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Vari Lite VL3500 Spot Luminaire, Service Manual

The Vari Lite VL3500 Spot Luminaire is a powerful lighting fixture perfect for stage performances. For detailed instructions on how to properly operate and maintain this unit, make sure to download the free Service Manual from manualshive.com. Get your manual today and ensure your VL3500's peak performance.

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VARI

❋

LITE

®

 - VL3500™ S

POT

 L

UMINAIRE

 S

ERVICE

 M

ANUAL

x v i

0 2 . 9 6 7 8 . 0 0 1 8   A

Pan Motor Assembly.............................................................................................................  148
Pan Tube Assembly...............................................................................................................   149

Cable Assemblies

Pan EOT Sensor Electrical Assembly...................................................................................  151
LVS Chassis Ground Cable Assembly..................................................................................  152
Chassis To Yoke Ground Cable Assembly ...........................................................................  153
Head to Back Cap Ground Cable Assembly .........................................................................  154
Ignitor to Relay Cable Assembly ..........................................................................................  155
LVS to Yoke AC Fan Cable Assembly .................................................................................  156
Yoke to AC Fan Cable Assembly .........................................................................................  157
Backcap Interlock to Gobo Fan Interlock Cable Assembly..................................................  158
Relay to Gobo Fan Interlock Cable Assembly......................................................................  159
Front Head Fans Cable Assembly.........................................................................................  160
Yoke Fan and Relay (Standard) Cable Assembly .................................................................  161
Air Duct OT Switch Cable Assembly...................................................................................  162
Yoke Fan and Relay (Quiet) Cable Assembly ......................................................................  163
Yoke Fan (Standard) Cable Assembly ..................................................................................  164
Yoke Fan (Quiet) Cable Assembly .......................................................................................  165
Ignitor to Lamp Socket Cable Assembly ..............................................................................  166
Yoke to Head Ground Cable Assembly ................................................................................  167
Head Controller Cable Assembly .........................................................................................  168
AC Input Pigtail Cable Assembly .........................................................................................  170
EMI Filter to Power Switch Cable Assembly .......................................................................  171
AC Input Splitter Cable Assembly........................................................................................  172
Data I/O Link Cable Assembly .............................................................................................  174
Display Cable Assembly .......................................................................................................  175
Ballast to Controller Cable Assembly...................................................................................  176
DC Output Cable Assembly..................................................................................................  177
Pan/Tilt Control Cable Assembly .........................................................................................  178
Lamp Supply to Relay Cable Assembly ...............................................................................  179
Gobo/Rotate Interconnect Cable Assembly..........................................................................  180
LVS Chassis Ground Cable Assembly..................................................................................  182

Appendix A.  Technical Bulletins

VL3500 Technical Bulletins .................................................................................................  183

Appendix B.  Schematic and Wiring Diagrams

Solid State Ignitor PCB (Sheet 1 of 1) ..................................................................................  185
Gobo Index Sensor PCB (Sheet 1 of 1) ................................................................................  186
DMX Input PCB (Sheet 1 of 1) ............................................................................................  187
Gobo Interconnect PCB (Sheet 1 of 1) .................................................................................  188
Color Interconnect PCB (Sheet 1 of 1) .................................................................................  189
Color Sensor #1 PCB (Sheet 1 of 1) .....................................................................................  190
Color Sensor #2 PCB (Sheet 1 of 1) .....................................................................................  191
Pan/Tilt Encoder PCB (Sheet 1 of 1) ....................................................................................  192

Summary of Contents for VL3500 Spot Luminaire

Page 1: ...VL3500 Spot Luminaire 02 9678 0018 Service Manual...

Page 2: ...82 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...

Page 3: ...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 origi...

Page 4: ...ence 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 ow...

Page 5: ...en designed for use with specific lamp types The VL3500 Spot luminaires require an Osram HMI 1200 W S metal halide lamp Installing another type of lamp may be hazardous 2 Luminaires may be mounted on...

Page 6: ...hich 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...

Page 7: ...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 mont...

Page 8: ...n 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 4 Tragen Sie beim Aust...

Page 9: ...utilis s uniquement avec certaines type de lampes V rifier le type de lampe Osram HMI 1200 W S metal halide lamp avant de remplacer les lampes L installation d un autre type de lampe peut poser un dan...

Page 10: ...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 cau...

Page 11: ...sadas solamente con algunas l mparas Tome nota del tipo de l mpara Osram HMI 1200 W S metal halide lamp antes de reemplazarla Instalaci n de otro tipo de l mpara puede ser peligroso 2 Las luminarias s...

Page 12: ...maduras 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 incendi...

Page 13: ...FOREWORD 02 9678 0018 A xi...

Page 14: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL xii 02 9678 0018 A...

Page 15: ...Operation VL3500 Spot Luminaire 8 Functional Block Diagram 8 Chapter 2 Maintenance Testing Luminaire Self Tests 10 Calibration Sequence 10 Auto Recalibration 11 Partial Recalibration 11 Sensor Testin...

Page 16: ...47 Generic Luminaire Quiet Assembly 49 Head Assembly Head Structure Standard Assembly 51 Head Structure Quiet Assembly 52 Head Cover Assembly 53 Backcap Assembly 54 80mm Fan Assembly 56 UV Filter Bulk...

Page 17: ...09 Yoke Assembly Yoke Assembly 111 Tilt Motor Assembly 113 Relay Electrical Assembly 114 Yoke Fan Assembly 115 Head Yoke PCB Assemblies Shutter Cable Interconnect Assembly 117 Color Sensor PCB 1 Mount...

Page 18: ...ly 165 Ignitor to Lamp Socket Cable Assembly 166 Yoke to Head Ground Cable Assembly 167 Head Controller Cable Assembly 168 AC Input Pigtail Cable Assembly 170 EMI Filter to Power Switch Cable Assembly...

Page 19: ...VL3500 Controller PCB Sheet 7 of 10 199 VL3500 Controller PCB Sheet 8 of 10 200 VL3500 Controller PCB Sheet 9 of 10 201 VL3500 Controller PCB Sheet 10 of 10 202 VL3500 Motor Driver Piggy Back PCB She...

Page 20: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL xviii 02 9678 0018 A...

Page 21: ...e following models 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 Addit...

Page 22: ...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 VARI LITE equipment are is...

Page 23: ...02 9678 0018 A 3 CHAPTER 1 Description This chapter contains descriptions of luminaire features and components Features Components Principles of Operation...

Page 24: ...n tilt system Control by DMX512 protocol Fan cooled UV IR glass Specific Features VL3500 Spot Luminaire Four independent shutters 6 1 zoom optics system with 10 to 60 range Variable beam focus to morp...

Page 25: ...rovides controls for internal status information beam adjustment see detail below Upper Enclosure Assembly Houses power supply ballast and display board Truss Hook Bracket Attaches to enclosure base t...

Page 26: ...Cover Yoke Arm Cover Yoke Arm Houses lamp and reflector Provides knobs for lamp Backend Assembly adjustment Main Controller Board MCB Luminaire control circuit board Contains one rotating gobo wheel o...

Page 27: ...clarity Enclosure Top Covers 200W 24V 6 3A Input Panel Assembly 1200W Arc Ballast Module Enclosure Bottom Ventilation Cover Power Supply Fan Assembly containing DMX Input PCB and Menu Display Wire Co...

Page 28: ...es of Operation VL3500 Spot Luminaire Functional Block Diagram SHUTTER ROTATE ROTATE GOBO INTERCONNECT SHUTTER MOTOR 1A SHUTTER MOTOR 1B SHUTTER MOTOR 2A SHUTTER MOTOR 2B SHUTTER MOTOR 3A SHUTTER MOTO...

Page 29: ...nd standard maintenance procedures Testing Troubleshooting Maintenance Procedures WARNING As with any repairs or maintenance to Vari Lite luminaires service should only be performed by a trained and q...

Page 30: ...the VL3500 Spot User s Manual 02 9678 0019 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence Phase 1 Tilt Strobe Rotating Shutter Assembly Color Wheel...

Page 31: ...es Edge Zoom and Shutter Hold DMX value 140 for 3 seconds then 0 recals Dimmer and Strobe Sensor Testing Most mechanisms within the VL3500 luminaire are equipped with either optical or magnetic sensor...

Page 32: ...n 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...

Page 33: ...through 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...

Page 34: ...nfig ured Reconfigure lamp startup option in Lamp config menu n a Luminaire behaves oddly Profile Not Matched Profile not set correctly check Setup menu for correct type spot or wash check start DMX a...

Page 35: ...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 t...

Page 36: ...loth to thoroughly clean glass portion of lamp To install lamp Step 1 Ensure power is removed from luminaire Step 2 At rear of luminaire head loosen four 1 4 turn screws and slide lamp box back it is...

Page 37: ...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 fe...

Page 38: ...d 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 luminai...

Page 39: ...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 o...

Page 40: ...Turn Screw Gobo Wheel see detail CAUTION Do not touch glass with bare fingers Press on gobo carrier only Head covers are attached by tethers Gobo Wheel 2 Gobo Assembly Carrier Spring Retaining Clip R...

Page 41: ...loves 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 c...

Page 42: ...tep 5 Set luminaire on nose to access and remove bottom cover Step 6 Remove bottom cover handles side covers and end cover nearest to ballast Note the different size screws for the side and end covers...

Page 43: ...power source Step 2 Remove top head cover Step 3 Disconnect yoke cable at interconnect board Step 4 Remove interconnect board at side rail by gently pushing inward at top and then lifting up Step 5 R...

Page 44: ...source Step 2 Remove board side yoke leg cover Step 3 At MCB disconnect head wiring and remove screws to daughter board a Remove Standoffs and 2 screws securing MCB b While holding MCB outward discon...

Page 45: ...le from power source Step 2 Remove tilt side yoke leg cover Step 3 Disconnect four lamp wires and four screws securing the ignitor to the mounting plates as indicated inFigure 2 9 Step 4 Remove and re...

Page 46: ...bottom cover Step 4 Remove two connectors to pan encoder board Step 5 Remove four screws securing pan motor to chassis Step 6 Carefully lift motor upwards and remove tensioning springs Step 7 Slide be...

Page 47: ...2 Carefully lay luminaire on its side to have access to bottom of enclosure Step 3 At enclosure assembly remove bottom cover Step 4 Remove pan encoder board Step 5 Install in reverse order Make sure b...

Page 48: ...rom power source Step 2 Carefully lay luminaire on its side Step 3 At enclosure assembly remove bottom cover Step 4 Remove pan sensor Step 5 Install in reverse order Make sure bottom cover standoffs a...

Page 49: ...sure remove top cover at power supply side Step 3 At LVS remove wiring Step 4 Remove screw closest to pan tube Loosen two screws at opposite end of wiring Step 5 Remove LVS Step 6 Install in reverse o...

Page 50: ...fer fan assembly from optic assembly board Step 5 Disconnect yoke cable from color assembly wiring interconnect Step 6 Release color assembly yoke cable from two cable twist locks on transfer fan asse...

Page 51: ...ptic zoom box guide rods being careful not to let optic box fall Step 8 Remove spot optic assembly being careful not to let the guide rails fall Step 9 Remove guide rails Step 10 Install in reverse or...

Page 52: ...ep 4 Remove tilt motor assembly as indicated a Remove four screws securing tilt motor while holding motor to prevent it from falling b Remove two tensioning springs c Loosen tilt belt from around gear...

Page 53: ...nnect luminaire AC input cable from power source Step 2 Remove tilt side yoke leg cover Step 3 Remove tilt motor assembly from yoke leg as described on page 32 Step 4 Remove and replace encoder Figure...

Page 54: ...0003 Repair Procedure Step 1 Disconnect luminaire AC input cable from power source Step 2 Remove tilt side yoke leg cover Step 3 Remove sensor bracket Step 4 Remove and replace tilt sensor Figure 2 1...

Page 55: ...19 To time gobo wheels Step 1 Align all holes in wheels as shown below Step 2 Insert a 3 long 4 or M3 screw or 0 125 diameter pin completely through aligned holes in wheel and bulkhead plates as show...

Page 56: ...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 a...

Page 57: ...d parts breakdowns for all VL3500 Spot Luminaire assemblies Note The VL3500 Series Luminiares share many common assemblies and parts of the Vari Lite Series 3000 Luminaires Drawing Trees Top Assembly...

Page 58: ...Rev B Solid State Ignitor PCB 24 9661 3126 Rev 0 Yoke Fan and Relay Standard Cable Assembly 25 9678 0681 Rev C VL3500 Only AC Input Pigtail Cable Assembly 25 9678 0758 Rev A VL3500 Fixed Color Wheel...

Page 59: ...1 9678 0864 Rev E Pan Tube Assembly 21 9678 0881 Rev 0 Panel Assembly 21 9678 0805 Rev L SHIELDED BALLAST CCI 12 9678 1862 Upper Enclosure Fan Assembly 23 9678 0686 Rev 0 EMI Filter to Power Switch Ca...

Page 60: ...327 Rev B Solid State Ignitor PCB 24 9661 3126 Rev 0 Yoke Fan and Relay Quiet Cable Assembly 25 9678 0781 Rev A VL3500Q Only Yoke Fan Quiet Cable Assembly 25 9678 0759 Rev A VL3500Q Only Fixed Color W...

Page 61: ...bly 21 9678 0864 Rev E Pan Tube Assembly 21 9678 0881 Rev 0 Panel Assembly 21 9678 0805 Rev L SHIELDED BALLAST CCI 12 9678 1862 Upper Enclosure Fan Assembly Quiet 23 9678 0888 Rev 0 EMI Filter to Powe...

Page 62: ...00 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 POS 1 3 9 41 6030 5503 1 EA GOBO ASSY PALM LEAVES POS 2 2...

Page 63: ...amp 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 6 5 4 7 x2 1 19 3 2 8 9 10 11 12 Night Sky Palm Leaves Tr...

Page 64: ...SSY 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 8640 01 1 EA ASSY HOT BOX SPOT VL3500 ONLY 21 9678 8698 01 1 EA...

Page 65: ...REW 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...

Page 66: ...500 Spot Series Luminaire continued Figure 3 6 VL3500 Series Spot Luminaire 1 35 x2 4 5 9 6 7 8 22 x4 11 12 13 x4 14 15 x2 16 x2 17 18 30 x2 24 x2 22 x8 24 x2 27 x2 25 x2 33 x2 34 x2 31 x2 4 6 3 10 2...

Page 67: ...041 WIRE DIA 5 21 9678 0800 02 1 EA ASSY UPPER ENCLOSURE 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 0...

Page 68: ...ICE MANUAL 48 02 9678 0018 A Generic Luminaire Assembly continued Figure 3 7 Generic Luminaire Assembly VL3500 Only 1 2 3 4 5 6 x4 7 x5 8 x4 9 x4 10 11 x4 12 x3 13 x2 15 16 x5 3a 3b 3c x3 4a 4b 4c 4d...

Page 69: ...375 OD 1 00 LG 041 WIRE DIA 5 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 GRD5 ZINC PLT 7 53 6505 0020 5 EA BOLT 1 4 28X 3 4 HX HD GRD 8 ZINC...

Page 70: ...MANUAL 50 02 9678 0018 A Generic Luminaire Quiet Assembly continued Figure 3 8 Generic Luminaire Assembly VL3500Q Only 1 2 3 4 5 6 x4 7 x5 8 x4 9 x4 10 11 x4 12 x3 13 x2 15 16 x5 3a 3b 3c x3 4a 4b 4c...

Page 71: ...cture Assembly VL3500 Only 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 ASS...

Page 72: ...ly VL3500Q Only 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 0616 1 EA ASSEMBLY BACK...

Page 73: ...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...

Page 74: ...EA CABLE ASSY AC FAN YOKE TO FAN not shown 25 9678 0014 1 EA CABLE ASSY BACKCAP INTERLOK TO GOBO INTERLOK not shown 25 9678 0691 1 EA CABLE ASSY OT SWITCH not shown 25 9678 0690 1 EA CABLE ASSY OT SW...

Page 75: ...5AMP 150DEG 10 9678 0680 1 EA INSULATOR TEFLON TO 220 not shown 53 2200 0004 1 EA 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 No Item Qty U...

Page 76: ...Quiet Refer to Figure 3 5 Figure 3 5 80mm Fan Assembly VL3500 and VL3500 Quiet 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 EA NUT 6 32 KEP...

Page 77: ...3500 and VL3500 Q 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 1160 1 EA UV IR FILTER 3 00 X 3 00 VL3500 QUIET 41 9678 0608 1 EA UV IR...

Page 78: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 58 02 9678 0018 A Notes...

Page 79: ...ER 14 24 9663 1231 2 EA 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 1...

Page 80: ...bly 31 55 6506 0033 4 EA SPACER 3 8 RND 1 1 8 LG 257 ID THRU AL 32 55 6520 0001 4 EA WASHER WAVE SPRING 265 ID 367 OD 006 THK No Item Qty UM Description 16 19 x2 15 23 x8 14 21 x4 27 x4 20 x4 9 x2 22...

Page 81: ...1410 1 EA ASSY FIXED GOBO WHEEL 5 24 9678 1240 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 SCREW 4 40 X 3 16 PFZ 8 54 2007 0001 2 EA RING RETAINING...

Page 82: ...x 625 L x 0035 THICK 2 10 9678 1412 1 EA PLATE ROTATING GOBO WHEEL 3 10 9678 1425 6 EA FIXED GOBO 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...

Page 83: ...ACER TEFLON GOBO GEAR 3 10 9663 1240 5 EA BEARING GOBO WHEEL BORE 4 10 9678 0220 1 EA PLATE ROTATING GOBO WHEEL 5 10 9678 0224 5 EA RETAINING RING PLANET 6 12 9678 1223 1 EA SUN GEAR MOLDED WITH FLANG...

Page 84: ...Pivot Rotate Assembly 21 9678 1555 Rev 0 Refer to Figure 3 11 Figure 3 11 Roller Pivot Rotate Assembly No Item Qty UM Description 1 10 9678 1551 1 EA ROLLER PIVOT SHUTTER ROTATE 2 22 9678 1550 1 EA AS...

Page 85: ...0018 A 65 3 Shutter Rotate Roller Assembly 22 9678 1550 Rev B Refer to Figure 3 12 Figure 3 12 Shutter Rotate Roller Assembly No Item Qty UM Description 1 10 9678 1552 1 EA ROLLER SHUTTER ROTATE 2 54...

Page 86: ...Motor Assembly 21 9678 0243 Rev 0 Refer to Figure 3 13 Figure 3 13 Long Shaft Motor Assembly No Item Qty UM Description 1 10 9678 0330 1 EA PLATE MOTOR ADAPTER 2 44 9678 0249 1 EA MOTOR STEPPER 42MM X...

Page 87: ...12 10 9678 1542 1 EA BELT RING FLANGE STOP 13 10 9678 1543 1 EA BELT CLAMP BOTTOM 14 10 9678 1544 1 EA BELT CLAMP TOP 15 12 9678 1562 2 EA BLADE SHUTTER BOTTOM COATED 16 12 9678 1565 2 EA BLADE SHUTT...

Page 88: ...ICE MANUAL 68 02 9678 0018 A Shutter Assembly continued Figure 3 14 Shutter Assembly 1 27 3 4 28 x2 7 9 x4 20 x16 11 x3 17 16 x2 18 x6 5 x4 1 2 2 13 12 14 19 x2 11 x4 10 x4 24 x8 25 x16 21 x2 23 x8 15...

Page 89: ...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 EA SCREW M3 X 12 PFZ 5 53 6513 0045 8 EA SCREW M3 X 16 PFZ 6 55...

Page 90: ...RE SERVICE MANUAL 70 02 9678 0018 A Shutter Motor Disk Assembly continued Figure 3 15 Shutter Motor Disk Assembly 2 x8 5 x8 1 6 x4 11 9 7 x10 Frame 1A Frame 1B Frame 2A Frame 2B Frame 3A Frame 3B Fram...

Page 91: ...6568 0077 4 EA SPRING COMPRESSION 0 035 WIRE 0 300 DIA X 625 LG 11 12 9678 7151 1 EA REFLECTOR PRI 40 LUNE DUAL CURVATURE 25 9661 1522 1 EA CABLE ASSY HEAD TO BACKCAP GROUND Not Shown 25 9678 0789 1 E...

Page 92: ...LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 72 02 9678 0018 A Hot Box Assembly continued Figure 3 16 Hot Box Assembly 1 2 3 4 5 x3 6 11 13 x3 14 x2 12 x4 15 x8 16 x4 17 x4 18 x3 19 x3 20 8 x4 10 x4 7 x4...

Page 93: ...TENSION 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 000...

Page 94: ...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 188 250...

Page 95: ...sembly 23 9678 0684 Rev 0 VL3500 Only Refer to Figure 3 19 Figure 3 19 Head Front Fan Assembly VL3500 Only No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52 6523 0002 1 EA CONN HOU...

Page 96: ...sembly VL3500Q Only No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 2 52 6523 0002 1 EA CONN HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52 8347 0001 2 EA CONTACT 24 30AWG MALE CRIMP 4...

Page 97: ...78 1280 1 EA SHIELD ASSY SHUTTER ROTATE HARNESS 3 23 9678 0695 1 EA ASSY TRANSFER FAN 4 53 6558 0001 1 EA SCREW 6 32 X 375 LG PPZ 5 53 6571 0003 3 EA SCREW 6 32 X 1 500 LG PPB 6 55 2179 0001 1 EA CABL...

Page 98: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 78 02 9678 0018 A NOTES...

Page 99: ...174 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 CARRIAGE 16...

Page 100: ...001 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 NOT SHOWN 39 53 6617 0003 1 EA SCREW 6 32 X 1 PPB SEMS changed 3...

Page 101: ...OT OPTIC ASSEMBLY 02 9678 0018 A 81 3 Spot Optic Assembly continued Figure 3 22 Spot Optic Assembly View 1 23 33 x2 24 36 x4 21 33 x2 36 x4 20 26 35 33 x3 48 34 40 x2 41 x6 49 Detail F F Detail E E F...

Page 102: ...w 2 44 37 4 Interconnect PCB and Zoom Motor removed for clarity Detail A A Detail B B Detail C C 28 47 46 7 39 48 46 2 46 42 45 43 45 1 6 10 19 18 11 3 13 5 35 33 x2 33 x3 15 32 x6 27 3 50 3 Optical S...

Page 103: ...x Assembly 21 9678 0110 Rev F Refer to Figure 3 24 Figure 3 24 Zoom Box Assembly No Item Qty UM Description 1 10 9678 0124 1 EA ZOOM BOX 2 10 9678 0125 1 EA BRACE FOCUS 3 10 9678 0126 1 EA BRACE REAR...

Page 104: ...Figure 3 25 Figure 3 25 G4 Lens Mount Assembly No Item Qty UM Description 1 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 5...

Page 105: ...embly 22 9678 1103 Rev C Refer to Figure 3 26 Figure 3 26 Right Edge Bearing Assembly No Item Qty UM Description 1 12 9678 1102 1 EA EDGE BEARING MACHINED RIGHT 2 54 2056 0001 4 EA RING RETAINING EXTE...

Page 106: ...Assembly 22 9678 1105 Rev C Refer to Figure 3 27 Figure 3 27 Left Edge Bearing Assembly No Item Qty UM Description 1 12 9678 1104 1 EA EDGE BEARING MACHINE LEFT 2 54 2056 0001 4 EA RING RETAINING EXTE...

Page 107: ...y No Item Qty UM Description 1 10 9678 1107 1 EA ZOOM TIMING CAM 2 10 9678 1108 1 EA PULLEY FLANGE 3 10 9678 1118 1 EA TIMING PULLEY ZOOM 4 53 6613 0008 2 EA SCREW 6 32 X 1 2 PPZ changed 11 08 04 5 54...

Page 108: ...r Tensioning Assembly 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 53 555...

Page 109: ...Assembly 22 9678 1115 Rev D Refer to Figure 3 30 Figure 3 30 Interconnect Light Shield Assembly No Item Qty UM Description 1 10 9678 1114 1 EA SHIELD INTERCONNECT MOUNT LIGHT 2 24 9678 3116 1 EA PCB...

Page 110: ...fer to Figure 3 31 Figure 3 31 Rod Clamp Assembly No Item Qty UM Description 1 10 9678 0151 1 EA CLAMP OPTIC ROD CAST 2 53 6616 0001 2 EA SCREW 6 32 X 3 4 PPZ 3 55 6528 0001 2 EA WASHER 6 FLAT ZINC 4...

Page 111: ...ING BLOCK FIXED WHEEL 10 9678 0323 1 EA WHEEL MOUNT 54 1259 0004 2 EA BEARING RADIAL FLANGED 0 25 ID 0 625 OD changed 6 25 03 13 22 9678 0403 1 EA ASSY STROBE 22 9678 0463 1 EA ASSY STROBE VL3000 QUIE...

Page 112: ...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 I...

Page 113: ...embly continued Figure 3 32 Color Dimmer Strobe Assembly 1 2 3 x2 4 5 6 7 8 9 x5 10 11 12 13 14 15 16 17 18 19 20 21 22 23 x5 24 25 5 6 6 25 x2 25 x5 25 x4 26 x10 26 x2 27 x12 28 x5 29 x2 30 x5 31 32...

Page 114: ...pter Plate Assembly 21 9678 0331 Rev 0 Refer to Figure 3 33 Figure 3 33 Motor Adapter Plate Assembly No Item Qty UM Description 1 10 9678 0330 1 EA PLATE MOTOR ADAPTER 2 44 5031 0001 1 EA MOTOR STEPPE...

Page 115: ...01 1 EA COLOR FILTER DEEP RED VL3000 6 41 9678 0305 02 1 EA COLOR FILTER KELLY GREEN VL3000 7 41 9678 0305 03 1 EA COLOR FILTER CONGO BLUE VL3000 8 41 9678 0305 04 1 EA COLOR FILTER MAGENTA VL3000 9...

Page 116: ...02 9678 0018 A Fixed Color Wheel Assembly continued Figure 3 34 Fixed Color Wheel Assembly 1 2 x6 3 x6 4 11 x6 12 x3 13 14 x6 POS 1 POS 2 CONGO BLUE POS 3 ORANGE POS 4 KELLY POS 5 DARK POS 6 MAGENTA...

Page 117: ...Y RIGHT STROBE BLADE 4 22 9678 0468 1 EA ASSY LEFT STROBE BLADE 5 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR 6 53 6513 0032 8 EA SCREW M3X10MM SEMS PPZ EXT TO 7 53 6609 0500 4 EA SCREW 6 32 X 1 2...

Page 118: ...4 22 9678 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...

Page 119: ...re 3 37 Right Strobe Blade Assembly No Item Qty UM Description 1 10 9678 0464 1 EA STROBE BLADE 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...

Page 120: ...gure 3 38 Left Strobe Blade Assembly No Item Qty UM Description 1 10 9678 0464 1 EA STROBE BLADE 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...

Page 121: ...9 Figure 3 39 Strobe Motor Quiet Assembly VL3500Q Only 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 55 8346 0001 4 EA CO...

Page 122: ...embly 22 9678 0435 Rev D Refer to Figure 3 40 Figure 3 40 Dimmer Wheel Assembly No Item Qty UM Description 1 22 9678 0420 1 EA PULLEY ASSY WITH BEARING 2 41 9678 0494 1 EA GLASS COATED DIMMER WHEEL ch...

Page 123: ...78 0018 A 103 3 Cyan Wheel Assembly 22 9678 0472 Rev C Refer to Figure 3 41 Figure 3 41 Cyan Wheel Assembly No Item Qty UM Description 1 22 9678 0420 1 EA PULLEY ASSY WITH BEARING 2 41 9678 0471 1 EA...

Page 124: ...104 02 9678 0018 A Yellow Wheel Assembly 22 9678 0474 Rev B Refer to Figure 3 42 Figure 3 42 Yellow Wheel Assembly No Item Qty UM Description 1 22 9678 0420 1 EA PULLEY ASSY WITH BEARING 2 41 9678 047...

Page 125: ...0018 A 105 3 Magenta Wheel Assembly 22 9678 0476 Rev B Refer to Figure 3 43 Figure 3 43 Magenta Wheel Assembly No Item Qty UM Description 1 22 9678 0420 1 EA PULLEY ASSY WITH BEARING 2 41 9678 0475 1...

Page 126: ...MANUAL 106 02 9678 0018 A CTO Wheel Assembly 22 9678 0478 Rev B Refer to Figure 3 44 Figure 3 44 CTO Wheel Assembly No Item Qty UM Description 1 22 9678 0420 1 EA PULLEY ASSY WITH BEARING 2 41 9678 04...

Page 127: ...A Refer to Figure 3 45 Figure 3 45 Gobo Clamp Assembly No Item Qty UM Description 1 12 9678 0691 1 EA GOBO CLAMP 2 53 6685 0625 2 EA SCREW CAPTIVE PANEL 6 32 X 625 LG PPS ZINC PLATED 3 55 6538 0001 3...

Page 128: ...Rev A Refer to Figure 3 46 Figure 3 46 Color Clamp Assembly No Item Qty UM Description 1 12 9678 0692 1 EA COLOR CLAMP 2 53 6685 0625 2 EA SCREW CAPTIVE PANEL 6 32 X 625 LG PPS ZINC PLATED 3 55 6538...

Page 129: ...02 9678 0018 A 109 3 Edge Lead Screw Assembly 22 9678 1126 Rev B Refer to Figure 3 47 Figure 3 47 Edge Lead Screw Assembly No Item Qty UM Description 1 10 9678 1119 1 EA LEAD SCREW EDGE 2 55 6616 0007...

Page 130: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 110 02 9678 0018 A Notes...

Page 131: ...E ASSY YOKE FAN AND RELAY NOT SHOWN 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...

Page 132: ...500 SPOT LUMINAIRE SERVICE MANUAL 112 02 9678 0018 A Yoke Assembly cont Figure 3 48 Yoke Assembly 2 1 3 4 5 6 8 9 10 11 x8 13 x2 12 x2 13 x3 14 x4 15 x2 16 19 7 13 x2 13 x4 14 x2 4 13 13 x2 17 18 x2 1...

Page 133: ...TILT ENCODER changed 02 22 06 24 9661 8629 1 EA PCB ASSY PAN TILT ENCODER changed 02 22 06 VL3500 QUIET 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...

Page 134: ...7 Rev B Refer to Figure 3 50 Figure 3 50 Relay Electrical Assembly No Item Qty UM Description 1 04 9650 0044 1 EA LABEL RELAY WIRING VL7 2 52 8271 0005 2 EA RECEPT FASTON 1 4 16 14 AWG INSULATED 3 66...

Page 135: ...51 Yoke Fan Assembly 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 32CFM 3 53 2200 0006 1 EA NUT 6 32 KEPS SS 4 55 2179 0003 1 EA CABLE SADDLE 75 X...

Page 136: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 116 02 9678 0018 A Notes...

Page 137: ...Rev A Refer to Figure 3 52 Figure 3 52 Shutter Cable Interconnect Assembly 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...

Page 138: ...9678 0481 Rev B Refer to Figure 3 53 Figure 3 53 Color Sensor 1 PCB Mount Assembly No Item Qty UM Description 1 10 9678 0482 1 EA PCB MOUNT COLOR SENSOR 1 2 24 9678 3480 1 EA PCB ASSY COLOR SENSOR 1...

Page 139: ...or Sensor PCB 2 Mount Assembly 22 9678 0489 Rev B Refer to Figure 3 54 Figure 3 54 Color Sense PCB 2 Mount Assembly No Item Qty UM Description 1 10 9678 0452 1 EA PCB MOUNT COLOR SENSOR 2 2 24 9678 04...

Page 140: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 120 02 9678 0018 A Solid State Ignitor PCB 24 9661 3126 Rev 0 Refer to Figure 3 55 Only available as an assembly Figure 3 55 Solid State Ignitor PCB...

Page 141: ...9678 0018 A 121 3 Wheel Position Sensor PCB Assembly 24 9678 3240 Rev 0 Refer to Figure 3 56 Figure 3 56 Wheel Position Sensor PCB Assembly No Item Qty UM Description 1 17 9678 3240 1 EA PCB WHEEL POS...

Page 142: ...09 1 EA PCB COLOR INTERCONNECT 52 6467 0003 1 EA CONN FEM PLUG 3POS 30 24 AWG 52 6467 0005 1 EA CONN FEM PLUG 5POS 30 24AWG 52 6467 0007 1 EA CONN FEM PLUG 7POS 30 24AWG 52 6467 0024 1 EA CONTACT SOCK...

Page 143: ...HEAD YOKE PCB ASSEMBLIES COLOR INTERCONNECT PCB CABLE ASSEMBLY 02 9678 0018 A 123 3 Color Interconnect PCB Cable Assembly continued Figure 3 58 Color Interconnect PCB Assembly Wire Chart VL3500 Only...

Page 144: ...3 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...

Page 145: ...D YOKE PCB ASSEMBLIES COLOR INTERCONNECT QUIET PCB CABLE ASSEMBLY 02 9678 0018 A 125 3 Color Interconnect PCB Cable Assembly continued Figure 3 60 Color Interconnect PCB Assembly Wire Chart VL3500Q On...

Page 146: ...00 SPOT LUMINAIRE SERVICE MANUAL 126 02 9678 0018 A Pan Tilt Encoder PCB 24 9661 9629 Rev B VL3500 24 9661 8629 Rev 0 VL3500 Quiet Refer to Figure 3 61 Available only as an assembly Figure 3 61 Pan Ti...

Page 147: ...SEMBLIES VL3500 CONTROLLER PCB ASSEMBLY 02 9678 0018 A 127 3 VL3500 Controller PCB Assembly 24 9678 1730 Rev F Refer to Figure 3 62 Available only as an assembly Figure 3 62 VL3500 Controller PCB Top...

Page 148: ...RES 1 16W 1 2 67K OHM CHIP THK R3 R6 R9 R12 R16 R17 R27 R28 R36 R39 R42 R45 60 1161 7503 20 EA RES 1 16W 1 7 50K OHM CHIP THK R19 R22 R30 R31 R48 R51 60 1165 1004 10 EA RES 1 16W 5 10K OHM CHIP THK R...

Page 149: ...river Piggy Back PCB C15 C16 C25 C40 C41 62 4245 0272 5 EA CAP 2700PF 25V 10 CER CHIP SU C19 C22 C26 C27 C42 C45 62 4245 0471 10 EA CAP 470PF 25V 10 CER CHIP SU D1 D20 82 5362 0001 20 EA DIODE SCHOTTK...

Page 150: ...4 52 6260 0003 1 EA HEADER 2POS MTA 100 SHROUDED J2 52 6447 0004 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 J1 52 659...

Page 151: ...HEAD YOKE PCB ASSEMBLIES ARC ZOOM INTERCONNECT PCB ASSEMBLY 02 9678 0018 A 131 3 Zoom Interconnect PCB Assembly continued Figure 3 64 Arc Zoom Interconnect PCB Assembly...

Page 152: ...rget PCB Assembly 24 9678 0112 Rev 0 Refer to Figure 3 65 Figure 3 65 Zoom Sensor PCB Assembly Ref Item Qty UM Description 11 9678 1117 1 EA PCB VL3000 ZOOM SENSOR J1 52 6447 0003 1 EA HEADER SHROUDED...

Page 153: ...Rev B Refer to Figure 3 66 Figure 3 66 Index Sensor PCB Assembly Ref Item Qty UM Description 11 9663 1231 1 EA PCB INDEX SENSOR J1 52 6447 0004 1 EA HEADER SHROUDED 4 POSITION S1 86 7002 0004 1 EA SWI...

Page 154: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 134 02 9678 0018 A Notes...

Page 155: ...9 10 9686 0846 2 EA HANDLE CAST ENCLOSURE 10 10 9678 0869 1 EA BRACKET LVS 11 10 9678 0886 1 EA SPACER PAN BEARING 0 235 THK 12 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN 13 10 9678 1876 1 EA AIR D...

Page 156: ...Y TO RELAY not shown 25 9678 0843 1 EA CABLE ASSY AC FAN LVS TO YOKE not shown 27 52 8295 0002 1 EA TERMINAL STRIP 300V 12AWG 20A 28 53 2001 0003 1 EA NUT 10 32 NYLON INSERT 29 53 2019 0004 4 EA NUT 3...

Page 157: ...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...

Page 158: ...SPOT LUMINAIRE SERVICE MANUAL 138 02 9678 0018 A Upper Enclosure Assembly continued Figure 3 67 Upper Enclosure Assembly Part 1 2 3 5 8 8 9 9 18 14 15 15 20 44 x4 42 x4 43 x4 43 x2 66 x2 50 x4 14 59 6...

Page 159: ...ct Assembly 6 12 23 17 16 38 49 21 30 x2 19 19a 19b 19c 19d 22 7 24 26 28 29 x2 29 x2 31 x2 31 53 33 x4 32 x2 42 51 51 38 x2 52 54 x2 Part is shown exploded for clarity 73 63 38 43 56 62 43 57 x2 55 x...

Page 160: ...Assembly No Item Qty UM Description 1 10 9661 1249 4 EA POST TRUSS HOOK 2 10 9661 1350 1 EA COVER VENTILATION 3 10 9678 0893 1 EA 12 AIR SEAL UPPER ENCLOSURE changed 05 11 05 4 10 9678 0894 1 EA 6 AIR...

Page 161: ...OOK SHORT EARLY PRODUCTION 1b 10 9678 0833 4 EA SPACER 1 25 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 SE...

Page 162: ...00 SPOT LUMINAIRE SERVICE MANUAL 142 02 9678 0018 A Ventilation Cover Assembly VL3500 Quiet continued Figure 3 70 Ventilation Cover Assembly 1 x4 2 8 x4 9 x4 10 x4 6 3 4 5 7 x2 Early production Curren...

Page 163: ...R DISPLAY BOARD added 05 26 05 4 24 9663 3830 1 EA PCB ASSY DMX INPUT changed 07 01 06 5 24 9678 3825 1 EA PCB ASSY DISPLAY changed 07 01 06 6 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL changed 04...

Page 164: ...72 DMX Input PCB No Item Qty UM Description Ref 1 11 9663 1830 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 RECPT XLR 5P FEM PC MT VERT J1...

Page 165: ...0 9461 7502 1 EA RES 0 1W 5 750 0 OHM CHIP THK FILM SUR MT C1 62 3038 0101 1 EA CAP 100PF 50V 10 MONO CER CHIP SUR MT C6 C13 62 3038 0103 2 EA CAP 0 01UF 50V 10 MONO CER CHIP SUR MT C3 C4 C7 C9 C12 62...

Page 166: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 146 02 9678 0018 A Display PCB continued Figure 3 73 Display PCB Top Side Bottom Side View From Component Side...

Page 167: ...ey Assembly 21 9678 0807 Rev E Refer to Figure 3 74 Figure 3 74 Pan Pulley Assembly 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...

Page 168: ...678 0680 1 EA MOTOR 3 PHASE SIZE 23 HIGH TORQUE 5 53 2200 0008 4 EA NUT 8 32 KEPS SS 6 53 6546 0001 4 EA SCREW 8 32 X 5 8 PPB 7 53 6682 0002 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 8 55 2132 0014 2 EA S...

Page 169: ...sembly 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 002...

Page 170: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 150 02 9678 0018 A Notes...

Page 171: ...OT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 77 Figure 3 77 Pan EOT Sensor Electrical Assembly No Item Qty UM Description 1 52 6524 0006 1 EA CONN HOUSING 6 POS RECEPTACLE 2 52 8...

Page 172: ...embly 25 9661 1514 Rev A Refer to Figure 3 78 Figure 3 78 LVS Chassis Ground Cable Assembly No Item Qty UM Description 1 52 8231 0001 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8271 0001 1 EA FAST...

Page 173: ...153 3 Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Refer to Figure 3 79 Figure 3 79 Chassis To Yoke Ground Cable Assembly No Item Qty UM Description 1 52 8250 0006 2 EA TERM 8 RING 10AWG 2...

Page 174: ...o Back Cap Ground Cable Assembly 25 9661 1522 Rev B Refer to Figure 3 80 Figure 3 80 Head to Back Cap Ground Cable Assembly No Item Qty UM Description 1 52 8311 0003 2 EA TERM RING 6 14 16AWG NON INS...

Page 175: ...25 9661 1526 Rev C Refer to Figure 3 81 Figure 3 81 Ignitor to Relay Cable Assembly No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8312 0001 1 EA RECP FASTON...

Page 176: ...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 10...

Page 177: ...NTACT 22 26AWG MALE MATE N LOK 2 2 52 6665 0002 1 EA CONN HOUSING 2 POS PLUG MATE N LOC 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 T...

Page 178: ...Fan Interlock Cable Assembly 25 9678 0014 Rev B Refer to Figure 3 84 Figure 3 84 Backcap Interlock to Gobo Fan Interlock Cable Assembly No Item Qty UM Description 1 52 8414 0001 2 EA RECEPT FASTON 18...

Page 179: ...ssembly 25 9678 0675 Rev B Refer to Figure 3 85 Figure 3 85 Relay to Gobo Fan Interlock Cable Assembly No Item Qty UM Description 1 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG TAPE MOUNT 2 52 8414 00...

Page 180: ...er to Figure 3 86 Figure 3 86 Front Head Fans Cable Assembly No Item Qty UM Description 1 52 6396 3104 1 EA RECEPT 4POS MTA100 W POL TAB BLU CLSD END 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3...

Page 181: ...7 Figure 3 87 Yoke Fan and Relay Standard Cable Assembly VL3500 Only 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...

Page 182: ...bly No Item Qty UM Description 1 52 8414 0001 1 EA RECEPT FASTON 187 SERIES 24 20AWG UNISUL 2 52 8237 0002 1 EA TERM RING 4 24 20AWG 3 73 7089 0000 1 48 FT WIRE 22AWG BLK 300V 200C TEFLON STRANDED 4 5...

Page 183: ...ription 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...

Page 184: ...A VL3500 Only Refer to Figure 3 90 Figure 3 90 Yoke Fan Standard Cable Assembly VL3500 Only 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 E...

Page 185: ...Only 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...

Page 186: ...scription 1 52 8231 0005 2 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 2 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 PIDG 3 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 4 55 2200 0003 33 FT HEAT SHRINK 5...

Page 187: ...ead Ground Cable Assembly 25 9678 0689 Rev 0 Refer to Figure 3 93 Figure 3 93 Yoke to Head Ground Cable Assembly No Item Qty UM Description 1 52 8250 0011 2 EA TERM RING 10 122 10AWG REEL 2 73 7089 05...

Page 188: ...VER BACK 24 POS MT 13 52 6224 2034 1 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...

Page 189: ...SEMBLIES HEAD CONTROLLER CABLE ASSEMBLY 02 9678 0018 A 169 3 Head Controller Cable Assembly continued Figure 3 94 Head Controller Cable Assembly 16 x11 5 10 15 17 1 6 11 4 9 14 2 7 12 17 1 6 11 3 8 13...

Page 190: ...SKINTOP FLEX TYPE PG13 BLK 2 52 6401 2321 1 EA CONN PLUG CE MARKED 20A 250V TWIST LOCK MALE LINE 3 WIRE 3 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG 4 52 8298 1160 2 EA FERRULE WIRE 1X16 A...

Page 191: ...Power Switch 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 INS R A 3 55 2186 0001 1 EA...

Page 192: ...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 6...

Page 193: ...CABLE ASSEMBLIES AC INPUT SPLITTER CABLE ASSEMBLY 02 9678 0018 A 173 3 AC Input Splitter Cable Assembly continued Figure 3 97 AC Input Splitter Cable Assembly 3 x2 4 x2 12 5 9 5 10 13 11 6 2 1 7 x3 8...

Page 194: ...25 9678 0813 Rev A Refer to Figure 3 98 Figure 3 98 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...

Page 195: ...5 3 Display Cable Assembly 25 9678 0815 Rev E Refer to Figure 3 99 Figure 3 99 Display Cable Assembly No Item Qty UM Description 1 52 6396 3006 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD END 2 73 511...

Page 196: ...100 Figure 3 100 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 C...

Page 197: ...NG 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 5 EA CABLE TIE 01 x 4 00 SMALL 7 55 669...

Page 198: ...OVER 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 USE SXH CONTACTS 6 52 7007 0001 6 EA CONTACT 28 22AWG PHOSPHOR BRONZE TIN PLT...

Page 199: ...Cable Assembly No Item Qty UM Description 1 52 8312 0001 4 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 2 55 2186 0001 3 EA CABLE TIE 10 WD 4 00 LG SMALL 3 55 6699 0003 3 75 FT SLEEVING 1 2 NOM DIA POLY...

Page 200: ...02 9678 0018 A Gobo Rotate Interconnect Cable Assembly 25 9678 1209 Rev A Refer to Figure 3 104 and Figure 3 105 Figure 3 104 Gobo Rotate Interconnect Cable Assembly No Item Qty UM Description 1 25 96...

Page 201: ...CABLE ASSEMBLIES GOBO ROTATE INTERCONNECT CABLE ASSEMBLY 02 9678 0018 A 181 3 Gobo Rotate Interconnect Cable Assembly continued Figure 3 105 Gobo Rotate Interconnect Cable Assembly Wire Chart...

Page 202: ...678 1716 Rev A Refer to Figure 3 106 Figure 3 106 LVS Chassis Ground Cable Assembly 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...

Page 203: ...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 Retro...

Page 204: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL 184 02 9678 0018 A Notes...

Page 205: ...2 ASSY NEXT PCB NO Filename REVISIONS eProduct Designer 2 0 SIZE D REVISION DRAWING NUMBER REV SHEET OF APPD DSN CHK DOC MFG MOUNTING HOLES C3 C7 C9 R2 R5 R12 R13 R16 9 16 02 B C ENG RELEASE PER EO 0...

Page 206: ...WITHOUT THE ADVANCE USED DISCLOSED OR REPRODUCED OF VARI LITE INC AND MAY NOT BE IS THE SOLE AND EXCLUSIVE PROPERTY ALL INFORMATION CONTAINED HEREIN CONFIDENTIAL DRAWN BY MFG DOC CHK DSN DRAWING NUMBE...

Page 207: ...ND MAY NOT BE IS THE SOLE AND EXCLUSIVE PROPERTY ALL INFORMATION CONTAINED HEREIN CONFIDENTIAL DRAWN BY MFG DOC CHK DSN DRAWING NUMBER REVISION SIZE OF SHEET 8 201 REGAL ROW DALLAS TEXAS 75247 B A B C...

Page 208: ...11 A11 C12 A12 C13 A13 C14 A14 REL TO PROD PER EO 10361 GND GND GND GND GND GND GND EDGE_SENS VCC_R_IDX3 R7 1 4W 5 270 R1 1 4W 5 270 IRIS_OUT1B 1 8 2003_9 55 GOBO_INTERCONNECT 24 9678 0209 K FELDHAUS...

Page 209: ...2 D2 B2 2 REVISED PER EO 09071 8 7 02 K C F A REL TO PROD PER EO 10363 VCC_R_AMB VCC VCC_R_DIM R2 1 4W 5 270 R4 1 4W 5 270 CTO_SENS GND GND GND FXD_SENS VCC_R_MAG VCC_R_CTO DIM_SENS AMB_SENS VCC_R_FXD...

Page 210: ...4 3 1 2 2 ASSY NEXT PCB NO Date Time Filename eProduct Designer 2 0 DSN CHK DOC MFG B SIZE REVISION DRAWING NUMBER OF SHEET DATE APPD REV DESCRIPTION REVISIONS MOUNTING HOLES DIMMER CYAN CTO VCC_R_CT...

Page 211: ...CB NO Date Time Filename eProduct Designer 2 0 DSN CHK DOC MFG B SIZE REVISION DRAWING NUMBER OF SHEET DATE APPD REV DESCRIPTION REVISIONS MOUNTING HOLES DIMMER CYAN A REL TO PROD PER EO 09095 C 0 1UF...

Page 212: ...1 2 2 ASSY NEXT PCB NO Date Time Filename eProduct Designer 2 0 DSN CHK DOC MFG B SIZE REVISION DRAWING NUMBER OF SHEET DATE APPD REV DESCRIPTION REVISIONS MOUNTING HOLES A REL TO PROD PER EO 09086 11...

Page 213: ...DESIGNATORS LAST USED NOT USED C242 D92 FB1 J13 L2 PTC4 R304 S1 U45 VR4 Y1 GENLYTE PROTO VERSION Z4 PP2 TP1 B0 MODIFIED NET NAMES AND U16 12 12 03 1 9 04 NONE NONE C0 CHANGED CATHODES TO PIN 1 CHANGED...

Page 214: ...A6 PLL MULT 4X CLK IN 25 40 5MHz BE R W PAR PORT 16 BIT BUS AUTO ACK 2 B2 2 B3 2 B4 2 B4 2 B2 2 B3 2 B2 2 B3 2 B2 2 B3 2 B2 2 B4 2 A6 2 B2 2 B3 2 B4 2 B4 2 B2 2 B3 2 B2 2 B3 2 B2 2 B3 2 B2 2 B4 2 A6...

Page 215: ...B4 2 D4 2 C3 3 A3 2 D4 2 C3 3 A3 2 D4 2 C3 3 A3 2 C4 3 A2 10 A2 2 A6 10 A2 10 A1 10 A2 10 A1 2 D1 3 B7 2 C4 7 B7 10 A2 2 B4 3 B7 8 D8 3 B7 6 B7 10 A1 2 D1 2 C4 3 B3 3 B3 10 A1 10 A2 10 A1 10 A2 10 A2...

Page 216: ...4 A6 4 B6 4 B6 4 B6 4 B5 3 C3 3 C3 3 C3 3 C3 10 B5 10 B3 10 B5 10 B3 10 C3 10 C3 10 C5 10 D5 10 C5 10 D5 4 B7 4 B7 4 B7 4 B7 4 B7 4 B7 4 B7 4 B7 4 B7 4 B7 10 A3 10 A3 10 A5 10 A5 10 A5 10 A3 10 B3 4...

Page 217: ...10 D3 10 D3 10 D3 TILT PAN 3 C6 2 A3 6 C8 7 C8 8 C8 9 C8 3 C6 3 C6 3 C6 10 D7 10 C3 10 D7 10 C5 10 D7 10 C5 10 D7 10 C3 FRAME 2A GENLYTE SCHEMATIC VL3500 CONTROLLER C83 C87 R80 C92 C236 R100 C95 C73 C...

Page 218: ...3 C6 3 C6 3 C3 GENLYTE SCHEMATIC VL3500 CONTROLLER C125 R135 R140 R97 C99 R132 R130 C98 C112 R93 R150 R85 R122 R117 C124 R84 R109 C96 R141 C121 R148 C91 C111 U32 MA1 11 MB1 8 MA2 5 MB2 7 GND10 28 GND0...

Page 219: ...TE SCHEMATIC VL3500 CONTROLLER C161 C154 C118 R191 C156 C139 R149 C158 R173 R194 C149 R145 R181 C150 R158 R176 C153 R164 C146 R138 C140 R180 C138 C127 C147 R160 C136 R134 C144 R178 R175 R166 R171 R182...

Page 220: ...3500 CONTROLLER R237 C176 C174 C182 C163 C183 R214 C152 R202 C185 R235 R250 R225 R243 R240 R209 C168 U39 MA1 11 MB1 8 MA2 5 MB2 7 GND10 28 GND09 17 GND08 16 GND07 15 GND6 14 PHASE1 20 DIS1 21 VCC 23 V...

Page 221: ...A3 GENLYTE SCHEMATIC VL3500 CONTROLLER C234 R292 R276 R234 C218 R286 C229 R279 R262 C230 R271 R249 R284 C211 C209 C208 R265 C217 C216 R245 C219 R282 R295 C199 R274 R287 R288 R263 C204 C207 U43 MA1 11...

Page 222: ...C5 7 D5 10 C3 7 B5 10 B3 7 B5 10 B5 7 B5 10 B5 7 B5 10 B3 7 D2 10 B3 7 D2 10 B5 7 D2 10 B5 7 D2 10 B3 7 B2 10 B3 7 B2 10 B5 7 B2 10 B3 7 B2 10 B5 6 D5 10 C3 8 D5 10 A3 8 D5 10 A5 8 D5 10 A5 8 D5 10 A3...

Page 223: ...OUTPUT INPUT SPARE GATES REVERSE PIN ON ALL DIODES To J13 on sheet 10 of 10 on CONTROLLER BD PROTO RUN B0 NONE 5 20 04 2004 CHANGED SHUT TO FRAME C0 SO4 6 4 04 6 14 04 FRAME REF 2B 2B 3A 3A 3B 3B 4A 4...

Page 224: ...NS eProduct Designer 2 0 SIZE D REVISION DRAWING NUMBER REV SHEET OF APPD DSN CHK DOC MFG MOUNTING HOLES Tilt Switch 2 REVISED PER EO 09057 8 15 02 T E W R4 RELEASED FOR PRODUCTION PER EO 09088 A C5 1...

Page 225: ...UMBER OF SHEET DATE APPD REV DESCRIPTION REVISIONS ZOOM MOTOR GND MOUNTING HOLES ZOOM MOTOR EDGE MOTOR SENSE VCC_R ZOOM SENSOR FAN 1 FAN 2 UPPER FAN LOWER FANS 1 2 3 4 J2 B 4B PH K 1 2 3 4 J3 644488 4...

Page 226: ...TEXAS 75247 A B C D 1 3 4 5 6 7 8 D C B A 7 6 5 4 3 1 2 2 ASSY NEXT PCB NO Date Time Filename eProduct Designer 2 0 DSN CHK DOC MFG B SIZE REVISION DRAWING NUMBER OF SHEET DATE APPD REV DESCRIPTION R...

Page 227: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS 02 9678 0018 A 207 VL3500 Spot Luminaire Wiring Diagram Sheet 1 of 3...

Page 228: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS 02 9678 0018 A 208 VL3500 Spot Luminaire Wiring Diagram Sheet 2 of 3...

Page 229: ...VARI LITE VL3500 SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS 02 9678 0018 A 209 VL3500 Spot Luminaire Wiring Diagram Sheet 3 of 3...

Page 230: ......

Page 231: ...ari Lite 10911 Petal Street Dallas Texas 75238 Toll Free 1 877 VARI LITE Tel 214 647 7880 Fax 214 647 8038 www vari lite com 2001 2008 Genlyte Thomas Group LLC All rights reserved Printed in the U S A...

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