ETC IRIDEON AR500 User manual

AR500™ Exterior Luminaire
Owner’s Manual
Revision E
Copyright © Electronic Theatre Controls, Inc.
All Rights reserved.
Product information and specifications subject to change.
Part Number:
7091M1005 Rev E
Released: February 2003

Irideon
®
is a registered trademark owned by Electronic Theatre Controls
®
, Inc., 3030 Laura
Lane, Middleton, Wisconsin, USA, and is registered in the United Stated and other countries.
Composer
™
, Composer Lite
™
, AR50
™
, AR500
™
, AR6
™
, Building With Light
™
, and the Building
Designs are also trademarks owned by Electronic Theatre Controls, Inc.

IRIDEONAR500EXTERIOR WASH LUMINAIRE OWNERS MANUAL iii
7091M1005
02/17/03
AR500Exterior Wash Luminaire
Owners Manual
Reporting Errors and Recommending
Improvements
You can improve this manual. If you find any mistakes or if you know of
a way to improve procedures, please let us know. Send your comments to:
Electronic Theatre Controls, Inc.
C/O: Technical Communications Dept.
3030 Laura Lane
Middleton, WI 53562, USA
Fax: [phone]
Or Email to [email protected]
Revision History
Basic February 10,1995
Revision A June 1, 1996
Revision B May 16, 1997
Revision C December 16, 1998
Revision D August 28, 2000
Revision E February 20, 2003

IRIDEONAR500EXTERIOR WASH LUMINAIRE OWNERS MANUAL iii
7091M1005
02/17/03
Patent and Trademark Notice
Irideon® is a registered trademark owned by Electronic Theatre Controls,
Inc., 3030 Laura Lane, Middleton, Wisconsin, USA, and is registered in
the United States and other countries. Composer™ Composer Lite, ™
AR5™, AR6™, AR500™, Building With Light™, and the Building
Designs are also trademarks owned by Electronic Theatre Controls, Inc.
Irideon products are protected by one or more of the following patents,
and other pending patent applications worldwide:
U.S. Patents No. 5,728,994; 5,367,444; 5,186,536; 5,073,847; 4,779,176;
4,602,321; 4,392187;
U.S. Design Patents No. D 350,408;
Australia Patents No. 683,695; 667,109; 649,264; 646,588; 586,095;
576,400; 546,433;
Australia Designs Reg. 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 Patent No. 81,234; 81,233; 76,046;
Europe Design Reg. No. 0586 049; 0 547 732; 0 474 202; 0 192 882; 0
140 994; 0 060 068;
France Designs Reg. No. 370297 - 3703003;
German Patents No (DBP) 96314122.0; 69208615.3; 69121029; 3768727;
3279888; 3274291;
German Design Reg. No. M9402951.2;
Hong Kong Patents No. 965/1990; 285/1987;
Japan Patents No. 2,059,669; 2,055,324; 1,889,481; 1,770,241; 1,723,825;
1,683,007; 1,533,011;
Japan Design Reg. No. 1,002,123; 985,985;
Korea Patent No. 76,310; 42,639
Korea Designs Reg. No. 209,896; 209,895;
Mexico Patent No. 180,148;
Singapore Patents No. 663/90; 134/87;
Spain Patents No. 2.031.748; 2.020.960; 548.328;
Spain Design Reg. No. 137.502; 137.501; 133.573;
UK Design Reg. No. 2056387; 2056386; 2038212
© 2000 Electronic Theatre Controls, Inc. All Rights Reserved

IRIDEONAR500EXTERIOR WASH LUMINAIRE OWNERS MANUAL v
7091M1005
02/17/03
Contents
Chapter 1. Introduction
1.1 ....................................................................Scope 1-2
1.2 ......................................... Maintenance Concept 1-2
1.3 ........................Recommended Safety Practices 1-2
1.4 ...........................................Manual Organization 1-3
1.5 ..........................................Technical Assistance 1-3
Chapter 2. Description
2.1 ........................ Basic Features and Capabilities 2-2
2.1.1 ...................................................................Color 2-2
2.1.2 .................................................. Diffuser/Douser 2-2
2.1.3 ............................................................Controller 2-2
2.1.4 .............................................Luminaire Versions 2-3
2.1.5 .....................................Technical Specifications 2-3
2.2 .....................................................Configurations 2-5
2.2.1 ................................................................ Optical 2-5
2.2.2 .............................................................Electrical 2-6
2.2.2.1.............................................. Ballast Plate 2-6
2.2.2.2........................................Electronics Plate 2-7
2.2.3 ................................................. Control Systems 2-8
2.2.3.1........................... PC Only Control System 2-8
2.2.3.2.................................MCP Control System 2-9
2.2.3.3............... DMX Interpreter Control System 2-10
2.2.3.4DMX-512 Control System (DMX only Control PCB) 2-11
2.2.4 ...............................................Unit Configuration 2-12
Chapter 3. Installation
3.1 .................................. Installation Requirements 3-2
3.2 .................................................Site Preparations 3-2
3.2.1 ....... Mounting Platform for Stanchion Assembly 3-3
3.2.2 .Mounting Platform for Remote Head Assembly 3-4
3.2.3 ..... Clearance and Access for Standard Version 3-5
3.2.4 ....... Clearance and Access for Remote Version 3-6
3.2.5 ....................... Input Power and Control Cabling 3-7
3.2.5.1.............................. Data Wire Termination 3-8
3.2.6 ...........................................Cable Specifications 3-8
3.3 ...................... Luminaire Installation Procedure 3-9
3.3.1 ................................................Standard Version 3-9
3.3.2 ..................................................Remote Version 3-14
Chapter 3. Installation (Continued)
3.4 ................................................... Fixture Address 3-20
3.4.1 ...........Standard Version DMX Starting Address 3-21
3.4.2 .............................Composer Controller Version 3-22
3.5 ................................. Power-Up and Final Focus 3-23
Chapter 4. Tests
4.1 ............................................. Luminaire Self Test 4-2
4.1.1 ..............................................DMX Only Version 4.2
4.1.2 ............................Composer Controller Version 4-3
4.2 .......................... DMX-512 Controller Color Test 4-5

CONTENTS vii
7091M1005
02/17/03
Chapter 5. Trouble Shooting
5.1 ........Problem: Lamp Does Not Light or is Dim 5-2
5.1.1 ........................................ Test Lamp and Power 5-2
5.1.2 .........................................................Test Ballast 5-3
5.2 ....... Problem: Fixture Does Not Change Color 5-5
5.2.1 ..............................................DMX Only Version 5-5
5.2.2 ............................................ Composer Version 5-6
5.3 ....... Problem: Some Color Panels Not Moving 5-8
5.4Problem: Fixture Does Not Respond to DMX Control 5-9
5.4.1 .......................................................DMX Control 5-9
5.4.2 .............................................Composer Control 5-10
Chapter 6. Maintenance
6.1 ..............................................Basic Maintenance 6-2
6.1.1 ........................................... Replacing the Lamp 6-2
6.1.2 .............................................Replacing the Lens 6-3
6.1.3 ......................................Replacing the Reflector 6-4
6.1.4 ........................ Replacing the Color Mechanism 6-7
6.1.5 .Replacing the Linear Actuator Motor Assembly 6-9
6.1.6 .........................Replacing the Ballast Assembly 6-11
6.1.7 .........Replacing the Electronics Plate Assembly 6-11
6.1.8 ............................................ Replacing a Gasket 6-13
6.1.9 . Cleaning the Lens, Reflector, and Color Filters 6-14
6.2 .........Comprehensive Maintenance and Repair 6-16
6.2.1Replacing the Motor Drive Cable Assembly (Standard Version)
............................................................................ 6-16
6.2.2Replacing the Motor Drive Cable Assembly (Rmt. Ballast Version)
............................................................................ 6-18
6.2.3 ...................... Replacing a Series 30 Connector 6-18
6.2.4 ......................................Replacing a Color Filter 6-19
Chapter 6. Maintenance (Continued)
6.2.5 ............................... Replacing the Lamp Socket 6-20
6.2.6Replacing the Lamp Wire Assembly (Standard Version) 6-21
6.2.7Replacing the Lamp Wire Assembly (Remote Ballast Version)
............................................................................ 6-23
6.2.8 ....... Replacing the Motor Drive Shaft Assembly 6-24
6.2.9 .....................Replacing a Linear Actuator Motor 6-24
6.2.10 .............Replacing the Motor Drive Swivel Link 6-28
6.2.11 ..............Replacing the Yoke Termination PCB 6-28
6.2.12 .................................Ballast Assembly Figures 6-29
6.2.13 .......................... Replacing the Circuit Breaker 6-31
6.2.14 ......................................Replacing a Capacitor 6-31
6.2.15 .........Replacing the Igniter (Standard Version) 6-31
6.2.16Replacing the Igniter (Remote Ballast Version) 6-32
6.2.17 ..................................... Replacing the Inductor 6-34
6.2.18 ...............................Replacing the Transformer 6-34
6.2.19 .............................. Replacing the Ballast Plate 6-35
6.2.20 Replacing the AC/DMX Input Cable Assembly 6-35
6.2.21Replacing AC Output Cable (Remote Version Only) 6-36
6.2.22Replacing Data Output Cable to Head (Remote Version Only)
............................................................................ 6-37

CONTENTS vii
7091M1005
02/17/03
6.2.23 .................Electronics Plate Assembly Figures 6-38
6.2.24 ...............Replacing the Address Switch Cable 6-39
6.2.25 .................Replacing the Address Switch PCB 6-39
6.2.26Replacing the Data Output Cable in Stanchion Assembly 6-40
6.2.27Replacing the Electronics AC/DMX Input Cable Assembly 6-40
6.2.28 .................... Replacing the Lamp Control PCB 6-41
6.2.29 ..Replacing the PCB Power Connection Cable 6-42
6.2.30 ............................ Replacing the Power Supply 6-42
6.2.31Replacing Lamp Control PCB 1/16A, 125V, Pico II Fuse 6-43
6.2.32Electronics Plate Assembly Figures (Composer Controller Vers.)
............................................................................ 6-44
6.2.33 ............. Replacing Composer Controller PCB 6-45
6.2.34Replacing Composer Controller Low Voltage Power Supply
............................................................................ 3-46
6.2.35 .......Replacing AC/Data Input Cable Assembly 3-46
6.2.36Replacing DC Power Supply to Control PCB Cable Assembly
............................................................................ 3-47
6.2.37Replacing Data Output From Control Cable Assembly 3-47
Chapter 7. Optional Accessories
7.1 .........................Tamper-Resistant Hardware Kit 7-2
7.1.1 ................................................................... Parts 7-2
7.1.2 ...................................................................Tools 7-2
7.1.3 ......................................................... Procedures 7-3
7.2 .........Top Hats, Glare Shields and Rock Guard 7-10
7.2.1 ................................................................... Parts 7-10
7.2.2 ...................................................................Tools 7-11
7.2.3 ...........................................................Procedure 7-11
Chapter 8. Replacement Parts and Wiring Diagrams
8.1 ..............................................Replacement Parts 8-2
8.1.1 ................... Exploded View (Head & Stanchion) 8-2
8.1.2 ........... Exploded View (Remote Mounting Foot) 8-4
8.1.3 .....................Exploded View (Ballast Assembly) 8-6
8.1.4Exploded View (Electronics Plate Assembly, DMX Only) 8-8
8.1.5Exploded View (Electronics Plate Assembly, Composer Control)
.............................................................................. 8-9
8.2 ..................................................Wiring Diagrams 8-10
8.2.1 ............Stanchion Wiring (DMX Only Controller) 8-10
8.2.2 .......... Stanchion Wiring (Composer Controller) 8-11
8.2.3 ......Alternate Wiring for Remote Ballast Version 8-12
8.2.4 .......................................Head Enclosure Wiring 8-13
Chapter 9. Limited Warranty / Software License
9.1 ................................................. Limited Warranty 9-2
9.2 .................................................Software License 9-3
Chapter 1. Introduction

CHAPTER 1. INTRODUCTION 1-3
7091M1005
08/28/00
This chapter describes the scope and maintenance concept, as well as recommended safety
practices and manual organization.

CHAPTER 1. INTRODUCTION 1-3
7091M1005
08/28/00
Scope
This is an owners manual for the IRIDEONAR500exterior wash luminaire. The
information in this manual requires some basic knowledge of optics, electronics, and electrical
repair. This manual is divided into nine major topics: Introduction; Description; Installation;
Test; Troubleshooting; Maintenance; Optional Accessories; Replacement Parts/Wiring
Diagrams; and Software License/Limited Warranty.
Maintenance Concept
Luminaire installation, power connections, or internal electrical component repair should be
performed by an electrical contractor only. Maintenance, such as changing a lamp or linear
actuator, may be performed by in-house maintenance personnel. Please read each procedure
section thoroughly before performing any maintenance.
Recommended Safety Practices
• Extreme caution must be taken when working with any electrical
device.
• Never perform internal maintenance or external cable repair when
power is supplied to luminaire.
• Do not expose internal components to moisture, dust, or dirt.
• Do not drop, drag, or hammer on any part of the luminaire.
• Do not touch lamp, reflector, or dichroic filters with uncovered
fingers.
• The head assembly is very heavy; loosen with caution.
• Do not mount stanchion assembly up-side down. The stanchion
contains a very heavy ballast assembly that would slide out when
stanchion cap is removed.
• Electronic Theatre Controls, Inc. is not liable for any personal injury
or equipment damage that may occur when performing luminaire
maintenance.
WARNING: This appliance must be earthed. Flammable objects must be kept
a minimum of 13′-2″(4.0 m) from lens.
CAUTION: Be careful when loosening 1/4 inch Allen screw, 3/4 inch bolt
and 1 1/4 inch nut installed in tilt tube clamp and remote mounting foot. This
unit is very heavy and could rotate quickly once it is loosened.
WARNING: The MSD700 Watt, HID lamp must be changed at 3000 hours of
life. Failure to change lamp may result in catastrophic failure of bulb causing
extensive damage to luminaire.
Manual Organization
This manual contains all relevant information pertaining to the installation, testing,
troubleshooting, and maintenance of the AR500 standard and remote luminaire versions. In the

CHAPTER 1. INTRODUCTION 1-3
7091M1005
08/28/00
Installation chapter, the “Luminaire Installation Procedure” section contains complete
installation instructions for both standard and remote luminaire versions.
Reference dimensions and measurements are given in English and metric.
It is important to note that this manual incorporates distinct type styles to differentiate between
various types of text. These styles are defined as follows:
Boldface Trademarked product. Example: AR500
luminaire
Underline References to other chapters
or sections in this manual
Example: See
Wiring to
Stanchion.
WARNING: Indicates incorrect procedure may cause bodily harm.
CAUTION: Indicates incorrect procedure may cause equipment
damage.
Note: Indicates particular items of interest.
Technical Assistance
The AR500 luminaire is a low maintenance luminaire, but in the event of malfunction,
troubleshooting and repair procedures have been included. For further assistance or questions
regarding the AR500 luminaire, please contact
the Electronic Theatre Controls, Technical Support staff in Middleton, Wisconsin U.S.A. at 608-
831-4116 or toll-free at 800-688-4116. You may also Email ETC at [email protected].