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SUBJECT: Series 2500™ Strobe Stablizer Replacement Procedure
SERIES: 2500
DISTRIBUTION: Service Centers
STATUS: Routine
Introduction
Purpose
Note: This technical bulletin contains the procedure for replacing the strobe stabilizer (old-style
or new-style). This procedure is not necessary to achieve proper operation. Use this procedure
when replacing a strobe stabilizer on a VL2500™ Spot or Wash Luminaire.
Vari-Lite has made a change in the strobe stabilizer used in all VL2500™ Spot and VL2500™
Wash Luminaires. The new-style strobe stabilizer (part number 10.9676.8061) replaces the current
(or old-style) strobe stabilizer (10.9676.0061).
In addition, the Extension Spring used by the Stabilizer has changed from 55.6568.0016 (old
Spring) to 55.6568.0054 (new Spring).
Note: Vari-Lite recommends that the spring be replaced each time a stabilizer is replaced (never
reuse an spring once the stabilizer has been replaced).
This technical bulletin contains the procedure for replacing the current strobe stabilizer with a
new-style strobe stabilizer.
IMPORTANT! VL2500 Spot and Wash Luminaires manufactured after October 6, 2006 will
already have the new-style strobe stabilizer installed.
WARNING: This procedure is optional and should only be performed by a trained and qualified
service technician or at an Authorized Vari-Lite Service facility.
VARI❋ LITE®, VL500™, VL1000™, VL2000™, VL2500™, VL3000™, and VL3500™ are trademarks of Genlyte Thomas Group LLC
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BULLETIN NO.
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Parts
10.9676.8061
1 EA
STABILIZER, STROBE
55.6568.0054
1 EA
SPRING, EXTENSION, STABILIZER
Tool and Supplies
•
•
•
•
#2 Phillips Screwdriver
Master Appliance Corp., Model HG-751B
Heat Gun (750 to1000 Deg F / 399 to 538
Deg C) or Equivalent
1/16" Allen Wrench
Strobe Calibration Cable Assembly (VariLite Part Number 25.9676.0720)
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•
•
•
Loctite 242
Eastern Industries Model FG-35 Feeler
Gage/Gap Measurement Tool or
Equivalent
Small Mill (fine) flat metal file
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Procedures
Strobe Stabilizer Replacement Procedure
WARNING: Make sure all power is removed from luminaire before performing this modification.
Strobe Assembly Removal:
Step 1. Disconnect luminaire AC input cable from power source.
Step
2. Set luminaire on a stable work surface on its upper enclosure.
Step
3. At top head cover, gradually loosen two 8-32x3/8" PPB captive screws and remove
cover. (Note: The cover will remain attached by tether).
Head
Upper Enclosure
Figure 1: VL2500 Luminaire
Step
4. Remove bottom head cover by gradually loosening three 8-32x3/8" PPB captive screws.
Step
5. At CYM crossfade color bulkhead, disconnect wiring, remove two 6-32x1/4" PPB
screws, and remove assembly.
Step
6. If the unit is a Spot luminaire, remove Color/Gobo/Iris Assembly as follows:
a. At color/gobo/iris bulkhead, turn captive screw one-quarter turn to release bulkhead.
b. At color/gobo/iris bulkhead, disconnect wiring harness connectors from color wheel
motor, iris motor, and color sensor. (Note: Remaining motor and sensor connections
will have to be disconnected in Step 5e.)
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c. Slide bulkhead partially out of head assembly and disconnect gobo wheel motor,
gobo sensor and temperature sensor connectors.
d. Remove bulkhead from head assembly.
e. Proceed directly to Step 8.
CAUTION: Make careful note of wiring placement, so to not interfere with moving parts.
NOTE:
Yoke not shown for clarity.
Captive Screws
Removable Cover
CYM Crossfade Color /
Dimmer Bulkhead
Color/Gobo/Iris
Bulkhead
Figure 2: VL2500 Spot Color/Gobo/Iris Bulkhead Removal
Step
7. If the unit is a Wash luminaire, remove Fixed Color Assembly by as follows:
a. At fixed color bulkhead, turn captive screw one-quarter turn to release bulkhead.
b. At fixed color bulkhead, disconnect wiring harness connectors from color wheel
motor, color sensor, and thermal switch.
c. Remove bulkhead from head assembly.
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Captive Screws
CYM Crossfade Color /
Dimmer Bulkhead
Removable
Cover
Captive Screw
NOTE:
Yoke not shown for clarity.
Fixed Color
Bulkhead
Figure 3: VL2500 Wash Color Bulkhead Removal
Note: Step 8 (for Spot fixtures) and Step 9 (for Wash fixtures) are optional. This will allow direct
access to four mounting screws if right-angle screw driver is not available.
Step
8. If the unit is a Spot luminaire, remove Front Assembly as follows:
a. Remove front nose cover by removing two 10-32x1/2" PPB screws (one on each
side).
b. At front assembly, disconnect wire connectors from rotating gobo index motor and
rotating gobo wheel motor.
c. As shown in Figure 4, at junction connector, disconnect edge motor and zoom
motor wires.
d. Face head nose upward. At front of bulkhead, using #2 Phillips long handle screwdriver, remove four 6-32x3/8" PPB screws, and pull front assembly partially out of
head assembly
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Strobe Assembly
CYM Crossfade Color /
Dimmer Bulkhead
Color/Gobo/Iris
Bulkhead
Route wiring harness on this side
Front Nose Cover
Wire Connector
Junction Connector
Front Assembly
Screw (2)
Figure 4: VL2500 Spot Front Assembly Removal
e. At rear of bulkhead, disconnect wires from rotating gobo sensor PCB.
f.
Step
Proceed directly to Step 10.
9. If the unit is a Wash luminaire, remove Front Assembly as follows:
a. Remove front nose cover by removing two 10-32x1/2" PPB screws (one on each
side).
b. As shown in Figure 5, at junction connector, disconnect edge motor wiring.
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Strobe Assembly
CYM Crossfade Color /
Dimmer Bulkhead
Fixed Color Bulkhead
Front Assembly
Front Nose Cover
NOTE:
Yoke not shown for clarity.
Screw (2)
Figure 5: VL2500 Wash Front Assembly Removal
c. Face head nose upward. At front of bulkhead, using #2 Phillips long handle screwdriver, remove four 6-32x3/8" PPB screws, and pull front assembly out of head
assembly.
Step 10. At fan side of head, remove two 6-32x1/4" PPB screws.
Step 11. At strobe assembly, remove four 6-32x1/4" PPB screws.
Step 12. Carefully lift strobe assembly and disconnect wiring from strobe motors.
Strobe Assembly
Wire Connection
Strobe Blades
Wire Connection
Figure 6: VL2500 Strobe Assembly
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Step 13. Slide bulkhead out of head assembly.
Strobe Stabilizer Replacement
Step 14. Position strobe assembly on work surface with strobe blades on top.
Step 15. Using heat gun, carefully apply heat to strobe motor shaft to loosen adhesive on set
screws.
Step 16. Carefully, using 1/16" Allen Wrench, remove 6-32x1/8" set screws from strobe blades.
Step 17. Once set screws are removed, remove strobe blades from strobe motor.
Step 18. Using file, remove any burrs from strobe motor shaft (that may have been caused from
set screws biting into shaft).
Step 19. Replace strobe stabilizer and spring with new-style strobe stabilizer (10.9676.8061) and
new-style spring (55.6568.0054).
IMPORTANT! Do not reinstall strobe blades at this time.
Strobe Assembly Set-Up/Calibration and Strobe Blade Installation
Step 20. At board-side leg, remove yoke leg cover by removing four 6-32x5/16" PPB screws.
Note: To determine which yoke leg is which without having to remove the covers, rotate yoke
counterclockwise until it stops, then look at the luminaire while facing the input panel. The tiltside leg is the leg to the left; the board-side leg is the leg to the right.
Step 21. Disconnect all three wiring harnesses from MCB at J8, J9 and J11.
Step 22. Connect Strobe Assembly Calibration Cable (25.9676.0720) to MCB at J9 (34-pin connection). This cable will run outside of fixture.
Step 23. Connect Strobe Assembly Calibration Cable to strobe assembly motors.
IMPORTANT! As indicated in Figure 7 and Figure 8, make sure Strobe Motor 1, on the strobe
assembly, is connected to Strobe Motor 1 labeled connection AND Strobe Motor 2, on the strobe
assembly, is connected to Strobe Motor 2 labeled connection on the Strobe Assembly Calibration
Cable.
Strobe 2 Motor Connection
34-Pin Connector (to MCB)
Strobe 1 Motor Connection
Figure 7: Strobe Assembly Calibration Cable
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Step 24. With all DMX Cables removed, power luminaire. Allow strobe assembly to calibrate
completely.
Note: Many error messages will be reported on the display after calibration. They should all be
ignored at this time.
Note: The lamp will not strike with the Color/Gobo or Fixed Color Assemblies removed.
Step 25. Add one drop of Loctite 242 to set screws.
Step 26. Install set screws into strobe blades. Remove any excess Loctite.
Step 27. Install strobe blades on strobe motor shafts.
Note: The black side of the strobe blades must face away from strobe assembly as shown in
Figure 8.
Strobe Motor #1
Strobe Assembly
Strobe Motor #2
Black Side of Strobe Blades
Figure 8: VL2500 Strobe Blade Installation
Step 28. Using gap measurement tool, as indicated in Figure 9, set strobe blade height.
Strobe Blade
Strobe Blade
Strobe Motor #2
Strobe Motor #1
Strobe Assembly
Figure 9: VL2500 Strobe Blade Height
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Step 29. Hold strobe blade against closed position stop and tighten set screws.
Step 30. Repeat Steps 28 and 29 for other strobe blade.
Strobe Assembly Test
Step 31. With all DMX cables removed, cycle luminaire power and wait for calibration to
complete. Strobe blades should be in the closed position.
Note: Many error messages will be reported on the display after calibration. They should all be
ignored at this time.
Note: The lamp will not strike with the Color/Gobo or Fixed Color Assemblies removed.
Step 32. Using gap measurement tool, measure the distance from each strobe blade to its respective Strobe Stop (Closed). This distance should be 0.130" +/- 0.20" (3.3 mm +/- 0.5
mm). Refer to Figure 10.
Strobe Assembly
Strobe Stop (Closed)
Strobe Stop (Open)
Strobe Blade
Strobe Stop (Open)
Strobe Stop (Closed)
Strobe Blade
Figure 10: VL2500 Strobe Blade Position Measurements
Step 33. Press [Menu] button, "Address" is displayed.
Step 34. Press [/\] (up arrow button) two times, "Manual" is displayed.
Step 35. Press [Enter] button, "Pan" is displayed.
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Step 36. Press [\/] (down arrow button) two times, "Dimmer" is displayed.
Step 37. Press [Enter] button, "0" is displayed.
Step 38. Press [\/] button, "255" is displayed.
Step 39. Press [Menu] button, "Dimmer" is displayed.
Step 40. Press [\/] button, "Strobe" is displayed.
Step 41. Press [Enter] button, "3" is displayed.
Step 42. Press [\/] button, "2" is displayed. Strobe blades should be in their fully open position.
Note: Make sure the aperture in the strobe assembly is completely open and that the strobe blades,
when at the "2" DMX value, do not cover any part of the opening.
Step 43. Using gap measurement tool, measure the distance from each strobe blade edge to its
respective Strobe Stop (Open). This distance should be 0.091" +/- 0.20" (2.3 mm +/- 0.5
mm).
Step 44. Press [Menu] button twice. "Manual" is displayed.
Step 45. Press [\/] button, "Test" is displayed.
Step 46. Press [Enter] button, "ALL SEQ" is displayed.
Step 47. Press [\/] button five times, "Strobe" is displayed.
Step 48. Press [Enter] button, "Run Test" is displayed.
Step 49. Watch strobe blade action. make sure strobe blades do not hit any Strobe Stop.
Step 50. If Strobe Blade hits either Strobe Blade Stop, perform the following. If not, proceed to
next Step.
a. Stop test (by pressing [Menu] button or shutting off fixture).
b. Remove strobe blade hitting stops.
c. Reinstall strobe blade by repeating Steps 28 and 29.
d. Run test again.
Step 51. Once test is completed, disconnect power from luminaire.
Step 52. Disconnect and remove Strobe Assembly Calibration Cable.
WARNING: Do not disconnect Strobe Assembly Calibration Cable until power is completely
removed from luminaire or damage to the strobe motors and MCB can occur.
Reassemble Luminaire
Step 53. Reconnect all wiring harnesses to MCB.
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Step 54. Reinstall MCB-side yoke arm cover.
Step 55. Reinstall strobe assembly.
Step 56. Reinstall front assembly and front cover (if applicable).
Step 57. Reinstall removed bulkhead assemblies:
a. For spot fixtures, reinstall color/gobo/iris and CYM color assemblies.
b. For wash fixtures, reinstall fixed color and CYM color assemblies.
Step 58. Reinstall head covers.
Step 59. Power luminaire and test.
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