Vari Lite VL550 User manual

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
ii 25 March 2011 02.9683.0010 0
Neutrik®, PowerCon®, and EtherCon® are registered trademarks of Neutrik, Inc.
All other brand or product names which may be mentioned in this manual are trade-
marks or registered trademarks of their respective companies or organizations.
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. Philips
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 Philips Vari-Lite,
10911 Petal Street, Dallas, Texas 75238.
Version as of: 25 March 2011
Part number: 02.9683.0010 0
VL550 Wash Luminaires Service Manual
©2003 - 2011, Vari-Lite, a Philips group company. All Rights Reserved.
Note: VL550 wash luminaires share many components / parts of the VL500 wash luminaires.
This manual (02.9683.0010 0) covers maintenance procedures, information, and drawings
specific to VL550 wash luminaires only. Please refer to the current service manual
(02.9685.0010) for maintenance procedures, information, and drawings for VL500 wash
luminaires.

HOW TOOBTAIN WARRANTY SERVICE
02.9683.0010 0 25 March 2011 iii
How To Obtain Warranty Service
A copy of the Vari-Lite Limited Warranty was included in the shipping package for
this VARI❋LITE product.
To obtain warranty service, please contact customer service at 1.214.647.7880 or
1.877.VARI-LITE (1.877.827.4548) or [email protected] 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
VERSION DATE
Revision 0 (Initial Version) 25 March 2011

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
iv 25 March 2011 02.9683.0010 0
Compliance Notice
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 communica-
tions. Operation of this equipment in a residential area is likely to cause harmful inter-
ference, 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
(by Low Voltage Directive 2006/95/EC)
EN 60598-1:2000/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
(by Council Directive 2004/108/EC)
EN 61000-6-2:2001 Immunity for industrial environments
EN 61000-6-4:2001 Emission Standard for industrial environments
We certify that the product conforms to the protection requirements of council direc-
tives: 73/23/EEC (LVD) and 89/336/EEC (EMC)
FCC

SAFETY NOTICE
02.9683.0010 0 25 March 2011 v
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 ELEC-
TRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND
INJURY TO PERSONS CAN BE FOUND BELOW.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE
1. VARI❋LITE luminaires have been designed for use only with certain type of lamps. Note
specified lamp type 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
VARI❋LITE luminaires.
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL
SHOCK
1. VARI❋LITE luminaires are designed for dry locations only. Exposure to rain or moisture
may damage luminaire.
2. Disconnect power before servicing any VARI❋LITE equipment.
3. Servicing to be performed by qualified personnel only.
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
vi 25 March 2011 02.9683.0010 0
WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE
EXPOSURE TO UV RADIATION
1. Many VARI❋LITE luminaires use an HID type lamp that produces UV radiation. DO
NOT look directly at lamp.
2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet
screens shall be changed if they have become visibly damaged to such an extent that their
effectiveness is impaired. For example, by cracks or deep scratches.
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.

SICHERHEITSHINWEISE
02.9683.0010 0 25 March 2011 vii
Sicherheitshinweise
Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem
Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin
beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und
dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein.
Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:
NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHER-
HEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE
UV-STRAHLUNG UND KÖRPERVERLETZUNGEN.
WARNUNG:
HINWEISE ZUM FEUERSCHUTZ
1. VARI❋LITE-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Philips
und Osram HID-Lampen geeignet. Achten Sie auf den Lampentyp, bevor Sie die
jeweiligen Lampen ersetzen. Die Installation eines anderen Lampentyps kann gefährlich
sein.
2. Scheinwerfer können auf jeder beliebigen Oberfläche 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 Stärke.
4. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der
VARI❋LITE-Scheinwerfer von brennbarem Material oder beleuchteten Objekten.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK
1. VARI❋LITE-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen oder
Feuchtigkeit können die Scheinwerfer beschädigen.
2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE-Geräten
beginnen.
3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG
1. Viele VARI❋LITE-Scheinwerfer verwenden einen HID-Lampentyp, der UV-Strahlen
abgibt. SCHAUEN SIE NICHT direkt in die Lampe.
VORSICHT - weist auf möglichen Produktschaden hin.
WARNUNG - weist auf mögliche Körperverletzung und Leb-
ensbedrohung hin.

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
viii 25 March 2011 02.9683.0010 0
2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder
Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch
sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.
WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN
1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der
Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung
(Handschuhe, Augenschutz etc.).
2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und
lassen Sie die Lampe abkühlen, wenn Sie diese austauschen.
3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und
Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter
Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr
von Körperverletzung bzw. von Feuer, das von Lampenteilen ausgelöst werden kann.
4. Tragen Sie beim Austausch der Lampen einen Augenschutz.
5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit
beschädigten Lampen verwendet werden.
6. Wenn die Lampe mit bloßen Händen berührt wird, reinigen Sie sie mit isopropyl Alkohol
und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb
nehmen.
7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese
ausgetauscht werden.
WARNUNG:
HF-INTERFERENZ
1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt
Hochfrequenzstörungen verursachen. In diesem Fall müssen eventuell geeignete
Maßnahmen getroffen werden.
BESONDERHEITEN VON BOGENLAMPEN
1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach
Abkühlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung
des Lampeneinschaltungsstatus (L ON/ LOFF).
2. Die Brennposition ist Universal.

NOTES DE SÉCURITÉ
02.9683.0010 0 25 March 2011 ix
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:
DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES
1. Les luminaires VARI❋LITE ont été conçus pour être utilisés uniquement avec certaines
lampes Philips et Osram HID. Vérifier le type de lampe avant de remplacer les lampes.
L’installation d’un autre type de lampe peut poser un danger.
2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de
montage sont respectées. Voir les explications détaillées dans ce guide.
3. Ne remplacer les fusibles qu’avec ceux du même type, ayant les mêmes caractéristiques.
4. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et
les luminaires VARI❋LITE.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES
1. Les luminaires VARI❋LITE sont conçus pour une utilisation au sec uniquement. Une
exposition à la pluie et à l’humidité risque d’endommager le luminaire.
2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE.
3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE
AUX RAYONS UV
1. Plusieurs luminaires VARI❋LITE utilisent une lampe de type HID qui produit des rayons
UV. NE PAS fixer son regard sur la lampe.
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.

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
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2. L’utilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages,
lentilles ou écrans ultraviolet visiblement endommagés au point que leur efficacité en est
affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures.
AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT
ENTRAÎNER DES BLESSURES
1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche.
Pour manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger
suffisamment (gants, protection pour les yeux, etc.).
2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et
attendre que la lampe ait refroidi avant de la remplacer.
3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la
peau et une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute
tension à de très hautes températures. Si la lampe se casse, les particules de la lampe
cassée peuvent causer blessures et/ou incendie en s’éparpillant.
4. Se protéger les yeux pour remplacer la lampe.
5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier
des lampes endommagées.
6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool isopropyl et
l’essuyer avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire.
7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être
remplacée.
AVERTISSEMENT:
INTERFÉRENCE RF
1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer
des interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures
adéquates.
CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC
1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc
mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera
automatiquemet après s’être refroidie. Cela dépend de la manière dont le système est réglé
pour le statut de mise en marche de la lampe (L ON/ LOFF).
2. La position Brûler est Universelle.

AVISO SOBRE SEGURIDAD
02.9683.0010 0 25 March 2011 xi
Aviso sobre Seguridad
Es muy importante leer TODA la información e instrucciones sobre seguridad que se
indica en este manual así como en los documentos adjuntos antes de instalar y operar
los productos descritos. Se debe prestar atención a todos los avisos y advertencias
durante la instalación y uso de este producto.
Los símbolos de seguridad usados en este manual son los siguientes:
LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CON-
TRAGOLPES DE CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN
EXCESIVA A RADIACIÓN ULTRA VIOLETA Y LESIONES A LAS PERSONAS
SE PUEDE ENCONTRAR SEGUIDAMENTE:
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO
1. Las luminarias VARI❋LITE han sido diseñadas para ser usadas solamente con algunas
lámparas HID Philips y Osram. Tome nota del tipo de lámpara antes de reemplazarla.
Instalación de otro tipo de lámpara puede ser peligroso.
2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las
instrucciones de instalación. Vea las instrucciones detalladas en este manual.
3. Reemplaze los fusibles solamente con los del mismo tipo y especificación.
4. Tome nota de los requerimientos de distancia de materiales combustibles u objetos
iluminados para las luminarias VARI❋LITE.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE
ELÉCTRICO
1. Las luminarias VARI❋LITE están diseñadas solamente para lugares secos. La exposición
a la lluvia o humedad pueden dañar la luminaria.
2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE.
3. El servicio debe ser realizado solamente por personal calificado.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA
1. Muchas luminarias VARI❋LITE usan un tipo de lámpara HID que produce radiación UV.
NO mire directamente a la lámpara.
CUIDADO,indica posibles daños al producto.
ADVERTENCIA, indica posibles lesiones o muerte a las
personas.

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
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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 dañadas, y que su efectividad
pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.
ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS
1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un
equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga
ajustes en el equipo y componentes que están calientes.
2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la
energía y deje que la lámpara se enfríe antes de reemplazarla.
3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias
quemaduras a la piel e inflamación a los ojos. Además, las lámparas de arco operan a alta
presión y muy alta temperatura. Si la lámpara se rompe, puede existir el peligro de
lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se
caen.
4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.
5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando
trabaje con lámparas dañadas.
6. Si toca la lámpara con las manos, limpie la lámpara con alcohol isopropyl y con tela sin
pelusas antes de instalar o volver a conectar la luminaria.
7. Cambie la lámpara si está dañada 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 CARACTERÍSTICAS DE LA LÁMPARA DE
ARCO
1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de
una interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara
se volverá a iluminar en forma automática después que se ha enfriado dependiendo de la
configuración del sistema de energía de la lámpara (L ON / L OFF) (L encendida / L
apagada).
2. La posición de encendido es universal.

SAFETY NOTICE (JAPANESE)
02.9683.0010 0 25 March 2011 xiii

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xiv 25 March 2011 02.9683.0010 0

TABLE OF CONTENTS
02.9683.0010 0 25 March 2011 xv
Table of Contents
Introduction
Disclosure .................................................................................................................... 1
About This Manual...................................................................................................... 1
Additional Documentation........................................................................................... 2
Customer Service......................................................................................................... 2
Chapter 1. Description
Features
Product Features........................................................................................................... 4
Model Specific Features .............................................................................................. 5
Component Descriptions
External Luminaire Components................................................................................. 6
Luminaire Internal Head Components......................................................................... 7
Luminaire Yoke Components ...................................................................................... 8
Dimmer Models......................................................................................................... 10
Principles of Operation
VL550 Incandescent Luminaires............................................................................... 11
VL550 Incandescent Block Diagram - Without On-Board IGBT Dimmer (120V or
230V)................................................................................................................... 11
VL550D Incandescent Luminaires............................................................................ 12
VL550D Incandescent Block Diagram - With On-Board IGBT Dimmer (120V or
230V)................................................................................................................... 12
Chapter 2. Maintenance
Testing
Running Parameter Tests ........................................................................................... 14
Diagnostic Tests......................................................................................................... 16
Test Descriptions................................................................................................. 16
Test Menu System Chart..................................................................................... 17
Equipment Handling
Locations/Use ............................................................................................................ 18
Lamps......................................................................................................................... 18
Servicing.............................................................................................................. 18
Heat ..................................................................................................................... 18
Lamp Life............................................................................................................ 18
Solid State Electronics............................................................................................... 19
Electrostatic Discharge (ESD)............................................................................. 19
Printed Circuit Boards (PCBs)............................................................................ 19
Maintenance Procedures
Lamp Replacement - Incandescent............................................................................ 20

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
xvi 25 March 2011 02.9683.0010 0
Front Glass Replacement............................................................................................ 22
Magenta/Blue DICHRO*TUNE Rear Bulkhead Replacement.................................. 24
Amber/Diffuser DICHRO*TUNE Front Bulkhead Replacement.............................. 26
Color Filter and Diffuser Panel Replacement ............................................................ 28
Linear Actuator Motor Replacement (Magenta/Blue Bulkhead)............................... 30
Linear Actuator Motor Replacement (Amber/Diffuser Bulkhead) ............................ 32
Incandescent Lamp Socket Assembly Replacement.................................................. 34
Display PCB Replacement......................................................................................... 36
Main Control PCB/Fan Assembly Replacement........................................................ 37
Low Voltage Supply (LVS) Replacement................................................................... 39
Low Voltage Supply (LVS) Temperature PCB Replacement..................................... 40
Tilt Motor Assembly Replacement............................................................................. 41
Pan Motor Assembly Replacement............................................................................ 43
Pan/Tilt Encoder PCB Replacement........................................................................... 44
IGBT Dimmer Replacement - VL550D Only............................................................ 45
AC Input (PowerCon) Connector Replacement......................................................... 47
DMX PCB Assembly Replacement ........................................................................... 48
Cleaning Optical Lenses and Filters........................................................................... 49
Chapter 3. Illustrated Parts Breakdown
Drawing Trees
VL550 Incandescent Luminaires................................................................................ 52
VL550D Incandescent (with Dimmer) Luminaires.................................................... 54
Top Assembly
Included Items Kit ......................................................................................................56
VL550 (120V or 230V) Luminaire ............................................................................58
VL550D (with 120V IGBT Dimmer) Luminaire .......................................................60
VL550D (with 230V IGBT Dimmer) Luminaire .......................................................62
Generic Luminaire Assembly .....................................................................................64
Head Assembly
VL550 Generic Head Assembly .................................................................................67
Heatsink Assembly .....................................................................................................69
VL550 Magenta/Blue (Standard) Color Assembly.................................................... 71
VL550 Magenta/Blue (Pastel) Color Assembly .........................................................72
VL550 Amber/Diffuser Color Assembly ...................................................................73
Magenta/Blue Color Assembly ..................................................................................74
Magenta/Blue (Pastel) Color Assembly .....................................................................75
Amber/Diffuser Color Assembly ...............................................................................76
Bottom Bulkhead Assembly .......................................................................................77
Top Bulkhead Assembly ............................................................................................79
Drive Ring Assembly .................................................................................................81
Magenta/Blue Color Motor Assembly .......................................................................82
Amber/Diffuser Color Motor Assembly ....................................................................83
Yoke Assembly
VL550 Yoke Assembly ..............................................................................................85
VL550 Extra Hardware Kit ........................................................................................89

TABLE OF CONTENTS
02.9683.0010 0 25 March 2011 xvii
VL550 Pan/Tilt Motor Assembly .............................................................................. 90
MCB/FAN Assembly ................................................................................................. 92
MCB-Fan Assembly .................................................................................................. 93
Yoke Crossmember Assembly ................................................................................... 94
Lower Crossmember Assembly ................................................................................. 96
Upper Crossmember Assembly ................................................................................. 98
Pan Tube Assembly ................................................................................................... 99
Input Panel Assembly .............................................................................................. 100
DMX Input PCB Assembly ..................................................................................... 101
Note: Cables are available as complete assemblies only. The information contained in
this section is for reference only.
Cables
Incandescent Power Input Cable Assembly ............................................................. 103
VL550 Motor Cable Assembly ................................................................................ 104
AC Input Cable Assembly ....................................................................................... 105
Head Grounding Cable Assembly ........................................................................... 106
Display (Remote) Cable Assembly .......................................................................... 107
Yoke Lamp Jumper Cable Assembly ...................................................................... 108
Backcap Ground Cable Assembly ........................................................................... 109
VL550 Main Cable Assembly ................................................................................. 110
Appendix A. Technical Bulletins and Notices
VL550 Wash Luminaire Technical Bulletins and Notices....................................... 111

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
xviii 25 March 2011 02.9683.0010 0

INTRODUCTION :
02.9683.0010 0 25 March 2011 1
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
Note: VL550 wash luminaires share many components / parts of the VL500 wash luminaires.
This manual (02.9683.0010 0) covers maintenance procedures, information, and drawings
specific to VL550 wash luminaires only. Please refer to the current service manual
(02.9685.0010) for maintenance procedures, information, and drawings for VL500 wash
luminaires.
This manual provides descriptions, repair procedures, and illustrated parts breakdowns
for all configurations of the VL550 Wash Luminaires. 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:
Notes:
• *For these models, lamp type is specified by customer at time of ordering the fixtures.
• Color Mixing Systems:
a. “Standard” is standard colors.
b. “Pastel” is softer, Broadway-type color palette.
Model Part Number Lamp Type Color Mixing
System Luminaire Body Color Dimmer
VL550 Wash Luminaire 20.9683.0001 120V or 230V
Tungsten* Standard Black External - User Supplied
VL550 Wash Luminaire 20.9683.0011 120V or 230V
Tungsten* Pastel Black External - User Supplied
VL550D Wash Luminaire 20.9683.0002 120V Tungsten Standard Black Integral 120V IGBT Dimmer
VL550D Wash Luminaire 20.9683.0012 120V Tungsten Pastel Black Integral 120V IGBT Dimmer
VL550D Wash Luminaire 20.9683.0003 230V Tungsten Standard Black Integral 230V IGBT Dimmer
VL550D Wash Luminaire 20.9683.0013 230V Tungsten Pastel Black Integral 230V IGBT Dimmer

VARI❋LITE - VL550 WASH LUMINAIRES SERVICE MANUAL
2 25 March 2011 02.9683.0010 0
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 VARI❋LITE product.
Additional Documentation
A support web page for VL500 series luminaires is available at www.vari-lite.com
(follow the Support link).
A user’s manual is available for installation and operation of the VL550 wash
luminaire. This manual is available in electronic (PDF) format.
■VL550 Wash Luminaires User’s Manual (02.9683.0001).
Technical bulletins concerning the latest changes to VARI❋LITE 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 full-
time 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: [phone]
E-mail: [email protected]
Additional Resources
For additional resources and documentation, please visit our website at:
www.vari-lite.com and follow the Support link.