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3 - Vari-Lite

1. 12 Calibration Sequence i o Rae 12 Auto Recalibration tie iut ide ege er e Pb e eo ent desta 13 Sensor Leste u n 13 Troubleshooting Error Messages 15 Troubleshooting Guide ooo E De aret ere Ee per xri CO 16 Maintenance Procedures ences ee ee ade 18 Align bmp pee de edet e oa 19 Lamp Power Cut OfL S WItcli n pmi epe e ME e Pr ir Eee EUG 20 Gobo Replacement 5 1 2 Eusebii tie 21 Color Filter Replacement od peo bedeuten ety 23 Beam Spreader Wash Only sister 24 Color Dimmer Strobe Assembly essieu 25 Strobe Assembly Replacement z au aap a aaa sas 26 02 9678 0010 G xiii VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Main Control Board MCB PCB Replacement ss 27 Motor Driver IC Replacement for Socketed MCBs 28 Ignitor Board Replacement 1 e 29 Pan Motor Assembly Pan Belt 30 Pan Encoder PCB 32 Pan EOT Sensor Replacement e eee eee aa a ED Gee dno 33 Low Vol
2. No Item Qty UM Description 26 23 9678 1120 1 EA LINEAR ACTUATOR ASSEMBLY 44 9678 0119 1 EA LINEAR ACTUATOR EDGE DRIVE 52 6467 0004 1 EA 4POS 30 24 AWG CRIMP PHR 52 6467 0024 4 EA CONTACT SOCKET 30 24AWG CRIMP REEL PH JST 27 24 9678 3112 1 EA ASSY VL3000 ZOOM SENSOR 28 53 2004 0002 1 EA NUT 8 32 KEPS ZINC PLATE 29 53 2213 0001 7 EA NUT 6 KEPS changed 03 24 04 30 53 5564 0250 2 EA SCREW 6 32 X 1 4 PFB UNDERCUT added 04 07 06 31 53 5604 0375 5 EA SCREW 4 40 X 3 8 PPB changed 03 24 04 32 53 6513 0023 6 EA SCREW M3 X 8MM LG PFZ 33 53 6558 0009 17 SCREW 6 32 X 3 8 SEMS changed 03 24 04 34 53 6558 0016 1 SCREW 6 32 X 3 4 LG PPS SEMS changed 3 03 04 35 53 6596 0002 4 EA SCREW 4 40 X 5 16 LG PPZ SEMS changed 3 03 04 36 53 6609 0001 6 EA SCREW 6 32 X 3 8 PFZ 37 53 6613 0008 4 EA SCREW 6 32 X 1 2 LG PPZ SEMS added 3 03 04 38 53 6614 0003 2 EA SCREW 6 32 X 5 8 PFZ 39 53 6617 0003 1 EA SCREW 6 32 X 1 PPB SEMS changed 3 03 04 40 53 6682 0025 2 EA SCREW 8 32 X 5 8 LNG PPZ SEMS changed 11 19 03 41 54 1261 0001 6 EA BUSHING LOW DAMP THERMOPLASTIC 189 ID 5 OD 42 55 2234 0001 1 EA RING RETAINING E STYLE GRV 188 DIA changed 02 06 05 43 54 2053 0001 1 EA MXT T BELT PULLEY 20GRV 25WD 44 54 2054 0001 1 EA BELT TIMING MXL 080 PITCH
3. 193 Pan Tilt Control Cable Assembly 194 Lamp Supply to Relay Cable Assembly 195 LVS to Yoke AC Fan Cable nnne 196 Appendix A Technical Bulletins VL3000 amp VL3000Q Technical Bulletins 197 xvi 02 9678 0010 G INTRODUCTION ABOUT THIS MANUAL Introduction About This Manual This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VL3000 The manual is intended for use by Vari Lite personnel and by Vari Lite s customers clients Q WARNING It is important to read ALL accompanying safety and installation instructions to avoid damage to the product and potential injury to yourself or others This manual covers the following models Model Part Number Source VL3000 Spot Luminaire 20 9678 0001 Arc VL3000 Wash Luminaire 20 9678 0002 Arc VL3000Q Spot Luminaire 20 9678 0003 Arc VL3000Q Wash Luminaire 20 9678 0004 Arc 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 Additional Documentation For complete installation and operati
4. No Item Qty UM Description l 10 9678 0272 1 EA BULKHEAD IRIS 2 10 9678 0273 1 EA MOTOR MOUNT IRIS 3 10 9678 0274 1 EA APERTURE IRIS 4 10 9678 0276 1 EA CRANK IRIS 5 10 9678 0279 1 EA DIVERTER GOBO AIR 6 10 9678 0280 1 EA ADJUSTABLE IRIS STOP changed 09 17 03 7 22 9678 0271 1 EA LINK ASSY IRIS 7a 53 6605 0004 1 EA STUD 2 56 X 1 0 LG FULL THREAD STAINLESS STEEL 7b 54 1217 0005 2 EA KWIK LINK 2 56 SPRING STEEL 8 22 9678 0275 1 EA IRIS 49MM OD 9 44 9678 0278 1 EA MOTOR 17 94 SHAFT 11 8MH 5 50HM 10 53 5558 0125 2 EA SCREW 8 32 X 1125 SET SS 11 53 6513 0042 3 EA SCREW M2 X 4 X 4MM LG METRIC 12 53 6530 0013 2 EA RIVET 1 8 POP 0 328 AL CSK HD STL MNDRL 13 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 14 53 6609 0500 3 EA SCREW 6 32 X 1 2 LG PFZ 15 55 2211 0002 1 EA STANDOFF 1 4 RND 6 32 0 188 LG changed 09 17 03 16 55 6538 0005 4 EA WASHER 0 250 OD 0 65 ID 0 015 THK TEFLON 92 02 9678 0010 G HEAD ASSEMBLY IRIS ASSEMBLY 3 Iris Assembly continued 16 x4 m o 10 x2 i 7 gt 4 E jd 1403 15 e 6 gt T T 4 Detail 12 x2 Figure 3 10 Iris Assembly 02 9678 0010 G 93 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Hot Box Assembly 21 9678 8640 01 Rev H 21 9678 8640 02 Rev H 21 9678 8698 01 Rev F 21 9678 8698 02 Rev F VL3000 Spot VL3000 Wash VL
5. 67 Top Assembly Included Items Kit 8 feet neds iets 70 Included Items Kit Wash n vec een ete 72 VL3000 and VL3000Q Spot Luminaire see 73 VL3000 and VL3000Q Wash Luminaire 76 Generic Luminaire Assemblies _ _ _ 79 Head Assembly Head Structure Assembly sus i ipee d ger ahud ette 81 Head Cover Assembly slim e Here e 82 Backend Assembly toad tiu Shu s EH actore 83 80mm Fan Assembly ss m oe a a A E ett tee eet 85 UY Filter Bulkhead Assembly tee Ree ease ate Pete ite tete tee dete 86 Spot Gobo Assembly sisi e ete ree lata Iu gen Da e eee ee Lattes 87 Rotating Gobo Wheel Assembly nennen 89 Rotating Effects Wheel Assembly lt 90 Shaft Motor Assembly ee rente tee E ue 22 9 Ins Asseinbly iiid eire e Ee Po epe t tege Sua 92 Hot Box Assembly ue audet e p o Feet lar pote te tut Pat ie ee etat fat 94 xiv 02 9678 0010 G TABLE CONTENTS Gobo Color Fan Assembly VL3000Q Only 96 Dual Fan Tray Duct Assembly VL3000 Only 98 Head Fan sss a n 100 Head Front Fan Assembly VL3000Q Only 101 Transfer Fan Asse
6. 1 VL3000 Spot amp Wash ae VL3000 Q Spot amp Wash Luminaires AS 02 9678 0010 Service PHILIPS VARISKLITE 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 VAREKIMAGE VAREKBRITE and the Vari Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC VAREKLITEO 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 5 432 601 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
7. 131 Condenser Lens Assembly 2 npn tee tiet en oor tee P Rael ne t ET Ce bere 132 Aperture Bulkhead Assembly ss 133 Beam Spreader Light Baffle Assembly 134 Yoke Assembly Woke Assembly iste tee _ 135 tsar nn ne de ele 137 Yoke Fan Assembly nda t pen tete E err eee ee Lotte 139 Head Yoke PCB Assemblies Color Sensor PCB 1 Mount 141 Color Sense 2 Mount Assembly 142 XV E3000 Controller 280 te te e wn a re nn 143 Zoom Interconnect Assembly nnne nennen rennen 144 Enclosure Assembly Upper Enclosure Assembly gq kas anan a a Presto 147 Ventilation Cover Assembly Standard 153 Ventilation Cover Assembly VL3000 154 Panel Assembly nece Ea ed pega ets 156 DMX Input PCB ob 157 AC Input Pigtail Cable Assembly miens 158 Pan Pulley Assembly 159 02 9678 0010 G XV VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Pan Motor Assembly dues oet teen adt detained race e e 160 Pan Tube Assembly uu uya etiem etate 7 162 Cable Assemblies Pan EOT Sensor Electrical Assembly 163 LVS Chassis Ground Cable Assembly 164 Chassis Yoke Grou
8. No Item Qty UM Description l 10 9678 1131 1 EA FORWARD PULLEY SHAFT changed 12 15 04 2 10 9678 0127 1 EA PULLEY IDLER 3 10 9678 0129 2 EA SPACER ROLLER CAM 4 10 9678 0153 1 EA CABLE CLAMP CAST 5 10 9678 0156 2 EA BARREL STRAP G2 6 10 9678 0157 1 EA BARREL STRAP G3 7 10 9678 0171 1 EA SHAFT CAM PULLEY 8 10 9678 1185 1 EA LIGHT BAFFLE 2 9 10 9678 1186 1 EA LIGHT BAFFLE 3 10 10 9678 1191 1 EA LIGHT BAFFLE G3 11 12 9678 1174 1 EA LENS MOUNT MACHINE G3 12 12 9678 1179 01 1 EA LENS MOUNT MACHINE 13 12 9678 1179 02 1 EA LENS MOUNT MACHINE G2 14 21 9678 0110 1 EA ASSY ZOOM BOX 15 21 9678 0113 1 EA ASSY RAIL amp CARRIAGE 16 22 9678 1181 1 EA LENS ASSY GROUP 1 17 22 9678 0182 1 EA LENS ASSY GROUP 2 18 22 9678 0183 1 EA LENS ASSY GROUP 3 19 22 9678 0199 1 EA ASSY LENS MOUNT G4 20 22 9678 1103 1 EA ASSY EDGE BEARING RIGHT 21 22 9678 1105 1 EA ASSY EDGE BEARING LEFT 22 22 9678 1106 1 EA ZOOM CAM ASSY 23 22 9678 1113 1 EA ASSY ZOOM MOTOR TENSIONING 24 22 9678 1115 1 EA INTERCONNECT LIGHT SHIELD 25 22 9678 1190 1 EA LID ASSY ZOOM BOX changed 11 05 03 12 9678 1189 1 EA LID ZOOM BOX 53 2008 0006 1 EA NUT PUSH 6 53 6522 0001 1 EA SCREW 6 32 X 1 4 PPZ 55 3303 0006 1 EA WASHER 6 LOCK INT TOOTH SS 02 9678 0010 G 103 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL
9. 1 ETE 7 RK 237 ZJ ERAT OBS LIFE lt 22135 k 2 L C lt 78 amp VA Lamp Power Up State gt 27 LEUR STI 10867 F2 278 L 220619228 HO ET 2 7 27 BAAG C3 02 9678 0010 G TABLE CONTENTS Table of Contents Introduction About This Maniak 1 Additional 1 tu 2 Technical Bulletins and Notices 4 2 Chapter 1 Description Features Standard Peatures uen ette pO en HIR BHO Uds 4 Specific Features nee ene IRR de une eem etcetera 4 Technical Specifications t tr e E D e E ORDRES E i al 4 Components External Luminaire Components ss 5 VL3000 Spot Luminaire Head and Yoke Components 6 VL3000 Wash Luminaire Head and Yoke Components 7 Enclosure Components sleit t adii ep ies ene Mte Hoe Lola t nba 8 Principles of Operation VL3000 and VL3000Q Spot Luminaire seen 9 Functional Block Diagram inne hte peine 9 VL3000 VL3000Q Wash Luminaire 2 10 Functional Block Diagram en ire tete tete ite eee te bete tes 10 Chapter 2 Maintenance Testing
10. 0001 239 5 Gm mms ce pipe 3 _ 2 TOOT V00000000000000000000000000 lt lt oe 16 ifa ge c qnn Re pn CI CI Em E 2 gt Ann mm 401 qun L ing imi BN pour a Bt 8 BEBEBe Figure 3 49 VL3000 Controller PCB 02 9678 0010 G 143 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Refer to Figure 3 50 Zoom Interconnect PCB Assembly 24 9678 3116 Rev 0 Spot Only Ref Item Qty UM Description 04 9678 1116 00 1 LABEL SET ZOOM HARNESS Not Shown 11 9678 1116 1 PCB ZOOM INTERCONNECT J3 52 6259 0008 1 EA HDR 4POS NTWTA100 SD ANG 4 52 6260 0015 EA HEADER 2805 MTA 100 SHROUDED p 52 6447 0009 1 EA HEADER SHROUDED 4 POSITION 52 6467 0009 1 EA CONN FEM PLUG 3POS 30 24AWG 52 6467 0010 3 EA CONTACT SOCKET 30 24AWG CRIMP II 52 6598 0029 1 EA HDR 14P 2ROW MODU 52 6662 0007 1 EA HOUSING 6POS 125 2 2 00 52 8388 0003 4 EA CONTACT 24 30AWG FEMALE CRI 55 2186 0001 1 EA CABLE TIE 0 10 WD 4 00 LG SMALL RI 60 1440 2703 1 RES 1 4W 5 270 0 OHM 73 2324 0030 0 54 FT WIRE 24 AWG 3CD TW 300 200 73 2324 0124 0 46 FT WIRE 24 A
11. Screw Clamp Secure this side first when reinstalling Optic Assembly Side View Edge Screw Thread all the way into motor as shown before re installing Figure 2 22 VL3000 Spot Optic Assembly Replacement 02 9678 0010 G 41 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL 42 Tilt Motor Assembly and Tilt Belt Replacement VL Part No 21 9678 0765 Tilt Motor VL Part No 54 2055 0001 Tilt Belt Repair Replacement Procedure To remove and replace tilt motor Step Step Step Step Step Step Step Note 1 Disconnect luminaire input cable from power source At tilt side leg remove yoke leg cover by removing four 6 32 3 8 PTB screws At tilt motor assembly loosen four 10 32x1 2 PPZ screws Remove belt from tilt pulley Remove four 10 32x1 2 PPZ screws Be mindful of tensioning springs Disconnect wiring and remove tilt assembly Replace by performing steps 2 through 6 in reverse order Make sure wiring is not pinched during installation When tightening four 10 32x1 2 PPZ screws that mount Pan Motor Assembly you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring To remove and replace tilt motor belt Step 8 Step 9 10 11 12 13 Step Step Step Step Step Step 14 15 Disconnect luminaire AC input cable from power source At tilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws
12. DEEP MAGENTA N N RED 5 8 Figure 3 28 Fixed Color Wheel Assembly 02 9678 0010 G 119 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Strobe Assembly 22 9678 0403 Rev F Refer to Figure 3 29 No Item Qty UM Description l 10 9678 0491 4 EA BUMPER STOP STROBE changed 6 18 03 2 10 9678 0465 1 EA STROBE BULKHEAD 3 22 9678 0468 1 EA ASSY LEFT STROBE BLADE 4 22 9678 0467 1 EA ASSY RIGHT STROBE BLADE 5 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR 6 53 6513 0032 8 EA SCREW M3X10MM SEMS PPZ EXT TO 7 53 6609 0500 4 EA SCREW 6 32 X 1 2 LG PFZ 8 55 6659 0001 8 EA SPACER 1 4 RND 4 THRU 3 16 AL changed 03 01 04 9 55 3306 0006 8 EA WASHER 0 375 OD 0 149 ID 0 025 THK SS changed 08 12 03 10 55 6706 0001 8 EA GROMMET 9 32 ID 9 16 OD 1 4 SILICON RED changed 03 01 04 120 Set blade assemblies according to dimensions shown Black Side faces away from assembly Figure 3 29 Strobe Assembly 02 9678 0010G HEAD ASSEMBLY STROBE ASSEMBLY VL3000 QUIET 3 Strobe Assembly VL3000 Quiet 22 9678 0463 Rev B Refer to Figure 3 29 No Item Qty UM Description 1 10 9678 0491 4 EA BUMPER STOP STROBE 2 10 9678 0465 1 EA STROBE BULKHEAD 3 22 9678 0467 1 EA ASSEMBLY RIGHT STROBE BLADE 4 22 9678 0468 1 EA ASSEMBLY LEFT STROBE BLADE 5 23 9678 0499 2 EA
13. No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52 6523 0002 1 EA CONN HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 4 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 5 55 2268 0125 1 EA HEATSHRINK 1 8 CLEAR KYNAR UL 600V 150 DEG C 6 60 8440 6801 1 EA RESISTOR 10W 5 628 WIREWOUND 3 x2 4 1 N Figure 3 15 Head Front Fan Assembly VL3000Q Only 02 9678 0010 G 101 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Transfer Fan Assembly 21 9678 0678 01 Rev D Spot 21 9678 0678 02 Rev D Wash Refer to Figure 3 16 No Item Qty UM Description 1 10 9678 0679 1 EA TRANSFER FAN TRAY 2 23 9678 0695 1 EA FAN ASSY TRANSFER 3 53 6571 0003 3 EA SCREW 6 32 X 1 1 2 LG PPB changed 07 16 07 4 55 6543 0001 2 12 FT GROMMET STRIP SERRATED POLYETHYLENE 5 55 6769 0004 3 EA TWIST LOK 0 55 ID NOM WHT 85 C MAX FLAME RET added 11 11 03 Spot Only 55 6769 0004 2 EA TWIST LOK 0 55 ID NOM WHT 85 MAX FLAME RET added 11 11 03 Wash Only 5 Spot amp Wash v gt 5 Spot Only Spot Only Figure 3 16 Transfer Fan Assembly 102 02 9678 0010 HEAD ASSEMBLY SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly 22 9678 0103 Rev S Spot Only Refer to Figure 3 17 and Figure 3 18
14. Ventilation Cover Assembly VL3000 Quiet continued 4 S Current Production Early Production Figure 3 55 Ventilation Cover Assembly VL3000Q 02 9678 0010 G 155 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Panel Assembly 21 9678 0805 Rev N Refer to Figure 3 56 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 PCB 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 SNAP IN 3 LONG NYLON NATURAL 11 74 2000 0002 1 EA SWITCH ROCKER 2 POLE HIGH CURRENT BLACK 6 8 4 Included with Input Cable Figure 3 56 Panel Assembly 156 02 9678 0010 G ENCLOSURE ASSEMBLY INPUT 3 DMX Input PCB 24 9663 3895 Rev 0 Refer to Figure 3 57 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 5PIN FEMALE PCMT VERTICAL 4 52 6626 0006 1 CONN RECEPT
15. Yoke Assembly 21 9678 0701 Rev B VL3000Q Continued on page 66 Upper Enclosure Assembl 21 9678 0801 01 Rev Z VL3000Q Continued on page 69 Rod Clamp Assembly 22 9678 0149 Rev B Gobo Clamp Assembly 22 9678 0693 Rev A Color Clamp Assembly 22 9678 0694 Rev A Edge Lead Screw Assembly 22 9678 1126 Rev B VL3000 Controller 24 9678 3730 Rev 0 Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Front Head Fans Cable Assembly 25 9678 0677 Rev B Head Controller Cable Assembly 25 9678 0715 Rev C Included Items Kit Wash 28 9678 0002 Rev F VL3000Q Wash Luminaire Drawing Tree Part 1 67 68 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000Q Wash Luminaire continued Continued from page 67 Transfer Fan Assembly 21 9678 0678 02 Rev D Wash Head Cover Assembly 21 9678 8611 Rev 0 Beam Spreader Light Baffle Assembly 21 9678 0991 Rev A Wash Only Aperture Bulkhead Assembly 21 9678 0950 Rev B Wash Only Figure 3 11 Color Dimmer Strobe Assembly 22 9678 0402 Rev N VL3000 Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly 22 9678 0403 Rev F Left Strobe Blade Assembly 22 9678 0468 Rev C Right Strobe Blade Assembly 22 9678 0467 Rev C Dimmer Wheel Assembly 22 9678 0435 Rev D Color Sensor PCB 1 Mount Asse
16. 48 53 6626 0001 1 EA SCREW 10 32 X 1 2 PPZ 49 53 6634 1000 1 EA SCREW 3 8 16 X 1 00 LG SOC 02 9678 0010 G ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 No Item Qty UM Description 50 53 6653 0502 4 EA SCREW 1 4 20 X 1 2 LG SOC NOT USED ON VL3000Q 51 54 1206 0014 2 EA RING RETAINING 52 54 1255 0001 1 BEARING ASSY BLACK FLUSH MOU 53 54 2055 0001 1 BELT TIMING 52 210GROOVE 9MM 54 55 2150 0003 2 STANDOFF 1 4 6 32 1 125 L 55 55 2178 0001 2 CABLE ANCHOR MOUNT 8 SCREW 56 55 2179 0001 3 EA CABLE ANCHOR MOUNT 6 SCREW 57 55 2186 0001 5 CABLE TIE 10 WD 4 00 LG SMALL 58 55 2261 0001 1 SLEEVE NYLON THIN WALL 6 SCR 59 55 2267 0001 2 FT RUBBER STRIP SPONGE CLSD CELL 60 55 6677 0039 4 EA WASHER 0 438 OD X 0 219 ID X 0 040 THK 61 55 6532 0004 2 EA BRACKET 6 32 THREADED HOLES 62 55 6543 0001 0 312 FT GROMMET STRIP SERRATED 062 63 55 6543 0002 1 54 FT GROMMET STRIP SERRATED 125 64 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK NOT USED ON VL3000Q 65 55 6568 0074 2 EA SPRING CPRSN 420 OD 750 LG 0 055 DIA WIRE 66 55 6575 0001 4 EA SCREW 10 32 X 3 4 PPB 67 55 6577 0005 2 STANDOFF 1 2 HEX 6 32 X 1 625 L 68 55 6580 0002 2 EA CABLE TIE 0 18 WD 8 0 LG 69 55 2132 0012 1 EA STANDOFF 1 4 HEX 6 32 X 3 4 LG 70 55 6677 0044 1 EA WASHER 877 OD 170 ID 093 THK 71 55
17. ASSEMBLY STROBE MOTOR VL3000Q 6 53 6520 0001 8 EA SCREW 4 40 X 3 8 PPZ 7 53 6609 0500 4 EA SCREW 6 32 X 1 2 LG PFZ 8 55 3306 0006 8 EA WASHER 375 OD 149 ID 025 SS 9 55 6537 0001 8 EA WASHER 4 INTERNAL LOCK TOOTH 10 55 6659 0001 8 EA SPACER 1 4 RND 4 THRU 3 16 AL 11 55 6706 0001 8 EA GROMMET 9 32 ID 9 16 OD 1 4 TH SILICONE 02 9678 0010 G 455 TE 355 Motor leads not shown Orient motor leads same direction as shown connectors Set blade assemblies according to dimensions shown Black Side faces away from assembly Figure 3 30 Strobe Assembly 121 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Right Strobe Blade Assembly 22 9678 0467 Rev C Refer to Figure 3 31 No Item Qty UM Description 1 10 9678 0464 1 EA STROBE BLADE changed 07 29 04 2 10 9678 0432 EA HUB STROBE BLADE 3 10 9678 0466 1 EA STROBE BLADE DAMPER 4 53 5559 0250 2 EA SCREW 6 32 X 1 4 SET CONE POINT 5 53 6597 0001 3 EA SCREW 4 40 X 3 16 PPZ 6 55 3303 0004 3 EA WASHER 4 LOCK INT SS 2 E _ mm S St J Reflective Side Figure 3 31 Right Strobe Blade Assembly 122 02 9678 0010 G HEAD ASSEMBLY LEFT STROBE BLADE ASSEMBLY 3 Left Strobe Blade Assembly 22 9678 0468 Rev C Refer to Figure 3 32 No Item Qty UM Description l 10 9678 04
18. Refer to Figure 3 54 No Item Qty UM Description 1 10 9661 1249 4 EA POST TRUSS HOOK 2 10 9678 8350 1 EA COVER VENTILATION 3 10 9678 0893 1 EA 12 AIR SEAL UPPER ENCLOSURE changed 05 11 05 4 10 9678 0894 1 EA 6 AIR SEAL UPPER ENCLOSURE changed 05 11 05 5 10 9678 0896 1 EA 45 AIR SEAL UPPER ENCLOSURE changed 05 11 05 6 54 1206 0015 4 EA RING RETAINING PRESS ON 1 SH 4 Fa z Z 6 x4 Figure 3 54 Ventilation Cover Assembly 02 9678 0010 G 153 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Ventilation Cover Assembly VL3000 Quiet 21 9686 0840 02 Rev B VL3000Q Refer to Figure 3 55 No Item Qty UM Description 1 10 9686 1249 4 EA POST TRUSS HOOK la 10 9678 0850 4 EA POST TRUSS HOOK SHORT EARLY PRODUCTION 10 10 9678 0833 4 EA SPACER 1 25 EARLY PRODUCTION 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 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 154 02 9678 0010 G ENCLOSURE ASSEMBLY VENTILATION COVER ASSEMBLY 3000 QUIET 3
19. amp VL3000 Q SERVICE MANUAL Features SPOT n E Standard Features VL3000 series luminaire have the following standard features CYM color mixing system Variable CTO color correction Six position fixed color wheel Full field dimming system Dual blade strobe system Repositional pan tilt system Control by DMX512 protocol Fan cooled UV IR glass Precision glass reflector with dichroic cold mirror coating 1200W lamp source Specific Features VL3000 and VL3000Q Spot Luminaires 13 element 6 1 zoom optics system with 10 to 60 range Variable beam focus to morph between gobo wheels Two six position gobo wheels with five rotatable indexable gobo positions and one open position Five position gobo wheel with four rotatable indexable positions and one open position VL3000Q only 50 audible reduction in noise output from the VL3000 luminaires VL3000 and VL3000Q Wash Luminaires Zoomable beam spreader mechanism VL3000Q only 50 audible reduction in noise output from the VL3000 luminaires Technical Specifications For technical specifications refer to VL3000 Series Luminaire User s Manuals VL3000 02 9678 0001 and VL3000Q 02 9678 0005 02 9678 0010 G COMPONENTS EXTERNAL LUMINAIRE COMPONENTS 1 Components External Luminaire Components The following illustration shows the external luminaire components and controls 2 AC Input Cable Inp
20. 15 41 6030 7018 1 EA GOBO ASSY SHOCK BREAKUP POS 2 3 16 41 6030 7029 1 EA GOBO ASSY ALPHA RAYS POS 1 2 17 41 6030 8003 1 EA ASSY 3 FACET PRISM POS 3 2 18 41 6030 8503 1 EA GAG ASSY GLACIER POS 1 6 19 41 6030 8506 1 EA ASSY DROPLETS POS 2 6 20 41 6030 8509 1 EA GAG ASSY ICE BLOCKS POS 2 5 21 41 6030 8801 1 EA GOBO ASSY MULTI COLOR CIRCLES POS 3 3 22 71 2557 1200 EA LAMP 1200 WATT SHORT ARC DOUBLE ENDED 02 9678 0010 ASSEMBLY INCLUDED ITEMS KIT SPOT 3 Included Items Kit Spot continued 1 5 6 16 9 11 Alpha Rays Night Sky Tribal Break Up 10 15 8 ir Ay SSN AN SALS 4 44 SY Palm Leaves Shock Break Up Uneven Bars Ice Blocks Gag Droplets Gag 17 12 14 21 v S AN gt gt lt gt 2x S x vad 3 Facet Prism Circle of Ovals Triangle Break Up Multi Colored Gobo Figure 3 13 Included Items Kit Spot Note Do not handle lamp with bare hands When handling it is best to wear clean cotton gloves in order to keep the lamp s glass as dirt and grease free as possible 02 9678 0010 G 71 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Included Items Kit Wash 28 9678 0002 Rev F Refer to Figure 3 14 No Item Qty UM Description 1 02 8001
21. 2 070 670 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 other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or organizations V
22. No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 46 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 63 LVS Chassis Ground Cable Assembly 164 02 9678 0010 G CABLE ASSEMBLIES CHASSIS YOKE GROUND CABLE ASSEMBLY 3 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Refer to Figure 3 64 No Item Qty UM Description 1 52 8250 0006 2 TERM 8 RING 10AWG 2 73 7089 0504 15 17 FT WIRE 22 AWG 300V 200C TEF GRN YEL UL1180 1 62 2 7 x 26 0 LG Figure 3 64 Chassis Yoke Ground Cable Assembly 02 9678 0010 G 165 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Head to Back Cap Ground Cable Assembly 25 9661 1522 Rev B Refer to Figure 3 65 No Item Qty UM Description 1 52 8311 0003 2 EA TERM RING 6 14 16 AWG NON INS 2 73 7130 0001 1 33 FT WIRE 7 64 TUBULAR BRAID TINNED COPPER 1 x2 2 Figure 3 65 Head to Back Ground Cable Assembly 166 02 9678 0010 G CABLE ASSEMBLIES RELAY TO IGNITOR CABLE ASSEMBLY 3 Relay to Ignitor Cable Assembly 25 9661 1526 Rev C Refer to Figure 3 66 No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG changed 03 23 06 2 52 8312 0001 1 EA FASTON 1 4 18 1
23. Spot 28 9678 0001 Rev Continued page 59 Continued page 60 Figure 3 1 VL3000 Spot Luminaire Drawing Tree Part 1 58 02 9678 0010 G DRAWING TREES VL3000 SPOT LUMINAIRE 3 VL3000 Spot Luminaire continued Continued from page 56 Continued from page 58 Transfer Fan Assembly 21 9678 0678 01 Rev D Spot Head Cover Assembly 21 9678 8611 Rev 0 Spot Optic Assembly 22 9678 0103 Rev S Spot Only Group 4 Lens Mount Assembly 22 9678 0199 Rev 0 Right Edge Bearing Assembly 22 9678 1103 Rev C Left Edge Bearing Assembly 22 9678 1105 Rev C Zoom Cam Assembly 22 9678 1106 Rev B Zoom Motor Tensioning Assembly 22 9678 1113 Rev B Interconnect Light Shield Assembly 22 9678 1115 Rev C Figure 3 2 02 9678 0010 G Color Dimmer Strobe Assembly 22 9678 0402 Rev N VL3000 Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly 22 9678 0403 Rev F Left Strobe Blade Assembly 22 9678 0468 Rev C Right Strobe Blade Assembly 22 9678 0467 Rev C Dimmer Wheel Assembly 22 9678 0435 Rev D Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Color Sense PCB 2 Mount Assembly 22 9678 0489 Rev B Color Interconnect PCB Cable Assembly 25 9678 1409 Rev 0 VL3000 Only Yoke Assembly 21 9678 0700 Rev J VL3000 Tilt Motor Assembly 21 9678 0765 Yoke Fan Assembly 22 9661 0609 Rev C VL3000 Relay to Ignitor Cabl
24. and its tab covers 5096 of travel Pan and tilt encoders are best read with a scope to read the encoder ticks 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 9678 0010G Troubleshooting 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 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 16 for a list of possible causes and remedies associated with the error messages To access error messages Step 1 Press Menu TROUBLESHOOTING ERROR MESSAGES 2 Step 2 Press Up Down arrows until Fixture appears Press Enter Step 3 Press Up Down arrows to access Status Press Enter Display will no
25. 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 Lasl mparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e inflamaci n alos 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 Useun equipo de seguridad apropiado guantes protecci n para los ojos etc cuando trabaje con l mparas da adas 6 Si toca 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 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 DE 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 E
26. x2 04 31 4 Figure 3 15 VL3000 and VL3000O Spot Luminaire Only used with 22 9678 0705 Yoke Structure Rev D or later or 22 9686 0705 For prior versions of Yoke Structure use Center of Travel Flag part number 10 9678 0755 02 9678 0010 G 75 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 and VL3000Q Wash Luminaire 20 9678 0002 Rev R VL3000 Wash 20 9678 0004 Rev F VL3000Q Wash Refer to Figure 3 16 No Item Qty UM Description 02 8405 0001 1 EA AC DANGER TAG VL3000 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 9678 0041 01 1 EA LABEL AC INPUT RATING VL3000 not shown 04 9678 0061 1 LABEL AC INPUT VL3000Q not shown 10 9686 0617 EA YOKE CROSSMEMBER HEAT SHIELD changed 02 27 07 2 10 9678 0670 1 EA INTERCONNECT MOUNT CYM 3 10 9678 0732 2 EA COVER YOKE THERMOFORM 4 21 9678 0010 01 1 LUMINAIRE 3000 Only 21 9678 0011 01 EA ASSY GENERIC LUMINAIRE VL3000Q Only 5 21 9678 8611 2 EA ASSY HEAD COVER 6 21 9678 8640 02 1 EA ASSY WASH HOT BOX 21 9678 8698 02 1 EA ASSY HOT BOX VL3000Q WASH 7 21 9678 0660 01 1 EA ASSY FAN TRAY DUCT changed 03 01 05 21 9678 0659 01 1 EA ASSY FAN TRAY D
27. 0007 6 EA SCREW 6 32 X 1 4 PPZ SEMS 17 53 6559 0001 4 EA SCREW 4 40 X 1 4 PFZ 18 53 6609 0001 6 EA SCREW 6 32 X 3 8 PFZ 19 53 6613 0001 1 EA SCREW 6 32 X 1 2 PPZ 20 53 6614 0003 2 EA SCREW 6 32 X 5 8 PFZ 21 53 6616 0001 2 EA SCREW 6 32 X 3 4 PPZ 55 6538 0001 2 EA WASHER 4 LOCK EXTERNAL TOOTH 22 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS 23 55 2125 0003 4 EA STANDOFF 3 8 HEX 8 32 1 500 L 24 55 6538 0004 y EA WASHER 750 OD 312 ID 125 FLAT TEFLON 25 55 6541 0008 1 EA GROMMET 1 2 ID 7 8 OD 3 4 GRV 26 55 6706 0001 4 EA GROMMET 9 32 ID 9 16 OD 1 4 27 74 1099 0001 1 EA SWITCH MINIATURE 5 150DEG C NORM OPEN 02 9678 0010 G 83 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL No Item Qty UM Description 28 53 6613 0004 3 EA SCREW 6 32 X 1 2 SCZ added 07 18 03 29 10 9678 1645 1 FAN SHIELD LAMP COOLING added 12 09 04 30 25 9678 0691 1 EA CABLE ASSY AIR OT SWITCH cable not shown 25 9678 0690 1 EA CABLE ASSY AIR DUCT OT SWITCH VL3000 QUIET cable not shown 31 10 9678 0680 1 EA INSULATOR TEFLON TO 220 32 53 2200 0004 1 EA NUT 4 40 KEPS 23 x4 gt T Detail 2 202 26 E 10 V lt 12 x2 N Fan 4 Assembly Fan Shield N Shield Orientation Shield must mimic and cover fan hou
28. 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 75 Ignitor to Lamp Socket Cable Assembly 176 02 9678 0010 G CABLE ASSEMBLIES HEAD CONTROLLER CABLE ASSEMBLY 3 Head Controller Cable Assembly 25 9678 0715 Rev C Refer to Figure 3 76 No Item Qty UM Description 1 52 6224 1014 2 EA COVER FRONT 14 POS MT LATCHING 2 52 6224 1040 2 EA COVER FRONT 40 POS MT LATCHING 3 52 6224 1050 2 EA COVER FRONT 50 POS MT LATCHING 4 52 6224 2014 2 EA COVER BACK 14 POS MT 5 52 6224 2040 2 COVER BACK 40 POS MT 6 52 6224 2050 2 EA COVER BACK 50 POS MT 7 52 6610 0014 2 EA CONN HOUSING 14 POS 26 22 AWG DBL ROW UNLOADED changed 05 01 06 8 52 6610 0017 2 EA CONN HOUSING 50 POS 26 22 AWG DBL ROW UNLOADED changed 05 01 06 9 52 6610 0040 2 EA CONN HOUSING 40 POS 26 22 AWG DBL ROW UNLOADED changed 05 01 06 10 52 8351 0004 180 EA CONTACT 26 22 AWG RECP MTE REEL added 05 01 06 11 55 2186 0001 11 EA CABLE TIE 0 10 WD 4 00 LG SMALL 12 55 6699 0004 1 75 FT SLEEVING 3 4 NOM DIA POLY EXP BRAIDED 13 73 3026 0009 1 83 FT WIRE 26 AWG 300V 80C lt WHT gt 14 73 5116 0123 35 17 FT WIRE 24 AWG 4COND TW 300V 800 lt BLK BRN RED ORG gt UL1061 15 73 5126 0002 6 00 FT WIRE 26 AWG 2 COND TWIST
29. 26 VL3000 Ballast Assembly Replacement See next page for instructions on the new Style ballast 02 9678 0010 G 47 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Repair Replacement Procedure New Style Ballast Step Step Step Step 1 Using console internal menus run lens as far to the as possible 2 Disconnect luminaire AC input cable from power source 3 4 In each corner from top remove four 6 32x3 8 PPZ screws At each top enclosure cover remove two 6 32 1 4 PPB screws and remove cover A Be careful not to damage lens during next step Step 5 Carefully lay luminaire its side ensuring that lens does not come into contact with any Step Step Step Step Step Step Step Step Step 48 surface At bottom of enclosure remove four 1 4 20x1 2 socket screws and 1 4 split lock washers and remove ventilation cover as shown in Figure 2 26 on page 47 Remove both handles by removing two 10 32x5 8 PPB screws at each 8 At enclosure bottom remove four 6 32x1 4 PPB screws and both side covers 10 11 12 13 14 At enclosure bottom remove two 6 32x3 8 PPB screws APS side bracket and front cover from ballast side At ballast disconnect the following cable assemblies a Lamp wires b AC input c Control wiring Pull lamp wires through ferrite core At bottom of enclosure remove three 8 32 3 8 PFZ screws and four 8 3
30. 26 55 6528 0001 2 EA WASHER 6 FLAT ZINC 27 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 188 LG STL changed 5 27 03 28 55 6677 0033 4 EA WASHER 281 OD 125 ID 032 THK FLAT SS 29 53 6558 0007 2 EA SCREW 6 32 X 1 4 LG PPZ SEMS EXT ZINC PLT added 7 07 03 5 55 6699 0003 83 FT SLEEVING 1 2 NOM DIA POLY not shown 55 6699 0004 1 16 FT SLEEVING 3 4 NOM DIA POLY not shown 02 9678 0010 G 7T VARI LITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 and VL3000Q Wash Luminaire continued 18 x2 xe 28 4 Figure 3 16 VL3000 VL3000Q Wash Luminaire 78 02 9678 0010G ASSEMBLY GENERIC LUMINAIRE ASSEMBLIES 3 Generic Luminaire Assemblies 21 9678 0010 01 Rev H VL3000 21 9678 0011 01 Rev C VL3000Q Refer to Figure 3 17 No Item Qty UM Description 1 21 9678 0600 1 EA ASSY HEAD STRUCTURE 21 9678 0601 1 EA ASSY HEAD STRUCTURE VL3000 QUIET 2 21 9678 0700 1 EA ASSY YOKE 21 9678 0701 1 EA ASSY YOKE VL3000 QUIET 3 21 9678 0707 1 EA ASSY TILT 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 POP 126 187GL 4 21 9678 0767 1 EA ASSY STABILIZER 4a 10 9678 0757 1 EA STABILIZER 1 377DIA 4b 10
31. 9678 0403 VL Part No 22 9678 0453 Q Version Repair Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 26 Disconnect luminaire AC input cable from power source Remove top head cover by loosening four 1 4 turn captive stud connectors Remove Color Dimmer Strobe Assembly See Color Dimmer Strobe Assembly on page 25 Disconnect wiring from strobe motors Cut wire tie holding wiring harness to strobe assembly Remove four 6 32 KEPS nuts and lift strobe assembly straight up Replace assembly by performing steps 2 through 6 in reverse order Figure 2 8 VL3000 Color Dimmer Strobe Assembly Replacement 02 9678 0010 G MAINTENANCE PROCEDURES MAIN CONTROL BOARD MCB REPLACEMENT 2 Main Control Board MCB PCB Replacement VL Part No 24 9678 3730 Repair Replacement 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 32x3 8 PTB screws CAUTION Always use anti static precautions when working with PCBs Step 3 Disconnect wiring harness connectors J8 19 J10 and J11 Step 4 Remove four 4 6 32 screws securing MCB PCB
32. 9678 0677 1 EA CABLE ASSY FRONT HEAD FANS not shown 25 9678 0715 1 EA CABLE ASSY HEAD CONTROLLER not shown 28 9678 0001 1 EA INCLUDED ITEMS KIT VL3000 SPOT not shown 19 53 2001 0003 4 EA NUT 10 32 NYLON INSERT 20 53 2002 0003 4 EA NUT 6 32 HEX ZINC NYLON IN 21 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB 22 53 6558 0009 8 EA SCREW 6 32 X 3 8 LG PPZ SEMS 23 53 6558 0016 2 SCREW 6 32 X 3 4 PPS SEMS 24 53 6579 0001 4 EA SCREW 10 32 X 1 2 SCB 25 53 6613 0001 2 SCREW 6 32 X 1 2 PPZ 26 53 6614 0003 4 EA SCREW 6 32 X 5 8 PFZ 27 55 2284 0001 2 EA CARD GUIDE 3 LONG SNAP IN 28 55 6506 0024 2 EA SPACER 3 16 RND 1875 LG 0 141 THRU SS 29 55 6528 0001 2 EA WASHER 6 FLAT ZINC 30 55 6573 0001 2 EA HARDENED SHAFT 10MM DIA X 200MM HARDENED 31 55 6616 0001 4 EA STANDOFF 3 8 HEX 6 32 THRD 32 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 188 LG STL changed 05 27 03 33 55 6677 0033 4 EA WASHER 201 OD 125 ID 032 THK FLAT SS 34 53 6558 0007 4 EA SCREW 6 32 X 1 4 LG PPZ SEMS EXT ZINC PLT added 07 07 03 55 6699 0003 830 FT SLEEVING 1 2 NOM DIA POLY not shown 55 6699 0004 1 16 FT SLEEVING 3 4 NOM DIA POLY not shown 35 53 2202 0008 1 EA NUT 8 32 HEX SS NYLON INSERT added 05 24 04 74 02 9678 0010 G ASSEMBLY VL3000 AND VL3000Q 5201 LUMINAIRE 3 VL3000 Spot Luminaire continued 22 x2 33 x2 21 x8 32
33. BORE 3 10 9678 0221 1 EA PLATE ROTATING EFFECTS WHEEL 4 10 9678 0224 4 EA RETAINING RING PLANET 5 22 9678 0230 4 EA ASSY PLANET GEAR 5a 10 9678 0263 2 EA CLIP WIRE PLANET 5b 10 9678 0282 PLANET GEAR HOBBED CASTING 6 22 9678 0233 SUN GEAR MOLDED ELASTOMERIC INTEGRAL BEARING 7 22 9678 0234 EA ASSY PULLEY GOBO WHEEL HUB 10 9678 0227 1 EA PULLEY GOBO WHEEL 7b 54 1259 0001 2 EA BEARING RAD FLANGED 25 ID 625 0D 8 53 6650 0001 3 EA SCREW 2 56 5 16 9 55 2256 0001 1 MAGNET 2 17 SMCO 2 X 2MM X 3MM 10 10 9678 0250 EA MAGNET TAPE 375 W x 625 L x 0035 THICK changed 07 15 03 8 x3 6 Detail 5 4 Detail 7 Detail B 5a x2 Figure 3 8 Rotating Effects Wheel Assembly 90 02 9678 0010G HEAD ASSEMBLY LONG SHAFT MOTOR ASSEMBLY 3 Long Shaft Motor Assembly 21 9678 0243 Rev 0 Refer to Figure 3 9 No Item Qty UM Description 1 10 9678 0330 1 EA PLATE MOTOR ADAPTER 2 44 9678 0249 1 EA MOTOR STEPPER 42MM X 34MM 60MM SHAFT 3 53 6513 0002 4 EA SCREW 3MM X 5 LG PFZ METRIC Note orientation of motor plate adapter when mounting Figure 3 9 Long Shaft Motor Assembly 02 9678 0010 G 91 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Iris Assembly 21 9678 0270 Rev A Refer to Figure 3 10
34. I O Link Cable Assembly 25 9678 0813 Rev A Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Display Cable Assembly 25 9678 1825 LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Figure 3 9 VL3000 Wash Luminaire Drawing Tree Part 3 66 02 9678 0010 G DRAWING TREES VL3000Q WASH LUMINAIRE 3 VL3000Q Wash Luminaire Beam Spreader Assembly 21 9678 0910 Rev A Wash Onl Stationary Concave Lens Assembly 21 9678 0920 Rev A Wash Only Translating Convex Lens Assembly 21 9678 0930 Rev B Wash Only Condenser Lens Assembly 21 9678 0940 Rev C Wash Onl Hot Box Assembly 21 9678 8698 02 Rev F 30000 Wash Head to Back Ground Cable Assembly 25 9661 1522 Rev B Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Gobo Color Fan Assembly VL3000Q Only 21 9678 0659 01 Rev D Head Front Fan Assembly VL3000Q Only 23 9678 0699 Rev Continued on page 68 Figure 3 10 02 9678 0010 G VL3000Q Wash Luminaire 20 9678 0004 Rev F VL3000Q Wash eneric Luminaire Assemblies 21 9678 0011 01 Rev C VL3000Q Head Structure Assembly 21 9678 0601 Rev A VL3000Q Backend Assembly 21 9678 0616 Rev H VL3000Q 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0617 Rev A VL3000Q Yoke to AC Fan Cable Assembly 25 9678 0012 Rev A p Fan Interlok Cable Assembly 25 9678 0014 Rev B Air Duct OT Switch Cable Assembly 25 9678 0690 Rev 0 VL3000Q
35. Refer to Figure 3 22 No Item Qty UM Description l 10 9678 1107 1 EA ZOOM TIMING 2 10 9678 1108 1 EA PULLEY FLANGE 3 10 9678 1118 1 EA TIMING PULLEY ZOOM 4 53 6613 0008 2 EA SCREW 6 32 X 1 2 PPZ changed 11 08 04 5 54 1259 0004 2 EA BEARING RADIAL FLANGED 25 ID 625 OD changed 06 25 03 6 55 6763 0500 2 EA PIN DOWEL 5 LG 125 DIA 303SS Figure 3 22 Zoom Cam Assembly 110 02 9678 0010G HEAD ASSEMBLY ZOOM MOTOR TENSIONING ASSEMBLY 3 Zoom Motor Tensioning Assembly 22 9678 1113 Rev B Refer to Figure 3 23 No Item Qty UM Description 1 10 9678 0338 1 EA PULLEY ZOOM MOTOR changed 03 07 06 2 10 9678 1111 1 EA BRACKET ZOOM TENSION SHEETMETAL 3 44 9663 1326 1 EA MOTOR 17 53 SHAFT 11 8MH 5 5 OHM 4 53 5559 0250 2 EA SCREW 6 32 X 1 4 SET POINT 5 53 6522 0001 2 EA SCREW 6 32X 1 4 PPZ 6 55 3303 0006 2 EA WASHER 6 LOCK INT TOOTH SS 5 x2 6 x2 Pulley Installation Set pulley height from bracket as indicated 4 x2 Figure 3 23 Zoom Motor Tensioning Assembly 02 9678 0010 G 111 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Interconnect Light Shield Assembly 22 9678 1115 Rev C Refer to Figure 3 24 No Item Qty UM Description 1 10 9678 1114 1 EA SHIELD INTERCONNECT MOUNT LIGHT 2 24 9678 3116 1 EA ASSY ZOO
36. Spot Luminaire Spot Gobo Assembly 21 9678 0200 Rev K Spot Onl Rotating Gobo Wheel Assembly 21 9678 0210 Rev B Rotating Effects Wheel Assembly 21 9678 0211 Rev B Long Shaft Motor Assembly 21 9678 0243 Rev 0 Iris Assembly 21 9678 0270 Rev A Hot Box Assembly 21 9678 8698 01 Rev F VL3000Q Spot Head to Back Cap Ground Cable Assembly 25 9661 1522 Rev B Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Assembly VL3000Q Only 21 9678 0659 01 Rev D Head Front Fan Assembly VL3000Q Only 23 9678 0699 Rev A Continued on page 62 VL3000Q Spot Luminaire 20 9678 0003 Rev G VL3000Q Spot eneric Luminaire Assemblies 21 9678 0011 01 Rev C VL3000Q Head Structure Assembly 21 9678 0601 Rev A VL3000Q Backend Assembly 21 9678 0616 Rev H VL3000Q 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0617 Rev A VL3000Q Yoke to AC Fan Cable Assembly 25 9678 0012 Rev A Backcap Interlok to Gobo Fan Interlok Cable Assembly 25 9678 0014 Rev B Air Duct OT Switch Cable Assembly 25 9678 0690 Rev 0 VL3000Q Yoke Assembly 21 9678 0701 Rev B VL3000Q Continued on page 62 Upper Enclosure Assembl 21 9678 0801 01 Rev Z VL3000Q Continued on page 63 Rod Clamp Assembly 22 9678 0149 Rev B Gobo Clamp Assembly 22 9678 0693 Rev A Color Clamp Assembly 22 9678 0694 Rev A Edge Lead Screw Assembly 22 9678 1126 Rev B VL3000 Controller PCB 24 9
37. WD 3 750 LG TEF 73 2326 0123 17 34 FT WIRE 26AWG 4COND 300 200 7323267001 2 01 FT WIRE 26AWG 7COND 300 2006 TE 73 2326 5001 1 3 FT WIRE 26AWG 5COND 300V 2006 TE 73 2326 3003 1 04 FT WIRE 26AWG 3COND 300V 200C TEF Figure 3 77 Color Interconnect PCB Cable Assembly VL3000 Only 02 9678 0010 G 179 VARFKLITEG VL3000 amp VL3000 Q SERVICE MANUAL 180 Color Interconnect PCB Cable Assembly continued 5 E lt ans See oa Sale 5 ee 25254 Figure 3 78 Color Interconnect Assembly Wire Chart VL3000 Only 02 9678 0010 G CABLE ASSEMBLIES COLOR INTERCONNECT QUIET PCB CABLE ASSEMBLY 3 Color Interconnect Quiet PCB Cable Assembly 25 9678 1419 Rev A VL3000Q Only Refer to Figure 3 79 and Figure 3 80 No Item Qty UM Description 1 24 9678 1419 1 EA ASSY COLOR INTERCONNECT 2 28 9678 1419 1 EA WIRE KIT COLOR INTERCONNECT 04 9678 0409 00 1 EA LABEL SET C
38. XLR MALE MT VERTICAL 12 5 62 3039 0102 1 1000P 250V 20 CDE 1 2 OS 4 Figure 3 57 DMX Input PCB 02 9678 0010 G 157 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Refer to Figure 3 58 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 250 TWIST LOCK MALE 3 WIRE 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL 4 52 8298 1160 2 EA FERRULE WIRE 1 16 AWG L2 8MM BLACK 5 55 2268 0187 0 92 FT HEATSHRINK 3 16 CLEAR KYNAR UL 600V 150DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR UL 600V 150DEG C 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60C EURO BLK HD 22 11MM OD 4 x2 2 Figure 3 58 AC Input Pigtail Cable Assembly 158 02 9678 0010G ENCLOSURE ASSEMBLY PULLEY ASSEMBLY 3 Pan Pulley Assembly 21 9678 0807 Rev E Refer to Figure 3 59 No Item Qty UM Description 1 10 9678 0750 1 EA TIMING PULLEY 2MM GT 150 TOOTH 2 10 9678 0855 1 EA PAN FLAG 3 53 6530 0009 2 EA RIVET 1 8 OD POP 0 126 0 187GL changed 10 05 06 3 x2 2 02 9678 0010 G Figure 3 59 Pan Pulley Assembly 159 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Pan Motor Assembly 21 9678 0864 Rev E Refer to Fig
39. at each gear as they pass Adjust as necessary and recheck There should be no drag in the movement 02 9678 0010 G MAINTENANCE PROCEDURES GOBO GEAR PLANET ALIGNMENT Gobo Gear Planet Alignment continued 1 Start with center gear timing 2 Rotate center gear clockwise until timing mark mark facing Position 1 open is directly across from Position 6 Rotate Position 6 gear until timing marks align Alignment Mark Align both marks 3 Align remaining gobo gears 4 Verify alignment of all marks using the same method and adjust as necessary Figure 2 18 Aligning Gobo Planet Gears 02 9678 0010 G 39 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Spot Optic Assembly Replacement VL Part No 22 9678 0103 Repair Replacement Procedure To remove spot optics assembly Step Step Step Step Step 1 2 pna ee Disconnect luminaire AC input cable from power source Remove both top and bottom head covers by loosening four quarter turn captive locking screws Disconnect wiring for transfer fan and color gobo fans as well as head cable from zoom interconnect PCB Remove Gobo Assembly See Gobo Assembly Replacement on page 35 Remove one 8 32 Hex Nut from Actuator shaft A CAUTION Lens will move freely Be careful not to drop or damage lens Step Step Step Step 9 Loosen 8 captive 6 32 screws from the four mounting clamps two per clamp 6 T 8 Free Actua
40. containing DMX Input PCB and Menu Display AC Input Cable Requires standard AC power distribution from 200 264 VAC 50 60 Hz 7 to 12 A Enclosure Bottom Ne depending on the AC supply voltage Ventilation Cover Wire Connection Green Yellow AC Ground Blue AC Neutral Brown AC Line International Harmonized Standard 8 02 9678 0010 G PRINCIPLES OF OPERATION VL3000 AND VL3000Q SPOT LUMINAIRE 1 Principles of Operation VL3000 and VL3000Q Spot Luminaire Functional Block Diagram Lx 02 9678 0010 G 9 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 and VL3000Q Wash Luminaire Functional Block Diagram l 4 S 4 la 10 02 9678 0010 G 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Troubleshooting Maintenance Procedures 3J2IAMN3AS 02 9678 0010 G 11 VARFKLITEG VL3000 amp VL3000 Q 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 VL3000 User s Manual for your luminaire 02 9678 0001 or 02 9678 0005 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence Phase 1 Strobe Phase 2 e Ti
41. cover by removing four 6 32x3 8 PTB screws Step 3 Attilt motor assembly loosen four 10 32x1 2 PPZ screws Step 4 Remove belt from tilt pulley Step 5 Remove four 10 32x1 2 PPZ screws Be mindful of tensioning springs Step 6 Disconnect wiring and remove tilt assembly Step 7 On tilt assembly remove two 4 40 1 4 LG PPZ screws and remove encoder 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 and wiring is not pinched during installation When tightening four 10 32x1 2 PPZ 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 clarity Tilt Motor Assembly Detail Tilt Encoder Tilt Motor MEN Assembly WAR N Tilt Belt B Spring Sensor Bracket Figure 2 24 VL3000 Tilt Encoder PCB Replacement 44 02 9678 0010 G MAINTENANCE PROCEDURES SENSOR REPLACEMENT Tilt EOT Sensor Replacement VL Part No 23 9661 1253 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Attilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws Step 3 Atsensor bracket remove two 10 32x1 2 PPZ screws and remove bracket Step 4 Disconnect wiring from Tilt Encoder PCB Step 5 Atsensor remove two 6 32x3 8 PPZ s
42. magnet on dimmer wheel assembly as shown Step Apply two fillet beads of NUVASIL RTV on long edges of magnet to secure in place Step Allow to cure in for at least 24 hours at room temperature For best results run through a UV curing oven twice Figure 3 34 Dimmer Wheel Assembly 02 9678 0010 G 125 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Assembly 22 9678 0693 Rev Refer to Figure 3 35 Qty UM Description 1 12 9678 0691 1 2 53 6685 0625 2 EA SCREW PANEL 6 32 X 0 625 LG PPS ZINC PLATED 3 55 6538 0001 2 EA WASHER 6 LOCK INTERNAL TOOTH 4 53 6613 1126 1 EA SCREW 6 32 X 1 125 LG PPZ 1 2 x2 Figure 3 35 Gobo Clamp Assembly 126 02 9678 0010 G HEAD ASSEMBLY COLOR CLAMP ASSEMBLY 3 Color Clamp Assembly 22 9678 0694 Rev A Refer to Figure 3 36 No Item Qty UM Description 1 12 9678 0692 1 EA COLOR CLAMP 2 53 6685 0625 EA SCREW PANEL 6 32 X 625 LG PPS ZINC PLATED 3 55 6538 0001 2 EA WASHER 6 LOCK INTERNAL TOOTH 4 53 6613 1126 1 EA SCREW 6 32 X 1 125 LG PPZ 2 x2 Figure 3 36 Color Clamp Assembly 02 9678 0010 G 127 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Edge Lead Screw Assembly 22 9678 1126 Rev B Refer to Figure 3 37 No Item Qty
43. mark with hole in wheel Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor as shown Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange 02 9678 0010 MAINTENANCE PROCEDURES 6080 TIMING ADJUSTMENTS Gobo Timing Adjustments continued 1 Position index pulley so large flange is centered in optical sensor 2 Insert a 3 long 4 or M3 screw or 0 125 diameter pin completely through aligned holes in wheels and both bulkheads as shown This will lock the wheels in the open position 3 Adjust individual wheels as follows Wheel 3 First align planet gear timing mark with hole in wheel Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange Gobo Wheel 3 forward Figure 2 17 Gobo Timing Adjustments 02 9678 0010 G Wheel 2 First align outside planet gear timing mark with mark in sun gear Notch in wheel should be centered between opposite planet gear teeth Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between t
44. remove four 10 32x1 2 SCB Allen head screws using 5 32 Allen Wrench 8 Lift Beam Spreader assembly up through fixture Replace by performing steps 2 through 8 in reverse order Transfer Fan Assembly Top Head Cover Beam Spreader Figure 2 6 VL3000 Wash Beam Spreader Assembly Replacement 02 9678 0010 G MAINTENANCE PROCEDURES COLOR DIMMER STROBE ASSEMBLY 2 Color Dimmer Strobe Assembly VL Part No 22 9678 0402 VL Part No 22 9678 0462 Q Version Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove top head cover by loosening four 1 4 turn captive stud connectors Note The top cover is easily identified as follows maneuver head so the printing on the label on the rear of the head assembly is oriented correctly Step 3 Disconnect wiring harness from interconnect PCB Step 4 Remove interconnect by pushing top of PCB off studs Step 5 Loosen four captive screws two per clamp Note Do NOT remove long phillips head Screw it serves as a handle Step 6 Pull assembly straight up and out of luminaire Step 7 Replace assembly by performing steps 2 through 6 in reverse order Top Head Cover Color Dimmer Strobe Assembly Clamp TEM A Figure 2 7 VL3000 Color Dimmer Strobe Assembly Replacement 02 9678 0010 G 25 VL3000 VL3000 Q SERVICE MANUAL Strobe Assembly Replacement VL Part No 22
45. 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 9678 0010 G 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 ATTENTION symbole annonce que l appareil risque d tre endommag A AVERTISSEMENT Ce symbole annonce qu il a risque d accident grave fatal CETTE SECTION CONTIENT DES INFORMATIONS G N RALES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES LES INCENDIES L EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRA NER DES BLESSURES AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES INCENDIES 1 Les luminaires VAREKLITEQ ont t con us pour tre utilis s uniquement avec certaines type de lampes V rifier le type de lampe Osram HMI 1200 W S metal halide lamp avant de remplacer les lampes L installati
46. 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8052 0001 1 EA CARD LIMITED WARRANTY 3 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 4 02 9678 0002 1 EA UNPACK QUICK START SHEET VL3000 gt 04 4037 0001 5 LABEL 2 5 X 5 BARCODE not shown 07 9678 0036 1 EA CARDBOARD SHIPPING BOX VL3000 not shown 5 08 3000 0001 1 EA CD ROM VL3000 PRODUCT DOCUMENTATION USER 6 22 9661 1636 EA FAB ASSY BRACKET TRUSS HOOK 7 71 2557 1200 1 EA LAMP 1200 WATT SHORT ARC DOUBLE ENDED 1 3 y Figure 3 14 Included Items Kit Wash Note Do not handle lamp with bare hands When handling it is best to wear clean cotton gloves in order to keep the lamp s glass as dirt and grease free as possible 72 02 9678 0010G ASSEMBLY 3000 AND VL3000Q SPOT LUMINAIRE 3 VL3000 VL3000Q Spot Luminaire 20 9678 0001 Rev T VL3000 Spot 20 9678 0003 Rev G VL3000Q Spot Refer to Figure 3 15 No Item Qty UM Description 02 8405 0001 1 EA AC DANGER TAG VL3000 not shown 04 9661 0033 01 EA LABEL WARNING 2000 SERIES not shown 04 9661 0039 1 EA LABEL LINE CORD WARNING not shown 04 9678 0041 01 1 EA LABEL AC INPUT RATING VL3000 not shown 04 9678 0061 1 EA LABEL AC INPUT RATING VL3000Q not shown 10 9678 0609 1 EA FRONT FILTER FOAM ZOOM not shown 1 10 9686 0617 1 EA YOK
47. 012 80MM Fan Shield Installation Spot and Wash S3K 013 VL3000Q VL3500Q Vent Cover Fan Assy Change Q Models Only S3K 014 New Style Ballast Conversion Procedure Models 02 9678 0010 G 197 VL3000 amp VL3000 Q SERVICE MANUAL Notes 198 02 9678 0010 G 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 08 May 2009 Manual Part Number 02 9678 0010 G 2003 2009 A Philips Group Company All rights reserved Printed in the U S A
48. 0481 Rev B Color Sense PCB 2 Mount Assembly 22 9678 0489 Rev B Color Interconnect PCB Cable Assembly 25 9678 1409 Rev 0 VL3000 Only Yoke Assembly 21 9678 0701 Rev B VL3000Q Tilt Motor Assembly 21 9678 0765 Yoke Fan Assembly 22 9678 0609 Rev A VL3000Q Relay to Ignitor Cable Assembly 25 9661 1526 Rev C Fan and Relay Cable Assembly 25 9678 0681 Rev C Yoke Fan Cable Assembly 25 9678 0758 Rev A VL3000Q Spot Luminaire Drawing Tree Part 2 02 9678 0010 G DRAWING TREES VL3000Q 5201 LUMINAIRE 3 VL3000Q Spot Luminaire continued Continued from page 61 Upper Enclosure Assembly 21 9678 0801 01 Rev Z VL3000Q Ventilation Cover Assembly VL3000 Quiet 21 9686 0840 02 Rev B VL3000Q Pan Pulley Assembly 21 9678 0807 Rev E Pan Motor Assembly 21 9678 0864 Rev E Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev Panel Assembly 21 9678 0805 Rev N DMX Input PCB 24 9663 3895 AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Pan Tube Assembly 21 9678 0881 Rev 0 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C AC Input Splitter Cable Assembly 25 9678 0812 Data I 0 L
49. 0660 01 Rev B Refer to Figure 3 13 No Item Qty UM Description l 10 9678 0665 EA SPRING EXTENSION ELONGATED HOOK changed 06 29 06 2 22 9678 0661 1 EA ASSY FAN TRAY 3 22 9678 0665 1 EA DUCT ASSY 4 23 9678 0684 2 EA FAN ASSY HEAD FRONT 5 53 5506 1375 6 EA SCREW 6 32 X 1 3 8 LG PPB 6 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 7 53 6530 0006 2 EA RIVET 1 8 OD POP 188 250GL 8 55 6538 0002 2 EA WASHER 6 NYLON NATURAL 9 55 6818 0002 1 EA STANDOFF 45 DEG NYLON 6 6 KUR 10 74 1099 0001 1 EA SWITCH MINIATURE 5AMP 150DEG 98 02 9678 0010 G HEAD ASSEMBLY DUAL FAN TRAY DUCT ASSEMBLY VL3000 ONLY 3 Dual Fan Tray Duct Assembly VL3000 Only continued Spring installed as shown Figure 3 13 Dual Fan Tray Duct Assembly VL3000 02 9678 0010 G 99 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Head Front Fan Assembly 23 9678 0684 Rev 0 Refer to Figure 3 14 No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52 6523 0002 1 CONN HOUSING 2 SHROUDED WIRE WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 3 x2 100 Figure 3 14 Head Front Fan Assembly 02 9678 0010 G HEAD ASSEMBLY HEAD FRONT FAN ASSEMBLY VL3000Q ONLY 3 Head Front Fan Assembly VL3000Q Only 23 9678 0699 Rev A Refer to Figure 3 14
50. 08 4 EA SCREW 6 32 X 1 2 PPZ SEMS changed 3 03 04 10 55 6616 0007 1 EA STANDOFF 3 8 HEX 8 32 0 562 LG MF SS changed 8 04 03 Curved side of lens Figure 3 41 Condenser Lens Assembly 132 02 9678 0010G HEAD ASSEMBLY BULKHEAD ASSEMBLY 3 Aperture Bulkhead Assembly 21 9678 0950 Rev B Wash Only Refer to Figure 3 42 No Item Qty UM Description 1 10 9678 0225 2 EA SHAFT WHEEL 2 10 9678 0952 1 EA WASH BULKHEAD 3 10 9678 0953 1 EA WASH APERTURE PLATE 4 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ changed 11 11 03 5 53 6613 0001 4 EA SCREW 6 32 X 1 2 PPZ 6 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 187 L 7 55 6769 0004 3 EA TWIST LOK 0 55 ID NOM WHITE 85 DEG MAX FLAME RET NYL 8 53 5638 0252 2 EA SCREW 6 32 X 1 4 UNDERCUT HD 7 2 5 X4 8 2 EN 1 2 6 x2 4 4 N 2 02 9678 0010 G Figure 3 42 Aperature Bulkhead Assembly 133 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Beam Spreader Light Baffle Assembly 21 9678 0991 Rev A Wash Only Refer to Figure 3 43 No Item Qty UM Description 1 10 9678 0658 8 EA PLATE COUNTERWEIGHT 2 10 9678 0990 1 EA LIGHT BAFFLE SPREADER 3 53 6616 0001 4 EA SCREW 6 32 X 3 4 PPZ 1 8 SN NN SN Figure 3 43 Beam Spreader Light Baffle Assembly 134 02
51. 1 4 EA CABLE TIE 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 90 DC Output Cable Assembly 02 9678 0010 G 193 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Refer to Figure 3 91 No Item Qty UM Description 1 52 6610 0008 1 EA CONN HOUSING 20 POS DBL ROW UNLOADED changed 05 03 06 2 52 6224 1020 1 EA COVER FRONT 20 POS MT LATCHING 3 52 6224 2020 1 EA COVER BACK 20 POS MT 4 52 6524 0005 2 EA CONN HOUSING 5 POS RECEPTACLE 5 52 6588 0007 2 EA HOUSING 7 POS XH 250V 3A 2 5MM PITCH USE SXH CONTACTS 6 52 7007 0001 6 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT SXH 7 52 8346 0001 10 EA CONTACT 24 30 AWG FEMALE CRIMP 8 55 2186 0001 6 EA CABLE TIE 0 10 WD 4 00 LG SMALL 9 73 5119 0246 6 08 FT WIRE 24 AWG 3COND TW 600V 200 lt RED YEL BLU gt UL1213 10 73 5124 1289 6 17 FT WIRE 24 AWG 5COND 300 806 BLK BRN RED GRY WHT 11 52 8351 0004 16 EA CONTACT 26 22 AWG RECP MTE REEL added 05 03 06 194 1 2 8 11 x16 4 7 x5 10 5 6 x3 5 6 x3 4 7 x
52. 18 47 80 Figure 3 17 VL3000 and VL3000Q Generic Luminaire Assemblies 02 9678 0010G HEAD ASSEMBLY HEAD STRUCTURE ASSEMBLY 3 Head Assembly Head Structure Assembly 21 9678 0600 Rev C VL3000 21 9678 0601 Rev A VL3000Q Refer to Figure 3 1 No Item Qty UM Description 1 10 9678 8620 1 EA FRONT CASTING 2 12 9678 8623 1 EA RIGHT SIDE RAIL MACHINED 3 12 9678 8625 1 EA LEFT SIDE RAIL MACHINED 4 21 9678 0615 1 EA ASSY BACKEND 21 9678 0616 1 EA ASSY BACKEND VL3000 QUIET 5 53 6515 0001 6 EA SCREW 10 32 X 3 4 SCB CAP 6 53 6515 1000 1 EA SCREW 10 32 X 1 SOCKET CAP BLACK 7 53 6515 1125 3 EA SCREW 10 32 X 1 25 SOCKET CAP BLACK ls S E m Figure 3 1 Head Structure Assembly 02 9678 0010 G 81 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Head Cover Assembly 21 9678 8611 Rev 0 Refer to Figure 3 2 No Item Qty UM Description 1 10 9678 0612 1 EA HEAD COVER 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 added 10 01 03 5 12 9678 8610 1 EA HEAD COVER 6 53 5655 0250 4 EA SCREW 6 X 1 4 PPZ PLASTIC 7 53 6558 0003 1 EA SCREW 6 32 X 3 8 LG PPZ PLASTIC THD ROLL 8 55 2233 0016 4 EA
53. 2 06 06 02 9678 0010G HEAD ASSEMBLY Box ASSEMBLY 3 Hot Box Assembly continued 13 x4 14 4 12 x8 15 4 17 x3 Wash Version Spot Version Figure 3 11 Hot Box Assembly 02 9678 0010 G 95 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Gobo Color Fan Assembly VL3000Q Only 21 9678 0659 01 Rev D Refer to Figure 3 13 No Item Qty UM Description 1 10 9678 0665 1 EA SPRING EXTENSION ELONGATED 2 22 9678 0661 1 EA ASSY FAN TRAY 3 22 9678 0665 1 EA DUCT 55 4 23 9678 0699 2 EA FAN ASSY HEAD FRONT 5 53 5506 1375 6 EA SCREW 6 32 X 1 3 8 LG PPB 6 53 6519 0001 2 SCREW 4 40 X 5 8 PPZ 7 53 6530 0006 2 EA RIVET 1 8 OD POP 188 250GL 8 55 2179 0003 2 EA SADDLE CABLE 75 X 75 4 WAY ADH BACK WHT 9 55 2186 0001 2 EA CABLE TIE 10 WD X 4 LG SMALL not shown 10 55 6538 0002 2 EA WASHER 6 NYLON NATURAL 11 55 6818 0002 1 EA STANDOFF 45 DEG NYLON 6 6 KUR 12 74 1099 0001 1 EA SWITCH MINIATURE 5AMP 150DEG 02 9678 0010 G HEAD ASSEMBLY GOBO COLOR ASSEMBLY VL3000Q ONLY 3 Gobo Color Fan Assembly VL3000Q Only continued Spring installed as shown Figure 3 12 Gobo Color Fan Assembly VL3000Q 02 9678 0010 G 97 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Dual Fan Tray Duct Assembly VL3000 Only 21 9678
54. 2 6 in reverse order from page 27 ENEN son k 83 2828 8 H 900089 FE n cu s EU B BA AN 210 888886 JB Jt a 3 TITIO IET iE RFA P qESOSLI Stepper Motor Drivers locations U27 U30 U32 U44 Figure 2 10 VL3000 Series Motor Drivers on Main Control Board 02 9678 0010 G MAINTENANCE PROCEDURES IGNITOR BOARD REPLACEMENT Ignitor Board Replacement VL Part No 24 9661 3126 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Attilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws CAUTION Always use anti static precautions when working with PCBs Step 3 Disconnect ignitor PCB wires by removing four screws which secure wire ring terminals to PCB and remove ignitor PCB Step 4 Remove four 6 32x3 8 LG PPZ SEMS screws and remove ignitor PCB Step 5 Replace by performing steps 2 through 4 in reverse Note Make sure and orient ignitor properly as shown in Figure 2 11 From Relay Connections E lt Ignitor Board gt 2 Bulb Lamp Connections NOTE Some components not shown for clarity Figure 2 11 VL3000 Ignitor Board Replacement 02 9678 0010 G 29 V
55. 2 9678 0010 G 183 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Gobo Interconnect PCB Cable Assembly continued lt Figure 3 82 Gobo Interconnect PCB Cable Assembly 184 02 9678 0010 G CABLE ASSEMBLIES YOKE CABLE ASSEMBLY 3 Yoke Fan Cable Assembly 25 9678 0758 Rev A Refer to Figure 3 83 No Item Qty UM Description l 52 6396 3102 l EA RECEPT 2 POS MTA100 W POL BLUE CLSD END changed 05 02 06 2 52 6423 0003 l EA HOUSING 3POS MT RECEPT 2MM CT 28 26 AWG 3 73 5126 0002 0 50 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt UL1061 19STRND 1 2 3 Figure 3 83 Yoke Fan Cable Assembly 02 9678 0010 G 185 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Yoke Fan Cable Assembly VL3000Q 25 9678 0759 Rev A Refer to Figure 3 83 No Item Qty UM Description 1 52 6396 3102 1 EA RECEPT 2 POS MTA100 W POL TAB BLUE CLSD END 2 52 6423 0003 1 EA HOUSING 3 POS MT RECEPT 2MM 28 26 AWG 3 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 4 55 2268 0125 EA HEASTRINK 1 8 CLEAR KYNAR UL 600V 1509 C 5 60 7440 2002 1 EA RESISTOR 5W 5 200 OHM WIREWOUND 6 73 5126 0002 5 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt UL1061 19STRND 6 1 6 4 Figure 3 84 Yoke Fan Cable Assembly 186 02 9678 0010G CABLE ASSEMBLIES FILTER POWER S
56. 21 9678 0700 Rev J VL3000 Upper Enclosure Assembl 21 9678 0800 01 Rev NN VL3000 Rod Clamp Assembly 22 9678 0149 Rev B Gobo Clamp Assembly 22 9678 0693 Rev A Color Clamp Assembly 22 9678 0694 Rev A Edge Lead Screw Assembly 22 9678 1126 Rev B VL3000 Controller 24 9678 3730 Rev 0 Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Front Head Fans Cable Assembly 25 9678 0677 Rev B Head Controller Cable Assembly 25 9678 0715 Rev C Included Items Kit Wash 28 9678 0002 Rev F Continued on page 65 Continued on page 66 VL3000 Wash Luminaire Drawing Tree Part 1 02 9678 0010 G 3000 Wash Luminaire continued Continued from page 64 Transfer Fan Assembly 21 9678 0678 02 Rev D Wash Head Cover Assembly 21 9678 8611 Rev 0 Beam Spreader Light Baffle Assembly 21 9678 0991 Rev A Wash Only Aperture Bulkhead Assembly 21 9678 0950 Rev B Wash Only DRAWING TREES VL3000 WASH LUMINAIRE 3 Color Dimmer Strobe Assembly 22 9678 0402 Rev N VL3000 Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly 22 9678 0403 Rev F Left Strobe Blade Assembly 22 9678 0468 Rev C Right Strobe Blade Assembly 22 9678 0467 Rev C Dimmer Wheel Assembly 22 9678 0435 Rev D Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Color Sense PCB 2 M
57. 235 3 16 WIDE POLYU KEVLAR 45 54 1262 0001 2 EA BEARING FLANGED EXTENDED 1875 BORE changed 12 15 04 46 55 2283 0001 2 EA SHIM SPACER 253 IDX 010 47 55 6503 0004 3 EA WASHER 48 FLAT ZINC changed 03 24 04 48 55 6528 0001 5 EA WASHER 46 FLAT ZINC 49 55 6578 0073 1 EA SPRING EXTSN 375 OD 50 55 6846 0001 2 EA CAM FOLLOWER 3MM DIA STUD 51 10 9678 1140 1 5 added 12 15 04 52 10 0678 1141 l EA BACKING PLATE SHOCK PAD added 12 15 04 02 9678 0010G HEAD ASSEMBLY SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly continued 36 x2 33 x2 21 38 x2 33 x2 33 x3 40 x2 49 34 48 Detail IW 41 x6 9 Detail E E Figure 3 17 Spot Optic Assembly View 1 02 9678 0010 G 105 VARI LITE VL3000 amp VL3000 Q SERVICE MANUAL Spot Optic Assembly continued Detail A A G1 2 H p i 87 A Optical Sensor Oke Detail G3 G3 30 2 G2 G2 Figure 3 18 Spot Optic Assembly View 2 31 5 Detail G1 G1 106 02 9678 0010 G HEAD ASSEMBLY G
58. 2x3 8 PPZ screws which secure ballast module to enclosure Remove ballast module Install replacement assembly by performing Steps 2 13 in reverse order NOTE Some components not shown for clarity Route Lamp to Supply Cable as shown same as original cable assembly Back of Display 1200 Watt Ballast Assembly Lamp Supply to Relay Cable Assembly gt gt Cable must be routed through Ferrite Figure 2 27 VL3000 Ballast Replacement New Style 02 9678 0010 G MAINTENANCE PROCEDURES 80MMM REPLACEMENT 2 80MM Fan Replacement VL Part No 21 9678 0619 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove top head cover by loosening four quarter turn captive locking screws Top cover is identifiable as the cover on top when back label is such that words are displayed correct side up Step 3 At 80MM fan remove three 6 32 x 1 2 SCZ Allen screws and one 6 32 x 3 8 SCB Allen screw Step 4 Disconnect wiring from 80MM fan Step 5 Replace by performing steps 2 through 4 in reverse order A Note Be sure and orient fan properly air should flow TOWARDS lamp Refer to the next page for further instructions 02 9678 0010 G 49 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL 80MM Fan Replacement continued Note Fixtures manufactured before 02 17 05 do NOT have a heat shield installed between the 80MM f
59. 3000Q Spot VL3000Q Wash Refer to Figure 3 11 No Item Qty UM Description 1 10 9678 0043 03 1 EA LABEL PLATE VL3000 BACKCAP BLACK 10 9678 0043 01 1 EA LABEL PLATE VL3000 QUIET 2 10 9678 0641 1 3 10 9686 0642 4 10 9678 0643 1 EA LAMP ADJUST STOP 5 10 9678 0645 3 EA KNOB LAMP ADJ MOLDED 6 10 9678 0646 1 EA TILT PLATE XYZ ADJUSTMENT 7 10 9678 1648 4 EA GASKET PRIMARY REFLECTOR 8 10 9678 2647 4 EA CLAMP PRIMARY REFLECTOR 9 12 9678 7155 1 EA REFLECTOR PRIMARY SMOOTH Wash Only 12 9678 7151 1 EA REFLECTOR PRI 40 LUNE DUAL CURVATURE Spot Only 25 9661 1522 1 EA CABLE ASSY HEAD TO BACKCAP GROUND Not Shown 25 9678 0789 1 EA CABLE ASSY IGNITOR TO LAMP SOCKET Not Shown 10 53 2030 0001 3 EA NUT ACORN 10 32THD 3 8 WIDE 3 16 THD DP BLK ZINC 1 53 5508 0375 2 EA SCREW 8 32 X 3 8 PPSS 12 53 6530 0013 8 EA RIVET 1 8 OD 063 125 GL CSK HD ALUM 13 53 6582 0001 4 EA SCREW 6 32 X 3 4 PFZ 14 55 2233 0003 4 EA RETAINER PUSH ON TYPE 15 55 2233 0006 4 EA STUD 1 4 TURN OPR 455L STEEL 16 55 6546 0004 3 EA WASHER TEFLON 201ID X 4380 17 55 6568 0077 7 EA SPRING CPRSN 300 OD 625 LG 035 WIRE DIA SS 18 55 6759 0003 4 EA STANDOFF PEM 6 32 X 562 LG SST 19 71 2561 0002 1 EA LAMPHOLDER SFC10 4 WITH PREFOCUS SHARX changed 1
60. 4 9663 1766 2 EA MOTOR 17 1 24 SHAFT 11 8MH 5 18 53 5560 0187 12 EA SCREW 8 32 X 187 SET CONE changed 06 21 05 19 53 6520 0375 8 EA SCREW 4 40 X 3 8 PPZ SEMS 20 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 21 53 5638 0252 8 EA SCREW 6 32 X 3 8 PFZ UNDERCUT HD 22 53 6613 0001 16 EA SCREW 6 32 X 1 2 PPZ 23 54 2057 0001 3 EA BELT TIMING MXL 080 PITCH 14 24 54 2058 0001 3 EA BELT TIMING MXL 080 PITCH 16 25 55 2150 0002 4 EA STANDOFF 1 4 6 32 1 187 L 26 55 2150 0003 4 EA STANDOFF 1 4 6 32 1 125 L 27 55 2178 0001 4 EA CABLE ANCHOR MOUNT 8 SCREW 28 53 6682 0002 6 EA SCREW 4 40 X 1 4 PPZ SEMS 29 55 6506 0025 1 EA SPACER 3 8 RND 1 8 LG 257 ID 30 55 6506 0026 1 EA SPACER 3 8 RND 31 32 LG 257 ID 02 9678 0010 G 87 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL No Item Qty UM Description 31 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ 32 55 6506 0030 1 EA SPACER 3 8 RND 3 8 LG 257 ID THRU ALUM 33 55 2110 0002 1 EA WASHER 400 OD 260 ID 010 FLAT SS added 4 29 03 34 10 9678 0457 02 2 EA SPACER RND 3 8 OD 257 ID 190 LG AL added 4 29 03 35 55 6520 0001 2 EA WASHER WAVE SPRING 265 ID 367 OD 006 added 4 29 03 36 10 9678 0457 04 1 EA SPACER RND 3 8 OD 257 ID 031 LG AL added 6 09 03 15 3 2 1909 7 35 x2 10 x2 33 X 32 27 x4 Figure 3
61. 4 AWG INSULATED VO 3 73 7101 0009 0 42 FT WIRE 14 AWG 15 150C SILICONE 41 30 STRANDING 2 1 Figure 3 66 Ignitor to Relay Cable Assembly 02 9678 0010 G 167 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Yoke to AC Fan Cable Assembly 25 9678 0012 Rev A Refer to Figure 3 67 No Item Qty UM Description 1 52 6665 0001 2 EA CONTACT 22 26AWG MALE MATE N LOK 2 2 52 6665 0002 1 EA CONN HOUSING 2 POS PLUG MATE N LOK 2 3 52 8413 0001 2 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 58 FT SLEEVING FIBERGLASS 0 208 ID 6 55 2200 0003 0 25 FT HEATSHRINK 3 16 VITON 7 73 6222 0009 3 00 FT WIRE 22AWG 600V 2006 WHT UL1199 19STRAND 8 73 6222 0010 3 00 FT WIRE 22AWG 600V 200C TFE BLK 11 1199 Le Figure 3 67 Yoke To Fan AC Fan Cable Assembly 168 02 9678 0010 G CABLE ASSEMBLIES INTERLOK GOBO INTERLOK CABLE ASSEMBLY 3 Backcap Interlok to Fan Interlok Cable Assembly 25 9678 0014 Rev B Refer to Figure 3 68 No Item Qty UM Description 1 52 8414 0001 2 EA RECEPT FASTON 187 SERIES 24 20 AWG UNINSUL 2 73 7089 0000 2 00 FT WIRE 22AWG 300V 200C BLK 111180 Figure 3 68 Backcap Interlok to Gobo Fan Interlok Cable Assembly 02 9678 0010 G 169 VARIKLITE VL3000 amp VL3000 Q SERVICE MA
62. 4 NOM DIA POLY EXP BRAIDED 6 73 6222 0009 2 17 FT WIRE 22 AWG 600V 200C WHT UL1199 19STRAND 7 73 6222 0010 2 17 FT WIRE 22 AWG 600V 200C TFE BLK 111199 1 2 Figure 3 93 LVS to Yoke AC Fan Cable Assembly 196 02 9678 0010 G APPENDIX VL3000 amp VL3000Q TECHNICAL BULLETINS A APPENDIX A Technical Bulletins VL3000 amp VL3000Q Technical Bulletins The following table identifies the current technical bulletins associated with the VL3000 series luminaires These improvements have been incorporated into this manual where applicable and are available on the Vari Lite web site at www vari lite com Please note that not all bulletins or notices are applicable to all versions of the fixtures included in this manual Refer to each bulletin and notice for specific information and application Technical Bulletin Description Model s 53 001 Tilt Sensor Wire Routing Spot and Wash S3K 002 Improving Lamp and Reflector Cooling Spot and Wash S3K 003 Cancelled Not Applicable S3K 004 Light Baffle Retrofit Spot S3K 005 Front End Filter Installation Spot S3K 006 Lanyard Safety Cable Retrofit Spot and Wash S3K 007 LVS DC Output Cable Replacement Spot and Wash S3K 008 Zoom Box Assembly Lens Group Cleaning Spot S3K 009 Choke Paper Inspection Alignment SpotandWash S3K 010 Pan Tube Bushing Installation Spot and Wash S3K 011 MCB PCB Wire Protection Strip Spot and Wash S3K
63. 5 Figure 3 91 Pan Tilt Control Cable Assembly 02 9678 0010 G CABLE ASSEMBLIES LAMP SUPPLY TO RELAY CABLE ASSEMBLY 3 Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Refer to Figure 3 92 No Item Qty UM Description l 52 8245 0001 l EA TERM RING 10 16 14 AWG REEL PIDG 2 52 8312 0001 4 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 55 2186 0001 3 EA CABLE TIE 0 10 WD 4 00 LG SMALL 5 55 6699 0003 3 19 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 6 73 3516 0504 0 58 FT WIRE 16 AWG 300V 105 DEG C PVC GRN YEL UL 1569 7 73 7089 0000 3441 FT WIRE 22 AWG BLK 300V UL1180 TEFLON 19 34 STRANDED 8 73 7089 0009 34 41 FT WIRE 22 AWG WHT 300V UL1180 TEFLON 19 34 STRANDED 9 73 7130 0005 2 08 FT WIRE TUBULAR BRAID 7 16 4 2 x2 To Relay From Lamp Supply Figure 3 92 Lamp Supply to Relay Cable Assembly 02 9678 0010 G 195 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Refer to Figure 3 93 No Item Qty UM Description 1 52 6664 0001 2 EA CONTACT 22 26AWG FEMALE MATE N LOK 2 2 52 6664 0002 1 CONN HOUSING 2 POS 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 0 10 WD 4 00 LG SMALL 5 55 6699 0002 2 08 FT SLEEVING 1
64. 57 04 3 EA SPACER COLOR WHEEL L 031 8 10 9678 0469 1 EA REAR COLOR BULKHEAD 9 10 9678 0485 5 EA PULLEY COLOR MOTOR 10 21 9678 0331 1 EA ASSY MOTOR PLATE 11 21 9678 0334 1 ASSY FIXED COLOR WHEEL 12 22 9678 0335 1 EA ASSY BEARING BLOCK FIXED WHEEL 10 9678 0323 1 EA WHEEL MOUNT 54 1259 0004 2 EA BEARING RADIAL FLANGED 0 25 ID 0 625 OD changed 6 25 03 13 22 9678 0403 1 EA ASSY STROBE 22 9678 0463 1 EA ASSY STROBE VL3000 QUIET 14 22 9678 0435 1 EA ASSY DIMMER WHEEL 15 22 9678 0472 1 ASSY CYAN WHEEL 16 22 9678 0474 1 EA ASSY YELLOW WHEEL 17 22 9678 0476 1 EA ASSY MAGENTA WHEEL 18 22 9678 0478 1 EA ASSY WHEEL 19 22 9678 0481 1 EA MOUNT ASSY COLOR SENSE PCB 1 20 10 9678 0486 1 EA FRONT COLOR BULKHEAD 21 22 9678 0489 1 EA ASSY COLOR SENSE 2 MOUNT 2 24 9678 3240 1 EA ASSY WHEEL POSITION SENSOR changed 02 14 05 25 9678 1409 1 EA PCB CABLE ASSY COLOR INTERCNT not shown 25 9678 1419 1 EA PCB CABLE ASSY COLOR INTERCNT not shown VL3000 QUIET 23 44 9678 0455 5 EA COLOR MOTOR 24 53 2202 0008 1 EA NUT 8 32 HEX SS NYLON INSERT 25 53 2200 0006 12 EA NUT 6 32 KEPS SS 114 02 9678 0010 G HEAD ASSEMBLY COLOR DIMMER STROBE ASSEMBLY 3 No Item Qty UM Description 26 53 5559 0250 12 EA SCREW 6 32 X 1 4 SET CONE PO 27 53 5638 0252 12 EA SCREW 6 32 X 1 4 LG PFS UNDERCUT HEAD 28 53 655
65. 6 Spot Gobo Assembly 88 02 9678 0010 G HEAD ASSEMBLY ROTATING WHEEL ASSEMBLY 3 Rotating Gobo Wheel Assembly 21 9678 0210 Rev B Refer to Figure 3 7 No Item Qty UM Description 1 10 9663 1211 10 SPACER TEFLON GOBO GEAR 2 10 9663 1240 5 EA BEARING GOBO WHEEL BORE 3 10 9678 0220 PLATE ROTATING GOBO WHEEL 4 10 9678 0224 5 EA RETAINING RING PLANET 5 22 9678 0230 5 EA ASSY PLANET GEAR 5a 10 9678 0263 2 EA CLIP WIRE PLANET 5b 10 9678 0282 PLANET GEAR HOBBED CASTING 6 22 9678 0233 EA SUN GEAR MOLDED ELASTOMERIC INTEGRAL BEARING 7 22 9678 0234 1 EA ASSY PULLEY GOBO WHEEL HUB 10 9678 0227 1 EA PULLEY GOBO WHEEL 7b 54 1259 0004 2 EA BEARING RAD FLANGED 25 ID 625 OD 0005 changed 6 26 03 8 53 6650 0001 3 EA SCREW 2 56 5 16 9 55 2256 0001 1 MAGNET 2 17 SMCO 2 X 2MM X 3MM 10 10 9678 0250 MAGNET TAPE 8 3 1 x10 Detail 50 5 72 p 7 5 X5 Detail Detail Figure 3 7 Rotating Gobo Wheel Assembly 02 9678 0010 G 89 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Rotating Effects Wheel Assembly 21 9678 0211 Rev B Refer to Figure 3 8 No Item Qty UM Description 1 10 9663 1211 8 EA SPACER TEFLON GOBO GEAR 2 10 9663 1240 4 EA BEARING GOBO WHEEL
66. 64 EA STROBE BLADE changed 07 29 04 2 10 9678 0432 1 EA HUB STROBE BLADE 3 10 9678 0466 1 EA STROBE BLADE DAMPER 4 53 5559 0250 2 EA SCREW 6 32 X 1 4 SET POINT 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 Black Side 6 3 5 3 Figure 3 32 Left Strobe Blade Assembly 02 9678 0010 G 123 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000Q Strobe Motor Assembly 23 9678 0499 Rev A VL3000Q Refer to Figure 3 33 No Item Qty UM Description 1 44 5035 0001 1 STEPPER MOTOR 2 PHASE PK 2 52 6524 0004 1 EA CONNECTOR HOUSING 4 POS RECEPT 3 52 8346 0001 4 EA CONTACT 24 30 AWG FEMALE CRIMP 4 55 2200 0003 0 25 FT HEAT SHRINK 3 16 VITON 1 4 4 Wiring Pin Out Heatshrink 4 Green 3 Black 2 Red B Blue 7 3 of heatshrink from this surface Figure 3 33 VL3000Q Strobe Motor Assembly 124 02 9678 0010 G HEAD ASSEMBLY DIMMER WHEEL ASSEMBLY 3 Dimmer Wheel Assembly 22 9678 0435 Rev D Refer to Figure 3 34 I os ru CR 55 2256 0001 MAGNET 2 17 SMCO 2MM X 2MM Coated Side Copper RTV Bead Dimmer Wheel Magnet Glueing Magnet to Dimmer Wheel Assembly Step Make sure surface is clean and oil free J Step Apply High Temp Copper RTV to magnet as shown x Step Place
67. 6699 0010 0 50 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 72 55 6775 0009 1 EA BUSHING SNAP 750 ID 1 MT H 73 67 4018 0001 1 EA FERRITE 26 X 28 5 X 13 CYL 74 67 4021 0002 1 EA FILTER CCI 75 68 9678 0827 1 CHOKE COMMON MODE 76 69 3177 0151 1 POWER SUPPLY 150W 24 6 3 WMTH PLT LAMBDA 77 55 6799 0001 PAN TUBE BEARING SHIM 1 375 ID 1 875 OD 0 005 not shown 78 55 6799 0002 AR EA PAN TUBE BEARING SHIM 1 375 ID 1 875 OD 0 010 THK not shown AR gt As Required 02 9678 0010 G 149 VL3000 VL3000 Q SERVICE MANUAL Upper Enclosure Assembly continued Figure 3 51 Upper Enclosure Assembly Part 1 150 02 9678 0010 G ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 Upper Enclosure Assembly continued Electronics Assembly Run Lamp Wires Through Ferrite 42 x3 37 x2 Figure 3 52 Upper Enclosure Assembly Part 2 02 9678 0010 G 151 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Upper Enclosure Assembly continued Choke and Duct Assembly Part is shown exploded for clarity Note Shims used as required to remove any slack in pan tube assembly Detail A Pan Tube Mechanism Assembly Figure 3 53 Upper Enclosure Assembly Part 3 152 02 9678 0010G ENCLOSURE ASSEMBLY VENTILATION COVER ASSEMBLY STANDARD 3 Ventilation Cover Assembly Standard 21 9678 1254 Rev 0 VL3000
68. 678 3730 Rev 0 Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Front Head Fans Cable Assembly 25 9678 0677 Rev B Head Controller Cable Assembly 25 9678 0715 Rev C Included Items Kit Spot 28 9678 0001 Rev J Figure 3 4 VL3000Q Spot Luminaire Drawing Tree Part 1 02 9678 0010 G 61 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000Q Spot Luminaire continued Continued from page 61 Continued from page 61 Transfer Fan Assembly 21 9678 0678 01 Rev D Spot Head Cover Assembly 21 9678 8611 Rev 0 Spot Optic Assembly 22 9678 0103 Rev S Spot Only Group 4 Lens Mount Assembly 22 9678 0199 Rev 0 Right Edge Bearing Assembly 22 9678 1103 Rev C Left Edge Bearing Assembly 22 9678 1105 Rev C Zoom Cam Assembly 22 9678 1106 Rev B Zoom Motor Tensioning Assembly 22 9678 1113 Rev B Interconnect Light Shield Assembly 22 9678 1115 Rev C Figure 3 5 62 Color Dimmer Strobe Assembly 22 9678 0462 Rev E VL3000Q Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly VL3000 Quiet 22 9678 0463 Rev B VL3000Q Strobe Motor Assembly 23 9678 0499 Rev A VL3000Q Left Strobe Blade Assembly 22 9678 0468 Rev C Right Strobe Blade Assembly 22 9678 0467 Rev C Dimmer Wheel Assembly 22 9678 0435 Rev D Color Sensor PCB 1 Mount Assembly 22 9678
69. 8 0001 7 SCREW 6 32 X 3 8 PPZ 29 53 6597 0001 2 SCREW 4 40 X 3 16 PPZ 30 53 6608 0003 5 SCREW 6 32 X 3 16 LG PPZ 31 54 2036 0017 1 EA BELT TIMING N 150 W 125 URETHANE KEVLAR 32 54 2059 0001 4 EA TIMING BELT MXL PITCH 150 SI KEVLAR 33 54 2060 0001 1 EA BELT TIMING MXL PITCH 165 TOOTH SI KEVLAR 34 55 2132 0011 4 EA STANDOFF 1 4 HEX 6 32 X 1 093 L SS 35 55 2132 0012 4 EA STANDOFF 1 4 HEX 6 32 X 0 75 LG SS 36 55 3303 0004 2 EA WASHER 4 LOCK INT TOOTH SS 37 55 3303 0006 6 EA WASHER 6 LOCK INT TOOTH SS 38 55 6503 0004 1 EA WASHER 48 FLAT ZINC 39 55 6528 0001 2 EA WASHER 6 FLAT ZINC 40 55 2110 0002 2 EA SPACER 0 010 LG 55 2186 0002 5 EA CABLE TIE 0 09WD 0 375 LG TEFZEL not shown 41 10 9678 0457 06 1 EA SPACER COLOR WHEEL 0 015 L 42 55 6520 0001 2 WASHER WAVE SPRING 1 4 DIA added 05 17 04 VL3000 only 02 9678 0010 G 115 VL3000 VL3000 Q SERVICE MANUAL Color Dimmer Strobe Assembly continued NL 26 x10 33 28 x5 Figure 3 26 Color Dimmer Strobe Assembly 116 02 9678 0010G HEAD ASSEMBLY MOTOR ADAPTER PLATE ASSEMBLY 3 Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Refer to Figure 3 27 No Item Qty UM Description l 10 9678 0330 EA PLATE MOTOR ADAPTER 2 44 5031 0001 1 EA MOTOR STEPPER 42MM X 40 10 3 53 6513 0002 4 EA SCRE
70. 9678 0010G ASSEMBLY YOKE ASSEMBLY 3 Yoke Assembly Yoke Assembly 21 9678 0700 Rev J VL3000 21 9678 0701 Rev B VL3000Q Refer to Figure 3 44 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 22 9678 0609 2 EA ASSY YOKE FAN VL3000 QUIET 5 22 9686 0705 1 EA ASSY YOKE STRUCTURE 6 23 9650 3327 1 EA ELEC ASSY RELAY 7 23 9661 1253 1 EA ELEC ASSY TILT EOT SENSOR 8 24 9661 3126 1 EA PCB ASSY SOLID STATE IGNITOR 25 9661 1526 2 EA CABLE ASSY IGNITOR RELAY NOT SHOWN 25 9678 0681 1 EA CABLE ASSY YOKE FAN AND RELAY NOT SHOWN 25 9678 0781 1 EA CABLE ASSY YOKE FAN AND RELAY VL3000 QUIET NOT SHOWN 25 9678 0758 1 EA CABLE ASSY YOKE FAN NOT SHOWN 25 9678 0759 1 EA CABLE ASSY YOKE FAN VL3000 QUIET 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
71. 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 9678 0800 01 1 EA ASSY UPPER ENCLOSURE 21 9678 0801 01 1 EA ASSY UPPER ENCLOSURE VL3000Q 6 53 2019 0004 4 EA NUT 3 8 16 X 7 32 HEX JAM GRDS ZINC PLT 7 53 6505 0020 5 EA 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 WASHER 3 8 SPLIT LOCK 10 53 5564 0250 1 EA SCREW 6 32 X 1 4 PEB UNDERCUT changed 04 07 06 11 53 6624 0001 4 EA SCREW 10 32 X 1 2 LG changed 12 02 03 12 53 6513 0044 3 EA SCREW 5 X 10MM 511 CUP PT changed 10 13 03 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 5214 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 SS added 7 14 03 18 55 6799 0002 2 EA SHIM 1 3 8 ID 1 7 8 OD 005 SS added 7 14 03 02 9678 0010 G 79 VL3000 VL3000 Q SERVICE MANUAL r Detail A Generic Luminaire Assemblies continued Detail Detail B 3c x3 38 4 40 A Detail C 4 Detail B
72. A AIR DIST PLENUM 1200W S W BALLAST P S 14 12 9686 1236 2 EA COVER FRONT 15 12 9686 1238 2 EA COVER SIDE 16 12 9678 0842 1 EA AIR DUCT UPPER ENCLOSURE MOD 17 12 9678 1862 1 EA SHIELDED BALLAST CCI 18 21 9678 1254 1 EA ASSY COVER VENTILATION 21 9686 0840 02 1 EA ASSY COVER VENT VL3000 QUIET ALUMINUM not shown 19 21 9678 0767 1 EA ASSY STABILIZER 19a 10 9678 0757 1 EA STABILIZER 1 377DIA 19b 10 9678 0762 1 EA BRACKET STABLIZER 19c 53 6610 0003 1 EA SCREW 6 32 X 7 16 PPZ 19d 55 6568 0075 1 EA SPRING EXTSN 0 375 OD 1 00 LG 0 041 WIRE DIA 20 21 9678 0805 1 EA ASSY PANEL 21 21 9678 0807 1 EA ASSY PAN PULLEY 22 21 9678 0864 1 EA ASSY PAN MOTOR 02 9678 0010 G 147 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL No Item Qty UM Description 23 21 9678 0881 1 EA ASSY PAN TUBE 24 22 9678 0851 1 EA ASSY UPPER ENCLOSURE 25 23 9678 0686 1 EA FAN ASSY UPPER ENCLOSURE 26 23 9678 0687 1 EA ELEC ASSY PAN EOT SENSOR i 25 9661 1514 1 EA CABLE ASSY LVS CHASSIS GND not shown 25 9661 1520 1 EA CABLE ASSY CHASSIS TO YOKE GND not shown 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
73. ARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL 30 Pan Motor Assembly Pan Belt Replacement VL Part No 21 9678 0864 Pan Motor VL Part No 54 2055 0001 Pan Belt Repair Replacement Procedure Pan Motor Step 1 Step 2 Step 3 Step 4 Using console or internal menus run lens as far to the rear as possible Disconnect luminaire AC input cable from power source At each top enclosure cover remove two 6 32x1 4 PPB screws and remove cover In each corner from top remove four 6 32x3 8 PPZ screws CAUTION Be careful not to damage lens during next step Step Step Step Step Step Step Step Step Step Step Step 5 Carefully lay luminaire on its side ensuring that lens does not come into contact with surface At bottom of enclosure remove four 1 4 20x1 2 socket screws and 1 4 split lock washers and remove ventilation cover Remove pan motor side handle by removing two 10 32x5 8 PPB screws 8 Atenclosure bottom remove two 6 32x1 4 PPB screws and pan motor side cover 10 1 12 13 14 15 At side of enclosure remove two 6 32x3 8 PFZ screws two 6 32 KEPS nuts that hold two cable saddles Pull wiring out of way of pan motor Loosen but do not remove four 10 32x3 4 SCB Cap screws Move pan motor assembly toward pan pulley and remove belt Remove four 10 32x3 4 SCB Cap screws Pull assembly out be mindful of tension springs Disconnect wiring Replace by per
74. At tilt motor assembly loosen four 10 32x1 2 PPZ screws Remove belt from tilt pulley Remove four 10 32x1 2 PPZ screws Be mindful of tensioning springs 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 32x3 8 PPZ screws and 1 4 standoff c Disconnect ground wire from stud using 3 8 nut driver d Atinterconnect disconnect 80MM fan wiring Remove belt Replace by performing steps 2 through 7 in reverse order See next page for further instructions 02 9678 0010G MAINTENANCE PROCEDURES TILT MOTOR ASSEMBLY AND TILT BELT REPLACEMENT Tilt Motor Assembly and Tilt Belt Replacement continued A WARNING Make sure wiring is not pinched during installation When tightening four 10 32x1 2 PPZ 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 clarity Tilt Motor Assembly Sensor Bracket Tilt Belt Spring Figure 2 23 VL3000 Tilt Motor Assembly Replacement 02 9678 0010 G 43 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Tilt Encoder PCB Replacement VL Part No 24 9661 9629 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Attilt side leg remove yoke leg
75. E CROSSMEMBER HEAT SHIELD changed 02 27 07 2 10 9686 0732 2 EA COVER YOKE THERMOFORM 3 10 9678 0670 1 MOUNT 4 10 9678 0671 1 MOUNT RG 5 10 9678 0658 10 COUNTERWEIGHT 6 21 9678 0010 01 1 EA ASSY GENERIC LUMINAIRE VL3000 Only 21 9678 0011 01 1 EA ASSY GENERIC LUMINAIRE VL3000Q Only 7 21 9678 0200 1 EA ASSY SPOT GOBO 8 21 9678 8640 01 1 EA ASSY HOT BOX SPOT VL3000 Spot Only 21 9678 8698 01 1 EA ASSY HOT BOX QUIET SPOT VL3000Q Spot Only 9 21 9678 0660 01 1 EA ASSY FAN TRAY DUCT 21 9678 0659 01 1 EA ASSY FAN TRAY DUCT QUIET SPOT 10 21 9678 0678 01 1 EA ASSY TRANSFER FAN 11 21 9678 8611 2 COVER 12 22 9678 0103 1 EA ASSY SPOT OPTIC 13 22 9678 0402 1 EA ASSY CLR DIM STROB 22 9678 0462 1 EA ASSY CLR DIM STROB QUIET SPOT 14 22 9678 0149 4 EA ASSY ROD CLAMP 15 22 9678 0693 2 EA ASSY CLAMP 16 22 9678 0694 2 EA ASSY COLOR CLAMP 17 22 9678 1126 1 EA ASSY LEAD SCREW EDGE 18 24 9678 3730 1 EA PCB ASSY VL3000 CONTROLLER 25 9678 0675 1 EA CABLE ASSY RELAY TO GOBO INTERLOCK SWITCH not shown 25 9661 1520 1 EA CABLE ASSY YOKE TO HEAD GND not shown 02 9678 0010 73 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL No Item Qty UM Description 25
76. EA CABLE ASSY DATA I O LINK not shown 25 9678 0816 1 EA CABLE ASSY BALLAST TO CONTROL not shown 25 9678 0818 1 EA CABLE ASSY PAN TILT CONTROL not shown 25 9678 0821 1 CABLE ASSY DC OUTPUT not shown a 25 9678 1825 1 EA CABLE ASSY DISPLAY not shown 25 9678 0829 1 EA CABLE ASSY LAMP SUPPLY TO RELAY not shown 25 9678 0843 1 EA CABLE ASSY FAN LVS TO YOKE not shown 27 52 8295 0002 1 EA TERMINAL STRIP 300V 12AWG 20A 28 53 2001 0003 1 EA NUT 10 32 NYLON INSERT 29 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX 30 53 2200 0006 4 EA NUT 6 32 KEPS SS 31 53 6505 0022 3 EA BOLT 3 8 16 X 3 4 LG CARR 32 53 6513 0044 3 EA SCREW M5 X 10MM STL CUP PT 33 53 6515 0001 4 EA SCREW 10 32 X 3 4 SCB CAP 34 53 6522 0001 1 EA SCREW 6 32 X 1 4 PPZ 35 53 6522 0004 2 EA SCREW 6 32 X 1 4 SOC HD 36 53 6525 0188 2 EA SCREW 6 32 X 3 16 PPZ SEMS 37 53 6530 0023 2 EA RIVET 1 8 OD POP 376 500GRP 38 53 6539 0001 4 EA WASHER 3 8 SPLIT LOCK 39 53 6545 0003 4 EA SCREW 8 32 X 3 8 PFZ 40 53 6545 0004 4 EA SCREW 8 32 X 3 8 PPZ 4l 53 6556 0002 EA SCREW 4 40 X 3 4 LG 42 53 6558 0009 13 EA SCREW 6 32 X 3 8 LG PPZ SEMS 43 53 6558 0010 11 SCREW 6 32 X 1 4 LG PPZ BLACK 44 53 6558 0015 4 EA SCREW 6 32 X 3 8 PPB SEMS EXT 45 53 6571 0003 1 EA SCREW 6 32 X 1 1 2 LG PPB 46 53 6591 0001 2 EA SCREW 6 32 X 1 4 PFZ 47 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ
77. ED lt RED BLK gt 16 73 5126 0007 1 83 FT WIRE 26 AWG 2 COND 300V 80C UL1061 19 STRND lt VIO BLK gt 17 73 5126 6009 2 33 FT WIRE 26 AWG 6 COND TWISTED lt WHT WHT BLU WHT BLK WHT BRN WHT GRN WHT RED gt 18 73 5126 7009 1 83 FT WIRE 26 AWG 7 COND TWISTED lt WHT WHT BLU WHT BLK WHT BRN WHT GRN WHT RED WHT VIO gt 02 9678 0010 G 177 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Head Controller Cable Assembly continued 9 2 5 8 3 6 8 3 6 Figure 3 76 Head Controller Cable Assembly 178 02 9678 0010 G CABLE ASSEMBLIES COLOR INTERCONNECT PCB CABLE ASSEMBLY 3 Refer to Figure 3 77 and Figure 3 78 Color Interconnect PCB Cable Assembly 25 9678 1409 Rev 0 VL3000 Only No Item Qty UM Description 1 24 9678 1409 1 EA ASSY COLOR INTERCONNECT 2 28 9678 1409 1 EA WIRE KIT COLOR INTERCONNECT 04 9678 0409 00 1 EA LABEL SET COLOR HARNESS z 11 9678 0409 1 EA PCB COLOR INTERCONNECT 52 6467 0003 1 EA CONN FEM PLUG 3POS 30 24 AWG 52 6467 0005 1 EA CONN FEM PLUG 5POS 30 24AWG 52 6467 0007 1 EA CONN FEM PLUG 7805 30 24AWG 52 6467 0024 1 CONTACT SOCKET 30 24AWG CRIMP 52 6661 0006 1 EA CONN RECEPT 6CIR WIRE 52 6467 0011 5 EA CONN FEM PLUG 11 POS 30 24AWG 52 8387 0001 3 EA CONTACT 26 28AWG FEMALE CRIM 55 2186 0002 20 EA CABLE TIE 09
78. FT WIRE TUBULAR BRAID 1 8 X 23 LG 5 73 6224 0005 0 208 FT WIRE 24AWG 600V 200 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 6 3 x3 _ gt gt ee fu gt 7 4 3 2 02 9678 0010 Figure 3 88 Display Cable Assembly 191 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Ballast to Controller Cable Assembly 25 9678 0816 Rev A Refer to Figure 3 89 No Item Qty UM Description 1 52 6396 3002 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END changed 05 03 06 2 52 6396 3005 1 EA RECEPT 5 POS MTA100 W POL TAB WHT CLSD END changed 05 03 06 3 52 6396 3008 1 EA RECEPT 8 POS MTA100 W POL TAB WHT CLSD END changed 05 03 06 4 73 5124 1289 3 67 FT WIRE 24AWG 5COND lt BLK BRN RED GRN WHT gt 2 3 Figure 3 89 Ballast to Controller Cable Assembly 192 02 9678 0010 G CABLE ASSEMBLIES DC OUTPUT CABLE ASSEMBLY 3 DC Output Cable Assembly 25 9678 0821 Rev E Refer to Figure 3 90 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 000
79. Interconnect board n a Zoom Edge or Beam Spreader Failure Zoom Edge or beam spreader mechanisms will not move MCB connector disconnected check MCB connector at J10 Check Interconnect board n a Gobos or Iris Failure Gobo or iris mecha nisms will not move MCB connector disconnected check MCB connector at J9 Check Interconnect board n a DMX Data Input Self tests will not run or software download does not work Detecting DMX data disconnect DMX input cable n a DMX Termination Erratic control of lumi naire No DMX termination or termination not correct check DMX terminator 02 9678 0010 G 17 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Maintenance Procedures Lamp Replacement VL Part No 71 2557 1200 AN WARNING Ensure that power is removed from luminaire when installing lamp CAUTION Wear cotton gloves or other covering while installing lamp Touching lamp glass or lamp AN holder contacts 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 and remove fingerprints Repair Replacement Procedure Step 1 Ensure power is removed from luminaire Step 2 Atrear of luminaire head loosen four 1 4 turn screws and slide lamp box back it is hinged Step 3 One side at a time gently pry pull up at metal connection of lamp lamp fr
80. KYNAR UL 600V 150 C 6 60 7440 2002 1 EA RESISITOR 5W 5 200 OHM WIREWOUND 7 73 3526 0002 1 25 FT WIRE 26AWG 300V 105C PVC RED 8 73 5126 0002 1 50 FT WIRE 26AWG 2 COND 300V 80C lt RED BLK gt 3 8 1 l 1 lt lt X 4 x 6 A 5 x2 rdi 7 Figure 3 73 Yoke Fan Relay Cable Assembly 174 02 9678 0010 G Switch to Interlok Cable Assembly 25 9678 0682 Rev C Refer to Figure 3 74 CABLE ASSEMBLIES SWITCH TO INTERLOK CABLE ASSEMBLY 3 No Item Qty UM Description 1 52 8371 0001 1 EA RECEPT FASTON 24 20AWG UNISUL TIN PLT BRS 250 X 032 TAB 2 52 8414 0001 1 EA RECEPT FASTON 0 187 SERIES 24 20 AWG UNISUL 3 73 7089 0000 0 79 FT WIRE 22AWG 300V 200C BLK UL1180 02 9678 0010 G Figure 3 74 OT Switch to Interlok Cable Assembly 175 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Rev B Refer to Figure 3 75 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 2000 SILICONE 2 X 17 5 73 7190 0001 3 66 FT WIRE 250 DEG C 6 55 2200 0003 33 FT HEAT SHRINK TUBING 2 X 2 7 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 PIDG 2 x3 1 3
81. Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour manceuvrer 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 Sila 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 une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERF RENCE RF 1 Cet appareil est de Classe Dans un environnement domestique cet appareil 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 inte
82. M INTERCONNECT changed 03 07 06 3 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 3 x4 gt 2 gt Figure 3 24 Interconnect Light Shield Assembly 02 9678 0010 G HEAD ASSEMBLY ROD CLAMP ASSEMBLY 3 Rod Clamp Assembly 22 9678 0149 Rev B Refer to Figure 3 25 No Item Qty UM Description 1 10 9678 0151 1 EA CLAMP OPTIC ROD CAST 2 53 2008 0006 2 EA SPRING CLIP 6 32 3 53 6616 0001 2 EA SCREW 6 32 X 3 4 PPZ 4 55 6528 0001 2 EA WASHER 46 FLAT ZINC 5 55 6538 0001 2 EA WASHER 46 LOCK INTERNAL TOOTH 02 9678 0010 G 3 2 5 X2 X2 1 d Spring Clip Installation 0 10 Set spring clip from clamp surface as indicated Figure 3 25 Rod Clamp Assembly 113 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Color Dimmer Strobe Assembly 22 9678 0402 Rev N VL3000 22 9678 0462 Rev E VL3000Q Refer to Figure 3 26 No Item Qty UM Description 1 10 9678 0324 1 EA PULLEY FIXED COLOR WHEEL 2 10 9678 0337 1 DRIVE PULLEY FIXED COLOR WHEEL changed 03 09 06 3 10 0678 0456 4 EA SHAFT COLOR WHEEL 4 10 9678 0457 07 EA SPACER COLOR WHEEL L 357 changed 07 22 04 5 10 9678 0457 02 2 EA SPACER COLOR WHEEL L 190 6 10 9678 0457 03 3 EA SPACER COLOR WHEEL L 123 10 9678 04
83. NUAL Air Duct OT Switch Cable Assembly 25 9678 0690 Rev 0 VL3000Q 25 9678 0691 Rev 0 VL3000 Refer to Figure 3 69 No Item Qty UM Description 1 52 8237 0002 1 TERM RING 4 24 20AWG 2 52 8414 0001 1 RECEPT FASTON 187 SERIES 24 20AWG UNISUL 3 55 2198 0002 083 FT HEATSHRINK 1 8 BLACK 4 55 2260 0133 375 FT SLEEVING FIBERGLASS 133 ID 5 63 2047 5130 1 EA THERMOSTAT 130 TO 220 OPEN ON RISE VL3000 Only 63 2047 5120 1 EA THERMOSTAT 120 TO 220 OPEN ON RISE VL3000Q Only 6 73 7089 0000 1 48 FT WIRE 22AWG BLK 300V 2006 TEFLON STRANDED 5 4 4 5 Side View 3 x2 0 5 Each 6 7 5 2 6 10 25 1 View 170 Figure 3 69 Air Duct Switch Cable Assembly 02 9678 0010 G CABLE ASSEMBLIES RELAY FAN INTERLOCK CABLE ASSEMBLY 3 Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Refer to Figure 3 70 No Item Qty UM Description 1 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG 2 52 8414 0001 1 EA RECEPT FASTON 0 187 SERIES 24 20 AWG UNINSUL 3 73 7089 0000 2 00 FT WIRE 22AWG 300V 200C TEF BLK 111180 3 Figure 3 70 Relay to Fan Interlock Cable Assembly 02 9678 0010 G 171 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Front Head Fans Cable Assembly 25 9678 0677 Rev B Refer to Figure 3 71 No Ite
84. OLOR HARNESS 11 9678 0409 1 EA PCB COLOR INTERCONNECT 52 6467 0003 1 EA CONN FEM PLUG 3POS 30 24 AWG 52 6467 0005 1 EA CONN FEM PLUG 5POS 30 24AWG 52 6467 0007 1 EA CONN FEM PLUG 7805 30 24AWG 52 6467 0024 19 CONTACT SOCKET 30 24AWG CRIMP 52 6661 0006 5 EA CONN RECEPT 6CIR WIRE TO z 52 6467 0011 1 EA CONN FEM PLUG 11 POS 30 24AWG 52 6523 0004 2 EA CONN HOUSING 4 POS PLUG 52 8347 0001 8 EA CONTACT 24 30AWG MALE CRIMP 52 8387 0001 20 EA CONTACT 26 28AWG FEMALE CRIM 55 2186 0002 11 EA CABLE TIE 09 WD 3 750 LG TEF 73 2326 0123 17 34 FT WIRE 26AWG 4COND 300 200 73 2326 7001 2 01 FT WIRE 26AWG 7COND 300V 200 TE 73 2326 5001 1 30 FT WIRE 26AWG 5COND 300V 200 TE 73 2326 3003 1 04 FT WIRE 26AWG 3COND 300V 200 Figure 3 79 Color Interconnect PCB Cable Assembly VL3500Q Only 02 9678 0010 G 181 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Color Interconnect PCB Cable Assembly continued Figure 3 80 Color Interconnect PCB Assembly Wire Chart VL3000Q Only 182 02 9678 0010 G CABLE ASSEMBLIES INTERCONNECT PCB CABLE ASSEMBLY 3 Interconnect PCB Cable Assembly 25 9678 2209 Rev 0 Refer to Figure 3 81 Note This cable must be ordered as an assembly Figure 3 81 Gobo Interconnect PCB Cable Assembly 0
85. ON Be careful not to damage lens during next step Step Step Step Step Step Bottom Cover 02 9678 0010 G Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface At bottom of enclosure remove four 1 4 20x1 2 socket screws and 1 4 split lock washers and remove ventilation cover 5 At pan sensor remove two 6 32x3 8 PPZ screws 6 Disconnect wiring from encoder PCB and remove sensor Replace sensor by performing steps 3 through 6 in reverse order NOTE Head not shown for clarity Enclosure Bottom View Pan Motor Assembly Figure 2 14 VL3000 Pan EOT Sensor Replacement 33 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Low Voltage Power Supply LVS Replacement VL Part No 69 3177 0151 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Atenclosure remove two 6 32x1 4 LG PPZ screws from display side cover and remove COVer Step 3 At power supply disconnect wiring Location Connector N White AC Wires L Black AC Wires V Red DC Wires V Red DC Wires V Black DC Wires V Black DC Wires Step 4 Remove one 6 32x3 8 LG PPZ screw Step 5 Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 Replace by performing steps 2 through 5 in reverse order Top Cover Power Supply LVS Bottom Cov
86. RE 16 AWG 600V 105C PVC BLK UL1015 11 73 6016 0504 2 08 FT WIRE 16 AWG 600V 105 GRN YEL UL1015 12 73 6018 0009 1 00 FT WIRE 18 AWG 600V 105C WHT UL1015 13 73 6018 0010 1 00 FT WIRE 18 AWG 600V 105C PVC BLK UL1015 188 02 9678 0010 6 CABLE ASSEMBLIES AC INPUT SPLITTER CABLE ASSEMBLY 3 AC Input Splitter Cable Assembly continued 4 x2 x2 Se 5 9 13 7 11 6 d we 2 1 lt Note Heatshrink not shown for clarity Figure 3 86 AC Input Splitter Cable Assembly 02 9678 0010 G 189 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Data 1 0 Link Cable Assembly 25 9678 0813 Rev A Refer to Figure 3 87 No Item Qty UM Description 1 52 6396 2904 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END changed 05 03 06 2 52 6396 2905 1 EA RECEPT 5 POS 100 W POL TAB RED CLSD END changed 05 03 06 3 73 5122 0259 2 17 FT CBL 22AWG STRND 4COND PVC INSUL 2 1 Figure 3 87 Data I O Link Cable Assembly 190 02 9678 0010 G CABLE ASSEMBLIES DISPLAY CABLE ASSEMBLY 3 Display Cable Assembly 25 9678 1825 Rev C Refer to Figure 3 88 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 CABLE TIE 10 WD 4 LG SMALL 4 73 7130 0004 0 958
87. RETAINER SPLIT RING changed 04 19 05 9 55 2233 0775 4 EA STUD 1 4 TURN OPR 775L STEEL BLK ZINC changed 5 21 03 10 55 9676 0255 4 EA WASHER BEVELED SPRING added 05 15 05 Bottom View Bottom View Figure 3 2 Head Cover Assembly 82 02 9678 0010 G HEAD ASSEMBLY BACKEND ASSEMBLY 3 Backend Assembly 21 9678 0615 Rev T VL3000 21 9678 0616 Rev H VL3000Q Refer to Figure 3 3 No Item Qty UM Description 1 10 9678 0631 1 EA SEPARATION BULKHEAD 2 10 9678 8635 1 EA EXHAUST BULKHEAD 3 10 9678 0637 2 EA CLIP RETRO REFLECTOR 4 10 9678 0638 1 EA AIR DIVERTER STROBE MOTOR 5 10 9678 0653 1 EA LIGHT BAFFLE EXHAUST 6 12 9678 7152 1 EA REFLECTOR RETRO SPHERICAL COATED 7 12 9678 0627 1 EA AFT BULKHEAD MACHINED 8 21 9678 0619 1 EA FAN ASSY 80MM 9 21 9678 0673 2 EA TETHER ASSY COVER 10 22 9678 3655 1 EA DUCT ASSY 80MM FAN 11 22 9678 0639 1 EA UV FILTER BULKHEAD ASSY 22 9678 0617 1 EA UV FILTER BULKHEAD ASSY VL3000 QUIET 25 9678 0012 1 EA CABLE ASSY FAN YOKE TO FAN not shown gt 25 9678 0014 1 EA CABLE ASSY INTERLOK 6080 INTERLOK not shown 12 53 2004 0002 6 EA NUT 8 32 KEPS ZINC PLATE 13 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 14 53 6545 0009 4 EA SCREW 8 32 X 1 375 LG PFZ 15 53 6523 0001 1 EA SCREW 6 32 X 3 8 SCB changed 7 18 03 16 53 6558
88. ROUP 4 LENS MOUNT ASSEMBLY 3 Group 4 Lens Mount Assembly 22 9678 0199 Rev 0 Refer to Figure 3 19 No Item Qty UM Description 1 12 9678 0198 2 RING BLOCK MACHINED G4 2 22 9678 0174 1 EA LENS ASSY GROUP 4 3 53 6558 0001 EA SCREW 6 32 X 3 8 PPZ 4 55 3303 0006 EA WASHER 46 LOCK INT TOOTH 55 5 55 6763 0500 EA PIN DOWEL 5 LG 125 DIA 30355 gt gt Figure 3 19 Group 4 Lens Mount Assembly 02 9678 0010 G 107 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Right Edge Bearing Assembly 22 9678 1103 Rev C Refer to Figure 3 20 No Item Qty UM Description 1 12 9678 1102 1 EA EDGE BEARING MACHINED CASTING RIGHT 2 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM 3 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 4 2 1 3 Figure 3 20 Right Edge Bearing Assembly 108 02 9678 0010 G HEAD ASSEMBLY LEFT EDGE BEARING ASSEMBLY 3 Left Edge Bearing Assembly 22 9678 1105 Rev C Refer to Figure 3 21 No Item Qty UM Description 1 12 9678 1104 1 EA EDGE BEARING MACHINE LEFT 2 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM 3 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 3 2 1 3 Figure 3 21 Left Edge Bearing Assembly 02 9678 0010 G 109 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Zoom Cam Assembly 22 9678 1106 Rev B
89. 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 8 GROOVE DIA 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 AL changed 05 27 03 02 9678 0010 G 135 VL3000 VL3000 Q SERVICE MANUAL Yoke Assembly continued Figure 3 44 Yoke Assembly 136 02 9678 0010 G YOKE ASSEMBLY TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21 9678 0765 Rev E Refer to Figure 3 45 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 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 SS 7 53 6525 0001 2 SCREW 6 32 X 5 16 PPZ 8 53 6546 0001 4 EA SCREW 8 32X 5 8 PPB 9 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 02 9678 0010 G 137 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Tilt Motor Assembly continued 2 See Detail A Detail A 7 x2 LAAT ATTN SSS Pressure Sensitive Adhesive Pulley Height Detail amp Insta
90. Step 5 Disconnect upper enclosure connectors 11 J2 J3 J4 and J12 at back of MCB Step 0 Install replacement assembly by performing Steps 2 5 in reverse order Step 7 Configure using menu functions as necessary Yoke Leg Cover Main Controller Board SS Figure 2 9 VL3000 Main Control Board Replacement 02 9678 0010 G 27 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Motor Driver IC Replacement for Socketed MCBs VL Part No 85 3773 0002 Repair Replacement Procedure Note To improve reliability Vari Lite has introduced main control boards MCB with the motor drivers mounted directly on the board Drivers cannot be replaced on these boards For boards with sockets to remove a motor driver IC you will need a Static Dissipative PLCC Extractor tool This tool is available from Stanley Supply amp Services part number 126 453 Step 1 Disconnect luminaire input cable from power source CAUTION Always use anti static precautions when working with PCBs Step Step Step Step 28 2 3 Remove Main Control Board PCB following procedure on page 27 Remove heatsink from Main Control Board PCB If thermal compound is used remove and replace with thermal pad Vari Lite part number 10 9678 0885 Thermal Transfer Kit Using PLCC extractor tool see above replace required stepper motor driver loca tions U27 U30 032 044 Reinstall Main Control Board PCB performing Steps
91. UCT VL3000Q WASH 8 21 9678 0678 02 EA ASSY TRANSFER FAN changed 11 11 03 9 21 9678 0910 1 EA ASSY BEAM SPREADER 10 21 9678 0991 2 EA ASSY LIGHT BAFFLE BEAM SPREAD 11 21 9678 0950 1 EA ASSY APERATURE BULKHEAD 12 22 9678 0149 2 EA ASSY ROD CLAMP 13 22 9678 0402 1 EA ASSY CLR DIM STROB 22 9678 0462 1 EA ASSY CLR DIM STROB VL3000Q WASH 14 22 9678 0693 2 EA ASSY GOBO CLAMP 15 22 9678 0694 2 EA ASSY COLOR CLAMP 16 24 9678 3730 1 EA PCB ASSY VL3000 CONTROLLER 25 9678 0675 1 EA CABLE ASSY RELAY FAN not shown 25 9678 0677 1 EA CABLE ASSY FRONT HEAD FANS not shown 25 9661 1520 1 EA CABLE ASSY YOKE TO HEAD GND not shown 25 9678 0715 1 EA CABLE ASSY HEAD CONTROL not shown 28 9678 0002 EA INCLUDED ITEMS KIT VL3000 WASH not shown 76 02 9678 0010 G ASSEMBLY 3000 AND VL3000Q WASH LUMINAIRE 3 Qty UM Description 17 53 6523 0013 8 EA SCREW 6 32 X 3 8 PPB 18 53 6558 0009 11 EA SCREW 6 32 X 3 8 LG PPZ SEMS 19 53 6558 0016 2 EA SCREW 6 32 X 3 4 PPZ SEMS 20 53 6579 0001 4 EA SCREW 10 32 X 1 2 SCB 21 53 6613 0001 2 EA SCREW 6 32 X 1 2 PPZ 22 53 6682 0022 8 EA SCREW 8 32 X 3 8 LG PPZ SEMS 23 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNT 24 55 2284 0001 1 EA CARD GUIDE 3 LONG SNAP IN 25 55 6506 0024 2 EA SPACER 3 16 RND 1875 LG 141 THRU SS
92. UM Description 1 10 9678 1119 1 LEAD SCREW EDGE 2 55 6616 0007 1 EA STANDOFF 3 8 HEX THRD 0 562 LG 1 2 Figure 3 37 Edge Lead Screw Assembly 128 02 9678 0010 G HEAD ASSEMBLY SPREADER ASSEMBLY 3 Beam Spreader Assembly 21 9678 0910 Rev A Wash Only Refer to Figure 3 38 No Item Qty UM Description 1 10 9678 0945 1 EA TUBE WASH LIGHT BAFFLE 2 21 9678 0920 1 EA ASSY CONCAVE LENS STATIONARY 3 21 9678 0930 1 EA ASSY CONVEX LENS TRANSLATING 4 21 9678 0940 1 EA ASSY CONDENSER LENS 5 24 9678 3916 1 EA PCB ASSY ZOOM INTERCONNECT WASH 6 53 6520 0375 4 EA SCREW 4 40 X 3 8 PPZ SEMS 7 53 6682 0022 2 EA SCREW 8 32 X 3 8 PPZ 8 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ Figure 3 38 Beam Spreader Assembly 02 9678 0010 G 129 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Stationary Concave Lens Assembly 21 9678 0920 Rev A Wash Only Refer to Figure 3 39 No Item Qty UM Description l 10 9678 0927 2 EA BEARING SHAFT SPREADER 2 10 9678 0928 2 EA LENS CLAMP BEAM SPREADER 3 12 9678 0168 1 EA MASKED CONCAVE LENS ARRAY MEDIUM 4 12 9678 0925 1 EA CONCAVE LENS MOUNT MACHINED 5 42 9678 1169 1 EA DIFFUSION LENS FRONT WASH 6 53 6530 0002 4 EA RIVET 1 8 OD POP 063 125 GR LENGTH Etched side of lens Figure 3 39 Stationary Concave Lens Assembl
93. VERLETZUNGEN 1 Bei Betrieb sind die AuBenfl 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 bloen 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 kann das Produkt Hochfre quenzst rungen verursachen In diesem Fall m ssen eventuell geeignete MaBnahmen getroffen werden BESONDERHEITEN VON BOGENLAMPEN 1 Bogenlampen ben tigen eine gewisse Zeitdauer
94. W 3MM X 5MM LG PFZ METR 2 Note orientation of adapter plate in relation to the motor Figure 3 27 Motor Adapter Plate Assembly 02 9678 0010 G VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Fixed Color Wheel Assembly 21 9678 0334 Rev D Refer to Figure 3 28 No Item Qty UM Description l 10 0678 0322 1 EA SPIN SHAFT COLOR WHEEL 2 10 9678 0332 6 EA SLIDING RETAINER 3 10 9678 0333 6 EA RETAINER CLIP 4 22 9678 1336 1 EA FAB ASSY FIXED WHEEL CLIP changed 9 03 03 5 41 9678 0305 01 1 EA COLOR FILTER DEEP RED VL3000 6 41 9678 0305 02 1 EA COLOR FILTER KELLY GREEN VL3000 7 41 9678 0305 03 1 EA COLOR FILTER CONGO BLUE VL3000 8 41 9678 0305 04 1 EA COLOR FILTER MAGENTA VL3000 9 41 9678 0305 05 1 EA COLOR FILTER ORANGE VL3000 10 41 9678 0305 06 1 EA COLOR FILTER DARK FUSHIA VL3000 11 53 6534 0001 6 EA RIVET 3 32 POP 3 32 GRIP RANGE 12 53 6608 1857 3 EA SCREW 6 32 X 3 16 LG PFSS 13 55 2256 0001 1 EA MAGNET 2 17 SMCO 2MM X 2MM X 14 55 6568 0076 6 EA SPRING CPRSN 0 120 OD 0 750 LG 15 10 9678 0250 1 EA MAGNET TAPE 118 02 9678 0010 G HEAD ASSEMBLY COLOR WHEEL ASSEMBLY 3 Fixed Color Wheel Assembly continued 12 x3 9 y POS 2 d lt ORANGE gt post 8053 CONGO KELLY GREEN POSS 95 DARK 10 FUSHIA 8086 poss V
95. WG TW 300V 200 02 9678 0010G HEAD YOKE PCB ASSEMBLIES ZOOM INTERCONNECT ASSEMBLY 3 Zoom Interconnect PCB Assembly continued 5 gt VARBLITE BHD Figure 3 50 Zoom Interconnect Assembly 02 9678 0010 G 145 VARF amp LITEG VL3000 amp VL3000 Q SERVICE MANUAL Notes 146 02 9678 0010 G ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly Upper Enclosure Assembly 21 9678 0800 01 Rev NN VL3000 21 9678 0801 01 Rev Z VL3000Q Refer to Figure 3 51 Figure 3 52 and Figure 3 53 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 9678 0040 01 1 EA LABEL VL3000 COMPLIANCE 04 9678 0045 1 EA LABEL VL3000 QUIET COMPLIANCE 4 06 6032 0009 1 EA CABLE MARKER TIE WHITE 19 X 7 5 10 9661 1258 1 EA BRACKET 5 SIDE 6 10 9661 1358 1 EA AIR SEAL DUCT 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 0886 1 EA SPACER PAN BEARING 0 235 12 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN 13 10 9678 1876 1 E
96. WITCH CABLE ASSEMBLY 3 EMI Filterto Power Switch Cable Assembly 25 9678 0811 Rev C Refer to Figure 3 85 No Item Qty UM Description l 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL REEL 2 52 8392 0001 2 EA RECP FASTON 187 X0 32 16 14 AWG FLAG DBL 3 55 2186 0001 EA CABLE TIE 0 10 WD 4 00 LG SMALL 4 73 6016 0009 0 83 FT WIRE 16AWG 600V 105C PVC WHT UL1015 5 73 6016 0010 0 83 FT WIRE 16AWG 600V 105C PVC BLK UL1015 2 x2 1 x2 4 White 3 White Black Black 8 Figure 3 85 Filter to Power Switch Cable Assembly 02 9678 0010 G 187 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL AC Input Splitter Cable Assembly 25 9678 0812 RevE Refer to Figure 3 86 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 3 52 8231 0008 2 EA TERM SPADE 6 RED 22 16 AWG INSERT 4 52 8392 0001 2 EA FASTON 187 X 0 32 16 14 AWG FLAG DBL 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 UL1015 10 73 6016 0010 1 83 FT WI
97. al resources and documentation please visit our website at www vari lite com and follow the Support link Technical Bulletins and Notices Technical bulletins concerning the latest changes to VARIKLITE 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 53K 001 VL3000 Series Luminaires Technical Bulletin number 1 A list of technical bulletins for these products is found in 3000 amp VL3000Q Technical Bulletins on page 197 Technical notices are also 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 2 02 9678 0010 G 1 Description This chapter contains descriptions of luminaire features and components Features Components Principles of Operation 3J2IAMN3AS 02 9678 0010 G 3 VARIKLITE VL3000
98. an and the lamp house 80 mm Fan Assembly Note Other components removed for clarity Fan Shield 2 see note above N Note fan air flow indicator Series 3000 Back End Assembly 80 mm Fan Assembly _ Fan Assembly 80MM Fan Assembly Front of Luminaire Shield Orientation Shield must mimic and cover fan housing Figure 2 28 VL3000 80MM Fan Replacement 50 02 9678 0010 G MAINTENANCE PROCEDURES TRANSFER FAN ASSEMBLY REPLACEMENT 2 Transfer Fan Assembly Replacement VL Part No 21 9678 0678 01 Spot VL Part No 21 9678 0678 02 Wash Repair Replacement Procedure Step Step Step Step Step 02 9678 0010 G 1 2 Disconnect luminaire input cable from power source Remove top head cover by loosening four quarter turn captive locking screws Top cover is identifiable as the cover on top when back label is such that words are displayed correct side up 3 Disconnect transfer fan wiring from zoom interconnect PCB At transfer fan assembly loosen four 6 32 x 3 8 PPZ screws and slide assembly off Gobo assembly Replace by performing steps 2 through 4 in reverse order Top Head Cover Transfer Fan Assembly lt gt 292 I Figure 2 17 VL3000 Tran 51 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Gobo Color Dual Fan Assembly Replacement VL Part No 21 9678 0659 01 VL Part No 21 9678 0660 01 Repair Repla
99. ari Lite A Philips Group Company 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 08 May 2009 Part number 02 9678 0010 G VL3000 amp VL3000 Q Luminaire Service Manual 2003 2009 Vari Lite a Philips group company 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 1 877 827 4548 or customerservice genlytecontrols com and request a Return Material Authori zation 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 t
100. arity Figure 2 19 VL3000 Yoke Fan Assembly Replacement 02 9678 0010 G 53 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Upper Enclosure Fan Assembly Replacement VL Part No 23 9678 0686 VL Part No 23 9678 0888 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Atenclosure remove two 6 32x1 4 LG PPZ screws from display side cover and remove COVer Step 3 At power supply disconnect wiring Location Connector N White AC Wires L Black AC Wires V Red DC Wires V Black DC Wires Step 4 Remove one 6 32x3 8 LG PPZ screw Step 5 Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 At fan remove three 6 32x3 8 PPZ screws and remove fan Step 7 Replace by performing steps 2 through 6 in reverse order Fan Assembly Display Cover NOTE Some components not shown for clarity Fan Assembly Figure 2 20 VL3000 Upper Enclosure Fan Assembly Replacement 54 02 9678 0010G MAINTENANCE PROCEDURES DISPLAY ASSEMBLY REPLACEMENT Display PCB Assembly Replacement VL Part No 24 9678 3825 Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Atenclosure remove two 6 32x1 4 LG PPZ screws from display side cover and remove COVer Step 3 At power supply disconnect wiring Location Connector N White AC Wi
101. bly 25 9678 0812 Data I O Link Cable Assembly 25 9678 0813 Rev A Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Display Cable Assembly 25 9678 1825 LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Figure 3 12 VL3000Q Wash Luminaire Drawing Tree Part 3 02 9678 0010 G 69 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Top Assembly Included Items Kit Spot 28 9678 0001 Rev J Refer to Figure 3 13 No Item Qty UM Description l 02 8001 0001 1 PRODUCT SUPPORT 5 VARI LITE CUSTOMER SERVICE 2 02 8052 0001 l EA CARD LIMITED WARRANTY 3 02 8406 0001 1 EA TAG LAMP NOTICE 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 5 02 9678 0002 EA UNPACK QUICK START SHEET VL3000 04 4037 0001 5 EA LABEL 2 5 X 5 BARCODE not shown 07 9678 0036 1 EA CARDBOARD SHIPPING BOX VL3000 not shown 6 08 3000 0001 EA CD ROM VL3000 PRODUCT DOCUMENTATION USER 7 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 8 41 6030 4211 1 EA GOBO ASSY UNEVEN BARS POS 2 4 9 41 6030 5011 1 ASSY NIGHT SKY POS 1 3 10 41 6030 5503 1 ASSY PALM LEAVES POS 2 2 11 41 6030 5523 1 EA GOBO ASSY TRIBAL BREAKUP POS 1 4 12 41 6030 6011 1 EA GOBO ASSY CIRCLE OF OVALS POS 3 5 13 41 6030 7002 1 EA GOBO ASSY PEBBLES POS 1 5 14 41 6030 7014 1 EA GOBO ASSY TRIANGLE BREAKUP POS 3 4
102. cement Procedure Step Step Step Step Step Step Note 52 1 2 Disconnect luminaire input cable from power source Remove both top and bottom head cover by loosening four quarter turn captive locking Screws Disconnect fan wiring from zoom interconnect pcb 3 4 5 6 At fan duct micro switch remove two 4 40x5 8 PPZ screws and remove micro switch At Fan assembly remove four 6 32x3 8 PPZ screws and remove fan assembly Replace by performing steps 2 through 5 in reverse order Some early production wash fixtures only have one fan mounted to dual fan assembly AII current production fixtures have two fans Gobo Color Fan Assembly SL Gobo Color Fan Assembly Figure 2 18 VL3000 Gobo Color Dual Fan Assembly Replacement 02 9678 0010 G MAINTENANCE PROCEDURES YOKE FAN ASSEMBLY X2 REPLACEMENT 2 Yoke Fan Assembly x2 Replacement VL Part No 22 9661 0609 VL Part No 22 9678 0609 Q Version Repair Replacement Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove yoke cover from side with fan being replaced by removing four 6 32 x 3 8 PTB screws Step 3 Disconnect wiring from fan Step 4 Remove four 4 40x1 4 PFSS screws two per side of yoke and remove fan Step 5 Replace by performing steps 2 through 4 in reverse order S Screws 2 per side 7 Screws Yoke Fan Assembly 2 per side NOTE Some components not shown for cl
103. crews and remove sensor from bracket Step 6 Replace by performing steps 2 through 5 in reverse order Tilt Motor SR Assembly UMS NOTE Head not shown for clarity Sensor Sensor Bracket JN Tilt Belt Spring Figure 2 25 VL3000 Tilt EOT Sensor Replacement 02 9678 0010 G 45 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Ballast Assembly Replacement VL Part No 23 9678 1269 Old Style VL Part No 12 9678 1862 New Style Note Vari Lite offers a conversion kit for converting old style ballasts to new style ballasts For information on the kit VL Part No 28 9678 0100 see Technical Bulletin S3K 014 Series 3000 New Style Ballast Conversion Procedure available on the Vari Lite Tech Center website Repair Replacement Procedure Old Style Ballast Step 1 Step 2 Step 3 Step 4 Using console or internal menus run lens as far to the rear as possible Disconnect luminaire AC input cable from power source At each top enclosure cover remove two 6 32x1 4 PPB screws and remove cover In each corner from top remove four 6 32x3 8 PPZ screws CAUTION Be careful not to damage lens during next step Step Step Step Step Step Step Step Step Step Step 46 3 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface At bottom of enclosure remove four 1 4 20 x 1 2 socket screws and 1 4 split lock washe
104. e Assembly 25 9661 1526 Rev C Yoke Fan and Relay Cable Assembly 25 9678 0681 Rev C Yoke Fan Cable Assembly 25 9678 0758 Rev A VL3000 Spot Luminaire Drawing Tree Part 2 59 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 Spot Luminaire continued Continued from page 56 Upper Enclosure Assembly 21 9678 0800 01 Rev NN VL3000 Ventilation Cover Assembly Standard 21 9678 1254 Rev 0 VL3000 Pan Pulley Assembly 21 9678 0807 Rev E Pan Motor Assembly 21 9678 0864 Rev E Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Figure 3 3 VL3000 Spot Luminaire Drawing Tree Part 3 60 Panel Assembly 21 9678 0805 Rev N DMX Input PCB 24 9663 3895 AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Pan Tube Assembly 21 9678 0881 Rev 0 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C AC Input Splitter Cable Assembly 25 9678 0812 Data I O Link Cable Assembly 25 9678 0813 RevA Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Display Cable Assembly 25 9678 1825 LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A 02 9678 0010G DRAWING TREES VL3000Q SPOT LUMINAIRE 3 VL3000Q
105. e lich f r den Einsatz mit bestimmten Lampentyps Achten Sie auf den Lampentyp Osram HMI 1200 W S metal halide lamp 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 VAREKLITEG 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 VAREKLITEG Ger ten beginnen 3 Die Ger te sollten nur von qualifiziertem Personal gewartet werden 02 9678 0010 G M VARIKLITE VL3000 amp VL3000 Q 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 Esist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen oder 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 K RPER
106. e of adhesive when LIT filter is secured AT LC Position UV filter in between 8 raised locating tabs on bulkhead and attach using UV glass clips and rivets as shown Be careful not to damage UV filter chip scratch crack etc during installation Figure 3 5 UV Filter Bulkhead Assembly 86 02 9678 0010 G HEAD ASSEMBLY SPOT ASSEMBLY 3 Spot Gobo Assembly 21 9678 0200 Rev K Spot Only Refer to Figure 3 6 No Item Qty UM Description 1 10 9678 0215 1 EA BULKHEAD GOBO MODULE FRONT 2 10 9678 0216 1 EA BULKHEAD MODULE REAR 3 10 9678 0225 4 EA SHAFT WHEEL 4 10 9678 0231 3 EA PULLEY MOTOR WHEEL DRIVE 5 10 9678 0232 3 EA PULLEY INSEX DRIVE 64 GROOVE 6 10 9678 0244 2 EA MOUNT INDEX SENSOR LONG 7 10 9678 0245 1 EA MOUNT INDEX SENSOR SHORT 8 10 9678 0246 3 EA ADJUST PLATE MOTOR 9 10 9678 0277 1 EA SPACER WHEEL IRIS 10 21 9678 0210 2 EA ASSY ROTATING GOBO WHEEL 11 21 9678 0211 1 EA ASSY ROTATING EFFECTS WHEEL 12 21 9678 0243 2 EA ASSY MOTOR LONG SHAFT 13 21 9678 0270 1 EA SUB ASSY IRIS 14 24 9663 3231 4 EA PCB ASSY INDEX SENSOR 15 24 9678 3240 3 EA PCB ASSY WHEEL POSITION SENSOR changed 02 11 05 25 9678 2209 1 PCB CABLE INTERCONN changed 06 28 06 Not Shown 16 44 9663 1202 2 EA MOTOR 17 2 42 SHAFT 11 8 17 4
107. ead Cover Bottom of Head View Hinged Duct Assembly Head covers are attached by tethers Disengages lamp power when raised Figure 2 3 Fan Duct Assembly View 20 02 9678 0010 G MAINTENANCE PROCEDURES 6080 REPLACEMENT Gobo Replacement A WARNING Remove power from luminaire before performing maintenance Gobos can be HOT after operation Allow to cool before replacing A WARNING Users of luminaires should not install or use metal gobos The use of metal gobos in any product may damage the luminaire and could void the luminaire s warranty Repair Replacement Procedure Step 1 Remove power from luminaire Step 2 Remove appropriate head cover by loosening four 1 4 turn screws a To access Wheels 1 and 3 remove bottom cover as shown in Figure 2 4 b To access Wheel 2 remove top cover as shown in Figure 2 4 Step 3 If accessing Wheels 1 and 3 also raise hinged fan duct assembly Fan duct has a lamp cutoff switch which will disengage power to lamp Step 4 Rotate 6000 wheel until required gobo position is accessible CAUTION Do not push on gobo glass Press on gobo carrier only CAUTION Do not touch gobos with bare fingers Wear cotton gloves or other covering while replacing Clean with isopropyl alcohol and soft cloth if required gt gt Step 5 Remove current gobo by carefully pressing on edges of gobo car
108. er NOTE Head not shown for clarity Figure 2 15 VL3000 Power Supply LVS Replacement 34 02 9678 0010G MAINTENANCE PROCEDURES ASSEMBLY REPLACEMENT 2 Gobo Assembly Replacement VL Part No 21 9678 0200 Repair Replacement Procedure Step 1 Run Edge to full forward position DMX 255 Step 2 Disconnect luminaire AC input cable from power source Step 3 Remove top head cover by loosening four quarter turn captive locking screws Top cover is identifiable as the cover on top when back label is such that words are displayed correct side up Step 4 Disconnect head cable from Color Assembly Interconnect PCB remove wiring from Transfer Fan clips Step 5 Disconnect Transfer Fan wiring from Zoom Interconnect Step 6 Disconnect head cable from Gobo Assembly Interconnect Step 7 At Gobo Assembly clamps loosen four 6 32 captive screws two per clamp and remove clamp Note the large Phillips screw in the middle is used as a handle DO NOT try to loosen that screw Step 8 Pull Gobo Assembly straight out of fixture Step 9 Replace by performing steps 3 through 8 in reverse order Top Head Cover Gobo Assembly Optic Assembly EN Must all the way forward lt 1 Figure 2 16 VL3000 Spot Gobo Assembly Replacement 02 9678 0010 G 35 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL 36 Gobo Timing Adjustments The index timing belt m
109. es 140 02 9678 0010 G HEAD YOKE PCB ASSEMBLIES COLOR SENSOR 1 MOUNT ASSEMBLY 3 Head Yoke PCB Assemblies Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Refer to Figure 3 47 No Item Qty UM Description 1 10 9678 0482 EA PCB MOUNT COLOR SENSOR 1 2 24 9678 3480 1 EA ASSY VL3000 COLOR SENSOR 1 3 53 6558 0001 2 EA SCREW 6 32X 3 8 PPZ 4 55 3303 0006 2 EA WASHER 6 LOCK INT TOOTH SS Figure 3 47 Color Sensor 1 PCB Mount Assembly 02 9678 0010 G 141 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Color Sense PCB Z2 Mount Assembly 22 9678 0489 Rev B Refer to Figure 3 48 142 No Item Qty UM Description 1 10 9678 0452 EA MOUNT COLOR SENSE 2 2 24 9678 3454 1 EA PCB ASSY COLOR SENSOR 2 3 53 6558 0007 2 EA SCREW 6 32 X 1 4 SEMS 3 x2 Figure 3 48 Color Sense PCB 2 Mount Assembly 02 9678 0010 G HEAD YOKE PCB ASSEMBLIES VL3000 CONTROLLER 3 VL3000 Controller PCB 24 9678 3730 Rev 0 A Note This item is only available as an assembly Refer to Figure 3 48 m 85 3773 002 IC DRIVER FOR USE WITH CARDS WITH SOCKETS ONLY BS lt 0860080 BE 8808880 HH d fit d AE eT m s S mmmn
110. forming steps 3 through 14 in reverse order Note Make sure wiring is 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 Repair Replacement Procedure Pan Belt Step Step Step Step 1 Using console internal menus run lens as far to the as possible 2 Disconnect luminaire AC input cable from power source 3 4 Disconnect the following cable assemblies At each top enclosure cover remove two 6 32x1 4 PPB screws and remove cover a Disconnect lamp wire from J202 and J203 02 9678 0010 G MAINTENANCE PROCEDURES PAN MOTOR ASSEMBLY PAN BELT REPLACEMENT 2 b Disconnect DC wire from LVS c Disconnect DMX wire from DMX PCB d Disconnect Display wire from Display e Remove ground wire from chassis Step 5 Remove pan motor assembly See Repair Replacement Procedure Pan Motor on page 30 Step 0 Pass wire through routing hole in chassis Step 7 Remove belt Step 8 Replace by performing steps 2 through 7 in reverse A Note Make sure wiring is 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 Head not shown for clarity Bottom Cover Enclosure Bottom Vie
111. he unit freight prepaid to Vari Lite Attention Warranty Service RMA 10911 Petal Street Dallas Texas 75238 USA As stated in the warranty it is required that the shipment be insured and FOB our service center 02 9678 0010 G i VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Compliance Notice FCC 6 This equipment has been tested found to comply with the limits for a Class 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 A2 1991 Specification for Luminaires for Stage and Studio Lighting EMC EN 61000 6 4 2001 We certify that the product conforms to the protection requirements of council di
112. ible Cause and Remedy n a DMX Failure No response to DMX MCB connector disconnected data check MCB DATA IN connection n a Lamp Douse Lamp douses frequently Fan failure check fans for proper connection and operation n a Lamp Strike Failure Lamp will not strike Lamp cutout switch engaged check lamp cutout switches at lamp box and fan ducts Bad lamp replace lamp n a Profile Not Matched Luminaire behaves Profile not set correctly oddly check Setup menu for correct type spot or wash No Sens Mechanism failed to find No control continuous Motor power not connected sensor reported for Blue recalibration and or connect motor power Amber Magenta Col mechanism at wrong Sensor not connected Wheel CTO 0001 position connect sensor Index1 Gobo2 Index2 Interconnect board not connected securely 0003 Index3 Zoom and check connection inspect for bent pins Edge Movement restricted or impeded remove obstruction check cable routing and or check voltage at MCB test point n a No power Luminaire does not Switch not turned on power up verify switch is turned on Not plugged in ensure A C cable is connected to power source Pan Pan Encoder Failure Luminaire will not pan 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 assemb
113. ink Cable Assembly 25 9678 0813 Rev A Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Display Cable Assembly 25 9678 1825 LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev Figure 3 6 VL3000Q Spot Luminaire Drawing Tree Part 3 02 9678 0010 G 63 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 Wash Luminaire Beam Spreader Assembly 21 9678 0910 Rev A Wash Onl Stationary Concave Lens Assembly 21 9678 0920 Rev A Wash Only Translating Convex Lens Assembly 21 9678 0930 Rev B Wash Only Condenser Lens Assembly 21 9678 0940 Rev C Wash Onl Hot Box Assembly 21 9678 8640 02 Rev H VL3000 Wash Head to Back Cap Ground Cable Assembly 25 9661 1522 Rev B Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Dual Fan Tray Duct Assembly VL3000 Only 21 9678 0660 01 Rev B Head Front Fan Assembly 23 9678 0684 Rev 0 Continued on page 65 Figure 3 7 64 VL3000 Wash Luminaire 20 9678 0002 Rev R VL3000 Wash eneric Luminaire Assemblies 21 9678 0010 01 Rev H VL3000 Head Structure Assembly 21 9678 0600 Rev C Backend Assembly 21 9678 0615 Rev T VL3000 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0639 Rev G VL3000 Yoke to AC Fan Cable Assembly 25 9678 0012 Rev A Backcap Interlok to Gobo Fan Interlok Cable Assembly 25 9678 0014 Rev B Air Duct OT Switch Cable Assembly 25 9678 0691 Rev 0 VL3000 Yoke Assembly
114. k lC U C lt K uA D ARR DEREDE 9 02 9678 0010 G xi VARI LITE VL3000 amp VL3000 Q SERVICE MANUAL i REO UV KES D 7L7 X V 7 h 1 FEB 22 H 00 Z Ze E Z HID 2 4 7 7 gt 2 gt 7 21 Jl Lcv x3 52 TSK ESV 2 Felip ERRER ATTA LERT LYR DIF BARA CUINES EX Er LIEU ZORN k 2 om b 05322 EIELETS EE lt 7 0 t gt F 1 UTW SE RIL TOIMIA 720 xd Aer PAY RAY F 0 99 5 PSC IR FAL T lt HSV 2 RA AIT L CUZ b RIL ZO 5 7059 lt 7 9 ET 7 gt 7 EA 3 568i 0 27 7611 F232 TH lt E 85 7704 KES DAL gt AJ C 5 7 02 2 Uv 5358234 0 ET 3 CL 3 gt ET VENEZA gt D gt lt 2 bb EJ 7 Z Wi H Ge L 07 5 7 0 RUHE CAD BACCO AWARDS 3 4 2 f RTE23 35 0 ET 4 Bip SL Sick 2221 lt lt RAV 5 WDE 23 LI C 6 4227 99 AMEN C lt C CHU D BA YY EU EREANS L BRBOWEIYV TCM 1 2 L7 7 22 7I3 0 L90 2 C lt JE RF 1 funi Clas A CSA LET CRF E SPARES 90 E Ox 49 2318 6 7 gt 15 HE 6 7 11LI372 5 72 D 3 7 7
115. lacement Procedure Step 1 At Menu Display select Lamp from Test menu If using console set intensity to 100 open beam size iris and focus for hard edge A Note Allow five minutes for lamp to achieve full temperature pressure Step 2 Position beam on a white wall at a distance of 10 to 20 feet Step 3 Atbackcap using X Y and Z adjustment screws adjust beam as required Backcap lt CAUTION RISK OF FIRE USE ONLY 1200 WATT H TYPE 100V METAL HALIDE LAMP SFc10 4 BASE ATTENTION N RISQUE D INCENDIE UTILISER UNIQUEMENT UNE LAMPA HALOGENE EN METAL DE TYPE H 1200 WATT 100V ET UN SUPPORT SFc10 4 CAUTION RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION DO NOT OPERATE WITHOUT COMPLETE LAMP ENCLOSURE PLACE WHEN LENS IS DAMAGED DISCONNECT FIXTURE BEFORE RELAMPING CAUTION HOT LAMP DO NOT OPEN FOR 5 MINUTES AFTER SWITCHING OFF Figure 2 2 Lamp Alignment 02 9678 0010 G 19 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Lamp Power Cut Off Switch The lower fan duct assembly is equipped with a lamp power cut off switch If the hinged duct is raised during operation the relay automatically disengages and the lamp will douse When the duct is closed lamp power is restored The fan duct assembly is located on the bottom half of the luminaire head as shown below Top Head Cover 1 4 Turn Screw Bottom H
116. llation 2 8 4 Apply 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 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 Tilt Motor Assembly 138 02 9678 0010 G ASSEMBLY YOKE ASSEMBLY 3 Yoke Fan Assembly 22 9661 0609 Rev C VL3000 22 9678 0609 Rev A VL3000Q Refer to Figure 3 46 No Item Qty UM Description 1 10 9661 0646 1 EA FAN TRAY 2 40 7113 0001 1 EA FAN 24V 80 X 80 X 25MM 32 3 53 2200 0006 1 EA NUT 6 32 KEPS SS 4 55 2179 0003 1 EA CABLE SADDLE 75 X 75 AWAY VL3000 QUIET NOT SHOWN 5 55 2186 0001 1 EA CABLE TIE 10 WD X 4 LG VL3000 QUIET NOT SHOWN 2 Direction of air flow Wire Connection Orientation Figure 3 46 Yoke Fan Assembly 02 9678 0010 G 139 VARF amp LITEG VL3000 amp VL3000 Q SERVICE MANUAL Not
117. lt Gobol Gobo2 Gobo3 Phase 3 Gobol Index Gobo2 Index Gobo3 Index Color Wheel Dimmer Phase 4 Edge Beam Spreader wash only CTO Blue Amber Magenta Phase 5 Pan Zoom Beam 02 9678 0010G TESTING AUTO RECALIBRATION x Auto Recalibration Most mechanisms with sensors will check their sensor when at a zero position if the sensor 15 not detected within 3 seconds the mechanism will recalibrate This applies to all except pan and tilt pan and tilt are corrected continuously if required by encoders fitted to the motor shaft 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 Hold DMX value 102 for 3 seconds then 0 recalls color Color wheel CYM CTO Dimmer e Hold DMX value 114 for 3 seconds then 0 recalls gobos Gobo wheels and Index Hold DMX value 128 for 3 seconds then recalls lenses Edge Zoom or beam spreader Hold DMX value 140 for 3 seconds then 0 recalls dimmer and strobe Sensor Testing Most mechanisms within the VL3000 luminaire are equipped with either optical or magnetic sensors The VL3000 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 enc
118. ly 16 02 9678 0010G TROUBLESHOOTING TROUBLESHOOTING GUIDE Table 2 2 Troubleshooting Guide Continued Message Description Symptom Possible Cause and Remedy Pan No Sens Pan Sensor Not Found Luminaire will not pan 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 Pan belt disconnected extremely loose or not installed properly properly install belt between pan motor and large pulley Tilt Encoder Fail Tilt Encoder Failure Luminaire will not tilt 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 Tilt Sensor Not Found Luminaire will not tilt 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 Failure Color dimmer or strobe mechanisms will not move MCB connector disconnected check MCB connector at J11 Check
119. ly 21 9678 0243 Rev 0 Iris Assembly 21 9678 0270 Rev A Hot Box Assembly 21 9678 8640 01 Rev H VL3000 Spot Head to Back Cap Ground Cable Assembly 25 9661 1522 Rev B Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Dual Fan Tray Duct Assembly VL3000 Only 21 9678 0660 01 Rev B Head Front Fan Assembly 23 9678 0684 Rev 0 Continued on page 59 VL3000 Spot Luminaire 20 9678 0001 Rev T VL3000 Spot eneric Luminaire Assemblies 21 9678 0010 01 Rev Head Structure Assembly 21 9678 0600 Rev C Backend Assembly 21 9678 0615 VL3000 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0639 Rev G VL3000 Yoke to AC Fan Cable Assembly 25 9678 0012 Rev A Backcap Interlok to Gobo Fan Interlok Cable Assembly 25 9678 0014 Rev B Air Duct OT Switch Cable Assembly 25 9678 0691 Rev 0 VL3000 Yoke Assembly 21 9678 0700 Rev J VL3000 Upper Enclosure Assembl 21 9678 0800 01 Rev NN VL3000 Rod Clamp Assembly 22 9678 0149 Rev B Gobo Clamp Assembly 22 9678 0693 Rev A Color Clamp Assembly 22 9678 0694 Rev A Edge Lead Screw Assembly 22 9678 1126 Rev B VL3000 Controller 24 9678 3730 Rev 0 Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Front Head Fans Cable Assembly 25 9678 0677 Rev B Head Controller Cable Assembly 25 9678 0715 Rev C Included Items Kit
120. m Qty UM Description 1 52 6396 3104 1 EA RECEPT 4POS 100 W POL TAB BLU CLSD END changed 05 03 06 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 4 73 5126 0002 2 67 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt 172 A Y Figure 3 71 Front Head Fans Cable Assembly 02 9678 0010 G CABLE ASSEMBLIES YOKE FAN AND RELAY CABLE ASSEMBLY 3 Yoke Fan and Relay Cable Assembly 25 9678 0681 Rev C Refer to Figure 3 72 No Item Qty UM Description l 52 6396 3103 1 EA RECEPT 3 POS 100 W POL TAB BLU CLSD END changed 05 01 06 2 52 6423 0003 1 EA HOUSING 3 POS MT RECEPT 2MM 3 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG 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 Figure 3 72 Yoke Fan and Relay Cable Assembly 02 9678 0010 G 173 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Yoke Fan and Relay Cable Assembly VL3000Q 25 9678 0781 Rev A Refer to Figure 3 72 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 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 5 55 2268 0125 1 IN HEATSHRINK 1 8 CLEAR
121. mbly 22 9678 0481 Rev B Color Sense PCB 2 Mount Assembly 22 9678 0489 Rev B Color Interconnect PCB Cable Assembly 25 9678 1409 Rev 0 VL3000 Only Continued from page 67 Yoke Assembly 21 9678 0700 Rev J VL3000 Tilt Motor Assembly 21 9678 0765 Yoke Fan Assembly 22 9661 0609 Rev C VL3000 Relay to Ignitor Cable Assembly 25 9661 1526 Rev C Fan and Relay Cable Assembly 25 9678 0681 Rev C Yoke Fan Cable Assembly 25 9678 0758 Rev A VL3000Q Wash Luminaire Drawing Tree Part 2 02 9678 0010 G DRAWING TREES VL3000Q WASH LUMINAIRE 3 VL3000Q Wash Luminaire continued Continued from page 67 Upper Enclosure Assembly 21 9678 0801 01 Rev Z VL3000Q Ventilation Cover Assembly VL3000 Quiet 21 9686 0840 02 Rev B VL3000Q Pan Pulley Assembly 21 9678 0807 Rev E Pan Motor Assembly 21 9678 0864 Rev E Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Panel Assembly 21 9678 0805 Rev N DMX Input PCB 24 9663 3895 AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Pan Tube Assembly 21 9678 0881 Rev 0 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C AC Input Splitter Cable Assem
122. mbly estere shamu u eiie 102 Spot Optic Assembly rinn s te endet ree e hi a a 103 Group 4 Lens Mount Assembly 107 Right Edge Bearing Assembly eee a i 108 Lett Edge Bearing Assembly a ener 109 Zoom Cam Assembly i RR pde RI edd 110 Zoom Motor Tensioning Assembly 111 Interconnect Light Shield Assembly 112 Rod Clamp Assembly eee tene ee Ett ee Pune en eerta eee diego 113 Color Dimmer Strobe Assembly ss 114 Motor Adapter Plate Assembly suite 117 Fixed Color Wh el ASSembly tede pep ett oet 118 Strobe Assembly u a et 120 Strobe Assembly VL3000 Quiet 121 Right Strobe Blade Assembly ss 122 Lett Strobe Blade Assemblsy dete de enin 123 VL3000Q Strobe Motor 124 Wheel Assembly 2 125 Gobo Clamp Assembly du E E ERE PORRO 126 Color Clamp Assembly 4 a a Aa S an u m a mq e asss 127 Edge Lead Screw Assembly 5 2 128 Beam Spreader Assembly e trai Fate ene epo Poe eor Rt ep tbe 129 Stationary Concave Lens Assembly a an an nD enne 130 Translating Convex Lens
123. n 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 9678 0010 G FOREWORD 5 9 AK lt 7 Ll BIS SMS BIE TACHA EAN E SERIES 22IXL 9 177 OAT SRI CIA OS FICHE LTS ESO KRV aAT UCL WFOREAV 7 REAL CWET l A HERR RICHES SZ ET RE UV HART BLUAJ ESSE lt 7 DOO RRR 2 lt KEV E 2XX02767L lt gt F 1 VAREKLITEG RIL FU STRATA Kk c 2 7 72570909 8 k 9 5 75 gt TERY TIA 2 RIRE THETA FO k 5 7 4 703 MX 9 1172 C72 0 ET K lt xa 7 V XI9 LC C ESV 3 lt 2 1 4 23261 8 X ACHA 737 loc 4 RIL PAPER E 7 30 02 D S Zg PBB TE LEME lt IM lt 7 202 L gt F 1 CEATA k 2 CWE 920 10 022 V 97 IL 0 172 080 257542789 gt k 90 ET 2 VAREKLITEG RAZ AA Ud 9 229809026 C ES VN 3 2 gt 2
124. nd Cable Assembly esee 165 Head to Back Cap Ground Cable Assembly 166 Relay to Ignitor Cable Assembly 167 Yoke to AC Fan Cable Assembly u uu anush RE Let LG Lee ee Le 168 Backcap Interlok to Gobo Fan Interlok Cable Assembly eee 169 Air Duct OT Switch Cable Assembly ss 170 Relay to Gobo Fan Interlock Cable Assembly ss 171 Front Head Fans Cable Assembly 172 Yoke Fan and Relay Cable Assembly 173 Yoke Fan and Relay Cable Assembly VL3000Q eene 174 OT Switch to Interlok Cable Assembly 175 Ignitor to Lamp Socket Cable Assembly 176 Head Controller Cable Assembly eese ener 177 Color Interconnect PCB Cable Assembly 179 Color Interconnect Quiet PCB Cable Assembly 181 Gobo Interconnect PCB Cable 183 Yoke Fan Cable Assembly 2 52 ocn Eat ree eot Ee rH PEL o td ead 185 Yoke Fan Cable Assembly VL3000Q 186 EMI Filter to Power Switch Cable Assembly 187 AC Input Splitter Cable Assembly un ss 188 Data I O Link Cable Assembly ses 190 Display Cable ote re Rete ig tete ce dat dena 191 Ballast to Controller Cable Assembly 192 DC Output Cable
125. oder readings The values can be used to determine whether a circuit is opening correctly or for further troubleshooting Guidelines values will change depending on whether the sensor reading is Open or Closed e The values will be different depending on the type of sensor optical or magnetic Asa general rule if a change occurs from 5 volts to 0 volts or visa versa then it is working 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 02 9678 0010 G 13 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL 14 Notes regarding specific mechanisms The four color mixers and dimmer will read high when the tab is in the optical sensor The fixed color wheel will read low when the magnet is at the sensor and high at other times The zoom and edge will read high when the sensor is closed or the tab is in the sensor The gobo wheel reads low when the magnet is at the sensor The gobo index rotation reads low when the slot is in the sensor Pan and tilt sensors read high when the tab is in the sensor The mechanism calibrates to the edge
126. om lamp socket Step 4 Position new lamp with dimple side down towards reflector One side at a time press lamp into lamp socket connector Ensure lamp is seated fully in place Note Dimple on lamp must be towards reflector as described above Position lamp before lamp is AN seated into lamp holder Because of the tension of the lamp holder trying to turn or reposition the lamp once installed is difficult and may break the lamp Step 5 Close lamp box and re tighten 1 4 turn screws Step 0 Align lamp for flat field after power up as detailed in Align Lamp on page 19 Lamp dimple side down A CUS Lamp Connector Do not touch lamp or CAUTION reflector with bare fingers Reflector SS EN gt Lamp Box NS Luminaire Head Not Shown For Clarity Figure 2 1 Lamp Replacement 18 02 9678 0010 G MAINTENANCE PROCEDURES ALIGN LAMP 2 Align Lamp The design of the VL3000 luminaire optical system allows for a flat or peaked field A flat field is one where there is no detectable hot spot and a peaked field is one where the intensity of the beam is greater at the center of the beam than at the perimeter After a new lamp is installed it will be necessary to align the lamp to optimize the beam Knobs located at the luminaire s backcap will allow adjustment WARNING adjustment knobs will be HOT during lamp operation Wear gloves to prevent burns Repair Rep
127. on 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 VARI KLITE AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les luminaires 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 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9678 0010 G vii VARIKLITE VL3000 amp VL3000 Q 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 affect e doivent tre remplac s par exemple s il y a des fissures ou de profondes rayures AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES ACCIDENTS POUVANT ENTRAINER DES BLESSURES 1
128. on instructions refer to the luminaire s user manual This manual is available in both printed and electronic PDF formats VL3000 Series Luminaire User s Manual 02 9678 0001 and e VL3000Q Series Luminaire User s Manual 02 9678 0005 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 02 9678 0010 G 1 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Customer Service Our Goal At Vari Lite we are committed to providing you the highest quality in customer service Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari Lite customer Whether your needs are telephone troubleshooting assistance product training or technical service our full time staff of experienced professionals are on hand to provide support How to Reach Us For assistance in your area call the dealer from which your product s were purchased Or Contact an Authorized Service Center Or Contact the Vari Lite Customer Service Department 9am 6pm CST Monday through Friday at the following phone 1 877 VARI LITE 1 877 827 4548 or 1 214 647 7880 fax 1 214 647 8038 E mail customerservice genlytecontrols com Additional Resources For addition
129. ount Assembly 22 9678 0489 Rev B Color Interconnect PCB Cable Assembly 25 9678 1409 Rev 0 VL3000 Only Continued from page 64 Yoke Assembly 21 9678 0700 Rev J VL3000 Tilt Motor Assembly 21 9678 0765 Yoke Fan Assembly 22 9661 0609 Rev C VL3000 Relay to Ignitor Cable Assembly 25 9661 1526 Rev C Fan and Relay Cable Assembly 25 9678 0681 Rev C Yoke Fan Cable Assembly 25 9678 0758 Rev A Figure 3 8 VL3000 Wash Luminaire Drawing Tree Part 2 02 9678 0010 G 65 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 Wash Luminaire continued Continued from page 64 Upper Enclosure Assembly 21 9678 0800 01 Rev NN VL3000 Ventilation Cover Assembly Standard 21 9678 1254 Rev 0 VL3000 Pan Pulley Assembly 21 9678 0807 Rev E Pan Motor Assembly 21 9678 0864 Rev E Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Panel Assembly 21 9678 0805 Rev N DMX Input PCB 24 9663 3895 AC Input Pigtail Cable Assembly 25 9678 0810 Rev B Pan Tube Assembly 21 9678 0881 Rev 0 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C AC Input Splitter Cable Assembly 25 9678 0812 Data
130. quier 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 ADVERTENCIA INSTRUCCIONES PARA PROTECCION CONTINUA CONTRA CHOQUE ELECTRICO 1 Lasluminarias est n disef 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 3 Hlservicio debe ser realizado solamente por personal calificado 02 9678 0010 G ix VARIKLITE VL3000 amp VL3000 Q 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 Es peligroso operar luminarias sin lentes o protectores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido da adas y que su efectividad pudiera estar deteriorada Por ejemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA 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
131. quipment 3 Servicing to be performed by qualified personnel only 02 9678 0010 G iii VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1 Many 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 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 Wear eye protection when relamping 5 Appropriate safety equipment gloves eye protection should be used when handling damaged lamps 6 Iflamp is touched with bare hands clean lamp with dena
132. rectives 73 23 EEC LVD and 89 336 EEC EMC 02 9678 0010 G 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 A 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 Series 3000 luminaires require an Osram HMI 1200 W S metal halide lamp 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 luminaires WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1 VARI LITE luminaires are designed for dry locations only Exposure to rain or moisture may damage luminaire 2 Disconnect power before servicing any VAREKLITE G e
133. res L Black AC Wires V Red DC Wires V Black DC Wires Step 4 Remove one 6 32x3 8 LG PPZ screw Step 5 Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 At Display PCB remove two 6 32x3 8 PPZ screws remove Display stiffener bracket and lift PCB out of slot on bottom of chassis Step 7 Carefully disconnect wiring from PCB Step 8 Replace by performing steps 2 through 7 in reverse order LVS Power Supply U 2 OSS Display ROS i PN Display Panel Assembly I Display Cover Display Panel os Assembly NOTE Some components not shown for clarity Display Figure 2 21 VL3000 Display PCB Assembly Replacement 02 9678 0010 G 55 VARF amp LITEG VL3000 amp VL3000 Q SERVICE MANUAL Notes 56 02 9678 0010G 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3000 and VL3000Q luminaire assemblies Drawing Trees Top Assembly Head Assembly Yoke Assembly Head Yoke PCB Assemblies Enclosure Assembly Cable Assemblies 02 9678 0010 G AN 57 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Drawing Trees VL3000 Spot Luminaire Spot Gobo Assembly 21 9678 0200 Rev K Spot Only Rotating Gobo Wheel Assembly 21 9678 0210 Rev B Rotating Effects Wheel Assembly 21 9678 0211 Rev B Long Shaft Motor Assemb
134. rier with fingers pressing gobo toward front end of luminaire toward lens and out of wheel Step 6 Install new gobo as follows a Align three tabs on gobo carrier with three notches in wheel gobo can only be oriented in one direction b Insert gobo carrier into wheel ensuring that carrier snaps into place Step 7 Close fan duct assembly and replace covers A Note For standard gobo and gag part numbers See Included Items Kit Spot on page 70 02 9678 0010 G 21 VL3000 VL3000 Q SERVICE MANUAL Gobo Replacement continued Gobo Wheel see detail Head covers are attached by tethers A Do not touch glass with bare fingers CAUTION Press on gobo carrier only Gobo Wheel Gobo Assembly Carrier Front of luminaire NN Press from this side Figure 2 4 Gobo Replacement 22 02 9678 0010 G MAINTENANCE PROCEDURES COLOR FILTER REPLACEMENT 2 Color Filter Replacement WARNING Remove power from luminaire before performing maintenance Filters may be HOT after operation Allow to cool before replacing Repair Replacement Procedure Step 1 Remove power from luminaire Step 2 Remove top head cover by loosening four 1 4 turn screws as shown in Figure 2 5 CAUTION Do not touch filters with bare fingers Wear cotton gloves or other covering while replacing Clean with isopropyl alcohol and soft cloth if required Step 3 Rota
135. rruption 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 syst me est r gl pour le statut de mise en marche de la lampe 2 La position Br ler est Universelle viii 02 9678 0010 G 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 Lasluminarias han sido disefiadas para ser usadas solamente con algunas l mparas Tome nota del tipo de l mpara Osram HMI 1200 W S metal halide lamp antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cual
136. rs and remove ventilation cover Remove both handles by removing two 10 32x5 8 PPB screws at each 8 At enclosure bottom remove four 6 32x1 4 PPB screws and both side covers 10 11 12 13 14 At enclosure bottom remove two 6 32x3 8 PPB screws APS side bracket and front cover from ballast side At ballast disconnect wiring Pull wires through ferrite core At bottom of enclosure remove three 8 32x3 8 PFZ screws and two 8 32x3 8 PPZ screws which secure ballast module to enclosure Remove ballast module Install replacement assembly by performing Steps 2 13 in reverse order Refer to figure and table on page 47 02 9678 0010G MAINTENANCE PROCEDURES BALLAST ASSEMBLY REPLACEMENT 2 Table 3 VL3000 Ballast Connector Locations Location Connector J102 2 Pos Connector J103 3 Pos Mate N Lok J108 Red 1 Choke J109 Dark Blue 2 Choke J110 Orange 3 Choke J111 Orange 4 Choke J112 8 Pos MTA J113 3 Pos MTA J202 Lamp Wires Black J203 Lamp Wires White J204 Light Blue Choke J205 Red Choke 1 10 32x5 8 PPB Screw 2 Front Cover 8 M APS Side Bracket Side Cover 2 ig 6 32 3 8 PPZ Screw 8 2 Ferrite core Pull wires through here Ballast lll Module NOTE Some components not shown for clarity 8 32 3 8 PFZ Screw 3 8 32x3 8 PPZ Screws 2 Figure 2
137. sing 80 mm Fan Shield Orientation Figure 3 3 84 22 30 31 32 S lt 18 x2 Backend Assembly 02 9678 0010 G HEAD ASSEMBLY 80MM FAN ASSEMBLY 3 80mm Fan Assembly 21 9678 0619 Rev B Refer to Figure 3 4 No Item Qty UM Description l 40 7145 0004 1 EA FAN TUBEAXIAL 80 X 80 X 38mm 28 230V added 03 11 04 2 53 2200 0006 4 EA NUT 6 32 KEPS SS 3 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 4 55 7016 0001 1 EA FAN GUARD 80MM NICKEL PLATED STEEL WIRE Figure 3 4 80mm Fan Assembly 02 9678 0010 G 85 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL UV Filter Bulkhead Assembly 22 9678 0639 Rev G VL3000 22 9678 0617 Rev A VL3000Q Refer to Figure 3 5 No Item Qty UM Description 1 10 9678 0634 1 UV FILTER BULKHEAD 2 10 9678 0648 2 EA CLIP UV GLASS 3 41 9678 0608 1 EA UV IR FILTER 3 00 X 3 00 VL3000 Only 41 9678 1160 1 UV IR FILTER ENHANCED VL3000Q Only 4 53 6530 0002 4 1 8 POP 063 125 GRIP ALUM 1 amp E N N amp UV Filter Installation 7 1 Install filter with marks indicating IR coating side of filter facing located outside of circular 4 OS N cutout in bulkhead CX i Apply a drop of Loctite 5083 NUVA SIL Curing 8 A Silicone to each corner of filter Drop size to NS produce 0 25 diameter circl
138. tage Power Supply LVS 34 Gobo Assembly Replacement n soles 8 89 35 Gobo Timing Adjustments er e te itte tente na linear opta 36 Gobo Gear Planet Alignment ses 38 Spot Optic Assembly Replacement ss 40 Tilt Motor Assembly and Tilt Belt Replacement ee ceceeeeeseeeeeecnceeseceeeeeseeeaeecaeeeaeenes 42 Tilt Encoder PEB Replacement Ee ie hits HC ERES 44 Tilt BOT Sensor Repl cement iere 45 Ballast Assembly Replacement eese ss 46 80MM Fan Replacements nanesi epit tee a wees de hee Son 49 Transfer Fan Assembly Replacement 51 Gobo Color Dual Fan Assembly 52 Yoke Fan Assembly x2 Replacement ss 53 Upper Enclosure Fan Assembly Replacement eese rennen 54 Display Assembly Replacement eese eee enne nennen etre 55 Chapter 3 Illustrated Parts Breakdown Drawing Trees X 58 M E30000 Spot Luminaires nine ste nn nt teen sane 61 VL3000 Wash LEuninaite 2 ant 64 VL30000 Wash LUMINATE seen
139. te color wheel until required filter position is accessible Step 4 Press spring lock back until color filter is free and remove filter Step 5 Install new filter coated side must be oriented towards lamp ensuring that it is securely in position Step 0 Replace head cover 2 Head Cover 1 4 Screw Color Wheel see detail A Do not touch filter with bare fingers CAUTION Wear cotton gloves Color Filter Spring Lock Color Wheel SA Push spring lock back 0 to release color filter gt Head covers attached by tethers Figure 2 5 Color Filter Replacement 02 9678 0010 G 23 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Beam Spreader Wash Only VL Part No 21 9678 0910 Repair Replacement Procedure Step Step Step Step Step Step Step Step Step 24 1 2 Disconnect luminaire AC input cable from power source Remove both top and bottom head covers by loosening four quarter turn captive locking Screws Disconnect wiring for transfer fan and color gobo fans as well as head cable from zoom interconnect PCB Remove transfer fan see procedure on page 51 5 At Beam Spreader remove eight four per side 6 32x3 8 PPZ screws from beam spreader covers and remove covers Loosen four screws on mounting clamps and remove two clamps screws are captive and will not come out At front noise ring of fixture
140. tor shaft from casting Remove guide rods from bearings Carefully pull Optics Assembly from fixture To re install spot optics assembly Step Step Step Step Step Step Step Step Step 40 10 11 12 13 14 15 16 17 18 Thread Actuator shaft into motor until hex head of shaft touches motor Insert guide rods into bearings Carefully place optics assembly back into fixture Align guide rods to be flush with lamp side bracket Install but DO NOT tighten four mounting clamps Check alignment of guide rods by sliding optics assembly back and forth Ensure assembly does not bind Tighten the actuator motor side clamps FIRST Then tighten opposite side Check that optics assembly moves freely If it binds loosen the mounting clamps and reset guides Repeat until lens moves freely Install 8 32 Hex nut on actuator shaft Tighten just enough to keep from spinning Manually run optics assembly back and forth to center actuator arm into casting Then tighten nut 02 9678 0010 G MAINTENANCE PROCEDURES SPOT ASSEMBLY REPLACEMENT 2 Step 19 Finish by performing steps 2 through 4 in the removal section in reverse order Note To prevent binding thread edge screw all the way into linear actuator motor before re installing Secure right side optic assembly clamps first when re installing Top Head Cover Fan Guide Rod Spot Optic Assembly Linear Actuator Motor see detail
141. tured 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 l 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 Arclamps require a period of time to relight after a power interruption or a severe voltage dip In some cases lamp will automatically relight after it has cooled depending on Lamp Power Up State configuration setting 2 Burning position is Universal iv 02 9678 0010 G 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 VorsichtsmaBnahmen 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 ALLGEMEINE HINWEISE BER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUER BERH HTE UV STRAHLUNG UND KORPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VAREKLITEG Scheinwerfer sind ausschli
142. ulley 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 60 Pan Motor Assembly 02 9678 0010 G 161 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Pan Tube Assembly 21 9678 0881 Rev 0 Refer to Figure 3 61 No Item Qty UM Description 1 10 9678 0809 1 EA PAN TOGGLE 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 5 1 468 GRV DIA 068 GRVWD EXTERNAL 6 54 1255 0002 1 EA BEARING ASSY FLUSH MOUNT HOUSING LARGE Figure 3 61 Pan Tube Assembly 162 02 9678 0010 G CABLE ASSEMBLIES SENSOR ELECTRICAL ASSEMBLY 3 Cable Assemblies Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 62 No Item Qty UM Description l 52 6524 0006 l 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 62 Pan EOT Sensor Electrical Assembly 02 9678 0010 G 163 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Refer to Figure 3 63
143. ure 3 60 No Item Qty UM Description 1 10 9678 0865 1 EA PLATE PAN MOTOR MOUNT 2 21 9678 0828 1 EA ASSY DRIVE PULLEY PAN 10 9686 8720 1 EA CODEWHEEL 120 COUNT LARGE ID 10 9678 0749 1 EA TIMING PULLEY 2MM GT 17 TOOTH 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET FLAT POINT 3 24 9678 9729 1 EA PCB ASSY VL3000 PAN ENCODER changed 06 27 07 4 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 7 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 8 55 2132 0014 2 EA STANDOFF 1 4 4 40 1 062 LG CS changed 05 18 06 160 02 9678 0010 6 ENCLOSURE ASSEMBLY PAN MOTOR ASSEMBLY 3 Pan Motor Assembly continued Detail Pressure Sensitive Adhesive See Detail 5 X4 Drive Pulley Detail amp Installation 6 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 Connector oriented on this side Note Vari Lite recommends that this assembly be replaced as a complete assembly Although you can replace only the motor the p
144. ust be aligned so that the mechanism clocks properly This belt is installed around the index gear and top gear of the gobo wheel The wheel position belt is installed around the wheel position gear and bottom gear of the gobo wheel and does not require alignment Each belt is also routed around one pulley For the following steps refer to Figure 2 17 To time gobo wheels Step 1 Position index pulley so that large flange is centered in optical sensor Step 2 Insert 3 long 4 or 3 screw or 0 125 diameter pin completely through aligned holes in wheels and both bulkheads as shown This will lock the wheels in the open position Step 3 To time Gobo Wheel 1 first align outside planet gear timing mark with notch in wheel Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange Step 4 To time Gobo Wheel 2 first align outside planet gear timing mark with mark in sun gear Notch in wheel should be centered between opposite planet gear teeth Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange Step 5 Totime Gobo Wheel 3 first align planet gear timing
145. ut Panel Provides DMX In and Thru and AC Power connections see detail below Backcap Assembly Provides access to lamp for replacement and controls for eam adjustment Yoke Assembly Houses Master Control Board MCB Upper Enclosure Assembly Houses power supply ballast and display board Truss Hook Bracket Attaches to enclosure base to allow truss hook installation Head Assembly Houses color gobo strobe zoom lens and or beam spreader mechanisms dependant on luminaire model Input Panel Components Product Label ID 4 Main Power Switch AC PWR DATAIN THRU N Qc AC Input Cable Data In Menu Display Used to input manual commands program test set defaults and access internal status information 2 A LV MENU ENTER Data Thru Beam Adjustment Controls 02 9678 0010 G VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL VL3000 Spot Luminaire Head and Yoke Components The following illustration shows the major sub assemblies that located in the luminaire head yoke assemblies Head Covers attached by tether Gobo Assembly Contains three rotating gobo wheels and beam Size iris mechanism Color Assembly Contains fixed color wheel me dimmer mechanism strobe Optics Assembly mechanism CYM color mixer Houses
146. w Pan Belt Pan Motor Assembly Figure 2 12 VL3000 Pan Motor Assembly Replacement 02 9678 0010 G 31 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Pan Encoder PCB Replacement VL Part No 24 9678 9729 Repair Replacement Procedure Step 1 Using console or internal menus run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source A CAUTION Be careful not to damage lens during next step Step 3 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Step 4 Atbottom of enclosure remove four 1 4 20x1 2 socket screws and 1 4 split lock washers and remove ventilation cover Step 5 Atencoder PCB remove two 4 40x1 4 PPZ screws Step 6 Disconnect wiring from encoder board Step 7 Replace by performing steps 3 through 6 in reverse order A Note Make sure the encoder disk passes through the optical sensor NOTE gt Head not shown for clarity Enclosure Bottom View Encoder Disk Encoder Bottom Cover Pan Motor Assembly Figure 2 13 VL3000 Pan Encoder PCB Replacement 32 02 9678 0010 G MAINTENANCE PROCEDURES PAN EOT SENSOR REPLACEMENT 2 Pan EOT Sensor Replacement VL Part No 23 9678 0687 Repair Replacement Procedure Step 1 Using console or internal menus run lens as far to the rear as possible Step 2 Disconnect luminaire AC input cable from power source A CAUTI
147. w scroll through any error messages or display OK if there are no errors Table 2 1 Error Messages Display OK Message 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 Index1 No Sens Gobo 1 Index sensor not found Gobo1 No Sens Rotating Gobo 1 sensor not found Index2 No Sens Gobo 2 Index sensor not found Gobo2 No Sens Rotating Gobo 2 sensor not found Index3 No Sens Gobo 3 Index sensor not found Gobo3 No Sens Rotating Gobo 3 sensor not found Dimmer No Sens Dimmer sensor not found Blue No Sens Blue sensor not found Amber No Sens Amber sensor not found Magenta No Sens Magenta sensor not found ColWheel No Sens Color wheel sensor not found CTO No Sens CTO sensor not found Zoom No Sens Zoom sensor not found Edge No Sens Edge sensor not found 02 9678 0010 G 15 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Troubleshooting Guide If a problem is suspected try recalibrating the luminaire to prompt an error message Refer to Error Messages on page 56 for more information The chart below provides possible causes and remedies for each message Table 2 2 Troubleshooting Guide Message Description Symptom Poss
148. wo guide marks on pulley flange Gobo Wheel 2 middle Wheel 1 First align outside planet gear timing mark with notch in wheel Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange Gobo Wheel 1 aft 37 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL 38 Gobo Gear Planet Alignment Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly Use the following procedure to re align the gears in the event the gobo wheel is disassembled To re align gobo gears Step Step Step Step Step 1 Place center sun gear at starting point so that timing mark 15 directly facing Position 1 open as shown in Figure 2 18 Set Position 6 planet gear as follows 3 Rotate center gear clockwise until timing mark is directly facing Position 6 Lift edee of center gear slightly so that it will not turn while at same time rotating Position 6 gear until timing mark is directly across from center gear timing mark Lower center gear into place and verify alignment Set remaining planet gears by following same procedure When all gears are aligned rotate center gear in full rotation to verify alignments and to verify that assembly spins freely When rotating marks should align perfectly
149. y 130 02 9678 0010 G HEAD ASSEMBLY TRANSLATING CONVEX LENS ASSEMBLY 3 Translating Convex Lens Assembly 21 9678 0930 Rev B Wash Only Refer to Figure 3 40 No Item Qty UM Description 1 10 9678 0936 1 EA STOP BEAM SPREADER 2 10 9678 0938 2 EA LENS CLAMP CONVEX 3 12 9678 0166 1 EA MASKED CONVEX LENS ARRAY MEDIUM 4 12 9678 0939 1 EA CONVEX LENS MOUNT MACHINED ADJUSTABLE 5 53 6515 0375 4 EA SCREW 10 32 X 3 8 LG SCB 6 53 6545 0003 2 EA SCREW 8 32 X 3 8 PFZ 7 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM SHAFT 8 55 2114 0001 4 EA WASHER LOCK 10 INTERNAL 9 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 6 x2 L 17 2 x2 5 4 Figure 3 40 Translating Lens Assembly 02 9678 0010 G 131 VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Condenser Lens Assembly 21 9678 0940 Rev C Wash Only Refer to Figure 3 41 No Item Qty UM Description 1 10 9678 0928 2 EA LENS CLAMP BEAM SPREADER 2 10 9678 0941 1 EA HOUSING BEAM SPREADER 3 10 9678 0942 1 EA LEAD SCREW BEAM SPREADER 4 10 9678 0944 1 EA CONDENSER LENS MOUNT 5 23 9678 1120 1 EA LINEAR ACTUATOR ASSEMBLY 6 42 9678 0174 1 EA 127MM CONDENSER LENS 7 53 6552 0001 4 EA SCREW 8 32 X 1 2 PFZ 8 53 6596 0002 4 EA SCREW 4 40 X 5 16 PPZ SEMS changed 3 03 04 9 53 6613 00
150. zoom lens and CTO color correction and edge mechanisms Yoke Arm Cover Fan Assembly Contains lamp power cut off switch so that it cannot be disengaged Main Coniroller Board MCB Luminaire control circuit board Backend Assembly Houses lamp and reflector Provides knobs for lamp Enclosure Assembly adjustment see page 8 02 9678 0010 G COMPONENTS VL3000 WASH LUMINAIRE HEAD AND YOKE COMPONENTS 7 VL3000 Wash Luminaire Head and Yoke Components wASH The following illustration shows the major sub assemblies that are located in the luminaire head and yoke assemblies Head Covers attached by tether Aperture Assembly Used in wash version only Color Assembly Contains fixed color wheel dimmer mechanism strobe mechanism CYM color mixer and CTO oolor correction Yoke Arm Cover Backend Assembly Houses lamp and reflector Provides knobs for lamp adjustment Enclosure Assembly Main Controller Board MCB see next page Luminaire control circuit board 02 9678 0010 G VARIKLITE VL3000 amp VL3000 Q SERVICE MANUAL Enclosure Components The following illustration shows the major sub assemblies that are located in the luminaire enclosure assembly Yoke and head assemblies not shown for clarity Enclosure Top Covers 1200W Arc Ballast Module 150W 24V 6 3 Power Supply Fan Assembly Input Panel Assembly

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