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VARI*LITE VL3500 Wash and VL3500 Wash FX Service Manual

1. RF 1 Clas 1 Lamp Power Up State gt 2 02 9686 0010 A TABLE CONTENTS Table of Contents Table of Contents IntroductionIntroduction 1 About This Sek EE lt 1 Additional Documentation ee 2 Customer S SSS e be ha A 3 Technical Bulletins and 4 Chapter 1 Description Features VL3500 Wash amp VL3500 Wash FX Standard 6 Technical Specifications 55 8 6 Components External Luminaire Components ss 7 Luminaire He
2. No Item Qty UM Description 1 10 9678 0764 1 EA PLATE TILT ENCODER MOUNT 2 10 9678 0756 1 EA IGNITOR SHIELD 3 21 9678 0765 1 EA ASSY TILT MOTOR 4 22 9661 0609 2 EA ASSY YOKE FAN 5 22 9686 0705 1 EA ASSY YOKE STRUCTURE 6 23 9650 3327 1 EA ASSY RELAY 7 23 9661 1253 1 EA ELEC ASSY PAN EOT SENSOR 8 24 9661 3126 l EA PCB ASSY SOLID STATE IGNITOR i 25 9661 1526 2 EA CABLE ASSY IGNITOR TO RELAY not shown 25 9678 0681 1 EA CABLE ASSY YOKE FAN AND RELAY not shown 25 9678 0758 1 EA CABLE ASSY YOKE FAN not shown 9 53 2019 0004 2 EA NUT 3 8 16 X 7 32 THK HEX 10 53 2200 0006 1 EA NUT 6 32 KEPS SS 11 53 5634 0250 8 EA SCREW 4 40 X 1 4 PFSS BL 12 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 13 53 6558 0009 12 EA SCREW 6 32 X 3 8 LG PPZ SEM 14 53 6626 0001 6 EA SCREW 10 32 X 1 2 PPZ 15 53 6634 0003 2 EA SCREW 3 8 16 X 1 2 LG SOC 16 55 2150 0002 1 EA STANDOFF 1 4 HEX 6 32 1 187 L 17 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNT 18 55 6528 0001 2 EA WASHER 6 FLAT ZINC 19 55 6541 0002 2 EA GROMMET 1 ID 1 3 4 OD 1 3 20 55 6568 0074 2 EA SPRING CPRSN 420 OD 750 LG 21 55 6658 0004 2 EA STANDOFF 1 4 HEX 6 32 750 LG F F AL 02 9686 0010 A 109 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Yoke Assembly continued Figure 3 31 Yoke Assembly 02 9686 0010A
3. BLK RED ORN BRN BRN BLK RED CM BR RED re I 46 47 e AMP Figure 3 56 Tilt Harness Cable Assembly Wiring Pin Out 144 02 9686 0010A CABLE ASSEMBLIES INTERNAL LENS INTERCONNECT CABLE ASSEMBLY 3 Internal Lens Interconnect Cable Assembly 25 9686 0204 Rev 0 Refer to Figure 3 57 No Item Qty UM Description 1 52 6610 0014 2 EA CONNECTOR HOUSING 14 POS 26 22 AWG 2 52 6224 1014 2 EA COVER FRONT 14 POS MT LATCHING 3 52 6224 2014 2 EA COVER BACK 14 POS MT 4 55 2186 0001 4 EA CABLE TIE 10 X 4 SMALL 5 55 6699 0004 0 6 FT SLEEVING 3 4 NOM DIA POLY EXP BRAID 6 73 5116 0123 4 0 FT WIRE 24 AWG 4 COND TW 300V 80C BLK BRN RED ORN 7 73 5126 0002 2 0 FT WIRE 26 AWG 2 COND TW 300V 80C BLK RED 8 73 5126 0007 2 0 FT WIRE 26 AWG 2 COND TW 300V 80C BLK ORN 9 73 3026 0009 2 0 FT WIRE 26 AWG 300V 80C WHT 10 52 8351 0004 26 EA CONTACT 26 22 AW
4. No Item Qty UM Description 1 21 9686 0615 1 EA ASSY BACKEND 2 12 9686 0623 1 EA RIGHT SIDE RAIL MACHINED 3 12 9686 0625 1 EA LEFT SIDE RAIL MACHINED 4 21 9686 0617 1 EA ASSEMBLY FRONT CASTING LENS VL3500 Wash Only 21 9686 1617 1 EA ASSEMBLY FRONT LENS CLEAR POLISHED VL3500 Wash FX Only 5 53 6515 0001 6 EA SCREW 10 32 X 3 4 SCB CAP 6 10 9686 0639 2 EA LIGHT BAFFLE FRONT 7 53 6682 0002 4 EA SCREW 4 40 X 1 4 PPZ SEMS Figure 3 1 Head Structure Assembly 02 9686 0010 A 63 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Front Stippled Lens Assembly 21 9686 0617 Rev A VL3500 Wash Only Refer to Figure 3 2 No Item Qty UM Description 1 10 9686 0641 4 EA CLIP FRONT LENS 2 12 9686 0627 1 EA CASTING CONVEX LENS 3 42 9686 0101 1 EA LENS ASPHERIC PLANO CONVEX STIPPLED 4 53 6598 0312 8 EA SCREW 4 40 X 5 16 5 53 6685 1125 4 EA SCREW CAPTIVE SH CAP 10 32 1 125 LG BLK ZN 1 x4 Figure 3 2 Front Stippled Lens Assembly 64 02 9686 0010A HEAD ASSEMBLY POLISHED PC CLEAR FRONT LENS ASSEMBLY 3 Polished PC Clear Front Lens Assembly 21 9686 1617 Rev VL3500 Wash FX Only Refer to Figure 3 3 No Item Qty UM Description 1 10 9686 0641 4 CLIP FRONT LENS 2 10 9686 2190 4 EA BUM PER LENS STOP 3 12 9686 0627 1 EA CASTING CONVEX LENS 4 42 96
5. Solder Side Component Side Figure 3 36 VL3500 Wash Controller PCB Assembly 02 9686 0010 A 117 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 118 02 9686 0010A ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly Upper Enclosure Assembly 21 9686 0800 Rev Refer to Figure 3 37 and Figure 3 38 No Item Qty UM Description 1 04 9640 0374 1 EA LABEL PE GROUND 2 04 9661 1218 01 1 EA LABEL PATENT VL2201 amp VL2400 SERIES LUM 3 04 9686 0040 1 EA LABEL VL3500 WASH SERIES COMPLIANCE 4 06 6032 0009 1 EA CABLE MARKER TIE 5 10 9661 1258 1 EA BRACKET APS SIDE 6 10 9678 1876 1 EA AIR DISTRIBUTION PLENUM 7 10 9678 0820 1 EA LANYARD PAN TUBE 8 10 9686 0839 2 EA COVER TOP 9 10 9686 0846 2 EA HANDLE CAST ENCLOSURE 10 10 9678 0869 1 EA BRACKET LVS 11 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN 12 10 9678 0886 1 EA SPACER PAN BEARING 235 13 12 9686 1236 2 EA COVER FRONT 14 12 9686 1238 2 EA MACHINED COVER SIDE 15 12 9678 0842 1 EA AIR DUCT UPPER ENCLOSURE MOD 16 21 9686 0840 02 1 EA ASSY COVER VENTILATION 17 21 9678 0767 1 EA ASSY STABILIZER 17a 10 9678 0757 1 EA STABILIZER 1 377DIA 17b 10 9678 0762 1 EA BRACKET STABLIZER 17c 53 6610 0003 1 EA SCREW 6 32 X 7 16 PPZ 17d
6. reo e P Is TI Head CCC 78 Internal Lens Assembly ed ett ee eee eerte ee eee ete Pec pere e s 79 Internal Lens Rail Assembly x iter det aks EE 81 Internal Lens Splitter Assembly ss 83 Actuator Assembly initial de 85 Fresnel Internal lenses n nunus a GE eed eee EE 86 Color Effect Strobe Module SS 87 Color Rotating Effect Strobe 90 VL3500 Wash Fixed Color Wheel 1 Assembly 93 VL3500 Wash Fixed Color Wheel 2 Assembly ss 95 VL3500 Wash FX Fixed Color Wheel 1 Assembly 97 VL3500 Wash FX Fixed Color Wheel 2 Assembly 99 VL3500 Wash FX Rotating Effect Wheel Assembly 101 xiv 02 9686 0010 A TABLE CONTENTS VL3500 Wash Strobe System Assembly 103 VL3500 Wash FX Strobe System Assembly eese ene 105 107 Front Strobe Blade Assembly sens 108 Yoke Assembly Yoke Assembly ite ER ee Is RR IE He 109 Tt Motor Assembly oniar e e teneret tete ipe tette tere esee ene Pie rigen 111 Yoke Fan Assembly nS EE EI lt 113 Head Yoke PCB Assemblies Head Cable I RR eo PR rs 115 VL3500 Wash Controller PCB Assembly
7. 2 3 4 5 LI C 6
8. A V MENU ENTER Data In Data Thru Y Z AC Input Cable 02 9686 0010 A 7 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Luminaire Head and Yoke Components The following illustration shows the major sub assemblies which are located in the luminaire head and yoke assemblies Color Assembly VL3500 Wash Luminaire contains fixed EN Head Covers color wheels dimmer mechanism aperture sn attached by tether wheel CYM color wheels CTO color ER correction wheel and strobe mechanism VL3500 Wash FX Luminaire contains rotating effects mechanism fixed color wheels dimmer mechanism CYM color SK Optics Assembly wheels CTO color correction wheel and N Houses zoom lenses strobe mechanism gt n and Vari Brite mechanism Backend Assembly Houses reflector and lamp Provides knobs for lamp adjustment Front Lens Assembly Yoke Arm Cover Enclosure Assembly See page 9 Head Fan Assemblies Main Controller Board MCB Luminaire control circuit board 8 02 9686 0010 A COMPONENTS ENCLOSURE COMPONENTS 7 Enclosure Components The following illustration shows the major sub assemblies which are located in the luminaire enclosure assembly Yoke and head assemblies not shown for clarity Enclosure Top Covers Enclosure Fan Assembly Input Panel Assembly containing DMX Input PCB and Menu Di
9. No Item Qty UM Description 1 52 6396 3002 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END 2 52 6396 3005 1 EA RECEPT 5 POS MTA100 W POL TAB WHT CLSD END 3 52 6396 3008 1 EA RECEPT 8 POS MTA100 W POL TAB WHT CLSD END 4 73 5124 1289 3 67 FT WIRE 24AWG SCOND lt BLK BRN RED GRN WHT gt 2 3 Figure 3 77 Ballast to Controller Cable Assembly 02 9686 0010 A 167 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL DC Output Cable Assembly 25 9678 0821 RevE Refer to Figure 3 78 No Item Qty UM Description 1 52 6464 0002 1 EA CONN HOUSING SL 156 2 POS 2 52 6464 0003 1 EA CONN HOUSING SL 156 3 POS 3 52 8231 0004 2 EA TERM RING 6 BLUE 12 10 AWG INSRT 4 52 8323 0002 4 EA CONTACT CRIMP 18 22 AWG SL 156 not shown 5 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 BLUE 150 OD MAX 6 55 2186 0001 4 EA CABLETIE 01 x 4 00 SMALL 7 55 6699 0003 2 08 FT SLEEVING 1 2 NOM DIA POLY EXP BRAID 8 73 3518 0002 1 58 FT WIRE 18 AWG 300V 105C PVC RED 9 73 3518 0010 1 58 FT WIRE 18 AWG 300V 105C PVC BLK 10 73 7060 0001 2 08 FT WIRE 18 AWG HI VOLT RED YOKE LMP 11 73 7060 0002 2 08 FT WIRE 18 AWG HI VOLT BLK YOKE LMP 3 2 6 6 8 Figure 3 78 DC Output Cable Assembly 168 02 9686 0010 A CABLE ASSEMBLIES PAN TILT CONTROL CABLE ASSEMBLY 3 Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Refer to Figure 3 79 and Figure 3
10. 37 Ienitor Board Replacement asesinar EE 38 Pan Motor Assembly 39 Pan Encoder Replacement nnne aee terere e IR eine tee eere etes 41 Pan FOT Sensor 43 Power Supply LYS Replacement issue nent 45 Tilt Motor Assembly Replacement 47 Tilt Encoder Replacement _ 49 Tilt EOT Sensor Replacement siennes 50 Chapter 3 Illustrated Parts Breakdown Drawing Tree VL3500 Wash VE3S00M Wash LumMalte 52 Drawing Tree VL3500 Wash FX V E3500 Wash PX Luminaire aa aa a 54 Top Assembly Included Items Kit une pne eet ds 56 VL3500 Wash VL3500 Wash FX Luminaires eene 58 Generic Luminaire Assembly seen 60 Head Assembly Head Structure Assembly russ ete e eie a e e dete on 63 Front Stippled Lens Assembly Ip n p eet ep ere el ee a 64 Polished PC Clear Front Lens Assembly 65 Front Clear Lens Assembly 5 nieve iue e a maa etes redd ie SHIP Eee pede 66 Front Fresnel Lens Assembly e aee Ra ses 67 Head Cover Assembly ennt Mr Ah etg ederet qus 68 Backend Assembly 69 A 71 Dual Fan Duct Assembly atencion ais 72 Reflector Mount Assembly 73 Hot Box Assembly t oe e 75 Dual Fan Tray Asseinbly
11. 2 Tilt Encoder Tilt Motor Assembly Springs 8 Tilt Motor Assembly Detail Figure 2 18 Tilt Encoder Replacement 02 9686 0010 A 49 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL 50 Tilt EOT Sensor Replacement Parts 23 9661 1253 Repair Procedure Step Step Step Step Step Step 1 2 3 Disconnect luminaire AC input cable from power source At tilt side leg remove yoke leg cover by removing four 6 32 x 5 16 PTB screws As shown in Figure 2 19 at the sensor bracket remove two 10 32 x 1 2 PPZ screws and remove bracket Disconnect wiring from tilt encoder board 5 Atsensor remove two 6 32 x 3 8 PPZ screws and remove sensor from bracket Replace by performing steps 2 through 5 in reverse order Sensor Sensor Bracket Figure 2 19 Tilt EOT Sensor Replacement 02 9686 0010 A 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for the VL3500 Wash and VL3500 Wash FX luminaire assemblies Note The VL3500 Wash and VL3500 Wash FX Luminaires share many common 2 SN assemblies and parts of the Vari Lite Series 3000 Luminaires AN Drawing Tree VL3500 Wash Drawing Tree VL3500 Wash FX Top Assembly Yoke Assembly Head Yoke PCB Assemblies Enclosure Assembly Cable Assemblies 02 9686 0010 A 51 VARIXLITE VL3500 WASH LUMINAIRE S
12. Allow lamp to cool CAUTION before servicing Lamp Connector Do not touch lamp or CAUTION reflector with bare fingers Lamp Box Luminaire Head Not Shown For Clarity Figure 2 1 Lamp Replacement 02 9686 0010 A 19 VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL Align Lamp The design of the VL3500 Wash luminaire optical system allows for a flat or peaked field A flat field has no detectable hot spot A peaked field has more intensity at the center of the beam than at the perimeter After you install a new lamp align the lamp to optimize the beam Use the knobs on the luminaire backcap to make the adjustments A WARNING Backcap and adjustment knobs are HOT during lamp operation Wear gloves to prevent burns To align lamp Step 1 Strike lamp Step 2 At Menu Display select Test and then select Lamp This setting facilitates lamp alignment by disabling the pan and tilt motors opening the dimmer and opening the internal lenses Step 3 Position beam on a white wall at a distance of 12 to 20 feet Step 4 At backcap using X Y and Z adjustment screws adjust beam as required CAUTION RISK OF FIRE USE ONLY 1500 WATT H 100V METAL HALIDE LAMP SFc10 BASE Vi ATTENTION N RISQUE D INCENDIE UTILISER UNIQUEMENT UNE LAMP A HALOGENE EN METAL TYPE 1500 WATT 100V UN SUPPORT SFc10 4 I CAUTION ar RISK OF EXPOSURE TO EXCESSIVE ULTRAVIO
13. CTO Amber Magenta Phase 5 Pan Zoom Cyan VL3500 WASH FX Phase 1 Tilt Strobe Color Wheel 1 Color Wheel 2 Phase 2 Dimmer Phase 3 FX Wheel Phase 4 VAREKBRITE CTO Amber Magenta Phase 5 Pan Zoom Cyan Phase 6 FX Index 02 9686 0010A TESTING AUTO RECALIBRATION 2 Auto Recalibration Most mechanisms with sensors will check their sensor when at a zero position if the sensor is not detected within 3 seconds the mechanism will recalibrate This applies to all except pan and tilt and zoom Pan and tilt are corrected continuously if required by encoders fitted to the motor shaft N Note Colors CTO and CYM only auto recalibrate when the dimmer has been closed for 3 seconds Partial Recalibration It is possible to recalibrate sections of the luminaire from a console This allows greater flexibility and speed by only forcing a recalibration on specific mechanisms Partial recalibration values on the control channel are as follows Hold DMX value 102 for 3 seconds then 0 recals Strobe Color Wheel 1 Color Wheel 2 CYM CTO and Dimmer Hold DMX value 128 for 3 seconds then 0 recals Zoom Dimmer Aperture and Internal Lenses Hold DMX value 140 for 3 seconds then 0 recals Dimmer and Strobe Sensor Testing Most mechanisms within the VL3500 Wash Luminaire are equipped with either optical or magnetic sensors The VL3
14. 02 9686 0010 A 3 2 15 17 10 18 2 7 14 x4 Figure 3 6 VL3500 Wash VL3500 Wash FX Luminaires 59 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Generic Luminaire Assembly 21 9686 0010 Rev E VL3500 Wash 21 9686 1010 Rev A VL3500 Wash FX Refer to Figure 3 7 No Item Qty UM Description 1 21 9686 0600 1 EA ASSY HEAD STRUCTURE VL3500 WASH VL3500 Wash Only 21 9686 1600 1 EA ASSY HEAD STRUCTURE VL3500 WASH VL3500 Wash FX Only 2 21 9686 0700 1 EA ASSY YOKE 3 21 9678 0707 1 EA ASSY DRIVEN PULLEY 3a 10 9678 0750 1 EA TIMING PULLEY 150 TOOTH 3b 10 9678 0754 1 EA FLAG CENTER OF TRAVEL TILT 3c 53 6530 0009 3 EA RIVET 1 8 OD POP 126 187G 4 21 9678 0767 1 EA ASSY STABILIZER 4a 10 9678 0757 1 EA STABILIZER 1 377DIA 4b 10 9678 0762 1 EA BRACKET STABLIZER 4c 53 6610 0003 1 EA SCREW 6 32 X 7 16 PPZ 4d 55 6568 0075 1 EA SPRING EXTSN 375 OD 1 00 LG 041 WIRE DIA 5 21 9686 0800 1 EA ASSY UPPER ENCLOSURE VL3500 WASH 52 0259 EA CABLE TIE 5 5 INTERMEDIATE not shown 6 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX JAM GRDS ZINC PLT 7 53 6505 0020 5 BOLT 1 4 28X 3 4 HX HD GRD 8 ZINC PLT FULL THRD 8 53 6505 0026 4 EA BOLT 3 8 16 X 500 LG H X HD GRADE 5 BLK 9 16 HEX HEAD X 23 TALL 9 53 6539 0001 4 EA WAS
15. 4 40 8 32 0 791 LG AL 3 10 9686 0841 1 EA ADAPTOR PLATE PAN SENSOR PCB 4 10 9686 0865 1 EA PLATE PAN MOTOR MOUNT 5 21 9686 0828 1 EA ASSY DRIVE PULLEY PAN Sa 10 9678 8720 1 EA CODEWHEEL 120 COUNT Sb 10 9686 0749 1 EA TIMING PUILLEY Sc 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET CONE POINT 6 24 9678 9729 1 EA PCB ASSY VL2203 PAN TILT ENCODER 7 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 8 53 2200 0008 4 EA NUT 8 32 KEPS 55 9 53 6546 0001 4 EA SCREW 8 32X 5 8 PPB 10 53 6575 0009 2 EA SCREW 8 32 X 3 8 LG PPZ SEMS 11 53 6682 0002 4 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 12 54 1259 0009 4 EA BEARING 1 4 ID 1 2 OD EXT INNER RACE 02 9686 0010 A 131 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly continued Detail Pressure Sensitive Adhesive See Detail A lt 8 X4 9 X4 Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Note Vari Lite recommends that this assembly be replaced as a complete assembly Although you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly
16. 55 6568 0075 1 EA SPRING EXTSN 375 OD 1 00 LG 041 WIRE DIA 18 21 9686 0805 1 EA ASSY PANEL 19 21 9686 0807 1 EA ASSY PAN PULLEY 20 21 9686 0864 1 EA ASSY PAN MOTOR 21 21 9678 0881 1 EA ASSY PAN TUBE 22 22 9686 0851 1 EA ASSY UPPER ENCLOSURE 23 23 9686 1500 1 EA ASSY BALLAST MODULE 1500W ARC INCLUDES ATTACHED FERRITE 24 23 9686 0824 1 EA FAN ASSY UPPER ENCLOSURE 02 9686 0010 A 119 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 25 21 9686 0811 1 EA FAN ASSY EXHAUST 26 23 9678 0687 1 EA ELEC ASSY PAN EOT SENSOR 25 9661 1514 1 EA CABLE ASSY LVS CHASSIS GROUND not shown 25 9661 1520 1 EA CABLE ASSY CHASSIS TO YOKE GROUND not shown s 25 9678 0811 1 EA CABLE ASSY EMI FILTER TO POWER not shown 25 9678 0812 1 EA CABLE ASSY AC INPUT SPLITTER not shown 25 9678 0813 1 EA CABLE ASSY DATA I O LINK not shown 25 9678 1825 1 EA CABLE ASSY DISPLAY not shown 25 9678 0816 1 EA CABLE ASSY BALLAST TO CONTROL not shown 25 9678 0821 1 EA CABLE ASSY DC OUTPUT not shown 25 9678 0818 1 EA CABLE ASSY PAN TILT CONTROL not shown 25 9678 0829 1 EA CABLE ASSY LAMP SUPPLY TO RELAY not shown 25 9686 0843 1 EA CABLE ASSY DUAL AC FAN LVS TO YOKE not shown 27 53 2001 0003 1
17. Manual VL3500 Wash amp M Wash Luminaires 0296860010 Service PHILIPS VARI2 LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 VL3500 Series 10007 Series 2000 Series 30007 DICHROXTUNE VARIXIMAGE VARIXBRITE and the Vari Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC 1 products are protected by one or more of the following patents and other pending patent applications worldwide U S Patents No 6 809 869 6 796 682 6 769 792 6 578 987 6 550 939 6 282 027 6 123 436 6 113 252 6 046 861 6 031 749 6 011 640 5 969 868 5 959 768 5 934 794 5 882 107 5 829 868 5 825 548 5 798 619 5 774 273 5 769 527 5 758 956 5 728 994 5 640 061 5 590 954 5 454 477 5 432 691 5 367 444 5 329 431 5 307 295 5 282 121 5 278 742 5 209 560 5 186 536 5 073 847 5 010 459 4 980 806 4 972 306 4 800 474 4 779 176 4 701 833 4 602 321 U S Design Patents No 524 245 457 678 452 339 451 890 442 944 439 356 420 332 417 300 415 301 414 888 413 995 377 338 366 712 359 574 350 408 347 113 Australia Patents No 693 691 683 695 667 109 649 264 646 588 586 095 576 400 Australia Design Patents No 128 796 128 795 Canada Patents No 2 070 6
18. WASH LUMINAIRE SERVICE MANUAL VL3500 Wash FX Rotating Effect Wheel Assembly continued Figure 3 26 VL3500 Wash FX Rotating Effect Wheel Assembly 102 02 9686 0010A HEAD ASSEMBLY VL3500 WASH STROBE SYSTEM ASSEMBLY 3 VL3500 Wash Strobe System Assembly 21 9686 0404 Rev H VL3500 Wash Refer to Figure 3 27 No Item Qty UM Description 1 10 9678 0491 4 EA BUMPER STOP STROBE 2 10 9686 0435 1 EA STROBE BULKHEAD COLOR ACCESS 3 10 9686 0438 1 EA SPRING COLOR ACCESS 4 10 9686 0440 1 EA SHIELD STROBE MOTOR HARNESS 5 10 9686 1450 1 EA REFLECTOR STROBE BULKHEAD 6 21 9686 1445 1 EA ASSY AIR DUCT 7 21 9686 1437 1 EA REAR STROBE BLADE ASSEMBLY 8 21 9686 1438 1 EA FRONT STROBE BLADE ASSEMBLY 9 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR6 10 53 6513 0026 8 EA SCREW M3 X 5 X 12MM LG PP 11 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 12 53 6558 0007 4 EA SCREW 6 32 X 1 4 PPZ SEMS 13 53 6609 0001 4 EA SCREW 6 32 X 3 8 LG PFZ 14 55 2023 0002 1 EA HINGE 1 00 LG X 1 00 WD ZINC STEEL 15 55 3303 0004 8 EA WASHER 4 LOCK INT TOOTH SS 16 55 3306 0006 8 EA WASHER 375 OD 149 ID 025 THK 17 55 6659 0001 8 EA SPACER 1 4 RND 4 THRU 3 16 18 55 6706 0001 8 EA GROMMET 9 32 ID 9 16 OD 1 4T 02 9686 0010 A 103 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash Strobe System Assembly cont
19. WIRE 16AWG 600V 105C PVC WHT UL1015 5 73 6016 0010 0 83 FT WIRE 16AWG 600V 105C PVC BLK UL1015 2 1 4 White 3 White Black Black 5 1 Figure 3 73 EMI Filter to Power Switch Cable Assembly 162 02 9686 0010 A CABLE ASSEMBLIES AC INPUT SPLITTER CABLE ASSEMBLY 3 AC Input Splitter Cable Assembly 25 9678 0812 Rev Refer to Figure 3 74 No Item Qty UM Description l 52 6231 0001 l EA PLUG HOUSING MNLOK PLUG 3 POS 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 52 8231 0008 2 EA TERM SPADE 6 22 16 AWG INSERT 4 52 8392 0001 2 EA RECP FASTON 187 X 0 32 16 14 AWG FLAG DBL CRP 5 52 8270 0001 2 EA CONTACT PIN 20 14 AWG MNLOK REEL 6 52 8314 0001 1 EA PIN GND 20 14 AWG MNLOK 060 130 INS DIA 7 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 8 55 6699 0003 1 50 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 9 73 6016 0009 1 83 FT WIRE 16 AWG 600V 105C PVC WHT 1711015 10 73 6016 0010 1 83 FT WIRE 16 AWG 600V 105C PVC BLK 111015 11 73 6016 0504 2 08 FT WIRE 16 AWG 600V 105C GRN YEL UL1015 12 73 6018 0009 1 00 FT WIRE 18 AWG 600V 105C PVC WHT UL1015 13 73 6018 0010 1 00 FT WIRE 18 AWG 600V 105C PVC BLK 111015 02 9686 0010 A 163 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly continued Note Heatshrink not shown for clarity Fig
20. YOKE ASSEMBLY TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21 9678 0765 RevE Refer to Figure 3 32 No Item Qty UM Description 1 10 9678 0763 1 EA PLATE TILT MOTOR MOUNT 2 21 9678 0708 1 EA ASSY DRIVE PULLEY 2a 10 9678 0720 1 EA CODEWHEEL 120 COUNT LARGE ID 2b 10 9678 1749 1 EA TIMING PULLEY 17 TOOTH SHORTENED 2c 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET CONE POINT 3 24 9661 9629 1 EA PCB ASSY PAN TILT ENCODER 4 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0006 2 EA NUT 6 32 KEPS SS 6 53 2200 0008 4 EA NUT 8 32 KEPS 7 53 6525 0001 2 EA SCREW 6 32X 5 16 PPZ 8 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 9 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 02 9686 0010 A 111 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Tilt Motor Assembly continued 2 See Detail A Detail A 7 x2 ann non SSS Pressure Sensitive Adhesive Pulley Height Detail amp Installation 2 8 X4 Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Note Vari Lite recommends that this assembly be replac
21. Tome nota del tipo de l mpara Osram SharXS HTI 1500 W D7 60 antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalaci n Vea las instrucciones detalladas en este manual 3 Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las luminarias VARIXLITE ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA CHOQUE ELECTRICO 1 Las luminarias est n dise adas solamente para lugares secos La exposici n a la lluvia o humedad pueden da ar la luminaria 2 Desconecte la energ a antes de dar servicio a cualquier equipo de VARI LITE 3 El servicio debe ser realizado solamente por personal calificado 02 9686 0010 A ix VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA LA EXPOSICI N EXCESIVA DE RADIACI N ULTRA VIOLETA 1 Muchas luminarias usan un tipo de l mpara que produce radiaci n UV NO mire directamente a la l mpara 2 EsS peligroso operar luminarias sin lentes o protectores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido da adas que su efectividad pudiera estar deteriorada Por eJemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA
22. 8 PPZ screws 4 5 6 Carefully remove the U V Reflector assembly Remove the springs from the reflector clamp and remove the reflector Replace the reflector and UV Reflector assembly in reverse order Make sure the mark on the reflector lines up with the mark on the top left reflector support see the illustration in Figure 2 10 35 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL 36 Reflector Replacement continued Disconnect Springs Reflector Clamp UV Reflector Assembly P m Z 4 40 x 1 3 8 screws 4 Assembly Removal Spring not shown for clarity Reflector Alignment Figure 2 10 Reflector Replacement 02 9686 0010 A MAINTENANCE PROCEDURES MAIN CONTROL BOARD MCB REPLACEMENT 2 Main Control Board MCB Replacement Parts 24 9686 1429 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source 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 tilt side leg is the leg to the left the board side leg is the leg to the right Step 2 At board side leg remove yoke leg cover by removing four 6 32 x 5 16 screws CAUTION Always use anti static precautions when working with PCBs Note Please note placement of cable tie to saddle and cut tie Step 3 Disconnect wiring harness connectors 18 19 J10 and J11 Ste
23. 80 No Item Qty UM Description l 52 6610 0008 1 EA HOUSING 20POS UNLOADED DBL ROW 2 52 6224 1020 1 EA COVER FRONT 20POS MT LATCHING 3 52 6224 2020 1 EA COVER BACK 20POS MT 4 52 6524 0005 2 EA CONN HOUSING 5POS RECEPTACLE 5 52 6588 0007 2 EA HOUSING 7POS XH 250V 3A 2 5MMPITCH 6 52 7007 0001 6 EA CONTACT 28 22AWG PHOSPHOR BRONZE TIN PLT 7 52 8346 0001 10 EA CONTACT 24 30AWG FEMALE CRIMP 8 55 2186 0001 6 EA CABLE TIE 10 WD 4 00 LG SMALL 9 73 5119 0246 6 08 FT WIRE 24AWG 3COND TW 600V 200C lt RED YEL BLU gt 10 73 5124 1289 6 17 FT WIRE 24AWG SCOND 300V 80C BLK BRN RED GRY WHT 11 52 8351 0004 16 EA CONTACT 26 22 AWG RECP MTE REEL NOT SHOWN 10 4 7 x5 2 5 6 x3 5 6 x3 AE 4 7 x5 Figure 3 79 Pan Tilt Control Cable Assembly 02 9686 0010 A 169 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Pan Tilt Control Cable Assembly continued Figure 3 80 Pan Tilt Control Cable Assembly Wiring Pin Out 170 02 9686 0010A CABLE ASSEMBLIES LAMP SUPPLY TO RELAY CABLE ASSEMBLY 3 Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Refer to Figure 3 81 No Item Qty UM Description l 52 8312 0001 4 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 2 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 3 55 6699 0003 3 19 FT SLEEVING 1 2 NOM DI
24. 9686 1143 2 EA LENS MOUNT FRESNEL SPLIT LENS 3 10 9686 2181 6 EA SPACER LENS MOUNTING 4 10 9686 2182 2 EA BUMPER PAD SPLIT LENSES 5 42 9686 0111 1 EA LENS ZOOM FRESNEL RIGHT 6 42 9686 0112 1 EA LENS ZOOM FRESNEL LEFT 7 53 6543 0001 4 EA SCREW 6 32 X 3 8 PPB 8 54 1259 0006 2 EA BEARING FLANGED EXT IN RACE 0 25 ID 9 54 1259 0007 2 EA BEARING FLANGED 0 25 ID 2 x2 Figure 3 18 Fresnel Internal Lenses 86 02 9686 0010A HEAD ASSEMBLY COLOR EFFECT STROBE MODULE 3 Color Effect Strobe Module 21 9686 0400 Rev K VL3500 Wash Refer to Figure 3 19 No Item Qty UM Description l 10 0676 0230 02 3 EA SPACER COLOR WHEEL 043 LG 2 10 9678 0246 5 EA ADJUST PLATE MOTOR 3 10 9686 0420 1 EA BULKHEAD COLOR MODULE FRONT 4 10 9686 0421 1 EA BULKHEAD COLOR MODULE REAR 5 10 9686 0422 2 EA SHAFT COLOR WHEEL FRONT 6 10 9686 0432 2 EA SHAFT COLOR WHEEL REAR 7 10 9686 0433 5 EA SPACER COLOR SYSTEM HALVES 8 10 9686 0442 1 EA BLOCKING PLATE AIR DIMMER 9 10 9686 0443 1 EA AIR DIVERTER DIMMER 10 10 9686 0444 1 EA AIR DIVERTER DIMMER BELT SIDE 11 10 9686 0446 2 EA MOTOR ADJUST PLATE 12 10 9686 0447 1 EA MOTOR ADJUST PLATE CABLE GUIDE 13 10 0686 0457 01 2 EA SPACER COLOR WHEEL 322 LG 14 10 0686 0457 02 2 EA SPACER COLOR WHEEL 125 LG 15 10 96
25. AWG FEMALE CRIMP 2 00 MM PITCH 3 73 2326 0123 0 75 FT WIRE 26 AWG 4 COND 300V 200C TEF UL1180 BLK BRN RED ORN 1 2 x4 3 x 7 BRN ORN OOM BLK RED Figure 3 71 Transfer Fans Cable Assembly 160 02 9686 0010 A CABLE ASSEMBLIES AC INPUT PIGTAIL CABLE ASSEMBLY 3 AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Refer to Figure 3 72 No Item Qty UM Description 1 52 6274 2313 1 EA STRAIN RELIEF SKINTOP FLEX TYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG CE MARKED 20A 250V TWIST LOCK MALE LINE 3 WIRE 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 5 55 2268 0187 0 92 FT HEATSHRINK 3 16 CLEAR KYNAR VDE UL 600V 150DEG 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR VDE UL 600V 150DEG C 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60C EURO BLK HD 22 11MMOD 2 7 1 6 Figure 3 72 Zoom Motor Cable 02 9686 0010 A 161 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL EMI Filter to Power Switch Cable Assembly 25 9678 0811 RevC Refer to Figure 3 73 No Item Qty UM Description 1 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 2 52 8392 0001 2 EA RECP FASTON 187 X0 32 16 14 AWG FLAG DBL CRP 3 55 2186 0001 1 EA CABLETIE 0 10 WD 4 00 LG SMALL 4 73 6016 0009 0 83 FT
26. No Sens CTO sensor not found Aperture No Sens Aperture sensor not found VL3500 Wash Only FX Wheel No Sens FX wheel sensor not found VL3500 Wash FX only FX Index No Sens FX index sensor not found VL3500 Wash FX only WARNING As with any repairs or maintenance to Vari Lite luminaires service should only be performed by a trained and qualified service technician or at an Authorized Vari Lite Service facility 02 9686 0010A TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 Troubleshooting Guide If a problem is suspected try recalibrating the luminaire to prompt an error message Refer to Error Messages on page 16 for more information The chart below provides possible causes and remedies for each message Table 2 2 Troubleshooting Guide Message Symptom Description Possible Cause and Remedy n a No response to DMX DMX Failure MCB connector disconnected data check MCB DATA IN connection n a Lamp douses frequently Lamp Douse Fan failure check fans for proper connection and operation n a Lamp will not strike Lamp Strike Failure Lamp cutout switch disengaged check lamp cutout switches at lamp box and fan ducts Bad lamp replace lamp Low input voltage check input power must be 200 to 264 VAC n a Lamp does not strike Lamp Off option is config Reconfigure lamp startup option in Lamp config upon start up ured menu n a Luminaire behaves
27. Profile Not Matched Profile not set correctly oddly check start DMX address No Sens No control continuous Mechanism failed to find Motor power not connected recalibration and or sensor reported for Blue connect motor power mechanism at wrong Amber Magenta Sensor not connected position ColWheel1 ColWheel2 connect sensor CTO or Aperture Interconnect board not connected securely check connection inspect for bent pins Movement restricted or impeded remove obstruction check cable routing and or check voltage at MCB test point n a Luminaire does not No power Switch not turned on power up verify switch is turned on Not plugged in ensure A C cable is connected to power source Pan Luminaire will not pan Pan Encoder Failure MCB pan tilt connector disconnected Encoder connect MCB pan tilt connector J8 Fail Pan motor disconnected connect pan motor power Encoder faulty replace pan end of travel encoder sensor assembly 02 9686 0010 A 17 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Table 2 2 Troubleshooting Guide Continued Message Symptom Description Possible Cause and Remedy Pan No Sens Luminaire will not pan Pan Sensor Not Found EOT flag attached to large pulley is not engaging the EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth sufficient to e
28. Step 5 Disconnect wiring from encoder board Step 6 Replace by performing steps 2 through 5 in reverse order 02 9686 0010 A 41 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Pan Encoder Replacement continued A Note Make sure the encoder disk is centered in the optical sensor gap Ventilation Cover x gt Encoder gt Motor Assembly Figure 2 14 Pan Encoder Replacement 42 02 9686 0010 A MAINTENANCE PROCEDURES PAN EOT SENSOR REPLACEMENT 2 Pan EOT Sensor Replacement Parts 23 0678 0687 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Place the luminaire on the upper enclosure CAUTION During the next step do allow the front lens to contact anything that could damage the lens coating Step 2 To provide access to the ventilation cover set the luminaire on the front lens casting Step 3 At bottom of the enclosure remove four 1 4 20 x 1 5 8 socket screws and 1 4 split lock washers Remove the ventilation cover Step 4 As shown in Figure 2 15 at the pan sensor remove two 6 32 x 3 8 PPZ screws Step 5 Disconnect wiring from the encoder PCB and remove the sensor Step 6 Replace sensor by performing steps 3 through 5 in reverse order 02 9686 0010 A 43 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Ventilation Cover Sensor Figure 2 15 Pan EOT Sensor Replacement 44 02 9686 0010A MAINTENA
29. lenses Fresnel and Plano Convex Stipple standard on both models e Additional Plano Convex Clear front lens VL3500 Wash only e Additional ULTRA Clear front lens VL3500 Wash FX only Repositional pan tilt system Control by DMX512 protocol WARNING Some exceptional conditions apply to the safe operation of the VL3500 Wash Luminaire See Warnings and Cautions on page 15 Technical Specifications For technical specifications refer to VL3500 Wash and VL3500 Wash FX Luminaires User s Manual 02 9686 0001 6 02 9686 0010 A COMPONENTS EXTERNAL LUMINAIRE COMPONENTS 7 Components External Luminaire Components The following illustration shows the external luminaire components and controls Head Assembly Houses color strobe and beam spreader mechanisms Front Lens Assembly AC Input Cable Input Panel In and Thru an ower connections Backcap Assembly see detail below Provides access to lamp for replacement and proves controls for eam adjustment Yoke Assembly Houses Master Control A Board MCB J Upper Enclosure Assembly m Houses power supply ballast and pas board Input Panel Components Beam Adjustment Controls Menu Display Used to input manual Product Label ID program test set defaults and access Main Power internal status information Switch ACPWR
30. 0 85 455 410 mr 1 355 Set blade assemblies according to dimensions shown Figure 3 28 VL3500 Wash FX Strobe System Assembly 106 02 9686 0010 A HEAD ASSEMBLY REAR STROBE BLADE ASSEMBLY 3 Rear Strobe Blade Assembly 21 9686 1437 Rev 0 Refer to Figure 3 29 No Item Qty UM Description 1 10 9678 0432 1 EA HUB STROBE BLADE 2 10 9678 0466 1 EA STROBE BLADE DAMPER 3 10 9686 1431 1 EA STROBE BLADE NOTCHED 4 53 5558 0188 2 EA SCREW 8 32 X 188 LG SET SS BRASS TIP UNC 2A 5 53 6597 0001 3 EA SCREW 4 40 X 3 16 PPZ 6 55 3303 0004 3 EA WASHER 4 LOCK INT TOOTH SS 02 9686 0010 A 4 x2 5 x3 Figure 3 29 Rear Strobe Blade Assembly 107 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Front Strobe Blade Assembly 21 9686 1438 Rev 0 Refer to Figure 3 30 No Item Qty UM Description 1 10 9678 0432 1 EA HUB STROBE BLADE 2 10 9678 0466 1 EA STROBE BLADE DAMPER 3 10 9686 1431 1 EA STROBE BLADE NOTCHED 4 53 5558 0188 2 EA SCREW 8 32 X 188 LG SET SS BRASS TIP UNC 2A 5 53 6597 0001 3 EA SCREW 4 40 X 3 16 PPZ 6 55 3303 0004 3 EA WASHER 4 LOCK INT TOOTH SS 6 x3 5 x3 Figure 3 30 Front Strobe Blade Assembly 108 02 9686 0010A Yoke Assembly Yoke Assembly 21 9686 0700 Rev A Refer to Figure 3 31 YOKE ASSEMBLY YOKE ASSEMBLY 3
31. 02 9686 0010A CABLE ASSEMBLIES YOKE FAN CABLE ASSEMBLY 3 Yoke Fan Cable Assembly 25 9678 0758 RevA Refer to Figure 3 66 No Item Qty UM Description 1 52 6396 3102 1 EA RECEPT 2POS MTA100 W POL TAB BLUE CLSD END 2 52 6423 0003 1 EA HOUSING 3POS MT RECEPT 2MM CT 28 26 AWG 3 73 5126 0002 0 5 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt UL1061 19STRND 1 2 Figure 3 66 Yoke Fan Cable Assembly 02 9686 0010 A 155 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL OT Switch to Backcap Interlok Cable Assembly 25 9686 0201 RevA Refer to Figure 3 67 No Item Qty UM Description 1 52 8230 0003 1 EA RECEPT FASTON 22 18AWG 1 4 52 8414 0001 1 EA RECEPT FASTON 187 SERIES 24 20 AWG UNISUL 3 73 7089 0000 3 00 FT WIRE 22AWG 300V 200C TEF BLK UL1180 Figure 3 67 OT Switch to Backcap Interlok Cable Assembly 156 02 9686 0010A CABLE ASSEMBLIES IGNITOR LAMP SOCKET CABLE ASSEMBLY 3 Ignitorto Lamp Socket Cable Assembly 25 9678 0789 Rev B Refer to Figure 3 68 No Item Qty UM Description 1 52 8231 0005 2 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 3 55 2260 0133 6 83 FT SLEEVING FIBERGLASS 133 ID 4 73 7100 0001 2 84 FT WIRE 16AWG 20KVDC 41 32 STRD 200C SILICONE 2 X 17 5 73 7190 0001 3
32. 10911 Petal Street Dallas Texas 75238 USA This manual is for informational use only and is subject to change without notice Vari Lite assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual Version as of 19 May 2009 Part number 02 9686 0010 A VL3500 Wash and VL3500 Wash FX Luminaires Service Manual 2003 2009 Vari Lite a Philips group company All Rights Reserved FOREWORD How To Obtain Warranty Service A copy of the Vari Lite Limited Warranty was included in the shipping package for this product To obtain warranty service please contact customer service at 1 877 VARI LITE 1 877 827 4548 1 214 647 7880 or customerservice genlytecontrols com 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 p
33. 2 EA COVER BACK 40 POS MT 4 52 6610 0034 1 EA CONNECTOR HOUSING 34 POS 26 22 AWG DBL ROW UNLOADED 5 52 6224 1034 1 EA COVER FRONT 34 POS MT LATCHING 6 52 6224 2034 1 EA COVER BACK 34 POS MT 7 52 6610 0017 1 EA CONNECTOR HOUSING 50 POS 26 22 AWG DBL ROW UNLOADED 8 52 6224 1050 1 EA COVER FRONT 50 POS MT LATCHING 9 52 6224 2050 1 EA COVER BACK 50 POS MT 10 52 8351 0004 118 EA CONTACT 26 22 AWG RECP MTE 11 52 6524 0004 EA CONNECTOR HOUSING 4 POS RECEPTACLE 30 24 AWG 12 52 8346 0001 6 EA CONTACT 24 30 AWG FEMALE CRIMP 13 73 5116 0123 29 6 FT WIRE 24 AWG 4 COND TW 300V 80C BLK BRN RED ORN 14 73 5126 0002 1 9 FT WIRE 26 AWG 2 COND TW 300V 80C BLK RED 15 55 2186 0001 2 EA CABLE TIE 10 X 4 SMALL 16 55 6699 0011 1 13 FT SLEEVING 3 4 NOM DIA WOVEN POLY ROUNDIT 200D 11 12 x2 11 12 x4 7 8 9 10 16 LZ 4 5 6 10 1 8 3 10 1 291071 02 9686 0010 A 13 14 Figure 3 55 Tilt Harness Cable Assembly 143 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Tilt Harness Cable Assembly continued Say uy or Malal CI CI CI z a zzzox x O C Fora REESE NIM lt NINNI CN Z oz zz azz xo amp C So CC w om mio m majo
34. 4 1 EA ASSEMBLY DUAL FAN DUCT 11 21 9686 0680 1 EA ASSEMBLY HOT BOX 12 21 9686 6619 2 EA FAN ASSY AC 80MM 36CFM 13 53 2002 0001 2 EA NUT 6 32 KEPS ZINC PLATED 14 53 2004 0002 4 EA NUT 8 32 KEPS ZINC PLATE 15 53 6545 0009 4 SCREW 8 32 X 1 375 LG PFZ 16 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 17 53 6558 0007 2 EA SCREW 6 32 X 1 4 PPZ SEMS 18 53 6581 0001 4 EA SCREW 4 40 X 1 3 8 PPZ 19 53 6609 0001 10 EA SCREW 6 32 X 3 8 PFZ 20 53 6614 0003 4 EA SCREW 6 32 X 5 8 PFZ 21 53 6617 0001 10 EA SCREW 6 32 X 1 PPB 22 55 2125 0003 4 EA STANDOFF 3 8 8 32 1 500 L 23 55 6706 0001 l EA GROMMET 9 32 ID 9 16 OD 1 4T 24 74 1099 0001 1 EA SWITCH MINIATURE 5AMP 150DEG 25 55 6541 0008 1 EA GROMMET 1 2 ID 7 8 OD 3 4 GRV 26 55 6506 0024 2 EA SPACER 3 16 RND 188 LG 141 THRU 27 55 6528 0001 2 EA WASHER 6 FLAT ZINC 28 55 6538 0004 4 EA WASHER 750 OD 312 ID 125 THK 29 53 6613 0001 2 EA SCREW 6 32 X 1 2 PPZ 30 55 6677 0042 2 EA WASHER 500 OD 145 ID 031 THICK 31 10 9678 1645 2 EA FANLIGHT SHIELD 02 9686 0010 A VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 32 55 6658 0500 2 EA STANDOFF 6 32 X 1 2 LG 1 4 HEX ZINC 25 9686 0012 1 EA YOKE TO DUAL AC FAN CABLE ASSY not shown 25 9686 0201 1 EA CABLE ASSY OT SWITCH TO BACKCAP INTERLOCK not shown 11 Detail A Deta
35. 4 EA CONTACT 24 30AWG FEMALE CRIMP 5 73 2324 0200 2 21 FT WIRE 26AWG 2COND 300V 200C lt BLK RED gt UL1213 6 52 8274 0001 2 EA CONNECTOR BUTT SPLICE 22 18 AWG INSULATED 152 1 3 x4 6 x2 5 2 4 x2 Figure 3 63 Transfer Fans Cable Assembly 2 4 2 02 9686 0010 A CABLE ASSEMBLIES UPPER ENCLOSURE FANS CABLE ASSEMBLY 3 Upper Enclosure Fans Cable Assembly 25 9686 0210 Rev 0 Refer to Figure 3 64 No Item Qty UM Description 1 52 6523 0004 1 EA CONN HOUSING 4POS RECEPTACLE 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3 52 8347 0001 4 EA CONTACT 24 30AWG MALE CRIMP 4 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 5 73 5126 0002 6 41 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt 1 3 X4 2 4 X2 2 4 X2 Figure 3 64 Upper Enclosure Fans Cable Assembly 02 9686 0010 A 153 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Yoke Fan and Relay Cable Assembly 25 9678 0681 Rev C Refer to Figure 3 65 No Item Qty UM Description 1 52 6423 0003 1 EA HOUSING 3 POS MT RECEPT 2MM 2 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG 3 52 6396 3103 1 EA RECEPT 3 POS MTA100 W POL TAB BLU CLSD END 4 73 3526 0002 1 25 FT WIRE 26AWG 300V 105C PVC RED 5 73 5126 0002 1 50 FT WIRE 26AWG 2 COND 300V 80C lt RED BLK gt 3 Figure 3 6S Yoke Fan and Relay Cable Assembly 154
36. 482 1 EA HARNESS GUIDE ROTATING EFFECTS 5 21 9686 0010 1 EA ASSY GENERIC LUMINAIRE VL3500 Wash Only 21 9686 1010 1 EA ASSY GENERIC LUMINAIRE VL3500 Wash FX Only 6 21 9686 0611 2 EA ASSY HEAD COVER 7 21 9686 0660 1 EA ASSY DUAL FAN TRAY DUCT 8 21 9686 2150 1 EA ASSY SPLIT LENS 9 21 9686 0400 1 EA ASSY COLOR DIMMER STROBE VL3500 Wash Only 21 9686 1400 1 EA ASSY COLOR ROTATING EFFECTS STROBE VL3500 Wash FX Only 10 24 9686 1429 1 EA ASSY VL3500 WASH CONTROLLER 21 9686 1121 1 EA CABLE ASSY HEAD CABLE INTERCONNECT not shown 25 9686 0209 1 EA CABLE ASSY TRANSFER FANS not shown 25 9686 0210 1 EA CABLE ASSY UPPER ENCLOSURE FANS not shown 28 9686 0001 1 EA INCLUDED ITEMS KIT VL3500 WASH VL3500 Wash Only not shown 28 9686 0011 1 EA INCLUDED ITEMS KIT VL3500 WASH VL3500 Wash FX Only not shown 11 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB 12 53 6543 0001 6 EA SCREW 6 32 X 3 8 PPB 13 53 6545 0007 10 EA SCREW 8 32 X 3 8 LG 14 53 6558 0007 4 EA SCREW 6 32 X 1 4 LG PPZ SEMS EXT ZINC PLT 15 53 6558 0009 6 EA SCREW 6 32 X 3 8 LG PPZ SEMS 58 02 9686 0010 A TOP ASSEMBLY VL3500 WASH VL3500 WASH FX LUMINAIRES No Item Qty UM Description 16 53 6558 0016 2 EA SCREW 6 32 X 3 4 LG PPS SEMS 17 55 6677 0033 4 EA WASHER 201 OD 125 ID 032 THK FLAT SS 18 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 X 1 188 LG MF STL
37. 5 2 42 FT WIRE 26 AWG 8 COND 300V 200C BLK WHT BLU WHT YEL WHT BLK WHT PUR RED ORG YEL UL1180 16 52 6467 0006 1 EA CONN FEMALE PLUG 6 POS 24 30 AWG JST PHR6 17 52 6467 0008 1 EA CONN FEMALE PLUG 8 POS 24 30 AWG JST PHR8 18 52 6524 0002 1 EA CONN HOUSING 2 POS RECEPT MOLEX 50 57 9402 19 52 8346 0001 2 EA 24 30AWG FEMALE CRIMP MOLEX 16 02 0097 20 0 75 FT WIRE 26 AWG 2 COND 300V 200C BLK RED UL1180 02 9686 0010A CABLE ASSEMBLIES VL3500 WAsH FX COLOR HARNESS CABLE ASSEMBLY 3 VL3500 Wash FX Color Harness Cable Assembly continued 10 11 10 11 10 11 Figure 3 60 VL3500 Wash FX Color Harness Cable Assembly 02 9686 0010 A 149 VL3500 Wash FX Color Harness Cable Assembly VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL continued 2 XIV XONI a 39 00 2 XTION 0115M L X43 919 y dOLON 2 Xld v NVJ 2076 15 05 X310M ma 9 1S rg 09POg SNIS 2 INOT Z SNIS 9 SHd 157 IT NHO div 49 wwoo z XTION SIYM 0315ML 1 gt NVAD ra saum 031 gt VINTIVH SIYM 03191 a E hi
38. 500 Wash master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan tilt encoder readings The values can be used to determine whether a circuit is opening correctly or needs further troubleshooting Guidelines The values will change depending on whether the sensor reading is Open or Closed The values will be different depending on the type of sensor optical or magnetic Asa general rule if a change occurs from 5v to Ov or visa versa then it is working An Open reading occurs when the sensor is not aligned tab not at sensor typically a non zero DMX value Closed reading occurs when the sensor is aligned tab in or at sensor typically a zero DMX value Optical sensors read high when the sensor is Closed Magnetic sensors read Low when the sensor is Closed High value 5 volts typically 4 9 volts Low value 0 volts or up to approximately 0 2 volts Notes regarding specific mechanisms 02 9686 0010 A 13 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL 14 The two fixed color wheels and four color mixers read high when the tab is in the optical sensor Pan and tilt sensors read high when the tab is in the sensor The mechanism calibrates to the edge and its tab covers 50 of travel Pan and tilt encoders are best read with a scope to read the encoder tick
39. 66 FT WIRE 250 DEG C 6 55 2200 0003 33 FT HEAT SHRINK TUBING X 2 7 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 PIDG 2 x3 1 3 1 x 44 each 4 1 x 17 each 1 4 1 x 17 each 5 1 x 24 each 0 x48 each 7 6 5 Note Some material removed to show wire detail Figure 3 68 Ignitor to Lamp Socket Cable Assembly 02 9686 0010 A 157 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Chassis to Yoke Ground Cable Assembly 25 9661 1520 Rev Refer to Figure 3 69 No Item Qty UM Description 1 52 8250 0006 2 EA TERM RING 8 10AWG 2 73 7089 0504 15 17 FT WIRE 22AWG 300V 200C TEF GRN YEL UL1180 2 1 j 1 Head Ground Yoke Ground Figure 3 69 Chassis to Yoke Ground Cable Assembly 158 02 9686 0010 A CABLE ASSEMBLIES ZOOM MOTOR CABLE ASSEMBLY 3 Zoom Motor Cable Assembly 23 9686 0208 Rev 0 Refer to Figure 3 70 No Item Qty UM Description 1 25 9686 0206 1 EA CABLE ASSY ZOOM MOTOR 2 24 9678 5916 1 EA PCB ASSY ZOOM INTERCONNECT 2 1 Note Item 1 is soldered to Item 2 as shown Figure 3 70 Zoom Motor Cable Assembly 02 9686 0010 A 159 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Zoom Motor Cable 25 9686 0206 Rev 0 Refer to Figure 3 71 No Item Qty UM Description 1 52 6662 0006 1 EA HOUSING 6 POS 125 2A 2 00 MM PITCH 2 52 6467 0024 4 EA CONTACT 24 30
40. 70 2 050 375 1 270 675 1 259 058 Canada Design Patents No 81 234 81 233 76 046 European UK Patents No 0 652 400 0 586 049 0 565 218 0 547 732 0 534 710 0 495 305 0 474 202 0 379 970 0 253 082 0 253 081 0 248 974 0 192 882 Germany Patents No 694 25 943 8 693 14 122 0 692 08 615 3 692 07 692 1 691 31 478 0 691 21 029 2 690 33 385 4 37 89 166 9 37 68 727 1 37 51 804 6 37 50 201 8 35 87 270 5 Germany Design Patents No M 98 01 745 4 M 96 04 515 9 M 96 04 514 0 M 94 07 689 8 M 94 02 951 2 M 499 03 583 6 M 498 11 203 9 G 93 12 884 3 Spain Patents No 2 090 191 2 084 289 2 020 960 0 548 328 Spain Utility Model Patent No 2 031 748 Spain Design Patents No 0 137 502 0 137 501 0 133 573 Greece Patent No 910 400 544 Japan Patents No 2 843 696 2 059 669 2 055 324 2 002 168 1 966 525 1 889 481 1 792 721 1 770 241 Japan Design Patents No 985 985 1 985 985 947 552 945 436 1 945 436 1 106 089 1 077 598 1 072 598 1 060 414 1 002 123 Korea Patents No 76 310 42 639 283 770 181 180 Korea Design Patents No 209 896 209 895 Mexico Patent No 180 148 Taiwan Patents No 78 726 66 975 65 380 28 275 United Kingdom Design Registrations No 2082526 2072562 2056387 2056386 2042174 2038212 2033108 2029499 All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or organizations Vari Lite
41. 86 0122 1 EA LENS ASPHERIC PC CLEAR POLISHED 5 53 6598 0312 8 EA SCREW 4 40 X 5 16 6 53 6685 2125 4 EA SCREW CAPTIVE SH CAP 10 32 1 125 LG ZN 2 x4 1 4 4 5 8 Figure 3 3 Polished PC Clear Front Lens Assembly 02 9686 0010 A 65 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Front Clear Lens Assembly 21 9686 0618 Rev C VL3500 Wash Refer to Figure 3 4 No Item Qty UM Description 1 10 9686 0641 4 EA CLIP FRONT LENS 2 12 9686 0627 1 EA CASTING CONVEX LENS 3 42 9686 0121 1 EA LENS ASPHERIC PLANO CONVEX CLEAR 4 53 6598 0312 8 EA SCREW 4 40 X 5 16 5 53 6685 1125 4 EA SCREW CAPTIVE SH CAP 10 32 1 125 LG BLK ZN 3 1 x4 4 AN 66 Figure 3 4 Front Clear Lens Assembly 02 9686 0010A HEAD ASSEMBLY FRONT FRESNEL LENS ASSEMBLY 3 Front Fresnel Lens Assembly 21 9686 0619 Rev D Refer to Figure 3 5 No Item Qty UM Description 1 10 9686 0641 4 EA CLIP FRONT LENS 2 10 9686 0682 4 EA COUNTERWEIGHT FRONT SHORT THIN 3 10 9686 0638 36 EA COUNTERWEIGHT FRONT LONG 4 12 9686 0629 1 EA CASTING MACHINED FRESNEL LENS 5 42 9686 0102 1 EA LENS FRESNEL 230 MM DIA 6 53 6598 0312 8 EA SCREW 4 40 X 5 16 7 53 6618 0001 8 EA SCREW 6 32 X 1 5 PPZ 8 53 6685 1500 4 EA SCREW CAPTIVE SH CAP 10 32 1 5 LG BLK ZN 3 x36 N 8 x4 e Fig
42. 86 0457 03 1 EA SPACER COLOR WHEEL 490 LG 16 10 9686 0457 04 1 EA SPACER COLOR WHEEL 090 LG 17 10 0686 0457 05 l EA SPACER COLOR WHEEL 271 LG 18 10 9686 0468 6 EA PULLEY COLOR WHEEL DRIVE MOTOR WITH FLANGES 19 10 9686 2468 2 EA PULLEY MOTOR NO FLANGES FOR CTO AND DIMMER WHEELS 20 21 9686 0404 1 EA ASSEMBLY STROBE SYSTEM 21 21 9686 0480 1 EA ASSY FIXED COLOR WHEEL 2 22 21 9686 0484 1 EA ASSY FIXED COLOR WHEEL 1 23 22 9686 0410 1 EA ASSY COLOR WHEEL CYAN 24 22 9686 0411 1 EA ASSY COLOR WHEEL YELLOW 25 22 9686 0412 1 EA ASSY COLOR WHEEL MAGENTA 26 22 9686 0413 1 EA ASSY COLOR WHEEL CTO 27 22 0686 0414 1 EA ASSY DIMMER WHEEL 28 22 9686 0490 1 EA ASSY APERTURE WHEEL 29 24 9686 0427 1 EA BOARD ASMB COLOR WHEEL SENSOR TRIPLE 30 24 9686 0428 1 EA BOARD ASMB COLOR WHEEL SENSOR QUAD 25 9686 0205 1 EA CABLE ASSY COLOR HARNESS not shown 02 9686 0010 A 87 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL No Item Qty UM Description 31 44 9663 1766 8 EA MOTOR ZOOM DIMMER 32 53 6525 0188 4 EA SCREW 6 32 X 3 16 PPZ SEMS 33 53 6530 0006 6 EA RIVET 1 8 OD POP 188 250 LG 34 53 6558 0009 10 EA SCREW 6 32 X 3 8 LG PPZ SEM 35 53 6609 0001 14 EA SCREW 6 32 X 3 8 PFZ 36 53 6613 0001 12 EA SCREW 6 32 X 1 2 PPZ 37 54 2057 0001 8 EA BELT TIMING MXL 188W 144 GRV URETH KEVLAR 38 55 6669 0014 6 EA
43. A POLY EXP BRAIDED 4 73 7089 0000 34 41 FT WIRE 22AWG BLK 300V TEFLON STRANDED 5 73 7089 0009 34 41 FT WIRE 22AWG WHT 300V TEFLON STRANDED 6 73 3516 0504 58 FT WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 7 52 8245 0001 1 EA TERM RING 10 16 14 AWG REEL PIDG 8 73 7130 0005 2 08 FT WIRE TUBULAR BRAID 7 16 NOT SHOWN 9 55 2183 0001 33 FT HEATSHRINK 1 2 BLACK NOT SHOWN 1 x2 x7 1 x2 To Relay From Lamp Supply 7 8 4 x7 3 2 x3 Figure 3 81 Lamp Supply to Relay Cable Assembly 02 9686 0010 A 171 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 172 02 9686 0010A APPENDIX PRODUCT TECHNICAL BULLETINS AND NOTICES A APPENDIX A Technical Bulletins and Notices Product Technical Bulletins and Notices The following table identifies the current technical bulletins and notices associated with the VL3500 Wash and VL3500 Wash FX Luminaires These improvements have been incorporated into this manual where applicable and are available on the Vari Lite web site at http www vari lite com Table A 1 Vari Lite VL3500 Wash VL3500 Wash FX Technical Notices Technical Notice Description Model s TN 248 Specified and Approved Lamps for use in All VARI LITE Luminaires TN 264 Split Lens Rail Change VL3500 Wash TN 274 Pack up Cues for Shipping VL3500 Wash TN 275 Lamp Part Number Change VL3500 Wash TN 278 Cyan and Yellow Color Wheels VL3500 Wash Ordering Info
44. ACER COLOR WHEEL 20 10 0686 2457 06 l EA SPACER COLOR WHEEL 21 10 0686 2457 07 2 EA SPACER COLOR WHEEL 22 10 0686 2457 08 l EA SPACER COLOR WHEEL 23 10 0686 2457 09 l EA SPACER COLOR WHEEL 24 10 9686 2468 2 EA PULLEY COLOR MOTOR WHL DRV NO FLANGES 25 21 9686 1404 l EA ASSEMBLY STROBE SYSTEM 26 21 9686 1405 1 EA ASSEMBLY ROTATING EFFECTS WHEEL LATCH 27 21 9686 1480 1 EA ASSEMBLY FIXED COLOR WHEEL 2 ROT EFF 28 21 9686 1484 1 EA ASSEMBLY FIXED COLOR WHEEL 1 ROT EFF 29 21 9686 1448 1 EA BLOWER ASSEMBLY ROTATING EFFECTS 30 22 9686 1410 1 EA ASSEMBLY COLOR WHEEL CYAN 31 22 9686 1411 1 EA ASSEMBLY COLOR WHEEL YELLOW 02 9686 0010 A HEAD ASSEMBLY COLOR ROTATING EFFECT STROBE MODULE 3 No Item Qty UM Description 32 22 9686 1412 1 EA ASSEMBLY COLOR WHEEL MAGENTA 33 22 9686 1413 1 EA ASSEMBLY COLOR WHEEL CTO 34 22 9686 1414 1 EA ASSEMBLY DIMMER WHEEL 35 24 9686 3427 1 EA PCB COLOR WHEEL SENSOR QUAD WITH HALL 36 24 9686 3428 1 EA PCB COLOR WHEEL SENSOR QUAD 25 9686 1205 1 EA CABLE ASSEMBLY COLOR EFFECTS HARNESS not shown 37 44 9663 1766 9 EA MOTOR ZOOM DIMMER 38 53 6525 0188 4 EA SCREW 6 32 X 3 16 LG PPZ SEMS 39 53 6530 0006 6 EA RIVET 1 8 OD POP 188 250 LG 40 53 6558 0009 12 EA SCREW 6 32 X 3 8 LG PPZ SEM 41 53 6609 0001 14 EA SCREW 6 32 X 3 8 LG PFZ 42 53 6613 0001 12 EA SCREW 6 32 X 1 2 LG PP
45. ALE CRIMP 3 x2 6 00 1 gt 1 78 Figure 3 13 Head Front Fan Assembly 02 9686 0010 A HEAD ASSEMBLY INTERNAL LENS ASSEMBLY 3 Internal Lens Assembly 21 9686 2150 Rev H Refer to Figure 3 14 No Item Qty UM Description l 10 0686 1155 1 EA CLAMP BELT FRONT 2 10 9686 2180 1 EA CROSS STRAP BEAM SPLITTER 3 10 9686 2190 1 EA BUMPER LENS 4 10 9686 7135 2 EA KNOB HEX ALUMINUM 5 21 9686 2140 1 EA ASSEMBLY RAIL SPLIT LENS 6 21 9686 2142 1 EA ACTUATOR ASSEMBLY 7 21 9686 2144 1 EA ASSEMBLY INTERNAL LENS SPLITTER 8 21 9686 2164 1 EA ASSEMBLY SPLIT ZOOM BUXOM RIGHT 9 21 9686 2165 1 EA ASSEMBLY SPLIT ZOOM BUXOM LEFT 10 53 6513 0032 4 EA SCREW M3 X 5 X 10MM LG PPZ METRIC 11 53 6513 0046 4 EA SCREW M3 X 6 LG SOC CAP LOW PROFILE BLK 12 53 6607 0001 1 EA SCREW 6 32 X 1 4 PPB 02 9686 0010 A 79 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Internal Lens Assembly Continued Figure 3 14 Internal Lens Assembly 80 02 9686 0010A HEAD ASSEMBLY INTERNAL LENS RAIL ASSEMBLY 3 Internal Lens Rail Assembly 21 9686 2140 Rev K Refer to Figure 3 15 No Item Qty UM Description l 10 9621 0097 1 EA STABILIZER STEPPER WHEEL 2 10 9678 0128 1 EA PULLEY ZOOM MOTOR 3 10 9678 1131 1 EA FO
46. ANUAL Tilt Motor Assembly Replacement continued A WARNING Make sure wiring is not pinched during installation When tightening four 10 32 x 1 2 PPZ screws that fasten the tilt motor assembly you must tighten then in a CLOCKWISE pattern starting with the screw in lower left hand side Yoke Cover Tilt Motor Springs Assembly Tilt Belt Figure 2 17 Tilt Motor Assembly Replacement 48 02 9686 0010A MAINTENANCE PROCEDURES TILT ENCODER REPLACEMENT Tilt Encoder Replacement Parts 24 9661 9629 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 As shown in Figure 2 17 at the tilt side leg remove yoke leg cover by removing four 6 32 x 5 16 PTB screws Step 3 Attilt motor assembly loosen four 10 32 x 1 2 PPZ screws Step 4 Remove belt from tilt pulley Step 5 Remove four 10 32 x 1 2 PPZ screws Remove tensioning springs Step 6 Disconnect wiring and remove the tilt motor assembly Step 7 Asshown in Figure 2 18 at the tilt assembly remove two 4 40 x 1 4 LG PPZ screws and remove encoder PCB Step 8 Replace by performing steps 2 through 7 in reverse order A Note Make sure encoder disk passes through sensor when installing encoder PCB Do not pinch wiring during installation When tightening four 10 32 x 1 2 PPZ screws that fasten the tlt motor assembly you must tighten then in a CLOCKWISE pattern starting with the screw in lower left hand side
47. ARNESS CABLE ASSEMBLY 3 VL3500 Wash Color Harness Cable Assembly continued 5j a IN sn wr C oO CC ES T ES gt ES E gt 5 Ur 7 on Figure 3 59 VL3500 Wash Color Harness Cable Assembly Wiring Pin Out 02 9686 0010 A 147 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash FX Color Harness Cable Assembly 25 9686 1205 Rev B VL3500 FX Wash Refer to Figure 3 60 and Figure 3 61 No Item Qty UM Description 1 52 6610 0040 1 EA CONNECTOR HOUSING 40 POS 26 22 AWG DBL ROW UNLOADED 2 52 6224 1040 1 EA COVER FRONT 40 POS MT LATCHING 3 52 6224 2040 1 EA COVER BACK 40 POS MT 4 52 6610 0034 1 EA CONNECTOR HOUSING 34 POS 26 22 AWG DBL ROW UNLOADED 5 52 6224 1034 1 EA COVER FRONT 34 POS MT LATCHING 6 52 6224 2034 1 EA COVER BACK 34 POS MT 7 52 8351 0004 60 EA CONTACT 26 22 AWG RECP MTE 8 52 6467 0011 2 EA CONNECTOR FEMALE PLUG 11 POS 30 24 AWG 9 52 6467 0024 22 EA CONTACT SOCKET 30 24 AWG CRIMP 10 52 6662 0006 9 EA HOUSING 6 POS 125 2A 2 0 MM PITCH 11 52 8388 0001 36 EA CONTACT 24 30 AWG FEMALE CRIMP 2 0 MM PITCH 12 55 2186 0001 8 EA CABLE TIE 10 X 4 SMALL 13 73 2324 0123 14 66 FT WIRE 24 AWG 4 COND TW 300V 200C BLK BRN RED ORG 14 73 2328 6000 0 875 FT WIRE 26 AWG 6 COND 300V 200C BLK WHT BLU WHT YEL WHT BLK WHT PUR RED UL1180 1
48. CORN 10 32THD 3 8 WIDE 8 53 5508 0375 2 EA SCREW 8 32 X 3 8 PPSS 9 53 6530 0013 8 EA RIVET 1 8 OD 063 125 GL CSK HD ALUM 10 55 2233 0003 4 EA RETAINER PUSH ON TYPE 11 55 2233 0006 4 EA STUD 1 4 TURN OPR 455L STEEL 12 55 6546 0004 3 EA WASHER TEFLON 2011D X 4380D X 04 THK 13 55 6568 0035 3 EA SPRING CPRSN 300 OD 875 LG 035 WIRE DIA SS 14 71 2561 0002 1 EA LAMPHOLDER SFC10 4 WITH PREFOCUS SHARX 02 9686 0010 A 75 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Hot Box Assembly continued 13 63 9 x8 11 x4 12 x3 N 10 x4 Figure 3 11 Hot Box Assembly 76 02 9686 0010 A HEAD ASSEMBLY DUAL FAN TRAY ASSEMBLY 3 Dual Fan Tray Assembly 21 9686 0660 Rev B Refer to Figure 3 12 No Item Qty UM Description 1 22 9686 0661 1 EA ASSY FAN TRAY 2 23 9686 0684 2 EA FAN ASSY HEAD FRONT 3 53 5506 1375 4 EA SCREW 6 32 X 1 3 8 LG PPB 4 55 6818 0002 1 EA STANDOFF 45 DEG NYLON 6 6 KUR 3 x4 Figure 3 12 Dual Fan Tray Assembly 02 9686 0010 A 77 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Head Front Fan Assembly 23 9686 0684 Rev 0 Refer to Figure 3 13 No Item Qty UM Description 1 12 9686 0664 1 EA FAN COOLING 24V MODIFIED 2 52 6523 0002 1 EA CONN HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG M
49. CTION 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 VARIXLITE equipment 3 Servicing to be performed by qualified personnel only 02 9686 0010 A iii VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1 Many VARI LITE luminaires use a lamp that produces UV radiation DO NOT look directly at lamp 2 Itis 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 Wea
50. Cable Assembly 25 9686 0204 Reflector Mount Assembly 21 9686 0605 Yoke Assembly 21 07 MESE Dual Fan Duct Assembly Actuator Assembly 22 9686 0674 21 9686 2142 Tilt Motor Assembly 21 9678 0765 continued next page Internal Lens Splitter Assembly 21 9686 2144 Internal Lens Rail Assembly 21 9686 2140 Hot Box Yoke Fan Assembly 22 9661 0609 24 9686 1429 Fan Relay Cable Assembl Ignitor to Lamp Socket Cable 25 9678 0681 Assembly 25 9678 0789 Head Cable Interconnect Ignitor to Relay Cable Assembly 21 9686 1121 25 9661 1526 80mm Fan Assembly 21 9686 6619 continued next page Yoke Fan Cable Assembl Transfer Fans Cable Assembly 25 9686 0209 Yoke to Dual AC Fan Cable Assembly 25 9686 0012 25 9678 0758 Upper Enclosure Fans Cable Assembly Upper Enclosure Assembly 21 9686 0800 OT Switch to Backcap Interlok 25 9686 0210 Cable Assembly 25 9686 0201 continued next page Included Items Kit Polished PC Clear Front Lens 28 9686 0011 Assembly 21 9686 1617 continued next page Figure 3 3 VI 35001M Wash FX Luminaire Subassembly Drawing Tree Part 1 54 02 9686 0010 A DRAWING TREE VL3500 WASH FX VL3500 WASH FX LUMINAIRE 3 VL3500 Wash FX Luminaire continued continued from previous page continued from previous page Color Rotating EffectStrobe Module 21 9686 1400 Upper Enclosure Assembly 21 9686 0800 IVL3500 Wash
51. Cable Assembly 25 9661 1514 RevA Refer to Figure 3 48 No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8271 0001 1 EA FASTON RECEPT 16 14 AWG REEL 3 73 3516 0504 3 5 IN WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 Figure 3 48 LVS Chassis Ground Cable Assembly 136 02 9686 0010A CABLE ASSEMBLIES IGNITOR TO RELAY CABLE ASSEMBLY 3 Ignitor to Relay Cable Assembly 25 9661 1526 Rev Refer to Figure 3 49 No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG LOOSE PIDG 2 52 8312 0001 1 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 73 7101 0009 0 42 FT WIRE 14AWG 15KV 150C SILICONE 41 30 STRANDING 2 1 Figure 3 49 Ignitor to Relay Cable Assembly 02 9686 0010 A 137 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Yoke to Dual AC Fan Cable Assembly 25 9686 0012 RevA Refer to Figure 3 50 No Item Qty UM Description 1 52 6665 0001 4 EA CONTACT 22 26AWG MALE MATE N LOK 2 2 52 6665 0002 2 EA CONN HOUSING 2 POS PLUG MATE N LOC 2 3 52 8413 0001 4 EA RECEPT FASTON 110 SERIES 22 18AWG INSULATED 4 55 2186 0002 2 EA CABLE TIE 09 WD 3 750 LG TEFZEL 5 55 2260 0208 2 75 FT SLEEVING FIBERGLASS 0 208 ID 6 55 2200 0003 0 50 FT HEATSHRINK TEFLON NATURAL COLOR 7 73 6222 0009 6 33 FT WIRE 22AWG 600V 200C W
52. E LA L MPARA DE ARCO 1 Las l mparas de arco requieren un per odo de tiempo para volver a iluminarse despu s de una interrupci n de energ a o de una severa ca da de voltaje En algunos casos la l mpara se volver a iluminar en forma autom tica despu s que se ha enfriado dependiendo de la configuraci n del sistema de energ a de la l mpara 2 La posici n de encendido es universal X 02 9686 0010 A FOREWORD 02 9686 0010 A VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL UV 1 VARI LITE UV HID 2 1
53. EA NUT 10 32 NYLON INSERT 28 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX 29 53 2200 0006 4 EA NUT 6 32 KEPS SS 30 53 6505 0022 3 EA BOLT 3 8 16 X 3 4 LG CARR 31 53 6515 0001 4 EA SCREW 10 32 X 3 4 SCB CAP 32 53 6522 0001 1 EA SCREW 6 32 X 1 4 PFZ 33 53 6522 0004 2 EA SCREW 6 32 X 1 4 SOC HD 34 53 6525 0188 2 EA SCREW 6 32 X 3 16 PPZ SEMS 35 53 6530 0023 2 EA RIVET 1 8 POP 376 500GRP 36 53 6539 0001 4 EA WASHER 3 8 SPLIT LOCK 37 53 6545 0003 4 EA SCREW 8 32 X 3 8 PFZ 38 53 6545 0004 4 EA SCREW 8 32 X 3 8 LG PPZ 39 53 6556 0002 1 EA SCREW 4 40 X 3 4 LG PPB 40 53 6558 0009 13 EA SCREW 6 32 X 3 8 LG PPZ SEMS 41 53 6558 0010 11 EA SCREW 6 32 X 1 4 LG PPZ BLACK 42 53 6558 0015 4 EA SCREW 6 32 X 3 8 PPB SEMS EXT 43 53 6571 0003 1 EA SCREW 6 32 X 1 1 2 LG PPB 44 53 6591 0001 2 EA SCREW 6 32 X 1 4 PFZ 45 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ 46 53 6626 0001 1 EA SCREW 10 32 X 1 2 PPZ 47 55 6575 0001 4 EA SCREW 10 32 X 3 4 PPB 48 53 6634 1000 1 SCREW 3 8 16 X 1 00 LG SOC 49 53 6513 0044 3 EA SCREW M5 X 10MM STL CUP PT 50 54 1206 0014 2 EA RING RETAINING 51 54 1255 0001 1 EA BEARING ASSY BLACK FLUSH MOU 02 9686 0010A ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 No Item Qty UM Description 52 54 2067 0001 1 EA BELT TIMI
54. EINE HINWEISE BER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUER UBERHOHTE UV STRAHLUNG UND K RPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VAREKLITEG Scheinwerfer sind ausschlie lich f r den Einsatz mit bestimmten Lampentyps Achten Sie auf den Lampentyp Osram SharXS HTI 1500 W D7 60 bevor Sie die jeweiligen Lampen ersetzen Die Installation eines anderen Lampentyps kann gef hrlich sein 2 Scheinwerfer k nnen auf jeder beliebigen Oberfl che montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der VARIXLITE Scheinwerfer von brennbarem Material oder beleuchteten Objekten WARNUNG HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK 1 VARI LITE Scheinwerfer eignen sich ausschlie lich f r trockene Standorte Regen oder Feuchtigkeit k nnen die Scheinwerfer besch digen 2 Unterbrechen Sie die Stromzufuhr bevor Sie mit der Arbeit an VARIXLITE Ger ten beginnen 3 Die Ger te sollten nur von qualifiziertem Personal gewartet werden 02 9686 0010 A V VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL WARNUNG HINWEISE ZUM SCHUTZ GEGEN UBERHOHTE UV STRAHLUNG 1 Viele VARI LITE Scheinwerfer verwenden die Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 2 Es ist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen od
55. ERVICE MANUAL Drawing Tree VL3500 Wash VL3500 Wash Luminaire VL3500 Wash Luminaire 20 9686 0001 Color Effect Strobe Module Generic Luminaire Assembly Head Cover Assembly 21 9686 0400 21 9686 0010 21 9686 0611 continued next page Head Structure Assembly Dual Fan Tray Assembly 21 9686 0600 21 9686 0660 Tilt Harness Cable Assembly 25 9686 2203 Backend Assembly Internal Lens Assembly 21 9686 0615 21 9686 2150 Internal Lens Interconnect Cable Assembly 25 9686 0204 Reflector Mount Assembly Internal Lens Rail Assembly 21 9686 0605 21 9686 2140 Yoke Assembly 21 9686 0700 Dual Fan Duct Assembly Actuator Assembly 22 9686 0674 21 9686 2142 Tilt Motor Assembly 21 9678 0765 continued next page Internal Lens Splitter Assembly 21 9686 2144 Hot Box A bl Yoke Fan Assembly ps 0680 J 22 9661 0609 VL3500 Wash Controller PCB Assembly Ignitor to Lamp Socket Cable 24 9686 1429 Ignitor to Relay Cable Assembly 25 9661 1526 Assembly 25 9678 0789 Head Cable Interconnect 21 9686 1121 oke Fan and Relay Cable Assembl 80mm Fan Assembly 25 9678 0681 21 9686 6619 continued next page Transfer Fans Cable Assembly 25 9686 0209 Yoke to Dual AC Fan Cable Assembly 25 9686 0012 Yoke Fan Cable Assembly 25 9678 0758 Upper Enclosure Fans Cable Assembly Upper Enclosure Assembly OT Switch to Backcap Interlok 25 9686 0210 21 9686 0800 Cable Assembly 25 9686 0201 co
56. Enclosure Assembly continued Figure 3 37 Upper Enclosure Assembly 122 02 9686 0010A ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 Upper Enclosure Assembly continued Note Shims used as required to remove any slack in pan tube assembly Part is shown exploded for clarity Detail Figure 3 38 Upper Enclosure Mechanical Components 02 9686 0010 A 123 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly continued 70 40 x3 v 67 60 34 2 68 55 41 72 39 29 X2 Ground Label 55 41 35 x2 37 Figure 3 39 Upper Enclosure Electrical Components 124 02 9686 0010 A ENCLOSURE ASSEMBLY VENTILATION COVER ASSEMBLY 3 Ventilation Cover Assembly 21 9686 0840 02 Rev B Refer to Figure 3 40 No Item Qty UM Description 1 10 9686 1249 4 EA POST TRUSS HOOK 2 10 9686 0883 1 EA COVER VENTILATION 3 10 9678 0837 1 EA AIR SEAL FAN SIDE 4 10 9678 0838 1 EA AIR SEAL APS SIDE 5 10 9678 0835 1 EA AIR SEAL SHORT STRIP 6 10 9678 0836 1 EA AIR SEAL LONG STRIP 7 10 9678 0887 2 EA RAIN COVER SOUND INSULATION ALUMINUM COVER 8 53 6653 0027 4 EA SCREW 1 4 20 X 1 5 8 SOC HEAD 9 54 1206 0015 4 EA RING RETAINING PRESS ON 1 SH 10 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK 02 9686 0010 A 125 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MAN
57. FX Fixed Color Wheel Ventilation Cover Assembly Pa Asset on 21 9686 0840 02 21 9686 1480 s 21 9686 0805 VL 3500 Wash FX Fixed Color Wheel Pan Pulley Assembly DMX Input PCB 1 Assembly 21 9686 0807 24 9663 3895 21 9686 1484 Pan Motor Assembly AC Input Pigtail Cable Assembly VL3500 Wash FX Rotating Effect 21 9686 0864 25 9678 0810 Wheel Assembly 21 9686 1405 Pan Tube Assembly Pan EOT Sensor Electrical 21 9678 0881 Assembly 23 9678 0687 Chassis to Yoke Ground Cable Assembly Exhaust Fan Assembly 25 9661 1520 21 9686 0811 Ballast to Controller Cable Assembly 25 9678 0816 VL3500 Wash FX Color Harness Cable Assembly 25 9686 1205 VL3500 Wash FX Strobe System Assembly 21 9686 1404 EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rear Strobe Blade Assembly 21 9686 1437 Data I 0 Link Cable Assembly AC Input Splitter Cable Assembly 25 9678 0813 25 9678 0812 Front Strobe Blade Assembly 21 9686 1438 Display Cable Assembly DC Output Cable Assembly 25 9678 1825 25 9678 0821 continued from previous page i le A Head Cable Interconnect Pan Tilt a ssembly Lamp N Cable e 25 9678 0829 LVS to Yoke Dual AC Fan Cable Assembly LVS Chassis Ground Cable Assembly 25 9661 1514 25 9686 0843 Zoom Motor Cable Assembly 23 9686 0208 LVS Chassis Ground Cable Assembly 25 9661 1514 Polished PC Clear Front Lens Assembly 21 9686 0617 Front Fresnel Lens Assembly 21 9686 0619 Fresnel
58. G RECP MTE 1 X2 2 x2 4 x4 6 7 8 9 5 3 x2 10 x2 Figure 3 57 Internal Lens Interconnect Cable Assembly 02 9686 0010 A 145 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash Color Harness Cable Assembly 25 9686 0205 Rev E VL3500 Wash Refer to Figure 3 58 and Figure 3 59 No Item Qty UM Description 1 52 6610 0040 1 EA CONNECTOR HOUSING 40 POS 26 22 AWG DBL ROW UNLOADED 2 52 6224 1040 1 EA COVER FRONT 40 POS MT LATCHING 3 52 6224 2040 1 EA COVER BACK 40 POS MT 4 52 6610 0034 1 EA CONNECTOR HOUSING 34 POS 26 22 AWG DBL ROW UNLOADED 5 52 6224 1034 1 EA COVER FRONT 34 POS MT LATCHING 6 52 6224 2034 1 EA COVER BACK 34 POS MT 7 52 8351 0004 52 EA CONTACT 26 22 AWG RECP MTE 8 52 6467 0011 2 EA CONNECTOR FEMALE PLUG 11 POS 30 24 AWG 9 52 6467 0024 20 EA CONTACT SOCKET 30 24 AWG CRIMP 10 52 6662 0006 8 EA HOUSING 6 POS 125 2A 2 0 MM PITCH 11 52 8388 0001 32 EA CONTACT 24 30 AWG FEMALE CRIMP 2 0 MM PITCH 12 55 2186 0001 8 EA CABLE TIE 10 X 4 SMALL 13 73 2324 0123 13 33 FT WIRE 24 AWG 4 COND TW 300V 200C TEF BLK BRN RED ORN 14 73 2328 5000 3 29 FT WIRE 26 AWG 6 COND TW 300V 200C UL1180 15 52 6467 0001 2 EA CONN FEMALE PLUG 6 POS 24 30 AWG 146 10 11 Figure 3 58 VL3500 Wash Color Harness Cable Assembly 02 9686 0010 A CABLE ASSEMBLIES VL3500 WASH COLOR H
59. HER 3 8 SPLIT LOCK 10 53 5564 0250 1 SCREW 6 32X 1 4 PFB UNDERCUT 11 53 6624 0001 4 EA SCREW 10 32X 1 2 LG 12 53 6513 0044 3 EA SCREW M5 X 10MM STL CUP PT 13 54 1206 0014 2 EA RING RETAINING 1 375 SHAFT 1 291 GRV DIA 056 GRVWD EXTERNAL 14 54 1255 0001 2 EA BEARING ASSY BLACK FLUSH MOUNT HOUSING 15 54 2055 0001 1 EA BELT TIMING S2M 210GROOVE 9MMWIDE URETHANE KEVLAR 16 55 6549 0001 5 EA WASHER 1 4 SPLIT LOCK 17 55 6799 0001 2 EA SHIM 1 3 8 ID 1 7 8 OD 010 THK SS 18 55 6799 0002 2 EA SHIM 1 3 8 ID 1 7 8 OD 005 THK SS 19 10 9686 0629 1 EA PLUG TILT TUBE 25 9686 2203 1 EA CABLE TILT HARNESS not shown 02 9686 0010 A ASSEMBLY GENERIC LUMINAIRE ASSEMBLY 3 em 25 9686 0204 EA CABLE ASSY VARI BRITE INTERCONNECT not shown 8 x4 9 x4 See Detail C See Detail A Detail Detail 3 3 4c n 9 4 864 3b 7 J 4 E v W NM o E 18 x2 17 x2 Figure 3 7 Generic Luminaire Assembly VL3500 Wash 02 9686 0010 A 61 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 62 02 9686 0010A HEAD ASSEMBLY HEAD STRUCTURE ASSEMBLY 3 Head Assembly Head Structure Assembly 21 9686 0600 Rev VL3500 Wash 21 9686 1600 Rev VL3500 Wash FX Refer to Figure 3 1
60. HT UL1199 19STRAND 8 73 6222 0010 6 33 FT WIRE 22AWG 600V 200C BLK UL1199 1 2 x2 4 x2 5 3 4 2 A 3 A 3 B 2 B d 3 D 1 2 x2 A Figure 3 50 Yoke Dual Fan Cable Assembly 138 02 9686 0010 A CABLE ASSEMBLIES LVS To YOKE DUAL AC FAN CABLE ASSEMBLY 3 LVS to Yoke Dual AC Fan Cable Assembly 25 9686 0843 Rev A Refer to Figure 3 51 No Item Qty UM Description l 52 6664 0001 4 EA CONTACT 22 26AWG FEMALE MATE N LOK 2 2 52 6664 0002 2 EA CONN HOUSING 2 POS CAP MATE N LOK 2 3 52 8231 0008 2 EA TERM SPADE 6 RED 22 16AWG INSERT 4 55 2186 0001 2 EA CABLE TIE 10 WD 4 00 LG SMALL 5 55 6699 0002 2 08 FT SLEEVING 1 4 NOM DIA POLY EXP BRAIDED 6 73 6222 0009 4 34 FT WIRE 22AWG 600V 200C TFE WHT UL1199 7 73 6222 0010 4 34 FT WIRE 22AWG 600V 200C BLK UL1199 1 2 4 x2 5 3 2 A RE EE RER RES 222 gt LIE 2 B 3 B 1 2 Figure 3 51 Yoke to Dual AC Fan Cable Assembly 02 9686 0010 A 139 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL OT Switch 1 to OT Switch 2 Cable Assembly 25 9686 0013 RevA Refer to Figure 3 53 No Item Qty UM Description 1 52 8371 0001 2 EA RECEPT FASTON 24 20 AWG UNINSUL TIN 2 73 7089 0000 0 42 FT WIRE 22AWG 300V 200C BLK UL1180 140 Fig
61. Internal Lenses 21 9686 0620 Figure 3 4 VL3500 Wash FX Luminaire Subassembly Drawing Tree Part 2 continued from previous page Backcap Interlok to OT Switch 1 Dual Fan Duct Assembly Cable Assembly 22 9686 0674 25 9686 0014 continued from previous page Included Items Kit 28 9686 0011 OT Switch 1 to OT Switch 2 Cable OT Switch to Ground Cable Assembly Assembly 25 9686 0013 25 9678 0015 02 9686 0010 A 55 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Top Assembly Included Items Kit 28 9686 0001 Rev A VL3500 Wash 28 9686 0011 Rev C VL3500 Wash FX Refer to Figure 3 5 No Item Qty UM Description 1 02 8001 0001 1 EA SHEET VARI LITE CUSTOMER SERVICE 2 02 8052 0001 1 EA CARD LIMITED WARRANTY 09 09 02 3 02 8001 0002 1 EA CERTIFICATE VARI LITE QA 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 04 4037 0001 5 EA LABEL 2 5 X 5 BARCODE not shown 5 08 3500 0002 1 EA CD ROM VL3500 WASH PRODUCT DOCUMENTATION 6 02 9686 0002 1 EA UNPACK QUICK START SHEET VL3500 WASH 7 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 8 71 9686 1502 1 EA LAMP 1500 WATT SHORT ARC DOUBLE ENDED IN LUMINAIRE 9 21 9686 0620 1 EA INTERNAL LENS FRESNEL 10 21 9686 0619 1 EA FRONT LENS ASSEMBLY FRESNEL 11 21 9686 0618 1 EA FRONT LENS ASSEMBLY CLEAR PC VL3500 WASH ONLY 21 9686 0617 1 EA FRONT LENS ASSEMBLY STIPPLE PC V
62. K 2 10 9686 1159 2 EA SPACER PIVOT 3 10 9686 1176 1 EA MOTOR MOUNT 1 SPLIT LENS MOTOR 4 10 9686 1179 2 EA HINGE ROD 5 10 9686 2175 1 EA MOUNT ZOOM LENS 6 10 9686 2189 1 EA EOT STOP VARI BRITE 7 21 9686 2160 2 EA PIVOT ASSY INTERNAL LENS 8 44 9686 0164 1 EA MOTOR SPLIT LENS 9 53 6524 0002 4 EA SCREW 6 32 X 5 16 PPB 10 53 6592 0250 2 EA SCREW 4 40 X 1 4 LG PPB SEMS 11 53 6607 0001 2 EA SCREW 6 32X 1 4 PPB 12 54 2007 0001 2 EA RING RETAINING EXTERNAL 1 4 02 9686 0010 A 83 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL 12 x2 7 x2 2 x2 Figure 3 16 Internal Lens Splitter Assembly 84 02 9686 0010A HEAD ASSEMBLY ACTUATOR ASSEMBLY 3 Actuator Assembly 21 9686 2142 Rev F Refer to Figure 3 17 No Item Qty UM Description 1 10 9686 1158 4 EA SPACER PIVOT LINK 2 10 9686 2190 1 EA BUMPER LENS 3 10 9686 4188 1 EA PLATE LINKAGE ACTUATOR 4 10 9686 4189 1 EA MOUNT LEAD SCREW 5 21 9686 2130 2 EA ASSEMBLY PIVOT LINK 6 53 6607 0001 2 EA SCREW 6 32 X 1 4 PPB 7 53 6678 0013 2 EA SCREW SHLDR 4 40TH 125DIA 188 SHLDR Figure 3 17 Actuator Assembly 02 9686 0010 A 85 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Fresnel Internal Lenses 21 9686 0620 Rev Refer to Figure 3 18 No Item Qty UM Description 1 10 9686 1141 2 EA ADAPTOR SPLIT LENS PIVOT 2 10
63. L3500 WASH FX ONLY 02 9686 0010A ASSEMBLY INCLUDED ITEMS KIT 3 1 Set of internal Fresnel Lenses Note Buxom lenses are installed in luminaire Supplied Lenses VL3500 Wash PC Clear Fresnel PC Stippled installed on luminaire VL3500 Wash FX PC Stipple Fresnel and Ultra Clear installed on luminaire Figure 3 5 Included Items Kit Note Do not handle lamp with bare hands To keep the lamp glass as free from dirt and grease as possible wear clean cotton gloves 02 9686 0010 A 57 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash VL3500 Wash FX Luminaires 20 9686 0001 Rev H VL3500 Wash 20 9686 0011 Rev C VL3500 Wash FX Refer to Figure 3 2 No Item Qty UM Description i 02 8405 0001 1 EA AC DANGER TAG VL3500 not shown 04 9661 0033 01 1 EA LABEL WARNING 2000 SERIES not shown 04 9661 0039 1 EA LABEL LINE CORD WARNING not shown 04 9686 0061 EA LABEL AC INPUT RATING VL3500 WASH VL3500 Wash Only not shown 04 9686 1061 1 EA LABEL AC INPUT RATING VL3500 WASH FX VL3500 Wash FX Only not shown 1 10 9686 0617 1 EA YOKE CROSSMEMBER HEAT SHIELD 10 9686 0168 1 EA ZOOM MOUNTING BRACKET LEFT not shown 2 10 9686 0169 1 EA ZOOM MOUNTING BRACKET RIGHT 3 10 9686 0732 2 EA COVER YOKE THERMOFORM 4 10 9686 1
64. LET RADIATION DO NOT OPERATE X L 1 t WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LENS IS DAMAGED orizonta AY Backcap BEFORE RELAMPING CAUTION HOT LAMP LUMINAIRE MUST REMAIN POWERED ON FOR 5 MINUTES AFTER DOUSING LAMP 1 DO NOT OPEN FOR 5 MINUTES AFTER SWITCHING OFF Y Vertical Figure 2 2 Lamp Alignment 20 02 9686 0010A MAINTENANCE PROCEDURES INTERNAL LENS REPLACEMENT Internal Lens Replacement Tools 2 Phillips screwdriver e Lint Free Cotton Gloves To replace the internal lens assembly Step 1 Using a control console close the internal lens assembly Move internal lens assembly to front of head close to the front lens DA WARNING Remove power from luminaire before performing maintenance Internal fixture components and assemblies can be HOT after operation Allow to adequately cool before replacing Step 2 Remove power from luminaire Step 3 As shown in Figure 2 3 remove the bottom head cover by loosening four 1 4 turn screws CAUTION Wear cotton gloves or other covering while replacing lenses II required clean any fingerprints or debris from the lenses with isopropyl alcohol and a soft cloth Step 4 Atthe internal lens assembly remove the two retaining knobs and the cross strap securing the lens Step 5 Slide each section of lens assembly straight up and off the hinge rods Step 6 Slide the replacement lens assemblies ont
65. MC EN 61000 6 4 2001 Emission Standard for industrial environments EN 61000 6 2 2001 Immunity for industrial environments We certify that the product conforms to the protection requirements of council directives 73 23 EEC LVD and 89 336 EEC EMC 02 9686 0010 A FOREWORD 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 CAUTION advising of potential damage to product A WARNING advising of potential injury or death to persons 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 VARI LITE luminaires have been designed for use with specific lamp types The VL3500 Wash Luminaire requires the Osram SharXS HTI 1500 W D7 60 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 Note distance requirement from combustible materials or illuminated objects for VARI LITE luminaires WARNING INSTRUCTIONS FOR CONTINUED PROTE
66. NCE PROCEDURES POWER SUPPLY LVS REPLACEMENT Power Supply LVS Replacement Parts 69 3177 0151 Repair Procedure Step I Disconnect luminaire AC input cable from power source Step 2 As shown in Figure 2 16 at the enclosure remove two 6 32 x 1 4 LG PPZ screws from the Step Step Step Step 02 9686 0010 A eA display side top cover and remove the cover At power supply disconnect wiring Location Connector N White AC Wires L Black AC Wires V Red DC Wires V Black DC Wires Remove 6 32 x 3 8 LG PPZ screw at the wiring end of the LVS Loosen two 6 32 x 3 8 LG PPZ screws and slide the LVS towards upper enclosure fan to remove it Replace by performing steps 2 through 5 in reverse order 45 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Power Supply LVS Replacement continued Display Side Top Cover Power Supply LVS NOTE Head not shown ICI clarity Fan Assembly Figure 2 16 Power Supply LVS Replacement 46 02 9686 0010 A MAINTENANCE PROCEDURES TILT MOTOR ASSEMBLY REPLACEMENT Tilt Motor Assembly Replacement Parts 21 9678 0765 Repair Procedure To remove and replace the tilt motor assembly Step 1 Disconnect luminaire AC input cable from power source Step 2 As shown in Figure 2 17 at the tilt side leg remove yoke leg cover by removing four 6 32 x 5 16 PTB screws Step 3 At tilt motor
67. NG S2M 448 MM 244 TEETH 53 55 2150 0003 2 EA STANDOFF 1 4 HEX 6 32 1 125 L 54 55 2178 0001 3 EA CABLE ANCHOR MOUNT 8 SCREW 55 55 2179 0001 3 EA CABLE ANCHOR MOUNT 6 SCREW 56 55 2261 0001 1 EA SLEEVE NYLON THIN WALL 6 SCR 57 55 2267 0001 2 FT RUBBER STRIP SPONGE CLSD CELL 58 55 6677 0039 4 EA WASHER 0 438 OD X 0 219 ID X 0 040 THK 59 55 6532 0004 2 EA BRACKET 6 32 THREADED HOLES 60 55 6543 0001 3 75 IN GROMMET STRIP SERRATED 0 062 61 55 6543 0002 1 54 FT GROMMET STRIP SERRATED 0 125 62 55 6658 0009 1 EA STANDOFF 1 4 HEX 6 32 X 3 4 63 55 6568 0074 2 EA SPRING CPRSN 0 420 OD 0 750 LG 64 55 6577 0005 2 EA STANDOFF 1 2 HEX 6 32 1 625 L 65 55 6677 0044 1 EA WASHER 0 877 OD 0 170 ID 0 093 THK 55 6699 0010 0 5 FT SLEEVING 5 16 NON DIA WOVEN POLY ROUNDIT not shown 66 55 6775 0009 1 EA BUSHING SNAP 750 ID 1 MT H 67 67 4018 0001 1 EA FERRITE 26X28 5 X 13MM CYL 68 67 9686 1500 1 EA FILTER EMI 1500W BALLAST 2 68 4541 0004 1 EA FERRITE CLAMP ON AXIAL not shown 69 68 9678 0827 l EA CHOKE COMMON MODE 70 69 3177 0151 1 EA LVS POWER SUPPLY 150W 24V 6 3A 71 10 9661 1358 1 EA AIR SEAL DUCT 72 52 8295 0002 1 EA THERMAL STRIP 300V 12AWG 20 73 55 6799 0001 AR EA SHIM 1 375 ID 1 875 OD 0 010 74 55 6799 0002 AR EA SHIM 1 375 ID 1 875 OD 0 005 THK AR As Required 02 9686 0010 A 121 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Upper
68. P IN 3 LONG NYLON NATURAL 11 74 2000 0002 1 EA SWITCH ROCKER 2 POLE HIGH CURRENT BLACK 6 8 x4 Included with AC Input Cable Figure 3 42 Panel Assembly 128 02 9686 0010A ENCLOSURE ASSEMBLY DMX INPUT 3 DMX Input PCB 24 9663 3895 Rev 0 Refer to Figure 3 43 No Item Qty UM Description Ref 1 17 9663 3895 1 EA PCB FAB DMX INPUT 2 52 6259 0006 1 EA HEADER 5POS MTA FRCT LOK STRT POST J3 3 52 6625 0006 1 EA CONN RECEPT XLR SPIN FEMALE PC MT VERTICAL 4 52 6626 0006 1 EA CONN RECEPT XLR SPIN MALE PC MT VERTICAL 12 5 62 3039 0102 1 EA CAP 1000P 250V 20 CDE X Y CI 1 2 NN 4 Figure 3 43 DMX Input PCB 02 9686 0010 A 129 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Pan Pulley Assembly 21 9686 0807 Rev Refer to Figure 3 44 No Item Qty UM Description 1 10 9686 0750 1 EA TIMING PULLEY 170 TOOTH 2 10 9678 0855 1 PANFLAG 3 53 6530 0009 2 EA RIVET 1 8 OD POP 126 187 GL 3 x2 2 Note orientation of Pan Flag gt XP 100 Figure 3 44 Pan Pulley Assembly 130 02 9686 0010A ENCLOSURE ASSEMBLY PAN MOTOR ASSEMBLY 3 Pan Motor Assembly 21 9686 0864 Rev D Refer to Figure 3 45 No Item Qty UM Description 1 10 9686 0457 01 2 EA SPACER COLOR 322 LG 2 10 9686 0840 2 EA STANDOFF 1 4
69. PROTECCI N CONTRA LESIONES DE PERSONAS 1 Las superficies exteriores de las luminarias est n calientes durante su operaci n Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando haga ajustes en el equipo y componentes que est n calientes 2 Cuando las luminarias est n en operaci n la l mpara estar muy caliente Desconecte la energ a y deje que la l mpara se enfr e antes de reemplazarla 3 Las l mparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e inflamaci n a los ojos Adem s las l mparas de arco operan a alta presi n y muy alta temperatura Si la l mpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las part culas de la l mpara rota que se caen 4 Use protecci n para los ojos cuando vuelve a colocar una l mpara nueva 5 Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando trabaje con l mparas da adas 6 Si toca la l mpara con las manos limpie la l mpara con alcohol desnaturalizado y con tela sin pelusas antes de instalar o volver a conectar la luminaria 7 Cambie la l mpara si est da ada 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 CARACTER STICAS D
70. RWARD PULLEY SHAFT BEARING 4 10 9686 1170 1 EA MOUNT RAIL 5 10 9686 1173 1 EA PAD ISOLATION ZOOM MOTOR 6 10 9686 1182 1 EA BLOCK MOUNTING IDLER PULLEY 7 10 9686 2130 1 EA END OF TRAVEL STOP 8 10 9686 3171 1 EA MOUNTING PLATE SPLIT LENS ZOOM ASSY 9 21 9686 1132 1 EA EOT STOP FRONT SPLIT LENS ASSEMBLY 10 22 9686 1154 1 EA LINEAR RAIL 12MM 2 LONG CARRIAGE 11 44 9663 1766 1 EA MOTOR 17 1 24 SHAFT 11 8MH 5 5 OHM 12 53 2200 0006 1 EA NUT 6 32 KEPS SS 13 53 6523 0001 5 EA SCREW 6 32 X 3 8 SCB ALLEN 14 53 6543 0001 5 EA SCREW 6 32X 3 8 PPB 15 53 6598 0312 1 EA SCREW 4 40 X 5 16 PFB 16 53 6613 0008 2 EA SCREW 6 32 X 1 2 LG PPZ SEMS 17 53 6614 0001 2 EA SCREW 6 32X 5 8 PPB 18 54 1262 0001 2 EA BEARING FLANGED 1875 BORE 19 54 2064 0192 1 EA BELT TIMING MXL 080 192 GRV 1 4 WIDE 20 54 2053 0001 1 EA MXTT BELT PULLEY 20 GRV 25WD 21 55 2234 0001 1 EA E RING 188 SHAFT DIA 22 55 6568 0016 1 EA SPRING EXTSN 0 125 OD 0 500 LG 02 9686 0010 A 81 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Internal Lens Rail Assembly Figure 3 15 Internal Lens Rail Assembly 82 Reverse Side 02 9686 0010A HEAD ASSEMBLY INTERNAL LENS SPLITTER ASSEMBLY 3 Internal Lens Splitter Assembly 21 9686 2144 Rev Refer to Figure 3 16 No Item Qty UM Description 1 10 9686 1156 1 EA BELT CLAMP BAC
71. STANDOFF 1 4 HEX 6 32 5 8 0 625 LG MF 02 9686 0010A HEAD ASSEMBLY COLOR EFFECT STROBE MODULE Color Effect Strobe Module continued Figure 3 19 Color Effect Strobe Module 02 9686 0010 A 89 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Color Rotating Effect Strobe Module 21 9686 1400 Rev K VL3500 Wash FX Refer to Figure 3 19 No Item Qty UM Description 1 10 9678 0246 5 EA MOTOR ADJUST PLATE 2 10 9686 0420 1 EA BULKHEAD COLOR MODULE FRONT 3 10 9686 0422 2 EA SHAFT COLOR WHEEL FRONT 4 10 9686 0432 2 EA SHAFT COLOR WHEEL REAR 5 10 9686 0433 5 EA SPACER COLOR SYSTEM HALVES 6 10 9686 0442 1 EA BLOCKING PLATE AIR DIMMER 7 10 9686 0443 1 EA AIR DIVERTER DIMMER 8 10 9686 0444 1 EA AIR DIVERTER DIMMER BELT SIDE 9 10 9686 0446 2 EA ADJUST PLATE MOTOR 10 10 9686 0447 1 EA MOTOR ADJUST PLATE CABLE GUIDE 11 10 9686 0468 1 EA MOTOR PULLEY W FLANGES 3 16 BELT 12 10 9686 1421 1 EA BULKHEAD COLOR MODULE REAR ROTATING EFFECTS 13 10 9686 1446 1 EA MOTOR ADJUST PLATE NOTCHED 14 10 9686 1468 4 EA MOTOR PULLEY W FLANGES 1 8 BELT 15 10 9686 1469 2 EA MOTOR PULLEY SINGLE FLANGE 1 8 BELT 16 10 9686 2457 01 2 EA SPACER COLOR WHEEL 17 10 9686 2457 02 1 EA SPACER COLOR WHEEL 18 10 9686 2457 03 1 EA SPACER COLOR WHEEL 19 10 9686 2457 05 1 EA SP
72. UAL Ventilation Cover Assembly continued 6 we 7 x2 EN ic 2 10 x4 8 x4 Figure 3 40 Ventilation Cover Assembly 126 02 9686 0010A ENCLOSURE ASSEMBLY EXHAUST FAN ASSEMBLY 3 Exhaust Fan Assembly 21 9686 0811 Rev C Refer to Figure 3 41 No Item Qty UM Description 1 10 9686 0810 1 EA MOUNTING PLATE EXHAUST FAN 2 40 7140 0001 1 EA BLOWER CENTRIFUGAL 24VDC 9CFM 3 X 3 3 52 6523 0002 1 EA CONN HOUSING 2 POS PLUG SHROUDED 4 52 8347 0001 2 EA CONTACT 24 30 AWG MALE CRIMP 5 55 6576 0001 EA SCREW 10 16 X 3 8 TYPE PFZ 5 x2 Table 3 1 Connector Pin Out 2 I VVII6 Black Red Figure 3 41 Exhaust Fan Assembly 02 9686 0010 A 127 VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL Panel Assembly 21 9686 0805 Rev B Refer to Figure 3 42 No Item Qty UM Description 1 10 9678 0852 01 1 EA LAYOUT ENCLOSURE OVERLAY 2 10 9678 0859 1 EA BRACKET INPUT 3 10 9678 0872 1 EA STIFFENER DISPLAY BOARD 4 10 9686 0820 1 EA FILLER PANEL DMX CONNECTOR 5 24 9663 3895 1 EA ASSY DMX INPUT 6 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 7 24 9678 3825 1 EA ASSY VL3000 DISPLAY 8 51 0541 4 EA SCREW 4 X 3 8 H L BLK ZINC PLT 9 53 6558 0009 2 EA SCREW 6 32 X 3 8 LG PPZ SEMS EXT ZINC PLT 10 55 2284 0001 1 EA CARD GUIDE SNA
73. 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 Obtain Support or Reach Us For assistance in your area call the dealer from which your product s was 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 E mail customerservice genlytecontrols com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link 02 9686 0010 A 3 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Technical Bulletins and Notices Technical bulletins concerning the latest changes to VARI LITE equipment are issued from the Dallas Texas USA office They are documentation supplements that contain procedures for equipment upgrades retrofits and repairs not found in the existing manuals Operator technical bulletins are also issued to document changes in control software Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Bulletins are categorized by assembly or subassembly and identified by a number such as S3K 001 VL3000 Series Luminaires Technical Bulletin number 1 Technical notices are als
74. Z 43 54 2057 0002 3 EA BELT TIMING MXL 144 GRV 0 125 WD UR KEV 44 54 2057 0003 5 EA BELT TIMING MXL 144 GRV 0 125 WD SIL KEV 45 54 2068 0003 1 EA BELT TIMING MXL 175 GRV 0 125 WD SIL KEV 46 55 6669 0014 6 EA STANDOFF 1 4 HEX 6 32 5 8 0 625 LG MF 02 9686 0010 A 91 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Color Rotating Effect Strobe Module continued 38 x2 4 2 44 x5 42 x12 For Cyan Yellow Magenta CTO and Dimmer Only Figure 3 20 Color Rotating Effect Strobe Module 92 02 9686 0010 A HEAD ASSEMBLY VL3500 VV 5LI FIXED COLOR WHEEL 7 ASSEMBLY 3 VL3500 Wash Fixed Color Wheel 1 Assembly 21 9686 0484 Rev H VL3500 Wash Refer to Figure 3 21 No Item Qty UM Description 1 10 9686 0487 1 EA WHEEL FIXED COLOR 1 WHEEL 1 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 21 9686 0419 1 EA TIMING PULLEY WITH BEARINGS 5 41 9686 0490 1 EA COLOR FILTER RED WHEEL 1 6 41 9686 0491 1 EA COLOR FILTER YELLOW WHEEL 1 7 41 9686 0492 1 EA COLOR FILTER MAGENTA WHEEL 1 8 41 9686 0493 1 EA COLOR FILTER KELLY GREEN WHEEL 1 9 41 9686 0494 1 EA COLOR FILTER CONGO BLUE WHEEL 1 10 53 6598 0312 4 EA SCREW 4 40 X 5 16 PFB 02 9686 0010 A 93 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Was
75. a Input Detecting DMX data disconnect DMX input cable n a Erratic control of luminaire DMX Termination No DMX termination or termination not correct check DMX terminator 18 02 9686 0010A MAINTENANCE PROCEDURES LAMP REPLACEMENT Maintenance Procedures WARNING As with any repairs or maintenance to Vari Lite luminaires service should only be performed by a trained and qualified service technician or at an Authorized Vari Lite Service facility Lamp Replacement Parts 71 9686 1502 AN WARNING Ensure that power is removed from luminaire when installing lamp Always wear eye protection when opening lamp box and replacing lamps CAUTION Wear cotton gloves or other covering while installing lamp Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life If touched use alcohol and cotton cloth to thoroughly clean glass portion of lamp To install lamp Step 1 Remove power from luminaire Step 2 At rear of luminaire head loosen four 1 4 turn screws and slide hinged lamp box back and out Step 3 Remove current lamp Step 4 Position new lamp with dimple side toward lamp socket Insert lamp in connector Ensure lamp is fully seated in place Step 5 Close lamp box and re tighten 1 4 turn screws Step 6 Align lamp for flat field after power up as detailed in Align Lamp on page 20 Lamp dimple side towards socket
76. ad and Yoke Components ss 8 Enclos re Components iiie er ute ue He EH en eee Pott LEG 9 Chapter 2 Maintenance Testing Luminaire Self Tests iS RA HIHI 12 Calibration Sequence peti e tie ci min a p iu dg 12 Auto Recalibration n Re ni ati ea eed ae ivan kn 13 Partial Recalibrati n 13 Sensor Testing SS EE 13 Warnings and Cautions Exceptional Safety Information for the VL3500 Luminaires 15 Troubleshooting Err r Message _ 16 Troubleshooting Guide 3 17 Maintenance Procedures Lamp Replacement V 19 Alien A CGE EE 20 Internal Lens Replacement cer eee 21 Front Lens Assembly Removal ss 23 Color Filter Replacement uu usu toe ua ua susu 25 Effects Pattern Replacement VL3500 Wash FX Only 27 Ballast Assembly Replacement sens 29 Color Dimmer Strobe Assembly Replacement n 31 Color Dimmer Strobe Assembly Replacement continued 32 Internal Lens Assembly Replacement eene nennen nnns 33 02 9686 0010 A xiii VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Reflector ni eii 35 Main Control Board MCB
77. amp Alignment Tab Orange N Dark N gt Fuchisa Detail A Y I Alignment Tab RTV beads should be applied at all positions where a filter can be used Figure 3 22 VL3500 Wash Fixed Color Wheel 2 Assembly 96 02 9686 0010 A HEAD ASSEMBLY VL3500 VV 5LI FIXED COLOR WHEEL 7 ASSEMBLY 3 VL3500 Wash FX Fixed Color Wheel 1 Assembly 21 9686 1484 Rev VL3500 Wash FX Refer to Figure 3 23 No Item Qty UM Description 1 10 9686 0487 1 EA WHEEL FIXED COLOR 1 WHEEL 1 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 22 9686 1416 1 EA FIXED COLOR WHEEL HUB WITH BEARINGS 5 41 9686 0490 1 EA COLOR FILTER RED WHEEL 1 6 41 9686 0491 1 EA COLOR FILTER YELLOW WHEEL 1 7 41 9686 0492 1 EA COLOR FILTER MAGENTA WHEEL 1 8 41 9686 0493 1 EA COLOR FILTER KELLY GREEN WHEEL 1 9 41 9686 0494 1 EA COLOR FILTER CONGO BLUE WHEEL 1 10 53 6598 0312 4 EA SCREW 4 40X 5 16 02 9686 0010 A 97 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash FX Fixed Color Wheel 1 Assembly continued Detail A Note All filters must be installed with the coating side towards the luminaire s lamp ET gt Open 7 ongo Blue red Alignment Tab Kelly N Yellow Green N Magenta N v Detail A 7 Alig
78. and cannot be removed intact If you order a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information Figure 3 45 Pan Motor Assembly 132 02 9686 0010A ENCLOSURE ASSEMBLY PAN TUBE ASSEMBLY 3 Pan Tube Assembly 21 9678 0881 Rev 0 Refer to Figure 3 46 No Item Qty UM Description 1 10 9678 0809 1 EA PANTOGGLE STOP 2 10 9678 0847 1 EA SILICONE FOAM WASHER 3 10 9678 0848 2 EA WASHER PAN TEFLON 4 12 9678 0877 1 EA PAN TUBE MACHINED 5 54 1206 0021 1 EA RING RETAINING 1 562 SHAFT 1 468 GRV DIA 068 GRVWD EXTERNAL 6 54 1255 0002 1 EA BEARING ASSY FLUSH MOUNT HOUSING LARGE 5 6 1 PA 3 y 2 4 02 9686 0010 A Figure 3 46 Pan Tube Assembly 133 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 134 02 9686 0010A CABLE ASSEMBLIES EOT SENSOR ELECTRICAL ASSEMBLY 3 Cable Assemblies Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 47 No Item Qty UM Description 1 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 2 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 3 86 7002 0003 1 EA SWITCH SLOTTED OPTICAL 1 3 Figure 3 47 Pan EOT Sensor Electrical Assembly 02 9686 0010 A 135 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL LVS Chassis Ground
79. areil peut causer des interf rences radio et si c est le cas l utilisateur peut avoir prendre des mesures ad quates CONSID RATIONS DES CARACT RISTIQUES DE LAMPES ARC 1 Apr s une interruption de courant ou une baisse importante de voltage les lampes arc mettent du temps avant de se rallumer Dans certains cas la lampe se rallumera automatiquemet apr s s tre refroidie Cela d pend de la mani re dont le systeme est r gl pour le statut de mise en marche de la lampe 2 La position Br ler est Universelle viii 02 9686 0010A FOREWORD Aviso sobre Seguridad Es muy importante leer TODA la informaci n e instrucciones sobre seguridad que se indica en este manual as como en los documentos adjuntos antes de instalar y operar los productos descritos Se debe prestar atenci n a todos los avisos y advertencias durante la instalaci n y uso de este producto Los s mbolos de seguridad usados en este manual son los siguientes A CUIDADO indica posibles da os al producto A ADVERTENCIA indica posibles lesiones o muerte a las personas LA INFORMACI N GENERAL RELACIONADA A LA PROTECCI N CONTRAGOLPES DE CORRIENTE EL CTRICA INCENDIO EXPOSICI N EXCESIVA A RADIACI N ULTRA VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA INCENDIO 1 Las luminarias han sido dise adas para ser usadas solamente con algunas l mparas
80. ash FX Fixed Color Wheel 2 Assembly 02 9686 0010A 100 HEAD ASSEMBLY VL3500 WASH FX ROTATING EFFECT WHEEL ASSEMBLY VL3500 Wash FX Rotating Effect Wheel Assembly 21 9686 1405 Rev 0 VL3500 Wash Refer to Figure 3 25 Figure 3 26 No Item Qty UM Description l 10 9686 1493 5 EA LATCH ROTATING EFFECTS PLANET 2 21 9686 1470 1 EA ASSEMBLY SUN GEAR 3 22 9686 1455 1 EA ROTATING EFFECTS WHEEL HUB WITH BEARINGS 4 22 9686 1475 4 EA PLANET GEAR ASSEMBLY 5 22 9686 1490 1 EA ASSEMBLY PLATE ROTATING EFFECTS WHEEL LATCH 6 41 6040 4002 1 EA PATTERN VL3500 WASH FX FOUR HOLE RAY 7 41 6040 4009 1 EA PATTERN VL3500 WASH FX MEDIUM TRIANGLE 8 41 6040 4326 1 EA PATTERN VL3500 WASH FX SPOKES 9 41 6040 5011 1 EA PATTERN VL3500 WASH FX NIGHT SKY 10 53 6530 0013 5 EA RIVET 1 8 OD POP 0 328 AL CS 11 53 6659 0008 3 EA SCREW 2 56 X 3 16 PFZ 12 54 1206 0020 1 EA RETAINING RING 0 625 SHAFT 0 018 THK 13 55 6677 0050 10 EA WASHER FLAT 0 129 ID 0 270 OD 0 031 TEFLON 14 55 6677 0051 5 EA WASHER FLAT 0 135 ID 0 312 OD 0 030 SST 15 55 6799 0004 5 EA SHIM 0 627 ID 0 875 OD 0 020 THK SST Four Hole Ray Triangle Note This graphic is for illustrative purposes only Refer to Figure 3 26 for component breakdown 02 9686 0010 A Figure 3 25 VL3500 Wash Gobo Patterns and Positions 101 VARIXLITE VL3500
81. assembly loosen four 10 32 x 1 2 PPZ screws Step 4 Remove belt from tilt pulley Step 3 4 Step 5 Remove four 10 32 x 1 2 PPZ screws Remove tensioning springs 6 Disconnect wiring and remove the tilt motor assembly 7 Step 7 Replace by performing steps 2 through 6 in reverse order A Note Make sure wiring is not pinched during installation When tightening four 10 32 x 1 2 PPZ screws that fasten the tilt motor assembly you must tighten then in a CLOCKWISE pattern starting with the screw in lower left hand side To remove and replace the tilt motor belt Step 1 Disconnect luminaire AC input cable from power source Step 2 As shown in Figure 2 17 at the tilt side leg remove yoke leg cover by removing four 6 32 x 5 16 PTB screws Step 3 At tilt motor assembly loosen four 10 32 x 1 2 PPZ screws Step 4 Remove belt from tilt pulley Step 5 Remove four 10 32 x 1 2 PPZ screws Be mindful of tensioning springs Step 6 Disconnect the following wiring and remove tilt assembly Disconnect lamp wire from ignitor b Remove ignitor assembly mounting bracket leave ignitor attached to bracket by removing three 6 32 x 3 8 PPZ screws and 1 4 standoff c Disconnect ground wire from stud using 3 8 nut driver d At interconnect disconnect 80mm fan wiring Step 7 Remove belt Step 8 Replace by performing steps 2 through 7 in reverse order 02 9686 0010 A 47 VARIXLITE VL3500 WASH LUMINAIRE SERVICE M
82. d 042 EOS X310A S3AMWA GALSIML 2 180415 NOION 8 1 v vie 197 au a oha MV HOLON SSO 2 280818 v 5 038 02 9686 0010 in Out iring VL3500 Wash FX Color Harness Cable Assembly W Figure 3 61 150 CABLE ASSEMBLIES INTERNAL LENS SPLIT MOTOR CABLE ASSEMBLY 3 Internal Lens Split Motor Cable Assembly 25 9686 0206 Rev 0 Refer to Figure 3 62 No Item Qty UM Description 1 52 6467 0004 1 EA CONNECTOR FEM PLUG 4 POS 30 24 AWG 2 52 6467 0024 4 EA CONTACT 24 30 AWG FEMALE CRIMP 2 00 MM PITCH 3 52 6696 0001 1 EA RECEPT WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 4 52 6694 0001 4 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2 MM PITCH 28 24 AWG 5 73 2326 0123 0 7 FT WIRE 26 AWG 4 COND 300V 200C UL1180 BLK BRN RED ORN 1 2 X4 3 4 x4 5 Figure 3 62 Internal Lens Split Motor Cable Assembly 02 9686 0010 A 151 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Transfer Fans Cable Assembly 25 9686 0209 Rev B Refer to Figure 3 63 No Item Qty UM Description 1 52 6523 0004 1 EA CONN HOUSING 4POS RECEPTACLE 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3 52 8347 0001 4 EA CONTACT 24 30AWG MALE CRIMP 4 52 8346 0001
83. e Fan and Relay Cable ASsSsemb y ss 154 Yoke Fan Cable Assembly nae e I III 155 OT Switch to Backcap Interlok Cable Assembly ss 156 Ignitor to Lamp Socket Cable Assembly 157 Chassis to Yoke Ground Cable Assembly ss 158 Zoom Motor Cable Assembly NE 159 Zoom Motor Cable ES EEE 160 AC Input Pigtail Cable Assembly ss 161 EMI Filter to Power Switch Cable Assembly 162 AC Input Splitter Cable Assembly ss 163 Data FO Link Cable Assembly nine T m nt een nt Pattes a 165 Display Cable Assembly slide ritate Set ca an Cera etu In 166 02 9686 0010 A VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL xvi Ballast to Controller Cable Assembly pp 167 DC Output Cable Assembly uu Ceep a it mate et t Aaa de Aaa RN 168 Pan Tilt Contrel Cable Ass embly a usa ge eee e en 169 Lamp Supply to Relay Cable Assembly 171 Appendix A Technical Bulletins and Notices Product Technical Bulletins and 173 02 9686 0010 A INTRODUCTION ABOUT THIS MANUAL Introduction About This Manual A Note The VL3500 Wash and VL3500 Wash FX Luminaires share many common assemblies and parts of the Vari Lite Series 3000 Luminaires This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VL3500 Wash Luminaire The manual is intended for use by Vari Lite personnel and by Vari Lite s customers clients WARNING I
84. ed as a complete assembly Although you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly and cannot be removed intact If you order a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information Figure 3 32 Tilt Motor Assembly 112 02 9686 0010A YOKE ASSEMBLY YOKE FAN ASSEMBLY 3 Yoke Fan Assembly 22 9661 0609 Rev C Refer to Figure 3 33 No Item Qty UM Description l 10 9661 0646 1 EA FANTRAY 2 40 7113 0001 1 EA FAN 24V 80MM X 80MM X 25MM 32 CFM 3 53 2200 0006 4 EA NUT 6 32 KEPS SS Direction of Air Flow Figure 3 33 Yoke Fan Assembly 02 9686 0010 A 113 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 02 9686 0010A HEAD YOKE PCB ASSEMBLIES HEAD CABLE INTERCONNECT 3 Head Yoke PCB Assemblies Head Cable Interconnect 21 9686 1121 RevA Refer to Figure 3 34 No Item Qty UM Description 1 10 9686 1120 1 EA BRACKET HEAD CABLE INTERCONNECT 2 23 9686 0208 1 EA CABLE ASSY ZOOM MOTOR cable portion not shown 25 9686 0206 1 EA CABLE ASSY VARI BRITE MOTOR not shown part of 23 9686 0208 3 53 6520 0002 4 EA SCREW 4 40 X 7 16 PPZ 4 55 6621 0001 4 EA WASHER 4 FLAT ZINC 5 52 6670 0040 1 EA HEADER ASSY MOD 11 40 POS MTG 6 52 6670 0034 1 EA HEADER ASSY MOD 11 34 POS MTG Fi
85. ee Caution on page 23 Figure 2 4 Front Lens Assembly Removal 24 02 9686 0010 A MAINTENANCE PROCEDURES COLOR FILTER REPLACEMENT Color Filter Replacement Tools 2 Philips screwdriver e Lint free cotton gloves AN WARNING Remove power from luminaire before performing maintenance Filters can be HOT after operation Allow the fixture to cool before removing filters To replace a color filter on Color Wheel 1 Step 1 Remove power from luminaire Step 2 Remove bottom head cover by loosening the four 1 4 turn screws Step 3 As shown in Figure 2 5 open door on the cooling air duct CAUTION Do not touch filters with bare fingers Wear cotton gloves or other covering while replacing filters To clean filters use isopropyl alcohol and soft cloth Step 4 Rotate Color Wheel I until the filter you are changing is accessible Step 5 Toimprove access to the filter rotate the mixed color wheels to position the cut outs next to the filter you are changing Step 6 Gently press the color filter toward the lamp until it is free of the lock pins Remove the filter from the wheel Step 7 Slide the new filter orient coating side towards lamp under the spring clip until it is securely retained by the lock pins Step 8 Close the air duct door Replace the head cover To replace a color filter on Color Wheel 2 Step 1 Remove power from luminaire Step 2 Remove top head cover by loosening the four 1 4 turn sc
86. embly is counter balanced inside the head Removal of the front lens assembly can result in instantaneous uncontrolled head movement To avoid uncontrolled movement when the luminaire is sitting on upper enclosure point the head straight up To avoid uncontrolled movement when the luminaire is hanging point the head up at an angle until it rests against the tilt stops as shown here Step 2 Asshownin Figure 2 4 remove front lens assembly by loosening the four captive 10 32 Allen head cap screws CAUTION Wear cotton gloves or other covering while handling the front lens assembly Clean any fingerprints or debris from lenses with isopropyl alcohol and soft cloth if required Step 3 Carefully position replacement front lens assembly so captive screws align with guide pins and mounting holes as illustrated in Figure 2 4 Step 4 Tighten each captive screw to secure the front lens assembly to luminaire head Step 5 The luminaire is ready for operation 02 9686 0010 A 23 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Front Lens Assembly Removal continued A Clean any fingerprints on lenses with CAUTION isopropyl alcohol and a lint free cloth Front Lens Assembly Mounting Holes Front Lens Assembly Guide Pins Front Lens Assembly Captive Screws Lens is heavy Horizontal orientation shown for clarity If lens is removed as shown head assembly will instantaneously rotate to CAUTION face upwards S
87. ep 4 Setthe luminaire on the front lens casting to access the ventilation cover Step 5 At bottom of the enclosure remove four 1 4 20 x 1 5 8 socket screws and 1 4 split lock Step Step Step Step Step Step Step Step Step 02 9686 0010 A Me pes 10 11 12 13 14 washers Remove the ventilation cover Remove both handles by removing two 10 32 x 5 8 screws for each handle At bottom of the enclosure remove four 6 32 x 1 4 screws and remove both side covers Remove two 6 32 x 3 8 screws the APS end bracket and the end cover from ballast side At bottom of the enclosure disconnect the exhaust fan cable At the exhaust fan remove four 8 32 x 3 8 screws Remove the exhaust fan At the ballast disconnect the following cable assemblies a ACinput at the wiring connector attached ferrite remains with the ballast b lamp wires c control wiring Hold the ballast assembly to prevent it from falling At bottom of enclosure remove three 8 32 x 3 8 flat head screws and four 8 32 x 3 8 philister head screws which secure the ballast assembly to the enclosure Carefully remove the ballast from the enclosure to avoid damage to cable assemblies Follow Steps 2 13 in reverse order to install the replacement ballast When reinstalling ventilation cover be sure standoffs are seated flush to chassis 29 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Ballast Assembly Replacement contin
88. er Ultraviolettschirme m ssen ausgetauscht werden sofern deren Schutzwirkung durch sichtbare Besch digung z B Spr nge oder Schrammen eingeschr nkt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN KORPERVERLETZUNGEN 1 Bei Betrieb sind die Au enfl chen der Scheinwerfer hei Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausr stung Handschuhe Augenschutz etc 2 Bei Betrieb der Scheinwerfer ist die Lampe hei Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abk hlen wenn Sie diese austauschen 3 Bogenlampen senden ultraviolette Strahlen aus die Hautverbrennungen und Augenentz ndungen verursachen k nnen Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen Temperaturen Sollte die Lampe zerbrechen besteht die Gefahr von K rperverletzung bzw von Feuer das von Lampenteilen ausgel st werden kann Tragen Sie beim Austausch der Lampen einen Augenschutz 5 Die geeignete Sicherheitsausr stung Handschuhe Augenschutz sollte beim Umgang mit besch digten Lampen verwendet werden 6 Wenn die Lampe mit blo en H nden ber hrt wird reinigen Sie sie mit denaturiertem Alkohol und einem flusenfreien Tuch bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen 7 Wenn die Lampe besch digt oder durch Hitzeeinwirkung deformiert ist mu diese ausgetauscht werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse A In einer Wohnumgebung
89. es luminaires VAREKLITEQ ont t con us pour tre utilis s uniquement avec certaines type de lampes V rifier le type de lampe Osram SharXS HTT 1500 W D7 60 avant de remplacer les lampes L installation d un autre type de lampe peut poser un danger 2 Les luminaires peuvent tre fix s sur tout type de surface tant que les directives de montage sont respect es Voir les explications d taill es dans ce guide 3 V rifier la distance respecter entre les mat riaux combustibles ou les objets illumin s et les luminaires AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les luminaires VARI LITE sont con us pour une utilisation au sec uniquement Une exposition la pluie et l humidit risque d endommager le luminaire 2 D brancher l appareil avant de proc der la r vision de tout mat riel VARIXLITE 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9686 0010 A vii VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL AVERTISSEMENT DIRECTIVES POUR SE PROT GER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1 Plusieurs luminaires VARI LITE utilisent une lampe qui produit des rayons UV NE PAS fixer son regard sur la lampe 2 L utilisation des luminaires sans lentille ou blindage pose des risques Tous blindages lentilles ou crans ultraviolet visiblement endommag s au point que leur efficacit en est affec
90. gure 3 34 Head Cable Interconnect 02 9686 0010 A 115 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash Controller PCB Assembly 24 9686 1429 Rev B Refer to Figure 3 36 No Item Qty UM Description 1 10 9661 1275 1 EA HEATSINK MAIN CONTROLLER 2 10 9678 0731 1 EA HEATSINK CONTROLLER 3 10 9678 0746 1 EA GROMMET PCB EDGE 4 10 9678 0885 1 EA KIT THERMAL TRANSFER MCB 5 53 2200 0006 3 EA NUT 6 32 KEPS SS 6 53 6404 0003 2 EA SCREW 4 40 X 1 PPZ 7 53 6616 0001 2 EA SCREW 6 32 X 3 4 PPZ 8 55 2179 0001 1 EA CABLE ANCHOR MOUNT 6 SCREW MOUNT 9 55 3303 0004 2 EA WASHER 4 LOCK INT TOOTH SS 10 55 6538 0002 2 EA WASHER 6 NYLON NATURAL Figure 3 35 VL3500 Wash Controller PCB Assembly 116 02 9686 0010A HEAD YOKE PCB ASSEMBLIES VL3500 WASH CONTROLLER PCB ASSEMBLY VL3500 Controller PCB Assembly continued couv eee Tx db we em POWER iz n gt 2 MM 2 MI HME E lA meh MM JERE g pee ses AA lA a XI AAV Viet 244 LL de Mida
91. h Fixed Color Wheel 1 Assembly continued Detail A Note All filters must be installed with the coating side towards the luminaire s lamp Open Alignment Tab B N gt Blue 990 Kelly Yellow Green Magenta N Z Detail A 7 Alignment Tab RTV beads should be applied at all positions where a filter can be used Figure 3 21 VL3500 Wash Fixed Color Wheel 1 Assembly 94 02 9686 0010A HEAD ASSEMBLY VL3500 VV 5LI FIXED COLOR WHEEL 2 ASSEMBLY 3 VL3500 Wash Fixed Color Wheel 2 Assembly 21 9686 0480 Rev VL3500 Wash Refer to Figure 3 22 No Item Qty UM Description l 10 9686 0481 1 EA WHEEL FIXED COLOR 2 WHEEL 2 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 21 9686 0419 1 EA TIMING PULLEY WITH BEARINGS 5 41 9686 0495 1 EA COLOR FILTER BLUE WHEEL 2 6 41 9686 0496 1 EA COLOR FILTER AMBER WHEEL 2 7 41 9686 0497 1 EA COLOR FILTER DARK FUCHSIA WHEEL 2 8 41 9686 0498 1 EA COLOR FILTER ORANGE WHEEL 2 9 41 9686 0499 1 EA COLOR FILTER GREEN WHEEL 2 10 53 6598 0312 4 EA SCREW 4 40 X 5 16 02 9686 0010 A 95 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash Fixed Color Wheel 2 Assembly continued Detail A Note All filters must be installed with the coating side towards the luminaire s l
92. he Head Cable Interconnect disconnect the head cables from both sides of the headers 4 cables Step 6 Disconnect zoom optics cable from interconnect Step 7 Disconnect the fan cable connector Step 8 As shown in Figure 2 8 remove the four 6 32 x 3 8 PPZ SEMS screws that hold the Color Effect Strobe module to the two attachment points on each side rail Note position of wire harness guide which will be removed in this step Step 9 Atthe yoke on the MCB side remove four 6 32 x 5 16 PTB screws and remove the yoke cover Carefully pass the cable assemblies you disconnected in Step 5 back through the tilt tube A CAUTION Be careful not to damage the wires or the module during the next step Step 10 To clear the opening between the attachment points on the right side rail lift the Color Effect Strobe module up and tilt it slightly toward the rear to enable the two motors on the bottom of the module to pass through the openings between the attachment points Step 11 Replace color dimmer strobe assembly in reverse order 02 9686 0010 A 31 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL 32 Color Dimmer Strobe Assembly Replacement continued Top Head Cover Screws x4 Wire Harness Guide Note position Color Dimmer Strobe Assembly e Figure 2 8 Color Dimmer Strobe Assembly Replacement 02 9686 0010A MAINTENANCE PROCEDURES INTERNAL LENS ASSEMBLY REPLACEMENT 2 Internal Lens Assembly Replaceme
93. igure 2 7 at the upper enclosure remove four 6 32 x 1 4 screws and remove both top covers Step 3 In the corners on the pan motor side remove two 6 32 x 3 8 screws CAUTION During the next step do not allow the front lens to contact anything that could damage the lens coating Step 4 Toprovide access to ventilation cover set the luminaire on the front lens casting Position the head so the pan pulley sensor tab is inside the optical sensor Step 5 Atbottom of the enclosure remove four 1 4 20 x 1 5 8 socket screws and 1 4 split lock washers Remove the ventilation cover Step 6 Remove the handle on the pan motor side by removing two 10 32 x 5 8 PPB screws Step 7 Atthe enclosure bottom remove two 6 32 x 1 4 PPB screws and the pan motor side cover Step 8 Atthe side of the enclosure remove two 6 32 x 3 8 PFZ screws and two 6 32 KEPS nuts that hold two cable saddles Pull the cables out of way of the pan motor Step 9 Disconnect the wiring from the pan encoder PCB Step 10 Atthe encoder PCB remove two 4 40 x 1 4 screws and remove the PCB Step 11 As shown in Figure 2 13 loosen but do not remove four 10 32 x 3 4 SCB cap screws Step 12 Move pan motor assembly toward pan pulley and remove the belt from the pan pulley Step 13 Carefully remove the belt from around the code wheel and pass it through the tension rollers Step 14 Remove the four 10 32 x 3 4 SCB Cap screws loosened in Step 11 Step 15 Pul
94. il A 27 2 29 x2 10 4 20 X4 19 x10 Detail B Figure 3 7 Backend Assembly 70 Detail B 3 x10 21 x10 IMPORTANT Note orientation of fans in relation to assembly Fans must be installed as shown 02 9686 0010 A HEAD ASSEMBLY 80MM FAN ASSEMBLY 3 80mm Fan Assembly 21 9686 6619 Rev A Refer to Figure 3 8 No Item Qty UM Description 1 40 7144 0001 1 EA FAN TUBEAXIAL 80 X 80 X 38 MM 230V 36 CFM BBEARING 95 C 2 53 2200 0006 4 EA NUT 6 32 KEPS SS 3 53 6558 0001 4 EA SCREW 6 32X 3 8 PPZ 4 55 7016 0001 1 EA FAN GUARD 80MM NICKEL PLATED STEEL WIRE 02 9686 0010 A a 3 X4 Figure 3 8 80mm Fan Assembly 71 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Dual Fan Duct Assembly 22 9686 0674 Rev B Refer to Figure 3 9 No Item Qty UM Description 1 10 9686 1672 1 EA DUAL FAN DUCT 2 10 9686 0673 1 EA TURNING VANE FAN DUCT 3 25 9678 0015 1 EA CABLE ASSY OT SWITCH 2 TO GND not shown 4 25 9686 0013 1 EA CABLE ASSY OT SWITCH 1 TO OT SWITCH 2 not shown 5 25 9686 0014 1 EA CABLE ASSY BACKCAP INTRLK TO OT SWITCH 1 not shown 6 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 7 53 6604 0002 4 EA SCREW 4 40 X 1 4 THREAD FORMING 8 74 1090 0001 2 EA OTI THERMAL SWITCH LIMIT 199 C 7 x2 7 x2 Figure 3 9 Dual Fan Duct As
95. inued 17 x8 13 x4 400 252 455 410 __ 355 Set blade assemblies according to dimensions shown Figure 3 27 VL3500 Wash Strobe System Assembly 104 02 9686 0010 A VL3500 Wash FX Strobe System Assembly HEAD ASSEMBLY VL3500 WASH FX STROBE SYSTEM ASSEMBLY 3 21 9686 1404 Rev 0 VL3500 Wash FX Refer to Figure 3 28 No Item Qty UM Description 1 10 9678 0491 4 EA BUMPER STOP STROBE 2 10 9686 0438 1 EA SPRING COLOR ACCESS 3 10 9686 0440 1 EA SHIELD STROBE MOTOR HARNESS 4 10 9686 1435 1 EA STROBE BULKHEAD COLOR ACCESS 5 21 9686 1445 1 EA ASSY AIR DUCT 6 21 9686 1437 1 EA REAR STROBE BLADE ASSEMBLY 7 21 9686 1438 1 EA FRONT STROBE BLADE ASSEMBLY 8 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR6 9 53 6513 0026 8 EA SCREW M3 X 5 X 12MM LG PP 10 53 6525 0188 4 EA SCREW 6 32X 3 16 PPZ SEMS ll 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 12 53 6609 0001 4 EA SCREW 6 32 X 3 8 LG PFZ 13 55 2023 0002 1 EA HINGE 1 00 LG X 1 00 WD ZINC STEEL 14 55 3303 0004 8 EA WASHER 4 LOCK INT TOOTH SS 15 55 3306 0006 8 EA WASHER 375 OD 149 ID 025 THK 16 55 6659 0001 8 EA SPACER 1 4 RND 4 THRU 3 16 17 55 6706 0001 8 EA GROMMET 9 32 ID 9 16 OD 1 4T 02 9686 0010 A 105 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash FX Strobe System Assembly continued 4
96. kann das Produkt Hochfre quenzst rungen verursachen In diesem Fall m ssen eventuell geeignete Ma nahmen getroffen werden BESONDERHEITEN VON BOGENLAMPEN 1 Bogenlampen ben tigen eine gewisse Zeitdauer um nach einem Stromausfall oder einem Spannungsgef lle wieder aufzuleuchten In einigen F llen wird die Lampe nach Abk hlung automatisch wieder aufleuchten je nach der Systemkonfigurationseinstellung des Lampenein schaltungsstatus 2 Die Brennposition ist Universal vi 02 9686 0010 A FOREWORD Notes de s curit Avant de proc der l installation des produits d crits dans ce guide et de les mettre en marche il est extr mement important de lire TOUS les renseignements et TOUTES les directives de s curit contenues dans ce guide ainsi que toute documentation jointe Tenir compte de tous les avertissements et suivre toutes les pr cautions pendant l installation et l utilisation de cet appareil Les symboles de s curit utilis s dans ce guide sont les suivants A ATTENTION Ce symbole annonce que l appareil risque d tre endommag A AVERTISSEMENT Ce symbole annonce qu il y a risque d accident grave ou m me fatal CETTE SECTION CONTIENT DES INFORMATIONS G N RALES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES LES INCENDIES LEXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRA NER DES BLESSURES AVERTISSEMENT DIRECTIVES POUR SE CONTRE LES INCENDIES 1 L
97. l motor assembly out of the enclosure Remove the tension springs from the enclosure Step 16 Disconnect the motor wiring Step 17 Replace by performing steps 2 through 16 in reverse order 02 9686 0010 A 39 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly Replacement continued A Note Make sure wiring 15 not pinched during installation When tightening four 10 32x3 4 SCB Cap screws that mount Pan Motor Assembly you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring NOTE Head not shown for s Ventilation Cover Pan Motor Assembly Encoder Wheel Tensioning spring SS Tensioning spring Figure 2 13 Pan Motor Assembly Replacement 40 02 9686 0010 A MAINTENANCE PROCEDURES PAN ENCODER REPLACEMENT Pan Encoder Replacement Parts 24 0678 9729 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Place the luminaire on the upper enclosure CAUTION During the next step do allow the front lens to contact anything that could damage the lens coating Step 2 To provide access to the ventilation cover set the luminaire on the front lens casting Step 3 At bottom of the enclosure remove four 1 4 20 x 1 5 8 socket screws and 1 4 split lock washers Remove the ventilation cover Step 4 As shown in Figure 2 14 at encoder board remove two 4 40 x 1 4 PPZ screws
98. ngage the sensor beam Pan belt disconnected extremely loose or not installed properly properly install belt between pan motor and large pulley Tilt Encoder Fail Luminaire will not tilt Tilt Encoder Failure MCB pan tilt connector disconnected connect MCB pan tilt connector J8 Tilt motor disconnected connect tilt motor power Encoder faulty replace tilt end of travel encoder sensor assembly Tilt No Sens Luminaire will not tilt Tilt Sensor Not Found EOT flag attached to large pulley is not engaging the EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth sufficient to engage the sensor beam Tilt belt disconnected extremely loose or not installed properly properly install belt between tilt motor and large pulley n a Color dimmer or strobe mechanisms will not move Color Dimmer or Strobe Failure MCB connector disconnected check MCB connector at J11 Check Interconnect board n a Zoom Edge or beam spreader mechanisms will not move Zoom Edge or Beam Spreader Failure MCB connector disconnected check MCB connector at J10 Check Interconnect board n a Aperture mechanism will not move Aperture Failure MCB connector disconnected check MCB connector at J9 Check Interconnect board n a Self tests will not run or software download does not work DMX Dat
99. nment Tab RTV beads should be applied at all positions where a filter can be used Figure 3 23 VL3500 Wash FX Fixed Color Wheel 1 Assembly 98 02 9686 0010A HEAD ASSEMBLY VL3500 WASH FX FIXED COLOR WHEEL 2 ASSEMBLY 3 VL3500 Wash FX Fixed Color Wheel 2 Assembly 21 9686 1480 Rev VL3500 Wash Refer to Figure 3 24 No Item Qty UM Description l 10 9686 0481 1 EA WHEEL FIXED COLOR 2 WHEEL 2 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 22 9686 1416 1 EA FIXED COLOR WHEEL HUB WITH BEARINGS 5 41 9686 0495 1 EA COLOR FILTER BLUE WHEEL 2 6 41 9686 0496 1 EA COLOR FILTER AMBER WHEEL 2 7 41 9686 0497 1 EA COLOR FILTER DARK FUCHSIA WHEEL 2 8 41 9686 0498 1 EA COLOR FILTER ORANGE WHEEL 2 9 41 9686 0499 1 EA COLOR FILTER GREEN WHEEL 2 10 53 6598 0312 4 EA SCREW 4 40 X 5 16 02 9686 0010 A 99 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL VL3500 Wash FX Fixed Color Wheel 2 Assembly continued Detail A m E 10 x4 Note All filters must be installed with the coating side towards the luminaire s lamp 2 Green Alignment Tab Gange Z Dark N Fuchisa Detail Alignment Tab X 7 RTV beads should be applied at all positions where a filter can be used Figure 3 24 VL3500 W
100. nt Parts 21 9686 2150 Repair Procedure Step 1 At the control console or the luminaire menu close the split lens assembly Step 2 Disconnect luminaire AC input cable from power source Step 3 Remove the Color Dimmer Strobe Assembly See Color Dimmer Strobe Assembly Replacement on page 31 for complete instructions Step 4 At the interconnect board disconnect the zoom motor and split lens motor connectors Step 5 As shown in Figure 2 9 remove the two 6 32 x 3 8 PPZ SEMS screws and remove the interconnect board Step 6 Remove one 6 32 x 3 8 PPZ SEMS screw and remove the 8 cable saddle Step 7 Remove the three 6 32 x 3 8 PPB screws Step 8 Remove the split lens assembly Step 9 Replace the split lens assembly in reverse order 02 9686 0010 A 33 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Internal Lens Assembly Replacement continued Interconnect Board Cable Saddle Internal Lens Assembly X Figure 2 9 Internal Lens Assembly Replacement 34 02 9686 0010 A MAINTENANCE PROCEDURES REFLECTOR REPLACEMENT 2 Reflector Replacement Parts 42 9686 0120 Repair Procedure Step Step Step Step Step Step 02 9686 0010 A 1 2 Disconnect luminaire input cable from power source Remove the Color Dimmer Strobe Assembly See Color Dimmer Strobe Assembly Replacement on page 31 for complete instructions 3 As shown in Figure 2 10 remove four 4 40 x 1 3
101. ntinued next page Included Items Kit Front Stippled Lens Assembly 28 9686 0001 21 9686 0617 continued next page Figure 3 1 VL3500 Wash Luminaire Subassembly Drawing Tree Part 1 52 02 9686 0010A DRAWING TREE VL3500 WASH VL3500 WASH LUMINAIRE 3 VL3500 Wash Luminaire continued continued from previous page continued from previous page Color Effect Strobe Module 21 9686 0400 Upper Enclosure Assembly 21 9686 0800 Ventilation Cover Assembly Panel Assembly 21 9686 0840 02 21 9686 0805 Pan Pulley Assembly DMX Input PCB 21 9686 0807 24 9663 3895 Pan Motor Assembly AC Input Pigtail Cable Assembly 21 9686 0864 25 9678 0810 VL3500 Wash Fixed Color Wheel 2 Assembly 21 9686 0480 VL3500 Wash Fixed Color Wheel 1 Assembly 21 9686 0484 VL3500 Wash Color Harness Cable Assembly 25 9686 0205 Pan Tube Assembly Pan EOT Sensor Electrical 21 9678 0881 Assembly 23 9678 0687 Chassis to Yoke Ground Cable Assembly Exhaust Fan Assembly 25 9661 1520 21 9686 0811 Ballast to Controller Cable Assembly 25 9678 0816 VL3500 Wash Strobe System Assembly 21 9686 0404 Rear Strobe Blade Assembly 21 96686 0407 EMI Filter to Power Switch Cable Assembly 25 9678 0811 Data I 0 Link Cable Assembly AC Input Splitter Cable Assembly 25 9678 0813 25 9678 0812 continued from previous page Display Cable Assembly DC Output Cable Assembly 25 9678 1825 25 9678 0821 Head Cable Interconnect 21 9686 1121 Pan Tilt Cont
102. o issued from the Dallas Texas USA office They are non procedural documents that contain information regarding product support issues current equipment problems software bugs and documentation corrections All technical notices begin with the prefix TN and are numbered sequentially such as TN 138 Tech Notice number 138 4 02 9686 0010A 1 Description This chapter contains descriptions of luminaire features and components Features Components JO1AYIS 02 9686 0010 A 5 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Features VL3500 Wash amp VL3500 Wash FX Standard Features Three filter color mixing system Variable CTO color correction wheel Full field dimming system Dual blade strobe system Fan cooled UV IR glass Dual wattage double ended lamp capable of operation at 2 900W Standby Mode 1200W or 1500VV mode selectable from fixture or console mode produces a tight intense column of light Zoomable beam optics mechanism for continuous beam size control with 10 to 50 range dependent on the lens configuration Dual five position plus open fixed color wheels Five position aperture wheel 52 40 35 30 and 25 mm VL3500 Wash only One rotating FX pattern wheel with four rotatable and indexable positions and one open position VL3500 Wash FX only Interchangeable front
103. o the hinge rods CAUTION As shown in Detail in Figure 2 3 insure that each lens is aligned and inserted into the keyed carrier and ensure lens is in front towards front lens of bumper stops Step 7 Secure lens assembly by replacing the cross strap and retaining knobs Hand tighten only Step 8 Replace head cover Step 9 Apply power the luminaire and test the function of the internal lens assembly 02 9686 0010 A 21 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Internal Lens Replacement continued Head Cover A Clean any fingerprints on lenses with CAUTION isopropyl alcohol and a lint free cloth 1 4 Turn Screw Detail A v Lens Assembly Retaining Knobs Post Stops Head covers are attached by tethers Keyed Carrier Note Some components not shown for clarity Figure 2 3 Internal Lens Replacement 02 9686 0010 A MAINTENANCE PROCEDURES FRONT LENS ASSEMBLY REMOVAL Front Lens Assembly Removal Tools 5 32 Allen wrench lint free cotton gloves To replace the front lens assembly A WARNING Remove power from luminaire before performing maintenance Internal fixture components assemblies and the front lens can be HOT after operation Allow components to adequately cool before replacing Step 1 Remove power from luminaire A CAUTION The luminaire head is a precisely balanced unit The weight of the front lens ass
104. p 4 Remove four 4 6 32 screws securing MCB PCB Step 5 Disconnect upper enclosure connectors J1 J2 J3 J4 and J12 at back of MCB Step 6 Install replacement assembly by performing Steps 2 5 in reverse order Step 7 Configure using menu functions as necessary Yoke Leg Cover Main Control Board MCB Figure 2 11 Main Controller Board MCB Replacement 02 9686 0010 A 37 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Ignitor Board Replacement Parts 24 9661 3126 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 At tilt side leg remove yoke leg cover by removing four 6 32 x 5 16 screws A CAUTION Always use anti static precautions when working with PCBs Step 3 Disconnect ignitor PCB wires by removing four screws that secure wire ring terminals to PCB and remove ignitor PCB Step 4 Remove four 6 32 x 3 8 screws Step 5 Replace by performing steps 2 through 4 in reverse A Note Make sure and orient ignitor properly as shown in Figure 2 12 Mounting Plate P Ignitor Board Remove Ignitor Board Mounting Screws Figure 2 12 Ignitor Board Replacement 38 02 9686 0010A MAINTENANCE PROCEDURES PAN MOTOR ASSEMBLY REPLACEMENT Pan Motor Assembly Replacement Parts 21 9686 0864 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Place the luminaire on the upper enclosure Step 2 As shown in F
105. r 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 denatured 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 the lamp will automatically relight after it has cooled depending on Lamp Power Up State configuration setting 2 Burning position is universal iv 02 9686 0010A FOREWORD Sicherheitshinweise Es ist u erst 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 Vorsichtsma nahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet A VORSICHT weist auf m glichen Produktschaden hin A WARNUNG weist auf m gliche K rperverletzung und Lebensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEM
106. repaid to Vari Lite 10911 Petal Street Dallas Texas 75238 USA Attention Warranty Service As stated in the warranty it is required that the shipment be insured and FOB our service center Note The VL3500 Wash and VL3500 Wash FX Luminaires share many common assemblies and parts of the Vari Lite Series 3000 Luminaires 02 9686 0010 A I VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Compliance Notice FCC C 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 communications Operation of this equipment in a residential area is likely to cause harmful interference 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 EN 60598 1 2000 Luminaire Safety Standard General Requirements EN 60598 2 17 1989 Specification for Luminaires for Stage and Studio Lighting E
107. result in premature wear or malfunction of the luminaire and may void the luminaire warranty 02 9686 0010 A 15 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Troubleshooting 16 Error Messages If a problem occurs during luminaire calibration at the end of the calibration sequence the Menu Display will cycle through any applicable error message s one at a time until the end of the list is reached To review the error messages again it will be necessary to access them using the Status function Refer to Troubleshooting Guide on page 17 for a list of possible causes and remedies associated with the error messages To access error messages Step 1 Press Menu Step 2 Press Up Down arrows until Fixture appears Press Enter Step 3 Press Up Down arrows to access Status Press Enter Display will now scroll through any error messages or display OK if no errors Table 2 1 Error Messages Display Message OK No Errors Found Pan No Sens Pan sensor not found Pan Encoder Fail Pan encoder failure Tilt No Sens Tilt sensor not found Tilt Encoder Fail Tilt encoder failure Dimmer No Sens Dimmer sensor not found Cyan No Sens Cyan sensor not found Yellow No Sens Yellow sensor not found Magenta No Sens Magenta sensor not found ColWheel No Sens Color wheel sensor not found ColWheel2 No Sens Color wheel sensor not found CTO
108. rews CAUTION Do not touch filters with bare fingers Wear cotton gloves or other covering while replacing filters To clean filters use isopropyl alcohol and soft cloth Step 3 Rotate Color Wheel 2 until the filter you are changing is accessible Step 4 Toimprove access to the filter rotate the mixed color wheels to position the cut outs next to the filter you are changing Step 5 As shown in Figure 2 5 gently press the color filter toward the lens until it is free of the lock pins Remove the filter Step 6 Slide the new filter orientation does not matter under the spring clip until it is securely retained by the lock pins Step 7 Replace the head cover 02 9686 0010 A 25 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL 26 Color Filter Replacement continued A Do not touch filters with bare fingers Assembly With Color Wheels CAUTION Wear cotton gloves Do not remove See detail Color Wheel 1 Color Filter Air Duct Door Color Wheel 2 Color Filter Figure 2 5 Replacing a Color Filter 02 9686 0010 A MAINTENANCE PROCEDURES EFFECTS PATTERN REPLACEMENT VL3500 WASH FX ONLY 2 Effects Pattern Replacement VL3500 Wash FX Only Tools 2 Philips screwdriver e Lint free cotton gloves AN WARNING Remove power from luminaire before performing maintenance Patterns can be HOT after operation Allow the fixture to cool before removing patterns To replace an effects pat
109. rmation Table A 2 Vari Lite VL3500 Wash VI 35001M Wash FX Technical Bulletins Technical Bulletin Description Model s cedures S3K 015 Cooling System Modification Kit VL3500 Wash S3K 016 Internal Lens Travel Stop Installation VL3500 Wash S3K 017 VL3500 Wash to VL3500 Wash FX Conversion Pro VL3500 Wash Technical Bulletins Software Updates support and other information is available online at http www vari lite com under the Support Tab Note To request access to the password protected support areas please contact Vari Lite Customer Service at 1 877 827 4548 or customerservice O genlytecontrols com 02 9686 0010 A 173 VARFKLITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 174 02 9686 0010 A VARISLITE Express yourself Vari Lite 10911 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 19 May 2009 Manual Part Number 02 9686 0010 A 2003 2009 A Philips Group Company All rights reserved Printed in the U S A
110. rol Cable Assembly Zoom Motor Cable Assembly 23 9686 0208 25 9678 0818 LVS Chassis Ground Cable Assembly 25 9661 1514 Front Strobe Blade Assembly 21 9686 1438 Lamp Supply to Relay Cable Assembly 25 9678 0829 LVS to Yoke Dual AC Fan Cable Assembly 25 9686 0843 LVS Chassis Ground Cable Assembly 25 9661 1514 Front Clear Lens Assembly 21 9686 0618 Front Fresnel Lens Assembly 21 9686 0619 Fresnel Internal Lenses 21 9686 0620 Figure 3 2 VL3500 Wash Luminaire Subassembly Drawing Tree Part 2 continued from previous page continued from previous page Backcap Interlok to OT Switch 1 Dual Fan Duct Assembly Cable Assembly 22 9686 0674 25 9686 0014 Included Items Kit 28 9686 0001 OT Switch 1 to OT Switch 2 Cable OT Switch to Ground Cable Assembly Assembly 25 9686 0013 25 9678 0015 02 9686 0010 A 53 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Drawing Tree VL3500 Wash FX VL3500 Wash FX Luminaire VL3500 Wash FX Luminaire 20 9686 0011 VL3500 Wash Controller PCB Assembly Color Rotating Effect Strobe Module Generic Luminaire Assembly Head Cover Assembly 21 9686 1400 21 9686 1010 21 9686 0611 continued next page Head Structure Assembly Dual Fan Tray 21 9686 1600 ual Fan Tray Assembly 21 Tilt Harness Cable Assembly RN 25 9686 2203 Backend Assembly 21 9686 0615 Internal Lens Assembly 21 9686 2150 Internal Lens Interconnect
111. s Notes regarding lamp control The douse command applies 5v to the out line When the start command is given this drops to Ov This can be measured at the MCB at the ballast connection The Out pin of the 5 pin connector should read Ov when the lamp is striking or On Config gt Lamp gt Power gt On When the douse command is given Config gt Lamp gt Power gt Off the reading should changed to 5v Likewise the standby circuit goes to standby when 5v is received on the standby line Equally if 5v is applied to the standby line the lamp will go into standby mode and if 5v is applied to the Out line the lamp will douse 02 9686 0010A WARNINGS AND CAUTIONS EXCEPTIONAL SAFETY INFORMATION FOR THE VL3500 LUMINAIRES 2 Warnings and Cautions gt Exceptional Safety Information for the VL3500 Luminaires The light intensity and power density of the VL3500 Wash and VL3500 Wash FX Luminaires exceeds other fixtures typically used in this application The warnings and cautions that follow are critically important to the safe operation of these luminaires These products are for commercial use only If you have any questions about the safe installation and operation of the VL3500 Wash and VL3500 Wash Luminaires please contact customer service at 1 877 VARI LITE 1 877 827 4548 1 214 647 7880 or customerservice genlytecontrols com WARNING Light Beam Projects Intense Heat Do not illuminate objects wi
112. sembly 72 02 9686 0010 A HEAD ASSEMBLY REFLECTOR MOUNT ASSEMBLY 3 Reflector Mount Assembly 21 9686 0605 Rev D Refer to Figure 3 10 No Item Qty UM Description 1 10 9686 0632 1 EA REFLECTOR CLAMP 2 10 9686 0644 4 EA SPRING REFLECTOR MOUNT 3 21 9686 0606 1 EA ASSEMBLY UV GLASS 4 42 9686 0120 1 EA REFLECTOR ELIPTICAL 5 53 6683 0015 4 EA SCREW 6 32 X 5 8 PPB SEMS Note Install filter with marks indicating IR coating side of the glass facing up and located outside of circular cutout in reflector mount 02 9686 0010 A LL Align tabs on reflector and top left support Figure 3 10 Reflector Mount Assembly 73 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 74 02 9686 0010A Hot Box Assembly 21 9686 0680 Rev Refer to Figure 3 11 HEAD ASSEMBLY Box ASSEMBLY 3 No Item Qty UM Description l 10 9678 0043 04 1 EA LABEL PLATE VL3500 WASH BACKCAP BLACK 2 10 9686 0642 1 EA BACKCAP PLATE 3 10 9678 0643 1 EA LAMP ADJUST STOP 4 10 9678 0645 3 EA KNOB LAMP ADJ MOLDED 5 10 9686 0681 1 EA HOTBOX 6 22 9686 0649 1 EA ASSEMBLY TILT PLATE LONG VANE 25 9661 1522 1 EA CABLE ASSY HEAD TO BACKCAP GND not shown lt 25 9678 0789 1 EA CABLE ASSY IGNITOR TO LAMP SOCKET not shown 7 53 2030 0001 3 EA NUT A
113. splay 150W 24V 6 3A Power Supply AC Input Cable Requires standard AC power distribution from 200 264 VAC 50 60 Hz 7 to 12 A depending on the AC supply voltage Enclosure Bottom Ventilation Cover Wire Connection Green Yellow AC Ground Blue AC Neutral Brown AC Line International Harmonized Standard 02 9686 0010 A 9 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Notes 02 9686 0010A 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Warnings and Cautions Troubleshooting Maintenance Procedures WARNING As with any repairs or maintenance to Vari Lite luminaires A service should only be performed by a trained and qualified service technician or at an Authorized Vari Lite Service facility 02 9686 0010 A SI AN 11 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Testing Luminaire Self Tests The luminaire is capable of running self tests by using the TEST menu functions For detailed instructions regarding the luminaire s self test function refer to the VL3500 Wash Luminaire User s Manual 02 9686 0001 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence VL3500 WASH Phase 1 e Tilt Strobe Color Wheel 1 Color Wheel 2 Phase 2 Dimmer Phase 3 Aperture Phase 4 VAREKBRITE
114. ss 116 Enclosure Assembly Upper Enclosure Assembly cinta en an San ein 119 Ventilation Cover Assembly 4 ette ER R Ba 125 Exhaust Fan Assembly u aa ann ag ate Bin E IE 127 PanelaASSernb ys a un me ere een neigen 128 DMX MPU POB r 595 129 Pan Pulley Assembly 130 Pan Motor Assembly _ EE 131 Pan T be Assembly ete eee gae es Rest due 133 Cable Assemblies Pan EOT Sensor Electrical Assembly ss 135 LVS Chassis Ground Cable Assembly ss 136 Ignitor to Relay Cable ss 137 Yoke to Dual AC Fan Cable Assembly u 138 LVS to Yoke Dual AC Fan Cable Assembly 139 OT Switch 1 to OT Switch 2 Cable Assembly eese 140 Backcap Interlok to OT Switch 1 Cable Assembly 141 OT Switch to Ground Cable Assembly n nennen rennen 142 Tilt Harness Cable Assembly cuicos Ek 143 Internal Lens Interconnect Cable Assembly sesseeeeeeseeseesesreesesrrsrestsersrrsserrtsressesrrsressesresrs 145 VL3500 Wash Color Harness Cable Assembly 146 VL3500 Wash FX Color Harness Cable AgsSemp1y eene 148 Internal Lens Split Motor Cable Assembly eene 151 Transter Fans Cable een een 152 Upper Enclosure Fans Cable Assembly ss 153 Yok
115. t e doivent tre remplac s par exemple s il y a des fissures ou de profondes rayures AVERTISSEMENT y DIRECTIVES POUR SE PROTEGER CONTRE LES ACCIDENTS POUVANT ENTRAINER DES BLESSURES 1 Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour man uvrer ou ajuster des appareils br lants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 La lampe du luminaire est br lante lorqu il est en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons ultraviolets pouvant causer de graves br lures sur la peau et une inflammation des yeux De plus les lampes arc fonctionnent sous haute tension de tr s hautes temp ratures Si la lampe se casse les particules de la lampe cass e peuvent causer blessures et ou incendie en s parpillant Se prot ger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropri s gants protection des yeux pour manier des lampes endommag es 6 Silalampe a t touch e avec des mains nues la nettoyer avec de l alcool d natur et l essuyer avec un chiffon non pelucheux avant d installer ou de brancher le luminaire 7 Silalampe a t endommag e ou a recu une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERF RENCE RF 1 Cet appareil est de Classe A Dans un environnement domestique cet app
116. t is important to read ALL accompanying safety and installation instructions to avoid damage to the product and potential injury to yourself or others This manual covers the following models Model Part Number Source VL3500 Wash Luminaire 20 9686 0001 Arc VL3500 Wash FX Luminaire 20 9686 0011 Arc A Note Performing maintenance procedures may void the product warranty Refer to the Vari Lite Limited Warranty card included in the product shipping package for more information 02 9686 0010 A 1 VARF amp LITEG VL3500 WASH LUMINAIRE SERVICE MANUAL Additional Documentation For complete installation and operation instructions refer to the VL35001M Wash amp VL35001M Wash FX Luminaires User s Manual This manual is available in both printed and electronic PDF formats e VL3500 M Wash amp VL3500 Wash FX Luminaires User s Manual 02 9686 0001 For more information regarding DMX512 systems refer to the DMX512 1990 amp AMX 192 Standards publication available from United States Institute for Theatre Technology Inc USITT USITT 6443 Ridings Road Syracuse NY 13206 1111 USA 1 800 93USITT www usitt org 2 02 9686 0010A INTRODUCTION CUSTOMER SERVICE 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
117. tern on Rotating Effects Wheel Step 1 Remove power from luminaire Step 2 Remove bottom head cover by loosening the four 1 4 turn screws Step 3 As shown in Figure 2 6 open door on the cooling air duct CAUTION Do not touch patterns with bare fingers Wear cotton gloves or other covering while replacing or cleaning patterns To clean patterns use isopropyl alcohol and soft cloth Step 4 Rotate Yellow Wheel until cut out faces up Step 5 Rotate Effects Pattern Wheel to desired pattern Step 4 5 Step 6 Atpattern s planet gear gently rotate two planet gear latches that secure pattern planet gear 7 Remove planet gear containing the pattern from assembly 8 Step 8 If replacing pattern perform the following if not proceed to Step 9 At planet gear rotate retaining spring from assembly b Gently press pattern out from planet gear c Install new pattern in same orientation including black side up in the gear as shown in Figure 2 6 reflective side must face lamp This ensures all will calibrate in the same orientation Note If installing same pattern in multiple fixtures utilize same orientation in relation to the planet gear in all fixtures d Use care in reinstalling retaining spring Spring can scratch pattern Step 9 Rotate rotating effects wheel until you see the small indexing hole in the sun gear Step 10 When reinstalling planet gear assembly you must align the index mark in the planet gear
118. thin 3 5 m 11 5 feet of the VL3500 Wash orVL3500 Wash FX Luminaire Objects within this range can scorch melt or ignite from the heat projected by the light beam WARNING High Intensity Light Output Do not look directly into the light beam Avoid looking at nearby surfaces illuminated by the beam It is hazardous to operate luminaires without lens or shield Shields lenses or ultraviolet screens must be changed if they have become visibly damaged to such an extent that their effectiveness is impaired For example by cracks deep scratches or coating breakdown WARNING Hot Exterior Surfaces The exterior surfaces of the luminaire can get very hot up to 170 C 338 F Do not touch any surface of the luminaire while it is operating Keep all combustible materials a minimum of 200 mm 8 inches away from the luminaire To maintain cooling fan operation after the lamp is doused keep the luminaire powered on for 5 minutes Wait an additional 5 minutes before touching the luminaire CAUTION Operating Environment Do not operate the luminaire when the ambient temperature exceeds 40 C 104 F Do not attempt to bypass thermostatic switches WARNING Approved Lamp Type Refer to the latest version of Vari Lite Technical Notice TN 248 for approved lamp type s this technical notice is found on the vari Lite web site at www vari lite com in the Support section The use of any lamp other than those specified or approved by Vari Lite can
119. ued Top Cover NOTE Head not shown for clarity Ballast Assembly includes attached ferrite Chassis ferrite Do not remove End Cover Exhaust fan D LD Left Side Cover Ventilation Cover a in Figure 2 7 Ballast Assembly Replacement 30 02 9686 0010A MAINTENANCE PROCEDURES COLOR DIMMER STROBE ASSEMBLY REPLACEMENT Color Dimmer Strobe Assembly Replacement Parts 21 9686 0400 VL3500 Wash Only Parts 21 9686 1400 VL3500 Wash FX Only Repair Procedure Step 1 Disconnect luminaire AC input cable from power source As shown in Figure 2 8 stand the luminaire on the upper enclosure Use the orientation of the backcap label to determine the top and bottom of luminaire head WARNING Before performing this modification remove all power sources from the luminaire Step 2 Loosen the four quarter turn fasteners and remove the top head cover Likewise remove the bottom head cover Step 3 Tilt the luminaire so the top of the backcap faces upward and front lens points downward The Head cable Interconnect must be facing up and the fans facing down A CAUTION Be careful not to damage wiring during the next step Step 4 Note the location of the wire on the head cable assembly Carefully cut the two wire ties that hold head cable assembly together Cut the two wire ties that attach the head cable assembly to the Color Effect Strobe module Step 5 Att
120. ure 3 5 Front Fresnel Lens Assembly 02 9686 0010 A 67 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Head Cover Assembly 21 9686 0611 Rev D Refer to Figure 3 6 No Item Qty UM Description 1 10 9678 0612 1 EA HEAD COVER FOAM BAFFLE 2 10 9678 0649 4 EA EJECTOR SPRING BLACK OXIDE 3 10 9678 0674 1 EA BRACKET COVER TETHER 4 10 9678 0696 1 EA FOAM FRAME HEAD COVER 5 10 9686 0610 1 EA HEAD COVER VL3500 WASH 6 53 5606 0375 1 EA SCREW 6 32 X 3 8 PPSS 7 53 6683 0015 4 SCREW 6 X 1 4 PPZ PLASTIC 8 55 2233 0016 4 EA RETAINER SPLIT RING 9 55 2233 0775 4 EA STUD 1 4 TURN 775L STEEL BLK ZINC 10 55 9676 0255 4 EA BELLEVILLE SPRING WASHER Bottom View ucc 2 x4 Figure 3 6 Head Cover Assembly 68 02 9686 0010A HEAD ASSEMBLY BACKEND ASSEMBLY 3 Backend Assembly 21 9686 0615 Rev M Refer to Figure 3 7 No Item Qty UM Description 1 10 9678 0653 1 EA LIGHT BAFFLE EXHAUST 2 10 9686 0635 1 EA EXHAUST BULKHEAD 3 10 9686 0636 10 EA COUNTERWEIGHT REAR 4 10 9686 0671 1 EA SEPARATION BULKHEAD 5 12 9678 0627 1 EA REAR CROSS CASTING MACHINED 6 10 9686 0659 1 EA INSULATOR FAN THIN 7 21 9678 0673 1 EA TETHER ASSY COVERED 8 21 9686 0673 1 EA TETHER ASSY BARE 9 21 9686 0605 1 EA ASSEMBLY REFLECTOR MOUNT 10 22 9686 067
121. ure 3 52 OT Switch 1 to OT Switch 2 Cable Assembly 02 9686 0010A CABLE ASSEMBLIES INTERLOK SwITCH 7 CABLE ASSEMBLY 3 Backcap Interlok to OT Switch 1 Cable Assembly 25 9686 0014 Rev A Refer to Figure 3 53 No Item Qty UM Description l 52 8414 0001 1 EA RECEPT FASTON 187 SERIES 24 20 AWG UNINSUL 2 52 8371 0001 1 EA RECEPT FASTON 24 20 AWG UNINSUL 3 73 7089 0000 0 33 FT WIRE 22AWG 300V 200C TEF BLK UL1180 2 1 3 Figure 3 53 Backcap Interlok to OT Switch 1 Cable Assembly 02 9686 0010 A 141 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL OT Switch to Ground Cable Assembly 25 9678 0015 RevA Refer to Figure 3 54 No Item Qty UM Description 1 52 8237 0002 1 EA TERM RING 4 24 20AWG 2 52 8371 0001 1 EA RECEPT FASTON 24 20AWG UNISUL TIN PLT BRS 250 X 032 TAB 3 73 7089 0000 0 25 FT WIRE 22AWG BLK 300V 200C TEFLON STRANDED 2 1 Figure 3 54 OT Switch to Ground Cable Assembly 142 02 9686 0010 A CABLE ASSEMBLIES TILT HARNESS CABLE ASSEMBLY Tilt Harness Cable Assembly 25 9686 2203 RevA Refer to Figure 3 55 and Figure 3 56 3 No Item Qty UM Description 1 52 6610 0040 2 EA CONNECTOR HOUSING 40 POS 26 22 AWG DBL ROW UNLOADED 2 52 6224 1040 2 EA COVER FRONT 40 POS MT LATCHING 3 52 6224 2040
122. ure 3 74 AC Input Splitter Cable Assembly 164 02 9686 0010A CABLE ASSEMBLIES DATA I 0 LINK CABLE ASSEMBLY 3 Data I O Link Cable Assembly 25 9678 0813 Rev A Refer to Figure 3 75 No Item Qty UM Description 1 52 6396 2904 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END 2 52 6396 2905 1 EA RECEPT 5 POS MTA100 W POL TAB RED CLSD END 3 73 5122 0259 2 17 FT CBL 22AWG STRND 4COND PVC INSUL 2 1 Figure 3 75 Data I O Link Cable Assembly 02 9686 0010 A 165 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Display Cable Assembly 25 9678 1825 RevC Refer to Figure 3 76 No Item Qty UM Description 1 52 6396 2406 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD END 2 73 5116 0123 1 02 FT WIRE 24AWG 4COND TW lt BLK BRN RED ORN gt 3 55 2186 0001 4 EA CABLETIE 10 WD 4 LG SMALL 4 73 7130 0004 0 958 FT WIRE TUBULAR BRAID 1 8 X 23 LG 5 73 6224 0005 0 208 FT WIRE 24AWG 600V 200C TFE GRN 2 5 LG 6 55 6699 0009 2 08 FT SLEEVING 3 8 NOM DIA POLY EXP 7 55 6621 0001 1 EA SLEEVE NYLON THIN WALL 6 SCR 1 0 LG 1 1 6 3 x3 k SS SSS SSL gt a 7 4 3 2 5 Figure 3 76 Display Cable Assembly 166 02 9686 0010 A CABLE ASSEMBLIES BALLAST TO CONTROLLER CABLE ASSEMBLY 3 Ballast to Controller Cable Assembly 25 9678 0816 Rev A Refer to Figure 3 77
123. with the index mark small indexing hole in sun gear Install pattern Step 11 Reengage two retaining latches Ensure the latches are properly and equally positioned over neighboring planet gear assemblies Step 12 Close the air duct door Step 13 Replace bottom head cover 02 9686 0010 A 27 VARIXLITE VL3500 WASH LUMINAIRE SERVICE MANUAL Effects Pattern Replacement VL3500 Wash FX Only continued Assembly With Rotating Effects Patterns Do not remove See detail Do not touch patterns with bare CAUTION fingers Wear cotton gloves Planet Gear Assembly Planet Gear Effects ES black side Indexing Mark Effects Pattern Retaining Spring Cooling Air Duct Yellow Wheel Retaining Latches Planet Gear Assembly Bulkhead plate and Cyan removed for clarity Assembly Sun Gear Figure 2 6 Effects Pattern Replacement VL3500 Wash FX Only 28 02 9686 0010A MAINTENANCE PROCEDURES BALLAST ASSEMBLY REPLACEMENT Ballast Assembly Replacement Parts 23 9686 1500 Repair Procedure Step 1 Step 2 Step 3 Disconnect luminaire AC input cable from power source Place the luminaire on the upper enclosure As shown in Figure 2 7 at the upper enclosure remove four 6 32 x 1 4 screws and remove both top covers In each top corner remove four 6 32 x 3 8 screws CAUTION During the next step do not allow the front lens to contact anything that could damage the lens coating St

VARI*LITE VL3500 Wash and VL3500 Wash FX Service Manual

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