Page 1 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Top Assembly Included Items Kit, Spot 28.9678.0001 Rev H Refer to Figure 3-9. Item Qty. Description 02.8001.0001 PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY 02.8406.0001 TAG, LAMP NOTICE 02.8700.0001 CARD, PRODUCT REGISTRATION 02.9678.0002...
Page 2 SSEMBLY NCLUDED TEMS Included Items Kit, Spot (continued) (x2) Alpha Rays Night Sky Tribal Break-Up Pebbles Glacier Gag Palm Leaves Shock Break-Up Uneven Bars Ice Blocks Gag Droplets Gag 3-Facet Prism Circle of Ovals Triangle Break-Up Multi-Colored Gobo Figure 3-9: Included Items Kit, Spot Note: * = Do not handle lamp with bare hands.
Page 3: Included Items Kit, Wash
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Included Items Kit, Wash 28.9678.0002 Rev F Refer to Figure 3-10. Item Qty. Description 02.8001.0001 PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY 02.8700.0001 CARD, PRODUCT REGISTRATION 02.9678.0002 UNPACK/QUICK START SHEET, VL3000 04.4037.0001...
Page 4 : VL3000 VL3000Q S SSEMBLY UMINAIRE VL3000 and VL3000Q Spot Luminaire 20.9678.0001 Rev P 20.9678.0003 Rev E Refer to Figure 3-11 Item Qty. Description 02.8405.0001 AC DANGER TAG, VL3000 (not shown) 04.9661.0033.01 LABEL, WARNING - 2000 SERIES (not shown) 04.9661.0039 LABEL, LINE CORD WARNING (not shown) 04.9678.0041.01 LABEL, AC INPUT RATING VL3000 (not shown)
Page 5 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Item Qty. Description 25.9678.0715 CABLE ASSY, HEAD CONTROLLER (not shown) 28.9678.0001 INCLUDED ITEMS KIT, VL3000 SPOT (not shown) 53.2001.0003 NUT, 10-32 NYLON INSERT 53.2002.0003 NUT, 6-32 HEX ZINC NYLON IN 53.6543.0001 SCREW, 6-32 X 3/8"...
Page 6 : VL3000 VL3000Q 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 3-11: VL3000 and VL3000Q Spot Luminaire 02.96 78.001 0 F...
Page 7 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ VL3000 and VL3000Q Wash Luminaire 20.9678.0002 Rev M 20.9678.0004 Rev F Refer to Figure 3-12 Item Qty. Description 02.8405.0001 AC DANGER TAG, VL3000 (not shown) 04.9661.0033.01 LABEL, WARNING - 2000 SERIES (not shown) 04.9661.0039 LABEL, LINE CORD WARNING (not shown) 04.9678.0041.01...
Page 8 : VL3000 VL3000Q W SSEMBLY UMINAIRE Item Qty. Description 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" PPZ SEMS 53.6579.0001 SCREW, 10-32 X 1/2" SCB 53.6613.0001 SCREW, 6-32 X 1/2" PPZ 53.6682.0022 SCREW, 8-32 X 3/8"...
Page 9 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ VL3000 and VL3000Q Wash Luminaire (continued) (x2) (x8) (x2) (x2) (x2) (x4) (x2) (x2) (x2) (x2) (x2) (x2) (x8) (x2) (x2) (x4) (x2) (x4) Figure 3-12: VL3000 and VL3000Q Wash Luminaire 02.96 78.001 0 F...
Page 10: Generic Luminaire Assemblies
SSEMBLY ENERIC UMINAIRE SSEMBLIES Generic Luminaire Assemblies 21.9678.0010.01 Rev G 21.9678.0011.01 Rev C Refer to Figure 3-13 Item Qty. Description 21.9678.0600 ASSY, HEAD STRUCTURE 21.9678.0601 ASSY, HEAD STRUCTURE, VL3000 QUIET 21.9678.0700 ASSY, YOKE 21.9678.0701 ASSY, YOKE, VL3000 QUIET 21.9678.0707 ASSY, TILT PULLEY - 10.9678.0750 TIMING PULLEY, 150 TOOTH - 10.9678.0754 *...
Page 11 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Generic Luminaire Assemblies (continued) (x3) (x2) (x4) (x4) (x4) (x2) (x3) Detail A (x4) (x5) (x5) Detail A (x2) (x2) Figure 3-13: VL3000 and VL3000Q Generic Luminaire Assemblies 02.96 78.001 0 F...
Page 12: Head Structure Assembly
SSEMBLY TRUCTURE SSEMBLY Head Assembly Head Structure Assembly 21.9678.0600 Rev C 21.9678.0601 Rev A (VL3000 Quiet) Refer to Figure 3-1 Item Qty. Description 10.9678.8620 FRONT CASTING 12.9678.8623 RIGHT SIDE RAIL, MACHINED 12.9678.8625 LEFT SIDE RAIL, MACHINED 21.9678.0615 ASSY, BACKEND 21.9678.0616 ASSY, BACKEND, VL3000 QUIET 53.6515.0001 SCREW, 10-32 X 3/4"...
Page 13: Head Cover Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Head Cover Assembly 21.9678.0611 Rev K (VL3000 Quiet) 21.9678.8611 Rev 0 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 10-01-03)
Page 14 SSEMBLY OVER SSEMBLY (x4) (x4) (x4) (x4) (x4) Bottom View Bottom View Figure 3-2: Head Cover Assembly 02.96 78.001 0 F...
Page 15: Backend Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Backend Assembly 21.9678.0615 Rev S 21.9678.0616 Rev G (VL3000 Quiet) 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 12.9678.7152...
Page 16 SSEMBLY ACKEND SSEMBLY Item Qty. Description 53.6613.0004 SCREW, 6-32 X 1/2" SCZ (added 07-18-03) 10.9678.1645 FAN SHIELD, LAMP COOLING (added 12-09-04) 25.9678.0691 CABLE ASSY, AIR DUCT OT SWITCH (cable not shown) 25.9678.0690 CABLE ASSY, AIR DUCT OT SWITCH, VL3000 QUIET (cable not shown) 10.9678.0680 INSULATOR, TEFLON, TO-220 53.2200.0004...
Page 17: 80Mm Fan Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ 80mm Fan Assembly 21.9678.0619 Rev B Refer to Figure 3-4 Item Qty. Description 40.7145.0004 FAN, TUBEAXIAL 80 X 80 X 38mm 28 CFM 230V (added 03/11/04) 53.2200.0006 NUT, 6-32 KEPS SS 53.6558.0001 SCREW, 6-32 X 3/8"...
Page 18: Uv Filter Bulkhead Assembly
: UV F SSEMBLY ILTER ULKHEAD SSEMBLY UV Filter Bulkhead Assembly 22.9678.0639 Rev C 22.9678.0617 Rev A (VL3000 Quiet) 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 19 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Notes 02.96 78.001 0 F...
Page 20: Spot Gobo Assembly
SSEMBLY SSEMBLY Spot Gobo Assembly 21.9678.0200 Rev H (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 21 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) 10.9678.0457.02 SPACER, RND, 3/8"...
Page 22: 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 23: 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...
Page 24: 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 02.96 78.001 0 F...
Page 25: 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 10.9678.0280 ADJUSTABLE IRIS STOP (changed 09-17-03) 22.9678.0271...
Page 26 SSEMBLY SSEMBLY Iris Assembly (continued) (x4) (x2) (x3) (x2) (x3) (x2) Figure 3-10: Iris Assembly 02.96 78.001 0 F...
Page 27: Hot Box Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Hot Box Assembly 21.9678.8640.01 Rev D (Spot) 21.9678.8640.02 Rev D (Wash) 21.9678.8698.01 Rev C (Quiet Spot) 21.9678.8698.02 Rev C (Quiet Wash) Refer to Figure 3-11 Item Qty. Description 04.9678.0042 LABEL, VL3000 BACKCAP 10.9678.0043 LABEL, BACKCAP, VL3000 QUIET...
Page 28 SSEMBLY SSEMBLY Hot Box Assembly (continued) (x4) (x4) (x2) (x3) (x4) (x4) (x4) (x4) (x8) (x4) (x3) (x3) Wash Version Spot Version (x3) Figure 3-11: Hot Box Assembly 02.96 78.001 0 F...
Page 29: Gobo/Color Fan Assembly - Vl3000Q Only
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Gobo/Color Fan Assembly - VL3000Q only 21.9678.0659.01 Rev D Refer to Figure 3-13 Item Qty. Description 10.9678.0665 SPRING, EXTENSION ELONGATED HO 22.9678.0661 ASSY, FAN TRAY 22.9678.0665 DUCT ASSY 23.9678.0699 FAN ASSY, HEAD FRONT 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPB...
Page 30 - VL3000Q ( SSEMBLY OLOR SSEMBLY CONTINUED Gobo/Color Fan Assembly - VL3000Q (continued) (x3) (x2) (x2) (x2) (x3) Spring installed as shown Figure 3-12: Gobo/Color Fan Assembly 02.96 78.001 0 F...
Page 31 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Dual Fan Tray/Duct Assembly 21.9678.0660.01 Rev B Refer to Figure 3-13 Item Qty. Description 10.9678.0665 SPRING, EXTENSION ELONGATED HOOK (changed 06-29-06) 22.9678.0661 ASSY, FAN TRAY 22.9678.0665 DUCT ASSY 23.9678.0684 FAN ASSY, HEAD FRONT 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPB...
Page 32: Head Front Fan Assembly
SSEMBLY RONT SSEMBLY Head Front Fan Assembly 23.9678.0684 Rev 0 Refer to Figure 3-14 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 3-14: Head Front Fan Assembly 02.96 78.001 0 F...
Page 33: Head Front Fan Assembly - Vl3000Q Only
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Head Front Fan Assembly - VL3000Q only 23.9678.0699 Rev A Refer to Figure 3-14 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 55.2186.0001...
Page 34: Transfer Fan Assembly
SSEMBLY RANSFER SSEMBLY Transfer Fan Assembly 21.9678.0678.01 Rev C (Spot) 21.9678.0678.02 Rev C (Wash) Refer to Figure 3-16 Item Qty. Description 10.9678.0679 TRANSFER FAN TRAY 23.9678.0695 FAN ASSY, TRANSFER 53.5506.1375 SCREW, 6-32 X 1-3/8"LG PPB 55.6543.0001 2.12 GROMMET STRIP, SERRATED POLYETHYLENE 55.6769.0004 TWIST-LOK 0.55"...
Page 35 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Notes 02.96 78.001 0 F...
Page 36: Spot Optic Assembly
SSEMBLY PTIC SSEMBLY Spot Optic Assembly 22.9678.0103 Rev R (Spot Only) Refer to Figure 3-17 Figure 3-18 Item Qty. Description 10.9678.1131 FORWARD PULLEY SHAFT (changed 12-15-04) 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 37 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) 24.9678.3112 PCB ASSY, VL3000 ZOOM SENSOR 53.2004.0002...
Page 38 SSEMBLY PTIC SSEMBLY Spot Optic Assembly (continued) (x2) (x4) (x2) (x2) (x4) (x3) (x2) Detail F-F Detail E-E (x6) Figure 3-17: Spot Optic Assembly View 1 02.96 78.001 0 F...
Page 39 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) Optical Sensor (x2) (x3) (x6) Detail G3-G3 Detail G2-G2 Detail G1-G1 (x2) (x5)
Page 40: Zoom Box Assembly
SSEMBLY SSEMBLY Zoom Box Assembly 21.9678.0110 Rev F Refer to Figure 3-19 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 3-19: Zoom Box Assembly 02.96 78.001 0 F...
Page 41: Group 1 Lens Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Group 1 Lens Assembly 22.9678.1181 Rev A (Formerly 22.9678.0181) Refer to Figure 3-20 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 42: Group 2 Lens Assembly
SSEMBLY ROUP SSEMBLY Group 2 Lens Assembly 22.9678.0182 Rev A Refer to Figure 3-21 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 3-21: Group 2 Lens Assembly 02.96 78.001 0 F...
Page 43: Group 3 Lens Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Group 3 Lens Assembly 22.9678.0183 Rev 0 Refer to Figure 3-22 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...
Page 44: Group 4 Lens Assembly
SSEMBLY ROUP SSEMBLY Group 4 Lens Assembly 22.9678.0199 Rev 0 Refer to Figure 3-23 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 45: Right Edge Bearing Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Right Edge Bearing Assembly 22.9678.1103 Rev C Refer to Figure 3-24 Item Qty. Description 12.9678.1102 EDGE BEARING, MACHINED CASTING RIGHT 54.2056.0001 RING, RETAINING EXTERNAL 19MM 55.6776.0010 LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE (x4) (x2) Figure 3-24: Right Edge Bearing Assembly...
Page 46: Left Edge Bearing Assembly
SSEMBLY EARING SSEMBLY Left Edge Bearing Assembly 22.9678.1105 Rev C Refer to Figure 3-25 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/PHENOLIC CAGE (x4) (x2) Figure 3-25: Left Edge Bearing Assembly 02.96 78.001 0 F...
Page 47: Zoom Cam Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Zoom Cam Assembly 22.9678.1106 Rev B Refer to Figure 3-26 Item Qty. Description 10.9678.1107 ZOOM TIMING CAM 10.9678.1108 PULLEY FLANGE 10.9678.1118 TIMING PULLEY, ZOOM 53.6613.0008 SCREW, 6-32 X 1/2" PPZ (changed 11-08-04) 54.1259.0004 BEARING, RADIAL FLANGED .25"ID .625"OD (changed 06-25-03) 55.6763.0500...
Page 48: Zoom Motor Tensioning Assembly
SSEMBLY OTOR ENSIONING SSEMBLY Zoom Motor Tensioning Assembly 22.9678.1113 Rev B Refer to Figure 3-27 Item Qty. Description 10.9678.0338 PULLEY, ZOOM MOTOR (changed 03-07-06) 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 49: Interconnect Light Shield Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Interconnect Light Shield Assembly 22.9678.1115 Rev D Refer to Figure 3-28 Item Qty. Description 10.9678.1114 SHIELD, INTERCONNECT MOUNT/LIGHT 24.9678.3116 PCB ASSY, ZOOM INTERCONNECT (changed 03-07-06) 53.6558.0009 SCREW, 6-32 X 3/8" PPZ SEMS (x4) Figure 3-28: Interconnect Light Shield Assembly 02.96 78.001 0 F...
Page 50: Rod Clamp Assembly
SSEMBLY LAMP SSEMBLY Rod Clamp Assembly 22.9678.0149 Rev B Refer to Figure 3-29 Item Qty. Description 10.9678.0151 CLAMP, OPTIC ROD CAST 53.2008.0006 SPRING CLIP, 6-32 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 (x2) (x2) (x2)
Page 51: Color/Dimmer/Strobe Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Color/Dimmer/Strobe Assembly 22.9678.0402 Rev M 22.9678.0462 Rev D (VL3000Q) Refer to Figure 3-30 Item Qty. Description 10.9678.0324 PULLEY, FIXED COLOR WHEEL 10.9678.0337 DRIVE PULLEY, FIXED COLOR WHEEL (changed 03-09-06) 10.9678.0456 SHAFT, COLOR WHEEL 10.9678.0457.07...
Page 52 SSEMBLY OLOR IMMER TROBE SSEMBLY Item Qty. Description 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE PO 53.5638.0252 SCREW, 6-32 X 1/4"LG PFS UNDERCUT HEAD 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 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 URETHANE/KEVLAR 54.2059.0001...
Page 53 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Color/Dimmer/Strobe Assembly (continued) (x4) (x5) Dimmer (x10) Yellow (x4) (x4) Cyan (x2) (x2) Magenta (x2) (x2) (x2) (x2) (x4) (x5) (x5) (x1) (x2) (x5) (x5) (x12) (x5) Figure 3-30: Color/Dimmer/Strobe Assembly 02.96 78.001 0 F...
Page 54: Motor/Adapter Plate Assembly
SSEMBLY OTOR DAPTER LATE SSEMBLY Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Refer to Figure 3-31 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 3-31: Motor/Adapter Plate Assembly 02.96 78.001 0 F...
Page 55: Fixed Color Wheel Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Fixed Color Wheel Assembly 21.9678.0334 Rev D Refer to Figure 3-32 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 56 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 3-32: Fixed Color Wheel Assembly 02.96 78.001 0 F...
Page 57: Strobe Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Strobe Assembly 22.9678.0403 Rev F Refer to Figure 3-33 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 58: Strobe Assembly (Vl3000 Quiet)
(VL3000 Q SSEMBLY TROBE SSEMBLY UIET Strobe Assembly (VL3000 Quiet) 22.9678.0463 Rev B Refer to Figure 3-33 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE 10.9678.0465 STROBE BULKHEAD 22.9678.0467 ASSEMBLY, RIGHT STROBE BLADE 22.9678.0468 ASSEMBLY, LEFT STROBE BLADE 23.9678.0499 ASSEMBLY, STROBE MOTOR, VL3000Q 53.6520.0001 SCREW, #4-40 X 3/8 PPZ 53.6609.0500...
Page 59: Right Strobe Blade Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Right Strobe Blade Assembly 22.9678.0467 Rev C Refer to Figure 3-35 Item Qty. Description 10.9678.0464 STROBE BLADE (changed 07-29-04) 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 60: Left Strobe Blade Assembly
SSEMBLY TROBE LADE SSEMBLY Left Strobe Blade Assembly 22.9678.0468 Rev C Refer to Figure 3-36 Item Qty. Description 10.9678.0464 STROBE BLADE (changed 07-29-04) 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 61: Vl3000Q Strobe Motor Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ VL3000Q Strobe Motor Assembly 23.9678.0499 Rev A Refer to Figure 3-37 Item Qty. Description 44.5035.0001 STEPPER MOTOR, 2 PHASE, PK 52.6524.0004 CONNECTOR, HOUSING, 4 POS RECEPT 52.8346.0001 CONTACT, 24-30 AWG FEMALE CRIMP 55.2200.0003 0.25 HEATSHRINK, 3/16"...
Page 62: Dimmer Wheel Assembly
SSEMBLY IMMER HEEL SSEMBLY Dimmer Wheel Assembly 22.9678.0435 Rev D Refer to Figure 3-38 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 3-38: Dimmer Wheel Assembly 02.96 78.001 0 F...
Page 63: Cyan Wheel Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Cyan Wheel Assembly 22.9678.0472 Rev C Refer to Figure 3-39 Item Qty. Description 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0471 GLASS, CYAN COLOR WHEEL Painted Timing Mark (Dichroic Coated Side Only) Dichroic Coated Side Figure 3-39: Cyan Wheel Assembly 02.96 78.001 0 F...
Page 64: Yellow Wheel Assembly
SSEMBLY ELLOW HEEL SSEMBLY Yellow Wheel Assembly 22.9678.0474 Rev B Refer to Figure 3-40 Item Qty. Description 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0473 GLASS, YELLOW COLOR WHEEL Painted Timing Mark (Dichroic Coated Side Only) Dichroic Coated Side Figure 3-40: Yellow Wheel Assembly 02.96 78.001 0 F...
Page 65: Magenta Wheel Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Magenta Wheel Assembly 22.9678.0476 Rev B Refer to Figure 3-41 Item Qty. Description 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0475 GLASS, MAGENTA COLOR WHEEL Painted Timing Mark (Dichroic Coated Side Only) Dichroic Coated Side Figure 3-41: Magenta Wheel Assembly 02.96 78.001 0 F...
Page 66: Cto Wheel Assembly
: CTO W SSEMBLY HEEL SSEMBLY CTO Wheel Assembly 22.9678.0478 Rev B Refer to Figure 3-42 Item Qty. Description 22.9678.0420 PULLEY ASSY, WITH BEARING 41.9678.0477 GLASS, COATED CTO Painted Timing Mark (Dichroic Coated Side Only) Dichroic Coated Side Figure 3-42: CTO Wheel Assembly 02.96 78.001 0 F...
Page 67: Gobo Clamp Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Gobo Clamp Assembly 22.9678.0693 Rev A Refer to Figure 3-43 Item Qty. Description 12.9678.0691 GOBO CLAMP 53.6685.0625 SCREW, CAPTIVE PANEL, 6-32 X 0.625"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 68: Color Clamp Assembly
SSEMBLY OLOR LAMP SSEMBLY Color Clamp Assembly 22.9678.0694 Rev A Refer to Figure 3-44 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 3-44: Color Clamp Assembly...
Page 69: Edge Lead Screw Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Edge Lead Screw Assembly 22.9678.1126 Rev B Refer to Figure 3-45 Item Qty. Description 10.9678.1119 LEAD SCREW, EDGE 55..6616.0007 STANDOFF, 3/8" HEX THRD 0.562" LG Figure 3-45: Edge Lead Screw Assembly 02.96 78.001 0 F...
Page 70: Beam Spreader Assembly
SSEMBLY PREADER SSEMBLY Beam Spreader Assembly 21.9678.0910 Rev A (Wash Only) Refer to Figure 3-46 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 24.9678.3916 PCB ASSY, ZOOM INTERCONNECT WASH 53.6520.0375 SCREW, 4-40 X 3/8"...
Page 71: Stationary Concave Lens Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Stationary Concave Lens Assembly 21.9678.0920 Rev A (Wash Only) Refer to Figure 3-47 Item Qty. Description 10.9678.0927 BEARING SHAFT, BEAM SPREADER 10.9678.0928 LENS CLAMP, BEAM SPREADER 12.9678.0168 MASKED, CONCAVE LENS ARRAY MEDIUM 12.9678.0925 CONCAVE LENS MOUNT, MACHINED 42.9678.1169...
Page 72: Translating Convex Lens Assembly
SSEMBLY RANSLATING ONVEX SSEMBLY Translating Convex Lens Assembly 21.9678.0930 Rev B (Wash Only) Refer to Figure 3-48 Item Qty. Description 10.9678.0936 STOP, BEAM SPREADER 10.9678.0938 LENS CLAMP, CONVEX 12.9678.0166 MASKED, CONVEX LENS ARRAY MEDIUM 12.9678.0939 CONVEX LENS MOUNT, MACHINED, ADJUSTABLE 53.6515.0375 SCREW, 10-32 X 3/8"...
Page 73: Condenser Lens Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Condenser Lens Assembly 21.9678.0940 Rev C (Wash Only) Refer to Figure 3-49 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...
Page 74: Aperture Bulkhead Assembly
SSEMBLY PERTURE ULKHEAD SSEMBLY Aperture Bulkhead Assembly 21.9678.0950 Rev B (Wash Only) Refer to Figure 3-50 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 75: 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 3-51 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 3-51: Beam Spreader Light Baffle Assembly...
Page 76: Yoke Assembly
SSEMBLY SSEMBLY Yoke Assembly Yoke Assembly 21.9678.0700 Rev J 21.9678.0701 Rev B (VL3000 Quiet) Refer to Figure 3-52 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 22.9678.0609 ASSY, YOKE FAN, VL3000 QUIET 22.9686.0705 ASSY, YOKE STRUCTURE 23.9650.3327...
Page 77 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 3-52: Yoke Assembly 02.96 78.001 0 F...
Page 78: Tilt Motor Assembly
SSEMBLY OTOR SSEMBLY Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-53 Item Qty. Description 10.9678.0763 PLATE, TILT MOTOR MOUNT 21.9678.0708 ASSY, DRIVE PULLEY - 10.9678.8720 CODEWHEEL, 120 COUNT LARGE ID (changed 10-05-06) - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 SCREW, 8-32 X 1/4"...
Page 79: Relay Electrical Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Relay Electrical Assembly 23.9650.3327 Rev B Refer to Figure 3-54 Item Qty. Description 04.9650.0044 LABEL, RELAY WIRING -VL7 52.8271.0005 RECEPT, FASTON 1/4" 16-14 AWG INSULATED 66.4510.0002 RELAY, 20A 250VAC DPDT UL/CSA 82.4307.4002 DIODE, 1N4002 RECTIFIER 100V 1A Figure 3-54: Relay Electrical Assembly...
Page 80: Yoke Fan Assembly
SSEMBLY SSEMBLY Yoke Fan Assembly 22.9661.0609 Rev C 22.9678.0609 Rev A (VL3000 Quiet) Refer to Figure 3-55 Item Qty. Description 10.9661.0646 FAN TRAY 40.7113.0001 FAN, +24V 80 X 80 X 25MM, 32CFM 53.2200.0006 NUT, 6-32 KEPS SS 55.2179.0003 CABLE SADDLE, .75 X .75 4WAY, VL3000 QUIET (NOT SHOWN) 55.2186.0001 CABLE TIE, .10 WD X 4"...
Page 81 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Notes 02.96 78.001 0 F...
Page 82: Head/Yoke Pcb Assemblies
PCB A PCB #1 M SSEMBLIES OLOR ENSOR OUNT SSEMBLY Head/Yoke PCB Assemblies Color Sensor PCB #1 Mount Assembly 22.9678.0481 Rev B Refer to Figure 3-56 Item Qty. Description 10.9678.0482 PCB MOUNT, COLOR SENSOR #1 24.9678.3480 PCB ASSY, VL3000 COLOR SENSOR #1 - 17.9678.3480 PCB, COLOR SENSOR #1 - 52.6447.0012...
Page 83 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Color Sense PCB #2 Mount Assembly 22.9678.0489 Rev B Refer to Figure 3-57 Item Qty. Description 10.9678.0452 PCB MOUNT, COLOR SENSE #2 24.9678.3454 PCB ASSY, COLOR SENSOR #2 - 11.9678.0454 PCB, COLOR SENSOR #2 - 52.6447.0010 HEADER, SHROUDED 5 POSITION...
Page 84: Solid State Ignitor Pcb
PCB A SSEMBLIES OLID TATE GNITOR Solid State Ignitor PCB 24.9661.3126 Rev 0 Refer to Figure 3-58 Ref. Item Qty. Description 11.9661.1126 PCB, SOLID STATE IGNITOR J1, J2, J3, 52.8218.0003 TERM, PC, 6-32 SCREW 53.6690.0001 SCREW, 6-32 X 1/4" PPMS NICKELP 60.1232.6493 RES, 1/4W 1% 6.49 K MF 60.1443.1007...
Page 85 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Solid State Ignitor PCB (continued) Figure 3-58: Solid State Ignitor PCB 02.96 78.001 0 F...
Page 86: Wheel Position Sensor Pcb Assembly
PCB A PCB A SSEMBLIES HEEL OSITION ENSOR SSEMBLY Wheel Position Sensor PCB Assembly 24.9678.3240 Rev 0 Refer to Figure 3-59 Item Qty. Description 17.9678.3240 PCB, WHEEL POSITION SENSOR 52.6447.0008 HEADER, SHROUDED 3 POSITION Figure 3-59: Wheel Position Sensor PCB Assembly 02.96 78.001 0 F...
Page 87: Vl3000 Controller Pcb
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ VL3000 Controller PCB 24.9678.3730 Rev 0 This item is only available as an assembly. Figure 3-60: VL3000 Controller PCB 02.96 78.001 0 F...
Page 88: Wash Zoom Interconnect Pcb Assembly
PCB A PCB A SSEMBLIES NTERCONNECT SSEMBLY Wash Zoom Interconnect PCB Assembly 24.9678.3916 Rev 0 (Wash Only) Refer to Figure 3-61 Ref. Item Qty. Description 11.9678.1116 PCB ZOOM INTERCONNECT 52.6259.0008 HDR 4POS NT\MTA100 SD RT ANG 52.6260.0015 HEADER, 2POS MTA-100 SHROUDED 52.6447.0009 HEADER, SHROUDED 4 POSITION 52.6598.0029...
Page 89: Arc Zoom Interconnect Pcb Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Arc Zoom Interconnect PCB Assembly 24.9678.3116 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 52.6259.0008 HDR 4POS NT\MTA100 SD RT ANG 52.6260.0015...
Page 90 PCB A PCB A SSEMBLIES NTERCONNECT SSEMBLY Zoom Interconnect PCB Assembly (continued) Figure 3-62: Arc Zoom Interconnect PCB Assembly 02.96 78.001 0 F...
Page 91: Zoom Sensor (Target) Pcb Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Zoom Sensor (Target) PCB Assembly 24.9678.3112 Rev 0 Refer to Figure 3-63 Ref. Item Qty. Description 11.9678.0112 PCB, VL3000 ZOOM SENSOR 52.6447.0008 HEADER, SHROUDED 3 POSITION 86.7002.0005 SWITCH, SLOTTED OPTICAL OPB610 6/16/03 c 2003 Figure 3-63: Zoom Sensor PCB Assembly...
Page 92: Index Sensor Pcb Assembly
PCB A PCB A SSEMBLIES NDEX ENSOR SSEMBLY Index Sensor PCB Assembly 24.9663.3231 Rev 0 Refer to Figure 3-64 Item Qty. Description Ref. 11.9663.1231 PCB, INDEX SENSOR 52.6447.0009 HEADER, SHROUDED 4 POSITION 86.7002.0005 SWITCH, SLOTTED OPTICAL OPB6 SOLDER SIDE VIEWED FROM SENSOR SIDE Figure 3-64: Index Sensor PCB Assembly 02.96 78.001 0 F...
Page 93 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Notes 02.96 78.001 0 F...
Page 94: Upper Enclosure Assembly
NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Enclosure Assembly Upper Enclosure Assembly 21.9678.0800.01 Rev NN 21.9678.0801.01 Rev Y (VL3000 Quiet) 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. 04.9678.0040.01 LABEL, VL3000 COMPLIANCE 04.9678.0045 LABEL, VL3000 QUIET COMPLIANCE...
Page 95 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Item Qty. Description 21.9678.0864 ASSY, PAN MOTOR 21.9678.0881 ASSY, PAN TUBE 22.9678.0851 ASSY, UPPER ENCLOSURE 23.9678.0686 FAN ASSY, UPPER ENCLOSURE 23.9678.0888 FAN ASSY, UPPER ENCLOSURE, SLOW, VL3000 QUIET 23.9678.0687 ELEC ASSY, PAN EOT SENSOR 25.9661.1514 CABLE ASSY, LVS CHASSIS GND (not shown)
Page 96 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Item Qty. Description 53.6626.0001 SCREW, 10-32 X 1/2" PPZ 53.6634.1000 SCREW, 3/8-16 X 1.00" LG SOC 53.6653.0502 SCREW, 1/4-20 X 1/2"LG SOC ( NOT USED ON VL3000Q 54.1206.0014 RING, RETAINING 54.1255.0001 BEARING ASSY, BLACK FLUSH MOU 54.2055.0001 BELT, TIMING S2M 210GROOVE 9MM 55.2150.0003...
Page 97 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Upper Enclosure Assembly (continued) (x2) (x4) (x2) (x2) (x4) (x2) (x4) (x4) (x4) Figure 3-65: Upper Enclosure Assembly Part 1 02.96 78.001 0 F...
Page 98 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly (continued) Run Lamp Wires Through Ferrite (x3) 55, 69 (x2) 73, 4 (x4) (x4) (x4) (x2) (x2) 10, 55 (x2) (x2) (x2) (x2) (x2) 45, 58 Part is shown exploded for clarity Electronics (x2) (x4)
Page 99: Ventilation Cover Assembly - Standard
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Ventilation Cover Assembly - Standard 21.9661.1254 Rev C Refer to Figure 3-67 Item Qty. Description 10.9661.1249 POST, TRUSS HOOK 10.9661.1350 COVER, VENTILATION 10.9678.0893 12" AIR SEAL, UPPER ENCLOSURE (changed 05-11-05) 10.9678.0894 6"...
Page 100: Ventilation Cover Assembly - Vl3000 Quiet
- VL3000 Q NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY UIET Ventilation Cover Assembly - VL3000 Quiet 21.9686.0840.02 Rev B Refer to Figure 3-67 Item Qty. Description 10.9686.1249 POST, TRUSS HOOK 10.9678.0850 POST, TRUSS HOOK, SHORT, EARLY PRODUCTION 10.9678.0833 SPACER, 1.25 " 10.9686.0883 COVER, VENTILATION 10.9678.0837...
Page 101 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Ventilation Cover Assembly - VL3000 Quiet (continued) (x2) (x4) (x4) (x4) (x4) (x4) Early production (x4) Current Figure 3-68: Ventilation Cover Assembly 02.96 78.001 0 F...
Page 102: Panel Assembly
NCLOSURE SSEMBLY ANEL SSEMBLY Panel Assembly 21.9678.0805 Rev L Refer to Figure 3-69 Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY (changed 01-06-04) 10.9678.0859 BRACKET, INPUT 10.9678.0872 STIFFENER, DISPLAY BOARD (added 05-26-05) 24.9663.3830 PCB ASSY, DMX INPUT (changed 07-01-06) 24.9678.3825 PCB ASSY, DISPLAY (changed 07-01-06) 25.9678.0810 CABLE ASSY, AC INPUT PIGTAIL (changed 04-28-05) 51-0541...
Page 103: Dmx Input Pcb
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ DMX Input PCB 24.9663.3830 Rev B Refer to Figure 3-70 Item Qty. Description Ref. 11.9663.1830 PCB FAB, DMX INPUT 52.6259.0006 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0006 CONN, RECPT XLR 5P FEM PC MT VERT 52.6626.0006 CONN, RECPT XLR 5P MALE PC MT VERT 62.3017.0102...
Page 104: Display Pcb
NCLOSURE SSEMBLY ISPLAY Display PCB 24.9678.3825 Rev A Refer to Figure 3-71 Ref. Item Qty. Description 11.9678.2825 PCB BOARD, VL3000 DISPLAY 40-0968 HEADER, 20 POS SAMTEC MTLW .1 LS 52.6365.0012 HEADER, 6POS MTA100 SHROUDED R/A 53.6659.0003 SCREW, 2-56 X 3/8" PPZ 55.3500.0001 WASHER, #2 FLAT 0.312"OD FIBER 55.6821.0002...
Page 105 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Display PCB (continued) Top Side Bottom Side View From Component Side Figure 3-71: Display PCB 02.96 78.001 0 F...
Page 106: Ac Input Pigtail Cable Assembly
: AC I NCLOSURE SSEMBLY NPUT IGTAIL ABLE SSEMBLY AC Input Pigtail Cable Assembly 25.9678.0810 Rev B 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 52.8298.1160...
Page 107: Pan Pulley Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Pan Pulley Assembly 21.9678.0807 Rev E Refer to Figure 3-73 Item Qty. Description 10.9678.0750 TIMING PULLEY, 2MM GT 150 TOOTH 10.9678.0855 PAN FLAG 53.6530.0009 RIVET, 1/8"OD POP 0.126-0.187GL (changed 10-05-06) (x2) Figure 3-73: Pan Pulley Assembly 02.96 78.001 0 F...
Page 108: Pan Motor Assembly
NCLOSURE SSEMBLY OTOR SSEMBLY Pan Motor Assembly 21.9678.0864 Rev E 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 SCREW, 8-32 X 1/4"...
Page 109: Pan Tube Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Pan Tube Assembly 21.9678.0881 Rev 0 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 12.9678.0877 PAN TUBE, MACHINED 54.1206.0021 RING, RETAINING 1.562"SHAFT 1.468"GRV DIA .068"GRVWD EXTERNAL...
Page 110: Cable Assemblies
EOT S ABLE SSEMBLIES ENSOR LECTRICAL SSEMBLY Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-76 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 3-76: Pan EOT Sensor Electrical Assembly 02.96 78.001 0 F...
Page 111: 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 3-77 Item Qty. Description 52.8231.0005 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 3-77: LVS Chassis Ground Cable Assembly...
Page 112: Chassis To Yoke Ground Cable Assembly
ABLE SSEMBLIES HASSIS ROUND ABLE SSEMBLY Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-78 Item Qty. Description 52.8250.0006 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22 AWG 300V 200C TEF GRN/YEL UL1180 (7 x 26.0" LG) (x2) Figure 3-78: Chassis To Yoke Ground Cable Assembly 02.96 78.001 0 F...
Page 113: 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 3-79. Item Qty. Description 52.8311.0003 TERM, RING #6 14-16 AWG NON-INS. TAPE 73.7130.0001 1.33 WIRE, 7/64" TUBULAR BRAID TINNED COPPER (x2) Figure 3-79: Head to Back Cap Ground Cable Assembly 02.96 78.001 0 F...
Page 114: Relay To Ignitor Cable Assembly
ABLE SSEMBLIES ELAY TO GNITOR ABLE SSEMBLY Relay to Ignitor Cable Assembly 25.9661.1526 Rev C Refer to Figure 3-80. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG (changed 03-23-06) 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009 0.42 WIRE, 14 AWG 15KV 150C SILICONE 41/30 STRANDING...
Page 115: Yoke To Ac Fan Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Yoke to AC Fan Cable Assembly 25.9678.0012 Rev A Refer to Figure 3-81 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 116: 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 B Refer to Figure 3-82 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 3-82: Backcap Interlok to Gobo Fan Interlok Cable Assembly 02.96 78.001 0 F...
Page 117: Air Duct Ot Switch Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Air Duct OT Switch Cable Assembly 25.9678.0690 Rev 0 (VL3000Q) 25.9678.0691 Rev 0 Refer to Figure 3-83 Item Qty. Description 52.8414.0001 RECEPT, FASTON .187 SERIES, 24-20AWG UNISUL 52.8237.0002 TERM, RING #4 24-20AWG 73.7089.0000 1.48 WIRE, 22AWG BLK 300V 200C TEFLON STRANDED...
Page 118: Relay To Gobo Fan Interlock Cable Assembly
ABLE SSEMBLIES ELAY TO NTERLOCK ABLE SSEMBLY Relay to Gobo Fan Interlock Cable Assembly 25.9678.0675 Rev B Refer to Figure 3-84. Item Qty. Description 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG (TAPE MOUNT) 52.8414.0001 RECEPT, FASTON 0.187 SERIES 24-20 AWG UNINSUL 73.7089.0000 2.00 WIRE.
Page 119: Front Head Fans Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Front Head Fans Cable Assembly 25.9678.0677 Rev B Refer to Figure 3-85 Item Qty. Description 52.6396.3104 RECEPT, 4POS MTA100 W/POL TAB BLU CLSD END (changed 05-03-06) 52.6524.0002 CONN, HOUSING 2POS RECEPTACLE 52.8346.0001 CONTACT, 24-30AWG FEMALE CRIMP 73.5126.0002...
Page 120: Yoke Fan And Relay Cable Assembly
ABLE SSEMBLIES AN AND ELAY ABLE SSEMBLY Yoke Fan and Relay Cable Assembly 25.9678.0681 Rev C Refer to Figure 3-86 Item Qty. Description 52.6396.3103 RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END (changed 05-01-06) 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003 RECEPT, 1/4"...
Page 121: Yoke Fan And Relay Cable Assembly - Vl3000Q
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Yoke Fan and Relay Cable Assembly - VL3000Q 25.9678.0781 Rev A Refer to Figure 3-86 Item Qty. Description 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG 52.6396.3103 RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END 55.2186.0001...
Page 122: 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 C Refer to Figure 3-88 Item Qty. Description 52.8371.0001 RECEPT, FASTON 24-20AWG UNISUL TIN PLT BRS .250 X .032 TAB 52.8414.0001 RECEPT, FASTON, 0.187 SERIES 24-20 AWG UNISUL 73.7089.0000 0.79 WIRE, 22AWG 300V 200C TEF BLK UL1180...
Page 123: Ignitor To Lamp Socket Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-89. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8274.1614 CONN, BUTT SPLICE, 16-14 PIDG 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL 55.2200.0003...
Page 124: 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 3-90 Item Qty. Description 52.8250.0011 TERM, RING #10, 122-10AWG (REEL) 73.7089.0010 15.17 WIRE, 22AWG , 19X34 MIL-16878/4 TYPE E (changed 08-31-06) (7 x 26.0"...
Page 125: Head Controller Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Head Controller Cable Assembly 25.9678.0715 Rev C Refer to Figure 3-91 Item Qty. Description 52.6224.1014 COVER, FRONT 14 POS MT LATCHING 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.1050 COVER, FRONT 50 POS MT LATCHING 52.6224.2014 COVER, BACK 14 POS MT...
Page 126 ABLE SSEMBLIES ONTROLLER ABLE SSEMBLY Head Controller Cable Assembly (continued) 9, 2, 5 9, 2, 5 7, 1, 4 7, 1, 4 (x11) 8, 3, 6 8, 3, 6 Figure 3-91: Head Controller Cable Assembly 02.96 78.001 0 F...
Page 127: Color Interconnect Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Color Interconnect Cable Assembly 25.9678.1409 Rev 0 25.9678.1419 Rev 0 (VL3000 Quiet) Refer to Figure 3-92 Must be ordered as an assembly. 9, 2, 5 7, 1, 4 7, 1, 4 (x11) Figure 3-92: Color Interconnect Cable Assembly 02.96 78.001 0 F...
Page 128: Gobo Interconnect Pcb/Cable Assembly
PCB/C ABLE SSEMBLIES NTERCONNECT ABLE SSEMBLY Gobo Interconnect PCB/Cable Assembly 25.9678.2209 Rev 0 Refer to Figure 3-93. Must be ordered as an assembly. Figure 3-93: Gobo Interconnect PCB/Cable Assembly 02.96 78.001 0 F...
Page 129: Yoke Fan Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Yoke Fan Cable Assembly 25.9678.0758 Rev A Refer to Figure 3-94 Item Qty. Description 52.6396.3102 RECEPT, 2 POS MTA100 W/POL TAB BLUE CLSD END (changed 05-02-06) 52.6423.0003 HOUSING, 3POS MT RECEPT, 2MM CT 28-26 AWG 73.5126.0002 0.50 WIRE, 26AWG 2COND 300V 80C <BLK-RED>...
Page 130: Yoke Fan Cable Assembly - Vl3000Q
- VL3000Q ABLE SSEMBLIES ABLE SSEMBLY Yoke Fan Cable Assembly - VL3000Q 25.9678.0759 Rev A Refer to Figure 3-94 Item Qty. Description 52.6396.3102 RECEPT, 2 POS MTA100 W/POL TAB BLUE CLSD END 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM CT 28-26 AWG 55.2186.0001 CABLE TIE, .10 X 4"...
Page 131: 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 C Refer to Figure 3-96 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, 0.10"...
Page 132: Ac Input Splitter Cable Assembly
: AC I ABLE SSEMBLIES NPUT PLITTER ABLE SSEMBLY AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-97 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 0.187"X0.32"...
Page 133 VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 (x3) Figure 3-97: AC Input Splitter Cable Assembly 02.96 78.001 0 F...
Page 134: Data I/O Link Cable Assembly
I/O L ABLE SSEMBLIES ABLE SSEMBLY Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-98 Item Qty. Description 52.6396.2904 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END (changed 05-03-06) 52.6396.2905 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END (changed 05-03-06) 73.5122.0259 2.17 CBL, 22AWG STRND 4COND PVC INSUL...
Page 135: Display Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Display Cable Assembly 25.9678.1825 Rev E Refer to Figure 3-99 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 55.2186.0001 CABLE TIE, 0.10" WD 4" LG SMALL 55.6621.0001 SLEEVE, NYLON THIN WALL #6 SCR 1.0"...
Page 136: Ballast To Controller Cable Assembly
ABLE SSEMBLIES ALLAST TO ONTROLLER ABLE SSEMBLY Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-100 Item Qty. Description 52.6396.3002 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 52.6396.3005 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 52.6396.3008 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 73.5124.1289...
Page 137: Dc Output Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-101 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) 52.8323.0002 CONTACT, CRIMP, 18-22 AWG SL-156 (changed 05-03-06) 52.8274.1614...
Page 138: Pan/Tilt Control Cable Assembly
ABLE SSEMBLIES ONTROL ABLE SSEMBLY Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-102 Item Qty. Description 52.6610.0008 CONN, HOUSING, 20 POS DBL ROW UNLOADED (changed 05-03-06) 52.6224.1020 COVER, FRONT 20 POS MT LATCHING 52.6224.2020 COVER, BACK 20 POS MT 52.6524.0005 CONN, HOUSING 5 POS RECEPTACLE 52.6588.0007...
Page 139: Lamp Supply To Relay Cable Assembly
VARI LITE - VL3000™ S ERIES UMINAIRE ERVICE ANUAL ® ❋ Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-103 Item Qty. Description 52.8245.0001 TERM, RING #10 16 - 14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 55.2183.0001 0.33 HEATSHRINK, 1/2"...
Page 140: 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 A Refer to Figure 3-104 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, 0.10"...

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