Philips Vari-lite VL3500 Wash FX Luminaries Service Manual Download Page 138

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VARI

❋

LITE

- VL3500™ W

ASH

UMINAIRE

ERVICE

ANUAL

1 2 0

0 2 . 9 6 8 6 . 0 0 1 0 A

21.9686.0811

FAN ASSY, EXHAUST

23.9678.0687

ELEC ASSY, PAN EOT SENSOR

25.9661.1514

CABLE ASSY, LVS CHASSIS GROUND (

not shown

)

25.9661.1520

CABLE ASSY, CHASSIS TO YOKE GROUND (

not shown

)

25.9678.0811

CABLE ASSY, EMI FILTER TO POWER (

not shown

)

25.9678.0812

CABLE ASSY, AC INPUT SPLITTER (

not shown

)

25.9678.0813

CABLE ASSY, DATA I/O LINK (

not shown

)

25.9678.1825

CABLE ASSY, DISPLAY (

not shown

)

25.9678.0816

CABLE ASSY, BALLAST TO CONTROL (

not shown

)

25.9678.0821

CABLE ASSY, DC OUTPUT (

not shown

)

25.9678.0818

CABLE ASSY, PAN/TILT CONTROL (

not shown

)

25.9678.0829

CABLE ASSY, LAMP SUPPLY TO RELAY (

not shown

)

25.9686.0843

CABLE ASSY, DUAL AC FAN LVS TO YOKE (

not shown

)

53.2001.0003

NUT, 10-32 NYLON INSERT

53.2019.0004

NUT, 3/8-16 X 7/32" THK HEX

53.2200.0006

NUT, 6-32 KEPS SS

53.6505.0022

BOLT, 3/8-16 X 3/4"LG CARR

53.6515.0001

SCREW, 10-32 X 3/4" SCB CAP

53.6522.0001

SCREW, 6-32 X 1/4" PFZ

53.6522.0004

SCREW, 6-32 X 1/4" SOC HD

53.6525.0188

SCREW, 6-32 X 3/16" PPZ SEMS

53.6530.0023

RIVET, 1/8"OD POP .376-.500GRP

53.6539.0001

WASHER, 3/8" SPLIT LOCK

53.6545.0003

SCREW, 8-32 X 3/8" PFZ

53.6545.0004

SCREW, 8-32 X 3/8" LG PPZ

53.6556.0002

SCREW, 4-40 X 3/4"LG PPB

53.6558.0009

SCREW, 6-32 X 3/8"LG PPZ SEMS

53.6558.0010

SCREW, 6-32 X 1/4"LG PPZ BLACK

53.6558.0015

SCREW, 6-32 X 3/8" PPB SEMS EXT

53.6571.0003

SCREW, 6-32 X 1-1/2"LG PPB

53.6591.0001

SCREW, 6-32 X 1/4" PFZ

53.6609.0001

SCREW, 6-32 X 3/8" PFZ

53.6626.0001

SCREW, 10-32 X 1/2" PPZ

55.6575.0001

SCREW, 10-32 X 3/4" PPB

53.6634.1000

SCREW, 3/8-16 X 1.00" LG SOC

53.6513.0044

SCREW, M5 X 10MM STL CUP PT

54.1206.0014

RING, RETAINING

54.1255.0001

BEARING ASSY, BLACK FLUSH MOU

No.

Item

Qty.

UM.

Description

Summary of Contents for Vari-lite VL3500 Wash FX Luminaries

Page 1: ......

Page 2: ...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 Spa...

Page 3: ...lable 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 ...

Page 4: ... 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 Luminair...

Page 5: ...e been designed for use with specific lamp types The VL3500 Wash Luminaire requires the Osram SharXS HTI 1500 W D7 60 Installing another type of lamp may be hazardous 2 Luminaires may be mounted on any type of surface as long as mounting instructions are followed See instructions detailed in this manual 3 Note distance requirement from combustible materials or illuminated objects for VARI LITE lum...

Page 6: ...which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at very high temperatures Should the lamp break there can exist a danger of personal injury and or fire from broken lamp particles being discharged 4 Wear eye protection when relamping 5 Appropriate safety equipment gloves eye protection should be used when handling damaged lamps 6 If lamp is ...

Page 7: ...pentyp Osram SharXS HTI 1500 W D7 60 bevor Sie die jeweiligen Lampen ersetzen Die Installation eines anderen Lampentyps kann gefährlich sein 2 Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden solange Sie die Montageanweisungen befolgen Detaillierte Hinweise finden Sie in diesem Handbuch 3 Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der VARI LITE Scheinwer...

Page 8: ...pen erfolgt unter Hochdruck und bei hohen Temperaturen Sollte die Lampe zerbrechen besteht die Gefahr von Körperverletzung bzw von Feuer das von Lampenteilen ausgelöst werden kann 4 Tragen Sie beim Austausch der Lampen einen Augenschutz 5 Die geeignete Sicherheitsausrüstung Handschuhe Augenschutz sollte beim Umgang mit beschädigten Lampen verwendet werden 6 Wenn die Lampe mit bloßen Händen berührt...

Page 9: ...e utilisés uniquement avec certaines type de lampes Vérifier le type de lampe Osram SharXS HTI 1500 W D7 60 avant de remplacer les lampes L installation d un autre type de lampe peut poser un danger 2 Les luminaires peuvent être fixés sur tout type de surface tant que les directives de montage sont respectées Voir les explications détaillées dans ce guide 3 Vérifier la distance à respecter entre l...

Page 10: ...ures sur la peau et une inflammation des yeux De plus les lampes à arc fonctionnent sous haute tension à de très hautes températures Si la lampe se casse les particules de la lampe cassée peuvent causer blessures et ou incendie en s éparpillant 4 Se protéger les yeux pour remplacer la lampe 5 Utiliser des appareils de protection appropriés gants protection des yeux pour manier des lampes endommagé...

Page 11: ...ser usadas solamente con algunas lámparas Tome nota del tipo de lámpara Osram SharXS HTI 1500 W D7 60 antes de reemplazarla Instalación de otro tipo de lámpara puede ser peligroso 2 Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalación Vea las instrucciones detalladas en este manual 3 Tome nota de los requerimientos de distancia de ...

Page 12: ...maduras a la piel e inflamación a los ojos Además las lámparas de arco operan a alta presión y muy alta temperatura Si la lámpara se rompe puede existir el peligro de lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se caen 4 Use protección para los ojos cuando vuelve a colocar una lámpara nueva 5 Use un equipo de seguridad apropiado guantes protección para l...

Page 13: ...FOREWORD 02 9686 0010 A xi ...

Page 14: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL xii 02 9686 0010 A ...

Page 15: ...nce Testing Luminaire Self Tests 12 Calibration Sequence 12 Auto Recalibration 13 Partial Recalibration 13 Sensor Testing 13 Warnings and Cautions Exceptional Safety Information for the VL3500 Luminaires 15 Troubleshooting Error Messages 16 Troubleshooting Guide 17 Maintenance Procedures Lamp Replacement 19 Align Lamp 20 Internal Lens Replacement 21 Front Lens Assembly Removal 23 Color Filter Repl...

Page 16: ...ssembly 60 Head Assembly Head Structure Assembly 63 Front Stippled Lens Assembly 64 Polished PC Clear Front Lens Assembly 65 Front Clear Lens Assembly 66 Front Fresnel Lens Assembly 67 Head Cover Assembly 68 Backend Assembly 69 80mm Fan Assembly 71 Dual Fan Duct Assembly 72 Reflector Mount Assembly 73 Hot Box Assembly 75 Dual Fan Tray Assembly 77 Head Front Fan Assembly 78 Internal Lens Assembly 7...

Page 17: ...able Assembly 138 LVS to Yoke Dual AC Fan Cable Assembly 139 OT Switch 1 to OT Switch 2 Cable Assembly 140 Backcap Interlok to OT Switch 1 Cable Assembly 141 OT Switch to Ground Cable Assembly 142 Tilt Harness Cable Assembly 143 Internal Lens Interconnect Cable Assembly 145 VL3500 Wash Color Harness Cable Assembly 146 VL3500 Wash FX Color Harness Cable Assembly 148 Internal Lens Split Motor Cable ...

Page 18: ...vi 02 9686 0010 A Ballast to Controller Cable Assembly 167 DC Output Cable Assembly 168 Pan Tilt Control Cable Assembly 169 Lamp Supply to Relay Cable Assembly 171 Appendix A Technical Bulletins and Notices Product Technical Bulletins and Notices 173 ...

Page 19: ...s intended for use by Vari Lite personnel and by Vari Lite s customers clients 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 Note Performing maintenance procedures may void the product warranty Refer to the Vari Lite Limited Warranty card include...

Page 20: ...er s Manual This manual is available in both printed and electronic PDF formats VL3500 Wash VL3500 Wash FX Luminaires User s Manual 02 9686 0001 For more information regarding DMX512 systems refer to the DMX512 1990 AMX 192 Standards publication available from United States Institute for Theatre Technology Inc USITT USITT 6443 Ridings Road Syracuse NY 13206 1111 USA 1 800 93USITT www usitt org ...

Page 21: ...l service our full time staff of experienced professionals are on hand to provide support How to Obtain Support or Reach Us For assistance in your area call the dealer from which your product s was purchased or Contact an Authorized Service Center or Contact the Vari Lite Customer Service Department 9am 6pm CST Monday through Friday at the following Phone 1 877 VARI LITE 1 877 827 4548 or 1 214 64...

Page 22: ... in control software Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised Bulletins are categorized by assembly or subassembly and identified by a number such as S3K 001 VL3000 Series Luminaires Technical Bulletin number 1 Technical notices are also issued from the Dallas Texas USA office They are non procedural documents that contain information r...

Page 23: ...02 9686 0010 A 5 CHAPTER 1 Description This chapter contains descriptions of luminaire features and components Features Components ...

Page 24: ...nfiguration Dual five position plus open fixed color wheels Five position aperture wheel 52 40 35 30 and 25 mm VL3500 Wash only One rotating FX pattern wheel with four rotatable and indexable positions and one open position VL3500 Wash FX only Interchangeable front lenses Fresnel and Plano Convex Stipple standard on both models Additional Plano Convex Clear front lens VL3500 Wash only Additional U...

Page 25: ...MP LUMINAIRE MUST REMAIN POWERED ON FOR 5 MINUTES AFTER DOUSING LAMP DO NOT OPEN FOR 5 MINUTES AFTER SWITCHING OFF DATA THRU ENTER MENU AC PWR DATA IN AC IN Main Power Switch AC Input Cable Data In Data Thru Product Label ID AC Input Cable Head Assembly Menu Display Used to input manual commands program test set defaults and access Houses Master Control Houses color strobe and beam spreader mechan...

Page 26: ... Controller Board MCB Luminaire control circuit board Head Fan Head Covers attached by tether Enclosure Assembly See page 9 Houses zoom lenses and Vari Brite mechanism Optics Assembly Assemblies Assembly Color Assembly VL3500 Wash Luminaire contains fixed color wheels dimmer mechanism aperture wheel CYM color wheels CTO color correction wheel and strobe mechanism VL3500 Wash FX Luminaire contains ...

Page 27: ...rity Enclosure Top Covers 150W 24V 6 3A Input Panel Assembly 1500W Arc Ballast Module Enclosure Bottom Ventilation Cover Power Supply Enclosure Fan containing DMX Input PCB and Menu Display International Harmonized Standard AC Input Cable Requires standard AC power distribution from 200 264 VAC 50 60 Hz 7 to 12 A depending on the AC supply voltage Wire Connection Green Yellow AC Ground Blue AC Neu...

Page 28: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 10 02 9686 0010 A Notes ...

Page 29: ...rd maintenance procedures Testing Warnings and Cautions Troubleshooting Maintenance Procedures WARNING As with any repairs or maintenance to Vari Lite luminaires service should only be performed by a trained and qualified service technician or at an Authorized Vari Lite Service facility ...

Page 30: ...00 Wash Luminaire User s Manual 02 9686 0001 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence VL3500 WASH VL3500 WASH FX Phase 1 Phase 1 Tilt Tilt Strobe Strobe Color Wheel 1 Color Wheel 1 Color Wheel 2 Color Wheel 2 Phase 2 Phase 2 Dimmer Dimmer Phase 3 Phase 3 Aperture FX Wheel Phase 4 Phase 4 VARI BRITE VARI BRITE CTO CTO Amber Amber Magenta Mage...

Page 31: ...er and Strobe Sensor Testing Most mechanisms within the VL3500 Wash Luminaire are equipped with either optical or magnetic sensors The VL3500 Wash master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan tilt encoder readings The values can be used to determine whether a...

Page 32: ...ing lamp control The douse command applies 5v to the out line When the start command is given this drops to 0v This can be measured at the MCB at the ballast connection The Out pin of the 5 pin connector should read 0v when the lamp is striking or On Config Lamp Power On When the douse command is given Config Lamp Power Off the reading should changed to 5v Likewise the standby circuit goes to stan...

Page 33: ...urfaces illuminated by the beam It is hazardous to operate luminaires without lens or shield Shields lenses or ultraviolet screens must be changed if they have become visibly damaged to such an extent that their effectiveness is impaired For example by cracks deep scratches or coating breakdown WARNING Hot Exterior Surfaces The exterior surfaces of the luminaire can get very hot up to 170ºC 338ºF ...

Page 34: ...gh any error messages or display OK if no errors 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 Table 2 1 Error Messages Display Message OK No Errors Found Pan No Sens Pan sensor not found Pan Encoder Fail Pan encoder failure Tilt No Sens Tilt sensor not...

Page 35: ...amp Off option is config ured Reconfigure lamp startup option in Lamp config menu n a Luminaire behaves oddly Profile Not Matched Profile not set correctly 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 ColWheel1 ColWheel2 CTO or Aperture Motor power not connected connect motor p...

Page 36: ...ed 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...

Page 37: ...use the lamp to explode or reduce lamp life If touched use alcohol and cotton cloth to thoroughly clean glass portion of lamp To install lamp Step 1 Remove power from luminaire Step 2 At rear of luminaire head loosen four 1 4 turn screws and slide hinged lamp box back and out Step 3 Remove current lamp Step 4 Position new lamp with dimple side toward lamp socket Insert lamp in connector Ensure lam...

Page 38: ... lamp alignment by disabling the pan and tilt motors opening the dimmer and opening the internal lenses Step 3 Position beam on a white wall at a distance of 12 to 20 feet Step 4 At backcap using X Y and Z adjustment screws adjust beam as required Figure 2 2 Lamp Alignment CAUTION RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION DO NOT OPERATE WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LE...

Page 39: ...4 turn screws CAUTION Wear cotton gloves or other covering while replacing lenses If required clean any fingerprints or debris from the lenses with isopropyl alcohol and a soft cloth Step 4 At the internal lens assembly remove the two retaining knobs and the cross strap securing the lens Step 5 Slide each section of lens assembly straight up and off the hinge rods Step 6 Slide the replacement lens...

Page 40: ...al Lens Replacement Detail A Note Some components not shown for clarity CAUTION Clean any fingerprints on lenses with isopropyl alcohol and a lint free cloth Head covers are attached by tethers Internal Lens Assembly Retaining Knobs Head Cover Retaining Knobs Post 1 4 Turn Screw Lens Assembly Keyed Carrier Bumper Stops ...

Page 41: ...ad movement To avoid uncontrolled movement when the luminaire is sitting on upper enclosure point the head straight up To avoid uncontrolled movement when the luminaire is hanging point the head up at an angle until it rests against the tilt stops as shown here Step 2 As shown in Figure 2 4 remove front lens assembly by loosening the four captive 10 32 Allen head cap screws CAUTION Wear cotton glo...

Page 42: ...ens Assembly Captive Screws Front Lens Assembly Mounting Holes Front Lens Assembly Guide Pins CAUTION Clean any fingerprints on lenses with isopropyl alcohol and a lint free cloth CAUTION Lens is heavy Horizontal orientation shown for clarity If lens is removed as shown head assembly will instantaneously rotate to face upwards See Caution on page 23 ...

Page 43: ...ly press the color filter toward the lamp until it is free of the lock pins Remove the filter from the wheel Step 7 Slide the new filter orient coating side towards lamp under the spring clip until it is securely retained by the lock pins Step 8 Close the air duct door Replace the head cover To replace a color filter on Color Wheel 2 Step 1 Remove power from luminaire Step 2 Remove top head cover ...

Page 44: ...er Replacement continued Figure 2 5 Replacing a Color Filter Color Filter Air Duct Door 1 Lock Pins 3 2 Assembly With Color Wheels Do not remove See detail CAUTION Do not touch filters with bare fingers Wear cotton gloves Color Wheel 1 Color Filter Lock Pins 2 1 Color Wheel 2 ...

Page 45: ...latches that secure pattern planet gear Step 7 Remove planet gear containing the pattern from assembly Step 8 If replacing pattern perform the following if not proceed to Step 9 a At planet gear rotate retaining spring from assembly b Gently press pattern out from planet gear c Install new pattern in same orientation including black side up in the gear as shown in Figure 2 6 reflective side must f...

Page 46: ...X Only Assembly With Rotating Effects Patterns Do not remove See detail CAUTION Do not touch patterns with bare fingers Wear cotton gloves Effects Pattern Planet Gear Effects Pattern Retaining Spring Indexing Mark Planet Gear Assembly Cooling Air Duct Yellow Wheel Bulkhead plate and Cyan removed for clarity Retaining Latches Planet Gear Assembly Assembly Sun Gear black side ...

Page 47: ...ews for each handle Step 7 At bottom of the enclosure remove four 6 32 x 1 4 screws and remove both side covers Step 8 Remove two 6 32 x 3 8 screws the APS end bracket and the end cover from ballast side Step 9 At bottom of the enclosure disconnect the exhaust fan cable Step 10 At the exhaust fan remove four 8 32 x 3 8 screws Remove the exhaust fan Step 11 At the ballast disconnect the following c...

Page 48: ... Ballast Assembly Replacement continued Figure 2 7 Ballast Assembly Replacement Top Cover Ventilation Cover Head not shown for clarity NOTE Left Side Cover End Cover Exhaust fan Chassis ferrite Do not remove Ballast Assembly includes attached ferrite APS end bracket ...

Page 49: ...ies that hold head cable assembly together Cut the two wire ties that attach the head cable assembly to the Color Effect Strobe module Step 5 At the Head Cable Interconnect disconnect the head cables from both sides of the headers 4 cables Step 6 Disconnect zoom optics cable from interconnect Step 7 Disconnect the fan cable connector Step 8 As shown in Figure 2 8 remove the four 6 32 x 3 8 PPZ SEM...

Page 50: ...NAIRE SERVICE MANUAL 32 02 9686 0010 A Color Dimmer Strobe Assembly Replacement continued Figure 2 8 Color Dimmer Strobe Assembly Replacement Color Dimmer Strobe Top Head Cover Screws x4 Assembly Wire Harness Guide Note position ...

Page 51: ... Dimmer Strobe Assembly See Color Dimmer Strobe Assembly Replacement on page 31 for complete instructions Step 4 At the interconnect board disconnect the zoom motor and split lens motor connectors Step 5 As shown in Figure 2 9 remove the two 6 32 x 3 8 PPZ SEMS screws and remove the interconnect board Step 6 Remove one 6 32 x 3 8 PPZ SEMS screw and remove the 8 cable saddle Step 7 Remove the three...

Page 52: ... LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 34 02 9686 0010 A Internal Lens Assembly Replacement continued Figure 2 9 Internal Lens Assembly Replacement Internal Lens Assembly Interconnect Board Cable Saddle ...

Page 53: ...be Assembly Replacement on page 31 for complete instructions Step 3 As shown in Figure 2 10 remove four 4 40 x 1 3 8 PPZ screws Step 4 Carefully remove the UV Reflector assembly Step 5 Remove the springs from the reflector clamp and remove the reflector Step 6 Replace the reflector and UV Reflector assembly in reverse order Make sure the mark on the reflector lines up with the mark on the top left...

Page 54: ...CE MANUAL 36 02 9686 0010 A Reflector Replacement continued Figure 2 10 Reflector Replacement 4 40 x 1 3 8 screws 4 UV Reflector Assembly Disconnect Springs Reflector Clamp Spring not shown for clarity Assembly Removal Reflector Alignment ...

Page 55: ...g is the leg to the right Step 2 At board side leg remove yoke leg cover by removing four 6 32 x 5 16 screws CAUTION Always use anti static precautions when working with PCBs Note Please note placement of cable tie to saddle and cut tie Step 3 Disconnect wiring harness connectors J8 J9 J10 and J11 Step 4 Remove four 4 6 32 screws securing MCB PCB Step 5 Disconnect upper enclosure connectors J1 J2 ...

Page 56: ...screws CAUTION Always use anti static precautions when working with PCBs Step 3 Disconnect ignitor PCB wires by removing four screws that secure wire ring terminals to PCB and remove ignitor PCB Step 4 Remove four 6 32 x 3 8 screws Step 5 Replace by performing steps 2 through 4 in reverse Note Make sure and orient ignitor properly as shown in Figure 2 12 Figure 2 12 Ignitor Board Replacement ESD I...

Page 57: ...ation cover Step 6 Remove the handle on the pan motor side by removing two 10 32 x 5 8 PPB screws Step 7 At the enclosure bottom remove two 6 32 x 1 4 PPB screws and the pan motor side cover Step 8 At the side of the enclosure remove two 6 32 x 3 8 PFZ screws and two 6 32 KEPS nuts that hold two cable saddles Pull the cables out of way of the pan motor Step 9 Disconnect the wiring from the pan enc...

Page 58: ...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 Figure 2 13 Pan Motor Assembly Replacement Ventilation Cover Head not shown for clarity NOTE Encoder Wheel Pan Motor Assembly Belt Tensioning spring Tensioning spring ...

Page 59: ...ont lens to contact anything that could damage the lens coating Step 2 To provide access to the ventilation cover set the luminaire on the front lens casting Step 3 At bottom of the enclosure remove four 1 4 20 x 1 5 8 socket screws and 1 4 split lock washers Remove the ventilation cover Step 4 As shown in Figure 2 14 at encoder board remove two 4 40 x 1 4 PPZ screws Step 5 Disconnect wiring from ...

Page 60: ...MINAIRE SERVICE MANUAL 42 02 9686 0010 A Pan Encoder Replacement continued Note Make sure the encoder disk is centered in the optical sensor gap Figure 2 14 Pan Encoder Replacement Ventilation Cover Encoder Pan Motor Assembly ...

Page 61: ...ontact anything that could damage the lens coating Step 2 To provide access to the ventilation cover set the luminaire on the front lens casting Step 3 At bottom of the enclosure remove four 1 4 20 x 1 5 8 socket screws and 1 4 split lock washers Remove the ventilation cover Step 4 As shown in Figure 2 15 at the pan sensor remove two 6 32 x 3 8 PPZ screws Step 5 Disconnect wiring from the encoder ...

Page 62: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 44 02 9686 0010 A Pan EOT Sensor Replacement continued Figure 2 15 Pan EOT Sensor Replacement Sensor Ventilation Cover ...

Page 63: ...move two 6 32 x 1 4 LG PPZ screws from the display side top cover and remove the cover Step 3 At power supply disconnect wiring Step 4 Remove one 6 32 x 3 8 LG PPZ screw at the wiring end of the LVS Step 5 Loosen two 6 32 x 3 8 LG PPZ screws and slide the LVS towards upper enclosure fan to remove it Step 6 Replace by performing steps 2 through 5 in reverse order Location Connector N White AC Wires...

Page 64: ...00 WASH LUMINAIRE SERVICE MANUAL 46 02 9686 0010 A Power Supply LVS Replacement continued Figure 2 16 Power Supply LVS Replacement Display Side Top Cover Head not shown for clarity NOTE Power Supply LVS Fan Assembly ...

Page 65: ...PZ screws that fasten the tilt motor assembly you must tighten then in a CLOCKWISE pattern starting with the screw in lower left hand side To remove and replace the tilt motor belt Step 1 Disconnect luminaire AC input cable from power source Step 2 As shown in Figure 2 17 at the tilt side leg remove yoke leg cover by removing four 6 32 x 5 16 PTB screws Step 3 At tilt motor assembly loosen four 10...

Page 66: ...Make sure wiring is not pinched during installation When tightening four 10 32 x 1 2 PPZ screws that fasten the tilt motor assembly you must tighten then in a CLOCKWISE pattern starting with the screw in lower left hand side Figure 2 17 Tilt Motor Assembly Replacement Tilt Motor Assembly Springs Yoke Cover Tilt Belt ...

Page 67: ...ioning springs Step 6 Disconnect wiring and remove the tilt motor assembly Step 7 As shown in Figure 2 18 at the tilt assembly remove two 4 40 x 1 4 LG PPZ screws and remove encoder PCB Step 8 Replace by performing steps 2 through 7 in reverse order Note Make sure encoder disk passes through sensor when installing encoder PCB Do not pinch wiring during installation When tightening four 10 32 x 1 2...

Page 68: ...ve yoke leg cover by removing four 6 32 x 5 16 PTB screws Step 3 As shown in Figure 2 19 at the sensor bracket remove two 10 32 x 1 2 PPZ screws and remove bracket Step 4 Disconnect wiring from tilt encoder board Step 5 At sensor remove two 6 32 x 3 8 PPZ screws and remove sensor from bracket Step 6 Replace by performing steps 2 through 5 in reverse order Figure 2 19 Tilt EOT Sensor Replacement Se...

Page 69: ...500 Wash and VL3500 Wash FX luminaire assemblies Note The VL3500 Wash and VL3500 Wash FX Luminaires share many common assemblies and parts of the Vari Lite Series 3000 Luminaires Drawing Tree VL3500 Wash Drawing Tree VL3500 Wash FX Top Assembly Yoke Assembly Head Yoke PCB Assemblies Enclosure Assembly Cable Assemblies ...

Page 70: ... Tilt Harness Cable Assembly 25 9686 2203 Head Cover Assembly 21 9686 0611 Color Effect Strobe Module 21 9686 0400 VL3500 Wash Controller PCB Assembly 24 9686 1429 Head Cable Interconnect 21 9686 1121 80mm Fan Assembly 21 9686 6619 Reflector Mount Assembly 21 9686 0605 Dual Fan Duct Assembly 22 9686 0674 Hot Box Assembly 21 9686 0680 Included Items Kit 28 9686 0001 Ignitor to Lamp Socket Cable Ass...

Page 71: ...438 Upper Enclosure Assembly 21 9686 0800 continued from previous page Ventilation Cover Assembly 21 9686 0840 02 Pan Pulley Assembly 21 9686 0807 Pan Motor Assembly 21 9686 0864 Pan Tube Assembly 21 9678 0881 Pan EOT Sensor Electrical Assembly 23 9678 0687 AC Input Pigtail Cable Assembly 25 9678 0810 Pan Tilt Control Cable Assembly 25 9678 0818 DC Output Cable Assembly 25 9678 0821 Lamp Supply to...

Page 72: ...6 0800 Tilt Harness Cable Assembly 25 9686 2203 Head Cover Assembly 21 9686 0611 Color Rotating Effect Strobe Module 21 9686 1400 VL3500 Wash Controller PCB Assembly 24 9686 1429 Head Cable Interconnect 21 9686 1121 80mm Fan Assembly 21 9686 6619 Reflector Mount Assembly 21 9686 0605 Dual Fan Duct Assembly 22 9686 0674 Hot Box Assembly 21 9686 0680 Included Items Kit 28 9686 0011 Ignitor to Lamp S...

Page 73: ... Assembly 21 9686 0800 continued from previous page Ventilation Cover Assembly 21 9686 0840 02 Pan Pulley Assembly 21 9686 0807 Pan Motor Assembly 21 9686 0864 Pan Tube Assembly 21 9678 0881 Pan EOT Sensor Electrical Assembly 23 9678 0687 AC Input Pigtail Cable Assembly 25 9678 0810 Pan Tilt Control Cable Assembly 25 9678 0818 DC Output Cable Assembly 25 9678 0821 Lamp Supply to Relay Cable Assemb...

Page 74: ...4 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 04 4037 0001 5 EA LABEL 2 5 X 5 BARCODE not shown 5 08 3500 0002 1 EA CD ROM VL3500 WASH PRODUCT DOCUMENTATION 6 02 9686 0002 1 EA UNPACK QUICK START SHEET VL3500 WASH 7 22 9661 1636 2 EA FAB ASSY BRACKET TRUSS HOOK 8 71 9686 1502 1 EA LAMP 1500 WATT SHORT ARC DOUBLE ENDED IN LUMINAIRE 9 21 9686 0620 1 EA INTERNAL LENS FRESNEL 10 21 9686 0619 1 EA FRON...

Page 75: ...ree from dirt and grease as possible wear clean cotton gloves 5 6 2 4 7 x2 1 8 3 1 Set of internal Fresnel Lenses Buxom lenses are installed in luminaire 9 10 11 Note Supplied Lenses VL3500 Wash PC Clear Fresnel PC Stippled installed on luminaire VL3500 Wash FX PC Stipple Fresnel and Ultra Clear installed on luminaire Lamp is installed in Luminaire ...

Page 76: ...86 0010 1 EA ASSY GENERIC LUMINAIRE VL3500 Wash Only 21 9686 1010 1 EA ASSY GENERIC LUMINAIRE VL3500 Wash FX Only 6 21 9686 0611 2 EA ASSY HEAD COVER 7 21 9686 0660 1 EA ASSY DUAL FAN TRAY DUCT 8 21 9686 2150 1 EA ASSY SPLIT LENS 9 21 9686 0400 1 EA ASSY COLOR DIMMER STROBE VL3500 Wash Only 21 9686 1400 1 EA ASSY COLOR ROTATING EFFECTS STROBE VL3500 Wash FX Only 10 24 9686 1429 1 EA PCB ASSY VL350...

Page 77: ...00 Wash FX Luminaires 16 53 6558 0016 2 EA SCREW 6 32 X 3 4 LG PPS SEMS 17 55 6677 0033 4 EA WASHER 201 OD 125 ID 032 THK FLAT SS 18 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 X 1 188 LG MF STL No Item Qty UM Description 6 x2 8 1 3 x2 2 4 5 7 9 10 11 x4 11 x4 12 x6 13 x10 14 x4 15 x4 18 x2 15 17 16 17 ...

Page 78: ...41 WIRE DIA 5 21 9686 0800 1 EA ASSY UPPER ENCLOSURE VL3500 WASH 52 0259 1 EA CABLE TIE 5 5 INTERMEDIATE not shown 6 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX JAM GRD5 ZINC PLT 7 53 6505 0020 5 EA BOLT 1 4 28X 3 4 HX HD GRD 8 ZINC PLT FULL THRD 8 53 6505 0026 4 EA BOLT 3 8 16 X 500 LG H X HD GRADE 5 BLK 9 16 HEX HEAD X 23 TALL 9 53 6539 0001 4 EA WASHER 3 8 SPLIT LOCK 10 53 5564 0250 1 EA SCREW ...

Page 79: ...Assembly VL3500 Wash 25 9686 0204 1 EA CABLE ASSY VARI BRITE INTERCONNECT not shown No Item Qty UM Description 1 2 3 5 6 x4 7 x5 8 x4 9 x4 10 11 x4 12 x3 13 x2 15 4a 4b 4c 4d 14 x2 Detail C 17 x2 18 x2 See Detail A 19 3a 3b 3c x3 Detail A Detail B See Detail B 4 16 x5 8 x4 9 x4 See Detail C ...

Page 80: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 62 02 9686 0010 A Notes ...

Page 81: ... Description 1 21 9686 0615 1 EA ASSY BACKEND 2 12 9686 0623 1 EA RIGHT SIDE RAIL MACHINED 3 12 9686 0625 1 EA LEFT SIDE RAIL MACHINED 4 21 9686 0617 1 EA ASSEMBLY FRONT CASTING LENS VL3500 Wash Only 21 9686 1617 1 EA ASSEMBLY FRONT LENS CLEAR POLISHED VL3500 Wash FX Only 5 53 6515 0001 6 EA SCREW 10 32 X 3 4 SCB CAP 6 10 9686 0639 2 EA LIGHT BAFFLE FRONT 7 53 6682 0002 4 EA SCREW 4 40 X 1 4 PPZ S...

Page 82: ... to Figure 3 2 Figure 3 2 Front Stippled Lens Assembly No Item Qty UM Description 1 10 9686 0641 4 EA CLIP FRONT LENS 2 12 9686 0627 1 EA CASTING CONVEX LENS 3 42 9686 0101 1 EA LENS ASPHERIC PLANO CONVEX STIPPLED 4 53 6598 0312 8 EA SCREW 4 40 X 5 16 PFB 5 53 6685 1125 4 EA SCREW CAPTIVE SH CAP 10 32 1 125 LG BLK ZN 2 3 5 x4 4 x8 1 x4 ...

Page 83: ...3 Figure 3 3 Polished PC Clear Front Lens Assembly No Item Qty UM Description 1 10 9686 0641 4 EA CLIP FRONT LENS 2 10 9686 2190 4 EA BUM PER LENS STOP 3 12 9686 0627 1 EA CASTING CONVEX LENS 4 42 9686 0122 1 EA LENS ASPHERIC PC CLEAR POLISHED 5 53 6598 0312 8 EA SCREW 4 40 X 5 16 PFB 6 53 6685 2125 4 EA SCREW CAPTIVE SH CAP 10 32 1 125 LG ZN 3 4 6 x4 5 x8 1 x4 2 x4 ...

Page 84: ...to Figure 3 4 Figure 3 4 Front Clear Lens Assembly No Item Qty UM Description 1 10 9686 0641 4 EA CLIP FRONT LENS 2 12 9686 0627 1 EA CASTING CONVEX LENS 3 42 9686 0121 1 EA LENS ASPHERIC PLANO CONVEX CLEAR 4 53 6598 0312 8 EA SCREW 4 40 X 5 16 PFB 5 53 6685 1125 4 EA SCREW CAPTIVE SH CAP 10 32 1 125 LG BLK ZN 2 3 5 x4 4 x8 1 x4 ...

Page 85: ... 9686 0641 4 EA CLIP FRONT LENS 2 10 9686 0682 4 EA COUNTERWEIGHT FRONT SHORT THIN 3 10 9686 0638 36 EA COUNTERWEIGHT FRONT LONG 4 12 9686 0629 1 EA CASTING MACHINED FRESNEL LENS 5 42 9686 0102 1 EA LENS FRESNEL 230 MM DIA 6 53 6598 0312 8 EA SCREW 4 40 X 5 16 PFB 7 53 6618 0001 8 EA SCREW 6 32 X 1 5 PPZ 8 53 6685 1500 4 EA SCREW CAPTIVE SH CAP 10 32 1 5 LG BLK ZN 4 8 x4 6 x8 1 x4 2 x4 3 x36 7 x8 ...

Page 86: ...649 4 EA EJECTOR SPRING BLACK OXIDE 3 10 9678 0674 1 EA BRACKET COVER TETHER 4 10 9678 0696 1 EA FOAM FRAME HEAD COVER 5 10 9686 0610 1 EA HEAD COVER VL3500 WASH 6 53 5606 0375 1 EA SCREW 6 32 X 3 8 PPSS 7 53 6683 0015 4 EA SCREW 6 X 1 4 PPZ PLASTIC 8 55 2233 0016 4 EA RETAINER SPLIT RING 9 55 2233 0775 4 EA STUD 1 4 TURN 775L STEEL BLK ZINC 10 55 9676 0255 4 EA BELLEVILLE SPRING WASHER 1 4 5 10 x...

Page 87: ...T 6 32 KEPS ZINC PLATED 14 53 2004 0002 4 EA NUT 8 32 KEPS ZINC PLATE 15 53 6545 0009 4 EA SCREW 8 32 X 1 375 LG PFZ 16 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 17 53 6558 0007 2 EA SCREW 6 32 X 1 4 PPZ SEMS 18 53 6581 0001 4 EA SCREW 4 40 X 1 3 8 PPZ 19 53 6609 0001 10 EA SCREW 6 32 X 3 8 PFZ 20 53 6614 0003 4 EA SCREW 6 32 X 5 8 PFZ 21 53 6617 0001 10 EA SCREW 6 32 X 1 PPB 22 55 2125 0003 4 EA STA...

Page 88: ...ABLE ASSY not shown 25 9686 0201 1 EA CABLE ASSY OT SWITCH TO BACKCAP INTERLOCK not shown No Item Qty UM Description 1 2 3 x10 4 5 6 7 8 9 11 10 27 x2 32 x2 16 x2 14 x4 15 x4 17 x2 30 x2 29 x2 20 x4 23 22 x4 24 25 12 x2 18 x4 21 x10 28 x4 Detail A 19 x10 31 x2 13 x2 Detail A 26 x2 Detail B Detail B IMPORTANT Note orientation of fans in relation to assembly Fans must be installed as shown ...

Page 89: ...to Figure 3 8 Figure 3 8 80mm Fan Assembly No Item Qty UM Description 1 40 7144 0001 1 EA FAN TUBEAXIAL 80 X 80 X 38 MM 230V 36 CFM BBEARING 95 C 2 53 2200 0006 4 EA NUT 6 32 KEPS SS 3 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 4 55 7016 0001 1 EA FAN GUARD 80MM NICKEL PLATED STEEL WIRE 1 2 x4 3 x4 4 ...

Page 90: ...DUCT 2 10 9686 0673 1 EA TURNING VANE FAN DUCT 3 25 9678 0015 1 EA CABLE ASSY OT SWITCH 2 TO GND not shown 4 25 9686 0013 1 EA CABLE ASSY OT SWITCH 1 TO OT SWITCH 2 not shown 5 25 9686 0014 1 EA CABLE ASSY BACKCAP INTRLK TO OT SWITCH 1 not shown 6 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 7 53 6604 0002 4 EA SCREW 4 40 X 1 4 THREAD FORMING 8 74 1090 0001 2 EA OT1 THERMAL SWITCH LIMIT 199 C 1 6 x2 4 2...

Page 91: ...686 0632 1 EA REFLECTOR CLAMP 2 10 9686 0644 4 EA SPRING REFLECTOR MOUNT 3 21 9686 0606 1 EA ASSEMBLY UV GLASS 4 42 9686 0120 1 EA REFLECTOR ELIPTICAL 5 53 6683 0015 4 EA SCREW 6 32 X 5 8 PPB SEMS 1 2 x4 Note Install filter with marks indicating IR coating side of the glass facing up and located outside of circular cutout in reflector mount 4 3 5 x4 Align tabs on reflector and top left support ...

Page 92: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 74 02 9686 0010 A Notes ...

Page 93: ...Y TILT PLATE LONG VANE 25 9661 1522 1 EA CABLE ASSY HEAD TO BACKCAP GND not shown 25 9678 0789 1 EA CABLE ASSY IGNITOR TO LAMP SOCKET not shown 7 53 2030 0001 3 EA NUT ACORN 10 32THD 3 8 WIDE 8 53 5508 0375 2 EA SCREW 8 32 X 3 8 PPSS 9 53 6530 0013 8 EA RIVET 1 8 OD 063 125 GL CSK HD ALUM 10 55 2233 0003 4 EA RETAINER PUSH ON TYPE 11 55 2233 0006 4 EA STUD 1 4 TURN OPR 455L STEEL 12 55 6546 0004 3...

Page 94: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 76 02 9686 0010 A Hot Box Assembly continued Figure 3 11 Hot Box Assembly 1 2 3 5 7 x3 6 14 4 x3 8 x2 9 x8 11 x4 12 x3 10 x4 13 x3 ...

Page 95: ... 9686 0660 Rev B Refer to Figure 3 12 Figure 3 12 Dual Fan Tray Assembly No Item Qty UM Description 1 22 9686 0661 1 EA ASSY FAN TRAY 2 23 9686 0684 2 EA FAN ASSY HEAD FRONT 3 53 5506 1375 4 EA SCREW 6 32 X 1 3 8 LG PPB 4 55 6818 0002 1 EA STANDOFF 45 DEG NYLON 6 6 KUR 1 2 x2 3 x4 4 ...

Page 96: ...mbly 23 9686 0684 Rev 0 Refer to Figure 3 13 Figure 3 13 Head Front Fan Assembly No Item Qty UM Description 1 12 9686 0664 1 EA FAN COOLING 24V MODIFIED 2 52 6523 0002 1 EA CONN HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 1 2 3 x2 Pin 1 6 00 ...

Page 97: ...EA BUMPER LENS 4 10 9686 7135 2 EA KNOB HEX ALUMINUM 5 21 9686 2140 1 EA ASSEMBLY RAIL SPLIT LENS 6 21 9686 2142 1 EA ACTUATOR ASSEMBLY 7 21 9686 2144 1 EA ASSEMBLY INTERNAL LENS SPLITTER 8 21 9686 2164 1 EA ASSEMBLY SPLIT ZOOM BUXOM RIGHT 9 21 9686 2165 1 EA ASSEMBLY SPLIT ZOOM BUXOM LEFT 10 53 6513 0032 4 EA SCREW M3 X 5 X 10MM LG PPZ METRIC 11 53 6513 0046 4 EA SCREW M3 X 6 LG SOC CAP LOW PROFI...

Page 98: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 80 02 9686 0010 A Internal Lens Assembly Continued Figure 3 14 Internal Lens Assembly 1 2 3 5 10 x4 7 8 12 4 x2 9 6 11 x4 ...

Page 99: ...LIT LENS ZOOM ASSY 9 21 9686 1132 1 EA EOT STOP FRONT SPLIT LENS ASSEMBLY 10 22 9686 1154 1 EA LINEAR RAIL 12MM 2 LONG CARRIAGE 11 44 9663 1766 1 EA MOTOR 17 1 24 SHAFT 11 8MH 5 5 OHM 12 53 2200 0006 1 EA NUT 6 32 KEPS SS 13 53 6523 0001 5 EA SCREW 6 32 X 3 8 SCB ALLEN 14 53 6543 0001 5 EA SCREW 6 32 X 3 8 PPB 15 53 6598 0312 1 EA SCREW 4 40 X 5 16 PFB 16 53 6613 0008 2 EA SCREW 6 32 X 1 2 LG PPZ ...

Page 100: ...L3500 WASH LUMINAIRE SERVICE MANUAL 82 02 9686 0010 A Internal Lens Rail Assembly Figure 3 15 Internal Lens Rail Assembly 1 22 11 4 Reverse Side 16 x2 17 x2 14 x2 7 2 13 x5 20 18 5 19 9 8 3 6 15 21 12 14 x3 10 18 ...

Page 101: ... PIVOT 3 10 9686 1176 1 EA MOTOR MOUNT 1 SPLIT LENS MOTOR 4 10 9686 1179 2 EA HINGE ROD 5 10 9686 2175 1 EA MOUNT ZOOM LENS 6 10 9686 2189 1 EA EOT STOP VARI BRITE 7 21 9686 2160 2 EA PIVOT ASSY INTERNAL LENS 8 44 9686 0164 1 EA MOTOR SPLIT LENS 9 53 6524 0002 4 EA SCREW 6 32 X 5 16 PPB 10 53 6592 0250 2 EA SCREW 4 40 X 1 4 LG PPB SEMS 11 53 6607 0001 2 EA SCREW 6 32 X 1 4 PPB 12 54 2007 0001 2 EA...

Page 102: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 84 02 9686 0010 A Figure 3 16 Internal Lens Splitter Assembly 1 2 x2 3 4 x2 5 6 7 x2 8 9 x2 10 x2 11 x2 12 x2 9 x2 ...

Page 103: ... No Item Qty UM Description 1 10 9686 1158 4 EA SPACER PIVOT LINK 2 10 9686 2190 1 EA BUMPER LENS 3 10 9686 4188 1 EA PLATE LINKAGE ACTUATOR 4 10 9686 4189 1 EA MOUNT LEAD SCREW 5 21 9686 2130 2 EA ASSEMBLY PIVOT LINK 6 53 6607 0001 2 EA SCREW 6 32 X 1 4 PPB 7 53 6678 0013 2 EA SCREW SHLDR 4 40TH 125DIA 188 SHLDR 1 x4 2 5 x2 3 4 6 x2 7 x2 ...

Page 104: ...OR SPLIT LENS PIVOT 2 10 9686 1143 2 EA LENS MOUNT FRESNEL SPLIT LENS 3 10 9686 2181 6 EA SPACER LENS MOUNTING 4 10 9686 2182 2 EA BUMPER PAD SPLIT LENSES 5 42 9686 0111 1 EA LENS ZOOM FRESNEL RIGHT 6 42 9686 0112 1 EA LENS ZOOM FRESNEL LEFT 7 53 6543 0001 4 EA SCREW 6 32 X 3 8 PPB 8 54 1259 0006 2 EA BEARING FLANGED EXT IN RACE 0 25 ID 9 54 1259 0007 2 EA BEARING FLANGED 0 25 ID 5 1 8 x2 9 x2 7 x...

Page 105: ... 01 2 EA SPACER COLOR WHEEL 322 LG 14 10 9686 0457 02 2 EA SPACER COLOR WHEEL 125 LG 15 10 9686 0457 03 1 EA SPACER COLOR WHEEL 490 LG 16 10 9686 0457 04 1 EA SPACER COLOR WHEEL 090 LG 17 10 9686 0457 05 1 EA SPACER COLOR WHEEL 271 LG 18 10 9686 0468 6 EA PULLEY COLOR WHEEL DRIVE MOTOR WITH FLANGES 19 10 9686 2468 2 EA PULLEY MOTOR NO FLANGES FOR CTO AND DIMMER WHEELS 20 21 9686 0404 1 EA ASSEMBLY...

Page 106: ... PPZ SEMS 33 53 6530 0006 6 EA RIVET 1 8 OD POP 188 250 LG 34 53 6558 0009 10 EA SCREW 6 32 X 3 8 LG PPZ SEM 35 53 6609 0001 14 EA SCREW 6 32 X 3 8 PFZ 36 53 6613 0001 12 EA SCREW 6 32 X 1 2 PPZ 37 54 2057 0001 8 EA BELT TIMING MXL 188W 144 GRV URETH KEVLAR 38 55 6669 0014 6 EA STANDOFF 1 4 HEX 6 32 5 8 0 625 LG MF No Item Qty UM Description ...

Page 107: ...0 A 89 3 Color Effect Strobe Module continued Figure 3 19 Color Effect Strobe Module 8 11 x2 34 x6 20 38 x6 34 x6 10 9 33 38 34 35 4 5 17 19 27 1 30 32 x2 23 15 18 21 1 26 2 x5 16 37 6 31 x8 36 x12 12 3 35 x14 5 13 24 14 28 13 22 1 25 29 32 x2 6 14 7 x5 ...

Page 108: ...NG EFFECTS 13 10 9686 1446 1 EA MOTOR ADJUST PLATE NOTCHED 14 10 9686 1468 4 EA MOTOR PULLEY W FLANGES 1 8 BELT 15 10 9686 1469 2 EA MOTOR PULLEY SINGLE FLANGE 1 8 BELT 16 10 9686 2457 01 2 EA SPACER COLOR WHEEL 17 10 9686 2457 02 1 EA SPACER COLOR WHEEL 18 10 9686 2457 03 1 EA SPACER COLOR WHEEL 19 10 9686 2457 05 1 EA SPACER COLOR WHEEL 20 10 9686 2457 06 1 EA SPACER COLOR WHEEL 21 10 9686 2457 ...

Page 109: ...RNESS not shown 37 44 9663 1766 9 EA MOTOR ZOOM DIMMER 38 53 6525 0188 4 EA SCREW 6 32 X 3 16 LG PPZ SEMS 39 53 6530 0006 6 EA RIVET 1 8 OD POP 188 250 LG 40 53 6558 0009 12 EA SCREW 6 32 X 3 8 LG PPZ SEM 41 53 6609 0001 14 EA SCREW 6 32 X 3 8 LG PFZ 42 53 6613 0001 12 EA SCREW 6 32 X 1 2 LG PPZ 43 54 2057 0002 3 EA BELT TIMING MXL 144 GRV 0 125 WD UR KEV 44 54 2057 0003 5 EA BELT TIMING MXL 144 G...

Page 110: ... continued Figure 3 20 Color Rotating Effect Strobe Module 40 x6 10 40 x14 46 25 39 x6 6 38 x2 35 7 8 17 5 x5 32 16 15 28 38 x2 26 22 43 14 x4 21 31 20 3 x2 1 x5 2 37 x9 42 x12 46 41 12 9 x2 13 19 24 x2 16 19 34 36 30 29 23 45 27 15 11 18 4 x2 44 x5 For Cyan Yellow Magenta CTO and Dimmer Only 33 21 45 ...

Page 111: ... WHEEL 1 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 21 9686 0419 1 EA TIMING PULLEY WITH BEARINGS 5 41 9686 0490 1 EA COLOR FILTER RED WHEEL 1 6 41 9686 0491 1 EA COLOR FILTER YELLOW WHEEL 1 7 41 9686 0492 1 EA COLOR FILTER MAGENTA WHEEL 1 8 41 9686 0493 1 EA COLOR FILTER KELLY GREEN WHEEL 1 9 41 9686 0494 1 EA COLOR FILTER CONGO BLUE WHEEL 1 10 53 ...

Page 112: ...1 VL3500 Wash Fixed Color Wheel 1 Assembly 1 2 3 4 10 x4 5 6 7 8 9 POS 1 OPEN RTV beads should be applied at all positions where a filter can be used Alignment Tab Note All filters must be installed with the coating side towards the luminaire s lamp Detail A Detail A Congo Blue Kelly Green Magenta Yellow Red Open Alignment Tab ...

Page 113: ... 2 WHEEL 2 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 21 9686 0419 1 EA TIMING PULLEY WITH BEARINGS 5 41 9686 0495 1 EA COLOR FILTER BLUE WHEEL 2 6 41 9686 0496 1 EA COLOR FILTER AMBER WHEEL 2 7 41 9686 0497 1 EA COLOR FILTER DARK FUCHSIA WHEEL 2 8 41 9686 0498 1 EA COLOR FILTER ORANGE WHEEL 2 9 41 9686 0499 1 EA COLOR FILTER GREEN WHEEL 2 10 53 659...

Page 114: ... 22 VL3500 Wash Fixed Color Wheel 2 Assembly 1 2 3 4 10 x4 5 6 7 8 9 POS 1 OPEN RTV beads should be applied at all positions where a filter can be used Alignment Tab Note All filters must be installed with the coating side towards the luminaire s lamp Detail A Detail A Dark Fuchisa Orange Amber Blue Alignment Tab Green Open ...

Page 115: ... WHEEL 1 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 22 9686 1416 1 EA FIXED COLOR WHEEL HUB WITH BEARINGS 5 41 9686 0490 1 EA COLOR FILTER RED WHEEL 1 6 41 9686 0491 1 EA COLOR FILTER YELLOW WHEEL 1 7 41 9686 0492 1 EA COLOR FILTER MAGENTA WHEEL 1 8 41 9686 0493 1 EA COLOR FILTER KELLY GREEN WHEEL 1 9 41 9686 0494 1 EA COLOR FILTER CONGO BLUE WHEEL ...

Page 116: ...3 VL3500 Wash FX Fixed Color Wheel 1 Assembly 1 2 3 4 10 x4 5 6 7 8 9 POS 1 OPEN RTV beads should be applied at all positions where a filter can be used Alignment Tab Note All filters must be installed with the coating side towards the luminaire s lamp Detail A Detail A Congo Blue Kelly Green Magenta Yellow Red Open Alignment Tab ...

Page 117: ...R 2 WHEEL 2 2 10 9686 0482 1 EA SPACER PLATE FIXED COLOR 3 10 9686 0483 1 EA SPRING PLATE FIXED COLOR 4 22 9686 1416 1 EA FIXED COLOR WHEEL HUB WITH BEARINGS 5 41 9686 0495 1 EA COLOR FILTER BLUE WHEEL 2 6 41 9686 0496 1 EA COLOR FILTER AMBER WHEEL 2 7 41 9686 0497 1 EA COLOR FILTER DARK FUCHSIA WHEEL 2 8 41 9686 0498 1 EA COLOR FILTER ORANGE WHEEL 2 9 41 9686 0499 1 EA COLOR FILTER GREEN WHEEL 2 ...

Page 118: ...3 24 VL3500 Wash FX Fixed Color Wheel 2 Assembly 1 2 3 4 10 x4 5 6 7 8 9 POS 1 OPEN RTV beads should be applied at all positions where a filter can be used Alignment Tab Note All filters must be installed with the coating side towards the luminaire s lamp Detail A Detail A Dark Fuchisa Orange Amber Blue Alignment Tab Green Open ...

Page 119: ... 41 6040 4002 1 EA PATTERN VL3500 WASH FX FOUR HOLE RAY 7 41 6040 4009 1 EA PATTERN VL3500 WASH FX MEDIUM TRIANGLE 8 41 6040 4326 1 EA PATTERN VL3500 WASH FX SPOKES 9 41 6040 5011 1 EA PATTERN VL3500 WASH FX NIGHT SKY 10 53 6530 0013 5 EA RIVET 1 8 OD POP 0 328 AL CS 11 53 6659 0008 3 EA SCREW 2 56 X 3 16 PFZ 12 54 1206 0020 1 EA RETAINING RING 0 625 SHAFT 0 018 THK 13 55 6677 0050 10 EA WASHER FL...

Page 120: ...ASH LUMINAIRE SERVICE MANUAL 102 02 9686 0010 A VL3500 Wash FX Rotating Effect Wheel Assembly continued Figure 3 26 VL3500 Wash FX Rotating Effect Wheel Assembly 12 2 11 x3 7 6 3 10 x5 4 x4 9 8 15 x5 1 x5 14 x5 13 x10 5 ...

Page 121: ...21 9686 1445 1 EA ASSY AIR DUCT 7 21 9686 1437 1 EA REAR STROBE BLADE ASSEMBLY 8 21 9686 1438 1 EA FRONT STROBE BLADE ASSEMBLY 9 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR6 10 53 6513 0026 8 EA SCREW M3 X 5 X 12MM LG PP 11 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 12 53 6558 0007 4 EA SCREW 6 32 X 1 4 PPZ SEMS 13 53 6609 0001 4 EA SCREW 6 32 X 3 8 LG PFZ 14 55 2023 0002 1 EA HINGE 1 00 LG X 1 00 ...

Page 122: ...02 9686 0010 A VL3500 Wash Strobe System Assembly continued Figure 3 27 VL3500 Wash Strobe System Assembly Set blade assemblies according to dimensions shown 400 410 455 355 1 x4 2 3 4 5 6 7 8 9 x2 10 x8 15 x8 16 x8 17 x8 11 x4 12 x4 1 x4 13 x4 14 18 x8 ...

Page 123: ...ASSY AIR DUCT 6 21 9686 1437 1 EA REAR STROBE BLADE ASSEMBLY 7 21 9686 1438 1 EA FRONT STROBE BLADE ASSEMBLY 8 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR6 9 53 6513 0026 8 EA SCREW M3 X 5 X 12MM LG PP 10 53 6525 0188 4 EA SCREW 6 32 X 3 16 PPZ SEMS 11 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 12 53 6609 0001 4 EA SCREW 6 32 X 3 8 LG PFZ 13 55 2023 0002 1 EA HINGE 1 00 LG X 1 00 WD ZINC STEEL 14 5...

Page 124: ... 02 9686 0010 A VL3500 Wash FX Strobe System Assembly continued Figure 3 28 VL3500 Wash FX Strobe System Assembly Set blade assemblies according to dimensions shown 400 410 455 355 4 2 3 5 6 7 8 x2 9 x8 14 x8 15 x8 16 x8 11 x4 10 x4 1 x4 12 x4 13 17 x8 ...

Page 125: ...ear Strobe Blade Assembly No Item Qty UM Description 1 10 9678 0432 1 EA HUB STROBE BLADE 2 10 9678 0466 1 EA STROBE BLADE DAMPER 3 10 9686 1431 1 EA STROBE BLADE NOTCHED 4 53 5558 0188 2 EA SCREW 8 32 X 188 LG SET SS BRASS TIP UNC 2A 5 53 6597 0001 3 EA SCREW 4 40 X 3 16 PPZ 6 55 3303 0004 3 EA WASHER 4 LOCK INT TOOTH SS 1 2 3 4 x2 5 x3 6 x3 ...

Page 126: ...Front Strobe Blade Assembly No Item Qty UM Description 1 10 9678 0432 1 EA HUB STROBE BLADE 2 10 9678 0466 1 EA STROBE BLADE DAMPER 3 10 9686 1431 1 EA STROBE BLADE NOTCHED 4 53 5558 0188 2 EA SCREW 8 32 X 188 LG SET SS BRASS TIP UNC 2A 5 53 6597 0001 3 EA SCREW 4 40 X 3 16 PPZ 6 55 3303 0004 3 EA WASHER 4 LOCK INT TOOTH SS 3 2 3 4 x2 5 x3 6 x3 1 ...

Page 127: ...wn 25 9678 0681 1 EA CABLE ASSY YOKE FAN AND RELAY not shown 25 9678 0758 1 EA CABLE ASSY YOKE FAN not shown 9 53 2019 0004 2 EA NUT 3 8 16 X 7 32 THK HEX 10 53 2200 0006 1 EA NUT 6 32 KEPS SS 11 53 5634 0250 8 EA SCREW 4 40 X 1 4 PFSS BL 12 53 6539 0001 2 EA WASHER 3 8 SPLIT LOCK 13 53 6558 0009 12 EA SCREW 6 32 X 3 8 LG PPZ SEM 14 53 6626 0001 6 EA SCREW 10 32 X 1 2 PPZ 15 53 6634 0003 2 EA SCRE...

Page 128: ...3500 WASH LUMINAIRE SERVICE MANUAL 110 02 9686 0010 A Yoke Assembly continued Figure 3 31 Yoke Assembly 2 1 3 4 5 6 8 9 10 11 x8 12 x2 13 x3 14 x4 15 x2 16 19 7 13 x2 13 x4 14 x2 4 13 13 x2 17 18 x2 19 20 x2 21 x2 ...

Page 129: ...CODEWHEEL 120 COUNT LARGE ID 2b 10 9678 1749 1 EA TIMING PULLEY 17 TOOTH SHORTENED 2c 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET CONE POINT 3 24 9661 9629 1 EA PCB ASSY PAN TILT ENCODER 4 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0006 2 EA NUT 6 32 KEPS SS 6 53 2200 0008 4 EA NUT 8 32 KEPS SS 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 66...

Page 130: ...a replacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information 2 1 3 Step 1 Apply one drop of Loctite 603 to motor shaft Step 2 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 3 Do not allow Loctite to drip into motor bearing Step 4 Set pulley height as shown above Step 5 Apply Loctite ...

Page 131: ...Fan Assembly 22 9661 0609 Rev C Refer to Figure 3 33 Figure 3 33 Yoke Fan Assembly No Item Qty UM Description 1 10 9661 0646 1 EA FAN TRAY 2 40 7113 0001 1 EA FAN 24V 80MM X 80MM X 25MM 32 CFM 3 53 2200 0006 4 EA NUT 6 32 KEPS SS 1 2 3 x4 Direction of Air Flow ...

Page 132: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 114 02 9686 0010 A Notes ...

Page 133: ...UM Description 1 10 9686 1120 1 EA BRACKET HEAD CABLE INTERCONNECT 2 23 9686 0208 1 EA CABLE ASSY ZOOM MOTOR cable portion not shown 25 9686 0206 1 EA CABLE ASSY VARI BRITE MOTOR not shown part of 23 9686 0208 3 53 6520 0002 4 EA SCREW 4 40 X 7 16 PPZ 4 55 6621 0001 4 EA WASHER 4 FLAT ZINC 5 52 6670 0040 1 EA HEADER ASSY MOD 11 40 POS MTG 6 52 6670 0034 1 EA HEADER ASSY MOD 11 34 POS MTG 1 3 x4 4 ...

Page 134: ...ATSINK MAIN CONTROLLER 2 10 9678 0731 1 EA HEATSINK CONTROLLER 3 10 9678 0746 1 EA GROMMET PCB EDGE 4 10 9678 0885 1 EA KIT THERMAL TRANSFER MCB 5 53 2200 0006 3 EA NUT 6 32 KEPS SS 6 53 6404 0003 2 EA SCREW 4 40 X 1 PPZ 7 53 6616 0001 2 EA SCREW 6 32 X 3 4 PPZ 8 55 2179 0001 1 EA CABLE ANCHOR MOUNT 6 SCREW MOUNT 9 55 3303 0004 2 EA WASHER 4 LOCK INT TOOTH SS 10 55 6538 0002 2 EA WASHER 6 NYLON NA...

Page 135: ...HEAD YOKE PCB ASSEMBLIES VL3500 WASH CONTROLLER PCB ASSEMBLY 02 9686 0010 A 117 3 VL3500 Controller PCB Assembly continued Figure 3 36 VL3500 Wash Controller PCB Assembly Solder Side Component Side ...

Page 136: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 118 02 9686 0010 A Notes ...

Page 137: ...11 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN 12 10 9678 0886 1 EA SPACER PAN BEARING 235 THK 13 12 9686 1236 2 EA MACHINED COVER FRONT 14 12 9686 1238 2 EA MACHINED COVER SIDE 15 12 9678 0842 1 EA AIR DUCT UPPER ENCLOSURE MOD 16 21 9686 0840 02 1 EA ASSY COVER VENTILATION 17 21 9678 0767 1 EA ASSY STABILIZER 17a 10 9678 0757 1 EA STABILIZER 1 377DIA 17b 10 9678 0762 1 EA BRACKET STABLIZER 17c ...

Page 138: ...53 2200 0006 4 EA NUT 6 32 KEPS SS 30 53 6505 0022 3 EA BOLT 3 8 16 X 3 4 LG CARR 31 53 6515 0001 4 EA SCREW 10 32 X 3 4 SCB CAP 32 53 6522 0001 1 EA SCREW 6 32 X 1 4 PFZ 33 53 6522 0004 2 EA SCREW 6 32 X 1 4 SOC HD 34 53 6525 0188 2 EA SCREW 6 32 X 3 16 PPZ SEMS 35 53 6530 0023 2 EA RIVET 1 8 OD POP 376 500GRP 36 53 6539 0001 4 EA WASHER 3 8 SPLIT LOCK 37 53 6545 0003 4 EA SCREW 8 32 X 3 8 PFZ 38...

Page 139: ... 0 125 62 55 6658 0009 1 EA STANDOFF 1 4 HEX 6 32 X 3 4 63 55 6568 0074 2 EA SPRING CPRSN 0 420 OD 0 750 LG 64 55 6577 0005 2 EA STANDOFF 1 2 HEX 6 32 1 625 L 65 55 6677 0044 1 EA WASHER 0 877 OD 0 170 ID 0 093 THK 55 6699 0010 0 5 FT SLEEVING 5 16 NON DIA WOVEN POLY ROUNDIT not shown 66 55 6775 0009 1 EA BUSHING SNAP 750 ID 1 MT H 67 67 4018 0001 1 EA FERRITE 26X28 5 X 13MM CYL 68 67 9686 1500 1 ...

Page 140: ...I LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 122 02 9686 0010 A Upper Enclosure Assembly continued Figure 3 37 Upper Enclosure Assembly 2 3 5 18 16 14 13 13 41 x4 8 x2 40 x4 14 57 9 x2 42 x4 41 x4 47 x4 16 ...

Page 141: ...nents 12 6 7 19 15 24 21 48 38 x4 20 17a 17b 17c 17d 26 11 25 27 28 33 x2 53 x2 36 58 x4 31 x4 49 x3 52 40 x2 59 x2 Part is shown exploded for clarity 17 46 54 x2 55 40 x3 50 x2 51 73 74 37 22 61 x3 30 45 x2 66 28 29 x2 30 36 36 41 44 x2 45 x2 63 x2 61 Detail A 71 See Detail A Note Shims used as required to remove any slack in pan tube assembly ...

Page 142: ...IRE SERVICE MANUAL 124 02 9686 0010 A Upper Enclosure Assembly continued Figure 3 39 Upper Enclosure Electrical Components 1 4 34 x2 35 x2 38 68 29 x2 70 32 23 65 56 69 37 43 67 62 60 10 64 40 x3 54 55 55 72 41 41 39 Ground Label ...

Page 143: ... 2 10 9686 0883 1 EA COVER VENTILATION 3 10 9678 0837 1 EA AIR SEAL FAN SIDE 4 10 9678 0838 1 EA AIR SEAL APS SIDE 5 10 9678 0835 1 EA AIR SEAL SHORT STRIP 6 10 9678 0836 1 EA AIR SEAL LONG STRIP 7 10 9678 0887 2 EA RAIN COVER SOUND INSULATION ALUMINUM COVER 8 53 6653 0027 4 EA SCREW 1 4 20 X 1 5 8 SOC HEAD 9 54 1206 0015 4 EA RING RETAINING PRESS ON 1 SH 10 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK...

Page 144: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 126 02 9686 0010 A Ventilation Cover Assembly continued Figure 3 40 Ventilation Cover Assembly 1 x4 2 8 x4 9 x4 10 x4 6 3 4 5 7 x2 ...

Page 145: ...mbly No Item Qty UM Description 1 10 9686 0810 1 EA MOUNTING PLATE EXHAUST FAN 2 40 7140 0001 1 EA BLOWER CENTRIFUGAL 24VDC 9CFM 3 X 3 3 52 6523 0002 1 EA CONN HOUSING 2 POS PLUG SHROUDED 4 52 8347 0001 2 EA CONTACT 24 30 AWG MALE CRIMP 5 55 6576 0001 2 EA SCREW 10 16 X 3 8 TYPE B PFZ 1 2 5 x2 3 4 x2 Table 3 1 Connector Pin Out Pin Wire 1 Black 2 Red ...

Page 146: ...NER DISPLAY BOARD 4 10 9686 0820 1 EA FILLER PANEL DMX CONNECTOR 5 24 9663 3895 1 EA PCB ASSY DMX INPUT 6 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 7 24 9678 3825 1 EA 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 ...

Page 147: ...Input PCB No Item Qty UM Description Ref 1 17 9663 3895 1 EA PCB FAB DMX INPUT 2 52 6259 0006 1 EA HEADER 5POS MTA FRCT LOK STRT POST J3 3 52 6625 0006 1 EA CONN RECEPT XLR 5PIN FEMALE PC MT VERTICAL J1 4 52 6626 0006 1 EA CONN RECEPT XLR 5PIN MALE PC MT VERTICAL J2 5 62 3039 0102 1 EA CAP 1000P 250V 20 CDE X Y C1 1 2 3 4 5 ...

Page 148: ...Assembly 21 9686 0807 Rev B Refer to Figure 3 44 Figure 3 44 Pan Pulley Assembly No Item Qty UM Description 1 10 9686 0750 1 EA TIMING PULLEY 170 TOOTH 2 10 9678 0855 1 EA PAN FLAG 3 53 6530 0009 2 EA RIVET 1 8 OD POP 126 187 GL 1 2 3 x2 Note orientation of Pan Flag 1 2 0 o 100o ...

Page 149: ...OTOR MOUNT 5 21 9686 0828 1 EA ASSY DRIVE PULLEY PAN 5a 10 9678 8720 1 EA CODEWHEEL 120 COUNT 5b 10 9686 0749 1 EA TIMING PUILLEY 5c 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET CONE POINT 6 24 9678 9729 1 EA PCB ASSY VL2203 PAN TILT ENCODER 7 44 9678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 8 53 2200 0008 4 EA NUT 8 32 KEPS SS 9 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 10 53 6575 0009 2 EA SCREW 8 32 ...

Page 150: ...r the pulley Item 2 Contact Vari Lite Customer Service for installation information 2 Step 1 Apply one drop of Loctite 603 to motor shaft Step 2 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 3 Do not allow Loctite to drip into motor bearing Step 4 Set pulley height as shown above Step 5 Apply Loctite 242 to pulley set screws Insure set scre...

Page 151: ...ssembly No Item Qty UM Description 1 10 9678 0809 1 EA PAN TOGGLE STOP 2 10 9678 0847 1 EA SILICONE FOAM WASHER 3 10 9678 0848 2 EA WASHER PAN TEFLON 4 12 9678 0877 1 EA PAN TUBE MACHINED 5 54 1206 0021 1 EA RING RETAINING 1 562 SHAFT 1 468 GRV DIA 068 GRVWD EXTERNAL 6 54 1255 0002 1 EA BEARING ASSY FLUSH MOUNT HOUSING LARGE 1 2 3 4 5 6 3 ...

Page 152: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 134 02 9686 0010 A Notes ...

Page 153: ...EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 47 Figure 3 47 Pan EOT Sensor Electrical Assembly No Item Qty UM Description 1 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 2 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 3 86 7002 0003 1 EA SWITCH SLOTTED OPTICAL 1 3 2 x4 ...

Page 154: ...sembly 25 9661 1514 Rev A Refer to Figure 3 48 Figure 3 48 LVS Chassis Ground Cable Assembly 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 1 2 3 ...

Page 155: ... 25 9661 1526 Rev C Refer to Figure 3 49 Figure 3 49 Ignitor to Relay Cable Assembly No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG LOOSE PIDG 2 52 8312 0001 1 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 73 7101 0009 0 42 FT WIRE 14AWG 15KV 150C SILICONE 41 30 STRANDING 2 3 1 ...

Page 156: ...OK 2 2 52 6665 0002 2 EA CONN HOUSING 2 POS PLUG MATE N LOC 2 3 52 8413 0001 4 EA RECEPT FASTON 110 SERIES 22 18AWG INSULATED 4 55 2186 0002 2 EA CABLE TIE 09 WD 3 750 LG TEFZEL 5 55 2260 0208 2 75 FT SLEEVING FIBERGLASS 0 208 ID 6 55 2200 0003 0 50 FT HEATSHRINK TEFLON NATURAL COLOR 7 73 6222 0009 6 33 FT WIRE 22AWG 600V 200C TFE WHT UL1199 19STRAND 8 73 6222 0010 6 33 FT WIRE 22AWG 600V 200C TFE...

Page 157: ...1 52 6664 0001 4 EA CONTACT 22 26AWG FEMALE MATE N LOK 2 2 52 6664 0002 2 EA CONN HOUSING 2 POS CAP MATE N LOK 2 3 52 8231 0008 2 EA TERM SPADE 6 RED 22 16AWG INSERT 4 55 2186 0001 2 EA CABLE TIE 10 WD 4 00 LG SMALL 5 55 6699 0002 2 08 FT SLEEVING 1 4 NOM DIA POLY EXP BRAIDED 6 73 6222 0009 4 34 FT WIRE 22AWG 600V 200C TFE WHT UL1199 7 73 6222 0010 4 34 FT WIRE 22AWG 600V 200C TFE BLK UL1199 1 2 3...

Page 158: ...h 1 to OT Switch 2 Cable Assembly 25 9686 0013 Rev A Refer to Figure 3 53 Figure 3 52 OT Switch 1 to OT Switch 2 Cable Assembly No Item Qty UM Description 1 52 8371 0001 2 EA RECEPT FASTON 24 20 AWG UNINSUL TIN 2 73 7089 0000 0 42 FT WIRE 22AWG 300V 200C TEF BLK UL1180 1 3 1 ...

Page 159: ...able Assembly 25 9686 0014 Rev A Refer to Figure 3 53 Figure 3 53 Backcap Interlok to OT Switch 1 Cable Assembly No Item Qty UM Description 1 52 8414 0001 1 EA RECEPT FASTON 187 SERIES 24 20 AWG UNINSUL 2 52 8371 0001 1 EA RECEPT FASTON 24 20 AWG UNINSUL 3 73 7089 0000 0 33 FT WIRE 22AWG 300V 200C TEF BLK UL1180 2 3 1 ...

Page 160: ... 25 9678 0015 Rev A Refer to Figure 3 54 Figure 3 54 OT Switch to Ground Cable Assembly No Item Qty UM Description 1 52 8237 0002 1 EA TERM RING 4 24 20AWG 2 52 8371 0001 1 EA RECEPT FASTON 24 20AWG UNISUL TIN PLT BRS 250 X 032 TAB 3 73 7089 0000 0 25 FT WIRE 22AWG BLK 300V 200C TEFLON STRANDED 1 2 3 ...

Page 161: ...LATCHING 6 52 6224 2034 1 EA COVER BACK 34 POS MT 7 52 6610 0017 1 EA CONNECTOR HOUSING 50 POS 26 22 AWG DBL ROW UNLOADED 8 52 6224 1050 1 EA COVER FRONT 50 POS MT LATCHING 9 52 6224 2050 1 EA COVER BACK 50 POS MT 10 52 8351 0004 118 EA CONTACT 26 22 AWG RECP MTE 11 52 6524 0004 2 EA CONNECTOR HOUSING 4 POS RECEPTACLE 30 24 AWG 12 52 8346 0001 6 EA CONTACT 24 30 AWG FEMALE CRIMP 13 73 5116 0123 29...

Page 162: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 144 02 9686 0010 A Tilt Harness Cable Assembly continued Figure 3 56 Tilt Harness Cable Assembly Wiring Pin Out ...

Page 163: ...4 1014 2 EA COVER FRONT 14 POS MT LATCHING 3 52 6224 2014 2 EA COVER BACK 14 POS MT 4 55 2186 0001 4 EA CABLE TIE 10 X 4 SMALL 5 55 6699 0004 0 6 FT SLEEVING 3 4 NOM DIA POLY EXP BRAID 6 73 5116 0123 4 0 FT WIRE 24 AWG 4 COND TW 300V 80C BLK BRN RED ORN 7 73 5126 0002 2 0 FT WIRE 26 AWG 2 COND TW 300V 80C BLK RED 8 73 5126 0007 2 0 FT WIRE 26 AWG 2 COND TW 300V 80C BLK ORN 9 73 3026 0009 2 0 FT WI...

Page 164: ...VER FRONT 34 POS MT LATCHING 6 52 6224 2034 1 EA COVER BACK 34 POS MT 7 52 8351 0004 52 EA CONTACT 26 22 AWG RECP MTE 8 52 6467 0011 2 EA CONNECTOR FEMALE PLUG 11 POS 30 24 AWG 9 52 6467 0024 20 EA CONTACT SOCKET 30 24 AWG CRIMP 10 52 6662 0006 8 EA HOUSING 6 POS 125 2A 2 0 MM PITCH 11 52 8388 0001 32 EA CONTACT 24 30 AWG FEMALE CRIMP 2 0 MM PITCH 12 55 2186 0001 8 EA CABLE TIE 10 X 4 SMALL 13 73 ...

Page 165: ...CABLE ASSEMBLIES VL3500 WASH COLOR HARNESS CABLE ASSEMBLY 02 9686 0010 A 147 3 VL3500 Wash Color Harness Cable Assembly continued Figure 3 59 VL3500 Wash Color Harness Cable Assembly Wiring Pin Out ...

Page 166: ...G 11 POS 30 24 AWG 9 52 6467 0024 22 EA CONTACT SOCKET 30 24 AWG CRIMP 10 52 6662 0006 9 EA HOUSING 6 POS 125 2A 2 0 MM PITCH 11 52 8388 0001 36 EA CONTACT 24 30 AWG FEMALE CRIMP 2 0 MM PITCH 12 55 2186 0001 8 EA CABLE TIE 10 X 4 SMALL 13 73 2324 0123 14 66 FT WIRE 24 AWG 4 COND TW 300V 200C TEF BLK BRN RED ORG 14 73 2328 6000 0 875 FT WIRE 26 AWG 6 COND 300V 200C TEF BLK WHT BLU WHT YEL WHT BLK W...

Page 167: ...6 0010 A 149 3 VL3500 Wash FX Color Harness Cable Assembly continued Figure 3 60 VL3500 Wash FX Color Harness Cable Assembly 12 x8 4 5 6 7 1 2 3 7 13 13 10 11 10 11 16 9 14 10 11 10 11 10 11 13 13 13 13 8 9 13 10 11 15 13 10 11 8 9 13 20 18 19 13 10 11 15 17 9 13 10 11 ...

Page 168: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 150 02 9686 0010 A VL3500 Wash FX Color Harness Cable Assembly continued Figure 3 61 VL3500 Wash FX Color Harness Cable Assembly Wiring Pin Out ...

Page 169: ... Cable Assembly No Item Qty UM Description 1 52 6467 0004 1 EA CONNECTOR FEM PLUG 4 POS 30 24 AWG 2 52 6467 0024 4 EA CONTACT 24 30 AWG FEMALE CRIMP 2 00 MM PITCH 3 52 6696 0001 1 EA RECEPT WIRE TO WIRE 4 POS 2 MM PITCH 28 24 AWG 4 52 6694 0001 4 EA CRIMP TERMINAL WIRE TO WIRE FEMALE 2 MM PITCH 28 24 AWG 5 73 2326 0123 0 7 FT WIRE 26 AWG 4 COND 300V 200C TEF UL1180 BLK BRN RED ORN 1 2 x4 5 3 4 x4 ...

Page 170: ... Item Qty UM Description 1 52 6523 0004 1 EA CONN HOUSING 4POS RECEPTACLE 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3 52 8347 0001 4 EA CONTACT 24 30AWG MALE CRIMP 4 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 5 73 2324 0200 2 21 FT WIRE 26AWG 2COND 300V 200C BLK RED UL1213 6 52 8274 0001 2 EA CONNECTOR BUTT SPLICE 22 18 AWG INSULATED 5 1 3 x4 6 x2 5 5 2 4 x2 2 4 x2 ...

Page 171: ...Figure 3 64 Upper Enclosure Fans Cable Assembly No Item Qty UM Description 1 52 6523 0004 1 EA CONN HOUSING 4POS RECEPTACLE 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3 52 8347 0001 4 EA CONTACT 24 30AWG MALE CRIMP 4 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 5 73 5126 0002 6 41 FT WIRE 26AWG 2COND 300V 80C BLK RED 5 1 3 x4 5 2 4 x2 2 4 x2 ...

Page 172: ...re 3 65 Yoke Fan and Relay Cable Assembly No Item Qty UM Description 1 52 6423 0003 1 EA HOUSING 3 POS MT RECEPT 2MM 2 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG 3 52 6396 3103 1 EA RECEPT 3 POS MTA100 W POL TAB BLU CLSD END 4 73 3526 0002 1 25 FT WIRE 26AWG 300V 105C PVC RED 5 73 5126 0002 1 50 FT WIRE 26AWG 2 COND 300V 80C RED BLK 1 3 5 4 2 ...

Page 173: ... 0758 Rev A Refer to Figure 3 66 Figure 3 66 Yoke Fan Cable Assembly No Item Qty UM Description 1 52 6396 3102 1 EA RECEPT 2POS MTA100 W POL TAB BLUE CLSD END 2 52 6423 0003 1 EA HOUSING 3POS MT RECEPT 2MM CT 28 26 AWG 3 73 5126 0002 0 5 FT WIRE 26AWG 2COND 300V 80C BLK RED UL1061 19STRND 1 2 3 ...

Page 174: ...ssembly 25 9686 0201 Rev A Refer to Figure 3 67 Figure 3 67 OT Switch to Backcap Interlok Cable Assembly No Item Qty UM Description 1 52 8230 0003 1 EA RECEPT FASTON 22 18AWG 1 4 2 52 8414 0001 1 EA RECEPT FASTON 187 SERIES 24 20 AWG UNISUL 3 73 7089 0000 3 00 FT WIRE 22AWG 300V 200C TEF BLK UL1180 1 3 2 ...

Page 175: ... 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 7 6 2 x3 1 From Ignitor Output To Arc Lamp Socket 7 6 3 1 x 44 each 3 1 x 48 each 5 1 x 20 each ...

Page 176: ...o Yoke Ground Cable Assembly 25 9661 1520 Rev C Refer to Figure 3 69 Figure 3 69 Chassis to Yoke Ground Cable Assembly No Item Qty UM Description 1 52 8250 0006 2 EA TERM RING 8 10AWG 2 73 7089 0504 15 17 FT WIRE 22AWG 300V 200C TEF GRN YEL UL1180 1 2 Yoke Ground Head Ground 1 ...

Page 177: ...Zoom Motor Cable Assembly 23 9686 0208 Rev 0 Refer to Figure 3 70 Figure 3 70 Zoom Motor Cable Assembly No Item Qty UM Description 1 25 9686 0206 1 EA CABLE ASSY ZOOM MOTOR 2 24 9678 5916 1 EA PCB ASSY ZOOM INTERCONNECT 1 2 Note Item 1 is soldered to Item 2 as shown ...

Page 178: ...o Figure 3 71 Figure 3 71 Transfer Fans Cable Assembly No Item Qty UM Description 1 52 6662 0006 1 EA HOUSING 6 POS 125 2A 2 00 MM PITCH 2 52 6467 0024 4 EA CONTACT 24 30 AWG FEMALE CRIMP 2 00 MM PITCH 3 73 2326 0123 0 75 FT WIRE 26 AWG 4 COND 300V 200C TEF UL1180 BLK BRN RED ORN ZOOM BRN ORN BLK RED 1 2 x4 3 ...

Page 179: ...OP FLEX TYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG CE MARKED 20A 250V TWIST LOCK MALE LINE 3 WIRE 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8298 1160 2 EA FERRULE WIRE 1X16 AWG L2 8MM BLACK 5 55 2268 0187 0 92 FT HEATSHRINK 3 16 CLEAR KYNAR VDE UL 600V 150DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR VDE UL 600V 150DEG C 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60C ...

Page 180: ...itch Cable Assembly No Item Qty UM Description 1 52 8313 0001 2 EA RCPT FASTON 1 4 18 14 AWG FLAG DBL CRP REEL 2 52 8392 0001 2 EA RECP FASTON 187 X0 32 16 14 AWG FLAG DBL CRP 3 55 2186 0001 1 EA 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 1 2 4 3 5 White Black White Black 1 2 ...

Page 181: ...187 X 0 32 16 14 AWG FLAG DBL CRP 5 52 8270 0001 2 EA CONTACT PIN 20 14 AWG MNLOK REEL 6 52 8314 0001 1 EA PIN GND 20 14 AWG MNLOK 060 130 INS DIA 7 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 8 55 6699 0003 1 50 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 9 73 6016 0009 1 83 FT WIRE 16 AWG 600V 105C PVC WHT UL1015 10 73 6016 0010 1 83 FT WIRE 16 AWG 600V 105C PVC BLK UL1015 11 73 6016 0504 2 08 ...

Page 182: ...0 WASH LUMINAIRE SERVICE MANUAL 164 02 9686 0010 A AC Input Splitter Cable Assembly continued Figure 3 74 AC Input Splitter Cable Assembly 3 x2 4 x2 12 5 9 5 10 13 11 6 2 1 7 x3 8 Note Heatshrink not shown for clarity ...

Page 183: ...y 25 9678 0813 Rev A Refer to Figure 3 75 Figure 3 75 Data I O Link Cable Assembly No Item Qty UM Description 1 52 6396 2904 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END 2 52 6396 2905 1 EA RECEPT 5 POS MTA100 W POL TAB RED CLSD END 3 73 5122 0259 2 17 FT CBL 22AWG STRND 4COND PVC INSUL 2 1 3 ...

Page 184: ...2406 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD END 2 73 5116 0123 1 02 FT WIRE 24AWG 4COND TW BLK BRN RED ORN 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 TFE GRN 2 5 LG 6 55 6699 0009 2 08 FT SLEEVING 3 8 NOM DIA POLY EXP 7 55 6621 0001 1 EA SLEEVE NYLON THIN WALL 6 SCR 1 0 LG 6 1 2 5 1 3 x3 3 ...

Page 185: ...igure 3 77 Figure 3 77 Ballast to Controller Cable Assembly No Item Qty UM Description 1 52 6396 3002 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END 2 52 6396 3005 1 EA RECEPT 5 POS MTA100 W POL TAB WHT CLSD END 3 52 6396 3008 1 EA RECEPT 8 POS MTA100 W POL TAB WHT CLSD END 4 73 5124 1289 3 67 FT WIRE 24AWG 5COND BLK BRN RED GRN WHT 2 3 1 4 ...

Page 186: ...G 6 BLUE 12 10 AWG INSRT 4 52 8323 0002 4 EA CONTACT CRIMP 18 22 AWG SL 156 not shown 5 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 BLUE 150 OD MAX 6 55 2186 0001 4 EA CABLE TIE 01 x 4 00 SMALL 7 55 6699 0003 2 08 FT SLEEVING 1 2 NOM DIA POLY EXP BRAID 8 73 3518 0002 1 58 FT WIRE 18 AWG 300V 105C PVC RED 9 73 3518 0010 1 58 FT WIRE 18 AWG 300V 105C PVC BLK 10 73 7060 0001 2 08 FT WIRE 18 AWG HI VOLT ...

Page 187: ...4 2020 1 EA COVER BACK 20POS MT 4 52 6524 0005 2 EA CONN HOUSING 5POS RECEPTACLE 5 52 6588 0007 2 EA HOUSING 7POS XH 250V 3A 2 5MMPITCH 6 52 7007 0001 6 EA CONTACT 28 22AWG PHOSPHOR BRONZE TIN PLT 7 52 8346 0001 10 EA CONTACT 24 30AWG FEMALE CRIMP 8 55 2186 0001 6 EA CABLE TIE 10 WD 4 00 LG SMALL 9 73 5119 0246 6 08 FT WIRE 24AWG 3COND TW 600V 200C RED YEL BLU 10 73 5124 1289 6 17 FT WIRE 24AWG 5C...

Page 188: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 170 02 9686 0010 A Pan Tilt Control Cable Assembly continued Figure 3 80 Pan Tilt Control Cable Assembly Wiring Pin Out ...

Page 189: ...1 3 EA 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 22AWG BLK 300V TEFLON STRANDED 5 73 7089 0009 34 41 FT WIRE 22AWG WHT 300V TEFLON STRANDED 6 73 3516 0504 58 FT WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 7 52 8245 0001 1 EA TERM RING 10 16 14 AWG REEL PIDG 8 73 7130 0005 2 08 FT WIRE TUBULAR BRAID 7 16 NOT SHOWN 9 55 2183 ...

Page 190: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 172 02 9686 0010 A Notes ...

Page 191: ... the password protected support areas please contact Vari Lite Customer Service at 1 877 827 4548 or customerservice genlytecontrols com Table A 1 Vari Lite VL3500 Wash VL3500 Wash FX Technical Notices Technical Notice Description Model s TN 248 Specified and Approved Lamps for use in VARI LITE Luminaires All TN 264 Split Lens Rail Change VL3500 Wash TN 274 Pack up Cues for Shipping VL3500 Wash TN...

Page 192: ...VARI LITE VL3500 WASH LUMINAIRE SERVICE MANUAL 174 02 9686 0010 A Notes ...

Page 193: ......

Page 194: ...1 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 19 May 2009 Manual Part Number 02 9686 0010 A 2003 2009 A Philips Group Company All rights reserved Printed in the U S A ...

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