Philips VL500 Wash Luminaires Service Manual
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Philips VL500 Wash Luminaires Service Manual

Vl500 wash luminaires
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  • Page 2 VARI❋LITE® - VL500™ L 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™ (and the individual product designations), VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the ™...
  • Page 3 BTAIN ARRANTY ERVICE How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548) or customerservice@genlytecontrols.com and request a Return Material Authorization (RMA) for warranty service.
  • Page 4 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
  • Page 5 AFETY OTICE Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product.
  • Page 6 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired.
  • Page 7 ICHERHEITSHINWEISE Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin.
  • Page 8 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1.
  • Page 9 OTES DE SÉCURITÉ Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 10 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2.
  • Page 11 VISO SOBRE EGURIDAD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto.
  • Page 12 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas. ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS 1.
  • Page 13 AFETY OTICE APANESE 02. 96 85. 001 0 A 21-May-2009 xiii...
  • Page 14 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL xi v 21-May-2009 02 .9 685 .00 10 A...

  • Page 15: Table Of Contents

    ABLE OF ONTENTS Table of Contents Introduction Disclosure ........................1 About This Manual ...................... 1 Additional Documentation................... 1 Customer Service ......................2 Chapter 1. Description Features Product Features......................4 Model Specific Features ....................5 Component Descriptions External Luminaire Components ................. 7 Luminaire Internal Head Components.................
  • Page 16 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lamp Life......................23 Solid State Electronics....................24 Electrostatic Discharge (ESD) ................24 Printed Circuit Boards (PCBs)................24 Maintenance Procedures Lamp Replacement - Incandescent................25 Lamp Replacement - Arc.................... 27 Align Lamp For Maximum Beam Irradiance............. 29 Front Glass Replacement....................
  • Page 17 ABLE OF ONTENTS VL500D (with 120V IGBT Dimmer) Luminaire ............87 VL500D (with 240V IGBT Dimmer) Luminaire ............89 VL500 80V (with 80V Dimmer) Luminaire .............. 91 VL500A (700W Arc) Luminaire ................93 Generic VL500 Luminaire Assembly ................ 95 Head Assembly VL500 Generic Head Assembly ................
  • Page 18 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Dimmer Communication Cable Assembly (VL500/VL500D) ........157 24V Power Cable Assembly (VL500/VL500D) ............158 VL500 Motor Cable Assembly ................159 Relay to Ignitor Cable Assembly ................161 VL500 AC Input Cable Assembly ................162 VL500 Arc Ballast Input Cable Assembly ...............163 VL500 Pan / Tilt Cable Assembly ................164 VL500 Head Grounding Cable Assembly ..............166 VL500 Ignitor to Socket Cable Assembly ..............167...

  • Page 19: Disclosure

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

  • Page 20: Customer Service

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL A user’s manual is available for installation and operation of the VL500™ wash luminaire. This manual is available in electronic (PDF) format. VL500™ Luminaire User’s Manual (02.9685.0001). ■ ❋ Technical bulletins concerning the latest changes to VARI LITE®...

  • Page 21: Chapter 1. Description

    HAPTER Description This chapter provides an overview of luminaire features, components and operations. • Features • Component Descriptions • Principles of Operation 02. 96 85. 001 0 A 21-May-2009...

  • Page 22: Features

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Features Product Features VL500™ Wash Luminaire have the following features: Color Enhanced DICHRO❋TUNE radial color changing mechanism featuring independent magenta, blue, and amber color control capable of smooth, timed color crossfades or changes. Pastel (Dichroic Glass) Option: As an option, all versions of the VL500™...

  • Page 23: Model Specific Features

    ESCRIPTION Model Specific Features Each individual configuration has the following specific features: VL500 Wash Luminaire (20.9685.0001) • 120V (or 240V), 1200W (or 1000W) Tungsten Halogen lamp source. • Standard color dichroic glass DICHRO❋TUNE color system. VL500 Wash Luminaire (20.9685.0011) • 120V (or 240V), 1200W (or 1000W) Tungsten Halogen lamp source.
  • Page 24 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V Wash Luminaire (20.9685.0014) • 80V, 1200W Tungsten Halogen lamp source. • Pastel color dichroic glass DICHRO❋TUNE color system. • 80V on-board dimmer. VL500A Wash Luminaire (20.9685.0006) • 700W arc lamp source with external ballast unit. •...

  • Page 25: Component Descriptions

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

  • Page 26: Luminaire Internal Head Components

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

  • Page 27: Luminaire Yoke Components

    ESCRIPTION Luminaire Yoke Components The following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly. Note: Head assembly not shown for clarity. Tilt Mechanism Yoke Arm Cover (Power Supply Side) Main Controller PCB Luminaire control circuit board. Power Supply Side Yoke Arm Cover VL500 Models (120V or 240V)
  • Page 28 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Luminaire Yoke Components (continued) The following illustrations show additional model variations for the power supply side of the luminaire yoke assembly. VL500D Models (120V or 240V) Pan Mechanism IGBT Dimmer Yoke Arm Cover 120W Power Supply Supplies power to electronic and motor...

  • Page 29: Arc Ballast Unit

    ESCRIPTION Arc Ballast Unit An external ballast unit is included with VL500A arc models. In this case, the lamp power input cable is already connectorized for use with this unit. The following illustration shows the external arc ballast components. Truss Hook Mount Used to attach a truss hook.

  • Page 30: Principles Of Operation

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Principles of Operation VL500 Incandescent Luminaires VL500 Incandescent Block Diagram - Without On-Board IGBT Dimmer (120V or 240V) Tilt Motor Motor Tilt Encoder Encoder VL500 Main Control Board (MCB) Magenta Motor Thermal Display Blue Switch Motor...

  • Page 31: Vl500D Incandescent Luminaires

    ESCRIPTION VL500D Incandescent Luminaires VL500D Incandescent Block Diagram - With On-Board IGBT Dimmer (120V or 240V) Tilt Motor Motor Tilt Encoder Encoder VL500 Main Control Board (MCB) Magenta Motor Thermal Display Blue Switch Motor Remote Conn. Amber Thru In Motor IGBT Diffuser Terminal...

  • Page 32: Vl500 80V Incandescent Luminaires

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V Incandescent Luminaires VL500 80V Incandescent Block Diagram - With On-Board 80V Dimmer Tilt Motor Motor Tilt Encoder Encoder VL500 Main Control Board (MCB) Magenta Motor Ferrite Core Thermal Display Blue Switch Motor Remote Conn.

  • Page 33: Vl500A Luminaire

    ESCRIPTION VL500A Luminaire VL500A Arc Block Diagram - With External Arc Ballast Backcap Lamp Interlock Tilt Motor Motor ARC Ballast Ignitor Relay Tilt Encoder Encoder VL500 Main Control Board (MCB) Magenta Motor Thermal Display Blue Switch Motor Remote Conn. Amber Thru In Motor Dimmer...
  • Page 34 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 21-May-2009 02 .9 685 .00 10 A...

  • Page 35: Chapter 2. Maintenance

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

  • Page 36: Testing

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Testing Running Parameter Tests The luminaire is capable of running self tests by using the TEST menu functions. For “Diagnostic Tests” on page 20 complete details and values for each test refer to When running tests on multiple luminaires, a DMX termination connector is required at the last luminaire in the chain.
  • Page 37 AINTENANCE Movement Disable The Movement option allows pan and tilt to be disabled so that the luminaire can be placed in any position for testing without movement occurring. In order to regain full control of the luminaire, Movement will need to be enabled after testing. Note: When using the Movement option, pan and tilt will be disabled for all the luminaires that are linked.

  • Page 38: Diagnostic Tests

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

  • Page 39: Test Menu System Chart

    AINTENANCE Test Menu System Chart The following table shows all the tests that can be performed by accessing the tests via the luminaire’s on-board tech display. Table 2-1: VL500 Test Menu System Chart 1st Level 2nd Level 3rd Level 4th Level 5thLevel Test ** ALL SEQ Sequence Through All...

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

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lamp Hours Progress Bar (Arc Models Only) For arc models, there is a Lamp Hours Progress Bar representing lamp hours used on the lamp. It is tied directly to the lamp hours within the MCB. The bar, when fully extended across the Figure 2 full width of the menu display, represents 750 lamp hours (as indicated in Resetting lamp hours will reset the progress bar.

  • Page 41: Equipment Handling

    AINTENANCE Equipment Handling Below are some basic tips and information on handling VL500 luminaires and their associated components. Locations/Use ❋ VARI LITE luminaires are designed for dry locations only. Exposure to rain or moisture (including, but not limited to, fog machines, misters, etc.) may damage luminaires. Lamps Servicing •...

  • Page 42: Solid State Electronics

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

  • Page 43: Maintenance Procedures

    AINTENANCE Maintenance Procedures Lamp Replacement - Incandescent Parts: 71.2529.0120 1200 WATT TUNGSTEN HALOGEN LAMP, 120 VAC (VL500 AND VL500D MODELS) 71.2526.0230 1 EA 1000 WATT TUNGSTEN HALOGEN LAMP, 230 VAC (VL500 AND VL500D MODELS) 71.9685.0082 1 EA 1200 WATT TUNGSTEN HALOGEN LAMP, 80 VAC (VL500 80V MODELS) Tools: •...
  • Page 44 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lamp Replacement - Incandescent (continued) WARNING: Wear cotton gloves or other covering while servicing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If required, use alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp.

  • Page 45: Lamp Replacement - Arc

    AINTENANCE Lamp Replacement - Arc Parts: 71.9685.0702 1 EA MSR700/2, 700 WATT MSR ARC LAMP Tools: • Cotton gloves or finger cots. WARNING: Remove power from luminaire before performing maintenance. To remove and replace arc lamp: Step 1. Remove power from luminaire. WARNING: Lamps will be extremely HOT after operation.
  • Page 46 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lamp Replacement - Arc (continued) WARNING: Wear cotton gloves or other covering while servicing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If required, use alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp.

  • Page 47: Align Lamp For Maximum Beam Irradiance

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

  • Page 49: Front Glass Replacement

    AINTENANCE Front Glass Replacement Parts: As needed: 42.9685.0201 1 EA GLASS, FRONT, CLEAR 42.9685.0207 1 EA GLASS, FRONT, STIPPLE 42.9685.0203 1 EA GLASS, FRONT, MED. FLOOD 8-ROW LENT. 42.9685.0206 1 EA GLASS, FRONT, MED. FLOOD 10-ROW LENT. 42.9685.0204 1 EA GLASS, FRONT, MED.
  • Page 50 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Front Glass Replacement (continued) CAUTION: Wear thick, protective gloves or other protective covering while handling front lens. The lens is extremely fragile and can break if too much force is applied. If dirty, clean with isopropyl alcohol and a soft, lint-free cloth.

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

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

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

    AINTENANCE Amber/Diffuser (or Dimmer) DICHRO*TUNE Front Bulkhead Replacement Parts: 21.9685.0171 1 EA ASSY, AMBER/DIFFUSER (INCANDESCENT MODELS) 21.9685.0172 1 EA ASSY, AMBER/DIMMER (ARC MODELS) Tools: • #2 Phillips Screwdriver To remove and replace Amber/Diffuser (or Dimmer) bulkhead assembly: Step 1. CLOSE ALL GLASS IN BULKHEADS - Power up unit and allow all DICHRO*TUNE glass to calibrate.
  • Page 54 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Amber/Diffuser (or Dimmer) DICHRO*TUNE Front Bulkhead Replacement (continued) Step 7. Disconnect wiring at two linear actuators on Amber/Diffuser (or Dimmer) DICHRO*TUNE Front Bulkhead. Figure 11 Step 8. As shown in , at side rails from top, remove four 6-32x3/8" LG PPZ SEMS screws.

  • Page 55: Color Filter And Diffuser Panel Replacement

    AINTENANCE Color Filter and Diffuser Panel Replacement Parts: 22.9685.0122 16 EA ASSY, FILTER, MAGENTA, DICHRO*TUNE (STD) 22.9685.0123 16 EA ASSY, FILTER, BLUE, DICHRO*TUNE (STD) 22.9685.0120 16 EA ASSY, FILTER, MAGENTA, DICHRO*TUNE (PASTEL) 22.9685.0121 16 EA ASSY, FILTER, BLUE, DICHRO*TUNE (PASTEL) 22.9685.0124 16 EA ASSY, FILTER, AMBER, DICHRO*TUNE...
  • Page 56 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Color Filter and Diffuser Panel Removal (contin- ued) Step 6. Disconnect actuator screw from Swivel Coupler using tweaker screwdriver by carefully prying apart from Drive Ring Link. Color Filter/ Pad Lip Diffuser Panel Silicone Pad Insert Filter Carrier Pin...

  • Page 57: Arc Dimmer Panel Replacement

    AINTENANCE Arc Dimmer Panel Replacement Parts: 10.9685.0210 16 EA DIMMER BLADE (PANEL), VL500 Tools: • #1 Phillips screwdriver • Tweaker Screwdriver • Cotton Gloves or Finger Cots • Clean, lint-free (soft) cloth To remove and replace dimmer panels: Step 1. Ensure all glass filters and dimmer panels are in closed position. WARNING: Remove power from luminaire before performing maintenance.
  • Page 58 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Dimmer Panel Replacement (Continued). Carrier Dimmer Panel Insert Panel Bearing Here Bulkhead Center Hub Figure 14: Dimmer Panel Replacement Step 11. Replace by performing steps 3 through 10 in reverse order. 21-May-2009 02 .9 685 .00 10 A...

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

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

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

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

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

    AINTENANCE Incandescent Lamp Socket Assembly (VL500 and VL500D Only) Replacement Parts: 23.9685.0780 1 EA ASSY, LAMP SOCKET (VL500 AND VL500D ONLY) Tools: • #2 Phillips Screwdriver • 1/4" Hex Nutdriver To remove and replace lamp socket assembly: Step 1. CLOSE ALL GLASS IN BULKHEADS - Power up unit and allow all DICHRO*TUNE glass to calibrate.
  • Page 64 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Figure 20 Step 9. As indicated in , at light baffle, remove three 6-32x1/8" PPB screws. Backcap Light Leak Foam Lamp Socket Reflector Light Baffle 6-32x1/4" PPZ Screws (x2) 8-32x1/2" PPZ SEM Screws (x4) Reflector Clips (x3) 1/4"...

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

    AINTENANCE Arc Lamp Socket Assembly (VL500A and VL500 80V Only) Replacement Parts: 23.9685.0780 1 EA ASSY, LAMP SOCKET (VL500 AND VL500D ONLY) Tools: • #2 Phillips Screwdriver • 1/4" Hex Nutdriver • 5/64" Allen Wrench To remove and replace lamp socket assembly: Step 1.
  • Page 66 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Step 8. Using soft cloth to protect lamp, remove lamp from socket. Figure 22 Step 9. As indicated in , at light baffle, remove three 6-32x1/8" PPB screws. 10-32x1-1/2" PPB Screws VL500A Only 10-32x1"...

  • Page 67: Display Pcb Replacement

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

  • Page 68: Main Control Pcb/Fan Assembly Replacement

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Main Control PCB/Fan Assembly Replacement Parts: 21.9685.0731 1 EA ASSY, VL500 MAIN CONTROL PCB/FAN Tools: • 1/4" Hex Nutdriver • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace main control PCB/fan assembly: Step 1.
  • Page 69 AINTENANCE Main Control PCB/Fan Assembly Replacement (continued) Menu Display 6-32x1/4" PPB (x4) Yoke Arm Cover 1/4" Hex (9/32" Long) Standoff (x4) Display PCB 1/4" Hex (13/16" Long) Standoff (x4) Main Control PCB Main Control PCB NOTE: Some components not shown for clarity. Figure 24: Main Control PCB/Fan Replacement Step 7.

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

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Low Voltage Supply (LVS) Replacement (VL500/ VL500D/VL500A Only) Parts: 69.3178.0121 1 EA POWER SUPPLY, 120W, 24VDC Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. WARNING: With power applied, LIVE AC is present at heatsink. Do not touch when unit is powered.

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

    AINTENANCE Low Voltage Supply (LVS) Temperature PCB Replacement (VL500/VL500D/VL500A Only) Parts: 24.9685.0740 1 EA TEMPERATURE BOARD, LVS Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. WARNING: With power applied, LIVE AC is present at heatsink. Do not touch when unit is powered.

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

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Low Voltage Supply (LVS) Replacement (VL500 80V Only) Parts: 69.3178.0121 1 EA POWER SUPPLY, 120W, 24VDC Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. WARNING: With power applied, LIVE AC is present at heatsink. Do not touch when unit is powered.
  • Page 73 AINTENANCE Step 5. Remove LVS Temperature Sensor PCB by following “Low Voltage Supply (LVS) Temperature PCB Replacement (VL500 80V Only)” on page 56 Step 6. Disconnect the following wiring connections: a. 3-position connector (AC Input) b. 6-position MTA connector (DC Output) Figure 27 Step 7.

  • Page 74: Low Voltage Supply (Lvs) Temperature Pcb Replacement (Vl500 80V Only)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Low Voltage Supply (LVS) Temperature PCB Replacement (VL500 80V Only) Parts: 24.9685.0740 1 EA TEMPERATURE BOARD, LVS Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. WARNING: With power applied, LIVE AC is present at heatsink. Do not touch when unit is powered.
  • Page 75 AINTENANCE Step 4. Disconnect the following wiring connections on PCB: a. 2-position connector (LVS Fan) b. 4-position connector (LVS Fan from MCB) Figure 28 Step 5. As shown in , remove one 6-32x3/8" PPZ securing LVS Temperature PCB to LVS fan mount. Step 6.

  • Page 76: Tilt Motor Assembly Replacement

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Tilt Motor Assembly Replacement Parts: 21.9685.0540 1 EA ASSY, PAN/TILT MOTOR Tools: • #2 Phillips Screwdriver • Diagonal Cutters WARNING: Remove power from luminaire before performing maintenance. To remove and replace tilt motor assembly: Step 1.
  • Page 77 AINTENANCE Step 7. Loosen (do NOT remove) four 8-32x7/16" PPZ screws that mount Pan/Tilt motor assembly to Tilt Motor Slide Plate. Tilt Motor Assembly NOTE: Some components not shown for clarity. 8-32x7/16" PPZ Tilt Motor Assembly Tilt Motor Slide Plate Yoke Arm Cover 8-32x7/16"...

  • Page 78: Pan Motor Assembly Replacement

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

  • Page 79: Pan/Tilt Encoder Pcb Replacement

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

  • Page 80: Arc Ignitor Pcb Replacement (Vl500A Only)

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

  • Page 81: Igbt Dimmer Replacement - Vl500D Only

    AINTENANCE IGBT Dimmer Replacement - VL500D Only Parts: 69.3173.0115 1 EA DIMMER, IGBT, 1200W 120V REV PHASE CONT (VL500D 115V MODELS ONLY) 69.3173.0240 1 EA DIMMER, IGBT, 1200W 240V REV PHASE CONT (VL500D 240V MODELS ONLY) Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance.
  • Page 82 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL IGBT Dimmer Replacement - VL500D Only (con- tinued) NOTE: Some components not shown for clarity. 6-32x3/8" PTB Screws (x4) Yoke Arm Cover (Dimmer Side) 6-32x3/8" PPZ Screws (x4) IGBT Dimmer Figure 33: IGBT Dimmer Replacement (VL500D Only) Step 7.

  • Page 83: 80V Dimmer Replacement - Vl500 80V Only

    AINTENANCE 80V Dimmer Replacement - VL500 80V Only Parts: 21.9685.2750 1 EA ASSY, 80V DIMMER Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace 80V dimmer: Step 1. Disconnect luminaire AC input cable from power source. Step 2.
  • Page 84 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL NOTE: Some components not shown for clarity. 6-32x3/8" PTB Screws (x4) Yoke Arm Cover (Dimmer Side) 6-32x3/8" PPZ Screws (x4) 80V Dimmer Figure 34: 80V Dimmer Replacement (VL500 80V only) Step 7. Replace 80V Dimmer by performing Steps 2 through 6 in reverse. 21-May-2009 02 .9 685 .00 10 A...

  • Page 85: Arc Ballast Replacement (Vl500A Only)

    AINTENANCE Arc Ballast Replacement (VL500A Only) Parts: 21.9685.0802 1 EA ASSY, BALLAST, 700W Tools: • None WARNING: Remove power from luminaire before performing maintenance. To remove and replace arc ballast dimmer: Step 1. Disconnect luminaire AC input cable from power source. Note: The Arc Ballast Unit is separate from the luminaire.

  • Page 86: Safety Relay Replacement (Vl500A Only)

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

  • Page 87: Ac Input (Powercon) Connector Replacement

    AINTENANCE AC Input (PowerCon) Connector Replacement Parts: 25.9685.0756 1 EA CONNECTOR, AC INPUT (POWERCON) Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace AC input (PowerCon) connector: Step 1. Remove power from luminaire. Step 2.

  • Page 88: Mini-Xlr (Display/Remote Programming) Connector Replacement

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

  • Page 89: Dmx Pcb Assembly Replacement

    AINTENANCE DMX PCB Assembly Replacement Parts: 24.9663.3895 1 EA ASSY, DMX INPUT PCB Tools: • #2 Phillips Screwdriver WARNING: Remove power from luminaire before performing maintenance. To remove and replace DMX PCB assembly: Step 1. Remove power from luminaire. Step 2. Position light to access top of pan tube assembly. Figure 38 Step 3.

  • Page 90: Cleaning Optical Lenses And Filters

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Cleaning Optical Lenses and Filters WARNING: Remove power from luminaire before performing maintenance. WARNING: Acetone is a harsh cleaning agent and solvent. Acetone is very flammable. Please handle acetone according to manufacturer’s safety instructions and precautions. The front lens, optics/color filters, and reflector may require cleaning after extended use.

  • Page 91: Chapter 3. Illustrated Parts Breakdown

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

  • Page 92: Drawing Trees

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Drawing Trees VL500 and VL500D Incandescent Luminaires VL500 (120V or 240V) Luminaire Incandescent Versions 20.9685.0001 Rev G (Standard DICRO*TUNE Colors) 20.9685.0011 Rev B (Pastel DICRO*TUNE Colors) 20.9685.0002 Rev F (Standard DICRO*TUNE Colors) 20.9685.0012 Rev B (Pastel DICRO*TUNE Colors) 20.9685.0003 Rev F (Standard DICRO*TUNE Colors) 20.9685.0013 Rev B (Pastel DICRO*TUNE Colors)
  • Page 93 LLUSTRATED ARTS REAKDOWN VL500 and VL500D Incandescent Luminaires (continued) continued from previous page continued from previous page VL500 Amber/Diffuser Color VL500 Yoke Assembly Assembly 21.9685.0520 (VL500) Rev U 21.9685.0171 Rev G 21.9685.0521 (VL500D) Rev U Top Bulkhead Assembly Arc Yoke Lamp Cable Assembly 21.9685.0151 Rev C (VL500A) 25.9685.0790 Rev J (VL500 and...

  • Page 94: Vl500 80V Incandescent Luminaires

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V Incandescent Luminaires VL500 80V (with 80V Dimmer) Luminaire 20.9685.0004 Rev L (Standard DICRO*TUNE Colors) 20.9685.0014 Rev G (Pastel DICRO*TUNE Colors) Generic VL500 Luminaire Assembly VL500 Magenta/Blue Color VL500 Motor Cable Assembly 21.9685.0012 Rev S (Incandescent - with Assembly Internal 80V Dimmer)
  • Page 95 LLUSTRATED ARTS REAKDOWN VL500 80V Incandescent Luminaires (contin- ued) continued from previous page VL500 80V Yoke Assembly 21.9685.0523 (VL500 80V) Rev Q VL500 80V Main Harness Cable Assembly 25.9685.2792 Rev A (VL500 80V) VL500 Extra Hardware Kit 28.9685.0999 Rev 0 MCB-Fan Assembly 23.9685.0782 Rev 0 Yoke Crossmember Assembly...

  • Page 96: Vl500A Arc Luminaires

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500A Arc Luminaires VL500A (700W Arc) Luminaire 20.9685.0006 Rev H (Standard DICRO*TUNE Colors) 20.9685.0016 Rev B (Pastel DICRO*TUNE Colors) Generic VL500 Luminaire Assembly VL500 Magenta/Blue (Arc) VL500 Motor Cable Color Assembly 21.9685.0013 Rev S (Arc) Assembly 21.9685.0173 Rev A (Standard 25.9685.0753 Rev B...
  • Page 97 LLUSTRATED ARTS REAKDOWN VL500A Arc Luminaires (continued) continued from previous page continued from previous page VL500A (700W Arc) Luminaire VL500 Yoke Assembly 28.9685.0006 Rev G (700W Arc, Standard Colors, Arc Ballast) Figure 21.9685.0522 (VL500A) Rev U 3-7. MCB-Fan Assembly VL500 Arc Ballast Interconnect Cable Assembly 21.9685.0731 Rev 0 25.9685.0767 Rev B VL500 Extra Hardware Kit...

  • Page 98: Top Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Top Assembly Included Items Kit 28.9685.0001 Rev G (120V or 240V, Standard Colors, No Dimmer) 28.9685.0002 Rev G (Standard Colors, 120V IGBT On-Board Dimmer) 28.9685.0003 Rev G (Standard Colors, 240V IGBT On-Board Dimmer) 28.9685.0004 Rev G (Standard Colors, 80V On-Board Dimmer) 28.9685.0006 Rev G (700W Arc, Standard Colors, Arc Ballast) Refer to...
  • Page 99 LLUSTRATED ARTS REAKDOWN Included Items Kit (continued) (Arc Models Only) (Arc Models Only) Figure 3-7: Included Items Kit 02. 96 85. 001 0 A 21-May-2009...

  • Page 100: Label Locations

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Label Locations 16.9685.00YY Rev D Refer to Figure 3-8. Note: (CLR) = Clear labels - for use with non-black fixtures. Item Qty. Description 04.9661.0034 LABEL, RELAMPING - 2000 SERIES 04.9663.1837 LABEL, PATENT 04.9685.0911 LABEL, WARNING VL500 04.9685.0911.00 LABEL, WARNING VL500 (CLR)
  • Page 101 LLUSTRATED ARTS REAKDOWN Item Qty. Description 04.9685.0920 LABEL, AC INPUT RATING (VL500 MODELS ONLY) 04.9685.0920.00 LABEL, AC INPUT RATING (CLR) (VL500 MODELS ONLY) 04.9685.0921 LABEL, AC INPUT RATING (VL500 PASTEL MODELS ONLY) 04.9685.0921.00 LABEL, AC INPUT RATING (CLR) (VL500 PASTEL MODELS ONLY) 04.9685.0922 LABEL, AC INPUT RATING (VL500D 120V MODELS ONLY) 04.9685.0922.00...
  • Page 102 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Label Locations (continued) (VL500 Models Only) (Non-Arc Models Only) (Non-Arc Models Only) 10911 PETAL STREET LI ST DALLAS, TX. 75238 U.S.A. − NOT FOR RESIDENTIAL USE Vari-Lite, Inc. 1.877.VARILITE IMPROPERE A L’USAGE DOMESTIQUE WWW.VARI−LITE.COM SUITABLE FOR DRY LOCATIONS ONLY.

  • Page 103: Vl500 (120V Or 240V) Luminaire

    LLUSTRATED ARTS REAKDOWN VL500 (120V or 240V) Luminaire 20.9685.0001 Rev G (Standard DICRO*TUNE Colors) 20.9685.0011 Rev B (Pastel DICRO*TUNE Colors) Refer to Figure 3-9 Item Qty. Description 04.9685.0573 LABEL, MCB YOKE COVER 04.9685.0574 LABEL, MCB YOKE COVER 04.9685.0588 LABEL, YOKE COVER, PLAIN, VL500 10.9685.0525 LOUVER PLATE, TOP COVER 10.9685.0580...
  • Page 104 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 (120V or 240V) Luminaire (continued) (x2) (x8) (x4) (x8) (x8) Figure 3-9: VL500 (120V or 240V) Luminaire 21-May-2009 02 .9 685 .00 10 A...

  • Page 105: Vl500D (With 120V Igbt Dimmer) Luminaire

    LLUSTRATED ARTS REAKDOWN VL500D (with 120V IGBT Dimmer) Luminaire 20.9685.0002 Rev F (Standard DICRO*TUNE Colors) 20.9685.0012 Rev B (Pastel DICRO*TUNE Colors) Refer to Figure 3-10 Item Qty. Description 04.9685.0573 LABEL, MCB YOKE COVER 04.9685.0574 LABEL, MCB YOKE COVER 04.9685.0576 LABEL, YOKE COVER, DIMMER 04.9685.0577 LABEL, YOKE COVER, DIMMER 10.9685.0525...
  • Page 106 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500D (with 120V IGBT Dimmer) Luminaire (continued) (x2) (x8) (x4) (x8) (x8) (x2) (x8) Figure 3-10: VL500D (with 120V IGBT Dimmer) Luminaire 21-May-2009 02 .9 685 .00 10 A...

  • Page 107: Vl500D (With 240V Igbt Dimmer) Luminaire

    LLUSTRATED ARTS REAKDOWN VL500D (with 240V IGBT Dimmer) Luminaire 20.9685.0003 Rev F (Standard DICRO*TUNE Colors) 20.9685.0013 Rev B (Pastel DICRO*TUNE Colors) Refer to Figure 3-11 Item Qty. Description 04.9685.0573 LABEL, MCB YOKE COVER 04.9685.0574 LABEL, MCB YOKE COVER 04.9685.0576 LABEL, YOKE COVER, DIMMER 04.9685.0577 LABEL, YOKE COVER, DIMMER 10.9685.0525...
  • Page 108 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500D (with 240V IGBT Dimmer) Luminaire (continued) (x4) (x2) (x8) (x8) (x2) (x8) (x8) Figure 3-11: VL500D (with 240V IGBT Dimmer) Luminaire 21-May-2009 02 .9 685 .00 10 A...

  • Page 109: Vl500 80V (With 80V Dimmer) Luminaire

    LLUSTRATED ARTS REAKDOWN VL500 80V (with 80V Dimmer) Luminaire 20.9685.0004 Rev L (Standard DICRO*TUNE Colors) 20.9685.0014 Rev G (Pastel DICRO*TUNE Colors) Refer to Figure 3-12 Item Qty. Description 04.9685.0573 LABEL, MCB YOKE COVER 04.9685.0574 LABEL, MCB YOKE COVER 04.9685.0578 LABEL, YOKE COVER, 80V DIMMER 04.9685.0579 LABEL, YOKE COVER, 80V DIMMER 10.9685.0525...
  • Page 110 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V (with 80V Dimmer) Luminaire (con- tinued) (x2) (x4) (x8) (x8) (x4) (x8) (x4) Figure 3-12: VL500 80V (with 80V Dimmer) Luminaire 21-May-2009 02 .9 685 .00 10 A...

  • Page 111: Vl500A (700W Arc) Luminaire

    LLUSTRATED ARTS REAKDOWN VL500A (700W Arc) Luminaire 20.9685.0006 Rev H (Standard DICRO*TUNE Colors) 20.9685.0016 Rev B (Pastel DICRO*TUNE Colors) Refer to Figure 3-13 Item Qty. Description 04.9685.0573 LABEL, MCB YOKE COVER 04.9685.0574 LABEL, MCB YOKE COVER 04.9685.0588 LABEL, YOKE COVER, PLAIN, VL500 10.9685.0525 LOUVER PLATE, TOP COVER 10.9685.0580...
  • Page 112 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500A (700W Arc) Luminaire (continued) (x2) (x4) (x8) (x8) (x8) Figure 3-13: VL500A Luminaire (700W Arc) 21-May-2009 02 .9 685 .00 10 A...

  • Page 113: Generic Vl500 Luminaire Assembly

    LLUSTRATED ARTS REAKDOWN Generic VL500 Luminaire Assembly 21.9685.0010 Rev S (Incandescent - without Internal Dimmer) 21.9685.0011 Rev S (Incandescent - with Internal IGBT Dimmer) 21.9685.0012 Rev S (Incandescent - with Internal 80V Dimmer) 21.9685.0013 Rev S (Arc) Refer to Figure 3-14, Figure 3-15, and...
  • Page 114 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Item Qty. Description 53.6558.0009 SCREW, 6-32X3/8", PPZ, SEMS (VL500 ONLY) 53.6558.0009 SCREW, 6-32X3/8", PPZ, SEMS (VL500D AND VL500 80V ONLY) 53.6558.0009 SCREW, 6-32X3/8", PPZ, SEMS (VL500A ONLY) 53.6558.0010 SCREW, 6-32X1/4", PPB, SEMS 53.6596.0002 SCREW, 4-40X5/16"...
  • Page 115 LLUSTRATED ARTS REAKDOWN Generic VL500 Luminaire Assembly (contin- ued) (VL500D Only) (VL500 Only) (VL500D Only) (x4) Figure 3-14: Generic VL500 Luminaire Assembly (VL500 and VL500D) 02. 96 85. 001 0 A 21-May-2009...
  • Page 116 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Generic VL500 Luminaire Assembly (contin- ued) (x4) Figure 3-15: Generic VL500 Luminaire Assembly (VL500 80V) 21-May-2009 02 .9 685 .00 10 A...
  • Page 117 LLUSTRATED ARTS REAKDOWN Generic VL500 Luminaire Assembly (contin- ued) (x4) 29, 40 (x4) Figure 3-16: Generic VL500 Luminaire Assembly (VL500A) 02. 96 85. 001 0 A 21-May-2009...
  • Page 118 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 21-May-2009 02 .9 685 .00 10 A...

  • Page 119: Head Assembly

    LLUSTRATED ARTS REAKDOWN Head Assembly VL500 Generic Head Assembly 21.9685.0310 (VL500 and VL500D) Rev K 21.9685.0311 (VL500A) Rev K 21.9685.0312 (VL500 80V) Rev K Refer to Figure 3-17, Figure 3-18, and Figure 3-19. Item Qty. Description 10.9634.0162 2.125 GASKET, LENS, FRONT CASTING 10.9685.0340 SUPPORT, RIB 10.9685.0344...
  • Page 120 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Generic Head Assembly (continued) (x2) (x4) (x2) (x2) (x4) Figure 3-17: VL500 Generic Head Assembly (VL500 and VL500D) 21-May-2009 02 .9 685 .00 10 A...
  • Page 121 LLUSTRATED ARTS REAKDOWN VL500 Generic Head Assembly (continued) (x2) (x2) (x4) (x2) (x2) (x4) Figure 3-18: VL500 Generic Head Assembly (VL500A) 02. 96 85. 001 0 A 21-May-2009...
  • Page 122 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Generic Head Assembly (continued) (x2) (x4) (x2) (x2) (x4) Figure 3-19: VL500 Generic Head Assembly (VL500 80V) 21-May-2009 02 .9 685 .00 10 A...

  • Page 123: Heatsink Assembly

    LLUSTRATED ARTS REAKDOWN Heatsink Assembly 21.9685.0320 (VL500 and VL500D) Rev H 21.9685.0321 (VL500A) Rev H 21.9685.0322 (VL500 80V) Rev H Refer to Figure 3-20, Figure 3-21, and Figure 3-22. Item Qty. Description 10.9634.0103 PAD, REFLECTOR MOUNT 10.9685.0343 CLIP, REFLECTOR 10.9685.0345 CLIP, SOCKET (VL500A AND VL500 80V ONLY) 10.9685.0360 FOAM, HEATSINK LIGHT LEAK...
  • Page 124 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Heatsink Assembly (continued) (x3) (x2) (x2) (x4) (x3) (x3) (x3) Figure 3-20: VL500 Heatsink Assembly (VL500 and VL500D) 21-May-2009 02 .9 685 .00 10 A...
  • Page 125 LLUSTRATED ARTS REAKDOWN VL500 Heatsink Assembly (continued) (x3) (x3) (x3) (x3) (x2) (x2) (x4) (x2) (x3) (x3) (x3) Figure 3-21: VL500 Heatsink Assembly (VL500A) 02. 96 85. 001 0 A 21-May-2009...
  • Page 126 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Heatsink Assembly (continued) (x3) (x3) (x3) (x2) (x2) (x2) (x4) (x3) (x3) (x3) Figure 3-22: VL500 Heatsink Assembly (VL500 80V) 21-May-2009 02 .9 685 .00 10 A...

  • Page 127: Vl500 Magenta/Blue Color Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Magenta/Blue Color Assembly 21.9685.0170 Rev H (Standard DICRO*TUNE Colors) Refer to Figure 3-23. Item Qty. Description 10.9685.0257 LIGHT BAFFLE, REAR BULKHEAD 21.9685.0160 ASSY, MAGENTA/BLUE, STANDARD, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16"...

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

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Magenta/Blue (Pastel) Color Assembly 21.9685.0174 Rev A (Pastel DICRO*TUNE Colors) Refer to Figure 3-24. Item Qty. Description 10.9685.0257 LIGHT BAFFLE, REAR BULKHEAD 21.9685.0164 ASSY, MAGENTA/BLUE, PASTEL, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 53.6592.0250 SCREW, 4-40X1/4"...

  • Page 129: Vl500 Amber/Diffuser Color Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Amber/Diffuser Color Assembly 21.9685.0171 Rev G Refer to Figure 3-25. Item Qty. Description 10.9685.0245 LIGHT BAFFLE, TOP 21.9685.0161 ASSY, AMBER/DIFFUSER, DICRO❋TUNE 21.9685.0281 MOTOR ASSY, AMBER/DIFFUSER 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x4) Figure 3-25: VL500 Amber/Diffuser Color Assembly...

  • Page 130: Vl500 Amber/Dimmer Color Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Amber/Dimmer Color Assembly 21.9685.0172 Rev F Refer to Figure 3-26. Item Qty. Description 10.9685.0245 LIGHT BAFFLE, TOP 21.9685.0162 ASSY, AMBER/DIMMER, DICRO❋TUNE 21.9685.0281 MOTOR ASSY, AMBER/DIFFUSER 53.6592.0250 SCREW, 4-40X1/4" PPB SEMS 55.6704.0015 STANDOFF, 5/16" HEX, 6-32X0.593" LG (x4) (x4) Figure 3-26: VL500 Amber/Dimmer Color Assembly...

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

    LLUSTRATED ARTS REAKDOWN VL500 Magenta/Blue (Arc) Color Assembly 21.9685.0173 Rev A (Standard DICRO*TUNE Colors) Refer to Figure 3-27. Item Qty. Description 10.9685.0246 CLIP, UV GLASS 10.9685.0257 LIGHT BAFFLE, REAR BULKHEAD 21.9685.0160 ASSY, MAGENTA/BLUE, STANDARD, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 42.9685.0130 GLASS, UV 53.6592.0250 SCREW, 4-40X1/4"...

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

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Magenta/Blue (Arc Pastel) Color Assembly 21.9685.0175 Rev A (Pastel DICRO*TUNE Colors) Refer to Figure 3-28. Item Qty. Description 10.9685.0246 CLIP, UV GLASS 10.9685.0257 LIGHT BAFFLE, REAR BULKHEAD 21.9685.0164 ASSY, MAGENTA/BLUE, PASTEL, DICRO❋TUNE 21.9685.0280 MOTOR ASSY, MAG/BLUE 42.9685.0130...

  • Page 133: Magenta/Blue Color Assembly

    LLUSTRATED ARTS REAKDOWN Magenta/Blue Color Assembly 21.9685.0160 Rev E (Standard DICRO*TUNE Colors) Refer to Figure 3-29. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 21.9685.0150 ASSY, BOTTOM BULKHEAD 22.9685.0122 ASSY, FILTER, MAGENTA, DICRO❋TUNE 22.9685.0123 ASSY, FILTER, BLUE, DICRO❋TUNE (x16)

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

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Magenta/Blue (Pastel) Color Assembly 21.9685.0164 Rev 0 (Pastel DICRO*TUNE Colors) Refer to Figure 3-30. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 21.9685.0150 ASSY, BOTTOM BULKHEAD 22.9685.0120 ASSY, FILTER, MAGENTA, PASTEL, DICRO❋TUNE...

  • Page 135: Amber/Diffuser Color Assembly

    LLUSTRATED ARTS REAKDOWN Amber/Diffuser Color Assembly 21.9685.0161 Rev F Refer to Figure 3-31. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 21.9685.0151 ASSY, BULKHEAD, TOP 22.9685.0124 ASSY, FILTER, AMBER, DICRO❋TUNE 22.9685.0126 ASSY, DIFFUSER PANEL (x16)

  • Page 136: Amber/Dimmer Color Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Amber/Dimmer Color Assembly 21.9685.0162 Rev E Refer to Figure 3-32. Item Qty. Description 10.9634.0034 SPRING, DRIVE ARM, FILTER 10.9634.0035 LINK, DRIVE ARM 10.9634.0166 CARRIER, FILTER, METAL INJ MOLD 10.9647.0121 BAFFLE, INNER LIGHT 10.9661.0307 CARRIER, DIMMER 10.9661.0312 BEARING, DIMMER...
  • Page 137 LLUSTRATED ARTS REAKDOWN Amber/Dimmer Color Assembly (continued) (x16) (x16) (x16) (x16) (x16) (x16) (x16) (x16) (x16) (x16) Figure 3-32: Amber/Dimmer Color Assembly 02. 96 85. 001 0 A 21-May-2009...

  • Page 138: Bottom Bulkhead Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Bottom Bulkhead Assembly 21.9685.0150 Rev C Refer to Figure 3-33. Item Qty. Description 10.9661.0315 SUPPORT, BULKHEAD 21.9685.0251 ASSY, DRIVE RING 22.9634.0119 ASSY, CENTER HUB 22.9685.0201 ASSY, GENERIC BULKHEAD 53.6682.0002 SCREW, 4-40X1/4" PPZ SEMS 55.6612.0008 PIN, 1/8"...
  • Page 139 LLUSTRATED ARTS REAKDOWN Bottom Bulkhead Assembly (continued) (x4) (x10) (x8) (x4) (x4) Figure 3-33: Bottom Bulkhead Assembly 02. 96 85. 001 0 A 21-May-2009...

  • Page 140: Top Bulkhead Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Top Bulkhead Assembly 21.9685.0151 Rev C Refer to Figure 3-34. Item Qty. Description 10.9661.0315 SUPPORT, BULKHEAD 10.9685.0219 AUX RING, COLOR BULKHEAD 21.9685.0251 ASSY, DRIVE RING 22.9634.0120 ASSY, LIGHT BAFFLE 22.9685.0201 ASSY, GENERIC BULKHEAD 53.6682.0002 SCREW, 4-40X1/4"...
  • Page 141 LLUSTRATED ARTS REAKDOWN Top Bulkhead Assembly (continued) (x4) (x2) (x4) (x8) (x10) (x4) (x4) Figure 3-34: Top Bulkhead Assembly 02. 96 85. 001 0 A 21-May-2009...

  • Page 142: Drive Ring Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Drive Ring Assembly 21.9685.0251 Rev D Refer to Figure 3-36. Item Qty. Description 10.9634.0105 LINK, SWIVEL 10.9685.7240 ROLLER, DRIVE RING 22.9685.0238 RING, DRIVE, WITH PINS 53.5554.0875 SCREW, 4-40X7/8" SET SS FLAT POINT 53.6659.0013 SCREW, 2-56X1/8"...

  • Page 143: Magenta/Blue Color Motor Assembly

    LLUSTRATED ARTS REAKDOWN Magenta/Blue Color Motor Assembly 21.9685.0280 Rev A Refer to Figure 3-36. Item Qty. Description 10.9634.0061 ACTUATOR MOUNT, VL500 10.9634.0075 HEAT SHIELD, MAGENTA/BLUE 44.9685.0230 MOTOR, LINEAR, 0.002"/STEP 53.6520.0001 SCREW, 4-40X3/8" PPZ 53.6682.0002 SCREW, 4-40X1/4" PPZ SEMS 54.1217.0004 LINK, VL500 ACTUATOR-DRIVE RING (x3) Actuator Screw (x4)

  • Page 144: Amber/Diffuser Color Motor Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Amber/Diffuser Color Motor Assembly 21.9685.0281 Rev A Refer to Figure 3-36. Item Qty. Description 10.9634.0061 ACTUATOR MOUNT, VL500 10.9634.0074 HEAT SHIELD, AMBER/DIFFUSER 44.9685.0230 MOTOR, LINEAR, 0.002"/STEP 53.6520.0001 SCREW, 4-40X3/8" PPZ 53.6682.0002 SCREW, 4-40X1/4" PPZ SEMS 54.1217.0004 LINK, VL500 ACTUATOR-DRIVE RING (x3)

  • Page 145: Yoke Assembly

    LLUSTRATED ARTS REAKDOWN Yoke Assembly VL500 Yoke Assembly 21.9685.0520 (VL500) Rev U 21.9685.0521 (VL500D) Rev U 21.9685.0522 (VL500A) Rev U Refer to Figure 3-38 Figure 3-39. Item Qty. Description 10.9685.0534 COVER, PAN TUBE 10.9685.0537 PLATE, MOUNTING, LAMP POWER PIGTAIL (VL500 ONLY) 10.9685.0538 BEZEL, LAMP POWER PIGTAIL (VL500 ONLY) 10.9685.1560...
  • Page 146 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Item Qty. Description 53.6519.0001 SCREW, 4-40X5/8" PPZ 53.6521.0001 SCREW, 8-32X1/2" PPB 53.6526.0002 SCREW, 6-32X5/8" PPZ TYPE F 53.6546.0003 SCREW, 8-32X7/16" PPZ 53.6552.0002 SCREW, 8-32X1/2" PFB 53.6559.0002 SCREW, 4-40X1/4" PFB 53.6606.0001 SCREW, 4-40X1/2" PFB 53.6608.0750 SCREW, 6-32X3/8"...
  • Page 147 LLUSTRATED ARTS REAKDOWN VL500 Yoke Assembly (continued) (x6) (x2) (x2) (x4) (VL500A) (VL500D) (x4) (x4) (x2) (x2) (x2) (x4) Figure 3-38: VL500 Yoke Assembly (VL500/VL500D/VL500A) 02. 96 85. 001 0 A 21-May-2009...
  • Page 148 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Yoke Assembly (continued) (x4) (x4) (x4) (x6) (x4) (x3) (x3) (x4) (x12) (x6) Figure 3-39: VL500 Yoke Assembly (VL500/VL500D/VL500A) 21-May-2009 02 .9 685 .00 10 A...

  • Page 149: Vl500 80V Yoke Assembly

    LLUSTRATED ARTS REAKDOWN VL500 80V Yoke Assembly 21.9685.0523 (VL500 80V) Rev Q Refer to Figure 3-40, Figure 3-41. Item Qty. Description 10.9685.0542 SHIELD, WIRE 10.9685.0543 SHIELD, SENSOR BOARD 10.9685.1554 COVER, PAN TUBE, 80V 10.9685.0557 COVER, VENT, LVS 10.9685.0558 FAN MOUNT, LVS 10.9685.1560 YOKE LEG, TILT SIDE 10.9685.1561...
  • Page 150 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Item Qty. Description 54.2065.0001 BELT, TIMING, S2M 252 GROOVE 55.2203.0001 SCREW, 4-40X1/4" PPZ 55.3301.0008 WASHER, #8 FLAT SS 55.3301.0010 WASHER, #10 FLAT 55.6543.0001 GROMMET STRIP, SERRATED, 0.062 55.6568.0056 SPRING, CPRSN, 0.600 OD, 0.080 WIRE 55.6568.0058 SPRING, CPRSN, 0.600 OD, 0.085 WIRE, .625 LG 55.6669.0005...
  • Page 151 LLUSTRATED ARTS REAKDOWN VL500 80V Yoke Assembly (continued) (x6) (x4) (x2) (x4) (x4) (x2) (x2) (x2) (x2) Figure 3-40: VL500 80V Yoke Assembly 02. 96 85. 001 0 A 21-May-2009...
  • Page 152 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Yoke Assembly (continued) (x4) (x4) (x4) (x6) (x12) (x6) Figure 3-41: VL500 80V Yoke Assembly 21-May-2009 02 .9 685 .00 10 A...

  • Page 153: Vl500 Extra Hardware Kit

    LLUSTRATED ARTS REAKDOWN VL500 Extra Hardware Kit 28.9685.0999 Rev 0 Note: This kit contains addtional US-standard hardware (that may be difficult to find outside North America). It is packaged into the foot of the fixture (underneath the pan tube cover). Refer to Figure 3-43.

  • Page 154: Vl500 Pan/Tilt Motor Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Pan/Tilt Motor Assembly 21.9685.0540 Rev C Refer to Figure 3-43. Item Qty. Description 10.9685.0541 PLATE, TENSION ADJUSTMENT, PAN/TILT 21.9685.0545 ASSY, DRIVE PULLEY, VL500 10.9685.0524 PULLEY, DRIVE - PAN/TILT, 2MM GT 18 TOOTH 10.9678.8720 CODEWHEEL, 120 COUNT 24.9685.7735...
  • Page 155 LLUSTRATED ARTS REAKDOWN VL500 Pan/Tilt Motor Assembly (continued) (x2) (x2) Detail A See Detail A (x4) (x4) Drive Pulley Detail & Installation Drive Pulley Installation: 0.090" from Pulley to Motor Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2.

  • Page 156: Vl500 Mcb/Fan Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 MCB/FAN Assembly 21.9685.0731 Rev 0 Refer to Figure 3-44. Item Qty. Description 10.9676.0735 HEATSINK, PAN/TILT DRIVERS 10.9676.0885 PAD, THERMAL TRANSFER, PAN/TILT 10.9685.0594 BRACKET, FAN, MCB 10.9685.0595 SEAL, AIR 23.9685.0782 ASSY, FAN, MCB 24.9685.3730 MCB, VL500 53.2200.0004...

  • Page 157: Mcb-Fan Assembly

    LLUSTRATED ARTS REAKDOWN MCB-Fan Assembly 23.9685.0782 Rev 0 Refer to Figure 3-43. Item Qty. Description 40.7113.0007 FAN, 12VDC, 30X10 MM, 3.3CFM 52.6450.0002 CONNECTOR, MTA 100 IDC 2-POS, 28 AWG Pin 2 (Black) Pin 1 (Red) 6-inch leads Figure 3-45: MCB-Fan Assembly 02.

  • Page 158: Yoke Crossmember Assembly (Vl500/Vl500D/Vl500A)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Yoke Crossmember Assembly (VL500/VL500D/ VL500A) 21.9685.0515 Rev E Refer to Figure 3-46. Item Qty. Description 10.9685.0547 BUSHING, WIRE PROTECTION, 0.95" OD 10.9685.7590 TOGGLE STOP, PAN 10.9685.7591 TOGGLE, PAN 21.9685.0512 ASSY, LOWER CROSSMEMBER 21.9685.0513 ASSY, UPPER CROSSMEMBER 21.9685.0535 ASSY, PAN TUBE...
  • Page 159 LLUSTRATED ARTS REAKDOWN Yoke Crossmember Assembly (VL500/VL500D/ VL500A) (continued) (x4) (x4) (x2) Figure 3-46: Yoke Crossmember Assembly (VL500/VL500D/VL500A) 02. 96 85. 001 0 A 21-May-2009...

  • Page 160: Yoke Crossmember Assembly (Vl500 80V)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Yoke Crossmember Assembly (VL500 80V) 21.9685.0516 Rev 0 Refer to Figure 3-47. Item Qty. Description 10.9685.0547 BUSHING, WIRE PROTECTION, 0.95" OD 10.9685.7590 TOGGLE STOP, PAN 10.9685.7591 TOGGLE, PAN 21.9685.0512 ASSY, LOWER CROSSMEMBER 21.9685.0513 ASSY, UPPER CROSSMEMBER 21.9685.0536 ASSY, PAN TUBE, VL500 80V...
  • Page 161 LLUSTRATED ARTS REAKDOWN Yoke Crossmember Assembly (VL500 80V) (continued) (x4) (x4) (x2) Figure 3-47: Yoke Crossmember Assembly (VL500 80V) 02. 96 85. 001 0 A 21-May-2009...

  • Page 162: Lower Crossmember Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Lower Crossmember Assembly 21.9685.0512 Rev K Refer to Figure 3-48. Item Qty. Description 10.9685.1509 LOWER CROSSMEMBER 10.9685.0522 PLATE, PAN LOCK 10.9685.0527 WASHER, CENTERING, STEP 10.9685.0533 LANYARD, SAFETY 53.2001.0003 NUT, 10-32 NYLON INSERT 53.2019.0004 NUT, 3/8-16 HEX 53.2020.0001 NUT, 1/4X20 HEX STL ZINC PLTD...
  • Page 163 LLUSTRATED ARTS REAKDOWN Lower Crossmember Assembly (continued) (x2) (x2) (x2) (x2), (x2) (x2) (x2) (x2) Figure 3-48: Lower Crossmember Assembly 02. 96 85. 001 0 A 21-May-2009...

  • Page 164: Upper Crossmember Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Upper Crossmember Assembly 21.9685.0513 Rev H Refer to Figure 3-48. Item Qty. Description 10.9685.1510 UPPER CROSSMEMBER 10.9685.0527 WASHER, CENTERING, STEP 53.2020.0001 NUT, 1/4X20 HEX STL ZINC PLTD 54.1255.0001 ASSY, BEARING/HOUSING 55.6549.0001 WASHER, 1/4" SPLIT LOCK (x2) (x2) (x2)

  • Page 165: Pan Tube Assembly (Vl500/Vl500D/Vl500A)

    LLUSTRATED ARTS REAKDOWN Pan Tube Assembly (VL500/VL500D/VL500A) 21.9685.0535 Rev D (VL500/VL500D/VL500A) Refer to Figure 3-50. Item Qty. Description 10.9685.0521 PULLEY, DRIVEN, PAN/TILT 10.9685.0531 PAN TUBE 10.9685.0532 PAN PULLEY SPACER 53.2200.0006 NUT, 6-32 KEPS SS 53.6608.0750 SCREW, 6-32X3/4" PFB (x2) (x4) Figure 3-50: Pan Tube Assembly (VL500/VL500D/VL500A) 02.

  • Page 166: Pan Tube Assembly (Vl500 80V)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Pan Tube Assembly (VL500 80V) 21.9685.0536 Rev A (VL500 80V) Refer to Figure 3-51. Item Qty. Description 10.9685.0521 PULLEY, DRIVEN, PAN/TILT 10.9685.0532 PAN PULLEY SPACER 12.9685.1553 PAN TUBE, 80V 53.2200.0006 NUT, 6-32 KEPS SS 53.6608.0750 SCREW, 6-32X3/4"...

  • Page 167: Dmx Input Pcb Assembly

    LLUSTRATED ARTS REAKDOWN DMX Input PCB Assembly 24.9663.3895 Rev 0 Refer to Figure 3-52. Item Qty. Description 17.9663.3895 PCB, DMX INPUT 52.6259.0006 HEADER, 5POS MTA FRCT LOK STRT 52.6625.0006 CONN, RECEPT XLR 5PIN FEMALE 52.6626.0006 CONN, RECEPT XLR 5PIN MALE 62.3039.0102 CAP, 1000PF 250V RAD CER DISC 20% X-Y Figure 3-52: DMX Input PCB Assembly...
  • Page 168 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 21-May-2009 02 .9 685 .00 10 A...

  • Page 169: Incandescent Power Input Cable Assembly

    LLUSTRATED ARTS REAKDOWN Cables Note: Cables are only available as complete assemblies. The information contained in this section is for reference only. Incandescent Power Input Cable Assembly 25.9663.2030 Rev A (VL500 Only) Refer to Figure 3-53. Item Qty. Description 52.6274.2313 STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG...

  • Page 170: Disconnect Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Disconnect Cable Assembly 25.9685.0350 Rev B Refer to Figure 3-54. Item Qty. Description 10.9685.0351 MOUNT, DISCONNECT 10.9685.0352 CONTACT, DISCONNECT 52.8230.0003 RECPT, 1/4" FASTON, 22 - 18 AWG TAPE 53.6534.0006 RIVET, SOLID, 0.094" DIA X 3/16" AL 100 DEG CSK 73.1624.0005 WIRE, 24 AWG 300V TYPE EE MIL-W-16878/5 GRN (x2)

  • Page 171: 80V Lvs Ac Cable Assembly

    LLUSTRATED ARTS REAKDOWN 80V LVS AC Cable Assembly 25.9685.0742 Rev 0 Refer to Figure 3-55. Item Qty. Description 52.6264.0004 CONN HOUSING, 3-POS SL156 W/ RAMP NO TABS 52.8317.0002 CONTACT, SL156 24-18AWG 73.6018.0002 0.71 WIRE, 18 AWG 600V 105DEGC PVC RED UL1015 73.6018.0010 0.63 WIRE, 18 AWG 600V 105DEGC PVC BLACK UL1015...

  • Page 172: Power Cable Assembly (Vl500 80V)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 24V Power Cable Assembly (VL500 80V) 25.9685.0744 Rev 0 Refer to Figure 3-56. Item Qty. Description 52.6442.2003 RECEPT, 3 POS MTA156 W/TAB YEL (20 AWG) 52.6442.2004 RECEPT, 4 POS MTA156 W/TAB YEL (20 AWG) 52.6442.2006 RECEPT, 6 POS MTA156 W/TAB YEL (20 AWG) 73.7137.0011...

  • Page 173: Yoke Lamp Cable Assembly (Vl500 80V)

    LLUSTRATED ARTS REAKDOWN Yoke Lamp Cable Assembly (VL500 80V) 25.9685.0745 Rev A Refer to Figure 3-57. Item Qty. Description 52.8244.0001 RECEPT, FASTON FLAG, 0.250" 16-14 AWG (REEL) 52.8329.0001 TERM, RING #6 22-16 AWG NON-INS 55.2183.0001 0.33 HEATSHRINK, 1/2" BLACK 73.3520.0005 0.63 WIRE, 20 AWG 300V 105 DEGC PVC GRN UL1015 73.6014.0012...

  • Page 174: 80V Surge Protector Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 80V Surge Protector Cable Assembly 25.9685.0746 Rev 0 Refer to Figure 3-58. Item Qty. Description 33-0441 MOV, 430V 6500A 20MM ZNR 52.8231.0005 TERM RING, #6 BLUE 16-14 AWG REEL PIDG 55.2198.0001 0.08 HEATSRINK, 1/8" BLACK 55.2199.0001 0.13 HEATSRINK, 1/16"...

  • Page 175: Dimmer Communication Cable Assembly (Vl500/Vl500D)

    LLUSTRATED ARTS REAKDOWN Dimmer Communication Cable Assembly (VL500/VL500D) 25.9685.0750 Rev B Refer to Figure 3-59. Item Qty. Description 52.6396.2603 RECEPT, 3 POS MTA100 W/POL TAB BLUE CLOSED END 73.2326.0029 2.83 WIRE, 26 AWG 3 COND 300V 200 DEGC TEF <BLK-RED-WHT> UL1180 Figure 3-59: Dimmer Communication Cable Assembly (VL500 / VL500D) 02.

  • Page 176: Power Cable Assembly (Vl500/Vl500D)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 24V Power Cable Assembly (VL500/VL500D) 25.9685.0752 Rev C Refer to Figure 3-60. Item Qty. Description 52.6442.2003 RECEPT, 3 POS MTA156 W/TAB YEL (20 AWG) 52.6442.2004 RECEPT, 4 POS MTA156 W/TAB YEL (20 AWG) 52.6442.2006 RECEPT, 6 POS MTA156 W/TAB YEL (20 AWG) 52.8271.0005...

  • Page 177: Vl500 Motor Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Motor Cable Assembly 25.9685.0753 Rev B Refer to Figure 3-61. Item Qty. Description 52.6224.1034 COVER, FRONT 34-POS MT LATCHING 52.6224.2034 COVER, BACK 34-POS MT 52.6610.0034 CONN, HOUSING 34-POS DBL ROW UNLOADED 52.6694.0001 CRIMP, TERMINAL WIRE TO WIRE FEMALE 2MM 28-24 AWG 52.6696.0001 RECEPT, WIRE TO WIRE 4-POS 2MM PITCH 28-24 AWG 52.8351.0004...
  • Page 178 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Motor Cable Assembly (continued) 4 (x4), 5 1, 2, 3, 6 4 (x4), 5 4 (x4), 5 (x2) 4 (x4), 5 Figure 3-61: VL500 Motor Cable Assembly 21-May-2009 02 .9 685 .00 10 A...

  • Page 179: Relay To Ignitor Cable Assembly

    LLUSTRATED ARTS REAKDOWN Relay to Ignitor Cable Assembly 25.9685.0755 Rev B Refer to Figure 3-62. Item Qty. Description 52.8271.0005 RECPT, FASTON 1/4" 16-14 AWG INSULATED (REEL) 55.2186.0001 CABLE TIE, 0.10"X4" SMALL 73.6014.0012 0.29 WIRE, 14 AWG 600V 200DEGC FEP BLACK STRAND 168/36 0.104 DIA 73.6014.0013 0.42 WIRE, 14 AWG 600V 200DEGC FEP WHITE STRAND 168/36 0.104 DIA...

  • Page 180: Vl500 Ac Input Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 AC Input Cable Assembly 25.9685.0756 Rev B Refer to Figure 3-63. Item Qty. Description 52.6541.0003 CONN, CHASSIS POWER 3-POLE LOCKING 52.8231.0005 TERM, RING #6 16-14 AWG REEL PIDG 52.8331.0003 FASTON RECPT., 16-14 AWG PIDG BLU 0.170" ID 55.2186.0001 CABLE TIE, 0.10"X4"...

  • Page 181: Vl500 Arc Ballast Input Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Arc Ballast Input Cable Assembly 25.9685.0757 Rev C Refer to Figure 3-64. Item Qty. Description 52.6400.0027 RECPT, 17-14 SQ FLANGE REV SEX THRD CPC 52.6420.0002 SOCKET, GOLD 18-14 AWG TYPE 3+ LOOSE 0.08-0.100 INS DIA 52.8201.0007 SOCKET, GOLD 24-20 AWG TYPE 3+ (REEL) 0.04-0.08 INS DIA 52.8321.0005 TERM, RING #6 16-14 AWG REEL PIDG...

  • Page 182: Vl500 Pan / Tilt Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Pan / Tilt Cable Assembly 25.9685.0758 Rev A Refer to Figure 3-65 Figure 3-66. Item Qty. Description 52.6224.0020 HOUSING, 20 POS 26-22 AWG PRELOADED MT RECEPT DBL ROW 52.6224.1020 COVER, LATCH MT RECEPT 20 PIN 52.6224.2020 COVER, BACK MT 20 PIN 52.6524.0004...
  • Page 183 LLUSTRATED ARTS REAKDOWN VL500 Pan / Tilt Cable Assembly (continued) Figure 3-66: VL500 Pan / Tilt Cable Assembly (Pin Outs) 02. 96 85. 001 0 A 21-May-2009...

  • Page 184: Vl500 Head Grounding Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Head Grounding Cable Assembly 25.9685.0760 Rev C Refer to Figure 3-67. Item Qty. Description 52.8231.0000 TERM, RING #6 RED 22-16 AWG INSUL REEL 73.6014.0011 1.33 WIRE, 14 AWG 600V 200DEGC FEP GRN STRND 168/36 0.104 DIA (x2) Figure 3-67: VL500 Head Earthing Cable Assembly 21-May-2009...

  • Page 185: Vl500 Ignitor To Socket Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Ignitor to Socket Cable Assembly 25.9685.0766 Rev C Refer to Figure 3-68. Item Qty. Description 25.9685.0777 CABLE ASSY, BACK CAP GROUND, VL500 52.8244.0001 FASTON RECEPT FLAG, 0.250 16-14 AWG INSULATED (REEL) 55.2186.0001 CABLE TIE, 0.10"X4" SMALL 55.2260.0133 2.33 SLEEVING, FIBERGLASS 0.133"...

  • Page 186: Vl500 Arc Ballast Interconnect Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Arc Ballast Interconnect Cable Assembly 25.9685.0767 Rev B Refer to Figure 3-69. Item Qty. Description 52.6400.0020 PLUG, 17-14 REV SEX CPC 600V KEY A 52.6400.0120 PLUG, 17-9 REV SEX CPC 600V KEY A 52.6431.0002 BACKSHELL, CPC17 NYLON 0.300-0.525 CBL RNG 52.8201.0005...
  • Page 187 LLUSTRATED ARTS REAKDOWN VL500 Arc Ballast Interconnect Cable Assem- bly (Continued) (x4) (x4) (x3) (x3) (x2) (x2) Pinout Pinout Wire Description Wire Description VIOL14 AWG LAMP POWER OPEN GRN/16 AWG GROUND OPEN ORN/14 AWG LAMP POWER GRN/16 AWG GROUND BLK/16 AWG POWER (HOT) BLK/16 AWG POWER (HOT)

  • Page 188: Vl500 Display Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Display Cable Assembly 25.9685.0769 Rev C Refer to Figure 3-70. Item Qty. Description 52.6363.0001 CONN HOUSING, 6 PIN MTA CLOSED END BLUE 52.6264.0005 CONN HOUSING MOD4 CRIMP SNAP-IN 0.1 X 0.1 52.6240.0003 CONTACT FEMALE MOD4 CRIMP SNAP-IN 52.6696.0001 RECEPT, WIRE TO WIRE 4 POS 2 MM PITCH 28-24 AWG...

  • Page 189: Vl500 Display (Remote) Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Display (Remote) Cable Assembly 25.9685.0770 Rev B Refer to Figure 3-71. Item Qty. Description 10.9685.0536.01 ADAPTER PLATE, MINI XLR, BLACK 10.9685.0536.02 ADAPTER PLATE, MINI XLR, WHITE 52.6694.0002 CRIMP TERM, WIRE TO WIRE, MALE 52.6696.0003 PLUG, WIRE TO WIRE, 4-POS 53.6501.0002 CONN, MINI XLR, 4-PIN, PANEL MOUNT 73.2326.0123...

  • Page 190: Yoke Lamp Cable Assembly (Vl500/Vl500D)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Yoke Lamp Cable Assembly (VL500/VL500D) 25.9685.0771 Rev C Refer to Figure 3-72. Item Qty. Description 52.8244.0001 RECEPT, FASTON FLAG, 0.250" 16-14 AWG (REEL) 73.6014.0012 2.33 WIRE, 14 AWG 600V 200 DEGC FEP BLK STRAND 168/36 0.104 73.6014.0013 2.33 WIRE, 14 AWG 600V 200 DEGC FEP WHT STRAND 168/36 0.104...

  • Page 191: Vl500 Yoke Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Yoke Ground Cable Assembly 25.9685.0772 Rev C Refer to Figure 3-73. Item Qty. Description 52.8231.0005 TERM, RING #6 16-14 AWG REEL PIDG 73.6014.0011 WIRE, 14 AWG 600V 200 DEGC FEP GRN STRAND 168/36, 0.104 DIA Figure 3-73: Yoke Ground Cable Assembly 02.

  • Page 192: Lvs Ac Cable Assembly (Vl500/Vl500D/Vl500A)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL LVS AC Cable Assembly (VL500/VL500D/ VL500A) 25.9685.0773 Rev C Refer to Figure 3-74. Item Qty. Description 52.6264.0004 CONN HOUSING, 3 POS SL156 W/ RAMP NO TABS 52.8317.0002 CONTACT, SL156 24-18 AWG 73.7137.0011 2.42 WIRE, 20 AWG 600V 200 DEGC FEP BLK STRAND 105/40, 0.06 DIA 73.7137.0012 2.42...

  • Page 193: Vl500 Yoke Dmx Communication Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Yoke DMX Communication Cable Assembly 25.9685.0774 Rev E Refer to Figure 3-75. Item Qty. Description 52.6234.0001 CONN HOUSING, 4 PIN MTA CLOSED END BLUE 52.6270.0002 CONN HOUSING, 5 PIN MTA CLOSED END BLUE 52.8311.0001 TERM., RING #6 26-22 AWG NON-INS TAPE 73.2326.0123 WIRE, 26 AWG 4-COND 300V 200DEGC (BLK-BRN-RED-ORN) UL1180...

  • Page 194: Vl500 Yoke Lamp Jumper Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Yoke Lamp Jumper Cable Assembly 25.9685.0776 Rev A Refer to Figure 3-76. Item Qty. Description 52.8348.0001 TAB, ULTRA-FAST 1/4" 16-14 AWG INSULATED (LOOSE) 0.13 WIRE, 14 AWG 200DEGC STRAND TEF WHT (x2) Figure 3-76: VL500 Yoke Lamp Jumper Cable Assembly 21-May-2009 02 .9 685 .00 10 A...

  • Page 195: Vl500 Backcap Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Backcap Ground Cable Assembly 25.9685.0777 Rev A Refer to Figure 3-77. Item Qty. Description 52.8329.0001 TERM, RING #6 RED 22-16 AWG NON-INSUL 52.8329.0003 TERM, RING #8 RED 22-16 AWG NON-INSUL 73.7130.0002 1.17 WIRE, 7/64" TUBULAR BRAID SILVER PLATED Figure 3-77: VL500 Backcap Ground Cable Assembly 02.

  • Page 196: Lvs Fan Cable Assembly (Vl500/Vl500D/Vl500A)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL LVS Fan Cable Assembly (VL500/VL500D/ VL500A) 25.9685.0778 Rev A Refer to Figure 3-78. Item Qty. Description 52.6234.0001 CONN HOUSING, 4 PIN MTA CLOSED END BLUE 55.2186.0001 CABLE TIE, 0.10" X 4" SMALL 73.2326.0123 2.67 WIRE, 26 AWG 4 COND 300V 200 DEGC TEF <BLK-BRN-RED-ORN>...

  • Page 197: Vl500 Mcb Yoke Ground Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 MCB Yoke Ground Cable Assembly 25.9685.0782 Rev 0 Refer to Figure 3-79. Item Qty. Description 52.8231.0005 TERM, RING #6 16-14 AWG REEL PIDG 73.6014.0011 WIRE, 14 AWG 600V 200 DEGC FEP GRN STRAND 168/36, 0.104 DIA Figure 3-79: VL500 MCB Yoke Ground Cable Assembly 02.

  • Page 198: Arc Yoke Lamp Cable Assembly (Vl500A)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Arc Yoke Lamp Cable Assembly (VL500A) 25.9685.0783 Rev B Refer to Figure 3-80. Item Qty. Description 52.8244.0001 RECEPT, FASTON FLAG, 0.250" 16-14 AWG (REEL) 52.8329.0001 TERM RING, #6 22-16 AWG NON-INS 55.2183.0001 0.33 HEATSHRINK, 1/2", BLACK 73.3520.0005 0.75...

  • Page 199: Shielded Display/Dmx Communication Cable Assembly (Vl500A)

    LLUSTRATED ARTS REAKDOWN Shielded Display/DMX Communication Cable Assembly (VL500A) 25.9685.0784 Rev C Refer to Figure 3-81. Item Qty. Description 25.9685.0769 CABLE ASSY, DISPLAY 25.9685.0774 CABLE ASSY, YOKE DMX 52.8311.0004 TERM, RING #6 16-14 AWG NON-INS (BOX) 55.2186.0001 CABLE TIE, 0.10" X 4" SMALL 73.7130.0006 8.33 WIRE, 5/64"...

  • Page 200: Vl500 80V Display Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V Display Cable Assembly 25.9685.0785 Rev 0 Refer to Figure 3-82. Item Qty. Description 52.6363.0001 CONN HOUSING, 6 PIN MTA CLOSED END BLUE 52.6264.0005 CONN HOUSING MOD4 CRIMP SNAP-IN 0.1 X 0.1 52.6240.0003 CONTACT FEMALE MOD4 CRIMP SNAP-IN 52.6696.0001...

  • Page 201: Vl500 80V Yoke Dmx Communication Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 80V Yoke DMX Communication Cable Assembly 25.9685.0786 Rev A Refer to Figure 3-83. Item Qty. Description 52.6234.0001 CONN HOUSING, 4 PIN MTA CLOSED END BLUE 52.6270.0002 CONN HOUSING, 5 PIN MTA CLOSED END BLUE 52.8311.0001 TERM., RING #6 26-22 AWG NON-INS TAPE 73.2326.0123 3.17 WIRE, 26 AWG 4-COND 300V 200DEGC (BLK-BRN-RED-ORN)

  • Page 202: Vl500 80V Lvs Fan Cable Assembly

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V LVS Fan Cable Assembly 25.9685.0787 Rev 0 Refer to Figure 3-84. Item Qty. Description 52.6234.0001 CONN HOUSING, 4 PIN MTA CLOSED END BLUE 55.2186.0001 CABLE TIE, 0.10" X 4" SMALL 73.2326.0123 3.67 WIRE, 26 AWG 4 COND 300V 200 DEGC TEF <BLK-BRN-RED-ORN>...

  • Page 203: Shielded Display/Dmx Communication Cable Assembly (Vl500 80V)

    LLUSTRATED ARTS REAKDOWN 80V Shielded Display/DMX Communication Cable Assembly (VL500 80V) 25.9685.0788 Rev A Refer to Figure 3-85. Item Qty. Description 25.9685.0785 CABLE ASSY, DISPLAY, 80V VL500 25.9685.0786 CABLE ASSY, YOKE DMX COMM, 80V VL500 25.9685.0787 CABLE ASSY, LVS FAN, 80V VL500 52.8311.0004 TERM, RING #6 16-14 AWG NON-INS (BOX) 55.2186.0001...

  • Page 204: Dimmer Communication Cable Assembly (Vl500 80V)

    VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL 80V Dimmer Communication Cable Assembly (VL500 80V) 25.9685.1794 Rev 0 Refer to Figure 3-86. Item Qty. Description 28A2432-0A2 SPLIT CORE FERRITE 160 OHMS 100MHZ 8.2 MM ID 52-0274 18.5 HEATSHRINK TUBE, 1/4", BLACK 52.6396.2603 RECEPT, 3 POS MTA 100 W/POL TAB BLUE CLOSED END 52.6396.2604...

  • Page 205: Vl500 Main Harness Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Main Harness Cable Assembly 25.9685.0790 Rev J (VL500 and VL500D) Refer to Figure 3-87. Item Qty. Description 25.9685.0750 CABLE ASSY, DIMMER COMM 25.9685.0752 CABLE ASSY, 24V POWER 25.9685.0758 CABLE ASSY, PAN/TILT 25.9685.0769 CABLE ASSY, DISPLAY CABLE 25.9685.0771 CABLE ASSY, YOKE LAMP WIRES 25.9685.0772...
  • Page 206 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Main Harness Cable Assembly (contin- ued) (x8) Figure 3-87: VL500 Main Harness Cable Assembly (VL500 and VL500D) 21-May-2009 02 .9 685 .00 10 A...

  • Page 207: Vl500 Arc Main Harness Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 Arc Main Harness Cable Assembly 25.9685.0791 Rev C (VL500A) Refer to Figure 3-88. Item Qty. Description 25.9685.0752 CABLE ASSY, 24V POWER 25.9685.0758 CABLE ASSY, PAN/TILT 25.9685.0772 CABLE ASSY, YOKE GROUND 25.9685.0773 CABLE ASSY, LVS AC 25.9685.0778 CABLE ASSY, LVS FAN 25.9685.0782 CABLE ASSY, MCB YOKE GROUND...
  • Page 208 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Arc Main Harness Cable Assembly (con- tinued) (x8) Figure 3-88: VL500 Arc Main Harness Cable Assembly (VL500A) 21-May-2009 02 .9 685 .00 10 A...

  • Page 209: Vl500 80V Main Harness Cable Assembly

    LLUSTRATED ARTS REAKDOWN VL500 80V Main Harness Cable Assembly 25.9685.2792 Rev A (VL500 80V) Refer to Figure 3-89. Item Qty. Description 25.9685.1794 CABLE ASSY, 80V DIMMER COMM, VL500 80V 25.9685.0744 CABLE ASSY, 24V POWER, VL500 80V 25.9685.0745 CABLE ASSY, 80V YOKE LAMP WIRES 25.9685.0758 CABLE ASSY, PAN/TILT 25.9685.0772...
  • Page 210 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 80V Main Harness Cable Assembly (con- tinued) (x8) Figure 3-89: VL500 80V Main Harness Cable Assembly (VL500 80V) 21-May-2009 02 .9 685 .00 10 A...

  • Page 211: Vl500 80V Lamp Wire Harness

    LLUSTRATED ARTS REAKDOWN VL500 80V Lamp Wire Harness 25.9685.0793 Rev B Refer to Figure 3-90. Item Qty. Description 25.9685.0777 CABLE ASSY, BACK CAP GROUND, VL500 52.8244.0001 FASTON RECEPT FLAG, 0.250 16-14 AWG INSULATED (REEL) 52.8298.1140 FERRULE, WIRE 1 X 14AWG, NON-INSUL 55.2186.0002 CABLE TIE, 3-3/4"...
  • Page 212 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 21-May-2009 02 .9 685 .00 10 A...

  • Page 213: Arc Ballast Assembly

    LLUSTRATED ARTS REAKDOWN Arc Ballast Assembly VL500 Arc Ballast Assembly 21.9685.0802 Rev H Refer to Figure 3-91. Item Qty. Description 04.9685.0941 LABEL, PRODUCT, VL500APS-700W 04.9685.0942 LABEL, PRODUCT, VL500APS COMPLIANCE (BLK) 04.9685.0946 LABEL, BALLAST WATTAGE, 700W 10.9669.0034 PLATE, NUT 10.9685.0822 MOUNT PLATE, BALLAST 10.9685.0823 BOTTOM PLATE, BALLAST (BLK) 10.9685.0824...
  • Page 214 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL VL500 Arc Ballast Assembly (continued) (x4) (x4) (x4) (x5) (x16) (x4) (x4) (x4) (x2) (x12) Figure 3-91: VL500 Arc Ballast Assembly 21-May-2009 02 .9 685 .00 10 A...

  • Page 215: Ballast I/O Cable Assembly

    LLUSTRATED ARTS REAKDOWN Ballast I/O Cable Assembly 25.9685.0807 Rev A Refer to Figure 3-92. Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3-POS 52.6396.2904 RECEPT, 4-POS MTA100 W/POL RED 52.6400.0111 RECEPT, 17-9 STD SEX CPC 600V FLANGE 52.8201.0005 PIN, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA 52.8202.0001 PIN, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA 52.8202.0011...
  • Page 216 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Ballast I/O Cable Assembly (continued) (x3) (x5) 12, 13, 14 (x2) (x3) (x5) Figure 3-92: Ballast I/O Cable Assembly 21-May-2009 02 .9 685 .00 10 A...

  • Page 217: Appendix A. Technical Bulletins And Notices

    PPENDIX Technical Bulletins and Notices VL500™ Wash Luminaire Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the VL500™ wash luminaire. If applicable, these improvements have been incorporated into this manual. Technical Bulletin Description or Notice S5K-001...
  • Page 218 VARI❋LITE® - VL500™ L UMINAIRE ERVICE ANUAL Notes 21-May-2009 02 .9 685 .00 10 A...
  • Page 220 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA ❋ 1.877.VARI-LITE Fax 1.214.647.8038 www.vari-lite.com Date: 21-May-2009 / Manual Part Number: 02.9685.0010 A ©2003-2009 Vari-Lite, a Philips group company. All rights reserved. Printed in the U.S.A.

This manual is also suitable for:

Vari-lite vl500Vari-lite vl500d washVari-lite vl500 80v washVari-lite vl500a wash

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