM_PH_2
10/A4
R200
R199
DIS1
18
VR1
C157
MA1
11
MB1
8
MA2
5
MB2
7
ZOOM_OUT1B
10/B7,10/C4
10/B7,10/C4
GND1
PHASE2
24
DIS2
27
VR2
22
ZOOM_OUT2A
ZOOM_OUT2B
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
16
9
GND4
GND07
15
13
GND5
GND6
14
R175
ZOOM_OUT1A
U35
25
PWM_OUT_2
C158
4
12
PHASE1
21
1
3/C3
3/C6
20
R171
10/A4
VMM1
PWM_PH_1
R170
PWM_OUT_1
C150
PHASE2
R162
FXDG_OUT1A
VMM2
23
VCC
4
VMM2
8
GND1
25
PWM_OUT_16
3/C6
11
MB1
C154
10/B7,10/C4
10/B7,10/C4
VCC
VCC
E2
1
PWM_PH_16
MA1
U33
C2
VR1
R157
3/C6
R191
DIS1
18
E1
C132
PHASE1
21
C1
C133
20
R173
E2
PWM_PH_15
R158
PWM_OUT_15
C2
3/C6
R187
3/B6
VMM1
VCC
23
12
R160
R159
R161
C134
R112
C138
6
26
10
19
6
26
10
19
+24V
C
R172
R116
R174
C153
R134
C156
C
+24V
+3.3V
R138
+3.3V
+2.5V
2/A3,5/C2,6/C8,8/C8
MTR_EN-
+2.5V
+1.8V
VCC
VCC
+24V
+24V
C146
+
C109
VCC
EDGE
25
24
C149
R168
MB1
8
MA2
5
3/C6
C160
FXDC_OUT2A
C159
R176
VR2
22
MB2
7
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
13
GND5
GND6
14
C1
19
FXDC_OUT2B
PWM_PH_4
10/A4
R204
3/B6
R165
C167
R123
C166
PHASE1
21
DIS1
18
VR1
R181
C147
4
VMM1
VMM2
MA1
11
MB1
8
MA2
5
MB2
7
PHASE2
24
DIS2
27
VR2
22
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
13
GND5
GND6
14
R178
R127
C161
EDGE_OUT1A
10/C4,10/B1
B
U36
EDGE_OUT1B
10/C4,10/B1
GND1
25
C162
R167
C143
R182
PWM_OUT_4
16
20
1
3/D6
10/A4
DIS2
27
C145
10/A4
GND1
PHASE2
12
23
VCC
4
VMM1
VR1
PWM_PH_3
R177
PWM_OUT_3
C1
C144
3/D3
10/A4
R201
FXDC_OUT1B
19
R193
PWM_OUT_18
FXDC_OUT1A
E2
R194
3/C6
11
6
PWM_PH_18
GND
EDGE_OUT2A
EDGE_OUT2B
10/C4,10/B1
10/C4,10/B1
16
E2
1
3/C3
MA1
U34
C2
R163
C127
6
DIS1
E1
C141
+
C2
PHASE1
21
18
C142
C164
26
20
26
3/C6
PWM_PH_17
R164
VMM2
23
VCC
R192
PWM_OUT_17
10
3/B3
B
+1.8V
+24V
R179
12
R166
E1
FXD COLOR MOTOR
+24V
10
VCC
R180
R145
C165
R149
A
A
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
SCHEMATIC VL2500 CONTROLLER
COP YRIGHT 2004
D ate:
5
02.96 76.002 0 A
4
3
01-July-2008
2
Rev
Document Number
14-9676-0730
D
Tuesday, July 20, 2004
SHEET
B0
7
OF
10
1
134
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
5
4
3
2
VCC
VCC
+24V
D
+24V
+24V
C173
VCC
C137
+
3/C6
R209
3/C6
20
PHASE1
21
DIS1
18
C169
C168
R210
R219
PWM_PH_20
R218
C176
C175
24
DIS2
27
VR2
22
MB1
8
MA2
5
MB2
7
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
13
GND5
GND6
14
C171
10/D6,10/A5
AMB_OUT2A
AMB_OUT2B
3/C6
C195
PHASE1
21
DIS1
18
VR1
R243
1
3/B6
10/D6,10/A5
PWM_PH_24
10/D6,10/A3
R252
20
R251
C203
16
C202
MA1
11
MB1
8
MA2
5
MB2
7
MAG_OUT1B
10/C6,10/A3
10/C6,10/A5
GND1
PHASE2
24
DIS2
27
VR2
22
MAG_OUT2A
MAG_OUT2B
RC
GND10
28
2
GND2
GND09
17
3
GND3
GND08
9
GND4
GND07
15
13
GND5
GND6
14
R250
MAG_OUT1A
U40
25
PWM_OUT_24
3/B6
VMM2
PWM_PH_23
4
12
23
VCC
4
3/B6
R244
PWM_OUT_23
C196
PHASE2
R217
10/D6,10/A3
R242
AMB_OUT1B
GND1
25
PWM_OUT_20
3/C6
AMB_OUT1A
11
MA1
U37
VR1
1
3/B3
VMM1
PWM_PH_19
R211
C163
+
MAGENTA
VMM2
23
VCC
AMBER
PWM_OUT_19
D
C200
R247
12
R214
+24V
VMM1
VCC
1
C198
10/C6,10/A5
10/C6,10/A3
16
R215
E2
C2
VCC
6
26
E1
C1
R213
C
10
19
6
E2
C2
26
10
19
E1
C1
VCC
R246
R248
C
+24V
C170
R188
C174
R189
C197
R202
C201
R203
+24V
+3.3V
2/A3,5/C2,6/C8,7/C8
MTR_EN+3.3V
+2.5V
+2.5V
VCC
VCC
+24V
+24V
C182
+
VCC
C148
C184
R228
DIS2
27
VR2
22
RC
3
9
13
5
MB2
7
28
GND2
GND09
17
GND3
GND08
16
GND4
GND07
15
GND5
GND6
14
E1
10
19
R224
CYAN_OUT2A
CYAN_OUT2B
R195
C186
R232
10/D6,10/A5
3/C3
R241
3/C3
PHASE1
21
DIS1
1
PWM_PH_26
10/D6,10/A3
R240
PWM_OUT_26
C194
C193
R239
C189
R226
C179
PHASE2
DIS2
27
VR2
22
RC
9
13
C183
VMM1
VMM2
11
MB1
8
MA2
5
MB2
7
10/D6,10/A3
GND
GND10
28
GND2
GND09
17
GND3
GND08
GND4
GND07
15
GND5
GND6
14
R235
R196
DIM_OUT1A
DIM_OUT1B
B
10/D6,10/A5
GND1
24
3
MA1
U39
VR1
25
2
4
12
23
VCC
VMM1
4
MA2
20
18
C187
GND10
C1
C180
PHASE2
24
PWM_PH_25
R233
PWM_OUT_25
C188
DIM_OUT2A
DIM_OUT2B
10/D6,10/A5
10/D6,10/A3
16
E2
C185
3/C3
3/B3
GND1
25
2
10/D6,10/A5
6
R229
PWM_OUT_22
10/D6,10/A3
C1
R230
PWM_PH_22
VR1
CYAN_OUT1B
19
3/B3
CYAN_OUT1A
E2
1
MB1
8
6
R221
11
R231
C2
C177
MA1
U38
C2
DIS1
26
PHASE1
21
E1
20
18
C178
3/B3
PWM_PH_21
R222
PWM_OUT_21
26
3/B3
R220
3/C6
C152
+1.8V
DIMMER
VMM2
23
VCC
CYAN
B
+1.8V
+
R236
12
R225
+24V
C191
10
VCC
+24V
R237
R197
C192
R198
A
A
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
SCHEMATIC VL2500 CONTROLLER
Document Number
D
COP YRIGHT 2004
D ate:
5
02.96 76.002 0 A
4
3
01-July-2008
2
Tuesday, July 20, 2004
Rev
14-9676-0730
SHEET
B0
8
OF
10
1
135
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
7
6
5
4
3
2
1
D
D
VCC
VCC
+24V
+24V
C
C
+3.3V
+3.3V
+2.5V
+2.5V
+1.8V
+1.8V
GND
B
B
ALL PARTS WERE REMOVED
A
A
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
3
2
SCHEMATIC LV2500 CONTROLLER
Rev
Document Number
B0
14-9676-0730
Monday, July 12, 2004
SHEET
9
OF
10
1
136
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Main Control Board (MCB) Schematic (continued)
8
7
6
5
4
3
2
1
VCC
+24V
DIA. .166"
+24V
D13
5/C1,10/C3
D14
D49
8/D5,10/A3
IRIS_OUT2A
D15
D50
8/D5,10/A5
5/C1,10/C5
D52
AMB_OUT2A
1
2
3
4
5
6
D51
6/D5,10/C3
D53
1
2
3
4
5
6
D54
D56
CYAN_OUT1B
CYAN_OUT2A
8/B5,10/A5
RGOBO_OUT2B
6/D5,10/C3
D55
CYAN_OUT2B
8/B5,10/A3
IDX_OUT1A
6/B5,10/C3
ENCODER_A1
D57
DIM_OUT1A
4/B5
8/B2,10/A3
IDX_OUT1B
4/B5
6/B5,10/C5
D58
DIM_OUT1B
4/B5
8/B2,10/A5
D24
IDX_OUT2A
D23
1
2
3
4
5
6
ENCODER_B1
ENCODER_A2
ENCODER_B2
4/B5
6/B5,10/C5
D60
DIM_OUT2A
1
2
3
4
5
6
2
2
3
3
4
4
5
5
6
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
LAMP_CNTL_OUT
4/C6
PAN_PHC_OUT
5/C4
PAN_PHA_OUT
PAN_PHB_OUT
LAMP_ON_IN-
PAN
5/D4
4/C6
5/C4
LAMP_STBY
2/C4
TILT_PHA_OUT
DISPLAY CONTROL
5/B4
D
2
3
3
4
4
5
5
1
1
2
2
3
3
4
4
1
1
2
2
3
3
1
1
2
2
BALLAST CONTROL
5/B4
TILT_COT_SENS
4/B3
PAN_COT_SENS
J5
4/B3
COMIN+
4/C1
8/B2,10/A5
DIM_OUT2B
COMINCOMOUT+
4/C1
COMOUT-
4/C1
MAG_OUT1A
2
TILT
8/B2,10/A3
D61
1
5/B4
TILT_PHC_OUT
4/C1
D59
6/D2,10/C3
1
TILT_PHB_OUT
STROBE1_OUT1A
D26
SCL_OUT
2/A8
J2
IDX_OUT2B
6/B5,10/C3
D25
SDA_OUT
2/A8
J8
8/B5,10/A5
D22
1
VCC
8/B5,10/A3
6/D5,10/C5
D21
1
2
3
4
5
6
1
MNTG7
CYAN_OUT1A
RGOBO_OUT2A
D19
1
2
3
4
5
6
J4
DIA. .166"
MNTG6
8/D5,10/A5
RGOBO_OUT1B
6/D5,10/C5
D20
DIA. .166"
MNTG5
AMB_OUT2B
RGOBO_OUT1A
D18
DIA. .166"
MNTG4
1
2
3
4
5
6
8/D5,10/A3
D17
DIA. .166"
MNTG3
IRIS_OUT2B
5/C1,10/C3
D
AMB_OUT1B
DIA. .166"
MNTG2
1
2
3
4
5
6
AMB_OUT1A
IRIS_OUT1B
5/C1,10/C5
D16
DIA. .166"
MNTG1
IRIS_OUT1A
DMX IN
8/D2,10/A3
STROBE1_OUT1B
6/D2,10/C5
D62
MAG_OUT1B
8/D2,10/A5
D28
STROBE1_OUT2A
D27
6/D2,10/C5
D64
MAG_OUT2A
8/D2,10/A5
STROBE1_OUT2B
+24V
6/D2,10/C3
D63
J3
VCC
MAG_OUT2B
8/D2,10/A3
D29
STROBE2_OUT1A
6/B2,10/C3
C
D30
J9
STROBE2_OUT1B
VCC
STROBE1_OUT2A
6/D2, 10/C8
D32
STROBE2_OUT2A
D31
STROBE1_OUT1B
6/B2,10/C5
6/D2, 10/C8
6/B2, 10/C8
STROBE2_OUT2B
STROBE2_OUT2A
STROBE2_OUT1B
6/B2,10/C3
6/B2, 10/C8
ZOOM_OUT2A
7/D2, 10/B8
D33
FXDG_OUT1A
D34
7/D2,10/B8
7/D5,10/C3
7/B2,10/B7
FXDG_OUT1B
7/B2,10/B7
7/D5,10/C5
6/D6,10/D7
D36
FXDG_OUT2A
D35
6/D6,10/C7
7/D5,10/C5
6/B6,10/C7
FXDG_OUT2B
6/B6,10/C7
7/D5,10/C3
D37
FXDC_OUT1A
6/B2
7/B5,10/B3
D38
3/B6
ZOOM_OUT1B
EDGE_OUT2A
EDGE_OUT1B
RGOBO_OUT2A
RGOBO_OUT1B
IDX_OUT2A
IDX_OUT1B
RGOBO_OUT_SENS
SPARE_1
FXDC_OUT1B
7/B5,10/B5
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
28
28
29
29
30
30
31
31
32
32
34
34
33
D40
FXDC_OUT2A
D39
POWER IN
C
6/B2,10/C5
7/B5,10/B5
33
STROBE1_OUT2B
6/D2,10/C8
STROBE1_OUT1A
STROBE2_OUT2B
STROBE 1
6/D2,10/C8
6/B2,10/C8
STROBE2_OUT1A
STROBE 2
6/B2,10/C8
ZOOM_OUT2B
7/D2,10/B8
ZOOM_OUT1A
EDGE_OUT2B
EDGE_OUT1A
RGOBO_OUT2B
RGOBO_OUT1A
IDX_OUT2B
IDX_OUT1A
ZOOM
J1
+24V
7/D2,10/B8
7/B2,10/B8
EDGE
7/B2,10/B8
6/D6,10/D8
GOBO ROTATE
6/B5,10/D8
6/B5,10/D8
YOKE FANS/RELAY
GOBO INDEX
6/D2,10/D8
J12
IDX_OUT_SENS
SPARE_2
SPARE_TP1
6/B2,10/C7
3/B6
4/B1
1
1
2
2
3
3
VCC
FXDC_OUT2B
7/B5,10/B3
D41
ZOOM_OUT1A
VCC
7/D2,10/B3
D42
B
ZOOM_OUT1B
B
7/D2,10/B5
+24V
D44
ZOOM_OUT2A
7/D2,10/B5
D43
ZOOM_OUT2B
+24V
7/D2,10/B3
VCC
D45
EDGE_OUT1A
VCC
7/B2,10/B3
+3.3V
D46
EDGE_OUT1B
J11
7/B2,10/B5
8/B5,10/D6
+3.3V
D48
8/B5,10/D6
EDGE_OUT2A
7/B2,10/B5
D47
8/D5,10/D6
EDGE_OUT2B
8/D5,10/D6
+2.5V
7/B2,10/B3
8/D2,10/C6
8/D2,10/C6
8/B2,10/C6
+2.5V
8/B2,10/C6
7/D4,10/C8
7/D4,10/C8
+1.8V
7/B4,10/B8
7/B4,10/B8
+1.8V
5/C2,10/D8
5/C2,10/D8
CYAN_OUT2A
CYAN_OUT1B
AMB_OUT2A
AMB_OUT1B
MAG_OUT2A
MAG_OUT1B
DIM_OUT2A
DIM_OUT1B
FXDG_OUT2A
FXDG_OUT1B
FXDC_OUT2A
FXDC_OUT1B
IRIS_OUT2A
IRIS_OUT1B
FXDG_SENS
4/B1
GND
A
AMB_SENS
4/B1
MAG_SENS
4/B1
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
15
17
14
14
15
16
16
17
18
18
13
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
28
28
29
29
30
30
31
31
32
32
34
34
33
33
35
35
36
36
37
37
38
38
39
39
40
40
CYAN_OUT2B
CYAN_OUT1A
AMB_OUT2B
AMB_OUT1A
MAG_OUT2B
MAG_OUT1A
DIM_OUT2B
DIM_OUT1A
FXDG_OUT2B
FXDG_OUT1A
FXDC_OUT2B
FXDC_OUT1A
IRIS_OUT2B
IRIS_OUT1A
FXDC_SENS
8/B5,10/D6
8/B5,10/D6
CYAN
8/D5,10/D6
8/D5,10/D6
AMBER
8/D2,10/C6
8/D2,10/C6
MAGENTA
8/B2,10/D6
8/B2,10/D6
DIMMER
7/D4,10/C8
7/D4,10/C8
FXD GOBO
7/B4,10/B8
7/B4,10/B8
FIXED COLOR
5/C2,10/D8
5/C2,10/D8
IRIS
4/B1
A
CYAN_SENS
DIMMER_SENS
4/B1
4/B1
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238
INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED
OR DISCLOSED WITHOUT WRITTEN CONSENT.
CHECKED BY :
PROJECT ENGR. :
DOC. CONTROL :
Title
Size
D
COP YRIGHT 2004
D ate:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
3
2
SCHEMATIC VL2500 CONTROLLER
Rev
Document Number
14-9676-0730
Tuesday, July 20, 2004
SHEET
B0
10
OF
10
1
137
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
DMX Input Schematic
8
7
6
5
4
3
1
2
REVISIONS
REV
A
DESCRIPTION
DATE
Released per EO #09110
APPD
9/27/01 MTD
J1
NC5FBV
D
SHIELD
1
DMX/VL_IN-
2
DMX/VL_IN+
3
VL_OUT-
4
VL_OUT+
5
CHASSIS
6
D
J2
NC5MBV
C
SHIELD
1
DMX/VL_IN-
2
DMX/VL_IN+
3
VL_OUT-
4
VL_OUT+
5
CHASSIS
6
C
J3
640456-5
B
SHIELD
1
DMX/VL_IN+
2
DMX/VL_IN-
3
VL_OUT+
4
VL_OUT-
5
B
C1
1000PF
20%
250V
CHASSIS
DRAWN BY
NEXT
A
PCB NO.
Filename:
Date/Time:
8
02.96 76.002 0 A
7
6
5
01-July-2008
4
R
MARC DYBLE
ASSY
11-9663-1830
CONFIDENTIAL
DSN
MTD
09/01
VL1000 DMX INPUT BOARD
CHK
ALL INFORMATION CONTAINED HEREIN
IS THE SOLE AND EXCLUSIVE PROPERTY DOC
OF VARI-LITE, INC. AND MAY NOT BE
USED, DISCLOSED, OR REPRODUCED MFG
IN ANY MANNER WITHOUT, THE ADVANCE
WRITTEN CONSENT OF VARI-LITE, INC.
ViewDraw for Windows 7.5
3
201 REGAL ROW
DALLAS, TEXAS 75247
2
SIZE
REVISION
B
A
A
DRAWING NUMBER
SHEET
14-9663-1830
1
OF
1
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138
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL
REFERENCE FOLD-OUTS
Solid State Ignitor Schematic
8
7
6
5
4
3
1
2
REVISIONS
REV
NOTES: UNLESS OTHERWISE SPECIFIED
1. ALL CAPACITOR VALUES ARE IN MICROFARADS.
2. ALL RESISTOR VALUES ARE IN OHMS.
DESCRIPTION
DATE
1
ENGINEERING PROTOTYPE
2
ENG RELEASE PER EO #09082
A
REL. TO PROD. PER EO #09089
APPD
7/16/02
9/16/02
B.C.
B.C.
D
D
REFERENCE DESIGNATORS
LAST USED
C10
D6
J4
L1
Q3
R19
U1
NOT USED
J4
8191
J2
8191
L1
C3,C7,C9
1
1
2
2
4
3
3
2
1
3
4
D5
MUR8100E
R17
10K
5%
1/4W
C2
10UF
20%
50V
D4
C10
0.1UF
20%
50V
R4
820K
5%
1W
MUR8100E
R2,R5,R12,R13,R16
R6
51K
5%
1W
D3
1N4937
D6
1N5955B
4
R3
820K
5%
1W
D2
1N4747A
C
C
16
8-BYPASS
R9
6.8
5%
1W
R8
6.8
5%
1W
U1
MC14536BCP
6
VCC
9
A
10
B
R11
7.15K
1%
1/4W
11
13
C
C4
4.7UF
20%
50V
DECODE_OUT
12
D
2
4
OUT1
14
OSC_INH
15
5
MONO-IN
OUT2
C8
0.1UF
20%
50V
C5
330PF
5%
200V
RESET
SET
3
8
GND
R1
51K
5%
1/4W
IN1
R14
20
5%
1/4W
CLOCK_INH
Q3
2N4403
R7
120K
5%
1/4W
R10
100K
5%
1/4W
Q1
IXBH15N160
R15
2K
5%
1/4W
7
C1
1000PF
10%
3KV
Q2
2N4401
1
C6
100PF
10%
200V
J3
8191
B
J1
8191
1
1
2
2
3
3
4
4
B
D1
2ML
MOUNTING HOLES
MTG1
MTG2
MTG3
MTG4
NEXT
24-9661-1126
DRAWN BY
A
PCB NO.
8
02.96 76.002 0 A
11.9661.1126
CONFIDENTIAL
DSN
7
6
5
01-July-2008
4
3
6-27-02
201 REGAL ROW
DALLAS, TEXAS 75247
B.C.
SOLID STATE IGNITOR
CHK
ALL INFORMATION CONTAINED HEREIN
IS THE SOLE AND EXCLUSIVE PROPERTYDOC
OF VARI-LITE, INC. AND MAY NOT BE
USED, DISCLOSED, OR REPRODUCED MFG
IN ANY MANNER WITHOUT, THE ADVANCE
WRITTEN CONSENT OF VARI-LITE, INC.
Filename: SSIGNITOR
Date/Time: 11-14-2002_14:21
R
B. CURBO
ASSY
eProduct Designer 2.0
2
SIZE
REVISION
DRAWING NUMBER
D
A
14-9661-1126
SHEET
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OF
A
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1
139
Vari-Lite
10911 Petal Street
Dallas, Texas 75238
Toll Free 1-877-VARI-LITE Tel 214.647.7880 Fax 214.647.8038
www.vari-lite.com
©2008 Philips Group. All rights reserved. Certain products listed in this document
may be protected by applicable patents and patents pending. Philips will aggressively defend all of its intellectual property. We reserve the right to change details
of design, materials and finishes.