Service manual

ManualsBrandsVari Lite ManualsFlood LightVL3500 Spot Luminaire

Summary of content (149 pages)

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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. VL500™, VL1000™,VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, VL3500™, Series 500™, 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@genlytecontrols.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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CHAPTER 3. Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3500™ Spot Luminaire assemblies. Note: The VL3500 Series Luminaires share many common assemblies and parts 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 Luminaire 20.9678.0019 Rev H (VL3500 Only) Generic Luminaire Assembly 21.9678.0010.02 Rev H (VL3500 Only) Head Structure Assembly 21.9678.0600 Rev C (VL3500 Only) Backcap Assembly 21.9678.0615 Rev T (VL3500 Only) continued next page Yoke Assembly 21.9678.0700 Rev J (VL3500) Tilt Motor Assembly 21.9678.0765 Rev E Yoke Fan Assembly 22.9661.0609 Rev C (VL3500) Head Cover Assembly 21.9678.
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DRAWING TREES : VL3500 SPOT LUMINAIRE 3 VL3500 Spot Luminaire (continued) continued from previous page Spot Optic Assembly 22.9678.0103 Rev S continued from previous page Color/Dimmer/Strobe Assembly 22.9678.0402 Rev N (VL3500) Interconnect Light Shield Assembly 22.9678.1115 Rev D Group 4 Lens Assembly 22.9678.0199 Rev 0 Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Fixed Color Wheel Assembly 21.9678.0334 Rev D Right Edge Bearing Assembly 22.9678.1103 Rev C Zoom Cam Assembly 22.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500 Spot Luminaire (continued) continued from page 44 Upper Enclosure Assembly 21.9678.0800.02 Rev NN (VL3500 Only) Ventilation Cover Assembly Standard 21.9678.1254 Rev 0 Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Pan Pulley Assembly 21.9678.0807 Rev E LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Pan Motor Assembly 21.9678.0864 Rev E Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Pan Tube Assembly 21.9678.
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DRAWING TREES : VL3500Q SPOT LUMINAIRE 3 VL3500Q Spot Luminaire VL3500Q Spot Luminaire 20.9678.0020 Rev I (VL3500Q Only) Generic Luminaire Assembly 21.9678.0011.02 Rev C (VL3500Q Only) Head Structure Assembly 21.9678.0601 Rev 0 (VL3500Q Only) Backcap Assembly 21.9678.0616 Rev H (VL3500Q Only) continued next page Yoke Assembly 21.9678.0701 Rev B (VL3500Q) Tilt Motor Assembly 21.9678.0765 Rev E Yoke Fan Assembly 22.9678.0609 Rev A (VL3500Q) Head Cover Assembly 21.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500Q Spot Luminaire (continued) continued from previous page Spot Optic Assembly 22.9678.0103 Rev S continued from previous page Color/Dimmer/Strobe Assembly 22.9678.0462 Rev E (VL3500Q) Interconnect Light Shield Assembly 22.9678.1115 Rev D Group 4 Lens Assembly 22.9678.0199 Rev 0 Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Fixed Color Wheel Assembly 21.9678.0334 Rev D Right Edge Bearing Assembly 22.9678.1103 Rev C Zoom Cam Assembly 22.
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DRAWING TREES : VL3500Q SPOT LUMINAIRE 3 VL3500Q Spot Luminaire (continued) continued from page 44 Upper Enclosure Assembly 21.9678.0801.02 Rev Z (VL3500Q Only) Ventilation Cover Assembly VL3500 Quiet 21.9686.0840.02 Rev B (VL3500Q) Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Pan Pulley Assembly 21.9678.0807 Rev E LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Pan Motor Assembly 21.9678.0864 Rev E Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Pan Tube 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 3-7. 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 3-7: 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 H (VL3500 Only) 20.9678.0020 Rev I (VL3500Q Only) Refer to Figure 3-8 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) 52 Description - 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) - 25.9661.1520 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 Description 20 53.2002.0003 4 EA NUT, 6-32 HEX ZINC NYLON IN 21 53.2202.
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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 26 (x4) 31 3 23 (x2) 6 17 4 19 (x4) 24 (x2) 32 (x2) 10, 37 4 23 (x2) 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 3-8: VL3500 Series Spot Luminaire 54 02 .9 678 .
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TOP ASSEMBLY : GENERIC LUMINAIRE ASSEMBLY 3 Generic Luminaire Assembly 21.9678.0010.02 Rev H (VL3500 Only) 21.9678.0011.02 Rev C (VL3500Q Only) Refer to Figure 3-9 No. Item Qty. UM. 1 21.9678.0600 1 EA ASSY, HEAD STRUCTURE 21.9678.0601 1 EA ASSEMBLY, HEAD STRUCTURE, QUIET 21.9678.0700 1 EA ASSY, YOKE 21.9678.0701 1 EA ASSEMBLY, YOKE, QUIET 21.9678.0707 1 EA ASSEMBLY, TILT PULLEY 2 3 Description 3a - 10.9678.0750 1 EA TIMING PULLEY, 150 TOOTH 3b - 10.9678.
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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) Detail A 11 (x4) 7 (x5) 2 4 16 (x5) 5 3c (x3) 3a 3b 4c Detail A 4a 4b 4d 18 (x2) 17 (x2) Figure 3-9: Generic Luminaire Assembly 56 02 .9 678 .
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HEAD ASSEMBLY : HEAD STRUCTURE ASSEMBLY 3 Head Assembly Head Structure Assembly 21.9678.0600 Rev C (VL3500 Only) 21.9678.0601 Rev 0 (VL3500Q Only) Refer to Figure 3-1 No. Item Qty. UM. Description 1 10.9678.8620 1 EA FRONT CASTING 2 12.9678.8623 1 EA RIGHT SIDE RAIL, MACHINED 3 12.9678.8625 1 EA LEFT SIDE RAIL, MACHINED 4 21.9678.0615 1 EA ASSY, BACKEND (VL3500 ONLY) 21.9678.0616 1 EA ASSEMBLY, BACKEND (VL350OQ ONLY) 5 53.6515.0001 6 EA SCREW, 10-32 X 3/4" SCB CAP 6 53.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Head Cover Assembly 21.9678.8611 Rev Refer to Figure 3-2 No. Item Qty. UM. Description 1 10.9678.0612 1 EA HEAD COVER FOAM BAFFLE 2 10.9678.0649 4 EA EJECTOR SPRING, BLACK OXIDE 3 10.9678.0674 1 EA BRACKET, COVER TETHER 4 10.9678.0696 1 EA FOAM FRAME, HEAD COVER 5 12.9678.8610 1 EA HEAD COVER, PAINTED 6 53.6558.0003 1 EA SCREW, 6-32 X 3/8"LG PPZ PLASTIC THD ROLL 7 53.5655.
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HEAD ASSEMBLY : BACKCAP ASSEMBLY 3 Backcap Assembly 21.9678.0615 Rev T (VL3500 Only) 21.9678.0616 Rev H (VL3500Q Only) Refer to Figure 3-3 No. Item Qty. UM. 1 10.9678.0631 1 EA SEPARATION BULKHEAD 2 10.9678.8635 1 EA EXHAUST BULKHEAD 3 10.9678.0637 2 EA CLIP, RETRO-REFLECTOR 4 10.9678.0638 1 EA AIR DIVERTER, STROBE MOTOR 5 10.9678.0653 1 EA LIGHT BAFFLE, EXHAUST 6 12.9678.7152 1 EA REFLECTOR, RETRO SPHERICAL COATED 7 12.9678.0627 1 EA AFT BULKHEAD, MACHINED 8 21.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 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 10.9678.1645 1 EA FAN SHIELD, LAMP COOLING 30 55.6538.
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HEAD ASSEMBLY : 80MM FAN ASSEMBLY 3 80mm Fan Assembly 21.9678.0619 Rev B (VL3500 and VL3500 Quiet) Refer to Figure 3-4 No. Item Qty. UM. Description 1 40.7145.0004 1 EA FAN, TUBEAXIAL 80 X 80 X 38MM 230V 28 CFM 2 53.2200.0006 4 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) 2 (x4) 1 Figure 3-4: 80mm Fan Assembly - VL3500 and VL3500 Quiet 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL UV Filter Bulkhead Assembly 22.9678.0617 Rev D (VL3500 Q) 22.9678.0639 Rev G (VL3500) Refer to Figure 3-5 No. Item Qty. UM. 1 10.9678.0634 1 EA UV FILTER BULKHEAD 2 10.9678.0648 2 EA CLIP, UV GLASS 3 41.9678.0608 1 EA UV/IR FILTER, 3.00" X 3.00" 41.9678.1160 1 EA UV/IR FILTER, 3.00" X 3.00" (VL3500 QUIET) 53.6530.0002 4 EA RIVET, 1/8 OD POP,.063-.
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HEAD ASSEMBLY : GOBO/SHUTTER ASSEMBLY 3 Gobo/Shutter Assembly 21.9678.1200 Rev G Refer to Figure 3-6 No. Item Qty. UM. Description 1 10.9678.0338 1 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, INDEX 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.
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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 3-6: Gobo/Shutter Assembly 64 02 .9 678 .
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HEAD ASSEMBLY : ROTATING GOBO WHEEL ASSEMBLY, SHUTTER 3 Rotating Gobo Wheel Assembly, Shutter 21.9678.1205 Rev B Refer to Figure 3-7 No. Item Qty. UM. Description 1 10.9678.1216 1 EA BULKHEAD, SHUTTER MODULE, REAR 2 10.9678.1225 2 EA SHAFT, GOBO WHEEL, CANTILEVER 3 21.9678.1210 1 EA ASSY, ROTATING GOBO WHEEL 4 21.9678.1410 1 EA ASSY, FIXED GOBO WHEEL 5 24.9678.3240 2 EA ASSY, PCB, WHEEL POSITION SENSOR 6 53.6520.0001 4 EA SCREW, 4-40 X 3/8" PPZ 7 53.6601.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Fixed Gobo Wheel Assembly 21.9678.1410 Rev B Refer to Figure 3-8 No. Item Qty. UM. Description 1 10.9678.0250 1 EA MAGNET TAPE.375"W x.625" L x.0035" THICK 2 10.9678.1412 1 EA PLATE, ROTATING 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.
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HEAD ASSEMBLY : ROTATING GOBO WHEEL ASSEMBLY 3 Rotating Gobo Wheel Assembly 21.9678.1210 Rev 0 Refer to Figure 3-9 No. Item Qty. UM. Description 1 10.9678.0250 1 EA 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Roller Pivot Rotate Assembly 21.9678.1555 Rev 0 Refer to Figure 3-10 No. Item Qty. UM. Description 1 10.9678.1551 1 EA ROLLER PIVOT, SHUTTER ROTATE 2 22.9678.1550 1 EA ASSY, SHUTTER ROTATE, ROLLER 3 53.6609.0001 1 EA SCREW, 6-32 X 3/8" PFZ 1 Flange side of bearing 2 3 Figure 3-10: Roller Pivot Rotate Assembly 68 02 .9 678 .
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HEAD ASSEMBLY : SHUTTER ROTATE ROLLER ASSEMBLY 3 Shutter Rotate Roller Assembly 22.9678.1550 Rev B Refer to Figure 3-11 No. Item Qty. UM. Description 1 10.9678.1552 1 EA ROLLER SHUTTER ROTATE 2 54.1259.0005 1 EA BEARING, FLANGED,.25" ID,.625" OD,.0001 1 2 Figure 3-11: Shutter Rotate Roller Assembly 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Long Shaft Motor Assembly 21.9678.0243 Rev 0 Refer to Figure 3-12 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 Note orientation of adapter plate in relation to the motor. Figure 3-12: Long Shaft Motor Assembly 70 02 .9 678 .
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HEAD ASSEMBLY : SHUTTER ASSEMBLY 3 Shutter Assembly 21.9678.1510 Rev J Refer to Figure 3-13 No. Item Qty. UM. 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Shutter Assembly (continued) 17 2 4, 28 (x2) 1 27 1 5 (x4) 2 18 (x6) 24 (x8) 11 (x4) 10 (x3) 20 (x16) 13 11 (x3) 23 (x8) 12 9 (x4) 14 7 22 (x16) 15 (x2) 19 (x2) 3 (x16) 8 3 26 (x8) 6 (x8) 21 (x2) 16 (x2) 21 (x2) 25 (x16) Figure 3-13: Shutter Assembly 72 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 3-14 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Shutter Motor Disk Assembly (continued) 5 (x8) 4 (x8) 1 8 (x8) 2 (x8) 6 (x4) 3 (x4) Frame 4B Frame 1A Frame 4A 7 (x10) Frame 3B 9 11 Frame 1B Frame 2A Frame 3A Frame 2B Figure 3-14: Shutter Motor Disk Assembly 74 02 .9 678 .
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HEAD ASSEMBLY : HOT BOX ASSEMBLY 3 Hot Box Assembly 21.9678.8698.01 Rev F Refer to Figure 3-15 No. Item Qty. UM. Description 1 10.9678.0043.03 1 EA LABEL PLATE, VL3000 BACKCAP, BLACK 2 10.9678.0641 1 EA HOT BOX 3 10.9686.0642 1 EA BACKCAP PLATE 4 10.9678.0643 1 EA LAMP ADJUST STOP 5 10.9678.0645 3 EA KNOB, LAMP ADJ MOLDED 6 10.9678.0646 1 EA TILT PLATE, XYZ ADJUSTMENT 7 10.9678.1648 4 EA GASKET, PRIMARY REFLECTOR 8 10.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Hot Box Assembly (continued) 8 (x4) 17 (x4) 7 (x4) 13 (x4) 9 18 (x4) 11 (x2) 14 (x4) 4 12 (x8) 15 (x4) 2 6 19 17 (x3) 3 1 16 (x3) 5 (x3) 10 (x3) Figure 3-15: Hot Box Assembly 76 02 .9 678 .
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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 3-16 No. Item Qty. UM. Description 1 10.9678.0665 1 EA SPRING, EXTENSION ELONGATED HOOKS 2 22.9678.0661 1 EA ASSY, FAN TRAY 3 22.9678.1265 1 EA DUCT ASSY, SHUTTER/GOBO 4 23.9678.0684 2 EA FAN ASSY, HEAD FRONT 5 53.5506.1375 6 EA SCREW, 6-32 X 1 3/8"LG PPB 6 53.6519.0001 2 EA SCREW, 4-40 X 5/8" PPZ 7 53.6530.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Dual Fan Tray Duct (Quiet) Assembly 21.9678.0659.03 Rev D (VL3500Q Only) Refer to Figure 3-17 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.
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HEAD ASSEMBLY : HEAD FRONT FAN (STANDARD) ASSEMBLY 3 Head Front Fan (Standard) Assembly 23.9678.0684 Rev 0 (VL3500 Only) Refer to Figure 3-18 No. Item Qty. UM. Description 1 40.7125.0001 1 EA FAN, 24V FAL6F24LH 2 52.6523.0002 1 EA CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52.8347.0001 2 EA CONTACT, 24-30AWG MALE CRIMP 2 3 (x2) 1 Figure 3-18: Head Front Fan Assembly - VL3500 Only 02.96 78.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Head Front Fan (Quiet) Assembly 23.9678.0699 Rev A (VL3500Q 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 4 55.2186.0001 1 EA CABLE TIE,.10 X 4" SMALL 5 55.2268.0125 1 EA HEAT SHRINK, 1/8" CLEAR KYNAR UL 600V 150 DEG C 6 60.8440.
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HEAD ASSEMBLY : TRANSFER FAN ASSEMBLY 3 Transfer Fan Assembly 21.9678.1263 Rev 0 Refer to Figure 3-20 No. Item Qty. UM. Description 1 10.9678.0679 1 EA TRANSFER FAN TRAY 2 22.9678.1280 1 EA SHIELD ASSY, SHUTTER ROTATE HARNESS 3 23.9678.0695 1 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 54
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 82 02 .9 678 .
PAGE 55
HEAD ASSEMBLY : SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly 22.9678.0103 Rev S Refer to Figure 3-21 and Figure 3-22 No. Item Qty. UM. 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 10.9678.1185 1 EA LIGHT BAFFLE #2 9 10.
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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 57
HEAD ASSEMBLY : SPOT OPTIC ASSEMBLY 3 Spot Optic Assembly (continued) 23 F 33 (x2) F 36 (x2) 33 (x2) E E 24 21 38 (x2) 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 3-21: Spot Optic Assembly View 1 02.96 78.
PAGE 58
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 59
HEAD ASSEMBLY : GROUP 4 LENS ASSEMBLY 3 Group 4 Lens Assembly 22.9678.0199 Rev 0 Refer to Figure 3-23 No. Item Qty. UM. Description 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 0.5" LG 0.125" DIA 303SS 4 (x4) 3 (x4) 1 5 (x4) 1 2 Figure 3-23: G4 Lens Mount Assembly 02.96 78.
PAGE 60
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Right Edge Bearing Assembly 22.9678.1103 Rev C Refer to Figure 3-24 No. Item Qty. UM. Description 1 12.9678.1102 1 EA EDGE BEARING, MACHINED RIGHT 2 54.2056.0001 4 EA RING, RETAINING EXTERNAL 19MM 3 55.6776.0010 2 EA LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE 2 (x4) 3 (x2) 1 Figure 3-24: Right Edge Bearing Assembly 88 02 .9 678 .
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HEAD ASSEMBLY : LEFT EDGE BEARING ASSEMBLY 3 Left Edge Bearing Assembly 22.9678.1105 Rev C Refer to Figure 3-25 No. Item Qty. UM. Description 1 12.9678.1104 1 EA EDGE BEARING, MACHINE LEFT 2 54.2056.0001 4 EA RING, RETAINING EXTERNAL 19MM 3 55.6776.0010 2 EA LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE 2 (x4) 3 (x2) 1 Figure 3-25: Left Edge Bearing Assembly 02.96 78.
PAGE 62
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Zoom Cam Assembly 22.9678.1106 Rev B Refer to Figure 3-26 No. Item Qty. UM. Description 1 10.9678.1107 1 EA ZOOM TIMING 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 .
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HEAD ASSEMBLY : ZOOM MOTOR TENSIONING ASSEMBLY 3 Zoom Motor Tensioning Assembly 22.9678.1113 Rev B Refer to Figure 3-27 No. Item Qty. UM. Description 1 10.9678.0338 1 EA PULLEY, ZOOM MOTOR 2 10.9678.1111 1 EA BRACKET, ZOOM TENSION SHEETMETAL 3 44.9663.1326 1 EA MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM 4 53.5559.0250 2 EA SCREW, 6-32 X 1/4" SET CONE POINT 5 53.6522.0001 2 EA SCREW, 6-32 X 1/4" PPZ 6 55.3303.0006 2 EA WASHER, #6 LOCK INT.
PAGE 64
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Interconnect Light Shield Assembly 22.9678.1115 Rev D Refer to Figure 3-28 No. Item Qty. UM. Description 1 10.9678.1114 1 EA SHIELD, INTERCONNECT MOUNT/LIGHT 2 24.9678.3116 1 EA PCB ASSY, ZOOM INTERCONNECT 3 53.6558.0009 4 EA SCREW, 6-32 X 3/8" PPZ SEMS 3 (x4) 2 1 Figure 3-28: Interconnect Light Shield Assembly 92 02 .9 678 .
PAGE 65
HEAD ASSEMBLY : ROD CLAMP ASSEMBLY 3 Rod Clamp Assembly 22.9678.0149 Rev B Refer to Figure 3-29 No. Item Qty. UM. Description 1 10.9678.0151 1 EA CLAMP, OPTIC ROD CAST 2 53.2008.0006 2 EA SPRING CLIP, 6-32 3 53.6616.0001 2 EA SCREW, 6-32 X 3/4" PPZ 4 55.6528.0001 2 EA WASHER, #6 FLAT ZINC 5 55.6538.0001 2 EA WASHER, #6 LOCK INTERNAL TOOTH 3 (x2) 5 (x2) 4 (x2) 1 Spring Clip Installation 0.10" 2 (x2) Set spring clip from clamp surface as indicated.
PAGE 66
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color/Dimmer/Strobe Assembly 22.9678.0402 Rev N (VL3500) 22.9678.0462 Rev E (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 3 10.9678.0456 4 EA SHAFT, COLOR WHEEL 4 10.9678.0457.07 1 EA SPACER, COLOR WHEEL L.357 5 10.9678.0457.02 2 EA SPACER, COLOR WHEEL L.190 6 10.9678.0457.03 3 EA SPACER, COLOR WHEEL L.123 7 10.9678.0457.
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HEAD ASSEMBLY : COLOR/DIMMER/STROBE ASSEMBLY 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 Description 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color/Dimmer/Strobe Assembly (continued) 13 20 25 (x4) 27 (x8) 5 14 11 4 9 (x5) Dimmer 26 (x10) 16 33 Yellow 6 6 40 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 (x4) 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 3-30: Color/Dimmer/Strobe Assembly 96 02 .9 678 .
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HEAD ASSEMBLY : MOTOR/ADAPTER PLATE ASSEMBLY 3 Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Refer to Figure 3-31 No. Item Qty. UM. Description 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) Note orientation of adapter plate in relation to the motor. Figure 3-31: Motor/Adapter Plate Assembly 02.96 78.
PAGE 70
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Fixed Color Wheel Assembly 21.9678.0334 Rev D Refer to Figure 3-32 No. Item Qty. UM. 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 98 Description 4 22.9678.1336 1 EA FAB ASSY, FIXED WHEEL/CLIP (changed 9-03-03) 5 41.9678.0305.01 1 EA COLOR FILTER, DEEP RED VL3000 6 41.9678.0305.02 1 EA COLOR FILTER, KELLY GREEN VL3000 7 41.9678.0305.
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3 HEAD ASSEMBLY : FIXED COLOR WHEEL ASSEMBLY Fixed Color Wheel Assembly (continued) 4 13 14 (x6) 15 2 (x6) 11 (x6) 3 (x6) 1 12 (x3) 9 6 7 POS 2 ORANGE POS 1 CONGO BLUE POS 3 KELLY GREEN POS 4 DARK FUSHIA OPEN POS 6 DEEP RED 5 10 POS 5 MAGENTA 8 Figure 3-32: Fixed Color Wheel Assembly 02.96 78.
PAGE 72
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Strobe Assembly 22.9678.0403 Rev F (VL3500 Only) Refer to Figure 3-33 No. Item Qty. UM. 1 10.9678.0491 4 EA BUMPER STOP, STROBE (changed on 6-18-03) 2 10.9678.0465 1 EA STROBE BULKHEAD 3 22.9678.0468 1 EA ASSY, LEFT STROBE BLADE 4 22.9678.0467 1 EA ASSY, RIGHT STROBE BLADE 5 44.5029.0001 2 EA MOTOR, STEPPER 42MM X 34MM -AR 6 53.6513.0032 8 EA SCREW, M3X10MM SEMS PPZ EXT TO 7 53.6609.
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3 HEAD ASSEMBLY : STROBE (QUIET) ASSEMBLY Strobe (Quiet) Assembly 22.9678.0463 Rev B (VL3500Q Only) Refer to Figure 3-33 No. Item Qty. UM. 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 53.6609.0500 4 EA SCREW, 6-32 X 1/2"LG PFZ 8 55.3306.
PAGE 74
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Right Strobe Blade Assembly 22.9678.0467 Rev C Refer to Figure 3-35 No. Item Qty. UM. Description 1 10.9678.0464 1 EA STROBE BLADE (changed 07-29-04) 2 10.9678.0432 1 EA HUB, STROBE BLADE 3 10.9678.0466 1 EA STROBE BLADE, DAMPER 4 53.5559.0250 2 EA SCREW, 6-32 X 1/4" SET CONE POINT 5 53.6597.0001 3 EA SCREW, 4-40 X 3/16" PPZ 6 55.3303.0004 3 EA WASHER, #4 LOCK INT.
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3 HEAD ASSEMBLY : LEFT STROBE BLADE ASSEMBLY Left Strobe Blade Assembly 22.9678.0468 Rev C Refer to Figure 3-36 No. Item Qty. UM. Description 1 10.9678.0464 1 EA STROBE BLADE (changed 07-29-04) 2 10.9678.0432 1 EA HUB, STROBE BLADE 3 10.9678.0466 1 EA STROBE BLADE, DAMPER 4 53.5559.0250 2 EA SCREW, 6-32 X 1/4" SET CONE POINT 5 53.6597.0001 3 EA SCREW, 4-40 X 3/16" PPZ 6 55.3303.0004 3 EA WASHER, #4 LOCK INT.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Strobe Motor (Quiet) Assembly 23.9678.0499 Rev A (VL3500Q Only) Refer to Figure 3-37 No. Item Qty. UM. Description 1 44.5035.0001 1 EA STEPPER MOTOR, 2 PHASE, PK 2 52.6524.0004 1 EA CONNECTOR, HOUSING, 4 POS RECEPT 3 52.8346.0001 4 EA CONTACT, 24-30 AWG FEMALE CRIMP 4 55.2200.0003 0.25 FT HEAT SHRINK, 3/16" VITON 1 4 2 3 (x4) Wiring Pin Out Heatshrink 3.
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HEAD ASSEMBLY : DIMMER WHEEL ASSEMBLY 3 Dimmer Wheel Assembly 22.9678.0435 Rev D Refer to Figure 3-38 No. Item Qty. UM. 1 55.2256.0001 1 EA Description MAGNET, 2:17 SMCO 2MM X 2MM Coated Side Copper RTV Bead 1 Dimmer Wheel Magnet Glueing Magnet to Dimmer Wheel Assembly Step 1. Make sure surface is clean and oil free Step 2. Apply High Temp Copper RTV to magnet as shown. Step 3. Step 4. Place magnet on dimmer wheel assembly as shown.
PAGE 78
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Gobo Clamp Assembly 22.9678.0693 Rev A Refer to Figure 3-39 No. Item Qty. UM. Description 1 12.9678.0691 1 EA GOBO CLAMP 2 53.6685.0625 2 EA SCREW, CAPTIVE PANEL, 6-32 X 0.625"LG PPS ZINC PLATED 3 55.6538.0001 2 EA WASHER, #6 LOCK INTERNAL TOOTH 4 53.6613.1126 1 EA SCREW, 6-32 X 1.125 LG PPZ 1 3 (x2) 2 (x2) 4* * Note: Install item 4 with Loctite® 242. Figure 3-39: Gobo Clamp Assembly 106 02 .9 678 .
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HEAD ASSEMBLY : COLOR CLAMP ASSEMBLY 3 Color Clamp Assembly 22.9678.0694 Rev A Refer to Figure 3-40 No. Item Qty. UM. Description 1 12.9678.0692 1 EA COLOR CLAMP 2 53.6685.0625 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) 2 (x2) 4* * Note: Install item 4 with Loctite® 242. Figure 3-40: Color Clamp Assembly 02.96 78.
PAGE 80
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Edge Lead Screw Assembly 22.9678.1126 Rev B Refer to Figure 3-41 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 0.562" LG 1* 2 * Note: Apply one drop of Loctite® 272 to the threads of item 1. Figure 3-41: Edge Lead Screw Assembly 108 02 .9 678 .
PAGE 81
YOKE ASSEMBLY : YOKE ASSEMBLY 3 Yoke Assembly Yoke Assembly 21.9678.0700 Rev J (VL3500) 21.9678.0701 Rev B (VL3500Q) Refer to Figure 3-42 No. Item Qty. UM. Description 1 10.9678.0764 1 EA PLATE, TILT ENCODER MOUNT 2 10.9678.0756 1 EA IGNITOR SHIELD 3 21.9678.0765 1 EA ASSY, TILT MOTOR 4 22.9661.0609 2 EA ASSY, YOKE FAN 22.9678.0609 2 EA ASSY, YOKE FAN, VL3500 QUIET 5 22.9686.0705 1 EA ASSY, YOKE STRUCTURE 6 23.9650.3327 1 EA ELEC ASSY, RELAY 7 23.9661.
PAGE 82
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Yoke Assembly (continued) 4 19 5 9 6 19 13 (x2) 18 (x2) 10 8 2 21 (x2) 13 (x4) 13 (x3) 4 12 (x2) 14 (x4) 11 (x8) 15 (x2) 3 20 (x2) 13 7 16 17 13 (x2) 1 14 (x2) Figure 3-42: Yoke Assembly 110 02 .9 678 .
PAGE 83
YOKE ASSEMBLY : TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-43 No. Item Qty. UM. 1 10.9678.0763 1 EA PLATE, TILT MOTOR MOUNT 2 21.9678.0708 1 EA ASSY, DRIVE PULLEY 2a 10.9678.0720 1 EA CODEWHEEL, 120 COUNT, LARGE ID 2b 10.9678.1749 1 EA TIMING PULLEY, 17 TOOTH, SHORTENED 2c 53.5560.0250 2 EA SCREW, 8-32 X 1/4" SET CONE POINT 3 24.9661.9629 1 EA PCB ASSY, PAN/TILT ENCODER 4 44.9678.0680 1 EA MOTOR, 3 PHASE SIZE 23 HIGH TORQUE 5 53.
PAGE 84
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Tilt Motor Assembly (continued) 2 See Detail A 9 (x2) Detail A 7 (x2) 2b 3 2c (x2) 5 (x2) 2a 1 Pressure-Sensitive Adhesive 6 (x4) Pulley Height Detail & Installation 2 3 8 (x4) 0.257" 1 4 Step 6. Apply one drop of Loctite 603 to motor shaft. Step 7. Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite. Step 8. Do not allow Loctite to drip into motor bearing. Step 9. Step 10.
PAGE 85
YOKE ASSEMBLY : YOKE FAN ASSEMBLY 3 Yoke Fan Assembly 22.9661.0609 Rev C (VL3500) 22.9678.0609 Rev A (VL3500Q) Refer to Figure 3-44 No. Item Qty. UM. Description 1 10.9661.0646 1 EA FAN TRAY 2 40.7113.0001 1 EA FAN, +24V 80 X 80 X 25MM, 32CFM 3 53.2200.0006 4 EA NUT, 6-32 KEPS SS - 55.2179.0003 1 EA CABLE SADDLE, .75 X .75 4WAY, VL3500 QUIET (NOT SHOWN) - 55.2186.0001 1 EA CABLE TIE, .
PAGE 86
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 114 02 .9 678 .
PAGE 87
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 3-45 No. Item Qty. UM. Description 1 10.9678.1245 1 EA MOUNT, CABLE INTERCONNECT, SHUTTER 2 52.6670.0034 1 EA HEADER, MOD II, 34 PIN, DUAL SIDED 3 52.6670.0040 1 EA HEADER, MOD II, 40 PIN, DUAL SIDED 4 53.6520.0002 4 EA SCREW, 4-40 X 7/16" PPZ 5 55.6621.
PAGE 88
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Sensor PCB #1 Mount Assembly 22.9678.0481 Rev B Refer to Figure 3-46 No. Item Qty. UM. Description 1 10.9678.0482 1 EA PCB MOUNT, COLOR SENSOR #1 2 24.9678.3480 1 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 3-46: Color Sensor #1 PCB Mount Assembly 116 02 .9 678 .
PAGE 89
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 3-47 No. Item Qty. UM. Description 1 10.9678.0452 1 EA PCB MOUNT, COLOR SENSOR #2 2 24.9678.3454 1 EA PCB ASSY, COLOR SENSOR #2 3 53.6558.0007 2 EA SCREW, 6-32 X 1/4" SEMS 3 (x2) 2 1 Figure 3-47: Color Sense PCB #2 Mount Assembly 02.96 78.
PAGE 90
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Interconnect PCB/Cable Assembly 25.9678.1409 Rev B (VL3500 Only) Refer to Figure 3-48 and Figure 3-49 No. Item Qty. UM. Description 1 24.9678.3409 1 EA PCB ASSY, COLOR INTERCONNECT 2 28.9678.0409 1 EA WIRE KIT, COLOR INTERCONNECT 1 EA LABEL SET, COLOR HARNESS - - 04.9678.0409.00 - - 11.9678.0409 1 EA PCB, COLOR INTERCONNECT - - 52.6467.0003 1 EA CONN, FEM PLUG 3POS 30-24 AWG - - 52.6467.
PAGE 91
HEAD/YOKE PCB ASSEMBLIES : COLOR INTERCONNECT PCB/CABLE ASSEMBLY 3 Color Interconnect PCB/Cable Assembly (continued) Figure 3-49: Color Interconnect PCB Assembly Wire Chart - VL3500 Only 02.96 78.
PAGE 92
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Color Interconnect (Quiet) PCB/Cable Assembly 25.9678.1419 Rev A (VL3500Q Only) Refer to Figure 3-50 and Figure 3-51 No. Item Qty. UM. Description 1 24.9678.0409 1 EA PCB ASSY, COLOR INTERCONNECT 2 28.9678.0419 1 EA WIRE KIT, COLOR INTERCONNECT 1 EA LABEL SET, COLOR HARNESS - - 04.9678.0409.00 - - 11.9678.0409 1 EA PCB, COLOR INTERCONNECT - - 52.6467.0003 1 EA CONN, FEM PLUG 3POS 30-24 AWG - - 52.6467.
PAGE 93
HEAD/YOKE PCB ASSEMBLIES : COLOR INTERCONNECT (QUIET) PCB/CABLE ASSEMBLY 3 Color Interconnect PCB/Cable Assembly (continued) Figure 3-51: Color Interconnect PCB Assembly Wire Chart - VL3500Q Only 02.96 78.
PAGE 94
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL VL3500 Controller PCB Assembly 24.9678.4730 Rev F Refer to Figure 3-52 Note: Available only as an assembly. Includes 24.9678.3732, Motor Driver (Piggy Back) PCB. Figure 3-52: VL3500 Controller PCB 122 02 .9 678 .
PAGE 95
HEAD/YOKE PCB ASSEMBLIES : MOTOR DRIVER (PIGGY BACK) PCB 3 Motor Driver (Piggy Back) PCB 24.9678.1732 Rev C Refer to Figure 3-53 Note: Available only as an assembly. Included with 24.9678.4730, VL3500 Controller PCB Assembly. Figure 3-53: Motor Driver (Piggy Back) PCB 02.96 78.
PAGE 96
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Arc Zoom Interconnect PCB Assembly 24.9678.1116 Rev 0 Refer to Figure 3-54 Ref. Item Qty. UM. - 04.9678.1116.00 1 EA LABEL SET ZOOM HARNESS - 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 52.6447.0009 1 EA HEADER, SHROUDED 4 POSITION 52.6467.0003 1 EA CONN, FEM PLUG 3POS 30-24AWG 52.6467.
PAGE 97
HEAD/YOKE PCB ASSEMBLIES : ARC ZOOM INTERCONNECT PCB ASSEMBLY 3 Zoom Interconnect PCB Assembly (continued) Figure 3-54: Arc Zoom Interconnect PCB Assembly 02.96 78.
PAGE 98
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 126 02 .9 678 .
PAGE 99
ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly Upper Enclosure Assembly 21.9678.0800.02 Rev NN (VL3500 Only) 21.9678.0801.02 Rev Z (VL3500Q Only) Refer to Figure 3-55 and Figure 3-56 No. Item Qty. UM. Description 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.
PAGE 100
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL No. Item Qty. UM. Description 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 26 23.9678.0687 1 EA ELEC ASSY, PAN EOT SENSOR - 25.9661.1514 1 EA CABLE ASSY, LVS CHASSIS GND (not shown) - 25.9661.1520 1 EA CABLE ASSY, CHASSIS TO YOKE GND (not shown) - 25.9678.
PAGE 101
ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY 3 No. Item Qty. UM. Description 48 53.6626.0001 1 EA SCREW, 10-32 X 1/2" PPZ 49 53.6634.1000 1 EA SCREW, 3/8-16 X 1.00" LG SOC 50 53.6653.0502 4 EA SCREW, 1/4-20 X 1/2"LG SOC (VL3500 Only) 51 54.1206.0014 2 EA RING, RETAINING 52 54.1255.0001 1 EA BEARING ASSY, BLACK FLUSH MOU 53 54.2055.0001 1 EA BELT, TIMING S2M 210GROOVE 9MM 54 55.2150.0003 2 EA STANDOFF, 1/4"HEX 6-32 1.125"L 55 55.2178.
PAGE 102
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly (continued) 2 5 15 59 66 (x2) 9 3 14 14 43 (x2) 15 8 43 (x4) 9 66 (x2) 20 42 (x4) 43 (x2) 44 (x4) 8 18 64 (x4) 50 (x4) Figure 3-55: Upper Enclosure Assembly Part 1 130 02 .9 678 .
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3 ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY Upper Enclosure Assembly (continued) 42 7 17 34 42 62 (x3) 12 55, 69 32 (x3) 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 41 1 75 31 (x2) 63 Electronics Assembly 19 72 45, 58 70 Part is shown exploded for clarity 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 28 56 5
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly - Standard 21.9678.1254 Rev 0 Refer to Figure 3-57 No. Item Qty. UM. Description 1 10.9661.1249 4 EA POST, TRUSS HOOK 2 10.9678.8350 1 EA COVER, VENTILATION 3 10.9678.0893 1 EA 12" AIR SEAL, UPPER ENCLOSURE 4 10.9678.0894 1 EA 6" AIR SEAL, UPPER ENCLOSURE 5 10.9678.0896 1 EA 4.5" AIR SEAL, UPPER ENCLOSURE 6 54.1206.
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ENCLOSURE ASSEMBLY : VENTILATION COVER ASSEMBLY - VL3500 QUIET 3 Ventilation Cover Assembly - VL3500 Quiet 21.9686.0840.02 Rev B (VL3500Q) Refer to Figure 3-58 No. Item Qty. UM. 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 ", EARLY PRODUCTION 2 10.9686.0883 1 EA COVER, VENTILATION 3 10.9678.0837 1 EA AIR SEAL, FAN SIDE 4 10.9678.0838 1 EA AIR SEAL, APS SIDE 5 10.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly - VL3500 Quiet (continued) 4 3 5 6 9 (x4) 2 1 (x4) 10 (x4) 8 (x4) Current Production 7 (x2) Early Production 1b (x4) 1a (x4) Figure 3-58: Ventilation Cover Assembly - VL3500 Quiet 134 02 .9 678 .
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ENCLOSURE ASSEMBLY : PANEL ASSEMBLY 3 Panel Assembly 21.9678.0805 Rev N Refer to Figure 3-59 No. Item Qty. UM. Description 1 10.9678.0852.01 1 EA LAYOUT, ENCLOSURE OVERLAY 2 10.9678.0859 1 EA BRACKET, INPUT 3 10.9678.0872 1 EA STIFFENER, DISPLAY BOARD 4 10.9686.0820 1 EA FILLER PANEL, DMX CONNECTOR 5 24.9663.3895 1 EA PCB ASSY, DMX INPUT 6 25.9678.0810 1 EA CABLE ASSY, AC INPUT PIGTAIL 7 24.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL DMX Input PCB 24.9663.3895 Rev 0 Refer to Figure 3-60 No. Item Qty. UM. Description Ref. 1 17.9663.3895 1 EA PCB FAB, DMX INPUT 2 52.6259.0006 1 EA HEADER, 5POS MTA FRCT LOK STRT POST J3 3 52.6625.0006 1 EA CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL J1 4 52.6626.0006 1 EA CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL J2 5 62.3039.0102 1 EA CAP, 1000P 250V 20% CDE X-Y C1 - 1 5 2 4 3 Figure 3-60: DMX Input PCB 136 02 .
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ENCLOSURE ASSEMBLY : AC INPUT PIGTAIL CABLE ASSEMBLY 3 AC Input Pigtail Cable Assembly 25.9678.0810 Rev C Refer to Figure 3-61 No. Item Qty. UM. Description 1 52.6274.2313 1 EA STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 2 52.6401.2321 1 EA CONN, PLUG "CE MARKED" 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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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan Pulley Assembly 21.9678.0807 Rev E Refer to Figure 3-62 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 3-62: Pan Pulley Assembly 138 02 .9 678 .
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ENCLOSURE ASSEMBLY : PAN MOTOR ASSEMBLY 3 Pan Motor Assembly 21.9678.0864 Rev E Refer to Figure 3-63 No. Item Qty. UM. Description 1 10.9678.0865 1 EA PLATE, PAN MOTOR MOUNT 2 21.9678.0828 1 EA ASSY, DRIVE PULLEY, PAN - 10.9686.8720 1 EA CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 1 EA TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 2 EA SCREW, 8-32 X 1/4" SET CONE POINT 3 24.9678.9729 1 EA PCB ASSY, VL3000 PAN ENCODER (changed 06-27-07) 4 44.9678.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan Motor Assembly (continued) Detail A Pressure-Sensitive Adhesive 2a 2 See Detail A 7 (x2) 2b 3 2c (x2) 8 (x2) 5 (x4) 1 4 Drive Pulley Detail & Installation 2 6 (x4) 0.875" Connector oriented on this side Step Step 1. 2. Step Step Step 3. 4. 5. Apply one drop of Loctite 603 to motor shaft. Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite. Do not allow Loctite to drip into motor bearing.
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ENCLOSURE ASSEMBLY : PAN TUBE ASSEMBLY 3 Pan Tube Assembly 21.9678.0881 Rev 0 Refer to Figure 3-64 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 142 02 .9 678 .
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CABLE ASSEMBLIES : PAN EOT SENSOR ELECTRICAL ASSEMBLY 3 Cable Assemblies Note: Cables are only available as complete assemblies. The information contained in this section is for reference only. Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-65 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.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-66 No. Item Qty. UM. 1 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8271.0001 1 EA FASTON RECEPT, 16-14 AWG (REEL) 3.5 IN WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 3 73.3516.0504 1 Description 2 3 Figure 3-66: LVS Chassis Ground Cable Assembly 144 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 3-67 No. Item Qty. UM. 1 52.8250.0006 2 EA TERM, #8, RING, 10AWG 15.17 FT WIRE, 22 AWG 300V 200C TEF GRN/YEL UL1180 2 73.7089.0504 1 (x2) Description 2 (7 x 26.0" LG) Figure 3-67: 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 C Refer to Figure 3-68. No. Item Qty. UM. 1 52.8250.0014 2 EA TERM, RING #10 16-14 AWG NON-INS. REEL 2 73.7130.0001 1.33 FT WIRE, 7/64" TUBULAR BRAID TINNED COPPER 1 (x2) Description 2 Figure 3-68: Head to Back Cap Ground Cable Assembly 146 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 3-69. No. Item Qty. UM. Description 1 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG (changed 03-23-06) 2 52.8312.0001 1 EA RECP, FASTON 1/4" 18-14 AWG INSULATED VO 3 73.7101.0009 0.42 FT WIRE, 14 AWG 15KV 150C SILICONE 41/30 STRANDING 2 1 3 Figure 3-69: 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 3-70 No. Item Qty. UM. Description 1 52.6664.0001 2 EA CONTACT, 22-26AWG FEMALE MATE-N-LOK 2 2 52.6664.0002 1 EA CONN, HOUSING 2 POS CAP MATE-N-LOK 2 3 52.8231.0008 2 EA TERM, SPADE #6 RED 22-16AWG INSERT 4 55.2186.0001 2 EA CABLE TIE, 0.10" WD 4.00" LG SMALL 5 55.6699.0002 2.08 FT SLEEVING, 1/4"NOM.DIA. POLY EXP BRAIDED 6 73.6222.0009 2.
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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 3-71 No. Item Qty. UM. Description 1 52.6665.0001 2 EA CONTACT, 22-26AWG MALE MATE-N-LOK 2 2 52.6665.0002 1 EA CONN, HOUSING 2 POS PLUG MATE-N-LOK 2 3 52.8413.0001 2 EA RECEPT, FASTON .110 SERIES 22-18AWG INSULATED 4 55.2186.0002 2 EA CABLE TIE, .09"WD 3.750"LG TEFZEL 5 55.2260.0208 2.58 FT SLEEVING, FIBERGLASS 0.208 ID 6 55.2200.0003 0.
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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 3-72 No. Item Qty. UM. 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 Description 2 1 Figure 3-72: Backcap Interlok to Gobo Fan Interlok Cable Assembly 150 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 3-73. 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 0.187 SERIES 24-20 AWG UNINSUL 3 73.7089.0000 2.00 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 1 Description 3 2 Figure 3-73: 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 3-74 No. Item Qty. UM. Description 1 52.6396.3104 1 EA RECEPT, 4POS MTA100 W/POL TAB BLU CLSD END (changed 05-03-06) 2 52.6524.0002 2 EA CONN, HOUSING 2POS RECEPTACLE 3 52.8346.0001 4 EA CONTACT, 24-30AWG FEMALE CRIMP 4 73.5126.0002 2.67 FT WIRE, 26AWG 2COND 300V 80C 2 (x2) 3 (x4) 1 4 Figure 3-74: Front Head Fans Cable Assembly 152 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 3-75 No. Item Qty. UM. Description 1 52.6396.3103 1 EA RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END (changed 05-01-06) 2 52.6423.0003 1 EA HOUSING, 3 POS MT RECEPT, 2MM 3 52.8230.0003 1 EA RECEPT, 1/4" FASTON 22-18AWG 4 73.3526.0002 1.25 FT WIRE, 26AWG 300V 105C PVC RED 5 73.5126.0002 1.
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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 3-76 No. Item Qty. UM. 1 52.8237.0002 1 EA TERM, RING #4 24-20AWG 2 52.8414.0001 1 EA RECEPT, FASTON .187 SERIES, 24-20AWG UNISUL 3 55.2198.0002 .083 FT HEATSHRINK, 1/8" BLACK 4 55.2260.0133 .375 FT SLEEVING, FIBERGLASS, .133" ID 5 63.2047.5130 1 EA THERMOSTAT, 130º TO-220 OPEN ON RISE (VL3000 Only) 63.2047.
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3 CABLE ASSEMBLIES : YOKE FAN AND RELAY (QUIET) CABLE ASSEMBLY Yoke Fan and Relay (Quiet) Cable Assembly 25.9678.0781 Rev A (VL3500Q Only) Refer to Figure 3-75 No. Item Qty. UM. Description 1 52.6423.0003 1 EA HOUSING, 3 POS MT RECEPT, 2MM 2 52.8230.0003 1 EA RECEPT, 1/4" FASTON 22-18AWG 3 52.6396.3103 1 EA RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END 4 55.2186.0001 1 EA CABLE TIE, .10 X 4" SMALL 5 55.2268.0125 1 IN HEATSHRINK, 1/8" CLEAR KYNAR UL 600V 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 3-78 No. Item Qty. UM. Description 1 52.6396.3102 1 EA RECEPT, 2POS MTA100 W/POL TAB BLUE CLSD END 2 52.6423.0003 1 EA HOUSING, 3POS MT RECEPT, 2MM CT 28-26 AWG 3 73.5126.0002 0.50 FT WIRE, 26AWG 2COND 300V 80C UL1061, 19STRND 1 2 3 Figure 3-78: Yoke Fan (Standard) Cable Assembly - VL3500 Only 156 02 .9 678 .
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3 CABLE ASSEMBLIES : YOKE FAN (QUIET) CABLE ASSEMBLY Yoke Fan (Quiet) Cable Assembly 25.9678.0759 Rev A (VL3500Q Only) Refer to Figure 3-78 No. Item Qty. UM. Description 1 52.6396.3102 1 EA RECEPT, 2 POS MTA100 W/POL TAB BLUE CLSD END 2 52.6423.0003 1 EA HOUSING, 3 POS MT RECEPT, 2MM CT 28-26 AWG 3 55.2186.0001 1 EA CABLE TIE, .10 X 4" SMALL 4 55.2268.0125 1 EA HEASTRINK, 1/8" CLEAR KYNAR UL 600V 150O C 5 60.7440.2002 1 EA RESISTOR, 5W, 5% 200 OHM WIREWOUND 6 73.5126.
PAGE 130
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-80. No. Item Qty. UM. Description 1 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 55.2186.0001 3 EA CABLE TIE, .10"WD 4.00"LG SMALL 3 55.2260.0133 6.83 FT SLEEVING, FIBERGLASS .133" ID 4 73.7100.0001 2.84 FT WIRE, 16AWG 20KVDC 41/32 STRD 200C SILICONE 2 X 17" 5 73.7190.0001 3.66 FT WIRE, 250 DEG C 6 55.2200.0003 .
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CABLE ASSEMBLIES : HEAD CONTROLLER CABLE ASSEMBLY 3 Head Controller Cable Assembly 25.9678.1715 Rev A Refer to Figure 3-81 No. Item Qty. UM. 1 52.6610.0014 1 EA CONN HOUSING, 14 POS DBL ROW UNLOADED 2 52.6610.0024 1 EA CONN HOUSING, 24 POS DBL ROW UNLOADED 3 52.6610.0034 1 EA CONN HOUSING, 34 POS DBL ROW UNLOADED 4 52.6610.0040 3 EA CONN HOUSING, 40 POS DBL ROW UNLOADED 5 52.6610.0017 1 EA CONN HOUSING, 50 POS DBL ROW UNLOADED 6 52.6224.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL 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 3-81: Head Controller Cable Assembly 160 02 .9 678 .
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3 CABLE ASSEMBLIES : SHUTTER DISK CABLE ASSEMBLY Shutter Disk Cable Assembly 25.9678.1717 Rev A Refer to Figure 3-81 No. Item Qty. UM. 1 04.9678.1717.00 1 EA LABEL SET, SHUTTER DISK HARNESS 2 52.6610.0040 1 EA CONN, HOUSING, 40-POS DBL ROW UNLOADED 3 52.6224.1040 1 EA COVER, FRONT 40-POS MT LATCH 4 52.6224.2040 1 EA COVER, BACK 40-POS MT 5 52.6696.0001 8 EA RECEPTACLE, WIRE TO WIRE, 4-POS 2 MM PITCH 28-24 AWG 6 52.6694.
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VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Shutter Disk Cable Assembly (continued) 1 5 (X8), 6 (X8) 9, 10, 11, 12 2, 3, 4, 7 8 Figure 3-82: Shutter Disk Cable Assembly 162 02 .9 678 .
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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 3-83 No. Item Qty. UM. Description 1 52.8313.0001 2 EA RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL) 2 52.8392.0001 2 EA RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP 3 55.2186.0001 1 EA CABLE TIE, 0.10" WD 4.00" LG SMALL 4 73.6016.0009 0.83 FT WIRE, 16AWG 600V 105C PVC WHT UL1015 5 73.6016.0010 0.
PAGE 136
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-84 No. Item Qty. UM. 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 5, 9 13 5, 10 11, 6 2 1 Note: Heatshrink not shown for clarity. 7 (x3) 8 Figure 3-84: AC Input Splitter Cable Assembly 02.96 78.
PAGE 138
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-85 No. Item Qty. UM. Description 1 52.6396.2904 1 EA RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END (changed 05-03-06) 2 52.6396.2905 1 EA RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END (changed 05-03-06) 3 73.5122.0259 2.17 FT CBL, 22AWG STRND 4COND PVC INSUL 2 1 3 Figure 3-85: Data I/O Link Cable Assembly 166 02 .9 678 .
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3 CABLE ASSEMBLIES : DISPLAY CABLE ASSEMBLY Display Cable Assembly 25.9678.1825 Rev C Refer to Figure 3-86 No. Item Qty. UM. Description 1 52.6396.2406 2 EA RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 2 73.5116.0123 1.02 FT WIRE, 24AWG 4COND TW 3 55.2186.0001 4 EA CABLE TIE, .10" WD 4" LG SMALL 4 73.7130.0004 0.958 FT WIRE, TUBULAR BRAID, 1/8" X 23" LG 5 73.6224.0005 0.208 FT WIRE, 24AWG 600V 200C TFE GRN 2.5" LG 6 55.6699.0009 2.
PAGE 140
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-87 No. Item Qty. UM. Description 1 52.6396.3002 1 EA RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 2 52.6396.3005 1 EA RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 3 52.6396.3008 1 EA RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 4 73.5124.1289 3.
PAGE 141
3 CABLE ASSEMBLIES : DC OUTPUT CABLE ASSEMBLY DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-88 No. Item Qty. UM. Description 1 52.6464.0002 1 EA CONN, HOUSING, SL-156 2 POS 2 52.6464.0003 1 EA CONN, HOUSING, SL-156 3 POS 3 52.8231.0004 2 EA TERM, RING #6 BLUE 12-10 AWG INSRT 4 52.8323.0002 4 EA CONTACT, CRIMP, 18-22 AWG SL-156 (not shown) 5 52.8274.1614 2 EA CONN BUTT SPLICE 16-14 BLUE .150" OD MAX 6 55.2186.0001 4 EA CABLE TIE, .01" x 4.00" SMALL 7 55.
PAGE 142
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-89 No. Item Qty. UM. Description 1 52.6610.0008 1 EA CONN, HOUSING, 20 POS DBL ROW UNLOADED (changed 05-03-06) 2 52.6224.1020 1 EA COVER, FRONT 20 POS MT LATCHING 3 52.6224.2020 1 EA COVER, BACK 20 POS MT 4 52.6524.0005 2 EA CONN, HOUSING 5 POS RECEPTACLE 5 52.6588.0007 2 EA HOUSING, 7 POS XH 250V/3A 2.5MM PITCH - USE SXH CONTACTS 6 52.7007.
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CABLE ASSEMBLIES : LAMP SUPPLY TO RELAY CABLE ASSEMBLY 3 Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-90 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 3.19 FT SLEEVING, 1/2" NOM. DIA POLY EXP BRAIDED 4 73.7089.0000 34.41 FT WIRE, 22 AWG BLK 300V TEFLON STRANDED 5 73.7089.0009 34.41 FT WIRE, 22 AWG WHT 300V TEFLON STRANDED 6 73.3516.
PAGE 144
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Gobo/Rotate Interconnect Cable Assembly 25.9678.1209 Rev A Refer to Figure 3-91 and Figure 3-92 No. Item Qty. UM. 1 25.9678.1209 1 EA Description CABLE ASSY, GOBO/ROTATE INTERCONNECT 1 Figure 3-91: Gobo/Rotate Interconnect Cable Assembly 172 02 .9 678 .
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CABLE ASSEMBLIES : GOBO/ROTATE INTERCONNECT CABLE ASSEMBLY 3 Gobo/Rotate Interconnect Cable Assembly (continued) Figure 3-92: Gobo/Rotate Interconnect Cable Assembly Wire Chart 02.96 78.
PAGE 146
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9678.1716 Rev A Refer to Figure 3-93 No. Item Qty. UM. Description 1 52.8231.0005 1 EA TERMINAL, RING, #6 BLUE, 16-14 AWG REEL PIDG 1 52.8231.0008 1 EA TERMINAL, SPADE, #6 RED, 22-16 AWG INSERT 2 73.3516.0504 1.08 FT WIRE, 16 AWG 300V 105 DEG C PVC UL1569 1 2 3 Figure 3-93: LVS Chassis Ground Cable Assembly 174 02 .9 678 .
PAGE 147
VARI❋LITE® - VL3500™ SPOT LUMINAIRE SERVICE MANUAL Notes 176 02 .9 678 .
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Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA 1.877.VARI-LITE ❋ Fax 1.214.647.8038 www.vari-lite.com Date: 10-June-2009 / Manual Part Number: 02.9678.0018 B ©2003-2009 A Philips Group Company. All rights reserved. Printed in the U.S.A.