Vari Lite VL2500 Spot Luminaire Service Manual
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Vari Lite VL2500 Spot Luminaire Service Manual

Vl2500 spot luminaire
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  • Page 2 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL ® VARI❋LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries. VL500™, VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, ™...
  • Page 3 OREWORD 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 customerservice@genlytecontrols.com and request a Return Material Authorization (RMA) for warranty service.

  • Page 4: Safety Notice

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
  • Page 5 OREWORD 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.
  • Page 6 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired.
  • Page 7 OREWORD Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin.
  • Page 8 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1.
  • Page 9 OREWORD Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 10 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2.
  • Page 11 OREWORD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto.
  • Page 12 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación UV. NO mire directamente a la lámpara. 2.
  • Page 13 AFETY OTICE APANESE Ô ç æ Ð á¿  Á 'ê”ùÕ Q>X^Åî éQ>X^é_ æ Ô±Žã[ ÔôáÅ\úÊÛп•ù Ú”sÙæ  ÌÚö ÔÙæê”Ôôáé çP Å î TæÐçÒáÞ ÒáÊÛп• Q>X^âꔏé_ Qo" ö Òá¿ùÔ• æ à ¾ ǽùÔ• qŠPæßåÇ ¾ ǽùÔ• õ” 4” |¿æ»Ô é:´”ÅîqŠP ËÚüé 屎æß¿áꔏé[ Å\úÊÛп• ËÚü...
  • Page 14 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL æÐ Ðå¿Úü Ef; Êê” Õ 2J \fJ ª 1. VARI❋LITE® Òá¿ùÔ•\fJ ÔÎãê ÌáÊÛп• _f-ùÚê*o^< Õæ P.Ôã âÔ•_f-” *o^<” ¹ ê”íî ÿ ¿ ÞÆÈ åäæ”Ø 2 Ç å ÁæåÞÚ  ÃÁæÒùÔ• 2 ËÚü Ef; ÇP.Òá¿ãÈê”Ø ¥Ç²ÊåùÔ•²ÊåÞÚ ÿ&fPo@f;...

  • Page 15: Table Of Contents

    ABLE OF ONTENTS Table of Contents Introduction About This Manual ...................... 1 Additional Documentation................... 1 Customer Service ......................2 Technical Bulletins / Technical Notices............... 2 Chapter 1. Description Features Overview........................4 Features ......................... 4 Major Components External Components....................5 Menu Display ......................6 Menu Controls.......................
  • Page 16 Drawing Tree VL2500 Series Spot Luminaire .................. 44 Top Assembly VL2500 Spot Included Items Kit ................46 VL2500 Spot Luminaire..................... 48 VL2500 Generic Luminaire ..................50 Front Assembly ......................52 Lens Barrel Assembly ....................54 Sub-Barrel Group 2 Assembly ................... 56 Motor Zoom Optics Assembly ...................
  • Page 17 Ballast to Controller Cable Assembly..............118 Lamp Supply to Relay Cable Assembly ..............119 DC Output Cable Assembly..................120 Appendix A. Technical Bulletins and Notices VL2500 Spot Luminaire Technical Bulletins and Notices ........121 02. 96 76. 002 0 B 29-May-2009 xvii...
  • Page 18 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Notes xvi i i 29-May-2009 02 .9 676 .00 20 B...

  • Page 19: About This Manual

    This manual covers the following models: Model Part Number Source VL2500 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®...

  • Page 20: Customer Service

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

  • Page 21: Chapter 1. Description

    HAPTER Description This chapter provides an overview of luminaire features, components and operations. • Features • Major Components • Principles of Operation 02. 96 76. 002 0 B 29-May-2009...

  • Page 22: Features Overview

    ERVICE ANUAL 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 700- watt shortarc lamp, impressive lumen output, and a zoom range from 18.5°...

  • Page 23: Major Components

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

  • Page 24: Menu Display

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

  • Page 25: Head Components

    ESCRIPTION AJOR OMPONENTS 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 / CYM Color/Dimmer Bulkhead Lamp Assembly Fixed Color / Fixed Gobo / Iris Bulkhead Fan Assembly...

  • Page 26: Yoke Components

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL 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.) Fan Assembly Yoke Arm Cover Ignitor PCB Relay Yoke Structure Yoke Arm Cover Tilt-Side Leg Main Control Board (MCB)

  • Page 27: Enclosure Components

    ESCRIPTION AJOR OMPONENTS 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 Input Panel Assembly containing DMX Input PCB and Menu Display 150W +24V/6.3A...

  • Page 28: Principles Of Operation

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

  • Page 29: Chapter 2. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Troubleshooting • Maintenance Procedures WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation.

  • Page 30: Testing

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL 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.

  • Page 31: Troubleshooting

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

  • Page 32: Troubleshooting Guide

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL 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 Symptom...
  • Page 33 AINTENANCE ROUBLESHOOTING Table 2-2: Troubleshooting Guide (Continued) Message Symptom Description Possible Cause and Remedy Pan No Luminaire will not pan or Pan Sensor Not Found EOT flag attached to large pulley is not engaging the Sens hits against stop EOT sensor... - ensure flag is attached to the large pulley.

  • Page 34: Maintenance Procedures

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly. Lamp Replacement Parts: 71.2528.0700 WARNING: Remove power from luminaire before performing maintenance. To remove and replace lamp: Step 1.
  • Page 35 AINTENANCE AINTENANCE ROCEDURES Lamp Replacement (continued) 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.

  • Page 36: Color/Gobo/Iris Bulkhead Assembly Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Color/Gobo/Iris Bulkhead Assembly Replacement Parts: 21.9676.4120 To remove and replace color/gobo/iris bulkhead assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At top head cover, gradually loosen two 8-32x1/2" captive screws and remove cover.

  • Page 37: Standard Gobo/Color Filter Replacement

    AINTENANCE AINTENANCE ROCEDURES 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 ®...

  • Page 38: Strobe Bulkhead Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Strobe Bulkhead Replacement Parts: 22.9676.0016 To remove and replace strobe bulkhead assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At luminaire, remove both top and bottom covers as follows: a.

  • Page 39: Front Assembly Removal

    AINTENANCE AINTENANCE ROCEDURES Front Assembly Removal Parts: 22.9676.0016 Note: 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 luminaire, remove both top and bottom covers as follows: a.
  • Page 40 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Front Assembly Removal (continued) Step 7. At junction connector, disconnect edge motor and zoom motor wires. Step 8. Face head nose upward. At front of bulkhead, using #2 Phillips long handle screwdriver, remove four 6-32 X 3/8" PPZ screws (note, tether will be attached to one screw), and pull front assembly partially out of head assembly.

  • Page 41: Rotating Gobo Sensor Pcb Replacement

    AINTENANCE AINTENANCE ROCEDURES Rotating Gobo Sensor PCB Replacement Parts: 24.9667.1321 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 Step 3.
  • Page 42 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Rotating Gobo Sensor PCB Replacement (continued) 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. Rotating Gobo 4-40×1/4” Sensor PCB PFZ Screws Figure 2-8: Rotating Gobo Sensor PCB Replacement...

  • Page 43: Edge Motor Assembly Replacement

    AINTENANCE AINTENANCE ROCEDURES Edge Motor Assembly Replacement Parts: 21.9667.0310 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 Step 3. Cut cable ties that secure edge motor wires to front assembly. (Edge motor is larger of two linear actuator motors.) Step 4.
  • Page 44 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Edge Motor Assembly Replacement (continued) CAUTION: If you use pliers instead of 1/4-inch wrench in next step, ensure you place pliers on standoff on edge motor shaft. Do not hold edge motor shaft with pliers, or shaft may be damaged.
  • Page 45 AINTENANCE AINTENANCE ROCEDURES Edge Motor Assembly Replacement (continued) 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 Step 7. Remove two 4-40×3/8" PPZ screws and nuts which secure motor to bulkhead and remove motor assembly.

  • Page 46: Lens Barrel Assembly Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Lens Barrel Assembly Replacement Parts: 21.9676.4306 To remove and replace lens barrel assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At top head cover, gradually loosen two 8-32 x 3/8" captive screws. Step 3.
  • Page 47 AINTENANCE AINTENANCE ROCEDURES Lens Barrel Assembly Replacement (continued) 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.

  • Page 48: Yoke Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL 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 To remove and replace tilt motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 49: Main Control Board (Mcb) Pcb Replacement

    AINTENANCE AINTENANCE ROCEDURES Main Control Board (MCB) PCB Replacement Parts: 24.9676.3730 To remove and 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" PTB screws.

  • Page 50: Ignitor Pcb Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Ignitor PCB Replacement Parts: 24.9661.3126 To remove and 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.
  • Page 51 AINTENANCE AINTENANCE ROCEDURES Ignitor PCB Replacement (continued) 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"...

  • Page 52: Enclosure Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL 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.

  • Page 53: Removing Enclosure Covers (Continued)

    AINTENANCE AINTENANCE ROCEDURES Removing Enclosure Covers (continued) CAUTION: Be careful not to damage lens during next step. Step 4. Carefully lay luminaire on its side as shown in Figure 2-20. Make sure that lens does not come into contact with any surface.. Figure 2-20: Laying Luminaire on Its Side Step 5.

  • Page 54: Ballast Module Assembly Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Ballast Module Assembly Replacement Parts: 69.9676.0700 To remove and replace ballast module assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove ballast-side and ventilation covers. Refer to “Removing Enclosure Covers”...
  • Page 55 AINTENANCE AINTENANCE ROCEDURES Ballast Module Assembly Replacement (continued) Step 6. At ballast, disconnect the following cable assemblies: a. Lamp wires b. AC input a. Control wiring Step 7. Pull lamp wires through ferrite core. Step 8. At bottom of enclosure, remove three 8-32x3/8" PFZ screws and four 8/ 32x3/8"...

  • Page 56: Pan Motor / Pan Belt Assembly Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Pan Motor / Pan Belt Assembly Replacement Parts: 21.9678.0864 - Pan Motor Assembly 54.2055.0001 - Pan Motor Belt To remove and replace pan motor assembly: Step 1. Using console or internal menus, run lens as far to the rear as possible. Step 2.
  • Page 57 AINTENANCE AINTENANCE ROCEDURES To remove and replace pan motor belt: 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 x 1/4" PPB screws and remove cover.

  • Page 58: Pan Encoder Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Pan Encoder Replacement Parts: 24.9678.9729 To remove and replace pan encoder: 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. CAUTION: Be careful not to damage lens during next step.

  • Page 59: Pan Eot (End Of Travel) Sensor Replacement

    AINTENANCE AINTENANCE ROCEDURES Pan EOT (End of Travel) Sensor Replacement Parts: 86.7002.0003 To remove and replace pan EOT sensor: 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. CAUTION: Be careful not to damage lens during next step.

  • Page 60: Lvs (Low-Voltage Supply) Power Supply Replacement

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL LVS (Low-Voltage Supply) Power Supply Replacement Parts: 69.3177.0151 To remove and replace LVS power supply: Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove two 6-32 x 1/4" LG PPZ screws from display side cover and remove cover.

  • Page 61: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500™ Spot Luminaire. • Drawing Tree • Top Assembly • Yoke • Enclosure • Cables WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation.

  • Page 62: Drawing Tree

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Drawing Tree VL2500 Series Spot Luminaire VL2500 Spot Luminaire 20.9676.0001 Rev L VL2500 Generic Luminaire Front Assembly 21.9676.0010 Rev J 21.9676.4006 Rev D Rotating Gobo Wheel Assembly Upper Enclosure Assembly 21.9660.0105 Rev E 21.9676.0800 Rev T...
  • Page 63 LLUSTRATED ARTS REAKDOWN RAWING Drawing Tree (continued) Continued from previous page VL2500 Spot Luminaire (continued) Upper Enclosure Assembly 21.9676.0800 Rev T Reflector Assembly Connector Panel Assembly Connector Panel Assembly 22.9676.0018 Rev B 21.9676.0805 Rev B 21.9676.0805 Rev B Fan Assembly...

  • Page 64: Top Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Top Assembly VL2500 Spot Included Items Kit 28.9676.0001 Rev G Refer to Figure 3-1. Item Qty. Description 02.8001.0001 PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY 02.80001.0002 VARI-LITE QUALITY ASSURANCE CERTIFICATE (not shown) 02.8406.0001 TAG, LAMP NOTICE 02.8700.0001...
  • Page 65 LLUSTRATED ARTS REAKDOWN SSEMBLY VL2500 Spot Included Items Kit (continued) 4 Facet Prism Circle of Ovals Hypnospiral Spiral Stones Pinwheel Standard Gobos Figure 3-1: VL2500 Spot Included Items Kit 02. 96 76. 002 0 B 29-May-2009...

  • Page 66: Vl2500 Spot Luminaire

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL VL2500 Spot Luminaire 20.9676.0001 Rev L Refer to Figure 3-2. Item Qty. Description 10.9638.0052 DAM, AIR, VL6 10.9676.8632 COVER, YOKE THERMOFORM 16.9676.0004.01 LABEL LOCATION, VL2500 LUMINAIRE (not shown) 21.9676.0023 ASSY, FRONT COVER 21.9676.4006 ASSY, FRONT 21.9676.0010...
  • Page 67 LLUSTRATED ARTS REAKDOWN SSEMBLY VL2500 Spot Luminaire (continued) (x6) (x2) (x4) (x4) (x4) Note: Loop lamp wires through ferrite. (x2) (x8) (x2) Figure 3-2: VL2500 Spot Luminaire Top Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 68: Vl2500 Generic Luminaire

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL VL2500 Generic Luminaire 21.9676.0010 Rev J Refer to Figure 3-3. Item Qty. Description 10.9628.0211 STABLIZER, PAN/TILT 10.9676.8617 HEATSHIELD, YOKE CROSSMEMBER 10.9676.0083 BAFFLE, REAR CASTING 10.9676.0163 HARNESS, GUARD, RIGHT 10.9676.0161 HARNESS, GUARD, LEFT 21.9676.0139 ASSY, REAR HEAD 21.9676.0600 ASSY, YOKE...
  • Page 69 LLUSTRATED ARTS REAKDOWN SSEMBLY VL2500 Generic Luminaire (continued) (x8) (x8) (x2) (x2) (x2) (x5) (x5) (x5) (x4) (x4) (x4) (x4) Figure 3-3: VL2500 Generic Luminaire Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 70: Front Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Front Assembly 21.9676.4006 Rev D Refer to Figure 3-4. Item Qty. Description 10.9660.0129 SHAFT STOP, ROTATING GOBO WHEEL 10.9660.0130 SHAFT, ROTATING GOBO WHEEL 10.9660.0219 SHAFT 1, FOCUS BEARING 10.9676.4255 SHAFT, SUPPORT, LENS 10.9660.0263 SUPPORT, LENS 10.9667.0313 SUPPORT, LENS, CABLE MOUNT...
  • Page 71 LLUSTRATED ARTS REAKDOWN SSEMBLY Item Qty. Description 55.6506.0009 SPACER, 1/2" RND .125" LG .375" ID SHAFT 55.6589.0003 STANDOFF, 1/4" RND 4-40 .606" LG MF 55.6663.0007 STANDOFF, 3/8" RND, 1.75" LG, FF (x4) Note: Orient items 28 and 29 (spring washers) as shown with concave side facing item 12 (lens mounting bulkhead).

  • Page 72: Lens Barrel Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Lens Barrel Assembly 21.9676.4306 Rev D Refer to Figure 3-5. Item Qty. Description 10.9676.4254 SHAFT, ZOOM BEARING 10.9676.4256 WEAR STRIP, EDGE LENSES 10.9676.4258 WEAR STRIP, EDGE BARREL 10.9676.4259 WEAR STRIP, ZOOM BALL PLUNGER 10.9676.4260 WEAR STRIP BUMPER, EDGE LENSES 12.9676.4248...
  • Page 73 LLUSTRATED ARTS REAKDOWN SSEMBLY Lens Barrel Assembly (continued) (x2) Detail A (x4) (x2) (x2) Detail A Detail A (x4) (x2) Figure 3-5: Lens Barrel Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 74: Sub-Barrel Group 2 Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Sub-Barrel Group 2 Assembly 21.9676.4229 Rev C Refer to Figure 3-6. Item Qty. Description 10.9676.4223 BARREL, ZOOM, LOWER 10.9676.4350 SPACER 1, ZOOM LENSES 10.9676.4251 SPACER 2, ZOOM LENSES 12.9676.4224 BARREL, ZOOM, UPPER 21.9676.4258 ASSY, ZOOM BUSHING 42.9660.0023 LENS 6, ZOOM OPTICS...

  • Page 75: Motor Zoom Optics Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Motor Zoom Optics Assembly 21.9667.0311 Rev A Refer to Figure 3-7. Item Qty. Description 44.9660.0262 MOTOR, 1" LINEAR - ZOOM 52.6579.0005 CONN, 5CIR PNL MT SGL ROW W/MTG EARS 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP (x4) Figure 3-7: Motor Zoom Optics Assembly 02.

  • Page 76: Rotating Gobo Wheel Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Rotating Gobo Wheel Assembly 21.9660.0105 Rev E Refer to Figure 3-8. Item Qty. Description 10.9660.0110 GOBO CARRIER, SPINNING GOBO WHEEL 10.9660.0112 SUN GEAR, SPINNING GOBO WHEEL 10.9660.0153 MAGNET, HALL EFFECT SENSOR .07ID 10.9667.0333 MOUNTING PLATE, FRONT (ROTATING GOBO WHEEL) 10.9667.0334 MOUNTING PLATE, AFT (ROTATING GOBO WHEEL)

  • Page 77: Top Cover Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Top Cover Assembly 22.9676.0008 Rev I Refer to Figure 3-9. Item Qty. UM. Description 06.6018.0011 0.041 VELCRO, DOUBLE HOOK, 2" BLACK ADH BACKED 07.5049.0001 LANYARD, NYLON COATED, 8" LONG 10.9676.8009 COVER, TOP VL2500 10.9676.0010 FILTER, TOP HEAD COVER 12.9676.0076 BAFFLE, RIGHT, TOP COVER 12.9676.0077...

  • Page 78: Bottom Cover Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Bottom Cover Assembly 22.9676.0011 Rev E Refer to Figure 3-10. Item Qty. UM. Description 10.9676.8012 COVER, LOWER 53.2008.0008 NUT, #8 PUSH 53.6521.0001 SCREW, 8-32 X 1/2" PPB 55.6599.0001 WASHER, #10 FLAT BLACK (x3) (x3) (x3) Figure 3-10: Bottom Cover Assembly...

  • Page 79: Reflector Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Reflector Assembly 22.9676.0018 Rev B Refer to Figure 3-11. Item Qty. UM. Description 10.9678.0647 CLAMP, MOUNTING, REFLECTOR 22.9660.0338 ASSY, DISCONNECT LAMP 22.9676.0130 ASSY, REFLECTOR MOUNT 41.9660.7021 ELLIPSOIDAL REFLECTOR, LUNED 53.6599.0001 SCREW, 4-40 X 3/8" PFZ 55.6669.0016 STANDOFF, 1/4"...

  • Page 80: Back Cap Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Back Cap Assembly 22.9676.0115 Rev E Refer to Figure 3-12. Item Qty. Description 10.9638.0117 KNOB, KNURLED, VL6 BACK CAP/LAMP ASSY. 10.9638.0128 BRACKET, IGNITOR CABLE 10.9638.0130 SPRING, BULB WIRE SHEATH 10.9638.0164 WASHER, FELT 10.9667.0411 LAMP CARRIAGE 10.9667.0412 LAMP TILT PLATE...
  • Page 81 LLUSTRATED ARTS REAKDOWN SSEMBLY Back Cap Assembly (continued) (x3) (x2) (x2) 30(x2) (x2) (x2) (x2) (x2) (x4) (x2) (13.5") (x2) (x2) (9.0") Figure 3-12: Back Cap Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 82: Fan Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Fan Assembly 22.9676.0090 Rev D Refer to Figure 3-13. Item Qty. Description 10.9676.0068 AIR DUCT, FRONT FAN 22.9676.0091 ASSY, FAN BULKHEAD 22.9676.0095 AIR DUCT, REAR FAN 25.8007.2212 CABLE ASSY, GROUND STRAP, #6 RING 3" LG 40.7113.0002 FAN, +24 VOLT, 80 X 80 X 25MM, 39CFM 40.7146.0002...
  • Page 83 LLUSTRATED ARTS REAKDOWN SSEMBLY Fan Assembly (continued) (x4) (x4) (x2) (x3) (x2) 7, 8 (x5) Figure 3-13: Fan Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 84: Iris/Color/Gobo Bulkhead Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Iris/Color/Gobo Bulkhead Assembly 21.9676.4120 Rev C Refer to Figure 3-14. Item Qty. Description 10.9676.4124 BULKHEAD, IRIS/GOBO/COLOR 21.9676.0118 ASSY, IRIS/GOBO MOTOR 21.9676.0119 ASSY, COLOR MOTOR 22.9676.4146 ASSY, GOBO WHEEL 22.9676.4145 ASSY, COLOR FILTER WHEEL 22.9676.1145 IRIS, 53MM OD, CUSTOM 25.9676.0125...
  • Page 85 LLUSTRATED ARTS REAKDOWN SSEMBLY Iris/Color/Gobo Bulkhead Assembly (continued) (x3) (x7) (x3) (x2) (x3) Figure 3-14: Iris/Color/Gobo Bulkhead Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 86: Crossfade Color Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Crossfade Color Assembly 21.9676.0201 Rev N Refer to Figure 3-15. Item Qty. Description 10.9676.0230.01 SPACER, COLOR WHEEL 10.9676.0230.02 SPACER, COLOR MOTOR 10.9676.0234 AFT BULKHEAD, CROSSFADE COLOR SYSTEM 10.9676.0238 BULKHEAD SPACER 2, COLOR SYSTEM 10.9676.0235 SPACER, BULKHEAD, COLOR SYSTEM 10.9676.0284...
  • Page 87 LLUSTRATED ARTS REAKDOWN SSEMBLY Item Qty. Description 55.9676.0255 BELLEVILLE SPRING WASHER, SPEC B0500-018-S (x4) (x2) (x2) (x4) (x5) (x4) (x2) (x4) Yellow Cyan Detail A (x2) Magenta Dimmer (x4) (x2) (x5) 29 1 (x5) Detail A Yellow Dimmer (x3) Cyan Magenta Figure 3-15: Crossfade Color Assembly 02.

  • Page 88: Iris/Gobo Motor Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Iris/Gobo Motor Assembly 21.9676.0118 Rev D Refer to Figure 3-16. Item Qty. Description 10.9621.0097 STABILIZER, STEPPER, GOBO WHEEL 10.9667.1111 MOTOR BULKHEAD, IRIS/GOBO 10.9667.0126 IRIS CRANK 24.9676.1114 PCB ASSY, SENSOR, VL6B 44.9676.0116 MOTOR, GOBO/COLOR WHEEL 44.9676.0118 MOTOR, IRIS 53.6578.0001...

  • Page 89: Color Motor Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Color Motor Assembly 21.9676.0119 Rev D Refer to Figure 3-17. Item Qty. Description 10.9621.0097 STABILIZER, STEPPER, GOBO WHEEL 10.9676.1120 COLOR MOTOR BULKHEAD 24.9676.1114 PCB ASSY, SENSOR, COLOR/GOBO 44.9676.0116 MOTOR, GOBO/COLOR WHEEL 55.2203.0001 SCREW, 4-40 X 3/16" PPZ 53.6599.0001 SCREW, 4-40 X 3/8"...

  • Page 90: Gobo Wheel Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Gobo Wheel Assembly 21.9676.4146 Rev A Refer to Figure 3-18. Item Qty. Description 22.9676.4142 ASSY, GOBO WHEEL, 12 POSITION FIXED 41.6006.4202 ASSY, VL6 GOBO, VERTICAL BARS (ST) 41.6006.5009 ASSY, VL6 GOBO LIQUID TEXTURE (P.O.) 41.6006.5011 ASSY, VL6 GOBO, NIGHT SKY (ST) 41.6006.5501...

  • Page 91: Color Filter Wheel Assembly

    LLUSTRATED ARTS REAKDOWN SSEMBLY Color Filter Wheel Assembly 21.9676.4145 Rev A Refer to Figure 3-19. Item Qty. Description 22.9676.4142 ASSY, GOBO WHEEL, 12 POSITION FIXED 41.6006.0020 ASSY, VL6 FILTER, MAGENTA (ST) 41.6006.0150 ASSY, VL6 FILTER, PINK (ST) 41.6006.0240 ASSY, VL6 FILTER, LIGHT RED (ST) 41.6006.0320 ASSY, VL6 FILTER, BASTARD AMBER #1 (ST) 41.6006.0440...

  • Page 92: Strobe Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Strobe Assembly 22.9676.0016 Rev H Refer to Figure 3-20. Item Qty. Description 10.9676.0043 BULKHEAD, STROBE MOUNTING 10.9676.0019 STROBE BLADE, DIMPLED 10.9676.0060 MOUNTING COLLAR, STROBE BLADE 10.9676.8061 STABLIZER, STROBE MOTOR 10.9676.0069 MOUNTING PLATE, STROBE MOTOR 10.9678.0491 BUMPER STOP, STROBE 44.9678.0455...
  • Page 93 LLUSTRATED ARTS REAKDOWN SSEMBLY Strobe Assembly (continued) (x2) (x2) (x4) (x4) (x2) (x2) (x6) (x2) (x2) (x4) (x2) (x2) (x2) (x8) Black Side Note connector orientation on motors Figure 3-20: Strobe Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 94: Uv / Ir Window Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL UV / IR Window Assembly 22.9676.0140 Rev G Refer to Figure 3-21. Item Qty. Description 10.9676.0058 UV / IR FRAME 10.9676.0141 INSULATOR, THERMAL SWITCH 41.9678.0608 UV / IR FILTER, 3.00" X 3.00" 53.5504.0187 SCREW, 4-40 X 3/16"...

  • Page 95: Yoke

    LLUSTRATED ARTS REAKDOWN Yoke Yoke Assembly 21.9676.0600 Rev G Refer to Figure 3-22. Item Qty. Description 22.9676.8605 ASSY, YOKE STRUCTURE ASSY, FAN 22.9676.0609 ASSY, TILT MOTOR 22.9676.0610 ASSY, ELEC., RELAY 23.9650.3327 PCB ASSY, SOLID STATE IGNITOR 24.9661.3126 25.9676.0030 CABLE ASSY, IGNITOR TO RELAY (not shown) TOROID CORE ZW-42206-TC (not shown) 43.0298 53.6525.0001...
  • Page 96 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Yoke Assembly (continued) (x2) (x2) (x2) (x4) (x4) (x2) (x4) (x2) (x3) (x2) (x2) Figure 3-22: Yoke Assembly 29-May-2009 02 .9 676 .00 20 B...

  • Page 97: Tilt Motor Assembly

    LLUSTRATED ARTS REAKDOWN Tilt Motor Assembly 22.9676.0610 Rev C Refer to Figure 3-23. Item Qty. Description 10.9676.7298 PLATE, TENSION ADJUST, PAN MOTOR 22.9661.0608 ASSY, DRIVE PULLEY - 10.9661.8640 CODEWHEEL, 90 COUNT - 10.9661.0649 TIMING PULLEY, 2MM GT, 17 TOOTH - 53.5561.0250 SCREW, 6-40 X 1/4"...
  • Page 98 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Tilt Motor Assembly (continued) Detail A Detail A (x2) (x2) (x2) (x2) (x2) (x2) Pulley Height Detail & Installation 0.080" (x4) Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2.

  • Page 99: Yoke Fan Assembly

    LLUSTRATED ARTS REAKDOWN Yoke Fan Assembly 22.9676.0609 Rev A Refer to Figure 3-24. Item Qty. Description 10-9676.0646 FAN TRAY, YOKE ARM 40.7113.0001 FAN, +24V 80 X 80 X 25 MM 32CFM RECPT, 2POS MTA100 W/ POL TAB RED CLSD END 52.6396.2202 NUT, 6-32 KEPS SS 53.2200.0006...
  • Page 100 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Notes 29-May-2009 02 .9 676 .00 20 B...

  • Page 101: Enclosure

    LLUSTRATED ARTS REAKDOWN NCLOSURE Enclosure Upper Enclosure Assembly 21.9676.0800 Rev T Refer to Figure 3-25 Figure 3-26. Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 04.9673.0040 LABEL, 2000 SERIES COMPLIANCE 04.9661.1218.01 LABEL, PATENT, VL2201 & VL2400 SERIES LUMINAIRES 10.9661.1258 BRACKET, APS SIDE 10.9661.1358 AIR SEAL, DUCT 06.6032.0009...
  • Page 102 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Item Qty. Description 69.9676.0700 ASSY, BALLAST MODULE, 700W ARC, SHIELDED 23.9678.0686 FAN ASSY, UPPER ENCLOSURE 23.9678.0687 ELEC ASSY, PAN EOT SENSOR 25.9661.1514 CABLE ASSY, CHASSIS GROUND (not shown) 25.9661.1520 CABLE ASSY, CHASSIS TO YOKE GROUND (not shown) 25.9676.0818 CABLE ASSY, PAN/TILT CONTROL (not shown) 25.9678.0811...
  • Page 103 LLUSTRATED ARTS REAKDOWN NCLOSURE Item Qty. Description 54.1206.0014 RING, RETAINING, 1.375" SHAFT 1.291" DIA GRV X .056" WD 54.1255.0001 BEARING ASSY, BLACK FLUSH MOUNT HOUSING 54.2055.0001 BELT, TIMING S2M 210 GRV 9 MM WIDE URTH/KVLR 55.2150.0003 STANDOFF, 1/4" HEX 6-32 X 1.125" LG FF STL 55.2178.0001 CABLE ANCHOR, MOUNT, #8 SCREW MOUNTING 55.2179.0001...
  • Page 104 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x2) (x4) 83 59, 18 (x3) (x8) (x2) (x3) (x2) (x2) (x2) (x4) 39, 52 (x2) (as required) (x2) Part exploded (as required) for clarity. (x2) (x2) (x2) (x2) (x2) (x3) (x3)
  • Page 105 LLUSTRATED ARTS REAKDOWN NCLOSURE Upper Enclosure Assembly (continued) (x2) (x4) (x2) (x4) (x2) (x4) (x4) (x2) (x4) (x4) Figure 3-26: Upper Enclosure Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 106: Connector Panel Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Connector Panel Assembly 21.9676.0805 Rev B Refer to Figure 3-27. Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY 10.9678.0859 BRACKET, INPUT 10.9678.0872 STIFFNER, DISPLAY BOARD 10.9686.0820 FILLER, PANEL, DMX CONNECTOR 24.9663.3895 PCB ASSY, DMX INPUT 24.9678.3825 PCB ASSY, DISPLAY 25.9678.0810...

  • Page 107: Dmx Input Pcb Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE DMX Input PCB Assembly 24.9663.3895 Rev 0 Refer to Figure 3-28 Item Qty. Description Ref. 17.9663.3895 PCB FAB, DMX INPUT 52.6259.0006 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0006 CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL 52.6626.0006 CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL 62.3039.0102...

  • Page 108: Ac Input Pigtail Cable Assembly

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

  • Page 109: Pan Tube Assembly

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

  • Page 110: Pan Motor Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Pan Motor Assembly 21.9678.0864 Rev E Figure 3-31 Refer to Item Qty. Description 10.9678.0865 PLATE, PAN MOTOR MOUNT 21.9678.0828 ASSY, DRIVE PULLEY, PAN - 10.9686.8720 CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 SCREW, 8-32 X 1/4"...
  • Page 111 LLUSTRATED ARTS REAKDOWN NCLOSURE Pan Motor Assembly (continued) Detail A Pressure-Sensitive Adhesive See Detail A (x2) (x2) (x2) (x4) Drive Pulley Detail & Installation (x4) 0.875" Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2. Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite.

  • Page 112: Upper Enclosure Fan Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Upper Enclosure Fan Assembly 23.9678.0686 Rev 0 Refer to Figure 3-32. Item Qty. Description FAN, 24V FAL6F24LH 40.7125.0001 TERM, SPADE #6 26-24 AWG INS YELLOW 52.8231.0007 (x2) Figure 3-32: Upper Enclosure Fan Assembly 29-May-2009 02 .9 676 .00 20 B...

  • Page 113: Pan Eot Sensor Electrical Assembly

    LLUSTRATED ARTS REAKDOWN NCLOSURE Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-33. Item Qty. Description CONN, HOUSING 6 POS. RECEPTACLE 52.6524.0006 CONTACT, 24-30 AWG FEMALE CRIMP 52.8346.0001 SWITCH, SLOTTED OPTICAL 86.7002.0003 1, 2 (x4) Figure 3-33: Pan EOT Sensor Electrical Assembly 02.
  • Page 114 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Notes 29-May-2009 02 .9 676 .00 20 B...

  • Page 115: Ground Strap Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Cables Note: Cables are only available as complete assemblies. The information contained in this section is for reference only. Ground Strap Cable Assembly 25.8007.2212 Rev 0 Refer to Figure 3-48. Item Qty. Description 52.8329.0001 TERM, RING # 6 22-16 AWG NON-INS 73.7130.0002 0.33 WIRE, 7/64"...

  • Page 116: Lvs Chassis Ground Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-49. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8271.0001 FASTON RECEPT, 16-14 AWG (REEL) 73.3516.0504 WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 Figure 3-49: LVS Chassis Ground Cable Assembly 29-May-2009 02 .9 676 .00 20 B...

  • Page 117: Chassis To Yoke Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-50. Item Qty. Description 52.8250.0006 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (7 x 26.0" LG) (x2) Figure 3-50: Chassis To Yoke Ground Cable Assembly 02.

  • Page 118: Yoke To Head Ground Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Yoke To Head Ground Cable Assembly 25.9667.0028 Rev A Refer to Figure 3-50. Item Qty. Description 52.8250.0001 TERM, #8, RING, 10AWG 73.7089.0010 15.17 WIRE, 22AWG 19X34 MIL-16878/4 TYPE E (7 x 24.0" LG) (x2) Figure 3-51: Chassis To Yoke Ground Cable Assembly 29-May-2009...

  • Page 119: Ignitor To Relay Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Ignitor To Relay Cable Assembly 25.9676.0030 Rev 0 Refer to Figure 3-52. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009 1.17 WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING Figure 3-52: Ignitor To Relay Cable Assembly 02.

  • Page 120: Tilt Plate Ground Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Tilt Plate Ground Cable Assembly 25.9667.0413 Rev A Refer to Figure 3-53. Item Qty. Description 52.8311.0003 TERM, RING #6 BLUE 14-16 AWG NON-INS. 73.7130.0002 0.21 WIRE, 7/64" TUBULAR BRAID SILVER PLATED (x2) Figure 3-53: Tilt Plate Ground Cable Assembly 29-May-2009 02 .9 676 .00 20 B...

  • Page 121: Color/Gobo T-Stat Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Color/Gobo T-Stat Cable Assembly 25.9676.0125 Rev B Refer to Figure 3-54. Item Qty. Description 52.6523.0002 CONN, HOUSING 2POS. PLUG SHROUD 52.8347.0001 CONTACT, 24-30 AWG MALE CRIMP 55.2268.0125 1.00 HEATSHRINK, 1/8" CLEAR KYNAR 63.2047.1105 THERMOSTAT, 105 DEG C, PCB MOUNT 73.3524.1008 0.50 WIRE, 24 AWG 300V 105 DEG C PVC GRAY...

  • Page 122: Color/Fixed Bulkheads Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Color/Fixed Bulkheads Cable Assembly 25.9676.0715 Rev F Refer to Figure 3-55. Item Qty. Description 04.9676.0715.00 LABEL SET, VL2500 COLOR HARNESS 52.6610.0040 HOUSING, 40 POS DBL ROW UNLOADED 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.2040 COVER, BACK 40 POS MT 52.6396.3103...
  • Page 123 LLUSTRATED ARTS REAKDOWN ABLES Color/Fixed Bulkheads Cable Assembly (contin- ued) 14, 7, 8 14, 9, 10 (x4 each) 2, 3, 4, 18 (x7) 16, 5, 6 14, 7, 8 (x2) 14, 7, 8 17, 7, 8 15, 5, 6 Figure 3-55: Color/Fixed Bulkheads Cable Assembly 02.

  • Page 124: Optics/Strobe Bulkheads Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Optics/Strobe Bulkheads Cable Assembly 25.9676.0716 Rev F Refer to Figure 3-56. Item Qty. Description 04.9676.0716.00 LABEL SET, VL2500 COLOR HARNESS 52.6610.0034 HOUSING, 34 POS 26-22 AWG DBL ROW UNLOADED 52.6224.1034 COVER, FRONT 34 POS MT LATCHING 52.6224.2034 COVER, BACK 34 POS MT 52.6467.0004...
  • Page 125 LLUSTRATED ARTS REAKDOWN ABLES Optics/Strobe Bulkheads Cable Assy (contin- ued) 16, 6, 7 16, 10, 12 2, 3, 4, 18 17, 5, 7 16, 8, 11 (x4) 16, 6, 7 16, 9, 11 16, 8, 11 Figure 3-56: Optics/Strobe Bulkheads Cable Assembly 02.

  • Page 126: Strobe 1 Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Strobe 1 Cable Assembly 25.9676.0717 Rev B Refer to Figure 3-57. Item Qty. Description 04.9676.0716.01 LABEL, STROBE 1 52.6523.0004 CONN, HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE 52.6661.0006 CONN, RECEPT 6CIR WIRE TO WIRE 1.25 MM PITCH 52.8347.0001 CONTACT, 24-30 AWG MALE CRIMP 52.8387.0001...

  • Page 127: Fans/Disconnect Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Fans/Disconnect Cable Assembly 25.9676.0718 Rev G Refer to Figure 3-58. Item Qty. Description 52.6396.2403 RECEPT, 3 POS MTA100 W/ POL TAB 24 AWG 52.6524.0002 CONN, HOUSING 2 POS RECEPT 52.6524.0005 CONN, HOUSING 5 POS RECEPT 52.8230.0003 RECEPT, 1/4"...

  • Page 128: Ot Switch To Reflector Assy. Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL OT Switch to Reflector Assy. Cable Assembly 25.9676.0719 Rev A Refer to Figure 3-59. Item Qty. Description 52.8271.0010 RECEPT, FASTON 24-22 AWG NON-INSUL 0.016" TAB 110SERIES 52.8371.0001 RECEPT, FASTON 24-20 AWG UNINSUL TIN PLT BRS .250 X 0.32 73.2624.0008 0.67 WIRE, 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E...

  • Page 129: Pan/Tilt Control Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Pan/Tilt Control Cable Assembly 25.9676.0818 Rev B Refer to Figure 3-60. Item Qty. Description 52.6610.0008 HOUSING, 20 POS 26-22 AWG DBL ROW UNLOADED 52.6224.1020 COVER, FRONT 20 POS MT LATCHING 52.6224.2020 COVER, BACK 20 POS MT 52.6524.0005 CONN, HOUSING 5 POS RECEPT 52.6588.0007...
  • Page 130 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Pan/Tilt Control Cable Assembly (continued) 4, 7 (x5) 1, 2, 3, 11 (x7) 6 (x3),5 6 (x3),5 4, 7 (x5) Figure 3-60: Pan/Tilt Control Cable Assembly 29-May-2009 02 .9 676 .00 20 B...

  • Page 131: Emi Filter To Power Switch Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-61 Item Qty. Description 52.8313.0001 RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL) 52.8392.0001 RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP 55.2186.0001 CABLE TIE, 0.10"...

  • Page 132: Ac Input Splitter Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-62 Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3 POS 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8231.0008 TERM, SPADE #6 RED 22-16 AWG INSERT 52.8392.0001 RECP, FASTON .187"...
  • Page 133 LLUSTRATED ARTS REAKDOWN ABLES AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 Note: Heatshrink not shown for clarity. (x3) Figure 3-62: AC Input Splitter Cable Assembly 02. 96 76. 002 0 B 29-May-2009...

  • Page 134: Data I/O Link Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-63 Item Qty. Description 52.6396.2904 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 52.6396.2905 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 73.5122.0259 2.17 CBL, 22AWG STRND 4COND PVC INSUL...

  • Page 135: Display Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Display Cable Assembly 25.9678.1825 Rev 0 Refer to Figure 3-64 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 73.5116.0123 1.02 WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN> 55.2186.0001 CABLE TIE, .10" WD 4" LG SMALL 73.7130.0004 0.958 WIRE, TUBULAR BRAID, 1/8"...

  • Page 136: Ballast To Controller Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-65 Item Qty. Description 52.6396.3002 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 52.6396.3005 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 52.6396.3008 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 73.5124.1289...

  • Page 137: Lamp Supply To Relay Cable Assembly

    LLUSTRATED ARTS REAKDOWN ABLES Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-66 Item Qty. Description 52.8245.0001 TERM, RING #10 16 - 14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 55.2183.0001 0.33 HEATSHRINK, 1/2"...

  • Page 138: Dc Output Cable Assembly

    VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-67 Item Qty. Description 52.6464.0002 CONN, HOUSING, SL-156 2 POS 52.6464.0003 CONN, HOUSING, SL-156 3 POS 52.8231.0004 TERM, RING #6 BLUE 12-10 AWG INSRT 52.8323.0002 CONTACT, CRIMP, 18-22 AWG SL-156 52.8274.1614...

  • Page 139: Appendix A. Technical Bulletins And Notices

    PPENDIX Technical Bulletins and Notices VL2500 Spot Luminaire Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the VL2500™ Spot Luminaire. If applicable, these improvements have been incorporated into this manual. Technical Bulletin...
  • Page 140 VARI❋LITE® - VL2500™ S UMINAIRE ERVICE ANUAL Notes 29-May-2009 02 .9 676 .00 20 B...
  • Page 142 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA ❋ 1.877.VARI-LITE Fax 1.214.647.8038 www.vari-lite.com Date: 29-May-2009 / Manual Part Number: 02.9676.0020 B ©2003-2009 Vari-Lite, a Philips group company. All rights reserved. Printed in the U.S.A.

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