Vari Lite VL3500 Service Manual
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Vari Lite VL3500 Service Manual

Wash luminaire
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VL3500
Wash Luminaire
™
02.9686.0010

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Summary of Contents for Vari Lite VL3500

  • Page 1: Vl3500 Wash Luminaire

    VL3500 Wash Luminaire ™ 02.9686.0010...
  • Page 2 Genlyte Thomas Group LLC and is registered in the United States and other countries. ™ ™ VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, VL3500™, Series 1000 , Series 2000 ™ ™...
  • 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), +1-214-647-7880, or customerservice@genlyte.com and request a Return Material Authorization (RMA) for warranty service.
  • Page 4 ❋ VARI LITE® - VL3500™ W 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

    FOUND BELOW. WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1. VARI❋LITE ® luminaires have been designed for use with specific lamp types. The VL3500™ Wash Luminaire requires the Osram SharXS ® ® 1500 W/D7/60 . Installing another type of lamp may be hazardous.
  • Page 6 ❋ VARI LITE® - VL3500™ W 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® - VL3500™ W 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...
  • 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® - VL3500™ W 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.
  • 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® - VL3500™ W 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.
  • Page 13 OREWORD 02.96 86.001 0 0...
  • Page 14 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 0 2.9686 .0 010 0...

  • Page 15: Table Of Contents

    Features Standard Features........................4 Specific Features........................4 Technical Specifications......................4 Components External Luminaire Components....................5 VL3500 Wash Luminaire Head and Yoke Components ............6 Enclosure Components ......................7 Chapter 2. Maintenance Testing Luminaire Self-Tests ....................... 10 Calibration Sequence ....................... 10 Auto Recalibration........................
  • Page 16 Tilt EOT Sensor Replacement ....................47 Chapter 3. Illustrated Parts Breakdown Drawing Trees VL3500™ Wash Luminaire ....................50 Top Assembly VL3500 Wash Included Items Kit................... 52 VL3500™ Wash Luminaire ....................54 Generic Luminaire Assembly ....................56 Head Assembly Head Structure Assembly ......................59 Front Stippled Lens Assembly....................
  • Page 17 Color Sensor PCB Inline Assembly ..................99 Solid State Ignitor PCB ......................100 Wheel Position Sensor PCB Assembly ................. 101 Pan/Tilt Encoder PCB......................102 VL3500 Wash Controller PCB Assembly................103 Enclosure Assembly Upper Enclosure Assembly ....................105 Ventilation Cover Assembly....................111 Exhaust Fan Assembly ......................
  • Page 18 VL3500™ Wash Luminaire Technical Bulletins ..............157 Appendix B. Schematics and Wiring Diagrams Schematics and Diagrams List....................159 VL3500 Wash Wiring Diagram (Sheet 1 of 3)..............161 VL3500 Wash Wiring Diagram (Sheet 2 of 3)..............162 VL3500 Wash Wiring Diagram (Sheet 3 of 3)..............163 Solid State Ignitor PCB (Sheet 1 of 1)...................

  • Page 19: Introduction

    ANUAL Introduction About This Manual Note: The VL3500™ Wash Luminaires share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL3500™ Wash Luminaire. The manual is intended for use by Vari-Lite personnel and by Vari-Lite’s customers/clients.

  • Page 20: Customer Service

    ❋ VARI LITE® - VL3500™ W 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 21: Chapter 1. Description

    HAPTER Description This chapter contains descriptions of luminaire features and components. • Features • Components 02.96 86.001 0 0...

  • Page 22: Features

    • 1500W, double-ended, short arc lamp. • Five-position aperture wheel: 52, 40, 35, 30, and 25 mm. WARNING: Some exceptional conditions apply to the safe operation of the VL3500™ Wash Luminaire. See “Warnings and Cautions” on page Technical Specifications For technical specifications, refer to VL3500™ Wash Luminaire User’s Manual (02.9686.0001).

  • Page 23: Components

    OMPONENTS XTERNAL UMINAIRE OMPONENTS Components External Luminaire Components The following illustration shows the external luminaire components and controls. Head Assembly Houses color, strobe, and beam spreader mechanisms Front Lens Assembly AC Input Cable Input Panel Provides DMX In and Thru, and AC Power connections.

  • Page 24: Vl3500 Wash Luminaire Head And Yoke Components

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL VL3500 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 Color Assembly (attached by tether)

  • Page 25: Enclosure Components

    OMPONENTS NCLOSURE OMPONENTS 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 1500W Arc Ballast Module Input Panel Assembly containing DMX Input PCB and Menu Display 150W +24V/6.3A Power Supply...
  • Page 26 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 27: Chapter 2. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Warnings and Cautions • Troubleshooting • Maintenance Procedures WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should only be performed by a trained and qualified service technician or at an Authorized Vari-Lite Service facility.

  • Page 28: Testing

    Testing Luminaire Self-Tests The luminaire is capable of running self tests by using the TEST menu functions. For detailed instructions regarding the luminaire’s self-test function, refer to the VL3500™ Wash Luminaire User’s Manual (02.9686.0001). Calibration Sequence The following is an outline of the luminaire’s standard calibration sequence: Phase 1 •...

  • Page 29: Partial Recalibration

    Most mechanisms within the VL3500™ Wash Luminaire are equipped with either optical or magnetic sensors. The VL3500 Wash master control board (MCB) has labeled test points for reading DC voltages at each sensor. Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan/tilt encoder readings.
  • Page 30 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL standby circuit goes to standby when 5v is received on the standby line. Equally, if 5v is applied to the standby line, the lamp will go into standby mode, and if 5v is applied to the Out line, the lamp will douse.

  • Page 31: Warnings And Cautions Exceptional Safety Information For The Vl3500 Wash

    The warnings and cautions that follow are critically important to the safe operation of the VL3500 Wash. This product is for commercial use only. If you have any questions about the safe installation and operation of the VL3500™ Wash Luminaire, please contact VARI❋LITE customer service at 1-877-VARI-LITE (1-877-827-4548), +1-214-647-7880, or...

  • Page 32: Troubleshooting

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s), one at a time until the end of the list is reached.

  • Page 33: Troubleshooting Guide

    ROUBLESHOOTING ROUBLESHOOTING UIDE Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error Messages” on page 14 for more information. The chart below provides possible causes and remedies for each message. Table 2-2: Troubleshooting Guide Message Symptom...
  • Page 34 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Table 2-2: Troubleshooting Guide (Continued) Message Symptom Description Possible Cause and Remedy Pan No Luminaire will not pan Pan Sensor Not Found EOT flag attached to large pulley is not engaging the Sens EOT sensor...

  • Page 35: Maintenance Procedures Lamp Replacement

    AINTENANCE ROCEDURES EPLACEMENT Maintenance Procedures WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should only be performed by a trained and qualified service technician or at an Authorized Vari-Lite Service facility. Lamp Replacement VL Part No: 71.9686.1502 WARNING: Ensure that power is removed from luminaire when installing lamp.
  • Page 36 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Lamp (dimple side towards socket) Allow lamp to cool CAUTION: before servicing. Lamp Connector Do not touch lamp or CAUTION: reflector with bare fingers. Lamp Box * Luminaire Head Not Shown For Clarity Figure 2-1: Lamp Replacement 02 .9 686.00 10 0...

  • Page 37: Align Lamp

    Align Lamp The design of the VL3500 Wash luminaire optical system allows for a flat or peaked field. A flat field has no detectable hot spot. A peaked field has more intensity at the center of the beam than at the perimeter.

  • Page 38: Internal Lens Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Internal Lens Replacement Tools: • #2 Phillips screwdriver • Lint-Free Cotton Gloves To replace the internal lens assembly: Step 1. Using a control console, close the internal lens assembly. Move internal lens assembly to front of head (close to the front lens) WARNING: Remove power from luminaire before performing maintenance.

  • Page 39: Internal Lens Replacement (Continued)

    AINTENANCE ROCEDURES NTERNAL EPLACEMENT CONTINUED Internal Lens Replacement (continued) Clean any fingerprints on lenses with CAUTION: isopropyl alcohol and a lint-free cloth. Head Cover * Retaining Knobs 1/4-Turn Screw Internal Lens Assembly Detail A Lens Assembly Retaining Knobs Post Keyed Carrier * Head covers are attached by tethers.

  • Page 40: Front Lens Assembly Removal

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Lens Assembly Removal Tools: • 5/32" Allen wrench • lint-free cotton gloves To replace the front lens assembly: WARNING: Remove power from luminaire before performing maintenance. Internal fixture components, assemblies, and the front lens can be HOT after operation. Allow components to adequately cool before replacing.

  • Page 41: Front Lens Assembly Removal (Continued)

    AINTENANCE ROCEDURES RONT SSEMBLY EMOVAL CONTINUED Front Lens Assembly Removal (continued) Clean any fingerprints on lenses with CAUTION: isopropyl alcohol and a lint-free cloth. Front Lens Assembly Mounting Holes Front Lens Assembly Guide Pins Front Lens Assembly Captive Screws Lens is heavy. Horizontal orientation shown for clarity. If lens is removed as shown, head assembly will instantaneously rotate to page 22 CAUTION...

  • Page 42: Color Filter Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color Filter Replacement Tools: • #2 Philips screwdriver • lint-free cotton gloves WARNING: Remove power from luminaire before performing maintenance. Filters can be HOT after operation. Allow the fixture to cool before replacing filters.

  • Page 43: Color Filter Replacement (Continued)

    AINTENANCE ROCEDURES OLOR ILTER EPLACEMENT CONTINUED Color Filter Replacement (continued) Assembly With Color Wheels Do not touch filters with bare fingers. (Do not remove. See detail) CAUTION: Wear cotton gloves. Color Filter Lock Pins Air Duct Door Color Wheel 1 Color Filter Lock Pins Color Wheel 2...

  • Page 44: Ballast Assembly Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ballast Assembly Replacement 23.9686.1500 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. Step 2. As shown in Figure 2-6, at the upper enclosure, remove four 6-32 x 1/4"...
  • Page 45 AINTENANCE ROCEDURES ALLAST SSEMBLY EPLACEMENT Top Cover NOTE: Head not shown for clarity. Ballast Assembly (includes attached ferrite) Chassis ferrite (Do not remove) End Cover APS end bracket Exhaust fan Left Side Cover Ventilation Cover Figure 2-6: Ballast Assembly Replacement Step 14.

  • Page 46: Color/Dimmer/Strobe Assembly Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly Replacement 21.9686.0400 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. As shown in Figure 2-7, stand the luminaire on the upper enclosure. Use the orientation of the backcap label to determine the top and bottom of luminaire head.
  • Page 47 AINTENANCE ROCEDURES OLOR IMMER TROBE SSEMBLY EPLACEMENT Top Head Cover Screws Color/Dimmer/Strobe Assembly Figure 2-7: Color/Dimmer/Strobe Assembly Replacement 02.96 86.001 0 0...

  • Page 48: Split Lens Assembly Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Internal Lens Assembly Replacement 21.9686.2150 VL Part No: Repair Procedure Step 1. At the control console or the luminaire menu, close the split lens assembly. Step 2. Disconnect luminaire AC input cable from power source.
  • Page 49 AINTENANCE ROCEDURES NTERNAL SSEMBLY EPLACEMENT Interconnect Board Cable Saddle Internal Lens Assembly Figure 2-8: Internal Lens Assembly Replacement 02.96 86.001 0 0...

  • Page 50: Reflector Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Reflector Replacement 42.9686.0120 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove the Color/Dimmer/Strobe Assembly. See “Color/Dimmer/Strobe Assembly Replacement” on page 28 for complete instructions.
  • Page 51 AINTENANCE ROCEDURES EFLECTOR EPLACEMENT Disconnect Springs Reflector Clamp UV/Reflector Assembly 4-40 x 1 3/8" screws (4) Assembly Removal Spring not shown for clarity Reflector Alignment Figure 2-9: Reflector Replacement 02.96 86.001 0 0...

  • Page 52: Main Control Board (Mcb) Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Main Control Board (MCB) Replacement 24.9686.0429 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Note: To determine which yoke leg is which without having to remove the covers, rotate yoke counterclockwise until it stops, then look at the luminaire while facing the input panel.

  • Page 53: Ignitor Board Replacement

    AINTENANCE ROCEDURES GNITOR OARD EPLACEMENT Ignitor Board Replacement 24.9661.3126 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" screws. CAUTION: Always use anti-static precautions when working with PCBs.

  • Page 54: Pan Motor Assembly Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Motor Assembly Replacement 21.9686.0864 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. Step 2. As shown in Figure 2-6, at the upper enclosure, remove four 6-32 x 1/4"...
  • Page 55 AINTENANCE ROCEDURES OTOR SSEMBLY EPLACEMENT Note: Make sure wiring is not pinched during installation. When tightening four 10-32x3/4" SCB Cap screws that mount Pan Motor Assembly, you must tighten in a CLOCKWISE pattern starting with screw in lower left-hand side from spring. NOTE: Head not shown for clarity.

  • Page 56: Pan Encoder Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Encoder Replacement 24.9678.9729 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. CAUTION: During the next step, do allow the front lens to contact anything that could damage the lens coating.
  • Page 57 AINTENANCE ROCEDURES NCODER EPLACEMENT Note: Make sure the encoder disk is centered in the optical sensor gap. Ventilation Cover Encoder Pan Motor Assembly Figure 2-13: Pan Encoder Replacement 02.96 86.001 0 0...

  • Page 58: Pan Eot Sensor Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan EOT Sensor Replacement VL Part No: 23.9678.0687 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. CAUTION: During the next step, do allow the front lens to contact anything that could damage the lens coating.
  • Page 59 EOT S AINTENANCE ROCEDURES ENSOR EPLACEMENT Ventilation Cover Sensor Figure 2-14: Pan EOT Sensor Replacement 02.96 86.001 0 0...

  • Page 60: Power Supply (Lvs) Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Power Supply (LVS) Replacement VL Part No: 69.3177.0151 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-15, at the enclosure, remove two 6-32 x 1/4" LG PPZ screws from the display-side top cover and remove the cover.
  • Page 61 (LVS) R AINTENANCE ROCEDURES OWER UPPLY EPLACEMENT Display-Side Top Cover Power Supply (LVS) NOTE: Head not shown for clarity. Fan Assembly Figure 2-15: Power Supply (LVS) Replacement 02.96 86.001 0 0...

  • Page 62: Tilt Motor Assembly Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt Motor Assembly Replacement VL Part No: 21.9678.0765 Repair Procedure To remove and replace the tilt motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in...
  • Page 63 AINTENANCE ROCEDURES OTOR SSEMBLY EPLACEMENT WARNING: Make sure wiring is not pinched during installation. When tightening four 10-32 x 1/2" PPZ screws that fasten the tilt motor assembly, you must tighten then in a CLOCKWISE pattern starting with the screw in lower left-hand side. Yoke Cover Springs...

  • Page 64: Tilt Encoder Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt Encoder Replacement 24.9661.9629 VL Part No: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-16, at the tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16"...

  • Page 65: Tilt Eot Sensor Replacement

    EOT S AINTENANCE ROCEDURES ENSOR EPLACEMENT Tilt EOT Sensor Replacement VL Part No: 23.9661.1253 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" PPB screws. Step 3.
  • Page 66 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 67: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for the VL3500 Wash assemblies. Note: The VL3500 Series Luminiares share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. • Drawing Trees • Top Assembly • Yoke Assembly •...

  • Page 68: Drawing Trees

    Assembly Assembly 25.9678.0681 25.9661.1526 Yoke to Dual AC Fan Cable Ignitor to Relay Cable Assembly Assembly 25.9686.0012 25.9661.1526 Upper Enclosure Assembly 21.9686.0800 continued next page Figure 3-1: VL3500™ Wash Luminaire Subassembly Drawing Tree Part 1 02 .9 686.00 10 0...
  • Page 69 LVS Power Supply, 150W Assembly 69.3177.0151 25.9678.0829 AC Input Splitter Cable Assembly LVS to Yoke Dual AC Fan Cable 25.9678.0812 Assembly 25.9686.0843 LVS Chassis Ground Cable Assembly 25.9661.1514 Figure 3-2: VL3500™ Wash Luminaire Subassembly Drawing Tree Part 2 02.96 86.001 0 0...

  • Page 70: Top Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Top Assembly VL3500 Wash Included Items Kit 28.9686.0001 Rev A Refer to Figure 3-3. Item Qty. Description 02.8001.0001 SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY (09-09-02) ❋ 02.8001.0002 CERTIFICATE, VARI LITE QA 02.8700.0001...
  • Page 71 (Stippled PC lens is installed on luminaire.) (Buxom lenses are installed in luminaire) Figure 3-3: VL3500 Wash Included Items Kit Note: * = Do not handle lamp with bare hands. To keep the lamp glass as free from dirt and grease as possible, wear clean cotton gloves.

  • Page 72: Vl3500™ Wash Luminaire

    AC DANGER TAG, VL3500 (not shown) 04.9661.0033.01 LABEL, WARNING - 2000 SERIES (not shown) 04.9661.0039 LABEL, LINE CORD WARNING (not shown) 04.9686.0061 LABEL, AC INPUT RATING VL3500 WASH (not shown) 10.9686.0617 YOKE CROSSMEMBER, HEAT SHIELD 10.9686.0168 ZOOM MOUNTING BRACKET, LEFT 10.9686.0169 ZOOM MOUNTING BRACKET, RIGHT 10.9686.0732...

  • Page 73: Vl3500™ Wash Luminaire (Continued)

    : VL3500™ W SSEMBLY UMINAIRE VL3500™ Wash Luminaire (continued) (x2) (x2) (x4) (x4) (x10) (x8) Figure 3-4: VL3500™ Wash Luminaire 02.96 86.001 0 0...

  • Page 74: Generic Luminaire Assembly

    ANUAL Generic Luminaire Assembly 21.9686.0010 Rev C Refer to Figure 3-5 Item Qty. Description 21.9686.0600 ASSY, HEAD STRUCTURE, VL3500 WASH 21.9686.0700 ASSY, YOKE 21.9678.0707 ASSY, DRIVEN PULLEY - 10.9678.0750 TIMING PULLEY, 150 TOOTH - 10.9678.0754 FLAG, CENTER OF TRAVEL, TILT - 53.6530.0009...
  • Page 75 SSEMBLY ENERIC UMINAIRE SSEMBLY Generic Luminaire Assembly (continued) (x3) (x2) (x2) Detail A (x3) (x4) (x5) (x5) (x4) (x4) (x4) Detail A (x2) (x2) Figure 3-5: Generic Luminaire Assembly - VL3500 Wash 02.96 86.001 0 0...
  • Page 76 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 77: Head Assembly

    SSEMBLY TRUCTURE SSEMBLY Head Assembly Head Structure Assembly 21.9686.0600 Rev B Refer to Figure 3-1 Item Qty. Description 21.9686.0615 ASSY, BACKEND 12.9686.0623 RIGHT SIDE RAIL, MACHINED 12.9686.0625 LEFT SIDE RAIL, MACHINED 21.9686.0617 ASSEMBLY, FRONT CASTING/LENS 53.6515.0001 SCREW, 10-32 X 3/4" SCB CAP 10.9686.0619 RETAINER, WIRING HARNESS 53.6558.0007...

  • Page 78: Front Stippled Lens Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Stippled Lens Assembly 21.9686.0617 Rev B Refer to Figure 3-2 Item Qty. Description 12.9686.0627 CASTING, CONVEX LENS 42.9686.0101 LENS, ASPHERIC PLANO CONVEX STIPPLED 10.9686.0641 CLIP, FRONT LENS 53.6685.1125 SCREW, CAPTIVE, SH CAP 10-32 1.125 LG BLK ZN 53.6598.0312...

  • Page 79: Front Clear Lens Assembly

    SSEMBLY RONT LEAR SSEMBLY Front Clear Lens Assembly 21.9686.0618 Rev C Refer to Figure 3-3 Item Qty. Description 12.9686.0627 CASTING, CONVEX LENS 42.9686.0121 LENS, ASPHERIC PLANO CONVEX CLEAR 10.9686.0641 CLIP, FRONT LENS 53.6685.1125 SCREW, CAPTIVE, SH CAP 10-32 1.125 LG BLK ZN 53.6598.0312 SCREW, 4-40 X 5/16"...

  • Page 80: Front Fresnel Lens Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Fresnel Lens Assembly 21.9686.0619 Rev D Refer to Figure 3-4 Item Qty. Description 12.9686.0629 CASTING, MACHINED, FRESNEL LENS 42.9686.0102 LENS, FRESNEL 230 MM DIA 10.9686.0641 CLIP, FRONT LENS 53.6685.1500 SCREW, CAPTIVE, SH CAP 10-32 1.5 LG BLK ZN 53.6598.0312...

  • Page 81: Head Cover Assembly

    Description 10.9678.0612 HEAD COVER FOAM BAFFLE 10.9678.0674 BRACKET, COVER TETHER 10.9678.0696 FOAM FRAME, HEAD COVER 10.9686.0610 HEAD COVER, VL3500 WASH 53.5606.0375 SCREW, 6-32 X 3/8, PPSS 53.6683.0015 SCREW, #6 X 1/4" PPZ PLASTIC 55.2233.0003 RETAINER, PUSH-ON TYPE 55.2233.0775 STUD, 1/4 TURN .775L STEEL BLK ZINC 10.9678.0649...

  • Page 82: Backend Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Backend Assembly 21.9686.0615 Rev M Refer to Figure 3-6 Item Qty. Description 10.9678.0653 LIGHT BAFFLE, EXHAUST 10.9686.0635 EXHAUST BULKHEAD 10.9686.0636 COUNTERWEIGHT, REAR 10.9686.0671 SEPARATION BULKHEAD 12.9678.0627 REAR CROSS-CASTING, MACHINED 10.9686.0659 INSULATOR, FAN, THIN 21.9678.0673...
  • Page 83 SSEMBLY ACKEND SSEMBLY Item Qty. Description 55.6658.0500 STANDOFF, 6-32 X 1/2" LG, 1/4" HEX, ZINC 25.9686.0012 YOKE TO DUAL AC FAN CABLE ASSY (not shown) 25.9686.0201 CABLE ASSY, OT SWITCH TO BACKCAP INTERLOCK (not shown) (x10) (x2) (x2) (x2) (x2) (x2) (x2) (x4)

  • Page 84: 80Mm Fan Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 80mm Fan Assembly 21.9686.6619 Rev A Refer to Figure 3-7 Item Qty. Description 40.7144.0001 FAN, TUBEAXIAL 80 X 80 X 38 MM, 230V, 36 CFM, BBEARING, 95°C 53.2200.0006 NUT, 6-32 KEPS SS 53.6558.0001...

  • Page 85: Dual Fan Duct Assembly

    SSEMBLY SSEMBLY Dual Fan Duct Assembly 22.9686.0674 Rev B Refer to Figure 3-8 Item Qty. Description 10.9686.1672 DUAL FAN DUCT 10.9686.0673 TURNING VANE, FAN DUCT 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 53.6604.0002 SCREW, 4-40 X 1/4 THREAD FORMING 74.1090.0001 OT1 THERMAL SWITCH, LIMIT, 199°C 74.1090.0001 OT2 THERMAL SWITCH, LIMIT, 199°C 25.9678.0015...

  • Page 86: Reflector Mount Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Reflector Mount Assembly 21.9686.0605 Rev C Refer to Figure 3-9 Item Qty. Description 10.9686.0632 REFLECTOR CLAMP 10.9686.0633 CLIP, UV REFLECTOR 12.9686.0631 REFLECTOR MOUNT, MACHINED CASTING 42.9686.0105 UV/IR BLOCKING FILTER 42.9686.0120 REFLECTOR, ELIPTICAL 53.6530.0002...

  • Page 87: Hot Box Assembly

    SSEMBLY SSEMBLY Hot Box Assembly 21.9686.0680 Rev D Refer to Figure 3-10 Item Qty. Description 10.9678.0043-04 LABEL PLATE, VL3500 WASH BACKCAP, BLACK 10.9686.0642 BACKCAP PLATE 10.9678.0643 LAMP ADJUST STOP 10.9678.0645 KNOB, LAMP ADJ MOLDED 10.9686.0681 HOT BOX 22.9686.0649 ASSEMBLY, TILT PLATE, LONG VANE 53.2030.0001...
  • Page 88 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Hot Box Assembly (continued) (x2) (x8) (x4) (x4) (x3) (x3) (x3) (x3) Figure 3-10: Hot Box Assembly 02 .9 686.00 10 0...

  • Page 89: Dual Fan Tray Assembly

    SSEMBLY SSEMBLY Dual Fan Tray Assembly 21.9686.0660 Rev B Refer to Figure 3-11 Item Qty. Description 22.9686.0661 ASSY, FAN TRAY 23.9686.0684 FAN ASSY, HEAD FRONT 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPB 55.6818.0002 STANDOFF, 45 DEG NYLON 6/6 KUR (x4) (x2) Figure 3-11: Dual Fan Tray Assembly 02.96 86.001 0 0...

  • Page 90: Head Front Fan Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Head Front Fan Assembly 23.9686.0684 Rev 0 Refer to Figure 3-12 Item Qty. Description 12.9686.0664 FAN, COOLING, 24V MODIFIED 52.6523.0002 CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP...

  • Page 91: Internal Lens Assembly

    SSEMBLY NTERNAL SSEMBLY Internal Lens Assembly 21.9686.2150 Rev G Refer to Figure 3-13 Item Qty. Description 21.9686.2140 ASSEMBLY, INTERNAL LENS RAIL 21.9686.2144 ASSEMBLY, INTERNAL LENS SPLITTER 21.9686.2142 ACTUATOR ASSEMBLY 53.6607.0001 SCREW, 6-32 X 1/4 PPB 53.6513.0046 SCREW, M3 X 6 LG SOC CAP, LOW PROFILE, BLK 53.6513.0032 SCREW, M3 X 5 X 10MM LG, PPZ, METRIC 21.9686.3102...
  • Page 92 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL (x2) (x2) (x4) (x4) Figure 3-13: Internal Lens Assembly 02 .9 686.00 10 0...

  • Page 93: Internal Lens Rail Assembly

    SSEMBLY NTERNAL SSEMBLY Internal Lens Rail Assembly 21.9686.2140 Rev H Refer to Figure 3-14 Item Qty. Description 10.9678.0128 PULLEY, ZOOM MOTOR 10.9678.1131 FORWARD PULLEY SHAFT, BEARING 10.9686.1170 MOUNT, RAIL 10.9686.3171 MOUNTING PLATE, SPLIT LENS ZOOM ASSY 10.9686.1182 BLOCK, MOUNTING, IDLER PULLEY 55.2234.0001 E-RING, .188 SHAFT DIA.
  • Page 94 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL (x2) (x5) (x2) (x7) Figure 3-14: Internal Lens Rail Assembly 02 .9 686.00 10 0...

  • Page 95: Internal Lens Splitter Assembly

    SSEMBLY NTERNAL PLITTER SSEMBLY Internal Lens Splitter Assembly 21.9686.2144 Rev D Refer to Figure 3-15 Item Qty. Description 10.9686.2175 MOUNT, ZOOM LENS 10.9686.1179 HINGE ROD 21.9686.2160 PIVOT ASSY, INTERNAL LENS 10.9686.2189 EOT STOP, VARI-BRITE 10.9686.1156 BELT CLAMP, BACK 10.9686.1159 SPACER, PIVOT 10.9686.1176 MOTOR MOUNT 1, SPLIT LENS MOTOR 44.9686.0164...
  • Page 96 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) Figure 3-15: Internal Lens Splitter Assembly 02 .9 686.00 10 0...

  • Page 97: Actuator Assembly

    SSEMBLY CTUATOR SSEMBLY Actuator Assembly 21.9686.2142 Rev F Refer to Figure 3-16 Item Qty. Description 10.9686.2190 BUMPER, LENS 10.9686.1158 SPACER, PIVOT LINK 10.9686.4189 MOUNT, LEAD SCREW 10.9686.4188 PLATE, LINKAGE ACTUATOR 21.9686.2130 ASSEMBLY, PIVOT LINK 53.6607.0001 SCREW, 6-32 X 1/4" PPB 53.6678.0013 SCREW, SHLDR 4-40TH .125DIA .188 SHLDR (x2)

  • Page 98: Fresnel Internal Lenses

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Fresnel Internal Lenses 21.9686.0620 Rev A Refer to Figure 3-17 Item Qty. Description 21.9686.3103 LENS, ZOOM, FRESNEL, LEFT 21.9686.3104 LENS, ZOOM, FRESNEL, RIGHT 21.9686.3105 KIT, SPLIT LENS MOUNTING (x2) Figure 3-17: Fresnel Internal Lenses...

  • Page 99: Internal Lens Mounting Kit

    SSEMBLY NTERNAL OUNTING Internal Lens Mounting Kit 21.9686.3105 Rev A Refer to Figure 3-18 Item Qty. Description 10.9686.1141 INTERNAL LENS PIVOT ADAPTER 10.9686.2181 SPACER, LENS MOUNTING 53.6524.0002 SCREW, 6-32 X 5/16 PPB 54.1259.0006 BEARING, FLANGED, EXTENDED RACE 0.25" ID 54.1259.0007 BEARING, FLANGED, 0.25"...

  • Page 100: Color/Effect/Strobe Module

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color/Effect/Strobe Module 21.9686.0400 Rev G Refer to Figure 3-20 Figure 3-20 Item Qty. Description 10.9686.0468 PULLEY, COLOR WHEEL DRIVE MOTOR, WITH FLANGES 10.9676.0230.02 SPACER, COLOR WHEEL .043" LG 10.9686.0446 MOTOR ADJUST PLATE 10.9686.0420...
  • Page 101 SSEMBLY OLOR FFECT TROBE ODULE Item Qty. Description 10.9678.0246 ADJUST PLATE, MOTOR 25.9686.0205 CABLE ASSY, COLOR HARNESS (not shown) 10.9686.0442 BLOCKING PLATE, AIR, DIMMER 10.9686.0443 AIR DIVERTER, DIMMER 10.9686.0444 AIR DIVERTER, DIMMER, BELT SIDE 53.6530.006 RIVET, 1/8" OD POP, .188 - .250 LG 10.9686.2468 PULLEY, MOTOR, NO FLANGES, FOR CTO AND DIMMER WHEELS 10.9686.0447...
  • Page 102 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color/Effect/Strobe Module (continued) (x16) (x14) (x6) (x8) (x6) (x4) (x5) (x8) 37 (6) (x2) Figure 3-20: Color Effect Section 02 .9 686.00 10 0...

  • Page 103: Fixed Color Wheel Assemblies

    SSEMBLY IXED OLOR HEEL SSEMBLIES Fixed Color Wheel Assemblies 21.9686.0484 Rev G Wheel #1 21.9686.0480 Rev G Wheel #2 Refer to Figure 3-21 Item Qty. Description 10.9686.0487 WHEEL, FIXED COLOR 1 (#1) -10.9686.0481 WHEEL, FIXED COLOR 2 (#2) 10.9686.0482 SPACER PLATE, FIXED COLOR 10.9686.0483 SPRING PLATE, FIXED COLOR 21.9686.0419...
  • Page 104 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Fixed Color Wheel Assemblies (continued) POS 1 OPEN (x4) Note: RTV beads should be applied at all positions where a filter can be used. TIMING TAB TIMING TAB POS 1 OPEN...

  • Page 105: Strobe System Assembly

    SSEMBLY TROBE YSTEM SSEMBLY Strobe System Assembly 21.9686.0404 Rev F Refer to Figure 3-22 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE 10.9686.0435 STROBE BULKHEAD, COLOR ACCESS 22.9686.0437 REAR STROBE BLADE ASSEMBLY 22.9686.0438 FRONT STROBE BLADE ASSEMBLY 44.5029.0001 MOTOR, STEPPER 42MM X 34MM - AR6 53.6513.0026 SCREW, M3 X .5 X 12MM LG PP 53.6609.0001...
  • Page 106 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL .400 .455 .410 .355 Set blade assemblies according to dimensions shown (x2) (x4) (x4) (x8) (x8) (x8) (x8) (x8) (x4) (x4) Figure 3-22: Strobe System Assembly 02 .9 686.00 10 0...

  • Page 107: Rear Strobe Blade Assembly

    SSEMBLY TROBE LADE SSEMBLY Rear Strobe Blade Assembly 22.9686.0437 Rev 0 Refer to Figure 3-23 Item Qty. Description 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE, DAMPER 10.9686.0431 STROBE BLADE 53.5558.0188 SCREW, 8-32 X .188 LG SET SS BRASS TIP UNC-2A 53.6597.0001 SCREW, 4-40 X 3/16"...

  • Page 108: Front Strobe Blade Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Strobe Blade Assembly 22.9686.0438 Rev 0 Refer to Figure 3-24 Item Qty. Description 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE DAMPER 10.9686.0431 STROBE BLADE 53.5558.0188 SCREW, 8-32 X .188 LG SET SS BRASS TIP UNC-2A 53.6597.0001...

  • Page 109: Yoke Assembly Yoke Assembly

    SSEMBLY SSEMBLY Yoke Assembly Yoke Assembly 21.9686.0700 Rev A Refer to Figure 3-25 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 22.9686.0705 ASSY, YOKE STRUCTURE 23.9650.3327 ELEC ASSY, RELAY 23.9661.1253 ELEC ASSY, PAN EOT SENSOR 24.9661.3126...
  • Page 110 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Yoke Assembly (cont.) (x2) (x2) (x2) (x4) (x3) (x8) (x2) (x2) (x4) (x2) (x2) (x2) Figure 3-25: Yoke Assembly 02 .9 686.00 10 0...

  • Page 111: Tilt Motor Assembly

    SSEMBLY OTOR SSEMBLY Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-26 Item Qty. Description 10.9678.0763 PLATE, TILT MOTOR MOUNT 21.9678.0708 ASSY, DRIVE PULLEY 24.9661.9629 PCB ASSY, PAN/TILT ENCODER 44.9678.0680 MOTOR, 3 PHASE SIZE 23 HIGH TORQUE 53.2200.0006 NUT, 6-32 KEPS SS 53.2200.0008 NUT, 8-32 KEPS SS 53.6525.0001...

  • Page 112: Relay Electrical Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Relay Electrical Assembly 23.9650.3327 Rev B Refer to Figure 3-27 Item Qty. Description 23.9650.3327 ELECTRICAL ASSEMBLY, RELAY Figure 3-27: Relay Electrical Assembly 02 .9 686.00 10 0...

  • Page 113: Yoke Fan Assembly

    SSEMBLY SSEMBLY Yoke Fan Assembly 22.9661.0609 Rev C Refer to Figure 3-28 Item Qty. Description 10.9661.0646 FAN TRAY 40.7113.0001 FAN, +24V 80MM X 80MM X 25MM, 32 CFM 53.2200.0006 NUT, 6-32 KEPS SS Direction of Air Flow (x4) Figure 3-28: Yoke Fan Assembly 02.96 86.001 0 0...
  • Page 114 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 115: Head/Yoke Pcb Assemblies

    PCB A SSEMBLIES ABLE NTERCONNECT Head/Yoke PCB Assemblies Head Cable Interconnect 21.9686.1121 Rev A Refer to Figure 3-29 Item Qty. Description 10.9686.1120 BRACKET, HEAD CABLE INTERCONNECT 53.6520.0002 SCREW, 4-40 X 7/16 PPZ 55.6621.0001 WASHER, #4 FLAT ZINC 52.6670.0040 HEADER ASSY, MOD 11 40 POS MTG 52.6670.0034 HEADER ASSY, MOD 11 34 POS MTG 23.9686.0208...

  • Page 116: Color Sensor Pcb Offset Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color Sensor PCB Offset Assembly 24.9686.0427 Rev B Refer to Figure 3-30 Figure 3-30: Color Sensor PCB Offset Assembly 02 .9 686.00 10 0...

  • Page 117: Color Sensor Pcb Inline Assembly

    PCB A PCB I SSEMBLIES OLOR ENSOR NLINE SSEMBLY Color Sensor PCB Inline Assembly 24.9686.0428 Rev C Refer to Figure 3-31 Figure 3-31: Color Sensor PCB Inline Assembly 02.96 86.001 0 0...

  • Page 118: Solid State Ignitor Pcb

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Solid State Ignitor PCB 24.9661.3126 Rev A Refer to Figure 3-32 Figure 3-32: Solid State Ignitor PCB 02 .9 686.00 10 0...

  • Page 119: Wheel Position Sensor Pcb Assembly

    PCB A PCB A SSEMBLIES HEEL OSITION ENSOR SSEMBLY Wheel Position Sensor PCB Assembly 24.9661.9629 Rev A Refer to Figure 3-33 Figure 3-33: Wheel Position Sensor PCB Assembly 02.96 86.001 0 0...

  • Page 120: Pan/Tilt Encoder Pcb

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan/Tilt Encoder PCB 24.9678.9729 Rev A Refer to Figure 3-34 Figure 3-34: Pan/Tilt Encoder PCB 02 .9 686.00 10 0...

  • Page 121: Vl3500 Wash Controller Pcb Assembly

    PCB A : VL3500 W PCB A SSEMBLIES ONTROLLER SSEMBLY VL3500 Wash Controller PCB Assembly 24.9686.0429 Rev B Refer to Figure 3-35 Item Description Ref. 10.9661.1275 HEATSINK, MAIN CONTROLLER 10.9678.0731 HEATSINK, CONTROLLER 10.9678.0746 GROMMET, PCB EDGE 10.9678.0885 KIT, THERMAL TRANSFER MAIN CONTROLLER 53.2200.0006...
  • Page 122 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL VL3500 Controller PCB Assembly (continued) Bottom Side Note: Heatsink not shown Top Side Figure 3-35: VL3500 Wash Controller PCB Assembly 02 .9 686.00 10 0...

  • Page 123: Enclosure Assembly Upper Enclosure Assembly

    Figure 3-37 Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 04.9661.1218.01 LABEL, PATENT, VL2201 & VL2400 SERIES LUM. 04.9686.0040 LABEL, VL3500 WASH SERIES COMPLIANCE 06.6032.0009 CABLE MARKER TIE 10.9661.1258 BRACKET, APS SIDE 10.9678.1876 AIR DISTRIBUTION PLENUM 10.9678.0820 LANYARD, PAN TUBE 10.9686.0839 COVER, TOP 10.9686.0846...
  • Page 124 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Item Qty. Description 21.9686.0811 FAN ASSY, EXHAUST 23.9678.0687 ELEC ASSY, PAN EOT SENSOR 25.9661.1514 CABLE ASSY, LVS CHASSIS GROUND (not shown) 25.9661.1520 CABLE ASSY, CHASSIS TO YOKE GROUND (not shown) 25.9678.0811 CABLE ASSY, EMI FILTER TO POWER (not shown) 25.9678.0812...
  • Page 125 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Item Qty. Description 54.1255.0001 BEARING ASSY, BLACK FLUSH MOU 54.2067.0001 BELT, TIMING S2M, 448 MM, 244 TEETH 55.2150.0003 STANDOFF, 1/4"HEX 6-32 1.125"L 55.2178.0001 CABLE ANCHOR MOUNT, #8 SCREW 55.2179.0001 CABLE ANCHOR MOUNT, #6 SCREW 55.2186.0001 CABLE TIE, .10"WD 4.00"LG SMALL ( NOT SHOWN 55.2261.0001...
  • Page 126 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x4) (x2) (x4) (x4) (x4) (x4) (x2) (x4) (x4) Figure 3-36: Upper Enclosure Assembly 02 .9 686.00 10 0...
  • Page 127 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure (Standard) Assembly (continued) (x3) (x4) (x4) (x2) (x2) (x2) (x2) (x4) Part is shown exploded for clarity (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x5) (x3) (x3) Figure 3-37: Upper Enclosure Mechanical Components 02.96 86.001 0 0...
  • Page 128 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL (x3) (x2) (x2) (x2) Figure 3-38: Upper Enclosure Electrical Components 02 .9 686.00 10 0...

  • Page 129: Ventilation Cover Assembly

    NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY Ventilation Cover Assembly 21.9686.0840.02 Rev B Refer to Figure 3-39 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 AIR SEAL, FAN SIDE 10.9678.0838 AIR SEAL, APS SIDE 10.9678.0835...
  • Page 130 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ventilation Cover Assembly (continued) (x2) (x4) (x4) (x4) (x4) (x4) Early production (x4) Current Figure 3-39: Ventilation Cover Assembly 02 .9 686.00 10 0...

  • Page 131: Exhaust Fan Assembly

    NCLOSURE SSEMBLY XHAUST SSEMBLY Exhaust Fan Assembly 21.9686.0811 Rev B Refer to Figure 3-40 Item Qty. Description 40.7140.0001 BLOWER, CENTRIFUGAL, 24VDC 9CFM 3" X 3" 10.9686.0810 MOUNTING PLATE, EXHAUST FAN 55.6576.0001 SCREW, #10-16 X 3/8 TYPE B PFZ 52.6523.0002 CONN, HOUSING, 2 POS PLUG SHROUDED ( NOT SHOWN 52.8347.0001 CONTACT, 24-30 AWG MALE CRIMP (...

  • Page 132: Panel Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Panel Assembly 21.9686.0805 Rev A Refer to Figure 3-41 Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY 10.9678.0859 BRACKET, INPUT 24.9663.3895 PCB ASSY, DMX INPUT 24.9678.3825 PCB ASSY, VL3000 DISPLAY 25.9678.0810 CABLE ASSY, AC INPUT PIGTAIL 51.0541...

  • Page 133: Dmx Input Pcb

    : DMX I NCLOSURE SSEMBLY NPUT DMX Input PCB 24.9663.3895 Rev 0 Refer to Figure 3-42 Item Qty. Description Ref. 17.9663.3895 PCB FAB, DMX INPUT 52.6259.0006 HEADER, 5POS MTA FRCT LOK STRT POST 52.6625.0006 CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL 52.6626.0006 CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL 62.3039.0102...

  • Page 134: Display Pcb

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Display PCB 24.9678.3825 Rev A Refer to Figure 3-43 Figure 3-43: Display PCB 02 .9 686.00 10 0...

  • Page 135: Pan Pulley Assembly

    NCLOSURE SSEMBLY ULLEY SSEMBLY Pan Pulley Assembly 21.9686.0807 Rev B Refer to Figure 3-44 Item Qty. Description 10.9686.0750 TIMING PULLEY, 170 TOOTH 10.9678.0855 PAN FLAG 53.6530.0009 RIVET, 1/8"OD POP .126-.187 GL (x2) Figure 3-44: Pan Pulley Assembly 02.96 86.001 0 0...

  • Page 136: Pan Motor Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Motor Assembly 21.9686.0864 Rev C Refer to Figure 3-45 Item Qty. Description 10.9686.0865 PLATE, PAN MOTOR MOUNT 21.9686.0828 ASSY, DRIVE PULLEY, PAN - 10.9686.8720 CODEWHEEL, 120 COUNT LARGE ID - 10.9686.0749 TIMING PULLEY, 2MM GT 15 TOOTH - 53.5560.0250...
  • Page 137 NCLOSURE SSEMBLY OTOR SSEMBLY Note: Vari-Lite recommends that this motor be replaced as a complete assembly. Although (x4) you can replace only the motor, the pulley (Item 2) is bonded to the motor shaft during assembly and cannot be removed intact. If you order a replacement motor (Item 4), also order the pulley (Item 2).

  • Page 138: Pan Tube Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Tube Assembly 21.9678.0881 Rev 0 Refer to Figure 3-46 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 54.1255.0002...

  • Page 139: 1500W Arc Ballast Module Assembly

    : 1500W A NCLOSURE SSEMBLY ALLAST ODULE SSEMBLY 1500W Arc Ballast Module Assembly 23.9686.1500 Rev 0 Refer to Figure 3-47. Figure 3-47: 1500W Arc Ballast Module Assembly (Side View) 02.96 86.001 0 0...
  • Page 140 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 141: Cable Assemblies

    EOT S ABLE SSEMBLIES ENSOR LECTRICAL SSEMBLY Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-48 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 3-48: Pan EOT Sensor Electrical Assembly 02.96 86.001 0 0...

  • Page 142: Lvs Chassis Ground Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-49 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...

  • Page 143: 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 3-50 Item Qty. Description 52.8250.0006 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (x2) Figure 3-50: Chassis To Yoke Ground Cable Assembly 02.96 86.001 0 0...

  • Page 144: Ignitor To Relay Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ignitor to Relay Cable Assembly 25.9661.1526 Rev C Refer to Figure 3-51. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG (LOOSE) PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009...

  • Page 145: Lvs To Yoke Dual Ac Fan Cable Assembly

    : LVS AC F ABLE SSEMBLIES ABLE SSEMBLY LVS to Yoke Dual AC Fan Cable Assembly 25.9686.0843 Rev A Refer to Figure 3-52 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...

  • Page 146: Yoke To Dual Ac Fan Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Yoke to Dual AC Fan Cable Assembly 25.9686.0012 Rev A Refer to Figure 3-53 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...

  • Page 147: Ot Switch 1 To Ot Switch 2 Cable Assembly

    : OT S OT S ABLE SSEMBLIES WITCH WITCH ABLE SSEMBLY OT Switch 1 to OT Switch 2 Cable Assembly 25.9686.0013 Rev A Refer to Figure 3-55 Item Qty. Description 52.8371.0001 RECEPT, FASTON, 24-20 AWG UNINSUL 73.7089.0000 0.42 WIRE. 22AWG 300V 200C TEF BLK UL1180 Figure 3-54: OT Switch 1 to OT Switch 2 Cable Assembly 02.96 86.001 0 0...

  • Page 148: Backcap Interlok To Ot Switch 1 Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Backcap Interlok to OT Switch 1 Cable Assembly 25.9686.0014 Rev A Refer to Figure 3-55 Item Qty. Description 52.8414.0001 RECEPT, FASTON, .187 SERIES 24-20 AWG UNINSUL 52.8371.0001 RECEPT, FASTON, 24-20 AWG UNINSUL 73.7089.0000...

  • Page 149: Ot Switch To Ground Cable Assembly

    : OT S ABLE SSEMBLIES WITCH TO ROUND ABLE SSEMBLY OT Switch to Ground Cable Assembly 25.9678.0015 Rev A Refer to Figure 3-56 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 200C TEFLON STRANDED...

  • Page 150: Tilt Harness Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt Harness Cable Assembly 25.9686.0203 Rev G Refer to Figure 3-61 Item Qty. Description 52.6610.0040 CONNECTOR, HOUSING 40 POS, 26-22 AWG DBL ROW UNLOADED 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.2040...

  • Page 151: Internal Lens Interconnect Cable Assembly

    ABLE SSEMBLIES NTERNAL NTERCONNECT ABLE SSEMBLY Internal Lens Interconnect Cable Assembly 25.9686.0204 Rev 0 Refer to Figure 3-61 Item Qty. Description 52.6610.0014 CONNECTOR, HOUSING 14 POS, 26-22 AWG 52.6224.1014 COVER, FRONT 14 POS MT LATCHING 52.6224.2014 COVER, BACK 14 POS MT 55.2186.0001 CABLE TIE, .10 X 4"...

  • Page 152: Color Harness Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color Harness Cable Assembly 25.9686.0205 Rev E Refer to Figure 3-59 Item Qty. Description 52.6610.0040 CONNECTOR, HOUSING 40 POS, 26-22 AWG DBL ROW UNLOADED 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.2040...

  • Page 153: Internal-Lens Split Motor Cable Assembly

    ABLE SSEMBLIES NTERNAL PLIT OTOR ABLE SSEMBLY Internal-Lens Split Motor Cable Assembly 25.9686.0206 Rev 0 Refer to Figure 3-60 Item Qty. Description 52.6467.0004 CONNECTOR, FEM PLUG 4 POS, 30-24 AWG 52.6467.0024 CONTACT, 24-30 AWG FEMALE CRIMP 2.00 MM PITCH 52.6696.0001 RECEPT, WIRE TO WIRE 4 POS, 2 MM PITCH 28-24 AWG 52.6694.0001 CRIMP, TERMINAL WIRE-TO-WIRE FEMALE 2 MM PITCH 28-24 AWG...

  • Page 154: Zoom Motor Cable

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Zoom Motor Cable 25.9686.0207 Rev 0 Refer to Figure 3-61 Item Qty. Description 52.662.0006 HOUSING, 6 POS, 125/2A 2.00 MM PITCH 52.6467.0024 CONTACT, 24-30 AWG FEMALE CRIMP 2.00 MM PITCH 73.2326.0123 0.75...

  • Page 155: Transfer Fans Cable Assembly

    ABLE SSEMBLIES RANSFER ABLE SSEMBLY Transfer Fans Cable Assembly 25.9686.0209 Rev B Refer to Figure 3-62 Item Qty. Description 52.6523.0004 CONN, HOUSING 4POS RECEPTACLE 52.6524.0002 CONN, HOUSING 2POS RECEPTACLE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP 52.8346.0001 CONTACT, 24-30AWG FEMALE CRIMP 73.2324.0200 2.21 WIRE, 26AWG 2COND 300V 200C <BLK-RED>...

  • Page 156: Upper Enclosure Fans Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Fans Cable Assembly 25.9686.0210 Rev B Refer to Figure 3-63 Item Qty. Description 52.6523.0004 CONN, HOUSING 4POS RECEPTACLE 52.6524.0002 CONN, HOUSING 2POS RECEPTACLE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP 52.8346.0001 CONTACT, 24-30AWG FEMALE CRIMP 73.5126.0002...

  • Page 157: 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 3-64 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 73.3526.0002 1.25 WIRE, 26AWG 300V 105C PVC RED...

  • Page 158: Yoke Fan Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Yoke Fan Cable Assembly 25.9678.0758 Rev A Refer to Figure 3-65 Item Qty. Description 52.6396.3102 RECEPT, 2POS MTA100 W/POL TAB BLUE CLSD END 52.6423.0003 HOUSING, 3POS MT RECEPT, 2MM CT 28-26 AWG 73.5126.0002...

  • Page 159: Ot Switch To Interlok Cable Assembly

    : OT S ABLE SSEMBLIES WITCH TO NTERLOK ABLE SSEMBLY OT Switch to Interlok Cable Assembly 25.9686.0201 Rev A Refer to Figure 3-66 Item Qty. Description 52.8230.0003 RECEPT, FASTON 22-18AWG 1/4" 52.8414.0001 RECEPT, FASTON, .187 SERIES 24-20 AWG UNISUL 73.7089.0000 3.00 WIRE.

  • Page 160: Ot Switch 1 To Ot Switch 2 Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL OT Switch 1 to OT Switch 2 Cable Assembly 25.9686.0013 Rev A Refer to Figure 3-67 Item Qty. Description 52.8371.0001 RECEPT, FASTON 24-20AWG UNISUL TIN 73.7089.0000 0.42 WIRE. 22AWG 300V 200C TEF BLK UL1180 Figure 3-67: OT Switch 1 to OT Switch 2 Cable Assembly 02 .9 686.00 10 0...

  • Page 161: Ignitor To Lamp Socket Cable Assembly

    ABLE SSEMBLIES GNITOR TO OCKET ABLE SSEMBLY Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-68. 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 6.83 SLEEVING, FIBERGLASS .133"...

  • Page 162: Chassis To Yoke Ground Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Chassis to Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-69 Item Qty. Description 52.8250.0006 TERM, RING #8, 10AWG 73.7089.0504 15.17 WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 (x2)

  • Page 163: Zoom Motor Cable Assembly

    ABLE SSEMBLIES OTOR ABLE SSEMBLY Zoom Motor Cable Assembly 23.9686.0208 Rev 0 Refer to Figure 3-70 Item Qty. Description 25.9686.0207 CABLE ASSY, ZOOM MOTOR 24.9678.5916 PCB ASSY, ZOOM INTERCONNECT Figure 3-70: Zoom Motor Cable Assembly 02.96 86.001 0 0...

  • Page 164: Ac Input Pigtail Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev B Refer to Figure 3-71 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...

  • Page 165: Emi Filter To Power Switch Cable Assembly

    : EMI F ABLE SSEMBLIES ILTER TO OWER WITCH ABLE SSEMBLY EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-72 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 166: Ac Input Splitter Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-73 Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3 POS 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8231.0008...
  • Page 167 : AC I ABLE SSEMBLIES NPUT PLITTER ABLE SSEMBLY AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 (x3) Figure 3-73: AC Input Splitter Cable Assembly 02.96 86.001 0 0...

  • Page 168: Data I/O Link Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-74 Item Qty. Description 52.6396.2904 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 52.6396.2905 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 73.5122.0259...

  • Page 169: Display Cable Assembly

    ABLE SSEMBLIES ISPLAY ABLE SSEMBLY Display Cable Assembly 25.9678.1825 Rev C Refer to Figure 3-75 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 73.5116.0123 1.02 WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN> 55.2186.0001 CABLE TIE, .10" WD 4" LG SMALL NOT SHOWN 73.7130.0004 .958...

  • Page 170: Ballast To Controller Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-76 Item Qty. Description 52.6396.3002 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 52.6396.3005 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 52.6396.3008...

  • Page 171: Dc Output Cable Assembly

    : DC O ABLE SSEMBLIES UTPUT ABLE SSEMBLY DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-77 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 52.8323.0002 CONTACT, CRIMP, 18-22 AWG SL-156 (not shown) 52.8274.1614...

  • Page 172: Pan/Tilt Control Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-78 Item Qty. Description 52.6610.0008 HOUSING, 20POS UNLOADED DBL ROW 52.6224.1020 COVER, FRONT 20POS MT LATCHING 52.6224.2020 COVER, BACK 20POS MT 52.6524.0005...

  • Page 173: Lamp Supply To Relay Cable Assembly

    ABLE SSEMBLIES UPPLY TO ELAY ABLE SSEMBLY Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-79 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 3.19 SLEEVING, 1/2" NOM. DIA POLY EXP BRAIDED 73.7089.0000 34.41 WIRE, 22AWG BLK 300V TEFLON STRANDED...
  • Page 174 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 175: Appendix A. Technical Bulletins

    Technical Bulletins VL3500™ Wash Luminaire Technical Bulletins The following table identifies the current technical bulletins associated with the VL3500™ Wash 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.
  • Page 176 VARI❋LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 177: Appendix B. Schematics And Wiring Diagrams

    Schematics and Wiring Diagrams Schematics and Diagrams List The following list includes the schematics and diagrams included in Appendix B: • VL3500 Wash Wiring Diagram (Sheet 1 of 3) • Solid State Ignitor PCB (Sheet 1 of 1) • DMX Input PCB (Sheet 1 of 1) •...
  • Page 178 VARI❋LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686.00 10 0...

  • Page 179: Vl3500 Wash Wiring Diagram (Sheet 1 Of 3)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Wash Wiring Diagram (Sheet 1 of 3) 02.96 86.001 0 0...

  • Page 180: Vl3500 Wash Wiring Diagram (Sheet 2 Of 3)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Wash Wiring Diagram (Sheet 2 of 3) 02.96 86.001 0 0...

  • Page 181: Vl3500 Wash Wiring Diagram (Sheet 3 Of 3)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Wash Wiring Diagram (Sheet 3 of 3) 02.96 86.001 0 0...

  • Page 182: Solid State Ignitor Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3500™ W 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.

  • Page 183: Dmx Input Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3500™ W 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-...

  • Page 184: Color Sensor Offset Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Color Sensor Offset PCB (Sheet 1 of 1) REV. NO REV. NO REV. NO ECO # ECO # ECO # DESCRIPTION DESCRIPTION DESCRIPTION DATE DATE DATE...

  • Page 185: Color Sensor Inline Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Color Sensor Inline PCB (Sheet 1 of 1) ECO # ECO # ECO # DESCRIPTION DESCRIPTION DESCRIPTION APPROVED APPROVED APPROVED REV. NO REV. NO REV. NO...

  • Page 186: Pan/Tilt Encoder Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Pan/Tilt Encoder PCB (Sheet 1 of 1) ECO # ECO # ECO # DESCRIPTION DESCRIPTION DESCRIPTION APPROVED APPROVED APPROVED REV. NO REV. NO REV. NO DATE...

  • Page 187: Vl3500 Controller Pcb (Sheet 1 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 1 of 10) REV. NO ECO # DESCRIPTION DATE APPROVED NONE PROTO VERSION 12/12/03 NOTES: UNLESS OTHERWISE SPECIFIED 1/9/04 NONE MODIFIED NET NAMES AND U16 1.) ALL CAPACITOR VALUES ARE IN MICROFARADS.

  • Page 188: Vl3500 Controller Pcb (Sheet 2 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 2 of 10) +3.3V D[0..3 1] 3/B3,3/A3 +1.8V +1.8V +1.8V +1.8V +1.8V CS_MTR- 2/B4,3/A6 A[0 ..24] 2/C3,3/D6,3/A3 CS_UART- 2/B4,3/A6 A 15 CS_FLASH- 2/C4,2/C4 +1.8V...

  • Page 189: Vl3500 Controller Pcb (Sheet 3 Of 10)

    ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 3 of 10) +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V ALTERA EP1K100FC256-3 +3.3V +3.3V 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 +2.5V...

  • Page 190: Vl3500 Controller Pcb (Sheet 4 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 4 of 10) DO NOT STUFF +3.3V +24V ISO_VCC ISO_VCC ISO_VCC U10C TX_EN_C- BIAS ISO_VCC POWER TXDB LED_TX- VIN+ VOUT+ 2/B5 TXD1...

  • Page 191: Vl3500 Controller Pcb (Sheet 5 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 5 of 10) +24V +24V +24V TILT +24V PWM3_OUT_1 TILT_PHA_OUT 3/D3 OUT1 10/D3 PWM3_OUT_2 TILT_PHB_OUT 3/A6 10/D3 OUT2 PWM3_OUT_3 TILT_PHC_OUT 10/D3 3/A5...

  • Page 192: Vl3500 Controller Pcb (Sheet 6 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 6 of 10) +24V +24V +24V +24V C101 C119 R114 R136 FIXED GOBO GOBO1 ROTATE PWM_PH_7 ROT1_OUT1A PWM_PH_11 FXDG_OUT1A 3/C6 10/D7,10/C3 3/C3...

  • Page 193: Vl3500 Controller Pcb (Sheet 7 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 7 of 10) +24V +24V +24V +24V C136 C100 C155 C118 FRAME 1A R160 R173 ZOOM PWM_PH_15 FRAME1A_OUT1A PWM_PH_1 ZOOM_OUT1A 3/C6 10/B7,10/C3...

  • Page 194: Vl3500 Controller Pcb (Sheet 8 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 8 of 10) +24V +24V +24V +24V C173 C137 C200 C163 R214 R247 AMBER MAGENTA PWM_PH_19 AMB_OUT1A PWM_PH_23 MAG_OUT1A 3/C6 10/D6,10/A3 3/B6...

  • Page 195: Vl3500 Controller Pcb (Sheet 9 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 9 of 10) +24V +24V +24V +24V C208 C172 C232 C199 R265 R292 FXD COLOR STROBE1 PWM_PH_27 FXDC_OUT1A PWM_PH_31 STROBE1_OUT1A 3/B6 10/C6,10/A3...

  • Page 196: Vl3500 Controller Pcb (Sheet 10 Of 10)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS VL3500 Controller PCB (Sheet 10 of 10) +24V +24V DIA. .166" DIA. .166" DIA. .250" DIA. .250" DIA. .166" DIA. .166" DIA. .250" FRAME2A_OUT1A MNTG1 MNTG2...

  • Page 197: Display Pcb (Sheet 1 Of 1)

    ® ❋ VARI LITE - VL3500™ W UMINAIRE ERVICE ANUAL CHEMATICS AND IRING IAGRAMS Display PCB (Sheet 1 of 1) REVISIONS DESCRIPTION DATE APPD NOTES: UNLESS OTHERWISE SPECIFIED 5-29-02 TEW1 RELEASED TO ENGINEERING PER EO #09054 1. ALL CAPACITOR VALUES ARE IN MICROFARADS.
  • Page 199 Vari-Lite 10911 Petal Street Dallas, Texas 75238 Toll Free 1-877-VARI-LITE Tel 214.647.7880 Fax 214.647.8038 www.vari-lite.com ©2001-2007 Genlyte Thomas Group LLC. All rights reserved. Printed in the U.S.A.

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