Vari Lite VL3000 Wash Service Manual
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Vari Lite VL3000 Wash Service Manual

Vl3000 series
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  • Page 2 ® 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™, Series 1000 , Series 2000 ™ ™...
  • Page 3 OREWORD 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) or customerservice@vari-lite.com and request a Return Material Authorization (RMA) for warranty service.

  • Page 4: Declaration Of Conformity

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Compliance Notice 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.

  • Page 5: Safety Notice

    OREWORD 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.
  • Page 6 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.
  • Page 7 OREWORD 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.
  • Page 8 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.
  • Page 9 OREWORD 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.
  • Page 10 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.
  • Page 11 OREWORD 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.
  • Page 12 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.
  • Page 13 OREWORD 02.9 678.00 10 D...
  • Page 14 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 02.96 78.001 0 D...

  • Page 15: Table Of Contents

    Technical Specifications ......................4 Components External Luminaire Components ....................5 VL3000 Spot Luminaire Head and Yoke Components............. 6 VL3000 Wash Luminaire Head and Yoke Components ............7 Enclosure Components ......................8 Principles of Operation VL3000 Spot Luminaire ......................9 Functional Block Diagram ....................9 VL3000 Wash Luminaire......................
  • Page 16 Gobo Timing Adjustments...................... 38 Gobo Gear Planet Alignment....................40 Chapter 3. Illustrated Parts Breakdown Drawing Trees VL3000 Spot Luminaire ......................44 VL3000 Wash Luminaire......................46 Top Assembly Included Items Kit........................48 VL3000 Spot Luminaire ......................49 VL3000 Wash Luminaire......................52 Generic Luminaire Assembly ....................
  • Page 17 ABLE OF ONTENTS Zoom Cam Assembly......................86 Zoom Motor Tensioning Assembly ..................87 Interconnect Light Shield Asssembly ..................88 Rod Clamp Assembly ......................89 Color/Dimmer/Strobe Assembly..................... 90 Motor/Adapter Plate Assembly....................93 Fixed Color Wheel Assembly ....................94 Strobe Assembly ........................96 Right Strobe Blade Assembly ....................
  • Page 18 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL AC Input Pigtail (Euro) Cable Assembly ................148 Pan Pulley Assembly ......................149 Pan Motor Assembly......................150 Pan Tube Assembly....................... 151 1200W Arc Ballast Module Assembly ................. 152 1200W Ballast PCB Assembly ..................... 155 1200W Ballast Rider PCB Assembly ...................
  • Page 19 VL3000 Spot Luminaire Wiring Diagram (Sheet 2 of 3) ............. 219 VL3000 Spot Luminaire Wiring Diagram (Sheet 3 of 3) ............. 220 VL3000 Wash Luminaire Wiring Diagram (Sheet 1 of 3)............ 221 VL3000 Wash Luminaire Wiring Diagram (Sheet 2 of 3)............ 222 VL3000 Wash Luminaire Wiring Diagram (Sheet 3 of 3)............
  • Page 20 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL xvii i 02.96 78.001 0 D...

  • Page 21: About This Manual

    Model Part Number Source VL3000 Spot Luminaire 20.9678.0001 VL3000 Wash Luminaire 20.9678.0002 Note: Performing maintenance procedures may void the product warranty. Refer to the Vari-Lite Limited Warranty card included in the product shipping package for more information. Additional Documentation For complete installation and operation instructions, refer to the VL3000 Series Luminaire. This manual is available in both printed and electronic (PDF) formats: •...

  • Page 22: Customer Service

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.

  • Page 23: Chapter 1. Description

    HAPTER Description This chapter contains descriptions of luminaire features and components. • Features • Components • Principles of Operation 02 .9678 .0010 D...

  • Page 24: Features

    Two, six-position gobo wheels with five rotatable, indexable gobo positions and one open position. • Five-position gobo wheel with four rotatable, indexable positions and one open position. VL3000 Wash Luminaire • Zoomable beam spreader mechanism. Technical Specifications For technical specifications, refer to VL3000 Series Luminaire User’s Manual (02.9678.0001).

  • Page 25: Components

    OMPONENTS XTERNAL UMINAIRE OMPONENTS 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.

  • Page 26: Vl3000 Spot Luminaire Head And Yoke Components

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL VL3000 Spot Luminaire Head and Yoke Components The following illustration shows the major sub-assemblies which are located in the luminaire head and yoke assemblies. Head Cover (attached by tether) Gobo Assembly Contains three rotating gobo wheels and beam- size iris mechanism.

  • Page 27: Vl3000 Wash Luminaire Head And Yoke Components

    : VL3000 W OMPONENTS UMINAIRE EAD AND OMPONENTS VL3000 Wash Luminaire Head and Yoke Components The following illustration shows the major sub-assemblies which are located in the luminaire head and yoke assemblies. Head Cover (attached by tether) Aperture Assembly Used in wash version only.

  • Page 28: Enclosure Components

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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 Input Panel Assembly containing DMX Input PCB...

  • Page 29: Principles Of Operation

    : VL3000 S RINCIPLES OF PERATION UMINAIRE Principles of Operation VL3000 Spot Luminaire Functional Block Diagram 02.9 678.00 10 D...

  • Page 30: Vl3000 Wash Luminaire

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL VL3000 Wash Luminaire Functional Block Diagram 02. 9678.0 010 D...

  • Page 31: Chapter 2. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Troubleshooting • Maintenance Procedures 02 .9678 .0010 D...

  • Page 32: Testing

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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 VL3000 User’s Manual (02.9678.0001).

  • Page 33: Auto Recalibration

    ESTING ECALIBRATION 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, pan and tilt are corrected continuously if required by encoders fitted to the motor shaft. It is possible to recalibrate sections of the luminaire from a console.
  • Page 34 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Notes regarding specific mechanisms: • The four color mixers and dimmer 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. •...

  • Page 35: Troubleshooting Error Messages

    ROUBLESHOOTING RROR ESSAGES 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 a time until the end of the list is reached.

  • Page 36: Troubleshooting Guide

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error Messages” on page 56 for more information. The chart below provides possible causes and remedies for each message.
  • Page 37 ROUBLESHOOTING ROUBLESHOOTING UIDE Table 2-2: Troubleshooting Guide (Continued) Message Description Symptom Possible Cause and Remedy Pan No Pan Sensor Not Found Luminaire will not pan EOT flag attached to large pulley is not engaging the Sens 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.

  • Page 38: Maintenance Procedures

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Maintenance Procedures 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. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life.

  • Page 39: Align Lamp

    AINTENANCE ROCEDURES LIGN Align Lamp The design of the VL3000 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.

  • Page 40: Lamp Power Cut-Off Switch

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.

  • Page 41: Gobo Replacement

    AINTENANCE ROCEDURES EPLACEMENT Gobo Replacement 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.
  • Page 42 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Top Head Cover * Do not touch glass with bare fingers. CAUTION: Press on gobo carrier only. 1/4-Turn Screw Gobo Wheel Gobo Assembly (see detail) Gobo Wheel Front of luminaire Carrier Bottom Head Cover * Press from this side...

  • Page 43: Color Filter Replacement

    AINTENANCE ROCEDURES OLOR ILTER EPLACEMENT 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.

  • Page 44: Ballast Assembly Replacement

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Ballast Assembly Replacement VL Part No: 23.9661.1269 Troubleshooting Symptom(s) Error Code (if applicable) Lamp Won’t Strike Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At enclosure, remove top and bottom covers. Step 3.

  • Page 45: Beam Spreader (Wash Only)

    AINTENANCE ROCEDURES PREADER Beam Spreader (Wash Only) VL Part No: 21.9678.0910 Troubleshooting Symptom(s) Error Code (if applicable) No Beam Control Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove top head cover. Step 3. Disconnect wiring. Step 4.

  • Page 46: Color/Dimmer/Strobe Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly VL Part No: 22.9678.0402 Troubleshooting Symptom(s) Error Code (if applicable) No Color Control / Colors Sticking Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 47: Controller Board Replacement

    AINTENANCE ROCEDURES ONTROLLER OARD EPLACEMENT Controller Board Replacement VL Part No: 24.9678.0730 Troubleshooting Symptom(s) Error Code (if applicable) No DMX Control No Motor Control No Power to Luminaire Sensor Failures Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 48: Ignitor Board Replacement

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Ignitor Board Replacement VL Part No: 24.9661.1126 Troubleshooting Symptom(s) Error Code (if applicable) Lamp Won’t Strike Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove tilt-side yoke leg cover. Step 3.

  • Page 49: Pan Motor Assembly Replacement

    AINTENANCE ROCEDURES OTOR SSEMBLY EPLACEMENT Pan Motor Assembly Replacement VL Part No: 21.9678.0864 Troubleshooting Symptom(s) Error Code (if applicable) No Pan Movement (Belt or Motor Damage) Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Carefully lay luminaire on its side. Step 3.

  • Page 50: Pan Encoder Replacement

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Pan Encoder Replacement VL Part No: 24.9678.0729 Troubleshooting Symptom(s) Error Code (if applicable) Pan Encoder Failure Pan/Encoder/Fail Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Carefully lay luminaire on its side. Step 3.

  • Page 51: Pan Eot Sensor Replacement

    EOT S AINTENANCE ROCEDURES ENSOR EPLACEMENT Pan EOT Sensor Replacement VL Part No: 86.7002.0003 Troubleshooting Symptom(s) Error Code (if applicable) Pan Sensor Failure Pan/Sensor/Fail Step 1. Repair Procedure Step 2. Disconnect luminaire AC input cable from power source. Step 3. Carefully lay luminaire on its side. Step 4.

  • Page 52: Power Supply (Lvs) Replacement

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Power Supply (LVS) Replacement VL Part No: 69.3128.0150 Troubleshooting Symptom(s) Error Code (if applicable) 24 Volts Not Present Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2.

  • Page 53: Gobo Assembly Replacement

    AINTENANCE ROCEDURES SSEMBLY EPLACEMENT Gobo Assembly Replacement VL Part No: 21.9678.0200 Troubleshooting Symptom(s) Error Code (if applicable) No Gobo Control / Gobos Sticking Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove top head cover. Step 3.

  • Page 54: Spot Optic Assembly Replacment

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Spot Optic Assembly Replacment VL Part No: 22.9678.0103 Troubleshooting Symptom(s) Error Code (if applicable) No Zoom Control Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove top head cover. Step 3.

  • Page 55: Tilt Motor Assembly

    AINTENANCE ROCEDURES OTOR SSEMBLY Tilt Motor Assembly VL Part No: 21.9678.0765 Troubleshooting Symptom(s) Error Code (if applicable) No Tilt Movement (Belt or Motor Damage) Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove tilt-side yoke leg cover. Step 3.

  • Page 56: Tilt Encoder Replacment

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Tilt Encoder Replacment VL Part No: 24.9678.0729 Troubleshooting Symptom(s) Error Code (if applicable) Tilt Encoder Failure Tilt/Encoder/Fail Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove tilt-side yoke leg cover. Step 3.

  • Page 57: Tilt Eot Sensor Replacment

    EOT S AINTENANCE ROCEDURES ENSOR EPLACMENT Tilt EOT Sensor Replacment VL Part No: 86.7002.0003 Troubleshooting Symptom(s) Error Code (if applicable) Tilt Sensor Failure Tilt/No Sens Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove tilt-side yoke leg cover. Step 3.

  • Page 58: Gobo Timing Adjustments

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Gobo Timing Adjustments The index timing belt must be aligned so that the mechanism "clocks" properly. This belt is installed around the index gear and top gear of the gobo wheel. The wheel position belt is installed around the wheel position gear and bottom gear of the gobo wheel, and does not require alignment.
  • Page 59 AINTENANCE ROCEDURES IMING DJUSTMENTS Position index pulley so large flange is Insert a 3" long #4 or M3 screw (or 0.125" diameter centered in optical sensor pin) completely through aligned holes in wheels and both bulkheads as shown. This will lock the wheels in the "open"...

  • Page 60: Gobo Gear Planet Alignment

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 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.
  • Page 61 AINTENANCE ROCEDURES LANET LIGNMENT 1) Start with center gear timing 2) Rotate center gear clockwise until timing mark mark facing Position 1 (open). is directly across from Position 6. Rotate Position 6 gear until timing marks align. Alignment Mark open Align both marks 4) Verify alignment of all marks 3) Align remaining gobo gears...
  • Page 62 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Notes 02. 9678.0 010 D...

  • Page 63: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3000 assemblies. • Drawing Trees • Top Assembly • Head Assembly • Yoke Assembly • Head/Yoke PCB Assemblies • Enclosure Assembly • Cable Assemblies 02 .9678 .0010 D...

  • Page 64: Drawing Trees

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Drawing Trees VL3000 Spot Luminaire VL3000 Spot Luminaire 20.9678.0001 Rev M Generic Luminaire Gobo Clamp Assembly Color Clamp Assembly Rod Clamp Assembly Assembly 22.9678.0693 Rev A 22.9678.0694 Rev A 22.9678.0149 Rev A 21.9678.0010 Rev E Head Cover Assembly Edge Lead Screw...
  • Page 65 : VL3000 S RAWING REES UMINAIRE VL3000 Spot Luminaire (continued) continued from previous page continued from previous page Spot Optic Assembly Upper Enclosure Assembly 22.9678.0103 Rev J (Spot Only) 21.9678.0800 Rev U Panel Assembly Chassis To Yoke Ground Zoom Box Assembly 21.9678.0805 Rev C Cable Assembly 21.9678.0110 Rev D...

  • Page 66: Vl3000 Wash Luminaire

    Color Interconnect PCB/ 22.9678.0474 Rev 0 Cable Assembly Upper Enclosure Assembly 25.9678.0409 Rev B 21.9678.0800 Rev U CTO Wheel Assembly 22.9678.0478 Rev 0 continued next page Figure 3-3: VL3000 Wash Luminaire Subassembly Drawing Tree Part 1 02. 9678.0 010 D...
  • Page 67 Lamp Supply to Relay Cable Assembly LVS Chassis Ground Cable 25.9678.0819 Rev A Assembly 25.9661.1514 Rev A LVS to Yoke AC Fan Cable Assembly 25.9678.0843 Rev 0 Figure 3-4: VL3000 Wash Luminaire Subassembly Drawing Tree Part 2 02.9 678.00 10 D...

  • Page 68: Top Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Top Assembly Included Items Kit 28.9678.0001 Rev C Refer to Figure 3-5. Item Qty. Description 02.8001.0001 SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY 02.8406.0001 TAG, LAMP NOTICE (added 09-03-03) 02.8700.0001 CARD, PRODUCT REGISTRATION 04.4037.0001...

  • Page 69: Vl3000 Spot Luminaire

    : VL3000 S SSEMBLY UMINAIRE VL3000 Spot Luminaire 20.9678.0001 Rev M Refer to Figure 3-6 Item Qty. Description 02.8405.0001 AC DANGER TAG, VL3000 (not shown) 04.9661.0033 LABEL, WARNING -2000 SERIES (not shown) 04.9661.0039 LABEL, LINE CORD WARNING (not shown) 04.9678.0041 LABEL, AC INPUT RATING VL3000 (not shown) 10.9678.0609 FRONT FILTER, FOAM, ZOOM (not shown)
  • Page 70 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Qty. Description 53.6558.0009 SCREW, 6-32 X 3/8"LG PPZ SEMS 53.6616.0016 SCREW, 6-32 X 3/4" PPZ SEMS 53.6579.0001 SCREW, 10-32 X 1/2" SCB 53.6613.0001 SCREW, 6-32 X 1/2" PPZ 53.6614.0003 SCREW, 6-32 X 5/8"...
  • Page 71 : VL3000 S SSEMBLY UMINAIRE VL3000 Spot Luminaire (continued) (x2) (x2) (x4) (x2) (x2) (x4) (x4) (x2) (x2) (x2) (x2) (x2) (x2) (x4) (x2) (x8) (x2) (x10) (x2) (x4) (x4) (x4) Figure 3-6: VL3000 Spot Luminaire 02.9 678.00 10 D...

  • Page 72: Vl3000 Wash Luminaire

    CABLE ASSY, FRONT HEAD FANS (not shown) 25.9678.0689 CABLE ASSY, YOKE TO HEAD GND (not shown) 25.9678.0715 CABLE ASSY, HEAD CONTROL (not shown) 28.9678.0002 INCLUDED ITEMS KIT, VL3000 WASH (not shown) 53.6543.0001 SCREW, 6-32 X 3/8" PPB 53.6558.0009 SCREW, 6-32 X 3/8"LG PPZ SEMS 53.6558.0016 SCREW, 6-32 X 3/4"...
  • Page 73 : VL3000 W SSEMBLY UMINAIRE Item Qty. Description 55.2178.0001 CABLE ANCHOR MOUNT, #8 SCREW MOUNT 55.2284.0001 CARD GUIDE, 3" LONG SNAP IN 55.6506.0024 SPACER, 3/16"RND .1875"LG .141 55.6528.0001 WASHER, #6 FLAT ZINC 55.2150.0002 STANDOFF, 1/4 " HEX 6-32 1.188"LG MF STL (changed 5-27-03) 55.6677.0033 WASHER, .201"...
  • Page 74 VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL VL3000 Wash Luminaire (continued) (x2) (x8) (x2) (x2) (x2) (x4) (x2) (x2) (x2) (x2) (x2) (x2) (x8) (x2) (x2) (x4) (x2) (x4) Figure 3-7: VL3000 Wash Luminaire 02. 9678.0 010 D...

  • Page 75: Generic Luminaire Assembly

    SSEMBLY ENERIC UMINAIRE SSEMBLY Generic Luminaire Assembly 21.9678.0010 Rev E Refer to Figure 3-8 Item Qty. Description 21.9678.0600 ASSY, HEAD STRUCTURE 21.9678.0700 ASSY, YOKE 21.9678.0707 ASSY, TILT PULLEY - 10.9678.0750 TIMING PULLEY, 150 TOOTH - 10.9678.0754 * FLAG, CENTER OF TRAVEL, TILT - 53.6530.0006 RIVET, 1/8"OD POP .188-.250GL 21.9678.0767...
  • Page 76 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Generic Luminaire Assembly (continued) (x3) (x2) (x4) (x4) (x4) (x2) (x3) Detail A (x4) (x5) (x5) Detail A (x2) (x2) Figure 3-8: Generic Luminaire Assembly 02. 9678.0 010 D...

  • Page 77: Head Assembly

    SSEMBLY TRUCTURE SSEMBLY Head Assembly Head Structure Assembly 21.9678.0600 Rev B Refer to Figure 3-1 Item Qty. Description 10.9678.0620 FRONT CASTING (changed 7-02-03) 12.9678.0623 RIGHT SIDE RAIL, MACHINED 12.9678.0625 LEFT SIDE RAIL, MACHINED 21.9678.0615 ASSY, BACKEND 53.6515.0001 SCREW, 10-32 X 3/4" SCB CAP 53.6515.1000 SCREW, 10-32 X 1"...

  • Page 78: Head Cover Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Head Cover Assembly 21.9678.0611 Rev F Refer to Figure 3-2 Item Qty. Description 10.9678.0612 HEAD COVER FOAM BAFFLE 10.9678.0649 EJECTOR SPRING, BLACK OXIDE 10.9678.0674 BRACKET, COVER TETHER 10.9678.0696 FOAM FRAME, HEAD COVER (added 10-011-03) 12.9678.0610 HEAD COVER, PAINTED (changed 9-10-03) 53.6558.0003...

  • Page 79: Backend Assembly

    SSEMBLY ACKEND SSEMBLY Backend Assembly 21.9678.0615 Rev J Refer to Figure 3-3 Item Qty. Description 10.9678.0631 SEPARATION BULKHEAD 10.9678.0635 EXHAUST BULKHEAD 10.9678.0637 CLIP, RETRO-REFLECTOR 10.9678.0638 AIR DIVERTER, STROBE MOTOR 10.9678.0653 LIGHT BAFFLE, EXHAUST 12.9678.0152 REFLECTOR, RETRO SPHERICAL COATED 12.9678.0627 AFT BULKHEAD, MACHINED 21.9678.0619 FAN ASSY, 80MM 21.9678.0673...
  • Page 80 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Qty. Description 74.1100.0001 SWITCH, THERMAL 15 AMP 255 DEG 53.6613.0004 SCREW, 6-32 X 1/2" SCZ (added 7-18-03) (x4) (x3) (x2) (x2) (x2) (x4) (x2) (x4) (x4) (x4) (x4) (x4) (x2) (x2) (x2)

  • Page 81: 80Mm Fan Assembly

    : 80 SSEMBLY SSEMBLY 80mm Fan Assembly 21.9678.0619 Rev A Refer to Figure 3-4 Item Qty. Description 40.7145.0001 FAN, TUBEAXIAL 80 X 80 X 38MM 230V 53.2200.0006 NUT, 6-32 KEPS SS 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.7016.0001 FAN GUARD, 80MM NICKEL PLATED STEEL WIRE (x4) (x4) Figure 3-4: 80mm Fan Assembly...

  • Page 82: Uv Filter Bulkhead Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL UV Filter Bulkhead Assembly 22.9678.0639 Rev C Refer to Figure 3-5 Item Qty. Description 10.9678.0634 UV FILTER BULKHEAD 10.9678.0648 CLIP, UV GLASS 41.9678.0608 UV/IR FILTER, 3.00" X 3.00" (added 01-08-04) 53.6530.0002 RIVET, 1/8 OD POP, .063-.125 GRIP, ALUM (x4)

  • Page 83: Spot Gobo Assembly

    SSEMBLY SSEMBLY Spot Gobo Assembly 21.9678.0200 Rev E (Spot Only) Refer to Figure 3-6 Item Qty. Description 10.9678.0215 BULKHEAD, GOBO MODULE FRONT 10.9678.0216 BULKHEAD, GOBO MODULE REAR 10.9678.0225 SHAFT, GOBO WHEEL 10.9678.0231 PULLEY, MOTOR GOBO WHEEL DRIVE 10.9678.0232 PULLEY, INSEX DRIVE 64 GROOVE 10.9678.0244 MOUNT, INDEX SENSOR LONG 10.9678.0245...
  • Page 84 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Qty. Description 53.6609.0001 SCREW, 6-32 X 3/8" PFZ 55.6506.0030 SPACER, 3/8" RND 3/8" LG .257" ID THRU ALUM 55.2110.0002 WASHER, .400" OD .260 ID .010" THK FLAT SS (added 4-29-03) 10.9678.0457.2 SPACER, RND, 3/8"...

  • Page 85: Rotating Gobo Wheel Assembly

    SSEMBLY OTATING HEEL SSEMBLY Rotating Gobo Wheel Assembly 21.9678.0210 Rev B Refer to Figure 3-7 Item Qty. Description 10.9663.1211 SPACER, TEFLON GOBO GEAR 10.9663.1240 BEARING, GOBO WHEEL BORE 10.9678.0220 PLATE, ROTATING GOBO WHEEL 10.9678.0224 RETAINING RING, PLANET 22.9678.0230 ASSY, PLANET GEAR 22.9678.0233 SUN GEAR, MOLDED ELASTOMERIC INTEGRAL BEARING 22.9678.0234...

  • Page 86: Rotating Effects Wheel Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Rotating Effects Wheel Assembly 21.9678.0211 Rev B Refer to Figure 3-8 Item Qty. Description 10.9663.1211 SPACER, TEFLON GOBO GEAR 10.9663.1240 BEARING, GOBO WHEEL BORE 10.9678.0221 PLATE, ROTATING EFFECTS WHEEL 10.9678.0224 RETAINING RING, PLANET 22.9678.0230 ASSY, PLANET GEAR...

  • Page 87: Long Shaft Motor Assembly

    SSEMBLY HAFT OTOR SSEMBLY Long Shaft Motor Assembly 21.9678.0243 Rev 0 Refer to Figure 3-9 Item Qty. Description 10.9678.0330 PLATE, MOTOR ADAPTER 44.9678.0249 MOTOR, STEPPER 42MM X 34MM 60MM SHAFT 53.6513.0002 SCREW, 3MM X 5MM LG PFZ METRIC (x4) Figure 3-9: Long Shaft Motor Assembly 02.9 678.00 10 D...

  • Page 88: Iris Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Iris Assembly 21.9678.0270 Rev A Refer to Figure 3-10 Item Qty. Description 10.9678.0272 BULKHEAD, IRIS 10.9678.0273 MOTOR MOUNT, IRIS 10.9678.0274 APERTURE, IRIS 10.9678.0276 CRANK, IRIS 10.9678.0279 DIVERTER, GOBO AIR 22.9678.0271 LINK ASSY, IRIS - 53.6605.0004 STUD, 2-56 X 1.0"...
  • Page 89 SSEMBLY SSEMBLY Iris Assembly (continued) (x4) (x2) (x3) (x2) (x3) (x2) Figure 3-10: Iris Assembly 02.9 678.00 10 D...

  • Page 90: Reflector Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Reflector Assembly 21.9678.0640.01 Rev F (Spot) 21.9678.0640.02 Rev F (Wash) Refer to Figure 3-11 Item Qty. Description 04.9678.0042 LABEL, VL3000 BACKCAP 10.9678.0641 HOT BOX 10.9678.0642 BACKCAP PLATE 10.9678.0643 LAMP ADJUST STOP 10.9678.0645 KNOB, LAMP ADJ MOLDED 10.9678.0646...
  • Page 91 SSEMBLY EFLECTOR SSEMBLY Reflector Assembly (continued) (x2) (x3) (x4) (x4) (x4) (x4) (x8) (x3) (x3) (x3) Wash Version Spot Version Figure 3-11: Reflector Assembly 02.9 678.00 10 D...

  • Page 92: Gobo/Color Fan Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Gobo/Color Fan Assembly 21.9678.0660.01 Rev A (Spot) 21.9678.0660.02 Rev A (Wash) Refer to Figure 3-12 Item Qty. Description 10.9678.0669 SPRING, EXTENSION ELONGATED HO 22.9678.0661 ASSY, FAN TRAY 22.9678.0665 DUCT ASSY 23.9678.0684 FAN ASSY, HEAD FRONT (2 FOR SPOT / 1 FOR WASH) 53.5506.1375...

  • Page 93: Head Front Fan Assembly

    SSEMBLY RONT SSEMBLY Head Front Fan Assembly 23.9678.0684 Rev 0 Refer to Figure 3-13 Item Qty. Description 40.7125.0001 FAN, 24V FAL6F24LH 52.6523.0002 CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP (x2) Figure 3-13: Head Front Fan Assembly 02.9 678.00 10 D...

  • Page 94: Transfer Fan Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Transfer Fan Assembly 21.9678.0678.01 Rev C (Spot) 21.9678.0678.02 Rev C (Wash) Refer to Figure 3-14 Item Qty. Description 10.9678.0679 TRANSFER FAN TRAY 40.7125.0002 FAN, 24V FAL6F24LL 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPB 55.6543.0001 2.12 GROMMET STRIP, SERRATED POLYETHYLENE...

  • Page 95: Spot Optic Assembly

    SSEMBLY PTIC SSEMBLY Spot Optic Assembly 22.9678.0103 Rev J (Spot Only) Refer to Figure 3-15 Figure 3-16 Item Qty. Description 10.9678.0118 FORWARD PULLEY SHAFT 10.9678.0127 PULLEY, IDLER 10.9678.0129 SPACER, ROLLER CAM 10.9678.0153 CABLE CLAMP, CAST 10.9678.0156 BARREL STRAP, G1 & G2 10.9678.0157 BARREL STRAP, G3 10.9678.0171...
  • Page 96 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Qty. Description 23.9678.1120 LINEAR ACTUATOR ASSEMBLY - 44.9678.0119 LINEAR ACTUATOR EDGE DRIVE - 52.6467.0004 4 POS 30-24 AWG CRIMP PHR - 52.6467.0024 CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST) 24.9678.0112 PCB ASSY, VL3000 ZOOM SENSOR 53.2004.0002...
  • Page 97 SSEMBLY PTIC SSEMBLY Spot Optic Assembly (continued) (x2) (x4) (x2) (x2) (x4) (x3) (x2) Detail F-F Detail E-E (x6) Figure 3-15: Spot Optic Assembly View 1 02.9 678.00 10 D...
  • Page 98 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Spot Optic Assembly (continued) * Interconnect PCB and Zoom Motor removed for clarity. Detail A-A Detail B-B Detail C-C (x3) (x3) (x3) Optical Sensor (x2) (x2) (x3) (x6) Detail G3-G3 Detail G2-G2 Detail G1-G1 (x2)

  • Page 99: Zoom Box Assembly

    SSEMBLY SSEMBLY Zoom Box Assembly 21.9678.0110 Rev D Refer to Figure 3-17 Item Qty. Description 10.9678.0124 ZOOM BOX 10.9678.0125 BRACE, FOCUS 10.9678.0126 BRACE, REAR 53.6530.0006 RIVET, 1/8"OD POP .188-.250GL (x12) Figure 3-17: Zoom Box Assembly 02.9 678.00 10 D...

  • Page 100: Group 1 Lens Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Group 1 Lens Assembly 22.9678.1181 Rev 0 (Formerly 22.9678.0181) Refer to Figure 3-18 Item Qty. Description 10.9678.0187 LENS CAP, GROUP 1 10.9678.0175 SPACER, RIBBED, L1-L2/G1 10.9678.1128 SPACER, LENS 3-4/G1 (changed 6-26-03) 10.9678.0185 LENS BARREL, GROUP 1 42.9678.0131...

  • Page 101: Group 2 Lens Assembly

    SSEMBLY ROUP SSEMBLY Group 2 Lens Assembly 22.9678.0182 Rev A Refer to Figure 3-19 Item Qty. Description 10.9678.1127 LENS RETAINER, GROUP 2 (changed 6-12-03) 10.9678.0177 LENS SPACER, L6-L7/G2 10.9678.0189 LENS BARREL, GROUP 2 42.9678.0135 LENS, #5 42.9678.0136 LENS, #6 42.9678.0137 LENS, #7 Figure 3-19: Group 2 Lens Assembly 02.9 678.00 10 D...

  • Page 102: Group 3 Lens Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Group 3 Lens Assembly 22.9678.0183 Rev 0 Refer to Figure 3-20 Item Qty. Description 10.9678.0193 LENS RETAINER, GROUP 3 10.9678.0192 SPACER, LENS 8-9/G3 10.9678.0191 LENS BARREL, GROUP 3 42.9678.0140 LENS, #10 42.9678.0139 LENS, #9 42.9678.0138...

  • Page 103: Group 4 Lens Assembly

    SSEMBLY ROUP SSEMBLY Group 4 Lens Assembly 22.9678.0199 Rev A Refer to Figure 3-21 Item Qty. Description 12.9678.0198 RING BLOCK, MACHINED G4 22.9678.0174 LENS ASSY, GROUP 4 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.3303.0006 WASHER, #6 LOCK INT.TOOTH SS 55.6763.0500 PIN, DOWEL .5"LG .125"DIA 303SS (x4) (x4)

  • Page 104: Right Edge Bearing Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Right Edge Bearing Assembly 22.9678.1103 Rev A Refer to Figure 3-22 Item Qty. Description 12.9678.1102 EDGE BEARING, MACHINED RIGHT 54.2056.0001 RING, RETAINING EXTERNAL 19MM 55.6776.0010 LINEAR BUSHING, 10MM STEEL W/P (x4) (x2) Figure 3-22: Right Edge Bearing Assembly...

  • Page 105: Left Edge Bearing Assembly

    SSEMBLY EARING SSEMBLY Left Edge Bearing Assembly 22.9678.1105 Rev A Refer to Figure 3-23 Item Qty. Description 12.9678.1104 EDGE BEARING, MACHINE LEFT 54.2056.0001 RING, RETAINING EXTERNAL 19MM 55.6776.0010 LINEAR BUSHING, 10MM STEEL W/P (x4) (x2) Figure 3-23: Left Edge Bearing Assembly 02.9 678.00 10 D...

  • Page 106: Zoom Cam Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Zoom Cam Assembly 22.9678.1106 Rev A Refer to Figure 3-24 Item Qty. Description 10.9678.1107 ZOOM TIMING CAM 10.9678.1108 PULLEY FLANGE 10.9678.1118 TIMING PULLEY, ZOOM 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 54.1259.0004 BEARING, RADIAL FLANGED .25"ID .625"OD (changed 6-25-03) 55.3303.0006...

  • Page 107: Zoom Motor Tensioning Assembly

    SSEMBLY OTOR ENSIONING SSEMBLY Zoom Motor Tensioning Assembly 22.9678.1113 Rev 0 Refer to Figure 3-25 Item Qty. Description 10.9678.0128 PULLEY, ZOOM MOTOR 10.9678.1111 BRACKET, ZOOM TENSION SHEETMETAL 44.9663.1326 MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6522.0001 SCREW, 6-32 X 1/4"...

  • Page 108: Interconnect Light Shield Asssembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Interconnect Light Shield Asssembly 22.9678.1115 Rev B Refer to Figure 3-26 Item Qty. Description 10.9678.1114 SHIELD, INTERCONNECT MOUNT/LIGHT 24.9678.1116 PCB ASSY, ZOOM INTERCONNECT 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.3303.0006 WASHER, #6 LOCK INT.TOOTH SS Figure 3-26: Interconnect Light Shield Assembly 02.

  • Page 109: Rod Clamp Assembly

    SSEMBLY LAMP SSEMBLY Rod Clamp Assembly 22.9678.0149 Rev A Refer to Figure 3-27 Item Qty. Description 10.9678.0151 CLAMP, OPTIC ROD CAST 53.6616.0001 SCREW, 6-32 X 3/4" PPZ 55.6528.0001 WASHER, #6 FLAT ZINC 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH 53.2008.0006 SPRING CLIP, 6-32 (x2) (x2) (x2)

  • Page 110: Color/Dimmer/Strobe Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly 22.9678.0402 Rev F Refer to Figure 3-28 Item Qty. Description 10.9678.0324 PULLEY, FIXED COLOR WHEEL 10.9678.0325 DRIVE PULLEY, FIXED COLOR WHEEL 10.9678.0456 SHAFT, COLOR WHEEL 10.9678.0457.01 SPACER, COLOR WHEEL L.387 10.9678.0457.02 SPACER, COLOR WHEEL L.190 10.9678.0457.03...
  • Page 111 SSEMBLY OLOR IMMER TROBE SSEMBLY Item Qty. Description 53.6597.0001 SCREW, 4-40 X 3/16" PPZ 53.6608.0003 SCREW, 6-32 X 3/16"LG PPZ 54.2036.0017 BELT, TIMING N=150 W=.125 54.2059.0001 TIMING BELT, MXL PITCH 150 TOO 54.2060.0001 BELT, TIMING MXL PITCH 165TOOT 55.2132.0011 STANDOFF, 1/4"HEX 6-32 1.093"L 55.2132.0012 STANDOFF, 1/4"HEX 6-32 .75"LG 55.3303.0004...
  • Page 112 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly (continued) (x4) (x5) (x10) (x2) (x4) (x4) (x2) (x2) (x2) (x2) (x2) (x4) (x5) (x5) (x1) (x2) (x5) (x5) (x12) (x5) Figure 3-28: Color/Dimmer/Strobe Assembly 02. 9678.0 010 D...

  • Page 113: Motor/Adapter Plate Assembly

    SSEMBLY OTOR DAPTER LATE SSEMBLY Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Refer to Figure 3-29 Item Qty. Description 10.9678.0330 PLATE, MOTOR ADAPTER 44.5031.0001 MOTOR, STEPPER 42MM X 40MM,10 53.6513.0002 SCREW, 3MM X 5MM LG PFZ METR (x4) Figure 3-29: Motor/Adapter Plate Assembly 02.9 678.00 10 D...

  • Page 114: Fixed Color Wheel Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Fixed Color Wheel Assembly 21.9678.0334 Rev D Refer to Figure 3-30 Item Qty. Description 10.9678.0322 SPIN SHAFT, COLOR WHEEL 10.9678.0332 SLIDING RETAINER 10.9678.0333 RETAINER CLIP 22.9678.1336 FAB ASSY, FIXED WHEEL/CLIP (changed 9-03-03) 41.9678.0305.01 COLOR FILTER, DEEP RED VL3000 41.9678.0305.02...
  • Page 115 SSEMBLY IXED OLOR HEEL SSEMBLY Fixed Color Wheel Assembly (continued) POS 2 ORANGE POS 3 POS 1 KELLY CONGO GREEN BLUE POS 4 OPEN DARK FUSHIA POS 6 POS 5 DEEP MAGENTA (x6) (x6) (x6) (x6) (x3) Figure 3-30: Fixed Color Wheel Assembly 02.9 678.00 10 D...

  • Page 116: Strobe Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Strobe Assembly 22.9678.0403 Rev D Refer to Figure 3-31 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE (changed on 6-18-03) 10.9678.0465 STROBE BULKHEAD 22.9678.0467 ASSY, RIGHT STROBE BLADE 22.9678.0468 ASSY, LEFT STROBE BLADE 44.5029.0001 MOTOR, STEPPER 42MM X 34MM -AR 53.6513.0032...

  • Page 117: Right Strobe Blade Assembly

    SSEMBLY IGHT TROBE LADE SSEMBLY Right Strobe Blade Assembly 22.9678.0467 Rev 0 Refer to Figure 3-32 Item Qty. Description 10.9678.0431 STROBE BLADE, BRIGHT DIP 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE, DAMPER 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6597.0001 SCREW, 4-40 X 3/16"...

  • Page 118: Left Strobe Blade Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Left Strobe Blade Assembly 22.9678.0468 Rev 0 Refer to Figure 3-33 Item Qty. Description 10.9678.0431 STROBE BLADE, BRIGHT DIP 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE, DAMPER 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6597.0001 SCREW, 4-40 X 3/16"...

  • Page 119: Dimmer Wheel Assembly

    SSEMBLY IMMER HEEL SSEMBLY Dimmer Wheel Assembly 22.9678.0435 Rev B Refer to Figure 3-34 Item Qty. Description 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0494 GLASS, COATED DIMMER WHEEL (changed on 01-23-04) 55.2256.0001 MAGNET, 2:17 SMCO 2MM X 2MM Coated Side Figure 3-34: Dimmer Wheel Assembly 02.9 678.00 10 D...

  • Page 120: Cyan Wheel Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Cyan Wheel Assembly 22.9678.0472 Rev A Refer to Figure 3-35 Item Qty. Description 12.9678.0490 PAINTED TIMING TAB 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0471 GLASS, CYAN COLOR WHEEL Coated Side Figure 3-35: Cyan Wheel Assembly 02.

  • Page 121: Yellow Wheel Assembly

    SSEMBLY ELLOW HEEL SSEMBLY Yellow Wheel Assembly 22.9678.0474 Rev 0 Refer to Figure 3-36 Item Qty. Description 12.9678.0490 PAINTED TIMING TAB 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0473 GLASS, YELLOW COLOR WHEEL Coated Side Figure 3-36: Yellow Wheel Assembly 02.9 678.00 10 D...

  • Page 122: Magenta Wheel Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Magenta Wheel Assembly 22.9678.0476 Rev 0 Refer to Figure 3-37 Item Qty. Description 12.9678.0490 PAINTED TIMING TAB 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0475 GLASS, MAGENTA COLOR WHEEL Coated Side Figure 3-37: Magenta Wheel Assembly 02.

  • Page 123: Cto Wheel Assembly

    : CTO W SSEMBLY HEEL SSEMBLY CTO Wheel Assembly 22.9678.0478 Rev 0 Refer to Figure 3-38 Item Qty. Description 12.9678.0490 PAINTED TIMING TAB 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0477 GLASS, COATED CTO Coated Side Figure 3-38: CTO Wheel Assembly 02.9 678.00 10 D...

  • Page 124: Gobo Clamp Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Gobo Clamp Assembly 22.9678.0693 Rev A Refer to Figure 3-39 Item Qty. Description 12.9678.0691 GOBO CLAMP 53.6685.0625 SCREW, CAPTIVE PANEL, 6-32 X .625"LG PPS ZINC PLATED 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH 53.6613.1126 SCREW, 6-32 X 1.125 LG PPZ (x2)

  • Page 125: Color Clamp Assembly

    SSEMBLY OLOR LAMP SSEMBLY Color Clamp Assembly 22.9678.0694 Rev A Refer to Figure 3-40 Item Qty. Description 12.9678.0692 COLOR CLAMP 53.6685.0625 SCREW, CAPTIVE PANEL, 6-32 X .625"LG PPS ZINC PLATED 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH 53.6613.1126 SCREW, 6-32 X 1.125 LG PPZ (x2) (x2) Figure 3-40: Color Clamp Assembly...

  • Page 126: Edge Lead Screw Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Edge Lead Screw Assembly 22.9678.1126 Rev B Refer to Figure 3-41 Item Qty. Description 10.9678.1119 LEAD SCREW, EDGE 55..6616.0007 STANDOFF, 3/8" HEX THRD .562" LG Figure 3-41: Edge Lead Screw Assembly 02.

  • Page 127: Beam Spreader Assembly

    SSEMBLY PREADER SSEMBLY Beam Spreader Assembly 21.9678.0910 Rev A (Wash Only) Refer to Figure 3-42 Item Qty. Description 10.9678.0945 TUBE, WASH LIGHT BAFFLE 21.9678.0920 ASSY, CONCAVE LENS STATIONARY 21.9678.0930 ASSY, CONVEX LENS TRANSLATING 21.9678.0940 ASSY, CONDENSER LENS 24.9678.0916 PCB ASSY, ZOOM INTERCONNECT WASH 53.6520.0375 SCREW, 4-40 X 3/8"...

  • Page 128: Stationary Concave Lens Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Stationary Concave Lens Assembly 21.9678.0920 Rev 0 (Wash Only) Refer to Figure 3-43 Item Qty. Description 10.9678.0927 BEARING SHAFT, BEAM SPREADER 10.9678.0928 LENS CLAMP, BEAM SPREADER 10.9678.0929 FRONT LENS RING, BEAM SPREADER 12.9678.0168 MASKED, CONCAVE LENS ARRAY MEDIUM 12.9678.0925...

  • Page 129: Translating Convex Lens Assembly

    SSEMBLY RANSLATING ONVEX SSEMBLY Translating Convex Lens Assembly 21.9678.0930 Rev 0 (Wash Only) Refer to Figure 3-44 Item Qty. Description 10.9678.0928 LENS CLAMP, BEAM SPREADER 12.9678.0166 MASKED, CONVEX LENS ARRAY MEDIUM 12.9678.0935 CONVEX LENS MOUNT, MACHINED 53.6530.0002 RIVET, 1/8"OD POP .063-.125 GR.LENGTH 54.2056.0001 RING, RETAINING EXTERNAL 19MM SHAFT 55.6776.0010...

  • Page 130: Condenser Lens Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Condenser Lens Assembly 21.9678.0940 Rev B (Wash Only) Refer to Figure 3-45 Item Qty. Description 10.9678.0928 LENS CLAMP, BEAM SPREADER 10.9678.0941 HOUSING, BEAM SPREADER 10.9678.0942 LEAD SCREW, BEAM SPREADER 10.9678.0944 CONDENSER LENS MOUNT 23.9678.1120 LINEAR ACTUATOR ASSEMBLY...

  • Page 131: Aperture Bulkhead Assembly

    SSEMBLY PERTURE ULKHEAD SSEMBLY Aperture Bulkhead Assembly 21.9678.0950 Rev B (Wash Only) Refer to Figure 3-46 Item Qty. Description 10.9678.0225 SHAFT, GOBO WHEEL 10.9678.0952 WASH BULKHEAD 10.9678.0953 WASH APERTURE PLATE 53.6609.0001 SCREW, 6-32 X 3/8" PFZ (changed 11-11-03) 53.6613.0001 SCREW, 6-32 X 1/2" PPZ 55.2150.0002 STANDOFF, 1/4"HEX 6-32 1.187"L 55.6769.0004...

  • Page 132: Beam Spreader Light Baffle Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Beam Spreader Light Baffle Assembly 21.9678.0991 Rev A (Wash Only) Refer to Figure 3-47 Item Qty. Description 10.9678.0658 PLATE, COUNTERWEIGHT 10.9678.0990 LIGHT BAFFLE, BEAM SPREADER 53.6616.0001 SCREW, 6-32 X 3/4" PPZ (x8) (x4) Figure 3-47: Beam Spreader Light Baffle Assembly...

  • Page 133: Yoke Assembly Yoke Assembly

    SSEMBLY SSEMBLY Yoke Assembly Yoke Assembly 21.9678.0700 Rev G Refer to Figure 3-48 Item Qty. Description 10.9678.0764 PLATE, TILT ENCODER MOUNT 10.9678.0756 IGNITOR SHIELD 21.9678.0765 ASSY, TILT MOTOR 22.9661.0609 ASSY, YOKE FAN 22.9678.0705 ASSY, YOKE STRUCTURE 23.9650.3327 ELEC ASSY, RELAY 23.9661.1253 ELEC ASSY, PAN EOT SENSOR 24.9661.1126...
  • Page 134 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Yoke Assembly (cont.) (x2) (x2) (x2) (x4) (x3) (x8) (x2) (x2) (x4) (x2) (x2) (x2) (x2) Figure 3-48: Yoke Assembly 02. 9678.0 010 D...

  • Page 135: Tilt Motor Assembly

    SSEMBLY OTOR SSEMBLY Tilt Motor Assembly 21.9678.0765 Rev B Refer to Figure 3-49 Item Qty. Description 10.9678.0763 PLATE, TILT MOTOR MOUNT 21.9678.0708 ASSY, DRIVE PULLEY - 10.9678.0720 CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5562.0250 SCREW, 8-32 X 1/4"...

  • Page 136: Relay Electrical Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Relay Electrical Assembly 23.9650.3327 Rev 0 Refer to Figure 3-50 Item Qty. Description 04.9650.0044 LABEL, RELAY WIRING -VL7 52.8271.0006 RECP, FASTON 1/4" 16-14 AWG INS. 66.4510.0002 RELAY, 20A 250VAC DPDT UL/CSA/VDE 82.4307.4002 DIODE, 1N4002 RECTIFIER 100V 1A Figure 3-50: Relay Electrical Assembly...

  • Page 137: Head/Yoke Pcb Assemblies Color Sensor Pcb #1 Mount Assembly

    PCB A PCB #1 M SSEMBLIES OLOR ENSOR OUNT SSEMBLY Head/Yoke PCB Assemblies Color Sensor PCB #1 Mount Assembly 22.9678.0481 Rev 0 Refer to Figure 3-51 Item Qty. Description 10.9678.0482 PCB MOUNT, COLOR SENSOR #1 24.9678.0480 PCB ASSY, COLOR SENSOR #1 - 11.9678.0480 PCB, COLOR SENSOR #1 - 52.6447.0007...

  • Page 138: Color Sense Pcb #2 Mount Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Color Sense PCB #2 Mount Assembly 22.9678.0489 Rev B Refer to Figure 3-52 Item Qty. Description 10.9678.0452 PCB MOUNT, COLOR SENSE #2 24.9678.0454 PCB ASSY, COLOR SENSOR #2 - 11.9678.0454 PCB, COLOR SENSOR #2 - 52.6447.0005 HEADER, SHROUDED 5 POSITION...

  • Page 139: Solid State Ignitor Pcb

    PCB A SSEMBLIES OLID TATE GNITOR Solid State Ignitor PCB 24.9661.1126 Rev B Refer to Figure 3-53 Ref. Item Qty. Description 11.9661.1126 PCB, SOLIC STATE IGNITOR J1, J2, J3, 52.8218.0002 TERM, PC VERT MNT 6-32 SCREW 15A RES, 1/4W 1% 6.49 K MF 60.1230.6493 (changed 9-12-03) 60.1431.1007...
  • Page 140 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Solid State Ignitor PCB (continued) Figure 3-53: Solid State Ignitor PCB 02. 9678.0 010 D...

  • Page 141: Gobo Interconnect Pcb/Cable Assembly

    PCB A PCB/C SSEMBLIES NTERCONNECT ABLE SSEMBLY Gobo Interconnect PCB/Cable Assembly 25.9678.0209 Rev B Refer to Figure 3-54 Figure 3-55 Item Qty. Description 24.9678.1209 PCB ASSY, GOBO INTERCONNECT 28.9678.0209 WIRE KIT, GOBO INTERCONNECT - 04.9678.0209.00 LABEL SET, GOBO HARNESS - 52.6467.0003 CONN, FEM PLUG 3POS 30-24 AWG - 52.6467.0004 CONN, FEM PLUG 4POS 30-24 AWG...
  • Page 142 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Gobo Interconnect PCB/Cable Assembly (continued) Figure 3-55: Gobo Interconnect PCB Assembly Wire Chart 02. 9678.0 010 D...

  • Page 143: Wheel Position Sensor Pcb Assembly

    PCB A PCB A SSEMBLIES HEEL OSITION ENSOR SSEMBLY Wheel Position Sensor PCB Assembly 24.9678.0240 Rev A Refer to Figure 3-56 Item Qty. Description 11.9678.0240 PCB, WHEEL POSITION SENSOR 52.6447.0003 HEADER, SHROUDED 3 POSITION 86.7005.0001 SENSOR, HALL-EFFECT A3141LLT Figure 3-56: Wheel Position Sensor PCB Assembly 02.9 678.00 10 D...

  • Page 144: Color Interconnect Pcb/Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Color Interconnect PCB/Cable Assembly 25.9678.0409 Rev B Refer to Figure 3-57 Figure 3-58 Item Qty. Description 24.9678.1409 PCB ASSY, COLOR INTERCONNECT 28.9678.0409 WIRE KIT, COLOR INTERCONNECT - 04.9678.0409.00 LABEL SET, COLOR HARNESS - 11.9678.0409 PCB, COLOR INTERCONNECT - 52.6467.0003...
  • Page 145 PCB A PCB/C SSEMBLIES OLOR NTERCONNECT ABLE SSEMBLY Color Interconnect PCB/Cable Assembly (continued) Figure 3-58: Color Interconnect PCB Assembly Wire Chart 02.9 678.00 10 D...

  • Page 146: Pan/Tilt Encoder Pcb

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Pan/Tilt Encoder PCB 24.9678.0729 Rev A Refer to Figure 3-59 Ref. Item Qty. Description 11.9678.0729 PCB, VL3000 PAN/TILT ENCODER 52.6613.0005 HEADER, 5POS SGL ROW SHROUDED LATCHING 52.6613.0006 HEADER, 6POS SGL ROW SHROUDED LATCHING R1, R2 60.9460.1802 RES, .1W 5% 180.0 OHM 100V CHIP SUR MT...

  • Page 147: Vl3000 Controller Pcb

    PCB A : VL3000 C SSEMBLIES ONTROLLER VL3000 Controller PCB 24.9678.0730 Rev F Refer to Figure 3-60 Item Description Ref. 10.9661.1275 HEATSINK, MAIN CONTROLLER 10.9678.0731 CONTROLLER HEATSINK 10.9678.0885 KIT, THERMAL TRANSFER 11.9678.0730 PCB BOARD, VL3000 CONTROLLER 50.2769.0001 SOCKET, 28PIN PLCC SMT X27, X28, X29, X30, X32, X33, X34, X35, X36, X37, X38, X39, X40, X41, X42,...
  • Page 148 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Description Ref. R132, R139, R143, R150, R157, R162, R163, R168, R171, R175, R176, R181, R261, R268, R279, R286, R288, R295, R91, R99 60.1161.7503 RES, 1/16W 1% 7.50 K CHIP THK FLM SMT0402 R210, R217, R221, R228, R232, R239, R243, R250, R270, R277...
  • Page 149 PCB A : VL3000 C SSEMBLIES ONTROLLER Item Description Ref. 62.4209.0224 CAP, .22UF 50V 10% TANT CHIP SUR MT C72, C75 62.4210.0103 CAP, .01UF 50V 10% MONO CER CHIP SUR MT C71, C74 62.4225.0107 CAP, 100UF 35V 20% ALUM ELECTRO SUR MT C1, C,2 C3, C4 62.4227.0107 CAP, 100UF 10V 20% ALUM ELECTRO SUR MT...
  • Page 150 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Description Ref. D23, D24, D25, D26, D27, D28, D29, D30, D31, D32, D33, D34, D35, D36, D37, D38, D39, D40, D41, D42, D43, D44, D45, D46, D47, D48, D49, D50, D51, D52, D53, D54, D55, D56, D57, D58, D59, D60, D61, D62, D63, D64, D65, D66, D67, D68, D69, D70, D71, D72, D73, D74, D75, D76, D77, D78, D79, D80, D81, D82, D83, D84, D85, D8, D87, D88, D89, D90, D91, D92 83.3174.0001...
  • Page 151 PCB A : VL3000 C SSEMBLIES ONTROLLER VL3000 Controller PCB (continued) Figure 3-60: VL3000 Controller PCB 02.9 678.00 10 D...

  • Page 152: Wash Zoom Interconnect Pcb Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Wash Zoom Interconnect PCB Assembly 24.9678.0916 Rev 0 (Wash Only) Refer to Figure 3-61 Ref. Item Qty. Description 11.9678.1116 PCB ZOOM INTERCONNECT 52.6259.0004 HDR 4POS NT\MTA100 SD RT ANG 52.6260.0003 HEADER, 2POS MTA-100 SHROUDED 52.6447.0004 HEADER, SHROUDED 4 POSITION...

  • Page 153: Arc Zoom Interconnect Pcb Assembly

    PCB A PCB A SSEMBLIES NTERCONNECT SSEMBLY Arc Zoom Interconnect PCB Assembly 24.9678.1116 Rev 0 (Spot Only) Refer to Figure 3-62 Ref. Item Qty. Description 04.9678.1116.00 LABEL SET ZOOM HARNESS (Not Shown) 11.9678.1116 PCB ZOOM INTERCONNECT 52.6259.0004 HDR 4POS NT\MTA100 SD RT ANG 52.6260.0003 HEADER, 2POS MTA-100 SHROUDED 52.6447.0004...
  • Page 154 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Zoom Interconnect PCB Assembly (continued) Figure 3-62: Arc Zoom Interconnect PCB Assembly 02. 9678.0 010 D...

  • Page 155: Zoom Sensor (Target) Pcb Assembly

    PCB A ) PCB A SSEMBLIES ENSOR ARGET SSEMBLY Zoom Sensor (Target) PCB Assembly 24.9678.0112 Rev 0 Refer to Figure 3-63 Ref. Item Qty. Description 11.9678.1117 PCB, VL3000 ZOOM SENSOR 52.6447.0003 HEADER, SHROUDED 3 POSITION 86.7002.0004 SWITCH, SLOTTED OPTICAL OPB610 6/16/03 c 2003 Figure 3-63: Zoom Sensor PCB Assembly...

  • Page 156: Index Sensor Pcb Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Index Sensor PCB Assembly 24.9663.1231 Rev B Refer to Figure 3-64 Ref. Item Qty. Description 11.9663.1231 PCB, INDEX SENSOR 52.6447.0004 HEADER, SHROUDED 4 POSITION 86.7002.0004 SWITCH, SLOTTED OPTICAL OPB610 SOLDER SIDE VIEWED FROM SENSOR SIDE Figure 3-64: Index Sensor PCB Assembly 02.

  • Page 157: Enclosure Assembly Upper Enclosure Assembly

    NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Enclosure Assembly Upper Enclosure Assembly 21.9678.0800 Rev U Refer to Figure 3-65 Figure 3-66 Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 04.9661.1218.01 LABEL, PATENT, VL2201 & VL2400 SERIES LUM. (changed 01-06-04) 04.9678.0040.01 LABEL, VL3000 COMPLIANCE (changed 11-11-03) 10.9640.0002 PAD, CHOKE 10.9661.1258...
  • Page 158 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Item Qty. Description 22.9678.0851 ASSY, UPPER ENCLOSURE 23.9678.1269 ASSY, BALLAST MODULE, 1200W ARC 23.9678.0686 FAN ASSY, UPPER ENCLOSURE 23.9678.0687 ELEC ASSY, PAN EOT SENSOR 25.9661.1514 CABLE ASSY, LVS CHASSIS GND (not shown) 25.9661.1520 CABLE ASSY, CHASSIS TO YOKE GND (not shown) 25.9678.0811...
  • Page 159 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Item Qty. Description 53.6626.0001 SCREW, 10-32 X 1/2" PPZ (changed 10-09-03) 53.6627.0001 SCREW, 10-32 X 5/8" PPB (changed 10-09-03) 53.6634.1000 SCREW, 3/8-16 X 1.00" LG SOC 53.6653.0502 SCREW, 1/4-20 X 1/2"LG SOC 53.6513.0044 SCREW, M5 X 10MM STL CUP PT (changed 10-13-03) 53.6686.0002 STUD, 10-32X2.0LG FULL TRD STZ 54.1206.0014...
  • Page 160 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x4) (x4) (x4) (x4) (x4) (x4) (x4) Figure 3-65: Upper Enclosure Assembly Part 1 02. 9678.0 010 D...
  • Page 161 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly (continued) Electronics Assembly (x2) (x4) (x2) (x2) (x2) (x2) (x2) Part is shown exploded for clarity (x2) (x3) (x2) (x2) (x2) (x2) Choke and Duct (x2) Assembly (x2) (x2) (x2) Pan Tube Mechanism Assembly (x2)

  • Page 162: Ventilation Cover Assembly (Standard)

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Ventilation Cover Assembly (Standard) 21.9661.1254 Rev B Refer to Figure 3-67 Item Qty. Description 10.9661.1249 POST, TRUSS HOOK 10.9661.1350 COVER, VENTILATION 10.9661.1377 KIT, AIR SEAL, UPPER ENCLOSURE (changed 8-01-03) 54.1206.0015 RING, RETAINING, PRESS-ON, 1"...

  • Page 163: Ventilation Cover Assembly (Quiet Mode)

    NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY UIET Ventilation Cover Assembly (Quiet Mode) 21.9678.0840.02 Rev A - Aluminum Refer to Figure 3-67 Item Qty. Description 10.9661.1249 POST, TRUSS HOOK 10.9678.0833 SPACER, 1.125" ENCLOSURE 10.9678.0835 FOAM AIR SEAL, SHORT STRIP 10.9678.0836 FOAM AIR SEAL, LONG STRIP 10.9678.0837 FOAM AIR SEAL, QUIET VERSION, FAN SIDE 10.9678.0838...

  • Page 164: Panel Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Panel Assembly 21.9678.0805 Rev C Refer to Figure 3-69 Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY(changed 01-06-04) 10.9678.0859 BRACKET, INPUT 24.9663.1830 PCB ASSY, DMX INPUT 24.9678.0825 PCB ASSY, VL3000 DISPLAY 25.9661.1511 CABLE ASSY, AC INPUT PIGTAIL (EURO) 53.6551.0001...

  • Page 165: Dmx Input Pcb

    : DMX I NCLOSURE SSEMBLY NPUT DMX Input PCB 24.9663.1830 Rev A Refer to Figure 3-70 Item Qty. Description Ref. 11.9663.1830 PCB FAB, DMX INPUT 52.6259.0001 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0005 CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL 52.6626.0005 CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL 62.3017.0102...

  • Page 166: Display Pcb

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Display PCB 24.9678.0825 Rev 0 Refer to Figure 3-71 Ref. Item Qty. Description 11.9678.0825 PCB BOARD, VL3000 DISPLAY 52.6365.0006 HEADER, 6POS MTA100 SHROUDED R/A 52.6631.0002 CONN, ZEBRA ELASTOMERIC VL2203 53.6659.0003 SCREW, 2-56 X 3/8"...
  • Page 167 NCLOSURE SSEMBLY ISPLAY Display PCB (continued) Figure 3-71: Display PCB 02.9 678.00 10 D...

  • Page 168: Eries Luminaire Service Manual

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL AC Input Pigtail (Euro) Cable Assembly 25.9661.1511 Rev D Refer to Figure 3-72. Item Qty. Description 52.6274.2313 STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 52.6401.2321 CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3- WIRE 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG...

  • Page 169: Pan Pulley Assembly

    NCLOSURE SSEMBLY ULLEY SSEMBLY Pan Pulley Assembly 21.9678.0807 Rev C Refer to Figure 3-73 Item Qty. Description 10.9678.0750 TIMING PULLEY, 2MM GT 150 TOOTH 10.9678.0855 PAN FLAG 53.6530.0006 RIVET, 1/8"OD POP .188-.250GL (x2) Figure 3-73: Pan Pulley Assembly 02.9 678.00 10 D...

  • Page 170: Pan Motor Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Pan Motor Assembly 21.9678.0864 Rev A Refer to Figure 3-74 Item Qty. Description 10.9678.0865 PLATE, PAN MOTOR MOUNT 21.9678.0828 ASSY, DRIVE PULLEY, PAN - 10.9678.0720 CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5562.0250...

  • Page 171: Pan Tube Assembly

    NCLOSURE SSEMBLY SSEMBLY Pan Tube Assembly 21.9678.0880 Rev B Refer to Figure 3-75 Item Qty. Description 10.9678.0809 PAN TOGGLE STOP 10.9678.0847 SILICONE FOAM WASHER 10.9678.0848 WASHER, PAN TEFLON 12.9678.0891 PAN TUBE 54.1206.0021 RING, RETAINING 1.562"SHAFT 1.468"GRV DIA .068"GRVWD EXTERNAL 54.1255.0002 BEARING ASSY, FLUSH MOUNT HOUSING LARGE Figure 3-75: Pan Tube Assembly 02.9 678.00 10 D...

  • Page 172: 1200W Arc Ballast Module Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 1200W Arc Ballast Module Assembly 23.9678.1269 Rev A (Formerly 23.9661.1269) Refer to Figures 3-76 and 3-77. Item Qty. Description 06.6032.0009 CABLE MARKER TIE, WHITE 19 X 7.4" 10.9661.1260 HEAT SINK, LEFT 1200 WATT POWER SUPPLY 10.9661.1261 HEAT SINK, RIGHT 1200 WATT POWER SUPPLY 10.9661.1262...
  • Page 173 : 1200W A NCLOSURE SSEMBLY ALLAST ODULE SSEMBLY Item Qty. Description 82.4323.0001 DIODE, BRIDGE D25XB60 600V 25A SIP 82.5341.0001 DIODE, DSEI30-06A FRED 25-37A T0-247 AD (x2) (x4) Figure 3-76: 1200W Arc Ballast Module Assembly 02.9 678.00 10 D...
  • Page 174 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 1200W Arc Ballast Module Assy (continued) (x4) (x4) Figure 3-77: 1200W Arc Ballast Module Assembly (Side Views) 02. 9678.0 010 D...

  • Page 175: 1200W Ballast Pcb Assembly

    : 1200W B PCB A NCLOSURE SSEMBLY ALLAST SSEMBLY 1200W Ballast PCB Assembly 24.9661.1110 Rev H Refer to Figure 3-78. Ref. Item Qty. Description 10.9661.1356 GUIDE, APS RIDER PCB 11.9661.1110 PCB, VLFS 1200W ARC BALLAST J113 52.6229.0001 HEADER, 3POS MTA FRIC LOK STRT POST J102 52.6261.0002 HEADER, 2PIN MTA156...
  • Page 176 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Ref. Item Qty. Description R225, R226 60.1426.1003 RES, 1/4W 5% 100.0 K CF R217 60.1431.1007 RES, 1/4W 5% 10.0 OHM R115, R116 60.3421.5104 RES, 2W 5% 51.0 K CF R209 60.7440.1002 RES, 5W 5% 100.0 OHM WW C219...
  • Page 177 : 1200W B PCB A NCLOSURE SSEMBLY ALLAST SSEMBLY Ref. Item Qty. Description Q205, Q210 80.2643.0001 TRANSISTOR, MPSW63 1W PNP DARLINGTON 30V 500MA 1W TO-92 D206-D210 82.4308.4937 DIODE, 1N4937 FAST 600V 1A D212 82.4317.5819 DIODE, 1N5819 RECTIFIER 40V 1A D104 82.5318.0160 DIODE, MUR160, 600V, 1A D215...

  • Page 178: 1200W Ballast Rider Pcb Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 1200W Ballast Rider PCB Assembly 24.9661.1111 Rev G Refer to Figure 3-79. Ref. Item Qty. Description 10.9661.1355 STABILIZING EXTRUSION, APS RIDER BD PCB 11.9661.1111 PCB, BALLAST RIDER XU402 50.4002.0014 SOCKET, 14 PIN DIP GULL WING SUR MT OPEN FRAME J402 52.6297.0001 HEADER, 2PIN MTA FRCT LOK STRT POST...
  • Page 179 : 1200W B PCB A NCLOSURE SSEMBLY ALLAST IDER SSEMBLY Ref. Item Qty. Description R421 60.9464.7505 RES, 1/8W 5% 750.0 K 200V CHP THK FLM S-MT1206 R305 60.9464.8204 RES, 1/8W 5% 82.0 K 200V CHP THK FLM S-MT1206 C417 62.3009.0473 CAP, .047UF 50V 10% MONO CER CHIP SUR MT C309 62.4000.0102...
  • Page 180 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL 1200W Ballast Rider PCB Assembly (continued) Figure 3-79: 1200W Ballast Rider PCB Assembly 02. 9678.0 010 D...

  • Page 181: Cable Assemblies

    EOT S ABLE SSEMBLIES ENSOR LECTRICAL SSEMBLY Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-80 Item Qty. Description 52.6524.0006 CONN, HOUSING 6 POS RECEPTACLE 52.8346.0001 CONTACT, 24-30AWG FEMALE CRIMP 86.7002.0003 SWITCH, SLOTTED OPTICAL (x4) Figure 3-80: Pan EOT Sensor Electrical Assembly 02.9 678.00 10 D...

  • Page 182: Lvs Chassis Ground Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-81 Item Qty. Description 52.8231.0001 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8271.0001 FASTON RECEPT, 16-14 AWG (REEL) 73.3516.0504 WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 Figure 3-81: LVS Chassis Ground Cable Assembly...

  • Page 183: Chassis To Yoke Ground Cable Assembly

    ABLE SSEMBLIES HASSIS ROUND ABLE SSEMBLY Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev 0 Refer to Figure 3-82 Item Qty. Description 52.8250.0001 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (x2) Figure 3-82: Chassis To Yoke Ground Cable Assembly 02.9 678.00 10 D...

  • Page 184: Head To Back Cap Ground Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Head to Back Cap Ground Cable Assembly 25.9661.1522 Rev B Refer to Figure 3-83. Item Qty. Description 52.8311.0003 TERM, RING #6 14-16AWG NON-INS. TAPE 73.7130.0001 1.33 WIRE, 7/64" TUBULAR BRAID TINNED COPPER (x2) Figure 3-83: Head to Back Cap Ground Cable Assembly 02.

  • Page 185: Ignitor To Relay Cable Assembly

    ABLE SSEMBLIES GNITOR TO ELAY ABLE SSEMBLY Ignitor to Relay Cable Assembly 25.9661.1526 Rev B Refer to Figure 3-84. Item Qty. Description 52.8223.0001 TERM, RING #6 BLUE 16-14 AWG (LOOSE) PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009 0.42 WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING Figure 3-84: Ignitor to Relay Cable Assembly...

  • Page 186: Yoke To Ac Fan Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Yoke to AC Fan Cable Assembly 25.9678.0012 Rev 0 Refer to Figure 3-85 Item Qty. Description 52.6665.0001 CONTACT, 22-26AWG MALE MATE-N-LOK 2 52.6665.0002 CONN, HOUSING 2 POS PLUG MATE-N-LOC 2 52.8413.0001 RECEPT, FASTON .110 SERIES 22-18AWG INSULATED 55.2186.0002...

  • Page 187: Backcap Interlok To Gobo Fan Interlok Cable Assembly

    ABLE SSEMBLIES ACKCAP NTERLOK TO NTERLOK ABLE SSEMBLY Backcap Interlok to Gobo Fan Interlok Cable Assembly 25.9678.0014 Rev A Refer to Figure 3-86 Item Qty. Description 52.8414.0001 RECEPT, FASTON .187 SERIES 24-20 AWG UNINSUL 73.7089.0000 2.00 WIRE. 22AWG 300V 200C TEF BLK UL1180 Figure 3-86: Backcap Interlok to Gobo Fan Interlok Cable Assembly 02.9 678.00 10 D...

  • Page 188: Ot Switch To Ground Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL OT Switch to Ground Cable Assembly 25.9678.0015 Rev 0 Refer to Figure 3-87 Item Qty. Description 52.8237.0002 TERM, RING #4 24-20AWG 52.8371.0001 RECEPT, FASTON 24-20AWG UNISUL TIN PLT BRS .250 X .032 TAB 73.7089.0000 0.25 WIRE, 22AWG BLK 300V TEFLON STRANDED...

  • Page 189: Head To Backcap Ground Cable Assembly

    ABLE SSEMBLIES ACKCAP ROUND ABLE SSEMBLY Head To Backcap Ground Cable Assembly 25.9678.0016 Rev 0 Refer to Figure 3-88 Item Qty. Description 52.8250.0014 TERM RING, #10 16-14AWG NON-INS. 73.7130.0001 1.83 WIRE, 7/64 TUBULAR BRAID TINNED COPPER (x2) Figure 3-88: Head To Backcap Ground Cable Assembly 02.9 678.00 10 D...

  • Page 190: Relay To Gobo Fan Interlock Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Relay to Gobo Fan Interlock Cable Assembly 25.9678.0675 Rev B Refer to Figure 3-89. Item Qty. Description 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG (TAPE MOUNT) 52.8414.0001 RECEPT, FASTON .187 SERIES 24-20 AWG UNINSUL 73.7089.0000 2.00 WIRE.

  • Page 191: Front Head Fans Cable Assembly

    ABLE SSEMBLIES RONT ABLE SSEMBLY Front Head Fans Cable Assembly 25.9678.0677 Rev A Refer to Figure 3-90 Item Qty. Description 52.6396.2604 RECEPT, 4POS MTA100 W/POL TAB BLU CLSD END 52.6524.0002 CONN, HOUSING 2POS RECEPTACLE 52.8346.0001 CONTACT, 24-30AWG FEMALE CRIMP 73.5126.0002 2.67 WIRE, 26AWG 2COND 300V 80C <BLK-RED>...

  • Page 192: Yoke Fan And Relay Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Yoke Fan and Relay Cable Assembly 25.9678.0681 Rev B Refer to Figure 3-91 Item Qty. Description 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG 52.6396.2603 RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END 73.3526.0002 1.25 WIRE, 26AWG 300V 105C PVC RED...

  • Page 193: Ot Switch To Interlok Cable Assembly

    : OT S ABLE SSEMBLIES WITCH TO NTERLOK ABLE SSEMBLY OT Switch to Interlok Cable Assembly 25.9678.0682 Rev B Refer to Figure 3-92 Item Qty. Description 52.8371.0001 RECEPT, FASTON 24-20AWG UNISUL TIN PLT BRS .250 X .032 TAB 52.8414.0001 RECEPT, FASTON, .187 SERIES 24-20 AWG UNISUL 73.7089.0000 0.79 WIRE.

  • Page 194: Ignitor To Lamp Socket Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Ignitor to Lamp Socket Cable Assembly 25.9678.0688 Rev A Refer to Figure 3-93. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL 55.2260.0133 7.67 SLEEVING, FIBERGLASS .133"...

  • Page 195: Yoke To Head Ground Cable Assembly

    ABLE SSEMBLIES OKE TO ROUND ABLE SSEMBLY Yoke to Head Ground Cable Assembly 25.9678.0689 Rev 0 Refer to Figure 3-94 Item Qty. Description 52.8250.0011 TERM, RING #10, 122-10AWG (REEL) 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (x2) Yoke Ground Head Ground Figure 3-94: Yoke to Head Ground Cable Assembly 02.9 678.00 10 D...

  • Page 196: Head Controller Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Head Controller Cable Assembly 25.9678.0715 Rev B Refer to Figure 3-95 Item Qty. Description 52.6224.0014 HOUSING, 14 POS 26-22 AWG PRELOADED MT RECEPT DBL TOW 52.6224.0040 HOUSING, 40POS 26-22AWG PRELOADED MT RECEPT DBL ROW 52.6224.0050 HOUSING, 50POS 26-22AWG PRELOADED MT RECEPT DBL ROW 52.6224.1014...
  • Page 197 ABLE SSEMBLIES ONTROLLER ABLE SSEMBLY Head Controller Cable Assembly (continued) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x10) Figure 3-95: Head Controller Cable Assembly 02.9 678.00 10 D...

  • Page 198: Yoke Fan Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Yoke Fan Cable Assembly 25.9678.0758 Rev 0 Refer to Figure 3-96 Item Qty. Description 52.6396.2602 RECEPT, 2POS MTA100 W/POL TAB BLUE CLSD END 52.6423.0003 HOUSING, 3POS MT RECEPT, 2MM CT 28-26 AWG 73.5126.0002 WIRE, 26AWG 2COND 300V 80C <BLK-RED>...

  • Page 199: Ac Input Pigtail Cable Assembly

    : AC I ABLE SSEMBLIES NPUT IGTAIL ABLE SSEMBLY AC Input Pigtail Cable Assembly 25.9678.0810 Rev A Refer to Figure 3-97 Item Qty. Description 52.6274.2313 STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 52.6401.2321 CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3-WIRE 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8298.1160...

  • Page 200: Emi Filter To Power Switch Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev A Refer to Figure 3-98 Item Qty. Description 52.8313.0001 RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL) 52.8392.0001 RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL 73.6016.0009...

  • Page 201: Ac Input Splitter Cable Assembly

    : AC I ABLE SSEMBLIES NPUT PLITTER ABLE SSEMBLY AC Input Splitter Cable Assembly 25.9678.0812 Rev D Refer to Figure 3-99 Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3POS 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8231.0008 TERM, SPADE #6 RED 22-16AWG INSERT 52.8392.0001 RECP, FASTON .187"X0.32"...
  • Page 202 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 (x3) Figure 3-99: AC Input Splitter Cable Assembly 02. 9678.0 010 D...

  • Page 203: Data I/O Link Cable Assembly

    I/O L ABLE SSEMBLIES ABLE SSEMBLY Data I/O Link Cable Assembly 25.9678.0813 Rev 0 Refer to Figure 3-100 Item Qty. Description 52.6396.2204 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 52.6396.2205 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 73.5122.0259 2.17 CBL, 22AWG STRND 4COND PVC INSUL...

  • Page 204: Display Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Display Cable Assembly 25.9678.0815 Rev 0 Refer to Figure 3-101 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 73.5116.0123 WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN> (x2) Figure 3-101: Display Cable Assembly 02.

  • Page 205: Ballast To Controller Cable Assembly

    ABLE SSEMBLIES ALLAST TO ONTROLLER ABLE SSEMBLY Ballast to Controller Cable Assembly 25.9678.0816 Rev 0 Refer to Figure 3-102 Item Qty. Description 52.6396.2402 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 52.6396.2405 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 52.6396.2408 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 73.5124.1289...

  • Page 206: Dc Output Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL DC Output Cable Assembly 25.9678.0821 Rev A (formally 25.9678.0817 Rev A) Refer to Figure 3-103 Item Qty. Description 52.6464.0002 CONN, HOUSING, SL-156 2 POS 52.6464.0003 CONN, HOUSING, SL-156 3 POS 52.8231.0004 TERM, RING #6 BLUE 12-10 AWG INSRT (added 01-20-04) 52.8323.0001...

  • Page 207: Pan/Tilt Control Cable Assembly

    ABLE SSEMBLIES ONTROL ABLE SSEMBLY Pan/Tilt Control Cable Assembly 25.9678.0818 Rev A Refer to Figure 3-104 Item Qty. Description 52.6224.0020 HOUSING, 20POS 26-22AWG PRELOADED MT RECEPT DBL ROW 52.6224.1020 COVER, FRONT 20POS MT LATCHING 52.6224.2020 COVER, BACK 20POS MT 52.6524.0005 CONN, HOUSING 5POS RECEPTACLE 52.6588.0007 HOUSING, 7POS XH 250V/3A 2.5MMPITCH -USE SXH CONTACTS...

  • Page 208: Lamp Supply To Relay Cable Assembly

    ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Lamp Supply to Relay Cable Assembly 25.9678.0819 Rev A Refer to Figure 3-105 Item Qty. Description 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL 55.6699.0003 3.75 SLEEVING, 1/2"...

  • Page 209: Lvs To Yoke Ac Fan Cable Assembly

    : LVS AC F ABLE SSEMBLIES ABLE SSEMBLY LVS to Yoke AC Fan Cable Assembly 25.9678.0843 Rev 0 Refer to Figure 3-106 Item Qty. Description 52.6664.0001 CONTACT, 22-26AWG FEMALE MATE-N-LOK 2 52.6664.0002 CONN, HOUSING 2 POS CAP MATE-N-LOK 2 52.8231.0008 TERM, SPADE #6 RED 22-16AWG INSERT 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL...
  • Page 210 ❋ VARI LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Notes 02. 9678.0 010 D...

  • Page 211: Appendix D. Technical Bulletins

    A : VL3000 T PPENDIX ECHNICAL ULLETINS PPENDIX Technical Bulletins VL3000 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. Technical Bulletin Description Model(s)
  • Page 212 VARI❋LITE® - VL3000™ S ERIES UMINAIRE ERVICE ANUAL Notes 02. 9678.0 010 D...

  • Page 213: Chapter 5. Schematic And Wiring Diagrams

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Schematic and Wiring Diagrams Encoder Sensor PCB (Sheet 1 of 1) REVISIONS DESCRIPTION DATE APPD Released per EO # Notes: Unlesss Otherwise specified. All capacitor values are microfarads. All resistor values are ohms.

  • Page 214: 1200 Watt Ballast Pcb (Sheet 1 Of 2)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS 1200 Watt Ballast PCB (Sheet 1 of 2) REVISIONS DESCRIPTION DATE APPD Notes: Released per EO #04545 9/20/99 B.C. Unlesss Otherwise specified. Revised per EO #06419 2/11/00 B.C.

  • Page 215: 1200 Watt Ballast Pcb (Sheet 2 Of 2)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS 1200 Watt Ballast PCB (Sheet 2 of 2) D205 MUR460 1.5KE250A 1.5KE250A D213 1.5KE250A D203 D204 4.7UF C207 4.7UF C209 R212 R214 0.1UF 4.7UF 1/C3,2/D2,2/D3, C208 2/C8,2/B6,2/B2 C213...

  • Page 216: Ballast Rider Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Ballast Rider PCB (Sheet 1 of 1) REVISIONS R428 D406 DESCRIPTION DATE APPD 1/C7,1/B6 1/8W LL4148 Released per EO #04545 9/20/99 B.C. R401 R417 BUCKPWM D405 D404 Revised per EO #06419...

  • Page 217: Solid State Ignitor Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Solid State Ignitor PCB (Sheet 1 of 1) REVISIONS DESCRIPTION DATE APPD NOTES: UNLESS OTHERWISE SPECIFIED ENGINEERING PROTOTYPE 7/16/02 B.C. 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. ENG RELEASE PER EO #09082 9/16/02 B.C.

  • Page 218: Gobo Index Sensor Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Gobo Index Sensor PCB (Sheet 1 of 1) REVISIONS DESCRIPTION DATE APPD RLSE TO PRODUCTION ECO 8894 11/08/01 OPB610 B 4B-PH-K VCC_R SENSOR MTG1 MTG2 DRAWN BY NEXT 201 REGAL ROW...

  • Page 219: Dmx Input Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS DMX Input PCB (Sheet 1 of 1) REVISIONS DESCRIPTION DATE APPD Released per EO #09110 9/27/01 NC5FBV SHIELD DMX/VL_IN- DMX/VL_IN+ VL_OUT- VL_OUT+ CHASSIS NC5MBV SHIELD DMX/VL_IN- DMX/VL_IN+ VL_OUT-...

  • Page 220: Gobo Interconnect Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Gobo Interconnect PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 2-103166-3 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 7-24-02 K.C.F. REL TO ENGINEERING PER EO #09065 2.

  • Page 221: Color Interconnect Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Color Interconnect PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 7-24-02 K.C.F. REL TO ENGINEERING PER EO #09065 2.

  • Page 222: Color Sensor #2 Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Color Sensor #2 PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. ENG REL PER EO #09062 07-02-02 K.C.F.

  • Page 223: Color Sensor #1 Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Color Sensor #1 PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. REL TO PROD PER EO #09094 2.

  • Page 224: Pan/Tilt Encoder Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Pan/Tilt Encoder PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. ENG REL PER EO #09056 6-17-02 K.C.F.

  • Page 225: Vl3000 Controller Pcb (Sheet 1 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 1 of 10) REVISIONS DESCRIPTION DATE APPD TEW2 Released to Engineering per EO #09054 5/28/02 T.E.W. Revised per EO #09061 7/3/02 T.E.W.

  • Page 226: Vl3000 Controller Pcb (Sheet 2 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 2 of 10) +3.3V 4.7K CS_MTR- D[0:31] D[0:31] D[0:31] 3/B3,3/A3 2/B4,3/A6 A[0:24] A[0:24] +1.8V +1.8V +1.8V +1.8V +1.8V 1/16W 4.7K CS_UART- 2/B4,3/A6 2/C3,3/D6,3/A3 4.7K...

  • Page 227: Vl3000 Controller Pcb (Sheet 3 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 3 of 10) +3.3V +2.5V +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V A[0:24] 2/D4,2/C3,3/A3 GOBO2_IDX_IN 0.01UF 0.01UF 0.01UF 0.01UF 0.01UF 0.01UF 4/B8 IO77 GOBO3_IDX_IN 4/B8...

  • Page 228: Vl3000 Controller Pcb (Sheet 4 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 4 of 10) ISO_VCC +3.3V +24V ISO_VCC HCPL-0600 1/16W 0.1UF 0.1UF 0.1UF 1/16W 4.7K 1/16W ISO_VCC SP232ACN 74ACT00SC 0.1UF 1/4W TX_EN_C- 3/D6 SN75176BD GREEN...

  • Page 229: Vl3000 Controller Pcb (Sheet 5 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 5 of 10) +24V +24V +24V +24V SS14 SS14 SS14 L6234PD 3/D3 PWM3_OUT_1 PAN_PHA_OUT 10/D3 OUT1 PWM3_OUT_2 PAN_PHB_OUT 3/A6 OUT2 10/D3 PWM3_OUT_3 PAN_PHC_OUT 3/D3...

  • Page 230: Vl3000 Controller Pcb (Sheet 6 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 6 of 10) +24V +24V C101 C119 GOBO1 ROTATE GOBO2 ROTATE 0.1UF 0.1UF 10UF 10UF +24V +24V R114 R136 1/16W 1/16W VMM1 VMM2 VMM1...

  • Page 231: Vl3000 Controller Pcb (Sheet 7 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 7 of 10) +24V +24V C136 GOBO3 ROTATE C155 0.1UF C100 ZOOM 10UF 0.1UF C118 10UF +24V R160 +24V R173 1/16W 1/16W VMM1 VMM2...

  • Page 232: Vl3000 Controller Pcb (Sheet 8 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 8 of 10) +24V +24V C173 C200 AMBER MAGENTA 0.1UF C137 0.1UF C163 10UF 10UF +24V +24V R214 R247 1/16W 1/16W VMM1 VMM2 VMM1...

  • Page 233: Vl3000 Controller Pcb (Sheet 9 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 9 of 10) +24V +24V C208 C232 FXD COLOR STROBE1 0.1UF C172 0.1UF C199 10UF 10UF +24V +24V R265 R292 1/16W 1/16W VMM1 VMM2...

  • Page 234: Vl3000 Controller Pcb (Sheet 10 Of 10)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Controller PCB (Sheet 10 of 10) +24V +24V MTG1 MTG2 MTG3 MTG4 MTG5 MTG6 MTG7 MTG HOLE MTG HOLE MTG HOLE MTG HOLE MTG HOLE MTG HOLE MTG HOLE IRIS_OUT1A...

  • Page 235: Display Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Display PCB (Sheet 1 of 1) REVISIONS DESCRIPTION DATE APPD NOTES: UNLESS OTHERWISE SPECIFIED TEW1 RELEASED TO ENGINEERING PER EO #09054 5-29-02 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. REVISED PER EO #09057 8-15-02 T.E.W.

  • Page 236: Zoom Interconnect Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Zoom Interconnect PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. RELEASE TO PROD. PER EO #10359 2.

  • Page 237: Zoom Sensor Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Zoom Sensor PCB (Sheet 1 of 1) REVISIONS NOTES: UNLESS OTHERWISE SPECIFIED DESCRIPTION DATE APPD 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. REL. TO PROD. PER EO #09093 2.

  • Page 238: Vl3000 Spot Luminaire Wiring Diagram (Sheet 1 Of 3)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Spot Luminaire Wiring Diagram (Sheet 1 of 3) 02.9 678.00 10 D...

  • Page 239: Vl3000 Spot Luminaire Wiring Diagram (Sheet 2 Of 3)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Spot Luminaire Wiring Diagram (Sheet 2 of 3) 02.9 678.00 10 D...

  • Page 240: Vl3000 Spot Luminaire Wiring Diagram (Sheet 3 Of 3)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Spot Luminaire Wiring Diagram (Sheet 3 of 3) 02.9 678.00 10 D...

  • Page 241: Vl3000 Wash Luminaire Wiring Diagram (Sheet 1 Of 3)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Wash Luminaire Wiring Diagram (Sheet 1 of 3) 02.9 678.00 10 D...

  • Page 242: Vl3000 Wash Luminaire Wiring Diagram (Sheet 2 Of 3)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Wash Luminaire Wiring Diagram (Sheet 2 of 3) 02.9 678.00 10 D...

  • Page 243: Vl3000 Wash Luminaire Wiring Diagram (Sheet 3 Of 3)

    ® ❋ VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3000 Wash Luminaire Wiring Diagram (Sheet 3 of 3) 02.9 678.00 10 D...
  • Page 245 E x p r e s s y o u r s e l f . Vari-Lite 10911 Petal Street Dallas, Texas 75238 1-877-VARI-LITE Fax 214.647.8038 www.vari-lite.com © 2001-2004 Genlyte Thomas Group LLC. All rights reserved. Printed in the U.S.A.

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