Service manual

ManualsBrandsVari Lite ManualsFlood LightVL3500 Spot Luminaire

VL3500

™

Spot Luminaire

02.9678.0018

Service Manual

Summary of content (231 pages)

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Manual VL3500™ Spot Luminaire Service 02.9678.
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VARI❋LITE® is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries. VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, VL3500™, Series 1000™, Series 2000™, Series 3000™, DICHRO❋TUNE™, VARI❋IMAGE™, VARI❋BRITE™, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC.
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FOREWORD How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548), +1-214-647-7880, or customerservice@genlyte.com and request a Return Material Authorization (RMA) for warranty service.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Compliance Notice FCC This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.
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FOREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product. WARNING advising of potential injury or death to persons.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use a lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired. For example, by cracks or deep scratches.
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FOREWORD Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG 1. Viele VARI❋LITE®-Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt. SCHAUEN SIE NICHT direkt in die Lampe. 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist.
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FOREWORD Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2. L’utilisation des luminaires sans lentille ou blindage pose des risques.
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FOREWORD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto. Los símbolos de seguridad usados en este manual son los siguientes: CUIDADO, indica posibles daños al producto. ADVERTENCIA, indica posibles lesiones o muerte a las personas.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara que produce radiación UV. NO mire directamente a la lámpara. 2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada.
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FOREWORD 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL xii 02.967 8.
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TABLE OF CONTENTS Table of Contents Introduction About This Manual ................................................................................................................... Additional Documentation........................................................................................................ Customer Service ...................................................................................................................... Technical Bulletins and Notices................................
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan Encoder Replacement ...................................................................................................... Pan EOT Sensor Replacement ................................................................................................ Power Supply (LVS) Replacement ......................................................................................... Gobo/Shutter Assembly Replacement ......................................................
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TABLE OF CONTENTS Left Edge Bearing Assembly .................................................................................................. 86 Zoom Cam Assembly.............................................................................................................. 87 Zoom Motor Tensioning Assembly ........................................................................................ 88 Interconnect Light Shield Assembly............................................................................
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly............................................................................................................. Pan Tube Assembly............................................................................................................... Cable Assemblies Pan EOT Sensor Electrical Assembly................................................................................... LVS Chassis Ground Cable Assembly...................................
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TABLE OF CONTENTS VL3500 Controller PCB (Sheet 1 of 10) .............................................................................. VL3500 Controller PCB (Sheet 2 of 10) .............................................................................. VL3500 Controller PCB (Sheet 3 of 10) .............................................................................. VL3500 Controller PCB (Sheet 4 of 10) ..............................................................................
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL xviii 02.967 8.
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INTRODUCTION : ABOUT THIS MANUAL Introduction About This Manual Note: The VL3500™ Spot Luminaires share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL3500™ Spot Luminaire. The manual is intended for use by Vari-Lite personnel and by Vari-Lite’s customers/clients.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Customer Service Our Goal At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone troubleshooting assistance, product training or technical service, our full-time staff of experienced professionals are on-hand to provide support.
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CHAPTER 1. Description This chapter contains descriptions of luminaire features and components. • Features • Components • Principles of Operation 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Features Standard Features All VL3500 series luminaire have the following standard features: • CYM color mixing system. • Variable CTO color correction. • Six-position, fixed color wheel. • Full field dimming system. • Dual blade strobe system. • Repositional pan/tilt system. • Control by DMX512 protocol. • Fan cooled. • UV/IR glass.
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1 COMPONENTS : EXTERNAL LUMINAIRE COMPONENTS Components External Luminaire Components The following illustration shows the external luminaire components and controls. Upper Enclosure Assembly Houses power supply, ballast, and display board. AC Input Cable Truss Hook Bracket Attaches to enclosure base to allow truss hook installation. Input Panel Provides DMX In and Thru, and AC Power connections.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Luminaire Head and Yoke Components The following illustration shows the major sub-assemblies which are located in the luminaire head and yoke assemblies. Shutter / Gobo Assembly Contains one rotating gobo wheel, one fixed gobo wheel and the shutter mechanism. Head Cover (attached by tether) Color Assembly Contains fixed color wheel, dimmer mechanism, strobe mechanism, CYM color mixer and CTO color correction.
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COMPONENTS : ENCLOSURE COMPONENTS 1 Enclosure Components The following illustration shows the major sub-assemblies which are located in the luminaire enclosure assembly. (Yoke and head assemblies not shown for clarity.) Enclosure Top Covers 1200W Arc Ballast Module Fan Assembly 200W +24V/6.3A Power Supply Enclosure Bottom Ventilation Cover Input Panel Assembly containing DMX Input PCB and Menu Display AC Input Cable Requires standard AC power distribution from 200-264 VAC, 50/60 Hz.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Principles of Operation VL3500 Spot Luminaire Functional Block Diagram SHUTTER ROTATE SHUTTER MOTOR 1A SHUTTER MOTOR 1B TRANSFER HEAD FAN DUAL HEAD FANS SHUTTER MOTOR 2B SHUTTER MOTOR 2A SHUTTER MOTOR 3A ROTATE / GOBO INTERCONNECT SHUTTER MOTOR 4A SHUTTER MOTOR 3B SHUTTER MOTOR 4B 8 02 .9 678 .
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CHAPTER 2. Maintenance This chapter contains test, service, and 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 qualified service technician or at an Authorized Vari-Lite Service facility. 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Testing Luminaire Self-Tests The luminaire is capable of running self tests by using the TEST menu functions. For detailed instructions regarding the luminaire’s self-test function, refer to the VL3500 Spot User’s Manual (02.9678.0019).
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TESTING : AUTO RECALIBRATION 2 Auto Recalibration Most mechanisms with sensors will check their sensor when at a zero position, if the sensor is not detected within 3 seconds, the mechanism will recalibrate. This applies to all except pan and tilt, and zoom and edge. Pan and tilt are corrected continuously if required by encoders fitted to the motor shaft. Note: Colors (CTO and CYM) will only auto recalibrate when the dimmer has been closed for 3 seconds.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL • Low value - 0 volts, or up to approximately 0.2 volts. Notes regarding specific mechanisms: • The four color mixers will read high when the tab is in the optical sensor. • The fixed color wheel will read low when the magnet is at the sensor and high at other times. • The zoom and edge will read high when the sensor is closed, or the tab is in the sensor. • The gobo wheel reads low when the magnet is at the sensor.
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TROUBLESHOOTING : ERROR MESSAGES 2 Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s), one at a time until the end of the list is reached. To review the error messages again, it will be necessary to access them using the Status function. (Refer to “Troubleshooting Guide” on page 14 for a list of possible causes and remedies associated with the error messages.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error Messages” on page 13 for more information. The chart below provides possible causes and remedies for each message. Table 2-2: Troubleshooting Guide Message Symptom Description Possible Cause and Remedy n/a No response to DMX data DMX Failure MCB connector disconnected... n/a Lamp douses frequently Lamp Douse Fan failure..
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TROUBLESHOOTING : TROUBLESHOOTING GUIDE 2 Table 2-2: Troubleshooting Guide (Continued) Message Pan No Sens Symptom Luminaire will not pan Description Pan Sensor Not Found Possible Cause and Remedy EOT flag attached to large pulley is not engaging the EOT sensor... - ensure flag is attached to the large pulley. - ensure that flag passes through the sensor at a depth sufficient to engage the sensor beam. Pan belt disconnected, extremely loose or not installed properly...
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Maintenance Procedures WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should only be performed by a trained and qualified service technician or at an Authorized Vari-Lite Service facility. Lamp Replacement VL Part No: 71.2557.1200 WARNING: Ensure that power is removed from luminaire when installing lamp. CAUTION: Wear cotton gloves or other covering while installing lamp.
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MAINTENANCE PROCEDURES : ALIGN LAMP 2 Align Lamp The design of the VL3500 luminaire optical system allows for a flat or peaked field. A flat field is one where there is no detectable hot spot and a peaked field is one where the intensity of the beam is greater at the center of the beam than at the perimeter. After a new lamp is installed, it will be necessary to align the lamp to optimize the beam. Knobs located at the luminaire’s backcap will allow adjustment.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Lamp Power Cut-Off Switch It should be noted that the lower fan duct assembly is equipped with a lamp power cut-off switch. If the hinged duct is raised during operation, the relay will automatically disengage and the lamp will douse. Once the duct is closed, lamp power will be restored. The fan duct assembly is located on the bottom half of the luminaire head as shown below.
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MAINTENANCE PROCEDURES : GOBO REPLACEMENT - GOBO WHEELS 1 AND 2 2 Gobo Replacement - Gobo Wheels 1 and 2 WARNING: Remove power from luminaire before performing maintenance. Gobos may be HOT after operation. Allow to cool before replacing. WARNING: Users of VARI❋LITE luminaires should not install or use metal gobos. The use of metal gobos in any VARI❋LITE product may damage the luminaire and could void the luminaire’s warranty. To replace a gobo: Step 1. Remove power from luminaire. Step 2.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL e. Replace covers. Top Head Cover * 1/4-Turn Screw Gobo Wheel (see detail) CAUTION: Do not touch glass with bare fingers. Press on gobo carrier only. GOBO WHEEL 1 Bottom Head Cover * Gobo Assembly Gobo Wheel Front of luminaire Carrier * Head covers are attached by tethers.
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MAINTENANCE PROCEDURES : COLOR FILTER REPLACEMENT 2 Color Filter Replacement WARNING: Remove power from luminaire before performing maintenance. Filters may be HOT after operation. Allow to cool before replacing. To replace a color filter: Step 1. Remove power from luminaire. Step 2. Remove top head cover by loosening four 1/4-turn screws as shown in Figure 2-5. CAUTION: Do not touch filters with bare fingers. Wear cotton gloves or other covering while replacing.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ballast Assembly Replacement VL Part No: 23.9678.1869 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove top covers. Step 3. Remove wiring to ballast noting placement for reconnection Step 4. Remove four (4) screws securing side covers to end-covers as indicated in Figure 2-6.
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MAINTENANCE PROCEDURES : COLOR/DIMMER/STROBE ASSEMBLY REPLACEMENT 2 Color/Dimmer/Strobe Assembly Replacement VL Part No: 22.9678.0402 (VL3500 Only) VL Part No: 22.9678.0462 (VL3500Q Only) Repair Procedure Step 1. Disconnect luminaire AC input cable from 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. Remove clamps. Step 6.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Main Control Board (MCB) Replacement VL Part No: 24.9678.1730 Repair Procedure Step 1. Disconnect luminaire AC input cable from power 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, disconnect wiring from upper enclosure and remove MCB. Step 4. Install in reverse order.
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MAINTENANCE PROCEDURES : IGNITOR BOARD REPLACEMENT 2 Ignitor Board Replacement VL Part No: 24.9661.3126 Repair Procedure Step 1. Disconnect luminaire AC input cable 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 replace ignitor board.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly Replacement VL Part No: 21.9678.0864 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 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 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.
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MAINTENANCE PROCEDURES : PAN ENCODER REPLACEMENT 2 Pan Encoder Replacement VL Part No: 24.9678.9729 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 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 bottom cover standoffs are seated fully against chassis.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan EOT Sensor Replacement VL Part No: 86.7002.0003 Repair Procedure Step 1. Disconnect luminaire AC input cable from 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 are seated fully against chassis.
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MAINTENANCE PROCEDURES : POWER SUPPLY (LVS) REPLACEMENT 2 Power Supply (LVS) Replacement VL Part No: 69.3176.0201 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, 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 order. Make sure that no wires get pinched or caught in fan assembly.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Gobo/Shutter Assembly Replacement VL Part No: 21.9678.1200 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove top head cover. Step 3. Ensure that optic assembly is all the way forward. (Grip assembly by motor bracket and carefully pull forward along guide rods.) Step 4. Disconnect wiring for transfer fan assembly from optic assembly board. Step 5.
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MAINTENANCE PROCEDURES : SPOT OPTIC ASSEMBLY REPLACEMENT 2 Spot Optic Assembly Replacement VL Part No: 22.9678.0103 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove both head covers. Step 3. Disconnect all fan wires and yoke cable from optic assembly interconnect board. Step 4. Remove fan (or entire gobo assembly). Step 5. Remove lower head fan assembly for edge screw access. Step 6.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Tilt Motor Assembly Replacement VL Part No: 21.9678.6865 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove tilt-side yoke leg cover. Step 3. Remove motor connector. Step 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 gears. d.
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MAINTENANCE PROCEDURES : TILT ENCODER REPLACEMENT 2 Tilt Encoder Replacement VL Part No: 24.9678.9629 / 24.9678.8629 Repair Procedure Step 1. Disconnect 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. 1) 2) Tilt Encoder Tilt Motor Assembly Sensor Bracket Tilt Belt Spring Tilt Motor Assembly Detail NOTE: Head not shown for clarity.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Tilt EOT Sensor Replacement VL Part No: 86.7002.0003 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. Tilt Motor Assembly Sensor Sensor Bracket Spring NOTE: Head not shown for clarity. Figure 2-18: Tilt EOT Sensor Replacement 34 02 .9 678 .
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MAINTENANCE PROCEDURES : GOBO TIMING ADJUSTMENTS 2 Gobo Timing Adjustments The index timing belt must be aligned so that the mechanism "clocks" properly. This belt is installed around the index gear (top gear) of the gobo wheel. The wheel position belt is installed around the wheel position gear (bottom gear) of the gobo wheel, and does not require alignment. Each belt is also routed around one motor pulley. For the following steps, refer to Figure 2-19. To time gobo wheels: Step 1.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Gobo Gear Planet Alignment Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly. Use the following procedure to re-align the gears in the event the gobo wheel is disassembled. To re-align gobo gears: Step 1. Place center (sun) gear at starting point so that timing mark is directly facing Position 1 (open) as shown in Figure 2-20. Step 2. Set Position 6 planet gear as follows: Step 3.
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CHAPTER 3. Illustrated Parts Breakdown This chapter contains illustrated 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 • Head Assembly • Yoke Assembly • Head/Yoke PCB Assemblies • Enclosure Assembly • Cable Assemblies 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Drawing Trees VL3500 Spot Luminaire VL3500 Spot Series Luminaire 20.9678.0019 Rev F (VL3500 Only) Generic Luminaire Assembly 21.9678.0010.02 Rev H (VL3500 Only) Head Structure (Standard) Assembly 21.9678.0600 Rev C (VL3500 Only) Backcap Assembly 21.9678.0615 Rev S (VL3500) Air Duct OT Switch Cable Assembly 25.9678.0691 Rev 0 Yoke Fan (Standard) Cable Assembly 25.9678.0758 Rev A (VL3500 Only) Gobo Clamp Assembly 22.9678.
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DRAWING TREES : VL3500 SPOT LUMINAIRE 3 VL3500 Spot Luminaire (continued) continued from previous page continued from previous page Spot Optic Assembly 22.9678.0103 Rev R (Spot Only) Zoom Box Assembly 21.9678.0110 Rev F Right Edge Bearing Assembly 22.9678.1103 Rev C Upper Enclosure Assembly 21.9678.0800.01 Rev NN Panel Assembly 21.9678.0805 Rev L DMX Input PCB 24.9663.3830 Rev B Display PCB 24.9678.3825 Rev A Left Edge Bearing Assembly 22.9678.1105 Rev C Pan Pulley Assembly 21.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500Q Spot Luminaire VL3500Q Spot Luminaire 20.9678.0020 Rev G (VL3500Q Only) Generic Luminaire (Quiet) Assembly 21.9678.0011.02 Rev C (VL3500Q Only) Head Structure (Quiet) Assembly 21.9678.0601 Rev 0 (VL3500Q Only) Backcap Assembly 21.9678.0616 Rev G (VL3500 Q) Air Duct OT Switch Cable Assembly 25.9678.0690 Rev 0 (VL3500Q) Yoke Fan (Quiet) Cable Assembly 25.9678.0789 Rev B Gobo Clamp Assembly 22.9678.0693 Rev A Color Clamp Assembly 22.9678.
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DRAWING TREES : VL3500Q SPOT LUMINAIRE 3 VL3500Q Spot Luminaire (continued) continued from previous page Spot Optic Assembly 22.9678.0103 Rev R (Spot Only) Zoom Box Assembly 21.9678.0110 Rev F Right Edge Bearing Assembly 22.9678.1103 Rev C continued from previous page Upper Enclosure Assembly 21.9678.0801.01 Rev Y (VL3500 Quiet) Panel Assembly 21.9678.0805 Rev L DMX Input PCB 24.9663.3830 Rev B Display PCB 24.9678.3825 Rev A Left Edge Bearing Assembly 22.9678.1105 Rev C Pan Pulley Assembly 21.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Top Assembly Included Items Kit, Spot 28.9678.0020 Rev E Refer to Figure 3-5. No. Item Qty. UM. 1 02.8001.0001 1 EA PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 2 02.8052.0001 1 EA CARD, LIMITED WARRANTY 3 02.8406.0001 1 EA TAG, LAMP NOTICE 4 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION 5 02.9678.0002 1 EA UNPACK/QUICK START SHEET, VL3000 - 04.4037.0001 5 EA LABEL, 2.5 X .5 BARCODE (not shown) - 07.9678.
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TOP ASSEMBLY : INCLUDED ITEMS KIT, SPOT 3 Included Items Kit, Spot (continued) 1 2 5 6 4 3 7 (x2) 19* 8 9 10 11 12 Night Sky Palm Leaves Tribal Break-Up Circle of Ovals Pebbles 13 14 15 16 17 Triangle Break-Up Shock Break-Up Alpha Rays Glacier Gag Ice Blocks Gag 18 Multi-Colored Gobo Figure 3-5: Included Items Kit, Spot Note: * = Do not handle lamp with bare hands.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Series Luminaire 20.9678.0019 Rev F (VL3500 Only) 20.9678.0020 Rev G (VL3500Q Only) Refer to Figure 3-6 No. Item Qty. UM. - 02.8405.0001 1 EA AC DANGER TAG, VL3000 (not shown) - 04.9661.0033.01 1 EA LABEL, WARNING - 2000 SERIES (not shown) - 04.9661.0039 1 EA LABEL, LINE CORD WARNING (not shown) - 04.9678.0063 1 EA LABEL, AC INPUT RATING VL3500 (VL3500 ONLY - not shown) - 04.9678.
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TOP ASSEMBLY : VL3500 SPOT SERIES LUMINAIRE No. Item Qty. UM. - 25.9678.0677 1 EA CABLE ASSY, FRONT HEAD FANS (not shown) - 25.9678.0689 1 EA CABLE ASSY, YOKE TO HEAD GND (not shown) - 25.9678.1715 1 EA CABLE ASSY, HEAD CONTROL (not shown) - 28.9678.0020 1 EA INCLUDED ITEMS KIT, VL3500 SHUTTER (not shown) 19 53.2001.0003 4 EA NUT, 10-32 NYLON INSERT 20 53.2002.0003 4 EA NUT, 6-32 HEX ZINC NYLON IN 21 53.2202.0008 1 EA NUT, 8-32 HEX SS, NYLON INSERT 22 53.6543.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Series Luminaire (continued) 6 15 (x2) 16 (x2) 11 9 13 (x4) 12 14 35 (x2) 21 24 (x4) 31 3 23 (x2) 6 17 4 10 19 (x4) 24 (x2) 23 (x2) 32 (x2) 4 7 25 (x2) 27 (x2) 33 (x2) 18,30 (x2) 20 (x4) 24 (x2) 22 (x8) 34 (x2) 2 (x4) 1 5 31 (x2) 28 (x4) 8,22 (x4) 29 (x4) 2 (x6) 36 (x4) Figure 3-6: VL3500 Series Spot Luminaire 46 02 .9 678 .
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TOP ASSEMBLY : GENERIC LUMINAIRE ASSEMBLY 3 Generic Luminaire Assembly 21.9678.0010.02 Rev H (VL3500 Only) Refer to Figure 3-7 No. Item Qty. UM. Description 1 21.9678.0600 1 EA ASSY, HEAD STRUCTURE 2 21.9678.0700 1 EA ASSY, YOKE 3 21.9678.0707 1 EA ASSY, TILT PULLEY 3a - 10.9678.0750 1 EA TIMING PULLEY, 150 TOOTH 3b - 10.9678.0754 1 EA FLAG, CENTER OF TRAVEL, TILT - 53.6530.0006 3 EA RIVET, 1/8"OD POP .188-.250GL 1 EA ASSY, STABILIZER 3c 4 21.9678.0767 4a - 10.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Generic Luminaire Assembly (continued) 3 12 (x3) 13 (x2) 1 8 (x4) 15 9 (x4) 10 6 (x4) 14 (x2) 3c (x3) 3a Detail A 3b 11 (x4) 7 (x5) 2 4 16 (x5) 4c 4a 5 4b 4d Detail A 18 (x2) 17 (x2) Figure 3-7: Generic Luminaire Assembly - VL3500 Only 48 02 .9 678 .
PAGE 69
TOP ASSEMBLY : GENERIC LUMINAIRE (QUIET) ASSEMBLY 3 Generic Luminaire (Quiet) Assembly 21.9678.0011.02 Rev C (VL3500Q Only) Refer to Figure 3-8 No. Item Qty. UM. Description 1 21.9678.0601 1 EA ASSEMBLY, HEAD STRUCTURE, QUIET 2 21.9678.0701 1 EA ASSEMBLY, YOKE, QUIET 3 21.9678.0707 1 EA ASSEMBLY, TILT PULLEY 3a - 10.9678.0750 1 EA TIMING PULLEY, 150 TOOTH 3b - 10.9678.0754 1 EA FLAG, CENTER OF TRAVEL, TILT - 53.6530.0006 3 EA RIVET, 1/8"OD POP .188-.
PAGE 70
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Generic Luminaire (Quiet) Assembly (continued) 3 12 (x3) 13 (x2) 1 8 (x4) 15 9 (x4) 10 6 (x4) 14 (x2) 3c (x3) 3a Detail A 3b 11 (x4) 7 (x5) 2 4 16 (x5) 4c 4a 5 4b 4d Detail A 18 (x2) 17 (x2) Figure 3-8: Generic Luminaire Assembly - VL3500Q Only 50 02 .9 678 .
PAGE 71
HEAD ASSEMBLY : HEAD STRUCTURE (STANDARD) ASSEMBLY 3 Head Assembly Head Structure (Standard) Assembly 21.9678.0600 Rev C (VL3500 Only) Refer to Figure 3-1 No. Item Qty. UM. Description 1 10.9678.8620 1 EA FRONT CASTING 2 12.9678.8623 1 EA RIGHT SIDE RAIL, MACHINED 3 12.9678.8625 1 EA LEFT SIDE RAIL, MACHINED 4 21.9678.0615 1 EA ASSY, BACKEND 5 53.6515.0001 6 EA SCREW, 10-32 X 3/4" SCB CAP 6 53.6515.1000 1 EA SCREW, 10-32 X 1" SOCKET CAP BLACK 7 53.6615.
PAGE 72
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Head Structure (Quiet) Assembly 21.9678.0601 Rev 0 (VL3500Q Only) Refer to Figure 3-1 No. Item Qty. UM. Description 1 10.9678.8620 1 EA FRONT CASTING 2 12.9678.8623 1 EA RIGHT SIDE RAIL, MACHINED 3 12.9678.8625 1 EA LEFT SIDE RAIL, MACHINED 4 21.9678.0616 1 EA ASSEMBLY, BACK CAP 5 53.6515.0001 6 EA SCREW, 10-32 X 3/4" SCB CAP 6 53.6515.1000 1 EA SCREW, 10-32 X 1" SOCKET CAP BLACK 7 53.6615.1125 3 EA SCREW, 10-32 X 1.
PAGE 73
HEAD ASSEMBLY : HEAD COVER ASSEMBLY 3 Head Cover Assembly 21.9678.8611 Rev Refer to Figure 3-3 No. Item Qty. UM. Description 1 10.9678.0612 1 EA HEAD COVER FOAM BAFFLE 2 10.9678.0649 4 EA EJECTOR SPRING, BLACK OXIDE 3 10.9678.0674 1 EA BRACKET, COVER TETHER 4 10.9678.0696 1 EA FOAM FRAME, HEAD COVER 5 12.9678.8610 1 EA HEAD COVER, PAINTED 6 53.6558.0003 1 EA SCREW, 6-32 X 3/8"LG PPZ PLASTIC THD ROLL 7 53.5655.
PAGE 74
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Backcap Assembly 21.9678.0615 Rev S (VL3500) 21.9678.0616 Rev G (VL3500 Q) Refer to Figure 3-4 No. Item Qty. UM. 1 10.9678.0631 1 EA SEPARATION BULKHEAD 2 10.9678.8635 1 EA EXHAUST BULKHEAD 3 10.9678.0637 2 EA CLIP, RETRO-REFLECTOR 4 10.9678.0638 1 EA AIR DIVERTER, STROBE MOTOR 5 10.9678.0653 1 EA LIGHT BAFFLE, EXHAUST 6 12.9678.7152 1 EA REFLECTOR, RETRO SPHERICAL COATED 7 12.9678.
PAGE 75
HEAD ASSEMBLY : BACKCAP ASSEMBLY No. Item Qty. UM. 26 55.6706.0001 4 EA GROMMET, 9/32"ID 9/16"OD 1/4T 27 74.1099.0001 1 EA SWITCH, MINIATURE 5AMP 150DEG - 10.9678.0680 1 EA INSULATOR, TEFLON TO-220 (not shown) - 53.2200.0004 1 EA NUT, 4-40 KEPS SS 28 53.6613.0004 3 EA SCREW, 6-32 X 1/2" SCZ 29 10.9678.
PAGE 76
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL 80mm Fan Assembly 21.9678.0619 Rev B (VL3500 and VL3500 Quiet) Refer to Figure 3-5 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 KEPS SS 3 53.6558.0001 4 EA SCREW, 6-32 X 3/8" PPZ 4 55.7016.0001 1 EA FAN GUARD, 80MM NICKEL PLATED STEEL WIRE 4 3 (x4) 1 2 (x4) Figure 3-5: 80mm Fan Assembly - VL3500 and VL3500 Quiet 56 02 .9 678 .
PAGE 77
HEAD ASSEMBLY : UV FILTER BULKHEAD ASSEMBLY 3 UV Filter Bulkhead Assembly 22.9678.0617 Rev A (VL3500 Quiet) 22.9678.0639 Rev C (VL3500 Only) Refer to Figure 3-6 No. Item Qty. UM. 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 FILTER, 3.00" X 3.00" 53.6530.0002 4 EA RIVET, 1/8 OD POP, .063-.
PAGE 78
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 58 02 .9 678 .
PAGE 79
HEAD ASSEMBLY : GOBO/SHUTTER ASSEMBLY 3 Gobo/Shutter Assembly 21.9678.1200 Rev G Refer to Figure 3-7 No. Item Qty. UM. Description 1 10.9678.0338 1 EA PULLEY, ZOOM MOTOR 2 10.9678.0225 6 EA SHAFT, GOBO WHEEL 3 10.9678.0231 2 EA PULLEY, MOTOR GOBO WHEEL DRIVE 4 10.9678.0232 1 EA PULLEY, INSEX DRIVE 64 GROOVE 5 10.9678.0246 3 EA ADJUST PLATE, MOTOR 6 10.9678.1215 1 EA BULKHEAD, SHUTTER MODULE FRONT 7 10.9678.1244 1 EA MOUNT, INDEX SENSOR LONG 8 10.9678.
PAGE 80
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. Description 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 13 (x2) 29 18 (x6) 10 25 (x2) 28 1 30 6 27 (x4) 5 (x3) 20 (x4) 21 (x4) 24 (x2) 16 14 8 31 (x4) 14 26 32 (x4) 19 (x2) 15 12 (x2) 11 2 (x6) 23 (x8) 3,17 7 9 (x2) 4,17 22 (x6) Figure 3-7: Gobo/Shutter Assembly 60 02 .9 678 .
PAGE 81
HEAD ASSEMBLY : ROTATING GOBO WHEEL ASSEMBLY, SHUTTER 3 Rotating Gobo Wheel Assembly, Shutter 21.9678.1205 Rev B Refer to Figure 3-8 No. Item Qty. UM. Description 1 10.9678.1216 1 EA BULKHEAD, SHUTTER MODULE, REAR 2 10.9678.1225 2 EA SHAFT, GOBO WHEEL, CANTILEVER 3 21.9678.1210 1 EA ASSY, ROTATING GOBO WHEEL 4 21.9678.1410 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.
PAGE 82
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Fixed Gobo Wheel Assembly 21.9678.1410 Rev B Refer to Figure 3-9 No. Item Qty. UM. Description 1 10.9678.0250 1 EA MAGNET TAPE .375"W x .625" L x .0035" THICK 2 10.9678.1412 1 EA PLATE, ROTATING 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" PTHZ 6 53.6650.0001 3 EA SCREW, 2-56 X 5/16" PPZ 7 55.2256.
PAGE 83
HEAD ASSEMBLY : ROTATING GOBO WHEEL ASSEMBLY 3 Rotating Gobo Wheel Assembly 21.9678.1210 Rev 0 Refer to Figure 3-10 No. Item Qty. UM. Description 1 10.9678.0250 1 EA MAGNET TAPE .375"W x .625" L x .0035" THICK 2 10.9663.1211 10 EA SPACER, 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 FLANGE, MODIFIED 7 22.9678.
PAGE 84
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Roller Pivot Rotate Assembly 21.9678.1555 Rev 0 Refer to Figure 3-11 No. Item Qty. UM. Description 1 10.9678.1551 1 EA ROLLER PIVOT, SHUTTER ROTATE 2 22.9678.1550 1 EA ASSY, SHUTTER ROTATE, ROLLER 3 53.6609.0001 1 EA SCREW, 6-32 X 3/8" PFZ 1 2 3 Figure 3-11: Roller Pivot Rotate Assembly 64 02 .9 678 .
PAGE 85
HEAD ASSEMBLY : SHUTTER ROTATE ROLLER ASSEMBLY 3 Shutter Rotate Roller Assembly 22.9678.1550 Rev B Refer to Figure 3-12 No. Item Qty. UM. Description 1 10.9678.1552 1 EA ROLLER SHUTTER ROTATE 2 54.1259.0005 1 EA BEARING, FLANGED, .25" ID, .625" OD, .0001 1 2 Figure 3-12: Shutter Rotate Roller Assembly 02.96 78.
PAGE 86
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Long Shaft Motor Assembly 21.9678.0243 Rev 0 Refer to Figure 3-13 No. Item Qty. UM. Description 1 10.9678.0330 1 EA PLATE, MOTOR ADAPTER 2 44.9678.0249 1 EA MOTOR, STEPPER 42MM X 34MM 60MM SHAFT 3 53.6513.0002 4 EA SCREW, 3MM X 5MM LG PFZ METRIC 3 (x4) 1 2 Figure 3-13: Long Shaft Motor Assembly 66 02 .9 678 .
PAGE 87
HEAD ASSEMBLY : SHUTTER ASSEMBLY 3 Shutter Assembly 21.9678.1510 Rev G Refer to Figure 3-14 No. Item Qty. UM. Description 1 10.9678.1526 2 EA PIVOT, SHUTTER BLADE, SHORT 2 10.9678.1527 2 EA PIVOT, SHUTTER BLADE, LONG 3 10.9678.1528 16 EA CAM STOP 4 10.9678.1529 1 EA CABLE CLAMP, SHUTTER 5 10.9678.1532 4 EA GLIDE, BLADE PIVOT 6 10.9678.1534 8 EA ACTUATOR ARM, BEARING, SHUTTER 7 10.9678.1535 1 EA GLIDE SHEET, SHUTTER, BOTTOM 8 10.9678.
PAGE 88
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Shutter Assembly (continued) 17 23 (x8) 7 4, 28 (x2) 9 (x4) 2 1 3 (x16) 22 (x16) 15 (x2) 21 (x2) 24 (x8) 3 1 27 8 5 (x4) 2 18 (x6) 26 (x8) 6 (x8) 11 (x4) 20 (x16) 16 (x2) 10 (x4) 11 (x3) 14 19 (x2) 13 12 21 (x2) 25 (x16) Figure 3-14: Shutter Assembly 68 02 .9 678 .
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HEAD ASSEMBLY : SHUTTER MOTOR DISK ASSEMBLY 3 Shutter Motor Disk Assembly 21.9678.1515 Rev E Refer to Figure 3-15 No. Item Qty. UM. 1 10.9678.1560 1 EA BASE PLATE, SHUTTER 2 44.9678.1517 8 EA MOTOR, PANCAKE, SIZE 16, .47" SHAFT 3 53.2202.0030 4 EA NUT, M3 X .5 HEX NYLOC ZINC 4 53.6513.0029 8 EA SCREW, M3 X 12 PFZ 5 53.6513.0045 8 EA SCREW, M3 X 16 PFZ 6 55.2178.0001 4 EA CABLE ANCHOR, #8 SCREW MOUNT 7 55.2186.0001 10 EA CABLE TIE, .10" X 4" SMALL 8 10.9678.
PAGE 90
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Shutter Motor Disk Assembly (continued) Frame 4A Frame 4B Frame 3B Frame 1A 9 11 Frame 1B Frame 3A Frame 2A Frame 2B 7 (x10) 1 5 (x8) 4 (x8) 8 (x8) 6 (x4) 2 (x8) 3 (x4) Figure 3-15: Shutter Motor Disk Assembly 70 02 .9 678 .
PAGE 91
HEAD ASSEMBLY : HOT BOX ASSEMBLY 3 Hot Box Assembly 21.9678.8640.01 Rev E (Spot) 21.9678.8698.01 Rev C (Quiet Spot) Refer to Figure 3-16 No. Item Qty. UM. 1 04.9678.0042 1 EA LABEL, VL3000 BACKCAP 10.9678.0043 1 EA LABEL, BACKCAP, VL3000 QUIET 2 10.9678.0641 1 EA HOT BOX 3 10.9678.0642 1 EA BACKCAP PLATE 4 10.9678.0643 1 EA LAMP ADJUST STOP 5 10.9678.0645 3 EA KNOB, LAMP ADJ MOLDED 6 10.9678.0646 1 EA TILT PLATE, XYZ ADJUSTMENT 7 10.9678.
PAGE 92
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Hot Box Assembly (continued) 12 (x4) 7 (x4) 11 14 (x2) 20 2 6 19 (x3) 16 (x4) 8 (x4) 10 (x4) 9 (x4) 15 (x8) 17 (x4) 4 1 18 (x3) 3 5 (x3) 13 (x3) Figure 3-16: Hot Box Assembly 72 02 .9 678 .
PAGE 93
HEAD ASSEMBLY : DUAL FAN TRAY DUCT (STANDARD) ASSEMBLY 3 Dual Fan Tray Duct (Standard) Assembly 21.9678.0660.03 Rev B (VL3500 Only) Refer to Figure 3-17 No. Item Qty. UM. Description 1 10.9678.0665 1 EA SPRING, EXTENSION ELONGATED HOOKS 2 22.9678.0661 1 EA ASSY, FAN TRAY 3 22.9678.1265 1 EA DUCT ASSY, SHUTTER/GOBO 4 23.9678.0684 2 EA FAN ASSY, HEAD FRONT 5 53.5506.1375 6 EA SCREW, 6-32 X 1 3/8"LG PPB 6 53.6519.0001 2 EA SCREW, 4-40 X 5/8" PPZ 7 53.6530.
PAGE 94
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Dual Fan Tray Duct (Quiet) Assembly 21.9678.0659.03 Rev D (VL3500Q Only) Refer to Figure 3-18 No. Item Qty. UM. Description 1 10.9678.0665 1 EA SPRING, EXTENSION ELONGATED HO 2 22.9678.0661 1 EA ASSY, FAN TRAY 3 22.9678.1265 1 EA DUCT ASSY, SHUTTER/GOBO 4 23.9678.0699 2 EA FAN ASSY, HEAD FRONT 5 53.5506.1375 6 EA SCREW, 6-32 X 1 3/8"LG PPB 6 53.6519.0001 2 EA SCREW, 4-40 X 5/8" PPZ 7 53.6530.
PAGE 95
HEAD ASSEMBLY : HEAD FRONT FAN (STANDARD) ASSEMBLY 3 Head Front Fan (Standard) Assembly 23.9678.0684 Rev 0 (VL3500 Only) Refer to Figure 3-19 No. Item Qty. UM. 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 2 3 (x2) Description 1 Figure 3-19: Head Front Fan Assembly - VL3500 Only 02.96 78.
PAGE 96
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Head Front Fan (Quiet) Assembly 23.9678.0699 Rev A (VL3500Q Only) Refer to Figure 3-20 No. Item Qty. UM. Description 1 40.7125.0001 1 EA FAN, 24V FAL6F24LH 2 52.6523.0002 1 EA CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52.8347.0001 2 EA CONTACT, 24-30AWG MALE CRIMP 4 55.2186.0001 1 EA CABLE TIE, .10 X 4" SMALL 5 55.2268.0125 1 EA HEATSHRINK, 1/8" CLEAR KYNAR UL 600V 150 DEG C 6 60.8440.
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HEAD ASSEMBLY : TRANSFER FAN ASSEMBLY 3 Transfer Fan Assembly 21.9678.1263 Rev 0 Refer to Figure 3-21 No. Item Qty. UM. Description 1 10.9678.0679 1 EA TRANSFER FAN TRAY 2 22.9678.1280 1 EA SHIELD ASSY, SHUTTER ROTATE HARNESS 3 23.9678.0695 1 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 CABLE ANCHOR, #6 SCREW MOUNT - 55.2186.0001 2 EA CABLE TIE, .
PAGE 98
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL NOTES 78 02 .9 678 .
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HEAD ASSEMBLY : SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly 22.9678.0103 Rev R (Spot Only) Refer to Figure 3-22 and Figure 3-23 No. Item Qty. UM. Description 1 10.9678.1131 1 EA FORWARD PULLEY SHAFT (changed 12-15-04) 2 10.9678.0127 1 EA PULLEY, IDLER 3 10.9678.0129 2 EA SPACER, ROLLER CAM 4 10.9678.0153 1 EA CABLE CLAMP, CAST 5 10.9678.0156 2 EA BARREL STRAP, G1 & G2 6 10.9678.0157 1 EA BARREL STRAP, G3 7 10.9678.0171 1 EA SHAFT, CAM PULLEY 8 10.9678.
PAGE 100
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 26 23.9678.1120 1 EA LINEAR ACTUATOR ASSEMBLY - 44.9678.0119 1 EA LINEAR ACTUATOR EDGE DRIVE - 52.6467.0004 1 EA 4 POS 30-24 AWG CRIMP PHR - 52.6467.0024 4 EA CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST) 27 24.9678.3112 1 EA PCB ASSY, VL3000 ZOOM SENSOR 28 53.2004.0002 1 EA NUT, 8-32 KEPS ZINC PLATE 29 53.2213.0001 7 EA NUT, #6 KEPS (changed 03-24-04) 30 53.5564.
PAGE 101
HEAD ASSEMBLY : SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly (continued) 23 F 33 (x2) F 36 (x4) 33 (x2) E E 24 21 25 33 (x2) 36 (x4) 33 (x3) 20 35 26 34 41 (x6) 48 Detail F-F 40 (x2) 9 49 Detail E-E Figure 3-22: Spot Optic Assembly View 1 02.96 78.
PAGE 102
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Spot Optic Assembly (continued) 44 A A B B C C 37 22 4 * Interconnect PCB and Zoom Motor removed for clarity.
PAGE 103
HEAD ASSEMBLY : ZOOM BOX ASSEMBLY 3 Zoom Box Assembly 21.9678.0110 Rev F Refer to Figure 3-24 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 4 53.6530.0006 12 EA RIVET, 1/8"OD POP .188-.250GL 4 (x12) 3 1 2 Figure 3-24: Zoom Box Assembly 02.96 78.
PAGE 104
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Group 4 Lens Assembly 22.9678.0199 Rev 0 Refer to Figure 3-25 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 55.3303.0006 4 EA WASHER, #6 LOCK INT.TOOTH SS 5 55.6763.0500 4 EA PIN, DOWEL .5"LG .125"DIA 303SS 1 4 (x4) 2 3 (x4) 5 (x4) 1 Figure 3-25: G4 Lens Mount Assembly 84 02 .9 678 .
PAGE 105
HEAD ASSEMBLY : RIGHT EDGE BEARING ASSEMBLY 3 Right Edge Bearing Assembly 22.9678.1103 Rev C Refer to Figure 3-26 No. Item Qty. UM. Description 1 12.9678.1102 1 EA EDGE BEARING, MACHINED RIGHT 2 54.2056.0001 4 EA RING, RETAINING EXTERNAL 19MM 3 55.6776.0010 2 EA LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE 2 (x4) 3 (x2) 1 Figure 3-26: Right Edge Bearing Assembly 02.96 78.
PAGE 106
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Left Edge Bearing Assembly 22.9678.1105 Rev C Refer to Figure 3-27 No. Item Qty. UM. Description 1 12.9678.1104 1 EA EDGE BEARING, MACHINE LEFT 2 54.2056.0001 4 EA RING, RETAINING EXTERNAL 19MM 3 55.6776.0010 2 EA LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE 2 (x4) 3 (x2) 1 Figure 3-27: Left Edge Bearing Assembly 86 02 .9 678 .
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HEAD ASSEMBLY : ZOOM CAM ASSEMBLY 3 Zoom Cam Assembly 22.9678.1106 Rev B Refer to Figure 3-28 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 54.1259.0004 2 EA BEARING, RADIAL FLANGED .25"ID .625"OD (changed 06-25-03) 6 55.6763.0500 2 EA PIN, DOWEL .5"LG .
PAGE 108
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Zoom Motor Tensioning Assembly 22.9678.1113 Rev B Refer to Figure 3-29 No. Item Qty. UM. Description 1 10.9678.0338 1 EA PULLEY, ZOOM MOTOR 2 10.9678.1111 1 EA BRACKET, ZOOM TENSION SHEETMETAL 3 44.9663.1326 1 EA MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM 4 53.5559.0250 2 EA SCREW, 6-32 X 1/4" SET CONE POINT 5 53.6522.0001 2 EA SCREW, 6-32 X 1/4" PPZ 6 55.3303.0006 2 EA WASHER, #6 LOCK INT.TOOTH SS 5 (x2) 6 (x2) 3 .
PAGE 109
HEAD ASSEMBLY : INTERCONNECT LIGHT SHIELD ASSEMBLY 3 Interconnect Light Shield Assembly 22.9678.1115 Rev D Refer to Figure 3-30 No. Item Qty. UM. Description 1 10.9678.1114 1 EA SHIELD, INTERCONNECT MOUNT/LIGHT 2 24.9678.3116 1 EA PCB ASSY, ZOOM INTERCONNECT (changed 03-07-06) 3 53.6558.0009 4 EA SCREW, 6-32 X 3/8" PPZ SEMS 3 (x4) 2 1 Figure 3-30: Interconnect Light Shield Assembly 02.96 78.
PAGE 110
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Rod Clamp Assembly 22.9678.0149 Rev B Refer to Figure 3-31 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 55.6538.0001 2 EA WASHER, #6 LOCK INTERNAL TOOTH 5 53.2008.0006 2 EA SPRING CLIP, 6-32 2 (x2) 4 (x2) 3 (x2) 1 5 (x2) Figure 3-31: Rod Clamp Assembly 90 02 .9 678 .
PAGE 111
HEAD ASSEMBLY : COLOR/DIMMER/STROBE ASSEMBLY 3 Color/Dimmer/Strobe Assembly 22.9678.0402 Rev F (VL3500) 22.9678.0462 Rev 0 (VL3500Q) No. Item Qty. UM. 1 10.9678.0324 1 EA PULLEY, FIXED COLOR WHEEL 2 10.9678.0337 1 EA DRIVE PULLEY, FIXED COLOR WHEEL (changed 03-09-06) 3 10.9678.0456 4 EA SHAFT, COLOR WHEEL 4 10.9678.0457.07 1 EA SPACER, COLOR WHEEL L.357 (changed 07-22-04) 5 10.9678.0457.02 2 EA SPACER, COLOR WHEEL L.190 6 10.9678.0457.03 3 EA SPACER, COLOR WHEEL L.
PAGE 112
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 27 53.5638.0252 12 EA SCREW, 6-32 X 1/4"LG PFS UNDERCUT HEAD 28 53.6558.0001 7 EA SCREW, 6-32 X 3/8" PPZ 29 53.6597.0001 2 EA SCREW, 4-40 X 3/16" PPZ 30 53.6608.0003 5 EA SCREW, 6-32 X 3/16"LG PPZ 31 54.2036.0017 1 EA BELT, TIMING N=150 W=.125 URETHANE/KEVLAR 32 54.2059.0001 4 EA TIMING BELT, MXL PITCH 150 TOOTH SI/KEVLAR 33 54.2060.0001 1 EA BELT, TIMING MXL PITCH 165 TOOTH SI/KEVLAR 34 55.2132.
PAGE 113
3 HEAD ASSEMBLY : COLOR/DIMMER/STROBE ASSEMBLY Color/Dimmer/Strobe Assembly (continued) 13 20 25 (x4) 5 14 11 4 9 (x5) Dimmer 26 (x10) 16 33 Yellow 6 6 42 15 31 22 35 (x4) 32 (x4) Cyan 36 (x2) 2 6 29 (x2) 8 Magenta 26 (x2) 18 17 5 CTO 7 7 25 (x2) 12 39 (x2) 3 (x2) 34 (x4) 19 1 38 25 (x5) 21 24 25 23 (x5) 10 37 (x1) 28 (x2) 28 (x5) 37 (x5) 27 (x12) 30 (x5) Figure 3-32: Color/Dimmer/Strobe Assembly 02.96 78.
PAGE 114
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Refer to Figure 3-33 No. Item Qty. UM. Description 1 10.9678.0330 1 EA PLATE, MOTOR ADAPTER 2 44.5031.0001 1 EA MOTOR, STEPPER 42MM X 40MM,10 3 53.6513.0002 4 EA SCREW, 3MM X 5MM LG PFZ METR 2 1 3 (x4) Figure 3-33: Motor/Adapter Plate Assembly 94 02 .9 678 .
PAGE 115
HEAD ASSEMBLY : FIXED COLOR WHEEL ASSEMBLY 3 Fixed Color Wheel Assembly 21.9678.0334 Rev D Refer to Figure 3-34 No. Item Qty. UM. Description 1 10.9678.0322 1 EA SPIN SHAFT, COLOR WHEEL 2 10.9678.0332 6 EA SLIDING RETAINER 3 10.9678.0333 6 EA RETAINER CLIP 4 22.9678.1336 1 EA FAB ASSY, FIXED WHEEL/CLIP 5 41.9678.0305.01 1 EA COLOR FILTER, DEEP RED VL3000 6 41.9678.0305.02 1 EA COLOR FILTER, KELLY GREEN VL3000 7 41.9678.0305.
PAGE 116
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Fixed Color Wheel Assembly (continued) 9 7 6 POS 3 ORANGE POS 4 KELLY GREEN POS 2 CONGO BLUE POS 5 DARK FUSHIA POS 1 OPEN POS 7 DEEP RED 10 POS 6 MAGENTA 5 8 13 14 (x6) 15 2 (x6) 11 (x6) 3 (x6) 1 12 (x3) 4 Figure 3-34: Fixed Color Wheel Assembly 96 02 .9 678 .
PAGE 117
HEAD ASSEMBLY : STROBE ASSEMBLY 3 Strobe Assembly 22.9678.0403 Rev F (VL3500 Only) Refer to Figure 3-35 No. Item Qty. UM. Description 1 10.9678.0491 4 EA BUMPER STOP, STROBE 2 10.9678.0465 1 EA STROBE BULKHEAD 3 22.9678.0467 1 EA ASSY, 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"LG PFZ 8 55.6659.
PAGE 118
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Strobe (Quiet) Assembly 22.9678.0463 Rev B (VL3500Q Only) Refer to Figure 3-36 No. Item Qty. UM. Description 1 10.9678.0491 4 EA BUMPER STOP, STROBE 2 10.9678.0465 1 EA STROBE BULKHEAD 3 22.9678.0467 1 EA ASSEMBLY, RIGHT STROBE BLADE 4 22.9678.0468 1 EA ASSEMBLY, LEFT STROBE BLADE 5 23.9678.0499 2 EA ASSEMBLY, STROBE MOTOR, VL3000Q 6 53.6520.0001 8 EA SCREW, #4-40 X 3/8 PPZ 7 53.6609.
PAGE 119
HEAD ASSEMBLY : RIGHT STROBE BLADE ASSEMBLY 3 Right Strobe Blade Assembly 22.9678.0467 Rev C Refer to Figure 3-37 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, 6-32 X 1/4" SET CONE POINT 5 53.6597.0001 3 EA SCREW, 4-40 X 3/16" PPZ 6 55.3303.0004 3 EA WASHER, #4 LOCK INT.
PAGE 120
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Left Strobe Blade Assembly 22.9678.0468 Rev C Refer to Figure 3-38 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, 6-32 X 1/4" SET CONE POINT 5 53.6597.0001 3 EA SCREW, 4-40 X 3/16" PPZ 6 55.3303.0004 3 EA WASHER, #4 LOCK INT.
PAGE 121
HEAD ASSEMBLY : STROBE MOTOR (QUIET) ASSEMBLY 3 Strobe Motor (Quiet) Assembly 23.9678.0499 Rev A (VL3500Q Only) Refer to Figure 3-39 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 CONTACT, 24-30 AWG FEMALE CRIMP 4 55.2200.0003 0.
PAGE 122
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Dimmer Wheel Assembly 22.9678.0435 Rev D Refer to Figure 3-40 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 (changed on 01-23-04) 3 55.2256.0001 1 EA MAGNET, 2:17 SMCO 2MM X 2MM 2 Coated Side 3 1 Figure 3-40: Dimmer Wheel Assembly 102 02 .9 678 .
PAGE 123
HEAD ASSEMBLY : CYAN WHEEL ASSEMBLY 3 Cyan Wheel Assembly 22.9678.0472 Rev C Refer to Figure 3-41 No. Item Qty. UM. Description 1 22.9678.0420 1 EA PULLEY ASSY, WITH BEARING 2 41.9678.0471 1 EA GLASS, CYAN COLOR WHEEL Coated Side 1 2 Figure 3-41: Cyan Wheel Assembly 02.96 78.
PAGE 124
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Yellow Wheel Assembly 22.9678.0474 Rev B Refer to Figure 3-42 No. Item Qty. UM. Description 1 22.9678.0420 1 EA PULLEY ASSY, WITH BEARING 2 41.9678.0473 1 EA GLASS, YELLOW COLOR WHEEL 2 Coated Side 1 Figure 3-42: Yellow Wheel Assembly 104 02 .9 678 .
PAGE 125
HEAD ASSEMBLY : MAGENTA WHEEL ASSEMBLY 3 Magenta Wheel Assembly 22.9678.0476 Rev B Refer to Figure 3-43 No. Item Qty. UM. Description 1 22.9678.0420 1 EA PULLEY ASSY, WITH BEARING 2 41.9678.0475 1 EA GLASS, MAGENTA COLOR WHEEL 2 Coated Side 1 Figure 3-43: Magenta Wheel Assembly 02.96 78.
PAGE 126
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL CTO Wheel Assembly 22.9678.0478 Rev B Refer to Figure 3-44 No. Item Qty. UM. Description 1 22.9678.0420 1 EA PULLEY ASSY, WITH BEARING 2 41.9678.0477 1 EA GLASS, COATED CTO Coated Side 2 1 Figure 3-44: CTO Wheel Assembly 106 02 .9 678 .
PAGE 127
HEAD ASSEMBLY : GOBO CLAMP ASSEMBLY 3 Gobo Clamp Assembly 22.9678.0693 Rev A Refer to Figure 3-45 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 EA WASHER, #6 LOCK INTERNAL TOOTH 4 53.6613.1126 1 EA SCREW, 6-32 X 1.125 LG PPZ 3 (x2) 1 2 (x2) 4 Figure 3-45: Gobo Clamp Assembly 02.96 78.
PAGE 128
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Clamp Assembly 22.9678.0694 Rev A Refer to Figure 3-46 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 55.6538.0001 2 EA WASHER, #6 LOCK INTERNAL TOOTH 4 53.6613.1126 1 EA SCREW, 6-32 X 1.125 LG PPZ 1 3 (x2) 4 2 (x2) Figure 3-46: Color Clamp Assembly 108 02 .9 678 .
PAGE 129
HEAD ASSEMBLY : EDGE LEAD SCREW ASSEMBLY 3 Edge Lead Screw Assembly 22.9678.1126 Rev B Refer to Figure 3-47 No. Item Qty. UM. Description 1 10.9678.1119 1 EA LEAD SCREW, EDGE 2 55..6616.0007 1 EA STANDOFF, 3/8" HEX THRD .562" LG 1 2 Figure 3-47: Edge Lead Screw Assembly 02.96 78.
PAGE 130
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 110 02 .9 678 .
PAGE 131
YOKE ASSEMBLY : YOKE ASSEMBLY 3 Yoke Assembly Yoke Assembly 21.9678.0700 Rev J (VL3500) 21.9678.0701 Rev B (VL3500Q) Refer to Figure 3-48 No. Item Qty. UM. 1 10.9678.0764 1 EA PLATE, TILT ENCODER MOUNT 2 10.9678.0756 1 EA IGNITOR SHIELD 3 21.9678.0765 1 EA ASSY, TILT MOTOR 21.9678.8765 1 EA ASSY, TILT MOTOR 22.9661.0609 2 EA ASSY, YOKE FAN 4 Description 22.9678.0609 2 EA ASSY, YOKE FAN, VL3500 QUIET 5 22.9686.0705 1 EA ASSY, YOKE STRUCTURE 6 23.9650.
PAGE 132
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Yoke Assembly (cont.) 4 19 5 9 19 21 (x2) 13 (x2) 18 (x2) 6 10 13 (x4) 2 13 (x3) 4 14 (x4) 11 (x8) 8 15 (x2) 12 (x2) 3 13 (x2) 20 (x2) 7 13 17 16 13 (x2) 1 14 (x2) Figure 3-48: Yoke Assembly 112 02 .9 678 .
PAGE 133
YOKE ASSEMBLY : TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21.9678.0765 Rev E (VL3500) 21.9678.6865 Rev 0 (VL3500 Quiet) Refer to Figure 3-49 No. Item Qty. UM. 1 10.9678.0763 1 EA PLATE, TILT MOTOR MOUNT 10.9678.8763 1 EA PLATE, TILT MOTOR MOUNT (VL3500 QUIET) 21.9678.0708 1 EA ASSY, DRIVE PULLEY - 10.9678.8720 1 EA CODEWHEEL, 120 COUNT LARGE ID (changed 10-05-06) - 10.9678.0749 1 EA TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 2 EA SCREW, 8-32 X 1/4" SET CONE POINT 24.9661.
PAGE 134
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Relay Electrical Assembly 23.9650.3327 Rev B Refer to Figure 3-50 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 66.4510.0002 1 EA RELAY, 20A 250VAC DPDT UL/CSA 4 82.4307.4002 1 EA DIODE, 1N4002 RECTIFIER 100V 1A 1 3 2 4 Figure 3-50: Relay Electrical Assembly 114 02 .9 678 .
PAGE 135
YOKE ASSEMBLY : YOKE FAN ASSEMBLY 3 Yoke Fan Assembly 22.9661.0609 Rev C (VL3500) 22.9678.0609 Rev A (VL3500Q) Refer to Figure 3-51 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 .75 4WAY, VL3500 QUIET (NOT SHOWN) 5 55.2186.0001 1 EA CABLE TIE, .
PAGE 136
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 116 02 .9 678 .
PAGE 137
HEAD/YOKE PCB ASSEMBLIES : SHUTTER CABLE INTERCONNECT ASSEMBLY 3 Head/Yoke PCB Assemblies Shutter Cable Interconnect Assembly 21.9678.1246 Rev A Refer to Figure 3-52 No. Item Qty. UM. Description 1 10.9678.1245 1 EA MOUNT, CABLE INTERCONNECT, SHUTTER 2 52.6670.0034 1 EA HEADER, MOD II, 34 PIN, DUAL SIDED 3 52.6670.0040 1 EA HEADER, MOD II, 40 PIN, DUAL SIDED 4 53.6520.0002 4 EA SCREW, 4-40 X 7/16" PPZ 5 55.6621.
PAGE 138
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Sensor PCB #1 Mount Assembly 22.9678.0481 Rev B Refer to Figure 3-53 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 3 53.6558.0001 2 EA SCREW, 6-32 X 3/8" PPZ 4 55.3303.0006 2 EA WASHER, #6 LOCK INT.TOOTH SS 3 (x2) 4 (x2) 2 1 Figure 3-53: Color Sensor #1 PCB Mount Assembly 118 02 .9 678 .
PAGE 139
HEAD/YOKE PCB ASSEMBLIES : COLOR SENSOR PCB #2 MOUNT ASSEMBLY 3 Color Sensor PCB #2 Mount Assembly 22.9678.0489 Rev B Refer to Figure 3-54 No. Item Qty. UM. Description 1 10.9678.0452 1 EA PCB MOUNT, COLOR SENSOR #2 2 24.9678.0454 1 EA PCB ASSY, COLOR SENSOR #2 3 53.6558.0007 2 EA SCREW, 6-32 X 1/4" SEMS 3 (x2) 2 1 Figure 3-54: Color Sense PCB #2 Mount Assembly 02.96 78.
PAGE 140
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL 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 120 02 .9 678 .
PAGE 141
HEAD/YOKE PCB ASSEMBLIES : WHEEL POSITION SENSOR PCB ASSEMBLY 3 Wheel Position Sensor PCB Assembly 24.9678.3240 Rev 0 Refer to Figure 3-56 No. Item Qty. UM. Description 1 17.9678.3240 1 EA PCB, WHEEL POSITION SENSOR 2 52.6447.0008 1 EA HEADER, SHROUDED 3 POSITION 1 2 Figure 3-56: Wheel Position Sensor PCB Assembly 02.96 78.
PAGE 142
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Interconnect PCB/Cable Assembly 25.9678.0409 Rev B (VL3500 Only) Refer to Figure 3-57 and Figure 3-58 No. Item Qty. UM. Description 1 24.9678.3409 1 EA PCB ASSY, COLOR INTERCONNECT 2 28.9678.0409 1 EA WIRE KIT, COLOR INTERCONNECT - - 04.9678.0409.00 1 EA LABEL SET, COLOR HARNESS - - 11.9678.0409 1 EA PCB, COLOR INTERCONNECT - - 52.6467.0003 1 EA CONN, FEM PLUG 3POS 30-24 AWG - - 52.6467.
PAGE 143
HEAD/YOKE PCB ASSEMBLIES : COLOR INTERCONNECT PCB/CABLE ASSEMBLY 3 Color Interconnect PCB/Cable Assembly (continued) Figure 3-58: Color Interconnect PCB Assembly Wire Chart - VL3500 Only 02.96 78.
PAGE 144
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Interconnect (Quiet) PCB/Cable Assembly 25.9678.0419 Rev A (VL3500Q Only) Refer to Figure 3-59 and Figure 3-60 No. Item Qty. UM. Description 1 24.9678.0409 1 EA PCB ASSY, COLOR INTERCONNECT 2 28.9678.0419 1 EA WIRE KIT, COLOR INTERCONNECT - - 04.9678.0409.00 1 EA LABEL SET, COLOR HARNESS - - 11.9678.0409 1 EA PCB, COLOR INTERCONNECT - - 52.6467.0003 1 EA CONN, FEM PLUG 3POS 30-24 AWG - - 52.6467.
PAGE 145
HEAD/YOKE PCB ASSEMBLIES : COLOR INTERCONNECT (QUIET) PCB/CABLE ASSEMBLY 3 Color Interconnect PCB/Cable Assembly (continued) Figure 3-60: Color Interconnect PCB Assembly Wire Chart - VL3500Q Only 02.96 78.
PAGE 146
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL 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/Tilt Encoder PCB 126 02 .9 678 .
PAGE 147
HEAD/YOKE PCB ASSEMBLIES : VL3500 CONTROLLER PCB ASSEMBLY 3 VL3500 Controller PCB Assembly 24.9678.1730 Rev F Refer to Figure 3-62 Available only as an assembly. Bottom Side Top Side Figure 3-62: VL3500 Controller PCB 02.96 78.
PAGE 148
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Motor Driver (Piggy Back) PCB 24.9678.1732 Rev C Refer to Figure 3-63 Ref. Item Qty. UM. 11.9678.1732 1 EA PCB, MOTOR DRIVER PGY BK VL3500 U6 36-0090 1 EA IC, 74HC14 SCH TRIG SOIC-14 J2 52.6599.0048 1 EA CONN, HDR 24POS SHRD .1LS VERT J1 52.8412.0026 1 EA CONN, 26 PIN .025" SQ PIN SOCKET R7, R8, R13, R14, R18, R29, R40, R41, R46, R47 60.1161.2673 10 EA RES, 1/16W 1% 2.
PAGE 149
HEAD/YOKE PCB ASSEMBLIES : MOTOR DRIVER (PIGGY BACK) PCB Ref. Item Qty. UM. 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, SCHOTTKY BARRIER RECTIFIER U1-U5 85.3773.0001 5 EA IC., STEP MOTOR DRIVER 3 Description Figure 3-63: Motor Driver (Piggy Back) PCB 02.96 78.
PAGE 150
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Arc Zoom Interconnect PCB Assembly 24.9678.1116 Rev 0 Refer to Figure 3-64 Ref. Item Qty. UM. - 04.9678.1116.00 1 EA LABEL SET ZOOM HARNESS (Not Shown) - 11.9678.1116 1 EA PCB ZOOM INTERCONNECT J3 52.6259.0004 1 EA HDR 4POS NT\MTA100 SD RT ANG J4 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.
PAGE 151
HEAD/YOKE PCB ASSEMBLIES : ARC ZOOM INTERCONNECT PCB ASSEMBLY 3 Zoom Interconnect PCB Assembly (continued) Figure 3-64: Arc Zoom Interconnect PCB Assembly 02.96 78.
PAGE 152
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Zoom Sensor (Target) PCB Assembly 24.9678.0112 Rev 0 Refer to Figure 3-65 Ref. Item Qty. UM. Description - 11.9678.1117 1 EA PCB, VL3000 ZOOM SENSOR J1 52.6447.0003 1 EA HEADER, SHROUDED 3 POSITION S1 86.7002.0004 1 EA SWITCH, SLOTTED OPTICAL OPB610 S1 6/16/03 c 2003 Figure 3-65: Zoom Sensor PCB Assembly 132 02 .9 678 .
PAGE 153
HEAD/YOKE PCB ASSEMBLIES : INDEX SENSOR PCB ASSEMBLY 3 Index Sensor PCB Assembly 24.9663.1231 Rev B Refer to Figure 3-66 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 SWITCH, SLOTTED OPTICAL OPB610 2 3 24-96631231 REV B INDEX SENSOR VARI-LITE 1 SOLDER SIDE VIEWED FROM SENSOR SIDE Figure 3-66: Index Sensor PCB Assembly 02.96 78.
PAGE 154
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 134 02 .9 678 .
PAGE 155
ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly Upper Enclosure Assembly 21.9678.0800.01 Rev NN 21.9678.0801.01 Rev Y (VL3500 Quiet) Refer to Figure 3-67 and Figure 3-68 No. Item Qty. UM. 1 04.9640.0374 1 EA LABEL, P.E. GROUND 2 04.9661.1218.01 1 EA LABEL, PATENT, VL2201 & VL2400 SERIES LUM. 3 04.9678.0040.01 1 EA LABEL, VL3000 COMPLIANCE 04.9678.0045 1 EA LABEL, VL3000 COMPLIANCE, VL3500 QUIET 4 06.6032.0009 1 EA CABLE MARKER TIE, WHITE 19 X 7 5 10.9661.
PAGE 156
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 22 21.9678.0864 1 EA ASSY, PAN MOTOR 23 21.9678.0881 1 EA ASSY, PAN TUBE 24 22.9678.0851 1 EA ASSY, UPPER ENCLOSURE 25 23.9678.0686 1 EA FAN ASSY, UPPER ENCLOSURE 23.9678.0888 1 EA FAN ASSY, UPPER ENCLOSURE, SLOW, VL3500 QUIET 26 23.9678.0687 1 EA ELEC ASSY, PAN EOT SENSOR - 25.9661.1514 1 EA CABLE ASSY, LVS CHASSIS GND (not shown) - 25.9661.
PAGE 157
ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY 3 No. Item Qty. UM. 48 53.6626.0001 1 EA SCREW, 10-32 X 1/2" PPZ 49 53.6634.1000 1 EA SCREW, 3/8-16 X 1.00" LG SOC 50 53.6653.0502 4 EA SCREW, 1/4-20 X 1/2"LG SOC 51 54.1206.0014 2 EA RING, RETAINING 52 54.1255.0001 1 EA BEARING ASSY, BLACK FLUSH MOU 53 54.2055.0001 1 EA BELT, TIMING S2M 210GROOVE 9MM 54 55.2150.0003 2 EA STANDOFF, 1/4"HEX 6-32 1.125"L 55 55.2178.0001 2 EA CABLE ANCHOR MOUNT, #8 SCREW 56 55.2179.
PAGE 158
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly (continued) 2 5 15 59 66 (x2) 9 3 14 8 43 (x4) 14 43 (x2) 15 8 9 20 66 (x2) 42 (x4) 43 (x2) 44 (x4) 18 64 (x4) 50 (x4) Figure 3-67: Upper Enclosure Assembly Part 1 138 02 .9 678 .
PAGE 159
3 ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY Upper Enclosure Assembly (continued) 42 7 17 34 42 62 (x3) 12 55, 69 32 (x2) 73, 4 13 36 33 (x4) 60 (x4) 21 63 (x4) 76 65 (x2) 74 53 22 27 51 67 (x2) 42 29 (x2) 26 38 (x2) 10, 55 30 (x2) 52 54 (x2) 42 51 1 75 63 Electronics Assembly 19 73 45, 58 70 Part is shown exploded for clarity 31 (x2) 63 (x2) 41 29 (x2) 25 43 56 57 68 39 (x4) 42 (x3) 40 (x4) 37 (x2) 16 24 6 30 (x2) 47 (x2) 38 57 (x2) 55 (x2) Duct Assembly 43
PAGE 160
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly - Standard 21.9661.1254 Rev C Refer to Figure 3-69 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 SEAL, UPPER ENCLOSURE (changed 05-11-05) 5 10.9678.0896 1 EA 4.5" AIR SEAL, UPPER ENCLOSURE (changed 05-11-05) 6 54.1206.
PAGE 161
ENCLOSURE ASSEMBLY : VENTILATION COVER ASSEMBLY - VL3500 QUIET 3 Ventilation Cover Assembly - VL3500 Quiet 21.9686.0840.02 Rev B Refer to Figure 3-69 No. Item Qty. UM. 1 10.9686.1249 4 EA POST, TRUSS HOOK 1a 10.9678.0850 4 EA POST, TRUSS HOOK, 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 SEAL, SHORT STRIP 6 10.
PAGE 162
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly - VL3500 Quiet (continued) 4 3 5 6 7 (x2) 9 (x4) 1b (x4) 2 1 (x4) 1a (x4) 10 (x4) Early production 8 (x4) Current Figure 3-70: Ventilation Cover Assembly 142 02 .9 678 .
PAGE 163
ENCLOSURE ASSEMBLY : PANEL ASSEMBLY 3 Panel Assembly 21.9678.0805 Rev L Refer to Figure 3-71 No. Item Qty. UM. Description 1 10.9678.0852.01 1 EA LAYOUT, ENCLOSURE OVERLAY (changed 01-06-04) 2 10.9678.0859 1 EA BRACKET, INPUT 3 10.9678.0872 1 EA STIFFENER, 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.
PAGE 164
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL DMX Input PCB 24.9663.3830 Rev B Refer to Figure 3-72 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 4 52.6626.0006 1 EA CONN, RECPT XLR 5P MALE PC MT VERT J2 5 62.3017.0102 1 EA CAP, 1000PF 250V RAD CER DISC 20% Y-TYPE C1 1 5 2 4 3 Figure 3-72: DMX Input PCB 144 02 .
PAGE 165
ENCLOSURE ASSEMBLY : DISPLAY PCB 3 Display PCB 24.9678.3825 Rev A Refer to Figure 3-73 Ref. Item Qty. UM. - 11.9678.2825 1 EA PCB BOARD, VL3000 DISPLAY - 40-0968 1 EA HEADER, 20 POS SAMTEC MTLW .1 LS J1 52.6365.0012 1 EA HEADER, 6POS MTA100 SHROUDED R/A - 53.6659.0003 4 EA SCREW, 2-56 X 3/8" PPZ - 55.3500.0001 4 EA WASHER, #2 FLAT 0.312"OD FIBER - 55.6821.0002 4 EA STANDOFF, 5/32"RND 2-56 .125"LG BRASS SWAGE TYPE, .105" SHANK R7, R14, R15 60.9461.1003 3 EA RES, 0.
PAGE 166
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Display PCB (continued) Top Side Bottom Side View From Component Side Figure 3-73: Display PCB 146 02 .9 678 .
PAGE 167
ENCLOSURE ASSEMBLY : PAN PULLEY ASSEMBLY 3 Pan Pulley Assembly 21.9678.0807 Rev E Refer to Figure 3-74 No. Item Qty. UM. Description 1 10.9678.0750 1 EA TIMING PULLEY, 2MM GT 150 TOOTH 2 10.9678.0855 1 EA PAN FLAG 3 53.6530.0009 2 EA RIVET, 1/8"OD POP 0.126-0.187GL (changed 10-05-06) 3 (x2) 2 1 Figure 3-74: Pan Pulley Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21.9678.0864 Rev E Refer to Figure 3-75 No. Item Qty. UM. Description 1 10.9678.0865 1 EA PLATE, PAN MOTOR MOUNT 2 21.9678.0828 1 EA ASSY, DRIVE PULLEY, PAN - 10.9678.0720 1 EA CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 1 EA TIMING PULLEY, 2MM GT 17 TOOTH - 53.5562.0250 1 EA SCREW, 8-32 X 1/4" SET FLAT POINT 3 24.9678.9729 1 EA PCB ASSY, VL3000 PAN ENCODER (changed 06-27-07) 4 44.9678.
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ENCLOSURE ASSEMBLY : PAN TUBE ASSEMBLY 3 Pan Tube Assembly 21.9678.0881 Rev 0 Refer to Figure 3-76 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 150 02 .9 678 .
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CABLE ASSEMBLIES : PAN EOT SENSOR ELECTRICAL ASSEMBLY 3 Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-77 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 2 (x4) 3 Figure 3-77: Pan EOT Sensor Electrical Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-78 No. Item Qty. UM. 1 52.8231.0001 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8271.0001 1 EA FASTON RECEPT, 16-14 AWG (REEL) 3.5 IN WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 3 73.3516.0504 1 Description 3 2 Figure 3-78: LVS Chassis Ground Cable Assembly 152 02 .9 678 .
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CABLE ASSEMBLIES : CHASSIS TO YOKE GROUND CABLE ASSEMBLY 3 Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-79 No. Item Qty. UM. Description 1 52.8250.0006 2 EA TERM, #8, RING, 10AWG 2 73.7089.0504 15.17 FT WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 1 (x2) 2 Figure 3-79: Chassis To Yoke Ground Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Head to Back Cap Ground Cable Assembly 25.9661.1522 Rev B Refer to Figure 3-80. No. Item Qty. UM. 1 52.8311.0003 2 EA TERM, RING #6 14-16AWG NON-INS. TAPE 2 73.7130.0001 1.33 FT WIRE, 7/64" TUBULAR BRAID TINNED COPPER 1 (x2) Description 2 Figure 3-80: Head to Back Cap Ground Cable Assembly 154 02 .9 678 .
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CABLE ASSEMBLIES : IGNITOR TO RELAY CABLE ASSEMBLY 3 Ignitor to Relay Cable Assembly 25.9661.1526 Rev C Refer to Figure 3-81. 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 1/4" 18-14 AWG INSULATED VO 3 73.7101.0009 0.42 FT WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING 1 2 3 Figure 3-81: Ignitor to Relay Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL LVS to Yoke AC Fan Cable Assembly 25.9678.0843 Rev A Refer to Figure 3-82 No. Item Qty. UM. Description 1 52.6664.0001 2 EA CONTACT, 22-26AWG FEMALE MATE-N-LOK 2 2 52.6664.0002 1 EA CONN, HOUSING 2 POS CAP MATE-N-LOK 2 3 52.8231.0008 2 EA TERM, SPADE #6 RED 22-16AWG INSERT 4 55.2186.0001 2 EA CABLE TIE, .10"WD 4.00"LG SMALL 5 55.6699.0002 2.08 FT SLEEVING, 1/4"NOM.DIA. POLY EXP BRAIDED 6 73.6222.0009 2.
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CABLE ASSEMBLIES : YOKE TO AC FAN CABLE ASSEMBLY 3 Yoke to AC Fan Cable Assembly 25.9678.0012 Rev A Refer to Figure 3-83 No. Item Qty. UM. Description 1 52.6665.0001 2 EA CONTACT, 22-26AWG MALE MATE-N-LOK 2 2 52.6665.0002 1 EA CONN, HOUSING 2 POS PLUG MATE-N-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 TEFZEL 5 55.2260.0208 2.58 FT SLEEVING, FIBERGLASS 0.208 ID 6 55.2200.0003 0.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Backcap Interlock to Gobo Fan Interlock Cable Assembly 25.9678.0014 Rev B Refer to Figure 3-84 No. Item Qty. UM. Description 1 52.8414.0001 2 EA RECEPT, FASTON .187 SERIES 24-20 AWG UNINSUL 2 73.7089.0000 2.00 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 1 2 1 Figure 3-84: Backcap Interlock to Gobo Fan Interlock Cable Assembly 158 02 .9 678 .
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CABLE ASSEMBLIES : RELAY TO GOBO FAN INTERLOCK CABLE ASSEMBLY 3 Relay to Gobo Fan Interlock Cable Assembly 25.9678.0675 Rev B Refer to Figure 3-85. No. Item Qty. UM. 1 52.8230.0003 1 EA RECEPT, 1/4" FASTON 22-18AWG (TAPE MOUNT) 2 52.8414.0001 1 EA RECEPT, FASTON .187 SERIES 24-20 AWG UNINSUL 3 73.7089.0000 2.00 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 1 Description 3 2 Figure 3-85: Relay to Gobo Fan Interlock Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Front Head Fans Cable Assembly 25.9678.0677 Rev B Refer to Figure 3-86 No. Item Qty. UM. 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 52.8346.0001 4 EA CONTACT, 24-30AWG FEMALE CRIMP 4 73.5126.0002 2.67 FT WIRE, 26AWG 2COND 300V 80C 1 Description 4 3 (x4) 2 (x2) Figure 3-86: Front Head Fans Cable Assembly 160 02 .9 678 .
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CABLE ASSEMBLIES : YOKE FAN AND RELAY (STANDARD) CABLE ASSEMBLY 3 Yoke Fan and Relay (Standard) Cable Assembly 25.9678.0681 Rev C (VL3500 Only) Refer to Figure 3-87 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Air Duct OT Switch Cable Assembly 25.9678.0690 Rev 0 (VL3500Q) 25.9678.0691 Rev 0 Refer to Figure 3-88 No. Item Qty. UM. Description 1 52.8414.0001 1 EA 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 55.2260.0133 .375 FT SLEEVING, FIBERGLASS, .133" ID 5 55.2198.0002 .083 FT HEATSHRINK, 1/8" BLACK 6 63.2047.5130 1 EA THERMOSTAT, 130º TO-220 OPEN ON RISE 63.
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CABLE ASSEMBLIES : YOKE FAN AND RELAY (QUIET) CABLE ASSEMBLY 3 Yoke Fan and Relay (Quiet) Cable Assembly 25.9678.0781 Rev A (VL3500Q Only) Refer to Figure 3-89 No. Item Qty. UM. 1 52.6423.0003 1 EA HOUSING, 3 POS MT RECEPT, 2MM 2 52.8230.0003 1 EA RECEPT, 1/4" FASTON 22-18AWG 3 52.6396.3103 1 EA RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END 4 55.2186.0001 1 EA CABLE TIE, .10 X 4" SMALL 5 55.2268.0125 1 IN HEATSHRINK, 1/8" CLEAR KYNAR UL 600V 150O C 6 60.7440.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Yoke Fan (Standard) Cable Assembly 25.9678.0758 Rev A (VL3500 Only) Refer to Figure 3-90 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 .5 FT WIRE, 26AWG 2COND 300V 80C UL1061, 19STRND 2 1 3 Figure 3-90: Yoke Fan (Standard) Cable Assembly - VL3500 Only 164 02 .9 678 .
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CABLE ASSEMBLIES : YOKE FAN (QUIET) CABLE ASSEMBLY 3 Yoke Fan (Quiet) Cable Assembly 25.9678.0759 Rev A (VL3500Q Only) Refer to Figure 3-90 No. Item Qty. UM. Description 1 52.6396.3102 1 EA RECEPT, 2 POS MTA100 W/POL TAB BLUE CLSD END 2 52.6423.0003 1 EA HOUSING, 3 POS MT RECEPT, 2MM CT 28-26 AWG 3 55.2186.0001 1 EA CABLE TIE, .10 X 4" SMALL 4 55.2268.0125 1 EA HEASTRINK, 1/8" CLEAR KYNAR UL 600V 150O C 5 60.7440.2002 1 EA RESISTOR, 5W, 5% 200 OHM WIREWOUND 6 73.5126.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-92. No. Item Qty. UM. Description 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 55.2260.0133 6.83 FT SLEEVING, FIBERGLASS .133" ID 6 73.7100.0001 2.
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CABLE ASSEMBLIES : YOKE TO HEAD GROUND CABLE ASSEMBLY 3 Yoke to Head Ground Cable Assembly 25.9678.0689 Rev 0 Refer to Figure 3-93 No. Item Qty. UM. 1 52.8250.0011 2 EA TERM, RING #10, 122-10AWG (REEL) 2 73.7089.0504 15.17 FT WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 1 (x2) Description 2 Yoke Ground Head Ground Figure 3-93: Yoke to Head Ground Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Head Controller Cable Assembly 25.9678.1715 Rev A Refer to Figure 3-94 No. Item Qty. UM. Description 1 55.6610.0014 1 EA CONN HOUSING, 14 POS DBL ROW UNLOADED 2 55.6610.0024 1 EA CONN HOUSING, 24 POS DBL ROW UNLOADED 3 55.6610.0034 1 EA CONN HOUSING, 34 POS DBL ROW UNLOADED 4 55.6610.0040 3 EA CONN HOUSING, 40 POS DBL ROW UNLOADED 5 55.6610.0017 1 EA CONN HOUSING, 50 POS DBL ROW UNLOADED 6 52.6224.
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CABLE ASSEMBLIES : HEAD CONTROLLER CABLE ASSEMBLY 3 Head Controller Cable Assembly (continued) 4,9,14 17 1,6,11 1,6,11 5,10,15 16 (x11) 17 3,8,13 2,7,12 4,9,14 Figure 3-94: Head Controller Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev B Refer to Figure 3-95 No. Item Qty. UM. Description 1 52.6274.2313 1 EA STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 2 52.6401.2321 1 EA CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3-WIRE 3 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 4 52.8298.1160 2 EA FERRULE, WIRE 1X16 AWG L2=8MM BLACK 5 55.2268.0187 0.
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CABLE ASSEMBLIES : EMI FILTER TO POWER SWITCH CABLE ASSEMBLY 3 EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-96 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 CABLE TIE, .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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-97 No. Item Qty. UM. Description 1 52.6231.0001 1 EA PLUG HOUSING, MNLOK PLUG 3 POS 2 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 52.8231.0008 2 EA TERM, SPADE #6 RED 22-16 AWG INSERT 4 52.8392.0001 2 EA RECP, FASTON .187" X 0.32" 16-14 AWG FLAG DBL CRP 5 52.8270.0001 2 EA CONTACT PIN, 20-14 AWG MNLOK (REEL) 6 52.8314.
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CABLE ASSEMBLIES : AC INPUT SPLITTER CABLE ASSEMBLY 3 AC Input Splitter Cable Assembly (continued) 4 (x2) 3 (x2) 12 2 5, 9 13 5, 10 11, 6 1 7 (x3) 8 Figure 3-97: AC Input Splitter Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-98 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 Figure 3-98: Data I/O Link Cable Assembly 174 02 .9 678 .
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CABLE ASSEMBLIES : DISPLAY CABLE ASSEMBLY 3 Display Cable Assembly 25.9678.0815 Rev E Refer to Figure 3-99 No. Item Qty. UM. Description 1 52.6396.3006 2 EA RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 2 73.5116.0123 2.0 FT WIRE, 24AWG 4COND TW 1 (x2) 2 Figure 3-99: Display Cable Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-100 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 2 3 4 1 Figure 3-100: Ballast to Controller Cable Assembly 176 02 .
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CABLE ASSEMBLIES : DC OUTPUT CABLE ASSEMBLY 3 DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-101 No. Item Qty. UM. Description 1 52.6464.0002 1 EA CONN, HOUSING, SL-156 2 POS 2 52.6464.0003 1 EA CONN, HOUSING, SL-156 3 POS 3 52.8231.0004 2 EA TERM, RING #6 BLUE 12-10 AWG INSRT 4 52.8323.0002 4 EA CONTACT, CRIMP, 18-22 AWG SL-156 (not shown) 5 52.8274.1614 2 EA CONN BUTT SPLICE 16-14 BLUE .150" OD MAX 6 55.2186.0001 5 EA CABLE TIE, .01" x 4.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-102 No. Item Qty. UM. Description 1 52.6610.0008 1 EA CONN HOUSING, 20POS DBL ROW UNLOADED 2 52.6224.1020 1 EA COVER, FRONT 20POS MT LATCHING 3 52.6224.2020 1 EA COVER, BACK 20POS MT 4 52.6524.0005 2 EA CONN, HOUSING 5POS RECEPTACLE 5 52.6588.0007 2 EA HOUSING, 7POS XH 250V/3A 2.5MMPITCH -USE SXH CONTACTS 6 52.7007.
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CABLE ASSEMBLIES : LAMP SUPPLY TO RELAY CABLE ASSEMBLY 3 Lamp Supply to Relay Cable Assembly 25.9678.0819 Rev D Refer to Figure 3-103 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 EXP BRAIDED 4 73.7089.0000 33.25 FT WIRE, 22AWG BLK 300V TEFLON STRANDED 5 73.7089.0009 33.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Gobo/Rotate Interconnect Cable Assembly 25.9678.1209 Rev A Refer to Figure 3-104 and Figure 3-105 No. Item Qty. UM. 1 25.9678.1209 1 EA Description CABLE ASSY, GOBO/ROTATE INTERCONNECT 1 Figure 3-104: Gobo/Rotate Interconnect Cable Assembly 180 02 .9 678 .
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CABLE ASSEMBLIES : GOBO/ROTATE INTERCONNECT CABLE ASSEMBLY 3 Gobo/Rotate Interconnect Cable Assembly (continued) Figure 3-105: Gobo/Rotate Interconnect Cable Assembly Wire Chart 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9678.1716 Rev A Refer to Figure 3-106 No. Item Qty. UM. Description 1 52.8231.0005 1 EA TERMINAL, RING, #6 BLUE, 16-14 AWG REEL PIDG 1 52.8231.0008 1 EA TERMINAL, SPADE, #6 RED, 22-16 AWG INSERT 2 73.3516.0504 1.08 FT WIRE, 16 AWG 300V 105 DEG C PVC UL1569 2 1 3 Figure 3-106: LVS Chassis Ground Cable Assembly 182 02 .9 678 .
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APPENDIX A : VL3500 TECHNICAL BULLETINS A APPENDIX A. Technical Bulletins VL3500 Technical Bulletins The following table identifies the current technical bulletins associated with the VL3000 series luminaires. These improvements have been incorporated into this manual (where applicable) and are available on the Vari-Lite web site at www.vari-lite.com.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 184 02 .9 678 .
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS ASchematic and Wiring Diagrams Solid State Ignitor PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS REV NOTES: UNLESS OTHERWISE SPECIFIED 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. DESCRIPTION DATE 1 ENGINEERING PROTOTYPE 2 ENG RELEASE PER EO #09082 A REL. TO PROD. PER EO #09089 APPD 7/16/02 9/16/02 B.C. B.C.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Gobo Index Sensor PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS REV A DESCRIPTION DATE RLSE TO PRODUCTION ECO 8894 11/08/01 APPD MTD D D C C S1 OPB610 4 1 J1 B 4B-PH-K 3 2 VCC_R 1 SENSOR 2 GND 3 N/C 4 MTG1 MTG2 B B DRAWN BY NEXT A PCB NO. 8 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS DMX Input PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS REV A DESCRIPTION DATE Released per EO #09110 APPD 9/27/01 MTD J1 NC5FBV D SHIELD 1 DMX/VL_IN- 2 DMX/VL_IN+ 3 VL_OUT- 4 VL_OUT+ 5 CHASSIS 6 SHIELD 1 DMX/VL_IN- 2 DMX/VL_IN+ 3 VL_OUT- 4 VL_OUT+ 5 CHASSIS 6 D J2 NC5MBV C C J3 640456-5 B SHIELD 1 DMX/VL_IN+ 2 DMX/VL_IN- 3 VL_OUT+ 4 VL_OUT- 5 B C1 1000PF 20% 250V CHASS
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Gobo Interconnect PCB (Sheet 1 of 1) 8 7 6 5 4 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Color Interconnect PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED REV 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Color Sensor #1 PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED REV DESCRIPTION -- REL TO PROD PER EO #09094 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Color Sensor #2 PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED REV 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. D DESCRIPTION 1 ENG REL PER EO #09062 A REL. TO PROD. PER EO #09095 DATE APPD 07-02-02 K.C.F.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Pan/Tilt Encoder PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED REV 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. D LAST USED 1 ENG REL PER EO #09056 A REL. TO PROD. PER EO #09086 DATE APPD 6-17-02 K.C.F.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 1 of 10) 8 7 6 5 4 3 2 NOTES: UNLESS OTHERWISE SPECIFIED 1.) ALL CAPACITOR VALUES ARE IN MICROFARADS. 2.) ALL RESISTOR VALUES ARE IN OHMS. 1 REV.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 2 of 10) 8 7 6 5 4 3 2 1 +3.3V D[0..3 1] +1.8V +1.8V +1.8V +1.8V 3/B3,3/A3 R52 +1.8V CS_MTR- 2/B4,3/A6 C69 C51 C44 C45 C46 A[0 ..24] CS_UART- U17 2/B4,3/A6 R51 CS_FLASH- +1.8V +1.8V +1.8V +1.8V 2/C4,2/C4 +1.8V R62 C68 C67 C48 C49 TIN0 C47 2/B5 TIN1 +3.3V +3.3V C28 +3.3V C27 +3.3V C55 +3.3V C54 +3.3V C77 C53 2/B5 R36 +3.3V HIZ- 2/A5 DSI +3.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 3 of 10) 10/A1 +2.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 4 of 10) 8 7 6 5 4 3 2 1 DO NOT STUFF VCC +3.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 5 of 10) 8 7 6 5 +24V D +24V 4 3 2 1 +24V D TILT D87 D89 D91 +24V U11 PWM3_OUT_1 3/D3 PWM3_OUT_2 3/A6 PWM3_OUT_3 3/A5 U25 PWM3_EN_1 2 3/A6 7 IN1 8 EN1 4 IN2 3 EN2 14 IN3 13 EN3 4 OUT1 6 OUT2 5 OUT3 15 SENSE1 2 SENSE2 19 VREF 16 VCC R77 VCC VCP 17 VBOOT 18 1 GNDA 10 GNDB 11 GNDC VSSA 9 20 GNDD VSSB 12 C82 TILT_PHA_OUT 10/D3 TILT_
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 6 of 10) 8 7 6 5 4 3 VCC 1 VCC +24V VCC 2 +24V +24V C101 VCC C78 + +24V C119 C85 + D D 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 10 19 E1 C1 C99 ROT1_OUT2A ROT1_OUT2B C114 R132 10/D7,10/C3 PWM_PH_12 10/D7,10/C3 R140 R141 PWM_OUT_12 C122 16 C121 R139 DIS1 18 VR1 4 VMM2 VMM1 PHASE1 2
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 7 of 10) 5 4 3 2 VCC D VCC +24V VCC 1 +24V +24V C136 VCC C100 + D +24V C155 C118 + FRAME 1A C132 R157 PHASE1 21 DIS1 R191 PWM_PH_16 R190 PWM_OUT_16 C140 C139 R162 11 MB1 8 MA2 5 MB2 7 3/C3 10/B7,10/C3 R169 FRAME1A_OUT1B 10/B7,10/C5 3/B3 C150 PHASE2 24 DIS2 27 VR2 22 FRAME1A_OUT2A FRAME1A_OUT2B 20 PHASE1 21 DIS1 18 GND1 25 PWM_PH_1 R170
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 8 of 10) 5 4 3 2 VCC VCC +24V D +24V +24V C173 VCC C137 + 3/C6 R209 C168 R210 PHASE1 21 DIS1 R219 PWM_PH_20 R218 PWM_OUT_20 C176 C175 R217 11 MB1 8 MA2 5 MB2 7 10/D6,10/A3 10/D6,10/A5 3/C6 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C171 AMB_OUT2A AMB_OUT2B PWM_PH_23 R244 PWM_OUT_23 C195
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 9 of 10) 8 7 6 5 4 3 VCC 1 VCC +24V VCC 2 +24V +24V C208 VCC C172 + +24V C232 C199 + D D C229 PHASE2 24 DIS2 27 VR2 22 FXDC_OUT2B RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 10 19 E1 C1 C207 R264 C FXDC_OUT2A C228 R288 10/C6,10/A5 PWM_PH_32 10/C6,10/A3 R293 3/B6 R296 PWM_OUT_32 C234 16 C235 R295 PHASE
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 10 of 10) 8 7 6 5 4 3 2 1 +24V VCC +24V DIA. .166" FRAME2A_OUT1A D14 D49 D50 AMB_OUT1B 8/D5,10/A5 5/C1,10/C5 D52 AMB_OUT2A DIA. .250" MNTG2 1 2 3 4 5 6 8/D5,10/A3 FRAME2A_OUT2A D15 AMB_OUT1A FRAME2A_OUT1B 5/C1,10/C5 D16 DIA. .
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Motor Driver (Piggy Back) PCB (Sheet 1 of 1) 5 4 3 2 +24V +24V D1 2 1 2 +24V D3 2 R7 1 PWM_PH_36 R10 PWM_OUT_36 C11 C12 R13 MB1 8 MA2 5 MB2 7 R5 FRAME2B_OUT1B R6 PWM_OUT_39 C7 24 DIS2 27 VR2 22 RC R8 DIS1 18 VR1 R12 PWM_OUT_40 D MA1 11 MB1 8 MA2 5 MB2 7 FRAME3B_OUT1B +24V GND1 PHASE2 FRAME3B_OUT2A D9 2 24 DIS2 27 VR2 22 RC GND10 28 2 +24V GND2 GND09 1
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Display PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS DESCRIPTION REV NOTES: UNLESS OTHERWISE SPECIFIED TEW1 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. D DATE APPD RELEASED TO ENGINEERING PER EO #09054 5-29-02 2 REVISED PER EO #09057 A RELEASED FOR PRODUCTION PER EO #09088 8-15-02 TEW T.E.W.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Zoom Interconnect PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED REV 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. D - DESCRIPTION DATE APPD RELEASE TO PROD.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Zoom Sensor PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. D REV DESCRIPTION - REL. TO PROD.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Spot Luminaire Wiring Diagram (Sheet 1 of 3) 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Spot Luminaire Wiring Diagram (Sheet 2 of 3) 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Spot Luminaire Wiring Diagram (Sheet 3 of 3) 02.96 78.
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