PRG VL5+ User manual

USER MANUAL
02.9634.0002
VL5+™Wash Luminaire
VL5Arc+™Wash Luminaire

VL5+™, VL5+Arc™, AutoPar™, PRG Series 400™, Mbox Extreme™, Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and Visionary™3D
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.
VL5™, VL5Arc™, VL5B™, VL6™, VL6B™, VL6C™, VL7™, VL7B™, Smart Repeater™, Series 200™, Series 300™, APS6™, C3™,
DICHRO❋WHEEL™, VACU❋DEP™, VARI❋BEAM™ and the Vari-Lite Asterisk are trademarks owned by Genlyte Thomas Group LLC.
All other brand or product 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 latest version.
PRG assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual.
VL5+™ Series Wash Luminaire User Manual
Version as of: September 10, 2008 | PRG part number: 02.9634.0002
Production Resource Group
Dallas Office
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
www.prg.com
VL5+™ Series Wash Luminaire User Manual
©2008 Production Resource Group, LLC. All Rights Reserved.

FOREWORD
02.9634.0002 i
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.
FCC
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
ii 02.9634.0002
WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXPOSURE TO EXCESSIVE
ULTRAVIOLET 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.
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.

FOREWORD
02.9634.0002 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.

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
iv 02.9634.0002
Revision History
This manual has been revised as follows:
Version Release Date Notes
BASIC September 10, 2008 Initial release.

TABLE OF CONTENTS
02.9634.0002 v
Table of Contents
Introduction
About This Manual .......................................................................................................................... 1
Additional Documentation............................................................................................................... 1
Customer Service ............................................................................................................................. 2
Chapter 1. Description
Features
Overview.......................................................................................................................................... 4
Upgrade Summary ........................................................................................................................... 5
Components
Exterior Components ....................................................................................................................... 6
Interior Head Components............................................................................................................... 7
Interior Yoke Components ............................................................................................................... 8
Replacement Items and Accessories................................................................................................ 9
Operation Overview
External Power and Data Configuration ........................................................................................ 10
Smart Repeater Units ..................................................................................................................... 11
Internal Power and Data Distribution ............................................................................................ 13
Chapter 2. Installation
Mounting the Luminaire
Attaching a Truss Hook ................................................................................................................. 16
Hanging Methods........................................................................................................................... 17
Standard Hang ......................................................................................................................... 17
Three-Point Hang .................................................................................................................... 19
Custom Hang........................................................................................................................... 19
Floor Mounting .............................................................................................................................. 20
System Connection
Connecting to System (Typical)..................................................................................................... 22
Three-Phase Power Source...................................................................................................... 22
Input Voltage........................................................................................................................... 23
Configuring Modular Rack, C3 Modules and APS6 Modules................................................ 24

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
vi 02.9634.0002
Chapter 3. Operation
Power-Up Procedures
Powering Up the Luminaire........................................................................................................... 30
Lamp Douse Switch (VL5Arc+).................................................................................................... 31
Smart Repeater Modes
Setting Smart Repeater DMX512 Modes ...................................................................................... 32
DMX512 Mapping
DMX512 Mapping by Mode.......................................................................................................... 34
DMX Mode 1 .......................................................................................................................... 34
DMX Mode 2 .......................................................................................................................... 35
DMX Mode 3 .......................................................................................................................... 36
DMX Mode 4 .......................................................................................................................... 37
DMX Mode 5 .......................................................................................................................... 38
DMX Mode 6 .......................................................................................................................... 39
DMX Mode 7 .......................................................................................................................... 40
DMX Mode 8 .......................................................................................................................... 41
DMX Mode 9 .......................................................................................................................... 42
DMX Mode 10 ........................................................................................................................ 43
Timing Channels ............................................................................................................................ 44
Color............................................................................................................................................... 45
Chapter 4. Troubleshooting and Maintenance
Troubleshooting
Basic Troubleshooting Guide......................................................................................................... 52
Equipment Handling
Proper Lamp Servicing and Operation........................................................................................... 53
Routine Maintenance
Replacing the Lamp (VL5+).......................................................................................................... 54
Replacing the Lamp (VL5Arc+).................................................................................................... 55
Adjusting the Lamp (VL5Arc+) .................................................................................................... 56
Replacing the Front Lens............................................................................................................... 58
Installing a Tophat/Gelframe ......................................................................................................... 59
Cleaning the Luminaire.................................................................................................................. 61

TABLE OF CONTENTS
02.9634.0002 vii
Appendix A. Technical Specifications
VL5+™ Wash Luminaire............................................................................................................... 64
Description .............................................................................................................................. 64
Programmable Functions......................................................................................................... 64
VL5Arc+™ Wash Luminaire......................................................................................................... 65
Description .............................................................................................................................. 65
Programmable Functions......................................................................................................... 65
Appendix B. Glossary
Glossary of Terms ................................................................................................................... 68

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
viii 02.9634.0002
Notes

INTRODUCTION
02.9634.0002 1
Introduction
About This Manual
This manual provides necessary information regarding product safety, installation, and operation for
the following equipment:
•VARI❋LITE® VL5+™ Wash Luminaire (20.9634.0002)
•VARI❋LITE® VL5Arc+™ Wash Luminaire (20.9647.0002)
Familiarizing yourself with this information will help you get the most out of your lighting system.
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 extended service information, refer to the following manual:
• VL5+™ Series Wash Luminaire Service Manual (02.9634.0020)
For additional information regarding the use of VL5™ series luminaires in lighting systems, refer to
the following manuals:
•VARI❋LITE Series 200™/300™ System Installation and Checkout Manual (02.3004.0200)
•VARI❋LITE Interface Devices Service Manual (02.5014.0010)
•VARI❋LITE Series 300™ Modular Rack Service Manual (02.9640.0010)
• Virtuoso® System Installation and Checkout Manual (02.3004.0400)
• Controlling VARI❋LITE Equipment Using a DMX512 Console (02.3004.0300.54)
Support for this product is provided by Production Resource Group. Technical updates regarding this
equipment are issued by the PRG Dallas office (see “Customer Service” on page 2). These updates are
in the form of Technical Bulletins, which contain procedures for equipment upgrades, retrofits, and
repairs not found in the existing manual(s).
For additional documentation, please visit our support tech center at: www.prg.com/support

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
202.9634.0002
Customer Service
Our comprehensive technical services department ensures you get the full benefit of being a PRG
customer. Whether your needs are simple or complex, our full-time staff of experienced professionals
are on-hand to provide support. For assistance, contact your nearest PRG office:
For additional resources and documentation, please visit our website at: www.prg.com
PRG Dallas (International Service)
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
Ph: 214.630.1963
Fx: 214.630.5867
Service Fx: 214.638.2125
Service Email: [email protected]
PRG Hi-Tech Atlanta
1053 Willingham Dr.
Atlanta, Georgia 30344
Ph: 404.214.4800
Fx: 404.214.4801
PRG Chicago
90 Rawls Rd.
Des Plaines, Illinois 60018
Ph: 847.227.5171
Fx: 847.557.9033
PRG Las Vegas
6050 South Valley View Blvd.
Las Vegas, Nevada 89118
Ph: 702.942.4774
Fx: 702.942.4775
PRG Los Angeles
9111 Sunland Blvd.
Sun Valley, California 91352
Ph: 818.252.2600
Fx: 818.252.2620
PRG Nashville
8351 Eastgate Blvd.
Mount Juliet, Tennessee 37122
Ph: 615.834.3190
Fx: 615.834.3192
PRG New Jersey
7777 West Side Avenue
North Bergen, New Jersey 07047
Ph: 201.758.4000
Fx: 201.758.4312
PRG Orlando
1902 Cypress Lake Dr.
Orlando, Florida 32837
Phone: [phone]
Fax: [phone]
PRG Canada
2480 Tedlo Street
Mississauga, Ontario L5A 3V3 Canada
Ph: 905.270.9050
Fx: 905.270.2590
PRG Asia
Asagami Fukagawa Logistics Center B-4F
2-2-1 Shiohama, Koto-ku, Tokyo, Japan 135-0043
Ph: 81.3.5439.4091
Fx: 81.3.5439.4092
PRG Europe
The Cofton Centre
Grovely Lane
Longbridge, Birmingham
B31 4PT, England
Ph: +44 (0) 845.470.6400
Fx: +44 (0) 845.470.6401
Essential Lighting
Unit E
Imber Court Trading Estate
Orchard Lane
East Molesey, Surrey
KT8 0BY, England
Ph: +44 (0) 208.335.6000
Fx: +44 (0) 208.398.7205

02.9634.0002 3
1.
Description
This chapter contains descriptions of luminaire features, components, and operations.
• Features
• Components
• Operation Overview

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
402.9634.0002
Features
Overview
The VL5+™ Wash Luminaire from PRG Lighting is an
improved version of the VARI❋LITE® VL5™ Wash
Luminaire, while the VL5Arc+™ Wash Luminaire is an
improved version of the VARI❋LITE® VL5Arc™ Wash
Luminaire. All VL5+ Series Luminaires feature newly designed
Blue, Amber and Magenta color filters to provide improved
color matching from luminaire to luminaire. A new reflector has
been installed to increase light output, and a thicker, more
durable UV glass has been relocated to the rear of the luminaire
head to reduce interior heat. Upgrades to the ventilation system
provide superior reliability for all circuit boards and motors,
while upgraded wiring and connectors further enhance the
dependability and consistency of all motors and pan/tilt
mechanisms. In addition, improvements to the VL5Arc
luminaire’s ignitor technology reduce hot restrike time from 8
minutes (VL5Arc) to 1 minute (VL5Arc+).
The VL5+ Series Luminaires can be controlled by PRG consoles or a wide variety of DMX512
consoles. Operation is identical to the standard VL5 models.
Features:
• 3200° tungsten halogen lamp source (VL5+) or 575W arc source (VL5Arc+).
• Lamp power provided by conventional dimmers or C3™ dimmer modules (VL5+) or APS6™
power supply modules (VL5Arc+).
• Luminaire power and data provided by either a Smart Repeater™ or Smart Repeater™ Plus unit.
• 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.
• Internal douser provides intensity control.
• Interchangeable front lens.
• Low expansion glass reflector.
• Solid state ignitor with a hot restrike time of 1 minute (VL5Arc+).
• Smooth, time-controlled continuous 360° pan and 270° tilt movement.
• Control by PRG consoles or a wide variety of DMX512 consoles.
• Compatible with Series 300™ truss hooks for versatile hanging configurations.
• Optional floor stand.

DESCRIPTION : FEATURES
02.9634.0002 5
1
Upgrade Summary
The VL5+™ Series Wash Luminaires feature many improvements over the standard VL5™ Wash
Luminaire and VL5Arc™ luminaire, both to the exterior and interior components. The following is a
complete summary of improvements:
• Improved color matching from luminaire to luminaire. This improvement was accomplished by
installing newly designed Blue, Amber and Magenta color filters (made using an improved ion-
assist process). The new color filters have less color shift problems. An anti-backlash drive ring
was also installed to improve color match and dimmer accuracy, and increase repeatability of those
functions.
• Increased reliability of the Controller PCB. This improvement was accomplished by adding
ventilation holes to improve air flow.
• Increased reliability of Pan and Tilt functions. This improvement was accomplished by retrofitting
the pan/tilt mechanisms with new clutches and encoders, replacing the pan/tilt cable assemblies
and installing a newly designed pan stop which prevents sticking.
• Increased reliability of power and data transmission. This improvement was accomplished by
replacing the Input Cable Assembly.
• Increased reliability of color and dimmer functions. This improvement was accomplished by
replacing all linear actuator motors and connectors.
• Improved light output. This improvement was accomplished by installing a new reflector.
• Improved yoke covers. This improvement was accomplished by installing new yoke sheet metal
which adds support to the yoke covers which will prevent damage to them during normal use.
Ventilation holes have been added to the yoke leg for PCB cooling and air flow, along with heavy
duty yoke covers and new safety tethers to prevent covers from falling off.
• Reduced head temperature. This improvement was accomplished by moving the UV glass to the
rear of the luminaire head, while also switching to a thicker, more durable UV glass. This will
allow replacement of the glass without the need to disassemble the luminaire, along with reducing
the temperature of the Blue/Amber bulkhead, extending the life of filter pads and linear actuators.
• Increased reliability of motor harness. This improvement was accomplished by designing a new
harness with highly stranded 24AWG PVC wire which makes a more reliable connection in the
MTA connectors.
•(VL5Arc+ only) Increased reliability of the lamp strike. This improvement was accomplished by
installing a new solid state ignitor which reduces hot restrike time from 8 minutes (VL5Arc) to 1
minute (VL5Arc+).
•(VL5Arc+ only) Added lamp douse switch to yoke cross-member. The switch should be used to
douse the arc lamp before disconnecting the pigtail cable. This will prevent damage to the contacts
in the CPC connector, which can be caused by drawing an arc during disconnect.

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
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Components
Exterior Components
The following illustration shows the exterior VL5+™ Series Wash Luminaire components and
controls.
Figure 1-1: Exterior Components
Head Assembly
Hinged Backcap Assembly
(to access lamp for replacement)
Lamp Adjustment Controls
Yoke
Hanging Safety Cable
Series 300
Truss Hook
Yoke Leg
Safety Cable
Assembly
Lamp
Douse
Switch
Input Cable
Lamp Adjustment
Screws
Latch
Hinge

DESCRIPTION : COMPONENTS
02.9634.0002 7
1
Interior Head Components
The following illustration shows the major sub-assemblies located in the VL5+™ Series Wash
Luminaire Head.
Figure 1-2: Head Components
Hinged Rail Assembly
Lamp
Reflector
Latched Rail Assembly Blue/Amber Bulkhead
Magenta/Dimmer Bulkhead
Front Lens
Motor Assembly
Motor Assembly

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
802.9634.0002
Interior Yoke Components
The following illustration shows the major sub-assemblies located in the VL5+™ Series Wash
Luminaire Yoke.
Figure 1-3: Yoke Components
Pan
Tilt
Main
Relay
TILT-SIDE YOKE LEG BOARD-SIDE YOKE LEG
To determine which yoke leg is which, without
having to remove the covers:
Position the luminaire so that you are facing the front
with the latch facing to the left. The tilt-side yoke leg
is to the right; the board-side yoke leg is to the left.
BOARD-SIDE
TILT-SIDE
YOKE LEG
YOKE LEG
Latch
Ignitor
Mechanism
Controller
PCB
Mechanism
YOKE TOP VIEW
Pan
Mechanism
PCB

DESCRIPTION : COMPONENTS
02.9634.0002 9
1
Replacement Items and Accessories
The following items can be ordered from PRG. (Please order by PRG part number.)
* Cannot exceed 200 ft. in length.
PRG P/N Accessory
71.2526.0100 1000W 100 VAC Tungsten Lamp (VL5+)
71.2526.0120 1000W 120 VAC Tungsten Lamp (VL5+)
71.2526.0230 1000W 230 VAC Tungsten Lamp (VL5+)
71.2529.0120 1200W 120 VAC Tungsten Lamp (VL5+)
71.2528.0575 575W Arc Lamp (VL5Arc+)
22.9634.0206 Top Hat/Gel Holder with Rings
22.9634.0207 Top Hat/Gel Holder without Rings
22.9634.0145 Series 300 Safety Cable
22.9634.0161 Series 300 Floor Stand
22.9634.0195 Series 300 Third-Point Truss Hook
22.9634.0217 Series 300 Double Truss Hook
25.7042.0006 6 ft. Shielded Series 300 Lamp Cable
25.7042.0012 12 ft. Shielded Series 300 Lamp Cable
25.7042.0020 20 ft. Shielded Series 300 Lamp Cable
25.7155.0050 50 ft. Shielded Series 300 Lamp Cable (Smart Lamp Plus)
25.7155.0100 100 ft. Shielded Series 300 Lamp Cable (Smart Lamp Plus)
25.7155.0XXX Custom Length Shielded Series 300 Lamp Cable *
20.9623.0111 Smart Repeater Unit
20.9623.0600 Smart Repeater Plus Unit
22.9620.0217 Series 200 Truss Hook (2 each required for Smart Repeater)
20.9625.0018 Series 300 Molded Plastic Six Luminaire Case
20.9625.0024 Series 300 Molded Plastic Work Trunk
42.5002.0004 Clear Lens
42.5002.0005 Stipple Lens
42.5002.0006 8-Row Lenticular Lens
42.5002.0007 10-Row Lenticular Lens
42.5002.0008 12-Row Lenticular Lens

VL5+™ SERIES WASH LUMINAIRE USER MANUAL
10 02.9634.0002
Operation Overview
External Power and Data Configuration
Control data signals, 24Vdc, and lamp power are provided by a Series 300™ Smart Repeater™ or
Smart Repeater™ Plus processing unit to Series 300™ luminaires via lamp cables. Up to (6) VL5+
Series Luminaires may be powered from a single Smart Repeater or Smart Repeater Plus unit. Lamp
power for VL5+™ Wash Luminaires is provided by conventional dimmers or C3™ dimmer modules
located in a Series 300™ Modular Rack. Lamp power for VL5Arc+™ Wash Luminaires is provided
by APS6™ power supply modules also located in a Series 300 Modular Rack. The following diagram
shows how data and power are distributed to VL5+ Series Luminaires in a sample DMX512 system.
Note: Refer to the VARI❋LITE® Interface Devices Service Manual (02.5014.0010), VARI❋LITE
Series 300 Modular Rack Service Manual (02.9640.0010) and Controlling VARI❋LITE Equipment
Using a DMX512 Console Manual (02.3004.0300.52) for more information about the associated
equipment.
Figure 1-4: Power and Data Configuration (Typical DMX512 System)
S300 LAMP RUN
POWER INPUT
APS TRUNK CABLE
(LAMP POWER)
S300 MODULAR RACK
INPUT OUTPUT
S300 SMART REPEATER OR
INPUT OUTPUT
VL5+
DMX CONSOLE
120/208 VOLT 3Ø AC LINE
SMART REPEATER PLUS UNIT
W/ C3 AND APS6 MODULES
VL5A+