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3 - Vari-Lite

1. 4 5 LTS 6 RF 1 Class A 1
2. Lamp Power Up State 2 02 9678 0018 TABLE CONTENTS Table of Contents Introduction About This Maniak au uuu e e ia de lla mm 1 Additional 1 Customer SIC tu 2 Technical Bulletins and Notices 2 Chapter 1 Description Features gt 4 Specific Features nee ene IRR de une eem EE SNE 4 Technical Specifications ss ss tr e 2 ee I EE E T p IR DI 4 Components External Luminaire Components ss 5 VL3500 Spot Luminaire Head and Yoke Components 6 Rfnclosure OnPDonentStaitriantutN E Bien ui 7 Principles of Operation VL3500 Spot Lummaire eii heard 8 Functional Block Diagram 8 Chapter 2 Maintenance Testing Luminaire EI 10 Calibration Sequence 10 Auto Recalibrat n 2 eue 11 Partial Recalibration tre E ette e e ec ees yu aa 11 Sensor Testing RARE Set LE 11 Troubleshooting 5 5
3. RE 2 3 4 VARI LITE 1 VARI LITE 2 VARI LITE 3 02 9678 0018 B Xi VARIXLITEO VL3500 SPOT LUMINAIRE SERVICE MANUAL Eu UV
4. 1 VARI LITE UV HID 2 BE 1 2 3
5. VARBRLITE we O wD 556 02 9678 00188 HEAD YOKE PCB ASSEMBLIES MOTOR DRIVER PIGGY BACK PCB 3 Motor Driver Piggy Back PCB 24 9678 1732 RevC Refer to Figure 3 53 Note Available only as an assembly Included with 24 9678 4730 VL3500 Controller PCB Assembly H H t H H H Huhn mln n Figure 3 53 Motor Driver Piggy Back PCB 02 9678 0018 B 123 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Refer to Figure 3 54 24 9678 1116 Rev 0 Arc Zoom lnterconnect PCB Assembly Ref Item Qty UM Description 04 9678 1116 00 1 EA LABEL SET ZOOM HARNESS i 11 9678 1116 1 EA PCB ZOOM INTERCONNECT 13 52 6259 0004 1 EA HDR 4POS NTWTA100 SD RT ANG J4 52 6260 0003 1 EA HEADER 2POS MTA 100 SHROUDED 12 52 6447 0009 1 EA HEADER SHROUDED 4 POSITION 52 6467 0003 1 EA CONN FEM PLUG 3POS 30 24AWG 52 6467 0024 3 EA CONTACT SOCKET 30 24AWG CRIMP 52 6598 0028 1 EA HDR 14P 2ROW MODU R A 52 6662 0006 1 EA HOUSING 6POS 125V 2A 2 00 52 8388 0001 4 EA CONTACT 24 30AWG FEMALE CRI 55 2186 0001 1 EA CABLE TIE
6. No Item Qty UM Description 1 52 8312 0001 4 EA RECP FASTON 1 4 18 14 AWG INSULATED 2 55 2186 0001 3 CABLE TIE 10 WD 4 00 LG SMALL 3 55 6699 0003 3 19 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 4 73 7089 0000 34 41 FT WIRE 22 AWG BLK 300V TEFLON STRANDED 5 73 7089 0009 34 41 FT WIRE 22 AWG WHT 300V TEFLON STRANDED 6 73 3516 05604 0 58 WIRE 16 AWG 300V 105 DEG C PVC GRN YEL 111569 7 52 8245 0001 1 EA TERM RING 10 16 14 AWG REEL PIDG 8 73 7130 0005 2 08 FT WIRE TUBULAR BRAID 7 16 9 55 2183 0001 0 33 FT HEATSRINK 1 2 BLACK 7 1 x2 To Relay From Lamp Supply To Relay From Lamp Supply Figure 3 90 Lamp Supply to Relay Cable Assembly 02 9678 0018 B 171 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Gobo Rotate Interconnect Cable Assembly 25 9678 1209 Rev A Refer to Figure 3 91 and Figure 3 92 25 9678 1209 CABLE ASSY GOBO ROTATE INTERCONNECT Figure 3 91 Gobo Rotate Interconnect Cable Assembly 172 02 9678 0018B CABLE ASSEMBLIES GOBO ROTATE INTERCONNECT CABLE ASSEMBLY 3 Gobo Rotate Interconnect Cable Assembly continued FL SENSOR 24 9678 EDCE SENSOR PCE 24 663 Figure 3 92 Gobo Rotate Interconnect Cable Assembly Wire Chart 02 9678 0018 B 173 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25 9678 1716 Rev A Refer to Figure 3
7. 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 200 TFE WHT UL1199 19STRAND 8 73 6222 0010 3 00 FT WIRE 22AWG 600V 200C BLK UL1199 Le Figure 3 71 Yoke To Fan AC Fan Cable Assembly 02 9678 0018 B 149 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Backcap Interlock to Gobo Fan Interlock Cable Assembly 25 9678 0014 Rev B Refer to Figure 3 72 Le 52 8414 0001 aa RECEPT FASTON 187 SERIES 24 20 AWG UNINSUL 73 7089 0000 2 00 FT WIRE 22AWG 300V 200C TEF BLK UL1180 Figure 3 72 Backcap Interlok to Gobo Fan Interlok Cable Assembly 150 02 9678 0018B CABLE ASSEMBLIES RELAY FAN INTERLOCK CABLE ASSEMBLY 3 Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Refer to Figure 3 73 No Item Qty UM Description 1 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG TAPE MOUNT 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 BLK 111180 1 3 Figure 3 73 Relay
8. Module NOTE Some components not shown for clarity 8 32x3 8 PFZ Screw 3 _ 8390 PPZ Screws 2 Figure 2 6 VL3000 Ballast Assembly Replacement See next page for instructions on the new style ballast 02 9678 0018 B 23 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Repair Replacement Procedure New Style Ballast Step Step Step Step 1 Using console or internal menus run lens as far to the rear 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 32x1 4 PPB screws and remove cover A CAUTION Be careful not to damage lens during next step Step 5 Carefully lay luminaire on its side ensuring that lens does not come into contact with any Step Step Step Step Step Step Step Step Step 24 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 6 on page 23 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
9. este 111 Yoke Fan Assembly Si 113 Head Yoke PCB Assemblies Shutter Cable Interconnect Assembly 115 Color Sensor PCB 1 Mount Assembly 116 Color Sensor PCB 2 Mount Assembly nccnnannn canaria noo 117 Color Interconnect PCB Cable Assembly 118 Color Interconnect Quiet PCB Cable Assembly 120 VL3500 Controller PCB Assembly 122 Motor Driver Piggy Back PCB sn an 123 Arc Zoom Interconnect PCB Assembly 124 Enclosure Assembly Upper Enclosure Assembly a rre d ae tbe italia ceci 127 Ventilation Cover Assembly Standard 132 Ventilation Cover Assembly VL3500 Quiet ss 133 Panel Assembly bn e arn daos ree E 135 DMX Input PCB 136 Input Pigtail Cable Assembly een ns 137 Pan Pulley Assembly 138 Pan Motor icis ses eu 139 Pan Tube Assembly eere e erri e o dete de 141 Note Cables are only available as complete assemblies The information contained in this section is for reference only Cable Assemblies Pan EOT Sensor Electrical Assembly 143 LVS Chassis Ground Cable Assembly 144 Chassis Yoke Ground Cable Assembly
10. Main Control Board MCB daughter board attached Figure 2 9 Main Control Board MCB Replacement 02 9678 0018B MAINTENANCE PROCEDURES IGNITOR BOARD REPLACEMENT Ignitor Board Replacement VL Part No 24 9661 3126 To remove and replace ignitor board assembly 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 10 Ignitor Board From Relay Connections To Bulb Lamp Connections NOTE Some components not shown for clarity Figure 2 10 Ignitor Board Replacement 02 9678 0018 B 27 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 28 Pan Motor Assembly Pan Belt Replacement VL Part No 21 9678 0864 Pan Motor VL Part No 54 2055 0001 Pan Belt To remove and replace pan motor assembly pan belt Step 1 Step 2 SteD 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
11. 13 Troubleshooting ti ett cette nn nie 14 Maintenance Procedures Lamp Replacement 16 Align Eamp ecce ee Du S ed a eta A cane EE 17 Lamp Power CuteOPESWIt hu onum ee EE 18 Gobo Replacement Gobo Wheels 1 and 2 19 Color Filter Replacement 2 SS EE 21 Ballast Assembly Replacement ss 22 Color Dimmer Strobe Assembly Replacement ss 25 Main Control Board MCB Replacement ss 26 Isnitor rette e Pete e PER te pete dee eerie eene aedes 27 Pan Motor Assembly Pan Belt Replacement essere 28 02 9678 0018 B xiii VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Pan Encoder PCB Replacement cni ead 30 Pan FOT Sensor Replacement tii Rotor Ee e tete et ee rete certa 31 Power Supply LVS Replacement siens 32 Gobo Shutter Assembly Replacement ss 33 Spot Optic Ass mbly Replaeement u a ss 34 Tilt Motor Assembly and Tilt Belt Replacement 36 Tilt Encoder PC BB Replacement iu ntn tentent ede eren Re Eier 38 Tilt EOT Sensor Replacem nt 5 2 e cer Re 39 Gobo Timing Adjustments aus nee a tp i rdi rera De 40 Gobo Gear Planet Alignment EE 41 Gobo Gear Planet Alignment continued ss 42 C
12. 73 2326 3003 1 04 FT WIRE 26AWG 3COND 300V 200C Figure 3 48 Color Interconnect PCB Cable Assembly VL3500 Only 02 9678 0018B HEAD YOKE PCB ASSEMBLIES COLOR INTERCONNECT PCB CABLE ASSEMBLY 3 Color Interconnect PCB Cable Assembly continued Figure 3 49 Color Interconnect PCB Assembly Wire Chart VL3500 Only 02 9678 0018 B 119 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Color Interconnect Quiet PCB Cable Assembly 25 9678 1419 Rev A VL3500Q Only Refer to Figure 3 50 and Figure 3 51 No Item Qty UM Description 1 24 9678 0409 1 PCB ASSY COLOR INTERCONNECT 2 28 9678 0419 1 EA WIRE KIT COLOR INTERCONNECT 04 9678 0409 00 1 EA LABEL SET COLOR HARNESS 11 9678 0409 1 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 7POS 30 24AWG 52 6467 0024 19 EA CONTACT SOCKET 30 24AWG CRIMP 52 6661 0006 5 EA CONN RECEPT 6CIR WIRE TO 52 6467 0011 1 CONN FEM PLUG 11 POS 30 24AWG 52 6523 0004 2 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 CABLE TIE 09 WD 3 750 LG 73 2326 0123 1734 FT WIRE
13. YOKE CROSSMEMBER HEAT SHIELD 2 10 9678 0658 10 PLATE COUNTERWEIGHT 3 10 9678 0670 1 EA INTERCONNECT PCB MOUNT 4 10 9686 0732 2 EA COVER YOKE THERMOFORM 5 21 9678 0010 02 1 EA ASSY GENERIC LUMINAIRE VL3500 ONLY 21 9678 0011 02 1 EA ASSY GENERIC LUMINAIRE VL3500Q ONLY 6 21 9678 8611 2 EA ASSY HEAD COVER 7 21 9678 8698 01 1 EA ASSY HOT BOX SPOT 8 21 9678 0660 03 1 EA ASSY DUAL FAN TRAY DUCT VL3500 ONLY 21 9678 0659 03 1 EA ASSY DUAL FAN TRAY DUCT VL3500Q ONLY 9 21 9678 1200 1 EA ASSY GOBO SHUTTER MODULE 10 21 9678 1246 1 EA ASSY CABLE INTERCONNECT SHUTTER 11 21 9678 1263 1 ASSY TRANSFER FAN 12 22 9678 0103 1 EA ASSY SPOT OPTIC 13 22 9678 0149 4 ASSY ROD CLAMP 14 22 9678 0402 1 EA ASSY COLOR DIMMER STROBE VL3500 ONLY 22 9678 0462 1 EA ASSY COLOR DIMMER STROBE VL3500Q ONLY 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 4730 1 EA PCB ASSY VL3500 CONTROLLER 25 9678 0675 1 EA CABLE ASSY RELAY TO GOBO FAN not shown 02 9678 0018B AssEMBLY VL3500 SPOT SERIES LUMINAIRE 3 No Item Qty UM Description 25 9678 0677 1 EA CABLE ASSY FRONT HEAD FANS not shown 25 9661 1520 1 CABLE ASSY YOKE TO HEAD GND not shown
14. eese 145 Head to Back Cap Ground Cable Assembly 146 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Ignitor to Relay Cable Assembly ss 147 LVS to Yoke AC Fan Cable Assembly ss 148 Yoke to AC Fan Cable Assembly eiie be e PR EUR Hans 149 Backcap Interlock to Gobo Fan Interlock Cable Assembly 150 Relay to Gobo Fan Interlock Cable Assembly 151 Front Head Fans Cable Assembly 152 Yoke Fan Relay Standard Cable Assembly 153 Air Duct OT Switch Cable Assembly ss 154 Yoke Fan and Relay Quiet Cable Assembly ss 155 Yoke Fan Standard Cable Assembly ss 156 Yoke Fan Quiet Cable Assembly sise 157 Ignitor to Lamp Socket Cable 158 Head Controller Cable Assembly 000000000 nennen enne nennen 159 Shutter Disk Cable Assembly isc nS EE 161 EMI Filter to Power Switch Cable Assembly 163 AC Input Splitter Cable Assembly 164 Data VO Link Cable Assembly u nn en ana 166 Display Cable Assembly 3 e hE eet it 167 Ballast to Controller Cable Assembly 168 DC Output Cable Assembly nenne erregen hi 169 Pan Tilt Control Cable Assembly ss 170 Lamp Supply to Relay Cable Assembly 171 Gobo Rotate Interconnect Cable Assembly 172 LVS Chassis Ground Cable Assembly 174 Appendix A Technical Bulletins VL3500 amp VL3500Q Technical Bulletins 175 XVi 02 9678
15. 02 9678 0018 B ASSEMBLY GENERIC LUMINAIRE ASSEMBLY 3 Generic Luminaire Assembly 21 9678 0010 02 Rev H VL3500 Only 21 9678 0011 02 Rev C VL3500Q Only Refer to Figure 3 9 02 9678 0018 B No Item Qty UM Description 1 21 9678 0600 1 EA ASSY HEAD STRUCTURE 21 9678 0601 1 EA ASSEMBLY HEAD STRUCTURE QUIET 2 21 9678 0700 1 EA ASSY YOKE 21 9678 0701 1 EA ASSEMBLY YOKE QUIET 3 21 9678 0707 1 EA ASSEMBLY 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 0006 3 EA RIVET 1 8 OD POP 0 188 0 250GL 4 21 9678 0767 1 EA ASSEMBLY STABILIZER 4a 10 9678 0757 1 EA STABILIZER 1 377 DIA 4b 10 9678 0762 1 EA BRACKET STABILIZER 4c 53 6610 0003 1 EA SCREW 6 32 X 7 16 PPZ 4d 55 6568 0075 1 EA SPRING EXTSN 0 375 OD 1 00 LG 0 041 WIRE DIA 5 21 9678 0800 02 1 EA ASSY UPPER ENCLOSURE 21 9678 0801 02 1 EA ASSEMBLY UPPER ENCLOSURE QUIET 6 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK 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 0 500 LG H X HD GRADE 5 BLK 9 16 HEX HEAD X 0 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 PFB UNDERCUT 11 53 6624 0001 4 EA SCREW 10 32 X 1 2 LG P
16. No Item Qty UM Description l 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 2 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 3 86 7002 0003 1 SWITCH SLOTTED OPTICAL 1 3 Figure 3 65 Pan EOT Sensor Electrical Assembly 02 9678 0018 B 143 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25 9661 1514 Rev 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 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 144 Figure 3 66 LVS Chassis Ground Cable Assembly 02 9678 0018B CABLE ASSEMBLIES CHASSIS TO YOKE GROUND CABLE ASSEMBLY 3 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Refer to Figure 3 67 No Item Qty UM Description 1 52 8250 0006 2 EA TERM 8 RING 10AWG 2 73 7089 0504 15 17 FT WIRE 22 AWG 300V 200C TEF GRN YEL UL1180 102 2 7 x 26 0 LG Figure 3 67 Chassis To Yoke Ground Cable Assembly 02 9678 0018 B 145 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Head to Back Cap Ground Cable Assembly 25 9661 1522 Rev C Refer to Figure 3 68 No Item Qty UM Description 1 52 8250 0014 2 EA TERM RING 10 16 14 AWG NON INS REEL 2 73 7130 0001 1 33 FT WIRE 7 64 TUBULAR BRAID TINNED C
17. Rotating Gobo Wheel Assembly Shutter Assembly Shutter 21 9678 1510 Rev J 21 9678 1205 Rev B Rotating Gobo Wheel Assembly Shutter Motor Disk Assembly 21 9678 1210 Rev 0 21 9678 1515 Rev E UV Filter Bulkhead Assembly 80mm Fan Assembly 22 9678 0639 Rev G VL3500 21 9678 0619 Rev B VL3500 and VL3500 Quiet Fixed Gobo Wheel Assembly 21 9678 1410 RevB Air Duct OT Switch Cable Yoke to AC Fan Cable Assembly Assembly 25 9678 0012 RevA 25 9678 0691 Rev 0 Backcap Interlock to Gobo Fan Interlock Cable Assembly 25 9678 0014 Rev B Figure 3 2 VL3500 Spot Luminaire Subassembly Drawing Tree Part 2 02 9678 0018 B 45 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Luminaire continued continued from page 44 Upper Enclosure Assembly 21 9678 0800 02 Rev NN VL3500 Ventilation Cover Assembly Standard 21 9678 1254 Rev 0 Pan Pulley Assembly 21 9678 0807 Rev E Pan Motor Assembly 21 9678 0864 Rev E Pan Tube Assembly 21 9678 0881 Rev 0 Upper Enclosure Fan Assembly 23 9678 0686 Rev 0 Panel Assembly 21 9678 0805 Rev N DMX Input PCB 24 9663 3895 AC Input Pigtail Cable Assembly 21 9678 0807 Rev E Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Gobo Rotate Interconnect Cable Assembly 25 9678 0843 Rev A Figure 3 3 VL3500 Spot Luminaire Subassembly Drawing Tree Part 3 46 Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A LVS Chassis Ground Cable Assembly 25 9
18. 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 0018 B 83 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 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 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 PCB ASSY VL3000 ZOOM SENSOR 28 53 2004 0002 1 EA NUT 8 32 KEPS ZINC PLATE 29 53 2213 0001 EA NUT 6 KEPS changed 03 24 04 30 53 5564 0250 2 SCREW 6 32 X 1 4 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 X 8MM LG PFZ METR 33 53 6558 0009 17 EA SCREW 6 32 X 3 8 SEMS changed 03 24 04 34 53 6558 0016 1 EA 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 PP
19. ss 79 Head Front Fan Quiet Assembly ss 80 Transfer Fan Assembly ee ia 81 spot Optic Assembly 5 aedi ete e eee t e 83 Group Lens Assembly RR Eee tennis donee te t 87 Right Edge Bearing Assembly u a ie TH d ee bee ee 88 Left Edge Bearing Assembly eee tite ERAT SEI Re ERE ste shinies pue 89 CS MM 90 XIV 02 9678 00188 TABLE CONTENTS Zoom Motor Tensioning Assembly ss 91 Interconnect Light Shield Assembly 92 Rod Clamp Assembly 0 93 Color Dimmer Strobe Assembly 94 Motor Adapter Plate Assembly 5 4 e 97 Fixed Color Wheel Assembly nennen 98 Strobe Assembly cie nein ehe as 100 strobe Quiet Assembly u rei ere pet tr e HEY hist 101 Right Strobe Blade Assembly esee 102 Left Strobe Blade Assembly nennen nn 103 Strobe Motor Quiet Assembly sise 104 Dimmer Wheel Assembly nada dictados bd Me plena 105 Gobo Clamp Assembly oret eee metti tdeo Ri 106 Color Clamp Assembly 0 rhe cities inte eie EP EP E 107 Edge lead Screw Assembly te nter bete ena e c aa 108 Yoke Assembly Yoke Assembly 109 Motor Assembly rire te te cites eec e eb Lee ike ae Fea pa Led
20. Manual VL3500 amp VL3500 Q Spot Luminaires 02 9678 0018 2 Service NL AN PHILIPS VARISLITE VARI LITE is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries VL500 VL1000 VL2000 VL2201 VL2202 VL2400 and the individual product designations VL3000 VL3500 Series 500 Series 1000 Series 2000 Series 3000 DICHROXTUNE VAREKIMAGE VAREKBRITE and the Vari Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC VARIXLITEO products are protected by one or more of the following patents and other pending patent applications worldwide U S Patents No 6 809 869 6 796 682 6 769 792 6 578 987 6 550 939 6 282 027 6 123 436 6 113 252 6 046 861 6 031 749 6 011 640 5 969 868 5 959 768 5 934 794 5 882 107 5 829 868 5 825 548 5 798 619 5 774 273 5 769 527 5 758 956 5 728 994 5 640 061 5 590 954 5 454 477 5 432 691 5 367 444 5 329 431 5 307 295 5 282 121 5 278 742 5 209 560 5 186 536 5 073 847 5 010 459 4 980 806 4 972 306 4 800 474 4 779 176 4 701 833 4 602 321 U S Design Patents No 524 245 457 678 452 339 451 890 442 944 439 356 420 332 417 300 415 301 414 888 413 995 377 338 366 712 359 574 350 408 347 113 Australia Patents No 693 691 683 695 667 109 649 264 646 588 586 095 576 400 Australia Design Patents No 128 796 128 795 Canada Patents No 2 070 670 2
21. SCREW 6 32 X 1 4 LG PPZ BLACK 44 53 6558 0015 4 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 02 9678 0018B ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 No Item Qty UM Description 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 50 53 6653 0502 4 EA SCREW 1 4 20 X 1 2 LG SOC VL3500 Only 51 54 1206 0014 2 EA RING RETAINING 52 54 1255 0001 1 EA BEARING ASSY BLACK FLUSH MOU 53 54 2055 0001 1 EA BELT TIMING S2M 210GROOVE 9MM 54 55 2150 0003 2 EA STANDOFF 1 4 6 32 1 125 L 55 55 2178 0001 3 EA CABLE ANCHOR MOUNT 8 SCREW 56 55 2179 0001 3 EA CABLE ANCHOR MOUNT 6 SCREW 57 55 2186 0001 5 EA CABLE TIE 0 10 WD 4 00 LG SMALL not shown 58 55 2261 0001 1 EA 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 65 55 6568 0074 2 EA SPRING CPRSN 420 OD 750 LG 0 055 DIA WIRE 66 55 6575 0001 4 EA S
22. SHUTTER DISK CABLE ASSEMBLY 3 Shutter Disk Cable Assembly 25 9678 1717 Rev A Refer to Figure 3 81 No Item Qty UM Description 1 04 9678 1717 00 1 EA LABEL SET SHUTTER DISK HARNESS 2 52 6610 0040 1 EA CONN HOUSING 40 POS DBL ROW UNLOADED 3 52 6224 1040 1 EA COVER FRONT 40 POS MT LATCH 4 52 6224 2040 1 EA COVER BACK 40 POS MT 5 52 6696 0001 8 EA RECEPTACLE WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 6 52 6694 0001 32 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2 MM PITCH 28 24 AWG 7 52 8351 0004 32 EA CONTACT 26 22 AWG RECPT MTE REEL 8 55 6699 0009 14 00 FT SLEEVING 3 8 NOM SIA POLY EXP BRAIDED FLAME RET 9 73 5127 0003 15 00 FT WIRE 26 AWG 300V 200 DEG RED 10 73 5127 0005 15 00 FT WIRE 26 AWG 300V 200 DEG YELLOW 11 73 5127 0006 15 00 FT WIRE 26 AWG 300V 200 BLUE 12 73 5127 0008 15 00 FT WIRE 26 AWG 300V 200 ORANGE 02 9678 0018 161 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Shutter Disk Cable Assembly continued 5 X8 6 X8 9 10 11 12 Figure 3 82 Shutter Disk Cable Assembly 162 02 9678 0018 B CABLE ASSEMBLIES EMI FILTER TO POWER SWITCH CABLE ASSEMBLY 3 EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev Refer to Figure 3 83 No Item Qty UM Description 1 52 8313 0001 2 EA RCPT FAST
23. SPOT LUMINAIRE SERVICE MANUAL Head Cover Assembly 21 9678 8611 Rev Refer to Figure 3 2 No Item Qty UM Description 1 10 9678 0612 1 EA HEAD COVER FOAM BAFFLE 2 10 9678 0649 4 EA EJECTOR SPRING BLACK OXIDE 3 10 9678 0674 1 EA BRACKET COVER TETHER 4 10 9678 0696 1 EA FOAM FRAME HEAD COVER 5 12 9678 8610 1 EA HEAD COVER PAINTED 6 53 6558 0003 1 EA SCREW 6 32 X 3 8 LG PPZ PLASTIC THD ROLL 7 53 5655 0250 4 EA SCREW 6 32 X 1 4 LG PPZ PLASTIC THD ROLL 8 55 2233 0016 4 EA RETAINER SPLIT RING 9 55 2233 0775 4 EA STUD 1 4 TURN OPR 775L STEEL 10 55 9676 0255 4 EA WASHER BELLEVILLE SPRING D 58 Bottom View Bottom View Figure 3 2 Head Cover Assembly 02 9678 0018B HEAD ASSEMBLY BACKCAP ASSEMBLY 3 Backcap Assembly 21 9678 0615 Rev T VL3500 Only 21 9678 0616 Rev H VL3500Q Only Refer to Figure 3 3 No Item Qty UM Description l 10 9678 0631 1 EA SEPARATION BULKHEAD 2 10 9678 8635 1 EA EXHAUST BULKHEAD 3 10 9678 0637 2 CLIP RETRO REFLECTOR 4 10 9678 0638 1 EA AIR DIVERTER STROBE MOTOR 5 10 0678 0653 1 LIGHT BAFFLE EXHAUST 6 12 9678 7152 1 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 TE
24. Spring Figure 2 23 Tilt Motor Assembly Replacement 02 9678 0018 B 37 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Tilt Encoder PCB Replacement VL Part No 24 9661 9629 To remove and replace tilt encoder PCB Step 1 Disconnect luminaire AC input cable from power source Step 2 At tilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws Step 3 At tilt 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 40x1 4 LG PPZ screws and remove encoder PCB Step 8 Replace by performing steps 2 through 7 in reverse order A Note Make sure encoder disk passes through sensor when installing encoder PCB 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 Assembly Tilt Belt Spring Sensor Bracket Figure 2 24 Tilt Encoder PCB Replacement 38 02 9678 0018 B MAINTENANCE PROCEDURES TILT EOT SENSOR REPLACEMENT Tilt EOT Sensor Replacement VL Part No 23 9661 1253 To remove and replace tilt EOT sensor Step 1 Dis
25. 22 9678 1126 Rev B Refer to Figure 3 41 No Item Qty 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 Note Apply one drop of Loctite 272 to the threads of item 1 Figure 3 41 Edge Lead Screw Assembly 108 02 9678 0018B ASSEMBLY YOKE ASSEMBLY 3 Yoke Assembly Yoke Assembly 21 9678 0700 Rev J VL3500 21 9678 0701 Rev B VL3500Q Refer to Figure 3 42 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 22 966 1 0609 2 ASSY YOKE FAN 22 9678 0609 2 EA ASSY YOKE FAN VL3500 QUIET 5 22 9686 0705 l 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 TO RELAY NOT SHOWN 25 9678 0681 1 EA CABLE ASSY YOKE FAN AND RELAY NOT SHOWN B 25 9678 0781 1 EA CABLE ASSY YOKE FAN AND RELAY VL3500 QUIET NOT SHOWN 25 9678 0758 1 EA CABLE ASSY YOKE FAN NOT SHOWN 25 9678 0759 1 EA CABLE ASSY YOKE FAN VL3500 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 11 53 5634 0250 8 EA SCREW 4 4
26. Phase 1 Strobe Rotating Shutter Assembly Color Wheel Phase 2 Dimmer Shutter Frame 1A Shutter Frame 18 Shutter Frame 2A Shutter Frame 2B Phase 3 Shutter Frame 3A Shutter Frame 3B Shutter Frame 4A Shutter Frame 4B Phase 4 Edge CTO Yellow Magenta Phase 5 Pan Zoom Cyan Phase 5 Index 1 Rotating Gobo Fixed Gobo 02 9678 0018B TESTING AUTO RECALIBRATION 2 Auto Recalibration Most mechanisms with sensors will check their sensor when at a zero position if the sensor is not detected within 3 seconds the mechanism will recalibrate This applies to all except pan and tilt and zoom and edge Pan and tilt are corrected continuously if required by encoders fitted to the motor shaft Note Colors CTO and CYM will only auto recalibrate when the dimmer has been closed for 3 N seconds Partial Recalibration It is possible to recalibrate sections of the luminaire from a console This allows greater flexibility and speed by only forcing a recalibration on specific mechanisms Partial recalibration values on the control channel are as follows e Hold DMX value 102 for 3 seconds then 0 recals color Color wheel CYM CTO Dimmer Hold DMX value 114 for 3 seconds then 0 recals gobos Gobo wheels and Index Hold DMX value 128 for 3 seconds then recals lenses Edge Zoom and Shutter Hold DMX value 140 for 3 second
27. Pull assembly straight up and out of luminaire Replace assembly by performing steps 2 through 6 in reverse order Top Head Cover Color Dimmer Strobe Assembly gt 2 22 x 8 Color Dimme 25 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Main Control Board MCB Replacement VL Part No 24 9678 1730 To remove and replace main control board MCB 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 Step Step Step Step Step 26 3 Disconnect wiring harness connectors J2 on daughter board J8 J9 J10 and J11 Remove two 6 32 x 3 8 PPZ screws and remove daughter board 5 At MCB remove two 6 32 x 1 4 standoffs two 6 32 x 3 4 PPZ screws and gently tilt MCB away from yoke assembly 6 Disconnect wiring harness connectors J1 J2 J3 J4 and J12 at back of MCB Install replacement assembly by performing steps 2 through 6 in reverse order Configure using menu functions as necessary Yoke Leg Cover
28. Quiet Assembly 23 9678 0699 Rev A VL3500Q Only Refer to Figure 3 19 No Item Qty UM Description l 40 7125 0001 1 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 HEAT SHRINK 1 8 CLEAR KYNAR UL 600V 150 DEG C 6 60 8440 6801 1 EA RESISTOR 10W 5 68 OHM WIREWOUND 1 3 x2 4 80 Figure 3 19 Head Front Fan Assembly VL3500Q Only 02 9678 0018B HEAD ASSEMBLY TRANSFER FAN ASSEMBLY 3 Transfer Fan Assembly 21 9678 1263 Rev 0 Refer to Figure 3 20 No Item Qty UM Description 1 10 9678 0679 1 EA TRANSFER FAN TRAY 2 22 9678 1280 1 EA SHIELD ASSY SHUTTER ROTATE HARNESS 3 23 9678 0695 1 ASSY TRANSFER 4 53 6558 0001 1 SCREW 6 32 X 375 LG PPZ 5 53 6571 0003 3 SCREW 6 32 X 1 500 LG PPB 6 55 2179 0001 1 EA CABLE ANCHOR 6 SCREW MOUNT 55 2186 0001 2 CABLE TIE 10 WD 4 LG SMALL not shown 7 55 6543 0001 2 12 IN GROMMET STRIP SERRATED POLYETHYLENE 8 55 6769 0004 2 TWIST LOK 0 55 ID NOM WHT 85 C MAX FLAME RET 5 gt gt gt 3 1 1 j 5 4 Jo j 6 1 8 x2 Figure 3 20 Transfer Fan Assembly 02 9678 0018 B 81 V
29. 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 any 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 At enclosure bottom remove two 6 32x1 4 PPB screws and pan motor side cover 10 11 12 13 14 15 At side of enclosure remove two 6 32x3 8 PFZ screws and 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 performing 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 or internal menus run lens as far to the rear as pos
30. 050 375 1 270 675 1 259 058 Canada Design Patents No 81 234 81 233 76 046 European UK Patents No 0 652 400 0 586 049 0 565 218 0 547 732 0 534 710 0 495 305 0 474 202 0 379 970 0 253 082 0 253 081 0 248 974 0 192 882 Germany Patents No 694 25 943 8 693 14 122 0 692 08 615 3 692 07 692 1 691 31 478 0 691 21 029 2 690 33 385 4 37 89 166 9 37 68 727 1 37 51 804 6 37 50 201 8 35 87 270 5 Germany Design Patents No M 98 01 745 4 M 96 04 515 9 M 96 04 514 0 M 94 07 689 8 M 94 02 951 2 M 499 03 583 6 M 498 11 203 9 G 93 12 884 3 Spain Patents No 2 090 191 2 084 289 2 020 960 0 548 328 Spain Utility Model Patent No 2 031 748 Spain Design Patents No 0 137 502 0 137 501 0 133 573 Greece Patent No 910 400 544 Japan Patents No 2 843 696 2 059 669 2 055 324 2 002 168 1 966 525 1 889 481 1 792 721 1 770 241 Japan Design Patents No 985 985 1 985 985 947 552 945 436 1 945 436 1 106 089 1 077 598 1 072 598 1 060 414 1 002 123 Korea Patents No 76 310 42 639 283 770 181 180 Korea Design Patents No 209 896 209 895 Mexico Patent No 180 148 Taiwan Patents No 78 726 66 975 65 380 28 275 United Kingdom Design Registrations No 2082526 2072562 2056387 2056386 2042174 2038212 2033108 2029499 All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or organizations Vari Lite A Ph
31. 25 9678 1715 1 EA CABLE ASSY HEAD CONTROL not shown 28 9678 0020 1 EA INCLUDED ITEMS KIT VL3500 SHUTTER 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 2202 0008 1 EA NUT 8 32 HEX SS NYLON INSERT 22 53 6523 0013 8 EA SCREW 6 32 X 3 8 PTB 23 53 6558 0007 4 EA SCREW 6 32 X 1 4 LG PPZ SEMS EXT ZINC PLT 24 53 6558 0009 8 EA SCREW 6 32 X 3 8 LG PPZ SEMS 25 53 6558 0016 2 EA SCREW 6 32 X 3 4 LG PPB ZINC SEMS EXT 26 53 6579 0001 4 EA SCREW 10 32 X 1 2 SCB 27 53 6613 0001 2 EA SCREW 6 32 X 1 2 PPZ 28 53 6614 0003 4 EA SCREW 6 32 X 5 8 PFZ 29 53 6616 0001 4 EA SCREW 6 32 X 3 4 PPZ 30 55 2141 0001 2 EA STANDOFF 5 16 HEX 6 32 X 7 16 LG MF 31 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 188 LG MF STL 32 55 2284 0001 2 EA CARD GUIDE 3 LONG SNAP IN 33 55 6506 0024 2 EA SPACER 3 16 RND 0 1875 LG 0 141 34 55 6528 0001 2 EA WASHER 6 FLAT ZINC 35 55 6573 0001 2 EA HARDENED SHAFT 10 MM DIA X 200 36 55 6677 0033 4 EA WASHER 0 201 OD 0 125 ID 0 032 THK FLAT SS 37 10 9678 0671 1 INTERCONNECT PCB MOUNT RG 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 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Series Luminaire continued Figure 3 8 VL3500 Series Spot Luminaire 54
32. 27 A Optical Sensor Oke Detail G3 G3 30 2 G2 G2 Figure 3 22 Spot Optic Assembly View 2 31 5 Detail G1 G1 86 02 9678 0018 B HEAD ASSEMBLY GROUP 4 LENS ASSEMBLY 3 Group 4 Lens Assembly 22 9678 0199 Rev 0 Refer to Figure 3 23 No Item Qty UM Description l 12 9678 0198 2 EA RING BLOCK MACHINED G4 2 22 9678 0174 1 EA LENS ASSY GROUP 4 3 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 4 55 3303 0006 4 EA WASHER 6 LOCK INT TOOTH SS 5 55 6763 0500 4 EA PIN DOWEL 0 5 LG 0 125 DIA 30355 Figure 3 23 G4 Lens Mount Assembly 02 9678 0018 B 87 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Right Edge Bearing Assembly 22 9678 1103 Rev C Refer to Figure 3 24 No Item Qty UM Description 1 12 9678 1102 1 EA EDGE BEARING MACHINED RIGHT 2 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM 3 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 2 x4 3 x2 Figure 3 24 Right Edge Bearing Assembly 88 02 9678 0018B HEAD ASSEMBLY LEFT EDGE BEARING ASSEMBLY 3 Left Edge Bearing Assembly 22 9678 1105 Rev C Refer to Figure 3 25 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 00
33. 40 10 3 53 6513 0002 4 EA SCREW X 5MM LG PFZ METR 2 Note orientation of adapter plate in relation to the motor Figure 3 31 Motor Adapter Plate Assembly 02 9678 0018 B 97 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Fixed Color Wheel Assembly 21 9678 0334 Rev D Refer to Figure 3 32 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 l EA COLOR FILTER KELLY GREEN VL3000 7 41 9678 0305 03 l 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 l EA MAGNET 2 17 SMCO 2MM X 2MM X 3MM 14 55 6568 0076 6 EA SPRING CPRSN 0 120 OD 0 750 LG 15 10 9678 0250 1 EA 98 02 9678 0018 HEAD ASSEMBLY FIXED COLOR WHEEL ASSEMBLY 3 Fixed Color Wheel Assembly continued 12 x3 9 pos 2 d 7 ORANGE gt OS1 J POS3 NN CONGO KELLY GREEN f POSH 95 DARK
34. 93 No Item Qty UM Description 1 52 8231 0005 1 EA TERMINAL RING 6 BLUE 16 14 AWG REEL PIDG 1 52 8231 0008 1 EA TERMINAL SPADE 6 RED 22 16 AWG INSERT 2 73 3516 0504 1 08 FT WIRE 16 AWG 300V 105 DEG C PVC lt GRN YEL gt UL1569 Figure 3 93 LVS Chassis Ground Cable Assembly 174 02 9678 0018B APPENDIX A APPENDIX A VL3500 amp VL3500Q TECHNICAL BULLETINS A Technical Bulletins VL3500 amp VL3500Q Technical Bulletins The following table identifies the current technical bulletins associated with the Series 3000 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 S3K 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 Spot and Wash S3K 0
35. Box Luminaire Head Not Shown For Clarity Figure 2 1 Lamp Replacement 16 02 9678 0018 B MAINTENANCE PROCEDURES ALIGN LAMP 2 Align Lamp The design of the VL3500 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 A WARNING Backcap and adjustment knobs will be HOT during lamp operation Wear gloves to prevent burns To align lamp Step 1 At Menu Display select Lamp from Config menu If using console set intensity to 100 open beam size iris and focus for hard edge Step 2 Position beam on a white wall at a distance of 10 to 20 feet Step 3 At backcap using X Y and Z adjustment screws adjust beam as required Backcap CAUTION RISK OF FIRE USE ONLY 1200 WATT H TYPE 100V METAL HALIDE LAMP SFc10 4 BASE ATTENTION RISQUE D INCENDIE UTILISER UNIQUEMENT UNE LAMPA HALOGENE EN METAL DE TYPE H 1200 WATT 100V ET UN SUPPORT SFc10 4 CAUTION X Horizontal RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION DO NOT OPERATE WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LENS IS DAMAGED DISCONNECT FIXTURE BEFORE RELAMPING CAUTI
36. MOUNT 9 25 9678 1717 1 EA CABLE ASSEMBLY SHUTTER DISK 02 9678 0018 B 73 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 74 Shutter Motor Disk Assembly continued 5 x8 Frame 4B Frame 4A 7 x10 Frame 1A S Frame 3B Frame 1B Y Frame 3A Frame 2A Frame 2B Figure 3 14 Shutter Motor Disk Assembly 02 9678 0018B HEAD ASSEMBLY Box ASSEMBLY 3 Hot Box Assembly 21 9678 8698 01 Rev F Refer to Figure 3 15 No Item Qty UM Description 1 10 9678 0043 03 1 EA LABEL PLATE VL3000 BACKCAP BLACK 2 10 9678 0641 1 EA HOT BOX 3 10 9686 0642 1 EA BACKCAP PLATE 4 10 9678 0643 1 EA LAMP ADJUST STOP 5 10 0678 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 CLAMP PRIMARY REFLECTOR 9 12 9678 7151 1 EA REFLECTOR PRI 40 LUNE DUAL CURVATURE 25 9661 1522 1 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 11 53 5508 0375 2 SCREW 8 32 X 3 8 PPSS 12 53 6530 0013 8 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 15 55 2233 0006 4 EA STUD 1 4
37. Rev 0 Gobo Rotate Interconnect Cable Assembly 25 9678 1209 Rev Shutter Rotate Roller Assembly 22 9678 1550 Rev B Rotating Gobo Wheel Assembly Shutter Assembly Shutter 21 9678 1510 Rev J 21 9678 1205 Rev Rotating Gobo Wheel Assembly 21 9678 1210 Rev 0 Shutter Motor Disk Assembly 21 9678 1515 RevE Fixed Gobo Wheel Assembly 21 9678 1410 RevB Zoom Motor Tensioning Assembly Right Strobe Blade Assembly continued from previous page Color Dimmer Strobe Assembly 22 9678 0462 Rev E VL3500Q Motor Adapter Plate Assembly Fixed Color Wheel Assembly 21 9678 0331 Rev 0 21 9678 0334 Rev D Strobe Quiet Assembly 22 9678 0463 Rev B VL3500Q Only Dimmer Wheel Assembly 22 9678 0435 Rev D Dimmer Wheel Assembly 22 9678 0467 Rev C 22 9678 0435 Rev D Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Left Strobe Blade Assembly 22 9678 0468 Rev C Color Sensor PCB 2 Mount Assembly 22 9678 0489 Rev B Color Interconnect Quiet PCB Cable Assembly 25 9678 1419 RevA VL3500Q Only continued from previous page Backcap Assembly 21 9678 0616 Rev H VL3500Q Only UV Filter Bulkhead Assembly 80mm Fan Assembly 22 9678 0617 Rev D VL3500 21 9678 0619 Rev B VL3500 Q and VL3500 Quiet Yoke to AC Fan Cable Assembly 25 9678 0012 RevA Air Duct OT Switch Cable Assembly 25 9678 0690 Rev 0 VL3500Q Backcap Interlock to Gobo Fan Interlock Cable Assembly 25 9678 0014 Rev B Figure 3 5 V
38. Rev E Yoke Fan Assembly 22 9661 0609 Rev C VL3500 Ignitor to Relay Cable Assembly 25 9661 1526 Rev C Yoke Fan and Relay Standard Cable Assembly 25 9678 0681 Rev C VL3500 Only Yoke Fan Standard Cable Assembly 25 9678 0758 Rev A VL3500 Only Upper Enclosure Assembly 21 9678 0800 02 Rev NN VL3500 Only continued on page 46 Head Cover Assembly 21 9678 8611 Rev Hot Box Assembly 21 9678 8698 01 Rev F Dual Fan Tray Duct Standard Assembly 21 9678 0660 03 Rev B VL3500 Only Head Front Fan Standard Assembly 23 9678 0684 Rev 0 VL3500 Only Shutter Cable Interconnect Assembly 21 9678 1246 Rev A Gobo Shutter Assembly 21 9678 1200 Rev G continued next page Color Dimmer Strobe Assembly 22 9678 0402 Rev N VL3500 continued next page Transfer Fan Assembly 21 9678 1263 Rev 0 Rod Clamp Assembly 22 9678 0149 Rev B Edge Lead Screw Assembly 22 9678 1126 Rev B VL3500 Controller PCB Assembly 24 9678 4730 Rev F Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Front Head Fans Cable Assembly 25 9678 0677 Rev B Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Head Controller Cable Assembly 25 9678 1715 Rev Included Kit Spot 28 9678 0020 Rev E Gobo Clamp Assembly 22 9678 0693 Rev A Color Clamp Assembly 22 9678 0694 Rev A Spot Optic Assembly 22 9678 0103 Rev S continued next page Figure 3 1 VL3500 Spot
39. SCREW 4 40 X 3 16 PFZ 8 54 2007 0001 2 EA RING RETAINING EXTERNAL 1 4 SHAFT DIA 9 54 2057 0001 1 EA TIMING BELT MXL 144 GRV 188 WD KEVLAR 10 54 2061 0001 1 EA TIMING BELT MXL 144 GRV 125 WD KEVLAR 11 55 2110 0002 2 EA WASHER 400 OD 260 ID 010 THK FLAT SS 12 55 6506 0034 1 EA SPACER 375 OD 257 ID 063 LG AL 13 55 6520 0001 2 EA WASHER WAVE SPRING 265 ID 367 OD 006 THK Figure 3 7 Rotating Gobo Wheel Assembly 02 9678 0018 B 65 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Fixed Gobo Wheel Assembly 21 9678 1410 Rev B Refer to Figure 3 8 No Item Qty UM Description 1 10 9678 0250 1 EA MAGNET TAPE 375 W x 625 L x 0035 THICK 2 10 9678 1412 1 EA PLATE ROTATING WHEEL 3 10 9678 1425 6 EA FIXED RETAINING WIRE 4 22 9678 1415 1 EA ASSY PULLEY FIXED WHEEL HUB 5 53 6601 0002 12 EA SCREW 4 40 X 3 16 PTHZ 6 53 6650 0001 3 EA SCREW 2 56 X 5 16 PPZ 7 55 2256 0001 1 EA MAGNET 2 17 SMCO 2MM X 2MM X 3MM 8 55 3301 0008 6 EA WASHER 8 FLAT SS 9 55 6568 0078 6 EA SPRING CURVED DISK 322 OD 174 ID 005 T 66 Figure 3 8 Fixed Gobo Wheel Assembly 02 9678 0018 B HEAD ASSEMBLY ROTATING WHEEL ASSEMBLY 3 Rotating Gobo Wheel Assembly 21 9678 1210 Rev 0 Refer to Figure 3 9 No Item Qty UM Description 1 10 9678 0250 1 EA MAG
40. Se IN A y SIA UY PT See re gt gt a es En 57 dire Night Sky Palm Leaves Tribal Break Up Circle of Ovals Pebbles 13 14 15 AX 404 4 N Triangle Break Up Shock Break Up Alpha Rays Glacier Gag Ice Blocks Gag 18 Multi Colored Gobo Figure 3 7 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 0018 B 51 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Series Luminaire 20 9678 0019 Rev H VL3500 Only 20 9678 0020 Rev VL3500Q Only Refer to Figure 3 8 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 LABEL LINE CORD WARNING not shown 04 9678 0063 1 LABEL AC INPUT RATING VL3500 VL3500 ONLY not shown 04 9678 1000 2 EA LABEL WHITE ROHS COMPLIANT not shown 04 9678 1001 2 EA LABEL GREEN ROHS COMPLIANT not shown 04 9678 0064 1 LABEL AC INPUT RATING VL3500Q 1 35000 ONLY not shown 10 9678 0609 1 FRONT FILTER FOAM ZOOM not shown l 10 9686 0617 1
41. TURN OPR 455L STEEL 16 55 6546 0004 3 EA WASHER TEFLON 201ID X 4380 17 55 6568 0077 7 EA SPRING CPRSN 300 0D 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 12 06 06 02 9678 0018 B 75 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Hot Box Assembly continued 14 4 12 x8 15 4 76 8 x4 17 4 18 x4 Figure 3 15 Hot Box Assembly 7 4 13 x4 02 9678 0018 B HEAD ASSEMBLY DUAL FAN DUcT STANDARD ASSEMBLY 3 Dual Fan Tray Duct Standard Assembly 21 9678 0660 03 Rev B VL3500 Only Refer to Figure 3 16 No Item Qty UM Description 1 10 9678 0665 1 EA SPRING EXTENSION ELONGATED HOOKS 2 22 9678 0661 1 EA ASSY FAN TRAY 3 22 9678 1265 1 EA DUCT ASSY SHUTTER GOBO 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 WASHER 6 NYLON NATURAL 9 55 6818 0002 1 STANDOFF 45 DEG NYLON 6 6 KUR 10 74 1099 0001 1 EA SWITCH MINIATURE 5 150DEG Spring installed as shown Figure 3 16 Dual Fan Tray Duct Standard Assembly VL3500 Only 02 9678 0018 B 77 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL
42. UL1015 164 02 9678 0018 B CABLE ASSEMBLIES AC INPUT SPLITTER CABLE ASSEMBLY 3 AC Input Splitter Cable Assembly continued 4 x2 x2 Se 5 9 13 7 11 6 2 1 Note Heatshrink not shown for clarity Figure 3 84 AC Input Splitter Cable Assembly 02 9678 0018 B 165 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Data I O Link Cable Assembly 25 9678 0813 Rev A Refer to Figure 3 85 No Item Qty UM Description 1 52 6396 2904 1 RECEPT 4 POS MTA100 W POL RED CLSD END changed 05 03 06 2 52 6396 2905 1 EA RECEPT 5 POS MTA100 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 85 Data I O Link Cable Assembly 166 02 9678 0018B CABLE ASSEMBLIES DISPLAY CABLE ASSEMBLY 3 Display Cable Assembly 25 9678 1825 Rev C Refer to Figure 3 86 No Item Qty UM Description 1 52 6396 2406 2 EA RECEPT 6 POS MTA100 W POL 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 FT WIRE TUBULAR BRAID 1 8 X 23 LG 5 73 6224 0005 0 208 FT WIRE 24AWG 600V 200C 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 x
43. WIRE 18 AWG HI VOLT RED YOKE LMP 11 73 7060 0002 2 08 FT WIRE 18 AWG HI VOLT BLK YOKE LMP 3 x2 6 6 8 Figure 3 88 DC Output Cable Assembly 02 9678 0018 B 169 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Pan Tilt Control Cable Assembly 25 9678 0818 Rev B Refer to Figure 3 89 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 COVER FRONT 20 POS MT LATCHING 3 52 6224 2020 1 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 200C lt RED YEL BLU gt UL1213 10 73 5124 1289 6 17 FT WIRE 24 AWG SCOND 300V 80C BLK BRN RED GRY WHT 11 52 8351 0004 16 EA CONTACT 26 22 AWG RECP MTE REEL added 05 03 06 170 1 2 8 11 x16 4 7 x5 10 5 6 x3 5 6 x3 4 7 x5 Figure 3 89 Pan Tilt Control Cable Assembly 02 9678 0018 B CABLE ASSEMBLIES LAMP SUPPLY TO RELAY CABLE ASSEMBLY 3 Lamp Supply to Relay Cable Assembly 25 9678 0829 RevA Refer to Figure 3 90
44. 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 and its tab covers 50 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 0018B TROUBLESHOOTING ERROR MESSAGES 2 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 at a time until the end of the list is reached To review the error messages again it will be necessary to access them using the Status fu
45. antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalaci n Vea las instrucciones detalladas en este manual 3 Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las luminarias ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA CHOQUE ELECTRICO 1 Las luminarias VARI LITE est n dise adas solamente para lugares secos La exposici n a la lluvia o humedad pueden da ar la luminaria 2 Desconecte la energ a antes de dar servicio a cualquier equipo de VARI LITEO 3 El servicio debe ser realizado solamente por personal calificado 02 9678 0018 B ix VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA LA EXPOSICI N EXCESIVA DE RADIACI N ULTRA VIOLETA 1 Muchas luminarias usan un tipo de l mpara que produce radiaci n UV NO mire directamente a la l mpara 2 EsS peligroso operar luminarias sin lentes o protectores Debe cambiar los protectores lentes o pantallas ultravioletas si se aprecia que han sido da adas que su efectividad pudiera estar deteriorada Por eJemplo si tuvieran rajaduras o raspaduras profundas ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTRA LESIONES DE PERSONAS 1 Las superficies exteriores
46. to Gobo Fan Interlock Cable Assembly 02 9678 0018 B 151 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Front Head Fans Cable Assembly 25 9678 0677 Rev B Refer to Figure 3 74 No Item Qty UM Description 1 52 6396 3104 1 EA RECEPT 4005 MTA100 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 24 30AWG FEMALE CRIMP 4 73 5126 0002 2 67 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt 152 Y Y Figure 3 74 Front Head Fans Cable Assembly 02 9678 0018 B CABLE ASSEMBLIES YOKE FAN AND RELAY STANDARD CABLE ASSEMBLY 3 Yoke Fan and Relay Standard Cable Assembly 25 9678 0681 Rev C VL3500 Only Refer to Figure 3 75 No Item Qty UM Description 1 52 6396 3103 1 EA RECEPT 3 POS MTA100 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 75 Yoke Fan and Relay Standard Cable Assembly VL3500 Only 02 9678 0018 B 153 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Air Duct OT Switch Cable Assembly 25 9678 0690 Rev 0 VL35000 25 9678 0691 Rev 0 Refer to Figure 3 76 No
47. 0 Refer to Figure 3 57 No Item Qty UM Description l 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 4 10 9678 0894 1 EA 6 AIR SEAL UPPER ENCLOSURE 5 10 9678 0896 1 EA 4 5 AIR SEAL UPPER ENCLOSURE 6 54 1206 0015 4 EA RING RETAINING PRESS ON 1 SH 7 7 4 2 A Z 2 2 7 5 2 2 4 A gt E 6 4 1 x4 Figure 3 57 Ventilation Cover Assembly Standard 132 02 9678 0018B ENCLOSURE ASSEMBLY VENTILATION COVER ASSEMBLY VL3500 QUIET 3 Ventilation Cover Assembly VL3500 Quiet 21 9686 0840 02 Rev B VL3500Q Refer to Figure 3 58 No Item Qty UM Description 1 10 9686 1249 4 EA POST TRUSS HOOK la 10 9678 0850 4 POST TRUSS HOOK SHORT EARLY PRODUCTION 1b 10 9678 0833 4 SPACER 1 25 EARLY PRODUCTION 2 10 9686 0883 1 COVER VENTILATION 3 10 9678 0837 1 AIR SEAL FAN SIDE 4 10 9678 0838 1 EA AIR SEAL APS SIDE 5 10 9678 0835 1 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
48. 0 X 1 4 PFSS BL 12 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 13 53 6558 0009 12 EA SCREW 6 32 X 3 8 LG PPZ SEM 14 53 6626 0001 6 EA SCREW 10 32 X 1 2 PPZ 15 53 6634 0003 2 EA SCREW 3 8 16 X 1 2 LG SOC 16 55 2150 0002 1 EA STANDOFF 1 4 HEX 6 32 1 187 L 17 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNT 18 55 6528 0001 2 EA WASHER 6 FLAT ZINC 19 55 6541 0002 2 EA GROMMET 1 ID 1 3 4 OD 1 3 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 F F AL 02 9678 0018 B 109 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Yoke Assembly continued Figure 3 42 Yoke Assembly 02 9678 0018 B YOKE ASSEMBLY TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21 9678 0765 Rev E Refer to Figure 3 43 No Item Qty UM Description 1 10 9678 0763 1 PLATE TILT MOTOR MOUNT 2 21 9678 0708 1 EA ASSY DRIVE PULLEY 2a 10 9678 0720 1 EA CODEWHEEL 120 COUNT LARGE ID 2b 10 9678 1749 1 EA TIMING PULLEY 17 TOOTH SHORTENED 2 53 5560 0250 2 SCREW 8 32 X 1 4 SET CONE POINT 3 24 9661 9629 1 PCB ASSY PAN TILT ENCODER 4 44 9678 0680 1 MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0006 2 EA NUT 6 32 KEPS SS 6 53 2200 0008 4 EA NUT 8 32 KEPS 7 53 6525 0001 2 EA SCREW 6 32 X 5 16 PPZ 8 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 9 53 6682
49. 00 264 VAC 50 60 Hz 7 to 12 A depending on the AC supply voltage Wire Connection Enclosure Bottom Ventilation Cover Green Yellow AC Ground Blue AC Neutral Brown AC Line International Harmonized Standard 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Principles of Operation VL3500 Spot Luminaire Functional Block Diagram E SHU gt R TC gt gt TRANSFER DUAL HEAD HEAD FAN FANS 8 02 9678 0018B 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Troubleshooting Maintenance Procedures WARNING maintenance procedures to be performed with power removed from the luminaire Never remove cover or backcap while lamp is in oper ation WARNING Maintenance repairs and adjustments should only be performed by a qualified factory trained service technician at an Authorized VAREKLITEG Service Center 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Testing Luminaire Self Tests The luminaire is capable of running self tests by using the TEST menu functions For detailed instructions regarding the luminaire s self test function refer to the VL3500 Spot Luminaire User s Manual 02 9678 0019 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence
50. 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 02 9678 0018 B 111 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Tilt Motor Assembly continued 2 See Detail A Detail 7 x2 ann non SSS Pressure Sensitive Adhesive Pulley Height Detail amp Installation 2 8 4 Apply one drop of Loctite 603 to motor shaft Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Do not allow Loctite to drip into motor bearing Set pulley height as shown above Apply Loctite 242 to pulley set screws Insure set screws are aligned and tightened on flat sides of motor shaft Note Vari Lite recommends that this assembly be replaced as a complete assembly Although you can replace only the motor the pulley Item 2 is bonded to the motor shaft during assembly 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 43 Tilt Motor Assembly 112 02 9678 0018B ASSEMBLY YOKE FAN ASSEMBLY 3 Yoke Fan Assembly 22 9661 0609 Rev C VL3500 22 9678 0609 Rev A VL3500Q Refer to Figure 3 44 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 4 EA NUT 6 32 KEPS SS 55 2179 0003 1 EA CABLE SADDL
51. 0018B INTRODUCTION ABOUT THIS MANUAL Introduction About This Manual A Note The Series 3500 Luminaires share many common assemblies and parts of the Series 3000 Luminaires This manual provides descriptions repair procedures and illustrated parts breakdowns for all configurations of the VL3500 Spot Luminaire The manual is intended for use by Vari Lite personnel and Authorized Service Centers and technicians 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 VL3500 Spot Luminaire 20 9678 0019 Arc VL3500Q Spot Luminaire 20 9678 0020 Arc A Note Performing maintenance procedures may void the product warranty Refer to the Vari Lite Limited Warranty card included in the product shipping package for more information Additional Documentation For complete installation and operation instructions refer to the VL3500 Series Luminaire User s Manual This manual is available in electronic PDF format e VL3500 Series Luminaire User s Manual 02 9678 0019 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 N
52. 1 4 turn screws a To access Wheel 1 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 Wheel 1 also raise hinged fan duct assembly Fan duct has a lamp cutoff switch which will disengage power to lamp Step 4 Rotate gobo 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 glass cleaner and soft cloth if required gt Step 5 For Gobo Wheel 1 a Remove current gobo by carefully pressing on edges of gobo carrier with fingers pressing gobo toward front end of luminaire toward lens and out of wheel b Install new gobo as follows c Align three tabs on gobo carrier with three notches in wheel gobo can only be oriented in one direction d Insert gobo carrier into wheel ensuring that carrier snaps into place e Close fan duct assembly and replace covers Step 6 For Gobo Wheel 2 Release open spring retaining clip as shown in Figure 2 4 a b Slide gobo out of gobo whee 1 Slide new gobo in wheel be sure key on gobo carrier fits into slot d Reinstall close gobo spring retaining clip Ensure clips are positioned correctly and clear position sensor 02 9678 0018 B 19 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL e Replace covers To
53. 10 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 2 x4 Figure 3 25 Left Edge Bearing Assembly 02 9678 0018 B 89 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Zoom Cam Assembly 22 9678 1106 Rev B Refer to Figure 3 26 No Item Qty UM Description 1 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 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 30355 Figure 3 26 Zoom Cam Assembly 90 02 9678 0018B HEAD ASSEMBLY ZOOM MOTOR TENSIONING ASSEMBLY 3 Zoom Motor Tensioning Assembly 22 9678 1113 Rev B Refer to Figure 3 27 No Item Qty UM Description 1 10 9678 0338 1 EA PULLEY ZOOM MOTOR 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 CONE POINT 5 53 6522 0001 2 EA SCREW 6 32 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 27 Zoom Motor Tensioning Assembly 02 9678 0018 B 91 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Interconnect Li
54. 10 Pan Tube Bushing Installation Spot and Wash S3K 011 MCB PCB Wire Protection Strip Spot and Wash S3K 012 80MM Fan Shield Installation Spot and Wash S3K 013 VL3000Q VL3500Q Vent CoverFan Assy Change Q Models Only S3K 014 New Style Ballast Conversion Procedure All Models 02 9678 0018 B 175 VL3500 SPOT LUMINAIRE SERVICE MANUAL Notes 176 02 9678 0018B 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 10 June 2009 Manual Part Number 02 9678 0018 B 2003 2009 A Philips Group Company All rights reserved Printed in the U S A
55. 10 WD 4 00 LG SMALL RI 60 1425 2703 1 EA RES 1 4W 5 270 0 OHM CF 73 2324 0029 54 FT WIRE 24AWG 3CD TW 300V 200C 73 2324 0123 46 FT WIRE 24AWG 4CD TW 300V 200C 02 9678 0018B HEAD YOKE PCB ASSEMBLIES ARC ZOOM INTERCONNECT PCB ASSEMBLY 3 Zoom Interconnect PCB Assembly continued KE REC eee J BABB VARBELTE Figure 3 54 Arc Zoom Interconnect PCB Assembly 02 9678 0018 B 125 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Notes 126 02 9678 0018 B ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly Upper Enclosure Assembly 21 9678 0800 02 Rev NN VL3500 Only 21 9678 0801 02 Rev Z VL3500Q Only Refer to Figure 3 55 and Figure 3 56 02 9678 0018 B No Item Qty UM Description 1 04 9640 0374 1 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 COMPLIANCE VL3500 QUIET 4 06 6032 0009 1 EA CABLE MARKER TIE WHITE 19 X 7 5 10 9661 1258 1 EA BRACKET APS 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 HAN
56. 15 1 EA ASSY SHUTTER MOTOR PLATE 18 53 2202 0004 6 EA NUT 4 40 HEX SS NYLON INSERT 19 53 6659 0003 2 EA SCREW 2 56 X 3 8 PPZ 20 53 6567 0001 16 EA SCREW 4 40 X 1 2 PPZ 21 53 6659 0005 4 EA SCREW 2 56 X 1 4 PFZ 22 53 6659 0014 16 EA SCREW 2 56 X 3 8 PFZ 23 53 6596 0001 8 EA SCREW 4 40 X 5 16 PPZ 24 53 6664 0001 8 EA STANDOFF 1 4 HEX 4 40 3 8 LG FF 25 53 6667 0004 16 EA SCREW 6 32 X 1 8 LG SET BLACK 26 54 1209 0004 8 EA BEARING 0 093 ID 3 16 OD FLANGED SST 27 54 2064 0001 1 EA TIMING BELT MXL 330 188 WD KEVLAR gt 55 2186 0001 17 EA CABLETIE 0 10 X 4 SMALL not shown 02 9678 0018 B 71 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Shutter Assembly continued 9 x4 22 x16 _ 15 x2 19 2 gt gt Y En 26 x8 21 x2 25 x16 Figure 3 13 Shutter Assembly 72 02 9678 0018B HEAD ASSEMBLY SHUTTER MOTOR DISK ASSEMBLY 3 Shutter Motor Disk Assembly 21 9678 1515 Rev E Refer to Figure 3 14 No Item Qty UM Description 1 10 9678 1560 1 EA BASE PLATE SHUTTER 2 44 9678 1517 8 EA MOTOR PANCAKE SIZE 16 47 SHAFT 3 53 2202 0030 4 EA NUT M3 X 5 HEX NYLOC ZINC 4 53 6513 0029 8 SCREW M3 X 12 PFZ 5 53 6513 0045 8 SCREW M3 X 16 PFZ 6 55 2178 0001 4 EA CABLE ANCHOR 8 SCREW MOUNT 7 55 2186 0001 10 EA CABLETIE 10 X 4 SMALL 8 10 9678 1566 8 EA SPACER MOTOR
57. 26AWG 4COND 300V200C 73 2326 7001 201 FT WIRE 26AWG 7COND 3004 200C 73 2326 5001 1 30 FT WIRE 26AWG SCOND 300V 200C TE 73 2326 3003 1 04 FT WIRE 26AWG 3COND 300V 200C 120 Figure 3 50 Color Interconnect PCB Cable Assembly VL3500Q Only 02 9678 0018B HEAD YOKE PCB ASSEMBLIES COLOR INTERCONNECT QUIET PCB CABLE ASSEMBLY 3 Color Interconnect PCB Cable Assembly continued CYAN 5 og te to T DTE MOTOR BRN 12 s BLK RED BLK oe AMBER MOTOR MAGEN MOTOR Figure 3 51 Color Interconnect PCB Assembly Wire Chart VL3500Q Only 02 9678 0018 B 121 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 122 VL3500 Controller PCB Assembly 24 9678 4730 Rev F Refer to Figure 3 52 Note Available only as an assembly Includes 24 9678 3732 Motor Driver Piggy Back PCB ect lt 000000 0000 1030 HHI m 1041 III ERR d ut uti il ll UI LU III IIIIIII 00000 p IED 00 SUEZ 79 BS RU im Figure 3 52 VL3500 Controller PCB TI 0 III III 000 000 El pes des
58. 3 x SSS SSS L1 LI 4 2 02 9678 0018 B Figure 3 86 Display Cable Assembly 167 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Ballast to Controller Cable Assembly 25 9678 0816 Rev A Refer to Figure 3 87 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 100 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 SCOND lt BLK BRN RED GRN WHT gt 2 3 4 Figure 3 87 Ballast to Controller Cable Assembly 168 02 9678 0018B CABLE ASSEMBLIES DC OUTPUT CABLE ASSEMBLY 3 DC Output Cable Assembly 25 9678 0821 Rev E Refer to Figure 3 88 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 CONTACT CRIMP 18 22 AWG SL 156 not shown 5 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 BLUE 150 OD MAX 6 55 2186 0001 4 CABLETIE 01 x 4 00 SMALL 7 55 6699 0003 2 08 FT SLEEVING 1 2 NOM DIA POLY EXP BRAID 8 73 3518 0002 1 58 FT WIRE 18 AWG 300V 105C PVC RED 9 73 3518 0010 1 58 FT WIRE 18 AWG 300V 105C PVC BLK 10 73 7060 0001 2 08 FT
59. 5 9678 1715 Rev A Yoke Fan Assembly 21 9678 1200 Rev G 22 9678 0609 Rev A VL3500Q Included Items Kit Spot continued next page 28 9678 0020 Rev E Ignitor to Relay Cable Assembly 25 9661 1526 Rev Color Dimmer Strobe Assembly 22 9678 0462 Rev E VL3500Q Gobo Clamp Assembly 22 9678 0693 Rev A Yoke Fan and Relay Quiet Cable Assembly 25 9678 0781 Rev A VL3500Q Only continued next page Color Clamp Assembly Transfer Fan Assembly 22 9678 0694 Rev A Yoke Fan Quiet Cable Assembly 21 9678 1263 Rev 0 25 9678 0759 Rev A VL3500Q Only Spot Optic Assembly Rod Clamp Assembly 22 9678 0103 Rev S 22 9678 0149 Rev B Upper Enclosure Assembly 21 9678 0801 02 Rev Z VL3500Q Only continued next page continued on page 46 Figure 3 4 VL3500Q Spot Luminaire Subassembly Drawing Tree Part 1 02 9678 0018 B 47 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL VL3500Q Spot Luminaire continued continued from previous page Spot Optic Assembly 22 9678 0103 Rev S Interconnect Light Shield Assembly 22 9678 1115 Rev D Group 4 Lens Assembly 22 9678 0199 Rev 0 Right Edge Bearing Assembly 22 9678 1103 Rev C Zoom Cam Assembly 22 9678 1106 Rev B Left Edge Bearing Assembly 22 9678 1105 Rev C 22 9678 1113 Rev B continued from previous page Gobo Shutter Assembly 21 9678 1200 Rev G Long Shaft Motor Assembly 21 9678 0243 Rev 0 Roller Pivot Rotate Assembly 21 9678 1555
60. 6549 0001 4 EA WASHER 1 4 SPLIT LOCK 02 9678 0018 133 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly VL3500 Quiet continued 4 S Current Production Early Production Figure 3 58 Ventilation Cover Assembly VL3500 Quiet 134 02 9678 0018 B ENCLOSURE ASSEMBLY PANEL ASSEMBLY 3 Panel Assembly 21 9678 0805 Rev N Refer to Figure 3 59 No Item Qty UM Description 1 10 9678 0852 01 1 EA LAYOUT ENCLOSURE OVERLAY 2 10 9678 0859 1 EA BRACKET INPUT 3 10 9678 0872 1 EA STIFFENER DISPLAY BOARD 4 10 9686 0820 1 EA FILLER PANEL DMX CONNECTOR 5 24 9663 3895 1 EA ASSY DMX INPUT 6 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 7 24 9678 3825 1 EA PCB 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 02 9678 0018 B 6 8 x4 Included with AC Input Cable Figure 3 59 Panel Assembly 135 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL DMX Input PCB 24 9663 3895 Rev 0 Refer to Figure 3 60 No Item Qty UM Description Ref 1 17 9663 3895 1 PCB FAB DMX INPUT 2 52 6259 0006 1 EA HEADER 5
61. 661 1514 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C AC Input Splitter Cable Assembly 25 9678 0812 Rev E Data I O Link Cable Assembly 25 9678 0813 Rev Ballast to Controller Cable Assembly 25 9678 0816 RevA Pan Tilt Control Cable Assembly 25 9678 0818 Rev B DC Output Cable Assembly 25 9678 0821 RevE Display Cable Assembly 25 9678 1825 Rev C LVS Chassis Ground Cable Assembly 25 9678 1716 RevA 02 9678 0018B DRAWING TREES VL3500Q SPOT LUMINAIRE 3 VL3500Q Spot Luminaire VL3500Q Spot Luminaire 20 9678 0020 Rev I VL3500Q Only Generic Luminaire Assembly Head Cover Assembly 21 9678 0011 02 Rev C VL3500Q Edge Lead Screw Assembly Only A 22 9678 1126 Rev B Head Structure Assembly Hot Box Assembly ller PCB A 21 9678 0601 Rev 0 VL3500Q 21 9678 8698 01 Rev F nn Only Dual Fan Tray Duct Quiet Relay to Gobo Fan Interlock Cable Assembly Assembl 21 9678 0659 03 Rev D 25 9678 0675 B VL3500Q Only Backcap Assembly 21 9678 0616 Rev H VL3500Q Only continued next page Head 2 Front Head Fans Cable Assembly Y se bly 99 Rev e 21 9678 0701 Rev B VL3500Q VL3500Q Only Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Shutter Cable Interconnect Assembly 21 9678 1246 Rev A Tilt Motor Assembly 21 9678 0765 Rev E Head Controller Cable Assembly Gobo Shutter Assembly 2
62. 678 0457 02 2 EA SPACER COLOR WHEEL L 190 6 10 9678 0457 03 3 EA SPACER COLOR WHEEL L 123 7 10 9678 0457 04 3 EA SPACER COLOR WHEEL L 031 8 10 9678 0469 1 EA REAR COLOR BULKHEAD 9 10 9678 0485 5 PULLEY COLOR MOTOR 10 21 9678 0331 1 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 BEARING RADIAL FLANGED 0 25 TD 0 625 OD 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 CTO 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 PCB 2 MOUNT 22 24 9678 3240 1 EA ASSY WHEEL POSITION SENSOR 25 9678 1409 1 EA PCB CABLE ASSY COLOR INTERCNT not shown 25 9678 1419 1 EA PCB CABLE ASSY COLOR INTERCNT not shown VL3500 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 26 53 5559 0250 12 SCREW 6 32 X 1 4 SET CONE PO 02 9678 0018B HEAD ASSEMBLY COLOR DIMMER STROBE ASSEMBLY 3 No Item Qty UM
63. 7 10 FUSHIA y POS6 poss WV DEEP MAGENTA S RED 5 8 Figure 3 32 Fixed Color Wheel Assembly 02 9678 0018 B 99 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Strobe Assembly 22 9678 0403 Rev F VL3500 Only Refer to Figure 3 33 No Item Qty UM Description 1 10 9678 0491 4 EA BUMPER STOP STROBE changed on 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 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 4T SILICON RED changed 03 01 04 Set blade assemblies according to dimensions shown Black Side faces away from assembly Figure 3 33 Strobe Assembly VL3500 Only 100 02 9678 0018B HEAD ASSEMBLY STROBE QUIET ASSEMBLY 3 Strobe Quiet Assembly 22 9678 0463 Rev B VL3500Q Only Refer to Figure 3 33 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 22 967
64. 8 0468 1 EA ASSEMBLY LEFT STROBE BLADE 5 23 9678 0499 2 EA 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 THK 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 1 4 TH SILICONE 02 9678 0018 B Figure 3 34 455 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 Strobe Assembly VL3500Q Only 101 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Right Strobe Blade Assembly 22 9678 0467 Rev Refer to Figure 3 35 No Item Qty UM Description l 10 9678 0464 1 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 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 TOOTH SS Reflective Side 4 x2 Figure 3 35 Right Strobe Blade Assembly 102 02 9678 0018B HEAD ASSEMBLY LEFT STROBE BLADE ASSEMBLY 3 Left Strobe Blade Assembly 22 9678 0468 Rev C Refer to Figure 3 36 No Ite
65. 9678 0018 B ENCLOSURE ASSEMBLY PAN MOTOR ASSEMBLY 3 Pan Motor Assembly 21 9678 0864 Rev E Refer to Figure 3 63 No Item Qty UM Description 1 10 9678 0865 1 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 CONE POINT 3 24 9678 9729 1 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 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 HEX 4 40 1 062 LG CS changed 05 18 06 02 9678 0018 B 139 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly continued See Detail 5 x4 J _ 6 4 Connector oriented on this side Detail A Pressure Sensitive Adhesive 2a AS k 55 ZI lt Drive Pulley Detail amp Installation 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 s
66. A NUT 4 40 KEPS SS 28 53 6613 0004 3 EA SCREW 6 32 X 1 2 SCZ 29 10 9678 1645 1 EA FAN SHIELD LAMP COOLING 30 55 6538 0001 2 EA WASHER 4 LOCK INTERNAL TOOTH 14 x4 3 x2 24 x4 16 x4 11 17 x4 30 x2 21 x2 4 19 Figure 3 3 Backcap Assembly 60 02 9678 0018B HEAD ASSEMBLY 80MM FAN ASSEMBLY 3 80mm Fan Assembly 21 9678 0619 Rev B VL3500 and VL3500 Quiet Refer to Figure 3 4 No Item Qty UM Description 1 40 7145 0004 1 EA FAN TUBEAXIAL 80 X 80 X 38MM 230V 28 CFM 2 53 2200 0006 4 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 4 ii 2 2 x4 Figure 3 4 80mm Fan Assembly VL3500 and VL3500 Quiet 02 9678 0018 B 61 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL UV Filter Bulkhead Assembly 22 9678 0617 Rev D VL3500 Q 22 9678 0639 Rev G VL3500 Refer to Figure 3 5 No Item Qty UM Description 1 10 9678 0634 1 EA 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 41 9678 1160 1 EA UV IR FILTER 3 00 X 3 00 VL3500 QUIET 4 53 6530 0002 4 RIVET 1 8 POP 063 125 GRIP ALUM Note Install glass 3 with marks indicating IR coating side of filter facing 4 x4 up and located outside of ci
67. AL Troubleshooting Guide If a problem is suspected try recalibrating the luminaire to prompt an error message Refer to Error Messages on page 13 for more information The chart below provides possible causes and remedies for each message Table 2 2 Troubleshooting Guide Message Symptom Description Possible Cause and Remedy n a No response to DMX data DMX Failure MCB connector disconnected check MCB DATA IN connection n a Lamp douses frequently Lamp Douse Fan failure check fans for proper connection and operation n a Lamp will not strike Lamp Strike Failure Lamp cutout switch disengaged check lamp cutout switches at lamp box and fan ducts Bad lamp replace lamp Low input voltage check input power must be 200 to 264 VAC n a Luminaire behaves oddly Profile Not Matched Profile not set correctly check Setup menu for correct type spot or wash check start DMX address No Sens No control continuous recalibration and or mechanism at wrong position Mechanism failed to find sensor reported for Blue Amber Magenta Col Wheel CTO Gobo1 Index1 Gobo2 Zoom and Edge Motor power not connected connect motor power Sensor not connected connect sensor Interconnect board not connected securely check connection inspect for bent pins Movement restricted or impeded remove obstruction check
68. ARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Notes 82 02 9678 0018 B HEAD ASSEMBLY SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly 22 9678 0103 Rev S Refer to Figure 3 21 and Figure 3 22 No Item Qty UM Description 1 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 amp G2 6 10 9678 0157 1 EA BARREL STRAP G3 7 10 9678 0171 1 EA SHAFT 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 G1 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
69. B 155 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Yoke Fan Standard Cable Assembly 25 9678 0758 Rev VL3500 Only Refer to Figure 3 78 No Item Qty UM Description 1 52 6396 3102 1 EA RECEPT 2POS MTA100 W POL TAB BLUE CLSD END 2 52 6423 0003 1 EA HOUSING 3POS MT RECEPT 2MM 28 26 AWG 3 73 5126 0002 0 50 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt UL1061 19STRND 2 8 Figure 3 78 Yoke Fan Standard Cable Assembly VL3500 Only 156 02 9678 0018B CABLE ASSEMBLIES YOKE FAN CABLE ASSEMBLY 3 Yoke Fan Quiet Cable Assembly 25 9678 0759 Rev A VL3500Q Only Refer to Figure 3 78 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 CT 28 26 AWG 3 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 4 55 2268 0125 1 EA HEASTRINK 1 8 CLEAR KYNAR UL 600V 150 C 5 60 7440 2002 1 EA RESISTOR 5W 5 200 OHM WIREWOUND 6 73 5126 0002 0 50 FT WIRE 26AWG 2COND 300V 80C lt BLK RED gt UL1061 19STRND 2 Figure 3 79 Yoke Fan Quiet Cable Assembly VL3500Q Only 02 9678 0018 B 157 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Rev B Refer to Figure 3 80 No Item
70. BLY 3 Color Sensor PCB 2 Mount Assembly 22 9678 0489 Rev B Refer to Figure 3 47 No Item Qty UM Description 1 10 9678 0452 1 EA PCB MOUNT COLOR SENSOR 2 2 24 9678 3454 1 EA ASSY COLOR SENSOR 2 3 53 6558 0007 2 EA SCREW 6 32 X 1 4 SEMS 3 x2 Figure 3 47 Color Sense PCB 2 Mount Assembly 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Color Interconnect PCB Cable Assembly 25 9678 1409 Rev B VL3500 Only Refer to Figure 3 48 and Figure 3 49 No Item Qty UM Description 1 24 9678 3409 1 EA ASSY COLOR INTERCONNECT 2 28 9678 0409 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 CONN FEM PLUG 7POS 30 24AWG 52 6467 0024 1 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 WD 3 750 LG 73 2326 0123 17 34 FT WIRE 26AWG 4COND 300V200C 73 2326 7001 2 01 FT WIRE 26AWG 7COND 300V 200C TE 73 2326 5001 1 3 FT WIRE 26AWG 5COND 300V 200C TE
71. CLOCKWISE pattern starting with screw in lower left hand side from spring To remove and replace tilt motor belt Step Step Step Step Step Step Step Step 36 8 Disconnect luminaire AC input cable from power source 9 At tilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws 10 At tilt motor assembly loosen four 10 32x1 2 PPZ screws 11 Remove belt from tilt pulley 12 Remove four 10 32x1 2 PPZ screws Be mindful of tensioning springs 13 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 At interconnect disconnect 80MM fan wiring 14 Remove belt 15 Replace by performing steps 2 through 7 in reverse order See next page for further instructions 02 9678 0018B 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 ina 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
72. CREW 10 32 X 3 4 PPB 67 55 6577 0005 2 EA 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 6699 0010 0 50 FT SLEEVING 5 16 NOM DIA WOVEN POLY ROUNDIT 72 55 6775 0009 1 EA BUSHING SNAP 750 TD I MT H 73 67 4018 0001 1 EA FERRITE 26 X 28 5 X 13MM CYL 74 67 4021 0002 1 EA FILTER EMI CCI 75 68 9678 0827 1 EA CHOKE COMMON MODE 76 69 3176 0201 1 EA POWER SUPPLY 200W 24V 8 5A WMTH PLT LAMBDA 77 55 6799 0001 AR EA PAN TUBE BEARING SHIM 1 375 ID 1 875 OD 0 005 THK not shown 78 55 6799 0002 AR EA PAN TUBE BEARING SHIM 1 375 ID 1 875 OD 0 010 THK not shown AR As Required 02 9678 0018 B 129 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly continued Figure 3 55 Upper Enclosure Assembly Part 1 130 02 9678 0018 B ENCLOSURE ASSEMBLY UPPER ENCLOSURE ASSEMBLY 3 Upper Enclosure Assembly continued 67 x2 30 32 Z Part is shown exploded for clarity E Electronics 2 amp 19 Assembly Duct Assembly Pan Tube Assembly CCS 92 Ta S 47 x2 3 31 49 Figure 3 56 Upper Enclosure Assembly Part 2 02 9678 0018 B 131 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly Standard 21 9678 1254 Rev
73. D 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 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 a 25 9678 0821 1 EA CABLE ASSY DC OUTPUT not shown 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 25 9678 1716 l CABLE ASSY LVS CHASSIS GROUND not shown 27 52 8295 0002 1 EA TERMINAL STRIP 300V 12AWG 20 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 5 X 10MM STL CUP PT 33 53 6515 0001 4 EA SCREW 10 32 X 3 4 SCB 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 41 53 6556 0002 1 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 EA
74. DLE CAST ENCLOSURE 10 10 9678 0869 1 EA BRACKET LVS 11 10 9678 0886 1 SPACER PAN BEARING 0 235 THK 12 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN 13 10 9678 1876 1 EA AIR DIST PLENUM 1200W S W BALLAST P S 14 12 9686 1236 2 EA MACHINED COVER FRONT 15 12 9686 1238 2 EA MACHINED COVER SIDE 16 12 9678 0842 1 EA AIR DUCT UPPER ENCLOSURE MOD 17 12 9678 1862 1 SHIELDED BALLAST CCI 18 21 9678 1254 1 ASSY COVER VENTILATION 21 9686 0840 02 1 EA ASSY COVER VENT VL3500 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 19 53 6610 0003 1 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 127 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL No Item Qty UM Description 22 21 9678 0864 l ASSY PAN MOTOR 23 21 9678 0881 1 ASSY PAN TUBE 24 22 9678 0851 1 ASSY UPPER ENCLOSURE 25 23 9678 0686 1 EA FAN ASSY UPPER ENCLOSURE 26 23 9678 0687 1 EA ELEC ASSY PAN BOT SENSOR 25 9661 1514 1 EA CABLE ASSY LVS CHASSIS GND not shown 25 9661 1520 1 EA CABLE ASSY CHASSIS TO YOKE GN
75. Description 27 53 5638 0252 12 EA SCREW 6 32 X 1 4 LG PFS UNDERCUT HEAD 28 53 6558 0001 7 EA SCREW 6 32 X 3 8 PPZ 29 53 6597 0001 2 EA SCREW 4 40 X 3 16 PPZ 30 53 6608 0003 5 EA 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 TOOTH 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 8 FLAT ZINC 39 55 6528 0001 2 EA WASHER 6 FLAT ZINC 55 2110 0002 3 EA WASHER 0 400 OD 0 260 ID 0 010 L 55 2186 0002 5 EA CABLETIE 0 09WD 0 375 LG TEFZEL not shown 40 55 6520 0001 2 EA WASHER WAVE SPRING 1 4 DIA 02 9678 0018 B 95 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Color Dimmer Strobe Assembly continued Z v 20 27 8 26 x10 ED Dimmer 16 33 28 5 Figure 3 30 Color Dimmer Strobe Assembly 96 02 9678 0018B HEAD ASSEMBLY MOTOR ADAPTER PLATE ASSEMBLY 3 Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Refer to Figure 3 31 No Item Qty UM Description l 10 9678 0330 1 PLATE MOTOR ADAPTER 2 44 5031 0001 1 EA MOTOR STEPPER 42MM X
76. Dual Fan Tray Duct Quiet Assembly 21 9678 0659 03 Rev VL3500Q Only Refer to Figure 3 17 No Item Qty UM Description 1 10 9678 0665 1 EA SPRING EXTENSION ELONGATED HO 2 22 0678 0661 1 EA ASSY FAN TRAY 3 22 9678 1265 1 EA DUCT ASSY SHUTTER GOBO 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 EA 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 WHITE 9 55 2186 0001 2 EA CABLETIE 10 WD 4 00 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 78 Spring installed as shown Figure 3 17 Dual Fan Tray Duct Quiet Assembly VL3500Q Only 02 9678 0018 B HEAD ASSEMBLY HEAD FRONT FAN STANDARD ASSEMBLY 3 Head Front Fan Standard Assembly 23 9678 0684 Rev 0 VL3500 Only Refer to Figure 3 18 No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52 6523 0002 1 CONN HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 2 1 3 x2 02 9678 0018 B Figure 3 18 Head Front Fan Assembly VL3500 Only 79 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Head Front Fan
77. E 75 X 75 4WAY VL3500 QUIET NOT SHOWN 55 2186 0001 1 EA CABLE TIE 10 WD X 4 LG VL3500 QUIET NOT SHOWN 2 8 x4 EN Direction of air flow Wire Connection Orientation Figure 3 44 Yoke Fan Assembly 02 9678 0018 B 113 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Notes 02 9678 0018 B HEAD YOKE PCB ASSEMBLIES SHUTTER CABLE INTERCONNECT ASSEMBLY 3 Head Yoke PCB Assemblies Shutter Cable Interconnect Assembly 21 9678 1246 RevA Refer to Figure 3 45 No Item Qty UM Description 1 10 9678 1245 1 EA MOUNT CABLE INTERCONNECT SHUTTER 2 52 6670 0034 1 EA HEADER MOD II 34 PIN DUAL SIDED 3 52 6670 0040 1 EA HEADER MOD II 40 PIN DUAL SIDED 4 53 6520 0002 4 EA SCREW 4 40 X 7 16 PPZ 5 55 6621 0001 4 EA WASHER 4 FLAT ZINC N Figure 3 45 Shutter Cable Interconnect Assembly 02 9678 0018 B 115 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Refer to Figure 3 46 No Item Qty UM Description 1 10 9678 0482 1 EA PCB MOUNT COLOR SENSOR 1 2 24 9678 3480 1 PCB ASSY COLOR SENSOR 1 3 53 6558 0001 2 SCREW 6 32 X 2 8 PPZ 4 55 3303 0006 2 EA WASHER 6 LOCK INTTOOTH SS 3 2 4 2 Figure 3 46 Color Sensor 1 PCB Mount Assembly 116 02 9678 0018 B HEAD YOKE PCB ASSEMBLIES COLOR SENSOR PCB 2 MOUNT ASSEM
78. EA COVER FRONT 50 POS MT LATCHING 11 52 6224 2014 2 EA COVER BACK 14 POS MT 12 52 6224 2024 1 EA COVER BACK 24 POS MT 13 52 6224 2034 l EA COVER BACK 34 POS MT 14 52 6224 2040 3 EA COVER BACK 40 POS MT 15 52 6224 2050 1 EA COVER BACK 50 POS MT 16 55 2186 0001 11 EA CABLE TIE 10 WD 4 00 LG SMALL 17 55 6699 0004 1 92 FT SLEEVING 3 4 NOM DIA POLY EXP BRAIDED 18 73 3026 0009 1 83 FT WIRE 26 AWG 300V 80 C PVC WHITE 19 73 3026 0329 1 83 FT WIRE 26 AWG 3 COND TW 300V PVC lt RED WHT VIO BLK gt 20 73 5116 0123 41 42 FT WIRE 24 AWG 4 COND TW 300V 80C lt BLK BRN RED ORG gt UL1061 21 73 5126 0002 3 75 FT WIRE 26 AWG 2 COND TWISTED lt RED BLK gt 22 73 5126 0007 1 83 FT WIRE 26 AWG 2 COND 300V 80C UL1061 19STRND lt BLK V1O gt 23 73 5126 0029 1 83 FT WIRE 24 AWG 3 COND TW 300V PVC lt RED WHT BLK gt 24 73 5126 0129 1 83 FT WIRE 26 AWG 3 COND TW 300V PVC lt RED WHT RED BLK gt 25 73 5126 0229 1 83 FT WIRE 26 AWG 3 COND TW 300V lt RED WHT BLK BLK gt 26 73 5126 6009 1 92 FT WIRE 26 AWG 6 COND TWISTED lt WHT WHT BLU WHT BLK WHT BRN WHT GRN WHT RED gt 27 52 8351 0004 226 EA CONTACT 26 22AWG RECP MTE REEL NOT SHOWN 02 9678 0018 B 159 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Head Controller Cable Assembly continued 245 12 4 9 14 Figure 3 81 Head Controller Cable Assembly 160 02 9678 0018B CABLE ASSEMBLIES
79. FB 12 53 6513 0044 3 EA SCREW M5 X 10MM STL CUP PT 13 54 1206 0014 2 EA RING RETAINING 1 375 SHAFT 1 291 GRV DIA 0 056 GRVWD EXT 14 54 1255 0001 2 EA BEARING ASSY BLACK FLUSH MOUNT HOUSING 15 54 2055 0001 1 EA BELT TIMING 52 210 GROOVE 9MM WIDE 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 0 010 THK SS 18 55 6799 0002 2 EA SHIM 1 3 8 ID 1 7 8 OD 0 005 THK SS VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Generic Luminaire Assembly continued 8 x4 9 x4 6 x4 14 x2 Detail III 2 Detail Figure 3 9 Generic Luminaire Assembly 56 02 9678 0018 B HEAD ASSEMBLY HEAD STRUCTURE ASSEMBLY 3 Head Assembly Head Structure Assembly 21 9678 0600 Rev C VL3500 Only 21 9678 0601 Rev 0 VL3500Q Only 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 VL3500 ONLY 21 9678 0616 1 EA ASSEMBLY BACKEND VL3500Q ONLY 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 6615 1125 3 EA SCREW 10 32 X 1 25 SOCKET CAP BLACK Aro II J Figure 3 1 Head Structure Assembly 02 9678 0018 B 57 VARIXLITE VL3500
80. Item Qty UM Description 1 52 8237 0002 1 EA TERM RING 4 24 20AWG 2 52 8414 0001 1 EA 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 200C TEFLON STRANDED 5 4 4 5 Side View 3 x2 0 5 Each 6 7 5 2 6 10 25 1 View 154 Figure 3 76 Air Duct Switch Cable Assembly 02 9678 0018B CABLE ASSEMBLIES YOKE FAN AND RELAY QUIET CABLE ASSEMBLY 3 Yoke Fan and Relay Quiet Cable Assembly 25 9678 0781 Rev A VL3500Q Only Refer to Figure 3 75 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 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 N 4 J X 6 A 5 x2 2 7 Figure 3 77 Yoke Fan and Relay Quiet Cable Assembly VL3500Q Only 02 9678 0018
81. L35000 Spot Luminaire Subassembly Drawing Tree Part 2 48 02 9678 0018B DRAWING TREES VL3500Q SPOT LUMINAIRE 3 VL3500Q Spot Luminaire continued continued from page 44 Upper Enclosure Assembly 21 9678 0801 02 Rev Z VL3500Q Ventilation Cover Assembly VL3500 Quiet 21 9686 0840 02 Rev B Pan Pulley Assembly 21 9678 0807 Rev E Pan Motor Assembly 21 9678 0864 Rev E Pan Tube Assembly 21 9678 0881 Rev 0 Upper Enclosure Fan Assembly 23 9678 0686 Rev 0 Panel Assembly 21 9678 0805 Rev N DMX Input PCB 24 9663 3895 AC Input Pigtail Cable Assembly 21 9678 0807 Rev E Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Gobo Rotate Interconnect Cable Assembly 25 9678 0843 Rev A Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C EMI Filter to Power Switch Cable Assembly 25 9678 0811 Rev C AC Input Splitter Cable Assembly 25 9678 0812 Rev E Data I O Link Cable Assembly 25 9678 0813 Rev Ballast to Controller Cable Assembly 25 9678 0816 RevA Pan Tilt Control Cable Assembly 25 9678 0818 Rev B DC Output Cable Assembly 25 9678 0821 RevE Display Cable Assembly 25 9678 1825 Rev C LVS Chassis Ground Cable Assembly 25 9678 1716 RevA Figure 3 6 VL35000 Spot Luminaire Subassembly Drawing Tree Part 3 02 9678 0018 B 49 VARI LITE VL3500 SPOT LUMINAIRE SE
82. Luminaire Subassembly Drawing Tree Part 1 44 02 9678 0018 B DRAWING TREES VL3500 SpO7 LUMINAIRE 3 VL3500 Spot Luminaire continued continued from previous page 2 continued from previous Spot Optic Assembly Color Dimmer Strobe 22 9678 0103 Rev S Assembly 22 9678 0402 Rev N VL3500 Interconnect Light Shield Group 4 Lens Assembly Motor Adapter Plate Assembly Fixed Color Wheel Assembly Assembly 22 9678 0199 Rev 0 21 9678 0331 Rev 0 21 9678 0334 Rev D 22 9678 1115 Rev D Right Edge Bearing Assembly Zoom Cam Assembly Strobe Assembly Dimmer Wheel Assembly 22 9678 1103 Rev 22 9678 1106 Rev B 22 9678 0403 Rev F VL3500 22 9678 0435 Rev D Only Left Edge Bearing Assembly Zoom Motor Tensioning Assembly Right Strobe Blade Assembly Dimmer Wheel Assembly 22 9678 1105 Rev 22 9678 1113 Rev B 22 9678 0467 Rev 22 9678 0435 Rev D Left Strobe Blade Assembly Color Sensor PCB 1 Mount 22 9678 0468 Rev Assembly continued from previous page 22 9678 0481 Rev B Gobo Shutter Assembly 21 9678 1200 Rev G Color Sensor PCB 2 Mount Assembly 22 9678 0489 Rev B Long Shaft Motor Assembly Roller Pivot Rotate Assembly 21 9678 0243 Rev 0 21 9678 1555 Rev 0 Color Interconnect PCB Cable Assembly 25 9678 1409 Rev B VL3500 Only Gobo Rotate Interconnect Cable Shutter Rotate Roller Assembly Assembly 22 9678 1550 Rev B continued from previous page 25 9678 1209 Rev A Backcap Assembly 21 9678 0615 Rev T VL3500 Only
83. NET TAPE 375 W x 625 L x 0035 THICK 2 10 9663 1211 10 EA SPACER TEFLON GEAR 3 10 9663 1240 5 EA BEARING WHEEL BORE 4 10 9678 0220 1 EA PLATE ROTATING WHEEL 5 10 9678 0224 5 EA RETAINING RING PLANET 6 12 9678 1223 1 EA SUN GEAR MOLDED WITH FLANGE MODIFIED 7 22 9678 0230 5 ASSY PLANET GEAR 8 22 9678 1234 1 EA ASSY PULLEY GOBO WHEEL HUB 9 22 9678 1235 1 ASSY WHEEL HUB INDEX 10 53 6659 0009 3 EA SCREW 2 56 7 16 PPZ 11 55 2256 0001 1 EA MAGNET 2 17 SMCO 2MM X 2MM X 3MM 02 9678 0018 B Figure 3 9 Rotating Gobo Wheel Assembly 67 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Roller Pivot Rotate Assembly 21 9678 1555 Rev 0 Refer to Figure 3 10 No Item Qty UM Description 1 10 9678 1551 1 EA ROLLER PIVOT SHUTTER ROTATE 2 22 9678 1550 1 EA ASSY SHUTTER ROTATE ROLLER 3 53 6609 0001 1 EA SCREW 6 32 X 3 8 PFZ Flange side of bearing 5 Figure 3 10 Roller Pivot Rotate Assembly 68 02 9678 0018B HEAD ASSEMBLY SHUTTER ROTATE ROLLER ASSEMBLY 3 Shutter Rotate Roller Assembly 22 9678 1550 Rev B Refer to Figure 3 11 No Item Qty UM Description 1 10 9678 1552 1 ROLLER SHUTTER ROTATE 2 54 1259 0005 1 BEARING FLANGED 25 ID 625 OD 0001 1 Figure 3 11 Shutter Rotate Roller Assembly 02 9678 0018 B 69
84. ON HOT LAMP DO NOT OPEN FOR 5 MINUTES AFTER SWITCHING OFF Y Vertical Figure 2 2 Lamp Alignment 02 9678 0018 B 17 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 18 Lamp Power Cut Off Switch It should be noted that the lower fan duct assembly is equipped with a lamp power cut off switch If the hinged duct is raised during operation the relay will automatically disengage and the lamp will douse Once the duct is closed lamp power will be restored The fan duct assembly is located on the bottom half of the luminaire head as shown below Head covers are attached by tethers Top Head Cover 1 4 Turn Screw Bottom Head Cover Bottom of Head View Hinged Duct Assembly Disengages lamp power when raised Figure 2 3 Fan Duct Assembly View 02 9678 0018 B MAINTENANCE PROCEDURES GOBO REPLACEMENT GOgO WHEELS 7 AND 2 Gobo Replacement Gobo Wheels 1 and 2 WARNING Remove power from luminaire before performing maintenance Gobos may be HOT after operation Allow to cool before replacing gt 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 gt To remove and replace a gobo Step 1 Remove power from luminaire Step 2 Remove appropriate head cover by loosening four
85. ON 1 4 18 14 AWG FLAG DBL REEL 2 52 8392 0001 EA RECP FASTON 187 X0 32 16 14 AWG FLAG DBL CRP 3 55 2186 0001 1 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 5 Figure 3 83 EMI Filter to Power Switch Cable Assembly 02 9678 0018 B 163 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25 9678 0812 Rev E Refer to Figure 3 84 No Item Qty UM Description l 52 6231 0001 l EA PLUG HOUSING MNLOK PLUG 3 POS 2 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 3 52 8231 0008 2 TERM SPADE 6 RED 22 16 AWG INSERT 4 52 8392 0001 2 EA RECP 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 1711015 10 73 6016 0010 1 83 FT WIRE 16 AWG 600V 105C PVC BLK 111015 11 73 6016 0504 2 08 FT WIRE 16 AWG 600V 105C GRN YEL UL1015 12 73 6018 0009 1 00 FT WIRE 18 AWG 600V 105C PVC WHT UL1015 13 73 6018 0010 1 00 FT WIRE 18 AWG 600V 105C PVC BLK
86. OPPER 1 x2 2 146 Figure 3 68 Head to Back Cap Ground Cable Assembly 02 9678 0018 B CABLE ASSEMBLIES IGNITOR TO RELAY CABLE ASSEMBLY 3 Ignitor to Relay Cable Assembly 25 9661 1526 Rev C Refer to Figure 3 69 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 RECP FASTON 1 4 18 14 AWG INSULATED VO 3 73 7101 0009 0 42 FT WIRE 14 AWG 15 150C SILICONE 41 30 STRANDING 2 1 Figure 3 69 Ignitor to Relay Cable Assembly 02 9678 0018 B 147 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Refer to Figure 3 70 No Item Qty UM Description 1 52 6664 0001 2 EA CONTACT 22 26AWG FEMALE MATE N LOK 2 2 52 6664 0002 1 EA CONN HOUSING 2 POS CAP MATE N LOK 2 3 52 8231 0008 2 EA TERM SPADE 6 RED 22 16AWG INSERT 4 55 2186 0001 2 EA CABLE TIE 0 10 WD 4 00 LG SMALL 5 55 6699 0002 2 08 FT SLEEVING 1 4 NOM DIA POLY EXP BRAIDED 6 73 6222 0009 2 17 FT WIRE 22 AWG 6004 200C TFE WHT UL1199 19STRAND 7 73 6222 0010 2 17 FT WIRE 22 AWG 600V 200C TFE BLK 111199 1 2 Figure 3 70 LVS to Yoke AC Fan Cable Assembly 148 02 9678 0018B CABLE ASSEMBLIES FAN CABLE ASSEMBLY 3 Yoke to AC Fan Cable Assembly 25 9678 0012 Rev A Refer to Figure 3 71
87. POS MTA FRCT LOK STRT POST J3 3 52 6625 0006 1 EA CONN RECEPT XLR SPIN FEMALE PC MT VERTICAL 4 52 6626 0006 1 CONN RECEPT XLR SPIN MALE MT VERTICAL 12 5 62 3039 0102 1 EA CAP 1000P 250V 20 CDE X Y Cl 1 2 NN 4 Figure 3 60 DMX Input PCB 136 02 9678 0018B ENCLOSURE ASSEMBLY AC INPUT PIGTAIL CABLE ASSEMBLY 3 AC Input Pigtail Cable Assembly 25 9678 0810 Rev C Refer to Figure 3 61 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 204 250V TWIST LOCK MALE LINE 3 WIRE 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL 4 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 5 55 2268 0187 0 92 FT HEATSHRINK 3 16 CLEAR KYNAR UL 600V 150DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR UL 600V 150DEG 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60C EURO BLK HD 22 11MM OD 4 x2 2 Figure 3 61 AC Input Pigtail Cable Assembly 02 9678 0018 B 137 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Pan Pulley Assembly 21 9678 0807 Rev E Refer to Figure 3 62 138 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 Figure 3 62 Pan Pulley Assembly 02
88. Qty UM Description 1 52 8231 0005 2 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 3 55 2260 0133 6 83 FT SLEEVING FIBERGLASS 133 ID 4 73 7100 0001 2 84 FT WIRE 16AWG 20KVDC 41 32 STRD 200C SILICONE 2 X 17 5 73 7190 0001 3 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 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 80 Ignitor to Lamp Socket Cable Assembly 158 02 9678 0018 B CABLE ASSEMBLIES HEAD CONTROLLER CABLE ASSEMBLY 3 Head Controller Cable Assembly 25 9678 1715 Rev A Refer to Figure 3 81 No Item Qty UM Description 1 52 6610 0014 1 EA CONN HOUSING 14 POS DBL ROW UNLOADED 2 52 6610 0024 1 EA CONN HOUSING 24 POS DBL ROW UNLOADED 3 52 6610 0034 1 EA CONN HOUSING 34 POS DBL ROW UNLOADED 4 52 6610 0040 3 EA CONN HOUSING 40 POS DBL ROW UNLOADED 5 52 6610 0017 1 EA CONN HOUSING 50 POS DBL ROW UNLOADED 6 52 6224 1014 2 EA COVER FRONT 14 POS MT LATCHING 7 52 6224 1024 1 EA COVER FRONT 24 POS MT LATCHING 8 52 6224 1034 l EA COVER FRONT 34 POS MT LATCHING 9 52 6224 1040 3 EA COVER FRONT 40 POS MT LATCHING 10 52 6224 1050 1
89. R BERH HTE UV STRAHLUNG UND K RPERVERLETZUNGEN WARNUNG HINWEISE ZUM FEUERSCHUTZ 1 VAREKLITEG Scheinwerfer sind ausschlie lich f r den Einsatz mit bestimmten Lampentyps Achten Sie auf den Lampentyp Osram 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 VARIXLITE Ger ten beginnen 3 Die Ger te sollten nur von qualifiziertem Personal gewartet werden 02 9678 0018 B V VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL WARNUNG HINWEISE ZUM SCHUTZ GEGEN BERH HTE UV STRAHLUNG 1 Viele VARI LITE Scheinwerfer verwenden die Lampentyp der UV Strahlen abgibt SCHAUEN SIE NICHT direkt in die Lampe 2 Es ist gef hrlich Leuchten ohne Linsen oder Blenden zu bedienen Blenden Linsen oder Ultraviolettschirme m ssen ausgetauscht werden sofern deren Schu
90. REW 6 32 X 3 8 LG PPZ SEMS 22 53 6609 0001 6 SCREW 6 32 X 3 8 PFZ 23 53 6613 0001 8 SCREW 6 32 X 1 2 PPZ 24 53 6682 0002 2 EA SCREW 4 40 X 1 4 PPZ SEMS 25 54 1259 0004 2 EA BEARING FLANGED 25 ID 625 OD 0005 RP 26 54 2062 0001 1 EA BELT TIMING MXL 080 PITCH 160 GRV 1 8 W POL KVLR 27 55 2178 0001 4 EA CABLE ANCHOR MOUNT 8 SCREW 28 55 6506 0001 1 EA SPACER 3 8 RND 297 LG 257 ID 29 55 6506 0030 1 EA SPACER 3 8 RND 3 8 LG257 ID THRU ALUM 30 55 6506 0032 1 EA SPACER 3 8 RND 1 1 4 LG 257 ID THRU AL 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL No Item Qty UM Description 31 55 6506 0033 4 EA SPACER 3 8 RND 1 1 8 LG257 TD THRU AL 32 55 6520 0001 4 EA WASHER WAVE SPRING 265 ID 367 OD 006 THK 64 Figure 3 6 Gobo Shutter Assembly 02 9678 0018B HEAD ASSEMBLY ROTATING WHEEL ASSEMBLY SHUTTER 3 Rotating Gobo Wheel Assembly Shutter 21 9678 1205 Rev B Refer to Figure 3 7 No Item Qty UM Description 1 10 9678 1216 1 EA BULKHEAD SHUTTER MODULE REAR 2 10 9678 1225 2 EA SHAFT WHEEL CANTILEVER 3 21 9678 1210 1 EA ASSY ROTATING WHEEL 4 21 9678 1410 1 EA ASSY FIXED WHEEL 5 24 9678 3240 2 EA ASSY PCB WHEEL POSITION SENSOR 6 53 6520 0001 4 EA SCREW 4 40 X 3 8 PPZ 7 53 6601 0001 6 EA
91. RVICE MANUAL Top Assembly Included Items Kit Spot 28 9678 0020 Rev E Refer to Figure 3 7 No Item Qty UM Description l 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8052 0001 l EA CARD LIMITED WARRANTY 3 02 8406 0001 1 TAG LAMP NOTICE 4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 5 02 9678 0002 1 EA UNPACK QUICK START SHEET VL3000 04 4037 0001 5 LABEL 2 5 X 5 BARCODE not shown 07 9678 0036 1 EA CARDBOARD SHIPPING BOX VL3000 not shown 6 08 3500 0001 1 EA CD ROM VL3500 PRODUCT DOCUMENTATION USER 7 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 8 41 6030 5011 1 EA GOBO ASSY NIGHT SKY 9 41 6030 5503 1 EA GOBO ASSY PALM LEAVES 10 41 6030 5523 1 EA GOBO ASSY TRIBAL BREAKUP 11 41 6030 6011 1 EA ASSY CIRCLE OF OVALS 12 41 6030 7002 1 EA GOBO ASSY PEBBLES 13 41 6030 7014 1 ASSY TRIANGLE BREAKUP 14 41 6030 7018 1 EA GOBO ASSY SHOCK BREAKUP 15 41 6030 7029 1 EA GOBO ASSY ALPHA RAYS 16 41 6030 8503 1 GAG ASSY GLACIER 17 41 6030 8509 1 GAG ASSY ICE BLOCKS 18 41 6030 8801 1 EA GOBO ASSY MULTI COLOR CIRCLES 19 71 2557 1200 1 EA LAMP 1200 WATT SHORT ARC DOUBLE ENDED 50 02 9678 0018B ASSEMBLY INCLUDED ITEMS KIT 3 Included Items Kit Spot continued 8 9 10 11 12 NT CELA soo get a
92. SSEMBLY REPLACEMENT 2 Step 28 Finish by performing steps 2 through 4 in the removal section in reverse order A 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 Spot Optic Assembly Linear Actuator q S Motor see detail Clamp Secure this side Screw first when reinstalling Optic Assembly Side View Edge Screw Thread all the way into motor as shown before re installing Figure 2 22 Spot Optic Assembly Replacement 02 9678 0018 B 35 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Tilt Motor Assembly and Tilt Belt Replacement VL Part No 21 9678 0765 Tilt Motor VL Part No 54 2055 0001 Tilt Belt To remove and replace tilt motor Step Step Step Step Step Step Step A Note 1 Disconnect luminaire AC 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 A D spe 9 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
93. THER 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 VL3500 QUIET 25 9678 0012 EA CABLE ASSY AC FAN YOKE TO FAN not shown 25 9678 0014 1 EA CABLE ASSY BACKCAP INTERLOK INTERLOK not shown 25 9678 0691 1 CABLE ASSY OT SWITCH not shown 25 9678 0690 1 EA CABLE ASSY OT SWITCH VL3500 QUIET 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 PEZ 15 53 6523 0001 1 SCREW 6 32 X 3 8 SCB 16 53 6558 0007 6 EA SCREW 6 32 X 1 4 PPZ SEMS 17 53 6559 0001 4 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 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 SCREW 6 32 X 3 4 PPZ 22 53 6682 0002 2 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 7 EA WASHER 750 OD 312 TD 125TH 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 4T 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL No Item Qty UM Description 27 74 1099 0001 1 EA SWITCH MINIATURE 5AMP 150DEG 10 9678 0680 1 EA INSULATOR TEFLON TO 220 not shown 53 2200 0004 1 E
94. VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Long Shaft Motor Assembly 21 9678 0243 Rev 0 Refer to Figure 3 12 No Item Qty UM Description l 10 9678 0330 1 PLATE MOTOR ADAPTER 2 44 9678 0249 1 EA MOTOR STEPPER 42MM X 34MM 60MM SHAFT 3 53 6513 0002 4 EA SCREW X 5MM LG PFZ METRIC Note orientation of adapter plate in relation to the motor Figure 3 12 Long Shaft Motor Assembly 70 02 9678 0018B Shutter Assembly 21 9678 1510 Rev J Refer to Figure 3 13 HEAD ASSEMBLY SHUTTER ASSEMBLY 3 No Item Qty UM Description l 10 9678 1526 2 EA PIVOT SHUTTER BLADE SHORT 2 10 9678 1527 2 EA PIVOT SHUTTER BLADE LONG 3 10 9678 1528 16 EA CAM STOP 4 10 9678 1529 1 EA CABLE CLAMP SHUTTER 5 10 9678 1532 4 EA GLIDE BLADE PIVOT 6 10 9678 1534 8 EA ACTUATOR ARM BEARING SHUTTER 7 10 9678 1535 1 EA GLIDE SHEET SHUTTER BOTTOM 8 10 9678 1536 1 EA GLIDE SHEET SHUTTER MIDDLE 9 10 9678 1537 4 EA SPACER SHUTTER BLADE 10 10 9678 1540 3 EA BELT RING SECTOR 11 10 9678 1541 7 EA BELT RING FLANGE SECTOR 12 10 9678 1542 1 EA BELT RING FLANGE STOP 13 10 9678 1545 1 EA BELT RING SECTOR CLAMP 14 10 9678 1546 1 EA BELTCLAMP 15 12 9678 1562 2 EA BLADE SHUTTER BOTTOM COATED 16 12 9678 1565 2 EA BLADE SHUTTER TOP COATED PAINTED 17 21 9678 15
95. Y 13206 1111 USA 1 800 93USITT www usitt org 02 9678 0018 B 1 VARIXLITEO VL3500 SPOT LUMINAIRE 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 was purchased or Contact an Authorized Service Center or Contact the Vari Lite Customer Service Department 9am 6pm CST Monday through Friday at the following phone 1 877 VARI LITE 1 877 827 4548 e mail customerservice genlytecontrols com Additional Resources For additional resources and documentation please visit our website at www vari lite com and follow the Support link Technical Bulletins and Notices Technical bulletins concerning the latest changes to 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 integra
96. Z 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 235 G 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 THK 47 55 6503 0004 3 EA WASHER 8 FLAT ZINC changed 03 24 04 48 55 6528 0001 5 EA WASHER 6 FLAT ZINC 49 55 6578 0073 1 EA SPRING EXTSN 375 OD 50 55 6846 0001 2 EA FOLLOWER DIA STUD 51 10 9678 1140 1 EA SHOCK PAD added 12 15 04 52 10 9678 1141 1 EA BACKING PLATE SHOCK PAD G1 added 12 15 04 02 9678 0018B 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 21 Spot Optic Assembly View 1 02 9678 0018 B 85 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Spot Optic Assembly continued Detail A A G1 H me
97. agnet as shown Step Place 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 38 Dimmer Wheel Assembly 02 9678 0018 B 105 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Gobo Clamp Assembly 22 9678 0693 Rev A Refer to Figure 3 39 No Item Qty UM Description 1 12 9678 0691 1 EA GOBO CLAMP 2 53 6685 0625 EA SCREW CAPTIVE 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 2 x2 Note Install item 4 with Loctite 242 Figure 3 39 Gobo Clamp Assembly 106 02 9678 0018B HEAD ASSEMBLY COLOR CLAMP ASSEMBLY 3 Color Clamp Assembly 22 9678 0694 Rev A Refer to Figure 3 40 No Item Qty UM Description 1 12 9678 0692 1 EA COLOR CLAMP 2 53 6685 0625 SCREW CAPTIVE 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 Note Install item 4 with Loctite 242 Figure 3 40 Color Clamp Assembly 02 9678 0018 B 107 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Edge Lead Screw Assembly
98. ari Lite Service facility 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 A 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 To remove and replace luminaire lamp 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 from lamp socket 4 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 A 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 6 Align lamp for flat field after power up as detailed in Align Lamp on page 17 A Lamp dimple side down Do not touch lamp or CAUTION reflector with bare fingers Lamp Connector Reflector Lamp
99. cable routing and or check voltage at MCB test point n a Luminaire does not power up No power Switch not turned on verify switch is turned on Not plugged in ensure A C cable is connected to power source Pan Encoder Fail 14 Luminaire will not pan Pan Encoder Failure MCB pantilt connector disconnected connect MCB pan tilt connector J8 Pan motor disconnected connect pan motor power Encoder faulty replace pan end of travel encoder sensor assembly 02 9678 0018B TROUBLESHOOTING TROUBLESHOOTING GUIDE Table 2 2 Troubleshooting Guide Continued Message Symptom Description Possible Cause and Remedy Pan No Sens Luminaire will not pan Pan Sensor Not Found EOT flag attached to large pulley is not engaging the EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth sufficient to 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 Luminaire will not tilt Tilt Encoder Failure MCB pan tilt connector disconnected connect MCB pan tilt connector J8 Tilt motor disconnected connect tilt motor power Encoder faulty replace tilt end of travel encoder sensor assembly Tilt No Sens Luminaire will not tilt Tilt Sensor Not Fou
100. connect luminaire AC input cable from power source Step 2 At tilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws Step 3 At sensor bracket remove two 10 32x1 2 PPZ screws and remove bracket Step 4 Disconnect wiring from Tilt Encoder PCB Step 5 At sensor remove two 6 32x3 8 PPZ screws and remove sensor from bracket Step 6 Replace by performing steps 2 through 5 in reverse order Tilt Motor SR Assembly BEN x NOTE Head not shown for clarity Sensor Sensor Bracket JN Tilt Belt Spring Figure 2 25 Tilt EOT Sensor Replacement 02 9678 0018 B 39 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Gobo Timing Adjustments The index timing belt must be aligned so that the mechanism clocks properly This belt is installed around the index gear top gear of the gobo wheel The wheel position belt is installed around the wheel position gear bottom gear of the gobo wheel and does not require alignment Each belt is also routed around one motor pulley For the following steps refer to Figure 2 26 To time gobo wheels Step 1 Align all holes in wheels as shown below Step 2 Insert a3 long 4 or M3 screw or 0 125 diameter pin completely through aligned holes in wheel and bulkhead plates 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 i
101. de las luminarias est n calientes durante su operaci n Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando haga ajustes en el equipo y componentes que est n calientes 2 Cuando las luminarias est n en operaci n la l mpara estar muy caliente Desconecte la energ a y deje que la l mpara se enfr e antes de reemplazarla 3 Las l mparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e inflamaci n a los ojos Adem s las l mparas de arco operan a alta presi n y muy alta temperatura Si la l mpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las part culas de la l mpara rota que se caen 4 Use protecci n para los ojos cuando vuelve a colocar una l mpara nueva 5 Use un equipo de seguridad apropiado guantes protecci n para los ojos etc cuando trabaje con l mparas da adas 6 Si toca la l mpara con las manos limpie la l mpara con alcohol desnaturalizado y con tela sin pelusas antes de instalar o volver a conectar la luminaria 7 Cambie la l mpara si est da ada o deformada termicamente ADVERTENCIA INTERFERENCIA RF 1 Este es un producto de Clase A En el ambiente de la casa este producto puede ocasionar radiointerferencia en cuyo caso el usuario debe tomar las medidas adecuadas CONSIDERACIONES SOBRE LAS CARACTER STICAS DE LA L MPARA DE ARCO 1 Las l mparas de arco requieren un per odo
102. de tiempo para volver a iluminarse despu s de una interrupci n de energ a o de una severa ca da de voltaje En algunos casos la l mpara se volver a iluminar en forma autom tica despu s que se ha enfriado dependiendo de la configuraci n del sistema de energ a de la l mpara 2 La posici n de encendido es universal x 02 9678 0018 B FOREWORD UV 1
103. es eye protection should be used when handling damaged lamps 6 If lamp is touched with bare hands clean lamp with denatured alcohol and wipe with lint free cloth before installing or powering up the luminaire 7 The lamp shall be changed if it has become damaged or thermally deformed WARNING RF INTERFERENCE 1 This is Class A product In a domestic environment this product may cause radio interference which case the user may be required to take adequate measures ARC LAMP CHARACTERISTIC CONSIDERATIONS 1 Arc lamps require a period of time to relight after a power interruption or a severe voltage dip In some cases the lamp will automatically relight after it has cooled depending on Lamp Power Up State configuration setting 2 Burning position is universal iv 02 9678 0018B FOREWORD Sicherheitshinweise Es ist u erst wichtig ALLE Sicherheitsinformationen und hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen bevor Sie die hierin beschriebenen Produkte installieren bzw bedienen Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsma nahmen ein Folgende Sicherheitssymbole werden in diesem Handbuch verwendet A VORSICHT weist auf m glichen Produktschaden hin A WARNUNG weist auf m gliche K rperverletzung und Lebensbedrohung hin NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE BER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK FEUE
104. ght Shield Assembly 22 9678 1115 Rev D Refer to Figure 3 28 No Item Qty UM Description 1 10 9678 1114 1 EA SHIELD INTERCONNECT MOUNT LIGHT 2 24 9678 3116 1 EA ASSY ZOOM INTERCONNECT 3 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 92 3 x4 Figure 3 28 Interconnect Light Shield Assembly 02 9678 0018B HEAD ASSEMBLY ROD CLAMP ASSEMBLY 3 Rod Clamp Assembly 22 9678 0149 Rev B Refer to Figure 3 29 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 6 FLAT ZINC 5 55 6538 0001 2 EA WASHER 6 LOCK INTERNAL TOOTH 02 9678 0018 B 3 2 5 X2 X2 1 d Spring Clip Installation 0 10 Set spring clip from clamp surface as indicated Figure 3 29 Rod Clamp Assembly 93 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Color Dimmer Strobe Assembly 22 9678 0402 Rev N VL3500 22 9678 0462 Rev E VL35000 No Item Qty UM Description 1 10 9678 0324 1 PULLEY FIXED COLOR WHEEL 2 10 9678 0337 1 DRIVE PULLEY FIXED COLOR WHEEL 3 10 9678 0456 4 EA SHAFT COLOR WHEEL 4 10 9678 0457 07 1 EA SPACER COLOR WHEEL L 357 5 10 9
105. gned for dry locations only Exposure to rain or moisture may damage luminaire 2 Disconnect power before servicing any VARIXLITEO equipment 3 Servicing to be performed by qualified personnel only 02 9678 0018 B iii VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1 Many VARI LITE luminaires use a lamp that produces UV radiation DO NOT look directly at lamp 2 Itis hazardous to operate luminaires without lens or shield Shields lenses or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired For example by cracks or deep scratches WARNING INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1 Exterior surfaces of the luminaire will be hot during operation Use appropriate safety equipment gloves eye protection etc when handling and adjusting hot equipment and components 2 Luminaires will have a hot lamp when operating Disconnect power and allow lamp to cool before replacing 3 Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at very high temperatures Should the lamp break there can exist a danger of personal injury and or fire from broken lamp particles being discharged Wear eye protection when relamping 5 Appropriate safety equipment glov
106. gobo positions and one open position One seven position fixed gobo wheel with six positions and one open position Technical Specifications For technical specifications refer to VL3500 Spot Luminaires User s Manual 02 9678 0019 02 9678 0018B COMPONENTS EXTERNAL LUMINAIRE COMPONENTS Components External Luminaire Components The following illustration shows the external luminaire components and controls Upper Enclosure Assembly Houses power supply ballast and Input Cable Truss Hook Bracket Attaches to enclosure base Input Panel Provides DMX In and Thru and AC Power connections see detail below Backcap Assembly Provides access to lamp for replacement and MG controls for eam adjustment Yoke Assembly Head Assembly Houses Master Control Houses color gobo strobe zoom lens Board tilt motor and or beam spreader mechanisms ignitor and cooling fans dependant on luminaire model Input Panel Components Beam Adjustment Controls Menu LCD Display Used to input manual Product Label ID commands program test set defaults and access Main Power internal status information Switch Ac PWR DATAIN DATA THRU N A MENU ENTER Programming Data Thru Buttons Y Z Focus AC Input Cable Data In to allow truss hook installat
107. hapter 3 Illustrated Parts Breakdown Drawing Trees XN E3500 Spot LUMINATE esiet na ee e te eie 44 VL33000 Spot Luminaire seis 023 Erin re RO deer 47 Top Assembly Included Items Kit Spot a entm nial Wawa ine ea t lt 50 VE3500 Spot Series Luminaite ras han aan 52 Generic Luminaire Assembly eee 55 Head Assembly Flead Structure Assembly u ES nn O mO ma len 57 Head Cover Assembly coccion uusha a Mon Sa Sa singed ties isa 58 L 59 sOmm Fan Assembly usa a iaa 61 UV Filter Bulkhead ASSembly ced nun u ee e re ma ragt 62 Gobo Shutter Assembly u u dur tre etr t ete ram 63 Rotating Gobo Wheel Assembly Shutter ana 65 Fixed Gobo Wheel a u u na 66 Rotating Gobo Wheel Assembly ss 67 uuu a a Beeren 68 Shutter Rotate Roller Assembly sa een 69 Long Shatt Motor Ass mblyx uuu 2 ibtd tie ene de bo ee 70 Shutter Assetnbly au u NA 71 Shutter Motor Disk Assembly ss 73 aede EE 75 Dual Fan Tray Duct Standard Assembly TI Dual Fan Tray Duct Quiet Assembly ss 78 Head Front Fan Standard Assembly
108. ides 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 63 Pan Motor Assembly 140 02 9678 0018B ENCLOSURE ASSEMBLY PAN TUBE ASSEMBLY 3 Pan Tube Assembly 21 9678 0881 Rev 0 Refer to Figure 3 64 No Item Qty UM Description l 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 5 2 3 N gt N Pa 3 N 2 4 A Figure 3 64 Pan Tube Assembly 02 9678 0018 B 141 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Notes 142 02 9678 0018 B CABLE ASSEMBLIES PAN EOT SENSOR ELECTRICAL ASSEMBLY 3 Cable Assemblies Note Cables are only available as complete assemblies The information contained in this section is for reference only Pan EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 65
109. ilips 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 10 June 2009 Part number 02 9678 0018 B VL3500 amp VL3500 Q Spot Luminaire Service Manual 2003 2009 Vari Lite a Philips group company All Rights Reserved FOREWORD How To Obtain Warranty Service copy of the Vari Lite Limited Warranty was included in the shipping package for this VARI LITE product To obtain warranty service please contact customer service at 1 877 VARI LITE 1 877 827 4548 1 214 647 7880 or customerservice genlytecontrols com and request a Return Material Authorization RMA for warranty service You will need to provide the model and serial number of the item being returned a description of the problem or failure and the name of the registered user or organization If available you should have your sales invoice to establish the date of sale as the beginning of the warranty period Once you obtain the RMA pack the unit in a secure shipping container or in its original packing box Fill out the RMA form included at the end of this manual and place in shipping container along with a copy of your invoice if available Write the RMA number legibly on or near the shipping address label and return the un
110. ion 1 02 9678 0018 B VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Luminaire Head and Yoke Components The following illustration shows the major sub assemblies which are located in the luminaire head and yoke assemblies Head Cover attached by tether Shutter Gobo Assembly Contains one rotating gobo wheel one fixed gobo wheel and the shutter mechanism Head Fan Assembly Color Assembly Contains fixed color wheel al L dimmer mechanism strobe Optics Assembly mechanism CYM color mixer Houses zoom lenses and CTO color correction m SER and edge mechanisms Yoke Arm Head Fan Assembly Cover MS dy v Head Cover NG vY gt 2 attached by tether Main Controller Board MCB Luminaire control circuit board E Yoke Arm Cover Enclosure Assembly Backend Assembly Houses lamp and reflector Provides knobs for lamp adjustment see page 7 02 9678 0018 B COMPONENTS ENCLOSURE COMPONENTS Enclosure Components The following illustration shows the major sub assemblies which are located in the luminaire enclosure assembly Yoke and head assemblies not shown for clarity Enclosure Top Covers 200W 24V 6 3A Power Supply 1200W Arc Ballast Module Fan Assembly Input Panel Assembly Contains DMX Input PCB and Menu Display AC Input Cable Requires standard AC power distribution from 2
111. iquement 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 installation d un autre type de lampe peut poser un danger 2 Les luminaires peuvent tre fix s sur tout type de surface tant que les directives de montage sont respect es Voir les explications d taill es dans ce guide 3 V rifier la distance respecter entre les mat riaux combustibles ou les objets illumin s et les luminaires VARIXLITE AVERTISSEMENT DIRECTIVES POUR SE PROTEGER CONTRE LES DECHARGES ELECTRIQUES 1 Les luminaires VARI LITE sont con us pour une utilisation au sec uniquement Une exposition la pluie et l humidit risque d endommager le luminaire 2 D brancher l appareil avant de proc der la r vision de tout mat riel VARIXLITE 3 Les r visions doivent tre effectu es uniquement par des personnes qualifi es 02 9678 0018 B vii VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL AVERTISSEMENT DIRECTIVES POUR SE PROTEGER 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 p
112. it freight prepaid to Vari Lite 10911 Petal Street Dallas Texas 75238 USA Attention Warranty Service As stated in the warranty it is required that the shipment be insured and FOB our service center A Note The Series 3500 Luminaires share many common assemblies and parts of the Series 3000 Luminaires 02 9678 0018 B i VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Compliance Notice FCC C This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with Vari Lite system service and safety guidelines may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his her own expense Declaration of Conformity We declare under our sole responsibility that this product complies with the relevant clauses of the following standards and harmonized documents Safety EN 60598 1 2000 Luminaire Safety Standard General Requirements EN 60598 2 17 1989 A2 1991 Specification for Luminaires for Stage and Studio Lighti
113. ll m ssen eventuell geeignete Ma nahmen getroffen werden BESONDERHEITEN VON BOGENLAMPEN 1 Bogenlampen ben tigen eine gewisse Zeitdauer um nach einem Stromausfall oder einem Spannungsgef lle wieder aufzuleuchten In einigen F llen wird die Lampe nach Abk hlung automatisch wieder aufleuchten je nach der Systemkonfigurationseinstellung des Lampenein schaltungsstatus 2 Die Brennposition ist Universal vi 02 9678 0018B 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 extremement important de lire TOUS les renseignements et TOUTES les directives de s curit contenues dans ce guide ainsi que toute documentation jointe Tenir compte de tous les avertissements et suivre toutes les pr cautions pendant l installation et l utilisation de cet appareil Les symboles de s curit utilis s dans ce guide sont les suivants A ATTENTION Ce symbole annonce que l appareil risque d tre endommag A AVERTISSEMENT Ce symbole annonce qu il a risque d accident grave ou m me fatal CETTE SECTION CONTIENT DES INFORMATIONS G N RALES POUR SE PROT GER CONTRE LES D CHARGES LECTRIQUES LES INCENDIES LEXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRAINER DES BLESSURES AVERTISSEMENT DIRECTIVES POUR SE CONTRE LES INCENDIES 1 Les luminaires VARI LITE ont t con us pour tre utilis s un
114. 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 PCB Step 6 Disconnect head cable from Gobo Shutter Assembly Interconnect PCB Step 7 At Gobo Shutter 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 Shutter Assembly straight out of fixture Step 9 Replace by performing steps 3 through 8 in reverse order Top Head Cover Clamp Gobo Shutter Assembly Optic Assembly Must be all the way forward d M Figure 2 15 Gobo Shutter Assembly Replacement 02 9678 0018 B 33 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Spot Optic Assembly Replacement VL Part No 22 9678 0103 To remove and replace spot optics assembly Step Step Step Step Step 10 11 12 13 14 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 a
115. m Qty UM Description l 10 9678 0464 1 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 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 TOOTH SS Black Side 6 x3 5 x3 Figure 3 36 Left Strobe Blade Assembly 02 9678 0018 B 103 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Strobe Motor Quiet Assembly 23 9678 0499 Rev VL3500Q Only Refer to Figure 3 37 No Item Qty UM Description 1 44 5035 0001 1 EA 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 L CO D 4 Wiring Pin Out Heatshrink 4 Green 3 Black 2 Red B Blue i 3 of heatshrink from this surface Figure 3 37 Strobe Motor Quiet Assembly 104 02 9678 0018 B HEAD ASSEMBLY DIMMER WHEEL ASSEMBLY 3 Dimmer Wheel Assembly 22 9678 0435 Rev D Refer to Figure 3 38 pei 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 Step Apply High Temp Copper RTV to m
116. nction Refer to Troubleshooting Guide on page 14 for a list of possible causes and remedies associated with the error messages To access error messages Step 1 Press Menu Step 2 Press Up Down arrows until Fixture appears Press Enter Step 3 Press Up Down arrows to access Status Press Enter Display will now scroll through any error messages or display OK if no errors Table 2 1 Error Messages Display Message OK No Errors Found Pan No Sens Pan Encoder Fail Pan encoder failure Til No Sens Tilt sensor not found Tilt Encoder Fail Index1 No Sens Gobo1 No Sens Pan sensor not found Tilt encoder failure Gobo 1 Index sensor not found Rotating Gobo 1 sensor not found WARNING As with any repairs or maintenance to Vari Lite luminaires service should only be performed by a trained and qualified service technician or at an Authorized Vari Lite Service facility 02 9678 0018 B Fixed Gobo2 No Sens Fixed Gobo 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 13 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANU
117. nd EOT flag attached to large pulley is not engaging the EOT sensor ensure flag is attached to the large pulley ensure that flag passes through the sensor at a depth sufficient to engage the sensor beam Tilt belt disconnected extremely loose or not installed properly properly install belt between tilt motor and large pulley n a Color dimmer or strobe mechanisms will not move Color Dimmer or Strobe Failure MCB connector disconnected check MCB connector at J11 Check Interconnect board n a Zoom Edge or beam spreader mechanisms will not move Zoom Edge or Beam Spreader Failure MCB connector disconnected check MCB connector at J10 Check Interconnect board n a Gobo or iris mecha nisms will not move Gobos or Iris Failure MCB connector disconnected check MCB connector at J9 Check Interconnect board n a Self tests will not run or software download does not work DMX Data Input Detecting DMX data disconnect DMX input cable n a Erratic control of lumi naire DMX Termination No DMX termination or termination not correct check DMX terminator 02 9678 0018 B 15 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Maintenance Procedures WARNING As with any repairs or maintenance to Vari Lite luminaires service should only be performed by a trained and qualified service technician or at an Authorized V
118. ndex 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 Insert screw or pin here Align Figure 2 26 Gobo Wheel 1 Timing Adjustments 40 02 9678 0018B MAINTENANCE PROCEDURES GOBO GEAR PLANET ALIGNMENT 2 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 1 Place center sun gear at starting point so that timing mark is directly facing Position 1 open as shown in Figure 2 27 Step 2 Set Position 6 planet gear as follows Step 3 Rotate center gear clockwise until timing mark is directly facing Position 6 Step 4 Lift edge 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 Step 5 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 at each gear as they pass Adjust as necessary and recheck There should be no drag in the movemen
119. ng EMC EN 61000 6 4 2001 Radiated and Conducted Emissions We certify that the product conforms to the protection requirements of council directives 73 23 EEC LVD and 89 336 EEC EMC 02 9678 0018B 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 LITEQ luminaires have been designed for use with specific lamp types The VL3500 Spot luminaires require an Osram HMI 1200 W 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 VARIXLITEO luminaires WARNING INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1 VARI LITE luminaires are desi
120. ower 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 At bottom of enclosure remove four 1 4 20 1 2 socket screws and 1 4 split lock washers and remove ventilation cover Step 5 At encoder 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 AT NOTE gt Head not shown for clarity Enclosure Bottom View Encoder Disk Encoder Bottom Cover Pan Motor Assembly Figure 2 12 Pan Encoder PCB Replacement 30 02 9678 0018B MAINTENANCE PROCEDURES PAN EOT SENSOR REPLACEMENT 2 Pan EOT Sensor Replacement VL Part No 23 9678 0687 To remove and replace pan EOT sensor 1 Using console or internal menus run lens as far to the rear as possible Step 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 Step Step Step Step 4 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 f
121. p Head Cover 1 4 Turn Screw Gobo Wheel see detail A Do not touch glass with bare fingers CAUTION Press on gobo carrier only Front of luminaire Z Carrier Head covers attached by tethers Press from this side Gobo Assembly Carrier R x Spring Retaining Clip Key LL A Slide gobo carrier closed Gobo Wheel 2 4 into gobo slot p A note gobo is keyed Spring Retaining Clip opened Make sure key is positioned correctly d in slot Release and rotate SGCCUICIy IIT SIO Da x spring retaining clip Figure 2 4 Replacing Gobos 20 02 9678 0018B MAINTENANCE PROCEDURES COLOR FILTER REPLACEMENT 2 Color Filter Replacement A WARNING Remove power from luminaire before performing maintenance Filters may be HOT after operation Allow to cool before replacing To remove and replace a color filter 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 glass cleaner and soft cloth if required Step 3 Rotate 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 note filter must be installed with coating side
122. rcular cutout A in bulkhead Item 1 d 5 Figure 3 5 UV Filter Bulkhead Assembly 62 02 9678 0018 B HEAD ASSEMBLY GOBO SHUTTER ASSEMBLY 3 Gobo Shutter Assembly 21 9678 1200 Rev G Refer to Figure 3 6 No Item Qty UM Description 1 10 9678 0338 1 PULLEY ZOOM MOTOR 2 10 9678 0225 6 EA SHAFT WHEEL 3 10 9678 0231 2 EA PULLEY MOTOR WHEEL DRIVE 4 10 9678 0232 1 EA PULLEY INDEX DRIVE 64 GROOVE 5 10 9678 0246 3 EA ADJUST PLATE MOTOR 6 10 9678 1215 1 BULKHEAD SHUTTER MODULE FRONT 7 10 9678 1244 1 EA MOUNT INDEX SENSOR LONG 8 10 9678 1558 1 EA SPRING TENSION SHUTTER ROTATE 9 21 9678 0243 2 ASSY MOTOR LONG SHAFT 10 21 9678 1205 1 EA ASSY ROTATING WHEEL SHUTTER 11 21 9678 1510 1 ASSY SHUTTER 12 21 9678 1555 2 EA ASSY ROLLER PIVOT ROTATE 13 22 9678 1550 2 EA ASSY SHUTTER ROTATE ROLLER 14 24 9663 3231 2 PCB ASSY INDEX SENSOR 25 9678 1209 1 EA CABLE ASSY GOBO ROTATE INTERCONNECT Not Shown 15 44 9663 1202 1 EA MOTOR 17 2 42 SHAFT 11 8MH 16 44 9663 1766 1 EA MOTOR 17 1 24 SHAFT 11 8MH 5 17 53 5558 0125 8 SCREW 8 32 X 125 SET SS 18 53 5638 0252 6 EA SCREW 6 32 X 3 8 PFZ UNDERCUT HD 19 53 6520 0375 2 EA SCREW 4 40 X 3 8 PPZ SEMS 20 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 21 53 6558 0009 4 EA SC
123. rofondes rayures AVERTISSEMENT y DIRECTIVES POUR SE PROTEGER CONTRE LES ACCIDENTS POUVANT ENTRAINER DES BLESSURES 1 Les surfaces externes du luminaire deviennent br lantes quand l appareil est en marche Pour manceuvrer ou ajuster des appareils brQlants et leurs composants se prot ger suffisamment gants protection pour les yeux etc 2 La lampe du luminaire est br lante lorqu il est en marche D brancher le courant et attendre que la lampe ait refroidi avant de la remplacer 3 Les lampes arc mettent des rayons ultraviolets pouvant causer de graves br lures sur la peau et une inflammation des yeux De plus les lampes arc fonctionnent sous haute tension de tr s hautes temp ratures Si la lampe se casse les particules de la lampe cass e peuvent causer blessures et ou incendie en s parpillant Se prot ger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropri s gants protection des yeux pour manier des lampes endommag es 6 Silalampe a t touch e avec des mains nues la nettoyer avec de l alcool d natur et l essuyer avec un chiffon non pelucheux avant d installer ou de brancher le luminaire 7 Silalampe a t endommag e ou a une d formation thermique elle doit tre remplac e AVERTISSEMENT INTERF RENCE RF 1 Cet appareil est de Classe A Dans un environnement domestique cet appareil peut causer des interf rences radio et si c est le cas l utili
124. rom encoder PCB and remove sensor Replace sensor by performing steps 3 through 6 in reverse order p Head not shown for clarity Bottom Cover 02 9678 0018 B Enclosure Bottom View Pan Motor Assembly Figure 2 13 Pan EOT Sensor Replacement 31 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Power Supply LVS Replacement VL Part No 69 3176 0201 To remove and replace LVS Step 1 Step 2 Step 3 Step 4 SteD 5 Step 6 32 Disconnect luminaire AC input cable from power source At enclosure remove two 6 32x1 4 LG PPZ screws from display side cover and remove cover At power supply disconnect wiring including ground wire 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 Remove one 6 32x3 8 LG PPZ screw Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Replace by performing steps 2 through 5 in reverse order Top Cover Power Supply LVS Bottom Cover NOTE Head not shown for clarity Figure 2 14 Power Supply LVS Replacement 02 9678 0018 B MAINTENANCE PROCEDURES GOBO SHUTTER ASSEMBLY REPLACEMENT 2 Gobo Shutter Assembly Replacement VL Part No 21 9678 1200 To remove and replace gobo shutter assembly Step 1 Run Edge to full forward position DMX 255 Step 2 Disconnect
125. s then 0 recals Dimmer and Strobe Sensor Testing Most mechanisms within the VL3500 luminaire are equipped with either optical or magnetic sensors The VL3500 master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan tilt encoder readings The values can be used to determine whether a circuit is opening correctly or needs further troubleshooting Guidelines The values will change depending on whether the sensor reading is Open or Closed The values will be different depending on the type of sensor optical or magnetic Asa general rule if a change occurs from 5v to Ov or visa versa then it is working 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 02 9678 0018 B 11 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 12 Low value 0 volts or up to approximately 0 2 volts Notes regarding specific mechanisms The four color mixers 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
126. s well as head cable from zoom interconnect PCB Remove Gobo Shutter Assembly See Gobo Shutter Assembly Replacement on page 33 Remove 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 15 16 17 18 Loosen 8 captive 6 32 screws from the four mounting clamps two per clamp Free Actuator 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 34 19 20 21 22 23 24 25 26 27 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 0018B MAINTENANCE PROCEDURES SPOT OPTIC A
127. sateur peut avoir prendre des mesures ad quates CONSID RATIONS DES CARACT RISTIQUES DE LAMPES ARC 1 Apr s une interruption de courant ou une baisse importante de voltage les lampes arc mettent du temps avant de se rallumer Dans certains cas la lampe se rallumera automatiquemet apr s s tre refroidie Cela d pend de la mani re dont le systeme est r gl pour le statut de mise en marche de la lampe 2 La position Br ler est Universelle viii 02 9678 0018 B FOREWORD Aviso sobre Seguridad Es muy importante leer TODA la informaci n e instrucciones sobre seguridad que se indica en este manual as como en los documentos adjuntos antes de instalar y operar los productos descritos Se debe prestar atenci n a todos los avisos y advertencias durante la instalaci n y uso de este producto Los s mbolos de seguridad usados en este manual son los siguientes A CUIDADO indica posibles da os al producto A ADVERTENCIA indica posibles lesiones o muerte a las personas LA INFORMACI N GENERAL RELACIONADA A LA PROTECCI N CONTRAGOLPES DE CORRIENTE EL CTRICA INCENDIO EXPOSICI N EXCESIVA A RADIACI N ULTRA VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE ADVERTENCIA INSTRUCCIONES PARA PROTECCI N CONTINUA CONTRA INCENDIO 1 Las luminarias han sido dise adas para ser usadas solamente con algunas l mparas Tome nota del tipo de l mpara Osram HMI 1200 W S metal halide lamp
128. sible 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 0018B 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 To remove and replace pan motor assembly pan belt on page 28 Step 6 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 NOTE JD Head not shown for clarity Bottom Cover Enclosure Bottom View Pan Belt Pan Motor Assembly Figure 2 11 Pan Motor Assembly Replacement 02 9678 0018 B 29 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Pan Encoder PCB Replacement VL Part No 24 9678 9729 To remove and replace pan encoder PCB Step 1 Using console or internal menus run lens as far to rear as possible Step 2 Disconnect luminaire AC input cable from p
129. t See next page for further instructions 02 9678 0018 B 41 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Gobo Gear Planet Alignment continued 1 Start with center gear timing 2 Rotate center gear clockwise until timing mark facing Position 1 open mark is directly across from Position 6 Rotate Position 6 gear until timing marks align Alignment Mark Align both marks 3 Align remaining gobo gears using 4 Verify alignment of all marks and the same method adjust as necessary Figure 2 27 Aligning Gobo Planet Gears 42 02 9678 0018B CHAPTER 3 Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3500 Spot Luminaire assemblies Note The VL3500 Series Luminaires share many common assemblies and parts Wy of the VARIXLITESO Series 3000 Luminaires AN Drawing Trees Top Assembly Head Assembly Yoke Assembly Head Yoke PCB Assemblies Enclosure Assembly Cable Assemblies 02 9678 0018 B 43 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Drawing Trees VL3500 Spot Luminaire VL3500 Spot Luminaire 20 9678 0019 Rev VL3500 Only Generic Luminaire Assembly 21 9678 0010 02 Rev H VL3500 Only Head Structure Assembly 21 9678 0600 Rev C VL3500 Only Backcap Assembly 21 9678 0615 Rev T VL3500 Only continued next page Yoke Assembly 21 9678 0700 Rev J VL3500 Tilt Motor Assembly 21 9678 0765
130. ted into the appropriate equipment manuals as those manuals are revised Bulletins are categorized by assembly or subassembly and identified by a number such as S3K 001 VL3500 Series Luminaires Technical Bulletin number 1 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 0018B 1 Description This chapter contains descriptions of luminaire features and components Features Components Principles of Operation JOIAUIS 02 9678 0018 B 3 VARIXLITE VL3500 SPOT LUMINAIRE SERVICE MANUAL Features Standard Features VL3500 series luminaire have the following standard features CYM color mixing system UN e Variable CTO color correction Six position fixed color wheel Full field dimming system A Dual blade strobe system Repositional pan tilt system Control by DMX512 protocol Fan cooled UVAIR glass Specific Features VL3500 Spot Luminaire Four independent shutters 6 1 zoom optics system with 10 to 60 range Variable beam focus to morph between gobo wheels One six position gobo wheel with five rotatable indexable
131. towards lamp ensuring that it is securely in position Step 6 Replace head cover A Do not touch filter with bare fingers gt Top Head Cover CAUTION Wear cotton gloves 4 Screw Color Wheel see detail ES Color Wheel Color Filter Spring Lock Push spring lock back 2 to release color filter Head covers attached by tethers Figure 2 5 Color Filter Replacement 02 9678 0018 B 21 VARIXLITE VL3500 SPOT LUMINAIRE 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 A CAUTION Be careful not to damage lens during next step Step Step Step Step Step Step Step Step Step Step 22 5 Carefully lay luminaire on its side ens
132. tzwirkung durch sichtbare Besch digung z Spr nge oder Schrammen eingeschr nkt ist WARNUNG HINWEISE ZUM SCHUTZ GEGEN K RPERVERLETZUNGEN 1 Bei Betrieb sind die Au enfl chen der Scheinwerfer hei Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausr stung Handschuhe Augenschutz etc 2 Bei Betrieb der Scheinwerfer ist die Lampe hei Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abk hlen wenn Sie diese austauschen 3 Bogenlampen senden ultraviolette Strahlen aus die Hautverbrennungen und Augenentz ndungen verursachen k nnen Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen Temperaturen Sollte die Lampe zerbrechen besteht die Gefahr von K rperverletzung bzw von Feuer das von Lampenteilen ausgel st werden kann Tragen Sie beim Austausch der Lampen einen Augenschutz 5 Die geeignete Sicherheitsausr stung Handschuhe Augenschutz sollte beim Umgang mit besch digten Lampen verwendet werden 6 Wenn die Lampe mit blo en H nden ber hrt wird reinigen Sie sie mit denaturiertem Alkohol und einem flusenfreien Tuch bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen 7 Wenn die Lampe besch digt oder durch Hitzeeinwirkung deformiert ist mu diese ausgetauscht werden WARNUNG HF INTERFERENZ 1 Es handelt sich um ein Produkt der Klasse A In einer Wohnumgebung kann das Produkt Hochfre quenzst rungen verursachen In diesem Fa
133. uring that lens does not come into contact with any surface At bottom of enclosure remove four 1 4 20 x 1 2 socket screws 1 4 split lock washers 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 23 02 9678 0018B 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 TM 6 32x3 8 PPZ Screw 8 2 Ferrite core Pull wires through here Ballast
134. wiring Pull lamp wires through ferrite core At bottom of enclosure remove three 8 32x3 8 PFZ screws and four 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 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 Cable must be routed through Ferrite Figure 2 7 VL3000 Ballast Replacement New Style 02 9678 0018B MAINTENANCE PROCEDURES COLOR DIMMER STROBE ASSEMBLY REPLACEMENT 2 Color Dimmer Strobe Assembly Replacement VL Part No 22 9678 0402 VL3500 Only VL Part No 22 9678 0462 VL3500Q Only To remove and replace color dimmer strobe assembly 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 Step Step Step Step 02 9678 0018 B 3 Disconnect wiring harness from interconnect PCB Remove interconnect PCB by pushing top of PCB off studs 5 Loosen four captive screws two per clamp Note Do NOT remove long phillips head screw it serves as a handle 6

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