PRG VARI LITE VL5 User manual

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VARI❋LITE VL5™WASH LUMINAIRE
SERVICE MANUAL

AutoPar®, Bad Boy®, PRG Series 400®, Mbox Extreme®, OHM™, V476™, V676™, Virtuoso®, Virtuoso® DX, Virtuoso® DX2,
and VL6C+™ are trademarks of Production Resource Group, LLC, registered in the U.S. and other countries.
VARI❋LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries.
All other brand names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies.
This manual is for informational use only and is subject to change without notice. Please check www.prg.com for the latest version.
PRG assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual.
VL5™ Wash Luminaire Service Manual
Version as of: October 26, 2011
PRG part number: 02.9634.0010 F
Production Resource Group
Dallas Office
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
www.prg.com
VL5™ Wash Luminaire Service Manual
©2006-2011 Production Resource Group, LLC. All Rights Reserved.

VL5 ™ WASH LUMINAIRE SERVICE MANUAL I
FOREWORD
Compliance Notice
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1) This device
may not cause harmful interference, and 2) This device must accept any interference received, including interference
that may cause undesired operation.
Conforms to:
UL STD 1573
Certified to:
CAN/CSA STD E598-1
CAN/CSA STD E598-2-17
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:
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) PRG luminaires have been designed for use only with specific lamps. Note lamp type before replacing. Installing
another type of lamp may be hazardous.
2) PRG 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) Minimum distance from head to any flammable object is 2m.
WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK
1) PRG luminaires are designed for dry locations only. Exposure to rain or moisture may damage luminaire.
2) Disconnect power before servicing any PRG equipment.
3) Servicing to be performed by qualified personnel only.
WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXPOSURE TO EXCESSIVE ULTRAVIO-
LET RADIATION
1) PRG luminaires may use an HID type lamp which produces UV radiation. DO NOT look directly at lamp.
2) It is hazardous to operate luminaires without complete lamp enclosure in place or when lens is damaged. Lenses
or UV shields shall be changed if they have become visibly damaged to such an extent that their effectiveness is
impaired.
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

II VL5 ™ WASH LUMINAIRE SERVICE MANUAL
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. Service and maintenance should
be performed only by qualified personnel as determined by the high pressure lighting fixture manufacturer.
2) Arc lamps generate intense heat. Disconnect power and allow lamp to cool for 15 minutes before relamping.
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) The lamp shall be changed if it has become damaged or thermally deformed.
5) Wear eye protection when relamping.
6) If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with lint-free cloth before
installing or powering up the luminaire.
7) Serious injury may result from the generation of ozone by this lamp system. A proper means of venting must be
provided.

VL5 ™ WASH LUMINAIRE SERVICE MANUAL III
Notes de sécurité
Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement
important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que
toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant
l’installation et l’utilisation de cet appareil.
Les symboles de sécurité utilisés dans ce guide sont les suivants :
CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE PROTÉGER CONTRE LES DÉCHARGES
ÉLECTRIQUES, LES INCENDIES, L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRAÎNER DES BLESSURES.
AVERTISSEMENT: Risque d’ explosion.
1) Le service et le maintenance ne devront être assurés que par des personnes qualifiées comme precisé par le
frabricant des lampes à haute pression.
2) Des vêtement de protection et les procédures précisées dans le manuel du frabricant doit être fournies.
AVERTISSEMENT: Réglage des lampes
1) Chaleur intense. Débrancher le matériel et laisser refroidir pendant 15 minutes avant de rallumer.
2) Risque l’incendie. N’utilise que des METAL HALIDE MSR 700 Watt G 22 Base.
AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS
UV
1) Risque d’explosion en cas de radiation ultraviolet imprantes.
2) Ne pas intervener en l’absence de confinement de la lampe en place ou quand la lentille est abîmée.
AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT ENTRAÎNER DES
BLESSURES
1) Chaleur intense. Eviter tout contact avec des personnes ou des tissues. Attention, de graves blessures peuvent
résulter de production d’ozone par cette lampe. Un système de ventilation adapté doit être fournies
2) La température de surface = 300.c
La temperature de l’ambiance = 50.c
3) Ne convient pas pour un usage résidential.
4) Utilisable seulement dans les locaux secs
ATTENTION Ce symbole annonce que l’appareil risque d’être endommagé.
AVERTISSEMENT Ce symbole annonce qu’il y a risque d’accident grave ou même fatal.

IV VL5 ™ WASH LUMINAIRE SERVICE MANUAL
Revision History
This manual has been revised as follows:
Version Release Date Notes
C January 28, 2004 Miscellaneous updates.
D February 15, 2005 Miscellaneous updates.
E1 February 7, 2008 Miscellaneous updates.
E2 December 3, 2010 Updated book format. (No change to technical information.)
F October 26, 2011 Added Yoke Leg Cover Assembly to IPB “Covers and Hooks Assy.”

VL5 ™ WASH LUMINAIRE SERVICE MANUAL V
TABLE OF CONTENTS
Introduction
About This Manual........................................................................................................................................................................ 1
Additional Documentation............................................................................................................................................................ 1
Special Note ................................................................................................................................................................................. 1
Customer Service......................................................................................................................................................................... 2
Chapter 1. Description
Features
Overview....................................................................................................................................................................................... 4
Standard Features................................................................................................................................................................. 4
Specific Features................................................................................................................................................................... 4
Major Components
Exterior Components.................................................................................................................................................................... 6
Head Components ....................................................................................................................................................................... 7
VL5/VL5B Luminaire Head Components .............................................................................................................................. 7
VL5Arc Luminaire Head Components................................................................................................................................... 8
Yoke Components ........................................................................................................................................................................ 9
Principles of Operation
Power and Data Flow Diagrams................................................................................................................................................. 10
VL5/VL5B Luminaire............................................................................................................................................................ 10
VL5Arc Luminaire ................................................................................................................................................................ 11
Chapter 2. Maintenance
Equipment Handling
Solid State Electronics ............................................................................................................................................................... 14
Testin g
Smart Repeater Test Mode Operation........................................................................................................................................ 15
Smart Repeater Test Codes ....................................................................................................................................................... 18
Maintenance Procedures
Head Assembly .......................................................................................................................................................................... 19
VL5/VL5B Lamp Replacement ............................................................................................................................................ 19
VL5 Arc Lamp Replacement ............................................................................................................................................... 20
VL5Arc Lamp Adjustment ................................................................................................................................................... 21
VL5Arc Lens and Bellows/Motor Assembly Replacement.................................................................................................. 23
Separating VL5/VL5B Head and Yoke Assemblies............................................................................................................. 25
Separating VL5Arc Head and Yoke Assemblies ................................................................................................................. 28
Separating Front and Rear Bulkheads ................................................................................................................................ 32
Color Filter and Diffuser/Douser Panel Replacement ......................................................................................................... 34
Drive Ring Pin Replacement................................................................................................................................................ 36
Linear Actuator Motor Replacement ................................................................................................................................... 40
Yoke Assembly ........................................................................................................................................................................... 42
Tilt Mechanism Assembly Replacement ............................................................................................................................. 42
Pan Mechanism Assembly Replacement............................................................................................................................ 45
Pan/Tilt Belt Tension Adjustment........................................................................................................................................ 49
LCB PCB Assembly Replacement ...................................................................................................................................... 50
VL5Arc Luminaire Ignitor Board Assembly Replacement ................................................................................................... 51
VL5Arc Luminaire Relay Replacement................................................................................................................................ 52
Servicing
Cleaning...................................................................................................................................................................................... 54
VL5Arc Lens Cleaning and Fluid Level Check .................................................................................................................... 54
Color Filter and Reflector Cleaning ..................................................................................................................................... 54
Cleaning the Luminaire........................................................................................................................................................ 55

VI VL5 ™ WASH LUMINAIRE SERVICE MANUAL
Chapter 3. Illustrated Parts Breakdown
Drawing Trees
VL5 Drawing Tree........................................................................................................................................................................ 58
VL5Arc Drawing Tree .................................................................................................................................................................. 59
VL5B Drawing Tree ..................................................................................................................................................................... 60
To p A s s e m b ly
VL5 Series Wash Luminaire ........................................................................................................................................................ 61
Covers and Hooks
Covers and Hook Assembly ....................................................................................................................................................... 62
Head
VL5/VL5B Head Assembly.......................................................................................................................................................... 65
VL5Arc Head Assembly .............................................................................................................................................................. 67
VL5/VL5B Hinged Rail Assembly................................................................................................................................................ 69
VL5Arc Hinged Rail Assembly .................................................................................................................................................... 71
VL5 Latched Rail Assembly........................................................................................................................................................ 73
VL5Arc Latched Rail Assembly................................................................................................................................................... 74
VL5 Blu/Amb Bulkhead Assembly.............................................................................................................................................. 75
VL5 Blu/Amb Bulkhead Assembly (cont.)................................................................................................................................... 76
VL5B Mag/Amb Bulkhead Assembly.......................................................................................................................................... 77
VL5 Mag/Dif Bulkhead Assembly ............................................................................................................................................... 79
VL5Arc Magenta/Dimmer Bulkhead Assembly........................................................................................................................... 81
VL5B Blu/Dif Bulkhead Assembly............................................................................................................................................... 83
VL5 Center Hub Assembly.......................................................................................................................................................... 85
Filter Panel Assemblies............................................................................................................................................................... 86
VL5 Drive Ring Assembly ........................................................................................................................................................... 87
VL5 Light Baffle Assembly.......................................................................................................................................................... 88
VL5 Diffuser Panel Assembly...................................................................................................................................................... 90
VL5Arc Dimmer Blade Assembly................................................................................................................................................ 91
VL5 Blue/Amber Motor Assembly .............................................................................................................................................. 92
VL5 Magenta/Diffuser Motor Assembly...................................................................................................................................... 93
VL5Arc Lens and Bellows/Motor Assembly ............................................................................................................................... 94
VL5Arc Motor-Bellows Assembly ............................................................................................................................................... 95
Yoke
Yoke Assembly ........................................................................................................................................................................... 97
VL5 Pan/Tilt Mechanism Assembly .......................................................................................................................................... 100
VL4 Tilt Clutch Assembly.......................................................................................................................................................... 102
VL5Arc Ignitor Board Assembly................................................................................................................................................ 103
VL7 Ignitor PCB Assembly ....................................................................................................................................................... 104
Lamp Control PCB Assembly................................................................................................................................................... 105
VL5 PCB Assembly Components Kit........................................................................................................................................ 106
VL6 PCB Assembly Components Kit........................................................................................................................................ 109
Cables
#6 Ring/#6 Ring 11" GND Strap Assembly .............................................................................................................................. 113
#6 Ring/18-14AWG Faston 11" GND Strap Assembly............................................................................................................. 114
#8 Ring/#8 Ring 11" GND Strap Assembly .............................................................................................................................. 115
Tilt Cable Assembly .................................................................................................................................................................. 116
Pan Cable Assembly................................................................................................................................................................. 117
VL5 Ground Safety Cable Assembly ........................................................................................................................................ 118
VL5 Input W/Grn-Yel Cable Assembly...................................................................................................................................... 119
Ignitor Board Output Cable Assembly...................................................................................................................................... 120
Ground Cable Assembly........................................................................................................................................................... 121
VL5Arc Ignitor Cable Assembly ................................................................................................................................................ 122
VL5Arc Bulb Wires Cable Assembly......................................................................................................................................... 123
Bellows Motor Extension Cable Assembly............................................................................................................................... 124
VL5A Input Cable Assembly Grn-Yel ........................................................................................................................................ 125
VL5Arc Disconnect Cable Assembly ........................................................................................................................................ 126

VL5 ™ WASH LUMINAIRE SERVICE MANUAL VII
Appendix A. Technical Bulletins
List of Technical Bulletins ......................................................................................................................................................... 128
Appendix B. Wiring Diagrams
VL5/VL5B Wiring Diagram........................................................................................................................................................ 129
VL5Arc Wiring Diagram ............................................................................................................................................................ 130

VIII VL5 ™ WASH LUMINAIRE SERVICE MANUAL
Notes

VL5 ™ WASH LUMINAIRE SERVICE MANUAL 1
INTRODUCTION
About This Manual
This manual provides testing, maintenance procedures, and illustrated parts breakdowns for the following equipment:
+ VARI❋LITE VL5™ Wash Luminaire (20.9634.0001)
+ VARI❋LITE VL5Arc™ Wash Luminaire (20.9647.0001)
+ VARI❋LITE VL5B™ Wash Luminaire (20.9634.0201)
WARNING: It is important to read ALL accompanying safety and installation instructions to avoid damage to
the product and potential injury to yourself or others.
Additional Documentation
For additional information regarding the use of VL5 series luminaires in lighting systems, refer to the following
manuals:
+ VARI❋LITE Interface Devices Service Manual (02.5014.0010)
+ VARI❋LITE Series 300™ Modular Rack Service Manual (02.9640.0010)
Special Note
Customer support for this product is provided by Production Resource Group (not Vari-Lite). Refer to "Customer
Service" on page 2.
Technical updates regarding this product are issued by the PRG Dallas office.

2VL5 ™ WASH LUMINAIRE SERVICE MANUAL
Customer Service
For technical assistance, contact the PRG International Service Center or contact your nearest PRG office. Contact
information for all PRG office locations can be found on our website at: www.prg.com/about-us/locations/
PRG Dallas (International Service)
8617 Ambassador Row, Suite 120
Dallas, Texas 75247 USA
Phone: [phone]
Fax: [phone]
Service Fax: [phone]
Service Email: [e-mail]
For additional resources and documentation, please visit our website at: www.prg.com

1.
DESCRIPTION
+FEATURES
+MAJOR COMPONENTS
+PRINCIPLES OF OPERATION

4VL5 ™ WASH LUMINAIRE SERVICE MANUAL
FEATURES
Overview
VL5 Wash Luminaires are available in three different configurations: VL5, VL5Arc, and VL5B wash luminaires. A label,
located on the yoke, identifies the VL5Arc and VL5B luminaires.
Standard Features
VL5 wash luminaires contain the following standard features:
+ Enhanced DICHRO❋TUNE cross-fadable dichroic colors feature independent cyan, magenta and amber color
control. Smooth, timed color crossfades can occur in as little as 0.7 second.
+ Control by PRG consoles or a wide variety of DMX512 consoles.
+ Smooth, time controlled continuous 360° pan and 270° tilt movement.
+ Power is provided by a Smart Repeater unit to operate all luminaire systems except the lamp, which is powered
by a specific external device, depending on which VL5 luminaire version is being operated.
+ 8-inch glass dichroic cold-mirror reflector.
+ A truss hook and floor stand allow flexible installation.
Specific Features
Each individual luminaire configuration has the following features:
VL5/VL5B models
+ 3200° tungsten halogen lamp source.
+ Lamps are powered by conventional dimmers or C3 dimmer modules through the smart repeater unit.
+ Interchangeable front lens work with the internal diffusing mechanism to provide a wide range of beam control
sizes and shapes.
+ Textured diffusion panels intercept the beam providing a continuous, time variable diffusion range for each
available lens.
Note: The only difference between the VL5 and VL5B luminaires, is that the VL5B luminaire is a pastel version of the
VL5 luminaire.
VL5 VL5Arc VL5B

VL5 ™ WASH LUMINAIRE SERVICE MANUAL 5
VL5Arc models
+ 575W arc lamp source.
+ Internal douser provides intensity control.
+ VARI❋BEAM mechanism provides continuous time beam control or standard VL5Arc lenses may be used.
+ Lamps are powered by the APS6 module.

6VL5 ™ WASH LUMINAIRE SERVICE MANUAL
MAJOR COMPONENTS
Exterior Components
The following illustration shows the major VL5 series wash luminaire components:
Truss Hook
Bracket Assembly
Head Assembly Covers
(Top and Bottom)
Yoke Assembly
Ac Input Cable
NOTE:
VL5 luminaire shown.

VL5 ™ WASH LUMINAIRE SERVICE MANUAL 7
Head Components
VL5/VL5B Luminaire Head Components
The following illustration shows the major sub-assemblies located in the VL5/VL5B luminaire head assemblies:
.
Hinged Rail Assembly
Lamp
Reflector
Blue/Amber Bulkhead Assembly (VL5)
Magenta/Amber Bulkhead Assembly (VL5B)
Magenta/Diffuser Bulkhead Assembly (VL5)
Blue/Diffuser Bulkhead Assembly (VL5B)
Latched Rail
Assembly

8VL5 ™ WASH LUMINAIRE SERVICE MANUAL
VL5Arc Luminaire Head Components
The following illustration shows the major sub-assemblies located in the VL5Arc luminaire head assembly:
Hinged Rail Assembly
Lamp
Reflector
Latched Rail Assembly
Blue/Amber Bulkhead Assembly
Magenta/Dimmer
Bulkhead Assembly
Lens and Bellows/Motor Assembly

VL5 ™ WASH LUMINAIRE SERVICE MANUAL 9
Yoke Components
The following illustration shows the major sub-assemblies located in the VL5 series wash luminaire head assemblies:
Board-Side Yoke
Leg (VL5Arc) Tilt-Side Yoke Leg (VL5Arc)
Pan Mechanism Assembly
Tilt Mechanism Assembly
Lamp Control Board
PCB Assembly
Ignitor Board Assembly
(VL5Arc only)
Relay Assembly (VL5Arc Only)
Terminal Strip (VL5/VL5B Only)

10 VL5 ™ WASH LUMINAIRE SERVICE MANUAL
PRINCIPLES OF OPERATION
Power and Data Flow Diagrams
VL5/VL5B Luminaire
The following diagram shows how data and power are distributed in the VL5/VL5B luminaires:
PAN
MOTOR TILT
MOTOR
+5V
LAMP CONTROL PCB
PAN
ENCODER TILT
ENCODER
DATA
DATA
LAMP
DATA
DATA
+24V
+24V
+24V
DATA
CPC CONNECTOR
+5V
DATA
+24V +24V
BLUE
MOTOR MOTOR
AMBER
DATA
MAGENTA
MOTOR DIFFUSER
MOTOR
DATA DATA
TERMINAL
BOARD