Philips VL3500 WASH Service Manual
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Philips VL3500 WASH Service Manual

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  • Page 2 This manual is for informational use only and is subject to change without notice. Vari-Lite assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual. Version as of: 19-May-2009 Part number: 02.9686.0010 A VL3500™ Wash and VL3500™ Wash FX Luminaires Service Manual ©2003-2009 Vari-Lite, a Philips group company. All Rights Reserved.
  • 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 [email protected] 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 OREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product.
  • Page 6 ❋ VARI LITE® - 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 Beschädigung (z.
  • Page 9 OREWORD Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 10 ❋ VARI LITE® - 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. 2.
  • Page 11 OREWORD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto. Los símbolos de seguridad usados en este manual son los siguientes: CUIDADO, indica posibles daños al producto.
  • Page 12 ❋ VARI LITE® - 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. 2.
  • Page 13 OREWORD 02.96 86.001 0 A...
  • Page 14 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 02 .9 686 .00 10 A...

  • Page 15: Table Of Contents

    Additional Documentation......................2 Customer Service........................3 Technical Bulletins and Notices ....................4 Chapter 1. Description Features VL3500 Wash & VL3500 Wash FX Standard Features ............6 Technical Specifications ......................6 Components External Luminaire Components....................7 Luminaire Head and Yoke Components ..................8 Enclosure Components ......................
  • Page 16 VL3500 Wash Fixed Color Wheel 1 Assembly............... 93 VL3500 Wash Fixed Color Wheel 2 Assembly............... 95 VL3500 Wash FX Fixed Color Wheel 1 Assembly ..............97 VL3500 Wash FX Fixed Color Wheel 2 Assembly ..............99 VL3500 Wash FX Rotating Effect Wheel Assembly ............101...
  • Page 17 ABLE OF ONTENTS VL3500 Wash Strobe System Assembly ................103 VL3500 Wash FX Strobe System Assembly ................. 105 Rear Strobe Blade Assembly ....................107 Front Strobe Blade Assembly ....................108 Yoke Assembly Yoke Assembly ........................109 Tilt Motor Assembly......................111 Yoke Fan Assembly .......................
  • Page 18 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ballast to Controller Cable Assembly ................... 167 DC Output Cable Assembly ....................168 Pan/Tilt Control Cable Assembly ..................169 Lamp Supply to Relay Cable Assembly................171 Appendix A. Technical Bulletins and Notices Product Technical Bulletins and Notices ................

  • Page 19: Introductionintroduction

    NTRODUCTION BOUT ANUAL Introduction About This Manual Note: The VL3500™ Wash and VL3500™ Wash FX 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™...

  • Page 20: Additional Documentation

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Additional Documentation For complete installation and operation instructions, refer to the VL3500™ Wash & VL3500™ Wash FX Luminaires User’s Manual. This manual is available in both printed and electronic (PDF) formats: •...

  • Page 21: Customer Service

    NTRODUCTION USTOMER ERVICE Customer Service Our Goal At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone troubleshooting assistance, product training or technical service, our full-time staff of experienced professionals are on-hand to provide support.

  • Page 22: Technical Bulletins And Notices

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Technical Bulletins and Notices Technical bulletins concerning the latest changes to VARI❋LITE equipment are issued from the ® Dallas, Texas USA office. They are documentation supplements that contain procedures for equipment upgrades, retrofits, and repairs not found in the existing manuals.

  • Page 23: Chapter 1. Description

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

  • Page 24: Features

    • Dual, five-position (plus open) fixed color wheels. • Five-position aperture wheel: 52, 40, 35, 30, and 25 mm (VL3500 Wash only). • One rotating FX pattern wheel with four rotatable and indexable positions and one open position (VL3500 Wash FX only).

  • Page 25: 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 26: Luminaire Head And Yoke Components

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Luminaire Head and Yoke Components The following illustration shows the major sub-assemblies, which are located in the luminaire head and yoke assemblies. Color Assembly VL3500™ Wash Luminaire -contains fixed Head Covers color wheels, dimmer mechanism, aperture (attached by tether) wheel, CYM color wheels, CTO (color...

  • Page 27: 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 Enclosure Fan Assembly Input Panel Assembly containing DMX Input PCB and Menu Display 150W +24V/6.3A...
  • Page 28 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 29: 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 30: Luminaire Self-Tests

    VL3500™ Wash Luminaire User’s Manual (02.9686.0001). Calibration Sequence The following is an outline of the luminaire’s standard calibration sequence: VL3500 WASH VL3500 WASH FX Phase 1 Phase 1 • Tilt •...

  • Page 31: Auto Recalibration

    ESTING ECALIBRATION Auto Recalibration Most mechanisms with sensors will check their sensor when at a zero position, if the sensor is not detected within 3 seconds, the mechanism will recalibrate. This applies to all except pan and tilt, and zoom. Pan and tilt are corrected continuously if required by encoders fitted to the motor shaft. Note: Colors (CTO and CYM) only auto recalibrate when the dimmer has been closed for 3 seconds.
  • Page 32 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL • The two fixed color wheels and four color mixers read high when the tab is in the optical sensor. • Pan and tilt sensors read high when the tab is in the sensor. The mechanism calibrates to the edge and its tab covers 50% of travel.

  • Page 33: Warnings And Cautions

    VL3500 L ARNINGS AND AUTIONS XCEPTIONAL AFETY NFORMATION FOR THE UMINAIRES Warnings and Cautions Exceptional Safety Information for the VL3500 Luminaires The light intensity and power density of the VL3500™ Wash and VL3500™ Wash FX Luminaires exceeds other fixtures typically used in this application. The warnings and cautions that follow are critically important to the safe operation of these luminaires.

  • Page 34: Troubleshooting

    CTO sensor not found. Aperture/No Sens Aperture sensor not found (VL3500 Wash Only). FX Wheel/No Sens FX wheel sensor not found (VL3500 Wash FX only). FX Index/No Sens FX index sensor not found (VL3500 Wash FX only) 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 35: 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 16 for more information. The chart below provides possible causes and remedies for each message. Table 2-2: Troubleshooting Guide Message Symptom...
  • Page 36 ❋ 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 37: 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 71.9686.1502 Parts: WARNING: Ensure that power is removed from luminaire when installing lamp. Always wear eye protection when opening lamp box and replacing lamps.

  • Page 38: Align Lamp

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 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 39: Internal Lens Replacement

    AINTENANCE ROCEDURES NTERNAL EPLACEMENT 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 40 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 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 Bumper Stops...

  • Page 41: Front Lens Assembly Removal

    AINTENANCE ROCEDURES RONT SSEMBLY EMOVAL 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 42 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 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.

  • Page 43: Color Filter Replacement

    ILTER EPLACEMENT 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 removing filters. To replace a color filter on Color Wheel 1: Step 1.
  • Page 44 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color Filter Replacement (continued) Do not touch filters with bare fingers. CAUTION: Wear cotton gloves. Assembly With Color Wheels (Do not remove. See detail) Color Wheel 1 Color Filter Lock Pins Air Duct Door Color Wheel 2 Color Filter...

  • Page 45: Effects Pattern Replacement - Vl3500 Wash Fx Only

    - VL3500 W FX O AINTENANCE ROCEDURES FFECTS ATTERN EPLACEMENT Effects Pattern Replacement - VL3500 Wash FX Only Tools: • #2 Philips screwdriver • Lint-free cotton gloves WARNING: Remove power from luminaire before performing maintenance. Patterns can be HOT after operation. Allow the fixture to cool before removing patterns.
  • Page 46 Effects Pattern Retaining Spring Cooling Air Duct Retaining Latches Yellow Wheel Planet Gear Assembly Bulkhead plate and Cyan removed for clarity Assembly Sun Gear Figure 2-6: Effects Pattern Replacement - VL3500 Wash FX Only 02 .9 686 .00 10 A...

  • Page 47: Ballast Assembly Replacement

    AINTENANCE ROCEDURES ALLAST SSEMBLY EPLACEMENT Ballast Assembly Replacement 23.9686.1500 Parts: 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 2-7, at the upper enclosure, remove four 6-32 x 1/4" screws and remove both top covers.
  • Page 48 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ballast Assembly Replacement (continued) 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 2-7: Ballast Assembly Replacement 02 .9 686 .00 10 A...

  • Page 49: Color/Dimmer/Strobe Assembly Replacement

    EPLACEMENT Color/Dimmer/Strobe Assembly Replacement 21.9686.0400 (VL3500 Wash Only) Parts: 21.9686.1400 (VL3500 Wash FX Only) Parts: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. As shown in Figure 2-8, stand the luminaire on the upper enclosure. Use the orientation of the backcap label to determine the top and bottom of luminaire head.

  • Page 50: Color/Dimmer/Strobe Assembly Replacement (Continued)

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly Replacement (continued) Top Head Cover Screws (x4) Wire Harness Guide (Note position) Color/Dimmer/Strobe Assembly Figure 2-8: Color/Dimmer/Strobe Assembly Replacement 02 .9 686 .00 10 A...

  • Page 51: Internal Lens Assembly Replacement

    AINTENANCE ROCEDURES NTERNAL SSEMBLY EPLACEMENT Internal Lens Assembly Replacement 21.9686.2150 Parts: 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. Step 3. Remove the Color/Dimmer/Strobe Assembly. See “Color/Dimmer/Strobe Assembly Replacement”...
  • Page 52 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Internal Lens Assembly Replacement (continued) Interconnect Board Cable Saddle Internal Lens Assembly Figure 2-9: Internal Lens Assembly Replacement 02 .9 686 .00 10 A...

  • Page 53: Reflector Replacement

    AINTENANCE ROCEDURES EFLECTOR EPLACEMENT Reflector Replacement 42.9686.0120 Parts: 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 31 for complete instructions. Step 3. As shown in Figure 2-10, remove four 4-40 x 1 3/8"...
  • Page 54 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Reflector Replacement (continued) 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 2-10: Reflector Replacement 02 .9 686 .00 10 A...

  • Page 55: Main Control Board (Mcb) Replacement

    (MCB) R AINTENANCE ROCEDURES ONTROL OARD EPLACEMENT Main Control Board (MCB) Replacement 24.9686.1429 Parts: 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 56: Ignitor Board Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ignitor Board Replacement 24.9661.3126 Parts: 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 57: Pan Motor Assembly Replacement

    AINTENANCE ROCEDURES OTOR SSEMBLY EPLACEMENT Pan Motor Assembly Replacement 21.9686.0864 Parts: 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 2-7, at the upper enclosure, remove four 6-32 x 1/4" screws and remove both top covers.
  • Page 58 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Motor Assembly Replacement (continued) 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.

  • Page 59: Pan Encoder Replacement

    AINTENANCE ROCEDURES NCODER EPLACEMENT Pan Encoder Replacement 24.9678.9729 Parts: 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 60 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Encoder Replacement (continued) Note: Make sure the encoder disk is centered in the optical sensor gap. Ventilation Cover Encoder Pan Motor Assembly Figure 2-14: Pan Encoder Replacement 02 .9 686 .00 10 A...

  • Page 61: Pan Eot Sensor Replacement

    EOT S AINTENANCE ROCEDURES ENSOR EPLACEMENT Pan EOT Sensor Replacement 23.9678.0687 Parts: 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 62 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan EOT Sensor Replacement (continued) Ventilation Cover Sensor Figure 2-15: Pan EOT Sensor Replacement 02 .9 686 .00 10 A...

  • Page 63: Power Supply (Lvs) Replacement

    (LVS) R AINTENANCE ROCEDURES OWER UPPLY EPLACEMENT Power Supply (LVS) Replacement 69.3177.0151 Parts: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-16, at the enclosure, remove two 6-32 x 1/4" LG PPZ screws from the display-side top cover and remove the cover.
  • Page 64 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Power Supply (LVS) Replacement (continued) Display-Side Top Cover Power Supply (LVS) NOTE: Head not shown for clarity. Fan Assembly Figure 2-16: Power Supply (LVS) Replacement 02 .9 686 .00 10 A...

  • Page 65: Tilt Motor Assembly Replacement

    AINTENANCE ROCEDURES OTOR SSEMBLY EPLACEMENT Tilt Motor Assembly Replacement 21.9678.0765 Parts: 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 Figure 2-17, at the tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16"...
  • Page 66 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt Motor Assembly Replacement (continued) 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.

  • Page 67: Tilt Encoder Replacement

    AINTENANCE ROCEDURES NCODER EPLACEMENT Tilt Encoder Replacement 24.9661.9629 Parts: Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-17, at the tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16"...

  • Page 68: Tilt Eot Sensor Replacement

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt EOT Sensor Replacement 23.9661.1253 Parts: 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" PTB screws. Step 3.

  • Page 69: Chapter 3. Illustrated Parts Breakdown

    This chapter contains illustrated parts breakdowns for the VL3500™ Wash and VL3500™ Wash FX luminaire assemblies. Note: The VL3500 Wash and VL3500 Wash FX Luminaires share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. • Drawing Tree (VL3500 Wash) •...

  • Page 70: Drawing Tree (Vl3500 Wash)

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Drawing Tree (VL3500 Wash) VL3500™ Wash Luminaire VL3500™ Wash Luminaire 20.9686.0001 Color/Effect/Strobe Module Generic Luminaire Assembly Head Cover Assembly 21.9686.0400 21.9686.0010 21.9686.0611 continued next page Head Structure Assembly Dual Fan Tray Assembly 21.9686.0600...
  • Page 71 VL3500™ Wash Luminaire (continued) continued from previous page continued from previous page Color/Effect/Strobe Module Upper Enclosure Assembly 21.9686.0400 21.9686.0800 Ventilation Cover Assembly VL3500 Wash Fixed Color Wheel 2 Panel Assembly 21.9686.0840.02 Assembly 21.9686.0805 21.9686.0480 Pan Pulley Assembly DMX Input PCB VL3500 Wash Fixed Color Wheel 1 21.9686.0807...

  • Page 72: Drawing Tree (Vl3500 Wash Fx)

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Drawing Tree (VL3500 Wash FX) VL3500™ Wash FX Luminaire VL3500™ Wash FX Luminaire 20.9686.0011 Color/Rotating Effect/Strobe Module Generic Luminaire Assembly Head Cover Assembly 21.9686.1400 21.9686.1010 21.9686.0611 continued next page Head Structure Assembly Dual Fan Tray Assembly 21.9686.1600...
  • Page 73 VL3500™ Wash FX Luminaire (continued) continued from previous page continued from previous page Color/Rotating Effect/Strobe Module Upper Enclosure Assembly 21.9686.1400 21.9686.0800 VL3500 Wash FX Fixed Color Wheel Ventilation Cover Assembly Panel Assembly 2 Assembly 21.9686.0840.02 21.9686.0805 21.9686.1480 VL3500 Wash FX Fixed Color Wheel...

  • Page 74: Top Assembly Included Items Kit

    LAMP, 1500 WATT SHORT ARC, DOUBLE-ENDED ( IN LUMINAIRE 21.9686.0620 INTERNAL LENS, FRESNEL 21.9686.0619 FRONT LENS ASSEMBLY, FRESNEL 21.9686.0618 FRONT LENS ASSEMBLY, CLEAR PC (VL3500 WASH ONLY) 21.9686.0617 FRONT LENS ASSEMBLY, STIPPLE PC (VL3500 WASH FX ONLY) 02 .9 686 .00 10 A...
  • Page 75 Note: (Buxom lenses are installed in luminaire) Supplied Lenses - VL3500 Wash - PC Clear, Fresnel, PC Stippled (installed on luminaire) / VL3500 Wash FX - PC Stipple, Fresnel, and Ultra Clear (installed on luminaire) Figure 3-5: Included Items Kit Note: * = Do not handle lamp with bare hands.

  • Page 76: Vl3500™ Wash / Vl3500™ Wash Fx Luminaires

    LABEL, LINE CORD WARNING (not shown) 04.9686.0061 LABEL, AC INPUT RATING VL3500 WASH (VL3500 Wash Only - not shown) 04.9686.1061 LABEL, AC INPUT RATING VL3500 WASH FX (VL3500 Wash FX Only - not shown) 10.9686.0617 YOKE CROSSMEMBER, HEAT SHIELD 10.9686.0168 ZOOM MOUNTING BRACKET, LEFT (not shown) 10.9686.0169...
  • Page 77 : VL3500™ W / VL3500™ W FX L SSEMBLY UMINAIRES Item Qty. Description 53.6558.0016 SCREW, 6-32 X 3/4" LG PPS SEMS 55.6677.0033 WASHER, .201" OD .125" ID .032" THK FLAT SS 55.2150.0002 STANDOFF, 1/4" HEX 6-32 X 1.188" LG MF STL (x2) (x10) (x4)

  • Page 78: Generic Luminaire Assembly

    Figure 3-7 Item Qty. Description 21.9686.0600 ASSY, HEAD STRUCTURE, VL3500™ WASH (VL3500 Wash Only) 21.9686.1600 ASSY, HEAD STRUCTURE, VL3500™ WASH FX (VL3500 Wash FX Only) 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 79 SSEMBLY ENERIC UMINAIRE SSEMBLY Item Qty. Description 25.9686.0204 CABLE ASSY, VARI-BRITE INTERCONNECT (not shown) (x4), (x4) See Detail C See Detail A (x4) See Detail B (x2) (x2) (x3) (x5) (x5) (x4) Detail A Detail B Detail C (x3) (x4) (x4) (x2) (x2)
  • Page 80 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 81: Head Assembly

    RIGHT SIDE RAIL, MACHINED 12.9686.0625 LEFT SIDE RAIL, MACHINED 21.9686.0617 ASSEMBLY, FRONT CASTING/LENS (VL3500 Wash Only) 21.9686.1617 ASSEMBLY, FRONT LENS, CLEAR POLISHED (VL3500 Wash FX Only) 53.6515.0001 SCREW, 10-32 X 3/4" SCB CAP 10.9686.0639 LIGHT BAFFLE, FRONT 53.6682.0002 SCREW, 4-40 X 1/4 PPZ SEMS...

  • Page 82: Front Stippled Lens Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Stippled Lens Assembly 21.9686.0617 Rev A (VL3500 Wash Only) Refer to Figure 3-2 Item Qty. Description 10.9686.0641 CLIP, FRONT LENS 12.9686.0627 CASTING, CONVEX LENS 42.9686.0101 LENS, ASPHERIC PLANO CONVEX STIPPLED 53.6598.0312...

  • Page 83: Polished Pc Clear Front Lens Assembly

    PC C SSEMBLY OLISHED LEAR RONT SSEMBLY Polished PC Clear Front Lens Assembly 21.9686.1617 Rev D (VL3500 Wash FX Only) Refer to Figure 3-3 Item Qty. Description 10.9686.0641 CLIP, FRONT LENS 10.9686.2190 BUM PER, LENS STOP 12.9686.0627 CASTING, CONVEX LENS 42.9686.0122...

  • Page 84: Front Clear Lens Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Clear Lens Assembly 21.9686.0618 Rev C (VL3500 Wash) Refer to Figure 3-4 Item Qty. Description 10.9686.0641 CLIP, FRONT LENS 12.9686.0627 CASTING, CONVEX LENS 42.9686.0121 LENS, ASPHERIC PLANO CONVEX CLEAR 53.6598.0312 SCREW, 4-40 X 5/16"...

  • Page 85: Front Fresnel Lens Assembly

    SSEMBLY RONT RESNEL SSEMBLY Front Fresnel Lens Assembly 21.9686.0619 Rev D Refer to Figure 3-5 Item Qty. Description 10.9686.0641 CLIP, FRONT LENS 10.9686.0682 COUNTERWEIGHT, FRONT, SHORT, THIN 10.9686.0638 COUNTERWEIGHT, FRONT, LONG 12.9686.0629 CASTING, MACHINED, FRESNEL LENS 42.9686.0102 LENS, FRESNEL 230 MM DIA 53.6598.0312 SCREW, 4-40 X 5/16"...

  • Page 86: Head Cover Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Head Cover Assembly 21.9686.0611 Rev D Refer to Figure 3-6 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 10.9686.0610 HEAD COVER, VL3500™...

  • Page 87: Backend Assembly

    SSEMBLY ACKEND SSEMBLY Backend Assembly 21.9686.0615 Rev M Refer to Figure 3-7 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 TETHER ASSY, COVERED 21.9686.0673 TETHER ASSY, BARE 21.9686.0605...
  • Page 88 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 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) Detail B (x4) (x4)

  • Page 89: 80Mm Fan Assembly

    : 80 SSEMBLY SSEMBLY 80mm Fan Assembly 21.9686.6619 Rev A Refer to Figure 3-8 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 SCREW, 6-32 X 3/8" PPZ 55.7016.0001 FAN GUARD, 80MM NICKEL PLATED STEEL WIRE (x4)

  • Page 90: Dual Fan Duct Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Dual Fan Duct Assembly 22.9686.0674 Rev B Refer to Figure 3-9 Item Qty. Description 10.9686.1672 DUAL FAN DUCT 10.9686.0673 TURNING VANE, FAN DUCT 25.9678.0015 CABLE ASSY, OT SWITCH 2 TO GND (not shown) 25.9686.0013 CABLE ASSY, OT SWITCH 1 TO OT SWITCH 2 (not shown) 25.9686.0014...

  • Page 91: Reflector Mount Assembly

    SSEMBLY EFLECTOR OUNT SSEMBLY Reflector Mount Assembly 21.9686.0605 Rev D Refer to Figure 3-10 Item Qty. Description 10.9686.0632 REFLECTOR CLAMP 10.9686.0644 SPRING, REFLECTOR MOUNT 21.9686.0606 ASSEMBLY, UV GLASS 42.9686.0120 REFLECTOR, ELIPTICAL 53.6683.0015 SCREW, 6-32 X 5/8, PPB, SEMS (x4) (x4) Note: Install filter with marks indicating IR coating side of the glass facing up and located outside of circular cutout in reflector mount.
  • Page 92 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 93: Hot Box Assembly

    SSEMBLY SSEMBLY Hot Box Assembly 21.9686.0680 Rev E Refer to Figure 3-11 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 25.9661.1522...
  • Page 94 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Hot Box Assembly (continued) (x2) (x3) (x8) (x4) (x3) (x3) (x4) (x3) Figure 3-11: Hot Box Assembly 02 .9 686 .00 10 A...

  • Page 95: Dual Fan Tray Assembly

    SSEMBLY SSEMBLY Dual Fan Tray Assembly 21.9686.0660 Rev B Refer to Figure 3-12 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 3-12: Dual Fan Tray Assembly 02.96 86.001 0 A...

  • Page 96: Head Front Fan Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Head Front Fan Assembly 23.9686.0684 Rev 0 Refer to Figure 3-13 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 (x2) 6.00"...

  • Page 97: Internal Lens Assembly

    SSEMBLY NTERNAL SSEMBLY Internal Lens Assembly 21.9686.2150 Rev H Refer to Figure 3-14 Item Qty. Description 10.9686.1155 CLAMP, BELT, FRONT 10.9686.2180 CROSS STRAP, BEAM SPLITTER 10.9686.2190 BUMPER, LENS 10.9686.7135 KNOB, HEX, ALUMINUM 21.9686.2140 ASSEMBLY, RAIL, SPLIT LENS 21.9686.2142 ACTUATOR ASSEMBLY 21.9686.2144 ASSEMBLY, INTERNAL LENS SPLITTER 21.9686.2164...
  • Page 98 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Internal Lens Assembly (Continued) (x2) (x4) (x4) Figure 3-14: Internal Lens Assembly 02 .9 686 .00 10 A...

  • Page 99: Internal Lens Rail Assembly

    SSEMBLY NTERNAL SSEMBLY Internal Lens Rail Assembly 21.9686.2140 Rev K Refer to Figure 3-15 Item Qty. Description 10.9621.0097 STABILIZER, STEPPER, GOBO WHEEL 10.9678.0128 PULLEY, ZOOM MOTOR 10.9678.1131 FORWARD PULLEY SHAFT, BEARING 10.9686.1170 MOUNT, RAIL 10.9686.1173 PAD, ISOLATION, ZOOM MOTOR 10.9686.1182 BLOCK, MOUNTING, IDLER PULLEY 10.9686.2130 END OF TRAVEL STOP...
  • Page 100 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Internal Lens Rail Assembly (x5) (x2) (x2) (x3) (x2) Reverse Side Figure 3-15: Internal Lens Rail Assembly 02 .9 686 .00 10 A...

  • Page 101: Internal Lens Splitter Assembly

    SSEMBLY NTERNAL PLITTER SSEMBLY Internal Lens Splitter Assembly 21.9686.2144 Rev E Refer to Figure 3-16 Item Qty. Description 10.9686.1156 BELT CLAMP, BACK 10.9686.1159 SPACER, PIVOT 10.9686.1176 MOTOR MOUNT 1, SPLIT LENS MOTOR 10.9686.1179 HINGE ROD 10.9686.2175 MOUNT, ZOOM LENS 10.9686.2189 EOT STOP, VARI-BRITE 21.9686.2160 PIVOT ASSY, INTERNAL LENS...
  • Page 102 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL (x2) (x2) (x2) (x2) (x2) (x2) (x2) (x2) Figure 3-16: Internal Lens Splitter Assembly 02 .9 686 .00 10 A...

  • Page 103: Actuator Assembly

    SSEMBLY CTUATOR SSEMBLY Actuator Assembly 21.9686.2142 Rev F Refer to Figure 3-17 Item Qty. Description 10.9686.1158 SPACER, PIVOT LINK 10.9686.2190 BUMPER, LENS 10.9686.4188 PLATE, LINKAGE ACTUATOR 10.9686.4189 MOUNT, LEAD SCREW 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 104: Fresnel Internal Lenses

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Fresnel Internal Lenses 21.9686.0620 Rev C Refer to Figure 3-18 Item Qty. Description 10.9686.1141 ADAPTOR, SPLIT LENS PIVOT 10.9686.1143 LENS MOUNT, FRESNEL, SPLIT LENS 10.9686.2181 SPACER, LENS MOUNTING 10.9686.2182 BUMPER PAD, SPLIT LENSES 42.9686.0111 LENS, ZOOM FRESNEL, RIGHT 42.9686.0112...

  • Page 105: Color/Effect/Strobe Module

    SSEMBLY OLOR FFECT TROBE ODULE Color/Effect/Strobe Module 21.9686.0400 Rev K (VL3500 Wash) Refer to Figure 3-19 Item Qty. Description 10.9676.0230.02 SPACER, COLOR WHEEL.043" LG 10.9678.0246 ADJUST PLATE, MOTOR 10.9686.0420 BULKHEAD, COLOR MODULE, FRONT 10.9686.0421 BULKHEAD, COLOR MODULE, REAR 10.9686.0422 SHAFT, COLOR WHEEL, FRONT 10.9686.0432...
  • Page 106 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Item Qty. Description 44.9663.1766 MOTOR, ZOOM/DIMMER 53.6525.0188 SCREW, 6-32 X 3/16" PPZ SEMS 53.6530.0006 RIVET, 1/8" OD POP,.188 -.250 LG 53.6558.0009 SCREW, 6-32 X 3/8"LG PPZ SEM 53.6609.0001 SCREW, 6-32 X 3/8" PFZ 53.6613.0001 SCREW, 6-32 X 1/2"...
  • Page 107 SSEMBLY OLOR FFECT TROBE ODULE Color/Effect/Strobe Module (continued) (x2) (x5) (x6) (x14) (x2) (x2) (x5) 31(x8) (x6) (x12) (x6) Figure 3-19: Color/Effect/Strobe Module 02.96 86.001 0 A...

  • Page 108: Color/Rotating Effect/Strobe Module

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color/Rotating Effect/Strobe Module 21.9686.1400 Rev K (VL3500 Wash FX) Refer to Figure 3-19 Item Qty. Description 10.9678.0246 MOTOR ADJUST PLATE 10.9686.0420 BULKHEAD, COLOR MODULE, FRONT 10.9686.0422 SHAFT, COLOR WHEEL, FRONT 10.9686.0432 SHAFT, COLOR WHEEL, REAR 10.9686.0433...
  • Page 109 SSEMBLY OLOR OTATING FFECT TROBE ODULE Item Qty. Description 22.9686.1412 ASSEMBLY, COLOR WHEEL, MAGENTA 22.9686.1413 ASSEMBLY, COLOR WHEEL, CTO 22.9686.1414 ASSEMBLY, DIMMER WHEEL 24.9686.3427 PCB, COLOR WHEEL SENSOR, QUAD WITH HALL 24.9686.3428 PCB, COLOR WHEEL SENSOR, QUAD 25.9686.1205 CABLE ASSEMBLY, COLOR/EFFECTS HARNESS (not shown) 44.9663.1766 MOTOR, ZOOM/DIMMER 53.6525.0188...
  • Page 110 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Color/Rotating Effect/Strobe Module (continued) (x6) (x2) (x14) (x5) (x4) (x2) (x5) (x9) (x6) (x2) (x2) (x2) (x2) (x12) (x5)* *For Cyan, Yellow, Magenta CTO and Dimmer Only Figure 3-20: Color/Rotating Effect/Strobe Module 02 .9 686 .00 10 A...

  • Page 111: Vl3500 Wash Fixed Color Wheel 1 Assembly

    : VL3500 W SSEMBLY IXED OLOR HEEL SSEMBLY VL3500 Wash Fixed Color Wheel 1 Assembly 21.9686.0484 Rev H (VL3500 Wash) Refer to Figure 3-21 Item Qty. Description 10.9686.0487 WHEEL, FIXED COLOR 1 (WHEEL #1) 10.9686.0482 SPACER PLATE, FIXED COLOR 10.9686.0483 SPRING PLATE, FIXED COLOR 21.9686.0419...
  • Page 112 Alignment Tab Congo Blue Kelly Yellow Green Magenta Detail A Alignment Tab RTV beads should be applied at all positions where a filter can be used. Figure 3-21: VL3500 Wash Fixed Color Wheel 1 Assembly 02 .9 686 .00 10 A...

  • Page 113: Vl3500 Wash Fixed Color Wheel 2 Assembly

    : VL3500 W SSEMBLY IXED OLOR HEEL SSEMBLY VL3500 Wash Fixed Color Wheel 2 Assembly 21.9686.0480 Rev H (VL3500 Wash) Refer to Figure 3-22 Item Qty. Description 10.9686.0481 WHEEL, FIXED COLOR 2 (WHEEL #2) 10.9686.0482 SPACER PLATE, FIXED COLOR 10.9686.0483 SPRING PLATE, FIXED COLOR 21.9686.0419...
  • Page 114 Green Alignment Tab Orange Amber Dark Fuchisa Detail A Alignment Tab RTV beads should be applied at all positions where a filter can be used. Figure 3-22: VL3500 Wash Fixed Color Wheel 2 Assembly 02 .9 686 .00 10 A...

  • Page 115: Vl3500 Wash Fx Fixed Color Wheel 1 Assembly

    : VL3500 W FX F SSEMBLY IXED OLOR HEEL SSEMBLY VL3500 Wash FX Fixed Color Wheel 1 Assembly 21.9686.1484 Rev A (VL3500 Wash FX) Refer to Figure 3-23 Item Qty. Description 10.9686.0487 WHEEL, FIXED COLOR 1 (WHEEL #1) 10.9686.0482 SPACER PLATE, FIXED COLOR 10.9686.0483...
  • Page 116 Alignment Tab Kelly Yellow Green Magenta Detail A Alignment Tab RTV beads should be applied at all positions where a filter can be used. Figure 3-23: VL3500 Wash FX Fixed Color Wheel 1 Assembly 02 .9 686 .00 10 A...

  • Page 117: Vl3500 Wash Fx Fixed Color Wheel 2 Assembly

    : VL3500 W FX F SSEMBLY IXED OLOR HEEL SSEMBLY VL3500 Wash FX Fixed Color Wheel 2 Assembly 21.9686.1480 Rev A (VL3500 Wash FX) Refer to Figure 3-24 Item Qty. Description 10.9686.0481 WHEEL, FIXED COLOR 2 (WHEEL #2) 10.9686.0482 SPACER PLATE, FIXED COLOR 10.9686.0483...
  • Page 118 Alignment Tab Orange Amber Dark Fuchisa Detail A Alignment Tab RTV beads should be applied at all positions where a filter can be used. Figure 3-24: VL3500 Wash FX Fixed Color Wheel 2 Assembly 02 .9 686 .00 10 A...

  • Page 119: Vl3500 Wash Fx Rotating Effect Wheel Assembly

    SHIM, 0.627" ID, 0.875" OD, 0.020 THK SST Open Four Hole Night Spokes Triangle Triangle Spokes Night Four Hole Note: This graphic is for illustrative purposes only. Refer to Figure 3-26 for component breakdown. Figure 3-25: VL3500 Wash Gobo Patterns and Positions 02.96 86.001 0 A...
  • Page 120 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL VL3500 Wash FX Rotating Effect Wheel Assembly (continued) (x4) (x10) (x5) (x5) (x5) (x3) (x5) Figure 3-26: VL3500 Wash FX Rotating Effect Wheel Assembly 02 .9 686 .00 10 A...

  • Page 121: Vl3500 Wash Strobe System Assembly

    : VL3500 W SSEMBLY TROBE YSTEM SSEMBLY VL3500 Wash Strobe System Assembly 21.9686.0404 Rev H (VL3500 Wash) Refer to Figure 3-27 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE 10.9686.0435 STROBE BULKHEAD, COLOR ACCESS 10.9686.0438 SPRING, COLOR ACCESS 10.9686.0440 SHIELD, STROBE MOTOR/HARNESS 10.9686.1450...
  • Page 122 VL3500 Wash Strobe System Assembly (continued) (x4) (x4) (x8) (x2) (x8) (x8) (x8) (x8) (x4) (x4) (x4) .400 .455 .410 .355 Set blade assemblies according to dimensions shown Figure 3-27: VL3500 Wash Strobe System Assembly 02 .9 686 .00 10 A...

  • Page 123: Vl3500 Wash Fx Strobe System Assembly

    : VL3500 W FX S SSEMBLY TROBE YSTEM SSEMBLY VL3500 Wash FX Strobe System Assembly 21.9686.1404 Rev 0 (VL3500 Wash FX) Refer to Figure 3-28 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE 10.9686.0438 SPRING, COLOR ACCESS 10.9686.0440 SHIELD, STROBE MOTOR/HARNESS 10.9686.1435...
  • Page 124 VL3500 Wash FX Strobe System Assembly (continued) (x4) (x4) (x8) (x2) (x8) (x8) (x8) (x8) (x4) (x4) .400 .455 .410 .355 Set blade assemblies according to dimensions shown Figure 3-28: VL3500 Wash FX Strobe System Assembly 02 .9 686 .00 10 A...

  • Page 125: Rear Strobe Blade Assembly

    SSEMBLY TROBE LADE SSEMBLY Rear Strobe Blade Assembly 21.9686.1437 Rev 0 Refer to Figure 3-29 Item Qty. Description 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE, DAMPER 10.9686.1431 STROBE BLADE, NOTCHED 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 126: Front Strobe Blade Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Front Strobe Blade Assembly 21.9686.1438 Rev 0 Refer to Figure 3-30 Item Qty. Description 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE DAMPER 10.9686.1431 STROBE BLADE, NOTCHED 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 127: Yoke Assembly Yoke Assembly

    SSEMBLY SSEMBLY Yoke Assembly Yoke Assembly 21.9686.0700 Rev A Refer to Figure 3-31 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 128 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Yoke Assembly (continued) (x2) (x2) (x2) (x4) (x3) (x8) (x2) (x2) (x4) (x2) (x2) (x2) Figure 3-31: Yoke Assembly 02 .9 686 .00 10 A...

  • Page 129: Tilt Motor Assembly

    SSEMBLY OTOR SSEMBLY Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-32 Item Qty. Description 10.9678.0763 PLATE, TILT MOTOR MOUNT 21.9678.0708 ASSY, DRIVE PULLEY 10.9678.0720 CODEWHEEL, 120 COUNT, LARGE ID 10.9678.1749 TIMING PULLEY, 17 TOOTH, SHORTENED 53.5560.0250 SCREW, 8-32 X 1/4" SET CONE POINT 24.9661.9629 PCB ASSY, PAN/TILT ENCODER 44.9678.0680...
  • Page 130 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt Motor Assembly (continued) See Detail A (x2) Detail A (x2) (x2) (x2) Pressure-Sensitive Adhesive (x4) Pulley Height Detail & Installation (x4) 0.257" Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2.

  • Page 131: Yoke Fan Assembly

    SSEMBLY SSEMBLY Yoke Fan Assembly 22.9661.0609 Rev C Refer to Figure 3-33 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 3-33: Yoke Fan Assembly 02.96 86.001 0 A...
  • Page 132 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 133: Head/Yoke Pcb Assemblies

    PCB A SSEMBLIES ABLE NTERCONNECT Head/Yoke PCB Assemblies Head Cable Interconnect 21.9686.1121 Rev A Refer to Figure 3-34 Item Qty. Description 10.9686.1120 BRACKET, HEAD CABLE INTERCONNECT 23.9686.0208 CABLE ASSY, ZOOM MOTOR (cable portion not shown) 25.9686.0206 CABLE ASSY, VARI-BRITE MOTOR (not shown - part of 23.9686.0208) 53.6520.0002 SCREW, 4-40 X 7/16 PPZ 55.6621.0001...

  • Page 134: Vl3500 Wash Controller Pcb Assembly

    SCREW, 6-32 X 3/4" PPZ 55.2179.0001 CABLE ANCHOR MOUNT, #6 SCREW MOUNT 55.3303.0004 WASHER, #4 LOCK INT TOOTH SS 55.6538.0002 WASHER, #6 NYLON, NATURAL (x2) (x2) (x3) (x2) (x2) Figure 3-35: VL3500 Wash Controller PCB Assembly 02 .9 686 .00 10 A...
  • Page 135 PCB A : VL3500 W PCB A SSEMBLIES ONTROLLER SSEMBLY VL3500 Controller PCB Assembly (continued) Component Side Solder Side Figure 3-36: VL3500 Wash Controller PCB Assembly 02.96 86.001 0 A...
  • Page 136 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 137: Enclosure Assembly Upper Enclosure Assembly

    Figure 3-38 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 138 ❋ 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 CABLE ASSY, AC INPUT SPLITTER (not shown)
  • Page 139 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Item Qty. Description 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 55.2261.0001 SLEEVE, NYLON THIN WALL #6 SCR 55.2267.0001 RUBBER STRIP, SPONGE CLSD CELL 55.6677.0039...
  • Page 140 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x2) (x4) (x4) (x2) (x4) (x4) (x4) Figure 3-37: Upper Enclosure Assembly 02 .9 686 .00 10 A...
  • Page 141 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly (continued) Note: *Shims used as required to remove any slack in pan tube assembly. (x3) (x4) (x4) (x2) (x2) (x2) 51, 73*, 74* (x2) Part is shown exploded for clarity (x4) See Detail A (x2) (x2) (x2)
  • Page 142 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x3) (x2) (x2) Ground Label (x2) Figure 3-39: Upper Enclosure Electrical Components 02 .9 686 .00 10 A...

  • Page 143: Ventilation Cover Assembly

    NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY Ventilation Cover Assembly 21.9686.0840.02 Rev B Refer to Figure 3-40 Item Qty. Description 10.9686.1249 POST, TRUSS HOOK 10.9686.0883 COVER, VENTILATION 10.9678.0837 AIR SEAL, FAN SIDE 10.9678.0838 AIR SEAL, APS SIDE 10.9678.0835 AIR SEAL, SHORT STRIP 10.9678.0836 AIR SEAL, LONG STRIP 10.9678.0887...
  • Page 144 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Ventilation Cover Assembly (continued) (x2) (x4) (x4) (x4) (x4) Figure 3-40: Ventilation Cover Assembly 02 .9 686 .00 10 A...

  • Page 145: Exhaust Fan Assembly

    NCLOSURE SSEMBLY XHAUST SSEMBLY Exhaust Fan Assembly 21.9686.0811 Rev C Refer to Figure 3-41 Item Qty. Description 10.9686.0810 MOUNTING PLATE, EXHAUST FAN 40.7140.0001 BLOWER, CENTRIFUGAL, 24VDC 9CFM 3" X 3" 52.6523.0002 CONN, HOUSING, 2 POS PLUG SHROUDED 52.8347.0001 CONTACT, 24-30 AWG MALE CRIMP 55.6576.0001 SCREW, #10-16 X 3/8 TYPE B PFZ (x2)

  • Page 146: Panel Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Panel Assembly 21.9686.0805 Rev B Refer to Figure 3-42 Item Qty. Description 10.9678.0852.01 LAYOUT, ENCLOSURE OVERLAY 10.9678.0859 BRACKET, INPUT 10.9678.0872 STIFFENER, DISPLAY BOARD 10.9686.0820 FILLER PANEL, DMX CONNECTOR 24.9663.3895 PCB ASSY, DMX INPUT 25.9678.0810 CABLE ASSY, AC INPUT PIGTAIL 24.9678.3825...

  • Page 147: Dmx Input Pcb

    : DMX I NCLOSURE SSEMBLY NPUT DMX Input PCB 24.9663.3895 Rev 0 Refer to Figure 3-43 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 148: Pan Pulley Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL 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) Note orientation of Pan Flag. Figure 3-44: Pan Pulley Assembly 02 .9 686 .00 10 A...

  • Page 149: Pan Motor Assembly

    NCLOSURE SSEMBLY OTOR SSEMBLY Pan Motor Assembly 21.9686.0864 Rev D Refer to Figure 3-45 Item Qty. Description 10.9686.0457.01 SPACER, COLOR, .322 LG 10.9686.0840 STANDOFF, 1/4", F-F 4-40/8-32, 0.791" LG AL 10.9686.0841 ADAPTOR PLATE, PAN SENSOR PCB 10.9686.0865 PLATE, PAN MOTOR MOUNT 21.9686.0828 ASSY, DRIVE PULLEY, PAN 10.9678.8720...
  • Page 150 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan Motor Assembly (continued) (x2) Detail A Pressure-Sensitive Adhesive (x2) (x4) (x2) See Detail A (x2) (x2) (x2) (x4) (x2) Drive Pulley Detail & Installation 0.915" (x4) Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2.

  • Page 151: Pan Tube Assembly

    NCLOSURE SSEMBLY SSEMBLY 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 BEARING ASSY, FLUSH MOUNT HOUSING LARGE Figure 3-46: Pan Tube Assembly...
  • Page 152 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 153: Cable Assemblies

    EOT S ABLE SSEMBLIES ENSOR LECTRICAL SSEMBLY Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-47 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 3-47: Pan EOT Sensor Electrical Assembly 02.96 86.001 0 A...

  • Page 154: 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 3-48 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 3-48: LVS Chassis Ground Cable Assembly 02 .9 686 .00 10 A...

  • Page 155: Ignitor To Relay Cable Assembly

    ABLE SSEMBLIES GNITOR TO ELAY ABLE SSEMBLY Ignitor to Relay Cable Assembly 25.9661.1526 Rev C Refer to Figure 3-49. 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 0.42 WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING Figure 3-49: Ignitor to Relay Cable Assembly...

  • Page 156: 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 3-50 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 157: 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 3-51 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 158: 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 3-53 Item Qty. Description 52.8371.0001 RECEPT, FASTON, 24-20 AWG UNINSUL TIN 73.7089.0000 0.42 WIRE. 22AWG 300V 200C TEF BLK UL1180 Figure 3-52: OT Switch 1 to OT Switch 2 Cable Assembly 02 .9 686 .00 10 A...

  • Page 159: Backcap Interlok To Ot Switch 1 Cable Assembly

    OT S ABLE SSEMBLIES ACKCAP NTERLOK TO WITCH ABLE SSEMBLY Backcap Interlok to OT Switch 1 Cable Assembly 25.9686.0014 Rev A Refer to Figure 3-53 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 0.33 WIRE.

  • Page 160: Ot Switch To Ground Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL OT Switch to Ground Cable Assembly 25.9678.0015 Rev A Refer to Figure 3-54 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 161: Tilt Harness Cable Assembly

    ABLE SSEMBLIES ARNESS ABLE SSEMBLY Tilt Harness Cable Assembly 25.9686.2203 Rev A Refer to Figure 3-55 Figure 3-56 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 COVER, BACK 40 POS MT 52.6610.0034 CONNECTOR, HOUSING 34 POS, 26-22 AWG DBL ROW UNLOADED 52.6224.1034...
  • Page 162 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Tilt Harness Cable Assembly (continued) Figure 3-56: Tilt Harness Cable Assembly Wiring / Pin Out 02 .9 686 .00 10 A...

  • Page 163: Internal Lens Interconnect Cable Assembly

    ABLE SSEMBLIES NTERNAL NTERCONNECT ABLE SSEMBLY Internal Lens Interconnect Cable Assembly 25.9686.0204 Rev 0 Refer to Figure 3-57 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 164: Vl3500 Wash Color Harness Cable Assembly

    1, 2, 3, 7 10, 11 10, 11 8, 9 15, 9 10, 11 10, 11 (x8) 10, 11 8, 9 4, 5, 6, 7 15, 9 10, 11 Figure 3-58: VL3500 Wash Color Harness Cable Assembly 02 .9 686 .00 10 A...
  • Page 165 : VL3500 W ABLE SSEMBLIES OLOR ARNESS ABLE SSEMBLY VL3500 Wash Color Harness Cable Assembly (continued) Figure 3-59: VL3500 Wash Color Harness Cable Assembly Wiring / Pin Out 02.96 86.001 0 A...

  • Page 166: Vl3500 Wash Fx Color Harness Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL VL3500 Wash FX Color Harness Cable Assembly 25.9686.1205 Rev B (VL3500 FX Wash) Refer to Figure 3-60 Figure 3-61 Item Qty. Description 52.6610.0040 CONNECTOR, HOUSING 40 POS, 26-22 AWG DBL ROW UNLOADED 52.6224.1040...
  • Page 167 1, 2, 3, 7 10, 11 16, 9 10, 11 8, 9 18, 19 (x8) 10, 11 10, 11 4, 5, 6, 7 8, 9 17, 9 10, 11 Figure 3-60: VL3500 Wash FX Color Harness Cable Assembly 02.96 86.001 0 A...
  • Page 168 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL VL3500 Wash FX Color Harness Cable Assembly (continued) Figure 3-61: VL3500 Wash FX Color Harness Cable Assembly Wiring / Pin Out 02 .9 686 .00 10 A...

  • Page 169: 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 3-62 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 170: Transfer Fans Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Transfer Fans Cable Assembly 25.9686.0209 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 73.2324.0200 2.21 WIRE, 26AWG 2COND 300V 200C ...

  • Page 171: Upper Enclosure Fans Cable Assembly

    ABLE SSEMBLIES PPER NCLOSURE ABLE SSEMBLY Upper Enclosure Fans Cable Assembly 25.9686.0210 Rev 0 Refer to Figure 3-64 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 6.41 WIRE, 26AWG 2COND 300V 80C ...

  • Page 172: Yoke Fan And Relay Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Yoke Fan and Relay Cable Assembly 25.9678.0681 Rev C Refer to Figure 3-65 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 173: Yoke Fan Cable Assembly

    ABLE SSEMBLIES ABLE SSEMBLY Yoke Fan Cable Assembly 25.9678.0758 Rev A Refer to Figure 3-66 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 WIRE, 26AWG 2COND 300V 80C UL1061, 19STRND Figure 3-66: Yoke Fan Cable Assembly 02.96 86.001 0 A...

  • Page 174: Ot Switch To Backcap Interlok Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL OT Switch to Backcap Interlok Cable Assembly 25.9686.0201 Rev A Refer to Figure 3-67 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 175: 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 176: 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 Head Ground Yoke Ground Figure 3-69: Chassis to Yoke Ground Cable Assembly 02 .9 686 .00 10 A...

  • Page 177: 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 25.9686.0206 CABLE ASSY, ZOOM MOTOR 24.9678.5916 PCB ASSY, ZOOM INTERCONNECT Note: Item 1 is soldered to Item 2 as shown. Figure 3-70: Zoom Motor Cable Assembly 02.96 86.001 0 A...

  • Page 178: Zoom Motor Cable

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Zoom Motor Cable 25.9686.0206 Rev 0 Refer to Figure 3-71 Item Qty. Description 52.6662.0006 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 WIRE, 26 AWG, 4 COND, 300V 200C TEF UL1180 (BLK-BRN-RED-ORN) 1, 2...

  • Page 179: Ac Input Pigtail Cable Assembly

    : AC I ABLE SSEMBLIES 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 180: Emi Filter To Power Switch Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-73 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 181: 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 3-74 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 TERM, SPADE #6 RED 22-16 AWG INSERT 52.8392.0001...
  • Page 182 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 Note: Heatshrink not shown for clarity. (x3) Figure 3-74: AC Input Splitter Cable Assembly 02 .9 686 .00 10 A...

  • Page 183: 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 3-75 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 2.17 CBL, 22AWG STRND 4COND PVC INSUL...

  • Page 184: Display Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Display Cable Assembly 25.9678.1825 Rev C Refer to Figure 3-76 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 55.2186.0001 CABLE TIE, .10"...

  • Page 185: 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 3-77 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 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 73.5124.1289...

  • Page 186: Dc Output Cable Assembly

    ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-78 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 187: Pan/Tilt Control Cable Assembly

    ABLE SSEMBLIES ONTROL ABLE SSEMBLY Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-79 Figure 3-80 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 CONN, HOUSING 5POS RECEPTACLE 52.6588.0007 HOUSING, 7POS XH 250V/3A 2.5MMPITCH 52.7007.0001...
  • Page 188 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Pan/Tilt Control Cable Assembly (continued) Figure 3-80: Pan/Tilt Control Cable Assembly Wiring / Pin Out 02 .9 686 .00 10 A...

  • Page 189: 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 3-81 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 190 ❋ VARI LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...

  • Page 191: Appendix A. Technical Bulletins And Notices

    Cooling System Modification Kit VL3500 Wash S3K-016 Internal Lens Travel Stop Installation VL3500 Wash S3K-017 VL3500 Wash to VL3500 Wash FX Conversion Pro- VL3500 Wash cedures Technical Bulletins, Software Updates, support, and other information is available online at http:// www.vari-lite.com (under the Support Tab).
  • Page 192 VARI❋LITE® - VL3500™ W UMINAIRE ERVICE ANUAL Notes 02 .9 686 .00 10 A...
  • Page 194 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA 1.877.VARI-LITE ❋ Fax 1.214.647.8038 www.vari-lite.com Date: 19-May-2009 / Manual Part Number: 02.9686.0010 A ©2003-2009 A Philips Group Company. All rights reserved. Printed in the U.S.A.

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