Service manual

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Summary of content (142 pages)

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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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™, VL3500™, Series 500™, Series 1000™, Series 2000™, Series 3000™, DICHRO❋TUNE™, VARI❋IMAGE™, VARI❋BRITE™, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC.
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FOREWORD How To Obtain Warranty Service A copy of the Vari-Lite, Inc. Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548) or customerservice@genlytecontrols.com and request a Return Material Authorization (RMA) for warranty service.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Compliance Notice FCC This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
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FOREWORD GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND INJURY TO PERSONS CAN BE FOUND BELOW. WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1. VARI❋LITE® luminaires have been designed for use only with certain Philips and Osram HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps. Installing another type of lamp may be hazardous. 2.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use an HID type lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired. For example, by cracks or deep scratches.
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FOREWORD Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß.
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FOREWORD Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe de type HID qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2. L’utilisation des luminaires sans lentille ou blindage pose des risques.
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FOREWORD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto. Los símbolos de seguridad usados en este manual son los siguientes: CUIDADO, indica posibles daños al producto. ADVERTENCIA, indica posibles lesiones o muerte a las personas.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara HID que produce radiación UV. NO mire directamente a la lámpara. 2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 6: é UV |¿æÐ Ð å¿ÚüéEf; 1. VARI❋LITE® ÿzUé ÊêUV |¿ ¢Õ HID 2 Jé\fJ öª Òá¿ùÔ\fJ åÞÔ Îãê±ÌáÊÛÐ¿ _f-ùÚê*o^< ö ÕæÿzU P.Ô ãÂ¾âÔ_f- *o^<¡ "¹Yêíî ÿÓ¿ÞÆÈÍåäæ Øé2 ÇÊå ÁæåÞÚ §Ã ÁæÒùÔ 6: G2 ZËÚüéEf; ÿzUÇP.Òá¿ ãÈêØé ¥Ç²Êå ùÔ²ÊåÞÚzU ÿ&fPo@f; ÒÁÙæê¡¾åUÔ»<ÿ; ª ÜÕ ö ªÒáÊÛÐ¿ ÿzUÇP.Òá¿ ãÈêØé\fJÇ²Êå ùÔ\fJ dµ Ô 'êÿzUé . ¾ \fJé÷2Ç Ç ùâÙÞáÊÛ Ð¿\fJécñÚ ½Ì ã¤¿, 64ÇÛ¿á\fJé .Ç ¾ 'Ç½ ùÔ o".
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TABLE OF CONTENTS Table of Contents Introduction About This Manual ...................................................................................................... Additional Documentation........................................................................................... Customer Service ......................................................................................................... Technical Bulletins / Technical Notices...............................................................
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Removing Enclosure Covers (continued) ............................................................ 35 Ballast Module Assembly Replacement .............................................................. 36 Pan Motor / Pan Belt Assembly Replacement..................................................... 38 Pan Encoder Replacement ................................................................................... 40 Pan EOT (End of Travel) Sensor Replacement ....
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TABLE OF CONTENTS Cables Note: Cables are only available as complete assemblies. The information contained in this section is for reference only. Ground Strap Cable Assembly................................................................................... 97 LVS Chassis Ground Cable Assembly....................................................................... 98 Chassis To Yoke Ground Cable Assembly ................................................................ 99 Yoke To Head Ground Cable Assembly ..
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Notes xvi i i 29-May-2009 02 .9 676 .
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INTRODUCTION Introduction About This Manual This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL2500™ Spot Luminaire. The manual is intended for use by Vari-Lite personnel and by Vari-Lite’s customers/clients. WARNING: It is important to read ALL accompanying safety and installation instructions to avoid damage to the product and potential injury to yourself or others.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Customer Service Our Goal At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone/troubleshooting assistance, product training or technical service, our fulltime staff of experienced professionals are on-hand to provide support.
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CHAPTER 1. Description This chapter provides an overview of luminaire features, components and operations. • Features • Major Components • Principles of Operation 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Features Overview The VL2500 Spot luminaire comes complete with all of the qualities and options designers love from the original Series 2000™ fixtures. It is still small, lightweight, and fast with a 700watt shortarc lamp, impressive lumen output, and a zoom range from 18.5° to 42°. Features 4 • Color Mixing System: A three-filter CYM cross-fading mechanism.
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DESCRIPTION : MAJOR COMPONENTS 1 Major Components External Components The following illustration shows major luminaire components and controls.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Menu Display The menu system is a programmable set of commands used to configure, address, operate, and test the luminaire. The menu system is controlled at the Menu Display available at the enclosure input panel. Menu Display AC PWR ~ AC IN DATA IN DATA THRU MENUENTER The menu system has seven main functions which are referred to as “1st level.
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DESCRIPTION : MAJOR COMPONENTS 1 Head Components The following illustration shows the major sub-assemblies that are located in the luminaire head assembly. (Yoke and enclosure not shown for clarity.) Removable Cover Dual Blade Strobe Assembly Back Cap / Lamp Assembly CYM Color/Dimmer Bulkhead Fixed Color / Fixed Gobo / Iris Bulkhead Fan Assembly Removable Cover Front Assembly Contains Lens Barrel and Rotating Gobo Wheel Nose Cover Note: This illustration shows current VL2500 components.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Yoke Components The following illustration shows the major sub-assemblies that are located in the luminaire yoke assembly. (Head and enclosure not shown for clarity.
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DESCRIPTION : MAJOR COMPONENTS 1 Enclosure Components The following illustration shows the major sub-assemblies that are located in the luminaire enclosure assembly. (Yoke and head assembly not shown for clarity.) Enclosure Top Covers 700W Arc Ballast Module Fan Assembly Input Panel Assembly containing DMX Input PCB and Menu Display 150W +24V/6.3A Power Supply AC Input Cable Requires standard AC power distribution from 100-264 VAC, 50/60 Hz., 7 to 12 A depending on the AC supply voltage.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Principles of Operation Power and Data Flow Diagram The following diagram shows how data and power are distributed in the luminaire.
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CHAPTER 2. 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. WARNING: Maintenance, repairs, and adjustments should only be performed by a qualified, factory-trained service technician at an Authorized VARI❋LITE® Service Center. 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Testing Testing Software Testing software is available in all Series 2000 luminaires through the luminaire’s menu system TEST function. For information on specific tests and test parameters, see the VL2500™ Spot Luminaire User’s Manual (VL Part no. 02.9676.0019). Note: After 10 seconds of inactivity, the menu display will change to the default state showing the address. Lamp The Lamp option is available in the test menu.
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MAINTENANCE : TROUBLESHOOTING 2 Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s), one at a time until the end of the list is reached. To review the error messages again, it will be necessary to access them using the Status function. (Refer to “Troubleshooting Guide” on page 14 for a list of possible causes and remedies associated with the error messages.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Troubleshooting” on page 13 for more information. The chart below provides possible causes and remedies for each message. Table 2-2: Troubleshooting Guide Message n/a n/a Symptom Description No response to DMX data DMX Failure Lamp douses frequently Lamp Douse Possible Cause and Remedy MCB connector disconnected...
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MAINTENANCE : TROUBLESHOOTING 2 Table 2-2: Troubleshooting Guide (Continued) Message Pan No Sens Symptom Luminaire will not pan or hits against stop Description Pan Sensor Not Found Possible Cause and Remedy EOT flag attached to large pulley is not engaging the EOT sensor... - ensure flag is attached to the large pulley. - ensure that flag passes through the sensor at a depth sufficient to engage the sensor beam. Pan belt disconnected, extremely loose or not installed properly...
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Maintenance Procedures Head Assembly This section provides removal and replacement procedures for components found in the luminaire head assembly. Lamp Replacement Parts: 71.2528.0700 WARNING: Remove power from luminaire before performing maintenance. To remove and replace lamp: Step 1. Remove power from luminaire. WARNING: Lamps will be extremely HOT after operation. Allow enough time for the lamp to cool before replacing. Step 2.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. Step 4. Remove lamp by pulling straight out of socket. Step 5. Install new lamp by pressing into socket. Ensure lamp is fully seated in socket and parallel to guide rods.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. (Cover remains attached by tether.) Figure 2-3. Step 3. At CYM crossfade color bulkhead, disconnect wiring, remove two 6-32x1/4" PPB SEMS screws, and remove assembly. Step 4.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 Standard Gobo/Color Filter Replacement WARNING: Users of VARI❋LITE® luminaires should not install or use metal gobos. The use of metal gobos in any VARI❋LITE® product may damage the luminaire and could void the luminaire’s warranty. Parts: Standard Gobo or Color Filter as required To remove and replace a standard gobo or color filter: Step 1. Disconnect luminaire AC input cable from power source. Step 2.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. Loosen two captive screws and remove top cover as shown in Figure 2-5 (the cover is attached by tether). b. At bottom cover, loosen three 8-32 x 1/2" PPB screws and remove cover. Step 3. Remove CYM crossfade color assembly.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. Loosen two captive screws and remove top cover as shown in Figure 2-6 (the cover is attached by tether). b. At bottom cover, loosen three 8-32 x 1/2" PPB screws and remove cover.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. Step 9. At rear of bulkhead, disconnect wires from rotating gobo sensor PCB. Figure 2-7. Step 10.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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 21. Step 3. At rotating gobo wheel, remove two 4-40×3/8" PFZ screws (do not remove middle screw) and remove wheel. Figure 2-7.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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 Sensor PCB 4-40×1/4” PFZ Screws Figure 2-8: Rotating Gobo Sensor PCB Replacement Step 5. Install replacement assembly by performing Steps 2 through 4 in reverse order. 24 29-May-2009 02 .9 676 .
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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 21. Step 3. Cut cable ties that secure edge motor wires to front assembly. (Edge motor is larger of two linear actuator motors.) Step 4.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. Step 5. At lens barrel assembly, use 1/4-inch open-ended wrench to hold standoff on edge motor shaft, and using another 1/4-inch open-ended wrench, remove 440 SS KEPS nut from end of motor shaft. Figure 2-10.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. Figure 2-12. Edge Motor Assembly 4-40×3/8" PPZ Screws 1/4" Nuts Figure 2-12: Edge Motor Assembly Replacement Step 8.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. Remove front nose cover by removing two 10-32×1/2" PPB screws (one on each side). Figure 2-6. Step 4. Cut cable ties which secure zoom optics motor wires to front assembly.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. At each side of optical support ring, remove two 6-32×1/2" PPZ screws and #6 flat washers. Remove optical support ring. Step 9.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. At tilt-side leg, remove yoke leg cover by removing four (two on each side) 6-32×5/16" PTB screws. Figure 2-15. To find tilt-side leg, refer to page 8.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. To find board-side leg, refer to page 8. CAUTION: Always use anti-static precautions when working with PCBs. Screws Yoke Leg Cover MCB PCB Figure 2-16: MCB PCB Replacement Step 3.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. At each yoke leg, remove yoke leg cover by removing four 6-32×5/16" PTB screws. Figure 2-17. Step 3. Remove MCB PCB (See “Main Control Board (MCB) PCB Replacement” on page 31.). Step 4.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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" Hex 6-32 .500" LG Standoff (2) Figure 2-18: Ignitor PCB Standoff Removal Step 9. Install replacement assembly by performing Steps 2 through 8 in reverse order. 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Enclosure Assembly This section provides removal and replacement procedures for components found in the luminaire enclosure assembly. Removing Enclosure Covers To gain access to enclosure components, it will be necessary to remove the top and bottom covers. To remove and replace enclosure covers: Step 1. Using console or internal menus, run lens as far to the rear as possible. Step 2. Disconnect luminaire AC input cable from power source. Step 3.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. At bottom of enclosure, remove four 1/4-20 × 1/2" socket screws and 1/4" split lock washers and remove ventilation cover. Step 6. Return luminaire to upright position. 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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” on page 34. Note: Throughout this procedure, please note different size screws and their respective locations Step 3. Remove both handles by removing two 10-32 x 5/8" PPB screws at each.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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" PPZ screws which secure ballast module to enclosure. Step 9. Remove ballast module. Step 10. Install replacement assembly by performing Steps 2 through 9 in reverse order.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. 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. Step 4. In each corner from top, remove four 6-32 x 3/8" PPZ screws.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. Step 4. Disconnect the following cable assemblies: a. Disconnect lamp wire from J202 and J203. b. Disconnect DC wire from LVS. c. Disconnect DMX wire from DMX PCB. d.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. Step 3. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any surface. Step 4.
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MAINTENANCE : MAINTENANCE PROCEDURES 2 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. Step 3. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any surface. Step 4.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL 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. Step 3. At power supply, disconnect wiring: Location Connector N White AC Wires L Black AC Wires V+ Red DC Wires V+ Red DC Wires V- Black DC Wires V- Black DC Wires Step 4.
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CHAPTER 3. Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for assemblies in the VL2500™ Spot Luminaire. • Drawing Tree • Top Assembly • Yoke • Enclosure • Cables WARNING: All maintenance procedures are to be performed with power removed from the luminaire. Never remove cover or backcap while lamp is in operation.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Drawing Tree VL2500 Series Spot Luminaire VL2500 Spot Luminaire 20.9676.0001 Rev L Front Assembly VL2500 Generic Luminaire 21.9676.4006 Rev D 21.9676.0010 Rev J Rotating Gobo Wheel Assembly Upper Enclosure Assembly 21.9660.0105 Rev E 21.9676.0800 Rev T Lens Barrel Assembly 21.9676.4306 Rev D Iris/Color/Gobo Bulkhead Assembly 21.9676.4120 Rev C Continued on the next page Yoke Assembly 21.9676.0600 Rev G Iris/Gobo Motor Assembly 21.9676.
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ILLUSTRATED PARTS BREAKDOWN : DRAWING TREE 3 Drawing Tree (continued) Continued from previous page VL2500 Spot Luminaire (continued) Upper Enclosure Assembly 21.9676.0800 Rev T Reflector Assembly 22.9676.0018 Rev B Connector Panel Assembly Connector Panel Assembly 21.9676.0805 Rev B 21.9676.0805 Rev B Fan Assembly 22.9676.0090 Rev D Ground Strap Cable Assembly 25.8007.2212 Rev 0 UV / IR Window Assembly 22.9676.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Top Assembly VL2500 Spot Included Items Kit 28.9676.0001 Rev G Refer to Figure 3-1. No. Item Qty. UM. 1 02.8001.0001 1 EA PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 2 02.8052.0001 1 EA CARD, LIMITED WARRANTY - 02.80001.0002 1 EA VARI-LITE QUALITY ASSURANCE CERTIFICATE (not shown) 3 02.8406.0001 1 EA TAG, LAMP NOTICE 4 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION - 2000 SERIES 5 02.9676.
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ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 VL2500 Spot Included Items Kit (continued) 1 3 2 8 7 5 4 9 10 6 15 13 12 14 11 4 Facet Prism Circle of Ovals Hypnospiral Spiral Stones Pinwheel Standard Gobos Figure 3-1: VL2500 Spot Included Items Kit 02. 96 76.
PAGE 66
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL VL2500 Spot Luminaire 20.9676.0001 Rev L Refer to Figure 3-2. No. Item Qty. UM. Description 1 10.9638.0052 1 EA DAM, AIR, VL6 2 10.9676.8632 2 EA COVER, YOKE THERMOFORM 3 16.9676.0004.01 1 EA LABEL LOCATION, VL2500 LUMINAIRE (not shown) 4 21.9676.0023 1 EA ASSY, FRONT COVER 5 21.9676.4006 1 EA ASSY, FRONT 6 21.9676.0010 1 EA GENERIC LUMINAIRE, VL2500 7 21.9676.4120 1 EA BULKHEAD ASSY, IRIS/COLOR/GOBO 8 21.9676.
PAGE 67
3 ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY VL2500 Spot Luminaire (continued) 25 19 (x6) 11 14 8 1 12 18 (x2) 24 (x4) 7 15 19 (x4) 16 18 (x4) 22 23 Note: Loop lamp wires through ferrite. 20 5 6 13 4 9 21 (x2) 17 (x8) 10 2 (x2) Figure 3-2: VL2500 Spot Luminaire Top Assembly 02. 96 76.
PAGE 68
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL VL2500 Generic Luminaire 21.9676.0010 Rev J Refer to Figure 3-3. No. Item Qty. UM. 1 10.9628.0211 1 EA STABLIZER, PAN/TILT 2 10.9676.8617 1 EA HEATSHIELD, YOKE CROSSMEMBER 3 10.9676.0083 1 EA BAFFLE, REAR CASTING 4 10.9676.0163 1 EA HARNESS, GUARD, RIGHT 5 10.9676.0161 1 EA HARNESS, GUARD, LEFT 6 21.9676.0139 1 EA ASSY, REAR HEAD 7 21.9676.0600 1 EA ASSY, YOKE - 25.9667.
PAGE 69
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 VL2500 Generic Luminaire (continued) 11 (x8) 23 20 (x8) 13 (x2) 18 19 6 3 22 17 (x2) 4 1 5 17 (x2) 12 2 7 10 (x5) 21 (x5) 14 (x5) 9 8 24 (x4) 16 (x4) 15 (x4) 17 (x4) Figure 3-3: VL2500 Generic Luminaire Assembly 02. 96 76.
PAGE 70
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Front Assembly 21.9676.4006 Rev D Refer to Figure 3-4. No. Item Qty. UM. 1 10.9660.0129 1 EA SHAFT STOP, ROTATING GOBO WHEEL 2 10.9660.0130 1 EA SHAFT, ROTATING GOBO WHEEL 3 10.9660.0219 1 EA SHAFT 1, FOCUS BEARING 4 10.9676.4255 2 EA SHAFT, SUPPORT, LENS 5 10.9660.0263 1 EA SUPPORT, LENS 6 10.9667.0313 1 EA SUPPORT, LENS, CABLE MOUNT 7 10.9676.4349 1 EA SUPPORT RING, OPTICAL 8 10.9676.
PAGE 71
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY No. Item Qty. UM. 32 55.6506.0009 1 EA SPACER, 1/2" RND .125" LG .375" ID SHAFT 33 55.6589.0003 2 EA STANDOFF, 1/4" RND 4-40 .606" LG MF 34 55.6663.0007 1 EA STANDOFF, 3/8" RND, 1.75" LG, FF 5 23 (x4) Description 29 28 32 2 34 8 3 Note: Orient items 28 and 29 (spring washers) as shown with concave side facing item 12 (lens mounting bulkhead).
PAGE 72
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Lens Barrel Assembly 21.9676.4306 Rev D Refer to Figure 3-5. No. Item Qty. UM. 1 10.9676.4254 1 EA SHAFT, ZOOM BEARING 2 10.9676.4256 1 EA WEAR STRIP, EDGE LENSES 3 10.9676.4258 1 EA WEAR STRIP, EDGE BARREL 4 10.9676.4259 1 EA WEAR STRIP, ZOOM BALL PLUNGER 5 10.9676.4260 1 EA WEAR STRIP BUMPER, EDGE LENSES 6 12.9676.4248 1 EA EDGE BARREL, BOTTOM 7 12.9676.4247 1 EA EDGE BARREL, TOP 8 21.9660.
PAGE 73
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Lens Barrel Assembly (continued) Detail A 4 14 (x2) 20 11 17 (x4) 16 21 22 7 1 18 (x2) 14 10 23 (x2) 22 16 12 3 Detail A 8 Detail A 13 3 9 6 15 (x4) 2 4 19 (x2) 5 Figure 3-5: Lens Barrel Assembly 02. 96 76.
PAGE 74
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Sub-Barrel Group 2 Assembly 21.9676.4229 Rev C Refer to Figure 3-6. No. Item Qty. UM. Description 1 10.9676.4223 1 EA BARREL, ZOOM, LOWER 2 10.9676.4350 1 EA SPACER 1, ZOOM LENSES 3 10.9676.4251 1 EA SPACER 2, ZOOM LENSES 4 12.9676.4224 1 EA BARREL, ZOOM, UPPER 5 21.9676.4258 1 EA ASSY, ZOOM BUSHING 6 42.9660.0023 1 EA LENS 6, ZOOM OPTICS 7 42.9660.0024 1 EA LENS 7, ZOOM OPTICS 8 42.9660.
PAGE 75
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Motor Zoom Optics Assembly 21.9667.0311 Rev A Refer to Figure 3-7. No. Item Qty. UM. 1 44.9660.0262 1 EA MOTOR, 1" LINEAR - ZOOM 2 52.6579.0005 1 EA CONN, 5CIR PNL MT SGL ROW W/MTG EARS 3 52.8347.0001 4 EA CONTACT, 24-30AWG MALE CRIMP Description 3 (x4) 2 1 Figure 3-7: Motor Zoom Optics Assembly 02. 96 76.
PAGE 76
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Rotating Gobo Wheel Assembly 21.9660.0105 Rev E Refer to Figure 3-8. No. Item Qty. UM. 1 10.9660.0110 4 EA GOBO CARRIER, SPINNING GOBO WHEEL 2 10.9660.0112 1 EA SUN GEAR, SPINNING GOBO WHEEL 3 10.9660.0153 1 EA MAGNET, HALL EFFECT SENSOR .07ID 4 10.9667.0333 1 EA MOUNTING PLATE, FRONT (ROTATING GOBO WHEEL) 5 10.9667.0334 1 EA MOUNTING PLATE, AFT (ROTATING GOBO WHEEL) 6 10.9667.
PAGE 77
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Top Cover Assembly 22.9676.0008 Rev I Refer to Figure 3-9. No. Item Qty. UM. Description 1 06.6018.0011 0.041 FT VELCRO, DOUBLE HOOK, 2" BLACK ADH BACKED 2 07.5049.0001 1 EA LANYARD, NYLON COATED, 8" LONG 3 10.9676.8009 1 EA COVER, TOP VL2500 4 10.9676.0010 1 EA FILTER, TOP HEAD COVER 5 12.9676.0076 1 EA BAFFLE, RIGHT, TOP COVER 6 12.9676.0077 1 EA BAFFLE, LEFT, TOP COVER 7 53.2008.0008 2 EA PUSH NUT, #8 8 53.5655.
PAGE 78
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Bottom Cover Assembly 22.9676.0011 Rev E Refer to Figure 3-10. No. Item Qty. UM. Description 1 10.9676.8012 1 EA COVER, LOWER 2 53.2008.0008 3 EA NUT, #8 PUSH 3 53.6521.0001 3 EA SCREW, 8-32 X 1/2" PPB 4 55.6599.0001 3 EA WASHER, #10 FLAT BLACK 1 2 (x3) 3 (x3) 4 (x3) Figure 3-10: Bottom Cover Assembly 60 29-May-2009 02 .9 676 .
PAGE 79
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Reflector Assembly 22.9676.0018 Rev B Refer to Figure 3-11. No. Item Qty. UM. Description 1 10.9678.0647 4 EA CLAMP, MOUNTING, REFLECTOR 2 22.9660.0338 1 EA ASSY, DISCONNECT LAMP 3 22.9676.0130 1 EA ASSY, REFLECTOR MOUNT 4 41.9660.7021 1 EA ELLIPSOIDAL REFLECTOR, LUNED 5 53.6599.0001 2 EA SCREW, 4-40 X 3/8" PFZ 6 55.6669.0016 4 EA STANDOFF, 1/4" HEX, 6-32 M/F, SS, L = 0.
PAGE 80
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Back Cap Assembly 22.9676.0115 Rev E Refer to Figure 3-12. No. Item Qty. UM. 1 10.9638.0117 3 EA KNOB, KNURLED, VL6 BACK CAP/LAMP ASSY. 2 10.9638.0128 1 EA BRACKET, IGNITOR CABLE 3 10.9638.0130 1 EA SPRING, BULB WIRE SHEATH 4 10.9638.0164 1 EA WASHER, FELT 5 10.9667.0411 1 EA LAMP CARRIAGE 6 10.9667.0412 1 EA LAMP TILT PLATE 7 12.9676.8112 1 EA BACKCAP, MACHINED, VL2500 8 22.9638.
PAGE 81
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Back Cap Assembly (continued) 4 18 1 (x3) 13 32 25 15 2 11 19 19 21 27 22 27 20 (x2) 7 6 12 (x2) 30(x2) 5 28 29 (x2) 25 (x2) 16 (x2) 23 (x2) 17 (x4) 31 26 (x2) 24 (13.5") 14 (x2) 10 (x2) 9 3 24 (9.0") Figure 3-12: Back Cap Assembly 02. 96 76.
PAGE 82
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Fan Assembly 22.9676.0090 Rev D Refer to Figure 3-13. No. Item Qty. UM. 1 10.9676.0068 1 EA AIR DUCT, FRONT FAN 2 22.9676.0091 1 EA ASSY, FAN BULKHEAD 3 22.9676.0095 1 EA AIR DUCT, REAR FAN 4 25.8007.2212 1 EA CABLE ASSY, GROUND STRAP, #6 RING 3" LG 5 40.7113.0002 1 EA FAN, +24 VOLT, 80 X 80 X 25MM, 39CFM 6 40.7146.0002 1 EA DC FAN, 3.15" SQ X 1.0" BB LOW FLOW 7 52.6523.0005 1 EA CONN, HOUSING, 5 POS.
PAGE 83
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Fan Assembly (continued) 1 3 6 2 11 (x4) 10 4 5 11 (x4) 12 13 (x2) 16 (x3) 15 (x2) 17 7, 8 (x5) 9 14 Figure 3-13: Fan Assembly 02. 96 76.
PAGE 84
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Iris/Color/Gobo Bulkhead Assembly 21.9676.4120 Rev C Refer to Figure 3-14. No. Item Qty. UM. 1 1 EA BULKHEAD, IRIS/GOBO/COLOR 2 10.9676.4124 21.9676.0118 1 EA ASSY, IRIS/GOBO MOTOR 3 21.9676.0119 1 EA ASSY, COLOR MOTOR 4 22.9676.4146 1 EA ASSY, GOBO WHEEL 5 22.9676.4145 1 EA ASSY, COLOR FILTER WHEEL 6 22.9676.1145 1 EA IRIS, 53MM OD, CUSTOM 7 25.9676.0125 1 EA CABLE ASSY, T-STAT, COLOR/GOBO 8 53.2200.
PAGE 85
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Iris/Color/Gobo Bulkhead Assembly (continued) 2 9 (x3) 10 14 (x7) 6 12 (x3) 5 11 13 (x2) 1 9 (x3) 3 4 8 7 Figure 3-14: Iris/Color/Gobo Bulkhead Assembly 02. 96 76.
PAGE 86
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Crossfade Color Assembly 21.9676.0201 Rev N Refer to Figure 3-15. No. Item Qty. UM. 1 10.9676.0230.01 4 EA SPACER, COLOR WHEEL 2 10.9676.0230.02 1 EA SPACER, COLOR MOTOR 3 10.9676.0234 1 EA AFT BULKHEAD, CROSSFADE COLOR SYSTEM 4 10.9676.0238 1 EA BULKHEAD SPACER 2, COLOR SYSTEM 5 10.9676.0235 5 EA SPACER, BULKHEAD, COLOR SYSTEM 6 10.9676.0284 1 EA SHAFT, COLOR SYSTEM 7 10.9678.0485 4 EA PULLEY, COLOR MOTOR 8 21.
PAGE 87
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY No. Item Qty. UM. 29 55.9676.0255 1 EA 3 Description BELLEVILLE SPRING WASHER, SPEC B0500-018-S 22 (x4) 14 (x2) 28 26 (x2) 15 (x4) 5 (x5) 4 24 23 17 (x4) 18 (x2) 7 (x4) 21 24 Yellow 23 13 Detail A Cyan 14 (x2) Magenta 8 Dimmer 11 25 10 1 9 19 (x4) 12 16 6 2 1 1 25 (x2) 20 (x5) 27 (x5) 3 29 1 Detail A Yellow Dimmer 13c (x3) 13b Magenta Cyan 13a Figure 3-15: Crossfade Color Assembly 02. 96 76.
PAGE 88
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Iris/Gobo Motor Assembly 21.9676.0118 Rev D Refer to Figure 3-16. No. Item Qty. UM. 1 10.9621.0097 1 EA STABILIZER, STEPPER, GOBO WHEEL 2 10.9667.1111 1 EA MOTOR BULKHEAD, IRIS/GOBO 3 10.9667.0126 1 EA IRIS CRANK 4 24.9676.1114 1 EA PCB ASSY, SENSOR, VL6B 5 44.9676.0116 1 EA MOTOR, GOBO/COLOR WHEEL 6 44.9676.0118 1 EA MOTOR, IRIS 7 53.6578.0001 1 EA SCREW, 4-40 X 1/8" SET 8 53.6596.
PAGE 89
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Color Motor Assembly 21.9676.0119 Rev D Refer to Figure 3-17. No. Item Qty. UM. Description 1 10.9621.0097 1 EA STABILIZER, STEPPER, GOBO WHEEL 2 10.9676.1120 1 EA COLOR MOTOR BULKHEAD 3 24.9676.1114 1 EA PCB ASSY, SENSOR, COLOR/GOBO 4 44.9676.0116 1 EA MOTOR, GOBO/COLOR WHEEL 5 55.2203.0001 2 EA SCREW, 4-40 X 3/16" PPZ 6 53.6599.0001 1 EA SCREW, 4-40 X 3/8" PFZ 7 55.2203.0001 3 EA SCREW, 4-40 X 1/4" PPZ 8 55.3301.
PAGE 90
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Gobo Wheel Assembly 21.9676.4146 Rev A Refer to Figure 3-18. No. Item Qty. UM. Description 1 22.9676.4142 1 EA ASSY, GOBO WHEEL, 12 POSITION FIXED 2 41.6006.4202 1 EA ASSY, VL6 GOBO, VERTICAL BARS (ST) 3 41.6006.5009 1 EA ASSY, VL6 GOBO LIQUID TEXTURE (P.O.) 4 41.6006.5011 1 EA ASSY, VL6 GOBO, NIGHT SKY (ST) 5 41.6006.5501 1 EA ASSY, VL6 GOBO, LEAVES (ST) 6 41.6006.5523 1 EA ASSY, VL6 GOBO, TRIBAL BREAKUP (P.O.) 7 41.
PAGE 91
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Color Filter Wheel Assembly 21.9676.4145 Rev A Refer to Figure 3-19. No. Item Qty. UM. Description 1 22.9676.4142 1 EA ASSY, GOBO WHEEL, 12 POSITION FIXED 2 41.6006.0020 1 EA ASSY, VL6 FILTER, MAGENTA (ST) 3 41.6006.0150 1 EA ASSY, VL6 FILTER, PINK (ST) 4 41.6006.0240 1 EA ASSY, VL6 FILTER, LIGHT RED (ST) 5 41.6006.0320 1 EA ASSY, VL6 FILTER, BASTARD AMBER #1 (ST) 6 41.6006.0440 1 EA ASSY, VL6 FILTER, ORANGE (ST) 7 41.6006.
PAGE 92
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Strobe Assembly 22.9676.0016 Rev H Refer to Figure 3-20. No. Item Qty. UM. 1 10.9676.0043 1 EA BULKHEAD, STROBE MOUNTING 2 10.9676.0019 2 EA STROBE BLADE, DIMPLED 3 10.9676.0060 2 EA MOUNTING COLLAR, STROBE BLADE 4 10.9676.8061 2 EA STABLIZER, STROBE MOTOR 5 10.9676.0069 2 EA MOUNTING PLATE, STROBE MOTOR 6 10.9678.0491 4 EA BUMPER STOP, STROBE 7 44.9678.0455 2 EA MOTOR, COLOR 8 53.2200.
PAGE 93
ILLUSTRATED PARTS BREAKDOWN : TOP ASSEMBLY 3 Strobe Assembly (continued) 10 (x2) 7 (x2) 6 (x4) 9 (x4) 1 13 (x2) 5 (x2) 12 (x6) 16 (x2) 3 (x2) 14 (x4) 11 (x2) 4 (x2) 8 (x2) 15 (x8) 2 Black Side Note connector orientation on motors Figure 3-20: Strobe Assembly 02. 96 76.
PAGE 94
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL UV / IR Window Assembly 22.9676.0140 Rev G Refer to Figure 3-21. No. Item Qty. UM. Description 1 10.9676.0058 1 EA UV / IR FRAME 2 10.9676.0141 1 EA INSULATOR, THERMAL SWITCH 3 41.9678.0608 1 EA UV / IR FILTER, 3.00" X 3.00" 4 53.5504.0187 2 EA SCREW, 4-40 X 3/16" PPSS 5 55.6569.0001 2 EA WASHER, #2 LOCK 6 74.1034.0001 1 EA THERMAL SWITCH, 15 AMP 315 DEG F OPEN Note: Only available in a complete assembly - except item 6.
PAGE 95
ILLUSTRATED PARTS BREAKDOWN: YOKE 3 Yoke Yoke Assembly 21.9676.0600 Rev G Refer to Figure 3-22. No. Item Qty. UM. Description 1 22.9676.8605 1 EA ASSY, YOKE STRUCTURE 2 22.9676.0609 1 EA ASSY, FAN 3 22.9676.0610 1 EA ASSY, TILT MOTOR 4 23.9650.3327 1 EA ASSY, ELEC., RELAY 5 24.9661.3126 1 EA PCB ASSY, SOLID STATE IGNITOR - 25.9676.0030 2 EA CABLE ASSY, IGNITOR TO RELAY (not shown) 43.0298 2 EA TOROID CORE ZW-42206-TC (not shown) 6 53.6525.
PAGE 96
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Yoke Assembly (continued) 6 (x2) 11 (x2) 1 4 10 (x2) 2 13 12 (x4) 6 (x4) 8 (x4) 14 (x2) 5 3 10 (x2) 13 7 (x3) 9 6 (x2) 12 (x2) Figure 3-22: Yoke Assembly 78 29-May-2009 02 .9 676 .
PAGE 97
ILLUSTRATED PARTS BREAKDOWN: YOKE 3 Tilt Motor Assembly 22.9676.0610 Rev C Refer to Figure 3-23. No. Item Qty. UM. Description 1 10.9676.7298 1 EA PLATE, TENSION ADJUST, PAN MOTOR 2 2a 22.9661.0608 1 EA ASSY, DRIVE PULLEY - 10.9661.8640 1 EA CODEWHEEL, 90 COUNT 2b - 10.9661.0649 EA TIMING PULLEY, 2MM GT, 17 TOOTH 2c - 53.5561.0250 1 2 EA SCREW, 6-40 X 1/4" SET CONE POINT 1 EA ELEC ASSY, PAN EOT SENSOR - 52.6524.0006 1 EA CONN, HOUSING 6-POS RECEPTACLE - 52.8346.
PAGE 98
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Tilt Motor Assembly (continued) Detail A 2 6 (x2) Detail A 9 (x2) 2b 10 (x2) 8 (x2) 3 2c (x2) 4 10 (x2) 2a 1 Pulley Height Detail & Installation 2 3 5 5 0.080" 7 (x4) 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. Step 3. Do not allow Loctite to drip into motor bearing. Step 4. Set pulley height as shown above.
PAGE 99
ILLUSTRATED PARTS BREAKDOWN: YOKE 3 Yoke Fan Assembly 22.9676.0609 Rev A Refer to Figure 3-24. No. Item Qty. UM. Description 1 10-9676.0646 1 EA FAN TRAY, YOKE ARM 2 40.7113.0001 1 EA FAN, +24V 80 X 80 X 25 MM 32CFM 3 52.6396.2202 1 EA RECPT, 2POS MTA100 W/ POL TAB RED CLSD END 4 53.2200.0006 4 EA NUT, 6-32 KEPS SS Direction of Air Flow 2 4 1 3 Figure 3-24: Yoke Fan Assembly 02. 96 76.
PAGE 100
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Notes 82 29-May-2009 02 .9 676 .
PAGE 101
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE 3 Enclosure Upper Enclosure Assembly 21.9676.0800 Rev T Refer to Figure 3-25 and Figure 3-26. No. Item Qty. UM. Description 1 04.9640.0374 1 EA LABEL, P.E. GROUND 2 04.9673.0040 1 EA LABEL, 2000 SERIES COMPLIANCE 3 04.9661.1218.01 1 EA LABEL, PATENT, VL2201 & VL2400 SERIES LUMINAIRES 4 10.9661.1258 1 EA BRACKET, APS SIDE 5 10.9661.1358 1 EA AIR SEAL, DUCT 6 06.6032.0009 1 EA CABLE MARKER TIE, 19 X .7 7 10.9678.
PAGE 102
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 26 69.9676.0700 1 EA ASSY, BALLAST MODULE, 700W ARC, SHIELDED 27 23.9678.0686 1 EA FAN ASSY, UPPER ENCLOSURE 28 23.9678.0687 1 EA ELEC ASSY, PAN EOT SENSOR 29 25.9661.1514 1 EA CABLE ASSY, CHASSIS GROUND (not shown) 30 25.9661.1520 1 EA CABLE ASSY, CHASSIS TO YOKE GROUND (not shown) 31 25.9676.0818 1 EA CABLE ASSY, PAN/TILT CONTROL (not shown) 32 25.9678.
PAGE 103
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE 3 No. Item Qty. UM. Description 64 54.1206.0014 2 EA RING, RETAINING, 1.375" SHAFT 1.291" DIA GRV X .056" WD 65 54.1255.0001 1 EA BEARING ASSY, BLACK FLUSH MOUNT HOUSING 66 54.2055.0001 1 EA BELT, TIMING S2M 210 GRV 9 MM WIDE URTH/KVLR 67 55.2150.0003 2 EA STANDOFF, 1/4" HEX 6-32 X 1.125" LG FF STL 68 55.2178.0001 2 EA CABLE ANCHOR, MOUNT, #8 SCREW MOUNTING 69 55.2179.0001 3 EA CABLE ANCHOR, MOUNT, #6 SCREW MOUNTING 70 55.6580.
PAGE 104
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly (continued) 78 (x2) 45 (x4) 58 (x8) 9 14 44 (x3) 23 Part exploded for clarity.
PAGE 105
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE 3 Upper Enclosure Assembly (continued) 3 2 4 72 (x2) 53 (x4) 80 (x2) 11 15 16 21 16 15 11 54 (x4) 80 (x2) 54 (x4) 55 (x4) 10 (x2) 19 77 (x4) 63 (x4) Figure 3-26: Upper Enclosure Assembly 02. 96 76.
PAGE 106
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Connector Panel Assembly 21.9676.0805 Rev B Refer to Figure 3-27. No. Item Qty. UM. Description 1 10.9678.0852.01 1 EA LAYOUT, ENCLOSURE OVERLAY 2 10.9678.0859 1 EA BRACKET, INPUT 3 10.9678.0872 1 EA STIFFNER, DISPLAY BOARD 4 10.9686.0820 1 EA FILLER, PANEL, DMX CONNECTOR 5 24.9663.3895 1 EA PCB ASSY, DMX INPUT 6 24.9678.3825 1 EA PCB ASSY, DISPLAY 7 25.9678.
PAGE 107
3 ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE DMX Input PCB Assembly 24.9663.3895 Rev 0 Refer to Figure 3-28 No. Item Qty. UM. Description Ref. 1 17.9663.3895 1 EA PCB FAB, DMX INPUT - 2 52.6259.0006 1 EA HEADER, 5POS MTA FRCT LOK STRT POST J3 3 52.6625.0006 1 EA CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL J1 4 52.6626.0006 1 EA CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL J2 5 62.3039.
PAGE 108
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev B Refer to Figure 3-28 No. Item Qty. UM. Description 1 52.6274.2313 1 EA STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 2 52.6401.2321 1 EA CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3WIRE 3 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 4 52.8298.1160 2 EA FERRULE, WIRE 1X16 AWG L2=8MM BLACK 5 55.2268.0187 0.
PAGE 109
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE 3 Pan Tube Assembly 21.9678.0880 Rev C Refer to Figure 3-30. No. Item Qty. UM. Description 1 10.9678.0809 1 EA PAN TOGGLE STOP 2 10.9678.0847 1 EA WASHER, SILICONE FOAM 3 10.9678.0848 2 EA WASHER, PAN TEFLON 4 12.9678.0891 1 EA PAN TUBE, MACHINED 5 54.1206.0021 1 EA RING, RETAINING 1.562" SHAFT 1.468" GRV DIA 6 54.1255.0002 1 EA BEARING ASSY, FLUSH MOUNT HOUSING LARGE 5 6 3 1 3 2 4 Figure 3-30: Pan Tube Assembly 02. 96 76.
PAGE 110
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21.9678.0864 Rev E Refer to Figure 3-31 No. Item Qty. UM. 1 10.9678.0865 1 EA PLATE, PAN MOTOR MOUNT 2 21.9678.0828 1 EA ASSY, DRIVE PULLEY, PAN - 10.9686.8720 1 EA CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 1 EA TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 2 EA SCREW, 8-32 X 1/4" SET FLAT POINT 92 Description 3 24.9678.9729 1 EA PCB ASSY, VL3000 PAN ENCODER (changed 06-27-07) 4 44.9678.
PAGE 111
ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE 3 Pan Motor Assembly (continued) Detail A Pressure-Sensitive Adhesive 2a 2 See Detail A 7 (x2) 2b 3 2c (x2) 8 (x2) 5 (x4) 1 4 Drive Pulley Detail & Installation 2 6 (x4) 0.875" Step Step 1. 2. Step Step Step 3. 4. 5. Connector oriented on this side Apply one drop of Loctite 603 to motor shaft. Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite. Do not allow Loctite to drip into motor bearing.
PAGE 112
VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Upper Enclosure Fan Assembly 23.9678.0686 Rev 0 Refer to Figure 3-32. No. Item Qty. UM. 1 40.7125.0001 1 EA FAN, 24V FAL6F24LH 52.8231.0007 2 EA TERM, SPADE #6 26-24 AWG INS YELLOW 2 Description 1 2 (x2) Figure 3-32: Upper Enclosure Fan Assembly 94 29-May-2009 02 .9 676 .
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ILLUSTRATED PARTS BREAKDOWN: ENCLOSURE 3 Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-33. No. Item Qty. UM. Description 1 52.6524.0006 1 EA CONN, HOUSING 6 POS. RECEPTACLE 2 52.8346.0001 4 EA CONTACT, 24-30 AWG FEMALE CRIMP 3 86.7002.0003 1 EA SWITCH, SLOTTED OPTICAL 3 1, 2 (x4) Figure 3-33: Pan EOT Sensor Electrical Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Notes 96 29-May-2009 02 .9 676 .
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3 ILLUSTRATED PARTS BREAKDOWN: CABLES 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. No. Item Qty. UM. Description 1 52.8329.0001 2 EA TERM, RING # 6 22-16 AWG NON-INS 2 73.7130.0002 0.33 FT WIRE, 7/64" TUBULAR BRAID SILVER-PLATED 1 2 1 Figure 3-48: Ground Strap Cable Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-49. No. Item Qty. UM. Description 1 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8271.0001 1 EA FASTON RECEPT, 16-14 AWG (REEL) 3 73.3516.0504 3.5 IN WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 2 1 3 Figure 3-49: LVS Chassis Ground Cable Assembly 98 29-May-2009 02 .9 676 .
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-50. No. Item Qty. UM. 1 52.8250.0006 2 EA TERM, #8, RING, 10AWG 15.17 FT WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 2 73.7089.0504 1 (x2) Description 2 (7 x 26.0" LG) Figure 3-50: Chassis To Yoke Ground Cable Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Yoke To Head Ground Cable Assembly 25.9667.0028 Rev A Refer to Figure 3-50. No. Item Qty. UM. 1 52.8250.0001 2 EA TERM, #8, RING, 10AWG 15.17 FT WIRE, 22AWG 19X34 MIL-16878/4 TYPE E 2 73.7089.0010 1 (x2) Description 2 (7 x 24.0" LG) Figure 3-51: Chassis To Yoke Ground Cable Assembly 100 29-May-2009 02 .9 676 .
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Ignitor To Relay Cable Assembly 25.9676.0030 Rev 0 Refer to Figure 3-52. No. Item Qty. UM. Description 1 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8312.0001 1 EA RECP, FASTON 1/4" 18-14 AWG INSULATED VO 3 73.7101.0009 1.17 FT WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING 2 3 1 Figure 3-52: Ignitor To Relay Cable Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Tilt Plate Ground Cable Assembly 25.9667.0413 Rev A Refer to Figure 3-53. No. Item Qty. UM. 1 52.8311.0003 1 EA TERM, RING #6 BLUE 14-16 AWG NON-INS. 0.21 FT WIRE, 7/64" TUBULAR BRAID SILVER PLATED 2 73.7130.0002 1 (x2) Description 2 Figure 3-53: Tilt Plate Ground Cable Assembly 102 29-May-2009 02 .9 676 .
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3 ILLUSTRATED PARTS BREAKDOWN: CABLES Color/Gobo T-Stat Cable Assembly 25.9676.0125 Rev B Refer to Figure 3-54. No. Item Qty. UM. Description 1 52.6523.0002 1 EA CONN, HOUSING 2POS. PLUG SHROUD 2 52.8347.0001 2 EA CONTACT, 24-30 AWG MALE CRIMP 3 55.2268.0125 1.00 IN HEATSHRINK, 1/8" CLEAR KYNAR 4 63.2047.1105 1 EA THERMOSTAT, 105 DEG C, PCB MOUNT 5 73.3524.1008 0.50 FT WIRE, 24 AWG 300V 105 DEG C PVC GRAY 5 (3" long each) 4 1, 2 (x2) 3 (0.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Color/Fixed Bulkheads Cable Assembly 25.9676.0715 Rev F Refer to Figure 3-55. No. Item Qty. UM. Description 1 04.9676.0715.00 1 EA LABEL SET, VL2500 COLOR HARNESS 2 52.6610.0040 1 EA HOUSING, 40 POS DBL ROW UNLOADED 3 52.6224.1040 1 EA COVER, FRONT 40 POS MT LATCHING 4 52.6224.2040 1 EA COVER, BACK 40 POS MT 5 52.6396.3103 2 EA RECEPT, 3 POS MTA100 W/POL TAB BLUE CLOSED END 6 52.6424.
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Color/Fixed Bulkheads Cable Assembly (continued) 14, 7, 8 14, 9, 10 (x4 each) 2, 3, 4, 18 11 (x7) 16, 5, 6 12 1 1 1 1 1 1 1 14, 7, 8 13 (x2) 17, 7, 8 1 15, 5, 6 14, 7, 8 Figure 3-55: Color/Fixed Bulkheads Cable Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Optics/Strobe Bulkheads Cable Assembly 25.9676.0716 Rev F Refer to Figure 3-56. No. Item Qty. UM. 1 04.9676.0716.00 1 EA LABEL SET, VL2500 COLOR HARNESS 2 52.6610.0034 1 EA HOUSING, 34 POS 26-22 AWG DBL ROW UNLOADED 3 52.6224.1034 1 EA COVER, FRONT 34 POS MT LATCHING 4 52.6224.2034 1 EA COVER, BACK 34 POS MT 5 52.6467.0004 1 EA CONN, FEMALE 4 POS 30-24 AWG CRIMP PHR 6 52.6467.
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Optics/Strobe Bulkheads Cable Assy (continued) 16, 6, 7 16, 10, 12 17, 5, 7 2, 3, 4, 18 1 15 1 1 16, 8, 11 16, 6, 7 14 (x4) 13 16, 9, 11 16, 8, 11 Figure 3-56: Optics/Strobe Bulkheads Cable Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Strobe 1 Cable Assembly 25.9676.0717 Rev B Refer to Figure 3-57. No. Item Qty. UM. Description 1 04.9676.0716.01 1 EA LABEL, STROBE 1 CONN, HOUSING 4 POS PLUG SHROUDED WIRE TO WIRE 2 52.6523.0004 1 EA 3 52.6661.0006 1 EA CONN, RECEPT 6CIR WIRE TO WIRE 1.25 MM PITCH 4 52.8347.0001 4 EA CONTACT, 24-30 AWG MALE CRIMP CONTACT, 26-28 AWG FEMALE, CRIMP 1.25 MM PITCH (REEL) 5 52.8387.0001 4 EA 6 55.6706.
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Fans/Disconnect Cable Assembly 25.9676.0718 Rev G Refer to Figure 3-58. No. Item Qty. UM. Description 1 52.6396.2403 1 EA RECEPT, 3 POS MTA100 W/ POL TAB 24 AWG 2 52.6524.0002 1 EA CONN, HOUSING 2 POS RECEPT 3 52.6524.0005 1 EA CONN, HOUSING 5 POS RECEPT 4 52.8230.0003 2 EA RECEPT, 1/4" FASTON 22-18 AWG 5 52.8346.0001 7 EA CONTACT, 24-30 AWG FEMALE CRIMP 6 55.2186.0001 1 EA CABLE TIE, 0.10" X 4" SMALL 7 73.5127.0003 2.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL OT Switch to Reflector Assy. Cable Assembly 25.9676.0719 Rev A Refer to Figure 3-59. No. Item Qty. UM. Description 1 52.8271.0010 1 EA RECEPT, FASTON 24-22 AWG NON-INSUL 0.016" TAB 110SERIES 2 52.8371.0001 1 EA RECEPT, FASTON 24-20 AWG UNINSUL TIN PLT BRS .250 X 0.32 3 73.2624.0008 0.67 FT WIRE, 24 AWG 600V 200 DEG C TEFLON GRAY TYPE E 2 1 3 Figure 3-59: OT Switch to Reflector Assy. Cable Assembly 110 29-May-2009 02 .9 676 .
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Pan/Tilt Control Cable Assembly 25.9676.0818 Rev B Refer to Figure 3-60. No. Item Qty. UM. 1 52.6610.0008 1 EA HOUSING, 20 POS 26-22 AWG DBL ROW UNLOADED 2 52.6224.1020 1 EA COVER, FRONT 20 POS MT LATCHING 3 52.6224.2020 1 EA COVER, BACK 20 POS MT 4 52.6524.0005 2 EA CONN, HOUSING 5 POS RECEPT 5 52.6588.0007 2 EA HOUSING, 7 POS 250V/3A 2.5 MM PITCH 6 52.7007.0001 6 EA CONTACT, 28-22 AWG PHOSPHOR BRONZE TIN-PLT 7 52.8346.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Pan/Tilt Control Cable Assembly (continued) 4, 7 (x5) 1, 2, 3, 11 8 (x7) 6 (x3),5 6 (x3),5 4, 7 (x5) Figure 3-60: Pan/Tilt Control Cable Assembly 112 29-May-2009 02 .9 676 .
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-61 No. Item Qty. UM. Description 1 52.8313.0001 2 EA RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL) 2 52.8392.0001 2 EA RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP 3 55.2186.0001 1 EA CABLE TIE, 0.10" WD 4.00" LG SMALL 4 73.6016.0009 0.83 FT WIRE, 16AWG 600V 105C PVC WHT UL1015 5 73.6016.0010 0.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-62 No. Item Qty. UM. 1 52.6231.0001 1 EA PLUG HOUSING, MNLOK PLUG 3 POS 2 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 52.8231.0008 2 EA TERM, SPADE #6 RED 22-16 AWG INSERT 4 52.8392.0001 2 EA RECP, FASTON .187" X 0.32" 16-14 AWG FLAG DBL CRP 5 52.8270.0001 2 EA CONTACT PIN, 20-14 AWG MNLOK (REEL) 6 52.8314.
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 AC Input Splitter Cable Assembly (continued) 4 (x2) 3 (x2) 12 5, 9 13 5, 10 11, 6 2 1 Note: Heatshrink not shown for clarity. 7 (x3) 8 Figure 3-62: AC Input Splitter Cable Assembly 02. 96 76.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-63 No. Item Qty. UM. Description 1 52.6396.2904 1 EA RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 2 52.6396.2905 1 EA RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 3 73.5122.0259 2.17 FT CBL, 22AWG STRND 4COND PVC INSUL 2 3 1 Figure 3-63: Data I/O Link Cable Assembly 116 29-May-2009 02 .9 676 .
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Display Cable Assembly 25.9678.1825 Rev 0 Refer to Figure 3-64 No. Item Qty. UM. Description 1 52.6396.2406 2 EA RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 2 73.5116.0123 1.02 FT WIRE, 24AWG 4COND TW 3 55.2186.0001 4 EA CABLE TIE, .10" WD 4" LG SMALL 4 73.7130.0004 0.958 FT WIRE, TUBULAR BRAID, 1/8" X 23" LG 5 73.6224.0005 0.208 FT WIRE, 24AWG 600V 200C TFE GRN 2.5" LG 6 55.6699.0009 2.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-65 No. Item Qty. UM. Description 1 52.6396.3002 1 EA RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 2 52.6396.3005 1 EA RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 3 52.6396.3008 1 EA RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 4 73.5124.1289 3.
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ILLUSTRATED PARTS BREAKDOWN: CABLES 3 Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-66 No. Item Qty. UM. 1 52.8245.0001 1 EA TERM, RING #10 16 - 14 AWG REEL PIDG 2 52.8312.0001 4 EA RECP, FASTON 1/4" 18-14 AWG INSULATED VO 3 55.2183.0001 0.33 FT HEATSHRINK, 1/2" BLACK 4 55.2186.0001 3 EA CABLE TIE, 0.10" WD 4.00" LG SMALL 5 55.6699.0003 3.19 FT SLEEVING, 1/2" NOM. DIA POLY EXP BRAIDED 6 73.3516.0504 0.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-67 No. Item Qty. UM. Description 1 52.6464.0002 1 EA CONN, HOUSING, SL-156 2 POS 2 52.6464.0003 1 EA CONN, HOUSING, SL-156 3 POS 3 52.8231.0004 2 EA TERM, RING #6 BLUE 12-10 AWG INSRT 4 52.8323.0002 4 EA CONTACT, CRIMP, 18-22 AWG SL-156 5 52.8274.1614 2 EA CONN BUTT SPLICE 16-14 BLUE .150" OD MAX 6 55.2186.0001 4 EA CABLE TIE, .01" x 4.00" SMALL 7 55.6699.
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APPENDIX A. 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.
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VARI❋LITE® - VL2500™ SPOT LUMINAIRE SERVICE MANUAL Notes 122 29-May-2009 02 .9 676 .
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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.