VL500 Service 0

VARILITE - VL500 LUMINAIRE SERVICE MANUAL
VARILITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries.
VL500 (and the individual product designations), VL1000, VL2000, VL2201, VL2202, VL2400 (and the
individual product designations), VL3000, VL3500, Series 500, Series 1000, Series 2000, Series 3000,
DICHROTUNE, VARIIMAGE, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC.
VARILITE products are protected by one or more of the following patents, and other pending patent applications worldwide:
U. S. Patents No. 6,123,436; 6,113,252; 6,046,861; 6,031,749; 6,011,640; 5,969,868; 5,959,768; 5,934,794; 5,882,107;
5,829,868; 5,825,548; 5,798,619; 5,774,273; 5,769,527; 5,758,956; 5,728,994; 5,640,061; 5,590,954; 5,454,477; 5,432,691;
5,367,444; 5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806; 4,972,306;
4,800,474; 4,779,176; 4,701,833; 4,602,321;
U. S. Design Patents No. 439,356; 420,332; 417,300; 415,301; 413,995; 377,338; 366,712; 359,574; 350,408; 347,113;
Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646,588; 586,095; 576,400; 546,433;
Australia Design Patents No. 128,796; 128,795;
Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058; 1,181,795;
Canada Design Patents No. 81,234; 81,233; 76,046;
European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710; 0 495 305; 0 474 202; 0 379 970; 0 253 082;
0 253 081; 0 248 974; 0 192 882; 0 140 994; 0 060 068;
Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89
166.9; 37 68 727.1; 37 51 804.6; 37 50 201.8; 35 87 270.5; 32 79 888.1; 32 74 291.6;
Germany Design Patents No. M 98 01 745.4; M 96 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 951.2; M 499 03 583.6; M
498 11 203.9; G 93 12 884.3;
Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328;
Spain Utility Model Patent No. 2.031.748;
Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573;
Greece Patent No. 910.400.544;
Hong Kong Patents No. 965/1990; 285/1987;
Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241; 1,723,825;
1,683,007; 1,533,011;
Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1,072,598; 1,060,414;
1,002,123;
Korea Patents No. 76,310; 42,639; 283,770; 181,180;
Korea Design Patents No. 209,896; 209,895;
Mexico Patent No. 180,148;
Singapore Patents No. 663/90; 134/87;
Taiwan Patents No. 78,726; 66,975; 65,380; 28,275;
United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.
Neutrik, PowerCon, and EtherCon are registered trademarks of Neutrik, Inc.
All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their
respective companies or organizations.
VL500 Luminaire Service Manual
The information furnished in this manual is for informational use only and is subject to change without notice. Please check
www.vari-lite.com for latest version. Vari-Lite assumes no responsibility or liability for any errors or inaccuracies that may
appear in this manual. All information and graphics are property of Genlyte Thomas Group LLC, 10911 Petal Street, Dallas,
Texas 75238.
Version as of: 17-July-2006
Part number: 02.9685.0010 0
VL500 Luminaire Service Manual

2006 Genlyte Thomas Group LLC. All Rights Reserved.
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HOW TO OBTAIN WARRANTY SERVICE
How To Obtain Warranty Service

A copy of the Vari-Lite Limited Warranty was included in the shipping package for
this VARILITE product.
To obtain warranty service, please contact customer service at 1-877-VARI-LITE
(1-877-827-4548) or customerservice@genlytecontrols.com and request a Return
Material Authorization (RMA) for warranty service. You will need to provide the
model and serial number of the item being returned, a description of the problem or
failure and the name of the registered user or organization. If available, you should
have your sales invoice to establish the date of sale as the beginning of the warranty
period.
Once you obtain the RMA, pack the unit in a secure shipping container or in its
original packing box. Fill out the RMA form included at the end of this manual and
place in shipping container along with a copy of your invoice (if available). Write the
RMA number legibly on or near the shipping address label and return the unit, freight
prepaid to:
Vari-Lite
Attention: Warranty Service (RMA# ________)
10911 Petal Street
Dallas, Texas 75238 USA
As stated in the warranty, it is required that the shipment be insured and FOB our
service center.
Manual Revision History
02.96 85.001 0 0
VERSION
DATE
Rev. 0 (Initial)
17-July-2006
17-July-2006
iii
Compliance Notice
FCC
This equipment has been tested and found to comply with the limits for a Class A
digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when this equipment is operated in
a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with Vari-Lite system,
service, and safety guidelines, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her
own expense.
Declaration of Conformity
We declare, under our sole responsibility, that this product complies with the relevant
clauses of the following standards and harmonized documents:
Safety
EN 60598-1:200/A11:2000 + A12:2002 Luminaire Safety Standard, General Requirements
EN 60598-2 17:1989/A2:1991 Specification for Luminaires for Stage and Studio Lighting
EMC
EN 61000-6-4:2001 Emission Standard for industrial environments
EN 61000-6-2:2001 Immunity for industrial environments
We certify that the product conforms to the protection requirements of council directives:
73/23/EEC (LVD) and 89/336/EEC (EMC)
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SAFETY NOTICE
Safety Notice
It is extremely important to read ALL safety information and instructions provided in
this manual and any accompanying documentation before installing and operating the
products described herein. Heed all cautions and warnings during installation and use
of this product.
Safety symbols used throughout this manual are as follows:
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.
GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND
INJURY TO PERSONS CAN BE FOUND BELOW.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE
1. VARILITE luminaires have been designed for use only with certain Philips and
Osram HID lamps. Note lamp type (MSR400, MSR575HR etc.) before replacing lamps.
Installing another type of lamp may be hazardous.
2. Luminaires may be mounted on any type of surface as long as mounting instructions are
followed. See instructions detailed in this manual.
3. Replace fuses with same type and rating only.
4. Note distance requirement from combustible materials or illuminated objects for
VARILITE luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARILITE luminaires are designed for dry locations only. Exposure to rain or
moisture may damage luminaire.
2. Disconnect power before servicing any VARILITE equipment.
3. Servicing to be performed by qualified personnel only.
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WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE
EXPOSURE TO UV RADIATION
1. Many VARILITE luminaires use an HID type lamp that produces UV radiation. DO
NOT look directly at lamp.
2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet
screens shall be changed if they have become visibly damaged to such an extent that their
effectiveness is impaired. For example, by cracks or deep scratches.
WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS
1. Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety
equipment (gloves, eye protection, etc.) when handling and adjusting hot equipment and
components.
2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to
cool before replacing.
3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye
inflammation. Additionally, arc lamps operate under high pressure at very high
temperatures. Should the lamp break, there can exist a danger of personal injury and/or
fire from broken lamp particles being discharged.
4. Wear eye protection when relamping.
5. Appropriate safety equipment (gloves, eye protection) should be used when handling
damaged lamps.
6. If lamp is touched with bare hands, clean lamp with isopropyl alcohol and wipe with
lint-free cloth before installing or powering up the luminaire.
7. The lamp shall be changed if it has become damaged or thermally deformed.
WARNING:
RF INTERFERENCE
1. This is a Class A product. In a domestic environment this product may cause radio
interference, in which case, the user may be required to take adequate measures.
ARC LAMP CHARACTERISTIC CONSIDERATIONS
1. Arc lamps require a period of time to relight after a power interruption or a severe voltage
dip. In some cases, lamp will automatically relight after it has cooled depending on Lamp
Power-Up State (L ON/ LOFF) system configuration setting.
2. Burning position is universal.
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SICHERHEITSHINWEISE
Sicherheitshinweise
Es ist uerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem
Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin
beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und
dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmanahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
VORSICHT - weist auf mglichen Produktschaden hin.
WARNUNG - weist auf mgliche Krperverletzung und Lebensbedrohung hin.
NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, BERHHTE
UV-STRAHLUNG UND KRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARILITE-Scheinwerfer sind ausschlielich fr den Einsatz mit bestimmten Philips
und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp (MSR400,
MSR575HR etc.), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines
anderen Lampentyps kann gefhrlich sein.
2. Scheinwerfer knnen auf jeder beliebigen Oberflche montiert werden, solange Sie die
Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch.
3. Ersetzen Sie Sicherungen nur mit Sicherungen vom gleichen Typ und gleicher Strke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARILITE-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARILITE-Scheinwerfer eignen sich ausschlielich fr trockene Standorte. Regen
oder Feuchtigkeit knnen die Scheinwerfer beschdigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARILITE-Gerten
beginnen.
3. Die Gerte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN BERHHTE UV-STRAHLUNG
1. Viele VARILITE-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.
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2. Es ist gefhrlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
Ultraviolettschirme mssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschdigung (z. B. Sprnge oder Schrammen) eingeschrnkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KRPERVERLETZUNGEN
1. Bei Betrieb sind die Auenflchen der Scheinwerfer hei. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe hei. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkhlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzndungen verursachen knnen. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Krperverletzung bzw. von Feuer, das von Lampenteilen ausgelst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschdigten Lampen verwendet werden.
6. Wenn die Lampe mit bloen Hnden berhrt wird, reinigen Sie sie mit isopropyl Alkohol
und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb
nehmen.
7. Wenn die Lampe beschdigt oder durch Hitzeeinwirkung deformiert ist, mu diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstrungen verursachen. In diesem Fall mssen eventuell geeignete
Manahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen bentigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgeflle wieder aufzuleuchten. In einigen Fllen wird die Lampe nach
Abkhlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.
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NOTES DE SCURIT
Notes de scurit
Avant de procder linstallation des produits dcrits dans ce guide et de les mettre en
marche, il est extrmement important de lire TOUS les renseignements et TOUTES
les directives de scurit contenues dans ce guide ainsi que toute documentation jointe.
Tenir compte de tous les avertissements et suivre toutes les prcautions pendant
linstallation et lutilisation de cet appareil.
Les symboles de scurit utiliss dans ce guide sont les suivants :
ATTENTION Ce symbole annonce que lappareil risque
dtre endommag.
AVERTISSEMENT Ce symbole annonce quil y a risque
daccident grave ou mme fatal.
CETTE SECTION CONTIENT DES INFORMATIONS GNRALES POUR SE

PROTGER CONTRE LES DCHARGES LECTRIQUES , LES INCENDIES,
LEXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRANER DES BLESSURES.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE LES INCENDIES
1. Les luminaires VARILITE ont t conus pour tre utiliss uniquement avec certaines
lampes Philips et Osram HID. Vrifier le type de lampe (MSR400, MSR575HR etc.)
avant de remplacer les lampes. Linstallation dun autre type de lampe peut poser un
danger.
2. Les luminaires peuvent tre fixs sur tout type de surface tant que les directives de
montage sont respectes. Voir les explications dtailles dans ce guide.
3. Ne remplacer les fusibles quavec ceux du mme type, ayant les mmes caractristiques.
4. Vrifier la distance respecter entre les matriaux combustibles ou les objets illumins et
les luminaires VARILITE.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE LES DCHARGES LECTRIQUES
1. Les luminaires VARILITE sont conus pour une utilisation au sec uniquement. Une
exposition la pluie et lhumidit risque dendommager le luminaire.
2. Dbrancher lappareil avant de procder la rvision de tout matriel VARILITE.
3. Les rvisions doivent tre effectues uniquement par des personnes qualifies.
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AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE UNE EXPOSITION EXCESSIVE
AUX RAYONS UV
1. Plusieurs luminaires VARILITE utilisent une lampe de type HID qui produit des
rayons UV. NE PAS fixer son regard sur la lampe.
2. Lutilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages,
lentilles ou crans ultraviolet visiblement endommags au point que leur efficacit en est
affecte doivent tre remplacs, par exemple sil y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTGER CONTRE LES ACCIDENTS POUVANT
ENTRANER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brlantes quand lappareil est en marche.
Pour manuvrer ou ajuster des appareils brlants et leurs composants, se protger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brlante lorquil est en marche. Dbrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes arc mettent des rayons ultraviolets pouvant causer de graves brlures sur la
peau et une inflammation des yeux. De plus, les lampes arc fonctionnent sous haute
tension de trs hautes tempratures. Si la lampe se casse, les particules de la lampe
casse peuvent causer blessures et/ou incendie en sparpillant.
4. Se protger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropris (gants, protection des yeux) pour manier
des lampes endommages.
6. Si la lampe a t touche avec des mains nues, la nettoyer avec de lalcool isopropyl et
lessuyer avec un chiffon non-pelucheux avant dinstaller ou de brancher le luminaire.
7. Si la lampe a t endommage ou a reu une dformation thermique, elle doit tre
remplace.
AVERTISSEMENT:
INTERFRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interfrences radio, et si cest le cas, lutilisateur peut avoir prendre des mesures
adquates.
CONSIDRATIONS DES CARACTRISTIQUES DE LAMPES ARC
1. Aprs une interruption de courant ou une baisse importante de voltage, les lampes arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet aprs stre refroidie. Cela dpend de la manire dont le systme est rgl
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brler est Universelle.
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AVISO SOBRE SEGURIDAD
Aviso sobre Seguridad

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

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

EXCESIVA A RADIACIN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTINUA CONTRA INCENDIO
1. Las luminarias VARILITE han sido diseadas para ser usadas solamente con algunas
lmparas HID Philips y Osram. Tome nota del tipo de lmpara (MSR400, MSR575HR
etc.) antes de reemplazarla. Instalacin de otro tipo de lmpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalacin. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificacin.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARILITE.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTINUA CONTRA CHOQUE
ELCTRICO
1. Las luminarias VARILITE estn diseadas solamente para lugares secos. La
exposicin a la lluvia o humedad pueden daar la luminaria.
2. Desconecte la energa antes de dar servicio a cualquier equipo de VARILITE.
3. El servicio debe ser realizado solamente por personal calificado.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTINUA CONTRA LA EXPOSICIN
EXCESIVA DE RADIACIN ULTRA VIOLETA
1. Muchas luminarias VARILITE usan un tipo de lmpara HID que produce radiacin
UV. NO mire directamente a la lmpara.
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2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores,
lentes o pantallas ultravioletas si se aprecia que han sido daadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias estn calientes durante su operacin. Use un
equipo de seguridad apropiado (guantes, proteccin para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que estn calientes.
2. Cuando las luminarias estn en operacin la lmpara estar muy caliente. Desconecte la
energa y deje que la lmpara se enfre antes de reemplazarla.
3. Las lmparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamacin a los ojos. Adems, las lmparas de arco operan a alta
presin y muy alta temperatura. Si la lmpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partculas de la lmpara rota que se
caen.
4. Use proteccin para los ojos cuando vuelve a colocar una lmpara nueva.
5. Use un equipo de seguridad apropiado (guantes, proteccin para los ojos, etc.) cuando
trabaje con lmparas daadas.
6. Si toca la lmpara con las manos, limpie la lmpara con alcohol isopropyl y con tela sin
pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lmpara si est daada o deformada termicamente.
ADVERTENCIA:
INTERFERENCIA RF
1. Este es un producto de Clase A. En el ambiente de la casa este producto puede ocasionar
radiointerferencia, en cuyo caso, el usuario debe tomar las medidas adecuadas.
CONSIDERACIONES SOBRE LAS CARACTERSTICAS DE LA LMPARA DE
ARCO
1. Las lmparas de arco requieren un perodo de tiempo para volver a iluminarse despus de
una interrupcin de energa o de una severa cada de voltaje. En algunos casos, la lmpara
se volver a iluminar en forma automtica despus que se ha enfriado dependiendo de la
configuracin del sistema de energa de la lmpara (L ON / L OFF) (L encendida / L
apagada).
2. La posicin de encendido es universal.
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SAFETY NOTICE (JAPANESE)
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CHAPTER 1.
Description
This chapter provides an overview of luminaire features, components and operations.
Features
Component Descriptions
Principles of Operation
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Features
Product Features
VL500 wash luminaires have the following features:
Color
Enhanced DICHROTUNETM radial color changing mechanism
featuring independent magenta, blue, and amber color control
capable of smooth, timed color crossfades or changes.
Pastel (Dichroic Glass) Option:
As an option, all versions of the VL500 wash luminaire are available with pastel or
lighter colored magenta and blue color filters. VL500 wash luminaires fitted with
pastel-colored dichroic glass maintain the electrical specifications of the standard
version of the VL500 wash.
Intensity Control
Tungsten models offer an optional integral dimmer or may be dimmed with a
customer supplied external dimmer. Arc models contain an internal mechanical
douser.
Beam Control
In all models, a selection of six, easily interchangeable front lenses provide a variety
of beam size and shape options. In the VL500, VL500D, and VL500 80V models an
internal, variable diffuser mechanism provides additional beam control. With stipple
lens (standard on all models) in place and adjustment of diffusion, beam angle is
capable of variance from 8-24.
LCD Display
All VL500 wash luminaires come with a on-board, backlit LCD display for luminaire
status, address, set-up, etc.
Pan and Tilt
Smooth, time-controlled continuous motion by way of a three-phase stepper motor
system. Range: Pan - 540, Tilt - 270. Pan/Tilt Accuracy: 0.3 resolution.
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DESCRIPTION :
Model Specific Features

Each individual configuration has the following specific features:
VL500 Wash Luminaire (20.9685.0001)
120V (or 230V), 1200W (or 1000W) Tungsten Halogen lamp source.
Standard color dichroic glass DICHROTUNETM color system.
VL500 Wash Luminaire (20.9685.0011)
120V (or 230V), 1200W (or 1000W) Tungsten Halogen lamp source.
Pastel color dichroic glass DICHROTUNETM color system.
VL500D Wash Luminaire (20.9685.0002)
120V, 1200W Tungsten Halogen lamp source.
120V on-board IGBT dimmer.
VL500 80V Wash Luminaire (20.9685.0004)
80V on-board dimmer.
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xvii
VL500 80V Wash Luminaire (20.9685.0014)
80V on-board dimmer.
VL500A Wash Luminaire (20.9685.0005)
575W arc lamp source with external ballast unit.
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DESCRIPTION :
External Luminaire Components
The following illustration shows the external luminaire components and controls.
Input Panel Connections
Lamp Power
Input Cable
Mini XLR for Remote

Data Thru
Data In
3-Pole Neutrik
Locking Connector
for AC Input
Input Panel
Provides DMX In and
Thru, and AC Power
connections.
Base
Provides hook mounting
holes and safety cable
connection.
AC Power
Input Cable
Lamp Power
Input Cable
Yoke Leg (Power)

Contains power supply,
and dimmer (dimmer models).
Yoke Leg (Control)

Contains main control
PCB and display PCB.
Head Assembly
Houses color, dimmer (arc models) or
difusser (tungsten models) mechanisms.
Heatsink Assembly
Provides access to lamp
for replacement.
Menu Display
Used to input manual
commands, program, test,
set defaults and access
internal status information.
Menu Display Controls
LCD
Display
Softkeys - The menu has four

softkey buttons that change to
accommodate menu selection.
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xix
Luminaire Internal Head Components

The following illustration shows the major sub-assemblies which are located in the
luminaire head assembly.
Note: Yoke assembly not shown for clarity.
Amber/Diffuser Assembly (Tungsten Models)

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

mounted blackout panels for dimming operation
and amber dichroic glass for color mixing.
Backcap Assembly
Provides access to lamp
for replacement
Backend / Heatsink Assembly

Contains reflector and heatsink.
Front Ring
Provides frame for mounting lenses - stipple (standard with fixture).
Optional lenses: clear, 8-row, 10-row, 12-row, or buxom.
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DESCRIPTION :
Luminaire Yoke Components

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

(Power Supply Side)
Main Controller PCB

Luminaire control circuit board.
Power Supply Side
Yoke Arm Cover

(Display Side)
VL500 Models (120V or 230V)
Display LCD
Luminaire technical status/info.
Pan Mechanism
120W Power Supply

Supplies power to
electronic and motor
components. (Except
models with 80V dimmers).
See next page for other individual model variations
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xxi
Luminaire Yoke Components (continued)

The following illustrations show additional model variations for the power supply side
of the luminaire yoke assembly.
VL500D Models (120V or 230V)

Pan Mechanism
IGBT Dimmer Yoke

Arm Cover
120W Power Supply

Supplies power to
electronic and motor
components.
VL500 80V Models
120V or 230V IGBT
Dimmer Module
Pan Mechanism
VL500A Models (575W or 700W)

Pan Mechanism
Standard Yoke
Arm Cover
80V Dimmer
Module
80V Dimmer Yoke
Arm Cover
Ignitor PCB
Ignites lamp in arc models
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DESCRIPTION :
Arc Ballast Unit

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

Used to attach a truss hook.
Ballast Unit
Provides power for
arc lamp source.
Lamp Power Input Cable

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

CPC-type connector for connecting
Lamp Power Input cable from luminaire.
Note: The Lamp Power Input Cable has conductors for lamp power and ballast
control. It is NOT compatible with VARILITE Series 300 lamp runs.
Dimmer Models
An on-board dimmer is
included with VL500D and
VL500 80V incandescent
dimmer models. The dimmer
heatsink is visible on the powerside yoke leg as shown in this
illustration.
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On-Board Dimmer
VL500D Models - Internal lamp power
dimmer configured for either 120V or
230V operation depending on model.
VL500 80V Models - Internal lamp power
dimmer configured specifically for 80V
lamps.
xxiii
VL500 Incandescent Luminaires
VL500 Incandescent Block Diagram - Without On-Board
IGBT Dimmer
Pan
Motor
Tilt
Motor
Pan
Encoder
Tilt
Encoder
J4
VL500 Main Control Board (MCB)
J7
J6
J8
J3
Magenta
Motor
Blue
Motor
Display
DMX
PCB
Thermal
Switch
Remote
Conn.
LVS
Amber
Motor
Diffuser
Motor
Thru In
Fan
Fan
Terminal
Block
Luminaire
Power In
Lamp
Power In
Lamp
Note: For detailed information on wiring, connections, signals, etc., please refer to
VL500 Wiring Diagram - Sheet 1 of 1 on page 163.
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DESCRIPTION :
VL500D Incandescent Luminaires

VL500D Incandescent Block Diagram - With On-Board
IGBT Dimmer
Pan
Motor
Tilt
Motor
Pan
Encoder
Tilt
Encoder
J4
J7
J6
J8
J3
J2
Magenta
Motor
Blue
Motor
Display
DMX
PCB
Thermal
Switch
Remote
Conn.
LVS
Amber
Motor
Diffuser
Motor
Thru In
Fan
Terminal
Block
Luminaire
Power In
Fan
IGBT
Dimmer
Lamp
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xxv
VL500 80V Incandescent Luminaires

VL500 80V Incandescent Block Diagram - With On-Board
80V Dimmer
Pan
Motor
Tilt
Motor
Pan
Encoder
Tilt
Encoder
J4
J7
J6
J8
J3
J2
Magenta
Motor
Blue
Motor
Display
DMX
PCB
Remote
Conn.
LVS
Amber
Motor
Diffuser
Motor
Thru In
Fan
Terminal
Block
Luminaire
Power In
Ferrite
Core
Thermal
Switch
Fan
80V
Dimmer
Fan
Lamp
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DESCRIPTION :
VL500A Luminaire
VL500A Arc Block Diagram - With External Arc Ballast
Lamp
Backcap
Interlock
Fan 700W Ballast Only
Tilt
Motor
Pan
Motor
Ignitor
PCB
Pan
Encoder
Relay
ARC Ballast
(575W or 700W)
Tilt
Encoder
J4
J5
J7
J6
J8
J3
Magenta
Motor
Blue
Motor
Display
DMX
PCB
Thermal
Switch
Remote
Conn.
LVS
Amber
Motor
Dimmer
Motor
Thru In
Fan
Fan
Terminal
Block
Luminaire
Power In
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xxvii
Notes
xxv iii
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TABLE OF CONTENTS
Table of Contents
Chapter 1. Description
Features
Product Features........................................................................................................ xvi
Model Specific Features .......................................................................................... xvii
External Luminaire Components .............................................................................. xix
Luminaire Internal Head Components....................................................................... xx
Luminaire Yoke Components ................................................................................... xxi
Arc Ballast Unit ...................................................................................................... xxiii
Dimmer Models ...................................................................................................... xxiii
VL500 Incandescent Luminaires ............................................................................ xxiv
VL500 Incandescent Block Diagram - Without On-Board IGBT Dimmer ..... xxiv
VL500D Incandescent Luminaires .......................................................................... xxv
VL500D Incandescent Block Diagram - With On-Board IGBT Dimmer ........ xxv
VL500 80V Incandescent Luminaires .................................................................... xxvi
VL500 80V Incandescent Block Diagram - With On-Board 80V Dimmer..... xxvi
VL500A Luminaire................................................................................................ xxvii
VL500A Arc Block Diagram - With External Arc Ballast ............................. xxvii
Introduction
Disclosure ....................................................................................................................
About This Manual ......................................................................................................
Additional Documentation...........................................................................................
Customer Service .........................................................................................................
1
1
2
2
Chapter 1. Maintenance
Testing
Running Parameter Tests ............................................................................................. 4
Diagnostic Tests ........................................................................................................... 6
Test Descriptions................................................................................................... 6
Test Menu System Chart ....................................................................................... 7
Lamp Hours Progress Bar (Arc Models Only) ............................................................ 8
Equipment Handling
Locations/Use .............................................................................................................. 9
Lamps........................................................................................................................... 9
Servicing................................................................................................................ 9
Heat ....................................................................................................................... 9
Lamp Life .............................................................................................................. 9
Solid State Electronics ............................................................................................... 10
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Electrostatic Discharge (ESD) ............................................................................. 10

Printed Circuit Boards (PCBs)............................................................................. 10
Maintenance Procedures
Lamp Replacement - Incandescent............................................................................. 11
Lamp Replacement (Arc Model)................................................................................ 13
Align Lamp For Maximum Beam Irradiance............................................................. 15
Front Glass Replacement............................................................................................ 17
Magenta/Blue DICHRO*TUNE Rear Bulkhead Replacement.................................. 19
Amber/Diffuser (or Dimmer) DICHRO*TUNE Front Bulkhead Replacement ........ 21
Color Filter and Diffuser Panel Replacement ............................................................ 23
Arc Dimmer Panel Replacement ................................................................................ 25
Linear Actuator Motor Replacement (Magenta/Blue Bulkhead) ............................... 27
Linear Actuator Motor Replacement (Amber/Diffuser [or Dimmer] Bulkhead) ....... 29
Incandescent Lamp Socket Assembly (VL500 and VL500D Only) Replacement .... 31
Arc lamp Socket Assembly (VL500A and VL500 80V Only) Replacement ............ 33
Display PCB Replacement ......................................................................................... 35
Main Control PCB/Fan Assembly Replacement........................................................ 36
Low Voltage Supply (LVS) Replacement (VL500/VL500D/VL500A Only)............ 38
Low Voltage Supply (LVS) Temperature PCB Replacement (VL500/VL500D/VL500A
Only)........................................................................................................................... 39
Low Voltage Supply (LVS) Replacement (VL500 80V Only)................................... 40
Low Voltage Supply (LVS) Temperature PCB Replacement (VL500 80V Only) ..... 41
Tilt Motor Assembly Replacement............................................................................. 42
Pan Motor Assembly Replacement ............................................................................ 44
Pan/Tilt Encoder PCB Replacement........................................................................... 45
Arc Ignitor PCB Replacement (VL500A Only)......................................................... 46
IGBT Dimmer Replacement (VL500D Only)............................................................ 47
80V Dimmer Replacement (VL500 80V Only) ......................................................... 49
Arc Ballast Replacement (VL500A Only) ................................................................. 51
Safety Relay Replacement (VL500A Only)............................................................... 52
AC Input (PowerCon) Connector Replacement ......................................................... 53
Mini-XLR (Display/Remote Programming) Connector Replacement....................... 54
DMX PCB Assembly Replacement ........................................................................... 55
Cleaning Optical Lenses and Filters........................................................................... 56
Chapter 2. Illustrated Parts Breakdown

Drawing Trees
VL500 and VL500D Incandescent Luminaires.......................................................... 58
VL500 80V Incandescent Luminaires........................................................................ 60
VL500A (575W/700W) Arc Luminaires ................................................................... 62
Top Assembly
Included Items Kit ......................................................................................................64
Label Locations .......................................................................................................... 66
VL500 Luminaire (120V or 230V) ............................................................................69
VL500D (with 120V IGBT Dimmer) Luminaire .......................................................71
VL500D (with 230V IGBT Dimmer) Luminaire .......................................................73
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TABLE OF CONTENTS
VL500 80V (with 80V Dimmer) Luminaire .............................................................. 75

VL500A Luminaire (575W Arc) ............................................................................... 77
VL500A Luminaire (700W Arc) ............................................................................... 79
Generic VL500 Luminaire Assembly ........................................................................ 81
Head Assembly
VL500 Generic Head Assembly ................................................................................ 87
Heatsink Assembly .................................................................................................... 91
VL500 Magenta/Blue Color Assembly ..................................................................... 95
VL500 Magenta/Blue (Pastel) Color Assembly ........................................................ 96
VL500 Amber/Diffuser Color Assembly ................................................................... 97
VL500 Amber/Dimmer Color Assembly ................................................................... 98
VL500 Magenta/Blue (Arc) Color Assembly ............................................................ 99
VL500 Magenta/Blue (Arc Pastel) Color Assembly ............................................... 100
Magenta/Blue Color Assembly ................................................................................ 101
Magenta/Blue (Pastel) Color Assembly ................................................................... 102
Amber/Diffuser Color Assembly ............................................................................. 103
Amber/Dimmer Color Assembly ............................................................................. 104
Bottom Bulkhead Assembly .................................................................................... 106
Top Bulkhead Assembly .......................................................................................... 108
Drive Ring Assembly ............................................................................................... 110
Magenta/Blue Color Motor Assembly ..................................................................... 111
Amber/Diffuser Color Motor Assembly .................................................................. 112
Yoke Assembly
VL500 Yoke Assembly ............................................................................................ 113
VL500 80V Yoke Assembly .................................................................................... 117
VL500 Extra Hardware Kit ...................................................................................... 121
VL500 Pan/Tilt Motor Assembly ............................................................................ 122
VL500 MCB/FAN Assembly .................................................................................. 123
MCB Fan Assembly ................................................................................................. 124
Yoke Crossmember Assembly ................................................................................. 125
Yoke Crossmember Assembly (VL500 80V) .......................................................... 126
Lower Crossmember Assembly ............................................................................... 127
Upper Crossmember Assembly ............................................................................... 129
Pan Tube Assembly ................................................................................................. 130
80V Pan Tube Assembly ......................................................................................... 131
DMX Input PCB Assembly ..................................................................................... 132
VL500 Main Control Board PCB Assembly ........................................................... 133
Cables
Incandescent Power Input Cable Assembly ............................................................. 137
80V LVS AC Cable Assembly ................................................................................ 138
80V Surge Protector Cable Assembly ..................................................................... 139
VL500 Motor Cable Assembly ................................................................................ 140
Relay to Ignitor Cable Assembly ............................................................................. 142
VL500 AC Input Cable Assembly ........................................................................... 143
VL500 Arc Ballast Input Cable Assembly .............................................................. 144
VL500 Head Grounding Cable Assembly ............................................................... 145
VL500 Ignitor to Socket Cable Assembly ............................................................... 146
VL500 Arc Ballast Interconnect Cable Assembly ................................................... 147
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VL500 Display (Remote) Cable Assembly ..............................................................149

VL500 Yoke Lamp Jumper Cable Assembly ...........................................................150
VL500 Backcap Ground Cable Assembly ...............................................................151
VL500 Main Harness Cable Assembly ....................................................................152
VL500 Arc Main Harness Cable Assembly .............................................................154
VL500 80V Main Harness Cable Assembly ............................................................156
Arc Ballast Assembly
VL500 Arc Ballast Assembly ...................................................................................159
Ballast I/O Cable Assembly .....................................................................................161
VL500 Wiring and Schematic Diagrams
VL500 Wiring Diagram - Sheet 1 of 1 ..................................................................... 163
DMX Input PCB (24.9663.1895) Schematic ........................................................... 164
VL500 Controller PCB (24.9685.0730) Schematic - Sheet 1 of 6........................... 165
Appendix A. Technical Bulletins

VL500 Wash Luminaire Technical Bulletins ........................................................... 171
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INTRODUCTION :
Introduction
Disclosure
This technical manual is confidential property of Vari-Lite. All information contained
herein is the sole and exclusive property of Vari-Lite and may not be used, disclosed,
or reproduced in any manner without the prior written consent of Vari-Lite.
WARNING: It is important to read ALL accompanying safety instructions to avoid
damage to the product and potential injury to yourself or others.
About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL500 Luminaire. The manual is intended for use by
Vari-Lite personnel and by Authorized Vari-Lite Dealers and Service Centers only.
This manual covers the following models:
Model
VL500 Luminaire
Part Number
Source
Comments
20.9685.0001
Tungsten
120V or 230V*, Standard Color System
VL500 Luminaire
20.9685.0011
Tungsten
120V or 230V*, Pastel Color System
VL500DTM Wash Luminaire
20.9685.0002
Tungsten
120V, Integral IGBT Dimmer, Standard Color System
VL500DTM Wash Luminaire
20.9685.0012
Tungsten
120V, Integral IGBT Dimmer, Pastel Color System
VL500D
TM
Wash Luminaire
20.9685.0003
Tungsten
230V, Integral IGBT Dimmer, Standard Color System
VL500D
TM
Wash Luminaire
20.9685.0013
Tungsten
230V, Integral IGBT Dimmer, Pastel Color System
Wash Luminaire
20.9685.0004
Tungsten
80V, Dimmer (100 - 240V Input), Standard Color System
VL500 80VTM Wash Luminaire
20.9685.0014
Tungsten
80V, Dimmer (100 - 240V Input), Pastel Color System
VL500ATM Wash Luminaire
20.9685.0005
Arc
575W, Ballast, Standard Color System
VL500ATM Wash Luminaire
20.9685.0015
Arc
575W, Ballast, Pastel Color System
VL500 80V
TM
TM
Wash Luminaire
20.9685.0006
Arc
700W, Ballast, Standard Color System
TM
Wash Luminaire
20.9685.0016
Arc
700W, Ballast, Pastel Color System
VL500A
VL500A
N ot e : * = L a m p T yp e i s s p e c i f i e d b y c u s t o me r a t t i m e o f o r d e r i n g .
Note: Performing maintenance procedures contained in this manual may void the
product warranty. Refer to the Vari-Lite Limited Warranty card included in the
shipping package for this VARILITE product.
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Additional Documentation
A support web page for VL500 series luminaires is available at www.vari-lite.com
(follow the Support link).
A users manual is available for installation and operation of the VL500 luminaire.
This manual is available in both printed and electronic (PDF) formats.
VL500 Luminaire Users Manual (02.9685.0001).
Technical bulletins concerning the latest changes to VARILITE equipment are also
available at the web site Technical Support Center. These are documentation
supplements that contain procedures for equipment upgrades, retrofits, and additional
repairs. Technical bulletins are integrated into the appropriate equipment manuals as
those manuals are revised.
Customer Service
Our Goal
At Vari-Lite, we are committed to providing you the highest quality in customer

service. Our comprehensive resources are available to help your business succeed and
ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are
telephone troubleshooting assistance, product training or technical service, our fulltime staff of experienced professionals are on-hand to provide support.
How to Reach Us
For assistance in your area, call the dealer from which your product(s) were
purchased.
or
Contact an Authorized Service Center.
or
Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through
Friday, at the following:
phone: 1.877.VARI-LITE (1-877.827.4548) or 1.214.647.7880
fax: 1.214.647.8038
E-mail: customerservice@genlytecontrols.com
Additional Resources
For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.
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CHAPTER 2.
Maintenance
This chapter contains test, service, and standard maintenance procedures.
Testing
Equipment Handling
WARNING: All maintenance procedures are to be performed with power removed from the
luminaire. Never remove cover or backcap while lamp is in operation.
WARNING: Maintenance, repairs, and adjustments should only be performed by a qualified, factory-trained service technician at an Authorized VARILITE Service Center.
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Testing
Running Parameter Tests
The luminaire is capable of running self tests by using the TEST menu functions. For
complete details and values for each test refer to Diagnostic Tests on page 6.
When running tests on multiple luminaires, a DMX termination connector is required at the
last luminaire in the link. (Refer to users manual for more information regarding the
construction of this connector.)
Note: There is a known issue with all versions of code for the VL500 wash luminaires
concerning the Test menu options. Issues arose when running a test from one VL500
wash luminaire to multiple VL500 wash luminaires (of a different type) across the VL500
wash platform. To alleviate this, when testing in groups, only test same Lamp Type luminaires
(for example: VL500A wash [575W arc] with other VL500A wash [575W arc] lights,
VL500 wash [120V/1200W tungsten] wash with other VL500 wash [120V/1200W
tungsten] lights, etc.). The issue, described above, does not pose any problems when operating
VL500 wash luminaires during normal operation under DMX control.
Master Luminaire (running test)
Slave Luminaire
AC In
Slave Luminaire
AC In
AC In
Data Thru
Data Thru
Termination
Figure 1: Test Setup

To run tests:
Step
1. Press [Menu].
Step
2. Press [Up] / [Down] arrows until Test appears. Press [Enter].
Step
3. Use [Up] / [Down] arrows to select a parameter to test. Refer to VL500 Test
Menu System Chart on page 7 for a complete list of test parameters which can
be chosen.
Step
4. Press [Enter] to run test.
Step
5. Press [Menu] to stop test at any time.
Note: Connected luminaires may not respond on the first action (may delay) of the master
luminaire.
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MAINTENANCE :
Movement Disable
The Movement option allows pan and tilt to be disabled so that the luminaire can be placed
in any position for testing without movement occurring. In order to regain full control of the
luminaire, Movement will need to be enabled after testing.
Note: When using the Movement option, pan and tilt will be disabled for all the luminaires
that are linked.
To set movement option:
Step
1. Press [Menu].
Step
2. Press [Up] / [Down] arrows until Config appears. Press [Enter].
Step
3. Press [Up] / [Down] arrows until Pan/Tilt appears. Press [Enter].
Step
4. Movement will be displayed. Press [Enter].
Step
5. Use [Up] / [Down] arrows to select Enable or Disable. Press [Enter] to select.
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Diagnostic Tests
The following diagnostic tests are available in the test menu.
Test Descriptions
All Seq................. Tests all functions in sequential order.
Pan/Tilt ................ Tests different pan and tilt movements.
Pan...................... Tests different pan movements.
Tilt........................ Tests different tilt movements.
Dimmer................ Tests different dimmer moves/operation.
Diffuser ................ Tests diffuser movement.
Cyan.................... Tests Cyan color wheel movements.
Yellow .................. Tests Yellow color wheel movements.
Magenta .............. Tests Magenta color wheel movements.
Encoder............... Disables pan and tilt and displays encoder value.
Fan ...................... Tests fan level (speed 1 to 7, 7 is fastest).
Temperature ........ Displays LVS or MCB temperatures (in oC).
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MAINTENANCE :
Test Menu System Chart

The following shows all the tests that can be performed by accessing the tests via the
luminaires on-board tech display.
Table 2-1: VL500 Test Menu System Chart
1st Level
Test **
System Test
2nd Level
3rd Level
ALL SEQ Sequence Through All

Tests
RunTest
Pan/Tilt Pan/Tilt
RunTest
Pan Pan
Pan 1
4th Level
5thLevel
Press [Menu] to stop tests
Pan 2
Tilt Tilt
Tilt 1
Tilt 2
Dimmer Dimmer
Dimmer 1
Dimmer 2
Dimmer 3
Diffuser Diffuser
Diffuser 1
Diffuser 2
Diffuser 3
Cyan Cyan Color System
Cyan 1
Cyan 2
Cyan 3
Yellow Yellow Color System
Yellow 1
Yellow 2
Yellow 3
Magenta Magenta Color System
Magenta 1
Magenta 2
Magenta 3
Encoder Encoder (Allows hand

movement to check values)
Pan
Value Displays encoder

value
Tilt
Value Displays encoder

value
Fans Fans Test
Value 1 (slow) to 7 (fastest)
Temp Temperature
LVS Temp Low Voltage

Supply temperature
Value Displays
temperature in oC
MCB Temp Main Control

Board temperature
Value Displays
temperature in oC
** Refer to Diagnostic Tests on page 6 for more information.
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Lamp Hours Progress Bar (Arc Models Only)

For arc models, there is a Lamp Hours Progress Bar representing lamp hours used on the lamp.
It is tied directly to the lamp hours within the MCB. The bar, when fully extended across the
full width of the menu display, represents 750 lamp hours (as indicated in Figure 2).
Resetting lamp hours will reset progress bar. This bar is only for a quick graphical
representation of the lamp hours used. For actual lamp hours used, please read the note below.
Note: 750 hours is the default setting for the Lamp Hours Progress Bar. However, the scale of
the progress bar is user definable by adjusting "Warning Hours" in [Config].When the lamp
hours exceed the allotted (or defined) hours, the display will reverse contrast with a warning of
"Exceeded Lamp Hours".
Series 500 Menu Display

Arc Lamp Hours Progress Bar
575W ARC NORMAL
750 Hours
MENU
169
ENTER
Menu Display
Softkeys - The menu has four softkey

buttons that change to accommodate
menu selection.
Figure 2: VL500A Luminaire Menu Display
Note: To identify the exact number of hours used, users should still refer to the [Config] [Lamp] - "Lamp Hours" setting within the menu system.
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MAINTENANCE :
Equipment Handling
Below are some basic tips and information on handling luminaires and their associated
components.
Locations/Use
VARILITE luminaires are designed for dry locations only. Exposure to rain or moisture
(including, but not limited to, fog machines, misters, etc.,) may damage luminaire.
Lamps
Servicing
When handling a lamp, hold it by the ceramic base while wearing cotton gloves or finger
cots. Do not touch the glass envelope (bulb). If you touch the glass with bare fingers,
immediately wipe off any fingerprints with isopropyl alcohol.
Use care when opening and closing the rear castings (or covers) of luminaires and
cleaning reflectors. Any jarring can undo the optical alignment of the lamp.
Heat
On Forced Air Cooled Units
When lamps are lit, the interior of the luminaires becomes very hot. To aid in the airflow
circulation within the luminaires, after dousing the lamps, wait ten minutes before
removing power to the luminaires. This will provide enough time for the equipment fan to
cool off the unit.
On Natural Convection Cooled Units
When lamps are lit, the interior and exterior heatsink of the luminaires becomes very hot.
Naturally convection cooled units require longer to fully cool before being handled. Users
should wait until the unit is cool to the touch before servicing or handling.
Lamp Life
When operating arc lamps, allow luminaires to operate for at least 3 minutes. It takes
about 3 minutes for the fill components (mercury and halogen-metal compounds) in the
lamp tubes to vaporize completely. If the lamps are switched off earlier than 3 minutes, the
fill components are partially vaporized. The inadequately vaporized fill components and
the electrode material (tungsten) are deposited in the areas of the lamp tubes that have
remained cool. As a result, the lamp tubes blacken prematurely and reduce the service life
of the lamps.
If system will be unattended for more than two hours, luminaire lamps should be doused.
Standby mode should not be used for more than two hours.
02.96 85.001 0 0
17-July-2006
When the lamp is struck, the luminaire should be maintained in a horizontal position when
not in use.
For arc lamp luminaires, heads should be tilted horizontal before starting lamps. Lamps
generate light by an electrical discharge arc, whereby the electrons from two electrodes
excite the fill components to give off light. Because of the alternating current position,
the electrons are alternately given off by the two electrodes. When a lamp is set in a
vertical position, the halogen-metal compounds, which determine the color temperature of
the lamp, collect at the top end of the glass envelope. When the lamp is started, color
deviations occur since the concentration of halogen compounds is greater around the top
electrode than the bottom electrode. In addition, the fill components that are difficult to
vaporize congeal around the bottom electrode, thereby reducing lamp life.
Solid State Electronics

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

All PC boards should be shipped in electrostatic shielding bags. When handling PC boards or
components, devices such as conductive mats and conductive wrist straps should be used
whenever possible. If these precautionary devices are not available, handling of PC boards and
components should be avoided.
CAUTION: Black foam (used to package solid state electronics) should never be used for
packing batteries or put in contact with PC boards which contain batteries.
10
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Lamp Replacement - Incandescent
Parts:
71.2529.0120
1EA
71.2526.0230
1 EA
71.9685.0080
1 EA
1200 WATT TUNGSTEN HALOGEN LAMP, 120 VAC

(VL500 AND VL500D MODELS)
(VL500 AND VL500D MODELS)
(VL500 80V MODELS)
Tools:
Cotton gloves or finger cots.
WARNING: Remove power from luminaire before performing maintenance.

To remove and replace incandescent lamp:
Step
1. Remove power from luminaire.
WARNING: Lamps will be extremely HOT after operation. Allow lamp to cool before
replacing.
Step
2. Set the luminaire head horizontally.
Step
3. Engage service tilt lock to secure luminaire head in horizontal position to access
heatsink latch.
Step
4. As shown in Figure 3, at heatsink assembly, open latch and swing open back of
luminaire.
CAUTION:
Ensure lamp is seated
straight in socket before
re-installing backcap.
Heatsink
Assembly
Latch
Incandescent Lamp
Figure 3: Replacing Lamp
02.96 85.001 0 0
17-July-2006
11
WARNING: Wear cotton gloves or other covering while servicing lamp. Touching lamp
glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If
required, use alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp.
12
Step
5. Remove lamp by pulling straight out of socket.
Step
6. Carefully clean reflector with soft, lint-free cloth to remove dust and other debris.
Step
7. Install lamp by pressing firmly into socket. Ensure lamp is fully seated in socket
with base of lamp against socket base.
Step
8. Close and re-latch back of luminaire.
Step
9. Disengage service tilt lock to allow luminaire head to move freely.
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Lamp Replacement (Arc Model)

Parts:
71.2528.0575
1 EA
71.9685.0702
1 EA
MSR575, 575 WATT ARC LAMP

(VL500A 575W MODELS)
MSR700/2, 700 WATT MSR ARC LAMP
(VL500A 700W MODELS)
Tools:
Cotton gloves or finger cots.

To remove and replace arc lamp:
Step
replacing.
Step
Step
heatsink latch.
Step
luminaire.
CAUTION:
Ensure lamp is seated
straight in socket before
re-installing backcap.
Heatsink
Assembly
Back Cap
Assembly
Arc Lamp
Menu
Latch
Figure 4: Installing Arc Lamp in VL500A Models
02.96 85.001 0 0
17-July-2006
13
WARNING: Wear cotton gloves or other covering while servicing lamp. Touching lamp
glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If
required, use alcohol and soft, lint-free cloth to thoroughly clean glass portion of lamp.
Step
5. Remove lamp by pulling straight out of socket.
Step
6. Carefully clean reflector and facing UV glass lens with soft, lint-free cloth to
remove dust and other debris.
Step
7. Install lamp by pressing firmly into socket. Ensure lamp is fully seated in socket
with base of lamp against socket base.
Step
8. Close and re-latch back of luminaire.
Step
Step 10. Align lamp. (Refer to Align Lamp For Maximum Beam Irradiance on
page 15.)
Step 11. If required, and only on arc models, reset lamp hour counter as follows. (Refer to
"Menu Systems Functions" in the VL500 Users Manual for more information.)
a. Power up luminaire.
b. At Menu Display, press [Menu].
c. Press [Up] / [Down] arrows until CFG (Configuration) appears. Press [Enter].
d. Press [Up] / [Down] arrows until LAMP appears. Press [Enter].
e. Press [Up] / [Down] arrows to access RHrs . Press [Enter] to reset lamp hour
and strike counters.
14
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Align Lamp For Maximum Beam Irradiance

After a new lamp is installed in a VL500A luminaire, it will be necessary to align the lamp to
optimize the beam.
Tools:
#1 Phillips Screwdriver
1/4" Nutdriver
Cotton Gloves or Finger Cots
Clean, Lint-free (Soft) Cloth

To align lamp for maximum bean irradiance:
Step
replacing.
Step
Step
heatsink latch.
Step
luminaire.
Heatsink
Assembly
Backcap
Assembly
Latch
Arc Lamp
Figure 5: Accessing the Reflector in VL500A Fixtures
02.96 85.001 0 0
17-July-2006
15
Step
5. Ensure the following:

a. Reflector is mounted in center of rear casting and secure enough to prevent it
from moving. If not, at three reflector mounting clips, using #1 Phillips screwdriver, remove three 6-32x1/8" PPSS screws. remove light baffle ring and
loosen three 1/4" hex standoffs.
b. Center reflector and retighten reflector clips by tightening standoffs. Make sure
clips are square so the light baffle ring will fit perfectly over the clips.
c. Reinstall light baffle ring.
d. Lamp is properly and completely seated in the lamp socket in the centered in
opening of reflector. Adjust as necessary.
Step
6. Using soft, lint-free dry cloth, wipe lamp and reflector clean of any dust or fingerprints.
Step
7. Close and latch heatsink assembly.
Step
Step
9. Supply power to luminaire.
Step 10. Disable pan/tilt (if necessary).

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

* Do not remove or use to access lamp.
Figure 6: Lamp Alignment Screws

Step 15. Close and latch front lens ring.
16
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Front Glass Replacement

Parts:As needed:
42.9685.0201
42.9685.0207
42.9685.0203
42.9685.0206
42.9685.0204
42.9685.0205
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
GLASS, FRONT, CLEAR

GLASS, FRONT, STIPPLE
GLASS, FRONT, MED. FLOOD 8-ROW LENT.
GLASS, FRONT, VERY WIDE FLOOD - BUXOM
Tools:
Clean, Lint-free (Soft) Cloth
To remove and replace front glass:
Note: It is often easier to replace the lenses when the fixture is warm. However, use caution
when handling a warm fixture as damage to glass components can occur (lamp, reflector, etc.).
Step
Step
2. At front ring assembly, open latch and swing open. Refer to Figure 7.
Front Ring
Assembly
Head Assembly
Front Lens
Hinge Latch
Figure 7: Replacing Front Glass
02.96 85.001 0 0
17-July-2006
17
CAUTION: Wear thick, protective gloves or other protective covering while handling front
lens. The lens is extremely fragile and can break if too much force is applied. If dirty, clean
with common glass cleaner and a soft, lint-free cloth.
Step
3. At front ring assembly, carefully press front side of lens inward with thumbs while
holding ring with fingers until glass is free of holder. Remove lens.
WARNING: When installing a new or replacement lens in a VL500ATM (ARC) Wash, all
lens types must be installed curve out (convex). In tungsten fixtures (VL500TM, VL500DTM,
and VL500 80VTM Wash), Clear and Stipple lenses may be installed curve in (concave) and all
Lenticular (8-Row, 10-Row, and 12-Row) and Buxom lenses must be installed curve out
(convex).
Step
4. Position new glass in front ring assembly. Be sure glass is fully and properly seated
into rubber ring. See Table 2-2, Lens Mounting Orientation, for each model.
Incandescent Models (VL500, VL500D, and VL500 80V)
Clear Lens
Concave or Convex
Stipple Lens
Concave or Convex
8-Row Lens
Convex Only
10-Row Lens
Convex Only
12-Row Lens
Convex Only
Buxom Lens
Convex Only
Arc Models (VL500A)

Clear Lens
Convex Only
Stipple Lens
Convex Only
8-Row Lens
Convex Only
10-Row Lens
Convex Only
12-Row Lens
Convex Only
Buxom Lens
Convex Only
Note: Concave = Bubble In / Convex = Bubble Out
Table 2-2: Lens Mounting Orientation

Step
18
5. Close and latch front ring assembly.
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Magenta/Blue DICHRO*TUNE Rear Bulkhead

Replacement
Parts:
21.9685.0170
1 EA
21.9685.0174
1 EA
21.9685.0173
1 EA
21.9685.0175
1 EA
ASSY, MAGENTA/BLUE (STANDARD DICHRO*TUNE

COLORS - INCANDESCENT)
ASSY, MAGENTA/BLUE (PASTEL DICHRO*TUNE
COLORS - INCANDESCENT)
ASSY, MAGENTA/BLUE (STANDARD DICHRO*TUNE
COLORS - ARC)
ASSY, MAGENTA/BLUE (PASTEL DICHRO*TUNE
COLORS - ARC)
Tools:
To remove and replace Magenta/Blue bulkhead assembly:

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

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

Step
2. Disconnect luminaire AC input cable from power source.
Step
3. Engage tilt lock so luminaire head is in horizontal position with top cover (one with
bubble) facing up (as shown in Figure 8).
Step
4. As indicated in Figure 8, open heatsink by releasing latch.

Magenta/Blue Assembly
Top Cover
Amber/Diffuser Assembly*
(Incandescent Models)
or
Amber/Dimmer Assembly*
(Arc Models)
Heatsink Assembly
*See separate procedure for

removing and replacing these
assemblies.
NOTE:
Some components not shown for clarity.
Figure 8: Magenta/Blue Color Bulkhead
02.96 85.001 0 0
17-July-2006
19
Step
5. At top cover, remove four 6-32x1/4" PPB SEMS screws.
Step
6. Remove top cover.
Step
7. Disconnect wiring at two linear actuators on Magenta/Blue DICHRO*TUNE

Bulkhead.
Step
8. As shown in Figure 9, at side rails from top, remove four 6-32x3/8" LG PPZ
SEMS screws.
6-32x3/8" PPZ SEMS (x4)
Side Rail
NOTE:
Figure 9: Magenta/Blue Color Bulkhead

Step
9. Carefully lift Magenta/Blue bulkhead out of luminaire head.
Step 10. Replace by performing steps 2 through 10 in reverse order.
Note: This is also the procedure to convert a standard color bulkhead to pastel color bulkhead
or vice versa.
20
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Amber/Diffuser (or Dimmer) DICHRO*TUNE

Front Bulkhead Replacement
Parts:
21.9685.0171
21.9685.0172
1 EA
1 EA
ASSY, AMBER/DIFFUSER (INCANDESCENT MODELS)

ASSY, AMBER/DIMMER (ARC MODELS)
Tools:
To remove and replace Amber/Diffuser (or Dimmer) bulkhead assembly:

Step


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

Magenta/Blue Assembly*
Top Cover
Amber/Diffuser Assembly

removing and replacing this
assembly.
or
Amber/Dimmer Assembly
(Arc Models)
Front Ring
NOTE:
Figure 10: Amber/Diffuser (or Dimmer) Bulkhead

Step
Step
Step
7. Disconnect wiring at two linear actuators on Amber/Diffuser (or Dimmer)

DICHRO*TUNE Front Bulkhead.
02.96 85.001 0 0
17-July-2006
21
Step
8. As shown in Figure 11, at side rails from top, remove four 6-32x3/8" LG PPZ
SEMS screws.
NOTE:
6-32x3/8" PPZ SEMS (x4)

Amber/Diffuser (or Dimmer) Assembly
Side Rail
Figure 11: Amber/Diffuser (or Dimmer) Bulkhead

Step
9. Carefully lift Amber/Diffuser (or Dimmer) bulkhead out of luminaire head.
22
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Color Filter and Diffuser Panel Replacement

Parts:
22.9685.0122
22.9685.0123
22.9685.0120
22.9685.0121
22.9685.0124
22.9685.0126
16 EA
16 EA
16 EA
16 EA
16 EA
16 EA
ASSY, FILTER, MAGENTA, DICHRO*TUNE (STD)

ASSY, FILTER, BLUE, DICHRO*TUNE (STD)
ASSY, FILTER, MAGENTA, DICHRO*TUNE (PASTEL)
ASSY, FILTER, BLUE, DICHRO*TUNE (PASTEL)
ASSY, FILTER, AMBER, DICHRO*TUNE
ASSY, FILTER, DIFFUSER PANEL
Tools:
#1 Phillips screwdriver
Tweaker Screwdriver
Clean, lint-free (soft) cloth
To remove and replace color filters or diffuser panels:

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

Step
Step
Step
heatsink latch.
Step
5. Remove desired bulkhead assembly as follows:

a. For Magenta/Blue bulkhead removal, refer to, Magenta/Blue DICHRO*TUNE
Rear Bulkhead Replacement on page 19. Remove Magenta/Blue bulkhead.
b. For Amber/Diffuser bulkhead removal, refer to, Amber/Diffuser (or Dimmer)
DICHRO*TUNE Front Bulkhead Replacement on page 21. Remove Amber/
Diffuser bulkhead.
02.96 85.001 0 0
17-July-2006
23
WARNING: Wear cotton gloves or other covering while handling filters or diffuser panels.
If required, use isopropyl alcohol and soft, lint-free cloth to thoroughly clean glass portion of
lamp.
CAUTION: Work carefully when removing filter and panels. Filters and panels are secured
to silicone pad with UV-cured RTV and pad can become separated. If they become separated,
a new filter or panel must be installed since RTV must be UV-cured.
Step
6. Disconnect actuator screw from Swivel Coupler using tweaker screwdriver by

carefully prying apart from Drive Ring Link.
Color Filter/
Diffuser Panel
Pad Lip
Silicone Pad
Insert Filter
Carrier Pin
Center Hub
Carrier Arch
Filter Carrier
Bulkhead
Figure 12: Color Filter and Diffuser Panel Removal

Step
7. Open glass filter or diffuser panels.
Step
8. Remove filter or panel as follows (shown in Figure 12):

a. At filter or panel, gently push assembly (with silicon pad) in towards center hub
(away from carrier) and work end of tweaker screwdriver between silicon pad
and carrier.
b. Gently work side of silicone pad (not under carrier arch) free.
c. After side of silicone pad is free from carrier, remove silicone pad from under
carrier arch and remove filter or panel.
Step
9. Insert filter carrier pin (of replacement filter or panel) into center hub as shown in
Figure 12.
Step 10. Place side of silicone pad with lip into arch on installed carrier.
Step 11. Using tweaker screwdriver, gently run screwdriver tip over silicone pad, driving
silicone pad into carrier and fully seating silicone pad.
Step 12. Reassemble luminaire.
24
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Arc Dimmer Panel Replacement

Parts:
10.9685.0210
16 EA
DIMMER BLADE (PANEL), VL500
Tools:
#1 Phillips screwdriver
Tweaker Screwdriver
Clean, lint-free (soft) cloth
To remove and replace dimmer panels:

Step
1. Ensure all glass filters and dimmer panels are in closed position.

Step
Step
Step
heatsink latch.
Step
5. Unlatch and swing open front ring.
Step
6. Remove Amber/Diffuser bulkhead by following procedure, Amber/Diffuser (or

Dimmer) DICHRO*TUNE Front Bulkhead Replacement on page 21.
Step
7. Disconnect actuator screw from swivel coupler using tweaker screwdriver by

carefully prying apart from Drive Ring Link.
Step
8. Open dimmer panels slightly.
Step
9. Remove one 4-40 x 1/8" PPB screw that attaches dimmer panel to Dimmer Carrier.
4-40x1/8" PPB Screw
Dimmer Panel
Bearing
Carrier
Spring
Drive Arm Link
Figure 13: Dimmer Panel
02.96 85.001 0 0
17-July-2006
25
Step 10. Remove dimmer panel from center hub.

Dimmer Panel
Carrier
Insert Panel
Bearing Here
Center Hub
Bulkhead
Figure 14: Dimmer Panel Replacement

26
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Linear Actuator Motor Replacement (Magenta/

Blue Bulkhead)
Parts:
44.9685.0230
2 EA
MOTOR, LINEAR, 0.002"/STEP
Tools:
#2 Slotted Screwdriver

To remove and replace linear actuator motor assembly:
Step
Step
Step
3. Engage tilt service lock to secure luminaire head in horizontal position to access
heatsink latch.
Top Cover
Amber/Diffuser Assembly*
or
Linear Actuator Motor Assembly
Amber/Dimmer Assembly*
(Arc Models)
Heatsink Assembly

linear motor replacement for
these assemblies.
Front Ring
NOTE:
Figure 15: Magenta/Blue Color Bulkhead - Linear Actuator Motors

Step
4. Remove top head cover.
Note: Linear actuator motors should be seen with cover removed. If not, flip head position.
02.96 85.001 0 0
17-July-2006
27
Step
5. At linear actuator motor to be replaced on Magenta/Blue assembly, disconnect

wiring at both motors.
Step
6. Remove linear actuator motor assembly as follows:

a. At linear actuator motor assembly, using #1 Phillips screwdriver, remove three
4-40x1/4" PPZ screws and three #4 lock washers securing motor mount to
luminaire head.
b. At linear actuator motor assemblies, using #2 slotted screwdriver, disconnect
actuator/drive ring links from swivel links on drive rings.
Step
7. At linear actuator motor, using #1 Phillips screwdriver, remove two 4-40x1/4" PPZ
screws securing linear actuator motor to actuator mount, and remove motor. See
Figure 16.
4-40x1/4 PPZ Screw (2 for each motor)

Actuator Screw
Note:
Versilube Silicon Grease (G321) is

used to lubricate the actuator screw.
Motor Mount
Linear Actuator Motor

Drive Ring Link
Figure 16: Magenta/Blue Linear Actuator Motor Replacement

Step
8. Place linear actuator motor in place on actuator mount.
Step
9. Re-install two 4-40x1/4" PPZ screws and two #4 lock washers and, using #1 Phillips
screwdriver, tighten to secure linear actuator motor and heatsink to actuator mount.
Step 10. Secure actuator/drive ring link to drive ring swivel link.
Step 11. Attach wiring.
Step 12. Re-install top head cover.
Step 13. Release tilt service lock.
28
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Linear Actuator Motor Replacement (Amber/Diffuser [or Dimmer] Bulkhead)

Parts:
44.9685.0230
2 EA
Tools:
#2 Slotted Screwdriver

To remove and replace linear actuator motor assembly:
Step
Step
Step
3. Engage tilt service lock to secure luminaire head in horizontal position to access
heatsink latch.
Magenta/Blue Assembly*
linear motor replacement for
these assemblies.
Top Cover
Linear Actuator
Motor Assembly
Amber/Diffuser Assembly
Heatsink Assembly
or
Amber/Dimmer Assembly
(Arc Models)
Front Ring
NOTE:
Figure 17: Amber/Diffuser (or Dimmer) Bulkhead - Linear Actuator Motors

Step
4. Remove top head cover.
Note: Linear actuator motors should be seen with cover removed. If not, flip head over.
02.96 85.001 0 0
17-July-2006
29
Step
5. At linear actuator motor to be replaced on Amber/Diffuser (or Dimmer) assembly,

disconnect wiring at both motors.
Step
6. Remove linear actuator motor assembly as follows:

a. At linear actuator motor assembly, using #1 Phillips screwdriver, remove three
4-40x1/4" PPZ screws and three #4 lock washers securing motor mount to
luminaire head.
b. At linear actuator motor assemblies, using #2 slotted screwdriver, disconnect
actuator/drive ring links from swivel links on drive rings.
Step
7. At linear actuator motor, using #1 Phillips screwdriver, remove two 4-40x1/4" PPZ
screws securing linear actuator motor to actuator mount, and remove motor. See
Figure 18.
4-40x1/4 PPZ Screw (2 for each motor)
Actuator Screw
Note:

Motor Mount
Linear Actuator Motor

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

Step
8. Place linear actuator motor in place on actuator mount.
Step
9. Re-install two 4-40x1/4" PPZ screws and two #4 lock washers and, using #1 Phillips
screwdriver, tighten to secure linear actuator motor and heatsink to actuator mount.
Step 10. Secure actuator/drive ring link to drive ring swivel link.
Step 11. Attach wiring.
Step 12. Re-install top head cover.
Step 13. Release tilt service lock.
30
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Incandescent Lamp Socket Assembly (VL500

and VL500D Only) Replacement
Parts:
23.9685.0780
1 EA
ASSY, LAMP SOCKET (VL500 AND VL500D ONLY)
Tools:
1/4" Hex Nutdriver
To remove and replace lamp socket assembly:

Step


Step
Step
Step
4. Open heatsink by releasing latch.

Top Cover
Magenta/Blue Bulkhead Assembly
Heatsink Assembly
NOTE:
Heatsink Latch
Lamp
Figure 19: Accessing the Lamp Socket in VL500 and VL500D Fixtures
Step
Step
Step
7. Remove Magenta/Blue Bulkhead Assembly as described in Magenta/Blue

DICHRO*TUNE Rear Bulkhead Replacement on page 19. Remove Magenta/Blue
bulkhead.
Step
8. Using soft cloth to protect lamp, remove lamp from socket.
02.96 85.001 0 0
17-July-2006
31
Step
9. As indicated in Figure 20, at light baffle, remove three 6-32x1/8" PPB screws.
Backcap
Light Leak Foam
Lamp Socket
Reflector
Light Baffle
6-32x1/4" PPZ
Screws (x2)
8-32x1/2" PPZ SEM Screws (x4)
Reflector Clips (x3)

1/4" Hex Standoff (x3)
6-32x1/8" PPB Screws (x3)
Figure 20: Heatsink Assembly - Lamp Socket Removal (VL500 and VL500D Only)
Step 10. Remove light baffle.
Step 11. Loosen, but do not remove, three 1/4" hex standoffs and turn reflector clips out of
way and remove reflector.
Step 12. Remove yoke arm cover opposite display side by removing four 6-32x3/8" LG PTB
screws.
Step 13. If applicable, remove dimmer. See, IGBT Dimmer Replacement (VL500D Only) on
page 47 for IGBT dimmer removal.
Step 14. At inside of side rail, remove two 4-40x1/8" LG PPB screws and remove Lamp
Wire Cover.
Step 15. At support rib closest to tilt tube, remove one 6-32x1/4" LG PPG screw and remove
ground strap.
Step 16. Remove tilt tube plug and pass lamp wires through tilt tube.
Step 17. Inside heatsink, remove four 8-32x1/2" LG PPZ SEM screws and remove back cap
Step 18. Remove heatsink light leak foam and pass lamp wire through heatsink.
Step 19. At socket, remove two 6-32x1/4" LG PPZ SEM screws and remove socket.
Step 20. Replace by performing Steps 3 through 19 in reverse order.
32
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
Arc lamp Socket Assembly (VL500A and VL500

80V Only) Replacement
Parts:
23.9685.0780
1 EA
ASSY, LAMP SOCKET (VL500 AND VL500D ONLY)
Tools:
1/4" Hex Nutdriver
5/64" Allen Wrench
To remove and replace lamp socket assembly:

Step


Step
Step
Step
4. Open heatsink by releasing latch.

Top Cover
Magenta/Blue Bulkhead Assembly
Heatsink Assembly
NOTE:
Heatsink Latch
Lamp
Figure 21: Accessing the Lamp Socket in VL500A and VL500 80V Fixtures
Step
Step
Step
7. Remove Magenta/Blue Bulkhead Assembly as described in Magenta/Blue

DICHRO*TUNE Rear Bulkhead Replacement on page 19. Remove Magenta/Blue
bulkhead.
02.96 85.001 0 0
17-July-2006
33
Step
8. Using soft cloth to protect lamp, remove lamp from socket.
Step
9. As indicated in Figure 22, at light baffle, remove three 6-32x1/8" PPB screws.
10-32x1-1/2" PPB Screws VL500A Only
10-32x1" SCB Screws VL500 80V Only
Spring (x3) VL500A Only
Backcap Extension
Backcap
Lamp Socket
Reflector
Light Baffle
8-32x3/8" PPZ
Screws (x2)
1/4" Hex
Standoff (x3)
8-32x1/2" PPZ SEM Screws (x4)

Reflector Clips (x3)
6-32x1/8" PPB Screws (x3)
Figure 22: Heatsink Assembly - Lamp Socket Removal (VL500A and VL500 80V Only)
Step 10. Remove light baffle.
Step 11. Loosen, but do not remove, three 1/4" hex standoffs and turn reflector clips out of
way and remove reflector.
Step 12. Inside heatsink, remove four 8-32x1/2" LG PPZ SEM screws and remove back cap
Step 13. Remove lamp alignment screws as follows:
a. For VL500A models, at backcap, remove three 10-32x1-1/2" LG PPB screws
and springs.
b. For VL500 80V models, at backcap, remove three 10-32x1" LG SCB screws.
Step 14. Remove backcap extension.
Step 15. At socket, remove two 8-32x3/8" LG PPZ SEM screws and two socket clips.
Step 16. Remove socket from backcap.
Step 17. Using 5/64" Allen wrench, loosen two set-screws and remove lamp wires from
socket.
Step 18. Replace lamp socket by performing Steps 3 through 17 in reverse order.
34
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MAINTENANCE :
Display PCB Replacement

Parts:
24.9685.0826
1 EA
ASSY, VL500 DISPLAY PCB
Tools:
1/4" Hex Nutdriver

To remove and replace display PCB assembly:
Step
Step
2. Remove display-side yoke arm cover by removing four 6-32x3/8" screws.
Step
3. At display overlay, as indicated in Figure 23, remove four 6-32x1/4" PPB screws.
6-32x1/4" PPB (x4)
1/4" Hex (9/32" Long)

Standoff (x4)
Menu
Display
Display Lens
Yoke Arm
Cover
Display Overlay
Display PCB
NOTE:
Figure 23: Display PCB Replacement

Step
4. Remove display overlay.
Step
5. As indicated in Figure 23, remove four 1/4" hex (9/32" long) standoffs.
Step
6. At display PCB, disconnect the following wiring connections:

a. 4-position MTA connector (24V DC)
b. 2-position connector (MCB Fan)
c. 4-position connector (LVS Fan/Temperature Switch)
d. 6-position connector (Display Communication)
Step
7. Remove Display PCB.
Step
8. Replace by performing Steps 2 through 7 in reverse order.
02.96 85.001 0 0
17-July-2006
35
Main Control PCB/Fan Assembly Replacement

Parts:
21.9685.0731
1 EA
ASSY, VL500 MAIN CONTROL PCB/FAN
Tools:
1/4" Hex Nutdriver

To remove and replace main control PCB/fan assembly:
Step
Step
2. Remove display-side yoke arm cover by removing four 6-32x3/8" screws.
Step
3. Remove Display PCB as described in, Incandescent Lamp Socket Assembly (VL500
and VL500D Only) Replacement on page 31.
Step
4. At Main Control PCB/Fan Assembly, disconnect the following wiring connections:

a. Pan/Tilt wiring harness
b. Head motor wiring harness
c. 3-position connector (Dimmer communications - VL500D and VL500 80V
models only)
d. 10-position AMP connector (Display Communications)
e. 4-position connector (DMX communications)*
CAUTION: *This connector is similar to the connector for the LVS Fan/Temperature
Switch connector used on the Display PCB. It is imperative that you do not confuse the two.
f.
3-position connector (24V DC)
g. 5-position connector (Ballast communications - VL500A models only)

Step
36
5. Remove two 6-32x3/8" PPZ screws (one has a ground wire terminal attached).
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MAINTENANCE :
Step
6. Remove four 1/4" hex (13/16" long) standoffs as indicated in Figure 24.
6-32x1/4" PPB (x4)
1/4" Hex (9/32" Long)

Standoff (x4)
Menu
Display
Yoke Arm
Cover
Display PCB
1/4" Hex (13/16" Long)

Standoff (x4)
Main Control PCB
NOTE:
Figure 24: Main Control PCB/Fan Replacement

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

order.
Step
9. Configure Main Control PCB using menus as needed.
02.96 85.001 0 0
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37
Low Voltage Supply (LVS) Replacement (VL500/

VL500D/VL500A Only)
Parts:
69.3178.0120
1 EA
POWER SUPPLY, 120W, 24VDC
Tools:
WARNING: With power applied, LIVE AC is present at heatsink. Do not touch when unit
is powered.
To remove and replace LVS:
Step
Step
2. Remove yoke arm cover opposite display side by removing four 6-32x3/8" screws.
Wire Shield (fish paper)

LVS Power Supply
6-32x3/8" PPZ (x4)
NOTE:
Figure 25: LVS Replacement (VL500/VL500D/VL500A Only)

Step
3. Disconnect the following wiring connections:

a. 3-position connector (AC Input)
b. 6-position MTA connector (DC Output)
38
Step
4. As shown in Figure 25, remove four 6-32x3/8" PPZ, SEMS screws.
Step
5. Remove LVS. Note fish paper (Wire Shield) behind LVS, save and reuse with
replacement LVS.
Step
6. Replace by performing steps 2 through 5 in reverse order.
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MAINTENANCE :
Low Voltage Supply (LVS) Temperature PCB

Replacement (VL500/VL500D/VL500A Only)
Parts:
24.9685.0740
1 EA
TEMPERATURE BOARD, LVS
Tools:
is powered.
To remove and replace LVS temperature PCB:
Step
Step
2. Remove LVS by following procedure, Low Voltage Supply (LVS) Replacement

(VL500/VL500D/VL500A Only) on page 38.
Yoke Arm
LVS Temperature PCB
1/4" Hex Standoff
NOTE:
Figure 26: LVS Temperature PCB Replacement (VL500/VL500D/VL500A Only)

Step
3. Disconnect the following wiring connections on PCB:

a. 2-position connector (LVS Fan)
b. 4-position connector (LVS Fan from MCB)
Step
4. As shown in Figure 26, remove one 1/4" hex standoff.
Step
5. Remove LVS Temperature PCB.
Step
02.96 85.001 0 0
17-July-2006
39
Low Voltage Supply (LVS) Replacement (VL500

80V Only)
Parts:
69.3178.0121
1 EA
POWER SUPPLY, 120W, 24VDC
Tools:
is powered.
To remove and replace LVS:
Step
Step
2. Position light to access top of pan tube assembly.
Step
3. At pan tube cover, remove six 8-32x1/2" PFB screws.
Step
4. Remove pan tube cover. (Note, tether will still hold cover).
Do not remove this screw
Pan Tube Cover
8-32x1/2" PFB Screws (x6)

4-40x1/4" PPZ Screws (x4)
Cover Tether
LVS Power Supply

Wire Shield (fish paper)
Pan Tube
NOTE:
Some components not

shown for clarity.
Figure 27: LVS Replacement (VL500 80V Only)

Step
5. Disconnect the following wiring connections:

a. 3-position connector (AC Input)
b. 6-position MTA connector (DC Output)
40
Step
6. As shown in Figure 27, remove four 4-40x1/4" PPZ screws.
Step
7. Remove LVS. Note fish paper (Wire Shield) under LVS, save and reuse with
replacement LVS.
Step
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MAINTENANCE :
Low Voltage Supply (LVS) Temperature PCB

Replacement (VL500 80V Only)
Parts:
24.9685.0740
1 EA
Tools:
is powered.
To remove and replace LVS temperature PCB:
Step
Step
2. Remove LVS by following procedure, Low Voltage Supply (LVS) Replacement

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

6-32x3/8" PPZ
Pan Tube
NOTE:
Some components not

shown for clarity.
Figure 28: LVS Temperature PCB Replacement (VL500/VL500D/VL500A Only)

Step
3. Disconnect the following wiring connections on PCB:

a. 2-position connector (LVS Fan)
b. 4-position connector (LVS Fan from MCB)
Step
4. As shown in Figure 26, remove one 6-32x3/8" PPZ securing LVS Temperature
PCB to fan bracket assembly.
Step
5. Remove LVS Temperature PCB.
Step
02.96 85.001 0 0
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41
Tilt Motor Assembly Replacement

Parts:
21.9685.0540
1 EA
ASSY, PAN/TILT MOTOR
Tools:
Diagonal Cutters

To remove and replace tilt motor assembly:
42
Step
Step
2. Remove display side yoke cover by removing four 6-32x3/8" LG PTB screws.
Step
3. Remove Display PCB and Main Control PCB by following procedures Display PCB
Replacement on page 35 and Main Control PCB/Fan Assembly Replacement on page
36.
Step
4. Remove 4 x 6-32 x 3/8" PFB screws (two each side of yoke) that hold Top Cover
Louver Plate and remove plate.
Step
5. Disconnect wiring from motor and encoder PCB.
Step
6. Cut wire tie connecting wiring to yoke arm.
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MAINTENANCE :
Step
7. Loosen (do NOT remove) four 8-32x7/16" PPZ screws that mount Pan/Tilt motor
assembly to Tilt Motor Slide Plate.
Tilt Motor
Assembly
NOTE:

8-32x7/16" PPZ
Tilt Motor Assembly

Tilt Motor Slide Plate
Yoke Arm Cover
8-32x7/16" PPZ (x4)
Spring
8-32x7/16" PPZ
Figure 29: Tilt Motor Assembly Replacement

Step
8. Press motor towards spring to loosen belt tension.
Step
9. Remove belt from both drive pulley and driven pulley.
Step 10. Remove four 8-32x7/16" PPZ screws that mount Tilt Motor Slide Plate to yoke and
remove ENTIRE assembly.
Step 11. Remove four 8-32x7/16" PPZ screws that mount Pan/Tilt Motor Assembly to Tilt
Motor Slide Plate and remove Pan/Tilt Motor Assembly (be careful of spring).
Step 12. Replace by performing Steps 2 through 10 in reverse order.
Note: When tightening four 8-32x7/16" PPZ screws that mount Pan/Tilt Motor Assembly to
Tilt Motor Slide Plate, you must tighten in a CLOCKWISE pattern starting with screw in
lower left-hand side from spring.
02.96 85.001 0 0
17-July-2006
43
Pan Motor Assembly Replacement

Parts:
21.9685.0540
1 EA
Tools:

To remove and replace pan motor assembly:
Step
Step
2. Remove yoke cover opposite of display by removing four 6-32x3/8" LG PTB

screws.
Step
3. Remove 4 x 6-32 x 3/8" PFB screws (two each side of yoke) that hold Top Cover
Louver Plate and remove plate.
Step
4. Disconnect wiring from motor and encoder PCB.
Step
5. As shown in Figure 30, loosen, but do not remove, four 8-32x1/2" PPB screws.
Step
6. Press motor towards driven pulley and remove belt from drive pulley.
Step
7. Remove four 8-32x1/2" PPB screws from Step 5.
Step
8. Remove Pan/Tilt Motor Assembly.

NOTE:
Spring
8-32x1/2" PPB (x4)
Pan Belt
Pan Motor
Assembly
Pan Motor Assembly
Yoke Arm
Figure 30: Pan Motor Assembly Replacement

Step
9. Replace pan motor assembly by performing Steps 2 through 8 in reverse.
Note: When tightening four 8-32x1/2" PPB screws, you must tighten in a CLOCKWISE
pattern starting with screw in lower left-hand side from spring.
44
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MAINTENANCE :
Pan/Tilt Encoder PCB Replacement

Parts:
24.9685.7735
1 EA
BOARD ASSY, PAN/TILT ENCODER
Tools:

To remove and replace pan/tilt encoder PCB:
Step
Step
2. To access pan/tilt encoder PCB:

a. For Tilt Motor Encoder PCB removal, remove display side yoke cover by
removing four 6-32x3/8" LG PTB screws.
b. For Pan Motor Encoder PCB removal, access pan motor assembly see, Pan
Motor Assembly Replacement on page 44.
Step
3. At encoder PCB, disconnect wiring harness from assembly.
Step
4. As shown in Figure 31, remove two 6-32x3/8" PPZ screws and remove assembly.
Pan/Tilt Motor Encoder PCB
6-32x3/8" PPZ
Encoder Disk
Figure 31: Pan/Tilt Motor Encoder PCB Replacement

Step
5. Replace by performing Steps 2 through 4 in reverse order.
Note: Ensure that encoder disk passes freely through the optical sensor on PCB.
02.96 85.001 0 0
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45
Arc Ignitor PCB Replacement (VL500A Only)

Parts:
24.9685.1000
1 EA
IGNITOR, ARC (VL500A ONLY)
Tools:

To remove and replace ignitor PCB:
Step
Step

screws.
Step
3. At Ignitor PCB, disconnect Input and Output lamp wires.
Step
4. As shown in Figure 32, remove four 6-32x3/8" PPZ SEMS screws from PCB.
NOTE:
Ignitor PCB
6-32x3/8" PPZ SEMS (x4)
Ignitor PCB
Yoke Arm Cover
Figure 32: Ignitor PCB Replacement

Step
5. Remove Ignitor PCB.
Note: Make sure and install ignitor with proper orientation. Wires from Relay attached to
posts labeled "From Relay". Wires going to lamp attach to posts labeled "To Bulb".
Step
46
6. Replace Ignitor PCB by performing Steps 2 through 6 in reverse.
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MAINTENANCE :
IGBT Dimmer Replacement (VL500D Only)

Parts:
69.3173.0115
1 EA
69.3173.0230
1 EA
DIMMER, IGBT, 1200W 115V REV PHASE CONT

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

To remove and replace IGBT dimmer:
Step
Step
2. Remove yoke cover on dimmer side by removing four 6-32x3/8" LG PTB screws.
Step
3. As shown in Figure 33, at dimmer, loosen, but do not remove, four 6-32x3/8" PPZ
screws.
Step
4. Carefully remove IGBT dimmer. Note that there will be wires connected to dimmer
on the back side.
CAUTION: All AC wiring is same color. It is a good idea to mark the connector attached to
both the AC Line Input and Load (Output) terminals on the IGBT dimmer with a black marker
before removing so the phasing can be maintained.
Step
5. At dimmer, carefully note (and label before removing) and disconnect following
wiring:
a. 3-position (Dimmer Communication from MCB)
b. Four Faston (Quick Connects - AC Input / lamp Power Output)
Step
02.96 85.001 0 0
6. Remove four 6-32x3/8" PPZ screws from Step 3. Install these screws in replacement
IGBT dimmer.
17-July-2006
47
NOTE:
6-32x3/8" PTB Screws (x4)
Yoke Arm Cover (Dimmer Side)
IGBT Dimmer
Figure 33: IGBT Dimmer Replacement (VL500D Only)

Step
48
7. Replace IGBT Dimmer by performing Steps 2 through 6 in reverse.
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MAINTENANCE :
80V Dimmer Replacement (VL500 80V Only)

Parts:
21.9685.0750
1 EA
ASSY, 80V DIMMER
Tools:

To remove and replace 80V dimmer:
Step
Step
2. Remove yoke cover on dimmer side by removing four 6-32x3/8" LG PTB screws.
Step
3. As shown in Figure 34, at dimmer, loosen, but do not remove, four 6-32x3/8" PPZ
screws.
Step
4. Carefully remove 80V dimmer. Note that there will be wires connected to dimmer
on the back side.
CAUTION: All AC wiring is same color. It is a good idea to mark the connector attached to
both the AC Line Input and Load (Output) terminals on the IGBT dimmer with a black marker
before removing so the phasing can be maintained.
Step
5. At dimmer, carefully note (and label before removing) and disconnect following
wiring:
a. 4-position (Dimmer Communication from MCB)
b. Four Faston (Quick Connects - AC Input / lamp Power Output)
Step
02.96 85.001 0 0
6. Remove four 6-32x3/8" PPZ screws from Step 3. Install these screws in replacement
80V dimmer.
17-July-2006
49
NOTE:
6-32x3/8" PTB Screws (x4)
Yoke Arm Cover (Dimmer Side)
80V Dimmer
Figure 34: 80V Dimmer Replacement (VL500 80V only)

Step
50
7. Replace 80V Dimmer by performing Steps 2 through 6 in reverse.
17-July-2006
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MAINTENANCE :
Arc Ballast Replacement (VL500A Only)

Parts:
21.9685.0800
21.9685.0802
1 EA
1 EA
ASSY, BALLAST, 625W (575W MODELS ONLY)

ASSY, BALLAST, 700W (700W MODELS ONLY)
Tools:
None

To remove and replace arc ballast dimmer:
Step
Note: The Arc Ballast Unit is separate from the luminaire.

Step
2. Disconnect Ballast Interconnect Cable Assembly from ballast and luminaire.
Step
3. Connect Ballast Interconnect Cable Assembly to replacement ballast and luminaire.
Figure 35: Arc Ballast Assembly
02.96 85.001 0 0
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51
Safety Relay Replacement (VL500A Only)

Parts:
23.9650.3327
1 EA
RELAY, ELECTRICAL ASSY (VL500A ONLY)
Tools:

To remove and replace safety relay assembly:
Step
Step

screws.
Step
3. At Relay, disconnect following wiring:

a. Bundled AC from Ballast
b. White AC to Ignitor
c. Red +24V DC from MCB
d. Green -24V DC from Backcap Interlock (Kill) Switch
Step
4. At Relay, loosen, but do not remove, two 4-40x5/16" PPZ SEMS screws.
NOTE:
Relay
4-40x5/16" PPZ SEMS (x2)
Relay
Yoke Arm Cover
Step
5. Carefully slide Relay out of yoke arm.
Note: When replacing Relay, do not overtighten screws securing Relay (as described in Step
4). Doing so may crack plastic tabs on Relay.
Step
52
6. Replace Relay by performing Steps 2 through 5 in reverse.
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MAINTENANCE :
AC Input (PowerCon) Connector Replacement

Parts:
25.9685.0756
1 EA
CONNECTOR, AC INPUT (POWERCON)
Tools:

To remove and replace AC input (PowerCon) connector:
Step
Step
Step
3. As shown in Figure 36, at pan tube cover, remove six 8-32x1/2" PFB screws.
Step
8-32x1/2" PFB
Screws (x6)

Pan Tube Cover
NOTE:
Some components not

shown for clarity. This
procedure is applicable
for all models.
Pan Tube Assembly
Cover Tether
VL500 80V
Pan Tube Assembly
4-40x1/2" PFB
Screws (x2)
AC Input (PowerCon) Connector
Figure 36: AC Input (PowerCon) Connector Replacement

Step
5. Remove two 4-40x1/2" PFB screws at front of PowerCon.
Step
6. Disconnect wiring from PowerCon.
Step
7. Replace PowerCon by performing Steps 3 through 6 in reverse.
02.96 85.001 0 0
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53
Mini-XLR (Display/Remote Programming) Connector Replacement

Parts:
25.9685.0770
1 EA
CONNECTOR, MINI-XLR (DISPLAY / REMOTE

PROGRAMMING)
Tools:

To remove and replace Mini-XLR connector:
Step
Step
Step
Step
8-32x1/2" PFB
Screws (x6)

Pan Tube Cover
NOTE:
Some components not

for all models.
Pan Tube Assembly
Cover Tether
Mini-XLR
Connector
VL500 80V
Pan Tube Assembly
4-40x1/4" PFB
Screws (x2)
Figure 37: Mini-XLR (Display/Remote Programming) Connector Replacement
54
Step
5. Disconnect wiring from Mini-XLR.
Step
6. Remove two 4-40x1/4" PFB screws at front of Mini-XLR connector.
Step
7. Replace Mini-XLR by performing Steps 3 through 6 in reverse.
17-July-2006
02 .9 685.00 10 0
MAINTENANCE :
DMX PCB Assembly Replacement

Parts:
24.9663.1895
1 EA
ASSY, DMX INPUT PCB
Tools:

To remove and replace DMX PCB assembly:
Step
Step
Step
Step
8-32x1/2" PFB
Screws (x6)

Pan Tube Cover
NOTE:
Some components not

for all models.
Pan Tube Assembly
Cover Tether
VL500 80V
Pan Tube Assembly
DMX PCB
Assembly
#4x3/8" HLN PN
BLK ZN Screws (x4)
Figure 38: DMX PCB Assembly Replacement

Step
5. Disconnect wiring from DMX PCB Assembly.
Step
6. Remove four #4x3/8" H/L PN BLK ZN screws at front of DMX PCB Assembly.
Step
7. Replace DMX PCB Assembly by performing Steps 3 through 6 in reverse.
02.96 85.001 0 0
17-July-2006
55
Cleaning Optical Lenses and Filters

WARNING: Acetone is a harsh cleaning agent and solvent. Acetone is very flammable.
Please handle acetone according to manufacturers safety instructions and precautions.
The front lens, optics/color filters, and reflector may require cleaning after extended use.
FRONT LENS: Use a common glass cleaner along with a soft, lint-free cloth to clean the
front lens.
OPTICS/COLOR FILTERS: Use Acetone or Isopropyl Alcohol along with a soft, lint-free
cloth to clean the optics/color filters.
REFLECTOR: Use Acetone or Isopropyl Alcohol along with a soft, lint-free cloth to clean
the reflector.
CAUTION: Do not continuously rub color filters or reflector - it may damage or remove the
optical coating.
56
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CHAPTER 3.
Illustrated Parts Breakdown
This chapter contains illustrated parts breakdowns for all VL500 wash luminaire
assemblies including the arc ballast unit.
Drawing Trees
Top Assembly
Head Assembly
Yoke Assembly
Cables
Note: The following abbreviations are used to identify parts specific to certain
models.
VL500 Model Parts Identifiers

ABBREVIATION
VL500
VL500D
VL500 80V
VL500A
02.96 85.001 0 0
MODEL (INCLUDES STANDARD AND PASTEL COLOR SYSTEMS)

VL500 Incandescent Luminaire (120V or 230V)
VL500D Incandescent Luminaire with IGBT On-Board Dimmer (120V or 230V)
VL500 80V Incandescent Luminaire with 80V On-Board Dimmer
VL500A Arc Luminaire (575W or 700W) with External Ballast
17-July-2006
57
Drawing Trees
VL500 and VL500D Incandescent Luminaires
VL500 Luminaire (120V or 230V) Incandescent Versions
20.9685.0001 Rev G (Standard DICRO*TUNE Colors) or 20.9685.0011 Rev B (Pastel DICRO*TUNE Colors) or 20.9685.0002 Rev F (Standard
DICRO*TUNE Colors) or 20.9685.0012 Rev B (Pastel DICRO*TUNE Colors) or 20.9685.0003 Rev F (Standard DICRO*TUNE Colors) or 20.9685.0013
Rev B (Pastel DICRO*TUNE Colors)
Generic VL500 Luminaire Assembly

21.9685.0010 Rev P (Incandescent - without Internal
Dimmer) or 21.9685.0011 Rev P (Incandescent with Internal IGBT Dimmer)
VL500 Generic Head Assembly
VL500 Motor Cable

Assembly
VL500 Magenta/Blue Color

Assembly
25.9685.0753 Rev B
21.9685.0170 Rev H (Standard

DICRO*TUNE Colors)
VL500 Head Grounding

Cable Assembly
or
21.9685.0310 (VL500 and VL500D)

Rev H
25.9685.0760 Rev C
VL500 Magenta/Blue
(Pastel) Color Assembly
Included Items Kit

Heatsink Assembly
28.9685.0001 Rev G
(120V or 230V, Standard
Colors, No Dimmer) or
28.9685.0011 Rev G
(120V or 230V, Pastel
Colors, No Dimmer) or
28.9685.0002 Rev G
(Standard Colors, 120V
IGBT On-Board Dimmer)
or 28.9685.0012 Rev G
(Pastel Colors, 120V IGBT
On-Board Dimmer) or
28.9685.0003 Rev G
(Standard Colors, 230V
IGBT On-Board Dimmer)
or 28.9685.0013 Rev G
(Pastel Colors, 230V IGBT
On-Board Dimmer)
21.9685.0174 Rev A (Pastel

DICRO*TUNE Colors)
21.9685.0320 (VL500 and VL500D)

Rev G
VL500 Backcap Ground Cable

Assembly
25.9685.0777 Rev A
VL500 Yoke Assembly

21.9685.0520 (VL500) Rev S or
21.9685.0521 (VL500D) Rev S
VL500 Pan/Tilt Motor

Assembly
21.9685.0540 Rev B
VL500 MCB/FAN Assembly

21.9685.0731 Rev 0
VL500 Main Control Board

PCB Assembly
Amber/Diffuser Color
Motor Assembly
21.9685.0281 Rev A
Magenta/Blue Color Motor

Assembly
21.9685.0280 Rev A
Magenta/Blue (Pastel)
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)
Bottom Bulkhead Assembly

21.9685.0150 Rev C
Drive Ring Assembly

21.9685.0280 Rev A

Assembly
21.9685.0280 Rev A
24.9685.0730 Rev B
MCB Fan Assembly

23.9685.0782 Rev 0
DMX Input PCB Assembly

24.9663.1895 Rev A
Assembly
21.9685.0161 Rev F
VL500 Amber/Diffuser
Color Assembly
Magenta/Blue Color
Assembly
21.9685.0160 Rev E (Standard
DICRO*TUNE Colors)

21.9685.0150 Rev C
21.9685.0171 Rev G
Drive Ring Assembly
continued next page
21.9685.0280 Rev A
continued next page
Figure 3-1: VL500 and VL500D Incandescent Luminaires Drawing Tree (Part 1)
58
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ILLUSTRATED PARTS BREAKDOWN :
VL500 and VL500D Incandescent Luminaires

(continued)
continued from previous page
VL500 Yoke Assembly

21.9685.0520 (VL500) Rev S or
21.9685.0521 (VL500D) Rev S
VL500 Amber/Diffuser Color

Assembly
21.9685.0171 Rev G
Top Bulkhead Assembly

VL500 Main Harness Cable
Assembly
21.9685.0151 Rev C
25.9685.0790 Rev J (VL500 and

VL500D)
Drive Ring Assembly

21.9685.0280 Rev A
VL500 Extra Hardware Kit

28.9685.0999 Rev 0
MCB Fan Assembly

23.9685.0782 Rev 0
Yoke Crossmember Assembly

21.9685.0515 Rev E
Lower Crossmember Assembly

21.9685.0512 Rev H
Upper Crossmember Assembly

21.9685.0513 Rev F
Pan Tube Assembly

21.9685.0535 Rev D (VL500/VL500D/
VL500A)
VL500 AC Input Cable Assembly

25.9685.0756 Rev B
VL500 Display (Remote) Cable

Assembly
25.9685.0770 Rev B
VL500 Yoke Lamp Jumper Cable

Assembly
25.9685.0776 Rev A
Incandescent Power Input Cable

Assembly
25.9663.2030 Rev A (VL500 Only)
Figure 3-2: VL500 and VL500D Incandescent Luminaires Drawing Tree (Part 2)
02.96 85.001 0 0
17-July-2006
59
VL500 80V Incandescent Luminaires

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

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

21.9685.0312 (VL500 80V) Rev H
VL500 Motor Cable

Assembly
VL500 Magenta/Blue Color

Assembly
25.9685.0753 Rev B
21.9685.0170 Rev H (Standard

DICRO*TUNE Colors)

Cable Assembly
or
25.9685.0760 Rev C
VL500 Magenta/Blue
(Pastel) Color Assembly
21.9685.0322 (VL500 80V) Rev G
Included Items Kit
21.9685.0174 Rev A (Pastel

DICRO*TUNE Colors)

Assembly
28.9685.0004 Rev G
(Standard Colors, 80V OnBoard Dimmer) or
28.9685.0014 Rev G (Pastel
Colors, 80V On-Board
Dimmer)
Heatsink Assembly
25.9685.0777 Rev A
VL500 Ignitor to Socket Cable

Assembly
25.9685.0766 Rev C
VL500 Amber/Diffuser Color

Assembly
VL500 80V Yoke Assembly
21.9685.0171 Rev G

Assembly
21.9685.0280 Rev A
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)
21.9685.0523 (VL500 80V) Rev G

Assembly
21.9685.0540 Rev B
Amber/Diffuser Color Motor

Assembly
Drive Ring Assembly

21.9685.0731 Rev 0
21.9685.0161 Rev F
24.9685.0730 Rev B
MCB Fan Assembly
21.9685.0150 Rev C
21.9685.0281 Rev A
Assembly

PCB Assembly
21.9685.0280 Rev A

Assembly
21.9685.0280 Rev A
21.9685.0151 Rev C
Drive Ring Assembly

21.9685.0280 Rev A
23.9685.0782 Rev 0
Magenta/Blue Color
Assembly
DICRO*TUNE Colors)
21.9685.0150 Rev C
24.9663.1895 Rev A
Drive Ring Assembly

21.9685.0280 Rev A
continued next page
Figure 3-3: VL500 80V Incandescent Luminaires Drawing Tree (Part 1)
60
17-July-2006
02 .9 685.00 10 0
VL500 80V Incandescent Luminaires (continued)


21.9685.0523 (VL500 80V) Rev G
VL500 80V Main Harness Cable

Assembly
25.9685.0792 Rev C (VL500 80V)

28.9685.0999 Rev 0
MCB Fan Assembly

23.9685.0782 Rev 0

(VL500 80V)
21.9685.0516 Rev 0

21.9685.0512 Rev H

21.9685.0513 Rev F
80V Pan Tube Assembly

21.9685.0536 Rev 0 (VL500 80V)

25.9685.0756 Rev B

Assembly
25.9685.0770 Rev B
Incandescent Power Input Cable

Assembly
25.9685.0742 Rev 0
80V Surge Protector Cable

Assembly
25.9685.0746 Rev 0
Figure 3-4: VL500 80V Incandescent Luminaires Drawing Tree (Part 2)
02.96 85.001 0 0
17-July-2006
61
VL500A (575W/700W) Arc Luminaires

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

21.9685.0013 Rev P (Arc)

21.9685.0311 (VL500A) Rev H
VL500 Motor Cable

Assembly
VL500 Magenta/Blue (Arc)

Color Assembly
25.9685.0753 Rev B
21.9685.0173 Rev A (Standard

DICRO*TUNE Colors)

Cable Assembly
25.9685.0760 Rev C
VL500 Magenta/Blue (Arc

Pastel) Color Assembly
Included Items Kit
21.9685.0174 Rev A (Pastel

DICRO*TUNE Colors)
Heatsink Assembly
21.9685.0321 (VL500A) Rev G

Assembly
25.9685.0777 Rev A
VL500 Ignitor to Socket Cable

Assembly
25.9685.0766 Rev C
28.9685.0005 Rev G (575W

Arc, Standard Colors, Arc
Ballast) or 28.9685.0015 Rev
G (575W Arc, Pastel Colors,
Arc Ballast) or 28.9685.0006
Rev G (700W Arc, Standard
Colors, Arc Ballast) or
28.9685.0016 Rev G (700W
Arc, Pastel Colors, Arc
Ballast)
VL500 Yoke Assembly

21.9685.0522 (VL500A) Rev S

Assembly
VL500 Amber/Dimmer
Color Assembly
21.9685.0172 Rev F
21.9685.0540 Rev B
Amber/Diffuser Color Motor

Assembly
21.9685.0281 Rev A
21.9685.0731 Rev 0

PCB Assembly
Assembly

Assembly
21.9685.0280 Rev A
Color Assembly
21.9685.0164 Rev 0 (Pastel
DICRO*TUNE Colors)

21.9685.0150 Rev C
Drive Ring Assembly

21.9685.0280 Rev A

Assembly
21.9685.0280 Rev A
21.9685.0162 Rev E
24.9685.0730 Rev B

MCB Fan Assembly
or
21.9685.0151 Rev C
23.9685.0782 Rev 0
Magenta/Blue Color
Assembly
DICRO*TUNE Colors)
Drive Ring Assembly

21.9685.0280 Rev A
continued next page

21.9685.0150 Rev C
24.9663.1895 Rev A
continued next page
Drive Ring Assembly

21.9685.0280 Rev A
Figure 3-5: VL500A (575W/700W) Arc Luminaires Drawing Tree (Part 1)
62
17-July-2006
02 .9 685.00 10 0
VL500A (575W/700W) Arc Luminaires (continued)

VL500 Yoke Assembly
VL500A Luminaire (575W Arc) or VL500A Luminaire (700W Arc)
21.9685.0522 (VL500A) Rev S
28.9685.0005 Rev G (575W Arc, Standard Colors, Arc Ballast) or

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

21.9685.0731 Rev 0
VL500 Arc Ballast Interconnect Cable Assembly
28.9685.0999 Rev 0
25.9685.0767 Rev B
Relay to Ignitor Cable Assembly

25.9685.0755 Rev B
25.9685.0756 Rev B
VL500 Arc Ballast Input Cable

Assembly
25.9685.0757 Rev C
VL500 Arc Ballast Assembly

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

Assembly
Ballast I/O Cable Assembly

25.9685.0807 Rev A
25.9685.0770 Rev B
VL500 Arc Main Harness Cable

Assembly
25.9685.0791 Rev C (VL500A)

21.9685.0515 Rev E

21.9685.0512 Rev H

21.9685.0513 Rev F
Pan Tube Assembly

21.9685.0535 Rev D (VL500/VL500D/
VL500A)
Figure 3-6: VL500A (575W/700W) Arc Luminaires Drawing Tree (Part 2)
02.96 85.001 0 0
17-July-2006
63
Top Assembly
Included Items Kit
28.9685.0001
28.9685.0011
28.9685.0002
28.9685.0012
28.9685.0003
28.9685.0013
28.9685.0004
28.9685.0014
28.9685.0005
28.9685.0015
28.9685.0006
28.9685.0016
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
Rev
G
G
G
G
G
G
G
G
G
G
G
G
(120V or 230V, Standard Colors, No Dimmer)

(120V or 230V, Pastel Colors, No Dimmer)
(Standard Colors, 120V IGBT On-Board Dimmer)
(Pastel Colors, 120V IGBT On-Board Dimmer)
(Standard Colors, 230V IGBT On-Board Dimmer)
(Pastel Colors, 230V IGBT On-Board Dimmer)
(Standard Colors, 80V On-Board Dimmer)
(Pastel Colors, 80V On-Board Dimmer)
(575W Arc, Standard Colors, Arc Ballast)
(575W Arc, Pastel Colors, Arc Ballast)
(700W Arc, Standard Colors, Arc Ballast)
(700W Arc, Pastel Colors, Arc Ballast)
Refer to Figure 3-7.
No.
Item
Qty.
UM.
02.8001.0001
EA
PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE
02.8001.0002
EA
QA CERTIFICATE, VARI-LITE
02.8052.0001
EA
CARD, LIMITED WARRANTY
02.8700.0001
EA
CARD, PRODUCT REGISTRATION - VL500
02.9685.0002
EA
UNPACK/QUICK START SHEET, VL500
07.9685.1005
EA
SHIPPING BOX, CARDBOARD - VL500
08.0500.0001
EA
CD ROM, VL500 PRODUCT, DOCUMENTATION
52.6541.0001
EA
CONN, BLUE CABLE PWR INLET 3-POLE LOCKING - POWERCON
53.6505.0027
EA
BOLT, 1/2" X 13 X 1" LG HX HD ZINC (VL500A MODELS ONLY)
10
55.6539.0001
EA
WASHER, 1/2" SPLIT LOCK (VL500A MODELS ONLY)
11
71.2526.0230
EA
230V/1000W TUNGSTEN HALOGEN LAMP, (VL500D, 230V ONLY)
71.2528.0575
EA
575W MSR ARC LAMP, (VL500A, 575W ONLY)
71.2529.0120
EA
120V/1200W TUNGSTEN HALOGEN LAMP, (VL500D, 120V ONLY)
71.9685.0080
EA
80V/1200W TUNGSTEN HALOGEN LAMP, (VL500 80V ONLY)
71.9685.0702
EA
700W MSR ARC LAMP, (VL500A, 700W ONLY)
64
Description
17-July-2006
02 .9 685.00 10 0
Included Items Kit (continued)

1
4
2
7
3
8
11
9 (Arc Models Only)
10 (Arc Models Only)
Figure 3-7: Included Items Kit
02.96 85.001 0 0
17-July-2006
65
Label Locations
16.9685.00YY Rev D

Note: (CLR) = Clear labels - for use with non-black fixtures.
No.
Item
Qty.
UM.
04.9661.0034
EA
LABEL, RELAMPING - 2000 SERIES
04.9663.1837
EA
LABEL, PATENT
04.9685.0911
EA
LABEL, WARNING VL500
04.9685.0911.00
EA
LABEL, WARNING VL500 (CLR)
04.9685.0912
EA
LABEL, COMPLIANCE VL500
04.9685.0912.00
EA
LABEL, COMPLIANCE VL500 (CLR)
04.9685.0913
EA
LABEL, LAMP TYPE 120V OR 230V INCANDESCENT (VL500

MODELS ONLY)
04.9685.0913.00
EA
LABEL, LAMP TYPE 120V OR 230V INCANDESCENT (CLR) (VL500

MODELS ONLY)
04.9685.0914
EA
LABEL, LAMP TYPE 120V INCANDESCENT (VL500D 120V MODELS

ONLY)
04.9685.0914.00
EA
LABEL, LAMP TYPE 120V INCANDESCENT (CLR) (VL500D 120V

MODELS ONLY)
04.9685.0915
EA
LABEL, LAMP TYPE 230V INCANDESCENT (VL500D 230V MODELS

ONLY)
04.9685.0915.00
EA
LABEL, LAMP TYPE 230V INCANDESCENT (CLR) (VL500D 230V

MODELS ONLY)
04.9685.0916
EA
LABEL, LAMP TYPE 575W ARC (VL500A 575W MODELS ONLY)
04.9685.0916.00
EA
LABEL, LAMP TYPE 575W ARC (CLR) (VL500A 575W MODELS

ONLY)
04.9685.0917
EA
LABEL, LAMP TYPE 700W ARC (VL500A 700W MODELS ONLY)
04.9685.0917.00
EA
LABEL, LAMP TYPE 700W ARC (CLR) (VL500A 700W MODELS

ONLY)
04.9685.0918
EA
LABEL, LAMP TYPE 80V INCANDESCENT (VL500 80V MODELS

ONLY)
04.9685.0918.00
EA
LABEL, LAMP TYPE 80V INCANDESCENT (CLR) (VL500 80V

MODELS ONLY)
66
Description
17-July-2006
02 .9 685.00 10 0
No.
Item
Qty.
UM.
04.9685.0920
EA
LABEL, AC INPUT RATING (VL500 MODELS ONLY)
04.9685.0920.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 MODELS ONLY)
04.9685.0921
EA
LABEL, AC INPUT RATING (VL500 PASTEL MODELS ONLY)
04.9685.0921.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 PASTEL MODELS ONLY)
04.9685.0922
EA
LABEL, AC INPUT RATING (VL500D 120V MODELS ONLY)
04.9685.0922.00
EA
LABEL, AC INPUT RATING (CLR) (VL500D 120V MODELS ONLY)
04.9685.0923
EA
LABEL, AC INPUT RATING (VL500D 120V PASTEL MODELS ONLY)
04.9685.0923.00
EA
LABEL, AC INPUT RATING (CLR) (VL500D 120V PASTEL MODELS

ONLY)
04.9685.0924
EA
LABEL, AC INPUT RATING (VL500D 230V MODELS ONLY)
04.9685.0924.00
EA
LABEL, AC INPUT RATING (CLR) (VL500D 230V MODELS ONLY)
04.9685.0925
EA
LABEL, AC INPUT RATING (VL500D 230V PASTEL MODELS ONLY)
04.9685.0925.00
EA
LABEL, AC INPUT RATING (CLR) (VL500D 230V PASTEL MODELS

ONLY)
04.9685.0926
EA
LABEL, AC INPUT RATING (VL500 80V MODELS ONLY)
04.9685.0926.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 80V MODELS ONLY)
04.9685.0927
EA
LABEL, AC INPUT RATING (VL500 80V PASTEL MODELS ONLY)
04.9685.0927.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 80V PASTEL MODELS

ONLY)
04.9685.0928
EA
LABEL, AC INPUT RATING (VL500 575W MODELS ONLY)
04.9685.0928.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 575W MODELS ONLY)
04.9685.0929
EA
LABEL, AC INPUT RATING (VL500 575W PASTEL MODELS ONLY)
04.9685.0929.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 575W PASTEL MODELS

ONLY)
04.9685.0930
EA
LABEL, AC INPUT RATING (VL500 700W MODELS ONLY)
04.9685.0930.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 700W MODELS ONLY)
04.9685.0931
EA
LABEL, AC INPUT RATING (VL500 700W PASTEL MODELS ONLY)
04.9685.0931.00
EA
LABEL, AC INPUT RATING (CLR) (VL500 700W PASTEL MODELS

ONLY)
04.9685.0940
EA
LABEL, PRODUCT, 575W ARC BALLAST (NOT SHOWN)
04.9685.0940.00
EA
LABEL, PRODUCT, 575W ARC BALLAST (CLR) (NOT SHOWN)
04.9685.0941
EA
LABEL, PRODUCT, 700W ARC BALLAST (NOT SHOWN)
04.9685.0941.00
EA
LABEL, PRODUCT, 700W ARC BALLAST (CLR) (NOT SHOWN)
04.9685.0942
EA
LABEL, COMPLIANCE, ARC BALLAST (NOT SHOWN)
04.9685.0942.00
EA
LABEL, COMPLIANCE, ARC BALLAST (CLR) (NOT SHOWN)
02.96 85.001 0 0
Description
17-July-2006
67
Label Locations (continued)
2
6 (VL500 Models Only)
3
6 (Non-Arc Models Only)
5 (Non-Arc Models Only)

R
C LI ST
US
ED
10911 PETAL STREET
DALLAS, TX. 75238 U.S.A.

NOT FOR RESIDENTIAL USE
1.877.VARILITE
WWW.VARILITE.COM IMPROPERE A LUSAGE DOMESTIQUE
SUITABLE FOR DRY LOCATIONS ONLY.

EMPLACEMENT SECS
NO USER SERVICEABLE PARTS INSIDE.
Vari-Lite, Inc.
VL500D-120V-B
120 VAC
11A 50/60Hz
Figure 3-8: Label Locations
68
17-July-2006
02 .9 685.00 10 0
VL500 Luminaire (120V or 230V)

20.9685.0001 Rev G (Standard DICRO*TUNE Colors)
20.9685.0011 Rev B (Pastel DICRO*TUNE Colors)
Refer to Figure 3-9
No.
Item
Qty.
UM.
04.9685.0573
EA
LABEL, MCB YOKE COVER
04.9685.0574
EA
04.9685.0588
EA
LABEL, YOKE COVER, PLAIN, VL500
10.9685.0525
EA
LOUVER PLATE, TOP COVER
10.9685.0580
EA
YOKE ARM COVER, DISPLAY SIDE
10.9685.0584
EA
YOKE ARM COVER, POWER SUPPLY SIDE
21.9685.0010
EA
ASSY, GENERIC VL500, INCANDESCENT
21.9685.0170
EA
ASSY, COLOR, MAGENTA / BLUE, STANDARD (20.9685.0001 ONLY)
21.9685.0174
EA
ASSY, COLOR, MAGENTA / BLUE, PASTEL (20.9685.0011 ONLY)
21.9685.0171
EA
ASSY, COLOR, AMBER / DIFFUSION
10
22.9685.0086
EA
HEAD COVER, TOP
11
22.9685.0087
EA
HEAD COVER, BOTTOM
25.9685.0753
EA
CABLE ASSY, VL500 MOTOR (NOT SHOWN)
25.9685.0760
EA
CABLE ASSY, HEAD GROUNDING (NOT SHOWN)
28.9685.0001
EA
INCLUDED ITEMS KIT, VL500 INCANDESCENT (NOT SHOWN)
12
42.9685.0207
EA
LENS, PAR 64 NSP (STIPPLE)
13
53.6523.0013
EA
SCREW, 6-32X3/8" LG PTB
14
53.6558.0009
EA
SCREW, 6-32X3/8" LG PPZ SEMS
15
53.6558.0010
EA
SCREW, 6-32X1/4" PPB SEMS
16
53.6608.0001
EA
SCREW, 6-32X3/8" PFB
02.96 85.001 0 0
Description
17-July-2006
69
4 (x2)
16 (x8)
1
7
6
2
10
8
9
15 (x8)
11
13 (x8)
3
14 (x8)
12
Figure 3-9: VL500 Luminaire (120V or 230V)
70
17-July-2006
02 .9 685.00 10 0
VL500D (with 120V IGBT Dimmer) Luminaire

20.9685.0002 Rev F (Standard DICRO*TUNE Colors)
Refer to Figure 3-10
No.
Item
Qty.
UM.
04.9685.0573
EA
04.9685.0574
EA
04.9685.0576
EA
LABEL, YOKE COVER, DIMMER
04.9685.0577
EA
10.9685.0525
EA
10.9685.0565
EA
MOUNT, DIMMER
10.9685.0580
EA
10.9685.0582
EA
YOKE ARM COVER, DIMMER SIDE
21.9685.0011
EA
ASSY, GENERIC VL500, INCANDESCENT W/ DIMMER
10
21.9685.0170
EA
21.9685.0174
EA
11
21.9685.0171
EA
12
22.9685.0086
EA
HEAD COVER, TOP
13
22.9685.0087
EA
HEAD COVER, BOTTOM
25.9685.0753
EA
25.9685.0760
EA
28.9685.0002
EA
14
42.9685.0207
EA
15
53.6523.0013
EA
16
53.6558.0001
EA
SCREW, 6-32X3/8" LG PPZ
17
53.6558.0009
EA
18
53.6558.0010
EA
19
53.6608.0001
EA
20
69.3173.0115
EA
DIMMER, 1200W 115V REV PHASE CONT
02.96 85.001 0 0
Description
17-July-2006
71
5 (x2)
19 (x8)
1
9
2
8
12
10
11
3
18 (x8)
13
15 (x8)
16 (x8)
6 (x2)
20
14
17 (x8)
Figure 3-10: VL500D (with 120V IGBT Dimmer) Luminaire
72
17-July-2006
02 .9 685.00 10 0
VL500D (with 230V IGBT Dimmer) Luminaire

20.9685.0003 Rev F (Standard DICRO*TUNE Colors)
No.
Item
Qty.
UM.
04.9685.0573
EA
04.9685.0574
EA
04.9685.0576
EA
04.9685.0577
EA
10.9685.0525
EA
10.9685.0565
EA
MOUNT, DIMMER
10.9685.0580
EA
10.9685.0582
EA
YOKE ARM COVER, DIMMER SIDE
21.9685.0011
EA
ASSY, GENERIC VL500, INCANDESCENT W/ DIMMER
10
21.9685.0170
EA
21.9685.0174
EA
11
21.9685.0171
EA
12
22.9685.0086
EA
HEAD COVER, TOP
13
22.9685.0087
EA
HEAD COVER, BOTTOM
25.9685.0753
EA
25.9685.0760
EA
28.9685.0003
EA
14
42.9685.0207
EA
15
53.6523.0013
EA
16
53.6558.0001
EA
17
53.6558.0009
EA
18
53.6558.0010
EA
19
53.6608.0001
EA
20
69.3173.0230
EA
DIMMER, 1000W 230V REV PHASE CONT
02.96 85.001 0 0
Description
17-July-2006
73
5 (x2)
19 (x8)
1
9
2
8
12
10
11
3
18 (x8)
16 (x8)
6 (x2)
20
13
15 (x8)
14
17 (x8)
Figure 3-11: VL500D (with 230V IGBT Dimmer) Luminaire
74
17-July-2006
02 .9 685.00 10 0
VL500 80V (with 80V Dimmer) Luminaire

20.9685.0004 Rev H (Standard DICRO*TUNE Colors)
20.9685.0014 Rev C (Pastel DICRO*TUNE Colors)
No.
Item
Qty.
UM.
04.9685.0573
EA
04.9685.0574
EA
04.9685.0578
EA
LABEL, YOKE COVER, 80V DIMMER
04.9685.0579
EA
LABEL, YOKE COVER, 80V DIMMER
10.9685.0525
EA
10.9685.0580
EA
10.9685.0586
EA
YOKE ARM COVER, 80V DIMMER SIDE
10.9685.0870
EA
BRACKET, MOUNTING, LEFT, 80V DIMMER
10.9685.0871
EA
BRACKET, MOUNTING, RIGHT, 80V DIMMER
10
21.9685.0012
EA
ASSY, GENERIC VL500 80V, INCANDESCENT W/ DIMMER
11
21.9685.0170
EA
21.9685.0174
EA
12
21.9685.0171
EA
13
21.9685.0750
EA
ASSY, DIMMER, 80V
14
22.9685.0086
EA
HEAD COVER, TOP
15
22.9685.0087
EA
HEAD COVER, BOTTOM
25.9685.0753
EA
25.9685.0760
EA
28.9685.0004
EA
INCLUDED ITEMS KIT, VL500 80V INCANDESCENT (NOT SHOWN)
16
42.9685.0207
EA
17
53.6523.0013
EA
18
53.6558.0001
EA
19
53.6558.0009
EA
20
53.6558.0010
EA
21
53.6608.0001
EA
22
67.4006.0007
EA
CLAMP, CABLE EMI SUP. FERRITE 0.193" ID
02.96 85.001 0 0
Description
17-July-2006
75
5 (x2)
21 (x8)
1
10
22
9
13
7
20 (x8)
14
15
3
19 (x8)
11
12
8
4
18 (x8)
16
17 (x8)
Figure 3-12: VL500 80V (with 80V Dimmer) Luminaire
76
17-July-2006
02 .9 685.00 10 0
VL500A Luminaire (575W Arc)

No.
Item
Qty.
UM.
04.9685.0573
EA
04.9685.0574
EA
04.9685.0588
EA
10.9685.0525
EA
10.9685.0580
EA
10.9685.0584
EA
YOKE ARM COVER, IGNITOR SIDE
21.9685.0013
EA
ASSY, GENERIC VL500, ARC
21.9685.0172
EA
ASSY, COLOR, AMBER / DIMMER
21.9685.0173
EA
ASSY, COLOR, MAGENTA / BLUE, ARC, STANDARD (20.9685.0005

ONLY)
21.9685.0175
EA
ASSY, COLOR, MAGENTA / BLUE, ARC, PASTEL (20.9685.0015

ONLY)
21.9685.0800
EA
ASSY, BALLAST, 625W EXTERNAL (NOT SHOWN)
10
22.9685.0086
EA
HEAD COVER, TOP
11
22.9685.0087
EA
HEAD COVER, BOTTOM
25.9685.0753
EA
CABLE ASSY, VL500 MOTOR
25.9685.0755
EA
CABLE ASSY, RELAY HARNESS (NOT SHOWN)
25.9685.0760
EA
25.9685.0767
EA
CABLE ASSY, BALLAST INTERCONNECT, 575/700W (NOT SHOWN)
28.9685.0005
EA
INCLUDED ITEMS KIT, VL500 ARC (NOT SHOWN)
12
42.9685.0207
EA
13
53.6523.0013
EA
14
53.6558.0009
EA
15
53.6558.0010
EA
16
53.6608.0001
EA
02.96 85.001 0 0
Description
17-July-2006
77
4 (x2)
16 (x8)
1
7
6
2
10
9
8
15 (x8)
11
13 (x8)
14 (x8)
12
Figure 3-13: VL500A Luminaire (575W Arc)
78
17-July-2006
02 .9 685.00 10 0
VL500A Luminaire (700W Arc)

No.
Item
Qty.
UM.
04.9685.0573
EA
04.9685.0574
EA
04.9685.0588
EA
10.9685.0525
EA
10.9685.0580
EA
10.9685.0584
EA
YOKE ARM COVER, IGNITOR SIDE
21.9685.0013
EA
ASSY, GENERIC VL500, ARC
21.9685.0172
EA
ASSY, COLOR, AMBER / DIMMER
21.9685.0173
EA
ASSY, COLOR, MAGENTA / BLUE, ARC, STANDARD (20.9685.0006

ONLY)
21.9685.0175
EA
ASSY, COLOR, MAGENTA / BLUE, ARC, PASTEL (20.9685.0016

ONLY)
21.9685.0802
EA
ASSY, BALLAST, 700W EXTERNAL (NOT SHOWN)
10
22.9685.0086
EA
HEAD COVER, TOP
11
22.9685.0087
EA
HEAD COVER, BOTTOM
25.9685.0753
EA
CABLE ASSY, VL500 MOTOR
25.9685.0755
EA
CABLE ASSY, RELAY HARNESS (NOT SHOWN)
25.9685.0760
EA
25.9685.0767
EA
CABLE ASSY, BALLAST INTERCONNECT, 575/700W (NOT SHOWN)
28.9685.0006
EA
INCLUDED ITEMS KIT, VL500 ARC (NOT SHOWN)
12
42.9685.0207
EA
13
53.6523.0013
EA
14
53.6558.0009
EA
15
53.6558.0010
EA
16
53.6608.0001
EA
02.96 85.001 0 0
Description
17-July-2006
79
4 (x2)
16 (x8)
1
7
6
2
10
9
8
15 (x8)
11
13 (x8)
14 (x8)
12
Figure 3-14: VL500A Luminaire (700W Arc)
80
17-July-2006
02 .9 685.00 10 0

21.9685.0010
21.9685.0011
21.9685.0012
21.9685.0013
Rev
Rev
Rev
Rev
P
P
P
P
(Incandescent - without Internal Dimmer)

(Incandescent - with Internal IGBT Dimmer)
(Incandescent - with Internal 80V Dimmer)
(Arc)
Refer to Figure 3-15, Figure 3-16, and Figure 3-17

No.
Item
Qty.
UM.
10.9685.0521
EA
PULLEY, DRIVEN, PAN/TILT
10.9685.0542
EA
SHIELD, WIRE, LVS (VL500/VL500D/VL500A ONLY)
10.9685.0555
EA
LENS, DISPLAY, VL500
10.9685.0556
EA
OVERLAY, DISPLAY, VL500
10.9685.0564
EA
PANEL, TILT, CLOSEOUT
10.9685.0566
EA
PLATE, TILT LOCK
10.9685.0567
EA
HEAT SHIELD, TILT SIDE
10.9685.0568
EA
HEAT SHIELD, DIMMER/POWER SUPPLY SIDE
10.9685.0569
EA
HEAT SHIELD, CROSSMEMBER
10
10.9685.0570
EA
SPACER, TILT TUBE
11
10.9685.0571
EA
PLUG, TILT TUBE
12
10.9685.0572
EA
CONTERWEIGHT, VL500 (VL500 80V ONLY)
10.9685.0575
EA
CONTERWEIGHT, VL500 (VL500D ONLY)
13
21.9685.0310
EA
ASSY, GENERIC VL500, INCANDESCENT (VL500 AND VL500D

ONLY)
14
21.9685.0311
EA
ASSY, GENERIC VL500, ARC (VL500A ONLY)
15
21.9685.0312
EA
ASSY, GENERIC VL500, INCANDESCENT, 80V (VL500 80V ONLY)
16
21.9685.0520
EA
ASSY, YOKE, BASE, INCANDESCENT (VL500 ONLY)
17
21.9685.0521
EA
ASSY, YOKE, BASE, INTERNAL IGBT DIMMER (VL500D ONLY)
18
21.9685.0522
EA
ASSY, YOKE, BASE, EXTERNAL BALLAST (VL500A ONLY)
19
21.9685.0523
EA
ASSY, YOKE, BASE, INTERNAL 80V DIMMER (VL500 80V ONLY)
20
21.9685.0731
EA
ASSY, MCB / FAN
21
23.9650.3327
EA
RELAY, ELECTRICAL ASSY (VL500A ONLY)
22
24.9685.0826
EA
ASSY, VL500 DISPLAY BOARD
23
24.9685.1000
EA
IGNITOR, ARC (VL500A ONLY)
25.9685.0776
EA
YOKE LAMP JUMPER WIRES (VL500 ONLY) (NOT SHOWN)
24
53.2001.0003
EA
NUT, 10-32 HEX NYLON INSERT
25
53.2019.0004
EA
NUT, 3/8-16X7/32" THK HEX JAM G
26
53.6539.0001
EA
WASHER, 3/8" SPLIT LOCK
02.96 85.001 0 0
Description
17-July-2006
81
No.
Item
Qty.
UM.
27
53.6558.0009
11
EA
SCREW, 6-32X3/8", PPZ, SEMS (VL500 ONLY)
53.6558.0009
10
EA
SCREW, 6-32X3/8", PPZ, SEMS (VL500D AND VL500 80V ONLY)
53.6558.0009
14
EA
SCREW, 6-32X3/8", PPZ, SEMS (VL500A ONLY)
28
53.6558.0010
11
EA
SCREW, 6-32X1/4", PPB, SEMS
29
53.6596.0002
EA
SCREW, 4-40X5/16" LG PPZ SEMS (VL500A ONLY)
30
53.6608.0001
11
EA
SCREW, 6-32X3/8", PFB
31
53.6634.0003
EA
SCREW, 3/8-16X1/2" SOC HD CAP
32
53.6634.1000
EA
SCREW, 3/8-16X1.00" SOC HD CAP
33
54.1206.0021
EA
RING, RETAINING, 1.562" SHAFT
34
54.1255.0002
EA
ASSY, BEARING/HOUSING
35
54.1261.0001
EA
BUSHING, LOW DAMP THRMOPLS.189
36
54.2066.0001
EA
BELT, TIMING, S2M, 396 GRV, 9MM WIDE
37
55.2187.0001
EA
CABLE SADDLE, #6 MOUNTING HOLE (VL500 ONLY)
38
55.2287.0001
EA
STANDOFF, MF 6-32X9/32" LG, 1/4" HEX
39
55.2288.0001
EA
STANDOFF, MF 6-32X13/16" LG, 1/4" HEX (VL500/VL500D/VL500 80V

ONLY)
55.2288.0001
12
EA
STANDOFF, MF 6-32X13/16" LG, 1/4" HEX (VL500A ONLY)
40
55.3301.0010
EA
WASHER, #10 FLAT
41
55.6517.0001
EA
WASHER, 0.375" OD, 0.150 ID, 0.031" THK (VL500A ONLY)
42
55.6677.0041
EA
WASHER, 0.750" OD, 0.203" ID, 0.04" THK
43
69.3178.0120
EA
POWER SUPPLY, 120W +24V 3X5 (VL500/VL500D/VL500A ONLY)
82
Description
17-July-2006
02 .9 685.00 10 0
Generic VL500 Luminaire Assembly (continued)

4
28
12 (VL500D Only)
3
38
22
39
16 (VL500 Only)
17 (VL500D Only)
36
30 (x4)
20
2
43
27
27
25
26
25
32
5
11
31
8
7
31
34
25
33
6
1
34
10
42
35
40
24
11
13
Figure 3-15: Generic VL500 Luminaire Assembly (VL500 and VL500D)
02.96 85.001 0 0
17-July-2006
83
4 3
28
19
12
38
22
36
30 (x4)
39
27
20
27
26
25
25
32
5
7 31
42
35
40
24
11
1
31
10
34
25
34
33
11
15
Figure 3-16: Generic VL500 Luminaire Assembly (VL500 80V)
84
17-July-2006
02 .9 685.00 10 0

4
28
38
22
39
18
36
27
20
30 (x4)
43
27
21
29, 41
39 (x4)
27
26
25
32
25
23
5
11
34
25
8
7
31
33
6
1
34
31
10
42
35
40
24
11
14
Figure 3-17: Generic VL500 Luminaire Assembly (VL500A)
02.96 85.001 0 0
17-July-2006
85
Notes
86
17-July-2006
02 .9 685.00 10 0
Head Assembly
21.9685.0310 (VL500 and VL500D) Rev H
21.9685.0311 (VL500A) Rev H
21.9685.0312 (VL500 80V) Rev H
Refer to Figure 3-18, Figure 3-19, Figure 3-20.
No.
Item
Qty.
UM.
Description
10.9634.0162
EA
GASKET, LENS, FRONT CASTING
10.9685.0340
EA
SUPPORT, RIB
10.9685.0344
EA
COVER, LAMP WIRE
12.9685.0331
EA
SIDE RAIL, HINGE, MACHINED CASTING
12.9685.0333
EA
SIDE RAIL, LATCH, MACHINED CASTING
12.9685.0388
EA
FRONT RING, VL500
21.9685.0315
EA
ASSY, COUNTERWEIGHT SUPPORT
21.9685.0320
EA
ASSY, HEATSINK, INCANDESCENT (VL500/VL500D ONLY)
21.9685.0321
EA
ASSY, HEATSINK, ARC (VL500A ONLY)
10
21.9685.0322
EA
ASSY, HEATSINK, 80V INCANDESCENT (VL500 80V ONLY)
11
25.9685.0350
EA
CABLE ASSY, DISCONNECT (VL500A ONLY)
12
53.6556.0004
EA
SCREW, 4-40X1/8" LG PPB
13
53.6598.0187
EA
SCREW, 4-40X0.187" LG PFB UNDERCUT HD
14
53.6607.0001
EA
15
54.1226.0001
EA
LATCH ASSEMBLY
16
54.1226.0002
EA
STRIKE, LATCH
17
55.2203.0001
EA
SCREW, 4-40X1/4" LG PPZ (VL500A ONLY)
18
55.3500.0002
EA
WASHER, #10 FIBRE FLAT 0.196" ID
19
55.3500.0003
EA
WASHER, 3/8" FIBRE FLAT 0.385" ID
20
55.6612.0005
EA
PIN, FRONT CASTING PIVOT
21
55.6612.0009
EA
PIN, REAR CASTING PIVOT
02.96 85.001 0 0
17-July-2006
87
VL500 Generic Head Assembly (continued)
16
12 (x2)
19
14 (x4)
15
12 (x2)
3
12 (x2)
20
21
18
1
2
6
2
7
13 (x4)
Figure 3-18: VL500 Generic Head Assembly (VL500 and VL500D)
88
17-July-2006
02 .9 685.00 10 0
17 (x2)
11
16
12 (x2)
19
14 (x4)
15
12 (x2)
3
12 (x2)
20
21
18
1
2
6
2
7
13 (x4)
Figure 3-19: VL500 Generic Head Assembly (VL500A)
02.96 85.001 0 0
17-July-2006
89
10
16
12 (x2)
19
14 (x4)
15
12 (x2)
3
12 (x2)
20
21
18
1
2
6
2
7
13 (x4)
Figure 3-20: VL500 Generic Head Assembly (VL500 80V)
90
17-July-2006
02 .9 685.00 10 0
Heatsink Assembly
21.9685.0320 (VL500 and VL500D) Rev G
21.9685.0321 (VL500A) Rev G
21.9685.0322 (VL500 80V) Rev G
Refer to Figure 3-21, Figure 3-22, Figure 3-23.
No.
Item
Qty.
UM.
Description
10.9634.0103
EA
PAD, REFLECTOR MOUNT
10.9685.0343
EA
CLIP, REFLECTOR
10.9685.0345
EA
CLIP, SOCKET (VL500A AND VL500 80V ONLY)
10.9685.0360
EA
FOAM, HEATSINK LIGHT LEAK
12.9685.0335
EA
HEATSINK, MACHINED CASTING
12.9685.0337
EA
BACKCAP, INCANDESCENT, MACHINED CASTING (VL500 ONLY)
12.9685.0339
EA
BACKCAP, ARC, MACHINED CASTING (VL500A AND VL500 80V

ONLY)
12.9685.0346
EA
BACKCAP, EXTENSION, HEATSINK, MODIFIED (VL500A AND

VL500 80V ONLY)
22.9685.0215
EA
LIGHT BAFFLE, REFLECTOR
10
23.9685.0780
EA
ASSY, VL500 LAMP SOCKET, HIGH TEMP (VL500 ONLY)
25.9685.0766
EA
575W/700W/80V LAMP WIRES, IGNITOR TO SOCKET (VL500A AND

VL500 80V ONLY) (NOT SHOWN)
25.9685.0777
EA
CABLE ASSY, BACKCAP GROUND (NOT SHOWN)
11
42.9685.0190
EA
REFLECTOR, PARABOLIC
12
53.6515.1000
EA
SCREW, 10-32X1" LG SCB (VL500 80V ONLY)
13
53.6543.0002
EA
14
53.6558.0007
EA
SCREW, 6-32X1/4" LG PPZ SEM (VL500 ONLY)
15
53.6575.0010
EA
SCREW, 8-32X1/2" LG PPZ SEM
16
53.6682.0022
EA
SCREW, 8-32X3/8" LG PPZ SEM (VL500A AND VL500 80V ONLY)
17
53.6594.0001
EA
SCREW, 10-32X1-1/2" LG PPB (VL500A ONLY)
18
54.1226.0001
EA
ASSY, LATCH
19
55.2203.0002
EA
20
55.2132.0013
EA
STANDOFF, 1/4 HEX X 0.218" LG 6-32 MF
21
55.6568.0022
EA
SPRING, CPRSN 0.300" OD, 1.25" LG (VL500A ONLY)
22
55.6635.0010
EA
WASHER, #10 SPHERICAL (VL500A AND VL500 80V ONLY)
23
71.2560.0001
EA
SOCKET, LAMP, ARC (VL500A AND VL500 80V ONLY)
02.96 85.001 0 0
17-July-2006
91
VL500 Heatsink Assembly (continued)

6
10
4
5
11
1 (x3)
9
14 (x2)
19 (x2)
18
15 (x4)
2 (x3)
20 (x3)
13 (x3)
Figure 3-21: VL500 Heatsink Assembly (VL500 and VL500D)
92
17-July-2006
02 .9 685.00 10 0

17 (x3)
22 (x3)
21 (x3)
23
5
4
1 (x3)
11
3 (x2)
16 (x2)
19 (x2)
18
15 (x4)
20 (x3)
2 (x3)
13 (x3)
Figure 3-22: VL500 Heatsink Assembly (VL500A)
02.96 85.001 0 0
17-July-2006
93
12 (x3)
7
23
22 (x3)
1 (x3)
11
3 (x2)
16 (x2)
8
19 (x2)
18
15 (x4)
2 (x3)
13 (x3)
20 (x3)
Figure 3-23: VL500 Heatsink Assembly (VL500 80V)
94
17-July-2006
02 .9 685.00 10 0
VL500 Magenta/Blue Color Assembly

No.
Item
Qty.
UM.
Description
10.9685.0257
EA
LIGHT BAFFLE, REAR BULKHEAD
21.9685.0160
EA
ASSY, MAGENTA/BLUE, STANDARD, DICROTUNE
21.9685.0280
EA
MOTOR ASSY, MAG/BLUE
53.6592.0250
EA
55.6704.0015
EA
STANDOFF, 5/16" HEX, 6-32X0.593" LG
2
3
4 (x4)
4 (x4)
Figure 3-24: VL500 Magenta/Blue Color Assembly
02.96 85.001 0 0
17-July-2006
95
VL500 Magenta/Blue (Pastel) Color Assembly

21.9685.0174 Rev A (Pastel DICRO*TUNE Colors)
No.
Item
Qty.
UM.
Description
10.9685.0257
EA
21.9685.0164
EA
ASSY, MAGENTA/BLUE, PASTEL, DICROTUNE
21.9685.0280
EA
53.6592.0250
EA
55.6704.0015
EA
2
3
4 (x4)
4 (x4)
Figure 3-25: VL500 Magenta/Blue (Pastel) Color Assembly
96
17-July-2006
02 .9 685.00 10 0
VL500 Amber/Diffuser Color Assembly

21.9685.0171 Rev G
No.
Item
Qty.
UM.
Description
10.9685.0245
EA
LIGHT BAFFLE, TOP
21.9685.0161
EA
ASSY, AMBER/DIFFUSER, DICROTUNE
21.9685.0281
EA
MOTOR ASSY, AMBER/DIFFUSER
53.6592.0250
EA
55.6704.0015
EA
4 (x4)
2
1
3
4 (x4)
5
Figure 3-26: VL500 Amber/Diffuser Color Assembly
02.96 85.001 0 0
17-July-2006
97
VL500 Amber/Dimmer Color Assembly

21.9685.0172 Rev F
No.
Item
Qty.
UM.
Description
10.9685.0245
EA
LIGHT BAFFLE, TOP
21.9685.0162
EA
ASSY, AMBER/DIMMER, DICROTUNE
21.9685.0281
EA
MOTOR ASSY, AMBER/DIFFUSER
53.6592.0250
EA
55.6704.0015
EA
4 (x4)
2
1
3
4 (x4)
5
Figure 3-27: VL500 Amber/Dimmer Color Assembly
98
17-July-2006
02 .9 685.00 10 0
VL500 Magenta/Blue (Arc) Color Assembly

21.9685.0173 Rev A (Standard DICRO*TUNE Colors)
No.
Item
Qty.
UM.
Description
10.9685.0246
EA
CLIP, UV GLASS
10.9685.0257
EA
21.9685.0160
EA
ASSY, MAGENTA/BLUE, STANDARD, DICROTUNE
21.9685.0280
EA
42.9685.0130
EA
GLASS, UV
53.6592.0250
EA
55.6704.0015
EA
3
4
6 (x4)
2 (x2)
7
5
6 (x4)
1 (x4)
Figure 3-28: VL500 Magenta/Blue (Arc) Color Assembly
02.96 85.001 0 0
17-July-2006
99
VL500 Magenta/Blue (Arc Pastel) Color

Assembly
21.9685.0175 Rev A (Pastel DICRO*TUNE Colors)
No.
Item
Qty.
UM.
Description
10.9685.0246
EA
CLIP, UV GLASS
10.9685.0257
EA
21.9685.0164
EA
ASSY, MAGENTA/BLUE, PASTEL, DICROTUNE
21.9685.0280
EA
42.9685.0130
EA
GLASS, UV
53.6592.0250
EA
55.6704.0015
EA
3
4
6 (x4)
2 (x2)
7
5
6 (x4)
1 (x4)
Figure 3-29: VL500 Magenta/Blue (Arc) Color Assembly
100
17-July-2006
02 .9 685.00 10 0
Magenta/Blue Color Assembly

21.9685.0160 Rev E (Standard DICRO*TUNE Colors)
No.
Item
Qty.
UM.
10.9634.0034
32
EA
SPRING, DRIVE ARM, FILTER
10.9634.0035
32
EA
LINK, DRIVE ARM
10.9634.0166
32
EA
CARRIER, FILTER, METAL INJ MOLD
21.9685.0150
EA
ASSY, BOTTOM BULKHEAD
EA
ASSY, FILTER, MAGENTA, DICROTUNE
EA
ASSY, FILTER, BLUE, DICROTUNE
22.9685.0122
16
22.9685.0123
16
Description
3 (x16)
6 (x16)
1 (x16)
2 (x16)
2 (x16)
5 (x16)
3 (x16)
1 (x16)
Figure 3-30: Magenta/Blue Color Assembly
02.96 85.001 0 0
17-July-2006
101
Magenta/Blue (Pastel) Color Assembly

21.9685.0164 Rev 0 (Pastel DICRO*TUNE Colors)
No.
Item
Qty.
UM.
Description
10.9634.0034
32
EA
10.9634.0035
32
EA
LINK, DRIVE ARM
10.9634.0166
32
EA
21.9685.0150
EA
ASSY, BOTTOM BULKHEAD
22.9685.0120
16
EA
ASSY, FILTER, MAGENTA, PASTEL, DICROTUNE
22.9685.0121
16
EA
ASSY, FILTER, BLUE, PASTEL, DICROTUNE
3 (x16)
6 (x16)
1 (x16)
2 (x16)
2 (x16)
5 (x16)
3 (x16)
1 (x16)
Figure 3-31: Magenta/Blue (Pastel) Color Assembly
102
17-July-2006
02 .9 685.00 10 0
Amber/Diffuser Color Assembly

21.9685.0161 Rev F
No.
Item
Qty.
UM.
10.9634.0034
32
EA
10.9634.0035
32
EA
LINK, DRIVE ARM
10.9634.0166
32
EA
21.9685.0151
EA
ASSY, BULKHEAD, TOP
EA
ASSY, FILTER, AMBER, DICROTUNE
EA
ASSY, DIFFUSER PANEL
22.9685.0124
16
22.9685.0126
16
Description
3 (x16)
1 (x16)
6 (x16)
2 (x16)
5 (x16)
3 (x16)
2 (x16)
1 (x16)
Figure 3-32: Amber/Diffuser Color Assembly
02.96 85.001 0 0
17-July-2006
103
Amber/Dimmer Color Assembly

21.9685.0162 Rev E
No.
Item
Qty.
UM.
10.9634.0034
32
EA
10.9634.0035
32
EA
LINK, DRIVE ARM
10.9634.0166
16
EA
10.9647.0121
EA
BAFFLE, INNER LIGHT
10.9661.0307
16
EA
CARRIER, DIMMER
10.9661.0312
16
EA
BEARING, DIMMER
10.9661.0313
EA
BAFFLE, OUTER LIGHT, DIMMER
10.9685.0210
16
EA
DIMMER BLADE, VL500
21.9685.0151
EA
ASSY, BULKHEAD, TOP
10
22.9685.0124
16
EA
ASSY, FILTER, AMBER, DICROTUNE
11
53.6556.0004
16
EA
SCREW, 4-40X1/8" PPB
104
Description
17-July-2006
02 .9 685.00 10 0
6 (x16)
8 (x16)
11 (x16)
5 (x16)
1 (x16)
2 (x16)
3 (x16)
2 (x16)
10 (x16)
1 (x16)
Figure 3-33: Amber/Dimmer Color Assembly
02.96 85.001 0 0
17-July-2006
105

21.9685.0150 Rev C
No.
Item
Qty.
UM.
10.9661.0315
EA
SUPPORT, BULKHEAD
21.9685.0251
EA
ASSY, DRIVE RING
22.9634.0119
EA
ASSY, CENTER HUB
22.9685.0201
EA
ASSY, GENERIC BULKHEAD
53.6682.0002
12
EA
SCREW, 4-40X1/4" PPZ SEMS
55.6612.0008
10
EA
PIN, 1/8" OD X 3/8" LG AL DRIV-LOX
55.6669.0009
EA
STANDOFF, 1/4" HEX, #40-40X0.625" MF
106
Description
17-July-2006
02 .9 685.00 10 0
Bottom Bulkhead Assembly (continued)

2
3
5 (x4)
6 (x10)
7 (x4)
5 (x8)
1 (x4)
4
2
Figure 3-34: Bottom Bulkhead Assembly
02.96 85.001 0 0
17-July-2006
107

21.9685.0151 Rev C
No.
Item
Qty.
UM.
Description
10.9661.0315
EA
SUPPORT, BULKHEAD
10.9685.0219
EA
AUX RING, COLOR BULKHEAD
21.9685.0251
EA
ASSY, DRIVE RING
22.9634.0120
EA
ASSY, LIGHT BAFFLE
22.9685.0201
EA
ASSY, GENERIC BULKHEAD
53.6682.0002
12
EA
55.6612.0008
10
EA
PIN, 1/8" OD X 3/8" LG AL DRIV-LOX
55.6669.0009
EA
STANDOFF, 1/4" HEX, #40-40X0.625" MF
55.6858.0002
EA
STANDOFF, 1/4" HEX, #40-40X0.343" MF
108
17-July-2006
02 .9 685.00 10 0
Top Bulkhead Assembly (continued)

3
6 (x4)
2 (x2)
9 (x4)
6 (x8)
7 (x10)
1 (x4)
8 (x4)
Figure 3-35: Top Bulkhead Assembly
02.96 85.001 0 0
17-July-2006
109
Drive Ring Assembly

21.9685.0251 Rev B
No.
Item
Qty.
UM.
Description
10.9634.0105
EA
LINK, SWIVEL
10.9685.7240
EA
ROLLER, DRIVE RING
22.9685.0238
EA
RING, DRIVE
53.5554.0875
EA
SCREW, 4-40X7/8" SET SS FLAT POINT
53.6659.0013
EA
55.6603.0001
EA
SPRING, SS 4.6#/IN EXTENSION
55.6612.0004
EA
PIN, 1/16" OD X 1/2" LG TYPE C 303 S/S
7 (x8)
Insure screws are flush with inside drive

ring surface (no protrusion).
5 (x2)
1
6
2 (x8)
Spring
2-56 Screw (x2)
Figure 3-36: Drive Ring Assembly
110
17-July-2006
02 .9 685.00 10 0
Magenta/Blue Color Motor Assembly

21.9685.0280 Rev A
No.
Item
Qty.
UM.
Description
10.9634.0061
EA
ACTUATOR MOUNT, VL500
10.9634.0075
EA
HEAT SHIELD, MAGENTA/BLUE
44.9685.0230
EA
53.6520.0001
EA
SCREW, 4-40X3/8" PPZ
53.6682.0002
EA
54.1217.0004
EA
LINK, VL500 ACTUATOR-DRIVE RING
4 (x3)
Actuator Screw
5 (x4)
1
3 (x2)
6 (x2)
Note:

Figure 3-37: Magenta/Blue Color Motor Assembly
02.96 85.001 0 0
17-July-2006
111
Amber/Diffuser Color Motor Assembly

21.9685.0281 Rev A
No.
Item
Qty.
UM.
Description
10.9634.0061
EA
ACTUATOR MOUNT, VL500
10.9634.0074
EA
HEAT SHIELD, AMBER/DIFFUSER
44.9685.0230
EA
53.6520.0001
EA
53.6682.0002
EA
54.1217.0004
EA
LINK, VL500 ACTUATOR-DRIVE RING
4 (x3)
3 (x2)
1
5 (x4)
Note:
2
6 (x2)
Actuator Screw

Figure 3-38: Amber/Diffuser Color Motor Assembly
112
17-July-2006
02 .9 685.00 10 0
Yoke Assembly
VL500 Yoke Assembly
21.9685.0520 (VL500) Rev S
21.9685.0521 (VL500D) Rev S
21.9685.0522 (VL500A) Rev S
Refer to Figure 3-39, Figure 3-40.
No.
Item
Qty.
UM.
1
2
Description
10.9685.0534
EA
COVER, PAN TUBE
10.9685.0537
EA
PLATE, MOUNTING, LAMP POWER PIGTAIL (VL500 ONLY)
10.9685.0538
EA
BEZEL, LAMP POWER PIGTAIL (VL500 ONLY)
10.9685.0560
EA
YOKE LEG, TILT SIDE
10.9685.0561
EA
YOKE LEG, DIMMER SIDE
10.9685.0562
EA
PLATE, TILT MOTOR, SLIDE
10.9685.0596
EA
MOUNT, FAN, LVS
21.9685.0515
EA
ASSY, YOKE CROSSMEMBER
21.9685.0540
EA
10
23.9685.0782
EA
ASSY, FAN MCB
11
24.9663.1895
EA
PCB ASSY, DMX INPUT
12
24.9685.0740
EA
13
25.9663.2030
EA
CABLE ASSY, INCANDESCENT POWER (VL500 ONLY)
14
25.9685.0756
EA
CABLE ASSY, AC INPUT
15
25.9685.0757
EA
CABLE ASSY, ARC BALLAST INPUT (VL500A ONLY)
16
25.9685.0770
EA
DISPLAY CABLE RECEPTACLE, BLACK
25.9685.0790
EA
CABLE ASSY, MAIN HARNESS, INCANDESCENT (VL500 AND

VL500D ONLY) (NOT SHOWN)
25.9685.0791
EA
CABLE ASSY, MAIN HARNESS, ARC (VL500A ONLY) (NOT

SHOWN)
28.9685.0999
EA
KIT, EXTRA US HARDWARE (NOT SHOWN)
17
51-0541
EA
SCREW, #4X3/8" H/L PN BLK ZN
18
52.8295.0002
EA
TERMINAL BLOCK, 300V 12 AWG 20A 2-POS
19
53.2001.0003
EA
NUT, 10-32 NYLOCK
20
53.2200.0004
EA
NUT, 4-40 KEPS SS
21
53.2200.0006
EA
NUT, 6-32 KEPS SS (VL500D AND VL500A ONLY)
22
53.2202.0004
EA
NUT, 4-40 HEX SS NYLON INSERT
02.96 85.001 0 0
17-July-2006
113
No.
Item
Qty.
UM.
23
53.6519.0001
EA
24
53.6521.0001
EA
25
53.6526.0002
EA
SCREW, 6-32X5/8" PPZ TYPE F
26
53.6546.0003
EA
27
53.6552.0002
18
EA
28
53.6559.0002
EA
29
53.6606.0001
EA
30
53.6608.0750
EA
31
53.6624.0001
EA
32
53.6596.0001
EA
33
54.2065.0001
EA
BELT, TIMING, S2M 252 GROOVE
34
55.2166.0250
EA
STANDOFF, 1/4" HEX 6-32, 0.250" LG MF SS
35
55.2288.0001
EA
STANDOFF, 1/4" HEX 6-32 X 13/16" LG
36
55.3301.0008
EA
WASHER, #8 FLAT SS
37
55.3301.0010
EA
WASHER, #10 FLAT
38
55.6543.0001
2.4
FT
GROMMET STRIP, SERRATED, 0.062
39
55.6568.0056
EA
SPRING, CPRSN, 0.600 OD, 0.080 WIR
40
55.6662.0010
EA
HOLE PLUG, 1.093" DIA, BLK NYLON (VL500D ONLY)
41
55.6669.0005
EA
STANDOFF, 6-32 X 0.500" LG 1/4" HEX
42
55.6669.0012
EA
STANDOFF, 6-32 X 1.00" LG 1/4" HEX MF CSTL ZINC
114
Description
17-July-2006
02 .9 685.00 10 0
VL500 Yoke Assembly (continued)
27 (x6)
31
1
25 (x2)
18 (x2)
37
19
21 (x4)
15 (VL500A)
40 (VL500D)
11
30 (x4)
8
17 (x4)
20 (x2)
14
29 (x2)
2
16
30 (x4)
28 (x2)
13
Figure 3-39: VL500 Yoke Assembly (VL500/VL500D/VL500A)
02.96 85.001 0 0
17-July-2006
115
24 (x4)
39
36 (x4)
33
26
7
22 (x4)
26 (x6)
32
10
36 (x4)
23 (x3)
6
42
12
34
35 (x3)
38
44 (x4)
39
27 (x12)
5
41 (x6)
Figure 3-40: VL500 Yoke Assembly (VL500/VL500D/VL500A)
116
17-July-2006
02 .9 685.00 10 0

21.9685.0523 (VL500 80V) Rev G
Refer to Figure 3-41, Figure 3-42.
No.
Item
Qty.
UM.
Description
10.9685.0542
EA
SHIELD, WIRE
10.9685.0543
EA
SHIELD, SENSOR BOARD
10.9685.0554
EA
COVER, PAN TUBE, 80V
10.9685.0557
EA
COVER, VENT, LVS
10.9685.0558
EA
FAN MOUNT, LVS
10.9685.0560
EA
YOKE LEG, TILT SIDE
10.9685.0561
EA
YOKE LEG, DIMMER SIDE
10.9685.0562
EA
PLATE, TILT MOTOR, SLIDE
21.9685.0516
EA
ASSY, YOKE CROSSMEMBER, 80V
10
21.9685.0540
EA
11
23.9685.0782
EA
ASSY, FAN MCB
12
24.9663.1895
EA
PCB ASSY, DMX INPUT
13
24.9685.0740
EA
25.9685.0742
EA
80V LVS AC, VL500 (NOT SHOWN)
25.9685.0746
EA
80V SURGE PROTECTOR, VL500 (NOT SHOWN)
14
25.9685.0756
EA
CABLE ASSY, AC INPUT
15
25.9685.0770
EA
DISPLAY CABLE RECEPTACLE, BLACK
25.9685.0792
EA
CABLE ASSY, MAIN HARNESS, 80V, VL500 (NOT SHOWN)
28.9685.0999
EA
KIT, EXTRA US HARDWARE (NOT SHOWN)
16
51-0541
EA
SCREW, #4X3/8" H/L PN BLK ZN
17
52.8295.0002
EA
TERMINAL BLOCK, 300V 12 AWG 20A 2-POS
18
53.2001.0003
EA
NUT, 10-32 NYLOCK
19
53.2200.0004
EA
NUT, 4-40 KEPS SS
20
53.6521.0001
EA
21
53.6546.0003
EA
22
53.6552.0002
18
EA
23
53.6558.0001
EA
24
53.6559.0002
EA
25
53.6606.0001
EA
26
53.6616.0001
EA
SCREW, 6-32X3/4" PPZ TYPE F
27
53.6624.0001
EA
02.96 85.001 0 0
17-July-2006
117
No.
Item
Qty.
UM.
28
54.2065.0001
EA
BELT, TIMING, S2M 252 GROOVE
29
55.2203.0001
EA
30
55.3301.0008
EA
WASHER, #8 FLAT SS
31
55.3301.0010
EA
WASHER, #10 FLAT
32
55.6543.0001
2.4
FT
GROMMET STRIP, SERRATED, 0.062
33
55.6568.0056
EA
SPRING, CPRSN, 0.600 OD, 0.080 WIR
34
55.6669.0005
EA
STANDOFF, 6-32 X 0.500" LG 1/4" HEX
35
69.3178.0121
EA
POWER SUPPLY, 120V +24V 3X5
118
Description
17-July-2006
02 .9 685.00 10 0
VL500 80V Yoke Assembly (continued)
22 (x6)
27
31
35
18
29 (x4)
13
2
26
5
17
12
24 (x2)
4
24 (x4)
16 (x4)
11
19 (x2)
24 (x2)
23
15
14
19 (x2)
25 (x2)
Figure 3-41: VL500 80V Yoke Assembly
02.96 85.001 0 0
17-July-2006
119
20 (x4)
30 (x4)
28
33
21
21 (x6)
10
30 (x4)
8
10
32
33
22 (x12)
34 (x6)
7
Figure 3-42: VL500 80V Yoke Assembly
120
17-July-2006
02 .9 685.00 10 0

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).
No.
Item
Qty.
UM.
Description
07.5044.0002
EA
BAG, 4-MIL X 2" X 3", ZIP PRESS POLYETHYLENE
53.6008.0001
EA
53.6523.0013
EA
SCREW, 6-32X3/8" PTB
53.6558.0001
EA
53.6558.0009
EA
53.6558.0010
EA
2 (x4)
6 (x4)
3 (x4)
1
4 (x4)
5 (x4)
Figure 3-43: VL500 US Extra Hardware Kit
02.96 85.001 0 0
17-July-2006
121
VL500 Pan/Tilt Motor Assembly

21.9685.0540 Rev B
No.
Item
Qty.
UM.
Description
10.9685.0541
EA
PLATE, TENSION ADJUSTMENT, PAN/TILT
21.9685.0545
EA
ASSY, DRIVE PULLEY, VL500
- 10.9685.0720
EA
PULLEY, DRIVE - PAN/TILT, 2MM GT 18 TOOTH
- 10.9678.0720
EA
CODEWHEEL, 120 COUNT, LARGE ID
24.9685.7735
EA
BOARD ASSY, PAN/TILT ENCODER, VL500
44.9678.0680
EA
MOTOR, 3-PHASE SZ 23 HIGH TORQUE
53.2200.0008
EA
NUT, 8-32 KEPS SS
53.6558.0001
EA
53.6575.0004
EA
55.6627.0001
EA
WASHER, #6 SPLIT LOCK
6 (x2)
3
8 (x2)
5 (x4)
1
7 (x4)
Figure 3-44: VL500 Pan/Tilt Motor Assembly
122
17-July-2006
02 .9 685.00 10 0

21.9685.0731 Rev 0
No.
Item
Qty.
UM.
Description
10.9676.0735
EA
HEATSINK, PAN/TILT DRIVERS
10.9676.0885
EA
PAD, THERMAL TRANSFER, PAN/TILT
10.9685.0594
EA
BRACKET, FAN, MCB
10.9685.0595
EA
SEAL, AIR
23.9685.0782
EA
ASSY, FAN, MCB
24.9685.0730
EA
MCB, VL500
53.2200.0004
EA
NUT, 4-40 KEPS SS
53.6556.0001
EA
53.6592.0001
EA
10
55.6537.0001
EA
WASHER, #4 LOCK INTERNAL TOOTH
9 (x3)
8 (x2)
10 (x2)
3
2
2
1
7
Figure 3-45: VL500 MCB/Fan Assembly
02.96 85.001 0 0
17-July-2006
123
MCB Fan Assembly

23.9685.0782 Rev 0
No.
Item
Qty.
UM.
Description
40.7113.0007
EA
FAN, 12VDC, 30X10 MM, 3.3CFM
52.6450.0002
EA
CONNECTOR, MTA 100 IDC 2-POS, 28 AWG
Pin 2 (Black)
Pin 1 (Red)
6-inch leads
Figure 3-46: MCB Fan Assembly
124
17-July-2006
02 .9 685.00 10 0

21.9685.0515 Rev E
No.
Item
Qty.
UM.
10.9685.0547
EA
BUSHING, WIRE PROTECTION, 0.95" OD
10.9685.7590
EA
TOGGLE STOP, PAN
10.9685.7591
EA
TOGGLE, PAN
21.9685.0512
EA
ASSY, LOWER CROSSMEMBER
21.9685.0513
EA
ASSY, UPPER CROSSMEMBER
21.9685.0535
EA
ASSY, PAN TUBE
53.6552.0002
EA
53.6667.0005
EA
SCREW, 10-32X3/8" SET CUP POINT
54.1206.0014
EA
RING, RETAINING 1.375" SHAFT
Description
7 (x4)
7 (x4)
2
3
8 (x2)
9
4
Figure 3-47: Yoke Crossmember Assembly (VL500/VL500D/VL500A)
02.96 85.001 0 0
17-July-2006
125
Yoke Crossmember Assembly (VL500 80V)

21.9685.0516 Rev 0
No.
Item
Qty.
UM.
Description
10.9685.0547
EA
BUSHING, WIRE PROTECTION, 0.95" OD
10.9685.7590
EA
TOGGLE STOP, PAN
10.9685.7591
EA
TOGGLE, PAN
21.9685.0512
EA
ASSY, LOWER CROSSMEMBER
21.9685.0513
EA
ASSY, UPPER CROSSMEMBER
21.9685.0536
EA
ASSY, PAN TUBE, VL500 80V
53.6552.0002
EA
53.6667.0005
EA
SCREW, 10-32X3/8" SET CUP POINT
54.1206.0014
EA
RING, RETAINING 1.375" SHAFT
1
7 (x4)
9
5
7 (x4)
9
2
8 (x2)
9
4
Figure 3-48: Yoke Crossmember Assembly (VL500 80V)
126
17-July-2006
02 .9 685.00 10 0

21.9685.0512 Rev H
No.
Item
Qty.
UM.
Description
10.9685.0509
EA
LOWER CROSSMEMBER
10.9685.0522
EA
PLATE, PAN LOCK
10.9685.0526
EA
WASHER, CENTERING, STEP
10.9685.0533
EA
LANYARD, SAFETY
53.2001.0003
EA
NUT, 10-32 NYLON INSERT
53.2019.0004
EA
NUT, 3/8-16 HEX
53.2020.0001
EA
NUT, 1/4X20 HEX STL ZINC PLTD
53.6539.0001
EA
53.6634.0875
EA
SCREW, 3/8-16X7/8" SCSS
10
53.6648.0001
EA
11
54.1255.0001
EA
12
54.1261.0001
EA
BUSHING, LOW DAMP THRMOPLS.189
13
55.3301.0010
EA
WASHER, #10 FLAT
14
55.6549.0001
EA
15
55.6677.0035
EA
WASHER, 0.750" OD, 0.187" ID
02.96 85.001 0 0
17-July-2006
127
Lower Crossmember Assembly (continued)
10 (x2)
15 (x2)
7 (x2)
14 (x2)
3 (x2)
11
8
9
12 (x2)
13 (x2)
5 (x2)
Figure 3-49: Lower Crossmember Assembly
128
17-July-2006
02 .9 685.00 10 0

21.9685.0513 Rev F
No.
Item
Qty.
UM.
Description
10.9685.0510
EA
UPPER CROSSMEMBER
10.9685.0526
EA
WASHER, CENTERING, STEP
53.2020.0001
EA
NUT, 1/4X20 HEX STL ZINC PLTD
54.1255.0001
EA
55.6549.0001
EA
3 (x2)
5 (x2)
2 (x2)
Figure 3-50: Upper Crossmember Assembly
02.96 85.001 0 0
17-July-2006
129
Pan Tube Assembly

21.9685.0535 Rev D (VL500/VL500D/VL500A)
No.
Item
Qty.
UM.
Description
10.9685.0521
EA
10.9685.0531
EA
PAN TUBE
10.9685.0532
EA
PAN PULLEY SPACER
53.2200.0006
EA
NUT, 6-32 KEPS SS
53.6608.0750
EA
1
3
5 (x2)
4 (x4)
Figure 3-51: Pan Tube Assembly (VL500/VL500D/VL500A)
130
17-July-2006
02 .9 685.00 10 0
80V Pan Tube Assembly

21.9685.0536 Rev 0 (VL500 80V)
No.
Item
Qty.
UM.
Description
10.9685.0521
EA
10.9685.0532
EA
PAN PULLEY SPACER
12.9685.0553
EA
PAN TUBE, 80V
53.2200.0006
EA
NUT, 6-32 KEPS SS
53.6608.0750
EA
5 (x2)
4 (x4)
Figure 3-52: 80V Pan Tube Assembly (VL500 80V)
02.96 85.001 0 0
17-July-2006
131

24.9663.1895 Rev A
No.
Item
Qty.
UM.
Description
Ref
11.9663.1895
EA
PCB, DMX INPUT
35-0053
EA
DIODE, ZENER, 6.2V 1W SM (NOT SHOWN)
D1, D2
52.6259.0001
EA
HEADER, 5POS MTA FRCT LOK STRT POST
J3
52.6625.0005
EA
CONN, RECEPT XLR 5PIN FEMALE PC MT

VERTICAL
J1
52.6626.0005
EA
CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL
J2
62.3017.0102
EA
CAP, 1000PF 250V RAD CER DISC 20% Y-TYPE
C1
1
5
2
Figure 3-53: DMX Input PCB Assembly
132
17-July-2006
02 .9 685.00 10 0
VL500 Main Control Board PCB Assembly

24.9685.0730 Rev B

Item
UM.
Description
Ref.
10-0207
EA
RESISTOR, 47K, 1/10W, 5% SM 0805
R167, R168
10-0211
EA
RESISTOR, 100K, 1/10W, 5% SM 0805
R144
10-0269
EA
RESISTOR, 100, 1/10W, 5% SM 0805
R169
10-0621
EA
RESISTOR, 0, 1/10W, 5% SM 0805
R37
10.9661.1275
EA
HEATSINK, MAIN CONTROLLER
10.9676.0735
EA
HEATSINK, CONTROLLER, PAN/TILT DRIVERS
10.9678.0885
EA
KIT, THERMAL TRANSFER MAIN CONTROLLER
11.9685.0730
EA
PCB, CONTROLLER BOARD, VL500
13-0071
EA
RESISTOR, 1K, 1/4W, 5% SM 1210
R71
13-0114
EA
RESISTOR, 1K, 1/8W, 1% SM 0805
R146-154
13-0115
EA
RESISTOR, 10K, 1/10W, 1% 805
22-0036
EA
CAP, 470PF, 50V, 5% SM NPO 805
C48
25-0059
EA
CAP, 4.7UF, 35V
C28
25-0100
EA
CAP, 220PF, 50V, 10% NPO CER 0805
33-0043
EA
DIODE, 3A, 1N5404
D45, D46
33-0118
EA
DIODE, ZNR 3.3V 1N4684
D47, D48
40-0867
EA
HEADER, 10-POS SHROUDED
J3
52.6259.0003
EA
HEADER, 3 POS MTA156 STRT FRCT LOK
J8
52.6260.0004
EA
HEADER, 4 POS MTA-100 SHROUDED STRAIGHT
J6
52.6260.0005
EA
J5
52.6260.0006
EA
J4
52.6260.1004
EA
HEADER, 3 POS MTA-100 SHROUDED
J2
52.6599.0029
EA
HEADER, 14 PIN DUAL ROW AMP MODU VERT THRU
J9
52.6599.0040
EA
J4
52.6599.0068
EA
J7
52.8412.0026
EA
CONNECTOR, 26-PIN, 0.025" SQ PIN SOCKET
J1
53.6519.0001
EA
SCREW, 4-40 X 5/8" PPZ
55.3303.0004
EA
WASHER, #4 LOCK INT.TOOTH SS
60.1160.0000
EA
RES, 1/16W 0 OHM CHIP THK FLM SMT0402
60.1161.4323
EA
RES, 1/16W 1% 4.32 K CHIP THK FLM SMT0402
02.96 85.001 0 0
17-July-2006
R145, R155-162
R24, R39, R52

R91, R99, R112, R116,
R125, R128, R136, R139
133
Item
60.1161.7503
UM.
16
EA
Description
Ref.
R89, R90, R95, R96,
R110, R111, R114, R115,
R123, R124, R126, R127, R134, R135, R137, R138
134
60.1165.1002
EA
RES, 1/16W 5% 100 OHM CHIP THK FLM SMT0402
R28, R74, R76-78,R81,

R83, R163-164
60.1165.1003
20
EA
RES, 1/16W 5% 1.0K CHIP THK FLM SMT0402
R12-18, R20, R35, R4143, R45-49, R57, R59,

R62
60.1165.1004
12
EA
RES, 1/16W 5% 10 K CHIP THK FLM SMT0402
R53, R56, R75, R79,

R101-102, R117-118,
R129-130, R140, R141
R66, R67
60.1165.1803
EA
60.1165.2201
EA
60.1165.2404
EA
60.1165.2702
EA
R73
60.1165.3302
EA
R55, R61, R65, R69
60.1165.3604
EA
R64, R70, R80, R82
60.1165.4702
EA
60.1165.4703
15
EA
60.3242.1000
EA
RES, 1W 1% 1.0 OHM WW SUR MT
60.4500.4703
EA
RES, .1W 5% 4.7 K CHIP THK FLM SMT
60.9460.1003
EA
RES, .1W 5% 1.0 K 100V CHIP THICK FILM SMT0805
60.9460.1004
12
EA
RES, .1W 5% 10.0 K 100V CHIP THICK FILM
60.9460.1502
EA
RES, .1W 5% 150.0 OHM 100V CHIP THICK FILM

SMT0805
R84
60.9466.4703
EA
RES, 1/4W 5% 4.7K 200V CHIP THK FLM SMT1210
R60
62.3038.0472
EA
CAP, 4700PF 50V 10% X7R CER 805
62.4003.0104
EA
CAP, 0.1UF 50V 10% CER CHIP SUR MT X7R EIA0805
62.4003.0105
EA
CAP, 220PF 50V 10% X7R SM 0603
C132-133
62.4004.0221
EA
CAP, 220PF 50V 20% CER CHIP S
C122-128
62.4206.0105
EA
CAP, 1UF 16V 10% TANT CHIP
C84, C94
62.4209.0224
EA
CAP, .22UF 50V 10% TANT CHIP SUR MT
C85, C95
62.4225.0107
EA
CAP, 100UF 35V 20% ALUM ELECTRO SUR MT
C1-2, C5-6
62.4227.0107
EA
C3-4, C7-12
62.4228.0106
EA
C58, C76, C86-87, C9697, C99, C108
17-July-2006
R31-34
R87, R109, R122, R133
R54, R58, R63, R68

R3-11, R22, R36, R85-86,
R165-166
R105-106, R119-120,
R131-132, R142-143
R38, R40, R170
R44, R50
R1-2, R19, R21, R23,
R25-27, R29-30, R113,
R121
C52-55
C80-81, C88, C92-93, C98
02 .9 685.00 10 0
Item
UM.
Description
Ref.
62.4240.0103
16
EA
CAP, .01UF 25V 10% CER CHIP SUR MT X7R EIA0603
C13-17, C24-25, C29,

C62, C66, C78, C82,
C101, C103, C110, C112
62.4240.0104
39
EA
C18-23, C26, 27, C30-42,

C131
62.4240.0223
EA
C63, C67, C79, C83,

C102, C104, C111, C113
62.4245.0272
EA
CAP, 2700 PF 25V 10% CER CHIP SUR MT X7R EIA0402
C70, C89, C105, C114
62.4245.0471
EA
CAP, 470PF 25V 10% CER CHIP SUR MT X7R EIA0402
C72-73, C90-91, C106107, C115-116
64.4029.0001
EA
OSCILLATOR, 40.000 MHZ SM7745HV SUR MT
Y1
67.4012.0001
EA
FILTER, EMI 600 OHM 1MHZ CHIP FERRITE
FB1
68.4581.0001
EA
INDUCTOR, 100UH 2.22A PE-54037S
L1-2
70.3763.0001
EA
FUSE, PTC 500MA 60V SMD050
74.1097.0001
EA
SWITCH, TACT, TIGHT ANGLE, THRU HOLE
82.5326.0002
EA
DIODE, DL4148CT RECTIFIER
82.5329.0001
EA
DIODE, MBRS340T3 40V 3A SCHOTTKY SUR MT
D1-2
82.5350.0001
EA
DIODE, BAT54SLT1 DUAL SCHOTTKY CATHODE TO

ANODE CONNECTED 30V 200MA
D7-8
82.5361.0001
EA
DIODE, ZENER TVS 10V 23A SMT
Z1-6
82.5362.0001
28
EA
DIODE, SCHOTTKY BARRIER RECTIFIER, 40V, 1A,

SMT
83.3174.0001
EA
IC, 2596S VOLTAGE REG 5V TO-26
VR1
83.3174.0004
EA
IC, LM2596S-3.3 VOLTAGE REGULATOR PWR

CONVERTER 150K HZ 3A STEPDOWN 0
VR2
83.3206.0001
EA
IC, LP3965ES-1.8 1.8V SMT
VR4
83.3209.0001
EA
IC, 74LCX244MTC LOW VOLT BUFFER / LINE DRIVER

SMT
83.3215.0001
EA
IC, TPS72515 1.5V REGH DDPAK
VR3
84.4234.0002
EA
IC, RS485 TRANSCEIVER SUR MT SOIC PKG
U14
84.4297.0002
EA
IC, MT48LC4M16A2TG-75 DRAM 1MEGX6X4 SMT
84.4300.0001
EA
IC, CY2305SC-1 PLL CLOCK DRIVER 3.3V SMT
84.4305.0001
EA
IC, NC7SZ04M5 UHS INVERTER -SMT
84.4306.0001
EA
IC, NC7SZ08M5 UHS 2-INPUT AND GATE
U8, U18
84.4350.0001
EA
IC, MCF5407FT162A MICROPROCESSOR
U1
84.7408.0001
EA
IC, 74ACT00SC SOIC-14-N
84.7420.0003
EA
IC, LTC1480 SOIC-8-N
84.7430.0001
EA
IC, MAU202 SIP DC-DC CONVERTER
84.7433.0001
EA
IC, MCP3008ADC10BIT2.7V SOIC-16
85.3773.0001
EA
IC, STEPMOTOR DRIVER
U25, U28, U32-33
17-July-2006
135
02.96 85.001 0 0
FTC1-4
D12, D16, D20, D24
D9-11, D13-15, D17-19,

D21-23, D25-28, D33-44
U23-24
U3, U5
U22, U29, U31, U34
U13
Item
UM.
Description
Ref.
85.5134.0001
EA
IC, SN75LBC180D LOW-POWER DIFF LINE DRVR &

RCVR PAIRS
U20
85.5164.0002
EA
IC, L6234PD SO-20
85.5168.0001
EA
IC, DS1834AS DUAL RESET MONITOR W/

PUSHBUTTON SMT
86.6105.0001
EA
IC, HCPL-0600 OPTO COUPLER SMD
87.7248.0001
EA
IC, AM29LV400BB-44REI 4MEGBIT FLASH MEMORY
U2
87.7404.0001
EA
IC, M24C02WMN6T EEPROM (BLANK) 2K BIT (256X8)

SERIAL I2C BUS
U6
87.7405.0001
EA
IC, CYCLONE EP1C3T144 TQFP-144
U10
88.8145.0001
EA
LED, REVERSE MOUNT RED SMT
D5
88.8145.0002
EA
LED, REVERSE MOUNT GREEN SMT
88.8145.0003
EA
LED, REVERSE MOUNT YELLOW SMT
U4
U12, U16, U19, U21
D3-4
D6
Top Side
Bottom Side
Figure 3-54: VL500 Main Control Board PCB Assembly
136
17-July-2006
02 .9 685.00 10 0
Cables
Incandescent Power Input Cable Assembly
25.9663.2030 Rev A (VL500 Only)
No.
Item
Qty.
UM.
Description
52.6274.2313
EA
STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK
52.8231.0005
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
52.8298.1160
EA
FERRULE, WIRE 1X16 AWG L2=8MM BLACK
55.2268.0187
FT
HEATSHRINK, 3/16" CLEAR KYNAR VDE UL 600V 150DEG C
55.2268.0500
0.13
FT
HEATSHRINK, 1/2" CLEAR KYNAR VDE UL 600V 150DEG C
73.9636.0153
FT
CORDAGE, 1.5/3 750V 60C EURO BLK HD-22 11MMOD
L
BRN
N
BLU
GRN/YEL
GND
Figure 3-55: Incandescent Power Input Cable Assembly (VL500 Only)
02.96 85.001 0 0
17-July-2006
137
80V LVS AC Cable Assembly

25.9685.0742 Rev 0
No.
Item
Qty.
UM.
Description
52.6264.0004
EA
CONN HOUSING, 3-POS SL156 W/ RAMP NO TABS
52.8317.0002
EA
CONTACT, SL156 24-18AWG
73.6018.0002
0.71
FT
WIRE, 18 AWG 600V 105DEGC PVC RED UL1015
73.6018.0010
0.63
FT
WIRE, 18 AWG 600V 105DEGC PVC BLACK UL1015
1, 2 (x2)
Figure 3-56: 80V LVS AC Cable Assembly
138
17-July-2006
02 .9 685.00 10 0
80V Surge Protector Cable Assembly

25.9685.0746 Rev 0
No.
Item
Qty.
UM.
Description
33-0441
EA
MOV, 430V 6500A 20MM ZNR
52.8231.0005
EA
TERM RING, #6 BLUE 16-14 AWG REEL PIDG
55.2198.0001
0.08
FT
HEATSRINK, 1/8" BLACK
55.2199.0001
0.13
FT
55.2200.0001
0.08
FT
73.6016.0504
0.75
FT
WIRE, 16 AWG 600V 105DEGC GREEN/YELLOW UL1015
4 (4 pl)
6
1 (x2)
Figure 3-57: 80V Surge Protector Cable Assembly
02.96 85.001 0 0
17-July-2006
139
VL500 Motor Cable Assembly

25.9685.0753 Rev B
No.
Item
Qty.
UM.
Description
52.6224.1034
EA
COVER, FRONT 34-POS MT LATCHING
52.6224.2034
EA
COVER, BACK 34-POS MT
52.6610.0034
EA
CONN, HOUSING 34-POS DBL ROW UNLOADED
52.6694.0001
16
EA
CRIMP, TERMINAL WIRE TO WIRE FEMALE 2MM 28-24 AWG
52.6696.0001
EA
RECEPT, WIRE TO WIRE 4-POS 2MM PITCH 28-24 AWG
52.8351.0004
34
EA
CONTACT, 26-22 AWG RECP MTE (REEL)
55.2186.0001
EA
CABLE TIE, 0.10"X4" SMALL
55.6699.0010
FT
SLEEVING, 5/16" NOM DIA WOV POLY, ROUNDIT 2000
73.2326.0123
5.35
FT
WIRE, 26 AWG 4-COND 300V 200DEGC TEF (BLK-BRN-RED-ORG)
140
17-July-2006
02 .9 685.00 10 0
VL500 Motor Cable Assembly (continued)

4 (x4), 5
1, 2, 3, 6
4 (x4), 5
8
4 (x4), 5
7 (x2)
4 (x4), 5
Figure 3-58: VL500 Motor Cable Assembly
02.96 85.001 0 0
17-July-2006
141
Relay to Ignitor Cable Assembly

25.9685.0755 Rev B
No.
Item
Qty.
UM.
Description
52.8271.0005
EA
RECPT, FASTON 1/4" 16-14 AWG INSULATED (REEL)
55.2186.0001
EA
73.6014.0012
0.29
FT
WIRE, 14 AWG 600V 200DEGC FEP BLACK STRAND 168/36 0.104 DIA
73.6014.0013
0.42
FT
WIRE, 14 AWG 600V 200DEGC FEP WHITE STRAND 168/36 0.104 DIA
2
1 (x4)
Figure 3-59: Relay to Ignitor Cable Assembly
142
17-July-2006
02 .9 685.00 10 0

25.9685.0756 Rev B
No.
Item
Qty.
UM.
Description
52.6541.0003
EA
CONN, CHASSIS POWER 3-POLE LOCKING
52.8231.0005
EA
TERM, RING #6 16-14 AWG REEL PIDG
52.8331.0003
EA
FASTON RECPT., 16-14 AWG PIDG BLU 0.170" ID
55.2186.0001
EA
73.6014.0005
0.58
FT
WIRE, 14 AWG 600V 105DEGC PVC GRN UL1015
73.6014.0009
0.33
FT
WIRE, 14 AWG 600V 105DEGC PVC WHT UL1015
73.6014.0010
0.33
FT
WIRE, 14 AWG 600V 105DEGC PVC BLK UL1015
4
3 (x3)
7
2
Figure 3-60: VL500 AC Input Cable Assembly
02.96 85.001 0 0
17-July-2006
143
VL500 Arc Ballast Input Cable Assembly

25.9685.0757 Rev C
No.
Item
Qty.
UM.
52.6400.0027
EA
Description
RECPT, 17-14 SQ FLANGE REV SEX THRD CPC
52.6420.0002
EA
SOCKET, GOLD 18-14 AWG TYPE 3+ LOOSE 0.08-0.100 INS DIA
52.8201.0007
EA
SOCKET, GOLD 24-20 AWG TYPE 3+ (REEL) 0.04-0.08 INS DIA
52.8321.0005
EA
TERM, RING #6 16-14 AWG REEL PIDG
53.7015.0005
EA
CONN, HOUSING 5CIR MTA100 BLU
73.2326.0029
2.79
FT
WIRE, 26 AWG 3COND 300V 200DEGC TEF (BLK-WHT-RED) UL1180
73.6014.0002
0.46
FT
WIRE, 14 AWG 600V 105DEGC PVC RED UL1015
73.6014.0003
0.46
FT
WIRE, 14 AWG 600V 105DEGC PVC ORG UL1015
73.6014.0005
0.88
FT
WIRE, 14 AWG 600V 105DEGC PVC GRN UL1015
10
73.6014.0009
0.75
FT
WIRE, 14 AWG 600V 105DEGC PVC WHT UL1015
11
73.6014.0010
0.75
FT
WIRE, 14 AWG 600V 105DEGC PVC BLK UL1015
2 (x7)
4
1
7
9 8 11 9
10
6
3 (x3)
Figure 3-61: VL500 Arc Ballast Input Cable Assembly
144
17-July-2006
02 .9 685.00 10 0
VL500 Head Grounding Cable Assembly

25.9685.0760 Rev C
No.
Item
Qty.
UM.
52.8231.0000
EA
TERM, RING #6 RED 22-16 AWG INSUL REEL
73.6014.0011
1.33
FT
WIRE, 14 AWG 600V 200DEGC FEP GRN STRND 168/36 0.104 DIA
1 (x2)
Description
Figure 3-62: VL500 Head Earthing Cable Assembly
02.96 85.001 0 0
17-July-2006
145
VL500 Ignitor to Socket Cable Assembly

25.9685.0766 Rev C
No.
Item
Qty.
UM.
25.9685.0777
EA
Description
CABLE ASSY, BACK CAP GROUND, VL500
52.8244.0001
EA
FASTON RECEPT FLAG, 0.250 16-14 AWG INSULATED (REEL)
55.2186.0001
EA
55.2260.0133
2.33
FT
SLEEVING, FIBERGLASS 0.133" ID
55.6699.0010
1.33
FT
SLEEVING, 5/16" NOM. DIA. WOVEN POLY, ROUNDIT 2000
73.3517.0001
4.00
FT
WIRE, 14 AWG 5KV 200DEGC SILICON 7X24/36 STRAND
2 (x2)
6
3
5
4 (2 pl)
6
1
Figure 3-63: VL500 Iginitor to Socket Cable Assembly
146
17-July-2006
02 .9 685.00 10 0
VL500 Arc Ballast Interconnect Cable

Assembly
25.9685.0767 Rev B
No.
Item
Qty.
UM.
Description
52.6400.0020
EA
PLUG, 17-14 REV SEX CPC 600V KEY A
52.6400.0120
EA
PLUG, 17-9 REV SEX CPC 600V KEY A
52.6431.0002
EA
BACKSHELL, CPC17 NYLON 0.300-0.525 CBL RNG
52.8201.0005
EA
PIN, GOLD 24-20 AWG TYPE 3+ REEL 0.04-0.08 INS DIA
52.8201.0007
EA
SOCKET, GOLD 24-20 AWG TYPE 3+ REEL 0.04-0.08 INS DIA
52.8341.0001
EA
PIN, GOLD 18-14 AWG TYPE 3+ REEL 0.11-0.15 INS DIA
52.8342.0001
EA
SOCKET, GOLD 18-14 AWG TYPE 3+ REEL 0.11-0.15 INS DIA
52.8344.0006
EA
PIN, CPC POWER 14 AWG 23A LOOSE
52.8344.0008
EA
SOCKET, CPC POWER 14 AWG 23A LOOSE
10
73.7087.0013
5.00
FT
CABLE, COMPOSITE V500 ARC POWER INPUT
02.96 85.001 0 0
17-July-2006
147
VL500 Arc Ballast Interconnect Cable Assembly (Continued)

1
4 (x4)
6 (x3)
8 (x2)
2
5 (x4)
7 (x3)
9 (x2)
10
Pinout
Pinout
Pin
Wire
Description
Pin
Wire
Description
OPEN
N/A
VIOL14 AWG
LAMP POWER
OPEN
N/A
GRN/16 AWG
GROUND
GRN/16 AWG
GROUND
ORN/14 AWG
LAMP POWER
BLK/16 AWG
POWER (HOT)
BLK/16 AWG
POWER (HOT)
DRAIN/22 AWG
DRAIN WIRE
DRAIN/22 AWG
DRAIN WIRE
OPEN
N/A
WHT/16 AWG
NEUTRAL
WHT/16 AWG
NEUTRAL
WHT/22 AWG
NEUTRAL
WHT/22 AWG
DATA
BLK/22 AWG
DATA
BLK/22 AWG
DATA
RED/22 AWG
DATA
10
RED/22 AWG
DATA
11
OPEN
N/A
12
ORN/14 AWG
LAMP POWER
13
OPEN
N/A
14
VIOL14 AWG
LAMP POWER
Figure 3-64: VL500 Arc Ballast Interconnect Cable Assembly
148
17-July-2006
02 .9 685.00 10 0
VL500 Display (Remote) Cable Assembly

25.9685.0770 Rev B
No.
Item
Qty.
UM.
Description
10.9685.0536.01
EA
ADAPTER PLATE, MINI XLR, BLACK
52.6694.0002
EA
CRIMP TERM, WIRE TO WIRE, MALE
52.6696.0003
EA
PLUG, WIRE TO WIRE, 4-POS
53.6501.0002
EA
CONN, MINI XLR, 4-PIN, PANEL MOUNT
73.2326.0123
0.25
FT
WIRE, 26 AWG 4-COND 300V 200DEGC (BLK-BRN-RED-ORN)

UL1180
2 (x4)
3
Figure 3-65: VL500 Display (Remote) Cable Assembly
02.96 85.001 0 0
17-July-2006
149
VL500 Yoke Lamp Jumper Cable Assembly

25.9685.0776 Rev A
No.
Item
Qty.
UM.
Description
52.8348.0001
EA
TAB, ULTRA-FAST 1/4" 16-14 AWG INSULATED (LOOSE)
TBD
0.13
FT
WIRE, 14 AWG 200DEGC STRAND TEF WHT
1 (x2)
Figure 3-66: VL500 Yoke Lamp Jumper Cable Assembly
150
17-July-2006
02 .9 685.00 10 0
VL500 Backcap Ground Cable Assembly

25.9685.0777 Rev A
No.
Item
Qty.
UM.
Description
52.8329.0001
EA
TERM, RING #6 RED 22-16 AWG NON-INSUL
52.8329.0003
EA
TERM, RING #8 RED 22-16 AWG NON-INSUL
73.7130.0002
1.17
FT
WIRE, 7/64" TUBULAR BRAID SILVER PLATED
Figure 3-67: VL500 Backcap Ground Cable Assembly
02.96 85.001 0 0
17-July-2006
151
VL500 Main Harness Cable Assembly

25.9685.0790 Rev J (VL500 and VL500D)
No.
Item
Qty.
UM.
25.9685.0750
EA
CABLE ASSY, DIMMER COMM
25.9685.0752
EA
CABLE ASSY, 24V POWER
25.9685.0758
EA
CABLE ASSY, PAN/TILT
25.9685.0769
EA
CABLE ASSY, DISPLAY CABLE
25.9685.0771
EA
CABLE ASSY, YOKE LAMP WIRES
25.9685.0772
EA
CABLE ASSY, YOKE GROUND
25.9685.0773
EA
CABLE ASSY, LVS AC
25.9685.0774
EA
CABLE ASSY, YOKE DMX COMM
25.9685.0778
EA
CABLE ASSY, LVS FAN
10
25.9685.0782
EA
CABLE ASSY, MCB YOKE GROUND
11
55.2186.0001
EA
12
55.6699.0003
1.19
FT
SLEEVING, 1/2" NOM DIA WOVEN POLY
13
55.6699.0010
0.92
FT
SLEEVING, 5/16" NOM DIA WOVEN POLY ROUNDIT 2000
152
Description
17-July-2006
02 .9 685.00 10 0
VL500 Main Harness Cable Assembly (continued)
7
10
5
3
3
4
12
13
12
11 (x8)
10
3
1
8
Figure 3-68: VL500 Main Harness Cable Assembly (VL500 and VL500D)
02.96 85.001 0 0
17-July-2006
153
VL500 Arc Main Harness Cable Assembly

25.9685.0791 Rev C (VL500A)
No.
Item
Qty.
UM.
25.9685.0752
EA
CABLE ASSY, 24V POWER
25.9685.0758
EA
25.9685.0772
EA
25.9685.0773
EA
CABLE ASSY, LVS AC
25.9685.0778
EA
CABLE ASSY, LVS FAN
25.9685.0782
EA
25.9685.0783
EA
CABLE ASSY, ARC YOKE LAMP WIRES
25.9685.0784
EA
CABLE ASSY, SHIELDED DISPLAY/DMX COMM
55.2186.0001
EA
10
55.6699.0003
1.19
FT
11
55.6699.0010
0.92
FT
154
Description
17-July-2006
02 .9 685.00 10 0
VL500 Arc Main Harness Cable Assembly (continued)
4
6
5
8
5
7
2
10
11
10
9 (x8)
6
2
8
8
Figure 3-69: VL500 Arc Main Harness Cable Assembly (VL500A)
02.96 85.001 0 0
17-July-2006
155
VL500 80V Main Harness Cable Assembly

25.9685.0792 Rev C (VL500 80V)
No.
Item
Qty.
UM.
25.9678.0743
EA
CABLE ASSY, 80V DIMMER COMM, VL500 80V
25.9685.0744
EA
CABLE ASSY, 24V POWER, VL500 80V
25.9685.0745
EA
CABLE ASSY, 80V YOKE LAMP WIRES
25.9685.0758
EA
25.9685.0772
EA
25.9685.0788
EA
CABLE ASSY, SHIELDED DISPLAY/DMX COMM, VL500 80V
25.9685.0782
EA
55.2186.0001
EA
55.6699.0003
1.19
FT
10
55.6699.0010
0.92
FT
156
Description
17-July-2006
02 .9 685.00 10 0
VL500 80V Main Harness Cable Assembly (continued)
3
5
8
4
4
8
10
8 (x8)
7
1
6
6
Figure 3-70: VL500 80V Main Harness Cable Assembly (VL500 80V)
02.96 85.001 0 0
17-July-2006
157
Notes
158
17-July-2006
02 .9 685.00 10 0

VL500 Arc Ballast Assembly
21.9685.0800 Rev G (625W - VL500A 575W Arc)
21.9685.0802 Rev G (700W - VL500A 700W Arc)
No.
Item
Qty.
UM.
04.9685.0940
EA
LABEL, PRODUCT, VL500APS-575W (575W ARC ONLY)
04.9685.0941
EA
LABEL, PRODUCT, VL500APS-700W (700W ARC ONLY)
04.9685.0942
EA
LABEL, PRODUCT, VL500APS COMPLIANCE (BLK)
04.9685.0945
EA
LABEL, BALLAST WATTAGE, 575W (575W ARC ONLY)
04.9685.0946
EA
LABEL, BALLAST WATTAGE, 700W (700W ARC ONLY)
10.9669.0034
EA
PLATE, NUT
10.9685.0822
EA
MOUNT PLATE, BALLAST
10.9685.0823
EA
BOTTOM PLATE, BALLAST (BLK) (700W ARC ONLY)
10.9685.0824
EA
TOP PLATE, BALLAST (BLK)
10
10.9685.0825
EA
COVER, BALLAST (BLK)
11
10.9685.0826
EA
PANEL, FILLER, BALLAST (BLK)
12
10.9685.7823
EA
BOTTOM PLATE, BALLAST (BLK) (575W ARC ONLY)
13
12.9685.0821
EA
HEATSINK, BALLAST, MACHINED (BLK)
14
23.9685.0827
EA
FAN ASSY, ARC BALLAST, 700W (700W ARC ONLY)
15
25.9685.0807
EA
CABLE ASSY, BALLAST I/O
16
53.2002.0001
EA
NUT, 6-32 KEPS, ZINC (700W ARC ONLY)
17
53.2003.0001
EA
NUT, 4-40 KEP ZINC PLATED
18
53.6520.0001
EA
19
53.6545.0001
EA
20
53.6551.0001
EA
21
53.6571.0002
EA
SCREW, 6-32X1-1/4" LG PPB (700W ARC ONLY)
22
53.6575.0021
12
EA
SCREW, 8-32X5/8" PPB TYPE-F
23
53.6607.0002
EA
24
53.6614.0001
16
EA
25
69.9685.0626
EA
BALLAST, 625W, SCHEIDERWERKS (575W ARC ONLY)
26
69.9685.0701
EA
BALLAST, 700W, SCHEIDERWERKS (700W ARC ONLY)
02.96 85.001 0 0
Description
17-July-2006
159
VL500 Arc Ballast Assembly (continued)

25 (575W Only)
26 (700W Only)
19 (x4)
10
9
23 (x4)
13
17 (x4)
13
18 (x5)
6
15
24 (x16)
16 (x4)
12 (575W Only)
8 (700W Only)
14
7
20 (x4)
21 (x4)
23 (x2)
22 (x12)
11
1 (575W Only)
2 (700W Only)
4 (575W Only)
5 (700W Only)
Figure 3-71: VL500 Arc Ballast Assembly
160
17-July-2006
02 .9 685.00 10 0
Ballast I/O Cable Assembly

25.9685.0807 Rev A
No.
Item
Qty.
UM.
Description
52.6231.0001
EA
PLUG HOUSING, MNLOK PLUG 3-POS
52.6396.2904
EA
RECEPT, 4-POS MTA100 W/POL RED
52.6400.0111
EA
RECEPT, 17-9 STD SEX CPC 600V FLANGE
52.8201.0005
EA
PIN, GOLD 24-20AWG TYPE3+ REEL .040-.080 INS DIA
52.8202.0001
EA
PIN, GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA
52.8202.0011
EA
PIN, GND GOLD 18-16AWG TYPE 3+ REEL .080-.100 INS DIA
52.8231.0005
EA
TERM, RING #6 BLUE 16-14 AWG REEL PIDG
52.8257.0002
EA
PIN, PHOS BRZ 20-14AWG (REEL) MNLOK .060"- .130"INS DIA
52.8313.0001
EA
RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL)
10
52.8314.0001
EA
PIN, GND 20-14AWG (REEL) MNLOK .060"- .130"INS DIA
11
55.2186.0001
EA
CABLE TIE, .10"WD 4.00"LG SMALL
12
73.3522.0002
1.25
FT
WIRE, 22AWG 300V 105C PVC RED UL1569
13
73.3522.0009
1.25
FT
WIRE, 22AWG 300V 105C PVC WHT UL1569
14
73.3522.0010
1.25
FT
WIRE, 22AWG 300V 105C PVC BLK UL1569
15
73.6016.0003
1.33
FT
WIRE, 16AWG 600V 105C PVC ORN UL1015
16
73.6016.0007
1.33
FT
WIRE, 16AWG 600V 105C PVC VIO UL1015
17
73.6016.0009
1.33
FT
WIRE, 16AWG 600V 105C PVC WHT UL1015
18
73.6016.0010
1.33
FT
WIRE, 16AWG 600V 105C PVC BLK UL1015
19
73.6016.0504
3.0
FT
WIRE, 16AWG 600V 105C PVC GRN/YEL UL1015
02.96 85.001 0 0
17-July-2006
161
Ballast I/O Cable Assembly (continued)
7 (x3)
19
9
11 (x5)
16
19
15
17
1
8 (x2)
10
12, 13, 14
18
3
4 (x3)
5 (x5)
6
Figure 3-72: Ballast I/O Cable Assembly
162
17-July-2006
02 .9 685.00 10 0
REFERENCE FOLD-OUTS
VL500 Wiring and Schematic Diagrams

VL500 Wiring Diagram - Sheet 1 of 1
02.96 85.001 0 0
17-July-2006
163
REFERENCE FOLD-OUTS
DMX Input PCB (24.9663.1895) Schematic
A0
ECO #
REV. NO
S05-945
DESCRIPTION
APPROVED
DATE
12/14/05
RELEASE
FAE
J1
D1
2
SHIELD
DMX/VL_INDMX/VL_IN+
VL_OUTVL_OUT+
CHASSIS
1
2
3
4
5
6
D2
2
J2
C
SHIELD
DMX/VL_INDMX/VL_IN+
VL_OUTVL_OUT+
CHASSIS
1
2
3
4
5
6
SHIELD
DMX/VL_IN+
DMX/VL_INVL_OUT+
VL_OUT-
1
2
3
4
5
J3
C1
DRAWN BY :
FAE
A
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238

INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CHECKED BY :
PROJECT ENGR. :
Title
DOC. CONTROL :
Size
B
C 2005 Genlyte Group LLC
Date:
5
02.96 85.001 0 0
17-July-2006
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED

OR DISCLOSED WITHOUT WRITTEN CONSENT.
SCHMATIC VL1000 DMX INPUT BD.

Document Number
Rev
14-9663-1895
Wednesday, December 14, 2005
SHEET
A0
OF
164
REFERENCE FOLD-OUTS
VL500 Controller PCB (24.9685.0730) Schematic - Sheet 1 of 6
ECO #
REV. NO
A0
NOTES: UNLESS OTHERWISE SPECIFIED
1.) ALL CAPACITOR VALUES ARE IN MICROFARADS.
n/a
B0
n/a
C0
S05-701
DESCRIPTION
APPROVED
DATE
PROTO RUN
6/1/05
FAE
MODIFY J3, J9 & U18
7/5/05
FAE
MODIFY DISPLAY COMMUNICATIONS
9/26/05
FAE
2.) ALL RESISTOR VALUES ARE IN OHMS.
+24V
VCC
VR1
D45
18V BATT
C2
Gnd
C1
C3
C4
18V BATT
D1
24V_DET
VCC
1
3/C3
R167
TAB
L1
D47
VCC
18V BATT
+3.3V
VR2
D46
C5
C6
Gnd
TAB
L2
C7
C8
+24V
D2
R168
+24V
+3.3V
3/B3 BATT_DET
D48
+3.3V
+1.5V
+3.3V
+1.5V
R1
VR3
+1.5V
+1.8V
CONNECT SENSE AT LOAD

+
C9
TAB
GND
C10
+1.8V
GND
+3.3V
R2
VR4
+1.8V
CONNECT SENSE AT LOAD
GND
3
C11
C12
TAB
+
+
DRAWN BY :
FAE
GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238

INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE
CHECKED BY :
CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED

OR DISCLOSED WITHOUT WRITTEN CONSENT.
PROJECT ENGR. :
Title
SCHEMATIC VL500 CONTROLLER
DOC. CONTROL :
Size
Document Number
D
C 2005 Genlyte Group LLC
Date:
02.96 85.001 0 0
17-July-2006
Rev
14-9685-0730
Wednesday, October 26, 2005
SHEET
C0
1OF
165
REFERENCE FOLD-OUTS
D[0..31]
3/D1, 3/B1, 3/C3
+3.3V
+3.3V
R3
CS_MTR-
C15
C16
2/B3, 3/B3
C17
R4
CS_UART-
D0
2/B3, 3/C1
R5
+3.3V
+3.3V
+3.3V
C19
+3.3V
C20
+3.3V
C21
CS_FLASH-
+3.3V
C22
C23
D2
2/B3, 2/C2
TIN0
2/B4
R7
TIN1
2/B4
R8
HIZ-
C25
R9
DSI
2/B5, 2/A3
R10
BKPT-
R11
DSCLK
2/B5, 2/C3, 3/D1
R13
VCC
AS-
2/C4
RSTI2/C4, 2/B5, 2/A3, 2/C2
2/C3, 2/C2, 3/B3
R15
IRQ7-
+3.3V
U4
2/B3
R16
A2
D17
A3
A3
D18
A4
A4
D19
D5
A5
A5
D20
D6
A6
A6
D21
D7
A7
A7
D22
A8
A9
A9
D24
A10
A10
D25
D11
A11
A11
D26
D12
A12
A12
D27
D13
A13
A13
D28
A14
D0
A14
D1
A13
D2
A12
D3
A11
D4
A10
D5
A9
D6
A2
A17
D7
A3
A18
D8
A4
A19
D9
A5
A20
D10
A6
A21
D11
A7
A24
D12
R17
TX_INT-
2/C3, 3/B1
R18
IRQ1-
2/B3
R20
RSTI-
D1
D2
D3
A14
D4
D5
D6
D8
A15
A15
D30
A22
A16
A16
D31
A23
D17
A17
A17
D18
A18
A18
D19
A19
D10
D11
D13
A9
D14
A10
D12
D13
2/B3
2/B3
CS_FLASH-
2/D4, 2/B3
D21
A21
D22
A22
2/C4, 2/C3, 3/B3
D23
A23
2/C5, 2/C4, 2/B5, 2/A3
D24
A24
2/B1, 2/B3
OE-
2/B3
R/W-
RAS0-
A12
CAS3-
A13
D15
D16
A14
CAS2-
D17
A15
DRAMW-
A20
2/B1, 2/B2
SRAS-
A21
2/B2, 2/B1
SCAS-
D18
A16
D19
A17
D20
A18
RSTI-
D21
+3.3V
2/B3, 2/B1
+3.3V
2/A4
DCLK
A11
D14
2/B3, 2/B1
A19
A19
CLK_EN
D22
A20
CLK1
D23
A21
3/A5, 3/C3, 3/C5
D27
DATA
D28
INIT_DONE
D24
D30
STATUS-
D31
CONFIG-
A22
+3.3V
3/A5, 3/C3
CONF_DONE
D9
A8
D29
D16
A20
A1
D7
D15
D29
D0
A0
D23
D10
D26
2/C3, 3/B1
D25
A23
D26
3/D3
A24
3/C5, 3/A5, 3/B1
D27
3/C5, 3/A5, 3/B1
D28
3/C5, 3/C3
D29
2/C5, 2/B5, 2/A3, 2/C2
D30
LAMP_STBY
S1
A8
A15
D25
RX_INT-
C26
D16
A2
U1
D20
R14
R/W-
A1
D15
2/B5, 2/A3
R12
TA-
A1
D4
D14
2/B5, 2/A3
3/D3, 3/D1, 3/C1
U3
D3
D9
+1.8V
C24
U2
A0
D8
2/A4
+1.8V
A[0..24]
+3.3V
D1
R6
C18
7
13
21
29
37
45
52
65
81
89
97
113
121
129
137
145
167
191
205
+3.3V
C14
+1.8V
VCC3.3-1
VCC3.3-2
VCC3.3-3
VCC3.3-4
VCC3.3-5
VCC3.3-6
VCC3.3-7
VCC3.3-8
VCC3.3-9
VCC3.3-10
VCC3.3-11
VCC3.3-12
VCC3.3-13
VCC3.3-14
VCC3.3-15
VCC3.3-16
VCC3.3-17
VCC3.3-18
VCC3.3-19
+3.3V
C13
VCC1.8-1
VCC1.8-2
VCC1.8-3
VCC1.8-4
VCC1.8-5
VCC1.8-6
VCC1.8-7
VCC1.8-8
VCC1.8-9
VCC1.8-10
+3.3V
1
57
73
105
152
157
171
175
185
197
+3.3V
R22
6/D4
PP1
EDGESEL
D31
R19
+3.3V
D0
2/A3
PP2
PLL MULT = 4X
R21
VCC
R24
R/WAS-
2/C4
25-40.5MHz
R23
2/C4, 2/C2, 3/D3
TA-
2/B5, 2/D4, 3/D1
CLK IN =
D1
+3.3V
MTR_ENABLE-
D2
R36
C27
R25
BE = R/W
D3
2/A3
2/C5, 2/C4, 2/A3, 2/C2
2/A3
2/A3
2/A3
2/A3
IRQ7-
2/C4
J1
RSTI-
PST6
PST4
PST2
PST0
BKPTDSCLK
2/A3, 2/D4
2/D4, 2/A3
DSI
DSO
PST7
PST5
PST3
PST1
2/D4, 2/A3
2/A3
2/A3
2/A3
2/A3
2/A3
PSTCLK
TA-
2/A3
2/D4, 2/C3, 3/D1
3/B1, 2/C4
RX_INT-
2/C4, 3/B1
TX_INT-
CS_FLASH-
R26
+3.3V
2/D4, 2/C2
D4
MTR_EN-
PAR PORT
U5
18V BATT
R27
5/C5, 6/C3
IRQ1-
2/C4
U8
R28
TCK
A15
D16
A14
D17
A13
D18
A12
D19
D5
16 BIT BUS
R29
18V BATT
D6
CS_WBCS_MTRCS_UARTOE-
TIN0
2/D4
3/B3
R30
AUTO ACK
A11
D20
2/D4, 3/C1
A10
D21
2/C2
A9
D22
A17
D23
A18
D24
A19
D25
A20
D26
A21
D27
A24
D28
2/D4, 3/B3
TIN1
2/D4
PLACE RESISTORS CLOSE TO MICROPROCESSOR

R31
UART_OUT_B
4/C3
RAS0-
RAS_0-
2/B1, 2/C1
UART_IN
3/C3, 4/C3
TX_EN_B-
4/D3
CAS0CAS1CAS2-
TXDB
4/C5
CAS3RXDB
4/C5
R32
SRAS-
2/C1, 2/B1
SCAS-
2/C1, 2/B1
D31
A23
CAS1-
2/B3
U6
2/B1,2/C1
R34
DRAMW-
DRAMWR-
2/B1, 2/C1
SCL
+3.3V
CAS0-
2/B3
S_CASCLK_EN
+3.3V
RAS0-
2/C1, 2/B3
R33
SDA
+24V
A22
2/D1
S_RAS-
SCL
+24V
D30
2/D1
+3.3V
SDA
VCC
D29
2/B1
2/B1
VCC
D7
2/B3, 2/C1
DRAMW-
2/B3, 2/C1
SRAS-
2/C1, 2/B2
SCAS-
2/C1, 2/B3
CLK_EN
+1.5V
+3.3V
RSTI-
2/C5, 2/C4, 2/C2

+3.3V
RSTO-
+3.3V
EDGESEL
2/C4
Y1
BKPT-
U7
DSO
CLK0
DSI
CLK1
2/C1
CLK2
2/A1
CLK3
3/C3
DSCLK
TCK
HIZ-
2/D4
PSTCLK
PST0
PST1
PST2
+1.8V
PST3
PST4
FB1
PST5
+3.3V
PST6
R38
PST7
C28
C29
R39
2/B5
+3.3V
+1.8V
2/B5, 2/D4
2/B5, 2/D4
2/B5
+1.8V
2/B5
2/B5
2/B5
2/B5
GND
2/B5
2/B5
2/B5
2/B5
2/B5
4
10
17
25
33
41
48
53
61
69
77
85
93
101
104
109
117
125
133
141
148
156
162
169
173
183
188
194
201
208
R40
+1.5V
CLK2
2/A4
2/B5, 2/D4
GND1
GND2
GND3
GND4
GND5
GND6
GND8
GND7
GND9
GND10
GND11
GND12
GND13
GND14
GND15
GND16
GND17
GND18
GND19
GND20
GND21
GND22
GND23
GND24
GND25
GND26
GND27
GND28
GND29
GND30
3/B1
FB2
DO NOT
STUFF
Size
Document Number
Date:
Rev
C0
14-9685-0730
5
02.96 85.001 0 0
17-July-2006
Sheet
of
166
REFERENCE FOLD-OUTS
+3.3V
C31
C32
+1.5V
+24V
+1.5V
+3.3V
R144
46
15
VCC15_1
VCC15_2
137
115
VCC33_8
102
VCC33_7
81
VCC33_6
66
VCC33_5
44
VCC33_4
INIT_DONE
VCC33_3
A[0..24]
R145
VCC33_2
2/D1
29
2/C3
VCC33_1
135
C35
117
C34
VCC15_5
+1.5V
C33
64
+1.5V
VCC15_4
C30
+3.3V
VCC15_3
+3.3V
TA-
2/B5, 2/D4, 2/C3
A9
PWM_PH_8
A6
R146
I_SENSE
A0
A8
6/B4
C122
A7
D17
A5
D19
U10
PWM_OUT_13
R147
R41
3/D1
STATUS-
2/C3, 3/B1, 3/A5
PWM_OUT_14
R148
3/A5, 2/C3
R149
THERMAL_1
2/C3, 3/C5
6/B4
D16
PWM_PH_13
DATA
PWM_PH_14
CONFIG-
PWM_OUT_7
TX_EN_A-
R42
CONFIG-
CLK3
C123
R150
2/A4
TX_EN_C-
2/C3, 3/C3
A1
D29
VCC
R43
3/B5
DCLK
SPARE_PWM_OUT_11
MSEL0
2/C3, 3/A5, 3/C3
VCC
R44
CONF_DONE
R152
THERMAL_2
CS_UART-
3/C5
R151
C
CE-
MSEL1
PWM_OUT_8
DCLK
UART_OUT_A
3/B5
+3.3V
R153
2/C3, 3/A5, 3/C5
A3
6/B4
2/C3, 3/B1, 3/A5
R45
C129
PWM_PH_7
C130
TMSA
PWM_OUT_1
3/B1
2/B3, 4/C3
UART_IN
V_SENSE
LED_RX-
6/B4
LED_STATUS
D7
A8
D8
A9
D9
A10
D10
A11
D11
A12
D12
A13
D13
D14
D15
A16
D16
A17
D17
A18
D18
A19
D19
A20
D20
A21
D21
A22
D22
A23
D23
A24
D24
3/B1, 2/D1
5/B3
5/B3
5/B2
5/B2
5/D5
D25
4/C3
D26
4/D3
D27
2/D1
D28
2/D1
D29
5/D3
D30
2/D4, 2/B3
D31
5/D5
4/C3
2/D1
18V BATT
LAMP_ON-
U13
LAMP_CNTL
PWM_OUT_2
D25
6/D3
PWM_OUT_3
D26
6/B3
R157
6/B4
R158
C126
3/C3
VCC
D24
4/B5
3/C3
18V BATT
VCC
D23
4/B5
MSEL0
5/D5
6/D3
D22
4/C4
C125
R156
A/D_SPARE_1
D6
A7
D21
4/C4
3/B1
R47
MSEL1
D5
A6
2/D1
D20
4/C4
R155
R48
D4
A5
D18
LED_TXTDIA
D3
A4
C124
R154
R46
D2
A3
A15
A4
1/C4 24V_DET
D1
A2
A14
VCC
A2
D0
A1
5/D4
D[0..31]
+3.3V
A0
CLK_A/D
D27
DOUT_A/D
D28
+24V
+24V
DIN_A/D
CS_SHDN_A/D
D30
D31
R159
R51
OPT_31
TX_INT-
OPT_41
RX_INT-
BATT_DET
TDIA
4/A3
A/D_SPARE_2
6/B4
DO NOT STUFF
1/C4
D[0..31]
3/D1, 2/D1
2/C4, 2/C3
4/A3
C127
R160
+3.3V
2/C4, 2/C3
SPARE_PWM_OUT_12
DTXE
+3.3V
3/C5
5/D3
SPARE_2
4/B1, 6/A4
R52
+1.5V
PWM_OUT_4
6/B3
PWM_PH_4
PWM_PH_2
6/B2
R161
A/D_SPARE_3
6/D2
OPT_1_IN
+1.5V
4/A3
6/B4
PWM3_EN_1
R49
C128
R162
CE-
TMSA
5/B5
PWM3_OUT_2
3/C3
TCKA
5/B5
OPT_2_IN
STATUS-
4/A3
2/B3
R50
RSTO-
CONF_DONE
R/WTCKA
SPARE_PWM_PH_12
2/C4, 2/C3, 2/C2
3/B1
2/D4, 2/B3
3/B5
+1.8V
2/C3, 3/A5, 3/C5

2/C3, 3/A5, 3/C5
5/D2
+1.8V
CS_MTRCS_WB-
SPARE_PWM_PH_11
2/B3
5/B5
3/C5
PWM_PH_1
PWM3_OUT_1
5/D2
6/D2
DRX
4/A4
4/A4
GND14
6/B2
138
GND13
136
GND11
GND12
118
116
GND10
101
GND8
GND9
80
DISPLAY CONTROL
65
9
DCOMR71
GND7
PWM_PH_3
PWM3_EN_2
63
INT / EXT
C131
PWM3_OUT_5
GND6
5/A5
J3
45
5/A5
R80
DO NOT STUFF
GND5
R72
PHASE_A_1
43
R37
GND
4/A4
DTX
PHASE_B_1
GND4
R35
U9
DO NOT STUFF
PHASE_A_2
PWM3_OUT_4
30
5/A5
PWM3_OUT_3
GNDG_PLL1
5/A5
PHASE_B_2
PWM3_OUT_6
GNDA_PLL1
5/B5
GND3
18V BATT
19
VCC
18
4/A3
VCC
+3.3V
DCOM+
+3.3V
U11
2/C3, 3/C3
A
2/C3, 3/C5, 3/C3

2/C3, 3/C5, 3/B1
2/C3, 3/C5, 3/B1
DATA
DCLK
STATUS-
C132
CONF_DONE
R82
Z5
C133
Z6
SOCKET IS XU15

Size
Document Number
Date:
Rev
C0
14-9685-0730
5
02.96 85.001 0 0
17-July-2006
Sheet
of
167
REFERENCE FOLD-OUTS
VCC
18V BATT
VCC
VCC
C36
R53
ISO_VCC
ISO_VCC
18V BATT
ISO_VCC
U12
R54
U14
C38
14
C37
R55
VCC
VCC
TX_EN_C-
3/C1
VCC
ISO_VCC
ISO
U17C
+3.3V
VCC
5
U34
+3.3V
R57
+24V
TXDB
C39
C40
R56
ISO_VCC
C41
C42
R60
+24V
R61
TX_EN_A-
D3
+24V
U15
R58
U17D
14
R59
TX
ISO_VCC
U16
VCC
2/B4
R170
VCC
VCC
+3.3V
3/C1
TX_EN_B-
2/B3
VCC
D4
+3.3V
D5
LED_RX-
+3.3V
R62
3/C3
LED_STATUS
RXDB
VCC
3/C3
U18
2/B4
POWER
LED_TX-
3/C3
J2
+3.3V
RX
R169
C46
VCC
ISO_VCC
ISO_VCC
ISO_VCC
ISO_VCC
U19
C47
14
14
STATUS
C48
UART_OUT_A
D6
R63
+1.5V
R65
3/C1
R64
U20
UART_OUT_B
+1.5V
U17A
FTC1
U17B
COMOUT+
2/B3
6/C4
COMOUT-
6/C4
CI+
FTC2
FTC3
R66
CI-
VCC
+1.8V
COMIN+
ISO_VCC
VCC
+1.8V
6/C4
COMIN-
6/C4
R68
C49
R67
U21
FTC4
R69
Z1
UART_IN
C50
3/C3, 2/B3
1
1
Z3
GND
Z4
VCC
3
VCC
Z2
R70
D7
C51
R163
PANB1
C52
PANA1
TILTA1
3/C3
6/A3
4/A3
R164
OPT_3
U22
SPARE_3
6/A4
4/A3
R73
LAMP_CNTL
LAMP_CNTL_OUT
R74
6/D4
ENCODER_A1
PHASE_A1
4/A4
R165
6/A5
R166
R76
R75
SPARE_4
OPT_4
C53
TILTB1
PHASE_A2
VCC
SPARE1
ENCODER_A2
4/A4
6/A5
D8
R77
SPARE2
ENCODER_B1
PHASE_B1
4/A4
VCC
6/A5
R78
VCC
4/A3
ENCODER_B2
PHASE_B2
6/A5
R81
OPT_2
R79
3/B3, 6/A4
4/A3
C54
C55
R83
R84
LAMP_ON-
SPARE_2
SPARE_1
OPT_1
LAMP_ON_IN-
4/A3
6/D4
3/C3
6/A3
R85
R86
SPARE3
SPARE4
VCC
+3.3V
+3.3V
C56
PHASE_B1
3/A1
OPT_1_IN
4/B4
3/B3
4/B4
3/B3
PHASE_A2
PHASE_A_2
4/B4
3/A1
VCC
20
VCC
PHASE_B_1
U24
PHASE_A1
20
C57
U23
PHASE_A_1
3/A1
OPT_1
4/B2
OPT_2_IN
OPT_2
PHASE_B_2
PHASE_B2
OPT_31
OPT_3
3/A3
4/B2
4/A3, 4/B4
3/B3
4/B2
OPT_4
OPT_41
4/B2
GND
10
10
GND
3/B3

Size
Document Number
Date:
Rev
C0
14-9685-0730
02.96 85.001 0 0
17-July-2006
Sheet
of
168
REFERENCE FOLD-OUTS
VCC
VCC
+24V
+24V
VCC
SPARE
(DO NOT STUFF)
MAGENTA
PWM_PH_7
23
R91
MAGENTA_OUT1B
C63
MAGENTA_OUT2A
R92
SPARE_OUT1B
6/A4, 6/D5
R94
3/B1
SPARE_PWM_PH_12
SPARE_OUT2A
6/A4, 6/C5
SPARE_OUT2B
6/D5, 6/A3
R96
R97
3/B1
C67
6/A3, 6/D5
U26
C65
6/D5, 6/A4
PWM_OUT_8
C66
SPARE_OUT1A
SPARE_PWM_OUT_11
C64
PWM_PH_8
MAGENTA_OUT2B
R95
3/C1
6/D5, 6/A4
R93
3/D1
SPARE_PWM_PH_11
U25
R90
PWM_OUT_7
C62
3/C1
3/B1
6/D5, 6/A3
C118
VCC
MAGENTA_OUT1A
C59
R88
4
VMM2
3/C1
R89
3/C1
VMM1
VCC
23
12
R87
C61
C117
VMM2
C58
12
C60
VMM1
VCC
6/A3, 6/C5
R98
SPARE_PWM_OUT_12
18V BATT
R99
C68
C69
R100
18V BATT
R102
C72
R105
VCC
E2
C2
26
E1
C1
R101
10
19
E2
6
26
E1
10
19
C2
C71
C1
C70
R103
C73
R106
VCC
R104
C74
R107
C75
+24V
R108
+24V
+3.3V
6/C3, 2/A2
MTR_EN-
+3.3V
+1.5V
+24V
+24V
+24V
VCC
TILT
+1.5V
+24V
D9
D10
D11
VCC
+24V
C77
C76
C119
+1.8V
TILT_PHB_OUT
DIFFUSER
R109
6/A5
PWM3_OUT_3
3/C1
TILT_PHC_OUT
6/A5
3/A3
U29
D12
R110
3/C1
PWM3_EN_1
D13
3/B3
D14
VMM1
VCC
23
6/A5
PWM_PH_13
+1.8V
TILT_PHA_OUT
PWM3_OUT_2
3/B3
VMM2
PWM3_OUT_1
3/A3
12
U27
DIFFUSER_OUT1A
6/A3, 6/C5
R111
U28
PWM_OUT_13
DIFFUSER_OUT1B
6/A4, 6/C5
D15
C78
C79
GND
R112
3/C1
VCC
DIFFUSER_OUT2A
PWM_PH_14
6/A4, 6/C5
C80
B
VCC
DIFFUSER_OUT2B
6/A3, 6/C5
R113
D16
R114
C81
3/C1
R115
PWM_OUT_14
C82
C85
C86
C83
R116
C87
+24V
E2
6
+24V
19
+24V
PAN
C2
C89
C1
C88
26
E1
C84
10
R117
D17
D18
R118
D19
+24V
U30
PWM3_OUT_4
PAN_PHA_OUT
PWM3_OUT_5
PAN_PHB_OUT
3/A3
3/A3
C90
R119
C91
R120
6/A5
6/A5
PWM3_OUT_6
PAN_PHC_OUT
3/A3
6/A5
U31
D20
PWM3_EN_2
D21
3/A3
D22
D23
VCC
C92
VCC
R121
D24
C93
C94
C95
C98
C96
C97

Size
Document Number
Date:
Rev
C0
14-9685-0730
5
02.96 85.001 0 0
17-July-2006
Sheet
of
169
REFERENCE FOLD-OUTS
VCC
+24V
+24V
VCC
AMBER
D27
3/A1
R123
MAGENTA_OUT2A
6/A4, 5/D4
D28
3/C1
PWM_PH_1
R124
C120
4
VMM2
MAGENTA_OUT1B
6/A4, 5/D4
D
12
23
VCC
6/A3, 5/D4
D26
C99
R122
MAGENTA_OUT1A
VMM1
D25
C100
AMBER_OUT1A
6/A3, 6/C5
D
U32
AMBER_OUT1B
PWM_OUT_1
C101
MAGENTA_OUT2B
C102
6/A4, 6/C5
R125
6/A3, 5/D4
3/B1
AMBER_OUT2A
PWM_PH_2
6/A4, 6/B5
AMBER_OUT2B
R126
3/C3
C103
SPARE_OUT1A
6/A3, 5/D2
18V BATT
BALLAST CONTROL
E2
LAMP_STBY
2/C3
VCC
LAMP_ON_IN-
2/B5
C2
6/A4, 5/D2
SPARE_OUT2B
C105
LAMP_CNTL_OUT
2/B5
26
SPARE_OUT2A
D32
18V BATT
J5
DO NOT
STUFF
E1
6/A4, 5/D2
C1
D31
SPARE_OUT1B
6/A3, 6/B5
R128
19
6/A3, 5/D2
D30
C104
10
D29
R127
PWM_OUT_2
R129
R130
VCC
D33
C106
J6
DIFFUSER_OUT1A
6/A3, 5/B2
R131
C107
R132
+24V
COMIN+
4/C1
D34
COMINDIFFUSER_OUT1B
4/C1
6/A4, 5/B2
DMX IN
COMOUT+
+24V
4/C1
COMOUT-
D35
DIFFUSER_OUT2A
D36
4/C1
6/A4, 5/B2
2/A2, 5/C5
DIFFUSER_OUT2B
MTR_EN-
+3.3V
6/A3, 5/B2
+3.3V
VCC
VCC
J8
+24V
+24V
+1.5V
AMBER_OUT1A
VCC
POWER IN
6/D2, 6/A3
6/D2, 6/A4
C121
3/A1
AMBER_OUT2B
VCC
6/D2, 6/A3
R134
3/C3
PWM_PH_3
R135
+1.8V
VMM2
VCC
AMBER_OUT2A
D40
C108
R133
BLUE
12
6/D2, 6/A4
D39
C109
+1.5V
AMBER_OUT1B
VMM1
D38
23
D37
BLUE_OUT1A
BLUE_OUT1B
C110
6/B5, 6/A3
U33
PWM_OUT_3
C111
+1.8V
6/B5, 6/A4
R136
J9
3/B3
I_SENSE
PWM_PH_4
BLUE_OUT2A
6/B5, 6/A4
3/D4
V_SENSE
BLUE_OUT2B
3/C4
D41
BLUE_OUT1A
THERMAL_1
6/B2, 6/A3
3/C4
R137
THERMAL_2
D42
3/C4
BLUE_OUT1B
3/B3
A/D_SPARE_1
6/B2, 6/A4
GND
6/B5, 6/A3
R138
PWM_OUT_4
3/B4
C112
A/D_SPARE_2
C113
R139
3/B4
D43
BLUE_OUT2A
A/D_SPARE_3
6/B2, 6/A4
A/D INPUTS
3/B4
C114
D44
BLUE_OUT2B
E2
6
C2
26
E1
10
19
C1
6/B2, 6/A3
R140
C115
VCC
R141
R142
C116
R143
VCC
J7
VCC
SPARE_OUT2A
SPARE_OUT2B
SPARE_OUT1B
SPARE_OUT1A
DIFFUSER_OUT2A
DIFFUSER_OUT2B
DIFFUSER_OUT1B
DIFFUSER_OUT1A
AMBER_OUT2A
AMBER_OUT2B
AMBER_OUT1B
AMBER_OUT1A
BLUE_OUT2A
BLUE_OUT2B
BLUE_OUT1B
BLUE_OUT1A
6/C5, 5/D2
J4
6/C5, 5/B2
PAN_PHC_OUT
6/C5, 5/B2
5/A4
5/A4
PAN
PAN_PHB_OUT
5/A4
5/B4
5/B4
6/B2, 6/B5
MAGENTA_OUT2A
MNTG1
DIA. .166"
MNTG2
DIA. .166"
MNTG3
BLUE
MAGENTA_OUT2B
6/D5, 5/D4
6/D5, 5/D4
MAGENTA_OUT1B
MAGENTA_OUT1A
6/D5, 5/D4
ENCODER_B1
DIA. .166"
AMBER
6/B2, 6/B5
5/B4
4/B3
A
TILT
DIFFUSER
6/C5, 6/D2
6/B2, 6/B5
TILT_PHB_OUT
TILT_PHC_OUT
6/B5, 6/D2
6/C5, 6/D2
6/B2, 6/B5
TILT_PHA_OUT
SPARE
6/D5, 5/D2
6/C5, 5/B2
6/C5, 5/B2
6/B5, 6/D2
PAN_PHA_OUT
ENCODER_A1
6/C5, 5/D2
6/D5, 5/D2
MAGENTA
6/D5, 5/D4
SPARE_1
4/B3
ENCODER_A2
4/B1
4/B3
ENCODER_B2
SPARE_2
4/B3
3/B3, 4/B1
SPARE_3
4/B1
DIA. .166"
SPARE_4
4/B1
MNTG5
DIA. .166"
MNTG6
DIA. .166"
MNTG4

Size
Document Number
Date:
Rev
C0
14-9685-0730
02.96 85.001 0 0
17-July-2006
Sheet
of
170
APPENDIX A.
Technical Bulletins
VL500 Wash Luminaire Technical Bulletins
The following table identifies the current technical bulletins associated with the
VL500 wash luminaire. If applicable, these improvements have been incorporated into
this manual.
Technical Bulletin
S5K-001
Description
Series 500 Yoke Leg/Cross Member Screw Torquing Procedure
Technical Bulletins, Technical Notices, Software Updates, and support, and other
information is available online at http://www.vari-lite.com/Support/. To request access
to the password-protected support areas, please contact Vari-Lite Customer Service at
1-877-827-4548 or customerservice@genlytecontrols.com.
02.96 85.001 0 0
17-July-2006
171
Notes
172
17-July-2006
02 .9 685.00 10 0
Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
1.877.VARI-LITE o 1.214.647.7880 o Fax 1.214.647.8038
www.vari-lite.com
2006 Genlyte Group LLC. All rights reserved. Printed in USA

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VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 Luminaire Service Manual

HOW TO OBTAIN WARRANTY SERVICE

How To Obtain Warranty Service

Manual Revision History

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

WARNUNG - weist auf mgliche Krperverletzung und Lebensbedrohung hin.

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

CETTE SECTION CONTIENT DES INFORMATIONS GNRALES POUR SE

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

AVISO SOBRE SEGURIDAD

Aviso sobre Seguridad

ADVERTENCIA, indica posibles lesiones o muerte a las

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

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

SAFETY NOTICE (JAPANESE)

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

Model Specific Features

Standard color dichroic glass DICHROTUNETM color system.

VL500 Wash Luminaire (20.9685.0011)

Pastel color dichroic glass DICHROTUNETM color system.

VL500D Wash Luminaire (20.9685.0002)

120V, 1200W Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

120V on-board IGBT dimmer.

VL500D Wash Luminaire (20.9685.0012)

120V, 1200W Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

120V on-board IGBT dimmer.

VL500D Wash Luminaire (20.9685.0003)

230V, 1000W Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

230V on-board IGBT dimmer.

VL500D Wash Luminaire (20.9685.0013)

230V, 1000W Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

230V on-board IGBT dimmer.

VL500 80V Wash Luminaire (20.9685.0004)

80V, 1200W Tungsten Halogen lamp source.

Standard color dichroic glass DICHROTUNETM color system.

80V on-board dimmer.

VARILITE - VL500 LUMINAIRE SERVICE MANUAL

VL500 80V Wash Luminaire (20.9685.0014)

80V, 1200W Tungsten Halogen lamp source.

Pastel color dichroic glass DICHROTUNETM color system.

80V on-board dimmer.

VL500A Wash Luminaire (20.9685.0005)

575W arc lamp source with external ballast unit.

Standard color dichroic glass DICHROTUNETM color system.

VL500A Wash Luminaire (20.9685.0015)

575W arc lamp source with external ballast unit.

Pastel color dichroic glass DICHROTUNETM color system.

VL500A Wash Luminaire (20.9685.0006)

700W arc lamp source with external ballast unit.

Standard color dichroic glass DICHROTUNETM color system.

VL500A Wash Luminaire (20.9685.0016)

700W arc lamp source with external ballast unit.

Pastel color dichroic glass DICHROTUNETM color system.

Mini XLR for Remote

Yoke Leg (Power)